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1 QUICK REFERENCE INDEX
FOREWORD
SERVICE MANUAL
GENERAL INFORMATION SECTION
G611GE1
TROUBLESHOOTINGSECTION G611GE3
WIRING DIAGRAM SECTION G611GE4
This Service Manual is divided into four volumes by section so that it can be used with ease at
work. Refer to the Table of Contents select and use the necessary section
Each chapter in the manual is basically made of the following four types of areas
The description of each area is provided with four types of titles different in size as shown below.
The Title No or Symbol prefixes each title in order that the construction of the article and the flow
of explanation can be easily understood
(Example of usage)
In this manual, the following Symbols are used.
: Selective part
: Replacement part
: Sealing point
: Tightening torque
WARNING: Indicates the item which must be observed precisely during performance of maintenance
services in order to avoid injury to the mechanics and other persons.
CAUTION: Indicates the item which must be followed precisely during performance of maintenance
services so as to avoid damage and breakage to the vehicle and its parts and
components.
NOTE: Indicates the hints. knacks. etc. which make the maintenance job easier.
SPECIAL TOOLS
When any special tool is required to perform the job. it is identified by "ST" in the applicable illustration
and its part number is shown in the manual.
TABLE OF CONTENTS
2-1 *************************
2-2 On-Car Services
2-3 Engine
2-4 Engine Lubrication System
2-5 Engine Cooling System
ENGINE SECTION 2-6 *************************
2-7 Fuel Injection System
2-8 Fuel System
2-9 Exhaust System
2-10 Clutch
2-11 Engine and Transmission Mounting System
3-1 Manual Transmission and Differential
********** 2.1
ON-CAR SERVICES 2.2
ENGINE 2.3
ENGINE LUBRICATION SYSTEM 2.4
ENGINE COOLING SYSTEM 2.5
2.1 **********
2.2 ON-CAR SERVICES
Page
W SERVICE PROCEDURE......................................................................................................... 2
1. Foreword............................................................................................................................. 2
2. Ignition Timing..................................................................................................................... 2
3. Engine Idle Speed...............................................................................................................3
4. Engine Compression...........................................................................................................4
6. Valve Clearance.................................................................................................................. 6
2.2 SERVICE PROCEDURE
1. Foreword 2. Ignition Timing
1. Foreword
2. Ignition Timing
A: INSPECTION
1) Warm up the engine.
2) Confirm that the idle switch is ON. (Throttle pedal
OFF).
3) Turn ignition switch to OFF.
4) Connect test mode connector (2).
5) Remove engine room cover.
NOTE:
2
SERVICE PROCEDURE 2.2
2.Ignition Timing 3. Engine Idle Speed.
B: ADJUSTMENT
1) Loosen the 8 mm bolt securing distributor.
2) Turn the distributor housing. The timing is advanced
when the distributor housing is turned clockwise and is
retarded when turned counterclockwise.
3) Tighten the bolts and make sure that the timing is
correct.
4) After adjusting ignition timing, adjust the engine idle
speed.
Tightening torque:
14.2 - 17.2 Nm (1.45 - 1.75 kg-m, 10.5 - 12.7ft-lb)
3
2.2 SERVICE PROCEDURE
3, Engine Idle Speed 4. Engine Compression
B: ADJUSTMENT
Adjust engine idle speed outside specification by
rotating idle adjusting screw on throttle body.
4. Engine Compression
A: MEASUREMENT
1) After Warming up the engine, turn ignition switch to
OFF.
2) Make sure that the battery is fully charged.
3) Remove all spark plugs.
4) Disconnect connectors from all fuel injectors.
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory performance
and operation.
7) Crank the engine by means of the starter motor, and
read the maximum value on the gauge When the
pointer is steady.
Hold the compression gauge tight against the spark
plug hole.
8) Perform at least two measurements per cylinder, and
make sure that the values are correct.
Engine Compression:
1373 - 1520 kPa (14-15.5kg/cm, 199-220 psi)
/300 rpm
4
SERVICE PROCEDURE 2.2
5. Intake Manifold Vacuum
5
2.2 SERVICE PROCEDURE
6. Valse Clearence
6. Valve Clearance
NOTE:
Inspection and adjustment should be performed while
engine is cold.
A: INSPECTION
1) Disconnect blow by hose from rocker cover.
2) Remove rocker cover.
NOTE:
The valves marked "o" in the table can be measured
fore valve clearance.
B: ADJUSTMENT
1) Loosen adjusting screw locknut.
2) Adjust valve clearance to specified value by using
ST.
ST 498767000 VALVE CLEARANCE ADJUSTER
3) Tighten locknut.
Tightening torque:
17-23 N m (1.7 2.3 kg-m, 12-17 ft-lb)
6
2.3 ENGINE
S SPECIFICATION AND SERVICE DATA...................................................................................2
1.Engine.................................................................................................................................. 2
C COMPONENT PARTS............................................................................................................. 6
1. Crankcase and Cylinder Head.............................................................................................6
2. Valve System...................................................................................................................... 7
3. Lubrication and Cooling Equipment.....................................................................................8
4. Crankshaft and Balancer Shaft............................................................................................9
W SERVICE PROCEDURE.......................................................................................................10
1. General Precautions.......................................................................................................... 10
2. Timing Belt......................................................................................................................... 11
3. Valve Rocker Assembly.....................................................................................................17
4. Camshaft........................................................................................................................... 20
5. Cylinder Head................................................................................................................... 28
6. Cylinder Block................................................................................................................... 41
T TROUBLESHOOTING........................................................................................................... 62
1. Engine Trouble in General.................................................................................................62
2. Engine Noise..................................................................................................................... 65
2.3 SPECIFICATION AND SERVICE DATA
1.Engine
1.Engine
A: SPECIFICATIONS
Model EMPi
Type In-line, 3-cylinder, with balancer shaft
Valve arrangement Belt driven, single over-head camshaft
Bore x Stroke 78.0 x 83.0 mm (3.07 x 3.27 in)
Piston displacement 1,189 cm3 (1,189cc, 72.55 cu in)
Compression ratio 9.1
Open (BTDC) 19 \
Intake valve timing
Close (ABDC) 53
Open (BBDC) 70
Exhaust valve timing
Close (ATDC) 12
Intake 0.13 0.17 mm (0.0051 0.0067 in)
Valve lash (Clearance)
Exhaust 0.23 - 0 27 mm (0.0091 - 0.0106 in)
Idling speed [At neutral position] 850 50 rpm
Firing order 1->3->2
Ignition timing BTDC 5 3 |
Ignition timing control Electric controlled advance
2
SPECIFICATION AND SERVICE DATA 2.3
1.Engine
B: SERVICE DATA
Valve rocker Rocker arm inner diameter STD 18 0 - 18.023 mm (0.7087 - 0.7096 in)
shaft runout 17.984 - 17.966 mm (0.7080 - 07073 In)
Rocker shaft outer diameter STD
Clearance between shaft and arm STD 0.016 - 0.057 mm (0.0006 - 0.0022 in)
Camshaft Camshaft runout Limit 0.020 mm (0.0079 in)
Camshaft bend Limit 0.025 mm (0.0010 in)
Front 38.940 - 38.965 mm (1.5331 - 1.5341 in)
Camshaft journal outer diameter STD Center 45.940 - 45.965 mm (1.8087 - 1.8096 in)
Rear 46.940 - 46.965 mm (1.8480 - 1.8490 in)
Front 39.000 - 39.025 mm (1.5354 - 1.536 in)
Journal bore diameter STD Center 46.000 - 46.025 mm (1.8110-1.8120 in)
Rear 47.000 - 47.025 mm (1.8504 - 1.8514 in)
STD 0.035 - 0.085mm (0.0014 - 0.0033 in)
Camshaft journal clearance
Limit 0.10 mm (0.0039 in)
IN 38.489 - 38.589 mm (1.5153-1.5192 in)
STD
EX 38.071 -39.071 mm (1.4989- 1.5382 in)
Cam height
IN 38.189 mm (1.5035 in)
Limit
EX 37.771 mm (1.4870 in)
STD 0.03-0.38 mm (0.0012-0.0150 in)
Thrust clearance
Limit 0.50 mm (0.020 in)
Valve STD 51.55 mm (2.030 in) 1
spring Free length
Limit 50.50 mm (1.988 in) |
Outer
Tension/maximum spring height STD 432 N (44.0 kg, 97 lb)/31.5 mm (1.24 in)
Out-of-squareness Limit 2.5, 1.8 mm (0.07 in) |
STD 45.08 mm (1.775 in) |
Free length
Limit 44.00 mm (1.732 in) j
Inner
Tension/maximum spring height STD 289 N (29.5 kg, 65.0 lb)/30.5 mm (1.20 in)
Out-of-squareness Limit 2.5, 1.8 mm (0.07 in)
Intake valve seat contact width STD 1.00 mm (0.039 in)
Valve seat
Exhaust valve seat contact width STD 1.40 mm (0.055 in)
Intake and STD 1.00 mm (0.039 in)
exhaust valves Intake valve head thickness 0.50 mm (0.020 in)
Limit
Catalyst STD 1.30 mm (0.051 in)
Exhaust valvemodel Limit 0.80 mm (0.031 in)
head thickness Non-Catalyst j STD 1.00 mm (0.039 in)
model Limit 0.50 mm (0.020 in)
Cylinder head Flatness of gasketed surface_ Limit 0.05 mm (0.0020 in)
Allowance of (gasketed surface) 0.20 mm (0.0079 in)
Limit
regrinding
[ Cylinder head height STD 100.0 mm (3.94 in) |
3
2.3 SPECIFICATION AND SERVICE DATA
1.Engine
4
SPECIFICATION AND SERVICE DATA 2.3
1.Engine
5
2.3 COMPONENT PARTS
1. Crankcase and Cylinder Head
(1) Pitching stopper bracket (8)Main bearing cap 3 (17)Crankcase (26) Exhaust valve oil seal
(RWD model) (9)Main bearing cap 2 (18) Oil pump sprocket shaft (27) Exhaust valve guide
(2) Crankcase stiffener (10)Main bearing cap (19) Cylinder head gasket (28) Plug
(4WD model) (11)Crankshaft bearing 4 (20) Valve spring retainer key (29) Cylinder head
(3) Plug (12)Crankshaft bearing 3 (21) Valve spring retainer (30) Exhaust valve
(4) Balancer shaft bearing 2 (13)Crankshaft bearing 2 (22) Valve spring, outer (31) Intake valve
(5) Balancer shaft bearing (14)Crankshaft bearing (23) Valve spring, inner (32) Oil seal
(6) Bearing cap seal (15) Coolant drain plug (24) Intake valve oil seal
(7) Main bearing cap 4 (16) Plug (25) Intake valve guide
6
COMPONENT PARTS 2.3
2. Valve System
2. Valve System
(1) Camshaft (9) Washer (18.3x24x1) (17) Bolt (25) Timing belt cover 2
(2) Snap ring (10) Rocker shaft spring (18) Belt cover mount (26) Belt cover plug
(3) Spring washer (11) oil filler cap (19) Spacer (27) Tensioner springdamper
(4) Valve rocker shaft (12) oil filler gasket (20) Timing beIt (28) Tensioner spring
(5) Valve rocker screw (13) Valve rocker cover (21) Camshaft driven pulley (29) Timing belt tensioner
(6) Valve rocker nut 1 (14) Valve rocker cover gasket (22) Distributor cord stay
(7) Valve rocker arm 1 (15) Timing belt cover (23) Timing belt cover plate
(8) Valve rocker arm 2 (16) Spacer (24) BeIt cover sealing
7
2.3 COMPONENT PARTS
3. Lubrication and Cooling Equipment
(1) Flywheel housing (9) Oil relief valve (17) Impeller (25) oil pump inner rotor
(2) Rubber plate (10) Relief valve spring (18) Gasket (26) Oil pump outer rotor
(3) Rubber plate 2 (11) Oil pump relief plug (19) Water pump cover (27) O-ring
(4) Oil pan (12) Oil level gauge guide (20) O-ring (28) Oil pump cover
(5) Oil drain plug (13) Oil strainer (21) Oil seal (29) Oil cooler
(6) Gasket (14) Mechanical seal (22) Oil pressure switch (30) Oil filter
(7) Oil seal (15) Plate (23) Shaft pin
(8) Crankcase cover (16) O-ring (24) Oil pump shaft
8
COMPONENT PARTS 2.3
4. Crankshaft and
Balancer Shaft
9
2.3 SERVICE PROCEDURE
4. Crankshaft and Balancer Shaft
1. General Precautions
CAUTION:
All parts should be thoroughly cleaned, paying
special attention to the engine oil passages,
pistons and bearings.
Rotating parts and sliding parts such as piston
bearing and gear should be coated with oil prior to
assembly.
Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be
reinstalled in the original positions and directions.
Gaskets and lock washers must be replaced with
new ones. Sealant should be used where specified
to prevent leakage.
Bolts, nuts and washers should be replaced with
new ones as required.
Even if necessary inspections have been made in
advance, proceed with assembly work while making
rechecks.
Coat the oil seal lips with clean engine oil before
reassembling.
Confirm the clearance of each portion during
assembling.
10
SERVICE PROCEDURE 2.3
1. General Precautions
2. Timing Belt
A: REMOVAL
1) Loosen generator installation bolts and remove V-
belt.
11
2.3 SERVICE PROCEDURE
2. Timing Belt
CAUTION:
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]
12
SERVICE PROCEDURE 2.3
2. Timing Belt
NOTE:
If crankshaft sprocket can not be removed by hand, use
ST1, ST2 and bolts (M6 x 20) to detach it from
crankshaft.
ST1 899521421 PULLER
ST2 399520802 BOLT
B: INSPECTION
1. TIMING BELT
1) Check timing belt teeth for breaks, cracks, and wear.
If any fault is found, replace belt.
2) Check the condition of back side of belt; if any crack
is found, replace belt.
CAUTION:
Be careful not to let oil, grease or coolant contact
the belt. Remove quickly and thoroughly if this
happens.
Do not bend the belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]
When timing belt teeth are skipped, replace the
timing belt.
13
2.3 SERVICE PROCEDURE
2. Timing Belt
3. SPROCKET
check sprocket for wear. If defective, replace the
sprocket.
C: INSTALLATION
CAUTION:
Be careful not to apply oil and coolant to each
sprocket on timing belt.
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]
14
SERVICE PROCEDURE 2.3
2. Timing Belt
15
2.3 SERVICE PROCEDURE
2. Timing Belt
16
SERVICE PROCEDURE 2.3
2. Timing Belt
(1) Washer
(2) Spring washer
(3) Rocker shaft
(4) Valve rocker arm 2
(5) Rocker shaft spring
(6) Valve rocker arm 1
17
2.3 SERVICE PROCEDURE
3. Valve Rocker Assembly
B: INSPECTION
1. ROCKER ARM
1) Make a visual inspection to ascertain that the arm
can be operated freely. Replace the arm if defective.
2) Check the wear on the inside diameter of the rocker
arm and the outside diameter of the rocker shaft. Then
calculate the clearance between rocker arm inside
diameter and rocker shaft outside diameter if the limit is
exceeded, replace.
Specification:
(1) Rocker arm inside diameter
Standard: 18.000- 18.023 mm (0.7087- 0.7096in)
(2) Rocker shaft outside diameter
Standard: 17.984- 17.966mm (0.7080- 0.7073in)
(3) Clearance between (1) and (2)
Standard: 0.016 - 0.057mm (0.0006 - 0.0022 in)
3) Check the cam-riding face of arm for cracks and
wear. Repair or replace the arm if defective.
4) Check the tip of adjusting screw for wear.
Replace the adjusting screw if defective.
5)
2. ROCKER SHAFT
1) Check the runout of rocker shaft for cracks and wear.
Repair or replace the rocker shaft if defective.
2) Check the oil passage for clogging. Clean the oil
passage if defective.
3)
C: INSTALLATION
1) Position rocker arms and rocker shaft springs, and
then insert the rocker shaft in position.
2) Install spring washer, washer, and snap ring on each
end of the rocker shaft.
(1) Washer (4) Valve rocker arm 2
(2) Spring washer (5) Rocker shaft spring
(3) Rocker shaft (6) Valve rocker arm 1
18
SERVICE PROCEDURE 2.3
3. Valve Rocker Assembly
19
2.3 SERVICE PROCEDURE
3. Valve Rocker Assembly
4. Camshaft
A: REMOVAL
1) Loosen generator installation bolts and remove
belt.
2)
20
SERVICE PROCEDURE 2.3
4. Camshaft
CAUTION:
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]
21
2.3 SERVICE PROCEDURE
4. Camshaft
12) Remove clips from both end of the rocker shaft, and
slide out the rocker shaft.
13) Remove rocker arms and rocker shaft springs.
CAUTION:
There are two types of shape in valve rocker arms.
When disassembling the rocker arm assembly, be
sure to place the removed arm, washer, wave
spring, etc. in the order of disassembly. This will
help the parts to be installed in the proper order.
(1) Washer
(2) Spring washer
(3) Rocker shaft
(4) Valve rocker arm 2
(5) Rocker shaft spring
(6) Valve rocker arm 1
22
SERVICE PROCEDURE 2.3
4. Camshaft
B: INSPECTION
1. CAMSHAFT RUNOUT AND BEND
23
2.3 SERVICE PROCEDURE
4. Camshaft
3. CAM HEIGHT
Check cam face condition; remove minor faults by
grinding With oil stone. Measure the height of lobe.
Replace if the limit is exceeded.
Cam height: H
Standard: IN: 38.489-38.589 mm (1.5153-1.5192 in)
EX: 38.071-39.071 mm (1.4989-1.5382 in)
Limit: IN: 38.189 mm (1.5035 in)
EX: 37.771 mm (1.4870 in)
4. THRUST CLEARANCE
C: INSTALLATION
1) Apply a coat of engine oil to camshaft journals and
install camshaft into the cylinder head.
2) Apply engine oil to the oil seal lip, and install
camshaft oil seal into cylinder head.
24
SERVICE PROCEDURE 2.3
4. Camshaft
25
2.3 SERVICE PROCEDURE
4. Camshaft
CAUTION:
In this time, the valves that is marked "o" in the
table can be adjusted the valve clearance.
26
SERVICE PROCEDURE 2.3
4. Camshaft
27
2.3 SERVICE PROCEDURE
4. Camshaft
5. Cylinder Head
A: REMOVAL
1) Loosen generator installation bolts and remove v-belt
28
SERVICE PROCEDURE 2.3
5. Cylinder Head
CAUTION:
Do not bend or twist the timing belt sharply.
[The bending radius must be greater than 60 mm
(2.40 in).]
29
2.3 SERVICE PROCEDURE
5. Cylinder Head
CAUTION:
When removing the bolts which install cylinder
head onto cylinder block, loosen all bolts two-three
times in numerical order shown in figure.
B: DISASSEMBLY
1) Loosen adjusting screws of valve clearance after
loosening lock nuts.
30
SERVICE PROCEDURE 2.3
5. Cylinder Head
(1) Washer
(2) Spring Washer
(3) Rocker shaft
(4) valve rocker arm 2
(5) Rocker shaft spring
(6) Valve rocker arm 1
4) Remove camshaft.
CAUTION:
When removing camshaft, use care not to damage
the bearing.
C: INSPECTION
1. VALVE SPRING
1) Check valve springs for damage, free length, and
preload length. Replace the valve spring if the
specification is exceeded.
Free length (Standard)
Outer: 51.55 mm (2.030 in)
Inner: 45.08 mm (1.775 in)
31
2.3 SERVICE PROCEDURE
5. Cylinder Head
2. VALVE SEAT
1) Inspect intake and exhaust valve seats, and repare
the seating contact face by cutting and regrinding. And
lap the valve face with compound if required.
CAUTION:
Be careful not to enter the compound into the valve
stem and guide.
Valve seat contact width: W
intake
Standard: 1.00 mm (0.039 in)
Exhaust
Standard: 1.40 mm (0.055 in)
32
SERVICE PROCEDURE 2.3
5. Cylinder Head
3. VALVE GUIDE
1) Measure the clearance: W between the valve guide
and valve stem for intake and exhaust valves with a dial
gauge. If the limit is exceeded, replace valve or valve
guide.
Valve stem diameter: d
Intake
Standard: 6.965 - 6.980 mm
(0.2742 - 0.2748 in)
Exhaust
Standard: 6.945 - 6.960 mm
(0.2734 - 0.2740 in)
Valve guide inner diameter: D
Standard: 7.000 7.015 mm
(0.2756 - 0.2762 in)
Valve guide to valve stem clearance: w = D - d
Intake
Standard: 0.020 0.050 mm
(0.0008 - 0.0020 in)
Limit: 0.130 mm (0.0051 in)
Exhaust
Standard: 0.040 0.070 mm
(0.0016 0.0028 in)
Limit: 0.150 mm (0.0059 in)
33
2.3 SERVICE PROCEDURE
5. Cylinder Head
34
SERVICE PROCEDURE 2.3
5. Cylinder Head
6. CYLINDER HEAD
1) Check the gasket and gasketed surface for leakage
of combustion gas.
2) Check the cylinder head for crack or other damage.
CAUTION:
Do not scratch or nick the surface of cylinder
head. Gas leakage and other damages may result.
Do not scratch or nick the gasketed surface. Gas
leakage may result.
NOTE:
Remove carbon from combustion chamber.
Clean sealant of the mating surface by using scraper.
35
2.3 SERVICE PROCEDURE
5. Cylinder Head
D: ASSEMBLY
1) Installation of valve spring and valve.
(1) Coat stem of each valve with engine oil and
insert valve into valve guide.
(2) Install valve spring and retainer.
CAUTION:
When inserting the valve into valve guide, use
special care not to damage the oil seal lip.
Be sure to install the vaIve springs with their
closecoiled end facing the seat on the cylinder
head.
36
SERVICE PROCEDURE 2.3
5. Cylinder Head
E: INSTALLATION
1) Install cylinder head gasket and cylinder head on
cylinder block.
CAUTION:
Clean the mating faces before installing the
cylinder head on the cylinder block.
Use a new cylinder head gasket.
37
2.3 SERVICE PROCEDURE
5. Cylinder Head
38
SERVICE PROCEDURE 2.3
5. Cylinder Head
39
2.3 SERVICE PROCEDURE
5. Cylinder Head
40
SERVICE PROCEDURE 2.3
5. Cylinder Head
6. Cylinder Block
A: DISASSEMBLY
1) Lock up crankshaft by using ST onto flywheel.
