1983Subaru EA81Owners Manual
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TAB LE OF CONTENTS
SUBARU
1600
I BOO
FOREWORD
This service manual has been prepared to
provide SUBARU service personnel with the
necessary information and data for the
correct maintenance and repair of SUBARU
1600 and 1800 series.
This manual completely covers the proce.
dures . for maintenance, disassembling, reassembling, inspection and adjustment of components and troubleshooting for gUidance of
both the fully qualified and the less-experienced mechanics. .
Please peruse and utilize this manual fully to
ensure complete maintenance and repair
work for satisfying our customers by
keeping their vehicles in op-timum condition.
When replacement of parts during maintenance is needed , be su :~e to use SUBARU
genuine parts.
All information, illustrations and specifications contained in this manual are based on
the latest product infonnation available at
the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
-
©
-8-
fI
and
are trademarks of FUJI HEAVY INDUSTRIES LTD .
Copyright 1982 FUJI HEAVY INDUSTRIES LTD.
· ·AU,
Not to be reproduced in whole or in part without the prior written
permission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN .
CHAPTER'iJ
GENERAL INFORMATION
p.
1- 1. GENERAL SPECIFICATIONS ................................................................ 1- 2
1- 2. VEHICLE IDENTIFICATION NUMBERS (V.I.N.) ................................. 1- 4
1. Applicable V.I.N. of This Manual.......................................................... 1- 4
2. The Meaning of V.I.N. .......................................................................... 1- 6
1- 3. IDENTIFICATION NUMBERS ................................................................ 1- 6
1. Vehicle Identification Number .............................................................. ··1- 6
2. Engine Serial Number ••••••••••••••••••••••••••••••••••••••••••••••••••.••••.•.••••••••••••••••• 1- 8
3. Transmission Serial Number ................................................................. 1- 6
.
LARE LS .................................................................................................... 1- 8.~'·"
~'""t
1- 4.
1. Safety Certification Plate ..................................................................... 1-
i
2. Vehicle Emi.ion Control Information Labels ...................................... 1- 6
3. Emission Data Label (California Models Only) .................~~............... 1- 6
4. VehicleldentiflCltion Number Plate ............................. L ...........~t .•"'\;;
' ' '.1_
5. Color Code Label ..•..........•••.•....•.•..•.•.•.••.•....•...••..••.•••.••.••..••.•..•.•.•....•. 1- 1
1- 6. RECOMMENDED LUBRICANTS ........................................................... 1- 7
1- 6. RECOMMENDED SEALANTS, ADHESIVES AND
,.
.~'.
GREASES .••••.••••••••••••••.•••••••.•••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••• 1- 8
1- 7. TIGHTENING TORQUE OF STANDARD BOLTS AND NUTS ......... 1- 9
,
1- 8. OPENING ENGINE HOOD .................................................................... 1-10
1- 9. LIFTING POINTS AND PROCEDURE ................................................. 1-10
1. Pantograph Jack .................................................................................. 1-10
2. GarageJack ......................................................................................... 1-11
3. Lift ...................................................................................................... 1-11
1-10. TOWING HOOKS ................................................................................... 1-12
•
B·.I1I1
........
-----~----.-----~--~~-~-~."........,--
--.---~--~-~~~-~-~----.~-~-
--
1600
1600
1800
1800
•
-
1800
1600
I
Station Wagon
Hardtop
Sedan
Hatchback
----._.r'r~
~
--
D
-
BRAT
----...,.,
1\..
\
--
STD
4MT
DL
GL
5MT
5MT
AT
4WD
STD
4MT
4WD
GL
Dfr
DL
GL
5MT
5MT
AT
DL
GL
5MT
5MT
AT
~
5MT
5MT
AT
4WD
GL
4WD
DL
4WD
GL
4WD
DL
I
4MT
Dfr
AT
4MT
Dfr
AT
I
Overall length
Overall width
mm
(in)
1610
(63.4)
1610
(63.4)
1615
(63.6)
Overall height
mm
(in)
1365
(53.7)
1365
(53.7)
1410
1365
(53.7) (55.7)
1700
(66.9)
mm
Length (in)
Compartment
I ['~~-"]
1620
(63.8)
1620
(63.8)
1610
(63.4)
---- I-----1415
1365
(55.7) (53.7)
1615
(63.6)
1610
(63.4)
1615
(63.6)
1610
(63.4)
1615
(63.6)
1620
(63.8)
1620
(63.8)
1620
(63.8)
1635
(64.4)
1635
(64.4)
1635 I
(64.4)
1365
(53.7)
1350
(53.1)
1350
(53.1)
1390
(54.7)
1390
(54.7)
1440
(56.7)
1445
(56.9)
1445
(56.9)
1440
(56.7)
1445
(56.9)
1445
(56.9)
•• 960
1750
(68.9)
·'1500 ·'1500 ·'1500 ·'1500 .' 1500 •• 960 •• 960
(59.1) (59.1) (37.8) (37.8)
1750 (59.1) (59.1) (59.1)
(68.9) .2 785 .2 785 .2 785 .2 785 .2 785 ·$1610 ·'1610
(30.9) (30.9) (30.9) (30.9) (30.9) (63.4) (63.4)
1700
(66.9)
1700
(66.9)
1700
(66.9)
1700
(66.9)
1750
(68.9)
1750
(68.9)
two_u
··CalJ0 space at
~
is
GL
4425
4425
4285
4285
4285
4300
4425,1
4270 4280
4250 4270 4250
3985
4010 3995 3995
mm 3985
(in) (156.9) (156.9) (157.9) (157.3) (157.3) (167.3) (168.1) (167.3) (168.1) (168.5) (169.3) (168.7) (168.7) (168.7) (174.2) (174.2) (174.2)
r
-
DL
··CalJ°space
~~
1345
(53.0)
1345
(53.0)
1345
(53.0)
1345
(53.0)
1345
(53.0)
1345
(53.0)
1300
1345
(53.0) .11320 .21320 .11320 .21320 .21320 (51.2)
(52.0) (52.0) (52.0) (52.0) (52.0)
H'gh mm
el t (in)
1115
(43.9)
1115
(43.9)
1115
(43.9)
1115
(43.9)
1115
(43.9)
1115
(43.9)
1115
(43.9)
1105
(43.5)
1105
(43.5)
mm
(in)
2380
(93.7)
2380
(93.7)
2380 '2370
(93.7) (93.3)
2370
(93.3)
2460
(96.9)
2460
(96.9)
2460
(96.9)
2460
(96.9)
Front
mm
(in)
1330
(52.4)
1330
(52.4)
1330
(52.4)
1310
(51.6)
1335
(52.6)
1330
(52.4)
1330
(52.4)
Rear
mm
(in)
1345
(53.0)
1345
(53.0)
1345
(53.0)
1345
(53.0)
1370
(53.9)
1345
(53.0)
mm
165
(6.5)
165
(6.5)
165
(6.5)
205
(8.1)
210
(8.3)
165
(6.5)
BRAT - rear
CUlO bed only
Wheelbase
860 .3 860 .3 860 . l 860 .3 860
(33.9) (33.9) (33.9) (33.9) (33.9)
.3
1300
(51.2)
1300
(51.2)
-
2455
(96.7)
2445
(96.3)
2445
(96.3)
2445
(96.3)
2445
(96.3)
2445
(96.3)
2445
(96.3)
1330 1330
(52.4) (52.4)
1325
(52.5)
1325
(52.5)
1310
(51.6)
1335
(52.6)
1335
(52.6)
1310
(51.6)
1335
(52.6)
1335
(52.6)
1345
(53.0)
1345
1345
(53.0) (53.0)
1345
(53.0)
1345
1340
(53.Q) (52.8)
1365
(53.7)
1365
1340
(53.7) (52.8)
1365
(53.7)
1365
(53.7)
165
(6.5)
165
(6.5)
165
(6.5)
175
(6.9)
175
(6.9)
210
(8.3)
205
(8.1)
210
(8.3)
210
(8.3)
--
Minimum road clearance
(in)
-
.': Between rear end of seat and rear gate
.': Between back panel and rear gate
--
205
(8.1)
.
0
::I
Co)
m
Z
m
::D
»
rZ
."
205
(8.1)
3:
~
0
Z
-
2455
(96.7)
Tread
n
,.
•_.
::D
1345
(53.0)
Width
·'1610
(63.4)
"3-._...
0
·'1290 ·'1290 ·'1290 ·'1290 .11290
(50.8) (50.8) (50.8) (50.8) (50.8)
1345
(53.0)
four . .Is
(37.8)
I
en
~
1800
1600
1600
Hatchback
DL
GL
4WD
STD
4WD
GL
DL
GL
DL
GL
DL
GL
4WD
DL
4MT
5MT
5MT
AT
4MT
Dfr
5MT
5MT
AT
5MT
5MT
AT
5MT
5MT
AT
4MT
610
(1345)
Curb weight *
f"~~GL4)
!C
GLF models
··SMTofDL
model and
ATofGL&
GLF models
kg
(Ib)
347
(765)
347
(765)
~
w
359
(790)
384
.., 367 (845)
(810)
lit;
934
383
(845)
399
(880)
379
(835)
962
(2120)
374
(825)
.. I
.. I
365
387 (805)
(855)
.. 1
4MT
Dfr
AT
612
(1350)
.. I
.. I
.. I
391
(860)
401
(885)
406
(895)
1032
1018
1021
987
1072
1091
1105
976
1014
966
957
(2275)
(2245)
5
(2435)
(2110)
(2365)
(2405)
(2250)
(2150)
(2235)
(2130)
(217
)
.. , 1005
.. 21011
..2 982
"'1066
(2165)
(2350)
(2230)
(2215)
Total
Front
780
780
kg
780
803
780
780
796
803
803
780
780
803
803
803
803
803
803
(Ib) (1770) (1770) (1770) (1720) (1720) (1770) (1770) (1770) (1770) (1770) (1770) (1720) (1720) (1755) (1720) (1720) (I 720)
Rear
kg
658
658
658
680
680
658
658
658
658
(lb) (1450) (1450) (1450) (1500) (1500) (1450) (1450) (1450) (1450)
Total
1569
1569
kg 1461
1461
1461
1461
1461
1461
1547
1569
1592
1569
1565
1569
1461
1461
1461
(Ib) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3410) (3450) (3460) (3460) (3510) (3460) (3460) (3460)
______
~
________________
_____ __________
.~1
~
__
~
-
Z
."
o
i:
~
oz
789
789
789
789
796
744
762
789
(1640) (1680) (1740) (1740) (1755) (1740) (1740) (1740)
- -
~
»
r
::D
.. 11048
(2310)
kg
930
(Ib) (2050)
(2~0)
C)
m
Z
m
::D
435
(960)
.. I
* Vehicle with optional eqUipment is out of this specifications.
__________
AT
474
469
469
422
.. , 379 (930) .. , 442 (1035) (1035) (1045)
(835)
(975)
989
(2180)
993
(2190)
.. I
Gross
Vehicle weight
.. I
Dfr
4WD
GL
4WD
DL
4WD
GL
617
626
596
603
kg
622
631
583
587
592
615
587
592
599
(lb) (1285) (1295) .., 615 (1305) (1355) (1295) .. 1 624 (1305) ..1 626 (1320) .. , 624 (1330) (1370) (1390) (1315) (1360) (1380)
(1355)
(1375)
(1375)
(1380)
' .. I
Rear
615
(1335)
.. I
BRAT
Station Wagon
Hardtop
STD
603
(1330)
.
1800
1600
Sedan
.. I
Front
1800
____________
~
____________
_.
__.-
)
GENERAL INFORMATION
1·2. Vehicle Identification Numbers (V.I.N.)
1. Applicable V.I.N. of This Manual
• 1600 cc Engine
o0
o0
2-Door Hatchback
2-DoO£ Hatchback
STD
DL
(4MT)
(SMT)
J F 1 A F 2 1 B X D A 1 0
J F 1 A F 2 2 B X D B 1 0
4-Door Sedan
DL
(SMT)
J F 1 A B 2 2 B X DB 2 0 0
Hardtop
DL
(SMT)
J F 1 A W 2 2 B X D B 3 0 0 0 0 1 and after
2-DoO£ Hatchback
2·Door Hatchback
2-Door Hatchback
2-DoO£ Hatchback
GL
GL
4WDSTD
4WDGL
(SMT)
(AT)
(4MT)
(4MT. Dual-range)
J
J
J
J
0
0
0
0
o0
o0
o0
o0
1
1
1
1
4-Door Sedan
4·Door Sedan
GL
GL
(SMT)
(AT)
J F 1 A B 4 3 B X D B 2 0 0
J F 1 A B 4 3 B X D C 2 0 0
o0
o0
1 and after
1 and after
Hardtop
Hardtop
GL
GL
(SMT)
(AT)
J F 1 AW 4 3 B X DB 3 o 0 0 0 1 and after
J F 1 AW 4 3 B X DC 3 0 0 o 0 1 and after
Station Wagon
Station Wagon
Station Wagon
Station Wagon
Station Wagon
Station Wagon
DL
GL
GL
4WDDL
4WDGL
4WDGL
(SMT)
(SMT)
(AT)
(4MT)
(4MT, Dual-range)
(AT)
J
J
J
J
J
J
BRAT
BRAT
BRAT
4WDDL
4WDGL
4WDGL
(4MT)
(4MT, Dual.range)
(AT)
J F 2 AT 5 2 BX DD 5
J F 2 AT 5 3 BX DE 5
J F 2 AT 5 3 B X DF 5
0 1 and after
0 1 and after
o0
1 and after
• 1800 cc Engine
Abbreviations used
4MT: 4-speed manual transmission
SMT: S·speed manual transmission
AT: Automatic transmission
1-4
F
F
F
F
F
F
F
F
F
F
1
1
2
2
1
1
1
2
2
2
A
A
A
A
F
F
F
F
AM
AM
AM
AM
AM
AM
4
4
5
5
4
4
4
5
5
5
3
3
1
3
2
3
3
2
3
3
B
B
B
B
B
B
B
B
B
B
X
X
X
X
X
X
X
X
X
X
D
D
D
D
B
C
D
E
DB
DB
DC
DD
DE
DF
1
1
1
1
4
4
4
4
4
4
0
0
0
0
o0
o0
o0
o0
o0
o0
o0
0 0
o0
o0
0 0
o0
o0 o0
o0 o0
o0 o0
1
1
1
1
1
1
and after
and after
and after
and after
and after
and after
and after
and after
and after
and after
1 and after
1 and after
1 and after
GENERAL INFORMATION
2. The Meaning of V.I.N •
. . - - - - - - - - - - - - - - - - - - - - - - - - : - - - - - - Maker identifier
, . - - - - - - - - - - - - - - - - - - - - - - Vehicle attribute
Vehicle identification
..--""'---." .-,_---lL--_-., I'- - - - ' - - - - - ,
JFIAF2
BXDAIOOOOI
_---=----------[
Sequential number
100001 and after
200001 and after
300001 and after
400001 and after
500001 and after
Hatchback
4-Ooor Sedan
Hardtop
Station Wagon
BRAT
Plant of manufacture and transmission type
A: Gunma manufacture - 4MT
B : Gunma manufacture - 5MT
C : GUnma manufacture - AT
D: Gunma manufacture - 4WD 4MT
E : Gunma manufacture - 4WD 4MT, Dual-range
F : Gunma manufacture - 4WD AT
Model year
D: 1983
Check digit
othru 9 and X, varies
Weight class
B: 3,000 to 4,000 lb GVWR
Model
1
Standard model
2 : DLmodel
3 : GLmodel
Series and engine type
1 : 1300 cc engine
2
1600 cc engine
3
1600 cc engine 4WD
4
1800 cc engine
5
1800 cc engine 4WD
Body type
F : Hatchback
B : 4-Ooor Sedan
W: Hardtop
M: Station Wagon
T : BRAT
Line restraint type
A : Fuji Subaru line and seat belts
B : Fuji Subaru line and air bag
Type of vehicle
1 : Passenger vehicle
2 : Multipurpose passenger vehicle
Manufacturer and make
Fuji Heavy Industries Ltd. SUBARU
t-5
GENERAL INFORMATION
~1·3.
Identification Numbers
1. Vehicle Identification
Number
The vehicle identification number is
stamped on the bulkhead panel of the
engine compartment.
OM·442
Fig. 1·2 Engine serial number location
Fig. 1·1 V.I.N. location
3. Transmission Serial
2. Enaine Serial
Number
The engine serial number is stamped
on the righ t side of the crankcase at
the front.
Fig. 1-3
tA-075
The transmission number label is
stuck on the right upper surface of
main case (MT) or converter housing
(AT).
NOTE:
Engine, transmission and vehicle
identification numbers are used for
factory communications such as
Technical information, Service bulletins and other information.
2. Vehicle Emission
3. Emission Data Label
Number
1·4. Labels
1. Safety Certification
Plate
Safety certification plate is stuck
near the driver's side door striker.
(California Models
Only)
Control Information
Labels
Vehicle emission control information labels are stuck under the engine
hood.
Certification label
High altitude label
(Altitude kit equipped vehicle
only)
Fig.
Vacuum connections lIbel
Fig.
I
1-4 Safety cartification plate
OM.819
Fig. 1-5 Vehicle emission control
labels
1-6
'·6 Emission data label
GENERAL INFORMATION
4. Vehicle Identification
Number Plate
5. Color Code Label
OM·820
Fig.
'-7
Vehicle identification
number plate
Fig. ,-8 Colorcade label
1-5. Recommended Lubricants
API
ITEM
SAE viscosity No. and Applicable Temperature
CIa.·
aficllion
("P)
-30"
0°
30"
60"
90"
("C)
-34·
-180
0"
16·
32°
J-.
40
y
130, 20W40, 20W-SO
• Engine oil
-
SE
SF
<
SW-30
I
I
lOW·30. lOW40. lOW-SO
I
(SW-30 is not recommended for sustained high speed drivillll.)
.• Transmission and differential
gear oil
• 4WD rear differential gear oil
I
GL-S
<
I
80W
90
SSW
I
3
NOTE:
Each oil manufacturer ha its baa oil and additives. Thus do not mix two or more brands.
GENERAL INFORMATION
P:1-6.
Recommended Sealants, Adhesives and Greases
f
-----=--1.
Sealant
Mating surfaces of crank and transmission
cases, plugs, etc.
Fuji Bond D
(PIN 004403005)
Cover gasket of water pump (Fuji Bond C
can be used instead), etc.
Three Bond 1215
(PIN 004403007)
Flywheel bolts, mating surface of fly·
wheel housing.
Dow Corning's
No. 7038
Three Bond 120 I
(PIN 004403008)
Cylinder head gaskets (Super Three Bond
50 can be used for the same purpose).
Dow Coming's
No. 3145
Starcalking B·33A
(pIN 000018901)
Sealing against water and dust entry
through weatherstrips, grommets, etc.
Butyl Rubber
Sealant
Weatherstrips and other rubber parts,
plastics and textiles except soft vinyl
parts.
3M's
EC·I770
EC·1368
Soft vinyl parts, and other parts subject
to gasoline, grease or oil.
e.g. trim leather, gear shift boot, door
inner remote cover, etc.
3M's
EC·776
EC·847
EC·1022 (Spray
Type)
Bonding metals, glass, plastic and rubber
parts. Repairing slightly tom weatherstrips, etc.
Armstrong's
Eastman
910
Weatherstrips securing windshield to body
panels to meet the requirements of Motor
Vehicle Safety Standard.
Essex Chemical
Corp's
Urethane E
-
Cemedine 540
Adhesive
Cemedine 3000
Starseal U-70 for
USA & Canada
-
3.
Grease
Equivalent
Fuji Bond C
(pIN 004403004)
Cemedine 5430L
2.
Application
Recommended
FX clutch grease
(P IN 000040901)
Splines of transmission main shaft.
Molylex No.2
(PIN 623029980)
CVJ and DOJ joints of axle shafts.
PBC
(pIN 003607000)
Stopper plugs of the front disk brake
caliper.
Silicone KS64
(pIN 003606010)
Brake caliper body (piston, spindle
adjuster O·ring), battery terminals,
distributor, hood latch, etc.
Silicolube G·30M
(P IN 004404002)
Control cables and carburetor linkages
subject to cold weather, water·pump
impeller, door latch, striker, battery
terminals, etc.
ABK 100
(pIN 003602000)
Contacting surfaces of drum brake shoes
and shoe clearance adjuster.
Niglube RX·2
(pIN 003606000)
Disk brake caliper (lever, connecting link
and spindle head).
Valiant grease M·2
(pIN 003608001)
~teering
Dow Coming's
No. 7038
gearbox (Both manual and power
teering)
NOTE: The adhesives in the above table are not avail ble from our parts department. Some of them and their equivalent
products may be purchased from your local ven, ors.
GENERAL INFORMATION
1·7. Tightening Torque of Standard Bolts and Nuts
(1) ENGINE & TRANSMISSION
Unit· N·m (kg.m, ft·lb)
5T
7T
9T
lOT
1.03 - LS2
(0.105 - 0.155,
0.76 - 1.12)
2.50- 2.99
(0.255 - 0.305,
1.84 - 2.21)
4.4 - 5.4
(0.45 - 0.55,
3.3 -4.0)
12 -14
(1.2 - 1.4,
9 -10)
25 - 28
(2.5 - 2.9,
18 - 21)
41 -49
(4.2 - 5.0,
30-36)
11-84
(7.2 - 8.6,
52 - 62)
1.52 - 2.01
(0.155 - 0.205,
1.12 - 1.48)
2.9 - 3.9
(0.30 - 0.40,
2.2 - 2.9)
5.9 -6.9
(0.60 - 0.70.
4.3 - 5.1)
14.2-17.2
(1.45 - 1.75,
10.5 - 12.7)
30-36
(3.1 - 3.7,
22 - 27)
53 -63
(5.4 - 6.4.
39 -46)
88 - 106
(9.0 -10.8,
65 -18}
2.50- 2.99
(0.255 - 0.305,
1.84 - 2.21)
4.9 - 5.9
(0.50 - 0.60,
3.6 -4.3)
9.37 - 10.84
(0.955 - 1.105,
6.91 - 7.99)
2.99 - 3.48
(0.305 - 0.355,
2.21 - 2.57)
5.4-6.4
(0.55 - 0.65.
4.0 - 4.7)
10-12
(1.0 - 1.2.
7 -9)
25 -28
(2.5 - 2.9,
18 - 21)
49.5 - 58.4
(5.05 - 5.95)
36.5 -43.0)
88 -106
(9.0 - 10.8,
65 -18)
147 - 175
(15.0 - 17.8,
!O8 - 129)
4T
7T
9T
22.6 -42.2
(2.30 - 4.30,
16.6 - 31.1)
51.0 - 86.3
(5.20 - 8.80,
37.6 - 63.7)
88.3 - 156.9
(9.00 - 16.00,
65.1 - 115.7)
31.4 - 51.0
(3.20 - 5.20,
23.1 - 37.6)
62.8 - 101.9
(6.40 - 11.00,
46.3 -79.6)
117.7 - 196.1
(12.00 - 20.00,
86.8 - 144.7)
Dia. x Pitch (mm)
4 x 0.75
5 x 0.9
6 x 1.0
8 x 1.25
lOx 1.25
12 x 1.5
14 x 1.6
(2)
23 - 26
(2.3 - 2.7,
17 - 20)
46-54
(4.7 - 5.5,
34- 40)
84 -98
(8.6 - 10.0,
62 - 72)
139 - 165
(14.2 - 16.8,
103 - 122)
BODY
Unit· N·m (kg·m , ft.lb)
Dia.(mm)
4
~
5
6
Qt:::"b
8
~
10
TC·002
12
Fig. '·9
~
4
~
5
~
6
TC·OO3-
8
Fig. 1-10
Including bolt or nut with
washer or spring washer
only
10
12
1.1 2.6
(0.17 - 0.27,
1.2 - 2.0)
2.9 - 5.9
(0.30 - 0.60,
2.2 -4.3)
5.4 - 9.3
(0.55 - 0.95,
4.0 - 6.9)
12.7 - 22.6
(1.30 - 2.30,
9.4 - 16.6)
275 -41.1
(2.80 - 4.80,
20.3 - 34.7)
52.0 - 85.3
(5.30 - 8.70,
38.3 - 62.9)
1.2 - 2.2
(0.12 - 0.22,
0.9 - 1.6)
2.5 -4.4
(0.25 -0.45,
1.8 - 3.3)
4.4 7.4
(0.45 - 0.75,
3.3 - 5.4)
9.8 -17.7
(1.00-1.80,
7.2 - 13.0)
22.6 - 36.3
(2.30 - 3.70,
16.6 - 26.8)
39.2 - 64.7
(4.00 - 6.60,
28.9 - 47.7)
Note: The mark is embossed on the bolt head as follows:
4T
5T
7T
4
9T--9
5
IOT---1O
7
17.7 - 31.4
(1.80 - 3.20,
13.0 - 23.1)
37.3 -66.7
(3.80 - 6.80,
27.5 -49.2)
68.6 - 117.7
(7.00 - 12.00,
50.6 - 86.8)
23.S (2.40 17.4 48.1 (4.90 35.4 88.3 (9.00 65.1 -
39.2
4.00,
28.9)
83.4
8.50,
61.5)
147.1
15.00,
IOS.5)
GENERAL INFORMATION
1-8. Opening Engine Hood
1) Engine hood can be lifted slightly
by pulling engine hood lock release
located at the lower area of instrument
panel.
3) Lift hood and unfasten stay from
holder and put the top of stay into the
stopper on hood.
I
I
A4·161
I\
Fig. 1-14 Setting the stay
OM-S02
Fig. 1-11 Engine hood lock release
2) Push up safety catch with hood
pushed down slightly and unlock it.
A1·064
Fig. 1·13 Setting the stay
4) If engine hood needs to be opened
wider than normal position, remove
stay and set it as shown in figure.
5) When clOSing engine hood, detach
stay with hood lifted slightly.
Mter setting stay on holder, lower
hood.
Then push down the front end of
hood to lock it.
NOTE:
OM-S03
Make sure thlt the hood is locked
completely before driving.
Fig. 1·12 Re/68sing hood lock
1-9. Lifting Points and Procedure·
1. Pantoaraph Jack
• Mark shows each pantograph jack
setting positions.
NOTE:
I.
Never get under the vehicle while it
is supported only by the jlck.
Always use safety stands to support
body when you have to get under
the Clr.
b. Block the wheels dilgonilly by
wheel chocks.
c. Make sure the jack is set at the
correct position on the fllnge of
side sill.
OM·61S6
Fig. 1-15 Lifting points
1-10
Fig. 1-16 Settingjack
-
,.
A
ph
GENERAL INFORMATION
2. Garaa. Jack
~
NOTE:
a. When jacking up the vehicle, place
chocks to hold wheels.
b. After jacking up the vehicle with
garage jack, be sure to support the
vehicle with safety stands for
safety.
c. Mike sure the stands are set at the
correct position on the flange of
side sill. (The same setting positions
as those of pantograph jack)
IJUIJ
A1-076
Fig. 1·17
Correct position
Fig. 1-19
A1-077
Fig. 1·18
3. Lift
d. For rear lifting points of 4WO,
apply garage jack under rear dif·
ferential.
NOTE:
Be sure to lift vehicle at the same four
positions as those of pantograph jack.
E:3a
FRONT
A1-078
Fig. 1-20
GENERAL INFORMATION
1·10. Towing Hooks
Towing hooks are provided in front
and rear ends of vehicle.
Front
• Rear
(Hatchback, Sedan and Hardtop)
Rear
Right Left Right Left
Hatchback
Sedan
Hardtop
• • •
-
Station
Wagon
BRAT
• • •
-
• : installed
- : not installed
MPH).
Fig. 1-22
• Front
....
....
----
(Station Wagon and BRAT)
Front towing hOOk..!
OM-439
Fig. 1-21
Fig. 1-23
NOTE:
When towing the vehicle, pay attention to the following.
a. Before towing the car, make certain
that the parking brake is released
and transmission is in neutral.
b. Never turn the ignition key to the
"LOCK" position while the car is
being towed.
c. When the Automatic transmission
vehicle is being towed with the
front wheels on the ground, place
the selector lever in "N" position
and do not exceed 30 km/h (20
A1-012
Whenever towing the car more than
10 km (6 miles) distance, tow the
car with the front wheels raised off
the ground. In case of an inoperative transmission, always tow it
with the front wheels raised off the
ground.
d. Avoid towing another car with
front towing hooks.
e. Not only towing hooks but also
other body parts might be damaged
if pulling too quickly the rope
winded round the hooks and if
pulling strongly the rope side ways
against the hook.
f. Never use tie down tabs for towing.
CHAPTER~
PERIODIC MAINTENANCE SERVICES
Page
2-1.
SCHEDULE OF MAIN-rENANCE SERVICES ................. 2- 2
2-2.
PROCEDURES OF MAINTENANCE SERVICES ..............
1. Inuke and Exhaust Valve Clearances . . . . . . . . . . . . . . . . . . . ..
2. Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . ..
3. Cylinder Head Nuts, Bolts and Intake Manifold Bolts ..........
4. Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5. Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
6. Engine Coolant ...................................
7. Cooling System, Hoses and Connections. . . . . . . . . . . . . . . . . ..
8. Engine Idie Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . ..
9. Choke Mechanism Lubrication .........................
10. Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11. Fuel and Evaporative System Hoses and Connections ..........
12. Air Filter Elements (Air Cleaner, P.C.V. Air Filter) . . . . . . . . . . ..
13. Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14. Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
15. Engine Oil, Transmission Gear Oil and Differential
Gear Oil for Leaks .................................
16. Automatic Transmission Fluid .........................
17. Differential Gear Oil (Automatic Transmission) .. . . . . . . . . . . ..
18. Rear Differential Gear Oil (4WD Vehicle) ................ ..
19. Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
20. Disc Brake Pad and Disc. . . . . . . . . . . . • . . . . . . . . . . . . . . . ..
21. Brake lining and Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
22. Brake System for Leaks or Damage ......................
23. Brake System, Parking Brake and Brake Servo System Operations. ..
24. Cups and Dust Seals of Master Cylinder and Wheel Cylinders .....
25. Lubricate Front Disc Caliper. . . . . . . . . . . . . . . . . . . . . . . . . ..
26. Vacuum Hose and Check Valve of Brake Servo System .........
27. Clutch and Hill Holder Systems. . . . . . . . . . . . . . . . . . . . . . . ..
28. Steering System, Front and Rear Axle Boots . . . . . . . . . . . . . . ..
29. Power Steering System ..............................
30. Suspension (Ball Joint and Dust Cover) . . . . . . . . . . . . . . . . . . ..
31. Grease on Front and Rear Wheel Bearings . . . . . . . . . . . . . . • . ..
32. Wheel Alignment ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
33. Retighten Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
34. Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
35. Lubricate .Hinges and Locks of Doors, Hood and Trunk lid .. . . ..
SlIBARU
2-3.
222222222222222-
3
3
4
4
5
6
6
6
6
7
7
7
9
9
9
2-10
2-10
2-11
2-11
2-12
2-13
2-13
2-14
2-14
2-15
2-15
2-16
2-16
2-17
2-18
2-20
2-20
2. -21
2-21
2-22
2-23
SPECIAL TOOLS ........•........................... 2-23
PERIODIC MAINTENANCE SERVICES
2-1. Schedule of Maintenance Services
Symbols used
A
R
I
P
E
(I) or (R)
Adjust
Replace
Inspect, correct or replace ifnecessary
Perform
Item for emission control sYstem
Recommended service for safe vehicle operation
MAINTENANCE INTERVAL
[Number of months or km (miles) whichever occurs fust)
MAINTENANCE ITEM
1.6
7.5
15
22.5
30
37.5
45
12
24
36
48
60
72
37.5
45
1<1;
e
+. n
52.5
60
84
96
52.5
60
E
1
Intake and exhaust valve clearance
E
2
Drive belt
E
3
Retighten cylinder head nuts and manifold bolts
E
4
Engine oil
R
R
E
5
Engine oil filter
R
R
E
6
Engine coolant
E
7
Cooling system, hoses and connections
E
8
Engine idle speed
E
9
Choke mechanism lubrication
E
10
Fuel filter
E
11
Fuel and evaporative system hoses and connections
E
12
Air filter elements (air cleaner, PCV air filter)
R
E
13
Spark plugs
R
14
Transmission oil
1
R
I
R
15
gear oil for leaks
Ensine oil, transmission gear oil and differential
I
1
1
I
16
Automatic transmission fluid
I
R
I
R
17
Differential gear oil (automatic transmission)
18
Rear differential gear oil (4WD vebicle)
I
R
1
R
19
Brake fluid
R
R
R
R
ffi
tel
I
II
(I)
P
I
1
(I)
R
R
R
R
R
R
R
R
R
R
R
R
(R)
(I)
(R)
(I)
(I)
~
P
P
I
(R)
(R)
(R)
(R)
(I)
(I)
I
Disc brake pad and disc
I
I
I
I
1
Brake lining and drum
R
I
I
R
I
I
I
L
I
I
Brake system for leaks or damage
23
Brake sYstem, parking brake and brake servo system
operation
24
Cups and dust sealS of master cylinder and wheel cylinders
25
Lubricate front disc caliper
26
Vacuum hose and check valve of brake servo system
21
Qutch and hill-holder systems
28
s.teering sYstem, front and rear axle boots
1
~
A
2-2
R
I
I
I
22
R
I
I
I
I
I
1
I
I
R
R
P
p-
P
P
I
I
I
I
I
I
I
I
I
I
I
;=f.
I
I
I
I
I
~ ..~
I
i
PERIODIC MAINTENANCE SERVICES
7.5
15
22.5
30
37.5
45
52.5
60
1.6
12
24
36
48
60
72
84
96
1
7.5
15
22.5
30
n5
45
52.5
60
Months
MAINTENANCE ITEM
xl000km
xlOOO miles
I
I
I
29
Power steering system
30
Suspension (ball joint and dust cover)
31
Grease on front and rear wheel bearings
I
I
32
Wheel alignment
I
I
33
Retighten wheel nuts
34
Headlight aiming
35
Lubricate hinges and locks of doors, hood and
trunk lid
P
I
I
I
P
P
P
P
I
I
p
I
p
p
p
NOTE:
When operating your vehicles under any of following conditions, change the
engine oil every 6,000 km (3,150 miles) or 3 months whichever occurs first.
• Operation in extremely cold Mather
• Repeated short trips
• Driving on dusty roads
2·2. Procedures of Maintenance Services
To maintain the best perfonnance of
vehicle and to drive safely, periodic
maintenance services must be perfonned at least at the designated
intervals and strictly in the correct
procedures.
And also use the SUBARU genuine
parts whenever replacing parts.
At the specified intervals, inspect,
replace or adjust each item as follows.
Standard ofValve clearance (when engine is cold)
l~
I
All models except those
with hydraulic lifter
Hydraulic lifter
equipped models
Intake
0.23 - 0.27 mm
(0.009 - 0.011 in)
Omm
(0 in)
Exhaust
0.33 - 0.37 mm
(0.013 - 0.015 in)
Omm
(0 in)
1. Intake .nd Exhaust
Valve Clearances
4) Tighten locknuts.
NOTE:
It is not necessary to adjust valve
dearances on hydraulic lifter equipped
models.
1) Bring piston of cylinder to the top
dead center at compression stroke.
2) Insert a thickness gauge between
valve stem and rocker ann to measure
the valve clearance.
3) To adjust the clearance, use Valve
Clearance Adjuster (498767000).
Loosen locknuts and turn adjusting
screws to obtain the specified valve
clearance.
Torque
ST'031
14-18N·m
(1.4 1.8 kg-m.
10 - 13 ft-lb)
5) Adjust each valve clearance according to the follOWing sequence.
Fig. 2-1 Adjusting valve clearances
Cylinder number
#1 ... #3 ... #2 ... #4
PERIODIC MAINTENANCE SERVICES
6) Rechec k the valve clearances on
both sides after rotating crankshaft
several times.
NOTE:
a. Adjust the valve clearances when
the engine is cold with its coolant
temperature between 20 and 40"C
(68 and 104"F).
b. When making the adjustment within the first maintenance interval,
retighten the cylinder head nuts in
advance.
2) Wipe off any oil or water on belt
and pulleys.
3) Replace belt if crack or other
damage is found.
NOTE:
When replacing belt with new one,
adjust its tension to 10 mm (0.39 in)!
98 N (10 kg, 22Ib).
• Oil pump belt for power
steering
.~
Oil pump belt tension
2. Drive Belt
15
• Alternator belt
20mm(0.59-0.79in)/
98N(IOkg,22lb)
.
20 - 29 N·m
~··--·-I--------l
Torque
( ~• 3 kg.l1J
I. (Idler lock bolt)
14 _ 22 n.lb)
L ... _ _.. ___
__. _________ ~
i
NOTE:
a. When installing idler cap, turn it
while pushing. If not available to do
so, apply grease on lip of idler cap
and try to install it again.
b. Make sure to install idler cap
securely by turning it.
Wipe off any oil or water on belt,
pulley and idler.
3) Replace belt if crack or other
damage is found.
2)
I
Alternator belt tension
i
Power steering pump
98 N (10 kg, 221b)
13
14 mm (0.51 0.55 in)/
98 N (10 kg, 22lb)
:,.
. 15
I
20mm
(0.59 - 0.79 in)
13
(0.51
Crank·
shaft
Idler
Fig.24 Oil pump belt tension
for power steering
OM 101
Fig. 2·2 Alternator belt tension
I) Inspect alternator belt tension,
and adjust it if necessary as follows.
Loosen alternator mounting bolt and
change alternator installing position so
as to obtain the specified belt tension.
I) Inspect oil pump belt tension for
power steering and adjust it if necessary as follows.
( I) Loosen lock bolt installing idler
after taking out idler cap, and then
turn adjust bolt so as to obtain the
specified belt tension.
3. Cylinder Head Nuts,
Bolts and Intake
Manifold Bolts
1) Remove both sides of valve rocker
covers.
2) Loosen the tlHee bolts securing
the intake manifold on the;l:l
#3
cylinder head by 60°. The other
#4 cy·
manifold bolts 011 the #2
linder head side should be intact.
J) Loosen No.1 nut on cylinder
head by around 60° and apply suf.
ficlent engine oil to its thread portion
as shown in figure.
After repeating 4 to 5 times of
loosening and tightening operation in
the range of 60°, retighten the No.1
nut to the specified torque.
NOTE:
Do not loosen the nut more than 90°,
since water leak might occur.
,,)~0
Apply engine oil
'0'''0
,\'1
Repeat
4 to 5
times.
A3·186
Fig. 2·5 Turning adjust bolt
A3·111
Fig. 2·3 Tightening.alternator
mounting bolt
(2) Retighten idler lock bolt anJ in·
stall idler cap.
2-4
Fig. 2·6 Loosening nut and applving
engine oil
PERIODIC MAINTENANCE SERVICES
64N·m
(6.5 kg-m,47
r.
4) Retighten all nuts in the sequence shuwn in figure with same
manner.
2) Open engine oil filler cap for
quick draining the engine oil.
0.23 -- 0.27 mm
. (0.009 - O.Qll in)
Intake valve
. : 0,33 I (0.013
lEXhaust valve
0.37 mm
0.Ql5 in)
9)
Install the rocker covers.
!
Torque
3 - 4 N·m
(0.3 0.4 kg·m,
2.2 - 2.9 ft·lb)
OM-514
4. Engine Oil
Fig.2-9 Engine oil filler cap
I) Drain engine oil by loosening
engine oil drain plug.
3) Tighten engine oil drain plug after
draining engine oiL
A3-119
Fig. 2·7 Tightening sequence for
cylinder head nuts and bolts
25 N·m
(2.5 kg-m, 18 ft·lb)
NOTE:
a. As a rule, retightening operation
should be carried out when engine
is in cold condition below 40°&
(104°F).
b. Use Socket Wrench (499987006)
to retighten No.1 and No.9 nuts.
c. Use Socket Wrench (899988607)
to retighten No. 4 and 5 bolts.
d. Retightening procedure for the
nuts should be carried out one
by one.
5) After tightening all nuts, reo
tighten No. 1 nut again to the speci·
fied torque without loosening.
6) Also tighten all nuts on another
side cylinder head with the same
manner.
7) Retighten the intake manifold
bolts on the #1 - #3 cylinder head
side to the specified torque.
Torque
18 - 22 N·m
(1.8 - 2.2 kg·m,
13 16 ft-lb)
4) Fill engine oil through filler pipe
up to upper point on level gauge. Make
sure that vehicle is placed level when
checking oil level. Use engine oil of
proper quality and viscosity, selected
in accordance with the next table.
A3-007
Fig.2-8 Draining engine oil
ITlM
API
Classili~a-
lion
SAL VI~i.'osi!y No. and Applicable Temperature
(OF I
30"
0"
30"
("0
34"
_III"
U"
60°
16"
'pc,
90"
I 30. 20W-4U. 2UW·SO .
fngilll: oil
SE
<
SF
SIY-JII
I
IOW-3I1, lOW-40, lOW-50
I
I
(SW-30 oil is not recommended for sustained high speed driving.)
The proper viscosity helps car get good
cold and hot starting by reducing
viscous friction and thus increasing
cranking speed.
NOTE:
8) Adjust the intake and exhaust
valve clearances when engine is cold.
(Except hydraulic lifter equipped
models)
Each oil manufac1Urer has its own base
oil and additives.
Thus, do not mix two or more oils of
different brands.
2-5
OM·745
Fig. 2-10 Checking engine oil level
PERIODIC MAINTENANCE SERVICES
Engine oil capacity
1800 cc
Engine
Upper
level
Lower
level
4.0 II
(4.2 USqt )
3.S Irnpqt
Coolant capacity
1600 cc
Engine
1800 cc
Engine
1600 cc
Engine
3.S!!
C.7
USqt )
3.1lmpqt
3.0 II
2.s!!
(3.2 USqt )
2.6lmpqt
(2.6 USqt )
2.2lmpqt
Approx.
5.5 Q
e.8
OM-519
US qt )
4.8 Imp qt
Approx.
5.3 Q
(S.6US q t )
4.7 Imp qt
Fig.2·11 Inspecting coolant level
5) Close engine oil filler cap.
6) Start engine and warm it up for a
time.
7) After stop engine, recheck the oil
level.
If necessary, add the engine oil up to
upper point on level gauge.
s.
Engine Oil Filter
1) Remove oil nIter with an oil fIlter
wrench.
2) Get a new oil fIlter and apply a
thin coat of engine oil to the seal
rubber.
3) Install oil fIlter by turning it with
hand, being careful not to damage
seal rubber.
4) Tighten more approximately two
thirds tum after the seal rubber con·
tacts the oil pump case. Do not
tighten excessively, or oil may leak.
5) After installing oil fIlter, run
engine and make sure that no oil is
leaking around seal rubber.
NOTE:
a. The radiator is of the pressurized
type. Do not attempt to open the
radiator cap immediately after the
engine has been stopped.
b. The SUBARU Coolant containing
anti-freeze and anti-rust agents is
especially made for SUBARU engine, which has an aluminum crankcase. Always use SU BARU Coolant,
since other coolant may cause corrosion.
• Replacing
1) Put heater control knob on instru·
ment panel to heat position.
2) Loosen coolant drain cock after
installing hose onto drain plug, and
drain coolant.
NOTE:
The filter element and filter case are
permanently joined; therefore, interior
cleaning is not necessary.
6. Engine Coolant
7. Cooling System,
Hoses and
Connections
1) Check the components of· the
cooling system and each connection
for leak.
2) If the coolant temperature ex·
o
ceeds 86.5 to 89.S C (188 to 193°F)
while radiator is not so hot, check
thermostat.
3) If thermostat does not open
o
at 86.5 to 89.S C (188 to 193°F),
replace it with a new one.
4) If electric fan does not operate
with coolant temperature above 93
to 97°C (199 to 207° F), check
thermoswitch or fan motor.
5) If radiator hoses are damaged,
replace with new ones.
6) If by-pass hoses or overflow tube
are clogged, clean the inside of hoses
or tube with cleaning oil.
Fig.2·12 Draining coolant
8. Engine Idle Speed
• Inspecting
Inspect that the coolant level is above
level plate by removing radiator cap.
Top up coolant to level plate if the
coolant level is 10 mm (0.39 in) or
more below it.
6) Install radiator cap and close
firmly.
7) Start engine and warm it up for a
time.
8) Stop engine, and wait until the
engine temperature is decreased.
9) Inspect the coolant level.
If necessary, add coolant up to level
plate.
3) Open radiator cap for quick draining coolant.
4) Tighten drain cock firmly.
5) Fill the SUBARU coolant up to
level plate.
2-6
NOTE:
Inspection of engine idle speed should
be carried out after inspection of
intake and exhaust valve clearances.
(Except hydraulic lifter equipped
models)
PERIODIC MAINTENANCE SERVICES
1) Disconnect purge hose from pipe
and clog hose with plug or the like.
10. Fuel Filter
Fuel fIlter cannot be disassembled as
it is of the cartridge type.
]
A3·254
Fig. 2·13
A3·256
2) Start engine and warm it up for
5 minutes or more.
3) Inspect idle speed.
Fig. 2·15
11. Fuel and
Evaporative System
Hoses and
Connections
1) Fuel piping and connections
Check fuel piping and connections for
leakage.
2) Evaporative emission system
(I) Evaporation line from fuel tank to
canister.
a. Remove fuel rdler cap.
b. Disconnect evaporation line at
evaporation pipe CP.
c. Check for unobstructed evaporation line on fuel tank side except
for a little resistance due to 2-way
valve by blowing air into hose.
d. Check for unobstructed evaporation
line on canister side with no resistance by blowing air into hose.
Idling speed (rpm)
All models except
automatic
transmission vehicle
7oo± 100
Automatic
transmission vehicle
800 ± 100
[At neutral (or N) or P position]
Tank vapOr line
9. Choke Mechanism
Lubrication
Lubricate choke linkage and other
operating parts.
A3·257
Fig.2-16 Evaporation line
(2) Two way valve
a. Check for air passage with slight
resistance due to the valve by blowing air into the nipple on the side
marked with letters "To engine".
b. Repeat the same step on the other
nipple.
c. Check for the valve case with no
crack. If cracked, replace it with
new one.
R~~"
To canister
To fuel tank
~~§ ..
1 Valve "8"
2 Valve "A"
3 Cue
4 Spring .
5 Retainer
A3·256
A3·192
Fig.2-17 Two way valve
Fig. 2-74
2-7
PERIODIC MAINTENANCE SERVICES
(3) Purge line
a. Disconnect purge hose from the
pipe CP CD.
b. Check for unobstacled line by
blowing air into the hose.
~.
@From carburetor
I
Purge vent
Vacuum release
orifice
0.4 mm (0.016 inl dia.
From fuel tank
Vacuum vent
®
1
Orifice
1.5 mm (0.059 inl
dia.
00
000
00
00
Purge control valve
Activated
carbon
PipeCP
2 Canister
3 Carburetor
A3·258
Filter
4 Hose clamp
A3-259
Fig.2·18 Purge line
Fig. 2·19
(4) Canister
a. Disconnect vacuum vent hose from
pipe CP CD. Then check for no air
leak of vacuum chamber for purge
control valve in canister by blowing
into hose. If air can be blown into
canister, replace it with new one
because disphragrn is broken.
b. Disconnect two hoses of carburetor
vapor line and tank vapor line from
pipe CP CD. Then check for air
passage by blowing lightly in it. If
air does not pass, replace canister
with new one.
c. Disconnect hose of purge line from
pipeCP CD.
Check for air passage by blowing in
it. If air passes, replace canister
with new one.
d. If canister case is cracked, replace it
with new one.
(5) Vacuum switching valve and
thermo valve (California models and
non4WD of non-California models)
a. After the engine has cooled below
50°C (122°F), disconnect the hose
@ from the vacuum switching
valve CD. Blow through the open
end of the hose to ensure there is
no air flow at the port in the
thermo valve ®. If there is air
flow, replace the thermo valve.
b. After the engine has warmed above
64°C (l47°F), disconnect the hose
@ from the vacuum switching
valve CD. Blow through the open
end of the hose to check if there is
air flow at the port in the thermo
valve. If there is no air flow, replace
the thermo valve.
c. Disconnect the hoses @ and @
from the vacuum switching valve
CD . Blow through the nipple of the
vacuum switching valve on the
carburetor side to ensure there is
no leakage. Similarly, blow through
the nipple on the thermo valve side
2-8
A3-260
I
2
3
4
Vacuum switching valve
Thermo valve
Hose
Hose
5 Carburetor
Fig. 2·20
to ensure there is no leakage. In
either case, if there is a leak, replace
the vacuum switching valve.
PERIODIC MAINTENANCE SERVICES
d. After the temperature of engine
coolant has reached 64°C (l47°F)
or more, disconnect the hose ®
from the vacuum switching valve.
With the engine running, blow
through the nipple on the carbure·
tor side to ensure there is air flow.
If there is not, replace the vacuum
switching valve.
Spark plug gap
1.0 - 1.1 mm
(0.039 0.043 in)
OM'755
Fig. 2-24 P.C. V. air filter
To
thermo vacuum
valve III
A3·261
Fig. 2-21 Vacuum switching valve
1.0 . 1.1 mmlO.039 ·0.043 in)
NOTE:
Do not attempt to clean the air
cleaner element.
The filter paper of the element is
wetted with a special noninflammable
slow-evaporating viscous liquid. It is
resistant to cold weather and has a
long service life. Dirt adhering to this
filter paper forms porous laminations
with the viscous liquid, which function
as a filtration layer to reduce dust
penetration into the filter paper. If
this filter paper is cleaned, the filtration layer thus formed will be lost
along with the viscous liquid.
Spark plug thread
Oia. = 14 mm CO.55 in)
Pitch = 1.25 mm (0.0492 in)
Fig. 2·25 Spark plug
When installing spark plugs on cylinder
head, tighten them to the specified
torque.
18 24 N·m
( 1.8 - 2.4 kg·m,
13 17 ft·lb)
Torque
13. Spark Plugs
Fig. 2-22 Thermo vacuum valve III
12. Air Filter Elements
(Air Cleaner
P.C. V. Air Filter)
NGK: BPR6ES-Il (or
BPR5ES·ll, BPR7ES·ll)
Nippondenso: W20EPR·Ull
For
(or W l6EPR.UlI,
U.S.A.
W22EPR.UII)
Champion: RN9YCA
(or RNllYC4)
For i IChampion: RN9YCA
I Canada
(or RNlIYC-4)
I
NOTE:
a. Be sure to place the gasket between
the cylinder head and spark plug.
b. When replacing the spark plug on
#4 cylinder head, be careful about
the air suction manifold switch
maybe hot.
Recommended spark plugs
A3·262
A9·163
14. Transmission Oil
I
I
NOTE:
Use transmission gear oil of proper
quality and viscosity that is selected
in accordance with the next table.
Recommended oil
API
ITEM
•
•
Classification
Transmission and
differential gear oil
4WD rear differen·
tial gear oil
SAE Viscosity No. and Applicable Temperature
(OF)
-30°
0°
30°
60°
90°
(oC)
_34°
18°
0°
16°
32°
~
GL-5
.
I
I
"
Fig. 2-23 Air cleaner element
~
SSW
SOW
OM·539
90
r
~
NOTE:
Each oil manufacturer has its base oil and additives. Thus, do not mix two or more
brands.
2-9
PERIODIC MAINTENANCE SERVICES
• Inspecting
Capacity
Inspect the transmission gear oil level.
If the oil level is at the lower point
or below, add some oil through the oil
level gauge hole up to the upper point
of gauge.
4-speed and S-speed
(except 4WD)
2.7 f.
(2.9 US qt )
2.4 Imp qt
3.0 f.
4WD
Fig. 2-26
OM·515
• Replacing
1) Drain oil by removing drain plug.
C·2USqt)
2.6 Imp qt
15. Engine Oil,
Transmission Gear
011 and Differential
Gear 011 for Leaks
3) Place selector lever in "P" position and run engine on at idling speed.
4) Remove level gauge and wipe it
clean.
S) Reinsert the level gauge all the
way.
6) Remove it again and note reading.
If the fluid level is below the lower
limit mark, add recommended ATF
until the fluid level is within the specified range (within upper and lower
limit marks). When transmission is hot,
the level should be above the center of
upper and lower marks, and when it is
cold, the level should be below the
center of these two marks.
ATF level gauge hole also serves as
fluid filler.
NOTE:
Do not fill the fluid above upper point
of level gauge.
•
Inspect the underside of engine, transmission gear case and differential gear
case (include 4WD rear differential
gear case).
If the oil leaks are found, correct
them.
A3·244
Fig. 2-29
OM·746
Fig. 2-27
2) Reinstall drain plug after draining
oil and tighten it to the specified
torque.
Torque
OM·748
Fig. 2·28 Inspecting oil leaks
44N·m
(4.5 kg-m, 33 ft-Ib)
NOTE:
a. Be sure to place a gasket ..tween
die transmission case and drain
plug.
b. Replace iIle gasket widl new one.
3) Fill transmission gear oil through
the oil level gauge hole up to upper
point on level gauge.
16. Automatic
Transmission Fluid
• Inspecting
1) Drive vehicle several miles to bring
automatic transmission fluid (ATF)
up to nonnal operating temperature.
Nonnal operating temperature is 60 to
80°C (140 to 176°F).
2) Park vehicle on a level surface.
2-10
Recommended automatic transmission
fluid (ATF Dexron)
B.P.
B.P. Autran DX
CALTEX
Texamatic fluid
6673 Dexron
CASTROL
CASTROLTQ
Dexron
MOBIL
Mobil ATF 220
TEXACO
Texamatic Fluid
6673 Dexron
.. -.---.~
I
PERIODIC MAINTENANCE SERVICES
• Replacing
17. Differential Gear
Oil (Automatic
Transmission)
1) Drain fluid by removing drain
plug.
• Inspecting
Oil level should be maintained be-
3) Fill differential gear oil through
the oil level gauge hole up to upper
point on the level gauge.
I
Capacity
l.H
(1.3
US qt )
1.1 Imp qt
tween two points on the level gauge. If
the oil level is at lower point or below,
add some oil up to upper point.
18. Rear Differential
Gear Oil (4WD
Vehicle)
OM·335
Fig. 2-30
• Inspecting
2) Reinstall drain plug after draining
fluid, and tighten it to the specified
torque.
Torque
Fig. 2-37
OM-516
• Replacing
25N·m
(2.5 kg·m, 18 ft-Ib)
I) Drain oil by
plug.
Remove plug of ftller hole and check
the oil level. Oil level should be
maintained fully to the mouth of filler
hole.
If the oil level is below the mouth of
filler hole, add some oil up to the
mouth.
removing drain
NOTE:
a. Be sure to place a gasket between
oil pan and drain plug.
b. Replace the gasket with new one.
3) Fill ATF through the fluid level
gauge hole.
Capacity
OM-517
Non4WDAT
4WDAT
I
5.6 6.02
( 5.9 - 6.3 US qt )
4.9 5.3 Imp qt
Fig. 2-33
:1J
6.0 6.42
( 6.3 - 6.8 US qt )
5.3 - 5.6 Imp qt
NOTE:
When replacing ATF, the normal
refilling capacity is 4.02 (4.2 US qt,
3.5 Imp qt).
4) Check the ATF level according to
the above inspection procedure 1) to
6).
OM-747
i
I
Fig. 2-32
2) Reinstall drain plug after draining
oil, then tighten it to the specified
torque.
Torque
25N·m
(2.5 kg·m, 18 ft·lb)
NOTE:
a. Be sure to place a gasket betlNeen
the differential gear case and the
drain plug.
b. Replace the gasket with new one.
2-11
• Replacing
1) Drain oil by remOVing drain plug_
2) After installing drain plug onto
rear differential gear case firmly, fill
oil up fully to the mouth of ftller hole.
I
Capacity
0.8 Q (0.8 US qt )
0.7 Imp qt
3) Install ftller hole plug onto rear
differen tial v;ear case firmly.
PERIODIC MAINTENANCE SERVICES
19. Brake Fluid
1) Either jack up the front end of
vehide and place a safety stand under
it, or drive vehicle onto the pit and
then jack up the front end.
2) Remove both left and right front
wheels.
3) Remove filler cap from brake
fluid tank.
Install one end of a vinyl tube onto
the air bleeder of master cylinder and
insert the other end of the tube into a
container to collect the brake fluid.
To drain fluid into container, open
the air bleeder and repeatedly depress
and release the brake pedal until a
small amount of fluid remains in the
reservoir tank.
Always begin changing the brake
fluid on the primary side and subsequently work on the secondary
side.
For convenience and safety, it is
advisable to have two men working.
b. Be careful not to spill brake fluid
onto the painted surface.
c. Discard the drained brake fluid and
do not reuse it.
4) Refill reservoir tank with recommended brake fluid. To purge air
out of brake system lines, slowly and
repeatedly depress and release the
brake completely until a solid stream
of brake fluid (containing no air
bubbles) runs through vinyl tube.
Then tighten air bleeder securely.
~'----'---~'---'----'---~---,
Recommended brake fluid
I-----.-------.-.---.-.~-
FMVSS No. 116,
fresh DOn brake fluid
NOTE:
a. Avoid mixing different brands of
brake fluid to prevent degrading
the quality of the fluid.
b. Be careful not to allow dirt or dust
to get into the reservoir tank.
c. Use fresh DOT 3 brake fluid when
replacing or refilling the fluid.
Fig. 2-34
NOTE:
a. The brake piping consists of a dual
system, cross design. The piping on
the primary side connects the right
front brake and the rear left brake
and the piping on the secondary
side connects the left front brake
and rear right brake.
Front right
5) Install one end of a vinyl tube
onto the air bleeder of wheel cylinder
located farthest from master cylinder
and put the other end of tube into the
container for receiving brake fluid.
Rear right
6) Open the air bleeder, and depress
and release brake pedal until old brake
fluid is drained out and new fluid
flows through vinyl tube.
Then close the bleeder.
NOTE:
a. Always check to be sure a small
amount of brake fluid is in the tank
while changing brake fluid.
b. The amount of brake fluid required
is approximately 80 cm 3 (80 ee,
4.88 cu in) for each pipe on the
primary and secondary sides.
7) Use the same procedure as the one
described above to change brake fluid
of front wheel cylinder.
8) Always start with the primary side
and then work on the secondary side.
9) After brake fluid has been
changed, bleed air from the brake lines
as follows:
NOTE:
Start with the bleeder located farthest
from the master cylinder.
(l) Install one end of a vinyl tube
onto air bleeder screw and put the
other end into the container.
(2) Attach a wrench to bleeder screw,
but do not loosen it at this point.
(3) Instruct your co-worker to depress the brake pedal slowly two or
three times and then hold it depressed.
(4) Loosen bleeder screw approximately 1/4 turn until a small amount
of brake fluid drains into container,
and then quickly tighten screw.
(5) Repeat steps (3) and (4) above
until there are no air bubbles in
drained brake fluid.
NOTE:
Add brake fluid as necessary while
performing the air bleed operation, in
order to prevent the tank from run·
ning short of brake fluid.
(6) After completing the bleeding
operation, hold brake pedal depressed
and tighten screw and install bleeder
cap.
Primary
Torque
(bleeder screw)
Front left
Rear left
A3-124
A17-150
Fig. 2-35
Fig. 2-36
I
7 -9N·m
(0.7 0.9 kg-m,
5.1 6.5 ft-Ib)
(7) Bleed air from front wheel cylinder using the same procedures as
described in steps I) through 6) above.
PERIODIC MAINTENANCE SERVICES
10) Upon completion of air bleeding
for the primary and secondary brake
lines, depress brake pedal to determine
if its operation and stroke length are
correct.
11) Depress brake pedal again with a
force of approximately 294 N (30 kg,
66 Ib) and hold it there for approximately 20 seconds. At this time check
pedal to see if it shows any unusual
movement.
Visually inspect bleeder screws and
brake pipe joints to make sure that
there is no fluid leakage.
I
Brake disc pad thickness
.
:
21. Brake Lining and
Drum
I
Standard
IS mm (0.59 in)
Wear limit
7.5 mm (0.295 in)
J
Lining
Pressure plate
Inspect brake linings and drums of
both sides of the rear brake at the
same time by removing brake drums.
For the removing and installing procedures of the rear brake, refer to
"BRAKES".
1) Inspect brake shoes for damage or
deformities and check brake linings for
wear.
NOTE:
Always replace both leading and trailing brake shoes for the left and right
wheels at the same time.
Thickness of pad
A3-154
Fig. 2-38 Measuring thickness
afdisc pad
I
Brake lining thickness
I
I
Brake disc thickness
Standard
Solid
disc
!
I
A3-125
12) Install front wheels, and drive car
for a short distance between 2 to 3 km
(1 to 2 miles) to make sure that brakes
are operating properly.
5 mm (0.20 in)
Wear limit
1.5 mm (0.059 in)
I
i
I
' - -_ _ _...L.-_ _ _ _ .~
I
Ventilated
disc
Fig. 2-37
i
12.5 mm
(0.492 in)
Standard
Wear
limit
lOmm
(0.39 in)
Standard
18mm
(0.71 in)
Wear
limit
15.5 mm
(0.610 in)
J
I
I
I
I
J
I
1\.
~
Thickness of
A3'156
I
Fig. 2-40 Measuring thickness of
brake lining
d;'J
Thickness of
2) Check brake drum for wear, dents
or other damage.
Brake drum inside diameter
20. Disc Brake Pad and
Disc
Inspect disc brake pads and discs of
both sides of front brake at the same
time by removing the disc brake
pads. For the removing and installing
procedures of brake pads, refer to
"BRAKES".
NOTE:
DO not touch the brake pedal with
disc pads removed.
b. Do not disconnect. the brake tubes
and hoses.
I.
A3-155
Fig. 2·39 Measuring thickness of
brake disc
I
Standard
180 mm (7.09 in)
Wear limit
182 mm (7.17 in)
L
Maximum permissible disc
rotor runout
0.10 mm (0.0039 in)
NOTE:
Measure the disc rotor runout at a
point less than 5 mm (0.20 in) from
the outer periphery of the rotor.
2-13
Measuring inside diameter
A3·157
Fig.2-41 Measuring brake drum
PERIODIC MAINTENANCE SERVICES
22. Brake System for
Leaks or Damage
1) Check scratches, swelling and/or
traces of fluid leakage on brake hoses
or pipe joints.
0
c. Turn back adjusting screw by 180
and lining clearance will be 0.1 to
0.15 mm (0.004 to 0.0059 in).
d. Be sure to' rotate tire and wheel
lightly by hand.
e. Adjust lining clearance of another
side rear brake with the same manner.
Brake pedal free play
5 - II mm (0.20 - 0.43 in)
A3·126
Fig. 245 Adjusting screw for lining
clearance
Fig. 243
Fig. 2·42
A3-127
I f the free play is not within the
specified range, adjust the length of
master-vac operation rod and/or the
position of stop lamp switch until
correct adjustment has been made.
2) Check the possibility of adjacent
parts interfering with brake pipes/
hoses during driving, and loosen con·
nections/clamps.
3) Check any trace of fluid leakage,
scratches, etc. on master cylinder or
wheel cylinder.
3) Measure the distance between
brake pedal and floor when the pedal
is depressed with a force of approximately 294 N (30 kg, 66 lb).
I
Brake pedal reserve distance
More than 80 mm (3.15 in)!
294 N (30 kg, 66 Ib)
2
NOTE:
When the brake fluid level in the
reservoir tank is lower than the specified limit, the brake fluid warning
light on the instrument panel will
come on.
\
\
..
!
1 Master vac \..
operation rod ' \
2 Stop lamp SWitCh"'\.
\
'\..
.'"
~~
A3,152
...................
23. Brake System,
Parking Brake and
Brake Servo
System Operations
• Brake system
1) Check the free play of brake pedal
by lightly depressing the pedal with
your finger.
Fig. 244
13.15 in) \ .
2) Adjust lining clearances of rear
brake as follows.
a. Jack up vehicle to release tires and
wheels slightly from the ground.
b. Tighten adjusting screw on back
side of rear brake drum fully until
tire and wheel ceases to rotate.
2-14
Fig. 246
4) Check to see
draulic brake line
pedal operation.
exist in the line,
system.
..........
.......
A3-153
if air is in the hyby the feel of the
If air appears to
bleed it from the
-----.,
PERIODIC MAINTENANCE SERVICES
5) Check for even operation of all
brakes, using a brake tester or by
driving the vehicle for a short distance
on a straight road.
• Parking brake
1) After confirming the proper operation of brake pedal, pull parking
brake lever with a force of approximately 245 N (25 kg, 55 Ib) to make
sure lever still has a short length of
stroke to go.
c. Lightly depress and release brake
pedal as necessary until the parking
brake lever pull is within the specifications.
d. Make sure that vehicle stops on
uphill road properly by operating
parking lever.
• Brake servo system
24. Cups and Dust
Seals of Master
Cylinder and Wheel
Cylinders
Replace the cups and dust seals of
master cylinder and wheel cylinders
according to "BRAKES".
NOTE:
1) Connect a vacuum gauge to the
line between the master-vac and the
check valve.
Carry out this replacing operation
before replacing brake fluid.
Parking brake lever stroke
!
Standard
' 3 - 4 notches!
245N (25kg, 551b)
\
Total number
I II notches
2) If the parking brake lever pull
is not within the above specifications,
adjust it as follows:
a. Pull parking brake lever forcibly
three to five times.
b. Loosen the lock nut and change the
setting of adjuster until the play at
point A is 0 to 0.5 mm (0 to 0.020
in).
A3·130
I Cable
2 Equalizer
Fig. 247
A17·149
A3-230
A3-231
Fig. 248
2) Start engine and keep it running
until a vacuum of 66.7 kPa (500
mmHg, 19.69 inHg) is indicated on the
vacuum gauge.
Do not depress brake pedal.
3) Stop engine and watch the gauge
to make sure that the vacuum drops
below 3.3 kPa (25 mmHg, 0.98 inHg),
within 15 seconds.
If the vacuum drops below 3.3 kPa
(25 mmHg, 0.98 inHg), the brake
servo system is functioning properly.
4) If a vacuum gauge is not available,
check the vacuum using the following
procedures:
(l) Wit h engine off, depress brake
pedal several times applying the same
amount of pressure so that a vacuum
will not be created. After several
applications of pedal pressure, check
the pedal height above floor to make
sure that it does not vary with each
depression of pedal.
(2) With brake pedal depressed, start
engine.
(3) As engine starts, if brake pedal
moves slightly toward floor, master·_-'\I'IIcls functioning properly.
2-15
Rubber cup
2 Dust seal
A3-162
Fig.2-49 Replacing cups and dust
seals of master cylinder
and wheel cylinder
25. Lubricate Front
Disc Caliper
• Parking brake lever
I) Remove lever cap ring.
2) Take off lever cap.
3) Remove grease, and clean the lip
of lever cap and its slot of caliper
body to be free from any foreign
matter.
NOTE:
If the slot gathers rust, rub it off by a
wire brush.
PERIODIC MAINTENANCE SERVICES
4) Apply sufficient amount of specified grease to the space around lever
& spindle so as to be filled inside of
lever cap after fitting it.
Especially apply grease to the ends of
lever & spindle, cone spring and the
lever cap fitting slot without fail.
26. Vacuum Hose and
Check Valve of
Brake Servo
System
Grease
Silicon Compound
(725191050 or vV.J'UV'JV
--~-.---~--
,
. .-~~
Grease
NIGLUBE RX-2 grease
(725191040 or 003606000)
A3·265
Fig. 2-51 Grease application to
guide pin portion
1) Check vacuum hose for cracks or
other damage.
2) Remove check valve and manually
blow through valve to check its operation. When air is drawn in through the
opening of check valve on the engine
side, air flows through master-vac. If
air is drawn in through the opening on
the master-vac side, air will not flow
and therefore check valve should be
replaced with a new one.
3) Check valve conducts air in one
direction only.
When installing, note the direction of
check valve and correctly connect
valve to vacuum hoses.
Fig.2-50 Grease application
NOTE:
Never use any grease except the specified; otherwise the lever cap will be
deteriorated and will cause damage to
the function of the disc brake.
5) Pull parking brake lever several
times.
6) Fit lever cap properly into the slot
of caliper body.
7) Attach cap ring onto lever cap.
A3·266
Fig. 2-52 Grease application to
lock pin portion
Fig. 2-53
NOTE:
NOTE:
Be careful not to damage the lever cap
by the edge of the cap ring. If the lever
cap is deformed or damaged, replace it
with a new one.
A3·232
3) Then, install caliper body ASSY
and tighten lock pin to the specified
torque.
When installing the check valve onto
the vacuum hose or when installing
the vacuum hose on the engine and
master·vae, do not use soapy water or
lubricating oil on their connections.
4) Check all vacuum hoses to make
sure they are tight and secure .
• Slide pin
16 24 N·m
(1.6 ~ 2.4
12 ~ 17 ft-Ib)
l)
Remove caliper body assembly
from support.
2) Remove foreign materials from
guide pin and sleeve, and apply
Silicon Compound (725191050 or
003606010) to this area.
NOTE:
Use
only
Silicon
Compound
(725191050 or 003606010) for guide
pin and lock pin portions.
NOTE:
a. After assembly, make sure that
boots are properly fitted in grooves
on guide pin and sleeve.
b. If boot contains too much air and is
expanded, press it to purge out air.
2-16
27. Clutch and Hill
Holder Systems
I) Inspect free play of clutch pedal
by operating pedal by hand.
If it is out of the specified value,
adjust it by turning adjusting nut on
engine side end of clutch cable at
release fork.
PERIODIC MAINTENANCE SERVICES
Adjustment standard of free play
.
I At clutch pedal!
~
13
(0.5 I
A"'nt'~ o;-\r(
2
20
0.79 in)
~
3
I
2) Confinn stopping and starting
perfonnance by activing hill-holder on
an uphill road of 3° or higher inclination.
(I) Ifvehicle does not stop;
Tighten adjust nut of PHV cable.
28. Steering System,
Front and Rear
Axle Boots
1. Steering System
If it is necessary to correct the steering
system, refer to "STEERING SySTEM".
cable on clutchll (0.08 - o.~~~n)
: release for~~L_ _ _ _ _ _-'
I
• Steering wheel
A3·233
Fig. 2-55
Pedal play
13 20mm (0.51 - 0.79 in)
OM·526
[Free play 2 - 3 mm (0.08 - 0.12 in)]
Full stroke
17 -18mm (0.67 - 0.71 in)
1 Lock nut
2 Adjusting nut
3 Release fork
A20-051
Fig.2-54 Adjusting free play of
clutch pedal
Torque
(Adjusting
( 2) If vehicle does not start properly;
• Case A
When hill-holder is released later than engagement of
clutch (engine tends to stall):
Loosen adjusting nut gradually
until smooth starting is enabled.
• Case B ~ When hill-holder is released earlier than engagement of
clutch (vehicle slips down slightly):
Tighten adjust nut so that hillholder is released later than engagement of clutch (status in Case A).
Then make adjustment the same as
in Case A.
I) Set steering wheel in a straightahead position, and check wheel
spokes to make sure they are correctly
set in their specified positions.
2) Lightly turn steering wheel to the
left and right to determine the point
where front wheels start to move.
Measure the distance of the movement
of steering wheel at the outer periphery of wheel.
Steering wheel free play
0- 25 mm
(0 0.98 in)
Free play
25mm
(0·0.98 in)
o
NOTE:
a, Whenever turning adjust nut, prevent PHV cable from revolving as
following illustration.
A3·267
5.4 ~ 9.3 N'm
(0.55- 0.95 kg-m,
4.0 6.9 ft-lb)
NOTE:
a. When replacing clutch cable with
new one and/or making free play
adjustment of clutch pedal, make
adiustment of hill-holder system
without fail as follows.
b. After replacing clutch cable and/or
pressure hold valve (PHV) cable
with new one, depress clutch pedal
about thirty (30) times as a
running-in operation prior to this
adjustment.
Fig. 2·57
3) Move steering wheel verticaJIy
toward the shaft to ascertain if there is
play in that direction.
Maximum permissible play:
0.5 mm (0.020 in)
Fig. 2-56
b, Replace pressure hold valve (PHV),
return spring of PHV or PHV cable
with new one, if they are defective
and/or damaged. (See "BRAKES",)
2-17
4) Drive vehicle and check the
following items during operation.
(1) Steering force ............. .
The effort required for steering
should be smooth and even at all
points, and should not vary.
PERIODIC MAINTENANCE SERVICES
(2) Pull to one side .......... ..
Steering wheel should not pull to
either side while driving on a level
surface.
(3) Wheel runout ........... .
Steering wheel should not show
any sign of runout.
(4) Return factor ........... .
Steering wheel should return to its
original position after it has been
turned and then released.
If any unusual noise is noticed, adjust
the gear backlash as follows:
(I) Loosen gear box mounting
clamps, and slightly lower gear box.
(2) Loosen lock nut by using Spanner
(925640000) and tighten adjusting
screw fully.
29. Power Steering
System
For vehicles with power steering
system, inspect the system as follows
in addition to the previous article.
• Power steering fluid level
1) Place vehicle with engine "off'
on the flat and level surface.
2) Check the fluid level by removing
filler cap of oil pump.
• Steering shaft joint
1) Disconnect universal joint of
steering shaft and check it for any play
and yawing torque (at the point of
the crossing direction). Also inspect
for any damage to sealing or worn
serrations.
2) Check rubber coupling for deformities, cracks, or peeling off.
If oil comes in contact with coupling,
wipe it clean.
• Gear box
I) With wheels placed on a level
surface, turn steering wheel 90° in
both the left and right directions.
While wheel is being rotated, reach
under vehicle and check for looseness
in gear box.
'A3·135
Fig. 2-59
(3) From that position, turn back
adjusting screw IS° and then tighten
lock nut securely.
r--:rque
I
29 49 N·m
(3.0 - 5.0 kg-m,
22 36 ft-Ib)
OM-750
Fig. 2-60 Oil pump for power
steering
a. Check at temperature 21°C (70°F)
on reservoir surface of oil pump
NOTE:
Hold the adjusting screw with a
wrench to prevent it from turning
while tightening the lock nut.
• Tie rod
Fig. 2-58
A3-134
2) Check boot for damage, cracks or
deterioration.
3) With vehicle on a level surface,
quickly turn steering wheel to the left
and right.
While steering wheel is being rotated,
check the gear backlash.
OM-752
I) Check tie rod and tie-rod ends
for bends, scratches or other damage.
2) Check connections of knuckle ball
joints for play, inspect for damage on
dust seals, and check the free play of
ball studs.
3) Make sure that tie rod lock nut
is tight and secure.
Fig. 2-61 Indicator of filler cap
b. Check at temperature 6Q°C
(l40°F) on reservoir surface of oil
pump
2. Front and Rear Axle Boots
Inspect front and rear axle boots
for deformation, damage or failure.
If faulty, replace them with new
ones. For replacing procedure, refer
to "SUSPENSION, WHEELS AND
AXLES".
2-18
OM-751
Fig.2-62 Indicator of filler cap
PERIODIC MAINTENANCE SERVICES
3) Fluid level should be maintained
in the each specified range on the
indicator of filler cap.
If fluid level is at lower point or
below, add fluid to keep the level in
the specified range of indicator.
If fluid level is at upper point or
above, drain fluid to keep the level in
the specified range of indicator by
using a syringe or the like.
• Hoses of oil pump for damages
NOTE:
A3·199
Recommended fluid (ATF Dexron)
Fig. 2-63 Hoses of oil pump
B.P.
B.P. Autran DX
CALTEX
Texamatic fluid 6673
Dexron
CASTROL
CASTROL TQ Dexron
MOBIL
MOBIL ATF 220
NOTE:
SHELL
SHELL ATF Dexron
Prevent hoses from revolving andlor
turning when installing hoses.
TEXACO
Texamatic fluid 6673
Dexron
Check pressure hose and return hose
of oil pump for clack, swell or damage.
Replace hose with new one if neces·
sary.
a. When air vent pipe comes off hole
of gearbox boot, it is also caused by
means of clogging of air vent pipe.
b. Rotate Band C position of gearbox
boot against twist of it produced by
adjustment of tow-in etc.
In this case, never rotate A position
of gearbox boot
• Fitting bolts and nuts
Inspect fitting bolts and nuts of oil
pump and bracket for looseness, and
retighten them if necessary.
NOTE:
Inspect andlor retighten them when
engine is cold.
• Gearbox boots
Fluid capacity
5) Air ven t pipe is inserted in the
specified hole without fail.
6) Grease or other obstructions
against air flow are not contained in
air vent pipe.
Inspect both sides of gearbox boots
as follows, and correct the defects if
necessary.
0.8 liter
(0.8 US qt, 0.7 Imp qt)
• Power steering fluid for leaks
Inspect the underside of oil pump and
gearbox for power steering system,
hoses, piping and their couplings for
fluid leaks.
If fluid leaks are found, correct them
by retightening their fitting bolts (or
nuts) and/or replacing their parts.
NOTE:
a. Wipe the leakage fluid off after
correcting fluid leaks, or a wrong
diagnosis is taken later.
b. Also pay attention to clearances
between hoses (or pipings) and
other parts when inspecting fluid
leaks.
A3·201
1 Clip (small)
1
2 Clip (middle)
3 Boot
4 Clip (large)
S Air vent pipe
A3-200
.
Fig. 2-64 Gearbox boot
~
I) A, Band C positions of gearbox
boot are fitted correspondingly in A, B
and C grooves of gearbox and the rod.
2) Clips are fitted outside of A, B
and C positions of boot.
3) Projection of boot is fitted in
hole on A groove of gearbox to pre·
vent boot rotating.
4) Boot have not clack, hole (except
for air vent pipe) or damage.
2-19
A3·202
Fig. 2·65 Fitting bolts and nuts
, I1
PERIODIC MAINTENANCE SERVICES
•
Front wheel bearing
Torque N·m (kg-m, ft-lb)
Torque N·m (kg-m, ft-Ib)
Nut A
(one)
44 - 54
(4.5 - 5.5, 33 - 40)
Bolt B
(two)
44 - 54
(4.5 - 5.5,33 - 40)
Bolt C
(three)
25 - 34
(2.5 - 3.5, 18 - 25)
Nut 0
(one)
49 - 59
(5.0 - 6.0, 36 - 43)
Bolt E
(four)
14 - 18
(l.4 - 1.8,10 - 13)
Ball stud transverse
link castle nut
39
(4.0, 29)
29 - 39
(3.0 - 4.0,
22 - 29)
Ball joint to
housing bolt
1) Raise front wheel with a jack, and
remove wheel. Remove cotter pin
from axle shaft and remove castle nut.
2) Remove bolts which secure disc
rotor to front wheel hub, and remove
hub.
NOTE:
Be careful not to allow the tapered
area of the ball stud to come in
contact with grease.
7) Check the tightness of strut
mounting nuts on front suspension
and retighten the nuts to the specified
torque.
A3·137
Torque
N·m (kg-m, ft-lb)
30. Suspension
System,
59 -74
(6.0 - 7.5,
43 - 54)
1) Jack up the front end of vehicle,
and remove front wheels.
2) Remove cotter pin and castle nut
from ball stud and disengage ball stud
from transverse link.
1(1
j, /
:r~
-~ I '\
j£1
,,",,,
,
,~
...:.~. ..-.
)~
Fig. 2-66
3) Remove oil seal from housing, and
check the condition of bearing grease.
NOTE:
a. If either the grease appears to be
white or if only a small amount of
grease remains, remove the bearing
from the housing, clean it, and pack
it with grease.
Refer to "SUSPENSION, WHEELS
AND AXLES" for further details.
b. Discard the old seal and install a
new one.
8) Check the tightness of rear crossmember installing bolts on rear suspension and Tighten the bolts to the
specified torque.
~r
» ~-:J~
"
)
"
LI I,
.";..~
I
A3-279
Fig. 2 - 67
Fig. 2 - 68
A3·136
'"
3) Remove bolts which secure
housing to ball joint, and remove ball
joint.
4) Check the axial play of ball stud.
If play exists, replace ball joint with a
newone.
5) Check rubber boot for cracks or
damage.
If necessary, replace ball joint.
6) Tighten nuts and bolts which are
used to secure ball joint, to the
specified torque setting indicated in
the chart below.
Torque
N·m (kg-m, ft-Ib)
118 - 147
(l2.0 - 15.0,
87 - 108)
A3·158
Fig. 2 - 69
31. Grease on Front
and Rear Wheel
Bearinas
Inspect the condition and the amount
of front and rear wheel bearing grease
as follows.
2-20
4) Installation is in the reverse order
of removal.
Torque
(Castle nut)
196 N·m
(20 kg-m, 145 ft-lb)
PERIODIC MAINTENANCE SERVICES
NOTE:
Af1er tightening 1118 castle nut to 1I1e
specified torque, tighten additionally
in one six1l1 (1/6) 1Urn until both holes
of bolt and castle nut align each other.
I(Hub
Torque
to disc
!
I rotor bolts)
44 - 58N·m
(4.5 5.9 kg-m,
33 - 43 ft-lb)
• Rear wheel bearing
Remove rear brake drum and check
its condition and the amount of
bearing grease. Refer to "SUSPENSION, WHEELS AND AXLES" for
removal and installation of rear brake
drum.
parts as necessary.
• Tire pressure
• Wear or damage of tires
• Wheel balance
• Looseness on suspension
• Looseness and smooth operation
on axle linkage and connection
• Looseness and smooth operation on
steering linkage and connection
• Shock absorber operation and oil
leakage
• Damage, deformation, etc. on body
attaching portion of suspension,
axle and steering linkage and con·
nection
• Vehicle height [It is recommended
that the difference of vehicle height
between the front and rear ends, or
the left and right sides is less than
10 mm (0.39 in) in the unloaded
condition.]
• Stain, rust, grease leakage, etc.
on front end parts
4) After completing the toe-in
adjustment, tighten lock nut to the
specified torque setting.
Torque
78 88 N·m
(8 - 9 kg-m,
58 - 65 ft·lb)
A3·133
Fig. 2 -72
1) Check the toe-in.
Toe·in
Except 4WD
inl±lmm
(0.04 ± 0.04 in)
4WD
out 5 ± 1 mm
(0.20 ± 0.04 in)
3) If the toe·in is not within the
specified range, turn left and right tie
rods by equal angles, and adjust the
toe-in.
33. Retlshten Wheel
Nuts
(
Fig. 2 -70
32. Wheel AlIsnment
Before checking/adjusting front wheel
alignment, be sure to make a prior
inspection of the following points and
repair/replace the damaged portions/
A3·203
A3·132
Fig. 2-71
Fig.2·73 Wheel nuts
2-21
PERIODIC MAINTENANCE SERVICES
I
Torque
, (Wheel nuts)
b. On vehicles with two (2) headlights,
adjust lower beam axis only_
78 98 N·m
(8 - 10 kg-m,
58 - 72 ft-Ib)
Vertical
NOTE:
a. Do not use air impact tools to
retighten wheel nuts.
b. Tighten wheel nuts in the order
shown in the following illustration.
Center of high intensity
area should be at headlight center.
Horizontal
v
Adjusting screw for vertical direction
OM-868
Headlight
height
High intensity
area
A3-246
Fig. 2-76
A3-205
b. Low beam (passing beam):
Fig. 2·14
OM-869
Adjusting screw for
horizontal direction
NOTE:
Low beam adjustment is available only
for vehicles with four (4) headlights.
Vertical
Upper end of high intensity
area makes contact with
H line.
Horizontal
Left-hand end of high
intensity area makes contact with V line.
34. Headlight Aiming
1) Adjust the tire pressure to the
specifications.
2) Put vehicle and screen on a level
surface. Position screen at a distance
of7.6 m (24.9 ft) from headlights.
3) Have vehicle in its unladen condition. (with maintenance tools, a spare
tire & wheel and full fuel tank)
4) Check the aim of headlight. If
necessary, turn adjusting screws to
adjust the beam axis vertically and
hOrizontally in accordance with specifications.
iII
Fig_ 2-75 Adjusting screws
a_ High beam (driving beam):
NOTE:
a. On vehicles with four (4) headlights, cover the outer headlights on
both sides with black cloth or
shades, and adjust the inner headlight only.
2-22
High intensity
area
Fig:2·11
A3-247
PERIODIC MAINTENANCE SERVICES
35. Lubricate Hinges and Locks of Doors, Hood and Trunk Lid
A3-141
A3-140
A3-139
'L Roller
-----A3·142
A3-143
Fig. 2·78
2·3. Special Tools
498767000
499987006
899988607
925640000
Adjuster
Socket wrench
Socket wrench
Spanner
Intake & exhaust valve
Cylinder head nuts
Cylinder head nuts
Steering gearbox
ST -029
Fig. 2-80
ST-030
Fig. 2·81
2-23
A3-066
Fig. 2-82
A3-167
CHAPTER~
ENGINE
p.
3- 1.
SPECIFICATIONS AND SERVICE DATA ..•.••..•.•...•..•. 3- 2
3- 2.
COMPONENT PARTS ................................. 3-14
3- 3.
ON·CAR SERVICES .................................. 3-30
3- 4.
DISMOUNTING AND REMOUNTING.. . . • • . . • • • • . . . • . • • . •• 3-38
3- 5.
REMOVAL ................................................................
3- 6.
DiSASSEMBLy...................................... 3-46
3- 7.
INSPECTION AND ADJUSTMENT ........................ 3.-46
3- 8.
ASSEMBL Y •....••.••.•••.•..•...•.••••..••••..•.•. 3-61
3- 9.
INSTAllATION ..................................... 3-67
3-10.
TROUBLESHOOTING ................................. 3-75
3-11.
SPECIAL TOOLS ..•.•••.•.....•••...•..•..•..•.....• 3-84
It
..
..
..
....
3.-43
,
alBAAI ,
~.,
ENGINE
3-1. Specifications and Service Data
1. Entire Enalne Specifications
~
SUBARU 1800
WithMT
SUBARU 1600
Other than 4WD
Type
Piston displacement
Other than 4WD
I
4WD-AT
Overhead type
mm (in)
92)( 60
(3.62)( 2.36)
92 )( 67 (3.62 )( 2.64)
cc (cu in)
1,595 (97.33)
1,781 (108.68)
9.0
8.7
1,206 (12.3, 175)
1,177 (12.0, 171)
Compression ratio
Compression
pressure
(at 350 rpm)
4WD
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement
Bore )( Stroke
With AT
kPa (kg/cm 1 , psi)
I
I
I
Number of piston rings
Pressure ring: 2, Oil ring: 1
Opening
20· BTDC
Intake valve timing
Closing
60· ABDC
64° ABDC
Opening
60° BBDC
64° BBDC
Exhaust valve timing
Closing
r.Iol
Z
G
z
r.Iol
Valve clearances
(when engine is cold)
mm (in)
Idling speed
]
[ At neutral
(or N) or P position
Engine dimensions
mm (in)
20· ATDC
Intake
0.25 (0.010)
0(0)
Exhaust
0.35 (0.014)
0(0)
700 ± 100
800 ± 100
rpm
Length
419 (16.50)
Width
701 (27.60)
712 (28.03)
Height
Weight of engine without
kg (Ib)
transmission
(Oil and coolant are included)
607 (23.90)
*1: 105 (232)
·2: 101 (223)
*1: 108 (238)
*2: \04 (229)
*3: 103 (227)
* 1:
*2:
*3:
*4:
·1: 99 (218)
*2: 95 (209)
*3: 94 (207)
*2: 95 (209)
*4: 94 (207)
PCV system
• Crankcase emission control system:
• Evaporative emission control system: Canister storage type with fuel return
Three-way catalyst [49 States (except 4WD &. 4WD AT)
• Exhaust emission control system:
and California I + Oxidation catalyst (other than
California) + EGR + Air injection
Firing order
Ignition timing
*2: 104 (229)
*4: 103 (227)
Viscous type
Air cleaner element
Emission control system
411 (16.18)
422 (16.61)
I
BTDC 8°/700 rpm
49 States
California
Canada
49 States and Canada
3-2
3-2-4
BTDC 8° /800 rpm
ENGINE
2. Lubrication System Specifications
SUBARU 1600
SUBARU 1800
Forced feed, full flow filtration, splash type
Lubrication method
Trochoid type
Pump type
Discharge - Pressure
Discharge
performance
I
4.0R/min
(4.2 US qt/min, 3.S Imp qt/min)
or more - 343 kPa (3.S kg/cm', SO psi)
SOO rpm
Speed
7S - 8S·C (167 - l8S·F)
Oil temperature
Oil pump
Discharge
performance
II
Discharge - Pressure
21.012/min
(22.2 US qt/min. lS.S Imp qt/min)
or more - 392 kPa (4.0 kg/em', S7 psi)
Speed
Pressure at which
valve starts to open
Oil by-pass
valve
Pressure at which
valve starts to open
IS.OIl/min
(15.9 US qt/min, 13.2 Imp qt/min)
or more - 392 kPa (4.0 kg/cm'. S7 psi)
2,500 rpm
7S - SS·C (167 - 18S·F)
Oil temperature
Oil relief
valve
3.01!/min
(3.2 US qt/min, 2.6 Imp qt/min)
or more - 24S kPa (2.S kg/em', 36 psi)
392 - 441 kPa (4.0 - 4.S kg/cm', S7 - 64 psi)
147 kPa (1.S kg/cm', 21 psi)
Type
9S kPa (1.0 kg/cm', 14 psi)
Paper. cartridge type
Oil filter
O.IS m' (1.6
Filtration area
Iq
ft)
Upper level
4.011
(4.2 US qt, 3.S Imp qt)
3.H
(3.7 US qt, 3.1 Imp qt)
Lower level
3.011
(3.2 US qt, 2.6 Imp qt)
2.B
(2.6 US qt, 2.2 Imp qt)
Engine oil capacity
ENGINE
3. Encin. 011 Flow Diacram
Crankshaft
1-+
r" front
Crankcase
(Right)
Main gallery
main bearing
til connecting
rod bearing
~
111 &./13 cylinIII &'/13 cylin...,. der valve lifters f-1o der push rods
r-r-
Oil filter
i
1
I
Crankcase 1-.... Crankshaft
center
(Left)
main bearing
Main gallery
112 &.113 con.., necting rod
bearings
Crankshaft
...,. rear
main bearing
..,. /14 connecting
1-
Valve rocker
.....
Valve rocker
I-
I
_----By-pass
r
i
--I!
.-- valve
I
r
I
I
rod bearing
'
I
:
Rotor
112 &.114 cylin112 &.114 cylin.., der valve lifters ...... der push rods
Relief
valve
-t
Cam bearing
I
Oil
strainer
Oil pan
A6'012
(SUBARU 1800)
(SUBARU 1600)
Oil pump drive gear
Left side main gallerv
Camshaft
Oil pump drive gear
Left side main gallerv
Bv-pass valve
Relief valve ~iver gear
~
Relief valve ~Bv-pass v81ve
o
Rou"
,
Drive gear
Rotor
Oil filter
A6-013
Cross section of trochoid pump (A-A)
Cross section of trochoid pump lA-A)
Fig_ 3-1
3-4
A6-014
ENGINE
4. Cooling System Specifications
SUBARU 1600
SUBARU 1800
~
Electric fan + Forced cooling water circulation system
Cooling system
!----~
5.511 (5.8 US qt, 4.8 Imp qt)
Total coolant capacity
Type
Centrifugal impeller type
7 II/min (7.4 US qt/min, 6.2 Imp qt/min) or more
Discharge
Discharge
performance
I
Pump speedtotal water head
1,000 rpm - 0.29 m Aq (0.95 ft Aq)
75 - 8s·C (167 - 18s·F)
Water temperature
Water pump
5.311 (5.6 US qt, 4.7 Imp qt)
Discharge
Discharge
performance
II
SOli/min (13.2 US gal, 11.0 Imp gal) or more
Pump speedtotal water head
4,000 rpm - 5.0 m Aq (16.4 ft Aq)
75
Water temperature
Impeller diameter
--.---
8S·C (167 - 18s·F)
64 mm (2.52 in)
Number of impeller vanes
5
Pump pulley diameter
84 mm (3.31 in)
-- f - - _ .
Type
Wax pellet type
Starts to open
Thermostat
88 ± l.S·C (190 ± 3°F)
Fully opens
100°C (212·F)
Valve lift
8 mm (0.31 in)
Valve bore
31 mm (1.22 in)
Type
Thermo
valve
Wax pellet type
27 ± 2·C (81 ± 3.6·F)
Fully closes
~~
25 ± 2·C (77 :t 3.6·F)
Fully opens
Thermoswitch
Electric fan
ON
95 :t 2°C (203 :t 3.6·F)
OFF
91 :t 2°C (196 ± 3.6·F)
Fan dia.
280 mm (11.02 in)
Type
Radiation capacity
4.82 m' (51.9 sq ft)
AT & 4WD-AT: 0.789 kW
(678 kcal/min, 2,690 BTU/min)
4WD:
0.715 kW
(615 kcal/min, 2,440 BTU/min)
Others:
0.630 kW
(542 kcal/min, 2,151 BTU/min)
0.529 kW (455 kcal/min, 1,805 BTU/min)
at
Radiator capacity
Pressure range in which cap valve is
open
Fins
• Temperature difference between
coolant and ambient atmosphere:
• Air velocity:
\
I
i
4s2/min
(11.9 US gal/min, 9.9 Imp gal/min)
{ • W.to< flo.,
mm (in)
,
AT & 4WI)..AT: 7.83 m' (84.3 sq ft)
4WD:
7.29 m' (78.4 sq ft)
Others:
5.90 m' (63.5 sq ft)
Radiator
~
•·d.·..
Cross flow, pressure type
Total radiation area
Core dimensions
,I
120W or less
Motor
6s·C (l49·F)
8 m/sec (26 ft/sec)
SUBARU 1800 AT & 4WD-AT: 625 x 334 x 32 (24.61 x 13.15 x 1.26)
580 x 334 x 32 (22.83 x 13.15 x 1.26)
Others:
1.9£ (2.0 US qt, 1.7 Imp qt)
Above 88 :t 10 kPa (0.9:t 0.1 kg/em', 13 :t 1.4 psi)
Below -4.9 to -10 kPa (-0.05 to -0.1 kg/em" -0.7 to -1.4 psi)
Corrugated fin type
ENGINE
5. Coolent
It is recommended to use "SUBARU
genuine coolant" when replacing or
refllling the engine coolant.
SUBARU COOLANT
(net 18 liter)
Parts No. 000016218
This coolant is anti-freeze, anticorrosive ethylene glycol coolant, and
is especially made for SUBARU vehi-
NOTE:
I. Avoid using Iny coollnt or only
water other thin this designated
type to prevent corrosion.
b. SUBARU'a engine is Iluminum
IlIoy, Ind aD specill clre is neces-
sary.
cle.
SUBARU Coolant specifications are as follows:
Coolant Specifications
Specific gravity
Lowest atmospheric
anticipated temperllture
SUBARU
coolant-to·wllter ratio
(Volume) %
It 10·C
(SO°F)
at 20°C
(68°F)
It 30°C
(86°F)
It 40·C
(104°F)
It 50·C
(122°F)
Above -30°C (-22°F)
SO - SO
1.078
1.072
1.067
1.058
LOSS
Freezing point
-36·C (-33°F)
• It il recommended that distilled water be used.
8. Coolant Flow Dle.ram
Intake
manifold
Intake eir
preheating
(Carburetor!
'--------------------1 start
ThermoAS·6SB
1
2
3
4
S
6
7
8
9
10
11
12
13
14
IS
16
17
18
Fig. 3-2 Flow of coolant in cooling S)f$tIm
Radiator inlet hose
Water by-pass hose
Thermostat cover
Thermostat
Water by-pass hose
Water by·pass pipe
Water by-pass hose
3-wey cock
Water by-pass hose
Intake maoifold
Water by-pass pipe
Water by-pass hose
Radiator outlet hose
Water pump
Thermo switch
Electric
Thermo valve
Water by-pass hose
fan
AS-6!59
3-6
_.
-.---.~-
ENGINE
The operation of the cooling system is
as follows:
I) Cooling with thermostat closed
When the coolant temperature is under
the specified degrees, coolant flows
only through the by-pass passage. This
limited coolant circulation reduces
cooling action, thus shortening engine
warm-up time.
By-pass passage:
a. Intake manifold -+ Carburetor -+
Thermo valve -+ Water by-pass base
and pipe -+ Water pump
When the environmental temperature around thermo valve exceeds
the specified degrees, the coolant
passage from carburetor to water
by-pass pipe is shut off by means of
thermo valve so that the fuel in
carburetor is not heated.
To intake manifold
b. Intake manifold -
t
Thermostat
case~
3-way cock Water by-pass hose
.\. /andPiPe
He~er
.\.
Water pump
11:~~1\..-=::=~==~To radiator
--+
A5-660
Fig. 3-3 Cross section of thermo valve
2) Cooling with thermostat open
When the coolant temperature exceeds
the specified degrees, thermostat
begins to open and coolant flows
through radiator and by-pass passage,
increasing the cooling function.
3) Cooling with electric fan in operation
When the coolant temperature exceeds
the specified degrees, the thermoswitch turns on to operate the electric
fan.
7. Automatic Transmission Fluid Coolin. System
Automatic transmission fluid
cooling system
(SUBARU 1800 AT & 4WD-AT)
Radiation
capacity
.p
1.570 kW (1,350 kcal/h, 5,357 BTU/h)
Oil flow:
6~/min (l.6 US gal/min, 1.3 Imp gal/min)
Water flow: 20~/min (5.3 US gal/min, 4.4 Imp gal/min)
Temperature difference between
water inlet and oil inlet:
30c e (86°F)
The fluid cooling system of automatic
transmission consists of an cooler built
in radiator, pipes and hoses to circulate
fluid between torque converter and
cooler.
Heated fluid circulating through
torque converter returns to cooler and
is cooled by coolant, thereby being
maintained at an adequate temperature.
1
1·1
1·2
1-3
1-4
Pipe complete
Hose clamp
Cooler
Radiator
Side frame
Hose assembly
Outlet hOle
Inlet hose
Clamp
Clip
Fig. 3-4 Component pam of automatic trllflltn/.lon fluid
cooling 'ystem
3-7
--""'I
ENGINE
8. Hydraulic Valve Lifter
Camshaft
~M'ln"'''V
CD (V @@@ @
1
2
3
4
5
6
Check ball retainer
Check ball spring
Plunger spring
Check ball
Plunger
Valve body
AS·561
7 Push rod seat
8 Clip
Fig. 3·5 Hydraulic valve lifter
The hydraulic valve lifter always
maintains the valve clearance at zero
by means of engine oil pressure.
The hydraulic valve lifter consists
basically of a push rod seat, plunger,
check ball and valve body.
Plunger spring always pushes out
plunger. Therefore, plunger moves out·
ward when the clearance to produced
in the valve mechanism. At this time,
the check ball is separated from the
plunger and opens the passage to the
pressure chamber. This causes engine
oil to flow into the pressure chamber.
As this happens, the plunger is pushed
up so that the valve clearance is zero.
When the valve lifter is pushed by the
cam lobe, the check ball comes into
contact with the plunger.
Push rod
Pressure
chamber
Reservoir chamber
AS·662
Fig. 3-6 Operation of the hydraulic valve lifter
In this condition, engine oil pressure
in the pressure chamber increases
rapidly and this moves the intake or
exhaust valve through push rod and
valve rocker arm.
NOTE:
a. Immediately after the engine sterts,
the valve lifter may sometimes
meke clicking noises within 10
seconds. This is not an indication of
abnormality. It occurs bec:au_ the
viscosity of engine 01 increases due
to low ambient temperature and
therefore the valve lifter does not
respond accordingly.
b. The valve lifter also clicks continuo
ally for a long time if air enters the
pressure chamber of the valve lifter
(although this occurs very _Idom).
When this happens, check the
engine oil level and add engine oil if
the level is at the lower level or
below on the gauge. Then, maintein
the engine at a speed of 1,500 to
2,000 rpm and allow it to idle for
10 to 20 minutes. The air is then
expelled from the pressure chamber
and the clicking ceases. (Check the
valve lifter according to "3·1, 8
Valve Lifter", if the clicking does
notc....)
This happens also after removing/
instilling valve rocker ASSY. cylin.
der head and/or entire engine.
---~----~~-------.~
..
ENGINE
9. Service Data
Head surface warpage
Head surface grinding
Standard height
"0
."
CI,)
.s::
...
Valve seat
CI,)
"0
Limit
Limit
1600
1800
Refacing angle
Contacting width
Intake
Exhaust
:Ei>.
u
Valve guide
Valve overall length
Valve head edge thickness
Wear limit
Inner diameter
Protrusion
Intake
Exhaust
Intake
Exhaust
Intake
STO
Limit
STO
Limit
Exhaust
~
7iI
>
Stem diameter
Stem oil clearance
Intake
Exhaust
Intake
STO
Limit
STO
Limit
Exhaust
• With solid valve lifter
Free length
Tension/spring height
Outer spring
Inner spring
Outer spring
~
'J:
Inner spring
~
~
>
Square ness
• With hydraulic valve lifter
Free length
Outer spring
Inner spring
Outer spring
Inner spring
3-9
0.05mm
O.5mm
89.6mm
90.6mm
90°,150°
(0.0020 in)
(0.020 in)
(3.528 in)
(3.567 in)
0.7 - 1.3 mm
1.0 - 1.8 mm
O.5mm
8.000 - 8.015 mm
17.5-18.5mm
22.5 - 23.5 mm
(0.028 - 0.051 in)
(0.039 - 0.071 in)
(0.020 in)
(0.3150 - 0.3156 in)
(0.689 - 0.728 in)
(0.886 - 0.925 in)
l09mm
109.3 mm
1.0mm
O.5mm
1.3 mm
0.8mm
7.950 - 7.965 mm
7.945 -7.960mm
0.035 - 0.065 mm
0.15 mm
0.040 - 0.070 mm
0.15 mm
(4.29 in)
(4.30 in)
(0.039 in)
(0.020 in)
(0.051 in)
(0.031 in)
(0.3I30 - 0.3136 in)
(0.3128 - 0.3134 in)
(0.0014 - 0.0026 in)
(0.0059 in)
(0.0016 - 0.0028 in)
(0.0059 in)
45.3 mm
(1.783 in)
48.8mm
(1.921 in)
146.1 - 169.7 N/39.5 mm
(14.9 - 17.3 kg/39.5 mm,
32.9 - 38.1lb/1.S55 in)
500.2 - 568.8 N/30.5 mm
(51.0 - 58.0 kg/30.5 mm,
112.5 - 127.91b/1.201 in)
84.3 - 98.1 N/37.5 mm
(8.6 - 10.0 kg/37.5 mm,
19.0 - 22.11b/1.476 in)
185.4 - 214.8 N/285 mm
(18.9 - 21.9 kg/28.5 mm,
41.7 - 48.31b/1.122 in)
(0.079 in or less)
2.0 mm or less
2.1 mm or less
(0.083 in or less)
48.5 mm
53.0mm
(1..909 in)
(2.087 in)
t
-.--
~
ENGINE
,------,~
---- - -
.... _
-
--- - --
....-------~
Outer spring
Tension/spring height
Inner spring
Outer spring
[nner spring
Squareness
...
uu
>..:.0:
"iilg
> ..
• Solid valve lifter
Lifter hole inner diameter of crankcase
Outer diameter of lifter
Lifter to lifter hole clearance
• Hydraulic valve lifter
Lifter hole inner diameter of crankcase
Outer diameter of lifter
Lifter to lifter hole clearance
]
iii
£
~u
"5...
u
2.3 mm or less
(0.091 in or less)
STD
Limit
21.000 - 21.021 mm (0.8268 - 0.8276 in)
20.949 - 20.970 mm (0.8248 0.82S6 in)
0.030 0.072 mm (0.0012 - 0.0028 in)
0.100 mm
(0.0039 in)
STD
Limit
20.988 21.040 mm (0.8263 - 0.8283 in)
20.950 - 20.968 mm (0.8248 - 0.8255 in)
0.020 - 0.090 mm (0.0008 - 0.0035 in)
0.100 mm
(0.0039 in)
1600 (Knurling: 2)
1800 with solid valve
lifter (Knurling: I)
1800 with hydraulic valve lifter
(Knurling: nothing) (Steel tube)
Deflection at center
Cylinder bore
(Both 1800 and 1600)
228.5 - 261.8 N/39.S mm
(23.3 26.7 kg/39.S mm,
51.4 - S8.9 Ib/l.SS5 in)
518.8 - 599.2 N/32.0mm
(52.9 61.1 kg/32.0 mm,
116.6 134.7Ib/l.260 in)
115.7 - 133.4 N/37.5 mm
(11.8 13.6 kg/37.5 mm,
26.0 - 30.6Ib/1.476 in)
201.0 - 230.5 N/30.0 mm
(20.S 23.5 kg/30.0 mm,
45.2 - S 1.8 Ib/l.18I in)
2.1 mm or less
(0.083 in or less)
\8.016 - 18.034 mm (0.7093 0.7100 in)
17.982 18.003 mm (0.7080 - 0.7088 in)
0.013 - 0.052 mm (O.oooS - 0.0020 in)
Inner diameter of rocker arm
Outer diameter of rocker shaft
Rocker arm to rocker shaft clearance
Overall length
---------- ----_.-
Diameter
Taper
STD
Limit
Out of roundness
STD
Limit
Cylinder to piston clearance
STD
Limit
Enlarging limit of cylinder inner diameter
Inner diameter difference limit between cylinders
Limit
Case surface warpage (mating with head)
Protrusion of stud bolt from mating surface
1800
1600
3-10
219 - 219.4 mm
230.7 - 231.1 mm
(8.62 - 8.64 in)
(9.08 9.10 in)
231.7 - 232.2 mm
(9.12 - 9.14 in)
0.4mm
(0.016 in) or less
91.98S - 92.015 mm (3.6214 - 3.6226 in)
O.QlS mm
(0.0006 in)
(0.0020 in)
0.050mm
O.OlOmm
(0.0004 in)
(0.0020 in)
0.050mm
0.010 - 0.040 mm (0.0004 - 0.0016 in)
(0.0024 in)
0.060mm
(0.0197 in)
0.50mm
(0.0020 in)
0.05 mm
(0.0020 in)
0.05 mm
(3.602 - 3.681 in)
91.5 - 93.S mm
(3.563 - 3.642 in)
90.5 - 92.5 mm
ENGINE
r-----.------------~----.-.-.~--.--_r_----~-------------
.~
Piston outer diameter
STD
0.25 mm (0.0098 in) as
0.50 mm (0.0197 in) as
§
.."
~
]
Piston pin hole inner diameter of piston
Piston pin outer diameter
Piston pin to hole in piston clearance
...§
;f!
Piston ring gap
Top ring
Second ring
Oil ring rail
Piston ring to piston ring groove clearance
Top ring
Second ring
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
.5
...u
g
1800
1600
Limit
STD
Limit
Bend or twist per 100 mm (3.94 in) in length
Thrust clearance
c
o
u
-
Piston pin to bushing clearance
Bushing bore
.5.5
..
uO
'2
'"cu
.0
¢;;
iii'"
1u..
Front & rear
sro
0.03 nun (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
Center
sro
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
Front & rear
sro
1600
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
Center
sro
0.03 mm (0.0012 in) US
0.05 mm (0.0020 in) US
0.25 mm (0.0098 in) US
1800
sro
Cam lobe height
Wear limit
¢;;
iii'"
5
u
Bend limit
Thrust clearance
Camshaft journal outer diameter
sro
Front & center
Limit
1600
1800
Rear
sro
Camshaft journal to cam bore clearance
Limit
i
iii
5 :;
Run out
Crankshaft gear to cam gear backlash
Limit
sro
Limit
u&
·1: With solid valve lifter
·2: With hydraulic valve lifter
3-12
0.010 - 0.030 nun (0.0004 - 0.0012 in)
0.055 nun
(0.0022 in)
0.010 - 0.025 nun (0.0004 - 0.0010 in)
0.045 nun
(0.0018 in)
0.010 - 0.035 nun (0.0004 - 0.0014 in)
0.055 mm
(0.0022 in)
0.010 - 0.030 mm (0.0004 - 0.0012 in)
0.045mm
(0.0018 in)
44.995 - 45.010 mm (1.7715 - 1.7720 in)
44.945 - 44.960 nun (1.7695 - 1.7701 in)
44.745 - 44.760 nun (1.7616 - 1.7622 in)
0.020 - 0.070 nun (0.0008 - 0.0028 in)
(0.0039 in)
0.1 mm
2.015 2.030 2.040
2.140 2.015 2.030 2.040
2.140 2.001 2.017 2.022 2.122 2.003 2.017 2.022 2.122 -
2.019 mm
2.034 mm
2.044mm
2.144 mm
2.028 mm
2.043 mm
2.053 mm
2.153 mm
2.008 mm
2.030 mm
2.035 mm
2.135 mm
2.015 mm
2.030 mm
2.035 mm
2.135 nun
(0.0793 (0.0799 (0.0803 (0.0843 (0.0793 (0.0799 (0.0803 (0.0843 (0.0788 (0.0794 (0.0796 (0.0835 (0.0789 (0.0794 (0.0796 (0.0835 -
0.0795 in)
0.0801 in)
0.0805 in)
0.0844 in)
0.0798 in)
0.0804 in)
0.0808 in)
0.0848 in)
0.0791 in)
0.0799 in)
0.0801 in)
0.0841 in)
0.0793 in)
0.0799 in)
0.0801 in)
0.0841 in)
·1: 32.24 - 32.34 mm (1.2693 - 1.2732 in)
·2: 35.90 - 36.00 mm (1.4134 - 1.4173 in)
(0.0059 in)
0.15 mm
(0.0020 in)
0.05mm
0.020 - 0.090 mm (0.0008 - 0.0035 in)
(0.0079 in)
0:20mm
25.959 - 25.975 mm (1.0220 - 1.0226 in)
31.959 - 31.975 mm (1.2582 - 1.2589 in)
35.959 - 35.975 mm (1.4157 - 1.4163 in)
0.025 0.059mm (0.0010 - 0.0023 in)
(0.0039 in)
O.IOOmm
0.25mm
0.010 - 0.050 mm
O.lOmm
(0.0098 in)
(0.0004 - 0.0020 in)
(0.0039 in)
ENGINE
Drive gear outer diameter
Rotor outer diameter
Drive gear to rotor tip clearance
c.
§
c.
=
0
STD
Limit
Rotor to case and gear to case axial clearance
STD
Limit
Rotor to case radial clearance
STD
Limit
Relief valve spring
Free length
Installed length
Load when installed
By-pass valve spring
Free length
1600
Installed length
Load when installed
1800
1600
1800
1600
1800
Oil fllter flltration area
29.70 - 29.74 mm (1.1693 - 1.1709 in)
40.53 - 40.56 mm (1.5957 - 1.5968 in)
0.02 - 0.12 mm
(0.0008 - 0.0047 in)
(0.008 in)
0.2mm
0.03 - 0.13 mm
(0.0012 - 0.0051 in)
(0.008 in)
0.2mm
0.15 - 0.21 mm
(0.0059 - 0.0083 in)
0.25mm
(0.0098 in)
47.1 mm
(1.854 in)
33.5 mm
(1.319 in)
38.05 - 41.97 N
(3.88 - 4.28 kg, 8.56 - 9.44lb)
4O.7mm
(1.602 in)
(1.461 in)
37.1 mm
(1.224 in)
31.1 mm
25.1 mm
(0.988 in)
3.580 - 3.972 N
(0.365 - 0.405 kg,0.805 - 0.893 lb)
5.178 - 6.159 N
(0.528 - 0.628 kg, 1.164 - 1.3851b)
0.15 m2
(1.6 sq ft)
. y. "
3-13
ENGINE
3·2. Component Parts
1. Crankcase
Torque
i
Thread size
I
10mm
I
I
Smm
23·26 N'm (2.3 - 2.7 kg-m. 17 - 20 ft-Ibl
6mm
4.4 - 5.4 N·m 10.45 - 0.55 kg-m. 3.3 - 4_0 ft-Ibl
39 - 47 N·m (4.0 - 4.S kg-m, 29 - 35 ft-Ibl
Apply liquid gasket (Fuji Bond C or
equivalent) on the mating surfaces ..----r-...-----.
@(j)
CD
r.,
~\
~@"'"
/~
@
•
Tightening torque N·m (kg-m. ft-Ib)
Apply liquid gasket
(Fuji Bond C or equivalentl
on the thread
T1: 25 - 34 (2.5 - 3.5, 1S - 25)
T2: 62 - 76 16.3 - 7.7.46 - 56)
T3: 34 - 44 (3.5 - 4.5, 25 - 331
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Crankcase assembly
Stud bolt
Bolt (10 x 108 x 28 mm)
Bolt
Washer
Bolt (10 x 145 x 28 mm)
Washer (10.5 x 18 x 2 mm)
Main gallery plug
Bolt
Crankcase front hanger
(Hitachi carburetor)
Nut
Bolt (10 x 70 x 28 mm)
Bolt
Washer
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Fig. 3-8 Crankcase
3-14
Gasket (26.2 x 31.5 x 1 mm)
Crankcase plug
Crankcase O-ring
Back up ring
Bolt &. washer (6 x 13 x 13 mm)
Clip
Crankcase plug
Gasket (36.2 x 44 x 1 mm)
Crankcase assembly
Nut (10 x 8 mm)
Bolt (10 x 135 x 28 mm)
Stud bolt (10 x 120 x 26 mm)
Bolt
Crankcase front hanger
Crankcase front hanger
(C·W carburetor)
AS-S88
ENGINE
2. Cylinder Heads
,r
Tightening torque N·m (kg-m. ft-lbl
T: 22 27 (2.2 - 2.8. 16 - 20)
1
2
3
4
S
6
7
8
9
10
11
12
13
14
Valve guide
Oil seal
Cylinder head (1,600 ee)
Cylinder head 0.800 ee)
Cylinder head gasket
Cylinder head 2 (1,600 ee)
Cylinder head 2 (1,800 ee)
Washer
Nut
Bolt (11 x 162 x 34 mm)
Stud bolt
Plug
Gasket
Stud bolt
1st step
29 N·m (3.0 kg-m. 22 ft-Ib)
2nd step
59 N·m (6.0 kg-m. 43 it·lb)
3rd step
64 N·m 16.5 kg-m. 47 ft-lb)
Applv sealant "Three Bond 1201" or equivalent
evenly to both sides of cylinder head gasket
with a brush.
A5-589
Fig. 3-9 Cylinder heads
ENGINE
3. Flywheel Housing and Fittings
1 Flywheel housing CP
2 Stud
on
3
seal (70 x 87 x 8.5 mm)
4 Timing hole plug
5 Crankcase rear hanger
6 Pitching stopper bracket
7 Nut
8
9
10
11
Bolt
Bolt
Bolt
Washer
12 Washer
13 Spring washer
14 Spring washer
Coat with liquid gasket (Three Bond 1215 or
equivalent) on mating surface and dry the
coated surface for 5 to 10 minutes before
installation.
@
I'
Tightening torque: N·m (kg-m, ft-lb)
T1: 46·64 (4.7· 6.6, 34 - 40)
T2: 20· 27 12.0 - 2.8, 14 . 20)
Fig. 3·10 Flywheel housing and fittings
15
16
17
18
19
20
Flywheel housing CP
Stud
on seal (76 x 93 x 10 mm)
Timing hole plug
Bolt
Bolt
21 Stiffener
22 Stiffener 2
23 Oip
24 Washer
25 Spring washer
26 Bolt
27 Accelerator cable bracket
(C'W carburetor)
Oip
A5·666
3-16
ENGINE
4. Crankshaft and Related Parts
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
I
I
I
I
I
I
Bolt
O-ring
Crankshaft pulley
Drive belt
on seal
Distributor drive gear
Woodruff key II
Crankshaft
Woodruff key
Crankshaft gear
Crankshaft bearing set
Center bearing set
Connecting rod CP
Nut
Connecting rod bearing set
Piston ring set
Piston pin
Circlip
Piston set
Bo1t(Mn
Bolt (An
Converter back plate (An
Converter drive plate (AT)
Connecting rod bolt
Connecting rod bushing
I
I
I
I
I
I
I
,/
,/
I
I
I
I
I
I
I
I
V
,
@
•
•
Apply engine oil on the thread.
Apply liquid gesket (Three Bond 1215 or equivalent! on the flange seat.
Fig. 3·11 Crankshaft and related parts
Tightening torque: N·m (kg·m. ft-lb)
T1: 41·45 (4.2·4.6,30·33)
T2: 39· 42 (4.0· 4.3, 29 • 311
T3: 49· 53 (5.0· 5.4, 36 • 39)
T4: 64·74 (6.5·7.5,47·541
A 8-687
,
I
1
I
\
ENGINE
s.
Valve System
Tightening torque: N·m (kg-m, ft-lb)
T: 3· 4 (0.3 . 0.4, 2.2 . 2.9)
@
@
1 Bolt
2 Valve rocker cover seal washer
3 Valve rocker cover
4 Valve rocker cover gasket
5 Valve rocker ASSY (R.H.)
6 Exhaust valve
7 Valve spring retainer key
8 Valve spring retainer
Valve spring
Valve spring 2
Intake valve
Valve push rod
13 Valve lifter
14 Bolt
15 Lock washer
9
10
11
12
16 Camshaft gear
17 Camshaft plate
18
19
20
21
22
Valve rocker ASSY
Camshaft
Woodruff key
Hydraulic valve lifter
Push rod (for hydraulic valve lifter)
AS·668
Fig. 3-12 Valve system
3-18
ENGINE
6. Valve Rocker
1,800 cc engine
AS·669
;
~:!~e ;:~ker ASSY (R.H.)
11 Val
Valve rock er arm CP 2
12
1
ve rocker ASSY
I!V
Ralve rocker ASSY ii·HH·)
ocker shaft
. .)
15 Val
spacer
16 Valve rocker shaft
17
rocker ASSY (LoH.)
18
e rocker arm
19 Valve rocker arm 2
Lock washer (on!
hydraullc valve lifter)
y for
3
4
5
6
7
8
9
Nut
Washer
Valve rocker
w
Rocker shaft scn:
Rocker shaf sprmg washer
Valve rock t supporter
R
erarm CP
ocker shaft
10 Valve rocker shaft
spacer
Fig.3·13
va::
a verocker
~I
3-19
ENGINE
7. Emission Control Equipment
1) Hitachi Carburetor Type
*: Except 49 States 4WD &.
4WD-AT and Canada
* 1 Bracket
* 2 Vacuum switch I
* 3 Vacuum switch II
4 Bolt &. washer
5 EGR pipe cover
6 EGRpipe
* 7 Solenoid valve III
* 8 Oxygen sensor
9 Nut
10 Washer
11 Clamp
12 EGRvalve
13 Gasket
*14 Duty solenoid valve
15 Bolt &. washer
16 Thermosensor
17 Bolt &. washer
*18 Solenoid valve I
19 Thermo vacuum valve II
*20 Carburetor protector 3
21 Vacuum pipe CP
(Except 4WD and AT)
22 Thermo vacuum valve I
23 Vacuum pipe CP
(4WDand AT)
*24 Electronic control module
*25 Ignition relay
*26 Revolution sensor
*27 Carburetor protector
*28 Carburetor protector 2
*29 Solenoid valve II
(49 States only)
®
Fig. 3·14 EmiSlion control6quipmsnt (Hitachi carburetor type)
3-20
.6.15·670
ENGINE
2) COW Carburetor Type
1 Bracket
2 Vacuum switch I
3 Vacuum switch II
4 Bolt &. washer
5 EGR pipe cover
6 EGRpipe
7 Solenoid valve II
8 Oxygen sensor
9 Nut
10 Washer
11 EGRvalve
12 Gasket
13 Thermo vacuum valve I
14 Vacuum pipe CP
15 Bolt &. washer
16 Electronic control mudule
17 Thermosensor
18 Revolution sensor
19 Solenoid valve I
20 Ignition relay
@
Fig. 3- 75 Emilflion control equipment (C-W carbuffltor type)
3-21
11.5·671
ENGINE
8. Air Injection System
*1 Electronic control module
*2 Solenoid valve I
*3 Check valve II
*. Except 49 States
4WD&4WD-AT
and Canada
4 Air induction hose
5 Thermosensor
6 Air cleaner
7 Silencer
8 Air induction hose
9 Air suction valve
10 Air suction pipe
11 Air suction valve II
12 Silencer
13 Air suction pipe
14 Silencer
15 Air induction hose
16 Air suction valve III
(49 States 4WD &
4WD-AT and Canada)
y.~
~
~~Ill
@
49 Stages (Except
& 4WO-A T) only
(Spacer)
(Air suction valve II
(Air suction valve Ill)
(Air suction valve III
ASV cover
Reed valve ASSY --~
ASV case
f, J
Screw & waSher-.l
Fig. 3-16 Air injection system
AS-672
3-22
ENGINE
9. Intake Manifold
1) Hitachi Carburetor Type
1 Nut
2 Air cleaner
3 Air cleaner bracket
4 Washer
5 Bolt & washer
6 Carburetor bolt
7 Air cleaner gasket
8 Carburet or
9 Nut
10 Spring washer
11 Bolt
12 Spring washer
13 Accelerator cable bracket
14 Carburetor gasket
15 Intake manifold
16 Stud bolt
17 Stud bolt
18 Bolt
19 Fuel hose stay
20 Bolt
21 Spring pin
22 Intake manifold gasket
23 Air cleaner bracket
24 Stay 2
,
25 Air cleaner bracket
(for power steen'ng vehIcle)
26 Screw & washer
27 Stay
28 Insulator
29 Vacuum hose clamp
30 Stay
31 Washer
A5-595
Fig, 3-17 Intake mam'f!0 Id (Hitachi carburetor type)
ENGINE
2) CoW Carburetor Type
Tightening torque: N'm (kg-m. ft.Jb)
T: 18·22(1.8-2.2,13·16)
~
"""I ""A"" " \
~®~
@
1
2
3
4
S
6
7
8
9
10
11
12
13
@
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Nut
Air cleaner
Air cleaner bracltet
Washer
Bolt & wuher
Sprin& pin
Bolt
Sprin& washer
Fuel boa stay
Bolt
Intake manifold pstet
Intake manifold
Vacuum bo. damp
Stud bolt
Stud bolt
FJ.anae ()..rlna
Insulator
Bolt & washer
Stay
Stay 2
Washer
Air cleaner bracket
Carbu.retor
Washer
Nut
Carbu.retor pstet 2
Connector
Clamp
Ho.
Bolt & washer
Air cleaner p*et
Carburetor bolt
Carburetor spacer
34 Air clelDClr bracket
(for power steerin.)
A&-696
Fig. ... ,. Intake manifold (C-W carburetor type)
3-24
ENGINE
10. 011 Pan, 011 Filler Duct and Flttln••
(i)~
@'----,,..--_-
@
@
Tightening torque: N'm (kg-m, ft·lb)
T1: 23·2612.3·2.7,17·20)
T2: 22·27 (2.2·2.8, 16·201
T3: 4.4· 5.4 10.45·0.55, 3.3 . 4.0'
1 on level gauge
2 Oil flter duct
3 Oil filler cap CP
4 Gasket
5 Air breather duct gasket
6 on filler duct stay
(SUBARU 1800)
7 Oil f"dIer duct stay
(SUBARU 1600)
8 Bolt and washer
9 Bolt and washer
..~;
10 Bolt
11 Spring washer
12 Oil sttainer stay
13 O-ring
14 Oil strainer
15 Bolt
16 Spring washer
17 Nut
18 on strainer stay 2
19 Bolt & washer
20 Oil pan gasket
21 Bolt & washer
22 Oil pan CP
23 Plug
24 Gasket
'. ;',
'fl.-.
Fig. 3· 19 Oil PIIIl, oil filler duct and fittings
AB·a7B
3-25
·-.-.-.~--
ENGINE
11. Oil Pump
(1800 cc engine)
1
2
3
4
5
6
7
~
~?
'--- @4
'Z..z...
/
@
Oil pump assembly
Oil relief valve
Relief valve spring
Washer
Washer
Plug
O-ring
8 Oil pump rotor
9 Oil pump drive gear
10 Oil pump body holder
11 Pan head screw
'
~,~
12 Plug (Models without pressure gauge)
13 Ball
~
14 By-pus valve spring
15 O-ring
16 Oil pressure switch
(Models without pressure gause)
17 Plug (1/8")
(Models with pressure gause)
18 Oil pump body gasket
thread.
19
20
21
22
23
24
25
Oil mter
Bolt
Bolt
Washer
Oil presswe gause
(Models with pressure gause)
26 Stay
~
Tightening torque N·m (kg"",, ft·lbl
O-rinl
o-rinl
T1: 31 - 37 (3.2 - 3.B. 23 - 271
T2: 22 - 2712.2 - 2.B. 16 20)
A6·023
torque N·m (kg"",, ft·lbl
(1600 cc engine)
1 - 37 13.2 - 3.8. 23 - 271
1
2
3
4
5
6
7
Oil pump assembly
Oil relief valve
Relief valve spring
Washer
Washer
Plug
O-rinl
8 Oil pump rotor
9 Oil pump drive gear
10 Oil pump body holder
11 Pan head screw
• Apply liquid gasket
(Fuji Bond C or
equivalent) to the
thread.
12
13
14
15
16
,
17
18
19
20
* Apply a thin
coat of oil to
the seal
rubber.
21
Plug (Models without pressure gauge)
Ball
By-pass valve spring
O-rinl
Oil presswe switch
(Models without pressure gause)
Oil pump body gasket
Oil rdter
Bolt
Bolt
Washer
22 O-rinl
23 PlUS (Models with pressure gaup)
24 Oil presswe gause
(Models with pressure gauge)
25 Stay
Fig.3-20
A6·024
3-26
ENGINE
12. Radiator Assembly and Electric Fan
NOTE:
There are two manufacturers in fan
ASSY. One is Hitachi and another is
Mitsuba. Each is exclusively composed,
so there is no interchangeability
between two manufacturers.
1 Ground cord
2 Tapping screw
3 Hose clamp
4 Flange nut
5 Flange bolt
6 Shroud
7 Radiator inlet hose
8 Thenno switch
9 Packing
10 Radiator outlet hose
11 Radiator assembly
12 Radiator cap
13 Overflow tube
14 Drain plug
15 Water drain
16 Packing
17 Cushion
18 Spacer
19 Grommet
20 Washer
21 -Bolt &. washer
22 Motor
23 Washer
24 Fan
25 Fan washer
26 Washer
27 Nut
28 Plug (AT only)
29 Gasket
,,
~~~~-)
r------~~--------,
Tightening torque N·m (kg·m, ft·lb)
--.---.
T: 10-18(1.0-1
® i8
~
7-131
A7..Q98
Fig. 3·21 Engine cooling system (Radiator ASSY and electric fan)
1 Hose clamp
2 Tapping screw
3 Oil cooler pipe clamp
4 Oil cooler hose
5 'Oil cooler pipe complete
6 Oil cooler pipe clamp
7 Spring washer
8 Bolt
9 Clip
Fig.3·22 Engine cooling system [Oil cooler fA T) )
\
ENGINE
13. Water Pump and Relative Flttln ••
1 Bolt &. washer
2 Thermostat cover
3 Bolt &. washer
®~
I
/
I
!
I
!
e;::Y -~'1
I
I
I
I
I
I
'··;,;·:·;·~'1·:
I
I
I
I
@iI
I
I
l
"
,
I
'...t
I
I
I
I
I
I
I
I
1
I
I
I
@
I
4 Hose clamp
5 Hose (For C·W carburetor)
6 Thermostat cover
@
,
I
#
'~~
<, ,
,
"-
"-
" "l
I
,
®----O '
I
I
I
I
I
:
';:
'.
"
"
I
I
I
I
I
I
I
/
I
I
I
I
I
I
Fig. 3·23 Engine cooling system (Water pump and relative fittings)
3-28
",
J
(For power steering)
7 Water by-pass pipe
'I
I ~\
I
I II "
I I
I
I II
I
I I
I I
I I
I
I
I I
I
I
I
I
",
I
I
""
8 Protector stay
Water pump gasket
Water pump
Bolt &. washer
Bolt &. washer
13 Hose calrnp
14 Hose
15 Hose
16 Thermostat
17 Thermostat cover gasket
18 Solenoid valve bracket
19 Hose
20 Heater hose clamp
21 Hose
22 Thermo valve
23 Hose (For Hitachi carburetor)
24 Hose
25 Water pump pulley
26 Water pump shaft
27 Water pump mechanical seal
28 Water pump plate CP
29 Water pump impeller
9
10
11
12
A5-676
-~
ENGINE
14. Exhaust System
(
"'---'("~-:::-)
.. -.,
. - - - - -.. --.-.:=:::.::=;--.-r ..\
C_ .. _)
j
: Ll=
Hatchback only
@
49 States !except 4WO & 4WO·ATI only
.. ~
/
___ J
""'-.
...........
.-
{~
~.
··---A <~~,
~-.--~.l
C"
-::::::-._.:_~~:_~.lL.-~c-'___
".
:::::::::!#E::':
0
..,
.. -
,J
___
'!:-_!C
_'''':_:;--_[
9,
-.'---~.~.
cG
j
,
~
49 States (except 4WO & 4WO·ATI only
Gasket
Oetail"F"
Spring
Detail "A"
Selflocking nut
0
Detail "C"
Detail
"e"
Detail "0"
AT
Detail"B"
Fig. 3·24
MT
1 Front exhaust pipe
2 Rear exhaust pipe
3 Muffler
4 Bracket
S Cushion
6 Tail pipe cutter
Tightening torque: N·m Ikg-m, ft·lb)
T1: 10-1811.0 -1.8, 7 ·131
T2: 25 • 29 (2.6· 3.0, 19 • 22)
T3: 22·33 (2.2·3.4,16·26)
T4: 42 - 52 (4.3 - 5.3, 31 • 38)
T5: 14·22 (1.4·2.2, 10·161
T6: 26·34 (2.5·3.5, 18·25)
A5·677
ENGINE
3-3. On-car Services
Also after reassembling and remounting the engine, perform the following
checks and adjustments.
For other checks and adjustments,
refer to Chapter 2.
NOTE:
a. Upon completion of the engine
adjustments, check the oil and
coolant level. Add up the oil and
coolant if necessary.
b. Check to see if there is any leakage
of the engine oil or coolant.
c. Check the wiring cords, pipes,
hoses, etc. for undesirable interference.
d. If one or both of the cylinder heads
are removed in engine disassembly,
never fail to perform the retighten·
ing of the cylinder head nuts &
bolts and intake manifold bolts and
the adjustment of the valve clear·
ances as instructed in 2·2 in CHAP·
TER 2 after the engine has been
run for about 10 minutes and
cooled down to ambient tempera·
ture.
1. IKnltlon TlmlnK
Perform inspection and/or adjustment of ignition timing according to
the folloWing procedures.
1) Checking Ignition Timing
2) Adjusting Ignition Timing
Before adjusting ignition timing,
disconnect the vacuum hose of advancer from the distributor to stop the
vacuum advance function of the distributor, and, while checking ignition
timing, plug the end of the vacuum
hose with small rod as shown in the
figure.
I) Loosen the 6 mOl bolt on the
mounting plate of the distributor.
2) Turn the distributor housing. The
timing is advanced when the distrib·
utor housing is turned clockwise and
is retarded when turned counterclockwise.
3) Tighten the bolt and make sure
tha t the timing is correct.
1 Vacuum hose
A5-S07
2 Rod
Fig. 3-25 Plugging vacuum hose
A5·379
To check the ignition timing, connect a timing light to #1 cylinder
spark plug cord, adjust the engine idle
speed to the specification and illuminate the timing marks on the flywheel
with the timing light.
If the timing is not correct, proceed
to the next paragraph for adjustment.
I
2. EnKlne Compression
1) After warming up the engine,
turn off the ignition-starter switch.
2) Make sure that the battery is
fully charged.
3) Remove all the spark plugs.
4) Fully open the throttle valve.
5) Check the starter motor for satisfactory performance and operation.
6) Crank the engine by means of the
starter motor, and read the maximum
value on the gauge when the pointer is
steady.
Ignition timing
Without vacuum advance function,
and with gear in neutral position
(MT) or N or P position (AT), and
lights off.
Fig. 3-26
1,600
1,800
MT
AT&
1,800 4WDAT
·1 8 ± 2° BTOC
at 700 rpm
.2 8 ± 2° BTDC
at 800 rpm
*1: 49 States 4WD vehicle with High
Altitude Kit: 12 ± 2° BTOC at
700 rpm
*2: 49 States 4WD·AT vehicle with
High Altitude Kit: 12 ± 2° BTOC
at 800
rpm
Fig. 3-28 Adjusting ignition timing
NOTE:
Hold the compression gauge tight
against the spark plug hole.
