Nissan 1989 240Sx Repair Manual Service

1989 1989

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240SX
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1989

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SERVICE<
MANUAL
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QUICK REFERENCE INDEX

NISSAN
j

24DSX

MODEL

-

S13

SERIES

.

GENERALINFORMATION

GI

MAINTENANCE

MA

ENGINEMECHANICAL

EM

ENGINELUBRICATION
& COOLING
SYSTEMS-

LC

ENGINEFUEL& EMISSIONCONTROL
SYSTEM-

EF

ENGINECONTROL,
FUEL& EXHAUST
SYSTEM-

FE

CLUTCH

CL

MANUALTRANSMISSION

MT

AUTOMATIC
TRANSMISSION

AT

PROPELLER
SHAFT& DIFFERENTIAL
CARRIER-

PD

FRONTAXLE& FRONTSUSPENSION

FA

REARAXLE& REARSUSPENSION

RA

BRAKESYSTEM

SR

STEERING
SYSTEM

ST

BODY

SF

HEATER
& AIRCONDITIONER

HA

ELECTRICAL
SYSTEM

EL

,
cg 1988 NISSAN MOTOR CO., LTD.

Printed in U.S.A.

Not to be reproduced in who~e or in part without the prior written permission of Ni~n
..

<""

Motor Company Ltd., Tokyo, Japan.

&EC

FOREWORD
This manual contains maintenance and repair procedures for the 1989
Nissan 240SX.
In order to assure your safety and the efficient functioning of the
vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in
specifications and methods at a~y time without notice.

IMPORTANT
SAFETYNOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a
manner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and
the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by
NISSAN must first completely satisfy himself that neither his safety
nor the vehicle's safety will be jeopardiz~d by the service method
selected.

.

NISSAN MOTORCo.,LTD.
Overseas Service Department
Tokyo, Japan

.

GENERAL
INFORMATION
I

GI

SECTION

CONTENTS
PRECAUTIONS

GI- 2

HOW TO USE THIS MANUAL

GI- 5

HOW TO READ WIRING DIAGRAMS

~

GI- 7

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

GI-10

IDENTIFICATION INFORMATION

GI-13

"""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

LIFTING POINTS AND TOW TRUCK TOWING

GI-17

TIGHTENING TORQUE OF STANDARD BOLTS

GI-20

-

PRECAUTIONS
Observe the following precautions ~o ensure safe and proper
servicing. These precautions are not described in each individual section.

1. Do not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as
gasoline, refrigerant gas, etc. When working in a pit or other
enclosed area, be sure to properly ventilate the area before
working with hazardous materials.
Do not smoke while working on the vehicle.
SGI285

2. Before jacking up the vehicle, apply wheel chocks or other
tire blocks to the wheels to prevent the vehicle from moving.
After jacking up the vehicle, support the vehicle weight with
safety stands at the points designated for proper lifting and
towing before working on the vehicle.
These operations should be done on a level surface.
3. When removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance
and drop them. Also, do not allow them to strike adjacent
parts, especially the brake tubes and master cylinder.
SGI231

4. Before starting repairs which do not require battery power,
always turn off the ignition switch, then disconnect the
ground cable from the battery to prevent accidental short
circuit.

SGI232

5. To prevent serious burns, avoid contact with hot metal parts
such as the radiator, exhaust manifold, tail pipe and muffler.
Do not remove the radiator cap when the engine is hot.

SGI233

GI-2

PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery and
carpeting with appropriate covers.
Take caution that keys, buckles or buttons on your person
do not scratch the paint.

SGI234

7. Clean all disassembled parts in the designated liquid or
solvent prior to inspection or assembly.
8. Replace oil seals, gaskets, packings, O-rings, locking
washers, cotter pins, self-locking nuts, etc. with new ones.
9. Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
10. Arrange the disassembled parts in accordance with their
assembled locations and sequence.
11. Do not touch the terminals of electrical components which
use microcomputers (such as electronic control units).
Static electricity may damage internal electronic components.
12. After disconnecting vacuum or air hoses, attach a tag to
indicate the proper connection.
13. Use only the lubricants specified in MA section.
14. Use approved bonding agent, sealants or their equivalents
when required.
15. Use tools and recommended special tools where specified
for safe and efficient service repairs.
16. When repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
17. Dispose of drained oil or the solvent used for cleaning parts
in an appropriate manner.

Precautions for E.F.I. or E.C.C.S. Engine

SGI291

1. Before connecting or disconnecting E.F.I. or E.C.C.S. harness connector to or from any E.F.I. or E.C.C.S. control unit,
be sure to turn the ignition switch to the "OFF" position and
disconnect the negative battery terminal.
Otherwise, there may be damage to control unit.
2. Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure to eliminate
danger.
3. Be careful not to jar components such as control unit and
air flow meter.

GI-3

PRECAUTIONS
Precautions for Catalyst

Clean floor
SG 1290

If a large amount of unburned fuel flows into the converter, the
converter temperature will be excessively high. To prevent this,
follow the procedure below:
1. Use unleaded gasoline only. Leaded gasoline will seriously
damage the catalytic converter.
2. When checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
3. Do not run engine when the fuel tank level is low, otherwise
the engine may misfire causing damage to the converter.
4. Do not place the vehicle on inflammable material. Keep
inflammable material off the exhaust pipe.

Precautions for Fuel
Unleaded gasoline of
at least 87 AKI number (RON 91)

GI-4

HOW TO USE THIS MANUAL
1. A QUICK REFERENCE INDEX, a black tab (e.gJ18) is provided on the first page. You can quickly find
the first page of each section by mating it to the section's black tab.
2. THE CONTENTS are listed on the first page of each section.
3. THE TITLE is indicated on the upper portion of each page and shows the part or system.
4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and
a number (e.g. "BR-5").
5. THE lARGE IllUSTRATIONS
are exploded views (See below) and contain tightening torques,
lubrication points and other information necessary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriate PARTS CATALOG.
"Example"

Pad retainer

r;~'~
Torque
member

~

~

~

,/I

J~

~

5~ 641556.5.40

~

~.
::;:;:::

/

.

Pin boot

r-

471
Main pin

IE!

to sliding portion

/

Outer shim

SBR364A

6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools,
knacks of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic
transaxle or transmission, etc. are presented in a step-by-step format where necessary.
7. The followings SYMBOLS AND ABBREVIATIONS are used:

~
E1I

~
rJ
~
~
EaI~

@>

:

"f:l

:

*

S.O.S.
L.H., R.H. .

Tightening torque
Should be lubricated with grease.
Unless otherwise indicated, use
recommended multi-purpose grease.
Should be lubricated with oil.
Sealing point
Checking point
Always replace after every disassembly.
Apply petroleum jelly.
Apply A.T.F.
Select with proper thickness.
Adjustment is required.
Service Data and Specifications
Left-Hand, Right-Hand

GI-5

M/T
A/T
Tool
L.H.D.
R.H.D.
A.T.F.
0,
02
03
D.
0.0.
22
2,
12
1,

Manual Transaxle/Transmission
Automatic Transaxle/Transmission
Special Service Tools
Left-Hand Drive
Right-Hand Drive
Automatic Transmission Fluid
Drive range 1st gear
Drive range 2nd gear
Drive range 3rd gear
Drive range 4th gear
Overdrive
2nd range 2nd gear
2nd range 1st gear
1st range 2nd gear
1st range 1st gear

",.

HOW TO USE THIS MANUAL
8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
"Example"
Tightening torque:
59 - 78 Nom (6.0 - 8.0 kg-m, 43 - 58 ft-Ib)
9. TROUBLE DIAGNOSES are included in sections dealing with complicated components.
10. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of
data.
11. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
WARNING indicates the possibility of personal injury if instructions are not followed.
CAUTION indicates the possibility of component damage if instructions are not followed.

.
.
.

BOLD TYPED STATEMENTSexcept WARNING and CAUTIONgive you helpfulinformation.

GI-6

HOW TO READ WIRING DIAGRAMS
""'=

WIRING DIAGRAM
Symbols used in WIRING DIAGRAM are shown below:
Example
CONNECTOR
Th is shows that these con nectors
white 6 terminal connectors.

POWER SUPPLY
-This shows the ignition switch position
in which the system
can be ope rated.
- See POWER SUPPLY
ROUTING in EL
section for the detai led
wiring diagram.

are

BRANCH
M/T model

n
~

.

'-LAMP-!

1m

lG~

.

~B~
A/T model

~

.

~ 2

~~

~~B-SCLG~
~

: MfT model

@

: AfT model

>

I

I

lyw IiliJ

~Whi"~

m

G

~

LOCATION NUMBER
This number shows where the
connector is located. See
HARNESS LAYOUT in EL
section. The number is
identical with the one in
HARNESS LAYOUT.
I

t

ABBREVIATIONS

~@!
I:

~

l-l

SWITCH

.rn '""".~
'""
~

---

SWITCH
This shows that continuity exists between
terminals CD and CID,
when the switch is
turned to ON position.

Instrument
harness

g

'WIRE

-b
BODY D
GROUN

~

COLOR CODING

BR

B -BI,,'

OR

W
R
G
Y
L

P
PU
GY
SB

LG

~
~
~
~~

White
Red
Green
Blue
Yellow
.

~

~

~

~

~

~

Brown
Orange
Pink
Purple
Gray
Sky Blue

ht Green

~ Llg

.
d the base
is stripe,
.
When. the iven
wire first,
co orfollowe d by the stripe
color as
IS gshown below:
Example:

I

L/W

~

Blue with Whtte Stripe

M:
Main harness
S G 1543

SWITCH POSITIONS
Normally open

~~

~

Normally closed

........

=

,

0---

Wiring diagram switches are shown with the vehicle in the
following condition.
Ignition switch "OFF",
Doors, hood and trunk lid/back door closed.
Pedals are not depressed and parking brake is released.

..
.

~
SEL764E

GI-7

HOW TO READ WIRING DIAGRAMS
CONNECTOR SYMBOLS
All connector symbols in wiring diagrams are shown from
the terminal side.

Example

.

..4:

Connector
SG 1362

Example

EE

.

M.~ te,m;nal

.

~

Male and female terminals
Connector guides for male terminals are shown in black and
female terminals in white in wiring diagrams.

G";d'-[~
Connector

Connector symbol

Female terminal

Efj

Guide

Connector
Connector symbol
SG 1363

MULTIPLESWITCH
The continuity of the multiple switch is identified in the switch
chart in wiring diagrams.

Example

WIPER SWITCH

Continuity circuit of wiper switch
SWITCH POSITION
-B/Y

-R.

-W/B
-L/Y

CONTINUITY CIRCUIT

OFF

B E
C (f)

1 5
@ 2

-B.

3-4

INT

3 - 4,5 - 6

LO

3-6

HI

2.6

WASH

1 -6

-yo

Example: Wiper switch in LO position

Continuity circuit:

Red wire - @ terminal -

CID terminal

- Wiperswitch (@ - @:

LO) - @ terminal - CD terminal - Black wire

SG 1365

GI-8

HOW TO READ WIRING DIAGRAMS
SUPER MULTIPLE JUNCTION (S.M.J.)
The "S.M.J." indicated in wiring diagrams is shown in a
simplified form. The terminal arrangement should therefore
be referred to in the foldout at the end of the Service
Manual.
The foldout should be spread to read the entire wiring
diagram.

.

.

Example

STARTING

STARTING SYSTEM
Wiring Diagram

W

w

SUPER MULTIPLE JUNCTION (S.M.J.)
T..minal

g

rnIJ ~

SYSTEM

FF

Dm3

A"angament

Check

0
0

[ ,=fd:0CI~ crhKk
0

-

'"

~

],

,~

r-

liJ

0

j

¥

.-::

:=

Super Multiple Junction
(S.M.J.)

y--R

.S.M.J.

L--S

't

Refer to last page

( (Foldout

page).

J

r-R~
~B
(Main harness)

DO

L---1

+-+

BR~
(Instrument
harness)

r-B

(Main harness)

(Instrument

harness)

BR---l.

SEL653F

GI-9

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

m"

(

INSPECTION START)

~m

-=-

SG I561

iii

~
lu

I

iii

CHECK GROUND CIRCUIT.
1) Turn ignition switch "OFF".

_MECT

[ill

rill

~

CHECK POWER SUPPLY.
Check the following items.
1) Turn ignition switch "ON" .~ [ IN.G. 1) Harness continuity betWeen
2) Check voltage between
crank angle sensor and battery.
terminal @ and ground.
2) E.C.C.S. relay-1 (See page EF &
T~Battery voltage should exist.
EC-106.)
3) "BR" fusible link
O.K.
2
4) Power source for E.C.U.
(See page EF & EC-104.)
5) Ignition switch

~~
00

2) Disconnect crank angle
sensor harness connector.
3) Check resistance betWeen
terminal @ and ground.
Resistance:
Approximately

Check the following items.
1) Harness continu ity betWeen
crank angle sensor and
I N.G~
grou nd
2) Ground circuit for E.C.U.
(See page EF & EC-104.)

on

I

SG 1562

O.K.

NOTICE
The flow chart indicates work procedures required to diagnose
problems effectively. Observe the following instructions before
diagnosing.
1) Use the flow chart after locating probable causes of a
problem following the "Preliminary Check" or the "Symptom Chart".
2) After repairs, re-check that the problem has been completely eliminated.
3) Refer to Component Parts Location and Harness Layout
for the Systems
described
in each section
for
identification/location
of components and harness connectors.
4) Refer to the Circuit Diagram for Quick Pin Point Check.
If you must perform circuit continuity between harness
connectors more detail, such as in case of sub harness is
used, refer to Wiring Diagram and Harness Layout in EL
section for identification of harness connectors.
5) When checking circuit continuity, ignition switch should be
"OFF" .
6) Before checking voltage at connectors, check battery
voltage.
7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness
connectors are reconnected as it was.

GI-10

HOW TO FOllOW

FLOW CHART IN TROUBLE DIAGNOSES
HOW TO FOllOW
ITJ

m

THIS FLOW CHART

Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in
enclosed blocks, as shown in the following example.
I
...

CHECK POWER SUPPLY.
1) Turn ignition switch "ON".
2) Check

.--

Check

voltage between

terminal @ and ground.
Battery voltage should exist.

item being performed.

Procedure,
measurement

}

steps or
results

O.K.
I2J Measurement

results

Required results are indicated in bold type in the corresponding block, as shown below.
These have the following meanings:
Battery voltage ~ 11 14V or approximately
12V
Voltage:
Approximately OV ~ Less than 1V

-

~

Cross reference of work symbols in the text and
illustrations
Illustrations are provided as visual aids for work procedures.
For example, symbol m indicated in the left upper portion
of each illustration corresponds with the symbol in the
flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration m .

@] Symbols used in illustrations
Symbols included in illustrations refer to measurements or
procedures. Before diagnosing a problem, familiarize yourself
with each symbol.

Example
View from terminal side

Connector symbol

~

Direction

mark

~
View from harness side

Connector

Connector

symbol

~
[it
Direction

Direction mark
A direction mark is shown to clarify the side of connector (terminal side or harness side).
Direction marks are mainly used in the illustrations indicating
terminal inspection.

.
.

~:

View f,om lermlnel side n' r.s.
All connector symbols shown from the terminal side are
enclosed by a single line.

~:

Viewf,omhernessside .n

H.S.

All connector symbols shown from the harness
enclosed by a double line.

mark

SGI364

GI-11

side are

HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
Key to symbols signifying measurements or procedures
Symbol

Symbol explanation

..-cT

IV
CONNECT

£)
@-

00
00
OOACC

F

Symbol

Symbol explanation

Check after disconnecting the
connector to be measured.

AIC switch

Check after connecting the
connector to be measured.

AIC switch is "ON".

Insert key into ignition switch.

REC switch is "ON".

Turn ignition switch to "OFF"
position.

REC switch is "OFF".

Turn ignition switch to "ON"
position.

DEF switch is "ON".

Turn ignition switch to "START"
position.

VENT switch is "ON".

Turn ignition switch from "OFF" to
"ACC" position.

Fan switch is "ON". (At any position except for "OFF" position)

Turn ignition switch from "ACC" to
"OFF" position.

Fan switch is "OFF".

"cfi1234.

Turn ignition switch from "OFF" to
"ON" position.

OOF

0
trJ

Apply battery voltage directly to
components.

7

Turn ignition switch from "ON" to
"OFF" position.

Drive vehicle.

Do not start engine,or check

Disconnect battery negative cable.

with engine stopped.
Start engine.

or check

is "OFF".

with engine

Depress

running.

brake

pedal.

Apply parking brake.

Release brake pedal.

Release parking brake.

Depress accelerator pedal.

CffH

Check after engine is warmed up
sufficiently.

Release accelerator pedal.

l!V

Voltage should be measured with a
voltmeter.

-

La)

II CIUIIT
foi--

Circuit resistance should be
measured with an ohmmeter.

€
II

-

Le1J
Currentshould be measuredwith
an ammeter.

GI-12

Pin terminal check for S.M.J.
type E.C.U.and AIT control
unit connectors.
For details regarding the
terminal arrangement, refer
to the foldout page.

'

IDENTIFICATION INFORMATION

Model Variation
Destination

Model

Body

Transmission

Engine

Coupe

HLS13FU

Fastback

RHLS13FU

Coupe

HLS13AU

Fastback

RHLS13AU

Coupe

HLS13FV

Fastback

RHLS13FV

Coupe

HLS13AV

Fastback

RHLS13AV

Coupe

HLS13FN

Fastback

RHLS13FN

Coupe

HLS13AN

Fastback

RHLS13AN

Differential
carrier

FS5W71C
Non-California
RE4R01A

FS5W71C
California

KA24E

R200
RE4R01A

FS5W71 C
Canada
RE4R01A

Prefix and suffix designations:
R

0:
R :

Coope
Fastba~

H:

KA24E engine

L:

L.H. drive

H

L S13

A

N (R)

L

T

(R) : With A.B.S.
N : Canada
V : California
U:

Non-California

A : Automatic transmission
F :

0 : means no indication.

GI-13

5-speed manual transmission

IDENTIFICATION

INFORMATION

Identification Number
Vehicle identification

plate

Vehicle identification

number (Chassis number)

F.M.V .5.5. certification
Vehicle identification

label

number plate
SGI547

VEHICLE IDENTIFICATION

NUMBER ARRANGEMENT
IN 1 H S 3 6 P X K W 000051

Manufacturer

I

IT

IN 1: N issan passenger vehicle
Engine type
H: KA24E

Vehicle serial number

Manufacture plant
W: Kyushu
Model year
K: 1989 year model

. Vehicle line
S: NISSAN 240SX

Check digit (0 to 9 or XI
The code for the check digit is
determined by mathematical
computation.

Model change (0 to 91
Body type
4: Coupe
6: Fastback

Restraint system
S: Standard
P: Automatic

GI-14

IDENTIFICATION

INFORMATION

Identification Number (Cont'd)
IDENTIFICATION

PLATE

NISSAN MOTORCO.,LTD. JAPAN

~:it

~i:J

ill

1
2
3
4
5
6
7
8
9

CHASSIS NO
NO DE CHASIS
MODEL

.&

MOOElO

0
I

&"

",-COlOR
TRiM
f 'Jk COlOR GUMNICION
;,.0

'/;,.0

ENGIN[
MOTOR

;; ';~: :::; ~ElE

0

ffi&
&&

CC

& &
I tf;

S jJt ~ ItJ :if[** :it ~ U

::::A
MADEINJAPAN

Type
Vehicle identification number (Chassis numbed
Model
Body color code
Trim color code
Engine model
Engine displacement
Transmission model
Axle model

SGI315

ENGINE SERIAL NUMBER
KA24E engine

TL 1006M

MANUAL TRANSMISSION

NUMBER

AUTOMATIC

SGI274

TRANSMISSION

NUMBER

SGI513

GI-15

IDENTIFICATION INFORMATION

Dimensions

Unit: mm (in)

Coupe

Fastback

Overall length

4,520 (178.0)

4,520 (178.0)

Overall width

1,690 (66.5)

1,690 (66.5)

Overall height

1,290 (50.8)

1,290 (50.8)

Front tread

1,465 (57.7)

1,465 (57.7)

Rear tread

1,460 (57.5)

1,460 (57.5)

Wheelbase

2,475 (97.4)

2,475 (97.4)

Wheels and Tires
Road wheel

Steel

6-JJx 15

Aluminum

6-JJx 15

Offset
Tire size

mm (in)

40 (1.57)

Conventional

195/60R 15 86H
205/60R 15 89H *

Spare

T125/70D 15

*: Option

GI-16

LIFTING POINTS AND TOW TRUCK TOWING
Garage Jack and Safety Stand
WARNING:
Never get under the vehicle while it is supported only by
the jack. Always use safety stands to support the frame
when you have to get under the vehicle.
Place wheel chocks at the front wheels when the rear
wheels are raised and place wheel chocks at the rear
wheels when the front wheels are raised.
CAUTION:
Place a wooden or rubber block between safety stand and
vehicle body when the supporting body is flat.

.
.

Garage jack points

SGI552

GI-17

LIFTING POINTS AND TOW TRUCK TOWING
2-pole Lift
WARNING:
When lifting the vehicle, open the lift arms as wide as
possible and ensure that the front and rear of the vehicle are
well balanced.
When setting the lift arm, do not allow the arm to contact the
brake tubes and fuel lines.

Sill

~

Put the sill in the slit of the lift pad to prevent
the sill from deforming. If the pad does not have
lift pad

//

the slit, prepare

a suitable

attachment

with slit.

Note:
Lift-up points
are the same as
pantograph jack
points.

SGI553

Tow Truck Towing
CAUTION:

.

.

.

~
~

All applicable state or Provincial (in Canada) laws and
local laws regarding the towing operation must be obeyed.
It is necessary to use proper towing equipment to avoid
possible damage to the vehicle during towing operation.
Towing is in accordance with Towing Procedure Manual at
dealer.
When towing with the rear wheels on the ground, release
the parking brake and move the gearshift lever to neutral
(UN" position).

NISSAN recommends that vehicle be towed with the driving
(rear) wheels off the ground as illustrated.

'i::ij,iiii.2ii;~1',,,';1tiii:.;

-.

SG 1383

GI-18

LIFTING

POINTS

AND TOW TRUCK

TOWING

Tow Truck Towing (Cont'd)
TOWING AN AUTOMATIC TRANSMISSION MODEL WITH
FOUR WHEELS ON GROUND OR TOWING WITH FRONT
WHEELS RAISED (With rear wheels on ground)
Observe the following restricted towing speeds and distances.
Speed:
Below 50 km/h (30 MPH)
Distance:
Less than 65 km (40 miles)
If the speed or distance must necessarily be greater, remove
the propeller shaft beforehand to prevent damage to the
transmission.
TOWING POINT
Alwayspull the cable straightout from the vehicle.Never pull
on the hook at a sidewaysangle.

Front

Rear

CE1 DD9M

GI-19

TIGHTENINGTORQUE OF STANDARD BOLTS

Grade

Bolt size

Bolt

dia-

meter* mm

Tightening torque (Without lubricant)

Pitch mm

Hexagon head bolt
N.m

4T

M6

6.0

M8

8.0

M10
M12

12.0

M14

14.0

M6

6.0

M8
7T

M10
M12

9T

10.0

8.0
10.0
12.0

6.1

0.62

4.5

5.1

1.25

13

1.3

9

15

1.5

11

1.0

13

1.3

9

16

1.6

12

1.5

25

2.5

18

29

3.0

22

1.25

25

2.6

19

30

3.1

22

1.75

42

4.3

31

51

5.2

38

1.25

46

4.7

34

56

5.7

41

1.5

74

7.5

54

88

9.0

65

1.0

8.4

0.86

6.2

10

1.0

7

1.25

21

2.1

15

25

2.5

18

1.0

22

2.2

16

26

2.7

20

1.5

41

4.2

30

48

4.9

35

1.25

43

4.4

32

51

5.2

38

1.75

71

7.2

52

84

8.6

62

1.25

77

7.9

57

92

9.4

68

14.0

1.5

127

13.0

94

147

15.0

108

M6

6.0

1.0

12

1.2

9

15

1.5

11

M8

8.0

1.25

29

3.0

22

35

3.6

1.0

31

3.2

23

37

3.8

26
27

1.5

59

6.0

43

70

7.1

51

1.25

62

46

74

7.5

54

1.75

98

6.3
10.0

72

118

12.0

87

1.25

108

11.0

80

137

14.0

101

1.5

177

18.0

130

206

21.0

152

M12
M14

10.0
12.0
14.0

1. Special parts are excluded.
2. This standard is applicable to bolts having the following
marks embossed on the bolt head.

4T
7T
9T

3.8

1.0

kg-m
0.52

M14

M10

Grade

ft-Ib

Hexagon flange bolt
N.m
ft-Ib
kg-m

*: Nominal diameter

Mark
4
7
9

M

1

GI-20

6
""""L-

Nominal diameter of bolt threads (Unit: mm)
Metric screw threads

'..~

MAINTENANCE

MA

.J

SECTION

I

CONTENTS
PERIODIC MAINTENANCE ...

MA- 2

GENERAL MAINTENANCE.

MA- 4

RECOMMENDED LUBRICANTS AND FLUIDS

MA- 6

ENGINE MAINTENANCE

MA- 8

"'"''''''''''''

CHASSIS AND BODY MAINTENANCE
SERVICE DATA AND SPECIFICATIONS (S.D.S.)

MA-14
:"

MA-20",

l1li

PERIODIC MAINTENANCE
The following charts show the normal maintenance schedule. Under severe driving conditions, additional or
more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions".
The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the
first 15,000 miles (24,000 km) or 12 months.
EMISSION CONTROL SYSTEM MAINTENANCE
MAINTENANCE. OPERATION
Perform at number of miles,
kilometers or months, whichever
comes first.
Drive belts

MAINTENANCE
15
30

INTERVAL
45
60

Miles x 1,000

7.5

(km x 1,000)

(12)

(24)

(48)

(72)

(96)

6

12

24

36

48
1*

Months

See NOTE (1).

Replace every 30,000 miles
(48,000 km).
1*
1*
1*
1*

Air cleaner filter

Vapor lines
Fuel lines
Fuel filter

See NOTE (2)*.
R

Engine coolant
Egnine oil

R

Engine oil filter
(Use Nissan PREMIUM

R

R

Then replace every 7,500 .
miles (12,000 km) or
6 months.
Then replace every
second oil change.

type or equivalent.)

Ignition wires

MA-8
MA-10
MA-13
MA-9
MA-10
MA-8
MA-11

MA-11

Replace every 30,000 miles
(48,000 km).
Inspect every 3 years. *

Spark plugs

Reference page

MA-12
MA-12

CHASSIS AND BODY MAINTENANCE
MAINTENANCE OPERATION
Perform at number of miles,
kilometers or months, whichever
comes first.

Miles x 1,000

15

(km x 1,000)

(24)
12

Months

Break lines & cables

I
I
I

Brake pads & discs
Manual and automatic transmission & differential gear oil
Steering gear & linkage, and axle & suspension parts
Exhaust system

MAINTENANCE
INTERVAL
30
45
(48)
24
I
I
I
I
I

(72)
36
I
I
I

60

Reference page

(96)
48
I
I
I
I
I

MA-16
MA-17
MA-14,15,16
MA-18, FA-4,RA-4
MA-14

NOTE:
(1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km).
(2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either
extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately.
(3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need
not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
Abbreviations:

R = Replace. I = Inspect. Correct or replace if necessary.

MA-2

PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING

CONDITIONS

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to.
be performed on the following items as shown in the table.
Severe driving conditions
A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing
B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use
C - Driving in dusty conditions
D - Driving on rough, muddy, or salt spread roads
E - Towinga trailer, usinga camper or a car-top carrier

Driving condition
C
ABC

A.

.
A.

DE

C D E

.

item

Maintenance
interval

Reference

More frequently'

MA-10

Engine oil & oil filter

R

Every 3,000 miles
(5,000 km) or 3 months

MA-11

Every 7,500 miles
(12,000 km) or 6 months

MA-17

Every 30,000 miles
(48,000 km) or 24 months

MA-14, 15, 16

Brake pads & discs

D .

Steering gear & linkage, and
axle & suspension parts

Maintenance operations:

operation

R

Manual and automatic transmission & differential gear oil

D E

Maintenance

Air cleaner filter

D E

CD.
.

Maintenance

R

page

MA-18, FA-4, RA-4
Every 7,500 miles
(12,000 km) or 6 months

Steering linkage ball joints
& front suspension ball joints
Exhaust system

MA-18,FA-4

MA-14

I = Inspect. Correct or replace if necessary. R

= Replace.

MA-3

GENERAL MAINTENANCE
General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicl~isto continue operating properly. The owners can perform the
checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge.
Item

Reference page

OUTSIDE THE VEHICLE
The ma!ntenance items listed here should be performed from time to time, unless otherwise
specified.
Tires Check the pressure with a gauge periodically when at a service station, including the
spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or
excessivewear.
Wheel nuts When checking the tires, make sure no nuts are missing,and check for any loose
nuts. Tighten if necessary.
Tire rotation Tires should be rotated every 12,000 km (7,500 miles.)

MA-18

Wheel alignment and balance If the vehicle should pull to either side while driving on a
straight and level road, or if you detect uneven or abnormal tire wear, there may be a need
for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel
balancing may be needed.

MA.17
FA-6
RA-6

Windshieldwiper blades Check for cracks or wear if they do not wipe properly.
Doors and engine hood Check that all doors and the engine hood operate smoothly as well as
the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary
latch is released.
When driving in areas using road salt or other corrosive materials, check lubrication frequently.
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when
performing periodic maintenance, cleaning the vehicle, etc.
Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights
are all operating properly and installed securely. Also check headlight aim.

MA-19

Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are
operating properly.
Windshield wiper and washer Check that the wipers and washer operate properly and that
the wipers do not streak.
Windshield defroster Check that the air comes out of the defroster outlets properly and in
sufficient quantity when operating the heater or air conditioner.
Steering wheel Check that it has the specified free play. Be sure to check for changes in the
steering condition, such as excessivefree play, hard steering or strange noises.
Free play: Lessthan 35 mm (1.38 in)
Seats Check seat position controls such as seat adjusters, seatback recliner, etc. to ensure
they operate smoothly and that all latches lock securely in every position. Check that the
head restrains move up and down smoothly and that the locks (if so equipped) hold securely
in all latched positions. Check that the latches lock securely for folding-down rear seatbacks.
.
Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the belt
webbing for cuts, fraying, wear or damage.

MA-4

MA-19

GENERAL MAINTENANCE
Item

Reference page

Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free
travel.

CL-5

Brakes Check that the brake does not pull the vehicle to one side when applied.
Brake pedal Check the pedal for smooth operation and make sure it has the proper distance
under it when depressed fully. Check the brake booster function.

BR-7

Parking brake Check that the lever has the proper travel and confirm that your vehicle is
held securely on a fairly steep hill with only the parking brake applied.

BR-23

Automatic transmission "Park" mechanism Check that the lock release button on the
selector lever operates properly and smoothly. On a fairly steep hill check that your vehicle
is held securely with the selector lever in the "P" position without applying any brakes.

UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically (e.g. each time you check
the engine oil or refuel).
Windshieldwasher fluid Check that there is adequate fluid in the tank.
Engine coolant level Check the coolant levelwhen the engine is cold.

MA-9

Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves,
etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or
loose connections.
Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the
"MAX" and "MIN" lines on the reservoir.

MA-14,16

Engine drive belts Makesure that no belt is frayed, worn, cracked or oily.

MA-8

Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and
turning off the engine.

MA-11

Power steering fluid level and lines Check the level when the fluid is cold and the engine is
turned off. Check the lines for proper attachment, leaks, cracks, etc.

MA-18

Automatic transmission fluid level Check the level on the dipstick after putting the selector
lever in "P" with the engine idling.

MA-15

Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the
exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble
and correct it.

MA-14

Underbody The underbody is frequently exposed to corrosive substances such as those used
on icy roads or to control dust. It is very important to remove these substances, otherwise
rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end
of winter, the underbody should be thoroughly flushed with plain water, being careful to
clean those areas where mud and dirt can easily accumulate.
Fluid leaks Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle
has been parked for a while. Water dripping from the air conditioner after use is normal. If
you should notice any leaks or gasoline fumes are evident, check for the cause and correct it
immediately.

MA-5

RECOMMENDED LUBRICANTS AND FLUIDS
Lubricants and Fluids
Capacity (Approximate)

Engine oil (Refill)
With oil filter
Without

oil filter

Cooling system (with reservoir tank)
Reservoir tank
Manual transmission
Differential

oil

gear oil

Automatic transmission fluid
Power steering fluid

Recommended lubricants and fluids

US
measure

Imp
measure

Liter

3-3/4 qt

3-1/8 qt

3.5

3-3/8 qt

2-7/8 qt

3.2

7-1/8 qt

5-7/8 qt

6.7

3/4 qt

5/8 qt

0.7

5-1/8 pt

4-1/4 pt

2.4

API GL-4*2

2-3/4 pt

2-1/4 pt

1.3

API GL-5*2

8-3/4 qt

7-1/4 qt

8.3

1 qt

0.9

3/4 qt

Genuine Nissan Motor Oil*1 or equivalent
(Energy Conserving Oils of API SF or SG)*2, *3

Anti-freeze coolant (Ethylene glycol base)

Genuine Nissan ATF*1 or equivalent
Type DEXRON

TM

Type DEXRON

TM

Brake fluid

Genuine Nissan Brake Fluid*1 or equivalent
DOT 3 (US FMVSS No. 116)

Multi-purpose grease

NLGI No.2 (Lithium soap base)

*1: Available in mainland U.S.A. through you Nissan dealer.
*2: For further details, see "SAE Viscosity Number".
*3: Energy Conserving Oils
These oils can be identified by such labels as energy conserving, energy saving, improved fuel economy, etc.

MA-6

RECOMMENDED LUBRICANTS AND FLUIDS
SAE Viscosity Number
Outside Temperature
Anticipated
ENGINE

Outside Temperature Range
Anticipated Before Next Oil Change
GEAROIL

Range

Before Next Oil Change

OIL

140 .

°C",OF

-----

+4011+104"'--+30111+86

-

+16111+60--+10111

0111+32

+50

~

-181110

-29111-20- -5W-30

T10002

T10003

10W-30 is preferable if the ambient temperature is
above -18°C (0° F). 20W-40 and 20W-50 are
usable if the ambient temperature is above 10°C
(50° F) for all seasons.

MA-7

8OW-90 is preferable if the ambient temperature is
below 40°C (104°F).

ENGINE MAINTENANCE

Power steering oil pump
IAJ

Water pump

lAJQ'
l:~:o,

I

Crank pulley
T : Tension checking points
IAJ: Adjusting bolts

lAJA;,,ood;,;oo",

Checking Drive Belts
1, Inspect for cracks, fraying, wear or oil adhesion, If necessary,
replace with a new one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed the limit.
Belt deflection:
Inspect drive belt deflections when engine is cold.

compressor

Unit:

mm (in)

8MAOO2C

Used belt deflection

Set deflection of
new belt

Limit

Adjusted
deflection.

Alternator

11 (0.43)

7-8
(0.28 - 0.31)

6-7
(0.24 - 0.28)

Air conditioner
compressor

12 (0.47)

7-8
(0.28 - 0.31)

(0.24

Power steering
oil pump

13 (0.51)

8-9
(0.31 - 0.35)

7-8
(0.28 - 0.31)

Applied pushing
force

6.7

- 0.28)

98 N (10 kg, 22 Ib)

Changing Engine Coolant

~~~
[~O1234

m

~
~

m

.-

WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
1. Move heater "TEMP" control lever all the way to "HOT"
position.

8M AOO3C

2. Open drain cock at the bottom of radiator, and remove
radiator cap.

MA-8
"'.

ENGINE MAINTENANCE
Changing Engine Coolant (Cont'd)
3. Remove cylinder block drain plug.
4. Close drain cock and tighten drain plug securely.
Apply sealant to the thread of drain plug.
to;J:34 44 N.m
(3.5 - 4.5 kg-m, 25 - 33 ft-Ib)

L

.

J

-

5. Open air relief plug.

.

6. Fill radiator with water and close air relief plug and radiator
cap.
7. Run engine and warm it up sufficiently.
8. Race engine 2 or 3 times under no-load.
9. Stop engine and wait until it cools down.
10. Repeat step 2 through step 9 until clear water begins to
drain from radiator.
11. Drain water.

12. Open radiator cap and air relief plug.
13. Fill rafdiator with coolant up to specified level.
Follow instructions attached to anti-freeze container for
mixing ratio of anti-freeze to water.
Coolant capacity. (With reservoir tank)
6.7 Q (7-1/8 US qt, 5-7/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air in
system to escape.

MAX.
MIN.

14. Close air relief plug.
15. Remove reservoir tank, drain coolant, then clean reservoir
tank.
16. Install reservoir tank and fill it with coolant up to "MAX"
level and then install radiator cap.
17. Run engine and warm it up sufficiently.
18. Race engine 2 or 3 times under no-load.
19. Stop engine and cool it down, then add coolant as necesary.

SMA412B

Checking Fuel Lines
Inspect fuel lines and tank for improper attachment and for
leaks, cracks, damage, loose connections, chafing and deterioration.
If necessary, repair or replace faulty parts.

MA-9

ENGINE MAINTENANCE
Checking Fuel Lines
CAUTION:

3 mm 10.12 in)

,

~--,'-'

.

(Cont'd)

Tightenhigh-pressurerubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Ensure that screw does not contact adjacent parts.

,

--T-+-+--J__J.-_J

SMA804A

Changing Fuel Filter
WARNING:
Before removing fuel filter, release fuel pressure from fuel line.

1. Remove fuse for fuel pump.
2. Start engine.
3. After engine stalls, crank engine two or three times to make
sure that fuel pressure is released.
4. Turn. ignition switch off and install fuse for fuel pump.

5. Loosen fuel hose clamps.
6. Replace fuel filter.
Be careful not to spill fuel over engine compartment. Place
a shop towel to absorb fuel.
Use a high-pressure type fuel filter. Do not use a synthetic
resinous fuel filter.

.
.

. Whentighteningfuel hose clamps, refer to "CheckingFuel
Lines".

Changing

Air Cleaner

Filter

The viscous paper type filter does not need cleaning between
renewals.

MA-10

ENGINE MAINTENANCE

Changing Engine Oil
WARNING:
Be careful not to burn yourself, as the engine 011Is hot.
1. Warm up engine, and check for oil leakage from engine
components.
2. Remove drain plug and oil filler cap.
3. Drain oil and refill with new engine oil.
Refill oil capacity (Approximate):

~

Front
SMAOO9C

Unit: liter (US qt, Imp qt)
With oil filter change

3.5 (3.3/4,3-1/8)

Without oil filter change

3.2 (3-3/8,2-7/8)

CAUTION:

.

Be sure to clean drain plug and Install with new washer.
Drain plug:

tOJ:29 - 39 N.m

.

.

(3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Use recommended engine 011.

4. Check oil level.
5. Start engine and check area around drain plug and oil filter
for oil leakage.
6. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.

SMA042C

Changing

Oil Filter

1. Remove oil filter with a suitable tool.
WARNING:

Be careful not to burn yourself, as the engine and the engine
oil are hot.

2. Before installing new oil filter, clean the oil filter mounting
surface on cylinder block, and coat the rubber seal of oil
filter with a little engine oil.

~

SMA010

MA-11
---

ENGINE MAINTENANCE
Changing Oil Filter (Cont'd)
3. Screw in the oil filter until a slight resistance is felt, then
tighten additionally more than 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
2/3 of a turn

SMA229B

Changing

N.G.

O.K.

Spark Plugs

1. Disconnect ignition wires from spark plugs at boot.
Do not pull on the wire.

SMA017

2. Remove spark plugs with spark plug wrench.
Spark plug:
Standard type
ZFR5D-11
Hot type
ZFR4D-11
Cold type
ZFR6D-11

R
16mmV1
'o.um~
SEM294A
Side electrode

iii

3. Check plug gap of each new spark plug.
Gap: 1.0 - 1.1 mm (0.039 - 0~043 in)
4. Install spark plugs. Reconnect ignition wires according to
nos. indicated on them.
Spark plug:
~:20

- 29

N.m

(2.0 - 3.0 kg-m, 14 - 22 ft-Ib)

SMA476

Checking Ignition Wires
1. Inspect wires for cracks, damage, burned terminals and for
improper fit.
2. Measure the resistance of wires and check for intermittent
breaks by shaking them.
Resistance:
Less than 30 kil
.If it exceeds the limit, replace the ignition wire with a new
one.

~

SMA015A

MA-12

ENGINE MAINTENANCE

Checking Vapor Lines
1. Visually inspect vapor lines for. improper attachment and for
cracks, damage, loose connections, chafing and deterioration.
2. Inspect vacuum relief valve of fuel tank filler cap for clogging,
sticking, etc.
Refer to EVAPORATIVE EMISSION CONTROL SYSTEM
INSPECTION in EF & EC section.
/"

"

MA-13

.

CHASSIS AND BODY MAINTENANCE

Checking Exhaust System

.

Check exhaust pipes, muffler and mounting for improper
attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.

SMA211A

Checking Clutch Fluid Level and Leaks

.

Max.

If fluid level is extremely low, check clutch system for leaks.

Min.

SMA941B

Checking

M/T Oil

1. Check for oil leakage.

,
SMA429A

2. If leakage is found, check oil level.
Never start engine while checking oil level.
Filler plug:
~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)

K

SMA103

Changing

1. Drain oil and refill with new gear oil.
2. Check oil level.
Oil capacity:
2.4 Q (5-1/8 US pt, 4-1/4 Imp pt)
Drain plug:
~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)

~~~

.,.

M/T Oil

~.;. ~"~

SMA255A

MA-14

CHASSIS AND BODY MAINTENANCE

Checking

AIT Fluid

1. Check for fluid leakage.

.

.
SMA430A

.

Front side
Hot: 50 - aooc
(122 - 176°F)
Add"

2. If leakage is found, check fluid level.
Fluid level should be checked using "HOT" range on
dipstick at fluid temperatures of 50 to 80°C (122 to 176°F)
after vehicle has been driven approximately 5 minutes in
urban areas after engine is warmed up. But it can be
checked at fluid temperatures of 30 to 50°C (86 to 122°F)
using "COLD" range on dipstick for reference after engine
is warmed up and before driving. However, fluid level must
be rechecked using "HOT" range.
1) Park vehicle on level surface and set parking brake.
2) Start engine and then move selector lever through each
gear range, ending in "P".
3) Check fluid level with engine idling.
4) Remove dipstick and wipe it clean with lint-free paper.
5) Reinsert dipstick into charging pipe as far as it will go.
6) Remove dipstick and note reading. If level is at low side of
either range, add fluid to the charging pipe.
Do not overfill.

O.K.

~

3. Check fluid condition.
Check fluid for contamination. If fluid is very dark or smells
burned, or contains frictional material (clutches, band, etc.),
check operation of AlT.
Refer to section AT for checking operation of AlT.

Check fluid for contamination.
SMA853B

Changing

AIT Fluid

1. Drain fluid by removing oil pan.
2. Replace gasket with new one.
3. Refill with fluid and then check fluid level.
Oil capacity (With torque converter):
8.3 Q (8-3/4 US qt, 7-1/4 Imp qt)

~

SMA921B

MA-15

CHASSIS AND BODY MAINTENANCE

Checking Differential Gear Oil
1. Check differential carrier for oil leakage.

SMA012C

2. If leakage is found, check oil level.
Filler plug:
~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)

-

-

SMA257 A

Changing

~~

Differential Gear Oil

1. Drain oil and refill with new gear oil.
2. Check oil level.
Oil capacity:
1.3 Q (2-3/4 US pt, 2-1/4 Imp pt)
Drain plug:
~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)

-

0,,;" PI~

-

~
SMA363A

Checking Brake Fluid Level and Leaks

.

=

If fluid level is extremely low, check brake system for leaks.

MAX

=

MIN

Checking Brake Lines and Cables

.

Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc.

SMA732A

MA-16

CHASSIS AND BaDY MAINTENANCE
Checking Disc Brake

. Check condition of disc brake components.
ROTOR
. Check condition and thickness.
Unit: mm (in)
Front

Rear

CL22VB

CL9H

Standard thickness

20.0 (0.787)

9.0 (0.354)

Minimum thickness

18.0 (0.709)

8.0 (0.315)

Disc brake type
SMA260A

CALIPER

. Check operationand for leakage.

SMA922A

PAD
Check for wear or damage.

.

Unit: mm (in)

Disc brake type
Standard thickness

Minimum thickness

Front

Rear

CL22VB

CL9H

10.0 (0.394)

9.5 (0.374)

2.0 (0.079)

SMA847B

Balancing

.

Wheels

Adjust wheel balance using road wheel center.
Wheel balance (Maximum allowable unbalance
at rim flange):
Refer to S.D.S.
Tire balancing weight: Refer to S.D.S.

MA-17

CHASSIS AND BODY MAINTENANCE
Tire Rotation

FRONT

!

0

.

Do not include the T-type spare tire when rotating the tires.
Wheel nuts:
~: 98 - 118 N.m
(10.0 - 12.0 kg-m, 72 - 87 ft-Ib)

A!

0

SMA650B

Checking Steering Gear and Linkage
STEERING GEAR
Check gear housing and boots for looseness, damage or
grease leakage.
Check connection with steering column for looseness.
STEERING LINKAGE
Check ball joint, dust cover and other component parts for
looseness, wear, damage or grease leakage.

.
.
.

.
Q

: Check grease leakage
: Check tightening

torque

SMA851 B

Checking Power Steering Fluid and Lines

SMA940B

.

Check fluid level, when the fluid is cold.

.

Check lines for improper attachment, leaks, cracks, damage,

loose connections, chafing and deterioration.

SST107B

MA-18

CHASSIS AND BODY MAINTENANCE
LUBRICATING LOCKS, HINGES AND HOOD LATCHES
Fastback
-------

lEI

=~~

m

m.
SMA999B

CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS

CAUTION:
1. AUseat bait a..mblies, including retractors and
attaching hardwares such as guida rail set, etc"
should ba inspacted after any collision. Ni...n
recommends that aUseet bait ...amblies in use
during a collision ba replaced unless the collision was minor and the baits show no damage
and continue to operete properly. Seat bait
assemblies not in use during a collision should
allO ba inspacted and replaced if eithar damage
or improper operation is noted.
2. If tha condition of any component of a seat
bait is questionable, do not have seat bait
repaired, but raplaced as a bait 8118mbly.
3. If wabbing is cut, frayed, or damaged, replace
bait assembly.
4. Do not spill drinks, oil, etc. on inner lap bait
buckle. Never oil tongue and buckle.
5. Use a NISSAN genuine ..at bait assembly.

~ Anchor
bolt
24-31 N.m
(2.4 - 3.2 kg-m, 17 - 23 ft-Ib)
For automatic seat bait, refer to BF section.

Rear seat belt
Check function of
buckles and tongues
when buckled and
released.

Front seat belt

MA-19

SMAOO1C

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Engine Maintenance
Spark plug

INSPECTION AND ADJUSTMENT
Drive belt deflection
Unit: mm (in)
Used belt deflection
Adjusted
deflection

Limit

Alternator

Set deflection of
new belt

11 (0.43)

7-8
6-7
(0.28 - 0.311 I (0.24 - 0.28)
6-7
7-8
(0.28 - 0.311 I (0.24 - 0.28)

Air conditioner
compressor

12 (0.47)

Power steering
oil pump

13 (0.511 1(0.31-0.35) (0.28- 0.31)

8-9

ZFR5D-11

Hot type

ZFR4D-11

Cold type

ZFR6D.11

Plug gap

1.0 - 1.1 mm (0.039 . 0.043 in)

Ignition wire
Resistance kS1

TIGHTENING

7-8
I

Applied pushing force

Standard type

98 N (10 kg, 22 Ib)

N'm

kg-m

ft-Ib

Spark plug

20- 29

2.0 - 3.0

14- 22
25 - 33
22.29

Oil capacity (Refill)
Unit: 2 (US qt, Imp qt)

3.5 (3-3/4,3-1/8)

Without

3.2 (3-3/8,2-7/8)

oil filter

Coolant capacity
Unit: 2 (US qt, Imp qt)
With reservoir

tank

TORQUE

Unit

Drain plug

With oil filter

Less than 30

6.7 (7-118,5-7/8)

MA-20

-

Engine block

34 44

3.5-4.5

Oil pan

29-39

3.0-4.0

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Chassis and Body Maintenance
Brake

INSPECTION AND ADJUSTMENT
Clutch

Unit: mm (in)
Unit: mm (in)

- 196 (7.32.7.72)

Pedal free height "H"

186

Pedal free play" A"

1.0 - 3.0 (0.039 .0.118)

Disc brake
Pad
Standard thickness
CL22VB

10.0 (0.394)

CL9H

9.5 (0.374)

Minimum thickness
CL22VB

Front axle and front suspension(Unladen)*
-1°30'

Camber

degree

Caster

degree

Toe-in

mm (in)

to 0°

2.0 (0.079)

CL9H

6°00' . ~30'

Rotor
Standard th ickness
CL22VB

0 - 2 (0 - 0.08)

(Total toe-in)

degree

0' - 12'

Kingpin inclination

degree

12°30'- 14°00'

2.0 (0.079)

20.0 (0.787)

CL9H
Minimum thickness
CL22VB

Front wheel turning angle
Full turn
Inside/outside

d

9.0 (0.354)

39°

egree

-43° /33°

18.0 (0.709)

CL9H

*: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.

8.0 (0.315)

Pedal
Free height
M/T

177

A/T

Rear axle and rear suspension (Unladen)*
Camber

degree

Toe-out

mm (in)

(Total toe.out)

degree

-1°36'

186 - 196 (7.32 - 7.72)

Free play

1 - 3 (0.04 - 0.12)

to -0°36'
Depressed hElight
[under force of 490 N
(50 kg, 110 Ib) with
engine running]

0 - 5 (0 . 0.20)
0' - 28'

I

- 187 (6.97 - 7.36)

*: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.

100 (3.94) or more

Parking brake
Number of notches
[at pulling force 196 N
(20 kg, 44 Ib)]

6-8

Wheel bearing

Wheel bearing axle end
mm (in)
play
Wheel bearing lock nut
Tightening torque
N.m (kg-m, ft-Ib)

Front

Rear

0.03 (0.0012)
or less

0.05 (0.0020)
or less

-

-

147 216
(15 22,

235 314
(24-32,

108- 159)

174- 231)

Wheel balance
Wheel balance
(Maximum allowable unbalance
at rim flange)
g (OZ)
Tire balance weight

MA-21

g (OZ)

10 (0.35)

5.60 (0.18 -2.12)
Spacing 5 (0.18)

SERVICE DATA AND SPECIFICATI'ONS(S.D.S.)
Chassis and Body Maintenance (Cont'd)
TIGHTENING

TORQUE

Unit

N'm

Clutch
Pedal stopper lock nut
Clutch switch lock nut

16 22

- 15

1.6 - 2.2

12 - 16

12

1.2 - 1.5

9 - 11

Drain and filler plugs
Final drive
Drain plug

25

- 34

2.5 - 3.5

18 - 25

59 -98

6 - 10

43-72

Filler plug
Front axle and front

59 -98

6 - 10

43-72

37 - 46

3.8 - 4.7

27 - 34

12.6 - 14.6

91 - 106

Manual transmission

suspension
Tie-rod lock nut

kg-m

.

124

- 143

ft-Ib

Camber adjusting pin
Rear axle and rear
suspension
Toe adjusting pin

69 -88

7.0-9.0

51 - 65

Camber adjusting pin

69 -88

7.0-9.0

51 -65

7-9

Brake system
Air bleed valve

0.7 - 0.9

5.1 -6.5

Brake lamp switch lock
nut

12

- 15

1.2 - 1.5

9 - 11

Brake booster input
rod lock nut

16

-22

1.6 - 2.2

12 - 16

10.0 - 12.0

72 -87

Wheel and tire
Wheel nut

98 - 118

MA-22

ENGINEMECHANICAL

EM

SECTION

EM

CONTENTS
PRECAUTION

EM- 2

PREPARATION

EM- 3

OUTER COMPONENT PARTS

EM- 6

COMPRESSION PRESSURE

EM- 7

OIL PAN

EM- 8

TIMING CHAIN

EM-10

OIL SEAL REPLACEMENT

EM-16

CYLINDER HEAD

EM-18

ENGINE REMOVAL

EM-32

CYLINDER BLOCK

EM-34

SERVICE

DATA

AND

SPECIFICATIONS

(S.D.S.)

"""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
EM-46

PRECAUTION
LIQUID GASKET APPLICATION

~~
Groove

'

.

.

I~r
Side

Bolt hole

SEM371C

PROCEDURE

a. Before applying liquid gasket, remove all traces of old liquid
gasket from mating surface using a scraper.
b. Apply a continuous bead of liquid gasket to mating surface.
(Use Genuine Liquid Gasket or equivalent.)
c. Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide (for oil pan).
Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in)
wide (in areas except oil pan).
d. Apply liquid gasket to inner sealing surface around hole
perimeter area.
(Assembly should be done within 5 minutes after coating.)
e. Wait at least 30 minutes before refilling engine oil and engine
coolant.

EM-2

PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent.Moore No.)
Tool name

Description

ST0501S000
(

-

Disassembling and assembling

)

Engine stand
assembly
CD ST05011 000
(
)

-

Engine stand
@ ST05012000
(
Base

-

)

~

KV10105001
)
(
Engine attachment

-

KV101092SO
)
(
Valve spring
compressor

-

CD

Disassembling and assembling
valve components

CI<

KV10109210

-

(
)
Compressor
@KV10109220
)
(
Adapter

-

KV109B0010
(
)
Valve oil seal drift

-

~
Installing valve oil seal

~

KV10110300
(

-

Disassembling and assembling
piston with connecting rod

)

Piston pin press stand
assembly
CD KV10110310
(
)
Cap
@ KV10110330
(
)
Spacer
@ ST13030020
(
)
Press stand
@ ST13030030
(
)
Spring
@ KV10110340
(
)
Drift
@ KV10110320
(
)
Center shaft

3

~
?~~
EM-3

PREPARATION
Tool number
(Kent-Moore No.)
Tool name

Description

EM03470000
(J8037 )
Piston ring compressor

~

Installing piston assembly
into cylinder bore

(J36467)
Valveoil
seal remover

~

Displacement valve oil seal

KV10111100
(

-

)

Seal cutter

WS39930000

-

(
)
Tube presser

ST1661 0001
(J23907)
Pilot bushing puller

~
T

Removing oil pan

Pressing the tube of liquid
gasket

~

EM-4

PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name
Spark plug wrench

Description

c:Y

Q
16mm

(0.63 in)

Pulley holder

r

~

--

Valve seat cutter set

~
\

~~.-

Valve guide drift

installing

Holding camshaft pulley while
tightening or loosening camshaft
bolt

Finishing valve seat dimensions
.-

-

~

~

Piston ring expander

Removingand
spark plug

Removing and installing piston ring

Removing and installing valve guide
Diameter:

A¥:~

mm (in)

----

Intake

Exhaust

A

10.5 (0.413)

11.5 (0.453)

B

6.6 (0.260)

7.6 (0.299)

Reaming valve guide (CD) or
hole for oversize valve guide (@)

Valve guide reamer

Diameter:

~-

@

D.

EM;.5

mm (in)
Intake

Exhaust

01

7 (0.28)

8 (0.31)

Os

11.2 (0.441)

12.2'(0.480)

OUTER COMPONENT

PARTS

KA24E ENGINE

~

~

-

16 21 (1.6.2.1_,12

-15)

16

-21

(1.6

-21.

, 12-15)

B.P.T. valve
.
I A A umt

LI-I~~

I.-L
~

rA'..

(0.5-0.6,

3.6-4.3)

,r"

Adjusting bar

~

~~

142

10-12 (1.0-1.2,7 - 9)

-152(14.5- 15.5,105- 112)

~

: N.m (kg-m, ft-Ib)

rJ : Apply liquid gasket.
SEM336C

EM-6

COMPRESSION

PRESSURE

Measurement of Compression
1.
2.
3.
4.
5.

Pressure

Warm up engine.
Turn ignition switch off.
Disconnect fusible link for injectors.
Remove all spark plugs.
Disconnect distributor center cable.

Q)
6. Attach a compression tester to NO.1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
Always use a fully-charged battery to obtain specified
engine revolution.
Compression pressure:
kPa (kg/cm2,. psi)/rpm
Standard
1,324 (13.5, 192)/300
Minimum
981 (10, 142)/300
Difference limit between cylinders
98 (1.0, 14)/300
10. If cylinder compression in one or more cylinders is loyi. pour
a small amount of engine oil into cylinders through spark
plug holes and retest compression.
.
If. adding oil helps compression, piston rings may be worn
or damaged. If' so, replace piston rings after checking
piston.
If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. (Refer
to S.D.S.) If valve or valve seat Is damaged excessively,
replace them.
If compression in any two adjacent cylinders is low and if
adding oil does not help compression, there is I,akage
past the gasket surface. If so, replace cylinder head
gasket.

.

SEM 113B

.
.

.

EM-7

OIL PAN

Removal
1. Raise vehicle and support it with safety stands.
2. Drain engine oil.
3. Remove front stabilizer bar securing bolts and nuts from
side member.
4. Lift engine.

5. Remove oil pan bolts.
@
0

(jJ)
0

...Q...

2-

Front

0

@
@
Loosen bolts in reverse order.
@

SEM337C

6. Remove oil pan.
(1) Insert Tool between cylinder block and oil pan.
Do not drive seal cutter into oil pump or rear oil seal
retainer portion, or aluminum mating face will be damaged.
Do not insert screwdriver, or oil pan flange will be
deformed.

.
.

(2) Slide Tool by tapping its side with a hammer, and remove oil
pan.

SEM884A

7. Pull out oil pan from front side.

EM-8

OIL PAN
Installation
Scraper

1. Before installing oil pan, remove all traces of liquid gasket

.

from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
cylinder block.

SEM338C

2. Apply a continuous bead of liquid gasket to mating surface
of oil pan.
Use Genuine Liquid Gasket or equivalent.

.

SEM339C

Cut here.

~
Liquid gasket

.

Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.

:J
SLC906

7 mm 10.28

in)

--Lt-.

3. Apply liquid gasket to inner sealing surface as shown in
figure.
Attaching should be done within 5 minutes after coating.
4. Install oil pan.
Wait at least 30 minutes before refilling engine oil.

.
.

Inner
side

Groove

Bolt hole

SEM909B

EM-9

.

TIMING CHAIN

r
~
~

118.

Camshaft sprocket

'

,65787 - 1161

(1:~ain'tenSioner

7-8

08 5.'-5.81

(0.7.

. ,

~

~

~

~

rJ

~

I

L--.

Qj

Front cover

.~

.,
.

Crankshaft
sprocket

13-1.

(1.3 -1.9,
9 -141 .

L.

~

: N.m (kg-m, ft-Ibl

rJ : ApplV liquid gasket.

SEM578C

.

CAUTION:

\

After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.

EM-10

TIMING CHAIN
Removal
1.
2.
3.
4.

..
.

Disconnect battery terminal.
Drain coolant from radiator.
Remove radiator shroud and cooling fan.
Remove the following belts.
Power steering drive belt
Compressor drive belt
Alternator drive belt

5. Remove all spark plugs.
6. Set NO.1 piston,at T.D.C. on its compression stroke.

Q
Front

SEM199C

7. Remove the following parts.
Power steering pump, idler pulley and power steering pump
brackets
Compressor idler pulley
Crankshaft pulley
Oil pump with pump drive spindle

.
..
..

Rocker

SEM200C

SEM201C

EM-"

cover

.

TIMING CHAIN
Removal (Cont'd)
8. Remove oil pan. (Refer to OIL PAN.)
9. Remove front cover.

SEM202C

10. Remove the following parts.
. Chain tensioner
. Chain guides
. Timing chain and sprocket

.

Oil thrower, oil pump drive gear and crankshaft sprocket

Crank~h3ft
sprocket

SEM203C

Inspection
Check for cracks and excessivewear at roller links. Replace
if necessary.

Jf)
~

,~

'

SEM204C

EM-12

TIMING CHAIN
crankShaft
Crankshaft

~prOCket

~
~

Installation
1. Install crankshaft sprocket, oil pump drive gear and oil
thrower.
. Make sure that mating marks of crankshaft sprocket face
engine front.
.

"4~
.

O;I:;:~~~'\
n
~ 0
Front.

SEM205C

2. Install camshaft sprocket.
3. Confirm that NO.1 piston is set at T.D.C. on its compression
stroke.
4. Install timing chain.
Set timing chain by al.igning its mating marks with those of
crankshaft sprocket and camshaft sprocket.

~~~
'/0

~

(O@

.

\000
~.
'~ "

~

\\

II ~ Can ,",ocke<

))

"

ii

~r C"ok
.p-"

"

e: Punchmark
SEM206C

5. Tighten camshaft sprocket bolt.

6. Install chain guide and chain tensioner.

EM-13

TIMING CHAIN
Installation (Cont'd)
7. Apply liquid'gasket to front cover.
2.0

~

-3.0 mm

8. Apply lithium grease to sealing lip of crankshaft oil seal.

(0.079 . 0.118inl die.

9. Install front cover.
Be careful not to damage cylinder head gasket.
Do not forget 011seal.

..

SEM453C

10. Install rubber plug. (Refer to "Installation"
HEAD.)
11. Install oil pan. (Refer to Oil PAN.)

of CYLINDER

12. Install oil pump and distributor driving spindle with new
gasket in front cover.
(1) Assemble oil pump and driving spindle, aligning punchmark
on driving spindle with oil hole.

~

Punchmark

SEM212C

EM-14

TIMING CHAIN
Installation (Cont'd)
(2) Make sure that driving spindle is set as shown in figure.

Front

Q

SEM136C

13. Install distributor.
14. Make sure that NO.1 piston is set at T.D.C. and that
distributor rotor is set at NO.1 cylinder spark position.

Q
Front

SEM199C

EM-15

OIL SEAL REPLACEMENT
VALVE OIL SEAL
1. Remove rocker cover.
2. Remove rocker shaft assembly.
3. Remove valve spring and valve oil seal with Tool or suitable
tool.
Piston concerned should be set at T.D.C. to prevent valve
from falling.

(J36467)

KV10980010
(

-

4. Apply engine oil to new valve oil seal and install it with Tool.
Before installing valve oil seal, install valve spring seat.

)

15.6. 16.2
(0.614.0.638)

Valve
spring seat

Unit: mm (in)

SEM246C

OIL SEAL INSTALLING DIRECTION

Engine
inside

.

Oil seal lip

Engine
outside
Dust seal lip

SEM715A

FRONT OIL SEAL
1. Remove radiator shroud and crankshaft pulley.
2. Remove front oil seal.
Be careful not to damage crankshaft.

EM-16

9i-

SEAL REPLACEMENT
3. Apply engine oil to new oil seal and install it using suitable
tool.

SEM115B

REAR OIL SEAL
1. Remove flywheel or drive plate.
2. Remove rear oil seal retainer.
3. Remove traces of liquid gasket using scraper.

4. Remove rear oil seal from retainer.

.J'I;

l

it

5. Apply engine oil to new oil seal and install it using suitable
tool.

Diameter of
Iiqu id gasket:
2.0 - 3.0 mm

~ (0.079

6. Apply liquid gasket to rear oil seal retainer.

-

0.118 in)

EM-17

CYLINDER HEAD

~~-8
.,'0..

.0.8, 2.9' 5.8'

---Valve rocker cover-

Rocker cover gasket

~

37 - 41
(3.8 - 4.2, 27 - 30)

Valve and spring

Intake
Spring
retainer
Valve

'~w,

~

,\;~
~
,\
~J
@

,

~~

E'M":~

Oilseal

@

springseatA

\\

V"Wg";..~~
Valve seat

~

.

~

~

Cylinder head

\J @<~
'b@cg

~

Head bolt

~:

N'm (kg-m, ft-Ib)
SEM215C

EM-18

CYLINDER HEAD
CAUTION:
When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their
sliding surfaces.
. When tightening cylinder head bolts and rocker shaft bolts,
apply new engine oil to thread portions and seat surfaces
of bolts.

.

.

O.K.

Hydraulic valve lifters are installed in each rocker arm. If
hydraulic valve lifter is kept on its side, even when
installed in rocker arm, there is a possibility of air entering
it. After removal, always set rocker arm straight up, or
when laying it on its side, have it soak in new engine oil.

Ii
SEM878B

N.G.

.
.

Do not disassemble hydraulic valve lifter.
Attach tags to valve lifters so as not to mix them up.

SEM868B

Removal
1. Drain coolant from radiator and drain plug of block.
2. Remove the following parts.
Power steering drive belt
Power steering pump, idler pulley and power steering
brackets
Vacuum hoses of S.C.v. and pressure control solenoid valve
Accelerator wire bracket
3. Disconnect E.G.R. tube from exhaust manifold.
4. Remove bolts which hold intake manifold collector to intake
manifold.
5. Remove bolts which hold intake manifold to cylinder head
while raising collector upwards.
6. Remove rocker cover.
When removing rocker cover, do not hit rocker cover against
rocker arm.

.
.
..

EM-19

CYLINDER HEAD

~

Removal (Cont'd)
7. Set NO.1 piston at T.D.C. on its compression stroke.

-5/0°

5° 10° 15° 20°

Red painted

/

~
Front

SEM199C

8. Loosen camshaft sprocket bolt.
Support timing chain by using Tool as shown in figure.

.

SEM218C

9. Remove camshaft sprocket.

EM-20

CYLINDER HEAD
Removal (Cont'd)
10. Remove front cover tightening bolts to cylinder head.

SEM2106



Cam ;Urlace
I

I

ENGINE LUBRICATION SYSTEM
Oil Pressure Check
WARNING:
Be careful not to burn yourself, as the engine and 011may
hoL
/
011 pressure check should be done in "Neutral" gear
position.

.
.

1. Check oil level.
2. Remove oil pressure switch.

3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
ST25051 001
(J25695-1)

Engine rpm

Idle speed
3,000
SLC926

Approximate discharge pressure
kPa (kg/cm2, psi)
More than 78 (0.8, 11)
412-481
(4.2-4.9,60-70)

If difference is extreme, check oil passage and oil pump for
oil leaks.
6. Install oil pressure switch with sealant.

LC-4

ENGINE LUBRICATION SYSTEM
Oil Pump
\
Drive spindle

~tOJ

6. 10 (0.6 - 1.0,4.3.7.2)

--.::>/pump

body
Gasket

~

tOJ:

N.m (kg-m, ft-Ib)
SLC945

.

.

.

iT.

~~1~
Punch-

.

~AU)

Always replace with new oil seal and gasket.
When removing oil pump, turn crankshaft so that No.1
piston is at T.D.C. on its compression stroke.
When installing oil pump, align punchmark on drive spindle
and oil hole on oil pump.

mark
Oil

hole

~

Front

~~"4A
REGULATOR

VALVE INSPECTION

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.

.

EL076

LC-5

ENGINE LUBRICATION SYSTEM
Oil Pump (Cont'd)

~

OIL PRESSURE RELIEF VALVE INSPECTION
Inspect oil pressure relief valve for movement, cracks and
breaks by pushing the ball. If replacement is necessary, remove
valve by prying it out with suitable tool.
Install a new valve in place by tapping it.

-

OIL PUMP INSPECTION
Using a feeler gauge, check the following clearance.

CD

Unit: mm (in)

Rotor

Less than 0.12 (0.0047)

tip clearance CD

Outer rotor to body clearance

@

Side clearance (with gasket) CID

0.15 - 0.21 (0.0059 - 0.0083)
0.04 - 0.08 (0.0016 - 0.0031)

If it exceeds the limit, replace gear set or entire oil pump
assembly.

SLC732

LC-6

ENGINE COOLING SYSTEM
Cooling Circuit

~

Thermostat:

Open

~

Thermostat:

Closed

Radiator

Intake man ifold

Thermostat

SLC186A

System Check
WARNING:
Never remove the radiator cap when the engine is hot;
serious burns could be caused by high pressure fluid escaping from the radiator.
Wrap a thick cloth around cap and carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape and then turn the cap all the way off.
CHECKING

COOLING

SYSTEM HOSES

Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.

LC-7

ENGINE COOLING SYSTEM
System Check (Cont'd)
CHECKING COOLING SYSTEM FOR lEAKS
To check for leakage. apply pressure to the cooling system with
a tester.
Testing pressure:
98 kPa (1.0 kg/cm2, 14 psi)
CAUTION:

Higher than the specified pressure may cause radiator damage.
SMA990A

CHECKING RADIATORCAP
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
78

- 98 kPa (0.8 - 1.0 kg/cm2,11 - 14 psi)

SLC613

Water Pump

~
::~~~.~.~.m~

~

12'~'
\

~',P/

)!!7

.
SLC187A

INSPECTION
Check for excessive end play and rough operation.

(f

SLC738

INSTAllATION
Remove liquid gasket from mating surface of pump housing
using a scraper.

.
..

Be sure liquid gasket in grooves Is also removed.

,

Remove liquid gasket from mating surface of cylinder block.
Clean all traces of liquid gasket using white gasoline.

SLC188A

LC-8

ENGINE COOLING SYSTEM
Water Pump (Cont'd)

.
.

Cut off tip of nozzle of liquid gasket tube at point shown in
figure.
Use Genuine Liquid Gasket or equivalent.

.

Apply a continuous bead of liquid gasket to mating surface

Cut here.

~

]

KP510-00150

SLC822

Diameter of liquid gasket:
2.0.3.0
mm 10.079.0.118

of pump housing as shown.
a. Be sure diameter of liquid gasket Is within 2.0 to 3.0 mm
(0.079 to 0.118 In) dla. range.
b. Attach pump housing to cylinder block within five minutes
of applying liquid gasket.
c. After Installing pump housing, walt at least 30 minutes
before starting engine.

in)

SLC189A

Thermostat
INSPECTION
1. Check for valve seating condition at ordinary temperatures.
It should sea.ttightly.

Water inlet
SLC192A

.

2. Check valve opening

Upward

Jiggle valve

~~

A~

~

--~

temperature and maximum valve lift.

Valve opening temperature
°c (oF)

76.5 (170)

Max. valve lift
mmfC (infF)

8/90 (0.31/194)

3. Then check if valve closes at 5°C (9°F) below valve opening

.
SLC097

temperature.

.

After Installation, run engine for a few minutes, and check>.,
for leaks.

SLC343

LC-9

ENGINE COOLING SYSTEM
Thermostat

(Cont'd)

(

INSTAllATION

.
.

.

Remove liquid gasket from mating surface of thermostat
using a scraper.
Similarly, remove liquid gasket from mating surface of
cylinder block.
Clean all traces of liquid gasket using white gasoline.

.
.

Cut off tip of nozzle of liquid gasket tube at point shown in
figure.
Use Genuine LiqLJidGasket or equivalent.
..~

SLC790

Cut here.

~

KP510.()0150

]
SLC822

.

Apply a continuous bead of liquid gasket to mating surface
of water inlet.
a. Be sure diameter of liquid gasket is within 2.0 to 3.0 mm
(0.079 to 0.118 in).
b. Attach water inlet to cylinder block within five minutes
after applying liquid gasket.
c. After installing water inlet, wait at least 30 minutes before
refilling coolant and starting engine.

SLC824

'(
.~

LC -1 0

ENGINE COOLING SYSTEM

Radiator
A/T model only
~3 2 -4.2
10.33-0.43,

2.4-3.1)

7~

Automatic
transmission

~

@I

~

'~
~~3.2
-4.2
. ,""lIlY
10.33-0.43,2.4 -3.1)

LJ

~:

Radiator shroud

N-mIkg-m,ft-lb)

SLC190A

CAUTION:
When filling radiator with coolant, refer to MA section.

Cooling Fan
DISASSEMBLY AND ASSEMBLY

-~

'\"

<1( L-.J

V

~

~:

Fan

N'm (lrg-m;ft-Ibl

\~ ~o.~~1.0,4.3-7.2)

SLC558

INSPECTION
Check fan coupling for rough operation, oil leakage or bent
bimetal.

SLC072

LC-11

BATTERY
fus Ib I e

I GNI TI ON SWITCH
ACC or- ON

I GNITI ON SWITCH
ON or- START

FUSE

AIR

@D~

CONDI TI ON

RELAY

36

r(")

t'1
P
P

11

!fI

N

41

n
a
z
-I
::0
a
r
c
z
....
-I

I
~

THERMOSWITCH

To ther-mo

contro

I amp.

M
41
-=

36

0
!II
r
0
I\,)
w
m

»

@4Ib

CONDENSER
FAN MOTOR

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT
Wiring Diagram
AIR

=
(Sub-h arness)

~
-

CONNECTOR-ll

CONDENSER
F AN
MOTOR

I

~

@)

~ mIi]

Ie

lR;l ~
't1H

Ilnk-

Ii [!t

L/OR

I

~::;CD

~

~13Id
~

[!t

S.

M.

[Refer to
(Fo Idout

y..>r;;;,

-

,

CD

lBIB@
[EttBr;;--,

~
(E. F. I.
harness)

@l@)

1i

r--

>-

'" '"

I

,
'"
,

@

IGNITION
ON or

~

,,
CD...)
, ,
...

To thermo

SWITCH
START

contro

I amp.

-

'"...

BODY GROUND

E. ~ ~ S
(Refer to

CONTROL UNIT
EF&EC sect Ion. )

SLC238A

LC-13

SLC191A

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT
Trouble Diagnosis

m

@i5

Even though air conditioner operates normally under high
engine temperature conditions [above 9SoC (20SoF)] the
condenser fan motor does not rotate.

00

'+
L:::

m

-

000

-=
SLC239A

m

_MEeT

Iu

CHECK POWER SUPPLY
(Motor side).
1) Disconnect condenser fan
motor harness connector-H.
2) Turn ignition switch, air conditioner switch and blower
switch "ON".

@i5
[]I]

SLC241A

N.G.

lu

SLC242A

i5

0

Repair or replace harness
between terminals @
and @.

O.K.

CHECK POWER SUPPLY
(Relay side).
1) Turn ignition "OFF".
2) Disconnect air conditioner
relay.
3) Turn ignition "ON".
4) Check voltage between
terminals @, @ and ground.
Battery voltage should exist.

Check sub-harness for thermoswitch continuity. If N.G., repair
or replace them.

@is
N.G.
L--to

Check the followings:
8 Harness continuity between

terminal @ and battery

I

@is

CHECK RELAY.
Refer to HA section.
O.K.
E

N.G.

r Replace relay.

LC-14

Check the followings:
8 Harness continuity between

terminal @ and battery
l.

-=
SLC243A

EB

terminal.
8 "G" fusible link
If N.G. replace them.

O.K.

00

00

O.K.

CHECK THERMOSWITCH.
Check continuity between
thermoswitch terminals @ and
CD.
Condition
ContinuitY
Above
Yes
92 -98°C (198 -2OS°F)
Below
No
92 -98°C (198 -2OS°F)

iii

DISCONNECT

.

Ii]

lo.K.

'

-

CHECK GROUND CIRCUIT.
Check harness continuity between motor harness connector-I
terminal @ and ground.
Continuity should exist.
If N.G., repair harness.

CHECK POWER SUPPLY
(Motor side).
1) Turn ignition switch "OFF"
2) Disconnector fan motor
harness connector-I.
3) Turn ignition switch "ON".
4) Check voltage between
terminal @ and
ground.
Battery voltage should exist.

-

Ii

[!]

Ii
SLC240A

CHECK CONDENSER FAN
MOTOR.
1) Turn ignition and air conditioner switch "OFF".
2) Disconnect condenser fan
motor harness connector-I.
3) Check continuity between
connector-H terminal @ and
connector-I terminal @.
Continuity should exist.
If N.G. replace condenser fan
motor-.
O.K.

N.G.

iJ

Ii]

O.K.

3) Check voltage between fan
motor harness connector-II
terminal @ and ground.
Battery voltage should exist.

[ill

[!]

m

1

terminal
8 Fuse
8 Ignition switch

EB

I

CONDENSER FAN MOTOR ELECTRICAL CIRCUIT
Trouble Diagnosis (Cont'd)

iii
34

~

i5l
0

-=

SLC244A

[it

lOK

CHECK HARNESS
CONTINUITY,
1) Turn ignition switch "OFF",
2) Check continuity between
relay harness connector
terminal @ and fan motor
harness connector-I terminal
@.
Continuity should exist.

N.G.

Repair or replace harness or
connectors between terminals
@ and (d) .

[R]

~i5@

SLC245A

"-

LC-15

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Engine Lubrication System
Oil pump

Oil pressure check

Unit:

Engine rpm

Approximate discharge pressure
kPa (kg/em' , psi)

Idle speed

More than 78 (0.8, 11)

412.481 (4.2.4.9,60

3.000

Rotor tip clearance

- 70)

mm (in)

Less than 0.12 (0.0047)

Outer rotor to body clearance

0.15 - 0.21 (0.0059 - 0.0083)

Side clearance (with gasket)

0.04 - 0.08 (0.0016.0.0031)

Engine Cooling System
Thermostat

Radiator

Valve opening temperature
Max. valve lift

mmfc

°c (OF)

76.5 (170)

(infF)

8/90 (0.31/194)

Unit: kPa (kg/em'
Cap relief pressure
Leakage test pressure

.

lC-16

78

.psi)

-98 (0.8 - 1.0, 11 - 14)
98 (1.0, 14)

/"

ENGINEFUEL&
EMISSION
-CONTROL
SYSTEM

SECTIONEF

&

EC

CONTENTS
PREPARATION

... EF & EC-

2

PRECAUTIONS """""""""""""""'"''''''''''''''''''''''''''''''''''''

EF & EC-

3

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

EF & EC-

4

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

EF & EC-

9

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

EF & EC- 16

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

EF & EC- 26

TROUBLE DIAGNOSES

EF & EC- 31

FUEL INJECTION CONTROL SYSTEM INSPECTION

EF & EC-153

EVAPORATIVE EMISSION CONTROL SYSTEM

EF & EC-155

CRANKCASE EMISSION CONTROL SYSTEM

EF & EC-157

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

EF & EC-158

When you read wiring diagrams:
. Read GI section, "HOW TO READ WIRING DIAGRAIVIS".
See El section, "POWER SUPPLY ROUTING" for power distribution circuit.

.

When you perform trouble diagnoses, read GI section, "HOW TO FOllOW
FLOW CHART IN TROUBLE DIAGNOSES".

E.C.C.S. Wiring Diagram -

See pull-out following EL section.

-

/

PREPARATION
SPECIAL SERVICE TOOL
Tool number
(Kent-Moore No.)
Tool name
EG11160000
(

-

)

Ignition coil adapter
harness

Description

~

EF & EC-2

Measuring
engine speed

PRECAUTIONS
E.C.U.
Do not disassemble E.C.C.S.
control unit. (E.C.U.)
Do not turn diagnosis mode
selector forcibly.

.
.

.

.
.

If a batteryterminalis disconnected, the memory will return
to the ROM value. The E.C.C.S.'
will now start to self-control at
its initial value. Engine operation can vary slightly when the
terminal is disconnected. However, this is not an indication
of a problem. Do not replace
parts because of a slight variation.

.

.

.

Do not apply undue force to
mounting bracket.
Before connecting or disconnecting E.C.U. connector, make
sure red and green LEOs are
off after turning ignition key off.
Always install the properly
specified E.C.U. on car; otherwise, erroneous engine operation may result.
Disconnect connector by pulling it (not the harness) straight
out.
Before connecting connector,
make sure all pins are straight.

BATTERY
. Always use a 12 volt battery as
a power source.

.

.

WIRELESS EQUIPMENT
When installing a C.B. ham
radio or a mobile phone, be
sure to observe the following,
as installation location may affect the electronic control systems.
1) Keep antenna as far as possible away from electronic control units.
2) Keep antenna feeder line more
than 20 cm (7.9 in) away from
harness of electronic controls.
Do not let them run parallel for
a long distance.
3) Adjust antenna and feeder line
so that standing-wave ratio can
be kept smaller.
4) Be sure to ground radio to vehicle body.

.

INJECTOR
Do not disconnect injector har~
ness connectors with engine
running.
Do not apply battery power directly to injectors; otherwise
injectors will be damaged.

.

Do not disconnectbattery

.

cables while the engine is running.
Do not reverse polarity of battery when connecting it. Otherwise, E.C.U. and/or injectors
may be burned.

FUEL PUMP
Do not operate fuel pump
when there is no fuel in lines.
Do not reuse fuel hose clamps.
Tighten fuel hose clamps to
the specified torque.

.
..

E.C.C.S. PARTS HANDLING
Handle air flow meter carefully
to avoid damage.
Do not disassemble air flow
meter.
Do not clean air flow meter
with detergent.
.
Do not jolt or jar the crank
angle sensor.

.
.
.

~~
WHEN STARTING
Do not depress accelerator
pedal when starting.
Immediately after starting, do
not rev up engine unnecessarily.
.
Do not rev up engine just prior
to shutdown.

.
.

SEF121H

EF & EC-3

E.C.C.S. HARNESS HANDLING
Securely connect E.C.C.S. harness connectors.
A poor connection can cause
extremely high voltage to develop in the coil and condenser,
resulting in damage to ICs.
Keep E.C.C.S. harness at least
10 cm (3.9 in) away from adjacent harnesses, to prevent an
E.C.C.S. systerri malfunction
due to receiving external noise,
degraded operation of ICs, etc.
Keep E.C.C's' parts and harnesses dry.
Before removing parts, turn off
ignition switch and then disconnect battery ground cable.

.

.
.
.

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
E.C.C.S./Component Parts Location

.

E.C.C.S.relay

. Fuelpumprelay

Fuel pump

-E.G.R. control valve
Exhaust gas
temperature sensor
(For California model)

Pressure regulator

~~b

Pressure
regu lator control
solenoid valve

~

LA.A. unit

S.C.V.control

~'iWIW

~.~,
Fuel filter

e
A'I'V'

.

~
~

"

I

control
solenoid
valve

.

0
a

Ignition coil and
power transistor

~

~~
G

E. .R . control
solenoid valve

Distributor

-.w~
..f ~~;:~~
sensor

.

~.,~.
~"

A;,flowm.'"

Exhaust gas
sensor

SEF122H

EF & EC-4

E.G.R. control
Exhaust gas temperature sensor I.
(For California model)
\

\

solenoid valve7

/

\

"\

Ignition

\

switch

Throttle
valve

B

.sensol
7

~

: -'r---~-L-

m

"TI
J20

m
(")

\

Crank angle sensor
built-in distributor

I
C1I

lFuel pressure
regulator
I'.
!..
Engine

temperatu re
sensor

Transmission

~

lSJ

\'1'

!

\.Spark

C.

Vehicle
speed sensor

~

plug

\1

'11

Carbon
canister

Exhaust
gas sensor

A.I.V. control
solenoid valve
A.I.V.
Q:
en
m

-'"

"TI

w
:I

...:

Intake air flow

Exhaustgasflow

Air flow me

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
System Chart

E.C.C.S. CONTROL SYSTEM
I

Crankanglesensor

[

Air flow meter

!

r

.1
I

Exhaust gas sensor

[

Ignition switch

1

Starter switch

[

Idle switch

!

Throttle sensor

.

Power transistor

Idle speed control

Auxiliary air control
(A.A.CJ valve

A.I.V. control

A:I.V. control solenoid valve

E.G.R. control &
Canister control

E.G.R. control solenoid
valve

.

.
.
.
"

Air conditioner switch

Ignition timing control

.

~

[

Injectors

.

Engine temperature sensor

[

Fuel injection &
mixture ratio control

.

E.C.C.S.
control
unit

,"

Fuel pump control

-

Fuel pump

.~
Air regulator control

Air regulator

Acceleration cut
control

Air conditioner relay

S.C.V. (Swirl control
valve)control

S.C.V. control
solenoid valve

Exhaust gas sensor
monitor & self-diagnosis

Inspection lamps
(On the control unit)

Pressu re regu lator
control

Pressu re regulator control
solenoid valve

Neutral switch (M/T)
Inhibitor switch (AiT)

[

Vehicle speed sensor

.

Power steering oil pressure
switch

[

Battery

.

Exhaust gas temperature sensor
(For California model)

Fail-safe function

. Air flowmeter
. Throttle sensor
. Enginetemperaturesensor

EF & EC-6

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Vacuum Hose Drawing
s.c. V. actuator

@
-@-a

@-b
E.G.R. control
valve

~TWI~
@

@

Air regurator

tJi)
@ ./"'1

Canister

@

@/
1

Vacuum tubes-1
Air duct

SEF355H

EF 8r. EC- 7

I GNITION SWITCH
OFFACCON ST

FUSIBLE
LINK

-c8J-

CK

(

Ij/]

(
(

'-:::./
CHECK

FUSE
J-----rs}
r<:::"7I

46
NJ. NlOR

E. C. C. S.
RELAY
--

m

gAUST

To tachometer

SENSOR

::-

."

I

mm-

I "-------1

f20

m

RESISTOR

TRANSISTOR

{O

(")

PDWER

I

DISTRIBUTOR

rm
J>r
-<

"U
:[
c :]

L.:::T

AIR

108--<

3

>J
>J

116 --<

I

en

45

6

("")
0

43

Z
-i
;0
0
r
c
Z
....
-i

CONDENSER

co- co-

co- co-

ANGLE
SENSOR

SPARK PLUG

)

:

For

tt

11

Cal ifornla

M

REGULATOR

PUMP
::-

=

=

--

:

A/T

model

For

@:

M/T model

@:

For

5TH POSITION
SWITCH

(/)
m
"
w
0.....
:x:

With

:

Without

heaa-up

display

SWITCH

-v<::,...FULL
'Q

NEUTR

' SWITC

35
41
II

ENGINE
TEMPERATURE

-

3D
31

18

22
4D

8

$

SENSOR
EXHAUS T GAS

37

Canada

32
lIS

SENSOR
C
TEMPERA@URE

-n ------__n_--_n_n--_--_--_----

.HEAD-U
DISPLA
UNIT

THROTTLE

.

f

SENSOR

CONT
(

-

MJ

1 I I
r---

28

A/T
UNIT
CONTR&L

display

head-up

VALVE

IDLE

I

:

THROTTLE

POWER
STEERING
OIL PRESSURE

33

U. S. A.

A.S. C.D.

-=

44

: A/T modeI wi th A.S. C.D.
: A/T mode I without

I NHIB
RELA

M

::- SWI TCH

2D
:

I NHI B
RELAY
r-=

VALVE

FUELL..:....J
[Tl

W

CRANK

!:

...----J

SWITCH
I NHI BIT

29

co-

lIB;

L..::..:J

21--

I

::I
"U

L..::J

107

13

I

I

L::...J
A. A. C.

113
104

I GNITI ON COIL

I

co

VALVE

S. C. V. CONTROL
SOLENOID VALVE

12

16
17
39
48
19

SOLENOID

A. 1. V. CONTROL
SOLENOID VALVE

109

METER

REGULATOR

E. G. R. CONTROL
SOLENOID VALVE

102

4
47

PRESSURE

CONTROL

IDS

112

::-

LI
GHT C
ENGINE@
5
24
25

106

110

No. 4r:::=
L....:-

I

CONNECTOR

=

\

'--

Q

SENSOR

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION
E.C.C.S. Control Unit (E.C.U.)
The EC.U. consists of a microcomputer, inspection lamps, a.
diagnostic mode selector, and connectors for signal input and
output and for power supply. The unit controls the engine.

Crank Angle Sensor

Photo

diode

Wave
forming
SEF613B

circuit

Rotor

plate

1800 signal slit for No.1 cylinder

The crank angle sensor is a basic component of the entire
EC.C.S. It monitors engine speed and piston position, and
sends signals to the E.C.U. to control fuel injection, ignition
timing and other functions.
The crank angle sensor has a rotor plate and a wave-forming
circuit. The rotor plate has 360 slits for 10 signal and 4 slits for
1800 signal. Light Emitting Diodes (L.ED.) and photo diodes are
built in the wave-forming circuit.
When the rotor plate passes between the L.E.D. and the photo
diode, the slits in the rotor plate continually cut the light being
transmitted to the photo diode from the L.ED. This generates
rough-shaped pulses which are converted into on-off signals by
the wave-forming circuit, which are then sent to the E.C.U.

SEF853B

Rotor plate

Air Flow Meter

A
Air flow
meter

B
c

Battery
sou rce
Output voltage
Ground

16
E.C.C.S.
17 control
unit
109

SEF285H
Temperature
compensation

I

resistor

.. r-f

The air flow meter measures the mass flow rate of intake air.
Measurements are made so that the control circuit will emit an
electrical output signal corresponding to the amount of heat
dissipated from a hot wire placed in the stream of intake air.
The airflow past the hot wire removes the heat from the hot
wire. The temperature of the hot wire is very sensitive to the
mass flow rate. The higher the temperature of the hot wire, the
greater its resistance value. This temperature change (resistance) is determined by the mass air flow rate. The control
circuit accurately regulates current (I) in relation to the varying
resistance value (RH) so that VA always equals VB. The air flow
meter transmits a voltage value VA to the control unit where the
output is converted into an intake air signal.

RH;:~-Hotwire

RH
RK
RA. RB

: Hot wire resistance
: Temperature compensation resistance
: Constant resistance
SEF617B

EF & EC-9

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION
Engine Temperature Sensor
The engine temperature sensor detects the engine temperature,
which is dependent on engine coolant temperature, and transmits a signal to the E.C.U.
The temperature sensing unit employs a thermistor which is
sensitive to the change in temperature. Electrical resistance of
the thermistor decreases in response to the temperature rise.

Throttle Sensor & Soft/Hard Idle Switch
The throttle sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms
the throttle valve position into output voltage, and emits the
voltage signal to the E.C.U. In addition, the sensor detects the
opening and closing speed of the throttle valve and feeds the
voltage signal to the E.C.U.
Idle position of the throttle valve is determined by the E.C.U.
receiving the signal from the throttle sensor. This system is
called "soft idle switch" and controls engine operation such as
fuel cut. On the other hand, "hard idle switch", which is built in
the throttle sensor unit, is used not for engine control but for
self-diagnosis.

SEF903D

>

~

Not used

.,---0'---

~
~

E

(Full throttle

~:50

Idle
switch

Z

Throttle
sensor

.§ 4.0

switch)

2
3 )

:

Supply voltage:
5V (Applied between

terminal

NO.4 and 6)

6.0
Output voltage between
terminal NO.4 and 5

~
~
'"
!'"
-0

6}

f2.0

~
5

6

g
...
"

9"
0

0

0

45
90
Throttle valve opening angle (deg)

135

SEF287D

Fuel Injector
The fuel injector is a small, elaborate solenoid valve. As the
E.C.U. sends injection signals to the injector, the coil in the
injector pulls the needle valve back and fuel is released ,into the
intake manifold through the nozzle. The injected fuel is controlled by the E.C.U. in terms of injection pulse duration.
Brass wire is used in the injector coil and thus the resistance is
higher than a conventional injector.
SEF359H

EF &. EC-10

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Pressure Regulator

0 vacuum
Intake manifold

The pressure regulator maintains the fuel pressure at 299.1 kPa
(3.05 kg/cm2, 43,4 psi). Since the injected fuel amount depends
on injection pulse duration, it is necessary to maintain the
pressure at the above value.

Air chamber

Q

Fuel chamber

Fuel return
from injector

To
fuel tank Q
SEF6058

Exhaust Gas Sensor
Louver

Connector

Holder

Isolation bushing
Contact plate
SEC336A

?:

1

;;
'"
0>
~0

The exhaust gas sensor, which is placed into the exhaust
manifold, monitors the amount of oxygen in the exhaust gas.
The sensor has a closed-end tube made of ceramic zirconia.
The outer surface of the tube is exposed to exhaust gas, and
the inner surface to atmosphere. The zirconia of the tube
compares the oxygen density of exhaust gas with that of
atmosphere, and generates electricity. In order to improve the
generating power of the zirconia, its tube is coated with
pratinum. The voltage is approximately 1V in a richer condition
of the mixture ratio than the ideal air-fuel ratio, while approximately OV in leaner conditions. The radical change from 1V to
OV occurs at around the ideal mixture ratio. In this way, the
exhaust gas sensor detects the amount of oxygen in the
exhaust gas and sends the signal of approximately 1V or OV to
the E.C.U.

>
...
:J
C.

8 0I
Rich

---

~
I
Ideal ratio

--Lean

Mixture ratio

SEF288D

Fuel Pump

Outlet
0

Fuel damper

The fuel pump with a fuel damper is a submergible type, and
are located in the fuel tank.

Motor

1)
Inlet

SEF043C

Power Transistor
The ignition signal from the E.C.U. is amplified by the power
transistor, which turns the ignition coil primary circuit on and off,
inducing the proper high voltage in the secondary circuit. The
ignition coil is a small, molded type.

SEF125H

EF & EC-11

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION
Air Regulator

-

The air regulator provides an air by-pass when the engine is
cold for a fast idle during warm-up.
A bimetal, heater and rotary shutter are built into the air
regulator. When the bimetal temperature is low, the air by-pass
port opens. As the engine starts and electric current flows
through a heater, the bimetal begins to turn the shutter to close
the by-pass port. The air passage remains closed until the
engine stops and the bimetal temperature drops.
SEF636B

Idle Air Adjusting (I.A.A.) Unit
The I.A.A. unit is made up of the AA.C. valve, F.I.C.D. solenoid
valve and idle adjust screw. It receives the signal from the E.C.U.
and controls the idle speed at the preset value.
The F.I.C.D. solenoid valve compensates for changes in idle
speed caused by the operation of. the air compressor. A
vaCl/um control valve is also installed in this unit to prevent an
abnd'rmal rise in intake manifold vacuum pressure during deceleratton.

Idle
adjusting
screw

SEF126H

Auxiliary Air Control (A.A. C.) Valve
The E.C.U. actuates the A.A.C. valve by an ON/OFF pulse. The
longer that ON pulse is received, the larger the amount- of air
that will flow through the A.A.C. valve.

Air
SEF040E

Power Steering Oil Pressure Switch
The power steering oil pressure switch is attached to the power
steering high-pressure tube and detects the power steering
load, sending the load signal to the E.C.U. The E.C.U. then
sends the idle-up signal to the I.S.C. valve.

SEF286H

Magnetic

\ /'

Vehicle Speed Sensor

line

Reed

Reed

~SWitch
N S

(sS
I

G:0

Fieldplate

N

M;;Qnetic
I.me I\

//

\

"{

N) switch

t;\

The vehicle speed sensor provides a vehicle speed signal to the
E.C.U.
The speed sensor consists of a reed switch, which is installed
on the transmission unit and transforms vehicle speed into a
pulse signal.

y-/

Fieldplate
SEF624B

EF & EC-12

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

E.G.R. Control Valve
The E.G.R. control valve controls the quantity of exhaust gas to.
be led to the intake manifold through vertical movement of the
taper valve connected to the diaphragm, to which vacuum is
applied in response to the opening of the throttle valve.

SEF632B

B.P.T. Valve

To E.G.A.
control valve

Vacuum signal source

Air
filter

".'.1'
~~~'ff'

The B.P.T. valve monitors exhaust pressure to activate' the
diaphragm, controlling throttle chamber vacuum applied to the
E.G.R. control valve. In other words, recirculated exhaust gas is
controlled in response to positioning of the E.G.R. control valve
or to engine operation.

t
Exhaust pressure

EC344A

Air Induction Valve (AJ.V.)
The air induction valve sends secondary air to the exhaust
manifold, using a vacuum created by exhaust pulsation in the
exhaust manifold. When the exhaust pressure is below atmospheric pressure (negative pressure), secondary air is sent to the
exhaust manifold. When the exhaust pressure is above atmospheric pressure, the reed valves prevent secondary air from
being sent back to the air cleaner.
SEF127H

EF & EC-13

\.

