Professional Documents
Culture Documents
1987 Honda Prelude Service Manual
1987 Honda Prelude Service Manual
1987 Honda Prelude Service Manual
General Info
INTRODUCTION
How to Use This Manual
This manual is d i v ~ d e dinto 1 5 sections. The first page of each section is marked w i t h a black tab that lines up w i t h one of the thumb
index tabs o n the front and back covers. You can quickly find the
ftrst page o f each section without looking through a full table of
contents. The symbols printed at the top corner of each page can
also be used as a quick reference system.
Each section includes:
1 . A table of contents, or an exploded view ~ n d e xshowing:
Parts disassembly sequence.
Bolt torques and thread sizes.
Page references t o descriptions in text.
2. Disassembly:assembly procedures and tools.
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Special Information
Indicates a strong possibility of severe personal injury
e if instructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment
damage if instructions are not followed.
NOTE: Gives helpful information.
CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are not included.
Please note that this manual does contain warnings and cautions
against some specific service methods which could cause PERSONAL INJURY, or could damage a vehicle or make it unsafe. Please
understand that these warnings cannot cover all conceivable ways
in which service. whether or not recommended by American
Honda, might be done. or of the possible hazardous consequences
of each conceivable way, nor could American Honda investigate all
such ways. Anyone using service procedures or tools, whether or
not recommended by American Honda, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be -jeopar.
dized.
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the
right to make changes at any time without notice. No part of this
publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables.
Transaxle
Brakes
I
First Edition 9/86
All Rights Reserved
Specifications Apply t o U.S.A.
I
Electrical
General Information
Chassis and Paint Codes ................... 1 - 2
Identification Number Locations ......... 1-3
Label Locations ............................... 1-4
Lift and Support Points ..................... 1-6
Towing .......................................... 1-9
--..A-
Engine Type
A 1 8AI: W i t h Carburetor ( 18 0 0 )
A 2 0 A 3 : With Fuel-Injection ( 2 0 0 0 )
Model Year
1: 1 9 8 7
Emission Group
9: California (CAL)
6: 49ST
Serial Number
I
M : Passenger Car
Prelude (2000)
Transmission and Body Type
1 : 5-Speed rnanuall2-Door
2: 4-Speed autornaticl2-Door
Model
Check Digit
Model Year
H: 1 9 8 7
Factory Code
C: Sayarna Factory
Serial Number
------I
Manufacturer Code
Vehicle Type
M:Passenger Car
Prelude (1800)
Transmission and Body Type
1 : 5-Speed manuali2-Door
2: 4-Speed automaticl2-Door
Model
2: 1 8 0 0
Check Digit
Model Year
H: 1987
Factory Code
C: Sayama Factory
Serial Number
Chassis Number
Transmission Type
F 4 : Fuel-Injected Eng~ne
AS: Carbureted Engrne
Serial Number
6000001
-1
--
Color Code
Color
Montreal Blue Metallic
Polar White
Phoenix Red
COLOR
NH-91M
Chassis Number
Transmission Number
(Automatic)
Chassis Number
Transmission Number
(Manual)
Engine Number
label Locations
Fuel-Injected Engine:
RADIATOR
CAUTION
CAP
COOLING F A N CAUTION
EMISSION C O N T R O L
INFORMATION
L I F T BLOCK
(cont'd)
- Floor Jack
1.
Set the parking brake and block the wheels that are
not being lifted.
2.
When lifting the rear of the car, put the gear shift
lever in reverse (Automatic in PARK).
3.
4.
Front
o f jack l ~ f platform
t
Rear
bracket
In
the m ~ d d l e
ofjack l ~ f platform
t
Towing
If possible, always t o w the car wrth the front wheels off
the ground. D o not use the bumpers t o lift the car or t o
support the car's welght while towing. Check local
regulations for towrng w ~ t ha cham or frame-mounted
t o w bar. A chain may be attached t o the hook shown in
the illustratron. Do not attach a t o w bar t o either
bumper.
If the car IS t o be t o w e d w l t h four wheels on the ground,
observe the following precautions:
1.
2.
3.
4.
5.
f---- ---
-------
TOWING POINT
i--____
Special Tools
Engine ............................................ 2-2
Fuel and Emissions .....................