A: After
B: Before
7) Perform at least two measureAS-378
Fig. 3-27 Timing mark and pointer
3-30
ments per cylinder, and make sure that
the values are correct.
ENGINE
1.171112 1111
I
I
1,079 111, 1561
I
I
~
,
981110 1421
0.'
88319,1281
~
18518, 1141
;d,
'2 E
j
8:.
u ..
Q. -
I'
1,030
'10.5, 14911250
<11,16611
350
'
,
I
6861" 100!
200
/
1 __::s,::.and.,:.a_,d_ _ _ .I 1,019
t-883
834
19,1281:
185.12111250
250
350
300
350
S"II.ne.peed .• pm
A3·Q62
Fig. 3·29 Compression pressure
A5381
Fig. 3-31 Measuring vacuum
Fig. 3·30 Measuring compression
3. Intake Manifold
Vacuum
~
Difference be· 196kPa 2
(2.0 kgJcm , 28 psi)
tween cylinders
or less
1) Warm up the engine.
2) Disconnect the vacuum hose (air
cleaner to intake manifold) and install
the vacuum gauge to the hose fitting
on the manifold as shown in figure.
3) Keep the engine at the idle speed
and read the vacuum gauge indication.
By observing the gauge needle
movement, the internal condition of
the engine can be diagnosed as
described in Table below.
- - - ..
Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication
Possible engine condition
.-~
1.
Needle is steady but lower than normal position.
This tendency becomes more evident as engine
temperature rises.
Leakage around intake manifold gasket or carburetor
gasket.
..--~-
2. When engine speed is reduced slowly from higher
Back pressure too high, or exhaust muffler clogged.
speed, needle stops temporarily when it is
lowering or becomes steady above normal
position.
3,
Needle intermittently drops to position lower
than normal position.
4. Needle is steady but slightly lower than normal
position.
S.
Needle is steady but slightly higher than normal
position.
6. Needle drops slightly and intermittently from
Leakage around cylinder.
Retarded ignition
clearances.
timing
or
insufficient
valve
Advanced ignition timing.
Leaking valves or irregular valve clearances.
normal position.
.
7. Needle drops suddenly and intermittently from
Sticky valves.
normal position.
S. When engine speed is gradually increased, needle
Weak or broken valve springs.
begins to vibrate rapidly at certain speed, and
then vibration increases as engine speed increases.
9. Needle vibrates above and below normal position
in narrow range.
Defective ignition system or incorrect carburetor idle
adjustment.
ENGINE
4. Hot Air Control
System
Inspect the hot air control system
periodically as follows.
In warm weather, it is difficult to
find out malfunction of the hot air
control system. In cold weather, however, malfunction of the air control
valve due to disconnection or deterioration of the vacuum hose between the
intake manifold and vacuum motor
and insufficient durability of the air
control valve will cause insufficient
automatic control operation for intake
air, and result in engine disorders:
I) Stall or hesitation of engine operation,
2) Increase in fuel consumption, and
3) Lack of power.
These phenomena reveal malfunction of hot air control system. If these
phenomena should occur, check the
hot air control system for the following items before carrying out inspection of the carburetor.
1) Vacuum Hoses
Check each hose for cracks and
proper connections.
2) Vacuum Motor
1) With the engine stopped, place a
mirror at the end of the air cleaner
inlet pipe as shown in the figure, and
check to see if the air control valve is
Mirror
Vacuum motor
Air intake hose
A5·385
Fig.3-33 InlP6Cting vsl", position
1 Vacuum motor
2 Temperature sensor
3 Throttle valve
4 Intake manifold
S Vacuum hose
6 Air stove
7 Air intake bose
8 Air control valve
9 Air hom (Snorkel tube)
A5·383
The air control valve is in correct
position if its under hood air inlet is
open and hot air inlet is closed. Check
the condition of the air control valve
linkage.
2) Disconnect the vacuum motor
inlet vacuum hose, and connect another hose to the inlet to apply vacuum to the vacuum motor. Vacuum can
be applied by sucking at the hose end
as shown in the figure.
Place a mirror at the end of the air
cleaner inlet pipe, and check to see if
the air control valve is in correct
position.
2 Vacuum motor
1 Vacuum motor
2 Temperature sensor
A 5·386
FIg.3-34 InlP6Cting vsl", position
Correct position of the air control
valve is the reverse of that described in
I) above. The air control valve is in
correct position if the under hood air
inlet is closed, and the hot air inlet is
open.
FIg. 3-32 Hot ,ir control systBm
3-32
ENGINE
3) With the hot air inlet in open
position. as described in 2). pinch the
vacuum hose with fingers so that the
air does not enter the vacuum motor.
In this condition. check that the air
control valve maintains the condition
described in 2) for more than 30
seconds. and that the hot air inlet is
open. If the diaphragm spring actuates
the air control valve by its spring force
to open the under hood air inlet
within 30 seconds. replace the vacuum
motor as an assembly since this may
have resulted from air leak at the
vacuum motor diaphragm.
3) Temperature Sensor
Check temperature sensor for proper function by proceeding as follows.
Be sure to keep the engine cold before
starting this test.
1) With the engine stopped. check
the position of the air control valve. In
this case, underhood air inlet should
be open. Use a mirror for inspection as
2) - I).
2) Start the engine and keep it
idling. Immediately after engine starting, check the air control valve for
correct position as described above. In
this case, the correct position of the
air control valve is the reverse of
2)-1); the under hood air inlet is
closed. and the hot air inlet is open.
3) Check that the air control valve
gradually moves to open the under
hood air inlet as the engine warms up.
When the environmental temperature
around the temperature sensor is low.
spend more time for engine warming
up operation to facilitate smooth operation of the air control valve.
4) Rubber Plate
Check the rubber plate for stickiness.
5} Air Intake Hose
Check the air intake hose for damage and its connections for leaks.
Operation of air control valve and sensor valve
Under hood air
temperature
Vacuum on vacuum motor diaphragm
Air control valve operation
Below S.3 kPa (40 mmHg. 1.57 inHg)
Cool air admission
Above 16.0 kPa(120 mmHg, 4.72 inHg)
Hot air admission
Below 38°C (100°F)
Sensor valve
operation
Close
38 - S3°C (100 - 127°F)
Cool and hot air mixture
admission
Open
Above S3°C (l27°F)
Cool air admission
Open
.S. En.lne Idle Speed and Idle Mixture
1) Engine Idle Speed
Refer to 2·2. 8. Engine Idle Speed in
Chapter 2.
2) Engine Idle Mixture
NOTE:
Perform the idle mixture adiultment
only when dismounting carburetor
from angina or ditalsambling carb.
retor. And after completion of adjustment, ba lUre to pr_ spring pin into
the hole in throttle chambar.
ENGINE
1) For 49 States (except 4WO & 4WO-A T) and California
Perform the engine idle mixture adjustment according to the following diagram.
*
Does the poin ler () f duty meter swing
normally?
(ie. Is duty ratio
t:(
Idling speed
Yes
=N
Duty ratio
lntrolled'!)
~
**
J
No
[
1
Z
=N
=Z
Idling speed
l
Adjust duty ratio.
Duty ratio
No
Yes
Yes
Keep engine speed \II ithin 2,000 - 3,000
rpm for 2 - 3 minu res.
I
Warm up engine by
driving around for
10 minutes.
End
No
t
~~
()e~ the ~~~ter 0 f duty meier swing
G.
normally?
Confirm
JdUng speed .. N
Duty ratio" Z
See Troubleshooting
in Chapter 5.
Yes
~
f--
Yes
(ie. Is duty ratio c ontrolJed?)
End
Nn
See Troubleshooting in Chapter 5.
700 ± 100 rpm (MT)
( 800 ± 100 rpm (AT)
*N
,
Z=
NOTE:
Perform the above adjustment on
both main and slow duty solenoid
valve by using check terminal.
b. Adjustment method by using dwell
meter is as follows.
(1) Set the range switch to 'four
cycle - four cylinde(.
(2) Adjust the idle adjusting screw
so that the needle points out
according to the following calculation.
90
Dwell (deg) =- x Duty (%)
100
B.
Vehicle with
CoW carburetor
Vehicle with
HITACHI carburetor
Standard value
Duty ratio'" Z
r::J
deg)1
3S%
l31 .S
Z'" 35% (31.5 deg)
/
(
Z is constant
)
regardless of the
altitude.
f--l--;tl('
/']
I
deg)~
SO m
1,600 m
{164 hI
(S.2S0 ft)
Z is determined according to )
( the altitude.
, adjusting
Allowan~
~-----+-----------------------------~--------~
At
checking
*"
±5% (±4.5 deg)
:1:20% (t18 deg)
Adjust idle adjusting screw so that duty meter indicates 35 ± 10%.
3-34
ENGINE
2) For 49 States 4WD &
4WD·AT, and Canada
Check rubber seal on cap for tears,
cracks or deterioration after cleaning
it.
Adjust engine idle mixture as follows:
I) Start engine and warm up suffi·
ciently,
2) Inspect idle speed and CO per·
centage in exhaust gas with secondary
air,
Other
than
AT
Idle speed (rpm)
CO
percent·
age (%)
Without
secondary
air
With
secondary
air
AT&
4WD·AT
Install the cap on a tester and if cap
does not hold or does not release the
specified pressure, replace cap.
Standard pres·
sure at which
valve starts to
open
88 kPa
(0.9 kg/cml,
13 psi)
700±100 800±IOO
2.0±1.0
1.S±1.0
I)
Disconnect both the blow·by and
PCV hoses.
2) Remove the valve rocker cover.
3) Using the special tool (Socket
Wrench: 899988607), loosen the valve
rocker ASSY and remove the push rod.
4) Raise the vehicle body with a jack
and support it on a safety stand.
S) Remove the nuts which secure the
front engine mounting and slightly
raise the engine using a floor crane.
6) Remove the drain plug to drain
the engine oil completely. Detach the
oil pan.
7) Remove the hydraulic valve lifter.
Use of a magnet facilitates removal.
0- O.S
--
3) Disconnect air suction hose be·
tween air suction valve and secondary
air cleaner.
4) Clog air suction pipe with rubber
cap or the like,
5) Inspect idle speed and CO per·
centage in exhaust gas without second·
ary air.
6) If necessary, adjust idle speed and
CO percentage in exhaust gas while
clogging air suction pipe,
a. Adjust both throttle adjusting screw
and idle mixture adjusting screw to
obtain the specified idle speed and
CO percentage without secondary
air.
b, Remove the plug clogging air
suction pipe, and connect the pipe
to secondary air cleaner hose.
c. With secondary air, recheck that
idle speed and CO percentage
satisfy the specifications.
Fig. 3-35 Testing the cap
8. Testing of radiator leakage
Inspect radiator for leakage using a
cap tester and applying a pressure of
157 kPa(1.6 kg/cml, 23 psi).
If a leakage is detected, repair or
replace the radiator.
8) The valve lifter can be installed in
the reverse order.
8. Adjustment
A7·026
Fig.3-36 Testing the radiator
6. Radiator
Check radiator, hoses and their con·
nections for damage, clogging or
leakage.
7. Hydraulic Valve
Lifter
A. Replacement
A. Testing of radiator cap
Check the valve, spring and packing in
the cap for damage.
A5·678
Fig, 3·37
The hydraulic valve lifter can be
replaced even when the engine is
mounted on the vehicle as follows:
I) Perform adjustment in cold con·
dition [coolant temperature: 20 to
40°C (68 to 104°F)).
2) Retighten cylinder head nuts and
bolts previously if necessary.
3) Adjust hydraulic valve lifter with
the following procedures:
a. Perform adjustment in two (2)
sequences.
Sequence (I)
Position #1 cylinder at TDC
(compression), and adjust the
valve lifters for intake and
exhaust valves on #1 cylinder,
for exhaust valve on #3 cylinder
and for intake valve on #4
cylinder.
ENGINE
Sequence (II) - - - - Position #l cylinder at TDC
(compression), and adjust all
the others, i.e. for intake and
exhaust valves on #l cylinder,
for intake valve on #3 cylinder
and for exhaust valve on #4
cylinder.
b. Raise up the bend of lock washer,
loosen the lock nut, and then turn
the valve rocker screw clock·
wise by approx. four (4) turns
using Valve Clearance Adjuster
498767000.
f. Tighten the lock nut, and bend the
lock washer.
Unscrew gradually.
AS·702
8. Exhaust System
e. Moreover, unscrew the valve rocker
screw counterclockwise by 1.5
turns.
Valve opens.
.~
~
.
'\ Hydraulic velve
\fter is adjusted
A5·700
~byl5t"~
NOTE:
If muffler or exhaust pipe clearance is
excessively small due to a deformed or
A6·703
c. Leave it with the valves opened
for approx. 15 minutes.
1) After installing the exhaust sys·
tern, check all clearances to ensure
that they exceed the specified values.
2) If a clearance is small at any
particular point, loosen all connections,
then readjust clearances by utilizing
free play existing at each bolt location
until correct clearances are obtained.
Finally, tighten all connections to
the specified value.
broken exhaust cover, repair or replace
1IIe cover, and adjust 1IIe clearance
correctly.
Front crossmember
Leave for approx.
15 minutes then
pressure chamber
volume becomes
Crossmember for manual transmission
Crossmember for automatic transmission
minimum~alve mov~~~
close a little.
L-
~~
~ ..
Rear crossmember
a
.. _
AS·701
.. -
i
Xhaust cover
"/ -~'=_
.. _ ... . r - . . ,
~~~~~~::~~===d~/~..
p.
More than
1510.591
d. Unscrew the valve rocker screw
gradually. Then, the rocker arm
stops moving due to the closing of
valve. Th~ condition is called
"Zero Point".
More than
10 (0.39)
Re:zrSkirt
More than
20 (0.791
f~
I
--r
More than
More than 20 10.791
2010.791
Unit: mm (in)
More than
12 (0.471
Fig. 3-38
A22·065
3-36
ENGINE
9. Oxycen (02 ) Sensor
Oxygen (0,) sensor is installed on
front exhaust pipe, and is one of the
important emission control parts.
Therefore, replace it as follows only
when it is damaged by external force,
or if it seems to be out of order
according to troubleshooting etc.
3) Loosen oxygen (0,) sensor by
turning it 10 to 40 degrees with special
tool (Socket: 499990100) and wrench.
Fig. 3-40
1) Removal
4) Apply
SUBARU
GUARD
(000902821) to threaded portion of
oxygen (Ol) sensor again, and leave it
for one minute or more.
S) Remove oxygen (0,) sensor by
using special tool (Socket: 499990100)
and wrench.
1) Disconnect 0, sensor cord.
2) Apply
SUBARU
GUARD
(000902821) or its equivalent to
threaded portion of oxygen (0,)
sensor, and leave it for one minute or
more.
NOTE:
When removing, do not force oxygen
(0 2 ) sensor especially when front
exhaust pipe is cold; othelWise it will
damage the front exhaust pipe.
Fig. 3·39
1) Apply anti-seize compound ("SS30" made by JET-LUBE Inc. in U.S.A.
or its equivalent) only to threaded
portion of oxygen (0,) sensor to make
the next removal easier.
NOTE:
Never apply anti-seize compound to
protector of oxygen (0 2 ) sensor.
AS'S80
A5-679
2) Installation
2) By using special tool (Socket:
499990100) and torque wrench, install
oxygen (0,) sensor onto front exhaust
pipe by tightening it to the specified
torque.
Torque
[oxygen (Ol)
sensor}
22 - 29 N'm
(2.2 - 3.0 kg-m,
16 - 22 ft-Ib)
3) Securely connect oxygen (0,)
sensor cord.
ENGINE
3·4. Dismounting and Remounting
1. Precautions
I) Perform the job at a place where a
chain hoist or a floor crane is available.
If possible, it is desirable to perform
the job over a pit together with a chain
hoist or a floor crane.
2) Be careful not to soil the vehicle
interior (particularly windows and
seats).
3) Be careful not to allow brake
fluid and coolant to come in contact
with the painted surfaces of the vehicle body. It is desirable to cover the
fenders with covers during the work,
if possible.
2) Detach spare wheel & tire and its
supporter. In this process, pay attention to prevent damage of air cleaner.
3) Remove ground cable between
battery and engine, and ground wiring
for noise condenser from engine.
4) Disconnect hoses and electric
wiring from air cleaner. Remove bolts
and nuts, and take out air cleaner.
NOTE:
Plug the carburetor opening to prevent
dirt or dust from entering carburetor.
5) Disconnect hoses from carburetor,
intake manifold, etc.
a. Fuel delivery hose and fuel return
hose from carburetor
NOTE:
Gasoline remammg in delivery hose
may flow out. Therefore receive this
gasoline with an appropriate container.
2. Dismounting
I) Open/put engine hood widely by
setting its stay in the correct position.
A1-G63
A4-161
Fig.341 Opening engine hood
b. Vacuum hose, carburetor vent hose
and purge hose from evapolation
pipe complete
c. Vacuum hose for brake booster
(Master-vac) from intake manifold
d. (AT only) Vacuum hose for kickdown solenoid from vacuum pipe
6) Disconnect electric wiring, hoses,
etc.
a. Engine wiring harness
b. High tension cords
c. Alternator wiring
d. Starter wirings
e. Vacuum switch hose(s)
7) Disconnect cables, pitching stopper, etc.
a. Accelerator cable from carburetor
b. (MT only) Clutch return spring
c. (Vehicle with Hill-holder) P.H.V.
(Pressure Hold Valve) cable from
bracket
d. Pitching stopper
8) (AT only) Remove four bolts
connecting torque converter to drive
plate through timing hole.
9) Loosen bolts and nuts connecting
transmission to engine, and then
remove upper two bolts only.
3-38
Fig. 342 Removing upper bolts and
loosening lower nuts
10) Take out radiator as follows:
a. Detach right-hand side under cover.
b. Connect a vinyl hose to radiator
drain plug, and drain out coolant.
Fig.3-43 Draining coolant
c. Disconnect both inlet and ou tlet
radiator hoses.
NOTE:
Use a container to catch coolant
running out of inlet and outlet hoses.
d. Disconnect electric connectors for
thermoswitch and fan motor, and
ground wiring of radiator.
e. (AT only) Disconnect cooler hoses
at radiator.
f. Remove two bolts, and take out
radiator.
ENGINE
16) Remove lower two nuts loosened
previously.
17) To facilitate dismounting engine,
lower the jack.
IS) Visually check again that nothing
has been over-locked.
19) Carefully lift engine until bolts
retaining engine mount rubber cushion
clear crossmember.
20) Support transmission using another jack.
g. Disconnect both inlet and outlet
heater hoses.
11) (Vehicle with power steering)
Remove oil pump ASSY and bracket
as follows:
a. Detach idler cap with pliers with
waste cloth around it in order not
to damage it.
?
Correct position
A4·194
A4·152
Fig. 3-46
Fig. 3·44 Removing cap
A4-097
b. Loosen lock bolts and adjust bolt
of idler pulley, and then detach oil
pump belt.
c. Remove bolts and nut, and put oil
pump ASSY on bulkhead.
A4·196
13) Separate front exhaust pipe from
engine as follows:
a. Disconnect oxygen (0 2 ) sensor
cord.
b. Remove nuts securing front exhaust
pipe to the exhaust ports of engine.
c. Loosen bolt connecting front exhaust pipe to bracket of body.
14) Remove nuts securing cushion
rubbers used to support the front
portion of engine.
15) Attach a lifting wire to front and
rear hangers of engine, and hang it
with a crane or similar equipment.
But do not lift it at this time.
NOTE:
a. Make sure that the lifting wire hook
is securely attached to the hanger.
b. Take care so that a lifting wire does
not damage the engine parts.
Fig. 345 Removing oil pump ASS Y
Fig.3-48 Supporting transmission
21) Slowly move engine forward to
prevent transmission mainshaft from
interfering with flywheel housing, and
then take engine out of engine room.
NOTE:
Be careful not to strike engine against
any adiacent parts, or car body during
dismounting.
3. Remounting
l) Set (repaired or new) engine near
by transmission as follows.
a. Lift engine using a crane or similar
equipment.
b. Move/put it near the center of
engine room.
c. Lower engine until the centerline of
crankshaft aligns with mainshaft of
transmission.
NOTE:
a. Be careful that the oil does not
flow out.
b. Be careful that the two oil hoses
does not damage.
NOTE:
a. While engine is lowered, be careful
to prevent engine from striking any
adjacent parts or car body.
b. Apply grease to splines of mainshaft in advance.
d. Detach bracket.
12) Raise the front end of vehicle
using a jack, and support with safety
stands at the correct positions.
2) Turn crank pulley until mainshaft
is aligned with clutch disc at their
splines, and secure engine to transmission as follows.
A4-199
Fig. 3-47
ENGINE
NOTE:
Be careful to prevent mainshaft splines
from interferinll with clutch diaphragm
spring. This can cause damage to
sprinll·
Torque
23 - 26 N·m
(2.3 - 2.1 kg·m,
11- 20 ft-lb)
I
•
I
~
I
r
1$''.1
Gasket
NOTE:
Be careful not to drop bolts into
torque converter housinll.
An-031
Fig. 3·52 Installing gasket
b. Tighten bolt at bracket of body.
A4-200
Torque
Fig.349 Turning crankshaft
a. Temporarily tighten upper two
bolts, and then lower nuts.
b. Make sure that engine is properly
aligned with transmission.
c. Securely tighten both upper bolts
and lower nuts.
Torque
(Bolts and
nuts)
46 - 54 N·m
A4·112
Fig. 3·50 Connecting torque converter and drive plate
5) Raise the vehicle with a jack just
enough to work underneath it and
support with safety stands.
6) Securely tighten engine mount
cushion rubbers on the crossmember.
(4.1 - 5.5 kg·m,
34 - 40 ft·lb)
Torque
3) Put engine in position as follows.
a. Lower the jack supporting transmis·
sion, and take it out.
b. Position engine mount rubbers onto
crossmember.
c. Lower engine moreover.
d. Detach lifting wire from engine,
and carry away crane.
4) (AT only) Install drive plate on
torque converter as follows:
a. Jack up the car until front wheels
are slightly off the floor.
b. Turning crank pulley with a wrench,
bring the mounting hole for drive
plate to the center of the timing
hole.
c. Turn front wheels until the mount·
ing holes for torque converter are
aligned with the mounting holes for
drive plate, and tighten them by
bolts ..
d. Crank engine with a wrench and
securely tighten all four mounting
bolts - one bolt at a time for each
turn - to retain torque converter
and drive plate.
25 - 34 N·m
(2.5 3.5 kg-m,
18 - 25 ft-Ib)
20- 33 N'm
(2.0 - 3.4 kg-m,
14 - 25 ft-Ib)
A4·161
Fig. 3·53 Installing front exhaust
pipe
c. Then tighten four nuts to the speci·
fied torque.
Torque
25 - 29N·m
(2.6 3.0 kg-m.
19 22 ft·lb)
A4·095
Fig.3-51 Tightening cushion rubber
nuts
It:=::
1) Connect front exhaust pipe to
engine as follows.
a. Attach new gaskets to the engine
exhaust ports, and temporarily
tighten nuts.
Fig. 3-54
NOTE:
Place the flat surface of the gasket to
the enlline exhaust port.
d. Connect 0, sensor cord.
8) Lower the vehicle to the floor.
3-40
A4-093
ENGINE
9) Install pitching stopper as follows:
a. Insert pitching stopper rod into the
bracket on the engine side, and
tighten it at the car body side.
b. Tighten the rear nut on pitching
stopper of the engine side so that
the specified clearance exists between rubber cushion and washer.
b. (Vehicle with Hill-holder) Connect
P.C.V. cable, and adjust Hill·holder
system.
(Refer
to
Chapter
"Brakes" .)
,---
Torque
Nut A
(one)
44-54N·m
(4.5 - 5.5 kg-m.
33 - 40 ft-Ib)
Bolt B
(two)
44-54N·m
(4.5 - 5.5 kg.m,
33 - 40 ft·lb)
Bolt C
(three)
25 - 34N'm
(2.5 - 3.5 kg.m,
18 - 25 ft-Ib)
BoltD
(one)
20- 29 N·m
( 2 - 3 kg-m.
14 - 22 ft-Ib)
Specified clearance
MT
LT
0.8- 1.2 mm
(0.031 - 0.047 in)
1.8 - 2.2 mm
(0.071 - 0.087 in)
c. Attach a wrench to the rear nut on
pitching stopper of the engine side
to prevent it from turning, and
tighten the front nut securely.
Torque
10-18N·m
(1.0 - 1.8 kg-m,
7 - 13 ft-Ib)
Fig. 3·57
c. Connect accelerator cable, and
adjust its tension by adjusting nuts.
NOTE:
After making the accelerator cable
adjustment, depress the accelerator
pedal to ensure that the throttle valve
fully opens.
• Hitachi carburetor
NOTE:
Always make a precise adjustment of
pitching stopper to prevent engine
from vibrating during operation.
A3-20l
Accelerator cable
A4·247
• COW carburetor
A4-113
Fig. 3-55 Installing pitching stopper
10) Attach supporter of spare wheel
& tire.
11) Connect cables as before.
a. Connect clutch cable to release fork
with free play.
Free play 2
AS'581
3 mm (0.08 - 0.12 inl
Full stroke
17 - 18 mm 10.61- 0.11 in)
Fig.3·59 Fitting bolts and nuts
A4·248
Fig. 3-58 Installing accelerator cable.
(,
{
@
1 Lock nut
2 Adjusting nut
. 3 Release fork
Fig. 3-56 Adjusting clutch release
fork
12) (Vehicle with power steering)
Install bracket, oil pump ASSY and oil
pump belt. After adjusting the belt
tension (refer to Chapter "Steering
System"). tighten lock bolt and attach
idler cap.
3-41
13) Install radiator on the car body,
and connect hoses and electric wiring.
Torque
10-18N'm ( 1.0 - 1.8 kg·m,
7 - 13 ft·lb)
ENGINE
15) Connect hoses as before.
a. (AT) Vacuum hose to vacuum pipe
for kick-down solenoid
A4-100
I Fuel delivery hose
2 Fuel return hose
Fig. 3-60
a. Ground wiring of radiator
b. Connectors for thennoswitch and
fan motor
c. Inlet and outlet hoses to radiator
d. (AT only) Cooler hoses to radiator
e. Inlet and outlet hoses to heater unit
A4-185
Fig. 3-66 Connecting fuel hoses
1 Vacuum hose2 Vacuum pipe
A4-188
Fig. 3-63
b. Vacuum hose to intake manifold
for brake booster (Master-vac)
\
\6) Attach air cleaner onto carburetor
and connect the following hoses.
CD Air intake hose
® P.C.V. hose
@ P.C.V. vacuum hose
@ A.T.C. vacuum hose
@ Vacuum hose to thermo vacuum
valve II (Hitachi carburetor) or
thermo vacuum valve III (C-W
carburetor)
® Vacuum hose to thermo vacuum
valve I
rJ) Hose to A.S.V.
Fig. 3-61
f. Then, fill radiator with SUBARU
genuine coolant to the specified
level.
14) Connect electric wiring as before.
a. Two multiple connectors for engine
wiring harness
A4-187
Fig. 3-64 Connecting master-vac
vacuum hose
Connecting hoses
c. Vacuum hose, carburetor vent hose
and purge hose to pipe complete
Then, tighten bolts and wing nuts
securely.
17) Put hoses onto stay, and hold
them with hose clamp.
CD Vacuum hose
® Carburetor vent hose
@ Fuel delivery hose
@ Fuel return hose
@ Purge hose
1 Harness connector
2 Harness connector for auto-choke,
and carburetor selection (C-W)
A4-245
Fig. 3-62
b. High tension cords
c. Connectors for alternator
NOTE:
(Vehicle with power steering) Securely
fit cord supporter onto blow-by hose
paint marking and high tension cord.
1 Vacuum hose
2 Carburetor vent hose
3 Pwgehose
A4-186
Fig. 3-65 Connecting hoses
d. Fuel delivery hose and fuel return
hose to carburetor
3-42
Fig. 3-68
A4-181
ENGINE
18) Install ground cable onto battery
and engine, and ground wiring for
noise condenser onto engine.
19) Attach spare wheel & tire in
position.
20) Close engine hood, and lock it
thoroughly.
4. Inspection and Test
1) Check both the engine oil and
coolant levels to ensure that they are
even with the specified marks. Start
the engine and check for the condition
of various parts. If necessary, take
corrective action.
Check the exhaust pipe connection to
make sure that there is no sign of gas
leakage.
2) Stop the engine and allow it to
rest for some length of time. Check
the engine oil and coolant levels again.
If the levels are below the specified
marks, replenish as necessary.
NOTE:
The radiator is a high pressure type.
Never open the radiator cap while the
engine is hot. Ooing so may burn your
hand. Allow the engine to cool off
before checking the coolant level.
3-5. Removal
1) Install Engine Stands (399814300
x 2) and drain the engine oil and
coolant by removing engine oil drain
plug and coolant drain plug. After
draining, install plugs in place.
NOTE:
Take care not to allow oil or water to
come in contact with the clutch cover
or disc. (MT)
Engine Stand 1399814300 x 21
A5-472
Fig. 3-69 Installing engine stand
1 Oil drain plug
2 Coolant drain plug
A5·255
Fig. 3-70 Position of drain plugs
2) Carburetor protector. (For 49
States (except 4WD & 4WD·AT) and
California 1
3) Distributor.
a. Disconnect vacuum hose from distributor.
b. Unclamp distributor lead wire.
c. Disconnect spark plug cords from
spark plugs and cord supporters,
and distributor cord from cord
supporter.
d. Remove distributor and distributor
plate.
4) Alternator with air cleaner bracket, spark plug cord stay and drive belt.
5) E.G.R. pipe cover.
6) ASV pipe and ASV.
7) Battery cable bracket and ASV
bracket [vehicle without power steering for 49 States (except 4WD & 4WDAT)] or oil pump bracket (vehicle
with power steering).
8) Loosen the connectors of E.G.R.
pipe at intake manifold and cylinder
head.
9) Disconnect the wiring harness lead
of oil pressure switch or oil pressure
gauge.
10) Disconnect connecting hoses from
rocker covers.
II) Unclamp heater hose.
12) Disconnect two water by-pass
hoses and heater hose from intake
manifold.
13) Intake manifold ASSY and E.G.R.
pipe.
14) Generator bracket complete and
generator bracket 3 as an ASSY, and
bracket 2.
3-43
15) Oil filler duct and oil filler duct
stay as an ASSY.
* Remove stiffener 2 at this time
(4WD).
16) Pulley by tapping it lightly.
NOTE:
a. Insert a screwdriver or the like into
a hole in the drive plate (AT) or the
flywheel (MT) through the timing
hole to prevent the crankshaft from
turning.
b. Use Puller Set (899524100) in
such a case of pulley fitted tightly.
17) Oil pump together with oil filter.
18) Water pump, hose, pipe complete
and by-pass hose as an ASSY and
another by·pass hose.
19) Clutch cover and clutch disc.
NOTE:
a. Insert a screwdriver or the like into
a hole in the flywheel through the
timing hole to prevent the flywheel
from turning.
b. Take care not to allow oil or water
to come in contact with the clutch
disc.
20) Flywheel with a-ring (MT) or
converter drive plate with back plate
and a-ring (AT).
NOTE:
Insert a screwdriver or the like into a
hole in the converter drive plate
through the timing hole to prevent it
from turning.
21) Invert engine.
22) Crankcase oil pan, oil pan gasket
and transmission cover II (MT).
ENGINE
23) Invert engine.
24) Flywheel housing.
25) Spark plugs.
26) Valve rocker covers and gaskets.
27) After loosening valve rocker lock
nuts and adjusting screws for other
than hydraulic valve lifters, remove
the valve rocker assemblies and valve
push rods.
32) Piston pins for #3 and #4 pistons,
using Piston Pin Remover (3990943 10)
inserted through the rear service hole.
NOTE:
a. Never loosen valve rocker lock nuts
and adjusting screws for hydraulic
valve lifters.
b. If the push rods are to be reused,
keep them in order, so that they are
installed in the original positions.
28) Cylinder head attaching nuts.
NOTE:
Loosen nuts according to the sequence
below.
A5·276
Fig. 3·72 Removing piston pin
Fig. 3-71 Loosening sequence of
cylinder head nuts
NOTE:
a. Use a chisel when removing the oil
strainer.
b. Never attempt to remove the strain·
er unless it is really necessary.
31) Piston pin circlip on the rear side
of each #3 and #4 piston;
Set piston to its bottom dead center
by turning crankshaft and insert long
nose pliers through the rear service
hole to reach circlip.
NOTE:
To turn the crankshaft with a wrench,
install the crankshaft pulley bolt on
the crankshaft front end.
to prevent the lifters (other than
hydraulic valve lifter) in the upper
crankcase from dropping off.
b. Before separating the crankcase,
pull the camshaft toward the rear
so that is does not interfere with
the crankcase.
c. Also remove the crankcase hanger
(F) and stiffener (4WD).
,,; 1
1 Piston Pin Remover
(399094310)
2 Piston pin
33) Crankcase plugs from crankcase
with an Allen wrench 14 mm (0.55 in)
wide across flats.
29) Cylinder heads and cylinder head
gaskets.
30) Remove bolt and nut retaining oil
strainer stay.
If necessary, drive out oil strainer
together with stay as a unit.
NOTE:
a. Use Valve Lifter Clips (899804100)
Use this shape of wranch
Fig. 3·73 Removing crankcase plug
34) Piston pin circlips and piston pins
for # I and #2 pistons in the same way
as before, but use the front service
holes (crankcase plug holes) this time.
35) Straighten lockwashers for cam·
shaft attaching bolts, working through
the camshaft gear holes, and remove
bolts.
36) Tilt crankcase, and take out
hydraulic valve lifters.
NOTE:
Keep them in order so that they are
not mixed up.
37) Separate crankcase by removing
bolts and nuts with # 1 and #3 cylin.
ders facing upward.
3-44
A5·279
Fig. 3·74 Pulling camshaft
38) Oil seal at the front of crankcase,
O-ring and back-up ring.
39) Oil seal at the front of crankcase,
O-ring and back·up ring.
40) Crankshaft together with connecting rods, distributor gear and crankshaft gear as a unit.
41) Camshaft together with camshaft
gear and camshaft plate.
42) Solid valve lifters and keep them
in order, so that they can be reinstalled into their original holes.
43) Pistons from crankcase.
NOTE:
a. Keep the pistons and piston pins
together for each cylinder so that
they are not mixed up.
b. Make marks on the pistons so as
not to change their installed posi·
tions.
44) Crankshaft bearings.
NO'rE:
If the bearings are to be used again, do
not mix them up.
45) Oil pressure switch (Vehicle with·
out pressure gauge) or plug (Vehicle
with pressure gauge).
46) Engine Stands (399814300 x 2)
from the crankcase halves.
ENGINE
3·6. Disassembly
1. Intake Manifold
Assembly
l. Thennosensor
3) C·W Carburetor Type
1) Hitachi Carburetor Type for
49 States (except 4WD &
4WD·AT) and California
1) Disconnect wiring harness.
2) Remove vacuum hoses, hoses and
related parts.
a. Thennostat cover, solenoid valve I
and bracket, protector stay, gasket
and thennostat.
b. Actuator ASSY (A/C only), clip
and stay & clip.
c. E.G.R. valve, gasket and duty sole·
noid valve connector clamp.
d. Carburetor, two gaskets and an
insulator.
e. P.C.V. hose.
f. Heater hose.
g. Duty solenoid valves (slow and
main) and carburetor protector 2.
h. Vacuum pipe CP and carburetor
protector 3.
1. Thenno vacuum valve III.
j. P.C.V. valve.
k. Thenno vacuum valve I.
1. Accelerator cable bracket.
m. Thennosensor.
n. Solenoid valve II (except for
California).
o. Solenoid valve III.
2) Hitachi Carburetor Type for
49 States 4WD & 4WD·AT
and Canada
1) Disconnect wiring harness.
2) Remove (vacuum) hoses and
related parts.
a. Thennostat cover, stay, gasket and
thennostat
b. Actuator ASSY (A/C only), clip
and stay & clip
c. E.G.R. valve, gasket and AAV pipe
& hose
d. Carburetor, two gasket and insulator
e. P.C.V. hose
f. Heater hose
g. Vacuum pipe
h. Thenno vacuum valve II
i. P.C.V. valve
j. Thenno vacuum valve I
k. Accelerator cable bracket
1) Disconnect wiring harness.
2) Remove vacuum hoses, hoses, and
related parts.
a. Thennostat cover, gasket and ther·
mostat.
b. Solenoid valve I.
c. Actuator ASSY (A/C only).
d. E.G.R. valve and gasket.
e. Carburetor, two gaskets and an in·
sulator.
f. P.C.V. hose.
g. Heater hose.
h. Stay & clip.
i. Clip.
j. P.C.V. valve.
k. Thenno vacuum valve I.
1. Thennosensor.
m. Vacuum pipe CPo
n. Solenoid valve II.
.0.5-286
Fig. 3·75 Removing valve and spring
2) Remove spacer with gasket.
4. Crankshaft
Remove connecting rods from crankshaft by unscrewing connecting rod
nuts.
Remove bearings from connecting rod.
2. Valve Rocker
Assembly
.0.5-039
Disassemble valve rocker ASSY to
each component part.
NOTE:
a. Keep the disassembled parts in
order.
b. Never loosen rocker arm screws for
hydraulic valve lifter. In addition,
be sure not to mix rocker arms
since their screws are adjusted with
every cylinder.
Fig.3·76 Disassembled connecting
rod
NOTE:
a. Arrange the disassembled parts in
order and be careful not to mix
them up.
b. For the replacement of connecting
rod small end bushing, refer to 14.
Connecting Rod in 3·7.
s.
3. Cylinder Head
1) Remove valves, springs, spring
retainers, and retainer keys from
cylinder head, by using Spring Press
(899724100).
NOTE:
Put a mark on the individual valves,
and be careful not to mix them up.
.,
AE:
Camshaft
Remove cam gear from camshaft using
Remover Set (899714110) and press.
Then remove woodruff key and camshaft plate.
6. Piston
Remove piston rings with a piston ring
expander. Also remove circlip.
ENGINE
NOTE:
Arrange the removed piston rings in
order and be careful not to mix them
up.
7. Oil Pump
8. Water Pump
Disassemble oil pump to each component part.
a. Oil filter
b. Two screws
c. Oil pump body holder, drive gear,
rotor and O-ring
d. O-ring, by-pass valve spring and ball
e. Oil pressure gauge or plug
f. Relief valve plug, two washers,
spring and relief valve
Disassemble water pump to each component part.
a. Water pump pulley
b. Water pump shaft
NOTE:
Do not press the shaft, or the bearings
will be damaged. Press the bearing
outer race.
c. Impeller
d. Mechanical seal
Piston ring expander
AS·03B
Fig. 3-77 Removing piston rings
3 .. 7. Inspection and ,Adjustment
1. Precautions
Warping limit
O.OSmm (0.0020 in)
I) Before cleaning parts, make sure
that no leakage exists in parts which
carry coolant or oil.
2) Clean all parts carefully and make
sure that adhering gaskets and other
substances are removed.
3) Blow compressed air into the oil
passages to make sure that they are
not clogged.
4) When removing deposits such as
carbon, be careful not to damage the
part surface.
5) Arrange all relative parts in order,
so that they are not mixed up.
Grinding limit
O.Smm (0.020 in)
Standard
height of
cylinder
head
1600 cc
Engine
89.6mm
(3.528 in)
1800 cc
Engine
90.6 mm
(3.567 in)
3) Inspect intake and exhaust valve
seats, and correct the contact surfaces
if they are defective or when valve
guides are replaced.
Fig. 3-79 Dimensions of intake and
exhaust valve seats
2. Cylinder Head
1) Make sure that no crack or other
damage exists. In addition to visual
inspection, inspect important areas by
means of red check.
2) Measure the warping of the cylinder head surface that mates with
crankcase by using a straight edge and
thickness gauge.
If the warping exceeds 0.05 mm
(0.0020 in), regrind the surface with a
surface grinder.
Fig. 3-78 Measuring cylinder head
for warping
NOTE:
Uneven torque for the cylinder head
nuts can cause warping. When r.
assembling, pay special attention to
the torque so as to tighten evenly.
3-46
Intake
0.7 - 1.3 mm
(0.028 - 0.051 in)
Exhaust
1.0 - 1.8 mm
(0.039 - 0.071 in)
W
Wear limit of
valve seat
(measured in
direction of
valve axis)
0.5 mm (0.020 in)
for both intake
and exhaust
valves
I
ENGINE
c. Apply a thin coat of Prussian blue
or red lead to the contacting surface of valve to see the contact·
ing condition of valve and valve
seat.
d. Rotate valve with light pressure.
If the blue or red lead is transferred
to the center of the valve seat surface, the contact is satisfactory.
e. In case of improper contact, apply
a small amount of grinding com·
pound (about #400) on the valve
surface and lap the valve and seat
surface so that they obtain proper
fit.
The correction procedure is as follows:
a. Precautions
(I) When valve seat correction is
required, check intake and exhaust
valve stems and valve guides for
wear, and the springs for squareness, tension, etc. If defective,
replace them before proceeding the
valve seat correction work.
(2) When reconditioning valve and
valve seat surfaces, remove intake
valve oil seals. Install new oil seals
with oil after completing the work.
b. Reface valve seat with valve seat
cutters or grinders to the dimen·
sions shown in the above figure.
a. Place cylinder head on Cylinder
Head Table (399765101) with the
combustion chamber upward so
that valve guides enter the holes
in Cy linder Head Table.
b. Insert Valve Guide Remover
(899764104) into valve guide and
press it down to remove valve
guide.
NOTE:
The above is important because the
valve and seat must have a gastight fit.
f. Clean valves and valve seats to
remove chips.
4) Inspect exhaust pipe stud bolts
installed on the cylinder head, and
replace if defective.
t. p,;;;:,:
I,ng~ of ,IUd
b9
ltS
54 mm (2.13 in)
A5·288
-~----~-~-~----~
3. Valve Guide
Fig. 3-80 Refacing valve seat with
valve seat cutter
Check the clearance between valve
guide and stem. The clearance can be
checked by measuring the outside
diameter of valve st~m and the inside
diameter of valve guide wi th outside
and inside micrometers respectively.
If the clearance between valve
guide and stem exceeds the specification, replace guide as follows:
NOTE:
Refacing of the valve seat should be
closely coordinated with the refacing
of the valve face, so that the finished
seat and valve face will be concentric
and specified interference angle will be
maintained.
VaJve Guide Remover
(899764104)
A5·289
2 Cylinder head table
(399765101)
Fig.3-81 Removing valve guide
c. Turn cylinder head upside 4Jown
and place Valve Guide Adjuster
(899768602 for exhaust valve guide,
899768603 for intake valve guide)
as shown in the figure.
Valve gutde adjuster
(899768603)
Valve guide adjuster
(899768602)
---Specifications for valve stem and valve gUide
~~--
Standard cI earance
between val ve gUide
and valve stem
Intake
Exhaust
Intake
0.040
--
Fig. 3-82 Valve guide adjusters
0.065 mm (0.0014 - 0.0026 in)
~-
~
--~--
Limit of de arance
between val ve guide
and valve st em
0.035
'---
-~
0.070 mm (0.0016 - 0.0028 in)
0.1 5 mm (0.0059 in)
~----
Exhaust
0.15 mm (0.0059 in)
--------'----------
Standard in side diameter of valve
guide
8.000 - 8.0 IS mm (0.31 SO - 0.3156 in)
--
Standard di ameter of
valve stem
Intake
7.950 - 7.965 mm (0.3130 - 0.3136 in)
Exhaust
7.945 - 7.960 mm (0.3128 - 0.3134 in)
----- ------ ----------
~
d. Before installing new valve guide,
make sure that neither scratches
nor damages exist on the inside surface of the valve guide holes in
cylinder head.
e. Put new valve guide, coated with
sufficient oil, in cylinder, and
insert Valve Guide Remover
(899764104) into valve guide.
Press in until the valve guide upper
end is flush with the upper surface
of Valve Guide Adjuster.
ENGINE
h. Recheck the contact condition
between valve and valve seat after
replacing valve guide.
AS-008
Rotor-tocase
radial
clearance
Stand·
0.15 - 0.21 mm
ard
(0.0059 - 0.0083 in)
Limit
0.25 mm (0.0098 in)
I
Fig. 3-125 Oil relief valve and spring
3) By-pass valve and spring
The checking method is as same as
that of paragraph 2).
By·pass valve spring
•
1,800 cc
1,600 cc
Free length
37.1 mm
(1.461 in)
40.7mm
(1.602 in)
Installed length
25.1 mm
(0.988 in)
31.1 mm
(1.224 in)
5.178 6.159 N
(0.528 - 0.628 kg,
1.164 - 1.385 Ib)
3.580 3.972 N
(0.365 - 0.405 kg,
0.805 - 0.893 lb)
Stand·
0.03 - 0.13 mm
aId
(0.0012 - 0.0051 in)
Limit
38.05 4L97N
(3.88 - 4.28 kg,
8.56 - 9.441b)
Load when
installed
1 Oil relief valve
2 ReUef valve SPrina
Fig. 3·122 Measuring drive gear-torotor clearance
clearance
Installed
length
e. Radial clearance between pump
rotor and pump case
Replace either the rotor or case as
necessary if the clearance exceeds
the limit.
A6-019
case
47.1 mm
(1.854 in)
AS·OOS
Limit
Fig.3·123 Measuring rotor· to-case
and gear·ta-case clearance
Rotor·to·
case and
gear-to-
Free length
Load when
installed
3-60
I
ENGINE
4) Oil pump holder
Check the pump shaft hole for wear,
and other surfaces for damage.
5) Oil pump case
Check the oil pump case for clogged
oil passage, worn rotor chamber,
cracks, and other faults.
19. Water Pump
NOTE:
Clean all 1I1e disassembled parts
1I1oroughly.
1) Inspect the pump shaft for wear,
damage, and operation.
1 Water pump shaft
2 Water pump impeller
3) Inspect the other parts for crack,
wear and damage, and replace if
defective.
20. Thermostat
Replace the thennostat if the valve
does not close completely at an
ambient temperature or if the following test shows unsatisfactory results.
Immerse the thennostat and a thennometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve
begins to open and when the valve is
fully opened. During the test, agitate
the water for even temperature distribution. The measurement should be to
the specification.
21. Thermo Valve
Connect vinyl tubes to output ports
of thenno valve.
Soak the valve in cool water [approx.
IOoC (50°F)] for some time, and then
heat the water.
Blow air into the valve through one
vinyl tube, and confinn that the valve
opens or closes in response to the
specified temperature. (Refer to page
3-5)
- Vinyl hose
Thermo valve
A7·063
AS·6B7
Fig. 3-128
Fig.3-126 Shaftand impeller
2) Inspect the impeller surface that
contacts the mechanical seal for wear
and damage.
Fig. 3-127 Temperature test for
thermostat
3-8. Assembly
1. Precautions
1) All parts should be thoroughly
cleaned, paying special attention to
the engine oil passages, pistons and
bearings.
2) Rotating parts and sliding parts
such as piston, bearing and gear should
be coated with oil prior to ASSY.
3) All removed parts, if to be reused,
should be reinstalled in the original
positions and directions.
4) Gaskets and lock washers must be
replaced with new ones. Liquid gasket
should be used where specified to
prevent leakage.
5) Bolts, nuts and washers should be
replaced with new ones as required.
6) Even if necessary inspections have
been made in advance, proceed with
ASSY work while making rechecks.
NOTE:
In the following procedures, items
wi1l1 * mark should be rechecked.
2. Intake Manifold
Assembly
Fig. 3-129
1) Hitachi Carburetor Type
2) Install the following parts.
a. Thenno vacuum valve II.
1) Install thennostat and thennostat
cover with new gasket.
NOTE:
Install it wi1l1 1I1e iiggle .pin upward.
Torque
AS·59B
23":' 26N'm
(2.3 - 2.7 kg-m,
17 - 20 ft-Ib)
ENGINE
NOTE:
NOTE:
a. Apply liquid gasket (Three Bond
1201 -PIN 004403008, or equivalent) on the thread.
b. Install thermo valve with its pipe
oudet facing outside.
Apply liquid gasket (Fuji Bond C or
equivalent) on the thread.
b. Stay & clip, clip and actuator ASSY
(A/C only).
c. Solenoid valve I, bracket and protector stay.
d. Thennosensor.
NOTE:
Be careful not to bend the terminal.
e. Accelerator cable bracket.
f. P.C.V. valve.
Torque
23 - 26 N'm
(2.3 - 2.7 kg-m,
17 - 20 ft-lb)
5) Attach electric wmng harness,
connect electric connectors, and then
clip harness.
g. Thenno vacuum valve I.
23 - 26 N·m
(2.3 - 2.7 kg-m,
17 - 20 ft-Ib)
Torque
NOTE:
2) CoW Carburetor Type
Install thermo valve with its pipe
outlet facing fOlWard.
h. Vacuum pipe CP with carburetor
protector 3, and vacuum hoses.
i. Control air cleaner, P.C.V. hose,
duty solenoid valves, carburetor
protector 2 and hoses.
j. Heater hose and purge hose.
1) Install thennostat and thermostat
cover with new gasket.
NOTE:
Install it with the jiggle pin upward.
2) Install the following parts.
a. Stay & clip.
b. Clip.
c. Gasket, thennostat cover, solenoid
valve I and bracket, and connect
hose.
d. Thennosensor.
NOTE:
Be careful not to bend the terminal.
e. P.C.V. valve.
®
.: Except 49 states 4WD & 4WD4WJ).A T and Canada
I
2
3
4
• 5
6
7
8
9
·10
·11
·12
Thermo vacuum valve 11
Thermostat cover
Solenoid valve bracket
Protector stay
Solenoid valve I
Thermosensor
PCV valve
Thermo vacuum valve I
Vacuum pipe CP
Carburetor protector 3
Duty solenoid valve
Carburetor protector 2
Fig. 3-130
Torque
23
(2.3
17
26 N'm
2.7 kg-m,
20 ft-Ib)
NOTE:
Apply liquid gasket (Fuji Bond C or
its equivalent) on the thread.
AS·S88
3) Install carburetor with two gaskets
and an insulator, and connect hoses.
4) Install E.G.R. valve with gasket
and connector clamp, and connect
hose.
f. Thenno vacuum valve I.
Torque
23
(2.3
17
26 N·m
2.7 kg-m,
20 ft-Ib)
NOTE:
1 EGR valve
2 Connector clamp
Install the valve with its pipe facing
outside.
AS·S89
g. Vacuum pipe CP and vacuum hoses.
Fig. 3-131
3-62
ENGINE
S) Attach electric wmng harness,
connect electric connectors, and then
clip harness.
3. Valve Rocker
Assembly
NOTE:
1
2
3
4
5
6
7
Thermostat cover
Solenoid valve bracket
Solenoid valve I
Thennosensor
Thenno vacuum valve 1
Vacuum pipe CP
PCVvalve
a. Pay special attention to the direction of the rocker shaft, the posi·
tion of the spring washers, the
number of plain washers, the difference between the rocker arms,
and the marks on the spacer.
b. Before assembling, apply a generous
amount of oil to the sliding surface
of each part.
A5·690
Fig. 3·132
Valve rocker assembly
3) Install carburetor with two gaskets
and an insulator, and connect hoses.
4) Install the following parts.
a. E.G.R valve with gasket, and hose.
b. Heater hose.
c. p.e.v. hose ASSY.
d. (Ale only) FleD actuator and hose.,
1
2
3
4
Heater hose
EGR valve
PCV hose ASSY
Actuator (A/C only)
Fig. 3·133
A5·691
1,800 cc
1,600 cc
~
180.6 mm
(7.11 in)
176.9 mm
(6.96 in)
~
35.8 mm
(1.409 in)
34.2 mm
0.346 in)
£3
34.8 mm
(1.370 in)
33.2 mm
(1.307 in)
Mark on spacer
(RH)
-RH
RH
Mark on spacer
(LH)
-LL
LH
ENGINE
A5·692
1
2
3
4
5
6
7
8
9
10
Valve rokcer ASSY (R.H.)
Snap ring
Nut
Washer
Valve rocker screw
Rocker shaft spring washer
Rocker shaft supporter
Valve rocker arm CP
Rocker shaft spacer
Valve rocker shaft
11
12
13
14
15
16
17
18
19
Valve rocker arm CP 2
Valve rocker ASSY (L.H.)
Valve rocker ASSY (R.H.)
Rocker shaft spacer
Valve rocker shaft
Valve rocker
Valve rocker arm
Valve rocker arm 2
Lock washer (only for
hydraulic valve lifter)
Fig. 3· 134 Assembling valve rocker parts
4. Cylinder Head
1) Press oil seal onto intake valve
guide. Refer to 3-7,4.
NOTE:
Apply oil to the oil seal prior to
pressing.
2) Apply oil to stems of intake and
exhaust valves prior to installation.
3) Install intake and exhaust valves
with inner and outer valve springs,
'valve spring retainers and retainer
keys on cylinder head by using Valve
Spring Press (899724100).
1 Outer valve spring
2 Inner valve spring
3 Retainer key
4 Valve spring retainer
5 Valve stem
A5·324
Fig.3-135 Installing valve and related
parts
3-64
NOTE:
a. Take care not to damage the lips of
the intake valve oil seals when
installing the intake valves.
b. Place the inner and outer valve
springs with the paint mark toward
the valve spring retainer, or with
the close coil side toward the cylinder head.
c. After installing all the parts, tap the
spring top lightly with a plastic
hammer or the like to give better
seating of the valve.
ENGINE
Torque
(Connecting
rod nut)
39 -42 N'm
(4.0 - 4.3 kg-m,
29 - 31 ft-Ib)
with oil on threads
NOTE:
a. Pay attention to the assembling
direction of camshaft plate and cam
gear.
1,800 cc engine
1 Valve spring retainer
2 Close coil side
A5-325
+
Up
Paint mark
~"
NOTE:
a. Position each connecting rod with
the side marked f) facing forward.
b. Each connecting rod has its own
mating cap. Make sure that they are
assembled correctly by checking
their matching number.
c. When tightening the connecting rod
nuts, apply oil on the threads.
*
CI~'{~
A5-328
1,600 cc engine
Side clearance and oil clearance
(Refer to 3-7, 14.)
A5-326
o
Fig. 3-136 Installed direction of valve
spring
A5-329
4) Install spacer with gasket for air
injection system.
.----- ..
A5·l00
b. Place the camshaft journal on
Remover Set (899114110) when
pressing the cam gear.
-~
Discrimination mark on spacer
* For right-hand
side (# I & #3)
cylinder head
1600
Engine
7
1800
Engine
8
For left-hand side (#2 &
#4) cylinder head
Matching number
6. Camshaft
Install woodruff key on camshaft.
Place camshaft plate in position and
install cam gear by using Remover
Set (899714110).
Crankshaft
1) Install connecting rod bearings on
connecting rods and connecting rod
caps_
NOTE:
Apply oil to 1hesurfaces of the
connecting rod bearings.
2) Install connecting rods and connecting rod caps on crankshaft with
connecting rod bolts and nuts.
Thrust clearance (Refer to 3-7,
16.)
A5·101
LH
(except 4WD & 4WD-AT)
s.
*
Fig. 3-137 Installing connecting rods
* Only for 49 States
Fig.3-139 Camshaft plate and cam
gear
7. Piston
I) Install piston rings on pistons as
follows.
Install oil ring spacer, upper rail
and lower rail in this order by hand.
Then install second ring and top.
ring with a piston ring expander.
~
... _:
R mark
Top ring
~
~
-: .
Second ring
Oil ring
~
cr
<
Fig. 3-138 Installing cam gear
Rmark
_
~. ~ . ,,:.-~
/
Remove Set
(899714110)
., J
upper rail
Spacer
Lower feil
A5-073
Fig. 3·140 Cross section of piston
rings (Riken Piston Ring)
ENGINE
2) Assemble ball, by-pass valve spring
and O-ring in pump body.
3) Assemble oil pump rotor, drive
gear, O-ring and pump body holder in
pump body.
4) Install oil filter.
c. Position stopper pins.
C-Nmark
Top ring
~Nmark
Second ring ~
Oil ri ng
EE
.
upper rail
Spacer
9. Water Pump
Lower rail
AS·074
Fig. 3·141 Cross section of piston
rings (Nippon Piston Ring)
NOTE:
a. Position the gaps of the piston
rings.
Front
AS-333
Fig. 3-144 Stopper pin position
d. The top and second rings are provided with "R" or "N" mark as
shown in Figs. 5·84 and 5-85. Be
sure to install the rings with this
mark facing upward.
*
AS-330
Fig. 3·142 Piston ring gap position
b. Install oil ring as shown in the
figure.
I) Install the water pump shaft into
pump body with a press.
NOTE:
a. Before pressing, heat the pump
body to 80 to 100°C (176 to
212 F).
b. 00 not press the shaft, or the
bearings will be damaged. Press the
bearing outer race.
0
Ring to groove clearance (Refer
to 3-7, 13.)
2) Insert piston pin circlip into the
stopper pin side of the piston.
Oil ring lower rail
NOTE:
a. Replace the mechanical seal with a
new one.
b. Apply liquid gasket where required.
NOTE:
a. The installed circlip should be
directed as shown in the figure.
Circlip
(Riken Piston Ring)
- - - - - - - - Upper side rail
A7-06S
~~,
Stopper pin
I
Fig. 3-146 PreSSing water pump shaft
Lower side rail
((f\Y'-';"
AS-331
(Nippon Piston Ring)
Piston
AS·334
Fig. 3-145 Installed direction of
circlip
b. If the piston pin hole has burrs
made by the circlip end during its
removal, correct so that the piston
pin can be inserted smoothly into
the piston pin hole with fingers.
2) Apply liquid gasket (Fuji Bond D
or equivalent) to the periphery of the
mechanical seal and press the seal
into the pump body with the carbon
washer of the seal facing the impeller.
3) With a thin coat of oil on the
shaft surface, install the impeller
onto the pump shaft with a press.
8. Oil Pump
NOTE:
Replace washers and O-rings with new
ones.
A5·332
Fig. 3-143 Installation of oil ring
1) Assemble oil relief valve, spring,
two washers and plug in pump body.
3-66
A7-067
Fig. 3-147 Installing impeller
ENGINE
4) Support the impeller side of the
pump shaft end and insta1l the pulley
by using a press until the distance
"L" between the pump body surface,
which mates with the gasket, and the
center of belt groove of the pulley
becomes specified value.
NOTE:
Apply coolant on the sliding surface
between mechanical seal and impeller.
Check for the following clearance
after installation and correct if defective.
Clearance
between
impeller
and pump
body
Press
Clearance between
impeller and pump
body
0.5 - 0.7 mm
(0.020 - 0.028 in)
O.S - 0.7 mm
(0.020
0.028 in)
Mechanical seal
2 Pump body
3 Impeller
L
L
A7·089
A7·101
Fig. 3-148 Impeller clearances
Fig. 3-150
L
1800 cc Engine
61.1 ··61.7 mm
(2.406 - 2.429 in)
Fig. 3-149 Checking impeller-to-pump
body clearance
1600 cc Engine
64.1
(2.524
64.7 mm
2.547 in)
NOTE:
Before pressing, apply oil on the pump
shaft.
3·9. Installation
1. Precautions
I) All parts should be thoroughly
cleaned, paying special attention to
the engine oil passages, pistons, cylinders and bearings.
2) Rotating parts and sliding parts
such as the piston, cylinder, bearing
and gear should be coated with oil
prior to reinstallation.
3) All removed parts, if to be reused,
should be reinstalled in the original
positions and directions.
4) Oil seal lips should be coated
with grease before reinstallation.
S) Gaskets and lock washers must be
replaced with new ones. Liquid gasket
should be used where specified to prevent leakage.
6) Bolts, nuts, washers, and cotter
pins should be replaced with new ones
as required.
7) Even if necessary inspections
have been made in advance, proceed
with reinstallation work while making
rechecks.
8) If one or both of the cylinder
heads are removed in engine disassembly, perform the retightening of the
cylinder head nuts and intake
manifold bolts and the adjustment of
the valve clearances (except engine
with hydraulic valve lifter) as instruct·
ed in 2-2 in CHAPTER 2 after the
engine has been assembled, mounted
on the car, run for about 10 minutes,
and cooled down to ambient temperature.
NOTE:
In the following procedures, items
with * mark should be rechecked.
I) Install Engine Stand (399814300)
to each crankcase half.
Engine Stand (399814300)
A5-335
Fig.3-151 Installingenginestand
ENGINE
9) Bring together the crankcase
halves and tighten the crankcase bolts
and nut with a plain washer to the
specified torques and in the specified
sequence.
2) Install oil pressure switch (Vehicle
without pressure gauge) or plug
(Vehicle with pressure gauge) on
crankcase. Before installation, apply
liquid gasket (Fuji Bond C or equivalent) to the threads of pressure switch
body or plug body.
22 - 27 N·m
(2.2 - 2.8 kg·m,
16 - 20 ft·lb)
TortJ.ue
3) Install
crankcase.
crankshaft
bearings on
Torque for crankcase bolts and nut
1 Crankshaft gear
2 Large chamfer
3 Punch AS·337
4 Camshaft gear
Fig. 3·153 Aligning crankshaft and
camshaft gears
Thread size
Torque
IOmm ...... 6
39-47N·m
(4.0 4.8 kg-m,
29 - 35 ft·lb)
i
6)
* Oil passage.
Install O·ring and backup ring
on the crankcase half having #2 and
#4 cylinders,
8mm ...... 2
I
1
6 mm ...... 2
i
I
I
23 - 26 N'm
(2.3 - 2.7 kg·m,
17 - 20 ft·lb)
4.4 5.4 N'm
(0.45 - 0.55 kg·m,
3.3 4.0 ft·lb)
Crankshaft bearings
AS-336
Fig.3·152 Installing crankshaft
bearings
1 O-ring
2 Backup ring
4)
Fig. 3·154 Installing D·ring and
backup ring
Insert valve lifters into the lifter
in crankcase and hold them on
#1 and #3~,~~linder side by using
Valve Ufter CliP 899804100 (only for
hydraulic valve lifter).
""~("'s
NOTE:
Apply oil to the valve lifters before
instanation.
s) {n.stallcranbhaft and camshaft on
?~,cr~se half having #2 and #4
~f!tin~J":
NOTE:
a. Apply oil to the camshaft and
crankshaft bearings before installa·
tion.
b. One of the bolt holes in the crank·
shaft gear has a larger chamfer
than others. Install the crankshaft
so that the punch mark on the cam
gear can be seen through this bolt
hole in the crankshaft gear.
c. Whenever the camshaft is replaced
because of its abnormality, replace
the valve lifters with new ones too.
*
Oil clearance of crankshaft (Refer
to 3-7,15.)
AS·338
7) Apply liquid gasket (Fuji Bond
C or eqUivalent) on the mating surface
of crankcase.
'
NOTE:
Before applying liquid gasket. clean
the mating surfaces of the crankcase
so that they are free of oil, grease and
dust by using thinner or the like.
AS·340
Fig. 3-156 Tightening ~uence for
crankcase bolts and nut
NOTE:
a. Install the front hanger at this time.
b. Pull cam gear fully;
c. Make sure that the O·ring is installed exactly.
d. Install stiffener (4WD) at this time
temporarily.
e. Take out Valve Lifter Clips (only
for solid valve lifter).
A5·339
Fig.3·155 Applying liquid gasket
8) Put
Valve
Ufter
Clips
(899804100) between valve lifters in
the crankcase half having the #1 and
#3 cylinders, to prevent lifters from
dropping off (for solid valve lifter).
3-68
10)
So"", ,,"""aft plate on
of!
case with the two bolts and.· ck
washers, working through tbe hOle in
cam gear.
NOTE:
:-"" ..
Bend the lock washers to secuflll~
the bolts.
~A~'
ENGINE
to horizontal
whether piston
or not by
watching
12)
AS·278
Fig. 3·157 Installing camshaft plate
*
*
Backlash of cam gear (Refer to
3-7,16.)
Thrust clearance of crankshaft
(Refer to 3-7,15.)
AS-343
13) Apply liquid gasket (Fuji Bond
C or equivalent) on crankcase plugs
and tighten them with aluminum
gasket.
Fig. 3-159 Installing piston
c. Install piston pin and circlip
through the front service hole after
aligning the service hole, piston pin
hole, and connecting rod small end
with Piston Pin Guide (399284300).
Torque
(Crankcase
plug)
62 -76 N'm
(6.3 - 7.7 kg-m,
46 - 56 ft-Ib)
Use this shape of wrench
AS·346
Fig.3·162 Installing crankcase plugs
AS·342
Fig.3·158 Checking crankshaft
thrust clearance
14) If oil strainer has been removed,
install it with a new O-ring by driving
with an aluminum bar.
Fig.3·160 Inserting piston pin
15) Install oil strainer stay with
8 mm bolt, nut and spring washer.
NOTE:
When measuring the backlash of cam
gear and thrust clearance of crankshaft,
use an appropriate plate as an attach·
ment.
11) Install pistons in cylinder as
follows.
a. Apply oil to the circumference of
piston and the inner surface of cyl·
inder.
b. With the #2 and #4 cylinders
facing downwards, turn crankshaft
until the #2 connecting rod comes to
the bottom dead center. Then insert
the #2 piston into cylinder by using
Piston Guide (398744300).
NOTE:
If any of the pistons are reused, be
sure to direct them in the seme way as
before they were disassembled.
Torque
(Oil strainer
stay)
23 - 26 N'm
(2.3 - 2.7 kg-m,
17 - 20 ft·lb)
1
1
i
1 Circlip
2 Long nose pliers
AS·345
Fig.3·161 Installing circlip
d. Install #4 piston, piston pin,
circIip into cylinder in the same
manner, but carry out this job from
the flywheel housing side.
e. Turn the crankcase upside down
so that #1 and #3 cylinder face downward and perform the same job as
described in a) to b).
1 Oil strainer stay
2 O-ring
3 0 il strainer
4 Bolt
5
6
7
8
Spring washer
Nut
Oil strainer stay 2
Bolt and washer
Fig. 3-163 Installing oil strainer stay
ENGINE
16) Install a new cylinder head
gasket, #2 - #4 cylinder head, valve
push rods and also valve rocker as
follows.
a. Install a new cylinder head gasket.
1600
NOTE:
Inst;] II #2
1800 with hydraulic
valve lifter
d. install valve rocker.
When tightening nuts and bolts,
apply oil to the threads and tighten
them in two or three successive steps
un til the final tightening is at the
specified torque.
In each step, tighten them in the
specified sequence.
29 N·m
kg-m, 22 ft-Ib)
NOTE:
FRONT
t
Nothing
NOTE:
#4 cylinder head.
The cylinder head installing direction
is as in the figure.
Install #1
#3 cylinder head
a new gasket and push rods and
rocker assembly (RH) in the
way as instructed in 16).
18) Press oil seal (Rear) into the
flywheel housing if oil seal has been
removed.
1800 with solid valve
. lifter
a. Before installing the cylinder head
gasket, clean the mating surfaces of
the cylinder head and crankcase so
that they are free of oil, grease and
dust by usi.,g thinner or the like.
b. Apply head gasket sealant THREE
BOND 1201 (004403008) or DOW
CORNING #92-024 evenly to
both sides of the new cylinder head
gasket with a brush. Do not apply
excessive sealant. Install the gasket
on to the crankcase quickly after
applying sealant.
b.
17)
with
valve
same
Number of
2nd step
59N·m
(6.0 kg-m, 43 ft-Ib)
3rd (final)
step
64 N'm
(6.5 kg-m, 47 ft-Ib)
a. Apply oil on the circumference of
the oil seal prior to pressing.
b. Oil seal dimensions.
1,800 cc .... 76 x 93 x 10 mm
(2.99 x 3.66 x 0.39 in)
1,600 cc .... 10 x 81 x 8.5 mm
(2.76 x 3.43 x 0.335 in)
19) Install flywheel housing to
crankcase with the mating surface
coated with liqUid gasket [THREE
BOND 1215 (PIN 004403007) or
equivalent] .
I
Torque
I
20 - 27 N·m
(2.0 - 2.8 kg-m,
14 20 ft-Ib)
A5·125
Fig. 3-164 Installed position of
cylinder heads
c. Take out Valve Lifter Clip
899804100 (for hydraulic valve lifter),
and insert valve push rods in alignment
with valve lifters.
A5·615
Fig. 3-166
A5-350
Fig. 3-167 Installing flvwheel housing
NOTE:
NOTE:
Do not misuse the push rod.
A5-348
Fig. 3-165 Discrimination of push rod
a. When tightening CD, ® nuts, use
Socket Wrench (499987006).
b. After tightening all the cylinder
head nuts and bolts, retighten the
center nut CD to insure it is correct·
Iy torqued.
c. Do not use washers in installing
valve rocker.
d. Make sure that the valve rocker
is correctly assembled.
3-70
NOTE:
a. Clean the mating surfaces of the
flywheel housing and crankcase so
that they are free of oil, grease and
dust by using thinner or the like
before applying liquid gasket.
b. Be careful net to damage the oil
seal lip and not to detach the spring
when installing the flywheel hous·
ing.
ENGINE
c. When using THREE BOND 1215,
dry the coated surface for 5 to 10
minutes before installation.
d. Remove Valve Lifter Clips
(899804100) before installing oil
pan.
20) Install crankcase oil pan, oil
pan gasket and transmission cover II
(MT).
I Transmission cover II (MT)
2 Oil pan
A5·271
Fig. 3-168 Installing oil pan
Torque
(Oil pan)
4.4 - 5.4 N'm
(0.45 0.55 kg·m,
3.3 - 4.0 ft·lb)
21)
Install pitching stopper bracket
i
A5·353
Fig. 3-170 Installing drive plate and
I'
back plate (A T)
and crankcase rear hanger, if it has
been removed, to flywheel housing.
On CoW carburetor, install accelerator
cable bracket with hanger.
NOTE:
Do not misplace the washer.
(SUBARU 1600)
ConV'erter drive plate
2 Hole
3 Mark
4 Back plate
c. When using THREE BOND 1215,
dry the bolts coated with it for 5 to
10 minutes before $l:rewing them
in.
23) Install clutch disc and clutch
cover with bolts and spring washers,
aligning clutch disc with flywheel by
inserting
Clutch
Disc
Guide
(499747000) into needle bearing fitted
in flywheel. (MT)
I
2
3
4
5
6
7
8
9
10
11
Torque
(Clutch cover)
Nut
Bolt
Spring washer
Crankcase rear hanger
Pitching stopper bracket
Timing hole hanger
Bolt
Timing hole hanger
Stiffener RH (4WD)
Stiffener LH (4WD)
Accelerator cable bracket
(C-W carburetor)
16 N·m
(1.6 kg-m, 12 ft-Ib)
A5·693
I r,
Fig. 3-169 Installing crankcase hanger
Clutch Disc Guide (499747000)
22) Install flywheel with O·ring (MT)
or converter drive plate with back
plate and O-ring (AT) on the crankshaft gear.
Apply liquid gasket [THREE
BOND 1215 (pIN 004403007)) to the
threads of the bolts.
~
AT
MT
49-53N·m
41-45 N'm
Torque (5.0 - 5.4 kg-m, (4.2 - 4.6 kg-m,
36 - 39 ft-Ib)
30 - 33 ft-Ib)
NOTE:
a. The flywheel or drive plate and
back plate can be installed only in
one position since not all the bolt
holes are positioned at equal
intervals.
b. When installing back plate, align
the mark on back plate and the
hole in drive plate. (AT)
A5-354
Fig. 3-171 Installing clutch cover
NOTE:
Position the clutch cover so that the
"0" marks on the flywheel and clutch
cover are spaced 120 0 or more.
24) Install water pump, hose, pipe
compi. and heater hose as an assembly
and install another hose.
ENGINE
NOTE:
a. When tightening the bolt, insert a
screw driver through the timing
hole into the hole in the drive plate
(A T) or flywheel (MT) to prevent
the crankshaft from turning.
e. After loosening the bolt @
by two Huns or more, tighten it again
to the specified torque.
f. Temporarily install bracket 2.@ .
13
~
19N·m
(1.3 - 1.9 kg-m,
9 - 14'ft·lb)
Torque
A5·694
Fig.3-172 Installing water pump
25) After assembling oil filter and
oil pump, install it with O-ring and
oil pump gasket.
\
.
Crankshaft pu lIey .J
A5-502
Fig.3-175 Installing crankshaft
pulley
b. Apply engine oil on the thread, and
liquid gasket (THREE BOND 1215
or the equivalent) on the flange seat.
c. Pulley dia. is as follows.
1600 cc: 109 mm (4.29 in)
1800 cc: 119 mm (4.69 in)
II
) 'I
A5-356
/1
Fig. 3-173 Installing oil pump
28) Install oil filler duct, oil filler
duct stay and gasket on crankcase.
On 4WD, install oil fllier duct, stiffener 2, and gasket on crankcase.
NOTE:
. a. Use new gaskets and O-rings.
b. When installiilll, _align the rotor
shaft with
groove in die cam·
shaft end.
the
1 Oil filler duct
2 Oil filler duct stay
4 Bolt
5 Bolts
6 Bracket 2
1 BracketCP
2 Bracket 3
3 Bolts
A5·696
Fig. 3·177 Installing generator
brackets
NOTE:
Be sure to use die
generator bracket 2.
Odlen are CD ones.
l!J
bolt for die
-
30) (Except engine with hydraulic
valve lifter) Adjust the valve clearances
as described in 2-2 Procedures of
maintenance services in Chapter 2.
A5·695
Fig. 3·176 Installing oil filler duct
29) Install generator bracket comp!.,
bracket 2 and bracket 3 as follows.
a. Temporarily
connect bracket
comp!.
and bracket 3, @ until
the spring washer is deformed a
little.
b. Install the sub·assembled bracket
prepared in a onto the engine by
tightening bolts @ @ temporarily.
c. At first tighten fully the two bolts
@ and after that tighten the bolt
@ to the specified torque.
d. Tighten fully the two bolts @
to the specified torque.
CD
A5-357
Fig. 3-174 Installing oil seal
27) Install crankshaft pulley
crankshaft with flange bolt.
Torque
64
(6.5
47
74 N·m
7.5 kg-m
S4ft-lb)
on
I
t
3-72
I Exhaust valvelt
2 Intake valves
3 Thickness gauge
4 Valve Oearance
Adjuster
(498767000)
. Fig. 3·178 Adjusting valve clearance
Valve clearance (Cold)
Intake
0.23 - 0.27 mm
(0.009 - om 1 in)
Exhaust
0.33 - 0.37 mm
(0.013 - oms in)
ENGINE
NOTE:
Use T.O.C. marking on pulley.
31) Install valve rocker covers with
valve rocker cover gaskets, seal washers
and bolts.
Torque
32)
34) Tighten E.G.R. pipe.
35) Install battery cable bracket and
A.S.V. bracket {vehicle without power
steering for 49 States (except 4WD &
4WD·AT)] or oil pump bracket
(vehicle with power steering).
2.9 - 3.9N·m
(0.30 - 0.40 kg-m,
2.2 - 2.9 ft-Ib)
Install spark plugs with gaskets.
Torque
18-24N·m
(1.8 - 2.4 kg·m,
13 - 17 ft-Ib)
33) Install the intake manifold as·
sembly prepared before as follows.
a. Install the intake manifold as·
sembly with intake manifold gasket,
air cleaner bracket, fuel hose stay, and
EGR pipe. And connect water by-pass
hoses.
Torque
Fig. 3·181
38) Install alternator on the genera· "
tor brackets with air cleaner bracket,
spark plug cord stay and drive belt.
,
Battery cable
bracket
2 A.S.V. bracket
Fig. 3·179
36) Install A.S.V. pipe and A.s.V.
18 - 22 N·m
(1.8 - 2.2 kg·m,
13 - 16 ft·lb)
AI5-474
Fig. 3·182 Installing alternator with
relative parts
NOTE:
Discrimination knurling for E.G.R.
pipe.
Vehicle
Knurling
1600 cc
2
CoW carburetor type
3
AS-697
Except the above
Nothing
b. Connect the harness lead to oil
pressure gauge or oil pressure switch,
and clip it.
c. Connect the P.C.V. hose to rocker
cover and clip it at the upper portion.
Drive belt tension
NOTE:
a. For further particulars of vacuum
hose, wiring harness, water hose
and P.C.V. hose. refer to label
behined engine hood, 15-12. in
chapter 15 and Parts Catalogue.
b. Be sure to connect E.C.M. (Elec'
tronic Control Module) earth at
right front bolt
NOTE:
a. After aligning the air cleaner
bracket and air cleaner, secure the
bracket.
b. Do not forget tightening fully the
bolt for generator bracket 2.
c. Adjust the drive belt tension as
described in 2·2 Procedures of
maintenance services in Chapter 2.
AS'69B
13 - 14 mm (0.51 - 0.55 in)!
98 N (10 kg, 221b)
Fig. 3·180
37)
Install E.G.R. pipe cover.
When replacing with new one, the
tension is 10 mm (0.39 in)/98 N
(10 kg, 22Ib).
ENGINE
13-14mm
(0.51-0.55 in)
c. Install distributor plate on crankcase with bolt.
98N
(10 kg. 22 Ib) "
Crank·
shaft
e. Install distributor into crankcase
taking care not to damage distributor
gear and O-ring.
f. Connect vacuum hoses to distributor.
g. Clip the distributor lead wire.
NOTE:
Be careful that the holes in the
distributor plate and crankcase are
correctly lined up.
OM· tOt
Fig.3-183 Drive belt tension
HITACHI
AS·SOS
39) Install distributor as follows.
a. Set #1 piston at its top dead
center in the compression stroke.
b. Align the distributor matching
marks.
Fig. 3-184 Aligning distributor
matching marks
d. Apply oil to the circumference of
distributor shaft and gear.
3-74
40) Connect spark plug cords to
spark plugs and cord supporters and
distributor cord to cord supporter.
41) Install oil level gauge if it has
been removed.
42) Install carburetor protector. [For
49 States (except 4WD & 4WD·AT)
and California]
43) Remove
Engine
Stands
(399814300).
ENGINE
3-10. Troubleshooting
Trouble and possible cause
I. Engine does
not start
I. Starter motor
does not rotate
Corrective action
1) Defective battery and/or charging
system
• Over discharged batt~ry.
• Defective charging system
2) Defective starting system
Charge or replace.
See "Troubleshooting of charging
system" in Chapter 15.
See "Troubleshooting of starting
system" in Chapter 15.
,--"-
3)
I
2. Starter motor
rotates but
engine does not
start.
Defective engine
Bearing seizure on crankshaft, con·
necting rod, etc.
• Piston seizure or sticking
•
Repair or replace.
Repair or replace.
1) Defective starting system (starting
speed too low, pinion does not mesh
with ring gear, etc.)
See "Troubleshooting of starting
system" in Chapter 15.
2) Defective ignition system (no con·
tinuity ignition current, etc.)
See "Troubleshooting of ignition
system" in Chapter 15.
3) Defective fuel system (malfunction
of choke system, over flow, no
flow of fuel, etc.)
See "Troubleshooting of carburetor"
in Chapter 4.
See "Troubleshooting of fuel system"
in Chapter 4.
2. Rough idle,
stalls
1. Defective igni·
tion system
4)
Insufficient engine compression
pressure
See 3-3,2 in this Chapter.
5)
Improper engine oil
Replace with recommended oil.
I) Improper ignition timing
Adjust.
2) Defective spark plug
Improper spark plug gap
Fouled spark plug
• Defective insulator
Adjust or replace.
Clean or replace.
Replace.
•
•
3) Defective cord or wiring
• Loose and/or damaged contacts
of ignition system connection
• Defective cord or wires
4) Defective ,ignition coil and outer
resistor (except 4WD)
5) Malfunction of distributor
Inspect, repair or replace.
Replace.
Replace
See "Troubleshooting of ignition
system" in Chapter 15.
ENGINE
Trouble and possible cause
Corrective action
6) Defective distributor
• Cap troubles (cracked cap, damaged
or corroded cord contacts, etc.)
• Malfunction of operating parts
(vacuum advance, centrifugal
advance mechanism, etc.)
• Improper air gap or defective pick
up coil.
Clean or replace.
Repair or replace
Adjust or replace.
7) Defective ignition control system.
• Clogged vacuum lines
• Malfunction of operating parts
(Thermo vacuum valve I, check
valve etc.)
2. Defective fuel
and air intake
system
I)
Inspect, repair or replace.
Replace.
Improper idle speed.
Adjust.
Replace.
2) Clogged air cleaner element
3) Defective carburetor
Improper float level
Malfunction of choke system
Plugged jets or air bleeds
Malfunction of antidieseling switch
(Hitachi carburetor) or idle stop
solenoid (C-W carburetor) or defective wire connection
• Defective metering rod (C-W
carburetor)
• Others
Adjust.
Adjust, repair or replace.
Clean or replace.
Repair or replace.
•
•
•
•
4) Defective fuel pump, filter, delivery
line, etc.
S) Vacuum leaks
• Leakage from vacuum lin!:s
• Loose intake manifold bolts or
defective gasket.
• Loose carburetor nuts or defective
gasket
• Defective EG R valve, PCV valve,
6) Malfunction of fuel feed system.
7) Malfunction of ECC system.
3. Insufficient
engine compression pressure
i
I)
I 2)
Improper valve clearance
Loose spark plug or defective gasket
3) Loose cylinder head nuts or defective
Repair or replace.
!
See "Troubleshooting of carburetor"
in Chapter 4.
See "Troubleshooting of fuel system"
in Chapter 4.
Inspect, repair or replace.
Tighten or replace.
Tighten or replace.
Replace.
Adjust, repair or replace.
Refer to Chapter S.
• AdjUSt.
Tighten or replace.
Tighten or replace.
head gasket
4) Defective valve seat contact
Resurface valve and valve seat.
S) Seizure of valve stem
Repair or replace.
3-76
I
ENGINE
Trouble and possible cause
6)
Deterioration or damage of valve
spring
Replace.
7)
Seizure or worn piston ring, cylinder,
piston
Repair or replace.
8)
Improper valve timing
Disassemble and correct.
9) Improper engine oil (low viscosity)
3. Lowoutput,
hesitation,
poor accelera·
tion
I. Defective
ignition system
Corrective action
I I)
2)
3)
Replace with oil of proper grade.
Improper ignition timing
Adjust.
Defective spark plug.
• Improper spark plug gap
• Fouled spark plug
• Defective insulator
Adjust or replace.
Clean or replace.
Replace.
Defective cord or wiring
Loose and/or damaged contacts of
ignition system connection
• Defective cords or wires
•
Inspect, repair or replace.
Replace.
4)
Others
See "Troubleshooting" in
Chapter 15.
1)
Improper idle speed and mixture
Adjust.
2)
Clogged air cleaner element
Replace.
3)
Defective carburetor
• Improper float level
• Clogged main jet
• Defective accelerator pump
• Malfunction of secondary
diaphragm (Hitachi carburetor)
• Defective power valve (Hitachi
carburetor)
• Malfunction of ECC system
• Others
2. Defective fuel
and air intake
system
I
4) Defective fuel pump, filter, delivery
line, etc.
5) Vacuum leaks (vacuum lines, etc.)
3. Insufficient
engine compression pressure
1)
Improper valve clearance
Adjust.
Clean
Inspect, repair or replace.
Inspect, repair or replace.
Inspect, clean or replace.
Refer to Chapter 5.
See "Troubleshooting of carburetor"
in Chapter 4.
See "Troubleshooting of fuel system"
in Chapter 4.
inspect, repair or replace.
Adjust.
2) Loose spark plug or defective gasket
Tighten or replace.
3)
Tighten or replace.
Loose cylinder head nuts or defective
head gasket
4) Others
See 3-3, 2 in this Chapter.
ENGINE
Trouble and possible cause
4. Others
Corrective action
I) Malfunction of EGR system.
Inspect, repair or replace.
..
;--~~.~------ ----~---
2) Over cooling or overheating
See "Troubleshooting of engine cool·
ing system" on page 3-83.
3) Excessive carbon deposit in comb ustion chamber.
Clean.
~~r--
4) Slipping of clutch
Inspect, adjust or replace.
~~"----"
5) Dragging of brake
Inspect and adjust.
4. Engine speed
does not reo
turn to normal
idle speed.
2) Malfunction of choke system
5. Dieseling
3) Malfunction of ignition control
system
Repair or replace.
Malfunction orvacuum controller
or centrifugal advancer in distributor
Inspect, repair or replace.
• Clogged vacuum lines
Replace.
Malfunction of operating parts
(Thermo vacuum valve I, check
valve, etc.)
r-I) Improper ignition timing
Adjust.
1) Defective throttle linkage or accelera·
. Inspect, adjust and repair.
tor cable
'~-.'
.
-.
Adjust, repair pr replace.
•
•
--~~
6. Explosive after·
burning in ex·
haust system
7. Excessive en·
gine oil con·
sumption
1. Oil leakage
2) Improper idle speed
Adjust.
3) Malfunction of antidieseling switch
(Hitachi carburetor) or idle stop
solenoid (C·W carburetor) or defec·
tive wire connection
Repair or replace.
4) Malfunction of choke system
Adjust, repair or replace.
1) Improper ignition timing
Adjust.
2) Improper idle speed
Adjust.
3) Improper valve clearance
Adjust.
4) Malfunction of choke system
Adjust, repair or replace.
S) Malfunction of EGR system
Inspect, repair or replace.
6) Malfunction of AAV system
Replace.
1) Loose oil drain plug or defective
gasket.
Tighten or replace.
........
ENGINE
Trouble and possible cause
2. Oil enters
combustion
chamber
past piston
ring.
2)
Loose oil pan attaching bolts or
defective oil pan gasket
Tighten or replace.
3)
Loose oil pump attaching bolts or
defective oil pump gasket
Tighten or replace.
4)
Defective oil filler sealing
Replace.
5) Defective crankshaft oil seals
Replace.
6) Defective rocker cover gasket
Replace.
1) Improper piston ring gap
Replace.
2) Worn or damaged piston ring, cylinder, piston
Replace.
3. Oil enters com- 1) Worn or damaged intake valve oil seal
bustion chamber through
2) Excessive clearance between valve
valve stem-tostem and guide
guide clearance.
8. Excessive fuel
consumption
1. Defective ignition system
1)
Improper ignition timing
2) Defective spark plug
• Improper spark plug gap
• Fouled spark plug
• Defective insulator
3) Defective cord or wiring
Loose and/or damaged contacts of
ignition system connection
Defective cords or wires
2. Defective fuel
and air intake
system
Corrective action
Replace.
Replace.
Adjust.
Adjust.
Clean or replace.
Replace.
•
•
Inspect, repair or replace.
4) Others
See "Troubleshooting" in
Chapter IS.
1) Improper idle speed
Adjust
2) Clogged air cleaner element
Replace.
3)
4)
Defective cord, wiring or vacuum line
• Improper float level
• Loose main jet or clogged main
air bleed
• Clogged vacuum pipe or disconnected hose
• Others
Defective fuel pump, filter, delivery
line, etc.
S) Malfunction of ECC system
Replace.
Adjust.
Tighten, clean or replace.
Check or replace pipe.
See "Troubleshooting of carburetor"
in Chapter 4.
See "Troubleshooting of fuel system"
in Chapter 4.
Refer to Chapter S.
ENGINE
Corrective action
Trouble and possible cause
3. Insufficient
engine compression pres·
sure
4. Others
1) Improper valve clearance
Adjust.
2) Loose spark plug or defective gasket
Tighten or replace.
3) Loose cylinder head nuts or defective
head gasket
Tighten or replace.
4) Others
See 3·3, 2 in this Chapter.
1) Overcooling (defective thermostat)
Replace.
2)
Slipping of clutch
3) Dragging of brake
Inspect and adjust.
4) Improper air pressure of tire
Correct.
9. Overheating,
overcooling,
coolant leaks
See "Troubleshooting of engine
cooling system" on page 3-83.
10. Odor of fuel
1) Fuel leakage from fuel tank, filler
cap, fuel pump and fuel lines.
Type of sound
Excessive
.11. en$ine
noise
Inspect, adjust or replace.
Regular clicking
sound
Check for cracks or cloggings.
Retighten connecting clamps
or replace.
2) Overflow from float chamber in
carburetor
Adjust float level.
3) Leaking evaporative emission lines
Check for cracks or cloggings of
evaporative emission lines.
Retighten clamps on connections.
Replace if necessary .
Condition
Possible cause
Valve clearance is not normal.
Sound increases as
engine speed increase.
• Worn valve rocker arm.
Bent push rod.
Valve clearance is
Broken valve spring.
normal.
• Worn valve lifter hole.
•
•
Heavy and dull
metallic knock
Oil pressure is low
• Worn crankshaft main bearing.
• Worn connecting rod bearing
(big end).
Oil pressure is normal.
•
•
Loose flywheel mounting bolts.
Damaged engine mounting
ENGINE
Type of sound
Condition
High-pitched
Sound is noticeable when accelerating
metaJlic knock
with an overload
(Engine knocking)
Possible cause
timing advanced.
• Ignition
Accumulation of carbon inside
• combustion
chamber.
• Wrong spark plug.
Defective distributor vacuum
• controJler.
• Improper gasoline.
Metallic knock
Sound is reduced when spark plug in
when engine speed noisy cylinder is shortened out.
is medium (1,000
to 2,000 rpm).
• Worn crankshaft main bearing.
• Worn bearing at crankshaft end
of connecting rod.
Knocking sound
when engine is
operating under
idling speed and
engine is warm.
• Worn cylinder liner and piston
ring.
Broken or stuck piston ring.
• Worn piston pin and hole at piston
end of connecting rod.
Sound is reduced when spark plug in
noisy cylinder is shortened out.
Sound is not reduced if each spark plug
is shortened out in turn.
•
• UnusuaJly worn valve lifter.
• Worn cam gear.
• Worn camshaft journal bore in
crankcase.
Squeaky sound
• Insufficient alternator lubrication.
Rubbing sound
• Defective alternator brush and
rotor contact.
Gear scream when
starting engine.
Defective ignition starter switch.
• Worn
ring gear and starter pinion.
Sound like
polishing glass
with a dry cloth
Hissing sound
•
Loose drive belt.
•• Defective
water pump shaft.
Loss of compression.
• Air
in air intake system.
• hoses,leakage
connections or manifolds.
J
ENGINE
1. Lubrication System
Before troubleshooting, make sure that the engine oil level is correct and no oil leakage exists.
~rouble
Corrective action
Possible cause
I) Oil pressure
switch failure
, Cracked diaphragm
Replace.
-~---~-
~---~
"~--~-
Oil leakage within switch
Replace.
Clogged oil filter
Replace.
Malfunction of oil by-pass valve
Clean or replace.
~"~
~~
~-
Malfunction of oil relief valve
2) Low oil
I. Warning light
remains on.
pressure
Clean or replace.
,.....---
Clogged oil passage
Clean.
Excessive tip clearance and side clearance
of oil pump rotor and gear
Replace.
"~--"~
Clogged oil strainer or broken pipe
r----~---
-----~--~~ ~---
Replenish.
Insufficient engine oil
---~-
3) No oil pressure
~--"~----
Replace.
Stuck oil pump drive gear and rotor
Replace_
-~-.-
1) Burnt-out bulb
does not go
on.
3. Warning light
flickers
momentarily.
r--~--"
Broken pipe of oil strainer
c--~
2. Warning light
Clean or replace.
----~-.--~--------
r-----
---
--"--"----
Replace.
~----.~-~---~--
2) Poor contact of switch contact points
-------
Replace.
3) Disconnection of wiring
Repair.
1) Poor contact at terminals
Repair.
2) Defective wiring harness
Repair.
----~----------~-
3) Low oil pressure
----
~-~-~~~----
Check for the same
possible causes as listed in 1.-2.
ENGINE
2. Cooling System
Over-heating
Over-cooling
Coolant leaks
Noise
Corrective action
Possible cause
Trouble
a.
Insufficient coolant.
Replenish coolant, inspect for leakage, and
repair.
b.
Loose drive belt.
Adjust drive belt tension.
c.
Oil on drive belt.
Replace.
d.
Malfunction of thermostat.
Replace.
e.
Malfunction of water pump.
Repair or replace.
f.
Clogged coolant passage.
Clean.
g.
Improper ignition timing.
Adjust.
h.
Clogged or leaking radiator.
Clean or repair, or replace.
i.
Improper engine oil.
Replace.
j.
Air-fuel mixture too thin.
Inspect and repair fuel system.
k.
Excessive
system.
Clean or replace.
I.
Insufficient clearance between piston
and cylinder.
back pressure in exhaust
Adjust or replace.
m. Improper valve clearance.
Adjust.
n.
Slipping clutch.
Repair or replace.
o.
Dragging brake.
Adjust.
p.
Improper transmission oil.
Replace.
q.
Defective thermostat.
Replace.
r.
Malfunction of electric fan.
Replace.
a.
Outside temperature extremely low.
Partly cover radiator front area.
b.
Defective thermostat.
Replace.
a.
Loosened or damaged connecting units
on hoses.
Repair or replace.
b.
Leakage from water pump.
Repair or replace.
c.
Leakage from thermo valve.
Replace.
d.
Leakage from intake manifold.
Repair or replace.
e.
Leakage around cylinder head gasket.
Retighten cylinder head nuts or replace
gasket.
f.
Damaged or cracked cylinder head and
crankcase.
Repair or replace.
g.
Damaged or cracked thermostat case.
Repair or replace.
h.
Leakage from radiator.
Repair or replace.
a.
Defective drive belt.
Replace.
b.
Defective electric fan.
Replace.
c.
Defective water pump bearing.
Replace.
d.
Defective water pump mechanical seal.
Replace.
ENGINE
3·11. Special Tools
~___._39_9~8_1_43_0_0_____ ~_______89_9_7_2_4_1_0_0_____
ENGINE STAND
SPRING PRESS
l--
8_9_97_6_8_60_2______+-__~_8_9_8_8_7_8_6oo
______~
I VALVE GUIDE ADJUSTER
---------·------------~--------------T
Crankcase
Valve spring
,
Exhaust valve guide
Fig. 3-789
AS·14l
I
899524100
PULLER SET
_._---
Fig. 3·793
A5·l45
Crankcase stud bolt
----t---------------;
I--------"---------+--------------+-
Fig. 3-785
STUD BOLT WRENCH
A5·l48
Fig. 3·197
A5·l52
899714110
899768603
499067000
REMOVER SET
VALVE GUIDE ADJUSTER
OIL SEAL INSTALLER
Cam shaft
Intake valve guide
Oil seal (crankcase)
Crankshaft pulley
Puller (899521411)
Q
Cap
•
f!j
c;;J
CD
'
'
0
Bolt 18995214121
Fig. 3-786
399094310
PISTON PIN REMOVER
Piston pin
()
•
Fig. 3·187
Fig. 3·790
A5·l42
~
A5·143
899804100
,
A12.181! Fig.
399765101
!
Valve lifter
899764105
Fig. 3·198
AI5-388
398744300
CYLINDER HEAD TABLE
VALVE GUIDE REAMER
PISTON GUIDE
Cylinder head
Valve guide
Piston
~
Ii
0""
Fig. 3·191
A5·148
899764104
VALVE LIFTER CLIP
A5·149
3·194
IFig. 3·195
898858600
i
8
:::g
AII·1110
Fig. 3·799
AII·11111
399284300
VALVE GUIDE REMOVER
OIL SEAL INSTALLER
PISTON PIN GUIDE
Valve guide
Valve gUide oil seal
Piston pin
:LP
C
__
Fig. 3·788
All·'....
Fig. 3·192
AII·' ..7
Fig. 3·196
AII·'II'
Fig. 3.200
All·' II'
ENGINE
499987006
499747000
498767000
499037000
SOCKET WRENCH
CLUTCH DISC GUIDE
VALVE CLEARANCE
ADJUSTER
REMOVER & REPLACER
Cylinder head nuts
Clutch disc
Intake and exhaust valves
Connecting rod bushing
~
~
Fig. 3·201
ST·030
499990100
SOCKET
Oxygen (0 2 ) sensor
v
J,.'
.
.
,
Fig. 3·205
A1()'133
Fig. 3·202
A11·014
,
Fig. 3·203
\',
,
ST·029
Fig. 3·204
\\
';
A 5·389
CHAPTER~
FUEL SYSTEM
Page
4- 1. SPECIFICATIONS AND SERVICE DATA •..•.••.••..•.•..•. 4- 2
4- 2. HITACHI CARBURETOR •.•..••••••.••.•...••...•••... 4- 5
4- 3. CARTER·WEBER CARBURETOR ••.••.•..•..•..•••.••..•.
4- 4. COMPONENT PARTS OF FUEL SYSTEM (Except Carburetor) . • ••
4- 5. FUEL TANK ..•..•.•.......••.......•.•••.•.•.•••••
4- 6. FUEL FILLER PIPE . • . • . . . • . • • . . . . . . • • . • . • . . . • . . • . . •.
4- 7. FUEL SEPARATOR ..................................
4- 8. FUEL FILTER •..•....••.•...•...••......••.••.....•
4- 9. FUEL PUMP •...•.......•....•..•.......••..•.....•.
4-10. VAPOR SEPARATOR .•..•....•..•.....••.•.•...•..•.•
4-11. FUEL DELIVERY AND FUEL RETURN LINE ....•.••.•••••
4-12. EVAPORATION LINE AND CANISTER •.•......•.•.•..••••
4-13. TROUBLESHOOTING .................................
4-14. SPECIAL TOOLS ......... , ..........................
4-20
4-29
4-31
4-32
4-33
4-34
4-35
4-36
4-:-37
4-.
4-31,~
_,?- ':-:It':'~;,:_""
"
4-45
."
FUEL SYSTEM
4-1. Specifications and Service Data
1. Recommended Fuel
The SUBARU 1600 cc and 1800 cc
engines are designed to get satisfactory
engine perfonnance and to keep clean
exhaust gas by using gasoline no less
than 90 octane.
NOTE:
a. Octane as selected by Raseareh
method.
b. Usa unleaded gasoline only.
2. Hitachi Carburetor
All California models and non4WD of
non.california models
Vehicle
I
1600
1800
DCP306-17
I
DCP306·18
1800
i
MT
. Carburetor
All Canada models and 4WD of
non.california models
AT
MT
AT
DCP306-19
DCP306-21
DCP306-22
Air horn dia. (Inner dia. x Outer dia.)
55 x 59 mm (2.17 x 2.32 in)
Throttle bore (P·S)
26 - 30 mm (1.02 - 1.18 in)
1.7 mm (0.067 in)
Inner dia. of needle valve
Main jet (P-8)
#116 - #145
Main air bleed (p·S)
e
4U
-...
~
S
2.8 x 4.0 mm (0.110 x 0.157 in)
Main nozzle end surface
angle
P
5°
S
0
Emulsion tube
(Inner dia. x Outer dia.
x Length)
P
Emulsion hole
(Dia. number of holes)
P
S
Slow jet (P-S)
~
Slow air bleed (P-S)
l\l
til
O.S mm (0.020 in) x 2,
0.8 mm (0.031 in) x 24
0.8 mm (0.031 in) x 16
#43
#80
#150 - #50
#160
#50 - -20.0 kPa (-150 mmHg, -S.91 inHg)
Weight of accelerating pump
injector
4.4 g (0.155 oz)
-;
Type
Diaphragm type
i=
Primary throttle valve opening
angle and clearance when
secondary throttle valve starts
to open
~
8
#150 - #90
#35 - -20.0 kPa
(-150 mmHg, -S.91 inHg)
0.5 mm (0.020 in)
>
~
#90
#9S - #90
8 a.~
-<
2.4 x 3.6 x 40 mm
(0.094 xO.142 x 1.575 in)
0.7 mm (0.028 in) x 8
Accelerating pump nozzle dia.
"'eQ)
.s=~
#80
1.5 x 2.5 x 39.5 mm (0.OS9 x 0.098 x l.SSS in)
.a a. e
-;j
#145
0
2.4 x 3.6 x 34 mm (0.094 x 0.142 x 1.339 in)
Economizer bleed (p·S)
Power jet - vacuum required
#109
2.3 x 3.5 mm (0.091 x 0.138 in)
2.6 x 3.5 mm (0.102 x 0.138 in)
P
e
0
#70
#60 - #80
S
~
#109 - #140
#114 - #145
Main nozzle dia.
(Inner dia. x Outer dia.)
.~
:::e
I
G~
= 6.0 mm (0.236 in)
() =49 0
4-2
I (Plugged)
-
FUEL SYSTEM
All Canada models and 4WD of
non-Califomia models
All California models and non-4WD of
non-California models
I-----
Vehicle
I
1600
t------
1800
1800
AT
MT
AT
DCP306-19
DCP306-21
DCP306-22
MT
DCP306-17
Carburetor
Automatic choke
e
Choke system
t;:;
~
Choke valve angle when fully
closed
...
Fast idle opening angle and
clearance of primary throttle
valve
~--
'''' @@;
..
®
w
..
~
I
~ Ii
,~II
JliiI\..J.
tI <-«,¥:"I'
£,"'"
<'
'if:.
16
11
19
18
20
21
22
23
24
25
'\
r: Ir
I
226 Solenoid valve CP
7 Washer
..",
28 Pr'
Secondary main jet
Float
29
P
un~ slow air bl ed 30
Pr'
main jet
ower Jet
e
Washer
31 Float h
32 Lock pclaamber plug
Injector
.
Plug
weight
33
te
Throttle ad'Just screw
34 Th
Primar
1
rottle
adj
Pi
y s ow jet
35 Idle adj
ust spring
B~on return spring
.ust screw
36 Idl
e adjust spring
Fl~'
w::::
Fig. 4-16
Washer
O-ring
Washer
Screw
Cotter pin
Washer
Adjust plate
Fast idle lever A
Cam
. rod
S . c onnectlng
prmg
Sleeve
Conn
. lever
Sl ecung
eeve A
Return plate
Screw &.
Idle a . washer
F
.dJust spring
sast Idle lever B
crew
Washer
Pum P connecting d
Conn'
ro
ctmg
COlla:
lever
59
60 Throttl
Thr
e return spring
61 F ottle lever
62
.I.~.D. lever
Spnng washer
63 Nut
64 Retum sprin
65 Insulator
g
66 Gasket
67 Throttle cham
68 "E" nng
.
ber
69
Screw
&.
10 Di
washer
aphragm chambe
71 Gasket
r
72 Float chambe
73 Screw &.
r
washer
74 Se
75 Se condary slow jet
condary main .
au
bleed
y
76
Prim
77 Gask: main air bleed
78 SecOndary slow air
b leed
79 Spnng
. washer
80 Washer
81 Pump
Iever spring
82
Pu
83
mp lever
84 Pump lever shaft
85 ~:T.C. bimetal CP
86 Sunetal cover
87 Screw &. washer
crew &. washer
Lead wir
88
89 Blind . e holder
nvet
90 Connector
AB-495
4-13
FUEL SYSTEM
3. Removal
Air cleaner.
Disconnect hoses for fuel.
Fuel hose
Fuel return hose
Carburetor air vent hose
Disconnect vacuum hoses.
Main diaphragm
Distributor advance
E.G.R.
Retard (All California models and
non-4WD of non-California models)
4) Disconnect hoses for duty solenoid valves. (All California models and
non-4WD of non-California models)
a. Duty solenoid valve (slow)
b. Duty solenoid valve (main)
5) Disconnect hoses.
a. Main diaphragm
b. Secondary main air bleed (High
altitude configuration only)
6) Duty solenoid valve connector
clamp. (All California models and non4WD of non-California models)
7) Disconnect harness connector.
8) Disconnect accelerator cable from
throttle lever.
9) Drain coolant so as to prevent it
from flowing out.
10) Four carburetor attaching nuts
and carburetor.
1)
2)
a.
b.
c.
3)
a.
b.
c.
d.
NOTE:
After removal, cover the area on the
intake manifold where the carburetor
was installed, in order to prevent dust
from entering into the engine.
4. Disassembly
spring, washer and spring washer.
3) Cam connecting rod, cotter pins
and washers.
6) Disassembling Float
Chamber
NOTE:
Leave pump connecting rod as it is.
1) Piston return spring, ball and
injector weight.
2) Primary and secondary main air
bleeds.
3) Primary and secondary plugs and
slow jets.
4) Lock plate, float chamber drain
plugs and primary and secondary main
jets.
3) Removing Choke Chamber
Return spring of return plate.
2) Unclamp harness at two points.
3) Anti-dieseling switch.
1)
NOTE:
Be careful not to lose the 12.2 mm
washer.
4) Choke chamber, gasket and five
NOTE:
Be careful not to lose the 9 mm
washers.
screws.
5)
NOTE:
Since the choke chamber is fitted with
a float, take care not to damage the
float.
NOTE:
Be careful not to lose the 8 mm
washer.
and Throttle Chamber
NOTE:
a. Be careful when putting the float
chamber upside down because some
parts (spring, bailor injector
weight) may drop off.
b. Be careful not to damage the
longest screw, since it has a hole
which is vacuum passage for the
power valve.
1) Precautions
1) Use wrenches and screwdrivers of
proper size to remove nuts and screws.
Be careful not to cause burr or damage.
2) Keep disassembled parts in order
not to mix them up when reassembling.
3) Use clean gasoline and compressed air to clean the jets and fuel
passages. Never use a wire or cloth.
2) Removing Linkage
I) Throttle return spring.
2) Pump lever shaft, pump lever,
7) Disassembling Throttle
Chamber
4) Separating Float Chamber
1) Snap ring of secondary diaphragm.
2) Secondary diaphragm, gasket and
three screws.
3) Separate float chamber and
throttle chamber by removing three
screws.
5) Disassembling Choke
Chamber
I) Accelerating pump piston and
pump cover.
2) Float shaft and float.
3) Needle valve.
NOTE:
Be careful not to lose the 10 mm
washer.
4) Primary and secondary slow air
bleeds.
5) Switch vent solenoid valve, gasket
and three screws.
4_14
Power valve.
1) Throttle adjusting Screw and
spring.
2) Idle adjusting screw and spring.
NOTE:
Remove spring pin beforehand.
3) Nut and parts on throttle valve
shaft.
NOTE:
Keep the disassembled parts in order.
5. Inspection
Disassembled components should
be washed in clean gasoline before
inspection. Particularly small holes and
hollows such as fuel passage must be
blown with compressed air to remove
dust and dirt.
Do not use drills or wires to clean
the small passages, otherwise the carburetor performance may be adversely
affected due to cut or deformation.
1) Choke Chamber
Air horn
Check for cracks, damage on
mating surfaces, damage on threads,
and excessive wear of choke valve
shaft contact areas.
2) Choke valve
Check for deformation and rust.
3) Choke valve shaft
1)
FUEL SYSTEM
4)
Check for wear and twist.
Power piston
Check for correct operation.
Idle mixture adjusting screw
Check for damage on tip of the
screw.
4)
Float
Check for deformation, damage of
seat and stopper, and wear of Ooat
shaft hole.
6) Needle valve
Check for damage and correct con·
tact against valve seat.
7) Filter
Check for deformation and damage.
8) Air bleed
Check for damage on thread and
groove.
9) Choke spring
Check for rust and deterioration.
10) Accelerating pump ,
II::'I J1-::1 i.f;
PCV valve
10iO.39)dia.
(b)_____
I
I
L_
--
Heat shield
l
:+
L
I
Duty solenoid
valve (Slow)
IG.
temperature)~.
--l
I
Duty
solenoid'
I valve(Main)
,r:----------:-.----,
II
:
~J_,--l~
I
I
I Surge
r::c--------l
tenk
I
I
I
In'
:;
ijJ :: L
Relay~
Solenoid valvem
Thermo valveu~r
-C-h -k- -1- (-11-)
(Wall
ec va. ve
I
Relay
r-r-1,1-- -----,
----=-=====::.::.::::.::.-:.-- -, :
r---------;i
.-----~
::::
To fuel tank
... ---,
kic~-d?Wn
solenoid via
relay-"""1
(AT only)
I
,
Distributor
To
----
IPTCautochoke
I
®
1'1..,
U"I
I I
L
:
Battery IG switch
~
t-_
--- ------- -
EGRvalve
r
r -·
Silencer'
L
1600 Model Orifice
only
[0.7(0.028)dia.J
(10 advance
system)
~
[1.0(0.039)dia.]
t
~
....,
(II
•
•
n en W
!!. n •
...a
:'1'1
'iii'
CD
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o
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o
....
o
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a
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n
Z
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r-
en
-<
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3:
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~.
IG
~
Idle compensator
[55-65°C(131-149°F))
ATC
~
- - - - - O P for H/Avehicle
n
till
:J
till
a.
till
---@
1I:!!Jnr br~;;;e
~I
~I
t
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1 &>:: [0.510.020)"'.[
I
.~-~
II ~
Ii
!:
Choke break diaphragm
To fuel pump
[1.4 (0.055) dia.)
OrifIce
I
'
L
-ll____
._.
f
L
I
L- _____ -...,.
Anti after
burning valve
j' • .
•
I
li
~
Distributor
Orifice
[1.0{0.039)dia.)
-- I -@
___
I
II
II
T -
t t~:;f~r
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till
:J
a.
~
0
9-
z0
.
'GRwl~ @l !Ii
I
I
CD
;r
0
••
Silencer
3!:
0
a.
:J
n
Thermo valve (II)
(Water temperature
over 18°C(64°F): OFF)
PTC
auto choke
!!.
~
~
:J
0
Z
0~
iii'
3!:
~ t=uel return orifice
[0.7(0.028)dia.)
~ r:- ---~
0
Z
X
;:j.'
0
~
n
till
To fuel
tenk
... - - - ,
~
C"
c
0--;"1 ! hSii"
~
~
0
.:!..
Unit: mm(in)
*1. Orifice
S/L
..~
MT
except
4WD
0.7{0.028)
dia.
4WD
MT
0.5(0.020)
dia.
»
I AT
.......
1 AT
4WD
H/A
Unit: mmlin)
1.010.039)
dia.
Without
leak
Without
leak
*2. Orifice
1.3(0.051)
MT
dia.
except4WD
1.3(0.051)
dia.
4WDMT
0.7(0.028)
dia.
...
AT
& 4WD AT
--_
Thermo valve
(Under hood temperature
over 2PC(Sl° F): OFF)
-
..
:.
__ - ...
-
Unit: mm (in)
n
8.
CD
;;
Thermo valve (f)
(Wall temperature)
m
3!:
-f
::D
.en
-<
~
m
3!:
."
Thermo valvelIlI)
[Water temper·
ature over SO°C
. .
1140"F): ON)
Vacuum
switching
valve
tiS·
z:
-.-'ii"~
~
~
: ., ,In,l'rr
•
I [1.0[O.O"~
r
ATC
Air cleaner
I
I
Orifice
'1
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I,
---.Ll® j
@).....
@
_.
Silencer
®,
L
Silencer
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L
'
-------- -
~~
Choke break diaphragm
E
_
•
-
----
: fl
-·iS~S~~;d::
-
I
valve
Hm
I I I
I I I
1600 Model r - - - - - - - -,
EGR valve
only
I
~
f I
~
__ _
(10 advance I
I
0
,
system)
I
Orifice
I.
- - - _ -.......--.
..
L
[0.810.0311dia.!.J
Orifice
,---[0.710.028)dia.) .....
..'
sOllenOid via
reay
IATonlyl
_..J I I
::i"
::
(TI
II
J"
10.028)dia.)
--+0
Bowl vent
solenoid
I
l
~\
\
L ~
Lf,
....
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LL~~-
~.
.
::::I
ECM
T IN
n
!!.
i
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r
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s:
8.
CD
I
H/A
/'ii»...
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n
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dia .
1.010.0391
dia .
Catalyst
IPt:Rh=9:1)
...cr
n
C»
82
~...
0
0
2
-f
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....
en
-<
en
-f
m
s:
[Unter hood temVacuum switchll)
peratu re over
[0- -13.3kPa(0- -100mmHg,
27°CI81°F): OFF]
0- ~.94inHg): ON]
IG
coil
=
~
-
[0--2S.7kPato- -20OmmHg
0- -7.87inHg}: OFF]
,
~
:::J:
c
(fr--;~ )
I
Vacuums;;itch(II)~
~
s:
~
To fuel pump
m
;;"
-
r-":
Duty solenOid
I
valve lSI ow}
L - - "!"S\
IG switch . . - ---.;:v
..
ECS light
Secondary main air
IOn dashboard)
bleed ICarb.l
IHigh altitude
configuration only)
To temperature gauge
~
Thermo valve
Unit: mm Un)
h)
2
II
I
~
c
20
'L-G)
~J--::.J
_ _ _...c-;;;
\
• Orifice
9
_ _- ,
Thermosensor
.--j-h,
.....
Relay
t-,
,
.
::::I
OU
--_
I
n----1 :
nister
»
I
2
0
L ___ IDigitall
,-
L::l:4Lj'1
_I''~F:e-;-;:;;;;;;n-;;;;e[0.7
1£:..1 ,
I L-I
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I
Surge
I
tank Duty solenoid
r:::!:0rm;;[1.910.075} dia.
valve IMainl •
.4-J...----+------:---n
SIL
0.710.028)
dia.
Without
leak
'I'I
Air filter
"
I
IG switch
____ _
i.
~}J-"'--11
i
r,----;,- _----1I
L--------
Battery
I
L"Orifice[1.7 I
IG
tto.067in)diaJ'1
switch IMT at SIL
only)
I
--:.--=--=-- __ J II'
Q,;f;" [~5!.O~I~;":[J
-
Check valve UI
Klck-O?w~
OP for
H/A vehicle
iMd
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i" =':1 :~I
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r----ID'
rPi!l
Relay~
I
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.":.==:'::l
::-
fr r·-t.=-_ -
-
Unit: mm (in)
~
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tP"
~
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H/A vehicle
ATe
i~
i
_ _--.J'Ijl,n! fl,flf' ~ fJ8i'---®
S;I."~, (j). ! ~
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EGR valve
..
,_-__
___
o
i
~
:::;00'"wlwlll
Distributor
temperaturer
To fuel
tan k
---, 1'Wi.
•
;:,:::,~IJ
0
J t.orificel :
I
I
i
0
I
I
0
0
-
0
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I
0 0
• 0
m::Jl
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Z
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I
I
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----
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I
:
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~
I
~
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ACC '"
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I
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n
ECM
i! ~ :'::f~~ ~~~
~ ~~=-=--~=-~-::-----~'
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r-~':.~-J
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____
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'r--
+1-+1-l,U,11 1.
pump
To dashboard
temperature meter
~~
ot
canister
S/l
0.810.0311
dia.
~
9
-....
(0)
H/A
1.7(0.0671
dia.
----~
Thermo valve
Air suction [Under hood temperature
valve II
over 27"CI81°FI: OFF]
Catalyst (Pd:Rh=5:11
I
!LEl
Sll~h) j .
- -
E!
~
.:::!.
~lF---~
•
0
0
Ai r suc tion valve I
IWith cut valvel
Unit: mm lin)
• Orifice
'0
..
..
Dol •
j-J
CD
0
Z
-t
tr
C
Vacuum switch 1111
[0- -40.0kPalO- -300mmHg,
0- -11.81inHg): OFF]--
~
Vacuum switch III
[0- -13.3kPa(0- -100mmHg.
0- -3.94inHgI: ON)
IG
coil
~
\.~
____ . . . . . . 1
Unit: mm (in)
s:
~
tr
;:::.
~
I»
131O.51)dia.
m
~
0Z
0
_ :
0 ... -~
Q.
CD
en
'0
I»
..
Selection signal
for carburetor
~
r~~=k=----1
I
0
@C-· 10
:------=-:.:.r----'
~
0
::r
-- -- ---0
I
::E
0
ECS lamp
IOn dashboard)
,____ ____
I
Relay
IL ______ .JI
.r:;-:LJIL'Silencer
h
Z
0
::r
J::,.
II
,
J:
~____
t- 'to!I 1 - -,~~-11-1rtt-:":=':--:
.
,..-----,
A;,"_"
0
Battery I G switch
0
:D
r-
en
-<
en
-t
m
s:
."~;
" . , ..
'
.....
;So
-a
"'EIiE
Ignition-startar
- switch
Y'I
......
.~-
I.', ~
3:
&.
CD
~a
I
F/P
r----Icontrol
o.
;;
m
~
c
-e'
"D
8-
I
~
KID hold relay!
-LOn{- /
;::;.-
L
::r
m
•..---:::I
".a"...a
(")
(")
Cleek
*
N
•
gJ
I~ I
1111111
II! II,
w:: ~
en
<
IG
,relay
=CD
3
I~
rg
0
Z
(")
0'1
0
Ground for control
10pul",
J:,
Z
-f
IG source
0, monitOf"
Sub input (I)
KID switch
::D
Input 0" sensor
Input carburetCM" setection
PTCcontrol
en
Sub input (2)
GrOlmd fOf" control
-<
Duty monitor
~
Sub OUtput (3)
Shield
Sub output (2)
Trouble code
OutPUt solenoid wive 11
Sub output 111
Warni"9 leCS)
m
3:
InputH/Asw
Input VAC ow I
Input VAC sw II
Output solenoid wive III
Input thennosentOf'
J.I J;.":=:~C
Output KID hold
.J Output solenoid velve I
Output duly
Modee_
....
~:
...
9
~
,..
l>
LO
.r.. .....
....
t PC;1jQ]I{7 m:
""
'" .... iJI
_'.OY~
0
r-
• ,.....- ...
w
-
'"rI
N
ciS'
- >-
to
fTEllfl~
0.85
L
y~0.85~
0.85L
~
m
3:
YB
;t
LY~Y~
8
BW
Anti-dieseling
solenoid
PTC\'U
If
YG
BW
Y
To rear
c=r:r"/
harness ~
-::-
»
.....,..
9
IJI
(5
2
LB
2BW
m
3:
~
Oil
Thermo
pressure switch
switch
-:::-
0.85LR
;~'"
F/P
EMISSION CONTROL SYSTEM
3. Description
I) Component layout
1) Three-way Catalyst Attended
with ECC System
I) California models and non-4WD
of non-California models
carburetor)
2
The basic material of three-way
catalyst is platinum (Pt) and rhodium
tRh), and a thin film of their mixture
is applied onto honeycomb or porous
ceramics of an oval shape (carrier). To
avoid damaging the catalyst, only unleaded gasoline should be used.
The catalyst is used to reduce HC, CO
and NOx in exhaust gases, and permits
simultaneous oxidation and reduction.
To obtain an excellent purification
efficiency on all components HC, CO
and NOx, a balance should be kept
among the concentrations of the components. These concentrations vary
with the air-fuel ratio.
The air-fuel ratio needs to be controlled to a value within the very
narrow range covering around the
theoretical (stoichiometric) air-fuel
ratio to purify the components efficiently.
Electronically Controlled Carburetor
(ECC) system is employed with threeway catalyst for this purpose. ECC
system is mainly made up of following
component parts.
a. Oxygen (0 1 ) sensor
b. Electronic control module (ECM)
c. Duty solenoid
d. Carburetor
They compose a feedback system to
control the air-fuel ratio during operation by supplying a measured air into
air bleeders of the carburetor.
For high altitude configuration, the
Hitachi carburetor is also provided
with a circuit to supply air to the
secondary main air bleed.
To avoid application of feedback
during certain driving conditions, vacuum switches, a thermosensor and an
engine speed sensing circuit are also
provided in this system.
I Control air cleaner
2 Intake manifold
3 Duty solenoid
valve (main)
4 Duty solenoid
\~Iifornia
valve (slow)
\odelOnlY
5 Carburetor
6 Surge tank
7 Thermosensor
8 Oxygen sensor
9 Vacuum switch I
10 Vacuum switch II
11 Exhaust manifold
12 Electronic control
unit
13 Ignition coil
To temperature
sensor of air
temperature
control
I
I
I
I
I
I
I
I
I
I
l-----I1~'
I
[--
-,
1
I
,
I
r
-~
TIrr
I
@
Orifice
1.91O.07S)dia.
I
J _I .J
_____
,
I
:
"'-----_ ..
,I
'
High altitude
configuration
only
Unit: mm (in)
~
Fig. 5-9
A10-177
2) Non-4WD of non-California models (C-W carburetor)
To temperature sensor
of air temperature control
.,
I
I
,
I
1
I
I
I
I
I
1
I
I
I
I
(
®
~--....--iI
I
I
I
2
3
4
5
6
7
8
9
10
Intake manifold
Duty solenoid valve
Carburetor
Thermosensor
Oxygen sensor
Vacuum switch I
Vacuum switch II
Exhaust manifold
Electronic control unit
Ignition coil
I
I
:0":
I
I
I
-
'--
-----
I
I
@ :I
-----,,
---.,
I
I
®
I
- --- ---_--=.=1J .JI
_____
:--~--:
I
,...
,
-
'
~
7
'
1
High altitude
configuration only
Fig. 5·10
A10-178
5-10
EMISSION CONTROL SYSTEM
2) Component parts of ECC system
1) Oxygen (0,) sensor
0, sensor is a kind of concentration
cell that generates electromotive force
according to the ratio of 0, concentration in air to that in exhaust gases, and
has a characteristic that the electromotive force is changed drastically
with respect to the stoichiometric airfuel ratio. The force is larger on the
rich side (smaller air-fuel ratio) and
smaller on the lean side (larger air-fuel
ratio) of the mixture.
0, sensor is installed on exhaust
manifold.
electromotive force of 0, sensor is
higher than the specified level. As the
result, ECM issues signals to duty
solenoid valves to let much air into
carburetor.
On the other hand, the air-fuel ratio is
judged to be lean mixture when the
electromotive force is lower. ECM
issues signals to duty solenoid valves
to let a little air into carburetor so that
the air-fuel ratio will be changed toward rich mixture. According to these
feedback operations, the air-fuel ratio
maintains at around the stoichiometric
value.
1 cycle
-
~
[ON duty
Open
I tJ
r-
r-
A10-t)93
Fig. 5-14
The ON-duty duration varies at a fixed
acceleration, with the Rich-Lean
mixture as measured by the O2 sensor.
In steady-state operation [where the
vacuum switch (II) is on], the acceleration rate beyond a certain engine
speed is changed in steps to obtain
greater acceleration at higher engine
rpm. This allows the valve to sensitive·
ly respond to the Rich-Lean mixture
as measured by the O2 sensor.
A 10-181
A5-679
Fig,5-13 Electronic control module
tEeM)
Fig_ 5-11
Contact plate
c
/Louver
~/Zirconia tube
A10-180
Fig.5-12 O 2 sensor
2) Electronic control module (ECM)
According to the signal from 0, sensor,
ECM judges whether the exhaust gas
at the manifold is made from rich or
lean mixture against the stoichiometric,
and issues signals to duty solenoid
valves. The current air-fuel ratio is
judged to be rich mixture when the
3) Duty solenoid valve
On Hitachi carburetor, two duty
solenoid valves are installed on the
intake manifold, while on CoW carburetor, one duty solenoid valve is
unified in the carburetor as shown in
the figure.
Duty solenoid valve has a construction
as shown in the illustration.
The light-weight valve (A) repeats
opening!closing at a short cycle according to the signal output from ECM.
The average flow rate of air passing
through this valve to carburetor
changes depending upon the period of
time during which the valve is opened,
thereby the air-fuel ratio is varied.
The status that a voltage is applied to
solenoid, that is, the valve is lifted is
called "ON-duty", and duty ratio is
given by the follOWing equation.
time x lOOotIto
· =ON-duty
.
Dut y rat 10
Cycle
(Hitachi)
I Duty solenoid valve (main)
2 Duty solenoid valve (slow)
3 Connectors
Al0-141
(C-W)
I Feedback: solenoid valve
2 Connector
A10-142
Fig. 5-15
EMISSION CONTROL SYSTEM
(Hitachi)
Spring
To electronic
control module
For ECM
For temperature
gauge
•
Lead wire
Thermistor
element 1
Thermistor
element 0
To intake manifold
or carburetor
Diaphragm
Solenoid ..
To control
air cleaner •
To carburetor.
A10·145
Fig. 5-18 Vacuum switch
A10-148
A10-o92
Fig. 5-20 Thermossnsor
(Hitachi)
(C-W)
To low speed circuit
or high speed circuit
control module
A10-146
(C-W)
S) Vacuum switch (II)
The acceleration (increasing/decreasing
rate of the ON-duty duration) increases
for several seconds immediately after
this switch is turned off, allowing the
valve to sensitively respond to the
Rich-Lean mixture as measured by the
O2 sensor. After a lapse of S seconds,
the acceleration returns to the steadystate operating condition.
A10·143
Fig. 5-16
4) Vacuum switch (I), thermosensor
and engine speed sensing circuit
These are additionally provided in the
ECC system so that better driveability is assured by avoiding the
application of feedback.
A10-147
Fig.5-19 Thermossnsor
3) Determination of the duty ratio is as follows.
I~
1 Connectors
2 Vacuum switch (0)
3 Vacuum switch (I)
Fig.5-17 Vacuum switch
A10..Q94
Item
1
Carburetor
2
Water temperature
3
Is O2 sensor activated or not?
4
Engine rpm
S
Vacuum
6
Sea level or high altitude?
5-12
Device
ECM
Thermoser
O 2 sens6r
Engine speed sensing circuit
Vacuum switch (I)
Grounding wire (Optional)
EMISSION CONTROL SYSTEM
2) Oxidation Catalyst
Canada models, California models and 4WD of non·California models
The basic material of the oxidation
catalyst is as follows:
Canada models and 4WD of non·
California models: Platinum (Pt) and
Palladium (Pd)
Non4WD of non-California models:
Palladium (Pd) and Rhodium (Rh)
A thin film of their mixture is applied
onto honeycomb or porous ceramics
of an oval shape (carrier). To avoid
damaging the catalyst, only unleaded
gasoline should be used.
The catalyst is used to reduce HC, CO
in exhaust gases.
(MT)
(AT)
rAir cleaner
I
I
,I
LEGR valve
Thermo vacuum
Thermo vacuum}
valve I
EGR pipe valve I
EGR pipe
3) Exhaust Gas Recirculation
(EGR) System
Exhaust gas recirculation (EGR) system is aiming at reduction of NOx by
reducing the top combustion tempera·
ture in cylinders through recirculating
a part of exhaust gas into cylinders.
The EGR valve opens in response to
the engine driving conditions and a
part of exhaust gas flows into cylinders
through the intake manifold.
The vacuum signal to control the EGR
valve is picked up from the port near
the slightly up stream portion of
throttle valve after being modulated
with the atmospheric pressure through
the orifice (EGR leak orifice equipped
models). At the specific wall tempera·
ture of intake manifold or below, the
vacuum signal is modulated with the
atmospheric pressure through the
thermo vacuum valve I.
Additionally for non4WD of non·
California models, the vacuum signal is
modulated with the atmospheric pressure through solenoid valve II at the
specified driving condition.
\..#1. #3
Cylinder head
\#1, #3
Cylinder head
OM-721
OM·722
Fig. 5-21
INon4WD of non-California models I
(MT)
(AT)
Solenoid
valve II
,
,,
,
EGR
,
I
valve
L---D--~i
ECM
EGR leak orifice
:
Thermosensor
mm(in}
US.A.
HUadd
c·w
"""..""
-
0.5
(0.«10)
0.7
(0.028)
0.1
(O.oJI)
0.1
(0.028)
(0.020)
-
-
-
-
-
-
-
-
1.0
(0.039)
1.7
1.1
(0.067)
-
-
-
0.1
(0.028)
-
0.7
NT
(0.021)
AT
NT
H/A
AT
Non"'W
.""
NOlt.cWO
SlL
c.....
Non-Califomi4
Cafifomi.
.wo
(0.061)
1.0
(O.ll39)
-
~
ct
4W1>
GaRb
w'
/
l'"
A10·182
valve
L"-D"'~
1
Thermosensor
pipe
...
Fig. 5·22
EGR
I
ECM
#1-#3
"
D.5
,,,
*
ct
#1-#3
EGR
pipe
.. ..
QR.qt>
, r
A10·183
EMISSION CONTROL SYSTEM
4) Air Injection (AI) System
The AI system is a major emission
control system whose purpose is to
promote oxidation of hydrocarbons
(HC) and carbon monoxide (CO) while
the engine is cold.
1) California models
1) Component parts
• Air suction valve I (ASV) with cutoff valve
• Silencer
• Air suction pipe
• Air introduction hoses
• Air cleaner
• Thermosensor
• Solenoid valve I
• Check valve II
• ECM
Secondary air is supplied to the
exhaust port on the #2-#4 cylinders
side by ASV.
2) Operational principle
The exhaust gas pulsation is transmitted to the air suction valve (a kind
of check valve having. reed valves)
through the air suction pipe.
When the negative pressure of pulsation is transferred to the ASV, the
reeds of air suction valve are opened
~Electronic
rI
:
and simultaneously fresh air from the
air cleaner is sucked by itself into the
exhaust passage.
When, on the other hand, the positive
pressure reaches the ASV, the reeds
are closed to prevent the adverse flow
of exhaust gas.
The AI system is controlled both by
coolant temperature sensed by the
thermosensor and time governed by
the ECM.
When the coolant temperature is below
35"C (95°F), the ECM gives a command to open the intake manifold
vacuum passage of the solenoid valve I
for the period of 123 seconds, whereby the cutoff valve being opened by
the diaphragm vacuum actuator to
operate the ASV.
Under such driving condition as wideopen-throttle acceleration, the check
valve closes the vacuum circuit to
confine the vacuum so as to hold the
cutoff valve open for that period.
After the period, the ECM gives a
command to close the vacuum passage
of the solenoid valve and open the
atmospheric pressure passage, then the
vacuum in the vacuum chamber of the
cutoff valve goes out through the solenoid valve I, whereby the cutoff valve
being closed to deactivate the ASV.
control unit
U ------------~
rThermosensor
Check valve II
:
I
I
~
AI....
Exhaust manifold
?
~,
Air suctiOn};
pipe
Air suction valve I
with cutoff valve
A10·184
Fig. 5-23 AI system
5-14
Secondary
air outlet
A10-185
Fig. 5·24 ASV I with cutoff valve
(Nippon Denso)
CD
4
1
2
3
4
5
6
Diaphragm
Vacuum inlet
Secondary air inlet
Reed
Stopper
Secondary air outlet
®
A10-18G
Fig. 5-25 ASV I with cutoff valve
(NOK)
2) Canada models and 4WD of non·
California models
I) Component parts
• ASV III without cutoff valve
• Silencer
• Air suction pipe
• Air introduction hose
• Air cleaner
Secondary air is supplied to the
exhaust port on the #2-#4 cylinders
side by ASV.
2) Operational principle
The exhaust gas pulsation is transmitted to the air suction valve (a kind
of check valve having reed valves)
through the air suction pipe.
When the negative pressure of pulsation is transfered to the ASV, the
reeds of air suction valve are opened
and simultaneously fresh air from the
air cleaner is sucked by itself into the
exhaust passage.
When, on the other hand, the positive
pressure reaches the ASV, the reeds
are closed to prevent the adverse flow
of exhaust gas.
EMISSION CONTROL SYSTEM
Air cleaner
Air induction
hose
A10·187
Fig. 5-26 A I system
Secondary air inlet
Secondary air outlet
A1o.188
mitted to the air suction valve (a kind
of check valve having reed valves)
through the air suction pipe.
When the negative pressure of pulsation is transfered to the ASV, the
reeds of air suction valve are opened
and simultaneously fresh air from the
air cleaner is sucked by itself into the
exhaust passage.
When, on the other hand, the positive
pressure reaches the ASV, the reeds
are closed to prevent the adverse flow
of exhaust gas.
An ASV without cutoff valve always
operates regardless of coolant temperature and ECM signal. On the other
hand, two ASVs with cutoff valves are
controlled both by coolant temperature sensed by the thennosensor and
time governed by the ECM.
When the coolant temperature is below
35°C (95°F), the ECM gives a command to open the intake manifold
vacuum passage of the solenoid valve I
for the period of 123 seconds, whereby the two cutoff valves being opened
by the diaphragm vacuum actuator to
operate the two ASV s.
Under such driving condition as wideopen-throttle acceleration, the check
valve closes the vacuum circuit to
confine the vacuum so as to hold the
cutoff valve open for that period.
After the period, the ECM gives a
command to close the vacuum passage
of the solenoid valve and open the
atmospheric pressure passage, then the
vacuum in the vacuum chambers of
the cutoff valves goes out through the
solenoid valve I, whereby the two
cutoff valves being closed to deactivate
the two ASV s.