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION
A.I.V. Control Solenoid Valve
The A. LV. control solenoid valve cuts the intake manifold
vacuum signal for A.I.V. control. It responses to the ON/OFF
signal from the E.C.U: When the solenoid is off, the vacuum
signal from the intake manifold is cut. When the control unit
sends an ON signal, the coil pulls the plunger downward and
feeds the vacuum signal to the A.I.V. control valve.

E.G.R. Control Solenoid Valve
SEF287H

The E.G.R. system is controlled only by the E.C.U. At both lowand high-speed engine revolutions, the solenoid valve turns on
and accordingly the E.G.R. valve cuts the exhaust gas leading
to the intake manifold.

Pressure Regulator (P.R.) Control Solenoid
Valve
The solenoid valve responds to the ON/OFF signal from the
E.C.U. When it is off, a vacuum signal from the intake manifold
is fed into the pressure regulator. When the control unit sends
an ON signal, the coil pulls the plunger downward and cuts the

vacuum signal.

S.C.V. Control Solenoid Valve
The S.C.V. control solenoid valve cuts the intake manifold
vacuum signal for swirl control valve. It responds to the
ON/OFF signal from the E.C.U. When the solenoid is off, the
vacuum signal from the intake manifold is cut. When the control
unit sends an ON signal the coil pulls the plunger and feeds the
vacuum signal to the swirl control valve actuator.

Fuel Filter
The specially designed fuel filter has a metal case in order to
withstand high fuel pressure.

SEF256A

Carbon Canister
The carbon canister is filled with active charcoal to absorb
evaporative gases produc~d in Jhe fuel tank. These absorbed
gases are then delivered to the intake manifold by ,manifold
vacuum for combustion purposes.
The vacuum in the intake passage upstream of the throttle valve
increases in response to the amount of the intake air.
When the vacuum of the intake passage is higher than a preset
value, the 2nd purge control valve opens and the absorbed
gases are sucked into the intake passage for combustion
purposes.

EF & EC-14

.

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION
Check Connector for E.C.C.S. Checker Box
The check connector for E.C.C.S. checker box is beside fuse

box.

.

SEF296H

Exhaust Gas Temperature Sensor
(For California model)
The exhaust gas temperature sensor monitors in exhaust gas
temperature and transmits a signal to the E.C.U. The temperature sensing unit employs a thermistor whi~h is sensitive to the
change in temperature. Electric resistance of the thermistor
decreases in response to the temperature rise.

SEF072G

\.

EF &. EC-15

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fuel Injection Control
INPUT/OUTPUT SIGNAL 'LINE
Engine speed and piston position
Crank angle sensor

Amount of intake air

Air flow meter

.

Engine temperature
Engine temperature

sensor
Density of oxygen in exhaust gas

Exhaust gas sensor

Throttle

sensor

Throttle valve position

Throttle valve idle position

Idle switch

Neutral switch (MfT)
Inhibitor switch (AfT)

E.C.C.S.
control
unit

Injector

Gear position

Vehicle speed
Vehicle speed sensor

Ignition switch

Start signal

Battery voltage
Battery

BASIC FUEL INJECTION

CONTROL

The amount of fuel injected from the fuel injector, or the length
of time the valve remains open, is determined by the E.C.U. The
basic amount of fuel injected is a programmable value mapped
in the E.C.U. ROM memory. In other words, the programmable
value is preset by engine operating conditions determined by
input signals (for engine rpm and air intake) from both the crank
angle sensor and the air flow meter.

~i
Low

-

Water temperature

High
SEF923C

VARIOUS FUEL INJECTION INCREASE/DECREASE
COMPENSATION
In addition, the amount of fuel injection is compensated for to
improve engine performan~e under various operating conditions
as listed below:

1) During warm-up
2) When starting the engine
3) During acceleration
4) Hot-engine operation

1) During deceleration

EF & EC-16

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fuel Injection Control (Cont'd)
CLOSED LOOP
CONTROL

)

FeedAgnal
Exhaust

~
E.C:C.S.'
control
~nit
/ .
ection pulse

e

~

InJ

(gas
sensor) t\

combusti~

Injector

injection

~

SEF639B

MIXTURE RATIO FEEDBACK CONTROL
Mixture ratio feedback system is designed to precisely control
the mixture ratio to the stoichiometric point so that the
three-way catalyst can reduce CO, HC and NOx emissions. This
system uses an exhaust gas sensor in the exhau,st manifold to
check the air-fuel ratio. The control unit adjusts the injection
pulse width according to the sensor voltage so the mixture ratio
will be within the range of the stoichiometric air-fuel ratio.
This stage refers to the closed-loop control condition. The
open-loop control condition refers to that under which the
E,C.U. detects any of the following conditions and feedback
control stops in order to maintain stabilized fuel combustion.
1) Deceleration
2) High-load, high-speed operation
3) Engine idling
4) Malfunctioning of exhaust gas sensor or its circuit
5) Insufficient activation of exhaust gas sensor at low engine
temperature
6) Engine starting
MIXTURE RATIO SELF-LEARNING

CONTROL

The mixture ratio feedback control system monitors the mixture
ratio signal transmitted from the exhaust gas sensor. This
feedback signal is then sent to the E.C.U: to control the amount
of fuel injection to provide a basic mixture ratio as close to the
theoretical mixture ratio as possible. However, the basic mixture
ratio is not necessarily controlled as originally designed. This is
due to manufacturing errors (e.g., air flow meter hot wire) and
changes during operation (injector clogging, etc.) of E.C.C.S.
parts which directly affect the mixture ratio.
Accordingly, a difference between the basic and theoretical
mixture ratios is quantitatively monitored in this system. It is
then computed in terms of "fuel injection duration" to automatically compensate for the difference between the two ratios.
FUEL INJECTION TIMING
No.1 CYlinder

fL

Injection pulse

rL

No.2 cylinder

n

No.3 cylinder

n

No.4 cylinder

1---1

SEF976E

enginecycle--j

No.1 cylinderJl

n

No.2 cylinder.Jl

n

No.3 cylinder.Jl

n

1L1LfL-

.
No. 4 cyIInd er J1

n

f"L-

~

Fuel is injected once a cycle for each cylinder in the firing order.

1 engine cycle

When engine starts, fuel is injected
simultaneously twice a cycle.

j

SEF841D

EF & EC-17

into all four cylinders

,

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fuel Injection Control (Cont'd)
FUEL SHUT-OFF

Fuel to all cylinders is cut off during deceleration or high-speed
operation.

Ignition Timing Control
INPUT/OUTPUT SIGNAL LINE
Engine speed and piston position
Crank angle sensor
Amount of intake air
Air flow meter
Engine temperature

Enginetemperature sensor
Idle switch

Throttle sensor

Neutral switch (MfT)
Inhibitor switch (AfT)

Throttle valve idle position

E.C.C.S.
control
unit

Throttle valve opening angle

Neutral position

Start signal
Ignition switch

,
E.

EF & EC-18

Power transistor

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Ignition Timing Control (Co nt' d)
SYSTEM DESCRIPTION
The ignition timing is controlled by the E.C.U. in
order to maintain the best air-fuel ratio in response to every running condition of the engine.
The ignition timing data is stored in the ROM
located in the E.C.U., in the form of the map
shown below.
The E.C.U. detects information such as the injection pulse width and crank angle sensor signal
which varies every moment. Then responding to
this information, ignition signals are transmitted to
the power transistor.
e.g.
N: 1,800 rpm, Tp: 1.50 msec
A °S.T.D.C.

In addition to this,
1 At starting
2 During warm-up
3 At idle
4 At low battery voltage
5 During swirl control valve operates
6 Hot engine operation
7 At acceleration
the ignition timing is revised by the E.C.U. according to the other data stored in the ROM.

Tp
(msec)
I

1.75I

A

1.50I
Injection
pulse
width

1.25 I

1.00 I

0.75 I

---

600

- ---

1,000

-1,400
---

1,800

N
2,200

Engine speed (rpm)
SEC750A

EF & EC-19

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Idle Speed Control
INPUT/OUTPUT SIGNAL LINE
Engine speed
I

I

Crank angle sensor

Enginetemperature sensor

1
I

I

Ignition switch

I

Engine temperature

Start signal

.

Throttle valve idle position

.

I

Idle switch
I

I

.1

I

I

Inhibitorswitch
switch(M/T)
(A/T)
Neutral

1 Neutral
I

I

I

A.A.C. valve

F.I.C.D. solenoid valve

I

1

I

Air conditioner switch

I

Powersteeringoil pressureswitchI

.
Battery voltage

Battery

I Vehicle speed sensor

E.C.C.S.

control
unit

I

1 Air conditioner operation

I

I

position

I

1I

Vehicle speed

SYSTEM DESCRIPTION
This system automatically controls engine idle
speed to a specified level. Idle speed is controlled
through fine adjustment of the amount of air
which by-passes the throttle valve via AAC. valve.
The A.AC. valve repeats ON/OFF operation at a
rate of 100 to 200 Hz according to the signal sent
from the E.C.U. The crank angle sensor detects
the actual engine speed and sends a signal to the

E.C.U. The E.C.U. then controls the ON/OFF time
of the A.AC. valve so that engine speed coincides
with the target value memorized in ROM. The
target engine speed is the lowest speed at which
the engine can operate steadily. The optimum
value stored in the ROM is determined by taking
into consideration various engine conditions, such
as noise and vibration transmitted to the compartment, fuel consumption, and engine load.

EF & EC-20

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fuel Pump Control
INPUT/OUTPUT SIGNAL LINE

I

I

Crank angle sensor
Ignition switch

]

1

.

Engine speed

E.C.C.S.
control
unit

1-Fuel pump relay

Start signal

SYSTEM DESCRIPTION

Condition

The E.C.U. activates the fuel pump for several
seconds after the ignition switch is turned on to
improve engine startability. If the E.C.U. receives a
1° signal from the crank angle sensor, it knows
that the engine is rotating, and causes the pump
to perform. If the 1° signal is not received when
the ignition switch is on, the engine stalls. The
E.C.U. stops pump operation and prevents battery
discharging, thereby improving safety. The E.C.U.
does not directly drive the fuel pump. It controls
the ON/OFF fuel pump relay, which in turn controls the fuel pump.

Ignition switch is tunred to ON.
Engine running and cranking

Fuel pump operation
Operates for
5 seconds
Operates

When engine is stopped

Stops in 1 second

Except as shown above

Stops

Air Regulator Control
INPUT/OUTPUT SIGNAL LINE
Engine speed
[

.

Crank angle sensor
Start signal
Ignition switch

E.C.C.S.
control
unit

SYSTEM DESCRIPTION
Condition

The air regulator is controlled by the E.C.U. at the
same time as fuel pump ON-OFF control.

Ignition switch is turned to ON
While engine is running and
cranking

EF

Air regulator

Air regulator
operation
Operates for
5 seconds
Operates

When engine is stopped

OFF in 1 second

Except as shown above

OFF

8r. EC-21

I

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Air Induction Valve (A.I.V.) Control
INPUT/OUTPUT SIGNAL LINE
Enginetemperature
Engine temperature sensor
Idle switch

Throttle valve idle position

E.C.C.S.
control
unit

Engine speed
Crank angle sensor

Vehicle speed sensor

A.LV. control
solenoid valve

Vehicle speed

SYSTEM DESCRIPTION
The air induction system is designed to send
secondary air to the exhaust manifold, utilizing the
vacuum caused by exhaust pulsation in the exhaust manifold.
The exhaust pressure in the exhaust manifold
usually pulsates in response to the opening and
closing of the exhaust valve and decreases below
atmospheric pressure periodically.
If a secondary air intake pipe is opened to the
atmosphere under vacuum conditions, secondary

air can be drawn into the exhaust manifold in
proportion to the vacuum.
The air induction valve is controlled by the E.C.C.S.
control unit, corresponding to the engine temperature. When the engine is cold, the A.I.V. control
system operates to reduce HC and CO.
In extremely cold conditions, A.I.V. control system
does not operate to reduce after-burning. This
system also operates during deceleration for the
purpose of blowing off water around the air
induction valve.

Enginecondition

Water temperature
°c (oF)

A.LV. control solenoid
valve

A.LV. control system

Idle or deceleration

Between 28 (82) and
115 (239)

ON

Operates

EF

8r.

EC-22

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

E.G.R. (Exhaust Gas Recirculation) Control
INPUT/OUTPUT SIGNAL LINE
Engine speed
Crank angle sensor

I

-.

I

Amount of intake air
Air flow meter

I

1
I

.

I

Enginetemperature sensor

Engine temperature

..,..

I

Start signal

.

Ignition switch
I

I

DESCRIPTION
In addition, a system is provided which precisely
cuts and controls port vacuum applied to the
E.G.R. valve to suit engine operating conditions.
This cut-and-control operation is accomplished
through the E.C.U. When the E.C.U. detects any of
the following conditions, current flows through the
solenoid valve in the E.G.R. control vacuum line.

E.C.C.S.

E.G.R. control
solenoid valve

control
unit

I

SYSTEM

This causes the port vacuum to be discharged
into the atmosphere so that the E.G.R. control
valve remains closed.
1) Low engine temperature
2) Engine starting
3) High-speed engine operation
4) Engine idling

E.G. R. control solenoid valve operation
E.G. R. control solenoid valve

Condition
When starting
Below 60 (140)
Water temperature

ON

°c (oF)
Above 105 (221)

Idle & heavy load conditions
OFF

Other conditions

E.G.R. system operation
E.G. R. system operates under only the following conditions.
B.P.T. valve
Water temperature
°c (oF)

Above 60 (140)
Below 105 (221)

Exhaust gas
pressure

Operation

High

Closed

Throttle position

E.G.R. control
solenoid valve

E.G.R. system

Partially open

OFF

Operates

EF & EC-23

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fuel Pressure Regulator Control
INPUT/OUTPUT

SIGNAL LINE
Engine temperature

Engine temperature sensor

E.C.C.S.

Start signal

Ignition switch

P.R. control
solenoid valve

control
unit

Engine speed
Crank angle sensor

SYSTEM DESCRIPTION

above 90°C (194° F)

The fuel "pressure-up" control system briefly increases fuel pressure for improved starting performance of a hot engine. Under normal operating
conditions, manifold vacuum is applied to the fuel
pressure regulator. When starting the engine,
however, the E.C.U. allows current to flow through
the ON/OFF solenoid valve in the control vacuum
line, opening this line to the atmosphere. As a
result, atmospheric pressure is applied, throttling
the fuel passage to increase fuel pressure.

START

Ignition
switch

OFF

P.R.control

OFF

n

ON

I

solenoid
valve

ON

.. Approx. 3 min

r

SEF741B

0<'
-r,

Swirl Control Valve (S.C.V.) Control
INPUT/OUTPUT SIGNAL LINE
Idle switch
I

I

Idle signal

.

Start signal

.

I

Ignition switch

I

Engine speed

Crank angle sensor

Enginetemperature sensor

E.C.C.S.
control
unit

S.C.V. control
solenoid valve

Engine temperature

SYSTEM DESCRIPTION
This system has a swirl control valve (S.C.V.) in
the intake passage of each cylinder.
While idling the S.C.V. closes. Thus the velocity of
the air in the intake passage increases, promoting
the vaporization of the fuel and producing a swirl
in the combustion chamber.
Because of this operation, this system tends to
increase the burning speed of the gas mixture,

improve fuel consumption, and increase the stability in running conditions.
Also, except when idling, this system opens the
S.C.v. In this condition, this system tends to
increase power by improving intake efficiency via
reduction of intake flow resistance, intake flow.
The solenoid valve controls S.C.v.'s shut/open
condition. This solenoid valve is operated by the
E.C.U.

Idle switch

Water temperature

Engine rpm

Solenoid valve

S.C.V.

ON

Above 35°C (95°F)

Below 1,400

ON

Close

OFF

Open

Except above

EF & EC-24

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Acceleration

Cut Control

INPUT IOUTPUT SIGNAL LINE
A/C ON signal
[

.

Air conditioner system
Throttle sensor

Throttle valve opening angle

E.C.C.S.
control
unit

Air conditioner
relay

SYSTEM DESCRIPTION
When accelerator pedal is fully depressed, air
conditioner is turned off for a few seconds.
This system improves acceleration when air conditioner is used.

Fail-safe System
AIR FLOW METER MALFUNCTION
If the air flow meter output voltage is above or
below the specified value, the E.C.U. senses an air
flow meter malfunction. In case of a malfunction,
the throttle sensor substitutes for the air flow
meter.
Though air flow meter is malfunctioning, it is
possible to drive the vehicle and start the engine.
But engine speed will not rise more than 2,400
rpm in order to inform the driver of fail-safe
system operation while driving.
Operation
System
E.G.R. control system

Fixed condition

ENGINE TEMPERATURE
MALFUNCTION

When engine temperature sensor output voltage is
below or above the specified value, water temperature is fixed at the preset value as follows:
Operation
Condition

20°C (68°F)

More than 6 minutes after
ignition ON or Start

80°C (176°F)

OFF
A duty ratio is fixed at
the preprogrammed value.
Fuel is shut off above

Fuel injection control
system

THROTTLE

2,400 rpm.
(Engine speed does not
exceed 2,400 rpm.)

Engine
temperature decided

Just as ignition switch is
turned ON or Start

Except as shown above
Idle speed control system

SENSOR

SENSOR

20. 80°C (68 - 176°F)
(Depends on the time)

MALFUNCTION

When throttle sensor output voltage is below or
above the specified value, throttle sensor output
is fixed at the preset value.

EF & EC-25

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION
PREPARATION
1. Make sure that the following
good order.

.
.
..

parts are in

Battery

Ignition system
.
Engine oil and coolant levels

Fuses

. E.C.U.harnessconnector
. Vacuumhoses

. Air intakesystem
(Oil filler cap, oil level gauge, etc.)
Fuel pressure

..

A.I.V. hose

.
.

Engine compression
E.G.R. control valve operation

.

2. On air conditioner equipped models, checks
should be carried out while the air conditioner is "OFF".
3. On automatic transmission equipped models,
when checking idle rpm, ignition timing and
mixture ratio, checks should be carried out
while shift lever is in "N" position.
4. When measuring "CO" percentage, insert
probe more than 40 em (15.7 in) into tail pipe.
WARNING:
a. When checking or adjustment, move selector
lever to "N" position, set parking brake and
chock rear wheels.
b. After the adjustment has been made, remove
wheel chocks.

Throttle valve and throttle valve switch

Overall inspection

sequence

INSPECTION START

.

N.G.
Perform self-diagnosis.

Repair or replace.
/

O.K.

1

Check or adjust idle speed and
ignition timing.

Chec k ex haust gas sensor

I

N.G.

function by using E.C.U. inspection lamp (Green).

Check exhaust gas sensor
harness.

N.G.

O.K.

O.K.

Check idle mixture ratio by
using E.C.U. inspection lamps
(Red and Green) [in diagnostic
mode II] .

N.G.
I Repair or replace harness.

O.K.
Check base idle CO.
N.G.

O.K.
Replace exhaust gas sensor.

Check emission control parts
and repair or replace if
necessary.

INSPECTION END

EF & EC-26

N.G., Check exhaust gas sensor
function.

~

IDLE SPEED/IGNITION TIMING/IDLE

MIXTURE RATIO INSPECTION

INSPECTION START

Visually check the following:
. Air cleaner clogging
. Hoses and ducts for leaks
. E.G.R. control valveoperation
. Electrical connectors

. Gaskets

~

. Throttle valveand throttle valveswitch operation

~

Start engine and warm it up until water temperature
indicator points to the middle of gauge.

SEF457C

3

Open engine hood and run engine at about 2,000
rpm for about 2 minutes under no-load.

4

2 ,~,,\""\""L"""):

~

"'~
1{
0;
.1OOO,/m,"

...'.«6
"!:-\
~1
f
-8

I
O.K.

SEF477B

Check, correct or replace malfunctioning parts.

Does engine run smoothly?
Yes

I
Check and clean injectors, and replace injectors if
necessary.

Race engine two or three times under no-load,
then run engine at idle speed.

Check idle speed.
M/T: 750:!:50 rpm
AfT: 750:!:50 rpm (in "N" position)
O.K.

N.G.

.

Check ignition timing with
a timing light.
15°:!:2° B.T.D.C.

N.G.

O.K.

Ensure that engine speed is below 800 rpm.
.
O.K.
Adjust idle speed to less than 800 rpm
by turning idle speed adjusting screw.
SMA189A

@

@

EF & EC-27

c

IDLE SPEED/IGNITION

TIMING/IDLE

MIXTURE RATIO INSPECTION

A

C

Check ignition timing with
a timing light.
1S°:t2° B.T.D.C.
O.K.

N.G.
Adjust ignition timing by turning distributor
after loosening bolt which secures distributor.
1S°:t2° B.T.D.C.

Adjust idle speed by turning idle speed adjusting
screw.
M/T: 700:tSOrpm
AfT: 70O:tSOrpm (in "N" position)

3
4
2 '*"""~"""'" 5
'~"-.(6
~

~

\

1'1'

0=

,'000""';"

~7

Run engine at about 2,000 rpm for about 2
minutes under no-load.

~

1.8I

SEF477B

Make sure that inspection lamp (Green) on E.C.U. goes IN.G.
on and off periodically more than 5 times during 10
seconds at 2,000 rpm under no-load.
O.K.

~r\

~V~~J
~/~
SEF450H

~r\

~V ~~/-i~/
'--'~Jf))
,

@
r,'

iDIY
'

~

"-'"

Set the diagnosis mode of E.C.U.to mode II.
Check inspection lamps (Red and Green) on
E.C.U. blink at 2,000 rpm.
They should blink simultaneously.
Yes

No

INSPECTION END

J~

SEF292H

D'

EF &. EC-28

E

C'

IDLE SPEED/IGNITION TIMING/IDLE MIXTURERATIO INSPECTION

D

@

Exhaust gas sensor

~~'!
E.C.C.S. harness

-

.

19

nl'-'~'
SEF353H

~i

c

Check exhaust gas sensor harness:
1) Turn off engine and disconnect battery ground
cable.
2) Disconnect harness connector from E.C.U.
3) Disconnect exhaust gas sensor harness connector
and connect terminal for exhaust gas sensor
harness connector to ground with a jumping
wire.
4) Check for continuity between terminal No. 19
of E.C.U. harness connector and ground metal
on vehicle body.

Continuity exists.
Continuity does not exist """"""'''''''''
N.G.
O.K.

O.K.
N.G.

Repair or replace E.C.C.S.harness
and connect battery ground cable.
Connect harness connector to E.C.U. and disconnect
jumping wire from exhaust gas sensor.

.

Disconnect engine temperature sensor harness
connector.
. Connect a resistor (2.5 kil) between terminals
of engine temperature sensor harness connector.
. Disconnect A.I.V. hose and install a suitable
plug in A.I.V. pipe.
. Connect battery ground cable.

Start engine and warm it up until water temperature indicator points to the middle of gauge.
(Wait more than 5 minutes after starting.)
Race engine two or three times under no-load then
run engine at idle speed.

Check "CO"% and if engine runs smoothly.
Idle CO: Less than 5%
After checking CO%
1) Turn off engine.
2) Disconnect the resistor from terminals of engine
temperature sensor harness connector.
3) Connect engine temperature sensor harness connector to engine temperature sensor.
4) Connect A.I.V. hose.

O.K.

G

EF & EC-29

c

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION
@

G'

Connect exhaust gas sensor harness to exhaust gas
sensor.

Replace exhaust gas sensor.

N.G. Run engine at 2,000 rpm and make sure that green
inspection lamp on E.C.U.goes ON and OFF more
than 5 times during 10 seconds.

. O.K.

Check fuel pressure regulator.
(See page EF & EC-124.)

Check air flow meter.
(See page EF & EC-88.)

Check injector.
(See page EF & EC-126.)
Clean or replace if necessary.

Check engine temperature sensor.
(See page EF & EC-90.)

EF & EC-30

c

TROUBLE DIAGNOSES
Contents
How to PerformTrouble Diagnosesfor Quick and Accurate Repair

EF & EC- 33

"

,

Diagnostic Table

EF & EC- 37

1. Impossible to start

-

no combustion

EF & EC- 38

2. Impossible to start
3. Impossible to start
4. Impossible to start

-

EF & EC- 39
EF & EC- 40

5. Hard to start
6. Hard to start
7. Hard to start
8. Hard to start
9. Abnormal idling
10. Abnormal idling
11. Abnormal idling
12. Unstable idling
13. Unstable idling
14. Poor driveability
15. Poor driveability
16. Poor driveability
17. Poor driveability
18. Engine stall
19. Engine stall
20. Engine stall
21. Engine stall
22. Engine" stall
23. Engine stall

-

24. Backfire
25. Backfire

-

partial combustion
partial combustion (not affected by throttle position)
partial combustion (throttle position changes
combustion quality)
before warm-up
after warm-up
every time
morning after a rainy day
no fast idle
low idle (after warm-up)
high idle (after warm-up)
before warm-up
after warm-up
stumble (while accelerating)
surge (while cruising)
lack of power
detonation
during start-up
while idling
while accelerating
while cruising
while decelerating/just after stopping
"
while loading (power steering, air conditioner,
headlamps, etc.)
through the intake
through the exhaust

Self-diagnosis-

Description

EF & EC- 60
EF & EC- 61
EF & EC- 62

.."..

Self-diagnosis -- Mode I (Exhaust gas sensor monitor)
Self-diagnosis - Mode II (Mixture ratio feedback control monitor)
Self-diagnosis - Mode III (Self-diagnostic system)
:
Self-diagnosis - Mode IV (Switches ON/OFF diagnostic system)
Self-diagnosis - Mode V (Real-time diagnostic system)
Diagnostic Procedure
Diagnostic Procedure 1
MAIN POWER SUPPLY AND GROUND CIRCUIT
Self-diagnostic item
Diagnostic Procedure 2
CRANK ANGLE SENSOR
Diagnostic Procedure 3
AIR FLOW METER
Diagnostic Procedure 4
ENGINE TEMPERATURE SENSOR
Diagnostic Procedure 5
VEHICLE SPEED SENSOR
Diagnostic Procedure 6
.
IGNITION SIGNAL
Diagnostic Procedure 7
ENGINE CONTROL UNIT.:
Diagnostic Procedure 8

EF & EC- 63
EF
EF
EF
EF
EF
EF

"
"

"

&
&
&
&
&
&

ECECECECECEC-

67
67
68
74
76
82

EF & EC- 84

EF & EC- 86

~
~

,

EF & EC- 88
EF & EC- 90

~

~
~ E.G.R. FUNCTION
Diagnostic Procedure 9
~ EXHAUST GAS SENSOR
Diagnostic Procedure 10
~ EXHAUST GAS TEMPERATURE

EF & EC- 41
EF & EC- 42
EF & EC- 43
EF & EC- 44
EF & EC- 45
EF & EC- 46
EF & EC- 47
EF & EC- 48
EF & EC- 49
EF & EC- 50
EF & EC- 51
EF & EC- 52
EF & EC- 53
EF & EC- 54
EF & EC- 55
EF & EC- 56
EF & EC- 57
EF & EC- 58
EF & EC- 59

EF & EC- 92
EF & EC- 94
EF & EC~ 98
"

EF & EC-100

EF & EC-104
SENSOR

EF & EC-31

EF & EC-106

TROUBLE DIAGNOSES
Contents (Cont'd)
Diagnostic Procedure 11
THROTTLE SENSOR

~
~

EF & EC-110

DiagnosticProcedure12

.

INJECTOR LEAK
Switch ON/OFF diagnostic item
Diagnostic Procedure 13
IDLE SWITCH
Diagnostic Procedure 14
START SWITCH
Not self-diagnostic item
Diagnostic Procedure 15
FUEL PUMP
Diagnostic Procedure 16
PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE
Diagnostic Procedure 17
INJECTORS
Diagnostic Procedure 18
SWIRL CONTROL VALVE (S.C.v.) CONTROL SOLENOID VALVE
Diagnostic Procedure 19
AIR REGULATOR
Diagnostic Procedure 20
AUXILIARY AIR CONTROL (A.A.C.) VALVE
"
Diagnostic Procedure 21
LA.A. CONTROL (F.LC.D. CONTROL)
Diagnostic Procedure 22
AIR INDUCTION VALVE (A.LV.) CONTROL SOLENOID VALVE

DiagnosticProcedure23
.
NEUTRALSWITCH,INHIBITORSWITCHAND INHIBITORRELAY
Electrical Components Inspection

EF & EC-114
EF & EC-116
EF & EC-118

EF & EC-120
EF & EC-124
EF & EC-126
EF & EC-128
EF & EC-130
EF & EC-134
EF & EC-136
EF & EC-138
;

EF & EC-140
EF & EC-142

EF 8r. 'EC-32

TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick
and Accurate Repair

~ .~.~
:A
~wol """

~~

SEF232G

INTRODUCTION
The engine has an electronic control unit to control major systems such as fuel control, ignition control, idle speed control,
etc. The control unit accepts input signals from sensors and
instantly drives actuators. It is essential that both kinds of signals
are proper and stable. At the same time, it is important that
there are no conventional problems such as vacuum leaks, fouled
spark plugs, or other problems with the engine.
It is much more difficult to diagnose a problem that occurs
intermittently
rather than continuously. Most intermittent
problems are caused by poor electric connections or faulty
wiring. In this case, careful checking of suspicious circuits may
help prevent the replacement of good parts.
A visual check only may not find the cause of the problems.
A road test with a circuit tester connected to a suspected circuit
shou Id be performed.
Before undertaking actual checks, take just a few minutes to
talk with a customer who approaches with a driveability complaint. The customer is a very good supplier of information on
such problems, especially intermittent ones. Through the talks
with the customer, find out what sy.mptoms are present and
under what conditions they occur.
Start your diagnosis by looking for "conventional" problems
first. This is one of the best ways to troubleshoot driveability
problems on an electronically controlled engine vehicle.

SE F234G

EF & EC-33

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
WORK FLOW
CHECK

STEP 1

SERVICE MANUAL
REFERENCE ITEMS& PAGES

IN

------

LISTEN TO CUSTOMERCOMPLAINTS

DIAGNOSTIC WORKSHEET
EF & EC-35

------

STEP 2
Can be
performed

Can not be performed
CHECK MAIN POWER
SUPPLY AND GROUND
CIRCUIT

<'

<

---

Self-diagnosis
EF & EC-63

Diagnostic Procedure
EF & EC-84

No
DUPLICATIONOF
OPERATING CONDITIONS
THAT LEAD TO MALFUNCTION

STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

INTERMITTENT
SIMULATION
EF & EC-36

<

r.
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
J
I

INSPECTION ON THE BASE OF EACH COMPONENT

REPAIR/REPLACE

:N.G.
I
L
FINAL CHECK
O.K.

CHECK OUT

EF & EC-34

-------

PROBLEM

~~~~~~;able
Diagnostic Procedure
EF & EC-86

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)

KEY POINTS
WHAT
WHEN
WHERE

Vehicle & engine model
Date, Frequencies
Road conditions

HOW

Operating conditions,
Weather conditions,
Symptoms

DIAGNOSTIC WORKSHEET
There are many kinds of operating conditions that lead to malfunctions on engine components.
A good grasp of such conditions can make trouble-shooting faster
and more accurate.
In general, feelings for a problem depend on each customer. It is
important to fully understand the symptoms or under what conditions a customer complains..
Make good use of a diagnostic worksheet such as the one shown
below in order to utilize all the complaints for trouble-shooting.
Worksheet sample

Customer name

MR/MS

Model & Year

VIN

Engine #

Trans.

Mileage

Incident Date

Manuf. Date

In Service Date

0 Startability

0 No combustion
0 Partial combustion
0 Impossible to start
0 Partial combustion affected by throttle position
0 Partial combustion NOT affected by throttle position
0 Possible but hard to start
0 Othl!rs [

0 Idling

0 No fast id Ie
0 Others [

0

0 Driveability

0 Stumble
0
0 Intake backfire
0 Others [

0 Detonation
Surge
0 Exhaust backfire

Symptoms

0 Engine stall

0 At the time of start
0 While accelerating
0 Just after stopping
0 Just after delivery
0 In the morning

Frequency

0 All the time

Weather conditions

0 Not effected

Weather

0 Fine

0

Temperature

0 Hot

0

0 Cold

0 In town

Driving conditions

0
0
0
0

Check engine light

Lack of power

While idling
While decelerating

0
0

0
0

I

2,000

0

0

Others [

Cold

0

Highway

I

,

I

,

20

Not turned on

EF & EC-35

]

Humid

I

30

.

I

40

.

of
I

J
8,000 rpm

0

Off road (up/down)

I

.

While idling
0 At racing
0 While cruising
0 While turning (RH/LH)

10

Sometimes

After warm-up
I
I
I
4,000
6,000

I

In suburbs

0

0

Snowing

Cool

I

'

In the daytime

Under certain conditions

During warm-up

Not affected
At starting
0
While accelerating
While decelerating

0 Turned on

0

Low idle

0 - While loading

Raining

0

Vehicle speed

0

High idle
]

0 Recently
0
0 At night

Warm

E.
d I
ngme spee
0
Road conditions

0
0

0

0

0

]

Incident occurrence

Engine conditions

Unstable

]

50

I
60 MPH

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
INTERMITTENT PROBLEM SIMULATION
In order to duplicate an intermittent problem, it is effective to
create similar conditions for component parts, under which the
problem might occur.
Perform the activity listed under Service procedure and note the
resu It.

'
Variable factor
1

2

3

4

5

6

Mixture ratio

Ignition timing

Influential part

Target condition

Service procedure

Made lean

Remove vacuum hose and apply vacuum.

Made rich

Remove vacuum hose and apply pressure.

Advanced

Rotate distributor clockwise.

Retarded

Rotate distributor counterclockwise.

Pressure regulator

Distributor

Mixture ratio
feedback control

Exhaust gas sensor

Suspended

Disconnect exhaust gas sensor harness connector.

Control unit

Operation check

Perform self-diagnosis (Mode I/II) at 2,000 rpm.

Raised

Turn idle adjusting screw counterclockwise.

Idle speed

I.A.A. unit
Lowered

Turn idle adjusting screw clockwise.

Poor electric
connection or
faulty wiring

Tap or wiggle.

Electric
connection
(Electric
continuity)

Temperature

Harness connectors
and wires

Race engine rapidly. See if the torque reaction of
the engine unit causes electric breaks.

Cooled

Cool with an icing spray or similar device.

Warmed

Heat with a hair drier.
[WARNING: Do not overheat the unit.]

Control unit

Wet.
[WARNING:

7

Moisture

Electric parts

Damp

8

Electric loads

Load switches

Loaded

Turn on head lights, air conditioner, rear defogger,
etc.

9

Idle switch
condition

Control unit

ON-OFF switching

Perform self-diagnosis (Mode IV).

Ignition spark

Timing light

Spark power check

Try to flash timing light for each cylinder.

10

EF &. EC-36

Do not directly pour water on
components. Use a mist sprayer.!

TROUBLE DIAGNOSES
Diagnostic Table
To assist with your trouble diagnoses,some typical diagnostic procedures for the following symptoms are.
described.
REMARKS

In the following pages, the numbers such as 0, . in the above chart correspond to those in the
serviceprocedure described below.
Possiblecauses can be checked through the serviceprocedure shown by the mark "0".

EF 8r. EC-37

TROUBLE DIAGNOSES

Diagnostic Table (Cont'd)
SYMPTOM & CONDITION

SPECIFICATIONS

1 II mpossible
to start

-

no combustion

POSSIBLECAUSES

.. 8 8 0

Mixture ratio (too lean)

0

I

"

0 8

0

0

0
0

Ignition sparks (weak, missing)

0

Ignition timing
FUEL SYSTEM

Fuel pump (no operation)

0

Fuel pump relay (open circuited)

0
0

Injectors (no operation, clogged)

IGNITION

SYSTEM

Ignition switch

0

0

0

0

0

Main relay

0

0

0

0

0

0

0

0

Ignition coil

0

0

Center cable (ignition leaks)

0

0

Ignition wires (ignition leaks)

0

Power transistor

0
0

Spark plugs
CONTROL SYSTEM

0

Crank angle sensor

0

0

0

SERVICE PROCEDURE

.

LISTEN

LISTEN

N.G.

I

---+

~~
../

f)

Check fuel pump and/or
related circuits.
[See page EF & EC-120.J

Fuel pump

,
SEF279G
Listen for fuel pump
operating sound.

'-

N.G
-.:

START

2l'

,,\

o-~

' 5

\.

[0 .! Timinglight
. CHECK

I.*

@
~

-6 /.

Tachometer

Ignition
switch
SEF283G

SEF281G)

Make sure tachometer
needle moves when cranking.
CHECK

.~

~
//11
. II

.,

Check flashes of timing
light for weak ness.

--+ ,.
N.G.

ignition

SE

Injector
F280G

MEASURE

~
\UyJ

N.G.
--+

Replace the wire.

O.K.

,0

---+

CHECK

SEF315G
Measure resistance of
suspect wires.

N.G. AdJust
'
..
Ignition timing.

--+

[See page EF & EC-26.J

((@S""~G
Check

injector circuit.

[See page EF & EC-126.J

Listen for injector
operating sound.

CHECK

8

N.G.

--+Check

timing.

EF &. EC-38

Remove spark plugs and
check their ignition sparks.

TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION

SPECI FICA nONS

Table (Cont'd)

21 Impossibleto start - partial combustion

POSSIBLE CAUSES

0 f)

"

Mixture ratio

0

0

0

0
0

Fuel pressure (too low)

0

Ignition timing
FUEL SYSTEM

"

Fuel pump

0

Fuel pump relay (open circuited)

0

Injectors (clogged)

0

SERVICE PROCEDURE

.

LISTEN
N.G.

I

Check fuel pump and/or
related circuits.
[See page EF & EC-120.J

-.~
.1

~
.

Fuel pump

sou,

~

L
~K

.1

8

~
\.

:J

APPL Y

,.
Improved

Checkinjectorcircuit.

Injector
SEF280G
operating

r.
D

.

~

PRESSURE
,

SEF291G..I

MEASURE
Fuel pressure gauge

t

'SE".6G

Remove vacuum hose from
pressure regulator, and
apply vacuum and/or
pressure, and try to start.

Connect vacuum hose to
pressure regulator and
measure fuel pressure.

Adjust ignition timing.
[See page EF & EC-26.J

1
Check mixture ratio
feedback system.
[See page EF & EC-26.J

CHECK

.

~
~~~:ng

,

..

N.G.

[See page EF & EC-126.J

Listen for injector
sound.

~.VACUUM

.

-

//11II

SEF279G

L~sten for fuel ~ump
operating

LISTEN

f)

~

-

sm~G

Check ignition timing.

"<

EF & EC-39

TROUBLE DIAGNOSES
Diagnostic
SYMPTOM& CONDITION 31 Impossible to start

- partial combustion

. . .. . . . . . 0 .

POSSIBLE CAUSES
SPECIFICATIONS

Mixture ratio

0

Fuel pressure (too low)

0

0

0

0

0
0

Fuel filter (clogged)

0

Fuel line (clogged)
0

Injectors (clogged)

0

Pressure regulator
0

Pressure regulator vacuum hose (clogged)
IGNITION SYSTEM

0

Ignition wires (ignition leaks)

0
0

Spark plugs (wet with fuel)
0

Ignition switch
INTAKE SYSTEM

CONTROL SYSTEM

0

Throttle chamber (with ports clogged)

0

Throttle valve (clogged)

0

Engine temperature

0

0

SERVICE PROCEDURE

.

LISTEN
N.G.

~

Check injector circuit.
[See page EF & EC-126.J

//11
InJ'ector
, "
. ,
SEF280G
Listen for injector operating
sound.

8

0

sensor

Crank angle sensor

.

(not affected by throttle position)

0

Ignition timing
FUEL SYSTEM

Table (Cont'd)

CHECK
N.G.

--+

Throttle chamber

CIean t h e ports and/or

throttle

valve.

s~

Check throttle chamber
ports and valve for clogging.

. lo.K.
CHECK
O.K.

1---+

'A

V

[

MEASURE

REMOVE

Pressureregulator

Improved
,.

.

2.

Fuel pressure
Connect vacuum hose to
pressure regulator and
measure fuel pressure.

. Check mixture ratio
feedback system.
[See page EF & EC.26.J

SEF291G
Remove vacuum hose from
pressure regulator, and try
to start.

SEF287G
Check vacuum hose of pressure regulator for clogging.

1 N.G.
Repair or replace the hose.

0

.

.

CHECK

~

CHECK

MEASURE

, , Timing light

N.G.

~.

~

- (r@.<..~
""'~G

Ignition

1 N.G.
Adjust ignition timing.
[See page EF & EC-26.J

resistance

of

'","oct;'"}~~'
Replace

N.G.
Self-diagnosis
Mode IV

CHECK

wire

-~

PERFORM
G>

O.K.

if?rn
SEF315G
Measure

SEF283G
Check flashes of timing
light for weakness.

Check ignition timing.

(!)

+ Check starter circuit.
[See page EF & EC-118.J

Perform self-diagnosis
Mode IV (for start signal).

EF &.EC-40

the wires.

Spark plug
SEF282G
Remove spark plugs and
check their ignition sparks
by cranking.

TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION

41 Impossibleto start

POSSIBLE CAUSES
INTAKE SYSTEM

-

Table (Cont'd)
partial combustion (throttle position changes
combustion qu~lity)
10

Throttle chamber (with ports clogged)

.

8

0

Throttle valve (clogged)

0

Air regulator (stuck closed)
CONTROL SYSTEM

.

0

IdIe speed control valve

0

Engine temperature sensor
Idle switch

0

Neutral switch

0

0

SERVICE PROCEDURE

0

.

r.

CHECK

N.G.

Throttle chamber

-

Cleantheports.

~.

..~

SEF290G
Check throttle valvefor
clogging.

Check throttle chamber
ports for clogging.
r.

..

,

-

CHECK
.

N.G.

I

jj

CHECK
Throttle chamber

Check air regulator and/or
its circuit.
[See page EF & EC-130.J

SEF293G

Make sure air regulator stays
open before warm-up

8

CHECK

-

N.G.

.,~"

START
,

@*

C.hec~ idle speed control
Circuit.
[See page EF & EC-134.J

SEFOO6H
Check terminal voltage of
A.A.C. valve while cranking.

EF & EC-41

N.G.
Cleanthe valve.

---+

TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION

51 Hard to start

-

Table (Cont'd)

before warm-up

I

POSSIBLE CAUSES
Mixture ratio

0 f) 8 0 0

IGNITION SYSTEM

Ignition switch (no start signal)

0

INTAKE SYSTEM

Air regulator
Engine temperature sensor
Idle switch

SPECIFICATIONS

CONTROL SYSTEM

OTHERS

0

0
0

0
0
0

Neutral switch

0

Starter (operation too slow)

0

Battery (voltage too low)

0

0

SERVICE PROCEDURE
CHECK

0

N.G.
START 1
+

"i,. ;5
o-~ -6
"

Tachometer

MEASURE
N.G. (less than 12V)
--+Charge
the battery.

I.*

@
~

~

Ignition
switch

SEF281G

SEF296G
Measure battery voltage.

Make sure tachometer
indicates about 300 rpm
while cranking.

'0

f)

CHECK

N.G.
+ Check air regulator and/or
its circuit.
[See page EF & EC-130.J

if
"

CRANK

g
i)~

Self-diagnosis
Mode IV

Perform self-diagnosis
Mode IV (for start signal
and idle switch!.

stays

N.G.
START ~Check

*

PERFORM

SEF285G

SEF293G

Make sure air regulator
open before warm-up.

e

I

sensor circuit.
[See page EF & EC-90.J

~ @
~

.

Ignition

Engine tempera- switch
-!ure sensor
SEF292G.
Start with engine temperature sensor connector
disconnected.

EF & .EC-42

N.G.
--+

Check the malfunctioning
switches and/or circuits.
[See page EF & EC-118
(start signal).
page EF & EC-116
(idle switch).]

TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION

61 Hard to start

-

Table (Cont'd)

after warm-up

0

POSSIBLE CAUSES
SPECIFICATIONS

FUEL SYSTEM

.

I

.

00

Mixture ratio

0

0

Fuel pressure

0

0

Fuel line (hot fuel)

0

Pressure regulator (low fuel pressure)

0

Pressure regulator vacuum hose (clogged)

0

..
0

0

Pressure regulator control solenoid

0

0

Pressure regulator control solenoid vacuum hose
Fuel temperature sensor (open circuited)
IGNITION SYSTEM
CONTROL SYSTEM

0

Ignition switch (no start signal)

0

Engine temperature sensor
Air flow meter

OTHERS

Starter (operation too slow)

0

Battery (voltage too low)

0

SERVICE PROCEDURE
CHECK

.

MEASURE

'0

N.G.

f)

STARTI~

,*

2~'

~
@

,,'
o-~
SEF281G

SEF296G
Measure battery voltage.

'

,

S eIf-diagnosIs
Mode IV

SEF374G
Cool fuel lines with wet
rags, etc. and try to start.

!

N.G. (less than 12V)
Charge the battery.

PERFORM

0

LINES

Ignition
switch

Make sure tachometer
indicates about 300 rpm
while cranking.
,

No
change
~
Proceed to other steps.

CRANK

FUEL

I ",5
-6 /.

Tachometer

0

N.G.

~

. Check starter circuit.
[See page EF & EC-118.]

171~
SEF285G
Perform self-diagnosis
Mode IV (for start signal),

.

CHECK
O.K.
--+

SEF287G
Check vacuum hose of
pressure regulator for

clogging.

CHECK

1 N.G.

Repair or replace the hose.

(pressure
regulator
control solenoid

¥

0\

N.G.
--+

(

LISTEN
Pressure regulator
control solenoid

0'

START

i;.~

Ignition
'-SEF294G
switch
Check terminal voltage of
pressure regulator control
solenoid while cranking.

Listen for clicking sound
from pressure regulator
control solenoid when
applying battery voltage.
o.K.
~ N.G.
Replace the solenoid.
Check the solenoid circuit.
[See page EF & EC-124.]

l

EF & EC-43

Improved
+ Proceed to other steps.
If everything is O.K.,
check fuel vapor pressure.

TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION

71 Hard to start

-

every time

. . . o . (I). G . . . .

POSSIBLE CAUSES
SPECIFICATIONS

Table (Cont'd)

Mixture ratio

0

I

0

0

Fuel pressure

0

0

Ignition sparks (missing)
FUEL SYSTEM

Fuel pump (improper operation)

0

0

0

0

0

Fuel line (clogged)
Canister (air leaks)

0
0

Pressure regulator (low fuel pressure)
Ignition wires (ignition leaks)

IGNITION SYSTEM

0
0

Ignition timing

0

Spark plugs (improper gap)
CONTROL SYSTEM

0
0

Crank angle sensor
Engine temperature sensor

0

Idle switch
OTHERS

0

Neutral switch

0

Starter (operation too slow)

0

Battery (voltagetoo low)

0

0

SERVICE PROCEDURE

0

LISTEN
N.G.
---+Check
fuel pump and/or
related circuits.
[See page EF &I;C-120.]

~

START --+

It ,,\2i' CHECK
',5
0-~~

8

..

~

Charge the battery.

N.G.

~*

switch

Check mixture

.

REMOVE

-

N.G.

I

.Repair or replace the hose.

ratiO

;]

SEF297G
feedback system.
Advance/retard ignition
[See page EF & EC-26.]
timing and try to start.
Improved

~

Measurebattery voltage.

~

SEF281G
Make sure tachometer
indicates about 300 rpm
while cranking.
CHECK

No change
Distributor
-+
Proceed to other steps.
Advance ST ART
~
Retard ~

Ignition

Battery
rMEASUREl

switch

CRANK

.--

@
~

-"

N.G.

Tachometer Ignition

,
SEF279G
Listen for f.uel pump
operating sound.

~

/.*

ro---MEASURE,

+\

-

Fuel pressure

Connect vacuum hose to
Pressure
regu Iat or

pressure regulator and
measure fuel pressure.

..

PERFORM
N.G.
Self-diagnosis
Mode IV

. Check the malfunctioning
circuits.
[See page EF & EC-116
(idle switch).]

Replace the wires.

N.G.
--+

O

[

tN,G.
MEASURE

I>

MEASURE
O.K.

--+

Ignition wire

if?rn
SEF283G
Check flashes of timing
light for weakness.

canister for air leaks.

Perform self-diagnosis
Mode IV (for idle switch).

SEF291 G

Remove vacuum hose
from pressure regulator,
and try to start.
CHECK«3 , 1 Timing light

~";~
,
SEF298G
Check vacuum hose of

-~

SEF315G
Measure resistance of
suspect ignition wires.

O.K.
--+

e

I.

CHECK

S~'k'~G~
Spark plug
SEF299G

Remove spark plugs and
measure their 9

0

0

Ignition timing (too advanced)
INTAKE SYSTEM

8e

0

N.G.

Check the idle switch circuit.
[See page EF & EC-116.]

N.G.

CRANK

((

i5 ;U~
~

~

START

(l]

Ignition

Engine tempera- switch
ture sensor
SEF292G
Start with engine temperature sensor connector
disconnected.

circuit.

EF & EC-48

Check sensor circuit.

[See page EF & EC-90.J

TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION

121 Unstableidling- before warm-up
0

POSSIBLE CAUSES

0

SYSTEM

SYSTEM

0

0

0

Air regulator (not open enough)

0

Idle speed control valve (remaining OFF)
CONTROL

0 0

0

0

Ignition timing
INTAKE

f) 8

Mixture ratio

SPECIFICATIONS

I

Engine temperature sensor

E.G.R. SYSTEM

0

E.G.R. control valve (stuck open)

0

E.G.R. solenoid (remaining OFF)

0

0

~...

SERVICE PROCEDURE
.-CHECK

~

-

~~~:ng
~

~ ""':G

Check ignition

.

~

--

CHECK

0

Checkmixtureratio

Does not turn ON
+Check
its circuit.

feedback system.
[See page EF & EC-26.J

[See page EF & EC-134.J

Pressu re
regu lator

-

SEF291G

CHECK

~~

,

~

a
~

(j"E.G.R.
I!
control
valve
,
SEF547A...J
Check E.G.R. control valve
for operation.

SEFOO7H

Check terminal voltage of
A.A.C. valve while idling.

Apply vacuum pressure to
pressure regulator after
disconnecting vacuum
hose, and check idling.

0

air regulator and/or
its circuit.
[See page EF & EC-130.J

SEF293G

PRESSURE

-

iit

Improved

VACUUM

N.G.
~Check

Make sure air regulator
stays open before warm-up.

timing.

APPLY

8

CHECK

f)

N.G.
--+Adjust
ignition timing.
[See page EF & EC-26.J

Stays

~rw

/A

CHECK
'0

RUN

E.G.R. solenoid
"

~Ui6~

g

,l:c;\ :::
S'J

~

/

N.G
ST ART
~*

:.Ji!J
"

~"~
SEF303G

Engine tem pera- SIgnition
t ure sensor
witch
SEF292G

Check terminal voltage of
E.G.R. solenoid while
idling.
N.G.

Start and run engine with
engine temperature sensor
connector disconnected.

u

1
Check the solenoid circuit.
[See page EF & EC-100.J

EF & EC-49

]

~

r
Check senso
[S
$

p'"

'

"

CircUit

EF & EC-90.]

TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
SPECIFICAnONS

131 Unstable idling - after warm-up

POSSIBLE CAUSES

0

8

8

0

Mixture ratio

0

0

0

0

Ignition sparks

I

0

0

8

0

0

0

0

G) 4D f)

0

Ignition timing

0

Compression pressure
FUEL SYSTEM

0

Fuel line (clogged)
0

Canister (air leaks)

0

Pressure regulator control solenoid
Power transistor

IGNITION SYSTEM

INTAKE SYSTEM

0

Ignition coil

0

Ignition wires

0

0
0

0

0

Blow-by hose (leaks)

0

Air duct (leaks)
CONTROL SYSTEM

0

Idle switch

0

Load switches
E.G.R. SYSTEM

E.G. R. control valve

0

E.G.R. solenoid

0

SERVICE PROCEDURE

,

.

CHECK

0

~~

BIOW_bY
hose

~

1 N.G.
leaks.
Repair/replace the hose.

~";f:t
SEF298G

Check purge line for leaks.

1 N.G.

1 N.G.

Repair/replace the hose.

Repair/replace the part.

CHECK
Timing light

CHECK

N.G.
--+

CHECK

MEASURE

0

'.

.

IgOitlon wIre

I

,

O.K.

+

.0

~~

-

SEF315G

Check flashes of timing
light for weakness.

MEASURE

.

CHECK

~~

,

COMPRESSION
PRESSURE

SEF309G
Measure compression
pressu reo

N.G.

~

6~
~

E.G.R'
control
valve
,
SEF547A/
Check E.G.R. control valve
for operation.

Stays

I~'"

(~

CHECK
E.G.R. solenoid

~fii6~

n

u ~.~
SEF303G
Check terminal voltage of
E.G.R. solenoid while idling.

1
Check cylinder head and
gasket.
[See EM section.]

~
-

U

~.=.
SEF303G

Check terminal voltage.of
the solenoid while idling.

+ N.G.
Check the solenoid circuit.
[See page EF & EC-124.J
CHECK

SEF282G

Remove spark plugs and
check their ignition sparks.

Measure resistance of
suspect wires.
~ N.G.
Replace the wire.

0

CHECK
Pressure regulator
control solenoid

o~

~ru
SEF283G

e

r~

11/"-'

SEF301G
Check intake system for
air leaks.

SEF300G
Check blow-by hose for

0.,

Leak

Engine

I

.

.

CHECK

0

~ N.G.
Check the solenoid circu it.
[See page EF & EC-100.J

EF & EC-50

~"""~G
Check ignition timing.
~ N.G.
Adjust ignition timing.
[See page EF & EC-26.J
PERFORM

f)

Self-diagnosis
Mode IV

~

SEF285G
Perform self-diagnosis
Mode IV (for idle switch).

1 N.G.
Check the idle switch circuit.
[See page EF & EC-116.J

TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
14 Poor driveability - stumble (while accelerating)

SYMPTOM & CONDITION

. f) 8 0

POSSIBLECAUSES
SPECIFICATIONS

Mixture ratio

(;)

0

Fuel pressure
FUEL SYSTEM

.

.

0

0

0

0

Fuel filter (clogged)

0

Fuel line (clogged)

0

Injectors (clogged)
IGNITION

SYSTEM

0

Ignition coil

0

Ignition wires (ignition leaks)

0

CONTROL

Crank angle sensor

SYSTEM

0

0
0
0

0
0

Spark plugs (ignition leaks, improper gap)
Air'duct (leaks)

0
0

0

0

0

Air flow meter

0

Engine temperature

sensor

Exhaust gas sensor

0

Idle switch (remaining OFF)
OTHERS

0

0

Power transistor

INTAKE SYSTEM

0

0

Fuel (poor quality)

SERVICE PROCEDURE
"

0,

.

CHECK

MEASURE

--

N.G.Replacethe wires.
--

N.G.

Timing light

Ignition wire

\{I
i

8

CHECK

O.K.

@

GJ
-'}

SEF315G

SEF283G

Measure resistance
suspect wires.

Check flashes of timing
light for weakness.
~CHECK

Leak

N.G.

--

Repair/replacethe part.

Remove spark plugs and
check their ignition sparks.

~

N.G.
Self-diagnosis

ModeIV

~

SEF301G

Check intake system
air leaks.

PERFORM

0

()III~

Eng ine

.--

SEF282G

of

for
"

REMOVEPressu re regu lator

Improved

. I0

MEASURE

Check the idle switch
circuit.
[See page EF & EC-116.J

SEF285G
Perform self-diagnosis
Mode IV (for idle switch).

. feedback
Check mixture ratio
system.

Fuel pressure gauge

~.

[See page EF & EC-26.J

SEF291G
Remove vacuum hose from
pressure regulator, and try to drive.
PERFORM
«!)

Self-diagnosis

~V

U%'~
SEF285G
Perform self-diagnosis Mode
V (for air flow meter).

N.G.

Connect vacuum hose to
pressure regulator and
measure fuel pressure while
driving.

DISCONNECT

0

-.."

1:8

Improved

. Replace the sensor.

II!

. Check the malfunctioning
parts and/or circuits.
[See page EF & EC.88
(air flow meter).]

No change
sensor
('.,~
~;
E'h,"~";~'/'>=
~~.

-

SEF307G

Disconnect exhaust gas
sensor con nector, and try
to drive.

EF & EC-51

. Check mixture ratio
feedback system.
[See page EF & EC-26.]

TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION

15 Poor driveability

-

surge (while cruising)
. ...

0 f)

Mixture ratio (too lean)

0

SPECI FICA TIONS

POSSIBLE CAUSES

. e

Fuel pressure (low)

SYSTEM

0

0

0

0

(missing)

INTAKE SYSTEM

CONTROL

0

0

Ignition timing
IGNITION

0 0 8 fi) "
0

SYSTEM

Air duct (leaks)

0

Throttle chamber (air leaks)

0

Intake manifold (gasket) (air leaks)

0

Crank angle sensor

0

Air flow meter

0
0

Exhaust gas sensor
Idle switch
E.G.R. SYSTEM

0

E.G. R. control valve (stuck open)

0

E.G.R. solenoid (remaining OFF)

0

E.G.R. vacuum hose (removed)

0

0

SERVICE PROCEDURE

.~ ~p!

~CHECK

CHECK

leak

()11/

Engine

~

(t@s"'~a

Check intake system
air leaks.

CHEC~

for

Check

l

ignition

timing.

II

,

. e

:::"./:

control
valve
SEF547 A./

U

REMOVE

.

Improved

Pressure regulator

~.

. 0

~N.G.
Check the solenoid circuit.
[See page EF & EC-100.J

MEASURE
Fuel pressure gauge

,

t

feedback system.
[See page EF & EC-26.1

'",,,.,a

Connect vacuum hose to
pressure regulator and
measure fuel pressure while
driving,

PERFORM
DISCONNEC!.-"

Self-diagnosis
N.G.

. Check the malfunctioning
parts and/or circuits.
[See page EF & EC-86
(crank angle sensor),
page EF & EC-88
(air flow meter),
page EF & EC-94
(ignition signa!).!

PERFORM
Self~

)

Check starter signal circuit.

O.K.

i~

("'I
riJf!jt
~--;'t\0)
~
~'-~
SE F299H

Lift the rear of the vehicle.

N.G.

Drive vehicle. Make sure that a green
inspection lamp goes "ON" when vehicle
speed is 20 km/h (12 MPH) or faster.
O.K.
Turn ignition switch "OFF".

Reinstall the E.C.U. in place.

(

DIAGNOSIS

END

CAUTION:

.

)

SE F288H

N.G.

Make sure that a red inspection lamp goes
"ON" during turning ignition switch
"ST ART"*.

~SE'29.H

Mode IV

Check idle switch circ~

-.----O.K.

Accelerator pedal

S;~~T

Flashing 4 times

After the inspection lamps have flashed 4
times, turn diagnostic mode selector fully
counterclockwise.

For safety, do not drive rear wheels at higher speed than required.

EF & EC-75

I

)

Check vehicle speed sensor
circuit.

TROUBLE DIAGNOSES

-

Self-diagnosis

Mode V

(Real-time diagnostic

system)
In real-time diagnosis, if the following items are judged

to be

working incorrectly,a malfunction willbe indicated immediately.
. Crank angle sensor (180° signal & 1° signal) output signal

.

Ignition signal

.

Air flow

meter

Consequently,
the

above

output

signal

this diagnosis
systems

cause

very effectively determines
the

Compared

with

self-diagnosis,

sitive and

can

detect

regarded

as

malfunction,
real-time

malfunctions

malfunctions

during

diagnosis

instantly.

in this diagnosis

whether

driving

However,

are

test.

is very

not

senitems

stored

in

E.C.U. memory.

SELF-DIAGNOSTIC PROCEDURE

(

)

DIAGNOSIS START

I
Pull out E.C.U. from under

the

assist

seat.

Start engine.

Turn

diagnostic

mode

selector

on

E.C.U.

fullyclockwise.

After the inspection lamps have flashed
times, turn diagnostic mode

5

selectorfully

counterclockwise.

~r\
~V
~(~~

'-~C0

(
Make

)

sure that inspection

flashing for 5 min. when

lamps

N.G.

are not

)

Mode V

SEF288H

Ifflashing,count no. of
flashes.

idling or racing.

O.K.

SE F292 H
Turn

ignition switch

Turn

"OFF".

See

ignition switch

decoding

"OFF".

chart.

Reinstallthe E.C.U. in place.

(

Perform

DIAGNOSIS END

)

system

real-time diagnosis
inspection.

If malfunction

part is found,

repair or replace it.

CAUTION:
In real-time

diagnosis,

and does not memorize

pay

attention

to

inspectio.n

lamp

flashing.

E.C.U.

the inspection.

EF &. EC-76

displays

the

malfunction

code

only

once

TROUBLE DIAGNOSES
Self-diagnosis - Mode V (Real-time diagnostic
system) (Cont'd)
DECODING CHART
DISPLAY CODE

MALFUNCTIONING
OR PARTS

CIRCUIT

CONTROL UNIT SHOWS A
MALFUNCTION SIGNAL WHEN
THE FOLLOWING CONDITIONS
ARE DETECTED.
(Compare with Self-diagnosis

- ModeIII.)

CRANK ANGLE SENSOR
.
Unit: sec

RED L.E.D.

3.2

3.2

The 10 or 1800 signal is momentarily
missing, or, multiple, momentary
noise signals enter.

3.2

'9' ON-[

Malfunction of crank angle sensor circuit

0 OFF
REAL-TIME DIAGNOSTIC
INSPECTION
See page EF & EC-86.
SEF047F

AIR FLOW METER

.
GREEN
LED

..

:0:
','

3.2

Unit: sec
3.2

3.2

Abnormal, momentary increasein air
flow meter output signal

ON

Malfunction of air flow meter circuit

0 OFF

LI1.6lnl1.61

0.4
0.60.4 V
--0.6

-V

1.6

0.4
0.6

REAL-TIME DIAGNOSTIC
INSPECTION
See page EF & EC-88.
SEF048F

IGNITION SIGNAL
.

Unit: sec

GREEN
3.2
3.2
"L.E.D. rT
'9,: ON --

Signalfrom the primary ignition coil
momentarily drops off.

~~
r
Malfunction of ignition signal

0 OFF
1.8
0.2

REAL-TIME DIAGNOSTIC
INSPECTION
See page EF & EC-94.
SEF049F

EF & EC-77

TROUBLE DIAGNOSES

Self-diagnosis-

Mode V (Real:-timediagnostic

system) (Cont'd)
I

Crank Angle Sensor

.

REAL-TIME DIAGNOSTIC

I

X : Avallab Ie
-: Not available

INSPECTION

Check parts
Check
sequence

1

Check items

Check
conditions

Tap harness connector or
component during realtime diagnosis.

E.C.U.
harness
connector

If malfunction, perform
the following items.

Middle
connectors

Sensor &
actuator

During
real-time
diagnosis

X

X

X

Go to check item 2.

X

-

-

Go to check item 3.

Check harness continuity

Engine

at connector.

stopped

3

Disconnect harness connector, and then check
dust adhesion to harness
connector.

Engine
stopped

X

-

X

Clean terminal surface.

4

Check pin terminal bend.

Engine
stopped

-

-

X

Take out bend.

5

Reconnect harness connector and then recheck
harness continuity at
connector.

Engine
stopped

X

-

-

Replace terminal.

6

Tap harness connector or
component during realtime diagnosis.

During
real-time
diagnosis

X

X

X

If malfunction codes are
displayed during real-time
diagnosis, replace terminal.

2

CJ
L J

-E.C.U.

harness connector

SEF130H

EF & EC-78

TROUBLE DIAGNOSES

Self-diagnosis-

Mode V (Real-time diagnostic

system) (Cont'd)
I

Air Flow Meter

x: Available
-: Not available

I
Check parts

Check
sequence

Check items

Check
conditions

1

Tap harness connector or.
component during realtime diagnosis.

2

Middle
connectors

Sensor &
actuator

E.C.U.
harness
connector

During
real-time
diagnosis

X

X

X

Go to check item 2.

Check harness continuity
at connector.

Engine
stopped

X

-

-

Go to check item 3.

3

Disconnect harness connector, and then check
dust adhesion to harness
connector.

Engine
stopped

X

-

X

Clean terminal surface.

4

Check pin terminal bend.

Engine
stopped

-

-

X

Take out bend.

5

Reconnect harness connector and then recheck
harness continuity at
connector.

Engi ne
stopped

X

-

-

Replace terminal.

6

Tap harness connector or
component during realtime diagnosis.

During
real-time
diagnosis

X

X

X

If malfunction codes are
displayed during real-time
diagnosis, replace terminal.

r

If malfunction, perform
the following items.

=-l
E.C.U. harness connector

Air flow meter harness connector

.. I"~

,<1/A

SEF131H

EF & EC-79

TROUBLE DIAGNOSES

Self-diagnosis-

Mode V (Real-time diagnostic

system) (Cont'd)
I

Ignition Signal

X:
-:

I

Available
Not available

Check parts
Check
sequence

Check items

1

Tap harness connector or
component during realtime diagnosis.

2

Check
conditions

If malfunction, perform
the following items.

Middle
connectors

Sensor &
actuator

E.C.U.
harness
connector

During
real-time
diagnosis

X

X

X

Go to check item 2.

Check harness continuity
at connector.

Engine
stopped

X

-

-

Go to check item 3.

3

Disconnect harness connector, and then check
dust adhesion to harness
connector.

Engine
stopped

X

-

X

Clean terminal surface.

4

Check pin terminal bend.

Engine
stopped

-

-

X

Take out bend.

5

Reconnect harness connector and then recheck
harness continuity at
connector.

Engine
stopped

X

-

-

Replace terminal.

6

Tap harness connector or
component during realtime diagnosis.

During
real-time
diagnosis

X

X

X

If malfunction codes are
displayed during real-time
diagnosis, replace terminal.

,

LE.C.U. harness connector

L Ignition coil and power transistor
harness con nector
SEF132H

EF & EC-80

TROUBLE DIAGNOSES
NOTE

EF &. EC-81

TROUBLE DIAGNOSES

Diagnostic Procedure
CAUTION:

1. Before connecting or disconnecting the E.C.U. harness
connector to or from any E.C.U., be sure to turn the
ignition switch to the "OFF" position and disconnect the
negative battery terminal in order not to damage E.C.U. as
battery voltage is applied to E.C.U. even if ignition switch
is turned off. Failure to do so may damage the E.C.U.
SEF289H

2. When performing E.C.U. input/output signal inspection,
remove connector protector to insert tester probe into
connector.

SEF290H

3. When connecting or disconnecting pin connectors into or
from E.C.U., take care not to damage pin terminals.
4. Make sure that there are not any bends or breaks on
E.C.U. pin terminal, when connecting pin connectors.

SEF291H

5. Before replacing E.C.U., perform E.C.U. input/output signal
inspection and make sure whether the E.C.U. unit functions properly or not. (See page EF & EC-142.)

SEF330D

6. After performing this "Diagnostic Procedure",
E.C.C.S. self-diagnosis and driving test.

SEF292H

EF & EC-82

perform

TROUBLE

DIAGNOSES

Diagnostic
Procedure
(Cont'd)
7. When measuring E.C.U. controlled components supply
voltage with a circuit tester, separate one tester probe
from the other.
If the two tester probes accidentally make contact with
each other during measurement,

the circuit will be shorted,

resulting in damage to the control unit power transistor.

Solenoid valve

SEF599D

EF 8r. EC-83

'

TROUBLE DIAGNOSES
Diagnostic Procedure 1
MAIN POWERSUPPLYAND GROUND CIRCUIT
COMBINATION METER

@ ,

With

~,

Without head-up display

head-up display

CHECK
ENGINE
LIGHT

CHECK
ENGINE
LIGHT

I GNI T! ON SWITCH
ON or START

I

17o--@--<>I 6,
FUSE BLOCK
(Refer to "POWER
SUPPL Y ROUT! NG"

r-t
1:1 r.iiI
~

E. C. C S
CONTR'OL'

UNIT

@

I

Iii
~

~ottt-O

~

tWh I te)

1""'00arness)

107-B.'---

G

jI

108-B

'Fi'r;;n'\
(E. F.

~

-~
~

CID

G

..

12

I (~~strument

@)eo@

116-B

4-R/B

05

[rmef-H-iJ[gOO:!]

In EL section.)

@ ;;

2' 0---@

~

~~

~

rness)

J.

harness)

6-B
13-B

"II"

EE

~I"I~

-

@@

24-R

UTI
harness)

B/W~

~~~~ine

room

36-B/R

48-B
'1!
1391481

@)

~~ @)

E.

~
C.

~

~@)

~

OFFACCON ST
J J
1
J J
2
J
3
4
11m
5

\
link

~.

EF

&

EC-84

~

~

ITiJ~
FUSIBLE
LINK

FUSE AND
FUSI BLE LI NK

(Jn RELAY BOX)

S.

I GNI

T! ON

SWITCH

~
BATTERY

Component location
I

C.

RELAY

ENGINE
GROUND

/"BR;'
fusible
~"G" fusible link

~~

..

@)lMJ

47-B/W

'1:

~:~

....

39-B

"481391

Iffl

:~:--,,:~:~
@@)
1111
~.. ~
"

SEF261H

TROUBLE DIAGNOSES

m

"-

INSPECTION START

='

CHECK DIAGNOSTIC MODE
ON THE E.C.U.
Verify that diagnostic mode
selector on the E.C.U. is turned
"OFF".

-

~

COMBINATION METER

~ GD~~

.....

>->.

>-

>- >-

@"..QD

~ (Refer
FUSE BLOCK
to "POWER

~

SUPPL

E. C. C. S.

8S7iROL

@

Y

ROUT

I NG"

@@

I

In EL sect Ion.)

8

r-=-.
@@

~

11

@~<§)

.~o

BODY
GROUND

G

G
Y/8

Y/l

".II,~.

y/G
(E.

F.

(Main)

I.

harness)

, ,

... ..
>- >-

harness

:

@D

-

Y/8

Y/G (jnstru nt
harnes~f

~ ~
age

f

Y/l
Y/8~

>-

(Eng
I Ine room
harness)
I

3'-

Y/l

ffi..ffi
".
\;t!::
Y/l

' ,
>-

~

->-

@:D~

@
~,

, With heed-up display
Without

EF

head-up

&

display

EC-92

~

SPEED
SENSOR

SE F224H

TROUBLE DIAGNOSES
INSPECTION START

PI

-

Is speedometer

working

No

properly?

Yes

CHECK VEHICLE SPEED
SENSOR AND SPEEDOMETER
UNIT.
(See EL section.)

PI
SEF804F

Ii]
II

ClUNIT

~i5
&a
SEF151H

§]CONNECTORII
32

[ill

CHECK INPUT SIGNAL.
1) Perform switch ON/OFF
diagnosis (in Mode IV).
2) Make sure green inspection
lamp on E.C.U. comes "ON"
when vehicle speed reaches 20
km/h (12 MPH).
,
N.G.

O.K.

(

INSPECTION END

Ii]

CHECK CONTINUITY
BETWEEN E.C.U. AND
VEHICLE SPEED SENSOR.
1) Turn ignition switch "OFF".
2) Disconnect E.C.U. harness
connector.
3) Check continuity between
E.C.U. terminal @ and
ground by rotating rear wheel
by hand.
Continuity should come and
go.

N.G.

Repair or replace harness or
connectors.

O.K.
Reinstall any part removed.

Erase the self-diagnosis memory.
Make sure Code No. 55 is displayed in Mode III.

1) Perform switch ON/OFF
diagnosis (in Mode IV) again.
2) Make sure green inspection
lamp on E.C.U. comes "ON"
when vehicle speed reaches
20 km/h (12 MPH).

O.K.
INSPECTION END

EF & EC-93

N.G.

1) Perform self-diagnosis and
find malfunction code.
2) According to displayed code
No., perform diagnosis.

)

TROUBLE DIAGNOSES
Diagnostic Procedure 6
IGNITION

SIGNAL

(Code No. 21)

E. C.C.S.
CONTROL
UNIT

@

r.11;:t

p:leJ

~

FUSE AND
FUSI BlE LI NK


I

B/R~

I I
I I

-w

~B/R

," ,
I I
I I
I I

""

""
""
"
,,
:I
':

I"

~

III

@)L8
@)i - i@)
.

.

ENGINE
GROUND

~

1111
~'"
"''\

FUSIBLE
LINK

f1
IGNITION

"

III

~

~~

@I~

G

ii ~ ~@

III

~~

I

G

cn

@)g

," I
," ,
"
i:I I I

'"

fJ

@)

LQ

'"
'\

~111~

~

~mm[i] 1Ir!1

III

([@~

DISTRIBUTOR

~ ij

.

POWER
TRANSISTOR

CONDENSER RESISTOR

BATTERY
~

- - - SPARK PLUG

111]

1
2
3
4
5

OFFACe ON ST
c
0
C
:J
0

I GNI TI ON SWITCH
SEF225H

Componentlocation
l

SE F34 7H

EF & EC-94

TROUBLE DIAGNOSES
"..

mLit~
CGIIBT

00

Battery

---.


ID

e

SEF370H

~ ~i5

O.K.

CCNECTOR
II SEF444H

[!]

CHECK E.C.U. INPUT LINE.
1) Stop engine.
2) Disconnect harness con.
nectors from power transistor
and E.C.U.
3) Check continuity between
terminals @ and @.
Continuity should exist.
If N.G., check following.
8 Resistor
8 Harness or connector

Ii]

[!]

~i5

~Jur

CHECK E.C.U. INPUT
SIGNAL (Power transistor side).
1) Start engine.
2) Verify that pulse signal exists
between power transistr
harness connector terminal
@ and ground with logic
probe.
Pulse signal should exist.
N.G.

[ill

n

./

I

~

IE)

....,

INSPECTION START

CHECK E.C.U. OUTPUT
SIGNAL (Power transistor side).
Verify that pulse signal exists
between power transistor
harness connector terminal
@ and ground with logic
probe.
Pulse signal should exist.

CGIIBT

N.G.

CHECK E.C.U. OUTPUT
SIGNAL (E.C.U. side).
Verify that pulse signal exists
between E.C.U. harness con-

nectorterminal CD andground
with logic probe.
Pulse signal should exist.
If N.G., check the E.C.U. pin
terminals for damage or the
E.C.U. harness connection.

O.K.

lo.K.

00

1$ 81

ID

I'

Repair harness, connector, or
resistor between terminals @
and CD.

e
SEF152H

Ii]

~[
~
00.

ClUNIT
1

'8

CONNECTOR

II

CONIIECT

tID

Battery


e
Logic probe

II
CHECK POWER SUPPLY.
1) Stop engine.
2) Disconnect harness connector
from ignition coil.
3) Turn ignition switch "ON".
4) Check voltage between ignition coil harness connector
terminal @ and ground.
Battery voltage should exist.
O.K.

SEF153H

00

Ii!lCoili~i5

w

~

::E

~

SEF154H

E

EF & EC-95

N.G.

-

CHECK HARNESSCONTINUITY BETWEEN
BATTERY AND IGNITION
COIL.
Check the following items.
8 Harness
8 "G" fusible link
8 Ignition switch

TROUBLE DIAGNOSES

Ii

ffi

cilltv~i5

Ii

[ill

~i5~

SEF366H

[!1

cillE>~i5~

[!1

[ill

SEF156.H

CHECK HARNESS CONTINUITY BETWEEN
IGNITION COIL AND POWER
TRANSISTOR.
1) Turn ignition switch "OF F".
2) Disconnect power transistor
harness connector.
3) Che9k continuity between
ignition coil harness connector
terminal @ and power
transistor harness connector
terminal @.

-=-

N.G.

Repair or replace harness
between @ and @.

O.K.

CHECK GROUND CIRCUIT.
Check continuity between power
transistor harness connector
terminal @ and ground.
Continuity should exist.

N.G. 1) Repair harness or connectors.
I

2) Check continuity.
3) Check engine ground.

O.K.
CHECK COMPONENTS.
Check ignition coil and power
transistor.
(See page EF & EC-148.)

N.G.

Replace ignition coil or power
transistor.

O.K.
Reinstall any part removed.

Erase the self-diagnosis memory.

Perform driving test and then
perform self-diagnosisagain.
O.K.
INSPECTION END

EF & EC-96

N.G.

1) Perform E.C.U. input/output
signal inspection test.
2) If N.G.. recheck the E.C.U.
pin terminals for damage or
the connection of E.C.U.
harness connector.

TROUBLE DIAGNOSES
NOTE

EF & EC-97

TROUBLE DIAGNOSES

Diagnostic Procedure 7
ENGINE CONTROL UNIT (Code No. 31)Q
INSPECTIONSTART

1) Turn ignition switch "ON".
2) Erasethe self-diagnosis
memory.

Perform self-diagnosis again.

Yes

Does E.C.U. display Code No.
31 again?

Replace E.C.U.

No

(

INSPECTION END

EF & EC-98

)

TROUBLE DIAGNOSES
NOTE

EF & EC-99

TROUBLE DIAGNOSES

E.G.R. FUNCTION (CodeNo. 32)

Diagnostic Procedure 8

Q

[Not self-diagnosticitem (For non-California models))
E.G.R.
CONTROL
SOLENOID
VALVE

81

E. C. C. s.
CONTROL
UNIT

@

P

~
@)W -<> Ii]
"'II::

...I"

105-

]

LG

FUSE

till
@@)

B/R

(E. F. I.
harness)

(Eng I ne room
harness)

8R-'

'-B

BR

W

G

w

B~

~
..

~

(ill) [IJI

1
2
3
4
5

J

C

:J

(
c

I GNITI ON
SWITCH

FUS Bt~D LI NK
F~SI
RELA Y BOJO

Un

=~~
BATTERY

EF & EC-100

~

FUSIBLE
LINK

@)Q

OFFACC ON ST

~

~:~ ~

~
~

R

SE F269H

TROUBLE DIAGNOSES

m

INSPECTION START

m

Responds

(

CHECK E.G.R. CONTROL
VALVE OPERATION.
1) Start engine and warm it up
sufficiently.
2) Make sure E.G.R. control
valvespring responds to
your touch (use your
fingers) and also when
engine is raced.

SEF445H

Ii]

INSPECTION END

/

Does not respond

Ii]

CHECK VACUUM SOURCE
TO E.G.R. CONTROL
VALVE.
1) Stop engine.
2) Disconnect vacuum hose
connected to E.G.R. control
valve and B.P.T. valve.
3) Start engine.
4) Make sure vacuum exists
when racing engine.

SEF157H

[i

~-

~~
Clagg'og
=='--

.:C\

CHECK VACUUM HOSE.
1) Stop engine.
2) Check vacuum hose for clogging, cracks, and proper
connections.
SEF816F

N.G.
Replace E.G.R. control valve.

N.G.

O.K.

Ii]

If necessary, replace vacuum
hose or reconnect vacuum hose
firmly.

Ii]

CHECK E.C.U. OUTPUT
SIGNAL (Solenoid side).
1) Start engine and warm it up
sufficiently.
2) Check voltage betwen E.G.R.
control solenoid valve harness
connector terminal @ and
ground.

CONNECT

£)

001
trJ C.f'H

100

SEF158H

Engine
condition
Idle

(I

II
CONNECT

C;'UNI T
105

§f

CONNECTOR

II

tD

Racing

Voltage
Battery

voltage

Temporarily
drops to 0 - 1 V

O.K.

£)
00

(I

.

I

!

I

. Improperconnection
~ ""

,

CHECK COMPONENT.
Check E.G.R. control valve.
(See page EF & EC-148J

N.G.

[i

~

O.K.

N.G.

CHECK E.C.U. OUTPUT
SIGNAL (E.C.U. side).
Check voltage between E.C.U.
harness connector terminal @)
and ground.
Engine
condition
Idle
Raci ng

Voltage
Battery

voltage

Temporarily
dropstoO-1V

If N.G., check the E.C.U. pin
terminals for damage or the
connection of E.C.U. harness
connector.

O.K.

UW

Repair harness or connectors
between terminals @ and @.

C.f'H
SEF159H

EF &. EC-101

)

TROUBLE DIAGNOSES

Ii

1

Test condition
Drive vehicle under the following conditions
with a suitable shift position.
. Engine speed:
3,100:1:300
3,000:1:400

.

rpm (AfT)
rpm (MfT)

Intake manifold vacuum:
-42.7:1:8.0kPa
(-320:1:60

mmHg, -12.60:1:2.36

CHECK COMPONENT.
1) Stop engine.
2) Check E.G.R. control solenoid valve. (See page EF &
EC-149J

inHg)

Driving mode
Test condition
16 seconds or more
@

N.G.

Replace E.G.R. control solenoid
valve.

O.K.
CHECK COMPONENT.
Check E.G.R. control valveand
B.P.T. valve.
(See page EF & EC-148J

Vehicle
driving

N.G.

Valve spring may be stuck.
Clean if necessary.
If this does not correct trouble,
replace E.G. R. control valve.

O.K.
For non-California

O.K.
For California

INSPECTION END

Idling ----.

Ignition'JLj
Time
switch: I IC))
0 F F -+-t----Until green and red inspection lamps go off.
CD Start engine and warm it up sufficiently.
@ Turn off ignition switch and keep it off
until green and red inspection lamps go off.
CID Start
engine and make sure that air conditioner switch and rear defogger are turned
"OFF" during driving test.
@ Shift to suitable gear position and drive
in "Test condition" for at least 16 seconds.
CID Decrease
engine revolution to less than
2,000 rpm.
@ Repeat steps @ through CID at least 1
time.
SEF037H

[!1

Check resistance of exhaust gas
temperature sensor.
(See page EF & EC-149.)

Reinstall any part removed.

Erase the self-diagnosis memory.
Make sure Code No. 55 is displayed in Mode III.

Ii
Perform driving test under the
following conditions.
1) Warm up engine sufficiently.
2) Use test driving modes
indicated in figure Ii.

~~E~

[!1

CHECK ENGINE LIGHT
SEF924F

Comes

Make sure check engine light does I"ON"
not come "ON" during driving
test.
Does not come "ON"
INSPECTION END

EF & EC-102

Perform self-diagnosis and find
malfunction code. According to
displayed code No., perform
diagnosis.

TROUBLE DIAGNOSES
NOTE

EF &. EC-103

TROUBLE DIAGNOSES
Diagnostic Procedure 9

~

EXHAUST GAS SENSOR (CodeNo. 33)
E. C. c. S.
CONTROL
UNIT

(E. F. 1harness)
19-W

:~:

nnn

,m

ii

nnnnnnnnn_nn

I
I
I
I
I
I
I

mmmm

m__m

m

I
I
I
I
I
I
I

1:_'

m_:::::::::~I

~

(ill)

@-=<>
Ii]

0

m

i@
"::"

EXHAUST
GAS
SENSOR

ENGINE
GROUND

SEF226H

Component

location

EF & EC-104

TROUBLE DIAGNOSES

m

~

INSPECTION START

':)

m

([IT))
SEF153D

I;]

I;]

.-cT

eJ

II

~IT

~
=

[ill
connector

'8 CONNECTOR

II

19

Exheust
ges sensor

O.K.
INSPECTION END

CHECK INPUT SIGNAL.
1) Start engine and warm it up
sufficiently.
2) Make sure green inspection
lamp on E.C.U. blinks at
2,000 rpm.

~
.-cT
eJ

~

SEF446H

N.G.
N.G.

CHECK EXHAUST GAS
SENSOR CIRCUIT.
1) Stop engine.
2) Disconnect E.C.U. harness
connector.
3) Disconnect exhaust gas
sensor harness connector.
4) Connect a jumper wire from
exhaust gas sensor harness
connector to ground.
5) Check continuity between
E.C.U. harness connector
terminal @ and ground.
Continuity should exist.

Repair or replace harness.

O.K.
Replace exhaust gas sensor.

Reinstall any part removed.

Erase the self-diagnosis memory.
Make sure Code No. 55 is displayed in Mode III.

1) Start engine and warm it up
sufficiently.
2) Set diagnosis mode to Mode
I.
3) Makesure that green inspection lamp on E.C.U. goes on
and off periodically more
than 5 times during 10
seconds at 2,000 rpm.
O.K.
INSPECTION END

EF & EC-105

N.G. .

Perform IDLE SPEED/IGNITION TIMING/IDLE MIXTURE
RATION INSPECTION.
(See page EF & EC-26J

TROUBLE DIAGNOSES
Diagnostic Procedure 10
EXHAUST GAS TEMPERATURE SENSOR (CodeNo. 35)

~

E. C. c. S.
CONTROL
f'"F2I
UNI T
~

(E. F. 1harness)
8-R/L

@

@
(Eng I ne room

R/~j t:/L

21-8

@

harness)

@

(Eng I ne
harness

room
no. 2)

R/L]tiJ ~R/LI<
<1881mB

I:IR/~::ft) ~~/LII:

@@
..J
"aiD<

F7

m

Ii1[!]

@E)Q?~

~
1i1[!]

0

:A/T

mode I

@

:M/T

model

~
EXHAUST
GAS
TEMPERATURE
SENSOR

SEF204H

Component

location

A/T mOde;

(/- /rv
SEF~73H

EF & EC-106

TROUBLE DIAGNOSES
INSPECTION START

m~~

m

CONNECT

£)
[Y]

~

:+:

~0
I~~
H

SEF201

Ii)

~~i5

CHECK INPUT SIGNAL
(Exhaust gas temperature sensor
side).
1) Start engine and warm it up
sufficiently.
2) Keep engine speed at approximately 2,000 rpm.
3) Check voltage between
exhaust gas temperature
sensor harness connector
terminal @ and ground under
the following conditions.

[ill

Condition

'+:. ,-

00

~i{)u
[i

~

Voltage

Wh~n vacuum is not
applied to E.G.R.
control valve

~

CIUN!:!:8COtNECTOR

When vacuum
II

applied
control

SEF202H

~i5

1.0- 2.0V

is

0 - 1.0V

to E.G.R.
valve

A sufficient vacuum applied
with a hand vacuum pump may
cause the engine to stall.

[ill

N.G.

Ii)

'+

00
~i5u

O.K. EBEB

,

CHECK HARNESS CONTINUITY BETWEEN E.C.U.
AND EXHAUST GAS TEMPERATURE SENSOR.
1) Stop engine.
2) Disconnect E.C.U. harness
connector.

21

ClUNIT :EI CONNECTORII
SEF203H

3) Disconnect

N.G.

1) Check harness and middle
harness connector connection
between terminals @ and
@.
2) If necessary, repair or replace
harness.

exhaust gas

temperature sensor harness
connector.
4) Check continuity between

'terminals @ and @.
Continuity should exist.

[i

O.K.
CHECK GROUND CIRCUIT.
Check continuity between
terminals @ and @.
Continuity should exist.

O.K.

EB
EF & EC..'07

N.G.

1) Check middle harness connector connection.
2) If necessary, repair or replace
harness.

TROUBLE DIAGNOSES

CHECK COMPONENTS.
Check exhaust gas temperature
sensor. (See page EF & EC-149.)

N.G.

Replace exhaust gas temperature
sensor.

O.K.

Reinstall any part removed.

Erase the self-diagnosis memory.
Make sure Code No. 55 is
displayed in Mode III.

Perform driving test, then
perform self-diagnosis.

.....-O.K.

INSPECTION END

EF & EC-108

N.G.

1) Perform E.C.U. input/output
signal inspection test.
2) If N.G., recheck the E.C.U.
pin terminals for damageor
the connection of E.C.U.
harnessconnector.

TROUBLE DIAGNOSES
NOTE

EF & EC-109

TROUBLE DIAGNOSES

THROTTLESENSOR (Code No. 43)

~

Diagnostic Procedure 11

E. C.c. S.
CONTROL f-

FUSE

m
(E.

F.

1.

harness)

JI

OR

(Ma In h arness )
rnJ

OR

~
,
m
>-

@

S. M. J.
~efer to last age
(FoIdout page). f

@])

~nglne

room harnes~

w
w

:

BR~

...