ST 498275600 FLYWHEEL STOPPER
41
2.3 SERVICE PROCEDURE
6. Cylinder Block
42
SERVICE PROCEDURE 2.3
6. Cylinder Block
CAUTION:
To avoid damaging to crankshaft journal, install a
short piece of tube over the rod bolt thread as a
protector.
43
2.3 SERVICE PROCEDURE
6. Cylinder Block
44
SERVICE PROCEDURE 2.3
6. Cylinder Block
B: INSPECTION
1. CYLINDER BLOCK
1) Clean the gasketed surface and the oil pump contact
surface.
CAUTION:
Do not scratch and nick the upper and lower
surfaces of cylinder block by using a sharp-edged
tool.
2) Remove carbon from cylinder bore.
CAUTION:
Do not scratch and nick the cylinder bore by using
a sharp-edged tool.
3) Visual inspection
(1) Check the cylinder block for crack and other
damage. Especially, check the oil pump and water
pump contact surfaces for crack and other damage.
(2) Check the oil passages for clogging.
45
2.3 SERVICE PROCEDURE
6. Cylinder Block
5) Cylinder bore
Using a cylinder bore gauge, measure the cylinder bore
in axial and thrust directions at three points ((1) (2) (3)
in Figure.) If cylinder bore is Worn: the cylinder bore
diameter exceeds the specification, or measurement in
axial and thrust directions exceeds the taper limit on
out-of-roundness limit, perform reboring and horning to
the cylinder and use oversize piston.
A. Top
B. Bottom
C. Exhaust port side
D. Crankshaft pulley side
46
SERVICE PROCEDURE 2.3
6. Cylinder Block
4) Piston-to-cylinder clearance
Measure the cylinder bore diameter at the center of
cylinder and the piston diameter at the height of 10.5
mm (0.413 in) from the piston skirt end. The piston-to-
cylinder clearance is the difference between the
cylinder bore diameter and the piston diameter. If the
limit is exceeded, perform reboring and honing to the
cylinder and use oversize piston.
Piston-to-cylinder clearance:
Standard; 0.013 - 0.037 mm (0.0005 - 0.0015 in) Limit;
0.060 mm ( 0.0024 in)
5) Check the piston bore and its groove for burr. Repair
the piston bore such that the piston pin can be moved
by a finger push if defective.
47
2.3 SERVICE PROCEDURE
6. Cylinder Block
3. PISTON RING
1) visual inspection
If piston ring is broken, damaged, or Worn, or if its
tension is insufficient, or When the piston is replaced,
replace piston ring With a new one of the same size as
the piston.
"R" or "2R" is marked on the end of the top and second
rings. When installing the rings to the piston, face this
mark upward.
CAUTION:
"R" or "2R" is marked on the end of the top and
second rings. When installing the rings to the
piston, face this mark upward.
48
SERVICE PROCEDURE 2.3
6. Cylinder Block
4. CONNECTING BOD
1) Install connecting rod fitted with bearing to
crankshaft and measure the side clearance (thrust
clearance). Replace connecting rod if the side
clearance exceeds the limit.
Connecting rod side clearance:
Standard; 0.07- 0.30 mm (0.0028 - 0.0118 in)
Limit; 0.35 mm (0.0138 in)
2) Replace connecting rod, if the large or small end
thrust surface is damaged.
49
2.3 SERVICE PROCEDURE
6. Cylinder Block
50
SERVICE PROCEDURE 2.3
6. Cylinder Block
5. CRANKSHAFT
1) With crankshaft cleaned, check the crankshaft for
cracks or other damage.
2) Check crankshaft runout
Measure the runout at the crank journal center diameter
by using a dial gauge. If the limit is exceeded, replace
the crankshaft.
Crankshaft runout:
Limit: 0.030 mm (0.0012 in)
51
2.3 SERVICE PROCEDURE
6. Cylinder Block
Unit: mm (in)
52
SERVICE PROCEDURE 2.3
6. Cylinder Block
53
2.3 SERVICE PROCEDURE
6. Cylinder Block
54
SERVICE PROCEDURE 2.3
6. Cylinder Block
C: ASSEMBLY
1) Install balancer shaft bearing 2 (rear).
CAUTION:
When installing the bearing, ensure that the oil hole
of the bearing is properly aligned with the oil hole
of the crankcase.
(1) Install new balancer shaft bearing 2 with S'! 1
and ST2 by using a hydraulic press.
ST1 498835801 REAR BALANCER METAL PRESS
ST2 498835803 REAR BALANCER METAL SPACER
(2) Install plug by tapping it from the rear side of the
cylinder block with ST1.
ST 1 498835801 REAR BALANCER METAL PRESS
55
2.3 SERVICE PROCEDURE
6. Cylinder Block
56
SERVICE PROCEDURE 2.3
6. Cylinder Block
17) Install the piston pin and circlip to the piston and
connecting rod assembly.
57
2.3 SERVICE PROCEDURE
6. Cylinder Block
58
SERVICE PROCEDURE 2.3
6. Cylinder Block
22) Install crankshaft front oil seal and balance shaft oil
seal.
CAUTION:
Do not reuse the oil seal, and be careful not to allow
oil seal lip turn inside out.
CAUTION:
Coincide the groove of the oil pump shaft.
Do not drop the O-ring for oil pump in mating
surface of crankcase cover and cylinder block.
Tightening torque:
14.2- 17.2 Nm(1.45- 1.75 kg-m, 12.7ft-ib)
24) Install oil pump rotor (inner and outer), and oil pump
cover.
25) Install oil cooler and oil filter.
59
2.3 SERVICE PROCEDURE
6. Cylinder Block
29) Apply fluid packing to the oil pan plate and install oil
pan plate to cylinder block.
Fluid packing: THREE BOND #1207C
60
SERVICE PROCEDURE 2.3
6. Cylinder Block
61
2.3 TROUBLESHOOTING
1. Engine Trouble in General
Dieseling (Run-on).
Knocking
Surging
62
TROUBLESHOOTING 2.3
1. Engine Trouble in General
TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
INTAKE SYSTEM
2 2 1 2 2 1 2 2 1 Improper idle adjustment.
3 1 1 1 3 1 1 Loosened or cracked blow-by hose.
3 1 2 1 1 2 1 Loosened or cracked vacuum hose.
2 2 2 2 2 1 Defective intake manifold gasket.
3 2 2 2 2 2 Defective PCV valve.
2 2 2 3 2 3 Loosened oil filler cap.
3 3 1 2 2 1 Dirty air cleaner element.
FUEL LINE
2 3 2 2 Defective fuel pump.
3 3 2 2 Clogged fuel line.
2 2 2 2 3 3 Lack of or insufficient fuel.
BELT
2 2 2 Defective.
2 2 2 3 2 2 2 2 2 Defective timing.
FRICTION
3 Seizure of crankshaft and connecting rod bearing.
3 Seized camshaft.
3 Seized or stuck piston and cylinder.
COMPRESSION
3 3 3 2 2 2 2 3 2 Incorrect valve clearance.
3 3 3 2 2 3 3 3 Loosened spark plugs or defective gasket.
3 3 3 2 2 3 3 3 Loosened cylinder head bolts or defective gasket.
3 3 3 2 2 3 2 2 Improper valve seating
3 3 3 3 3 3 3 1 3 Defective valve stem.
2 2 2 2 2 2 3 3 Worn or broken valve spring.
3 3 3 2 3 3 3 1 2 Worn or stuck piston rings, cylinder and piston.
2 2 2 1 1 1 1 2 2 Incorrect valve timing.
2 2 2 2 2 2 Improper engine oil (low viscosity).
1 2 3 4 5 6 7 8 9 10 11 12 13
63
2.3 TROUBLESHOOTING
1. Engine Trouble in General
TROUBLE No.
POSSIBLE CAUSE
1 2 3 4 5 6 7 8 9 10 11 12 13
LUBRICATION SYSTEM
2 2 3 3 Incorrect oil pressure.
2 Loosened oil pump attaching bolts.
2 Defective oil filter seal.
2 Defective crankshaft oil seal.
2 Defective rocker cover gasket.
2 Loosened oil drain plug.
2 Loosened oil pan bolts or defective oil pan.
COOLING SYSTEM
3 3 2 2 1 Overheating.
3 3 3 Over cooling.
OTHERS
Malfunction of Evaporative Emission Control System.
1 1 3 3
<Ref. to 2- 7>
2 1 Stuck or damaged throttle valve.
3 2 2 2 Accelerator cable out of adjustment.
1 2 3 4 5 6 7 8 9 10 11 12 13
64
TROUBLESHOOTING 2.3
2. Engine Noise
2. Engine Noise
65
2.4 ENGINE LUBRICATION SYSTEM
Page
S SPECIFICATION AND SERVICE DATA...................................................................................2
1. Engine Lubrication System..................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Oil Pan and Oil Strainer.......................................................................................................3
2. Oil Pump............................................................................................................................. 4
W SERVICE PROCEDURE......................................................................................................... 5
1. Oil Pan and Oil Strainer.......................................................................................................5
2. Oil Pump............................................................................................................................. 7
3. Oil Cooler.......................................................................................................................... 10
4. Oil Pressure Switch........................................................................................................... 11
T TROUBLESHOOTING........................................................................................................... 12
1. Engine Lubrication System................................................................................................12
2.4 SPECIFICATION AND SERVICE DATA
1. Engine Lubrication System
Forced lubrication
Lubrication method
Pump type Trochoid type
Inner rotor 4
Number of teeth Number
Outer rotor 5
Outer rotor diameter x thickness 40.56 x 14.7 mm (1.597 x 0.579
Oil pump - pressure 167 kPa (1.7 kg/cm*, 24 psi)
1,500 rpm Discharge
Capacity - quantity 6.7 L (7.1 US qt, 5.9 Imp qt)/min.
80C (176F) - pressure 324 kPa (3.3 kg/cm2, 47 psi)
3,000 rpm Discharge
- quantity 11 L (H.6 US gal, 9.7 Imp gal)/min.
Relief valve operation pressure I 294.2-318.7 kPa (3.0-3.25 kg/cm2, 42.7-46.2 psi)
Type Full-flow filter type
Filtration area 800 cm2 (124.0 sq in)
Oil filter By-pass valve Opening pressure 78.5 - 117.7 kPa (0.8 - 1.2 kg/cm2, 11.4-17.1 psi)
Outer diameter x width 68 x 65 mm (2.7 x 2.6 in)
Oil filter to engine thread size M 20 x 1,5p
Type Immersed contact point type
Working voltage Wattage 12 V - 3.4 W or less
Oil pressure
switch Warning light activation pressure 14.7 - 24.5 kPa (0.15 - 0.25 kg/cm2, 2.1 - 3.6 psi)
Proof pressure More than 981 kPa (10 kg/cm2,142 psi)
Oil capacity (at replacement) 3.5 L (3.7 US qt, 3.1 Imp qt)
B: SERVICE DATA
STD 0.02 - 0.12 mm (0.0008 - 0.0047 in)
Tip clearance between inner and outer rotor
LIM 0.2 mm (0.008 in)
Side clearance between inner rotor and crankcase STD 0.05 - 0.16 mm (0.002 - 0.0063 in)
cover LIM 0.18 mm (0.0071 in)
Case radial clearance between outer rotor and STD 0.15 - 0.21 mm (0.0059 - 0.0083 in)
crankcase cover LIM 0.25 mm (0.01 in)
ST: STANDARD
LIM : LIMIT
2
COMPONENT PARTS 2.4
1. Oil Pan and Oil
Strainer
3
2.4 COMPONENT PARTS
2. Oil Pump
2. Oil Pump
(1) Oil IeveI gauge (7) Oil pump cover (13) O-ring
(2) Oil level gauge guide (8) Gasket (14) Gasket
(3) O-ring (9) Oil pump outer rotor
(4) OiI filter (10) Oil pump inner rotor
(5) OiI cooler (11) Crankcase cover
(6) Gasket (12) OiI pump drive gear
4
SERVICE PROCEDURE 2.4
2. Oil Pump
5
2.4 SERVICE PROCEDURE
1. Oil Pan and Oil Strainer
B: INSPECTION
Make sure not to damage oil pan and oil strainer by
visual check.
C: INSTALLATION
CAUTION:
Before installing oil pan, clean sealant from oil pan,
oil pan plate and engine block.
1) Apply fluid packing to mating surfaces of oil pan
plate.
Fluid packing:
THREE BOND 1207C
2) Install oil pan plate to cylinder block.
6
SERVICE PROCEDURE 2.4
1. Oil Pan and Oil Strainer
5) Install oil pan and tighten bolts Which install oil pan
onto engine block.
Tightening torque:
4.4 - 5.4 Nm (0.45 - 0.55 kg-m, 3.3 - 4.4 Mb)
2. Oil Pump
A: REMOVAL
1) Open rear gate and rear bumper.
2) Removal oil level gauge and oil level gauge guide.
7
2.4 SERVICE PROCEDURE
2. Oil Pump
8
SERVICE PROCEDURE 2.4
2. Oil Pump
B: INSPECTION
1. OIL PUMP SHAFT
Check oil pump shaft damage and wear.
C: INSTALLATION
1) Install oil pump outer rotor and inner rotor.
9
2.4 SERVICE PROCEDURE
2. Oil Pump
3. Oil Cooler
A: REMOVAL AND INSTALLATION
1) Open rear gate and rear bumper.
2) Remove oil level gauge and oil level gauge guide,
3) Loosen alternator installing bolt, and remove V-belt
10
SERVICE PROCEDURE 2.4
3. Oil Cooler
11
2.4 TROUBLESHOOTING
1. Engine Lubrication
System
12
2.5 ENGINE COOLING SYSTEM
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Engine Cooling System.......................................................................................................2
C COMPONENT PARTS............................................................................................................. 2
1. Water Pump........................................................................................................................ 4
2. Thermostat.......................................................................................................................... 5
3. Radiator............................................................................................................................... 6
4. Cooling System...................................................................................................................7
W SERVICE PROCEDURE......................................................................................................... 2
1. Precaution........................................................................................................................... 8
2. Water Pump...................................................................................................................... 10
3. Thermostat........................................................................................................................ 17
4. Radiator............................................................................................................................. 18
T TROUBLESHOOTING........................................................................................................... 20
1. Engine Cooling System.....................................................................................................20
2.5 SPECIFICATION AND SERVICE DATA
1. Engine Cooling System
2
SPECIFICATION AND SERVICE DATA 2.5
1. Engine Cooling System
B: MAINTENANCE STANDARDS
Water pump Standard 0.3 0.9 mm (0.012 0.035 in)
Clearance between impeller and case
Limit 1.1 mm (0.043 in)
"Thrust" runout of impeller end 0.5 mm (0.020 in)
C: RECOMMENDED COOLANT
SUBARU Lowest anticipated atmospheric tempera-
Above -30C (-22 F) Above -10C (-14F)
Genuine ture
Coolant SUBARU coolant-to-water* ratio
Part No. 50% - 50% 30% - 70%
(Volume)
000016218
net 18 L Specific gravity at 10C (50F) 1.078 1.047
(4.8 US gal, at 20C (68 F) 1.074 1.044
4.0 Imp gal) at 30C (86 F) 1.069 1.041
at 40C (104 F) 1.063 1.036
at 50C (122F) 1.057 1.031
Freezing point -36C (-33F) -16C (-3F)
*: It is recommended that distilled water be used.
3
2.5 COMPONENT PARTS
1. Water Pump
1. Water Pump
4
COMPONENT PARTS 2.5
2. Thermostat
2. Thermostat
5
2.5 COMPONENT PARTS
3. Radiator
3. Radiator
6
COMPONENT PARTS 2.5
4. Cooling System
4. Cooling System
(1) Coolant filler pipe (9) Radiator inlet pipe (17)Air vent hose B
(2) Coolant filler cap (10) Radiator outlet pipe (18) Rear heater hose A
(3) coolant filler hose (11) Heater pipe (19) Rear heater hose B
(4) Air breather hose A (12) Engine inlet hose (20) Heater hose A
(5) Air breather hose B (13) Engine outlet hose (21) Heater hose B
(6) Reservoir tank hose (14) Heater hose (22) Heater inlet hose
(7) Reservoir tank (15) Air vent plug (23)Heater outlet hose
(8) Air breather pipe (16) Air vent hose A
7
2.5 SERVICE PROCEDURE
4. Cooling System
1. Precaution
A: DRAINING OF COOLANT
WARING:
The radiator is of the pressurized type, do not
attempt to open the radiator cap immediately after
the engine has been stopped.
1) Set heater lever to FULL.
2) Lift up the vehicle.
3) Fit vinyl tube to drain pipe on radiator.
4) Loosen drain cock, and drain coolant into container.
5) After draining coolant, tighten drain cock.
B: FILLING OF COOLANT
1) Remove spare tire.
2) Remove air vent plug from air vent hose.
8
SERVICE PROCEDURE 2.5
1. Precaution
CAUTION:
The SUBARU Genuine Coolant containing
antifreeze and-rust agents is especially made for
SUBARU engine, which has an aluminum
crankcase. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
9
2.5 SERVICE PROCEDURE
1. Precaution
2. Water Pump
A: REMOVAL
1) Open rear gate and rear bumper.
2) Remove oil level gauge and oil level gauge guide.
10
SERVICE PROCEDURE 2.5
2. Water Pump
CAUTION:
Hold drive shaft onto transverse link with wire, etc.
11
2.5 SERVICE PROCEDURE
2. Water Pump
12
SERVICE PROCEDURE 2.5
2. Water Pump
B: DISASSEMBLY
1) Remove crankcase cover.
2) Remove mechanical seal.
(1) Press mechanical seal by using ST1.
ST1 498835400 MECHANICAL SEAL PRESS
(2) Set ST3 onto water pump side of crankcase
cover.
(3) Pull out mechanical seal by using ST2.
ST2 499715400 MECHANICAL SLAL REMOVER
ST3 499685510 MECHANICAL SEAL REMOVER
PLATE
C: INSPECTION
Check all removed parts, and replace if defective.
1) Check water pump impeller and ceramic seal for
cracks.
2) Check the contact surface of mechanical seal and
ceramic seal for wear and damage.
3) Check water pump impeller for corrosion or damage.
4) Check oil seal lip for wear, damage or hardening.
5) Check all other parts for crack, wear or damage.
D: ASSEMBLY
1) Install mechanical seal.
Press mechanical seal into crankcase cover by using
ST1 and ST2.
ST1 498835400 MECHANICAL SEAL PRESS
ST2 499795400 MECHANICAL SEAL INSTALLER
13
2.5 SERVICE PROCEDURE
2. Water Pump
E: INSTALLATION
1) Manually press Water pump impeller to balance
shaft, and measure the tip clearance. \
CAUTION:
When installing new water pump impeller add one
or two spacers and measure tip clearance
Standard:
0.3 - 0.9 mm (0.012 - 0.035 in)
Service limit:
1.1 mm (0.043 in)
14
SERVICE PROCEDURE 2.5
2. Water Pump
15
2.5 SERVICE PROCEDURE
2. Water Pump
16
SERVICE PROCEDURE 2.5
2. Water Pump
CAUTION:
Install a washer as shown in figure. Be careful
about its installation direction.
Tightening torque:
65 -75 Nm (6.5 -7.5 kg-m, 47-54 ft-lb)
3. Thermostat
A: REMOVAL AND INSTALLATION
1) Disconnect Water hoses from thermostat cover
17
2.5 SERVICE PROCEDURE
3. Thermostat
4. Radiator
A: REMOVAL
1) Lift up the vehicle.
2) Attach vinyl tube to drain cock.
3) Loosen drain cock and drain coolant into container.
18
SERVICE PROCEDURE 2.5
4. Radiator
B: INSTALLATION
Installation is in the reverse order of removal procedure.
19
2.5 TROUBLESHOOTING
1. Engine Cooling System
20
2.7 FUEL INJECTION SYSTEM
C COMPONENT PARTS............................................................................................................. 2
1. Air Intake System................................................................................................................2
2. ThrottIe body....................................................................................................................... 3
W SERVICE PROCEDURE......................................................................................................... 4
1. Air Cleaner.......................................................................................................................... 4
2. Throttle Body....................................................................................................................... 4
3. Intake Manifold....................................................................................................................5
4.Intake Air Temperature Sensor.............................................................................................7
5. Water Temperature Sensor..................................................................................................7
6. Pressure Sensor.................................................................................................................7
7. Oxygen (O2) Sensor........................................................................................................... 7
8. Solenoid Valves................................................................................................................... 8
9. Fuel Injector........................................................................................................................ 9
10. Electric Control Unit.........................................................................................................10
11. Main Relay and Fuel Pump Relay ..................................................................................10
T TROUBLESHOOTING........................................................................................................... 12
1. General Troubleshooting Table..........................................................................................12
2.7 COMPONENT PARTS
1. Air Intake System
(1) Throttle body (6) PCV valve (11) Intake air temperature sensor
(2) Fuel injector holder assembly (7) Grommet (12) Air filter
(3) Fuel return hose (8) Grommet
(4) FueI delivery hose (9) Collector chamber*:RWD model only
(5) Fuel pipe assembly (10) Gasket
2
COMPONENT PARTS 2.7
2. Throttle body
2. Throttle body
3
2.7 SERVICE PROCEDURE
2. Throttle body
1. Air Cleaner
A: REMOVAL AND INSTALLATION
1) Remove bolts Which hold air cleaner case on rocker
cover bracket.
2) disconnect blow-by hose.
3) Remove bolt Which holds air intake duct on body
2. Throttle Body
A: REMOVAL AND INSTALLATION
1) Remove air cleaner assembly. <Ref. to 2-7 [W1A0]>
4
SERVICE PROCEDURE 2.7
2. Throttle Body
3. Intake Manifold
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to C.2-8 [W1A0]>
2) Remove air cleaner assembly. <Ref. to 2-7 [W1A0]>
5
2.7 SERVICE PROCEDURE
3. Intake Manifold
6
SERVICE PROCEDURE 2.7
3. Intake Manifold
7
2.7 SERVICE PROCEDURE
7. Oxygen (O2) Sensor
B: INSTALLATION
1) Before installing oxygen sensor apply
compound only to threaded portion of oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE Inc. or equivalent
CAUTION:
Never apply anti-seize compound to protect the
oxygen sensor.
Tightening torque:
25 - 34 N m (2.5 - 3.5 kg~m, 18 - 25 ft-lb)
8. Solenoid Valves
A: LOCATION
1) Turn ignition switch to OFF.
2) Remove bracket Which install each solenoid valve,
3) Disconnect hoses from each solenoid valve.
4) Disconnect connector from each solenoid valve.
5) Remove bolts Which install each solenoid valve.
6) Installation is in the reverse order of removal.