2-2
Clutch ............................................ 2-2
Manual Transmission ........................ 2-3
Automatic Transmission <F4> ........... 2-3
Automatic Transmission <AS> .......... 2 - 3
Differential ....................................
2-4
Power Steering ................................ 2 - 4
Suspension ..................................... 2 - 4
Brakes ........................................... 2-5
Body ............................................
2-5
Heater and Air Conditioner ................ 2-5
Special Tools
NOTE: Some tools may appear in more than one section of this list if they are used for more than one job.
I
DESCRIPTION
TOOL NUMBER
PAGE REFERENCE
Driver
Ring Gear Holder
Ball Joint Remover
Valve Guide Remover, 7 . 0 rnm [Exhaust]
Valve Guide Remover, 6 . 6 m m [Intake]
Camshaft Seal Driver
Seal Driver
Seal Driver Attachment
Adj. Piston Pin Driver
Piston Base Head
Pilot Collar
Piston Pin Base Insert
Piston Pin DisIAssembly Tool Set
"Piston Base
"Piston Base Spring
Valve Guide Reamer 7.0 m m [Exhaust]
Valve Guide Reamer, 6.6 m m [Intake]
* : Carbreted Engine
1 0 m m T-Wrench
Ring Gear Holder
Clutch Disc Alignment Tool
(not shown)
6-1 5
r Manual Transmission
TOOL NUMBER
DESCRIPTION
Adj. Bearing Remover, 2 5 - 4 0 m m
Attachment, 5 2 x 5 5 mrn
Driver
Mainshaft Holder, Manual
BearingITransmission Case Puller
Seal Driver Attachment
Seal Driver
Driver Attachment, E
or 0 7 9 6 0 - 6 1 2 0 0 0 +
07960-6890100
Transm~ssionH o u s ~ n gPuller
Clutch Spring Compressor Set
"Compressor Attachment
*Compressor Bolt Assembly
"Compressor Attachment
Oil Pressure Gauge Set
1
i
or 0 7 9 6 0 - 6 1 2 0 0 0 +
07960--6890100
I
PAGE REFERENCE
Special Tools
,1-
Differential
TOOL NUMBER
r - - - - - - - ^ - - - - - - - - - - - - - -
1
-1
I-
/1
07746-00301 0 0
07749 -001 0000
07947-61 10500
07947-6340500
DESCRIPTION
-
Driver, 4 0 m m I.D
Driver
Seal Dr~verAttachment
Dr~verAttachment, E
PAGE REFERENCE
16-4
16-8
16-10
16-8
Power Steering
0 7 C A K - SE00110
07GAK-SE00120
07406-0010701
01406- 0 0 10300
07406 0010 4 0 0
07725 0030000or
0 7 7 2 5 - 0 0 1 0 10 0
3 7 7 4 6 - 0 0 1 0 3 0 0 or
07965-6920500
07749 -001 0000
07900- SA50000
"07974-SA50100
" 07974-SA50200
* 07974-SA50300
"07974-SA504OO
"07974-SA50600
07916-SA50001
07941 6920002
07974-SA50800
07974-6790000
19-9
19-9
19-1 1
19-9
19-9
19-20
Attachment, 4 2 x 4 7 m m
19-39
Dr~ver
P/S Seal Replacement Tool Set
" P ~ s t o nSeal R ~ n gG u ~ d e
"Plston Seal R ~ n gS ~ z ~ nTool
g
"Cyl~nderEnd Pack~ngSl~der
'End Seal Guide
"Dust Seal G u ~ d e
Steer~ngGearbox Locknut Wrench, 4 0 m m
Ball J o ~ n tRemover
Ball J o ~ n tClip lnstallat~onGu~de,B
Tie-Rod Boots D r ~ v e r
19-39
(not shown)
19-41
19-41
19-42
19-44
19-46
19-8
19-34
19-27
19-27
r Suspension
r Brakes
TOOL NUMBER
DESCRIPTION
'1 I
,
Body
PAGE REFERENCE
. Driver
22-43
07GAZ- SE30100
I1
-4
Specifications
Standards and Service Limits ............. 3-2
Design Specifications ...................... 3-13
Body Specifications ....................