~

cD
>-

,
m

~:~

~~

@)
I

,
m
>-

34-0R

~

~~

~

@)g

~

,

FUSIBLE
LINK

FUSE
AND
FUS I BlE LI NK
(In RElA Y BOX)

1m
OFFACC ON ST
c
0
I
c
0
2
0
3
4
5
I GNITI

ON

SWITCH

~
-

BATTERY
SEF214H

EF & EC-118

TROUBLE DIAGNOSES

-

m
II

CAJNIT

lit is

INSPECTION START

8 CONNECTORII

Perform switch ON/OFF diagnosis (in Mode IV).

34

m

00
SEF213H

INSPECTION END

N.G.

CHECK INPUT SIGNAL.
1) Turn ignition switch
"START".
2) Check voltage between terminal @ and ground.
Battery voltage should exist.
If N.G., repair harness and
connectors.

O.K.
INSPECTION END

EF & EC-119

N.G.

Check the following items.
1) "G" fusible link
2) Ignition switch
3) Middle harness connector

TROUBLE DIAGNOSES
Diagnostic Procedure 15
FUEL PUMP (Not self-diagnosticitem)
FUEL
PUMP

E. C.C.S.
CONTROL~

UNIT @~....

r=I r=I

G;J
..?7 iii Inl

@J){i@5)

IU-8/P

rffi3l~
>-

BODY
GROUND

107-8

..
--1

,

..

I

>-

,..
@
(E. F. 1.

0

harness)

@@

--

(Ma I n

harness)

FUSE

S.M.J.

m,
>..

8/R

(Eng I ne room
harness)

8/P-ffi. .tB- 8/P
8/Y~

8/W

~8/Y

w

,.. ~
>-

,
....
£@)

@Y~

,~ ....
~~

@lMJ
IIlnii if Ifm

FUEL
PUMP
RELAY

AIR
REGULATOR

III

~:~

~

~
\!!!I

1
2
3
4
5

SEF268H

g

EF & EC-120

~

I

FUSI
LI NKBlE
FUSE AND
FUSI BlE LI NK
(I n RElA Y BOX)

~

BATTERY

Component location

~

[DJ~

@)Q

OFFACC N ST

I GNI TI ON
SWITCH

8~

I'

0:

~

~

page

[Refer
to
'ast
(Fa I dout
page).)

SEF236H

TROUBLE DIAGNOSES

INSPECTION START

m~~
~tttill1

m

i5

[Y]

~
(2J

SEF264H

I!J

.

CHECK POWER SUPPLY

~~_r

IImtalV

(Fuel pump side).
1) Disconnect fuel pump harness
connector.
2) Turn ignition switch "ON".
3) Check voltage between
terminal @ and ground.
Battery voltage indication
should appear for 5 seconds
after turning ignition switch
"ON".

00

L

O.K.

CHECK GROUND CIRCUIT.
Check continuity between terminal @ and ground.
Continuity should exist.
If N.G., repair harness or connectors.

[!J
SEF266H

[:iI
.--r

CHECK COMPON~NTS.
1) Turn ignition "OFF".
2) Check fuel pump.
(See page EF & EC-149,)
If N.G., replace fuel pump.

I!J

N.G.

[ill

[!J

O.K.

:filiL
@"l)]

10

[Y]

CHECK POWER SUPPLY
(Relay side).
1) Turn ignition switch "OFF".
2.) Disconnect fuel pu,,",prelay.
3) Turn ignition switch "ON".
4) Check voltage between terminals @, @ and ground.
Battery voltage should exist.

N.G. CHECK HARNESSCONTINUITY BETWEEN
BATTERYAND FUEL PUMP
RELAY.
Check following.
. Harness or connectors

. "BR" fusiblelink

O.K.

lZJOO
Ii]

~
_r

IV

00

=
SE F377H

illTI:0"'lII

rnJ

CHECK COMPONENTS.
1) Turn ignition "OFF".
2) Check fuel pump relay.
(See page EF & EC-150,)

Ii]

i5[:i1~
SEF379H

N.G.

Replace fuel pump relay.

O.K.

CHECK HARNESS CONTINUITY.
Check continuity between relay

harnessconnectorterminal CD
and fuel pump harness connector terminal @.
O.K.

EF & EC-121

N.G.

Repair or replace harness or
connectors between terminals
CD and @.

TROUBLE DIAGNOSES

Ii
CONNECT 104

If)

00

-

IT B" CONNECTOR
II

l

0
SEF266H

-

Ii

_r ~

ClUNrT §J CONNECTOR
III/!.r:!:\

II

'liiV ~

104

Ii

CHECK E.C.U. OUTPUT
SIGNAL (E.C.U.side).
1) Reconnect fuel pump harness
connector and fuel pump
relay.
2) Turn ignition switch "ON".
3) Check voltage between E.C.U.
harness connector ~
and
ground.
Battery voltage indication
should appear after 5 seconds.
O.K.

[ill

00
1211
4R3

SEF267H

Ii

INSPECTION END

~
_r

N.G.

CHECK HARNESS CONTINUITY.
1) Turn ignition switch "OFF".
2) Disconnect E.C.U. harness
connector.
3) Check continuity between
terminal (jQ!) and relay harness connector terminal

@.

Continuity should exist.
If N.G., repair or replace
harness and connectors
between terminals ~
and

@.
O.K.
Recheck the E.C.U. pin terminals
for damage or the connection of
E.C.U. harness connector.

IV

EF & EC-122

TROUBLE DIAGNOSES
NOTE

EF & EC-123

TROUBLE DIAGNOSES
Diagnostic Procedure 16
,
PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE (Not self-diagnostic
item)
PRESSURE
REGULATOR
CONTROL
SOLENOID
VALVE

go~'T~;l
UNIT

@~

/7

[;]

~
@W~ml!J[;]
LID

]

I06-PU

FUSE

~

8/R

@@)
(E. F. 1.

(Eng Ine room
harness)

harness)
8RJ

8R

t8R

(=m::~
I@l~~~~

~

~
ID

I'\. OFFACC ON ST
r
1
c
::>
2
::>
3
4
5
I GNITI ON
SWIT CH

~

FUSIBLE
, LINK

@)~

FUSE AND
FUSI BLE LI NK
-'"
"CD

FUSE

@

@)

~nglne

rnJ

room harnes~

8/R

8RJP '-BR

12-GY

8R

~. F. 1.
harness)

w
w

8q] ~

~:~

@)
'"

,
~
CD

(illY~
1m
1
2
3
4
5

OFFACC ON ST
c
c
J
J

1 GN1TI ON
SWI TCH

~

@)~

I

.

~

~

[ll)
FUSIBLE
LINK

FUSE AND
FUSI BLE LI NK
(1 n RELA Y BOX)

~BATTERY
SEF231H

Component location

EF & EC-128

TROUBLE DIAGNOSES

m

INSPECTION START

m
eJ.

CH ECK

[Y]

€
L.:::

-

SEF227H

1!1

N.G.

POWE R SOU RCE.

1) Disconnect S.C.V. control
solenoid valve harness connector.
2) Turn ignition switch "ON".
3) Check voltage between terminal @ and ground.
Battery voltage should exist.

CHECK HARNESS CONTINUITY FOR POWER
SOURCE.
Check following.

. "G" fusiblelink
. Ignitionswitch

. Harness

O.K.

CIIIIET

£)
00

ID
IJ

l

YJ

.

+

CH
SEF229H

O.K.

Ii)

~~i5
12
CAJN~

CONtECTaR II
SEF230H

Lass than
"approx. 1,400 rpm

0.5 - 1.0V

More than
approx. 1,400 ';Pm

Battery
voltage

CHECK HARNESS CONTINUITY BETWEEN
SOLENOID AND E.C.U.
11 Stop

engine.

2) Disconnect S.C.V. control
solenoid valve harness connector and E.C.U. harness
connector.
3) Check continuity between

Voltage
between
terminal @
and grou nd

Engine speed

Replace S.C.V. control solenoid
valve.

[!J

N.G.

CHECK OUTPUT SIGNAL.
1) Reconnect S.C.V. control
solenoid valveharness connector.
2) Start engine and warm it up
sufficiently.
3) Check voltage between terminal @ and ground.

[ID

00'
~i511

N.G.
CHECKCOMPONENTS.
1) Turn ignition switch "OFF".
21 Check S.C.V. control solenoid
valve. (See page EF & EC-149.)

terminals @ and @

.

Continuity should exist.
If N.G., repair or replace
harness or connector.

O.K.
1) Perform E.C.U. input/output
signal inspection test.
(Terminal @)
2) If N.G., recheck the E.C.U.
pin terminals for damage or
the connection of E.C.U.
harness connector.

O.K.

CHECK COMPONENT.
Check swirl control valve
actuator.

(See

and

EF & EC-150.)

page
I

O.K.

(

INSPECTION

END

EF & EC-129

)

Replace swirl control valve or
actuator.

TROUBLE DIAGNOSES
Diagnostic Procedure 19
AIR REGULATOR

(Not self-diagnosticitem)
FUEL
PUMP

E. C. C. S.
CONTROL fM\
UNIT
~~~U8

~

nil nil

@D~@])
10'-B/P

~~

107-B

BODY
GROUND

rffBl@)
...
,

.0

I (Ma I n harness)
...

,
.0

@
(E. F. r.
harness)

@iD

--

GJ
...

FUSE
page

,.0

@@
B/P-ffi
B/Y~

S. M. J.
last
(Fo I dout page).]
ffiefer to

~

B/R

(Eng I ne
harness)

room

ffi-B/P
~B/Y

B/W
W

BR~

I"

0:

,.. ;t

[!]1]1i
...
,
.0.0

"
S\ ".0.0 .0.0
@lMJ
...Q.

@)£

d;fh
m(;]1]
WJ
.

;1

.

@i
ENGINE

FUEL
PUMP
RELAY

~~§UlA TOR GROUND

~~

;t;t

1m
OFF ACC ON ST
:) :)
1
:J
2
3
4
5
I GNITI ON
SWITCH

'I

g

EF & EC-130

~

cn~

@)~
rru\
~

I

FUSI
LI NKBlE
FUSE AND
FUSI BlE LI NK

.J

.
1!1[!J

BATTERY

'"a

,.J

(Ma In
harness)

UP

II:
I

FUSE BLOCK
!Refer
to 'POWER
SUPPLY ROUTI NG'
In EL section.)

'"
a
I

,.J
(ill)
(E. F. 1.
harness)
G/Y~

~G/Y

L/G e:r

w

L/G

[Refer

(Fo I dout

cD
'"
a
,.J

ffi

@@

ll-G/Y

S. M.J.

N

::

to

last

page).

r

age

!Eng I ne room
harness)

'"
"",
a >-"'0

,.J '"
"'.J.J

@~

I.

i@)

AIR
CONDI TI ONER
RELAY

ENGINE
GROUND

SEF270H

Component location

EF 8r. EC-136

TROUBLE DIAGNOSES

m

INSPECTION START

\.
m

A/C

..

CHECK INPUT SIGNAL.
1) Start

PU

engine and warm it

CHECK IDLE SPEED WHEN
AIR CONDITIONER SWITCH
IS "ON".
M/T: 1,OOO:t50rpm
A/T:
1,OOO:t50rpm
(at uN" range)
If out of specification, adjust
idle speed.
(See page EF & EC-26J

Yes
up

sufficiently.
2) Does engine revolution rise
when air conditioner switch is
turned "ON"?

SEF129GI
No

r;]

!f
eJ

I

I

I

I

Disconnect F.I.C.D. solenoid
valve harness connector.
3) Turn ignition switch and air
2)

7

SEF447H

-eJ ,

conditioner switch "ON".

nal @ andground.

00

0

ClUNIT
11

8

1) Turn ignition switch "OFF".

.

N.G.

'

I

7

I I CHECK
COMPONENTS.
1) Turn ignition switc'.h .OFF"

SEF448H

£)

HECKGROUNDCIRCUIT.

Battery voltage should exist.

rEIDl

I

II

CONNECTOR II

lEL
JJ

CHECK HARNESS CON-

N.G.

2) Turn ignition switch "ON".
3) Check voltage between E.C.U.
terminal (jJ) and ground.
A/C switch
ON

Voltage
0.5 - 1.0V

OFF

Battery voltage

INSPECTIONEND

TINUITY BETWEEN
BATTERYAND E.C.U.
Check following.
8 Fuse
8 Ignition switch
8 Harness or connectors.

I

I O.K.
Recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness
connector.

O.K.

EF & EC-137

connectors.

relay.

CHECK OUTPUT SIGNAL.
1) Reconnect F.I.C.D.solenoid
valveharness connector.

C

terminal @ andground.
Continuityshouldexist.
If N.G.,repairharnessor

Replace air conditioner relay.

O.K.

I;]

2) Check continuity between

I

2) Check
(See HA
air section.)
conditioner

IO.K.

[i

4) Check voltage betWeentermi-

00
filii

INSPECTIONEND

CHECK COMPONENTS.
Check F.I.C.D. solenoid valve.
(See page EF & EC-151J
If N.G., repair or replace F.I.C.D.
solenoid valve.

1) Stop engine.

[:it

CONNECT

O.K.

CHECK POWERSOURCE.

ilJ

I;]

(

r;]

oo

[i

I O.K.

)

TROUBLE DIAGNOSES

Diagnostic Procedure 22
AIR INDUCTION VALVE (A.I.V.) CONTROL SOLENOID VALVE (Notself-diagnosticitem)

E. C.c. s.
CONTROLtf2)
UNIT

~

~

/'

FUSE

[i
room harnes~

~nglne
P

102-P

(E. F. 1.
harness)

ii

@

B/R

P

~

BR

:req]

@)

G=I]
G=I]

[ll]

(ill)

FUSIBLE
LINK

FUSE AND
FUSI BLE LI NK
(1 n RELAY BOX)

'"
,ID ~

'"
lDo.

@

(@)~

@)&

1m

rims?

~

A. 1. V.
CONTROL
SOLENOID
VALVE

OFFACCON ST
1
0
C
2
c
3
4
5
IGNITION
SWITCH

BATTERY

SEF234H

Component location

EF & EC-138

TROUBLE DIAGNOSES

II

INSPECTION START

18

II

[Y]
&

m
I;]

SEF227H

-

N.G.

CHECK POWER SOURCE.
1) Disconnect A.I.V. control
solenoid valve harness connector.
2) Turn ignition switch "ON".
3) Check voltage between terminal @ and ground.
Voltage: Battery voltage

W

CHECK HARNESSCONTINUITY BETWEENA.I.V.
CONTROL SOLENOID
VALVE AND BATTERY.
Check harness or connector.

O.K.

COllECT

if)

ool

tID
,

[!] @}

CHECK COMPONENTS.
' N.G.
1) Turn ignition switch "OFF".
2) Check A.I.V. control solenoid
valve. (See page EF & EC-149.)

CYH

l1t

SEF229H

i5

~
~

DlSCGltIlt:CT 102

1811

ClUNIT

[!]
N.G.

CHECK OUTPUT SIGNAL.
1) Reconnect A.I.V. control
solenoid valve harness connector.
2) Start engine and warm it up
sufficiently.
3) Check voltage between
terminal @ and ground.

[ill
~

O.K.

I;]

Ef C~CTOR

II

Accelerator
pedal position
Released

SEF233H

Depressed

Voltage

0.5 - 1.0V
Battery

voltage

O.K.
CHECK COMPONENT.
Check air induction valve.
(See page EF & EC-151.)
,
O.K.

(

Replace A.I.V. control solenoid
valve.

INSPECTION END

CHECK HARNESS CONTINUITY BETWEEN A.I.V.
CONTROL SOLENOID
VALVE AND E.C.U.
1) Stop engine.
2) Disconnect A.I.V. control
solenoid valve harness connector.
3) Disconnect E.C.U.harness
connector.
4) Check continuity between
terminals @ and @.
Continuity should exist.
If N.G., repair harness or
connector.

N.G.

)

1) Perform E.C.U. input/output
signal inspection test.
2) If N.G., recheck the E.C.U.
pin terminals for damage or
the connection of E.C.U.
harness connector.

Replace air induction valve.

EF & EC-139

TROUBLE DIAGNOSES
Diagnostic Procedure 23
NEUTRAL

SWITCH, INHIBITOR

E. C. c. S.
CONTROL
UNIT

RELAY

(Not self-diagnosticitem)
I GNI T! ON SWITCH
ON or START

0

@

SWITCH AND INHIBITOR

@
@
@

:A/T

model

:M/T

mode I

:A/T

model

:A/T

mode I without

UP

with

..

A. S. C. D.
FUSE BLOCK
(Refer
to "POWER
SUPPL Y ROUT! NG"
1n EL sect Ion. )

A. S. C. D.

@

I

...J

,"
(MaIn harness)

[Refer

@)@)

S. M.J.
to Iast

(Fa I dout
W-G/OR
(~a~;"' I:Ss)

35- G/OR

G/OR-Im

j[[
::r-

0:

"ID

ID

m[l<==-~@)

SWITCH

-

i5 [:it

-ffi. .ffi.@83"~@3)

r:=I
ell

B

~~~~

IJ

M
IDID

J;!;II ~

81

~

B

,'"
...J

room

~

no. 2)

~~

~dP

@)

QJ 0

=arness

G/

@)

QD

II
0:
0

,"'ID

lMJ@)

L,WJ
=
I~I

I NHI BI TOR

I NHI BI TOR

RELAY

RELAY

CSZJ

OO(D

"
<>

harnes~

G/OR

@@)

INHIBITOR

f

page).

,"

(Eng i ne

A

'0:

1;]81

m

room

--"

35

t

~ngine

age

I

...J

-=

SEF350H

EF & EC-140

ft i@

-=-=-=
@!@)
BODY
GROUND

m~~

NEUTRAL
SWITCH
SEF246H

TROUBLE DIAGNOSES
INSPECTION START

I;]

~[@b)
IIISCOIIIlECT

N.G.

EO

CHECK COMPONENTS.
Check neutral switch (M/T) or
inhibitor switch and inhibitor
relay (A/T).
(Seepage EF & EC-152.)

[ill

~

m

taEO~
[ill

N.G.

CHECK CONTINUITY
BETWEEN SWITCH AND
GROUND.
I;]

SEF243H

M/T

Check the following.
. Harnesscontinuity

. Fuse
. S.M.J.

model

Check continuity

between
terminal @ and ground.
[!J A/T model
1) Turn ignition switch "OFF".
2) Check continuity betWeen
terminals @, CD and ground.
Continuity should exist.

(;]

~C@Th)
IIISCOIIIlECT

[ill

EO

~
35

r="'

B

Cf'UNI T

CONNECTOR II
SEF244H

CHECK CONTINUITY
BETWEEN SWITCH (M/T),
RELAY (A/T) AND E.C.U.

(;] M/T

131~

i5
00

131

" ~i5

NI
T

§T CONNECTOR

For A/T model
with A.S.C.D.

model

Check continuity between @
and @.
131A/T model
Check continuity between
inhibitor relay connector
CDand @
@ and @. (A.S.C.D. model)
Continuity should exist
O.K.

SEF245H

II

INSPECTION END

~; i5 ~
-~

n

[ill

~

liI
35

SEF349H

If N.G., repair or replace.

N.G. Repair or replace harness or
connector.

O.K.

i5~[[

I1Cf'U

.

, CHECK POWER SUPPLY FOR
INHIBITOR SWITCH.
1) Turn ignition switch "ON".
2) Check voltage between terO.K.
minal @ and ground.
Battery voltage should exist.

[!J
~~_IIECT~

O.K. (A/T)

O.K. (M/T)

SEF242H

~

Replace switch or relay.
[

u

ClUNJ

T

~

CONNECTOR II

IIISCOIIIlECT

E0
EF

&.

EC-141

N.G.

Repair or replace harness or
connector.

TROUBLE DIAGNOSES

Electrical Components Inspection
E.C.U. INPUTIOUTPUT SIGNAL INSPECTION
E.C.U. Inspection table
TERMI.
NAL
NO.

ITEM

*Dataare referencevalues.

CONDITION

*DATA

0.3 - 0.6V
Ignition signal

1.2 - 1.5V
Engine speed is 2,000 rpm

3

Ignition check

9

- 12V

0 -1V
4

Within approximately 1 second
after turning ignition switch "OF F"

E.C.C.S.relay
(Mainrelay)

BATTERY VOLTAGE
(11.14V)

For approximately 1 second
after turning ignition switch
"OFF"

8

Exhaustgastemperature I
I sensor(Onlyfor California
model)
,.

1.0 - 2.0V
L Idle speed

-

- ,

,

0 -1.0V

E.G.R. system is operating.

Both A/Cswitchand blower
11

I Air conditioner relay

I

I

0 -1.0V

switch are "ON"

A/C switch is "OFF".

BATTERY VOLTAGE
(11.14V)

0 - 1.0V
12

S.C.V. control solenoid
valve
Engine speed is 2,000 rpm.

EF & EC-142

BATTERY VOLTAGE
(11 . 14V)

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.

EF & EC-143

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.

TERMINAL
NO.

*DATA

CONDITION

ITEM

OV

Ignition switch "OFF"
36

Ignition switch

BATTERY VOLTAGE
(11

- 14V)

37

Throttle sensor power
supply

Approximately

38
47

Power supply for E.C.U.

BATTERY VOLTAGE
(11-14V)

Both air conditioner switch and
41

I

Air conditioner switch

II

u

.~~o~ers~~~chlare "ON".

I

5V

OV

I

BATTERY VOLTAGE
Air conditioner switch is "OFF".

(11 - 14V)

ne is running.1
S

43

I Power steering oil
pressure switch

I

.

0.1 - 0.3V

teenng wheel is being turned.

I 11::11\:1"'1::
I~IUII'"II\:I.I
.

I

Steenng wheel is not being turned.
tch "ON"

I

8-9V
.

I

Approximately
I
44

I

Idle switch (EB side)

Throttle valve: .idle position

I I Ignnlon SWIl:cnVI'II I
Throttle valve:
Except idle position

..

45

15th position switch
(M/T models)

~

G
I
ear ISIn 5th position.
I I Ignl1lon SWltcn VI'll I

9

- 10V

I

I

BATTERY VOLTAGE
(11

- 14V)

rOV

I
6-8V

Gear is except in 5th position.

46

I Power supply (Back-up)

I I Ignition

switch "OFF"I

EF & EC-144

I

BATTERY

(11

- 14V)

VOLTAGE

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont' d)
*Data are reference values.

TERMI.
NAL

I

CONDITION

ITEM

*DATA

NO.

Injector No.1

103

Injector No.3

BATTERY VOLTAGE
(11.14V)

Engine is running.

110
112

Injector No.2
I

Injector No.4

0.1.0V
102

A.I.V. control solenoid
valve
BATTERY VOLTAGE
(11.14V)

Accelerator pedal is depressed.
After warming up

For 5 seconds after turning
ignition switch "ON"

104

Fuel pump relay

I

Engine is running.

0.7.0.9V

I

"

Within 5 seconds after turning
ignition switch "ON"

Engine is cold.
Water temperature

[

0.7.0.9V
is below

60°C (140°F).

105

E.G. R. control
valve

solenoid

]

After warming up
Water temperature

BATTERY VOLTAGE
(11.14V)

BATTERY VOLTAGE
(11.14V)

is between

60°C (140°F) and 105°C

[ (221°F).

EF & EC-145

]

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.
TERMINAL
NO.

*DATA

CONDITION

ITEM

0 - 1.0V
(for 3 minutes after ignition switch
is turned off.)

Stop and restart engine after
warming it up.

106

Pressure regulator control
solenoid valve

Water temperature
90°C (194°F)

is above

BATTERY VOLTAGE
(After 3 minutes)

Stop and restart engine after
warming it up.
Water temperature
90°C (194°F)

BATTERY VOLTAGE
(11 - 14V)

is below

7 -10V

113

A.A.C. valve

Steering wheel is being turned.
Air conditioner is operating.
Rear defogger is "ON".
Headlamps are in high position.

E.C.U. PIN CONNECTOR

4-7V

TERMINAL LAYOUT

~i)
SEF419H

EF & EC-146

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
E.C.C.S. RELAY
Check continuity between terminals

=

CID

and

CID.

Condition

Continuity

12V direct current supply
between term inals CD and c:v

Yes

No supply

No

SEF054F

CRANK ANGLE SENSOR
1. Remove distributor from engine. (crank angle sensor harness connector is connected.)
2. Turn ignition switch "ON",
3. Rotate crank angle sensor shaft slowly and check voltage
between terminals @, @ and ground.

SEF364H

(I

~

4. Visually check rotor plate for damage or dust.

SEF176E

AIR FLOW METER

.

Visually check hot wire air passage

for dust.

SEF365H

ENGINE TEMPERATURE

SENSOR

Check engine temperature

sensor

resistance.

Temperature °c (F)

Resistance kQ

20 (68)

2.1 - 2.9

80 (176)

0.30 - 0.33

[ill
SE F536H

EF & EC-147

TROUBLE

[ill

DIAGNOSES

Electrical Components
Inspection
IGNITION COIL
Check ignition coil resistance.

(Cont'd)

Terminal

Resistance

@-@

Approximately O.7il

SEF332H

POWER TRANSISTOR

[ill

SEF333H

Check continuity between power transistor terminals.
Terminal No.

Tester polarity

@

EB

@

8

@

8

@

EB

@

EB

@

8

@

8

@

EB

Continuity
No

Yes

No

Yes

E.G.R. CONTROL VALVE
Apply vacuum to E.G.R.vacuum port with a hand vacuum pump.
E.G.R. control valve spring should lift.

SEF820F

B.P.T. VALVE
Plug one of two ports of B.P.T. valve.
Apply a pressure above 0.490 kPa (50 mmH20, 1.97 inH2O) to
check for leakage. If a leak is noted, replace valve.

13

t
EC381A

EF & EC~148

TROUBLE

DIAGNOSES

Electrical Components
Inspection (Cont'd)
E.G.R. CONTROL SOLENOID VALVE, A.I.V. CONTROL
SOLENOID VALVE, P.R. CONTROL SOLENOID- VALVE
AND S.C.V. CONTROL SOLENOID VALVE
Check air passages continuity.
Condition

@
SEF335H

12V direct cu rrent
supply between

terminals

CD

Air passage
continuity
between @ and @

Air passage
continuity
between @ and @

Yes

No

No

Yes

and @

No supply

EXHAUST GAS TEMPERATURE

SENSOR

Check resistance change and resistance value at 100°C (212°F).
Resistance should decrease in response to temperature
increase.
Resistance: 100°C (212°F)
85.3 :t 8.53 k n

.

THROTTLE SENSOR
Make sure that resistance between terminals
changes when opening throttle valve manually.
Resistance should change.

FUEL PUMP
Check continuity between terminals @ and @.
Continuity should exist.

EF & EC-149

@

and CD

TROUBLE DIAGNOSES
Electrical Components, Inspection (Cont'd)
FUEL PUMP RELAY
Check continuity between terminals

=

and @.
Continuity

Condition
12V direct current supply

Yes

betweenterminalsCID and @

No

No supply

-

CD

SEF537H

INJECTORS

.

Check injector resistance.
Resistance:
Approximately 10 15n
Remove injector and check nozzle for clogging.

-

.

SWIRL CONTROL VALVE
Supply vacuum to actuator and check swirl control valve
operation.
Condition

Swirl control valve

Supply vacuum to actuator

Close

No supply

Open

-------

~

~

SEF371H

AIR REGULATOR

.

.

Check air regulator resistance.
Resistance:
Approximately 75 n
Check air regulator for clogging.

[ill
SEF339H

A.A.C. VALVE
Check A.A.C. valve resistance.
Resistance:
Approximately 10 n

.

SEF538H

A~ve'--GV

EF & EC-150

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
Check plunger for seizure or sticking.

..

Check springfor broken.

SEF381H

F.I.C.D. SOLENOID

.

VALVE

Check that clicking sound is heard when applying 12V dirct
current to terminals.

SEF341H

. Check plungerfor seizure or sticking.

.

L l:I"(~

Check for broken spring.

~

Plunger

SEF342H

AIR INDUCTION VALVE
Apply vacuum to vacuum motor, suck or blow hose to make
sure that air flows only towards the air induction side.

IDLE SWITCH

.

Check continuity between
moving throttle valve.

terminals

@ and

Accelerator pedal condition

Continuity

Fully closed

Yes

Open

No

EF & EC-151

@ while

TROUBLE DIAGNOSES
Electrical Components Inspection (Co nt' d)
NEUTRAL SWITCH

.

[:it

b

[ill
c;JJ

Check continuity between terminals @ and @.
Conditions

~~

Continuity

Shift to Neutral

Yes

Shift to other position

No

INHIBITOR

SWITCH

Check continuity between terminals @ and @. CD.
Continuity between
terminals @ and @

Continuity between
terminals @ and CD

Shift to "P" position

Yes

No

Shift to "N" position

No

Yes

Shift to positions
other than "P" and "N"

No

No

Conditions

SEF344H

INHIBITOR

For A/T model
without A.S.C.D.

.

RELAY

Check continuity between terminals @ and CD (Without
A.S.C.D.), @ and @ (With A.S.C.D.).

Condition
Battery

12V direct current supply
between terminals
SEF345H

CD and

W (WithoutA.S.C.D.),

Continuity between terminals
@ and @ (Without A.S.C.D.).
@ and @ (With A.S.C.D.)

Yes

@ and CD (Without A.S.C.D.)
For AlT model
with A.S.C.D.

[ill

No supply

Battery

SEF348H

EF & EC-152

No

FUEL INJECTION CONTROL SYSTEM INSPECTION

Releasing Fuel Pressure
Before disconnecting fuel line, release fuel pressure from fuel
line to eliminate danger.
1. Remove fuel pump fuse.
2. Start engine.
3. After engine stalls, crank it two or three times to release all
fuel pressure.
4. Turn ignition switch off and reconnect fuel pump fuse.

Fuel Pressure
Pressure regulator

Fuel pump and damper
Fuel tank
SEF892D

SEF135H

Check

a. When reconnecting fuel line, always use new clamps.
b. Make sure that clamp screw does not contact adjacent
parts.
c. Use a torque driver to tighten clamps.
d. Use Pressure Gauge to check fuel pressure.
e. Do not perform fuel pressure check while fuel pressure
regulator control system is operating; otherwise, fuel
pressure gauge might indicate incorrect readings.
1. Release fuel pressure to zero.
2. Disconnect fuel hose between fuel filter and fuel tube (engine side).
3. Install pressure gauge between fuel filter and fuel tube.
4. Start engine and check for fuel leakage.

5. Read the fuel pressure gauge indication.
At idling:
When fuel pressure regulator valve
vacuum hose is connected.
More than 226 kPa (2.3 kg/cm2, 33 psi)
When fuel pressure regulator valve
vacuum is disconnected.
Approximately 294 kPa (3.0 kg/cm2, 43 psi)
6. Stop engine and disconnect fuel pressure regulator vacuum
hose from intake manifold.
7. Plug intake manifold with a rubber cap.
8. Connect variable vacuum source to fuel pressure regulator.

EF & EC-153

FUEL INJECTION CONTROL SYSTEM INSPECTION
Fuel Pressure Check (Cont'd)
9. Start engine and read fuel pressure gauge indication as

Vacuum

Fuel pressu re

.

vacuum changes.

Fuel pressure should decrease as vacuum increases. If
results are unsatisfactory, replace fuel pressure regulator.

to

pressure regulator

SEF718B

Injector Removal and Installation
1. Release fuel pressure to zero.
2. Remove or disconnect the following:

.
.

B.P.T. valve

Fuel tube securing bolts
3. Remove injectors with. fuel tube assembly.
4. Remove injector from fuel tube.
5. Install injector as follows:
1) Clean exterior of injector tail piece.
2) Use new O-rings.
CAUTION:
After properly connecting injectors to fuel tube, check connection for fuel leakage.
6. Assemble injectors with fuel pipe to intake manifold.

EF & EC-154

EVAPORATIVE EMISSION CONTROL SYSTEM
Description
Throttle chamber

Vapor vent line
Main purge
orifice
Purge control
valve

~

-

-

Fuel tank

()

0~

Carbon canister

Q

: Air

..

: Fuelvapor
SEC544A

The evaporative emission control system is used to reduce
hydrocarbons emitted to the atmosphere from the fuel system.
This reduction of hydrocarbons is accomplished by activated
charcoals in the carbon canister.
The fuel vapor from the sealed fuel tank is led into the canister
which contains activated carbon and the vapor is stored there
when the engine is not running.
The canister retains the fuel vapor until the canister is purged
by the air drawn through the bottom of the canister to the
intake manifold when the engine is running. When the engine
runs at idle, the purge control valve is closed.
Only a small amount of stored vapor flows into the intake
manifold through the constant purge orifice. As the engine
speed increases, and the throttle vacuum increases, the purge
control valve opens and the vapor is sucked into the intake
manifold through both the main purge orifice and the constant
purge orifice.

Q@

@c)

Inspection
CARBON CANISTER
Check carbon canister as follows:
@:
Blow air and ensure that there is no leakage.
@:
Blow air and ensure that there is leakage.

EF &. EC-155

EVAPORATIVE

EMISSION
Inspection

CONTROL

SYSTEM

(Cont'd)

FUELTANK VACUUM RELIEF VALVE
1. Wipe valve housing clean.
2. Inhale air through the cap. A slight resistance accompanied
by valve clicks indicates that valve is in good mechanical
condition. Note also that, by further inhaling air, the resistance should disappear with valve clicks.
3. If valve is clogged or if no resistance is felt, replace cap as
an assembly.

~
SEC308A

..
~

Q

..

Air
Fuel vapor

FUEL CHECK VALVE
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air
flow should be directed toward the canister.
2. Blow air through connector on canister side.
Air flow should be smoothly directed toward fuel tank.
3. If fuel check valve is suspected of not properly functioning
in steps 1 and 2 above, replace it.

SEC309A

~

-

\

\
l'

\

EF & EC-156

CRANKCASE EMISSION CONTROL SYSTEM
Description

Steel net
Baffle plate
-

{t9t=R:/lL '--Seal

u

lBJ
..

SEF156E

C:?

~

..

type oil
lever gauge
: Fresh air
: Blow-by gas

This system returns blow-by gas to both the intake manifold
and air cleaner.
The positive crankcase ventilation (P.C.V.) valve is provided to
conduct crankcase blow-by gas to the intake manifold.
During partial throttle operation of the engine, the intake
manifold sucks the blow-by gas through the P.C.V. valve.
Normally, the capacity of the valve is sufficient to handle any
blow-by and a small amount of ventilating air.
The ventilating air is then drawn from the air cleaner, through
the hose connecting the air cleaner to rocker cover, into the
crankcase.
Under full-throttle condition, the manifold vacuum is insufficient
to draw the blow-by flow through the valve, and its flow goes
through the hose connection in the reverse direction.
On vehicles with an excessively high blow-by some of the flow
will go through the hose connection to the air cleaner under all
conditions.

Inspection
P.C.V. (Positive Crankcase Ventilation)
With engine running at idle, remove ventilation hose from P.C.V.
valve; if valve is working properly, a hissing noise will be heard
as air passes through it and a strong vacuum should be felt
immediately when a finger is placed over valve inlet.

SEC137A

VENTILATION HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.

ET277

EF &.

EC-157

, '1

SERVICE DATA AND SPECIFICATIONS

General Specifications
IGNITION

TIMING

IDLE SPEED

°S.T.D.C.

15%2
M/T 750%50

rpm

A/T 750%50 (in uNu position)

Inspection

and Adjustment

,

ENGINE TEMPERATURE SENSOR
Thermistor resistance

20°C (68°F)

80°C (176°F)

2.1 -2.9

0.30 - 0.33

k11

IDLE SWITCH
Engine speed when idle switch
is changed from "OFF" to
"ON"
rpm
FUEL PRESSURE at idling
(Measuring point: between fuel
filter and fuel pipe)
Vacuum hose is connected
kPa (kg/em' ,psi)
Vacuum hose is disconnected
kPa (kg/em' , psi)
FUEL INJECTOR
Coil resistance

11

AIR REGULATOR
Resistance

11

M/T
A/T

1,000% 150
1 ,000% 150

(in uN" position)

Approximately
226 (2.3,33)
Approx imately
294 (3.0,43)

Approximately

-

10 15

Approximately 75

EXHAUST GAS TEMPERATURE
SENSOR
100°C (212°F)
Therm istor resistance

k11
85.3:t8.53

EF & EC-158

(S.D.S.)

ENGINECONTROL,
FUEL"
EXHAUST
SYSTEMS
I

FE

SECTION

~~I~~~~!~

SYSTEM

FE-2

FUEL SYSTEM '...
EXHAUST SYSTEM

FE-3
,

.

FE-4

-

ENGINE CONTROL SYSTEM

.
.
.

..

Accelerator Control System
When removing accelerator wire, make a mark to indicate lock nut's initial position.
Check that throttle valve fully opens when accelerator pedal is fully depressed and that it returns to idle
position when pedal is released.
Adjust accelerator wire according to the following procedure.
Tighten "adjusting nut" until "throttle drum" starts to move.
From that position turn back "adjusting nut" 1.5 to 2 turns, and fasten it with a lock nut.
Check accelerator control parts for improper contact with any adjacent parts.
When connecting accelerator wire, be careful not to twist or scratch its inner wire.

Lock nut
tOJ 8

- 11 (0.8 -1.1,5.8

- 8.01

Adjusting nut
tOJ8 -11 (0.8 -1.1,5.8

-8.01
A.S.C.D. actuator

wire
Adjusting nut

tOJ3 -4

~-.

,... . OA,22 -2..,\
.~.~

o:~

m

Locknut

-

tOJ 8 12
(0.8 -1.2,
5.8 -8.7)
Adjusting nut
Accelerator
pedal

Accelerator wire bracket

Throttle drum

tOJ : N.m (kg-m, ft-Ibl

SFE012A

FE-2

FUEL SYSTEM
WARNING:
When replacing fuel line parts, be sure to observe the following:

. Put a "CAUTION: INFLAMMABLE" sign in workshop.
.. Do
not smoke while servicing fuel system. Keep open flames and sparks away from work area.
Be sure to disconnect battery ground cable before conducting operations.
. Put drained fuel in an explosion-proof container and put licit on securely.
CAUTION:
. For
electric fuel pump model, before disconnecting fuel hose, release fuel pressure from fuel line.
Refer to "Fuel Filter Replacement" in MA section.
.. Do
not disconnect any fuel line unless absolutely necessary.
Plug hose and pipe openings to prevent entry of dust or dirt.
. Always replace O-ring and clamps with new ones.
. Do not kink or twist hose and tube when they are installed.
. Do not tighten hose clamps excessively to avoid damaging hoses.
.. When
installing fuel check valve, be careful of its designated direction. (Refer to section EF & EC.)
Run engine and check for leaks at connections.
tDJ 2.0 - 2.5
10.20 - 0.26'
1.4 -1.9)

7

~

Fuel return hose

U

:"-

l

i

.

~~~
I

L!

A

~26-36
12.7 - 3 7
20 - 27j ,

"-tDJ

3.2 - 4.310.33 - 0.44, 2.4 - 3.2)

I

~

!
26 -36 12.7 -3.7,20

-27)

tDJ : N.m (kg-m, ft-Ib)

SFE013A

FE-3

EXHAUST SYSTEM
CAUTION:

.
.
.

Always replace exhaust gaskets with new ones when disassembling.
Check all tube connections for exhaust gas leaks, and entire system for unusual noises, with engine
running.
After installation, check that mounting brackets and mounting Insulator are free from undue stress.
If any of above parts are not installed properly, excessive noise or vibration may be transmitted to
vehicle body.

Catalytic

~

conve'rter

13-16(1.3-1.6,9-121

~

: N.m (kg.m, ft-Ib)

SFE014A

FE-4

CLUTCH
I

CL

SECTION

CONTENTS
PRECAUTIONSAND PREPARATION

,

CL- 2

CLUTCH SYSTEM

CL- 4

INSPECTION AND ADJUSTMENT

CL- 5

HYDRAULICCLUTCH CONTROL

,. CL- 7

CLUTCH RELEASE MECHANISM

CL-10

CLUTCH DISC AND CLUTCH COVER

CL-12

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

CL-14

III

PRECAUTIONS AND PREPARATION
Precautions

..

Recommended fluid is brake fluid "DOT 3".
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
When removing and installing clutch piping, use Tool.

.

.
.
.

~
GG9431 0000
(

-

Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
Never use mineral oils such as gasoline or kerosene. It
will ruin the rubber parts of the hydraulic system.

)
SBR500

WARNING:

After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air,

Preparation
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name

Description

,
ST20050010
(
)
Base plate

~

-

. - ~"., . ,

., :',

~'::..

. -,:,

Inspecting diaphragm spring of clutch
cover

"

,.- :

, , .'. :. ,',' :/.
,

ST20050100
(
)
Distance piece

-

GG9431 0000
)
(
Flare nut torque
wrench

-

ST20600000
(J26366)
Clutch aligning bar

ST20050240
- )
(
Diaphragm spring
adjusting wrench

,

=

-@:j

Inspecting diaphragm spring of clutch
cover

@~
.

\!II

~m

-~

Removing and installing each clutch piping

t"'

==-p

.

Installing clutch cover and clutch disc

~
~ ~
CL-2

Adjusting unevenness of diaphragm spring
of clutch cover

PRECAUTIONS AND PREPARATION
Preparation (Cont'd)
COMMERCIAL
Tool name

SERVICE TOOLS

Description

~

Bearing puller

Bearing drift

a~

V

CL-3

Removing release bearing

a: 50 mm (1.97

In".mn, "I

in) dia.

be,,;n,

r~

~
~f
c

0

1/

,

,~

h
~

(1.6- 2.2,12- 161

~~8-11

(0.8- 1.1,5.8-8.01

~~
~

~
~--

16- 22

~

Return spring

----",.

Lock nut

12-15 (1.2-1.5,9-111
. Pedal stopper

-~

~

'~

16-22(1_6-2.2,1

Clutch switch

Pedalstopper

0

rI

Release
bearing

~
c'"";, p;" m~-//

Clutch pedal

EI(b)

III
(')

r
to)
en
I\)

.A:

N'm (kg-m, ft-Ib)

EI Cb): Apply lithium-based grease
including molybdenum disulphide.

~ . Clutch
switch

INSPECTION AND ADJUSTMENT

Adjusting Clutch Pedal
Pedal bracket
Push rod

Lock nut

~

8

- 11

1/

Clutch switch or pedal
stopper lock nut

.-

~ . Clutch
switch

(0.8 -1.1, 5.8 - 8.0) 12.15 (1.2 .1.5,9.11)
Pedal stopper

22 11.6.2.2,12 - 16)
).<" A
\ ~
Pad

16
\

~,"-'

1. Adjust pedal height with pedal stopper or clutch switch.
Pedal height "H":
186 - 196 mm (7.32 - 7.72 in)
2. Adjust pedal free play with master cylinder push rod. Then
tighten lock nut.
Pedal free play "A":
1.0 - 3.0 mm (0.039 - 0.118 in)
Pedal free play means the following total measured at position of pedal pad:
Play due to clevis pin and clevis pin hole In clutch pedal.

..

Playdue to piston and push rod.

Dash lower
panel
Melt sheet

A

:

N.m Ikg-m.ft-Ib)
SCL323

- U.S.A. model only 3. Adjust clearance "C" between pedal stopper rubber and
threaded end of clutch interlock switch while depressing
clutch pedal fully.
Clearance C:
1.0 - 2.0 mm (0.039 - 0.079 in)

Clutch interlock switch

SCL274

CL-5

INSPECTION AND ADJUSTMENT
Bleeding Procedure
Bleed air according to the following procedure.
Clutch damper -+ Clutch operating cylinder
Carefully monitor fluid level at master cylinder during bleeding operation.
1. Top up reservoir with recommended brake fluid.
2. Connect a transparent vinyl tube to air bleeder valve.
3. Fully depress clutch pedal several times.
4. With clutch pedal depressed, open bleeder valve to release
air.
5. Close bleeder valve.

.

SCL288

6. Repeat steps 3 through 5 above until brake fluid flows from
air bleeder valve without air bubbles.

/

SCL203

CL-6

HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder

Return spring

Reservoir

Piston assembly

cap

Reservoir

Reservoir band
Cylinder body

EI @

Rubbing

surface
to piston
assembly

Dust cover

lEI @
Stopper ring
Packing
. Apply brake fluid when assembling.

Valvestopper

Rubbing surface to
push rod

0

~

Push rod
lEI @ Contact surface to piston assembly

A

1.6 - 2.9 (0.16 - 0.3,1.1 - 2.21
. Remove this stopper, when
removing piston and return spring.

EI

@ : Apply rubber grease.
A:

N.m (kg-m, ft-lbl
SCL348

DISASSEMBLY AND ASSEMBLY
Push piston into cylinder body with screwdriver when
removing and installing valve stopper.

.

.
.
IJJJ.JJJJJJJJJj

em

--

--

Align groove of piston assembly and valve stopper when
installing valve stopper.
Check direction of piston cups.

~11J)

Groove

n
SCL214

CL-7

HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder (Cont'd)
INSPECTION

.
.
.
.
.

Check cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
Check piston with piston cup for wear or damage. Replace if
necessary.
Check return spring for wear or damage. Replace if necessary.
Check reservoir for deformation or damage. Replace if
necessary.
Check dust cover for cracks, deformation or damage.
Replace if necessary.

Operating Cylinder

~

~
l

Piston assembly

~I Operating
lEI @

cylinder
Rubbing surface to piston assembly

Piston spring

Piston cup

IEI@

lEI @ :

Apply rubber grease.
SCL356

INSPECTION

.
.
.
.

Check rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
Check piston with piston cup for wear or damage. Replace if
necessary.
Check piston spring for wear or damage. Replace if necessary.
Check dust cover for cracks, deformation or damage.
Replace if necessary.

CL-8

HYDRAULIC CLUTCH CONTROL
Clutch Damper

~~I[';:':

~

\\ \ \
~

L Bleeder screw

~ ..,.,

lEI @

Spring

Piston cup EI

,.o.U-721

Rubbing surface to
piston assembly

@

Piston assembly
Contact surface to piston assembly
Damper rubber
Damper

EI @

cover

EI

@ : Apply rubber grease.
~:
N.m (kg-m,ft-Ib)
SCL363

INSPECTION
Check cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
Check damper rubber and piston cup for cracks, deformation or damage. Replace if necessary.

.
.

CL-9

CLUTCH RELEASE MECHANISM

c;7
;6e:z
.
~

:;:d'~"7 r~~~:~?~
m(Q
m(Q

---

~
~

~
~

'

Release sleeve

Release bearing

m (b):

Apply lithium-based grease including molybdenum disulphide.
SCL326

REMOVAL AND INSTAllATION
Install retainer spring and holder spring.

.

~-.
-~

~~!£)
U)o///~..

-~-

-.

10

(')

.J

SCL217

.

Remove release bearing.

CL145

.

Install release bearing

Drift

SC L222

CL-10

with suitable

drift.

CLUTCH RELEASE MECHANISM
INSPECTION

.
.

Check release bearing to see that it rolls freely and is free
from noise, cracks, pitting or wear. Replace if necessary.
Check release sleeve and withdrawal lever rubbing surface
for wear, rust or damage. Replace if necessary.

LUBRICATION

.

Apply recommended grease to contact surface and rubbing
surface.
Too much lubricant might damage clutch disc facing.
Pack this recess

.

IEEI(!): Apply

lithium-based grease including

mOlybdenum

disulphide.

SCL223

CL-11

CLUTCH DISC AND CLUTCH COVER

m

Cbi: Apply lithium-basedgreaseincluding
molybdenum disulphide.
SC L354

jJ
.

.

~

:

i

Clutch Disc
INSPECTION
Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)

sa
I E

!

E

C')
ci

SCL229

.

.

Check clutch disc for backlash of spline and runout of
facing.
Maximum backlash of spline (at outer edge of disc):
0.9 mm (0.035 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
107.5 mm (4.23 in)
Check clutch disc for burns, discoloration or oil or grease
leakage. Replace if necessary.

SCL221

INSTAllATION

.

Apply recommended grease to contact surface of spring

portion.
Too much lubricant

CL-12

might damage

clutch disc facing.

CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel
INSPECTION

.
.

.
.

AND ADJUSTMENT

Set Tool and check height and unevenness of diaphragm
spring.
Diaphragm spring height "A":
33.0 - 35.0 mm (1.299 - 1.378 in)
Check thrust rings for wear or damage by shaking cover
assembly and listening for chattering noise, or lightly hammering on rivets for a slightly cracked noise. Replace clutch
cover assembly if necessary.
Check pressure plate and clutch disc contact surface for
slight burns or discoloration. Repair pressure plate with
emery paper.
Check pressure plate and clutch disc contact surface for
deformation or damage. Replace if necessary.

A

SCL219

.

ST20050240

H

Adjust unevenness of diaphragm spring with Tool.
Uneven limit:
0.7 mm (0.028 in)

FLYWHEEL INSPECTION
Flywheel

.
.

Check contact surface of flywheel for slight
discoloration. Repair flywheel with emery paper.
Check flywheel runout.
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)

burns

or

SCL349

INSTAllATION

/(c)
~

.

Insert Tool into clutch disc hub when installing clutch cover
and disc.

Q)J

CL-13

SERVICE DATA AND SPECIFICATIONS (S.O.S.)
General Specifications
.

CLUTCH CONTROL

SYSTEM

CLUTCH DISC
Hydraulic

Type of clutch control

Model

CLUTCH MASTER CYLINDER
Inner diemeter

mm (In)

CLUTCH OPERATING
. Inner diameter

mm (In)

15.87 (5/8)

225 LTD

Facing size
(Outer dia. x inner dia.
x thickness)
mm (in)

225 x 150 x 3.5
(8.86 x 5.91 x 0.138)

Thickness of disc assembly
With loed
mm (in)

7.6.8.0 (0.299 - 0.315)
with 5,394 N
(550 kg, 1,213 Ib)

CYLINDER
17.46

CLUTCH COVER

(11/16)

C225S

Model

CLUTCH DAMPER
Inner diameter

mm (in)

Fuilioed

N (kg,lb)

4.413 (450,992)

19.05 (3/4)

Inspection and Adjustment
CLUTCH COVER

CLUTCH PEDAL

Unit: mm (in)

Unit: mm (in)
Pedal height "H*"

186.196

Pedal free play
(8acklash at clevis)

1.0 . 3.0 (0.039 .0.118)

Clearence between pedel
stopper rubber and threeded
end of clutch interlock

Model

(7.32.7.72)

Diaphragm

1.0-2.0 (0.039.0.079)

CLUTCH DISC
Unit: mm (In)
225L TD

Wear limit of facing surface to
rivet heed

0.3 (0.012)

Aunout limit of facing

1.0 (0.039)

Distance of runout check
point (from the hub center)
Maximum beck lash of spline
(at outer edge of disc)

spring height

Uneven limit of diaphragm
spring toe height

*: Measured from surfece of melt sheet to pedal ped

Model

C225S

107.5 (4.23)

0.9 (0.035)

CL-14

33.0.36.0

(1299 - 1.378)

0.7 (0.028)

MANUALTRANSMISSION
.

MT

SECTION

CONTENTS
PREPARATION
ON-VEHICLE SERVICE

MT- 2
""'"''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''

MT- 4

REMOVAL AND INSTAllATION...

MT- 5

MAJOR OVERHAUL

MT- 6

DISASSEMBLY

MT- 9

INSPECTION

MT-14

ASSEMBLY

MT-16

SERVICE DATA AND SPECIFICATIONS (S.O.S.)

MT-26

-

PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name

Description

9
~

ST2381 0001
(

-

..

)

VW
. ..

Adapter setting plate

KV31100401
(

-

)

Transmission press
stand

ST23540000
(J25689-A)
Pin punch

ST22350000
(J25678-01 )
Drift

ST23800000
(J25691-01)
Drift

Tightening mainshaft lock nut

Removing and installing fork rod retaining
pin

~

ST30031 000
(J22912-01 )
Puller

ST22360002
(J25679-01 )
Drift

Pressing counter gear and mainshaft

w
~

ST22520000
(J26348)
Wrench

ST23860000
(
)
Drift

Fixing adapter plate with gear assembly

~

'Or;",~

Removing and installing 1st gear bushing
Removing main drive gear bearing
Measuring wear of baulk rings

Installing counter drive gear

mm11.50I.' do.
::: :mm

(1.30 in)dia.

Installing counter gear front and rear end
bearings
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.

Installing O.D. gear bushing

a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) die.

Installing front cover oil seal

a: 44 mm (1.73 in) dia.
b: 31 mm (1.22 in) dia.

MT-2

PREPARATION
Tool number
(Kent-Moore No.)
Tool name
ST33400001
(J26082)
Drift

ST33290001
(J25810-A)
Puller

Description

~

Installing rear oil seal

a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.

Removing rear oil seal

~

ST30720000
(
)
Drift

Install ing mainshaft ball bearing

LS

r~7mmC3'.3;")d'"
~
ST30613000
(J25742-3)
Drift

b: 55.5 mm (2.185 inl dia.
Installing main drive gear bearing

iJ

a: 71.5 mm (2.815 in) dia.
b: 47.5 mm (1.870 in) dia.

ST33200000
(J26082)
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm 11.752 in) die.

Installing counter rear bearing
Installing 3rd & 4th synchronizer
assembly

COMMERCIAL SERVICE TOOL
Tool name

Description

Puller

Removing counter bearings, counter drive
and O.D. gears

;!V/

MT-3

ON-VEHICLE SERVICE

Replacing Rear Oil Seal
REMOVAL

INSTAllATION

~ST33400001
,(J26082)
SMT477A
~

----

Check of Position Switch
BACK-UPlAMP SWITCH
Check continuity.

.

Gear position

Continuity

Reverse

Yes

Except reverse

No

NEUTRAL SWITCH

.

Check continuity.
Gear position

Continuity

Neutral

Yes

Except neutral

No

SMT384B

O.D. SWITCH

.

Check continuity.

Gear position

Continuity

5th

Yes

Except 5th

No

MT-4

REMOVAL AND INSTAllATION

Removal

.

~
~

.
..
.

.
.
.

Remove shift lever.

Remove propeller shaft. - Refer to section PD.
Insert plug into rear oil seal after removing propeller shaft.
Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
Support engine by placing a jack under oil pan.
Do not place jack under oil pan drain plug.
Remove transmission from engine.
Support manual transmission, while removing it.

Installation

~
@
SMT381 B

.

Tighten all transmission bolts.
Bolt No.
1
2
3
4

Tightening torque N.m (kg-m,ft-Ib)
39 - 49
39 - 49
29 - 39
39 - 49

Gusset to
engine

MT-5

(4.0 - 5.0, 29 - 36)
(4.0 - 5.0, 29 - 36)
(3.0 - 4.0, 22 - 29)
(4.0 - 5.0, 29 - 36)

29 - 39 (3.0 - 4.0, 22 - 29)

Qmm(in)
70
60
30
25

(2.76)
(2.36)
(1.18)
(0.98)
-

Neutral switch
(OJ 20 29 (2.0 . 3.0, 14 22)

r4 Thread

-

of bolts

3:

-I
I

~

Drain plug
(OJ 25. 34 (2.5 . 3.5, 18 . 25)

C/)

(OJ: N'm (kg-m,

s:
-i
w
to

(II
to

r4:
",.

Apply reco
genuine par
equivalent.

MAJOR OVERHAUL
Gear Components
Needle
bearing

---------------------

sh''''n''n~7i~-J
.j
"

~
\~~3ro&4Oh

~

.

~

,

~

hub-(:r
- ~ :\

M

//

~

"'"'

r'/

~
~

~
'

"

" "

"

R)

B

,

~Q

;?j~)
1 '

~~

~
~~

0.0

~~'

.

Snap ring

Snapring*

~ "

~~MainShaftIOC~
Thrust

l\\f'\'\J

synchronizer

N d

,

Shifting insert spring
/

~
~
~
'

,"~

b"dn.
Sh,"on9i-" *"---4?
,

Ins~rt
""on.

IU & 2n'

S peedometer driveg ge

I

N"dI,""''''

~

\

-

~
=
~~~'

"'.JY

~

r

jI

ring (~)~J

Mainshaft rear end bearin

washe

1~.0 - 17.0, 101 - 123)
no' ....

(W

""

n." 137.'.7
r

IthoutT
Countershaft

I
I

R~I""',i...
. (5th ge~r
bushing WMh" * ~
Ow""w
tOJ 98 . 127 0'
(
~

main gear

aulk
ever.ring
counter gear

'

~

;J

~

~\1

10.0. 13.0,

-

72.941

,

/"<
In~

ffi1a'n"

/

j

0.0. (5th) synchroni",,,,

'oJ'

'

.-; I~

ffinn'
r

I

W
oo'ru" k"

.

"",,",'iw /

~~\ )j \
Coon'" .h,,, J
front bearing
Snap r',n,

* ~""

J

\\;
\(

r

~

.Y L

,

:"-- drive
Counte
gear'"

t..

Sub -gear spring -(:r
Sub-gear
ub-gear bracke t

S

'- R

R

'-

in.

Reverse idler thrust

R everse idler gear bearing
r
everse 'dl
I er thrust washe

~,~
idl"oil .h."
P y geer
to
geers
synchronizers,
.end be ,~heft.,
Ap
* I: S e Iect with

washer

_mbllng.

", : Payatt
,proper thickness.
WhM
I'n'I : N'm (k g-m,
entlonft-Ib)
to"'''''
its d' Irectlon.
.
SMT037B

MT-7

Return
Return

spring

~

RM"';~~??\
If)

-

spring plug

f.4

Thread

~

20 29 (2.0 - 3.0, 14.221

of bolts

-

Bushing
m
Mating surfece to control

lever

Returnspring

'i
Select check plunger

Striking arm J

Lockpin -

/'
<::A

I ~-

Striking lever

I

-I

tDJ 9.12'°,9.'..,

~ ~

., ( "V"@@

-25 . -101
tDJ MO"'.i 11,'
" -~~.O, 1O. 131

1.

.

i1I

~; "2.0

~,

1st & 2nd fork rod

R...,";~ pl.

~

/

@
/ .

~

2 ...8.7

i

D TII,.., ofbo",

CII",' boil

~-.. (1.9 - 2.5,1
"" 10

M12 bolt:

20. ~.o, 14.221

~

~

~~;"';..
O SocketIE!
@{
~/

Chod< boil p'"

CII"" "",..

I

00

rr@

\~

.

1

S,,'ki~ ,,'" --&../

s:

r ~/
;:

~

\

~

~
\

I

Mating surface,
to housing and
control

~

I

lever

Spring

C.."o' 110..'..--\ \

Interlock plunger

Retainingpin ~/

"";

~ ~
3rd & 4th fork rod ~

~

""C'

'6."",,d,..-

I

a.D.

3rd & 4th shift fork

~\Y/~~

II)
s:
-I
w
C»
'-I
C»

a.D.

& reverse fork rod

~

~
~T~

& reverse shift fork

-

~

49 59 (5 - 6, 36 - 431

~

~/

~:

N

f.4

: Ap
ge
eq

DISASSEMBLY
Case Components
1. Remove rear extension.
a. Remove control housing, check ball, return spring plug,
select check plunger and return springs.

SMT982

b. Remove rear extension by lightly tapping it.

Soft hammer

:r

SMT320B

2. Remove front cover, gasket, shim of countershaft front
bearing, and snap ring of main drive gear ball bearing.

')
//

0~

SMT011

3. Remove transmission case by tapping lightly.

TM753

4. Remove front cover oil seal.

,.
~.

SMT035

MT-9

DISASSEMBLY
Shift Control Components
1. Set up Tool on adapter plate.
2. Remove check ball plugs, check springs, and check balls.

ST2381 0001
(
)

-

TM754

3. Drive out retaining pins. Then drive out fork
remove interlock balls.

rods and

ST23540000
(J25689-A)

""

SMT984

4. Remove lever bracket securing bolt.

5. Draw out 3rd-4th fork rod.

6. Remove E-ring from 0.0. and reverse fork rod.

MT -1 0

DISASSEMBLY
Shift Control Components (Cont'd)
7. Draw out 0.0. and reverse fork shaft by rotating 0.0. and
reverse bracket counterclockwise. .
.

.~
SMT792A

~
Gear

Mainshaft

bushing

or

_1

Gear Components

EndPlaY

1. Before removiQg gears and shafts, measure each gear end
play.
Gear end play: Refer to S.D.S.
If not within specification, disassemble and check contact
surface of gear to hub, washer, bushing, needle bearing and
shaft.

~,~

SMT025

2. Mesh 2nd and reverse gear, then draw out counter front
bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket,
sub-gear spring and sub-gear.

Suitable

puller
SMT174A

4. Draw out counter drive gear with main drive gear assembly
with suitable puller.
When drawing out main drive gear assembly, be careful
not to drop pilot bearing and baulk ring.

.

5. Remove rear side components
gear.

on mainshaft and counter

a. Release staking on countershaft nut and mainshaft nut and
loosen these nuts.
Mainshaft nut: Left-hand thread

MT -11

DISASSEMBLY
Gear Components
(Cont'd)
b. Pull out 0.0. counter gear with bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft and draw out
reverse idler gear, thrust washers and reverse idler gear
bearing.
e. Remove speedometer drive gear and steel ball.

Suitable puller

f.
g.
h.
i.
j.
k.

Remove snap ring and pull out overdrive mainshaft bearing,
then remove snap ring.
Remove mainshaft nut.
Remove steel roller and washer.
Remove roller bearing and washer.
Remove 0.0. main gear, needle bearing and baulk ring (0.0.).
Remove 0.0. coupling sleeve, shifting inserts and shifting
insert springs.

SMT040B

.

I. Press out mainshaft and counter gear alternately.
Make sure to alternate pressing of mainshaftand counter
gear so as not to allow the frontsurface of one to contact
the rear surface of the other.

SMT751A

6. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.

c. Press out 2nd main gear together with 1st gear bushing and
1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.

ST30031000
(J22912-01

)

SMT384A

MT-12

DISASSEMBLY
Gear Components (Cont'd)
e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.

SMT385A

7. Remove main drive gear bearing.
a. Remove main drive gear snap ring and spacer.
b. Press out main drive gear bearing.

SMT420A

MT -13

INSPECTION
Shift Control Components
Check contact surface and sliding surface for wear,
scratches, projections or other damage.

.

~

~

6

SMT137

Gear Components
GEAR AND SHAFT

..

Check shafts for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.

SMT386A
Counter

gear

SMT550A
Shifting

insert

~

-

SYNCHRONIZERS

.

..

t

.

Check spline portion of coupling sleeves, hubs and gears
for wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.

SMT387A

MT -14

INSPECTION
Gear Components

.

(Cont'd)

Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear
(1st, 3rd, main drive and O.D. baulk ring):
Dimension

Standard

1st

1.2 - 1.6
(0.047 - 0.063)

3rd and main drive

1.2 - 1.6
(0.047 - 0.063)

a.D.

1.2 - 1.4
(0.047 - 0.055)

Unit: mm

(in)

Wear limit

0.8 (0.031)

SMT140

If the clearance is smaller than the wear limit, replace baulk ring.

.

Measure wear of 2nd baulk ring.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far
as it will go, measure dimensions "A" and "B"

bulk ring
Inner\ 2nd
a. Inner baulk ring.
. hr onizer cone

~~r

ST30031000

(J22912-01)
SMT041 B

~

Unit: mm (in)

~Dial
indicator
ST30031OO0
(J22912-01 )

Dimension

Standard

A

0.6 - 1.1
(0.024 - 0.043)

B

0.7 - 0.9
(0.028 - 0.035)

Wear limit

0.2 (0.008)

Outer baulk ring

Feeler gauge

~

c. If dimension "A" or "B"
replace baulk ring.

is smaller than the wear limit,

!5"

B

""

Synchronizer cone

2nd outer baulk ring

SMT042B

BEARINGS

.

Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT418A

MT -1 5

ASSEMBL Y

Gear Components

Mainshaft ball bearing in adapter plate

lJ')

1. Install bearings into case components.
ST30720000
(

-

)

Counter rear bearing in adapter plate

~"-

~

~

2. Assemble adapter plate parts.
Install oil gutter on adapter plate and expand on rear side.

.

Upper

~

'*

Front

.

Install bearing retainer.
a.. Insert reverse shaft, then install bearing retainer.

SMT028

b. Tighten each screw, then stake each at two points.

MT-16

ASSEMBL Y
Gear Components (Cont'd)
3. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Install main drive gear spacer.

c. Select proper main drive gear snap ring to minimize clearance of groove and install it.
.
Allowable clearance of groove:
0 - 0.13mm (0 - 0.0051 In)
Main drive gear snap ring:
Refer to S.D.S.

SM T 426A

4. Assemble synchronizers.
1st & 2nd synchronizer

.

1 ~Insert

spring

H

~

j

Hub Ind coupling .leeve

.

Check coupling sleeve and synchronizer hub orientation.

CoupJ.ing sleeve

Front.id.

SMT045B

MT -1 7

ASSEMBL Y
Gear Components (Cont'd)

SMT046B

SMT047B

Coupling

Synchronizer

/
(

/

.

3rd & 4th synchronizer

.

0.0. synchronizer

sleeve

hub

- -, ,

~

I

Shi~t~g}l!sert

O.D. (5th) synchronizer
hub

SMT095A

5. Install front side components on main shaft.
a. Assemble 2nd main gear, needle bearing and 1st & 2nd
synchronizer assembly, then press 1st gear bushing on
mainshaft.
b. Install 1st main gear.

\

1st gear
thrust washer

\

SMT752A

MT -1 8

ASSEMBL Y
Gear Components (Cont'd)
c. Install steel ball and 1st gear washer.
Apply multi-purpose grease to steel ball and 1st gear
washer before installing.

SMT403A

6. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Press mainshaft assembly to adapter plate with Tool.

KV31100401
(
)

TM439

I

b. Press counter gear into adapter plate with Tool.
c. Install 3rd main gear and then press 3rd & 4th synchronizer
assembly.

ST33200000
(J26082)
I

KV31100401
(
)

\\

.
Coupling

Synchronizer

/
r

/

hub

- --,

~

Pay attention to direction of 3rd & 4th synchronizer.

sleeve

,
I

Shi!ti~9_il}sert

d. Install thrust washer on mainshaft and secure it with
mainshaft front snap ring.
Select proper snap ring to minimize clearance of groove in
mainshaft.
Allowable clearance of groove:
0 - 0.18mm (0 - 0.0071 in)
Mainshaft front snap ring:
Refer to S.D.S.
e. Apply gear oil to mainshaft pilot bearing and install it on
mainshaft.
TM441

MT -1 9

ASSEMBLY
Gear Components (Cont'd)
f.

Press counter drive gear with main drive gear with Tool.

KV311OO401
(
),

-

TM442

.

Pay attention to direction of counter drive gear.

Front.

SMT620A

g. Install sub-gear components.
(1) Install sub-gear and sub-gear bracket on counter drive gear
and then select proper snap ring to minimize clearance of
groove in counter gear.
Allowable clearance of groove:
0 - 0.18mm (0 - 0.0071 In)
Counter drive gear snap ring: Refer to S.D.S.
(2) Remove snap ring, sub-gear bracket and sub-gear from
counter gear.
(3) Reinstall sub-gear, sub-gear spring and sub-gear bracket.
h. Install selected counter drive gear snap ring.

TM366

i.

Press counter gear front bearing onto counter gear.

ST22360002
(J25679-01 )

KV311OO401
(
)

-

TM443

MT-20

ASSEMBL Y
Gear Components

(Cont'd)

7. Install rear side components on mainshaft and counter gear.

a. Install reverse idler gear to reverse idler shaft with spacers,
snap rings and needle bearing.

-

Front

I

L-~

I

TM451

.

b. Install insert retainer and 0.0. synchronizer to mainshaft.
Pay attention to direction of hub.

0.0. 15thl synchronizer
hub

SMT095A

c. Install 0.0. gear bushing with Tool.
d. Install 0.0. main gear and needle bearing.
e. Install spacer, reverse counter gear and 0.0. counter gear.
O.D. main gear and O.D. counter gear should be handled
as a matched set.
f. Install washer, roller bearing, steel roller and thrust washer.
g. Tighten mainshaft lock nut temporarily.
Always use new lock nut.

Gear bushing

.
.

SMT531

h. Install countershaft rear end bearing with Tool.

SMT043

8. Mesh 2nd and reverse gears, then tighten mainshaft lock
nut with Tool.

ST22520000
IJ263481

SMTOO3A

MT - 21

.

ASSEMBLY
Gear Components (Cont'd)

.

c

Tool

Use the left chart when deciding the reading torque.
(Length of torque wrench vs. setting or reading torque)
9. Tighten countershaft lock nut.
. Always use new lock nut.

Torque wrench

L m (ft)

0.10 m'
(0.33 ft) N.m
(ft-lbI

~

157(kg-m)
(16)

(110)

147
(15)

'"
::J
c-

o

i

'"
'"
a:

137
(100)

f

(14)

0.6

.
SMTOO4A
Mainshaft

I

(1.5)
L: Length

(2.0)
of torque

0.7
I

0.8
m

(2.5) (h)
wrench

10. Stake mainshaft lock nut and countershaft
punch.

Countershaft

lock nut with a

11. Measure gear end play. For the description,
ASSEMBLY for Gear Components.

refer to DIS-

Shift Control Components
Fork rod
(1st & 2nd)
Fork rod
(3rd & 4th)
Interlock plunger

1. Install shift rods, interlock plunger, interlock balls and check
balls.

Interlock
ball

SMT992

a. 1st-2nd shift fork

SMT989

MT-22

ASSEMBL V
Shift Control Components (Cont'd)
b. 3rd-4th shift fork

SMT990

c. a.D.-reverse

shift fork or reverse shift fork.

SMT991

2. Install 0.0. and reverse fork shaft by rotating 0.0. and
reverse bracket clockwise.

SMT791 A

3. Install E-ring on 0.0. and reverse fork rod.

4. Install lever bracket securing bolt.

MT-23

ASSEMBLY
Case Components
1. Install front cover oil seal.
Apply multi-purpose grease to seal lip of 011seal before
installing.

.

SMT036

2. Apply sealant to mating surface of transmission case.

3. Install gear assembly onto transmission case.

SMT013

4. Install snap ring of main drive bearing.

5. Apply sealant to mating surface of adapter plate.
6. Install rear extension.

MT-24

ASSEMBL Y
Case Components (Cont'd)
A: Distance from bearing
surface to transmission
@

case

7. Select counter front bearing shim.
Counter front bearing shim: Refer to S.D.S.
8. Install gasket and front cover.

1 Transmission case
2 Counter gear front bearing
3 Counter gear
TM371

9. Install return spring plugs, check ball, return springs and
select check plunger.
10. Install control housing and gasket.

SMT982

MT-25

SERVICE DATA AND SPECIFICATIONS

(S.D.S)

General Specifications
Transmission model

FS5W71C
5

Number of speeds
Shift patern

.

Gear ratio

Number of teeth
Mainshaft

Countershaft

5

2

I.

R

I
4

1st
2nd
3rd
4th
O.D.
Reverse

3.321
1.902
1.308
1.000
0.759
3.382

Drive
1st
2nd
3rd
O.D.
Reverse

22
33
27
26
21
36

Drive
1st
2nd
3rd
O.D.
Reverse

31
14
20
28
39
15

Reverse idler gear

Remarks

3

Warner

Synchromesh type

Oil capacity

1

Q (US pt, Imp pt)

21
2.4 (5-1/8, 4-1/4)

Sub-gear

0

Mainshaft braking
mechanism

0

Double baulk ring
type synchronizer

2nd synchronizer

MT-26

SERVICE DATA AND SPECIFICATIONS (S.D.S)
Inspection and Adjustment
GEAR END PLAY

Mainshaft front

Gear

End play

Allowable clearance

mm (in)

1st gear

0.31 -0.41

(0.0122

-0.0161)

2nd gear

0.11 -0.21

(0.0043

-0.0083)

3rd gear

0.11 -0.21

(0.0043

-0.0083)

O.D. gear

0.24 - 0.41 (0.0094

CLEARANCE
AND GEAR

0 -0.18 mm (0 -0.0071 in)

Thickness mm (in)

Part number

2.4 (0.094)
2.5 (0.098)
2.6 (0.102)

- 0_01611

BETWEEN BAULK RING

32263-V5200
32263-V5201
32263-V5202

Mainshaft rear end bearing
Allowable clearance

0 - 0.14 mm (0 - 0.0055

in)

1st, 3rd, main drive and O.D. baulk ring
Thickness mm (in)

Part number

Unit: mm (in)

Standard
1st

1.2-1.6
(0.047 - 0_063)

3rd and main drive

1.2 - 1.6
(0.047 - 0.0631

O.D.

1.2- 1.4
(0.047- 0.055)

1.1
1.2
1.3
1.4

Wear limit

(0.043)
(0.047)
(0.0511
(0.055)

32228-20100
32228-20101
32228-20102
32228-20103

0.8 (0.031)

Counter drive gear
Allowable clearance

2nd baulk ring

0 -0.18 mm (0 -0.0071 in)

Thickness mm (in)

Unit: mm (in)

Part number

1.4 (0.055)
1.5 (0.059)
1.6 (0.063)

Outer baulk ring
B

32215-E9000
32215-E9001
32215-E9002

AVAILABLE SHIMS
Counter front bearing

Inner baulk ring
Synchronizer cone
Dimension

Standard

A

0.6 - 1.1
(0.024 - 0.043)

SMT0448

mm (in)

CD
@

Wear limit

A: Distance from bearing
surface to transmission
case

0.2 (0.008)

1 Transmission case
2 Counter gear front bearing
3 Counter gear

0.7 - 0.9

B

Unit:

(0.028 - 0.035)
TM371

Main drive gear bearing
Allowable

clearance

Thickness mm (in)
1.73
1.80
1.87
1.94
2.01
2.08

(0.0681)
(0.0709)
(0.0736)
(0.0764)
(0.0791)
(0.0819)

Thickness
of shim

"A"

AVAILABLE SNAP RINGS
4.52 -4.71
0 - 0.13 mm (0 - 0.0051 in)

Part number
32204-78005
32204-78000
32204-78001
32204-78002
32204-78003
32204-78004

4.42
4.32
4.22
4.12
4.02
3.92

MT-27

(0.1780

-4.51 (0.1740
-4.41 (0.1701
-4.3110.1661
-4.21 (0.1622
-4.11 (0.1583
-4.01 (0.1543

-0.1854)

-0.1776)
-0.1736)
-0.1697)
-0.1657)
-0.1618)
- 0.1579)

Part number
Not necessary

0.1
0.2
0.3
0.4
0.5
0.6

(0.004)
(0.008)
(0.012)
(0.016)
(0.020)
(0.024)

32218-V5000
32218-V5001
32218-V5002
32218-V5003
32218-V5004
32218-V5005

AUTOMATIC
TRANSMISSION

AT

/

SECTION
/

/

CONTENTS
PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-. . . . . . . . . . . . . . . . . . . .. ATPRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. AT-

3

AfT CONTROL DIAGRAM

4

2

AT-

ON-VEHICLE SERVICE... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . AT- 7
TROUBLE DIAGNOSES
REMOVAL AND INSTALLATION
MAJOR OVERHAUL

"

AT- 11
AT- 85
AT- 86

DISASSEMBLY. . . ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR FOR COMPONENTPARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMB LY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AT-

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

AT-165

AT-101
AT -146

When you read wiring diagrams:
Read GI section, "HOW TO READ WIRING DIAGRAMS".
See EL section, "POWER SUPPLY ROUTING.. for power distribution circuit.
When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES".

.
.

90

-

PREPARATION
SPECIALSERVIC~ TOOLS
Tool number
(Kent-Moore No.)
Tool name

/f

Description

ST2505S001
(J25695-A)
Oil pressure gauge set
CD

/CD

CID

~ ~ ----@

ST25051001

-

(
)
Oil pressure gauge

@ ST25052000
(

-

'

)

Hose
CID

Measuring line pressure

ST25053000

-

(
)
Joint pipe
@ ST25054000
(

-

~.:.

U!!
"

o/~~

)

Adapter
CID

ST25055000

-

(
Adapter

)

ST07870000
(J37068)
Transmission case
stand

Disassembling and assembling
AfT

KV31102100
(J37065)
Torque converter oneway clutch check tool

Checking one-way clutch in
torque converter

ST25850000
(J25721-A)
Sliding hammer

Removing oil pump assembly

~

KV31102400
(J34285 and
J34285-87)
Clutch spring
compressor

Removing and installing clutch
return springs.

~,
0
ST33200000
(J37067)
Drift

(J34291 )
Shim setting gauge
set

,

a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

~

Ir;==:J

~T~t~~

1?1/li
~~

AT-2

Installing oil pump housing
oil seal
Installing rear oil seal

Selecting oil pump cover
bearing race and oil pump
thrust washer

PRECAUTIONS

.

.
.
.
.
.

~

Service Notice

Before proceeding with disassembly, thoroughIy clean the outside of the transmission. It is
important to prevent the internal parts from
becoming contaminated by dirt or other
foreign matter.
Disassembly should be done in a clean work
area.

.

It is very important to perform functional tests.
whenever they are indicated.
The valve body contains precision parts and requires extreme care when parts are removed
and serviced. Place removed parts in order on a
parts rack so they can be put back in the valve
body in the same positions and sequences. Care

.

Use lint-free cloth or towels for .wiping parts

will also prevent springs and small parts from

clean. Common shop rags can leave fibers that
could interfere with the operation of the transmission.
When disassembling parts, place them in order
in a parts rack so that they can be put back
into the unit in their proper positions.
All parts should be carefully cleaned with a
general purpose, non-flammable solvent before
inspection or reassembly.
Gaskets, seals and O-rings should be replaced.
any time the transmission is disassembled.

becoming scattered or lost.
Properly installed valves, sleeves, plugs,~
will
slide along their bores in the valve body under
their own weight.
Before assembly, apply a coat of recommended
A.T.F. to all parts. Petroleum jelly may be
applied to O-rings and seals and used to hold
small bearings and washers in place during reassembly. Do not use grease.
Extreme care should be taken to avoid damage
to O-rings, seals and gaskets when assembling.
After overhaul, refill the transmission with new
A.T.F.

.
.

.

~

)

AT-3

~

I
Lock-up
solenoid

g

,

/'011
[cooler

~~~,~

L'

relielvalve

9

lubrlcalion

Modifier
accunlulator

/

L~r

~

I~'ve

lubrication

I

,

II"Lr-

m

Pressure
modifier
valve

m,

I

Ii

~

i

,'

Servo
changer
valve

converter

/;;;'t

"R" line pressure'
check port

~~

Ii

'-

--

II=::II"

I/)

»~

~
Co)

m

-

1
1
1
I
I
I
I
I
I
I
I
I
I
,

L

JlIT:Jill:JUL

I=;

Feedback
accumulator
piston

~~~~

~:~
I

J[

Pilot valve

~

Line pressure
solenolo

r
II

--'~

-J~

USh~

1m;~~oiO A

solenOIOB

Z Overrun

~

-- -

x
n --

I
I

PRND21

I
I

"~"

I

J

solenoid

w
r~
'Manual

~~-

valve

AfT CONTROL DIAGRAM
Electrical Control Chart

-

Vehicle signal

~

Speed sensor

. Electrical singnal
: Hydraulic pressure
Vehicle signal

Engine

Overdrive
switch
Kickdown switch

AfT

Overdrive off
indicator lamp

Power supply

Control signal'

---------r----I
I Inhibitor switch
I
temperature
I Fluid
.
sensor
I
I
Revolution
I
sensor
I

Idle switch
Full-throttle

switch
Throttle sensor
Engine rpm
signal

Shift solenoid A
Shift solenoid B
Overrun clutch
solenoid
lock-up solenoid

- - - - _.~

---------

L__--

AfT control

unit

SAT8178

Mechnical Operation
Band servo
Shift
position

Reverse
clutch

High
clutch

Forward
clutch

Overrun
clutch

2nd
apply

3rd
re lease

4th
apply

Forward
one-way
clutch

Low
one-way
clutch

Low &
reverse
brake

Lock-up

p

PARK

N

*4

2

1st

0

2nd

0

.,

0

0

0

*20

0

4th

0

0

*30

0

1st

0

2nd

0

1st

0
0

2nd

0
0
0

NEUTRAL

.. .

3rd

1
*

REVERSE

0

0

R

D

Remarks

Automatic shift

1-2-3-4

.

0

.

..
.

0
0

0

.

Automaticshift

1-2

0

Locks (held stationary)

in 1st

speed 1 ..... 2

1. Operates when overdrive switch is set to "OFF".

*2. Oil pressure is applied to both 2nd "apply" side and 3rd "release" side of band servo piston. However, because oil pressure area on the
"release" side is greater than that on the "apply" side, brake band does not contract.
*3. Oil pressure is applied to 4th "apply" side in condition *2 above, and brake band contracts.
*4. A/T will not shift to 4th when overdriveswitch isset to "OFF" position.

0

.

. Operates.

0

. Operates

~

. Operates during "progressive" acceleration.
. Operates but does not affect power transmission.
. Operates4l/llhen throttle opening is less than 1/16 but does not affect engine brake.

e

when throttle

opening

is less than

1/16.

Engine brake activates.

AT-5

/~

Lock-up

piston

Torque

converter
Converter

housing

Front planetary gear

Transmission case

~

Rear planetary
Forward

gear
clutch

Brake band
Forward one-way clutch
Reverse clutch

Low & reverse brake

Overrun clutch
High clutch

Low one-way clu

~
I

0)

\00 \0

\

010
0

\

en
:I>
j
I\J
C1
III

Input shaft

Oil pumlJ

Control

valve

Outpu

ON-VEHICLE SERVICE

Control Valve Assembly and Accumulators
Inspection
1. Remove oil pan and gasket and drain A.T.F.

2. Remove oil strainer.

I

3. Remove control valve assembly by removing fixing bolts and
disconnecting harness connector.
Bolt length and location
Bolt symbol

Length mm (in)

@

37 (1.46)

@

50 (1.97)

4. Remove solenoids and valves frbm valve body if necessary.
5. Remove terminal cord assembly if necessary.

6. Remove accumulator A, S, C and D by applying compressed
air if necessary.
Hold each piston with rag.
7. Reinstall any part removed.
Always use new sealing parts.

.
.

AT-7

""

ON-VEHICLE SERVICE

Revolution Sensor Replacement
1. Remove rear engine mounting member from body panel
while supporting AIT with jack.
2. Lower AIT assembly as much as possible.

3. Remove revolution sensor from AIT assembly.
4. Reinstall any part removed.
Always use new sealing parts.

.

Rear Oil Seal Replacement
1. Remove propeller shaft from vehicle. 2. Remove rear oil seal.

3. Install rear oil seal.
Apply A.T.F. before installing.
4. Reinstall any part removed.

Refer to section PD.

'\

.

Parking Components Inspection
1. Remove propeller shaft from vehicle. - Refer to section PD.
2. Remove rear engine mounting member from AIT assembly.

AT-8

ON-VEHICLE SERVICE
Parking Components Inspection (Cont'd)
3. Remove rear extension from transmission case.
4. Replace parking components if necessary.
5. Reinstall any part removed.
Always use new sealing parts.

.

SAT133B

Inhibitor Switch Adjustment
1. Remove manual control linkage from manual shaft of AIT
assembly.
2. Set manual shaft of AIT assembly in "N" position.
3. Loosen inhibitor switch fixing bolts.

4. Insert pin into adjustment holes in both inhibitor switch and
manual shaft of AIT assembly as near vertical as possible.
5. Reinstall any part removed.
6. Check continuity of inhibitor switch. - Refer to "Electrical
Components Inspection".

,\
--1\
SAT081B

Manual Control Linkage Adjustment
Move selector lever from "P" range to "1" range. Y~hould
be able to feel the detents in each range.
If the detents cannot be felt or the pointer indicating the range
is improperly aligned, the linkage needs adjustment.
1. Place selector lever in "P" range.
2: Loosen lock nuts.

3. Tighten lock nut @ until it touches trunnion pulling selector
lever toward "R" range side without pushing button.
4. Back off lock nut @ 1 turn and tighten lock nut (!) to the
specified torque.
Lock nut:
~: 11 - 15 N.m (1.1 - 1.5 kg-m, 8 - 11 ft-Ib)
5. Move selector lever from "P" range to "1" range. Make sure
that selector lever can move smoothly.
Lock nut (!)
Luck nut @
SAT788B

AT-9

ON-VEHICLE SERVICE
NOTE

AT-'O

TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
AT-13
Preliminary Check
:
AT-14
AfT Electrical Parts Location
AT-25
Circuit Diagram for Quick Pin Point Check
AT-27
Wiring Diagram
AT-28
Self-diagnosis
''''''''''''''
AT-30
SELF-DIAGNOSTIC PROCEDURE
AT-30
JUDGEMENT OF SELF-DIAGNOSIS CODE
:
AT-32
REVOLUTION SENSOR CIRCUIT CHECK """'"''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
AT-36
SPEED SENSOR CIRCUIT CHECK
; AT-36
THROTTLE SENSOR CIRCUIT CHECK
AT-37
SHIFT SOLENOID A CIRCUIT CHECK
(
AT-38
SHIFT SOLENOID B CIRCUIT CHECK
j
AT-39
OVERRUN CLUTCH CIRCUIT CHECK
AT-40
LOCK-UP SOLENOID CIRCUIT CHECK
AT-41
FLUID TEMPERATURE SENSOR CIRCUIT AND A/T CONTROL UNIT
POWER'SOURCE CIRCUIT CHECKS
AT-42
ENGINE REVOLUTION SIGNAL CIRCUIT CHECK
AT-43
LINE PRESSURE SOLENOID CIRCUIT CHECK
;
AT-44
INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH CIRCUIT CHECKS
AT-45
Diagnostic Procedure 1
(SYMPTOM: 0.0. OFF indicator lamp does not come on for about 2 seconds
when turning ignition switch to "ON".)
AT-47
Diagnostic Procedure 2
(SYMPTOM: Engine cannot be 'Started with selector lever in "P" or "N" range or
engine .can be started with selector lever in "0", "2", "1" or "R" range.)
AT-48
Diagnostic Procedure 3
(SYMPTOM: Vehicle moves when it is pushed forward or backward
with selector lever in "P" range.)
""""""""""'"
AT-48
Diagnostic Procedure 4
(SYMPTOM: Vehicle moves forward when setting "N" range.)
AT-49
Diagnostic Procedure 5
(SYMPTOM: There is large shock when changing from "N" to "R" range.)
AT-50
Diagnostic Procedure 6
(SYMPTOM: vehicle does not creep backward when selecting "R" range.)
AT-51
Diagnostic Procedure 7
(SYMPTOM: Vehicle does not creep forward when selecting "0" , "2" and "1" range.)
AT-52
Diagnostic Procedure 8
(SYMPTOM: Vehicle cannot be started from 01 on Cruise test-Part
1.) """''''''''''''''''''''''''''''''''''
AT-53
Diagnostic Procedure 9
(SYMPTOM: A/T does not shift from 01 to 02 at specified speed.
A/T does not shift from 04 to O2when depressing accelerator pedal fully at
the specified speed.)
. AT-54
Diagnostic Procedure 10
(SYMPTOM: A/T does not shift from 02 to 03 at the specified speed.)
AT-55
Diagnostic Procedure 11
(SYMPTOM: A/T does not shift from 03 to 04 at the specified speed.) ""'"''''''''''''''''''''''''''''''''''''
AT-56
Diagnostic Procedure 12
(SYMPTOM: A/T does not perform lock-up at the specified speed.)
AT-57
Diagnostic Procedure 13
(SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds.)
AT-58
Diagnostic Procedure 14
(SYMPTOM: Lock-up is not released when accelerator pedal is released.) ""'"''''''''''''''''''''''''''''''
AT-58

AT-11

TROUBLE DIAGNOSES
Contents

(Cont'd)

Diagnostic Procedure 15
(SYMPTOM: Engine speed does not return to idle smoothly when AfT is shifted
from D4 to D3 with accelerator pedal released.
Vehicle does not decelerate by engine brake when changing overdrive switch
to "OFF" position with accelerator pedal released.
Vehicle does not decelerate by engine brake when changing selector lever
from "D" to "2" range with accelerator pedal released.)

AT-59

Diagnostic Procedure 16
(SYMPTOM:

Vehicle

does not start from D1 on Cruise test -

Part 2.) """""""""""'"''''''''''''''''''

AT-60

Diagnostic Procedure 17
(SYMPTOM:
to

"OFF"

Vehicle

does not shift from D4 on D3 when changing

position.)

"""""""""""

overdrive

switch

"'"''''''''''''''''''''''''''''

"""'"''''''''''''

AT-'60

""""'"

Diagnostic Procedure 18
(SYMPTOM:AfT does not shift from D3on D2when changing selector lever
from"

D"

to "2"

range.)

""""""""""

"""''''''''

""''''''''''''''''''''''

AT-61

""""""""""

Diagnostic Procedure 19
(SYMPTOM: Vehicle does not shift from 22 on 11when changing selector lever
from "2" to ",1" range.)
""""
Diagnostic Procedure 20
(SYMPTOM: Vehicle does not decelerate by enigne brake when shifting from 22 (12) to 1,.)

Electrical Components
Final Check
Symptom

Chart

...

AT-61
AT-61
AT-62
. AT-68

Inspection
"""""""""""""""
""""""'"

""""""""'"

""

AT-72
AT-75

""""""""""""""

AIT Shift Lock System

,.

,

SHIFT LOCK SYSTEM ELECTRICAL PARTS LOCATION
CIRCUIT DIAGRAM FOR QUICK PIN POINT CHECK
WIRING DIAGRAM
DIAGNOSTIC PROCEDURE 1

AT-75
AT-76
AT-77

(SYMPTOM: Selector lever cannot be moved from "P" range when applying
brake pedal or can be moved when releasing brake pedal.)
DIAGNOSTIC PROCEDURE 2

AT-78

\

(SYMPTOM: Ignition key cannot be removed when selector lever is set to "P" position
or can
be CONTROL
removed when
lever is set to any position except "P".)
SHIFT
LOCK
UNIT selector
INSPECTION
SHIFT LOCK CONTROL UNIT INSPECTION TABLE
COMPONENT CHECK
'"''''''''''''''''''''''''''''''''

AT-12

\
'"''''''''

AT-80
AT-82
AT-83

AT-84

TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accura,e Repair
WORK FLOW
CHECK IN

<

Reference item

LISTEN TO CUSTOMER
COMPLAINTS.

CHECK A/T FLUID
AND CONDITION.

LEVEL

AfT FLUID CHECK
(SeepageAT-14.)
Preliminary
Check

r-----I

I
I
I
I
I
I
I
I

--

I
I
I
I
I
I
I
I
I
I
I
I
I
I

--~I

.
.

PERFORM ROAD TESTING.
PERFORM SELF-DIAGNOSIS.

Self-diagnosis
(See page AT-30.)

Self-diagnosis
(See page AT -30.)

INSPECT MALFUNCTION ON
THE BASIS OF EACH COMPONENTS CONDITION.

Diagnostic Procedure
(See page AT -47.)

Symptom Chart
(SeepageAT -72.)

REPAI R/REPLACE.

I

L- ---------N.G.

ROAD TESTING
(SeepageA T-15.)

FINAL CHECK

AT-13

Final Check
(See page AT -68.)

~

TROUBLE DIAGNOSES
Preliminary

~
~Q

81
~~

~

Check

AIT FLUID CHECK
Fluid leakage check

e

1. Clean area suspected of leaking, -

for example, mating
surface of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in "0"
range and wait a few minutes.
3. Stop engine.

SAT767B

4. Check for fresh leakage.

,
SAT801A

Fluid condition check
Fluid color

Suspected problem

Dark or black with burned odor

Wear of frictional material

Milky pink

-

Water contamination

SA T638A

Varnished fluid, light to dark
brown and tacky

Fluid level check
Refer to section MA.

AT-14

Road water entering through
filler tube or breather

Oxidation
-

Over or under filling
Overheating

I

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
ROAD TESTING

ROAD TEST PROCEDURE
1. Check before engine is started.

0
I

3. Cruise test.

.

.

2. Check at idle.

0
I

Description
The purpose of this road test is to determine overall
performance of automatic transmission and analyze causes
of problems.
The road test consists of the following three parts:
1. Check before engine is started
2. Check at idle
3. Cruise test

SAT786A

.
.