8
SERVICE PROCEDURE 2.7
8. Solenoid Valves
9. Fuel Injector
WARNING:
Place "No fire" signs near the work area when
removing and installing fuel injector.
A: REMOVAL
1) Release the fuel pressure.
<Ref. to 2-8 [W1A0]>
2) Remove air cleaner assembly.
<Ref. to 2-7 [W1A01]>
B: INSTALLATION
CAUTION:
Replace O-ring and seal with a new one.
9
2.7 SERVICE PROCEDURE
9. Fuel Injector
A: LOCATION
(1) Main relay
(2) Fuel pump relay
B: INSPECTION
1) Check main relay.
(1) Measure resistance between main relay con-
nector terminals as following.
Terminals / Specified resistance
No.3 - No.5 / Above 1 M
No.4 - No.6 / Above 1 M
10
SERVICE PROCEDURE 2.7
11. Main Relay and Fuel Pump Relay
11
2.7 TROUBLESHOOTING
1. General Troubleshooting
Table
Lack of warming up
Electric load switch
ECU power supply
Pressure regulator
Accelerator cable
Thermo air valve
Pressure sensor
Valve clearance
Throttle switch
Fuel injector
Ignition coil
Spark plug
Fuel pump
O2 sensor
startFailure of engine to
Engine staIIs 3 2 2 3 3 3 3 3 2 3 3 1 3
Rough idling 2 2 3 3 3 3 3 2 3 2 3 1 1 2 3 2
Hard to drive at constant speed 3 3 2 2 3
Poor acceIeration / deacceIeration 3 3 2 2 2 2 2 1
Poor return to idling 3 3 2 3 2 3 1 1 3 2
Back fire 3 3 3 2 1 1 3
Knocking 2 2 1
Excessive fuel consumption 2 1 2 2 1
Shocks while driving 2 2 1 2
Poor engine revving 2 2 2 2 2 2 1 2 2
Out of specifications for idle mixture 2 2 2 2 2
Remarks *1 *2 *2 *2 *2
12
2.8 FUEL SYSTEM
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Fuel System........................................................................................................................ 2
C COMPONENT PARTS............................................................................................................. 3
1. Fuel Line............................................................................................................................. 3
2. Fuel Tank............................................................................................................................. 5
W SERVICE PROCEDURE......................................................................................................... 6
1. Precaution........................................................................................................................... 6
2. On Car Service....................................................................................................................7
3. Fuel Tank............................................................................................................................. 9
4. Fuel Filler Pipe.................................................................................................................. 10
5. Fuel Filter.......................................................................................................................... 10
6. Fuel Pump......................................................................................................................... 10
7. Fuel Delivery, Return and Evaporation Lines.....................................................................11
8. Roll Over Valve.................................................................................................................. 12
9. Canister............................................................................................................................. 13
2.8 SPECIFICATION AND SERVICE DATA
1. Fuel System
1. Fuel System
A: SPECIFICATIONS
EMPi model
Capacity 40 L (10.6 US gal, 8.8 Imp gal)
Fuel tank
Location Under rear floor
Type Impeller type
Fuel pump Discharge pressure 294.2 kPa (3.0 kg/cm2, 42.7 psi)
Discharge volume More than 45 L (11.9 US gal, 9.9 Imp gal)/h
Fuel filter Cartridge type
2
COMPONENT PARTS 2.8
1. Fuel Line
1. Fuel Line
1. WAGON MODEL
3
2.8 COMPONENT PARTS
1. Fuel Line
2. VAN MODEL
4
COMPONENT PARTS 2.8
2. Fuel Tank
2. Fuel Tank
5
2.8 SERVICE PROCEDURE
2. Fuel Tank
WARNING:
Place "No fire" signs near the work area.
Be careful not to spill fuel on the ground.
Disconnect ground cable from battery.
1. Precaution
A: RELEASING OF FUEL PRESSURE
1) Lift up the vehicle.
2) Disconnect fuel pump connector.
B: DRAINING OF FUEL
1) Remove fuel filler cap.
2) Disconnect fuel filler hose (1) from pipe.
6
SERVICE PROCEDURE 2.8
1. Precaution
2. On Car Service
A: MEASUREMENT OF FUEL PRESSURE
1) Release fuel pressure. <Ref. to 2-8 [W1A0]>
2) Connect fuel pump connector.
4) Start engine.
5) Measure fuel pressure while disconnecting pressure
regulator vacuum hose from intake manifold.
Fuel pressure:
294.1 kPa (3.0 kg/cm2, 42.7 PSI
7
2.8 SERVICE PROCEDURE
2. On Car Service
3. Fuel Tank
A: REMOVAL
1) Lift up the vehicle.
8
SERVICE PROCEDURE 2.8
3. Fuel Tank
B: INSTALLATION
1) Install fuel tank onto body.
WARNING:
Two men are required to perform step 1) above.
When raising up fuel tank, connect connector of
fuel meter unit.
Tightening torque:
18 - 32 N m (1.8 - 3.2 kg-m, 13 - 23 ft-lb)
9
2.8 SERVICE PROCEDURE
3. Fuel Tank
5. Fuel Filter
A: REMOVAL AND INSTALLATION
1) Lift up the vehicle.
2) Release fuel pressure.
<Ref. to 2-8 [W1A0]>
6. Fuel Pump
A: REMOVAL AND INSTALLATION
1) Release fuel pressure.
<Ref. to 2-8 [W1A0]>
2) Keep connector disconnected.
10
SERVICE PROCEDURE 2.8
6. Fuel Pump
(1) Roll over valve (4) Fuel filter (7) Fuel filter pipe
(2) Canister (5) Fuel pump
(3) Purge control solenoid valve (6)Fuel tank
11
2.8 SERVICE PROCEDURE
7. Fuel Delivery, Return and Evaporation
Lines
B: INSTALLATION
Install in the reverse order of removal.
1) Connect delivery hose to delivery pipe as figure.
A : 1 - 4 mm (0.04 - 0.16 in)
B : 20 - 25 mm (0.79 - 0.98 in)
12
SERVICE PROCEDURE 2.8
8. Roll Over Valve
B: INSPECTION
1) Connect hose to valve as shown.
2) While blowing through open end of tube, tilt valve at
least 90 left and right from normal position.
3) Ensure that there is no air flow when tube is tilted
greater than 90.
C: INSTALLATION
Installation is in the reverse order of removal.
Observe the following:
1) Do not install top side of valve down.
2) Before installing bracket on body, securely fit
concave part of bracket to hole in body.
9. Canister
A: REMOVAL AND INSTALLATION
1) Lift up the vehicle.
2) Remove canister from bracket.
3) Disconnect canister hoses from evaporation pipes.
4) Installation is in the reverse order of removal.
CAUTION:
When installing canister, through air vent hose into
the frame.
13
2.9 exhaust system
C COMPONENT PARTS............................................................................................................. 2
1. Exhaust System.................................................................................................................. 2
W SERVICE PROCEDURE......................................................................................................... 3
1. Exhaust System.................................................................................................................. 3
2.9 COMPONENT PARTS
1. Exhaust System
1. Exhaust System
(1) Under heat shield cover (7) Seat (13) Mounting cushion RH
(2) Gasket (8) Washer (14) Muffler mounting rod
(3) Oxygen sensor (9) Catalyst converter (15) Mounting cushion LH
(4) Exaust pipe (10) Gasket (16) Muffler
(5) Gasket (11) Heat shield cover (17) Rear mounting cushion
(6) Holder (12) Mounting bracket RH
2
SERVICE PROCEDURE 2.9
1. Exhaust System
1. Exhaust System
A: REMOVAL
1) Disconnect battery terminal.
2) Remove rear bumper.
3
2.9 SERVICE PROCEDURE
1. Exhaust System
4
SERVICE PROCEDURE 2.9
1. Exhaust System
C: INSTALLATION
1) Install exhaust system components onto the vehicle.
5
2.9 SERVICE PROCEDURE
1. Exhaust System
6
SERVICE PROCEDURE 2.9
1. Exhaust System
7
2.10 CLUTCH
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Clutch.................................................................................................................................. 2
C COMPONENT PARTS............................................................................................................. 3
1. Clutch.................................................................................................................................. 3
W SERVICE PROCEDURE......................................................................................................... 4
1. Clutch Release Lever & Fork...............................................................................................4
2. Clutch Disc.......................................................................................................................... 6
T TROUBLESHOOTING............................................................................................................. 9
1. Clutch.................................................................................................................................. 9
2.10 SPECIFICATION AND SERVICE DATA
1. Clutch
1. Clutch
A: SPECIFICATIONS
Type Dry single plate
Outer diameter x inner diameter x 180 x 125 x 3.5 mm
thickness (7.09 x 4.92 x 0.138 in]
Clutch disc
Facing Material Woven (asbestos-free) "
Compression thickness at setting 7.8 mm (0.307 in)
Tree thickness 8.3 mm (0.327 in)
Outer diameter 181 mm (7.13 in)
Inner diameter 117 mm (4.61 in)
Clutch Pressure
cover plate 2.47- 3.021 N
Setting load
(252- 308 kg, 556- 679 lb)
Diaphragm height at installation 27.5- 29.5 mm (1.08-1.16 in)
B: MAINTENANCE STANDARDS
Sinkage limit of rivet head 0.3 mm (0.012 in)
Clutch disc Deflection 0.5 mm (0.020 in) at 170 mm (6.7 in) diameter
Runout limit 0.5 mm (0.020 in)
Clutch free On cable center of clutch release fork
1 - 2 mm (0.04 - 0.08 in)
play adjusting portion
2
COMPONENT PARTS 2.10
1. Clutch
1. Clutch
3
2.10 SERVICE PROCEDURE
1. Clutch
4
SERVICE PROCEDURE 2.10
1. Clutch Release Lever & Fork
C: INSTALLATION
1) Apply grease to clutch release lever and install to
clutch housing to match pin hole of clutch release fork.
CAUTION:
Slits of spring pins should be at 90 angles to
release lever shaft (portion) centerline.
5
2.10 SERVICE PROCEDURE
1. Clutch Release Lever & Fork
2. Clutch Disc
A: REMOVAL
1) Remove transmission.
B: INSPECTION
Check all removed parts and replace if defective.
1) Check diaphragm spring end and replace if
excessive wear is evident.
2) If clutch cover produces noise when swung up and
down or if damage to rivets is evident, replace.
3) Check disc compression surface of pressure plate
and replace if wear, distortion or damage is evident.
6
SERVICE PROCEDURE 2.10
2. Clutch Disc
C: INSTALLATION
Install all parts by reversing order of removal, while
paying attention to the following points.
1) Insert ST into clutch disc and install to flywheel.
ST 499745500 CLUTCH DISC GUIDE
2) Line up dowel pin hole of clutch cover with dowel pin
of flywheel, and secure clutch cover to flywheel with
bolts.
Tightening torque:
10 1.0 Nm (1.0 0.75 kg-m, 7.3 0.8 ft-lb)
7
2.10 SERVICE PROCEDURE
2. Clutch Disc
3) Install transmission.
CAUTION:
Tighten bolts in the numerical order shown in
Figure.
NOTE:
Before installing transmission, apply a coat of clutch
grease (FX2200) to splines of mainshaft. (Do not apply
too much grease.)
8
TROUBLESHOOTING 2.10
1. Clutch
1. Clutch
DIAGNOSTIC DIAGRAM OF CLUTCH DRAGS
Test (1)
Test (2)
Test (3)
Judgment
Cause:
Cracked clutch disc
Broken or Worn clutch cover
Faulty clutch release mechanism
Insufficient amount Of clutch release
Excessive free play Of clutch pedal
9
2.10 TROUBLESHOOTING
1. Clutch
10
TROUBLESHOOTING 2.10
1. Clutch
11
2.11 ENGINE AND TRANSMISSION
MOUNTING SYSTEM
Page
C COMPONENT PARTS............................................................................................................. 2
1. Engine and Transmission Mounting....................................................................................2
W SERVICE PROCEDURE......................................................................................................... 3
1. Engine and Transmission....................................................................................................3
2.11 COMPONENT PARTS
1. Engine and Transmission Mouting
2
SERVICE PROCEDURE 2.11
1. Engine and Transmission
7. Disconnect cables, connectors and hoses.
8. Drain coolant from radiator.
9. Remove diagonalmember and rear under guard.
10. Remove rear drive shaft from transmission.
11. Remove propeller shaft. (4WD model only).
12. Disconnect clutch cable.
13. Disconnect water hose from pipes.
14. Set two transmission jacks under engine and transmission.
15. Remove front engine mounting bracket.
16. Remove bolts which install engine mounting crossmember to frame.
25. Remove engine and transmission from vehicle.
3
2.11 SERVICE PROCEDURE
1. Engine and Transmission
4
SERVICE PROCEDURE 2.11
1. Engine and Transmission
5
2.11 SERVICE PROCEDURE
1. Engine and Transmission
6
SERVICE PROCEDURE 2.11
1. Engine and Transmission
MEMO:
7
2.11 SERVICE PROCEDURE
1. Engine and Transmission
8
SERVICE PROCEDURE 2.11
1. Engine and Transmission
9
2.11 SERVICE PROCEDURE
1. Engine and Transmission
10
SERVICE PROCEDURE 2.11
1. Engine and Transmission
11
2.11 SERVICE PROCEDURE
1. Engine and Transmission
12
SERVICE PROCEDURE 2.11
1. Engine and Transmission
13
2.11 SERVICE PROCEDURE
1. Engine and Transmission
8) Drain coolant.
(1) Lift up the vehicle.
(2) Fit vinyl tube to drain cock of radiator.
14
SERVICE PROCEDURE 2.11
1. Engine and Transmission
CAUTION:
Be sure to use an empty container to each oil
flowing out when removing propeller shaft.
Be sure not to damage oil seal and frictional
surface of sleeve yoke.
Be sure to plug the opening in transmission after
removal of propeller shaft.
15
2.11 SERVICE PROCEDURE
1. Engine and Transmission
16
SERVICE PROCEDURE 2.11
1. Engine and Transmission
B: INSTALLATION
2. Tighten bolts Which install engine mounting crossmember to frame.
3. Install front engine mounting bracket.
4. Remove transmission jacks.
5. Connect Water hoses to pipes.
6. Connect clutch cable.
7. Connect Connector to fuel pump.
8. Install rear drive shafts to transmission.
9. Install propeller shaft. (4WD model Only)
10. Install diagonalmember and rear under guard.
11. Connect cables, connectors and hoses.
12. Install exhaust system.
13. Install rear bumper.
14. Install air cleaner assembly.
15. Connect battery cable.
16. Fill coolant.
17
2.11 SERVICE PROCEDURE
1. Engine and Transmission
18
SERVICE PROCEDURE 2.11
1. Engine and Transmission
19
2.11 SERVICE PROCEDURE
1. Engine and Transmission
20
SERVICE PROCEDURE 2.11
1. Engine and Transmission
21
2.11 SERVICE PROCEDURE
1. Engine and Transmission
22
3 TRANSMISSION AND DIFFERENTIAL SECTION
2
SPECIFICATION AND SERVICE DATA 3.1
1. Manual Transmission and
Differential
B: MAINTENANCE STANDARDS
3
3.1 SPECIFICATION AND SERVICE DATA
1. Manual Transmission and Differential
4
COMPONENT PARTS 3.1
1. Transmission Case
1. Transmission Case
1. RWD MODEL
(1)Transmission main ease (8) Ball bearing (15) Back lamp switch (22) Oil seal
(2) Oil seal (9) Oil seal (16) Gasket (23) Snap ring
(3) Oil drain plug (10) Needle bearing (17) Hanger (24) Snap ring
(4) Oil filter plug (11) Oil seal (18) Speedometer shaft (25) Air cleaner stay
(5) Washer (12) Oil guide (19) Speedometer guide (26)Band clip
(6) Clutch housing (13) CIutch housing retainer (20) Washer
(7) Straight pin (14) Transmission side case (21) Washer
5
3.1 COMPONENT PARTS
1. Transmission Case
2. 4WD MODEL
(1) Transmission main Case (9) Back lamp switch (17) Washer (25) Oil reservoir plate
(2) Ball bearing (10) Gasket (18) Snap ring (26) Clutch housing retainer
(3) Oil seal (11) Hanger (19) Clutch housing (27) Straight pin
(4) Oil drain plug (12) Speedometer Shaft (20) Ball bearing (28) Air cleaner stay
(5) Washer (13) Oil seal (21) Oil seal (29) Band clip
(6) Clip (14) Washer (22) Oil seal
(7) Oil ffIler plug (15) Snap ring (23) Oil seal
(8) Transmission side case (16) Speedometer gear (24) Oil guide
6
COMPONENT PARTS 3.1
2. Gear Shift Control
7
3.1 COMPONENT PARTS
3. Gear Component Parts
(1) Reverse idler gear (16) Synchronizer hub (31) Synchronizer ring
(2) Reverse idler gear shaft (17) Synchronizer hub insert (32) Gear thrust spacer key 3
(3) Roller bearing (18) Synchronizer spring (33) Gear thrust spacer key 2
(4) Spring pin (19):Synchronizer hub sleeve (34) Bushing
(5) Bushing (20) Synchronizer hub (35) 5th gear thrust washer
(6) Snap ring (21)Synchronizer hub insert (36) Thrust washer
(7) Main shaft (22) Synchronizer spring (37) Ball bearing
(8) Ball bearing (23) Gear thrust spacer key (38) Synchronizer hub
(9) 5th drive gear (24) Gear thrust spacer key (39) 5th driven gear
(10) Washer (25) Gear thrust spacer (40) Insert stopper plate
(11) Lock washer (26) 1 st driven gear (41) Bearing retainer plate
(12) Lock nut (27) 2nd driven gear
(13)Dnve pinion shaft (28) 3rd driven gear
(14) Washer (29) 4th driven gear
(15) Reverse driven gear & sleeve (30)Synchronizer ring
8
COMPONENT PARTS 3.1
4. Differential Gear
4. Differential Gear
9
3.1 COMPONENT PARTS
5. Extension & Transfer Gear
10
SERVICE PROCEDURE 3.1
5. Extension & Transfer Gear
1. Preparations
1) Before disassembling the transmission
CAUTION:
Wrap vinyl tape around spline at end of both dif-
ferential side gears (to prevent damage to oil seal).
Disassembled parts should be washed clean first
and then inspected carefully.
When oil seal is removed, replace it with a new
one.
When oil seal is washed or replaced, apply gear
oil to lips.
Use care to prevent damage to switch leads and
air breather pipes.
NOTE;
Clean oil, grease, dirt and dust from transmission.
Before cleaning, cap vacuum pipe with vinyl tape to
prevent entry of dust (4WD model).
Bearing should be replaced if burns, wear, noise,
unsmooth rotation, etc. are evident.
To check for noise and unsmooth rotation, apply gear
oil and check bearings by turning.
2) Drain oil by removing drain plug. After draining,
retighten plug as before. <Ref. to 1-5 [014A1]>
CAUTION:
Replace gasket with a new one.
Tightening torque:
34 4 N m (3.5 0.4 kg-m, 25 3 ft-lb)
11
3.1 SERVICE PROCEDURE
2. Transmission Side Cover
4) Cut and pry out lock nut stopper tabs away from
drive pinion shaft.
CAUTION:
Use care not to damage drive pinion shaft.
Do not reuse lock nut.
6) Drive out spring pin from reverse shifter rail using ST.
ST 398791600 STRAIGHT PIN REMOVER 2
12
SERVICE PROCEDURE 3.1
2. Transmission Side Cover
13
3.1 SERVICE PROCEDURE
2. Transmission Side Cover
B: ASSEMBLY
1. ASSEMBLY SNAP RING (OUTER 50)
1) Place ST1 on drive pinion center ball bearing [22 x
50 x 14 mm (0.87 x 1.97 x 0.55 in)], and install snap
ring (outer 50) on guide taper.
2) Shift gears to 2nd to allow ball bearing groove to be
raised over main case end face, operating shifter and
selector levers.
Then, press snap ring (outer 50) into bearing groove
with ST2.
ST1 499755501 SNAP RING GUIDE
ST2 499755502 SNAP RING PRESS
14
SERVICE PROCEDURE 3.1
2. Transmission Side Cover
15
3.1 SERVICE PROCEDURE
2. Transmission Side Cover
10) Drive spring pin in 5th shifter fork and shifter rail.
ST 398791600 STRAIGHT PIN REMOVER 2
CAUTION:
Install spring pin so that slit of spring pin is
aligned with shifter rail centerline.
Do not reuse spring pin.
16
SERVICE PROCEDURE 3.1
2. Transmission Side Cover
B: ASSEMBLY
1) Install snap ring onto speedometer shaft from
speedometer driven gear side.
CAUTION:
Be sure not to install snap ring from oil seal sliding
portion side.
17
3.1 SERVICE PROCEDURE
3. speedometer Driven Gear
18
SERVICE PROCEDURE 3.1
4. Gear Shifter & Selector Assembly
B: ASSEMBLY
1) Place transmission so transmission cover side is up.
And shift gears in neutral.
2) Install collar into transmission main case.
19
3.1 SERVICE PROCEDURE
4. Gear Shifter & Selector Assembly
NOTE:
If installing selector shaft, tighten selector shaft bolt,
aligning its edge to groove on selector shaft.
Tightening torque:
10.0 0.7 Nm (1.0 0.075 kg-m, 7.0 0.5ty,
CAUTION:
Install spring pin so that slit of spring pin is
aligned with shifter shaft centerline.
Do not reuse spring pin.
Check to ensure that O-rings is in proper direction
as shown in Figure.
20
SERVICE PROCEDURE 3.1
4. Gear Shifter & Selector Assembly
21
3.1 SERVICE PROCEDURE
5. Transmission Main case
22
SERVICE PROCEDURE 3.1
5. Transmission Main case
B: ASSEMBLY
CAUTION:
Always use a new gasket.
When disassembling oil seal, replace it with a new
one.
When replacing oil seal, apply grease to lip.
Apply gear oil to bearing and gear.
23
3.1 SERVICE PROCEDURE
5. Transmission Main case
24
SERVICE PROCEDURE 3.1
5. Transmission Main case
C = hi - (20.5-h2) (mm)
C = hi - (0.807-h2) (in)
Washer 61 x 71 x 0.2 mm
C (2.40 x 2.80 x 0.008 in)
Part No. 803061020
0.2 mm (0.008 in) or less None
Over 0.2 mm (0.008 in) and less
Use one
than 0.4 mm (0.016 in)
0.4 mm (0.016 in) or more Use two
25
3.1 SERVICE PROCEDURE
5. Transmission Main case
26
SERVICE PROCEDURE 3.1
5. Transmission Main case
6. Clutch Housing
A: DISASSEMBLY
1) Remove side cover and related parts.