..... 3-16
r
I
Carbureted Englne
1
I
MEASUREMENT
1I
Compresston
STANDARD lNEwl
Nomtnal
SERVICE LIMIT
1226kPa(125kgcm
*
M~ntrnurn
M a x ~ r n u mvartat~on
'
Warpage
Hetght
End play
01'clearance
No 1 3 and 5 Journals
k o 2 m a 4 jo~rnals
Runout
- C a m lobe helght
Manual and
Autornat~c
Manual
Cam lobe h e ~ g h t Manuel
Automattc
Valve clearance
Valve stem 0 D
Stem t o gutde clearance
Stem tnstalled hetght
Fuel-Injected Engtne
Valve seat
IN A
IN B
EX
IN A
IN B
EX
IN A
IN B
EX
IN
EX
IN
EX
IN
EX
IN
EX
width
IN and EX
178ps1i
125 psi)
149psli
90 13 541
0 0 5 - 0 15 10 0 0 2 - 0 0061
0 0 5 0 - 0 089 I0 0 0 2 - 0 004)
0 130-0 169 ( 0 0 0 5 - 0 0078
0 03 10 001) max
2 38 853 ( 1 52961
3 38 604 (1 51 981
2 38 796 I1 52741
* 38 86 ( 1 530)
* 38 41 (1 512)
* 38 92 (1 5321
* 38 67 ( 1 522)
* 38 22 (1 505'
* 38 42 (1 5131
0
0
0
0
5 I 0 02)
15 ( 0 0061
23 ( 0 0091
06 ( 0 0021
-
0 12-0 17 10 0 0 5 - 0 007)
0 25-0 30 I 0 0 1 0 - 0 0121
6 58-6 59 10 2591 - 0 25941
6 94-6 95 10 2732-0 27361
0 0 2 - 0 05 10 001 - 0 0021
0 0 6 - 0 0 9 ( 0 0 0 2 - 0 004)
48 59 I1 9131
47 66 11 8761
6 55 ( 0 258)
6 91 ( 0 2721
0 08 ( 0 003)
0 12 I0 005)
49 34 (1 9431
48 41 11 9061
1.25-1.55 (0.049-0.061)
2.0 10.08)
48.8 11.921
1.75 (0.068)
Valve g u ~ d e
6.65 (0.262)
7.05 (0.278)
0 0 8 10 0031
--
Rocker arm
A r m to-shaft clearance
Cylinder block
MEASUREMENT
Warpage of deck surface
Bore dtameter
P ~ s t o n - t o - r ~ nclearance
g
(top and second,
'
STANDARD (NEW)
SERVICE LIMIT
II
MEASUREMENT
1
Crankshaft
'
,-
1
i
i
0 . 7 0 - 0 . 3 5 (0.004-0.0141
0 . 0 2 4 t0.00091 max.
0 . 0 1 0 (0.00041
0 . 4 5 (0.0181
0 . 0 4 10.00161
0 0 2 6 0 , 0 5 5 10 0010-0.00221
0.032-0 061 ~0.0013-0.0024~
0.020-0.038
0.07 (0.003)
I
( 0 . 0 0 0 8 - 0 . 0 0 1 51
0 . 0 7 (0.0031
--
+-i
MEASUREMENT
Engine oil
STANDARD (NEW)
Displacement
SERViCE LIMIT
011pump
0 1 5 ( 0 0 0 6 1 rnax
0 1 0 - 0 1 8 ( 0 0 0 4 - 0 0071
030-010810001-0004;
!d!e
3 0 0 0 rpm
0 15 10 0061
Cooling - Senion 10
MEASUREMENT
Deflection midway between pulleys~load
!