Fig. 5-27 ASV III without cutoff valve
3) Non4WD of non-Califomia
models
1) Component parts
• Two ASVIs with cutoff valve
• ASV II without cutoff valve
• Air suction pipes
• Air introduction hoses
• Silencers
• Air cleaner
• Thennosensor
• Solenoid valve I
• Check valve II
• ECM
Secondary air is supplied to the
exhaust ports on # 1-#3 and #2-#4
cylinders sides by ASV with cutoff
valve.
Also the secondary air is supplied to
the exhaust port near the up stream
portion of oxidation catalyst by ASV
without cutoff valve that is installed
on rear exhaust pipe.
2) Operational principle
The exhaust gas pulsation is trans-
1 Electronic control mod ule
2 Solenoid valve I
3 Check valve II
4 Air ind uction hose
5 Thermosensor
6 Air cleaner
1 Silencer
8 Air induction hose
Fig. 5-28 AI system
9 Air suction valve I with cutoff valve
10 Air suction pipe
11 Air suction valve II
12 Silencer
13 Air suction pipe
14 Silencer
15 Air induction hose
16 Air suction valve I with cutoff valve
A10-189
EMISSION CONTROL SYSTEM
5) Ignition Control System
Ignition control system is aimed to
reduce HC, CO and NOx emission
through the whole operating conditions. Actual ignition timing is controlled by the combination of a centrifugal advancer and a vacuum conSecondary air inlet
troller (advancer) of distributor.
Operational and constitutional description of the centrifugal advancer is
performed in "Chapter 15; Distributor", so here is described how to controll the vacuum signal for the vacuum
controller (advancer).
(Vacuum signal for the vacuum controller)
A10·190
Vacuum signal (Advance signal only)
Fig. 5·29 ASV II without cutoff valve
1600 cc
Between 15 to 35°C (59 to 95°F) of the intake manifold wall
temperature, the vacuum passage is opened to atmospheric
pressure through the thermo vacuum valve I.
At temperature other than the above-mentioned, the vacuum
passage is connected to below-throttle ported vacuum through
the check valve when the engine is idling, and the vacuum
passage is connected to above-throttle ported vacuum due to
the check valve being closed when the engine is running at
speed above idling.
1800 cc
Between 15 to 35°C (59 to 95°F) of the intake manifold wall
temperature, the vacuum passage is opened to atmospheric
pressure through the thermo vacuum valve l.
At temperature other than the above-mentioned, the vacuum
passage is connected to above-throttle ported vacuum.
NOTE:
ASV I with cutoff valve is the same as
mat for California models.
11800 cc
To EGR valve ...
Thermo vacuum----;JPIII"...oCI
valve I
I
==n
Thermo v8Cuum--,_
valve I
I---tt-Intake
manifold
I---H-Intake
manifold
Orifice
OM-726
OM-727
Fig. 5·30
5-16
EMISSION CONTROL SYSTEM
6) Anti-afterburning System
During rapid deceleration the air-fuel
mixture becomes heavily concentrated
temporarily, as the vacuum pressure in
the intake manifold increases, causing
fuel residue on the inside wall of the
manifold to vaporize and to enter the
combustion chamber.
The anti-afterburning system prevents
this heavy concentration from occurring by introducing air into the intake
manifold at this time. This prevents
afterburning in the exhaust system.
During constant-speed running, the
valve is closed because chambers ®
and @ are at the same pressure. In
deceleration (when the throttle valve is
closed), the vacuum pressure in the
intake manifold increases and the
pressure in chamber @ decreases.
The diaphragm is forced down to open
the valve. This permits outer air to be
drawn into the intake manifold
through the filter.
After that, the pressure in chamber ®
gradually becomes equal to that of
chamber @ as the air flows through
the orifice. The diaphragm is then
pushed up by the spring, which in turn
closes the valve to stop the suction of
air.
Orifice
To intake
manifold
Air
A10-192
Fig. 5·32 Anti-afterburning valve
To ignition-starter switch
®
~.-------~------------~-------,
To battery
------'1'------,
Kick-down
switch
I
Air passage
\®
Electronic control
module
Relay
Kick-down
solenoid valve
2 Anti-afterburning valve
3 Orifice
4 Intake manifold
5 EGR valve
6 Vacuum line
A 10-191
Fig. 5-31 Anti-afterburning system
7) Shift-up Control System
Shift-up control system is provided
on automatic transmission vehicle only
and is used to reduce CO emission due
to rapid warm-up.
If the engine is started while the
coolant is in the preset temperature
range, ECM keeps the automatic transmission in a kick-down state for a
certain duration of time.
Ignition coil
Intake manifold
r6
LJ-A10-193
Fig. 5-33
EMISSION CONTROL SYSTEM
8) High-altitude Kit
When principally operating the vehicle
at altitudes above 1,200 m (4,000 ft)
(areas prescribed in the paragraph (a)
(5) of section 86.082-30 of EPA regulation), the emission control system
requires minor modification to meet
the emission standards at high-altitude.
Regarding the modification, please
refer to the modification instruction
sheet enclosed in the high altitude kit.
When a vehicle modified to highaltitude specifications is principally
used at altitudes below 1,200 m
(4,000 ft) (other than areas prescribed
in the paragraph (a) (5) of section
86.082-30 of EPA regulation), the
emission control system must be
remodified to the original specifications.
Regarding the remodification, please
restore the relative parts to their
original specifications.
4. Inspection
Check the ECC system as a whole
system, and its description is performed in the next section "5.
Troubleshooting for ECC system".
Therefore, here is described how to
inspect component parts of the other
systems.
1) EGR System
1) EGR wive and EGR flow passages (Vacuum and exhaust gas)
Remove EGR valve, and clean or replace the
EGR valve. (Refer to a. EGR valve cleaning.)
No
Viewing through an opening in the EGR
valve body, check if the valve shaft moves
when the engine speed reaches 3,000 to
3,500 rpm under no-load condition after
engine warmiAg up.
On non-4WD of non-California models:
After a lapse of 8 minutes or more of
engine start with engine warming up.
No
r--_
Check if EGR valve moves when
vacuum [about -26.7 kPa
(-200 mmHg, - 7 .87 inHg) is
applied to EGR valve by hand
vacuum pump.
~ Yes
Yes
Both EGR valve and vacuum passage to
EGR valve are normal.
A3·277
Fig. 5-34
Check and repair vacuum
passage to EGR valve.
Either engine rough idling or engine stall occurs when
vacuum [about -26.7 kPa (-200 mmHg, -7.87 inHg)]
is applied to EGR valve by hand vacuum pump after
engine warming up.
On non-4WD of non-California models:
Mter a lapse of 8 minutes or more of engine start
with engine warming up.
No
1----1
Clean or replace exhaust gas passage parts.
(Refer to b. Exhaust gas passage cleaning.)
EMISSION CONTROL SYSTEM
a. EGR valve cleaning
CAUTION:
Do not wash valve ASSY in solvents or
degreaser as permanent damage to
valve diaphragm may result.
(l) Hold the valve ASSY in hand,
then tap lightly on the sides and
end of the valve with a small plastic
hammer to remove the exhaust
deposits from the valve seat. Empty
loose particles. DO NOT PUT IN A
VISE.
(2) With a wire wheel or deposit
cleaning tool, buff the exhaust
deposits from the mounting surface
and around the valve.
(3) Depress the valve diaphragm and
look at the valve seating area
through the valve outlet for cleanliness. If valve and/or seat are not
completely clean, repeat Step (1).
(4) Look for exhaust deposits in the
valve outlet. Remove built-up deposite with a screwdriver.
(5) Blowout small particles and dust
remaining with air hose.
(6) Check EGR valve operation by
applying -26.7 kPa (-200 mmHg,
-7.87 inHg) vacuum with hand
vacuum pump. If valve does not
open completely, replace EGR
valve with a new part.
present, (more than 5 to 10%
blockage of the passage), remove
EGR pipe. Tap lightly on the sides
of the EGR pipe with a small
plastic hammer to loosen exhaust
deposits. Remove loose exhaust
deposits by blowing through EGR
pipe using compressed air. Reassemble EGR pipe.
(4) Inspect and clean EGR valve as
required (See a. EGR valve cleaning).
Cap
<,J()~-
Thermo vacuum
valve HI
A10·106
Fig. 5-36
2) Thenno vacuwn valve (I)
1) Connect vinyl tubes to output
ports to air cleaner and EGR valve,
and plug the output port to distributor
with a cap. Blow air into the valve as
shown in the illustration, and confirm
that the valve opens or closes in
response to intake manifold wall
temperature as specified.
Thermo vacuum valve (I) should be
open below 30°C (86°F) completely
and close above 40°C (l04°F) completely. If out of specification, replace
it with a new one.
NOTE:
Do not allow water to get into thermo
vacuum valve (I).
2) Connect vinyl tubes to output
ports to EGR valve and distributor,
and plug the output port to air cleaner
with a cap. Blow air into the valve as
shown in the illustration, and confirm
that the valve opens or closes in
response to intake manifold wall
temperature as specified,
Vinyl tube
•
NOTE:
When reassembling EGR valve, replace
EGR valve gasket with a new ORB.
Vinyl tube
,-----1 •
@
To air
cleaner
To E.G.A.
valva
Cap --Hl--:lIIrI /I
b. Exhaust gas passage cleaning
(1) Inspect EGR gas inlet to intake
manifold for presence of deposits.
Remove any deposits present with a
hooked awl taking care to minimize
the amount of material falling into
the intake manifold.
DO NOT USE AN ELECTRIC
DRILL.
(2) Remove all deposit material using
a vacuuming device.
(3) Examine EGR Gas Inlet for ex·
haust deposits. If excess deposits
.To
Jrr=::::i
distributor
~r-t-
Thermo vacuum
=:;~r;:;;;;:e:= valve
(j)----\lt+_
m
A10·107
Fig. 5-37
1 Wax
2 Valve
3 Spring
4 Valve seat
A10-105
Fig.5-35 Thermo vacuum valve (I)
Thermo vacuum valve (I) should be
open above 20°C (68°F) completely
and close below 10°C (50°F) completely.
EMISSION CONTROL SYSTEM
3) Solenoid valve II
Check the resistance between
(+) and (-) terminals.
Standard resistance:
32.7 39.9il
NO
YES
Check the resistance between
(+) or(-) terminal and body.
Standard resistance:
1Mil or more.
1 Screw
2 Control valve assy
3 Valve seat
4 Reed valve assy with gasket
5 Reed valve cover
NO
6 D·ring
YES
Check the vacuum passage for
opening and closing operation
while applying electric current
on both (+) and ( -) terminals.
NO
YES
NOTE:
Usually (when the current is OFF), the
plunger is forced upwards by the
.spring force to close the passage
'between ® and @.
When the current is ON in the solenoid, the plunger is attracted downwards to open the passage between
® and @.
To air cleaner
vacuum
valve I
@E~~
,
To ECM
A10·194
Fig.5-38 Solenoid valve II
2) AI System
1) ASV
1) ASV I with cutoff valve (Nippon
Denso)
a. Disassembly
(I) Separate the control valve ASSY,
valve seat, and reed valve cover by
removing 3 screws.
(2) Remove the reed valve ASSY and
gasket from the inside of the valve
cover.
(3) Remove the O-ring from the control valve ASSY.
b. Inspection
(1) Control valve ASSY
Apply a vacuum to the vacuum
inlet pipe to determine if the con·
trol valve operates normally.
A10·156
Fig. 5-39 ASV I with cutoff valve
(Nippon Denso)
(2) O-ring
Check for scratches, cracks, etc.
(3) Reed valve ASSY and gasket
• Gasket
Check for damage and cracks.
• Reed valve ASSY
After washing with gasoline,
check the ASSY to ensure that
it is free of the following defects:
a) Waves, cracks, or dents in the
reed valve seat.
b) A cracked or broken pOint of
the reed valve.
c) A rusty stopper.
c. Assembly
Assemble in the reverse order of
disassembly.
2) ASV I with cutoff valve (NOK)
a. Disassembly
(I) Separate the control valve ASSY
and reed valve cover by removing
3 screws.
(2) Remove the reed valve ASSY and
gasket from the inside of the valve
cover.
b. Inspection
(I) Control valve ASSY
Apply a vacuum to the vacuum
inlet pipe to determine if the con·
trol valve operates normally.
(2) Reed valve ASSY and gasket
• Gasket
Check for damage and cracks.
• Reed valve ASSY
After washing with gasoline,
check the ASSY to ensure that
it is free of the following defects:
a) Waves, cracks, or dents in the
reed valve seat.
b) A cracked or broken point of
the reed valve.
c) A rusty stopper.
c. Assembly
Assemble in the reverse order of
disassembly .
1
2
3
4
Screw
Control valve ASSY
Reed valve ASSY with gasket
A10.195
Reed valve cover
Fig. 5-40 ASV I with cutoff valve
(NOK)
EMISSION CONTROL SYSTEM
3) ASV II and III without cutoff
valve (NOK)
a. Disassembly
(1) Separate inlet case from outlet
case by removing 3 screws.
(2) Remove reed valve ASSY and
gasket from the inside of outlet
case.
b. Inspection
(l) Inlet case and outlet case
Check for damage and cracks.
(2) Reed valve ASSY and gasket
• Gasket
Check for damage and cracks.
• Reed valve ASSY
After washing with gasoline,
check the ASSY to ensure that
it is free of the following defects:
a) Waves, cracks, or dents in the
reed valve seat.
b) A cracked or broken point of
the reed valve.
c) A rusty stopper.
c. Assembly
Assemble in the reverse order of
disassembly.
ASV case
A10-197
Fig. 542 ASV II without cutoff valve
(NOK)
ASVcase
Screw &
f,
~
I
washer~
A10-196
Fig, 541 ASV III without cutoff valve
(NOK)
NOTE:
2) Solenoid valve I
Check the resistance between
(+) and ( -) terminals.
"t
Standard resistance:
32.7 - 39.90
So'
Usually (when the current is OFF), the
plunger is forced upwards by the
spring force to close the passage
between @ and @, and to open
the passage between @ and ©,
When the clurrent ~s ON in thde solenoid, the p unger IS attracte down.:
wards to open the passage b~n'
@ and @, and to close the passage
between @ and ©.
NO
YES
Check the resistance between
(+) or (-) terminal and body.
NO
Standard resistance:
IMO or more.
I
Replace
J
To intake manifold
®t
YES
Check the vacuum passage for
opening and closing operation
while applying electric current
on both (+) and (-) terminals.
J
Valve seat
®
Plunger
To cutoff k~=illi!
Spring To electronic
ll1l'diL''''=,,''''
valve
NO
Valve seat
YES
l Normal J
Al0-1S7
Fig. 543
.
J
EMISSION CONTROL SYSTEM
3) Check valve II
duty ratio according to the operating
condition.
Note that the duty changes from time
to time, being controlled by various
sensors. Accordingly, if the duty for
the duty solenoid valve is improper,
some malfunction occurs in the car.
Described below are the main points
of troubleshooting the ECC system.
®@@
\
I) Confirm that there is no air flow
from the carburetor side to the distribu tor side.
2) Confirm that there is air flow
from the distributor side to the carburetor side.
I
CD
To distributor
1 Valve
2 Spring
I) Self-diagnosing function
1 Intake manifold
2 Air passage
3 Anti·afterburning valve
4 Vacuum line
5 Ball
.11===
A10-108
Fig. 544 Check valve
This system has a self·diagnosing func·
tion. When trouble occurs, the ECS
(Electric Control System) lamp is
illuminated and the trouble code is
displayed on the O2 monitor lamp in
Morse Code.
A10-198
Fig. 545 Anti-afterburning system
3) Ignition Control System
2) Changeover from regular mode to
test mode
1) Thermo vacuwnvalve (I):
Refer to "EGR system".
2) Check valve (II):
Refer to "AI system".
1) Outline
4) Anti-afterburning System
The air-fuel ratio in the carburetor is
compensated by turning ON or OFF
the compensation air circuit of the
duty solenoid valve at an appropriate
1) Air passage hose
Check hose and its connection for
leakage and looseness. If leakage is
found, replace it with new one.
The self.diagnosing function is available in two modes: Regular Mode and
*Test Mode. It is automatically
changed over to the test mode by
connecting the test mode connector.
(The test mode connector must always
be disconnected after tests.)
* Test mode is a special mode pro·
vided for the dealer to perform selfdiagnosiS quickly.
5. Troubleshootinc for
ECC System
2) Vacuwn line
Check vacuum line for leakage and
looseness as foJlows.
1) Disconnect the vacuum hose from
AAV, then run the engine.
2) Confirm that air is sucked into the
vacuum hose.
3) If not, vacuum line is defective.
3) AAV
Holding a paper under the AAV, run
engine up to 3,000 rpm then close the
throttle valve quickly. If the paper is
sucked at this moment, the AAV
operates normally. If not, the AAV is
defective. Replace it with new one.
3) Relations between self-diagnosis,
ECS lamp, and O2 monitor lamp
[~
ECS lamp
O2 monitor lamp
Diagnosis
in
progress
Diagnosis result on display
Regular mode
Test mode
OK
NG
OK
NG
OFF
OFF
ON
Flickers
ON
O2
monitor
O2
monitor
Trouble
code
O2
monitor
Trouble
code
EMISSION CONTROL SYSTEM
4) How to see trouble code
Example: 23
10th digit
Unit digit
Paule
Repetition
,..--_"'1'0_--..,. r,..-........~-_'~r. . -------"A.------.. .,
ON
(0, monitor)
OFF
(Unit: sec.l
A-0.3
8-0.2
curred, ell their trouble cod.. are
displayed repeatedly in numerical
order.
NOTE:
The trouble code is displayed
repeatedly.
b. When multiple probleml have oc·
L
2) Requisites for Checking and
5) List of trouble codes
Trouble
code
Their Usages
Item
Remarks
12
11
22
Carter carbo (sea level mode)
Carter carbo (hlah altitude mode)
ignition pulse IYS. (NG)
(En&tne in OFF)
~
Hitachi carbo (sea level mode)
i-
21
Hitachi carbo (blah altitude mode)
23
0 , sensor sY" (NG)
32
Thermo sensor 'YI. (NG)
14
Vacuum switch I remainlOFF
41
Vacuum switch I remains ON
24
Vacuum switch II remain. OFF
42
Vacuum switch II remains ON
13
Duty solenoid valve remains OFF
31
Duty solenoid valve remains ON
25
Solenoid valve I remainlOFF
52
Solenoid valve I remains ON
15 ..
b. Be lure to turn OFF the ignition·
starter switch before replacing a
defective part, and reconnect the
hOlD and connectors completely
after that.
} I. I... mod••""
Fig. 5-46 MeaBuring voltage
(in engine room)
Solenoid valve III remain. OFF
51
SOlenoid valve III remain& ON
34
Auto choke power remain. OFF
43
Auto choke power remaina ON
33
Main Iystem in feedback system (NG)
6) The self.diagnosing functions for
the EGR system and shift.up control
system are not provided. So one must
carry out checks and make repairs
according to the troubleshooting flow
chart contained herein.
In the section "3) Troubleshooting
chart", requisites for checking and
their usages are as follows.
1) A circuit tester
a. A circuit tester is used to measure
voltage and resistance between
terminals of check connectors (I ,..,
IV) with it connected or disconnected.
In te.t mode only
NOTE:
ao Before performing the troubleshooting, check if the raspective
connectorl, air hollS and vacuum
hollS are connected property, end
also check all Plrts and electric
wirings for scratch.. or damage.
1 Check connector (III)
2 Check connector (IV)
3 Test mode connector
4 ECM
S 0 , monitor lamp
Fig. 5-47 Mflllwring voltage
fir, passenger room}
A10-200
..::-$-....,.;',......-'---~A':
EMISSION CONTROL SYSTEM
Check connector
m
f,ITj
tiliJ
NOTE:
NOTE:
Be sure to insert test bar from the'
harness side of the check connector.
a. Connector terminal for the CoW
solenoid valve is the same as that
for Hitachi',.
b. Be sure to insert test bars fr 1IIe
harness side of the connect"
(Wrong)
(Pink)
c. A circuit tester is used to measure
resistance of vacuum switches after
disconnecting their connectors.
Check connector (II)
~
~
(Pink)
A10·202
Fig. 549
Check connector (III)
b. A circuit tester is used to measure
resistance of duty solenoid valves
after disconnecting their connectors.
(Brown)
• Hitachi carburetor
Check connector (IV)
1 Connectors
1 Vacuum switch (0)
3 Vacuum switch (I)
(Pink)
\
1 To solenoid valve II (Y IL)
2 To high altitude signal (G)
3 To auto choke (0.85-L)
4 To fuel pump (O.85-L/R)
5 To selection for carburetor (LIB)
6 To ignition switch (O.85-B/W)
7 To kick-down solenoid valve (0.85-L/R)
8 To duty solenoid valve (Y /R)
9 To thermo sensor (W/B)
10 To ground (B)
II To ground for control (B/R)
12 To ground (B)
13 To trouble code (R)
14 To warning lamp (R/L)
15 To test mode (G/W)
16 To ignition switch (0.85-B/W)
17
solenoid valve II (Y /L)
18 To selection for carburetor (L/B)
19 To duty monitor (L/W)
20 To thermosensor (W/B)
21 To kick-down solenoid valve (0.85-L/B)
22 To power supply for ECM (B/Y)
23 To 0, sensor monitor (R/W)
24 To vacuum switch (1) (R/Y)
25 To vacuum switch (II) (G/B)
26 To solenoid valve III (L/R)
27 To auto choke relay (R/G)
28 To kick-down relay (L/G)
29 To solenoid valve I (L/Y)
to
30
A10·201
Fig. 548 Temrinals of check
connector
Duty solenoid"
valve (main)
2 Duty solenoid
valve (slow)
3 Connectors
,
Fig.5-53 Vacuum switches and
connectors
A10-141
Fig. 5-50 Duty solenoid valves and
connectors
Vacuum switch UI
To ground (S)
Duty solenoid valve (main or slow)
(+) (B/W)
A 10.()94
To ECM (Y/R or Y/GI
To ECM (R/Y)
A10-12S
Fig.5-51 Connector terminal of duty
solenoid valves
• CoW carburetor
A10-127
Vacuum switch
lB.
To ground IS)
To ECM (GIS)
1 Feedback solenoid valve
2 Connector
A10-142
Fig. 5-52 Duty solenoid valve and
connector
5-24
A10-128
Fig. 5-54 Connector terminals of
vacuum switches
EMISSION CONTROL SYSTEM
NOTE:
Be sure to insert test bars from the
harness side of the connector.
0, sensor cord
2) A stethoscope or a vinyl tube
A stethoscope or a vinyl tube is used
to check if there is operating sound
from duty solenoid valves.
A5-680
A10·203
Fig. 5·56
A10-129
Fig. 5·55
3) A dry cell
A dry cell, connecting plus (+) terminal
of it to O2 sensor wiring and minus (-)
one to earth instead of O2 sensor, is
used to check O2 sensor and its wiring
for defect.
NOTE:
When replacing oxygen (0 2 ) sensor,
remove or tighten it by using a special
tool (Socket; 499990100).
Fig. 5·57 Rep/acing O2 sensor
• NOTE FOR TROUBLESHOOTING
CHART:
1. Check the connector while itia
connected unless specified oUter·
wise.
2. Be sure to check again from the
beginning in order to prevent
secondary trouble caused by repair
work.
3. When checking with the vacuum .
hose disconnected from the vaclltmEl
switch at EtG on, be
the hose.
EMISSION CONTROL SYSTEM
3) Troubleshooting Chart
Wann up engine until
coolant temperature
rises to about 70°C
(158°F).
YES
EMISSION CONTROL SYSTEM
E/GON
(AT or non4WD
NO
of non-California
vehicle only)
>----1 F
,
Check if
voltage between
eck connector's kick·
down signal tenninal
(i?~) and earth tenninal
for drive (8) is
below IV.
Keep idling for over
1 second
Make kick-down
twice
(AT vehicle only)
YES
Wann up engine at
over 2,500 rpm
Check if
voltage between
check connector's
solenoid valve II tenninal
IL) and earth tenninal
for drive (8) is
over lOY.
YES
NO
(Non4WDof
non-California
vehicle only)
IG ON, E/G OFF
(AT or non4WD
Confinn trouble
code.
Make sequential
checks of trouble
code.
of non-California
vehicle only)
YES
E/GOFF
Check if
voltage between
check connector's kick·
down signal tenninal
i?~) and earth tenninal
for drive (8) is
over lOY.
Disconnect test mode
tenninal.
System OK
Check if
voltage between
check connector's
solenoid value II tenninal
IL) and earth tenninal
for drive (8) is
below 2V.
(Non4WDof
non-California
vehicle only)
YES;~-
EMISSION CONTROL SYSTEM
IGOFF
Check if
resistance between
check connector's
ground terminal for
control (B/R) and
body is below
lOll.
NO
Repair open
harness.
Check if
voltage between
check connector's
carb selection terminal
(LIB) and ground
terminal for control
(B/R) is below
2V.
NO
IGOFF
Check if
resistance between
check connector's
ground terminal for
drive (B) and
body is below
lOll.
NO
Repair open
harness.
rt
YES
Check if
resistance between
check connector's
carb selection terminal
(LIB) and ground
terminal for control
(B/R) is below
lOll.
NO
Replace ECM.
-'
h
YES
IGON
Check if
voltage between
check connector's
ECM power supply
terminal (B/Y) and
ground terminal
for drive (B) is
over IOV.
Check if
voltage between
check connector's
warning lamp terminal
(R/L) and ground
terminal for drive
(B) is over 7V
Repair shorted carb
selection (LIB) circuit
harness.
NO
>----11
NO
Check power
source, IG relay,
and harness.
Replace ECM.
Check if
voltage between
check connector's
carb selection terminal
(LIB) and ground
terminal for control
(B/R) is over
2V.
YES
NO
Replace ECS lamp_
Repair open
warning lamp
circuit harness.
Repair open carb
selection (LIB) circuit
harness.
Replace ECM.
EMISSION CONTROL SYSTEM
Check if
voltage between
check connector's
high-altitude signal
tenninal (G) and
ground tenninal for
drive (B) is
below 2V.
NO
Improper
installation of
high-altitude kit.
Repair.
Check if
fuel pump
operates.
NO
Repair open IG
pulse (Y) circuit
harness.
YES
E/GOFF
YES
Disconnect ECM
connector.
Repair open high-altitude
signal (G) circuit harness,
or replace ECM.
IGON
ECSlamp
comes on.
YES
Check if
voltage between
check connector's
high-altitude signal
tenninal (G) and
ground tenninal for
drive (B) is
below 2V.
Warning lamp (R/L)
circuit harness shortcircuited; repair.
NO
YES
IGOFF
Check if
esistance betwee
check connector's
high-altitude signal
tenninal (G) and
ground tenninal for
drive (B) is
below IOn.
YES
High-altitude signal (G)
circuit harness shortcircuited. Repair.
Replace ECM.
-~I
Replace ECM.
II
EMISSION CONTROL SYSTEM
Check if
voltage between
kick-down relay
connector (L/R) line
and car body is
over lOY.
Check if
voltage between
kick·down relay
connector (B/W) line
and car body is
below IV.
YES
Repair broken kick-down
(L/R) circuit harness.
YES
Disconnect kick-down
relay connector.
NO
Check if
resistance between
kick·down relay
connector (L/G) line
and car body is
below In.
NO
Check power source.
Check if
voltase between
kick-down relay
connector (L/G) line
and car body is
below 2V.
YES
ick-down relay
IGOFF
YES
Replace ECM.
Kick-down relay (L/G)
circuit harness broken .
. Repair.
5-30
YES
Kick·down (L/R) circuit
harness short-circuited.
Repair.
EMISSION CONTROL SYSTEM
NO
Disconnect solenoid
valve II connector.
YES
Replace solenoid
valve II.
NO
NO
Check power
source.
Solenoid valve II
(YIL) circuit
harness broken.
Repair.
Replace ECM.
Check if
voltase between
kick-down relay
connector (L/G) line
and car body is
below 2V.
Disconnect solenoid
valve II connector.
NO
Replace kickdown relay.
YES
I""l
X
YES
Replace ECM.
NO
DiSCOMect ECM
connector.
Disconnect ECM
connector.
NO
.f
Replace solenoid
valve II.
Kick-down relay
(L/G) circuit
harness shortcircuited.
Repair.
Check if
resistance betwee
check COMector's
solenoid valve II
(YIL) and sround
tenninal for drive
(8) is below
1On.
NO
Replace ECM.
Solenoid valve II
(YIL) circuit
harness shortcircuited.
Repair.
EMISSION CONTROL SYSTEM
Trouble code 23
E/G OFF
IGON
Disconnect cord from
O2 sensor.
,...,
Connect dry cell <±l pole
to O2 sensor cord and
e pole to car body.
r'"
%
!
Check if
voltage between
check connector's
O2 monitor (R/W)
and ground terminal
for control (8/R)
is over 2V.
Check if
voltage between
check connector's
0 1 monitor (R/W)
and ground terminal
for control (8/R)
is below 1V.
YES
0 1 sensor defective.
Replace.
NO
Repair open 0 1 sensor
cord.
YES
O2 sensor cord short·
circuited. Repair.
YES
Remove dry celL
Check if
resistance between
O2 sensor cord and
car body is
below IOn.
NO
Replace ECM.
EMISSION CONTROL SYSTEM
Trouble code 32
Check if
voltage between
check connector (IIIrs
thermo sensor terminal
(W IB) and ground
terminal for control
(B/R) is over
IV.
YES
Connect check
connector (U)'s thermo
sensor (W/B) to ground
terminal for drive (B).
NO
Disconnect thermo sensor
connector.
Check if
voltage between
check connector (III)'s
thermo sensor terminal
(W/B) and ground
terminal for control
(B/R) is over
IV.
NO
Check if
voltage between
check connector (Il)'s
thermo sensor terminal
(W/B) and ground
terminal for drive
(B) is below
O.2V.
YES
[ Replace thermo sensor.
NO
E/GOFF
Check if
resistance betwee
check connector (IIl)'s
thermo sensor terminal
(W/B) and ground
terminal for control
(B/R) is over
IOn.
YES
Replace ECM.
NO
Thermo sensor (W/B)
circuit harness shortcircuited. Repair.
NO
Repair open thermo sensor
(W/B) circuit harness.
EMISSION CONTROL SYSTEM
Trouble code 14
Disconnect vacuum
switch (I) (V/sw (I)
hose and stop it with
blind plug.
OK
,..,
Check if
voltage between
check connector's
Vlaw (I) (R/Y) and
terminal (B/R) is
below IV.
Replace ECM.
NO
Check if
voltage between
both terminals of
Vlaw (I) connector
is below
IV.
r
h
NO
YES
Repair open V/lw (I)
(R/Y) circuit harness.
NO
Replace VI sw (1).
5-34
EMISSION CONTROL SYSTEM
Trouble code 41
Disconnect V Isw (I)
connector.
YES
NO
YES
E/GOFF
NO
Check if
resistance between
check connector's
V/sw (I) tenninal
(R/Y) and ground
tenninal for control
(8/R) is below
Ion.
NO
II
Check vacuum hose line.
YES
VIsw (I)(R/Y)
circuit harness
short-circuited.
Replace.
Replace ECM.
,...,
r-
X
EMISSION CONTROL SYSTEM
Trouble code 24
Check if
voltage between
check connector's
V Isw (II) terminal
(G/8) and ground
terminal for control
(8/R) is below
Replace ECM.
%
IV.
Check if
voltage between
both terminals of
V Isw (II) connector
is below
...,
Repair open VIsw (II)
(G/B) circuit harness.
IV.
Check vacuum hose line.
YES
fteplace V/sw (II).
5-36
..
EMISSION CONTROL SYS"rEM
Trouble code 42
Disconnect V/sw (II)
hose and stop it with
blind plug.
OK
NO
Disconnect VIsw (II)
connector.
Replace V/sw (II).
E/GOFF
r-t
Check if
sistance between
check connector's
V/sw (II) tenninal
(G/B) and ground
tenninai for control
(B/R) is below
100.
NO
Replace ECM.
YES
V/sw (II) (G/B) circuit
harness short-circuited.
Repair.
%
...
- - - _....
_ _-----..
---~-.-
---~-
EMISSION CONTROL SYSTEM
Trouble code 13
Trouble code 25
IGOFF
IGOFF
Disconnect duty solenoid
connector.
Disconnect solenoid
valve I connector.
YES
YES
Replace solenoid
valve I.
Replace duty
solenoid.
.~.
NO
NO
Replace HeM.
Replace HeM.
Trouble code 15
IGOFF
Disconnect solenoid
valve III connector.
YES
Replace solenoid
valve III.
NO
·R.eplace ECM.
5-38
.....- - - -
EMISSION CONTROL SYSTEM
Trouble code 31
IG ON, EIG OFF
Disconnect duty solenoid
connector.
Check if
voltage between
duty solenoid connector
(B/W) line and car
body is below
2V.
YES
Check power source.
NO
IGOFF
Check if
resistance between
both terminals of duty
solenoid is over
lOOn.
NO
Check if
resistance between
. duty solenoid terminal
and car body is
below IOn.
YES
>---------,
!'
YES
Replace duty solenoid.
[I I Im~l ~
NO
Duty solenoid (Y/R)
circuit harness is broken.
Repair.
5-39
EMISSION CONTROL SYSTEM
Disconnect ECM
connector.
Check if
resistance between
duty solenoid connector
(Y/R) line and car
body is below
Ion.
NO
YES
Duty solenoid (Y/R)
circuit harness short·
circuited. Repair.
Replace ECM.
5-40
EMISSION CONTROL SYSTEM
Trouble code 52
IG ON, EtG OFF
Disconnect ECM
connector.
,..,
Check if
voltage between
check connector's
solenoid valve I terminal
(LtY) and ground
terminal for drive
(B) is below
2V.
......
X
NO
Disconnect solenoid
valve I connector.
YES
Check if
resistance between
both terminals solenoid
valve I is below
IOn.
NO
Replace ECM.
Check if
voltage between
solenoid valve I
connector (LtY) line
and car body is
below 2V.
Check if
voltage between
solenoid valve I
connector (BtW) line
and car body is
below2V.
NO
Solenoid valve I (LtY)
circuit harness broken.
Repair.
NO
>----------.
rr=================~
YES
Replace solenoid
valve I.
EMISSION CONTROL SYSTEM
Disconnect solenoid
valve I connector.
YES
Check power source.
Check if
resistance between
solenoid valve I
tenninal and car
body is below
Ion.
YES
Replace solenoid valve I.
NO
Solenoid valve I (L/y)
circuit harness short·
circuited. Repair.
5-42
EMISSION CONTROL SYSTEM
Trouble code 5 I
IG ON, E/G OFF
Disconnect ECM
connector.
..
1""1
Check if
voltage between
check connector's
solenoid valve III
terminal (L/R) and
ground terminal for
drive (D) is
below 2V.
X
NO
Disconnect solenoid
valve III connector.
YES
Check if
resistance between
both terminals of
solenoid valve III
is below
IOn.
NO
Replace ECM.
Check if
voltage between
solenoid valve HI
connector (L/R) line
and car body is
below 2V.
Check if
voltage between
solenoid valve III
connector (D/W) line
and car body is
below 2V.
NO
Solenoid valve III (L/R)
circuit harness broken.
Repair.
NO
Replace solenoid
valve III.
YES
Replace solenoid
valve III.
EMISSION CONTROL SYSTEM
Disconnect solenoid
valve III connector.
YES
Check power source.
NO
YES
Replace solenoid
valve III.
NO
Solenoid valve III (L/R)
circuit harness short·
circuited. Repair.
•
5-44
EMISSION CONTROL SYSTEM
Trouble code 34
Check if
voltage between
check connector's
auto choke tenninal
(L) and car body is
over lOY.
YES
Replace ECM.
Check if
voltage between
PTC relay connector
(L) line and car body
is over lOY.
Check if
voltage between
PTC relay connector
(B/W) line and car
body is over
lOY.
YES
PTC (L) circuit harness
broken. Repair.
NO
Disconnect PTC relay
connector.
Check if
resistance between
PTC relay connector
(L) line and car body
is below SU.
NO
Check power source.
YES
PTC (L) circuit harness
short-circuited.
Repair.
EMISSION CONTROL SYSTEM
Check if
voltage between
PTC relay connector
(RIG) line and car
body is below
2V.
YES
Replace f'I'C relay.
NO
-,
,...
IGOFF
%
Check if
resistance between
PTC relay connector
(RIG) line and check
connector's f'I'C relay
tenninal (RIG) is
below 100.
NO
f'I'C relay (RIG) circuit
harness broken.
Repair.
YES
Replace ECM.
5-46
EMISSION CONTROL SYSTEM
Trouble code 43
IG ON, E/G OFF
Check if
voltage between
check connector's
auto choke terminal
(L) and ground terminal
for drive (B) is
below IV.
Replace ECM.
NO
Check if
voltage between
check connector's
PTC relay terminal
(RIG) and ground
terminal for drive
(B) is below
2V.
Replace PTC relay.
NO
IGOFF
Disconnect ECM
connector.
Check if
resistance between
check connector's
PTC relay terminal
(RIG) and ground
terminal for drive
(B) is below
IOn.
NO
Replace ECM.
Trouble code 33
I
Main duty system
malfunctioned.
Repair.
YES
PTC relay (RIG) circuit
harness short-circuited.
Repair.
EEEEB
EMISSION CONTROL SYSTEM
5-4. Evaporative Emission Control System
1. Schematic Drawing
Carburetor
vapor
line
Fuel separator
Vapor volume
Tank vapor line
Fuel tank
Tank fuel volume
A3-257
Fig. 5-58
2. Description
The evaporative emission control
system is employed to prevent evaporative fuel from being discharged into
ambient ~tmosphere. This system includes a canister, a two-way valve, a
fuel separator, their connecting lines
etc.
Gasoline vapor evaporated from the
fuel in the fuel tank is introduced into
the canister located in the engine compartment through the tank fuel line,
and is absorbed on activated carbon in
it. A two-way valve and a vapor
separator are also incorporated on the
tank vapor line.
The carburetor vapor line, connecting
between the carburetor float chamber
and the canister, is employed in addition to the tank vapor line. Gasoline
vapor evaporated from the float
chamber is inducted into the canister
through solenoid valve (II) at all
positions except "ON" and "START"
positions of ignition-starter switch.
I) Canister
The purge control valve on the canister
is controlled by carburetor vacuum.
When the purge control valve is
opened, the adsorbed vapor is introduced from the canister into the intake
manifold.
When the engine is not running, the
purge control valve is closed by the
return spring.
Gasoline vapor does not purge to
intake manifold within the specified
temperature [IS to 35°C (59 to 95°F)]
because the carburetor vacuum is
leaked.
2) Two-way valve
The two-way valve is located in the
fuel vapor line and functions to control the pressure in the fuel tank.
When the fuel tank pressure is positive
above a certain point, the valve A is
open to permit the fuel vapor to the
canister, and when the fuel tank pressure is negative below a certain point,
the valve B is open to introduce fresh
air into the fuel tank.
From carburetor
Purge vent
Vacuum release
orifice
0.4 mm (0.016 in) dia.
From fuel tank
Vacuum vent
To canister
Al0·084
Orifice
1.5 mm (0.059 in)
dia.
Fig.5-60 Two-way valve
Purge control valve
Activated
carbon
Fig. 5-59
A3-259
Filter
5-48
3) Fuel separator
The vapor separator is to prevent
liqUid fuel from flowing into the
canister in case of abrupt cornering,
etc.
EMISSION CONTROL SYSTEM
All models except Hatchback
4) Fuel filler cap with vacuum relief
valve
The relief valve is adopted to prevent
the development of vacuum in the fuel
tank which may occur in case of
trouble in the fuel vapor line.
In normal condition, the filler pipe is
sealed at @ and at the packing
pressed against the filler pipe end. As
vacuum develops in the fuel tank,
atmospheric pressure forces the spring
down to open the valve; consequently
air is led into the fuel tank controlling
the inside pressure.
Hatchback
To canister"
@
A1G-078
A1G-079
1 Fuel tank
2 Breathefhose
3 Vapor separator
Fig. 5-61
1 Seal
2 Filler cap
3 Spring
4 Valve
5 Packing
A10-205
Fig. 5·62
3. Inspection
Inspect evaporative emission control
system in accordance with chapter 2,
2-2, 11.
5-5. Special Tool
499990100
SOCKET
Oxygen (01 ) sensor
j
j
j
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j
j
j
j
j
j
j
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j
j
j
j
j
j
j
j
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j
j
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CHAPTER@
MANUAL TRANSMISSION AND
DIFFERENTIAL
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
SI BARI'
SPECIFICATIONS AND SERVICE DATA ...................
1. Specifications ....................................
2. Service Data .....................................
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1. Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2. On-car Service ...................................
3. Rem oval . . . . . . . . . • . . . . . . .. . . . . . . . . . . . . . . . . . . . . ..
4. Inspection.......................................
5. Installation......................................
MANUAL TRANSMISSION AND DIFFERENTIAL ............
1. Cross Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2. Component Parts .......•..........................
3. 0 n-ca r Service .. . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4. Dismounting.....................................
5. Removal........................................
6. Disassembly......................................
7. Inspection.......................................
8. Assembly .......................................
9. Installation......................................
10. Remounting .....................................
TRANSMISSION CONTROL SYSTEM ......................
1. Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2. Removal and Disassembly .........................•..
3. Inspection.......................................
4. Assembly .......................................
5. Installation......................................
TROUBLESHOOTING .................................
1. Clutch .........................................
2. Manual Transmission and Differential ....................
SPECIAL TOOLS ....................................
1. Clutch .........................................
2. Manual Transmission and Differential ....................
Page
6- 2
6- 2
6- 3
6- 7
6- 7
6- 7
6- 8
6- 9
6-12
6-13
6-13
6-15
6-24
6-25
6-26
6-29
6-32
6-34
6-42
6-59
6-62
6-62
6-64
6-65
6-65
6-67
6-70
6-70
6-73
6-75
6-75
6-76
MANUAL TRANSMISSION AND DI·FFERENTIAL
6·1. Specifications and Service Data
1. Specifications
~~
1600
1800
5-speed
4-speed
All models
except
Station
Wagon
5-speed
Type
Facing
Surface area
Disc
225 x 150 )( 3.5 mm
(8.86 )( 5.91 x 0.138 in)
lSI x 2cm '
(2S.1 x 2 sq in)
220 x 2 cm'
(34.1 x 2 sq in)
Woven asbestos
Compression thickness
Free thickness
7.8 mm (0.307 in)
8.5 mm (0.335 in)
8.8 mm (0.346 in)
Hub spline
21.5 )( 21 x 1.0
Type
Spring
Clutch
cover
Diaphragm
Outer diameter
Plate thickness
Setting load
168 mm (6.61 in)
1.96 mm (0.0772 in)
2.04 mm (0.0803 in)
2,942 N (300 kg, 662 Ib)
3,432 N (350 kg, 772lb)
Driving type of pressure plate
Strap plate type
the nut center located on the clutch
Clutch play At
fork end
,
0
.~
c
'"
~
Auxiliary transmission gear
ratio
(Tooth number of gear)
Front
reduction
gear
Filial
Transfer
Rear
, reduction
: gear
3 mm (0.08
3.666
(44/12)
3.666
(44/12)
(43/13)
(43/13)
3.636 (40/11)
2nd
2.157
(41/19)
2.157
(41/19)
1.950
(39/20
1.950
39/20)
1.950 (39/20)
3rd
1.266
(38/30)
1.266
(38/30)
1.266
(38/30)
1.266
(38/30)
1.193(37/31)
4th
0.885
(31/35)
0.885
(31/35)
0.885
(31/35)
0.885
(31/35)
0.769 (30/39)
5th
~
0.725
(29/40)
0.725
(29/40)
0.725
(29/40)
4.100
(19/10 x
41/19)
3.583
(23/12 x
43/23)
3.583
(23/12 x
43/23)
4.100
(19/10 x
41/19)
3lOH{101
High
Tooth number
3.700 (37/10)
3.889 (35/9)
Helical
1.000 (34/34)
Hypoid
3.900 (39/10)
18
13
Side gear
Pinion gear
Transmission oil capacity
3.583 (23/12 x 43123)
Hypoid
Type of gear
Gear ratio
(Tooth number of gear)
Type of gear
Gear ratio
(Tooth number of gear)
Type of gear
Type and number of gears
Rear
differential
--------
1.000
1.462
(22/19 x
24/19)
Low
Gear ratio
(Tooth number of gear)
Type and number of gears
Side gear
Tooth number
Pinion gear
4-forward
speeds with
synchromesh and
I-reverse
4-forward
speeds with
synchro·
mesh and
I-reverse
(dual-range)
lst
5-forward speeds with
synchromesh and
I-reverse
Final
Front
differential
0.12 in)
5-forward
speeds with
Iynchromesh and
I-reverse
Reverse
'"
'!:j
2
4-forward
speeds with
Iynchromesh and
I-reverse
Type
Transmission gear ratio
(Tooth number of gear)
i
200)( 130)( 3.5 mm
(7.87)( 5.12)( 0.138 in)
Material
§
.aU
4WD
Dual-range
4WD
Dry single plate
Dimension (Outer diameter )(
inner diameter x thickness)
Clutch disc
Station
Wagon
Straight bevel gear (pinion: 2, Side gear: 2)
14
10
Straight bevel gear
(Pinion: 2, Side gear: 2)
16
10
2.72 (2.9 US qt, 2.4lmpqt)
-
Rear differential gear oil capacity
6-2
3.02
(3.2 US qt, 2.6 Imp qt)
0.8(>
(0.8 US qt, 0.7 Imp qt)
I
MANUAL TRANSMISSION AND DIFFERENTIAL
2. Service Data
.::::
.....
.E!
u
<..}
Clutch pedal full stroke
Pad surface position of clutch pedal
Release fork stroke
Play at release fork center
Depth of rivet head
STD
Sinking limit
Aluminum gasKet thickness (Neutral position adjustment)
Part No.
Remarks
803922021
Neutral position approahces reverse gear side
037022000 Standard
803922022 Neutral position approaches 1st/2nd gear side
803922023 Neutral position approaches lst/2nd gear side
I::
.5:
'"
.~
6i
I::
e
.....
ca
~
~
Dimension 'C' of reverse accent shaft
Part No.
Mark
Contact clearance
for 1600
442747001
1
becomes smaller
442747002
2
442747003
442747004
4
5
442747005
442747006
6
becomes larger
for 1800
Part No.
Mark
442747101
I
becomes smaller
442747102
2
442747103
442747104
4
442747105
5
becomes larger
442747106
6
Transmission main shaft snap ring (out-22) thickness
Part No.
805022010
805022011
805022012
805022013
805022014
805022015
805022016
805022017
805022018
805022019
805022030
805022031
I
6-3
(5.08 5.39 in)
129 ~ 137 mm
Above brake pedalleveJ by 15 mm (0.59 in)
(0.67 - 0.71 in)
17 - 18 mm
2.0 ~3.0mm
(0.079 - 0.118 in)
(0.055 in)
1.4mm
(0.012 in)
0.3mm
O.5mm
1.0mm
L5mm
2.0mm
(0.020 in)
(0.039 in)
(0.059 in)
(0.079 in)
16.2 16.6
17.0 17.4 17.8
18.2 -
16.4 mm
16.8mm
17.2 mm
17.6 mm
18.0mm
18.4 mm
(0.638
(0.654
(0.669 (0.685
(0.701 (0.717
0.646 in)
0.661 in)
0.677 in)
0.693 in)
0.709 in)
0.724 in)
12.2 12.6 13.0
13.4 13.8 14.2 -
12.4 mm
12.8 mm
13.2mm
13.6 mm
14.0 mm
14.4 mm
(0.480 (0.496
(0.512 (0.528 (0.543 (0.559 -
0.488 in)
0.504 in)
0.520 in)
0.535 in)
0.551 in)
0.567 in)
2.45 mm
2.48mm
2.51 mm
2.54mm
2.57mm
2.60mm
2.63 mm
2.66mm
2.69mm
2.85mm
2.42mm
2.39mm
(0.0965 in)
(0.0976 in)
(0.0988 in)
(0.1000 in)
(0.1012 in)
(0.1024 in)
(0.1035 in)
(0.1047 in)
(0.1059 in)
(0.1122 in)
(0.0953 in)
(0.0941 in)
MANUAL TRANSMISSION AND 01 FFERENTIAL
Washer thickness (Washer to case wall clearance adjustment)
Part No.
803015081
803015082
803015083
803015084
803015085
Main shaft rear plate thickness
Dimension 'A'
for 1600
3.50 - 3.63 mm
(0.1378 0.1429 in)
0.6
1.0 1.4 1.8 2.2
0.8mm
L2mm
1.6 mm
2.0mm
2.4mm
(0.024
(0.039
(0.055
(0.071
(0.087
Part No.
441342112
Stamp
T71-2
5.0mm
(0.197 in)
441342113
3.37 3.50mm
(0.1327 0.1378 in)
for 1800
Dimension 'A'
Part No.
4.50 4.63mm
441347001
(0.1772 0.1823 in)
441347002
4.37 4.50mm
(0.1720 0.1772 in)
Synchronizer ring face to gear facing gap
T71-3
5.13 mm
(0.2020 in)
Stamp
T81-1
5.0mm
(0.197 in)
T81-2
5.13 mm
(0.2020 in)
STD
-
0.031
0.047
0.063
0.079
0.094
in)
in)
in)
in)
in)
1.5 mm (0.059 in)
1.0mm (0.039 in) ... High-low synchroring
of 4WD Dual-range
,-.,
Limit
"0
II""-'-~~-~''''-'---------
__''''_--_______.""'v...e_"""'---______________-
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
4WD
Non-4WD
---::s
'1:1
II)
.....5
c::
0
(,)
'-'
c::
0
'fa
.~
..
Type
Automatic shift control over 3 forward speeds based on intake-manifold
vacuum and output shaft speed
Fluid
Automatic transmission fluid (ATF)
Texamatic Fluid 6673 Dexron
TEXACO
Texamatic Fluid 6673 Dexron
CALTEX
CASTROL: Castrol TQ Dexron
BP Autran Dexron
BP
MOBIL
Mobil ATF 220
..
'0
....c::
0
(,)
.S:!
..
"3
'"
-g,
::c
:;
Fluid capacity
f-o
(,)
5.6 - 6.0£
(5.9 - 6.3 US qt, 4.9 - 5.3 Imp qt)
+:I
'"
....§
~
c::
.~
.. 0
6.0 - 6.4£
(6.3 - 6.8 US qt, 5.3 - 5.6 Imp qt)
(Including transfer section)
Forced feed lubrication with oil pump
Lubrication system
.0 .-
::s ....
~~
CooIing
Oil
Automatic transmission fluid (above-mentioned)
Cooling system
Liquid-cooled oil cooler incorporated in radiator
Transfer gear ratio
-
0.948 (37/39)
.
...
Transfer clutch
-
Hydraulic multi-disc clutch
~
Control method
-
Hydraulic remote control
E!::
Lubricant
-
The same Automatic transmission fluid
used in Automatic transmission
0.974 (38/39)
1.026 (39/38)
c::
0
.,;:
(,)
£
:;
lst reduction gear ratio
~
'E
-5'"cu
ec::
2nd reduction
gear ratio
Front drive
3.700 (37/10)
Rear drive
3.900 (39/10)
1.090 (12/11)
Governor gear ratio
0
+:I
(,)
::s
Speedometer gear ratio
-.;
Lubricating oil
..
'1:1
cu
.5
API. GL-5, 75W-80
1.2£ (1.3 US qt, 1.1 Imp qt)
Front drive
"-
3.272 (36/11)
3.181 (35/11)
Oil capacity
Rear drive
-
0.8£ (0.8 US qt, 0.7 Imp qt)
7-3
-~
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2. Service Data
1) Service Standard Value
Measuring location
Standard value
Idling speed (N or P position)
800 ± 100 rpm
Stall speed
2,100 - 2,300 rpm
Brake band adjusting screw
Turning screw back two turns after
tightening it to the torque of9 N'm
(0.9 kg-m, 6.5 ft-Ib)
Axial clearance between governor cover and governor body
0.2 - 0.8 mm (0.008 - 0.031 in)
Thickness
Facing
1.6 mm (0.063 in)
4
(Forward clutch)
3
(Reverse clutch)
Number
Thickness
Steel plate
Forward/Reverse clutch
2.0 mm (0.079 in)
4
(Forward clutch)
3
(Reverse clutch)
Number
Thickness
1.8 mm (0.071 in)
Warping
1.2 mm (0.047 in)
Forward clutch
1.0 - 1.5 mm (0.039 - 0.059 in)
....;::s
Reverse clutch
1.6 - 1.8 mm (0.063 - 0.071 in)
U
Thickness
2.3 mm (0.091 in)
Number
4
Wave height
0.18 mm (0.0071 in)
Thickness
1.8 mm (0.071 in)
Number
4
Dish plate
Clutch clearance
..c:u
Facing
Low and reverse brake
clutch
Steel plate
0.5 - 1.2 mm (0.020 - 0.047 in)
Clutch clearance
Thickness
2.9 mm (0.114 in)
Number
3
Thickness
1.8 mm (0.071 in)
Number
2
Facing
Transfer clutch
Steel plate
0.4 - 0.8 mm (0.016 - 0.031 in)
Clutch clearance
Q..
E
;::s
-0
Clearance between inner/outer gear and transmission cover
0.02 - 0.04 mm (0.0008 - 0.0016 in)
Clearance between cresent and tooth tip of outer gear
0.14 - 0.21 mm (0.0055 - 0.0083 in)
Radial clearance between outer gear and oil pump carrier
0.05 - 0.20 mm (0.0020 - 0.0079 in)
Clearance between seal ring and groove
0.04 - 0.16 mm (0.0016 - 0.0063 in)
Q..
Clearance between planetary carrier and planetary pinion washer
7-4
0.15 - 0.60 mm (0.0059 - 0.0236 in)
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
Standard value
Measuring location
Clearance between manual plate and spacer
0.3 mm or less (0.012 in or less)
Clearance between rear shaft and intermediate case
0- 0.3 mm (0 - 0.012 in)
>.
'"
0..
"C
I::
W
Total axial end play
0.25 - 0.50 mm (0.0098 -.0.0197 in)
Reverse clutch drum end play
0.50 - 0.80 mm (0.0197 - 0.0315 in)
Run-out at the tip of reduction drive gear shaft
0.08 mm or less (0.0031 in or less)
Starting friction torque of drive pinion
1.23 - 1.62 N·m
(12.5 - 16.5 kg-cm, 10.9 - 14.3 in-Ib)
Distance from the final reduction case face to the end face of the reduction
drive gear
19.6 - 19.8 rom (0.772 - 0.780 in)
Run-out of converter drive plate surface
0.5 mm or less (0.020 in or less)
2) Automatic Shift Characteristics
(Non-4WD)
Kic~ownr....
I
13.3
.~ (100.
, 3.941
t
~
:
I 02~
28.7
i
-; (200.
~ 7.871
'
I
I
~
Ii
0,.
r-- r---- ~02
0/
0, I...L 02
I
40.0
> (300.
I
53.3
(400.
03
HoI!
",ronle
" ....... ,2
I
/
15.751
throttle
"'I
V
I
02 +t03 02-J.Ol Full
/
y lY'
03
I
0'±~2 __
I
I
V.
:t,!
11.811
~02
1
I
l
kiling
66.7
(500
19.1181
10
(81
20
30
40
80
80
1121
1191
(251
(311
(371
80
70
(431
(801
80
(661
100
(821
Vohielo opood km/h (MPHI
Fig. 7-1 Automatic shift characteristics
A13-254
3) Line Pressure
1) Line pressure characteristics
kPo
(kg/em', Pli)
1.854
118.87.
fU\l"'~- --jR ...
-- --
240)
'.379
!
I
i
I
-
(14.oe.
200)
-----,
~.
1.'OJ
(11.25.
I
1801
.... 828(8.44.
'20)
2_ _
"i_m,!~_---'--------
Ml2 (5.83.
-
Full..........
80)
1J
0
...
Mln_-
278 (2.81.
40)
O~--~----~---'----------r----T-----
o
'8
(10)
32
48
(20)
(30)
94
(40)
80
(80)
98
(80)
km/h
(MPH)
A13-220
Fig. 7-2 Line pressure characteristics
7-5
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Line pressure in each range
Unit: kPa (kg/cm 2 , psi)
Throttle
Range
Full-throttle
[-4.0 - -6.7 kPa
(-30 - -50 mmHg, -1.18 - -1.97 inHg)]
Minimum-throttle
[-57.3 - -60.0 kPa
(-430 - -450 mmHg, -16.93 - -17.72 inHg)]
before cut-down
after cut-down
before cut-down
after cut-down
D
834 - 981
(8.5 - 10.0, 121 - 142)
539 - 637
(5.5 - 6.5, 78 - 92)
294 - 392
(3.0 - 4.0, 43 - 57)
294 - 392
(3.0 - 4.0, 43 - 57)
2
1,000 - 1,157
(10.2 - 11.8, 145 - 168)
579 - 677
(5.9 - 6.9, 84 - 98)
1,000 - 1,157
(10.2 - 11.8, 145 - 168)
579 - 677
(5.9 - 6.9, 84 - 98)
R
461 - 559 (4.7 - 5.7,67 - 81)
1,373 - 1,569 (14.0 - 16.0, 199 - 228)
3) Change of line pressure with intake manifold vacuum (N, D ranges)
NOTE:
a. Line pressures in each of 0, 2 and
R ranges will change in steps at
certain points (where pressure
modifier valve functions) and these
points are called "Cut-down point".
"Before cut-down" stated in the
above table implies slow driving
condition [less than 15.3 km/h
(9.5 MPH)] and "after cut-down"
implies the vehicle speed of more
than 35.4 km/h (22.0 MPH).
b. The line pressure during idling of
the engine corresponds to the oil
pressure before cut-down operation
with the minimum throttle.
Intake manifold vacuum:
-kPa (-mmHg, -inHg)
Line pressure: kPa (kg/cm 2 , psi)
37.3 (280, 11.02)
510- 588 (5.2 - 6.0, 74 - 85)
40.0 (300,11.81)
481 - 559 (4.9 - 5.7,70 - 81)
44.0 (330, 12.99)
441 - 520 (4.5 - 5.3,64 - 75)
46.7 (350, 13.78)
412 - 490 (4.2 - 5.0,60 - 71)
50.7 (380, 14.96)
363 - 441 (3.7 - 4.5, 53 - 64)
53.3 (400,15.75)
333 - 412 (3.4 - 4.2, 48 - 60)
57.3 (430,16.93)
314 - 363 (3.2 - 3.7,46 - 53)
60.0 (450,17.72)
314 - 324 (3.2 - 3.3, 46 - 47)
I
I'
7-6
I
III
tl>1
t M
"W'
,
f
r
11
t.
fl.t"
1
I
r
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
4) Location and Dimension of Adjusting Parts
A13-397
Fig, 7-3
No.
Part Number
Dimension mm (in)
Application
Retaining plate 2
444267001-8
7.2,7.4,7.6,7.8,8.0,8.2,7.0,6.8
(0.283,0.291,0.299,0.307,0.315,
0.323,0.276,0.268 )
Adjusting clearance of low and
reverse brake
Washer (21 dl.2 , I)
803021048
803021049
803021040
1.0,1.2,1.4
(0.039,0.047,0.055)
Washer(21 ,31.5, I)
803021044 - 7
1.6, 1.8,2.0,2.2
(0.063,0.071,0.079,0.087)
3
Retaining plate
456712900 - 6
5.0,5.2,5.4,5.6,5.8,6.0,6.2
(0.197,0.205,0.213,0.220,0.228,
0.236,0.244)
Adjusting clearance of reverse
clutch
4
Washer
452810100 - 6
1.9,2.1, 2.}, 2.5, 2.7,1.5, !.7
(0.075,0.083,0.091,0.098,0.106,
0.059,0.067)
Adjusting end play of reverse
clutch drum
5
Oil pump gear
16.00 - 15.99 (0.6299 - 0.6295)
15.99-15.98(0.6295-0.6291)
15.98 - 15.97 (0.6291 - 0.6287)
Adjusting side clearance of oil
pump
Adjusting drive pinion height
I
Part Name
2
Inner gear
434610100 - 2
Outer gear
434710100 - 2
Adjusting total end play
6
Shim 2
442182511-8
0.15, 0.175,0.20,0.225,0.25
(0.0059,0.0069,0.0079,0.0089,
0.0098)
0.275,0.30,0.50
(0.0108,0.QI18,0.0197)
7
Shim
441967001 - 3
0,6,0.8,1.0
(0.024,0.031,0,039)
Adjusting preload of drive
pinion bearing
8
Spacer
446107001 - 8
9,600,9.625,9.650,9.675
(0.3780,0.3789,0,3799,0.3809)
9.700,9.725,9.750,9.775
(0.3819,0.3829,0,3839,0.3848)
AdjustinB preload of drive
pinion bearing
9
VICUurn diaphr. rod
493210110 - 4
34,34.5,35,35.5,36
(1.339,1.358,1.378,1.398,1.417)
Adjustinaline pressure
10
Wuher(42 x 51 x I)
803242010 - I
0.2,0,5
(0.008,0.020)
Adjusti... end play of rear
drive shaft
II
Front pressure plate
447677000 - 4
4.7,5.0,5.3,5.6,5.9
(0.185,0.197,0.209,0.220,0.232)
clulch
7-7
Adjusting clearance of transfer
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
5) Backlash
Forward sun gear to Short
pinion
0.15 - 0.2imm
(0.0059 - 0.0087 in)
Reverse sun gear to Long
pinion
0.15 - 0.22 mm
(0.0059 - 0.0087 in)
Short pinion to Long
pinion
0.15 - 0.22 mm
(0.0059 - 0.0087 in)
Long pinion to Planetary
output gear
0.18 - 0.25 mm
(0.0071 - 0.0098 in)
Planetary gear
1st reduction gears
0.05 - 0.12 mm
(0.0020 - 0.0047 in)
2nd reduction gears
0.13 - 0.18 mm
(0.0051 - 0.0071 in)
Governor gears
0.30 - 0.81 mm
(0.0118 - 0.0319 in)
Speedometer gears
0.30 - 0.81 mm
(0.0118 - 0.0319 in)
Transfer gears
0.051- 0.125 mm
(0.0020 - 0.0049 in)
7-8
L- __ _
1i'
HIF
"~--I
•
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
7-2. Automatic Transmission and Differential
1. Cross Sectional View
® CD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Stator shaft
Impeller
Turbine
Stator
Turbine shaft
Torque converter
Oil pump drive shaft
Converter housing
Crown gear
Drive pinion
Reduction gear
Onl>-way clutch
Oil pan
Control valve
Connecting shell
Transmission cover
Oil pump
Reverse clutch
Brake band
Transmission case
Forward clutch
Center support
Low & reverse brake
Planetary gear
Parking gear
Governor drive shaft
Governor shaft
Onl>-way clutch
Final reduction case
A13-398
Fig_ 7-4
7-9
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
redluC1tiOll---¥-Transmission case section-..,.>------ Transfer case section - - - - - - - I
case section
1
2
3
4
5
6
7
8
9
10
Stator shaft
Impeller
Turbine
Stator
Turbine shaft
Torque converter
Oil pump drive shaft
Converter housing
Crown gear
Drive pinion
11 Reduction gear
12 Oil seal holder
13 One-way clutch
14
15
16
17
18
19
20
21
22
23
24
Control valve
Connecting shell
Oil pump
Oil pump carrier
Reverse clutch
Brake band
Transmission case
Forward clutch
Center support
Low & reverse brake
Planetary gear
25
26
27
28
29
30
31
32
33
34
35
Parking gear
Speedometer & governor drive gear
Governor shaft
Final reduction case
Oil pan
Transfer drive shaft
Transfer gear
Intermediate case
Transfer clutch
Rear drive shaft
Extension case
A13-399
Fig. 7-5
7-10
~>''''~"'.~"'''''~"''~"4'''"'_''''''-~J,.,~''''~"",,,",n"'f-""
_''''',...'..' '1"11_ _-
_ _ _- - _ ,...._ _ _.......""''''''''...
, _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _- -
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2. Construction
and Operation
1 4WD AT
1.
Construction
1) Overall Construction
The 4WD automatic transmission is
basically composed of the conventional SUBARU 1800 automatic transmission, the transfer gear and rear
wheel hydraulic driving clutch attached to the rear end of the transmission,
and the hypoid pinion and transfer
gear are connected by the transfer
drive shaft. The transmission route
of power is unchanged from that of
the SUBARU 1800 4WD model (with
manual transmission).
case and transmission case have been
changed thoroughly, and an oil seal
holder has been newly introduced in
the reduction drive gear portion. The
hydraulic clutch, planetary gear, control valve and other elementary components of the automatic transmission
section are unchanged from those of
the current automatic transmission.
3) Rear Drive Portion
1) Transfer
The transfer consists of a hydraulic
multi-disc clutch, transfer clutch valve
and solenoid, and these units are
housed in the extension case together
with the transfer gear.
Hydraulic multi-disc
Extension case
2) Front Drive Portion
The basic construction is unchanged
from the current automatic transmission. Along with the adoption of a 4
wheel drive system, the final reduction
Transfer gear
A13-401
A13-400
Fig. 7-6 Transfer
The current to the solenoid is controlled by the 4WD selector switch located on the selector lever.
4WD selector switch
(pushbutton type)
Selector lever
CHECKER
UNIT
l
Fuse
Ignition switch
4WD pilot lamp
(on instrument panel)
Fusible link
*
Checker unit is tightened together
with intermittent wiper unit by one
screw at the back of instrument
panel.
4WD selector valve
(4WD-FWD)
Battery
Fig. 7-7 Transfer clutch control system
Al3-402
7-11
•
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
and rear wheels will rotate at the same
speed.
2) Rear differential
The rear differential is unchanged
from the SUBARU 1800 4WD (manual type). The difference in gear ratio
with the front side differential is
adjusted by the transfer gear (gear
ratio 37/39 = 0.948) so that the front
discharge side and control valve. Along
with this change, the oil supply circuit
to the torque converter and the lubricating circuit to the clutch and planetary gear portions have been partially
modified.
3) Transfer clutch control circuit
The transfer clutch circuit and transfer
valve have been added to the line
pressure circuit between the oil pump
AT for 83 MY
AT for 82 MY and before
Transfer (4WD)
Torque converter
Oil
r---------,
Lubrication
to rear
portion
-r.:::::::;;t---I"""rr (c1 utches)
pump
I
Torque converter
Oil pump
I
I
Oil
cooler
Lubrication
X
Lubrication
to front
portion
(planetary
one-way
clutch)
portion
(planetary
one-way
clutch)
Pressure
regulator
X
Drain
'*
Restriction
valve1~~~~
A13-403
Fig. 7-8 Comparison of hydraulic circuits
4) Transfer valve
The transfer valve is an of-off valve
which opens and clbses the line pressure circuit to the transfer clutch, and
this valve is operated by the solenoid.
In the FWD mode, the solenoid push
rod and valve are set at the right side
by the spring positioned on the left
side, and the line pressure to the
clutch is disconnected.
If the solenoid is energized by depressing of the 4WD selector switch, the
push rod is activated and the valve is
pressed to the left against the pressure
of the spring. As the valve is moved,
the transfer clutch circuit opens while
the drain circuit closes, and the line
Transfer clutch
pressure is led to the transfer clutch
circuit to engage the transfer clutch.
Line pressure
A13-404
Fig. 7-9 Transfer valve
7-12
I
III
11"
.'''~4
fJ1"'---_______________
".-'1' 41-'' ' ' ' ' ' '_ _
1'''''''''''1t...,_____- - -__•...,q_ _
....... -." .....
-~
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
Transfer (4WD)
2. Operation
r - - - - - - - --,
Torque converter
1) Front Wheel Drive (FWD)
I
· .
Oil pumpl
L ub ncatlOn
I
to r~ar
I
• The line pre~sure to the transfer
clutch is disconnected by the transfer valve, and the clutch is kept in
the disconnected state.
• All power is transmitted from the
transmission to the front wheels
through the front hypoid gear.
During operation, both the drive
member and driven member of the
transfer clutch are rotating at the
same speed.
I
I
-F.~:t---,t-=;r-portlon
(clutches)
I
I
LL.;:::=;~ I
I
I
Oil
cooler
I
I
I
x
Lubrication
to front
portion
(planetary
one-way
clutch)
I
I
I
I
I
I
Closed
Transfer valve
I
I
L _______ J
Pressure X
regulator
valve
X
Manual valve
(line pressure)
X : Drain
..L : Restriction
T
A13-405
Fig. 7-10 Hydraulic circuit in FWD mode
Torque converter
Front differential
Front hypoid pinion
Oil pump Transfer clutch
Transfer drive shaft
Rear drive shaft
Extension shaft
A13-406
Fig. 7-11 Transmission of power in FWD mode
7-13
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) 4-wheel Drive (4WD)
Transfer (4WD)
r--------,
Torque converter
If the pushbutton on the selector lever
is set to the 4WD position from the
FWD position, the transfer valve opens
the circuit to the transfer clutch as the
solenoid is activated, and, at the same
time, the green 4WD pilot lamp illuminates on the meter panel.
The line pressure, led through; transfer
pipe .... intennediate case .... rear drive
shaft, connects the transfer clutch
(hydraulic clutch).
The power is branched to the front
and to the rear on the front hypoid
pinion. The power branched to the
rear from the shaft end of the pinion
is led through; transfer drive shaft
.... transfer gear .... transfer clutch ....
rear drive shaft .... propeller shaft ....
rear differential, and transmitted to
the rear wheels.
These characteristics have been established as being necessary to transmit
the power from the engine to the rear
wheels. If an excessive brake torque is
created on the front and rear wheels in
a tight cornering operation, the transfer clutch acts as a torque limitter
(that is, the clutch slips), and weakens
the braking torque, and also protects
the driving members. As shown in the
characteristic curve in the figure, the
torque limiting function is more effective when the line pressure is lower
(that is, when the throttle opening is
smaller).
Oil pump'
Lubrication
I
of rear
I
-F=:=::;=+--+f:""""'I1- portion
--~~~(clutch)
,
I
I
,I
J~~b'
I
Oil
cooler
I
I
I
x
I
I
I
Lubrication
of front
portion
(planetary
one-way
clutch)
I
I
I
:
Transfer valve
L ________
1..:::== -+
X :
J
I
Manual valve
(line pressure)
Drain
: } : Restriction
A13-407
Fig. 7-12 Hydraulic circuit in 4WD mode
Oil pump
Torque converter
Front hypoid pinion
Rear dr i ve shaft
/
Transfer drive shaft
Extension case
A 13-408
Fig. 7-13 Transmission of power in 4WD mode
3) Characteristics of Transfer
Clutch
The line pressure is applied to the
transfer clutch, and the clutch capacity varies, like the other hydraulic
clutches, with the throttle opening
and vehicle speed, as shown in the
characteristic curve in the figure.
Throttle
full open
A13-409
o
490 (5,71)
981 (10,142)
Line pressure kPa (kg/cm 2 , psi)
Fig. 7-14 Characteristics of the
transfer clutch (before
o range "cut down")
7-14
l __
II"-,,,_~:=::.-=-;},
..
TF_.,..._-__. .
w
....' ...
ffif...
• ...•.......
,,~~,"fj"'f
·-1flliii_ _ _...
"'i
....................-..." " , _.: ."':_ _ _ _'f
_ _ _ _ _ _ _ _ _ _ _ _ _ _- -
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3. Precautions for 4WD
automatic transmission
1) Be sure to use recommended
au tomatic transmission fluid (A TF).
The use of any other fluid may cause
chattering of the transfer clutch.
2) If the driving mode is changed
from 4WD to FWD while making a
turn, a light shock may be felt in the
vehicle body. This shock is caused by
the releasing of the tight corner
braking feature, and is a normal
phenomenon.
A similar shock may also be felt when
changing from 4WD to FWD after a
sudden stop.
3) If the pilot lamp remains off even
after operating the 4WD selector
switch, the 4WD operating electrical
circuit may be faulty; the circuit must
be checked and repaired.
4) If the front wheels must be engaged with the front end of the vehicle
jacked up, or on a roller, be sure to set
the 4WD selector switch to the FWD
position, or disconnect the transfer
solenoid harness connector in the
engine compartment.
Remember, if the switch is kept in
the 4WD position, the vehicle may be
moved as the engine is started.
When disconnecting the harness in the
engine compartment, use extreme care
not to confuse the connectors.
5) The use of different sized tires
will cause a shock when releasing the
4WD mode even when driving straight
ahead, or will result in deteriorated
fuel consumption. Be sure to use tires
of the same size on all of four wheels.
The tire inflation pressure must be set
to the specifications.
6) When attempting to get out of a
immobile state by switchback opera-
tion (switchover between "D" and
"R"), avoid racing the engine with
the lever set in the N position.
7) If the engine or transmission has
failed, the vehicle must be towed with
the front wheels lifted up. In such an
event, the 4WD selector switch must
be set in the FWD position.
A13-411
Fig. 7-15 Transfer solenoid harness
connector
2 LOCK UP TORQUE
CONVERTER
1. Construction
An installation drawing in which the
centrifugal lock up clutch is built into
the torque converter and a view of the
shoe section as seen from the front of
the engine are shown below.
This lock up clutch transmits torque
by the centrifugal force acting on the
shoes that slide along the inner circumference of the turbine cover. It has a
very simple construction, consisting of
five components: shoes and weights
with paper facings pasted on their
outer surfaces, two leaf springs (main
and retractor springs) and pins. Eight
shoes are used.
Centrifugal lock-up clutch
A13-413
Fig. 7-16
7-15
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
CD
@ @ @
1
2
3
4
5
Shoe
Main spring
Retractor spring
Weight
Pin
A13-414
Fig. 7·17
• Operation of each component
Shoe ... The shoe rotates at the same
speed as the torque converter turbine,
and slides along the inner circumference of the turbine cover. The shoe
sometimes becomes completely engaged with the turbine cover, however,
it usually slides in a half-clutch condition. The engine torque is transmitted
from the turbine cover through the
shoe to the reaction plate and then to
the output shaft. Paper is used for the
facing.
Weight ... Using the centrifugal force
produced by the rotation of the
weight, the clutch transmits torque.
The weight's primary purpose is to
increase the transfer torque capacity
in the medium- and low-speed ranges.
Main spring '" The centrifugal force
acting on the weight is transmitted to
the shoe through the main spring. In
the medium- and low-speed ranges, the
load of the spring increases in proportion to the centrifugal force of the
weight, so that torque capacity also
increases. In the medium- and highspeed ranges, however, the spring load
becomes constant regardless of the
centrifugal force of the weight, functioning as a torque limiter.
Retractor spring '" This spring always
functions to pull the shoe inward,
which, in the low-speed range where
the centrifugal force is small, prevents
the shoe from touching the drum.
Pin ... The pin fixes the shoe in place
so that it will not come off the
reaction plate, and also serves as the
weight stopper.
2. Operation
1) First range (low-speed, nonoperating range)
Because the return force of the retractor spring is greater than the
centrifugal force acting on the shoe
and weight, the shoe is drawn inward
and kept away from the drum. Thus,
torque is not transmitted through the
shoe.
As the revolution increases and when
the centrifugal force becomes greater
than the return force of the spring, the
shoe contacts the drum and begins to
transfer torque (lower figure).
greater part of it pushes the shoe
through the main spring, working as
the power that transmits torque.
On the other hand, the centrifugal
force acting on the shoe itself becomes
the force that pushes the drum regardless of the movements of the weight.
Therefore, the press of the shoe necessary to transmit torque in this range
becomes: Shoe's centrifugal force +
(Weight's centrifugal force - Retractor
spring's return force).
When the speed of rotation goes still
higher, the centrifugal force of the
weight increases further, and the main
spring deflects more, both ends of the
weight butt against the pins (through
the retractor spring), so that the
weight will not move toward the
circumference.
A13·415
/
/
/
/
/
"
/
/
/
Fig. 7-19
A13-416
Fig. 7-18
2) Second range (medium- and lowspeed range, centrifugal clutch range)
The centrifugal force of the weight
deflects the main spring, and the
weight floats up off the concavity at
each end of the shoe (portion @ in
Fig. 7-19).
Although a portion of the weight's
centrifugal force is transmitted from
the retractor spring to the pin, the
3) Third range (medium- and highspeed ranges, torque limiter range)
Because the speed of rotation is high,
the weight is stopped, completely
pressed against the pins at both ends.
The centrifugal force acting on the
weight at this time is carried directly
from the weight to the pins and then
to the reaction plate, and therefore it
is not transmitted to the shoe. Accordingly, in this range the transfer torque
of the clutch is the frictional force
produced by the centrifugal force of
.II
7-16
,
!
j
11
. _I"
, I , "I,
~
··. ,. .
l·,-~··-···~
. . _. - ...........
'
~...,.H
.'_. ___,. ._. .
!_1-""'!~---
'.11_.,....",........,...,, __________________
11
II
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
the shoe. The increasing rate of torque
due to an increase in the rotational
speed is considerably lower than in the
second range; consequently, this is
what is called a torque limiter condition.
Further, the centrifugal force of the
main spring is balanced and offset by
the force with which the spring is
pushed, and there is no change in the
force pushing the shoe.
4) Fourth range (high-speed range)
The main spring deflects outward due
to its own centrifugal force, and
separates from the weight. Thus, the
upward pressing load with which the
weight pushes the spring dies away.
In the third range the centrifugal force
of the main spring is offset by the
pressing load of the weight. In the
fourth range, however, because the
centrifugal force of the main spring is
carried to the shoe as it is, the transfer
torque of the clutch greatly increases
as does the torque capacity somewhat
increases accordingly.
A13·418
Fig. 7-20
7-17
A13-419
Fig. 7-21
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3 OIL PRESSURE CIRCUIT
Brake
Transfer (4WD)
r---------,
I
I
I
Transfer
I
I
clutch:
I
I
I
I
I
I
I
I
I
I
I
(.1 '>
Pressure
Regulating Valve
Manual
Valve ',2)
p
Note: Marked X are Dra.n
_
Line pressure (Governor feed pressure)
_
Governor pressure
_
Torque converter pressure and lubrication
_
Throttle pressure
Governor
Valve
A13·420
Fig. 7-22
7-18
•
I
I
II
~I~'
"d-""-"~"4<4_'·-""
..'_.....
__
""I""~'_""
______. . --.. . . ,. .,. .,-.. . . .
'_r~,,
t..., -...
'"....tl'".'_ _ _ _ _ _ _ _ _ _ _ _ _"",_,_ _ _ _ _ _ _ _- -
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
4 FLUID PASSAGES
1
2
3
4
5
6
Oil seal air breather
Oil seal air breather circuit
Line pressure (Governor feed pressure)
Governor pressure
Drain
Governor pressure (To test plug)
1
2
3
4
5
6
7
8
9
10
Oil pump outlet port
Blind hole
Forward clutch pressure
Reverse clutch pressure
Oil pump inlet port
Servo connecting pressure
Servo release pressure
Governor pressure
Line pressure (Governor feed pressure)
Low & reverse brake pressure
Reverse clutch pressure
2 Air breather hole
3 Rear portion lubricating hole
4 Forward clutch pressure
A13·427
Fig. 7-29 Oil pump carrier
A 13-421
A13-424
Fig. 7-23 Final reduction case
1
2
3
4
5
Fig. 7-26 Transmission case bottom
side
1
2
3
4
5
6
7
Governor pressure
Line pressure (Governor feed pressure)
Drain
To circuit breather
To oil seal air breather
A13-422
Fig. 7-24 Transmission case front side
1
2
3
4
5
6
7
Air breather hole
To torque converter
To transfer clutch
Oil pump outlet port
Forward clutch pressure
Reverse clutch pressure
Oil pump inlet port
A13-428
Fig. 7-30 Transmission cover front
side
A13·425
o
0
Fig. 7-27 Intermediate case front side
Transfer clutch
pressure
To transfer
valve
1
2
3
4
Oil pump inlet port
Reverse clutch pressure
Forward clutch pressure
Oil pump outlet port
A13·426
A13-423
Fig. 7-25 Transmission case rear side
Fig. 7-28 Intermediate case rear side
7-19
To torque converter
Oil pump outlet port
Line pressure inspection hole
Forward clutch pressure
Reverse clutch pressure
Oil pump inlet port
Reverse clutch pressure inspection hole
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3. Component Parts
1) Torque Converter & Housing and Gauge & Piping System
,
,,
,
('
1 ATF oil gauge CP
2 Oil gauge CP
3
4
5
6
7
8
,
1-'
Hose
Vacuum pipe CP
Vacuum hose
Bolt & washer ASSY
Oil supply pipe CP
O-ring
Tightening torque N·m (kg-m, ft-Ib)
T1: 23-26(2.3-2.7,17-20)
T2: 46 - 54 (4.7 - 5.5, 34 - 40)
1 Torque converter ASSY
2
3
4
5
6
7
8
9
Bolt
Connector housing CP
Oil seal (42 x 60 x 9 mm)
Bushing
Stud
Bolt
Stator shaft gasket
Stator shaft CP
10 Spring washer
11 Bolt
12 Washer
13 Bolt
14 Washer
15 Spring washer
16 Nut
17 Hanger
A13-429
Fig. 7-31
7-20
, , ~
~ II
Ij ,I
'e.·.
'.-'''!''T....
' _,- _ _""'"_
' _ _ _ _ _""-' ' 'If...
j,·,~ . . ~~~"'-...,~,....,.._+~~ __.-";O-...
--. ..
f§...
' ....
· ...
, ...
, , -. .
. .-.--..r------------
---"""~,
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Final Reduction Case and Differential Gear
Tightening torque N·m (kg-m, ft-Ib)
T1: 14 -17 (1.4 - 1-7,10-12)
T2: 9-11 (0.9-1.1,6.5-8.0)
T3: 4 - 5 (0.4 - 0.5, 2.9 - 3.6)
T4: 8 - 11 (0.8 - 1.1, 5.8 - 8.0)
T5: 23 - 26 (2.3 - 2.7, 17 - 20)
T6: 22 - 27 (2.2 - 2.8, 16 - 20)
T7: 57 - 67 (5.8 - 6.8, 42 - 49)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Final reduction case
Oil seal (22 x 40 x 10 mm)
Needle bearing (22 x 28 x 12 mm)
Plug
Nipple
Needle bearing (45 x 55 x 20 mm)
Converter housing gasket
Bolt
Oil seal holder lock plate
Oil drain gasket
Oil drain plug
Snap ring
Ball
Speedometer driven gear
Oil seal (12 x 17.5 x 8 mm)
Speedometer shaft
Snap ring
Washer
Washer
Parking ball spring
Spring retainer
Ball
Parking actuator support
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Ball retaining plate
Bolt
Bolt
Oxygen sensor harness clip
Earth cord
Governor cover
Governor cover gasket
Washer
Governor body
Governor shaft
Governor driven gear
Spring pin
Bolt
Bolt
Governor shaft sleeve
Governor seal ring
Vacuum hose clamp
Spring washer
Nut
Washer
Bolt
Seal ring
1
2
3
4
5
6
7
8
9
10
*11
*12
13
14
15
16
Fig. 7-32
Oil seal (LH)
Axle shaft oil seal holder
Axle drive s,'\aft
Roller bearing
Bolt
Differential pinion shaft
Differential case
Straight pin
Differential pinion
Differential side gear
Snap ring
Washer
Pinion & crown gear set (Non-4WD)
Oil seal (RH)
O-ring
Pinion & crown gear set (4WD AT)
A13-430
7-21
#);1"
---'
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3) Transmission Case and Control Valve
*Selective parts
Tightening torque N·m (kg-m, ft-Ib)
T: 23 - 26 (2.3 - 2.7,17 - 20)
Transmission case CP
Stud bolt (8 x 47 x 12 mm)
Straight pin (8 x 18 mm)
Plug (1/8 in)
Parking lever pin
Transmission cover gasket (4WD AT)
Vacuum diaphragm ASSY
Diaphragm rod
O-ring (22 mm)
Downshift solenoid ASSY
Parking pawl shaft
Clip
Transmission case gasket (4 WD AT)
Clip
Parking pawl
3
4
5
6
7
8
*9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Parking pawl return spring
Parking shaft support plate
Parking rod
Nut
Manual plate
Manual shaft spacer
Washer (15.2 x 26 x 0.2 mm)
Parking lever
O-ring 00 mm)
Dust seal
Selector arm
Washer
Spring washer
Bolt
Bolt
2
3
4
5
6
7
8
9
10
11
12
Control valve ASSY
Bolt (6 x 36 x 18 mm)
Bolt (6 x 40 x 16 mm)
Bolt (6 x 25 x 16 mm)
Gasket
Oil pan CP
Oil drain gasket
Oil drain plug
Bolt & washer
Orifice
Servo-apply pipe
Servo-release pipe
,~.,
A 13-431
Fig. 7-33
7-22
.,~,
l
l.
1·11
_#.;
1
...q'''t'''Ht''''_'''I0111!_
""'~'.'''''''",''-'''~.J'''''~,,,",-,,,,~-,,,~~,,,,,,,
_
- - _ - -_ _ _ _ _
'''''_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
4) Shaft & Reduction Gear
*Selective parts
/1
1
1
1
I
I
1
1
I
I
)
(
i
I
1
I
1/
/
//
//
/",,/"
4WDAT
1/
0
1
1
1
1
2
3
4
5
*6
7
8
9
* 10
* 11
12
13
14
15
16
17
18
19
20
21
Oil pump drive shaft
Turbine output shaft
Reduction drive gear unit
Ball bearing
Snap ring
Drive pinion shim 2
Taper roller bearing
Thrust bearing retainer
Reduction driven gear
Drive pinion shim
Drive pinion spacer
Taper roller bearing
Lock washer
Lock nut
Bolt
Snap ring (IN-80)
Oil seal
O-ring
Oil seal holder
Washer
Spring washer
1
1
1
1
1
1
1
1-/
Tightening torque N'm (kg-m, ft-Ib)
T1: 23 - 26 (2.3 - 2.7, 17 - 20)
T2: 108-118 (11-12,80-87)
T3: 92 - 104 (9.4 - 10.6,68 - 77)
A13-432
Fig. 7-34
7-23
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
5) Planetary Gear and Low & Reverse Brake
*Selective parts
Tightening torque -N'm (kg-m, ft-Ib)
T: 14-16(1.4-1.6,10-12)
"'1,
,,,
12 Bolt
1
2
3
4
5
6
7
8
9
Needle bearing
Planetary pinion 2
Planetary pinion washer
Planetary pinion
Planetary pinion spacer
Planetary pinion pin
Low free wheel
Free wheel outer race
Planetary bushing
10 Planetary pinion washer
11 Free wheel race lock plate
23 Outch driven plate 2
24 Clutch drive plate 2
25 Outer snap ring (55 mm)
26 Low & reverse return spring
27 Thrust spring ring
28 O-ring (56 mm)
29 Lathe cut seal ring (132 mm)
30 Outch piston 2
31 Center support
32 Inner snap ring (144 mm)
13 Thrust bearing
14 Planetary input gear
15 Planetary carrier
16 Thrust bearing
17 Planetary output gear
18 Washer
19 Thrust b~airing
20 Planetary input gear 2
21 Circlip
*22 Retaining plate 2
A13-37~
Fig. 7-35
7-24
,.
j
j
1 ij
JI
~,,~j,
-.
"""""'t_
. _
..,......'1'1"""$,....""'_ _ _ _-
- - - ·...
1'.....
,-~,,""I·"-""--~""'i!
_ _ _ _ _" " " " - - -_ _ _ _ _ _ _ _ _ _ _ _ _ _- -
• 'fl ,
'''' ,
----~--l
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
6) Forward Clutch & Reverse Clutch
* Selective parts
I
I
1
1
.1
I
~~)
"
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
I
I
I
I
I
I
I
I
I
I
I
I
I
~,
,,
18
19
20
21
*22
A13-363
23
Connecting shell
Lock washer
Thrust bearing
Washer
Qutch hub
Forward clutch assembly
Snap ring
Retainer plate
Driven plate 115
Dished plate
Snap ring
Spring retainer
Spring
Qutch piston assembly
Drive plate 115
Forward clutch drum
Seal ring
Lathe cut seal ring
Thrust bearing
Washer
Reverse clutch assembly
Retainer plate
Reverse clutch drum
",,¥,"
Fig. 7-36
7-25
----'
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
7) Band Servo & Oil Pump
·Selective parts
®
/1
@
\
®
@
CD
1
2
3
*4
5
*6
7
8
9
10
11
*12
Oil pump ASSY
Transmission cover CP
Plug
Oil pump inner gear
O-ring
Oil pump outer gear
Bolt
Needle bearing
Oil pump carrier bushing
Seal ring
Seal ring
Washer
Snap ring
O-ring
Servo-piston cover
Seal ring
Servo-piston CP
Seal ring
Servo return spring
Brake band strut
Brake band ASSY
Brake band adjust screw
O-ring
Washer
Nut
Thrust washer
Thrust bearing
Oil pump drive shaft 2
Snap ring (Inner)
Snap ring (Outer)
Servo piston rod
O-ring
Accumulator piston
Accumulator spring
Accumulator supporter
Band servo clip
Intermediate case
13
14
15
16
17
18
19
20
21
22
23
24
25
*26
27
28
29
30
31
32
33
34
35
36
37
•
Tightening torque N·m (kg·m, ft-Ib)
T1: 6 - 8 (0.6 - 0.8, 4.3 - 5.8)
T2: 25 - 28 (2.5 - 2.9,18 - 21)
Fig. 7-37
Adjusting brake band
Tighten adjusting screw
to a torque of 9 N·m
(0.9 kg-m, 6.5 ft-Ib),
then turn it back two
turns.
Tighten lock nut to
secure the adjustment.
A13-433
7-26
- F· -I
,j
,
j,
1-#
41 '"
-~ ~ +'o~~;"
_ ..
1""'''"'''''1-----..,,-----'''',.,- . r".'_--_____
.
- ___- _______,).
-"~n ...~."._~~._'''''oji'''I'''''P''''_ _
'
- - --1
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8) Extension Case
*Selective parts
*I
Washer
2 Seal ring
3 Ball bearing
4 Washer
5 Transfer driven gear UN
6 Snap ring (IN 98.5)
*7 Pressure plate (F)
8 Driven plate 3
9 Drive plate 3
10 Pressure plate (R)
11 Transfer clutch drum
12 Rear drive shaft
13 Ball bearing
14 Externsion case CP
15 Needle bearing
16 Oil seal
17 Dust cover
18 Transfer clutch solenoid
19 O-ring
20 Gasket
21 Temperature switch ASSY
22 Pipe
23 Bolt
24 Clip
25 Transfer clutch valve ASSY
\
\
@
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Oip
Transfer valve body
Transfer valve spring
Transfer clutch valve
Plate
Extension gasket
Plug
Intermediate case CP
Coupling
Straight pin
Transfer drive shaft
Clamp
Snap ring (OUT 30)
Ball bearing
Thrust plate
Transfer drive gear
Bushing
Oip
Washer
Spring washer
Bolt
Tightening torque N·m (kg-m, ft-Ib)
T1: 23- 26 (2.3 - 2.7,17 - 20)
T2: 16 - 20 (1.6 - 2.0,12 -14)
A13-434
Fig. 7-38
7-27
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
4. Troubleshooting
and On-car Service
1 TROUBLESHOOTING
Many troubles of the automatic transmission may be corrected by performing the basic inspection and adjustment procedures. Before starting the
regular troubleshooting operation,
carry out the following preliminary
inspection.
1. Necessary Test Gauges
1) Tachometer (It is desirable to be
able to read to 50 rpm.)
2) Vacuum gauge (It is used for
measuring intake manifold vacuum.)
3) Oil pressure gauge [0 to 2,452 kPa
(0 to 25 kg/cm 2 , 0 to 356 psi) range].
Set above gauges so that the driver can
see them.
2. Preliminary Inspection
1) Confirm that the engine tune-up
has been completed. Check the idling
speed and idling boost.
If engine is out of adjustment, check
also the stall speed.
2) Check that the linkage between
the accelerator pedal and the carburetor is functioning properly.
(Check the full-opened and fully
closed positions.)
3) Ensure that the vacuum pipe is
not disconnected.
4) See that no fluid is leaking from
the ATF cooler circulation pipe.
5) Check that the kickdown switch
functions at the normal pedal position.
6) Check that the electrical circuits
of the kickdown solenoid, transfer
solenoid and inhibitor switch are functioning properly.
7) Confirm that the manual linkage
adjustment has been completed.
8) See that no fluid is leaking out of
the transmission.
9) See that the ATF level and differential oil level are normal.
After completing the above listed
operations, perform checks on the
items listed in 4. according to the
Troubleshooting chart.
NOTE:
Chattering of transfer clutch
• If considerable chattering is felt in
the transfer clutch when making a
turn in 4WD mode, replace two to
three liters of transmission oil with
the recommended ATF.
i:l'
ii
11
~j
Jr.-;
7-28
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,
,T~-I· ~-ll ;:1I'';-
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I ... ,j,·-i=-~""f-=~....
n_""''''''..........,"""...--________....,,""'.______-"4
·-v.......
- ...
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'q"'·-"§""IT"'_"'·_WR- -...
'fi"""'---_Sff_ _. _..
~
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3. Troubleshooting
On the car
check item
Trouble
Large shock when shifting "N" -+ "D"
G,J
j
Car will not run, slip, or acceleration is very poor in "D", "2", or "1".
(Car runs in "R".)
G,J
j, r
Car will not run, slip, or acceleration is very poor in "R". (Car runs in "D",
"2", and" 1".)
G,J
n,k,r
Car will not run in any range.
G,J
q, r, v
Slip is felt when starting in FWD D range. (Car runs in "1" range.)
G,J
r, t
Slip is felt when starting in 4WD mode. (Car runs in FWD mode.)
•
Off the car
check item
e
Car runs even in "N".
J
j, k
Low maximum speed, or poor acceleration.
H,L,G
m,n,h
Car is braked if lever is set in "R".
L
j,m, v
No shift from 1st to 2nd.
K,M,J,X
m,r
No shift from 2nd to 3rd.
K,L,M,J
k,r
Shift points too high from 1-2 and 2-3.
G,J
r
Shift occurs from 1 to 3.
L,K,G,M,J
m,r
Large shock when shifting 1-2.
L,G,J
m
Large shock when shifting 2-3.
L,G,M,J
k,m
No shock when shifting 1-2, or slip occurs.
L,G,M,J
m,r
No shock when shifting 2-3, or slip occurs. Engine races.
L,G,M,J
k,r
Car is braked when shifting 1·2.
J
n,k,t
Car is braked when shifting 2-3.
L,J
m
No shift from 3rd to 2nd.
K,G,M,J
k,m, r
No shift from 2nd to 1st, or from 3rd to lst.
K,L,J
m, t
Large shock is felt when car speed decreases when accelerator pedal released.
K,G,J
r
3-2 shift point or 2-1 shift point is too high.
K,G,J
r
No kickdown occurs when accelerator pedal is depressed from 3rd. (Within
kickdown limit speed.)
K,M,J
m,r
Kick down occurs or engine overruns when accelerator pedal is depressed from
3rd. (Above kickdown limit.)
G,K,J
k, r
Engine races when gear is changed from 3rd to 2nd and accelerator pedal is
depressed.
L,G,M,J
k,m, r
Gear remains in 3rd and is not changed to 2nd even when lever is set to "2".
L,G,M,J
m,r
No shock is felt, or engine races when shifted from" 1" to "2".
L,N,M,J
m
7-29
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
On the car
check item
Off the car
check item
Gear remains in 3rd and is not changed to 2nd even when lever is set to "1".
L,K,G,J
k,m, r
No engine brake is applied in 1st gear.
G,J
n, r
Gear shift 1-2 or 2-3 occurs in "1".
J
r
Gear shift 2-1 does not occur in "1".
K,L,J
n, r
Trouble
Car begins to move even when lever is set to "P", or parking gear remains
engaged even when lever is moved from "P".
v
Transmission overheats.
G,H,L
k, m, n, h,j
Fluid spouts out while running.
Car exhaust emits white smoke while running.
H,G,W
k, m, n, h,j
Unusual smell from oil supply pipe.
N
j, k, m, n
Large noise in "P" or "N" .
q
Large noise in "2", "1", or "R".
q, t, 1
Differential gear oil is contaminated with automatic transmission fluid.
Z,
Automatic transmission fluid is contaminated with differential gear oil.
z,g
Large noise when running in FWD 3rd gear.
w,x
Large noise when running in 4WD 3rd gear.
l'
4. Inspection Items
1) Inspection Items with
Automatic Transmission
Mounted on Vehicle
G Oil pressure check
H Stall speed
J Control valve
K Governor valve
L Brake band adjustment
M Servo pipe
N Inspection of fluid by draining
W Vacuum diaphragm
X Nylon gear
2) I nspection Item with
Automatic Transmission
Detached from Vehicle
e Transfer valve, transfer pipe, rear
drive shaft seal ring
f Transfer clutch
g Drive pinion rear oil seal
h Torque converter one-way clutch
j Forward clutch
k Reverse clutch
Planetary gear
l'
m
n
q
r
Transfer gear
Brake band and band support
Low & reverse brake
Oil pump
Leak from hydraulic circuit
Power train one-way clutch
v Parking linkage
w Hypoid gear
x Reduction gear
Z Stator shaft and reduction drive
gear oil seals and O-rings, and
governor shaft oil seal
2 ON-CAR SERVICE
1. Method of Inspection and
Adjustment
1) Fluid Level Check and Fluid
Replacement
1)
Automatic transmission fluid
(ATF)
1) Checking fluid level
a. Raise the ATF temperature to 60
to 80°C (140 to 176°F). [This
temperature may be attained by
7-30
r, g
running a distance of 5 to 10 km
(3 to 6 miles)].
NOTE:
The level of ATF varies with fluid
temperature. Pay attention to the
fluid temperature when checking oil
level. A change in the ATF level by
oil temperature is shown in the following figure.
b. Ensure the vehicle is level and set
the selector lever in "P" range.
Measure fluid level with the engine
idling.
NOTE:
After running, idle the engine for one
or two minutes before measurement
c. If the fluid level is below the lower
limit mark, add the recommended
ATF until the fluid level is found
within the specified range (within
upper and lower limit marks). When
the transmission is hot, the level
should be above the center of upper
and lower marks, and when it is
-,
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
cold, the level should be found
below the center of these two
marks.
Fluid temperature range
/ " for fluid level check
~
NOTE:
a. Use care not to exceed the upper
limit level shown in item 2) below.
b. Check the ATF level when deliver·
ing a car to a customer.
2) ATF level
a. ATF level varies with temperature
as shown in figure. Remember that
the addition of fluid to the upper
limit mark when the transmission is
cold will result in the overfilling of
fluid.
. . mm
Upper IImlt
r
marrk
(1.5i~
)
30
(1.18 )
8,
::J
~
Qj
i
E -c
E'-
co ~
>
M_
3
1
20
(0.79 )P""
~~
~
-
~
• up" range
• Idling (Engine rpm: 800 - 850 rpm)
IO.3~
Lower limit
mark
~
~
)
0
30
(86)
40
(104)
50
(122)
60
(140)
70
(158)
80
(176)
90
(194)
100°C
(212WF)
Automatic transmission fluid temperature
A13-435
Fig. 7-39 Automatic transmission fluid level (4WD A T)
b. Fluid temperature rising speed,
• By idling the engine
/
Time for rising temperature to
60°C (140°F) with atmospheric
temperature of O°C (32°F): More
than 25 minutes
(Reference)
Time for temperature rise to 30°C
(86°F) with atmospheric temperature
of O°C (32°F): Approx. 8 minutes
• By running the vehicle
Time for temperature rise to 60°C
(140°F) with atmospheric temperature of O°C (32°F): More than 10
minutes
c. Method for checking fluid level
upon delivery or at periodic inspection.
Check fluid level after a warm-up
run of approx. 10 minutes. During
this warm·up period, the automatic
transmission functions can also be
checked.
3) Inspection and replacement intervals
4) Replacement of ATF
a. After allowing the engine to cool
for 3 to 4 hours, remove the fluid
pan drain plug, and drain oil
thoroughly.
NOTE:
a. The fluid will be discharged to the
front as the drain plug is removed.
To avoid the stream of fluid, the
worker should stand under the oil
pan toward the front of the car
performing this procedure.
b. The amount of fluid that can be
drained is approx. 4Q (4.2 US qt,
3.5 Imp qt) of the total capacity of
6.0 to 6.4 Q (6.3 to 6.8 US qt, 5.3
to 5.6 Imp qt) for 4WD and 5.6 to
6.0 Q (5.9 to 6.3 US qt, 4.9 to 5.3
Imp qt) for non-4WD. Some fluid
will remain in the torque converter,
oil passage, or in the valve body.
b. Tighten the drain plug. [Tightening
torque: 25 N'm (2.5 kg·m, 18 ftlb )].
NOTE:
Inspection
Replacement
At delivery, after initial
1,600 km (l,000 miles)
and every 24,000 km
(lS,OOO miles) or 15
months
Every 48,000 km
(30,000 miles) or 30
months
Be sure to replace the gasket with a
new one.
c. Pour 4Q (4.2 US qt, 3.5 Imp qt) of
recommend~d ATF into the case
through the oil supply pipe.
d. Run the vehicle until the fluid
temperature rises to 60 to 80°C
(140 to 176°F), and then add fluid
7-31
until the oil level can be found
within the specified range.
NOTE:
a. If the drained fluid is black or
thick, it indicates that some com·
ponents in the transmission are
faulty. Disassemble and check the
transmission.
b. Be sure to use recommended ATF
when changing the transmission
fluid.
2) Differential gear oil
• Checking oil level
1) Ensure the vehicle is level.
NOTE:
Do not check the oil level nor add oil
to the case with the front end of the
vehicle jacked up; this will result in an
incorrect reading of the oil level.
2) Check whether the oil level is
between the upper and lower marks.
If it is below the lower limit mark, add
oil until the level reaches the upper
mark. The difference in level between
upper and lower marks corresponds
to 0.4Q (0.8 US pt, 0.7 Imp pt).
• Oil to be used
Recommended gear oil
API classification
GL·5
SAE viscosity No.
75W·80
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
• Inspection and replacement interval
Inspection
Every 12,000 km
(7,500 miles) or
7.5 months
Replacement
Every 48,000 km
(30,000 miles) or
30 months
• Replacement of oil
Remove the drain plug located on
the left side of the final reduction
case, and drain the oil completely.
Tighten the plug to a torque of
25 N·m (2.5 kg-m, 18 ft-lb), and
remove the oil gauge, and pour new
oil into the case through the opening until the oil level reaches the
upper level mark [total quantity of
oil: 1.2Q (1.3 US qt, 1.1 Imp qt»).
• Governor test plug
• Air breather
4)
• Mating surface of oil pan and transmission case
• O-ring on the outer diameter of
servo piston cover
• Test plug (Servo connecting side
and servo release side)
• Oil supply pipe connections
• ATF pipe connector
• Vacuum diaphragm location
• Downshift solenoid location
• O-ring on the outer diameter of
servo adjusting screw
• Oil pan drain plug
• Governor pressure and line pressure
checking blind plugs (steel ball)
5)
2) Oil Leakage Check Points
It is difficult to accurately determine
the precise position of a oil leak, since
the surrounding area also becomes wet
with oil. The places where oil seals and
gaskets are used are as follows:
1) Jointing portion of the case
• Transmission case and final reduction case jointing portion
• Final reduction case and converter
housing jointing portion
• Transmission case and transmission.
cover (or intermediate case)
jointing portion
• Intermediate case and extension
case jointing portion
2)
Converter housing
• Engine crankshaft oil seal
• Torque converter impeller sleeve oil
seal
• ATF pipe connector
3)
Final reduction case
• Final reduction case and governor
cover
• Axle shaft oil seal
• O-ring on the outside diameter of
axle shaft oil seal holder
• Differential oil fIller port
• Differential oil drain plug
• Speedometer cable mounting portion
Automatic transmission case
Intermediate case
• Test plugs (two plugs for line pressure, and plugs on forward clutch,
reverse clutch, and transfer clutch)
• Blind plug (steel ball)
6) Extension
• Rear drive shaft oil seal
• Transfer solenoid location
• Thermoswitch location
The points listed above should be
checked for fluid leak. Checking
method is as follows:
• Place the vehicle in the pit, and
check whether the leaking oil is
ATF or not. The ATF is wine red
in color, and can be discriminated
easily from engine oil and gear oil.
• Wipe clean the leaking oil and dust
from a suspectable area, using a
noninflammable organic solvent
such as carbon tetrachloride.
• Run the engine to raise the fluid
temperature, and set the selector
lever to "D" in order to increase
the fluid pressure and quickly
detect a leaking point.
3) Checking the Engine Idling
rpm
Excessively low engine idling rpm will
lead to rough engine operation and
excessively high idling rpm will lead to
a sudden shift shock or creeping when
shifting from N to D or R.
7-32
Idling rpm for
automatic
transmission cars
(N or Prange)
800 ± 100 rpm
4) Checking and Adjusting the
Kickdown Switch and
Downshift Solenoid
Set the ignition switch to ON, and
fully depress the accelerator pedal to
see whether the solenoid functions or
not. If no kickdown occurs, or if the
shift point occurs with the throttle
half open, check the kickdown switch,
downshift solenoid and associated
wires. If kickdown failure occurs infrequently, it may be due to malfunction of the solenoid contaminated
with dirt. Wash the inside of solenoid
while moving the push rod. After
washing, carefully check the operation
of the solenoid.
NOTE:
Before removing or installing the solenoid, drain approx. 2 Q (2.1 US qt, 1.8
Imp qt) of ATF.
5) Checking Negative Intake
Pressure
Check whether pressure is over -60.0
kPa (-450mmHg, -17.72inHg) at
idling speed of engine, and whether
pressure decreases in proportion to
increase of engine speed when accelerator pedal is depressed.
6) Checking Creeping
Check whether car exhibits a certain
amount of creeping when it is brought
to a temporary stop with selector lever
in "D", "2", "1" or "R" position.
7) Checking and Adjusting the
Manual Linkage
Adjustment of the manual linkage, like
the inspection of fluid level, is an
important operation in the automatic
transmission service. Remember that
improper adjustment may lead to a
damaged transmission.
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
R
N
0
Push button
Selector lever
Indicator
Slide plate
Inhibitor
switch
Operation indicated by solid arrow mark
.. must be done while pressing the push button.
¢:J Operation indicated by white arrow mark
may be done without pressing the button.
Rod
A13-436
Fig. 7-40 Selector system
1) Inspection
1) While pressing the release button,
move the selector lever from the "P"
to "1" range; a click will be heard in
each position. This clicking sound is
caused by a detent of the manual valve
in the transmission, and it indicates
the correct selector lever position.
Check to see that the indicator needle
is aligned to this position, and also see
that it is aligned with the groove of the
guide plate when the release button
and selector lever are released.
2) Confirm that the selector lever
cannot be moved into "R" from "N"
when pushed lightly, without first
pressing the release button.
3) Confirm that the engine can only
be started in "P" and "N" ranges.
4) Confirm that the backup lamp
will light only when the selector lever
is moved to the "R" range.
5) Place the vehicle on a slope, and
set the selector lever to "P" and check
whether the vehicle is locked properly.
3) Set the detent position so the
selector arm is aligned with the "N"
locating mark of the transmission case
[within the range of a 6 mm (0.24 in)
dia. boss].
A13-437
Fig. 7-41 Adjusting rod
4) Adjust the rod so that the "N"
mark of the guide plate is aligned
correctly with this detent position.
5) If the indicator needle is not aligned with the guide plate marking,
remove the console box, loosen the
four indicator mounting screws and
adjust the position of the indicator
ASSY.
2) Adjustment
If the manual valve detent position is
not aligned with the guide plate groove
position, perform the adjustment as
follows.
1) Set the selector lever to "N".
2) Loosen the adjusting nut of the
linkage rod.
8) Checking the Vacuum
Diaphragm and Vacuum
Hose
A loose or disconnected vacuum hose
will result in rough engine idling and
an abrupt shifting shock even with
light acceleration. In such a case,
7-33
check the vacuum hose for cracks or
check the vacuum hose joint. Excessively large shift shocks and the emission of white exhaust smoke while
running may indicate a broken vacuum
diaphragm. If such symptoms occur,
loosen the two bolts securing the
vacuum pipe (at governor cover and at
the engine and transmission jointing),
and turn the vacuum pipe upward
around the bracket of the diaphragm
joint until the bracket comes free
from the bolts.
Pull the vacuum hose and vacuum pipe
out toward you and drain approx. 2Q
(2.1 US qt, 1.8 Imp qt) of ATF.
Remove the vacuum diaphragm by
rotating by hand.
NOTE:
a. Be sure to remove the vacuum
diaphragm when the transmission is
cold. (To avoid a burn.)
b. Also take out the diaphragm rod.
9) Checking, Correcting,
Disassembling, and
Reassembling the Governor
Valve
If automatic shifting is not performed
normally while running in the D range,
or if acceleration is possible only up to
50 to 60 km/h (31 to 37 MPH) in the
D range, it is often attributable to malfunctioning of the governor valve.
Such malfunctioning may be caused
by sticking of the valve due to clogged
dirt, burrs or nicks on the valve body,
etc.
A13-438
Fig. 7-42 Component of governor
valve
1) Disassembly
1) Remove the three governor cover
mounting bolts from the right side of
the final reduction case, and remove
the governor cover by turning it slightly in order to avoid interference from
the vacuum pipe bracket.
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Pull the governor valve out while
carefully turning clockwise.
3) Remove the E·clip ® snap ring
@ then remove the valve @, spring
® and other parts from the body © .
4) Remove two bolts ® securing the
shaft CD and body © and disassemble
them.
2) Burrs and nicks at the edge of the
valve body groove should be removed
by using a small standard screwdriver.
3) Clean the repaired parts in clean
lamp oil or white gasoline. Fit the
governor valve and governor valve 2
into the valve body, and check for
smooth sliding of these parts by lightly
pressing them to the inside of the valve
body while rotating.
NOTE:
Be sure to perform the steps 3) and 4)
after pulling the governor valve out
from the final reduction case.
2) Confirm that there is no foreign
matter in the oil passage of the governor shaft, and tighten the shaft to the
governor body after washing.
Tightening
torque
NOTE:
When tightening, fix the flange of the
shaft, and be careful not to damage
the nylon gear of the shaft.
Check these areas.
2) Checking
3) When assembling the governor
Check the governor valve and body
visually and by feeling with a finger
for burrs and dents, and repair as
necessary. If the sliding surface of the
body or valve is defective, replace the
governor body ASSY with a new one.
valve to the final reduction case, it is
unnecessary to dry out the governor
valve. However, the governor valve
should be assembled after confirming
that the seal ring is normal.
A13·440
Fig. 744 Checking the edge of the
governor body groove
3) Correcting
NOTE:
When assembling, use special care not
to damage the seal ring, and the lip
of the oil seal installed inside the case.
NOTE:
If the governor valve checks out to
operate normally, the seal ring of
governor sleeve must be checked.
1) To correct the governor valve and
governor valve 2, lightly apply a fme
grained oil stone to the burred edge
as shown in the figure, and rotate the
valve one or two turns. Check whether
or not the burrs have been removed by
feeling with a finger.
Repeat this operation until the burrs
are no longer felt.
4)
4) Before assembling the governor
cover, replace the gasket (governor
cover) and confirm that the washer is
included.
Reassembling
Tightening
torque
O@~~D@-.
a. Note that the finishing of the end
face is not chamferring, but it is
light deburring. A sharp edge having
no burrs is desirable.
b. Replace the valve ASSY if flaws
and dents are noted on the sliding
surface.
Fig. 745 Reassembling the governor
valve
10) Adjusting the Brake Band
1) Reassemble the governor valve
components by referring to the figure
shown above.
Pay attention to the orientation of the
weight.
If the following abnormal shifting
conditions are noted in a road test, the
brake band must be adjusted.
1) Shift state and adjustment
1) The 2nd gear state can be achieved
but:
• the engine rpm increase excessively
shifting up from 2 to 3.
• a shift delay (over O. 7 sec) accompanies at kickdown from 3 to 2.
If any of these problems occurs, it is
attributable to excessive clearance
between the reverse clutch drum and
brake band: Tighten the adjust screw
by turning it clockwise.
2) The 2nd gear state can be
achieved, but:
• the shifting shock is too small at
shifting up from 1 to 2.
• a braking phenomenon is noted
when shifting up from 2 to 3.
Keep oil stone fixed.
Turn Wi:Jh - -+U---+fingers
....
'----
Correct these areas.
A13-439
Fig. 743 Correcting valve
__"._--___
7-34
•.
,'*
I
~,I,II
14 - 17 N·m
(1.4 - 1.7 kg-m,
1O-12ft-lb)
A13-441
NOTE:
-1,,---1
9 - 11 N·m
(0.9 - 1.1 kg-m,
6.5 - 8.0 ft-lb)
tj
I"
,.~
__""'itl_"''''r.r
-j",.,,41.~~_-_·.w..""""~<.t;""""""
t-_-1~'_'-
_______- _________-
"'~I""w
----------
------------,
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
If any of these phenomena are noted,
it is attributable to excessively small
brake band clearance: Loosen the
adjust screw by turning it counterclockwise.
3) When accelerating, direct shift up
from 1st to 3rd occurs:
........ Excessively large clearance.
When shifting up from 2nd to 3rd, tire
slip occurs:
. : ...... Excessively small clearance.
11) Inspection, Removal and
Installation of the Transfer
Solenoid (4WD Models)
If the 4WD pilot lamp on the instrument panel remains off even when the
4WD pushbutton switch has been depressed, check the transfer solenoid
and wiring.
If the 4WD mode is not achieved with
the lamp illuminated, the solenoid
may be malfunctioning. Check the
solenoid and transfer valve as follows.
10) Remove the rear crossmember.
(To ensure safety, support the oil pan
with a transmission jack.)
11) Remove the side cable from the
body clip. (Move it downward as far
as possible.)
12) Push the transmission to the left.
(Insert a piece of wood between the
clearance thus achieved.)
13) Remove the solenoid valve.
• Removal and installation of
solenoid (transfer valve)
• Removal
A13-442
Fig. 7-46 Adjusting the adjusting
screw
2) Adjustment of the adjusting screw
1) Using a socket wrench, immobilize the end of the 10 mm screw
projecting on the left side of the transmission case, and loosen the nut with
a double-end wrench.
In the case of occurrence of problems
1) and 2) mentioned previously, perform the adjustment by loosening or
tightening the nut within a range of
3/4 turn from this state.
1) Open the hood.
2) Disconnect the battery ground
cable.
3) Remove the spair tire.
4) Loosen the pitching stopper (to a
position just before it comes oft).
5) Disconnect the 4WD selector solenoid harness. (Keep the disconnected
harness suspended.)
Tool name
398603610
Socket wrench
I) Disassembly
A13-443
Fig, 7-47 Removing the 4WD selector
solenoid harness
00 not loosen excessively; otherwise,
the band strut on the servo piston will
drop off.
2) In case of the occurrence of problem 3) mentioned previously, perform
the adjustment as follows:
Adjusting procedure: Tighten adjust
screw to 9 N·m (0.9 kg-m, 6.5 ft-Ib)
torque, then back off two turns.
NOTE:
Do not tighten the adjusting screw
with an excessively large torque.
3) With the adjusting screw immobilized, tighten the lock nut to 26±2 N·m
(2.7±0.2 kg-m, 20±1.4 ft-Ib) torque.
• Installation
Reverse the sequence of removal procedure.
12) Disassembly, Inspection
and Assembly of the
Transfer Section
(4WD Model)
NOTE:
Tool No.
A13-444
Fig. 7-48 Removing the solenoid
valve
6) Remove the uppercover. [This is
necessary for removing the exhaust
pipe (F).]
7) Remove the exhaust pipe (F).
8) Remove the intermediate side
cable clamp.
.
9) Drain the torque converter oil
(one liter).
(The oil will not come out of the case
when the valve is removed, if one liter
of oil has been drained. Measure the
drained amount so that the amount to
be added after completing the inspection can be easily determined.)
7-35
1) Completely drain the AFT.
2) Remove the transfer solenoid.
Refer to the Removal and Installation
of the Transfer Solenoid for details.
3) Remove the temperature switch
harness from the clamp.
4) Remove the eight 8 mm bolts and
extract the transfer section and extension ASSY as a unit from the intermediate case.
NOTE:
a. Be careful not to drop the internal
component parts.
b. Place a container to collect the
remaining oil.
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
o
A13-445
Fig. 749 Removing the extension
ASSY
5) Separate the clamp from the pipe
at the bent position and disconnect
the transfer pipe from the valve body
and intermediate case.
A13-447
Fig. 7-51 Valve component parts
2) Attach the valve body to the
intermediate case and tighten with the
two 6 mm bolts.
Tightening
torque
A13-448
Fig. 7-52 Removing the solenoid,
diaphragm, etc.
6- 8 N·m
(0.6 - 0.8 kg-m,
4.3 - 5.8 ft-lb)
3) Remove the converter oil pan.
Be sure to place a container under the
oil pan to collect ATF remaining in
the oil pan.
4) Disconnect the servo pipes.
NOTE:
a. Do not forget to install the plate.
b. Pay attention to the direction of
the valve body.
c. Do not forget to install the clamp.
A13-446
Fig. 7-50 Removing the clip and pipe
6) Remove the two 6 mm bolts
securing the valve body.
7) Remove the E-clip and remove the
transfer valve from the body_
3) Insert the transfer pipe into the
intermediate case and tighten the
clamp by bending.
NOTE:
A13-449
Fig. 7-53 Removing the servo pipe
Always use a new pipe and clamp.
4) To assemble the transfer unit,
reverse the order of disassembly.
5) Remove the six 6 mm bolts
(shown by the arrow) and detach the
control valve ASSY.
NOTE:
NOTE:
Be careful not to lose the coil spring.
Be sure to install the rear drive shaft
seal ring.
2)
5) Replenish ATF and check the
level.
a. Be careful not to drop the manual
valve.
b. Be careful not to damage the oil
strainer.
c. Be careful not to allow dust or dirt
from getting into the valve ASSV.
NOTE:
Inspection
• Visually check all peripheries to
ensure they are free from burrs,
dirt, metal chips, etc.
• Cleaning all parts by washing them
and install them in the valve body.
Ensure these parts move smoothly
without binding_
• If the valve body or the frictional
surface of the - valve is faulty,
replace with a new one.
3) Assembly
13) Inspection of the Control
Valve Assembly
1)
Disassembly
1) Raise the vehicle with a jack and
drainATF.
2) Disconnect the vacuum hose, and
remove the downshift solenoid and
vacuum diaphragm.
NOTE:
1) To assemble the transfer valve
parts, refer to the following figure.
A13-450
Also remove the diaphragm rod
together with the vacuum diaphragm.
Fig. 7-54 Removing the control valve
7-36
t,,~
'r1".4·jf,·'t'I'j,,-",,_""~'~'''''''''''"'"'''
......'r-'·..
__
''''''''''''''''''''''''...
I'i_'....
t t...'-~r"""
"_lsr""'_--_______________-
f_ _ _ _ _ _ _ _...'"'"...
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2)
Inspection
Refer to the Control Valve ASSY
section.
3) Assembly
1)
Install the control valve ASSY.
NOTE:
Be sure to tighten the bolts equally one at a, time - using a torque wrench.
Tightening
torque
2)
6 -8 N·m
(0.6 - 0.8 kg·m,
4.3 - 5.8 ft-Ib)
For selection of a suitable diaphragm
rod, refer to "5. TRANSMISSION
CASE SECTION".
6) Install the downshift solenoid and
connect the vacuum hose.
NOTE:
Do not forget to install the "0" ring.
7) Replenish ATF and check the oil
level. The amount of ATF to be
replenished is approximately 4 liters
(4.2 US qt, 3.5 Imp qt).
2. Various Test Methods
1) Stall Tests and Interpretation of Test Results
Connect the servo pipes.
NOTE:
Always install new servo pipes.
The stall test is of extreme importance
in diagnosing the condition of the
automatic transmission and the engine.
It should be conducted to measure the
engine stall speeds in all shift ranges
except the P and N ranges.
1) Purposes of the stall test
A13-451
Fig. 7-55 Installing the servo pipe
3) Align the mating surfaces of the
converter oil pan and converter to en·
sure no clearance exists at any point.
The gasket should not be used at this
point.
4) Wipe any oil from the mating surfaces and install the converter oil pan
with the gasket in place.
NOTE:
Always use a new gasket.
Tightening
torque
3.4 - 4.4 N·m
(0.35 - 0.45 kg-m,
2.5 - 3.3 ft-Ib)
Drain plug
tightening
torque
25N·m
(2.5 kg-m, 18 ft-Ib)
5) Using the Diaphragm Rod Gauge
Set, check the length of the diaphragm
rod is within specifications and, if the
length is correct, install the vacuum
diaphragm.
1) To check the operation of the
automatic transmission clutch and
brake band.
2) To check the operation of the
torque converter.
3) To check engine performance.
2) Test methods
Prior to the stall tests, check to ensure
the carburetor throttle valve opens
fully, and that the levels of engine oil,
cooling water and ATF are correct.
Set the select lever in the P range and
idle the engine at 1,200 rpm for several
minutes until the ATF reaches approximately 60°C (l40°F).
1) Install an engine tachometer at a
location visible from the driver's compartment and mark the stall speed
range of 2,100 to 2,300 on the tachometer scale.
I Stall speed I 2,100 -
2,300 rpm
I
2) Place the wheel chocks at the
front and rear of all wheels and engage the parking brake.
3) Move the manual linkage to ensure it operates properly, and shift the
select lever to the D range.
7-37
4) While forcibly depressing the foot
brake pedal, gradually depress the
accelerator pedal until the engine operates at full throttle.
5) When the engine speed is stabilized, read that speed quickly and
release the accelerator pedal.
6) Shift the select lever to Neutral,
and cool down the engine by idling it
for more than one minute.
7) Record the stall speed.
8) Perform the stall tests with the
select lever in the 2, 1 and R ranges.
NOTE:
a. Do not continue the stall test for
MORE THAN FIVE SECONDS at
a time (from closed throttle, fully
open throttle to stall speed read·
ing). Failure to follow this instruction causes the engine oil and ATF
to deteriorate and the clutch and
brake band to be adversely affected.
Be sure to cool down the engine
for a, least one minute after each
stall test with the select lever set
in the P or N range and with the
idle speed lower than 1,200 rpm.
b. If the stall speed is higher than the
specified range, attempt to finish
the stall test in as short a time as
possible, in order to prevent the
automatic transmission from sustaining damage.
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3)
Interpretation of stall test results
Stall speed
Higher than
2,300 rpm
Slippage of automatic transmission clutch, brake band, etc.
(Further stall tests are not
necessary. )
Remarks
Cause
Assessment
• Low line pressure (If stall
speed is higher than specified range at any shift position).
• One-way clutch slippage.
(If stall speed is higher than
specified range only in the
D range.)
* 1: Brake band slippage
(If stall speed is higher
than specified range
only in the 2 range.)
*2: Slippage of low &
reverse brake or reverse
brake
(If stall speed is higher
than specified range
only in the R range.)
•
•
2,100 - 2,300
rpm
• Control members are in good
order in the D, 2, 1 and R
ranges.
• Engine in good order.
Lower than
2,100 rpm
• Throttle not fully opened.
• Erroneous engine operation
or one-way clutch slippage.
** Road test
• Acceleration is not properly
made up to 50 km/h
(31 MPH).
• Car speed does not attain
more than 80 km/h
(50 MPH).
• Operation is not proper at
all car speeds.
• One-way clutch can be
checked for condition by
road tests. **
One-way clutch slippage.
*3: One-way clutch jamming.
Erroneous engine operation.
7-38
!
II
"I,l'l
I.·
II!
fl'
* 1: Brake band slippage cannot
be judged by stall tests;
however, if it slips, engine
speed is higher than specified rpm while car is being
driven in the 2 range.
*2: Slippage of reverse clutch/
low & reverse brake can be
judged by road tests.
If engine compression can
be used as a brake with
select lever in the 1 range,
reverse clutch is slipping; if
it cannot be used, low &
reverse brake is slipping.
FE
P'P
"",Ff
*3: Abnormal temperature rise
occurs.
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2) Road Test
Shift
Car speed
km/h (MPH)
DI -+ D2
50 - 59 (31 - 37)
D2 -+ D3
89 - 99 (55 - 62)
D3 -+ D2
82 - 92 (51 - 57)
D2 -+ DI
37 - 47 (23 - 29)
DI -+ D2
15-22(9-14)
D2 -+ D3
41 - 51 (25 - 32)
D3 -+ D2 or D3 -+ D I
13-22(8-14)
Dl -+ DI
10-17(6-11)
Full-throttle
4.0 - 6.7 (30 - 50, l.18 - 1.97)
*1 2 -+ II
41-51(25-32)
Minimum throttle 57.3 - 60.0
(430 - 450,16.93 - 17.72)
*12-+11
41 - 51 (25 - 32)
Negative pressure
-kPa(-mmHg, -inHg)
Road tests should be conducted to
properly diagnose the condition of the
automatic transmission.
I) Speed change characteristics
Kickdown
4.0 - 6.7 (30 - 50, l.18 - 1.97)
The standard speed change characteristics are indicated in the following
table.
Half-throttle
26.7 (200, 7.87)
* 1: Reduce the car speed by shifting to 1st range from D range [while car speed is
50 km/h (31 MPH) or thereabout].
2) Shift characteristics
Pay careful attention to ensure the
shift is made smoothly at the proper
car speed at which shifting begins.
I) Shifting shocks are encountered
or smooth shifting does not occur.
2) Shifting occurs slowly in response
to the condition of the engine throttle.
The above two problems are due to
incorrect throttle pressure or other
factors involved in throttle pressure.
3) Checking for shift patterns
1) In the D range, shifting should be
made as DI -+ D2 -+ D3 smoothly and
vice versa; it should not be made in
the R range.
2) Kick down should activate properly_
3) When the select lever is shifted
from the D range to the 2 or 1 range,
shifting should be made as D2 -+
2 (1 2) -+ II' Engine compression can
be utilized as a brake at 12 and II.
4) Shifting should not occur while
the select lever is at the 1 range.
5) With the shift lever in the 2 range,
the 2nd gear is engaged and 2nd speed
is maintained.
6) The select lever should be locked
when placed in the Prange.
In road tests, if any abnormality is
noticed in the 2 range, it is necessary
to adjust the brake band. If by inspection the brake band is in good order,
check the servo piston for any sign of
oil leakage from the seal.
4)
stances, may be due to the line
pressure being too high.
• Slippage or inability to operate the
car may, in most cases, be due to
loss of oil pressure for the operation of the clutch, brake band or
control valve.
Check for the 4WD function
With the car in the 4WD mode, turn
the vehicle in a circle while lightly
depressing the accelerator pedal, and
then shift the vehicle into the FWD
mode. When the vehicle is shifted into
the FWD mode, a light shock should
be felt.
Whenever the transfer clutch facing is
replaced with a new one, the above
test should be conducted, for the
run-in purpose, two to three times
with the vehicle set in the 4WD mode
and with the steering wheel fully
turned.
I)
Measuring the line pressure
1) Temporarily attach the Oil Pressure Gauge ASSY to a suitable place
in the driver's compartment, remove
the blind plug located in front of the
toeboard and pass the hose of the
Gauge ASSY to the engine compartment.
3) Line Pressure Tests
If the clutch or the brake band shows
a sign of slippage or shifting sensation
is not correct, the line pressure should
be checked.
• Excessive shocks during upshifting
or shifting takes place at a higher
point than under normal circum-
I Pressure gauge hose
A 13·223
2 Hole in toe board (blank cap hole)
3 Brake pedal
Fig. 7-56 Measurement of line
pressure
7-39
----'
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
,---
Tool No.
398573600
Unit: kPa (kg/cm 2 , psi)
Tool Name
2) Using the socket wrench (7),
remove the pressure check plug from
transmission cover (or intermediate
case.)
3) Attach an oil pressu.re adapter to
the pressure check plug hole in transmission cover (or intermediate case.)
Full
-4.0 (-30 -1.18 -
Throttle
position
Oil pressure
gauge ASSY
throttle
6.7 kPa
50 mmHg,
1.97 inHg)
Minimum throttle *2
Before* 1
cutdown
After
cutdown
Before
cutdown
After
cutdown
D
834 - 981
(8.5 - 10.0,
121-142)
539 - 637
(5.5 - 6.5,
78 - 92)
294 - 392
(3.0 - 4.0,
43 - 57)
294 - 392
(3.0 - 4.0,
43 - 57)
2
1,000 - 1,157
(10.2 - 11.8,
145 - 168)
579 - 677
(5.9 - 6.9,
84 - 98)
1,000 - 1,157
(10.2-11.8,
145 - 168)
579 - 677
(5.9 - 6.9,
84 - 98)
Range
R
1,373 - 1,569
(14.0 - 16.0,199 - 228)
461- 559 (4.7 - 5.7,67 - 81)
NOTES:
Fig. 7-57 Removing the pressure
check plug
*1: The "cutdown point" refers to those points where the line pressure in each
shift range (1, 0, 2 and R) changes in steps or where the pressure modifier
valve activates. The "before cutdown" refers to the state of the line pressure in
which the engine is running at low speeds and the car speed is below approximately 15 kmlh (9 MPH), while the "after cutdown" refers to the state of line
pressure in which the engine is running at high speeds and the car speed is
above approximately 35 kmlh (22 MPH).
*2: The line pressure, while the engine is idling, corresponds to the oil pressure of
the "before cutdown" with the engine at the minimum throttle operation.
3)
Interpretation of line pressure
1) Car in the FWD (front-wheel drive) mode
A13-453
Fig. 7-58
Tool No.
498897000
Oil pressure
adapter
498597000
Socket wrench
(7)
Engine at idle
(1,500 rpm)
in N range
•
•
High
•
•
•
Leakage at vacuum hose or vacuum
diaphragm or diaphragm too long.
Pressure regulator valve jamming.
•
In most cases problems may be due
to jamming of vacuum throttle
valve, pressure regulator valve or
pressure regulator plug.
Pressure will
,not rise.
Engine at full
throttle
Line pressure in each select range
The following table indicates the
relationship between the line pressure
and throttle position in each select
range.
Probable cause
Low
Tool Name
4) Connect the oil pressure adapter
and the tip end of the gauge ASSY.
5) Run the engine and check the line
pressures with the engine at a
minimum-throttle and full-throttle
operations.
2)
Symptom
Installing the oil pressure
adapter
Pressure rises
but does not
enter specified
range.
Oil pump worn or clearance improperly adjusted.
Leakage in oil pressure circuit.
• Pressure regulator valve inoperative.
If pressure fails to rise even though
vacuum pressure drops, check to
see if diaphragm rod was not installed.
NOTE:
Change of the diaphragm rod by one rank or [0.5 mm (0.020 in)] causes the line
pressure to change approximately 29 kPa (0.3 kg/cm 2 , 4 psi).
7-40
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2)
Car in the 4WD mode
If an abnormality occurs in the 4WD
the transfer clutch oil circuit to determine the cause of the problem.
operation, check the line pressure in
;-~,,--I
Reverse cI utch pressure
Engine at idle
(1,500 rpm)
in Neutral
Symptom
Probable cause
Pressure difference between 4WD and FWD
operation modes is more
than 29 kPa (0.3 kg/cm 2 ,
4 psi).
• Transfer pipe disconnected.
• Rear shaft seal ring not installed.
r;~
ir:J~~--.-J
Fig. 7-62
Pressure difference between 4WD and FWD
operation modes is less
than 29 kPa (0.3 kg/cm 2 ,
4 psi).
4) Governor Pressure Test
If the governor valve operation is
questionable as a result of road tests,
conduct the governor pressure test.
1) Remove the test plug from the
right side of the final reduction case
and, in its place, install the Adapter.
Tool No.
Tool Name
398893600
Adapter
• Solenoid or transfer valve
inoperative.
JS:
Forward clutch pressure
A13-456
5. Dismounting
1) Open engine hood and hold it
securely by a stay.
2) Remove spare wheel.
NOTE:
Car speed
km/h (MPH).
Governor pressure
kPa (kg/cm 2 , psi)
Less than
10 (6)
Do not put the spare wheel or a hand
on the air cleaner case to prevent
damage of air cleaner case.
0(0,0)
3) Disconnect battery cable from
negative ( -) terminal.
4) Remove spare wheel supporter.
5) Disconnect diaphragm vacuum
hose.
6) Disconnect speedometer cable,
and unfasten clip on speedometer
cable.
7) Disconnect wiring connections.
a. Back-up lamp switch connector.
b. Ground cable (on the car body).
c. Starter harness.