<Ref. to 3-1 [W2A0]>
2) Remove main case and related parts.
<Ref. to 3-1 [W5A0]>
27
3.1 SERVICE PROCEDURE
6. Clutch Housing
B: ASSEMBLY
1) When oil seal [19.8 x 35x7 mm (0.780 x 1.378 x
0.276 in)] is installed to main shaft front, check to
ensure that grease has been applied to lips and install
oil seal with dust lip downward.
28
SERVICE PROCEDURE 3.1
6. Clutch Housing
2. HUB ASSEMBLY
1) Disassemble reverse driven gear (1st-2nd hub
assembly) (16).
Remove synchronizer spring (1), and pull out
synchronizer hub insert (2). Then separate reverse
driven gear
(3) and synchronizer hub (4).
2) Disassemble 3rd-4th hub assembly (7).
Remove synchronizer spring (5), and pull out
synchronizer hub insert (6). Then separate
synchronizer hub (7) and synchronizer hub sleeve (8).
29
3.1 SERVICE PROCEDURE
7. Drive Pinion Assembly
B: INSPECTION
1. GEAR
1) Check the gear tooth surface for abnormal wear,
damage, and replace if defective.
2) Replace if cone located at synchronizer ring is seized
or damaged.
3) Replace if inner wall at bearing location or end face
is excessively worn or damaged.
4) Replace if spacer end faces and bushing are
excessively worn or damaged.
5) Thrust clearance of gear (side clearance).
NOTE:
When inspecting clearance, see to <Ref. to 3-1
[S1B0]>.
2. SYNCHRONIZER RING
1) Check the inside surface and, tooth surface of
synchronizer ring for damage or abnormal wear, and
replace if defective.
2) Check the clearance between synchronizer ring and
cone. Press the ring against the cone and measure the
clearance C between the interfaces of the ring and
cone.
Standard value of C: 1.2 mm (0.047 in)
Limit of C: 0.5 mm (0.020 in)
30
SERVICE PROCEDURE 3.1
7. Drive Pinion Assembly
C: ASSEMBLY
1) Assemble reverse driven gear (1st-2nd hub
assembly) (16).
(1) After setting synchronizer insert onto
synchronizer hub, insert synchronizer hub into
reverse driven gear.
(2) Install synchronizer spring.
2) Assemble 3rd-4th hub assembly (7).
(1) After setting synchronizer insert onto
synchronizer hub, insert synchronizer hub into
synchronizer hub assembly.
(2) Install synchronizer spring.
CAUTION:
if disassembling washer (18) and bushing (19),
replace it with new one.
NOTE:
When installing synchronizer spring, set it by offsetting
inside diameter of one spring 120 with respect to that
of the other spring, and check to ensure that insert is in
position.
31
3.1 SERVICE PROCEDURE
7. Drive Pinion Assembly
13) Mount 5th driven gear thrust plate (2), and press-fit
5th driven gear bushing (3) using ST.
ST 899754112 SNAP RING PRESS
B: ASSEMBLY
Press ball bearing [22 x 56 x 16 mm (0.87 x 2.20 x 0.63
in)] onto main shaft, using ST.
ST1 899754112 SNAP RING PRESS
ST2 498515500 DRIVE PINION BEARING REPL-
ACER
32
SERVICE PROCEDURE 3.1
8. Main Shaft Assembly
9. Differential Assembly
A: DISASSEMBLY
1) Remove bolls, and take out final gear.
B: INSPECTION
1) Replace final gear if tooth face is damaged or shows
excessive wear.
2) Replace if pinion gear, bevel gear, washer [27.1 x 42
x t mm (1.067 x 1.654 x t in)] and differential shaft are
worn, seized or damaged.
3) Replace if case is cracked or otherwise damaged.
33
3.1 SERVICE PROCEDURE
9. Differential Assembly
C: ASSEMBLY
1) Replace if roiling surface of needle bearing (at drive
pinion shaft) or sliding surface of hexagonal splines ( at
gear) shows excessive wear.
2) Assemble ball bearing (#6207) onto final gear,using
ST.
3) Assemble ball bearing (#6207) using ST.
ST 899580100 BEARING INSTALLER
B: INSPECTION
1) Check to ensure that clearance between shifted fork
and groove in synchronizer sleeve is within
specifications.
Standard value:
0.4 - 0.6 mm (0.016- 0.024 in)
34
SERVICE PROCEDURE 3.1
10. Arms and Forks
C: ASSEMBLY
1) Fasten fork and arm onto rail with spring pin [5 x 22
mm (0,20 x 0.87 in)].
CAUTION:
Always use a new spring pin.
NOTE:
Install spring pin with its slit facing toward rail axial
direction.
2) Fasten reverse shifter arm (2) to reverse shifter rail
(1) with spring pin. With spring (3) and ball [5.556 mm
(0.21874 in)] (5), install in reverse shifter arm 2 (4),
insert rail into arm 2 (4) while holding ball (5) in position
with a screwdriver.
Then using ST, put snap rings into lower two ones of
three undercuts on reverse shifter rail.
ST 899471410 SNAP RING EXPANDER
NOTE:
Install ball (5) into reverse shifter arm 2 after applying
grease on ball (5).
35
3.1 SERVICE PROCEDURE
11. Other Parts
2.OIL SEAL
Check the oil seal lips for deformation, hardening, wear,
etc. and check the outside periphery of the oil seal for
damage and replace if defective.
A: DISASSEMBLY
1. EXTENSION
1) Remove bolts, and separate extension from clutch
housing.
36
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
37
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
38
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
39
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
40
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
B: ASSEMBLY
This sub-section describes assembly work required for
4WD model only.
Reassemble all parts by reversing order of
disassembly, while paying attention to the following
points.
1) Check bevel gear for damage, burns, abnormal
wear, etc. and replace if defective.
Drive gear and driven gear should be replaced as a set.
2) Whenever oil seals are removed from extension,
speedometer gear, gear shifter, main shaft, and
differential, they must be replaced with a new one.
3) When oil seals are replaced or washed, apply grease
to their lips.
4) Use a new lock nut for bearing case assembly and
transfer shaft assembly.
5) There must be no oil or dust on diaphragm.
6) When gaskets irrespective of paper and aluminum
one are disassembled, replace them all with a new one.
7) Coat sliding surfaces of bearings and gears with
gear oil.
41
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
42
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
43
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
2. BEARING CASE
Adjustment of bevel gear height (selection of bevel
gear height adjusting shims)
1) Install front and rear bearing races into bearing case,
using ST 1, ST2 and ST3.
ST1 398477701 DRIVE PINION OUTER RACE
DRIFT HANDLE
ST2 398477702 BEARING OUTER RACE DRIFT
ST3 498215402 DIFFERENTIAL CARRIER
STAND
44
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
45
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
4) Install lock washer and nut. Using ST, tigten lock nut
until there is no play in bearing case and bevel driven
gear, then hook a spring balance into bolt hole of bearing
case to measure starting torque, if preload is insufficient,
retighten lock nut another 5 to 10. Do not perform
caulking until tooth contact pattern check is completed.
If preload is excessive, replace spacer.
ST 498405400 BEVEL GEAR STAND
Load:
9.32 - 18.63 N (0.95 - 1.90 kg, 2.09 - 4.19 lb)
Starting torque:
0.39 - 0.78 Nm (4.0 - 8.0 kg-cm, 3.5- 7.0 in lb)
5) Loosen and retighten lock nut, and stake at two
portions.
Tightening torque:
78 - 128 N m (8 13 kg-m, 58 - 94 ft-lb)
46
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
47
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
48
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
3) Check backlash.
Backlash specification:
0.10 - 0.15 mm (0.0039 - 0.0059 in)
ST 498247100 DIAL GAUGE
49
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
On bevel driven gear, convex side is drive side, wherea concave side is coast side.
4. EXTENSION ASSEMBLY
1) Press oil seal into extension case, using ST.
ST 498415700 OIL SEAL DRIFT
2) Apply liquid gasket to bolt hole pattern of extension
case.
50
SERVICE PROCEDURE 3.1
12. 4WD Mechanism
51
3.1 SERVICE PROCEDURE
12. 4WD Mechanism
52
TROUBLESHOOTING 3.1
1. Manual Transmission and
Differential
(1) Low lubricating oil or use of improper oil Add or change with genuine
(2) Worn or broken gears or bearings gear oil Replace
A high roar comes out only at high speed if tooth surfaces are worn. However,
knocks Comes out periodically even at low speed if broken.
(3) Worn splines of each gear Replace
14. Breakage of differential (case, gear, bearing, etc.)
Unusual noise comes out and chips caught among components hinder rotation, making
it impossible to drive vehicle.
53
3.1 TROUBLESHOOTING
1. Manual Transmission and
Differential
(1) Low Oil Or use Of improper Oil Disassemble transfer, check pans
(2) Use Of vehicle in severe conditions such as under excessive loads, faulty clutch and replace defective parts.
Operation, etc. Properly adjust bearing preload
(3) Improper adjustment Of taper roller bearings aim gear backlash. Add genuine
(4) Improper adjustment Of bevel gear height j oil up to specified level and avoid
(5) Excessive backlash due to worn bevel gear spacer Using vehicle in severe
(6) Loose bolts conditions.
7. Noisy transfer and bevel gear
Noises from transfer and bevel gear indicate troubles in those components.
However, care must be exercised in their diagnosis, because the noises are apt to
be mistaken for engine noise, exhaust noise, muffler's vibrating noise, tire noise,
bearing noise, and body noise.
Especially, be careful because noise can easily be taken for Other gear noises.
Noises can roughly be divided into following types:
(1) Gear noises during acceleration
When noise Increases as vehicle catches up speed, it is caused by lack of gear
Oil, improper gear engagement, Or broken gears.
(2) Gear noises during cruising
Gear noises come from damaged gears due to improper adjustment Of
bearings Or shims.
(3) Bearing noises during acceleration Or cruising
Bearing noises are caused by cracked Or damaged bearings.
54
TROUBLESHOOTING 3.1
1. Manual Transmission and
Differential
55
3.3 COMPONENT PARTS
1. Gear Shift Lever
(1) Knob (RWD) (7) Clip (13) Bush (19) Shift lever (RWD)
(2) Boot (8) Bracket (14) Lever COMPL (20) Bail block
(3) 4wD/RwD selector switch (9) Shift control cable (15) Bush (21) Spacer
(4) Knob (4wD) (10) Snap pin (16) spring
(5) Connector (11) Select control cable (17) Spring seat
(6) Shift lever (4WD) (12) Select shaft (18) Bush
2
COMPONENT PARTS 3.3
2. selective 4WD
System
(1) Bracket
(2) 4WD/RWD solenoid valve
3
3.3 SERVICE PROCEDURE
2. selective 4WD System
4
SERVICE PROCEDURE 3.3
1. Gear Shift Lever ^
7) Remove snap pin (1) and clip (2) and then discon-
nect shift control cable from transmission.
8) Lift up vehicle.
9) Remove snap pin (1) and clip (2) and then
disconnect select control cable from transmission.
B. DISASSEMBLY
1) Remove select shaft.
C. ASSEMBLY
Assembly is in the reverse order of disassembly.
5
3.3 SERVICE PROCEDURE
1. Gear Shift Lever ^
NOTE:
When assembling the ball block to the bracket, check
the alignment of the locater (1).
Assemble without trapping the spring between the
lever CP and the spring seat.
When the bracket and ball block are separated make
adjustments in the vertical direction of the lever
a: Temporarily close the coupling bolt of the bracket
and ball block.
b: Attach the gear shift control lever assembly to
the vehicle, couple the shift and selector cable
c: With the lever in the upright position, move the
ball block forwards and backwards.
d: After adjusting, take out the gear shift control
lever assembly, close the coupling bolts to the stip-
ulated torque and fit the lever assembly to the
vehicle.
D. INSTALLATION
Installation is in the reverse order of removal.
NOTE:
After properly installing parts ensure that lever moves
smoothly with reasonable force.
6
3.4 4WD system
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. 4WD System....................................................................................................................... 2
C COMPONENT PARTS............................................................................................................. 4
1. Front Differential and Propeller Shaft..................................................................................4
2. Front Differential Mounting..................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Propeller Shaft.................................................................................................................... 6
2. Front Differential ................................................................................................................. 8
T TROUBLESHOOTING........................................................................................................... 26
1. Front Differential................................................................................................................ 26
2. Propeller Shaft.................................................................................................................. 27
3.4 SPECIFICATION AND SERVICE DATA
1. 4WD System
1. 4WD System
A: SPECIFICATIONS
Gear ratio 3.900
Reduction gear
Tooth number of gear 39/10
Front differential Tooth number of pinion 13
Differential gear
Tooth number of side gear 18
Fluid capacity 0.8 t (0.8 US qt, 0.7 Imp qt)
Type 2-joint type
Propeller shaft Distance between joints 1,182.5 mm (46.56 in)
Tube outer diameter x tube thickness 63.5 x 1.6 mm (2.5 x 0.063 in)
B: MAINTENANCE STANDARDS
DIFFERENTIAL
Differential gear backlash 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Washer (35.1 x 45 x t mm) thickness Part No. 803135011 0.950 mm (0.0374 in)
803135012 0.975 mm (0.0384 in)
803135013 1.000 mm (0.0394 in)
803135014 1.025 mm (0.0404 in)
803135015 1.050 mm (0.0413 in)
Drive pinion bearing preload Rotating torque:
0.39 - 0.98 N-m
(4.0 - 10.0 kg-cm, 2.6 - 8.7 in-lb)
Force at companion flange hole:
11.8 - 28.4 N (1.2 - 2.9 kg, 2.6 - 6.4 lb)
Drive pinion shim thickness for height adjustment Part No. 442185401 0.150 mm (0.0059 in)
442185402 0.175 mm (0.0069 in)
442185403 0.200 mm (0.0079 in)
442185404 0.225 mm (0.0089 in)
442185405 0.250 mm (0.0098 in)
442185406 0.275 mm (0.0108 in)
442185407 0.300 mm (0.0118 in)
442185408 0.500 mm (0.0197 in)
Side clearance between axle shaft and pinion shaft 0 - 0.2 mm (0 - 0.008 in)
Snap ring thickness Part No. 805026010 1.05 mm (0.0413 in)
031526000 1.2 mm (0.047 in)
Drive pinion (hypoid gear) backlash 0.1 -0.18 mm (0.0039 - 0.0071 in)
Differential side bearing preload Tighten axle shaft holder by 1/2 notch.
PROPELLER SHAFT
Runout limit 0.6 mm (0.024 in)
Joint bending resistance 0.3 -1.5 N-m
(0.03 - 0.15 kg-m, 0.2 - 1.1 ft-lb)
Axial play of journal 0 mm (0 in)
2
SPECIFICATION AND SERVICE DATA 3.4
1. 4WD System
C: ADJUSTING POINTS
3
3.4 COMPONENT PARTS
1. Front Differential and Propeller Shaft
(1) Propeller shaft (11) Oil seal (21) Differential drive pinion shaft
(2) Lock nut (12) Gasket (22) Differential ease
(3) Washer (13) Drive pinion spacer (23) Washer
(4) Companion flange (14) Roller bearing (24) Differential gear
(5) Oil seal (15) Drive pinion shim (25) Snap ring
(6) Roller bearing (16) Pinion gear (26) Differential pinion
(7) Differential carrier (17) Crown gear (27) Air breather pipe
(8) Lock plate (18) Axle drive shaft (28) Air breather nipple
(9) O-ring (19) Roller bearing (29) Differential carrier cover
(10)Axle shaft oil seal holder (20) Straight pin (30) Oil drain plug
4
COMPONENT PARTS 3.4
2. Front Differential
Mounting
5
3.4 SERVICE PROCEDURE
2. Front Differential Mounting
1. Propeller Shaft
A: ON-CAR SERVICE
Check the following points with propeller shaft installed
in vehicle.
1) Joints and connections
Check for any looseness of yoke flange connecting
bolts.
B: REMOVAL
NOTE:
Before removing propeller shaft, wrap metal parts with
a cloth or rubbered material.
1) Remove bolts attaching propeller shaft to front dif-
ferential.
6
SERVICE PROCEDURE 3.4
1. Propeller Shaft
C: INSPECTION
Check the following items and replace if detective.
1) Dents or cracks on shaft pipe.
2) Twist or abnormal wear of splines.
3) Shaft deflection
Propeller shaft runout limit:
0.6 mm (0.024 in)
Measure deflection of front and rear shafts at their cen-
ter with a dial gauge.
4) Unsmooth operation of joints and unusual noise
developed in joints.
5) Abnormally worn or damaged oil seal,
D: INSTALLATION
1) Apply gear oil to splined portion and outside
periphery of sleeve york.
7
3.4 SERVICE PROCEDURE
1. Propeller Shaft
2. Front Differential
A: ON-CAR SERVICE
1. GEAR OIL LEAKAGE AND LEVEL
1) Check for oil leakage around engaging, face of dif-
ferential, oil shield, dram plug, filler plug, etc.
8
SERVICE PROCEDURE 3.4
2. Front Differential
Tightening torque:
34 4 N m (3.5 0.4 kg-m, 25 3 ft-lb)
B: REMOVAL
1) Remove propeller shaft.
(1) Remove bolts attaching propeller shaft to front
differential.
9
3.4 SERVICE PROCEDURE
2. Front Differential
10
SERVICE PROCEDURE 3.4
2. Front Differential
C: DISASSEMBLY
To detect real cause of trouble. inspect the following
items before disassembling. <Ref. to 3-4 [W2E0|>
Tooth contact of hypoid drive gear and pinion, and
backlash.
Runout of drive gear at its back surface
Turning resistance of drive pinion
11
3.4 SERVICE PROCEDURE
2. Front Differential
7) Remove cover.
8) Wrap vinyl tape around splined portion of each axle
drive shaft.
9) Remove right and left lock plates.
12
SERVICE PROCEDURE 3.4
2. Front Differential
13
3.4 SERVICE PROCEDURE
2. Front Differential
17) Remove bearing race from right and left holder with
ST1 and ST2,
ST1 499705401 BEARING OUTER RACE PULLER
ASSY
ST2 499705404 OUTER RACE PULLER SEAT
18) Remove oil seal from right and left holder with ST.
ST 498107000 BUSHING REPLACER
14
SERVICE PROCEDURE 3.4
2. Front Differential
D: INSPECTION
Wash all the disassembled parts clean, and examine
them for wear, damage, or other defects. Repair or
replace defective parts as necessary.
1) Crown gear and drive pinion
(1) If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at
assembly. Replace as a set if excessively worn or
incapable of adjustment.
eg h crack, score, or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion gear
(1) Replace if crack, score, or other defects are evident
on tooth surface.
(2) Replace if thrust washer contacting surface is worn
or seized. Slight damage of the surface can be
corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging during
rotation, abnormal noise or other defect is evident.
4) Differential case
Replace if its sliding surfaces are worn or cracked.
6) Oil seal
Replace if deformed or damaged, and at every
disassembling.
7) Differential carrier
Replace if the bearing bores are worn or damaged.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.
15
3.4 SERVICE PROCEDURE
2. Front Differential
E: ASSEMBLY
1) Precautions for assembling
(1) Assemble in the reverse order of disassem-
bling. Check and adjust each part during assembly.
(2) Keep the shims and washers in order, so that
they are not misinstalled.
(3) Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed
(4) Apply gear oil when installing the bearings and
thrust washers.
(5) Replace removed oil seal, gasket, lock nut and
differential side bearing with new ones.
(6) Replace the oil seal with new one at every dis-
assembly. Apply chassis grease between the lips
when installing the oil seal of differential carrier
side.
CAUTION:
Apply gear oil to oil seal lip of axle shaft oil seal
holder.
Do not reuse drive pinion spacer. Use new one.
2) Assemble differential.
16
SERVICE PROCEDURE 3.4
2. Front Differential
Washer 35.1 x 45 x t mm
Part No. Thickness mm (in)
803135011 0.950 (0.0374)
803135012 0.975 (0.0384)
803135013 1.000 (0.0394)
803135014 1.025 (0.0404)
803135015 1.050 (0.0413)
(3) Install straight pin from the crown gear side and
stake.
ST 899904100 STRAIGHT PIN REMOVER
17
3.4 SERVICE PROCEDURE
2. Front Differential
3) Assemble holder
(1) Do not confuse right if side oil seal with left side
oil seal. Do not disturb combination of bearing race
and bearing cone.
ST 399790110 AXLE SHAFT OIL SEAL INSTALLER
18
SERVICE PROCEDURE 3.4
2. Front Differential
CAUTION:
Do not install drive pinion spacer and height
adjusting shim.
Apply gear oil to bearing. Use a new lock nut.
ST 498505502 DRIVE PINION DUMMY SHAFT
19
3.4 SERVICE PROCEDURE
2. Front Differential
20
SERVICE PROCEDURE 3.4
2. Front Differential
21
3.4 SERVICE PROCEDURE
2. Front Differential
Snap ring
Part No. Thickness mm (in)
805026010 L05 (0.0413)
031526000 1.2(0.047)
22
SERVICE PROCEDURE 3.4
2. Front Differential
23
3.4 SERVICE PROCEDURE
2. Front Differential
Adjusting shim (drive pinion shim) Reduce the thickness of drive pinion
thickness is too large. shim.
M3A0274
24
SERVICE PROCEDURE 3.4
2. Front Differential
F: REMOUNTING
Remount by reversing order of dismounting while pay-
ing attention to the following points.
1) When mounting stoppers, do not confuse upper with
lower one.
2) Use a new self-locking nut to tighten bracket.
3) Ensure sufficient clearance between air breather
pipe and axle shaft.
4) insert air breather pipe end that is cut slantwise into
a hole in body frame.
Ensure that hose end bottoms on frame wall.
5) Use new circlips to connect differential assembly to
rear axle shafts.
Tightening torque:
T1:79 5 N m (8.0 0.5 kg-m, 58 4 ft-lb)
T2:58 10 N m (5.9 1.0 kg-m, 43 8 ft-lb)
T3:58 9 N m (6.0 1.0 kg-m ,44 8 ft-lb)
NOTE'
. Match DOJ spline to rear differential spline, press rear
housing to DOJ.
Confirm that DOJ is firmly pressed.
25
3.4 TROUBLESHOOTING
1. Front Differential
1. Front Differential
26
TROUBLESHOOTING 3.4
1. Front Differential
Note:
Vibration while cruising may be caused by an unbalanced tire, improper inflation pressure, improper
wheel alignment, etc.