Before road test, familiarize yourself with all test procedures
and items to check.
Conduct tests on all items. Troubleshoot items which check
out No Good after road test. Refer to "Self-diagnosis" and
"Diagnostic Procedure".

~

SA T639A

AT-15

TROUBLE DIAGNOSES

--

Preliminary Check (Cont'd)
1. Check before engine is started

0

0
Park vehicle on flat surface.

SAT787A

fA
Move selector lever to "P"
range.

fA

fir:)

~
.IJ
SA T768B

Does O.D. OFF indicator lamp.
come on for about 2 seconds?
Yes
Does O.D. OFF indicator lamp
flicker for about 8 seconds?
I

No

a:J\

~
SAT836B

Perform self-diagnosis.
- Refer to SELF-DIAGNOSIS
PROCEDURE and note N.G.
items.

Go to "ROAD TESTING
- 2. Check at idle".

AT-16

Perform self-diagnosis. .
- Refer to SELF-DIAGNOSIS
PROCEDURE.

TROUBLE DIAGNOSES,
Preliminary Check (Cont'd)
2. Check at idle

0

0
Park vehicle on flat surface.

6
SA T787 A

Move selector lever to "P" or
"N" range.

6

Is engine started?

.

Yes

N°I

Go to Diagnostic Procedure 2.1

SAT7698

BJ

BJ

Moveselector lever to "D", "1",
"2" or "R" range.

Yes
Go to Diagnostic Procedure 2.
SAT7708

II
II
Move selector lever to "P" range.

SA T7688

m

m

~

Push vehicle forward or backward.

Yes
Does vehicle move when it is
pushed forward or backward?
I
No

SAT796A

A

AT-17

Go to DiagnosticProcedure 3.

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
:A)

m

~

m

Move selector lever to "N" range.

I

~

SAT771B

."';"";"

fJ

~t,ST

Brake peda I

~

~
I

SA T797 A

Does vehicle move forward or
backward?

fJ

Yes I Go to Diagnostic Procedure 4.1

[NO

Appl'Y'foot brake.

m

m
Move selector lever to "R" range.

Yes
Is there large shock when
changing from "N" to "R"
range?

m

Go to Diagnostic Procedure 5.1

No

Release foot brake for several
seconds.

SAT772B

m

I

Does vehicle creep backward
when foot brake is released?

Brake pedal

Yes

iii]

Move selector lever to "D", "1"
and "2" range and check if
vehicle creeps forward.

Does vehicle creep forward in all
three ranges?
No

For several seconds
SAT799A

iii]
I

Go to Diagnostic.Procedure 7.

SAT773B

AT-18

Go to Diagnostic Procedure 6.

TROUBLE DIAGNOSES
t half throttle open

~
~

AfT control~it

terminal

\

\Atfull

Preliminary Check (Cont'd)
3. Cruise test
Check all items listed in Parts 1 through 3.
Throttle position can be controlled by voltage across termi-.
nals (jJ)and @ of AfT control unit.

..

\throttleopen

~

~~I.J~
SAT802A
Cruisetest - Part 1
0

0

Warm up engine until engine oil
and A.T. F. reach operating temperature after vehicle has been
driven approx. 10 minutes.
A.T.F. operating temperature:
50 80°C (122 176°F)

-

-

SAT779A

Park vehicle on flat surface.

II

i]

/

II
Set overdrive switch to "ON"
position.

-.

ID
Move selector lever to "P" range.

SAT7748

~

II

G

II
Move selector lever to "D" range.

m

SAT7758

Accelerate vehicle by constantly
depressing accelerator pedal halfway.

Does vehicle start from D1 ?
Yes

SA T803A

@

AT-19

Go to Diagnostic Procedure 8.

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
~

6

m

II

'll N

8/8

m ,...-

6
0/8

.. , ..

m

8/811

II

IU

?l

~~

0/8

Does AfT shift from D3 to D4
at the specified speed?
Specified speed when shifting
from D3 to D4 :
Refer to Shift schedule.

~l
SAT805A

.

m

IEm

81)
0T-------------

»

0/8

If

SA T806A

~

IE II]
8/8

,..
.,..,..
...-,..

...("
I
I
I

0/8

("--

Nb

Go to Diagnostic Procedure 10.

No
Go to Diagnostic Procedure 11.

No
Go to Diagnostic Procedure 12.

Does AfT hold lock-up condition
for more than 30 seconds?

1

1

Go to Diagnostic Procedure 9.

Yes

Does AfT perform lock-up at
the specified speed?
Specified speed when lock-up
occurs:
Refer to Shift schedule.
,
Yes

~

No

Yes

m
.

u

~I

l~

Does AfT shift from D1 to D2
at the specified speed?
Specified speed when shifting
from D1 to D2:
Refer to Shift schedule.
.
Yes
Does AfT shift from D2 to D3
at the specified speed?
Specified speed when shifting
from D2 to D3 :
Refer to Shift schedule.

SA T804A

m

~

IE

Go to Diagnostic Procedure. 13.

I Yes

Release accelerator pedal.

8,

" ,..'"

I
,..,.."

,..-----

--- --

O~O

'I

,

m
Is lock-up released when
accelerator pedal is released?

No
Go to Diagnostic Procedure 14.

_..?l

'I)
~)
SA T807 A

IE

.I Yes

I

Decelerate vehicle by applying
foot brake lightly.

II]
Does engine speed return to idle
smoothly when AfT is shifted
from D4 to D3 ?
Yes

I

Stop vehicle.

I

I Go to "Cruise test
AT-20

-

Part 2".

No
Go to DiagnosticProcedure 15.

TROUBLE DIAGNOSES

Check (Cont'd)

Preliminary
Cruise test

-

Part 2

Confirm overdrive switch is in
"ON" position.

Confirm selector lever is in "D"
range.

SA T803A

Hlilf-way

.0

6

/
Accelerate vehicle by half
throttle again.

8/8

Does vehicle start from D1 ?

.

.

.

Go to Diagnostic Procedure 16.

Yes

6

Accelerate vehicle to A kmfh as
shown in illustration.

0/8

Accelerato~ pedal

II
8/8

II

I

O ta
O-.!.:T 21W

/
Depress
fully

Release

/.

.!}

Does AfT shift from D4 to D2
as soon as accelerator pedal is
depressed fully?

/

Release

Go to Diagnostic Procedure 9.

No

Does AfT shift from D2 to D3
at the specified speed?
Specified speed when
shifting from D2 to 03 :
Refer to Shift schedule.

m

No

Yes

m

8/81,

Go to Diagnostic Procedure 10.

Yes
Release accelerator pedal after
shifting from D2 to D3.

------

6
Does AfT shift from D3 to D4
and does vehicle decelerate by
engine brake?

SAT810A

Yes

[;)6
II
Accelerator
pedal

/

Release accelerator pedal and
then quickly depress it fully.

SAT808A

II

No

-- -- n 1W
8/8 SrI~~j_._m__C

03

Stop vehicle.

~

~
04
I

0/8 S~

0»

Go to "Cruise test

~s

SATB11A

AT-21

-

Part 3".

No
,+j Go to Diagnostic Procedure 11.

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
Cruisetest - Part3

0

.0

Confirm overdrive switch is in
"ON" position.
Confirm selector lever is in "D"
range.
Accelerate vehicle using halfthrottle to D4.

SAT812A

fA

.'-

fA
Release accelerator pedal.

I]
Set overdrive switch to "OFF"
position while driving in D4
range.

II
I

Does AfT shift from D4 to D3 ?
SAT813A

~

@

m

( D3 (O.D. OFF))

6

Engine brake

"ED
6(;]

@

Does AfT shift from D3 to 22 ?

Does vehicle decelerate by engine
brake?
Yes

. "1" range while ~riving in 22,
II!]
.
Does AfT shift from 22 to 11
range?
Yes

IIDII

~

@

~

I

Stop vehicle.

!

Perform self-diagnosis.- Refer
to SELF-DIAGNOSISPROCEDURE.

~
I

Go to Diagnostic Procedure 18.
Go to Diagnostic Procedure 15.

Go to Diagnostic Procedure 19.

...

Doe's vehicle decelerate by engine
brake?
Yes

SAT777B

~19

No

Yes

m

Engine brake

0

~ Yes

I

Move selector lever from "2" to

.

,~

Yes

m

CD3 (0.D.OFF0

m

Go to Diagnostic Procedure 15.

Moveselector lever from "D" to
"2" range while driving in D3.

SAT776B
G)

Go to Diagnostic Procedure 17.

Yes

Does vehicle decelerate by
engine brake?

I]

.

+-

No

@

....

SAT778B

AT-22

Go to Diagnostic Procedure 20.

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
Vehicle speed when shifting gears
Vehicle speed km/h (MPH)
Throttle position

D,

D, --> D,

D, -+ D.

D.

Full throttle

52 - 56
(32 - 35)

95 - 101
(59 - 63)

146 - 156
(91 - 97)

140 - 150
(87 - 93)

89 - 95
(55 - 59)

40- 44
(25- 27)

53 - 57
(33 - 35)

Half throttle

38 - 42
(24 - 26)

72 -78
(45-48)

111-121
(69 -75)

55 - 65
(34-40)

33 - 39
(21 - 24)

10 - 14
(6-9)

53 - 57
(33 - 35)

D,

-+

-+

D,

D, -+

D.

D,

-+

D,

1,

-+

1,

Vehicle speed when performing and releasing
lock-up
Vehicle speed km/h (MPH)
Throttle
position

Full throttle

Half throttle

O.D. switch [Shift range]

Lock-up
"ON"

Lock-up
"OFF"

ON
[D.]

146 - 156
(91 - 97)

140 - 150
(87 - 93)

OFF
[D,]

95 - 101
(59 - 63)

89 -95
(55 - 59)

ON
[D.]

112 - 120
(70 -75)

102-110
(63 - 68)

OFF
[D.]

76 - 84
(47 - 52)

71 - 79
(44-49)

\

AT-23

TROUBLE DIAGNOSES

Check (Cont'd)

Preliminary
Shift schedule (Overdrive ON)

Upshift

-- - - 8/8

Downshift

I

, Kickdown range

7/8

I

I
I

I-

6/8

1--r-2
I
I
/,
I
/
/
I
I
/
I
I
I
I
I
L-.I
2/8 II
I
1/81I
I

g> 5/8
'cCD
84/8
CD
t:
e 3/8
.c
I-

0/8
0

10

~

r

20

30

(10)

(0)

40
I

L,
(20)

50

r

70

60

~

80

+

(40)

(30)

(50)

.

90

100

I'

(60)

110

"

120

'

(70)

130

.'

(80)

140

"

150

'

(90)

160

I

170

180

','

(100)

190

,,

(110)

200

'

(120)

Vehicle speed km/h (MPH)

SAT804B

Shift schedule (Overdrive OFF)
Upshift

- - - -8/8

Downshift

.
I

7/8 ,

Kickdown range
I
I
I

6/81--

I
c: 6/8
'cCD

1-;-2

""

I
I

8- 4/8

/

I
I

CD

..

e

.c 3/8
I-

I

L_I

2/8

I

I

I

/,

/
Lock~p "ON"

I
I
I
I

1/8I0/8
0

I
(0)

10

'

20

, '
(10)

30

"

(20)

40
I

I

60
'

(30)

60
'

,

(40)

70
'

80
I
(60)

90
"

100
I
(60)

110
'r
(70)

Vehicle speed km/h (MPH)

AT-24

120
I

130
I

I

(80)

140

160

160

170

"

'

I

I

(90)

(100)

180

I'
(110)

190

200

"

'

(120)
SA T805B

TROUBLE DIAGNOSES.

AIT Electrical Parts Location

Control

(

valve

upper body

)
SAT806B

AT-25

TROUBLE DIAGNOSES
AfT Electrical Parts Location (Cont'd)

~

1;Inhibitor

switch

~
harness connectorrf'
:. AfT solenoid
,:;?harness connector

~
~~

0

SAT8258

AT -26

0 [SIEE]

@!j ~

lGNI TI ON SWITCH
ON or START

IGNITION

COIL

To distributor

@

0 ffiHBJ

@

a@0~

@

35213

db

'2112
15

."
r

c

INHIBITOR
SWITCH

@I

-i

"lJ

Z

-0

m
::I

(fI
m

@T 2:u

I
I
I

(fI

m
Z
(fI

r

0

;U

26 19 20 I 2

~(t)

N

A/T

6
8

......

9

23

7

12

29 30 28

24

@~
.:;;

r.-:1t;0

m

I

-=

r
c

-i

m
:u
»

~

@crb

:u
m
<
0

0

we

POWER
TRANSISTOR

crb
THROTTLE
SENSOR

<-i
;:; »:I
0. r;u

~c

1;U
I
I

-. m-i
<0

..0

-i
.~ (fir
:Em

:r..
-or

,Q

..0 -i-

..

-

-..

.

16

15

:r

17

10

4

CONTROL UNIT
35

36

22

21

34

33

s~

r-

0
;U
0

-Z

-=

Cl(t)
;U
m

@~

0

01

~v.XcgONTROL

S

E!!3

ION

@;

IOFF

»-I
00

-=

(fI
:I

(")

."
-i

m~
@)

I/)

- 6 @
A

-=

~
-i

<
m

-."
(fI
:I

-i

@

-=

@

(fI
0
r
m
Z
0

(fI
0
r
m
Z
0

0

0

Z
0

tD

»

0

-=

;U
;U
C
Z

"lJ
;U

r
C
-i
(")
:I

@

-

-=

-i
0
;U

m

m

(")

(fI
0
r
m

-

-

(")
:I

r
0
(")
A
I
C
"lJ

-rZ

(fI
(fI
C
;U
m

@

(fI
0

(fI
0

Z
0

Z
0
0

r
m

-=

-

w
00
,/

0

r
m
-=

:I

II
27
25
31
32

"lJ
"lJ

O. D. OFF
INDICATOR

(")

@

@)

-=

s

TROUBLE DIAGNOSES
Wiring Diagram
COMBINATION

METER
IGNITION
ON or

7

[Jffi@II]

CONTROL
SWITCH

n ~t;J

12

HEAD-UP
CONTROL

28

~

~~ll~o~~
co

@
f)3\
\.!::.J

co

-'III

III'
>- co ">->-

ID

Vi

GD

II

Y/G

Y/8
Y/L
G
(J nstrument

Y

DI SPLA
UNIT

~

~

[J-t-W.H-t-j]

">->- >-,

KICKO. D. OFF
DOWN
I NDI CATOR SWITCH

O. D.

24

ELECTRIC
SPEEDOMETER

6

SWITCH
START

harness)

o.

I
co

I

FUSE BLOCK
(Refer
toP POWER ;;:~
SUPPLY ROUTINGp co",
in EL section.)

Effi
0EW'" @~'"

@)~

..
.. ..

co,co

ID'co

L

@
Y/G.

Y/8.
Y/L.
G

MIh i te)

J I~

C?
IGNITION
ON or

co

(Black)

SWITCH
START

~

@IIIII~I~

@

IDIII
iii

@fi~
- -

@jj)fi@}}

BODY
GROUND

BODY
GROUND

@ 11111~11IIl
co

~

@

(E. F. 1. harness)
L

11S-L

:::::::::::::

1-W

3-

LG/R
Y/W
Y/G
W/L
8
LG/8
L

Y/R

Y/R

-{]II

I
@

:, :,

18-L/OR
21-8
28-W/L
29-8

1

,"
--_n

2D-W

nn

_n

n_n_' '
""
",

nn__nn_n

32-Y/G
33-Y/W
37-LG/R
44-Y

n_nn-

-,
"" ,
,,
""
,, ,,
,, ,,
,, ,

nn-

.

'' ,
,,

,'"
co

,111
~1
co ,
1

~
I~~:
co
..JID~

E. C. C. S.
CONTROL UNIT
(Refer
to "E. C. C. S.
SYSTEM" In
EF&EC sect Ion. )

~@)

@)ii
ENGINE
GROUND

00
RESISTOR

~@)

III

bJ~@)

~

@

..J>->-

$.~

~
"::>

...

POWER
TRANSISTOR

~c

-

THROTTLE

To

AT-28

@)

distributor

VALVE
SWITCH

~
I

I

..J~ID

m

THROTTLE
SENSOR

@

,

0

III..J

~

~

ENGI NE
TEMPERA TURE
SENSOR

TROUBLE DIAGNOSES
Wiring Diagram (Cont'd)
DROPPING
RESISTOR

- -

REVOLUTI ON
SENSOR

@m :Wlth

A/T CONTROL UNIT

in!

@)~@I~II~I

b

.E~~E ~

"''''

I
~

~~'~E'" ~

1

!

~

a

B9
B7
CB
AB
ClD
Hll
111

@
S.

E.

L'~""
.

a..

~

M.

...

To back-up

L'E
0

braking

lamp

EE~

'"

""""~L"'''''''~''

..a E"''''o

~~L~~"
INHIBITOR

SWITCH

=...

-

=N

5B
G/R
G/R
R/B
G/L
Y/B
Y/L

=0
=Z

I

BRG/W
BR
G/W
BR
G/L
G/B

J.

last

anti-lock

<;J;>@)

(@)

!Refer
to
(Fo Idout

:Wlthout
system

J

L___n_--5B
-G/R
-G/R
-R/B
-G/L
-Y/B
-Y/L

~

,

head-up display
:Wlthout head-up display
:Wlth anti-lock braking
system

~
~

page

page). )

'---

(ill)

=0..

@)
G~W

~

a:::J-

I
.

@

(Eng Ine room

1'i"W

P/L

harness)

OR/L
B
PU
GY/R
L/Y
L/W

L
LG/R
Y/W
Y/B
W/L
B
LB/B
L

I

ii

GY
R

I

rJil ~~!~Dr
lJU
(Subharness)

B
W
L
Y
G

Y/R

(§)

"
l6!B@)

:;a

"E

~ ~

~

..
~

......
.....

~

@)!i@)
BODY

GROUND

~(@)
"
......

-=

.....

(EngI ne
ess room
no.
harn

2)
Y/L-Lh
Y/B-G"

€==O

SPEED
SENSOR

0
n....
::10
IZ
)lUl
u..J
'")0
'JI

-=
1:
U
I::I
..J
<
U
0
0
...
z...
0
::10
It:Z I-Z
It:W U.UI
UI..J .....J
>0
1:0
OU)

U)U)

m
0
...
0
I-Z
u.w
.....J
1:0

U)U)

-=
UI
It:
::I
U)
U)
UlO
It:...
0..0
Z
UIUI
Z..J

...0

It:
0
U)
Z
UI
U)

W
It:
0::1
...1::1<
..J1t:
U.UI
a..
1-:1:

..JU)

(@)

SAT101C

AT-29

TROUBLE DIAGNOSES

0

Self-diagnosis

m

SELF-DIAGNOSTIC

PROCEDURE

DIAGNOSIS START
Start engine and warm it up to normal engine operating temperature.

~-

fa

SAT774B

0

II

(g

,

Set overdrive switch in "ON"

position.

PJ

Move selector lever to "P" range.

fifif:j

~

Does 0.0. OFF indicator lamp come on for about 2 seconds?

SAT779B

Yes

m

m

~i
.'

'

~
.

fNo

I

'

I Go to

.

.

I]
Move selector lever to "0"

range.

II

-CD

Set overdrive switch in "OFF"

SA T780B

fifif:j

~

m

6

position.

Wait for more than 2 seconds
#~

~~

~

0

after ignition switch "ON".

I

..&\ OVER

. \

'ON DRIVE,
OOFF

m
~ve

fit

I."

selector lever to "2" range.

Set overdrive switch in "ON" position.

6
Move selector lever to "1"

SAT781 B

range.

m

m

Set overdrive switch in "OF F" position.

Accelerator pedal

m

;;;:

Depress accelerator pedal fully and release it.

Depress

Release

SAT754A

@

AT-30

Diagnostic Procedure 1.1

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
A

II!]

II!]

.

Set overdrive switch in "ON" position.

Check O.D. OFF indicator lamp.
Refer to JUDGEMENTOF SELF-DIAGNOSISCODEon next page.

~-

DIAGNOSIS END
SAT782B

'---

I

AT-31

TROUBLE DIAGNOSES
Self-diagnosis
JUDGEMENT

OF SELF-DIAGNOSIS

(Cont'd)

CODE.
Damaged circuit

0.0. OFF indicator lamp:

All circuits that can be confirmed by self-diagnosis are
O.K.

All judgement flickers are same.

,&

//1\'

OlD
OFF

Self-diagnosis
start

I

-

Start
flickers-- signal 1Q-judgement
- Light

f--

\

- -

Shade

t, t,t, t, t, t, t, t, t, t, t,

tl

SAT723B

1st judgement flicker is longer than
others.
~~

Revolution sensor circuit is short-circuited or disconnected.

OlD

//1\

Revolution sensor

OFF

--,..---

-

--

Lig ht
16

r--

\

--

15

Arr control unit
Shade

.. Go to REVOLUTION

SENSOR CIRCUIT CHECK.

SAT140B

SAT724B

2nd judgement flicker is longer than
others.

Speed sensor circuit is short-circuited or disconnected.

~()~ OlD
//1\' OFF
Speed sensor

- - .....--.-

- - Light
24
Arr

1---1-

,-'

control

unit

Shade

.. Goto SPEEDSENSORCIRCUIT CHECK.

SAT726B

3rd judgement flicker is longer than
others.

SAT760A

Throttle sensor circuit is short-circuited or disconnected.
Throttle

sensor

~).l(~ OlD
/)r\' OFF
---

R-M-.- - - Light

.",.

15

- Shade

..
SA T726B

tl

= 2.5 seconds

t2

= 2.0

seconds

t3

=1.0 second
AT-32

11
AfT

control

10
unit

Goto THROTTLESENSORCIRCUIT CHECK'sAT761A

TROUBLE DIAGNOSES
Self-diagnosis

(Cont'd)
Damaged circuit

O.D. OFF indicator lamp:
4th judgement flicker is longer than
others.

Shift solenoid A circuit is short-circuited or disconnected.
Shift solenoid A

~()~ OlD
/11\' OFF
Terminal
cord
assembly

Self-diagnosis
start

-=

- -- Light
35

.

- Shade
SA T727 B

5th judgement flicker is longer than
others.

':()/

:;/1\'

A/T

control

unit

Go to SHIFT SOLENOID A CIRCUIT CHECK.
SAT766A

Shift solenoid B circuit is short-circuited or disconnected.
Shift solenoid B

OlD

OFF

--

-

--

Terminal
cord assembly

Light
36

'

--

- Shade
SAT728B

6th judgement flicker is longer than
others.
,\I~
:;g,

.

Arr control unit

Go to SHIFT SOLENOID B CIRCUIT CHECK.

SAT767A

Overrun clutch solenoid circuit is short-circuited or disconnected.
Overrunclutch
solenoid

OlD
OFF

---

-----

Terminal
assembly

Light

cord

21

-

-

\

- Shade
SA T729B

7th judgement flicker is longer than
others.

~~

//1\'

.

Arr control unit

Go to OVERRUN CLUTCHSOLENOID
CIRCUIT CHECK.

SAT768A

Lock-up solenoid circuit is short-circuited or disconnected.
Look-up
solenoid

OlD
OFF

Terminal
cord assembly

--

-=

-- Light
22

---

\

- Shade
SAT730B

.

AT-33

Arr control unit

Go to LOCK-UPSOLENOID CIRCUIT CHECK.
SAT769A

-----

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
0.0. OFF indicator lamp:

Damaged circuit

8th judgement flicker is longer than
others.
\ II
..:xk

Fluid temperature sensor is disconnected or AfT control
unit power source circuit is damaged.

OlD

/11\

OFF

Terminal cord
assembly

Self-diagnosis
start

--

- Light

..

Shade
SAT731 B

CHECK.

SAT143B

Engine revolution signal circuit is short-circuited or disconnected.

9th judgement flicker is longer than
others.
,\1//
//1\'

Go to FLUID TEMPERATURE SENSOR CIRCUIT
AND AfT CONTROL UNIT POWER SOURCE CI RCUIT

OlD
OFF

-0-

Resistor

- -....--.-

- - Light
25

+-

~-

AfT control

Shade
SAT733B

10th judgement
others.

flicker

is longer than

to ENGINE REVOLUTION
.. Go
CHECK.

~

solenoid

Dropping
resistor

- Light
34

'

4-- Shade

AfT

SAT732B

Flickers as shown below:

33
control

unit

.. Go to LINE PRESSURE SOLENOID CIRCUIT

CHECK.

Battery power is low.
Battery has been disconnected for a long time.
Battery is connected conversely.
(When reconnecting AfT control unit connectors.
is not a problem.)

~O/D
~'
OFF

- Light

- - Shade

t.
SAT734B

= 1.0

SAT624B

Terminal
cord
assembly

- - ...--.-

t4

SIGNAL CIRCUIT

Line pressure solenoid circuit is short-circuited or disconLine p~essure
nected.

..:::()~ OlD
/11\' OFF

I

unit

second

AT-34

SAT776A

-

This

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
O.D. OFF indicator lamp:

Dama~ed circuit

Does not come on.

0

Inhibitor switch, overdrive switch, kickCtownSWltchOT
idle switch circuit is disconnected or AIT control unit is
damaged.

010
OFF

Self-cliagnosls
start

- - - - - - - - - - -.- - -

Light

---

Shade

Throttle
valve
switch

.<:
~
.~
..
'"

:§

-=-

SAT157C

Overdrive
switch

ION

Kickdown
switch.

)

..

-=

Go to INHIBITOR,.OVERDRIVE, KICKDOWN AND
IDLE SWitCH CIRCUIT CHECKS.
SAT736B

/
\

.....

'\

\

c

AT-35

TROUBLE DIAGNOSES

Self-diagnosis

(Cont'd)

.

REVOLUTIONSENSORCIRCUIT CHECK
Revolution sensor

CHECK REVOLUTION
SENSOR. Refer to "Electrical

-

.Components

O.K.
N.G.

CHECK INPUT SIGNAL.
1. I

15

Arr control unit

~
f"

t:;!

SAT140B

.'' '.-'

I~

trJ

ST

",:"",.,.
,

A/T control unit and revolution sensor (Main hamess)

I!

>}

. Harnesscontinuitybetween
revolution sensor andE.C.U.
(Mainharness)
. Ground circuit for E.C.U.
- Refer to section EF & EC.

ground while driving. .
~Measure with A.C. range.)
Voltage:
At Okm/h (0 MPH): OV
At 30 km/h (19 MPH):
1V or more
(Voltage rises gradually in
response to vehicle speed)

-~,

.-~

Check the following .items.

. Harnesscontinuitybetween

2. Check voltage between A/T
control unit terminal @ and

m

Repair or replace revolution
sensor.

Inspection".

PI
16

N.G.

'/

O.K.
Perform self-diagnosis again after
driving for a while.

N.G.

. O;K.

/

00

INSPECTION END

1. Perform A/T control unit
input/output signal inspecti~n.
2. If N.G., recheck AfT control,
unit pin terminals for damage
or connection of A/T cORtrol
unit harness connector.

"
-=-

SAT737B

SPEED SENSOR CIRCUIT

PI

PI

Speed
sensor

CHECK INPUT SIGNAL.
1.

-=

CHECK

N.G.

'(,~I

24
A/T contrOl unit

~I

2.' Check voltage between A/T
control unit terminal @ and
ground while driving at 2 to 3
km/h (1 to 2 MPH)for 1 m
(3 ft) or more.
Voltage: Varies from OV
,

Check the following items.
. Speed sensor and ground
circuit for speed sensor
- Refer to section El.
. Harnesscontinuity between
A/T control unit and speed
sensor (Main harn,ss)

t05V

---.-O.K.
Perform self-diagnosis again after
driving for a while.

.

O.K.

INSPECTION END
SA T738B

AT-36

.

N.G.

1. Perform A/T controlu~it
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of A/T control
unit harness connector.

TROUBLE DIAGNOSES
Self-.diagnosis .(Cont'd)
-THROTTLESENSOR CIRCUIT CHECK

Throttle sensor

Perform self-diagnosis(Mode
III) for engine control.
O.K.

N.G.

Check throttle sensor circuit for
engine control. - Refer to section EF & EC.

N.G.

Check harness continuity
between E.C.U. and A/T control
unit regarding throttle sensor
circuit. (Main harness)

N.G.

1. Perform A/T control unit
input/output signal inspection.
2. If N.G.. recheck A/T control
unit pin terminals for damage
or connection of A/T control
unit harness connector.

II
";"

15

11

~

CHECK INPUT SIGNAL.

10

AfT control

I

unit
SAT761A

II

13

1.1
2. Check voltage between AlT
controlunit terminals @ and
@ while accelerator pedal is
depressed slowly.
Voltage:
Fully-closed throttle:

0.2- 0.6V
Fully-open throttle:

2.9- 3.9V
(Voltage rises gradually in
response to throttle valve
opening.)

[iI

O.K.

COllET

£)

Perform self-diagnosisagain after
driving for a while.
'O.K.
INSPECTION END

SA T739B

AT-37

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
SHIFTSOLENblDA CIRCUITCHECK
Shift solenoid A

m
N.G.

CHECK GROUND CIRCUIT.

unit
SAT766A

m
Sub-harness
connector

(@)~

is

1.1
I
2. Disconnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminal @ and ground.
Resistance: 20. 30il

SA T740B

I!)
DISCONNECT

[:it

18

1 O.K.
CHECK POWERSOURCE

N.G. Repair or replace harness
betweenA/Tcontrolunit and

CIRCUIT.

terminal cord assembly. (Main
harness)

13

I

2. Disconnect A/T control unit
16-pin connector.
3. Check resistance between
terminal @ and A/T control
unit terminal @.
Resistance:
Approximately Oil
4. Reinstall any part removed.
1 O.K.
Perform self-diagnosisafter
driving for a while.

lo.K.
INSPECTION

[ill

-

I!)

1.1
-=-

CLE SERVICE".
2. Check the following items.
8 Shift solenoid A Referto
"Electrical Components
Inspection".
8 Harnesscontinuity of terminal
cord assembly

13

35
AfT control

1. Remove control valve assem-

bly. - Referto "ON-VEHI-

Terminal
cord
assembly

AfT control unit
terminal

SAT741B

AT-38

END

."

N.G.

1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
SHIFT SOLENOID B CIRCUIT CI:IECK

Shift solenoid B

m
N.G.

CHECK GROUND CIRCUIT.
Terminal
cord assembly
AfT control

unit
SAT767A

~
lu

[;]

IIIKOIIIIECT

l

-

O.K.

N.G.

CHECK POWERSOURCE
CIRCUIT.

"1

2. Disconnect A/T control unit

-;:-

bly. - Refer to "ON-VEHICLE SERVICE".
2. Check the following items.
8 Shift solenoid B Referto
"Electrical Components
Inspection".
8 Harnesscontinuity of terminal
cord assembly

1.1
I
2. Disconnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminal @ and ground.
Resistance: 20 - 30n

36

SAT742B

1. Remove control valve assem-

I

Repair or replace harness
between A/T control unit and
terminal cord assembly. (Main
harness)

16-pin connector.

3. Check resistance between

[;]

terminal @ and A/T control
unit terminal @.
Resistance:
Approximately on
4. Reinstall any part removed.

_IIECT

~ IV

l

O.K.

N.G.

Perform self-diagnosis after
driving for a while.
lO.K.
INSPECTION
I

1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals

END
I

for damage

or connection of A/T control
unit harness connector.

/

SAT743B

AT-39

TROUBLE DIAGNOSES

Self-diagnosis

- (Cont'd)

OVERRUNCLUTCH SOLENOIDCIRCUIT CHECK

Overrun clutch
solenoid

m
N.G. 1. Removecontrolvalveassembly.- Referto "ON-VEHI.

CHECKGROUNDCIRCUIT.
Terminal cord
assembly

1.1

21

Arr control unit
SA T768A

m

~
IV

1 O.K.
N.G.

SA T744B

Subharness
connector

Repair or replace harness

betweenAlTcontrolunit and

CIRCUIT.

-eJ

@

-

I

I CHECK POWERSOURCE

1.1

I!]

CLE SERVICE".
2. Check the following items.
8 Overrun clutch solenoid.
Refer to liElectrical Components Inspection".
8 Harnesscontinuity of terminal
cord assembly

2. Disconnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminal @ and ground.
Resistance: 20 - 30n

I!]

~

-=

18

18

terminal cord assembly. (Main
harness)
I

2. Disconnect AIT control unit
16-pin connector.
3. Check resistance between
terminal @ and AIT control
unit terminal @.
Resistance:
Approximately on
4. Reinstall any part removed.
1 O.K.
Perform self-diagnosisafter
driving for a while.

lo.K.
INSPECTION END

P/L

[ill
SAT745B

AT-40

N.G.

1. Perform AfT control unit
input/output signal inspection.
2. If N.G.. recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
LOCK-UP SOLENOID CIRCUIT CHECK

Look-up
solenoid

m
CHECK GROUND CIRCUIT.
1.

N.G.

"ON-VEHICLE SERVICE".
2. Check the following items.
. Lock-up solenoid - Refer to

Ia

22
AfT control

unit
SA T769A

1. Removeoil pan.- Refer to

liElectrical Components
Inspection"

2. Disconnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminal @ and ground.
Resistance: 2.5 5n

.

. Harnesscontinuityof terminal
cord assembly

-

m
IIISQIIIIECT

EO

O.K.

Ii)

CHECK POWER SOURCE
CIRCUIT.
1.

N.G. Repair or replace harness
between AfT control unit and
terminal cord assembly. (Main
harness)

~
~

-=-

SA T746B

Ii]
IIISCONIIECT

[:iI
fm'I

~

IV
Sub-

E1tE1harness
GY/R

2. Disconnect AfT control unit
16-pin connector.
3. Check resistance between
terminal @ and AfT control
unit terminal @.
Resistance:
Approximately on
4. Reinstall any part removed.

22
J connector

O.K.
Perform self-diagnosis after
driving for a while.

. O.K.

[:ill{)

INSPECTION END

EEfHm
[ill
SAT747B

AT-41

N.G.

1. Perform AfT control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
Fluid temperature
sensor
Terminal cord
assembly

SAT143B

~
CIINNECT

£)
AfT control unit
terminal

SAT748B

I!]
Subharness
connector

EW3 @
yo12 15~

~

~
IIISCOIINECT

B

w

18

[ill

FLUID TEMPERATURE SENSOR CIRCUIT AND AIT
CONTROL UNIT POWER SOURCE CIRCUIT CHECKS

m
CHECK AfT CONTROL
UNIT POWER SOURCE.
1. I

N.G.

2. Check voltage between AfT
control unit terminals @ , @
and ground.
Battery voltage should exist.

Check the following items.

.

Harnesscontinuity between
ignition switch and AfT con.
trol unit (Mainharness)
. Ignition switch and fuse
- Refer to section EL.

O.K.

I!]

N.G.
CHECK FLUID TEMPERA.
TURE SENSOR WITH
TERMINAL CORD ASSEMBLY
1.

~

2. Discpnnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminals @ and @ when
AfT is cold.
Resistance:
Cold [20°C (6SoF)]
Approximately 2.5 kil
4. Reinstall any part removed.
O.K.

SAT749B

A

AT-42

1. Remove oil pan.
2. Check the following items.
. Fluid temperature sensor
- Refer to "Electrical Com.
ponents Inspection".
. Harnesscontinuity of terminal
cord assembly

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
@
[i
CHECK INPUT SIGNAL OF
FLUID TEMPERATURE
SENSOR.
'"
1.1
"'i"

'

!
13
G ' ON
'}

~
CONNECT

£)

AfT control unit
terminal

lD2;

:," ~.'

,)I;,

, ,",

N.G.

Check the following items.
. Harness continuity between
A/T control unit and terminal
cord assembly (Mainharness)

II

2. Check voltage between A/T
control unit terminal @ and
ground while warming up A/T.
Voltage:
Cold [20°C (6SoF)] -+
Hot [SO°C (176°F)] :
1.56V -+ O.45V

O.K.
Perform self-diagnosis after
driving for a while.

.

"::"

N.G.

O.K.

SAT750B

INSPECTION END

1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of A/T control
unit harness connector.

ENGINE REVOLUTION SIGNAL CIRCUIT CHECK
Perform self-diagnosis (Mode
III) for engine control. Check
ignition signal circuit condition.
Resistor

N'~I

Check ignition signal circuit for
engine control. - Refer to section
EF & EC.

N.G.

Check the followingitems.
. Harnesscontinuity between
A/T control unit and ignition
coil.

O.K.

m

CHECK INPUT SIGNAL.
25
AfT

control

unit

SA T624B

m~

0HHm:B l1t

CONNECT

AfT control unit
terminal

£)

"13
2. Check voltage between A/T
control unit terminal @ and
ground.
Voltage: 9.5 - 12V

.

-=-

SAT751B

. Ignitioncoil-

Refer to

sectionEF&EC.

O.K.

Perform self-diagnosisagain after IN.G.
driving for a while.

.

. Resistor

O.K.

INSPECTION END

AT-43

1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
LINE PRESSURE SOLENOID CIRCUIT CHECK

Li ne pressu re

solenoid
Terminal
cord assembly

CHECK GROUND CIRCUIT.

Dropping
resistor
34

1.1

33

AfT control

unit
SA T776A

m Sub-

harness
connector

34\

@ID)

m

~

2. Disconnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminal @ and ground.
Resistance: 2.5- 5il
1!1

~

IV

SAT762B

-.. 1.

1

2. DisconnectAfTcontrolunit
16-pinconnector.

I

8 Harnesscontinuity between

AfTcontrolunit @ and
terminalcordassembly
(Mainharness)

terminal @ and AfTcontrol
unit terminal@.
Resistance: 11.2- 12.ail

~i5

[!]

1O.K.

CHECK POWERSOURCE

CIRCUIT

1.1

em

-

N.G. Checkthe following items.
8 Dropping resistor - Referto
"ElectricalComponents
Inspection".

3. Checkresistance between
1!1[!]

Removecontrol valve assem-

bly.- Refer to "ON-VEHICLE SERVICE".
2. Check the following items.
8 Line pressure solenoid
Refer to "Electrical Components Inspection"-.
8 Harnesscontinuity of terminal
cord assembly

!O.K.

CHECK POWERSOURCE
CIRCUIT.

1.1

=-

N.G.

p

A/T control
unit terminal

SA T763B

2. Check resistance between
terminal @ and AfT control
unit terminal @.
Resistance:
Approximately Oil
3. Reinstall any part removed.
1 O.K.
Performself-diagnosisafter
driving for a while.

!

O.K.

INSPECTION END

AT-44

N.G. Repair or replace harness
betweenAfTcontrolunit @

I
N.G.

and terminal cord assembly.

1. PerformAfT control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH
CIRCUIT CHECKS

m
CHECK INHIBITOR SWITCH
CIRCUIT.

m

2. Check voltage between AfT
control unit terminals CD.@.
@. @, @ and ground while
moving selector lever through
each range.
Voltage:
B: Battery voltage
0: OV
No.

A/T control
unit terminal

@ @

@ CD CV

P,N

B

0

0

0

0

R

0

B

0

0

0

0

0

0

B

0

0

2

0

0

0

B

0

1

0

0

0

0

B

O.K.

1!1
BR/W

BR

CHECK OVER~RIVE
CIRCUIT.

1.
-=SAT7838

1!1

*

_caD

~

t!(g

Switch position

Voltage

ON

Battery voltage

OFF

1V or less

O.K.

lit

CIIIIIECT

~

~10~

IV n

e

(t'l

A/T control unit
terminal

SWITCH

2. Check voltage between AfT
control unit terminal @ and
ground when overdrive switch
is in "ON" position and in
"OFF" position.

~-

~G/R

-=SA T7848

Refer to

"Electrical Components
Inspection".
. Harnesscontinuity between
ignition switch and inhibitor
switch (Mainharness)
. Harnesscontinuity between
inhibitor switch and AfT
control unit (Mainharness)

fi/f:J..

Lever
position

Check the following items.

. Inhibitorswitch-

~

1. I

SAT7368

N.G.

A

AT-45

IN.G.

Check the following items.
. Overdriveswitch - Refer
"Electrical Components
Inspection" .

to

.

Harness continuity between
AfT control unit and overdrive switch (Main harness)

.

Harnesscontinuity of ground
circuit for overdrive switch
(Main harness)

TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
@

[!II!]
[!1

CHECK KICKDOWN SWITCH
CIRCUIT.

1.1

~

0

CONNECT

t£)

N.G.

Check the following items.

.
.

Kickdown switch
Harnesscontinuity between
AfT control unit and kick.
down switch (Mainharness)
. Harnesscontinuity of ground
circuit for kickdown switch

~

2. Check voltage between AfT
control unit terminal (j) and
ground while depressing
accelerator pedal slowly.
(after warming up engine)
Voltage:
When releasing accelerator
pedal: 3 8V
When depressing accelerator
pedal fully: 1V or less
,
O.K.

-

I!]

IN.G.
CHECK IDLE SWITCH
CI RCUIT.
SAT754S1 I. Check voltage between AfT
control unit terminal @ and
ground in the same way as
kickdown switch circuit.
Voltage:
When releasing accelerator
pedal: 8 15V
When depressing accelerator
pedal fully: 1V or less
,
O.K.

-

Perform

self-diagnosis

again after

drivingfor a while.
.
O.k.

I N.G.

Perform self-diagnosis (Mode
IV) for engine control.
Check idle switch circuit.
O.K.
Check harness
continuity
between AfT
control unit
and idle switch.
(Main harness)

AT-46

Check id Ie
switch circuit
for engine

control. Refer to sec.
tion EF & EC.

1. Perform AfT control unit
input/output signal inspection.
2. If N.G., recheck AfT control
-

INSPECTION END

N.G.

unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES

Diagnostic Procedure 1
SYMPTOM: 0.0. OFF indicator lamp does not come on
for about 2 seconds when turning ignition
switch to "ON".

0,
CHECK AfT CONTROL
UNIT POWER SOURCE.
1.
-=-

N.G. Check the following items.
.

t8

SAT755B

11

.

2. Check voltage between AfT
control unit terminals @, ~
and ground.
Battery voltage should exist.
O.K.

6
I

CHECK AfT CONTROL UNIT
GROUND CIRCUIT.
1.
-=-

Fuse

0.0. OFF
indicator
lamp

AfT control unit

O.K.

I]

[:tI
([ill)

[ill

£)

Check harness continuity
between AfT control unit and
ground.

2. Disconnect AfT control unit
16-pin connector.
3. Check resistance between AfT
control unit terminals @ , @
and ground.
Resistance:
Approximately on

Ignition
switch

CONNECT

N.G.

~

SAT756B

I]

Harness continuity between
ignition switch and AfT control unit (Main harness)
Ignition switch and fuse
- Refer to section EL.

I

CHECK LAMP CIRCUIT.
1.

N.G.

Check the following items.

. 0.0. OFF indicator lamp
- Refer to section EL.
. Harnesscontinuity between
ignition switch and 0.0. OFF
indicator lamp (Main
harness)
. Harnesscontinuity between
0.0. OFF indicator lamp
and AfT control unit

~

2. Disconnect AfT control unit
. 16-pin connector.
3. Check resistance between
AfT control unit terminals
@ and @.
Resistance: 50 -100n
4. Reinstall any part removed.
O.K.

N.G.
Check again.
O.K.
INSPECTION END

AT-47

1. Perform AfT control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES

D

0

Diagnostic Procedure 2

OlD
OFF

SYMPTOM: Enginecannot be started with selector
lever in "P" or "N" range or engine can be
started with selector lever in "0", "2", "1"
or "R" range.

Self-diagnosis
start

- - - - - - - - - - - - - - Light
--- Shade
SAT157C

D
Does self-diagnosis show damage
to inhibitor switch circuit?

Yes

Check inhibitor switch circuit.
- Refer to "Self-diagnosis".

No

fA

Check continuity of inhibitor
switch 2-pin connector. - Refer
to "Electrical Components
Inspection" .

N.G.
Repair or replace inhibitor switch.

O.K.
Check starting system. - Refer

Repair or replace damaged parts.

to sectionEL.
O.K.
SA T838B

INSPECTIONEND

Diagnostic Procedure 3

D

SYMPTOM: Vehicle moves when it is pushed forward
or backward with selector lever in "P"
range.

D
Check parking components. Refer to "ON-VEHICLE
SERVICE".
SAT133B

O.K.
INSPECTIONEND

AT-48

N.G'I

Repair or replace damaged parts.

I

TROUBLE DIAGNOSES

0

0

Diagnostic Procedure 4

010
OFF

SYMPTOM: Vehicle moves forward or backward when
selecting "N" range.

Self -diagnosis

start

0

- - - - - - - - - - - - - - Light

Does self-diagnosisshow damage
to inhibitor switch after cruise
test ?

- - Shade

No

SAT157C

m

"P" range

Yes

Check manual control linkage.
- Refer to "ON.VEHICLE
SERVICE".

Check inhibitor switch circuit.
- Refer to "Self.diagnosis".

f)
N.G.

Adjust manual control linkage.
Refer to "ON.VEHICLE
SERVICE".

-

O.K.
Refill A.T.F.

Check AfT fluid level again.

O.K.

II
Lock nut

00

LCiCk nut @
SA T788B

1. Remove oil pan.
2. Check AfT fluid condition.

.

O.K.

11

Check again.

O.K.
INSPECTIONEND
SA T638A

II

SAT171 B

AT-49

N.G.

1.
2.
.
.
.
.

DisassembleAfT.
Check the following items.
Forward clutch assembly
Overrun clutch assembly
Reverseclutch assembly
Accumulator piston D

1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck A/T control
unit pin terminals for damage
or connection of A/T control
unit harness connector.

TROUBLE DIAGNOSES

0

Diagnostic Procedure 5

~O
/1 \ '
\1//

%

OFF

Self-diegnosis
start

Throttle sensor circuit
Fluid temperature
sensor circuit
Line pressu re
solenoid
circuit
Light
Shade

._-----

SAT7588,

fJ
Fluid
'temperature
sensor

SYMPTOM: There Is large shock when changingfrom
"N" to "R" range.

0
Does self-diagnosis show damage
to throttle sensor, line pressure
solenoid or fluid temperature
sensor circuit?

Yes

to "Self-diagnosis".

No

.I)

.

Check throttle sensor. - Refer
to section EF & EC.

E.C.U.

Repair or replace throttle sensor.

O.K.

m

Check line pressure at idle with
selector lever in "0" range.
Refer to "PRESSURE
TESTING".

N.G.

-

Dropping

resistor

che~ damaged circuit. - Refer

O.K.
SA T0888

1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE".
2. Check the following items.
. Valves to control line pressure
~Pressure regulator valve,
modifier valve, pilot valve and
pilot filter)

. Linepressuresolenoid

0
N.G.
Check again.

O.K.
INSPECTIONEND

m

SA T643A

AT-50

1. Perform AfT control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 6
SYMPTOM:"Vehicledoes not creep backwardwhen
.~~~
"R" range.

0
0

Check A/T fluid level again.

SA T638A

N.G'.f RefillA.T.F.

:

O.K.
N.G. in both "1"
and" R" range
r
fA
Check stall revolution with
selector lever in" 1" and" R"
range.
O.K.
O.K. in "1" range
N.G. in "R" range.

II

8

Check line pressure at idle with
selector lever in "R" range.
- Refer to "PRESSURE
TESTING".
SA T642A

N.G.

1. Remove oil pan.
2. Check fluid condition.

N.G.

IN.G., 1. Perform AfT control unit
input/output signal inspection.
2. If N.G., recheck A/T control

r

r Check again.
O.K.
r

8 Reverseclutch assembly
8 High clutch assembly
8 Low & reverse brake assembly
8 Low one-way clutch

O.K.

SA T643A

Line pressure solenoid
3. Disassemble A/T.
4. Check the following items.
8 Oil pump assembly
8 Torque converter

O.K.

m

II

1. Remove.control valveassembly. - Refer to "ON-VEHICLE SERVICE".
2. Check the following items.
8 Valvesto control line pressure
(Pressure regulator valve,pilot
valveand pilot filter)

INSPECTION END

m

SAT171B

AT-51

I

unit pin terminals for damage
or connection of A/T control
unit harness connector.

TROUBLE DIAGNOSES
Diagnostic Procedure 7
SYMPTOM:Vehicle does not creep forward when

0

selecting "D", "2" and "1" range.

0
I

Check A/T fluid level again.

N.G.

.1

Refill A.T.F.

O.K.
B1

N.G.
Check stall revolution with
selector lever in "0" range.
- Refer to "STALL TESTING".
.
O.K.

SA T638A

B1

Check line pressure at idle with
selector lever in "0" range.
Refer to "PR.ESSU RE
TESTING".

N.G.

IA

SA T642A

. Linepressuresolenoid

3. DisassembleA/T

O.K.

II

1. Remove oil pan.
2. Check A/T fluid condition.

N.G. 4. Check the following items.
. Oil pump assembly

. Forwardclutchassembly
. Forwardone-wayclutch
. , Lowone-wayclutch
. Torqueconverter

O.K.

B1

N.G.
Check again.
O.K.
INSPECTION

II

SAT171B

AT-52

END

1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE".
2. Check the following items.
. Valvesto control line pressure
(Pressure regulator valve,
modifier valve, pilot valveand
pilot filter)

1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck A/T control
unit pin terminals for damage
or connection of A/T control
unit harness connector.

TROUBLE DIAGNOSES

D

~~
/11\'

OlD
OFF

Self-diagnosis
start

Light

--- --~Shade
SA T760B

~

Diagnostic Procedure 8

Revolution sensor
Speed sensor
Shift solenoid A
Shift solenoid B

SYMPTOM: Vehicle cannot be started from D1 on

Cruise test -

Part 1.
Go to Diagnostic Procedure 7.

Is Diagnostic Procedure 7 O.K.?
Yes

D

Does self-diagnosis show damage
to revolution sensor, speed
sensor, shift solenoid A or B
after cruise test?

Yes

Check damaged circuit. - Refer
to "Self-diagnosis".

No

0

Check throttle sensor.
section EF & EC.
O.K.

7""

Refer to I N.G.

Check line pressure at stall point
with selector lever in "D" range.
- Refer to "PRESSU RE
TESTING".

N.G.
1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE".
2. Check the following items.

O.K.

II

I]

1. Remove oil pan.
2. Check A/T fluid condition.
N.G.

O.K.

O.K.
O.K.

SA T643A

II

N.G.
Check again.

O.K.
INSPECTIONEND
SAT171B

AT-53

Repair or replace throttle sensor.

.
.
.
.
.
.

Shift valveA
Shift valveB
Shift solenoidA
ShiftsolenoidB
Pilotvalve
Pilotfilter

3.
4.
.
.
.
.
.
.

DisassembleA/T.
Check the following items.
Forward clutch assembly
Forward one-way clutch
Low one-way clutch
High clutch assembly
Torque converter
Oil pump assembly

1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of A/T control
unit harness connector.

TROUBLE DIAGNOSES

D 0

Diagnostic Procedure 9

OlD
OFF

Self-diagnosis
start

- - - - - - - - - - - - - - Light
- - Shade
SA T157C

m
Revolution sensor

SYMPTOM: AfT does not shift from D, to D2 at the
specified speed.
AfT does not shift from D4 to D2 when
depressing accelerator pedal fully at the
specified speed.
Are Diagnostic
8 O.K.?

Procedures 7 and
Yes

D

Does self-diagnosis show damage
to inhibitor switch after cruise
test?

m
Speed
sensor

Speedometer

Yes

Check inhibitor switch circuit.
- Refer to "Self-diagnosis".

N.G.

Repair or replace revolution
sensor and speed sensor circuits.

No

Check revolution

sensor and

speed sensor circuit.

"Self-diagnosis"

SA T629B

Go to Diagnostic Procedure 7 or :

8.

-

Refer to

.

O.K.

iJ

Check throttle sensor.- Refer
to section EF & EC.
0

0

Repair or replace throttle

O.K.

1. Remove oil pan.
2. Check AfT fluid condition.

N.G.

I

O.K.

O.K.
O.K.

m

m

N.G.

Check again.

~

O.K.
INSPECTION END

8/8

8/8

,

+".

Dl.:TD2"
/
Depress
fully

6)
0/8
SAT118B

I

1. Removecontrol valve.Referto "ON-VEHICLE
SERVICE".
2. Checkthe following items.
. Shift valveA
. Shift solenoidA
. Pilot valve
. Pilot filter
3.
4.
.
.
.

SAT171B

/

D27D3
(
0/8

~/(

Release

0
AT-54

sensor.

DisassembleA/T.
Check the following items.
Servo piston 'assembly
Brake band
Oil pump assembly

1. Perform AfT control unit
input/output signal inspection.
.2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harnessconnector.

TROUBLE DIAGNOSES

D

0

Diagnostic Procedure 10

DID
OFF

SYMPTOM: AIT does not shift from D2to D3 at the
specified speed.

5elf-diagnosis
start

- - - - - - - - - - - - - - Light

Yes

D
- - Shade
SAT157C

Go to Diagnostic Procedure 7 or
B.

Are Diagnostic Procedures 7 and
BO.K.?

Does self-diagnosis show damage
to inhibitor switch after cruise
test?

Yes

Check inhibitor switch circuit.
- Refer to "Self-diagnosis".

Check throttle sensor. - Refer
to section EF & EC.

0

Repair or replace throttle sensor.

O.K.
1. Remove oil pan.
2. Check A/T fluid condition.

N.G.

.O.K.

O.K.

BJ

O.K.

I

1. Remove control valveassembly. - Refer to "ON-VEHI.
CLE SERVICE".
2. Check the following items.
. ShiftvalveB
Shift solenoid B

.
.

3.
4.
.
.
.
SAT1718

II

8/8

II

II

N.G.

Check again.

Jl

O.K.
INSPECTION

0
0/8 l

'1

SAT1198

AT-55

END

Pilot valve

. Pilotfilter
DisassembleAlT.
Check the following items.
Servo piston assembly
High clutch assembly
Oil pump assembly

1. Perform AfT control unit
input/output signal inspection.
2. If N.G., recheck A/T control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES

D

\1/

/~
.

Diagnostic Procedure 11

Revolution sensor

OlD

r:I

OFF

Self-diagnosis
start

/

I

SYMPTOM: AIT does not shift from D3to D4at the

spee~sensor.
Shift solenoid

A
Shift s?lerioid B
Fluid

specified speed.

/ / r .-

::;;~ature
Light

Are
Di~gnostic Procedures 7 and
8 O.K..

I

- ---_M_M_-M-M---M--uShadel
.
SAT761B

D

light

I

10

-

T

~

" - mUH H

~.

I

I No
II

-' Go
8. to Diagnostic Procedure 7 or

Yes

Does self-diagnosisshow damage
to inhibitor
switch, overdrive
. h h.
.
SWltC,s
Ift soIenol,d A B,
revolution sensor, speed sensor
or fluid temperature sensor
. . f
.
"1
t

Yes

Ch~ck da~aged ~~~cUit.- Refer
I

to Self-diagnosIs.

. ClrcUi a ter crUise test.
No

+

Checkthrottle sensor.- Refer

to section EF & EC.

~

Repair or replace throttle sensor.

. O.K.

1. Remove oil pan.
2. Check AlT fluid condition.

I

1:01

I!I

./

/'

N.G.
11

O.K.

1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE".

. 2.
.
O.K. ~ .
.
O.K. II.
.

Checkthe followingitems.
Shift valveB
Overrunclutchcontrolvalve
Shift solenoidB
Pilotvalve
Pilotfilter

3. DisassembleA/T.
SAT171BI

II.

8/8 U

II

I

I

I.

I

I

I

II
Check again.

I0 .K .
0/8

II

U

SAT120B

I

I

INSPECTIONEND

.

I

~

1. Perform AfT control unit
input/output

I
I

AT -56

4. Checkthe followingitems.
. Servopistonassembly
. Brakeband
Torqueconverter
. Oil pumpassembly

signal inspection.

2. If N.G., recheck AfT control
unit pin terminals for damage
or connection of AfT control
unit harness connector.

TROUBLE DIAGNOSES

D

,\1//

Diagnostic Procedure 12

OlD

SYMPTOM: AIT does not perform lock-up at the
specified speed.

:;8,'" OFF
Self.

..

,--

UW
fJ
p
b

;=

-

L- -

j::

-

II

D.

==J

,J

II"

/

.

--

Forward one-way clutch

to;

I!.

=::J
l
oMwdtth

II

-

r"'\'

'"

-\

clutch

-

..t1-

.I

Overrun

//

--:511

'>i

D, 2 and 1 ranges

Idle

Judgement

a.

..

:g)

1 2

creep.

~

.

2

6

::1::1 ::I C

.

48

314

E..::I ]1!!]11

II II H 'c
g ~ ] H c(c(
c(!!!
~:J ...IOILc(

213

1

cI

~~
...
M 't.. i
':'NM.ct:
~ ~ 1!!5 !5!5!5,~~
'§.= &~

Engine does not start in "N", "P" ranges.

No creep at all,

124

it, 1;:

S ~z~ iii
O.c

48

61,62

120' 126'

..

i

:!1

E=!5.. .ge:gi! o~ ~!i
-e,~E.=!!!i
h: :;! ~ ~

Excellive

101

~

:?

~c ~e ~'6> '6>!
8~
u::8.E~et:.:i.jj:J

-

90,

7

- I

.c

~

7

!5
!

Numben ere arrenged in order of probability.
Perform inspections starting with number one
end working up. Circled numben indicate thet
the transmillion must be removed from the
vehicle.

!
~

66

7,
67

@

3

@
3

.

.<
I!!

II
c:
0

.:! .0

20

0.

~
u

. ..
0

~
~

4111 II

~it:;;i.EE
~888jn
0=
~.~ ~~
...««««!!!
~ 0 II:: J: ...... ~-' -'III

ij:;;

00

.

3

~

@

@

4

@I
4

4

.<§;

01

.<§;

0

@

$
1

..
..

Gear change shock felt during deceleration
by releasing accelerator pedal.

1

-

Too high a change point from ~'D." to "D, ",
from "D," to "D, ", from "D," to "D, ".

1

1

1

5 3 4
6 4

2

-

.

2

@ICID

@ .10

.

.

@I

.

4

2

@@

3

3 4

15

..

CIDI@

Qj)'@1@0
5

5 3 4

2

does not operate when depressing

.

01
@I. @I

.(j;

3

2

112

31 4

depressing pedal in "D. " beyond k ickdown
vehicle speed limit.

211

31 4

-

Races extremely fast or slips in changing
from "D." to "D," when depressing pedal.

2

3

5

-

Races extremely fast or slips in changing

1

2

3

6

pedal in "D."

within kickdowII vehicle speed.

operates or engine overruns when

to "D,"

-

4

5

@. . . .0

4

when depressing pedal.

-

Races extremely fast or slips in changing
from "D," to "D," when depressing pedal.

1

2

3

5

4

-

Races extremely fast or slips in changing from
"D." or "D," to "D," when depressing pedal.

1

2

3

5

4

Vehicle will not run in any range.

1

Transmission noise in "D",
ranges.

1

-

c:

1

to "D."

-

144

.@

Failure to change gear from "D,"
Or from "D," to "D. ".

from "D."

g.!!

.c
~
:J
U
>

1::

1

-

Kickdown

126. 1130
134

-

to "D,"

-

-~ ..

1

@@I

Failure to change gear from "D,"
Or from "D." to "D, ".

Kickdown

:!!

:!! i
g S

1

to "D,"

-

126,
137

1

-

Failure to change gear from "D."

-

120'
124

~
.. °.c
-N
:;;5505.~ ;~ -fi5.c.2!-fi' ~ ~ !
~!~:2:!!!!S
=!1~~!au
~~~~~I
80.u~
uO .:! i ."2
:2
0.c:
.:J
:J:J :J c:
~!~.!

1

to "D,".

Almost no shock or slipping in change from

i.

E

0.

214

"D,"to"D.".

-

c:

90,
101

7

~

1

to "D, ".

Almost no shock or slipping in change from
"D,"

7

~

>
:0

!~eaa~:;02
's.!
t::!::!:!
,jj::;8~~::;3o

~g~=~.~
':;C::E1~~
ii:8.E~lI::w

-

7,
67

67

S

-~~lIg~
I-o.';:;~

Too sharp a shock in change from "D,"
"D."

67

t: i

& -fi ~ ~.g
11 ."'!! 51.:!

-

67,
106

70

§
c:

-

«

c:
!
of
II::

OFF vehicle

ON vehicle

"2", "1" and "R"

2

3

8

@0. . . . @

0

@0.@

4

@"l ,. .1.
@

AT-73

I OJ

TROUBLE DIAGNOSES
Symptom Chart (Cont'd)

ON vehicle

~
..:.
~

..
i'
a.
8
c:
!
of
..
tr

Reference

9,
14

pege (A T-

66

66

-

5

i01

?:
.Q
E

61
-

-

Geer chenge from "I, "to
Does not chenge from "1,"

"1,"

when

.;!

Large shock chenging from "1,"
range.

21 1

120'
124

1

126'
137,

126'1130
134

144

.c:
~
.:
u

.c:"
u '"

~

~

E

0

015 01

M
E
01
c:
0
a.
E
0
u
'"
c:

1

0
c:
01
'tI '0
M
.-

..
-I:
a: ~

~
c:
01
M
e
:J

.

c

a)~
f! ~
~c:a e '0~"5
~ ~2
.. u
>01
OIM
a. E.!!!
~ e~ ~ ~ ~ ~ ; ~
c:

~~ ~~
(I)..J

U

(I)

OI:J

g~ .ag
..JOIL«

N M
.:. N
0 0
1;j 1;j
'5 '5
E E
:J:J

~~
... ..

~

M.c:
o.~
1;j ~

'5 c:
E 0
:J';

8 8 g'c
«««.!!!

.c:

~

u

8a.~~

~
~~
a. 0I.c:
> '"
~ 0 I~ i
~
0'
~

"5 ~ .c: u 01
~..
~ > t:
~g~~i"2
'E'E c:!
~.!

2

I

~~

ILIL

~~ ~e

O..J ..Ja)

6

514

3

@.

6

5

7

@.I@.

4

3

5

314

2

range.

.'

..

@

Transmission overheats.

3

Offensive smell et fluid charging pipe.

Lock-up point is extremelv high or low.

-

AfT does not shift to "D. " when driving
with overdrive switch "ON",

-

Engine is stopped at "R". "D",
renges,

"2" end "I"

416

5

@cvl@@I@.I@ .I@@
@
-I
Q)
..
01
Q)

FUSI BLE LI NK BOX
(Refer to "POWER SUPPLY
ROUTING" in EL section.)

BODY GROUND

TROUBLE

DIAGNOSES

AfT Shift Lock System (Cont'd)
DIAGNOSTIC PROCEDURE 1
SYMPTOM: Selector lever cannot be moved from "P"
range when applying brake pedal or can be
moved when releasing brak,e pedal.

0

R/W

0

N.G.
CHECK POWER SOURCE.

1.1
-=-

SAT818B

6

Control unit
terminal

~

~

. Fuse

. Ignitionswitch

2. Check voltage between

@i)[9
~EIDJ
[Y]

Check the following items:

. Harnesscontinuitybetween
battery and control unit

control unit terminals @ , @ ,
@ and ground.
Battery voltage should exist.

LIB

6

N.G.

~

Check the following items:
. Detention switch - Refer to
"COMPONENTCHECK".
. Key switch - Refer to
"COMPONENTCHECK".
. Harnesscontinuity between
detention switch and
control unit.

CHECK INPUT SIGNAL
(Detention switch).
-=-

SAT819B

1.1

I]

RIG'

OJ

2. Check voltage between control unit terminal @ and
ground while setting selector
lever in "P" position.

Control unit
terminal

Selector lever
release butto n

Voltage

Not pressed
-=-

Battery

voltage

SA T820B

I]
CHECK INPUT SIGNAL
(STOP LAMP SWITCH).

1. I

~

fI!if::j

2. Check voltage between
control unit terminal @ and
ground while applying brake
pedal.
Battery voltage should exist.

O.K.

@

AT-78

N.G.

Check the following items:

. Stop lampswitch
. Harnesscontinuitybetween
stop lampswitchand control
unit

TROUBLE DIAGNOSES
AfT Shift Lock System (Cont'd)

II

i5~ ~

Shift lock
harness I2

~~~ \~

/

~.~,'

-

~~

.tJPJ
I

.
I

..

.\

,.

~

J

.'

~' ~~ ~JJ~.)
.~1~

~

IJ

'

,~
~
~.

~/

/

1-

.

r.t\

~. ~
:\~

'

. .

.

\

,

\.

Needle bearing

m q».

/

m q»/
,./..

EI ~

/

Beari~grace'

~1
/

Fmm
"'"...' J

Needle bearing

\

\

Needle"

.

f'\~f::\

~W~

~

)

bilseal~~./

m

onp"mp"m" ';"h" *JaI(Ij

011pump cover

I

R.,,;";",
~...*

.

'''ko~y

Gasket

~
~,~

Overrunclutch hUb

Thrust washer mq»

~

Retaining
plate*/

//
,

./

Ealq»

BearingraceElq»

~

-

~~S""';"'

~ (i
B'l~\
-

~~~\
~
~

(with
Front rear
internal
planetary
gear carrier)

Output shaft ./front snap ring

\

~~
-

.
I

Rear sun gear

~
7

. .X~)~
L

:e

~ ~Needlebearingmq»
Front planetary carrier

AT-86

E.nd bearing

Forward one-way clutch

\ Snap ring

Forward clutc h hub

Thrust washer

Rear internal gear

I

:

D-ring~~.
/

'

Y\S";';"'~EI~

.

r'\1

~~OiIPumpcoverbearingrace*EI
q»
/
'
Needle bearing
/
""
'
B
q»
.
eanng race Eli>
'D

12 - 151 :
\

~~

~~

q»

~o~~
,~

~

.

"~16-21
(1'6_2'1'

,,/

~
~~

o.,;",~/

~J'

~

./

Rever~e clutch assembly

(4.0-5.0,2~361
/

.

O-ring~EI

coo,.";;::':,~ -

,

~

Friction ring/

~VaneElq»./

/'

1\

/

..~

Vanering.,/

0

\

.

I

Oil pump
./ housing

0

~ ~TOrqUeConverter
39 -49

<:\

,J,

0

0

1

..,(
'-. Cam ring i
'\.. O-ring
EI

Input shaft

./5 ,~

~/./

,

"":<:'i~ ,

/
'.

.

~ \\})
iP':>..~

:i~~

~

/'

61 64

~~.~,;~~

l~.

~~ ~~
'-

.

Cam nng return spnng

Pivot Pin--v>~
Control pistonR

o-ring~~

A

~

Side seal

OiIPumPhOUSingOilseal~~

{OJ (6.2 -6.5,45 -471
\

.

S pnng seat

m q»

MAJOR OVERHAUL

D-ring

~~

'1«

Oilseal ~~

_~~I

~

~~}"

.

(~~'J
I

~"}
I

),
//

I

./"

"" no. t:!EI~
'//
.~mblv
V'
l

t:!@>~
9 Am.m.'"''
mblv

So","

9.

I

~~

i

;::--

~
/'.

'

/l

~ 7. 9 '°.7-0.9,6., .

~

~

/"

~

.'L

Parking

i
~

~

Revolutio~

"".m" flow,

aft rear snap ring ~

."

,-.

.6 -0.7,

3~0-7
6

. , 14 - 18)
. .6".

20 - 2S '2.0 -2 6

..,

1"1

..

r

~

'

D
Il-A""m.,"@>

0-,'''' t:! "ATF

.

I

.':
...

I."-

~1I

0.",."",,, '''10""''''

o-,~ogt:!@>
~ .nog..,EI

g ge

Parkin
0

'

.'-tf~:
..1;1
,,,",," %
..CoT
/
Ano"".oo
00"
/'. R~
-./'
0-';",
,. ,', l:;;'

I

EIR)

t? ~~b'

(1~2)
Accumulator
piston C

SA T937 A

21. Remove manual shaft components, if necessary.
a. Hold width across flats of manual shaft (outside the transmission case) and remove lock nut from shaft.

AT.. 99

DISASSEMBLY
Disassembly (Cont'd)
b. Remove retaining pin from transmission case.
Oil seal

\:

Transmission

case

SA T042 B

c. While pushing detent spring down, remove manual plate and
parking rod from transmission case.

d. Remove manual shaft from transmission case.

\
e. Remove spacer and detent spring from transmission case.

f.

Remove oil seal from transmission case.

-In~

~~.~
'0_L
-/

~-~j-/c

~

@~~\I
I
\
r
,)

yj-

~
SAT044B
AT -1 00

REPAIR FOR COMPONENT PARTS

Oil Pump

~

EI. ~

Friction ring
O-ring

: N.m (kg-m, ft-Ib)
Apply A.T.F.
1EaI~ : Apply petroleum jelly.

~ <@

@:

Pivot pin

Side seal

Oil pump housing

EI ~

Control

Oil seal
O-ring

~<@

piston

Side seal

,~~

lEal~

Oil pump cover assembly

Vane ring

High clutch seal ring

Cam ring
Sp ring seat
Cam ring spring

.M-~EI~
SA T648A

DISASSEMBLY
1. Loosen bolts in numerical order and remove oil pump cover.

SAT649A

Inscribe

identification

mark

.

2. Remove rotor, vane rings and vanes.
Inscribe a mark on back of rotor for Identification of
fore-aft direction when reassembling rotor. Then remove
rotor.

.

3. While pushing on cam ring remove pivot pin.
Be careful not to scratch oil pump housing.

AT-101

REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
4. While holding cam ring and spring lift out cam ring spring.
Be careful not to damage oil pump housing.
Hold cam ring spring to prevent it from jumping.

..

5. Remove cam ring and cam ring spring from
housing.

oil pump

6. Remove pivot pin from control piston and remove control
piston assembly.

7. Remove oil seal from oil pump housing.
Be careful not to scratch oil pump housing.

.

SAT655A

INSPECTION
Oil pump cover, rotor, vanes, control piston, side seals, cam
ring and friction ring
Check for wear or damage.

.

SA T656A

AT -1 02

REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
Dial indicator

Side clearances
Measure side clearances between end of oil pump housing
and cam ring, rotor, vanes and control piston in at least four
places along their circumferences. Maximum measured values should be within specified ranges.
Before measuring side clearance, check that friction rins~,
O-ring, control piston side seals and cam ring sprinb are
removed.
Standard clearance:
Cam ring
0.01 - 0.024 mm (0.0004 - 0.0009 in)
Rotor, vanes, control piston
0.03 - 0.044 mm (0.0012 - 0.0017 in)
If not within standard clearance, replace oil pump assembly
except oil pump cover assembly.

.
.

Vane
SAT657A

.

Clearance

lr

Seal ring

~

Seal ring clearance
Measure clearance between seal ring and ring groove.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Wear limit:
0.25 mm (0.0098 in)
If not within wear limit, replace oil pump cover assembly.

.
.

SA T658A

ASSEMBLY
1. Drive oil seal into oil pump housing.
Apply A.T.F. to outer periphery and lip surface.

.

2. Install cam ring in oil pump housing by the following stops.
a. Install side seal on control piston.
Pay attention to its direction - Black surface goes toward
control piston.
Apply petroleum jelly to side seal.
b. Install control piston on oil pump

.
.

AT-1 03

REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
c. Install O-ring and friction ring on cam ring.
Apply petroleum jelly to O-ring.

.

d. Assemble cam ring, cam ring spring and spring seat. Install
spring by pushing it against pump housing.

e. While pushing on cam ring install pivot pin.

3. Install rotor, vanes and vane rings.
Pay attention to direction of rotor.

.

SAT662A

4. Install oil pump housing and oil pump cover.
a. Wrap masking tape around splines of oil pump cover
assembly to protect seal. Position oil pump cover assembly
in oil pump housing assembly, then remove masking tape.
b. Tighten bolts in a criss-cross pattern.

AT -104

REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
E!!I@
Small dia. seal rings

E!!I@
Large dia.
seal rings

j~~~
--::::~>

-

.

~~

.

YL~

~

~==,/- ~--:-,

£j

5. Install seal rings carefully after packing ring grooves with
petroleum jelly. Press rings down into jelly to a close fit.
. Sealrings come in two different diameters. Check fit
carefully in each groove.
Small dia. seal ring:
No mark
Large dia. seal ring:
Yellow mark in area shown by arrow
Do not spread gap of seal ring excessively while installing.
It may deform ring.

.

SA T663A

AT -1 05

REPAIR FOR COMPONENT PARTS
Control Valve Assembly

Harness clips

Harness clips

Lower body

Orifice check spring
Orifice check valve
Reamer bolt
Reamer bolt
Pilot filter
Lower separate gasket

~.-

~. -'

~

~

Separator plate

Upper separate gasket

~

Side plate

Upper body

\
'~
~~-~.
\-

O-"og~

wOO'CO""" ,o'oooid

-~

Q

I

~

\

-;~
\

O-'og~

~\

AT-106

.

0

.

(overrun clutch solenoid and
shift solenoids
and B)
3-00"
,o'oooid A
,,,"mb'y

~

: N.m (kg-m, ft-Ib)
SAT1938

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
DISASSEMBLY
1. Remove solenoids.
a. Remove lock-up solenoid and side plate from lower body.
b. Remove a-ring from solenoid.

SAT194B

c. Remove line pressure solenoid from upper body.
d. Remove a-ring from solenoid.

SA T667 A

e. Remove 3-unit solenoid assembly from upper body.
f. Remove a-rings from solenoids.

SAT668A

2. Disassemble upper and lower bodies.
a. Place upper body facedown, and remove bolts, reamer bolts
and support plates.
b. Remove lower body, separator plate and separate gasket as
a unit from upper body.
Be careful not to drop pilot filter, orifice check valve,
spring and steel balls.

.

c. Place lower body facedown, and remove separate gasket
and separator plate.
d. Remove pilot filter, orifice check valve and orifice check
spring.

SA T670A

AT-107

REPAIR FOR COMPONENT PA.RTS
Control Valve Assembly (Cont'd)
e. Check to see that steel balls are properly positioned in
upper body and then remove them from upper body.

SAT671A

INSPECTION
Lower and upper bodies

.

Check to see that there are pins and retainer plates in lower
body.

SAT672A

.
.

Check to see that there are pins and retainer plates in upper
body.
Be careful not to lose these parts.

.

Check to make sure that oil circuits are clean and free from

.

damage.
Check tube brackets and tube connectors for damage.

SAT673A

Tube
connector

0

O'o'--.r

00

0000

) ~ 00

o~
o~-

0

0

0

g,oooo
0 6' 00' 0

0

0

'0
0

-

0

0 C ' 00
0

'0
0 Do
0

00

0

0

a

OC 0

0 '"
0
0 0",", o~ 0
00

0 0
I

0

0

~

,

0

0

00

0'

0

~

0 0

0

0

0

0

0

'0

~ ,00

0

"0

0

Co 0

0

"",,,00

0

0

D "5
°g
0 "c0
0

0

oo ~

" 00 C '0 0
'b 0 015 00

= 0,
0 c"g
0
g °c? 0 00 OC "go

=
,[l
=

0

0

cc"
0'

0

0 00

c

DOO

0

o

"0 000 o()o
0
g :sO
0
0
.0
0 ~o

0

Separator plates
. Check to make sure that separator plate is free of damage
and not deformed and oil holes are clean.

.

0

g
0
0

0
.0.

SAT675A

AT - t08

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
Pilot filter

.

Check to make sure that filter is not clogged or damaged.

SA T676A

Lock-up solenoid
Check that filter is not clogged or damaged.
Measure resistance. - Refer to "Electrical
Inspection".

.
.

SAT091

Components

B

Line pressure solenoid
Check that filter is not clogged or damaged.
Measure resistance. - Refer to "Electrical
Inspection".

.
.

Components

SAT092B

3-unit solenoid assembly (Overrun clutch solenoid and shift
solenoids A and B)
Measure resistance of each solenoid. - Refer to "Electrical
Components Inspection".

.

SAT095B

Fluid temperature sensor
Measure resistance. Inspection" .

.

SAT196B

AT -1 09

Refer to "Electrical

Components

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
ASSEMBLY
1. Install upper and lower bodies.
a. Place oil circuit of upper body face up. Install steel balls in
their proper positions.

b. Install reamer bolts from bottom of upper body and install
separate gaskets.

Reamer bolt (short)
SAT681A

c. Place oil circuit of lower body face up. Install orifice check
spring, orifice check valve and pilot filter.

SAT682A

d. Install lower separate gaskets and separator plates on lower
body.
e. Install and temporarily tighten support plates, fluid temperature sensor and tube brackets.

Unit: mm (in)
SAT197B

AT-110

REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
f.

.

Temporarily assemble lower and upper bodies, using reamer
bolt as a guide.
Be careful not to dislocate or drop steel balls, orifice
check spring, orifice check valve and pilot filter.

SAT198B

g.

Install

and

temporarily tighten bolts and tube brackets in

their proper locations.
Bolt length and location:
Item
Bolt length

@--

mm (in)

a

b

c

d

70
(2.76)

50
(1.97)

33
(1.30)

27
(1.06)

2. Install solenoids.
a. Attach a-ring and install lock-up solenoid and side plates
onto lower body.

Side plate

SA T200B

b. Attach a-rings
upper body.

and install 3-unit solenoids assembly onto

SAT668A

c. Attach a-ring and install line pressure solenoid onto upper
body.
3. Tighten all bolts.

SAT667A

AT-111

Torque converter relief valve

CD R

\

/
Lock-up control valve

1
1;

Upper body

'

~

0
1~

13 Return spring

,

Pin

\
!i

@ Return spring

I

II

PI'ot"'"

II

N

\ \
~

crm1rn

i\

~

Retainer Plate/

\
'

,

-r

~

~

~

~/
.

~fjYP

0

~~/ ~
.
. ~

.r-..,~

;; 77
//
~~~GG/~/
\

/

)

1

/
,

\U

-

before their installation.

mPlug~

0Cf

'\

4-2 sequence valve@Returnspring\PIU9

\

p

.

.

j@R"''''':",
P'"
~
mk«co

I~

crnQ

~

Shift valve B

amL

~

.

~
~

-

Overrun clutch control valve

=yd]

Overrun clutch
reducing valve

P

Accumulator control Plug'

.

eturn spnng
4-2 relay valve

-

~Pi
Plug

Return

Sho
'

Retainer pl

Pin

/1'1"1;«(««<0
R
(7)

\

eeve

Z

@R"'"

/

CID

spnng

SI

;t fl~12L!: ~o
Ar I , ~
. .

~

'«««(Cf)

Pressure modifier valve

--.I

G1

CL.'
C-L-.

~

-'i«««««O
@ Return spring

Apply A.T.F. to all components

I
'"

~

L

/0~

CV Return s

P",~""",~" "',,

,r-'-~

'

cV /
- cJI-/

~

//

Pin-~\

!II
~
~
CD
W
....
CD

"W~#'
\
@"'7/

((((O

#.

Plug

/

J

'\)

spring

e

.

~/~?7

' «~«9--'

Shuttle shift valve S

(j])Return

.~

!~ct

Sleeve

e

Plug

~

)

C
,

Shift

««[((0

@ Return spring

'

«({{((((CQ".

valve

A

~~~~\
~~~ ~;§p~-;.':S5(~

~,,~

pin

~

4-2 sequence valve and relay valve are located far back in
upper body. If they are hard to remove, carefully push them
out using stiff wire.
Be careful not to scratch sliding surface of valve with wire.

(S;

~~

SAT828A

AT-114

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
INSPECTION
~
(jj
E

'"

i5
~
:;
0
0

-

~

Valve springs
Measure free length and outer diameter of each valve spring.
Also check for damage or deformation.
Numbers of each valve spring listed in table below are the
same as those in the figure on AT-112.

.
.

--r\

\\\ \

-

-

Q . Free length

SAT829A

Inspection standard

Unit: mm (in)
Item

Part No.

Parts

Q

D

CD

Torque converter relief valve spring

31742-41X18

32.3 (1.272)

9.0 (0.354)

CV

Pressure regulator valve spring

31742-41X16

61.5 (2.421)

8.9 (0.350)

CID

Pressure modifier valve spring

31742-41 X19

31.95 (1.2579)

6.8 (0.268)

@

Shuttle shift valve D spring

31762-41XOO

26.5 (1.043)

6.0 (0.236)

CID

4-2 sequence valve spring

31756-41 XOO

29.1 (1.146)

6.95 (0.2736)

<@

Shift valve B spring

31762-41 X01

25.0 (0.984)

7.0 (0.276)

m

4-2 relay valve spring

31756-41XOO

29.1 (1.146)

6.95 (0.2736)

@

Shift valve A spring

31762-41 X01

25.0 (0.984)

7.0 (0.276)

@

Overrun clutch control valve spring

31762-41X03

23.6 (0.929)

7.0 (0.276)

@

Overrun clutch reducing valve spring

31742-41 X20

32.5 (1.280)

7.0 (0.276)

([j)

Shuttle shift valve S spring

31762-41X04

51.0 (2.008)

5.65 (0.2224)

@

Pilot valve spring

31742-41X13

25.7 (1.012)

9.1 (0.358)

@

Lock-up control valve spring

31742-41X22

18.5 (0.728)

13.0 (0.512)

.

Replace valve springs if deformed or fatigued.

Control valves
Check sliding surfaces of valves, sleeves and plugs.

.

AT -11

5

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
ASSEMBLY
1. Lubricate the control valve body and all valves with A.T.F.
Install control valves by sliding them carefully into their
bores.
Be careful not to scratch or damage valve body.

.

.

.

~
'
':;'" -

~I I

~~
r

I

II
~.

--.J::::

~

~ij

~

~

0

~

C)J~"

I

I~

'\'\';!

)

~

II u71)) 7~

-

-

~

p.,'h',"~

Ughtly
in while turning It.

) If
!

'r'

/

.

If pressure

.

cannot be inserted into bore in upper body.
If this happens, use vinyl tape wrapped screwdriver
center sleeve until it can be inserted.
Turn sleeve slightly while installing.

:

regulator

plug is not centered

h
Vin ylI ~
tape
)'::---

-I

\~/"

I SAT832A
Accumulator control plug
. Align protrusion of accumulator control sleeve with notch in
plug.
Align parallel pin groove in plug with parallel pin, and install
accumulator control valve.

.

Notch

/"

1(0:;
~JJ

~~f~,
,
-----------

)

to

Center plug

n C-:J~/.~

~I

sleeve

in spool
bore
;..{

=--=--=--'--::

properly,

I ""'l7<\
"-

r--:-~'CZ~
II!
~_I"~)

~~

,=

""

~II
P - ~,-,='7S"S
':::-i)

-:.() l
'- ::,I'
.J--":-'Y' -x:...
~
c \ /' '"

-

~ r

Pressure regulator valve

Sleeve
Y-'--"';

Wrap a small screwdriver with vinyl tape and use it to insert
the valves into proper position.

I

+---rr~)~l~.

~

/

SA T833A

2. Install parallel pins and retainer plates.

SA T834A

AT-116

REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
. Whilepushingplug,installparallelpin.

~.,

.

.

)

.

:::2...y-/---uO-..:::::J

u~...:::;::-u;J~~:>'''>
v, ~r.:::--';:::::::::;;
~,.~~~~k/$~'
':J

~

~
rE
v/:-

,~}p!n~

-

~-'--&

4-2 sequence valve and relay valve
Push 4-2 sequence valve and relay valve with wire wrapped
in vinyl tape to prevent scratching valve body. Install parallel
pins.

.

Parallel

I,

~

':>

~

I.//. '--

~

,:J,,&~

':::::::::::

~-:

~(j~~~~;:;fS
Cj\\C) ~

Wire

\

if1-J-:G
.
II

GG

\

I

SAT835A

.

Insert retainer plate while pushing spring.

Retainer plate

00

SAT836A

AT-117

Lower body

Pin

!i
I

...
...

~

co

Retainer plate

3-2 timing valve

@ Return spring

~

--,

CD

~--

f!!!j-- Plug

RetainerPlate---\cl

~Pin

Manual valve

en
~
-i

(I)
to>

"
~

Apply A.T.F. to all components before their installation.

Numbers preceding valve springs correspond with t
page AT-119.

REPAIR FOR COMPONENT PARTS
Control Valve Lower Body (Cont'd)
DISASSEMBLY
1. Remove valves at parallel pins.
2. Remove valves at retainer plates.
For removal procedures, refer to "DISASSEMBLY" of Control Valve Upper Body.

SA T838A

INSPECTION
:;;
Qj
E
as
'6
:;;
'5
0
0

-

Valve springs
Check each valve spring for damage or deformation. Also
measure free length and outer diameter.
Numbers of each valve spring listed in table below are the
same as those in the figure on AT-118.

.
.

~

.~
.-

\\\ \
Q : Free length

SAT829A

Inspection standard:

Unit: mm (in)
Item

Part No.

Parts

Q

D

Modifier accumulator piston spring

31742-41X15

30.5 (1.201)

9.8 (0.386)

1st reducing valve spring

31756-41X05

25.4 (1.000)

6.75 (0.2657)

CID

3-2 timing valve spring

31742-41 X08

20.55 (0.8091)

6.75 (0.2657)

@

Servo charger valve spring

31742-41X06

23.0 (0.906)

6.7 (0.264)

CD
'@

.

Replace valve springs if deformed or fatigued.

Control valves
Check sliding surfaces of control valves, sleeves and plugs
for damage.

.

ASSEMBLY
Install control valves.
For installation procedures, refer to "ASSEMBLY" of Control
Valve Upper Body.

.

SA T838A

AT -11 9

REPAIR FOR COMPONENT PARTS

Reverse Clutch
For the number of clutch sheets (drive plate and
driven platel. refer to the below cross-58ction.

~:

*

Apply A.T.F.
: Select with proper thickness.

Direction of oil seal

R.~~. d"Iohd,"m~

Dish plate

Retaining plate
Snap ring

'-- Driven plate

SAT839A

DISASSEMBLY
1. Remove reverse clutch assembly from clutch pack.

SA T840A

2. Check operation of reverse clutch.
a. Install seal ring onto oil pump cover and install reverse
clutch. Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not move to snap ring, D-ring or oil
seal may be damaged or fluid may be leaking at piston
check ball.

SAT841A

AT -1 20

REPAIR' FOR COMPONENT PARTS
Reverse Clutch (Cont'd)
3. Remove drive plates, driven plates, retaining plate, dish plate
and snap ring.

SAT842A

4. Remove snap ring from clutch drum while compressing
clutch springs.
Do not expand snap ring excessively.
5. Remove spring retainer and return spring.

.

SAT843A

6. Install seal ring onto oil pump cover and install reverse
clutch drum. While holding piston, gradually apply compressed air to. oil hole until piston is removed.
Do not apply compressed
air abruptly.
7. Remove D-ring and oil seal from piston.

.

INSPECTION
Reverse clutch snap ring and spring retainer
Check for deformation, fatigue or damage.

.

SAT844A

Reverse clutch return springs
Check for deformation or damage. Also measure free length
and outside diameter.

.

...
Q)
Q;
E


---IJ

,

Dish plate

Overrun clutch plate

'

Forwad

~lutchPlate

I

O"'o,~@P

,

If

I

,~

So.."0'

O"_I~""""-

'

.-,it"

JI-'C

-

0

r J

ASSEMBLY
1. Install bearing onto one-way clutch inner race.
Pay attention to its direction - Black surface goes to rear
side.
Apply petroleum jelly to needle bearing.

.

.

...

@

SAT112B

Oil seal

D-ring<:@

~

2. Install oil seal and D-ring onto piston.
Apply A.T.F. to oil seal and D-ring.

.

SAT879A

t
3. Install piston by rotating it slowly and evenly.
Apply A.T.F. to inner surface of transmission
case.

.

AT -1 32

REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd)
4. Install return springs, spring retainer and low one-way clutch
inner race onto transmission case.

5. Install dish plate, low and reverse brake drive plates, driven
plates and retaining plate.
6. Install snap ring on transmission case.

Driven plate

Drive plate

SAT812B

7. Check operation of low and reverse brake clutch piston.
Refer to "DISASSEMBLY".

SAT872A

8. Measure clearance between retaining plate and snap ring.
If not within allowable limit, select proper retaining plate.
Specified clearance:
Standard
1.1 - 1.5 mm (0.043 - 0.059 in)
Allowable limit
2.5 mm (0.098 in)
Retaining plate:
Refer to S.D.S.

9. Install low one-way clutch inner race seal ring.

~J

I
'

/\

-

",]

~ I\

'

I

"

-

'\

[\ \

(

/"

~'-

I

\

~r

=~

,

~~

"

~- U

,

,

".

\ r.

;;'.
\

-

,

~

I,

"

.

~
I

-(

-

,

~=

t/.

,,*'/,~.

/1

f
,

~

I

-

(;-~

..

"

.

..

~,

17

~

/

'\:IC

~\

II.

"

\

I~N

!

(

:

I~

.

..

Apply petroleum jelly to seal ring.
Make sure seal rings are pressed
held by petroleum jelly.

\

r

(

( \0
SAT884A

AT -1 33

firmly into place and

REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly

Needle bearing

Forward clutch drum assembly

Snap ring
Low one-way clutch
Side plate
Snap ring

~
~

~"
~

-''''''''

0.., -.
J;J-. -. '>

-. -.

-!.
.., I
(

SAT886A

DISASSEMBLY
1. Remove snap ring from forward clutch drum.

2. Remove side plate from forward clutch drum.

0.
SA T888A

3. Remove low one-way clutch from forward ciutci. drum.

\/

SA T889A

AT -1 34

REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly (Cont'd)
4. Remove snap ring from forward clutch drum.

5. Remove needle bearing from forward clutch drum.

SAT891A

~

INSPECTION
Forward clutch drum
Check spline portion for wear or damage.
Check frictional surfaces of low one-way clutch and needle
bearing for wear or damage.

.
.

~~
...~

SAT892A

Needle bearing and low one-way clutch
Check frictional surface for wear or damage.

.

SAT893A

ASSEMBLY
1. Install needle bearing in forward clutch drum.

SAT113B

AT-135

REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly (Cont'd)
2. Install snap ring onto forward clutch drum.

3. Install low one-way clutch onto forward
pushing the roller in evenly.

clutch drum by

SAT894A

.

SAT895A

Install low one-way clutch with flange facing rearward.

)
4. Install side plate onto forward clutch drum.
5. Install snap ring onto forward clutch drum.

AT -1 36

REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub

Rear internal gear (with forward one-way clutch inner race)

Thrust washer

lEI @
Forward clutch hub (with forward one-way clutch outer race)
Snap ring
Forward one-way clutch

6ri~

End bearing

lEI

@: Apply petroleum jelly.
SA T896A

DISASSEMBLY
1. Remove rear internal gear by pushing forward clutch hub
forward.

SA T897 A

2. Remove thrust washer from rear internal gear.

f)

n

SAT898A

3. Remove snap ring from forward clutch hub.

SAT899A

AT-137

REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont' d)

0

4. Remove end bearing.

~...~

~
B/

IIT'n,,,

~

-~0'GIi)~

SAT900A

5. Remove forward one-way clutch and end bearing as a unit
from forward clutch hub.

...

"-

8

~

:::=-~!)

Illh
I-~~,f),

SAT955A

6. Remove snap ring from forward clutch hub.

SAT901A

INSPECTION
Rear internal gear and forward clutch hub
Check gear for excessive wear, chips or cracks.
Check frictional surfaces of forward one-way clutch and
thrust washer for wear or damage.
Check spline for wear or damage.

..

..
.

..

..

SAT902A

oc)
00

Snap ring and end bearing
Check for deformation or damage.

.

SAT903A

AT -1 38

REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont'd)
ASSEMBLY
1. Install snap ring onto forward clutch hub.
2. Install end bearing.

SAT901A

3. Install forward one-way clutch onto clutch hub.
Install forward one-way clutch with flange facing rearward.
4. Install end bearing.
5. Install snap ring onto forward clutch hub.

.

6. Install thrust washer onto rear internal gear.
Apply petroleum jelly to thrust washer.
Securely insert pawls of thrust washer into holes in rear
internal gear.

.
.