40 (25)
80 (50)
127 - 186
(1.3 - 1.9, 18 - 27)
363 - 461
(3.7 - 4.7, 53 - 67)
[For reference]
Locations of other oil pressure check
holes.
NOTE:
Do not disconnect the battery cable
from the starter.
8) Remove four bolts connecting
torque converter to drive plate
through timing hole.
A13-454
Fig. 7-60
pressure
A13-455
Fig. 7-59 Checking governor pressure
NOTE:
Be careful that the bolts do not fall
into the converter housing.
9) Disconnect oil cooler hose from
transmission.
2) Install the Gauge ASSY in a
suitable location in the driver's compartment and pass the gauge hose to
the engine compartment and attach
the Adapter to the hose end.
3) Warm up the engine by idling for
several minutes until the oil reaches
its operating temperature. While the
car is being driven, shift to the 2 range
and check the governor pressure.
Line pressure
2 Reverse clutch pressure
3 Forward clutch pressure
Standard governor pressure
Fig. 7-61
NOTE:
To prevent the oil from running out
of the hose, plug the open end of the
hose.
7-41
A13-337
10) Remove starter with battery cable,
and put it on bulkhead.
I I) Remove upper bolts which secure
engine to transmission; loosen lower
nuts.
12) Loosen nut [by approximately
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
10 mm (0.39 in)] which retains pitching stopper to the transmission side,
and tighten nut by an equal amount
on the engine side. Slightly tilt engine
backward in order to facilitate removal
of transmission.
NOTE:
Do not tighten the nut more than
10 mm (0.39 in).
18) Remove stabilizer.
19) Remove bolts which secure left
and right transverse links to front
crossmember, and lower transverse
links.
20) Drive both left and right spring
pins out of axle shaft.
NOTE:
Discard and do not re-use the spring
pins.
21) Pushing wheels toward the outer
side, separate axle shaft from drive
shaft.
22) Remove mount retaining nut from
rear crossmember.
23) Securely support transmission by
placing a jack under it.
24) Remove crossmember.
A4·113
Fig. 7-63
13) Disconnect O 2 sensor harness and
unclamp it.
14) Raise the front end of car by
placing a jack on the jack-up point in
front of side sill.
15) Remove front exhaust pipe ASSY
as follows:
a. Disconnect hot air intake hose.
b. Loosen nuts which secure exhaust
pipe ASSY to the eXhaust port of
engine.
c. Remove bolts which secure front
exhaust pipe to rear exhaust pipe.
d. Remove bolts which secure front
exhaust pipe to bracket on car
body.
e. Supporting front exhaust pipe
ASSY, remove nuts from the exhaust port of engine. Exhaust pipe
ASSY can now be removed.
NOTE:
Be careful not to strike the oxygen
sensor against any adjacent parts
during removal.
16) Drain out ATF and then disconnect oil supply pipe.
NOTE:
Be careful not to damage the O-ring.
17) Move the select lever to the "P"
position, and at this point, mark the
location of the connector nut and
separate the manual lever from the
linkage rod.
25) Remove two nuts which secure
engine to transmission, and move
transmission away from engine just
enough so that transmission mainshaft
does not interfere with engine.
Lower jack and dismount transmission,
exercising care not to strike it against
any adjacent parts.
6. Disassembly,
Inspection
and Assembly
GENERAL DESCRIPTION
When disassembling or assembling the
automatic transmission, observe the
following instructions.
I) Workshop
Provide a place that is clean and free
from dust. Principally the conventional
workshop is suitable except for a
dusty place.
In a workshop where grinding work,
etc. which produces fine particles is
done, make independent place divided
by the vinyl curtain or the equivalent.
2) Worktable
The size of I x 1.5 m (40 x 60 in) is
large enough to work, and it is more
desirable that its surface be covered
with flat plate like iron plate which is
not rusted too much.
3) Cleaning of exterior
Clean the exterior surface of transmission with steam and/ or kerosene
prior to disassembly, however it should
7-42
j,L
I
be noted that a cap be placed on the
airbreather to prevent infiltration of
the steam into the transmission and
also the cleaning job be done away
from the place of disassembly and
assembly.
4) Disassembly, assembly and cleaning
a. Disassemble and assemble the transmission while inspecting the parts
in accordance with the Troubleshooting.
b. During job, don't use gloves.
Don't clean the parts with rags:
Use chamois or nylon cloth.
c. Pay special attention to the air to
be used for cleaning.
Get the moisture and the dust rid
of the air as much as possible.
d. Complete the job from cleaning to
completion of assembly as continuously and speedily as possible in
order to avoid occurrence of secondary troubles caused by dust.
When stopping the job unavoidably
cover the parts with clean chamois
or nylon cloth to keep them away
from any dust.
e. Use kerosene, white gasoline or the
equivalent as washing fluid.
Use always new fluid for cleaning
the automatic transmission parts
and never reuse. The used fluid is
usable in disassemble and assemble
work of engine and manual transmission.
f. Although the cleaning should be
done by dipping into the washing
fluid or blowing of the pressurized
washing fluid, the dipping is more
desirable. Assemble the parts immediately after the cleaning without exposure to the air for a while.
Besides in case of washing rubber
parts, perform the job quickly not
to dip them into the washing fluid
for long time.
g. Apply the automatic transmission
fluid (ATF) onto the parts immediately prior to assembly, and
the specified tightening torque
should be observed carefully.
h. Use vaseline if it is necessary to
hold parts in the position when
assembling.
i. Refer to the Service Data in Chapter 2. for the serviceable limit.
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
j. Replace gaskets, seals, lock washers,
staking nuts, servo apply pipe and
servo release pipe with new ones
whenever they are disassembled.
k. Drain ATF and differential gear oil
into a saucer so that the conditions
of fluid and oil can be inspected.
2 TORQUE CONVERTER
SECTION
As torque converter is welded all
around it, it is impossible to disassemble it.
1) Removal
1) Remove oil pan drain plug and
drain the ATF .
NOTE:
Check the volume and state (color,
smell, etc.) of the ATF.
2) Take out the torque converter
ASSY from converter housing taking
care of the following.
a. Prepare the appropriate saucer
under converter housing to receive
the ATF which pours out from the
torque converter ASSY, turbine
shaft and/or oil pump drive shaft.
b. When taking out torque converter,
turbine shaft and oil pump drive
shaft may come out together.
In this case take them out straight
and gradually not to bend them.
2) Inspection
1) Check the one-way clutch function of stator with the spline of stator
shaft engaged into stator and replace
if defective.
It is normal that when turning stator
shaft
counterclockwise,
one-way
clutch is engaged, and when clockwise,
the clutch is released.
2) Check for the exterior damage, oil
leakage, bend and depression, and
replace if defective.
3) Completely take off the rust on
the pilot and/or sleeve of converter.
4) If the ATF is soiled or excessively
deteriorated, wash the interior of
torque converter as follows.
a. Take off the remained ATF in
torque converter.
b. Pour 0.5 Q (0.5 US qt, 0.4 Imp qt)
of gasoline. (unleaded gasoline or
kerosene)
c. Blow in the compressed air to wash
the interior and then drain the
gasoline.
d. Pour 0.5 Q (0.5 US qt, 0.4 Imp qt)
of ATF.
e. Blow in the compressed air and
drain the ATF.
3) Remove the temperature switch
with a wrench.
NOTE:
Ensure that the harness is detached
from .the clamp in advance.
3) Installation
Install torque converter straight onto
shaft while turning it slowly.
Temperature switch
3 DISASSEMBLING THE
ENTIRE AUTOMATIC
TRANSMISSION
A13-459
Fig. 7-66 Removing the temperature
switch
1) Transfer Section
(4WD Models)
1) Remove the rear engine mount
(rubber cushion) and place the transfer
unit on a work bench with the oil pan
facing down.
Fig. 7-64
Transfer unit
2) Remove the solenoid from the
transfer unit by turning it by hand.
NOTE:
a. Be sure to remove the solenoid
first.
b. Ensure that the harness is detached
from the clamp before separating
the transfer unit from the engine.
c. Remove the "0" ring together with
the harness.
A13-458
Fig. 7-65 Removing the solenoid
7-43
4) Remove the extension ASSY.
To do this, remove the eight 8 mm
bolts and extract the transfer section
together with the extension ASSY.
NOTE:
a. Place a container to receive ATF
remaining in the extension.
b. Be careful not to drop the rear
drive gear thrust plate and transfer
drive gear ASSY.
c. Remove the washer from the bearing bore on the upper side of the
intermediate case.
d. Do not place the opening of the
extension ASSY down, as this may
cause the rear shaft ASSY to drop.
2) Transmission Case Section
1)
Remove the rear extension ASSY.
(4WD)
2) Drain AFT. (AFT should be
drained when the transmission is dismounted from the vehicle.)
3) Carefully pull the turbine output
shaft and oil pump drive shaft straight
out.
If they are hard to remove by hand,
wrap their splines with a cloth or vinyl
tape and extract them using pliers. Be
careful not to damage the splines.
4) Disconnect the oil cooler pipe
from the transmission case.
5) Remove the lead wire clips.
To do this, remove the nuts which
secure the transmission case to the
final reduction case, and remove the
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
downshift solenoid, transfer solenoid
and temperature switch lead wire clips.
6) Remove the vacuum pipe and
ground lead wire.
To do this, remove the bolts which
retain the governor cover and disconnect the vacuum pipe and ground lead
wire.
7) Remove the oil supply pipe.
Disconnect the oil supply pipe from
the transmission case. Ensure that
ATF is drain out before disconnecting
the pipe.
in order not to damage the oil seal.
(4WD)
4) Separate the transmission case
section from the final reduction case
section.
NOTE:
1) Remove the washer from the
upper surface of the intermediate case
at the bearing bore location.
Be careful not to lose the "0" ring
located at the end of the pipe.
4 TRANSFER CASE
SECTION (4WD)
A13·463
Fig. 7-70 Removing the ball bearing
and driven gear UN
1) Disassembly
5) Remove drum AY using Remover
(499717000).
8) Drain the differential gear oil
completely.
9) Also drain ATF remaining in the
transmission case and place the transmission on a bench with the housing
down, as shown in the figure.
A13-464
A13-461
Fig. 7-68 Removing the extension
ASSY
A13-460
Fig. 7-67 Placing the transmission
on a bench
Fig. 7-71
Removing the drum
6) Drive the ball bearing (30x72x 12)
out, using Remover (499717000).
2) Remove the rear shaft ASSY from
the extension case.
NOTE:
Be careful not to damage the oil seal
located at the rear of the extension.
NOTE:
a. The automatic transmission and the
differential sections are not separated from each other under normal
circumstances.
b. However, if the two must be
separated, follow the disassembly
procedure of the final reduction
case section to separate the two,
and place the automatic transmission section on Stand (399933610).
3)
Final Reduction Case
Section
1) Remove extension ASSY. (4WD)
2) Remove oil pan and control valve.
(4WD)
3) Wrap vinyl tape around the spline
portions of the drive pinion rear end
Fig. 7-72 Removing the ball bearing
Rear shaft assembly
A13·462
Fig. 7-69 Removing the rear shaft
ASSY
3) Remove the seal ring.
4) Using Removers (8998641 (0) and
(499717000), drive out the ball bearing (20x52x 15), washer (20x38x4)
and transfer driven gear UN.
7-44
7) Disassemble the transfer clutch
ASSY. Pry off the snap ring (inner:
98.5) and remove the front pressure
plate, three plates UN3, two plates 3
and rear pressure plate.
Front pressure
Drum CP Clutch driven plate 3
plate
Rear pressure
Clutch drive \
plate
plate UN3
~
I
[?t;l (10]
.....
~- " ,
Inner snap ring
()]>~
A13-466
Fig. 7-73 Component parts of the
transfer clutch ASSY
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
6) Rear drive shaft seal ring
Replace if the seal ring is worn or
otherwise damaged.
..--
...c:
~-
U:
I
I
0
3) Assembly
A13-467
Fig. 7·74 Removing the snap ring
2) Inspection
Wash the disassembled parts and check
for the following:
1) Bearings
Replace any bearing if:
a. The balls, outer race or inner race
are damaged or rusted.
b. Various parts of the bearing are
worn excessively.
c. The bearing does not spin smoothly
or is noisy even after being lubri·
cated with gear oil.
d. Other abnormalities are noticed.
2) Transfer gear
Backlash
0.051 - 0.125 mm
(0.0020 - 0.0049 in)
Replace the transfer gear if:
a. The surface is chipped, worn or
otherwise damaged.
b. The roller surface is worn or otherwise damaged.
c. The bore of the transfer driven gear
UN or the end face is damaged.
3) Rear drive shaft
Repair or replace if the sliding surface
of the transfer driven gear UN is
excessively damaged.
4) Plates UN3 and 3
Replace if plates or surfaces are worn*
or damaged.
1) Transfer clutch ASSY
Apply a coat of recommended ATF to
all parts and assemble all parts in the
order of disassembly.
a. Assemble the bearing (30x72xI9)
and drum ASSY to the rear shaft.
b. Install the rear pressure plate, plates
3, plates UN3 and front pressure
plate.
Installer
(899874100)
:0
(I)
ill
""
l.fjI
.1'_.,..__________,_"_"'",. . . . . .,'. '______- ___________
'.k...·...· ---___
·_'....
h*-<-_"Ij.<1'!
II ~
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2. Removal
4. Inspection
NOTE:
1) Detach parking brake cover and
console box.
2) Disconnect electric connectors for
inhibitor switch and indicator illumi·
nation light.
3) Remove rod from transmission
selector arm.
Be careful not to damage the con·
nected parts.
2) Confirm the following parts for
operating condition before assembly.
1
2
3
4
Guide plate
Spring pin
Selector lever installing bolt
Boot
A19-076
Fig. 7·196 Driving the spring pin
A4·143
Fig. 7·194
4) Remove screws and
selector lever ASSY.
take
out
NOTE:
Before removing, set the selector lever
to "N" position.
1) Inspect the removed parts by
comparing with new ones for deforma·
tion, damage and wear. Correct or
replace if defective.
3) Remove selector lever installing
bolt and detach the boot by pushing
it from underneath, then disconnect
the selector lever from plate.
4) Install the grip and button to the
selector lever temporally, and drive
the spring pin out from rod, taking
care not to make damage on con·
nected parts.
a. Sliding condition of the button in
the grip. ... they should be moved
smoothly.
b. Insertion of the grip on the selector
lever ... When pushing the grip on
selector lever by hand, the screw
holes should be aligned in line.
c. Operation of the selector lever
and rod .... they should be moved
smoothly.
d. Insertion of the spacer into the
selector lever ... it should be insert·
ed lightly by fingers.
e. The spacer should be inserted
between guide plate and bracket.
Load
Rod
[3.5 - 3.8mm
(0.138-0.150 in)
dia.J
3. Disassembly
-----------1 Guide plate
2 Bracket
3 Spacer
1) Remove rod, grip, indicator and
inhibitor switch from selector lever
ASSY.
A19·078
Fig. 7·199
A19·026
Fig. 7·197 Driving out spring pin
NOTE:
Do not remove the bushings from
selector lever.
1 Rod
2 Grip
3 Indica~or
4 Inhibitor switch
5. Assembly
1) Clean all disassembled parts.
2) Assemble rod to selector lever.
a. Apply grease 01'\ both sliding part
ends of rod, then insert it into
selector lever.
A19'075
Fig. 7·195
2) Drive out the spring pin to the
position where it is detached from the
guide plate as shown in figure.
A19·027
Fig. 7·198 Selector lever bushings
A19·079
Fig. 7·200
7-73
I
---'-'
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
b. Match the oblong hole of selector
lever and the spring pin hole of
rod.
c. Press the spring pin into the selector lever and rod from arm side.
In order to prevent the spring pin
from contacting with the guide
plate, stop the spring pin at opposite side surface of the arm as
shown in figure.
12 - 20 N'm
(1.2 - 2.0 kg-m,
9-14ft-lb)
Torque
(Flange nut)
c. Drive in the spring pin to the
same level of arm outer surface.
Spring pin
1 Flange nut
2 Spacer
3 Bolt
4 Plate complete
A19·0S2
Fig. 7-205
A19-0Sl
Fig. 7-203
I Arm
2 Pressing direction
3 Spring pin
4 Rod
Fig. 7-201
b. Insert the boot into the plate
by pushing boot edge with fingers.
A19-029
5) Assembling inhibitor switch.
a. If there is no knock pin prepared
on the inhibitor switch, fix the
moving plate by inserting a 2 mm
(0.08 in) dia. rod into the knock
pin hole while matching a hole of
moving plate and knock pin hole at
the case.
PUSh ...
~ .~
Installing spring pin
I
3) Assemble the following parts to
selector lever.
I nsert groove Into
the plate firmlV.
A19-032
Fig. 7-204 Inserting boot
A13-25l
Fig. 7-206
1
2
3
4 Spacer
A19·0S0
Fig. 7-202
a. Spring
Apply grease to prevent noise.
b. Bushing
c. Boot
Coat grease on sliding surface of
the boot.
d. Spacer
Coat grease on the surface of spacer.
4) Assemble selector lever to plate.
a. Install the selector lever to the
plate complete, and insert the bolt.
Tighten flange nut to the specified
torque.
®
1
2
3
4
5
6
7
Moving plate
Case
Knock pin
Harness
Connector
Locator
Bolt hole
A19-0S3
Fig. 7-207
7-74
'----T
!
I,
I,
'~""
\,11
'If·1
.j
~
L.~
·-J""'·_""r"'"...,-_"'"_________""'''1'_''''''
F.r" ____________________
,... ,......-... ,.t"',j.~--"tFRT3Rli
__
'1
'-1
t
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
a. Bushing
Apply grease to the inside and
side surface of bushing.
b. Rod
c. Washer
d. Cotter pin
After inserting the cotter pin into
rod hole, be sure to bend it.
b. At the position where the selec~or
lever is shifted in the "N" range
and pushed to the "P" side lightly,
match the locator to bracket hole,
the moving plate pin to arm hole,
then tighten the bolts to the
specified torque.
4- 8 N'm
(0.4 - 0.8 kg·m,
2.9 - 5.8 ft·lb)
Torque
...
Front
N
p
\
PUlh IIlIhtlV to
"P" pOlltlon
.r-""'Oo<..-,.o
\
--r-'@
1 Grip
2 Sprlnl
3 Button
A 18·081
Fig. '·210
a. Apply grease on the sliding part
of the grip and button, and spring.
b. Insert the spring into the but·
ton and insert it into the grip from
the spring side.
c. Insert the grip on the selector
lever while pushing button in the
grip.
d. Set the button to driver's side, then
tighten screws to the speCified tor·
que with the torque driver.
Torque
5 to 6 mm (0.20 to 0.24 in) length
3 Sprinl pin position
4 Guide pllte
AHI·OB.
Fig. '·208
c. Pull out the 2 mm (0.08 in) dia. rod
(knock pin) at the inhibitor switch.
6) Assemble indicator to plate.
Torque
(Flange
screw)
1.3 - 2.6 N'm
(0.13 - 0.27 kg·m,
0.9 - 2.0 ft.lb)
8. Instanatlon
1) Install the following parts to
transmission selector arm.
1.3 - 2.6 N'm
(0.13 - 0.27 kg·m,
0.9 - 2.0 ft·lb)
1 Locltor
2 Movilll plate pin
10) Screw in one nut fully to the
threaded part of rod.
screw should be used.
8) After assembly, inspect the fol·
lowing items by shifting the selector
lever from "P" to "1" range while
pushing the grip button.
• Contact between indicator and
selector lever.
• Matching of the pointer and
position mark.
• Selector lever shifting force.
9) Assemble the following parts to
selector lever.
1 Bushinl
2 Connector
3 Wilber
4 Cotter pin
A111·088
Fig. '·212
a. Bushing
Apply grease to the inside and
side surface of bushing.
b. Connector
Insert the connector from trans·
mission side.
c. Washer
d. Cotter pin
Be sure to bend cotter pin.
2) Pass the rod through connector
and tighten a nut temporarily.
Fig. '·209
A18·085
A18·087
1 Bulhinl
2 Rod
7) Assemble the grip, spring and
button to selector lever.
3 Wilber
4 Cotter pin
Fig. '·211
7-75
A 111·0811
Fig. '·213
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3) Install selector lever assembly to
the body.
a. Affix butyl rubber tape around the
through hole but inside the four
thread holes.
a. While pushing the rod lightly by a
finger [2.0 to 6.9 N (0.2 to 0.7 kg,
0.4 to 1.51b)], set the nut A apart
from the connector by 1 ± 1 mm
(0.04 ± 0.04 in) as shown in the
above illustration.
b. While holding the nut A with a
spanner, tighten the nut B.
NOTE:
At this time, the select lever pin must
be kept at the position of the guide
plate as shown in the following
illustration.
Guide plate
Torque
(Nut)
Fig. 7-214
b. Tighten flange tapping screws.
Torque
4.4 - 7.4 N'm
(0.45 - 0.75 kg-m,
3.3 - 5.4 ft-Ib)
c. Set the selector lever in "N" position.
4) Set the transmission selector arm
in UN" position where the center of
connector is aligned with the casted
boss on transmission case.
Transmission case
10 - 18 N·m
(1.0 - 1.8 kg-m,
7 - 13 ft-Ib)
6) After completing installation,
make sure that the lever operates
properly as follows.
a. The lever moves smoothly through
all the positions.
b. In UN" or "D" position of the lever
with the engine stopped, make sure
the operation of the lever according
to the following procedure.
CD Set the lever to "N" position
while pushing the button.
ell Take your hand off the lever and
button.
@ Try to move the lever to "R"
position without pushing the
button, and make sure that the
lever does not move to "R" posi·
tion.
NOTE:
At this time, the select lever spring pin
must be kept at the position of the
guide plate as shown in the following
illustration.
Casted boss
Guide plate
A19·091
Fig. 7-215
5) Adjust connection of rod with
selector arm as follows.
Fig. 7·218
A19-150
7) Connect electric connectors for
inhibitor switch and indicator illumi·
nation light.
•
Front
A19-074
Fig. 7·219
8) Check inhibitor switch operation
as follows_
a. The engine can be started with
selector lever at only "N" or "P"
position.
b. The reverse lamp lights with selector lever at only "R" position.
c. There must be no position between
"P" and "N" positions wherein
the reverse lamp is lighted, and at
the same time, engine can be
started.
9) Install the console box and the
hand brake cover.
A19-149
Fig. 7-217
@ Proceed to set the lever to "D"
position while pushing the button.
@ Take your hand off the lever and
button.
@) Try to move the lever to "2"
A19·148
Fig. 7-216
position without pushing the
button and make sure that the
lever does not move to "2" position.
7-76
Console box
A19-073
Fig. 7-220
AUTOMATIC TRANSMISSION AND DIFFERENTIAL.
7 -4. Special Tools
1. Special Tools for Differential
499987100
398653600
498517000
399913601
Socket Wrench (35)
Shaft
Replacer
Master
Drive pinion
Drive pinion and
reduction drive gear
Drive pinion front
bearing core
Drive pinion
A13-511
Fig. 7-221
Fig. 7-225
A 13-192
Fig. 7-229
ST-151
Fig. 7-233
499267100
398833600
498477000
399913603
Spacer
Guide
Handle
Holder
Oil seal holder
Needle bearing
Bearing cup, needle bearing,
drive pinion front bearing
retainer and impeller
bushing.
Drive pinion
0
A13-516
Fig. 7-222
~
Fig. 7-226
A13-194
~
Fig. 7-230
ST-150
m
Fig. 7-234
499247200
399513600
399863610
399913604
Installer
Installer
Remover
Spacer
Final reduction case
Drive pinion rear
bearing cup
Needle bearing
Drive pinion
Fig. 7-223
A13-517
~
Fig. 7-227
A 13-196
~
Fig. 7-231
A 13-190
A13-189
({[a,
ST-152
Fig. 7-235
A13-187
398643600
398437700
499427000
499247000
Gauge
Drift
Installer
Installer
Low & reverse brake, total
endplay, oil pump, drive
pinion height
Drive pinion front
bearing cup
Drive pinion front bearing
cup, axle shaft bearing cUP.
and thrust bearing retainer
Drive pinion oil seal
I
Fig. 7-224
@
6
A,13-211
Fig. 7-228
A14-046
Fig. 7-232
7-17
A14-079
Fig. 7-236
A 13-518
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
399780111
899924100
398781600
899580100
Wrench
Handle
Re.duction drive gear
Stopper
Reduction drive gear
Installer
Drive pinion
Axle shaft oil seal holder
i
aJ
I
A12·18.
Fig. 1·231
399790110
Installer
Roller bearing (Differential)
Axle shaft oil seal
-
Laj
A12·175
Fig. 1·238
499827000
Press
Speedometer shaft oil seal
ST·1.,
Fig. 1·239
899904100
Remover
Differential case
•
Fig. '·240
Fig. 1·241
A12·1 ••
499897000
Pliers
Snap ring
~
Fig. 1·242
Fig. 1·246
498247001
Magnet Base
Backlash of gears
399520105
Seat
Roller bearing
(Differen tial)
Fig. 1·243
Fig. 1·244
Differential Stand
Final reduction section
A5·1.2
ST·158
Fig. 1·241
:9[
-
J'Q.
g
A
~
~
A13·50.
Fig. 1·260
499917200
Master 2
Drive pinion
9
-- 1
A12·171
399703600
Puller
Axle shaft bearing cup
~
.12·18'
Q
A12·17,
Fig. 1·249
499937000
is-
C.
A13·51.
498247100
Dial Gauge
Backlash of gears
i
A12·1'3
FIg. 1·245
899524100
Puller Set
Roller bearing
(Differential)
!
cI'
~
~
I
-...;,
Fig. 1·261
A13·510
498847000
Oil seal Guide
Oil seal holder
e~
ST·1iS7
Fig. '·248
A13·188
A13·515
Fig. '·252
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
498807000
Bearing Guide
Needle bearing
-
~
Fig. 7·253
A 1 3·S1 2
498567000
Pulley
Preload check
-
(~)
Fig. 7·254
A13·513
499247100
Oil Seal Installer
Oil seal holder
QFig. 7·255
A13-514
7-79
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
2. Special Tools for Transmission
398534800
398603610
399893600
499527000
Adapter 2
Socket
Plier
Puller Set
Line pressure
Brake band
Reverse clutch, forward
clutch and low & reverse
brake
Final reduction case
.Q (j?
A13-203
Fig. 7-256
~
~
A13-209
Fig. 7-260
A13-207
Fig. 7-264
,
,
A13-338
Fig. 7-268
499717000
398573600
498147000
499687000
Oil Pressure Gauge Assembly
Depth Gauge
Base
Remover
Line pressure and governor
pressure
Low & reverse brake
Low & reverse brake
Rear shaft bearing
,
Q
~
@
r",
,! ~~!~--;
-""- --.
c , :r)J.~.'
lJLi
~
A13-201
Fig. 7-257
ST-146
Fig. 7-261
ST-160
Fig. 7-265
A13-524
Fig. 7-269
398893600
398623600
499667000
398308700
Adapter
Seat
Thickness Gauge
Puller
Line pressure and governor
pressure
Center support assembly
Forward clutch, reverse
clutch, low & reverse
brake and oil pump etc.
Transmission case oil seal
C
ff{J[fJ
A13-202
Fig. 7-258
Fig. 7-262
r
~
E_ _
A13-210
o
,
Fig. 7-266
ST-159
d
A13-215
Fig. 7-270
398663600
398673600
399793600
Plier
Compressor
Installer
Installer 2
Final reduction case
Transmission case oil seal
Governor valve
Reverse clutch, forward
clutch and low & reverse
brake
~
~
-
C)
~
~
-
'.
Fig. 7-259
'11
ij-"
.a.,.:¢::,~
-~
A13-205
Fig. 7-263
f._!...
_ _"-,,,,,,,,,...
' -....'.....
lj.......
'Q ....
A13-208
~
Fig. 7-267
399248700
A13-214
a
Fig. 7-271
\
A13-216
7-80
........,.'....I""-_ _ _ _ _ _ _ _ _"....""""_ _ _ _ _-
'~-'1
_ _ _ _ _ _ _ _ _ _ _ __
AUTOMATIC TRANSMISSION AND DIFFERENTIAL
499337000
399903600
499917300
Vernier Calliper
Remover 2
Gauge Set
Vacuum diaphragm rod
selection
Needle bearing and bushing
on oil pump carrier
Vacuum diaphragm rod
~
W---~c:=>A13-217
Fig. 7-272
ST-158
Fig. 7-280
Fig. 7-276
498107000
498597000
Replacer
Socket Wrench (7)
Impeller bushing on
converter housing
Plug
~
Fig. 7-273
c:=TI
ST-155
Fig. 7-271
A13-520
398863600
498897000
Installer 2
Adapter
Needle bearing on oil
pump carrier
Measure the line pressure
9
Fig. 7-274
~
A13-213
Fig. 7-278
A13-521
399543600
499257100
Installer
Oil Seal Guide
Needle bearing and bushing
on oil pump carrier
Drive pinion oil seal
~
®
Fig. 7-275
A13-212
Fig. 7-279
A13-522
7-81
A13-523
,1'
.,,,"~,
......,........, ............
"'_ _ _
4.~''''I~'''~'
~
' f'_' .' 1!_·_'' ' '+' ' ' ·..·..-ttt..· , - -..
_ _'''''_ _ _ _ _
y·..._
.._ , - _ -. . ._ _., ._ ·...
'_
.._il..
' ........_ _ _ _,_,,_ _ _. .
CHAPTER [g)
REAR WHEEL DRIVING SYSTEM
(4WD MODEL)
Page
8-1.
SPECIFICATIONS AND SERVICE DATA. . • • . . • • . • . • • • • • • •• 8- 2
1. Speciflc.tiona ..•....•..
8- Z
Z. Service Dati ........••...........
8- 2
COMPONENT PARTS •••••.••••..••..••..••..••••••... 8- 4
REAR DIFFERENTIAL .•••.••••••••.••...••.•••••••.•. 8- &
1. Component Parts of Differential Alllmbly •.•...•..•...•••. 8- &
2. On-c.r SlrviCiI.
8- 8
3. Dllmountlng Differantlal Alllmbly ....•...••.•...•..•..• 8- 7
4. Di....mbly ..•••
8- 7
II Inlplctlon ......
8- 8
8. AUlmbly ..
8- 8
7. Mounting .•..••.••
8-13
DRIVE SHAFT ...
8-1&
PROPELLER SHAFT •.••
8-1&
1. RemovII.. '. . . . . . . . . . . . . . .
8-1&
2. Inspactlon.
8-1&
31 Dil.nlmbly
8-18
4. A.Mmbly
8-18
51 Instlnatlon.
8-18
TROUBLESHOOTING •••.••.•••••..••.•••..••••••.•.•• 8-17
1. Relr Differential .•.....•...
8-17
8-18
2. Propeller Shaft •.•.
8-18
SPECIAL TOOLS ••
I
8-2.
8-3.
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8-7.
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8-8.
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8-&.
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•
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
8-1. Specifications and Service Data
1. Specifications
~
Rear
reduction
gear
Rear differential
Tooth
number
of gear
Gear
ratio
~
Hatchback
Type
Final
39/10
3.900
Side
gear
16
1/
Pinion
gear
Type
of gear
10
V
Hypoid
Straight
bevel
gear
Distance
between
joints
Propeller
shaft
Tube outer
diameter x
tube thickness
Station Wagon
and Brat
2-joint type
1,057 mm
(41.61 in)
1,136 mm
(44.72 in)
63.5 x 1.6 mm
(2.500 x 0.063 in)
68.9 x 1.6 mm
(2.713 x 0.063 in)
A14·040
Fig. 8-1 Construction of propeller shaft
2. Service Data
Rear
differential
New bearing
Front & rear bearing preload at
companion flange bolt hole
Used bearing
Preload adjusting washer length
Preload adjusting spacer length
8-2
19.6 - 28.4 N
(2.0 - 2.9 kg, 4.4 - 6.4lb)
8.34 - 16.67 N
(0.85 - 1.7 kg, 1.87 - 3.75Ib)
Part No.
383705200
383715200
383725200
383735200
383745200
383755200
383765200
383775200
383785200
383795200
383805200
383815200
383825200
383835200
383845200
2.59 mm
2.57mm
2.55 mm
2.53 mm
2.51 mm
2.49 mm
2.47 mm
2.45 mm
2.43 mm
2.41 mm
2.39 mm
2.37 mm
2.35 mm
2.33mm
2.31 mm
Part No.
383695201
383695202
383695203
383695204
383695205
383695206
56.4 mm
56.6 mm
56.8 mm
57.0 mm
57.2 mm
(0.1020 in)
(0.1012 in)
(0.1004 in)
(0.0996 in)
(0.0988 in)
(0.0980 in)
(0.0972 in)
(0.0965 in)
(0.0957 in)
(0.0949 in)
(0.0941 in)
(0.0933 in)
(0.0925 in)
(0.0917 in)
(0.0909 in)
56.2 mm (2.213 in)
(2.220 in)
(2.228 in)
(2.236 in)
(2.244 in)
(2.252 in)
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
Rear
differential
( continued)
Part No.
383495200
383505200
383515200
383525200
383535200
383545200
383555200
383565200
383575200
383585200
383595200
383605200
383615200
383625200
383635200
383645200
383655200
383665200
383675200
383685200
Pinion height adjusting washer thickness
Side gear to thrust washer clearance
Side gear thrust washer thickness
(0.1217 in)
(0.1228 in)
(0.1240 in)
(0.1252 in)
(0.1264 in)
(0.1276 in)
(0.1287 in)
(0.1299 in)
(0.1311 in)
(0.1323 in)
(0.1335 in)
(0.1346 in)
(0.1358 in)
(0.1370 in)
(0.1382 in)
(0.1394 in)
(0.1406 in)
(0.1417 in)
(0.1429 in)
(0.1441 in)
0.1 - 0.2 mm
Part No.
383445201
383445202
383445203
Side bearing standard width
Side bearing retainer shim thickness
Part No.
383475201
383475202
383475203
383475204
383475205
Drive gear to drive pinion backlash
Drive gear runout on its back surface
Oil capacity
Propeller
shaft
3.09mm
3.12 mm
3.15 mm
3.18mm
3.21 mm
3.24 mm
3.27 mm
3.30 mm
3.33 mm
3.36 mm
3.39 mm
3.42 mm
3.45 mm
3.48 mm
3.51 mm
3.54 mm
3.57 mm
3.60 mm
3.63 mm
3.66 mm
Limit
Tube runout
Joint bending resistance
Axial play of journal
Axial play adjusting snap ring thickness
Limit
Maximum
Part No.
622033000
622033010
622033020
622033030
622033040
622033050
622033060
622033070
Paint color
White
Yellow
Red
Green
Blue
Light Brown
No paint
Pink
(0.004 - 0.008 in)
0.75 - 0.80 mm (0.0295 - 0.0315 in)
0.80 - 0.85 mm (0.0315 - 0.0335 in)
0.85 - 0.90 mm (0.0335 - 0.0354 in)
20.00 mm (0.7874 in)
0.20 mm (0.0079 in)
0.25 mm (0.0098 in)
0.30 mm (0.0118 in)
0.40 mm (0.0157 in)
0.50 mm (0.0197 in)
0.10 - 0.20 mm (0.0039 - 0.0079 in)
0.05 mm (0.0020 in)
0.8 Q(1.7 US pt, 1.4 Imp pt)
0.6 mm (0.024 in)
1.5 N·m (I5 kg.cm, 13 in.lb)
0.02 mm (0.0008 in) or less
2.00
2.02
2.04
2.06
2.08
2.10
2.12
2.14
± 0.01
± 0.01
± om
± 0.01
± 0.01
± 0.01
± 0.01
± 0.01
mm
mm
mm
mm
mm
mm
mm
mm
(0.0787 ± 0.0004 in)
(0.0795 ± 0.0004 in)
(0.0803 ± 0.0004 in)
(0.0811 ± 0.0004 in)
(0.0819 ± 0.0004 in)
(0.0827 ± 0.0004 in)
(0.0835 ± 0.0004 in)
(0.0843 ± 0.0004 in)
8-3
----!
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
8·2. Component Parts
Tightening torque N·m (kg-m, ft·lb)
T1:
T2:
T3:
T4:
69·78
31·36
18·215
39·49
(7.0·8.0,151 ·158)
(3.2·3.7,23·27)
(1.8·2.15,13·18)
(4.0·6.0,29·36)
1 Propeller lhaft II..mbly
2 Ditrerentlailiaembly
3 Drive Ihaft (R) II..mbly
4 Bolt compl.
5 Splnelle
6 Brelther CIP
7 Pick Ina
8 Pick Ina
9 O·rlna
10 Sprlna pin
11 Bolt
12 Sprlna wllher
13 Nut
14 Snip rlna
15 Cro.. Joint ....mbly
16 Dltrerential mount member ....mbly
17 Bolt ....mbly
18 Brlcket compl. (R.H.)
19 Brlcket compl. (L.H.)
20 Brlcket II..mbly (F)
21 Wllher
22 Dltrerentlal mount bolt
23 Wllher
24 Wimer
25 Stopper
26 Self lock nut
27 Self lock nut
Fig. 8·2 Construction of rBlr drive system
8-4
lit
sq."
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
8-3. Rear Differential
1. Component Parts of Differential Assembly
'Selective parts
Tightening torque N'm (kg-m, ft-Ib)
T1: 167 - 196 (17.0 - 20.0,123 - 145)
•
T2: 19 - 25 (1.9 - 2.6,14 -19)
Stake the pinion nut after tightening
T3: 69 - 78 (7.0 - 8.0, 51 - 58)
T4: 9 - 12 (0.9 - 1.2,6.5 - 8.7)
A14-098
1 Side gear
2 Pinion mate gear
3 Pinion crown gear set
4 Differential carrier
S Pinion mate gear washer
*6 Pinion height adjusting washer
7 Rear bearing
*8 Bearing preload adjusting spacer
*9 Bearing preload adjusting washer
10 Front bearing
11 Spacer
12 Pilot bearing
13 Front oil seal
14 Companion flange
1S
16
17
18
19
20
21
*22
23
24
Drive pinion nut
Side bearing
Side bearing retainer
Differential case
Side oil seal
Pinion mate shaft
Side bearing retainer O-ring
Side bearing retainer shim
Bolt (8x20x14 mm)
Pinion shaft lock pin
Fig_ 8-3 Component parts of differential assembly
8-5
2S Lock plate
26 Bolt (lOx20xl2 mm)
*27 Side gear thrust washer
28 Rear cover
29 Stud bolt
30 Plug
31 Plug cpo
32 Bolt (lOx30x18 mm)
33 Washer
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
2. On-car Services
g. Remove oil seal.
1) Replacing Front Oil Seal
a. Drain gear oil
b. Jack up rear wheels and support
the vehicle body with rigid racks.
c. Detach propeller shaft from companion flange.
d. Measure turning resistance of companion flange.
NOTE:
Measure turning resistance after making sure that the companion flange
turns smoothly.
b. Loosen both wheel nuts.
c. Jack up the vehicle and support
it with rigid racks.
d. Remove wheels.
e. Drive out spring pins of inner and
outer D.O.1.s by using 6 mm (0.24
in) diameter of steel rod.
Puller Assem bly
(398527700)
2 Oil seal
Fig. 8-7 Removing oil seal
h. Fit a new oil seal.
NOTE:
Apply chassis grease between the oil
seal lips.
1 Companion flange
2 Spring balance
A 14.058
Fig. 8-4 Measuring turning resistance
of companion flange
e. Remove drive pInIOn nut while
holding companion flange with
Flange Wrench (398427700).
Fig. 8-8 Fitting oil seal
i. Install companion flange.
j. Tighten drive pinion nut within the
specified torque range so that the
turning resistance of companion
flange becomes the same as that before replacing oil seal.
A14·059
Fig. 8-5 Removing drive pinion nut
f. Extract companion
a puller.
Torque
(Drive
pinion nut)
167 ~ 196 N·m
(17.0 ~ 20.0 kg-m,
123 - 145 ft-Ib)
A 16·180
Fig. 8-9 Driving spring pins out
f. Detach outer D.O.J. from spindle
of trailing arm with trailing arm
lowered fully and detach inner
D.O.J. from differential spindle and
then remove drive shaft assembly.
g. Loosen differential spindle set bolt
by using Wrench (925560000)
and remove spindle with packing.
h. Remove oil seal.
Puller Assembly (39852 7700)
A14·010
Fig.8-10 Removing oil seal
flange with
k. Reassembling procedure hereafter is
the reverse of the disassembling.
i. Drive in a new oil seal with Drift
(398437700).
NOTE:
Stake drive pinion nut after tightening.
Fig. 8-6 Removing companion flange
2) Replacing Side Oil Seal
NOTE:
Apply chassis grease between the oil
seal lips.
a. Remove two bolts which fix the
upper portion of shock absorber
to the body in unladen condition.
j. Reassembling procedure hereafter is
the reverse of the disassembly.
8-6
..,
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
3. Dismounting
Differential Assembly
f. Pull out differential carrier.
NOTE:
Be careful not to permit the teeth to
contact with the case.
a. to f.
Follow the same steps as those for
"2. 2) Replacing Side Oil Seal."
g. Remove propeller shaft assembly.
NOTE:
a. Prepare an oil can and cap since the
mission oil flows out from the extension at removing propeller shaft
assembly.
b. When removing propeller shaft
assembly, pay attention not to
damage the sliding surfaces of rear
drive shaft (extension) spline, oil
seal and sleeve yoke.
c. Insert the cap into the extension
to prevent mission oil from flowing
out immediately after removing
the propeller shaft assembly.
h. Support differential assembly with
jack and remove two nuts at the
center of differential mount member assembly.
i. Remove four nuts fIxing differential assembly to bracket assembly
(F).
j. Dismount differential assembly by
lowering jack.
4. Disassembly
1) Inspection before disassembling
To detect real cause of trouble, inspect
on the following items before disassembling.
(Refer to "6. Assembly" for inspection procedures.)
Attachment
(398217700)
~
A14-061
Fig. 8-11
Installing differential
b. Drain gear oil by removing plug.
c. Remove spindles by loosening bolts
with Wrench (925560000).
d. Remove rear cover by loosening
retaining bolts.
Fig. 8·12 Removing rear cover
e. Mark right and left side bearing retainers in order to identify them at
reassembly. Remove side bearing
retainer attaching bolts, set At·
tachment (398457700) to differentia! carrier, and extract right and
left side bearing retainers with a
puller.
NOTE:
Each shim, which is installed to adjust
the side bearing preload, should be
kept together with its mating retainer.
A14·014
Fig. 8·14 Removing drive gear
g. When replacing side bearing, pull
bearing cup from side bearing
retainer.
1 Puller Assem bly
(398527700)
2 Bearing cup
Fig.8-15 Removing side bearing
cup
h. Extract bearing cone with Puller
Set (399527700).
NOTE:
a. Set Puller so that its claws catch the
edge of the bearing cone.
b. Never mix up the right and left
hand bearing cups and cones.
Do not attempt to disassemble the
parts unless necessary.
')
a. Tooth contact of hypoid drive
gear and pinion, and backlash.
b. Runout of drive gear at its back
surface.
c. Turning resistance of drive pinion.
2) Disassembling
a. Set -Attachment (398217700) on
vise and install the differential
assembly to Attachment.
Differential carrier
Puller Set
(399527700)
Attachment
(398457700)
2 Side bearing retainer
A14·013
Fig. 8-13 Removing side bearing
retainer
A14-062
Fig.8-16 Removing side bearing
cone
8-7
)
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
i. Remove drive gear by spreading
lock plates and loosening drive gear
bolts.
Drift (398467700)
®
@
@
A14-021
1 Lock plate
2 Differential carrier
3 Drive gear
1
2
3
4
A 14·017
Drift (398467700)
Rear bearing cup
Front bearing
Pilot bearing
Fig. 8-21
Removing pilot bearing
Fig. 8-17 Removing drive gear
j. Drive out pinion shaft lock pin
from drive gear side.
NOTE:
A14-019
The lock pin is staked at the pin hole
end on the differential case; do not
drive it out forcibly before unstaking
r. When replacing bearings, tap front
bearing cup and rear bearing cup
in this order out of case by using
a brass bar.
Fig. 8-19 Removing drive pinion
it.
o. Remove rear bearing cone from
drive pinion by supporting cone
with Replacer (398517700).
Tap alternately wlth brass bar.
NOTE:
Place the replacer so that its centerrecessed side faces the pinion gear.
A14·0n
Fig. 8-22 Removing cups of front
and rear bearing
S. Inspection
A14·018
Fig.8-18 Driving out lock pin
k. Draw out pinion mate shaft and
remove pinion mate gears, side
gears and thrust washers.
NOTE:
The gears as well as thrust washers
should be marked or kept separated
left and right, and front and rear.
1. Hold companion flange with Flange
Wrench (398427700) and remove
drive pinion nut.
m. Extract the companion flange with
a puller.
n. Press the end of drive pinion shaft
and extract it together with rear
bearing cone, preload adjusting
spacer and washer.
NOTE:
Hold the drive pinion so as not to drop
it
A14-063
I Rear bearing cone
2 Replacer
(398517700)
Fig. 8-20 Removing rear bearing cone
p. Remove front oil seal from differential case.
q. Remove pilot bearing together with
front bearing cone.
8-8
'-<
,
i 4~"
I
,
•.
,~""
'"
'_t,. . . . .'. ". . . .
#l J "'4-,..........,..,·,,-+-,_'......•...
'"*,....
• ","'_ _....
,
Wash all the disassembled parts
clean, and examine them for wear,
damage, or other defects. Repair or
replace defective parts as necessary.
I) Drive gear and drive pinion
a. If abnormal tooth contact is
evident, find out the cause and
adjust to give correct tooth contact
at assembly. Replace the gear if
excessively worn or incapable of
adjustment.
b. If crack, score, or seizure is evident,
replace as a set. Slight damage of
tooth can be corrected by oil stone
or the like.
2) Side gear and pinion mate gear
a. Replace if crack, score, or other
defects are evident on tooth surface.
b. Replace if thrust washer contacting
surface is worn or seized. Slight
damage of the surface can be corrected by oil stone or the like.
------._._t1. ,. ,. ___________--__________
1...
1*....•....._ ,...
1It ....
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
3)
Bearing
Replace if seizure, peeling, wear,
rust, dragging during rotation, abnormal noise or other defect is
evident.
4) Thrust washers of side gear and
pinion mate gear
Replace if seizure, flaw, abnormal
wear or other defect is evident.
5) Oil seal
Replace if deformed or damaged,
and at every disassembling.
6) Differential case
Replace if the bearing bores are
worn or damaged.
7) Differential carrier
Replace if its sliding surfaces are
worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting
surfaces have flaws.
2) Adjusting preload for front and
rear bearings.
Adjust the bearing preload with
spacer and washer between front and
rear bearings. Pinion height adjusting
washer has nothing to do with this
adjustment. The adjustment must be
carried out without oil seal.
a. Press front and rear bearing cups
into differential case.
d. Turn Dummy Shaft with hand to
make it sealed, and tighten drive
pinion nut while measuring the preload with spring balance as shown
in the figure. Select preload adjusting washer and spacer so that the
specified preload is obtained when
nut is tightened to the specified torque.
NOTE:
a. Be careful not to give excessive preload.
b. When tightening the drive pinion
nut, lock Dummy Shaft with Block
(398507704) as illustrated here.
Handle &
Drift Kit
(397471600)
Fig. 8-24 Installing bearing cup
Block (398507704)
2 Dummy shaft (398507702)
Fig. 8-26
6. Assembly
I) Precautions for assembling
a. Assemble in the reverse order of
disassembling.
Check and adjust each part during
assembly.
b. Keep the shims and washers in
order, so that they are not misinstalled.
c. Thoroughly clean the surfaces on
which the shims, washers and bearings are to be installed.
d. Apply gear oil when installing the
bearings and thrust washers.
e. Be careful not to mix up the right
and left hand cups of the bearings.
f. Replace the oil seal with new one at
every disassembly. Apply chassis
grease between the lips (*) when
installing the oil seal.
b. Insert Dummy Shaft (398507702)
with pinion height adjusting washer
and rear bearing cone fitted on it
into case.
167 - 196 N·m
(17.0 - 20.0 kg-m,
123 - 145 ft-Ib)
NOTE:
Reuse the used washer if they show
normal tooth contact pattern when
checked before disassembly.
PInion height adjusting washer
Preload adjusting spacer
Preload ad lust InQ washer
\
Fig. 8-27 Measuring preload
Front & rear bearing preload
Dummy Collar
Dummy Shaft
(398507703)
(398507702)
A14·025
Fig. 8-25 Installing Dummy Shaft
Fig. 8-23 Applying grease to oil seal
Torque
(Drive
pinion nut)
A14-064
c. Then, install preload adjusting
spacer and washer, front bearing
cone, Dummy Collar (398507703),
companion flange, washer and
drive pinion nut.
8-9
For new bearing:
19.6-28.4N
(2.0 - 2.9 kg, 4.4 - 6.4lb) at
companion flange bolt hole
For used bearing:
8.34 - 16.67 N
(0.85 - 1.7 kg, 1.87 - 3.75 lb)
at companion flange bolt hole
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
T
Preload adjusting spacer
Preload adjusting washer
Part No.
Length mm (in)
Part No.
383705200
383715200
383725200
383735200
383745200
383755200
383765200
383775200
383785200
383795200
383805200
383815200
383825200
383835200
383845200
2.59 (0.1020)
2.57 (0.1012)
2.55 (0.1004)
2.53 (0.0996)
2.51 (0.0988)
2.49 (0.0980)
2.47 (0.0972)
2.45 (0.0965)
2.43 (0.0957)
2.41 (0.0949)
2.39 (0.0941)
2.37 (0.0933)
2.35 (0.0925)
2.33 (0.0917)
2.31 (0.0909)
383695201
383695202
383695203
383695204
383695205
383695206
Length mm (in)
56.2 (2.213)
56.4 (2.220)
56.6 (2.228)
56.8 (2.236)
57.0 (2.244)
57.2 (2.252)
3)
Adjusting drive pinion height
Adjust drive pinion height with
washer installed between rear bearing
cone and the back of pinion gear.
a. Install Dummy Shaft, Collar and
Gauge, as shown in the figure and
apply the specified preload on the
bearings. (Refer to 2) Adjusting
preload for front and rear bearings.)
=
To + N - (H x 0.01)
- 0.20 (mm),
where
T = Thickness of pIllion height
adjusting washer (0101)
To = Thickness of washer temporarily inserted (mm)
N = Reading of thickness gauge
(0101)
H = Figure marked on drive
pinion head
(Example of calculation)
To = 2.20 + 1.20 == 3.40 mm
N==0.23mm
H==+I,
T = 3.40 + 0.23 - 0.01
-0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the washer 383605200
NOTE:
At this time, install a pinion height
adjusting washer which is temporarily
selected or the same as that used
before.
1. Dummy Collar (398507703)
2 Dummy Shaft (398507702)
3 Gauge (398507701)
Pinion height
adjusting washer
A14·027
Fig. 8-28 Installation of Dummy Shaft Dummy Collar and Gauge
b. Measure the clearance N between
the end of Gauge and the end
surface of Dummy Shaft by using a
thickness gauge.
c. Obtain the thickness of pinion
height adjusting washer to be inserted from the following formula and
replace the temporarily installed
washer with this one.
NOTE:
Make sure that there is no clearance
between the case and Gauge.
8-10
v
•
Pinion height adjusting washers
-
Part No.
Thickness 0101 (in)
383495200
383505200
383515200
383525200
383535200
383545200
383555200
383565200
383575200
383585200
383595200
383605200
383615200
383625200
383635200
383645200
383655200
383665200
383675200
383685200
3.09 (0.1217)
3.12 (0.1228)
3.15 (0.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30 (0.1299)
3.33 (0.1311)
3.36 (0.1323)
3.39 (0.1335)
3.42 (0.1346)
3.45 (0.1358)
3.48 (0.1370)
3.51 (0.1382)
3.54 (0.1394)
3.57 (0.1406)
3.60(0.1417)
3.63 (0.1429)
3.66 (0.1441)
4) Install the selected pinion height
adjusting washer on drive pinion, and
press the rear bearing cone into
positif)fl with Installer (398177700).
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
I
~:----
8) Fit a new oil seal with Drift
(398417700).
I
->=---::::;::;;"
NOTE:
Apply grease between the oil seal lips.
(Refer to 1) Precautions for assembling)
9) Press-fit companion flange with
Installer (899874100) and Weight
(399780104).
1 Drive pinion
a. Measure the clearance between differential carrier and the back of
side gear.
b. Adjust the clearance as specified by
selecting side gear thrust washer.
Side gear
back clearance
A14-066
2 Installer (398177700)
Fig. 8-29 Installing rear bearing cone
5) Insert drive pinion into differential case, install the previously selected
preload adjusting spacer and washer.
6) Press-fit front bearing cone into
case.
Side gear thrust washer
Part No.
Thickness mm (in)
383445201
0.75 - 0.80
(0.0295 - 0.0315)
0.80 - 0.85
(0.0315 -- 0.0335)
(0.85 - 0.90
(0.0335 - 0.0354)
383445202
I
1 Installer (899874100)
2 Companion flange
A14-069
383445203
Fig. 8-32 Installing companion flange
10) Install
washer.
CD
drive
pinion nut with
c. Check the condition of rotation
after applying oil to the gear tooth
surfaces and thrust surfaces.
d. After driving in pinion shaft lock
pin, stake the both sides of the
hole to prevent pin from falling
off.
e. Install drive gear on differential
carrier, and bend lock plate.
®I-----<~
3
I Installer (899580100)
2 Dummy collar (398507703)
3 Weight (399780104)
A14-067
Fig. 8-30 Installing front bearing
cone
7) Insert spacer, then press-fit pilot
bearing with Weight (399780104) and
Installer (899580100).
A14-092
Fig. 8-33 Tightening drive pinion nut
Torque
(Drive
pinion nut)
167 - 196 N·m
(17.0 - 20.0 kg-m,
123 - 145 ft-lb)
11) Assembling differential carrier
Install side gears and pinion mate
gears, with their thrust washers and
pinion mate shaft, into differential carrier.
I
1 Installer (899580100)
2 Pilot bearing
Fig. 8-31
0.1 - 0.2 mm
(0.004 - 0.008 in)
A14-068
Installing pilot bearing
NOTE:
Apply gear oil on both sides of the
washer and on the side gear shaft
before installing.
Insert the pinion mate shaft into the
differential carrier by aligning the lock
pin holes.
8-11
Torque
(Drive gear
bolt)
69 -78 N·m
(7.0 - 8.0 kg-m,
51 - 58 ft-lb)
NOTE:
Tighten diagonally while tapping the
bolt heads.
12) Before installing side bearing, measure the bearing width by using a dial
gauge, Weight (398227700) and Gauge
(398237700).
Standard
bearing
width
20.00 mm
(0.7874 in)
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
NOTE:
Set the dial gauge needle to zero, using
a standard bearing or block of specified height in advance_
I f a number is not marked, regard it
as zero.
T1
NOTE:
Use several shims to obtain the calculated thickness.
Side bearing retainer shims
A14·073
Fig. 8-36 Adjustment of side bearing
retainer shim
1 Weight (398227700)
2 Gauge (398237700)
3 Side bearing
A14-071
Fig. 8-34 Measuring side bearing
width
13) Press side bearing cone onto differential
carrier
with
Drift
(398487700)
and
Adapter
(398497701) included in Puller Set
(399527700).
1 Drnt(398487700)
2 Adapter (398497701)
TI (Left) = (A+C+Gl-D)
x 0.01 + 0.76 - E (mm)
T2 (Righ t) = (B + D + G2 )
x om + 0.76 - F (mm)
T I & T2 :
Thickness of left and
right side bearing retainer
shim (mm)
A&B
Number marked on differential case.
(' & D
Number marked on differential carrier.
Difference of width of
E&F
left and right side bearing
from standard width
20.0 mm, expressed in a
unit of 0.01 mm.
For example, if the
bearing measured width
is 19.89 mm, value of E
or F is as follows. 20.00
- 19.89 = 0.11 (E or F)
Gl & G2:
Number marked on side
bearing retainer.
A14-072
Fig. 8-35 Installing side bearing
14) Adjusting side bearing retainer
shims
a. The drive gear backlash and side
bearing preload can be determined
by the side bearing retainer shim
thickness.
b. When replacing differential carrier,
differential case, side bearing, and
side bearing retainer, obtain the
right and left retainer shim thickness from the following formulas.
Part No.
Thickness mm (in)
383475201
383475202
383475203
383475204
383475205
0.20 (0.0079)
0.25 (0.0098)
0.30 (0.0118)
OAO (0.0157)
0.50 (0.0197)
I
Example of calculation
Ex. 1
A=5, B=5, C=3, D=3,
Gl =4,G2 = I,E=O.IOmm
F = 0.15 mm
Left side
TI = (A+C+GI-D) x 0.01+0.76-E
= (5+3+4-3) x 0.01 +0.76-0.1 0
= 0.09+0.76-0.10
= 0.75 mm
The correct shims are as follows
Thickness
Q'ty
= 0.25
0.25
1
x
= 0.50
x
1
0.50
Total shim thickness = 0.75 mm
Right side
T2 = (B+D+G2) xO.01+0.76-F
= (5+3+1) xO.01+0.76-0.15
= 0.09+0.76-0.15
= 0.70 mm
The correct shims are as follows
Q'ty
Thickness
0.20
x
1
0.20
= 0.50
x
1
0.50
= 0.70mm
Total shim thickness
Ex.2
A = 2, B = 3, C = 0, D = 3, GI = 2,
G2 =3, E=0.22mm,
F = 0.10 mm
Side bearing
retainer
G
A 14-074
Fig.8-37 Location of markings
8-12
Left side
TI = (A+C+GI -D)xO.OI +0.76-E
= (2+0+2-3)xO.OI+0.76-0.22
= 0.01+0.76-0.22
=0.55 mm
The correct shims are as follows
Thickness
Q'ty
0.25
x
1
= 0.25
x
1
= 0.30
0.30
Total shim thickness = 0.55 mm
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
Be sure to wipe off red lead completely upon completion of adjustment.
c. After completing the above adjustment, install oil seal in side bearing
retainer.
Right side
Tz = (B+D+Gz)xO.01+0.76-F
= (3+3+3)xO.01+0.76-0.10
= 0.09+0.76-0.10
= 0.75 mm
The correct shims are as follows
Q'ty
Thickness
0.25
x
1
= 0.25
0.50
x
= 0.50
Total shim thickness = 0.75 mm
c. Install the differential carrier assembly into differential case in the reverse order of disassembling.
d. Fit the selected shims and O-ring on
side bearing retainer and install
them on differential case with the
arrow mark on the retainer directed
as shown in Figure.
NOTE:
Be careful that side bearing cup is not
damaged by bearing roller.
NOTE:
Fig. 8-39 Measuring backlash
g. At the same time, measure the
turning resistance of drive pinion.
Compared with the resistance when
differential carrier is not installed,
if the increase of the resistance is
not within the specified range,
readjust side bearing retainer shims.
Turning
resistance
increase
0.05 mm (0.0020 in)
A14·031
Fig. 8-38 Arrow mark on side
bearing retainer
Backlash
a. Raise differential assembly using a
jack. Remount the differential assembly by temporarily tightening
four mounting nuts at the front and
two mounting nuts at the rear.
b. Install other parts in the reverse
order of dismounting.
c. After installation fill differential
case with gear oil to the upper plug
level.
0.8 Q
(1.7 US pt,
1.4 Imp pt)
d. Torque
A14·033
Fig. 8-40 Measuring runout at
drive gear back
0.10 - 0.20 mm
(0.0039 - 0.0079 in)
19 - 25 N·m
(1.9 - 2.6 kg-m,
14 - 19 ft-lb)
7. Mounting
Oil capacity
9-12N·m
(0.9 - 1.2 kg-m,
6.5 - 8.7 ft-lb)
f. Measure the drive gear-to-drive pinion backlash.
If the reading is not within the
specified range, correct by decreasing the shim thickness on one side
and increasing the shim thickness
on the other side the same amount.
Total shim thickness must be the
same to maintain proper preload.
Torque
(Rear
cover bolt
Dial gauge
e. Tighten side bearing retainer bolts.
Torque
(Side bearing
retainer)
d. Install rear cover.
0.1 - 0.6 N·m
(1 - 6 kg-cm,
0.9 - 5.2 in-lb)
h. Recheck drive gear-to-pinion backlash after readjusting shims.
i. Check the drive gear runout on its
back surface, and make sure pinion
and drive gear rotate smoothly.
Limit of
runout
a. Use Drift (398437700) to press the
oil seal into position.
b. Apply chassis grease between the
oil seal lips.
15) Checking and adjusting tooth contact of drive gear.
a. Paint evenly both sides of three or
four teeth on drive gear with red
lead. Check the contact pattern
after rotating drive gear several
revolutions back and forth until
definite contact pattern develops
on drive gear.
b. When the contact pattern is incorrect, readjust according to the instructions given in ''Tooth contact
pattern" .
8-13
Differential
assembly
mounting
nut
69 -78 N·m
(7.0 - 8.0 kg-m,
51-58ft-lb)
Propeller
shaft flange
yoke to
companion
flange
18-25N.m
(1.8 - 2.5 kg-m,
13 - 18 ft-lb)
Spindle
installing
bolt
31-36N·m
(3.2 - 3.7 kg-m,
23 - 27 ft-lb)
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
TOOTH CONTACT PATTERN
Condition
Contact pattern
Adjustment
Correct tooth contact
Tooth contact pattern slightly
shifted toward toe under no
load rotation.
(When loaded, contact pattern
moves toward heel.)
~~
-
Face contact
~
-
Backlash is too large.
This may cause noise and chip·
ping at tooth ends.
.. ~
E
~
Increase thickness of drive pinion height
adjusting washer in order to bring drive pinion
closer to drive gear center.
Flank contact
41
Backlash is too small.
This may cause noise and
stepped wear on surfaces.
.. ~
y
0
Reduce thickness of drive pinion height
adjusting washer in order to move drive pinion
away from drive gear.
Toe contact
4/
Contact area is small.
This may cause chipping at
toe ends.
.. ~ ~
Adjust as for flank cOfltact.
Heel contact
.. q
$
Contact area is small.
This may cause chipping at
heel ends.
0
:&
0
Adjust as for face contact.
A13·164
Fig. 8·41
8-14
,;a-~,;:-t",,"·i--=-;.!j
,,-.-,- .... I,tJ·...
..
'io--.---___. .__
......................
' tI ...
• ....
• - -.....
,1",1.......
' ,,.._',...,.-...,
• ....
,I.~--I~Vfl""
~
"'ITF.....
'll.I...__..._ _...15_ _ _ _ _~
_ _ _-
_ _ _ _ _ _..
"
i
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
8-4. Drive Shaft
Disassemble and reassemble the rear
drive shaft assembly in the same assembling procedure as of the D.O.J. of
the front axle shaft.
NOTE:
When replacing band only, winding up
type band (not handy type band) is
provided.
Baffle plate (A)
2 Rear 0.0.1. assembly
3 Snap ring
4 0.0.1. circlip
5 Band boot A
6 0.0.1. boot
7 Band boot B
8 Shaft rear
9 Baffle plate B
9
A14·095
Fig. 8-42 Construction of rear drive shaft
8-5. Propeller Shaft
1. Removal
a. Jack up the vehicle and support it
with rigid racks.
b. Detach propeller shaft flange yoke
from companion flange of differential assembly.
c. Insert the cap into the extension to
prevent mission oil from flowing
out immediately after removing the
propeller shaft assembly.
c. Take out propeller shaft assembly
rearward.
NOTE:
a. Prepare an oil can and cap since the
mission oil flows out from extension at removing propeller shaft
assembly.
b. When removing propeller shaft
assembly, pay attention not to
damage the sliding surfaces of
rear drive shaft (extension) spline,
oil seal and sleeve yoke.
2. Inspection
As a rule, do not disassemble the
propeller shaft assembly since it is
balanced. Inspect each part before
disassembling, and correct or replace if
any fault is evident.
I) Replace if the journal portion is
worn, damaged, or abnormal anyway.
2) Replace the snap ring if it is
damaged or its tension is insufficient.
8-15
3) Correct the loose joint by using a
selective snap ring.
4) Replace if any dent or crack is
evident on the tube surface.
5) Replace if runout of the tube
exceeds the limit when rotating with
the both end supported.
Limit of
runout
0.6 mm (0.024 in)
6) Correct or replace if joint movement is not smooth or the bending
resistance exceeds the limit.
Maximum
joint bending
resistance
1.5 N·m
(15 kg-cm,
13 in-Ib)
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
3. Disassembly
4. Assembly
When disassembling or repairing because of sheer necessity, proceed in
the following order, and never forget
to provide matching marks on the
sleeve yoke, flange yoke, tube, etc_
before disassembly.
1) Remove snap ring with a flat
blade screw driver.
2) Remove bearing race by tapping
the root of yoke with a hammer.
Selective
1) Assemble in the reverse order of
disassembling and never fail to align
the marks made prior to disassembling.
2) Since this joint is of the maintenance-free type, refill new grease
when reassembling.
3) Adjust journal axial play by
selecting proper snap rings. The
opposing snap rings must be of the
same thickness.
Journal
axial play
0.02 mm (0.0008 in)
or less
snap ring
Al~-094
Fig. 8-44 Selecting snap rings
5. Installation
1) Reverse removal procedures.
2) Apply grease to the spline and
outside of the sleeve yoke.
Torque
(Flange
yoke to
companion
flange)
18-25N·m
(1.8 - 2.5 kg-m,
13 - 18 ft-Ib)
A14-041
Selective snap rings
Fig. 8-43 Removing bearing race
3)
Remove journal from yoke.
NOTE:
Be careful not to damage journal when
pulling it out from yoke.
Paint color
Part No.
Thickness mm (in)
622033000
2.00 ± 0.01 (0.0787 ± 0.0004)
White
622033010
2.02 ± om (0.0795 ± 0.0004)
Yellow
622033020
2.04 ± 0.01 (0.0803 ± 0.0004)
Red
622033030
2.06 ± 0.01 (0.0811 ± 0.0004)
Green
622033040
2.08 ± 0.01 (0.0819 ± 0.0004)
Blue
622033050
2.10 ± 0.01 (0.0827 ± 0.0004)
Light Brown
622033060
2.12 ± 0.01 (0.0835 ± 0.0004)
No paint
622033070
2.14 ± 0.01 (0.0843 ± 0.0004)
Pink
8-16
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
8-6. Troubleshooting
1. Rear Differential
Remedy
Symptom and possible cause
Oil leakage
• Worn, scratched, or incorrectly seated front or side
oil seal. Scored, battered, or excessively worn sliding
surface of companion flange.
Repair or replace.
• Clogged or damaged air breather.
Clean, repair or .replace.
•
Tighten bolts to specified torque. Replace O-ring.
Loose bolts on differential spindle or side retainer, or
incorrectly fitted O-ring.
• Loose rear cover attaching bolts or damaged gasket.
Tighten bolts to specified torque. Replace gasket and
apply liquid packing.
• Loose oil filler or drain plug.
Retighten and apply liquid packing.
• Wear, damage or incorrectly fitting for spindle, side
retainer and oil seal.
Repair or replace.
Seizure
Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and
repaired or replaced as required.
• Insufficient backlash for hypoid gear.
Readjust or replace.
• Excessive preload for side, rear, or front bearing.
Readjust or replace.
• Insufficient or improper oil used.
Replace seized part and fill with specified oil to specified
level.
Damage
Damaged parts should be replaced and also other parts should be thoroughly checked for any defect and repaired or
replaced as required.
• Improper backlash for hypoid gear.
Replace.
• Insufficient or excessive preload for side, rear, or
front bearing.
Readjust or replace.
• Excessive backlash for differential gear.
Replace gear or thrust washer.
• Loose bolts and nuts such as drive gear bolt.
Retighten.
• Damage due to overloading.
Replace.
Noises when starting or shifting gears
Noises may be caused by differential assembly, universal joint, wheel bearing, etc. Find out what is actually making
noise before disassembly.
• Excessive backlash for hypoid gear.
Readjust.
• Excessive backlash for differential gear.
Replace gear or thrust washer.
• Insufficient preload for front or rear bearing.
Readjust.
• Loose drive pinion nut.
Tighten to specified torque.
• Loose bolts and nuts such as side bearing retainer
attaching bolt.
Tighten to specified torque.
8-17
J
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
"
Symptom and possible cause
Remedy
Noises when curving
•
Damaged differential gear.
• Excessive wear or damage of thrust washer.
• Broken pinion mate shaft.
• Seized or damaged side bearing.
Replace.
Replace.
Replace.
Replace.
Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes
mistaken for noises from differential assembly, be careful in checking them. Inspection methods to locate noises
include coasting, accelerating, cruising, and jacking up all four wheels. Perform these inspections according to
condition of trouble. When listening to noises, shift gears into four wheel drive and fourth speed position, trying to
pick up only differential noise.
• Improper tooth contact of hypoid gear.
Readjust or replace hypoid gear set.
• Improper backlash for hypoid gear.
• Scored or chipped teeth of hypoid gear.
• Seized hypoid gear.
• Improper preload for front or rear bearings.
• Seized, scored, or chipped front or rear bearing.
Replace hypoid gear set.
• Seized, scored, or chipped side bearing.
Replace.
• Vibrating differential carrier.
Replace.
Readjust.
Replace hypoid gear set.
Readjust.
Replace.
2. Propeller Shaft
Remedy
Trouble and possible cause
Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and transferred to vehicle body. Generally vibration increases
in proportion to vehicle speed.
• Worn or damaged universal joint needle bearing.
• Unbalanced propeller shaft due to bend or dent.
• Loose installation of propeller shaft.
Replace.
Replace.
Retighten.
Tapping when starting and noise while cruising, caused by propeller shaft.
•
Worn or damaged universal joint.
• Worn spline of sleeve yoke.
•
Loose installation of propeller shaft.
• Loose installation of joint.
Replace.
Retighten.
Adjust snap ring.
8-18
,
~... ,.•."'.......,'4u~~.•. "'lI._
Replace.
? "
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
I
..~
8-7. Special Tools
398427700
398457700
398517700
398507703
Flange Wrench
Attachment
Replacer
Dummy collar
Companion Flange
Side bearing retainer
Rear bearing cone
Pinion height and
preload adjustment
..--
-
.
Fig. 8-45
A14-043
i/-·~
Fig. 8-49
A14'047
Fig. 8-53
0
(
\
-
'\
:) 'I.)I
A14-076
Fig. 8-57
398527700
399527700
397471600
398507704
Pulley Ass 'y
Puller Set
Handle & Drift Kit
Block
Oil seal
Side bearing cup
Side bearing cone
Front and rear
bearing cup
Pinion height and
preload adjustment
'f"
~~~~~c _!'ilL---"
•
~
,
A14-044
6
\
\
It'
Fig. 8-46
I)
@
®
CD
Fig. 8-50
J.I
I
2
3
4
5
6
~
~
0
0
cw.=-
A14-075
Rolt(899521412)
Puller 1)99521702)
Hoider ()9952770)
Adapler 1398497101)
Boll 189952(107)
Nul (021008000)
@
------::::F
t
(j)
(I)
(2)
(3)
Handle
Drift
Orut 2
(398477701)
(398471102)
(398477703'
Fig. 8-54
ST-143
Fig. 8-58
398417700
899904100
398507701
398217700
Drift
Straight Pin Remover
Gauge
Attachment Set
Oil seal
Differential pinion shaft
lock pin
Pinion height adjustment
Differential case
~
Fig. 8-47
A14-045
![
I
!
Fig. 8-51
A12-187
Fig. 8-55
A14-080
Fig. 8-59
398467700
398507702
398177700
Drift
Drift
Dummy Shaft
Installer
Oil seal
Drive pinion
Pilot bearing
Front bearing cone
Pinion height and
Preload adjustment
Rear bearing cone
Fig. 8-48
Q
,
. A14-046
Fig. 8-52
I
~
)
A14-049
Fig. 8-56
8-19
I I
A14-083
c{)n~~
398437700
,\
A14-082
II
•
A14-081
A14-084
@
Fig. 8-60
A14-085
_J
----
4'
-
REAR WHEEL DRIVING SYSTEM (4WD MODEL)
399780104
398227700
Weight
Weight
Front bearing cone
Pilot bearing
Companion flange
Side bearing
0
Fig. 8-61
A12-172
Fig. 8-65
A14-087
899580100
398487700
Installer
Drift
Front bearing cone
Pilot bearing
Side bearing cone
~--
Fig. 8-62
A 12-179
0
Fig. 8-66
A14-088
899874100
925560000
Installer
Wrench
Companion flange
Differential spindle
set bolt
q
Fig. 8-63
({~,
.
~~
'-Q
A12-185
Fig. 8-67
ST-032
398237700
Gauge
Side bearing
0
Fig. 8-64
A14-086
l~=~~~_~
___=~'~lf~.~.~'~I~
___
.8.-.2~O_ _ _ _ _~_'~I~~!~' '~R
__
_____________
~
CHAPTER@
SUSPENSION,
WHEELS AND AXLES
Page
• SPECIFICATIONS AND SERVICE DATA ....................... 9- 2
• SUSPENSION
9- 1.
COMPONENT PARTS .... . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9- 6
9- 2.
FRONT SUSPENSION ................................. 9- 8
9- 3.
FRONT SUSPENSION DAMPER STRUT ................... 9-13
9- 4.
STABILIZER ....................................... 9-17
9- 5.
FRONT CROSSMEMBER ............................... 9-17
9- 6.
BALL JOINT ....................................... 9-18
9- 7.
REAR SUSPENSION .................................. 9-19
9- 8.
ADJUSTMENT OF POSTURE (4WD Models Onlv) ............. 9-23
9- 9.
ADJUSTMENT OF REAR ROAD CLEARANCE . . . . . . . . . . . . .. 9-24
• WHEELS AND AXLES
9-10.
COMPONENT PARTS ..... . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-25
9-11.
HOUSiNG .......................................... 9-26
9-12.
FRONT AXLE SHAFT ................................ 9-29
9-13.
REPLACEMENT OF D.O.J./D.O.J. BOOT OF FRONT AXLE
SHAFT ............................................ 9-32
9-14.
REAR AXLE (Except 4WD) ............................. 9-33
9-15.
REAR AXLE OF 4WD ................................ 9-35
9-16.
WHEEL ........................................... 9-38
• TROUBLESHOOTING ..................................... 9-41
• SPECIAL TOOLS ........................................ 9-42
SUBARU
1
·k
j
SUSPENSION, WHEELS AND AXLES
.SPECIFICATIONS AND SERVICE DATA
Type
Stabilizer
McPherson strut type, independent suspension
Bar diameter
Wire diameter
Coil spring
Coil diameter
Free length
Number of coils
Over all
Effective number
Coefficient of spring
Front
suspension
Outer cylinder length
Maximum length
Minimum length
Damper strut
Stroke
Piston rod diameter
Expansion
Compression
Semi-trailing arm type, independent suspension
Bar diameter
Damping force [at the piston
speed 0.3 m/sec (1.0 ft/sec)]
Typ~
Inside serration
Torsion bar
spring
Rear
suspension
Shock absorber
Number of teeth
Ou ter diameter
Number of teeth
Outside serration
Outer diameter
Cylindrical double action type
Hatchback, Sedan
and Hardtop
Hatchback 4WD
Maximum length
Station Wagon
Station Wagon 4WD
and BRAT
Hatchback, Sedan
and Hardtop
Hatchback 4WD
Minimum length
Station Wagon
Station Wagon 4WD
and BRAT
Hatchback, Sedan
and Hardtop
Hatchback 4WD
Stroke
Station Wagon
Station Wagon 4WD
and BRAT
Piston rod diameter
Damping force [at the piston
speed 0.3 m/sec (1.0 ft/sec)]
9-2
Expansion
Compression
20 mm (0.79 in)
Other than 4WD: 12.5 mm(0.492 in)
4WD: 12.0 mm (0.472 in)
130 mm (5.12 in)
319 mm (12.56 in)
5.4
3.9
23.5 N/mm (2.4 kg/mm, 134 lb/in)
Other than 4WD: 359 mm (14.13 in)
4WD: 376 mm (14.80 in)
Other than 4WD: 516 mm (20.31 in)
4WD: 521 mm (20.51 in)
Other than 4WD: 395 mm (15.55 in)
4WD: 412 mm (16.22 in)
Other than 4WD: 121 mm (4.76 in)
4WD: 109 mm (4.29 in)
20 mm (0.79 in)
785 N (80 kg, 176 Ib)
490 N (50 kg, 110 lb)
21 mm
37
(0.83 in)
28.5 mm (1.122 in)
34
26.25 mm (1.0335 in)
433.8 mm (17.08 in)
430.5 mm (16.95 in)
448.5 mm (17.66 in)
440.1 mm (17.33 in)
307.5 mm (12.11 in)
313.5 mm (12.34 in)
315 mm (12.40 in)
315.8 mm (12.43 in)
126.3 mm ( 4.97 in)
117 mm ( 4.61 in)
133.5 mm ( 5.26 in)
124.3 mm ( 4.89 in)
(0.39 in)
10mm
[SW & SW 4WD: 12.5 mm (0.492 in)]
785 N (80 kg, 176 lb)
392 N (40 kg, 881b)
[SW & SW 4WD: 490 N (50 kg, 110 lb)]
·'----<~
/
.
SUSPENSION, WHEELS AND AXLES
Damper strut
Bend limit
Wear limit of outer diameter
Outer diameter (TOKICO)
Outer diameter (KYB)
Outer diameter (SHOWA)
Clearance between outer shell
and piston rod
Piston rod
Z
0
Z
>l.l
~
CI.l
Posture
adjustment
SERVICE LI~IT
0.05 mm (0.0020 in)
0.02 mm (0.0008 in)
19.94 to 19.98 mm (0.7850 to 0.7866 in)
19.935 to 19.981 mm (0.7848 to 0.7867 in)
-~
19.98 to 20.01 mm (0.7866 to 0.7878 in)
0.8 mm (0.031 in) or less
0.1 mm (0.004 in)
30.05 to 30.15 mm (1.1831 to l.l870 in)
30.20 to 30.28 mm (1.1890 to 1.1921 in)
30.0 to 30.052 mm (1.1811 to 1.1831 in)
Oil quantity
(4WD)
(Other than 4WD)
220 cm 3 (220 cc, 13.42 cu in)
205 cm 3 (205 cc, 12.51 cu in)
Front
Rear
(4WD only)
(4WD only)
Only upward 25 mm (0.98 in)
Only upward 30 mm (1.18 in)
• Wheel Alignment
Hatchback,
Sedan and Hard top
Station Wagon
Camber
45' to 2° 15'
1° to 2°30'
Caster
-I ° 10' to 20'
-50' to 40'
Toe-in
Front
Side slip (With one person)
Road clearance* I
1° 40' to 3° 10'
_1°15' to 15'
-1°25' to 5'
OUT 5 ± 1 mm
(OUT 0.20 ± 0.04 in)
-3 to 3 mm
(-0.12 to 0.12 in)
2 to 8 mm
(0.08 to 0.31 in)
240 to 265 mm
(9.45 to 10.43 in)
245 to 270mm
(9.65 to 10.63 in)
265 to 290 mm*3
(10.43 to 11.42 in)
-25' to 1°05 ,
-45' to 45'
Toe-in
-3 to 3 mm
(-0.12 to 0.12 in)
Side slip (With one person)
-5 to 5 mm
(-0.20 to 0.20 in)
Rear
Road clearance*2
Station Wagon 4WD
and BRAT
I ± 1 mm
(0.04 ± 0.04 in)
Camber
*1
*2
*3
*4
*5
Hatchback
4WD
260 to 280 mm
(10.24 to 11.02 in)
280 to 300mm
(11.02 to 11.81 in)
320 to 340 mm*4
(12.60 to 13.39 in)
335 to 355 mm*5
(13.19 to 13.98 in)
Measure the road clearance at center of front end face of the transverse link attaching bolt.
Measure the road clearance at lower face of the crossmember.
GL model: 270 to 295 mm (10.63 to 11.61 in)
GL model: 325 to 345 mm (12.80 to 13.58 in)
GL model: 340 to 360 mm (13.39 to 14.17 in)
9-3
_
-.~
.r.
,
"'-'
0.2 mm (0.008 in)
Inner cylinder Bend limit
Wear limit of inner diameter
Inner diameter (TOKICO)
Inner diameter (KYB)
Inner diameter (SHOWA)
CI.l
I
STANDARD
ITEM
..:,'
SUSPENSION, WHEELS AND AXLES
• T,~re Si~8.~nd lnflati9J) Pressure
,
,.
Rim size
[Rim offset
rom (inn
'MOdel
Hatchback
(except 4WD')
STD
155SR13
,
Hatchback,
Sedan and,
Hardtop
(excepf4WD)
Load
condition
.-' Front
Rear
4~-J x 13
[55 (2.17)]
DL
177 (1.8,26)
".
GL
175/70SR 13
--
5-J x 13
[55 (2.17)]
,
Hatchback
4WD
*1
4~-J
165 SR 13
x 13
[55 (2.17)J
---------
------
-
1135/70 DIS
4Tx 15
135:(l.38)]
412(4.2,60)
185/70 SR 13
5-J x
[42 (1
.r::t
177 (1.8,.26)
177 (r8, 26)
-.
~------:~-----~-----~---
:;.
--------
"T135/70 D 15
j~
4T x 15
[35 (1.38)f
x 13
[55 (2.17)]
"
l}5/70 SR 13
-----------
-.
GL
"
1111
.
'
.,..
177(1.8._26)
177 (1.8, 26)
F1)ll Load
216 (2.2, 32)
216 (2.2,32)
5-1 x 13
[55 (2.17)J
d.<
165 SR l3
_412-(4.2,60)
........
4~-J
155 SR 13
4~-1
x.J3
[55 (2.17)1
--------
T13-5/70 D 15·
4T x 15
[35 (1.38»)
1~?/70 SR ~3
,/:i
5-J x 13
[42 (1.6.5)JV
--------
+-------
T135/70 DIS
4T x \5
[35
. , ' ,(138)J
Light Load
177 (1.'8:P6)
177 (1.8, 26)
.
".
17T~1.8, i6-f
Light Load
177 (1.8, 26)
"
Full Load
216l:2.2,32)
--------,
- -- --.11:"--
..v.
-!"
Light
,-~"."
''1-;-'
.•.. ;~
. ,
..
.
-
~
L..#
'~C"L
"#I.),, . ,
'~~.
216 (2.2,32)
Full Lood
-
... ~- "".type" tire (T135/70 D 15) for temporary use is prepared for 4WD vehicles as-a spare tire .
"'~;'"~"
.$.,~(.+
-- ...... _---
,
..~:
..•
t
susPeNSION, WHEELS AND AXLES
. '. Rear SusPension,
::rrQhtening,torque N·m (kg-m, ft-Ib)
T1: 74 - 93 (7.5 ""7.9.6.-Q.4 - 69)
T2: 88 - 118 (9 - 1 2, 65 - 87)
T3: 88 - 127 (9 - 13,65 - 94)
T4: 118-147112-15,87-108)
T5: 31 - 39 (3.2 - 4.0, 23 - 29)
~~~~G
Station Wagon only
.\"a'
.,.,.
CD
/
l
":Jl.,;>o.,.
@-----Q:!';;!
Inner bush
Inner arm
9 Shock absorber
10 Helper
"',.
nt parts of rear suspension (Except 4WD)
Fig.:
i~~:::~
l.
Tightening torque N·m (kg-m, ft-Ib)
~ -93 (7.5 - 9.5, 54 - 69),
T2: 88-118 (9 -12,65 - 87)
T3: 88 - 127 (9 - 13, 65 "- 94)
T4: 118 - 147(12 -15, 87 - 108)
T5: 31 - 39 (3.2 - 4.0, 23 -29)
T1:
;;:."",.
-1
Rear:bailrli>
2
4'
".
Cr()~cp
3 Front bush'"
,4 Torsion bar
~ OuHftlmsh
,,~
1"
6
7
8
9
10
~ ~"",
f
11
•
t'
12
·.13
14
,
.L:, ,:.'1
,*er, .
Inner bush
Inner arm
Sbock absorber
Center arm
Center arm bolt
Helper
Castle nut
Pm
, Fig. 9-4 Component parts of rear suspension' (4WD)
\®f\~
1,,]
i "
SUSPENSION, WHEELS AND AXLES
9-2. Front Suspension
1. Removal
3. Installation
1) Disconnect ground cable from
battery.
2) Apply parking brake.
3) Loosen fron t wheel nu ts.
4) Jack up vehicle, support it with
safety stands (rigid racks) and remove
front tires & wheels.
5) Release parking brake.
6) Remove parking brake cable
bracket from transverse link.
7) Disconnect parking brake cable
from brake caliper.
8) Disconnect brake hose from brake
pipe at apron bracket.
1)
NOTE:
a. Fit air bleeder cap onto brake
pipe to prevent brake fluid from
pouring.
b. When removing or installing flare
nut, use flare nut wrench without
fail.
Install strut mount to body.
29 - 39 N·m
(3.0 - 4.0 kg-m,
Torque
22 - 29 ft-lb)
A15-011
Fig.9-7 Inserting D.O.J. to drive
shaft
A15-076
Fig. 9-5
3) Install leading rod to rear crossmember according to the following
procedure.
(1) Install a bushing to leading rod.
(2) Install leading rod to rear crossmember, besides install a bushing, a
plate and a self-locking nut.
(3) Tighten self-locking nut.
36 - 42 N·m
9)
Drive out spring pin of D.O.1. at
inner end by using a steel rod of 6 mm
diameter.
10) Disconnect front end of stabilizer
from leading rod.
11) Remove leading rod from rear
crossmember.
12) Disconnect transverse link bush
from front crossmember.
13) Take out transverse link along
with leading rod.
14) Remove castle nut and ball stud
of tie-rod end.
15) Loosen nuts connecting strut
mount to body, then pull D.O.1. out
of differential spindle, and remove
front suspension assembly from body.
NOTE:
Take care of the installing direction of
strut mount.
)
Station Wagon,
4WD vehicle and
vehicle with power
(
steering
(HatchbaCk, Sedan)
and Hardtop
Torque
(3.7 - 4.3 kg-m,
27 - 31 ft-Ib)
Fig. 9-8
A15-146
Fig.9-6 Installing direction of
strut mount
2. Inspection
Check the removed parts for any
wear, damage and crack, and correct
or replace if defective.
~
~
. .
,- .....
...
'"
.
2) Align the spring pin holes of
D.0.1. and differential spindle, and
insert D.0.1. to differential spindle.
NOTE:
a. Self-locking nuts should be replaced
with new one whenever it is removed.
b. Before installing the bushing to the
leading rod, soak the bushing to the
soap solution for easy installing the
bushing to correct position.
9-8
$2
1
SUSPENSION, WHEELS AND AXLES
c. In case that the creaking noise
breaks out during the self-locking
nut fully tightening, there is possibility that the rubber bushing is
pinched between the pipe and
the washer. Then, loosen the selflocking nut at once and retighten
the nut after centering the leading
rod.
NOTE:
After tightening the nut to the specified torque, adjust groove on the
nut and hole on the ball joint by
retightening the nut from 0 to 60
degrees.
Torque
(Hand brake
cable bracket
installing
bolt)
6.4 - 9.3 N·m
(0.65 - 0.95 kg-m,
4.7 - 6.9 ft-lb)
4) Connect D.O.J. and differential
spindle by driving spring pin in.
NOTE:
a. Make sure that the holes are aligned
before driving the spring pin in.
b. When driving the spring pin in,
always use new one.
A15-078
A15-069
Fig.9-11
Installing tie rod end
Fig.9-13 Installing hand brake
cable bracket
7) After then, install new cotter pin
into the hole, and bend it firmly.
8) Connect stabilizer front end
through bracket to leading rod.
Torque
A15-015
18-3IN·m
(1.8 - 3.2 kg-m,
13 - 23 ft-lb)
II) Install hand brake outer cable by
attaching outer cable clip to brake
caliper.
Install the hand brake cable end to the
caliper lever.
Fig_ 9-9 Driving spring pin in
5) Install transverse link temporarily
to crossmember by using bolt and
self-locking nut.
A15-070
Fig. 9-14
1
2
3
Bracket
Leading rod
Stabilizer
A15-073
12) Install wheels.
Fig. 9-12
Torque
(wheel nut)
A15-077
Fig. 9-10 Installing transverse link
9) Attach brake hose to apron
bracket by using clip, and then connect brake hose to brake pipe.
6) Install tie rod end ball joint to
housing knuckle ann.
Torque
Torque
(Castle nut)
25 - 29 N·m
(2.5 - 3.0 kg-m,
18 - 22 ft-lb)
l2-l8N·m
(1.2 - 1.8 kg-m
9 - 13 ft-lb)
10) Install hand brake cable bracket
to transverse link.
9-9
78 - 98 N·m
(8 - 10 kg-m,
58 - 72 ft-lb)
13) Bleed air from brake system.
14) Lower vehicle and tighten selflocking nut which installs transverse
link to crossmember.
Torque
( self-locking
nut)
59 - 69 N·m
(6.0 - 7.0 kg-m,
43 - 51 ft-Ib)
..';
(
SUSPENSION, WHEELS AND AXLES
4. Adjustment
s.
Make sure to measure wheel alignment when removing and reinstalling
the suspension. Wheel alignment
should be adjusted or checked to the
specified values.
The following chart outlines the
basic inspection and adjustment procedures for the entire front suspension
system. Regarding specific procedures
Item to be checked
Inspection and Adjustment
for individual parts, refer to the
applicable instructions set forth in this
manual.
Remarks
Description
Vehicle posture
Park the vehicle on a level, solid surface, and check for lateral inclination of the vehicle.
Coil spring
Visual inspection
NOTE:
a. Make sure that all tires are inflated to the specified pressure.
b. If any noticeable lateral vehicle inclination is detected visually,
determine whether it is due to permanent' deformation of coil
spring (s), improper body alignment, or other factors.
c. If vehicle inclination (to either side) is due to permanent deformation of coil spring, remove the coil spring and measure its free
length.
If the free length is not within the specification, replace the coil
spring.
319 mm (12.56 in)
Specified free length:
d. Replace the coil spring if it is cracked, broken or damaged.
Damping Force/Noise
Rock the left side of the vehicle up and down, and then rock the right
side, to check for noise or variances in vehicle posture.
NOTE:
If the up-and-down movement (when hands have been released)
continues longer than usual or if any abnormal noise is detected,
check the condition of the strut itself.
Refer to instructions for inspection procedures.
Damper strut
Oil leakage
Check for oil leaks at or around the lower portion of the strut and oil
seal assembly.
NOTE:
It is normal for a trace of oil to be oozing at the oil seal assembly.
Cracks, Damage or Deformity
Check the strut housing for any cracks, damage or deformity. Replace
the dust cover if it is damaged.
9-10
Visual and tactile
inspection
SUSPENSION, WHEELS AND AXLES
Description
Item to be checked
Remarks
Preliminary Inspection
Before checking/adjusting front wheel alignment, be sure to make a
prior inspection of the following points and repair/replace the damaged portions/parts as necessary.
• Tire pressure
• Wear or damage of tires
• Wheel balance
• Looseness on suspension
• Looseness and smooth operation on axle linkage and connection
• Looseness and smooth operation on steering linkage and connection
• Shock absorber operation and oil leakage
• Damage, deformation etc. on body attaching portion of suspension, axle and steering linkage and connection
• Vehicle height [It is recommended that the difference of vehicle
height between the front and rear ends, or the left and right sides
is less than 10 mm (0.39 in) in the unloaded condition.]
• Stain, rust, grease leakage etc. on front end parts
Toe-in Adjustment
Wheel alignment
Loosen both the left and right lock nuts CD. If toe-in is not within
the specified value, turn the left and right tie rods ® equal amounts
until the toe-in is within the specified range.
1 Lock nut
2 Tie rod
Fig. 9-15
78 - 88 N·m
(8 - 9 kg-ru,
58 - 65 ft-lb)
Torque (lock nut)
NOTE:
a. If the tie rod and the tie rod end have been disassembled, assemble
these parts in advance so that the toe-in is near the specified range_
b. Both the left and right tie rods are right-hand threaded. To increase
toe-in, turn both tie rods counterclockwise equal amounts (as
viewed from the outside of the vehicle).
c_ If the side slip is not within the specified range but although the
toe-in within the specified value, check the steering gear box, ball
joints, and wheel bearings for plav, and repair or replace the part(s)
if defective_
d. Alwavs a"ust the toe-in after steering angle adjustment.
e. Refer to the Specifications for the specified toe-in.
9-11
Toe-in gauge
SUSPENSION, WHEELS AND AXLES
Item to be checked
Remarks
Description
Camber and Caster
Neither camber nor caster can be adjusted. To measure camber and
caster, place the wheel to be measured on the turning radius gauges
CD, and make sure the vehicle is level. Set Adapter Assembly @
(925621000 for steel wheel) into the center of the wheel, and then
install the alignment gauge @.
Wheel alignment
(continued)
Fig. 9-16
@
A15-147
NOTE:
a. Refer to the Specifications for the camber and caster values.
b. If the camber or caster measurement is not within the specified
range, check for body alignment, deformed transverse link or
faulty parts. Repair or replace the parts, if necessary.
Looseness
Check each mounting portion of the following for looseness and
inspect the castle nuts for missing cotter pins.
(1) Strut mount to car body
(8) Transverse link to
(2) Damper strut piston rod to strut
crossmember (front)
(9) Crossmember to body
mount
(3) Damper strut to housing
(10) Stabilizer to leading rod
(4) Housing to ball joint
(11) Stabilizer to
(5) Ball joint to transverse link
crossmember (rear)
(6) Transverse link to leading rod
(7) Leading rod to crossmember (rear)
General
Cracks, Damage or Deformity
Check the following parts for cracks., damage or deformity.
(5) Transverse link
(2) Damper strut
(6) Leading rod
(3) Housing
(7) Stabilizer
(4) Ball joint
Visual inspection
(1) Crossmembers (front and rear)
Rubber Parts
Check the following parts for deterioration, cracks or damage.
(1) Strut mount
(4) Transverse link bushing
(2) Damper strut dust cover
(5) Leading rod bushing
(3) Ball joint boot
(6) Stabilizer bushing
9-12
Visual inspection
----...J
\.'~,....-;=."....------...,.-----------------~--------------....
SUSPENSION, WHEELS AND AXLES
9-3. Front Suspension Damper Strut
1. Removal and
Disassembly
1) Disconnect ground cable from
battery.
2) Apply parking brake.
3) Loosen front wheel nuts.
4) Jack up vehicle, support it with
safety stands (rigid racks) and remove
front tires & wheels.
5) Release parking brake.
6) Disconnect parking brake hose
from brake pipe at apron bracket.
12) Hold damper strut assembly in a
horizontal state.
Carefully turn in the thread of Puller
and compress spring until the strut
upper seat surface is separated from
spring.
13) Loosen self-locking nut connecting rod of damper to strut mount by
using Wrench [included in Puller &
Wrench (925651000)] and 17 mm
box wrench.
c. Start the job after cleaning around
the oil seal assembly.
20) Pull out piston rod a little, and
remove packing.
Packing--(II4'l"'-"'"
(O-ring)
NOTE:
A15-086
a. Fit air bleeder cap onto brake pipe
to prevent brake fluid from pour·
ing.
b. Whenever removing or installing
flare nut, use flare nut wrench
without fail.
7) Disconnect brake hose from
caliper body, and detach brake hose.
8) Remove two damper strut installing bolts.
9) Pull strut out of housing gradually
and carefully with housing assembly
placed downward.
Fig. 9-19
21) Pull out piston rod and rod
guide.
NOTE:
A15·084
Fig. 9-18
14) Pull strut mount out of rod.
15) Remove thrust washer with oil
seal and washer (thrust bearing).
NOTE:
NOTE:
If strut i~ rusted, apply sufficient
"CRC" on housing and strut before
pulling strut out.
Take care not to drop them.
10) Remove nuts clamping strut
mount to body.
11) Set damper strut assembly on
Puller [included in Puller & Wrench
(925651000)] .
Fit the hook of Puller to the upper
end of coil spring.
16) Remove spring retainer (upper).
17) Carefully return coil spring unscrewing Puller to the original position
and remove Puller after spring is
completely extended.
18) Remove coil spring.
NOTE:
00 not strike rod of damper.
19) Remove oil seal assembly by
using special tool (Wrench 925390000).
NOTE:
A15·018
Fig. 9-17
a. Compress damper strut to its
minimum length to prevent piston
rod from damage.
b. When vising the damper strut at its
connecting portion to housing, vise
it through something like wooden
block to prevent it from damage.
Don't pull out piston rod quickly or
along with inner cylinder to prevent
oil spillage.
~
1
I
I
22) Remove inner cylinder slowly.
23) Pour oil out completely by
turning outer shell upside down.
24) After cleaning disassembled parts
with thinner or kerosene, blow off any
dust, sludge etc., by compressed air.
NOTE:
Don't use thinner or kerosene for non·
metalic parts. Clean them by using
compressed air only.
2. Inspection
Check the disassembled parts for
crack, damage and wear, and replace
with new parts if defective.
1) Damper strut
1) Insert inner cylinder and piston
rod into outer shell, and check if they
move smoothly.
2) If not, check the following.
a. Oil seal assembly
If oil leakage is found around oil
seal assembly while piston rod and
inner cylinder are normal, replace
oil seal as seal kit.
9-13
-----------------~)
SUSPENSION, WHEELS AND AXLES
NOTE:
Oozing out of oil is normal, and there
is no necessity for replacing oil seal.
b. Piston rod
Replace it with new damper strut if
defective.
(3) Check piston rod-to-outer shell
total clearance as shown.
~~~~t -:1g~;:::3
(1) If leaked oil spreads to near spring
(2 kg,
seat, check piston rod carefully for
damage, uneven wear and bend.
41b)
NOTE:
Since slight scratch can cause oil leak,
check piston rod as carefully as possible.
(2) Measure bend and wear as shown.
10 mm 10.39 in)
0.2mm
(0.008 in)
Wear limit
0.1 mm
(0.004 in)
Specified
inner diameter
A15·091
Clamp outer shell, and pull out piston
rod to its maximum stroke. Set dial
gauge, and apply 20 N (2 kg, 41b) of
force upwards and downwards at its
free end through spring balance, and
read dial gauge.
0.8 mm or less
(0.031 in)
c. Inner cylinder
Replace it with new damper strut
if defective.
(1) Check for wear and damage on
inner surface and for bend.
(2) Measure wear and bend as shown.
"TOKICO"
30.05 - 30.15 mm
(U831 - 1.1870 in)
"KYB"
30.20 - 30.28 mm
(1.1890 - 1.1921 in)
"SHOW A"
30.0 - 30.052 mm
(1.1811 - 1.1831 in)
Fig. 9-21 Measuring clearance
Indication of
dial gauge
1 Dial gauge Bend Measuring
2 Piston rod
3 V-block
Bend limit
d. Outer shell
Replace it with new damper strut if
defective.
(I) Distortion, crack and damage.
(2) Oil leakage around welded portion
at its lower end.
2) Strut mount
1) Check rubber part for creep, crack •
and deterioration, and replace it with
new one if defective.
2) If distortion is found on its connecting surface to body, replace it
with new one.
3) Thrust washer
Wear Measuring
1 Piston rod
2 Micro meter
A15·090
Fig. 9-20 Measuring piston rod
Bend limit
0.05 mm
(0.0020 in)
Wear limit
0.02mm
(0.0008 in)
Specified
outer diameter
1) Check for wear, distortion, damage etc., and replace it with new one if
defective.
2) If any scratch is found on sliding
surface, replace it along with washer
with new pair.
"TOKICO"
19.94 - 19.98 mm
(0.7850 - 0.7866 in)
"KYB"
19.935 - 19.981 mm
(0.7848 - 0.7867 in)
"SHOWA"
19.98 - 20.01 mm
(0.7866 - 0.7878 in)
1 Dial gauge
2 Inner cylinder
4) Oil seal
A15·092
Fig. 9-22 Measuring of bend
Check the lip of oil seal for wear,
damage and deterioration, and replace
it with new one if defective.
5) Dust cover
If any crack or damage is found,
replace it with new one.
6) . Coil spring
1 Cylinder gauge
2 Cylinder
A15·093
Fig.9-23 Measuring bore of cylinder
9-14
One having permanent strain should
be replaced with new one. When
vehicle posture is uneven although
there is not considerable reasons like
tyre puncture, uneven loading etc.,
check coil springs for its free length,
crack etc., with referring to specifications.
1
SUSPENSION, WHEELS AND AXLES
NOTE:
3. Assembly
Damper Strut
1) Insert piston rod into inner cylinder gradually.
Piston rod
Packing
Rod guide
NOTE:
a. Since all parts are made with accuracy, be careful not to drop it or
to damage by using plier etc.
b. Be careful not to use glove or cloth
to prevent it from getting dust.
c. When inserting piston rod into
inner cylinder, compress piston ring
slowly into cylinder by fingers not
to damage it.
A15·095
Fig.9-25 Installing rod guide
6) Install oil seal assembly to piston
rod with fitting Installer (925380000)
on thread portion of piston rod.
a. Tighten oil seal assembly with
piston rod being stretched to its
maximum stroke.
b. Use something like wooden block
to clamp outer shell not to damage
it.
c. Be careful not to damage piston rod.
8) Set damper strut on Puller [included in Puller & Wrench (925651000)] ,
and fit coil spring to spring seat
correctly as shown.
CD
®
2) Insert inner cylinder with piston
rod into outer shell slowly.
3) Pour oil into outer shell by using
measuring cylinder.
All models exeept 4WD
205 em'
(205 ee, 12.51 eu in)
spring
Fig. 9-28 Fitting coil spring
1 Installer (925380000)
2 Oil seal assembly
Oil quantity
A15-096
4WD
220 em'
(220 ee, 13.42 eu in)
Fig.9-26 Installing oil seal assembly
NOTE:
NOTE:
NOTE:
a. Use always new oil, which is
available as genuine parts "seal kit".
b. Measure oil with accuracy by using
measuring cylinder.
9) Fit hook of Puller near upper end
of coil spring, and turn thread of
Puller to compress spring enough.
a. Apply grease to lip of oil seal.
b. Use genuine grease contained in
"seal kit" for respective make of
damper strut.
c. When installing oil seal, use special
tool (lnsta"er 925380000) without
fail to prevent oil seal lip from
being damaged.
Be careful not to slip off spring.
7) Tighten oil seal assembly by using
special tool (Wrench: 925390000)
All5-0153
Torque
98 - 118 N·m
(10.0 - 12.0 kg-m,
n - 87 ft-lb)
Fig. 9-29 Compressing coil spring
10) Stretch piston rod to its maximum stroke, and install dust cover,
upper spring seat and thrust washer.
Fig.9-24 Pouring oil
4) Attach packing to rod guide as
rod guide assembly.
5) Install rod guide assembly to inner
cylinder fIrmly with care of not damaging it by thread of piston rod.
NOTE:
a. Be careful not to spill oil.
b. After installing, make sure that
packing does not rise from rod
guide.
A15·097
1 Wrench (925390000)
2 Wood block
Fig. 9-27 Tightening oil seal assembly
9-15
Fig. 9-30
A 16-163
(r--
SUSPENSION, WHEELS AND AXLES
11) Install washer into oil seal with
facing grinded surface of washer to
lip side of oil seal.
NOTE:
Apply grease on oil seal lip and sliding
surface of washer.
4. Installation
1) Set strut assembly in position,
and temporarily tighten nuts clamping
strut mount to body.
NOTE:
Take care of installing direction of
strut mount
2) Push and set stru t into housing
gradually and carefully.
3) Tighten two damper strut installing bolts.
5) Clamp brake hose with clip on
damper strut.
6) Connect brake hose to caliper
body.
Torque
(Union bolt)
15 - 20 N·m
(1.5 - 2.0 kg-m,
11-14ft-lb)
NOTE:
Always be sure to use flare nut wrench.
Torque
1
2
3
4
5
Washer
Oil seal
Thrust washer
Piston rod
Upper spring seat
Fig. 9-31
A15-100
Installing oil seal etc.
12) Install oil seal and washer assembly on to thrust washer.
Bol t installing
damper strut
bracket to
housing
29 - 39 N·m
(3.0 - 4.0 kg-m,
22 - 29 ft-lb)
Bolt clamping
damper strut
to housing
29 - 39 N·m
(3.0 - 4.0 kg-m,
22 - 29 ft-Ib)
NOTE:
Be sure to position oil seal lip to face
to coil spring.
Fig. 9-35
A15·082
7) Connect brake hose to brake pipe
at apron bracket.
Torque
13) Install strut mount to piston rod,
and tighten self-locking nut temporarily.
12-18N·m
(1.2 - 1.8 kg-m,
9 - 13 ft-lb)
NOTE:
Never use removed self-locking nut,
and replace it with new one.
'
}
f
I
14) Loosen Puller (included in Puller
& Wrench (925651000)] gradually,
and remove it.
15) Tighten self-locking nut by using
Wrench (included in Puller & Wrench
(925651000)] .
A15·083
o
Fig. 9-33
4) Securely tighten nuts clamping
strut mount to body.
Fig. 9-36
Torque
59 -74 N·m
(6.0 - 7.5 kg-m,
43 - 54 ft-lb)
Torque
29-39N·m
(3.0 - 4.0 kg-m,
22 - 29 ft-lb)
I
8) Install another side damper strut
in the same manner.
9) Install tires and wheels, and
tighten wheel nuts temporarily.
10) Apply parking brake, and lower
vehicle after taking ou t rigid racks.
11) Tighten wheel nuts.
Torque
(Wheel nut)
A1S-076
A15-Q84
Fig. 9-32
Fig. 9-34
9-16
A15·072
78 - 98 N·m
(8.0 - 10.0 kg-m,
58 - 72 ft-lb)
12) Bleed air from brake system.
13) Connect ground cable to negative
terminal of battery.
SUSPENSION, WHEELS AND AXLES
9-4. Stabilizer
2. Inspection
Check and replace if defective.
®
~-11~
1'1
.4--I\'
II "\ \
11
\\
11
Cracks, deterioration or sticking.
2) Stabilizer
®
I II
1) Bushing
Cracks at curved portions.
@
3. Installation
"
\
Reverse the removal procedure.
""
1
2
3
4
5
6
Stabilizer
Leading rod
Stabilizer front bracket
Stabilizer front bushing
Stabilizer rear bracket
Stabilizer rear bushing
A15-160
Fig.9-37 Stabilizer
1. Removal
1) Jack up body at the front.
2) Remove bolt at stabilizer front
bracket.
3) Remove nuts at stabilizer rear
bracket.
4) Remove brackets and bushings
from stabilizer.
5) Remove stabilizer.
NOTE:
a. Stabilizer rear bushing on rear
crossmember should be installed by
aligning the bushing inner end with
the marking on the stabilizer.
b. Each bushing must be fitted firmly
and fixed with tires on the ground
and with no load on the car.
Torque
Bolt at
front bracket
18 - 31 N·m
(1.8 - 3.2 kg-m,
13 - 23 ft-Ib)
Nut at
rear bracket
18-31 N·m
(1.8 - 3.2 kg-m
13 - 23 ft·lb)
9-5. Front Crossmember
1. Removal
1) Disconnect ground cable from
battery.
2) Apply parking brake, and remove
spare tire and wheel.
3) Loosen front wheel nuts.
4) Jack up vehicle, support it with
safety stands (rigid racks), and remove
front tires and wheels.
5) Release parking brake.
6) Remove air cleaner assembly and
pitching stopper rod.
NOTE:
Fit a cap onto carburetor to prevent
inside of bore from dust.
7) Remove parking brake cable
bracket from transverse link.
8) Remove cotter pin and castle nut
of ball stud on tie-rod end, and detach
tie-rod from knuckle arm.
9) Remove front exhaust pipe.
10) Remove transverse link from front
crossmember.
9-17
11) Remove cushion rubber from
crossmember.
12) Disconnect steering torque rod
from pinion shaft.
13) Lift engine assembly by approx.
10 mm by using chain block.
14) Remove crossmember installing
nuts with crossmember supported by
jack, and remove crossmember downward gradually along with steering
gear box.
SUSPENSION, WHEELS AND AXLES
2. Installation
I) Set crossmember along with steering gear box in position and carefully
support them with a jack.
4) Tighten nuts attaching engine
mount cushion rubber to crossmember.
20-32N.n~J
(2.0 -- 3.3 kg-m,
14 -- 24 ft-Ib)
NOTE:
Check crossmember for cracks and/or
damage, and replace it if necessary.
-----~
Torque
25 - 49 N·m
(2.5- 5.0 kg-m,
18 - 36 ft-lb)
Torque
(Castle nut)
---~--.--
8) Connect parking brake cable
bracket to transverse link.
9) Attach air cleaner assembly and
pitching stopper rod.
2) Lower engine assembly by operating chain block.
3) Tighten self-locking nuts connecting steering torque rod and pinion
shaft.
----_._ ...
6) Install front exhaust pipe.
7) Connect tie-rod end to knuckle
arm of housing.
10) Install front tires and wheels.
11) Apply parking brake and lower
vehicle to the ground.
12) Tighten nut connecting transverse link to crossmember to the
specified torque.
_---]
14 -- 20 N·m
(1.4 - 2.0 kg-m,
10 -- 14 ft-Ib) .
A15·103
Fig. 9-39
5) Connect transverse link to crossmember by temporarily tightening
nuts for transverse link bushing.
[ :---1
Torque
-'-
~J
59 - 69 N·m
(6.0 - 7.0 kg-m,
43 - 51 ft-Ib)
-_._-------
13) Connect ground cable to negative
terminal of battery.
Fig. 9-38
A15-104
A15-077
Fig. 9-40
9·6. Ball Joint
2) Remove cotter pin, castle nut and
bolt to remove ball joint.
2) Connect ball joint to transverse
link.
2. Installation
1)
A15-161
Fig. 941
Torque
(Castle nut)
Install ball joint onto housing.
Torque
(Bolt)
29 - 39 N·m
(3.0 - 4.0 kg-m,
22 - 29 ft-Ib)
1. Removal
1) Jack up body at the front to
remove wheels.
b. The ban joint and boot that have
been removed must be checked for
wear, damage or crack, and any
defective part must be replaced.
NOTE:
a. Pay attention not to stick grease
to tapered portion of ban stud.
39 N·m
(4.0 kg-m, 29 ft-lb)
3) Retighten castle nut further until
a slot in castle nut is aligned with the
hole in ball stud end, then insert new
cotter pin and bend it around castle
nut.4) Install front wheels, and lower
vehicle.
9-18
~..'O:.;;.4.-'~_"''''''+;
,I
.1.....'.,b"....I.....................- -.......- -_ _ _ _ _ _ _-
_ _ _ _ _ _-
.....1
. . . . ._ _ _ _ _ _ _- -_ _ _ _. . ._ _ _
-,.-.i
SUSPENSION, WHEELS AND AXLES
9·7. Rear Suspension
1. Removal and
Disassembly
NOTE:
NOTE:
When pulling off outer arm from crossmember, as inner end of torsion bar
engages with serration of crossmember, pay attention not to bend or twist
torsion bar.
a. At this time, vehicle should be in
the unloaded condition.
b. loosen bolts with extension bar
supported by tire outer surface,
and job will be easy.
13) Remove torsion bar from outer
arm.
14) Remove bolt and nut connecting
inner arm and crossmember.
1) Remove the two bolts attaching
shock absorber upper end to body.
A4·124
Fig. 9-42
2) Apply parking brake.
3) Loosen rear wheel nuts.
4) Jack up vehicle, support it with
safety stands (rigid racks) and remove
rear wheels and tires.
5) (4WD only) Remove following
parts and detach rear drive system.
a. Spring pins at both ends of drive
shaft.
NOTE:
Using a steel bar of 6 mm (0.24 in)
diameter, gradually drive out spring
pins.
e. Support rear differential with jack.
f. Self-locking nuts connecting rear
differential mounting member to
body
g. Rear differential - - Remove 4
nuts installing rear differential at its
front end to rear crossmember, and
carefully dismount rear differential.
6) Remove exhaust pipe (front and
rear).
7) Remove brake hose from brake
pipe at inner arm side bracket (on both
sides).
2. Inspection
Inspect disassembled parts for followings.
a. Wear, damage, distorsion, crack etc.
b. All thread for damage or distorsion.
c. Oil leakage at lower portion or oil
sealing portion of shock absorber.
NOTE:
If any damages or cracks are not found
in visual check, perform color flaw
check (dye penetrant investigation) on
peeled or corroded portion.
NOTE:
b. Rear axle shafts on both sides
- - - Remove outer D.O.J. of
drive shaft from rear axle spindle
by pushing inside D.O.J. of drive
shaft fully toward rear differential
and pushing brake drum downward.
Then remove inner end of drive
shaft.
c. Four bolts connecting propeller
shaft to rear differential.
NOTE:
Since transmission oil will flow out
when propeller shaft is pulled out
from transmission, prepare appropriate
cap and oil catcher in advance of
above job.
d. Propeller shaft - - Set oil
catcher at rear end of transmission,
and pull out propeller shaft slowly.
To prevent oil flowing out, insert
appropriate cap immediately.
a. Insert air bleeder cap to brake
hose end to prevent brake fluid
from pouring.
b. Whenever removing or installing
flare nut, use suitable flare nut
wrench only.
3. Assembly
1) Engage outer serration of torsion
bar with outer arm temporarily.
8) Support rear crossmember at its
center with a jack, and remove four
bolts holding rear crossmember.
9) Lower jack gradually and draw
out from beneath vehicle body with
rear suspension assembly on it.
NOTE:
Put dismounted rear suspension assembly on soft material like rag,
corrugated paper, tire etc. to prevent
brake backplate and/or brake drum
from being damaged.
10) Remove floating bush (except
4WD).
11) Remove shock absorber.
12) Remove outer arm along with
torsion bar.
9-19
1 Outer bush
2 Torsion bar
3 Outer arm
A15·121
Fig. 9-43 Installing torsion bar to
outer arm
2) Install outer arm along with torsion bar with adjusting engagement of
serrations of torsion bar with crossmember and outer arm, so that outer
arm comes to appropriate position.
SUSPENSION, WHEELS AND AXLES
3) Temporarily lock outer bush with
lock bolt.
6) Install shock absorber to inner
arm at lower end of shock absorber.
Torque
88-118N·m
(9.0 - 12.0 kg-m,
65 -- 87 ft-lb)
A15·126
Fig. 9-49 Aligning holes
A15·162
Fig. 9-44 Temporarily locking outer
bush
4)
2) Tighten the four bolts holding
rear crossrnember at both ends.
Install inner arm to crossmember.
A15·119
Torque
74 - 93 N·m
(7.5- 9.5 kg-m,
54 - 69 ft-lb)
Torque
Fig.9-47 Installing shock absorber
118 -147 N·m
(12 - 15 kg-m,
87 - 108 ft-lb)
L -_ _ _ _ _ _ _ _L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
4. Installation
1) Support rear crossmember at its
center with a jack, and set it in
position.
Fig. 9-50
Fig.9-45 Installing inner arm
3) Connect brake hose and brake
pipe on both sides.
5) Connect inner arm and outer arm.
Torque
A16-117
118 - 147 N·m
(12.0 - 15.0 kg-m,
87 -108 ft-lb)
Torque
NOTE:
Use suitable flare nut wrench.
®
/ CD
A16-116
Fig.9-48 Supporting rear
crossmember
1
2
3
4
Connecting bolts
Outer arm
Inner arm
Crossmember
12 - 18 N·m
(1.2 - 1.8 kg-m,
9 - 13 ft-lb)
A15-163
Fig. 9-46 Connecting inner arm and
outer arm
NOTE:
When setting crossmember to vehicle
body, insert 13 mm (0.51 in) diameter
of bar into holes on crossmember
bracket and body frame to facilitate
the job by aligning the holes.
9-20
Fig. 9-51
SUSPENSION, WHEELS AND AXLES
4) Install exhaust pipe (rear) and
muffler in position.
a. Al1 models except 4WD: Tighten
bolts connecting exhaust pipe (rear)
along with muffler and exhaust
pipe (front), and then connect with
three cushions.
Torque
b. Connect rear differential mounting
member to body.
Torque
(Self-locking
nut)
f. Drive spring pins in at both ends of
drive shaft gradual1y by using 6 mm
(0.24 in) dia. steel bar.
69 -78 N·m
(7.0 - 8.0 kg-m,
51-58ft-Ib)
42 - 52 N·m
(4.3 - 5.3 kg-m,
31-38ft-Ib)
A15-l08
Fig. 9-57
A15-ll0
Fig. 9-54
1 Connecting bolt
2 Cushion
Fig. 9-52
A15-ll2
b. 4WD: Tighten bolts connecting
exhaust pipe (rear) and exhaust
pipe (front), and exhaust pipe (rear)
and muffler.
Then connect with three cushions.
Torque
c. Insert propeller shaft carefully in to
rear end of transmission.
d. Instal1 propel1er shaft onto rear
differential.
6) Install front tires and wheels by
temporarily tightening wheel nuts.
7) Lower vehicle after taking out
safety stands (rigid racks).
8) Tighten wheel nut firmly.
Torque
Torque
18-25N·m
(I.8 - 2.5 kg-m,
13 - 18 ft-Ib)
42 - 52 N·m
(4.3 - 5.3 kg-m,
31 - 38 ft-Ib)
78-98N·m
(8.0- 10.0 kg-m,
58 -72 ft-Ib)
9) Connect shock absorber upper
end to body on each side with vehicle
unloaded.
Torque
88 - 127 N·m
(9.0 - 13.0 kg-m,
65 - 94 ft-Ib)
5) (4WD only) Install rear differential
as follows.
a. Set rear differential in position with
a jack, and tighten the four nuts.
Fig. 9-55
Torque
69 -78 N·m
(7.0 - 8.0 kg-m,
51-58ft-lb)
A4-123
e. Insert rear drive shafts on both
sides onto rear axle spindle and rear
differential.
A15-l07
Fig. 9-58
10) Tighten outer bushing lock bolts
with vehicle unloaded.
Torque
A1S-lll
Fig. 9-53
Fig. 9-56
A15-l09
9-21
31-39N·m
(3.2 - 4.0 kg-m,
23 - 29 ft-Ib)
SUSPENSION, WHEELS AND AXLES
11) Always be sure to check and
adjust the following:
a. Air bleeding of brake system
b. Rear vehicle height
c. Rear wheel alignment
3) Installation
1) Removal
1) Set inner arm on the press bed
1) To remove torsion bar, remove
through base of installer and supporter as shown so that axis of bore of
inner arm becomes vertical.
outer arm along with torsion bar from
dismounted rear suspension assembly.
S. Inner Bush
1) Removal
2) For 4WD model
Center arm can be taken out of crossmember, after two torsion bars in both
sides of crossmember are removed.
Remove inner bush using Bush installer (921390000) as follows.
1) Set inner arm boss end on base
cv.
2) Fit shank CD to outer tube of
inner bush.
3) Remove bush by using a press.
2) Inspection
1 Shank
2 Inner bush
3 Base
4 Inner arm
A15-132
Fig. 9-60 Setting inner arm on press
2)
Set inner bush and shank to bore
of inner arm.
3) Press bush into bore until end
surface of outer tube of inner bush
corresponds to upper end of boss of
inner arm.
1 Shank
NOTE:
When disengagement of torsion bar
from inner serration of crossmember
is difficult, tap outer end of opposite
torsion bar with wooden hammer, and
the torsion bar and outer arm can be
removed.
A15·129
2 Base
3 Inner arm
6. Torsion Bar and
Center Arm
Check for crack and damage, and
replace if defective.
3) Installation
1) Apply grease to inner serration
and outer serration of torsion bar.
2) For 4WD models, insert center
arm into crossmember.
3) Insert torsion bar engaged with
outer arm into crossmember, and
engage it with inner serration of crossmember or center arm.
NOTE:
Fig. 9-59 Removing inner bush
2) Inspection
Check removed torsion bars and
center arm for crack at its peeled and/
or corroded portion by means of
visual check and color flaw check.
1) If any flaw is found, replace it
with new one.
2) If no defect is found, touch up
it with black paint after rasping.
NOTE:
Center arm is adopted on 4WD models
only.
Do not confuse a torsion bar with
another one.
Confusion between R.H. one and L.H.
one will result early breakage of them.
When installing torsion bars, confirm
color of paint (R.H. - yellow, L.H. green) on outer end of torsion bar.
9-22
"-.~~~~I,"","'TJ.,-;-r;..~-~_......_ _ _ _......_ _ _ _ _ _ _ _ _ _ _ _ _ _ _....._
. . ._ _ _ _ _ _ _ _ _ _ _ _~-_-_..J
l
SUSPENSION, WHEELS AND AXLES
9-8. Adjustment of Posture (4WD Models Only)
Ground clearances of front and rear
suspensions of 4WD vehicles can be
adjusted according to the following
procedure.
ture, check air pressure of the all
tires and adiust to the specified
pressure if necessary.
NOTE:
a. Before adjusting the vehicle pos-
b. Place the vehicle under unloaded
condition on the flat ground.
1. Front Posture Adjustment
Vehicles
STD
2-door
Hatchback 4WD
Maximum adjustable
height
Specified ground
clearance "h"
--265 - 290 mm
(I0.43 - 11.42 in)
I
270 ~ 295 mm
(10.63 ~ 11.61 in)
---
DL
265 - 290 mm
(10.43- 11.42 in)
GL
270 - 295 mm
(10.63 -- 11.61 in)
_._-_._---
Station Wagon
4WD & Brat
NOTE:
a. When turning the adjusting nuts,
turn the both nuts on one side of
the strut by the same times.
m
f----- - - - - - - - - - - - - - - - - -.
GL
2) If "h" dimension is out of the
specified range in the above table,
adjust "h" dimension according to
following method.
3) Front posture is adjusted by
turning four (4) adjusting nuts on the
both sides of the struts.
I
m
I
I
I
only upward
25 mm (0.98 in)
--------
'------------
--
I) Check the ground clearance by
measuring between front end of transverse link attaching bolt and ground.
Adjusting nuts
width across flats;)
( 21 mm (0.83 in)
A1S-062
Fig. 9-62
A15-130
Fig. 9-61
b. Check and/or adiust the toe-in of
front wheels to the specified value
after turning the adjusting nuts of
front strut.
2. Rear Posture Adjustment
Specified ground
clearance "H"
Vehicles
2-door
Hatchback 4WD
STD
320 -340mm
(12.60 - 13.39 in)
GL
325 - 345 mm
(12.80 13.58 in)
DL
335 - 355 mm
(13.19 - 13.98 in)
GL
340 -360mm
(13.39 - 14.17 in)
Station Wagon
4WD & Brat
Maximum adjustable
height
only upward
30 mm (1.18 in)
A15-122
I) Measure height of crossrnember
pipe lowest point from the ground.
("H" dimension).
Fig. 9-63 Measuring "H" dimension
9-23
-
------
j
I
---------------
SUSPENSION, WHEELS AND AXLES
2) If "H" dimension is out of the
specificed range in the above table,
adjust "H" dimension according to
following method.
3) To adjust rear posture, turn ad·
justing bolt from service hole provided
on vehicle floor.
Turning to clockwise increases
vehicle height and turning to counter·
clockwise decreases it.
Service hole on vehicle
floor
2 Adjusting bolt of center
arm [width across flats;
19 mm (0.75 in)]
A15-102
Fig. 9-64
9·9. Adjustment of Rear Road Clearance
Rear road clearance can be adjusted
also by changing engagement of inner
and outer serrations of torsion bar.
Since numbers of teeth of inner and
outer serrations are 37 and 34 respec·
tively and distance between torsion
bar center and wheel center is approx.
400 mm (15.75 in), shifting the matching of inner or outer serration by one
pitch causes change in rear road
clearance by 68 mm or 74 mm (2.68
or 2.91 in) respectively.
Therefore, by shifting the matchings
of inner and outer serrations in opposite directions, various adjustments can
b.e made.
Adjustment with rear suspension
mounted on the vehicle can be made
as follows.
1) Measure rear road clearance, and
determine numbers of teeth to be
shifted on inner and/or outer serra·
tions.
2) Remove the bolt which attaches
shock absorber to the body at the top
of shock absorber.
3) Jack up the vehicle body and
remove wheels.
4) Remove lock bolt of outer bush·
ing.
5) Remove three bolts connecting
outer arm and inner arm, with brake
drum supported by a jack or the
like to prevent brake hose from
damage.
6) Mark on outer bushing, crossmember and torsion bar so as to
identify their original positions.
7) Measure vertical distance between
end of outer arm and vehicle body.
8) Pull out outer arm together
with torsion bar until inner serration
is disengaged completely.
9) Rotate torsion bar and outer arm
to shift matching of inner serration
by appropriate pitches, and engage
inner serration with crossmember.
10) Pull out outer arm from torsion
bar, and rotate outer arm to opposite
direction to shift matching of outer
serration by appropriate pitches.
NOTE:
Pay attention not to disengage inner
serration of torsion bar from cross·
member.
11) Install outer arm to trosion bar
and crossmember, and then measure
in the same manner as step 7).
Change in this distance shows a
half of change in rear road clearance
caused by adjustment.
12) Connect outer arm and inner
arm by installing three bolts.
13) Carry out same work on the
other wheel.
14) Install wheels, and put the
vehicle down on the ground.
15) Install shock absorber. to vehicle
body.
16) Install lock bolt of outer bushing.
17) Confirm that rear road clearance
is properly adjusted.
9-24
~"":;~~"~.t";tM>4<-:~~":'''"i..tk~'.'''·'''''''--I'''II·'''''
_
""'-.-----------------....,--------------~--
...............
0 ..........
• .......
,
.1
___
SUSPENSION, WHEELS AND AXLES
.WHEELS AND AXLES
9-10. Component Parts
®
• Front Axle
Tightening torque N'm (kg-m, ft-Ib)
T1: 196 (20, 145)
T2: 6 -14 (0.6 -1.4,4.3 -10.n
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
®
Housing
Bearing
Oil seal
Axle shaft assembly
Spring pin
Spacer
Disc cover
Spring washer
Bolt
Disc rotor
Hub complete
Center piece
Washer spring
Axle nut
Cotter pin
Fig. 9-65 Component parts of front axle
A16-147
• Rear Axle
1. Except 4WD
CD
Tightening torque N'm (kg-m, ft-Ib)
T: 78 - 98 (8.0 - 10.0, 58 - 72)
®
1
2
3
4
5
6
7
8
9
10
11
12
13
Spacer O-ring
Oil seal spacer
Oil seal
Inner taper roller bearing
Brake drum complete
Hub bolt
Wheel nut
Outer taper roller bearing
Lock plate
Lock washer
Axle nut
O-ring
Cap
Fig.9-66 Component parts of rear axle (Except 4WD)
A 16-148
9-25
r
SUSPENSION, WHEELS AND AXLES
2. 4WD
CD
1 Packing
2 Rear spindle
3 Inner 0 il seal
4 Ring nut
5
6
7
8
9
10
11
Bearing assembly
Outer oil seal
Brake drum complete
Center piece
Spring washer
Axle nut
Cotter pin
- - - - - - - - - - - - - ---------,
Tightening torque N'm (kg-m, ft-Ib)
T1: 172 - 221 (17.5 - 22.5, 127 - 163)
----T2: 196 (20, 145)
----------------.-!
A16-149
Fig.9-67 Component parts of rear axle (4WD)
9-11. Housing
1. Removal
1) Disconnect ground cable from
battery.
2) Apply parking brake.
3) Remove front wheel cap and
cotter pin, and loosen castle nut and
wheel nuts.
4) Jack up vehicle, support it with
safety stands (rjgid racks), and remove
front tires and- wheels.
5) Release parking brake.
6) Disconnect parking brake cable
from brake caliper.
7) Remove disc brake assembly from
housing, and hang it from a strut with
string.
\~
\\
\
10) Remove ball stud connecting
transverse link with h\l\lsing.
II) Disconnect strut from housing by
opelling slit of housing and by lowering housing gradually with care of not
damaging C.Y.J. boot.
A16·152
Fig. 9·68 Removing brake ASSY
8) Remove two damper strut instal·
ling bolts.
9) Remove cotter pin and castle nut,
and disconnect ball stud from knuckle
arm by using a puller.
9-26
A16-156
Fig.9-69 Removing strut
SUSPENSION, WHEELS AND AXLES
3) Turn upside down housing, and
apply about 10 to 13 g (0.35 to 0.46
oz) of bearing grease into inside of
housing.
4) Insert spacer.
12) Remove castle nut on axle shaft,
and take out disc and hub assembly.
13) Remove disc cover.
14) Pull housing off axle shaft.
I,
1
A16-158
Fig. 9-72 Removing outer bearing
Puller
1 Spacer
(921122000)
Al.5·164
Fig. 9-70 Removing housing
2. Disassembly
3) Pu II ou t spacer.
4) A pply an aluminum bar or a brass
bar to the inside surface of outer race
of inner bearing.
Lightly knock the bar by a pJastic
hammer to drive bearing out of
housing together with oil seal.
2 Housing
3' Die
A16-196
Fig. 9-74 Inserting the spacer
5) The other bearing is pressed in as
shown in figure.
NOTE:
a. When knocking the bearing, be
careful to applv the bar on all
around the outer race.
b. Do not reuse the oil seal.
1
Punch
2
3
3. A••embly
1 Housing
A16-195
2 on seal
3 Bearing
Fig. 9-75 Press-in of bearing
Press is necessary in assembling.
1) Set housing on Die (Installer:
925140000).
2)
Set bearing onto Punch (Installer:
925140000) and gradually press it
4 Spacer
Fig. 9-71 Bearing, spacer and oil seal
into housing till outer race of bearing
comes to contact with stopper.
1) Move up or down spacer by finger.
2) Apply an aluminum bar or a brass
bar to the inside surface of inner race
of au ter bearing.
Lightly knock the bar by a plastic
hammer to drive bearing out of
housing together with oil seal.
NOTE:
a. Do not knock the bearing by a hard
material, otherwise the bearing will
be damaged.
b. When knocking the bearing, be
care"l, to apply the bar on all
aroun,'the inner race.
A16-162
6) Set housing on Die.
Apply sufficient grease on the lip of
the inside of oil seal.
7) Insert oil seal into the groove of
Punch so that the oil seal lip faces the
groove, and gradually press it into
housing till the face of Punch comes to
contact with bearing outer race.
Pre..
Housing
Punch
3
4
Bearing (Outer)
I
2
Die
Fig. 9-73 Press-in of bearing
Punch
Oil seal (Outer)
3
4
Housing
Die
Fig. 9-76 Press-in of oil seal
9-27
--,-----_.-
-----
.---
1
I
A 16-160
1
2
.~
----~--
---
_._-,-,,_._--------------
SUSPENSION, WHEELS AND AXLES
8) Turn upside down housing and set
it on Die turned upside down also.
9) Insert oil seal intq the groove of
Punch so that the oil seal lip faces the
groove, and gradually press it into
housing.
3) Turn the handle ,*hile holding the
rod end by means , spanner, thus
housing is pushed in. I
df
Torque
J
1
6-14N·m
(0.6 - 1.4 kg-m,
4.3 - 10.1 ft-Ib)
7) Install disc and hub ASSY onto
axle shaft.
8) Install brake ASSY to housing by
two bolts.
Torque
A16-166
49 - 69 N·m
(5.0 -7.0 kg-m,
36 - 51 ft-Ib)
Fig. 9-79 Installing "qusing
I
1
2
Die
A16-164
4) Connect damper strut and housing
by installing two bolts.
Fig. 9-77 Press-in of oil seal
4. InstaUation
1) Fit housing onto axle shaft and
attach spacer of Installer (925130000)
on outer bearing inner race taking care
not to damage the oil seal lip.
Then, connect the rod of Installer
to the thread of axle shaft so that
housing does not drop off from axle
shaft.
2) Install transverse link ball stud to
housing.
Torque
29 - 39 N·m
(3.0 - 4.0 kg-m,
22 - 29 ft-Ib)
A16-168
Fig. 9-81
A16-167
Fig. 9-80 Installing ¢lamper strut
Torque
9) Connect hand brake cable to
brake ASSY.
29 - 39 N·m
(3.0 - 4.0 kg-m,
22 - 29 ft-Ib)
5) Connect tie-rod end and housing
knuckle arm.
Torque
(Castle nut)
Fig. 9-78 Installing transverse link
ball stud
Installing brake ASSY
25 - 29 N·m
(2.5 - 3.0 kg-m,
18 - 22 ft-Ib)
After tightening to the speCified
torque, further tighten castle nut within 60° to align holes of castle nut and
ball stud.