27
4 MECHANICAL COMPONENTS SECTION
SUSPENSION 4.1
WHEELS AND AXLES 4.2
STEERING SYSTEM 4.3
BRAKES 4.4
PEDAL SYSTEM AND CONTROL CABLES 4.5
HEATER AND VENTILATOR 4.6
4.1 SUSPENSION
1. Suspension
A: SPECIFICATIONS
Camber 1 45'
Caster 350' 1
Toe angle Per wheel : 0 018'
Front foe-in mm (in) 03 (00.12)
when toe-in is 0 3 (0 0.12)
King pin angle 1310'
+12 +0.47
Chassis reference point height mm (in) 339 -20 (13.35 -0.79 )
Camber -050 45'
Toe angle Per wheel : 003' 009'
Toe-in mm (in) 1 3 (0.040.12)
when toe-in is 1 3 (0.04 0.12)
Rear
+12 +0.47
Chassis reference point height mm (in) 298 -20 (11.73 -0.79 )
Thrust angle 0 20'
Toe-in
B - A = Positive
= Toe angle (per Wheel)
2
COMPONENT PARTS 4.1
1. Front Suspension
1. Front Suspension
3
4.1 COMPONENT PARTS
2. Rear Suspension
2. Rear Suspension
4
SERVICE PROCEDURE 4.1
2. Rear Suspension
1. On-car Services
A. WHEEL ALIGNMENT
Check adjust and/or measure wheel alignment in
accordance wit procedures indicated below:
Unit: mm (in)
Specified chassis reference point height
Front Rear
+12 +0.47 +12 +0.47
339 -80 (13.35 -0.79 ) 298 -80 (17.73 -0.79 )
5
4.1 SERVICE PROCEDURE
1. On-car Services
Camber: 1 45'
Caster : 3 50' 1
Measure when vehicle is not loaded.
Toe-in is increased
Toe-in is decreased
6
SERVICE PROCEDURE 4.1
1. On-car Services
NOTE:
When both the left and right wheel bolts are turned
equally in the same direction which increases the toe-
in, the toe-in increases approx. 3mm (0.12in).
3) Tighten self-locking nut.
Tightening torque:
59 10 N m (6.0 1.0 kg-m, 43 7.0 ft-lb)
4. THRUST ANGLE
Inspection
1) Position vehicle on a level surface.
2) Move vehicle 3 to 4 meters directly forward.
3) Determine centers of the front and rear axle loci.
4) Measure difference "L" between center lines of the
axle loci.
(For reference)
Thrust angle is less than 20' when "L" is less than 11
mm (0.43 in).
Adjustment
Make thrust angle adjustments for left and right rear
wheels by turning toe-in adjusting bolts equally in the
same direction.
(For reference)
When one rear wheel is adjusted in a toe-in direction,
adjust the other rear wheel equally in toe-out direction,
in order to make thrust angle adjustment.
When left and right adjustment bolts are turned
incrementally by one scale mark in the same direction,
the thrust angle will change approximately 9' ["L" is
nearly equal to 5 mm (0.20 in)].
Standard thrust angle:
Less than 10'
7
4.1 SERVICE PROCEDURE
1. On-car Services
6. STEERING ANGLE
Inspection
1) Place vehicles on a turning radius gauge.
2) While depressing brake pedal, turn steering wheel
fully to the left and right. With steering wheel held at
each fully turned position, measure both the inner and
outer wheel steering angle.
Steering angle:
+130'
Inner wheel : 32.9 -230'
+130'
Outer wheel : 30.4 -230'
Adjustment
Turn tie-rod to adjust steering angle of both inner and
outer wheels.
NOTE:
Check toe-in.
8
SERVICE PROCEDURE 4.1
1. On-car Services
B: DISASSEMBLY
1) Scribe an aligning mark on transverse link and rear
bushing.
2) Loosen nut and remove rear bushing.
C: INSPECTION
1) Check transverse link for wear, damage and cracks,
and correct or replace if defective.
2) Check bushings for cracks, fatigue or damage.
3) Check rear bushing for oil leaks.
9
4.1 SERVICE PROCEDURE
2- Transverse Link Assembly
D: ASSEMBLY
1) Install rear bushing to transverse link an align
aligning marks scribed on the two.
2) Tighten self-locking nut.
CAUTION:
Discard loosened self-locking nut and replace
with a new one.
While holding rear bushing do not change
position of aligning marks, tighten self-locking nut.
E: INSTALLATION
1) Temporarily tighten two bolts located behind the
transverse link at bushing location.
CAUTION:
Discard loosened self-locking nut and replace with
new one
2) Install bolts used to connect transverse link and
crossmember are temporarily tighten with nuts.
3) Insert ball joint into housing.
4) Insert bolt used to connect transverse link and
housing and temporarily tighten.
NOTE:
Confirm that bolts pass through concave portion in the
ball joint stud section.
5) Tighten the following points in the order shown below
when vehicle is empty and wheels are firmly on the
ground.
6) Check and adjust wheel alignment.
10
SERVICE PROCEDURE 4.1
3. Front Ball Joint
C: INSTALLATION
1) Connect ball joint to transverse link.
Torque (Castle nut):
39 N m (4.0 kg-m, 29 ft-lb)
2) Retighten castle nut further within 60 until a slot in
castle nut is aligned with the hole in ball stud end, then
insert new cotter pin and bend it around castle nut.
3) Install ball joint onto housing.
CAUTION:
Do not apply grease to tapered portion of ball stud.
4) Install front wheels.
5) Check and adjust wheel alignment.
11
4.1 SERVICE PROCEDURE
4. Front Strut Assembly
B: DISASSEMBLY
1) Mount Coil Spring Compressor to a vice.
12
SERVICE PROCEDURE 4.1
4. Front Strut Assembly
4) Loosen the nut that connect the strut mount and the
rod. Fit a hexagonal wrench key into the end of the strut
rod, and loosen the nut using a box wrench.
( Hexagonal wrench key: 6 mm)
C: INSPECTION
Check the disassembled parts for cracks, damage and
wear, and replace with new parts if defective.
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check its
operates smoothly without any binding.
13
4.1 SERVICE PROCEDURE
4. Front Strut Assembly
2. STRUT MOUNT
1) Check rubber part for creep, cracks and deteriora-
tion, and replace it with new one if defective
2) If distortion is found on its connecting surface to
body, replace it with a new one.
3. DUST COVER
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
One having permanent strain should be replaced with a
new one. When vehicle posture is uneven, although
there are no considerable reasons like tire puncture,
uneven loading, etc., check coil spring for
its cracks etc., and replace it with a new one if
defective.
5. HELPER
Replace it with new one if cracked or damaged.
D: ASSEMBLY
1) Before installing coil spring, strut mount, etc., on the
strut, check for the presence of air in the dampening
force generating mechanism of the strut since air
prevents proper dampening force from being produced
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod facing
up.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with fingertips,
move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39 in)
in step (3), purge air from the strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod
facing up.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the pis-
ton rod side down. The strut must stand vertically'
(4) Fully contact the piston rod.
(5) Repeat steps (1) through (4) above 3 or 4 times.
N0TE:
After completely purging air from the strut, be sure to
place the strut with the piston rod facing up. If it is laid
down, check for entry of air in the strut as outlined
under item 2) above.
14
SERVICE PROCEDURE 4.1
4. Front Strut Assembly
15
4.1 SERVICE PROCEDURE
4. Front Strut Assembly
14) After assembling, fit the cap above the self locking
nut.
E: INSTALLATION
1) Install the strut assembly in the reverse order of
removal procedures.
CAUTION:
Use a new self-locking nut.
2) Check and adjust wheel alignment.
5. Front Stabilizer
A: REMOVAL
1) Jack up the front part of the vehicle.
2) Remove bolts which secure clamp to chassis.
16
SERVICE PROCEDURE 4.1
5. Front Stabilizer
B: INSPECTION
1) Check bushing for cracks, fatigue or damage.
g) Check stabilizer links for deformities, cracks, or
damage, and bushing for protrusions beyond eye
portion of stabilizer links.
C: INSTALLATION
1) To install, reverse the removal procedure.
2) Always tighten rubber bushing location when
wheels are in full contact with the ground and vehicle is
curb weight.
6. Front Crossmember
A: REMOVAL
1) Disconnect ground cable from battery.
2) Loosen front wheel nuts.
3) Jack up vehicle, support it with safety stands (rigid
racks), and remove front tires and wheels.
17
4.1 SERVICE PROCEDURE
6. Front Crossmember
B: INSTALLATION
1) To install, reverse the removal procedure.
2) Always tighten rubber bushing location when wheels
are in full contact with the ground and vehicle is curb
weight.
3) Check and adjust wheel alignment.
18
SERVICE PROCEDURE 4.1
7. Trailing Arm Assembly
B: INSPECTION
Check the removed parts as follows, and if a fault is
defected on any parts, replace with a new one.
1) Check for wear, damage, deformation, or cracks.
2) Check the threads of bolts, nuts, and mating parts for
deformation or damage.
C: INSTALLATION
1) To install, reverse the removal procedure.
Refer to "COMPONENT PARTS" for the tightening
torque of the suspension parts.
CAUTION:
Use a new self-locking nuts.
Tighten nut when installing adjusting bolt.
19
4.1 SERVICE PROCEDURE
7. Trailing Arm Assembly
2) When installing the coil spring, fit the end of the coil
spring in the coil spring seat mounting recess of the
trailing arm.
3) Always tighten trailing arm when wheels are in full
contact with the ground and vehicle is curb weight.
B: INSPECTION
1) Check the rubber bush for distortion of damage
2) Check the smooth operation of the shock absorber
20
SERVICE PROCEDURE 4.1
8. Rear Shock Absorber
C: INSTALLATION
Install the shock absorber in the reverse order of
removal procedure.
CAUTION:
Use a new self-locking nut.
B: INSPECTION
Check the disassembled parts for cracks, damage and
wear, and replace with new parts if defective.
21
4.1 SERVICE PROCEDURE
9. Coil Spring and Helper
1. COIL SPRING
One having permanent strain should be replaced with a
new one. When vehicle posture is uneven, although
there are no considerable reasons like tire puncture
uneven loading, etc., check coil spring for its free
length, cracks, etc., referring to specifications, and
replace it with a new one if defective.
2. RUBBER SEAT
If any cracks or damage are found, replace it with a
new one.
3. HELPER
Replace it with new one if cracked or damaged
Measure the helper height.
Specified height:
H = 55 mm (2.17 in) or more.
If the height is less than specified, replace the helper.
C: INSTALLATION
1) To install, reverse the removal procedure.
Refer to "COMPONENT PARTS" for the tightening
torque of the suspension parts.
CAUTION:
Use a new self-lock nuts.
2) Always tighten trailing arm when wheels are in full
contact with the ground and vehicle is curb weight.
3) Notes on installation.
When installing the coil spring, fit the lower rubber
seat and the end of the coil spring in the coil spring
seat mounting recess of trailing arm.
4) Check and adjust rear wheel toe-in and thrust angle.
22
TROUBLESHOOTING 4.1
1. Suspension
1. Suspension
1. IMPROPER VEHICLE POSTURE OR IMPROPER
CHASSIS REFERENCE POINT HEIGHT
23
4.1 TROUBLESHOOTING
1. Suspension
3. NOISE
24
4.2 WHEELS AND AXLES
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Steering System..................................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Steering Wheel and Column................................................................................................3
2. Steering System..................................................................................................................4
3. Steering Gear Box...............................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Steering Column.................................................................................................................6
2. Steering Gear Box...............................................................................................................9
3. Center Lever & Drag Link Assembly..................................................................................17
4. Tie-rod Assembly............................................................................................................... 19
T TROUBLESHOOTING........................................................................................................... 21
1. Steering............................................................................................................................. 21
4.2 SPECIFICATION AND SERVICE DATA
1. Wheels and Axles
2
SPECIFICATION AND SERVICE DATA 4.2
1. Wheels and Axles
B: SERVICE Data
Wheel balancing Standard Service Limit
Dynamic unbalance Less than 10 g (0.35 Oz)
3
4.2 COMPONENT PARTS
1. Front Axle
1. Front Axle
1. 4WD model
4
COMPONENT PARTS 4.2
1. Front Axle
2. RWD model
5
4.2 COMPONENT PARTS
1. Front Axle
2. Rear Axle
6
SERVICE PROCEDURE 4.2
1. Front Axle
1. front Axle
A: REMOVAL AND INSTALLATION
1) Jack up vehicle, support it with safety stands, and
remove front wheels.
7
4.2 SERVICE PROCEDURE
1. front Axle
8
SERVICE PROCEDURE 4.2
1. front Axle
B: DISASSEMBLY
1. 4WD model
1) Using ST, support housing and hub securely.
2) Attach ST to housing and drive hub out.
ST1 927080000 HUB STAND
ST2 922590000 HUB PULLER
ST3 28099KC040 BUSH
9
4.2 SERVICE PROCEDURE
1. front Axle
2. RWD model
1) Remove hub from spindle.
2) Remove back plate from spindle.
10
SERVICE PROCEDURE 4.2
1. front Axle
C: INSPECTION
Check the removed parts tor wear and damage. If
defective, replace with a new one.
CAUTION:
If a bearing is faulty, replace it as the bearing set.
Be sure to replace oil seal at every overhaul.
D: ASSEMBLY
1. 4WD model
1) Attach hub to ST1, ST2 securely.
ST1 927080000 HUB STAND ST2 922630000
SPACER
2) Using a hydraulic press, press new hub bolts into
place until their seating surfaces contact the hub.
NOTE:
Use 12 mm (0.47 in) dia. holes in ST (HUB STAND) to
prevent bolts from tilting.
11
4.2 SERVICE PROCEDURE
1. front Axle
12
SERVICE PROCEDURE 4.2
1. front Axle
2. RWD model
1) Using ST1 and ST2, press new hub bolts into place.
NOTE:
Use a 12 mm (0.47 in) hole in ST to prevent hub bolt
from tilting during installation.
Ensure hub bolt closely contacts hub.
ST1 92708000 HUB STAND
ST2 922630000 SPACER
13
4.2 SERVICE PROCEDURE
2. Front Drive Shaft
B: DISASSEMBLY
1) Straighten bent claw of DOJ boot.
2) Loosen band by means of screwdriver or pliers with
care of not damaging boot.
3) Remove the larger end of DOJ boot from DOJ outer
race.
14
SERVICE PROCEDURE 4.2
2. Front Drive Shaft
C: INSPECTION
Check the removed parts for damage, wear, corrosion
and etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and excessive
play.
2) Shaft
Check excessive bending, twisting, damage and wear.
3) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive play.
4) Boot
Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.
D: ASSEMBLY
Specified grease:
DOJ and BJ side - Molylex No. 2
or Sunlight TB2-A
1) Install BJ boot in specified position, ad fill it with 60 to
70 g (2.12 to 2.47 oz) of specified grease.
2) Place DOJ boot at the center of shaft.
NOTE:
Be sure to wrap shaft splines with vinyltape to prevent
boot from scratches.
15
4.2 SERVICE PROCEDURE
2. Front Drive Shaft
4) Install DOJ inner race on shaft and fit snap ring with
snap ring pliers.
NOTE:
Confirm that the snap ring is completely shaft groove.
9) Align the outer race track and ball position and place
in the part where shaft, inner race, cage and balls are
previously installed, and then fit outer race.
16
SERVICE PROCEDURE 4.2
2. Front Drive Shaft
17
4.2 SERVICE PROCEDURE
2. Front Drive Shaft
17) Tap on the clip with the punch provided at the end
of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
18) Cut off band with an allowance of about 10 mm
(0.39 in) left from the clip and bend this allowance over
the clip.
CAUTION:
Be careful so that the end of band is in close
contact with clip.
19) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coaling.
E: INSTALLATION
1) Replace circlip from differential splines with new one.
2) Insert BJ into hub splines,
CAUTION:
Be careful not to damage inner oil seal lip.
3) Temporarily tighten axle nut.
4) Install dust seal onto differential splines.
5) Install DOJ onto differential.
18
SERVICE PROCEDURE 4.2
2. Front Drive Shaft
CAUTlON:
Use a new self-lock nut.
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact with
ground when axle nut is loose, wheel may be damaged.
Be sure to tighten axle nut to specified torque. Do not
overtighten it as this may damage wheel bearing.
3. Rear AxIe
A: REMOVAL
1) Set parking brake
2) Lift up vehicle and remove rear wheel.
19
4.2 SERVICE PROCEDURE
3. Rear AxIe
20
SERVICE PROCEDURE 4.2
3. Rear AxIe
B: DISASSEMBLY
1) Using the press, hub bolt out from brake drum.
CAUTION:
Be careful not to hammer hub bolts. This may
deform brake drum.
CAUTION:
a. Do not reuse the bearing which has been
removed by tapping the inner race. Such a bearing
can cause noise in operation.
b. Do not reuse the oil seal once removed.
c. Evenly tap all periphery of the inner race when
removing the bearing.
CAUTION:
a. Evenly tap all periphery of the outer race of the
bearing.
b. Do not reuse the oil seal once removed.
21
4.2 SERVICE PROCEDURE
3. Rear AxIe
C: INSPECTION
Check the following parts:
1) Bearing
Clean and check the inner race and outer race for
cracks or damage. Turn the outer race slowly while
holding the inner race, and check for binding in rotation.
2) Spacer
Clean the spacer and check for damage or
deformation.
3) Hub
Wipe the inner surface with a clean cloth, and check for
cracks or damage.
D: ASSEMBLY
1) Using the press, press new hub bolts into place.
CAUTION:
Insert the hub bolt until the seating surface is tight
against the drum.
3) Fully coat the oil seal with grease, and set the oil
seal on the outer bearing side. Force-fit the oil seal by
using a 65 mm (2.56 in) dia. bar or block.
ST1 922441000 STAND
CAUTION:
Do not excessively pack grease, otherwise, it may
leak out from the outer bearing to the inside of
brake drum, causing the brake to slip.
22
SERVICE PROCEDURE 4.2
3. Rear AxIe
6) Fully coat the oil seal with grease, and set the oil
seal to the hub. Set the 30 mm (1.18 in) dia. side of ST
to the oil seal, and force-fit the oil seal until the oil seal
contacts the end face of the bearing.
ST 921350000 HUB BEARING INSTALLER
CAUTION:
The oil seal must be correctly fitted. If fitted
improperly and there is a clearance at A, a change
may occur in the interference of the oil seal lip
causing the oil seal lip to wear.
E: INSTALLATION
1) Install the trailing arm to the vehicle body.
Refer to 4-1 [W7C0]
23
4.2 SERVICE PROCEDURE
3. Rear AxIe
24
SERVICE PROCEDURE 4.2
3. Rear AxIe
CAUTION:
Always use new cotter pin, and bend it after
insertion.
Ensure that cotter pin does not contact brake
drum.
B: DISASSEMBLY
1) Straighten bent claw of TJ boot.
2) Loosen band by means of screwdriver or pliers with
care of not damaging boot.
3) Remove the larger end of TJ boot from TJ outer
race.
25
4.2 SERVICE PROCEDURE
4. Rear Drive Shafts
26
SERVICE PROCEDURE 4.2
4. Rear Drive Shafts
C: INSPECTION
Check the removed parts for damage, wear, corrosion
and etc. If faulty, repair or replace.
1) TJ (Tripod Joint)
Check seizure, Corrosion, damage, wear and excessive
play.
2) Shaft
Check excessive bending, twisting, damage and wear.
3) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive play.
4) Boot
Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.
D: ASSEMBLY
Specified grease:
TJ side - SSG - 6003
BJ side - Molylex No. 2 or
Sunlight TB2-A
27
4.2 SERVICE PROCEDURE
4. Rear Drive Shafts
28
SERVICE PROCEDURE 4.2
4. Rear Drive Shafts
12) Tap on the clip with the puncj provided at the end of
ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
13) Cut off band with an allowance of about 10 mm
(0.39 in) left from the clip and bend this allowance over
the clip.
CAUTION:
Be careful so that the end of band is in close
contact with clip.
14) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract TJ to provide equal grease coating.
E: INSTALLATION
Install the rear axle according to steps 2-10 of the
procedure for installing the rear axle.
Refer to 4-2 [W3E0]
29
4.2 SERVICE PROCEDURE
4. Rear Drive Shafts
30
SERVICE PROCEDURE 4.2
5. SteeI Wheel and Tire
6. Wheel Balancing
1) Proper wheel balance may be lost if the tire is
moaned or if it wears. Check the tire for dynamic
balance, and repair as necessary.
2) To check for dynamic balance, use a dynamic
balancer. Drive in the balance weight on both the top
and rear sides of the rim.
3) Some types of balancer can cause damage to the
wheel. Use an appropriate balancer when adjusting the
wheel balance.
4) Use genuine balance weights.
Standard clearance: A
Weight for steel wheel
1.6 - 2.0 mm (0.063 - 0.079 in)
31
4.2 SERVICE PROCEDURE
7. InstaIIation of Wheel Assembly to Vehicle
32
4.3 STEERING SYSTEM
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Steering System..................................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Steering Wheel and Column................................................................................................3
2. Steering System..................................................................................................................4
3. Steering Gear Box...............................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Steering Column.................................................................................................................6
2. Steering Gear Box...............................................................................................................9
3. Center Lever & Drag Link Assembly..................................................................................17
4. Tie-rod Assembly............................................................................................................... 19
T TROUBLESHOOTING........................................................................................................... 21
1. Steering............................................................................................................................. 21
4.3 SPECIFICATION AND SERVICE DATA
1. Steering System
1. Steering System
A: SPECIFICATIONS
Type Rack and pinion
Minimum turning radius 4.2 m (13.8 ft)
Inside 32.9
Steering angle
Outside 30.4
Steering wheel diameter 370 mm (14.57 in) \
Turns, lock to lock 4.1
Steering lock Provided
Shock absorbing shaft Provided
Overall gear ratio 23
B: SERVICE DATA
Steering wheel Free play 0 - 25 mm (0 - 0.98 in)
Inner tire & wheel 30.4-34.4
Turning angle
Outer tire & wheel 27.9 - 31.9
Looseness 0 mm (0 in)
Universal joint
Maximum yawing torque 0.29 N-m (0.03 kg-m, 0.22 ft-lb)
Gearbox rack Bending limit (Runout) 0.25 mm (0.01 in)
2
COMPONENT PARTS 4.3
1. Steering Wheel and
Column
3
4.3 COMPONENT PARTS
2. Steering System
2. Steering System
(1) Snap pin (7) Drag link bushing (13) Center lever bushing (18) Clamp
(2) Castle nut (8) Drag link (14) Adjusting cap (19) Air vent tube
(3) Dust seal (9) Clip (15) Boot cover (20) Rubber coupling
(4) Tie_rod end (outer) (10) Center lever (16) Steering gear box (21) Torque rod
(5) Tie_rod (11) Rubber cap assembly
(6) Tie rod end (inner) (12) Center lever pin (17) Cover cliD
4
COMPONENT PARTS 4.3
3. Steering Gear Box
5
4.3 SERVICE PROCEDURE
3. Steering Gear Box
1. Steering Column
A: REMOVAL AND DISASSEMBLY
1) Disconnect harness from battery ground terminal.