7. Position forward clutch hub in rear internal gear.

8. After installing, check to assure that forward clutch hub
rotates clockwise.

SAT905A

AT-1 39

REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly
E-ring (large)
Return spring A
O-ring
Return spring B

~~

Servo piston spring retainer

Piston stem

O-ring

O-ring

I

~ <&V
O-ring

,

~ @V

~ <&V
O-ring

~ <&V

Gasket

~
0.0. servo
piston retainer

SAT908A

DISASSEMBLY
1. Block one oil hole in 0.0. servo piston retainer and the
center hole in 0.0. band servo piston.
2. Apply compressed air to the other oil hole in piston retainer
to remove 0.0. band servo piston from retainer.
3. Remove O-ring from 0.0. band servo piston.

a

SAT909A

.

4. Remove band servo piston assembly from servo piston
retainer by pushing it forward.

SAT910A

5. Place piston stem end on a wooden block. While pushing
servo piston spring retainer down, remove E-ring.

E-ring

SAT911A

AT-140

REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
6. Remove servo piston spring retainer, return spring C and
piston stem from band servo piston.

"e
n_@
SAT912A

7. Remove E-ring from band servo piston.

SAT913A

8. Remove servo cushion spring retainer from band servo
piston.
9. Remove O-rings from band servo piston.
10. Remove Q-rings from servo piston retainer.

~

SAT914A

INSPECTION

..

Pistons, retainers and piston stem
Check frictional surfaces for abnormal wear or damage.

.

....

..

f

Servo cushion spring retainer
SAT915A

Spring B

Return springs
. Check for deformation or damage. Measure free length and
outer diameter.

Inspectionstandard:
Spring A

SAT916A

Unit: mm (in)

Parts

Free length

Outer diameter

Spring A

45.6 (1.795)

3.3 (1.350)

Spring B

53.8 (2.118)

40.3 (1.587)

Spring C

29.0 (1.142)

27.6 (1.087)

AT-141

REPAIR FOR COMPONENT

PARTS

Band Servo Riston Assembly (Cont'd)
ASSEMBLY
1. Install O-rings onto servo piston retainer.
Apply A.T.F. to O-rings.
Pay attention to position of each O-ring.

.
.

2. Install servo cushion spring retainer onto band servo piston.

3. Install E-ring onto servo cushion spring retainer.

SAT919A

4. Install D-rings onto band servo piston.
Apply A.T.F. to D-rings.

.

5. Install servo piston spring retainer, return spring C and
piston stem onto band servo piston.

'@&

~@
SAT912A

AT-142

REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
6. Place piston stem end on a wooden block. While pushing
servo piston spring retainer down, install E-ring.

SAT921 A

7. Install band servo piston assembly onto servo piston retainer by pushing it inward.

SAT922A

8. Install O-ring on 0.0. band servo piston.
Apply A.T.F. to D-ring.

.

SAT923A

9. Install 0.0. band servo piston onto servo piston retainer by
pushing it inward.

SAT924A

AT-143

REPAIR FOR COMPONENT PARTS
Parking Pawl Components
Parking rod

~

24

- 29 N.m

(2.4- 3.0 kg-m,

17

- 22 ft-Ib)

Parking actuator support
Parking pawl shaft

Rear extension

Output shaft
SA T205B

DISASSEMBLY
1. Slide return spring to the front of rear extension flange.

2. Remove return spring, pawl spacer and parking pawl from
rear extension.
3. Remove parking pawl shaft from rear extension.

SAT927A

4. Remove parking actuator support and rod guide from rear
extension.

AT-144

REPAIR FOR COMPONENT PARTS
Parking Pawl Components (Cont'd)
INSPECTION

.

Parking pawl and parking actuator support

Check contact surface of parking rod for wear.

'"
SAT929A

ASSEMBLY
1. Install rod guide and parking actuator support
extension.
2. Insert parking pawl shaft into rear extension.

onto rear

3. Install return spring, pawl spacer and parking pawl onto
parking pawl shaft.

SAT927A

4. Bend return spring upward and install it onto rear extension.

AT-145

ASSEMBL Y

Assembly
1.
a.
.
.
b.

Install manual shaft components.
Install oil seal onto manual shaft.
Apply A.T.F. to oil seal.
Wrap threads of manual shaft with masking tape.
Insert manual shaft and oil seal as a unit into transmission
case.
c. Remove masking tape.
SAT931 A

d. Push oil seal evenly and install it onto transmission case.

\
e. Align groove in shaft with drive pin hole, then drive pin into
position as shown in figure at left.

SA T933A

f.

Install detent spring and spacer.

g. While pushing detent spring down, install manual plate onto
manual shaft.

AT -146

ASSEMBL Y

Assembly (Cont'd)
h. Install lock nuts onto manual shaft.

SAT936A

Front..
Accumulator

piston B

Accumulator

2. Install accumulator piston.
a. Install O-rings onto accumulator piston.

.

Apply A.T.F. to O-rings.
Unit: mm (in)

Accumulator piston O-rings:

tJ tr{'Ob

AE..o,
piston A

Accumulator

Accumulator

A

B

C

D

Small diameter end

29 (1.14)

32 (1.26)

45 (1.77)

29 (1.14)

Largediameter end

45 (1.77)

50 (1.97)

50 (1.97)

45 (1.77)

piston C

SA T937 A

b. Install return spring for accumutator
case.

A onto transmission

Unit: mm (in)

Free length of return spring:
Accumulator

A

Free length

43 (1.69)

c.

Install accumulator

.

ApplyA.T.F.to transmission case.

pistons

A, S, C and D.

3. Install band servo piston.
a. Install return springs onto servo piston.

SAT941 A

AT -14 7

ASSEMBLY
Assembly (Cont'd)
b. Install band servo piston onto transmission case.
Apply A.i.F. to O-ring of band servo piston and transmission case.

.

c. Install gasket for band servo onto transmission case.

d. Install band servo retainer onto transmission case.

4. Install rear side clutch and gear components.
a. Place transmission case in vertical position.

.

ST07870000
(J37068)

SAT943A

.;:I

Forward clutch drum

b. Slightly lift forward clutch drum assembly and slowly rotate it
clockwise until its hub passes fully over the clutch inner
race inside transmission case.

SAT944A

c. Check to be sure that rotation direction of forward clutch
assembly is correct.

-----------------

,

SAT945A

AT ~ 148

ASSEMBL Y
Assembly (Cont'd)
d. Install thrust washer onto front of overrun clutch hub.
. Apply petroleum jelly to the thrust washer.
Insert pawls of thrust washer securely into holes in
overrun clutch hub.

.

Hole for
pawl

SAT946A

e. Install overrun clutch hub onto rear internal gear assembly.

SAT947A

f.

.

Install needle bearing onto rear of overrun clutch hub.
Apply petroleum jelly to needle bearing.

SAT948A

g. Check that overrun clutch
holding forward clutch hub.

hub rotates

as shown while

SAT949A

h. Place transmission case into horizontal position.

SAT950A

AT-149

ASSEMBLY
Assembly (Cont'd)
i.

Install rear internal gear, forward clutch hub and overrun
clutch hub as a unit onto transmission case.

j.

Install needle bearing onto rear internal gear.
Apply petroleum jelly to needle bearing.

.

k. Install bearing race onto rear of front internal gear.
Apply petroleum jelly to bearing race.
. Securely engage pawls of bearing race with holes in front
internal gear.

.

I.

Install front internal gear on transmission case.

AT -1 50

ASSEMBL Y

Adjustment
When any parts listed in the following table are replaced, total
end play or reverse clutch end play must be adjusted.
Total end play

Part name

Reverse clutch
end play

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

High clutch drum

8

8

Oil pump cover

8

8

-

8

Transmission

case

Low one-way

clutch

Overrun

clutch

Rear internal

inner race

hub
gear

Rear planetary

carrier

Rear sun gear
Front

planetary

Front

sun gear

High clutch

carrier

hub

Reverse clutch

drum

1. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
Pay attention to its direction.

.

b. Install needle bearing on front of front planetary carrier.
Apply petroleum jelly to needle bearing.
c. Install needle bearing on rear of front planetary carrier.
Apply petroleum jelly to bearing.
Pay attention to its direction - Black side goes to front.

.
.
.

SAT967A

AT -151

ASSEMBL Y
Adjustment (Cont'd)
d. While rotating forward clutch drum clockwise,
planetary carrier on forward clutch drum.

/

..,

SAT969A

.
F rant planetary

,

carrier

Check that portion A of front planetary carrier protrudes
approximately 2 mm (0.08 in) beyond portion B of forward
clutch assembly.

'.-=

.:':.. ,..: '.. ..,

Portion

install front

A

...:::.'.

Forward clutch drum

Portion B
SAT970A

O---El~
~~

~f}Jj
~
r~:
""--~-L
'

//

e. Install bearing races on rear of clutch pack.
Apply petroleum jelly to bearing races.
Securely engage pawls of bearing race with hole In clutch
pack.

.
.

/
SA T204B

f.

Place transmission case in vertical position.

g. Install clutch pack into transmission case.

SAT973A

AT -1 52

ASSEMBLY
Adjustment

(Cont' d)

2. Adjust tetalend play.
Total end play "T,":
0.25 - 0.55 mm (0.0098 - 0.0217 in)

a. With needle bearing installed, place J34291-1 (bridge),
J34291-2 (legs) and the J34291-5 (gauging cylinder) ente eil
pump. The leng ends ef legs sheuld be placed firmly en
machined surface ef eil pump assembly and gauging cylinder sheuld rest en tep ef the needle bearing. Leck gauging
cylinder in place with set screw.

b. Install J34291-23 (gauging plunger) into. gauging cylinder.

c. With eriginal bearing race installed inside reverse clutch
drum, place shim selecting gauge with its legs en machined
surface ef transmissien case (no. gasket) and allew gauging
plunger to. rest en bearing race. Leck gauging plunger in
place with set screw.

d. Remeve To.el and use feeler gauge to. measure gap between
gauging cylinder and gauging plunger. This measurement
sheuld give exact tetal end play.
Total end play "T,":
0.25 - 0.55 mm (0.0098 - 0.0217 in)
If end play is eut ef specificatien, decrease er increase
thickness ef eil pump cever bearing race as necessary.
Available oil pump cover bearing race:
Refer to S.D.S.

.

SAT979A

AT -1 53

ASSEMBL Y
Adjustment (Cont'd)
3. Adjust reverse clutch drum end play.
Reverse clutch drum end play "12":
0.55 - 0.90 mm (0.0217 - 0.0354 in)

a. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5
(gauging cylinder) on machined surface of transmission case
(no gasket) and allow gauging cylinder to rest on front
thrust surface of reverse clutch drum. Lock cylinder in place
with set screw.

SAT981A

b. Install J34291-23 (gauging plunger) into gauging cylinder.

c. With original thrust washer installed on oil pump, place shim
setting gauge legs onto machined surface of oil pump
assembly and allow gauging plunger to rest on thrust
washer. Lock plunger in place with set screw.
Lock

d. Use feeler gauge to measure gap between gauging plunger
and gauging cylinder. This measurement should give you
exact reverse clutch drum and play.
Reverse clutch drum end play "12":
0.55 - 0.90 mm (0.0217 - 0.0354 in)
If end play is out of specification, decrease or increase
thickness of oil pump thrust washer as necessary.
Available oil pump thrust washer:
Refer to S.D.S.

.

Feeler gauge
SAT984A

AT-154

ASSEMBL Y

Assembly
1. Install output shaft and parking gear.
a. Insert output shaft from rear of transmission case while
slightly lifting front internal gear.
Do not force output shaft against front of transmission
case.

.

/

;~T216B
b. Carefully push output shaft against front of transmission
case. Install snap ring on front of output shaft.
Check to be sure output shaft cannot be removed in rear
direction.

.

c. Install needle bearing on transmission case.
Pay attention to its direction - Black side goes to front.
. Apply petroleum jelly to needle bearing.

.

d. Install parking gear on transmission case.

~

e. Install snap ring on rear of output shaft.
Check to be sure output shaft cannot be removed in
forward direciton.

.

SA T960A

AT -1 55

ASSEMBL Y
Assembly (Cont'd)
2. Install rear extension.
a. Install oil seal on rear extension.
Apply A.T.F. to oil seal.

.

SAT219B

b. Install O-ring on revolution sensor.
Apply A.T.F. to O-ring.
c. Install revolution 'sensor on rear extension.

.

SAT191B

d. Install rear extension gasket on transmission case.

SA T963A

e. Install parking rod on transmission case.

f.

Install rear extension on transmission case.

SAT189B

AT-156

ASSEMBL Y
Assembly (Cont' d)
3. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
Pay attention to its direction.

.

b. Make sure needle bearing is on front of front planetary
carrier.
Apply petroleum jelly to needle bearing.
c. Make sure needle bearing is on rear of front planetary
carrier.
Apply petroleum jelly to bearing.
Pay attention to its direction - Black side goes to front.

.
.
.

SAT967A

d. While rotating forward clutch drum clockwise, install front
planetary carrier on forward clutch drum.

/

SAT969A

~

Front planetary

.

carrier

Check that portion A of front planetary carrier protrudes
approximately 2 mm (0.08 in) beyond po.rtion B of forward
clutch assembly.

Portion A
Portion B
SAT970A

e. Make sure bearing races are on front and rear of clutch
pack.
Apply petroleum jelly to bearing races.
Securely engage pawls of bearing races with holes in
clutch pack.

.
.

Front

Rear
SAT971A

AT-157

ASSEMBLY
Assembly (Cont'd)
f.

Install clutch pack into transmission case.

SAT220B

4. Install brake band and band strut.
a. Install band strut on brake band.
Apply petroleum jelly to band strut.

.

SAT985A

b. Place brake band on periphery of reverse clutch drum, and
insert band strut into end of band servo piston stem.

c. Install anchor end bolt on transmission case. Then, tighten
anchor end bolt just enough so that reverse clutch drum
(clutch pack) will not tilt forward.

5. Install input shaft on transmission case.
Pay attention to its direction - O-ring groove side is front.
6. Install gasket on transmission case.

.

AT-158

ASSEMBLY
Assembly (Cont'd)
7. Install oil pump assembly.
a. Install needle bearing on oil pump assembly.
Apply petroleum jelly to the needle bearing.
b. Install selected thrust washer on oil pump assembly.
Apply petroleum jelly to thrust washer.

.
.

SA T989A

c. Carefully install seal rings into grooves and press them into
the petroleum jelly so that they are a tight fit.
Seal ring

m~

d. Install O-ring on oil pump assembly.
Apply petroleum jelly to O-ring.

.

a-ring

lEI ~
SAT991A

e. Apply petroleum jelly to mating surface of transmission case
and oil pump assembly.

SAT992A

f.

.

Install oil pump assembly.
Install two converter housing securing bolts in bolt holes
in oil pump assembly as guides.

SAT993A

AT-159

ASSEMBL Y
Assembly (Cont'd)
Transmission

case

Oil pump assembly

.

Insert oil pump assembly to the specified position in
transmission, as shown at left.

8. Install O-ring on input shaft.
Apply A.T.F. to O-rings.

.

SAT114B

9. Install converter housing.
a. Install O-rings on converter housing.

b. Apply
recommended
sealant
(Nissan genuine
part:
KP610-00250 or equivale.nt) to outer periphery of bolt holes
in converter housing.
Do not apply too much sealant.

.

SAT997A

c. Apply
recommended
sealant
(Nissan genuine part:
KP610-00250 or equivalent) to seating surfaces of bolts that
secure front of converter housing.

SA T998A

AT -1 60

ASSEMBL Y
Assembly (Cont'd)
d. Install converter housing on transmission case.

10.Adjust brake band.
a. Tighten anchor end bolt to specified torque.
Anchor end bolt:
~: 4

- 6 N.m

(0.4 - 0.6 kg-m, 2.9 - 4.3 ft-Ib)
b. Back off anchor end bolt two and a half turns.

c. While holding anchor end pin, tighten lock nut.

11. Install terminal cord assembly.
a. Install O-ring on terminal cord assembly.
Apply petroleum jelly to O-ring.
b. Compress terminal cord assembly stopper and install terminal cord assembly on transmission case.

.

12. Install control valve assembly.
a. Install accumulator piston return springs B, C and D.
Unit: mm (in)

Free length of return springs:
Item
Free length

AT-161

8

c

D

66 (2.60)

45 (1.77)

58.4 (2.299)

ASSEMBL Y

Assembly (Cont'd)
b. Install manual valve on control valve.
Apply A.T.F. to manual valve.

.

SATOO58

c. Place control valve assembly on transmission case. Connect
solenoid connector for upper body.
d. Install connector clip.

e. Install control valve assembly on transmission case.
f. Install connector tube brackets and tighten bolts @ and @.
Check that terminal assembly harness does not catch.

.

Bolt

Length

@

37 mm (1.46 in)

@

50 mm (1.97 in)

g. Install O-ring on oil strainer.
Apply petroleum jelly to O-ring.
h. Install oil strainer on control valve.

.

SAT2218

AT -1 62

ASSEMBLY
Assembly (Cont'd)

tI::~~1

i.

Securely fasten terminal harness with clips.

j.

Install lock-up solenoid and fluid temperature sensor connectors.

SATOO98

Connector

13. Install oil pan.
a. Attach a magnet to oil pan.

SAT0118

b. Install oil pan gasket on transmission case.
c. Install oil pan and bracket on transmission case.
Tighten four bolts In a criss-cross pattern to prevent
dislocation of gasket.

.

SAT0128

14. Install inhibitor switch.
a. Check that manual shaft is in "1" range.
b. Temporarily install inhibitor switch on manual shaft.
c. Move manual shaft to "N".

II

SAT0138

AT -163

ASSEMBL Y
Assembly (Cont'd)
d. Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin

-

vertically into locating holes in inhibitor switch and manual
shaft.

\\
--\\
SAT014B

15. Install torque converter.
a. Pour A.T.F. into torque converter.
Approximately 2 liters (2-1/8 US qt, 1-3/4 Imp qt) of fluid
are required for a new torque converter.
When reusing old torque converter, add the same amount
of fluid as was drained.

.
.

SAT015B

b. Install torque converter while aligning notches and oil pump.

SAT016B

c. Measure distance A to check that torque converter is in
proper position.
Distance "A":
26 mm (1.02 in) or more

AT-164

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
KA24E

Engine
Autorriatic transmission model

RE4R01A

Transmission model code number

45X06

Stall torque ratio

2.0: 1

Transmission gear ratio
1st .
2nd
Top
O.D.
Reverse

2.785
1.545
1.000
0.694
2.272
Automatic transmission
fluid Type DEXRONTM

Recommended oil
Oil capacity

II (US qt, Imp qt)

8.3 (8-3/4,7-1/4)

Specifications and Adjustment
VEHICLE

SPEED WHEN SHIFTING

GEARS
Vehiclespeed km/h (MPH)

Throttle position

DI -> D,

D, -> D.

D. -> D.

D. ->D.

D. -> D,

D, ->DI

1,->11

Full throttle

52 -56
(32 - 35)

95 - 101
(59 - 63)

146 - 156
(91 -97)

140 - 150
(87 - 93)

89-95
(55- 59)

40-44
(25 -27)

53 - 57
(33 - 35)

Half throttle

38-42
(24 - 26)

72 -78
(45-48)

111-121
(69 -75)

55-65
(34 - 40)

33 - 39
(21 - 24)

10 - 14
(6-9)

53 - 57
(33 - 35)

VEHICLE SPEED WHEN PERFORMING
RELEASING LOCK-UP

AND

STALL

REVOLUTION
Stall revolution

Vehicle speed km/h (MPH)
Throttle
position

O.D. switch
[Shift range]

Lock-up
"ON"

Lock-up
"OFF"

ON
[D.]

146 - 156
(91 -97)

140 - 150
(87 -93)

OFF
[D.]

95

Full throttle

-101

2,050

(59-63)

Engine speed
rpm

ON
[D.]

112-120
(70 -75)

102-110
(63 -68)

OFF
[D.]

(47 - 52)

71 -79
(44 -49)

76

-84

-2,250

LINE PRESSURf;

89-95
(55-59)

Half throttle

rpm

AT-165

line pressure kPa (kg/em' , psi)
D,2 and 1 ranges

R range

Idle

471 .510 '
(4.8 - 5.2, 68 - 74)

657 . 696
(6.7 -7.1,95 -101)

Stall

1,020 . 1,098
(10.4 -11.2,148 -159)

1.422 - 1,500
(14.5 - 15.3,206 - 218)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Specifications and Adjustment (Cont'd)
RETURN

SPRINGS
Unit: mm (in)
Item

Part No.

Free length

Outer diameter

Torque converter relief valve spring

31742-41X18

32.3 (1272)

9.0 (0.354)

Pressure regulator valve spring

31742-41X16

61.5 (2.4211

8.9 (0.350)

Pressure modifier valve spring

31742-41 X19

31.95 (12579)

6.8 (0268)

Shuttle shift valve D spring

31762-41XOO

26.5 (1.043)

6.0 (0.236)

4-2 sequence valve spring

31756-41XOO

29.1 (1.146)

6.95 (02736)

Shift valve B spring

31762-41 X01

25.0 (0.984)

7.0 (0.276)

4-2 relay valve spring

31756 -41XOO

29.1 (1.146)

6.95 (0.2736)

Shift valve A spring

31762-41X01

25.0 (0.984)

7.0 (0276)

Overrun clutch control valve spring

31762-41X03

23.6 (0.929)

7.0 (0276)

Overrun clutch reducing valve spring

31742-41X20

32.5 (1280)

7.0 (0.276)

Shuttle shift valve S spring

31762-41 X04

51.0 (2.008)

5.65 (0.2224)

Pilot valve spring

31742-41 X13

25.7 (1.012)

9.1 (0.358)

Lock-up control valve spring

31742-41X22

18.5 (0.728)

13.0 (0.512)

Modifier accumulator piston spring

31742-41X15

30.5 (1201)

9.8 (0.386)

1st reducing valve spring

31756-41X05

25.4 (1.000)

6.75 (02657)

3-2 timing valve spring

31742-41 X08

20.55 (0.8091)

6.75 (02657)

Servo charger valve spring

31742-41X06

23.0 (0.906)

6.7 (0264)

Parts

Upper
body
Control
valve

Lower
body

Reverse clutch

16 pcs

30505-41 X02

19.69 (0.7752)

11.6 (0.457)

High clutch

16 pes

31505-21X03

22.06 (0.8685)

11.6 (0.457)

Forward clutch
(Oiierrun clutch)
Low & reverse
brake

20 pes

31505-41X01

35.77 (1.4083)

9.7 (0.382)

18 pcs

31521-21XOO

23.7 (0.933)

11.6 (0.457)

Spring A

31605-41X05

45.6 (1.795)

34.3 (1.350)

Spring B

31605-41XOO

53.8 (2.118)

40.3 11.587)

Spring C

31605-41X01

29.0 (1.142)

27.6 (1.087)

Accumulator A

31605-41X02

43.0 (1.6931

Accumulator B

31605-41X10

66.0 (2.598)

Accumulator C

31605-41X09

45.0 (1.772)

Accumulator D

31605-41X06

58.0 (2283)

Band servo

Accumulator

AT-166

-------------------

SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Specifications
ACCUMULATOR

O-RING
Diameter mm (in)

Accumulator

and Adjustment (Cont'd)

IForward

A

B

C

D

Small diameter end

29 (1.14)

32 (1.26)

45 (1.77)

29 (1.14)

Large diameter end

45(1.77)

50 (1.97)

50 (1.97)

45 (1.77)

CLUTCHES AND BRAKES

IReverse clutch/
Number of drive plates

2

Number of driven plates

2

2.0 (0.079)
1.8 (0.071)

Clearance
mm (in)
Standard
Allowable limit

0.5 - 0.8 (0.020 - 0.031)
1.2 (0.047)

Number of driven plates

5

Thickness of drive plate
mm(in)
Standard
Wear limit

2.0 (0.079)
1.8 (0.0711

Clearance
mm (in)
Standard
Allowable limit

0.45 - 0.85 (0.0177 - 0.0335)
1.85 (0.0728)

Thickness of retaining plate

Thickness
mm (in)
4.6
4.8
5.0
5.2
5.4
5.6
5.8

31537-21XOO
31537-21 X01
31537-21X02
31537 -21 X03
31537-21X04
31567-41X13
31567-41 X14

Number of drive plates

4

Number of driven plates

4

Thickness of drive plate
mm (in)
Standard
Wear limit

1.6 (0.063)
1.4 (0.055)

Clearance
mm(in)
Standard
Allowable limit

1.8 - 2.2 (0.071 - 0.087)
3.0 (0.118)
Thickness
mm(in)
3.6
3.8
4.0
4.2
4.4
4.6
4.8
5.0

(0.142)
(0.150)
(0.157)
(0.165)
(0.173)
(0.181)
(0.189)
(0.197)

IOverrun

Part number

(0.181)
(0.189)
(0.197)
(0.205)
(0.213)
(0.220)
(0.228)

IHigh clutch I

Thickness of retaining plate

5

Thickness
mm (in)

Thickness of drive plate
mm(in)
Standard
Wear limit

Thickness of retaining plate

I

clutch
Number of drive plates

31537.41X61
31537-41X62
31537-41X63
31537-41X64
31537-41 X65
31537-41X66
31537-41 X67
31537-41X68

AT-167

(0.315)
(0.323)
(0.331)
(0.339)
(0.346)
(0.354)
(0.362)

31537-41

XOO

31537-41X01
31537-41 X02
31537-41X03
31537-41 X04
31537-41X05
31537-41X06

I

clutch
Number of drive plates

3

Number of driven plates

5

Thickness of drive plate
mm (in)
Standard
Wear limit

2.0 (0.079)
1.8 (0.071)

Clearance
mm(in)
Standard
Allowable limit

1.0 - 1.4 (0.039 - 0.055)
2.0 (0.079)

Thickness of retaining plate

Part number

8.0
8.2
8.4
8.6
8.8
9.0
9.2

Part number

Thickness
mm (in)

Part number

4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6(0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)

31537-41X79
31537-41 X80
31537-41X81
31537-41 X82
31537-41X83
31537-41 X84
31537-41 X20

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Specifications and Adjustment (Cont'd)
REVERSE CLUTCH DRUM END PLAY

ILow & reverse brake I
Number of drive plates

5

Number of driven plates

7

Thickness of drive plate
mm (in)
Standard
Wear limit.

I

Thickness of oil pump thrust
washer

8.6
8.8
9.0
9.2
9.4
9.6

I

(0.339)
(0.346)
(0.354)
(0.362)
(0.370)
(0.378)

31667-41X03
31667-41X04
31667-41X05
31667-41X06
31667-41X09
31667-41 X10

4.6
(0.4 - 0.6, 2.9 - 4.3)

Number of returning
revolutions for anchor
end bolt

I

-

Rotor, vanes and control
piston - oil.pump housing
Standard
Seal ring clearance
mm (in)
Standard
Allowable limit

TOTAL

Drive plate runout limit

0.Q1 - 0.024 (0.0004 - 0.0009)

- 0.044 (0.0012 - 0.0017)

0.10 - 0.25 (0.0039 - 0.0098)
0.25 (0.0098)

END PLAY
0.25 - 0.55 mm
(0.0098 0.0217 in)

Total e~ play "T I "

-

Thickness
mm (in)

Thickness of oil pump
cover bearing race

0.8
1.0
1.2
1.4
1.6
1.8
2.0

(0.031)
(0.039)
(0.047)
(0.0551
(0.063)
(0.071)
(0.079)

1 ..1 (0.043)

(0.051)
(0.059)
(0.067)
(0.075)

Manual control linkage
Number of returning
revolutions for lock nut

Distance between end of clutch
housing and torque converter

2.5

0.03

31528-21 XOO'
31528-21 X01
31528-21X02
31528-21 X03
31528-21 X04
31528-21 X05
31528-21 X06

REMOVAL AND INSTAllATION

Oil PUMP AND lOW ONE-WAY CLUTCH
Oil pump clearance
mm (in)
Cam ring oil pump housing
Standard

Part number

Part number

Lock nut tightening torque

Brake band
Anchor end bolt tightening
torque
N.m (kg-m, ft-Ib)

- 0.90 mm

0.7 (0.028)
0.9 (0.035)
1.3
1.5
1.7
1 .9

1.1 - 1.5 (0.043 - 0.059)
2.5 (0.098)
Thickness
mm (in)

0.55

(0.0217 - 0.0354 in)
Thickness
mm (in)

2.0 (0.079)
1.8 (0.071)

Clearance
mm lin)
Standard
Allowable limit

Thickness of retaining plate

Reverse clutch drum end play
"Ta ..

Part number
31429-21 XOO
31429-21 X01
31429-21 X02
31429-21 X03
31429-21X04
31429-21 X05
31429-21 X06

AT-168

-

(1.1-1.5

11 15 N.m
kg-m, 8 -11 ft-Ib)

26.0 mm (1.024 in) or more
0.5 mm (0.020

in)

PROPELLER
SHAFT&
DIFFERENTIAL
CARRIER
I

.

PD

SECTION

CONTENTS
PREPARATION...

."
"""""""""""

PROPELLER

SHAFT

ON-VEHICLE

SERVICE

"'..0

""'''''''''''''''''''0''''''''''''''''''''

(Final drive)

REMOVAL AND INSTALLATION
FRONT

FINAL

DRIVE

DISASSEMBLY

INSPECTION
ASSEMBLY

0

0

"""'"''''''''''''''''''''

0..
0

0"'"

0'''''

0...0"""0"

"'"''''''''''''''''''''''''''''''''''''''

"""''''''0'''''''''''''0''''''''

o.0

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

0 PD-

2

PD-

5

~

PD- 9

''''''''''''''''''''''''''''''''''''''''''''''''''''''

0
0

0"

..

""""''''''''''''''''''''''''''''

ADJUSTMENT

0'"''''

PD-11

0
"""""'''''''''''''...0
""""""'"''''''''''
'"''''''''''''

0'"''''''''''''0'''

...".

"''''''''''''''''''''''
0'"''''
0..""'''''''...0.0

PD-12

PD-13
0. PD-17

0'0'"''''''''''''''
0

PD-18
PD-25

PD-30

-

PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
ST38060002
(J34311)
Drive pinion flange
wrench
KV38100800

-

(

)

Equivalent tool
(J25604-D 1)
Differential
attachment

Description

~

Removing and installing propeller shaft
lock nut, and drive pinion lock nut.

Mounting final drive
(To use, make a new hole.)

~

V

a: 152 mm (5.98 in)

ST309OS000

-

(

Removing and installing drive pinion
rear cone

)

Drive pinion rear inner
race puller set
CD

ST30031000
(J22912-D1)
Puller

@ ST30901000

-

(

)

Equivalent tool
(J26010-D1)
Base

~
~

Removing and installing differential side
bearing inner cone

ST3306S001

-

(

)

Differential side
bearing puller set
CD ST33051001
(

-

)

Equivalent tool
(J22888)
Body
@ ST33061 000
(J8107-2)
Equivalent tool
(J26010-D1)
Adapter
ST30611000
(J25742-1)
Drift

Q}fi

~~

Installing pinion rear bearing outer race

~~ ~~\~.;II';~J..i'Hi1tlI'itr;;;'WJJ

PD-2

PREPARATION
Tool number
(Kent-Moore No.)
Tool name

Description

ST30613000
(J25742-3)
Drift

Installing pinion rear bearing outer race

~.

~

ST30701000
(J25742-2)
Drift

Installing pinion front bearing outer race

c

KV381 00200
(J26233)
Gear carrier
side oil seal
drift
KV38100500

-

(

)

Gear carrier front
oil seal drift

KV381 00300
(J25523)
Differential side
bearing inner cone

KV38100600
(J25267)
Side bearing spacer
drift
ST3127S000
(See J25765-A)
Preload gauge CD GG91030000
(J25765)
Torque wrench
@ HT62940000

-

(

)

~
roo
~
~
CD

~

r;==~

Installing side oil seal

Installing front oil seal

Installing side bearing inner cone

Installing side bearing spacer

Measuring pinion bearing preload
and total preload

D

~-~

Socket adapter
@ HT62900000
(
)
Socket adapter
HT72400000
(
)
Slide hammer

-

Removing differential case assembly

~

~

PD-3

PREPARATION
Tool number
(Kent-Moore No.)
Tool name

Description

(J34309)
Differential shim
selector

Adjusting bearing
preload and gear height

(J25269-4)
Side bearing discs
(2 Req'd)

Selecting pinion height
adjusting washer

(J8129)
Spring gauge

@

~

PD-4

Measuring carrier turning
torque

PROPELLER SHAFT

.~

~

3S63A-T
Washer
Apply a coat of multi-purpose lithium grease
containing molybdenum disulfide to the end
face of the center bearing and both sides of
the washer.

~

~

Lock nut
~245 -294
125- 30, 181 - 217)

25-39

12.6- 4.0, 19 - 29)

'fh

"1)
0
IX)
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'00

rn':'
Companion

en

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R", ,.,,,

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~ )Y'

.

/~, //

~r

Rn,-,
'

~

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~

LockP'" t:9

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G

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L

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P~

e,,,"'"

,

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CI

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P

t"J . 88. ."8(9. '

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LA

I
Inner

"i"'~

Breath

' ,
mate

nO r, J

~'''''

l~O

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Pinion

", "

Spe

\

a

""",,

bea

flange

* : Adjustment is re
* : Using locking ag
: N.m (kg-m, ft-Ib

~

DISASSEMBLY

Pre-inspection
Before disassembling final drive, perform the following inspection.
Total preload
1) Turn drive pinion in both directions several times to set
bearing rollers.
2) Check total preload with Tool.
Tool number: ST3127S000 (See J25765-A.)
Total preload:
1.4 - 1.7 N.m
(14 - 17 kg-em, 12 - 15 in-Ib)

.

SPD884

.

Ring gear to drive pinion backlash
Check ring gear-to-drive pinion backlash with a dial indicator
at several points.
Ring gear-to-drive pinion backlash:
0.10 - 0.15 mm (0.0039 - 0.0059in)

SPD513

.
.
0-

Ring gear runout
Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
Tooth contact
Check tooth contact. (Refer to Adjustment.)

../"/11

Runo~ ~m~: ~.~ m~~O.OO20in) SPD886

.

Side gear to pinion mate gear backlash
Measure clearance between side gear thrust washer and
differential case with a feeler gauge.
Clearance between side gear thrust washer and
differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)

SPD887

Differential Carrier
1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool.

Tool number:

PD-13

KV38100800

(

-

)

DISASSEMBLY
Differential Carrier (Cont'd)
2.

Paint or punch match marks on one side of the side bearing
cap so itcan be properly reinstalled.

Bearing caps are line-board during manufacture. Replace
them in their proper positions.

SP D889

3. Remove side bearing caps.

4. Lift differential case assembly
Tool number:

HT72400000

out with

(

-

Tool.
)

PD344

6
?

Keep the side bearing outer races together with inner cone
do not mix them up.

~.
SPD527

5. Loosen drive pinion nut and pull off companion

SPD890

PD-14

flange.

-

DISASSEMBLY
Differential Carrier (Cont'd)

SPD891

6. Take out drive pinion (together with rear bearing inner race,
bearing spacer and adjusting washer).
7. Remove oil seal.
8. Remove front bearing inner race.
9. Remove side oil seal.

10. Remove pinion bearing outer races with a brass drift.

PD349

\ ""'-7

<.~.

_H..

.--.
.

-

/.'-

-~

./

11. Remove pinion rear bearing inner race and drive pinion

I

height adjusting

.Tool

----- -

-- -PD179

PD-15

washer

with suitable tool.

DISASSEMBLY
Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
@ ST33051001( )
Equivalent tool (J22888)
@ ST33061000 (J8107-2)

SPD529

Be careful not to confuse left- and right-hand parts.

SPD022

2. Loosen ring gear bolts in a criss-cross fashion.
3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

4. Drive out pinion mate shaft lock pin, with punch from ring
gear side.
Lock pin is calked at pin hole mouth on differential case.

SPD025

PD-16

INSPECTION
Ring Gear and Drive Pinion
Check gear teeth for scoring, cracking or chipping. If any part is
damaged, replace ring gear and drive pinion as a set (hypoid
gear set).

Differential Case Assembly
Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.

SPD909

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set.

SPD715

PD-17

ADJUSTMENT
For quiet and reliable final drive operation, the following five
adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear-to-pinion backlash (Refer to ASSEMBLY.)
5. Ring and pinion gear tooth contact pattern

~

Side Bearing Preload
A selection of carrier side bearing preload shims is required
for successful completion of this procedure.

6
011

~
~

1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or DexronTMtype automatic transmission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.

SPD527

3. Put the side bearing spacer in place on the ring gear end of
the carrier.

4. Using the. J-25267 side bearing spacer drift, place both of
the original carrier side bearing preload shims on the carrier
end, opposite the ring gear.

PD-18

ADJUSTMENT
Side Bearing Preload (Cont'd)
5. Install the side bearing caps in their correct locations and
torque the bearing cap retaining bolts.
Specification:
88 - 98 N.m
(9 - 10 kg-m, 65 - .72 ft-Ib)
6. Turn the carrier several times to seat the bearings.

7. Measure the turning torque of the carrier at the ring gear
retaining bolts with a spring gauge, J-8129.
Specification:
34.3 - 39.2 N
(3.5 - 4 kg, 7.7 - 8.8 Ib)
of pulling force at the ring gear bolt.

8. If the carrier turning torque is not within the specification
range, increase or decrease the total thickl1ess of the side
bearing adjusting washers until the turning torque is correct.
If the turning torque is less than the specified range, install
washers of greater thickness; if the turning torque is greater
than the specification, install thinner washers. See the S.O.S.
section for washer dimensions and part numbers.
9. Record the total amount of washer thickness required for
the correct carrier side bearing preload.

L--I
I
I

.---i., ,

'-, ,

10. Remove the carrier from the final drive housing, saving the
selected preload washers for later use during the assembly
of the final drive unit.

PD344

Pinion Gear Height and Pinion Bearing Preload

- iPt= I

1. Make sure all parts are clean and that the bearings are well
lubricated.

I- ~

2. Assemble the pinion gear bearings into the pinion preload
shim selector Tool, J-34309.

I!DIiIIIIIIIIII

18

!:J
SPD769

PD-19

ADJUSTMENT
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)

.

.

Front pinion bearing - make sure the J-34309-3 front
pinion bearing seat is secured tightly against the J-34309-2
gauge anvil. Then turn the front pinion bearing pilot,
J-34309-5, to secure the bearing in its proper position.
Rear pinion bearing - the rear pinion bearing pilot,
J-34309-8, is used to center the rear pinion bearing only.
The rear pinion bearing locking seat, J-34309-4, is used to
lock the bearing to the assembly.

3. Place the pinion preload shim selector Tool, J-34309-1,
gauge screw assembly with the pinion rear bearing inner
cone installed into the final drive housing.

~!

C'/'
1\1 SPD893

4. Assemble the front, pinion bearing inner cone and the
J-34309-2 gauge anvil together with the J-34309-1 gauge
screw in the final drive housing. Make sure that the pinion
height gauge plate, J-34309-16, will turn a full 360 degrees,
and tig
hten the two sections together by hand.

5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the turning torque at the end of the J-34309-2
gauge anvil using torque wrench J-25765A.
'Turning torque specification:
1.0 - 1.3 N.m
(10 - 13 kg-em, 8.7 - 11.3 in-Ib)

PD-20

ADJUSTMENT
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
7. Place the J-34309-11 "R200A" pinion height adapter onto
the gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

-

PINION BEARING PRELOAD WASHER SELECTION

-

8. Place the solid pinion bearing spacer, small end first, over
the J-34309-2 gauge anvil and seat the small end squarely
against the tip of the J-34309-1 gauge screw in the tool
recessed portion.

9. Select the correct thickness of pinion bearing preload
adjusting washer using a standard gauge of 3.5 mm (0.138
in) and your J-34309-101 feeler gauge. The exact measure

you get with your gauges is the thickness of the adjusting washer required. Select the correct washer from the
following chart.
Drive pinion bearing preload adjusting washer:
Refer to S.D:S.

10. Set your selected, correct pinion bearing preload adjusting,
washer aside for use when assembling the pinion gear and
bearings into the final drive.

SPD774

PD-21

ADJUSTMENT
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
-

PINION HEIGHT ADJUSTING WASHER SELECTION

-

11. Now, position the side bearing discs, J-25269-4, and arbor
firmly into the side bearing bores.
Install the side bearing caps and tighten the cap bolts to
proper torque.

12. Select the correct standard pinion height adjusting washer
thickness using a standard gauge of 3 mm (0.12 in) and
your J-34309-101 feeler gauge. Measure the distance between the J-34309-10 pinion height adapter and the arbor.

13. Write down your exact total measurement.

SPD775

14. Correct the pinion height washer size by referring to the
"pinion head number."
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set and
should be the same as the number on the ring gear. The
second number is the "pinion head height number," and it
refers to the ideal pinion height from standard for quietest
operation. Use the following chart to determine the correct
pinion height washer.
SPD542

PD-22

ADJUSTMENT

Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
Pinion head height number
-6
-5
-4
-3
-2
-1
0
+1
+2
+3
+4
+5
+6

Add or remove from the standard
pinion height washer thickness
measurement
Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)
Use the selectedwasher th ickness
Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)

15. Select the correct pinion height washer from the following
chart.
Drive pinion height adjusting washer (R200):
Thickness mm (in)
3.09
3.12
3.15
3.18
3.21
3.24
3.27
3.30

(0.1217)
(0.1228)
(0.1240)
(0.1252)
(0.1264)
(0.1276)
(0.1287)
(0.1299)

3.33
3.36
3.39
3.42
3.45
3.48
3.51

(0.1311)
(0.1323)
(0.1335)
(0.1346)
(0.1358)
(0.1370)
(0.1382)

3.54.(0.1394)
3.57 (0.1406)
3.60 (0.1417)
3.63 (0.1429)
3.66 (0.1441)

Part No.
38164-P60 17
38154-P6Q 18
38154-P60 19
38154-P6020
381 54-P6021
38154-P6022
38154-P6023
38164-P6024
38154-P6025
38154-P6026
38154-P6027
38154-P6028
38154-P6029
38154-P6030
38154-P6031
38154-P6032
38154-P6033
38154-P6034
38154-P6035
38164-P6036

16. Remove the J-34309 pinion preload shim selector Tool from
the final drive housing and disassemble to retrieve the
pinion bearings.

PD-23

ADJUSTMENT

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly may be
noisy, or have short life, or both. Low noise and a long life can
be assured with a pattern check.

1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD357

3. Hold companion flange steady and turn the ring gear in both
directions.

Usually the pattern will be correct if you have calculated the shims correctly and the backlash is correct.
However, in rare cases you may have to use trial-and-errorprocessas until you get a good tooth contact pattern.
The tooth pattern is the best indication of how well a differential has been set up.
Heel contact

Face contact

Toe contact

~~

~~

To correct, increase thickness of pinion
height adjusting washer in order to bring
drive pinion close to ring gear.

~

To correct, reduce thickness of pinion
height adjusting washer in order to make
drive pinion go away from ring gear.

.
CM""-..

When adjustment is completed, be sure to wipe
off completely the ferric oxide and oil or their
equivalent.

Flank contact

~

~
PD-24

/

v-t~

SPDOO7

ASSEMBLY

Differential Case
1. Install side gears, pinion mate gears, thrust washers and
thrust block into differential case.

SPD552

2. Fit pinion mate shaft to differential case so that 'it meets
lock pin holes.

SPD553

3. Adjust clearance between rear face of side gear and thrust
washer by selecting side gear thrust washer. Refer to S.O.S.
Clearance between side gear thrust washer and
differential case:
0.10 - 0.20 mm (0.0039 - 0.0079 in)

SPD828

4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.

SPD030

5. Apply oil to gear tooth surfaces and thrust surfaces and
check that they turn properly.
Gear oil

SPD322

PD-25

ASSEMBLY
Differential Case (Cont'd)
6. Apply locking sealant to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt
head with a hammer.

7. Press~fit side bearing inner cones on differential case with
Tool.
Tool number:
@ KV38100300 (J25523)
@ ST33061000 (J8107-2)

Tool@

Tool @

PD353

Differential Carrier

~/~

if

1. Press-fit front and rear bearing outer races with Tools.
Tool number:
@ 5T30611000 (J25742-1)
@ 5T30613000 (J25742-3)
@ 5T30701000 (J25742-2)
2. Select pinion bearing adjusting washer and drive pinion
bearing spacer, referring to Adjustment.

Pinion front
bearing

outer race

w~
@

SPD679

Press

Adjusting
washer

3. Install drive pinion height adjusting washer in drive pinion,
and press-fit pinion rear bearing inner cone in it, using press
and Tool.
Tool number: 5T30901000 (

SPD377

PD-26

ASSEMBL Y
Differential Carrier (Cont'd)
4. Place pinion front bearing inner cone in final drive housing.

r-"

~
)~

E!!I

~

0

SPD581

I

J' ~

Pinion be' arlng adjDrive
Pinion
ust' lng
spacer
Pinion

be'

ad'

arlng

~

JuH;"~~'~~
@

~

. .
Pinion fron t b earln g Inner race

5. Set drive pinion assembly (as shown in figure at left) in
differential carrier and install drive pinion, with press and
suitable tool.
Stop when drive pinion touches bearing.
Apply multi-purpose grease to pinion rear bearing inner race,
pinion front bearing inner race and front pilot bearing.

E:

lIE!

SPD897

SPD896

6. Apply multi-purpose grease to cavity at sealing lips of oil
seal. Install front oil seal with Tool.
Tool number: KV38100500 (

SPD557

7.: Install companion flange, and tighten pinion nut to specified
torque with Tool.
Ascertain that threaded portion of drive pinion and pinion nut
are free from oil or grease.
Tool number: ST38060002 (J34311)
Tool

PD416

PD-27

ASSEMBLY
Differential Carrier (Cont'd)
8. Turn drive pinion in both directions several times, and
measure pinion bearing preload.
Pinion bearing preload:
1.1 - 1.4 N.m
(11 - 14 kg-em, 9.5 - 12.2 In-Ib)
When pinion bearing preload is outside the specifications,
replace pinion bearing adjusting washer and spacer with a
different thickness.

SP D884

Q

9. Select side bearing adjusting washer.
Refer to Adjustment.
10. Install differential case assembly with side bearing outer
races into gear carrier.

5'
SPD527

11. Insert left and right side bearing adjusting washers in place
between side bearings and carrier.

~~~
,
~( ::;..;;-..f\:i{;!
Tool

~

12. Drive in side bearing spacer with Tool.
Tool number: KV38100600 (J25267)
bo,,'"

~~'

SPD559

13. Align mark on bearing cap with that on gear carrier and
install bearing cap on gear carrier.

PD-28

ASSEMBL Y

Differential Carrier (Cont'd)
14. Apply multi-purpose grease to cavity at sealing lips of oil
seal. Install side oil seal.
Tool number: KV38100200 (J26233)

SP0560

15. Measure ring
indicator.

gear-to-drive

pinion

backlash with

a dial

Ring gear-to-drive pinion backlash:
0.10 - 0.15 mm
(0.0039 - 0.0059 in)
. If backlash is too small, decrease thickness of left shim and
increase thickness of right shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the
bearing preload.
SP0513

16. Check total preload with Tool.
When checking preload, turn drive pinion in both directions
several times to seat bearing rollers correctly.
Total preload:
Value more than 0.29 N.m (3.0 kg-em, 2.6 in-Ib)
added on measured value of drive pinion preload
If preload is too great, remove the same amount of shim to
each side.
If preload is too small, add the same amount of shim to
each side.
Never add or remove a different number of shims for each
side as it will change ring gear-to-drive
pinion backlash.
17. Recheck ring gear-to-drive pinion backlash because increase or decrease in thickness of shims will cause change
of ring gear-to-pinion backlash.

.
.

SP 0884

18. Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
If backlash varies excessively in different places, foreign
matter may be caught between the ring gear and the
differential case.
If the backlash varies greatly when the ring gear runout is
within a specified range, replace the hypoid gear set or
differential case.
19. Check tooth contact.
Refer to Adjustment.
20. Install rear cover and gasket.

.

.

SP0524

PD-29

SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Propeller Shaft
GENERAL

SPECIFICATIONS

SPECIFICATIONS

AND ADJUSTMENT

Unit: mm (in)
Applied model
Transmission
type
Propeller shaft
model

Propeller

M/T

A/T

3S63A-R

3S63A-T

Number of joints

3

Coupling method
with transmission

Sleeve type

Type of journal
bearings
Distance between
yokes
Shaft length
(Spider to spider)
1st
2nd
Shaft outer
diameter
1st

2nd

Unit: mm (in)

Propeller shaft runout limit
Journal axial play

Shell type (Non-disassembly type)
63.0 (2.480)

395.0 (15.55)

432.0 (17.011

605.0 (23.82)

605.0 (23.82)

75.0 (2.953)

75.0 (2.953)

shaft model

75.0 (2.953)
... Large side
63.5 (2.500)
... Small side

/~

PD-30

3S63A-R

1

3S63A- T

0.6 (0.024)
0 (0)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Final Drive
GENERAL

SPECIFICATIONS

Drive pinion preload adjustment

Final drive model

R200

Ring gear pitch diameter
mm (in)

4.083

Number of teeth
(Ring gear/Drive pinion)

49/12

Available

1.8 (3-7/8,3-1/8)

3.80 - 3.82
3.82 - 3.84
3.84-3.86
3.86 - 3.88
3.88 - 3.90
3.90 - 3.92
3.92 - 3.94
3.94-3.96
3.96 - 3.98
3.98 - 4.00
4.00-4.02
4.02 - 4.04
4.04 - 4.06
4.06 - 4.08
4.08 - 4.10

(R200)

Pinion bearing adjusting washer

Drive pinion to ring gear backlash
mm (in)

drive pinion

0.10 - 0.15 (0.0039 - 0.0059)

1.1 - 1.4 (11 - 14,9.5 -12.2)

bearing preload

Thickness mm (in)

SPECIFICATIONS AND ADJUSTMENT
Drive pinion adjustment
Drive pinion bearing
adjusting method

preload
N.m (kg-em, in-Ib)
With front oil seal

205 (8.07)

Gear ratio

Oil capacity (approx.)
Q (US pt, Imp pt)

Drive pinion

(0.1496 - 0.1504)
(0.1504 - 0.1512)
(0.1512 -0.1520)
(0.1520 - 0.1528)
(0.1528 - 0.1535)
(0.1535 - 0.1543)
(0.1543 - 0.1551)
(0.1551-0.1559)
(0.1559 - 0.1567)
(0.1567 - 0.1575)
(0.1575-0.1583)
(0.1583 - 0.1591)
(0.1591 - 0.1598)
(0.1598 - 0.1606)
(0.1606 - 0.1614)

adjusting

washer

Part number
38125-61001
38126-61001
38127-61001
38128-61001
38129-61001
38130-61001
38131-61001
38132-61001
38133-61001
38134-61001
38135-61001
38136-61001
38137-61001
38138-61001
38139-61001

AvaUable pinion height adjusting washer
Thickness

mm (in)

3.09 (0.1217)
3.12
3.15
3.18
3.21

(0.1228)
(0.1240)
(0.1252)
(0.1264)

3.24 (0.1276)
3.27 (0.1287)
3.30
3.33
3.36
3.39
3.42
3.45
3.48
3.51
3.54
3.57
3.60
3.63
3.66

(0.1299)
(0.1311)
(0.1323)
(0.1335)
(0.1346)
(0.1358)
(0.1370)
(0.1382)
(0.1394)
(0.1406)
(0.1417)
(0.1429)
(0.1441)

Available drive pinion bearing preload adjusting spacer

Part number

Length mm (in)

38154-P6017
38154-P60 18
38154-P6019
38154-P6020
38154-P6021
38154-P6022
38154-P6023
38154-P6024

55.10
55.40
55.70
56.00
56.25

,

38154-P6025
38154-P6026
38154-P6027
38154-P6028
38154-P6029
38154-P6030
38154-P6031
38154-P6032
38154-P6033
38154-P6034
38154-P6035
38154-P6036

PD-31

(2.1693)
(2.1811)
(2.1929)
(2.2047)
(2.2146)

Part number
38165-B4002
38165-B4003
38165-B4004
38165-61001
38166-61001

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Final Drive (Cont'd)
Total preload adjustment

Total preload

Side bearing adjustment
Value more than
0.29 N.m 13.0 kg-cm, 2.6 in-Ibl
added on measured -value
of drive pinion preload

Adjusting shim

Side bearing adjusting method
Side gear to pinion mate gear
backlash IClearance betWeen
side gear to differential easel
mm Iinl

0.03

-0.0910.0012

- 0.00351

Available side bearing adjusting washer
Thickness mm Iinl
2.00 10.07871
2.0510.08071
2.1010.0827)
2.1510.08461
2.20 10.08661
2.25 10.08861
2.30 10.09061
2.35 10.09251
2.40 10.0945)
2.45 10.09651
2.50 10.09841
2.55 10.10041
2.6010.10241
2.65 (0.10431

Available side gear thrust washer

Part number
38453-N3100
38453-N3101
38453-N3102
38453-N31 03
38453-N3104
38453-N3105
38453-N3106
38453-N3107
38453-N3108
38453-N3109
38453-N3110
38453-N3111
38453-N3112
38453-N3113

Thickness mm Iinl

Part number

0.80 10.03151
0.85 10.03351
0.90 10.03541
0.95 10.03741
1.00 10.03941
1.0510.04131
1.1010.0433)
1.1510.04531
1.2010.04721
1.25 10.04921
1.3010.05121
1.3510.05311
1.4010.05511
1.4510.05711
1.5010.05911

38424-40FOO
38424-40F08
38424-40F01
38424-40F09
38424-40F02
38424-40F10
38424-40F03
38424-40F 11
38424-40F04
38424-40F12
38424-40F05
38424-40F13
38424-40F06
38424-40F 14
38424-40F07

Ring gear runout
Ring gear runout limit

---------

PD-32

mm Iinl

0.05 10.00201

FRONTAXLE&
FRONT
~USPENSION
,
~

I

FA

SECTION

CONTENTS
PRECAUTIONS AND PREPARATION

...

FRONT AXLE AND FRONT SUSPENSION
CHECK AND ADJUSTMENT -

"""""'"''

FA- 2

"'"''

"

FA-

On-vehicle

4

FA- 5

FRONT AXLE

FA- 9

FRONT AXLE -

Wheel Hub and Knuckle

FRONT AXLE -

Baffle Plate

FA-10
"

FA-13

FRONT SUSPENSION
FRONT SUSPENSION -

FA-14
Coil Spring and Strut Assembly

FRONT SUSPENSION- Tension Rod and Stabilizer Bar
FRONT SUSPENSION -

FA-15
;

,'

Transverse Link and Lower Ball Joint

SERVICE DATA AND SPECIFICATIONS (S.O.S.) """"""V"""'"''''''''''''''''''''''''''''''''''''''''''''''''

FA-17

FA-18
FA-19

-

PRECAUTIONS AND PREPARATION
Precautions

.

.
.

When installing each rubber part, final tightening must be
carried out under unladen condition * with tires on ground.
* Fuel, radiator coolant and eRg!ne oil full. Spare tire,
jack, hand tools and mats in designated positions.
When removing each suspension part, check wheel alignment and adjust if necessary.
Use Tool when removing or installing brake tubes.

SBR500

Preparation
SPECIALSERVICETOOLS
Tool number
(Kent-Moore No.)
Tool name
HT72520000
(J25730-A)
Balljoint remover

HT71780000
(

-

)

Spring compressor

ST35652000
(

-

)

Strut attachment

GG94310000
(

-

)

Flare nut torque
wrench

Description

~
e5E

~~

Removing tie-rod outer end and lower
ball joint

Removing and installing coil spring

Fixing strut assembly

~

~
~

Removing and installing brake piping

FA-2

PRECAUTIONS AND PREPARATION
Preparation (Cont'd)
COMMERCIAL SERVICE TOOLS
Tool name

Description

Wheel bearing drift

OO)!
Wheel bearing drift

Baffle plate drift

~

~

Removing wheel bearing

~

A: 45 mm (1.77 in) dia.
B: 30 mm (1.18 in) dia.

2J

Installing wheel bearing

A: 68 mm (2~68 in) dia.
B: 60 mm (2.36 in) dia.

~

Installing baffle plate

B

A: 88 mm (3.46 in) dia.
B: 68 mm (2.68 in) dia.

Teosion rod bushing
drift

Removing and installing
tension rod bushing

A: 75 mm (2.95 in) dia.
B: 66 mm (2.60 in) dia.
c: 62 mm (2.44 in) dia.
D: 25.55 mm (0.98.2.17

FA-3

in) dia.

FRONT AXLE AND FRONT SUSPENSION

Final tightening for rubber parts requires to be carried
out under unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats in designated positions.
Strut mounting insulator
(with strut mounting bearingl

Spring upper seat

Coil spring

Strut assembly

Front suspension member

~

-

46 52

(4.7- 5.3,
34- 38)

"'.$. ~

I,
~39-49
(4.0-5.0,
29 -36)

c:::?
Front

I

~

Transverse
link assembly

~
Brake disc roter

Tension rod

~

: N.m (kg-m, ft-Ib)
SFA640A

FA~4

CHECK AND ADJOSTMENT -

On-vehicle

Front Axle and Front Suspension Parts

.

Check front axle and front suspension parts for looseness,
cracks, wear or other damage.
(1) Shake each front wheel.

/

SMA525A

(2) Retighten all nuts and bolts to the specified torque.
Tightening torque: Refer to S.O.S.
(3) Make sure that cotter pin is inserted.

(4) Check front axle and front suspension parts for wear, cracks
or other damage.

SFA541A

.

.

Check strut
damage.

(shock

absorber)

for oil leakage or other

Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage.

FA'" 5

CHECK AND ADJUSTMENT -

On-vehicle

Front Wheel Bearing

.
..
.

"
\

SFA543A

Check tightening torque of wheel bearing lock nut.
tOJ: 147 216 N.m
(15 22 kg-m, 108 - 159 ft-Ib)
Check that wheel bearings operate smoothly.

-

-

Check axial end play.
Axial end play: 0.03 mm (0.0012 in) or less
If axial end play is not within specification or wheel bearing
does not turn smoothly, replace wheel bearing assembly.
Refer to FRONT AXLE - Wheel Hub and Knuckle.

Front Wheel Alignment
Before checking front wheel alignment, be sure to make a
preliminary inspection.
PRELIMINARY INSPECTION

Inside

~.
SFA575S

Make following checks. Adjust, repair or replace if necessary.
Check tires for wear and improper inflation.
Check front wheel bearings for looseness.
Check wheel runout.

.
..

to S.D.S.
Check front suspension for looseness.

Refer

..
..

Check steering linkage for looseness.
Check that front shock absorbers work properly.
Check vehicle posture (Unladen):
"Unladen"
Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.

CAMBER, CASTER AND KINGPIN INCLINATION
Caster and kingpin inclination are preset at factory and
cannot be adjusted.

.

. Measure camber, caster and kingpin inclinationof both
right and left wheels with a suitable alignment gauge, and
adjust in accordance with the following procedures.

SFA894

Kingpin inclination:
12°30' 14°00'

-

90°
SFA573B

FA-6

CHECK AND ADJUSTMENT -

On-vehicle

Front Wheel Alignment
Caster:
6°00' 7°30'

(Cont'd)

-

SFA103A
Camber:

-1°30' to 0°
Camber

90°
SFA574A

If camber is not within specification, adjust by turning adjusting
pin as follows:
(1) Remove adjusting pin
Adjusting pin is installed with flat portion facing downward.

SFA105A

(2) Next replace adjusting pin with flat portion facing upward.
(3) Turn adjusting pin to adjust.
Camber changes
about 5' with each graduation
of adjusting pin.
(4) Tighten adjusting pin to specified torque.

~: 124

- 143 N.m (12.6 - 14.6 kg-m, 91 - 106 ft-Ib)

Adjusting
pin

SFA106A

TOE-IN
1. Draw a base line on tread surface of tires.
After lowering front of vehicle, move it up and down to
eliminate friction, and set steering wheel in straight-ahead
position.

SMA123

FA-7

CHECK AND ADJUSTMENT -

On-vehicle

Front Wheel Alignment

(Cont'd)

2. Measure toe-in.
Measure distance "A" and "B" at same height as hub center.
Toe-in:

A - B 0.3- 2.3mm(O.012- 0.091in)
2e (Totaltoe-in) l' - 6.5'

8M~

Front
t#

Toe-in =A
Total toe-in

9

SFA234A

-B

= 29
3. Adjust toe-in by varying length of steering tie-rods.
(1) Loosen lock nuts.
(2) Adjust toe-in by turning forward and reverse tie-rod.

~,

r

L

-,

-~

~

Make sure both tie-rods are the same length.
Standard length "L" - reference data:
174.8 mm (6.88 in)
(3) Fix lock nuts, then tighten them designed torque.

~: 37 - 46 N.m
(3.8- 4.7 kg-m,27 - 34 ft-Ib)

SFA545A

FRONT WHEEL TURNING ANGLE
1. Set wheels in straight-ahead position and then move vehicle
forward until front wheels rest on turning radius gauge
properly.

SMA 127

2. Rotate fully steering wheel to the right or left; measure
turning angle.
Wheel turning angle:

't

Front

Inside wheel: A

39° - 43°

Outside wheel: B

33°

Full turns

A: Inside
B: Outside

SFA898

FA-8

FRONT AXLE

Knuckle spindle
Suttle plate

Snap ring

Wheel hub

tOJ : N.m (kg-m, tt-Ib)
SFA546A

FA-'9

FRONT AXLE

-

Wheel Hub and Knuckle

Removal

.

Remove wheel bearing lock nut.

SFA090A

.

~

Remove brake caliper assembly.
Brake hose need not be disconnected from brake caliper. Be
careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.

SFA547A

.

Remove rotor and wheel hub from spindle.

.

Remove tie-rod ball joint and lower ball joint.

SF,o,571 B
Adjusting'pin

. Remove bolts and nuts as shown at left.
Make matchmarksbefore removingadjustingpin.

FA-10

FRONT AXLE -

Wheel Hub and Knuckle

Installation

..

SFA114A

.

Install wheel hub.
Tighten wheel bearing lock nut.

tOJ:147 - 216 N.m
(15 - 22 kg-m, 108 - 159 ft-Ib)

Check wheel bearing axial end play.
Axial end play: 0.03 mm (0.0012 In) or less

SFA543A

Disassembly
CAUTION:
When removing wheel bearing from wheel hub, replace wheel
bearing assembly (outer race, inner races and grease seal)
with a new one.
. Remove circular clip with suitable tool.

SFA215A

.press.

.

Press out wheel bearing assembly from wheel hub.

Inspection
WHEEL HUB

. Check
wheel hub for any cracks by
exploration or dyeing test.
CIRCULAR CLIP
. Check
circular clip for wear or cracks.
Replace if necessary.
FA-11

using a magnetic

FRONT AXLE

-

Wheel Hub and Knuckle

Assembly
1. Press new wheel bearing assembly into wheel hub from
inside of rotor disc (with wheel hub).
Maximum load P:
29 kN (3 t, 3.3 US ton, 3.0 Imp ton)
CAUTION:

..

Grease seal

m

Circular clip

Do not press inner race of wheel bearing assembly.
Do not apply oil or grease to mating surfaces of wheel
bearing outer race and wheel hub.
Be careful not to damage grease seal.

2. Install circular clip into groove of wheel hub.
3. Apply multi-purpose grease to sealing lip.

SFA218A

/

FA-12

FRONT AXLE

-

Baffle Plate

Removal

..

Mark match marks on baffle plate before removing.
If baffle plate raplacement requires removal of knuckle
spindle. separate it equally using a screwdriver.
Be careful not to scratch knuckle spindle.
Matchmarks

SFA548A

Installation

.

Align matchmarks previously marked on baffle plate and
install baffle plate by lightly tapping with a copper hammer
and suitable tool.

SFA549A

FA-13

FRONT SUSPENSION

cap

~~

-

59 78 (6.0

~

- 8.0,~"(

43 - 58)

~

~~

~

-

39 54 (4.0

-5.5,29- 40)

GaSket~
Strut

mounting

insulator

~~

Lock washer~
Bound bumper

u""''''''~

Coil spring

Strut assembly

PI..,;, d;P\
Front

fi

suspension

member

I
V

/

~~88-108

~ ~-J(9.0- 11.0,
65- SO)

f)~
}~"""J

"

~

J)

link

with ball joint

~

L~~46-52
(4.7-5.3,

r

39 - 49 (4.0 -5.0,~
29 - 36)

'

34-38)

~ ~88 - 108
(9.0.11.0,65- 80)

If ~

Tension rod
bracket

4-/r/~>\

~\

"~:J
a~~\

@

'

/
~:

Transverse

"-Tension

rod

",

l'\1~

N.m (kg-m, ft-Ib)

When inStalling Stabilizer bar, tension rod and transverse
link, final tightening requires to be carried out under unladen
condition* with tires on the ground.
* Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated position.
SFA550A

FA-14

FRONT SUSPENSION
Strut upper portion

I~

-

Coil Spring and Strut Assembly

Removal

.
..

Adjusting pin

Remove strut assembly fixing bolts and nuts (to hoodledge).
Do not remove piston rod lock nut on vehicle.
Put match marks on strut lower bracket and camber adjusting pin.

Disassembly
1. Set strut assembly on vise with Tool, then loosen piston rod
lock nut.
Do not remove piston rod lock nut.

.

Suitable
bar

SFA134A

2. Compress spring with a Tool so that strut mounting insulator can be turned by hand.

HT71780000
(
)

SFA135A

3. Remove piston rod lock nut.

ST35652000
(
)
SFA136A

Inspection
STRUT ASSEMBLY

.
.
.

Check for smooth operation through a full stroke, both
compression and extension.
Check for oil leakage occuring on welded or gland packing

portion.

.

Check piston rod for cracks, deformation or other damage.
Replace if necessary.

FA-15

FRONT SUSPENSION -Coil

Spring and Strut Assembly

Inspection (Cont'd)
STRUT MOUNTING INSULATOR
Check cemented rubber-to-metal portion for separation or
cracks. Check rubber parts for deterioration.

.

. Check thrust bearingparts for abnormalnoise or excessive
rattle in axial direction.
Replace if necessary.
LOCK WASHER

.

Check for cracks, deformation or other damage. Replace if
necessary.
COIL SPRING

.

Check for cracks, deformation or other damage. Replace if
necessary.

Assembly

.

Top

Bottom

When installing coil spring, be careful not to reverse top and
bottom direction. (Top end is flat.)

SFA760

.

~

When installing coil spring on strut, it must be positioned as

shown in figure at left.

r=sA"
\,

\

Fl.. .."

~"'"d

SFA'"

.
{}
Left

Front

Cutout

Install upper spring seat with its cutout facing the inner side
of vehicle.

Right

"

(Inner side of vehicle)
Upper seat

SFA576A

FA-16

FRONT SUSPENSION

-

Tension Rod and Stabilizer Bar

Removal and Installation

.

Remove tension rod and stabilizer bar.

SFA552A

Press.

,
SF A553A

~D"ft

Front

.
.

When removing tension rod bushing, place one drift on
lower side of bushing and the other on upper side, as
shown at left, and press bushing out.
Place arrow mark on bushing facing tension rod before
installing bushing.

.

Install stabilizer rear side bushings, then install front side
bushings.
When installing stabilizer bar clamp, make sure direction is
correct (as shown at left.)

~

SFA554A

.

When removing and installing stanbilizer bar, fix portion A.

.

Install stabilizer bar with ball joint socket properly placed.

SFA555A

View from B

mA~

~~

O.K.

~~
N.G.
SFAOO2A

FA-17

FRONT SUSPENSION

-

Transverse Link and Lower Ball Joint

Removal and Installation

.
.
.

Remove stabilizer, tension rod, ball joint and transverse link
assembly.
During installation, final tightening must be carried out at
curb weight with tires on ground.
After installation, check wheel alignment.
Refer to "Front Wheel Alignment" of CHECK AND ADJUSTMENT - On-vehicle.

SFA552A

Inspection
TRANSVERSE

.
.

LINK

Check transverse link for damage, cracks or deformation.
Replace it if necessary.
Check rubber bushing for damage, cracks and deformation.
Replace transverse link if necessary.

LOWER BALL JOINT

.

Measuring swing force

Swing force and turning torque
Before checking, turn ball joint at least 10 revolutions so that
ball joint is properly broken in.
Swing force:
(measure point: cotter pin hole of ball stud)
7.8 - 55.9 N (0.8 - 5.7 kg, 1.8 - 12.6 Ib)
Turning torque:
0.49 - 3.43 N.m (5.0 - 35 kg-em, 4.3 - 30.4 in-Ib)

Cotter pin hole
SFA756

Measuring

turning

Check ball joint for play. If ball stud is worn, play in axial
direction is excessive or joint is hard to swing, replace
transverse link assembly if necessary.

torque

SFA757

~\(

~ lower
Pry bar /

Dial
indicator

/

//:%
SFA556A

Vertical end play (On-vehicle)
(1) Jack up front of vehicle and set the stands.
(2) Clamp dial indicator onto transverse link and place indicator
tip on lower edge of brake caliper.
(3) Make sure front wheels are straight and brake pedal is
depressed.
(4) Place a pry bar between transverse link and inner rim of
road wheel.
(5) While pushing and releasing pry bar, observe maximum dial
indicator value.
Vertical end play: 0 mm (0 In)
(6) If not within above specification, replace transverse link.

FA-18

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

...

General Specifications
COIL SPRING

FRONT STABILIZER Bi'R
Model

Model
Item

Except Sports
package

Sports
package

Item

Wire diameter

mm (in)

13.3 (0.524)

13.5 (0.531)

Coil diameter

mm (in)

170 (6.69)

170 (6.69)

Free length

mm (in)

326 (12.83)

311 (12.24)

19.6 (2.0, 112)

21.6 (2.2, 123)

Orange x 1,
Purple x 1

Pink x 1,
Purple x 1

Stabilizer diameter
mm (in)
Identification color

Spring constant
N/mm (kg/mm, Ib/in)
Identification color

STRUT
Model
Item
Piston rod diameter
mm (in)
Stroke

Sports
package

Except Sports
package

20.0 (0.787)

mm (in)

160 (6.30)

Damping force
[at 0.1 m (0.3 ft)/sec.]
N (kg,lb)

Expansion

Compression

Damping force
[at 0.3 m (1.0 h)/sec.]
N (kg,lb)
Expansion
Compression

412-608
(42 - 62,93

471-706
- 137)

206 - 304
(21 - 31, 46 - 68)

I

(48 -72,106

- 159)

235 - 353
(24 - 36, 53 - 79)

912 - 1,245 (93 - 127,205 - 280)
392 - 588 (40 - 60,88 - 132)

FA-19

Except Sports
package

Sports
package

24 (0.94)

25 10.98)

White

Orange

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

.

Inspection and Adjustment
LOWER BALL JOINT

WHEEL ALIGNMENT (Unladen*1)
Camber

degree

-1°30'

to 0°

Caster

degree

6° 00'

- 7° 30'

Swing force
(Measuring point: cotter pin
hole of ball stud)

Toe-in (Total)

N (kg, Ib)
mm (in)

Kingpin inclination

0.3 - 2.3 (0.012

- 0.091)

degree

l' - 6.5'

degree

12°30' - 14°00'

Turning torque
N'm (kg-cm, in-Ib)

0.49 - 3.43
(5.0 - 35, 4.3 - 30.4)

Vertical end play

Front wheel turning angle
Full turn*2
inside/outside

7.8 - 55.9
(0.8 - 5.7,1.8 - 12.6)

d

egree

39°

mm (in)

-43° /33°

*1: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.
*2: On power steering models, wheel turning force (at circumference of steering wheel) .of 98 to 147 N (10 to 15 kg,
22 to 33'lb) with engine idle.

0 (0)

WHEEL RUNOUT (Radial and lateral)
Wheel type

Radial runout

Aluminum wheel
mm (in)

WHEEL BEARING

I

lateral runout

0.3 (0.012) or less

Steel wheel
mm (in)

Wheel bearing axial end play
mm (in)

0.03 (0.0012) or less

Wheel bearing lock nut
Tightening tirque
N'm (kg-m, ft-Ib)

147- 216 (15- 22,108 - 159)

FA-20

0.5 (0.020) or less1o.8

(0.031) or less

.

REARAXLE &
REARSUSPENSION
,

RA

SECTION

CONTENTS
PRECAUTIONS AND PREPARATION

"'"''.'''''''''''''''''''''''''''''''

REAR AXLE AND REAR SUSPENSION
CHECK AND ADJUSTMENT -

RA-

2

RA- 4

On-vehicle

" RA- 5

REAR 'AXLE AND REAR SUSPENSION ASSEMBLY

RA- 8

REAR AXLE -

Wheel Hub and Axle Housing

RA- 9

REAR AXLE -

Drive Shaft

RA-13

REAR SUSPENSION

RA-19

REAR SUSPENSION REAR SUSPENSION -

Coil Spring and Shock Absorber
Stabilizer Bar

REAR SUSPENSION -

Multi-link and Lower Ball Joint

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

""'"''''''''''''''''''''''''''''''''''''''''''''''

RA-20

RA-22
RA-23
RA-24

III

PRECAUTIONS AND PREPARATION
Precautions

.

~,
GG9431 0000
(

-

)

.
.
.

When installi~ each rubber part, final tightening must be
carried out under unladen condition. with tires on ground.
. Fuel, radiator coolant and .engine oil full. Spare tire, jack,
hand tools, and mats in designated positions.
Use Tool when removing or installing brake tubes.
When removing each suspension part, check wheel alignment and adjust if necessarY.
Do not jack up at the lower arm.

SBR500

Preparation
SPECIALSERVICETOOLS
Tool number
(Kent-Moore No.)
Tool name
HT71780000
(

-

)

Spring compressor

ST35652000
(
-.
)
Strut attachment

GG94310000
(

-

)

Flare nut torque
wrench
ST30031 000
(J22912-01 )
Bearing puller

ST38280000
(

-

)

Arm bushing remover

Description

~
~----.

~
~
~

Removing and installing coil spring

Fixing strut assembly

Removing and installing brake piping

Removing inner race of wheel bearing

~
~

Removing and installing bushing
of rear axle housing

RA-2

PRECAUTIONS AND PREPARATION

.

Precautions (Cont'd)
COMMERCIAL SERVICE TOOLS
Tool name
Attachment
Wheelalignment

Rear wheel hub drift

Description

~

}aJJ}
lIID)

Wheel bearing drift

1:EID J
Rear drive shaft plug
seal drift

rED

RA-3

Measure rear wheel alignment
A:
B:
e:
D:
E:

Screw M24 x 1.5
35 (1.38) dia.
65 (2.561 dia.
56 (2.20)
Unit:
12 (0.47)

mm (in)

Installing wheel bearing
A: 41 mm (1.61 in) dia.
B: 49 mm (1.93 in) dia.

Removing rear wheel hub
A: 26 mm (1.02 in) dia.
B: 40 mm (1.57 in) dia.

I nstalling rear driVe shaft plug seal
A: 67 mm (2.64 in) dia.
B: 85 mm (3.35 in) dia.

REAR AXLE AND REAR SUSPENSION

It

Spring upper seat

~

Dust cover
Coil spring

~-1S.'2-14)

~
Shock absorber

;:.E- 19

69 -88

(7.0 -9.0, 51 - 651

~

Lower link

69 -88

(7.0 - 9.0, 51 -651

I~

77 -98
(7.9 -10.0,
57 -721
Upper link
rear

@

~

l

L~43 -55
.
(4.4 - 5.6,32 -41)
~98-118
I
110.0

- 12.0,72

- 871

~

-

77 98
(7.9 - 10.0,57 -721

~

9-12
(0.9 -12,6.5

Final tightening for rubber parts requires to be carried
out under unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats in designated positions.

-8.71.

Upper link front

~:

N.m (kg-m,ft-Ib)

SRA093A

RA-4

v

CHECK ANDADJtlSTMENT -

On-vehicle

Rear Axle and Rear Suspension Parts

.

Check axle and suspension
damage.
(1) Shake each rear wheel.

parts for looseness,

wear or

SMA525A

(2) Retighten all nuts and bolts to the specified torque.
Tighteningtorque:
Refer to S.D.S.
(3) Make sure that cotter pin is inserted.
(4) Check rear axle and rear suspension parts for wear, cracks
or other damage.

(5) Check shock absorber for oil leakage or other damage.

SMA113

!

.

Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage.

RA-5

CHECK AND ADJUSTMENT -

On-vehicle

Rear Wheel Bearing

.
..

SRA107A

Check tightening torque of wheel bearing lock nut.
~: 235 314 N.m
(24 32 kg-m, 174 - 231 ft-Ib)
Check that wheel bearings op'erates smoothly.
Check axial end play.
Axial end play:
0.05 mm (0.0020 in) or less
If axial end play is not within specification or wheel bearing
does not turn smoothly, replace wheel bearing assembly.
Refer to REAR AXLE - Wheel Hub and Axle Housing.

-

Rear Wheel Alignment
Before checking rear wheel alignment,
preliminary inspection.
PRELIMINARY INSPECTION

Inside

~.
SFA575S

be sure to make

a

Make following checks. Adjust, repair or replace if necessary.
Check tires for wear and for improper inflation.
Check rear wheel bearings for looseness.
Check wheel runout.
Refer to S.D.S.
Check that rear shock absorber works properly.
Check rear axle and rear suspension parts for looseness.
Check vehicle posture (Unladen).
'
"Unladen" :
Fuel tank, radiator and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.

..
.
.
.
.

CAMBER

.

Measure camber of both right and left wheels with a
suitable alignment gauge and adjust in accordance with
the following procedures.

SRA096A

Camber:
-1°36'

'/

SRA097A

RA-6

to -0°36'

CHECK AND ADJUSTMENT -

On-vehicle

Rear Wheel Alignment

(Cont'd)

If camber is not within specification, adjust by turning the
adjusting pin.
(1) Turn the adjusting pin to adjust.
Camber changes about 5' with each graduation of the
adjusting pin.
(2) Tighten to the specified torque.

~:69 - 88 N.m
(7.0 - 9.0 kg-m,51 - 65 ft-Ib)
SRA098A

TOE-IN
1. Draw a base line across the tread.
After lowering rear of vehicle, move it up and down to
eliminate friction.

SMA123

2. Measure toe-in.
Measure distance "A"
center.
Toe-in:
A-B

Lines parallel to
center line of body

and "B"

at the same height as hub

0.5 - 4.5 mm (0.020 - 0.177 in)
2 () (Total toe-in)

1.5' - 12.5'
Front

~
SFA234A

Toe-in = A
6

-B

Total toe-in = 26

3. Adjust toe-in by turning adjusting pins.
Toe changes about 1.5 mm (0.059 in) [One side]
graduation of the adjusting pin.
4. Tighten to the specified torque.
~:69

with each

- 88 N.m

(7.0 - 9.0 kg-m, 51 - 65 ft-Ib)

Drive Shaft
Check boot and drive shaft for cracks, wear, damage or grease
leakage.

SRA796

RA-7

REAR AXLE AND REAR SUSPENSION ASSEMBLY
Removal and Installation

SRA 100A

.
.

Remove exhaust tube.
Disconnect propeller shaft rear end.

.

Remove brake caliper assembly.
Brake hose need not be disconnected from brake caliper.
Be careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.

SFA110A

.
.

Remove upper end nuts of shock absorber.
Do not remove piston rod lock nut.
Remove suspension member fixing nuts. Then draw out rear
axle and rear suspension assembly.

SRA101A

RA-8

REAR AXLE

-

Wheel Hub and Axle Housing

Adjusting cap

I

L.~
Wheel bearing

withflange~
~

: N'm(kg-m,ft-Ib)
SRA102A

Removal

.

Remove wheel bearing lock nut.

.

Remove brake caliper assembly and rotor.
Brake hose need not be disconnected from brake caliper. Be
careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.

SFA110A

RA-9

REAR AXLE

Wheel Hub and Axle Housing

-

Removal (Cont'd)

.

Separate drive shaft from axle housing by slightly tapping it.
When removing drive shaft, cover boots with waste cloth to
prevent them from being damaged.

SFA181A

.

Remove axle housing.

SRA104A

.

Remove wheel bearing with flange, and wheel hub from axle
housing.

SRA105A

Installation

..

Install axle housing with wheel hub.
Tighten wheel bearing lock nut.
tOJ:235

- 314N.m

(24 - 32 kg-m, 174 - 231 ft-Ib)

SRA106A

.

Check wheel bearing axial end play.
Axial end play: 0.05 mm (0.0020 in) or less

SRA107A

RA-10

REAR AXLE

- Wheel Hub and Axle Housing
Disassembly

SRA108A

.

CAUTION:
Wheel bearing with flange usually does not require maintenance. If any of the following symptoms are noted, replace
wheel bearing assembly (including flange, and inner and outer
seals).
Growling noise is emitted from wheel bearing during
operation.
Wheel bearing drags or turns roughly when hub is turned
with your hand after bearing lock nut is tightened to
specified torque.
After wheel bearing is removed from hub.

.
.
.
WHEEL HUB
. Remove
wheel bearing (with flange) and wheel hub as one
unit from axle housing before disassembling.

WHEEL BEARING
Using a press and drift as shown in figure at left, press
wheel bearing out.
Discard old wheel bearing assembly. Replace with a new
wheel assembly.

Press.

.
.

SRA109A

.

Remove inner race from hub using a bearing replacer/puller.

CAUTION:

a. Do not reuse o!d inner race although it is of the same
brand as the bearing assembly.
b. Do not replace grease seals as single parts.

ST30031 000
(J22912-01 )

SRA110A

RA-11

REAR AXLE

Wheel Hub and Axle Housing

-

Disassembly (Cont'd)
AXLE HOUSING

.

Attach a drift on outer shell of bushing as shown in figure at
left, remove bushing using arm bushing remover.
When placing axle housing In a vise, use wooden blocks or
copper plates as pads.
Axle housing
Drift

SRA111A

.
.

Ensure axle housing bore is free from scratches or deformities before pressing bushing into it.
Attach bushing to chamfered bore end of axle housing and
press it until it is flush with end face of axle housing.

SRA112A

Inspection
WHEEL HUB AND AXLE HOUSING

.
.

.

Check wheel hub and axle housing for cracks by using a
magnetic exploration or dyeing test.
Check wheel bearing for damage, seizure, rust or rough
operation.

.

Check rubber bushing for wear or other damage.
Replace If necessary.

Assembly
. Place hub on a block. Attach a drift to inner race of wheel
bearing and press it into hub as shown in figure at left.
Be careful not to damage grease seal.

Drift

Block
SRA113A

RA-12

REAR AXLE

-

Drive Shaft

Drive shaft

~I
(24.32,
~~"'''~-~
235.314174 - 231)
Insulator

~

J

@)~

I

Adjusting cap

: N.m (kg-m, ft-Ib)

SRA114A

Removal
When removing drive shaft, cover boots with waste cloth to
prevent damage to them.

FINAL DRIVE SIDE

.

Remove side flange mounting bolt and separate shaft.

WHEEL SIDE

.

Remove drive shaft by lightly tapping it with a copper
hammer.
To avoid damaging threads of drive shaft, install a nut while
removing drive shaft.

Installation

.
.
.

Insert drive shaft from wheel hub and temporarily tighten
wheel bearing lock nut.
Tighten side flange mounting bolts to specified torque.

Tighten wheel bearing lock nut to specified torque.

RA-13

REAR AXLE

-

Drive Shaft

Snap ring "A"
Final drive side
Plug seal

~

Spider assembly

IE!

Snap ring "B"

~

Housing
inner
side

~

m
Wheel hub side

~

;>
Boot band

~

SRA117A

Disassembly

Slide joint
housing

FINAL DRIVE SIDE
1. Remove plug seal from slide joint housing by lightly tapping
around slide joint housing.

2. Remove boot bands.
3. Put match marks on slide joint housing and drive shaft
before separating joint assembly.
4. Put match marks on spider assembly and drive shaft.

SRA118A

RA-14

REAR AXLE -Drive

Shaft

Disassembly (Cont'd)
5. Pry off snap ring, then remove spider assembly.
CAUTION:
Do not disassemble spider assembly.
6. Draw out slide joint housing.
7. Draw out boot.
Cover drive shaft serration with tape to prevent damage to
the boot.

SRA119A

WHEEL SIDE

1. Remove boot bands.
2. Put matchmarks on housing together with shaft and drive
shaft before separating joint assembly.
3. Put matchmarks on spider assembly and drive shaft.

SFA963

4. Pry off snap ring "A" with a screwdriver, and pull out slide
joint housing.

SRA120A

5. Pry off snap ring "B", then remove spider assembly.
CAUTION:
Do not disassemble spider assembly.
6. Draw out boot.
Cover drive shaft serration with tape to prevent damage to
the boot.

SFA964

Inspection
Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for deformation or other damage.
DRIVE SHAFT
Replace drive shaft if it is twisted or cracked.
BOOT
Check boot for fatigue, cracks, or wear. Replace boot with new
boot bands.

RA-15

REAR AXLE

-

Drive Shaft

Inspection

(Cont'd)

JOINT ASSEMBLY

.
.

.

Check

spider

assembly

for

bearing,

damage. Replace spider assembly if necessary.
Check housing for any damage. Replace housing set and
spider assembly, if necessary.

.

When replacing only spider assembly,
assembly from among those listed in
the number stamped on sliding joint
stamped on new part.
Housing alone cannot be replaced. It
together with spider assembly.

Slide joint

roller and washer

select a new spider
table below. Ensure
is the same as that
must be replaced

Stamped number

Part No.

00

3972010V10

01

39720 10V11

02

3972010V12

SRA121A

Assembly

.
.

After drive shaft has been assembled, make sure it moves
smoothly over its entire range without binding.
Use Nissan Genuine Grease or equivalent after every
overhaul.

FINAL DRIVE SIDE

~

1. Install new small boot band, boot and slide joint housing to
drive shaft.
Cover drive shaft serration with tape to prevent damage to
boot during installation.
Tape

SFA800

RA-16

REAR AXLE -

Drive Shaft

Assembly (Cont'd)
2. Install spider assembly securely, making sure marks are
properly aligned.
Press-fit with spider assembly serration chamfer facing shaft.
3. Install new snap ring.

*"{E;=

{r

~

.

~
<

Su itable tool

Chamfer
SFA397

4. Install coil spring, spring cap and new plug seal to slide joint
housing. Press plug seal.
Apply sealant to mating surface of plug seal.
CAUTION:

a. When pressing plug seal into place, hold it horizontal so
that spring inside it does not tilt or fall down.
b. Move shaft in axial direction to ensure that spring is
installed properly. If shaft drags or if spring is not installed
properly, remove plug seal and install a new one. Discard
plug seal after removal.

.

.
SRA123A

LI

5. Pack drive shaft with specified amount of grease.
Specified amount of grease:
185
195 g (6.52 - 6.88 oz)
6. Set boot so that it does not swell and deform when its
length is "L,".
Length" L1":
110.5 - 112.5 mm (4.35 - 4.43 in)
Make sure that boot is properly installed on the drive shaft
groove.

-

I

SRA124A

SFA395

RA-17

REAR AXLE

-

Assembly

Drive Shaft
(Cont'd)

7. Lock new larger boot band securely with a suitable tool,
then lock new smaller boot band.
Suitable
tool

SFA472

WHEEL SIDE
1. Install new small boot band and boot on drive shaft.
Cover drive shaft serration with tape to prevent damage to
boot during installation.

~

Tape

SFA800

~"
{I

2. Install spider assembly securely, making sure marks are
properly aligned.
Press-fit with spider assembly serration chamfer facing shaft.
3. Install new snap ring.

05=
~

.

~

Suitable tool

Chamfer
SFA397

4. Pack drive shaft with specified amount of grease.
Specified amount of grease:
145 - 155 g (5.11 - 5.47 oz)
5. Install slide joint housing, then install new snap ring "A".
6. Set boot so that it does not swell and deform whe'n its
length is "L2".
Length "L2":
110.5 - 112.5 mm (4.35 - 4.43 in)
Make sure that boot is properly installed on the drive shaft
groove.

0

~

SRA125A

7. Lock new larger and smaller boot bands securely with a
suitable tool.

SFA395

RA-18

REAR SUSPENSION

~~A16-19
Upper link rear

~~

69.88

C;~ 17,.,"..".061-

~

Suspension m

ember

~

43.55

fi/

~
Ao'I'

32 - 41)

\ ~'
Ii ~

]

..@I

A

~

~
~

11. 98

(1.9.10,51.12)

C;~
~ 11. 77.9817.9".,'7.721
98

~

~

~

(4.4 . 5,6,

,

'"
'"

.. -'

(1.9. 10,51.

11.6.1.9,12.14)

Gasket

~~18.24
(1.8.2.4,13.11)
Upper plate

Bushing
Upper spring seat
Upper rubber

~

12)

/

8

Mem';',

-

~ ~'~~i
1'

.

.

~21

(2.;.2.1,16.20)

~

I"

'

:j);
'

c;
~

-

i

'

0

21.26(2.1.2.1,16.20)
Differential

/~

~

Yf0/!

'\~ )
,

~

.@

@@.l
34. ~
(3.5.4.5,

Stabilizer

26. 33)

BUShingA

~

43.55
(4.4.5.6,32.41)

~

(6.0 -1.0,36 - 51)

~ 71...

(1.2 . 8.8,
52.64)

~~88.108

I

:"
,

~

- '-"""Mm

(et,I

h

~(~

~. 98.118110.12,12.81)

@

'",

I

.

69-88 (1.0.9.0,61.66)

~A49'69

,

(1;9-10,51-12)

"."2.72.871

~

I

~ ...~-~"'.11 -98~

~98.118

~

'

K

~Dustcover
-~~

~

Plate

c;~I:~"~,2.6," 8.7~

0

<:I'

vr

26

seat

Bushing

~

N--><

'

-

(9.0.11,86.80)
Drive shaft

-'---t :

L

1

!

~~

.

Shock absorber

'

Axle assembly
-

q"

~

Connecting

'.

rod

>B~§

e
@
~~

A
~

9.12
(0.9.1.2,6.5.8.1)

CAUTION:
Do not jack up at lower arm.
When installing each rubber part, final tightening must
be carried out under unladen condition* with tires on
ground.
* Fuel, radiator coolant and engine oil full. Spare
tire, jack, hand tools and mats in designated
positions.

~

J7! I~

-

235 314
(24.32,114.231)

Insulator

Adjusting
cap

A

J

~

I

: N.m (kg-m, ft-Ib)

SAA 132A

RA-19

REAR SUSPENSION

-

Coil Spring and Shock Absorber

Removal

..

Remove shock absorber upper and lower fixing nuts.
Do not remove piston rod lock nut on vehicle.

Disassembly
1. Set shock absorber on vise with attachment, then loosen
piston rod lock nut.
. Do not remove piston rod lock nut.

SRA782

2. Compress spring with Tool so that the strut upper spring
seat can be turned by hand.

SRA783

3. Remove piston rod lock nut.

SRA784

Inspection
SHOCK ABSORBER

.
.
.

ASSEMBLY

Check for smooth operation through a full stroke, both
compression and extension.
Check for oil leakage occuring on welded or gland packing
portion.
Check piston rod for cracks, deformation or other damage.
Replace if necessary.
UPPER RUBBER SEAT AND BUSHING
Check rubber parts for deterioration or cracks.
Replace if necessary.

.

RA-20

RI;ARSUSPENSION -Coil

Spring and Shock Absorber

Inspection (Cont'd)
COIL SPRING

.

Assembly

.

Top

Bottom

Check for cracks, deformation or other damage. Replace if
necessary.

When installing coil spring, be careful not to reverse top and
bottom direction. (Top end is flat.)

SFA760

.

~

When installing coil spring on strut, it must be positioned as
shown in figure at left.

r==A,.FI"""
\
\,

~"~d
Bigger inner diameter
side of lower
bushing

,,,.,,
Vehicle front

.

When installing upper spring seat, make sure that it is
positioned as shown.

Outside of
vehicle

Smaller inner
diameter side
of lower
bushing
SRA126A

RA-21

REAR SUSPENSION

-

Stabilizer Bar

Removal

.

Remove connecting rod and clamp.

Inspection

.
.

Check stabilizer bar for deformation or cracks. Replace if
necessary.
Check rubber bushings for deterioration or cracks. Replace
if necessary.

Installation

.

When installing connecting rod, make sure direction is
correct (as shown at left).

Connecting rod

Stabil izer

SRA128A

RA-22

REAR SUSPENSION

-

Multi-link and Lower Ball Joint

Removal and Installation

.

Refer to "Removal and Installation"
REAR SUSPENSION ASSEMBLY.

of REAR AXLE AND

Before removing, put matchmarks on adjusting pin.
When installing, final tightening must be carried out at curb
weight with tires on ground.
After installation, check wheel alignment.
Refer to "Rear Wheel Alignment" of CHECK AND ADJUSTMENT - On vehicle.

.
.

SRA129A

J;
Inspection
REAR SUSPENSION

.

MEMBER

Replace suspension member assembly if cracked or deformed or if any part (insulator, for example) is damaged.
UPPER AND LOWER LINKS

.

Replace upper or lower link as required
deformed or if bushing is damaged.

SUSPENSION

Swing force
Vertical end play
SRA131A

.
.

if cracked

or

LOWER BALL JOINT

Measure swing force, turning torque and vertical end play in
axial direction. (Use same measurement procedures as that
of FA section.)
If ball stud is worn, play in axial direction is excessive, or
joint is hard to swing, replace lower arm.
12.7 - 90.2 N
Swing force

Ball joint
specifications

0.5 - 3.4 N.m
Turning torque
Vertical end play

RA-23

(1.3 - 9.2 kg, 2.9 - 20.3 Ib)

(5 - 35 kg-em, 4.3 - 30.4 in-Ib)
0 mm (0 in)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

General Specifications
SHOCKABSORBER

COIL SPRING
Model

Except Sports
package

Item
Wire diameter

mm (in)

Coil diameter

mm (in)

Free length

mm (in)

Spring constant
N/mm (kg/mm, Ib/in)

11.0 (0.433)

Sports
package
11.3 (0.445)

90 - 100 (3.54 - 3.94)

I 367.5

(14.47)

355 (13.98)

Model

Pink x 2

mm (in)

12.5 (0.492)

Stroke

'mm (in)

155 (6.10)

Damping force
[at 0.1 m (0.3 ftl/sec.]

N (kg, Ib)

Expansion

314 - 471
(32 -48,
71 - 106)

392 . 588
(40 -60,
88 - 132).

Compression

157 - 235
(16 -24,
35 -53)

196 - 294
(20 -30,
44 -66)

Ught green x 2

Damping force
[at 0.3 m (1.0 ftl/sec.]
Expansion
Compression

DRIVE

Sports
package

Piston rod diameter

119.6 (2.0, 112) 121.6 (2.2, 123)

Identification color

Except Sports
package

Item

N (kg,lb)
647 - 902 (66 .92, 146 - 203)
363 - 539 (37 - 55, 82 -1211

SHAFT
Final drive side

Joint type
Final drive side

TS82F
TS82C

Wheel side
Diameter
Wheel side D I

mm (in)
30 (1.18)

Grease name
Final drive side

Nissan genuine grease
or equivalent

Wheel side

Nissan genuine grease
or equivalent

SRA133A

Wheel side

Specified amount of grease
g (oz)
Final drive side

185 - 195 (6.52 - 6.88)

Wheel side

145 -155 (5.11 -5.47)

Boot length
mm (in)
Final drive side (LI)
Wheelside (L2 )

REAR STABILIZER

Item

Identification color

110.5 -112.5 (4.35 -4.43)

BAR

Model

Stabilizer diameter

L2
SRA134A

mm (in)

. Except Sports
package

Sports
package

15 (0.59)

17 (0.67)

Ught green

Light blue

RA-24

SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection
WHEEL ALIGNMENT
Camber

(Unladen*)

degree

-1°36'

to -0°36'

Toe-out
mm (in)
(Total) degree

and Adjustment
WHEEL RUNOUT

(Radial and lateral)

Wheel type

Radial runout

Aluminum wheel

.mm (in)

Steel wheel

mm (in)

0.5 - 4.5 (0.020 - 0.177)
1.5' -12.5'

I

Lateral runout

0.3 (0.012)

0.5 (0.020)
or less

I

or less

0.8 (0.0311
or less

* Tankful of fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools, mats in designated position.

LOWER BALL JOINT
Swing force
(Measuring point: cotter pin
hole of ball stud)
N (kg, Ib)

WHEEL BEARING
Wheel bearing axial end play
mm(in)

0.05 (0.0020) or less
Turning torque
N.m (kg-cm, in-Ib)

Wheel bearing lock nut
Tightening torque

N.m (kg-m, ft-Ib)

12.7 -90.2
(1.3 - 9.2,2.9 - 20.3)

I 235 -314

(24

-32, 174.231)

Vertical end play

RA-25

mm (in)

0.5 - 3.4 (5 - 35, 4.3 - 30.4)
0 (0)

BRAKESYSTEM
I

BR

SECTION

CONTENTS
PRECAUTIONS

AND

PREPARATION

CHECK

AND ADJUSTMENT

BRAKE

HYDRAULIC

LINE

BRAKE

PEDAL

BRACKET

BRAKE

BOOSTER

VACUUM

AND

BR- 2
BR- 3

""""""".'.""'.'"''''''''''''.'''''''''''''''''''

BR- 4
BR- 6

''''''''''''''''''

PIPING

BR- 8
"'"''''

""""""""""""",.",.,.,.,.",,,,,,,,,,,,,...,

MASTER CYLINDER

BR-10

BR-12

FRONT DISC BRAKE (CL22VB, CL25VA) -

Caliper

BR-13

FRONT DISC BRAKE (CL22VB, CL25VA) -

Rotor

BR-17

REAR DISC BRAKE (CL9H) -

Caliper

BR-18

REAR DISC BRAKE (CL9H) PARKING BRAKE CONTROL

Rotor

BR-22
BR-23

:

ANTI-LOCK BRAKING SYSTEM

BR-25

TROUBLE DIAGNOSES

BR-29

SERVICE DATA AND SPECIFICATIONS (S.D.S.)

BR-54

all

PRECAUTIONS AND PREPARATION
Precautions

.
.
.

.
.

.

Recommended fluid is brake fluid "DOT 3".
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
Never use minerai oils such as gasoline or kerosene. They
will ruin rubber parts of hydraulic system.

Use Tool when removing and Installing brake tube.

WARNING:
. Clean brake pads and shoes with a waste cloth, then
collect dust with a dust collector.

SBR500

Preparation
SPECIAL SERVICE TOOL

Tool number
(Kent-Moore No.)
Tool name
GG94310000
(
)
Flare nut torque
wrench

-

Description

Removing and ins~alling
each brake piping

~
~

Measuring brake fluid pressure

KV991V0010
(
)
Brake fluid
pressure gauge

-

KV999P1000
(
- )
A.B.S. checker

0
@

0

@

@

Checking brake fluid pressure of
A.B.S. actuator

o.
0

c

KV999P1010
- )
(
A.B.S. checker adapter
harness

Checking brake fluid pressure of
A.B.S. actuator

BR-2

CHECK AND ADJUSTMENT
Checking Brake Fluid Level

.
.

=

MAX

=

Check fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
If fluid level is extremely low, check brake system for leaks.

MIN

Checking Brake System

.

6/@

.

*"

Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
Check for oil leakage by fully depressing brake pedal.

SMA 732A

Changing Brake Fluid
1. Drain brake fluid in each air bleeder valve.
2. Refill until new brake fluid comes out of each air bleeder

valve.

SBR992

..
.

.

Use same procedure as in bleeding hydraulic system to refill
brake fluid.
Refer to Bleeding Procedure.
Refill with recommended brake fluid "DOT 3".

Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.

BR-3

BRAKE HYDRAULIC LINE
Front brake (CL22VB)

Proportioning
valve
(Do not disassemble.)

~

: N.m (kg-m, ft-Ib)
0 : Flare nut
15 -18 /1.5 -1.8, 11 -13)
: Connecting bolt
17 .20/1.7 - 2.0,12.14)

: Primary line

.

: Secondary
line

Bleeding

SBR471A

Procedure

CAUTION:

.
.

Carefully monitor brake fluid level at master cylinder
during bleeding operation.
Fill reservoir with r~commended brake fluid. Make sure it
is full at all times while bleeding air out of system.

. Place a container beneath master cylinderto avoid spillage of brake fluid.
SBR995

.

Bleed air according to the following procedure.
Without Anti-lock Braking System:
Left rear caliper
,j,
Right rear caliper

t
Left front caliper
,j,
Right front caliper
SBR992

With Anti-lock Braking System:
Left rear caliper
,j,
Right rear caliper
,j,
Left front caliper
,j,
Right front caliper

t

Front side air bleeder on A.B.S. actuator
,j,

Rear side air bleeder on A.B.S. actuator

BR-4

BRAKE HYDRAULIC LINE
Removal and Installation
1. To remove brake hose, first
tube to hose, then withdraw
2. Cover openings to prevent
connecting hydraulic line.
3. All hoses must be free from
pulling.
4. After installing brake lines,
depressing brake pedal.

remove flare nut securing brake
lock spring.
entrance of dirt whenever disexcessive bending, twisting and
check for oil leakage by fully

SBR500

Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.

BR-5

BRAKE PEDAL AND BRACKET

Removal and. Installation

~16

S;
!@j"

-22

(1.6-2.2 12
,-161

/,/<

Stop lamp switch

[.q]12-15
(1.2 -1.5,
9 -111
A.S.C.D. cancet
switch

A (1.2-1.5,9-111
12-15

.

Replace clevis pin if plastic stopper.
which is located at the end of clevis
pin, is deformed or damaged.

Brake pedal

A

: N.m (kg-m, ft-Ibl
SBR472A

Inspection
Check brake pedal for following items.
Brake pedal bend

..
.

Clevis pin deformation

Crackof any weldedportion

BR-6

BRAKE PEDAL AND BRACKET
Adjustment

Floor carpet
Dash insulator

Check brake pedal free height from dash reinforcement panel.
Adjust if necessary.
H:
Free height
Refer to S.D.S.
D:
Depressed height
Refer to S.D.S.
Under force of 490 N (50 kg, 110 Ib)
with engine running
C1:
Clearance between pedal stopper and threaded
end of stop lamp switch
0.3 - 1.0 mm (0.012 - 0.039 in)
C2:
Clearance between pedal stopper and threaded
end of A.S.C.D. switch
0.3 - 1.0 mm (0.012 - 0.039 in)
A:
Pedal free play
1 3 mm (0.04 - 0.12 in)

-

Melt sheet
~:

N'm (kg.m, ft.lbl
SBR153A

1. Adjust pedal free height with brake booster input rod. Then
tighten lock nut.
Make sure that tip of input rod stays inside.

SBR930

2. Adjust clearance "C1" and "C2" with stop lamp switch and
A.S.C.D. switch respectively. Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamp is off when pedal is released.
4. Check brake pedal's depressed height while engine is
running.
If depressed height is below specified value, check brake
system for leaks, accumulation of air or any damage to
components (master cylinder, wheel cylinder, etc.); then
make necessary repairs.

BR-7

BRAKE BOOSTER
Removal and Installation

(
'"
"
I

,

,)

//

,"""

/ ,\

I

\.~

~---\

...// /

\

v..~,'"..-,

\

(~'>r---

f,"\ ,~' A-:.,
i\'.
, ""
\ \ \ , ",

,:..~
/

......-

\...,).-'~,\"......\' \ .

\

,...~:>\,

./

-

~;,~"
, "'"

~'\.

J

,

f,'~\
,~

-...--

/-<:~, \;.,.........-

''!

/' ~~') '"
,'r.v\\

8 -11 (0.8-1_1,5.8- 8.0]

~:

N.m (k~. ft-Ib)
SBR473A

Inspection
OPERATING

.
.

CHECK

Depress brake pedal several times with engine off, and
check that there is no change in pedal stroke.
Depress brake pedal, .then start engine. If pedal goes down

slightly, operation is normal.

.

SBROO2A

AIRTIGHT
O.K.

N.G.

~

CHECK

.

Start engine,

.

brake pedal several times slowly. If pedal goes further down
the first time and gradually rises after second or third time,
booster is airtight.
Depress brake pedal while engine is running, and stop
engine with pedal depressed. If there is no change in pedal
stroke after holding pedal down 30 seconds, brake booster
is airtight.

and stop it after one or two minutes.

Depress

SBR365A

OUTPUT ROD LENGTH CHECK
1. Supply brake booster with vacuum of -66.7 kPa (-500
mmHg, -19.69 inHg) using a handy vacuum pump.
2. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)

SBR281A

BR-8

BRAKE BOOSTER
Inspection (Cont'd)

~

3. Adjust rod length if necessary.
4. If rod length is without specification, replace brake booster.

BR-9

VACUlfM PIPING

Removal and Installation

\

Chod<
..w

~~~{a

.