Capactty itnc!. neater! t'
Cooling fan
STANDARD (NEW)
2 A u t o m a i ~ c6.7
74-103kPa10.75i.051~g~cm2.11-15ps1)
Primary:
82C 1 2 1 1 8 0 F i 3 1
Secondary: 85C t 2 ( 185OF * 31
/
Valve lift at full open
Water pump
Fan-tocore cIearan_e
Thermoswitch "Chi" ternperatiire
:
i
86-90C
* 1.29
;24,5,OCC !3i.7US. aai, b.i)GO r i i m ;
3 1.24
23.C (0.2/>,
E:'-P3"C
,788' - ;gGCF)
83C ( 1 6 : "F: o. more ,i?vstei~r.is2 ' C 135F' or more
II
Fuel
'
Delivery prcssure
Displacemeni
Pressure
---
Fuel Tank
--I
Capacity
;
1
Delivery pressure
D~splacernent
Pressure
regulator
STaMDASD (NEW)
MEASUREMENT
I
1187-1 94'F)
Fuel - Section 1 1
I
II
SERVICE LlMlT
0 . 0 1 0 (0.0004)
Ii
0 . 0 3 5 1000021 max.
End play
Runout
I1
4 9 970-49 9 9 4 11.9673-1.9683j
0 . 0 0 5 l0.00021 max.
44.976-45.000 (1.7707-7
Carbureted Englne
STANDARD (NEW)
M a ~ nb e a r i n g - t ~ - ~ c u r n a l
Oil clearance
Fuel-Injected Er~gine
PSI)
' - - G 7 -.T-, G 5 9 3
2 l a p CUI
(cont'd)
3-3
r1
I
STANDARD INEWI
Fast idle
/r~m/
Manual
Automatic
'
w l t h headlights and
cooltng fan off
Autornatlc
(in "N" or "P"1
1, *
Manual
Automatic
(in gedri
1 250-1,750
1.200- 1 7 0 0
CAL
I
I
800
50
800
50
700
50
0 1 %
Clutch pedal
Section 13
I
STANDARD INEW)
MEASUREMENT
Pedal height
^
Stroke
Pedal play
Disengagement height
Clutch arm
Flywheel
Clutch plate
176 ( 6 91 t o floor
137 ( 5 4) t o carpet
1 3 8 - 1 4 3 15 4 - 5 6 )
1 3 3 - 1 4 3 (5 2 - 5 6 )
2 3 - 2 8 ( 0 9 - 1 1)
8 6 13 41 mln t o floor
4 7 (1 91 mfn t o carDet
0 . 0 5 (0.0021 max
/
/
1 3 (0.05) mln.
0 . 8 (0.03) max.
0 . 7 - 2 . 1 (0.028-0.083)
8.1 - 8 . 8 ( 0 . 3 2 - 0 . 3 5 )
Clutch release
bearing holder
I.D.
Holder-to-guide sleeve clearance
Clutch cover
0 1,000- 1,800,
Model
Idle CO
,
Clutch
0 1 0 0 0 - 1,800.
G Manual
1
Carbureted Engln =
MEASUREMENT
ldle speed
(rpm1
Fuel Injected E r g t l e
Fuel - Section 11
SERVICE LIMIT
0 . 1 5 (0.0061
0.2
1.0
4.0
5.7
/
/
10.0081
(0.04)
(0.16)
10.22)
31.00--31 0 5 9 (1.220-1.223)
0 . 0 5 - 0 . 1 5 10.002--0.006)
0.22 ( 0 0 0 9 i
0 . 8 (0.031 max
1.0 10.041
MEASUREMENT
Transmission oil
Capacity t (US qt
STANDARD (NEW)
SERVICE LIMIT
' 2 6 ( 2 7 2 3) at assembly
Imp q t )
2 5 ( 2 6 2 21 at 011change
2 5 ( 2 6 2 2) at assembly
Malnshaft
Mainshat thtrd
and fourth
gears
Gear
Countershaft
I.D.
End play
End play
Th~ckness
004(00016)rnax
i
-
End play
Diameter of needle beartrig contact area
Dlameter of ball beartng contact area
Dtameter of low gear contact area
Runout
__t
I
Counershaft
low gear
ID
End plav
3 9 0 0 8 3 9 0 2 5 ( 1 5357 1 53641
003-008lOOO12-00031)
Countershaft
Secnd gear
ID
End piay
Th~ckness
4 3 0 0 8 - 3 0 2 5 ( 1 6932 - 1 69391 1
0003-010(00012-000391
3042-3047111976-;996r
1
j
3 9 0 7 ( 1 5381
018l0007
43 0 7 i l 6961
018\0007~
3 0 3 i 1931
--
-- -
30
MEASUREkqENT
STARCARC. IPJEW)
1_1--_----
1
--
Zrse
'
i
Shift rod g u ~ d e
----1
1.7 10.07!