6
SERVICE PROCEDURE 4.3
1. Steering Column
7
4.3 SERVICE PROCEDURE
1. Steering Column
B: INSPECTION
1) Clean the disassembled parts with a cloth.
(1) Check shaft distort, damage.
(2) Check bearing wave washer wear makes
unusual noise, does not rotate freely.
(3) Check earth brush wear, distort.
(4) Check snap ring distort.
(5) Check universal joint damage, wear.
NOTE:
Confirm that universal joint mounting bolt passes cut-
off portion of pinion serration.
If shaft friction is excessive, loosen each mounting
bolt, rotate shaft right and left several times, then
tighten bolts securely.
Refer to "Steering shaft component parts" for
tightening torque.
D: ADJUSTMENT
1) If steering wheel spokes are not horizontal whet1
wheels are set in the straight ahead position, and error
is more than 5 on the periphery of steering wheel,
correctly re-install the steering wheel.
Specified Length: L (On steering wheel)
0 - 25 mm (0 - 0.98 in)
8
SERVICE PROCEDURE 4.3
1. Steering Column
9
4.3 SERVICE PROCEDURE
2. Steering Gear Box
B: DISASSEMBLY
1) Secure the yoke of the gearbox in a vice, loosen the
self-locking nut, and remove the yoke.
2) Remove the clips from the boots. Remove the boots
from the gearbox while using care not to give damage
to them.
10
SERVICE PROCEDURE 4.3
2. Steering Gear Box
C: INSPECTION
1) Wash the disassembled parts, check for wear,
damage and other defects, and repair or replace if
necessary.
2) During disassembly, check to see if water has leaked
into the gearbox. If there is a trace of water, it may be
due to a poor pinion oil seal, broken boot, or defective
Sealant (adjusting screw). Check those parts carefully
and replace if defective.
11
4.3 SERVICE PROCEDURE
2. Steering Gear Box
Specified greases:
Kyodo Yushi ONE-L UBE SG
Showa Shell Sekiyu VALIANT M2
12
SERVICE PROCEDURE 4.3
2. Steering Gear Box
Pinion position
13
4.3 SERVICE PROCEDURE
2. Steering Gear Box
14
SERVICE PROCEDURE 4.3
2. Steering Gear Box
15
4.3 SERVICE PROCEDURE
2. Steering Gear Box
16
SERVICE PROCEDURE 4.3
2. Steering Gear Box
20) Connect the lower shaft and gearbox pinion via the
rubber coupling. Place all the coupling-pinion nuts on
the upper side of the coupling.
Tightening torque:
17 3 Nm (1.7 0.3 kg- 12 2.2 ft-lb)
(1) Lower shaft
(2) Gearbox
(3) Confirm that the bushing is fitted to each hole of the
rubber coupling.
17
4.3 SERVICE PROCEDURE
3. Center Lever & Drag Link Assembly
B: INSPECTION
Check all removed parts and replace if defective.
1) Check the center lever for damage and deformation.
2) Check the bushing for wear and damage.
3) Secure the center lever bushing in a vice as shown
and check for smooth operation.
Oscillating force:
P Standard value
20 N (2.0 kg, 4.4 lb)
(Reading of spring balance)
This measurement must be taken after oscillating the
center lever two or three times.
C: INSTALLATION
Install the parts by reversing the order of removal, while
paying attention to the following points.
1) After the center lever has been installed to the
chassis frame, make sure that the cotter pin is
positively bent.
CAUTION:
Use a new cotter pin.
Tightening torque:
Tighten to 113 9.8 N m ( 11.5 1.0kg-m,
25 2.2 ft-lb); then tighten further until
the cotter pin hole is aligned within a
+60 range.
2) Install the tie-rod end (inner) and drag link.
CAUTION:
Use a new cotter pin.
Tightening torque:
Tighten to 27 2.5 N m (2.75 0.25kg-m,
20 1.8 ft-lb) ; then tighten further until
the cotter pin hole is aligned within a
+60 range.
3) Connect the yoke and drag link.
Tightening torque:
49 10 N m (5.0 1.0 kg-m, 36 7 ft-lb)
18
SERVICE PROCEDURE 4.3
3. Center Lever & Drag Link Assembly
4. Tie-rod Assembly
A: REMOVAL
1) Lift up fie vehicle and remove the front wheels.
2) Remove the under cover.
3) Using a puller, remove the inner and outer tie-rod
ends from the center lever and knuckle arm.
B: INSPECTION
Check ail removed parts and replace if defective.
1) Check the dust seals at the tie-rod ends for damage
and wear.
2) Check the ball studs at the tie-rod ends for rattle.
3) Check the tie-rod ends for grease leakage.
4) Check the bend of the tie rods.
CAUTION:
The tie-rod ends are non-disassembly type. All of
them should be replaced as an assembly.
C: INSTALLATION
Install the parts by reversing the order of removal, while
paying attention to the following points.
1) Install the tie-rod by adjusting the distance between
ball studs so that the threaded portions at both ends of
tie-rod will be equal in length.
NOTE:
Tighten so that A and B portion maybe equal in length.
Installed tie-rod length : L
345.6 mm (13.61 in)
19
4.3 SERVICE PROCEDURE
4. Tie-rod Assembly
20
TROUBLESHOOTING 4.3
1. Steering
1. Steering
Trouble and probable cause Correction
1. Steering wheel operation is heavy.
jack up the fronf end of fhe vehicIe so that the front wheels are lifted off the ground, then separate the tie-rod ends
and turn the steering Wheel.
(A) Tight steering wheel: Tire air pressure or defects in suspension.
(1) Tire air pressure too low. Adjust to proper pressure.
(2) improper front-wheel alignment. Adjust (toe-in).
(3) Worn tires. Replace.
(B) Heavy steering wheel: Defects in steering system.
(1) Center lever bushing damaged. Replace.
(2) Steering gear box damaged. Replace.
(3) Insufficient lubrication. Lubricate.
(4) Excessive friction at tie-rod ends. Replace.
(5) improper rack and pinion backlash Adjust
2. Steering wheel vibration.
(1) Improper tire air pressure. Adjust to proper pressure
(2) improper front-wheel alignment. Adjust (toe-in).
(3) Wheel nuts loose. Tighten to specified torque
(4) Deformed wheel. Repair or replace.
(5) Wheel bearing damaged or worn. Replace.
(6) Suspension arm deformed or damaged. Repair or replace.
(7) Wear or looseness at tie-rod end. Adjust or replace.
(8) Worn center lever bushing. Replace.
(9) Improper front-wheel balance. Adjust.
3. Steering wheel pulls to one side.
(1) Improper tire air pressure. Adjust to proper pressure.
(2) Improper front-wheel alignment. Adjust
(3) Wheel bearing improperly adjusted or worn. Adjust or replace.
(4) Malfunctioning shock absorber. Replace.
(5) Suspension arm deformed or broken. Repair or replace.
(6) Loose drag link bush. Tighten to specified torque.
(7) Improper backlash of rack and pinion. Adjust.
(8) Excessive friction at tie-rod ends and drag link Replace.
4. Shock is transmitted to steering wheel.
(1) Tire air pressure is too high. Adjust to proper pressure.
5. Play or steering wneel is more than 25 mm (0.98 in)
(1) Worn rack and pinion. Replace.
(2) Damaged or worn steering shaft and serration of torque rod. Retighten or replace.
(3) Loose steering-wheel nut. Tighten to specified torque.
(4) Joint clamping bolt loose. Tighten to specified torque.
(5) Worn front-wheel bearing. Adjust or replace.
(6) Insufficient tightening of each joint. Tighten to specified torque or replace.
(7) Worn center lever bushing. Replace.
(8)Improper rack and pinion back lash. Adjust.
(9) Worn drag link bushing Replace.
21
4.4 BRAKES
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Brakes................................................................................................................................. 2
C COMPONENT PARTS............................................................................................................. 4
1. Front Disc Brake.................................................................................................................4
2. Rear Drum Brake................................................................................................................ 5
3. Master Cylinder and Brake Booster.....................................................................................6
4. Parking Brake...................................................................................................................... 7
W SERVICE PROCEDURE......................................................................................................... 8
1. Front Disc Brake.................................................................................................................8
2. Rear Drum Brake............................................................................................................... 11
3. Master Cylinder................................................................................................................. 17
4. Brake Booster................................................................................................................... 20
5. Parking Brake Cable......................................................................................................... 24
6. Parking Brake Lever.......................................................................................................... 25
7. Air Bleeding....................................................................................................................... 26
8. Brake Fluid Replacement..................................................................................................28
9. Dual Proportioning valve (DPV).........................................................................................31
10. Brake Hose and Pipe......................................................................................................32
T TROUBLESHOOTING........................................................................................................... 33
1. Entire Brake System.......................................................................................................... 33
4.4 SPECIFICATION AND SERVICE DATA
1. Brakes
1. Brakes
A: SPECIFICATIONS
type Supportless ventilated disc brake
Effective diameter 184 mm (7.24 in)
Front Effective cylinder diameter 51 mm (2.0 in)
brake 92 x 36 x 7 mm
Lining dimensions (Width x length x thickness)
(3.62 x 1.42 x 0.35 in)
Clearance adjustment Automatic adjustment
Type Leading-trailing drum brake
Effective diameter 180 mm (7.09 in)
Rear Effective cylinder diameter 17.46 mm (7/10 in)
brake 172.4 x 30 x 4.4 mm
Lining dimensions (Width x length x thickness)
(6.79 x 1.18 x 0.173 in)
Clearance adjustment Automatic adjustment
Master Type Tandem type
cylinder | Effective diameter 19.05 mm (3/4 in)
Brake Type Vacuum suspended type
booster r Effective diameter 177.8 mm (7 in)
Brake line Dual circuit system
Brake fluid tank capacity 123 cma (123 cc, 7.51 cu in)
Parking brake Mechanical on rear brakes
DPV Split point 1,961 kPa (20 kg/cm2, 284 psi)
(Dual Proportioning Valve) Reducing ratio 0.3
2
SPECIFICATION AND SERVICE DATA 4.4
1. Brakes
B: SERVICE DATA
ITEM STANDARD SERVICE LIMIT
Pad thickness
15 mm (0.59 in)
(including back metal) 8 mm (0.315 in)
Front brake
Disc thickness 18.0 mm (0.709 in) 16.5 mm (0.650 in)
Disc run-out 0.10 mm (0.0039 in)
Inside diameter 180 mm (7.09 in) 182 mm (7.17 in)
Rear brake
Lining thickness 4.4 mm (0.173 in) 1.7 mm (0.070 in)
Parking brake Lever stroke 7 to 9 notches/196 N (20 kg, 44 lb)
3
4.4 COMPONENT PARTS
1. Front Disc Brake
4
COMPONENT PARTS 4.4
2. Rear Drum Brake
(1) Hold down pin (6) Brake shoe (Leading) (11) Parking brake lever
(2) Bake plate (7) Upper shoe spring (12) Spring washer
(3) Packing (8) Lower shoe spring (13) Spring
(4) Wheel cylinder (9) Hold down spring
(5) Adjuster (10) Brake shoe (Trailing)
5
4.4 COMPONENT PARTS
3. Master Cylinder and Brake Booster
6
COMPONENT PARTS 4.4
4. Parking Brake
4. Parking Brake
7
4.4 SERVICE PROCEDURE
2. DISC ROTOR
1) Set a dial gauge on the disc rotor. Turn disc rotor to
check runout.
NOTE:
Make sure that dial gauge is set 5 mm (0.20 in) inward
of rotor outer perimeter.
Disc rotor runout limit:
0.1 mm (0.004 in)
8
SERVICE PROCEDURE 4.4
1. Front Disc Brake
B: REMOVAL
1) Remove pad cover.
2) Remove key spring and key.
3) Remove pad.
C: DISASSEMBLY
1) Clean mud and foreign particles from caliper body
assembly.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
2) Using a standard screwdriver, remove boot stopper
from piston.
3) Remove boot from piston end.
9
4.4 SERVICE PROCEDURE
1. Front Disc Brake
D: INSPECTION
1) Repair or replace faulty parts.
2) Check caliper body and piston for uneven wear,
damage or rust.
3) Check rubber parts for damage or deterioration.
E: ASSEMBLY
1) Clean caliper body interior using brake fluid.
2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner surface
of cylinder and outer surface of piston.
4) Insert piston seal into cylinder.
10
SERVICE PROCEDURE 4.4
1. Front Disc Brake
F: INSTALLATION
To install in reverse order of removal.
CAUTION:
When replacing the pad, replace pads of the right
and left wheels at the same time.
Replace brake hose gaskets with new ones.
Bleed air from brake system.
<Ref. to 4-4 [W7A0]>
NOTE;
For tightening torque, see Component Parts.
11
4.4 SERVICE PROCEDURE
2. Rear Drum Brake
12
SERVICE PROCEDURE 4.4
2. Rear Drum Brake
B: DISASSEMBLE
1) Remove right and left dust boots from wheel cylinder.
2) Remove piston, cup, spring and air bleeder screw
and cap.
C: INSPECTION
1) If the inside surface of brake drum is streaked,
correct the surface. And, if it is unevenly worn,
taperingly streaked, or the outside surface of brake
drum is damaged, correct or replace it.
D: ASSEMBLY
1) Clean all parts in brake fluid. Check and replace
faulty parts.
Cup and boot for damage or fatigue.
Cylinder, piston and spring or damage or rust form-
ation.
13
4.4 SERVICE PROCEDURE
2. Rear Drum Brake
E: INSTALLATION
NOTE:
For tightening torque, see Component Parts.
1) Install back plate on housing.
2) Install wheel cylinder assembly onto back plate.
3) Apply a proper amount of molybdenum grease to
trailing shoe pin. Install parking adjusting lever and
position clips in their pin grooves. Install parking lever
spring between parking lever and trailing shoe web.
Brake grease:
Dow Corning Molykote No.7439 (P/N 725191460 )
14
SERVICE PROCEDURE 4.4
2. Rear Drum Brake
15
4.4 SERVICE PROCEDURE
2. Rear Drum Brake
17) Tighten castle nut and insert cotter pin into its
holes.
Tightening torque:
+20 +2 +14
196 -0 N.m (20 -0 kg-m, 145 -0 ft-lb)
:20 *. 104
After tightening castle nut, retighten it within 30' so
that cotter pin holes are aligned.
CAUTION:
Always use new cotter pin, and bend it after inser-
tion.
18) After installing brake assembly, bleed air-from brake
line. <Ref. to 4-4 [W7A0]>
19) Be sure to adjust the parking lever stroke.
<Ref. to 4-4 [W5B1]>
16
SERVICE PROCEDURE 4.4
2. Rear Drum Brake
3. Master Cylinder
CAUTION:
Be extremely careful not to spill brake fluid. Brake
fluid spilt on the vehicle body will harm the painted
surface; wipe it off quickly if spilt.
A: REMOVAL
1) Extract the brake fluid from the bleeder screw of the
front and rear brake assembly.
NOTE:
By the air bleed operating sequence, keep stepping on
the brake pedal until the fluid has gone from the inside
of the vinyl hose.
2) Remove steering column. <Ref. to 4-3 [W1 A0]>
17
4.4 SERVICE PROCEDURE
3. Master Cylinder
B: DISASSEMBLY
1) Remove mud and dirt from the surface of break
master cylinder.
2) Clean Work bench.
18
SERVICE PROCEDURE 4.4
3. Master Cylinder
C: INSPECTION
If any damage, deformation, wear, swelling, rust, and
other faults are found on the primary piston, secondary
piston, secondary piston stopper, or gasket, replace the
faulty part.
CAUTION:
The primary and secondary pistons must be
replaced as complete assemblies.
The service limit of the clearance between each
piston and the master cylinder inner dia. is 0.11 mm
(0.0043 in).
When handling parts, be extremely careful not to
damage or scratch the parts, or let any foreign
matter get on them.
D: ASSEMBLY
1) When assembling, be sure to use recommended
brake fluid.
2) Ensure that the inside wall of cylinder, pistons, and
piston cups are free from dirt when assembling.
3) Be extremely careful not to damage, scratch, or dent
cylinder inside wall, pistons, and piston cups.
4) Do not drop parts. Never attempt to use any part that
has been dropped accidentally.
5) Assembling piston:
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston, and install
piston carefully into cylinder.
6) Assembling secondary piston stopper:
After installing piston into cylinder, push primary piston
in about 10 mm (0.39 in), using a rod, such as push rod
then assemble gasket and secondary piston stopper.
CAUTION:
If the gasket and secondary piston stopper are
assembled without pushing in the primary piston,
scratches may be caused on the secondary piston,
and no pressure may be built up in the secondary
side. To avoid such an error, be sure to push in the
primary piston before assembling these parts.
19
4.4 SERVICE PROCEDURE
3. Master Cylinder
E: INSTALLATION
1) To install the master cylinder to the body, reverse the
sequence of removal procedure.
2) Be sure to use recommended brake fluid 3; Bleed air
from brake system.
4) For tightening torque, see Component Parts
4. Brake Booster
CAUTION:
Be extremely careful not to spill brake fluid. Brake
fluid spilt on the vehicle body will harm the painted
surface; wipe it off quickly if spilt.
A: REMOVAL
1) Remove pedal bracket. <Refer to 4-5 [W2A0]>
2) Remove snap pin and clevis pin.
3) Remove the bracket.
B: INSTALLATION
1) To install in reverse order of removal.[W7A0]
2) Bleed air from brake system. <Ref. to 4-4[W7A0]>
3) For tightening torque, see Component Parts.
CAUTION:
Be sure to use recommended brake fluid.
20
SERVICE PROCEDURE 4.4
4. Brake Booster
2. OPERATION CHECK
1) With engine off, depress brake pedal several times
applying the same pedal force and make sure that the
pedal height does not vary with each depression of the
pedal.
2) With brake pedal depressed, start engine.
3) As engine starts, brake pedal should move slightly
toward the floor. If no change occurs in the pedal
height, brake booster is faulty.
21
4.4 SERVICE PROCEDURE
4. Brake Booster
22
SERVICE PROCEDURE 4.4
4. Brake Booster
E: HANDLING PRECAUTIONS
1) After protector has been removed from push-rod, do
not turn the master cylinder side of brake booster
downwards.
(1) If the master cylinder side is turned downwards,
push-rod may come loose by virtue of its own
weight, and reaction disc may drop into brake
booster.
23
4.4 SERVICE PROCEDURE
4. Brake Booster
24
SERVICE PROCEDURE 4.4
5. Parking Brake Cable
25
4.4 SERVICE PROCEDURE
6. Parking Brake Lever
7. Air Bleeding
A: BLEEDING PROCEDURE
CAUTION:
The FMVSS No.116, fresh DOT3 or 4 brake fluid
must be used.
Cover bleeder with waste cloth, when loosening it,
to prevent brake fluid from being splashed over
surrounding parts.
Avoid mixing different brands of brake fluid to
prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
During bleeding operation, keep the brake reserve
tank filled with brake fluid to eliminate entry of air.
Brake pedal operating must be very slow.
For convenience and safety, it is advisable to have
two man working.
26
SERVICE PROCEDURE 4.4
7. Air Bleeding
2) Fit one end of vinyl tube into the air bleeder and nut
the other end into a brake fluid container.
3) Slowly depress the brake pedal and keep it
depressed. Then, open the air bleeder to discharge air
together with the fluid.
Release air bleeder for 1 to 2 seconds.
Next, With the bleeder closed, slowly release the braKe
pedal.
Repeat these steps until tnere are no more air bubbles
in the vinyl tube.
Allow 3 to 4 seconds between two brake pedal
operations.
4) Tighten air bleeder securely When no air bubbles are
visible.
Tightening torque (Bieeder screw):
11 2Nm (1.0 0.2kg-m, 8 1 ft-lb)
27
4.4 SERVICE PROCEDURE
7. Air Bleeding
A: REPLACEMENT
CAUTION:
The FMVSS No.116, fresh DOT3 or 4 brake fluid
must be used.
Cover bleeder with waste cloth, when loosening it
to prevent brake fluid from being splashed over
surrounding parts.
Avoid mixing different brands of brake prevent
degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
During bleeding operation, keep the brake reservoir
tank filled with brake fluid to eliminate entry of air.
Brake pedal operating must be very slow.
For convenience and safety, it is advisable to have
two man working.
The amount of brake fluid required is approximatively
300 ml (10.1 US fl oz, 10.6 Imp fl oz) for total brake
system.
28
SERVICE PROCEDURE 4.4
8. Brake Fluid Replacement
29
4.4 SERVICE PROCEDURE
8. Brake Fluid Replacement
30
SERVICE PROCEDURE 4.4
8. Brake Fluid Replacement
A: CHECK
Check brake pipe connections for oil leaks. If leakage is
found, retighten or replace.
3) Install DPV.
NOTE:
Before installation, insert valve attaching bracket
protrusion into hole for securing valve body.
Tightening torque:
5.9 2 N m (1.8 0.5 kg-m, 4.35 1.1 ft-lb)
4) Tighten brake pipe flare nuts.
Tightening torque:
+3 +0.3 +2.2
15 -2 N m (1.5 -0.2 kg-m, 11 -1.4 ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
4) Bleed air from brake system. <Ref. to 4-4 [W7A0]>
31
4.4 SERVICE PROCEDURE
10. Brake Hose and Pipe
32
TROUBLESHOOTING 4.4
1. Entire Brake System
33
4.4 TROUBLESHOOTING
1. Entire Brake System
34
4.5 PEDAL SYSTEM AND CONTROL
CABLES
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Pedal System and Control CabIes......................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Pedal................................................................................................................................... 3
W SERVICE PROCEDURE......................................................................................................... 4
1. ON-CAR Service.................................................................................................................4
2. Brake and Clutch Pedal.......................................................................................................6
3. Accelerator Pedal................................................................................................................8
4. Installation of Each Cable..................................................................................................10
5. Accelerator Cable.............................................................................................................. 10
6. Clutch Cable...................................................................................................................... 12
7. Speedometer Cable.......................................................................................................... 13
T TROUBLESHOUTING........................................................................................................... 14
1. Pedal System and Control Cables.....................................................................................14
4.5 SPECIFICATION AND SERVICE DATA
1. Pedal System and Control CabIes
2
COMPONENT PARTS 4.5
1. Pedal
1. Pedal
3
4.5 SERVICE PROCEDURE
1. ON-CAR Service
A: ADJUSTMENT
4
SERVICE PROCEDURE 4.5
1. ON-CAR Service
4. ACCELERATOR PEDAL
1) Check pedal stroke and free play by operating
accelerator pedal by hand.