~
DJ

Brake
booster

IJ.

Intake manifold
CAUTION:
Do not apply any oil or lubricants
to vacuum hose end check valve.

.

SBR474A

Insert vacuum tube into vacuum hose more than 24 mm
(0.94 in).

'''_J)-=I

More than 24 mm 10.94 in)
SBROO4A

.

Install check valve, paying attention to its direction.

4

E=;=-;=:3
.. side
Brake
booster or
Intake
manifold ..
vacuum pump side
SBR202A

Inspection
HOSES AND CONNECTORS

.

Check vacuum lines, connections and check valve for
airtightness, improper attachment chafing and deterioration.

BR-'O

V~CUUM PIPING
Inspection (Cont'd)
CHECK VALVE

.

When pressure is applied to brake booster side of check
valve and valve does not open, replace check valve with a
new one.

..

Manifold
side

SBR475A

BR-11

MASTER CYLINDER

Removal and Installation
Reservoir~

cap

~

0;' fil'''~
Float~
Reservoir
tank
Primary

~

Seal

(Do not reuse.)

~

-

~

\

*: Lubricate piston cup with brake
fluid or rubber grease when
assembling master cylinder.

Dual proportioning
valve
(Do not disassemble.)

Secondary

~

.

piston

.";
~. I
'

f!. 1

..

.. .

Primary
.

':

\

I

SBR476A

..

Bend claws inwardwhen installingstopper cap.

..

Pay attention to direction of piston cups in figure at left.
Check parts for wear or damage. Replace if necessary.

Replace stopper cap if claw is damaged or deformed.

!;

)

':

piston
,.
;

I

,.

I

...
..,.
'"

'Ii
11II=II
.

Piston cup.

);.

\

SBR011A

piston assembly

SBR012A

BR-12

FRONT DISC BRAKE (CL22VB, CL25VA)

-

Caliper

CL22VB

IEI@

Pin bolt

~

22

Outer
shim

Torque member
fixting bolt
72 97

~

(7.3

-

-9.9,

53

-

(2.2 3.2,
16 23)

-

Dust seal~lEI@

lEI @

-31

- 72)

A:
N.m (kg-m, ft-Ib)
lEI @ : P.B.C. (Poly Butyl Cuprysil)grease or
silicone-based \lrease point
IE! @ : Rubber grease points
SBR477A
@ : Brake fluid point

.~
CL25V A

Torque member
fixing bolt

Main pin bolt

A

22

-31

(2.2

- 3.2,

16

- 23)

A 72 -97
(7.3

- 9.9, 53 - 721
Air
bleeder
A7-9
(0.7.0.9,
5.1 -6.5)

lEI

lEI

~

~

:
:

A:

BR-13

Connecting bolt
A17-20
(1.7 - 2.0,12 - 14)

Brake
hose

FRONT DISC BRAKE (CL22VB, CL25VA)

-

Caliper

Pad Replacement
1. Remove pin bolt.

SBR453A

2. Swing cylinder body upward. Then remove pad retainer, and
inner and outer shims.
CAUTION:
. When cylinder body is swung up, do not depress brake
pedal because piston will pop out.
Be careful not to damage dust seal or get oil on rotor.
Always replace shims when replacing pads.

.

SBR220A

Removal and Installation

.

Remove torque member fixing bolts and union bolt.

.

Install brake hose to caliper at protrusions securely.

Disassembly
Push out piston with dust seal using compressed air.

SBR772

BR-14

FRONT DISC BRAKE (CL22VB, CL25V A) -

Caliper

Inspection
CYLINDER

.

BODY

Check inside surface of cylinder for scoring, rust, wear,
damage or foreign materials. Replace if any such condition
exists.
Eliminate minor damage from rust or foreign materials by
polishing surface with fine emery paper.
CAUTION:
Use brake fluid to clean.
PISTON

.

.

Check piston for scoring, rust, wear, damage or foreign materials. Replace if any condition exists.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.

PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks
condition exists.

or other

damage. Replace if any

Assembly

.
.

Place piston boot over rear of piston. Fit piston boot's lip
properly in corresponding groove on cylinder body.
Insert piston into cylinder body and fit boot's lip properly in
corresponding groove on piston.

SBR480A

Inspection (On-vehicle)
INSPECTION OF BRAKE DRAG FORCE
1. Swing cylinder body upward.
2. Make sure that wheel bearing is adjusted properly. Refer to
section FA.
3. Measure rotating force (F1).

SBR456A

4.
5.
6.
7.
8.

Install caliper with pads to original position.
Depress brake pedal for 5 seconds.
Release brake pedal and rotate disc rotor 10 revolutions.
Measure rotating force (F2).
Calculate brake drag force by subtracting F, from F2.
Maximum brake drag force (F2 F1):
59.8 N (6.1 kg, 13.5 Ib)
If it is not within specification, check main pins and retainer
boots in caliper.

-

SBR457A

BR-15

FRONT DISC BRAKE (CL22VB, CL25VA)

- Caliper

DISC PAD
Check disc pad for wear or damage.
Pad standard thickness (A):
10.0 mm (0.394 in)
Pad wear limit (A):
2.0 mm (0.079 in)

SMA364A

BR-16

FRONT DISC BRAKE (CL22VB, CL25VA)

-

Rotor

Inspection
RUBBING

SURFACE

Check rotor for roughness, cracks or chips.

RUNOUT
Adjust wheel bearing preload. Check runout using a dial
indicator.
Rotor repair limit:
Maximum runout
(Total indicator reading at center of rotor pad
contact surface)
0.07 mm (0.0028 in)
SBR826

THICKNESS
Standard thickness:
20.0 mm (0.787 in)
Minimum thickness:
18.0 mm (0.709 in)

SBR827

BR-11

-

REAR DISC BRAKE (CL9H)

Air bleeder Copper washer

~

7 .9 (0.7 .0.9,5.1

~
-3.2,

Pin bolt
22 31 (2.2

~

- 6.5)

-

16-23)

~ j--~

~
}
e

/

Cylinder body
tC:J : N.m (kg-m, ft-Ib)
.'
B~:
P.B.C.(PolyButYICuprysil)
1
b
d
grease or Sl Icon- ase
grease point

Cam

grease
point
point

~~

~

'~

~\
/'

I.
- ,S2)'"
/'

,~

~.:

-

O-ring

Spring

~

m@

(!,

IE!I@

/

/
- '-..J'

~

~
'"

/'---

,

~

,/

~

.

Piston seal

fixingbolt
38 -52 (3.9 -5.3,28-38)

~

~ m@

Inner shim

0
~

-

Adjusting nut

Cup~m@

~..oo boo'

E!@

Pin

~
)) ~ ~~~
R

padr;.tainerm
In

~
~

Inner'

pad

0

uter pa

h

' ,:.;a°@,
.

d

.
Pad
"";OM EII@~

EII@

~
'-.,

~

~"N'4)

I'J@OO'OCOh'mj!?,-

~

rr-,,25.29(2.5-3.0'
~-"
18 -22)

Torquemember

>

v

&~"OO

~

-

i~~RingA
>-.J)

A~wavewasher
'~D_:-spacer
Ball bearing

/~

Spring washer

.(/

,~Spacer

,/~'

Return spring

(2.7 3.7,20 - 27)

/

~~Spring
<..:: -~. RlngB

Lever
dI

Cable stay

!--tC:J26 -36

m@

1.

~

'

!

Rod

Push rod
Key plate
RlngC

Y

m@
Cam bolt

tC:J22-31
16-23) (2.2-3.2,

~,

I

J..~ .
Seat

Gl..//

"I

/'.

~

~.

(v

-14)
Brake hose

-

":>, ,/

/'

r-

0

\)'

BU
@ : Rubber
"'@:Brakefluid

-

17 20 (1.7.2.0,12

Caliper

~/'
"

/

~

'~~

/'

'

W,

I

~

~/
Torque member

saR48' A

Pad Replacement
CAUTION:
When cylinder body is swung up, do not depress brake pedal
because piston will pop out.
Remove parking cable stay fixing bolt, pin bolts and lock
spring. Then remove pad retainers, pads and shims.

.
.

When installing pads, retract piston into cylinder body by
turning it clockwise.
Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.

SBR641

BR-18

REAR DISC BRAKE (CL9H) -

Caliper

Removal and Installation
Disconnect parking brake cable and brake hose, then remove
caliper assembly.

.

SBR482A

Disassembly
1. Remove piston by turning it counterclockwise
longnose pliers.

with suitable

SBR646

2. Pry off ring A from piston with suitable pliers and remove
adjusting nut.

SBR648

3. Disassemble cylinder body.
Pry off rings Band C with pliers, then remove spring cover,
spring and seat.

/

.

SBR891

.

Remove piston seal.
Be careful not to damage cylinder body.

SBR485A

BR-19

REAR DISC BRAKE (CL9H)

-

Caliper

Disassembly (Cont'd)
4. Remove return spring and lever.

..

SBR877

Inspection
CYLINDER

.
.

BODY

Check inside surface of cylinder for score, rust, wear or
other damage.
Minor damage from rust of foreign materials may be eliminated by polishing surface with a fine emery paper. Replace
if necessary.
CAUTION:
Use brake fluid to clean.
TORQUE

MEMBER

Check for wear, cracks or other damage. Replace if necessary.
PISTON
Check piston for score, rust, wear or other damage. Replace if
necessary .
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign matter is stuck to sliding surface.

PIN AND PIN BOOT
Check for wear, cracks or other damage. Replace if necessary.
Assembly
Install cup securely in the specified direction.

.

::::::::::::::

~f\t1t
1
I::::::::::::::

SBR849

.
Convex

Fit push rod into square hole in key plate. Also match
convex portion of key plate with concave portion of cylinder.

portion

@
SBR893

BR-20

REAR DISC BRAKE (CL9H) Assembly
Ring

.

c~

Keyplate

~.h

Caliper

(Cont'd)

Install ring C with suitable tool.

"1B'>

.

,oo-j

Rod

fi)
SB R878

.

Install seat, spring, spring cover and ring B with suitable
press and drift.

Tool

SBR492A

Inspection

.
FI

(On-vehicle)

INSPECTION OF BRAKE DRAG FORCE
1. Swing cylinder body upward.
2. Make sure that wheel bearing is adjusted properly. Refer to
section RA.
3. Measure rotating force (F,).

SBR227A

4.
5.
6.
7.
8.

Install caliper with pads to original position.
Depress brake pedal for 5 seconds.
Release brake pedal, rotate disc rotor 10 revolutions.
Measure rotating force (F2).
Calculate brake drag force by subtracting F, from F2.
Maximum brake drag force (F2 F,):
86.3 N (8.8 kg, 19.4 Ib)
If it is not within specification, check pins and pin boots in
caliper.

-

DISC PAD
Check disc pad for wear or damage.
Standard thickness (A):
9.5 mm (0.374 in)
Pad wear limit (A):
2.0 mm (0.079 in)

SMA364A

BR-21

REAR DISC BRAKE (CL9H)

-

Rotor

Inspection
RUBBING

SURFACE

Check rotor for roughness, cracks or chips.

..

RUNOUT

.
.

Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to section RA.
Rotor repair limit:
Maximum runout
(Total Indicator reading at center of rotor pad
contact surface)
0.07 mm (0.0028 In)

SBR845

THICKNESS
Rotor repair limit:
Minimum thickness
8.0 mm (0.315 In)

SBR847

BR-22

PARKING BRAKE CONTROL

Removal and Installation

m
.

~
~

l. H. rear
cable

Ell
SBR487A

REMOVAL
Before removing parking brake control, remove console box.
Loosen cable using control lever adjuster, and separate
front and rear cables.
Break clinched portion of control lever using a hammer and
chisel as shown in figure at left, and replace cables with new
parts.
Apply multi-purpose grease to areas between control lever
drum and cables.

.
.
.

SBR488A

INSTALLATION

Be careful not to damage boot and inner cable.
When installing parking brake cable at rear caliper, make
sure to align matchmark on parking cable stay and cable.

.

Cable guide
Matchmark

SBR489A

Inspection
1. Check control lever for wear or other damage. Replace if
necessary.
2. Check parking brake cables, lamp and switch. Replace if
necessary .
3. Check parts at each connecting portion for deformation or
damage. If found, replace.

BR-23

PARKING BRAKE CONTROL

Box wrench

Adjustment
1. Ensure that parking brake releases when control lever is
pulled down completely. If control lever does not release
parking brake, proceed as follows:
Pull control lever up by 4 or 5 notches.
Insert a box wrench into opening in control lever and loosen.
self-lock adjusting nut to slacken cables. Completely push
control lever down.
2. Forcefully depress brake pedal about five times (so that
caliper is automatically set in position.).
3. Pull lever up by 4 or 5 notches.
4. Turn adjusting nut as shown in figure at left and adjust lever
stroke to specified value.
5. Completely push control lever down and ensure that:
Parking brake is released completely.
Rear brakes are free from dragging.

..

SBR490A

.
.

6. Pull control lever with specified amount of force. Check lever
stroke and ensure smooth operation.
Number of notches:
Center lever type 6 8

-

SBR491 A

7. Bend parking brake warning lamp switch plate so that brake
warning light comes on when ratchet at parking brake lever
is pulled "A" notches and goes out when fully released.
Number of "A" notches: 1

SBR493A

Parking brake
warning lamp switch
plate

BR-24

ANTI-LOCK BRAKING SYSTEM
System Components
Warning

lamp

: Harness
: Piping
Front wheel sensor

SBR516A

Hydraulic Circuit

Proportioning
valve
(Do not disassemble.)

Master cylinder

Front R.H. wheel

,'

--Check valve
(Front L.H.)

Feeling
valve
(Front)

-~
Feeling
valve
Check valve
(Read
(Read

Rear R.H. wheel

I

SBR517 A

BR-25

~

ACTUATOR

4

6

]0

I GNI TI ON SWI TCH
ON or START

5

FRONT
WHEEL
SENSOR
0

I: : :

;0

0

;01/1

0

»m
-

n
"0

3

2

]

"

~P
@~

BODY
GROUND

II

..~
I
I I
I ,
I ,

Et
"'..,.....

..."',

",..

r:-

....

"..

I

,

:

:

:

:

I

I

@

~r

:

@

:

lmum-

,
...

--:

S. M. J.

[Refer to

en

~ngine

room

-

8R/Y
R/Y
L/Y
-Y
G/Y
L/R
LG/R
GY/R

L
-W/L
OR/L

rnnn~

@
@

[§j

:IE:IE

"'..

FUSE

1

FUSIBLE

FUSE AND FUSIBLE
(J n

RELAY BOX)

m

~

.."''''

-

BODY
GROUND

LINK

rnI
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I
I
I
I

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L/R
LG/R
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:

(B I ack)
(Ma in

R/GG/L-

harness)

I
n_nnn_~

~mmn__nmnm

8R/Y
R/YL/Y-

~- u- - - - n - - - -_h- ---n-

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Y/G
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II

,
,

..

rEtffi@Y
:IE

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,

..

(Engine
harness

(§

room
no. 2)

::BODY

GROUND
FRONT

VJ
CD
:0
0>
II)
U1
:I>

..

BATTERY

:IE

@£

- Y
G/Y
L/R
LG/R
GY/R
L
W/L
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W/R

W/R

.~
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8
8

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83
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H5
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18

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Iast page:

(FaIdout page).]
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harnes~

I
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~".)

,

:

o.

OJ
3
"C

R/Y~

FUSE BLOCK
(Refer
to
"POWER
SUPPLY
ROUTING"
in EL sect ion. )

harness)

III
c+
0
"C

...'"

G/L

(E. F. 1-

-i

0

9t@
....
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l_mn

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rr

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R. H.

STOP
LAMP
SWITCH

WHEEL
SENSOR

L. H.

W/R

i3J~
ALTERNATOR

I
I
I
I
I
I

~u_-~

"_n-n_-

@
-

Y/L
Y/G-f

ANTI-LOCK BRAKING SYSTEM

Removal and Installation
CAUTION:

Be careful not to damage sensor edge and sensor ro,or teeth.
FRONT WHEEL SENSOR
...,

-_or -r-'-"
I~:-- -L_,,-_!J

"

~
~

: N.m(kg-m,ft-Ib)

SBR519A

REAR SENSOR

Rear speed
seflsor

tOJ18.26~(1.8 - 2.7, 13. 20)

Drive pinion nut
tOJ 186
(19

~

-294
-30,137.217)

tOJ : N.m (kg-m,ft-Ib)

~

Sensor rotor

.-///

Companion flange

.

SBR520A

Remove rear sensor rotor with companion
propeller shaft removal.
Refer to PD section.

BR-27

flange after

ANTI-LOCK BRAKING SYSTEM
Removal and Installation (Cont'd)
ACTUATOR

..
.

Disconnect 3 connectors and brake tubes.
Remove relay bracket.
Remove actuator by removing 3 nuts fixing actuator
bracket.

BR~28

to

TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Symptom Chart
Preliminary Check 1

BR-30
BR-33
BR-34
BR-35

...

PreliminaryCheck2
Preliminary Check 3, 4 ...
Self-diagnosis
Component Parts Location
...
Harness Connector Location
Ground Circuit Check
Circuit Diagram for Quick Pinpoint Check
Diagnostic Procedure 1 ..
Diagnostic Procedure 2 .

DiagnosticProcedure3

......

BR-36
BR-37
...: BR-38
BR-39

...
""'''.'

BR-40

BR-41

BR-42
BR-43

."."."""""""""'.""""".'."""""""'.'...'..'."...'

Diagnostic Procedure 4 """..
Diagnostic Procedure 5
Diagnostic Procedure 6
Diagnostic Procedure 7
Diagnostic Procedure 8
Diagnostic Procedure 9
Diagnostic Procedure 10 .
Diagnostic Procedure 11
Diagnostic Procedure 12
Electrical Components Inspection

,

'..'...".."""""""""'.""'."".""

BR-44

...

... BR-44

...
...
...

...

...

BR-45
...

...

...

...

BR-45
...... BR-46
BR-47
BR-48
BR-49

...

BR-50
BR-51
... BR-52

BR-29

TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick
and Accurate Repair
INTRODUCTION

SEF234G

The A.B.S. system has an electronic control unit to control
major functions. The control unit accepts input signals from'
sensors and instantly drives actuators. It is essential that both
kinds of signals are proper and stable. At the same time, it is
important that there are no conventional problems such as air
leaks in the booster or lines, lack of brake fluid, or other
problems with brake system.
It is much more difficult to diagnose a problem that occurs
intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In
this case, careful checking of suspicious circuits may help
prevent the replacement of good parts.
A visual check only may not find the cause of the problems, so
a road test should be performed.
Before undertaking actual checks, take just a few minutes to
talk with a customer who approaches with a A.B.S. complaint.
The customer is a very good source of information on such
problems; especially intermittent ones. Through the talks with
the customer, find out what symptoms are present and under
what conditions they occur.
Start your diagnosis by looking for "conventional" problems first.
This is one of the best ways to troubleshoot brake problems on
an A.B.S. controlled vehicle.

BR..30

"
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
WORK FLOW
CHECK IN

r--------------------

I
I
I
I
I
I
I
I

1

item

LISTEN TO CUSTOMER
COMPLAINTS

DIAGNOSTIC WORKSHEET
(See page BR-32.)

INVESTIGATE ITEMS YOU
SHOULD CAR RY OUT
RELATED TO EACH
SYMPTOM AND NOTE

Symptom Chart
(See page BR-33.)

ELIMINATE GOOD SYSTEMS
ON GOOD PARTS

Preliminary Check
(See pages BR-34 - 36.)

Not self-diagnostic item

Self-diagnostic item

DETERMINE MALFUNCTIONING CIRCUIT(S) OR PART(S)

I
I
I
I
,I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I


OJ

~

a.
0

'"
::I
..'
CD

~
0
...
7':'

0

»
CT

::I
0

3
~

"

CD

a.
~
I»
n
..

<5"
::I

0

0

b
::I
ce
'"
..
""0

5'
ce
a.

~.

0

...
::I

5'
ce
I»
n..

<'
I»
..
CD
'"

I»
::I

fa

"'tI
CD

a.
~
<
CT
...
I»
~,
0
::I
g;o
::I
0
iii'
CD

0

0

0

-<
s:
"'tI
-I
0
s:

»
G')

m

BR-34

"'tI

Preliminary Check 2

BR-35

~
3

0

Preliminary Check 3

BR-36

0

0

Preliminary Check 4

BR-36

0

Diagnostic Procedure 1

BR-42

Diagnostic Procedure 2

BR-43

Diagnostic Procedure 3

BR-44

Diagnostic Procedure 4

BR-44

Diagnostic Procedure 5

BR"-45

Diagnostic Procedure 6

BR-45

LE.D. flashing1 - 4

BR-46

0
0

0
0

"'tI
:IJ
0
(')
m
0
C
:IJ
m

:IJ
m
-n
m
:IJ
m
Z
(')
m
"'tI

0

0

/

en

Preliminary Check 1
0

0

0

:E
I»

::I
I»
...

-<
(')
::I"
CD
n
7':'

0
iii'
ce
::I
0

'"
..

c)"
"'tI
...
0
nCD
a.
c::
...

CD

--.(I)

0

0

0

0

0

0

0

0

0

0

0

0

LE.D. flashing5 - 8

BR-47

0

0

0

0

0

0

L.E.D. flashing9

BR-48

0

0

0

0

0

0

LE.D. flashing 10

BR-49

0

0

0

0

0

0

LE.D. flashing 16

BR-50

0

0

0

0

0

0

L.E.D. goes off

BR-51

----

0

Sensor shield

BR-40

(')(')G')
::I"-, ...
CD n 0

Motor ground

BR-40

CD
CD
~9.
-. I»
::Ice

-"'::I
iiii

0

!!;-~;.
5' -. n
ce 0 "'tI
::I ...
Z~o
? ;:+. 2
::I" a.
r~
j"CD

0
0

b

n c:: c::
7':' ..
-, a.
::I

-"

0

Actuator inspection

BR-52

.::.~

1-18'1:>WOldw'l

.. "
a:~

Check 1.

Check whether brake fluid
pressuredistribution is normal.
D2/D1: 52 - 56n5

77

5
-~l

Perform Preliminary

PR ESSU R E.

--d--.

:;
'"
.."'.. .-'"
Q,Q,
'tJ ,,"

N.G.

L~_--_---

O.K.

Check whether front axles have
excessive looseness.

.

Yes

Remedy.

No

Perform Preliminary Check 2 and
Ground Circuit Check.

nn~

I
I
I
I

~
PI kPa (kg/em'. psi)
Front brake fluid pressure
SBR643A

I!J

(\

SMA626A

BR-45

TROUBLE DIAGNOSES

m

Diagnostic Procedure 7

Control unit connector
.(§)

ACTUATOR SOLENOID (L.E.D. flashing number 1 - 4)

-)J_T
[ill

eJ
~

INSPECTIONSTART
Remove battery negative
terminal connector.

m
I

SBR544A

iii

.

CHECK SOLENOID VALVE
RESISTANCE.

O.K.
Replace control unit.

Disconnect control unit connector.
Check resistance between control unit connector (vehicle side)
terminals.
Flashing number 1:
Terminals @ and (t)
Flashing number 2:
Terminals @ and @
Flashing number 3 or 4:
Terminals @ and @
Resistance: 0.7 - 1.60

Actuator connector

@

~
\:ill!

SBR545A

.

iii

N.G.

Disconnect actuator connector.
Check resistance between
actuator connector (actuator
side) terminals.
Flashing number 1:
Terminals @ and CD
Flashing number 2:
Terminals @ and (t)
Flashing number 3 or 4:
Terminals @ and @
Resistance: 0.7 - 1.60
N.G.

I

Replace actuator.

BR-46

O.K.

Repair harness between actuator
connector and control unit connector.

tROUBLE

m

DIAGNOSES

Diagnostic Procedure 8
WHE~LSPEED SENSOR (L.E.D. flashing number 5 - 8)

Control unit connector

~

)J

INSPECTION START
Remove battery negative
terminal connector.

[:iIi5
m
SBR546A

O.K.

CHECK SPEED SENSOR
RESISTANCE
Disconnect control unit connector.
Check resistance between control unit connector (vehicle side)
terminals.
Flashing number 5:
Terminals @ and @
Flashing number 6:
Terminals @ and @
Flashing number 7 or 8:
Terminals (j) and @
Resistance:

0.8

- 1.2

Replace control unit.

kil

N.G.
Refer to Preliminary Check 3
result.
Check whether sensor has 0.8 1.2 kQ resistance.

N.G.
Re~air harness between sensor
connector and control unit connector.

BR-47

N.G.
Replace sensor.

TROUBLE DIAGNOSES

m

Diagnostic Procedure 9

@

Control unit connector

ACTUATOR MOTOR RELAY (L.E.D. flashing number 9)

I

INSPECTION START
Remove battery negative
terminal connector.

~i5

[i]

Fa
SBR547 A

Ii)

Actuator connector

@

Effij

i5 ~

~

.Ii)CHECK MOTOR

[ill

-

SBR548A

@

~~

Replace fusible link.

\:mEY

[ill
SBR550A

~

~0

O.K.
Repair harness
between
actuator and
control unit.

RELAY

. Yes

[i]

N.G. ~isconnect actuator connector.
Check resistance between
actuator connector (actuator
side) terminals @ and @.
Resistance: 38 - 45n

DEACTIVATION.
Disconnect actuator connector.
Check continuity between
actuator connector (actuator
side) terminals @ and @.
No

Check if motor's fusible link
is blown.
Resistance:
Approximately on

0
~
-,
eJ

CHECK MOTOR RELAY
SOLENOID RESISTANCE.
Disconnect control unit connector.
Check resistance between control unit connector (vehicle side)
terminals @ and @.
Resistance:38 -45n

~

Motor rela;

SBR688A

BR-48

No

II

N.G.

Replace
motor
relay.

Perform Electrical Components
Inspection - ACTUATOR.
(See page BR-52.)
N.G.
.O.K.
Replace
actuator.

TROUBLE DIAGNOSES

m

Control unit connector

Diagnostic Procedure 10

~

ACTUATOR SOLENOID
number 10)

~~

[

_CT

INSPECTION START
Remove battery negative
terminal connector.

18
rnJ

m

Actuator connector

@)

~

~)

Ii

CHECK SOLENOID VALVE
RELAY RESISTANCE.
Disconnect control unit connector.
Check resistance between control unit connector (vehicle side)
terminals @ and @.
Resistance. 80 - 90Q

SBR552A

Ii)

VALVE RELAY (L.E.D. flashing

IVr:II~

N.G. rcheck resistance between
actuator connector (actuator
side) terminals (j) and 00.
Resistance: 80 - 90Q
O.K.
Repair harness
between
actuator and
control unit

[ill I
Ii)
SBR553A

[i

N.G.

Replacesolenoid valve
relay.

[i

CHECK SOLENOID VALVE
RELAY MOVEMENT.
Disconnect actuator connector.
Check continuity between
actuator connector (actuator
side) terminals @ and @.

Yes

r~
L~eplace solenoid valverelay.

No
Check if solenoid valve relay
fuse is blown.
Yes

I

Ii

Replacefuse.

Actuator connector

-,

@~eo~
[ill
SBR556A

BR-49

No

Perform Electrical Components
Inspection - ACTUATOR.
(See page B R-52.)

.

N.G.

O.K.
Replace
controlunit.

TROUBLE DIAGNOSES
Diagnostic Procedure 11
CONTROL UNIT (L.E.D. flashing number 16)
INSPECTION START

Control unit malfunction.

Replace control unit.

BR-50

TROUBLE DIAGNOSES

m

Control unit connector

(§)

)J

Diagnostic Procedure 12
CONTROLUNITOR POWERSUPPLYANDGROUND
CIRCUIT(Warning activates but L.E.D.comes off.)

ij~

INSPECTION START

PI
-=SBR557A

Ii)

Control unit connector

(§)

I~

CHECK CONTROL UNIT
POWER SUPPLY.
Disconnect control unit connector.
Check voltage between control
unit connector (vehicle side)

N.G. Check if control unit "10A" fuse
is blown.

terminal CD and body ground

[Y]

1

[:iI ij

Ii)

SBR55BA

(!J Control unit connector

with ignition switch turned on.

(§)

SBR559A

O.K.

CHECK ALTERNATOR L
TER~INAL VOLTAGE.
Disconnect control unit connector.
Check voltage between control
unit connector (vehicleside)
terminal @ and body ground
after engine starting.
Voltage: 6V or more
O.K.
(!J
Check continuity between
control unit connector (vehicle
side) terminal @ and body
ground with ignition switch
"OFF" .

O.K.
Replace control unit.

BR-51

N.G.

Repair harness
between alternator and
control unit.

N.G.
Repair ground harness.

Malfunctioning
alternator.
',.,

TROUBLE DIAGNOSES
Motor relay indicator
Power supply
indicator

'"'$SUR'
DEC

"" ".' .'"
'NC~

....

~/

in switch

Electrical Components Inspection
ACTUATOR (Not self-diagnostic

item)

INSPECTION START

,
mt5)." Checker~"W KV999P1000
(

-

)

Harness: KV999P1010
(
Motor switch
3,4 select switch

)

SBR560A

Connect A.B.S. checker to
actuator connector and vehicle
harness with battery terminal
connected and all checker switch
turning off. Check that battery'
voltage is at least 12 volts.
Use harness for 3 channel.
Set select switch to 3 channel.

Turn checker power supply
switch on.
Check power supply indicator
for coming on.

No

Replace battery with fully
charged new one, if checker
connection is correct.

Yes
Check checker valve relay
indicator for coming on.

Replace solenoid valve relay.
if checker connection is correct.

Yes
Select one valve.
Select pressure decreasing
position by switch then turn
motor switch on.
Turn motor switch off.
Select pressure increasing
position.

~

CAUTION:
Do not hold switch at the
pressure decreasing position
for more than 5 seconds.
Otherwise, solenoid valve
may be overheated and
damaged.

Repeat so that all
valve will be performed.

Check motor relay indicator
for coming on while motor
switch is turned on.

No

Replace motor relay. if checker
connection is correct.

Yes
Check motor for operational
sound beside the actuator in a
quiet place.
Yes

Bring checker in the vehicle and
depress the brake pedal.
Repeat step

~

~

~.~

~~R691A

@

BR-52

No

Replace actuator as assembly.
if Diagnostic Procedures 7 - 12 are
already performed and checker
connection is correct.

Valve select switch position RR
is used for 4 channel checking.
In the case of 3 channels, brake
pedal vibration or depression
will not occur in position RR. It
will occur, however, in position
RL.

TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
Ii:
N.G.: No vibration
Check brake pedal for vibration
while motor switch is turned on,

.

O.K.: Vibration

. Change operating valve~,th
motor switch "ON" and check
for pedal vibration.
I

N ..:
G

I'
.
N 0 VIb ration

O.K.: Vibration
Replace actuator as assembly.

Check brake pedal for depression
when select pressure increases.

O.K.
Actuator works normally.

BR-53

Replace actuator as assembly.

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
General-Specifications
Front brake
Brake model

CL22VB

CL25VA

Cylinder bore diameter

mm (in)

54.0 (2.126)

57.2 (2.252)

Pad length x width x thickness

mm lin)

112.8 x 44.8 x 10.0
(4.44 x 1.764 x 0.394)

134.1 x45.3x 11.0
(5.28 x 1.783 x 0.433)

252 x 20 (9.92 x 0.79)

257 x 22 (10.12 x 0.87)

Rotor outer diameter x thickness
mm lin)
Rear .brake
Brake model

CL9H

Cylinder bore diameter

mm lin)

33.96 (1.3370)

Pad length x width x thickness

mm lin)

75.0 x 40.0 x 9.5 (2.953 x 1.575 x 0.374)

Rotor outer diameter x thickness

258 x 9 (10.16 x 0.35)

mm (in)
Master cylinder
Cylinder bore diameter

mm lin)

Control valve
Valve model

22.22 (7/8)

Proportioning valve (within master cylinder)

Sprit point x reducing ratio
kPa (kg/em' , psi)
Brake booster
Booster model
Diaphragm diameter

23.81 (15/16)

3,923 (40, 569) x ().4

M23
mm lin)

M195T
Primary
Secondary

230 (9.06)

Brake fluid
Recommended brake fluid

DOT3

Parking brake
Control type

Center lever

BR-54

205 (8.07)
180 (7.09)

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Inspection and Adjustment
BRAKE PEDAL

FRONT DISC BRAKE
CL25VA

CL22VB

Free height
MfT

mm (in)
177.0

- 187.0

(6.97.7.36)

Item
AfT
Pad wear limit
Minimum thickness
mm(in)
Rotor repair limit
Minimum thickness
mm (in)
Maximum runout
mm (in)

2.0 (0.079)

18.0 (0.709)

20.0 (0.787)

0.07 (0.0028)

REAR DISC BRAKE

186.0 -196.0 (7.32 .7.72)

Depressed height
[under force of 490 N
(50 kg, 110 Ib) with
engine running)
mm (in)

100 (3.94) or more

Clerance between pedal
stopper and threeded end
of stop lamp switch
mm (in)

0.3 - 1.0 (0.012 - 0.039)

Clearance between pedal
stopper and threaded end
of A.S.C.D. switch
mm (In)

0.3 . 1.0 (0.012 - 0.039)

CL9H
Pedal free plav at clevis
mm (in)

Item
Pad wear limit
Minimum thickness
mm(in)
Rotor repair limit
Minimum thickness
mm (in)
Maximum runout
mm (in)

1.3

(0.04.0.12)

2.0 (0.079)

PARKING BRAKE
8.0 (0.315)

Center

lever

Item
0.07 (0.0028)

Number of notches
[under force of 196 N
(20 kg, 44 Ib))
Number of notches
(when warning switch
comes on)

BR-55

6-8

STEERING
SYSTEM

ST

SECTION

CONTENTS
PRECAUTIONS
PREPARATION

"

ON-VEHICLE

INSPECTION

ON-VEHICLE

INSPECTION

STEERING

WHEEL

ST - 3
ST- 5

(Power

steering)

AND STEERING

POWER

STEERING

GEAR

POWER

STEERING

OIL PUMP

SERVICE

ST- 2

""""""'"''

AND

ST- 7

COLUMN

LINKAGE

DATA AND SPECIFICATIONS

(Model

ST-10
PR24SC)

ST-14
ST-27

(S.O.S.)

ST-31

IDI

PRECAUTIONS

..

Before disassembly, thoroughly clean the outside of the unit.
Disassembly should be done in a clean work area. It is
important to prevent the internal parts from becoming
contaminated by dirt or other foreign matter.
When disassembling parts, be sure to place them in order "in
a parts rack so they can be reinstalled in their proper
positions.
Use nylon cloths or paper towels to clean the parts;
common shop rags can leave lint that might interfere with
their operation.
Before inspection or reassembly, carefully clean all parts
with a general purpose, non-flammable solvent.
Before assembly, apply a coat of recommended A.T.F.* to
hydraulic parts. Vaseline may be applied to a-rings and
seals. Do not use any grease.
Replace all gaskets, seals and a-rings. Avoid damaging
a-rings, seals and gaskets during installation. Perform
functional tests whenever designated.
*: Automatic transmission fluid

.
.
.
.

.

ST-2

PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
KV48100700
(J26364)
Torque adapter

ST27180001
(J25726-A)
Steering wheel puller

HT72520000
(J25730-A)
Ball joint remover

ST27091 000
(J26357)
Pressure gauge

KV48102500

-

(

)

Pressure gauge adapter

ST3127S000
(See J25765-A)
ill GG91030000
(J25765-A)
Torque wrench
@ HT62940000

-

(

)

Socket adapter
@ HT62900000

-

(

Description

Measuring pinion rotating
torque

~

~n
~

Removing ball joint

Measuring oil pressure

Measuring oil pressure

~@
~@

~

Removing and installing
steering wheel

CJI@
Measuring turning
torque

CD-fJ

~

@~
@-o

)

Socket adapter
Reforming teflon ring

KV481 04400
(

-

)

Rack seal ring
reformer

ST-3

PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name

Description

Rear oil seal drift

Installing rear oil seal

~"'di'
Pinion oil seal drift

Installing pinion oil seal

v:2.,.,dg
Oil pump attachment
Welding ,\1-\O.a.1\
40
11.57)
12
.;.~fb~10.47)
"".

~

,,\~ ~o.\
,~.
qp
Unit: mm lin)

ST-4

SST481 A

Disassembling and
assembling oil pump

ON-VEHICLE INSPECTION
Checking

Steering

Wheel

Play

.

With wheels in a straight-aheadposition,check steering
wheel play.
Steering wheel play:

.

If it is

35 mm (1.38
not

in) or less

within

specification,

check

rack' and

pinion

assembly.

Checking Neutral Position on Steering Wheel
O.K.

N.G.
Pre-checking
.

Verify that the steering
steering

gear

is centered

before

removing

the

wheel.

Checking
.

Check

that the steering

wheel

is in the neutral position

when

driving straight ahead.
.

If it is not in the neutral
and

.
SST104B

position, remove

the

steering

wheel

reinstall it correctly.

If the
tie-rod

neutral
lock

position
nut

by the same
compensate

and

is between
move

amount

two

tie-rod

on

for error in the

serrated

in the

both left and
neutral

teeth, loosen

opposite

direction

right sides to

position.

Front Wheel Turning Angle

. Rotatesteeringwheel
turning

all the way

right

and

left;measure

angle.

Turning angle of full turns:

Refer to section FA forS.D.S.

SMA 127
.

If it is not

within

specification,

Measured length "L":
Refer to S.D.S.

L

SST086B

ST-5

check

rack

stroke.

ON-VEHICLE INSPECTION
Checking Gear Housing Movement

.

Check the movement of steering gear housing during
stationary steering. The maximum allowable movement is as
follows:

Movement of gear housing:
.
:t 2 mm (:t 0.08 in) (on dry paved surface) or less
Apply a force of 49 N (5 kg, 11 Ib) to steering wheel to check
the gear housing movement.
On models equipped with power steering, turn off ignition key
while checking.

.

If movement

exceeds

the limit, replace

mount

insulator

after

confirming proper installation of gear housing clamps.

Adjusting Rack Retainer

.

Perform this driving test on a flat road.
1. Check whether vehicle moves in a straight line when
steering wheel is released.
2. Check whether steering wheel returns to neutral position
when steering wheel is released from a slightly turned (approx. 20°) position.
If any abnormality is found, correct it by resetting adjusting
screw.

.

ST~6

ON-VEHICLEINSPECTION (Power steering)
Checking and Adjusting Drive Belts
Refer to section MAfor DriveBelt Inspection.

Checking

Fluid Level

Check the level when the fluid is cold.
CAUTION:

..

Do not overfill.
Recommended
fluid is Automatic
"DEXRONTM
Type".

Checking

Transmission

Fluid

Fluid Leakage

Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing or deterioration.
1. Run engine at idle speed or 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to
80°C (140 to 176°F).
2. Turn steering wheel right-to-Ieft several times.
3. Hold steering wheel at each "lock" position for five seconds
and carefully check for fluid leakage.
CAUTION:
SST107B

Do not hold the steering wheel in a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.

Bleeding Hydraulic System
1. Raise front end of vehicle until wheels clear ground.
2. Add fluid into oil tank to specified level. Meanwhile,quickly
turn steering wheel fully to right and left and lightly touch
steering stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2 above.

. Incompleteair bleeding willcause the followingto occur.
When this happens, bleed air again.
ST-7

ON-VEHICLE INSPECTION (Power steering)
Bleeding Hydraulic System (Cont'd)
a. Generation of air bubbles in reservoir tank
b. Generation of clicking noise in oil pump
c. Excessive buzzing in oil pump
While the vehicle is stationary or while turning the steering
wheel slowly, fluid noise may occur in the valve or oil. pump.
This noise is inherent in this steering system, and it will not
affect performance or durability of the system.

Checking Steering Wheel Turning Force
1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Warm up power steering fluid to adequate operating temperature.
Temperature of fluid:
Approximately 60 - 80°C (140 - 176°F).
Tires need to be inflated to normal pressure.

4. Check steering wheel turning force with engine idling when
steering wheel has been turned 360° from neutral position.
Steering wheel turning force:
39 N (4 kg, 9 Ib) or less

Checking Hydraulic System
Before starting, check belt tension, driving pulley and tire
pressure.
1. Set Tool. Open shut-off valve. Then bleed air. (See "Bleeding Hydraulic System".)
2. Run engine.
Make sure temperature of fluid In tank rises to 60 to 80°C
(140 to 176°F).

ST-8

ON-VEHICLEINSPECTION (Power steering)
Checking Hydraulic System (Cont'd)
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, oil pressure in oil pump will
increase to relief pressure, resulting in an abnormal rise in oil
temperature.
3. Check pressure with steering wheel fully turned to left and
right positions with engine idling at 1,000 rpm.

ST27091000(J26357)

...

: Direction of oil flow

Low-pressure
hose

CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Oil pump maximum standard pressure:
6,865 kPa (70 kg/cm2, 995 psi)
at idling
4. If oil pressure is below the standard pressure, slowly close
shut-oft valve and check pressure.
When pressure reaches standard pressure, gear is damaged.
When pressure remains below standard pressure, pump is
damaged.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
5. If oil pressure is higher than standard pressure, pump is
damaged.
6. After checking hydraulic system, remove Tool and add fluid
as necessary, then completely bleed air out of system.

..

SST834

ST-9

STEERING WHEEL AND STEERING COLUMN

~~~

~
~L"!]~:'o ~.o.

22 - 291

Steering tube assembly

~N~
\L"!]

13'

- 19

(1~

- »>,9 - 13]

to.) 13.1811.3.1.8,9.13)

to.) : N.m (kg-m, ft-Ib)
SST109B

Removal
STEERING

.

WHEEL

Pull out horn pad.

If it is hard to pull out horn pad, temporarily loosen fixing screw
of horn pad retaining spring.

SST110B

SST275B

.

Remove steering wheel with Tool.

ST -1 0

STEERING WHEEL AND STEERING COLUMN
Installation
Ell

STEERING

.

WHEEL

When installing steering wheel, apply multi-purpose grease
to entire surface of turn signal cancel pin (both portions)
and also to horn contact slip ring.

SST112B

STEERING

.

.

'

Cutout port Ion

COLUMN

When installing steering column, fingertighten all lower
bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column.

When attaching coupling joint, be sure tightening bolt faces
cutout portion.

CAUTION:
After installing steering column, turn steering wheel to make
sure it moves smoothly and that the number of turns from the
straight forward position to left and right locks are equal.
Be sure that the steering wheel is in a neutral position when
driving straight ahead.
Lower joint

SST800A

ST -11

STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly

Hole cover

Steering column
upper shaft

~

: N.m (kg-m, ft-Ib)
SST113B

.
.
.

When disassembling and assembling, unlock steering lock
with key.
Ensure that rounded surface of snap ring faces toward
bearing when snap ring is installed.
Install snap ring CD before inserting shaft into jacket tube.

.

Instal1 snap ring on upper shaft with box wrench.

SST428A

---n

Upper shaft

SST770A

ST -1 2

STEERING WHEEL AND STEERING COLUMN
Disassembly

.

and Assembly

(Cont'd)

Tilt mechanism

Tighten adjusting nut to specification.
~: 4 - 5 N.m
(0.4 - 0.5 kg-m, 2.9 - 3.6 ft-Ib)

SST114B

.

Steering

lock

a) Break self-shear type screws with a drill or other appropriate
tool.

~~
i

b) Install self-shear type screws and then cut off self-shear
type screw heads.

Self-shear screw

SST742A

Inspection

.

L,

F~-

:1
SST098B

When steering wheel can not be rotated smoothly, check
the steering column for the following matters and replace
damaged parts.
a. Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace
steering column as an assembly, if ecessary.
b. Check steering column lower sh ft for deformation or
breakage. Replace if necessary.
When the vehicle is involved in a light collision, check
steering column length "L1" and steering column lower shaft
length "L2". If it is not within specifications, replace steering
column as an assembly.
Steering column length "L1":
653.1- 654.5 mm (25.71 - 25.77 in)
Steering column lower shaft length "L2":
323.7 - 325.3 mm (12.74 - 12~81 in)

1

.

L2

SST115B

L.

.

After installing steering column, check tilt mechanism operation.
L1: 9.8 mm (0.386 in)
L2: 19.5 mm (0.768 in) .
L3:29.3 mm (1.154 in)
L.: 58.2 mm (2.291 in)

SST116B

ST -1 3

POWER STEERING GEAR AND LINKAGE (Model PR24SC)
Removal and Installation

Rack mounting insulator

G." hoo.'ooonO.M'OO
b~,k..

tOJ 24.29 (2.4 - 3.0,

~

~

~I\

~

G.." ho",'" onOOM'",
"''''''..
."P

.

~

17.22)

V,",". "00'

~

~o
~

:

I

'

.

[qJ 29 . 39 (3 -4,
22 .29)

..,.I>

18

I

Gear and linkage
assembly

tOJ 88 . 108 (9.0 . 11.0,
66 .80)

tDJ: N.m (kg-m, ft.lb)
124B

.

Detach tie-rod outer sockets from knuckle arms with Tool.

.

Install pipe connector.

SST783A

CD

Low-pressure side
tOJ: 27
39 N.m (2.8 - 4.0 kg-m, 20 - 29 ft-Ib)

-

@ High-pressure side
.
tOJ:15 - 25 N.m (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)

SST080B

ST -14

POWER STEERING GEAR AND LINKAGE (Model PR24SC)
Removal and Installation (Cont'd)

.
.

Observe specified tightening torque when tightening highpressure and low-pressure pipe connectors. Excessive
tightening can damage threads or damaged connector
O-ring.
The O-ring in low-pressure pipe connector is larger than that
in high-pressure connector. Take care to install the proper
O-ring.
.

.

Initially, tighten nut on tie-rod outer socket and knuckle arm
to 29 to 39 N.m (3 to 4 kg-m, 22 to 29 ft-Ib). Then tighten
further to align nut groove with first pin hole so that cotter
pin can be installed.
CAUTION:
Tightening torque must not exceed 49 N.m (5 kg-m, 36 ft-Ib).

arm

SST824A

.
.

Before removing lower joint from gear, set gear in neutral
(wheels in straight-ahead position). After removing lower
joint, put matching mark on pinion shaft and pinion housing
to record neutral position of gear.
To install, set left and right dust boots to equal deflection,
and attach lower joint by aligning matching ~arks of pinion
shaft and pinion housing.
\

ST -1 5

POWER STEERING GEAR AND LINKAGE (Model PR24SC)
Disassembly and Assembly
The table below lists four ways to repair oil leaks in the steering gear, depending on the location of the leak.
See the following figure for oil leak locations.
CD Rear housing
cover and rear
housing
Operation

.

..
.
.

@ Boot

@ Boot

..

..
.
..

@ Cylinder tube

..

Replacement

. Replacement

. Replacement

. Replacement

Rear oil seal

Rack oil seal
Boot clamp

Rack oil seals
Rack oil seal
O-ring
Back-up collar

Cylinder tube

Pinion oil seal
O-ring
Snap ring

Copperwasher

Boot clamp

Remove gear from vehicle.

Measure rack starting 'force
and pinion rotating torque.
Procedure

Replace parts described above,

I I Replacecylinder

I I Replace rack oil seal.
I
I

tube.

I
I

Adjust adjusting screw.

Measure rack starting force and
pinion rotating torque.

Service parts
to be prepared

.

Pinion seal kit

.

Gear housing seal

kit

..

Rack oil seal
Pinion seal kit

.

Gear housing sealkit

SST117B

ST -1 6

POWER STEERING GEAR AND LINKAGE (Model PR24SC)

@

~

~r~
l ~ 0r
O'@J
~@

~16-21

~.

(1.6-2. 1 , 12-15)

~

R~

I

Adjusting screw

m

~

----~:9n_U~9

;

(40-6.0,

SP~;r~ng disc

29-43)
1J

be

rWasher

Pinion assembly

%@@

evli.",,,"
40"""\

/

So"og

~
-.!

~

Retainer

CenterbUShing\
Rack oil seal~

Pinion
seal
ring

<::::::>--O-ring

I

J

~Shirr:~
~ >< Pinion oil seal ~ m

"'"

~

~

m

jt;;g

~

\\\)~

m

l

R~kO'I_'~

'-~ '9 -74.. -7.5.

rn:

43 -54'

E.

Tie-rod

\

~
\

:~O,~
Bro,"'d~ ~
~~

~JL. Bo",",m,

Rack spacer

\

'\-.LOCkPlate

rJ

.

~
socket

Inner.
~Tie-rod
78 -98
(8.0 - 10"0 58 - 72)

.

~37 .46 (3.8- 4 .7 , 27 - 34)

Tie-rod outer
Do not disassemble.

~:

N.m (kg-rn,ft-Ib)

ssn1SB

ST -1 7

POWER STEERING GEAR AND LINKAGE (Model PR24SC)
Disassembly
1. Prior to disassembling, measure pinion rotating torque.
Record the pinion rotating torque as a reference.
Before measuring, disconnect cylinder tube and drain fluid.
Use soft jaws when holding steering gear housing. Han(lle
gear housing carefully, as it is made of aluminum. Do not
grip cylinder in a vise.
2. Remove pinion gear.
Be careful not to damage pinion gear when removing
pinion seal ring.

.
.
.

SST1198

3. Remove tie-rod outer sockets and boots.
4. Loosen tie-rod inner socket by prying up staked portion,
and remove socket.
5. Remove retainer.
6. Remove pinion assembly.

SST881

7. Drill staked portion of cylinder end cover with drill of 2 to 2.5
mm (0.079 to 0.098 in) diameter, until the staking is
eliminated.

SST450A

8. Remove gear housing end cover assembly with Tool.
9. Draw out rack assembly.

.

SST0818

10. Remove
Using a
(104°F).
Remove
Replace

.
.
.

Rack seal
ring

rack seal ring.
heat gun, heat rack seal to approximately 40°C
rack seal ring. Be careful not to damage rack.
rack seal ring and O-ring with new ones.

SST0828

ST -18

POWER STEERING GEAR AND LINKAGE (Model PR24SC)
Disassembly (Cont'd)
11. Remove center bushing and rack oil seal using tape wrapped socket and extension bar.
Do not scratch inner surfaces of pinion housing.

+1:''''°0

"" 29mm..ok"
SST472A

Assembly
1. Using a heat gun, heat rack seal ring (made of Teflon) to
approximately 40°C (104°F) and install it onto rack with your
hand.

~R"'k

",' cO",
SST083B

.

Using Tool, compress periphery of rack seal ring (made of
Teflon) to position and secure it on rack.
Always insert the tool from the rack gear side.

KV481 04400
(
)

Rack teeth
~lIJIfi11lJJJ11II11IIiIJ!I.

Position and
secu re seal.

SST084B

2. Insert rack oil seal.
Place plastic film into rack oil seal to prevent damage by
rack teeth.
Always remove plastic film after rack oil seal is positioned
properly.
Make sure lips of rack oil seal face each other.

.

.~

~

.
.

.~--

Film~~
Rack oil seal j
SST201A

3. Install center bushing and rack oil seal with rack assembly.

SST830A

ST -1 9

POWER STEERING GEAR AND LINKAGE (Model PR24SC)
Assembly (Cont'd)
4. Tighten cylinder end cover assembly with Tool.

.

SST081B
2-3mm
CO.08- 0.12 in)

5. Fasten cylinder end cover assembly to gear housing by
staking.

End cover
assembly
SST073B

6. Set rack gear in neutral position.
Measured length "L":
Refer to S.D.S.

L

L

SST086B

7. Coat seal lip of oil seal with multi-purpose grease and install
new pinion oil seal to pinion housing with suitable tool.
Make sure lip of oil seal faces up when installed.

...

.

Suitable tool

Oil seal

SST381

A

8. Install pinion bearing adjusting shim(s).
Whenever pinion assembly, gear housing and rear housing
are disassembled, replace shim(s) with new ones. Always
use the same number of shim(s) when replacing.

.

SST074B

ST -20

POWER STEERING GEAR AND LINKAGE (Model PR24SC)
Assembly (Cont'd)
9. Install pinion seal ring on pinion gear assembly.
Using a heat gun, heat pinion seal ring to approximately
40°C (104°F) before installing it onto pinion gear assembly.
Make sure pinion seal ring is properly settled in valve groove.

.
.

SST085B

10. Apply a coat of multi-purpose grease to needle bearing
roller and oil seal lip before installing pinion assembly in
gear housing.

SST075B

11. Install pinion assembly to pinion housing.
Be careful not to damage pinion oil seal.

SST552

12. Apply a coat of multi-purpose
before installing rear housing.

grease to rear oil seal lip

Gear housing

SST121B

- Protrusion

13. Install rear cover cap so that protrusion of rear housing
cover is positioned as shown in figure at left.
Be careful not to damage worm ring and oil seal.

ST -21

POWER STEERING GEAR AND LINKAGE(Model PR24SC)
Assembly

(Cont'd)

14. Install diaphragm spring at retainer.
Always install retainer, spring washer and diaphragm spring
in that order.
Make sure convex end (painted white) of diaphragm spring
faces outward when installing.
15. Install retainer spring and adjusting screw temporarily.

.
.

SST087B

. Attach lock plate to side rod inner socket
. Apply
locking sealant to inner socket threads @.
Screw inner socket into rack @ and tighten to
torque.
.CAUTION:
Clinch two places of lock plate at rack's groove.
CV

~

~(

r{ ~
@

<1;",h.

@

CD.

specified

To prevent scratching the boot, remove burrs from lock plate.

'-CD

Glass portion

fA

SBF177

BF-13

IGNITION SWITCH
ON or START
POWER WINDOW REGULATOR

(Driver side)
BA HERY
fusible

(V ia
I Ink-Gree~

Downward

Upward

@
W/R"""4..l.I
L/R-;::n,

~@
r-",

~

BREAKER
. I CIRCUI
T
I

@
(Door harness

@

L.H.)
W/B
R~B~
R/W~

@

~
.

(Main
harness)
W/B

R~B

:;!~I~:U~I

R/W

g,
."

R/W

I
~

R/B
W/B

~

.

.@
r-

r-~~
,,,,r-"'OI'

~

POWER
WINDOW
AMPLI

F I ER

~~
.

D

(Door harness

R. H. )

~

~

R/W

R/W

R/B

W~B
R/B
L

W/B

~:a~:ar-r:a0l0l~0I~

~@
DRIVER SIDE
LOCK
ONESWITCH
TOUCH MANUAL
U N 0 U N D ON OFF
a
1
a
a
2
:3
0
0
a
4

POWER W

(Passen

PASSENGER
SIDE
U N 0

a
<>
0 0
a

MOTOR

CIRCUIT
BREAKER

@ii(§)
- BODY GROUND

CJI

w
W
I'J
m

@ 8

01"""

5
6
7
m
"11

I GN I TI ON

RELAY

POWER WINDOW MAIN SWITCH

Wi
ope
di

DOOR
Power Window (Cont'd)
POWER WINDOW AMP. INSPECTION
FRONT DRIVER SIDE POWEfI
WINDOW SWITCH

Connections

From power window

AMP

From power window

AMP

~~
9

From

AMP

~

power

window

Ground

-=-

IGNITION SWITCH ON or ST
(Via power window relay)

VOLTMETER
FRONT DRIVER
SIDE POWER WINDOW
REGULATOR

Window
operating
direction
Upward

f I Current
flow

Downward

I\.1

direction

AMP.

\
51
52
-53
54
55

-

56
57

-

58

-

OPERATION
Connections

Operations

Manual operation
One-touch (Autol Operation
Power source OGNI
12V
12V
12V
12V
12V
12V
Ground
Gmund Ground Gmund Gmund Gmund
Ground
ON
or
ST
ON
or
ST
From ignition SW(ON or STI
ON or ST ON or ST ON or ST
ON or ST
To FR driver side power
OFF
OFF
OFF
OFF
OFF
ON
window SW (AUTO) Q)
'0;
To
FR
driver
side
power
OFF
ON
OFF
OFF
,
OFF
OFF
window SW (UP) @
To FR driver side power
OFF
ON
OFF
OFF
OFF
ON
window SW(DOWN) CV

.
I

Regulator

FR driver side regulator
(Upward power source)

Approx,
OV

Approx.
over 9V

Approx.
OV

Approx.
OV

Approx.
OV

Approx.
OV

FR driver side regulator
(Downward power source)

Approx.
OV

Approx.
OV

Appmx.
over 9V

Approx.
OV

Aprrox.
over 9V

Approx.
over 9V

Stop

Upward
operation

Down.
ward
opera.
tion

Starting

Keeping opera.
tion until fully
open, then
"ops
automatically.

Operating

Condition

Stop

Downward

Carry out this operation

operation

check in this chart from left to right continuously,
I

POWERWINDOW AMP. -IFront driver sidedoor (Behind door trim)
SBF789C

CIRCUIT

Time (sec.)

BREAKER

For example, when current is 30A, the circuit is broken within 8
to 20 seconds.
This circuit breaker is also used in the power door lock system.

100

'

50
20
10
8
5

1
0
SBF284E

INSPECTION

10 20 30 40 50 60 70
Current (A)

BF-15

.

SID~ D

PASSENGER

BATTERY (V I a
fus I b I e I Ink-Green)

ORB'L

~t
([ill)

@
CIRCUIT~
BREAKER~

rn::;-L/R

@@D

~W/R

DOOR LOCK CO
Lock

Between

lock"

un lock
n
a

Fom
I
lock to
un lock
Fom
I
un lock
to lock

PASSENGER SIDE
POSISTOR
c I rcu I t

 operation
.;;;
... SW-B
0.
.= operation

OFF

Turns
ON

ON

Turns
OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

Turns
ON

ON

After SW-A
Turns operation, Turns
OFF immediately OFF
turns ON

ON
(Approx. OFF
1.0 sec.)
... OFF

OFF

... 0.- Test lamp OFF
...c:
.2' operation
0"
.
.

ON
(Approx. OFF
1.0 sec.}
-+ OFF

OFF

Turns ON

Turns
OFF

ON... OFF OFF
... ON... OFF

Carry out the complete inspection in this chart from left to
right.
Do not carry out any switch operations that are not described
in the above chart so as to avoid breaking the door lock timer.

Lighting period of test lamp differs according to SW-B operation.
Moreover, test lamp may come on once or it may not come on
at all. If this occurs, do not judge it fau Ity solely from th is step.

INSPECTION CIRCUIT (This test circuit must be wired by the technician.)

---

TESTLAMP

BATTERY
SW-B

=
=

-=-

SW-A
DOOR

-::-

-

LOCK TIMER

CIRCUIT CONNECTIONS

- +

+ -

31

Power source (BAT)

32

To/From actuators (Lock power source & Unlock
ground)

33

To/From actuators (Unlock ground & Lock power
source)

34
35

To lock-unlock switches (Input signal for lock)
Ground

39

To lock-unlock switches (Input signal for unlock)

SBF377E

BF-17

INSTRUMENT PANEL
f

.

When removing instrument panel assembly, remove defroster grille, combination meter, A/C or heater
control, cluster lid C and S.M.J. first.

HEAD-UP DISPLAY (H.U.D.)
When removing H.U.D. finisher, be extremely careful not to scratch H.U.D.'s reflective surface. To avoid
scratching, cover H.U.D.'s reflective surface or finisher with a cloth or vinyl sheet. II

.

Defro ster grille

Super Mutiple
Junction
CS-M.J.) Fa

~
-~

Pewl

Ii)
;;;.

/~

.

-~*

.'

*

rPawl (I

~

~
.

~

~~
Combination meter

~~
Cluster lid C

~.Metal

~

cliPIJ

'1'"

I

~

*

: Instrument panel assembly mounting bolts

BF-18

~/

~P8WI

Ii]

INSTRUIYIENT PANEL

m

(j]

'

/

@J

--

Super Multiple
Junction (S.M.J.I
-:- Instrument
harness
Fuse block

Ii]

Pawl (2 places each for
upper and lower surface)

II

Pawl (4 places each for
upper and lower surface)

Ii

[!1

1:1

0

IJ

Ia

II

Tape H.U.D.'s
reflective surface
rWindshield

Metalclip

Pawl (To head up display assembly)

Cloth
or vinyl sheet

SBF178E

BF-19

INTERIOR AND EXTERIOR
Interior
SIDE, LUGGAGE AND FLOOR TRIM - Fastback

~
0
-;?o,;',

Speaker

--~:.
~
."."- fT

Door corner
finisher [i]

Metal clip

panel

Ii]

iii

~
U-:!

Assist grip
removal

\I

BF-20

[!I

INTERIOR AND EXTERIOR
Interior (Co,nt' d)

m

Ii]

[!]

(I

Ii

;t=.~~~
Garnish

Ii]

Pawl

Pawl

Pawl

[!I

SBF179E

BF-21

INTERIOR AND EXTERIOR
Interior (Cont'd)
SIDE TRIM

-

Coupe

x

x

x

~=,1J~\
Garnish

SBF180E

LUGGAGE

ROOM TRIM

-

Coupe
Clip removal

Ii)

Ii)

J-~

Removal

SBF181E

Bf=-22

INTERIOR AND EXTERIOR
Interior (Cont'd)
ROOF TRIM
Fastback

m

Back door
weatherstrip

Roof rear garnish"""

Coupe

.~~

U

~R~f

"'m ~,.". m

r-

/)

Ii)

1ass

Back door window
Roof

HoodnO;"'

M""<"p
~l

panel

g

~

7

\ r)}. 0-

~ ~
r-.~

/

~~tXL\

Roof rear garnish
SBF182E

BF-23

INTERIORAND EXTERIOR
Exterior

@

@

@

@

@>

@

(j)

@

SBF192E

BF-24

INTERIOR AND EXTERIOR
CD

Windshield upper and side molding

Method 1

Exterior (Cont'd)
CID,@ Cowl top grilleand hood rear sealingrubber

Cut off top portion of molding
and clean glass and panel
surfaces.

.

~.q~
~"~,

<@J;

Apply sealant
molding.

to top portion

/

of

~()

~

~9
~.,.,.,.,.,.,..:
~~;~

t

.

':1:--4
SBF211E

...

Cut off lower portion
of new molding.

CID

'r"~

SEV

Hood front sealingrubber

.',','.'.','. ."
':i/":::: 'J

Hood front sealing rubber

Finish well to give it a
good appearance.

Method 2
1. Cut off sealant at glass end.
2. Clean the side on which panel was mounted.
3. Set molding fastener and apply sealant &
primer to body panel, and apply primer to
molding.
Apply primer."\
Glass~
Dam rubber

~

~
(

-,

~

Double-faced adhesive tape
SBF212E

Apply sealant.

4. Install molding by aligning the molding mark
located on center with vehicle center.
Be sure to install tightly so that there is no gap
around the corner.

@ Center pillar finisher

SBF519B

~

s"u"'~"h7
~.

CV Windshield lower molding
It is mounted with screws.

Grommet

7

'

~

Sealing washl
Grommet?'
SBF213E

BF-25

INTERIOR AND EXTERIOR
Exterior (Cont' d)
(j) , @ Body side weatherstrip and weatherstrip retainer

~
II

m

: Butyl tape

[!) Coupe
Removal
ButYl tape

.--;

Double-faced
adhesive tape

Ii]

Windshield
pi liar garn ish
Body side welt

II

Weatherstrip
retainer

Ii

Body side
weatherstrip

Body side
weatherstrip

Seal

SBF214E

BF-26

INTERIOR AND EXTERIOR
Exterior (Cont' d)
@ Rear sight shield

@ Door weatherstrip
Apply butyl sealant where necessary
while installing the weatherstrip.

t""h"

W,""

\
SBF215E

SBF217E

@ Back window upper and side molding (Coupe)
Basically the same as windshield upper and side
molding.

@ Back door window upper and side molding
(Fastback)
Bonded on back door glass side.

(j]) Back window lower molding (Coupe)
It is mounted with screws.

@ Back door window lower molding
(Fastback)

@ Trunk lid weatherstrip
Moldingclip ~

.

~
"

(9 places)

Trunk lid
' weatherst .
.;..
np

There is a marking
at vehicle center.

SBF401B
SBF216E

BF-27

adhesive tape
(When install ing fastener. heat
body panel
and fastener
to approx.
30 to 40°C
(86 to
104° F)).

INTERIOR AND EXTERIOR
Exterior

(Cont' d)

@ Back door weatherstrip

(j]) Sun roof lid weatherstrip
Manual sun roof

Butyl seal

Sealant

Body
panel

SBF757Q

@ Sun roof weatherstrip
SBF424D

@ Rear panel finisher (Fastback)

SBF873C

SBF218E

@ Sun roof lid weatherstrip and sun roof frame
weatherstrip (Coupe)
Sun roof lid weatherstrip is bonded to lid.
Apply primer before bonding it.
Front
//

.///j

Roof panel
./ Sun roof lid

'

weatherstrip
Sun roof rd
I
I

SBF824D

BF-28

INTERIOR AND EXTERIOR
NOTE

BF-29

SEAT
Front Seat

IRJ 43 -55
(4.4.5.6,32.41)

IRJ

: N.m (kg-m, ft-Ib)

SBF183E

BF-30

SEAT
Rear Seat
Striker
installation

m

Seat back

I!J

adjustment

I!J

m

~
Bushing
~Grommet

~ '3.,.~1-::lli
(1.3-1.6j
9-12)'

I
SBF184E

~

: N.m (kg-m. ft-Ib)

BF-31

~

-

(10

..
)

AUTOMATIC SEAT BELT SYSTEM
Unit Location
Guide rail assembly
Rear limit switch &
shoulder belt buckle switch

[!J

Pawl

Drive motor

Lap belt

Ii) )

(Installation

~43

-55
14.4- 5.6,32 - 411
Shoulder belt assembly
(Installation m)

~~43-55
~.

14.4- 5.6, 32 - 41)

oD
i~.
Lap belt buckle
(L.H. only)

switch

~43-55
14.4 - 5.6, 32 - 411

Control unit

. Control unit is located under
center console box.

BF-32

AUTOMATIC SEAT BELT SV;STEM

Unit Location (Cont'd)
m
-

I~

-

rA

43-55

(4.4-5.6,32 -41)

Ii]

~

Lapbelt

retractor

~I

~~t~

A43 - 55
(4.4 - 5.6, 32 - 41)

(4.4 - 5.6, 32 - 41)

[!J
Guide rail assembly
Rear limit switch
(Bottom color: Green)
Guide cable

~~

J>ff

Shoulder belt
buckle assembly

.~.~
A

: N.m (kg-m. ft-Ib)

SBF185E

BF-33

AUTOMATIC SEAT BELT SYSTEM
Wiring Diagram
CIRCUIT
BREAKER

BATTERY (V I a
fus i b I e I Ink-Green)

(Eng i ne room
harness)

S. M.J.
[Refer to
(Fo Idout

I ast

I GNI TI ON

SWITCH
ON or SART

page)

page

.J

'"
~@})

m,
u:

'"

@D

WARNING
CHIME

E1

~

@r7
@~~'"
'" ..J
, ,
"

"''''

..J ~

..J
I

~.

j

R/B

(Mai n harness)

@
G

FUSE BLOCK
(Refer to npOWER SUPPLY
ROUTINGnln EL section.)

I

..J
'III
>-

~@
~@

(Ma I n harness)

..J
'III
>-

'"
,

'"

>-

'iii
U)
Q)

@

EEIBHEE @
CWhi te)

c

'-

III
.c

(B lack)

@

Q.
E
III

tHHHffil@
'"
,>-

'"
(J nstrument
harness)

WI)

,>-

~@

'"

'"

""
>-

0

[Sffi:B]@

~QD
I

~
@--<>

SEAT BELT
WARNING
LAMP

~

'III

>-

EW

'"

91 o

..J

E
0
0
0:

92

:
I

~
91 o @
o 92
SEAT BELT
WARNING
LAMP

1

[g
R. H. SIDE

COMBINATION

FRONT LIMIT

METER

BF-34

SWITCH

AUTOMATIC SEAT BELT SYSTEM
Wiring Diagram (Cont'd)
AUTOMATIC

SEAT

BELT

CONTROL

UNIT
~:With

head-up

~:Without

~
~

display

head-up

display

~~@V
m~~~~~~

""",m

~~~~~~~

~

m

,~~

~

~m

~~~~

~~

~~

~~~~

~~

',m"~~m"

R. H. SIDE

CD

~
~~~
G;R
G/B

j1
D

~L/W~~

~Lr~

y

w
~

Shoulder

REAR
LIMIT
SWITCH

belt

buckIe condItlon

~

FR IFR and RRIRR

'53
rst
Shoulder

buck Ie
SHOULDER \
BELT
Fastened
BUCKLE 55
:J
SWITCH 54
:J

belt
condl t Ion
IUnfastened
I
I
Belt
ope rat In9
dl rect Ion

rlFrontward
Raarward
L. H. SIDE

@E)
~~~
LG;R
LG/B

jl

D

CD~
~ti~R~
~L/W J

~

L~
i-.I

B

"'~Rl
~

REAR
LIMIT
SWITCH

SHOULDER
BELT
BUCKLE
SWI TCH

55
54

Shoul der belt
buckle condition
Fastened
Unfastened

B

II J ~
II 1: ~
W
~

. 0

L

i=9

L

Door condition
ODen Close

~

~

~

~

~

~

m'

@~

@Y~

~ ~
171

1121

BUCKLE
H.

s I de

dIdI

B

j

(R.H.side
door harness)

B

Door condition
ODen Close

@D

R

@})
BODY
GROUND

.

0

~M18 fn.)
DI
~
~

m

R:~

-0..

(L.H.sIde
door harness)

~

11
12
L. H. SIDE
DOOR LATCH SWITCH

@ ii
@D(@@~

1

LAP BELT
(L.

~ FID
~

,m

11

~
R. H. SIDE
DOOR LATCH SWITCH

BODY GROUND

SWITCH
on

I y)

L. H. SI DE
FRONT
LI MIT
SWITCH

SBF784E

BF-35

AUTOMATIC SEAT BELT SYSTEM
Description
FUNCTION
Shoulder belt buckle is mainly operated while ignition switch is "ON".
Condition (A): Ignition switch is "ON".
When door is opened, shoulderbelt buckle is moved frontward and when pp,er
i~closed, buckle is moved
rearward.
Condition (B): Ignition switch is "OFF".
When door is opened, shoulder belt buckle is moved frontward. When the door is closed, buckle will
remain in this position.
IVolt-

1';;;
:;
0.

OFF

ON

ON

ON

ON

ON

ON

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

Door latch switch

OFF

ON

OFF

OFF

OFF

ON

ON

ON

OFF

OFF

OFF

OFF

ON

ON

ON

OFF

Front

OFF

OFF

OFF

ON

ON

ON

ON

OFF

OFF

ON

ON

ON

ON

ON

OFF

OFF

Rear limit switch

ON

ON

ON

ON

OFF

OFF

ON

ON

ON

ON

OFF

OFF

OFF

ON

ON

ON

Drive motor power
source for frontward

OV

OV

OV

OV

OV

12V

12V

OV

OV

OV

OV

OV

12V

12V

OV

OV

OV

OV

12V

12V

OV

OV

OV

OV

12V

12V

OV

OV

OV

OV

OV

OV

Stop

Stop

Start to
move

Moving

Stop

Start to
move

Mov ing

Stop

Start to
move

Moving

Stop

Stop

Start to
move

Moving

Stop

Stop

Front

Between
Front&

Rear

Between
Front &

Front

Between
Front &
Rear

Rear

Between
Front &

Front

Front

switch

limit switch

o!:

1
';;;

of output signal is approximate valueJ

OFF

Ignition

operation

:;0.
:;
0

Drivemotor power
source

for rearward

operation
Function
Shoulder
buckle

belt
Position

Front

Front

Rear

Rear

TIMER

Rear

Front

Rear

Rear

Rear

(Ignition switch either "ON" or "OFF")

If limit switch does not operate (when accomplishing frontward operation, front limit switch can not be
turned "OFF" or when accomplishing rearward operation, rear limit switch can not be turned "OFF"),
control unit will continue to supply power to drive motor for 15 secondsand control unit will stop supplying power.
QUICK WARNING

(Ignition switch "ON")

If front limit switch is not turned "OFF" after accomplishingfrontward operation, control unit will stop
supplying power 15 seconds later and warning lamp will flash and chime will operate rapidly for approximately

6

seconds.

REAR LOCK
If quick warning functions twice successivelywhile ignition switch is "ON", shoulder belt buckle will move
to rear position when the door is closed as normal but will remain in rear position even if door is opened.
This function is canceledwhen ignition switch is "OFF".

BF-36

AUTOMATIC SEAT BELT SYSTEM
Description

(Cont'd)

WARNING
Priority

Warning item

Ignition switch

Shoulder anchors

Indication of warning (Indicating time is approximate value.)

ON

are not at rear

Lamp

I

lock position.

Chime
I

OFF -* ON

I
Lamp
Chime

.
And,",

Lamp

n..

R'~I - _h"

Chime

t::

Within 6 sec.

2

ON

I Shoulder belts
are not fastened.

I

Ancho,
Lamp

R'~
ON
OFF

Chime

ON
OFF

Belts

Unfastened

I

Fastened

Lamp
Ch

'

100 sec.

I

ON
OFF
ON

.me
Belts

OFF
Unfastened
Fastened

Lamp

O~~

Chime
Belts

ON
OFF
Unfastened

Fin
3

I Driver side lap

OFF -* ON

belt is not
fastened.

6 sec.

Fasten~~.I~ec.
Lamp
Chime
Belts

~

Within 6 sec.

r-aSIenea

4

I Normal (All belts

OFF -* ON

Lamp

are fastened and
shoulder anchors
are in rear lock
..
position. )

Chime

ON
OFF
O~~

I

BF-37

6 sec.

AUTOMATIC SEAT BELT SYSTEM
NOTE

BF-38

TROUBLE DIAGNOSES
Contents
Symptom Chart
Preliminary Check

BF-40
BF-41

Main Power Supply and Ground Circuit Check

,

Harness Layout
Circuit Diagram for Quick Pin Point Check
Diagnostic Procedure 1
(Check motor circuit and stop signals.)
Diagnostic Procedure 2
(Check door switch circuit)
Diagnostic Procedure 3
(Check front limit switch circuit)
Diagnostic Procedure 4
(Check rear limit switch circuit)
Diagnostic Procedure 5
(Check shoulder belt switch circuit)
Diagnostic Procedure 6
(Check lap belt switch circuit)
Diagnostic Procedure 7
(Check warning chime circuit)
Diagnostic Procedure 8
(Check warning lamp circuit.)
Electrical Components Inspection

BF-45

BF-46
BF-48
BF-49
BF-52
BF-54
BF-56
.."..

BF-58
BF-60
BF-62
BF-63
BF-64

Since left and right component parts are basically the same, harness layout and methods for electronic
components inspection are shown for one side only.
Although methods for checking component parts on both sides are described in the flow chart, making it
easier to trouble-shoot, apply checking procedures to either side that have problems during trouble diagnoses. For those methods enclosed by double rectangulars,however,component parts on both sides must be
checked as problems occurring on either side cannot be easily determined by a symptom.

BF-39

TROUBLE DIAGNOSES

Symptom Chart
0

Motor

BF-64

0
0

BF-64

co

Shoulder

BF-64

:i
Ii

Door latch switch

0

BF-64

Rear limit switch

0

0

BF.64

Front limit switch

0

0

..
...
c:
..
c:

BF-65

Lap belt switch

0

E

BF-64

Motor

0

Shoulder belt buckle switch

0

Door latch switch

0

BF-64

Rear limit switch

0

0

BF-64

Front limit switch

0

0

BF-65

Warning chime

0

0

Warning lamp

0

0

c:
0
of;

co

a

0

belt buckle switch

0

0

0

0
0

0

=

R

8
BF-64

t..

iii

BF-64

-

"
-0

0;;;
:i
....i

0

.

0

0
0

0

0

0
0

0

BF-63

Procedure 8

0

BF-62

Procedure 7

0

BF-60

Procedure 6

0

BF-58

Procedure 5

0

BF-56

Procedure 4

0

0

BF.54

Procedure

3

0

0

BF-52

Procedure

2

BF-49

Procedure

1

BF-45

Procedure

2

BF-45

Procedure 1

BF-43

Procedure 2

BF-41

Procedure 1

'
f
;,
iu

e
a.

u
°ji;
0c:

i
i5

:D"E
.. "E o.><

a.;'G
c: 0.
-0.00

e o!::6
.><

.E

'f°

a.

e;,

iu
0

Q:

co
i
0.
..u

"c:
j!
..
a:

0

0
0

0
0

0

0

0

0

0
0
0

-8i
i
..E 1ii
u
E
.. 0co-0
0
o:;;;
c: "':>< 0.
02 c: u ...

0

Ia.
>CI)

1iiC
;, c:
....
.0..
co co° E

g-

0°-00

c:

zE

BF-40

0

£ ..

..c>-

.!!
'><-o

u co
;'-0
.0.... ..
a;:i
.c.
a: ai

..
"..
°

0

E

:J:. ...
0
CI)..Jc:

-.. c:

:>< 0

u..

.&11_
""
!11
.. c: ..

°
...:..
:2.. f
;,

000

...

EE

ij;'''- 0
.011"
... .. 11

-!..
.a..!
:De g
-0.."

3::
000

EE

...

g

....

!..

.. .

00.
'"
c:
of
co

.. u ;,
;:£...

0

.2..
-0
°
£ >

'" c:
.: 02
E0

...
u
05

'fROUBLE DIAGNOSES
Preliminary Check
PROCEDURE

1

Turn ignition switch and all other electrical switches
"OFF", and close door.

Disconnect negative cable from battery.

Open door.

Move shoulder belt buckle to center (not rear lock
position and not front stop position) by wrench
supplied in tool bag or equivalent.

I

Close door.

r
Connect battery cable.
STEP 1
Does shoulder belt buckle move frontwards?

Yes

No

I

Open door.

STEP 2

I

Go to Diagnostic Procedure 2.
(See page SF.52.)

No

Does shoulder belt buckle move frontwards?

(Go to @ on next page.)

Yes
Close door, and turn ignition switch "ON".
STEP 3
No
Does shoulder belt buckle move rearwards?
Yes
END

BF-41

Go to Diagnostic Procedure 4.
(See page SF-56.)

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

Turn ignition switch "ON".

STEP 4
Does shoulder belt buckle move rearwards?

Yes

No

Go to Diagnostic Procedure 2.
(See page BF-52.)

Close door.

...

STEP 5
Does shoulder belt buckle move rearwards?

No

Go to PROCEDURE 2 of Main
Power Supply and Ground
Circuit Check.

Yes

(See page BF-45.)
Then go to Diagnostic
Procedure 1.
(See page BF-49.)

Go to Diagnostic Procedure 3.
(See page BF-54.)

BF-42

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PROCEDURE

2

Fasten all seat belt and open both doors.

Turn ignition switch "ON".
STEP 1
Does warning chime sound for 6 seconds after
switch is turned on?

No

Go to Diagnostic Procedure 7.
(See page BF-62.)

Yes
STEP 2

No

Is warning lamp flashing now?
Yes

Go to Diagnostic Procedure 8.
(See page BF-63.)

Close both doors.
STEP 3
I

Is warning lamp flashing although shoulder belt
buckles reached rear lock position?
No

Yes

Go to Diagnostic Procedure 4.
(See page BF-56.)

Unfasten L.H. shoulder belt.