Then insert cotter pin into ball stud
and bend it around castle nut.
6) Install disc cover to housing with
one bolt.
9-28
Fig. 9-82
10) Apply hand brake.
11) Fit center piece, conical spring
washer and axle nut in this order onto
front axle shaft and tighten castle nu t
to the speCified torque, then insert a
new cotter pin and bend it around axle
nut.
SUSPENSION, WHEELS AND AXLES
12)
13)
14)
tive
NOTE:
After tightening the nut to the spec·
ified torque, retighten further within
30° until a slot of the castle nut is
aligned to the hole in the axle shaft.
Install wheels and wheelcaps.
Put down vehicle from rigid racks.
Connect ground cable with negaterminal of battery.
\ Paint mark
Torque
196 N·m
(20kg'm, 145 ft·lb)
No< •
side
R.Yo "'''"
side
pi."
Cotter pin
2 Castle nut
3 Washer spring
4 Center piece
Washer spring
NOTE:
Connect leading rod to transverse link
if it was disconnected on removal.
A16-197
Fig. 9-83 Installing axle nut
9·12. Front Axle Shaft
1. Removal
1) Disconnect ground cable from
battery.
2) Apply parking brake.
3) Remove front wheel cap and
cotter pin, and loosen castle nut and
wheel nuts.
4) Jack up vehicle, support it with
safety stands (rigid racks), and remove
front tires and wheels.
5) Release parking brake.
6) Remove parking brake cable
bracket from transverse link.
7) Drive out spring pin of D.O.J.
8) Remove disc brake assembly, and
disconnect tie· rod , transverse link and
damper strut.
9) Remove axle shaft from differ·
ential spindle along with housing.
10) Remove housing from axle shaft
by using Puller (921122000).
6) Take out D.O.J. outer race from
shaft ASSY.
7) Wipe off grease and take out balls
and move cage to the boot side.
NOTE:
A16-198
Fig. 9-84 Removing boot band
3) Remove boot band on the small
end of D.O.J. boot in the same
manner.
4) Remove the larger end of D.O.J.
boot.
5) Pry and remove round circlip
located at the neck of D.O.J. outer
race with a screwdriver.
a. To remove the cage from the inner
race turn the cage by a half pitch
to the track groove of the inner
race and shift the cage.
b. Disassemble exercising care not to
lose balls (6 pcs).
c. The grease is a special grease (grease
for constant·velocity joint). Do not
confuse with other greases.
8) Remove C-type snap ring, which
fIxes inner race to shaft, by using
special pliers.
9) Take out D.OJ. inner race.
10) Take off D.O.J. cage from shaft
and remove D.OJ. boot with care of
not damaging it.
11) Pull out C.Y.J. boot.
12) Thus, disassembly of axle is
completed, but C.Y.J. is unable to be
disassembled.
2. Disassembly
1) Straighten bent claw of larger end
of D.O.J. boot.
2) Loosen band by means of screw·
driver or plier with care of not damag·
ing boot.
3. Inspection
A18·018
Fig. 9-85 Removing circlip
9-29
Check the removed parts for damage, .
wear, corrosion and etc.
If faulty, repair or replace.
____________________J
,-
I
SUSPENSION, WHEELS AND AXLES
9) Install circlip in the groove on
1) 110.1. (Double Offset Joint)
Check seizure, corrosion, damage,
wear and excessive play.
2) Shaft
Check excessive bending, twisting,
damage and wear.
3) C.VJ. (Constant Velocity Joint)
Check seizure, corrosion, damage and
excessive play.
4) Boot
Check wear, warping and breakage.
D.O.1. outer race.
NOTE:
A16-199
Fig. 9-87
5) Install cage, which was preViously
fitted, to inner race fixed upon shaft.
a. Assure that the balls, cage and inner
race are completely fitted in the
outer race of D.O.J.
b. Exercise care not to place the
matched position of circlip in the
ball groove of outer race.
c. Pull the shaft lightly and assure that
the circlip is completely fitted in
the groove.
NOTE:
a. Fit the cage with the protruded
part aligned with the track on the
inner race and then move by a half
pitch.
b. Apply the specified grease 20 to
30 g (0.11 to 1.06 oz) on the cage
pocket
4. Assembly
NOTE:
Use specified grease.
Specified grease for constant
velocity joint
A16-018
Fig. 9-90 Installing circlip
Molylex No.2 (pIN 623029980)
1) Install C.VJ. boot in specified
position, and ftll it with 60 to 70 g
(2.l2 to 2.47 oz)ofspecified grease.
Also fill the interior of C.V J. outer
race with approx. 60 g (2.12 oz) of
specified grease while yawing the joint.
2) Place D.OJ. boot at the center of
shaft.
3) Insert D.OJ. cage onto shaft.
NOTE:
Insert the cage with the recess facing
the outside, since the cage has an
orientation.
Cage
10) Add 20 to 30 g (0.71 to 1.060z)
of specified grease to the D.OJ.'s
interior.
11) Fill the boot interior with 20 to
30 g (0.71 to 1.06 oz) of specified
grease. Also apply grease on the shaft
area.
12) Install boots on D.O.J.
Fig. 9-88 Installing cage
6) Insert six balls into the cage
pocket.
7) Fill 20 to 30 g (0.71 to 1.06 oz)
of specified grease into the interior of
D.OJ. outer race.
8) Align the outer race track and ball
positions and place in the part where
shaft, inner race, cage and balls are
previously installed, and then fit outer
race.
NOTE:
a. The boot grooves shall be cleaned
so as to be free from grease and
other su bstance.
b. When installing D.O.J. boot, position outer race of D.O.J. at center
of its travel.
13) Put a band through the clip and
wind twice in alignment with band
groove of boots.
NOTE:
Use a new band.
14) Pinch the end of band with
pliers. Hold the clip and tighten securely.
A16-200
Fig.9-86 Cage of D.O.J.
NOTE:
4) Install D.OJ. inner race on shaft
and fit C-type snap ring with special
pliers.
NOTE:
Confirm that the C-type snap ring is
completely fitted in the shaft groove.
1
2
When tightening boot, exercise care so
that the air within the boot is appropriate.
Outer race
Grease
A16.019
Fig. 9-89 Inserting outer race
15) Tighten band by using Band
Tightening Tool (925091000).
9-30
'~"'~,-liI~.~
-1j.--'4#n.... -
......,",,-
"~_'
....
4,..--""""!,.....- -___I _..
*I _ _ _ _ _ _ _ _ _ _- . . , . . - -_ _ _ _ _- -_ _ __
...._ _ _ _...
4Z
I
SUSPENSION, WHEELS AND AXLES
!
I
NOTE:
a. Tighten band until it cannot be
moved by hand.
b. Former Band Tightening Tool
(925090000) is interchangeable
with this 925091000.
A16-169
A16-201
Fig. 9-91
Installing boot band
15) Tap on the clip with the punch
provided at the end of Band Tightening Tool.
NOTE:
Tap to an extent that the boot under·
neath is not damaged.
16) Cut off band with an allowance
of about 10 mm (0.39 in) left from
the clip and bend this allowance over
the clip.
17) Fix up boot on C.V.J. in the same
manner.
A16~170
Fig. 9-92 Installing axle shaft
Fig. 9-94 Connecting damper strut
2) Connect the rod of Installer to
the thread of axle shaft and turn the
handle while holding the rod end by
means of a spanner, thus axle shaft is
pulled in.
3) Align the spring pin holes of
0.0.1. and differential spindle.
4) Connect 0.0.1. and differential
spindle by driving spring pin in.
6) Install disc cover on housing with
one bolt.
NOTE:
a. Make sure that the holes are aligned
before driving the spring pin in.
b. When driving the spring pin, always
use new one.
6 -14N·m
(0.6 - 1.4 kg-m,
4.3 - 10.1 ft·lb)
Torque
7) Install hub and disc ASSY to
axle shaft.
Fig. 9-95 Installing disc hub
I
A15·015
Fig. 9-93 Driving spring pin in
5) Connect damper strut to housing,
and tighten two bolts.
5. Installation
1) Insert axle shaft into housing and
attach spacer of Installer (925130000)
on outer bearing inner race taking care
not to damage the oil seal lip.
Torque
29 - 39 N·m
(3.0 - 4.0 kg·m,
22 - 29 ft.lb)
8) Install or connect disc brake
ASSY, hand brake cable, center piece,
conical spring washer, axle nut, cotter
pin, brake hose, tie rod and transverse
link according to the same procedure
of "9-11 Housing - 4. Installation".
9) Install wheels and tighten wheel
nuts.
10) Install wheel caps in position.
11) Put down vehicle from rigid racks.
12) Connect ground cable with negative terminal of battery.
9-31
-
~-~~
-
-~---
-~ - - - -
-
~-
-
- - ~-~
--
~-~
--.-----
--~---~--~--.~
(
SUSPENSION, WHEELS AND AXLES
9·13. Replacement of D.O.J./D.O.J. Boot of Front Axle
Shaft
1. Replacement
8) Pull out D.O.1. outer race from
axle shaft ASSY.
1) Release parking brake and raise
vehicle using recommended lifting
points.
2) Disconnect oxygen (0 2 ) sensor
cord.
3) Remove front exhaust pipe.
a. Loosen nuts which connect front
exhaust pipe to engine and hold its
flanges loosely on engine.
A 15-165
Fig. 9-98 Separating D. O.J. from axle
drive shaft
6) Raise the staked ends of boot
band on both the large and small ends
of D.O.1. boot with a screwdriver and
remove bands.
1
2
Outer race
Grease
A16-019
Fig. 9-101
9) Remove snap ring which secures
D.O.1. inner race on axle shaft ASSY
with special pliers and pull out inner
race from axle shaft ASSY.
A4-093
Fig. 9-96 Removing front exhaust
p;pe from engine
b. Disconnect front exhaust pipe from
rear exhaust pipe and bracket.
A15-166
Fig.9-99 Removing D.O.J. boot
bands
A15-167
Fig.9-102 Removing D.O.J. inner
race from axle shaft ASSY
7) Slide out the large end of boot
from D.O.J. outer race and pry out
circlip from the groove near the D.O.J.
opening.
A22-061
Fig. 9-97
c. Remove front exhaust pipe.
4) Separate transverse link from
crossmember by removing the fixing
bolt.
5) Drive out spring pin which secures
D.O.J. to axle drive shaft and pull out
D.OJ. by hand.
A16-018
Fig.9-100 Removing D.O.J. circlip
10) Remove boot from axle shaft
ASSY.
11) Clean grease thoroughly from axle
shaft splines.
12) Disassemble inner race, clean the
balls, cage and inner race itself.
13) Clean grease thoroughly from
inside D.OJ. outer race.
NOTE:
Clean the axle shaft splines, inner race
and outer race with a brush and
cleaning solvent
__...-____•
9-32
-~.[lIII~llc",¥""'I:,~<;~~.11f7lf-·-·-T".. ~-_n_"_''''!''''fm
___, ""',r........'...' _,...._ ....,,_._______'..., _~'''''''-------_---.q''''.
SUSPENSION, WHEELS AND AXLES
2. Reassembly
NOTE:
Use specified grease.
Specified grease for constant
velocity joint
Molylex No.2 (P!N 623029980)
1) Put a new small boot band on axle
shaft.
2) Fit a new boot in position on axle
shaft.
3) Install inner race with cage oriented correctly on the axle shaft
splines and secure it by fitting snap
ring into the groove of axle shaft with
special pliers.
4) Apply 20 to 30 g (0.71 to 1.060z)
of specified grease to the cage pockets.
5) Fit six balls into the cage pockets.
6) Apply another 20 to 30 g (0.71 to
1.06 oz) of specified grease thoroughly to the inner surface of D.O.J. outer
race.
7) Install outer race over inner race,
aligning the former's ball tracks and
balls in cage, and fit circlip in the
groove of outer race.
NOTE:
a. Confirm that the circlip ends are
not positioned in any of the ball
tracks of outer race.
b. Confirm that circlip is completely
fitted into the groove by pulling
axle shaft outward lightly.
8) Apply 20 to 30 g (0.71 to 1.06 oz)
of specified grease to the D.O.J.'s
interior.
9) Apply 20 to 30 g (0.71 to 1.06 oz)
of specified grease to the boot interior
and fit the large end of boot onto
outer race.
Clean the band grooves on boot if they
are stained with grease or other substance.
10) Secure the boot ends in position
with new small and large bands in
accordance with the tightening procedure of "9-12 Front Axle Shaft 4. Assembly".
NOTE:
When tightening boot, exercise care
so that an appropriate amount of air
remains in boot.
Fit circlip
A15·168
Fig. 9-103 Assembling D.O.J.
components
II) Install D.O.J. onto axle drive shaft
aligning their spring pin holes and
drive in a new spring pin.
12) Connect transverse link with
crossmember.
13) Mount front exhaust pipe using
new gaskets and connect oxygen (0 2 )
sensor cord.
14) Lower vehicle on ground.
1
!
I
I
9-14. Rear Axle (Except 4WD)
1. Removal and
Disassembly
1) Apply parking brake, and loosen
rear wheel nuts.
2) Jack up vehicle, support it with
safety stands (rigid racks) and remove
rear tires and wheels.
3) Pry brake drum cap by screwdriver off drum.
4) Flatten lock washer and loosen
axle nut, then remove lock washer,
lock plate and brake drum so as not
to drop inner race of outer tapere
roller bearing.
Outer bearing, outer race of inner
bearing and oil seal can be removed
together with drum.
5) Remove spacer and inner race of
inner bearing with a gear puller, after
prying them by screwdriver.
6) Remove outer race of inner
bearing from drum. Remove oil seal
at this time.
CD
A 16·172
Fig. 9-104 Removing spacer and
inner race of inner bearing
1 Outer race of inner bearing
2 Outer race of outer bearing
A16-203
Fig.9-105 Removing outer race of
inner bearing
9-33
)
r
SUSPENSION, WHEELS AND AXLES
7) Remove outer
bearing from drum.
race
of outer
2. Inspection
Clean the removed parts and check
them for wear, damage and corrosion.
If faulty, repair or replace.
3. Assembly and
Installation
/
4) ApplyapproximateJy4g(O.14oz)
of grease to inner bearing and 3 g
(0.11 oz) to outer bearing.
Fill the hub of drum with approxi.
mately 30 g (1.06 oz) of grease.
5) Install spacer a·ring, spacer and
inner race of inner bearing onto the
spindle of trailing arm.
NOTE:
Be su re to use new spacer D-ring without fail.
Stepped su rface of the spacer must be
faced toward the bearing.
I) Press outer race of inner bearing
into drum using tapered roller bearing
installer (925120000) and a press.
Fig. 9-109 Adjusting preload of
bearing
2) Turn back nut 1/8 to 1/10 in
order to obtain correct starting torque.
Measure the starting force as shown.
Spring balance
Fig.9-106 Installing outer race of
inner bearing
NOTE:
Never exceed the load to the bearing
as it may damage it
2) Install oil seal into drum until its
outer end is flush with the drum
surface.
NOTE:
Apply a little amount of grease to the
lips of oil seal.
3) Press outer race of outer bearing
into drum using tapered roller bearing
installer (921130000) and a press.
Inner race of
inner bearing
2 Spacer
3 O-ring
CD
A1S-177
@
Fig.9-110 Measuring starting force
A16-206
Fig. 9-108 Installing spacer and inner
race of inner bearing
8.34- 14.22 N
(0.85 - 1.45 kg, 1.87 - 3.20 lb)
6) Install drum, inner race of outer
bearing, lock plate, lock washer and
axle nut in this order onto the spindle.
O_L=:-.lO
A16-205
Fig.9-107 Installing outer race of
outer bearing
3) Bend lock washer.
NOTE:
Be sure to use new lock plate and new
lock washer without fail.
4. Adjusting Rear
Wheel Bearing
Jl· .~~ ·jl
Recommended starting force
when measured at hub bolt
A16-202
Fig. 9-111
I) Tighten axle nut with tightening
torque of 49 N·m (5 kg-m, 36 ft-Ib),
and turn back nut a little, and then
turn drum bac k and forth alternately
several times to properly seat bearing
and ascertain bearing stability.
4) After installing a-ring to drum
cap, install cap to brake drum by
lightly tapping with plastic hammer.
NOTE:
a. Do not use steel hammer etc.
b. Be sure to use new O-ring.
9-34
',-
"',kM.. ~j_,·,I~~'.g.-
. bufFH
'1 1Iti IIIiii'
'wmxiV ;
,'
,.
SUSPENSION, WHEELS AND AXLES
9-15. Rear Axle of 4WD
1. Removal
17) Insert spindle from out side of
housing, and extract outer race of
inner bearing, spacer and outer bearing
by pushing inner race of outer bearing
through the spindle by a press.
18) Remove inner race of inner
bearing from spindle by using a press.
1) Apply parking brake.
2) Remove· rear wheel cap and cotter
pin, and loosen castle nut and wheel
nuts.
3) Detach shock absorber from inner
trailing arm.
4) Loosen locking bolts of crossmember outer bushing.
5) Jack up vehicle, support it with
safety stand (rigid racks) and remove
rear tires and wheels.
6) Remove castle nut and brake
drum.
7) Drive out spring pins of inner and
outer D.OJ.s by using a steel rod of
6 mm diameter.
8) Remove outer D.OJ. from spindle
of trailing arm with trailing arm
lowered fully, then remove inner
D.O.1. from differential spindle.
9) Remove rear exhaust pipe, muffler
and exhaust cover in that order.
10) Disconnect brake pipe from brake
hose.
NOTE:
Don't remove bearing outer races
when replacement of bearing is not
necessary, because removal of bearing
might damage the bearing.
2. Inspection
Inspect wear and damage of the
removed spindle, brake drum and
bearing.
Wrench
(925550000)
A15-169
Fig. 9-112 Tightening ring nut
5) Lock the ring nut by staking a
point on the housing surface facing
the ring nut groove.
NOTE:
If a bearing is faulty, replace it as the
bearing set.
3. Installation
NOTE:
1) Install inner race of inner bearing
Fit air breather cap onto end of brake
hose to prevent brake fluid from
pouring out.
on to the spindle, and install outer
races of inner bearing and outer bearing and spacer by using press.
.
NOTE:
Don't confuse orientation of bearing
ou ter races.
11) Remove brake assembly from
trailing arm.
12) Remove bolt holding inner bushing of inner trailing arm.
13) Remove three bolts, and take out
inner arm.
14) Vise inner arm, and straighten
staked portion of housing, then
remove ring nut by using special tool
(Wrench 925550000).
IS) Extract spindle inwardly by tapping it from out side with a plastic
hammer.
16) Remove oil seal.
NOTE:
Be sure to replace the oil seal at every
overhaul.
2) Apply grease of 20 to 30 g (0.71
to 1.06 oz) to bearing outer race in
housing.
3) Insert spindle from inside, and
press inner race of outer bearing from
outside by using a pipe of 35 mm
(1.38 in) in inner diameter while
tapping it with a hammer.
A16-188
Fig.9-113 Staking housing
6) Install outer oil seal by using
special tool (Installer 925530000).
NOTE:
Be sure to renew the oil seal.
7) Install inner oil seal by using
special tool (Installer 925530000).
NOTE:
Be sure to renew the oil seal.
8)
Mount inner arm to vehicle body.
NOTE:
Apply grease sufficiently on the inner
and outer bearing area.
4)
'>I!~
Torque
Inner bush bolt
74 - 93 N·m
(7.5 - 9.5 kg-m,
54 - 69 ft-Ib)
Inner and outer
arms connecting bolts
118 - 147 N·m
(12.0 - 15.0 kg-m,
87 - 108 ft-Ib)
Install ring nut to housing.
Torque
172 - 221 N·m
(17.5 - 22.5 kg-m,
127 -163 ft-lb)
9-35
r
SUSPENSION, WHEELS AND AXLES
9) Install rear brake assembly to
inner arm, and connect brake pipes
etc.
12)
Bleed brake system.
NOTE:
a. Before bleeding brake system,
check pedal play and brake fluid
level in reserve tank.
b. Bleed air from four wheels without
fail.
Inner D.O.J.
A16183
Fig. 9-114
A16-106
13) Tighten castle nut, insert cotter
pin and bend it firmly with foot
brake applied to lock the wheel and
axle.
70.5mm
++If--+-+(2.776 in)
dia.
10) Connect brake hose and brake
pipe.
Outer D.O.J.
A16·107.
NOTE:
After tightening castle nut to the specified torque, tighten further within
30° to align holes on nut and spindle.
Fig.9-117 Inner and outer D.O.J.
16) Install packing to rear spindle,
and mount 0.0.1. on rear drive shaft
onto spindle with trailing arm lowered
all the way.
11) Temporarily fit brake drum,
center piece, washer spring and castle
nut to spindle in this order.
NOTE:
a. Play on spindle experienced, when
mounting brake drum is not a fault.
b. Don't confuse orientation of washer
spring.
~.~
14) Install packing to differential
spindle.
15) Engage 0.0.1. of rear drive
shaft to differential spindle.
NOTE:
a. When mounting, mate the spline
teeth properlv so that the D.O.J.
and spindle spring pin hole will
align.
b. When mounting the rear drive
shaft assemblv, take care not to
mount the inner D.O.J. and outer
D.O.J. oppositely.
A16·189
Fig. 9-118 Installing D.O.J. and
spindle
17) Drive spring pins in to inner and
outer D.O.l.s respectively.
cD®@@
~
aint
mark
Nut. • Center piece
side
side
Washer spring
1
2
3
4
Cotter pin
Castle nut
Washer spring
Center piece
NOTE:
a. Before driving in the spring pin,
confirm alignment of the holes.
b. Be sure to renew the spring pin to
be driven in.
A16-197
Fig. 9-116 Installing castle nut
9-36
I,
_1
'.
,~
,.1_. .·. . . ·. . .",51_,...,...."""'"__, ' '_'________-''''"-_______- -___-''"'''''_____
... ~4"""""""'~.'''''_'~''·,~_·'''112...
·~ ...
tt" -.,...
;
I
I
1t
• F:
•
SUSPENSION, WHEELS AND AXLES
NOTE:
a. Disassembly and reassembly procedure of rear drive shaft is the
same as that of front drive shaft.
b. When reassembling the rear drive
shaft assembly, take care not to
mount the inner O.OJ. and outer
D.O.J. oppositely.
Dial gauge
A 16·1)66
Fig. 9-119
Fig. 9-122 Measuring pia V at ax Ie
(in axial direction)
18)
Install wheels, outer arms, etc.
Lower vehicle on the ground,
and install lower end of shock absorber.
19)
Fig. 9-120
Torque
gK
IlgN·m
(9
65
12 kg-Ill.
i)7 rt-Ib)
20) Check and adjust rear vehicle
hight and rear wheel alignment.
21) Tighten outer bushing lock bolts.
4. Checking Rear
Axle
Each part of axle must be checked
carefully before and during overhaul
to locate any possible cause of trouble.
I) Jack up body and turn wheel
by hand to check it s rotation. (At the
same time make sure drum does not
touch shue.) [I' there is abnorlllal noise
or if the rotation is not smooth, disasselll ble and examine axle carefully.
A damaged bearing, mud in the
hearing case, and so on are possible
c0.
~'l
Check removed wheels for followings.
I) Damage and/or warp of rim.
Since damaged or warped rim may
cause air leakage from tire, replace or
repair if defective.
2) Take stone, glass, nail etc. off the
tread groove.
3) Large crack on side wall, damage
or crack on tread and tread wear.
The tire should be replaced, when the
"tread wear indicator" appears as a
solid band across the tread.
Tread wear indicator
Pay attention to the following.
I) Be sure not to damage wheel rim
and tire.
2) If the bead section of tire is
damaged, replace it with a specified
new one.
3) If the flange portion of wheel rim
is deformed or damaged, replace it
with a specified new one.
4) Install a snap-in valve into the
valve hole of wheel rim properly not
to leak air.
Tire tread
S. Wheel Balancing
Fig.9-126 Tread wear indicator
?
II
. .
.:~
>~:
,~,
"
,~
- '-f!
OM-656
NOTE:
When replacing a tire, make sure to use
only the same size, type and load
range as originally installed. Avoid
mixing radial, belted bias or bias tires
on the vehicle.
3. Disassembly
OM-58l
Fig. 9-125 Jack-up points
4. Assembly
A16-045
'-
~
2) Damaged or warped rim may
cause air leakage from tire, so check
rims periodically.
Pay special attention to removing and
reinstalling tires.
3) As scratched bead of tire may also
cause the air leak from tire, tire should
be removed or installed carefully not
to mar the bead of tire.
2. Inspection
Loosening wheel nuts
2) Set jack at the correct jack-up
point, and turn the jack handle slowly
to jack car up, and then proceed to
remove wheel and tire by removing
wheel nuts completely.
--
NOTE:
a. When jacking the car up, make sure
the jack is set at the correct position on the flange of side sill.
b. When jacking the car up by using
a garage jack, refer to the section
"1-9. lifting Points and Procedure".
Tubeless tires are prepared for all
SUBARU vehicles, so pay attention to
the following.
1) Avoid using a hammer to prevent
damaging disc wheel and tire. If the
use of such a tool is unavoidable, use
a rubber hammer.
9-38
Unbalanced wheel (including disc
wheel and tire) can result from improper wheel alignment, lateral slippage, uneven wheel wear due to
insufficient air pressure, and wheel
repair work. After tire exchange or
wheel repair work has been performed,
be sure to check static and dynamic
balancing of wheels. Unbalanced wheel
does not greatly influence vehicle
operation at low and medium speeds.
At 60 km/h (37 MPH) and over,
however, the steering system can be
influenced, that is, as illustrated
below, force proportional to the
increase in the wheel revolu tion is
applied in the direction indicated by
the arrow.
This force causes "steering wheel
shimmy" or what can otherwise be
termed steering wheel instability.
i
Ii
~,
~:
SUSPENSION, WHEELS AND AXLES
NOTE:
There are various ways to correct
wheel unbalance. To correct precisely
wheel unbalance, use wheel balancer.
Wheel should be statically and dynamically balanced.
w,w'
F,F'
Amount of unbalance
Centrifugal force resulting
from unbalance
When replacing or reinstalling wheel,
retighten wheel nuts to the specified
torque after first 1,000 km (600 miles)
running.
A16·043
Fig.9-128 Installing balance weight
7. Adjusting Air
Pressure
6. Installation
F'
A 16·042
Fig.9-127 Wheel unbalance
I) Fit wheel over drum bolts, and
thread on four wheel nuts with a
wheel nut wrench.
NOTE:
When operating a wheel balancer, be
careful of the handling.
I) Correctly install hub nut. The
balancer shaft must be aligned with
the center of wheel to be corrected.
2) Firmly seat wheel on arbor.
3) Handle the disc wheel fitting section of balance weight carefully
because it is easily damaged.
4) After installing balance weight,
position it in the groove of disc
wheel.
5) Use genuine balance weights.
a. Do not use air impact tool to
tighten the wheel nuts.
b. Tighten the wheel nuts in the order
. as shown.
As shown in table on page 9-4, air
pressure must be adjusted to the prescribed value when tires are cool, or
before starting vehicle, as air pressure
increases as tire temperature rises
during vehicle operation. This rise
amounts to an increase of up to 20%
at times, and at such a high pressure
the ride is uncomfortable, abnormal
wear is promoted, various forms of
damage may result, steering instability
is likely, along with insufficient
braking, etc.
On the other hand, exceSSively low
air pressure in tires may result in
abnormal wear, various forms of
damage, loss of drive power, increased
fuel consumption, etc.
.
Tire air pressure must be adjusted in
accordance with these conditions.
~---~------
Parts No.
fur steel rim
OM-534
Weight
8. Tire Rotation
Fig. 9-129
--'~'-------'--
723141010
723141020
723141030
723141040
723141050
723141070
723141080
723141090
723141100
723141 I 10
10 g
20 g
30g
40 g
50 g
5g
15 g
25 g
35 g
45 g
(0.35 oz)
(0.71 oz)
(1.060z)
(1.41 oz)
(J .76 oz)
(0.180z)
(0.53 oz)
(0.88 oz)
(1.23 oz)
(1.59 oz)
c. When tightening wheel nuts, do not
apply oil to wheel nuts th read section of bolts nor tapered seats of
wheels.
2) Lower vehicle slowly by turning
the jack handle.
3) Sufficiently tighten wheel nuts in
the above-mentioned sequence.
Allowable dynamic unbalance
Torque
12 g (0.42 oz) at rim flange
If tires are maintained at the same
positions for a long period of time,
uneven wear results. Therefore, they
should be periodically rotated.
This lengthens service life of tires.
78-98N·m
(8.0 - 10.0 kg-m,
58 - 72 ft-Ib)
A16-210
Fig. 9-130 Order of tire rotation
9-39
SUSPENSION, WHEELS AND AXLES
a. When rotating tires, replace uneven
worn and damaged tires by new
ones.
b. In case "l·type" tire for temporary
use is prepared as a spare tire, tire
rotation is as follows.
"T-type" tire for temporary use is
prepared for 4WD vehicles as a spare
tire.
A1S-209
A1S-211
Fig. 9-131
I) Precaution when driving with
"T-type" tire fitted;
a. Do not drive it in a speed more
than 80 km/h (50 MPH) on highway.
b. Drive it as slowly as possible to prevent running over bump and/or
hump on off-road.
c Do not drive it with 4WD engaged.
d. Since this "T-type" tire is only for
temporary use. replace it with the
standard tire as soon as possible.
~) Notes for maintenance of "Ttype" ti re;
a. Ensure to keep the int1ation pressure always at 41 ~ kPa (4.~ kg/cm 2 •
60 psi).
b. When wear indicator appears on the
tread surface. replace tire with new
one without fail.
9. "T -type" Tire
NOTE:
Fig.9-132 T-type tire
9-40
F
T
,.
-, l t
fPliiPIl
SUSPENSION, WHEELS AND AXLES
• TROUBLESHOOTING
1. Suspension
1) Wrong Vehicle Posture
Possible causes
Countermeasures
(1) Permanent distorsion or breakage of torsion bar
Replace
(2) Unsmooth operation of shock absorber
Replace
(3) Wrong installation of inner arm
Re-install
(4)
Deformation
of
inner
arm
Replace
L - -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _- - - '_ _ _ _ _ _ _ _ ._ _ _ .. _ . _ _ _ _ _ _ _ _ _ .
2) Bad Comfortability
1)
2)
3)
Large rebound shock
Rocking of vehicle continues too long after running over bump and/or hump.
Large shock in bumping
- - , - - - - - - - - - - - _.._. - - - - - - -•.. -_.
Possible causes
Countemleasures"
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Breakage of torsion bar
Large deformation or loss of helper
Over inflation pressure oftire
Wrong vehicle posture
Fault in operation of shock absorber
Damage or deformation of shock absorber lower
end bushing
Unsuitability of maximum and/or minimum length
of shock absorber
Deformation or loss of bushing
Replace
Replace
Adjust
Adjust
Replace
Replace
Replace with proper parts
Replace
- - - - - - - - - - - _._------.-- . _ - - - - - - - - - '
3) Noise
-----------.-----------------------------~
Countermeasures
Possible causes
f - - - - - - - - - - -..
(I)
(2)
(3)
Wear or damage of shock absorber component parts
Damage or deformation of shock absorber lower
end bushing
Loosening of outer bushing lock bolt
Replace
Replace
Retighten to the specified torque.
When noise does not stop after .retightening lock bolt CD
to the specified torque, add lock bolt CV and tighten it
to the specified torque.
31 - 39 N·m
}-'
--/1{
Torque
~0fJ'
\ .,
, -CD Lock bolt
1LCV Lock bolt
Fig. 9-133
(4)
(5)
(6)
(7)
(8)
(9)
-- ----~
(3.2 - 4.0 kg-m,
23 -- 29 ft-lb)
(equipped)
A15-170
Replace
Retighten to the specified torque.
Replace with proper parts
Deformation or loss of bushings
Loosening of inner arm bracket
Unsuitability of maximum and/or minimum length
of shock absorber
Loss of helper
Breakage of torsion bar
Loosening of each bolts and/or nuts
Install new one
Replace
Retighten to the specified torque
9-41
SUSPENSION, WHEELS AND AXLES
eSPECIAL TOOLS
1. Suspension
921390000
925380000
925390000
925651000
Bush Installer
Installer
Wrench
Puller & Wrench
Inner bush of inner arm
Damper strut oil seal
Damper strut oil seal
Damper strut
0U 0
A 15·135
Fig. 9-134
Fig. 9-135
~
I
A 15-134
I
A15-133
Fig. 9-136
Hc:==:(dl
Fig. 9-137
ST·174
2. Wheels and Axles
*
925130000
921122000
921130000
925091000
Puller
Installer
Band Tightening Tool
Installer
Housing
Brake Drum Bearing
(Outer)
0.0.1. Boot
C.V.1. Boot
Housing
-;1
CD
-0
'::~.~~~"1
(~l;;;I
,
0
~'f)
Plate (2)
Fig. 9-138
ST-172
. Jig for band
®
~~
I
Fig. 9-139
2
Shank
Base
rA-
~
-
[
"
r-.-'-:-~
'"'-
. Ratchet wrench
A16-052
Fig. 9-140
A15-171
Fig. 9-141
'0
A16-047
925140000
925220000
925530000
925550000
Installer
Installer
Installer
Wrench
Housing Bearing
Brake Drum Bearing
(Inner)
Oil Seal (4WD)
Rear Axle Ring Nut
(4WD)
~
QJ?
~
Fig. 9-142
A16-046
Fig. 9-143
EJ
D\
t t
~~
A16-151
Fig. 9-144
-
--
A16-154
.
Fig. 9-145
A16-053
* Former Band Tightening Tool (925090000) is interchangeable with this 925091000.
9-42
l'
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,
hili'
11" f
l'
b
t'
'"
1
l'
1 f
, ...
1
"
CHAPTER
iJ@
BRAKES
Page
10- 1.
SPECIFICATIONS AND SERVICE DATA ................. 10- 2
10- 2.
FRONT BRAKE ................................... 10- 4
10- 3.
10- 4.
REAR BRAKE .................................... 10-12
MASTER CYLINDER ............................... 10-15
10- 5.
BRAKE BOOSTER (Master-Vac) ........................ 10-17
10- 6.
PARKING (Hand) BRAKE ............................ 10-20
~
REPLACEMENT OF BRAKE FLUiD .................... 10-22
10- 8.
BRAKE LINE ..................................... 10-24
10- 9.
TROUBLESHOOTING ............................... 10-27
10-10.
HILL-HOLDER
10-
1. Construction and Operation ......................... 10-29
2. Component Parts ................................ 10-31
3. Removal ...................................... 10-32
4. Inspection ..................................... 10-32
5. Installation .................................... 10-32
6. Adjustment•.................................... 10-33
7. Troubleshootmg ................................. 10-33
10-11.
SPECIAL TOOLS .................................. 10-35
II
BRAKES
10-1. Specifications and Service Data
~~
Hatchback, Sedan
and Hardtop
ITEM
Station Wagon and BRAT
Type
Disc (AD type)*
184 mm (7.24 in)
Effective disc diameter
53.97 mm (2.1248 in)
Effective cylinder diameter
Front
brake
Inner:
Outer:
Lining dimensions
(Width x length x thickness)
Inner:
Outer:
Lining surface area
Automatic adjustment
Type
Drum (Leading-Trailing)
180 mm e? .09 in)
Wheel cylinder effective
diameter
15.87 mm (5/8 in)
Lining dimensions
(Width x length x thickness)
42 x 2 x 2 cm 1 (6.5 x 2 x 2 sq in)
Manual adjustment
Clearance adjusting mechanism
Type
Tandem
20.64 mm (13/16 in)
Effective diameter
29.5 mm (1.161 in)
Maximum stroke
Built-in
Brake fluid level indicator
180 cm 3 (180 cc, 10.98 cu in)
-
Brake fluid reservoir capacity
Brake
booster
(MasterVac)
17.46 mm 01/16 in}
30 x 141 x 5 mm (1.18 x 5.55 x 0.20 in)
Lining surface area
Master
cylinder
40 x 2 cm 1 (6.2 x 2 sq in)
38 x 2 cm 1 (5.9 x 2 sq in)
Clearance adjusting mechanism
Effective drum diameter
Rear
brake
45 x 97 x 9 mm (1.77 x 3.82 x 0.35 in)
45 x 94 x 9 mm (1.77 x 3.70 x 0.35 in)
Vacuum suspended
Type
-- f-.
Effective diameter
152.4 mm (6 in)
177.8 mm (7 in)
f---.
Dual circuit system
Brake line
Mechanical on front brake
Parking brake type
* Station Wagon 4WD AT & BRAT 4WD AT:
Ventilated disc
10-2
--- - ----------
-~-------
BRAKES
\
"---Fin
A17-300
Fig. 10-1
Ventilated disc rotor
ITEM
Front brake
(Disc type)
STANDARD
15 mm (0.59 in)
12.5 mm (0.492 in)
18mm(0.71 in)
Pad thickness (including back metal)
Disc thickness
Solid disc
Ventilated disc
Disc run-out
SERVICE LIMIT
7.5 mm (0.295 in)
10 mm (0.39 in)
15.5 mm (0.610 in)
O. IO mm (0.0039 in)
~-------+---------------------------+-------------~----~-
Rear brake
(Drum type)
180 mm (7.09 in)
5 mm (0.20 in)
Inside diameter
Lining thickness
t--------------- --------------- -- - - - - - - - - - - - - - - - -
Brake booster
(Master-Vac)
Brake fluid pressure without engine running
1------- - - - - ---- - ---- --- - ------------- -
-----1
182 mm (7.17 in)
1.5 mm (0.059 in)
-------------------- ---------------------
At brake pedal force 147 N (15 kg, 33 Ib):
392 kPa (4 kg/em 2 , 57 psi)
At brake pedal force 294 N (30 kg, 66 Ib):
2,550 kPa (26 kg/cm 2 , 370 psi)
----------- ----------- --- ------------- - - - - - - ------------------------
Brake fluid pressure with engine running and
vacuum at 66.7 kPa (500 mmHg, 19.69 inHg)
At brake pedal force 147 N (15 kg, 33 lb):
3,432 kPa (35 kg/cm 2 , 498 psi)
At brake pedal force 294 N (30 kg, 66 Ib):
152.4 mm (6 in): 5,884 kPa
(60 kg/ cm 2 , 853 psi)
177.8 mm (7 in): 6,865 kPa
(70 kg/cm 2 , 995 psi)
1--------+------------------ -- --- ---------------- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
3 to 4 notches/245 N (25 kg, 55 lb)
Lever stroke
Parking brake
1 - - - - - - - + - - - - - - - - - - - - - - - - - - - - - - - - - - - -------- - - - - - - - - - - - - - - - - - - - - - j
0.6 mm (0.024 in)
Hill-holder
Thickness
Adjusting shim
0
(One shim increases an angle of approx. 0.5 .)
725807000
Part Number
' - - - - - - - - - - - - ' - - - - - - - - - - - - - - -- --------- ------- ------------ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - '
• Recommended Brake Fluid
FMVSS No. 116, DOTJ
NOTE:
a. Avoid mixing brake fluid of different brands to prevent the fluid performance from degrading.
b. When brake fluid is supplemented, be careful not to allow any dust into the reservoir.
c. Use fresh 00T3 brake fluid when replacing or refilling the fluid.
10-3
l
BRAKES
10-2. Front Brake
1. Component Parts
Tightening torque N·m (kg-m, ft-Ib)
T1 : 7 - 9 (0.7 - 0.9, 6.1 - 6.6)
T2: 37 - 49 (3.8 - 6.0, 27 - 36)
T3: 16 - 24 (1.6 - 2.4,12 -17)
T4: 49 - 69 (6.0 - 7.0,36 - 51)
12 Lever cap
Caliper body
I
13 Garter spring
2 Boot ring
3 Piston boot
4 Piston seal
5 Piston
6
7
8
9
10
Guide pin boot
Air bleeder screw
Air bleeder cap
Lever & spindle
Spring pin
11 Cap ring
Fig. 10-2 Component parts
14
15
16
17
18
19
20
21
22
Return spring
Connecting link
Bolt ASSY
Bracket
Spindle
O-ring
Cone spring
Snap ring
Support
10-4
,~
,,...
-,. ..,.1
j
j
••
~~+~
~
t
i'1:*1-,,"~ili".
i.
il
~,
.,
23
24
25
26
27
28
29
30
31
32
Outer pad
Inner pad
Lock pin boot
Sleeve
Lock pin
Shim
Outer pad clip
Inner pad clip
Lever cap (upper)
Inner pad clip
A17-301
f
""
~---~-~--~--
-~
-----,
BRAKES
• Grease Application
NIGLUBe FlX·2 grton
1725191040 or oo36OB000)
NIGLUBE FlX·2 groon
1725191040 or 0036060001
NIGLUBE RX·2 gr_
1725191040 or oo36OB0001
On the face of caliper body coming
into contact with cone springs
In lever cap fitting groove at the rear
of c.lip~r body
In the space between cone SPrings
NIGLUee RX·2 gr....
1725191040 or oo36OB0001
Inne' wall of bushings on caliper body
and .round lever" spindle
S ,I Icon Compound
1725191050 or oo36OB0101
NIGLUeE RX·2 gr....
1725191040 or 0036OB0001
Around ...ring stctton of caliper
body
Sufficiently .rOund lever
so I' to fill inside of lever
fitting it
a. Ipindl.
c~ .ft.,
NIGLUBe RX·:! gr....
1725191040 or 0036060001
NIGLUBE RX·2 gr ••M
1725191040 or 0038060001
I n groove of caliper body before
fitting piltOn boOt
On the hem of Ipindle luemblV
Silicon Compound
1725191050 or 0036OB010)
NIGLUBE RX·2 gr ....
1725191040 or 003606000)
Silicon Compound
1725191050 or 0036060101
Silicon Compound
1725191050 or 0036OB0101
Around pitton boot
In the groovI Ift.r instilling piston
into caliper body
Around piston seal
Around O-ring
Fig. 10-3
A 17-227
NIGLUBE RX·2 gr....
1725191040 or 003606000)
NIGLUBE RX·2 gr ....
1725191040 or 0036060001
In groove of lever & spindle
to be fitted to lever cap
Around lev., cap ring
A17·302
Fig. 10-4
Silicon
$illcor'l Compound
Compou~
1725191050 or 003Il060101
1725191050 Or 0036060101
In guid. pin fitti,. hoi. of cilliper
body
Around sleeve before
fitting boot
Silicon Compound
1725191050 or 0036OB010)
Around luid. pin b.for. inNrting
it into the hole
Fig. 10-5
NOTE:
8e sure to apply Silicon Compound (125191050 or 003606010) to guide pin and lock pin without fail.
Do not use the other grease.
10-5
BRAKES
2. Pads Replacement
6) Remove pads from support.
3) Installation
1) It is necessary to push back piston
into cylinder ,since piston protrudes
from cylinder in proportion to the
amount of pad wear, and the gap
where pads are to be inserted is
narrow.
Rotate piston clockwise with Wrench
(925590000) to force in piston to
caliper body, and set the piston notch
to the specified position.
1) Removal
1) Apply wheel chocks on rear
wheels and jack up the vehicle front,
then remove front wheels.
2) Return hand brake lever completely.
3) Remove inner cab Ie end from
lever, draw out outer cable clamp,
then disconnect hand brake cable from
caliper body ASSY.
A17-103
Fig. 10-9 Removing pad
NOTE:
a. Do not touch the brake pedal after
the pads have been removed.
b. Do not disconnect hose.
2) Inspection
1) Pad
Replace if it is wet with oil or worn.
A 17-304
Fig. 10-6 Removing hand brake cable
4)
Pad thickness including back metal
mm (in)
Fig. 10-10 Pushing back piston
15.0 (0.591)
Standard
Remove lock pin.
A17-291
7.5 (0.295)
Usable limit
,
d
';~
A17-305
Fig. 10-7 Removing lock pin
5) Spin caliper body ASSY on guide
pin.
NOTE:
a. Always replace the pads for both
the left and right wheels at the
same time. Also replace pad clips
if they are twisted or worn.
b. The clip incorporated with inner
pad is also used as a warning device
for worn pads. When wear occurs
on the pad to such an extent that
the clip comes into contact with
the rotor, unusual noise is produced
when brakes are not applied. If
such a noise is noticed, replace
the pad.
2) Disc rotor
Check for wear and damage, and
correct or replace if abnormal.
Disc rotor thickness mm (in)
I--
Solid
disc
Fig. 10-8 Spinning caliper body
ASSY
Ventilated
disc
Standard
12.5 (0.492)
Usable limit
10.0 (0.394)
Standard
18
Usable limit
15.5 (0.610)
10-6
(0.709)
A17-292
Fig. 10-11 Specified position of
piston notch
After pushing back piston, check
piston boot for twist. If twisted,
correct twist using a strip driver.
NOTE:
a. Do not disconnect hose.
b. Always return the piston to that
point which allows only a minimum
clearance for the pad to be inserted.
c. Be sure to use the special tool
when pushing in the piston to the
caliper body. If the piston is pushed
into the caliper body with a vice
and without rotating it, the spindle
(5·thread) may be buckled. To
prevent this, the piston should be
rotated clockwise when pushed into
the caliper body.
BRAKES
Remove rust and foreign materials
from the contact area of support with
the sliding part of pad. Apply PBe
grease (725191060 or 003603000) to
this area. Then, install a new genuine
SUBARU pad. Make sure that pad
clips are in normal operating condition
before installing new pad.
2)
NOTE:
a. Securely attach all pads to the frictional surfaces of their supports.
b. Do not install shim on inner pad.
Install clip with this longer
portion facing outward.
CD
I
2
3
4
5
6
CV@ CD
5) No further adjustment is needed,
since the clearance is automatically
adjusted every time the brake is
applied.
6) Put back tires and rotate them
several times. Then, wind a rope
around the circumference of tire, and
confirm that tire can be rotated with
a force of less than 39 N (4 kg, 9 Ib)
at,the outside diameter of tire.
a. If wheel bearing is worn or disc
rotor is not exactly perpendicular
to the counterpart, the surface of
disc rotor runs out in the axial
direction during rotation. This
causes disc rotor to be pressed
against lining, and rotational resistance increases.
When such trouble occurs, measure
the disc rotor run-out. If the runout exceeds the limit, change the
tightening position of rotor on hub
or the meshing position of hub to
axle shaft serration. If this does not
correct the run-out, replace rotor.
Outer pad clip
Outer pad
Shim
Inner pad dip
Inner pad clip
Inner pad
nect brake hose from caliper body
ASSY.
2) Remove hand brake cable and pad
in accordance with the removing procedure of pad. (Refer to page 10-6)
Pliers
2
Clamp
3 Union bolt
A17-234
Fig. 10-14 Disconnecting hand brake
cable and brake hose
3) Remove caliper ASSY by pulling
it out of support.
A 17-306
Disc rotor run-out
~.--~----------------~
Limit
I
0.10 mm (0.0039 in)
Fig. 10-12 Right installation of pad
NOTE:
3) Remove foreign materials from
lock pin.
Tighten lock pin to the specified
torque.
Measure the disc rotor run-out at a
point less than 5 mm (0.20 in) from
the outer periphery of the rotor.
A 17-295
NOTE:
Fit the boot securely to the sleeve
groove.
~
Fig. 10-15 Removing caliper ASSY
4)
--'T(~:
Torque
(Lock in)
p
16 - 24 N·m
The support should be removed only
when the disc rotor or the support is
replaced, and should not be removed
when performing the maintenance of
the caliper ASSY.
(1.6 - 2.4 kg-m,
12 - 17 ft-lb)
---------"
4) Upon completion of installing the
brake system, confirm that the pad
dowel (rise on pad back metal) fits
into the piston notch.
Depress brake pedal to an extent of
applying the normal braking force
several times. With the aforementioned
procedure, a proper amount of clearanee can be obtained, and the stroke
of hand brake lever can also be
adjusted to the normal value.
[The completion of the adjustment
can be confirmed as follows. Hand
brake lever moves 3 to 4 notches when
it is pulled with a force of 245 N
(25 kg, 55 lb).]
Remove support from housing.
NOTE:
A 17-109
Fig. 10-13 Measuring disc rotor
run-out
b. If the rotational resistance is over
the specified value due to the other
causes, recheck disc brake ASSY
and repair or replace it if necessary.
3. Disc Brake Assembly
1) Removal and Disassembly
1)
Remove union bolt and discon-
10-7
A17-307
Fig_ 10-16 Removing support
r
BRAKES
5) After removing caliper body
ASSY, remove sludge and dirt from
the outer part of caliper body ASSY.
NOTE:
Take special care to prevent dirt from
entering through the brake fluid inlet.
6) Remove sleeve, then remove lock
pin boot.
A 17·120
o~
~
..".".;"::: ..i
[3,,\ .'... .
Sleeve
A17·117
Fig. 10-22 Removing cap ring and
lever cap
Fig. 10-19 Removing piston
9) Removing guide pin boot.
Evenly tap the dowels (two places) of
boot.
Lock pin boot
NOTE:
The lever cap may only be pulled out
of the groove in the caliper body.
A17·30B
Fig. 10-17 Removing sleeve and lock
pin boot
7) Remove boot ring by using a strip
driver with taking special care so as
not to scratch piston boot. Then,
remove piston boot.
A17·11B
A17·121
Fig. 10-20 Removing guide pin boot
Fig. 10-23 Removing snap ring
NOTE:
Replace the removed boot with a new
one.
10) Remove piston seal by using a
strip driver with taking special care so
as not to scratch the inner wall of
cylinder.
A17·116
12) Press spring washer (coned disc
spring) with Puller (925471000) to
eliminate a load applied to lever &
spindle through spring washer, pull out
lever & spindle.
Detach Puller, and then remove connecting link and return spring.
Fig. 10-18 Removing boot ring and
boot
NOTE:
If the strip driver is not available, use
a screwdriver after the tip of the
screwdriver is rounded off, and burrs
are thoroughly eliminated.
8) Draw out piston from cylinder by
applying a compressed air or pressurized liquid gradually from the brake
fluid inlet of caliper ASSY.
NOTE:
Do not apply an excessively high
pressure, since such carelessness may
cause the piston to spring out of the
cylinder.
A17-296
Fig. 10-21 Removing piston seal
11) Remove cap ring and lever cap,
then remove snap ring from lever &
spindle.
10-8
A 17·309
Fig. 10-24 Removing lever & spindle
BRAKES
NOTE:
2) Inspection
Inspect the disassembled parts, correct
or replace if defective.
1) Caliper body
Uneven wear, damage or rust.
2) Piston
Uneven wear, damage or rust.
3) Rubber parts
Deformation, wear, damage, deterioration or coat of mineral oil.
4) Pad clip
Deformation, wear, damage or rust.
5) Spindle and cone spring
Damage or rust.
6) Lever and spindle
Damage or rust.
7) Support
Wear, damage or rust.
8) Other parts
Deformation, wear, damage or rust.
Be sure to apply the specified
grease or compound to the proper
sections without fail.
Fig. 10-26 Inserting piston
3) Upon completion of inserting
piston into cylinder, apply NIGLUBE
RX-2
grease
(725191040
or
003606000) into the grooves provided
in cylinder and along the circumference of piston head. Then fit boot into
the grooves. After confirming that
boot is not twisted, attach boot ring.
NOTE:
NOTE:
If the rubber parts are scratched or
coated with mineral oil, replace it with
a new one.
When attaching the boot ring, refer to
the figure.
CD
@
1 Caliper body
2 Cone spring
3 Spindle
NOTE:
a. When the cone spring is replaced
due to scratch, be sure to replace
the D-ring with a new one_ Also,
attach a new cone spring before
fitting the D-ring.
Six cone springs are incorporated.
The assembling combination is as
follows.
1) Clean the inner part of caliper
body (cylinder) with brake fluid.
Apply a thin coat of Silicon Compound (725191050 or 003606010) to
piston seal, and fit the seal to the
groove provided in the cylinder with
hand.
IWti
A17-l26
NOTE:
Pay special attention to prevent the
seal from twisting.
A17-29B
Fig_ 10-25 Inserting piston seal
Insert piston into cylinder.
NOTE:
Be sure to insert the piston into the
cylinder with hand.
Do not use a vice when inserting the
piston.
A17-223
Fig. 10-28 Spindle ASSY and grease
application
3) Assembly and Installation
2)
Niglube RX-2
Fig. 10-27 Fitting piston boot and
boot ring
4) Apply NIGLUBE RX-2 grease
(725191040 or 003606000) to the
cone springs fitting section of spindle,
into the space between cone springs
after fitting them, and onto the face of
caliper body coming into contact with
cone springs.
Apply a thin coat of Silicon Compound (725191050 or 003606010) to
the sealing section of caliper body
coming into contact with O-ring of
spindle ASSY.
Then, insert spindle ASSY into cylinder by turning clockwise from the
opening at the bottom of caliper body.
--_._-
WJ
A17-029
Fig. 10-29
b. After attaching cone springs, apply
thin coat of Silicon Compound
(125191050 or 003606010) to the
D-ring, and insert it with Adapter
(925600000) with taking care to
prevent the D-ring from being
damaged.
Adapter
(925600000)
NOTE:
Be sure to apply the specified grease
or compound to the proper sections
without fail.
10-9
Fig. 10-30 Fitting O-ring
A17-3l0
BRAKES
5) Apply NIGLUBE RX-2 grease
(725191040 or (03606000) to the
head of spindle ASSY and onto the
inner wall of bushings on caliper body
in which lever & spindle is to be fitted.
After setting connecting link and
return spring, press a set of cone
springs by Puller (92547 \000).
Apply
NIGLUBE
RX-2
grease
(725191040 or 003606000) to grooves
of lever & spindle in which lever cap
and connecting link are to be fitted.
Then, fit connecting link into the
groove at the head of spindle. Insert
lever & spindle provided with lever cap
and garter spring. Be sure to force in
the hooked portion of return spring to
the groove of lever & spindle as shown.
Then, remove Puller (925471000).
A 17-121
Fig. 10-33 Inserting lever & spindle
Fig. 10-36 Fitting snap ring
A17-198
NIGLUBE RX-2
~,
4 Return spring
5 Hooked portion of
return spring
1 Spindle
2 Connecting link
3 Lever & spindle
A17-133
Fig. 10-37 Installing cap ring
Fig. 10-34
NOTE:
When inserting the lever & spindle,
make sure that the bushing of caliper
body is clean and free from any
foreign matter.
A17-224
Lever & spindle
Niglube RX-2
A
..
~
I
A17-225
Fig. 10-31 Grease application
6) Fit snap ring into the groove of
lever & spindle.
Apply
NIGLUBE
RX-2
grease
(725191040 or 003606000) to the
groove of caliper body in which lever
cap is to be fitted and to snap ring.
Apply sufficient amount of NIGLUBE
RX-2
grease
(725191040
or
003606000) to the space around connecting link and lever & spindle so as
to fill inside of lever cap after fitting
it.
Fit lever cap properly into the groove
at the rear of caliper body.
Attach cap ring onto lever cap.
7) Remove any foreign matter from
the fitting hole of guide pin in caliper
body. Evenly tap the metal periphery
of guide pin boot to insert. (Be careful
not to scratch boot itself.)
After inserting, make sure that boot is
not damaged.
NOTE:
When once the guide pin boot is
removed, always replace it with a new
one.
NOTE:
Be careful not to damage the lever cap
by the edge of the cap ring.
Niglube
RX-2
A17-129
A17-312
Caliper
Fig. 10-32 Lever & spindle, lever cap
and garter spring in ASSY
body
A 17-237
Fig. 10-38 Installing guide pin boot
Fig. 10-35 Grease application
10-10
,
1
If --
*
..
Fe
F
BRAKES
8) Install lock pin boot to caliper
body. Apply Silicon Compound
(725IQI050 or 00360(010) to the
inside of lock pin boot and around
sleeve. Then insert sleeve into lock pin
boot.
11) Install outer pad clip and inner
pad clip properly.
t
~
\
Install clip with this longer
portion facing outward.
/
~L?
''1\
'//
NOTE:
Replace brake hose gaskets with new
ones.
~
~\
A17-313
I Outer pad dip
2 I nner pad clip
3 Inner pad clip
A17-314
--.
12) Install outer pad and inner pad
properly.
1:1) Make sure that caliper body and
support are properly coated with
grease. Insert the support guide pin
into the fitting hole in caliper body.
Tighten lock pin to the specified
torque.
A3-266
Fig. 10-40 Grease application to lock
pin portion
9) Rotate piston until the notch at
the head of piston comes in alignment
with the center of disc, and make sure
that all parts are properly attached.
10) Install support to housing.
I Torque
~upport bolt)
49 - 69 N'm
(5.0 - 7.0 kg-m,
36 - 51 ft-Ib)
A17-307
Fig. 10-41 Installing support
A3-265
Fig. 10-43 Grease application to
guide pin portion
I--~1-'
Torque
~:irrq~l~e:~r-l
screw)
Fig. 10-42 Installing pad clips
Fig. 10-39 Installing lock pin boot
and sleeve
·l
IS) Bleed air from the brake system.
LSleeve
\ - Lock pi n boot
14) Make sure that all parts are
properly attached, then connect brake
hose and hand brake cable.
ft~;"
16- 24 N·m
(J 6 - 24 k -
(Lock P;0)_,12 .. 17
NOTE:
a. Use only Silicon Compound
(725191050 or 003606010) grease
for the guide pin and lock pin
portions.
b. After assembly, make sure that
boots are properly fitted in the
grooves on the guide pin and sleeve.
c. If the boot contains too much air
and is expanded, press it to purge
out some air.
10-11
:t'= ~.~~~~j
5. J -, 6.5 ft-lb)
.
----
------.---.----~-
r
,
BRAKES
10-3. Rear Brake
1. Component Parts
CD
CD
1 Shoe hold down pin
2 Back plate ASSY
3 Upper shoe return spring
4 Brake shoe
5 Lower shoe return spring
6 Shoe hold down spring
7 Wheel cylinder body
8 Cup
9 Piston
10 Boot
11 Wheel cylinder air bleeder
screw
12 Air bleeder cap
13 Spring washer
14 Nut
15 Adjuster
TIght,nlng torque N·m (kll"m, ft·lbl
T1: 7 - 9 (0.7 - 0.9, 6.1 - 6.61
T2: 8 -10 (0.8 -1.0, 6.8 -7.2)
A17·311S
Fig. 10-44 Component p,rts
10-12
11
l
I
1
BRAKES
2. Removal
1) Loosen wheel nuts, jack up
vehicle, support it with rigid racks, and
remove wheels.
2) Unscrew brake pipe flare nut and
disconnect brake pipe.
Standard inside
diameter
180 mm (7.09 in)
Service limit
182 mm (7.17 in)
2) Measure the lining thickness. If it
exceeds the limit, replace shoe ASSY.
Lining thickness
Standard
5
mm (0.20 in)
Service limit
1.5 mm (0.059 in)
NOTE:
1 Flare nut wrench
2 Brake pipe
A17-240
Fig. 10-45 Removing flare nut
3) Remove brake drum, referring to
"WHEELS AND AXLES" in chapter
9.
4) Unscrew back plate installing bolts
and remove brake ASSY. Take care so
that spindle shaft and bearing are free
from dust.
Replace the leading and trailing shoes
on the right and left brake ASSV at
the same time.
3) If the deformation or wear of
back plate, shoe, etc. are notable,
replace them.
4) When the shoe return spring tension is excessively weakened, replace
it, taking care to identify upper and
lower springs.
5) If grease has leaked from brake
drum, replace oil seal or drum.
6) If drum bearing is abnormal or
loose, replace it.
1 Back plate
2 Back plate installing bolt
3 Adjuster
Fig. 10-46 Removing back plate
5) Remove shoe hold down spring
with pliers.
6) Pull out shoe on anchor side.
7) Pull out shoe on cylinder side.
3. Inspection
1) If the inside surface of brake
drum is streaked, correct the surface
with emery cloth (#60). If it is un·
evenly worn, taperingly streaked, or
the outside surface of brake drum is
damaged, correct or replace it.
Fig. 10-47 Assembling shoes
2) Apply brake grease (003602000)
to the surface of back plate where
shoe touches, the contacting surfaces
of anchor and shoe web, and the
contacting surfaces of wheel cylinder
piston and shoe web.
3) Fit shoe ASSY first to wheel
cylinder, then to anchor, and secure
both shoes with shoe hold down
springs.
4) Adjust the shoe diameter to about
179.8mm (7.08in) by turning the
wedge. Measure the shoe diameter at
three positions, upper, middle, and
lower position.
5) Tighten temporarily brake pipe
flare nut.
6) Fit spacer (seal) onto spindle and
install back plate. In this case, center
by using the outer circumference of
spacer as a faucet joint. Insert three
bolts from the back plate side.
Torque
(Back plate)
A17-042
A17-043
I Upper return spring
2 Lower return sprin~
46 - 58 N'm
(4.7 - 5.9 kg-m,
34 - 43 ft-Ib)
4. Installation
1) Assemble shoe ASSY with springs.
Pay attention to the shape and instal·
ling position of springs.
Upper
Lower
Wire
diameter
Thin
Thick
Installing
pOSition
On wheel
cylinder
and back
plate side.
On anchor
and back
plate side.
10-13
1 Back plate
2 Spacer
A17-044
Fig. 10-48 InstIlling back pllte
NOTE:
00 not allow forailn mattan to enter
the brake ASSV.
BRAKES
c. Special tools (Adapters) are avail·
able in different sizes. Use only the
tool of the correct size.
7) Tighten brake pipe flare nut to
the specified torque.
Torque
L -_ _ _ _ _ _ _
~C
----------Adapter
13-18N·m
( 1.3 - 1.8 kg-m,
9 - 13 ft-lb)
______
---------- - - - - - - - - - - - - - - - 1
Part No.
8) Install brake drum in parallel with
brake ASSY.
9) Bleed air from the brake system.
Torque
(Air bleeder
screw)
7 - 9 N'm
(0.7 - 0.9 kg-m,
5.1 - 6.5 ft-Ib)
1) Disassembly
The adjusting mechanism for the brake
lining clearance is of a manual type.
Follow the undermentioned procedure.
1) Jack up vehicle body to release
wheel from the ground.
2) Tighten the wedge fully until
wheel ceases to rotate. Screwing up
the wedge forces anchor to expand on
either side by the wedge action and
consequently shoes stick to drum.
0
3) Turn back the wedge for 180 ,
and the shoe clearance will be 0.1 to
0.15 mm (0.004 to 0.0059 in).
4) Be sure that tire and wheel can be
rotated easily by hand.
I) Remove boot from cylinder.
2) Take out piston, which is piston
ASSY with cup.
NOTE:
a. Wheel cylinder can be disassembled
and inspected with it mounted on
the back plate. Therefore it should
not be removed except replacing
the wheel cylinder ASSV etc.
b. When removing the cup from piston, be careful not to damage
piston. And be sure to use the new
cup.
2) Inspection
Inspect each parts after washing them
with brake fluid, and replace if the
following defects are found.
NOTE:
Do not use any cleaning solvent other
than brake fluid.
1) Cup: Damage, fatigue or wear.
2) Cylinder and piston frictional
surfaces: damage, uneven wear, corrosion or rust.
CD
3) Assembly
Assembly is the reverse order of disassembly.
NOTE:
A17-316
1
2
3
4
5
Wedge
Anchor
Brake shoe
Adjuster
Back plate
Fig_ 1049 Adjusting mechanism
925450000
15.87 mm (5/8 in)
925460000
17.46 mm (11/16 in)
Fig. 10-50 Adjusting shoe clearance
6. Wheel Cylinder
5. Adjustment of Rear
Brake Lining
Clearance
Applicable size
- - - - - . -- -----------------------1
a. When installing the cup, use the
special tool Adapter, apply brake
fluid to the frictional surface for
smooth installation and pay at·
tention to cup direction.
b. When replacing the repair kit, make
sure that the sizes of cylinder and
cup are the same as those which
were replaced.
10-14
d. While assembling, be careful to
prevent any metal chip, dust or
dirt from entering the wheel
cylinder.
BRAKES
10-4. Master Cylinder
1. Component Parts
1 Cylinder body
2 Primary piston ASSY
3 Secondary piston ASSY
4 Piston stopper washer
5 Stopper ring
6 Stopper screw
7 Gasket
8 Bolt
9 Brake fluid reservoir
10 Brake fluid level indicator
assembly
11 Check valve spring
12 Check valve
13 Tube seat
14 Check valve cap
15 Filter
16 Reservoir seal
A17-241
Fig. 10-51 Cross section of tandem master cylinder
2. Removal
NOTE:
Put cloth etc. to prevent the brake
fluid from spilling onto the painted
surface and then perform the work.
I) Disconnect connector for brake
fluid level indicator.
2) Remove nuts connecting brake
pipes to master cylinder.
A17-243
Fig. 10-54 Removing stopper screw
Fig. 10-53 Removing nuts
4)
Pull master cylinder out forward.
3. Disassembly
I) Remove level indicator assemblies
and filters, then drain out brake fluid.
2) Remove stopper screw while pushing piston fully into cylinder.
A17-242
Fig. 10-52 Removing nuts
3) Remove nuts connecting master
cylinder to brake booster.
NOTE:
Remove stopper screw at the position
where secondary piston does not
contact stopper screw by pushing
primary piston using screwdriver.
10-15
3) Remove stopper ring while pressing piston into cylinder with a screwdriver etc.
BRAKES
4) Remove stopper washer, primary
and secondary piston ASSY, and
return spring.
6. Installation
1) Install master cylinder to brake
booster.
NOTE:
a. Do not disassemble primary and
secondary piston ASSY.
b. When replacing piston cup etc.,
replace as a piston ASSY.
Torque
(Master
cylinder nut)
5) Check valve can be disassembled
easily by removing check valve cap.
"\
@
(J)
CD
A 17-246
1
2
3
4
5
6
7
8
9
10
NOTE:
Master cylinder
Check valve spring
Check valve
Tube seat
Check valve cap
Stopper screw
Secondary piston ASSY
Primary piston ASSY
Stopper washer
Stopper ring
Primary
system
Front right - Rear left
Secondary
system
Front left - Rear right
3) Connect connector.
Bleed air from brake system.
s.
Assembly
Assembly is the reverse order of dis·
assembly.
Torque
(Check valve
cap)
Torque
(Stopper
screw)
Inspect all parts after wa~hing them
with brake fluid, and replace if the
following defects are found.
NOTE:
1) Cylinder and piston frictional sur·
faces: damage, uneven wear, corrosion
or rust.
2) Primary and secondary cups,
check valve: damage, wear or fatigue.
3) Return spring and check valve
spring: Fatigue or defonnation.
13 - 18 N'm
(1.3 - 1.8 kg·m,
9 - 13 ft·lb)
4)
4. Inspection
Do not ule any cleaning lolvent other
than braka fluid.
Torque
(Brake pipe
flare nut)
Make sure that the piping is correct
Fig. 10-56 Disassembling master
cylinder
NOTE:
7-12ft·lb)
2) Connect brake pipes with master
cylinder.
<~1\
a. Never remove and/or disassemble
reservoir unless reservoir seal is
damaged. Replace it with new one
if necessary.
b. Level indicator is removed by turn·
ing it counterclockwise; installation
is clockwise.
10 - 16 N·m
(1.0 - 1.6 kg·m,
25 - 34 N·m
(2.5 - 3.5 kg·m,
18 - 25 ft.lb)
1.5 - 2.9 N'm
(0.15 - 0.3 kg·m,
1.1 - 2.2 ft·lb)
NOTE:
Replace galket with. new one.
b. ae caraful not to damage cylinder
and piston cup etc.
c. Install stopper screw while pulhing
primary pilton 10 that IIcondary
pilton il fully pushed.
d. Applying the brake fluid to frictional portion facilitates the work.
L
10-16
Torque
(Air bleeder
screw)
7 - 9N·m
(0.7 - 0.9 kg·m,
5.1 - 6.5 ft·lb)
BRAKES
10-5. Brake Booster (Master-Vac)
1. Construction
Tightening torque N-m (kg-m. ft-Ib)
T1: 13 - 18 (1.3 - 1.8.9 - 13)
T2: 10 -16 (1.0 -1.6. 7 -12)
1 Vacuum hose joint bolt
2 Clip
3 Vacuum hose
4 Clamp
5 Check valve
6 Master cylinder ASSY
7 Brake booster (Master-Vac)
8 Seal
9 Spacer
10 Clevis pin
11 Snap pin
A17-317
Fig_ 10-57 Brake booster (Master- Vac)
Operatlnl rod ASSY
Fig. to-58 Croll IIICtion of br.k, booster
Power pilton
Diaphr.,m
Key
Retliner
Filter
Silencer
10-17
8
9
10
11
12
13
14
Puah rod
ReacUon diIc
aeulna
Valve body ,uard
Retainer
C1evia
Front lbeU
Nut
Plate" leal ASSY 20 Return .prlq
Retliner
Rear Iben
Valve body leal
15
16
17
18
19
.'7-2'"
BRAKES
the nature of the failure if checking
is conducted in accordance with the
following procedure.
2. Removal
I) Remove the following parts at
engine compartment.
a. Disconnect connector for brake
fluid level indicator.
b. Remove nuts connecting brake
pipes to master cylinder.
c. Remove master cylinder installing
nuts.
d. Disconnect vacuum hose from
brake booster.
2) Remove the following parts from
the pedal bracket.
a. Snap pin and clevis pin.
b. Four brake booster installing nuts.
3) Remove brake booster while shunning brake pipes.
3. Installation
Mount brake booster in position.
I)
----------,
I--~--
. Torque
(Brake booster
to toe board)
13 -- 23 N'm
( 1.3- 2.3 kg-m,
9 - 17 ft-Ib)
I
JI
a.
Start engine, and run it for I to 2
minutes, then turn it off. Depress
brake pedal several times applying the
same pedal force as that used in
ordinary braking operations. The pedal
stroke should be greatest on the 1st
depreSSion, and it should become
smaller with each successive depression. If no change occurs in the pedal
height while in a depressed state, brake
booster is faulty.
Master cylinder
2 Vacuum hose
A17~250
Fig. 10-60
Connect electric connector for
brake fluid level indicator.
7) Tightening lock nut on operating
rod ASSY.
If brake pedal is not contacted stopper,
adjust clevis to contact stopper, then
tighten lock nut.
6)
NOTE:
In the event of defective operation,
inspect the condition of the check
valve and vacuum hose. Replace them
if faulty and conduct the test again.
If no improvement is observed, check
precisely with gauges.
NOTE:
The brake pedal should contact
stopper without being depressed.
b.
--.---
.
pedal several times applying the
same pedal force and make sure
that the pedal height does not
vary with each depression of the
pedal.
(2) With brake pedal depressed, start
engine.
(3) As engine starts, brake pedal
should move slightly toward the
floor. If no change occurs in the
pedal height, brake booster is
faulty.
Connect operating rod to brake
pedal with clevis pin and snap pin.
~I
I
~.' ~j
I,'
'---"'-~
.
»~/;'
./.
Nut
\,
~
A16-251
Fig. 10-61
:-j
Fig. 10-59
A17~318
---
8)
Connect vacuum hose to brake
booster.
4) Mount master cylinder onto brake
booster.
3)
l_(NU~ . __ L2 :;!~.1~
-------~-- ---~-~-~--~-~]
10- 16N-m
Torque
Connect brake pipes to master
cylinder.
I
Tightening lock nut on
operating rod ASSY
NOTE:
If faulty, check precisely with gauges.
Bleed air from brake system.
--~ -~.- -~- -I·-~ -.~~- -.-~
7- l)
Torque
(Air bleeder
screw)
I---_.--
c.
N·m
(0.7- 0.9 kg-m,
5.1 - 6.5 ft-Ib)
.----.~.----.
13 - 18 N'm
(1.3 - 1.8 kg-m,
9-13ft-Ib)
Loaded air tightness check
Depress brake pedal while engine is
running, and turn off engine while the
pedal is still depressed. Keep the pedal
depressed for 30 seconds; if no change
occurs in the pedal height, brake
booster is functioning normally; if the
pedal height increases, it is faulty.
-------------
4. Operation Check
NOTE:
When checking operation, be sure to
securely apply the hand brake.
NOTE:
If faulty, check precisely with gauges.
5)
Torque
(Brake pipe
[ flare nut)
Operation check
(I) With engine off, depress brake
2)
~
Air tightness check
1) Checking without Using
Gauges
2) Checking with Gauges
This method cannot determine the
exact portion which has failed, but it
can provide a rough understanding of
Connect gauges as shown in figure.
After bleeding air from pressure
gauges, proceed to each check.
10-·18
-1 1 -
,I
I
It
t'
.. tnT H Ii
,
f
'4 f
"f
BRAKES
Pressure gauge
Pressure gauge
Pedal force
N(kg,lb)
Fluid pressure
kPa (kgl cm 2 , psi)
147 (15, 33)
3,432 (35, 498)
294(30,66)
For 152.4 mm
(6 in) booster:
5,884 (60, 853)
For 177.8 mm
(7 in) booster:
6,865 (70,995)
Pedal force gauge
Adaper hose
~ Adapter
hose
A17·252
Fig. 10-62 Connection of gauges
a.
gauge.
I I' th e vacu urn drop range is less
than 3.3 kPa (25 mmHg, 0.98
inHg) within 15 seconds after
stopping engine, brake booster is
functioning properly.
If defective, refer to a. described
above.
Air tightness check
(l) Start engine and keep it running
until a vacuum of 66.7 kPa (500
mmHg. 19.69 inllg) is indicated
on vacuum gauge. Do not depress
b rake pedal.
(2) Stop engine and watch the gauge.
I f the vacuum drop range is less
than 3.3 kPa (25 mmHg, 0.9i1
inHg) within 15 seconds after
stopping engine, brake booster is
functioning properly.
If defective. the cause may be one of
those listed below.
• Check valve malfunction
• Leak from vacuum hose
• Leak from the shell jointed portion
or stud bolt welded portion
• Damaged diaphragm
• Leak from valve body seal and
bearing portion
• Leak from plate & seal ASSY
portion
• Leak from poppet valve ASSY
portion
b.
I) After protector has been removed
from push·rod, do not turn the master
cylinder side of brake booster downwards.
a. If the master cylinder side is turned
downwards, push-rod may come
loose by virtue of its own weight,
and reaction disc may drop into
brake booster.
b. Whether or not reaction disc has
dropped can be determined by
measuring the dimension "Q".
The projected amount "Q" of pushrod should be as follows:
Standard (Correct):
Incorrect:
c.
Q:
Q:
10 mm (0.39 in)
5.5 mm (0.217 in)
Lack of boosting action check
Turn off engine, and set the vacuum
gauge reading at "0". Then, check the
fluid pressure when brake pedal is
depressed. The pressure must be
greater than the standard value listed
below.
~~~I-force
!
I
N (kg, Ib)
TFIUid pressure
kPa (kg/cm 2 , psi)
47(115'33)
~
392 ( 4, 57)
- - - - -- ----+----------1
2,550 (26, 370)
294 (30, 66)
------ ---------
Loaded air tightness check
(I) Start engine and depress brake
pedal with pedal force of 196 N
(20 kg, 44 Ib). Keep engine run·
ning until a vacuum of 66.7 kPa
(500 mmHg, 19.69 inHg) is indicated on vacuum gauge while the
pedal is still depressed.
(2) Stop engine and watch vacuum
5. Handling Precautions
d.
Boosting action check
Set the vacuum gauge reading at
66.7 kPa (500 mmHg, 19.69 inHg) by
running engine. Then, check the fluid
pressure when brake pedal is depressed. The pressure must be greater than
the standard value listed below.
10-19
A 17·253
Fig. 10-63 Push rod projection
c. I f protector is fitted correctly,
reaction disc will not fall out.
2) Be careful not to drop brake
booster. Brake booster should be discarded if it has been dropped.
3) Use special care when handling
operating rod.
If excessive force is applied to operating rod, sufficient to cause a change in
the angle in excess of ±3°, it may
result in damage to the power piston
cylinder.
4) Use care when placing brake
booster on the floor.
BRAKES
Force
If external force is applied from above when
brake booster is placed
in this position, the
resin portion as indicated by "P", may be
damaged.
P
{J.
A17-254
Fig. 10-64 Handling precaution
10-6. Parking (Hand) Brake
1. Component Parts
r®
~@
&--@
Detail "C"
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Hand brake lever ASSY
Hand brake lever button
Hand brake lever grip
Hand brake lever spring
Hand brake switch
Flange tapping screw
Bolt & washer
Hand brake rod CP
Clevis pin
Cotter pin
Equalizer
Hand brake pin
Washer
Hand brake spring
Hand brake adjuster
Nut
Clamp
Hand brake clamp
Hand brake clamp
Bolt & washer
Flange nut
Hand brake cover
Flange bolt
Hand brake cable ASSY
Tightening torque N·m (kg-m, ft-Ib)
T1: 10-14(1.0-1.4,7-10)
T2: 4 - 6 (0.4 - 0.6, 2.9 - 4.3)
T3: 6.4 - 9.3 (0.65 - 0.95, 4.7 - 6.9)
Al7·319
Fig. 10-65 Component parts of Hand brake
10-20
'--
BRAKES
2. Parking (Hand) Brake
Lever
6) Pull out parking brake cable clamp
from caliper, and disconnect cable end.
9) Detach parking brake cable from
cable guide at rear crossmember.
• Replacement
1) Remove parking brake cover.
2) Disconnect electric connector for
parking brake switch.
3) Loosen parking brake adjuster,
and remove inner cable end from
equalizer.
4) Remove parking brake lever.
A17·304
Fig. 10-68 Removing hand brake
cable end
A17·146
Fig. 10-66 Removing hand brake lever
Install parking brake lever in the
reverse order of removal.
5)
Torque
(Lever
installing bolt)
Remove bolt and bracket from
transverse link.
7)
10 - 14 N·m
Fig. 10-71
10) Remove cable ASSY from cabin
by forcibly pulling it forward.
11) Install (new) parking brake ASSY
in the reverse order of removal.
NOTE:
Be sure to pass cable through cable
guide inside the tunnel.
Torque (Rear crossmember cable clamp)
(1.0 - 1.4 kg-m,
7 - 10 ft-lb)
Torque (Bracket
to transverse link)
6) Adjust parking brake. (See "Adjustment of parking brake".)
A17·148
6.4 - 9.3 N·m
(0.65 - 0.95 kg-m,
4.7 - 6.9 ft·lb)
4. Adjustment of
3. Parking (Hand) Brake
Cable
Parking (Hand) Brake
Fig. 10-69
A17-186
• Replacement
Loosen front wheel nuts.
2) Jack up vehicle, and support it
with safety stands (rigid racks).
3) Remove front tires and wheels.
4) Remove parking brake cover.
5) Loosen parking brake adjuster,
then remove inner cable end from
equalizer, and detach clamps.
1)
8) Remove bolt and clamp from rear
crossmember bracket.
NOTE:
a. Bleed air completely from the
brake system before attempting the
following operations.
b. Confirm that parking brake lever of
caliper returns fully after slackening
parking brake cable.
Clamps
A4·129
Fig. 10-67 Removing clamp
After adjusting the rear brake shoe
clearances, depress brake pedal several
times, and check the depressed height
(floor to the upper surface of brake
pedal pad).
Make sure that the distance above is as
specified [more than 80 mm (3.15
in)] , then perform the following operations.
Fig. 10-70
10-21
1) Forcibly pull hand brake lever 3
to 5 times.
2) Adjust hand brake lever by turning adjuster until the play at the A
portion is set at 0 to 0.5 mm (0 to
0.020 in), then lock adjuster.
BRAKES
A
:):
-p
~-~
,.
~
/
."
~----
~
~::::::;--.:-.::.:.::-::--::===.:...~~-~~--=-~-~..:::--~---=--::----
1 Cable
2 Equalizer
-
Torque
(Adjuster
lock nut)
~--I
4·- 6 N'm
II
(0.4 - 0.6 kg-m,
2.9 - 4.3 ft-Ib)
3) Repeat depressing brake pedal
slightly, and confirm that the hand
brake becomes effective with a lever
stroke of 3 to 4 notches when pulled
with a force of245 N (25 kg, 55Ib).
4) Forcibly pull hand brake lever 3
to 5 times and rotate tire and wheel
several times by hand. Then wind a
rope around the circum ference of tire,
and con firm that tire and wheel can be
rotated with a force of less than 39 N
(4 kg, 9 Ib).
A 17 ·149
Fig. 10-72
10-7. Replacement of Brake Fluid
NOTE:
a. Recommended brake fluid FMVSS
No. 116, DOTJ.
b. To always maintain the brake fluid
characteristics, replace the brake
fluid according to maintenance
schedule or earlier than that when
used in severe condition.
c. The brake piping consists of a dual
system, cross design_ The piping on
primary side connects the front
right brake and the rear left brake,
and the piping on secondary side
connects the front left brake and
rear right brake.
Rear right
Front right
Primary
tube into a container to collect brake
fluid. To drain the fluid into container.
open air bleeder and repeatedly depress
and release brake pedal until a small
amount of fluid remains in reservoir.
2) Refill reservoir with recommended
brake fluid. To refill reservoir, slowly
and repeatedly depress and release
brake pedal completely until a solid
stream of brake fluid (containing no
air bubbles) runs through vinyl tube.
Then securely tighten air bleeder of
master cylinder.
2) I nstall one end of a vinyl tube
onto air bleeder of wheel cylinder
located farthest from master cylinder
and put the other end of the tube into
container for receiving brake fluid.
4) Open air bleeder, and depress and
release brake pedal until old brake
fluid is drained out and new fluid
flows through vinyl tube. Then close
the bleeder.
NOTE:
Front left
Fig. 10-73
Rear left
A17-150
Always begin replacing the brake
fluid on the primary side and subsequently work on secondary side.
1. Replacement
Procedure
1) Remove filler cap from brake
fluid reservoir. Install one end of a
vinyl tube onto air bleeder of master
cylinder and insert the other end of
Add brake fluid as necessary while
performing the air bleed operation, in
order to prevent reservoir from running short of brake fluid.
5) Use the same procedure as the one
described above to change brake fluid
of front wheel cylinder.
6) Always start with the primary side
and then work on the secondary side.
7) Reconfirmation
Bleed air from the brake lines as
follows in the order shown below in
figure.
10-22
A17·151
Fig. 10-74 Air bleeding order
a. Install one end of a vinyl tube onto
air bleeder screw and put the other
end into container.
b. Attach a wrench to bleeder screw,
but do not loosen it at this point.
c. Instruct your co-worker to depress
brake pedal slowly 2 or 3 times and
then hold it depressed.
d. Loosen bleeder screw approximately 1/4 turn until a small
amount of brake fluid drains into
container, and then quickly tighten
the screw.
e. Repeat steps c) and d) above until
there are no air bubbles in the
drained brake fluid.
NOTE:
Add brake fluid as necessary while
performing the air bleed operation, in
order to prevent reservoir from running short of brake fluid.
BRAKES
2. Air Bleeding
2) Check after Bleeding Air
2) Proper air bleeding
Depress brake pedal to determine if its
operation and stroke length are
correct.
3) Fluid level in reservoir
Fill reservoir with brake fluid up to
the "MAX" level.
4) Drive car in low speed and depress
brake pedal a little strongly several
times to make sure that the brakes are
operating properly.
Air in wheel cylinder will cause brake
pedal to feel spongy, and also make
the pedal stroke longer, which can lead
to an accident. Upon completion of
the disassembly and assembly of the
brake, or after brake hose replacement
etc., be sure to bleed air from the
brake system.
1) Brake fluid leakage
Depress brake pedal strongly and hold
it there for approximately 20 seconds.
At this time check the pedal to see if it
shows any unusual movement, visually
inspect bleeder screws and brake pipe
joints to make sure that there is no
fluid leakage.
NOTE:
a. Use recommended brake fluid.
b. Always use new brake fluid.
c. The boiling point of the brake fluid
lowers as it absorbs moisture from
the air; be careful to protect the
brake fluid from contact with air
during storage.
f. After completing the bleeding
operation, hold brake pedal depressed and tighten the screw and
install bleeder cap.
Torque
(Air bleeder
screw)
7 - 9 N'm
(0.7 - 0.9 kg-m,
5.1 - 6.5 ft-lb)
1) Air Bleeding Procedure
Replenish b rake fluid reservoir with
new recommended brake fluid, and
start bleeding air from wheel cylinder
located farthest from master cylinder.
Bleed air according to 1, 7) Reconfirmation.
10-23
BRAKES
10-8. Brake Line
1. Component Parts
• Non-BRAT
1
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Brake pipe (Secondary)
Brake pipe (Primary)
Brake pipe (Rear L.H.)
2-3 way connector
Bolt ASSY
Brake pipe (Front L.H.)
Brake hose clamp
Brake pipe (Rear R.H.)
Brake hose (Rear)
Grommet (Fuel pipe)
Brake hose (Front)
Union bolt
Gasket
Brake pipe (Front R.H.)
Brake pipe (CTR. F. L.R.)
Clamp 5
Clamp 5-5-5
Brake pipe (CTR. F. R.H.)
Brake pipe (CTR. R.H.)
2-way connector
Clamp 7-15
Pipe ASSY (CTR. L.H.)
Clamp 5-7-8-6
Brake pipe cover (R.H.)
Brake pipe cover (L.R.)
Brake pipe (Secondary)
Brake pipe (Primary)
Brake pipe (Front L.H.)
@
Tightening torque N·m (kg-m, ft-Ib)
T: 15-21 (1.5-2.1,11-15)
Fig. 10-75 Component parts of brake line (Non-BRA T)
.
"~II'
II
J
-I
,.~ .~1"~".J'~" J>'."~" " "~" ' ' '~.'-+'-tl_' ' ' ' '
,;
A17-320
10-24
...
q ...
, ...
t'''''...
, .......11'............,_ _ _ _ _ _ _ _ _ _- _ -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1,
UTI,
I.
~
1
BRAKES
• BRAT
@
@
Tightening torq;::;u:e~~N·m- - : : - - - - T: 15 _ 21 (15
(kg-m, ft·lb)
. -2.1,11-15)
~
3
54
6
7
Brake hose (Front)
Brake hose clam
Clamp 5
p
p.
(F
Brake
CI
Ipe ront R.H )
amp 5-5-5
.
Brake pipe (CTR F
. . R.H.)
Clamp 7-15
8 Brake pipe (CTR R
11 Brak.
. .H.)
e pIpe (CTR
13 Clamp 5-7-8-6 . R. R.H.)
~~ P~pe ASSY (CTR-R)
2
o
21
22
23
24
25
26
27
28
29
30
31
32
3
3;
PIpe ASSY (CTR. L H
Brake pipe (CTR F· .)
2-3 w
. . L.H.)
U . ay connector
mon bolt
Gasket
Bolt ASSY
Brak
. (Front L H )
B e pIpe
Brake pipe (Primary) .
Brake pipe (Secondary)
Brake p~pe (Front L.H.)
rake pIpe (Pr.
Brake.
wary)
2pIpe (Secondary)
way connector
Brake hose (Rear)
:rake p~pe (Rear R.H.)
rake pIpe (Rear L.H.)
A 17-321
Fig. 10-76 Component parts of brake line (BRA T)
10-25
BRAKES
2. Brake Hose
1) Removal
1) Separate brake pipe from brake
hose.
(Always use flare nut wrench and be
careful not to deform flare nut.)
tighten flare nut to connect brake
pipe.
d) Fix brake hose with clamp at wheel
apron bracket.
e) While holding hexagonal part of
brake hose fitting with a wrench,
tighten flare nut to the specified
torque.
Torque
(Brake pipe
flare nut)
1) Removal
1) Remove brake pipe from clamp.
2) Push clamp claw portion (shown
with arrow) by screwdriver tip and
take out clamp from hole.
13 - 18 N'm
(1.3 - 1.8 kg-m,
9 - l3 ft-lb)
f) Bleed air from the brake system.
@
Rear brake hose
A17-159
1 Brake pipe
2 Camp
3 Brake hose
A17-155
Fig. 10-77 Separating brake pipe
2) Pull out clamp to remove brake
hose.
3) In case of front disc brake,
remove union bolt and pass the union
bolt side of brake hose through the
hole of damper strut bracket.
a) Pass brake hose through the hole of
bracket, and lightly tighten flare
nut to connect brake pipe.
b) Insert clamp upward to fix brake
hose.
c) Perform the same procedures as
beforementioned in steps e) and f).
A17-157
Fig. 10-79 Tightening flare nut
A17-322
Fig. 10-78 Removing front brake hose
2) Installation
3. Brake Pipe Clamp
There are different kinds of clamps
according to the installing positions.
In the engine compartment
Front brake hose
a) Pass the union bolt side of brake
hose through the hole of damper
strut bracket, and tighten union
bolt.
Torque
(Union bolt)
IS-21N·m
(1.5 - 2.1 kg-m,
11 - 15 ft-Ib)
b) Fix brake hose with clamp at
damper strut bracket.
c) Pass brake hose through the hole of
wheel apron bracket, and lightly
On the side sill
Fig. 10-81 Brake pipe clamps
10-26
Fig. 10-80 Removing clamp
2) Installation
1) Press the clamp claw into body
hole until it snaps.
2) Press brake pipe onto clamp.
NOTE:
a. Do not damage the brake pipe by
screwdriver etc.
b. When removing and installing the
brake pipe, be careful not to bend
it If it is bent a little, correct
before installing. If bent excessively, replace with a new one.
c. If the clamp claw is damaged,
replace with a new clamp.
BRAKES
10-9. Troubleshooting
Trouble and possible cause
I.
Corrective action
Insufficient braking
(1) Oil leakage from the hydraulic mechanism
Repair or replace (cup, piston, cylinder, pipe or hose).
(2) Entry of air into the hydraulic mechanism
Bleed the air.
(3)
(4)
Excessively wide shoe clearance
Adjust the clearance.
Wear, deteriorated surface material, adhering
water or oil on the lining
Replace, grind or clean.
(5) Improper operation of master cylinder, wheel
Correct or replace.
cylinder, disc caliper, brake booster or check
valve
2.
3.
4.
Unstable or uneven braking
(1) Oil on the lining, drum or rotor
Eliminate cause of oil leakage, clean, or replace.
(2) Drum or rotor eccentricity
Correct or replace the drum or rotor.
(3)
Worn brake drum, or damage to the drum
caused by sand
Correct by grinding, or replace.
(4)
Improper lining contact, deteriorated surface
material, improper inferior material, or wear
Correct by grinding, or replace.
(5) Deformed back plate
Correct or replace.
(6) Improper tire inflation
Inflate to correct pressure.
(7) Disordered front alignment
Adjust alignment.
(8) Loosened back plate or the support installing
bolts
Retighten.
(9) Loosened rear wheel bearing
Retighten to normal tightening torque.
(10) Trouble in the hydraulic system
Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the hand brake
Check, adjust, and replace the front brake and cable
system.
Excessive pedal stroke
(1) Entry of air into the hydraulic mechanism
Bleed the air.
(2) Excessive play in the master cylinder push rod
Adjust.
(3)
(4)
(5)
Oil leakage from the hydraulic mechanism
Repair or replace (cup, piston, cylinder, pipe or hose).
Improperly adjusted shoe clearance
Adjust.
Improper lining contact or worn liming
Correct or replace.
Brake dragging or improper brake return
(1) Insufficient pedal play
Adjust play.
(2) Improper master cylinder return
Clean or replace the cylinder.
(3)
(4)
Clogged hydraulic system
Replace.
Improper return or adjustment of hand brake
Correct or adjust
10-27
BRAKES
Corrective action
Trouble and possible cause
(5) Weakened spring tension or breakage of shoe
return spring
Replace the spring.
(6) Excessively narrow clearance between pad
Adjust the clearance by rotating the piston clockwise.
and disc rotor
5.
6.
7.
(7) Excessively narrow shoe clearance
Adjust the clearance.
(8) Improper wheel cylinder operation
Correct or replace.
(9) Improperly adjusted rear wheel bearing
Adjust or replace.
Brake noise (1) (creak sound)
(1) Hardened or deteriorated lining
Replace the shoe assembly or pad.
(2) Worn lining
Replace the shoe assembly or pad.
(3) Loosened back plate or the support
installing bolts
Retighten.
(4) Loose rear wheel bearing
Retighten to normal tightening torque.
(5) Dirty drum or rotor
Clean the drum or rotor, or clean and replace the
brake assembly.
Brake noise (2) (hissing sound)
(1) Worn lining
Replace the shoe assembly or pad.
(2) Improperly installed shoe or pad.
Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor.
Retighten or replace.
Brake noise (3) (click sound)
In the case ofthe front brake.
(1) Excessively worn pad or the support
Replace the pad or the support.
In the case of the rear brake.
(1) Excessively worn shoe ridge
Replace the back plate
(2) Excessively worn wheel cylinder piston
Replace the wheel cylinder assembly
(3) Lack of oil on the shoe ridge surface and
anchor
Add more grease
10-28
BRAKES
10-10. Hill-Holder
1. Construction and
Operation
Fork (clutch release)
1) Outline
Hill-holder is a device to make
starting on an uphill road easy and
permits even a driver not yet familiarized with starting by use of parking
brake to start the vehicle smoothly.
When pressing down the clutch
pedal with the brake pedal depressed
in order to start the vehicle on an
uphill road, this device holds the
brake temporarily upon taking your
foot off the brake pedal (until the
clutch pedal is released). Therefore,
smooth starting is enabled by usual
engagement of the clutch while depressing the accelerator pedal.
(Front)
(Rear!
Clutch pedal
PHV cable
A17-262
Fig. 10-82 Outline of hill-holder
2) Pressure Hold Valve (PHV)
PHV (Pressure Hold Valve) is
connected to one of the service brake
pipes and pushrod (8) is pushed in
and/or pulled out by cam shaft (2)
interlinked with the clutch pedal to
change the clearance between ball (3)
and seal (5), thereby opening and/or
closms the hydraulic circuit. Normally, on a flat road, ball (3) is located at
the front and the valve is kept opened
regardless of the position of the pushrod. (ntis status is the same as on a
downhill road.)
When stopping the vehicle on an
uphill road by depressing both brake
and clutch pedals, the ball roIls toward
the rear and, at the same time, the
pushrod retracts to close the valve, so
that hydraulic pressure is maintained.
Even when takins your foot off the
brake pedal, the hydraulic pressure is
maintained so far as the clutch pedal is
kept depressed. In this status, when
engaging the clutch ordinarily while
depressing the accelerator pedal, the
maintained hydraulic pressure is released simultaneously with the generation of driving force to permit
smooth starting.
To front LH
brake
Front
...
To rurRH
brake
1 Body
2 Ctmahaft
3 Ball
4 BallJUide
5 Seal
6 Plate apriq
7 Cap
8 Push rod
9 SPrina
10 Boot
11 Collar
12 Lever
13 O-rina
14 O-rina
A17-283
Fig. 1()..83 Pressure hold vllive
10-29
BRAKES
• Activating condition
This device is activated only when
depressing the clu tch and b rake pedals
with the vehicle stopped on an uphill
road.
This device is not designed to
operate on a flat road, except for
reversing.
b. During deceleration
3) Operational Precautions
A17-266
Fig. 10-86
Even when depressing the clutch
pedal, the ball is kept at the front
by decelerating force. In this status,
hydraulic pressure is not maintained.
A17-264
Fig. 10-84
When stopping the vehicle on an
uphill road, the ball rolls toward the
rear to seal the port and therefore the
hydraulic pressure is maintained even
by releasing the brake pedaL
2.
When stopping
A17-267
• Inactive status
This accessory is not activated in
any status other than the above.
1.
Fig. 10-87
While driving
a. During acceleration or usual driving
Even when stopping on an uphill
road, hydraulic pressure is not maintained unless the clutch pedal is depressed.
3.
On a flat road
A17-265
Fig. 10-85
Since the clutch pedal is not depressed, the pushrod is located outside the port. In this status, hydraulic pressure cannot be maintained.
A17-215
Fig. 10-88
10-30
1. Hill-holder is a device used to
facilitate starting on an uphill road.
For stoppage on the uphill road,
therefore, you must keep the brake
pedal depressed or pull the parking
brake.
2. Hill-holder may not be activated on
a slope of an extremely small inclination.
3. If the brake is not held sufficiently
upon releasing the brake pedal with
the clutch pedal depressed, press
down the brake pedal a little
strongly once again.
4. If depressing the clutch pedal again
in the course of starting operation,
the brake may be released. In this
case, depress the brake pedal again.
(Because the brake is released when
returning the clutch pedal halfway)
(For example, when interrupting
starting operation or shifting gear
from other than WW because of
misoperation)
5. Before you leave the driver's seat,
be sure to pull the parking lever and
confirm that the vehicle is kept
stopped upon releasing the clutch
pedal.
6. When reversing the vehicle on a flat
road, the following phenomena
may be felt. These phenomena are
caused by the activation of the hill
holder, which does not constitute
abnormality.
a. Brake effect remains even after
releasing the brake pedal if depressing the clutch and brake
pedals when reversing the vehicle.
b. A slight shock is given to the
vehicle when starting the vehicle
after stopping the reverse
movement.
BRAKES
2. Component Parts
Fork (clutch releasell
\
®
Clutch cable
8
1 PHV (Pressure hold valve)
2 Support
3 Hook (spring)
4 Stay (PHV)
5 Return spring
6 Bracket
7 Connector
8 PHV cable
9 Adjusting nut
10 Bracket (cable)
11 Clamp
12 Clip
13 Clip
Hose
Side frame
A17-268
Fig. 10-89 Component parts of hill-holder
Master cylinder
Connector (J-wav)
1
2
3
4
5
6
Brake
Brake
Brake
Brake
Brake
Brake
pipe (primary)
pipe (secondary)
pipe (Front LH)
pipe (Cenier front LH)
pipe (Center front RH)
pipe (Front RH)
:
:
:
:
:
:
Master cylinder (primary) - PHV
Master cylinder (secondary) - Connector
PHV - Front LH
Connector - Rear LH
PHV - Rear RH
Connector - Front RH
A17-269
Fig. 10-90 Piping of hill-holder
10-31
BRAKES
3. Removal
1) Drain brake fluid from reservoir
on primary side of master cylinder.
2) Remove adjusting nut and cable
clamp, and disconnect PHV cable from
cable bracket on engine.
3) Detach PHV cable from clips.
4) Remove cable clamp, and disconnect PHV cable from PHV stay.
s.
Installation
(
1) Assemble bracket with support of
PHV.
Torque
2)
NOTE:
Carefully protect boots and inner
cable from damage when disconnecting
PHV cable.
\
\
\
\
7 - 13 N'm
(0.7 - 1.3 kg-m,
5.1 - 9.4 ft-lb)
Install PHV onto side frame.
A16-272
Fig. 10·93
Torque
7 - 13 N·m
(0.7 - 1.3 kg-m,
5.1 - 9.4 ft-lb)
NOTE:
If cable clamp (and clips) is damaged,
replace it with a new one.
5)
Connect PHV cable with clips_
NOTE:
Avoid sharp bending of PHV cable as
it may cause breakage.
5) Separate connector bracket from
support ofPHV.
6) Disconnect brake pipes from PHV.
6) Install PHV cable onto cable
bracket on engine_
NOTE:
a. Pay attention not to drop brake
fluid onto body painting since it
may dissolve paint
b. Pay attention not to damage hexagonal head of flare nut by using
pipe wrench without fail.
A17·270
Fig. 10-91
7) Detach PHV along with support
from side frame.
3)
NOTE:
Exercise utmost care to prevent
foreign matter from entering into PHV
when removing it.
Connect brake pipes to PHV.
13 - 18 N'm
Torque
(1.3 - 1.8 kg-m,
Fig. 10-94
A16·273
9-13ft-lb)
7) Apply grease to the following
points.
• Hook portion of return spring
• Cable end portion of lever
• Cable end portion of clutch release
fork
4. Inspection
Grease used
Check up removed parts as follows,
and replace defective ones.
1) Check if boots of PHV cable are
damaged or degraded, and if inner
cable is damaged or corroded.
2) Check if return spring is worn out,
damaged or corroded.
3) Confirm that rolling sound of ball
is heard with PHV inclined and lever
rotates smoothly.
CAUTION:
Never disassemble P!'IV. Replace entire
PHV ASSY if necessary.
Idemitsu Auto Lex A
A16·271
Fig. 10-92
NOTE:
Confirm that brake pipes are not
deformed and/or damaged. Replace
them with new ones if necessary.
4)
Install PHV cable to PHV stay.
10-32
8) Be sure to bleed air from the
system.
NOTE:
After replacing PHV cable or clutch
cable with new one, operate clutch
pedal about 30 times as a running-in
operation prior to adjustment.
BRAKES
6. Adjustments
1) Inspect free play of clutch pedal
by depressing the pedal by hand. If it
is out of the specified value, adjust it
by turning adjusting nut on engine side
end of clutch cable at release fork.
Standard of free play
At clutch pedal
13-20mm
(0.51 - 0.79 in)
At center of cable
2-3mm
on clutch release
(0.08 - 0.12 in)
fork
Torque
Adjusting nut
of clutch cable
5.4 - 9.3 N'm
(0.55 - 0.95 kg-m,
4.0 - 6.9 ft-Ib)
Adjusting nut
of PH V cable
2.5 - 4.4 N'm
(0.25 - 0.45 kg-m,
1.8 - 3.3 ft-lb)
CAUTION:
Whenever turning adjust nut, prevent
PHV cable from revolving as shown in
following figure.
2) Confirm stopping and starting
performances by activating hill-holder
on an uphill road of 3° or higher
inclination.
a. If vehicle does not stop;
Tighten adjust nut of PHV cable.
b. If vehicle does not start properly;
• Case A - When hill-holder is
released later than engagement
of clutch pedal (Engine tends to
stall.):
Loosen adjust nut gradually
until smooth starting is enabled.
• Case B - When hill-holder is
released earlier than engagement
of clutch pedal (Vehicle slips
down slightly.):
Tighten adjust nut so that hillholder is released later than
engagement of clutch pedal
(status in Case A). Then make
adjustment the same as in Case
A3-234
Fig. 10-95 Turning adjust nut for
PHV cable
A.
7. Troubleshooting
Trouble and possible cause
1.
2.
3.
Corrective action
Counterforce of clutch pedal is too strong
(1) PHV cable is damaged or does not operate
properly
Repair or replace
(2) Lever of PHV is defective
Replace entire PHV ASSY
(3) Clutch system is anomalous
Refer to "Clutch and pedal cable system"
Machine does not stop on uphill road of 3° or higher inclination
(l) Front side of machine is lowered
Refer to "Suspension"
(2) PHV cable is broken
Replace
(3) Play of clutch is excessive
Adjust
(4) PHV cable is elongated
Adjust
(5) Sealing of PHV is poor
Replace entire PHV ASSY
Shock is felt when starting
(1) Poor adjustment of starting performance
Adjust
(2) When depressing the brake pedal strongly:
(The stronger brake pedal depressing force, the later hill
holder releasing)
(3) When starting on flat road after stopping
reverse movement:
(Because hill holder is activated)
10-33
BRAKES
Trouble and possible cause
4.
Corrective action
Machine slips down when starting
5.
(l) PHV cable is elongated
Adjust
(2) Clutch facing is worn out
Adjust or replace
(3) Bracket (cable) or stay (PHV) is deformed
Repair or replace
Machine cannot start after stoppage
(1) Return spring is fatigued or broken
Replace
(2) PHV lever won't return
Replace entire PHV ASSY
(3) When intentionally depressing brake pedal
[When the brake pedal is depressed by a force of 1,177 N
(120 kg, 265 Ib) or more]
strongly:
6.
Abnormal sound is generated upon releasing brake pedal when stopping
Rotor and pad, drum and lining matched with
each other due to inadequate depressing force
to brake pedal
7.
(Abnormal sound is not generated when depressing brake
pedal a little stronger)
Abnormal sound is generated when operating clutch pedal
(1) Grease is inadequate for the hook of return
Apply grease
spring and sliding portion of PHV cable end
(2) When releasing after maintaining high
fluid pressure:
(Flowing sound of fluid when releasing high fluid pressure)
(3) Clu tch system is anomalous
Refer to "Clutch and pedal cable system"
CAUTION:
a. Description in parentheses is a characteristic of hill-holder and does not indicate abnormality.
Depressing force required for clutch pedal equipped to hill-holder specifications is 20 to 29 N (2 to 3 kg, 4 to 7 Ib) larger than
the conventional specifications, which does not constitute abnormality.
b. When vehicle cannot travel (brake cannot be released) because return spring is broken, remove adjust nut, disconnect clutch
and PHV, and then return PHV lever to release the brake.
c. The hill-holder may not be activated on a slope of an extremely small inclination. If you want to correct it, insert a shim in
between the side frame and support, thereby raising the front of PHV.
When inserting a shim, be sure to confirm stopping status on a slope whenever inserting a single shim. It is recommendable to
avoid raising front of PHV excessively. Never insert 2 or more shims at a time.
Part Number
Part Name
725807000
Shim
Shim
[Thickness of shim is 0.6 mm (0.024
in), and one shim increases an angle of
0.5°.]
A17·274
Fig. 10-96 Inserting shim
·"t'·""
'j
,I~
.,.
k .•..
_a_.. ,. ',_. . .
c>,+,_."'...~.....
*)_
.......
I-,-----__ 1"'f------_-_____n_._,_.___
l l t....
' ....
' _ '....
_I....
" .....
' ..........
' ...
10-34
,~II....
I'I....
t*t
....
BRAKES
10-11. Special Tools
925450000
925460000
925471000
925590000
ADAPTER, WHEEL
CYLINDER 5/8'"
ADAPTER, WHEEL
CYLINDER 11/16"
PULLER, DISC BRAKE
CYLINDER
WRENCH, BRAKE
PISTON
Installing cap
Installing cap
Pressing cone spring
Rotating brake piston
c
-
~-
--
-
--
-_._-
---
Fig. 10-97
e
_D
C-==-O
A17-161
Fig. 10-98
e
A17-163
Fig. 10-99
925600000
ADAPTER, O-RING
Installing spindle O-ring
C
Fig. 10-101
;
~
~
)
A17-160
10-35
r\ [1
'~
~ t .;--F-
.
ST-148
Fig. 10-100
A 17-162
I
",',!
i,;,:,:
I
.~
;
,I,
CHAPTER
1] 1]
STEERING SYSTEM
Page
SlIBARU
11- 1.
SPECIFICATIONS AND SERVICE DATA....... . . . . . . . .. 11- 2
11- 2.
COMPONENT PARTS .............................. 11- 5
11- 3.
OPERATING PRINCIPLE (Power Steering System) .......... 11- 7
11- 4.
STEERING SHAFT ............................... 11- 8
11- 5.
TILT STEERING WHEEL ........................... 11-11
11- 6.
STEERING GEARBOX (Manual Steering System) .... . . . . . .. 11-18
11- 7.
STEERING GEARBOX (Power Steering System) . . . . . . . . . . .. 11-27
11- 8.
OIL PUMP (Power Steering System) .................... 11-37
11- 9.
BELT LINE (Power Steering System) ................... 11-42
11-10.
FLUID LINE (Power Steering System) .................. 11-46
11-11.
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-50
11-12.
SPECIAL TOOLS ................................. 11-63
STEER ING SYSTEM
11-1. Specifications and Service Data
1. Specifications
r--------,------------------------,-----------------------------------------------------Minimum turning radius
4.7 m (15.4 ft) (Hatchback)
4.8 m (15.7 ft) (Except Hatchback)
Inside
Steering angle
Outside
(STD and DL models)
(GL model)
2-spoke type
2·spoke soft type
~?ITl~J~?~ 16Jn~
I
Whole
System
Steering wheel diameter
!
I
I
I
A18-336
Fig. 11-1
Overall gear ratio
18.7
Turns, lock to lock
3.8
Toe-in (in empty)
Type
Gearbox
Pump
(Power
steering
system)
I ± I mm (0.04 ± 0.04 in)
4WD
OUT 5 ± I mm (0.20 ± 0.04 in)
Manual steering
Rack and pinion
Power steering
Rack and pinion, Integral
A18-337
Fig. 11-2
Gear ratio
00
Backlash
o(Automatically adjustable)
Valve (Power steering system)
Rotary valve
Type
Vane pump
Reservoir
Integrated to pump
Output
10 cm 3 (10 cc, 0.61 cu in)/rev.
Relief pressure
5,394 kPa (55 kg/cm 2 , 782 psi)
Hydraulic flux control.
Drooping in response to engine revolution
Hydraulic flux
Working
Fluid
(Power
steering
system)
Non-4WD
700 rpm
7 Litter (7.4 US qt, 6.2 Imp qt)/min.
3,000 rpm
3 Litter (3.2 US qt, 2.6 Imp qt)/min.
Range of revolution
600 - 7,000 rpm
Revoluting direction
Clockwise
Name
ATFDEXRON
Capacity
Reservoir
0.45 Litter (0.5 US qt, 0.4 Imp qt)
Total
0.8 Litter (0.8 US qt, 0.7 Imp qt)
11-2
I
I
STEERING SYSTEM
2. Service Data
ITEM
STANDARD
1
SERVICE LIMIT
Steering wheel
Free play
o to 25 mm (0 to 0.98 in)
Turning angle
Inner tire & wheel
Outer tire & wheel
35°30' to 37°30'
34° to 36°
Steering shaft
Overall length
857.9 ± 1.0 mm (33.78 ± 0.039 in)
Less than 32.6 mm (1.283 in)
Less than 0.6 mm (0.024 in)
Outer diameter of elliptical portion when rotating
Run-out
Collar portion
Shaft end portion
Universal joint
I to 3 mm (0.04 to 0.12 in)
Looseness
Zero mm (in)
0.6 N·m (0.06 kg-m, 0.4 ft-lb)
5.49 N (0.56 kg, l.231b) or less
Maximum yawing torque
Folding torque (only for power steering system)
Steering gearbox
(Manual steering
system)
Rack shaft
Pinion
Steering gearbox
(Power steering
system)
Sliding resistance
Oil pump
(Power steering
system)
Less than 1.2 mm (0.047 in)
Clearance between steering wheel and column
cover
Bend limit
0.1 mm (0.004 in)
0.3 mm (0.012 in)
Within 30 mm (1.18 in) from rack center at
straight-ahead position:
Less than 1.1 N·m(O.11 kg-m,0.8 ft-lb)
Maximum allowable value within 175 mm
(6.89 in) from rack center at straight-ahead
position:
1.5 N·m (0.15 kg-m, 1.1 ft-lb)
Free play limit
Rotating torque
245 N (25 kg, 55 lb) or less
Rack shaft play in radial direction
Right-turn steering
Left-turn steering
0.15 mm (0.0059 in) or less
Horizontal movement:
0.3 mm (0.012 in) or less
Vertical movement:
0.15 mm (0.0059 in) or less
Input shaft play In radial direction
In axial direction
0.15 mm (0.0059 in) or less
0.1 mm (0.004 in) or less
Turning resistance
Within 30 mm (1.18 in) from rack center at
straight-ahead position:
Less than 6.18 N (0.63 kg, 1.39 lb)
Maximum allowable value within 175 mm
(6.89 in) from rack center at straight-ahead
position:
8.43 N (0.86 kg, 1.901b)
Pulley shaft
0.2 mm (0.008 in) or less
0.3 mm (0.012 in) or less
1.0 mm (0.039 in) or less
9.22 N (0.94 kg, 2.071b) or less
0.8 Liter (0.8 US qt, 0.7 Imp qt)
981 kPa (10 kg/cm 2 , 142 psi) or less
4,609 to 5,884 kPa
(47 to 60 kgJcm 2 , 668 to 853 psi)
Pulley
Radial play
Axial play
Ditch deflection
Resistance to rotation
Fluid capacity
Regular pressure
Relief pressure and working pressure
11-3
STEERING SYSTEM
ITEM
Belt line
(Power steering
system)
Steering wheel
efforts (Power
steering system)
STANDARD
Belt tension
1
SERVICE LIMIT
IS to 20 mm (0.59 to 0.79 in)/
98 N (10 kg, 221b)
Idler pulley
Ditch deflection
1.0 mm (0.039 in) or less
Dust seal
Outer diameter
47.6 to 48.3 mm (1.874 to 1.902 in)
Outer diameter (Bearing side)
Inner diameter
47.6 to 48.5 mm (1.874 to 1.909 in)
19.3 to 19.8 mm (0.760 to 0.780 in)
In standstill with engine idling on concrete road
24.5 N (2.5 kg, 5.5 lb) or less
In standstill with engine stalled on concrete road
93.2 N (9.5 kg, 20.91b) or less
• Recommended Power Steering Fluid
B.P.
B.P. Autran DX
CALTEX
Texamatic Fluid 6673 Dexron
CASTROL
CASTROL TQ Dexron
MOBIL
Mobil ATF220
SHELL
Shell ATF Dexron
TEXACO
Texamatic Fluid 6673 Dexron
11-4
* .
-
"·"·~~~~·~;:,,~~_I."""
_'_''''';_'_'1
....
11.. _ .+-<11""'..........1>"""
t"1" " ' , - -_ _ _ _ _. . .,. . ,. . - ,
_rr...
' _ _ _ _ _ _ _-
_ _ _ _ _ _ _ __
STEERING SYSTEM
11·2. Component Parts
1. Manual Steering System
Tightening torque N·m (kg-m, ft-Ib)
T1: 20 - 31 (2'.0 - 3.2,14 - 23)
T2: 14 - 20 (1.4 - 2.0,10 -14)
T3: 22 - 25 (2.2 - 2.6, 16 - 19)
T4: 25 - 29 (2.5 - 3.0,18 - 22)
T5: 78 - 88 (8 - 9, 58 - 65)
T6: 44 - 54 (4.5 - 5.5, 33 - 40)
1 Bushing
2 Spring washer
3 Bolt
Universal joint
Torque rod
Rubber coupling
Washer
Self-locking nut
9 Coupling cover
10 Tapping screw
11 Castle nut
12 Cotter pin
13 CIampB
14 CIampA
15 Flange bolt
16 Protector
17 Steering gearbox
18 Steering shaft ASSY
@
4
5
6
7
8
A18-338
Fig_ 11-3 Component parts of manual steering system
11-5
STEERING SYSTEM
2. Power Steering System
Tightening torque N·m (kg-m, ft-Ib)
T1 : 20 - 31 (2.0 - 3.2, 14 - 23)
T2: 22 - 25 (2.2 - 2.6,16 - 19)
T3: 25 - 29 (2.5 - 3.0, 18 - 22)
T4: 44 - 54 (4.5 - 5.5, 33 - 40)
@
(j)
®
(j)
00'
®
i
([D
®
@
1 Bushing
2 Spring washer
3 Bolt
4 Universal joint
5 Joint
6 Rubber coupling
7 Washer
8 Self-locking nut
9 Grommet
10 Castle nut
11 Cotter pin
12 Flange nut
13 Clamp
14
15
16
17
18
19
20
21
22
23
24
25
26
Flange bolt
Protector
Steering gearbox ASSY
Steering shaft ASSY
Cap
Idler pulley
Ball bearing
Snap ring
Dust seal
Shaft
Bracket
V belt
Clip
27
28
29
30
31
32
33
34
35
36
37
38
39
Supporter
Oil pump ASSY
Connector bolt
Pipe B
Pipe A
PipeC
Pipe D
Clamp A
Clamp B
Connector
Pressure hose
Return hose
Hose clip
A18-339
Fig. 11-4 Component parts of power steering system
11-6
STEERING SYSTEM
11-3. Operating Principle (Power Steering System)
1) The engine drives vane pump (I)
through belt to deliver working fluid.
2) The delivered working fluid is
controlled to appropriate volume ac·
cording to engine speed by flow con·
trol valve (2) in the hydraulic pump
ASSY, and is fed to control valve (4)
through pressure hose (3).
3) When turning the steering wheel,
piston (8) and generates rightward or
leftward force on rack shaft (9),
thereby assisting and reducing the
steering effort.
5) When rack piston (8) is shifted,
working fluid in the other working
chamber is forced out and returned to
oil reservoir (11) via pipe (5) or (6),
control valve (4) and return hose (10).
the above·mentioned control valve (4)
coupled to the pinion shaft works to
form working fluid line according to
the steering direction. That is, working
fluid passes through pipe (5) or (6)
and enters working chamber A or B of
power cylinder (7).
4) The working fluid entering either
of the working chambers acts on rack
Working chamber A
®
Pinion axle
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Vane pump
Flow control valve
Pressure hose
Control valve
Pipe A
Pipe B
Hydraulic cylinder
Rack piston
Rack axle
Return hose
Oil reservoir
Relief valve
Connector
PipeC
Pipe D
Working chamber B
®
@
@
Oil pump assembly
Steering shaft
Engine
Steering wheel
A18-340
Fig. 11·5
NOTE:
a. If a trouble occurs on the hydraulic
system, the steering shaft is me·
chanically coupled with the pinion
shaft via control valve (4) and
operates the rack and pinion the
same as in the manual steering
system.
b. Relief valve (12) incorporated in
the hydraulic pump ASSY limits
the maximum hydraulic pressure
and reliaves pressure if an excassive
pressure works on the valve.
11-7
STEERING SYSTEM
11·4. Steering Shaft
1. Construction
2-spoke soft type
3
@ @
be
CD
CD
1
1 Steering wheel
2 Horn pad
3 Column cover
4 Steering column
5 Steering shaft
6 Nut
7 Tapping screw
8 Upper bearing
9 Combination switch
10 Hazard knob
(j)
2-spoke type
Fig. 11-6 Construction of steering shaft
A18-341
2. Removal
3. Disassembly
1) Open the front hood and disconnect the minus terminal of the battery.
2) Separate steering shaft and gear
box by removing universal joint
connecting bolt at steering shaft side.
3) Remove trim panel of driver's
side.
4) Remove ECM from steering
column.
5) Disconnect connector for ignitionstarter switch and combination switch
wiring harness under instrument panel.
1) Removing horn pad
In 2-spoke type steering wheel,
remov~- a screw at center of back side
of steering wheel and slide horn pad
downward while pressing it.
In 2-spoke soft type steering wheel;
a. Pull up lower areas a & b of pad to
unclip bosses from lower cover.
b. While lifting up lower ends of pad
with taking care of bosses not to
interfere with horn plate spring,
slide pad upwards.
Hook
Sectional view A-A
6) Remove the steering shaft installing bolts under instrument panel.
7) Pull out the steering shaft assembly from the hole on the toe board.
A18-084
Removing horn pad
(2-spoke type steering wheel)
11-8
A18-373
Fig. 11-7 Removing horn pad
(2-spoke soft type steering
whee/)
STEERING SYSTEM
2) Remove the steering wheel installing nut and pull out the steering
wheel from the steering shaft.
3) Remove five screws fitting lower
column cover to upper column cover,
and two combination switch installing
screws. Then remove upper and lower
column covers, and combination
switch.
4) Remove horn brush by loosening
a screw.
5) Remove th~ lower bearing installing screws and pull out the steering
shaft with the bearing downward.
2) Check the press calked part for
looseness.
3) Check the shaft for damage.
(Manual steering)
3) Steering Column Bearing
(Upper and lower)
Check for wear and damage. If any
trouble is found, replace it with a new
one.
(Power steering)
4) Snap ring
Check and replace if deformed.
5) Steering Shaft and Lower
Bearing
Looseness
A18·344
Fig. 11-9 Inspection of universal joint
3) Check the seal ring for damage or
the serration for wear.
Replace it with a new one, if it is
defective.
A18·l24
@
@
(i)
®
1 Snap ring
2 Washer
6 Steering column
3 O-ring
4 Screw
5 Shaft
7 Lock washer
8 Housing
9 Bearing
Fig. 11-8 Cross section of steering
shaft
6) Remove snap ring and then
remove washer, O-ring and bearing
with housing from steering shaft.
2) Steering Shaft Assembly
1) Check the steering shaft for its
length and straightness.
Standard steering
shaft length
S
8S7.9±1.0 mm
(33.78±0.039 in)
857.9 mm (33:78 in)
~
-kEEIIS! I·
NOTE:
If it is necessary to replace upper
column bearing, apply a wooden piece
[outer diameter: 25 to 28 mm (0.98
to 1.10 in)) to the bearing and tap it
with a hammer. Then, fit a new upper
column bearing so as to correspond
end surfaces of column and bearing by
the same manner of removal.
'Staked portion
A18-009
CD Elliptical portion
(outer dia. when
rotated)
1) Universal Joint
@
Less than
32.6 mm (1.283 in)
(runout)
Less than
0.6 mm (0.024 in)
Shaft end
portion (runout)
Less than
1.2 mm (0.047 in)
CD
2)
Zero mm (in)
Check yawing torque
Maximum
yawing
torque
0.6N·m
(0.06 kg-m, 0.4 ft-lb)
Assembly
1) Apply grease on the sliding
portion of steering shaft (at lower
bearing, upper bearing and horn brush).
Install the bearing, O-ring, washer
and snap ring to the steering shaft.
NOTE:
Be careful not to deform the snap ring.
2) Insert the steering shaft into the
steering column from the lower side.
Tighten the lower bearing installing
screws.
NOTE:
Straigh tness
® Collar portion
Looseness
s.
Fig. 11-10 Steering shaft length
4. Inspection
1) Check looseness along the axis
and the rotation.
--I
Check for looseness between them
along the shaft and vertically toward
the shaft. Replace the bearing and/or
O-ring if any trouble is found.
®
a. Align the cut of bearing housing
and electro-united portion of steering column pipe when inserting
steering shaft.
b. Check that lower bearing is installed with no free play in all directions.
@
~EE:E·~iEE~P~e;:C-~'~Support
(Upper bearing
portion)
Support
(Lower beari ng
portion)
Notch on bearing
housing
A18-095
Fig. 11-11 Measuring steering shaft
runout
11-9
Fig. 11-12
A18-066
STEERING SYSTEM
3)
Fin part of pad
Install the horn brush.
NOTE:
a. Check brush for deformation.
b. Install brush without fail because
it is ground connection for horn
circuit.
4) Install the combination switch
and column covers (upper & lower) to
the steering column.
5) Install the steering wheel to the
steering shaft.
~:~]Y
Lower
cover
Hook
6. Installation
1) Insert the end of the steering
shaft assembly into the universal joint
through the grommet of the toe board.
2) Tighten the steering shaft installing bolts under instrument pannel.
A18-374
Fig. 11-14 Installing pad
(2-spoke soft type steering
wheel)
(Power steering)
29 - 39 N·m
(3.0 - 4.0 kg-m,
22 - 29 ft-lb)
Torque
(Steering
wheel)
Pad assy
20 - 31 N·m
(2.0 - 3.2 kg-m,
14 - 23 ft-lb)
Torque
CD
6) Check clearance between the
steering wheel and the column cover.
1- 3mm
(0.04 - 0.12 in)
Clearance
(Manual steering)
®
If the clearance is not in the specified
range, loosen column cover installing
screws and adjust column cover.
1
2
3
4
5
6
7
Universal joint tightening bolt
Torque rod
Pinion
Gearbox
D.OJ.
Toe board
Steering shaft installing bolts
* Clearance 9.5 mm (0.374 in)
(Manual transmission vehicle)
16.5 mm (0.650 in)
(Automatic transmission vehicle)
Clearance:
1 - 3 mm (0.04 - 0.12 in)
A1S-345
Fig. 11-15 Installation of steering shaft
A1S-096
Fig. 11-13 Checking clearance
7) In 2-spoke type steering wheel,
install horn pad to steering wheel and
tighten screw securely from the back
side of steering wheel.
In 2-spoke soft type steering wheel;
a. Align fin part of pad with lower
cover front end, then depressing
(-.1) slightly, pull (-.2) pad so that
hook meets with insert.
b. Aligning pad and lower cover laterally, depress boss parts (a & b in
Fig. 11-7) of pad so as to clip into
lower cover.
NOTE:
After installation of pad, check horn
by depressing horn mark of pad.
3) Connect connector for ignitionstarter switch and combination switch
wiring harness under instrument panne!.
4) Tighten the universal joint bolt.
Torque
(Universal
joint bolt)
b. Make sure to insert bolt and washer
from the recession of universal
joint.
22 - 25 N'm
(2.2 - 2.6 kg-m,
16-19ft-Ib)
NOTE:
A1S-055
a. Confirm that the bolt is aligned
with the notch on the steering shaft
serration.
Fig. 11-16 Tightening universal joint
bolt
"
'
"
_
~
'
_
'
~
4
"
·
"
"
-
~
-
.
11-10
...., . . , , - -........
, - ,...................' ................
, ...
1· ......,..1_
.. t ...., _ _ _ _ _ _ _ _
, ""'_ _ _ _ _ _ _ _ _ _-
.......
, _ , _ _ _ _, _ ,_ _ _-
STEERING SYSTEM
11-5. Tilt Steering Wheel
Center of
rotation
1. General
The tilt steering wheel is designed
to adjust up or down in seven steps
from the neutral position: four steps
upward (9°48') and three steps downward (7°21').
Tilting of the steering wheel is
accomplished by means of a universal
joint (utilized as a pivot), which is
attached to the steering shaft located
beneath the instrument panel.
Two "arc" shaped gears are used to
engage and disengage all of the tilt
positions and are operated by the tilt
lever.
1 Column pipe
6
7
8
9
10
2 Column bracket
3 Roller
4 Sector gear
S Bolt
1 Column bracket
2 Universal joint
CD ®
Tilt lever
rotation
Steering lock
Steering wheel
Upper shaft
Tilt bracket
Fitted
II
12
13
14
Pin
Universal joint
Balance spring
Lower shaft
to column bracket
A18·307
@
Roller
Pin
Lock gear
Tilt lever
Sector gear
Guide groove
3 Tilt bracket
4 Upper shaft
S Lower shaft
A1B·308
Fig. 11-17
A18-346
Fitted to tilt brackat aligning
canter of rotation
Fig. 11-18
A18·309
2. Construction
3. Operation
The upper shaft ® is attached to
the steering lock (j) by a bearing. The
upper end of the upper shaft is
attached to the steering wheel ® and
the lower end is connected to the
lower shaft @ by means of the
universal joint @ .
The tilt bracket ®, which is attached to the column bracket ® by
the bolt @ and pin @, moves up or
down, along with the steering lock (j),
with the bolt and pin used as pivot.
The column pipe CD and column
bracket ® are welded into a one-piece
construction, and the lower shaft @
is incorporated in this one-piece
structure.
The balance springs @ are placed
between the column bracket ® and
tilt bracket ® to hold the steering
wheel in the upward direction by their
tension.
The shock absorbing unit is of an
elliptic, expanding pipe design while
the column bracket is a collapsible
column design.
1) The tilt lever is provided with a
guide groove of gourd design, as shown
in the figure. Into the groove is inserted a pin that is unitized with the lock
1 Roller
2 Lock gear
3 Return spring
4 Sector gear
S Pin
6 Guide groove
7 Tilt lever
A18·3l0
Lock gear disengaged
A18·3ll
Fig. 11-19
11-11
2) The tilt lever is equipped with a
roller that pushes the rear face of the
lock gear by the lever spring, locking
the engagement of the lock gear with
the sector gear without any clearance.
3) When the tilt lever is pushed
down, the roller on the tilt lever moves
away from the rear face of the lock
gear and the pin that is unitized with
the lock gear moves along the guide
groove. This then causes the lock gear
to release the sector gear.
4) With the steering wheel positioned
at any desired angle, releasing the tilt
lever will return the lever to the original position by return spring tension.
This causes the roller (unitized with
the tilt lever) to push the rear face of
the lock gear, so that the lock gear is
engaged with the sector gear.
The force of the roller against the
rear face of the lock gear is added by
the "wedging" effect.
STEERING SYSTEM
4. Component Parts
'\---CD
I
2
3
4
5
6
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
Spring washer
Coating clip
Steering column
Stopper
Lock washer
Tapping screw
Rod
Nut
Shaft (D)
Lock gear
Spacer
Shaft (B)
Tilt lever
Plate
Washer
Self-locking nut
Lever spring
Vinyl tube
Ground lead wire
Spring washer
Tapping screw
Balance spring
Tension cord
Steering shaft
~"
Lower bearing
I
O-ring
:
Washer
Snap ring
Tapping screw
Washer
Spring washer
Tapping screw
Coating plate
Vinyl tube
Washer
1;
®
n
I
'J
A18-347
Fig. 11-20
STEERING SYSTEM
Remove spring (A) using a sharp-end
tool.
Similarly, remove stop ring (8),
detach washer, needle (8) and race (8),
then remove spring (8) using a sharpend tool.
5. Removal
1) Disconnect tension cords, then
remove the cords and balance springs
together. To facilitate removal, it is
good practice to set steering wheel at
the extreme upward tilt position in
advance.
2) Remove universal joint retaining
bolt, loosen lower bearing screws, then
withdraw shaft and bearing as a unit
downward.
3) Remove snap ring, then detach
washer, O-ring, bearing and housing as
a unit from the shaft.
4) Remove ignition-starter switch
retaining bolts, then detach switch and
universal joint shaft from tilt bracket.
Remove stop ring (A) from the
switch using a sharp-end tool, then
withdraw needle (A) and race (A).
NOTE:
Be careful not to scratch bearing, race,
and mating surface of ignition-starter
switch to bearing.
5) Remove lever spring.
6) Remove two nuts and self-locking
nut, then detach plate.
7) Remove lock gear and lever assembly as a unit while sliding them.
8)
a. Remove snap ring, detach washer,
then withdraw shaft (E).
b. Remove bolt (A), then detach
bushing (A).
c. Remove tilt bracket.
NOTE:
Be careful not to lose wave washer.
d. Loosen two nuts, then detach shafts
(8), (D).
9) Do not remove rod unless it is
worn or otherwise damaged. If it
should be removed, set up one end of
column bracket vertically.
6. Inspection
Completely clean all disassembled
parts, removing grease and dust using a
clean cloth. Check for any abnormalities, such as wear, damage, etc. Repair
or replace any faulty part, as required.
No.
Part to check
Inspection
Remedial action
1
Lower column
bearing
• Wear or damage
Check both axial and radial play with
bearing installed on steering shaft.
Replace bearing and O-ring, as required.
2
Steering shaft
(collapsible
shaft)
• Length
Replace shaft, as required.
644.9 ± 1 mm
(25.39 ± 0.04 in)
Specs.
Fig. 11-21
A18-313
• Shaft runout
CD
®
Elliptic, pressed
portion (outer
dia. when
rotated)
32.6 mm (1.283 in)
or less
Tip end of shaft
(runout)
1.2 mm (0.047 in)
or less
®_Cf
CDC?
c:::r
11:
®
Fig. 11-22
E=L
B
-tL~omm
(0.39 in)
©
A18-314
A Lower bearing location
B Staked portion
C Upper support location
• Staked portion
• Damage
11-13
STEERING SYSTEM
No.
Remedial action
Inspection
Part to check
3
Snap ring
• Deformity or fatigue
Replace
4
Universal joint
shaft
• Looseness
• Yawing torque
Replace shaft, as reqUired.
Omm (0 in)
Looseness
Maximum yawing
torque
0.3 N·m
(0.03 kg-m, 0.2 ft-Ib)
VON;~'
I-
.,-?-
,OJJZ':
~
::::::::::,/
~
Looseness
A18·315
Fig. 11-23
• Damage to shaft and key lock collar at
needle bearing location
• Damaged or cracked key lock collar
5
Race (A)
Race (B)
• Deformity or scratches
Replace races (A), (B) and needles (A),
(B) as a unit.
6
Needle (A)
Needle (B)
• Deformity, scratches or damage
Replace needles (A), (B) and races (A),
(B) as a unit.
7
Spring (A)
Spring (B)
• Deformity or fatigue
Replace
8
Stop ring (A)
Stop ring (B)
• Deformity or breakage
Replace
9
Balance spring
• Fatigue
Replace
10
Lever spring
11
Tension cord
• Wear, breakage, or poor connection
Replace
12
Lock gear
• Dents, wear or cracks on gear teeth
Replace lock gear and tilt bracket as a
unit.
13
Tilt bracket
• Dents, wear or cracks on tooth faces
• Wear of pin portion
• Damage
Replace tilt bracket and lock gear as a
unit.
14
Tilt lever
• Roller jamming
Replace
15
Coating plate
• Deformity or cracks
Replace
11-14
~-,
., .~~ I" "
,~
"4k·., . . . . . . . __
·,> ..
1
v.,-url_I- - - - - -.......,...,...
...
, ....,....._ ,....
t
..j'~1h.....
I\' _ _--~+-
'~'-I-,
________- _______-_-
STEERING SYSTEM
7. Installation
1) Install bearing, O-ring, washer and
snap ring onto steering shaft. Apply a
coat of grease to the frictional surface
of the shaft (at the lower bearing
location).