If it is not within specified value, adjust it by turning nut
connecting accelerator cable to throttle body.
Free play at pedal pad: L
1-4mm (0.04-0.16in)
5
4.5 SERVICE PROCEDURE
1. ON-CAR Service
6
SERVICE PROCEDURE 4.5
2. Brake and Clutch Pedal
B: DISASSEMBLY
1. CLUTCH PEDAL
1) Remove the clip and washer at the shaft end.
2) Remove the clutch pedal, return spring and bushes
together from the shaft.
2. BRAKE PEDAL
1) Remove the clevis pin linking the brake booster and
pedal lever.
2) Remove brake booster.
3) Remove clip and washer at shaft end.
4) Remove bracket, brake pedal, return spring and
bushing.
C: INSPECTION
Check all removed parts and replace if deformed,
damaged, or worn.
D: ASSEMBLY
1) Apply sufficient grease to the bush and insert it into
the pedal boss.
2) To assembly in reverse order of disassembly.
7
4.5 SERVICE PROCEDURE
2. Brake and Clutch Pedal
E: INSTALLATION
1) Installation procedure is in the reverse order of
removal.
2) Adjust free play of fork lever using wing nut located
at inner end of clutch cable in engine compartement.
3) Apply a coat of grease to fork lever.
Fork lever free play: L
1-2 mm (0.04 - 0.08 in)
3. Accelerator Pedal
A: REMOVAL
8
SERVICE PROCEDURE 4.5
3. Accelerator Pedal
B: INSPECTION
Check all removed parts and replace if deformed,
damaged, or worn.
C: INSTALLATION
1) Coat the end of the accelerator cable With grease.
2) Installation is in the reverse order of removal.
3) Check pedal free play and stroke.
Ref .to ON-CAR SERVICE 4-5[W1 A4]
9
4.5 SERVICE PROCEDURE
4. Installation of Each Cable
5. Accelerator Cable
A: REMOVAL
1) Remove the nut securing accelerator pedal to body
on inside.
2) Remove the mud guard.
3) Remove the nut securing accelerator pedal to body
on outside.
4) Remove the accelerator pedal cover.
10
SERVICE PROCEDURE 4.5
5. Accelerator Cable
9) Remove the clips and bands and pull out the cable.
B: INSPECTION
Check the removed cable and replace if damaged,
rusty, or malfunctioning.
1) Check for smooth operation of the cable (damage
and a short stroke).
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
cracks.
4) Check the boot for damage, cracks, and deteriora-
tion.
C: INSTALLATION
1) Arrange the cable Ref. to Installation of each
cable.4-5[W400]
2) Apply grease to the front and rear ends of the inner
cable.
3) Installation is in the reverse order of removal.
a. Arrange the cable without making sharp bends
and twisting.
b. Fix each clip securely along the curve of the
cable so that the cable is not bent.
4) Check pedal free play.
Ref To ON-CAR SERVICE 4-5[W1 A4]
11
4.5 SERVICE PROCEDURE
5. Accelerator Cable
6. Clutch Cable
A: REMOVAL
1) Loosen the wing nut on the inner cable end at the
transmission side.
B: INSPECTION
Replace if defective.
1) Check for smooth operation of the clutch cable
(looseness and interference).
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage.
4) Check the boot for dislocation and damage.
C: INSTALLATION
1) Installation is in the reverse order of removal.
2) Check pedal free play.
Ref To ON-CAR SERVICE 4-5[W1A2]
12
SERVICE PROCEDURE 4.5
6. Clutch Cable
7. Speedometer Cable
A: REMOVAL
1) Disconnect Speedometer cable from transmission.
2) Remove combination meter.
B: INSTALLATION
1) Installation is in the reverse order of removal.
2) Turn the socket by hand as far as it goes in, then
tighten 45 to 90 degrees farther With a Wrench.
13
4.5 TROUBLESHOOTING
1. Pedal System and Control
Cables.
14
4.6 HEATER AND VENTILATOR
Page
C COMPONENT PARTS............................................................................................................. 2
1. Heater System.................................................................................................................... 2
2. Heater Unit.......................................................................................................................... 3
3. Heater Control..................................................................................................................... 4
4. Rear Heater Unit.................................................................................................................5
W SERVICE PROCEDURE......................................................................................................... 6
1. Heater Unit.......................................................................................................................... 6
2. Rear Heater Unit.................................................................................................................7
4.6 COMPONENT PARTS
1. Heater System
1. Heater System
2
COMPONENT PARTS 4.6
2. Heater Unit
2. Heater Unit
(1) Vent door lever (5) Mix door (9) Heater core
(2) Resister (6) DEF, heat door (10) Blower fan assembly
(3) Case (LH) (7) Case (RH) (11) DEF, heat door lever
(4) Vent door (8) Mix door link
3
4.6 COMPONENT PARTS
3. Heater Control
3. Heater Control
4
COMPONENT PARTS 4.6
4. Rear Heater Unit
5
4.6 SERVICE PROCEDURE
4. Rear Heater Unit
1. Heater Unit
A. REMOVAL
1) Disconnect battery ground cable
2) Remove instrument panel <Ref to 5-4 [W1A0]>.
3) Remove heater hose cover.
4) Drain coolant from radiator by drain cock.
b) Remove two hose clamps, then disconnect outlet
and inlet heater hoses.
NOTE:
When removing heater unit, close opening of pipes with
cloth to prevent coolant from spilling.
B. DISASSEMBLY
1) Remove blower motor ASSY.
2) Remove heater core.
3) Remove resistor.
4) Remove four clips and six screws and separate
heater unit into two sections.
C. ASSEMBLY
Installation is in the reverse order of disassembly.
6
SERVICE PROCEDURE 4.6
1. Heater Unit
D: INSTALLATION
1) Installation is in the reverse order of removal.
2) Connect inlet hose to resin pipe and connect outlet
hose to other pipe, and clamp heater hose securely.
Fitted length of heater hose over pipe:
20 - 30 mm (0.8 - 1.2 in)
3) Pour coolant. <Ref. to 2-5 [W1B0]>
5) Lift up vehicle.
6) Remove front wheel of left.
7) Remove hose clamps and then disconnect outlet and
inlet heater hoses.
NOTE:
When disconnect heater hoses, catch coolant by
vessel, and then close opening of pipes with cloth to
prevent coolant from spilling.
8) Disconnect harness connector.
7
4.6 SERVICE PROCEDURE
2. Rear Heater Unit
B. INSTALLATION
1) Installation is in the reverse order of removal.
2) Pour coolant. <Ref. to 2-5 [W1B0]>
8
5 BODY SECTION
2. BODY
2
SPECIFICATION AND SERVICE DATA 5.1
1. Datum Points And
Dimensions
3. CHASSIS FRAME
3
5.1 SPECIFICATION AND SERVICE DATA
2. Sun Roof
2. Sun Roof
4
COMPONENT PARTS 5.1
1. Front Bumper
1. Front Bumper
(1) Guard bar (3) Clip A lower (5) Beam upper (7) Bumper face
(2) Clip A upper (4) Clip B (6) Beam (8) Cover
2. Rear Bumper
5
5.1 COMPONENT PARTS
3. Sun Roof
3. Sun Roof
(1) Front glass lid (7) Rear rail ASSY (13) Front rail ASSY
(2) Lock handle ASSY (8) Rear rail Cover (14) Roller bracket and wire ASSY
(3) Spring ASSY (9) Control unit (15) Sun shade ASSY
(4) Hinge (10) Guide pipe ASSY (16) Bracket
(5) Rear glass lid (11) Motor ASSY
(6) Roller bracket (12) Handle
6
COMPONENT PARTS 5.1
4. Body Parts
4. Body Parts
(1) Clip
(2) Filler lid
(3) Key
(4) Gusset cover
(5) Outer mirror
7
5.1 SERVICE PROCEDURE
4. Body Parts
1. Front Bumper
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
2) Remove Front trun signal lights of both side.
CAUTION:
Be sure to hold socket section when disconn
not harness.
8
SERVICE PROCEDURE 5.1
1. Front Bumper
2. Rear Bumper
A: REMOVAL AND INSTALLATION
1. REAR BUMPER CENTER
1) Open rear bumper center
2) Remove four nuts and then remove rear bumper
center.
3) To install, reverse order of removal.
9
5.1 SERVICE PROCEDURE
3. Coating Method for PP
bumper
Mask specified part (black base) With masking tape. Use masking tape for PP (example
2 Masking
Nichiban No, 533. etc.) For details, see the following figures.
Degreasing. Clean all parts to be painted With White gasoline, normal alcohol, etc. to remove dirt, oil fat
3
cleaning etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [10 to 15 min. at 20C (68F)]. "" 1 In half-dried condition, PP
5 Drying primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
Solid color Metallic color
Use section (block) paint for top coat.
Paint in use (for each color)
Paint use (for each color)
Metallic paint
Solid paint
Hardener PB
Hardener PB
Thinner T-306
6 Top coat paint Thinner T-301
Mixing ratio:
Mixing ratio:
Main agent vs. hardener = 10:1
Main agent vs. hardener = 4:1
Viscosity: 10-13 sec/20C (68F)
Viscosity: 10-13 sec/20C (68F)
Film thickness: 15 - 20fi
Film thickness: 35 - 45p
Spraying pressure: 245 - 343 kPa
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi)
(2.5 3.5 kg/cm2, 36 - 50 psi)
Dry at normal temperature [10 min. or more
7 Drying Not required at 20C (68F)].
In half-dried condition, avoid dust, dirt.
Apply a clear coat to parts with top coat (I),
three times, at 5 - 7 minute intervals.
Paint in use
Metallic paint
Hardener PB
8 Top coat (II) Not required. Thinner T-306
Mixing ratio: Clear vs. hardener = 6:1
Viscosity: 14-16 sec/20C (68F)
Film thickness: 25 - 30p
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi) _^
60C (140F), 60 min. or 80C (176F), 30 min.
9 Drying If higher than 80C (176F), PP may be deformed. Keep maximum temperature of 80C
(176F)
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.
10
SERVICE PROCEDURE 5.1
4- Repair Instructions for
Colored PP Bumper
Process
Process name Job contents
No.
1 Cleaning Clean damaged area With Water.
Removal of damaged
2 Cut off protruding area, if any, due to collision, using a putty knife.
area
3 Sanding Grind the affected area With #100 to #500 sandpaper.
Resin section Coated section
4 Finish Perform Process No. 12 and subsequent oper-
Same as Process No.3 in the "(1)" section.
ations in the "(3)" section.
11
5.1 SERVICE PROCEDURE
4- Repair Instructions for
Colored PP Bumper
Process
Process name Job contents
No.
1 Bumper removal Remove bumper as required;
2 Part removal Remove parts built into bumper as required.
Surface Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable
4
preparation solvent (NRM No. 900 Precleno, white gasoline, or alcohol).
6 Sanding (I) Grind beveled surface with sandpaper (#40 to #60) to smooth finish.
17 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
Grind the side just opposite the beveled area With sandpaper (#40 to #60) and clean using a
solvent. Temporarily spot-weld the side, using a PP Welding rod and heater gun.
Temporary
8
Welding
M5A0141
Do not melt welding rod until it flows out. This results in reduced strength.
Leave the welded spot unattended until it cools completely.
12
SERVICE PROCEDURE 5.1
4- Repair Instructions for
Colored PP Bumper
Process
Process name Job contents
No.
Using a heater gur and PP welding rod, weld the beveled spot while melting the rod and damaged
area.
9 Welding
10 Sanding (II)
13
5.1 SERVICE PROCEDURE
4- Repair Instructions for
Colored PP Bumper
Process
Process name Job contents
NO.
16 Drying Allow the coated surface to dry for 60 minutes at 20C (68F) [or 30 minutes at 60C (140F)
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sandpaper and water.
Cleaning/
18 Same as Process No. 12.
degreasing
Solid color Metallic color
Use a "block" coating method.
Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
19 Top coat (I) SC Reducer (thinner)
Mixing ratio: 3 :1
(Suncryl: No. 307)
Viscosity: 11-13 sec/20C (68F)
Coated film thickness: 40 - 50ju. Coated film thickness: 20 30fi
Spraying thickness: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi)
Leave unattended at 20C (68F) for at least] 10
Leave minutes until the topcoated area is half-dry.
20 Not required
unattended Be careful to keep dust or dirt from coming I in
contact with the affected area.
Apply a clear coat three times at an interval of 3 to 5
minutes.
Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
21 Top coat (II) Not required SC Reducer (thinner)
Mixing ratio; 3 :1 (SC710: No. 307)
Viscosity: 10-13 sec/20C (68F)
Coated film thickness: 20 - 30fi
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kg/cm2, 36 - 50 psi)
Allow the coated surface to dry at 20C (68F) for two hours or 60C (140F) for 30 minutes.
22 Drying i Do not allow the temperature to exceed 80C (176F) since this will deform the PP
substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
Bumper
26 Install bumper.
installation
14
SERVICE PROCEDURE 5.1
4- Repair Instructions for Colored PP
Bumper
CAUTION:
Be careful not to scratch coated by cloth at body
when removing glass lid from vehicle.
5) To install, reverse order of removal.
B. INSPECTION
In the weather strip, there should be no creases,
kinks, turned up edges or worn corners etc..
Check when fully closed, fully opened partition,
looseness and interference etc., make adjustments.
Check that the tilt-lock handle operates smoothly.
15
5.1 SERVICE PROCEDURE
6. Rear Sun Roof
16
SERVICE PROCEDURE 5.1
6. Rear Sun Roof
B: INSTALLATION
1) Installing front rail and guide pipe ASSY.
2) Measure clearance between front rail left side and
right side.
C: ADJUSTMENT
Insert the shim in between the bracket of the glass
lid and the roller bracket of the front rail, and adjust any
height difference in the side of the body and glass.
The holes for the bolts of the roller bracket of the front
rail are elongated (slot-type), adjust any height
difference by moving the bracket up or down.
17
5.1 SERVICE PROCEDURE
6. Rear Sun Roof
D: INSPECTION
The operation from fully open to fully closed takes
about 7-9 secs.
At about 250rmn before fully closed, stop and again
switch ON the CLOSE switch to operate.
In the weather strip, there should be no creasses
kinks, turned up edges or worn corners etc..'
During operation, the movement should be smooth
with no strange noises or catching.
The sun shade should move smoothly without con-
flicting with the harness.
There should be no water leakage on the inside when
the sun-roof is fully closed.
18
5.2 DOORS AND WINDOWS
Page
S SPECIFICATIONS AND SERVICE DATA................................................................................2
1. Door Alignment....................................................................................................................2
C COMPONENT PARTS............................................................................................................. 3
1. Front Door........................................................................................................................... 3
2. Slide Door........................................................................................................................... 4
2. Rear Gate............................................................................................................................ 5
4. Window Glass and Weather Strip........................................................................................6
W SERVICE PROCEDURE......................................................................................................... 7
1. Front Door........................................................................................................................... 7
2. Slide Doors........................................................................................................................ 10
3. Rear Gate.......................................................................................................................... 14
4. Windshield......................................................................................................................... 15
5. Rear Window Glass........................................................................................................... 17
6. Rear Quarter Window Glass..............................................................................................17
5.2 SPECIFICATION AND SERVICE DATA
1. Door Alignment
1. Door Alignment
2
COMPONENT PARTS 5.2
1. Front Door
1. Front Door
(1) Shoulder molding (8) Striker (15) Escutcheon (22) Upper hinge (29) Inner handle
(2) Run channel (9) Outer handle (16) Door latch (23) Lower hinge (30) Trim bracket
(3) Inner weather strip (10) Outer handle protector(17) Remote rod (24)Front door panel (31) Trim panel
(4) Rear sash (11) Key cylinder clip (18) Regulator handle (25) Buffer
(5) Regulator (12) Sealing cover (19) Retainer spring (26) Protector
(6) Safety knob (13) Inner handle (20) Esculcheon (27) Checker pin
(7) Safety knob cover (14) Retainer spring (21) Front sash (28) Checker spring
3
5.2 COMPONENT PARTS
2. Slide Door
2. Slide Door
(1) Suspender (8) Outer handle (15) Latch (22)Escutcheon (29) Run Channel
(2) striker (9) Link (16) Striker (23) Knob (30) Lower arm
(3) Hook (10) Outer handle protector (17) Inner handle (24) Sealing Cover (31)Center rail
(4) Catcher (11) safety knob (18) Escutcheon (25) Weather strip (32) Center arm
(5) Upper arm (12) Remote ASSY (19) Slide door glass (26) Lower sash (33) Ornament
(6) Slide door (13) Pad (20) Regulator ASSY (27) Inner weather strip (34) checker
(7) Stopper (14) Remote rod (21) Regulator handle (28) Door shoulder molding
4
COMPONENT PARTS 5.2
2. Rear Gate
2. Rear Gate
5
5.2 COMPONENT PARTS
4. Window Glass and Weather Strip.
6
SERVICE PROCEDURE 5.2
4. Window Glass and Weather Strip.
1. Front Door
A. REMOVAL
1) Place o rag on door or body to prevent scratches
and drive out checker pin (1) with a hammer.
NOTE:
When detaching the door from tho vehicle body remove
the door trim while keeping a wire connected to the
head of the checker spring to stop from dropping inside
the door.
B. DISASSEMBLY
1) Lowering the front door glass and then remove the
retainer spring (1) and then regulator handle (2) and
inner handle.
Use a wire bent at one end, as shown figure, for easier
removal of retainer spring.
7
5.2 SERVICE PROCEDURE
1. Front Door
7) Lower the front door glass and then move the front
window glass forwarding motion so that remove regula-
tor roller (1) from glass holder (2).
8
SERVICE PROCEDURE 5.2
1. Front Door
C. ASSEMBLY
Assembly is in the reverse order of disassembly.
NOTE:
Attach the inner handle upward and inclined to the
front.
With the window fully shut, attach the regulator 45 up
and forward.
On the reverse side of the escutcheon there are
projections for determining the position, therefore,
attach carefully to the back.
D. INSTALLATION
Installation is in the reverse order of removal.
E. ADJUSTMENT
1. DOOR GLASS
1) Adjust the attitude of the glass with respect to the
sash by the installation bolts (1) of the guide channel.
2) Raise and lower window to check that it is properly
aligned.
2. DOOR STRIKER
1) If door does not fit tightly in the rear end or if it does
not close lightly, move striker (1) laterally by striking
with plastic hammer.
9
5.2 SERVICE PROCEDURE
1. Front Door
2. Slide Doors.
A. REMOVAL
1) Remove rear combination light (1) and ornament (2).
4) Half open the door and then remove upper arm (1)
from door.
5) Draw out the lower arm (1) from rear end of lower
rail.
10
SERVICE PROCEDURE 5.2
2. Slide Doors.
B. DISASSEMBLY
1) Remove the door trim. <Ref. to 5-2 [W1 B0]>
2) Remove the sealing cover. <Ref. to 5-2 [W1B0]>
3) Remove lower sash (1).
11
5.2 SERVICE PROCEDURE
2. Slide Doors.
C. ASSEMBLY
Assembly is in the reverse order of disassembly
NOTE:
Attach the inner handle upward and inclined to the
front.
With the window fully shut, attach the regulator 45 up
and forward.
On the reverse side of the escutcheon there are pro-
jections for determining the position, therefore, attach
carefully to the back.
D. INSTALLATION
Installation is in the reverse order of removal.
12
SERVICE PROCEDURE 5.2
2. Slide Doors.
2. REAR SIDE
Make vertical adjustment of the striker (1) attaching
portion.
NOTE:
Prior to striker adjustment, temporarily tighten the cen-
ter arm.
13
5.2 SERVICE PROCEDURE
2. Slide Doors.
2. REAR SIDE
Adjust to right and left at the striker (i) attaching portion,
and tighten.
3. Rear Gate
A. REMOVAL
1) Disconnect the battery ground cable.
2) Remove trim panel. <Ref to 5-2 [W1B0]>
3) Remove cover, and disconnect the vinyl hose (1) in a
access hole.
4) Disconnect the rear wiper motor and rear defogger
connectors.
NOTE:
If rear gate is to be reused, tie string to connector end
and remove harness and related parts from top of rear
gate.
Leave string undetached in side rear gate for use as a
guide for harness,etc.
During reinstallation.
5) Extract the harness from the rear gate.
NOTE:
The following work steps must be done with great care
by at least two persons working together.
14
SERVICE PROCEDURE 5.2
3. Rear Gate
NOTE:
Before discarding gas stay, place it at a slight angle
with the cylinder body side facing up and drill a 2 to 3
mm (0.08 to 0.12 in) dia. hole to completely discharge
the content. (Gas is odorless, colorless and harmless;
however, metal power may come out of the hole.)
It is good practice to place a vinyl cover over it before
drilling the hole because oil may spurt out. Be careful to
prevent vinyl cover from becoming entangled on the
drill.
B. INSTALLATION
1) Apply sealer to body and rear gate at mating sur-
faces of hinges.
2) Installation is in the reverse order of removal.
C. ADJUSTMENT
1. REAR GATE STRIKER
1) Loosen striker bolts.
2) For lateral adjustment align striker and latch at their
centers.
4. Windshield
A. REMOVAL
1) Lift up wiper arms.
2) Pry the lip of indoor weatherstrip at the top center
with a spatula (0 or the iike and push to outside of the
body flange.
15
5.2 SERVICE PROCEDURE
4. Windshield
B. INSTALLATION
1) Clean sealant from the glass and weatherstrip,
using white gasoline.
2) Fit the weatherstrip (1) onto the glass. Then, fit cord
(2) around the weatherstrip, and overlap the ends of the
ends of the cord at the bottom of the glass.
After the cord has been installed to the weatherstrip,
apply white gasoline to the entire periphery.
3) Place the glass correctly with respect to the window
frame of the body from outside the body and put the
cord inside the body.