Does warning chime sound for 6 seconds and
warning lamp glow after belt is unfastened?
.

.

No

Go to Diagnostic Procedure 5.
(See page BF-58.)

Yes

Fasten L.H. shoulder belt.

Unfasten R.H. shoulder belt.
STEP 5
Does warning chime sound for 6 seconds and
warning lamp glow after belt is unfastened?
Yes

No

Fasten R.H. shoulder belt.

Unfasten L.H. lap belt, and turn ignition switch
"OFF".

(Go to @ on next page.)

Bf-43

Go to Diagnostic Procedure 5.
(See page BF-58.)

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

Turn ignition switch "ON".

Does warning chime sound and warning lamp glow
for 6 seconds after the switch is turned on?

.

No

Yes

END

BF-44

Go to Diagnostic Procedure 6.
(See page SF-60.)

TROUBLE DIAGNOSES

Main Power Supply and Ground Circuit Check
PROCEDURE

1

Main power supply
Battery voltage existence condition
RIB

W/L

-

SBF336E

Terminals
Ignition switch "ON"

Other than ignition
switch "ON"

@ - Ground

Yes

No

- Ground

Yes

Yes

Yes

Yes

Yes

Yes

@

<@)- Ground

@

- Ground

Ground circuit

i5~
I~I
~

Terminals

l~

~
B

C.U.
connectors

Continuity

- Ground

Yes

@ - Ground

Yes

@ - Ground

Yes

-=SBF337E

_T

IV [it

Terminal
L.H. side: ~ and @
R.H. side: @ and @

PROCEDURE

2

Power supply for motor drive
Terminals

~

C.U. 10-pin connector

Battery voltage
existence

L.H. side

<@)

- Ground

Yes

R.H. side

@

- Ground

Yes

Ground circuit for motor drive
-

Terminals

Continuity

L.H. side

@ - Ground

Yes

R.H. side

@ - Ground

Yes

B

SBF33BE

-=-

BF-45

TROUBLE DIAGNOSES

Harness Layout

m Room
lamp
harness

m
--------------------@
R.H. front
limit switch

@
Body
ground

I;]
@
r.
.

@

~

18 Warning
(without

lamp

Warning
chime

head-up

display)
Warning lamp
(with head-up display)

~

[!1
@Dl.H. door latch switch
J@])R.H.

door latch switch-

.

L

/~
i' \
@!I

B F -46

TROUBLE DIAGNOSES
Harness Layout (Cont'd)
Ii

\

SBF368E

BF-47

TROUBLE DIAGNOSES
Circuit Diagram for Quick Pin Point Check
I GNI TI ON SWITCH
ON or START

(WIth
head-up

d I sp lay)

@!

0~

SEAT

BELT
WARNING

(WI thout

head-up

LAMP

d I sp lay)

;

@

BREAKER

/

2]

[IJ
M

9 0

BELT

33

30

26

SEAT

CONTROL UNIT

'36

29

39

@
nlO1

44

.

4]
45

'0 HH

40

3 9 H3'

38
37

46

25

26

43

42

3]

36

32

35

I
11::0

-I

I ,1/);2

I

@

@

i

U

@

I/)

O:J

-m
I...J
.W
...Jm

0@

-:EI--

@

I/).II::

-

I

IO
.0
-10

1/)1--

@i)

@

OC

@)

:JO

@

:...J-

@I

Will
m.I
Q...

@

5d

@!D-::!:~

i

I/)

I0

WI-0«
-...J
I/)
.11::
IO
.0
11::0

@-::!:@Y

.11::
I«
.w
...JII::

I
11::0
WI-...J
:JI/)
0
IW

0@

WO
O:J

Ei

I/)...J

-m
I/)

.1-I...J
.W
!r:m

.>
.11::

...JO

I/)

I
0

I--

I--

W:E

@

0-...J
I/)

.11::
I«
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!r:1I::

I

I
0

I--

@

.Z
IO
.11::
-ILL

11lIM

0-

wO...J
@

I/)W

0-...J
W:E

@

I/).1--

-

(0

-

I--

Ei

IW
WO

I
0
I--

I
0

0
I--

-

CD @

51/)

I

@@

I

5...J :
G)
@

@Y @})

I
0
I-

I-.>
.11::
I/)W

11::0

@

I

-

w6
en:

WARNING

@

34

\5

52

CHIME

I

--

S@
51

AUTOMATIC

22

CIRCUIT

@

'

@!

0~

G)@

1/1 FUSE

FUSE

0
I--

@

(0

@

I--

:E
WO...J
1/)1-.Z
IO
.11::
II::LL

@!D-::!:~
SBF7B5E

BF-48

TROUBLE DIAGNOSES

_T

Fa

@p

C.U. 10-pin connector

LHo"iwl
~40

IU

~

tt4~
aH°Ho"d'

START

Fa
CHECK MOTOR CIRCUIT.
1) Disconnect 10-pin connector
from control unit.
2) Check continuity.

~'Gm

SBF339E

m
C.U. 10-pin connector

IU

R.H. side:

@

LG/S

(Go to @ on next page.)

@-@
@-@

R.H. side

Terminal
L.H. side: @

N.G.

Terminals
L.H. side

~
~

~

@p

Diagnostic Procedure 1

Continuity should exist.
O.K.

m

Does continuity exist?

Yes

(Go to @ on next page.)

Terminals

-

SBF340E

[!]I~

C.U.10-pin

connector

"IJ

i5~
Frontward
operation

L.H.side

@ - Ground

R.H. side

@

- Ground

No
[!]I
I

CHECK MOTOR OPERATION.
Check shoulder belt buckle
movement.

O.K.

(Go to @ on page SF-51.)

N.G.
Go to DRIVE MOTOR ASSEMSLY of Electrical Components
Inspection. (See page SF-64.)

Rearward
operation

.

LG/R

O.K.

Replace guide rail assembly.

Rearward
GIS operation
G/R

SBF341E

BF-49

N.G.
Replace drive motor assembly.

TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Cont'd)
1i]@P

~motor connector
Drive

C.U.

10-pin connector

L.H. side

@

Ii]
1) Disconnect connector from
drive motor assembly.
2) Check continuity.

N.G.

Repair harness.

Terminals
LG/R

LG/B

@-<@
@-@
@-@
@-<@

L.H. side
R.H. side

~
Drive
motorconnector

~c.u.
10-pin connector

R.H. side

~i5

Continuity should exist.

O.K.
Check drive motor harness for
open circuit.

Repair drive motor harness.

O.K.
G/R

Replace drive motor.
SBF342E

r.I_CT

ellU

~
~

-.Eer

~Drivemotor

fill
D

52
LG/B4~'

~

L.H.
side IV ~R.H. sidelll
52

D

tEJ

connector G/Bhi'

~

Drivemotor
connector

1) Disconnect connector from
drive motor assembly.
2) Does continuity exist in at
least one point?

Yes

Repair harness.
There will be incorrect grounding.

Terminals

@ - Ground

L.H. side
SBF343E

":"

<@ - Ground

-=-

@ - Ground

R.H. side

<@ - Ground

No
Check drive motor harness for
incorrect grounding.
O.K.

Replace drive motor assembly.

BF-50

N.G.
Repair drive motor harness.

TROUBLE DIAGNOSES

Ii <§p

_NEeT

C.U. 10-pin
connector

Eu

~

Terminal
l.H. side: @
RH. side: @
VIR

Diagnostic Procedure 1 (Cont'd)
@
I
Ii
CHECK STOP SIGNAL.
1) Moveshoulder belt buckle to
center (not rear lock position
and not front).
2) Check continuity.

N.G.

Go to Diagnostic Procedure 3
(See page BF-54.) and return to
next step.

Terminals

-=-

SBF344E

l.H. side

@ - Ground
@ - Ground

R.H. side

Continuity should exist.

[i'IRefer to figure [i'Ito move
shoulder belt buckle.
O.K.

III

N.G.

Go to Diagnostic Procedure 4
(See page BF-56.) and return to
next step.

1) Disconnect 16-pin connector
from control unit.
2) Check continuity.

Rearward
operation

LG/R

Terminals
RH. side

l.H. side

@

RH. side

@

- Ground
- Ground

Continuity should exist.

.

Rearward
operation

O.K.

Is this the second time?

Yes

. Replace control unit.
I

No
SBF341 E

III
~

Reinstall any part removed.

IJISCOIINEeT

C.U. 16-pin
connector

18
Go to PROCEDURE 1 (START)
of Preliminary Check.
(See page BF-41.)

Terminal
l. H. side: @
RH. side: @

-=

SBF345E

BF-51

TROUBLE DIAGNOSES

m

~

lu
_IECT

Diagnostic Procedure 2

~

~

C.U. 16-pin
connector

Terminal
L.H. side: @
RH. side: @

L

-=

SBF346E

(

START

m

r

)

CHECK DOOR SWITCH
CIRCUIT.
1) Disconnect 16-pin connector
from control unit.
2) Check continuity.

Ter-

Ii)~

C.U. 16-pin

connector



~

~

IIISCIIIIIECT

Door latch

switch connectorlU

I~R.H.side
L

rmJ

Door
condition

&

L

@Ground

Open

Yes

Close

No

RH.
side

@Ground

Open

Yes

Close

No

N.G.

N.G.

1) Disconnect door latch ~witch
connector.
2) Check continuity.

~
L.H.
side

R.H.
side

(Go to @ on next page.)

Continuity

L.H.
side

Ii)

nfFOil~

~

minals

O.K.

Repair harness.

Terminals

@-@
@ - Ground (eM§!>,€~J§»
@-@
@ - Ground (~,
€J]:»

Continuity should exist.

1
[;]

_IECT

12J

~
~

~

Ug~IJ~[;]
CQD)or <§9>
Doorlatchswitch
connectorConnector
L.H. side:<@)
R.H. side:@9:>

Harness color
L.H. side: R
R.H. side: L
SBF348E

O.K.

SBF347E

-::-

Yes

Does continuity exist?
Connector

Terminals

L.H. side

C!ill>

@ - Ground

RH. side



@ - Ground

Go to DOOR LATCHSWITCH
of Electrical Components
Inspection. (See page BF-64.)
.
N.G.

O.K.

Repair harness.
There will be incorrect grounding
between terminals @ and (j]) or
@ and (j]).

Reinstall any part removed.

Go to PROCEDURE 1 (START)
of Preliminary Check.
(See page BF-41.)

Check door latch switch harness
for open and short circuit.
.
O.K.
Replace door lock assembly.

BF-52

Repair door latch switch harness.

TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
@
1
-

Is this the second time?
No
Reinstall any part removed.

Go to PROCEDURE 1 (START)
of Preliminary Check.
(See page BF-41.)

SF-53

Yes
Replace control unit.

TROUBLE DIAGNOSES

m

_CT

Diagnostic Procedure 3

[it

,8:~

~C.U.10-pin
connector

WiV

Terminal
L.H. side: @
R.H. side: @

START

m

-=

SBF344E

Frontward
operation

Terminals

L.H.
side

LG/R

Shoulder
belt
.buckle
position

Continuity

At front

No

Not
at front

Yes

At front

No

Not
at front

Yes

@Ground

R.H.
side

Rearward
operation

@Grou nd

Ii)Refer to figure Ii) to move
shoulderbelt buckle.

R.H. side

N.G.

[!]

~
-¥~~NB

Rearward
operation

G/R
UW/L \:.J
<&1~vC.U. 10-pin

~

IE)

SBF341E
<@)Front
limit
switch
connector'

connector

<&1~1).
C.U. 10-pln

~m

~

Terminals

L.H.
side
R.H.
side

@-G)
)

Continuity should exist.

O.K.

~

switch

IIISQIIIIIECT

assembly,£o;\
connector Wis.J

I~J
SBF352E

[it

Terminals

[it
0

LlLillJ

~
=

[ill

fJ
~
LM

tfj
L

(Go to @ on next page.)

BF-56

Repair harness.

TROUBLE DIAGNOSES

DiagnosticProcedure4 (Cont'd)

Ii]
o

m

i5~

CIDor(§)

~3 Rear switch
assembly
connector

Connector
L.H. side: CID
R.H. side: (§)
Harness color
L.H. side: L/W
R.H. side: L/W

1

Ii]
Does continuity

----- Connector

LID

Yes

exist?
Terminals

L.H. side

CID

- Ground

R.H. side

CID

- Ground

Repair harness.
There will be incorrect grounding
between terminals @ and ~ or
@ and ~.

No
SBF353E

-=-

Go to REAR LIMIT SWITCH of
Electrical Components
Inspection. (See page BF-64.)

O.K. (Go to @ below.)

~
Check rear limit switch harness
for open or short circuit.

Repair rear limit switch harness.

O.K.

I

Replace rear switch assembly.

1
Is this the second time?
No
Reinstall any part removed.

Go to PROCEDURE 1 (STEP 3)
(See page BF-41.) or PROCEDURE 2 (STEP 3) (See page
BF-43.) of Preliminary Check.

BF-57

Replace control unit.

TROUBLE DIAGNOSES

-,

m

IV

~
C.U. 16-pin
connector

rw
~

Diagnostic Procedure 5

Terminal
@
l.H. si.de:
R.H.
side:

@

1

START

Y/B

m

[

.

, CHECK SHOULDER BELT
BUCKLE SWITCH CIRCUIT.
1) Disconnect 16-pin connector
from control unit.
-::-

SBF354E

Ii1 ~:!!>j) C.U. 10-pin connector

i5~

l.H. side

RH. side

Ter-Shoulder
minals

beit

Continuity

l.H.
side

@Ground

Fasten

Yes

Unfasten

No

R.H.
side

@-

Fasten

Yes

Ground

Unfasten

No

belt buckle is

not rear lock position, do as
figure Ii1 to move it to rear.

SBF355E

N.G.

[i

1) Disconnect connector from
rear switch assembly.
2) Check continuity.

~

Repair harness.

@-~

@- Ground (~,
~)
@-~
@ - Ground ~,

RH.
side

CID Rear switch
assembly
connector

N.G.

Terminals

l.H.
side

C.U. 16-pin
connector

(Go to @ on next page.)

2) Check continuity when
shoulder belt buckle is at
rear lock position.

[;) If shoulder

~

O.K.

~)

Continuityshouldexist.
O.K.

Ii]

Yes

Does continuity exist?

---

ConnectorTerminals

l.H. side

,

1I8v ~

Diagnostic Procedure 6

~

~C.U.16-pin
connector

START

(

m

-=

SBF358E

I

CHECK

LAP BELT BUCKLE

SWITCH

CIRCUIT

Lap

~
c§V

~

C.U. 16-pin

S8"S9'

[!]

~
1180

DISCONNECT

@ - Ground

~
18

connector

belt

on next

page.)

Continuity

Lap belt
Fasten

No

Unfasten

Yes

~~~

N.G.

Ii]

[]l]

N.G.

L/R

~
l..m

@

connector
~ l.oIIIIB
~;..h
boo".
E"V ~1J'
fQ;,j

L/R

~

(Go to

(L.H.only).

~E§)

~

O.K.

1) Disconnect 16-pin connector
from control unit.
2) Check continuity.
Terminals

[;)i5

)

1) Disconnect lap belt switch
connector.

Repair harness.

2) Check continuity.
Terminals
@-@
@-Ground~.~)

Lap belt switch

connector

~

Continuity should exist.
L/R

[ill

O.K.

[!]

Does continuity exist?

Yes

Terminals

Repair harness.
There will be incorrect grounding.

@ - Ground
SBF360E

-=-

No
Go to LAP

SWITCH of

BELT

BUCKLE

Electrical

O.K.
(Go to @ on next page.)

Com-

ponents Inspection.

(See page BF-65.)
N.G.

Check lap belt buckle switch
harness for open and short
circuit.
O.K.

Replace shoulder belt
buckle assembly.

BF-60

N.G.

Repair lap belt buckle switch
harness.

TROUBLE DIAGNOSES
Diagnostic Procedure 6 (Cont'd)

T
Is this the second time?

Replace control unit.

No
Reinstall any part removed.

Go to PROCEDURE 2 (STEP 6)
of Preliminary Check.
(See page BF-44.)

../

BF-61

TROUBLE DIAGNOSES

Diagnostic Procedure 7

m <&IT9P
C.U. 16-pin connector

iS~

START
m
I

CHECK WARNING CHIME
CIRCUIT.
1) Disconnect 16-pin connector
from control unit.
2) Check warning chime.

~GM

1

N~"
Ground

intermittently.

-=-

SBF361E

Terminals
@)Warnlng
chime
connector

I!J <&;li)pC.U.16.pin
connector

ijril

~

@

ij[il

m
GM

GM

(Go to @ below.)

Result

Ground
interI Sound
mittently.

N.G.

I!J

N.G.

1) Disconnect connector from
warning chime.
2) Check continuity.

Repair harness.

Terminals

SBF362E

[!]

-Ground

Method

O.K.

@-@

is [iI

Continuity should exist.

O.K.

[!]

Does continuity exist?

[Q]

Ves

Repair harness.
There will be incorrect grounding.

Terminals
@ -Ground

SBF363E

Ii]

-=

No

Ii]

Check battery voltage existence.

is~

N.G.I Repairharness.
For details, refer to POWER
SUPPLV ROUTING in EL
section.

Terminals

-

@ Ground
Battery voltage should exist.

O.K.
Go to WARNINGCHIMEof
Electrical Components Inspection. (See page BF-65.)
SBF364E

-=

O.K. r.
Is this the second time?

No
Reinstall any part removed.

Go to PROCEDURE2 (START)
of Preliminary Check.
(See page BF-43.)

BF-62

N.G.
Replace warning chime.

r-@
Replace control unit.

TROUBLE DIAGNOSES

m

Diagnostic Procedure 8

DISCOIINECT

~
~

E~,°

QiljQv C.U. 16-pin
connector

I~
Ii)

~

C.U. 16-pin connector

Combination
meter connector

ffiJl f

r

CHECK WARNING LAMP
CIRCUIT.
1) Disconnect 16-pin connector
from control unit.
2) Check warning lamp.

T'G

SBF365E

)

START

C
m

Terminals

Resu It

@ - Ground

Glow

O.K.
(Go to @ below.)

N.G.

Ii)

N.G.

1) Disconnect connector from
combination meter.

i5

Repair harness.
[

2) Check continuity.,

Y/G

Terminals

:

center

SBF1 96E

Spacer mounting
portion
(Spacer should be installed
at slit portion of dam rubber.)

SBF198E

Fastener

,/1
(

~
"-

/

Panel

Double-faced
adhesive tape

SBF197E

~~~

Apply primer A.

Install molding fastener.
When installing it, heat body panel and
fastener to approx. 30 to 40°C (86 to
104°F).
.
.
upper & side molding
fastener

a

~

~m
rubber
joint portion

Unit: mm (in)

i~OO

vehicle
center

'

of glass
SBF719C

CAUTION:
Allow primers to dry for 10 to 15
minutes before proceeding to the next
step.

A

B

BF- 70

WINDSHIELD AND WINDOWS
Windshield (Cont' d)
@

1
Apply sealant evenly.

Apply primer E.

Morethan
12 (0.471

Glass
Unit: mm (in)

SBF038B

SBF199E

CAUTION:
Windshield glass should be installed
within 15 minu18sof applying 88alant
88alant starts to harden 15 minu18l
at18r it is applied.

CAUTION:
Allow primers to dry for 10 to 15
minute, before proceeding to the next
step.

Set glass in position and
press glass lightly and evenly.

Apply sealant additionally to Io_r portion of gland make it uniform as shown below:
Glass

SBF720C

Check for water leakage.

CAUTION:
For sealant drying time, refer to
"Drying Time for Sealant".

Apply sealant to upper & side molding
fixing portion.

Install moldings.
(For details, refer to "Exterior".)

BF-71

CAUTION:
Molding must be installed securely 10
that it is in position and I88V8Ino gap.

WINDSHIELD AND WINDOWS

Back Window-Coupe

.

.
.
.

Construction and removal/reinstallation methods of back window are basically the same as those of
windshield.
For details of service procedures, refer to "Windshield".
The difference between windshield and back window is as follows:
For sealant drying period, refer to "Drying Time for Sealant",
For details of moldings, refer to "Exterior",
Sealant quantity

",(/

m

~-

--

"

'I
:

I

II
1I
II
II
I I
II
II
1I
I I

~

III ,

'- ---,----------------Dam rubber and spacer

m

Ii)

~N_'
More
than

riJ Install molding

Vehicle

~

More than
12 (0,471

Ii]

Double-faced
adhesive tape
I
Spacer

fastener,
When installing it, heat body panel and
fastener to approx. 30 to 40°C (86 to
104° F).

420i
(16,54)

7 (0281

Unit: mm (in)

Unit: mm (in)

Ii] double-faced
Install dam rubber and spacers with
adhesive tape. (Body side)

Upper and side portion

Lower portion

Vehicle
center

Lbem rubber
joint portion

SBF200E

BF- 72

WINDSHIELD AND WINDOWS
Back Door Window-Fastback

.
.
.
.

Construction and removal/reinstallation method of back door window are basically the same as those of
windshield.
Major differences are that sealant & dam rubber are instailed to back door panel instead of glass surface.
Spacer position is also changed. Moreover, there are locating pins in lower portion of glass. For details,
refer to following figure.
For sealant drying period, refer to "Drying Time for Sealant".
For details of moldings, refer to "Exterior",

Locating
pin
(Left and right) 1m

xx:

Spacer

.:

Locatingpin

0:

Molding clip

Lower molding

and spacer (;J

(;J

1m

Back door glass

Ii]

Molding
When
panel
30 to

fastener
installing it, heat body
& fastener to approx.
40°C (86 to 104°FI.

[!)

Back door upper molding
Back door glass

Spacer
Unit: mm (in)

Backdoor side
~mOlding//

~u_~

Morethan
12 (0.47) ~n

0

=
Backdoor glass
7 (0,28)
Welt

Back door panel
Unit: mm (in)

Unit: mm (in)

BF- 73

SBF201E

WINDSHIELD AND WINDOWS
Side Window
Side window is a molded type. During;removal or installation,
observe the following instructions.
1. Cut sealant in the same manner as that outlined under
"Windshield.".
2. Be careful not to scratch molding when cutting sealant. If
molding is scratched, repair.
3. Remove clips and locating pins which have been exposed
from vehicle body.

Wire

Side
window

Body
panel

Wire

SBF376E

FASTBACK
Sealant

portion

I§)

Double-faced
adhesive tape

m

More than
7 (0.28)

I§)

(;]
Morethan
'12 (0.47)
Body panel
Body panel
More than
7 (0.28)

Unit: mm (in)

Unit: mm (in)

BF- 74

Unit: mm (in)

J
SBF203E

WINDSHIELD AND WINDOWS
Side Window (Cont' d)
COUPE

"

Seelent portion

Clip

E1

I]

Ii]

[I

Ii]

Dam rubber

30
(1.181

Clip
(Bonded to glassl

Unit: mm (in)

Sealant quantity

I]

Morethen
710.281

Unit: mm (in)

SBF202E

BF- 75

WINDSHIELD

AND WINDOWS

Drying Time for Sealant
\
Reference: Time required for sealant to dry to desired hardness.
Unit: days
90

50

25

40 (104)

1.5

2.5

5.0

25 (77)

2.5

4.0

7.5

5 (41)

5.0

13.0

20.5

'c (oF)

CAUTION:
Advise the user of the fact that vehicle should not be driven on
rough roads or surfaces until sealant has properly vulcanized.

Repairing Water leaks for Windshield and
Back Window (Coupe)/Back Door Window
(Fastback)
leaks can be repaired without removing and reinstalling glass.
If water is leaking between caulking material and body or between glass and caulking material, determine the
extent of the leak by applying water while pushing glass outward.
To stop the leak, apply primer and then sealant to the leak point.

.~

.-Flat stick

Apply sealant.

..,.

T,;m~

,V,,:
""

POlysulphide

or polyurethane

..

4'

1!f!/

4~60
/~
Work into joints.

sealant

SBF543B

Afterwards, install molding securely.

BF-76

MIRROR
Door Mirror

~
('

)

Fa

Mirror removal Fa
Mirror
SBF188E

WIRING DIAGRAM
I GNI TI ON SWITCH
ACC or ON

@

FUSE BLOCK

ITIIJI]]]

~..

(Refer
to "POWER
SUPPLY ROUTING"
In EL sect
ion. )
Y/B
PU/W
L/B

@

R. H. SIDE
DOOR MIRROR

@

II

@
Y/B
,-PyU::
Pu/w====-.rL/B
L/B
(Door

harness

Mirror
operat Ing
dl rectlon

~ Leftward

i

~

Rightward

R. H. )

L/W

(Main
harness)

~

III'
...J

~'"

~, J

@

_JlI>O:

'" J
>->

~~

Y/L
PU/W
L/R

~~15~~1
MIRROR

L. H. SIDE
DOOR MIRROR

@

II

@

~

~ Leftward
i Rightward
Mirror
operat Ing
dl rect Ion

~ Downward
i Upward

SW. CHANGE
OVER SW.

(1)A~
~~

6
7

DOOR MIRROR

,-

Y/L
PyU:;::
PU/W===-.sL/R
L/R
(Ooor
harness
L. H. )

Mirror
ope rat Ing
direct Ion

SWITCH

BODY GROUND
SBF335E

BF-77

REAR COMBINATION LAMP

.

Rear combination lamps are installed with nuts and butyl sealant.

~

Installation

Removal

Butyl seal

.

Warmup lamp assemblyarea to a
tem~ratu~ of a little below 60°C (140°F).

.
.

Apply butyl seal evenlyas it tends to
become thin in the corners.
Warmup lamp assemblyarea to a
tem~rature of a little below 60°C (140°F).
SBF189E

BF-78

FRONT AND REAR AIR SPOILER

.
.

When installing, make sure that there are not gaps or waves at ends of air spoiler.
Before installing spoiler, clean and remove oil from surface where spoiler will be mounted.
/

FRONT AIR SPOILER

r;7~~~

'----.

~
Double-faced
adhesive tape

!

'-~

r;1;:;;J/
~~~_/-o

~/~

I~J
,

,

L

.

~"'" ""'
I

r;-r r-.~

W~-

Double-faced
adhesive tape
SBF190E

REAR AIR SPOILER - Fastback

SBF191E

BF- 79

BODY ALIGNMENT

.
.
.
.

.
.

All dimensions indicated in figures are actual ones.
When a tram tracking gauge is used, adjust both pointers to equal length and check the/pointers and
gauge itself to make sure there is no free play.
When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
Measurements should be taken at the center of the mounting holes.
An asterisk (*) following the value at the measuring point indicates that the measuring point on the other
side is symmetrically the same value.
The coordinates of the measurement points are the distances measured from the standard line of "X",
"Y" and "Z".
"V"

"X"

@)

@

(:J

@

Q

=JQ
"Z"
"X"

"Z"
I-)

... I ...

1+1

''V''

@:

L.H.side

@:

R.H. side

"X" : Vehicle center
"V" : Center line of front axle
"Z" : Imaginary base line
[200 mm below datum line
I"OZ" at design plan)]

Engine Compartment
MEASUREMENT

Unit: mm

SBF193E

BF-80

BODY ALIGNMENT

Engine Compartment (Cont' d)
MEASUREMENT

POINTS

Unit: mm

I'

SBF223E

Front side member

Cowl top side

"
'

'CID1
()

<::)

.

CJ

7

SBF220E

SBF221E

Radiator core side

SBF222E

SF-81

~

()

~

<)

6dia.~
<')

()

()

SBF224E

SBF225E

BODY ALIGNMENT

Underbody
MEASUREMENT

~1J

E
E
...
'c

:J

8

N

*

~
...

cq.~
1

... 'It.
..., *

i
* *
coM
... GI
'It M
1

:2
OROIL - For NVR 140S (ATSUGI make)
COMPRESSOR- Model NVR 140S (ATSUGI make)
" . . . .. .. . .. .. . .. . .. .. .

AIC ELECTRICAL CIRCUIT

HAHAHAHA-

2
5
7
9

HA-12
HA-13

HA-14
HA-15
HA-17
HA-24
HA-25
HA-28

HA-33

HA-35

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-40

AIC COMPONENT LAYOUT
TROUBLE DIAGNOSES

HA-42
HA-44

SERVICE DATA AND SPECIFICATIONS(S.D.S.). . . . . . . . . . . . . . . . . . . . . . . .. . . . . .

HA-73

When you read wiring diagrams:
Read GI section, "HOW TO READ WIRING DIAGRAMS".
See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
Whenyou perform trouble diagnoses,read GI section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES".

.

.

mil

AIR FLOW AND COMPONENT LAYOUT
Air Flow
@

if

@

~

Floor and defroster

~~~
0123~1

~

if

10

.'"";'

@

To floor

CD To ventilator

if

Bi-Ievel

'O~~~
~..~

if

@

To defroster

CD To ventilator

.Ie

@

...

To floor
:>

: Airpassedthroughheatercore

<17181
MODE
DOOR
MOTOR

f@;1

,

From
.
I I I umInat Ion
system
.

{

-~

RHA378A

This push control system operates the intake and mode door motors to activate their corresponding doors.

SWITCHES AND THEIR CONTROL
"

FUNCTIONS

I

Indicator illuminates

AIC I

I 0

I

- ..

I

I 0

......

I

I

-fJ

AIC
-

...

...

Q

..;

I

... J
......

.
...-..

I

Air outlet

Intake air

I

I

I

I 0

I

I

I

I

I

B/L

I

I

I

I 0

I

I

I

I

FOOT

I

I

I

I

I

I

I

I

F/D

I

FRE

DEF

I

FRE

I

I

I

I

I

I

Compressor

ON*1

I

0

0
I

*1: Compressor is operated by thermo control amp.
.

I

*2: It dependson modeswitchposition.

HA-7

b:2: --------I.

.REC

I

ON*1

DESCRIPTION

-

Push Control

Intake Door Motor
The intake door motor is installed on the front portion of the
intake unit. Using a rod and link it opens and closes the intake
door.
When the REC switch is ON (OFF), the ground line of the intake
door motor is switched from terminal @ to @ (@ to @). This
causes the motor to start because the position switch contacts
built into it are set to the current flow position. The contacts
turn along with the motor. When they reach the non-current
flow position, the motor will stop. The motor always turl)S in the
same direction.

-

~I

MP---1
-

~
To push
control.

door

llntake
motor

{
RHA379A

Mode Door Motor
The mode door motor is located on the left side of the heater unit.
Through the side link it opens and closes the vent, foot and
defroster door.
When one mode switch is pushed, the position switch built into it
reads the corresponding mode to determine the direction of motor
rotation. As soon as the desired mode is set, the position switch
stops the motor.
Mode door motor
12216151413~111><17181

*: Current flows as
VENT indicated by the
arrow, motor
actuates as indicated by the words.
1

To
push
control

Terminal No.

Mode door motor
Mode door
9peration

Direction
of linkage
rotation

(j)

@

8

8

Stop

Stop

8

EB

VENT--DEF

Clockwise

EB

8

DEF --VENT

Counterclockwise

RHA380A

HA-8

PUSH CONTROL UNIT

~gj" fR92~1

Removal and Installation
1. Remove cluster lid C.

~

BB8
0,

/

,

Cluster lid C

\/

RHA384A

2.
Push
If control

asse'mbly
)U[f

Remove

audio

(radio).

3. Remove four screws of push control unit.
4. Remove temperature control cable.
5. Disconnect push control unit harness connectors.
6. Remove push control unit.
7. Installation is in the reverse order of removal.
Refer to Control Cable Adjustment for temperature control
cable.

===1,

(

Overhaul

-

Push control unit assembly

i

Co""o'
"..~

Control knob

1- -

',-

"-

1/'1
v'
~
~~
~

Control

box
'",,-- Finisher
plate

!

'/L

J

Coa,ro' ,,,...

A
,~84

'\

L E-ring

Temperature control cable

L

0

Temperaturecontrollever

Diode Temperature control lever assembly

RHA386A

HA-9

PUSH CONTROL UNIT

Overhaul -

Push control unit assembly(Cont'd)

1. Remove control knobs.
Wrap knobs with a cloth and pull in direction indicated by arrow
as shown in figure at left. Be careful not to scratch knobs during
removal.

2. Disconnect illumination harness connectors.

Small flat-bladed
,

screwdriver

:J~

Illumination
harness

3. Remove control base.
Undo hook at each end of control box and remove control
base from control box by moving it in direction indicated by
arrow.

4. Remove fan switch.

"-

Smail flat-b 'aded"<)
screwdrive!.
Control base
.

~

~

AHA390A

5. Remove illumination bulb.

HA-10

PUSH CONTROL UNIT

Overhaul -

Push control unit assembly(Cont'd)

6. Remove control knobs.
Wrap finisher with a cloth and remove knobs using pliers or .
similar tool. Be careful not to scratch finisher's surface.
7. Re ove control case.
8. Rem ve illumination plate.
Be care ul not to scratch control amp. when removing illumination plat "
.
9. Remov finisher plate.
10. Remov control amp.
Be careful not to damage substrate when removing,
'11. Discon -ect temperature control cable.
12. Install tion is in reverse order of removal.

..

-.

"
\

'"

,

~

HA-11

,.,..

HEATER ELECTRICAL CIRCUIT
~

Wiring Diagram
I GNIT ION SWITCH
ACC or ON

BLOWER
MOTOR

~
@)~

L/R
L/R
L/OR

Iii

@

, 0::,
..J ..J
1J

FUSE BLOCK
(Refer to "POWER
SUPPLY ROUTING"
in EL section.)
MODE

DOOR

MOTOR

G/Y

L/~
L/W
L/R
L/Y
L/OR
B

li)

V
B/L
FOOT
F/D
DEF

0

i

@

UI
Q)

cc

.- L

alai
5.£:

INTAKE
DOOR MOTOR
G/Y
G/B
L/OR

j
0

@

/

@)
To A/C system

G/Y
R/Y
-LG
LG/B
L/OR
G/Y
G/B
R/L

[

- B
- G
L/Y
L/W
- L
L/B
L/R
L/OR

~1J0::>-II>
~~~~~II>
1J

0::

>-11>

""
..J..J..J..J

@lffiJ

[]

RESISTOR

o~J

(Subharness)

@)~~~
~~~
'" OFF
4
25
26
27
23
28
21
20
1
If

1

I LLUMI

2

1314
1211
169
815
.17
7
65
43
2 I
8
19
20
21

~

PUSH
CONTROL
UNIT

3

4
From

illumination

} system
FAN
SWITCH
)l
NA TI ON

II>

@)~(@)
BODY GROUND
RHA392A

HA-12

PRECAUTIONS
WARNING:

.

Always wear eye protection
system.

when working around the

.

Always be careful that refrigerant does not come in

.
.

contact with your skin.
Keep refrigerant containers stored below 40°C (104°F) and
never drop them from high places.
Work in well-ventilated area because refrigerant gas
evaporates quickly and breathing may become difficult due
to lack of oxygen.

. Keep refrigerantaway from open flames because poisonous gas will be produced if it burns.

.

.
.
.

Do not increase can temperature beyond 40°C (104°F) in
charging.
Do not heat refrigerant can with an open flame. There is a
danger that can will explode.

CAUTION:

Do not use steam to clean surface of condenser or
evaporator. Be sure to use cold water or compressed air.
Compressed air must never be used to clean a dirty line.
Clean with refrigerant gas.

. Do not use manifoldgauge whose press point shape Is
different from that shown. Otherwise, insufficient evacuation
may occur.

N.G. \3

SHA919A

.
.

Do not over-tighten service valve cap.
Do not allow refrigerant to rush out. Otherwise, compressor oil will be discharged along with refrigerant.

HA-13

PRECAUTIONS FOR REFRIGERANT CONNECTION
WARNING:

Gradually loosen discharge side hose fitting, and remove It
after remaining pressure has been released.
CAUTION:

When replacing or ,cleaning refrigerant
observe the following.

.

cycle components,

Do not leave compressor on its side or upside down for
more than 10 minutes, as compressor
pressure chamber.

011 will enter low

. Whenconnectingtubes, always use a torque wrench.
SHA896A

.

After disconnecting tubes, plug all openings Immediately
to prevent entrance of dirt and moisture.

Plug
SHA058

. Alwaysreplace used O-rings.
Apply

o,rin~

not apply

oom".~,oil.w.,nw,

011.

N.G.

.
.

When connecting tube, apply compressor oil to portions
shown in illustration. Be careful not to apply 011 to
threaded portion.
O-ring must be closely attached to Inflated portion of tube.

N.G.
Inflated

portion

O.K.
SHA897A

. After inserting tube into union until O-ring is no longer

~

unlo@

visible, tighten nut to specified torque.

.
No'

~~~
~
D

After connecting line, conduct leak test and make sure
that there is no leakage from connections. When the gas
leaking point is found, disconnect that line and replace the
O-ring. Then tighten connections of seal seat to the
specified torque.

&

I~

~

~4)
SHA898A

HA-14

PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
KV998VROO1
(

-

)

Clutch disc puller

KV99231010
(

-

)

Clutch disc wrench

KV99235160
(J29751 )
Nut wrench

~

Description

~

Removing clutch disc

~

Removing shaft nut and clutch disc

Removing lock nut

\\Y

HA-15

PREPARATION
SERVICE TOOLS
Tool name

.0

Description

Manifold gauge

.

Charging hose

Charge valve

Thermometer

"
Dischargingand charging refrigerant

.;

Discharging, evacuating and checking
refrigerant

Discharging and charging refrigerant

Checking temperature

C'-

-3

Vacuum pump

Electric leak detector

Evacuating refrigerant

Nomineillftlitivity:
1..25. '0.53.""
UII

Checking refrigerant leaks

..

HA-16

DISCHARGING, EVACUATING, CHARGING AND CHECKING

In service AIC system

I

*1
When it is necessary to replace
pa rts

When it is not necessary to
replace parts

+

+

Check the spot where malfunction occurs.

Check the spot where
refrigerant leaks.

Point-'
Repair.

Discharging
I

i.
Replace

I

t
Add refrigerant

parts.

-

I

I

I
New AIC system

J

I

Point-2
Evacuating
Run pump for over 5 minutes.
Point-g
!
Checking airtightness
O.K.

*2

Once evacuating

I

N.G.

Point-4
Repair.

Twice evacuating

On condition that pump operates
over -98.6 kPa (-740 mmHg,
-29.13 inHg) and with low
humidity on a clear day.
Point-5

I

On condition that pump operates
below -98.6 kPa (-740 mmHg,
-29.13 inHg) and with high
humidity on a rainy day.

!

Point-6
Charging

Evacuating

Open high-pressure valve of manifold gauge and charge refrigerant
into system. When low-pressure
gauge reading is 98 kPa (1.0
kg/cm2 , 14 psi), completely
close high-pressure valve of manifold gauge and stop charging.

Run pump for over 20 minutes.
,

Point-3

N.G.
Checking airtightness

Point-5

1 O.K.
Evacuating

Run pump for over 20 minutes.
I

*1: Depending on the det
*2: Working operation dep
pump and the weather.
When servicing AIC sys
done under any condition.

.

In

Point-7

Charging
Checkingrefrigerantleaks

l O.K.
Checkoperationof AICsystem.

HA-17

I

N.G.

I

DISCHARGING, EVACUATING, CHARGING AND CHECKING
To high-pressure
service valve

To low-pressure
service valve

Point-1
Discharging

I

\

I

Slowly open the valves to discharge only refrigerant. If they are
opened quickly, compressor oil will also be discharged.

.
SHA240B

.

To high-pressure
service valve

To low-pressure
service valve

.

Low

~I

.
-

Vacuum

-,

Elevation
m (ft)

pump

SHA241 B

Vacuum of system*
kPa (mmHg, inHg)

0 (0)

101.3 (760,29.92)

300 (1,000)

98.0 (735,28.94)

600 (2,000)

94.61710,27.95)

900 (3,000)

91.3 (685,26.97)

Point-21

I

Evacuating the System
1. Start pump, then open both valves and run pump for over 5
minutes.
2. When low gauge has reached approx. 98.6 to 101.3 kPa (740
to 760 mmHg, 29.13 to 29.92 inHg), completely close both
valves of gauge and stop vacuum pump.
a. The low-pressure gauge reads lower by 3.3 kPa (25 mmHg,
0.98 inHg) per 300 m (1,000 ft) elevation. Perform evacuation according to the following table.
b. The rate ascension of the low-pressure gauge should be
less than 3.3 kPa (25 mmHg, 0.98 inHg) in 5 minutes.

*: Values show reading of the low-pressure gauge.

Point-3
Checking Airtightness
I

I

1. Close both low and high-pressure valves and leave them
unattended for approx. 5 to 10 minutes.
2. Make sure the pointer of the low-pressure gauge does not
deflect toward the "0" direction.
3. If the pointer deflects, gas leakage is present. Repair as
outlined under POint-41.
I

I

Point-4

I

Repair
If a problem is noticed under IPoint-31 above, locate and repair
the leaking point using the following table as a guide.
Leak at/around pipe connection

. a-ring fouled, damaged or
deformed
. Oil not applied to pipe connections during installation
. Pipe connections not properly
tightened (too tight or too loose)

HA-18

Leak at/around gauge manifold

.
.
.
.

Malfunctioning charging hose
Gauge improperly installed
Malfunctioning valve
Malfunctioning packing, etc.

DISCHARGING, EVACUATING, CHARGING AND CHECKING

.

To low-pressure
service valve

To high-pressure
service valve

.

~I:

10

.

='

I

pOint-51

Evacuating the System
1. Close manifold gauge valve securely and disconnect charging hose from refrigerant can.
2. Connect center charging hose to vacuum pump.
3. Start pump, then open both valves and run pump for over 20
minutes.

)

Vacuum pump

SHA241B

I Point-61

fU

Charging

~

1. Close manifold gauge valves securely and disconnect
charging hose from vacuum pump.
2. Purge air from center charging hose.
1) Connect center charging hose to refrigerant can through
charge valve.
2) Break seal of refrigerant can and purge air.

Close

Close

SHA242B

To low-pressure
service valve

.

To high-pressure

service valve

3. Charge refrigerant into system.
WARNING:

Ensure that engine is off.
1) Open high-pressure valve of manifold gauge and charge
refrigerant into system.
Open

LR~
RHA278
CAUTION:
To low-pressure
service valve

To high-pressure
service valve

~

If charging liquefied refrigerant into the system with the can
turned upside down to reduce charging time, charge it only
through high-pressure (discharge) service valve. After charging, the compressor should always be turned several times
manually.
2) When low-pressure gauge reading is 98 kPa (1.0 kg/cm2, 14
psi), completely close high-pressure valve of manifold gauge
and stop charging.

SHA244B

HA-19

DISCHARGING, EVACUATING, CHARGING AND CHECKING
Run engine at idll
(Below 1,500 rpml
To low-pressure
service valve
lI\

.

Turn
In or out

SHA245B

e

IL~ n ~
#>~fr

-..

Point-71
Charging

I

To high-pressure
service valve

Ii:) Close
H.h

II

Fan lever mode and
temperature dial:
Maximum cold and speed

1. Open manifold gauge low-pressure valve and charge refrigerant into system.
WARNING:
Ensure that engine is off.
2. When refrigerant charging speed slows down, start engine air conditioning system ON, maximum cold temperature set,
maximum blower speed set, can in upright position.
Monitor sight glass. Charge is complete when sight glass is
clear.
Cycling clutch systems will produce bubbles in sight glass
when clutch engages. Therefore, allow 5 seconds after clutch
engages to determine if bubbles continue, and, if so, add
refrigerant to clear sight glass.
WARNING:
Never charge refrigerant through high-pressure side (discharge
side) of system since this will force refrigerant back into
refrigerant can and it may explode.
3. Charge refrigerant while controlling low-pressure gauge
reading at 275 kPa (2.8 kg/cm2,40 psi) or less by turning in
or out low-pressure valve of manifold gauge.
Be sure to purge air from charging hose when replacing
can with a new one.

.

4. Charge the specified amount of refrigerant into system by
weighing charged refrigerant with scale. Overcharging will
cause discharge pressure to rise.
Refrigerant amount:
0.9 - 1.0 kg (2.0 - 2.2 Ib)

RHA504

HA-20

DISCHARGING, EVACUATING, CHARGING AND CHECKING

IPoint-71
Charging (Cont' d)
The state of the bubbles in the sight glass can only be used for
checking whether the amount of charged refrigerant is small or
not. The amount of charged refrigerant should be correctly
judged by means of the discharge pressure.
5. After charging, be sure to install valve cap on service valve.
6. Confirm that there are no leaks in system by checking with a
leak detector.

.

When refrigerant charging is performed with a charging cylinder,
charging station, or automatic charging equipment with engine
off, charge only through high pressure side. After specified
refrigerant amount has entered the system, close high-pressure
valve on gauge set. Start engine, return to idle speed, operate
AIC at maximum temperature setting, high blower. Observe
sight glass to confirm complete charge.
Overcharging will result in increased high pressures, and reduced performance.

HA-21

DISCHARGING,

EVACUATING, CHARGING AND CHECKING

Checking Refrigerant level
CONDITION
Door window:
A/C switch:
TEMP. lever position:
FAN lever position:
Check sight glass after a
minutes.

.
.
.
.
.

Almost

no refrigerant

Insufficient

Open
ON
Max. COLD
4
lapse of about

Suitable

five

Too much refrigerant

Check item
Temperature
of highpressure and lowpressure lines.

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 al)d something
like mist will flow when
refrigerant is nearly gone.

The bubbles are seen
at intervals of 1 - 2
seco nd s.

AImost transparent.
Bubbles may appear when
engine speed is raised and
lowered.

No bubbles can be seen.

No clear difference exists between these two conditions.

AC256

Pressure

Repair.

a.

of system.

High-pressure side is abnormally low.

Stop compressor immediately and conduct
an overall check.

AC257

Both pressures on high
and low-pressure sides are
slightly low.

AC258

Both pressures on high
and low-pressu re sides are
normal.

Check for gas leakage, repair as required, replenish
and charge system.

The bubbles seen through the sight glass are
influenced by the ambient temperature. Since
the bubbles are hard to show up in comparatively low temperatures below 20° C (68° F), it
is possible that a slightly larger amount of refrigerant would be filled, if supplied according
to the sight glass. Recheck the amount when it

HA-22

Both pressures on high
and low-pressure sides are
abnormally

high.

Discharge refrigerant from
service valve of lowpressure side.

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 appear even if the amount
or refrigerant is normal. In this case, the outlet
side pipe of ,~he receiver drier becomes considerably

cold. '~

DISCHARGING, EVACUATING, CHARGING AND CHECKING
Checking Refrigerant Leaks
ELECTRIC LEA~ DETECTOR
The leak detector is a delicate device that detects small
amounts of halogen.
To use the device properly, read the manufacturer's manuals.
Also perform the specified maintenance and inspections.

SHA733A

GENERAL PRECAUTIONS FOR HANDLING LEAK
DETECTOR
Place the probe on connection fitting and wait for 5 seconds or
more.
To check cooling unit, wait for 10 seconds or more.
If a leak is detected, keep the probe as still as possible for one
more minute.

UNION TYPE

RHA279

When testing single-bolt flange, place
opposite side of the fitting.

PLATE TYPE

the probe on the

~~L

RHA280

MEASUREMENT

STAN.DARD

If any leak is noted with a detector
having a nominal
sensitivity of 15 to 25 g (0.53 to 0.88 oz)/year, that leak must
be repaired.
The nominal sensitivity of the detector is determined under
the assumption that all the leaking gas is collected by the
detector. Accordingly, the quantity of gas actually leaking
can. amount to five to ten times the indicated value.
Generally speaking, leakage of 150 to 200 g (5.29 to 7.05 oz)
of refrigerant can cause insufficient cooling.
Oil deposited during assembling must be wiped off before
inspection. Refrigerant easily dissolves in oil, and the presence of oil can cause an error in measurement.
This precaution is important when checking a used car for
refrigerant leakage.
If oil is noted at or around connections, it indicates that
refrigerant is leaking.

.

.

.

HA-23

DESCRIPTION

OF AIR CONDITIONER

Acceleration

Cut System

This system is controlled by the E.C.C.S. control unit.
When the engine is heavily over loaded (throttle sensor judges
that throttle valve is at full throttle position), the compressor is
turned off for approx. 4 seconds to reduce overloading.
Additionally when the temperature of engine coolant rises above
approx. 113°C (235°F), the compressor is turned off.
To condenser
fan
motor
via
thermo-

switch

ENGINE
TEMPERATURE
SENSOR

COMPRESSOR

~

' For U.S.A.

~

' For Canada
RHA517A

HA-24

SERVICE PROCEDURES
Refrigeration Cycle
REFRIGERANT

FLOW

The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the receiver
drier, through the evaporator, and back to the compressor.
"The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case.
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the
compressor operation. When the evaporator coil temperature rises above the specification, the thermo
control amplifier allows compressor operation.
REFRIGERANT SYSTEM PROTECTION
Dual-pressure switch
The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the receiver drier. If the system pressure rises above, or falls below the specifications, the
dual-pressure switch opens to interrupt the compressor operation.
Fusible plug
Open at temperature above 105°C (221°F), thereby discharging refrigerant to the atmosphere. If this plug
is melted and opened, check the refrigerant line and replace receiver drier.
Pressure relief valve
The refrigerant system is also protected by a pressure relief valve, located on the end of high flexible hose
near compressor. When the pressure of refrigerant in the system increases to an abnormal level [more
than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and
releases refrigerant into the atmosphere.
Pressu re
relief valve

~
t '

High-pressure .
gas
'j High-pressu re
liquid

~
I,':':':':':':':d

Low-pressure
liquid
Low-pressu re

gas

lill

s

Outside air

u

Compressor

t

u

~

Condenser

0
Blower motor

.
Expansion valve
Receiver drier
Fusible plug
Dual-pressure switch
RHA393A

HA-25

SERVICE PROCEDURES
Refrigerant Lines

~
~

10.20
7.14)

(1.0.2.0,

15.25 (1.5.2.5,
11 -18)

rg
[]]J[1J

Expansion

valve

Condenser fan
motor* (U.S.A. only)

Low-pressure
(Suction)
service valve

Pressure relief valve
~7-17
(0.7 -1.7,5;1

Ie]
~~

-12.3)

D (Tightening torque)
0 0 (Wrench size)

*: For removal, it is necessary to remove condenser.

!AJ

Ie]
[g

20

-29

10

-20 (1.0-2.0,7 - 14)

(2.0

-3.0,

14

-22)

15 -25 (1.5-2.5,11 -18)

~:

N.m (kg-m,ft-Ib)
RHA394A

HA-26

SERVICE PROCEDURES
Compressor Mounting

-

60
(4.6.6.1,33.44)

co;J 45

.
~.

~-

"

~~

co;J 45 - 60
(4.6-6.1,33-44)

,

"- co;J45.60 (4.6 - 6.1, 33 - 44)

co;J: N'm (kg-m, ft-Ib)

RHA395A

Remove screws, which secure thermistor locating stay, from
front of cool~ng unit. Replace thermo control amp. assembly
with a new one. (Without removing cooling unit, thermo control
amp. can be replace.)

RHA396A

Belt Tension

.

Refer to MA section.

Fast Idle Control Device (F.I.C.D.)

.

Refer to EF & EC section.

HA-27

AIC PERFORMANCE TEST
Performance Chart
TEST CONDITION
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well ventilated place)
Doors: Closed
Door window: Open
Hood: Open
TEMP. lever position: Max. COLD

-;

MODE switch:
(Ventilation) set
REC switch: ~(Recirculation) set
FAN lever position: Max. position
Engine speed: 1,500 rpm
Time required before starting testing after air conditioner starts operating: More than 10 minutes
For U.S.A. model, make sure that condenser fan motor does not operate during the following tests.

TEST READING
Recirculating-to-discharge

air temperature table

Inside air (Recirculating air)
at blower assembly inlet
Relative humidity
%

Dischargeair temperature at center ventilator
°c tF)

Air temperature
°c (oF)

50 - 60

60 -70

20 (68)

1.6 - 2.7 (35 - 37)

25 (77)

4.4 - 6.0 (40 - 43)

30 (86)

9.2 - 11.3 (49 - 52)

35 (95)

14.8 - 17.0 (59 - 63)

40 (104)

18.1 - 20.3 (65 - 69)

20 (68)

2.7 -4.3 (37 - 40)

25 (77)

6.0 - 8.2 (43 - 47)

30 (86)

11.3 - 13.8 (52 - 57)

35 (95)

17.0 - 19.5 (63- 67)

40 (104)

20.3 - 22.8 (69 - 73)

Ambient air temperature-to-compressor

pressure table

Ambient air
Relative humidity
%

50 -70

High-pressure (Discharge side)
kPa (kg/cm2 , psi)

Low-pressure (Suction side)
kPa (kg/cm2 , psi)

20 (68)

1,030 - 1,255 (10.5 - 12.8, 149 - 182)

98.1 - 142.2 (1.0 - 1.45, 14.2 - 20.6)

25 (77)

1,196 - 1,471 (12.2 - 15.0, 173 - 213)

122.6 - 171.6 (1.25 - 1.75,17.8- 24.9)

30 (86)

1,402

- 1,706 (14.3 - 17.4,203

- 247)

161.8 - 210.9 (1.65 - 2.15, 23.5 - 30.6)

35 (95)

1,608 - 1,971 (16.4 - 20.1, 233 - 286)

205.9 - 259.9 (2.1 - 2.65, 29.9 - 37.7)

40 (104)

1,844 - 2,256 (18.8 - 23.0, 267 - 327)

259.9 - 318.7 (2.65 - 3.25, 37.7 - 46.2)

Air temperature
°c tF)

HA-28

AIC PERFORMANCE TEST
Performance Test Diagnoses
Characteristics revealed by the manifold gauge
readings for the air conditioning system are shown
in the following table.
For how to do the performance test, refer to the
item "Performance Chart".

In the following table, the portion smeared with
ink on each gauge scale indicates the range showing
that the air conditioning system is in good order.
This range is described in Performance Chart.

Condition

I

INSUFFICIENT 'REFRIGERANT

Probable cause

CHARGE

Corrective action

I.

Insufficient cool ing.
Bubbles appear in sight
glass.

Refrigerant is low, or
leaking slightly.

1. Leak test.
2. Repair leak.
3. Charge system.
Evacuate, as necessary, and
recharge system.

AC352A

I

ALMOST NO REFRIGERANT

I

Serious refrigerant leak.

No cooling action.
A lot of bubbles or
something like mist
appears in sight glass.

Stop compressor immediately.
1. Leak test.
2. Dischargesystem.
3. Repair leak(s).
4. Replace receiver drier if
necessary.
5. Check oil level.
6. Evacuate and recharge
system.

AC353A

I

MALFUNCTIONING EXPANSION VALVE

I

Slight cooling.
Sweat or frosting on
expansion valve inlet.

AC354A

HA-29

Expansion valve restricts
refrigerant flow.
. Expansion valve is
clogged.
. Expansion valve is inoperative.
Valve stuck closed.
Thermal bulb has
lost charge.

If valve inlet reveals sweat
or frost:
1. Discharge system.
2. Remove valve and clean
it. Replace it if necessary.
3. Evacuate system.
4. Charge system.
If valve does not operate:
1. Discharge system.
2. Replace valve.
3. Evacuate and charge
system.

AIC PERFORMANCE TEST
Performance Test Diagnoses
Condition
Insufficient cooling.
Sweat on suction line.

No cooling.
Sweat or frosting on
suction line.

(Cont'd)

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.

Malfunctioning expansion
valve.

1. Dischargesystem.
2. Replacevalve.
3. Evacuate and charge
system.

Air mixed with refrigerant
in system.

1. Dischargesystem.
2. Replacereceiver drier.
3. Evacuat~and charge
system.

Drier is saturated with
moisture. Moisture has
frozen in expansion valve.
Refrigerant flow is restricted.

1. Discharge system.
2. Replace receiver drier
(twice if necessary).
3. Evacuate system completely. (Repeat 30minutes evacuating
three times.)
4. Recharge system.

AC356A

IAIR

IN SYSTEM

I

Insufficient cool ing.
Sight glass shows occasional bubbles.

AC359A

I

MOISTURE IN SYSTEM

I

After short operation,
suction side may show
vacuum pressure reading.
During this condition,
discharge air will be warm.
As a warning of this,
reading vibrates around
39 kPa (0.4 kg/cm2 ,
6 psi).

AC360A

HA-30

AIC PERFORMANCE TEST
Performance

MALFUNCTIONING CONDENSER

Corrective action

I

No cooling action: engine
may overheat.
Bubbles appear in sight
glass of drier.
Suction line is very hot.

Usually a malfunctioning
condenser.

"

@

(Cont'd)

Probable cause

Condition

I

Test Diagnoses

. Check fan belt and fluid
coupling
. Check condenser fan
motor. (U.S.A. model
only)
. Check condenser for dirt
accumulation.
. Check engine cooling
.

system for overheating.
Check for refrigerant
overchargi ng.

If pressure remains high in
spite of all above actions
taken, remove and inspect
the condenser for possible
oil clogging.

@
AC361A

I

HIGH PRESSURE

LINE BLOCKED

I

Insufficient cooling.
Frosted high-pressure
liquid line.

Drier clogged, or restriction in high-pressure line.

1. Dischargesystem.
2. Removereceiver drier
or strainer and replace
it.
3. Evacuate and charge
system.

Interr1'al problem in compressor. or damaged gasket
and valve.

1. Discharge system.
2. Remove and check compressor.
3. Repair or replace compressor.
4. Check oil level.
5. Replace receiver drier.
6. Evacuate and charge
system.

AC362A

I

MALFUNCTIONING

COMPRESSOR

I

Insufficient cooling.

AC363A

HA-31

AIC PERFORMANCE TEST
Performance

Probable cause

Condition

TOO MUCH 01 L IN
SYSTEM (Excessive)

Test Diagnoses

Too much oil circulates

Insufficient cooling.

with refrigerant, causing
the cooling capacity of the
system to be reduced.

AC364A

HA-32

(Cont'd,)
Corrective action

Refer to COMPRESSOR01L
for correcting oilleve!.

COMPRESSOR OIL -

Checking

'I

The oil used to lubricate I the compressor
circulating
Whenever
tem or a
add oil to

For NVR 140S (ATSUGI make)

is

with the refrigerant.
replacing any component of the syslarge amount of gas leakage occurs,
maintain the original amount of oil.

and Adjusting
4. Check the purity of the oil and then adjust oil
level following the procedure below.
(a) When oil is clean;
Unit: mQ (US fl OZ, Imp fl oz)
Amount of oil drained

Above 90 (3.0, 3.2) *

Oil level is right.
Pour in same amount of oil
as was drained out.

Below 90 (3.0, 3.2)

Oil levelmay be low.
Pour in 90 mQ(3.0 US fl OZ,
3.2 Imp fl oz) of oil.

OIL CAPACITY
Unit: mQ (US fl OZ, Imp fl oz)
Applied model
Capacity
Total in system
Amount of oil which can
be drained
Compressor (Service
parts) charging amount

All models

200 (6.8, 7.0)
\
Approx. 100
(3.4,3.5)*

Adjusting procedure

*:

200 (6.8, 7.0)

If amount of oil drained is much greater than under
normal circumstances, flush air conditioner system
with refrigerant. Then pour in 200 mQ (6.8 US fl OZ,
7.0 Imp fl oz) of oil into air conditioner system.

*: All oil cannot be drained from system.

(b) When oil contains chips or other foreign
material;
After air conditioner system has been
flushed with refrigerant, replace receiver
drier. Then pour in 200 m Q (6.8 US fl oz,
7.0 Imp fl oz) of oil into air conditioner
system.

.

OIL RETURN OPERATION
Before checking and adjusting oil level, operate
compressor at engine idling speed, with controls
set for maximum cooling and high blower speed,
for 20 to 30 minutes in order to return oil to
compressor.

CHECKING AND ADJUSTING FOR
COMPRESSOR REPLACEMENT
CHECKING AND ADJUSTING FOR USED
COMPRESSOR
1. After oil return operation, stop the engine and
discharge refrigerant, and then remove compressor from the vehicle.
2. Drain compressor oil from compressor discharge port and measure the amount.
Oil is sometimes
hard to extract when com-

200 m Q (6.8 USfl OZ, 7.0 Imp fl oz) of oil is
charged in compressor (service parts). So it is
necessary to drain the proper amount of oil from
new compressor. Follow the procedure below.
1. After oil return operation, drain compressor oil
from used compressor and measure the
amount.
(It is the same procedure as CHECKING AND
ADJUSTING FOR USED COMPRESSOR.)

pressor is cooled. Remove oil while compressor
is warm [maintained to 40 to 50°C (104 to 122°F».
3.

If the amount is less than 90 m Q (3.0 US fl OZ,
3.2 Imp fl oz), some refrigerant may have leaked
out. Conduct leak tests on connections of each
system, and if necessary, repair or replace malfunctioning parts.

HA-33

COMPRESSOR OIL

-

For NVR 140S (ATSUGI make)

CheckinSl and Adjusting (Cont'd)
2. Check the purity of the oil and then adjust oil
level following the procedure below.
(a) When oil is clean;
Unit: mi! (US fl oz, Imp fl oz)
Amount of oil drained
from used compressor
Above 90 (3.0, 3.2)

~

Below 90 (3.0,- 3.2)

Draining amount of oil
from new compressor
200 (6.8, 7.0) - [Amount of
oil drained + 20 (0.7, 0.7)]
90 (3.0, 3.2)

*: If amount of oil. drained is greater than under
". normal circumstances, flush air conditioner system with
refrigerant. Then install new compressor. [200 mi! (6.8
US fl oz, 7.0 Imp fl oz) of oil is charged compressor
service parts.]
.

Example:
Unit: mi! (US fl OZ,Imp fl oz)
Amount of oil drained
from used compressor

.

Draining amount of oil
from new compressor

"

110 (3.7, 3.9)

70 (2.4,2.5)

70 (2.4, 2.5)

90 (3.0, 3.2)

(b) When oil contains chips or foreign material;
After air conditioner system has been
flushed with refrigerant,. replace receiver
drier. Then install new compressor. [200 m
Q (6.8 US fl OZ, 7.0 Imp fl oz) of oil is
charged in compressor service parts.]

HA-34

~

-

Model NVR140S (ATSUGI make)
Precautions

.

Plug all openings to prevent moisture and foreign matter
from entering.
.Do
not leave compressor on its side or upside down for
more than 10 minutes.
When replacing or repairing compressor, check compressor oil level in system.
When replacing with a new compressor, drain specified oil
from new compressor. Refer to COMPRESSOR OIL.
Be sure there is no oil or dirt on frictional surface of
clutch disc and pulley.
When replacing compressor clutch, be careful not to
scratch shaft or bend pulley.
When replacing compressor clutch assembly, do not forget BREAK-IN OPERATION.

.
.
.
.
.
.

Whel\ s~ring a compressor, be sure to fill it with refrigerant \to prevent rust formation. Add refrigerant at the
low-pressure side and purge air at the high-pressure side,
while rotating shaft by hand.

~

COMPRESSOR

HA-35

COMPRESSOR

-

Model NVR 1408 (ATSUGI make)
Thermal protector
tOJ 10. 15
11.0. 1.5,
7.111

/

Key

Adjusting shim

1

tOJ 29

-39

(3.0 - 4.0, 22 - 291

Center bolt
tOJ 9.1 . 11.8 (0.93 - 1.2,6.7 - 8.71

tOJ:

N.m (kg-m, ft-Ibl
RHA283

HA-36

COMPRESSOR

Model NVR 1408 (ATSUGI make)

-

Compressor Clutch
REPLACEMENT

.
.

When removing center bolt, hold clutch disc with clutch disc
wrench.
Using clutch disc puller, clutch disc can be removed.

SHA052B

.
.

~ c::t
After flattening lock washer tab,
loosen lock nut.

Bend down pawl of lock washer.
When removing pulley, remove lock nut with nut wrench.

SHA053B

INSPECTION
Clutch disc
If the contact surface shows signs of damage due to excessive
heat, the drive plate and pulley should be replaced.
Pulley

Clutch disc

Coil

~
SHA703B

Pulley
Check the appearance of the pulley assembly. If the contact
surface of the pulley shows signs of excessive grooving due to
slippage, both the pulley and drive plate should be replaced.
The contact surfaces of the pulley assembly should be cleaned
with a suitable solvent before reinstallation.
Coil
Check coil for loose connection or cracked insulation.

0.3 -0.6
Adjusting shim
(0.012 -0.024) [Thickness - 0.1, 0.3, 0.5, 0.8
(0.004,0.012,0.020,0.031)]

ADJUSTMENT

~

.

When assembling clutch disc, adjust disc-to-pulley clearance
with shims.

BREAK-IN

OPERATION

When replacing compressor clutch assembly, do not forget
break-in operation, accomplished by engaging and disengaging
the clutch about thirty times.
Break-in operation raises the level of transmitted torque.

* Spark plug gap gauge

~ ~
Unit: mm (in)

RHA843

HA-37

COMPRESSOR

Model NVR 140S (ATSUGI make)

-

Thermal Protector

.
.

When servicing, do not allow foreign matter to get into
compressor.

,

Check continuity between two terminals.

Thermal protector

SHA055B

HA-38

COMPRESSOR -

Model NVR140S (ATSUGI make)

NOTE

/

HA-39

AIC ELECTRICAL CIRCUIT
Wiring Diagram
BATTERY
fusible

THERMAL

I GNI TI ON SWITCH
ON or START

PROTEC1OR

nU

~

(V I a
IInk-Gree~

"

THERMO-

SWITCH

~

7

"

~i

h.cn.s~

~(SUb

AIR

@)

0
(J

~],I

~
~@)
~~ ci~ ~~, ~~~
CAN]""

CONDENSER
FAN
MOTOR

@)~ to

~~

"

,

to ,,,,III

111

u.s.A.

,

....

- to

'"

to

III

"

@~
@~

>- to

"

@)

to

,

""

,'"

III

@

~~~/G
F. I. C. D.
SOLENOID
VALVE

l

III

~
- @

ENGINE
GROUND

(E. F. I.

li

:~~~~~~~~~~~~---------------f~
~

'"
,

@@
~o:
1-0
OVJ
O:Z
ILU
I-VJ

m

~:

~

I

to
""~III

harness)

~
I~
::J
,
IIII....

ffi£@)

0
Z
::J
0
0:
(!Jill

~o:
zo

wO@
z~
(!J7

~VJ
(!JZ
ZLU
WVJ

~

@~I~~IIIFNlbb1Ii

Z
W

III ~ I~ II~

~ ~ ~ &
(Refer to

HA-40

I!!,.I'llII6MII'F!Ii

CONTROLUNIT
EF&EC sect Ion. )

I

AIC ELECTRICAL CIRCUIT
Wiring Diagram (Cont'd)
IGNITION
SWITCH
ACC or ON

BLOWER

~

L/R
L/R
L/OR

31' I>:
'\ '\
..J ..J

~

Iii

@

@~

FUSE BLOCK
(Refer
to "POWER
SUPPLY ROUTING"
in EL sect
ion. )
MODE DOOR MOTOR
G/Y
G
V
B/L
FOOT
F/D
DfF

@
INTAKE
DOOR MOTOR
G/Y
G/B
L/OR

S. M. J.
ffiefer

to

r

age

last

(Fo I dout page).

(@)

@)

j

0

@
THERMO
CONTROL AMP.

(Main
harness)

-L/OR

112

L/OR

-LG

HI2

LG -

-LG/R

HID

LG/R

L/G
LG/B
L/OR

0

:W
~RM'STOR

@

(§)
G/YR/Y-

- LG

1314
1211

LG/B
L/OR
G/Y
G/B
R/L
- B

I'"
@)

-

169
815
17
87
65
43
2 1

G

L/Y
L/W

-

L

L/B
L/R

,

L/OR

31'1>:>-'"
'\'\'\'\
..J..J..J..J

@~

RESISTOR

@)

(Subharness)

~~~
~~~
'\. OFF 1
24
2
26
27
2
8
21
20
1
1

2

3

19
0
21

O

~3:I>:>-'"

PUSH
CONTROL
UNIT

4
From

illumination

} system
FAN
SWITCH

(

(tJ(tl-\....,

I LLUMI NATI ON

'"

~:

@@~

(CAN):

For
For

U. S. A.

Canada

BODY GROUND
RHA398A

HA-41

AIC COMPONENT LAYOUT
Passenger compartment

Resistor
Inteke door motor

Engine compartment

\ Ther';'oswitch\
(U:S.A.

onl\)

\\

-'.~:
::

~

\

...1.--\'~

Condenser fan motor
(U.S.A. only)

HA-42

~/

RHA403A

AIC COMPONENT LAYOUT
NOTE

~

/

t

/

HA-43

TROUBLE DIAGNOSES

Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Symptom Chart
Preliminary Check
PRELIMINARY CHECK 1
(Intake door is not set at "FRESH" in DEF or FOOT mode.)
PRELIMINARY CHECK 2
(A/C does not blow cold air.) '"''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
PRELIMINARY CHECK 3

(Magnet clutch does not engage

in DEF

mode.)

PRELIMINARY CHECK 4
(Air outlet does not change.)
PRELIMINARY CHECK 5
(Noise)
Main Power Supply and Ground Circuit Check
Harness Layout for AIC System
Circuit Diagram for Quick Pin Point Check
Diagnostic Procedure 1
(SYMPTOM: Blower motor does not rotate.)
Diagnostic Procedure 2
(SYMPTOM: Air outlet does not change.)
Diagnostic Pfocedure 3
(SYMPTOM: Intake door does not change in VENT, B/L or FOOT mode.)

HA-45
HA-46
HA-48
HA-48
HA-49

"

HA-50

HA-51
HA-52
HA-53
HA-55
HA-56
HA-57
HA-59
HA-61

Diagnostic Procedure 4
(SYMPTOM: Magnet clutch does not engage with A/C switch and fan switch are ON.)

HA-62

Diagnostic Procedure 5
(SYMPTOM: Illumination or indicators of push control unit do not come on.)

Electrical Components

Inspection

HA-66
HA-70

/

HA-44

TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses
for Quick and Accurate Repair
WORK FLOW

<

Reference item

LISTEN TO CUSTOMER
COMPLAINTS AND CONFIRM.

----------------I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

Diagnostic procedure(s) (See page
HA-57 - 69.)
. Circuit diagram
for quick pin
point check (See
page HA-56.)

Symptom Chart
(See page HA-46 - 47.)

ELIMINATE GOOD SYSTEM(S)/
PART(S).

Preliminary Check
(See page HA-48 - 52.)

CHECK MAIN POWER SUPPLY
AND GROUND CIRCUITS.

Main Powerf.;upplY
and Ground Circuit
Check
(See page HA-53 - 54.)

ELIMINATE GOOD PART(S)/
HARNESS(ES)/CONNECTOR(S)
ELECTRICALLY.

. Harness Layout
for A/C System
(See page HA-55.)

.

Malfunctioning
harness(es)/
connector(s)

Malfunctioning
part(s)

Electrical Components Inspection
(See page HA-70- 72.)

REPAIR/
REPLACE.

I

/1

INVESTIGATE ITEMS YOU
SHOULD CARRY OUT RELATED
TO EACH SYMPTOM.

I
I
L

-- -- - -

----

N.G.

O.K.
CHECK OUT

HA-45

TROUBLE DIAGNOSES
Symptom Chart
DIAGNOSTIC

(

TABLE

Preliminary
Check

PROCEDURE

a)

It)

REFERENCE

It)

.It)

N

M

V

It)

.J:;
CJ

CJ
II)
.J:;
CJ

0

a)

PAGE

«:I: «:I:

It)

SYMPTOM

CJ
II)
.J:;
CJ
>
IV
c:

N
.J:;
CJ

>
IV
c:

< < :I: <
<
:I: :I: <
:I: :I:

>
IV
c:

>
IV
c:

CJ
II)
.J:;
CJ

>
IV
c:

E

'E

E

'E

E

'ii

'ii

'ii

'ii

Q.

'ii

Q.

Q.

Q.

Q.

.- N
« « «
:I: :I: :I:

M
II)

::::s

::::s

::::s

Q,

Q,

'i
CJ

0
Q,
CJ

.+:;
...
0
c:
C)
IV
i5

0

Blower motor does not rotate.

0

..

V

e

Intakedoor does not changein VENT,

0

M
It)

M

It)

< < <
:I: :I: :I:

II)

..

::::s

::::s

Q,

"II) 'i 'i
8 g g. g

"II)

.+:;
...
0
c:
C)
IV

.+:;
...
0

Q,
CJ
.+:;
...
0

C)

C)

i5 i5

i5

CJ

.+:;
...
0
c:
C)
IV

CJ

CJ

c:

IV

M
It)

,<
:I:

It)

c:

IV

i5

0

...
'c
:I
'0

...

II)
...
::::s

51
::::s

u.
«
It) .0
.-

u.
«

0

ci
E
IV
'0
...
c:
0
CJ
0

...
c:
0
CJ
E
.J:;
II)
...
::::s .J:;

Q.

0

I-

0

0

..

0

B/L or FOOT mode,

/

.

<0

II)

0

Air outlet does not change.

N

It)

II)

AICdoesnot blowcold air.---

Intake door is not set at "FRESH"
in DEF or FOOT mode.

0
<0

I"'It)

..-

Main Power
Supply and
Ground Circuit
Check

Diagnostic
Procedure

0

0

0

0

0

0

0

0

Magnet clutch does not engagewhen AIC
switch and fan switch are ON.

0

..

0

0

Magnet clutch does not engage in DEF
mode.

0 ..

0

0

0

Illumination or indicators of push

0

control unit do not come on,
Noise

0

0

0, ..: The numbermeanscheckingorder,
0 : Asfor checkingorder, referto eachflowchart, (It dependson malfunctioningportion.)

HA-46

\\
0

0

0

Blowermotor

0

0

Resistor

0

A/C switch

0

0

0

0

REC switch

0

0

VENTswitch

0

0

BILswitch

0

0

FOOT switch

0

0

FID switch

0

DEF switch

0

0

0

0

0

0

0

0

0

::I:
»I
~
"'-01

0

Fanswitch
Modedoor motor

0

Intakedoor motor

0

0

0

A/C relay

0

0

0

Thermo control amp.

0

0

0

Dual-pressur, switch

0

0

0

Compressor (Magnetclutch)

0

0

0

Thermal protector

0

0

0

E.C.C.S.control unit

0

Illumination system

0

Knob illumination

0

0

0

0

0

Push
control
unit

0

0

0

Harness

Compressor

&
R
E

TROUBLE DIAGNOSES

Preliminary Check
PRELIMINARY CHECK 1
Intake door is set at "FRESH" in DEF or F/D mode.
No
Is intake door in "Fresh" position
when REC switch is turned from
ON to OFF at VENT, B/L or
FOOT mode with ignition switch
at. ACe and fan speed at 4?
(Can you hear air moving from
the intake unit?)

Go to DiagnosticProcedure 3.

Yes

No
Go to Diagnostic Procedure 3.

Is intake door in "REC" position
when REC switch is turned from
OFF to ON at VENT, B/L or
FOOT mode with ignition switch
at ACC and fan speed at 4?
(Can you hear air moving from
the intake unit?

I

Yes
Is intake door in "Fresh" positionl
when F/D switch or DEF switch
is pushed?
(Can you hear air moving from
the intake unit?)
Yes
INSPECTION END

/

HA-48

No

Replace control amp. built-in
push control unit.

TROUBLE DIAGNOSES
Preliminary
"

PRELIMINARY CHECK 2
A/C does not blow cold air.

Check (Cont'd)
N.G.

DOES AIR FLOW FROM
VENTS?
Condition
. Ignition switch, AIC switch,

IS BLOWER MOTOR OPERAT.
ING NORMALLY?

CHECK BLOWER
MOTOR
OPERATION.

and fan switch are ON.

. Modeswitch isin VENT
mode and temperature lever
is in full cold position.

Go to Diagnostic
Procedure 1.

O.K.
CHECK COMPRESSOR BELT
TENSION.
Refer to MA section.

N.G.

CHECK COMPRESSOR
OPERATION.

CHECK REFRIGERATION
CYCLE PRESSURE WITH
MANIFOLD GAUGE
CONNECTED.
Refer to Performance Chart.

TN.G.
Adjust or replace
compressor belt

CHECK REFRIGERANT.

Go to Performance

Test

.

O.K.
(Does not
freeze up)

CHECK VENTILA.
TOR DUCT FOR
AIR LEAKS.

CHECK THERMO CONTROL
AMP. OPERATION.
Refer to Electrical Components
Inspection.

Go to Diagnostic Procedure 4

CHECK AIR MIX DOOR
ADJUSTMENT.
Refer to DOOR CONTROL.

N.G.
(F reeze up)

Diagnoses.

N.G.
CHECK FOR
REFRIGERANT
LEAKS

[

evaporator freezes.

O.K.

N.G.

Connect manifold gaugethen
check system pressure.

O.K.

CHECK FOR EVAPORATOR
I- COIL FREEZE UP.
Remove intake unit. Check if

O.K.

O.K.

No

Yes

I. O.K.

I CHECK EVAPORATOR

OUTLET AIR TEMPERATURE.
Refer to Performance Chart.
N.G.

/
CHECK THERMO

CONTROL

AMP. OPERATION.
Refer to Electrical

Components

Inspection.

HA-49

,.

TROUBLE DIAGNOSES
Preliminary

Check (Co nt' d)

PRELIMINARY CHECK 3
Magnet clu,ch does not engage In DEF mode.
Perform PRELIMINARYCHECK 2 before referring to the following flow chart.

.

With engine running, does
magnet clutch engage normally
when A/C switch and fan switch
are ON?

No
Go to Diagnostic Procedure 4.

Yes
Push A/C switch and turn A/C
system OFF. Make sure that
magnet clutch is disengaged.

With engine running, does
magnet clutch engagenormally
when DEF switch and fan switch
are ON?

No

Replace control amp. built-in
push control unit.

Yes
INSPECTION END

(

~

HA-50

TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 4
Air outlet does not change.
No
DOES AIR COME OUT FROM EACH DUCT NORMALLY WHEN
EACH MODE SWITCH IS PUSHED WITH IGNITION SWITCH AT
ACC?

I

Go to Diagnostic

Indicator illuminates

...,1 ,..
...
...
,1
...

"Q)
0

.
........

.

....1

Air outlet

0

VENT
0

,..

FOOT & VENT

.
....I

0

FOOT & DEF

.

0

........

FOOT & DEF
0

Air distributionratios
FOOT
VENT S/L

F/D

... ; s....
... .,...
'

DEF

DEF

...

I
I
I
I
I
I
I
I
I
I
I VENT
I
I
I
I
I
I
I
I
I
I
I
f

'''

(%)
100

I

80

!

50
40

I

0

I
I

Yes

/

INSPECTION END

HA-

51

/

Procedure
2.

TROUBLE DIAGNOSES
,

------

Preliminary Check (Cont'd)
PRELIMINARY CHECK 5
Noise
Check where noise
comes from.

Belt

Replace
expansion valve.

Replace
compressor.

The line is fixed
straight to the body.

The line is not
fixed.

Fix the line with
rubber or some vibration absorbing material.

(
Readjust belt tension.
Refer to ENGINE
MAINTENANCE
in MAsection.

~

HA-52

The pully center does
not match.
Readjust the pully
center.

TROUBLE DIAGNOSES
Main Power Supply and Ground Circuit Check
POWER SUPPLY CIRCUIT CHECK FOR AIC SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" in EL section and AIC
ELECTRICAL CIRCUIT.

Thermo control
connector
@

THERMO

amp.

AMP. CHECK

Check power supply circuit for thermo control amp. with ignition
switch ON.
1. Disconnect thermo control amp. harness connector.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. @ and body ground.

~~
L/OR

i5

Voltmeter terminal
Voltage

00
':"

CONTROL

RHA406A

EB

8

@

Body ground

Approx. 12V

~

(
.,
Thermo con trol amp.
ne ctor @

'O"~

[ill
-=

LG/B

~
i5
.~

Continuity exists: O.K.

00

§

RHA509A

Check body ground circuit for thermo control amp. with ignition
switch OFF, AIC switch ON and fan switch ON.
1. Disconnect thermo control amp. harness connector.
2. Connect ohmmeter from harness side.
3. Check for continuity between terminal No. @ and body
ground.
Ohmmeter terminal
EB

8

@

Body ground

/

HA-53

Continuity
Yes

TROUBLE DIAGNOSES
Main Power Supply and Ground Circuit Check
(Cont'd)

..-cT

lit IV 00

PUSH CONTROL

Check power supply circuit
switch at ACC.
1. Disconnect push control
2. Connect voltmeter from
3. Measure voltage across

Push control unit
connector @

~

~n

~!

RHA431A

unit harness connector.
harness side.
terminal No. @ and body ground.
I

e

Ei1

Body ground

Voltage

Approx.12V

Check body ground circuit for push control unit with ignition
switch OFF.
1. Disconnect push control unit harness connector.
2. Connect ohmmeter from harness side.
3. Check for continuity between terminal No. @ and body
ground.

[ID

Push control unit
connector @

IBffiEHEI

for push control unit with ignition

Voltmeter terminal

@

litij~

UNIT CHECK

(

::

B

RHAB96A

\

HA-54

TROUBLE DIAGNOSES

Harness Layout for A/C System
Passenger compartment

@
@
Engine compartment

'.

Condenser fan motor (U.S.A. only)

:;r.
~/
Main harness

Engine room harness
@):
@):
@):
@)-1:
@)-2:

Dual-pressure switch
Condenser fan motor
AIC relay
Compressor (Magnet clutch)
Compressor (Thermal protector)

@: Mode door motor
@) : Push control unit
@: Fan switch
@: Thermo control amp.
@: Resistor
@: Blower motor
@: Intake door motor

HA-55

RHA404A

BATTERY

(Via

fusible IInk-Green)

FUSE

M

'N

@

INTAKE
DOOR
MOTOR

@€3

<8

~

@ 10

m
m

I

DUALPRESSURE~
SWITCH @W

@

~

O~@@

@

@

.

1][1 6~~~~gL
~
AMP,

~

811213
I 3 5 7 1 159
1114 ~

246

PUSH

@

CONTROL _UNI T

THERMISTOR

I

~

r--

::E:

»

0)'

~rcr

BLOWER
MOTOR

«ED

RESI STOR

I

DEF.

~
~

F/O.

I

U1
en

1

-

VENT

8

2

,;:~

2
2

7

'---1'1

~
21

OEF;o

'

(1

F/0
B/L

6~~
~

~

\1-1

~ffi
-1;0
m::I

~~u
ILLUMINATION

~~
or.

i I Ium Inat Ion
system
For

{

U. S. A.

For Canada

l ~

.

11>1

.
.

All

connectors

shown

in this illustration

"-

zz

::I

zo

M

0'

Ci\ am
6 ;0

g~

~
~

-::!..

:1

~

<

~

I

~
m'

-I

O::Y;:

'

'

~
~

en."."
, ~

~
~
~

;0

From

~

~
I@

m
;0

I

:D
:I
~
~
0
(,II
~

0

en
en
FOOT 0

(J: ) ---1(2

(~):

~
EF

'~\1

2

I

E.
CO
UN

MODE
DOOR
MOTOR

<8

J

~:

r

~ FUSE

30
I'm

~
I

~

e

~

~~

~

@

are unit side connectors.

The unit 'side connectors with a double circle" 0 " are connected to the harness side connectors
shown in the "Harness Layout for A/C System", (See page HA-55,1
. The terminal numbers in the connector coincide with the circuit numbers surrounded by a single circle"
.: These switches are built in push control unit and mechanically linked to corresponding switches.

TROUBLE DIAGNOSES

Diagnostic Procedure 1

Flow chart
No.

INCIDENT

1

Fan fails to rotate.

2

Fan does not rotate at
1 peed.

3

Fan does not otate at
2peed.

4

Fan does not rotate at
3peed.

5

Fan does not rotate at
4peed.

SYMPTOM: Blower motor does not rotate. !
Perform PRELIMINARY CHECK 2 befor~ referring
following flow chart.

.

rn

Check if blower motor rotates
properly at each fan speed.
Conduct check as per flow chart
at left.

L1J

Fa

CHECK POWER SUPPLY
FOR BLOWER MOTOR.
Disconnect blower motor
harnessconnector.
Do approx. 12 volts exist between blower motor harness
terminal No. @ and body
ground?

\&",l1tis

~
"cfi'

Check circuit continuity between blower motor harness
terminal No. @ and body
ground.

[;J

;l1tiJ
Blower4m~
1
II

L1J

~

B)

~

(Q)

(g

(Go to next page.)
N.G.

Check 15A fusesat fuse block.
(Refer to "POWER SUPPLY
ROUTING" in EL section and
AIC ELECTRICAL CIRCUIT.)

O.K.

[;J

2 3 4,
RHA407A

~

~

rn

Fa

Blower motor
connector @

to the

N.G.

Reconnect blower motor harness
connector.

)

O.K.
Q

CHECK BLOWER MOTOR.

00

I

connector @

(Refer to Electrical
Components

Continuity exists: O.K.

N.G.

"~~

-

RHA510A

Inspection.)

Replace blower motor.

[i]

Resistor@

~m l1t i)

[i]

00
(

"0'

-=

23 4

.

CHECK BLOWER MOTOR
CIRCUIT BETWEEN BLOWER
MOTOR AND RESISTOR.
Do approx. 12 volts exist between resistor harnessterminal
No. @ and body ground?

RHA408A

Ii]

l1tu

Blower motor
connector @

O.K.

[ill

Disconnect blower motor and
resistor harness connectors.

Ii]

Note

Check circuit continuity between blower motor harness
terminal

No.

@

harness terminal

and resistor
No. @.

Resistor

connector @

Y~~lfOO
L/W

N.G.

L/W

A
(Go to next page.)
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

RHA518A

HA-57

TROUBLE DIAGNOSES
Diagnostic

Procedure

1 (Cont'd)
c

B'

~

~
RHA409A

B

00

CHECK RESISTOR AFTER
DISCONNECTING IT.
(Refer to Electrical Components Inspection.)

O.K.

/

II

~

~

I

CHECK FAN SWITCH
CIRCUIT.
Do approx. 12 volts exist between each fan switch harness
terminal and body ground?

AHA897 A

':"

~

~

[]J

Continuity exists: O.K.

Fan switch
@
L/R
connector
L/Y

LIB

Flow chart
No.

Terminal No.

[itij

e

@
@

~
Body Approx.
ground 12V

O.K.

--,
Lffl

27---,
L/Y

Resistor connector @

-'

Voltage

@
@

.-. L/R

~

Reconnect resistor harness connector.

~~i5

II

~

-eft' 2 3 .

':"

Fan switch
connector @

iii

~

E

D'

II

~
~
~

00

N.G.

Check circuit continuity between fan switch and resistor.

[2]
RHA519A

CHECK FAN SWITCH
AFTER DISCONNECTING IT.
(Refer to Electrical Components Inspection.)

O.K.

iii

N.G.
Replace fan switch.

Note

Check circuit continuity between fan switch harness
terminal No. @and body

ground.
O.K.
Replace blower motor.

Note:
If the result is N.G. after checking circuit continuity, repair harnessor
connector.

HA~58

Note

TROUBLE DIAGNOSES

Diagnostic Procedure 2

m

Push control unit
connector
@)

.

_lET

eJ

I

00

t
-=

(;)

Air outlet does not change.
Perform PRELIMINARYCHECK 4 and M;:ttn Power Supply
and Ground Circuit Check before referrir:tg to the following
flow chart.

SYMPTOM:

RHA410A

Mode door motor

connector@

.-r
Eu
00
RHA411 A

II

m
CHECK MODE DOOR MOTOR POSITION SWITCH.
1. Turn VENT switch ON with
ignition switch at ACC
position.
2. Turn ignition switch OFF.
Disconnect push control unit
connector.
3. Check if continuity exists

between terminal No. CD or
@ of push control unit harness connector and body
ground.
4. Using above procedures,
check for continuity in any
other mode. as indicated in
chart.
Mode
switch

00
,-,.-r-r
, ,

\

,(..,

\

---

,~\('
'O\(..,'-,~

,---,

,.