SUNLIGHT 2,
Grease brand
Auto Lex A or
its equivalent
3) Attach needle (A) to race (A), and
needle (B) to race (B), then insert
them into ignition-starter switch, as
shown in the figure.
NOTE:
Ensure that the mating surface of
ignition-starter switch is clean and free
of foreign matter.
Be careful not to deform snap ring.
2) Attach springs (A), (B) to the
grooves in ignition-starter switch.
NOTE:
Ensure that springs (A), (B) face in
direction in which races (A), (B) are
inserted as indicated by the arrows in
the figure.
Be careful not to drop wave washer.
CD
J
(j)
4) Install stop ring (A), washer, and
stop ring (B).
I
I~II
.J
I
I Bushing (A)
NOTE:
NOTE:
NOTE:
Ensure that stop rings are fitted properly in the grooves.
2 Tilt bracket
3 Snap ring
4 Washer
5 Wave washer
6 Shaft (E)
7 Steering column
A18-319
5) Apply about 3 grams (0. n oz) of
grease to the inner walls of needles
(A), (B).
SUNLIGHT 2,
Grease brand
Auto Lex A or
its equivalent
NOTE:
b
~~
b
Be careful not to drop or strike
ignition-starter switch wh ile handling
it.
1 Column bracket
2 Tilt bracket
3 Wave washer
A18-320
0
1 Race (A)
2 Needle (A)
3 Spring (A)
6) Install universal joint shaft to
ignition-starter switch, as shown in the
figure, to get their relative positions.
A18-316
Fig. 11-26
8) Align steering column and tilt
bracket at the holes, insert bushing (A)
and shaft (E), then install snap ring to
shaft with washer in place.
Apply a coat of grease to the inner
and outer walls of bushing as well as to
the outer wall of shaft.
NOTE:
58-0·1 mm
-0.5
)
(2 .28 -0·004.
-0.020 In
A18·318
Ensure that snap ring fits properly in
the groove on shaft (E).
Fig. 11-25
NOTE:
a. Be canful not to strike or apply
shocks to the joint shaft and switch
during installation.
b. After installation, turn the shaft to
ensure that it operates properly
without binds.
1 Stop ring (A)
2 Needle (A)
3 Race (A)
4 Spring (A)
Fig. 11-24
5 Race (B)
6 Washer
7 Stop ring (B)
8 Spring (8)
A18-317
7) Apply a coat of grease to the
frictional surface of steering column
against tilt bracket, position wave
washer, then install tilt bracket.
11-15
1 Washer
2 Snap ring
3 Shaft (E)
4 Tilt bracket
5 Wave washer
6 Bushing (A)
A18-321
Fig. 11-27
STEERING SYSTEM
9) Attach shafts (8), (0) and bolt
(A) to the steering column, then
temporarily tighten the two shafts
with spring washers and nuts.
15) Move tilt lever up and down
several times until the clearance between the cutout portion of plate and
tilt lever is 4 t08 mm (0.16 to O.31in),
then tighten all nuts securely.
NOTE:
Ensure that the brazed portions of the
two shafts are inserted into the steering column's holes.
Tightening torque
Sector gear
2 Lock gear
3 Roller
A18-324
Fig. 11-30
Nut
(4 places)
12 - 22 N·m
(1.2 - 2.2 kg-m,
9 - 16 ft-Ib)
Self-locking
nut
9 - 13 N·m
(0.9 - 1.3 kg-m,
6.5 - 9.4 ft-Ib)
12) Attach spacer to shaft (0). Install
plate while aligning it with bolt (A)
and shafts (0), (8) at holes.
Tighten nuts
temporarily
I Shaft (B)
2 Shaft (D)
3 Bolt (A)
A18-322
Fig. 11-28
Adjust so that the
clearance is
4 to 8 mm
(0.16 to 0.31 in)
10) Apply a coat of grease to shafts
(8), (0), then insert lock gear guide
pin into the groove on tilt lever. With
guide pin held in that position, install
tilt lever on shaft (8) and lock gear on
shaft (0).
A18-325
Fig. 11-31
13) Temporarily tighten shafts (8),
(0) with spring washers and nuts, and
bolt (A) with washer and self-locking
nut.
NOTE:
Ensure that the brazed portions of
shafts (B), (0) are aligned with, the
holes in plate.
14) Apply a thin coat of grease to
the surface of return spring, then
install a vinyl tube onto spring, and
attach spring to hook of tilt lever and
plate_
1 Lever assembly
2 Lockgear
3 Guide pin
Fig. 11-29
Return spring
2 Plate
3 Lever assembly
Fig. 11-32
11-16
"
,
NOTE:
This adjustment is important for
proper function of the tilt steering and
should always be made pr:iiJerly.
16) Guide the universal joint through
the hole in the tilt bracket, then install
the ignition-starter switch.
17) Install and tighten the ignitionstarter switch on the tilt bracket with
the four bolts. The lower two bolts
should be tightened together with the
coating clip.
8-12N·m
(0.8 - 1.2 kg-m,
5.8 - 8_7 ft-Ib)
18) Insert the steering shaft into the
lower side of the steering column until
it reaches the serration of the universal
joint.
II) Apply a coat of grease to the
outer periphery of roller and teeth
surfaces of both lock and sector gears.
NOTE:
Be sure to move the lever up and down
several times while applying grease,
until grease is applied evenly.
Fig_ 11-33
Tightening
torque
A18-323
A18-327
A18-326
NOTE:
Ensure that the universal joint fits into
the cutout in the steering shaft's
serration at the bolt hole location.
STEERING SYSTEM
NOTE:
a. Ensure that the eyes of tension
cords are properly inserted into the
concaves in the tilt bracket.
b. Ensure that tilt lever is locked at
each position when lever is oper·
ated.
e. Ensure that the tip end of universal
joint does not show any looseness
in both vertical and horizontal
directions.
1 Universal joint
2 Bolt
NOTE:
Ensure that both ignition-starter
switch and combination switch harnesses are arranged between the
column cover fixture and mounting
bracket.
24) Attach coating plates to steering
column.
3 Steering shaft
A18-328
Fig_ 11-34
19) Align the holes in the steering
shaft's bearing and the steering column, then tighten the lock washer and
tapping screw. Tighten the universal
joint with the bolt.
Tightening torque
Bearing
Universal
joint
1.8 - 2.7 N·m
(0.18 - 0.28 kg-m,
1.3 - 2.0 ft-Ib)
22 - 25 N·m
(2.2 - 2.6 kg-m,
16-19ft-Ib)
21) Properly insert combination
switch into universal joint shaft, then
clamp ignition-starter switch harness
and combination switch harness with
two coating clips each.
22) Install upper and lower column
covers while aligning them with the
bosses in ignition-starter switch, then
tighten combination switch and
column covers.
NOTE:
Do not twist column covers while
installing.
23) Install column cover fixture.
A 18-331
Fig. 11-37
NOTE:
The cutout portion makes it easier to
attach coating plates securely.
25) Install steering column on vehicle
body.
Tightening
torque
20- 29 N'm
(2 - 3 kg-m,
14 - 22 ft-Ib)
Body
20) Apply a thin coat of grease to
the surfaces of balance springs, and
install vinyl tubes onto springs. Then
attach springs to the hooks of steering
column and the eyes of tension cords
to the concave portions of tilt bracket.
CD
®
1 Column
2 Ground lead wire
3 Washer
4 Coating plate
@
@
A18-332
Fig. 11-38
1 Harness
2 Bracket
3 Column cover fixture
A18-329
Fig. 11·35
A18-330
Fig. 11-36
11-17
NOTE:
Ensure that the right side of the
column is tightened together with the
ground terminal and that coating
plates are not dislocated.
STEERING SYSTEM
11-6. Steering Gearbox (Manual Steering System)
1. Construction
CD
@-e;
@-o
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Tightening torque N'm (kg-m, ft-Ib)
T1: 29 - 49 (3 - 5, 22 - 36)
T2: 78 (8, 58)
T3: 78 - 88 (8 - 9,58 - 65)
Tie-rod end assembly (LH)
Tie-rod end assembly (RH)
Dust seal
Snap ring
Nut
Clip
Boot
Clip
Tie-rod complete
Lock washer
Rack
Pinion assembly
Oil seal
Snap ring
Ball bearing
Snap ring
Gearbox unit
Adapter B
Adapter A
Bushing A
Clip
Sleeve
Spring
O-ring
Adjusting screw
Lock nut
A18-125
Fig, 11-39 Construction of steering gearbox
11-18
STEERING SYSTEM
2. Removal
3. Disassembly
NOTE:
1) Disconnect ground cable from
battery.
2) Jack up vehicle, place safety
stands (rigid racks) under both front
lifting points, and then remove both
front wheels.
3) Pull out the cotter pin, loosen the
castle nut and remove the tie-rod end
from the knuckle arm of the housing
by using a puller etc.
In order to remove the tie-rod end
from the housing easily, apply a penetrating oil (CRC, LOOSEN, SUBARU
GUARD etc.) to the tie-rod end.
4) Remove the rubber coupling connecting nuts and disconnect the
pinion with gearbox from the rubber
coupling.
1) Vise the gearbox.
Hold the rack with a adjustable wrench
etc. to prevent it from turning.
NOTE:
When vising the gearbox, insert aluminum plates between the vise and
gearbox for preventing damage to the
gearbox.
Aluminum plates
A18-018
Fig. 1143 Removing ball joint
6) Loosen the lock nut on the gearbox adjusting screw and unscrew
fully the adjusting screw.
A18-085
Fig. 11-41
2) Remove tie rod end and lock nut
from the tie rod.
3) Remove clips (smaller and larger
ones) on outside end of boot, and then
remove boot from steering gearbox.
NOTE:
Be careful not to damage boot with a
driver or the like when removing clips
(smaller and larger ones).
A18·060
1 Adjusting screw
2 Lock nut
A18-304
Fig. 1140 Removing rubber coupling
Fig. 1144
5) Loosen nuts connecting the exhaust manifold with engine and
pull down the exhaust manifold.
6) Remove a boot protector.
7) Remove bolts fitting the gearbox bracket to the crossmember.
8) Pull down the steering gearbox
until pinion flange is pulled out of
the hole of crossmember. Turn gearbox backward and pull it out toward
the left side.
7) Remove spring and sleeve.
8) Detach the oil seal of pinion from
the gearbox unit with a slot screwdriver.
NOTE:
Take care not to damage the gearbox
boot.
~
NOTE:
Clip (large)
/8A
A18-126
Replace the oil seal with a new one
every disassembly.
Fig. 1142
4) Unbend the lock washer on ball
joint with slot screwdriver or chisel
etc.
5) Unscrew the ball joint and remove
the tie rod from the rack.
11-19
9) Remove the snap ring (larger one)
with snap ring pliers.
NOTE:
Be careful not to damage the housing
inner face by snap ring and pliers.
STEERING SYSTEM
13) Remove the ball bearing from
pinion with a press.
Aluminum bar
NOTE:
Support the depressing force with
inner race of bearing.
Bushing A
A·18·305
Fig. 11·45 Removing snap ring
(larger one)
A18·127
Fig. 11-48
Press
NOTE:
Be careful not to damage inside of
gearbox unit.
10) Pull out the pinion.
11) Pull out the rack from the pinion side of the gearbox unit.
NOTE:
Be careful not to damage the bushing
placed inside.
A18·091
12) Remove the snap ring (smaller
one) on the pinion with snap ring
pliers.
A18·090
Fig. 11-46 Removing snap ring
(smaller one)
Fig. 11-47 Removing ball bearing
14) Remove the oil seal and snap
ring (larger one) from pinion.
15) Remove clip from gearbox unit
with a slot screwdriver.
16) Remove bushing A from the end
of gearbox unit by using a aluminum
bar and a hummer.
11-20
"'Ir"'-~'''''''H
u_._,_._. . ,. . .,. .,_,_'
. . _. . . [1-'....'--,."1------..
...... __ ._.......
, ....
,1"""-·...
, ...
, ______
It _ _ _
....
, _ ._ _ _ _ _ _ __
STEERING SYSTEM
4. Inspection
Item
No.
I
2
3
Rubber coupling
Pinion assembly
boot or defective sealing of the adjusting screw O-ring. If necessary, replace
each parts with a new one.
2) If a water infiltration is found in
the steering gearbox when disassembling it may be caused by a defective oil seal on the pinion, cracked
I) In accordance with the following
table, inspect all removed parts for
wear and damage, if necessary make
repair or replacement.
Possible cause
Corrective action
Crack or damage
If wear or crack is notable, replace it with
new one.
I)
Replace it with new one as combination
of pinion and rack.
Damage on pinion teeth such as
indentation, wear or crack
2) Smoothness of rotation or looseness
of ball bearing
3)
Snap ring deformation
4)
Oil seal
I)
Damage on rack teeth such as
indentation, wear or crack.
2)
Bend of rack shaft
Replace it every disassembly.
[ Bend limit
Rack
Replace.
Be sure to use SUBARU genuine parts.
I
1
R'pl", it with n,w one" combin.tion
of pinion and rack.
0.1 mm (0.004 in)
I
~
7J
~~
~
A18-068
Fig. 11-49
4
Gear box unit
I) Crack on the die casted aluminum
case.
2) Crack, deformation or bend on the
tube portion
3) Wear or damage on bushing A
4) Disconnection of needle on needle
bearing
!} R'pl.ce g",box unit.
Replace.
Replace gearbox unit.
5) Wear or deterioration on adapter A
and B
Replace.
Replace.
5
Boot
Crack, damage or deterioration
6
Tie rod complete
I)
2)
7
Tie rod end
Damage or deterioration on dust seal
Replace.
8
Spring (Adjusting screw)
Deterioration
Replace.
9
Boot and clips
Deterioration
Replace.
10
O-ring of adjusting screw
Crack or deterioration
Replace.
11
Sleeve
Damage
Replace.
Looseness of baIl joint
Bend of tie rod
11-21
i
Replace.
STEERING SYSTEM
s.
Assembly
Pinion flange position
in straight-ahead drive
condition
NOTE:
6) Measure the clearance in the
direction parallel to pinion shaft.
Use only SUBARU genuine grease for
gearbox.
10 .3 mm (0.012 in) I
Limit
Specified grease for gearbox
VALIANT GREASE M2
[Parts No. 003608001,
netO.5kg(l.1lb)]
1) Apply grease on the bushing A
after fitting in bushing A and clip with
a press.
A18-093
Fig. 11-52 Direction of pinion ASSY
A18·094
Fig. 11-55
7)
Install the oil seal.
When the clearance between the
flange of oil seal and gearbox is more
than 0.9 mm (0.035 in), snap ring may
be improperly installed.
So remove oil seal and then check
snap ring installation.
Bushing A
A18'069
Fig. 11-50
2) Apply grease on the teeth portion
and sliding portion of the rack and
insert it into the gearbox unit.
Clearance 0.9 mm (0.035 in)
NOTE:
Insert rack from pinion side surely to
prevent bushing A from damage.
3) Set the rack end to be located at
76.7 mm (3.020 in) from the end of
the gearbox unit.
1 Ball bearing
2 Snap ring
3 Oil seal
A18-071
Fig. 11-53 Grease application
A18-072
Fig. 11-56
5) Install large size snap ring in to
groove to fix ball bearing.
NOTE:
76.7 mm
(3.020 in)
A18-092
After inserting snap ring, confirm that
snap ring turns smoothly for checking
of proper installation.
8) Install CD sleeve and ® spring in
turn and then screw in @ adjusting screw.
NOTE:
~
Fill up grease.
@
Fig. 11-51 Assembling rack
00
4) Apply grease on the teeth and
specified portion of the pinion assembly, and insert it into the gearbox
unit to mesh with the rack in a position where the direction of the pinion
flange is inclined, in the straight-ahead
drive condition, 36° clockwise from
the center line of the hole where the
sleeve is to be set.
®~
Snap ring
A18-073
A18-070
~:=
Fig. 11-57
Fig. 11-54
11-22
3 Adjusting screw
4 O-ring
STEERING SYSTEM
9) Adjust backlash between rack and
pinion as follows.
Turn adjusting screw until the
turning torque increase steeply, and
then turn back it 1/24 turn (ISO).
Lock the adjusting screw by lock nut.
This adjustment leaves a clearance
of 0.063 mm (0.0025 in) between the
screw tip and sleeve.
Torque
(Lock nut)
76.7mm (3.020 in)
76.7mm (3.020 in)
29 -49 N·m
(3.0 - 5.0 kg.m,
22 - 36 ft·lb)
A18-075
Fig. 11-59 Straight-ahead drive condition
NOTE:
Hold the adjusting screw with a
wrench to prevent it from turning
while tightening the lock nut.
NOTE:
Hold the rack with a wrench to
prevent it from turning while tighten·
ing the ball joint.
I-----@
Marking of straight ahead
drive condition
2 Oil seal
3 Pinion shaft
NOTE:
A18-076
Fig. 11-60
A18-074
1 Sleeve
2 Spring
3 O·ring
Lock nut
Adjusting screw
6 Apply grease
4
5
Fig. 11-58 Adjusting screw
11) Fit the lock washer on the
screwed portion of the rack end.
Aligning the cut portion of rack
and the nail of washer, screw in and
tighten ball joint assembly.
Torque
(Ball joint)
12) Bend the lock washer toward the
plain surface of the ball joint.
When bending the lock washer, always
put the ball joint on the plane block.
Do not leave sharp edge on bent lock
washer.
78 N·m
(8.0 kg·m, 58 ft·lb)
A18-128
Fig. 11-62 Bending lock washer
10) Check the engaging condition of
rack and pinion by turning the pinion
with hand. If turning is unusually
heavy or harsh, readjust backlash. Put
the rack and pinion in straight·ahead
drive position, paint marking on the
pinion shaft and oil seal.
Apply grease
A18-0l8
Fig. 11-61 Tightening ball joint
11-23
13) Apply grease to the specified
portions of the boot and then install
it to gearbox.
After installing, confirm that the
whole of boot turns smoothly.
STEERING SYSTEM
I
r
NOTE:
If boot deflates when pinion is turning,
refill air.
Reverse after installing
Apply grease
Apply grease
,:;;~
"I
6. Installation
A18·348
Fig. 11-63
NOTE:
a. Before installation of boots, draw
out rack until maximum turning
position and then apply grease
again to the teeth and the sliding
portion of rack for both sides.
b. Install the fitting portions of boots
,to the following portions in both
sides of assembled steering gearbox.
1. The groove on gearbox or the
groove on adaptor.
2. The groove on ball joint.
3. The groove on tie-rod.
c. Check boot is installed without unusual inflation or deflation.
15) Screw in the lock nut and tierod end to the screwed portion of tierod and tighten the lock nut temporally in a position shown in figure.
¢
1) Insert the gearbox ASSY into the
crossmember from the left side.
Be careful to avoid damaging the gearbox boots.
2) Align the gearbox with the crossmember brackets and tighten the
clamp installing bolts.
Torque
(clamp bolt)
44 - 54 N·m
(4.5 - 5.5 kg-m,
33 - 40 ft-lb)
NOTE:
Tighten the left clamp (pinion side)
first.
23 mm 109';0'
6l: e:g=:q.
+FE.
A18-080
Fig. 11-65
NOTE:
Pay attention to the difference between the right and left tie-rod ends.
Clip
(smaller
Right one RH
Identification mark
Left one
Install boot in
grooves firmly.
LH
16) Confirm the operation of the
pinion by turning round it.
A18·079
Fig. 11-64
1
2
3
4
Crossmember
Screw
Cover
Torque rod
5
6
7
8
Rubbercoupling
Bolt
Clamp
Gearbox
Pinion rotating torque
14) Fix clips (smaller and larger
ones) at the specified position of
boots.
NOTE:
Use screwdriver with blunted tip to
prevent boot from damage, when
installing.
After installing, check boot end is
positioned into the groove on tie-rod.
·1-<-,..""',...·"'..
....
,,~"l<
Straight-ahead
position within
±30 mm (1.18 in)
from rack center
Less than
1.1 N'm
(0.11 kg-m,
0.8 ft-lb)
Maximum
allowable torque
1.5 N'm
(0.15 kg-m,
1.1 ft-lb)
A18-06l
Fig_ 11-66 Installing gearbox
'-.,.r.·. . . .
....
t 1 _ ,....
, - ,...
,«~~_
11-24
* ....., _ . _ '.+\1
. ._
____
' ...
+',_"'..., -_ _ _ _ _ _ _- , _ ,_ _ _ _ _ _ __
1 ......
STEERING SYSTEM
3)
4)
When the steering wheel is turned
more than 9° [30 mm (1.18 in) round]
from the straight, correct the steering
wheel setting position to the straight.
Install a boot protector.
Install the exhaust manifold.
Torque
(Nut)
25 - 29N'm
(2.6 - 3.0 kg-m,
19 - 22 ft-lb)
5) Connect the rubber coupling with
the self-locking nuts.
Torque
(Self-locking
nut)
14 - 20N·m
(1.4 - 2.0 kg-m,
10 - 14 ft-lb)
NOTE:
a. Use new self-locking nut.
b. If the clearance between coupling
and cover is not uniform, adjust
the cover position bV loosening the
screws.
A15·078
Fig. 11-68 Connecting tie-rod end
with knuckle arm
7) Install the front wheels and
lower the vehicle.
8) Tighten wheel nuts.
9) Tighten the lock nuts of tie-rod
ends, after adjusting toe-in and turning
angles.
Torque
(Lock nut)
78 - 88 N'm
(8.0 - 9.0 kg-m,
58 - 65 ft-lb)
Fig. 11-70 Steering wheel setting
position
3) Check the toe-in.
@
Toe-in (when empty)
Except
4WD
Adjust the clearance all round
uniformly
A18·08l
1 Rubbercoupling
2 Cover
3 Screw
4 Self-locking nut
4WD
Fig. 11-67 Adjusting clearance
6) Connect tie-rod end to knuckle
arm and tighten it by using castle nut.
Torque
1 ± 1 mm
(0.04 ± 0.04 in)
OUT 5 ± 1 mm
(0.20 ± 0.04 in)
A18·064
Fig. 11-69 Tightening lock nut
When adjustment is necessary,
loosen the lock nuts of the tie-rod
ends and. then turn the 'tie-rods as
shown in figure.
25 - 29 N'm
(2.5 - 3.0 kg-m,
18 - 22 ft-lb)
NOTE:
7. Adjustment
a. After tightening the castle nut to
the specified torque, tighten additionalv in one-sixth (1/6) turn
until both holes of bolt and castle
nut align each other.
Then insert a new cotter pin and
bend it around the castle nut.
b. Do not strike the cap on the
bottom of tie-rod end with hammer or the like.
Adjust the toe-in of front tires.
1) Adjust the road clearance to the
standard value.
2) In order to put the rack to the
center of gearbox, match the white
paint marks on the gearbox and the
pinion.
Check the steering wheel setting
position.
11-25
A18-063
Fig. 11-71 Toe-in adjustment
STEERING SYSTEM
4)
Inspect the turning angle.
Inner wheel:
Turning angle
(in empty)
35°30' - 37°30'
Outer wheel:
34° - 36°
NOTE:
If the adjustment of steering angle is
necessary after adjusting toe-in, adjust
the right and left tie rods by turning
to the same direction and same turns
at a time.
Tie rod one-fourth (1/4) turn adjusts
steering wheel round distance 10 mm
(O.39 in).
Fig. 11-72 Adjusting tie-rod
A18·083
8. Measuring Axial Displacement of Ball Joint of Tie-rod Complete (On car)
Upon inspection, if tie-rod is found to
be abnormally loose, measure its axial
displacement in the following manner.
If the displacement is not within the
limit, replace tie-rod.
1) Boot must be moved aside. Clean
all mud off tie-rod.
2) Remove boot from gearbox, and
move it toward tie-rod end as far as it
will go. Do not allow clip on the small
end of boot to come off. Remove the
boot's small end from the tie-rod
groove first and then the large end.
Next move boot aside.
Place push rod end
on socket end face.
Move boot to tie-rod
end and hold it
stationary with
adhesive tape.
Rack
Fix magnet on tie·rod.
A18·350
Fig. 11-74
Large end
Small end
A18·349
Fig. 11-73
NOTE:
After removing boot, inspect ball joint.
If it is extremely soiled with mud or
rusty due to the entering of muddy
water, replace both tie-rod CP and
boot.
3)
4) This measurement requires two
operators.
Put vehicle on the ground. One
operator reads the dial gauge indicator
under vehicle while the other turns
steering wheel 15° to 20° right and
left several times.
If the reading exceeds the limit,
replace tie-rod CP with a new one.
Axial displacement
limit
O.4mm
(0.016 in)
Set a dial gauge as shown.
11-26
"
!
..., _ . . .
,~-.jU,..,--,
5) After the above work, coat ball
joint with specified grease (VALIANT
M2) and properly reinstall boot as
before.
NOTE:
Be sure that boot is properly fitted in
the grooves of gearbox and tie-rod CP
with clips attached in place.
'''11-'--------------------_--_______
41.-·........
' - , ' - ,...
I
,
STEERING SYSTEM
11-7. Steering Gearbox (Power Steering System)
1. Construction
1 Tie-rod end ASSY LH
@
2 Tie-rod end ASSY RH
\
3 Dust seal
4 Snap ring
5 Nut
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Clip
Boot
Clip
Tie-rod CP
Lock washer
Dust seal
Clip
Air vent pipe
Sleeve
Spring
O-ring
Adjusting screw
Lock nut
Gearbox unit
Adapter
Valve ASSY
,
'
,
CW@@@@
Tightening torque N·m (kg-m, ft-Ib)
T1 : 78 (8, 58)
T2: 29 - 49 (3 - 5, 22 - 36)
T3: 78 - 88 (8 - 9, 58 - 65)
A18-351
Fig. 11-75 Steering gearbox
Control valve
I
Power cylinder
- I nput shaft
Torsion bar
Valve housing
Rack piston
Rack axle
A 18-137
Fig. 11-76
11-27
STEERING SYSTEM
2. Removal
3. Disassembly
1) Disconnect ground cable from
battery, and take out spare tire.
2) Jack up vehicle and place safety
stands under both of front lifting
points and then remove both of front
tires and wheels.
3) Pull out cotter pin, loosen castle
nut and remove tie-rod end from
knuckle arm of housing by using a
puller etc.
In order to remove tie-rod end from
housing easily, apply a penetrating oil
(CRC, LOOSEN, SUBARU GUARD
etc.) to tie-rod end.
Remove tie-rod end on another side
housing in the same manner.
4) Detach jack-up plate.
5) Disconnect cap from O 2 sensor,
and remove front exhaust pipe.
6) Remove boot protector.
7) After removing flare nuts at
center of power steering gearbox, and
drain the working fluid while turning
steering wheel clockwise and counterclockwise.
1) Vise gearbox by using special tool
(Stand; 925690000).
NOTE:
a. When removing flare nuts, wrap
waste cloth around flare nuts.
b. After removing flare nuts, install
vinyl tubes onto gearbox and piping
to prevent the fluid from splashing.
Fig. 11-78 Removing flare nuts
10) Remove the bolt to fix both
piping and gearbox to crossmember.
Fig. 11·81
NOTE:
Be sure to vise gearbox by using
special tool. Never vise gearbox with
inserting aluminum plates etc. between
vise and gearbox.
A18·352
NOTE:
Be careful not to damage boot with a
11) After taking out piping, detach
power steering gearbox.
screwdriver or the like when removing
clip.
4) Take out boot with clip (large)
and clip (middle).
A18·156
Fig. 11-80
8) Remove bolts on bottom and top
sides of joint ASSY, and pull up joint
ASSY.
9) Remove flare nuts of control valve
above crossmember.
NOTE:
Remove a flare nut of which width
across flats is 14 mm (0.55 in) by
using special tools (Socket; 925670000
and Handle; 925680000).
A18-159
Fig. 11·82
NOTE:
a. Take care to prevent dust and
foreign matter from adhering andl
or entering onto joint portions of
hydraulic piping as well as gearbox.
b. Be careful not to damage flange
portion of gearbox by excessive
load when removing bolts.
c. Pay attention not to damage gearbox boot.
11-28
"'41-~,
2) Pull out air vent pipe from boot.
3) Remove clip (small) on outside
end of boot.
Fig. 11·79
A18·152
Fig. 11·77 Draining fluid
A18-157
5) Unbend lock washer on ball joint
with slot screwdriver or chisel etc.
NOTE:
Pay attention to prevent rack surface
on the right side from being damaged
by a tool or the like; otherwise oil
leakage might be caused.
-_4.·. ._. . . .'. . .,. .,.._,. .,_.1',-'...,,-_.-____....._,•.__________- _______
.........."'-"......1.....
STEERING SYSTEM
8) Take out spring and sleeve.
9) Remove dust seal by using a
screwdriver.
6) Unscrew ball joint and remove it
with tie rod from rack.
NOTE:
a. While removing left-hand ball joint
with tie rod, hold rack with a
wrench or special tool (Wrench;
925700000) to prevent it from revolving.
b. While removing right-hand ball joint
with tie rod, hold rack with special
tool (Wrench; 925700000) to prevent it from revolving.
NOTE:
When removing dust seal, carefully
prevent housing from being damaged
and foreign matter from entering the
inside.
Fig. 11·84 Removing right-hand ball
joint
7) Loosen lock nut on gearbox
adjusting screw, and unscrew fully
adjusting screw.
4. Inspection
• In accordance with the following
table, inspect all removed parts for
wear and damage, and make repair
or replacement if necessary.
NOTE:
A 18-160
Fig. 11-83 Removing left-hand ball
joint
Fig. 11-85 Loosening lock nut
If a water infiltration is found in the
steering gearbox when disassembling it
may be caused by a defective dust seal
on the input shaft, cracked boot or
defective sealing of the adjusting screw
O-ring. If necessary, replace each parts
with a new one.
Corrective action
Inspection
No.
Parts
I
Rubber coupling
Crack or damage
If wear or crack is notable, replace it with
new one.
2
Input shaft
(1) Bend of input shaft
If bend or damage is excessive, replace entire
gearbox .ASSY.
(2) Damage on serration
3
Dust seal
(1) Crack or damage
If outer wall slips, lip is worn out or damage
is found, replace it with new one.
(2) Wear
11-29
STEERING SYSTEM
No.
Parts
4
Rack and pinion
Corrective action
Inspection
Poor mating of rack with pinion
(1) Adjust backlash properly.
By measuring turning torque of gearbox
and sliding resistance of rack, check if
rack and pinion engage uniformly and
smoothly with each other.
(Refer to "Service limit".)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for
damage.
Even if abnormality is found in either (1)
or (2), replace entire gearbox ASSY.
5
Gearbox unit
(1) Bend of rack shaft
(2) Bend of cylinder portion
(3) Crack or damage on cast iron
Replace gearbox ASSY with new one.
portion
(4) Damage on coupled portion
(5) Wear or damage on rack
bushing
If free play of rack shaft in radial direction is
out of the specified range, replace gearbox
ASSY with new one. (Refer to "Service
limit" .)
(6) Wear on input shaft bearing
If free plays of input shaft in radial and axial
directions are out of the specified ranges,
replace gearbox ASSY with new one.
(Refer to "Service limit".)
6
Boot
Crack, damage or deterioration
Replace
7
Air vent pipe
Crack, damage or deterioration
Replace
8
Tie rod complete
(1) Looseness of ball joint
Replace
(2) Bend of tie rod
9
Tie rod end
Damage or deterioration on dust seal
Replace
10
Adjusting screw
spring
Deterioration
Replace
11
Boot clip
Deterioration
Replace
12
O-ring of
adjusting screw
Crack, damage or deterioration
Replace
13
Sleeve
Damage
Replace
11-30
STEERING SYSTEM
Rack shaft play in radial direction
• Service limit
Make a measurement as follows. If
it exceeds the specified service
limit, replace gearbox with a new
one.
(Right-turn steering)
Service
limit
0.15 mm (0.0059 in)
or less
NOTE:
When making a measurement, vise
gearbox by using special tool (Stand;
925690000). Never vise gearbox with
inserting aluminum plates etc. between
vise and gearbox.
A18-170
Fig. 11-90
Input shaft play
(In radial direction)
Service
limit
0.15 mm (0.0059 in)
or less
A18-164
Fig. 11-86
U
98N
Sliding resistance of rack shaft
(10 kg,
221b)
Service
limit
245 N (25 kg, 55 lb)
or less
A18-168
Fig. 11-89
(Right-turn steering)
(Left-turn steering)
A18-171
-l
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~ ./
1./" ~/
:\r(D~
Fig. 11-87
Service limit
Direction
0.3 mm (0.012 in)
or less
Direction
0.15 mm (0.0059 in)
or less
~
A18-165
(Left-tum steering)
A18-172
Fig. 11-91
98 N
(10 kg,
(In axial direction)
22 Ib)
Fig. 11-88
A18-169
A18-166
11-31
Service
limit
0.1 mm (0_004 in)
or less
STEERING SYSTEM
1) Apply grease to teeth of rack so
that grease applied is about as high as
teeth, and also apply a thin mm of
grease to sliding portion of rack shaft.
NOTE:
A18-173
Fig. 11-92
Turning resistance of gearbox
Service
limit
Straight-ahead
position
within 30 mm
(1.18 in) from
rack center
Less than
6.18 N
(0.63 kg,
1.391b)
Maximum
allowable
resistance
8.43 N
(0.86 kg,
1.901b)
a. When moving rack to stroke end
without tie-rod attached, prevent
shocks from being applied at the
end.
b. Do not apply grease to threaded
. portion at end of rack shaft.
c. Move rack shaft to stroke end two
(2) or three (3) times to squeeze
grease which accumulates on both
ends. Remove grease to prevent it
from choking air vent line.
2)
Apply grease to sleeve insertion
hole.
3) Apply grease to dust seal insertion hole.
5) Install sleeve and spring in turn
and then screw in adjusting screw.
NOTE:
Apply grease to O-ring set groove and
spring set space.
®~
00
~
m~
~
~
I
Slom
2 Spring
3 Adjusting screw
4 O-ring
A18-073
Apply clean grease with clean hands.
If material having a sharp edge is used
for applying grease, oil seal at the
inside might be damaged.
4) Press-fit dust seal while tapping it
via a spanner or the like so that
stepping between gearbox and dust
seal is nonnally 2 mm (0.08 in).
A18-353
Fig. 11-93
NOTE:
s.
Never directly hit dust seal when pressfitting it.
Fig. 11-95
NOTE:
(Maximum allowable resistance)
When measuring
radial direction,
into input shaft
that rack shaft
completely.
NOTE:
6) Adjust backlash of rack and
pinion in the following manner.
To make sure that sleeve is in
contact with rack, tighten adjust screw
to 5 N·m (0.5 kg-m, 3.6 ft-lb) and
return it about half a rotation.
Turn adjusting screw until turning
torque increase steeply, and then turn
back it 1/12 turn (30°).
Lock adjusting screw by lock .nut.
This adjustment leaves a clearance of
0.126 mm (0.0050 in) between screw
tip and sleeve.
Torque
(Lock nut)
rack shaft play in
put steering wheel
and turn it fully so
is out of gearbox
29 - 49 N·m
(3 - 5 kg-m,
22 - 36 ft-lb)
NOTE:
Assembly
Depth 2 mm
(0.08 in)
Hold adjusting screw with a wrench to
prevent it from turning while tightening lock nut.
or less
NOTE:
Use only SUBARU genuine grease for
gearbox.
Specified grease for gearbox
VALIANT GREASE M2
[Parts No. 003608001,
net 0.5 kg (1.1Ib))
Fill up grease
A 18-177
Fig. 11-94 Fitting dust seal
11-32
,.
·~"Hh'_~'~"-""""'·.......
~ ...................._
I - - - - - -n - - - - - - - - - - - - "'11- ' - - - - - - r-, -'1- -
....
' ....
, .....,....
, - ' -....
"""
it"
,
STEERING SYSTEM
H~~~
1 Sleeve
2 Spring
3 O-ring
Fig. 11-96
10.126 mm
- -1 (0.0050 in)
4 Lock nut
5 Adjusting screw
A18-179
7) Check for service limit as per
article of "4. Inspection, Service
limit". Make replacement and adjustment if necessary.
8) Fit new lock washer on screwed
portion of rack end. Aligning cut
portion of rack and nail of washer,
screw in and tighten ball joint and tie
rod.
Torque
(Ball joint)
b. While tightening right-hand ball
joint, hold rack with special tool
(Wrench; 925700000) to prevent it
from revolving.
c. Pay attention to prevent rack surface on the right side from being
damaged by a tool or the like,
otherwise oil leakage might be
caused.
9) Bend lock washer toward plain
surface of ball joint, after removing
gearbox assembly from stand.
NOTE:
a. By rotating boot, align stopper
projection with notch in gearbox
groove.
b. Install fitting portions of boots to
the following portions in both sides
of assembled steering gearbox.
1. The groove on gearbox
2. The groove on ball joint
3. The groove on tie rod
c. Make sure that boot is installed
without unusual inflation or deflation.
11)
NOTE:
When bending lock washer, always put
ball joint on plain block. Do not leave
sharp edge on bent lock washer.
Fix boot end with clip (small).
Clip (small)
78 N·m
(8.0 kg-m, 58 ft-Ib)
A18-181
Clip (middle)
Fig. 11-101
Fig. 11-99 Bending lock washer
10) Fit clips (large and middle) to
boot, and then install boot to gearbox
while holding boot flange.
A 18-160
NOTE:
a. Use screwdriver with blunted tip to
prevent boot from damage, when
installi ng.
b. After installing, check boot end is
positioned into groove on tie-rod.
12) Insert air vent pipe into the
specified hole in boot.
Fig. 11-97 Tightening left-hand ball
joint
A18-159
Install boot in
Apply grease
and install boot
in groove
firmly
EfBf==:::::1~rt=3
Fig. 11-98 Tightening right-hand ball
joint
NOTE:
a. While tightening left-hand ball
joint, hold rack with a wrench or
special tool (Wrench; 925700000)
to prevent it from revolving.
A18-182
Fig. 11-102 Inserting air vent pipe
/;~IiP (middle)
Reverse after installing
A18-372
Apply grease
and install boot
in groove firmly
Fig. 11-100
11-33
NOTE:
a. Do not apply grease to air vent
pipe; otherwise air connection
might be shut off Or pipe might be
pulled out easily.
STEERING SYSTEM
b. Insert pipe until it reaches stopper.
Proper insertion distance up to the
end is 13 mm (0.51 in). If pipe is
inserted less than the value, it is
liable to slip off. If it is inserted
with an excessive force, its tip
exceeds stopper and comes in contact with wall of boot, adversely
affecting air connection.
13) Screw in lock nut and tie-rod
end to screwed portion of tie-rod, and
tighten lock nut temporally in a position as shown in a illustration.
After all, make sure that boot is
installed in the specified position without deflation, that air vent pipe without being disconnected and that grease
is not sucked into air vent pipe.
Torque (Flare nuts)
Pipe A and
B
Pipe C
25 - 34 N·m
(2.5 - 3.5 kg-m*,
18 - 25 ft-lb)
PipeD
39 - 49 N'm
(4.0 - 5.0 kg-m,
29 - 36 ft-lb)
6. Installation
1) Insert gearbox assembly into
crossmember. Be careful to avoid
damaging gearbox boots.
2) Align gearbox with crossmember
brackets and tighten bolts to install
both clamp and gearbox.
23 mm (0.91 in)
Torque
(Bolts)
44 - 54 N'm
(4.5 - 5.5 kg-m,
33 - 40 ft-lb)
16 - 20 N·m
(1.6 - 2_0 kg-m,
12 - 14 ft-lb)
* Recommended value for the flare
nut at control valve.
4) Wind pipes A and B with clamp
and tighten a bolt to flx both gearbox
and the piping to crossmember.
A18-080
Fig. 11-103
NOTE:
Pay attention to difference between
right and left tie rod ends.
Identification
mark
Right one
RH
Left one
LH
A18-352
Fig. 11-107 Tightening a bolt
A 18-156
Fig. 11-105 Tigh tening bolts
14) Inspect gearbox assembly as
follows.
Torque
(Bolt)
NOTE:
Screw the front left bolt halfway.
3)
44 - 54 N·m
(4.5 - 5.5 kg-m,
33 - 40 ft-Ib)
Connect pipes A, B, C and D.
5)
NOTE:
Install boot protector.
Flare nut of pipe C at control valve
can easily be tightened with special
tool (Socket; 925670000, and Handle;
925680000).
A18-183
Fig. 11-104 Inspecting gearbox ASSY
A. Holding tie-rod end, repeat lock to
lock two (2) or three (3) times as
quickly as possible.
B. Holding tie-rod end, turn assembly
slowly at a radius one (1) or two
(2) times as large as possible.
A18-354
Fig. 11-108
A18-184
Fig. 11-106
6) Install exhaust manifold, and
connect cap of O2 sensor.
11-34
j~
f'
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··'"'1t-··J.-·~l-~_""'~.........,...I t _......._ _.....-.....
t-k...........
' - ,....' - i ........' - - - - - - -.......
- - - - - - - - - - - -1 - - - - - - - -
t,
STEERING SYSTEM
Torque
Nuts at
engine
25 - 29 N'm
(2.6 - 3.0 kg-m,
19 - 22 ft-lb)
Bolts and
nuts at
exhaust pipe
42 - 52 N'm
(4.3 - 5.3 kg-m,
31 - 38 ft-lb)
Bolt at
hanger
25 - 34 N·m
(2.5 - 3.5 kg-m,
18 - 25 ft-lb)
7) Install steering joint assembly as
follows.
1. Insert joint to steering shaft
fully.
2. Push down yoke fully towards
gearbox side.
3. Pull up joint after installing bolt
through yoke, and confirm bolt
to be aligned with notch on
serration.
4. Tighten bolt for yoke and then
tighten bolt for joint.
Torque
22 - 25 N·m
(2.2 - 2.6 kg-m,
16-19ft-lb)
NOTE:
a. After tightening castle nut to the
specified torque, tighten additionally in one-sixth (1/6) turn until both
holes of bolt and castle nut align
each other.
Then insert a new cotter pin and
bend it around the castle nut.
b. Do not strike cap on bottom of
tie-rod end with hammer or the
like.
15) Adjust the fluid level in the
reservoir. (For more details, refer to
the section regarding fluid line.)
16) Tighten lock nuts of tie-rod
ends after adjusting toe-in and turning
angles.
Torque
(Nuts)
78 - 88 N·m
(8.0 - 9.0 kg-m,
58 - 65 ft-lb)
A15-078
Fig. 11-110 Connecting tie-rod end
with knuckle arm
9)
Install front wheels by tightening wheel nuts.
10) Connect minus terminal of battery, and fit spare tire.
11) Feed the specified fluid and
discharge air. (For details, refer to the
section regarding fluid line.)
NOTE:
Never start the engine before feeding
the fluid; otherwise vane pump might
be seized up.
12) Jack up vehicle again and take
out safety stands, and then lower
vehicle.
13) Check the fluid leakage at flare
nuts after turning steering wheel from
lock to lock with engine running.
14) Tighten bolts to fix both jackup plate and clamps for piping.
A18-153
Fig. 11-112
NOTE:
At adjusting toe-in, clasp boots to
keep boots from rotating and twisting.
7. Adjustment
(See page 11-25.)
8. Measuring Axial
Displacement of Ball
Joint of Tie-rod
Complete (On-car)
(See page 1] -26.)
9. Replacement of Valve
Assembly
NOTE:
a. Clean all debris, dirt and grease
from around the steering gearbox
prior to removal of the unit from
the vehicle. Steam and/or a degreasing agent is suitable for this
procedure.
b. Care must be taken to avoid getting
any dirt into the gearbox ASSY
when servicing. Clean all fittings
carefully before removal.
Fig. 11-109
8) Connect tie-rod end to knuckle
arm and tighten it by using castle nut.
Torque
NOTE:
Make sure to hold piping properly by
the clamps.
25 - 29N'm
(2.5 - 3.0 kg-m,
18 - 22 ft-lb)
Fig. 11-111
11-35
STEERING SYSTEM
1) Removal
3) Remove two bolts securing the
valve ASSY.
4) Separate valve ASSY from gearbox by pulling input shaft and valve
housing as a unit.
Remove gearbox. (See page 11-28.)
2) Disassembly
1) Mount gearbox in Stand (Special
tool 925690000). Secure Stand in a
vise.
2) Apply SUBARU genuine steering
grease
(VALIANT
M2,
PIN,
00360800 I) to ball bearing and pinion
gear portion.
3) Set the rack to the extreme right
hand turn position.
4) While holding pinion into valve
housing, cut the shipping band.
NOTE:
NOTE:
a. Do not allow pinion to slip out of
housing as this will damage "V"
packing.
b. Do not remove 4 plugs until gearbox has been reinstalled into
vehicle.
Never attempt to vise gearbox alone as
this will damage the gearbox.
Stand
(925690000 )
A18·357
Fig. 11-115
1
I
I
. k1"
1
}-
I
5) Inspect needle bearing which is
pressed in gearbox for wear or deformation. Replace as necessary.
/)
)~';r ~
5) Install a new gasket on the gearbox.
6) Insert valve ASSY into gearbox
with the notch of input shaft facing
the adjusting screw on gearbox.
A18·356
Fig. 11-113
2) Loosen locknut on gearbox adjust·
ing screw. Unscrew adjusting screw
completely.
\
Notch portion of
input shaft
CD
3) Assembly
1) Prepare new ASSY for installation
by cleaning rust preventive grease from
pinion gear and bearing with clean
kerosene or degreaser.
1 Adjusting screw
2 Spanner (925640000)
NOTE:
A18·162
Do not allow the cleaner to enter the
Valve ASSV.
Fig. 11-114
A18-359
Fig_ 11-117
7) Tighten two housing bolts in
alternating sequence so as to draw the
components together evenly without
distortion.
Torque
A18-360
A1Q·358
Fig. 11-118
Fig. 11-116
11-36
"
20 - 29 N·m
(2 - 3 kg-m,
14 - 22 ft-lb)
j~
".k.,,,'-.+.d , ... ~..., _ ,...._ _....
, _
*._1'..._ ...,
.......
nl"'tl-'--------'. . .r_'. ...,_'___________________
- I...
· ...
STEERING SYSTEM
8) Adjust the backlash of rack and
pinion as follows:
a. Tighten adjusting screw until sleeve
contacts rack [5 N·m (0.5 kg-m,
3.6 ft-lb) torque] . Back the adjuster
out 1/2 turn.
b. Tighten adjusting screw until it gets
tight. Back it out 30° (1/12 turn).
c. While holding the adjuster, tighten
lock nut.
Torque
29 - 49 N·m
(3 - 5 kg-m,
22 - 36 ft-lb)
9) Check the adjustment by turning
the input shaft in both directions by
hand. If excessive tightness, binding or
looseness is felt, repeat the adjustment
procedure.
c.
d.
e.
f.
g.
h.
Oil level.
Steering condition.
Fluid leakage.
Noise and vibration.
Clearance.
Measurement of steering effort.
4) Installation
NOTE:
It is recommended to recheck the
As for the following service procedures
and checkings, refer to the power
steering section in this chapter.
a. Installation of gearbox.
b. Piping of fluid line.
above after several days.
11-8. Oil Pump (Power Steering System)
1. Construction
r--@
CD
I
®
I
I
I
(j)
®
Tightening torque N·m (kg-m, ft-Ib)
T1: 14 - 18 (1.4 . 1.8, 10 - 13)
Spring washer
Bolt
Spring washer
Bolt
Flange nut
Stay
Supporter
Spring washer
Bolt
Hose clamp
T2: 44 - 54 (4.5 - 5.5, 33 - 40)
Fig. 11·119
A18-361
11-37
STEERING SYSTEM
2. Removal
1) Remove ground cable from battery, and take out spare tire and carburetor shield.
2) Jack up vehicle and place safety
stands under both of front lifting
points.
3) J)etach jack-up plate.
4) Drain the working fluid by removing flare nuts at center of power
steering gearbox while turning steering
wheel clockwise and counterclockwise.
In case idler pulley fails to slide
upward with adjust bolt loosened,
loosen lock bolt by giving it about two
more turns, and gently hit the head of
adjust bolt by plastic hammer until the
idler pulley slides.
8) Disconnect hoses from air cleaner
and take out air cleaner by removing
bolts.
A18-192
Fig. 11-121
NOTE:
a. When removing flare nuts, wrap
waste cloth around flare nuts to
prevent fluid from splashing.
b. After removing flare nuts, install
vinyl tube onto gearbox for drainning fluid.
After taking out air cleaner, seal
carburetor to prevent dust and foreign
matter from entering.
5) Pinch brim of idler cap by pliers
with waste cloth around it, and take it
out.
9) Take out electric wirings and
hoses that extend beyond oil pump to
permit the removal of oil pump ASSY.
10) Remove hoses at the back side
of oil pump ASSY after taking out
engine oil level gauge.
NOTE:
2) Take out pulley with belt slackened.
3) To fix pulley in position, tighten
bolts halfway with belt slackened.
4) Adjust belt and then tighten bolts
completely.
Torque
(Bolts)
14-18N·m
(1.4 - 1.8 kg-m,
10 - 13 ft-lb)
NOTE:
In case pulley turns idly, the remedy
required can be effected in either of
NOTE:
Wrap clean waste cloth or the like
around the ends of hoses to keep dust
or the like out.
A 18-187
Fig. 11-120
NOTE:
Do not pinch idler cap directly by
pliers without cushioning waste cloth
around it nor remove it by using a
minus-head screwdriver; otherwise the
cap might be damaged.
two ways with two spanners or combination of a spanner and a screwdriver.
11) Take out stay by removing its
fixing bolt.
12) Remove bolts and a nut installing
oil pump ASSY onto brackets, and
take out oil pump ASSY.
NOTE:
Take care not to allow dust or the like
to collect on the junction with hoses.
A18-193
6) Loosen lock bolt by giving it
about two (2) turns.
7) Turn adjust bolt counterclockwise, and take out oil pump belt.
NOTE:
After adjust bolt is loosened by
turning counterclockwise, idler pulley
will normally be slid upward by the
tension of oil pump belt, and the belt
will become ready for easy removal.
3. Disassembly and
Assembly
1) To take out oil pump pulley,
remove bolts fixing the pulley to oil
pump ASSY in advance of removal of
oil pump with belt tightened.
11-38
A18-194
Fig. 11-122
STEERING SYSTEM
4. Inspection
• In accordance with the following
table, inspect all removed parts for
wear and damage, and make repair
or replacement if necessary.
Parts
No.
I
2
Oil pump
(Outside)
Pulley
Inspection
Corrective action
(1) Crack, damage or oil leakage
Replace oil pump assembly with a new one.
(2) Play of pulley shaft
Measure radial play and axial play.
If any of these exceeds the service limit,
replace oil pump assembly with a new one.
(Refer to "Service limit".)
(1) Damage
Replace it with a new one.
(2) Bend
Measure V ditch deflection.
If it exceeds the service limit, replace pulley
with a new one. (Refer to "Service limit".)
3
Cap
Crack or damage
Replace it with a new one.
4
Strainer
(1) Clogging with dirt
Wash it.
(2) Breakage
Replace it with a new one.
(1) Defect or burning of vane pump
Check resistance to rotation of pulley.
If it is past the service limit, replace oil pump
assembly with a new one.
(Refer to "Service limit".)
(2) Bend in the shaft or damage
Oil pump emits a noise that is markedly
different in tone and loudness from a sound
of a new oil pump when turning with a string
put around its pulley, replace oil pump assembly with a new one.
S
Oil pump (Interior)
to bearing
6
Stay
Deformation
Modify or replace it.
7
Supporter
Crack, deterioration or damage
Replace it with a new one.
8
Hose clamp
Crack, deterioration or damage
Replace it with a new one.
11-39
STEERING SYSTEM
NOTE:
(Axial play)
• Service limit
A rather higher value may be indicated
when pulley starts turning.
Measure the load during rotation and
make a judgement.
Make a measurement as follows. If
it exceeds the specified service
limit, replace oil pump assembly
with a nt;w one.
NOTE:
S. Installation
a. Fix oil pump assembly on a vise to
make a measurement. At this time,
securely hold oil pump assembly
between two wood pieces.
49 N
(5 kg, 11 Ib)
I) Fix oil pump assembly in position by tightening flange nut and
bolts.
A18-197
Fig. 11-125
Ditch deflection of pulley
Service
limit
1.0 mm or less
(0.039 in or less)
A18·195
Fig. 11-123
b. Do not set flange of reservoir or
pulley on a vise; otherwise flange or
pulley might be deformed. Select
properly sized wood pieces.
A18-198
Fig. 11-126
0.2 mm or less
( Direction) (0.008 in
or less)
I
I
Service
limit
Axial play 0.3 mm or less
(0.012 in
or less)
NOTE:
Radial play
(~n)
A18-191
Fig. 11-128
Play of pulley shaft
NOTE:
Read the value for one surface of V
ditch, and then the value for another
off the dial.
To tighten easily bolts at the front
side, align the screw holes using flange
nut tightened halfway at the rear end
as a support.
2)
Interconnect the hoses.
Resistance to rotation of pulley
Service
limit
(Radial play)
Maximum load;
9.22 N
(0.94 kg, 2.07 Ib)
or less
Clip
2 - 3 N'm
(0.2 - 0.3 kg-m,
1.4 - 2.2 ft-lb)
Joint
nut
39 - 49 N·m
(4.0 - 5.0 kg-m,
29 - 36 ft-lb)
Torque
A 18-199
Fig. 11-124
44 - 54 N·m
(4.5 - 5.5 kg-m,
33 - 40 ft-lb)
Torque
(Nut and
bolts)
A18-189
Fig. 11-129
Fig. 11-127
11-40
".. ",,1'
>,1.
, ••
,+-
··,..''"'I+-''''''"'<''"''_,_,_*'_ _
t * _....
, _ ,..........
, - -....TI-'_',_'_'....
,. _____"""""
_
., ..
, f __________________
"
t
-
STEERING SYSTEM
NOTE:
If a hose is twisted at this step, the
hose may come into contact with
some other parts.
(For more details, refer to the section
regarding fluid line.)
9) Connect minus terminal of battery, and fix spare tire and carburetor
shield in position.
10) Feed the specified fluid and
discharge air. (For details, refer to the
section regarding fluid line.)
3) Insert engine oil level gauge into
its hole.
4) Install stay by tightening bolt.
NOTE:
Never start the engine before feeding
the fluid; otherwise vane pump might
be seized up.
. . 98N
(10 kg, 22 Ib)
A18·200
Fig. 11-131
NOTE:
Make sure to fit idler cap properly by
turning it.
11) Jack up vehicle again and take
out safety stands, and then lower
vehicle.
12) Check the fluid leakage at flare
nuts after turning steering wheel from
lock to lock with engine running.
13) Tighten bolts to fix both jackup plate and clamps for piping.
8) Tighten flare nuts of piping to the
specified torque.
A18·362
Fig. 11-130
Torque
(Flare nuts)
16 - 20 N·m
(1.6 - 2.0 kg-m,
12 - 14 ft-lb)
NOTE:
The side surface of stay and that of
tank shell should contact with each
other when installing.
oj
A18·355
Fig. 11-133
5) Fix air cleaner in position.
6) Connect electric wirings and hoses
to air cleaner and hold them by connectors or clips.
7) Set oil pump belt and adjust its
tension, and then fit idler cap.
NOTE:
Make sure to hold piping properly by
the clamps.
A 18,151
Fig. 11-132
11-41
14) Adjust the fluid level in the
reservoir. (For m;:>re details, refer to
the section regarding fluid line.)
STEERING SYSTEM
11-9. Belt Line (Power Steering System)
1. Construction
In case idler pulley fails to slide
upward with adjust bolt loosened,
loosen lock bolt by giving it about two
more turns, and gently hit the head of
adjust bolt by plastic hammer until
the idler pulley slides.
Oil pump pulley
4) Disconnect air duct and hose connecting to right-hand side rocker cover
from air cleaner and remove bolts fixing air cleaner onto brackets and loose
a wing nut onto carburetor.
5) Remove bolts for the front of oil
pump assembly while lifting up air
horn portion of air cleaner slightly.
/
icrank
pulley
A18-203
Fig. 11-135
Tightening torque N·m (kg-m, ft-Ib)
T1: 25 - 34 (2.5 - 3.5,18 - 25)
NOTE:
T2: 20 - 29 (2 - 3, 14 - 22)
1
2
3
4
5
6
Front bracket assy
Lock bolt
Spring washer
Plain washer
Idler pulley
Ball bearing
7 Snap ring
8 Dust seal
9 Shaft
10 Adjust bolt
11 Spring washer
12 Spring washer
13
14
15
16
Fig. 11-134
Bolt
V belt
Idler cap
Bracket
A18-202
2. Removal
2) Loosen lock bolt by giving it
about two (2) turns.
1) Pinch brim of idler cap by pliers
with waste cloth around it, and take it
out.
3) After taking out carburetor shield,
turn adjust bolt counterclockwise, and
take out oil pump belt.
NOTE:
NOTE:
Do not pinch idler cap directly by
pliers without cushioning waste cloth
around it nor remove it by using a
minus-head screwdriver; otherwise the
cap might be damaged.
After adjust bolt is loosened by turning counterclockwise, idler pulley will
normally be slid upward by the tension
of oil pump belt, and the belt will
become ready for easy removal.
a_ It is sufficient to lift air horn by
about 25 mm (1 in). Lifting to an
excessive extent would result in
disconnection of pipes from air
cleaner. In case they are disconnected, connect them propErly.
b. Do not put an excessive load on oil
pump assembly since it is supported
by flange nut at rear end of it
alone.
6) Take out bracket with idler pulley
by removing bolts.
3. Disassembly
1) Remove adjust bolt and lock bolt
of pulley.
2) Draw out pulley.
11-42
.... ~~,,"....+,~.j......-
_'1_'....,.,!_.......,*_
......, . .'_'
. ....- - - - ,....,...'...''''''_11....'_._______...P _........., _ , '_ _ _ _ _ _ __
........, ..., . - - . - ,_ .......
, ...
'· ....
Ht'......
STEERING SYSTEM
NOTE:
NOTE:
a. Usually, pulley can be dislodged by
pressing it hard with hand. In case
it cannot be dislodged, give lock
bolt four to five turns again and
gently hit the head of the bolt with
a plastic hammer, and then remove
lock bolt and pulley.
b. Do not force pulley out with a
minus-head screwdriver inserted between pulley and bracket; otherwise damage might be caused to
area of bracket into which the lip
of dust seal comes into contact.
The shaft can normally be removed by
pressing it hard with hand. If it cannot
be easily removed, gently hit the end
of shaft with a plastic hammer, and
then shaft can be removed by pressing
it hard again with hand.
3)
Draw out dust seal and shaft.
No.
1
Parts
Bracket
Fig. 11-136
4. Inspection
4) Remove snap ring of pulley.
5) Remove ball bearing by using
Remover (925720000) and press.
• Inspect all removed parts for wear
and damage, and replace them if
necessary.
Corrective action
Inspection
(1) Crack or damage to thread
portion
Replace it with a new one.
(2) Deformation
Measure the deformation.
If it is past service limit, replace bracket
with a new one.
(Refer to "Service limit".)
2
Idler cap
Crack, damage or deterioration
Replace it with a new one.
3
Idler pulley
(1) Damage
Replace it with a new one.
(2) Deformation
Measure V ditch deflection.
If it is past service limit, replace it with
a new one.
(Refer to "Service limit".)
(1) Burn or damage
Replace ball bearing with a new one.
4
Ball bearing
A1S·20S
(2) Broken rubber seal
5
Dust seal
6
Shaft
7
Adjust bolt
8
Lock bolt
(1) Crack, damage or deterioration
Replace it with a new one.
(2) Wear of the lip
Measure the diameter of the lip. If it is
past service limit, replace dust seal with a
new one. (Refer to "Service limit".)
Damage to thread portion
Replace it with a new one.
11-43
STEERII\lG SYSTEM
------
No.
Corrective'action
Inspection
Parts
-
9
(1) Fraying, scale-off or crack
Belt
Replace it with a new on e.
(2) Wear of a side surface or
carbonization
If belt is stretched to suc h an extent that
it cannot be adjusted wit h idler pulley,
replace belt with a new 0 ne .
(3) Stretch
• Service limit
NOTE:
Measurement anywhere on the circumference should be within the appropriate range in the above table.
Deformation of bracket
A
Service
B&C
limit
D
32 ± 1.5 mm
(1.26 ± 0.059 in)
35 ± 2 mm
(1.38 ± 0.08 in)
95.25 ± 2 mm
(3.7500 ± 0.08 in)
Fig. 11-138
s.
Assembly
NOTE:
Read the value for one surface of V
ditch and then the value for another
off the dial.
1) Fit ball bearing in position by
using Remover (925720000) and
press.
Wear of dust seal
\-~
3
Service
limit
t__
A18·209
1 Surface A
2 Surface B
3 Surface D
A
47.6 - 48.3 mm
(1.874 - 1.902 in)
B
47.6 - 48.5 mm
(1.874 - 1.909 in)
C
19.3 - 19.8 mm
(0.760 - 0.780 in)
l
)
A18-213
Fig. 11-140
4 Surface C
Fig. 11-137
2)
Fix snap ring in position.
NOTE:
a. Bring the processed surface of
bracket into contact with V block
and hold bracket on it while
measuring.
b. Measure the levels of surfaces from
the top surface of V block.
Ditch deflection of pulley
Service
limit
1.0 mm or less
(0.039 in or less)
A18-207
Fig. 11-139
A18-212
Fig. 11-141
11-44
.....
, _'''''''1t....'....ef'...
' .....,-'...
,-'1"""""'_._____....-..__........_______--,. .,.___________
",~.,*.-~.'-"',-~*,,-.I~'~'--"'''''''-''''''''
STEERING SYSTEM
NOTE:
Turn snap ring to see if it is securely in
position. If it fails to turn smoothly,
ball bearing is not fully set in position.
NOTE:
Do not tighten them excessively. Use
of anything other than the bolts
specially provided for the purpose will
result in damage to cylinder head.
3) Apply grease to both outer and
inner circumferences of dust seal.
4) Fit dust seal to shaft together.
5) Apply grease to the inner circumference of pulley, and fix it in position.
3) Tighten bolts and a nut for oil
pump properly.
A18-188
NOTE:
a. Do not drive pulley in position with
a hammer or the like; otherwise V
ditch might be deformed.
b. Do not apply grease to any area
near V ditch. Wipe away grease
completely.
6)
Fig.
7) Loosen lock bolt by giving it
about two turns and give adjust bolt
five to six turns to set it into shaft.
6. Installation
1) Tighten bolts for bracket and oil
pump assembly halfway.
2) Tighten bolts for bracket properly.
~
145
NOTE:
If spring washer for adjust bolt is not
in close contact with the bolt, tighten
adjust bolt until the washer comes into
close contact with the bolt.
Tighten lock bolt halfway.
NOTE:
Completely wipe away surplus grease
between bracket and pulley; otherwise
grease will be splashed about possibly,
with resultant slip of not only oil
pump belt but also alternator belt.
11~
A18-191
11~143
Fig.
4) Tighten bolts and a wing nut for
air cleaner, and connect duct and hose
to it.
5) Set belt with hand in the sequence indicated below.
(I) Crank pulley
(2) Oil pump pulley
(3) Idler pulley
6) Adjust the belt tension by turning adjust bolt.
34 N·m
3.5 kg-m.
25 ft~lb)
8)
Fix idler cap in position.
NOTE:
a. Idler cap can be fixed easily in
position if a thin grease coat is
given to the contact areas of idler
pulley and cap.
b. Turn the cap to see if it is securely
in position.
9) Fit carburetor shield in position.
10) Confirm that idler cap is not removed and belt does not strike other
parts while engine is running at idling
speed.
NOTE:
At this time, do not run engine at
speed more than 3000 rpm and for
more than one minute; otherwise dust
seal in idler pulley might have a short
life due to overheating.
A 18-200
Fig.
11~144
::-_
L
7)
Tighten lock bolt.
Torque
A
Fig.
11~
142
18~204
20-29N'm
(2 - 3 kg-m,
I_4___2_2_f_t-_Ib_)__~
____ L _ _ _
11-45
----'
STEERING SYSTEM
11-10. Fluid Line (Power Steering System)
1. Construction
• Hoses and piping
1 Pipe B
2 Pipe A
3 Grommet
4 Clamp A
5 Hose A
6 Has;! clip
7 Hose B
Tightening torque N·m (kg-m, ft-Ib)
~
~'
T1 : 39 - 49 (4 - 5, 29 - 36)
T2: 2 - 3 (0.2 - 0.3, 1.4 - 2.2)
T3: 16 - 20 (1.6 - 2.0,12 ·14)
T4: 25 - 34 (2.5 - 3.5,18 - 25)
T5: 44 - 54 (4.5 - 5.5, 33 - 40)
A18·363
Fig. 11-146
®
CD
• Connector and piping
Tightening torque N·m (kg-m, ft-Ib)
T1 : 18-31 (1.8-3.2,13-23)
1 PipeC
2 Pipe D
3 Clamp B
4 Connector
5 Washer (small)
6 Grommet
7 Washer (large)
8 Spring washer
9 Connector bolt
0
T2: 39 - 49 (4 - 5, 29 - 36)
T3: 25 - 34 (2.5 - 3.5,18 - 25)
A18·364
Fig. 11-147
11-46
it!
"'f
I
I
I
r
STEERING SYSTEM
2. Removal
1) Disconnect minus terminal of
battery.
2) Jack up vehicle and place safety
stands under both of front lifting
points.
3) Take out jack-up plate by removing bolts.
4) After disconnecting cap of O 2
sensor, take out exhaust manifold by
removing nuts and bolts fixing it with
engine and body.
5) Remove boot protector.
6) After removing flare nuts at
center of power steering gearbox,
drain the working fluid while turning
steering wheel clockwise and counterclockwise.
NOTE:
a. Flare nuts can be easily removed if
top one is removed first and the
others are removed one by one in
the downward sequence since the
rotation angle of the wrench will be
increased.
b. Remove a flare nut of which width
across flats is 14 mm (0.55 in) by
using Socket (925670000) and
Handle (925680000).
c. 00 not use wrench with its flats
deformed; otherwise flare nuts are
damaged.
9) Take out pipes from crossmember without bending them.
NOTE:
Pay attention to keep flare portions of
pipes, flare nuts and couplings of gearbox clean from dirt or the like.
Fig. 11-150
NOTE:
a. When removing flare nuts, wrap
waste cloth around flare nuts.
b. After removing flare nuts, install
vinyl tubes onto gearbox and piping
to prevent the fluid from splashing.
A18-184
A18-216
10) Loosen bolts fixing connector
to crossmember, and slide the connector forward so easily as to remove flare
nuts at the connector. Then tighten
the bolts halfway.
11) Remove flare nuts at connector,
and take out pipes without bending
them.
NOTE:
Pay attention to keep flare portions
of pipes, flare nuts and screw holes of
connector clean from dirt or the like.
A18-152
Fig. 11-148
A 18-154
Fig. 11-149
7)
Remove flare nuts of control
valve above crossmember.
8) Remove a bolt to fix both piping
and gearbox to crossmember.
11-47
12) Remove nuts joined hoses to
connector.
13) Take out connector by removing bolts.
14) Draw out grommets from each
pipe.
STEERING SYSTEM
3. Inspection
Inspect all removed parts for wear
and damage, replace them if necessary.
Parts
No.
1
Inspection
Pipes
Corrective action
(1) Damage to flared surface
Replace the pipe with a new one.
(2) Damage to fare nut
(3) Crush
2
Connector
(1 ) Damage to tapered seat
Replace the connector with a new one.
(2) Damage to internal thread
3
Grommet
Wear or deterioration
Replace it with a new one.
4
Clamp
(1) Scale-off of the coat
Replace the clamp with a new one.
(2) Deterioration of the hold on
pipe
5
Hoses
(I) Damage to flared surface
(2) Damage to flare nut
(3) Crack on hose surface
Replace the hose with a new one.
(4) Swollen hose
(5) Wear of hose surface
(6) Damage to hose clip
NOTE:
4. Installation
Set grommets for connector in position that the side with a step will be
outside crossmember.
1) Set grommets for each pipe in
position so that the large-diameter side
will be outside crossmember.
2) Set grommets for connector and
fix the connector in position by
tightening bolts.
3) Set and fix pipes in the specified
positions between control valve and
gearbox or connector by tightening
flare nuts as following order.
18 - 31 N·m
(1.8 - 3.2 kg-m,
13 - 23 ft-Ib)
Torque
(Bolts)
Replace it with a new one.
(1) Pipe A to control valve and
gearbox
(2) Pipe B to control valve
(3) Pipe C to control valve and
connector
(4) Pipe D to control valve and
connector
(5) Pipe B to gearbox
Torque (Flare nuts)
For pipe A
and B
16 - 20 N·m
(1.6 - 2.0 kg-m,
12-14ft-Ib)
For pipe C
25 - 34 N·m
(2.5 - 3.5 kg-m*,
18 - 25 ft-Ib)
For pipe D
39 - 49 N'm
(4.0 - 5.0 kg-m,
29 - 36 ft-Ib)
A1S-151
* Recommended value for the flare
nut at control valve.
A1S-220
Fig. 11-151
11-48
,.,
""'.'''""'';;.,'''''-f~k.<-''''''~~.''_'''''''I'
'"*''''_''''.
__
'''''Tr"'''''''''-'-----...,...,..,...,...,""'-,-,________- _ - -_______
....
i • ...
, ....
, - , - ,...
,
STEERING SYSTEM
,---
NOTE:
a. Tighten a flare nut at connector
prior to one at oil pump so as to
keep the hose at a right angle with
crossmember as well as hose B.
b. Tighten flare nuts to prevent a hose
from twisting as well as hose B.
c. Keep the hose apart from washer
tank by 15 mm (0.59 in) or more.
A18-365
5) Fix hose B to connector and oil
pump.
Flare nut
39 - 49 N·m
at con(4.0 - 5.0 kg-m,
nector
29 - 36 ft-Ib)
Torque
Clip at
oil pump
2 - 3 N'm
(0.2 - 0.3 kg-m,
1.4 - 2.2 ft-Ib)
Torque
Nuts at
engine
25 - 29 N·m
(2.6 - 3.0 kg-m,
19 - 22 ft-lb)
Bolts and
nuts at
exhaust pipe
42 - 52 N·m
(4.3 - 5.3 kg-m,
31 - 38 ft-lb)
Bolt at
hanger
25 - 34 N'm
(2.5 - 3.5 kg-m,
18 - 25 ft-lb)
9) Connect minus terminal of battery.
10) Feed the specified fluid and
discharge air as follows.
Recommended fluid (ATF Dexron)
A18-184
B.P.
B.P. Autran DX
CALTEX
Texamatic fluid
6673 Dexron
CASTROL
CASTROL TQ Dexron
MOBIL
MOBIL ATF 220
Fig. 11-154
SHELL
SHELL ATF Dexron
NOTE:
TEXACO
Texamatic fluid
6673 Dexron
Fig. 11-152
NOTE:
Fix pipe C to control valve by
tightening a flare nut with Socket
(925670000) and Handle (925680000).
A3-199
4) Fix hose A to connector and oil
pump by tightening flare nuts to the
specified torques.
Torque
(Flare
nut)
At oil
pump
39 - 49 N·m
(4.0 - 5.0 kg-m,
29 - 36 ft-lb)
At connector
25 - 34N·m
(2.5 - 3.5 kg-m,
18 - 25 ft-lb)
Set hose B inside of hose A as shown
in the above illustration.
6) Set clamp to piping and tighten a
bolt to fix gearbox and the clamp to
crossmember.
Torque
(Bolt)
44 - 54 N'm
(4.5 - 5.5 kg-m,
33 - 40 ft-Ib)
NOTE:
NOTE:
A18-221
Fig. 11-153
(1) Feed the specified fluid with its
level being about 5 to 6 cm (2.0 to
2.4 in) lower than the mouth of
tank.
(2) Continue to turn steering wheel
slowly from lock to lock until
bubbles stop appearing in the tank
while keeping the fluid at that level.
a. Set clamp so as to see a marking
"lH" on it.
b. Make sure to hold piping properly
by the clamp.
In case air is absorbed to deliver
bubbles into piping because the fluid
level is lower, leave it about half an
hour and then do the step (2) all over
again.
7) Install boot protector.
8) Fix exhaust manifold in position
by tightening nuts and bolts to the
specified torques, and connect cap of
O2 sensor.
(3) Start, and idle the engine.
(4) Continue to turn steering wheel
slowly from lock to lock again until
bubbles stop appearing in the tank
while keeping the fluid at that level.
11-49
-"\
STEERING SYSTEM
It is normal that bubbles stop
appearing after three times turning
of steering wheel.
NOTE:
In case bubbles do not stop appearing
in the tank, leave it about half an hour
and then do the step (4) all over again.
(5) Stop the engine, and take out
safety stands after jacking up
vehicle again.
Then lower the vehicle, and idle the
engine.
(6) Continue to turn steering wheel
from lock to lock until bubbles
stop appearing and change of the
fluid level is within 3 mm (0.12 in).
b. In case the fluid leaks from flare
nut, it is caused by dust (or the
like) and/or damage between flare
and tapered seat in piping.
So remove the flare nut, tighten
again it to the specified torque after
cleaning flare and tapered seat. If
flare or tapered seat is damaged,
replace it with a new one.
Fluid capacity
0.8 liter
(0.8 US qt, 0.7 Imp qt)
(1) Check at temperature 21°C
(70°F) on reservoir surface of oil
pump
12) Install jack-up plate and clamps
by tightening bolts.
NOTE:
In case the following happens, leave it
about half an hour and then do step
(6) again.
a. The fluid level changes over 3 mm
(0.12 in).
b. Bubbles remain on the upper surface of the fluid.
c. Grinding noise is generated from oil
pump.
11) Check the fluid leakage at flare
nuts after turning steering wheel from
lock to lock with engine running.
NOTE:
a. Before checking, wipe off any fluid
on flare nuts and piping.
I
OM·752
Fig. 11·156 Indicator of filler cap
(2) Check at temperature 60°C
(140°F) on reservoir surface of oil
pump
Fig. 11·155
NOTE:
Make sure to hold plpmg properly
after installing clamps.
13) Inspect fluid level on flat and
level surface with engine "OFF" by
indicator of fIller cap.
If the level is at lower point or
below, add fluid to keep the level in
the specified range of the indicator. If
at upper point or above, drain fluid by
using a syringe or the like.
OM·751
Fig. 11·157 Indicator of filler cap
11-11. Troubleshooting
1. Manual Steering
Trouble and possible cause
1.
Corrective action
I
Steering wheel operation is heavy
Jack up and when the left and right front wheels are clear the ground, remove the tie-rod ends from the
housings and operate the steering wheel.
A) When easy
B) When heavy
Tire pressure and suspension
Steering system trouble
When heavy, separate the gearbox from steering shaft at the universal joint and operate the steering wheel.
A) When easy
B) When heavy
,~"'Ihl'
I, I."
•
*'
Trouble in connection with gearbox
Trouble in connection with steering shaft
11-50
tt'''''11-'-'_ •.""._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
...
tt - - '........' -....
t ...
, ........
, - ,....•...
' ...
--"~~'''4+''~'''''~'''''''''_1
'
"I
,
•
STEERING SYSTEM
Corrective action
Trouble and possible cause
l)
2)
Ad just to normal pressure
Adjust toe-in
Replace
Lubricate all parts
Adjust
Replace
Replace
Tire pressure too low
Improper front wheel alignment
3) Stuck ball joint
4) Insufficient lubrication
5) Too much tightening of adjusting spring
6) Worn tires
7) No smooth operation of universal joint
2.
Steering wheel vibration
This condition is manifest mostly at high speeds, on rough road or when play of the steering wheel exists.
I) Improper tire pressure
Adjust to normal pressure
Adjust toe-in
Correct
Tighten to correct torque
Correct or replace
Repair or replace
Replace
Inspect, and correct or replace
Incorrect front wheel alignment
3) Unbalanced wheels and tires
4) Loosened wheel nuts
5) Distorted wheel
6) Damaged or worn wheel bearing
7) Worn ball joint
8) Damaged suspension mounting
2)
3.
The steering wheel pulls to one side
This is a very dangerous vehicle condition, often attributable to abnormality in the front suspension system_
l)
2)
3)
4)
5)
6)
7)
8)
4.
Unbalanced tire pressure
Incorrect front wheel alignment
Worn or incorrectly adjusted wheel bearing
Insufficient operation of shock absorber
Damaged suspension or improper installing
Warped crossmember
Unequal left and right wheel base
Special character of tire
Adjust to correct pressure
Correct
Adjust or replace
Replace
Inspect, correct or replace
Replace
Correct
Rotate or Replace
Shock felt at the steering wheel
I) Incorrect front wheel alignment
2)
5.
Adjust toe-in
Adjust to normal pressure
Tire pressure too high
Steering wheel free play more over 25 mm (l in)
Set the steering wheel in straight ahead and when turning the wheel to both left and right, the distance along the
circumference should be less than 25 mm (I in) until the front wheels begin to turn.
I) Worn rack and pinion
2) Worn or damaged serration of steering shaft and
torque rod
3) Loose tightening of steering wheel installing nut
4) Loose universal joint bolt
5) Looseness on universal joint
6) Worn front wheel bearing
7) Loose connections and insufficient tightening
Replace
Tighten additionally or replace
Tighten to specified torque
Tighten to specified torque
Replace
Adjust or replace
Tighten to specified torque or replace
11-51
STEERING SYSTEM
2. Power Steering
1)
Steering condition
Heavy steering
effort in all
range
Heavy steering
effort at stand
still
Steering wheel
surges when
turning
Car leads to
one side or
the other
Poor return of
steering wheel
to center
•
~
V belt
Fluid line
l. Loose or damage of V belt
2. Poor uniformity of V belt
cross section
3. V belt touches to Pulley
bottom
4. Poor revolution of idler
pulley
5. Poor revolution of oil
pump pulley
1. Folded hose
2. Flattened pipe
NG
Adjust
or
replace
Tire and rim
1. Flat tire
2. Mix use of different tires
3. Mix use of different rims
4. Abnormal wear of tire
5. Unbalance of remained grooves
6. Unbalance of tire pressure
1
Tire and rim
l
NG
Fix
or
replace
NG
Adjust
or
retighten
NG
Adjust
or
instruct
customer
GOOD
Replace
or
reinflate
Front alignment
1. Improper or unbalance caster
3. Loose connection of suspension
GOOD
Fluid
1
NG
2. Improper or unbalance tow-in
l. Low fluid level
2. Aeration
3. Dust mix
4. Detrioration of fluid
5. Poor warming up of fluid *2
NG
Refill,
bleed air,
replace
or
instruct
customer
GOOD
Others
1. Unbalance of hight
2. One-sided weight
GOOD
GOOD
Idling speed
Reform
or
replace
GOOD
GOOD
l. Impwp" ,"" 0", of )
specification
*1
2. Improper rims out of
specification
3. Tires not properly
inflated
NG
*3
NG
l. Lower idling speed
2. Excessive drop of idling
speed at start with
turning steering wheel
Adjust
or
instruct
customer
Measure steering effort,
refer to the following article 3).
1 GOOD
Measure hydraulic pressure,
refer to the next article 2).
!
GOOD
Measure steering effort,
refer to the following
article 3).
*1 If tires and/or rims are wider, the load to power steering system is the more.
Accordingly, in a condition, for example before fluid warms up, relief valve
may work before maximum turning angle. In this case, steering effort may be
heavy. When measured hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance
of cold fluid. After warming up engine, tum steering wheel from stop t o stop
several times to warm up fluid. Then if steering effort reduces normally, t here is
no abnormal thing.
*3 In cold weather or with insufficient warm up of engine, steering effort may be
heavy due to excessive drop of idling speed when turning steering wheel. In this
case, it is recommended to start the car with increasing engine speed than usual.
Then if steering effort reduces normally, there is no abnormal thing.
11-52
...
' ....- '.......,...n..
' ......- -_ _........
, """,,_1t""'.....'11-...
' ..,________....
..,....,_,___________- - - - - - - - - - -
"'~"' ~'''''''''''''''''II-'
STEERING SYSTEM
2)
Measurement of hydraulic pressure
Note: Be sure to complete all items aforementioned in article 1), prior to measuring hydraulic pressure. Otherwise, pressure can
not be measured correcdy.
Measure regular pressure
at idling with valve opened.
(Refer to Fig. 11·158)
Result: 981 kPa(lOkg/cm2,
142 psi) or less
~
~
Flattened pipes or hoses
GOOD
?r
~
Measure working pressure at
idling with valve opened,
turning steering wheel from
stop to stop.
(Refer to Fig. 11·160)
Result: 4,609 to 5,884 kPa
(47 to 60 kg/cm 2,
668 to 853 psi)
-
1
Replace bad parts
Leakage of fluid line
Retighten or replace
Obstacle in fluid line
Replace fluid or com·
ponent of fluid line
GOOD
Measure relief pressure at
idling with valve closed.
(Refer to Fig. 11·159)
Result: 4,609 to 5,884 kPa
(47 to 60 kg/ cm 2,
668 to 853 psi)
I
Poor work of relief valve
Fluid leakage inside oil
pump Assy
>
J
Replace oil pump assembly
Excessive wear of vane
pump mechanism
Poor work of control valve
Replace gear box assembly
NOTE:
Do not lelve the valve of pressure gauge closed or hold the steering wheel at stop end for 5 seconds or more in any case, IS
the oil pump may be damaged due to long keep of these conditions.
b. Put cotton cloth waste at a place where fluid drops before pressure gauge is installed. Wipe off spilt fluid thoroughly after the
melsurement
c. Keep engine idling during the measurement.
I.
Regular
pressure
981 kPa
(10 kg/cm 2, 142 psi)
or less
Relief
pressure
4,609 - 5,884 kPa
(47 - 60 kg/cm 2,
668 - 853 psi)
A18·223
Fig. 11·158
Working
pressure
A 18·224
Fig. 11·159
A18·225
Fig. 11·160
11-53
4,609 - 5,884 kPa
(47 - 60kg/cm 2,
668 - 853 psi)
STEERING SYSTEM
3)
Measurement of steering effort.
*4
Measure steering efforts in stand still
with engine idling on concrete road.
(Refer to Fig. 11-161)
Result: 24.5 N (2.5 kg, 5.5 lb) or
less in both direction
*4 When turning steering more quickly than necessary
from a directi on to the other direction at an engine
speed over 2,000 rpm, steering effort may be heavy.
This is caused by flow characteristic of oil pump and
is no problem.
GOOD
r-
Measure steering efforts in stand still
GOOD
with engine stalled on concrete road.
eResult: 93.2 N (9.5 kg, 20.9 lb) or
less in both direction
NG
-1
Adjust back-lash
f--
Remove universal joint
Measure steering wheel effort
(Refer to Fig. 11-161)
Result: Maximum force is 2.26 N
(0.23 kg, 0.51 lb) or less in
both direction.
Fluctuation width is 1.08 N
(0.11 kg, 0.24Ib) or less.
Check, readjust,
replace if
necessary
NG
GOOD
Measure folding torques of the
universal joint.
(Refer to Fig. 11-162)
Result: 5.49 N (0.56 kg, 1.23 lb)
or less in four directions
NG
Replace with
a new one
GOOD
Check front wheels for unsteady
revolution or rattling and brake for
dragging.
NG
Inspect, readjust, replace
if necessary
GOOD
Remove tie-rod ends
Check tie-rod ends, tie-rods and ball
joints of suspension for unsteady
revolution or rattling.
NG
Inspect, replace
if necessary
GOOD
(To be continued)
11-54
"it_tiLl.,.",
r----_. .'.
,t_H*_'_'. .,....' ...'.'1f-11-'-...
·*-""'''.,..4t--j.,'''''....-,-...~~·_•. -....
, ....
' _...
'''''r_'...,-------__...'_r_________
STEERING SYSTEM
Measure rotating and sliding
resistance of gearbox ASSY.
(Refer to Fig. 11-163 and Fig.
11-164)
Result: Rotating resistance is 6.18 N
(0.63 kg, l.391b) or less
around center position and
8.43 N (0.86 kg, 1.90 Ib) or
less in all position within
20% differency between
clockwise and couterclockwise.
Sliding resistance is 245 N
(25 kg,S 5 lb) or less with
20% differency between
left and right directions.
Steering
effort
24.5 N
(2.5 kg, 5.5 lb) or less
Readjust backlash, if ineffective replace
gearbox
ASSY
NG
Rotating resistance
Sliding resistance
Straight-ahead
Less than
position within
6.18 N
30 mm (1.18 in)
(0.63 kg, 1.39 lb)
from rack center
Maximum
allowable torque
Right-turn
steering
Left-turn
steering
245 N
(25 kg, 55 Ib)
or less
8.43 N
(0.86 kg, 1.90 Ib)
A18-367
Fig. 11-161
Folding torques
of universal
joint in four
directions
5.49 N
(0.56 kg, 1.23 Ib)
or less
A18·l65
A18-368
.
Tighten to
22 - 25 N·m
(2.2 - 2.6 kg-m,
16 - 19 ft-Ib)
A18-166
A18-369
A18-227
Fig. 11-162
Fig. 11-164
Fig. 11-163
11-55
STEERING SYSTEM
4)
Fluid leakage
Note: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the
last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
Leakage from connecting
portions of pipes and hoses.
numbered with CD thru @
in Fig. 11-165
Leakage from hose @
and ® in Fig. 11-165
Insufficient tightening of
flare nut, catching dirt or
the like, damage to flare
or flare nut
Loosen and retighten, if
ineffective, replace
Poor insertion of hose, poor
clamping
Retighten or replace clamp
Damage in tapered seat
Replace pipe or hose with
new one, if ineffective,
N
~I Crack m damage in hose
Crack or damage in hose
hardware
Leakage from surrounding
of casted Iron portlon of
oil pump assembly @
and @ in Fig. 11-165
"place connector or gear·
box assembly
Replace with a new one
Damaged O-ring, @
Damaged oil seal, @
Replace oil pump assembly
Leakage from reservoir
of oil pump assembly, @,
@ and @ in Fig. 11-165
@
Crack in reservoir,
Damaged O-ring,
@,@
Damaged cap packing
Leakage from filler neck ~
Leakage from surrounding
of power cylinder of gearbox assembly, @ and
@ in Fig. 11-165
1-----1001
Replace cap
Crack in root of filler neck
Replace oil pump assembly
High fluid level
Adjust fluid level
*5
Damaged inside of power
cylinder, @
Damaged Y shaped packing
@,@
Replace gearbox assembly
Leakage from control valve
of gearbox assembly, @
and @ in Fig. 11-165
Damaged Y shaped packing
or oil seal, @, @
Damage in control valve,
@,@
*5 Fluid level is specified at optimum position (range) for ordinary use. Accordingly when the car is used in many times in hard
conditions like as very rough road or mountain area, fluid may bleed out from air vent hole of cap. This is not a problem.
If a customer complains strongly and he is not likely to satisfy for this phenomena, lower the fluid level so extent that fluid
does not bleed out at the above conditions and lead him to perform checking of fluid level and fluid deterioration more
frequently_
11-56
~I
eft
• · ..
1""+'.1
1
,
,
.,1"*
d
tt
..
STEERING SYSTEM
@
@
® ®
@
I
A18-370
Fig. 11-165
11-57
STEERING SYSTEM
5)
Noise and vibration
*6
Hiss noise (continuous)
While engine is running with
maximum turning angle
Relief
valve
sound
Rattling noise
(intermittent)
While engine is running
Generates at
Max. turning
Angle
Normal (Don't keep
this condition over
5 seconds.)
Generates
without steering
operation
Defective.
Replace oil pump
assembly.
Check clearance.
[Refer to next article 6)]
Correct if necessary
Interference with adjacent
parts
Loosened installation of
Oil pump Assy, Pump bracket,
Gearbox Assy, Cross member
or Connector
Knocking
When turning steering wheel
in both direction with small
angle repeatedly at engine
ON or OFF
-
Loosened installation of
Oil pump pulley or Idler pulley
-
Loosened linkage or play of
steering sys. or suspension.
Loosened tightening of
Universal joint, Rubber
coupling or Column sys.
Retighten
l Retighten
Retighten
or replace
Excessive backlash
Loosened Lock nut for
adjusting backlash
Adjust and
retighten
Loosened tightening or play
of Tie-rod, Tie-rod end
Retighten or
replace
*6 Don't keep the relief valve operated over 5 sec. at any time or inner parts of the oil pump may be damaged due to rapid
increase of fluid temperature.
*7 Grinding noise may be heard immediately after the engine start in extremely cold condition.
In this case, if the noise goes off during warm up there is no abnormal function in the system.
This is due to the fluid characteristic in extremely cold condition.
11-58
1,
1
,
STEERING SYSTEM
*7
Grinding noise
(continuous)
While engine is running
Inspect and retighten fluid
line connection.
Refill fluid and vent air.
Vane pump aeration
1 Vane pump seizing
Replace Oil pump
r-- Assy
Pulley bearing seizing
of Oil pump Assy
Squeal, squeak.
While engine is running.
Folded hose, flat pipe
Replace
Maladjustment of V belt
Damaged or chared
V belt
Adjust or
replace
Run out or soilage of
V-groove surface of
Oil pump pulley or Idler
pulley
Clean or
replace
I
Grease shortage for
Idler pulley
Sizzling noise
(continous)
while engine is running
I Fluid aeration
Damaged tapered seat in
Gearbox Assy or
Connector
Abnormal inside of hose
or pipe.
Flat hose or pipe
I
Apply grease
I
Fix wrong part
causing aeration.
Replace fluid
and vent air
Replace
J
Rectify
or replace
*8 Oil pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when steering wheel is
turned at standstill there is no abnormal function in the system provided that the noise eliminates when the car is running.
*9 When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light
steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between
the disk and pads. If the noise goes off when the brake is released, there is no abnonnal function in the system.
*10 There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the
component parts are properly adjusted and have no defects.
Hidraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of conbined
conditions, i.e.,
Road surface and tire surface, Engine speed and turning speed of steering wheel, Fluid temperature and braking condition.
This phenomena does not indicate there is some abnormal function in the system.
The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step with
parking brake applied on concrete road and in "D" range for automatic transmission vehicle.
11-59
STEERING SYSTEM
Whistle
(continuous)
while engine is running
Abnormal tapered seat in
Gearbox Assy, Connector
or abnormal inside of Hose
Replace
Gearbox Assy,
Connector, Hose
Whine or growl
(continuous or
intermittent)
while engine is running
with/without steering
turned
Loosened installation of
Oil pump Assy, Pump
bracket
Retighten
I
*8
Abnormal inside of
Oil pump Assy, Hose
Replace Oil pump
Assy, Hose, if the
noise can be heard when
running as well as stand
still
.1 Torque converter growl
Remove power steering
V belt and confum
Creaking noise
(intermittent)
while engine is running
with steering turned
Abnormal inside of
.Gearbox Assy
Replace
Gearbox Assy
Abnormal bearing for
Steering shaft
Apply grease
or replace
*9
If the noise goes
off when brake is
released, normal
Generates when turning
steering wheel with brake
(service or parking)
applied
*10
Vibration
while engine is running
with/without steerinR
turned
I
I
Too low E/G speed at start :
Vane pump aeration 1
Fix. wrong part.
Vent air
Damaged valve in Oil pump
Assy, Gearbox Assy
Replace Oil pump
Assy, Gearbox Assy
I
Looseness or play of
Steering, Suspension
parts
I
11-60
,.~"I,j",
,~,
>+
Q
"'f
,~,~,,,,,,,,,~,,,,,
~
t L!
""_"1"1_'...,-______"_,""',.....
k·....-H....
• - ,.......
' '..........-"'...
,
Adjust and
Instruct customers
Retighten
I
I
r_.________
""1•_ _ _ _ _ _ _ _ _....
1'
STEERING SYSTEM
6)
Clearance table
Min.
allowance
mm (in)
Location
CD
Movable side of E/G mounting rubber - Pipes
Fixed side of E/G mounting rubber - Pipes
5 (0.20)
CV
Boot protector - Pipe
2 (0.08)
®
Oil pan - Pipes
10 (0.39)
Location
®
®
®
Boot - Boot protector
DOJ boot - around Inputshaft
Rubber coupling - Brake pipe
Min.
allowance
mm (in)
1 (0.04)
.9.515 (0.374)
(0.59)
10 (0.39)
@ Rubber coupling - Heater hose
@ Air stove - Pipes
10 (0.39)
@ Pipe - Pipe
®
Pump bracket - Shroud
18(0.71)
V belt - Shroud
15 (0.59)
@ Hose - Spare tire supporter
Idler cap - Shroud
13 (0.51)
®
V belt - Distributor
5 (0.20)
(j]) DOJ - Valve housing
5 (0.20)
@ Crossmember - Cylinder
1 (0.04)
5 (0.20)
@ Connector - Crossmember
1 (0.04)
®
(j) ATC hose - V belt
Air horn - V belt
~'
,
@
(
Pipe - Crossmember
Hose - Washer tank
10 (0.39)
1 (0.04)
1 (0.04)
5 (0.20)
15 (0.59)
10 (0.39)
@
I i 8,
(J)
®
@
A18-371
Fig. 11-166
11-61
STEERING SYSTEM
7)
Breakage of Hoses
IPressure hose burst
I
Excessive holding time of
relief status
Instruct
customers
I Malfunction of relief valve I
Replace Oil
pump Assy
I
Poor cold characteristic
of fluid
11Forced out Return
hose
I
I
Replace
fluid
Poor connection
I
I
I
I Correct
Poor holding of clip
I
J Retighten
I
I Replace
I fluid
Poor cold characteristic
of fluid
Fluid bleeding out or
hose slightly
Wrong layout, tensioned
I
Replace hose
Excessive play of E/G due
to deterioration of engine
mounting rubber
Replace
defective parts
Inproper stop position of
pitching stopper
Replace
defective parts
Excessive holding time
of relief status
Replace
instruct customer
Excessive tightening torque
for return hose clip
Replace
Power steering fluid, brake
fluid, E/G oil, electrolyte
adhere on the hose surface
Replace
Pay attention
on service work
Too many times use in
extremely cold weather
Replace
Instruct
customers
*11
lcrack on hose
I
I
*11 Although surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low
temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and
automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free
from before-mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or
cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspection
frequently when the car is used in hot weather areas, cold weather areas and/or a driving condition in which many times
steerings are required in short time. Particularly continuous work of relief valve over 5 seconds causes to reduce service lives
of the hoses, the oil pump assembly, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
11-62
",,"~,·,
.....
~"'.j.,-.,-.j·~~_~""""'~f
'-"1'I-'--____,..t t_ _'1",_,__________- - - -______
__
lb""''''''''''''''_·....11-...' ...
STEERING SYSTEM
11-12. Special Tools
925640000
925670000
925680000
925690000
SPANNER
SOCKET
HANDLE
STAND
Steering gearbox
Flare nut of control valve
Flare nut of control valve
Steering gearbox
~
Fig. 11-167
A3·167
~.
/
.
Fig. 11-168
A18-230
Fig. 11-169
925700000
925710000
925720000
WRENCH
PRESSURE GAUGE
REMOVER
Tie-rod
Oil pump
Idler pulley bearing
(
Fig. 11-171
A18-233
Fig. 11-172
A 18·231
(»
~
-S
~
A18-234
Fig. 11-173
11-63
A18·236
Fig. 11-170
A18·232
CHAPTER
11~
PEDAL AND CABLE
Page
12-1.
PEDAL ........................................... 12-2
1. Com~onent Parts ................................. 12-2
2. On-car Services ................................... 12-3
3.
Removal and Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .. 12-3
4. Inspection ...................................... 12-4
5. Assembly....................................... 12-4
6. Installation...................................... 12-5
12-2. CABLE ........................................... 12-6
1.
Clutch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12-6
2. Accelerator Cable ................................. 12-7
3. Speedometer Cable ................................ 12-8
SlIBARU
PEDAL A NO CABLE
12·1. Pedal
1. Component P arts
1 Pedal bracket
2 Pedal shaft
3 Flange nut
~
6
7
8
9
10
Stop light switch
KIck-down switch
Accelerator
. (AT only)
St
spnng
opper
Accelerator pedal
~~~~~:ator pedal pad
11 Bushing
12 B rake pedal
13 CIeVlS
. pin
14 Snap pin
15 Pedal pad
16 Stopper
17
Brake pedal spring
18 Cl
utch pedal
19 Washer
20 Clip
21 Clevl's pm
.
22 Clip
23 Clutch
24
CI
cable clamp
utch cable
25 Clamp
26 Clamp
27 Clip
28 Clutch
.
bracket
(for c ~wltch
29 Cl
rUlse control)
utch switch (for
.
30 Washer (AT I cruIse control)
31 Clip (AT
on y)
32 S
only)
(::p & ~rake switch
r crUIse control)
Tightening torq
T1: 5.4 _9
ue N·m (kg-m, ft-Ib)
.3 (0.55 -0 9
T2: 13 _23 (
. 5,4.0 - 6.9)
., - 17)
1.3-239
j
A20-093
Fig. 12-1
I,
II
"~'_4~. 'k~_ffi~'~I12-~2~~,,~~~~~~
_____
,
__
1
PEDAL AND CABLE
2. On-car Services
2) Clutch Pedal
3) Accelerator Pedal
1) Brake Pedal
1) Check clutch pedal free play by
operating pedal by hand.
If it is not in specified value, adjust it
by turning adjusting nut on engine side
end of clutch cable.
Check pedal stroke and free play by
operating accelerator pedal by hand.
If it is not in specified value, adjust it
by turning nut connecting accelerator
cable to carburetor.
1) Check position of pedal pad.
If it is not in specified value, adjust it
by adjusting power brake unit operating rod length.
at clutch pedal pad
13 - 20 mm
(0.51 - 0.79 in)
Reserve distance
(Remaining clearance)
Free play
01
2 - 3 mm
(0.08 - 0.12 in)
Locking nut
tigh tening torq ue
0-5mm
(0 - 0.20 in)
at pedal pad
44- 50mm
['
om", of abl'
clutch release fork
More than 80 mm (3.15 in)!
294 N (30 kg, 66 Ib)
Check free play by operating pedal by
hand.
If it is not in specified value, adjust it
by adjusting position of stop lamp
switch.
Free play at
pedal pad
(1.73 - 1.97 in)
Stroke
at cable end
29 - 33 mm
(1.14 - 1.30 in)
5.4 - 9.3 N'm
(0.55 - 0.95 kg-m,
4.0 - 6.9 ft-lb)
NOTE:
Be careful not to rotate stop lamp
switch.
Brake pedal free play
5 - 11 mm (0.20 - 0.43 in)
I Stroke at cable end
2 Pedal bracket
Pedal play
13-20mm
(0.51 - 0.79 in)
r-~~
if(
Q)
Free play 2 - 3 mm (0.08 - 0.12 in)
I
\
® \
I I
\
OM-526
Full stroke
17 - 18 mm (0.67 - 0.71 in)
\
~\~~~ (V
3 Accelerator pedal
4 Stroke at pedal pad
5 Pin
6 Toe board
7 Accelerator cable
A20-073
Fig_ 12-4 Operation at accelerator
pedal
@\y~'\.@
@ \
I
2
3
4
5
6
Stop lamp switch
Free play
Stroke
Remaining clearance
Mat
Toe board
135- 150 mm
(5.31 - 5.91 in)
A20·054
3. Removal and
Disassembly
I Lock nut
2 Adjusting nut
3 Release fork
A20-051
Fig. 12-2 Checking brake pedal
Fig. 12-3 Adjusting clutch pedal
free play
2) Apply grease to operating rod
connecting pin to prevent it from
wearing_
2) Apply grease to connecting portion of clutch pedal and clutch cable
and contact point of clutch release
fork and clutch cable nut.
12-3
1) Disconnect ground cable from
battery.
2) Disconnect accelerator cable from
carburetor.
3) Disconnect/detach clutch cable
from the following parts.
a. Clutch release fork
b. Clamp on transmission case
c. Grommet of toe board
4) Detach trim panel and lower
steering column.
PEDAL AND CABLE
5) Disconnect the following parts
from pedal bracket.
a. Operating rod of brake booster
b. Electrical connectors (for stop light
switch, etc.)
c. Accelerator cable
2) Accelerator Pedal
Clean up all parts and inspect for wear
and damage.
Replace it with new one if defective.
NOTE:
t
•
Be careful not to kink accelerator
cable.
6) Remount pedal bracket ASSY
along with clutch cable while supporting brake booster in engine room.
7) Detach following parts from pedal
bracket assembly.
a. Accelerator pedal return spring
b. Accelerator pedal
c. Clutch cable
d. Brake pedal return spring
e. Circlip retaining pedal shaft
f. Clutch pedal and brake pedal
g. Stop light switch
A20-052
Fig. 12-7 Inspecting accelerator
pedal
1
2
3
4
Pedal shaft
Clutch pedal
Brake pedal
Brake pedal return spring
A20-0B1
Fig. 12-9 Installing pedal
4) Clean and apply grease to shaft
3) Stop Light Switch
Inspect switch stroke and operation.
If operation is not smooth and/or
stroke is not within specified value,
replace it with new one.
and inside of bore of accelerator pedal.
Install accelerator pedal onto pedal
bracket.
5) Set brake pedal position by adjusting position of stop light switch.
4. Inspection
1) Pedal Shaft and Bushing
1)
Clean off grease and dust, and in-
spect for wear and damage.
2) Inspect play between bushing and
shaft, replace bushing and/or shaft
with new one if defective.
_:-T
Push
1.8- 3.3 mm (0.071 - 0.130 in)
I 1II"iTi11r-..!iiiiilr--------..
Stop
light
switch
Switch ON
A20-009
f----
--175 mm
-i
(6.89 in)
Fig. 12-8 Inspecting stop light
switch
A20-053
5. Assembly
A20-040
Fig. 12-5 Inspecting play between
bushing and shaft
1) Attach stop light switch, etc. to
pedal bracket temporarily.
2) Clean inside of bores of clutch
pedal and brake pedal, apply grease,
and set bushings into bores.
3) Align bores of pedal bracket,
clutch pedal and brake pedal, attach
brake pedal return spring, and then
install pedal shaft completely to prevent it from rotating.
NOTE:
Fig. 12-6
a. Make sure of 2 washers being
installed at both sides of brake
pedal.
b. Clean up inside of bushes and apply
grease before installing shaft.
12-4
Fig. 12-10 Adjusting brake pedal
position
Torque
(Lock nut)
5.4 -- 9.3 N·m
(0.55 - 0.95 kg-m,
4.0 - 6.9 ft-lb)
6) Connect clutch cable to clutch
pedal by using clevis pin and clip.
Insert clutch cable outer end to
groove of pedal bracket, and hold it
with cable clamp.
7)
Clamp bolt
torque
5.4 - 9.3 N·m
(0.55 - 0.95 kg-m,
4.0 - 6.9 ft-lb)
PEDAL AND CABLE
5) Pull out accelerator inner cable to
its maximum stroke, and attach it to
accelerator pedal.
Pull accelerator cable from carburetor
side.
NOTE:
Make sure that outer end of clutch
cable and two washers are inserted
into groove of pedal bracket com·
pletely.
NOTE:
Be careful not to kink accelerator
cable.
6) Connect electrical connectors for
, A20-082
Fig. 12·11 Installing pedal ASS Y
6. Installation
1) Insert clutch cable into hole on
toe board, and set pedal bracket above
steering column.
NOTE:
Tightening
torque
13 - 23 N'm
(1.3 - 2.3 kg-m,
9 - 17 ft.lb)
4) Connect operating rod of brake
booster to brake pedal using clevis pin
and snap pin.
Be careful not to bend clutch cable
too much.
2) Insert bolts of brake booster into
holes on toe board, support it from
engine room, and fit holes of pedal
bracket onto the bolts. A t this time,
At this time, operating rod of brake
booster should be engaged with brake
pedal.
3) While pushing pedal bracket up·
ward firmly, tighten 4 nuts and 2 bolts
at its upper surface.
stop light switch, etc.
7) Install steering column as before.
8) Connect accelerator cable to
carburetor.
NOTE:
Make sure to check operation of
accelerator cable by operating accelerator pedal by hand.
9) Attach clutch cable grommet to
toe board, and then connect clutch
cable to clutch release fork.
NOTE:
Never fail to cover outer cable end
with boot.
1 Clevis pin
2 Snap pin
3 Operating rod
A20-083
Fig. 12-12 Connecting operating rod
and brake pedal
12-5
PEDAL AND CABLE
12·2. Cable
1. Clutch Cable
NOTE:
Apply grease to contact point of
adjusting nut and release fork.
Release fork
@;('"
Free play:
2-3mm
(0.08 - 0.12 in)
SUBARU 1600
1
2
3
4
5
~H
(Y---'
Stroke:
17mm
(0.67 in)
Locknut
Clutch cable adjusting nut
Clutch cable assembly
Clamp
Boot
Tightening torque N·m (kg-m. ft-Ib)
T: 5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.9)
Brake booster
(Master-Vac)
Insert outer cable end into the
/I
groove completely
NOTE:
a. When installing pedal and bush,
clean up inside of bore of them and
apply grease.
b. Apply grease to connecting portion
of clutch cable and pedal.
c. Make sure that outer end of clutch
cable and two washers are inserted
into groove of pedal bracket com·
pletely.
d. Make sure that one end of cable
clamp is engaged with slit of pedal
bracket firmly.
1
2
3 Clamp
A20-094
Fig. 12-13
12-6
,
I'
PEDAL AND
"~~C:A~B~L=E~____________
~---
2.
Accelerator
Cable
~r
//
Pitching stopp
/
TO"~"O !(I
'0.
Accelerator cable
,I
)
\
,
Spare ti re su p porter
::~::i
I
------------
~-;1l\.
~
- - ,~"~['\ (: /"
--~
mr--
;iii f
-
~-
I
I I Brake booster (Master-Vac)
-
<-
-'----',
0
- ----c:::..::
=-
:~i) ~"~j Ii
.. i--....
I
A20-095
Fig_ 12-14
12-7
PEDAL AND CABLE
3. Speedometer Cable
MT vehicle
Accelerator cable
Speedometer cable
Cross Sectional View @
Pedal bracket
Be sure to insert the tongue
of cable end into the groove
of speedometer shaft .
To speedometer
.,,\
~\ \
Brake booster
(Master·Vac)
~":'
~'l';\
" ..... ··~SPeedometer
..S
topp.e.
_ r
",~/ /
'.'
=.............---~--~-".../
~/
AT vehicle
-........-----,}
//~
/"
_ _ ..
I--~--
/
.-
/~s_'"'
oo"m"
View@)
A20·096
Fig. 12·15
12-8
I
....
,'
II
'
- yy-
CHAPTER
1J~
HEATING, VENTILATING AND
AIR·CONDITIONING SYSTEM
Page
13-1. SPECIFICATIONS AND SERVICE DATA ................... 13- 2
13-2. HEATING AND VENTILATING
1. Outline ......................................... 13- 4
2. On-car Services ................................... 13- 7
3. Repair for Component Parts .......................... 13- 9
13-3.
AIR-CONDITIONING
1. Outline ......................................... 13-12
2. On-car Services ................................... 13-19
3.
13-4.
Repair for Component Parts .......................... 13-30
TROUBLESHOOTING
1. Heating and Ventilating .............................. 13-38
2. Air-conditioning ................................... 13-41
13-5. SPECIAL TOOLS .................................... 13-50
REMARKS:
The description for air-conditioning system in this chapter pertains only to
the SUBARU AIR-CONDITIONING SYSTEM that is installed as original
equipment by the manufacturer (FUJI HEAVY INDUSTRIES, LTD.) .
SURA-RU
•
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
13-1. Specifications and Service Data
1. Heating and Ventilating
ITEM
Heating capacity
SPECIFICATIONS
CONDITION
4.536 kW (3,900 kcal/h, 15,475 BTU/h)
• Temperature difference between hot
water and inlet air: 65°C (149°F)
• Hot water flowing volume:
360 Q/h (95.1 US gal/h,
79.2 Imp gal/h)
340 m 3 /h (12,000 cu ft/h)
-
sirocco fan
140 x 65 mm (5.51 x 2.56 in)
-
160W
at 12 V magnet motor
140.5 x 180 x 49 mm
(5.53 x 7.09 x 1.93 in)
-
Air volume
Fan
type
diameter x width
Fan motor
Heater core size
(width x height x thickness)
2. Air-conditioning
Item
Type of air conditioner
Standard cooling efficiency (IMACA)
Refrigerant
Compressor
Type
Discharge
Max. permissible speed
Magnet clutch
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Condenser
Type
Front area
Core thickness
Radiation area
Receiver dryer
Capacity
Strainer
Expansion valve
Type
Evaporator
Type
Dimensions (W x H x T)
Specifications
Reheat air mix type
4.419 kW (3,800 kcal/h, 15,078 BTU/h)
R-12 (CCL 2 F 2 ) [0.74 - 0.79 kg (1.63 - 1.74Ib)]
Swash plate type MJS 170-5AV
170 cm3 (170 cc, 10.37 cu in)/rev.
7,000 rpm
Dry, single-disc type PMCI35-8AA
40W
A type
145 mm (5.71 in)
0.92
Corrugated fin type
0.147 m 2 (1.58 sq ft)
26 mm (1.02 in)
3.51 m 2 (37.8 sq ft)
410 cm 3 (410 cc, 25.02 cu in)
80 to 120 meshes
Automatic temperature control, internal pressure-balance type
Corrugated fin type
101 x 170 x 230 mm (3.98 x 6.69 x 9.06 in)
13-2
-
F'f'I.f
If"
t
f
r
F
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
Item
Specifications
Blower fan
Fan type
Outer diameter x width
Power consumption
Condenser fan
(Sub fan)
Motor type
Power consumption
Fan outer diameter
Print type
95 Wat 12 V
300 mm (I 1.81 in)
Radiator fan
(Main fan)
Motor type
Power consumption
Fan outer diameter
Magenet type
120Wat12V
280 mm (I 1.02 in)
Idling speed with F.I.C.D. in operation
Low-pressure-switch working pressure
High-pressure switch
Pressure switch (Main fan control)
Silocco fan type
140 x 65 mm (5.51 x 2.56 in)
160Wat12V
950 ± 50 rpm
196 ± 20 kPa (2 ± 0.2 kg/cm 1 , 28 ± 2.8 psi) G
2,403 ± 98 kPa (24.5 ± 1.0 kg/cm z , 348 ± 14 psi) G (ON -+ OFF)
1,912 ± 98 kPa (19.5 ± 1.0 kg/cm z ,277 ± 14 psi) G (OFF -+ ON)
1,569 ± 78 kPa (16.0 ± 0.8 kg/cm z ,228 ± 11 psi) G (ON -+ OFF)
1,275 ± 98 kPa (13.0 ± 1.0 kg/cmz, 185 ± 14 psi) G (OFF -+ ON)
13-3
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
13·2. Heating and Ventilating
1. Outline
1) Heater Unit and Duct
®
@
@
A23·128
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Heater case (L.H.)
Heater case (R.H.)
Upper lever
Upper shutter
Screw
Upper link
Bushing
Mode lever
Defroster link
Lower link
Air mixing shutter
Heater cock CP
Protector
Heater core
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Defroster shaft
Defroster shutter (R.H.)
Defroster shutter (L.H.)
Rod clamp
Lower lever
Lower shutter
Defroster rod
Defroster shutter shaft
Guide
Resistor
Intake packing
Shaft bushing
Hold spring A
Hold spring B
43
44
45
46
47
48
49
50
51
52
53
54
Ventilation link A
Ventilation shutter
Ventilation link B
Ventilation rod
Cushion
Lower duct
Rear duct (L.H.)
Rear duct (R.H.)
Hose clamp A
Hose clamp B
Hose bracket
Heater cock rod
Air mixing lever
Ventilation packing
Ventilation lever
Heater duct
Heater inlet hose
Heater outlet hose
Hose clamp
Hose clamp
Connector
Heater hose grommet
Clip
Vacuum connector
Vacuum hose
Vacuum hose grommet
Fig. 13-1 Component parts
13-4
'~"h'--I-
~
,,-'v.
i"•
.. ,- .........
~"
.....
i h
~
t
>4+_,........
~
1**
S
I
I,
I·.t n
pI
I ..
..
-
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
2) Blower Assembly and Control System
A23·048
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fresh air ventilation lever (Standard type)
Fresh air ventilation lever (Multi type)
Ventilation cable
Ventilation grille
Ventilation knob
Vacuum pipe
Vacuum hose
Check valve
Vacuum hose
Vacuum hose
Vacuum switch
Spring
Temperature control cable
Fan switch
Fig. 13·2 Component parts
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Bushing
Cable clamp
Mode control cable
Plate
Panel
Cigarette lighter cap
Rear defogger switch
Bulbs
Cord clamp
Cord assembly
Fan and temperature control knobs
Mode lever knob
Harness
Motor assembly
Blower
13-5
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Packing
Blower case (R.H.)
Bushing
Intake shutter lever
Spacer
Clip
Bushing
Actuator
Packing
Intake shutter return spring
Blower case (L.H.)
Intake shutter shaft
Intake shutter
Springs
------,
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
Control lever
VENT
The heater control system consists
of a mode lever which selects air out·
lets, temperature control dial which
regulates the outlet air temperature,
and fan switch.
The fresh air ventilation control
lever is located on the instrument
panel.
Fan switch dial
s:
Off
::::
OFF
=-=====:-J ON
ON
Mode lever
A23·126
A23·144
Fig. 13·3
Operation of control lever and air flow diagram
Position of
CIRC
A/C MAX
A/C
HEAT
B/L
DEF
Temperature
1>1)
.§
~"
\';
'
i"~
'1~»0"
,
e<:t
!~>,'
:I:
HOT
Fan switch
c::
-
.9
OFF
ON
ON
ON
ON
OFF
ON
ON
ON
ON
Temperature
~
i:
>
....
'c;j
-e
COLD
u
....
0
u..
Fan switch
A23·127
NOTE:
a.
fresh air flow
• heated air flow
b. It is possible to use fresh air ventila·
tion independent of above opera·
tion.
(J
D
means defroster shutter close
means defroster shutter open
c. In this diagram, the fresh air venti·
lation lever is set in the "OFF"
position.
Fig. 13·4 Air flow diagram
13-6
t
'IM,
t
I
VI I
,
T'
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
2. On-car Services
1) Mode Lever
Check
Check air leakage as follows.
1) Start the engine and set temperature control dial to COLD position.
Then set fresh air ventilation lever
of OFF position.
2) Then check air leakage after
switching on the fan to the fourth
step.
i) A/C position
a. With mode lever at this position, outside air is directed
to compartment only from
center and side air outlets.
If leakage exceeds 0.5 m/sec (1.6
ft/sec) through lower outlet or
more than 0.8 m/sec (2.6 ft/sec)
through DEF nozzle, it is necessary to adjust control system.
To center
outlet
ii) HEAT position
With mode lever in this position,
most of outside air is directed
through lower air outlets, with
air also discharged from defroster nozzle at a speed of 1 to 2
m/sec (3 to 7 ft/sec) into compartment.
If leakage exceeds OJ m/sec (1.0
ft/sec) through center or side
outlets, adjust control system.
iii) DEF position
With mode lever in this position, air is discharged only from
defroster nozzle. If leakage exceeds 0.5 m/sec (I.6 ft/sec)
through lower outlet or OJ
m/sec (1.0 ft/sec) through center
and side outlets, adjust the
control system.
6) After connecting the cable to
lever B, connect the cable to the clamp
while pulling the cable up backward.
Standard
Value F
48 mm (1.89 in)
eiRe
and ~
upper,
\
48mm (1.89inl
1 Cable
2 Oamp
3 Lever B
A23-072
Fig. 13-9 Connecting the cable'
Adjustment
1) Remove luggage shelf on the passenger's seat side.
2) Remove right defroster duct from
heater unit.
3) Disconnect the cable from the
clamp at heater unit.
7) Disconnect defroster shutter shaft
from plastic clamp at lever D.
outlet
Push
A23-081
If air leakage exceeds 0.5 m/sec (1.6 ft/secl.
1 Shaft
2 Lever D
3 Clamp
Fig. 13-10 Disconnecting the shaft
adjust control system.
A23-078
Fig. 13-5 Leakage at lower outlet
1 Cable
2 Clamp
A23-080
Fig. 13-7 Disconnecting the cable
b _ Use the following simple method
for checking air leakage.
Hold a lighted cigarette near air
outlet. If stream of cigarette
smoke flows in the dire~tion of
outlet air, air leakage of at least
0.3 m/sec (1.0 ft/sec) is present.
8) Connect the shaft to plastic clamp
at the lever D while pulling the shaft
up backward.
4) Set mode lever to CIRC position.
S) Set the linkage at the heater unit
side to CIRC position. (Pulling lever B
up backward)
eiRe
~":/
I~rc""'~
less than
0.3 m/sec (1.0 ft/secl
0.3 - 0.5 m/sec
(1.0 - 1.6 ft/secl
A23-082
Fig. 13-11 Connecting the shaft
A23-079
Fig. 13-6 Simple methods for
measuring leakage
Fig. 13-8 Setting the lever
13-7
9)
Install defroster duct.
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
10) In this situation, check air
leakage according to the predescribed
procedure.
Outside air
temperature
Outlet air
temperature
-20°C (-4°F) more than 50°C (122°F)
Ooc (32°F) more than 60°C (l40 0 F)
2) Disconnect the cable for temperature control from the clamp at
the heater unit side.
'.. 0
2) Temperature Control Dial
Check
Check outlet air temperature as
follows.
Start the engine and set fresh air
ventilation lever to OFF position.
After warming up the engine (about 7
to 10 minutes later), check the tern·
perature as follows.
i) LOWER position
a. Set fan switch dial to the first
step and temperature control
dial to COLD position.
b. Measure outlet air temperature
at lower outlet of heater unit.
(The measurement of outlet
air temperature can be carried
out by a usual thermometer.)
In this case outlet air temperature at lower outlet is same as
outside air temperature.
Lever~~
1
2 Clamp
3 Cable
A23·084
Fig. 13-13 Measuring the outlet air
temperature
c. If outlet air temperature does
not rise until these temperatures,
adjust the control system of
water cock.
d. When poor flow of outlet air
compared with other vehicles
arises, check connection of
defroster duct and nozzle or
defroster duct and heater unit.
A23-136
Fig. 13-16 Disconnecting the cable
3) Set temperature control dial to
COLD position.
4) Set lever E to COLD position.
Lever E
A23-137
Fig. 13-17 Setting lever E
Defroster nozzle
Defroster duct
A23·085
Heater unit
Fig. 13-14 Checking the connection
of defroster duct
Thermometer
5) After connecting the cable to
lever E, connect the cable to the clamp
while pulling the cable up.
Standard
value G
20 mm (0.79 in)
Adjustment
A23·083
Fig. 13-12 Measuring the outlet air
temperature
1) Disconnect water cock rod from
plastic clamp at lever A.
20mm
c. If outlet air temperature is more
higher (about 5 degrees) than
outside air temperature, adjust
the control system of water cock.
ii) DEF position
a. Set fan switch dial to the fourth
step and temperature control
dial to HOT position.
b. Measure outlet air temperature
at defroster nozzle. In this case
outlet air temperature rises as
follows.
(0.79 in)
1 Lever E 3 Clamp
2 Rod
4 Lever A
A23-135
Fig. 13-15 Disconnecting the rod
13-8
1 LeverE
2 Clamp
3 Rod
A23-138
Fig. 13-18 Connecting the cable
-~-
-----.--------~-------.
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
6) Set lever E at the water cock to
COLD position again.
7) Set lever A to COLD position.
8) Connect water cock rod to plastic
clamp at lever A.
2) Set ventilation lever to OFF posi·
tion.
3) Set the linkage at the heater unit
side to OFF position. (pulling lever C
up backward.)
A23-075
1 Lever E
2 Rod
3 Clamp
4 Lever A
A23-139
Fig. 13-21 Setting the lever
4) Remove heater hose grommet
from bulkhead.
5) Remove radio box or console box.
6) Remove luggage shelf and instru·
ment panel.
7) Detach heater duct between heat·
er unit and blower assembly.
8) Remove both defroster nozzles.
9) Remove two bolts on upper part
of heater unit.
10) Uft up heater unit about 10 mm
(0.39 in), and take it out backward.
11) Remove water cock.
12) Disconnect rod between left and
right defroster shutters from plastic
clamp at right defroster shutter.
13) Separate heater unit in two parts
(left and right).
14) Take out heater core and shut·
ters.
4) After connecting the cable to
lever C, connect the cable to the clamp
while pulling the cable up backward.
Fig. 13-19 Connecting the rod
Assembly and installation
3) Fresh Air Ventilation Lever
Standard
value H
29 mm (l.l4 in)
1) Attach heater core and shutters
to cases.
Check
Check air leakage as follows.
1) Set fan switch dial to OFF posi·
tion, mode lever to CIRC and fresh air
ventilation lever to OFF.
2) Measure the leakage at center
outlet while running at a speed of 80
to 100 km/h (50 to 62 MPH).
3) In this case, if leakage exceeds
0.3 m/sec (I.O ft/sec) through center
outlet, adjust the control system.
1 Lever C
2 Cable
3 Clamp
1 Ventilation shutter
A23-076
Fig. 13-22 Connecting the cable
Adjustment
2 Upper shutter
3 Air mixing shutter
4
Lower shutter
A23-068
Fig. 13-23
1) Disconnect the cable from the
clamp at the heater unit side.
3. Repair for
Component Parts
2) Fit two halves of unit heater case
together and secure with springs.
1) Heater Unit
Removal and disassembly
1 Cable
2 Clamp
A23-089
Fig. 13-20 Disconnecting the cable
1) Disconnect ground cable from bat·
tery.
2) Remove radiator drain plug, and
drain coolant.
3) Disconnect both inlet and outlet
hoses from heater pipe.
Springs
Fig. 13-24
13-9
--'
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
3) Connect rod between left and
right defroster shutters with clamp.
1
A23·049
A23·066
4) Attach water cock.
5) Install heater unit on body.
Bolts
Fig. 13-26
6) Install defroster nozzles on both
sides.
A23-058
Fig. 13-28
Fig. 13·30
12) Fill radiator with coolant.
13) Connect ground cable to battery.
3) Set both levers A and E to COLD
position, and connect water cock rod
with plastic clamp at lever A.
1 Rod
2 Clamp
Fig. 13-25
Inlet hose clamp
2 Outlet hose clamp
2) Water Cock
Removal
1) Follow the same procedures 1) to
4) for "Heater Unit".
2) Remove left defroster duct from
heater unit.
3) Detach water cock cover.
4) Disconnect water cock rod from
plastic clamp at lever A.
5) Remove both inlet and outlet
hose clamps.
®®r@(
C~~r
\~~ LJ~
CD ,/"
Clam~--------.J
1 Lever E
3
2 Rod
4 Lever A
A23·134
Fig. 13-31
NOTE:
Outlet hose clamp can be removed by
twisting cotter pin counterclockwise.
6) Remove water cock by pulling it
up forward.
Installation
1) Install water cock with three
screws.
1 Rod
2 Clamp
3 Lever A
A23-130
Fig. 13-32
4) Attach water cock cover.
Fig. 13-27
7) Attach heater ducts between heater unit and blower assembly.
8) Install luggage shelf and instrument panel on body.
9) Attach radio box or console box.
10) Fit heater hose grommet onto
bulkhead.
11) Connect both inlet and outlet
hoses with heater pipe.
A23-131
Fig. 13-29
A23-129
2) Connect both inlet and outlet
hoses with clamps.
13-10
Fig. 13-33 Removing water cock
cover
---
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
5) Attach left defroster duct.
6) Fit heater hose grommet onto
bulkhead.
7) Connect both inlet and outlet
hoses with heater pipe.
8) Fill radiator with coolant.
9) Connect ground cable to battery.
8) Install glove box and luggage
shelf.
9) Connect ground cable to battery.
4) Control System
Removal
3) Blower Assembly
Fig. 13-35
Removal and disassembly
1) Disconnect ground cable from
battery.
2) Remove luggage shelf and glove
3) Install blower assembly onto body.
1) Disconnect ground cable from
battery.
2) Remove radio box or console box.
3) Remove control panel from instrument panel.
4) Disconnect cables for temperature
control, mode
box.
control
and center
ventilation from heater unit.
3) Detach heater duct from blower
assembly.
4) Set mode lever to CIRC position
and disconnect vacuum hose from
actuator.
NOTE:
If mode lever is not set to CI RC
position, it is difficult to disconnect
vacuum hose.
5) Disconnect electric connector for
blower motor.
6) Remove actuator from blower assembly.
7) Remove blower assembly from
body.
8) Remove blower and motor, and
detach blower from motor.
9) Separate blower case into two
parts.
Fig. 13-36
4) Install actuator onto blower assembly with two screws and clip.
Fig. 13-39
5) Remove control assembly, and
disconnect electric wires and vacuum
hoses.
Installation
I) Connect electric wires and vacuum hoses with control assembly, and
then install it.
Assembly and installation
Screws
1) Install springs and intake shutter
return spring onto blower case.
Clip
A23-062
Screws
Fig. 13-37
5) Connect electric connector for
blower motor.
6) Connect vacuum hose to actuator.
7) Attach heater duct to blower assembly.
2
1 Springs
2 Return spring
Fig. 13-40
A23·147
Fig. 13-34
NOTE:
Check the operation of intake shutter
and its return spring.
2) Attach blower to motor, and install them onto blower case.
A23-061
Fig. 13-38
13-11
2) Connect cables as described in the
previous item "On-car Services".
3) Attach control panel to instrument panel.
4) Install radio box or console box.
5) Connect ground cable to battery.
,
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
13·3. Air·Conditioning
1. Outline
CD
Tightening torque N·m (kg-m, ft-Ib)
T1: 24 - 39 (2.4 - 4.0, 17 - 29)
T2: 23 - 26 (2.3 - 2.7,17 - 20)
T3: 22 - 25 (2.2 - 2.5, 16 - 18)
1
2
3
4
5
6
7
8
9
Compressor
Condenser
Receiver drier
Condenser cooling fan (Sub-fan)
Actuator (F.I.C.D.)
Belt
Compressor bracket
F.I.C.D. lever
Pipe and hose
10
11
12
13
14
15
16
17
18
Pipe and hose
Relay
Tension pulley
Evaporator
Drain hose
Grommet
Grommet
Grommet
Pipe
13-12
II
f
Pipe
Clamp
Spacer
Microswitch
Relay
Fuse (A)
Fuse (B)
Relay
A26·123
Fig. 13-41 Component parts
iJ.
19
20
21
22
23
24
25
26
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
1) Air Flow System
The flow of air in the system changes
according to the position of the
control lever, as follows:
CIRC-A/C MAX
1. Intake Shutter
Room air
2. Air Mix Shutter
Cooled air does not flow into heater core
3. Lower Shutter
Shut
4. Temp Dial
Cold
5. F.I.C.D.
Operative
A26-007
Fast idle control
device (F.LC.D.I
0-ltside ~ir
~ '\li
,
,
I
Magnet valve V
.
Upper shutter
Air mix
shutter
Outside air
~'L
Evapora~/~ Intake shutter
I
~~ J..----t--~ D~ :~om
Defroster
ent
nozzle
. shutter
I·
Heater
core
Blower
motor
~
~
r:-.--~-:-:--Dn.edfr~o;;st;;er~sh utter
:·Lower shutter
[[]]]]
Fig. 13-42
13-13
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
AIC
L Intake Shutter
Outside air
2_ Air Mix Shutter
Cooled air flow into heater core
3_ Lower Shutter
Shut
4_ F.LC.D.
Operative
A26-010
nozzle
shutter
A26-012
Fig_ 13-43
B/L (Bi-level)
L Intake Shutter
Outside air (Fresh air)
2. Lower Shutter
Open
3. FJ_C.D.
Inoperative
A26-013
A26-015
Fig_ 13-44
13-14
, *
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
HEAT
1. Intake Shutter
Outside air (Fresh air)
2. Lower Shutter
Open
3. Defroster Shutter
Shut
4. F.I.C.D.
Inoperative
A26-016
Fast idle control
device (F .I.C.~.l . ,Upper shutter Outside air
Outside air I Air mix shuttei
iL Intake
/
shutter
----u~_\
.- Ev~rat~JJJI
D«..J
-~
~
:~m
Heater L.J Blower
core ~~motor
!ED
, Defroster sh utter
Lower shutter,iIIiIilI
-~-1illID
.wj-~-~
A26-018
Fig_ 13-45
DEF (Defrosting)
1. Intake Shutter
Outside air (Fresh air)
2. Lower Shutter
Shut
3. Defroster Shutter
Open
4. F.I.C.D.
Operative
A26-019
.
~ 4fi
~"-""_-
.
Fast idle control
device (F .I.C.D.l
Outside air
." l. _ "l
. ' '-J
Magnet valve
Defroster Vent
L\.n.OZZleI
~~
¢:::~,
~
Shutt."
.
k- . '.-. - -.- D
¢:::'"
--------- - - _.- _._- '
--:-
U
h
Outside air
pper sutter
"
.·Air mix shutter[
~l Intake
E~q~~or
/
shutter
'.Jg~~'Room
~.~~eaw/~
I ,
core
c-.
.-
.
~ air
-
Blower
~motor
:::::::>~~
-----~-
Defroster shutter
Lower shutter
J
1]11::· . -.[i~=:-:::m
.. ,
A26-021
Fig. 13-46
13-15
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
2) Vacuum System
The vacuum system's composition
is shown below. It utilizes engine
vacuum to operate the lever of the
carburetor linkage (F.I.C.D.) and the
changeover shutter in order to intake
internal compartment or exterior air.
1) When the air conditioner switch
is turned on, the air valve communicates between the source and the
actuator sides to operate the actuator (F.I.C.D.). This pulls the lever
(F.I.C.D.), which causes idling speed
to increase until the set value (950 ±
50 rpm) is reached.
2) If the control lever is CIRC-A/C.
MAX., the vacuum switch closes between the source and actuator sides,
thus passenger compartment air alone
is drawn into the unit.
If the mode lever is in a different
position, the vacuum switch is open
between both sides, so the actuator
operates, and exterior air is introduced.
1
2
3
4
5
@
@
I ntake manifold
6
7
8
9
10
Actuator (F.I.C.D.)
Lever (F.I.C.D.)
Air valve
Connector
Check valve
Vacuum switch
Control lever
Actuator
Shutter
Vacuum hose
4
®
Outside air
®
®
A26-Q22
Fig. 13-47
13-16
~-.
---'
3) Electrical System
1) When the mode (control) lever is
set at "CIRC-A/C. MAX", "A/C", or
"DEF", the air conditioner switch
(microswitch) will be turned on. In
this condition, when the blower switch
is turned on, the blower relay, air
conditioner relay, and sub-fan relay
will activate. This in turn causes the
blower motor, air valve (F.I.C.D.),
compressor clutch, and sub-fan to
activate.
2) In addition, activating the pressure switch (main fan control) or the
thermo switch will cause the main fan
to activate.
3) With the main fan in operation,
turning on the headlights will cause
the condenser fan (sub-fan) to stop.
4) When either the low pressure
switch or the thermostat activates, all
air conditioner circuits except the
blower motor will deactivate. In this
condition, however, when the temperature of the coolant in the radiator is
high enough and the thermo switch
turns on, the radiator fan (main fan)
will activate.
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
Wiring harness installation and electrical devices
Front
Condenser far\ (Sub·fan)
Radiator thermo
Radiator fan (Main fan)
(Automatic transmission
~oc:>-.. vehicle only)
o
Battery
o
Compressor
Front wiring harness
Y RG
Air valve
(F.I.C.D.)
L
B RB BW
AIC relay
GTlJ
I:I:Jilil
Pressure switch
(Main fan control)
(Brown)
fan relay
(Engine room)
Main fan
control
relay
(Occupants room)
~He I" " )1
RB
~
'0
[]
lEr
------
Instrument panel harness
BY
~,
YW
YW
RB
~Blower
relay
Blower
switch
Thermostat
AIC
microswitch
~,
Blower
motor
A26-113
Fig. 13-48
13-17
r
,I
r---_--------------
"T'I
~*-
-
~.
C:-l
.t.
10
~\
il
~
~
--
To battery'
~
To lighting
switch
I
!
Fusible link
Sub-fan
relay (N.a.)