16
SERVICE PROCEDURE 5.2
4. Windshield
17
5.3 SEATS, SEATBELTS, AND
INTERIOR
C COMPONENT PARTS............................................................................................................. 2
1. Front Seat........................................................................................................................... 2
2. Second Seat........................................................................................................................ 4
3. Third Seat............................................................................................................................ 5
4. Seat Belt.............................................................................................................................. 6
5. Inner Trim............................................................................................................................ 7
6. Inner Accessary and Floor Mat............................................................................................8
7. Roof Trim............................................................................................................................. 9
W SERVICE PROCEDURE.......................................................................................................10
1. Front Seat......................................................................................................................... 10
2. Second Seat...................................................................................................................... 10
3. Third Seat.......................................................................................................................... 10
4. Front Seat Belt................................................................................................................... 11
5. Second Seat Belt............................................................................................................... 12
6. Third Seat Belt................................................................................................................... 12
7. Roof Trim........................................................................................................................... 13
5.3 COMPONENT PARTS
1. Front Seat
1. Front Seat
1. SWIVEL TYPE
(1) Reclining knob (7) Headrest bushing (13) Outer rail LH (19) Slider C
(2) Cover (8) Slider B (14) Lower frame COMPL (20) Slider A
(3) Reclining hinge (9) Cover rear (15) Lock (21) Arm front edge
(4) Hinge cover (10) Base assembly (16) Lock plate (22) Cover front edge
(5) Backrest assembly (11) Plate B (17) Outer rail RH (23) Cushion front edge
(6) Headrest (12) Inner rail LH (18) inner rail RH (24) Cushion assembly
2
COMPONENT PARTS 5.3
1. Front Seat
2- FIXED TYPE
3
5.3 COMPONENT PARTS
2. Second Seat
2. Second Seat
(1) Arm rest (7) Headrest bushing Torsion bar B (13) Link assembly
(2) Cover (8) Headrest (Q) Hinge cover upper LH (14) Lower cover
(3) Bracket (9) Board Reclining hinge LH (15) Lever knob
(4) Hinge cover upper RH (10) Shaft Hinge cover lower LH (16) Hinge cover lower RH
(5) Reclining hinge RH (11) Flat board Link base cover
(6) Backrest assembly (12) Hook plate Torsion bar A
4
COMPONENT PARTS 5.3
3. Third Seat
3. Third Seat
5
5.3 COMPONENT PARTS
4. Seat Belt
4. Seat Belt
1. FRONT SEAT BELT
(1) Adjust anchor (4) Grommet sheet (7) Outer belt assembly
(2) Adjuster Cover (5) Inner belt assembly(LH)
(3) ELR Cover(Blind van) (6) Inner belt assembly(RH)
6
COMPONENT PARTS 5.3
4. Seat Belt
5. Inner Trim
7
5.3 COMPONENT PARTS
6. Inner Accessary and Floor Mat
(1) Sun visor (5) Assist grip bracket (9) Deck edge (13) Cab ftoor mat
(2) Hook (6) Front assist grip (10) Rear shelf mat
(3) Rear view mirror (7) Cab floor edge (11) Deck mat
(4) Rear assist grip (8) Center floor edge (12) Center floor mat
8
COMPONENT PARTS 5.3
7. Roof Trim
7. Roof Trim
9
5.3 SERVICE PROCEDURE
7. Roof Trim
1. Front Seat
A: REMOVAL
1) Turn over floor mat
2) Release front seat lock of driver side
3) Remove bolts and then securing remove front
CAUTION:
Be careful not to scratch car body when removih
front seat from the vehicle.
NOTE:
Do not touch the slide adjuster lever until the front seat
is completely reinstalled in the car body.
B: INSTALLATION
Installation is in the reverse order of removal.
2. Second Seat
A: REMOVAL
1) Fold the backrest onto the seat cushion.
2) Remove bolts and then securing remove second
seat.
CAUTION:
Be careful not to scratch car body when removing
from the vehicle.
B: INSTALLATION
Installation is in the reverse order of removal.
3. Third Seat
A: REMOVAL
1) Fold the backrest onto the seat cushion.
2) Remove bolts and then securing remove third seat.
CAUTION:
Be careful not to scratch car body when removing
third seat from the vehicle.
10
SERVICE PROCEDURE 5.3
3. Third Seat
B: INSTALLATION
Installation is in the reverse order of removal.
2.INNER BELT
1) Remove console box <Ref to 5-4[W2A0]>.
2) Turn over floor mat.
3) Remove bolt and remove inner belt of right side.
4) Remove grommet sheet and then remove bolt and
inner belt of left side.
11
5.3 SERVICE PROCEDURE
4. Front Seat Belt
B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be careful not to twist belts during installation
B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be careful not to twist belts during installation.
12
SERVICE PROCEDURE 5.3
6. Third Seat Belt
B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be careful not to twist belts during installation.
7. Roof Trim
A: REMOVAL
1. WITH SUNROOF MODEL
1) Remove sunroof garnish, sunvisor, rearview
mirror,assist grip and roomlight.
2) Using ST remove clips(ST 92558CG00 PULLER and
then remove screws.
3) Detach roof trim.
CAUTION:
When removing clip,use great care to prevent
damaging the roof trim.
13
5.3 SERVICE PROCEDURE
7. Roof Trim
B: INSTALLATION
1. WITH SUNROOF MODEL
Installation is in the reverse order of removal.
14
5.4 INSTRUMENT PANEL
Page
C COMPONENT PARTS............................................................................................................. 2
1. Instrument Panel................................................................................................................. 2
2. Console Box........................................................................................................................ 3
W SERVICE PROCEDURE......................................................................................................... 4
1. instrument Panel................................................................................................................. 4
2. Console Box........................................................................................................................ 5
5.4 COMPONENT PARTS
1. Instrument Panel
1. Instrument Panel
(1) Instrument panel (7) Center reinforce (13) Radio BRKT (LH) (19) Radio cover
(2) Ventilator grill (Center) (8) Cover (14) Heater reinforce (20) Speaker grill (LH)
(3) Ventilator grill (RH) (9) Pocket (15) Ash tray (21) Meter visor
(4) Speaker grill (RH) (10) Striker (16) Lower cover (D) (22) Brake reservoir tank lid
(5) Lower cover (P) (11) Pocket cover (17) Lower cover (D) BRKT (23) Ventilation grill (LH)
(6) Lower cover (P) BRKT (12) Radio BRKT (RH) (18) Cigar lighter protector
2
COMPONENT PARTS 5.4
2. Console Box
2. Console Box
3
5.4 SERVICE PROCEDURE
2. Console Box
1. instrument Panel
A. REMOVAL
1) Disconnect ground cable from battery.
2) Remove lower covers.
5) Set Air inlet control lever (1), Air outlet control lever
(2), and Temperature control lever (3) to positions
according to diagram.
NOTE:
Do not move three levers from those positions until
completion of reinstallation of instrument panel.
4
SERVICE PROCEDURE 5.4
1. instrument Panel
B. INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Avoid jamming of any wire harness when installing
instrument panel.
2. Console Box
A. REMOVAL
1) Disconnect ground cable from battery.
2) Remove console box lid and then disconnect main
fuse box from console box front lid.
5
5.4 SERVICE PROCEDURE
2. Console Box
B. INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Avoid jamming of any wire harness when installing
console box.
6
6 ELECTRICAL SECTION
1. STARTER
Type Magnetic switch type
Model 128000-2530
Manufacturer NIPPON DENSO
Voltage and output 12 V-0.8 kW
Rotating direction Clockwise (when observed from pinion)
Number of pinion teeth 8
Hour rating 30 seconds
Non-load Voltage 11 V
characteristics Current 50 A or less
Rotating speed 5,000 rpm or more
2. ALTERNATOR
Type Rotating-field three-phase type with IC regulator
Model __ A1T06471
Manufacturer _ MITSUBISHI
Voltage and output 12 V-60 A
Polarity on ground side Negative
Rotating direction Clockwise (when observed from pulley side
Output current at 13.5 V, 20C (68F) 5,000 rpm - 57 A or more
Regulated voltage 14.2-14.8 V
3. DISTRIBUTOR
Model 229100 - 9620
Manufacturer NIPPON DENSO
Firing order 1-3-2
Rotating direction Counterclockwise (when observed from cover side)
Air gap 0.2 mm (0.008 in)
2
SPECIFICATION AND SERVICE DATA 6.1
1. Engine Electrical System
4. IGNITION COIL
Model F-740
Manufacturer DIAMOND
Primary coil resistance 1.35-1.65
Secondary coil resistance 22.1 -29.9 k
5. SPARK PLUG
Manufacturer NGK: BPR6ES-11
Spark plug gap 1 -0 - 1.1 mm (0,039 0.043 in)
3
6.1 SERVICE PROCEDURE
1. Engine Electrical System
1. Starter
A: REMOVAL AND INSTALLATION
1) Remove battery from the vehicle.
2) Disconnect connector and terminals from sta
3) Remove bolts which install starter on transm^
case, and remove starter. Ssin
B: PERFORMANCE TEST
CAUTION:
If starter does not rotate smoothly, the starter is
required a performance test before disassembly.
To prevent the coil from burning, a performance
test must be completed within 5 seconds.
1. NO-LOAD TEST
1) With starter clamped on test bench, set up system as
shown in figure.
2) Close switch and check that starter rotates smoothly
and freely at the specified current and voltage.
B: Battery terminal
M: Motor terminal
S : Magnetic switch terminal
4
SERVICE PROCEDURE 6.1
1. Starter
C: DISASSEMBLY
1) Disconnect the lead wire from the magnet switch.
5
6.1 SERVICE PROCEDURE
1. Starter
6
SERVICE PROCEDURE 6.1
1. Starter
12) Remove the snap ring and remove the stop collar
and clutch.
CAUTION:
If any short-circuit exists in armature coil,
circulating current is generated by alternating flux
of growler tester, and the affected portion of the
armature core is magnetized.
If an iron piece is brought close to that portion, it
will vibrate, locating the short-circuit.
2) Insulation test
Check insulation between commutator and armature
core using 500 V megger.
Insulation resistance should be 0.1 M or larger.
7
6.1 SERVICE PROCEDURE
1. Starter
2. MAGNETIC SWITCH
CAUTION:
Ensure that lead wire is disconnected from terminal
M of magnetic switch before beginning tests.
1) Checking pull-in coil
Connect one test lead between ground terminal of
battery and terminal M of magnetic switch and the other
between positive terminal and terminal S.
Check that plunger is forcefully pulled in when at least 8
volts, dc. is applied across terminals M and S. If not,
replace magnetic switch.
3. YOKE
Testing field coil for open circuit
Check field coil for continuity using circuit tester.
Continuity should exist.
4. BRUSH
1) Checking carbon brush
If carbon brush length has been reduced by more than
1/3 the original length, or if brush contact area has
been reduced largely due to brush breakage, replace
carbon brush.
Brush length:
Standard : 16mm (0.63 in)
Limit : 10.5 mm (0.41 in)
8
SERVICE PROCEDURE 6.1
1. Starter
2) Brush replacement
(1) Using a nipper, cut off brush lead wire.
5. CLUTCH
Check that pinion can be rotated in normal direction
only.
Check pinion gear for wear, damage, rusting, or binding
during rotation.
9
6.1 SERVICE PROCEDURE
1. Starter
6. BEARING
Check bearing portions of gear case and rear cover for
excessive play or damage.
E: ASSEMBLY
1) Assembly is in the reverse order of disassembly.
CAUTION:
When installing through bolts, be careful not to
cause a short by contacting brush,
Check for proper operation as required while
assembling parts.
Apply grease and engine oil, refer to "COMPO-
NENT PARTS".
CAUTION:
When taking measurement, push pinion lightly in
the direction of arrow.
If dimension L" is out of specification, insert or
remove dust cover to obtain correct dimension.
2. Alternator
A: REMOVAL AND INSTALLATION
1) Disconnect connector and terminal from alternator.
2) Remove bolts which install alternator to bracket.
3) Remove V-belt and alternator.
10
SERVICE PROCEDURE 6.1
2. Alternator
B: DISASSEMBLY
1) Remove pulley from alternator by using ST.
ST 499985900 SOCKET WRENCH
3) Remove rotor.
11
6.1 SERVICE PROCEDURE
2. Alternator
C. INSPECTION
1.ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any roughness of
the sliding surface.
Clean or polish with #500 to #600 emery paper if
defective.
12
SERVICE PROCEDURE 6.1
2. Alternator
2. DIODE
Check that diode has a continuity only in one direction
by using "k" range of circuit tester.
CAUTION:
Do not use the 500 V megger tester.
3. BRUSH
Measure brush length protruding from brush holder.
Brush length: L
Standard: 21.5 mm (0.846 in)
Limit: 8 mm (0.315 in)
Lower length: L'
13.5 mm (0.531 in)
CAUTION:
If brush is worn, replace brush holder assembly.
13
6.1 SERVICE PROCEDURE
2. Alternator
D. INSTALLAT ON
1) Install bearing to rotor by using a press and a pipe
14
SERVICE PROCEDURE 6.1
2. Alternator
8) Install rotator.
15
6.1 SERVICE PROCEDURE
2. Alternator
3. Distributor
A: REMOVAL AND INSTALLATION
1) Disconnect distributor connector.
2) Disconnect high tension cord and spark plug cords.
3) Remove bolts which install distributor onto cylinder
head.
B: INSPECTION
Check and adjust the air gap between pick-up coil and
pick-up cams.
Air gap: W
0.2 mm (0.008 in)
4. Ignition Coil
A: REMOVAL AND INSTALLATION
1) Disconnect connectors and high tension cord.
2) Remove ignition coil from body with bracket.
3) Installation is in the reverse order of removal.
B: INSPECTION
1) Continuity of primary coil.
Measure resistance between the battery (+) terminal
and the distributor (-) terminal.
Specified resistance: 1.35 - 1.65
16
SERVICE PROCEDURE 6.1
4. Ignition Coil
5. Spark Plug
A: REMOVAL AND INSTALLATION
1) Remove spark plug cords and dust cover.
2) Remove spark plugs.
17
6.1 SERVICE PROCEDURE
5. Spark Plug
B: INSPECTION
1) Normal
Brown to grayish-tan deposits and slight electrode wear
indicate correct spark plug heat range.
2) Carbon fouled
Dry fluffy carbon deposits on insulator and electrode
are mostly caused by slow speed driving in city, weak
ignition, too rich fuel mixture, dirty air cleaner, etc.
It is advisable to replace with plugs having hotter heat
range.
3) Oil fouled
Wet black deposits show excessive oil entrance into
combustion chamber through worn rings and pistons or
excessive clearance between valve guides and stems.
If same condition remains after repair, use a hotter
plug.
4) Overheating
While or light gray insulator with black or gray brown
spots and bluish burnt electrodes indicate engine
overheating. Moreover, the appearance results from
incorrect ignition timing, loose spark plugs, wrong
selection of fuel, hotter range plug, etc. It is advisable to
replace with plugs having colder heat range.
18
6.2 BODY ELECTRICAL SYSTEM
Page
W SERVICE PROCEDURE......................................................................................................... 2
1. Battery................................................................................................................................. 2
2. Fuse.................................................................................................................................... 5
3. Combination Meter..............................................................................................................6
4. Combination Switch.............................................................................................................6
5. Headlight............................................................................................................................. 7
6. Front Wiper......................................................................................................................... 8
7. Washer................................................................................................................................ 9
8. Rear Wiper........................................................................................................................ 10
9. Rear Window Defogger.....................................................................................................10
6.26.2 SERVICE PROCEDURE
BODY ELECTRICAL SYSTEM
1. Battery
A: PRECAUTION IN HANDLING
1) To prevent a short, first connect the plus-terminal
When making cable connections, and disconnect the
minus-terminal cable first when disconnecting.
2) When charging the battery, use a current input of
about one tenth the battery capacity.
3) Adjust the charging current so that the temperature
of the electrolyte will not rise over 45C (113F) during
charging.
4) During quick charging, the charging current should
be less than a rate expressed in a battery capacity of 5-
hour rate (5 HR).
5) When quick charging the battery while mounted on
the vehicle, be sure to disconnect the plus and minus
cables from the battery terminals to protect the
alternator diode.
B: INSPECTION
1) External parts
Check for the existence of dirt or cracks on the battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean With water and wipe with a dry cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2) Electrolyte level
Check the electrolyte level in each cell. If the level is
below MIN LEVEL, bring the level to MAX LEVEL by
pouring distilled water into the battery cell. Do not
beyond MAX LEVEL.
WARNING:
Electrolyte has toxicity: be careful handling the
fluid.
Avoid contact with skin, eyes or clothing.
Especially at contact with eyes, blush with water for
15 minutes and get prompt medical attention.
Battery generates explosive gas. Keep spark,
flame, cigarette away.
ventilate when charging or using In enclosec
space.
2
SERVICE PROCEDURE 6.2
1. Battery
3) Specific gravity
Serviceable specific gravity:
1.220 - 1.280 at 20C (68F)
The specific gravity of electrolyte can be measured with
a hydrometer. Holding the glass tube vertically, slowly
draw the liquid into the tube. Take the reading on the
float scale at the highest point of the liquid.
When reading, the eye should be level with the surface
of the liquid.
If the specific gravity reading is below L220 at 20 TJ
(68F), the battery must be recharged and, if necessary,
the specific gravity of the electrolyte must be adjusted.
I fie specific gravity changes according to temperature.
The standard temperature is considered to be 20C
(68F).
When measuring the specific gravity, calculate as
follows:
S = St + 0.007 (t 20)
C: CHARGING
Measuring the specific gravity of the electrolyte in the
battery will disclose the state of charge of the battery.
The relation between the specific gravity and the state
of charge is as shown in figure.
3
6.2 SERVICE PROCEDURE
1. Battery
1. NORMAL CHARGING (
If the specific gravity is below 1.220 at 20C (68R
normal charging must be made as soon as possible
Connect a charger to the battery as shown in the figure
and send a contact current of 6A until the voltage and
specific gravity reach the values for complete charge
Usually the charging is considered to be completed if
there is no further rise in specific gravity measured
every 30 minutes successively.
CAUTION:
Remove all the vent plugs since electrolyte
generates gas toward the end of charging.
Do not bring an open flame close to the battery at
this time.
Prior to charging, corroded terminals should be
cleaned with a brush and common baking soda
solution.
2. QUICK CHARGING
Quick charging is a method in Which the battery is
charged in a short period of time with a relatively large
current by using a quick charger.
Since a large current flow raises electrolyte
temperature, the battery is subject to damage if the
large current is used for prolonged time. For this
reason, the quick charging must be carried out within a
current range that Will not increase the electrolyte
temperature above 45C (113F).
It should be also remembered that the quick charging is
a temporary means to bring battery voltage up to a fair
value and, as a rule, a battery should be charged slowly
With a low current.
CAUTION:
Observe the items in NOTE in 1) Normal charging-
The battery should not be charged with 10A or
more.
4
SERVICE PROCEDURE 6.2
2. Fuse
2. Fuse
1. FUSE BOX
The fuse box is located underneath of the instrument
panel driver side.
The connection between each fuse and main electrical
units/devices is as shown in the "Wiring Diagram".
CAUTION:
When replacing fuse, be sure to use fuse of
specified rating.
If fuse is blown, be sure to eliminate cause before
installing new fuse in position.
Poor contact of any fuse holder will often lead to
voltage drop or heating in the circuit or fuse holder
and could result in blown fuse, so be careful with
holder contact, and clean metal parts if necessary.
Designation
Item
30A 40A 60A
100 mV or less 100 mV or less 100 mV or less
Voltage Voltage drop across terminals Voltage drop across terminals
Voltage drop across terminals
drop should be less than the above should be less than the above
should be less than the above value
value when a 15 A current value when a 20 A current
when a 30 A current flows.
flows. flows.
Melting Fusible metal should melt Fusible metal should melt Fusible metal should melt Within 15
charac- within 15 seconds at a current within 15 seconds at a current seconds at a current flow of 180
teristics flow of 90 amperes. flow of 120 amperes. amperes.
Case
Pink Green Yellow
Color
5
6.2 SERVICE PROCEDURE
2. Fuse
3. Combination Meter
A: REMOVAL AND INSTALLATION
1) Remove the steering wheel.
2) Remove the visor by taking off the tapping screws
4. Combination Switch
1) Remove the steering wheel.
2) Remove the column cover.
6
SERVICE PROCEDURE 6.2
4. Combination Switch
5. Headlight
1. Light Bulb Replacement
1) Remove the protector.
2) Disconnect the connector.
3) Remove boots.
4) Remove the light bulb retaining spring to remove the
bulb.
5) Replace the bulb with a new one and hook the
spring.
Install in the reverse order of removal.
CAUTION:
Since the tungsten halogen bulb operates at high
temperature, dirt and oil on the bulb surface
decreases the bulb's useful life. When replacing the
bulb, hold the flange portion and do not touch the
glass portion.
B: ADJUSTMENT
1) Adjust by turning the adjustment screw with a
screwdriver.
7
6.2 SERVICE PROCEDURE
5. Headlight
6. Front Wiper
A: REMOVAL AND INSTALLATION
1. BLADE
1) Pull out blade from arm while pushing up clip
2. ARM
1) Remove the arm cover.
2) Remove the arm by loosening the fitting nut.
8
SERVICE PROCEDURE 6.2
6. Front Wiper
B: ADJUSTMENT
1) Adjust blade in original position as shown in figure.
Original position: A
25 5 mm (0.98 0.20 in)
7. Washer
A: ADJUSTMENT
1) Adjust washer ejecting point on windshield glass as
shown in figure.
Ejecting point:
A 150 mm (5.91 in)
B 300 mm (11.8 in)
C 275 mm (10.8 in)
D 200 mm (7.87 in)
E 175 mm (6.89 in)
9
6.2 SERVICE PROCEDURE
7. Washer
8. Rear Wiper
A: REMOVAL AND INSTALLATION
1) Pull out the blade from the arm while pressing down
on the clip.
2) Remove the arm cover.
3) Loosen the arm fitting nut and remove the arm.
4) Remove the cap, nut and cushion.
5) Remove the rear gate trim from inside of the pas-
senger compartments
6) Disconnect the electrical connector, loosen the fitting
bolts, and take out the motor.
Install in reverse order of removal.
B: ADJUSTMENT
1) Adjust blade in original position as shown in figure.
Original position A:
A 15-20 mm (0.59 - 0.79 in)
10
SERVICE PROCEDURE 6.2
9. Rear Window Defogger
B: REPAIR
1) Clean broken wire and its surrounding area.
2) Cut off slit on thin film by 0.5 mm (0.020 in) width
area 10 mm (0.39 in) length.
3) Place the slit on glass along the broken wire, and
deposit conductive silver composition (DUPONT No.
4817) on the broken portion.
11