,
Q>'

>,

~~~:,
654

321

Mode door motor
connector @

Conti-

e

nuity

CD or @

B/L

@ or CID

FOOT

CIDor @

F/D

@ or 
flow

-

I

I =

I

I

::>

.

-

-

I

IL'
BATTERY

SW 1

BATTERY

BATTERY

Does not
flow

=

-1'""1
sw 1

I

0
SW 1

BATTERY

Does not
flow

9

I

I.-J

0

SW 1

BATTERY
Flows

Z

=

I

0
SW 1

)

II

.

s
SW 1

I'

BATTERY
SEL881H

TYPE OF STANDARDIZED RELAYS
1M
1T

1 Make
1 Transfer

2M
1M.l B

2 Make
1 Make 1 Break
2M

1M
1M

2M

,--- r',
,.

," (

I

'.

(

...

...

~

~~),

----

"

lM.1B

1T

1T

I
I
\

,

\

'I'

'

\

?---

...

'-r,

'

t 0','-

\

\
I

,'

'

:
\

I
I

1'

1B
\

~
1\
\

"

,\

"
1M
SE L882H

EL-3

STANDARDIZED RELAY
Circuit

Outer view

Type

Connector symbol
and connection

Casecolor

"J
m»
r-z
»0
-<."
tDC

x~tD
:;;@)
r-

...",

~@ ~@

"''''

'"

~
--

BATTERY

Win

OR/B-

t~~ ~ IBlo

Head Iamp L H.

Front

Tur

Hea
Tim
Rea
Met
crys

",

(@)
W~L~

GROUND

Me

disp
Aut
con

L -

'" ~
@
~.
I11R?1I @fIR:iJ
...
33
~ ~1 '" '""''''
~~~
1>\
\SJ (!---,;w

A. S

G/W-

lG

BODY

m
r-

G

"''''1''
RELAY- \,-

~

relay

--

G/Y

~~

@)~@)

]

swl tCh/

Retract

LAY

T

)

contra I u~ if"

RE
I GNITI ON

IIIIIIi r,."
''''
T
!\W1@i)1WJ
~ '" r.;;;;-,

)

Fue I pump.
All' regulator

Key

'"'' '" .."', 8m

CheCk

relay

ACCESSORY

OFFACC ON ST
0 0
0 0
0

~~

CJ RCUJ T BREAKER

..

n
U3

~;

@@j)~
BODY

GROUND

34

SB

G/R

--

OR G/l -

IRe

Jnte

~~~
chim
cont
cont
belt

Stop
unit.

Haza

Head
Not

Exter

Lice
Illum
Head
unit
E. C
Bac
A/T
cont
A. B

POWER SUPPLY ROUTING
-----

O.K.

Fuse
a. If fuse

Blown

is blown, be sure to eliminate cause of problem
before installing new fuse.
b. Use fuse of specified rating. Never use fuse of more than
specified rating.
c. Do not install fuse in oblique direction; always insert It
into fuse holder properly.
d. Remove fuse for clock if vehicle is not used for a long
period of time.

SEL954J

Fusible Link

SEL387L

A melted fusible link can be detected either by visual inspection
or by feeling with finger tip. If its condition is questionable, use
circuit tester or test lamp.
CAUTION:
a. If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
b. Never wrap periphery of fusible link with vinyl tape.
Extreme care should be taken with this link to ensure that
it does not come into contact with any other wiring
harness or vinyl or rubber parts.

FUSIBLE LINK VARIATION
Color

Maximum amperage (A)

15
20
30
35
40

Brown
Green
Red
Black
Gray
*Temperature condition:

El-6

Less than ao°c (176°F)

BATTERY
CAUTION:
a. If it becomes necessary to start the engine with a booster
battery and jumper cables, use a 12-volt booster battery.
b. After connecting battery cables, ensure that they are tightly
clamped to battery terminals for good contact.
c. Never add distilled water through the hole used to check
specific gravity.

\

How to Handle Battery
Keep clean and dry.

METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharging a battery.
The battery surface (particularly its top) should always be
kept clean and dry.
If the top surface of a battery is wet with electrolyte or
water, leakage current will cause the battery to discharge.
Always keep the battery clean and dry.

.

SEL711E

.

When the vehicle is not going to be used over a long period
of time, disconnect the negative battery terminal. (If the
vehicle has an extended storage switch, turn it off.)

/
SEL712E
Hydrometer

a

.

Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte.
Keep a close check on charge condition to prevent overdischarge.

SEL442D

EL-7

BATTERY

How to Handle

Battery

CHECKING ELECTROLYTE
WARNING:

'\

(Cont'd)
LEVEL

Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If the acid contacts the eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
Normally the battery does not require additional water. However, when the battery is used under severe conditions, adding
distilled water may be necessary during the battery life.

/

.
.

Removethe cell plug using a suitable tool.
Add distilled water up to the MAXlevel.

SELOO1K

Charging

voltage
1

Charging current

~
"-'

Normal battery
Sulphated

battery

Charging

voltage

--. Charging current
Duration of charge

SEL709E

SPECIFIC GRAVITY

Read top level
with scale

a

SULPHATION
When a battery has been left unattended for a long period of
time and has a specific gravity of less than 1.100, it will be completely discharged, resulting in sulphation on the cell plates.
Compared with a battery discharged under normal c.onditions,
the current flow in a "sulphated" battery is not as smooth
although its voltage is high during the initial stage of charging,
as shown in the f~gureat the left.

CHECK

1. Read hydrometer and thermometer indications at eye level.

SE L442D

EL-8

BATTERY
How to Handle Battery (Cont'd)

.

Hydrometer ~I~

When electrolyte level is too low, tilt battery case to raise it
for easy measurement.

/'

1

TI"~o-'

~

SEL710E

2. Convert into specific gravity at 20° C (68° F).
Example:
. When electrolyte temperatu re is 35° C (95° F) and specific
gravity of electrolyte is 1.230, converted specific gravity at
20° C (68° F) is 1.240.
When electrolyte temperature is 0° C (32° F) and specific
gravity of electrolyte is 1.210, converted specific gravity at
20°C (68°F) is 1.196.

.

Converted

specific gravity

(5201

1.30

en

1.28

II

a

1.26

II
Q

1.2"

I!

E
>

1.22

eti

1.20

..-

1.18

II

..
?;
'>
..
;;.
.!:!

-

'u
II
Q
I/)

1.16
1.1"
1.12

1.10
-30
1-221

-20
1-"1

-10
11..1

0
1321
Electrolyte

10
1501

20
1681

temperature

°c (0 F)
SE L042D

_/

EL-9

BATTERY
~

/

Battery Test and Charging Chart

Chart I

VISUAL INSPECTION
. Check battery case for cracks or bends.
. Check battery terminals for damage.
. If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in),
it is O.K.

N.G.

O.K.
Replace

CHECKING SPECIFIC GRAVITY
Refer to "Specific Gravity Check".

.

SLOW CHARGE
Refer to "A: Slow
Charge" .

STANDARD CHARGE
Refer to "B: Standard
Charge" .

CAPACITY TEST
Refer to "Chart II".

O.K.
Reacty
for use

battery .

Charge" .

CAPACITY TEST
Refer to "Chart II".

N.G.
Replace
battery.

Ready for use

CAPACITY TEST
Refer to "Chart II".

~

Ready
for use

. "STANDARDCHARGE" is recommended in -

.

N.G.
Ready for use
. Mount battery again
and check loose ter.
minals. Also, check
other related circuits.

CHECKING SPECIFIC GRAVITY
Refer to "Specific Gravity Check".

RECHARGE
Refer to "C: Quick Charge".
.If battery temperatUre rises above 60°C
C14O"F), stop charging. Always charge
battery when its temperatUre is below
60°C (140°FI.

O.K.

CAPACITY TEST
Refer to "Chart II".

QUICK CHARGE
Refer to "C: Quick

N.G.

Replace
battery.

that the vehicl. is in storageafter charging.

EL-10

QUICK CHARGE
Refer to "C: Quick
Charge" .
. Time required: 45 min.

CAPACITY TEST
Refer to "Chart II".
O.K.
Ready
for use

N.G.
Replace
battery.

BATTERY
Battery Test and Charging Chart (Cont'd)

Chart II

1//

.

~

Check battery

type and

determine the specified
current using the following
table.

Fig. 1 DISCHARGING
(load tester)
Test using battery
checker.

Test using load tester.

Follow manufacturer's

Read load tester voltage

instructions

when specified

to check and

determine if battery
serviceable.

O.K.
Ready for use

discharging

current (Refer to Fig. 1.1
flows through battery for
15 seconds.

is

N.G.

Go to next step.

Ready for use

CURRENT

Type

Current (A)

28B19R(l)
34B19R(l)
46B24R(l)
55B24R(l)
50D23R(L)
55D23R(l)
65D26R(l)
80D26R(l)

90
99
135
135
150
180
195
195

75031 R(L)
95031 R(L)
95E41 R (l)
130E41R(L)

210
240
300
330

Go to next step.

~~
..
0

6°010

SE L697 B

/"

EL-11

BATTERY
.~

Battery

Test and Charging

Chart (Cont'd)

A: SLOW CHARGE
Fig. 2 INITIAL

CHARGING

TYPE ==
==
BATTERYT
a:a:
0101

- IDID

Determine initial charging current from
specific gravity referring to Fig. 2.

4.0
(A)

Below 1.100
. Charge battery.
. Check charging voltage 30 minutes after
starting the battery charge.

.
.

CURRENT

SETTING

(Slow charge)

:i

:i:i

:i:i

:i:i

:i

a:a:

:i:i

a:a:

a:a:

a:

a: a:

NN
00
1n0
-

"

"''''

W@

~(@)
~

~~

"

",0:
'"

'"

~'"
'"

@)ft@)
BODY

(Eng i ne
harness)

room

GROUND

@)@)

~8/Y...o,.0
"O-8/Y

~8/W-'Q'

@,

For

@),

For Canada

U. S. A.

(Eng i ne
harness

room
no. 2)

~

>-

,'"

@)g

@.?)O

I

FUSI BlE
LINK

888 88J §
cr:=::o cr:=::o

§]

~M

FUSE

FUSE AND FUSIBLE lINK
CIn RElA Y BOX)

BATTERY

(ill)

STARTER MOTOR

7

SEl466L

AfT MODEL
INHIBITOR
IGNITION
SWITCH

1
2
3
4
5

SWITCH

P

N IP

OFFACC ON ST
:J C
()

WI

~@Y
~~

~@

'"

~@)

~~

....

(Eng Ine

harness)

@)1f2W
~

room

en ~
8/Y-o' "O-8/Y

(Eng I ne
harness

room
no. 2)

]
~

I

FUSI BlE
LINK

>-

,
'"

@)Q

@.?)O

888 88J §
cr:=::o cr:=::o

FUSE AND FUSIBLE
(J n RELAY BOX)

lINK

§]

8/R

FUSE

(ill)

7

SA HERY

STARTER

MOTOR

7

SE L67BM

EL-15

,

N.G.
Check Fuse and Fusible link
I

Does starter

motor

No

turn?

O.K.

.1

Check battery for charging condition
and battery terminals for connections and
corrosion.

VIS

Replace

.
.

N.G.

Ch
Re

batt

O.K.
Check pinion rollar clutch for damage.
Replace if necessery.

N.G.
Check wir ing of starting

Repair
. Ign
. Clut
swit
. Star
. Con

system.

O.K.
Check reduction geer. armature and gear
shaft for damage.
Replace if necessary.

Can you hear magnetic switch of
starter motor operating?

.

Rep

Ves

m
r-

Is meshing condition
gear O.K.7

I

....
0')

of pinion and ring

N.G.

.

Adju

.

Che
retu
for
Cor
and

O.K.

.

Remove starter motor from engine.
Does starter motor turn under no load
by connecting battery (jJ terminal to M
terminal of starter motor and battery
terminal to starter motor body?

e

.

Ves

N.G. (Turns slowly.)
Check battery for charging condition
and battery terminals for connections
and corrosion.

N.G.

.,

Ch
and
Re

Ch
Re

O.K.
Does engine turn by replacing
motor with a new one7

starter

Ves
Repair or replace starter motor.

1

No
i

I

Check inside of engine.

Starter motor does not
stop if ignition switch
is turned off.

I

Repair or replace ignition switch,
starter relay or magnetic switch.

I

-

.'-./,

~

hrOU9h-bOlt

..,-.

'

i--

. .2.3. 2,91

Rear cover

8,",h
"_bS-

A

: N.m Ikg-m. ft-Ib)
SEL834H

A2T14094

Rotor

I~~

IC voltage
assembly

regulator

A:

Stator

t:>

N'm Ikg-m.ft-Ib)
SEL695L

*Rear bearing
CAUTION:
Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. Be careful not to

lose this ringduring removal.

'

EL-25

CHARGING SYSTEM -

Alternator

-

Disassembly
REAR COVER REMOVAL
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
SEL628D
Ohmmeter

Rotor Slip Ring Check
1. Continuity test
No continuity...

.

Ohmmeter

Replace rotor.

2. Insulator test

.

Continuityexists. ... Replacerotor.

3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to S.D.S.

SE L630D

Brush Check
1. Check smooth movement of brush.
Not smooth ... Check brush holder and clean.

.

2. Check brush for wear.
Replace brush if it is worn down to the limit line.

.

SE L631 D

3. Check brush lead wire for damage.
Damaged... Replace.
4. Check brush spring pressure.
Measure brush spring pressure with brush projected
proximately 2 mm (0.08 in) from brush holder.

.

2 mm 10.08 inl

.

Spring pressure:
Refer to S.D.S.
Not within the specified values ... Replace.

E E049

EL-26

ap-

CHARGING,SYSTEM

~

Stator

-

AI.ternator

-

Check

To test the stator or diode, separate them by unsoldering the
connecting wires.
CAUTION:

Use only as much heat as required to melt solder. Otherwise,

diodes will be damaged by excessive heat.

SE L587

A

[MITSUBISHI make]
Long nose pliers
used as a heat sink

~

!

[HITACHI

make]

1. Continuity test
. No continuity... Replace stator.

[MITSUBISHI make]

EL-27

CHARGING SYSTEM

-

Alternator

Stator Check (Cont'd)
2. Groundtest

.

Continuity

SE L384L

EL-28

exists.

'" Replace

stator.

-~

CHARGING SYSTEM -

Alternator -

Diode Check
/

MAIN DIODES

.

.

Use an ohmmeter to check condition of diodes as indicated in chart below:
If any opthe test results is not satisfactory, replace diode assembly.
Ohmmeter probes
Positive (fJ

Continuity

Negativee

Positive diode plate

Diode terminals

Yes

Diode terminals

Positive diode plate

No

Negative diode plate

Diode terminals

No

Diode terminals

Negative diode plate

Yes

Diodes check (Positive side)

Diodes check (Negative side)

[HITACHI make]

[MITSUBISHI

make]
Sub-diodes

Negative diode
plate

SE L768D

EL-29

Positive
diode plate

Diode terminals
SEL385L

CHARGING SYSTEM

--~

Diode

-

Check

Alternator

-

(Cont'd)

SUB-DIODES

[MITSUBISHI make]

.
.

Attach ohmmeter's probe to each end of diode to check for
continuity.
Continuity is N.G. ... Replace diode assembly.

SE L494H

[HITACHI make]

(~:1
\ !I

{(

,J

~
.~

(- J

/

1/)

;'//.'
/.-

.
.

~

- (]Do

~
.4..L c--

-

0

Assembly
Carefully observe the following instructions.

.

When soldering

each stator

coil lead wire to diode assembly

terminal, carry out the operation as fast as possible.

WHEN SOLDERING

BRUSH LEAD WIRE

[MITSUBISHI make]
Position brush so that its wear limit line protrudes 2 mm
(0.08 in) beyond end face of brush holder.

.

Wear
limit line-,

SEL386L

[HITACHI make]
(1) Position brush so that it extends 10.5 to 11.5 mm (0.413 to
0.453 in) from brush holder.

SEL595A

EL-30

CHARGING SYSTEM

~

-

Alternator

-

Assembly (Cont'd)
(2) Coil lead wire 1.5 times around terminal groove. Solder
outside of terminal.
When soldering, be careful not to let solder adhere to
insulating tube as it will weaken the tube and cause it to
break.

Soldering points

/
After soldering.
place insulating tube
on terminal.
1 mm 10.04 inl

SE L596A

RING FITTING IN REAR BEARING

.

Fix ring into groove in rear bearing so that it is as close to
the adjacent area as possible.

REAR COVER INSTAllATION
(1) Before installing front cover with pulley and rotor with rear
cover, push brush up with fingers and retain brush by
inserting brush lift wire into brush lift hole from outside.
(2) After installing front and rear sides of alternator, pull brush
lift wire by pushing toward the center.
Do not pull brush lift wire by pushing toward outside of rear
cover as it will damage slip ring sliding surface.
SE L766D
/

~

EL-31

CHARGING SYSTEM

-"-

Alternator -

Service Data and Specifications (S.D.S.)
ALTERNATOR

/

Type

LR180-715

A2T14094
All

Applied model
Nominal rating

V-A

12-80

Groung polaritY

Negative

Minimum revolution under no-load
(When 13.5 volts is applied)
rpm

Hot output current

Alrpm

Less than 950

Less than 1,100

More than 22/1,300
More than 58/2,500
More than 17/5,000

More than 21/1 ,300
More than 60/2,500

Regulated output voltage

V

Minimum length of brush

mm (in)

6.0 (0236)

8.0 (0.315)

Brush spring pressure

N (g, oz)

1.471 - 3.334
(150 -340,
5.29 - 11.99)

3.040 -4217
(310-430,
10.93 -15.17)

Slip ring minimum outer diameter
mm (in)

26.8 (1.055)

22.1 (0.870)

EL-32

14.1 -14.7

COMBINATION SWITCH

Check

Variable
intermittent
wiper switch

----

TURN SIGNAL
R

,

{[

LIGHT

A

WASH

n:,(j

"

B

p

2nd

OFF

C

HI

<}
L

~

~

For wiper
switch

LIGHTING
QFF
A B CA
5
0
0
6
7
8
0
0
9
10
11

12
25
26
27

I

For A.S.C.D.
and Horn

For lighting
switch

INTERMITTENT
WIPER VOLUME

SWITCH
1
2
B C A B C
100

~

22
4

rq II

0

RNL

OO

HORN SWITCH

.Q.

2
3

TURN
SIGNAL
SWITCH

~

b

28
SEL388L

EL-33

,~

COMBINATION SWITCH

Replacement

.

Wiper and
washer

switch

l

.~

Each switch can be replaced without removing combination
switch base.

,
Lighting switch

SEL389L

.

To remove combination switch base, remove base attaching
screw and turn after pushing on it.

Attaching screw

SE L390L

EL-34

FUSE

~
I~A

TTERY

~

I

-0
RETRACTOR
SWITCH
OFFI

RETRACT
RELAY-4

ON

I

6
I~

t

<;>

...

I--

@5
RETRACT
RELAY-l

f--

,---

H

inat

RETRACT
RELAY-3

.--vm=;:

~

[of

~OJ
..L-

i I Ium

system

r1S

I

-=-

.-

To

I r+- }

RE TRAC

T
-=-

I

RELAY-2

m
rI

W
(J'I

-l--

-

1

cnc
::Err
~~

~rr,
nn
:r~
, ~
Z
G1

~ ~~--

-

l
-~,

1I

~D~W~ ~P~

4'~
3

G1

5'
..L
-=-

\

~

HEADLA~P

m
r

MOTOR L.H.

-~~
HEADLAMP
MOTOR

:

~!
~

R. H.

-

I

-

4

f

t1!

:~f*

@t,

>

1-

-~O~N
~ ~ ~~

[L1J

IS

3

~- --d,~~~
~U~

4
3

--4--

1

---

«

I

<

~

<

I
I

,

L--

-

C

7

-

HEAD LAMP

TIMER

-

-

-~

HEADLAMP MOTOR R. H.

RETRACT
RELAY-]

(D

RETRACT
RELAY-2

RETRACT
RELAY-3

RETRACT
RELAY-4

iii[l@~
~@)
..

..~
~

~@)
..

~@)
c..

rftl@

~~

..:~ ~~

~~~

".

.. .....

HEADLAMP TJ MER

RETRACTOR
SWI TCH

~> ~~~:"

..:~

OFF ON
1 a
2 a
3
4
5
6
B

1.1

@ -~@)

X

~,,~~~..~~~~ ~~
".
~.. ..

9

jj

To
Illumination
system

@

O~
m
r-

HEADLAMP
R. H.

I

W

en
rE~?LAMP

~
~

HEADLAMP MOTOR L. H.

BR/W
PU/W
OR
B
BR

EA
PU
'iff!:2
BR
-mBR/WOR

@)
P/B
~G/l
't}: R/G

@
~G/Y

@

@])@)

m

OR
P/B
P/B
R/G

BR/Y

R/l
G/R
R/B

OR/B
58
BR
PU
BR/W
BR/Y

P

....
(Eng I ne
harness)

~R/B

@

room

BR/Y

E2
FI

"'

01
A2
AS
C3
Cl
El
02
F2

..

B2
Bl
A'
C'
C'
C2

BR
PU
EA
ORBR/W m
OR
P/B
P/B
R/G
BR/ Y .ffi
R/l
G/R

R/B
OR/B
'B
SR
PU
BR/W""
8R/Y

(Ma i n harness)
S. M. J.
ffiefer to last page
(FoIdout page). ]

(D1.~P:f
cc
..,,"''''

..,".
......
~@!)

Ii
LIGHTING
SWITCH

FUSE AND
FUSI BLE LI NK
(J n RELA Y BOX)

[§3[§

s:

'" "''''

~~@)

FUSE

@
en
m
r
UI
CIO
UI

'"

~~

~

~

BATTERY

@

Ii
@)@)
BODY
GROUND

HEADLAMP

/

Description
BASIC OPERATION
Operation

Cond ition
Lighting switch

Retractor switch

OFF

1ST

OFF

1ST

2ND

OFF

2ND

1ST

OFF

1ST

OFF

OFF

Momentarily turned
to PASSING
OFF
*: Referto

/

C/O*

Headlamp motor
No operation

[A)

Open

Headlamps
OFF
ON after headlamp motor reaches
fully open position.

Held to open position

OFF

[B)

Closed

OFF

OFF

[C)

Opened and closed after
headlamps go off.

ON

[D)

Open

CIRCUIT OPERATION.

EL-37

Momentarily ON after headlamp
motor reaches fully open position,
and go off.
OFF

HEADLAMP
Description (Cont'd)
CIRCUIT OPERATION
[A]
When lightingswitch is switched from "1ST"
A-1:

~

"2ND"

While operating the headlamp motor to open position
FUSE

)

To Illumination
system

RETRACT
RELAY-4

RETRACT
RELA Y-3

RETRACT
RELAY-!

RETRACT
RELA Y-2

""
..."
0"

~

I

c-"
.m
I

I

--.J

~~

MEADLAMP
MOTOR L. H.

A-2:

7!J

I

'

,,>
.~"
"

"'"
~~
':">

~~
ij"

""

---~
HEADLAMP

Tl MER

HEADLAMP
MOTOR R. H.

SEL657L

After the head lamp motor reaches fully open position
FUSE

To

Illumination

J system

RETRACT
RELA Y- 4

RETRACT
RELAY-3

RETRACT
RELAY-!

RETRACT
RELAY-2

""
..."
0"
~

'"
...m

»
""
"
I

I

~~

HEADLAMP
MOTOR
L. H.

/

~!J

HEADLAMP

TIMER

HEADLAMP
MOTOR R. H.

SEL658L

EL-38

HEADLAMP
Description
[B]

When lightingswitch is switchedfrom "1ST"

~

(Cont'd)
"OFF"

(While operating the head lamp motor to closed position)
FUSE

To

Illumination

} system
RETRAC
RELAY-4

T
LI GHT! NG
SWI T CH
0
RETRACT
RELAY-3

RETRACT
RELAY-I

RETRACT
RELAY-2

..~
I

r~
.m
~»
.~

.
I

HEADLAHP
HEADLAHP
MDTDR
L. H.

[C]
C-1:

TIHER

_.~

+oJ

»

"..

"'~
;,~
.0
r»
""

r~
~~
..
;:~
""
..

HEADLAMP
MOTOR
R. H.

SEL659L

When lighting switch is switched to "PASSING"
While operating the head lamp motor to open position
FUSE

To Illumination

} system
RETRACT
RElAY-4

RETRACT
RELAY-3

RETRACT
RELA Y-I

RETRACT
RELAY-2

I

.
I

--.J

.:J
HEADLAMP
MDTDR
L. H.

HEADLAMP
MOTOR
R. H.

r~
.m
~»
.~
»
~

"'~
;,~
.~»
"

..~
r~
~~
..

;:~
..""

..

SEL660L

EL-39

HEADLAMP
Description (Cont'd)
C-2:

After the head lamp reaches fully open position
FUSE

)

To Illuolna@)
'"
'III
,..

@

I

L..J

to

HPOWER

SUPPLY ROUTINGH.)

~

@Y

JII

@

""''''

FUSE BLOCK
(Refer

"'-<

II

FRONT
COMBI NATI ON
LAMP R. H.


I NA TI ON
R. H.

@D
G/w-p~

S. M. J.
ffiefer to last page
(Fo Idout page). J

BACK-UP

B --E:J
~

LAMP L K

~~
"''''
(@)

@)~
(@)~

~~
"''''
II

I~IG;I~-UP
(Eng Ine
harness

room
no. 2)

~

G/L-{},
G/W--QJ

~

I

REAR
COMB

~

El-48

BACK-UP
LAMP

SWITCH

LAMP

I NA TI ON

L H.

~rii@
BODY

GROUND

SEL679M

.

DIODE

~@

-g9"
TO

'"
, '",

'" -<

0

H
25

~

. c

26

ir

27

I28

R/G
R/W
G/L

@

FOG

D~

LAMP n
RELAY U

@D@)
R/G

OR/B
OR/L

(Eng Ine room
harness)

G/L
OR

I

m

~

R/G

OR/L~OR/L

(MaIn
harness)

S. M. J.

ffiefer to
(Fo I dout

last
page
page).]

rI

~

CD

@
FRONT FOG ~
LAMPR. H. \bL

trn'I rr;;;\

CI[8::Ot/B

J=

~ ~

OR~B~

FRONT FOG ~
LAMP L.H.

\bL

B

CI[8::OR/B
~

~

[8::ot/B

(Sub-harness)
::IE

Ifr Ifr

"'co'"

@ii@)
(f)

m
r
'"
...,

r'"

BODY GROUND

~~

Ifr rr rr

co"''''
'"

USE AND FUSIBLE LINK
(I n RELAY BOX)

t

IGNITION SWITCH
ON or START

1

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display
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(X)
01
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/

EXTERIOR LAMP
Combination Flasher Unit Check

Test lamp (27W)

.
.

Before checking, ensure that bulbs meet specifications.
Connect a battery and test lamp to the combination flasher
unit, as shown. Combination flasher unit is properly functioning if it blinks when power is supplied to the circuit.

---

Battery

)

SEL122E

Bulb Specifications
Item
Headlamp (Sealed)

Wattage (W)
65/35

Front clearance lamp

8

Front turn signal lamp

27

Front side marker lamp

3.8

Rear side marker lamp

3.8

Turn signal lamp

27

Stop/Tail lamp

27/8

Back-up lamp

27

License plate lamp

7.5

Interior lamp

10

Spot lamp

8

Trunk room lamp

3.4

Foot well lamp

3

Luggagecompartment lamp

5

High-mounted stop lamp

18

EL-51

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20

11

3

17

14

16

30

6

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EL-54

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DIGITAL TYPE

=

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[

10 0 0 03

21

10

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0101

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display

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unit

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2

4

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SEL403L

EL-55

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UNIT

DIGITAL
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II

MPH
HEAD-UP
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DISPLAY
UNIT

1 7

6 2 3

II

km/h
5

8 9

4

To
}

Illumination

control system
To ~ ~ ~ &

-=

control unit

SPEED
SENSOR
SEL480L

EL-56

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L

I GNITI ON SWITCH
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)

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unit

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I GNI TI ON SWITCH
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FUEL TANK
GAUGE UNIT

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CONTROL UNIT

OIL
I'
OIL PRESSURE

SWITCH

FUEL
II
FUEL TANK GAUGE UNIT

WASHER
I'
WASHER

FLUID LEVEL SWITCH

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1

I
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5
6
7
B
9
10
11
12
2S
26
27
28

UP

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Inl

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SUPPL Y ROUTI NGp. ) ~'"

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harness)

room

S. M. J.
ffiefer
to last
page
(Fa I dout
page).]
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A

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m

TIME CONTROL UNIT
(Refer
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CONTROL SYSTEMp.)

I GNI TI ON SWITCH
ON or START

OFF 1ST 2ND
A BCAB CA B C

R/L
Y/R

~~~~

0
2
D2
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(Ma i n
harness)

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LINK

LINK

;

BATTERY

0ii
=
DOOR SWITCH
(Dr iver
side)

BODY

GROUND

WARNING LAMPS AND CHIME
Diode Check

w

..

.

Check continuity using an ohmmeter.
Diode is functioning properly if test results are as shown in
the figure at left.

\

SEL901F

.

Needle type model
0

Diodes for warning la~s
meter printed circuit.

~JJl
Diode

Digital type model
=:I

SEL409L

Warning Chime Check

EL-64

are built into the combination

TIME CONTROL SYSTEM

Schematic
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u
(0
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lJJ
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LL

L
0
LL

=
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=

window

defogger

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REAR WINDOW
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SEAT BELT
SWITCH
DOOR SWITCH
(Driver
side)

WARNING
CHIME
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.
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ILLUMINATION
CONTROL SWITCH

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DARKEN
I'

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SWI TCH

I LLUMI

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WIPER VOLUME

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FRONT
WASHER
MOTOR.

INTERMITTENT
SWITCH

~IO:
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\

FRONT
WIPER
AMP.

I'
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front

wiper

motor

I'

SEL486L

EL-65

a

DOOR SWI TCH
(Or i ver
side)
LI GHT I NG SWI TCH

1\ OFF 1ST 2ND
ABC ABC ABC
5
6
7
8
9
10
11
12
8
25
26

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S. M.J.
ffieferto last page
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(Fa Idout

harness)

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FUSE AND FUSIBLE
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PU
P
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~

::j

=

lG/R

~
8

FUSIBLE
LINK

BATTERY

To front

@ID-w

wiper motor

\G:'

PU

J

0

([ill)

@)Ii@)

[

It

FRONT
WASHERW1:fR

1111~II1JJ~~D
(BIackJ

1"'~"9@
~

(jnstrument
harness)

~,

19

6

T

.@
""-<

AND

OFFINT La HI WASH
13
TCH
14
15
..n
16
t
r
17
t
18
120

BODY GROUND

,'"
~

eft

@'@
8R

(Main
harness)

@(§)

@'@

s:

ilia
3

@j)~

~

~~

III
m
r
C11
OJ
-.J

--i
TI

5

(Eng

-=-

@

i

~

CONTROL UNIT

I~I

AzI

Ii

KEY SWITCH

~

TIME

~
~
;0
OJ

SWI TCH

~@
""

'"

"''''
c

@})

I

I LLUMI NAT ION
CONTROL

'-!.

cEtE

m
r-

WARNI NG
CHI ME

T.

~

27
28

SEA T
BEL T
SWI TCH

"YJ

-

'"

'"

~@

~
24 0---@---02
SEAT BELT

3 ' 17 o---@---o

WARNING LAMP

I

13

SEA T BEL T
WARNING LAMP
METER

" ~,

@

[liHE3ifI]

COMBINATION

_L

~

~,

@'
@'

TIME CONTROL SYSTEM
Description
FUNCTION

.

Time control

unit has the following

functions.
Details of control

Item
1

Intermittent

2

Washer and wiper combination

3

Illumination control

Regulates brightness of illumination in 16 stages depending on the
illumination control switch setting.

4

Light warning chime timer

When driver's door is opened with ti9ht switch ON and ignition switch
OFF, warning chime sounds.

5

Seat belt warning lamp timer

Seat-belt warning lamp blinks for about 7 seconds when ignition
switch is turned to "ON"

6

Seat belt warning chime timer

Sounds warning chime for about 7 seconds if ignition switch is turned
"ON" when seat belt switch is "ON" (seat belt is unfastened).

OPERATING

control

Wiper is operated in cojunction with washer switch.

CONDITIONS

,'

Item

Regulates intermittent time from approximately 3 to 12 seconds
depending on the intermittent wiper volume setting.

wiper control

OOt/) tertrJifli31
°t ter.
trJ/fli31

Intermittent wiper

Power
source from
battery

@

Ignition
switch
@or@

CD

ON

ACC or ON

combination control

@

ON

ACC or ON

Illumination control

(fJ)

ON

Light warning chime
timer

@

ON

OFF or ACC

@

ON

OFACC
ON

@

ON

OFF or ACC
ON

control
Washerand wiper

Seat belt warning lamp
timer
Seat belt warning

timer

chime

Driver's side
door switch
switch -----*1

Light
switch

Wiper switch
"INT"

Washer

@

@

@

\@

ON

Seat belt
switch
*2

Illumination
control
switch

@

(j) or @

/
ON

ON
ON

ON
ON

ON

*1 Door switch is turned ON when door is opened.
*2 Seat belt switch is turned ON when driver's side seat belt is unfastened.

EL-67

TIME CONTROL SYSTEM
Trouble-shooting
DIAGNOSTIC
PROCEDURE

Symptom

Wiper & washer

Illumination

Intermittent

wiper does not operate.

1

Intermittent

time of wiper cannot be adjusted.

2

Wiper and washer activate individually but not in combination

3

Illumination control system does not actuate.

4

Light warning chime does not activate.

5

Seat belt warning chime does not activate.

6

Seat belt warning lamp does not go off nor come on.

7

Ignition key warning chime does not activate.

8

Rear defogger does not activate, or does not go off.

9

Warning

Rear defogger

[it
9

PREPARATION FOR TROUBLE-SHOOTING
1. Remove driver's side dash side cover.
2. Remove time control unit with harness connected.
POWER SUPPLY CIRCUIT CHECK
1. Connect ohmmeter from harness side.
2. Check continuity between terminal @ and body ground.
~
Ohmmeter

terminals

Continuity

-

SEL689L

~

(+)

(-)

@

Body ground

3. Connect voltmeter from harness side.
4. Measure voltage across terminal @ and terminals @, @ or
@.
Voltmeter

@'@~

SEL690L

Yes

terminals

Ignition

switch position

(+)

(-)

OFF

ACC

ON

@

@

Approx. 12V

Approx. 12V

Approx. 12V

@

@

OV

OV

Approx. 12V

@

@

OV

Approx. 12V

Approx. 12V

EL-68

/

TIME CONTROL SYSTEM
Trouble-shooting

m

DIAGNOSTIC PROCEDURE-1
Intermittent wiper does not operate.

T.C.U. OUTPUT FOR WIPER RELAY
CIRCUIT CHECK
Measure voltage across CD and @.

~
~

8191101
1

1181i915<1

~
-

+

O.K.

Needle swings from 0 to 12V
every 3 to 12 seconds.

[Y]

SEL652L

WIPER SWITCH
Check continuity

CIRCUIT
between

j

TifT

I w;p" ~;",h

~

"ONT"

N.G.
Replace
wiper
relay.

O.K.

N.G.

SEL653L

Measure resistance between @ and @ while
turning intermittent wiper volume.

~@?]

@

taJ
[Q]

Check harness
between T.C.U.
and wiper relay.

Check wiper switch circuit
check.

Check harness
between T.C.U.
and wiper switch

#1kn

O.K.

N.G.

@

~

@

Check wiper relay. Refer to
"WIPER ANDWASHER".

Check T.C.U. output for wiper
relay circuit.

Ii)

CHECK
@ and @.

~oo
@

Check harness for T.C.U. power
supply circuit.

Go to "Power Supply Circuit
Check".

@) Wiper switch"'" "INT"

0

Ii)

~
~

(Cont'd)

~~

DIAGNOSTIC PROCEDURE-2
Intermittent time of wiper cannot be adjusted.
O.K.
Check intermittent
volume circuit.

Intermittent

wiper
knob
on at "S"
position
Approx
1kna;"L"

..
position
SEL654L

Replace
wiper
switch.

wiper

Replace T.C.U.

N.G.
Check intermittent
volume.

wiper

Replace wiper switch.

O.K.
Check harness between T.C.U.
and intermittent wiper volume.

EL-69

/

TIME CONTROL SYSTEM

)

Trouble-shooting

(Cont'd)

DIAGNOSTIC PROCEDURE-3
Wiper and washer activate individually but not in combination.
N.G.

Check harness betWeen
T.C.U. and washer switch.

Check washer switch circuit.

O.K.
N.G.
Check T.C.U. output for wiper
motor.

Replace T.C.U.
[

O.K.

I

m

DIAGNOSTIC PROCEDURE-4
Illuminationcontrol system does not actuate.

T.C.U. OUTPUT FOR liGHT SWITCH
CIRCUIT CHECK

~oo
~

@

Light switch

Replace wiper relay.

m
Check T.C.U. output for light
switch circuit.

... ON

Check harness betWeen T.C.U.
and light switch.

O.K.

Approx.12V

Check IIIumi nati on circuit.
SEL648L

Check for loose harness
connector.

O.K.

[1100

[!]

kJ
IllUMINATION

CHECK

Light switch ... OFF

O.K.
Replace T.C.U.

SEL649L

CONTROL CIRCUIT

1E5L---,

0

Check illumination control
circuit.

III 00

@@

[aJ
[ill
+

Ohmmeter
(+1 (-I
@
!J)

@
@

-

lIIum;nat;oncontrol .wltch
OARK
BRIGHT
on
Excep. on

Except on
on

ISEL650L

EL- 70

Check illumination control
switch.

TIME CONTROL SYSTEM
Trouble-shooting

(Co nt' d)

DIAGNOSTIC PROCEDURE-5
Light warningchime does not activate.
Do other warning chimes
activate?

O.K.

N.G.
Go to "PowerSupply
Check".

Circuit

Check harness for T.C.U.
power supply circuit.

O.K.

Check T.C.U. output for chime
circuit.

Check chime, and harness
between T.C.U. and chime.

Go to "T.C.U. output for light
switch circuit check".
(Refer to back page.)

Check harness between
T.C.U. and light switch.

O.K.

I

T.C.U. OUTPUT FOR CHIME CIRCUIT CHECK
Measure voltage across (j]) and @ when driver's
door is opened and closed.

~oo
@

~

f\Tl
LY'.J
+ -

Replace T.C.U.

DIAGNOSTIC

Seat belt warning chime does not activate.
Go to "Power Supply Circuit
Check".

@ .Light
switch ... 1ST
Approx.12Vwhen
driver's side door is closed.
.

PROCEDURE-6

Voltmeter needle swings
(0 -12V) when driver's

side door is opened.
SEL642L

Check harness for T.C.U. power
supply circuit. .

O.K.
Check T.C.U. output for chime
circuit.

Check chime, and harness
between T.C.U. and chime.

N.G.

SEAT BELT SWITCHCIRCUIT CHECK
1. Unfasten driver's seat belt.
2. Check continuity between (j]) and @.
3. Fasten driver's seat belt.
4. Check to determine if continuity does not
exist between (j]) and@.

. ~oo

W
[ill
+ -

Check seat belt switch circuit.

O.K.
Replace T.C.U.

SEL643L

EL-71

Check harness between T.C.U.
and seat belt switch.

TIME CONTROL SYSTEM
Trouble-shooting (Cont'd)
T.C.U. OUTPUT FOR BELT WARNING
CIRCUIT CHECK

LAMP

switch

PROCEDURE-7

Seat belt warning lamp does not go off nor comes on.

Measure voltage across @ and @ when
ignition

DIAGNOSTIC

is "ON".

~oo

Go to "Power Supply Circuit
Check".

N.G.

Check harness for T.C.U. power
supply circuit.

@

~ooJ il~

1 O.K.
SEL651L

Check T.C.U. oUtpUtfor belt
warning lamp circuit.
Voltmeter needle keeps sWinging
(approx. 0 +-+ 12V) for about
7 seconds after ignition switch
is turned ON.
1 O.K.
Check warning lamp, and
harness between T.C.U. and
warning lamp.

EL-72

N.G.

Replace T.C.U.

TIME CONTROL SYSTEM
Trouble-shooting
T.C.U. OUTPUT FOR CHIME CIRCUIT CHECK
Measurevoltageacross@ and@ when driver's
door is opened and closed.

~oo

w
.

DIAGNOSTIC

PROCEDURE-8

Ignition key warning chime does not activate.
Go to "Power Supply Circuit
Check".

I

Check harness for T.C.U. power
supply circuit.

I Checkkey

Check key switcQ circuit~

switch or harness.

I

O.K.

Approx. 12Vwhen

Check T.C.U. output for chime
circuit.

SEL639L
DOOR SWITCH CI RCUIT CHECK

Check continuity

N.G.I

O.K.

driver's side door is opened.

DRIVER'S

(Cont'd)

between @ and @.

Check chime and harness

.
O.K.,

between T.C.U. and chime.

N.G.
N.G '
.~

Check driver's door switch
circuit.

I

Check harness between
T.C.U.
.
and seat belt switch.

O.K.

~oo

LaJ
Driver's side door

Replace T.C.U.

/

... Open
SEL640L

KEY SWITCH CIRCUIT

CHECK

Measure voltage across

@ and@.

[it
@

@

laJ

@-~
'A

SEL641L

\

EL-73

TIME CONTROL SYSTEM
Trouble-shooting
T.C.U. OUTPUT FOR REAR DEFOGGER
CIRCUIT CHECK
Measure voltage across @ and @ while operating rear defogger switch.

=

1 2 3 4 5 6 7 8 9 10
1819

111213141516

@

@

lNJ
[Y]
+ -

.

~

DIAGNOSTIC PROCEQURE-9
Rear defogger does not activate, or does not go off.

00

Rear defogger

(Co nt' d)

Go to "Power Supply Circuit
Check".
switch

~

Rear defoggerswitch
"N": Approx. 12V

ON

N.G.

Check harness for T.C.U. power
supply circuit.

O.K.

. "TIMER":
Reardefogger
switch
Approx.OV

Check T.C.U. output for rear
defogger circuit.

SEL644L

O.K.

defpgger relay.

N.G.

DEFOGGER SWITCH CIRCUIT CHECK

Check rear defogger relay, and
harness between T.C.U. and rear

N.G.
Check defogger switch circuit.

[ilOO
0

t

@.

~d- j

.

Rear defogger switch
"OFF": Except on
Rear defogger switch
"TIMER": on

O.K.

Check defogger switch, and
harness between T.C.U. and
defogger switch.

"f'
I

Replace T.C.U.

SEL645L

-,

EL-74

I

WIPER

~:
~:

anti-lockbraking
system

With

Cill:@

~

UP

*

~

LG

@:@I~I

Without anti-lock braking
system

L

r
o",rlll
111"'"'''
111

I

J

/

(MaIn
harness)

~

S. M.J.

WIPER
(Eng I ne

@

.r
-=

m
r-

~

I

ffiefer to last page
(Fo I dout page).
J

room

harness)

LG/B
LG
PU
PAIl
B
L/Y

LG
OR

LG~B
LG/R

.....
UI

AI0
012
BI2
BIO
BII

i i

LG/B
LG
PU
P
B
L/Y

,L

@])@
WIPER
([@)

MOTOR
WASHER

~M

BR
LG/B
L/Y

@
~LG
~

P

I

LGfR
PU

[]

SWITCH
OFFINT LO HI WASH
13 0

14 0
IS
16
17
18
19

20
111

en
m
r

U1
OJ
OJ

s:

@)@@)
BODY GROUND

AND

WASHER

(

(

c
c
0

,....
i'

1
0

REAR WIPER

I GNI T1 ON SWITCH
ACC or ON

AMP.

[;]

UP

*

I

IDA

,~

r-

~~

@

r-r-r-r... °"',,'"
::a~u~

FUSE BLOCK

(Refer to "POWER
SUPPLY ROUTING".)

(Main
harness)

@ill)
L/W

~

~

(Back
L/W

harness)

:[

Lg~R . l?§:
0 Lg~R
(@})@)

m
r-

L/W

I

(Eng I ne
harness)

.....

en

rr-",

"~...

room

I::"l

L/W

(Main
harness)

LG/B~LG/B

S. M. J.
ffiefer
to last
page
(Fo I dout page). J

B -B.3 ffi~@

L/R
R/Y

'

To I I I um I nat Ion
contro
I system,
[

L

@])A~@A(@)
~~
~~
- -

(/)

m
r
a>

"
~

~

BODY
REAR WASHER
MOTOR

@

LGB"B
R/LI

~@

GROUND

B

door

le.~
~

2
~3
4

@
L~W

Lg~R

@@

WIPER AND WASHER
Wiper Removal and Installation

rP.J : N.m (kg-m, ft-Ib)
SEL410L

FRONT WIPER REMOVAL

';

Before removing front wiper motor link, turn wiper switch OFF
and disconnect motor leads at connectors.
1. Remove wiper ,arm.
2. Remove cowl cover.
3. Remove bolts which secure wiper motor.
,
4. Extract wiper motor so that wiper motor link comes out of
hole in front cowl top panel. Then, pull motor straight;out to
disconnect ball joint which connects motor link and wiper
link. Wiper motor can then be removed.
SEL411L 5. Remove wiper link pivot blocks on driver and passenger
sides.
6. Extract wiper link and pivot blocks (as one unit) from oblong
hole on left side of cowl top.

Pull
straight
ahead.

..

~

r
FRONT WIPER INSTAllATION

,\
""

~

l

~
.:.

Wiper
motor
link

~

Cowltop
front panel

Insert securely.

1. Position wiper link and pivot blocks (as one unit) in cowl top
through oblong hole.
2. Before installing pivot blocks on cowl top, hold end (motor
link side) of wiper link at hole in front cowl top panel and
insert motor link's ball pin into hole in wiper link.
3. Install front wiper in reverse order of above removal procedures.
Apply a small amount of grease to ball joints before
installation.

.

/'

SEL412L

EL- 77

WIPER AND WASHER

~

3.7 -5.0 N.m
1
(0.38 - 0.5f kg-m,
2.7 - 3.7 ft-Ibl /~

-"-"~

/

Rear wiper
motor
SEL413L

Wiper and Washer Adjustment

J

INSTAllATION
1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it "OFF"
(Auto Stop).
2. Lift the blade up and then set it down onto glass surface to set the blade center to clearance "L1" &
"L2" immediately before tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it "OFF".
4. Ensure that wiper blades stop within clearance "L1" & "L2".
Clearance "L/': 17.5 - 32.5 mm (0.689 - 1.280 in)
Clearance "L2": 25 35 mm (0.98 - 1.38 in)
Tighten wiper arm nuts to specified torque.
Front wiper: 17 - 23 N.m (1.7 - 2.3 kg-m, 12 - 17 ft-Ib)
Rear wiper: 13 - 18 N.m (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)

-

.

*1:
*2:
*3:
*4:
*5:
*6:
*7:
*8:

50 (1.971
28 (1.101
43 (1.691
21 (0.831
144 (5.671
155 (6.101
273 (10.751
385 (15.161

0
Clearance

Unit: mm (in)
* All the diameters of these circles are
less than 80 (3.151.

*7

"L,"

Clearance"

rt

rr~~.
Glass
end

'8

L1"

£

~
~

SEL425L

Glass end
*1:
*2:
*3:
*4:

93
85
38
25

(3.661
(3.351
(1.501
(0.981

Nozz~e1~b

Unit: mm {inl

SEL414L

EL- 78

WIPER AND WASHER
Wiper and Washer Adjustment (Cont'd)

SEL415L
.

Before reinstalling wiper arm, clean up the pivot area as
illustrated. This will reduce possibility of wiper arm
looseness.

SEL024J

Washer Nozzle Adjustment
. UsingTool (J36126),adjust windshieldwashernozzleto
correct its spray pattern.
Before attempting to turn the nozzle, gently tap the end of the

tool to free the nozzle.

(

This will prevent "rounding out" the small female square in
the center of the nozzle.

SEL117K

Check Valve

.

reservoir

':;0
F'om

.

To

A check valve is provided in the washer fluid line. Be careful
not to connect check valve to washer tube in the wrong
dir~ction.

~ D";'e

c~ ".I~
..

SEL411H
EL- 79

WIPER AND WASHER
Wiper Amplifier Check

Wiper relay

~~

1. Connect as shown in the figure at left.
2. If test lamp comes on when connected to terminal @ and
battery ground, wiper relay is normal.

:4;

Test
lamp

SEL6S1 I

EL-80

.

CIGARETTE

LlGHTER

A. S. C. D. STEERING SWI TCH

~
HORN
RELAY

~
~

~
@~

SLl

P

RI NG

- --

~~~~~~~

'

+t=

:,
:

4

.
.

SET/COAST

0

SWI TCH

HORN

0

~=SWITCH-

- n .~

fl

. (3

= 0 SWITCH

I

::
~

RES~ME/ACCEL

I

~

I GNI TI
AC

,
(

@~

2

III 0
:oJ

I

~

,

I

@

III

P0
,
:E
'"

,,
:E'III
"'''''''

,.

en

(Ma In

harness)

@:
:oJ

,

III

@:

III

HORN- HIGH

@

rr\--.@)

m
r-I
00

rJoIhite)

ii

~

(Eng Ine room
harness)

rr\--.
~@)
HORN-

ii

@J) @~

[D- G

BODY

~:

~

~:

~

@~I

III

~[D-G
-=

EEHHE:EJ EHffiIrn@)
III

~QD:oJ

(Black)

,

@)
GROUND

::r;:::
ID:J
,m
:Jc+
CD,
me
m3
CD
:J
c+

LOW

.~

'

'"

:E

,
III

@

'"

,
:E

Q0

:E

o=:::IJo::::IJ

FUSE

[§

II
'"

III

:oJ

'" '"

HORN

FUSIBLE

SWITCH

en
m
r
0>
....
"-I
s=

g@)

t

LlNK
FUSE AND FUSIBLE LINK
,... ~ ~~~:o""""'"
RD

@

DECK
DIN

0-c

UP

CASSETTE

RAOI 0

,-

CODE

~

I~

~

~@ @1Mll~@

....
"",...
III""

.. ~""""III
,..
~>,... ~ ~~~
,...~g g
co

:0

"..

,...

(Main
harness)

m
rI

co
c.n

@:

Radio

@):
@:

Cassette
Active

@:

Except

only

type
deck

type

speaker

type
MJII

@)ii@JJ

@

BODY
GROUND

@
@D

@)

@
III""":;;
-<:IE
rnl

@
DOOR

DOOR
SPEAKER
en
m
r
01
....
~
~

[D=ru

~I
AMP..
UNIT

.

11>'1

III
III"":;;
:IE
(Ai

tl.j~L/Y1

@
0

@ill)

'

[

L/W m'

L.
H.
SPEAKER

L. H.

eM:
..
..,...:;;
:IE

..,...,,:;;
-<:IE

mBR/W~
U BR ~

~

DOOR
SPEAKER
R ~

@ill)
L/W
L/Y

i

LG

l';'

.:1

~

BR/W

LG

(Door harness
L. H.)

(Door harness
R. H. )

BR

I~
o.

AMP.
UNI T

AUDIO AND ANTENNA
Location of Antenna

L
~~
Loosen~~

Main feeder cable

~2N~

(0.2 kg-m.1.4 ft-ibi

J

--

~
~,-(
\\
~1
\ \
\ \
\ \
\

\

\ \
\ \
\ \
)f/~.

r[~
Radio
(For AM/FM electronic tuning)

SEL416L

Radio Fuse Check

\
~

EL-86

AUDIO AND ANTENNA
Window Antenna Repair
ELEMENT CHECK
1. Attach probe circuit tester
terminal on each side.

(in ohm range) to antenna

Ohmmeter

[TI
@

SEL2501

2. If an element is broken, no continuity will exist.

Ohmmeter

[TI

@.
---'

No continuity

Continuity

exist

SEL251\

SEL2521

3. To locate broken point, move probe to left and right along
element to determine point where tester needle swings
abruptly.

Ohmmeter

[TI
@

SEL2531

ELEMENT REPAIR
Refer to REAR WINDOW DEFOGGER "Filament Repair".

EL-87

I GNITI
ON
SWITCH
ACC
or
ON

I GNI TI ON
SWITCH
ON
or
START

-@

FUSE

FUSE

A. s. C. D.

OFFI
A. S. C. D. STEERING

SWI

TCH

N ON
I

SWITCH

I

I

=

RESUME/ACCEL

SWITCH

A. S.

C. D.

HOLD
RELAY

-=-=-

To horn

m

A. S. C. D.

2

rI
~ ~ ~ ~

7

co
co

13

::I0
mo
--i::I
mro
;oz

12

0
;0
c
Ct1
m

»

--i
~

a
z

)

CONTROL

3

I

UNIT
10

CANCEL
SWITCH

4

11

I

A.

S.

C.

@

I

5
9

8
-r-'

To

8

D.

CLUTCH
SWITCH

A. S. C. D.
ACTUATOR

6

i I Iu

control

A/T
CONTROL
UNIT

-=-

~
-=-

SPEED
SENSOR
To

i IlumlnatiOn

control
rJ)

m
r

<.n
CX)
'"

~

-=-

system

-=[

0, A/T
@' M/T
@), With
@), Witho
@' With
syst
@' Witho
syst

AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Wiring Diagram
~
0
0
E

C C1

+' C1

'v
.-p

P",
c >-

"'"'

'" C

COMBINATIONMETER

:J C
0'.c~
.c~
+'''' P'"
.- L .- L
:;:D :;:D

~'"
:;:..
V)>-V)
Z
OL
~o
>-~z
zo
CJ

~..
Z
CJ

-

-",
,>-",
P

I
0
>-->--

I
0
>-~Z
:;:0
V)
L
ZO
0
~O
>--0

~ E
0 V
OP

~

1_~~

@@
HEAD-UP

10
ILL

01SPLA Y

CONTROL UNI

~

'

3

3

ILL

II

.1
(LIQUID CRYSTAL>

20

ILL.

ILL.

.

(LIQUID

CRYSTAL>

T

I~I

~~~--~

@~
.",
~

CRUISE

CRUISE

0~,

"~~m
:i ~~

m~

~

~0- " 0~l~~
, , '"
~bJ J J-TrT-III
~

~

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~

- ,
@

m"

~

.

-.

~
~-

@
'-a.

I

.

I

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m

n

I

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U

.

-

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I V
U .c

-

v v '"

U U
(J

, ,

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bIIII

~~~~

m

J

U 111'4 b II E:j

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~

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Y/G

8

m

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.

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r

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G/R

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II

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'-~I'

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.

.

Y/G

R/G

G/R

S, C, 0,

CLUTCH
SWI

T CH

A,

u;
"'
v
C
L
'"
r

S, C. 0,

U SWITCH
CANCEL

Q

Q

~ffim~

u:

,{K)!j)Y/G-l3::! 'B:L '/G

@

~

.,

G/W

'---

O/B--o..
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~

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O:::J

~

@

~
~
@

O/B---o'"

@~ffi

(

Ln.'

,

o~

LL
LL
<>

'

~

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,:

@
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Z

11

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L .~

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I<

I'

r

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~

V)

0
0
U;

.

W

~

I,

.,

@@@@

~111,d~IIE:j
I

is

>-- >-- P P

(Black)

m

V +-'

~ ~ rrr

harness)

0

m

(White)

@~I,~II,II~

nstrument

I

(j
I

UB-

(' V) V)

u;

<

SE L590M

EL-89

AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
A.S.C.D. Wire Adjustment
A.S.C.D. wire

f".-

.~r

--

~

SEL419L

CAUTION:

.
.

Be careful not to twist A.S.C.D. wire when removing it.
Do not tense A.S.C.D. wire excessively during adjustment.

After confirming that accelerator wire is properly adjusted,
adjust the tension of A.S.C.D. wire in the following manner.
(1) After adjusting the length of the accelerator wire, turn a
securing nut by 1/2 to 1 turn from throttle open starting
position to the wire loosening direction to fix. (Must be
securing carried out to prevent response delay of operation
of the A.S.CD.)
(2) Securely tighten lock nut to hold adjusting nut in place.
For A.S.C.D. stop switch and clutch switch adjustment, refer
to SR and CL sections.

.

EL-90

AUTOMATICSPEED CONTROL DEVICE (A.S.C.D.)

Trouble Diagnoses
DIAGNOSTIC
PROCEDURE

Symptom
A.S.C.D. control unit cannot be set properly.

1

Resume switch will not operate.

2

Cancel switch will not operate.

3

Engine hunts.

4

Large difference between set vehicle speed and actual speed.

5

Set speed cannot be cancelled.

6

A/T model
only

8 When A.S.C.D. is set while vehicle is operating in "0.0." range, 0.0.
will be cancelled and shifting to 0.0. cannot be made thereafter.
8 0.0. will not be cancelled even if actual vehicle speed is 6 km/h
(4 MPH) lower than set speed. (Set speed cannot be ,maintained.)
8 0.0. will not be cancelled even if accelerator switch is turned "ON".

7

PREPARATION FOR TROUBLE-SHOOTING
1. Remove R.H. dash side cover.
2. Remove A.S.C.D. control unit with harness connected.
3. Perform check from harness side using circuit tester, with harness connector connected.

A.S.C.D. control

unit

Q)I

~

R.H. dash
side

~
SEL418L

GROUND CIRCUIT CHECK

.

Check continuity between

CID

and body ground.

EL-91

AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
DIAGNOSTICPROCEDURE-1
A.S.C.D.control unit cannot be set properly.

POWER SUPPLY CIRCUIT CHECK
1. Turn A.S.C.D. main switch to "ON".
2. Check voltage between @ and CID.

~oo

Turn A.S.C.D. main switch
"OFF" and then "ON" to make
sure indicator illuminates.

Check indicator bulb, A.S.C.D..
main switch and hold relay.

O.K.

Approx. (4) @
12V

Check AS.C.D. power supply
harness.

Check power supply circuit for
A.S.C.D. control unit.

[Y]

O.K.
Voltmeter

Check cut-off circuit for
A.S.C.D. control unit.

CUT-OFF CIRCUIT CHECK
1. Step on brake pedal.
2. Turn A.S.C.D. main switch to "ON".
3. Check voltage between (j]) and CID.

O.K.

N.G.

Check AS.C.D. cancel switch,
clutch switch (M/T model),
inhibitor relay and inhibitor
switch (A/T model).

[ilOO
:11

Approx.
12V

Brake pedal

Step on.

Check A.S.C.D. set switch
circuit for A.S.C.D. control unit.
Voltmeter

O.K.

SEL629L

Check speed sensor circuit.

SET SWITCH CIRCUIT CHECK
1. Push A.S.C.D. set switch.
2. Check voltage between @ and CID.

@

Approx.

@

O.K.

[iI@a

Check actuator. Refer to
"Actuator Check".

l5J

O.K.

Voltmeter

Replace A.S.C.D. control unit.
SPEED SENSOR CIRCUIT CHECK
1. Disconnect speed sensor from transmission.
2. Connect a voltmeter between (j) and CID.
3. Slowly turn speed sensor by hand to make
sure voltmeter pointer deflects.
. Voltmeter pointer deflects twice per
rotation of pinion.

~@a
J~\
Lfi-J

Approx.O.5V

Voltmeter

SEL630L

EL-92

N.G. Check AS.C.D. set switch and
harness betWeen control unit
and set switch.

Check speed sensor and harness
betWeen A.S.C.D. control unit
and speed sensor signal output
terminal of combination meter.

Replace actuator.

AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC

PRESUME SWITCH CI RCUI T CHECK

1. Turn resume switch to "ON".
2. Check voltage between CD and@

PROCEDURE-2

Resume switch will not operate.

.

N.G.
Check resume switch circuit.

rilOO
Q)
1

Check resume switch.

O.K.
Replace A.S.C.D. control unit.

::~rox. @

lilJ
[YJ

Resume-switch

- ON

+ Voltmeter

SEL636L

/
DIAGNOSTIC

CANCEL SWITCH CIRCUIT CHECK
1. Turn cancel switch to "ON".
2. Check voltage between @ and @ or
CD and @ .

PROCEDURE-3

Cancel switch will not operate.
Check cancel switch circuit.

riI~
Q)or@ Approx.

l

~~~

Voltmeter

@

Cancel switch

- ON

O.K.
Replace A.S.C.D. control unit.

j
SEL637L

EL-93

Check cancel switch.

AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC

PROCEDURE-4

Engine hunts.
Check vacuum hose for

Repair or replace hose.

L breakage, cracks I or fracture.

O.K.
Does A.S.C.D.wire move
smoothly?

Repair or replace wire.

O.K.
Go to "Actuator Check".

N.G. [

4

Replace actuator.

O.K.
Replace A.S.C.D. control unit.

DIAGNOSTIC

/

PROCEDURE-5

Large difference between set vehicle speed and actual speed.
Check A.S.C.D. wire and
actuator move smoothl y.

N.G.
Replace wire or actuator.

O.K.
Check vacuum hose for

Repair or replace hose.

breakage, cracks or fracture.

O.K.
Go to "Actuator Check".

O.K.
Replace A.S.C.D. control unit.

EL-94

I~
I~

Replace actuator.

AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
CUT-OFF CIRCUIT CHECK
1. Turn A.S.C.D. main switch to "ON".
2. Turn A.S.C.D. main switch to "ON" again.
3. Step on brake pedal.
4. Step on clutch pedal (M/T) or shift in "N"
range (A/T).

5. Check voltagebetween CID and

CID

DIAGNOSTIC

PROCEDURE-6

Set speed cannot be canceled.
N.G.
Check cut-off circuit.

Check A.S.C.O. cancel switch,
clutch switch (M/T model),
inhibitor relay and inhibitor
switch (A/T model).

O.K.

.

\

~

OV

[JZJ
+ -

~oo
3 Brake pedal-> Step on.
Clutch pedal
(M/T)-> Step on.
AfT control-> "N" range
lever (A/T)

CHECK

Replace actuator.

O.K.

1. Step on brake pedal.

2. Check voltage between @ and

.

CID

Replace A.S.C.O. control unit

~
@

Check stop lamp switch and
power supply harness.

O.K.
Check actuator. Refer to
"Actuator Check".

Voltmeter

STOP LAMP CIRCUIT

N.G.
Check stop lamp circuit.

~

Approx.
12V

[JZJ
Voltmeter

SEL631L

O.D. CANCEL CIRCUIT CHECK FOR A.S.C.D.
CONTROL UNIT
1. Turn 0.0. control switch to "ON"

2. MeasurevOltageacross @ and

CID

.

DIAGNOSTIC PROCEDURE-7
AfT model only:

.
.
.

0.0. control

When A.S.C.D. is set while vehicle is operating in "O.D."
range, O.D. will be cancelled and shifting to O.D. cannot
be made thereafter.
O.D. will not be cancelled even if actual vehicle speed is 6
kmfh (4 MPH) lower than set speed. (Set speed cannot be
maintained.)
O.D. will not be cancelled even if accelerator switch is
turned "ON".

switch -> ON

Check 0.0. cancel circuit for
A.S.C.O. control unit.

O.K.
Voltmeter
SEL640M

Replace A.S.C.O. control unit.

EL-95

N.G.

Check harness betWeen0.0.
cancel solenoid, 0.0. control
switch and A.S.C.O. control
unit.

AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)

Actuator Check

18

~

'~~
[ill
-

DISCONNECT

1. Disconnect connector of actuator from main harness.
2. Check actuator operations as shown.

+

Check actuator.

~

-1'0

234

~

'\

~

~

O.K.

m

/ \ /J

Release valve
Air valve
Vacuum valve

~

SEL423L

Check to see if motor starts
when 12V D.C. is applied across
CD

m

N.G.

Replace actuator.

and @.
O.K.

~

Ii)
Check to see if A.S.C.D. wire is
pulled when 12V D.C. is applied
across CD. CV.:IDand @ .

Check to see if A.S.C.D. wire

I;)

Replace actuator.

O.K. (Wire is pulled.)

[!)
SE L691 L

N.G.

returns to original position 50 to
60 seconds after disconnecting
lead from @ .

N.G.

~
I

O.K. (Wire does
not return.)

(;]

Disconnect lead from CD to see

N.G.

if A.S.C.D. wire returns
immediately.

~

O.K. (Wire returns.)
SEL692L

Replace actuator.
!

Actuator is O.K.

[!)

~
SEL693L

(;]

~
SE L694L

EL-96

Replace actuator.
[

1/

LOCATION OF ELECTRICAL UNITS
Engine Compartment

~
[AJ

Accessory relay-2 (Blue)
A.S.C.D. hold relay (Blue)
Air conditioner relay
U.S.A.:

FRONT

[eJ

BrOwn

(Canada: Blue )
(

'~

~ ~";'
f?'

,/

I

Fuse block

Z

/~
'

~

I ~

Headlamp

11 E:~eadlamp retract relay-2
"/

(Black)
Headlamp retract
(Black)
retract relay-3

relay-1

Horn relay (Black)

SEL420L

EL-97

LOCATION OF ELECTRICAL UNITS

Passenger Compartment
Accessory

relay-1

E.C.C.S. control unit

(Blue)

Circuit breaker
Ignition relay
With power window: Brown
Without power window: Blue)
Bulb check relay (Blue)
Rear window defogger
relay (Black)
S.M.J.

A.S.C.D. control unit

\I

(

AfT control unit
Door lock timer

~

/

--

Combination flasher unit
Chime

A.S.C.D. cancel switch
Stop lamp switch

Headlamp timer

Shift lock control unit

Time control unit

Automatic seat belt
control unit

Q

SEL421L

EL-98

HARNESS LAYOUT
Outline
Back door harness

Fastback

Rear wiper sub-harness

Room lamp harness
Doo~ harness

R.H. .

Instrument harness

Engine room harness

\
Engine room harness no. 2

E.F.I. harness.

SEL496L

Coupe

Sun roof harness

Room lamp harness.
Door harness R.H.
Instrument harness

Engine room
harness
.D

Door harness L.H.

Engine room harness no. 2
SEL496L

EL-99

HARNESS LAYOUT

Main Harness

/

EL-100

@
@
@
@
@)
@
@
@
@
@
@

@
@
@
@
@
@
@
@
@
@)
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@)
@
@
@
@
@
@
@
@
@

m
rI
~

0
~

en
m
r
UI
CD
~
s:

: Time control unit
: Headlamptimer
: Check connector
: Warningchime
: Fuse block
: Accessoryrelay-'
: Circuit breaker (Modelwith power window system)
: Circuit breaker (For U.S.A.I
: Ignition relay (Modelwith power window system)
: Ignition relay (Modelwithout power window system)
: To engine room harness 0
: To engine room harness
(Blue)
: To engine room harness ([ill) (Black)
: Bulb check relay
: Rear window defoggerrelay
: A.S.C.D.clutch switch (M/T model with A.S.C.D.I
: To door harness L.H. @)
: To door harness L.H. @
: Drillerside front limit switch (For U.S.A.)
: Kickdownswitch (A/T model)
: A.S.C.D.cancel switch (Modelwith A.S.C.D.I
: Stop lamp switch
: A.S.C.D.main switch (Modelwith A.S.C.D.I
: Headlampretractor switch
: Illuminationcontrol switch
: Front fog lamp switch
: Shift lock control unit (A/T model)
: Combination flasher unit
: Modedoor motor
: Foot lamp L.H.
: O.D. off indicator lamp (A/T model)
: Rear wiper and washer switch
: Rear window defoggerswitch
: Hazard switch
: Radio
: Radio
: Cassettedeck
: Cassettedeck
: Push control unit
: Fan switch
: Diode
: To sub-harness @
: To main harness @
: Glovebox lamp
: Glovebox lamp switch

0

@
@
@)
@
@
@
@
@
@
@
@
@
@
@)
@
@

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

Diode

To instrument harness @ (Black)
To instrument harness @(White)
Thermo control amplifier
Heater resistor
Blowermotor
Foot lamp R.H.
To E.F.I. harness @
To door harness R.H. @ill)
To door harness R.H. @ill)
To room lamp harness @
Body ground
Intake door motor
To sub-harness @
To main harness @
Door lock timer
Washerwarninglamp (Modelwith Anti-lock Brak

@
Lighting switch

~

Front fog lamp switch

~

Brake warning lamp
Brake fluid level switch
Parking brake switch
Seat belt warning lamp

/

r
~

I

Retractor re
Headlamp ti

Lighting swi

L-

Headlamp R
Bulb check

Time control

L-

Seat belt sw

Bodygro""~

\

m
rI

...a

0
N

~

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

(§Y :
(§j) :
(§3) :
@@) :
(§9 :
~
:
e
:
(§V :
~
:
(§V :
~ :
(§D :
§
:
@9 :
~
:
~
:
@ill) :
~
:
(§!) :
~
:
@£) :
:

Body ground
Lap belt buckle switch (For U.S.A.)
Seat belt switch (For Canada)
Ash tray illumination
Cigarette lighter
Door mirror control switch
Automatic seat belt control unit (For U.S.A.)
Parking brake switch
AfT device (AfT illumination and O.D. control switch) (AfT model)
Shift lock solenoid (AfT model)
Door switch L.H.
Automatic seat belt motor assembly L.H. (For U.S.A.)
Body ground (For U.s.A.)
Body ground
Rear speaker L.H.
Rear side marker lamp L.H.
Rear combination lamp L.H.

~

m
rI

...a

0
Co\)

~
C/J
m

r-

U1
II)
0

s:

Rear combination lamp L.H.
Back-uplamp L.H.
Rear wiper amplifier
Licenselamp L.H.
Licenselamp R.H.
Body ground
Luggageroom lamp switch
Back-uplamp R.H.
Luggageroom lamp
Rearcombination lamp R.H.
Rear combination lamp R.H.
Rear side marker lamp R.H.
Fuel tank gaugeunit
Rear speaker R.H.
To back door harness @ill)
To back door harness ~
To back door harness @
Automatic seat belt motor assembly R.
Door switch R.H.
A.B.S.control unit (For Anti-lock Brak
Body ground (For Anti-lock BrakingSy
Rear sensor (For Anti-lock BrakingSys

m

r-I

...\
0
~

--

@:

~
~

@B) :

~ :
@9 :
@lJ :
~ :
@V :
~ :
@i) :
@3) :
@ill) :
(§) :
@l7) :

~
~

:
:
~ :
:
@ill) :
(§3) :
@ill) :
~
:
@B) :
@@) :
§ :
:
@ :
~
:
@ :
:

Body ground
Lap belt buckle switch (For U.S.A.)
Seat belt switch (For Canada)
Ash tray illumination
Cigarette lighter
Door mirror control switch
Automatic seat belt control unit (For U.S.A.)
Parking brake switch
AfT device (AfT illumination and a.D. control switch) (AfT model)
Shift lock solenoid (AfT model)
Door switch L.H.
Automatic seat belt motor assembly L.H. (For U.S.A)
Body ground (For U.S.A.)
Body ground
Rear speaker L.H.

~

0

~

m

,...
I
~

0
U'I

en
m
r
(II
00

s:

--------

Rear side marker lamp L.H.
Licenselamp L.H.
Licenselamp R.H.
Body ground
Rear side marker lamp R.H.
Fuel tank gaugeunit
Rear speaker R.H.
Automatic seat belt motor assembly
Door switch R.H.
Trunk room lamp switch
Trunk room lamp
High-mountedstop lamp
Rear window defogger
Rear combination lamp L.H.
Rear combination lamp R.H.
Not used

HARNESS LAYOUT

Instrument Harness
CID : To main harness @ (Black)
@ : To main harness @ (White)
@ : Head-updisplaycontrol unit

@:
@:
@:

Combination meter
(Model with head-up display)
Combination meter
(Model without head-up display)
Combi nation meter
(Model with head-up display)

QD :
@

Combination meter
(Model without head-up display)
: Combination meter
(Model without head-up display)

EL-106

SE L501 L

HARNESS LAYOUT
NOTE

~

EL-107

HARNESS LAYOUT

Engine Room Harness

'U
C
::I
0

..01
>

'U
0
ID

EL-108

@
@

@
@
@
@
.

:
:
:
:
:
:

@ : To E.F.I. harness @ (Brown)
@D :
@ :
@ :
@ :
@) :

@

m
r-I

@
@
@)
@
@
@
@
@':
@
@
@
@
@
@
@
@
@
@
@

Windshield wiper motor
A.S.C.D. actuator (Model without Anti-lock Braking System)
Rear washer motor
Front washer motor
Washer fluid level switch
To E.F.I. harness @ (White)
To engine room harness no. 2 (@D (MfT model)
Inhibitor switch (AfT model)
Revolution sensor (AfT model)
Inhibitor switch (AfT model) (Gray)
To solenoid valve sub-harness (AfT model) (Brown)

: Relay box (Refer to page EL-97.J

@
@

0
@
: To engine room harness no. 2 ~
: Body ground

@D
@)
@
@
@
@

:
:
:
:
:
:

@

: To engine room harness no. 2

@

: To engine room harness no. 2

Low.pressureswitch
Battery
.Battery
Bodyground
Clutch interlock relay (MfTmodel for U.S.A.)
Front side marker lamp R.H.

@
@
@
@
@)
@
@

~

0
CD

~

en
m
r
UI
(XI
I\)

~

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

To front fog lamp sub-harness@
HeattlampR.H.
Headlamp motor R.H.
Front combination lamp R.H.
Horn-high
Condenserfan motor
Horn-low
Headlamp motor L.H.
Headlamp L.H.
Front combination lamp L.H.
Front side marker lamp L.H.
Body ground
Relay box (Refer to page EL~7.1
Dropping resistor (AfT model.)
Compressor
A.I.V. control solenoidvalve
Brake fluid levelswitch
Windshieldwiper amplifier (Modelwithout A

: To engine room harness
: Front fog lamp R.H.

@

: Front fog lamp L.H.

:
:
:
:
:

Front wheel sensor L.H.(For Anti-lock Bra
Body ground (For Anti-lock BrakingSystem
Actuator (For Anti-lock BrakingSystem)
Windshieldwiper amplifier (Modelwith Ant
A.S.C.D.actuator (Modelwith Anti-lock Br

m
rI

..a
..a
0

,

@)

"'P

~~
~

0

(@j)

1t.7ii'\

~

0
0

E112 El11

@j) :
@3) :

0
0
B
(fJ
m

:
:
:

To main harness @
To main harness @ (Blue)
To main harness @ (Black)
Clutch switch (M/T model for U.S.AJ
Key lock solenoid
(AfT model)
Key switch

r-

@!) :
(@Y : gnition switch

~

0:
@

UI
CD
N

~

ombination switch
: C mbination switch

([8)

0
~

0
@Y

@
@
@

: To main
: E.C.C.S
: To engi
(AfT mo
: To engin

Body ground

@

(MfT mo

: To engine

: To engin
: To engin
: F.I.C.D.

m
r-

-'
-'-'
I

en
m
r
UI
co
W

;:

@) :
@
:
@
:
@
:
@) :
@
:
@
:
@
:
@
:
@
:
@
:
@) :
@) :
@
:
@
:
@
:
@) :
@
:
@
:
@
:
@
:
@
:
@
@

/

A.A.C.va
Injector n
Air regula
Injector n
Pressurere
S.C.V. con
Exhaust g
Injector n
Injector no
Enginegro
Crank ang
Enginetem
Thermal tr
Throttle v
Throttle se
E.G.R. con
Air flow m
Resistor
Condenser
Ignition co
Power tran
Front whe

(For Anti-l
: Body groun
: Air tempera

m
rI

...a
...a

N

@D : To engine room harness @D
(M/T model!
~
: To engine room harness @
~
: To engine room harness @
@! : To engine room harness @
: Battery
@) : Power steering oil pressure switch
@V : Alternator
: Oil pressure switch
@J : Starter motor
@!9 : Exhaust gas temperature sensor
@ : Vehicle speed sensor
: Back-up lamp switch
(M/T model!

~

~
~

~
en
m
r
01
0
....

r

: Neutral switch
(M/T model!

@!9 : 5th position switch
(M/T model!

HARNESS LAYOUT

Back Door Harness

@D
(Qlli)
@ill)
~

:
:
:
:
:
:
@
:
@D :
~
:
@ill) :

~
~

To main harness @ill)
To main harness ~
To main harness @E)
Rear window defogger
High-mounted stop lamp
To rear wiper sub-harness @D (White)
(Brown)
To rear wiper sub-harness
To back door harness ~
(White)
To back door harness @
(Brown)
Rear window wiper motor

~

SEL505L

EL-113

Body ground

)

m
r-

-'-'
~
I

In
m
r

U1
0
~
r

Room
@
:
@)
:
@
:
@
:
(~
:
@
:
@
:

lamp harness
To main harness @
To sun roof harness @
Spot lamp (Model with sun roof)
Interior lamp (Model without sun roof)
Interior lamp (Fastback with sun rootl
Interior lamp (Coupe with sun roof)
Automatic seat belt front limit switch (For U.S.A.)

Sun ro
:
@ :
@ :
@ :
@ :
@ :
@ :
@
:

@

HARNESS LAYOUT
Door Harness
L.H.
@
@
@
@

@
@

:
:
:
:
:
:

To main harness @
To main harness @
Door speaker (Active speaker type)
Door speaker (Standard speaker type)
Door mirror motor
Power window regulator

@)

@
@
@
@
@D

:
:
;
:
:

Power window main switch
Power window amplifier
Door lock actuator
Door lock switch
Door latch switch (For U.S.A.)
SEL503L

R.H.

~

0

~8
.@ill)~
@B
@§)
@§)

8
~

: To main harness @
: To main harness @
: Door speaker
(Active speaker type)
: Door speaker
(Standard speaker type)
: Door mirror motor

@

:
:
.~
:
@:IV :
@IV :

~

EL-115

Power window regulator
Power window sub switch
Door lock actuator
Door lock switch
Door latch switch
(For U.S.A.)

SEL504L

HARNESS LAYOUT
NOTE

j
l,
~
r

l,

,
I

~
r
I
I

EL-116

SUPER MULTIPLE JUNCTION (S.M.J.)
Disconnecting and Connecting

.
.

S.M.J. is located on left side of dash.
To disconnect S.M.J., loosen fixing bolt.

.

To install S.M.J., tighten bolts until orange "full-tight" mark
appears and then retighten to specified torque as required.
~: 3 - 5 N.m
(0.3 - 0.5 kg-m, 2.2 - 3.6 ft-Ib)
CAUTION:
Do not overtighten bolts, otherwise, they may be damaged.

S.M.J.
SEL422L

~

EL-117

SUPER MULTIPLE JUNCTION (S.M.J.)
Terminal Arrangement
MAIN

HARNESS

/

\
AlA2A3A4ASA6 A7A8A9AliA11A12
BIB2B3B4BsB6
CIC2C3C4CsC6
01 02
El E2
Fl F2
Gl G2G3G4GsG6
HIH21H3
H4HsH6
11121314IS16

B7B8B9BID
B11B12
C7C8C9CID
C11C12

LJ

011 012

Ell E12
F11 F12

G7G8G9GlDG
11612
H7H8H9HID
H11H12
171819IIDI11112

~
~

/
ENGINE ROOM HARNESS

l

E.C.C.S. CONTROL UNIT

[11
View from harness side

EL-118

INCHTO METRICCONVERSION
TABLE

METRICTO INCHCONVERSION
TABLE


~,

"

Circui t Diagram
Engine and Emission Control Parts
Air Temperature

4

!

Diagram"

................................... 65
7

Description

.........................\............

~

Sensor

Engine and Emtssion Control System Description
Igni tioll Timing Control
Swirl Control Valve" (S.C. V.) Control
Fail-safe
System
Idle Speed/Ignition
Timing/Idle Mixture Ratio Inspection
Trouble Diagnoses
Self-diagnosis
- Mode III (Self-diagnostic
System)
Diagnostic Procedure 8
Diagnostic

Procedure

~lectrical

Components Inspection

9
.11
.12
13
15
16

24

.,.19
21

~

Service Data and Specifications
..~
Please reference
this Bulletin
on the Contents
Sections of the 1989 24USXService Manual.

8

;... .23
pages

of

the

,t

EM and EF&EC
f'

*Vehicles
.modified

with an Air Temperature
engine.

Sensor
1/23

on the

air

cleaner

box have the

I
~

COMPRESSION

-It'

PRESSURE

Measurement
1.
2.
'3.
4.
5.

of Compression

Pressure

Warm up engine.
Turn igr;1ition switch off.
Disconnect fusible link for injectors.
Remove all spark plugs.
Disconnect distributor center cable.

f

g
6. Attach a compression tester to NO.1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
Always use a fully-charged battery to obtain specified
engine revolution.

.

I

Compression pressure:
kPa (kg/cm2, psi)/rpm
Standard
1,206 (12.3, 175)/250
Minimum
1,010 (10.3, 146)/250
Difference limit between cylinders
98 (1.0, 14)/250

SEM113B

10. If cylinder compression in one or more cylinders is low, pour
a small amount of engine oil into cylinders through spark
plug holes and retest compression.
If adding oil helps compression, piston rings may be worn

.

.
.

I

or damaged. If so, replace piston rings after checking
piston.
If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. (Refer
to S.D.S.) If valve or valve seat is damaged excessively,
replace them.
If compression in any two adjacent cylinders is low and if
adding oil does not help compression, there is leakage
past the gasket surface. If so, replace cylinder head
gasket.

'

",.

. 2/23

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
General

oil'

Specifications

~

"

KA24E

Engine model

4, in-line

Cylinder arrangement
Displacement

em' leu in)

Bore x stroke

mm lin)

2,3891145.78)
89 x 9613.50 x 3.78)

Valve arrangement

O.H.C.

Firing order

1-3-4.2

Number of piston rings
Compression
Oil
Number of main bearings

I

Compression ratio

2
1
5
8.6

I

Unit: kPa (kg/em' , psil/rpm
Compression pressure
Standard
Minimum
Differential limit between
cylinders

1,206 112.3, 175)/250
1,010 (10.3,146)/250
98 (1.0,14)/250

~

3/23

L

v.:
0\;,

;j

ENGINE AND EMISSION CONTROL OVERALL SYSTEM
E.C.C.S. Component Parts Location

~

E.C.C.S.control unit

.

E.C.C.S.relay,

.

Fuel pump relay

Fuelpump

E.G.R. control

Exhaust gas
temperature sensor
(For California model)

valve

t~

Pressure regulator
Pressure solenol
regUla.~Or
control
valve'

~ ~

s.c.v.contrOI

fijif~ ~

.

I.A.A. un"it

~"o,
Fuel filter

~

t9

Throttle sensorl
Throttle valve switch

Ignition coil and
power transistor

Throttle chamber

Air temperature

~
)

E.G.R. control
solenoid valve

~

iT

Engine

temperatu re
sensor

ankangle

cr

~"'o,

'"~

t

Jec or

,

~

o;?J ~
Exhaust gas
sensor

4/23

sensor

1

0

Air flow meter

SEF4601

--

E.G.R. control
solenoid valve

Exhaust gas temperature sensor \
(For California model)
\

/

7

Ignition switch

r Air regulator

, , ,

Throttle
valve

8a

sensoi

:-)" r--L

J

-,

Ignition
coil

01

--N
W

S.C.V. control--solenoid valve
Cran k angle sensor
built-in distributor
Neutral switch (M/T)
Inhibitor switch (AfT)

(

,
Fuel pressure

regulator
/

/

valve
Engine

Transmission

g
=

'\

I

Swirl control""'"

"- Spark plug

j

{}

temperature
sensor

Carbon
canister

':;. speed

Vehiclesensor

Exhaust
gas sensor
"

A.I. V. control
solenoid valve

A.I.V.

en
m
"~
C>

,

Q

: Intake air flow

..

: Exhaustgasflow

- Air flow me

ENGINE AND EMISSION CONTROL OVERALL SYSTEM

E.C.C.S.
CONTROLSYSTEM
Crank angle sensor

I

Engine temperature

I

.1

I

Air flow meter

I

sensor

'System Chart

I

I

.I

I

I

I

I

I

I

Exhaust gassensor

I

.1

Air temperature sensor

I

~.

Ignition switch

J

Idle switch

I

I

I Throttle sensor

I

Canister
control&
E.G.R. control

~

control
E.C.C.S.
unit

I

switch

I

~

I

~

I

)1

Auxiliary
air control
(A.A.CJ valve

)I

AJ.V. control solenoidvalve

~

valve
E.G.R.control
solenoid

AJ.V. control

~I

I

Idle speed control

Fuel pump control

Air conditioner

Injectors

)f Power transistor

Ignition timing control

I

~

I

~
~

~I

--1

[ Starter switch

I

mixture ratio control

I

I

I

Fuel injection&

I

I

-

,/1

Fuel pump

I

f

I
I

Air regulator control

~

Air regulator

I

Neutral
Inhibitor switch
switch (M/T)
(A/T)

I

Vehicle speedsensor

I

Power steering oil pressure

I

, switch

[

Battery

I

~I

~

I

I Acceleration cut
control

I
S.C.V.(Swirl control

I valve) control

I

~I

I monitor
Exhaust &
gasself-diagnosis
sensor

I

~I

I Pressu
reregu
Iator

~

~

~

Air conditioner relay

S.C.V.control
solenoid valve

(On
the control
Inspection
lampsunit)

r-Exhaust gas temperature
(For California

model)

sensor
Pressure regulator control
solenoid valve

control

Fail-safe function

8
8

Air flow meter
Throttle sensor

8
8

Engine temperature sensor
Air temperature sensor

6/23
~

I

(

IGNITION

FUSIBLE
LINK

SWITCH

CHECK CONNECTOR
r-

OFFIACCION I ST

{8J-

-@
CHECK
ENGINE
LI GHT@

FUSE

f--1S}
>34 382336

-0
E. C. C. s.

I

...:-.
iii

RELAY

1

SATTERY

-

46

5
24

10 I

25

INJECTOR

~
~
~
~

U
ffi3

PRESSURE REGULATOR
CONTROL

106

SOLENOID

110
105

103
112

SOLENOID VALVE
A. 1. V. CONTROL

102

SOLENOID VALVE
S. C. V. CONTROL

4

-=-

VALVE

E. G. R. CONTROL

12

47

SOLENOID

VALVE

109
16
17

I ~--_m-7

I A~~E~LOW

113

To tachometer
-=-

~

n---__n_-1...

'-.I
-....
I\.)
W

m48

P

1] 6

P

"'p

1

Y'

6

RESISTORm

_n--nn

(

$
-= -=

0

-= -=

@

:

For

(0

:

A/T model

@

en

m
"T1
~
C'I
'"

:

13

n
0
Z
--i
;u
0
r

@:

A/T model

@:
~:

A/T mode
With

~:

Without

I

head-up

THROTTLE
VALVE
SWITCH

SWITCH

~LL IDLE

--i
4]
11


.,!,.

S ENS 0 R

EXHAUST GAS
TEMPERAl.URE
SENSOR (g

I'.tI

AIR
TEMPERATURE
SENSOR

26
115

H
--~:::::::::::::::~

37

A. S. C. D.

ENGINE
TEMPERATURE

21LL
29

For U.S.A.

display

POWER STEERING
OIL PRESSURE

35

display

head-up

5TH POSITION

-=-

20

wi thout

'R

44
33

I

@:
with

~=~
~SWITCH

43

CONDENSER

ANGLE
SENSOR

@:

INHIBIr

-=-

=

Ca I Iforn Ia

M/T modeI

PUMP

45

c
z

cn__m_-T

CRANK

SPARK PLUG

n_-

RELAY

AIR REGULAT~
FUEL

!'1

3

L

INHIBITOR
SWI TCH @

A.A.C. VALVE -a

107
19

~:~
~~ [ff:i!I:i:

104

39

EXHAUST
GAS
SENSOR

a
a
a
a

-

A/T
CONTRQL
UNIT ~

0

SPEED
SENSOR

-

ENGINE AND EMISSION CONTROL PARTS DESCRIPTION
Air Temperature

Sensor

The air temperature sensor is used to control ignition timing when
the temperature of the intake air is extremely high, in order not to
cause predetonation.

~

+~I
SEF1651

~.

~

8/23

ENGINE AND EMISSION CONTROL SYSTEM

DESCRIPTION

Ignition Timing Control
~

INPUT/OUTPUT

SIGNAL LINE
d

E .
Crank angle sensor

I

I

Amount

I

'ti on

d Dist

Air flow meter

of intake air

I
Engine temperature

Engine temperature

Air temperature

sensor
Intake air temperature

sensor

Throttle

Idle switch
I

E.C.C.S.
control
unit

valve idle position

Power transistor

I

Throttle valveopening angle
I

Throttle sensor

I

Neutral position

Neutral switch (M/T)
Inhibitor switch (A/T)

Start signal

I

Ignition switch

I

~

~

9/23

'--

/

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Ignition Timing Control (Cont'd)
In addition to this,
1 At starting
2 During warm-up
3 At idle
4 At low battery voltage
5 During swirl control valve operates
6 Hot engine operation
7 At acceleration
8 When intake air temperature is extremely high
the ignition timing is revised by the E.C.U. according
to the other data stored in the ROM.

SYSTEM DESCRIPTION
The ignition timing is controlled by the E.C.U. in
order to maintain the best air-fuel ratio in response to every running condition of the engine.
The ignition timing data is stored in the ROM
located in the E.C.U., in the form of the map
shown below.
The E.C.U. detects information such as the injection pulse width and crank angle sensor signal
which varies every moment. Then responding to
this information, ignition signals are transmitted to
the power transistor.
e.g.
N: 1,800 rpm, Tp: 1.50 msec
A °S.T.D.C.

Tp
(msec)
1.75i

A

1.50I
Injection
pulse
width

1.25i

1.00I

0.75

600

-

- ---

1,400

1,000

1,800

-

2,200

N

Engine speed (rpm)
SEC750A

10/23

~

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Swirl Control Valve (S.C.V.) Control
INPUT/OUTPUT SIGNAL LINE
~

Idle switch
I

Idle signal

.

Start signal

.

I

Ignition

I

switch

I

Engine speed

Crank angle sensor

SYSTEM DESCRIPTION
This system has a swirl control valve (S.C.V.) in
the intake passage of each cylinder.
While idling the S.C.V. closes. Thus the velocity of
the air in the intake passage increases, promoting
the vaporization of the fuel and producing a swirl
in the combustion chamber.
Because of this operation, this system tends to
increase the burning speed of the gas mixture,

improve fuel consumption, and increase the stability in running conditions.
The solenoid valve controls S.C.V.'s shut/open
condition. This solenoid valve is operated by the
E.C.U.

Idle switch

Water temperature

Engine rpm

Solenoid valve

S.C.V.

ON

Above 3SoC (9SoF)

Below 1,800

ON

Close

OFF

Open

Except above

.

S.C.V. control
solenoid valve

Enginetemperature

Engine temperature sensor

~

E.C.C.S.
control
unit

This table shows the control when starting enginetemperatureis above 10°C (50°F).

~
11/23

ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fail-safe System
ENGINE TEMPERATURE
MALFUNCTION

AIR FLOW METER MALFUNCTION
If the air flow meter output voltage is above or
below the specified value, the E.C.U. senses an air
flow meter malfunction. In case of a malfunction,
the throttle sensor substitutes for the air flow
meter.
Though air flow meter is malfunctioning, it is
possible to drive the vehicle and start the engine.
But engine speed will not rise more than 2,400
rpm in order to inform the driver of fail-safe
system operation while driving.

E.G.R. control system

Operation
Condition

Fixed condition

20°C (68°F)

More than 6 minutes after
ignition ON or Start

80°C (176°F)

OFF
A duty ratio is fixed at
the preprogrammed value.
Fuel is shut off above

Fuel injection control
system

THROTTLE

2,400 rpm.
(Engine speed does not
exceed 2,400 rpm.)

Engine
temperature decided

Just as ignition switch is
turned ON or Start

Except as shown above
Idle speed control system

~

When engine temperature sensor output voltage is
below or above the specified value, water temperature is fixed at the preset value as follows:

Operation
System

SENSOR

SENSOR

20. 80°C (68. 176°F)
(Depends on the time)

MALFUNCTION

When throttle sensor output voltage is below or
above the specified value, throttle sensor output
is fixed at the preset value.
AIR TEMPERATURE
MALFUNCTION

SENSOR

~

When air temperature sensor is below or above the
specified value, air temperature value is fixed at the
preset value [20°C (68°F)].

~

12/23

..

..

-

--

--~

-~~

IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

(

INSPECTION START

~

)

Visually check the following:
. Air cleaner clogging
. Hosesand ducts for leaks
. E.G.R. control valve operation
. Electricalconnectors

. Gaskets
. Throttle valveand throttle valveswitch operation

I~~I

Start engine and warm it up until water temperature
indicator points to the middle of gauge.

SEF457C

2

""

~

)!'

1..!
§

0::

Open engine hood and run engine at about 2,000
rpm for about 2 minutes under no-load.

3
4
~,."..~",L../" 5

'~,.",,,,,,~,,,,,,. 5

~

~

~

1~
=

0:

.""""Im;n

'v"-(6
~~

\

~1
~
~8

Run engine at about 2,000 rpm for about 2
minutes under no.load.

I

SEF477B

~~\
~V

Make sure that inspection lamp (Green) on E.C.U. goes IN.G.
on and off periodically more than 5 times during 10
seconds at 2,000 rpm under no.load.
O.K.

j\.(r)J

~/~

Set the diagnosis mode of E.C.U.to mode II.
Check inspection lamps (Red and Green) on
E.C.U. blink at 2,000 rpm.
They should blink simultaneously.
Yes

SEF450H

~r\
~~

No

INSPECTION END

'--~(r)

)

d~,/i~~

~

SEF292H

j
D

14/23

@

c

TROUBLE DIAGNOSES
Self-diagnosis
system)

-

Mode III (Self-diagnostic

The E.C.U. constantly monitors the function of these sensors
and actuators, regardless of ignition key position. If a malfunction occurs, the information is stored in the EC.U. and can be
retrieved from the memory by turning on the diagnostic mode
selector, located on the side of the E.C.U. When activated, the
malfunction is indicated by flashing a red and a green L.ED.
(Light Emitting Diode), also located on the E.C.U. Since all the
self-diagnostic results are stored in the E.C.U.'s memory even
intermittent malfunctions can be diagnosed.
A malfunctionis indicated by the number of both red and green
flashing L.ED.s. First, the red L.ED. flashes and the green
flashes follow. The red L.ED. corresponds to units of ten and
the green L.ED. corresponds to units of one. For example,
when the red L.E.D.flashes once and the green L.ED. flashes
twice, this signifies the number "12", showing that the air flow
meter signal is malfunctioning. All problems are classified by
code numbers in this way.
. When the engine fails to start, crank it two or more
seconds before beginning self-diagnosis.

. Before starting self-diagnosis, do not erase the stored
memory before beginning self-diagnosis. If it is erased, the
self-diagnosis function for intermittent malfunctions will be
lost.
DISPLAY CODE TABLE
Detected items

Code No.

I

California

NonCalifornia

11

Crank angle sensor circuit

X

X

12

Air flow meter circuit

X

X

13

Engine temperature sensor circuit

X

X

14

Vehicle speed sensor circuit

X

X

21

Ignition signal missing in primary coil

X

X

31

E.C.U. IE.C.C.S. control unit)

X

X

32

E.G.R. function

X

-

33

Exhaust gas sensor circuit

X

X

35
41

Exhaust gas temperature sensor circuit
Air temperature sensor circuit

X
X

43

Throttle sensor circuit

X

X

45

Injector leak

X

-

55

No malfunction in the above circuit

X

X

X: Available -: Not available

,

15/23

X

I

TROUBLE DIAGNOSES

E.G.R. FUNCTION (CodeNo.32)

~

Diagnostic Procedure 8
[Not self-diagnostic
item (For non-Californiamodels)]

E. G.R.
CONTROL
SOLENOID
VALVE

E. C. C. S.
CONTROL
UNI T

@)

Iij

P

~

@)W
"'''' -=<> Ii]
_"XI

I

IDS-LG

FUSE

WJ
B/R

@)@)
(E. F. I.
harness)

(Eng I ne
harness)

BR-' tBR

room
BR

w
BR~

I~ ~:~

~

"1
2
3
4
5

~
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