Pressure switch
(Main fan control)
~~0::..:..8::.:5=--=-L-_c:~
It)
Thermo switch
B
I~~
~ 20A
Ignition~ Fuse for
switch
blower
00
20A
ci
0.85 L
0.85Y
3W
Z
0.85 L
-I
O.
r-
B
~
Air conditioner switch
Z
0.85 BW
...w
...I
RW: AIT
RG: MIT
G')
Front wiring
harness
connector
00
0.85 GW
0.85 BY
(:)
o
z
00
('oj
('oj
l>
'"cr>
~
'"...
Color
RB
RW
RG
YM
L
LR
LB
LG
BW
BY
GW
B
W
code
Red-Black
Red-White
Red-Green
Yellow-White
Blue
Blue-Red
Blue-Black
Blue-Green
Black-White
Black-Yellow
Green-Wh ite
Black
White
Air conditioner
relay (N.a.)
High pressure
switch
g
U
Air valve
(F.I.C.O.)
o
:0
;:
a:
Condenser fan
(Sub-fan)
»
z
Earth
»
Instrument
panel harness
connector
0.85Y
Z
<
m
'M
0.85
Automatic
transmission
vehicle
m
»-I
G')
Fuse for
condenser
0.85 LR
Radiator fan
(Main fan)
:::c
0.85 YW
~--~~~-------4~
Thermostat
Blower motor
o
-I
o
Z
Z
G')
en
-<
en
Low pressure
switch
-I
m
'--------i:~1
s:
Compressor clutch
l- _ _ _ _ _ _ _ _ .J
Blower switch
-
--------~~-
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
topics under "Refrigerant Level
Check".
2) Check the entire system for sign
1) Refrigerant R-12
of refrigerant leaks. Refer to relative
topics under "Checking for Leaks"
The refrigerant used in the air condiand
"Refrigerant Leaks".
tioner is generally called "RefrigerantIf any trace of oil is noted at and
12 (R-12)". No other refrigerant than
around connection fittings, it is a sure
the above refrigerant should be used.
indication that refrigerant is leaking.
This refrigerant is uSl,lally available
in L:fau~pan or a cylinder. In either .,: This condition can be corrected easily
by retightening the joints, If any joint
case, (t".uefied under high pressure
in th{~ontainer.
on line is suspected of small amount of
Refrigerant evaporates easily (has a
leakage, use a leak detector to locate
low evaporation point) and, moreover,
leaking points.
since the latent heat of the refrigerant
3) Check compressor drive belts for
is targe, it can absorb a large amount
proper deflection.
of heat when evaporating. Extreme
care must be exercised 'when handling
Season-off
the refrigerant:Observe the following maintenance
tips to allow the air conditioner to
2) ComPitssor Oil
,~.,
operate normally in the next season.
1) Keep the entire system free from
The "sumso. 5GS" refrigeration
refrigerant leakage by periodically
lubricant shouldb~ used to assure the
checking for refrigerant gas leak even
successful compressor operation. Use
out of season.
of oils other than recommended or
2) Turn the compressor for 10
mixing of the oil with other oils would
minutes
at least once a month by
cause chemical reaction or lead to
running
the
engine at 1,500 rpm.
lowered viscosity or deficient lubrication.
The oil absorbs moisture as it contacts
4) General Service Instruction
the air. This points out the need for
care not to expose it to atmosphere
The servicing of the air conditioner
for an extended period of time.
should be carried out only by welltrained servicemen. This chapter deNOTE:
scribes
essential points of servicing.
a. The oil should not be transfused
2. On-car Services
from a container into another, as
the failure will possibly cause moisture to mix with the oil.
b. The used 'lil should not be returned
into a container.
c. The oil should not be used if its
state of preservation is not clear
enough.
3) Maintenance
Periodical maintenance and
season-in inspection
Both periodic~. maintenance and
season-in inspection are most essential
to enable the air conditioner to give
full performance.
Perform the following checks.
1) Start engine and check refrigerant
level through sight glass on receiver
drier. For details, refer to relative
• If a large amount of dirt and sand
enter the system, they will be
carried with refrigerant and may
clog the system or scratch rotating
parts. This points out the need for
care in servicing the system. That
is, disconnecting joints should be
carried out in a clean place.
• Water should not be allowed to get
inside the system. The refrigerant
does not readily mix with water.
However, the presence of even a
minute amount of water will cause
a chemical reaction at high temperature which will in turn produce
hydrochloric acid (HCI), Since
hydrochloric acid is highly corrosive to metals, the aluminum and
copper piping, etc. will become
corroded and the refrigeration
system will become clogged.
• Water in the system will ice the
orifice when the high pressure refrigerant is changed to low pressure
refrigerant by expansion valve, etc.,
and will obstruct the refrigerant
flow.
5) Safety Precautions
1) Since direct contact of the liquid
refrigerant with your skin will cause
frostbite, always be careful when
handling the refrigerant. Wear gloves
or wrap a piece of cloth around service
valve to protect your fmgers against
frostbite by refrigerant. If any of the
refrigerant should get into your eyes
when charging the refrigerant, splash
your eyes with cool water to raise the
temperature gradually. Apply a protective fIlm to the eye to avoid infection.
Do not rub your eyes. Consult an eye
specialist. Always wear goggles or
glasses to' protect your eyes when
working around the system. Should
refrigerant strike your body, splash
on cool water and apply a protective
ftIm.
2) The refrigerant service container
has a safe strength. However, if handled incorrectly, it will explode.
Therefore, always follow the instructions on the label. In particular, never
store it in a hot location [above 52°C
(126°F)] or drop it from a high
height.
3) The refrigerant gas is odorless and
colorless and breathing may become
difficult due to the lack of oxygen.
Since the refrigerant gas is heavier than
air and will lay close to the floor, be
especially careful when handling it in
small, confined spaces.
4) The refrigerant itself is nonflammabie. However, a toxic gas (phosgene
gas) is produced when it contacts fire
and special care is therefore required
when checking for leaks in the system
with a halide torch.
5) Do not steam clean on the system, especially condenser since excessively high pressure will build up in the
system, resulting in explosion of the
system.
The above precautions are essential in
handling of Refrigerant-12, and their
strict observation requires sufficient
training. Therefore, it is of first importance that any other personnel
13-19
_ ... _~__---.--J
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
than a wen-trained serviceman should
2) When
not be allowed to handle the refrigerant.
mixed in system, a chemical reaction
will be produced and hydrochloric
6) Evacuating and Charging
acid which will adversely affect the
aluminum, copper, iron, and other
materials in system may be generated.
air
and
refrigerant are
System
3)
Next, loosen the connection fit-
ting of charging hose at manifold
gauge side for 2 to 3 seconds to purge
any air inside charging hose by the
pressurized gas in system_
(Disconnection from service valve)
Handling manifold gauge
During servicing, use caution to keep
air from getting into refrigerant.
When air enters the system, all refrigerant must be evacuated from system
prior to charging new refrigerant. Air
in refrigerant has the following deleterious effects:
1) Since the condensation temperature of the air is extremely low, the air
will not be condensed when refrigerant
gas is condensed in the condenser, and
the air will thus remain in gaseous
form. Consequently, the effective thermal transmission area of condenser for
refrigerant gas will be reduced and
refrigerant gas to be condensed will be
reduced. The pressure rise will become
proportional to the volume of the air
in system.
The pressure at the high- and low-sides
of system should be measured when
evacuating and charging refrigerant
and when diagnosing trouble in the
system. The manifold gauge is used for
these purposes. A manifold gauge has
two pressure gauges; a low pressure
gauge and a high pressure gauge. These
gauges are connected to the highand low-side service valves of system
through flexible charging hoses. The
construction of manifold gauge is
shown in Figure.
When valve stem is fully screwed, the
valve is front-seated and valve path and
the center path are blocked. When
valve stem is backed off, the paths are
opened.
Low-pressure ~auge
(Compound pressure gauge)
High-pressure gJlIge
Ila~k-sealed
Fronl-S''''''''~M
.....
~·'"I
,t'
1 it
..........
.u_.'.....'_1'...
· ...
, ,_.
...
, -_ _ _ _ _ _...
~1-f·
"~1_1''''''
_________..,...,_._____....__-
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
Amount of
refrigerant
Almost no refrigerant
Insufficient
Suitable
Too much refrigerant
Check item
f - - - - - - - - - - - " " > \ - - - - - - - - - + - - - - - - - - + - - - - - - - - - + - - - - . --.--.... --Temperature of high pressure
and low pressure pipes.
Almost no difference
between high pressure
and low pressure side
temperature.
High pressure side is
warm and low pressure
side is fairly cold.
High pressure side is
hot and low pressure
side is cold.
High pressure side is
abnormally hot.
State in sight glass.
Bubbles flow continuously. Bubbles will
disappear and
something like mist
will flow when
refrigerant is nearly
gone.
The bubbles are seen
at intervals of 1 - 2
seconds.
Almost transparent.
Bubbles may appear
when engine speed is
raised and lowered.
No bubbles can be seen.
Fig. 13-64
Fig. 13-65
A26-042
No clear difference exists between these two
conditions.
A26-043
Pressure of system.
High pressure side is
abnormally low.
Both pressure on high
and low pressure sides
are sligh t1y low.
Repair.
Stop compressor and
conduct an overall
check.
Check for gas leakage,
repair as required,
replenish and charge
system.
NOTE:
a. The bubbles seen through the sight
glass are influenced by the ambient
temperature. Since the bubbles are
hard to show up in comparatively
low temperatures below 200C
(68°F), it is possible that a slightly
larger amount of refrigerant would
be filled, if supplied according to
the sight glass. Be sure to recheck
the amount when it exceeds 20°C
(68° F). In higher temperature the
bubbles are easy to show up.
b. When the screen in the receiver
drier is clogged, the bubbles will
Fig. 13-66
Both pressures on high
and low pressure sides
are normal.
appear even if the amount of refrigerant is normal. In this case, the
outlet side pipe of the receiver drier
becomes considerably cold.
A26-044
Both pressures on high
and low pressure sides
are abnormally high.
Discharge refrigerant
from service valve of
low pressure side.
Overcharging will show up in higher
pressure on discharge side.
9) Compressor Oil Level Check
Perfonnance test
Check for the amount of refrigerant
in the system can be made by measuring pressure on discharge side.
The correct amount of refrigerant is
in the system, if pressure on the discharge side is within the specified
range. For details, refer to "Performance Test" described later.
13-27
The oil used to lubricate compressor circulates into system with refrigerant gas while compressor is operating.
If a considerable amount of leakage of
refrigerant gas happens, the leakage
of compressor oil is also considered.
There will be no compressor oil leakage from a completely sealed system.
When system operates under satisfying
HEATING , VENTILATING AND AIR-CONDITIONING SYSTEM
condition, the compressor oil level
check is unnecessary.
When checking the level of compressor
oil or when replacing any component
part of the system, use the following
service procedure. This facilitates to
return oil to compressor.
1) Operate compressor at engine
speed from 1,000 rpm to 1,500 rpm
with controls set for maximum cooling
and high blower speed for about 10
minutes in order to return compressor
oil to compressor.
2) Stop the engine and discharge
refrigerant of system and then remove
compressor from the car.
3) When exchanging the compressor
for new one which contains 150 cm 3
(ISO cc, 9.15 cu in) oil, drain 80 cm 3
(80 cc, 4.88 cu in) oil from it or
adjust the amount of oil to the same
of the removed compressor.
4) When exchanging for a service
compressor which contains 70 cm 3
(70 cc, 4.27 cu in) oil, install it without any adjusting.
5) When exchanging a cooling unit,
pour SO cm 3 (SO cc, 3.05 cu in) oil to
the compressor from the suction hose
after installing the cooling unit.
If compressor is inoperative due to
defective compressor or heavy loss of
refrigerant, exchange the compressor
through the procedure from 2 to S.
judge whether system is operating correctly and can also be used as a guide
in checking for problems.
1) Park the car indoors or in the
shade.
2) Open all the windows of the car
fully. However, close the doors.
3) Open the hood.
4) Connect manifold gauge to highand low-side service valves of the
system. Refer to "Handling Manifold
Gauge".
5) Set mode lever to AIC MAX position.
6) Set temperature control dial to
COLD position.
7. Set blower to its highest speed.
8. Start the engine and hold engine
speed at 1;500 rpm.
9) After the air conditioner has been
operated for about 10 minutes, measure system pressures at high-pressure
(discharge) side and low-pressure (suction) side.
10) Measure the temperatures of inlet
air to blower and outlet air at the
grilles.
11) Measure the temperature and
humidity of the ambient air at a point
1 m (3.3 ft) front of condenser. However, a dry bulb and wet bulb must
not be placed in direct sunlight.
12) Check for any abnormalities by
comparing the test results with standard pressure in "Performance Chart".
NOTE:
10) Performance Test
The cooling performance of the air
conditioner changes considerably with
changes in surrounding conditions.
Testing must be performed using the
correct method. This test is used to
a. The pressure will change in the
following manner with changes in
conditions:
• When blower speed is low, discharge pressure will drop.
• When the relative humidity of intake air is low, discharge pressure
will drop.
b. The temperature will change in the
13-28
following manner with changes in
conditions:
When the ambient air temperature
is low, the oudet air temperature
will become low.
If the test reveals that there is any
abnormality in system pressure, isolate
the cause and repair by reference to
"Troubleshooting".
11) Refrigerant Leaks
If leaks are noticeable, leaky parts
should be repaired. Then system
should be fllied with refrigerant. Do
not operate compressor with refrigerant level exceSSively low.
If this caution is neglected, a burnt
compressor will result since heavy loss
of refrigerant usually indicates heavy
loss of compressor oil.
If system has been exposed to atmosphere for an extended period of time,
receiver drier must be replaced. If
leaks are slight and no air is present
in system, add refrigerant as necessary.
To detect leaks, refer to relative
topics under "Checking for Leaks".
Here is how leaks are stopped.
1) Check torque on the conn~ction
fitting and, if too loose, tighten to the
proper torque. Check for gas leakage
with a leak detector.
2) If leakage continues even after the
fitting has been retightened, discharge
refrigerant from system, disconnect
the fittings, and check its seating face
for damage. Always replace even if
damage is slight.
3) Check compressor oil and add oil
if required.
4) Charge refrigerant and recheck
for gas leaks. If no leaks are found,
evacuate and charge system.
-------,
---------
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
12) Performance Chart
[kPa (kg/em', psi) G)
(OF)
(OC)
2,158
(22,313)
Conditions
Engine rotating speed: 1,500 rpm
Sunshine: No
Doors: Close
Door windows: Open
Engine hood: Open
Front wind velocity: 2 m/sec (7 ft/sec) or less
Air humidity of front window: 50 to 80 percents
Mode lever position: CIRC-A/C MAX
Fan switch: Highest position
1,961
(20,284)
.,...
.,
.,a.
.,...'"
.t:
1,765
(18,256)
:::J
III
III
1,569
(16,228)
1,373
1;1 (14, 199)
'ti
0
.,...
1,177
u0
981
(10,142)
III
III
c. (12,171)
E
70
20'
785
(8,114)
60
15
50
~
10
392
(4,57)
:::J
.,
III
III
a.c:
294
(3,43)
5
0
';;
t,)
:::J
III
0
::!
~
c.
E
0
u
196
(2,28)
~L
40
(1, :4)
(0,0)
o
20
15
60
25
70
30
80
(oC)
90
(OF)
Unit inlet air temperature
A26-079
Fig. 13-61
13-29
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
5) Loosen the compressor mounting
boits, (first the lower two and then the
upper one) and then remove the compressor.
3. Repair for Component Parts
1) Compressor
1 Upper bolt
2 Lower bolts
3 Bracket
(compressor)
4 Bracket
(upper)
Tightening torque N'm (kg-m. ft-Ib)
T1: 24 - 39 (2.4 - 4.0. 17 - 29)
T2: 23 - 36 (2.3 - 3.7.17 - 27)
1
2
3
4
Fig. 13-70
Compressor
Magnet clutch
Bracket (upper)
Bracket (lower)
A26-125
Fig. 13-68
The MIS-170 compressor employs an
oil-mist jet system in which some
lubricant is mixed in the refrigerant
and the mixture is sprayed directly to
the sliding portions from the compressor suction side.
2) Loosen bolts fixing tension pulley,
and slacken V-belt.
6) Detach upper and lower brackets
from compressor.
7) All removed parts should be installed in the reverse order of removal
with the following particulars. .
a. Tightening torques are as follows:
Torque N·m (kg-m, ft-Ib)
Bolts for
installing brackets
23 - 29
(2.3 - 3.0,
17 - 22)
Compressor
mounting bolts
24 - 39
(2.4 - 4.0,
17 - 29)
Flexible hose
(Pd) flare nut
20 - 29
(2.0 - 3.0,
14 - 22)
Flexible hose
(Ps) flare nut
25 - 34
(2.5 - 3.5,
18 - 25)
Compressor clutch
The most likely source of problem is
clutch slippage. Factors are listed here.
Exercise ample care.
l) Clearance between clutch hub and
pulley should be 0.5 to 0.8 mm (0.020
to 0.031 in) at all peripheral points.
2) Make sure that there is no oil or
dirt on friction surfaces of clutch disc
(clutch hub) and pulley. Remove any
oil or dirt with a dry rag.
3) Make sure that terminal voltage at
magnetic coil is above 10.5V.
Removal and installation
1) Disconnect electrical wiring from
compressor.
1 Bolts
2 Tension pulley
3 V-belt
4 Compressor
A26-082
Fig. 13-69
3) Discharge the refrigerant from the
system (refer to "Discharging the System").
4) Disconnect the flexible hose.
13-30
,., ·n
A26-083
b. When attaching the compressor to
the compressor bracket, push the
upper bracket's spacer 1 to 2 mm
(0.04 to 0.08 in) inward beforehand.
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
3) Using snap ring plier, take off
snapring from front cover.
I
_
Fig. 13·71
Push 11-2mm
(O.04-0.08inl]
Assembly
A26·085
A26'()51
Fig. 13-73
c. Be sure that there is a gap of at
least 20 mm (0.79 in) between the
flexible hose (Pd) and the compressor.
d. For belt adjustment, refer to Page
13-35.
e. For charging refrigerant, refer to
Page 13-20.
4)
Remove pulley and bearing ASSY.
Disassem bly
NOTE:
a. Before starting work, remove dirt
from outside the detached compres·
sor. Clean the workbench, tool, and
your hands.
b. Do not leave compressor on its side
or upside down for more than
10 minutes, as compressor oil will
enter low pressure chamber.
1) Using Clutch Hub Wrench
925770000, hold clutch hub. With
suitable socket wrench, remove shaft
nut from shaft. Using Hub Nut Socket
925790000, remove hub nut.
2) Using
Clutch
Hub
Puller
925780000, remove clutch hub.
Thread tool into the bore of clutch
hub, hold tool with wrench, and then
thread in center bolt.
and bearing assembly, and clutch hub
as a set.
2) Oil or dirt on the friction surfaces
should be cleaned with a suitable
solvent and a dry rag.
3) Check coil for shorted or opened
binding leads.
Fig. 13-74
A26'()52
5) Using screwdriver, loosen mounting screw of wire clamp. Using
snapring plier, take off snapring from
inside of coil ASSY.
1) Install coil assembly to compressor body make sure that terminal position is same as before the removal.
Install snapring (Using snap ring plier)
(Check snapring upper side or lower
side).
2) Using a plastic mallet, drive pulley
and bearing assembly (onto the nose
of front cover).
Turn the pulley, making sure that
there is no noise and that rotation is
free. Also make sure that there is no
pulley play.
3) Using snapring plier, install a
snapring to inside of coil ASSY. Oil
or dirt on the friction surfaces should
be cleaned up.
4) Fit key and clutch hub to the
shaft. Select adjusting spacer which
gives the correct clearance between the
pulley and clutch hub.
~Hubnut
Adjusting shim
Fig. 13-75
A26-,.,-1,,-"""'-,,!.,..,..,....._"' ..
~
oj_'..., ...r'' ' ··...' ...,_'...,___.........
......,_ _........,+I.........
qqq,_.,."....., _____- -____,.....________
' t _...'F
....,...
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
----- -----------,
Torque N.m (kg-m, ft-lb)
---:~~ntln:-~oltl (0~5~ =~:~5,
\
- Pipe nare nut -
4.0- 6.9)
[(:f-- ~~:-A26-094
7 - 14)
,
'--------------
Fig. 13-83
---
1 Bolts
2 Blower
mounting bolt
A26·092
Fig. 13-81
4) Check to SE'e if the evaporator fins
are clogged. 1ft hey are, clean tltem
with compressed air
4) Evaporator
Removal and installation
Disconnect the lead wirt! from the
battery.
2) Discharge refrigerant.
3) Disconnect the discharge pipe
from the evaporator. and then detach
the suction pipe.
I)
CAUTION:
Protect the open pipe connections
with caps to prevent moisture from
entering the system.
7) The evaporator should be installed
in the reverse order in which it was removed. When installing the evaporator
in the car body, make sure the wiring
harness does not get caught between
the body parts.
Disassembly and ASSY
1) Using a flat-bladed screwdriver,
remove the seven clamps and the
evaporator upper case.
NOTE:
Water must never be used to clean the
evaporator.
5) Check parts that have been removed for cracks or scratches, and
repair or replace them with new ones,
if necessary.
6) The evaporator should be reassembled in the reverse order in which
it was disassembled. Observe the
following points during the reassembly
process:
a. Confiml tha t the a-ring is inserted
in the specitied position.
b. Tightening torque
r---- - - - - - - -- ----- ------------
--l
Torque N·m (kg-m, ft-Ib)
.
------r--------- -----------1
Expan~lOn valve
mountmg nut
2 Suction pipe
3 Grommet
,
S
2.'i - 4.4
i
I (0.25- 0.45, I
i
1.8 - - 3.3) I
I--------------~--
A26-090
Fig. 13-80
A26-093
Fig. 13-82
J() --
Discharger pipe
union nut
I
---
20
(1.0 - 2.0,
!
i
7 - 14)
r-------- ---
4) Remove the grommet from the
evaporator's inlet and outlet pipe connections.
5) Remove the following parts in the
stated order:
a. Instrument panel lid and pocket.
h. Front shelf.
c. Lower duct.
d. Blower
6) Loosen two bolts, disconnect the
drain pipe connection, and then remove the evaporator.
Flare nut on
discharge side
2) Remove the lower case from the
evaporator.
3) Remove the component parts
from the evaporator.
a. Disconnect the connection between
the expansion valve and discharge
pipe.
b. Remove the expansion valve from
the header on top of the evaporator.
13-33
Flare nu t on
suction side
10- 20
(1.0 - 2.0,
I
7 - 14)
I
(2.0 - 3.0,
+---------l
20 - 29
I'
I
!
I
'---_________ L _____~~~___~_~L _J
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
5) Condenser Cooling Fan
1 Shroud
2 Motor
3 Bracket
4 Cooling fan
5 Washer
6 Washer
7 Spring
8 Nut
9 Screw
A26-056
Fig. 13-84
Idling speed
950 ± 50 rpm
Removal and installation
I) Remove the clip on the motor
wiring, and disconnect the coupler.
2) Remove the shroud by loosening
the mounting bolts.
3. Remove the fan by loosening the
mounting bolt.
4) Open the clip and remove the
wiring from the shroud.
S) Loosen the three screws to remove the motor bracket, and then
remove the motor from the shroud.
6) The fan should be installed in the
reverse order in which it was removed.
a. Be sure to position the motor
properly when installing it in the
shroud.
6) Actuator (F.I.C.D.) and
Lever
To adjust, follow the instructions below.
3
A26-058
1 Actuator (F .I.C.D.)
2 Lever (F.I.C.D.)
3 Vacuum hose
Fig. 13-86
Adjusting
screw
Procedure for adjusting engine
idling speed
2 Lock nut
A26·096
Fig. 13-88
Loosen the lock nut and turn the
adjustment screw with a flat-bladed
screwdriver.
a. Tum it clockwise to decrease the
idling speed.
b. Turn it counterclockwise to increase the idling speed.
Fig. 13-85
NOTE:
b. Tightening torque
Torque
(Fan mounting
nut)
If the clearance IS Improper, adjust
it by loosening the lever's (F.I.C.D.)
mounting bolts.
b. Vehicle with CARTER·WEBER carburetor: It should be approx. 4 mm
(0.16 in) when both actuator and
lever are installed in their normal
positions.
2) After warming the engine up, start
the air conditioner, depress the accelerator pedal 2 or 3 times, and turn the
adjustment nut of the actuator to set
the idling speed.
3 - 5 N·m
(0.3 - 0.5 kg-m,
2.2 - 3.6 ft-Ib)
c. After installing it, operate the fan
to see if it runs normally and
doesn't make any unusual noises or
vibrations.
1 Hook
2 Lever (F.I.C.D.)
3 Bolts
A26-095
Fig. 13-87
13-34
a. The air cleaner must be installed
when adjusting the idling speed and
the air conditioner is operating.
b. Make sure that the lever (F.l.e.D.)
is able to move all the way to the
fully open position.
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
7) Tension Pulley and Idler Pulley
24 - 39 N·m
(2.4 - 4.0 kg-m,
17-29ft-lb)
Torque
(Bolts)
3) Tighten the upper mounting bolt.
Tightening torque N·m (kg-m, ft-Ib)
8) Flexible Hose
T1: 24 - 39 (2.4 . 4.0, 17 - 29)
Flexible hose! (PS)
T2: 22 - 25 (2.2 - 2.5,16 - 18)
A
~~
Flexible hose (Pd)~
I
2
A26·060
3
4
5
6
7
8
9
//s
Bracket
Spacer
Pulley
Washer
Spring washer
Bolt
Plate nut
Bolt
Spring washer
\
'\\
®
Fig. 13-89 Tension pulley
Tightening torque N·m (kg-m, ft-Ib)
22 - 25 (2.2 - 2.5, 16 - 18)
Procedure for adjusting the V-belts
tension
A26-101
Fig. 13-92
I Box wrench
3 V-belt
2 Tension
4 Compressor
pulley
2
3
4
5
A26-059
Spacer
Pulley
Washer
Spring washer
Bolt
Fig. 13-90 Idler pulley
Replace tension pulley and/or idler
pulley if they rattle or make any
abnormal noises.
Torque N·m (kg-m, ft-lb)
Fig. 13-91
The V-belt's tension should be adjusted in the following manner.
1) Loosen the two bolts that mount
the tension pUlley.
2) Adjust the tension so the belt will
deflect to the specified value midway
between the tension pulley and the
compressor. Then tighten the lower
mounting bolt.
Bolt for tension
pulley
22 - 25
(2.2 - 2.5,
16 - 18)
V-belt tension
Bolt for idler
pulley
22 - 25
(2.2 - 2.5,
16 - 18)
Deflection 12 - 15 mm
(0.47 - 0.59 in)/at
98N (10 kg, 221b)
13-35
With the following cautions, replace
flexible hoses with new ones if they
are damaged or swollen.
1) The flexible hoses should be free
from twists and tension after they
have been connected.
1) The flexible hoses must not be
bent forcibly.
3) Flexible hose (Pd) should be more
than 20 mm (0.79 in) away from the
compressor pulley after it has been
connected.
4) Tightening torque of flexible hose
connections:
Torque N·m (kg-m, ft-lb)
Flare nut
Ps side
CD
on
Flare nut
Pd side
®
on
Flare nut @ on
Ps side
20 - 29
(2.0 - 3.0,
14 - 22)
20 - 29
(2.0 - 3.0,
14 - 22)
25 - 34
(2.5 - 3.5,
18 - 25)
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
Blower motor fuse harness A is located
on the back of the instrument panel.
The blower motor relay is attached to
the fuse box bracket.
9) Pipe (Ps side)
Removal and installation
1) Remove the spare tire.
2) Drain the fluid from the windshield washer tank. Then remove the
tank from the bracket and place it on
the front bulkhead.
3) Remove the battery and loosen
the lower pipe clamp bolt.
A26·106
Fig. 13-95
10) Move the pipe (Ps) to the right
and pull it downward from the left
end.
11) The unit should be installed in
the reverse order in which it was removed. Pay attention to the following
particulars during installation:
(1) Tightening torque
Torque
. [Flare nut
of pipe (Ps)]
Fig. 13-93
4)
Discharge
refrigerant (see Page
13-20).
5) Disconnect the pipe (Ps) from the
evaporator.
6) Remove the compressor V-belt.
7) Disconnect the flexible hose (Ps).
~\~
20 - 29N·m
(2.0 - 3.0 kg-m,
14 - 22 ft-Ib)
(2) Be sure that a gap of at least
10 mm (0.39 in) is present between
the brake pipe under the washer tank
and the pipe (ps).
(3) Keep a gap of at least 15 mm
(0.59 in) between the intake air preheat duct and the pipe.
(4) For charging the refrigerant, refer
to Page 13-20.
A26·108
Fig. 13-97
Inspection of the relay
4-pole relay
10) Relay and Fuse
.The air conditioner relay and sub fan
fuse harness B are installed in the
engine compartment, as shown in the
figure.
C
O~
~
Blower motor
fuse harness A
2 Blower motor
relay
6-pole relay
.1
A26·104
Fig. 13-94
A26-062
Fig. 13-98
8) Jack the car up, and remove the
undercover (right and left) and underguard (4WD vehicle only.)
9) Remove the pipe clamp bolt
under the radiator, and open the
clamp.
1 Air conditioner
relay
2 Sub-fan relay
3 Sub-fan control relay
4 Sub·fan fuse (B)
A26·127
Check conduction with a circuit tester
(ohm range) according to the following table.
Fig. 13-96
13-36
-
.I!.
10"
,'11,
'j.
...
--rro-"'......-...""....'
·~··-::-;;;-"';;"·"'-Ir~·~""~=~if ---tl...., .·....
·e
...
' ..............
· ....
tt ....
.-it...' ...' ...
'n...
· •...
pw
...··...."'"- '...
, - '...., " ' " ' - - - - - - '. .
--7
...
· - - - _ - -_ _ _ _ _ _ _ _ _ _ __
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
Sub-fan control relay
Main fan control relay
~
1
@
@
Sub-fan relay
arr
kV
~
CV
Fig. 13-99
A26-063
About 80n between
@ and @
on between
CD
and
CV
Fig. 13-100
A26-064
CD
3
~
2
@
@
-v
-0-
-CD
-0-
-®
A26-065
con between
con between
CD
CV
Lever control
Conduction
Free
None (con)
Push
Yes (0 n)
Removal and installation
Remove the front shelf and air
duct.
2) Remove the microswitch with
bracket which is installed on the
heater unit's right side.
reD
~
Fig. 13-102
A26-066
Abou t 80n between
CV and @
About 80n between
@ and @
and @
0-
-..r
3
11) Microswitch
1)
@
2
., ~
Fig. 13-101
About 80n between
CV and @
con between
Blower relay
Air conditioner relay
and @
and
®
con between
CD
and @
4) Apply a 12-V battery voltage to
the air valve after it has been removed,
and blow air into the source side from
your mouth to see if air is conducted.
4) The switch should be installed in
the reverse order in which it was removed.
&:"'12) Air Valve
Removal and installation
Screws
2 Microswitch
Batterv
A26-067
A26-110
Fig. 13-106
Fig. 13-103
3) Check the microswitch's operation while watching the circuit tester
(ohm range).
Voltage
Air conduction between
source and actuator
None
None
Yes
Yes
A26-112
Fig. 13-105
A26-111
Fig. 13-104
I)
2)
3)
and
Remove the vacuum hose.
Disconnect the connector.
Loosen the two mounting screws
remove the air valve.
5) The air valve should be installed in
the reverse order in which it was removed.
,
j
13-37
I
-~
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
13-4. Troubleshooting
r®
1. Heating and Ventilating
Poor heating performance
Low temperature of outlet air
®
No flows of outlet air (or poor flows)
©
Air leakage into the compartment
NOTE:
As a matter of fact, hot outlet air can
be adjusted only in ten (10) steps of
temperature control dial as shown in
the following illustration.
A23-140
Fig. 13-107
1) Low Temperature of Outlet Air
No.
Cause
Check point
Corrective action
1.
Thermostat leakage
1. The bite of facets and sands
2. Experience of overheating
Clean or replace
2.
Poor adjustment of water cock
The stroke of water cock lever is
Adjustment
22 ~~ mm. (0.87 ~g.08 in)
a
.
NOTE:
If lever stroke is shorter than
21 mm (0.83 in), disconnect water
cock rod and cable from lever E.
Then adjust the control in the
same way predescribed.
COLD
~ 22 mm (0.87 in)
•
HOT
A23-090
Fig. 13-108 Lever stroke
3.
Air mixing shutter cannot open
fully in spite of setting temperature
control dial to HOT.
Check connection of clamp and
cable without fail
\ Standard value
Adjustment
\20 mm (0.79 in) \
at HOT pOSition
4.
Faulty control cable or rod
1. Check excessive bending or
buckling of cable and rod.
2. Check disconnection of cable or
clamp.
1. Replace (for cable)
Repair or replace (for rod)
2. Connection
13-38
.,
r 1
,
1
f
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
2) No Flows of Outlet Air (Or Poor Flows)
No.
I.
Cause
Unsufficient performance of
blower assembly
Check point
Corrective action
1. Check connection of wiring har-
1. Connection
ness for looseness.
2. Check reverse connection of wiring
harness.
2. Repair
2.
Choke of air inlet
1. Check choke of air inlet with dry
leaves or alien substances.
1. Clean
3.
Disconnection of duct and
heater unit or blower assembly
1. Check by watching.
1. Connection
2. Check air leakage around the connection by hand.
3. Check damage of duct edge.
2. Repair
1. Check the control system according to "On-car Services".
2. Check excessive bending or buckling of cable and rod.
1. Adjustment
4.
5.
6.
Un sufficient operation of each
shutters
Disconnection of defroster duct
Un sufficient installation of
defroster nozzle
3. Repair or Replace
2. Replace (for cable)
Repair or replace
1. Check connection of duct and
heater unit for air leakage.
2. Check connection of duct and
defroster nozzle for air leakage.
3. Check action of both left and right
defroster shutters.
4. Check damage of duct.
4. Repair or replace
1. Check by watching.
1. Repair
1. Connection
2. Connection
3. Repair or adjustment
+3
+0.12.
12 _5 mm (0.47 _0.20 In)
~(@grn:mf
A23·091
Fig. 13-109 Installation of
defroster nozzle
2. Check choke of nozzle with alien
substances.
2. Clean
13-39
---
---~
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
3) Air Leakage into the Compartment
No.
Cause
1.
Air leakage at the passenger side.
Check point
1. Check sealing of shutter at blower
assembly.
2. If air leakage occures at CIRC position, it is due to disconnection or
break of intake shutter return
spring.
3. If air leakage occurs at positions
except CIRC of mode lever, it is
due to faulty of vacuum control
system.
4. Check connection of heater duct
and blower assembly or heater unit
without fail.
Corrective action
1. Repair
2. Connection or Replace
3. Repair
4. Connection
2.
Air leakage at the driver side
Check the control system according
to "On-car Services".
Adjustment
3.
Air leakage from center air
outlet
Check the control system according
to "On-car Services".
Adjustment
13-40
I
Noisy
I
I
I I
Compressor OFF
J
Blower makes
noise.
Repair or replace blower.
I
I
1
Compressor
itself makes
noise.
Repair or
replace compressor.
When engine
rpm is changed,
there are resonant sounds.
Retighten compressor bracket
bolts.
Piping is resonating. Add
cramp.
Belt is loose.
Adjust belt.
I
I
Insufficient cooling
I
I
Compressor ON
"---J
Bearings of com pressor clu tch or idler
pulley make noise.
Repair.
I
I
Bubbles in sight glass
I
No bubbles in sight glass
I
I
I
Check refrigeration line
for gas leaks, and repair
leaks if any. Charge
refrigerant to correct
level. In case of too
many leaks, stop compressor, discharge the
system, evacua te and
recharge the system.
As necessary, replace
receiver drier.
-~
--
Blower does not
rotate.
Compressor
does not run.
Refer to "Blower
Motor
Diagnoses".
Refer to "Compressor
Diagnoses".
With manifold gauge, check system pressures.
Measure temperature of discharge air.
Refer to "Performance Test".
Suction pressure
kPa (kg/cm', psi)
Head pressure
kPa (kg/cm', psi)
0
_.,._.::::I
0
::::I
_.
::::I
c:::a.
IIQ
21 (70)
26.5 (80)
32 (90)
38 (l00)
1,961 - 2,746
(20 - 28,
284 - 398)
13,534-16,476
(138 - 168,
1,962 - 2,389)
2,256 - 3,236
(23 - 33,
327 - 469)
14,097-18,143
(152 - 185,
2,161 - 2,631)
2,746 - 3,727
(28 - 38,
398 - 540)
17,162-20,497
(175 - 209,
2,489 - 2,972
3,629 - 4,707
(37 - 48,
526 - 683)
19,712-23,046
(201 - 235,
2,858 - 3,342)
Temperature
difference (Outside
air - discharge air)
°c (OF)
•
•
•
•
•..n_.•
J:
m
»-t
Z
Temperature of
outside air
°c (OF)
Air in system may
cause bubbles in sight
glass.
w
.N
C')
~
<
m
Z
-t
r-
»
-t
10 - 13.5
(50 - 56)
Engine speed
:
Fan switch
:
Mode lever
:
Temperature control dial:
10.5 - 14.5
(51 - 58)
13 - 17
(55 - 63)
15 - 19.5
(59 - 67)
Z
C')
»z
1,500 rpm
Highest position
CIRC A/C MAX
COLD position
c
»
:tJ
;;,
0
Z
System pressure and temperature of discharge air are
abnormal. Refer to "Performance Test Diagnoses"
for detail.
I
l
Suction pressure is low.
Pipe at receiver
drier outlet has
low temper;J.ture.
Receiver drier is
restricted. Replace
receiver drier.
I
Fin and tube of
evaporator have
some dents.
Replace or repair
evaporator.
Expansion valve is
close excessively,
or gas leakage from
thermo bulb.
Replace expansion
valve.
I
I
Suction pressure is high.
I
Expansion valve is
open excessively,
or expansion
O-ring is damaged.
Replace expansion
valve.
I
Head pressure is
high.
I
Overcharge of refrigerant.
Discharge some of refrigerant to correct level.
Air is mixed in. Discharge
system, and replace drier.
Evacuate and recharge
system.
Condenser's fin is dented
or clogged with dust.
Clean exterior surface
with water.
I
Suction pressure is
high, while head is
low.
I
Valve or gasket of
compressor is damaged.
Repair or replace
compressor.
C
-t
0
Temperature of discharge
air is abnormal, but system
pressure is normal.
I
Check air flow system.
Refer to "Air Flow System".
Check grommets on car's dash panel
for air leaks; check other seals of
car.
Z
Z
C')
en
-<
en
-t
m
s:
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
1) Performance Test Diagnoses
Of various conditions caused to the
air conditioning system, the character-
As to the method of a performance
test, refer to the item of "Performance
tables indicates a reading of the normal system when the temperature of
istics revealed on manifold gauge reading are shown in the following.
Test" .
Each shaded area on the following
outside air is 32.SoC (91°F).
Condition
Probable cause
'INSUFFICIENT REFRIGERANT CHARGE
Corrective action
I
Insufficient cooling.
Refrigerant is small, or
Bubbles appear in sight
glass.
leaking a little.
1. Leak test.
2. Repair leak.
3. Charge system.
NOTE:
Evacuate, as necessary, and
recharge system.
Fig. 13-110
A26.o69
, ALMOST NO REFRIGERANT
I
Stop compressor immediately.
No cooling action.
Serious refrigerant leak.
In sight glass appear a lot
of bubbles or something
like mist.
Fig. 13-111
I
Slight cooling.
Sweating or frosted expansion valve inlet.
A26.o71
13-42
,./1•.",lj.
I,
3. Repair leak(s).
4. Replace receiver drier if
necessary.
S. Check oil level.
6. Evacuate and recharge
system.
A26.o70
, FAULTY EXPANSION VALVE
Fig. 13-112
1. Leak test.
2. Discharge system.
Expansion valve restricts
refrigerant flow.
• Expansion valve is clogged.
• Expansion valve is inoperative.
Valve stuck closed.
Thermal bulb has
lost charge.
If valve inlet reveals sweat
or frost:
1. Discharge system.
2. Remove valve and clean
it. Replace it if necessary.
3. Evacuate system.
4. Charge system.
If
1.
2.
3.
valve does not operate:
Discharge system.
Replace valve.
Evacuate and charge
system.
HEATING, VENTILATING AND AIR·CONDITIONING SYSTEM
Condition
Insufficient cooling.
Sweated suction line.
A26-Q72
No cooling.
Sweating or frosted suction line.
Probable cause
Corrective action
Expansion valve allows too
much refrigerant through
evaporator.
Check valve for operation.
If suction side does not
show a pressure decrease,
replace valve.
Faulty seal of O-ring in
expansion valve.
1. Discharge system.
2. Remove
expansion
valve and replace 0ring.
3. Evacuate and replace
system.
A26-Q73
Fig. 13-113
________________L -____________
-+______________
I AIR
IN SYSTEM
~------------
I
Insufficient cooling.
Air mixed with refrigerant
I. Discharge system.
Sight glass shows occasional bubbles.
in system.
2. Replace receiver drier.
3. Evacuate and charge
system.
After operation for a
while, pressure on suction
side may show vacuum
pressure reading. During
this condition, discharge
air will be warm. As warning of this, reading shows
39 kPa (0.4 kg/cm 1 ,6 psi)
vibration.
Drier is saturated with
moisture. Moisture has frozen at expansion valve.
Refrigerant flow is restricted.
A26-Q74
Fig. 13-114
I MOISTURE
Fig. 13-115
IN SYSTEM
I
A26·075
13-43
1. Discharge system.
2. Replace receiver drier
(twice if necessary).
3. Evacuate system completely. (Repeat 30minute evacuating three
times.)
4. Recharge system.
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
Probable cause
Condition
Corrective action
IFAULTY CONDENSER
No cooling action: engine
may overheat.
Bubbles appear in sight
glass of drier.
Suction line is very hot.
Condenser is often found
not functioning well.
• Check condenser fan
motor.
• Check condenser for
dirt accumulation.
• Check engine cooling
system for overheat.
• Check for refrigerant
overcharge.
NOTE:
If pressure remains high in
spite of all above actions
taken, remove and inspect
the condenser for possible
oil clogging.
A26-076
Fig. 13-116
I
HIGH PRESSURE LINE BLOCKED
Insufficient cooling.
Frosted high
liquid line.
Fig. 13-117
pressure
Drier clogged, or restriction in high pressure line.
1. Discharge system.
2. Remove receiver drier
or strainer and replace
it.
3. Evacuate and charge
system.
Internal problem in compressor, or damaged gasket
and valve.
1. Discharge system.
2. Remove and check
com pressor.
3. Repair or replace compressor.
4. Check oil level.
5. Replace receiver drier.
6. Evacuate and charge
system.
A26-077
FAULTY COMPRESSOR
Insufficient cooling.
Fig. 13-118
A26-078
13-44
-
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
2) Blower Motor Diagnoses
I
Blower motor inoperative
I
Check 20A fuse for blower relay, and 15A fuse
between ignition switch and blower relay.
I
I
Fuse blown
Fuse OK
I
Locate short-circuited spot and repair or replace
faulty parts.
Ground black wire leading to relay
I
Blower runs.
Blower does not run.
1
Ground one of lead wires, yellow/green (Extra
Hi speed), yellow/black (Hi speed), yellow/red
(Med. speed), yellow (Low speed) leading to
.
blower switch.
'~~l?
Check lead wire connection.
When no problem is found, replace relay.
-
I
Blower runs.
Blower does not run.
I
Check ground circuit connection and lead wire
connection. When no problem is found, replace
blower speed switch.
Ground red/white wire of blower motor.
I
Blower runs.
Blower does not run.
I
Connect 12-volt test light to green/white wire leading of blower motor.
Check connection of resistor. When no problem is
found, replace resistor.
;,
.'
.\\,.
.'",",
I
",m
.'1~~~
Light ON
Light OFF
1
Check lead wire connection. When no problem
is found, replace blower motor.
,,:
.. -.'
13-45
.
Check connector and check fuse holder, too.
Repag or replace damaged parts, if any.
j
.
,
I
~
)
I
Compressor clutch is not
engaged.
1--
I
I
Compressor dutch is engaged, but compressor
Compressor dutch coil has voltage
decreased to less than I O.5V.
I
i
Clu tch slipping
j!
• Check and readjust gap of
clutch.
I
Refer to "Compressor
Clutch Diagnoses".
1
Ground terminal of coil is poor
on contact sur-
at connection.
face of elu tch.
I
1----
Belt slipping
Check belt tension
and adjust it.
I f belt is worn out
or damaged, replace it.
• Clean oil or dust
Repair connection.
If slipptng continues, replace
j
I
Seizured
compressor
("')
j
I
"ir-blow on spot where oill.,k eVidence is
found. Then check for refngerant leaks using
lelk detector.
Ir.ternal problem
inder.
Check system.
Repau or replace
If necessary.
I
I
No refngerant
Refrigerant leaking
leaking
I
Wipe - clean oil
with rag.
..:ompressor.
...
0
...
'0
C
Qj'
CC
::::I
0
)
in compressor cyl·
0
3
(1)
CIt
CIt
1
I
du!.:h.
I!
Compressor oille.kmg
Repall or replace
compressor
In case clutch is not engaged yet,
replace compressor clutch.
I
dves not run.
I
Lead wire of compressor
clutch is dead.
j
~
CIt
::I:
m
»
-I
Z
c:;)
<
m
Z
-I
r-
»
-I
Z
c:;)
I
1
Overcharge of refrigerant
1
Discharge refrigerant gas to an extent
that sight glass of receiver drier has
only a few bubbles.
Engine speed: 1,500 rpm
rl
1
I
Check for discharge pressure.
OK if discharge
pressure is
reduced.
I
reduced.
c
J
I
When torque is still great, repair
or replace compressor.
~.
»
:%I
Compressor is nOisy.
I
Discharge system from service
valve on discharge side.
Evacuate and recharge the
system.
Discharge pres-
sure is not
»
z
I
Air in refrigeration system
I
1
High torque
1
Noisy only when
dutch is engaged
I
1
Noisy when dutch
IS not engaged
n
0
z
0
-I
0
I
Check for loose
compressor mount·
ing bolts.
Retighten bolts.
Compressor dnve
belt is loosen. "djust
belt tension.
J
If compressor is
noisy yet, repair
or replace compressor.
I
Remove compressor
belt. Turn pulley of
compressor dutch by
hand, and check for
noise. If noise is
heard, repair compressor clutch.
Z
Z
c:;)
(/)
-<
(/)
-I
m
s:
,
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
4) Compressor Clutch Diagnoses
Compressor clutch is not engaged.
Check 20A fuse for blower relay. 15 A fuse be·
tween ignition switch and blower relay. and
20A fuse for condenser fan.
I
I
Fuse blown.
I
l
I
Locate short·circuited spot. and repair or replace
damaged parts.
Light ON
I
I
I
I
I
I
I
Replace air conditioner relay.
Light OFF
J
Connect 12·volt test light to red/green wire of relay.
Ground the other end of test light.
I
Light ON
J
Connect lZ·volt test light to compressor clutch lead
wire. Ground the other end of test light.
Check lead wire and ground wire of compressor clutch
for connection. When there is nothing wrong with
them. replace compressor clutch.
I
Fuse OK
I
I
I
1
Light OFF
J
Connect l2·Yolt test light to red/white wire of water
temperature switch.
Ground the other end of test light.
(Automatic transmission vehicle only)
I
I
Light ON
I
l
I
Check connection of wire.
Check the connector.
(Automatic transmission vehicle)
Light ON
I
I
I
I
Check lead wire connection.
When no problem is found. replace low pressure
switch.
Light ON
I
Light OFF
I
J
Connect 12·volt test light to Green/white wire of
micro switch.
Ground the other end of test light.
I
1
L
I
J
Connect l2·volt test light to black/yellow wire to low
pressure switch.
Ground the other end of test light.
I
I
Light OFF
I
I
Light OFF
j
I
Check wire discontinuity on the side of electric
power source.
Check lead wire connection.
When no problem is found. replace micro switch.
i
13-47
J
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
5) Radiator Fan (Main Fan) Diagnoses
NOTE:
Follow this chart while referring to the description of
the electrical system (page 13-16).
IRadiator fan (main fan) will not operate. I
I
I
I
Fuse is blown.
Check 15 A fuse for radiator fan
(main fan).
1
I
1
Locate short-circuited spot, and repair or replace
damaged parts.
I
Light ON
Light ON
I
I
Light ON
I
I
._. .
Light OFF
J
Light OFF
I
Check lead wire connections.
When no problem is found, replace main fan.
I
I
Check AlC relay connector.
If the connector is in good condition, replace AIC
relay.
"Ir-"'''''~*-I'''''--~_t
I
Check wire discontinuity on the side of electric
power source.
Turn AIC switch off, and disconnect electric
connectors for pressure switch (main fan control)
and sub fan relay. Connect one end of a 12-volt
test light to AIC relay Yellow wire and ground the
other end.
I
Fuse is normal.
Connect one end of a 12·volt test Ugh t to fan
motor lead wire, and ground the other end.
Turn AIC switch off.
Connect one end of a 12-volt test light to main fan
control relay Yellow/White wire and ground the
other end.
I
I
Light OFF
I
Check lead wire connection.
When no problem is found, replace main fan control
relay.
13-48
''''"1~~~I-........
I'~t....
, ...'...
' _ ,....""'
....
,,""',........
, _ , ,_ _ _ _ _ _......_
T
- - - -_ _ _ _ _ _ _ _ _ _ _ _ __
liift
Dr I
,.
• ,.
T
.,. . . ,
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
6) Condenser Fan (Sub-fan) Diagnoses
Condenser fan will not operate.
I
Check 20A fuse for blower relay, 15A fuse
between ignition switch and blower relay,
and 20A fuse for condenser fan (sub-fan).
NOTE:
Follow this chart vvhile referring
to the description of the electric
system (page 13-16).
I
Fuse is blown.
Fuse is normal.
Locate short-circuited spot, and repair or replace
damaged parts.
Connect one end of a 12-volt test light to the fan
motor lead wire, and ground the other end.
Light ON
Light OFF
Check lead wire and ground wire of fan motor for connection.
When' there is nothing wrong with them, replace fan
motor.
Connect one end of a 12-volt test light to the
sub-fan relay Blue/Green wire, and ground the other
end.
Light ON
Light OFF
Tum the headlight off. Connect one end of a 12-vol t
test light to the sub-fan control relay Blue/Black wire,
and ground the other end.
Check wire discontinuity on the side of electric
power source.
Light ON
Light OFF
Ifthe fan does not turn when the sub-fan relay
Yellow/White wire is grounded, check the wire
connector. If the connector is normal, replace the
sub-fan relay.
Connect one end of a 12-volt test light to the sub-fan
control relay Blue wire, and ground the other end.
Light ON
Light OFF
Check the sub-fan control relay wire connector.
If the connector is in good condition, replace the
sub-fan control relay.
13-49
-------
---- ---
HEATING, VENTILATING AND AIR-CONDITIONING SYSTEM
13·5~
Special Tools
Air-conditioning
1____ 9 =5?!~??O (G B339628)
925780000 (GB472430)
925790000 (GB472437)
925800000 (GB350533)
I
Clutch Hub Puller
Hub Nut Socket
Oil Separator
l'lurd, Hub Wrench
*
[ .u;,~o hOl~'~t'_h__h__U_b~_+___u~se_d_t_o_re_m_o_v_e_c_lu_tC_h_h_U_b-+-~~u_S;_d_t_o_r_em_ov_e_c_lu_t_ch_hU_b-+_~_~_:~_g~_~_a~_i~_t:_~_;_~~_em_O_il_fr_o_m----1
~c,p
~
F'!I_ 13-119
,
A26-045
Fig. 13-120
A26-046
Fig. 13-121
A26·047
Fig. 13-122
ST-176
- ------ ------~-+-------------+----~-~---_+__---~-----___i
'i2S;'.;.2UOOO (GB303961)
925840000 (GF304790)
925850000 (GF304791)
~------------------------t-------------t---------t------------1
Double Union *
Connector Pipe *
~ I'lexible I-jose *
1_\~Se~1 witJ~ __
O_il_S_ep_a_r_a_t_o_r)------i_(_U_s_ed_w_ith_O_il_S_e_pa_r_at_o_r)_t--(_U_s_ed_w_it_h_O_il_S_e_p_ar_a_to_r)_+-_~---------i
I::~
=
~-
Fig. 13-123
ST-178
Fig. 13-124
ST-179
Fig. 13-125
ST-180
* : Oil Separator Kit is composed of Oil Separator, Flexible Hose, Double Union and Connector Pipe.
13-50
1<.
I i I,
~
CHAPTER iJ~
BODY
Page
14- 1.
BODY CONSTRUCTION AND DATUM POINTS ............ 14- 2
14- 2.
GLASSES ........................................ 14-11
14- 3.
DOORS ......................................... 14-20
14- 4.
REAR GATE ..................................... 14-35
14- 5.
BODY PARTS AND OUTER ACCESSORIES .............. 14-41
14- 6.
INSTRUMENT PANEL ............................... 14-52
14- 7.
SEAT AND BELT .................................. 14-55
14- 8.
INNER ACCESSORIES .............................. 14-62
14- 9.
SUNROOF (Option) ................................ 14-66
14-10.
SPECIAL TOOLS .................................. 14-68
•
SlIBARU
BODY
14-1. Body Construction and Datum Points
• Body Construction
NOTE:
Body construction parts for Sedan are as follows. For others they are essentially the same as for Sedan.
A24-719
1
2
3
4
5
6
7
Roof
Rear quarter panel (Inner)
Center pillar (Inner)
Front pillar (Inner)
Rear shelf
Rear quarter panel (Outer)
Center pillar (Outer)
8
9
10
II
12
13
14
Front pillar (Outer)
Front bulkhead
Rear skirt
Rear floor
Floor
Toe board
Front wheel apron (R.H.)
15
16
17
18
19
20
21
Front wheel apron (L.H.)
Frame (R.H.)
Frame (L.H.)
Radiator panel
Front skirt
Rear wheel apron
Distance piece
Fig. 14-1 Body construction parts (4-Door Sedan)
14-2
I,
,I,
- .. ~--~-.........,--------------------
I
BODY
• Body Datum Points
1. Center Structure
1) Measuring Points
NOTE:
Measure dimensions with mounted parts removed.
A
B
c
o
G
J
H
K
L
M
N
o
A24·297
A
B
C, D
G, H
I
I
K
L, M
N,O
Hole for undergard mounting 8 mm bolt
Gauge hole of 15 mm (0.59 in) dia.
Holes for front crossmember mounting bolts
Holes for rear crossmember mounting bolts
Gauge hole of 15 mm (0.59 in) dia.
20 x 50 mm (0.79 x 1.97 in) elongated hole
Gauge hole of 20 mm (0.79 in) dia.
Holes for rear suspension mounting bolts
Gauge holes of 22 mm (0.87 in) dia.
Fig. 14-2 Measuring points of center structure
14-3
BODY
2) Center Structure Alignment Dimensions
NOTE:
Each dimension indicates a projected dimension between hole centers.
55
345 140
278
(2.17) (13.58) (5.51)(10.94)
307
(12.09)
510
(20.08)
320
(12.60)
570
(22.44)
150
~1)
re
N
~
of '
00
-
~
::
M ~.-~ !:!
-
~
to
10 ~
C"!
g
A
/
B
f7
~
f'
C
)
-.-
, CD'
"'(c)'
~ ~
f'
en
, ..0.
~.
f'
to
g
~~ .~~.
1----.-- f---_
~!8 ~g
' 10'
G
I~
f'
H
I
~~-F
~:
J
\
II LB~'hO"'~(
M
~
:;:en
"I;"
Bolt hole 11 (0.43) dia. (0.51) dia.
Gauge hole 15 (0.59) dla.
Bolt hole M8
to
en
~~.:
~ '~T
III
,.-......
;;::::::
f'
..2-
80
(3.15)
~
UII
-t:::f:iii
557
(21.93)
490 (19.29)
(2-Door
Hatchback)
8
(0.31)- f-
~
80
183
(3.15) (7.20)
'\!
Gauge hole 15 (0.59) dia.
Bolt hole M12
IY
N 0
M
K L
T/
"-
V
LBoit hole M12
Gauge hole 20 (0.79) dia.
\
-"
Gauge hole 22 (0.81) dia.
,
Elongated hole 20 x 50 (0.79 x 1.97)
-
M
M
-
Under surface of side sill
Unit: mm (in)
A24-298
~
1
1
j
Fig. 14-3 Center structure alignment dimensions
14-4
I"
II
. ,·-,"~;j...\"'''~·~''''''''''''''''--'''''""1r-rr------'''''''- , - - - - - - - - - - - - - - - - - - - -
J. .
~
BODY
NOTE:
Each dimension is arranged so that the left and right sides are symmetric.
·1 ......... For 4·Door Sedan, Hardtop
and Station Wagon
·2 ......... For 2·Door Hatchback
p
Unit: mm (in)
A24·299
Fig. 14-4 Center structure alignment dimensions
14-5
BODY
2. Front Structure
Measuring points and datum dimensions of front structure
A24·300
Affixed letters Land R indicate left and right side holes respectively.
AR. AL
BR. BL
CR. CL
DR. DL
ER. EL
FR. FL
...........
...........
...........
...........
...........
...........
Fender set holes [symmetrically arranged)
Radiator set pin tip centers (asymmetric)
Radiator set holes [19 mm (0.75 in) dia .• asymmetric)
Hood lock set holes (asymmetric)
Front crossmember set holes [11 mm (0.43 in) dia .• symmetric)
Front crossmember set holes [11 mm (0.43 in) dia .• symmetric)
GR. GL ........... Strut mount front holes (symmetric)
HR. HL ........... Fender set holes (symmetric)
I ..................... Spare tire set hole centerx (center of vehicle)
Fig. 14·5 Measuring points of front structure
14·!3
j
j.
•.
-..·1__..., - -...114'1....,..'..,---....,_,- __- - - - - - - - - - - - - - - - - - - - - -
~."',"">,..-~<-"'-,~ ..> ......
, . . . . . . . .'. . .
BODY
A24·301
Unit: mm (in)
AR-HR
AL -HL
AR -AL
HR-HL
AR- HL
AL -HR
BR -BL
CR -CL
BR -CL
977 (38.46)
J 275 (50.20)
1317(51.85)
1623 (63.90)
480 (18.90)
425 (16.73)
554 (21.81)
Unit: mm (in)
BL-CR
DR-HR
DL-HL
FR-GL
FL -GR
GR-GL
ER - I
EL - I
GR - I
GL - I
605 (23.82)
1228 (48.35)
1217(47.91)
920 (36.22)
954 (37.56)
570 (22.44)
511 (20.12)
NOTE:
Each dimension shows actual distance between hole centers.
Fig. 14-6 Front structure dimensions
14-7
BODY
3. Front Windshield and Rear Window
Roof
MeaSUring~
point
/
Glass}!"
,,~
. .../ ~ Weatherstrip
Datum for
measurement
Detail drawing
Unit: mm (in)
Unit: mm (in)
Rear window
Front windshield
1\
Hatchback
Sedan
Station Wagon
OpenM.P.V.
Hardtop
Sedan
Hardtop
a
654 (25.75)
659 (25.94)
593 (23.35)
660 (25.98)
b
656 (25.83)
655 (25.79)
590 (23.23)
665 (26.18)
c
1,127 (44.37)
1,128 (44.41)
1,094 (43.07)
1,128 (44.41)
d
1,300 (51.18)
1,297 (51.06)
1,277 (50.28)
1,330 (52.36)
e
45 ( 1.77)
34 ( 1.34)
32 ( 1.26)
30 ( 1.18)
f
374 (14.72)
370 (14.57)
352 (13.86)
415 (16.34)
Remarks
Standard dimensions
(Datum for measurement)
A24·724
Fig. 14·7
14-8
II
II
-,.-<1,
, t·· ...
. . . ,. . '---rrl
.
..'----v--"'-""----------------------)
'"'··'~"·"d~...-.""~ __ ~~_t._
---,
BODY
4. Doors
Each dimension shows actual distance.
mm (in)
• Sedan and Station Wagon
Distance between left and right
L,
L,
L3
L.
833
(32.80)
1,380
(54.33)
858
(33.78)
1.540
(60.63)
"L4" refers to distance between "b" (left)
and "b" (right).
=~~~::::::~:::::::~ "L2" refers to distance between "a"
(left) and "a" (right).
5 mm (0.20 in) dia. hole (for weatherstrip)
A24-725
Fig. 14-8
• Hatchback, Hardtop and Open M.P.V.
Each dimension shows
actual distance.
mm(in)
1,066 (41.97)
"L2" refers to distance between
"a" (left) and "a" (right).
5 mm (0.20 in) dia. hole
(for weatherstrip)
A24·726
Fig. 14-9
14-9
BODY
s.
Rear Gate
• Hatchback
Reer gate stey
lower mounting hole
Angle of flange
at rear gate location
Cross-section of
vehicle center
Rear skirt
Floor="
I
mm (in)
a
b
c
833 (32.80)
1,105 (43.50)
1,250 (49.21)
Fig. 14-10
A24-727
• Station Wagon
r
ROOf
~
Angle of flanJe
at rear gate
location
a
Cross-58ction of
vehicle center
Angle of flange
Floor
c
mm (in)
Relr combinltion
limp mounting
hole
14-10
I,
b
1,001 (39.41)
1,136 (44.72)
I
c
I 1,476 (58.11)
A24-72B
Fig. 14-11
I,
a
I
M1
*
r I
1
BODY
• BRAT
Rear gate striker fitting surface
J
-----1,245 mm-----i
(49.02 in)
Rear gate striker
Rear quater end (upper!
Rear quater (outer!
Cross-section A
A24-794
Fig. 14-12
14-2. Glasses
1. Front Windshield and Rear Window
Rear on BRAT
@@
®
@
1 Front windshield glass
2 Weatherstrip
3 Moulding
4 Joint
5 Grommet
6 Rear window glass
7 Sash
8 Rail
9 Slide glass
10 Lock
11 Channel
Fig. 14-13
@
@
A24-795
14-11
-~
BODY
@
• Front
NOTE:
1) Removal
a. Overlap the end of work cord at the
bottom of glass.
I) Raise windshield wiper arm forward.
2) Turn up the lip of weatherstrip
from the passenger compartment, and
force it out of body flange.
This is to be carried out on the top
and along about half of the side of the
glass.
3) Push out glass along with weatherstrip and mouldings from the passenger
compartment.
NOTE:
a. Apply an even force to glass at the
portion near weatherstrip.
b. If weatherstrip will not be reused,
cut it off with a knife and take it
out.
4
1 Glass
A24-416
2 Weatherstrip
3 Spatula
4 Body
A24-419
Fig. 14-18 Adjusting weatherstrip
Fig. 14-16
b. After work cords are fitted to
weatherstrip, apply kerosene to the
entire edge of weatherstrip.
3) Fit mouldings into the groove of
weatherstrip.
4) Position glass properly from outside, and bring work cords into
passenger compartment.
S) Apply kerosene along the entire
lip of weatherstrip.
6) Pull out the lip of weatherstrip for
the end of roof trim, and then fit
weatherstrip in such a manner that the
lip moves over body flange while
tapping glass with hand from the
outside and pulling work cord from
passenger compartment.
8) Settle the whole glass in the body
by tapping it with hand or a rubber
hammer.
9) Apply sealing agent (Starseal
U-70).
Wipe off exuded sealing agent.
A24-415
A24-089
Fig. 14-14 Pushing out windshield
CD
4) Detach mouldings from weatherstrip.
2) Installation
1) Wipe sealing compound off
weatherstrip with kerosene.
2) Attach weatherstrip to glass, and
then fit work cords into the grooves of
weatherstrip.
A24·418
Fig. 14-17 Installing windshield
a. Work should proceed from the
center of the glass to the left and
right.
b. Push or tap the glass by hand but
don't tap mOUldings.
c. Fit weatherstrip correctly to the
body.
Work cord
Weatherstrip
Fig. 14-15 Fitting work cords
A24·032
Glass
Fig. 14-19 Applying sealing agent
NOTE:
I
2
Weatherstrip
A24-420
7) Insert a spatula in between
weatherstrip and the flange of body,
and move it along the entire length
of weatherstrip.
• Rear
Removal and installation of rear
window glass can be carried out in the
same manner as in the front windshield.
NOTE:
When replacing slide glass on 4WD
Open M.P.V. GL model, insert (new)
slide glass into sash while expanding it.
14-12
I,
II
·~'~~'·''''·~~·~~~~~4->''''''''''''''''''''''''''''''''''I'-j'"~ilI......
••- - - '...,--,_...
, -------------------
BODY
2. Side Window on Hatchback
Out
In
c.--
7.8±2mm
(0.307 ± 0.08 in)
Rear Quarter panel
A24-438
Fig. 14-25 Cross section of D -
1 Side' window glass
2 Hinge plate
3 Flange screw
n
4 Nut plate
S Packing
6 Rosette
2) Removal
7 Screw
8 Hinge cover
9 Lock
A24-428
I) Detach hinge covers by prying
them off with screwdriver.
2) With the glass opened halfway,
remove two screws fixing lock.
3) Remove hinge set screws.
Fig. 14-20 Component parts
NOTE:
1) Adjustment of Glass Position
Although the glass won't fall in this
state (in stoppage), remove glass by
holding it with one hand so that the
glass does not fall accidentally.
1) Adjusting measures
a. Shifting glass position is made by
loosening screws fixing hinges and/
or lock to the body.
b. Rotation of the glass in the vertical
plane is made by loosening screws
fixing the glass to the hinge and/or
lock.
2) Measuring points of gap.
4) Carefully move the glass to the
outside and take it out from the rear.
1 _~oof side rail
2 Roof
3 Drip rail moulding
A24-436
Fig. 14-23 Cross section of B A24-432
Fig. 14-26 Removing side window
glass
A24-434
Fig. 14-21 Measuring points of gap
5) Remove hinge plates and lock assembly from the glass after placing it
on a rag, mat or the like so as to
protect it from damage.
6) Remove weatherstrip from flange
of body.
3) Installation
A24-437
Unit: mm (in)
A24-435
Fig. 14-22 Cross section of A -
Fig. 14-24 Cross section of C -
14-13
1) Install weatherstrip as follows.
a. First fit the rear lower corner of
weatherstrip down to the bottom
so that it mates properly to the
recess in the body.
BODY
b. Second, fit the front upper corner
in the same manner as above.
c. Then fit remaining portion to the
flange.
3. Side Window on Hardtop
NOTE:
a. Fit weatherstrip by tapping with
rubber hammer.
b. Never hit weatherstrip too strongly,
otherwise the flange might be deformed.
c. Since the groove of the weatherstrip serves to fix the trim panel, fit
weatherstrip to the body flange
with depressing trim panel toward
the body flange so as to place it
underneath the weatherstrip.
2) Install hinges and lock assembly
to the glass with screws.
NOTE:
a. To engage nut plate and hinge
or lock, align flats of them.
b. Tighten the screws temporarily in
this step, and tighten securely after
glass position adjustment is made.
Nut plate
1 Retainer
2 Roof side weatherstrip
3 Side window weatherstrip
4 Stopper B
S Outer weatherstrip
6 Corner patch
7 Stopper A
8 Adjust nuts
9 Regulator
10 Guide plate
A24-439
Fig. 14-28 Component parts
Since adjustment of side window glass
depends upon adjustment of door glass
adjustment, first adjust door glass
according to the door glass adjusting
procedure.
1) Adjustment
A24-433
Adjustment of the side window glass is
carried out with roof side weatherstrip
dismounted.
Fig. 14-27 Aligning flats of nut plate
and hinge or lock
Stopper A
Stopper B
3) Install the glass assembly to the
body by tightening screws while adjusting the glass position.
Fig. 14-29 Side window glass adjustment
14-14
I
,
A24-448
BODY
Adjusting measure
Movement of glass
A. Frontward/rearward shift
C. Frontward/rearward inclination
Uppermost position
B.
D. Inward/outward shift of glass
bottom at uppermost position
E. Inward/outward shift of glass top
at uppermost position
NOTE:
When frontward/rearward shift adjustment of door glass is necessary, refer
to door glass adjustment for Hardtop,
because adjusting measure for Hardtop
is different from that for 4-Door
Sedan and Station Wagon.
A Adjustment of contact pressure
1) Close the door glass all the way,
and temporarily adjust the gaps to
the dimensions shown in the following figure by moving side window
glass upward/downward and frontward/rearward.
(Shift door glass frontward or rearward by adjusting rear sash of door as
reqired. Refer t" the door section.)
~
LJ
Moving positions of guide plate by
loosening three nuts of upper and
lower adjuster
5 mm (0.20 in) forward &
5 mm (0.20 in) rearward
Moving positions of stopper A and B
5 mm (0.20 in) upward &
5 mm (0.20 in) downward
Screw or unscrew two bolts of upper
adjuster
3.5 mm (0.138 in) inward &
3.5 mm (0.138 in) outward
Screw or unscrew one bolt of lower
adjuster
8 mm (0.31 in) inward &
8 mm (0.31 in) outward
3) Open door glass all the way.
4) Position the glass at the window
shoulder as shown in the following
figure by revolving two bolts of upper
adjuster with screwdriver.
.....
Door glass
Unit: mm (in)
A24-449
Fig. 14-30 Dimensions of gaps
Out
=
In
~ ~
c>
-----c:::o...cs ~
C:I>
Unit: mm (in)
Approx.17.S (0.701)
(Parallel)
A24-450
Fig. 14-31 Adjusting contact pressure
at window shoulder
~
.
3:~~
Fix the stopper A.
Flange nut
tightening
torque
7 -9 N·m
(0.7 - 0.9 kg-m,
5.1 - 6.5 ft-lb)
Approx. 5 em (2.0 in)
A24-451
Fig. 14-32 Adjusting contact pressure
at rear pillar
14-15
A24-452
Fig. 14-33
B Adjustment of gap
1) Loosen two nuts of upper adjuster
and one nut oflower adjuster.
2) Applying a little upward force
to the glass by the regulator handle,
adjust the position and inclination of
the glass so that the gap between the
rear edge of glass and weatherstrip retainer corresponds the dimension
shown in the following figure, and
then fix three nuts and stopper B.
Tightening torque
(0.12 - 0.20 in)
9-----
2)
5) Adjust the gap between glass and
weatherstrip retainer at the top of the
glass to the dimension shown in the
following figure by revolving the bolt
of lower adjuster.
Approx. 17.S (0.701)
(Parallel)
Then make sure that the gap between
glass and weatherstrip retainer at rear
pillar corresponds to the dimension
shown in the follOWing figure. Adjust
the gap by upper adjust bolt, if
necessary.
6±2 (0.24±0.OS)
Adjustable length of adjuster
Flange nuts
of adjuster
18 - 23 N·m
(1.8 - 2.3 kg-m,
13 - 17 ft-Ib)
Hex. bolt
fixing
stopper B
5 -7 N·m
(0.5 - 0;7 kg-m,
3.6 - 5.1 ft-Ib)
BODY
(Refer to door glass.)
NOTE:
a. The above-mentioned adjustment
should be carried out with a slight
force applied to regulator handle
so as to eliminate free play.
Approx. 8.1 mm (0.319 in)
~
Parallel 6
±2
~
(0.24
In~Out
± 0.08
1
JL----~
~~ Stopper B
r
~
Approx.8.1 mm(Q.319in)
~o,~
in)~
-
A24-455
Fig. 14-36 Confirmation of gap
adjustment
A24·453
Fig. 74-34 Gap adjustment of glass
rear edge
b. Make sure that stopper A and B
come in uniform contact with glass
holder.
c. for readjusting the gap at the
top of the glass, carry out A-1)
and 2). and then 8-1) and 2). If
this order is neglected, the glass
might incline forward, whereby
proper gap won't be obtained.
Wrong
~
NOTE:
If the contact pressure is excessive,
erroneous engagement with the weatherstrip, abnormal wear, increase in
force needed to operate the regulator
or a similar trouble might be caused.
c. Door glass rear edge does not contact to the shoulder of weatherstrip on side window glass.
If it contacts, the gap is improperly
adjusted.
d. There is no clearance between door
glass and weatherstrip on side window.
If there is clearance, the contact
pressure is insufficiently adjusted.
4) Make sure tha t the gaps at side
window glass are provided in accordance with above figure.
C Check of side window adjustment
1) After adjusting side window glass,
fit roof side weatherstrip securely to
the retainer.
2) Confirm the following items so as
to prevent water leakage or the like
trouble_
a. The whole edge of glass is covered
with the lip of weatherstrip, leaving no clearance.
If there is a clearance, the gap is
inproperly adjusted.
b. No clearance appears by slightly
pushing the glass from the passenger compartment.
If a clearance does, the contact
pressure is insufficiently adjusted.
Shoulder of weatherstrip
1 Weatherstrip on side window
2 Moulding
3 Side window glass
4 Door glass
A24-457
Fig. 14-38 Checking adjustment
e. The weatherstrip on side window
glass is not bent to outside of door
glass upon operating door window
regulator or side window regulator.
If it is the gap or contact pressure
is improperly adjusted_
In
Door glass
I Stopper
2 Glass holder
Parallel
Weatherstrip
on side window glass
A24·454
Out
Fig. 14-35 Fixing stopper A and B
A24-458
3) Make sure that the gap between
door glass and weatherstrip on side
window glass has the same dimension
as shown in the following figure.
If necessary, shift the door glass
frontward or reaward by adjusting
rear sash.
Fig. 14-39 Bending of weatherstrip
Slightly pushing
I Weatherstrip retainer
2 Roof side weatherstrip
Fig. 14-37 Checking adjustment
14-16
I,
II
A24-456
3) After installing sealing cover,
sprash or shower water to make sure
that there is no leakage into the compartment.
BODY
2) Removal
NOTE:
a. When removing the parts, carefully
protect the body paint, glass, etc.
from damage.
b. Be careful not to damage trim
panel, sealing cover, etc.
9) Lower regulator arm by turning
regulator handle so as to facilitate reo
moving the side window glass.
10) Lift side window glass up to a
position 10 to 15 em (approx. 5 in)
below the roof, and then remove it
from front opening of the window
together with guide plate by turning it
forward.
I) Remove rear seat cushion and
back rest.
2) Remove seat belt shoulder anchor.
3) Detach regulator handle.
4) Detach arm rest, rear pillar trim,
upper trim panel and lower trim panel.
5) Remove seat belt retractor, dis·
connect electric connector for door
switch, and then detach sealing cover.
6) Lower side glass fully, and remove
one tapping screw fixing outer
weatherstrip from the inside. Also reo
move two tapping screws fixing grille
from the outside. Lift grille slightly
and pull out outer weatherstrip to the
forward.
7) Close the glass halfway and dis·
connect glass holder from regulator
arm.
a. Deformation or crack on weatherstripping.
b. Wear or damage on glass holder
roller.
c. Excessive free play or damage on
the parts of regulator.
d. Lubrication on regulator and guide
plate.
1) Install regulator in pOSition with
four bolts.
Torque
2) Position side window glass along
with guide plate, and tighten the 3 adjusting nuts which fix the guide plate.
A24·446
Torque
Fig. 14-41 Removing side window
glass
NOTE:
Be careful not to drop the nut into
interior of body panel.
NOTE:
In this case, keep adjust bolt fully
screwed in the guide plate so as to
facilitate removing side window glass.
However, it is recommended to mark
the set position of the adjust bolt to
make adjustment easy.
8) Remove stopper B and three ad·
juster nuts. Don't remove stopper A
in this step.
11) Remove four bolts fixing regula·
tor, and then take out the regulator
from the work hole.
18 - 23 N'm
(1.8 - 2.3 kg-m,
13 - 17 ft-lb)
NOTE:
When mounting side window glass in
combination with guide plate, carefully protect body paint and glass
from damage. Pay special attention
not to damage the rubber parts of
weatherstripping. Otherwise, water
might leak in.
3) Attach stopper B with bolt and·
washers.
Torque
NOTE:
It is recommended to put a mark to
recognize its original position.
5 -7 N'm
(0.5 - 0.7 kg·ro,
3.6 - 5.1 ft·lb)
4) Tighten flange nut to connect
regulator ann with glass holder.
Torque
CD--,--
5 -7 N'm
(0.5 - 0.7 kg·ro,
3.6 - 5.1 ft-Ib)
7-9N·m
(0.7 - 0.9 kg·m,
5.1 - 6.5 ft-Ib)
IJ
A 24-441
Fig. 14-42 Removing regulator
1 Regulator handle
2 Stopper B
3 Adjusting nuts
A24-445
Fig. 14-40 Removingstopperand
adjuster nut
3) Installation
NOTE:
Prior to installation, it is necessary to
check the following items.
Fig. 14-43
A24·444
14-17
------'
BODY
5) Attach outer weatherstrip and
corner patch.
6) Attach sealing cover, connect
electric connector for door switch, and
then install seat belt retractor.
NOTE:
Attach sealing cover properly to
prevent water leakage.
A24-691
7) Attach lower trim panel, upper
trim panel, rear pillar trim and arm
rest.
Fig. 14-46 Window regulator for
power window
2 Weatherstrip
NOTE:
2) Installation
a. When removing upper trim panel,
disconnect electric wires at connectors.
Install rear quarter glass in the same
manner as windshield.
A24-421
Fig. 14-48 Rear quarter glasses
NOTE:
a. Overlap the work cord at center
of front edge of rear quarter glass.
b. Apply a sealing agent (Cemedine
#366E) as shown following figure.
c. Make sure that there is no gap between weatherstrip and rear pillar
mOUlding.
A24-441
1 Rear pillar trim
2 Upper trim panel
3 Lower trim panel
Fig. 14-44
8) Attach regulator handle.
9) Install seat belt shoulder anchor.
10) Install rear seat cushion and back
rest.
4) Power Window (Option)
Switches for power window are
provided on upper trim panels instead
of window regulator handles, and a
window regulator has a electric motor.
Removal, installation and adjustment
procedures are common to the side
window with (manual) window regulator.
A24-692
Fig. 14-47 Electric wires and
connectors
b. When taking out window regulator,
also disconnect electric wire at
connector.
A24-422
Fig. 14-49 Setting work cord
4. Rear Quarter
Window on Sedan
and Hardtop
1) Removal
A24-690
Fig. 14-45 Switch for power window
1) Remove inner trim.
2) Remove rear pillar moulding or
opera grille.
3) Remove rear quarter glass in the
same manner as windshield.
Rear pillar
2 Rear pillar moulding
A24-423
Fig. 14-50 Sealing of rear quarter
glass (4-000r Sedan)
14-18
,t,
-'>.-~""",*",,,,,-... ,~ ...... -."... -,.,;~--- ...... ,~.~.--,- , - , - - ,- ,. -...
, - ,,.I------~,-,-,------------------
BODY
CD
I Rear pillar
2 Opera grille
A24-426
A24-424
Fig_ 14-51 Sealing of rear quarter
glass (Hardtop)
I Glass
2 Weatherstrip
A24-425
Fig. 14-53 Setting work cord
Fig_ 14-52 Rear Quarter glass
b. Apply sealing agent (Cemedine
#366E) into groove of weatherstrip
s.
Rear Quarter
Window on Station
Wagon
Pillar
2)
Installation
1) Removal
Install rear quarter glass in the same
manner as windshield.
I) Remove inner trim_
2) Remove rear quarter moulding.
3) Remove rear quarter glass in the
same manner as windshield.
NOTE:
a. Overlap the ends of work cord at
top of rear quarter glass.
14-19
A24-427
Fig. 14-54 Sealing of rear quarter
glass
BODY
14-3. Doors
1. Component Parts
• Front
1
2
3
4
5
6
7
8
9
10
11
12
13
Door panel
Upper hinge
Lower hinge
Regulator
Door glass
Glass holder
Door latch
Door striker
Inner remote assembly
Sealing cover
Upper trim panel
Lower trim panel
Arm rest
14
15
16
17
18
19
20
A24-702
Fig. 14-55
• Rear
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Rear door panel
Upper hinge
Lower hinge
Regulator
Rear door glass
Glass holder
Door latch
Door striker
Inner remote assembly
Sealing cover
Uppertrim panel
Lower trim panel
Arm rest
Inner weather strip
Outer weather strip
Door outer handle
Regulator handle
A24-693
Fig. 14-56
..,.1------.,. _I____....______________
14-20
I
I"
I
~~
..,....-- ••
''''~,.~
••
~'''''''"''_,
....
t+_.'",5
...........
,_
.....
_~,
t
.,
. .. ,_ _
,
BODY
2. On-car Services
• Outline of Whole Jobs on Door
NOTE:
This chart shows only major procedure for removing and installing the door.
For details refer to the relevant description in this manual.
I
I~I
Door wck
I
II
I
Door Regulator
,
•
I Door Glass I
I
J
I
Remove door trim, etc.
J
1
I Remove front and rear upper stoppers I
I Remove door I
~
Removal
l
I
I
Disconnect door glass and regulator
1
~
I Remove door glass J
,
I Remove regurator channel B I
I Remove door lock I I Remove regulator I
-
-
I
I Install regulator I
I
Install door
I I Install door lock II Install regulator channel B I I Insert door glass
I Adjust door lock I
Installation &
Adjustment
I
I
• •
Connect door glass and regulator
~
J
I Adjust door fitting I
I
Install front and rear stoppers
I
I Adjust striker I
! 1
Adjust glass position
~.
I
14-21
1
l
I
Install door trim, etc.
I
Check operation, etc.
I
•
~
I
I
I
I
I
BODY
• Fitting Adjustment
®
Door is adjusted back and forth
and vertically by loosening 8 mm
bolts, which fIxes the body side of
upper and lower hinges, using a special
tool (Door hinge wrench 925610000).
A24·463
A24·467
Fig. 14·57 Loosening door hinge
bolts on body side
Fig. 14-61 Detail of
®- ®
In
20 - 25 N'm
(2.0 - 2.6 kg-m,
14 - 19 ft-lb)
Tightening
torque of door
hinge bolt
..
9.3 ± 2 (0.366 ± 0.081
Front
:r
1j-®
1) 4-Door Sedan & Station Wagon
Out
Unit: mm (in)
A24·468
Front door panel
2 Center pillar
3 Rear door panel
Fig. 14-62 Cross section of ®
- ®
A24-464
Fig. 14-58 Measuring points for fitting adjustment
Fig. 14-63 Detail of
In
..
12.2± 2
1:.:....-;-,.
(0.480 ± 0.081
U
1
Front
Out
1 Front pillar
Fig. 14-59 Detail
CD - CD
In
Rear
Front
A24-465
.. ..
®- ®
2 Front door panel
Fig. 14-60 Cross section
14-22
Unit: mm (in)
A24·466
CD - CD
Out
1 Rear door panel
2 Rear quarter panel
Unit: mm (in)
Fig. 14-64 Cross section of ®
A24·470
- ®
'"'1'....,..1-----'-,.,-,------------------.
,~,~"",,, .~''''I-''''''_'~~'_-'~~'''~H'''''''''''''''...., - '...
, .........., - - ,
BODY
12.5 ± 2 (0.492 ± 0.08)
nfi
In
~
. c:;.-. ff'~
"2'
((.'
... 13l.~.
'~i6'
c:'J'.
I
w
~.
¥0.
Front . .
('IJ!
B.3 ± 2 (0.327 ± ?OB)
1:E... . ~.:~
¥
J \
1
( 1¥
Lj
+·l
'-',
-E~]
. . . . Rear
.
1 Fender
2 Front pillar
3 Front door
5.5± 1.5 (0.217±0.059)
Out
Unit: mm (in)
A24·471
Fig. 14·65 Cross section of
@- @
In
~l~.
'''=.
12.5 ± 2 (0.492 ± O.OB)
.
Front . .
9.6 ± 2
(O.37B ± O.OB)
r
l~J
~
5.6
1 Front door
2 Center pillar
3 Rear door
. . Rear
± 1.5 (0.220 ±0.059)
Out
Unit: mm (in)
A24·472
Fig. 14-66 Cross section of
@- @
14-23
BODY
Front _
_
Out
Rear
1 Front pillar
2 Door panel
12.5 ± 2 (0.492
±
Unit: mm (in)
A24-476
0.08)
Fig. 14-70 Cross section of
\.~:
.
\\:.~ ~L
1==-=.
00
.~~
Out
1 Rear door
2 Rear quarter panel
5.6 ± 1.5 (0.220 ± 0.059)
Unit: mm (in)
A24·473
Fig. 14-67 Cross section of
CD - CD
In
®- ®
Up
..
18.5 ± 2
(0.728 ± 0.08)
-
Rear
Front
18.5
±
2
(0.728 ± 0.081
In
Out
Out
1 Door inner panel
Unit: mm (in)
2 Rear quarter panel
Door
2 Side sill
Unit: mm Onl
Lower
Fig. 14-68 Cross section of (j)
Fig. 14-71 Cross section of 00
A24-477
- 00
A24·474
- (j)
2) Hatchback, Hardtop and BRAT
A24-475
Fig. 14-69 Measuring points for fitting adjustment
NOTE:
To obtain dimensions CD-CD and
@ -@, measure the distance between
sheet metals after removing the corner
patches of door and rear quarter panel.
14-24
1,,1.·,
"I""""'r- _____, ..., ...
, 1,..'_ _ _ _ _ _- - - - - - - - - - - - - -
-',..............,...
,_,...
,
".'~'_~M.,"."'*4""""""
BODY
~-,-,>!.!..!-_ _.......Jw..L...
~
~
(;nGlaSS
~t
3 - 4 (Free set value)
Unit: mm (in) (0.12 - 0.16)
A24-517
Fig. 14-93 Free set at window
shoulder
14-30
"
".
".1
•• 4
''' ..... -~,...... I.-~.,..
50
(1 .97)
Check for the followings
I) If the glass won't enter the com·
partment side over the top of weather·
strip when raising or lowering the
glass.
If it enters, the free set at window
shoulder is too much. Make adjust.
ment with referring discreption on
adjustment @.
-',..,.1------..,-,-----_--___________
..' - -......
' ...., _.....
, ...........
, , -...
1..
BODY
NOTE:
If regulator channel B is adjusted,
upper stoppers should be readjusted,
because even contact of upper stoppers
might be canceled.
Refer to adjustment @.
1 Weatherstrip
2 Glass
A24-518
Fig. 14-94 Checking (1)
2) If whole glass edge is covered by
the lip of weatherstrip with glass
closed all the way.
If not, glass stroke is insufficient.
Make adjustment by shifting upper
stoppers.
Refer to adjustment ® and @.
1 Weatherstrip
2 Glass
A24-519
Fig. 14-95 Checking (2)
3) If the gap against the body is
proper. (Pay special attention to the
center pillar side.)
If not, adjust by shifting bolts of front
sash.
Refer to adjustment © .
4) If the glass won't be inclined upon
fully closed.
If it inclines, the upper stoppers are in
uneven contact.
Make adjustment so as to obtain even
contact.
Refer to adjustment ® and @.
5) If the glass is moved properly.
If it moves in letter "8", make adjustment by shifting regulator channel B
up or down.
6) If gap is provided between glass
and roof side weatherstrip upon depressing the glass slightly by hand
from inside of passenger compartment.
If it is, make adjustment by turning
adjust bolts at the bottom of sashes.
Refer to adjustment @-2).
3. Repair for
Components
• Door
1) Removal and installation of front
door can be carried out by removing/
tightening 8 mm bolts of upper and
lower hinges on door side with Door
Hinge Wrench 925610000.
Torque
(8 mm bolt)
20- 25 N·m
(2.0 - 2.6 kg-m,
14 - 19 ft-Ib)
NOTE:
Confirm there is not water leakage
into passenger compartment by pouring water with a hose or shower.
7) If the glass is moved smoothly by
operating regulator handle.
If operating force is too large, ie. more
than 34.3 N (3.5 kg, 7.71b) when
raising, more than 53.9 N (5.5 kg,
12.1 Ib) at end of its stroke, possible
causes are as follows:
a. There is inclination of the bracket
for adjusting top of rear sash.
b. Each bottom of front and rear
sashes is not adjusted uniformly.
c. There is an excessive friction
between the glass and inner weather
strip at top of trim panel.
8) If the glass comes in contact with
the retainer of roof side weatherstrip
upon closing the door.
If it does, make adjustment with referring to adjustment ®, ® or ©.
9) If the lip of weatherstrip is engaged into inside of the glass upon
closing door with glass at its upmost
position.
If it is, the glass rises excessively, and
make adjustment with referring adjustment@.
A24-461
Fig. 14-98
2) With front door open, rear door
can be removed/installed in the same
manner as front door.
3) When remOving/installing door,
jack up the door with rag or wood
block placed at the bottom of door.
A24-462
--------------
---I
Fig. 14-99
///
i
No good
Good
A24-521
A24-520
Fig. 14-96 Checking (5)
Fig. 14-97 Checking (9)
14-31
4) Apply grease to the moving point
of door hinge.
5) Fill inside of grease cap with
grease.
BODY
• Inner Remote ASSY
1) Detach trim panel and sealing
4) Disconnect key lock ASSY from
door latch rod.
~~iVCr.
2) Disconnect two rods from door
latch.
NOTE:
a. After installation, make lure that
locking mechanilm operatel pro·
perly.
b. Check the following items.
• each movement of locking system .
• Lubrication to each sliding por·
tion .
• Outer Handle
A24·a17
Fig. 14·103 Disconnecting key lock
from rod
5) Remove screws, and take out door
latch through the lower work hole.
fig. 14·100 Rf/movlng SCfflW
I) Remove trim panel and sealing
cover.
2) Remove door glass, and discon·
nect outer handle rod and door latch
rod.
3) Detach outer handle from the
outside.
A24·4ea
Fig. 14·101 Df/rlChlng rod hold"
A24·a18
Fig. 14·104 Removing latch
3) Remove Inner remote ASSY.
A24·132
Fig. 14·706
6) Pull out retainer spring, and take
out key lock from the outside.
4) Installation can be carried out in
the reverse order of removal.
NOTE:
Adjust free play batween adjust nut
and door latch laver into 0.& to 1.0 mm
(0.020 to 0.038 in).
A24·a,a
Fig. 14·102
4) Installation can be carried out in
A24·820
Fig. 14· 706 Pulling out retainer spring
the reverse order of removal.
• Door Latch and Key Lock
1) Detach trim panel and sealing
cover.
2) Close door glass all the way.
3) Separate remote ASSY from door
latch.
Installation can be carried out In
the reverse order of removal.
7)
Torque
Latch Installing
screws
4-6N·m
(0.4 - 0.6 kg·m,
2.9 - 4.3 ft·lb)
14-32
1'1.,,11
•• ,
Au·a"
Fig. 14·101 Ff'H play of adjust nut
BODY
• Door Glall
Removing and installing procedures
are common to the front and rear
door glasses.
1) Detach trim panel and sealing
cover.
2) Remove outer weatherstrip.
3) Remove upper stoppers at the
front and rear of door by loosening
bolts, and detach two bolts fixing glass
holder to regulator channel A.
5) Installation can be carried out in
the reverse order of removal.
Tlahten1na torque
for reBulator
channel A flxlnB
Icrews
7 - 8 N·m
(0.7 - 0.8 ka-m,
5.1 - 5.8 fi·lb)
NOTE:
Place the claw of glan holder lecurelv
on the regulator channel A.
A24·I02
Fig. 14·111 R,movlng ",ullror
5) Remove all nutl, and take out
lash through the opening for the alall.
A24·488
Fig. 14·108
1 Claw
2 Relulator channel A
NOTE:
a. It il recommended to mark each
part before removal to facilitate
adjustment.
b. Whan removing the bolt of regula·
tor channel A, lower the gla.. until
the bolt comel in the .. rvice hole.
c. Never turn regulator in cloling
direction while gla. il removed,
otherwi.. the gear might be dil'
engaged.
4) Hold glass by both hands with
door openec1, and then pull it out
upward while pushing it slightly
against the front sash side (for 4·Door
Sedan and Station Wagon) or the
rear sash side (for 2·Door Hatchback
and Hardtop).
A24·IO'
Fig. 14·10 P/lelng e/lw onto "gu/lror
ehlnn,' A
FIg. 14·112
2) Inspection
• Door Olall Regulator and
Sish
Although following description II
based on front window reaulator,
removal and Installation of rear
window regulator can be carried out
in the same manner al that for the
front window regulator.
Check rel\1lator for followinl Iteml,
and replace with new one or repair it
if defective.
a. Gear for exee'live wear
b. Spring for breakaae
e. Other component partl fOf damale
or abnormal wear
d. Each sliding portion for proper
lubrication
1) Removil
~o
A24·IOO
FIg. 14·109
1) Detach trim panel and lealing
cover.
2) Remove outer weatherstrip and
end of door weatherstrip, and then
take out door gla••.
3) Remove four boltl fixina reau1a·
tor bale plate and two boltl fixina
reaulator channel B.
4) Take out reaulator ASSY throuah
the lower work hole of door panel.
14-33
AI4·IOI
FIg. 14·1'13 Wlndow,."ul'tor
BODY
NOTE:
Apply grease to the location indicated
by arrows in the above figure.
NOTE:
a. When removing trim panel, discon·
nect electric wires at connectors.
4. Power Window
(Option)
Switches for power window are pro·
vided on doors (except front passenger
side door) instead of window regulator
handles, and window regulator of each
door has a electric motor. Removal,
installation and adjustment procedures
are common to the door with (manual)
window regulator.
3) Installation
Reverse the steps in removal.
Torque
Regulator
mounting
bolts
7 - 8 N'm
(0.7 - 0.8 kg·m,
5.1 - 5.8 ft.lb)
A24-697
Sash
fixing
nuts
10-12N·m
(1.0 - 1.2 kg·m,
7 - 9 ft.lb)
A24-695
Fig. 14-116 Electric wires and
connectors
Fig. 14-114 Switch for power window
NOTE:
a. When mounting regulator to door
panel, first tighten four bolts of
base plate and then tighten two
bolts for regulator channel B
while making proper adjustment
b. In case of front door, for 4-Door
Sedan and Station Wagon front
sash has c..=J shaped section and
rear sash has C shaped section,
and vice versa for Z·Door Hatch·
back and Hardtop.
b. When taking out window regulator,
also disconnect electric wire at
connector.
A24-696
Fig. 14-115 Window regulator for
power window
14-34
_h~1
.,I"t,.,t,.... ,_...
~~.~.
_._'....
, _ _ _ _ _. , . . - - - -_ _ _ _- -_ _ _- - - -_ _ _ _ _ _ __
BODY
14-4. Rear Gate
1.
1 Hinge
2 Striker
3 Stopper
4 Air-vent grille
5 Gas stay
6 Weatherstrip
7 Key cylinder
8 Rod
9 Latch
10 Rear gate opener
cable
®
A24-522
®
Fig. 14-117 Component parts of rear gate (2-Door Hatchback)
®
CID
4
8
9
1 Stopper
Key cylinder
Outer handle
Latch
Air-vent grille
Gas stay
Hinge
8 Weatherstrip
9 Striker
2
3
4
5
6
7
A24-523
Fig. 14-118 Component parts of rear gate (Station Wagon)
14-35
BODY
2) Adjust striker as follows
a. To make sidewise and longitudinal
adjustments of striker, loosen fixing
bolts and shift the striker.
• Fitting Adjustment
1) Remove gas stays and striker,
loosen bolts fixing rear gate hinge to
the body, and then adjust the gaps
into the dimensions shown in following figures by shifting the door.
NOTE:
7.4:1: 1.6 (0.291:t0.069)
Aoof
Relr
glte
Unit: mm (In)
7.6:1: 1.6 (0.299:1:0.069)
Section A-A
a. Make sidewise adjustment with
special attention so as to align the
centers of striker and latch. With
the striker fixed temporarily, engage it with the latch, and it will
Ihift to aligned pOlition.
b. Make longitudinal adjultment so al
to provide proper gaps to the body
and to provide proper fitting pressure of weather Itrip.
In ca. of Station Wagon, this
adjultment Ihould be made with
key lock locked.
Aoof
Aelr glte
b. Make vertical adjustment by placing
spacer on fixing surface of the
striker so as to provide specified
dimensions as shown in the following figures with '" marked.
Unit: mm (In)
Section A-A
2·000r Hltchblck
Unit: mm (in)
Section B-B
6.6:1: 1.6 (0.220:1:0.069)
•
Mlrkld dimenllon Ihould
be equII It both lid...
A24·1131
Relr qUlrter
penel
Fig. 14-121 Adjustinggsps
(Ststion Wsgon)
Section B-B
Unit: mm (In)
•
Mlrked dlmenllon Ihould
be equll .t both Ild.l.
A24·1128
A24·1133
Fig. 14-119 Adjusting gBfJS
(2-000r Hstchbsck)
Stltlon Wlgon SPlclr
A24·1130
Fig. 14-120 Adjusting hinge position
(2-000r HstchbllCk)
A24·1132
Fig. 14-122 Adjusting hlng, position
(Ststlon Wsgon)
14-38
I· 1.11
A24-888
Fig. 14-123 Plsclng spIcer
BODY
b. Electric connector for rear wiper
c. Rear washer hose
d. (Station Wagon) Electric connector
for license lights
3) Dismount gas stay as follows:
a. Open rear gate all the way.
b. Remove bolt on rear gate side.
18.5 ± 2 (0.728 ± 0.081 *
NOTE:
Let the other person support rear gate
since it will fall upon removing gas
stay.
More than 1.5 (0.0591*
Unit: mm (inl
A24-535
Fig. 14-124 Vertical adjustment (2-Door Hatchback)
A24-698
More than 1.5 (0.0591 *
Fig. 14-126 Removing gas stay
...-\---+-@
c. Remove bolt on body side, and
then detach gas stay.
Unit: mm (inl
1 Striker
2 Base
3 Claw
CD
NOTE:
a. Never detach gas stays on both sides
at the same time.
b. Between body and rear gate on
each side, place a folded waste
cloth having a considerable thick·
ness in order to protect body and
rear gate from damage after remov·
ing gas stays.
A24-700
Fig. 14-125 Vertical adjustment (Station Wagon)
NOTE:
If * marked dimension can not be
provided by placing spacer, make
adjustment by shifting rear gate with
hinge bolt loosened.
3) Confirm that rear gate operates
properly after adjustment.
• Removal and Installation
Precautions:
• Carefully protect the body coating,
glass, etc. from scratches by placing
waste cloth or the like.
• Handle the trim panel, etc. with
utmost care so as to prevent them
from damage.
• Have two or more persons move
large·size parts.
• Exercise utmost care of handling
small·size parts so as to prevent
them from being damaged.
I) Remove clips by using Puller
925580000, and then detach trim
panel.
2) Disconnect electric connectors
and hose.
a. Electric
connectors for
rear
defogger
14-37
Fig. 14-127 Placing a waste cloth
4) Remove side rail trim, and remove
clips of roof trim as far as center pillar.
5) Let roof trim hang down (preventing it from being folded), and
remove hinges on both sides.
BODY
NOTE:
Carry out rem oval with extreme care
to protect body and rear gate coating
from scratches by placing a folded
waste cloth of considerable thickness
between body and rear gate.
NOTE:
a. Although the gas has no color, (Jdor
nor toxicity, pay special attention
while the gas is being discharged
since metal chips due to drilling
may be blown through the opening.
b. It is recommended to cut out the
bore with the cylinder body cov·
ered with a vinyl sack since oil, etc.
may splash over through the bore
upon drilling.
(Carefully prevent the vinyl sack
from being rolled round the drill
tip.)
(Station Wagon only)
22- 25 N·m
Latch set
bolt
(2.2 - 2.6 kg-m,
16-19ft-Ib)
Outer handle
set bolt &
nut
7 - lON·m
(0.7 - 1.0 kg-m,
5.1 - 7.2 ft-Ib)
Key cylinder
set screw
5 - 6 N·m
(0.5 - 0.6 kg-m,
3.6 - 4.3 ft-Ib)
(Hatchback only)
Latch set
screw
6- 8 N·m
(0.6 - 0.8 kg-m,
4.3 - 5.8 ft-Ib)
A24·528
Fig. 14-128 Removing hinge
A24·538
Fig. 14-130 Drilling gas stay
6) Detach rear gate ASSY from
vehicle body carefully.
7) Installation can be carried out in
the reverse order of removal while
making fitting adjustment.
Torque
Hinge fixing
bolt
(Gate side)
18 - 23 N·m
(1.8 - 2.3 kg-m,
13- 17 ft-Ib)
Hinge fixing
bolt
(Body side)
25 - 29N·m
(2.5 - 3.0 kg-m,
18 - 22 ft-Ib)
Gas stay set
bolt
6- 9N·m
(0.6 - 0.9 kg-m,
4.3 - 6.5 ft-Ib)
Striker set
bolt
22 - 25 N·m
(2.2 - 2.6 kg-m,
16-19ft-Ib)
• Gas Stay
1) Never disassemble the gas stay
since the cylinder part is fIlled with
high pressure gas.
2) If exchanging the gas stay assembly, fix the entire structure obliquely
with the body side of the cylinder
raised slightly, and bore an opening
of 2 to 3 mm (0.08 to 0.12 in) dia. in
the cylinder body, thereby completely
discharging high pressure gas.
10 - 20 mm (0.39 - 0.79 in)
(Bore in this area'!
.
.
To the door
To the body
A24·537
Fig. 14-129 Gasstay
14-38
3) Handle each part with utmost
care. Never scratch the exposed portion of piston rod nor apply paint or
oil to it.
4) Do not turn the piston rod· and/
or the cylinder with the gas stay fully
extended.
NOTE:
a. If the packing in the gas stay is
damaged, be sure to replace it with
new one.
b. Never allow the bolts to damage the
threaded portions of the nuts for
fixing the body and rear gate sides
of the gas stay.
c. Confirm the nameplate on the gas
stay to be installed since there are
two kinds of gas stays.
White marked one:
for rear gate with rear wiper
No marked one :
for rear gate without rear wiper
--
BODY
2. Rear Gate on BRAT
C
D
F
@
DETAILC
DETAIL 8
DETAIL D
DETAIL A
DETAIL E
Tightening torque N·m (kg·m, ft-Ib)
T1: 5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.91
T2: 32 - 42 (3.3 - 4.3, 24 - 311
T3: 4 - 5 (0.4 - 0.5, 2.9 - 3.6)
DETAIL F
1 Rear gate panel ASSY
2 Hinge
3 Cover
4 Rear gate handle
5 Ornament
6 Lever
7 Latch
8 Striker
9 Buffer
10 Stay
T4: 13 - 23 (1.3 - 2.3, 9 - 17)
A24-796
Fig. 14-131
• Fitting Adjustment
1) Adjust the clearance between rear
gate and rear quarter panel, as well as
the alignment between the two, until
the specified ranges are obtained, as indicated in the figure below.
(Rear gate I
-1.0 to 15 mm (-0.039 to 0.059 in)
Section A-A
light
-1.0 to 1.5mm
(-0.039 to 0.059 in)
4.0-7.0mm
-~c-+-- (0.157 - 0.276 in)
Section 8-8
Fig. 14-132
14-39
A24-762
------..,
BODY
To properly make the in-and-out and
alignment adjustments, proceed as
follows:
CD Up-and-down adjustment (shown
by "a" in the figure above)
Move the rear skirt end of hinge
up or down.
® Fore-and-aft adjustment (shown
by "b")
Move the rear gate side of hinge
forward or backward.
@ Left-and-right adjustment (shown
by "c")
Move the rear gate end of hinge
left or right.
• Latch
NOTE:
After hinge has been properly posi-
tioned, use touch-up paint where
necessary.
2) Carefully close rear gate until
striker contacts latch, then check and
adjust striker as follows:
a. Check striker to see if it is positioned in the center of the notch in
latch. If not, move striker up or
down until correct adjustment is
made.
1) Replacement
1) Detach covers of rear gate.
2) Remove screws connecting rods to
levers.
3) Remove latch along with rod by
removing 2 bolts.
4) Install (new) latch.
5.4 - 9.3 N·m
Torque
(0.55 - 0.95 kg-m,
4.0- 6.9 ft-Ib)
5) Connect rods to levers with screws
according to next "Adjustment".
Torque
(Bolts of
hinges)
13 - 23 N·m
(1.3 - 2.3 kg-m,
9 - 17 ft-Ib)
Equal in
length
Torque
3 - 6 N·m
(0.3 - 0.6 kg-m,
2.2 - 4.3 ft-Ib)
6) Attach covers as before.
A24-759
Fig. 14-135
2) Adjustment
1) Position claw of latch into lock
condition by pushing the claw with
screwdriver.
b. Add or remove spacer(s) until the
lateral clearance between striker's
flange and claw is within the specified range as indicated in the figure
below.
A24-763
Fig. 14-133 Up-and-down adjustment
Frontward/backward
adjustment
A24-758
Fig. 14-137
A24-760
Fig. 14-136
adjustment
A24-764
Fig. 14-134 Fore-and-aft and leftand-right adjustments
Torque
(Striker)
32 - 42 N'm
(3.3 - 4.3 kg-m,
24 - 31 ft-Ib)
14-40
2) In this condition, properly connect rods to levers with screws.
Do not pull rod excessively.
NOTE:
Before shutting rear gate, confirm that
latch is unlocked by operating outer
handle.
BODY
14-5. Body Parts and Outer Accessories
1. Front Bumper
4WD
,~-@
1
2
3
4
5
6
7
8
9
Plastic bumper
Bumper guard
Moulding
Side bracket
Bumper guard bracket
Beam
Stay
Side stay
Guard pipe
EXCEPT4WD
1
2
3
4
5
6
7
8
9
Fig. 14-138 Component parts of front bumper
Bumper center
Bumper side F .A.
Bumper side F .B.
Damper ASSY
Stop nut
Pin
Front bumper cover
Bumper protector
Rivet
A24-797
14-41
BODY
5) Connect electric connector for
front side marker light.
6) Attach mud guard to radiator and
front fender as before.
1. Removal
1) Disconnect mud guard from radiator panel at the front end of mud
guard, and from fender at the inside of
front bumper side B.
2) Disconnect electric connector for
front side marker light.
3) Remove bumper side B.
4) Remove bolts attaching guard
pipe to front skirt. (4WD)
5) Remove bolts and nuts attaching
dampers (or stays) to body, and then
take out bumper center along with
dampers ( or stays).
6) Separate dampers (or stays),
bumper side A and guard pipe (4WD
only) from bumper center.
3.
A24-326
\
The plastic front bumper and inner
beam can be replaced independently
of each other.
\
NOTE:
)r--
The rear bumper can be replaced in
the same manner as the front bumper.
NOTE:
a. Since the damper is filled with high
pressure gas, never put it in fire nor
disassemble it
b. Since bumper side is made of soft
plastics, be careful not to scratch it
Replacement of Plastic
Bumper
A24-331
Fig. 14-139 Removing bumper center
3) Attach guard pipe to front skirt.
(4WD)
f ~~~~c~' .. ~ •• ~
1) Remove the bumper ASSY from
the vehicle and detach the following
parts from the bumper ASSY.
a. Stay, side stay and guard pipe
b. Bumper guard and bracket
c. Side bracket
d. Moulding
2) Detach the flanged portion of the
beam from the upper and lower
grooves of the plastic bumper. Unfasten the clip of the bumper from the
hole in the beam and separate the
beam from the bumper.
2. Installation
1) Attach
dampers (or stays),
bumper side A and guard pipe (4WD
only) to bumper center.
A24-330
Fig. 14-140
47 -71 N·m
(4.8 - 7.2 kg-m,
35 - 52 ft-lb)
Torque
Damper pin
and nut
4) Install bumper side B with bolts
and nuts.
A24-805
Fig. 14-142
2) Install bumper center onto body
with bolts and nuts.
3) The plastic bumper and beam can
be assembled in the reverse order.
NOTE:
16 - 27 N·m
(1.6 - 2.8 kg-m,
12 - 20 ft-lb)
Torque
Damper bolts
and nuts
A24-325
Fig. 14-141
Ensure that the flanged portion of the
beam is inserted securely in the upper
and lower grooves of the bumper.
14-42
.~I
~
<•.
..."....,_...,...' ..,."....,..______''''''_----_--_________
,
,.~~"~~.-",.'~41,,,,"~_·"'+"""''''''_'_'''''
-~
BODY
2. Rear Bumper
Hatchback 4WD
1 Moulding
2 Bumper guard
3 Plastic bumper
4 Bumper guard
bracket
5 Side bracket
6 Beam
7 Stay
Station Wagon 4WD & 4WD-AT
BRAT
Others
r-@
1
2
3
4
5
6
Bumper center
Bumper side
Cover
License plate bracket
Stay
Reinforcement
1 Bumper center
2 Bumper side R.A.
3 Bumper side R.B.
4 Damper ASSY
5 Stop nut
6 Pin
7 Bumper protector
8 Bumper cover
9 Clip
It
e
/,
<~~')
®
~
'I{;
,
~
A24-798
Fig. 14-143 Component parts of rear bumper
(Station
Wagon only)
14-43
--
.-~
BODY
1. Removal
1) (except 4WD) Detach bumper
cover.
2) Remove bumper side B.
3) Remove bolts and nuts attaching
dampers (or stays) to body, and then
take out bumper center along with
dampers (or stays).
4) Separate dampers (or stays) and
bumper side A from bumper center.
NOTE:
a. Since the damper is filled with high
pressure gas, never put it in fire nor
disassemble it
b. Since bumper side is made of soft
plastic, be careful not to scratch it
47 -71 N·m
(4.8 - 7.2 kg-m,
35 - 52 ft-Ib)
Torque
Damper pin
and nut
2) Install bumper center onto body
with bolts and nuts.
16 - 27 N·m
(1.6 - 2.8 kg-m,
12 - 20 ft-lb)
Torque
Damper pin
and nut
A24·333
Fig. 14-145
4) Attach bumper cover with two
flange nuts in trunk room, and with
two clips fixing it to bumper side.
(except 4WD)
jU
2. Installation
1) Attach dampers ( or stays) and
bumper side A to bumper center.
A24-334
Fig. 14-144
3) Install bumper 'side B with bolts
and nuts.
A24-332
Fig. 14-146
14-44
I,
II
'O"'~
..
_ _ _"""""'_ _""I""_I_'
"""~'_'_lt"
"I_I~
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
BODY
3. Front Hood
~
CV
DETAIL "S"
1
2
3
4
5
Front hood
Grommet
Front hood release cable
Hood stay clip
Hood stay
DETAIL
6
7
8
9
10
"e"
DETAIL "A"
DETAIL "0"
11
12
13
14
15
Hinge
Striker assembly
Front hood lock
Hinge bracket
Front hood bracket
Rubber plate
A24-e78
Clip
Bolt
Spring washer
Washer
Fig. 14-147
• Adjustment
• Hood Lock
Release Cable
1) The forward and rearward, and
leftward and rightward adjustments of
the striker assembly and the lock
assembly are done by loosening the
installing bolts.
2) For upward and downward directions adjust depending upon the close
contact of the hood to baffer, the
stepped difference between the front
hood and the fender and the condition of an operating force of the
release cable.
The adjusting method is done by
loosening the lock nut of the striker,
and a length of the striker.
A24·310
Fig. 14-148 Adjusting striker
1) Release cable from the follOwing
parts.
a. Lock assembly
b. Clip on radiator panel
c. Clips on wheel apron
d. Release bracket under instrument
panel
2) Attach (new) release cable as before.
NOTE:
Confirm that the engagement of the
striker is correct and operation of the
release cable and locations of cable
dips are correct.
14-45
BODY
5) Connect cable to pullhandle.
4. Trunk Lid
B
A
\c
1
2
3
4
5
6
7
8
9
10
11
12
DETAIL B
"...... i.
"V''',/@
<
DETAIL A
Trunk lid complete
Weatherstrip
Hinge assembly
Roller
Torsion bar
Torsion bar
Trunk opener knob
Trunk opener handle
Trunk opener cable
Lock assembly
Clip
Key lock assembly
A24-313
Fig. 14-149
A24-319
Fig. 14-151
6) Fix cable as before with clips and
tapes, and install rear seat, front seat
hinge cover and side sill cover.
NOTE:
Renew all clips and tapes.
7) Connect cable to right-hand hinge
with clamp.
8) Connect cable to trunk lid lock.
9) Insert knob to puilliandle.
• Torsion Bar
1) Open trunk lid and remove torsion bar at opposite end of hinge.
2) Remove torsion bar end hooking
up with trunk lid hinge.
NOTE:
b. Clamp on right-hand hinge
c. Clips and tapes after removing rear
seat, front seat hinge cover and side
sill cover
d. Puilliandle
NOTE:
Be careful not to kink cable.
Care should be taken that when the
torsion bar is removed from the hinge,
hood might drop down with its dead
weight
3) Remove pullhandle from crossmember.
3)
4)
Remove torsion bar from bracket
at its center.
4) Attach (new) torsion bar as before.
• Weatherstrip
Attach the trunk room weatherstrip
by pushing it down from the upper
side so as to be attached to the
surrounding in position.
NOTE:
Install puilliandle with screw.
Set weatherstrip so that its juncture
comes to the center of rear skirt (rear
panel of trunk room).
NOTE:
a. Apply grease to the contact area of
roller and hinge.
b.. Since left and right torsion bars are
different, don't misuse them.
•
\0
o
• Trunk Lid Opener
1) Take out puilliandle knob by pulling forward.
2) Release cable from the following
parts.
a. Trunk lid lock
A24-320
Fig. 14-150
.
,j
-,'
_""""""'" ......
eo
."
>II
'
A24-321
Fig. 14-152 Installing weatherstrip
14-46
~".I
o
•
---_,-------.1_1----__----______---
- . . " " , - j.....
, - , _ ,. .
, .
BODY
s.
Front Fender
CD
1 Front fender
I
2 Fender stay
3 Sealer
I
~}
A24-738
Fig. 14-153
1) Remove the following parts.
a. Mud guard
b. Bolts ftxing bumper side
c. Front grille
d. Front bumper
e. Front combination light
f. Radio antenna along with bracket
g. Body side protector
h. Cowl panel
2) Detach front fender by removing
bolts.
A24·357
NOTE:
When removing fender, be careful not
to damage body with edge of fender.
Fig. 14-155 Gap between front door
3) Attach (new) front fender in position.
4) Uniformly arrange gaps between
front hood and fender and between
front door and fender.
6. Cowl Panel
and fender
1 Cawl panel
2 Cawl net
3 Cap
4 Screw
5 Screw grommet
A24·356
A 24-340
Fig. 14-154 Gap between front hood
and fender
5) Renew sealer.
6) Install the following parts as
before.
a. Cowl panel
b. Body side protector
c. Radio antenna along with bracket
d. Front combination light
e. Front bumper
f. Front grille
g. Bolts ftxing bumper side
h. Mud guard
Fig. 14-156 Cowl panel
14-47
BODY
I) Remove wiper arms, and open
front hood.
2) Remove five installing screws.
3) Remove cowl panel by shifting it
forward to pull its flange portion out
of front panel.
NOTE:
When removing cowl panel, be careful
not to damage painted surface of
body.
A24·350
Fig. 14-157
4) Install (new) cowl panel in position.
5) Install wiper arms as before.
7. Fuel Flap and Key Lock
5
~) Open fuel flap and remove clip at
behind of flap.
2) Pull out key lock, and attach new
one with clip.
3) Replace flap by removing/tightening screws attaching flap to body at
hinge.
®
1
2
3
4
5
6
NOTE:
Position hinge so that flap is attached
to body properly.
Flap
Clip
Key lock
Screw
Hinge
Striker
A24-682
Fig. 14-158
8. Mud Guard
1) Jack up the vehicle at its front, set
rigid rack, and remove front wheels.
2) Remove all screws and clips fixing
mud guard excluding clips inserted in
the flange of fender, shift mud guard
to the inside of the vehicle, and remove mud guard by pulling out clips
from the fender flange.
3) Install (new) mud guard in position.
NOTE:
Renew all clips.
1 Mudguard
2 Clip
3 Screw
4 Washer
5 Nut
6 Clip
A24-683
Fig. 14-159 Mud guard
14-48
.I"f·'~~"
.•• ,.~", ........ _
.. '
.1
It
,,1
«1
r.
II
1
:
I
4) Install front tires and wheels as
before.
BODY
9. Splash Board
A24-714
Fig. 14-163 Removing ornaments
2) The portions to be fitted with
ornaments, etc. are provided with
recess.
Install ornaments, etc. aligning with
the recess.
A24·580
Fig. 14-160
I) Detach upper splash board by removing three tapping screws and by removing one bolt which fixes both
upper splash board and lower splash
board.
2) Detach lower splash board as
follows.
a. Remove two fixing bolts (one of
them is fixing both upper and lower
splash board and is already removed
upon removing upper splash board).
b. Remove lower splash board by pulling out plastic clip from the rear
wheel apron.
3) Attach (new) lower and upper
splash boards in position.
NOTE:
Apply anticorrosive agent to the back
of the screws tightening upper splash
board as shown below.
10. Body Protector
1) Remove door trim panels.
2) Peel of sealing covers.
3) Push out clips with screwdriver.
For fender portions, push out clips
after removing mud guard.
CD
P~f-A
~n
out
1 Clip
2 Packing
A24-675
Fig. 14-162 Installation detail
4) Install (new) body protectors by
inserting clips by hand.
NOTE:
a. Renew double face adhesive tape at
every removal.
b. If ornaments, etc. are deformed, replace them with new ones.
12. Window Moulding
1) Remove corner joint by prying it
with screwdriver.
2) Raise slightly the edge of moulding, and detach the moulding while
sliding screwdriver under the moulding.
3) Installation can be carried out in
the reverse order of removal, paying
attention to the follOWing.
a. Apply soapy water or kerosene to
weatherstrip.
b. In case of wide stainless steel
moulding, set work cord to the lip
of weatherstrip, and then pull out
the work cord while depressing
moulding.
Depressing
11. Ornaments and
Letter Marks
A24-713
Fig. 14-161 Applying anticorrosive
agent
I) Ornaments, letter marks, etc. are
fixed by double face adhesive tapes.
Rip off the tapes by inserting a thin
but strong string like fishline.
14-49
1 Work cord
2 Moulding
A24-600
Fig. 14-164 Installing moulding
BODY
13. Roof Moulding
5) (Hardtop) Install roof moulding
to front pillar with a blind rivet.
1) (Hardtop) Cut off the heads of
three rivets fixing roof moulding to
front pillar.
2) (Hatchback and Station Wagon)
Remove joint between front and rear
roof mouldings.
3) Detach (front and rear) moulding
(along with clip) by pulling it with
fingers or cloth wound around screwdriver so as not to damage body
surface.
4) Install (new) roof moulding to
drip rail by depressing it with hand.
14. Rear Pillar
Moulding (Sedan)
1) Remove upper rear pillar turn
panel from inside of vehicle.
2) Remove two nuts through service
holes.
(Hardtop only)
15. Sealer, Sealing
Parts and Insulator
1) Plate partition and borings of the
body are provided with sealing compound so as to prevent water or dust
from entering the interior. After
repamng or overhauling, be sure to
apply the speCified sealing compound.
2) Since entrance of water or dust
through some of gage holes or work
holes utilized in manufacturing body
might adversely affect the vehicle,
they are closed by plugs or sealing
tapes.
After repairing or overhauling, be sure
to close the holes again with the
specified parts.
3) To eliminate water leakage
through rear window weatherstrip.
4-Door Sedan and Hardtop are equipped with drain tubes which are located
at both sides of trunk room interior.
(Others)
A24-613
Roof lTjoulding
Fig. 14-166 Removing nuts
Oepressing
Drip rail
3) Take out rear pillar moulding with
rear end of roof moulding raised.
4) Installation can be carried out in
the reverse order of removal.
A24·605
Fig. 14-165
14-50
,H ,.,
~
~-,'
"".'-'''''''''I'''''''''''!______.,...______- -_________- - -
..., _ . _ '
-,"~"~,~~-"""",._,,,,,,
BODY
A24-799
Fig. 14-167
14-51
BODY
14·6. Instrument Panel
1. Component Parts
NOTE:
Instrument panels for other combination meters i.e. with tachometer, etc.
and with digital meter, are essentially
the same as this configuration.
A24-741
1
2
3
4
5
6
7
8
9
10
11
Pad and frame assembly
Visor and switch box
Center grille
Side grille
Side ventilation grille
Side defroster grille L.H.
Side defroster grille R.H.
Wiper plate
Wiper indicator lamp
Lighting plate
Lishting indicator lamp
12
13
14
15
16
17
18
19
20
21
22
Defroster grille L_R.
Defroster grille R.R.
Center duct
Side defroster duct L.R.
Side defroster duct R.R.
Coin box
Glove box
Shelf
Panel
Glove box lid
Lock assembly
23 Stay
24 Striker
25 Instrument panel bracket
26 Speed nut
27
28
29
30
31
32
Side ventilation duct A (L.R.)
Side ventilation duct B (L.R.)
Joint L.H.
Side ventilation duct C (R.H.)
Side ventilation duct D (R.H.)
Joint R.H.
Fig. 14-168 Component parts of instrument panel
'.'
,_,"""',,~*
1_'. .
....
........ ,.u~"'~_""''''''_''''''
------.'_1--___" "'___________--
11" _ _ _ _
,..,..,
14-52
BODY
2. Instrument Panel
NOTE:
Although instrument panel can be
replaced with windshield glass installed,
it will facilitate removal/installation of
instrument panel to remove wind·
shield glass.
8) Detach defroster ducts and venti·
lator ducts on both sides.
9) Take out instrument panel by
lifting up obliquely toward the rear.
2) Installation
Installation can be carried out in the
reverse order of removal.
NOTE:
1) Removal
I) Remove the following parts.
a. Trim panel on driver side
b. Luggage shelf on front passenger
side
c. Radio box or console box
2) Remove two bolts fixing steering
column.
3) Disconnect the following cables,
etc.
a. Speedometer cable
b. Electrical wiring
c. Cables for heater control
d. Vacuum hoses for heater control
4) Remove one nut at the bottom of
combination meter.
Pay attention not to damage the
wiring harnesses, cables, vacuum hoses,
etc. when installing instrument panel
to the vehicle body.
3)
Cleaning
When white spots are appeared on
surface of instrument panel, clean it as
following procedure.
I) Wipe with clean and damp cloth.
2) If the spots remain, apply powder
of calcium carbonate with clean cloth.
Then, rub with clean and damp cloth
to remove the powder. Wipe again
with dry clean cloth.
A24·375
Fig. 14-172 Removing glove box
lighting
5) Remove screws at the top of glove
box.
6) Detach clamp of vacuum hose at
the bottom of glove box.
7) Pull out glove box toward you,
and disconnect electric connector for
glove box light and switch.
8) Installation can be carried out in
the reverse order of removal.
3. Glove Box
Fig. 14·169 Removing nut of
combination meter
1) Remove luggage shelf on front
passenger side.
2) Remove screws at the bottom of
glove box lid.
3) Pull out stay from the opening of
glove box while rotating lid upward,
and take out glove box lid.
5) Remove two nuts on both side
pillars.
6) Detach clips and take out defrost·
er grille.
7) Remove three installing bolts at
the top of instrument panel.
4. Heater Control Panel
I) Detach radio box or console box.
2) Pull out fan switch dial, tempera·
ture control dial and mode lever knob.
Fan switch diel
A24·743
A23·144
Fig. 14-171 Pulling out stay
Fig. 14·173 Removing dials etc.
I
A24·372
Fig. 14-170 Removing bolts at its top
4) Detach glove box light by rotating
it clockwise, and leave it in glove box
with electric wiring connected.
14-53
3) Remove nuts for fan switch and
temperature controler.
BODY
Nuts
/
~~bJCl~
~24-746
A25-246
A24-685
Screws
Fig. 14-174 Removing nuts
4) Remove screws fIxing the bottom
of control panel.
5) Disconnect respective electric
wiring for cigarette lighter, rear defogger switch and panel illumination
lights.
6) Installation can be carried out in
the reverse order of removal.
--=---1-
D~,
"
,"
,~-
A25·557
A25-556
Fig. 14-175
5. Meter Visor
1) Detach trim panel on driver side.
2) Remove installing screws, disconnect electric wiring for lighting switch,
etc., and then pull out meter visor
ASSY in parallel with steering column.
A25·558
Fig. 14-176
NOTE:
For GL model, remove ventilation
knob, covers and screws.
3) Installation can be carried ou t in
the reverse order of removal.
14-54
,~
.. . . . .
~"'--
~
...."....·_............•...·_t.,..._,_,...,_ _ _, . - - - -_ _ _ _- -_ _....._ _ _ _ _ _- _ _ _ _- -
_"~.;,
BODY
14· 7. Seat and Belt
1. Front Seats
GL & GLF models
1 Backrest assembly
2 Cushion assembly
3 Slide rail assembly
4 Hinge assembly
5 Hillle cover
6 Bushing
7 Hinge knob
8 Bolt
9 Link
10 Wire A
11 Wire B
12 Helper spring
13 Spring
14 Head rest
15 Backrest frame
16 Lumbar knob
17 Cushion frame
l----@
CIt
I
Tightening torque N·m (kg-m, ft-Ibl
T: 13 - 23 (1.3 - 2.3, 9 -171
A24-749
Fig. 14-177 Component parts of front seats
1) Removal
1) Slide front seat to the rearmost
position.
2) Remove two installing bolts at the
front side.
3) Slide front seat to the foremost
position.
4) Remove two installing bolts at the
rear side.
5) Remount both front seats, and
detach slide rails. For passenger's seat
of Hatchback (except STD) and
Hardtop, detach walk-in helper spring
from slide rails.
2) Installation
1) Set both inner and outer rails of
front seat at the, rearmost position
onto front seat.
2) Mount front seat on the body.
3) Temporarily ftx front bolts.
4) Slide front seat to the foremost
position.
14-55
5) Install and tighten rear bolts to
the specifted torque.
Torque
Front and
rear bolts
13 - 23 N·m
(1.3 - 2.3 kg-m,
9-17ft-Ib)
6) Slide front seat to the rearmost
position, and tighten two bolts to the
specifted torque.
7) Hook walk-in helper spring onto
slide rails.
BODY
2. Rear Seat
Sedan and Hardtop
1
2
3
4
Backrest assembly
Backrest cover assembly
Cushion'
Cushion cover assembly
A24-387
Station Wagon
R Backrest assembly
[Pad &; Frame assembly (P/B),
Cover assembly I
2 R Cushion assembly
[Pad &; Frame assembly (RIC),
Cover assembly I
3 Hook RIB V.
4 Trim plate
5 Hinge assembly
6 Lock assembly
7 Cover hook
8 Stopper rubber
9 Cushion rubber
10 Bush (RIB)
11 Spacer
12 Striker RIB V.
13 Hook
14 Flange bolt
15 Flange screw
16 Screw
17 Plain washer
Tightening torque N·m (kg·m, ft·lb)
T1: 3 - 6 (0.3 - 0.6, 2.2 - 4.3)
T2: 5.4 - 9.3 (0.55 - 0.95,4.0 - 6.91
Fig. 14-178
A24-388
-1*-'---.. .'. .lr------1_I-___. . .____________-14-56
."
.+."~ ..,,,.-~...............- , ......
BODY
Hatchback
@@
Bench type seat
7
\
\
CD~
Tightening torque N'm (kg·m, ft·lb)
T: 3 - 6 (0.3 - 0.6, 2.2 - 4.3)
Separatf'! type seat
A 24·388
Fig. 14·179 Component parts of rear seats (2·000r Hatchback)
14-57
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Cushion assembly
Cushion cover assembly
Pack rest assembly (Bench type)
Back rest cover assembly (Bench type)
Back rest assembly (Separate type)
Back rest cover asM,mbly (Separate type)
Mat (Bench type)
Mat (Separate type)
Striker assembly
Cushion hook bracket
Cushion hook and hinge
Flange bolt
Bolt
Spring washer
Washer
Mat top cover (Bench type)
Mat tall cover (Sparete type)
Tapping screw
Clip
--
-
I
I
BODY
BRAT
f-··--...,
'
~
'- J
@I-~IIIII
I
2
3
4
5
Rear seat
Head restraint
Rail (Head restraint)
Bolt.l; washer assembly
Oval head bolt
A24-248
Fig. 14-180
• Sedan and Hardtop
4) lift back rest along rear bulkhead,
and back rest is removed.
1) Removal
Torque
1) Remove two mounting bolts at
the front ofrear cushion.
2) lifting the front of rear cushion
slightly and depressing cushion near
the bracket of back rest, move cushion
foreward, and the rear cushion is
removed.
NOTE:
Pay attention not to jam the mat
3) Hook the rear of cushion to
bracket of back rest by pushing
cushion rearward while the front of it
lifted slightly.
4) Align the front of rear cushion
with the body. and install it with two
mounting bolts.
A24-392
Fig. 14-182 Removing back rest
2) Installation
A24-391
Fig. 14-181
Removing rear cushion
3) Remove two mounting bolts at
the bottom of back rest.
3 -6 N·m
(0.3 - 0.6 kg-m,
2.2 - 4.3 ft-lb)
1) Place back rest at its proper
position, and tap it to align the holes
of back rest bracket and of vehicle
body.
2) Install back rest mounting bolts.
Torque
3 - 6 N·m
(0.3 - 0.6 kg-m,
2.2 - 4.3 ft-Ib)
14-58
1%
,.
r'
I
,
p
BODY
• For both types, loosen bolts
fixing striker and make adjustment upward and downward,
leftward and rightward.
• Hatchback
I) Remove rear cushion as follows.
a. Remove two bolts fixing to the
body at front of cushion.
b. Raise slightly the front of cushion
and move it to front while depressing the center of cushion rear,
thereby detaching the cushion from
rear hook.
2) Remove back rest as follows.
a. Detach three hooks fixed at the
extreme end of luggage compartment mat.
b. In case of separate type, remove
two bolts for fixing hinge bracket
to the body at the center of body.
c. Disengage the hook by pulling
knob at the shoulder of back rest.
d. After inclining back rest a little
forwardly, where two chamfered
portions of hinge bushing matches
with the cutout of bracket, remove
back rest by pulling it up.
A24-396
Fig. 14-186 Turning bushing
• Station Wagon
1) Removal
I) Remove four bolts fixing hinges
of cushion to the body.
2) Disengage the lock at the rear
of cushion from hook on the body,
and remove cushion.
Fig. 14-184 Removing rear cushion
A24·393
Fig. 14-183 Removing back rest
3)
Tightening torque
of cushion installing
bolts
3 - 6 N'm
(0.3 - 0.6 kg-m,
2.2 - 4.3 ft-Ib)
Incline back rest forward.
!'II.
xJl·W[.·-~-~--- ~YJ_
g--
Pull up
\
'.
NOTE:
a. Make sure of absolute locking by
raising back rest and depressing it
until an engaging sound is generated.
b. If lock is not engaged properly,
make adjustment as follows .
• In case of separate type, loosen
bolts for fixing the hinge at the
center and make vertical adjustment.
5) Pull out hinge pin on right side
out of the hole on the bracket in the
right side of the body, while bringing
back rest to the extreme left end.
6) Bring back rest to the right and
pull out the left hinge pin, and back
rest is removed.
2. Installation
OM·473
3) Installation can be carried out in
the reverse order of removal.
Back rest
'
'
,
.----_.
I
.
...
I
.!":;-'~-:';"""~''-.,",,~''''''-.'''f..'~'~~'~~-"'Y"
OM-474
Fig. 14-185 Inclining back rest
4) Turn forwardly bushing of back
rest hinge on the left side of the
body to disengage it from hinge pin,
and-remove it from the body by pulling it toward the center of the body.
14-59
1) Insert the left side hinge pin at
the bottom of back rest completely
into the rear hole of hinge bracket
on the tire house.
2) Insert the right hinge pin into
the hole in the body, and bring back
rest to the extreme right end.
3) Insert the clip of hinge bushing
securely into the front hole of the
left bracket while keeping bushing
verically.
4) Turn the bushing toward back
rest hinge pin round clip portion of
bushing, and engage it with hinge
pin.
5) If a gap is provided between the
left bushing and back rest upon moving back rest to the extreme right end,
fit spacer according to the gap as follows.
Gap
dimension
Spacer
0< ~4
0
4< ~8
One on the left side
8< ~12
One each on both sides
6) Raise back rest and fix it by
depressing it so that an engaging sound
is heard from striker.
BODY
7) Engage the lock at the rear of
cushion with the hook mounted to the
body floor.
8) Install the two hinge assemblies
at the front of cushion onto the
vertical wall of the body rear floor
by four 6 mm bolts.
I
I
Torque
5.4 - 9.3 N'm
(0.55 - 0.95 kg-m,
4.0 - 6.9 ft-lb)
~-.~~------------~
2) Hooks on both sides of back rest.
a. If proper engagement is not ob·
tained vertically (the rod at the
front of the striker does not come
to the center of notched hole in the
hook cover of the back rest),
make adjustment by tapping the
tip of the striker with a rubber
hammer or the like.
b. If proper engagement is not obtained in the direction of body
width (the hook does not engage
striker properly because end bar
interferes engagement), make adjustment by placing washer on the
setting surface to the body.
3) Adjustment
After installing the cushion and back
rest, make sure that each lock is
engaged completely.
If not, make adjustment in the following manner.
1) Cushion lock
Make adjustment in the following
order.
a. Adjust setting of hook to body.
b. Adjust setting of lock assembly
to cushion pan.
c. Adjust setting of hinge to cushion
pan.
d. Adjust setting of hinge to body.
14-60
'"
t
BODY
/
3. Seat Belts
Front seat belt
only on Hatchback
Rear seat belt
only on BRAT.
1
2
3
4
5
6
7
8
Tightening torque N·m (kg-m, ft-Ib'
T: 25 - 34 (2.5 - 3.5,18 - 25'
Fig. 14-187 Component parts of seat belts
Front seat outer belt ASSY
Front seat inner belt ASSY
Webbing guide
Seat belt anchor cover
Belt retractor
Rear seat outer belt ASSY
Rear seat inner belt ASSY
Cover
A24·800
14-61
BODY
• Front
1) Removal
1) Remove rear cushion, rear back
rest, side sill cover, rear pillar trim
panel and/or rear quarter trim panel
as the occasion demands.
2) Remove outer belt as follows:
a. Lap belt anchor bolt
b. Shoulder anchor bolt
c. Felt guide
d. Retractor bolt
3) Remove inner belt anchor bolt,
disconnect seat belt switch connector,
and then take out inner belt.
NOTE:
a. Exercise utmost care tO'remove the
anchor bolt together with spacer,
washer, etc.
b. Never disassemble the ELR.
c. Use spanner size of 5/8 inch, since
bolts size of 7/16 inch are used.
I) Remove the following parts.
a. Rear seat cushion
b. Outer anchor bolt
c. Inner anchor bolt
2) Installation should be carried out
in the reverse order of removal.
2) Installation
Installation can be carried out in the
reverse order of removal.
I Torque
25 - 34 N·m
Vertical line
(2.5 - 3.5 kg-m,
(anchor bolt)
Fig. 14-188 Removing inner belt
• Rear
/
18 - 25 ft-Ib)
NOTE:
a. Although left and right HRs have
the same appearance, they are not
interchangeable each other since
each has a different type of sensor.
They are interchangeable on Hardtop models, however.
b. When installing belt, be careful not
to twist it.
A24-753
Fig. 14-189 Rear seat belt installation
14-8. Inner Accessories
1. Radio Box
1) For 4WD models, loosen cord of
4WD selector boot, and remove tray
from selector lever.
2) Remove hand brake cover from
hand brake lever.
3) Loosen cord of shifter lever boot,
and remove center shelf.
4) Remove two mounting screws at
the bottom.
5) After removing four mounting
screws at the left and right sides of
radio box, pull out radio box, and
disconnect wiring harnesses.
6) Place radio box at its proper
position, connect wiring harnesses, and
then install radio box in the reverse
order of removal.
Bracket
Radio box
Frame
NOTE:
Removal and installation of center
shelf should be carried out with gear
shifter at neutral, 4WD selector at
4WD position and hand brake lever
fully pulled.
A24-801
Fig. 14-190
14-62
t
If 11
'
I
r
BODY
NOTE:
2. Console Box and Parking (Hand) Brake Cover
a. Pay attention not to damage the
crisscross groove of the screw head
and thread portion.
b. Use genuine plastic screw only for
inner rear view mirror.
4. Luggage Shelf
,
•
1 Front luggage shelf
I
2
3
4
5
6
7
8
Fig. 14·191
9
10
11
Console box assembly
Tapping screw
Washer
Spring nut
Console bracket
Tapping screw
Flange screw
Hand brake cover
Hand brake cover tray
Hand brake cover bracket
Tapping screw
1) Remove the tray of hand brake
cover by disengaging the hook at the
rear of the tray with finger inserted
through the opening for hand brake
lever on the hand brake cover.
2) Remove two tapping screws fixing
both console box and hand brake
cover to the floor.
3) Replace console box by removing
4 tapping screws and the following
items.
a. Connect electric connector for
radio.
b. Be careful not to catch electric
wiring with console box.
c. For automatic transmission vehicles, also remove and install indicator cover.
4) Replace parking (hand) brake
cover by removing tapping screw in
pocket.
1D
i
r//
Fig. 14-193
2 Cushion
3 Tapping screw
4 Flange nut
5 Bracket
Replacement of front luggage shelf can
be carried out by removing clips and
screws.
)1l
@
A24-707
Rear luggage shelf
Clip
3. Inner Rear View
Mirror
A24-768
Fig. 14-194
~~
CD~
Inner rear
1 view mirror
2 Plastic screw
A"24-766
Fig. 14-192
1) Remove rear seat cushion and
back rest.
2) Remove caps and shoulder belt
anchors on both sides. (for Hardtop
only)
3) Remove assist rail on rear pillar.
(for Hardtop only)
4) Remove rear pillar trim panel.
5) Remove speakers if provided.
6) Replace rear luggage shelf by
detaching eight clips.
Replacement of inner rear view mirror
can be carried out by removing plastic
screw.
NOTE:
Make proper alignment of hand brake
cover with hand brake lever when
installing.
A24·767
Torque
1.0 - 1.4 N'm
(0.10 - 0.14 kg-m,
0.7 - 1.0 ft-Ib)
L -_ _ _---lL--_ _
14-63
J
A24-578
Fig. 14-195
BODY
In the above case, repair the cover
assembly to restore the vinyl leather as
follows:
1) While pushing and holding both
sldes of cases inside, roll up the vinyl
leather until approx. 200 mm (7.87 in)
remaining as shown in the illustration.
5. Luggage Area Cover
c:v
~
~
~i
\
CD
\
Roll
Push ...
~.r---'
Approx.
200 mm (7.87 in)
®
.--1. __ ._.
CJ
Front , . " .
1
2
3
4
5
6
7
8
9
A24-809
Fig. 14·199
Cover ASSY
Holder (R.H.)
Holder (1.H.)
Support (R.H.)
Support (1.H.)
Tapping screw
Washer
Tapping :;crew
Flange screw
2) Pull the vinyl leather as shown in
the following illustration, and press
the case (L.H.) against the slippery
surface of floor or wall to idle the case
(L.H.).
Case (L.H.)
A24-806
Fig. 14-196
r .. ~_._~
I
Luggage area cover assembly is composed of cases (L.H. and R.H.), a
clutch in case (L.H.), shaft (1) and (2),
spring (1) and (2), a pipe and vinyl
leather. One end of the vinyl leather is
fastened to the pipe with adhesive
agent, and another end has a handle
to pull and spread the vinyl leather.
When the cover assembly is not in
use, it also can be detached from the
holders.
1 Case (1.H.)
~'""
A24-810
Fig. 14-200
3) Turn the case (L.H.) for eight (8)
complete turns to rolling direction of
the vinyl leather while pushing the
case (L.H.) inside.
2 Clutch
3 Shaft (1)
4
5
6
7
8
--------------J
Spring (1)
Pipe
Shaft (2)
Spring (2)
Case (R.H.)
Case (L.H.)
A24-807
Fig. 14·197
In the following condition, case (L.H.)
will idle and vinyl leather cannot be
retracted.
a. When the cover assembly is detached from holders with the vinyl
leather spread,
b. and the vinyl leather comes off the
cut of the case (L.H.),
c. moreover, the case (L.H.) is pressed
to slippery surface of floor or wall.
Push ....
Case (L.H.)
A24-811
Fig. 14-201
A24-808
Fig. 14-198
14-64
4) Then, spread and roll up the vinyl
leather by turns several times while
pushing and holding the both sides of
cases inside.
BODY
6. Roof Trim
7. Side Sill Cover
I) Detach trim, weatherstrip clips,
etc. as necessary.
a. Front pillar (upper) trim
b. Center pillar upper trim
c. Rear pillar lower trim after removing rear seat back rest
d. Rear pillar upper trim
e. Roof side rail trim
f. Rear rail
g. (Hatchback)· Weatherstrip only at
upper edge of side window
1) (Sedan and Station Wagon) Detach
rear seat cushion.
2) (Vehicle with trunk opener) Pull
knob out of openerlever.
3) Remove hinge cover of front seat.
4) Remove screws, and detach (front
and rear) side sill cover.
Fig. 14-202 Taking out roof trim
NOTE:
Almost all trim is fixed with plastic
dips. Remove clips with Puller 925580000.
5) Installation can be carried out in
the reverse order of removal.
3) Detach inner rear view mirror, sun
visor, sun visor hook, assist rail, room
lamp, etc.
3) (Sedan and Hardtop) Remove
front windshield glass. (Others) Pull
out front edge of roof trim from lip of
windshield weatherstrip.
4) Take out roof trim through front
opening (front windshield) or rear gate
or front door opening.
A24·553
Torque
Rear view
mirror screw
1.0 - 1.4 N·m
(0.1 - 0.14 kg-m,
0.7 - 1.0 ft-Ib)
NOTE:
Pay careful attention not to catch trim
on electrical wiring.
14-65
NOTE:
Slide front seat appropriately to per·
form this job.
5) Installation can be carried out in
the reverse order of removal, paying
attention to the following.
a. Be careful not to catch it on
electrical wiring or come in contact
with clips of wirings, piping, etc.
b. Make proper alignment of front,
rear and center pillar trim.
c. Use stepped tapping screws except
for the extreme rear end of (rear)
side sill cover where an ordinary
tapping screw and a washer are
fitted. Be sure to use plain washer,
otherwise the screw might sink too
far.
BODY
14·9. Sunroof (Option)
1. Sedan and Hardtop
CD
@
View "A"
View"B"
1 Glass ASSY
2 Handle
3 Safety catcher
4 Male hinge
5 Weatherstrip
6 Drain tube
7 Base plate
8 Safety striker
9 Deflector
10 Female hinge
View"C"
A24·802
Fig. 14·203
Removal of Glass
1) Move handle down and then up,
and tilt (pop) up glass.
2) Remove handle from base plate.
Fig. 14·204
A24·803
3) Slide safety catcher knob to reo
lease safety lock.
",-"
~ "'~~~~.
~
Fig. 14·205
A24-733
4) Remove male hinge from female
hinge while lifting glass.
The glass should be detached along the
arc shape of male hinge.
5) Place glass into a suitable bag and
store in trunk room.
6) When installing glass, press on deflector with glass.
Observe the following precautions
during installation:
a. Ensure that weatherstrip is installed
properly. If it is rolled in or caught
by the car body, raise weatherstrip.
b. Be careful not to strike male hinge
against the car body.
c. Ensure that safety lock and handle
lock operate properly.
Repair of Drain Tubes
1) Front drain tube
a. Remove roof trim and side rail
trims.
b. Remove drain tube on the side of
the roof, then pull it out of the
roof.
c. Insert a (new) tube into the pillar
from the side of the roof, then
secure it to the roof.
d. Remove lower pillar trim, then
insert tube into the hole of separa·
tor.
\
III
I )
-
-~~~ ,~~:
o
..
Fig. 14-206
'<
' \
~~~
A24·734
e. Install all trims in their original
positions.
2) Rear drain tube
a. Remove roof trim.
b. Remove drain tube on the roof,
then pull it out of the roof.
c. Insert a (new) tube into place from
the roof side.
d. Remove trims from around rear
quarter window to ensure that the
tube can be seen.
14-66
r...·_·
• , __".,........... 4» ....... _.- , -....
- - , - '- , , _ ,,,",'
.-.~
_w_ _ _ _'''"'''_,_--_ _ _- - - - - - - - - - - - -
BODY
Fig. 14-207
2. BRAT
1 GlassASSY
2 HaneUe
3 Safety catcher
" Male hinge
S Weatherstrip
6 Ba.
Fig. 14-208
View "AH
A24-804
Removal of Glass
1) Move handle down and then up,
and tilt (pop) up glass.
2) Remove handle from bue plate
while pressing on the link of handle
at the spring location.
3) Slide safety catcher knob to
release safety lock.
4) Remove male hinge from female
hinge while lifting glass.
The glass should be detached along the
arc shape of male hinge.
A24-737
Fig. 14-209
14-67
Install glass with handle facing up,
then insert male hinge into its groow
on the lower portion of the back
panel. Securely futen the pass with
the holddown band.
6) Observe the following precautions
during installation:
a. Be careful not to strike male hinge
apinst the cu body.
b. Ensure that safety lock and handle
lock operate properly.
5)
BODY
14·10. Special Tools
925580000
925610000
Puller
Wrench
Trim Clip
Door Hinge
,
Fig. 14-210
ST-035
Fig. 14-211
ST-166
14-68
CHAPTER
11~·
ELECTRICAL SYSTEM
Page
SIBARU
15- 1.
SPECIFICATIONS ANO SERVICE DATA ................. 15-
2
15- 2.
BATTERY, FUSE AND FUSIBLE LINK .................. 15-
9
15- 3.
STARTER ....................................... 15- 13
15- 4.
ALTERNATOR .................................... 15- 23
15- 5.
DISTRIBUTOR .................................... 15- 29
15- 6.
IGNITION CDiL AND SPARK PLUG .................... 15- 35
15- 7.
COMBINATION METER ............................. 15- 37
15- 8.
SWITCHES .................................•..... 15- iii
15- 9.
LIGHTS ......................................... 15- 59
15-1~
WIPER AND WASHER .............................• 15- 65
15-11.
ElECTRICAL EQUIPMENT
15-12.
ELECTRICAL WIRING HARNESS ...................... 15- 90
15-13.
WIRING DIAGRAM AND TROUBLESHOOTING .......•.... 15-108
......................... 15- 72
ELECTRICAL SYSTEM
IS-I. Specifications and Service Data
1. Specifications
Item
.
Type
MT: 55D23R (MF), AT: 65D23R (MF) or 75D26R (MF)
:..
B
j
Designation
Reserve capacity
Capacity
MT: 90 minutes, AT: 100 minutes
Cold cranking
ampere
MT: 310 ampere, AT: 370 ampere or 450 ampere
Type
"'1: Magnetic switch type, "'2 and'" 3: Reduction type
Model
"'1: 028000-6520, "'2: 028000-8580, "'3: 028000-8570
Manufacturer
Nippondenso
Voltage and Output
"'I: 12V-0.8kW, "'2: 12V-1.0kW, *3: 12V-1.4kW
Direction of rotation
Counterclockwise (when observed from pinion)
Number of pinion teeth
No-load chuacteristici
.
!
9
Voltage
"'I: 11V, "'2 and "'3: 11.5V
Current
*1: 50A or less, *2 and *3: 90A or less
Rotating speed
:I
*1: 5,000 rpm or more, *2: 3,000 rpm or more, *3: 4,100 rpm or more
fI)
Voltage
*1: 9.5V, *2: 8Y, *3: 8.5V
Current
"'1: 270A or less, "'2: 230A or less, *3: 350A or less
Torque
*1: 7 N·m (0.7 kg-m, 5.1 ft-Ib), *2: 6.4 N·m (0.65 kg-m, 4.7 ft-Ib),
*3: 13.2 N·m (1.35 kg-m, 9.8 ft-Ib)
Load characteristics
Rotating speed
Lock chuacteristics
*1: 1,200 rpm or more, *2: 1,180 rpm or more, *3: 1,000 rpm or more
Voltage
*1: 7.7V, *2: 2.5V, *3: 2.4V
Current
"'1: 600A or less, *2: 300A or less, *3: 400A or less
Torque
*1: 13 N·m (1.3 kg-m, 9 ft-lb) or more, "'2: 7 N·m (0.7 kg-m, 5.1 ft-Ib) or more,
"'3: 11 N·m (1.1 kg-m, 8.0 ft-Ib) or more
Type
Rotating-field three-phase type, Voltage regulator built-in type
ModeJ
LR155-15C
Regulator type
TRIZ-56 (lC)
..
Manufacturer
Hitachi
!
Voltage and Output
12V-55A
Polarity on ground lide
Negative
S
B
:(
Clockwise (when observed from pulley side)
Rotating direction
3-phase Y-type
Armature connection
Rectifying system
*1: SUBARU 1600,
*2: SUBARU 1800 MT,
Full wave rectification by six self-contained silicone diodes
"'3: SUBARU 1800 AT (including 4WD AT)
16-2
• I,
I
!
II,
....
...il-_4 ...
v·-~~.l""''"'
+~~~··
.......... , ......
~,_''''
,_l1...
..... _ _ _
, _ ' _ '. . .' . . .
~_.~
_______
ELECTRICAL SYSTEM
Item
..
.s
..
!l
0:1
i:
Designation
Revolution speed at 13.5V; 20D C (68D F)
900 rpm or less
Output current
1,250 rpm - 20A or more
2,500 rpm - 50A or more
5,000 rpm - 55A or more
Regulated voltage
14.5
~
0
:;
0.3V [20D C (68 D F)]
Type
Breakerless type with control unit
Centrifugal governor and vacuum diaphragm advancers
Model
4WD: D4R80-03, Others (including 4WD-AT): 100291-0080
Manufacturer
..
±
4WD: Hitachi, Others (including 4WD-AT): Nippondenso
Firing order
1-3-2-4
Rotating direction
Counterclockwise (when observed from cap side)
.Q
·S
'"
Q
Air gap
except 4WD: 0.2 - 0.4 (0.008 - 0.016)
4WD: 0.3 - 0.5 (0.012 - 0.020)
mm (in)
Cap insulation resistance
Mn
More than 50
Rotor head insulation resistance
Mn
More than 50
90D
Ignition interval
Series resistance of pick-up coil
n
4WD: CIT-79, Others (including 4WD-An: K-31
Type
:=
0
u
i:
0
•.;::!
1
except 4WD: K-31, 4WD: CIT-63
Manufacturer
except 4WD: NIPPON DEN SO, 4WD: HITACHI
Primary coil resistance
n
except 4WD: 1.13 - 1.38, 4WD: 1.04 - 1.27
Secondary coil resistance
n
except 4WD: 10,795 - 14,605, 4WD: 7,360 - 11,040
Insulation resistance between primary terminal
and case
I>Il
More than 10 Mn
{ BPR6ES-11 (or BPR5ES-ll, BPR7ES-11) ......................... NGK
W20EPR-Ull (or WI6EPR-U 11 , W22EPR-Ull) .... Nippondenso
RNllYC-4 (or RN9YC-4) .......................................... Champion
For Canada: RNll YC-4 (or RN9YC-4) ........................................ Champion
For USA
Type and Manufacturer
~
.;.I
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p.
til
Thread size
14, P = 1.25
mm
Spark gap
mm (in)
1.0 - 1.1 (0.039 - 0.043)
Fuses
lOA - 6, 15A - 8, 20A - 2
Speedometer
.
!l
41
E
Eddy current type
Temperature gauge
Thermister-bimetal type
Fuel gauge
Resistor-cross coil type (GL mode\), Resistor-bimetal type (STD &; DL models)
I:
~0:1
.5
.Q
e0
u
l2V-3.4W (GL model only)
Bulb
Low fuel indicator light
On fuel tank (GL model only)
Switch position
Charge indicator light
12V-1.4W or 3.4W
12V-1.4W (except GL model)
Oil pressure indicator light
15-3
ELECTRICAL SYSTEM
---------------------------r--------Item
Designation
----------------- IHigh beam indicator hght
12V-1.4W
1---------------.--------Bulb
12V-1.4W
r------
Brake fluid level warning light
Switch position
On brake fluid reservoir tank cap
2-door Hatchback (except STD) Hardtop and BRAT: 12V-1.4W x 2
4-door Sedan and Station Wagon: 12V-1.4W x 4
Bulb
Door ajar warning light
~--
--
On side sill (except 2-door Hatchback STD)
Switch position
t
1----
l
Bulb
S~ tI,,1t w~i", Ugh'
12V-1.4W
Switch position
@ --
~------------
R~, ""
- - f---
*' w,ming I~h'
On seat belt backle
Bulb
Switch position
-------
12V-l.4W [Hatchback (except STD & 4WD STD) and Station Wagon)
f---
In rear gate latch [Hatchback (except STD & 4WD STD) and Station Wagon)
-------Bulb
-------------- ----Checker position
I Stop light warning light
I
12V-1.4W
--
In trunk room or rear combination light
--
1---
Bulb
1--Switch position
Parking brake warning lIght
-------
1-'
12V-1.4W
-------On parking brake lever
-4WD: 12V-3.4W or l.4W (4WD vehicles), LO: 12V-1.4W (Dual-range only)
Bulb
Four wheel drive indicator
light
4WD: On transmission (4WD vehicles) or on drive selector (Dual-range)
LO: On transmission (Dual-range only)
Switch position
-Electric impulse type (GL model only)
Tachometer
~-
Bimetal-bimetal type (GL model only)
Oil pre S5 me ga uge
I
Cross coil type (GL model only)
Voltmeter
-Digital type (GL model only)
Clock
I
---
~
Turn signal indicator light
--
----'-------
I
M eter illumination light
12V-1.4W x 2 or 12V-3.4W x 2
~-
GL model: 12V-3.4W x 5, 12V-1.4W x 3
Other models: 12V-3.4W x 5
Bulb
I-
In lighting switch
Switch position
The following circuits are closed through terminals of ignition-starter switch.
"ACC" terminal
Radio, Heater blower motor, Wiper and washer (front & rear) (auto-stop),
Cigarette lighter, Radiator cooling fan, Remote controlled rear view mirror
"IG" terminal
Ignition coil, Anti-dieseling solenoid, Gauge and warning, Door ajar warning
light, Fuel pump, Kick-down solenoid, Kick-down relay, Timer, Cruise control,
Back-up light, Turn Hazard unit, 4WD-AT solenoid, Power window relay, Rear
defogger, Automatic choke, Lighting relay
Ignition-starter switch
1--
Starter
"ST" terminal
-
Rheostat type
IIIuminatton intensity control switch
High beam
STD: t2V-60W, DL: 12V-65W, GL: 12V-65W (4WD) or 12V-50W + 35W
1--------
D immer
Low beam
STD: 12V-50W, DL: 12V-55W, GL: l2V-55W (4WD) or 12V-35W
In combination switch
Switch position
-
-
15-4
• I
1·1'
I,
I
I t . s'*
1*
ELECTRICAL SYSTEM
Designation
Item
Light position
Front and rear turn signal lights are flashed.
Switch position
On steering column
Hazard warning light
---------
Hazard warning unit
When hazard warning unit is operated, all front and rear turn signal lights and
indicator lights flash at the same time.
Turn signal unit
When turn signal unit is operated, front and rear turn signal lights and indicator
light flash on turning side.
Combination switch
Turn signal, headlight dimmer (headlight flasher) and hazard warning light
switches are combined.
Automatic transmission kickdown switch
On accelerator pedal of automatic transmission vehicle
Wattage
STD: 12V-60/S0W, DL: l2V-6S/SSW, GL: l2V-SOW + 3S/3SW (Halogen)
Headlight
On left side of control wing
Switch position
12V-27W
Bulb
:0:=
-------
Turn signal light
~~
In combination switch
Switch position
c::
U
..... 0
c::.0 .....
~ ~
Bulb
12V-3.BWor BW
Switch position
In lighting switch
Parking light
Front
l2V-3.BW
Rear
Hatchback, Sedan and Hardtop: 12V-3.BW, Other models: 02V-BW)
Bulb
Side reflex reflector & marker light
-----
In lighting switch
Switch position
l2V-27/BW
Bulb
Stop and taillight
.....
~
:.=
c::
0
•.;:1
c::
:s'"
e0
.c:
§ Stop light
';~ '.;:I.~
(/)8..
On brake pedal bracket
-In lighting switch
Tail
I
12V-27W
Bulb
Turn signalligh t
In combination switch
Switch position
.,'".
.-
U
Bulb
12V-27W
~
Back-up light
Swi tch position
Automatic transmission: Combined together with the inhibitor switch which is
installed at under side of selector lever.
On rear cover of transmission
Manual transmission:
Bulb
12V-3.BW or BW
Switch position
In lighting switch
License plate light
Bulb
Room light
l2V-8W
Beside room light
Switch position
Door ajar
warning light
Room light also serves as a door ajar warning light
Front ash tray illumination light
Automatic transmission selector
position indica tor
12V-1.4W
Illumination
light
12V-3.4W
In lighting switch
Switch position
15-5
ELECTRICAL SYSTEM
Item
Designation
GL models: 2-speed with intermittent operation
Other models: 2-speed .
Motor speed
Windshield wiper
Input
12V-50W or less
Switch position
On right side of control wing
Pump type
Windshield washer
Centrifugal
I2V-35W or less
Input
In windshield wiper switch
Switch position
I-speed
Motor speed
Rear window wiper
12V-30W
Input
In windshield wiper switch
Switch position
Centrifugal
Pump type
Rear window washer
12V-35W
Input
In windshield wiper switch
Switch position
AM/FM Mono, AM/FM Stereo
Type
Push-button station selection
On radio set
Switch position
Radio
(except Hatchback STD & 4WD STD)
Main switch
position
In ignition-starter switch
Illumination
light
(Variable illumination intensity type)
Upper panel of instrument panel
Speaker position
(GL model only) Rear luggage shelf Rear quarter trims Rear doors
Front doors
-
2-<100r Hatchback STD & 4WD STD: 12V-390 Hz
Other models: I2V420 Hz, 12V-350 Hz
Type
Horn
On steering wheel
Switch position
12V-120W
Input
Cigarette lighter
(except Hatchback STD & 4WD STD)
Illumination
light
(l2V-1.4W x 2)
12V-llOW
Input
Rear window defogger
(except Hatchback STD & 4WD STD)
Switch position
On heater and ventilator control panel
Indica tor light
12V-1.4W x 2
12V-3.4W
Vanity mirror light (GL model only)
Trunk room light
(Sedan GL and Hardtop GL)
I2V-5W
Bulb
On rear panel
Switch position
15-6
ii'
Sedan and Hardtop
Hatchback
Station Wagon
BRAT
ELECTRICAL SYSTEM
Designation
Item
Chime
In instrument panel (on right side; behind glove box)
Timer
Under instrument panel on driver's side
Seat belt & key warning chime
Rated voltage
12V
Rated current
7A or less
Rated revolutions
55 rpm
2.4 N·m (24 kg-em, 21 in-Ib)
Rated load
Power window (Option)
Stailing current
ISA or less
Stalling torque
S.3 N·m (S5 kg-cm, 74 in-Ib)
Working voltage
IOV - 15V
Working
temperature
Raising or
lowering time
Heater fan
-25 - SO°C (-13 - 176°F)
Approx. 3.5 seconds (varies depending on ambient temperature,
working voltage and type of glass)
Excess
raising force
Approx. 196 N (20 kg, 44 lb)
(varies depending on ambient temperature, working voltage and type of glass)
Motor type
Electromagnetic type
Input
12V-160W or less
Switch position
On heater and ventilator control panel
Motor type
Cooling fan
Electromagnetic type
Input
12V-120W or less
Switch position
On radiator
Input
12V-9.6W or less
Fuel pump
Switch position
In ignition-starter switch
15-7
ELECTRICAL SYSTEM
2. Service Dat a of Distributor
Unit: mm (in)
Specifications
No.
Item
4WD
All models
except 4WD
0.3 - 0.5
(0.012 - 0.020)
0.2 - 0.4
(0.008 - 0.016)
I
Air gap
2
Shaft diameter (Lower side)
12.43 - 12.44
(0.4894 - 0.4898)
--
3
Housing hole diameter
12.450 - 12.468
(0.4902 - 0.4909)
--
4
Clearance between shaft and
housing
0.010 - 0.038
(0.0004 - 0.0015)
--
5
Maximum clearance between
shaft and housing
(Correction limit)
0.06 (0.0024)
--
6
Shaft diameter (upper side)
7.986 - 7.995
(0.3144 - 0.3148)
--
7
Reluctor hole diameter
8.000 - 8.015
--
8
Clearance between shaft and
reluctor
0.005 - 0.029
(0.0002 - 0.0011)
--
9
Weight support shaft diameter
4.958 - 4.965
(0.1952 -0.1955)
--
10
Weight support shaft hole
diameter
4.985 - 4.998
(0.1963 - 0.1968)
--
11
Clearance between weight
support shaft and weight
support shaft hole
0.020 - 0.040
(0.0008 - 0.0016)
--
12
Length of carbon point
12 (0.472)
12 (0.472)
13
Wear limit of carbon point
2.0 (0.079)
2.2 (0.087)
(0.3150 - 0.3156)
15-8
, I
I
101,
ELECTRICAL SYSTEM
15-2. Battery, Fuse and Fusible Link
1. Battery
1) Removal & Installation
1) Disconnect the positive (+) tenninal after disconnecting the negative (-)
tenninal of the battery.
2) Remove the flange nuts from the
battery rods and take off the battery
holder.
3) Remove the battery.
4) Installation should follow the
removal procedure in the reverse
order.
A9·002
Fig. 15-2 Electrolyte level
NOTE:
a. Electrolyte has toxicity; be careful
handling the fluid.
b. Avoid contact with skin, eyes or
clothing. Especially at contact with
eyes, blush with water for 15
minutes and get prompt· medical
attention.
c. Batteries produce explosive gasses.
Keep sparks, flame, cigarettes away.
d. Ventilate when charging or using in
enclosed space.
Fig. 15-1 Installing battery
NOTE:
a. Clean battery cable terminals and
apply grease to retard the formation of corrosion.
b. Connect the positive (+) terminal of
the battery and then the negative
(-) terminal of the battery.
3) Specific gravity
Indicator is provided for checking the
specific gravity and the battery condition.
4) Voltage under high discharge
Charging (or discharging) the battery
raises (or lowers) the voltage but after
stopping the charging (or discharging)
the voltage gradually varies and finally
settles at about 2 volts per cell. Therefore, to check the real condition of the
battery, it is necessary to measure the
voltage with the battery under high
discharge. A simple method is the use
of a high-discharge battery tester.
Check that the individual cell voltages
are more than 1.5 volts and the voltage
differences between the cells are within 0.1 volt when the measurements are
made for 5 seconds per cell.
3) Charging
Measuring the specific gravity of the
electrolyte in the battery will disclose
the state of charge of the battery. The
relation between the specific gravity
and the state of charge is as shown in
figure.
~ 1.280
!e
u 1.250
~ 1.230
1.220
>
.; 1.190
co
a,
u
;;:
.~
INDICATOR SIGN
en
~Blue
1.130
1OO!-.;%:;---:;;7"='5%:::-::66"='%::-;-;:5""0%""'--""2'=57:%~':::"""
\
Charging condition (%)
Complete charge
A9·004
Fig. 15-4 Specific gravity and state of
charge
OK
@:::>-
2) Inspection
1) External parts
Check for the existence of dirt or
cracks on the battery case, top cover,
vent plugs, and tenninal posts. If necessary, clean with water and wipe with
a dry cloth.
Apply a thin coat of grease on the
tenninal posts to prevent corrosion.
2) Electrolyte level
Check the electrolyte level in each cell.
If the level is below MIN LEVEL,
bring the level to MAX LEVEL by
pouring distilled water into the battery
cell. Do not fill beyond MAX LEVEL.
Red or white
1) Nonnal charging
CHARGING
NECESSARY
A9-433
Fig. 15-3 Indicator sign
"OK"
"Charging
necessary "
Charged condition
Specific gravity> 1.15
The battery must be
recharged when engine
does not start.
Specific gravity < 1.15
15-9
NOTE:
a. Remove all the vent plugs since
electrolyte generates gas toward the
end of charging.
b. Do not bring an open flame close to
the battery at this time.
c. Prior to charging, corroded terminals should be cleaned with a brush
and common baking soda solution.
ELECTRICAL SYSTEM
@
@
~-----------+~~o
I
("~f~
i
®
1
..;6)~O~@~J
'-------'<:'1
Charger
Battery
A9-005
Fig. 15-5 Charger-to-battery
connection
The battery must be charged when
indicator shows "charging necessary"
and also engine does not start.
Perform charging for 5 hours or more
with a constant current of 6A.
At the condition of full charged, the
charging current is O.5A or less.
2) Quick charging
Quick charging is a method in which
the battery is charged in a short
period of time with a relatively large
current by using a quick charger.
Since a large current flow raises electrolyte temperature, the battery is
subject to damage if the large current
is used for prolonged time. For this
reason, the quick charging must be
carried out within a current range that
will not increase the electrolyte temperature above 40°C (I 04° F).
It should be also remembered that the
quick charging is a temporary means
to bring battery voltage up to a fair
value and, as a rule, a battery should
be charged slowly with a low current.
NOTE:
a. Observe the items in NOTE in 1)
Normal charging.
b. The battery should not be charged
with lOA or more.
2. Fuse
The fuse box is located on the left side
underneath of the instrument panel.
The connection between each fuse and
main electrical units/devices is as
shown in the following illustration.
(Also refer to the wiring diagram at
the end of this manual.)
15-10
, I,
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I
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OM-867
Fig. 15-6 Fuse box
8~~~~~G~
~~B~~g~~
A25-549
Fig. 15-7 Fuse disposition
ELECTRICAL SYSTEM
FL·3
~
r-1C><:IL
~
{Po""wer window (Option)
I
lOA
IClock, Stop light
I
lOA
Headlight (RH)
I
lOA
Headlight (LH)
I
l5A
License plate light, Taillight
I
IDA
Hom switch, Hazard switch
I
Automatic choke
J
l5A
Ignition coil
I
15A
Kick·down relay (AT only)
I
l5A
Cruise control (Option)
I
-u v--O
2
[0.5 mm (0.0008 sq in)]
Green
Lighting
relay
1
-
~O
10
10
11
2
c::::>r motor
A25·804
Fig. 15-211
NOTE:
Install wiper arm with nut to
specified tightening torque.
B.
1-·-..· · - - - - - ·.. - ..
!
2)
2. Replacement
• Wiper Blade Rubber
Wiper blade rubb<:1 can be replaced in
the same manner as for the front.
(Refer to page 15-67)
Pulling up caver of arm, and take
it out.
3) Remove nuts installing arms, and
take out them.
• Wiper Assembly
1) Disconnect blade from alms by
pus(lIng lever down and sliding them.
Ii
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T'"
19nte,I1mg
t r'
0 qUe;
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. _____ .. _ _ _ _ _ ,.
---~
I
4.4 ", 7.4 N·m
(04<; -- 07<; k·
i
...
.. - g m,
3.3 - 5.4 ft·lb)
I
I
~____
b. For 2-door Hatchback and Station
Wagon, wiper arm and blade are the
same part. However, wiper motor is
distinct part.
c. When wiper switch is in "OFF"
position, adjust blades in original
positions as shown in illustration
by changing wiper arm installation.
-----~~,/
._--
A25359
'~
Fig. 15-213 Removing nut
15 mm (0.59 in)
A25·357
Fig. 15-212 Disconnecting blade
4) Take out caps, nuts and cushions.
5) Take out rear gate trim by remov·
ing screws and crips.
6) Disconnect electric wires from
wiper motor at connector.
7) Remove bolts installing wiper
motor, and take out it.
15-70
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IIIU.~
lEU . r=~l ~ Clf£.J
A25-362
Fig. 15-216 Adjusting wiper blade
position (2-door
Hatchback)
ELECTRICAL SYSTEM
3) Take out joint between hose and
mbber hose of nozzle.
4) Take out rubber hose when rear
Gate is opened .
...
_--------.------------------
_
..
"
".--._-----------_._---. -------
------
~:~~~~-A25-363
Fig. 15·217 Adjusting wiper blade
position (Station Wagon)
--------------j '.
Fig. 15·219 Removing screws
-- Rubber hose
S) Dis('.onnect electric wirt'S from
washer pump at connector.
• Washer Tank (Station Wagon)
• Washer Tank (2·door Hatch·
back)
I) Take out trim by removing screws.
2) Disconnect hose froOl washer tank
and nozzle.
3) Take out drain hose with cap by
removing grommet of hose and crips
of cap.
1) Take out trim by removing crips
and serf-VIs.
2) Disconnect hose from washer tank
find nozzle.
3) Tate out washer tank by r~illi,,!;
it up.
---'-
'!
---.-.---- --I
\ i
_-----_~
I
A25-368
Fig. 15-221
Taking out rubber hose
S) For installation, follow the reo
maval procedure in reverse order.
1)
FOI 2-door Hatchback, take out
by straightening its claws.
noz.zh~
2) For Station Wagon, take out
nozzle by straightening its claws. If
not available to do so, take out nozzle
by ell tting it off.
NOTE:
For Station Wagon, check valve is
provided at washer tank side of pipe
to prevent counter flow from pipe to
tank. Therefore, install the pipe as
mentioned above.
A25··joo
Fig,. 15-220 Taking out wash!,r tank
4) Di£connect electric wires from
Fig. 15·218 Taking out drain hose
washer pump at connector,
5) For installation, follow thp- removal procedure in reverse order,
• Hoses
4) Take out washer tank by remov·
ing screws.
1) Toke out roof trim.
2) Remove crips and gum .. tapes.
15-·71
A25-528
Fig. 15·222 Check valve
ELECTRICAL SYSTEM
IS-II. Electrical Equipment
1. Radio
Rear speaker on BRAT
Rear speaker on Hatchback
(On both doors)
I
Rear speaker on Station Wagon
1 Radio
2 Antenna
3 Speaker
CD
()."~
(011 both doors)
A2li-SOIS
Fig. 15-223 Radio set installation
• Replacement
Pull the knob out for balance control
Fader control
5
1) Radio
a. Take out console box by removing
screws.
r====ilr=
volume control
;;;;;;;;;;=!~ ~
OM·1092
OM·841
Fig. 15·224
Fig. 15·225 Removing screws
15-72
I I'
I
~
I,
ELECTRICAL SYSTEM
b. Disconnect electric wires and antenna feeder cord.
A25·375
Fig. 15-226
3) Speaker on left side of instrument
panel
a. Detach speaker grille with screwdriver.
b. Remove 3 screws fitting speaker
bracket to instrument panel.
c. Take out speaker along with
bracket, and replace speaker.
4) Antenna
a. Detach antenna feeder cord from
clips inside of instrument panel.
b. Take out front pillar inner trim
through that antenna feeder cord
enters car.
I
c. Pull out turning and volume control
knobs.
d. Remove radio mounting nuts.
Antenna
grounding wire
Feeder cord
A25-S10
Fig. 15-232
• Adjustment
A 25-S07
Fig. 15-229 Taking out front pillar
inner trim
A25-376
f. Remove bolt installing antenna
earth cord, and pull antenna down.
c. Remove screws installing mud gard,
tear mud gard off partially, and pull
out antenna feeder cord.
1) Setting push button
There are five push buttons, so five
stations are selected as follows.
a. Select a station by turning the
turning dial.
b. Pull the push button and push it
back, and then the push button is
kept set at the station required.
Fig. 15-227 Removing mounting nuts
e. Remove radio mounting screw and
replace radio.
OM-742
A25-S0S
Fig. 15-230 Removing screws
Fig. 15-233 Setting push button
d. Detach antenna rod.
e. Remove nut and take cover out.
NOTE:
~::Flod
A25-377
Fig. 15-228 Removing mounting
screw
\
~!/
~
,
2) Speaker in instrument panel
a. Take out glove box by removing
installing screws.
b. Remove nuts installing speaker and
take out speaker.
c. Disconnect electric wires from
speaker at connector.
0"'
Y:-,:-..:..:"""
~
Tightening torque N·m (kg-m, ft-Ib)
T: 3 - 6 (0.3 - 0.6, 2.2 - 4.3)
Fig, 15-231
A25-809
15-73
•. Confirm the push button is set It
the center of the channel, otherwise
the tone becomes bad according to
an amount of discrepancy from the
center of the channel.
b. For FM/AM radio, push the FM
push button once before selecting
FM station.
2) Adjusting antenna trimmer
Antenna trimmer is adjusted in order
to make each radiosensitive in case
the sensitivity is poor or abnormal
noise exists (AM band only).
ELECTRICAL SYSTEM
h. Antenna is grounded to body
through antenna installing bolts,
when screws are not tightened
securely, it makes abnormal noise.
So, tighten antenna installing bolts
securdy,
A25·384
Fig. 15-234 Adjusting antenna
trimmer
a. Attach antenna rod in position.
b. Select the channel of a weak station
between 1,400 kHz and 1,600 kHz.
c. Adjust antenna trimmer to make
the sensitivity in maximum.
2. Horn
Hom switch is incorporated iT! steering
-Nheel. When horn button is pushed
down to actuate horn switch regardless
of any position of ignition-starter
<>witch, horn make a sound.
A25-S14
Fig. 15-238
• Removal & Installation
1) For low tone horn, take out front
grille, disconnect electric wire from
the horn and then take out it by
removing bolt.
2) For high tone horn, disconnect
electric wire from the horn and then
take out it by removing bolt.
3) For installation, follow the removal procedure in reverse order.
NOTE:
Antenna trimming is available only for
AM band.
2) Prevention of abnormal noise
a. Intermitting of contacts iri ignitiGE
system, alternator, and contact
points of brushes in motors are
sources which make an abnormal
noise in radio. In order to prevent
abnormal noise, high tension cord
which contains resistance, condens·
ers of ignition coil, and grounding
wire to body from engine are provided.
NOTE:
A25·287
After installing horn, connect electric
wire with it by keeping some slack to
prevent wire from disconnecting by its
vibration.
3. Cigarette Lighter
A25·812
Fig. 15-237 Horn switch
Fig. 15-235 Condenser of ignition coil
All models except Hatchback STD &
4WD STD are equipped with double
horns which consists of high tone and
low tone horns. Hatchback SrD &
4WD STD has high tone horn only.
OM·4S0
Fig. 15-239 Cigarette lighter
• Removal
A25·381
Fig. 15-236 Grounding wire of engine
A25-S13
15-74
1) Pull out knob of air outlet control
lever, temperature control dial and
dial of fan motor switch.
2) Take out heater & ventilator
control panel by removing screws
after pulling down console box by
removing screws.
-
ELECTRICAL SYSTEM
A"S-395
Fig. 15-246 Bulb replacement
A25-388
OM-454
Fig. 15-240 Taking out control panel
Fig. 15-243 Rear window defogger
switch
3) Disconnect electric wires from
cigarette lighter_
4) Remove socket by turning it
counterclockwise.
• Removal and Bulb Replacement of Switch
I) Take out heater and ventilator
control panel after pulling down
console box by removing screws.
2) Disconnect electric wire from
the switch_
• Inspection of Heat Wire
i) Start engine, and turn rear defogger switch on.
2) Check each heat wire at its center
position for di3CO!l.tmuity by setting
direct-current voltmeter.
19~itiOn-starterll
Connector
'\
sWItch
\ '
~
'~-
~ Fuse ::'\' ' - - - - _ . - - - - -
A25--389
-j
Fusible link
Fig. 15-241 Turning socket
-=-
Rear window
defogger switch
:- Battery
CAUTION:
In case of replacing cigarette lighter,
use genuine part only and always
replace both knob and socket combination.
1
,.~
L@} ~
~-
V~new
A25-397
Fig. 15-247 Checking by voltmeter
A25-396
Fig. 15-244 Disconnecting electric
wire
4. Rear Window
Defogger
Rear window defogger is actuated
when rear window defogger switch is
turned to "ON" with ignition-starter
switch "ON". Indicator light on
center of the switch knob glows when
operating rear window defogger.
3) Take out the switch by removing
installing screws.
3) If meter indicates 12 volts or 0 on
specific wire that line is broken.
Nonnal indication is about 6 volts.
4) For fmding out broken position
in the line, move positive lead of
voltmeter along the line until abrupt
variation in the meter indication is
encountered.
• Repair Procedure
A25·394
Fig. 15-245 Removing screws
OM-453
Fig. 15-242 Rear window defogger
4) Pull out socket by turning it
counterclockwise.
S) Pull out bulb from socket and
change it.
15-75
1) Clean broken wire and its surrounding area.
2) Cut off slit on (used) thin film by
0.5 mm (0.020 in) width and 10 mm
(0.39 in) length.
3) Place the slit on glass along the
broken wire, and deposit conductive
silver composition (DUPONT No.
4817) on the broken portion.
-,
ELECTRICAL SYSTEM
5. Seat Belt " Key
Warning Chime
Broken position
Masking thin
film
composition
A25-398
Fig. 15-248 Depositing composition
4) Dry out the deposited portion.
S) Inspect the repaired wire for
continuity.
Seat belt & key warning chime participates in both seat belt warning system
(aU models) and key warning system
(except 4WD).
1) Seat belt warning system
Fasten seat belt warning light in combination meter turns on for approx.
six (6) seconds after turning ignitionstarter switch to ON position.
Also, only when driver's seat belt is
not fastened, the chime will sound
about four (4) times.
2) Key warning system (except 4WD)
The chime will sound while door is
opened with the key plate inserted in
ignition-starter switch.
Key plate position in
ignition-starter switch
\
(START), ON
ACC,OFF,
LOCK
Zone A
Zone A
Zone A
ZoneB
Hatchback
STD
Others
(except
4WD)
Zone A: The chime will sound while only
front driver's door is open.
Zone B: The chime will sound whenever
front door, rear door or rear gate
is opened.
~~
~,
Door switch
Timer
Key warning switch
Room light
Seat belt switch
Chime
A25-815
Fig. 15-249
15-76
I,
--,
ELECTRICAL SYSTEM
• Removal
1) Timer
a. Remove trim panel under instru·
ment panel on driver's side.
b. Disconnect electric connector from
timer.
c. Remove a screw, and take out
timer.
2) Chime
a. Remove screws, and take out glove
box.
b. Disconnect electric connector for
chime.
c. Remove a screw, and take out
chime.
• Installation
1) Timer
a. Install timer by tightening a screw.
b. Connect electric connector to
timer.
-------
A25-619
1 Screw
2 Connector
3 Timer
Fig. 15·251
A25·618
Fig. 15·250
c. Install trim panel under instrument
panel on driver's side.
2) Chime
a. Install chime by tightening a screw.
b. Connect electric connector for
chime.
2
c. Install glove box by tightening
screws.
6. Power Window
(Option)
Electric motors are provided for
window glass regulator of each door
and rear quarter (Hardtop) to open
and close the window.
1
2
3
4
5
6
7
8
9
10
Motor (Front, RH)
Sub switch (RH)
Motor (Rear, RH)
Control unit
Motor (Front, LH)
Main switch
Relay CP (Relay &; Breaker)
Auto switch (Front, LH)
Motor (Rear, LH)
Sub switch (LH)
A25-631
Fig. 15·252
15-77
ELECTRICAL SYSTEM
r-------------,
Breaker Relay
Fuse~I;-]
IgOitlon-starter
switch
~-------------~
[[
Sj
Motor
Breaker
r------,
I
I
:!
Ignition-starter
switch
I
I
~
r-------,
I
I
1
Control
unit
M'ain switch
Battery
....L.
T
1
: 1--- 1
:
Battery
Main switch
: Auto switch
I" ____ J'
--'-
I
Circuit (other than driver's windowl
A25-817
A25-816
Fig. 15-254 Circuit (other than driver's window)
Fig. 15·253 Circuit (driver's window)
• Main switch
Main switch is located on center arm
rest, and has four (4) switch knobs and
a lock switch knob that makes the
three (3) motors other than the one
for the driver's window inoperative.
Each window is lowered or raised
while the applicable switch knob is
operated with the lock switch up
(OFF).
i Motor
I
I
Fuse~j
: :
!
I
I
,
Relay
• Sub switch
Sub switch is provided for both rear
doors or rear quarter. Each rear
window is lowered or raised while its
switch is operated with the lock switch
in main switch panel up (OFF).
]1J.~.·W
~
-----------
- - - - ---==-==-=-
-:...:---~--=--
OM-736
Fig. 15-257 Auto switch
=
Also remove auto switch by drawing
its clip out after taking out the door
trim and disconnecting its connector.
OM-737
Fig. 15-256 Sub switch on rear door
@
1
2
3
4
5
Remove sub switch by drawing out its
clip after taking out door trim (or rear
quarter trim) and disconnecting its
connector.
® @
Front passenger's window
Rear right window
Lock switch
Driver's window
Rear left window
A25-818
Fig. 15-255 Main switch
Remove main switch by removing
screws behind center arm rest, after
removing screws fitting center arm
rest Qnto body, and disconnecting its
connector.
• Auto switch
Auto switch is located only at driver's
door and controls drive's window
automatically in combination with
control unit.
Driver's window can be opened or
closed fully by lifting or depressing on
the auto switch for a moment.
Furthermore, driver's window can be
stopped on the way by operating the
auto switch for a moment in reverse
direction of the window movement.
15-78
, I
• Control unit
Control unit is fixed with bracket for
hood lock release lever. The control
unit consists of transistors, relay,
transformer etc. and controls up and
down of driver's window in combination with auto switch.
• Relay and Breaker
Relay and breaker are installed under
driver's sheet. The relay provides an
ignition interlock to all switches so
that windows cannot be operated
unless the ignition-starter switch is in
"ON" position for safety.
When overcurrent flows, breaker cuts
electric current to components and
electric wiring from damage and burn
out.
ELECTRICAL SYSTEM
7. Cruise Control
(Option)
1) General
The cruise control automatically controls car speed and allows the car to
run at a constant speed without depressing the accelerator pedal. In operation, when the driver sets a desired
speed with the cruise control switch,
the built-in micro-computer compares
the speed set in the memory with the
actual running speed detected by feedback signals from the speedometer.
This feedback system operates the
throttle of carburetor to correct the
speed difference, thereby keeping the
car at a constant speed.
NOTE:
a. The cruise control must never be
used in the following driving conditions.
(1) When going up or coming
down a steep slope
(2) On roads with poor traction,
for example, snow-covered, icy,
or gravel roads
(3) When a strong wind is blowing
(4) In congested traffic
(5) On a road with many curves
b. Modification of this device must
never be attempted.
c. The main switch of the cruise control must always be turned off, except when in use.
To accelerator
pedal
To actuator
Main switch
. Actuator ASSY
To carburetor
Link ASSY for
Hitachi carburetor
Clip
I
I'-"--J
!.iPP/e
To carburetor
A25-819
Fig. 15-258
15-79
ELECTRICAL SYSTEM
2) Operation and Function
Set function
Resume function
If the set switch is turned on while running at speeds between 40~g and 140~g km/h (25~~ and
87~~ MPH), the then car speed will be set in the memory of the cruise control unit and the car will
maintain that constant speed.
• With the preset speed in the memory, if the resume switch is turned on while running at a speed
within the speed setting range, the car will accelerate up to the memorized speed and maintain
that constant speed.
• If the resume switch is kept "ON" at a speed over 40 km/h (25 MPH), acceleration will continue
(up to the limit of the engine output).
If the resume switch is turned off, the car will slow down to the memorized speed and maintain
that constant speed. (Without any speed in the memory, the system will be turned off.)
NOTE:
If the main switch is turned on, the car will accelerate by means of resume switch even without any
speed set in the memory.
If the coast switch is turned "ON" when the car is running at a constant speed, the car will decelerate. If the coast switch is turned off while running at a speed within the speed setting range, the
speed at which the car is running when the switch is turned off will be set in the memory again and
the car will maintain that constant speed.
Coast function
NOTE:
Even when no speed is set in the memory, if the main switch is on and the car is running at a speed
within the speed setting range, the then car speed can be set by releasing the sub-switch after having
turned it to the coast position.
Cancel function
The function of the cruise control will be canceled by the following operations or in the following
conditions.
*(a) When the main switch is turned to "OFF".
*(b) When the ignition-starter switch is turned to "ACC" or "OFF"
(c) Depressing the brake pedal
The brake pedal is provided with a brake switch (N.C) and stop switch (N.O). When the pedal
is depressed, the switch connections are reversed, causing the signal to be transmitted to the
cruise control unit.
(d) Depressing the clutch pedal
The clutch pedal is provided with a clutch switch (N .C). When the pedal is depressed, the
switch connections are reversed, causing the signal to be transmitted to the criuse control
unit.
(e) Shifting the select lever to ® (AT vehicle only)
This actuates the inhibitor switch (N.O) and the signal is input to the unit.
*(f) When the engine speed reaches 5,500 rpm or more
(g) When the car speed slows down to 4O~~ km/h (25~ MPH) or less
*(h) When the car speed signal varies more than ±25 km/h (± 16 MPH) per second, including the
vibration of the speedometer cable
*(i) When the car has decelerated more than 15 km/h (9 MPH) from the memorized speed
*(j) When the resume switch and set switch are operated simultaneously, or when the coast switch
and set switch are operated simultaneously
* In the operations (a), (b), (t), (h), (i), and (j), the memory will also be erased. In the others, the
cruise control will be functionally canceled temporarily but the pre-set speed will remain in the
memory.
15-80
.r
1.
--I
ELECTRICAL SYSTEM
3) Cruise Control Unit
The cruise control unit compares the
actual car speed detected by feedback
signals from the speedometer with the
speed set in the memory memorized
when the set switch was turned on.
A signal is then transmitted according
to the difference between the two
speeds.
This signal is transmitted to the solenoid valve of the vacuum actuator
located in the engine compartment.
The movement of the actuator operates the carburetor throttle valve,
thereby keeping the car speed constant.
Detection of car speed
Slow car speed
Car speed pulse
j
I
:
{
Fast car speed
,r------I
I
T'm'", p.'e
j
~14---------------------~~1~·~~·1
I
I
\
I
Measurement of car speed
Operates solenoid valve
Comparison-of-car-speeds pulses
(Signal is transmitted according to
the comparison made while timing
pulses disappeared previously)
The number of pulses are transmitted while timing pulses appear,
and the car speeds are compared
when timing pulses disappear.
4) Actuator
Vacuum
Vacuum
valve
Valve movement
L
Safety valve and
bent valve
Filter
Vacuum
movement
movement
Diaphragm
Fig. 15-259
pressure
To link assembly
and carburetor
A25-625
Vacuum
The actuator has a vacuum valve, vent
valve, and safety valve. The opening
and closing of each valve introduces a
vacuum from the engine or air at
atmospheric pressure into the actuator
to operate the diaphragm, which in
turn operates the carburetor throttle
valve.
Inside actuator
Atmosphere
Electrified
Vacuum valve
Operation of
valves
Vent and safety
valves
When the cruise control is out of
operation, the safety valve and vent
valve are opened and the vacuum valve
is closed. Therefore, the inside of the
actuator is at atmospheriC pressure,
Not electrified
Valve closes
Electrified
Valve closes
0
Not electrified
and the diaphragm does not operate.
During constant-speed driving with the
main switch on, the safety valve closes,
and the vacuum valve and vent valve
open and close to introduce a vacuum
15-81
~
.....,
or air at atmospheric pressure into the
vacuum actuator. This moves the
diaphragm, which operates the carburetor throttle valve to provide control
over the car speed.
ELECTRICAL SYSTEM
---,
Safety valve
Vacuum valve
Vent valve
Open
Close
Open
< actual speed
Close
Close
Open
Memory = actual speed
Close
Close
Close
Memory> actual speed
Close
Open
Close
System OFF
Memory
System ON
5) Cruise Control Switch
the pedal is depressed when driving
with the cruise control in operation.
However, the pre-set car speed will
remain in the memory of the cruise
control unit.
2.
A25-626
Fig. 15-260
Clutch switch
(MT vehicle only)
The clutch switch is fitted to the
pedal bracket. When the clutch pedal
is depressed, the clutch switch is turned off and the operation of the cruise
control is canceled. However, the preset car speed will remain in the
memory of the cruise control unit.
Ii
When the cruise control operates, the
actuator pulls the lever CV through the
cable connecting the actuator to the
link ASSY. This movement causes the
lever 00 to pull the stopper CD of the
cable connecting the accelerator pedal
to the carburetor. Thus the carburetor
is controlled without depressing the
accelerator pedal.
Further, if the accelerator pedal is
depressed in this state, the cable con·
necting the accelerator pedal to the
carburetor is pulled, so that the carburetor throttle lever can be operated
regardless of the movement of the
lever 00 caused by the actuator.
1. Main switch
3.
This is a push-button switch located
on the steering column and is the main
power switch of the cruise control.
When the cruise button is depressed,
the green pilot'lamp above the button
illuminates and an electric current
flows in the cruise control unit.
2.
Sub-switch (Set lever)
Pushing the tip of the sub-switch knob
allows the set signal to be entered in
the cruise control unit. The resume
signal and coasting signal are entered,
respectively, by turning the knob in
the forward and backward directions
of the car.
Inhibitor switch
(AT vehicle only)
The inhibitor switch is attached to the
automatic transmission select lever.
When the select lever is shifted to the
"N" range, the switch turns on to
cancel the operation of the cruise
control. However, the pre-set car speed
will remain in the memory of the
cruise control unit.
8) Repair of Component Parts
• Cruise control unit
The cruise control unit is attached to
bracket for turn signal and hazard
signal unit, on the right underneath
instrument panel. To remove, loosen
screws.
7) Link Assembly
«
To actuator
2 3
12~15
6 7
~
9 10 11 4 13 14 15 16 17
6) Cancel Switch
1.
Stop & brake switch
The stop switch and brake switch are
fitted to the brake pedal. The stop
switch functions as an ordinary stop
light switch. When the brake pedal is
depressed, the stop switch is turned on
and the brake switch is turned off.
These two kinds of signals will cancel
the function of the cruise control if
A25-629
Fig. 15-262 Connector terminal for
cruise control unit
To carburetor
Stopper
2 Lever
3 Return spring
1
A25-627
Fig. 15-261
15-82
.. i 11 t
ltl'l' '"
ELECTRICAL SYSTEM
Terminal
No
CD
Description
Color of
wire
-
--
-
-
®
® range.
@
BY
Inhibitor switch
(AT vehicle only)
This terminal is grounded only when the select lever is set to the
(No terminal is provided in the MT vehicle.)
@
GY
Clutch switch
MT vehicle:
This terminal is usually grounded, and is disconnected from ground when the clutch
pedal is depressed.
AT vehicle:
It is always grounded.
@
Br
Main switch
If the main switch is turned on with the ignition-starter switch on, the battery voltage is transmitted. The voltage is cut off when it is turned off.
®
YR
Speed sensor
When the speedometer cable rotates with the ignition-starter switch on, on-off
signals at more then 5V and OV are repeatedly transmitted.
®
B
Ground
This is always grounded. (grounding wire of the control unit)
(j)
G
Vacuum valve
The signal for operating the vacuum valve is input.
®
YB
Resume switch
If the resume switch is turned with the ignition-starter switch on, the battery voltage is transmitted. The voltage is cut off if it is returned.
®
BR
Brake switch
With the ignition-starter switch on, the battery voltage is transmitted. When the
brake pedal is depressed, the voltage becomes OV.
®
Y
Ignition coil
It transmits ignition pulse signals while the engine is running.
@
WB
Valve (common)
While the cruise control is operating, the battery voltage is transmitted from the
control unit to each valve.
@
YW
Check
This is the check terminal used for quality inspection in the production line.
[The cruise control can be temporarily canceled by entering a pulse signal corresponding to the engine speed of 5,500 rpm or more.
@
LW
Vent valve
The signal for operating the vent valve is transmitted.
@
-
@
W
Set switch
If the set button is pressed with the ignition-starter switch on, the battery voltage is
transmitted. The voltage becomes OV if it is returned.
@
L
Coasting switch
If the coasting switch is turned with the ignition-starter switch on, the battery voltage is transmitted. The voltage is cut off if the switch is returned.
@
GB
Stop switch
When the brake pedal is depressed, the battery voltage is transmitted. The voltage is
cut off when it is released.
or
J
-
-
NOTE:
a. Of the above terminals, the signal from (j), @ ,and @ are not transmitted unless the cruise control unit is actually operated with the unit connected to the electric wire.
b. Check each of the terminals according to the troubleshooting chart
15-83
ELECTRICAL SYSTEM
1) To remove or install clutch switch,
remove connector for the switch and
nut (B) on the underside of the switch.
• Cruise control switch
Tightening
torque
(Nut B)
5.4 - 9.3 N·m
(0.55 - 0.95 kg-m,
4.0 - 6.9 ft-Ib)
2) Adjust the free play of clutch
pedal by loosening or tightening nut
(B) on the underside of clutch switch.
Terminll
CRVISE
1
Q
AEX 0.3
R
3
6
AEX 0.3
Br
AEX 0.3
B
OFF
Wiring
4
LEO
F.:::\
\.!Y
.A· vv
R560n
J
Free play of
clutch pedal
13 - 20mm
(0.51 - 0.79 in)
A25-630
Fig. 15-263 Main switch
NOTE:
Resume
Before starting the adjustment, electric
connector should be removed to prevent the wire from being twisted.
Firmly connect the connector after
the adjustment.
9) Cable Play Adjustment
~
T.rmin~
ClI>OrOti~
• Vehicle with HITACHI carburetor
1
2
3
4
~.~~
~.~~
~~
~~X
0.3W
CRUISE
RESUME
0-
ro
COAST
SET
,..,
,..,
J"\
A25-631
Fig. 15-264 Sub-switch
Replace main switch and/or sub-switch
as follows.
1) Lower steering column.
2) Remove steering wheel cover.
3) Remove steering wheel.
4) Divide steering column cover in
two, then remove electric connector.
5) Remove four tapping screws from
the back of the column cover, then
replace main switch.
6) Remove sub-switch from ignitionstarter switch by loosening two screws,
then install a (new) sub-switch there.
• Outch switch (MT vehicle only)
NOTE:
When installing column cover, be
careful to prevent electric wire from
becoming entangled with 01ller parts.
Fig. 15-265
15-84
Adjust cable play in the following
procedure by retightening nuts CD, @
and@.
1) Adjust dimension "A" between
the stopper and lever in the link ASSY
to approx. 2 mm (0.08 in) while
pulling the cable at position 4 toward
the throttle lever, and then retighten
nuts CD.
2) Adjust deflection "B" to less than
20 mm (0.79 in) [or free play "C" to
less than 4 mm (0.16 in)] without
movement of the throttle lever, and
then retighten nuts @.
3) Loosen nuts @ and detach the
grommet of the actuator. Retighten
nuts @ so that the throttle lever will
start moving when pushing the diaphragm in the actuator by approx.
5 mm (0.20 in).
-I
ELECTRICAL SYSTEM
To actuator
o
To accelerator
pedal
Nuts
Nuts
o
To carburetor
@
CD
Link ASSY
Bulkhead
To carburetor
Front
.......
_--
To accelerator pedal
Oil filler
duct
ke booster (Master·Vac)
Throttle
Nuts
o
00
Tightening torque N'm (kg-m, ft·lb)
T1: 2·6 (0.2·0.6, 1.4·4.3)
T2: 7·13 (0.7·1.3,5.1·9.4)
A25·820
Fig. 15·266
15-85
ELECT'UCAL SYSTEM
• Vehicle with CARTER·WEBER carburetor
Adjustment
Operation
Three cables connect to the drums in
the link ASSY.
• Cable A from accelerator pedal-+
Upper drum
• Cable B from carburetor -+ Center
drum
• Cable C from actuator -+ Lower
drum
1) When the cruise control is not
activated, depressing the accelerator
pedal causes the carburetor to operate
through the sequential movement of
cable A, center drum and cable B.
2) When the cruise control is activated, operation of the actuator is
transmitted through cable C, lower
drum, center drum and cable B, thus
activating the carburetor.
3) After the cruise control has been
set, depressing the accelerator pedal
activates cable A, upper drum, center
drum and cable B, in that order,
regardless of the operation of the
actuator, thus activating the carburetor.
1) Loosen nuts. Adjust the piay of
the cable A so that the upper drum
begins to operate when the cable's
axial play is less than 2 mm (0.08 in).
Tighten nuts.
2) Adjust the axial play of the cable
B at the carburetor until the play is
within 0 to 2 mm (0 to 0.08 in).
3) Adjust the axial play of the cable
C until the lower drum begins to
operate when the play is less than
2 mm (0.08 in). After the axial play is
adjusted, tighten nuts connecting the
cable to the actuator.
Link ASSY
To actuator
To carburetor
Actuator
ASSY
0
Cable B
(Bulkheadl
Cable A
To carburator
0--=«,......
:/
(Spare tire)
I
To accelerator
To accelerator
pedal
J
1
I
Cross sactional view
j
J
Tightening torque N·m (legem, ft·lb)
T: 2·6(0.2·0.6,1.4·4.3)
Fig. 15·267
16-86
A25·821
1
ELECTRICAL SYSTEM
8. Remote Controlled RearView Mirror (Option)
The remote controlled rearview mirror
switch consists of a left-right changeover select knob and a control lever.
The switch is ready to function only
when the ignition-starter switch is in
"ACC" or "ON". To set the rearview
mirror positions, move the select knob
to the left for the left rearview mirror
or to the right for the right one and
move the control lever to left, right,
up or down. Movement of the mirror
is accomplished by the motor in the
mirror. After releasing the control
lever when the mirror is in the desired
position, the motor stops automatically.
Cross sectional view of
mirror
Replacement of the Switch
Remove the console box or radio box.
Disconnect the 6-pin connector from
the rear, remove the dress nut and
replace the switch.
Remote controlled rearview
mirror switch
A25-822
Fig. 15-268
Replacement of the Electrical
Wiring
The wiring is routed from the instrument panel wiring harness connector
to the rearview mirror via the front
door cord and the rearview mirror
cord. The front door cord can be
removed after detaching the grommet.
The rearview mirror cord can be
detached by removing the two retaining clips. To install, remove the door
window glass, and make sure the glass
and cord do not interfere with each
other after installation.
Instrument panel
wiring harness
Detail "8"
Front
door
cord
Detail "A"
A25-823
Fig. 15-269
15-87
ELECTR1CAL SYSTEM
9. 4WD·AT Control System
Hydraulic multi-disc clutch
4WD select switch
(push button type)
Select
lever
Extension case
4WD·AT
checker
Fuse
Drain pressure
4WD changeover
valve (4WD .... FWD)
4WD indicating light
Fig. 15-270
The 4WD·AT vehicle is equipped with
an AT select lever and 4WD-AT switch
(push button type) instead of the 4WD
shift lever. By operating the 4WD·AT
switch, the 4WD changeover valve of
the automatic transmission is operated
through the 4WD-AT solenoid mounted on the extension case.
When the 4WD·AT switch is turned on,
the 4WD·AT checker unit detects the
electric current flowing to the 4WD·
AT ~olenoid, and illuminates the 4WD
indicating light in the combination
meter.
With the ignition· starter switch in
"ON" position, if the 4WD indicating
light fails to illuminate when the 4WD-
15-88
-'I
AT switch is turned on, check the
connector for disconnection, the 4WD·
AT solenoid for broken coils, and if
the 4WD-AT checker is in normal
condition. The 4WD-AT checker is
installed, together with the tum signal
and hazard unit, under the instrument
panel with a screw.
.,.,
~
~.
::s
C
S·
('D
085L Y
0'
...
-
W
'" ::I.
=
(')
'"
0 8. 5'
::s !!.(JQ
e: '" ...;;;.
::;. 3 ~.
Fusible link
e
I~
11",;;;,
nCD
I
ST
IG
l
- - ..n_.
(')
Battery
loA
0
•
.=.
~
roo
.......
M
Blower motor
0.85 YIN
• Ther mostat
* Low1l ressu re
switch
L-._ _ _-{'~"'~'
* Compressor clutch
leI . •.
: Genuine parts provided in air conditioner ki~..
Blower switch
I
1
'-
.
-
---------------
J
ElECTR ICAl SYSTEM
15·12. Electrical Wiring Harness
All models except BRAT
CD
®
®
®
\
1 Front wiring harness
2 ECM wiring harness [49 States (except
4WD & 4WD-AT) and California]
3 Engine wiring harness
4 Instrument panel wiring harness
5 Rear wiring harness
6 Room light cord
7 Center wiring harness
8 Power window wiring harness
9 Rear speaker cord
10 Fuel meter cord
11 Rear wiper and defogger cord
12 Rear combination light cord
@
I
(Station Wagonl
(Hatchback)
A25-701
BRAT
1
2
3
4
5
6
7
8
9
Front wiring harness
ECM wiring harness (California only)
Engine wiring harness
Instrument panel wiring harness
Rear wiring harness (A)
Room light cord
Center wiring harness
Rear wiring harness (B)
Rear combination light cord
A25-702
15-90
I I
j
~,
!'
H
.,
----~
--
ELECTRICAL SYSTEM
1. Front Wiring Harness
\
Fig. 15-272
A25-703
15-91
ELECTRICAL SYSTEM
Front wiring harness
Connector
No.
Connecting to
Pole
I
2
3
4
5
6
7
8
9
10
II
12
13
14
A2S-70S
Grounding point is shown by " . . "_
A2S-706
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
I
6
5
5
2
3
17
4
5
16
13
8
4
2
13
2
4
1
3
2
I
I
2
1x 2
3
1x2
2
3
2
1
2
3
1x 2
Appearance
Pink
Green
Green
Yellow
Black
Yellow
Blue
Blue
Brown
Black
2
2
3
1x2
4
6
4
2
1x2
4
4
9
6
6
4
4
1x2
1x2
2
3
2
2
2
2
1x2
7
Black
Black
Pink
Pink
Pink
Brown
Green
Green
Black
Ignition·starter switch
Cruise control sub-switch
Cruise control main switch
Kick·down switch
Tum signal & hazard unit
Cruise control unit
Wiper motor
)
1n',"~nt..,.<1
win". ..."""
(4WD-AT)
(AT)
Check terminals
Kick-down solenoid (AT & 4WD-AT)
Back-up switch (MT)
Starter
Brake fluid level sensor
Alternator
IC regulator
Air -conditioner compressor
Condenser fan (sub-fan) motor
Horn (High tone)
Headlight (LH)
Side marker light (LH)
Front combination light (LH)
Headlight (LH)
Front tum signal light (LH)
Thermo switch
Radiator fan (main fan) motor
Headlight (RH)
(To be connected)
Front tum signal light (RH)
Front combination light (RH)
Headlight (RH)
Side marker light (RH)
(Spare)
Check terminals
Check terminals
Check terminals
Air valve (F.I.C.D.)
Main fan control relay
Cruise control actuator
} ECM wiring harness
Air -conditioner relay
Sub-fan relay
Sub-fan control relay
Fuse for air-conditioner
Ignition coil
Pressure switch (Main fan control)
Low pressure switch
Washer motor
4WD-AT solenoid
4WD-AT fluid temperature switch
Horn diode
Horn (Low tone)
Engine wiring harness
A2S-724
Fig. 15·273
The connector is white if there is no indication in the connector appearance column.
15-92
, I
. . .t
f'
..
ELECTRICAL SYSTEM
2. Enaine and ECM Wirina Harness
A25-707
Fig. 15-274
Connector
Connecting to
No.
Pole
I
2
3
4
5
6
7
8
9
10
11
12
13
Appearance
6
9
9
4
Green
Green
1
2
2
1
1
2
17
Black
6
} Front wiring harness
} Engine wiring harness
Pink
Pink
Green
Green
Green
O2 sensor
High altitude switch
Vacuum switch (II)
Vacuum switch (I)
} (Spare)
Rear wiring harness
} Instrument panel wiring harness
-
15-93
--"
..
._---------------.._-_._-_.__...--
ELECTRICAL SYSTEM
Fig. 15-275
A25-708
J=I -
-~::ector
II
No.
I
Pole
i
3
i Appearance
4
I
9
I
5
2
3
6
7
I
1
\
2
")!
2x2
8
I
I
;i L ___
: .--'-___
I
______
.
f"
l
~';:::::it'h m
unit
j
C
A
A,U
A,B,C
I
_ _--'-_ _ _A_, .~~~~ .~_ . __ ._J
A:S
149 s,.,,,U.sIAc.lifomi.
- - - - - - - -
____ i With Carter carburetor
B
~______
.
....L-1------~
4WD& 4WD-AT
.____________ ~_. .~. L
15-94
I· •
l-c.:.:---
i------tI -- ------
WithHlTACBI~~bureto-r--~A
! - i- - -
I,
A (49 States only), B
A
_ . L - -_ _ _ _ _ _ _._
Appli"tion "hI,
Other than 4WD & 4WD-AT
I
1
Front wiring harness
Solenoid valve (III)
Solenoid valve (I)
Automatic choke
Solenoid valve (II)
Duty solenoid
Duty solenoid
Thermo sensor
2
9
I
-----------t---- ---~~,;- -------1
i\pplicat!on
(f"
. See the ollowing table.)
Connecting to
-----+-}-E-C-M-W-h-i-n-g-h-ar-n-e-s-s
7!
2
i
4
10
I
I
A
1
C
i
i
._ _.L.-_ _ _ ...._ _ j
I
ELECTRICAL SYSTEM
4
/
1
2
3
4
5
6
7
Thermo sensor
Oil pressure unit
Oil pressure switch
Anti-dieseling switch
Solenoid valve (I)
Kick-down solenoid (AT)
4WD switch or LO switch
(Dual-range only)
8 Back-up light switch
* 9 Duty solenoid valve
®
/
/.
®
/
®
A2S-709
T
/
1
2
•3
4
*5
*:
Fig. 15-276
Fusible link
Noise condenser
Vacuum switch
Brake fluid level sensor
02 sensor
49 States (except 4WD & 4WD·A T) and California
A2S-710
15-95
ELECTRICAL SYSTEM
3. Instrument Panel Wiring Harness
• SrD & DL models
A25-711
Fig. 15-277
15-96
I
,
--I
ELECTRICAL SYSTEM
Connector
No.
Connecting to
Pole
~
1·1
2·1
3
4
5
6
7
8
9
10
11
12
13
14
15
16·1
17·1
18·1
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42.
43·1
44
45
46
47·2
48
49·1
50·1
51
52
53
54
9
II
3
16
13
8
1x2
1
8
6
1
1
1
4
6
2x2
20
16
4
4
6
2
2
2
8
4
It
12
12
1
3
2
6
4
7
6
2
3
2
1x 2
2
2
4
1x 1
2
2
2
4
6
17
17
10
4
2
Appearance
Pink
Brown
Blue
Black
Yellow
} Check terminals
Remote controlled rearview mirror (LH)
} Front wiring harness
Clock
(Spare)
Timer
Fuel pump control unit
} Fuse (for A/C)
Green
Black
Black
Black
Green
Brown
Green
Brown
Brown
Black
Blue
Blue
Brown
Black
Black
Pink
Green
Green
Green
Blue
Blue
Black
(Spare)
Relay (for A/C)
Intermittent wiper unit
Check terminals
} ECM
lighting relay
Kick-down relay
lighting switch
TIlumination light
Key warning switch
Stop light switch
} Combination switch
}Combination meter
(Spare)
Blower motor switch
Air-conditioner switch
Windshield wiper switch
Rear wiper switch
Rearview mirror switch
Radio
TIlumination light (for ash tray)
Rear defogger switch
Illumination light (for control panel)
Cigarette lighter
Diode (for chime)
Diode (for parking brake warning light)
(Spare)
Thermo unit (for A/C)
Speaker
Chime
} Rear wiring harness
} ECM wiring harness
} Rear wiring harness
Blower motor
·1: 49 States (except 4WD & 4WD-AT) and California
·2: 49 States 4WD & 4WJ)..AT and Canada
15-97
---!
ELECTRICAL SYSTEM
• GLmodel
It)
N
t:-
It)
N
«
A25-713
Fig. 15·278
15-98
II
III,
r--------:-------'------'-'----------------
!
I
l-
No_
I *j
, ,,
4
16
13
3
5
8
I
CD
CD
L
8
1x 2
9
10
11
I
8
4
2
Blue
6
2
2
2
2
4
8
4
12
12
9
7
4
2
Yellow
C()!i,,;)lled
rcafview mirror (LH)
"
PUle
Clock
(Spare)
Timer
Blue
Blue
Brown
Green
Brown
Brown
Black
Blue
47
2
3
~
57*2
Fuel pump control unit
Check terminals
Lighting relay
Kick-down relay
Lighting switch
Illumination light (for switches)
Illumination light
Key warning switch
Clutch switch
Stop light switch
61 * I
62*1
63
64
65
66
I Combination switch
I
Clock
Car speed sensor
Illumination light (for clock)
(Spare)
Blower motor switch
Air-conditioner switch
Windshield wiper switch
6
!
* I:
70 *3
I
I
t_1
I
Blue
Blue
Blue
Green
Green
Remo,e controlled rearview mirror (RH) I
(4WD-AT)
Center wiring harness (AT)
Blue
Blue
Rear wiring harness
i
ro
\.Ireen
-1
::0
Speaker
(/)
} Rear wiring harness
(/)
I Real' wiring harness
I Combination meIer
49 States (except 4WU & 4WD-AT) and California
*2: 49 States 4WD & 4WD-AT and Canada
(")
(")
-<
-1
m
s:
Blower motor
I Black
m
r
m
»
r
ECM wiring harness
_ _ _ _ ---L _ _ _ - - - ' - -_ _ _ - L - - _ _ _ _ _ __
* 3: Digital type only
*4: Other than digital type
I
II
I
I
:2!
.,
I
I
Green
.
17
10
2
Diode ( for chime I
(Spare)
C;!ove hclX swicch ;!!ld light
Thermo unit (for A/C)
Speaker
Chime
17
~~
L
Black
2
:2
4
3
4
:2
5'1
b,:,-lnll'..<·r
Iiluminatioll ll<',h, i. ior *1
(Spare)
Relay (for A/C)
Speaker
Intermittent wiper unit
Black
Black
Black
Green
Black
Green
4,
44
45
46
4i1
4'1
} h"", wid", hom",
Yellow
I
3
2
6
Remc1!e
Black
2
6
4
4
C·,~,
I
Brown
I
4
20
16
6
2x2
i
i
i
!
I
r--------- -------------------------------c-------------'------- ----- -----,--,-
~----
I
10
<.n
_ _ _ _ _ _ _ _ _ _,
'-", ,;',[',ectH',s ! 0
-~--?-:I"-
2*2
3
12
13
14
l5
16
17
18*1
19*1
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34*4
35*4
36*4
37*4
38*4
39
40
41
42
_o.~.
I
r--- --
"
5
6*3
7*1
_ .. 0 _ _-
,:'r: 1fi\"C~ \';
I
J
ELECTRICAL SYSTEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fuel pump control unit
Cruise control unit
Glove box switch
Intermittent wiper unit
Chime
Timer
Ignition-starter switch and key
warning switch
ECM [49 States (except 4WD &
4WD-AT) and California]
Stop light switch
Kick-down switch (AT)
Stop & brake switch (for cruise control)
Outch switch (for cruise control)
Turn signal and hazard unit
Kick-down relay (A1)
A25-714
1
2
3
4
5
6
7
8
9
10
11
Inhibitor switch
Parking brake switch
4WD switch (Dual-range only)
Seat belt switch
Ignition relay
Door switch (Front)
Power window control unit
Power window relay
Power window breaker
Door switch (Rear)
Automatic choke relay
A25-715
Fig. 15-279
15-100
--
---,
ELECTRICAL SYSTEM
4. Rear Wirina Harne.s
--- ."
.~-.- .. -.
\
1
r
'/
A25·716
!
No.
I
2
3
4
5
6
7
S
9
10
A25-726
Fig. 15·280
II
12
13
14
15
16
17
18
19
20
21
22
Connector .-
r-;.;, r;;;.;;~ '-------_._-------- --- ---Connecting to
4
2
4
10
17
2
;:
I xl
2 .
3
I x2
4
4
4
2
4
1
I
2
I x2
2
Ix2
I x2
Blue
BlUe
Black
I Blue
I Blue
Green
I
Pink
I
)
f4WD·A"".,)
(Others)
Instrument panel wifing harness
ECM wiring harness
Room light cord
Room light
Power window wiring
Front speaker (RH)
Front door switch (RH)
Center wiring harness
Ignition relay
Automatic choke relay
Indicator light (AT only)
Inhibitor switch (AT only)
4WD-AT switch (4WD-AT only)
Parking brake switch
Seat belt switch
Rear door switch (RH)
Fuel pump
Front door switch (UI)
Rear door switch (LH)
15-101
_ -.-!
---~--
----
-----~~---~-~-----
~----------.,
ELECTRICAL SYSTEM
• Station Wagon
A26-720
Connector
--
No.
Pole
1
2
Fig. 15-283
6
6
3
2
4
5
6
1x2
6
7
8
2
9
10
11
12
13
14
15
6
6
1
4
1
2
1
2
1
15-104
I,
I
I
Connecting to
Appearance
Stop light checker
Combination light (RH)
} Rear combination light cord
Fuel meter unit
Rear washer motor
Combination light (LH)
Pink
} Rear wiper and defogger cord
Rear wiper motor
Rear defogger
License light (RH)
Rear gate switch
License light (LH)
Rear defogger (grounding)
~
1
I,
ELECTRICAL SYSTEM
• BRAT
Connector
No.
Connecting to
Pole
I
2
3
4
5
6
7
8
9
10
II
12
I3
14
IS
16
17
18
19
20
21
22
23
24
25
26
27
28
4
IO
17
4
4
Ix2
2
I
I x2
2
I x2
6
2
I x2
6
4
5
3
5
Ix2
2
2
5
4
4
2
2
4
Appearance
Black
Blue
Blue
I
Instrument panel wiring harness
Automatic choke relay
Ignition relay
4WD switch
Seat belt switch
Parking brake switch
Door switch (RH)
Room light cord
Room light
Stop light checker
Fuel pump
Door switch (LH)
A2S·730
Fig. 15-284
I Rear wiring harness (B)
Combination light (RH)
Blue
Yellow
} Rear combination light cord
Blue
Fuel meter unit
Ucense light (RH)
Ucense light (LH)
Combination light (LH)
Instrument panel wiring harness
Center wiring harness
4WD-AT switch
Indicator light
Inhibitor switch
15-105
I, ,
...
..,.,
~.
3L
2 WS
natE
r--_ _ _ _ _ _ _ _ _ _~2R~_ __.:- Headlight (R.H.l
2 RL
0.B5 RW
Headlight (L.H)
.. Tail light
License plate light
~_ _ _ _ _ _ _-=L=-9_ _ _ _ Clock
Stop light
.-_ _._ _ _ _ _. :.0:::.B.:.5. :.G_ _..._ Hazard switch
W
Horn switch
2 e 3W 3 BW
3L
2 WS
2~W
r----------~e~r---~(ECM)
Battery
e
~
'"'FoR
Ih!SR
5B
F--
IYo.SG
co
..,
~
co
3 BW
5w
2 WB
3ew r3W
2 WB
3L
2e
Fusible
link
OD
~
I
3ew
3W
2 WB
3L
2B
~
Charge indicator light
0.S51.Y
Radio Radiator fan
. - - - - - - - - - - Cigarette lighter
r-_ _ _-'-'1.~25"_=.L _
Remote controlled rear view
2 GW
__ Wiper switch
mirror switch
.~~~+-~~-+-+_-+~~~_-o~~~Q~
~
~
~
CD
11'1
CD
n
n
:::I
..
~
I»
I»
a
~
:1
ri
~
~
;-
t
lC
"
+•
~
~
....
C11
I
....
0
LI_...:3"-"B:..:.....R__ --.J
Starter
01
00
~
•
::r
..._.
~
______________
r-
JW
3L
2eW
2e
' . A 4 ...
'-
--"
~ {!!.;. ~c
Q !Q
ON
.-
2ew~
2BY
~'
2B:m
..J
N
., ., ~
N
s:
0
0
N
2BY
sr'
cc
ST
IG
'-
l
m
CD
."
3W
gWR
2W
en
-<
en
a-
WR
~~W~R~
(")
l>
r-
C
":"
;.
t
Fuel pump control unit
~ Automatic choke relay
(Vehicle with ECM)
*1111,111 ~
~
XI
...-I0
~
Alternator
(with IC regulator)
5W
2W
s~~~========~=t=t=+~W~R~
WR
L
(")
a.
3L
*
m
rm
:::I
2B
I~
I[s 2 BW
I»
I»
Fuse box
r-I
...
GQ
:I
r-_---jI--t:'0'C'.S::-5:::,!lW"-__ Kick-down relay (AT only)
0.S5LW ~ Rear defogger
1.25 BY
Turn signal switch
Back-up light
I
W
•
~
-.. ..._._
._. .
- GQ_.
CD
~
~--.----4.- 1.25 BW_ _ Ignition coil, fuel pump
r -_ _ _+-+0:.:.:::S5:..:L~9..:.Y_o_ (Cruise control)
AL-20
~
'<
U)
11345678
~o(c.~!~~~
_.
IQ
( It
r--~~~~~~~~~..:.2~L~B~____ Blower motor
L-v
• •
------"-----..-
r-
11'1
...en
...•
3ji
j
:::I
i6
IQ
"
Ignition-starter
switch
'~
..
,~",
BW 2 e
(2 BY - AT only)
2
,
..
'~
Air-i:onditioner
"
.-.
.~.~
..........
., ./
;
-~-
--
.~
-,
ELECTRICAL SYSTEM
..
, 1) Starting Systenf.! \
"
oj,
\
Starter does !lot rot«te with
no SOUP~~Jig1ietic switch
operatlo
.
Inspect battery for specific
gravity and electrolyte level.
f--
l
---
L-...,
Inspect starter switch and
circuit for the following points.
• Blown fusible link or
defective connection
• Grounded wiring or poor
connection
Defective contact of starter
switch
Arrange specific gravity and
electrolyte level to the specif1cations, or replace as necessary.
l
I Repair or replace.
Inspect magnetic switch for
broken or grounded wiring in
pull-in coil.
Inspect magnetic switch for
defective sliding of plunger.
Replace.]
J
r----
Inspect wirings of starting
circuit for poor connection.
f----
Inspect magnetic switch for
defective point contact.
~
Inspect starter for the following points.
• Grounded armature coil
and/ or field coil
• Defective brush contact
pressure
(Worn brush or defective
spring)
• Contaminated commutator
and high mica
• Seized bushing
15-109
Lubricate or repair.j
Arrange them to the specifications, or replace as necessary.
Inspect battery for specific
gravity and electrolyte level.
Starter does not rotate, but
sound of magnetic switch
operation can be heard.
I
I
Repair.
I
J Repair or replace.
I
Repair or replace.
I
I
I
i
.• I '~'I "I I •. "
~
•
>",»~~~,"»" >~.->~._ I
••
......... _ _
ELECTRICAL SYSTEM
3) Ignition System
A. Secondary circuit
Disconnect the high·tension
cord (DIST) from the distribu·
tor, and check for spark generation by holding the end of the
cord approx. 6 mm (0.24 in)
away from the engine body
(ground).
Check the high·tension cord
N.G for proper resistance, proper
fit to the terminal, and for
damage or cracks in the cord
and cap.
1--.
O.K.
~
Check the ignition coil for pro·
per resistance on the secondary
side, damage, and other faults.
O. K. Check the
~
•
primary
circuit.
INoGo
N.G.
Replace hightension cord.
Replace coil.
r-----------~.-------------
Reinstall the high-tension cord
to the distributor. and pull off
the plug end of the hightension cord of each cylinder.
~
Install a new plug to the cord, ~ No spark is generated
in
any
cylinder.
and check to see whether the
plug creates a spark by touchYes
ing the plug to the engine body.
Check the resistance value of a
high-tension cord generating no
spark.
r----------,
O.K.
O.K.
Check the distributor cap and rotor (note)
for contamination, the center carbon for
wear, the terminal for fitting, and the hightension cord and cap for damage and
cracks.
Clean, adjust, or replace as necessary.
Remove the plug from the engine and attach it to the hightension cord; then check for
N.G.
spark generation. Also check ;-+
the plug electrodes for wear,
contamination, or wetness,
and the insulator for cracks.
I+---J
NOTE: A special coating is applied to the
end of the rotor for preventing
radio noise. Do not file
(NIPPONDENSO) or wipe
(HITACHI) the end of the rotor.
"NIPPONDENSO": Powdered
cuprous oxide faced rotor.
"HITACHI" rotor: Coated rotor
with silicon gre.se.
Clean
adjust
replace
O.K.
Check the fuel system, ignition
timing, advance angle and the
firing order.
15-113
Replace hightension cord.
ELECTRICAL SYSTEM
2. Combination Meter
A. CONVENTIONAL TYPE
• STD and DL models
FL-3
FL-1
oI~'----I
Battery
II ~-- -I 111--_ _ _ _ _ _ _~_a::F=L-::::I2>------,
,----------------------,
Fusible link
Parking brake
.-'';:;c:: .-..u
O.r.
Oil pressure
.EJ!
Stop light
Brake fluid level
~
;c::
0
®©ee
51
51
51
51
LL.
LL.
LL.
LL.
~
~
~
~
I
/
Fuel
LTemperature
Defogger
switch
Rear defogger
Turn signal
Turn signal
High beam
Illumination
light
Illumination
control switch
Rear door
Rear door
Front door
Front door
Room light
L
Fasten seat belt
_________________
~
Combination meter
Fig. 15-288
A26-733
15-115
-,
ELECTRICAL SYSTEM
• GL model
FL-3
FL-'
Battery
'If-+---I
2
II ~-- -I111-_ _ _ _ _ _"""*'---aF=L::IJ>--_ ___
Fusible link
r-------------------l 1::...'"
..
I
ECS
~
c
Parking brake
O.c:
...
-.
'';; CJ
,c'.,,3:
Stop light
Brake fluid
Fuel
Temperature
Rear
defogger
switch
Turn signal
Turn signal
High beam
Illumination
light
_ _--'fl""--_
iTurn signal
Illumination
control switch
switch
~-4--~--~~~.---------~--~6~--------~~
pressure gauge
01
@I
1
1
Voltmeter
Digital clock
Rear gate
Rear door
Rear door
Front door
Front door
Room light
Fasten seat belt
r---------~~~--------------_{G~--------------~
L _________________
~
Combination meter
Fig. 15-290
A25-735
15-117
ELECTRICAL SYSTEM
1) Speedometer
,
II
Speedometer trouble
I
t
j
Speedometer pointer deflects beyond maximum point.
Speedometer pointer and/or odometer will not operate.
1
Determine whether speedometer
inner cable opera tes.
I
No
Speedometer pointer will not
return to zero nor exceed a
certain point.
1
• I
Oil rise
1
Yes
Speedometer cable
properly connected.
im-
I
•
•
•
Speedometer cable improperly
connected (on transmission
side).
Driven gear broken.
Speedometer cable broken.
l
Hair spring broken.
--
J
•
•
Hair spring deformed.
Pointer stopper deformed.
Foreign mattcr lodged in
magnet.
Replace driven gear or speedometer cable.
~
I
Yes
Replace speedomcter.
Speedometer pointer deflects erratically.
Speedometer operates, but odometer or tripmeter does not
operate.
Speedometer
routed.
Defective gear in speedometer.
cable improperly
No
Replace speedometer.
Speedometer cable near breaking
point.
Replace speedometer cable.
Correct speedometer cable route.
15-119
J
ELECTRICAL SYSTEM
3) Fuel Gauge and Fuel Gauge Unit
Fuse box
1.25 BW
1.25BW
m
Fuel gauge unit
(Low fuel sensor)
2 B
WY
BY
0.85"
5W
OF
3W
III
N
Fusible
link
Ace ON Sf
BY
S
cc
28
ST
IG
WY
Ignitionstarter switch
~.~
r'
I
I,
l
"
Low,.fuel
warning
light
I
BW
____________________________________~W~Y~
~W:~Y
~~W~Y
____~
r-8y______________________________________~B_Y~ rB_Y________~
A25·737
Fig. 15-292
15-121
ELECTRICAL SYSTEM
2.
GLmodel
Fuel gauge (meter) and fuel gauge (meter)
urnt are not properly conditioned.
Turn on ignition switch.
.---
,
for
No
If::
Determine whether l2V
appears at #5 terminal on
back of meter.
•
Instrumen t panel harness is
defective.
No
4
Yes
No
Check thermometer
normal operation.
Pointer will not operate.
• Po in ter remains in high position.
Pointer remains in low posi·
tion.
Inaccurate indication.
Determine if fuse #12
(15 A) in fuse box is blown.
Yes
I
l
Fuse is blown.
1
[
I
1
Replace.
Replace fuse (15 A).
Yes
Remove connector from fuel unit.
Connect resistor (70) to black/
yellow lead on harness side and
to ground, and see if meter points
at 1 (F).
No
Determine if 12V appears
at fuel unit black/yellow
lead after disconnecting it
from the unit.
Yes
Replace fuel unit.
Check if 12V appears at #8
terminal (black/yellow) of
12·P connector on back of
meter.
Yes
Yes
Fuel unit is defective.
No
Fuel meter is defective.
No
--,I
Thermometer is defective.
Replace.
Replace fuel meter.
-
Harness wiring is defective.
(0.5 black/yellow lead).
Repair.
16-123
ELECTRICAL SYSTEM
5) Tachometer
I
Tachometer trouble
t
Tachometer pointer will not operate.
No
I
Fuse is blown.
~
~
-
•
•
Adjusting resistor value deviates.
Deteriorated capacity of filter
condenser.
I
•
Pointer stopper deformed.
foreign matter interfering.
Pointer deformed.
I
t
I
I Replace fuse (l5A). I
See if fuel thermometer operates
normally. (substitu tive check of
power source and grounding.)
~
Replace tachometer.
Instrument
panel
harness is defective.
Yes
Repair or replace.
With ignition switch off, check
conduction between combination
meter #9 terminal and ignition
coil (-).
~
Signal wires (0.5 yellow) of
instrument panel and front
harness (tachometer) defective.
Yes
I
Tachometer is defective.
•
•
•
l
!
Hair spring is deformed.
•
•
See if # 12 fuse is blown.
Tachometer pointer will not return to 0 nor exceed certain
point.
Tachometer pointer deflects beyond maximum point.
I
Yes
1
•
Defective circuit.
Hair spring or coil broken.
Foreign matter caught
movement.
in
Replace tachometer.
15-125
Repair.
1
1
ELECTRICAL SYSTEM
7) Voltmeter
I
Pointer will not lower with ignition switch turned off.
I
~
Voltmeter is defective.
I
~
Poin ter will not rise.
I
Inaccurate indication.
Check with ignition switch
turned on.
I
Replace.
r
I
No
J
L
Voltmeter operates.
Yes
Replace fuse (15 A).
1
I
I
I
~
Fuse is blown.
Yes
I
See if fuse #12 (l5A) is
blown.
No
Repair.
1
I
I Voltmeter is defective. I
I
I
Yes
See if 12V is in #5 black/
yellow lead of 12-P connector on back side of
meter.
Determine if voltmeter indicates
12± 0.5 V by letting load such as
headlamps, rear defogger, etc. and
connecting fully-charged battery.
No
No
Defective ignition (+) har- I
ness of instrument panel.
l
Repair harness.
15-127
J
I
1
Voltmeter is defective.
I
Replace voltmeter.
I
ELECTRICAL SYSTEM
B. DIGITAL TYPE (OPTION)
01
C
6
14
9
~
7
36
35
17
19
$
I
27
II>
.~(~
1\1
.r:
c
...II>
-"'
11
~
i( f( ~ (~ ~( ~(~
(~~( ~u
(~
0
!
0
~ ~
6
~ •
22
1\1.1:
<~
C
Gi
II>
.r:
~
24
1\1
;;;
;:
..
1t
... ..
.;::
01
~
1\1
C
Gi
>
.!!
:2
'c...
0
...J
0
~
21
8 20 23
a: J
..~ I~
l!l
~.r:
=.21
--
E
1\1
:l1\1
-
-: . . -:01
...
::t ::t ~ ::t 1\1
ci J a: J
"( .!( ~ ~ ~( ~( ~~~ -( ~~ ~~ ~]
~(
c f~
... .r:
... ;I
c
C
C
01
0 ;I a:
r-~ ~ II:;I i
e
II:
LL
u:
.. ..
I
1~~
4
29
-: -:
~ ::t
'E
,
34 !31
t~~
....
:-::
.....
-, ....-
e
18
15
26
5 16 1210
L
BBr
~
T
Br
Buzzer
0
Pink
Skay blue
Br
Orange
BW
R
Gray
RW
47
38
RG
4345463940413744 42 49
BBr
-
~
I
I
I
I
I
I
,
r
I
I
,
"1
1
,
I
I
,
, 1,1
L
l
J
:
I
I
,
~~
(~
Digital
computer
unit
,I
---~
I
I
Tri
I
A25-826
Fig. 15-293
15-129
ELECTRICAL SYSTEM
,,'£:£~J :~:WfJfl6
,,' :
o-
0
_
0
-
0
-
~
-
~
_
00_
N
N
U
U
"
1.25 BW
1.25BW
WY r1~---..,
...--"':";";'-/
Fuel gauge unit
(Low fuel sensor!
BY
2B
Ignitionstarter switch
BY
o.
3W
S
cc
ST
2B
wv
IG
3~
2B
~
Low fuel
warning
light
Fuel
gauge
(
I
I
I
l
DC
BW
power
0.B5 BW
0.85 BW
:/F
=.,
~~
BY ______________~_ _ _ _ _ _ _ _ _ _ _ _ _B_Y~
f-W;..;.Y
_ _--'
~~B_Y_ _ _-J
BY
~-
OOB
A25-738
Fig. 15-296
15-131
ELECTRICAL SYSTEM
b.
Meter displays when ignition-starter switch is on, but trip computer is cancelled when turned off.
The trip computer comes into test program* condition each time the ignition-starter switch is turned on.
(These troubles are due to the condition where the battery power is not supplied to the micro-computer.)
CheckifNo.l fuse (lOA) is
blown.
Yes
Check cause and replace fuse.
I
No
-
Check if voltage always appears
at terminal @ of connector on
back of meter.
Check if connector (1 pole;
Green wiring), for preventing
running-down of battery,
under left side of instrument
panel is wired.
No
Yes
Check if terminal @ or @ of
junction on back of meter is
grounded.
No
Yes
No
Improper ground.
J
Improper ground.
I
Yes
Check if terminal @ of
connector on back of meter is
grounded.
No
I
Yes
Digital computer unit defective
or poor connection of connectors in the meter.
*Test program: By putting the digital meter and trip computer in the test program
condition, it is possible to check the wirings and operation of the
fluorescent display tubes, if the chime and buzzer sound, and if
low fuel warning light is broken.
15-133
I
I
Wire connector.
J
ELECTRICAL SYSTEM
e.
Fuel gauge will not operate.
Check if connection is propedy made between rear wiring
harness and fuel gauge cord,
and if fuel unit is properly
grounded.
No
Fuel unit improperly wired
and grounded.
Yes
Check if bar graph illuminates
up to ten (10) segments when
black/yellow wiring at fuel
unit is grounded.
Yes
J
l
Fuel unit defective.
I
No
Check if bar graph illuminates
up to ten (IO) segments when
terminal @ on meter back is
grounded.
Digital computer unit defective
or poor connection of connectors in the meter.
No
-
Yes
Wiring between fuel unit and
fuel gauge defective.
f.
Temperature gauge will not operate.
Check if connection is properly made between engine
wiring harness and thermo
sensor mounted on intake
manifold.
No
Thermo sensor improperly
wired.
!
Yes
Check if bar graph illuminates
up to ten (10) segments when
the wiring to thermo sensor is
grounded.
!
Yes
J
I
Thermo sensor defective.
J
No
Check if bar graph illuminates
up to ten (10) segments when
terminal @ on meter back is
grounded.
No
Digital computer unit defective
or poor connection of connectors in the meter.
!
Yes
Wiring between thermo sensor
and temperature gauge defective.
15-135
1
Side marker
light
OS5R
IN
2RW
Sedan and Hardtop
2R
ITDnITij
{ 11111111}
~
Fuse box
2RB
a:
Side marker
light 0.S5
CD",
0.S5:~
w
•
~cq
0 0....._ _ _---'
~
Parking light
2R
BM
0.85
RL
\
2RL
0.S5R
3aw
2a
.
;t
2RW
\
2RL
•
3BW
38A
\
OF Ace ON ST
3aw
2B
JBR
B
amrrin
Taillight
License plate
light
~
0.85~
RL
(')
::XI
0.S58
P
I
(')
»
r-
Hl. HV
2HW
~B~W
Headlight
(I)
0.85~
RL
-<
B
~
~ 1L.;2~R~L_+_+_t_+___1'
License plate
light
~2:..:R""W~-+-..
m
m
r-
~
B
U1
......
n
.
2B
2 RY
B
2 R 2 RW
FF I
0.S5RW
0.S5R
0.5RG
2B
1.25 B
---w
Lighting switch
relay
3 BW
M
$®
2 R 2 RS
~;ghting
0.S5
m
s:
Lighting switch
Ash tray
Taillight
-'
a:
Parking light
0.S5:~
ill
o
a:
CD",
Combination
meter
(GL modell
",co
ci ci
Center control
panel
Clock
Side marker
light
Illumination
light
(GLmodell
Glove box
(GLmodell
!~
~_R_",,B
L~_~_~,ro.~-+--~
Radio
,
0.S5
_ggR
~
BNa
Side marker
light
0.85
RL
B
--ffia
R
J
ELECTRICAL SYSTEM
When the lighting switch is
set to the I st or 2nd step, the
parking light, tail light, and/
or license light will not light.
Check after having set the]
lighting switch to the 1st
step.
Check if the fuses # 11 (15 A/
license, tail, and parking
lights) are not blown.
Yes~
I-----------------~
1 Check the cause and repair.
~~-...~~{ Replace the fuse.
I
No
Check if the voltage is 12 V at
the terminals 0.85 RW on the
loaded sides of the fuses
(15 A/license, tail, and parking lights).
No
• Connection of lighting
relay connector is poor, or
the relay is defective.
• The connector is in faulty
contact or the fusible link
is blown.
• Replace lighting relay.
Repair the connector or
replace the fusible link.
t - - -....
_~.
Yes
Remove the lighting switch,
and check if there is conducI
.
t-_N_o_Ool The contact on the switch is
1------.1 Replace the sWitch.
tion between 0.85 RW and
defective.
1
0.85 R when set to the 1st
~--------------~
and 2nd steps.
Yes
' - - - - - - - - - - -....~-J
The connector is in faulty
contact with the harness or
the wiring is broken bet~een
the lighting switch and each
light.
15-139
~_~
Repair the connector or
harness.
"'"---_ _ _ _ _ _ _ _.....J
--- ----'1
ELECTRICAL SYSTEM
~
Remove the lighting switch
connector, and check if the
voltage is 12 V at the terrmnal
H (2RY) of the harness.
No
f---
.-
• Poor connection of combination switch connector or
lighting switch connector.
• Wiring between comb ination switch and lighting
switch is defective.
Repair the connector and/or
wiring.
Yes
!.Check the conduction between H (2RY) and E (2B) of
the lighting switch.
I
N
1--
o__..
a.tl Replace the lighting switch.
Yes
There is faulty contact of the
connector between lighting
switch and harness; or the
harness is broken or improperly grounded.
---4-t
Repair the connector or harness.
15-141
---~
ELECTRICAL SYSTEM
1) Turn Signal Switch and Turn Signal & Hazard Unit
Lamp flashes irregularly or remains lighted.
Turn ignition switch to "ON."
Determine if lamp bulb is of
suitable wa ttage.
No
Yes
Increase power voltage by running
engine, and see if lamp flashes
regularly.
No
When bulb capacity is not suitable, it flashes too fast or too
slowly; when bulb is broken, it
remains lighted.
J
Replace bulb with specified one.
I
Charge or replace battery.
I
1
Battery voltage is too low.
I
FaUlty contact of harness connection and grounded part.
-I
I
Repair harness and connector.
I
Flasher unit is defective.
J
Replace flasher unit.
I
I
Yes
Determine if harness connection
and grounded part of lamp are
in good condition.
No
Yes
L
Only one lamp lights.
•
Check witl! ignition switch on.
~
Check conduction between combination switch connector and
turn signal lamp.
Conduction: O.SGR on RH side
and O.SGL on LH side.
t
No
Faulty connector contact between combination switch connector and turn signal lamp, or
broken harness wire.
J
l
Repair
connector
or
harness.
J
es
Check conduction of combination switch with harness connector removed.
* Turn signal lever controlled
to right O.SGW - O.SGR.
* Turn signal lever controlled
to left: O.SGW - O.SGL.
-
Faulty conduction of combination switch.
I
I
Replace combination switch.
I
15-143
__ ...J
ELECTRICAL SYSTEM
2) Hazard Warning Light Switch and Turn Signal & Hazard Unit
Hazard
lamp
does not light.
See if fuse #2 (lOA, HAZARD)
is blown.
I
Yes
I
I
·1
Fuse is blown.
I
Replace fuse.
No
Check voltage at 0.5G of comb ination switch connector.
No
Yes
Remove combination switch connector from switch. See if turn
signal lamp lights by connecting
0.5G and 0.5GR (RH) of connector on harness side or 0.5G
and 0.5GL (LH).
Yes
Turn on hazard switch, and check
conduction between 0.85G and
0.85YW, 0.85GW and 0.85GL,
and 0.85GW and 0.85GR.
No
Faulty connector connection between fuse box and combination
switch, or broken harness wire.
..
..
..
I
Hazard unit defective.
Faulty contact or broken wire
in harness between hazard unit
connector (0.85YW and 0.85
GW) and combination switch.
Faulty contact or broken wire
between combination switch
connector and hazard lamp.
(Connect all turn signal circuits, and confirm by controlling turn signals.)
Hazard switch defective.
15-145
.---.
Repair
connector
or
ha
Replace unit or repair hamess.
l
- - - - - - - - - - - - -_----.J
I
I
Replace combination swit
ELECTRICAL SYSTEM
• Automatic transmission vehicle
Fuse box
C1~:£:&:£:{J)}J!l6
«' :
o
_
0
...
0
0
~
--
~
........
0
0
_
N""U
U
1.25LW
:!
83i]
Sedan and Hardtop
GY
JHE
0.858
iE
28
~5W ~I
Fusible link
T ~r-t----
L
.~
Ignitionstarter switch
OF
ce ON ST
B
CC
ST
~
t----
Gy
6 16'
GY
1
0.858
1G
R
Back-up light
III
'"o
III
28
GY
0.858
GY"tB'LW
LW
GY
Inhibitor switch
Hatchback
Station Wagon
BRAT
GY
GY
EEr
GYm8
8jE
GYEffJ"8
1.258
GY
1.258
GY
B
Back-up light
GY
'""'
GY
OJ
0
[
GYmS
GY
GY
B
8
Back-up light
Back-up light
GY
1.258
I
tIl
1.25 B
GY
1.25B~
GY~1'25B
't:f!t'258
GY
A25-765
Fig. 15-300
15-147
-~
Lg
ftiwl
~ ~~t£;£~ ; ~ : : ~
F use box
r,
2
3
7
.---,
~-b-
"
1.25BW
......
___
"
trr=-
15
"'!
NL--_
---
i
~
2B
N
C11
.....I
~
CD
E
~
~
IIQSG
0.85R
~-==
I
Front door (left)
Front door (right)
Seat belt warning
light
r
3W
RL:B
BR
--f1--, •
~
OF ACC ON ST
~cc
S7
2B
-----r~
IG
~r--
I~~
I~~
~~
i -
"'
GY
--
~B
~ e-
U"
(l.H.)
i--
I
r'Timer
I
LB
L-B
•
Front door SWltc
fI-
-I
:lJ
(')
»
ren
-<
en
-I
m
3:
Seat belt switch
GW
BW---f1--.t
BW...., H
lL
~
1)
--=-t(ll]
III.
j
Rear door switch
(R. H.I
~
-::-
I--
~
J
Room light
LR
GY
a:
~
Front door
switch (R.H.I
r--LB
(')
"'
V
Ignition-starter
switch
~~W
-,
,
m
rm
"'a:
3~
2 WB
"-----
l
!
a:~
N
R
Rear door (left)
-
GB
2B
5 W
-,
~
-;:B GY GW
Fusible link
Rear door (right)
1
Lof<
LB
GY
aimn
N
N
----
rGW
LR
LB
GY
GB
1
r
.~~
Front
Battery
'8 $
~
"'
~r
2 WB
GW~
--;---,
BY
BY
I
RL
BR
0.85 RL
Lg
....I
"{$l;f;t.~$1~ ~o ~, 12~4 ~
0011)
BR
-
•
h
(
ELECTRICAL SYSTEM
I Dome lamp and door pilot lamp
do ~-""""I doo< ;, 0,<0"'.
Set dome lamp switch to door
side, and check.
--I
-.J
(room)~s-~----[!i
See if fuse # 1 (1; A)
blown, and if bulb is broken.
I
f
b Ib
ep ace use or u .
J
Yes
:
See if lamp lights by opening
other doors.
t
l
No
I
J
Check door switch, harness con-
----I nector and harness.
es- _
Determine if harness and con.:!
nectors in dome lamp and door
switch circuits are in good condition.
I
I
t----~
*
Unravel entangled door switch
cord.
* Repair harness connector.
Note: When ambient temperature
drops, switch may sometimes turn on slowly.
_--1
con-J~I- - - -..-o.lliiRepair harness connector or har-
Faulty contact of harness
nector, or break in harness.
ness.
~--------------------
Either dome lamp or door pilot
lamp does not light.
I
Broken bulb, faulty contact of
harness connector, or break in
harness.
15-151
Repair connector
replace bulb.
or harness;
ELECTRICAL SYSTEM
b)
When chime does not sound, but fasten seat belt warning light turns on;
rlur;
ignition· starter switch
I to ON position while driver's
L':"bE~-
.
(except 4WD) Use circuit
tester, and measure whether
'foltage at terminal (O.SY) 0 f
[ key warning switch is l2V or
I oot.___-.________
Confirm that fasten seat belt
warning light in telltale turns
on for approx. 6 seconds.
f--_~
No
•
•
Inspect fuse (lOA), connector
and wire between battery and
fuse box.
--
I
Replace fuse if it is blown.
Repair connector and
wire.
~
I
res
Use cir cuit tester, and measure wI! ether voltage at terminal ('!) (O.S-Y or O.S-LW)
of time r is 12V or not.
No
Inspect connector and wire
between
ignition-starter
switch and timer.
1Repair connector and wire_ I
-
L_
',see
or
inte~rao
No
tim
Il
Repair connector, or replace
timer.
connection between
er and its connector, or
de fective timer.
if timer discharges
mittently out-put voltage between its terminals ® (0.5YB) a~d ® (0.5-B). .
Yes
Inspect earth wire (O.S-B) ~
Poor connection between
VI
I No
timer and wire (O.S-YB) be- r--~ timer and its connector, or
tween timer and chime.
open wire.
f--_"",
Repair connector, or wire.
--.J
~-------------------
r-
I
if discontinuity
I
[Ch"k fo, wntinuity botw"n
Pom wnnedion m d,f"tion
'3erminals 7 (O.S-GW) and !t-I--'L---t between timer and its con(O.S-BY) of timer.
.
I'nector, and between seat belt
---
switch and its connector.
=:t
----,
fnsp eet earth wire (O.S-GW)
betw een timer and driver's
doo r switch.
* I:
f--_-""! Repair or replace.
Poor connection between
timer and its connector, or
defective wire, or defective
driver's door switch.
Never leave the switch in ON position all the way.
15-153
Repair connector, wire and
driver's door switch.
1
ELECTRICAL SYSTEM
B. BRAT
a)
When chime does not sound and also fasten seat belt warning light does not turn on;
Turn ignition-starter switch
to ON position while driver's
seat belt is not fastened. *1
Use circuit tester, and measure whether voltage at ON
tenninal (2-B) of ignition-
No
r--~
Inspect fusible link, connector and wire between battery
and ignition-starter switch.
starter switch is 12V or not.
• Replace fusible link if it is
blown.
• Repair connector and
wire.
Yes
Use circuit tester, and measure whether voltage at terminal CD (O.5-LW) is 12V
or not.
Inspect fuse (lOA), connector
~N._o_--t and wire between ignitionstarter switch and timer.
1---......
• Replace fuse if it is blown.
Repair connector and
wire.
Yes
• See if timer discharges
No
Poor connection between I--_~ Repair connector or replace
intermittently
out-put ~-_"'I timer and its connector, or
timer.
voltage between its termidefective timer.
~------------I
nals @ (O.5-WL) and ®
(0.5-B).
• Check for continuity between tenninals @ (0.5GB) and ® (0.5-B) of
timer for 6 seconds after
ignition-starter switch is
turned to ON.
Yes
Inspect connector and wire I---~ Repair connector and wire.
between timer and ground.
*1: Never leave the switch in ON position all the way.
15-155
-~------- .. -~
ELECTRICAL SYSTEM
7. Stop Light Warning System
Br
Sedan and Hardtop
Stop light checker
{ IIITIIII}
WR
III
WR
N
2WB~
....--lI:l:l:a-2 B
0.5 G
Stop
light
2WB
2B
~~---I-g-n-it-io-n----------~~~~--Y-G------~
III
0.85R
~
/
~
starter switch
~
OF Ace ON ST
G
~
t1tl!j
cc
ST
IG
0.85B
GY
2B
G
Br
Stop
light
BRAT
Station Wagon
Hatchback
B
Stop
lihgt
GW
Stop
light
Stop
light
G
rn
rn1.25B
0.B5B
tiR
~B
B
;=
III
1.25 B
" "'"!
GW
1.25 B
GW
' \____~G::.:W~
Stop light
checker
GB
Stoplight
checker
YG
GW
GB YG
GW
Stoplight ~
checker
~
GW
~
,H::El
G
Stop
light "--.,....-r-r-.,.......J
G
B
Station Wagon
B
Stop
light
~1.25B
GW
BRAT
A25-744
Fig. 15-304
15-157
...
____ ~ _
__.J
--I
ELECTRICAL SYSTEM
8. Parking Brake System
Fuse box
6'_______________- ,
~:....::..:.:..:...j...-----.
~ ~rt----~,______~211.~~B~W~___~~
2B
~
CD
,4P:-- (1111 1/11 )
WR
OF Ace ON ST
Yl
cc
.T
IG
fR]~8JJJ
Ignition-starter
switch
WR
Yl
,
I,
Alternator
,
(with Ie regulator) Fl-
O
,
WR
l
----............
Combination meter
A25-745
Fig. 15-305
15-159
__
~_
____
--------iIi'
ELECTRICAL SYSTEM
10. Four-wheel Drive System
Fuse box
;l:£t7:~:m6
::
3
o
.4WD
~
m
0
0
0
-
-
o-
~
~
00_
-
-
N
N
V
U
~
1.258W
28
F Ace ON ST
ST
Fusible link
IG
Ignition-starter
switch
8lB
4WD
indicator
., 5
1
, light
LA
BW
!
LA
4WD switch
Combination
meter
Fig. 15-307
A25·746
Fuse box
• 4WD Dual-range
ffiE
1.25BW
2B
4WD switch
Ignition-starter
swtich
,r-
B~
......--,
.
4WD·lo
indicator
, Ii,;;ht
I
.,5
LA
BW
G
LA
4WD·lo switch
Fig. 15·308
......--'
!4WD
1 indicator
\..---. light
.----.-.J
15-161
Combination
meter
A25-747
--
ELECTRICAL SYSTEM
(4WO-AT control system)
Set ignition-starter switch to
"ON" position.
r
Check if "4WD" indicating
light illuminates.
Check if operation of 4WD- .
AT solenoid sounds.
• #12 fuse blown.
• "4WO" indicator light
wiring broken.
No
J
-L Replace. ]
Yes
Check if # 16 fuse is not
blown.
No
J
Replace #16 fuse.
I
Yes
Check if l2V appears in LR
wire of 4WO-AT solenoid's
2-pole connector.
No
• 4WO-AT solenoid defective.
• Wirings and terminals
defective.
J Repair and replace.
L
4WO-AT checker defective. :
-I
Yes
Check if l2V appears in GR
wire of 4WD-AT checker's
4-pole connector.
No
J
J
Replace.
I
Yes
•
Check if there is conduction
between GR wire and B wire
of 2-pole connector when
4WO-AT switch is turned on.
No
J 4WD-AT switch defective.
I
Yes
B wire is improperly grounded
to body.
Repair.
I
15-163
I
I
J
T Replace.'
I
----------,
ELECTRICAL SYSTEM
1) Windshield Wiper
a.
Wiper will not operate (regardless of switch position)
Turn ignition switch to ACe.
Turn wiper switch to Lo (Hi).
Check for voltage at blue terminal
of wiper switch connector on
harness side.
I
No
See if fuse #7 is blown.
No
J
I
Replace fuse.
-I
Yes
Yes
*
*
*
Check for voltage at green (blue/
white in Hi) terminal of wiper
switch connector on harness side.
No
Wiper switch is defective.
Replace.
No
Repair harness between wiper
switch and wiper motor.
Check connector connections.
Repair harness.
Check key switch functions
normally.
Yes
Check for voltage at green (blue/
white in Hi) terminal of wiper
motor connector.
Yes
Determine whether resistance between wiper motor (-) cord
(black) and car body is zero.
No
*
*
Wiper motor (-) cord improperly installed.
Improper grounding of wiper
motor and body.
Yes
Motor is defective.
15-165
-
--~
ELECTRICAL SYSTEM
2) Intermittent Wiper (GL model)
a.
Wiper will not operate with ignition-starter switch in "ON" position when wiper swit<.:h is turned to INT.
~
[!"urn on key switch.
i S,nfh WiLO
:"
I
.
L~~~_ at
,,;f"~,::,~,ith ~'() ~r;;:R
[---t- "W'
ill t
.
0
Iper w no opera
--~~=er
t~
~
']
1.:--------
Y_e_,_ _ _ _ _
1
I Turn wiper switch to INT.
1"'---.
_ -'
1---
: Check to see if harness-side con-
I nector is securely connected to
L'"p" i""~mit"fmi",L
..---
I No (l)
,---Check for voltage at wiper inter- r----.--.,
See if fuse # 16 is blown.
mitten! connector (harness sidr, I
I
as follows (car body side ShOU}ld
i
No
be (-»:
(n B terminal (blue/white)
L(2) INT terminal (blue/red)
NO (21
I ____
_
_.
l
Yes
Yes
,--._------- -
_ ______
-
..
---
_ .. _-._---_.-
------ --
..
-:
(1) Check connector COllllecti,'n.
~-.I
(2)repair harness.
1
(3) Sec jf key s\vitch functk··n . ~
L_~~~ma~y.
I
...
~.
-~------.~--
__
- -- -
Replace iusc __ .______ _
L _ _._____
-------------1
II
--
I
-----~
____________ _
r - - - - - - - - - - - - - - - - J No
L--
See if voltage comes to wiper
switch blue/red terminal.
Wiper swit(;h is defective.
f-----.-j
__ J
Yes
r----- - ------ -- -------------- -
I
L-_ _ _ _ _ _ _ _ _
.-----j
Repair harness between wlpn
switch and wiper intermittelll
I or connect~r_connec~ __
1
•
Resistance between car body and
No
Repair harness or connector conwiper intermittent harness-sider ----~ nection.
connector grounding terminal
'--_ _ _ _ _ _ _ _ _ _ _ _--L
II'
I
(black) is zero.
Yes
,-------L------,No
See if voltage comes intermittent- t - - - -_ _~J
ly (once in about 5 seconds) to
SI terminal (yellow) of wiper
intermittent harness-side connector.
Wiper intermittent is defective.
I
Yes
See if voltage appears intermittently at yellow terminal of
wiper switch.
iNO
I
__
Repair harness between wiper
intermittent and wiper switch or
connector connections.
Yes
r--------------- ---,
1------------------------------~_l-:
15-167
Wiper switch is defective.
I
I
--~
------
ELECTRICAL SYSTEM
3) Windshield Washer
a.
Water does not come out with washer switch turned on.
Turn key switch to ACe.
I
Determine if fuse #7 is blown.
I Yes
I
J
Replace fuse.
J
Repair harness or connector connection.
I
J
No
Check for voltage at blue terminal of wiper washer
switch.
No
Check for voltage at red terminal when washer switch
is turned on.
No
I
I Washer motor is defective.
I
I
I
Yes
Check for voltage at red terminal of harness-side
connector of washer motor (when washer switch is
turned on).
No
J
I
Repair harness or connector connection.
No
J
Defective grounding.
J
Yes
Resistance is zero between car body and black terminal of harness-side connector of washer motor.
I
j
Yes
I
1
b.
Washer switch is defective.
I
Wiper will not operate when washer switch is turned on (When washer and wiper are interlocked)
Turn on key switch.
I
Wiper operates normally when wiper switch is turned
to INT.
No
_I
1---------...
Refer to "Intermittent Wiper"
I
1
Yes
Washer operates normally when washer switch is
turned on.
J
No
I
Refer to "Water does not come out with washer
switch turned on" in Item a above.
Yes
l
15-169
I Wiper intermittent is defective.
I
I
------
ELECTRICAL SYSTEM
1) Rear Window Wiper
(1)
Wiper will not operate.
Turn on key switch.
I
~
Determine whether fuse #7 is blown.
J
I
I
~ No
Check for voltage of about 12 V at blue terminal of
harness-side connector of rear wiper switch.
Replace fuse.
I
f--N_O_____________--t[
Repair connector connection or harness.
No
J
f---------------t
Replace switch.
J
~ Yes
Turn on rear wiper switch.
I
Check for voltage at green terminal of harnessside
connector of rear wiper switch.
l
I
JYes
f--N-o_ _ _ _ _ _ _ _ _ _ _
--."'l
Repair connector connections or harness.
I
.---------------ti
Repair connector connections or harness.
J
Check for voltage at green tenninal of harness-side
connector (4P) of wiper motor.
~ Yes
Remove 4-P connector of wiper motor.
lYes
J
lNO
l
Check for zero resistance between car body and
Yes
black terminal of harness-side connector of wiper f - - - - - - - - - - - - - -....
motor.
(2)
Replace wiper motor.
I
Wiper will not stop automatically
Turn on key switch.
:N..:o'-----------------_--+iL-_R_e_f_e_r_to_"_W_i_pe_r_w_ill_._n_o_t_o_p_e_r_at_e_"_i_n_l_te_m_(_I)_'_-,1
Determine that wiper operates.\-'Yes
I
. fuse #7 IS. blown. If-'--=---------------------II
l Yes
I Replace fuse.
See If
1....-_ _ _ _- '
No
Check for zero resistance between car body and green
tenninal of switcb-side connector of wiper switch
(when switch is oeo.
No
1----------.. . . "'·1.
Replace switch.
J
Yes
Check for volt3le at blue terminal of harness-side
connector (4P) of wiper motor.
No
1
Repair connector connections or harness.
J
Repair connector connections or harness.
I
Yes
Wiper operates when blue and yeUow terminals of
harness-side connector of wiper motor are connected.
No
r - - - - - - - - -.....""I
Yes
I
15-171
Replace wiper motor.
I
•
085 LY
_____
~[7
NI"o~
L8
3L
~
0.85 LY
~ ~ ~ ~ ~ G
c~~
-=
-r-
~
Fuse box
0.85 LY
B
r-
'HIE
0
c·
RG
~
Power grounding
Signal grounding
Power
~
//
7
"
2
3
4
...§.
Input (R.H.I
U1
.....I
E
~
til
~
OB5R
5W
[~
r
3W
3 L
•
LB
w,*Y
LB
CC
YW
3L
00
L:~
v
LB
r'v
"a: a:
0.85 R
RG
I-
""•
.
T
I-
FF I
I
( Othersl
m
(')
(')
YW
LB
LB
W
lvw
I
Rear (L.H.I
speaker
»
en
-<
en
-t
m
vw~
LB
3:
ftaLB
W
..
..
-t
:D
:t3
YW
L
w-I
Front (R.H.I
speaker
w
w
~
Rear (R.H.I
speaker
(Sedan and Hardtopl
ywijL=
a:
H
YR
LB
I
Lighting switch
Front (L.H.I
speaker
fo(
YW
LB
L
v
Rear (L.H.I
speaker
W
YR-Fl
JIa
RG
Rear (R.H.I
speaker
m
I
n
E
L-
wi
~
i,
LB
W l
YW I
W
3W
W
R
Joy
......
I
10
IG
LB
5 2 4
LB
w
YW
I
~
YW
ST
Fusible link
0
L:~
Input (L.H.I
~ t..y
r-
0
~
LB rYW
W
Ignitionstarter switch
'-... FAce ON ST
II
&:a.
I------rrJ-
r-~
e
t;
I-
R
LB
Y
3L
Battery
~
AM/FM
stereo radio
~ ~ ~
9 10 l' 12 13 1. 1S 16
R
- ::a
- -
AM/FM
antenna
YX
8)j[
2
~1£d~~~;~_
...
>
"==
'l1
==
'"
....W
LB-f!]
0.85
R
J
ELECTRICAL SYSTEM
Low sensitivity
a.
Turn ignition switch to ACe.
Check radio for curate tuning.
I
No
Inaccurate tuning.
I
Reset tuning knob.
I
Yes
Check antenna trimmer for proper adjustment.
No
Trimmer out of adjustment.
L
Readjust trimmer.
j
Yes
Installing another antenna to see
if sensitivity increases.
No
I
Radio is defective.
I
I
I
Repair or replace radio.
Yes
Defective antenna grounding or
insula tion.
b.
I
J
Tighten screws securing antenna
or replace antenna.
Noisy reception
Start up engine.
Check radio for noise while
operating other electrical parts.
No
Crunching sound
Howling sound
Scra tching sound
Whisling sound
No
Noise dies when antenna is removed from radio.
No
I
I
Fuel unit
Wiper motor
Ignition coil
Alternator
Radio is defective.
Repair connection at grounded
part, or replace condenser.
l
I
I
I
-I Repair or replace radio.
Yes
H
I
Check antenna feeder and harness
for close arrangement.
No
I
I
Loud noise from outside.
I
I
Defective antenna grounding.
I
I
condition.
I
I Check and repair grounded part.
I
I
Radio
is in
good
Yes
Arrange feeder wiring apart from
harness.
15-175
J
--~~
ELECTRICAL SYSTEM
2) Horn
Horn will not sound.
See if horn circuit fuse (lOA) in
fuse box is blown.
Ves
Fuse is blown.
I
I
J Replace fuse.
I
No
Check for voltage of 12 V between horn connector O.5G
(power source) and ground
(body).
No
-'
Break in harness between bat·
tery and horn.
Repair harness and connector.
Ves
Determine if horn sounds by
grounding horn terminal (grounding side).
No
I Horn is defective.
I
J Replace horn.
-I
I
Ves
Ground 0.5 wire in steering wheel
to see if hor.l sounds.
No
Break in harness between horn
grounding terminal and combination switch.
Ves
J Repair harness and connector.
I
Repair faulty contact between
brush on combination switch side
and ring on steering wheel side.
Either horn switch or grounded
part of steering column is defeclive.
Repair horn switch or grounded
part of steering column.
J
Horn has low volume or cracked
or vibrating tone.
l
Check mou ting bol IS for looseness, horn cord for proper tension, and horn for interference
with other parts.
No
1 Repair defective points.
~ Ves
I
Start engine (increase voltage to
normal level). and sound horn.
Not.: B. sur. to tightln
lock nut firmly foIlowing IdjUltment.
I
Low sound.
H
Cracked sound.
L.!
Vibrating sound.
i
I
Loosen lock nut. and turn adjusting screw counterclockwise at
pitch of abou t 20°.
I
Loosen lock nut. and adjust by
turning adjusting screw clockwise
20 to 30°.
I
I
Loosen lock nut. and adjust by
turning right and/or left at pitch
of about 200.
I
15-177
J
I
ELECTRICAL SYSTEM
a.
Defogger does not clear windowpane
Turn on key switch.
J
See if harness-side connector is securely connected
to terminal of printed heating wire.
No
I
J Connect connector properly.
Yes
Seeiffuse(ISA,Rear IYes
defogger) is blown.
I
I
Replace fuse.
No
Check for voltage at blue/white terminal of harnessside connector of rear defogger switch.
No
I
I Repair connector connection or harness.
I
J
Yes
No
Check for voltage at blue/red terminal of rear defogger
switch when it is turned on.
1
Defective switch.
I
Yes
No
Check terminal of printed heating wire for secure
soldering.
I Solder terminal.
I
Yes
Repair harness between rear defoger switch and
printed heating wire, OJ connector connections.
b.
Switch lamp does not light when defogger switch is turned on
I
Tum on key switch.
I
I
Check if windowpane is cleared.
;
Refer to "Defoger does not clear windowpane" in
Item a.
INo
I
Yes
I
Check for zero voltage between grounding terminal
(black) of defoger switch and car body.
I No
Repair defective groundinJ, faulty connector connections, or harness.
I
Yes
.
I Replace switch lamp bulb.
15-179
J
ELECTRICAL SYSTEM
(1)
All motcH do not opeIate.
, - Tum
igllition-s~~·~~-~:~t~ ,,~~••:----.
I
-,
-------1
.-1
__ ,_______________ . _________
I
rl~f fu~e~~;15A;~~use bo~-and f::;~le l:~~
bluWJl.
r
-1I
_Y,_cs_·_ _ _-'l-I
:- -
___._____.________._. ____ .. __,_________-1
I No
Replace fuses and fusible link.
L -______ _
~:-;rl.;:"';;;.~~~-~~~~~.;;;;~~y-O--_-~~:;~~~-,~-"-!~r_h ~\~ ~;_f_l_'·_'.
_________
rL~-~~i~~~;tage
brt;aker.
-------.-
_. __.
,
1
J~S
is ~PPro~~v -~~t:-m~r~a~~~-~}NO
-
_._ ... ----
----
J
I Yes
------
l
-.----- ----.-------
of relay.
I
0.1
l g~ ~:;::~ ~:~
--.-.------------~
epav: conne.::tor or wmng.
--_._--------_. - ----- - - - - -
-----------
r-1--100j ::~~~:y.breaker
,0
--!
I
l
(3) N,l
------- - - -----.-
t.~~
I---s~e-~-·~:~~~ is ~;.;ro~~~~-~t-:~:~:~t~~-~~)
Ji_
NU ____
1-----------
~
-------l
L_~P~c~_~~ s~~_tc~ _________________
J
15--181
Repair
L-.
c- ~:~~~,d~_;-.,,~~~o~~~-______t
=Iy,,__
-
--------]
--- --- ---~e!~~.~.:~:~_____ -----------------No
1.:---- ___
J
---.- . -----.---.---.------------
[s:, ;;-;;"'.~;,;;,;,;;~ ~~~-=-~ 1 ----~_R,P'" w~n,
s..
or rcpau wiring between breaker
________ ._______________,_ _ _ __
y~·-·------···----f--
I
of mal'! sWitch.
---
JI-E~~---{_;~~l::-conne.;t(lr-O~~iri:~~-------
terminal (LR)
I---.--.----
--
-----------------l
(1. N
See if voltage is applOX. 12'v' at foilowing tcrminals
I
~
0'
fitting
wnnect~Jf
--.--
')r
'=w_.__________
-J
winng.
----
R'r" wking.' f,ttm.
"rew.
-,
~
ELECTRICAL SYSTEM
(3) Driver's window operation is defective
Tum ignition-starter switch "ON".
~
See if driver's window operation is normal by means
of main switch.
No
1
Refer to previous articles (1) and (2).
~ Yes
Tum ignition-starter switch "OFF".
l
See if resistance is On between following terminals
and earth.
(1) terminal (8) of control unit
(2) terminal (8) of auto switch.
No
Repair wiring or connector.
• Yes
See if resistance is on between following wirings of
auto switch, when operating the auto switch.
(1) at raising; (W) and (8)
(2) at lowering; (WB) and (8)
No
Replace auto switch.
!
Yes
See if resistance is on between wiring (W8 or W) of
control unit and wiring (WB or W) of auto switch.
I
Repair wiring between control unit and auto switch,
or connector.
No
Yes
,
Tum ignition-starter switch "OFF".
See if voltage is approx. 12V at terminal (RW) of
control unit.
l
No
Repair wiring.
Yes
Replace control unit.
15-183
--~I
H.F.CTR!CA.L SYSTEM
._------_._---_.------------------------
(:lllSC
-----------------
and lcp!ace
(The cir.'Hit is not JivU
(No Yl):tltge is
the bUlb.)
Lrail~l11itted It)
l
I
i Y'~5
I
i--'--,__ ~. __ L _____ --'-.----'1
!
I
(he:;;.;, If Ill'; l-,'li:lfJI
pf(Jr~fly gr"uflu%.
:
Ullit IS
I_~'~_
{;'~~;~~IY ground
U!1, it,
l~~
rI ('heck--;'~~r
i
tlans!l:itlcd
switch tu the
----------.---.--.--.. --1
_
opera:Je~
Ye~
oIw, suh-
contf('111I~tt.
N
Nil
_ n_ _ _ _
----~
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~
I ~peedometer.
I
I"'
r-------.l--i
Check if lhf (
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