I.D.
Guide-to-shaf- clearance
[7;%00-:Q.068
10.5512
0.01 1 - 0.082
t
7 1.3...12.g ' ~ . n 6 $ - . - 0 . ~ 7 , ? i
1
0.2: --0.5 10.liQ5 0.026!
1 7 . $ - 12.0 (6.46-0.47:
0.05 -0.35 (0.002-0.0141
7.9.- 8.0 !0.317-0.31 51
0 . 1 --0.3 (0.0D4-0.0121
0.5 (0.021
0.0 (0.03)
---
0.6 (0.921
--
,
1
--
5 1.$-.'/2.G r~.i:~g-~j.*::72)
0.05-(1.25 IC?.I)!::-G..J?O;
1 9 . 0 5 - . 1 ~ 15 :c.::$F :$. .
470:
0.05-0.25 lt..Ci33 - C: 2 10!
0.01 -3.21: (C.C,'O'f: - ~>.ilS:'9i
0.8 (0.031
j!
0.5 ( 9 021
Transmiss~onoil
!1
."
..--.
0.9 (6.03;
Seleciion bvlth. 5 types of shims
A-
-- -
--
Hydraultc
pressure
:
'3
- --.-.
,I - - - - - - -
*+.
,):
c~,:,e>,,;e
,ssse?-,rii.
-.
.. . .
785 kPa
4 4 i --1383 4Pa
785 kPa
( 8 . 0 kgicm', 114 psi)
T!iiottle oresshre B
r
I
I
Check with car on level ground
S
t
a
l
l
s
p
e
e
d
--
;?,;.;
-*
i $ 5 - &8:1 i;?s
(;?.r-~
7 ' A
I .:D csii
2 22 -. L7 2 c 1: r-.:,
12 2:s-2.35-- !kc;,c,r~22-:,?
psr.
. - ~- -. . ..
.r1;5 .. 5: 9 kpR
!L. ~ 5 5-. 2 3 kc :;rn.
7 : -7.1
814 - 5 2 2 kFa
, s . ~ ;9.6
~ .a g j c m : , 1 2 l - j '.8---LS::
L; Throttle pressure A
Clutch
SERVICE LIMIT
- --
11
,:.z,
C ri;.3, 5 5)3:
ST,%MDji&RD:plE>j'&)
- -
_
1
1
1
_
_
_
_
1
.
MEtJ.SldREFn%EN%
--
.. 2
--
(0.46--0.48)
1 .0 i0.009-0.039)
9.05--7.25 i0.278 - 0.2851
0.05-0.35 (0.002-0 ill.?,)
6.0 (0.243
1.0 (0.64)
1 1. R - 1 2 . 1
j
I
6.75-6.85 iC'.26B~-C.270)
3
35 --0.65 ! 0 . 0 i--4 - i",.C:%FI
- ---
-.
Endgap
Fork-:o-reverse
Groove width
.I;.
---
1.
--
Synchron~rersleeve gear
Fork-lo svnchror;iztr sleeve clearance
17.09 10.8731
0.15 (0.0061
pushed agsirst
1
25.06 (0.9871
31.93 (1.2571
27.01 (1.063!
SERVICE LIMIT
O.D.
(Mainshaft
Shift arm
U n ~ t :mm (in 1
_ _ _ _ - - -
C ~ r h u r r t e dEngine
,n]ec3, a
ii
1s:
2 , i~i)Q
- - ?,lj()0 -pi?:
C.if:-C.G5 id C2E-0.035
'
,'
18.0 kgicm',
216 kPa
17.2 lkg!cni',
490 kFa
1 5 0 kglcrn',
135 kPa
(8.0 kgicm;,
-~
I74 psii
3 1 psi1
71 psi;
! 14 psi)
--___-.
--
arid
3rd. 4ih
Clutch
CluiciClurch
Clutch
1
I
29.0 I l . i r i 1
I>,-?,/grooves worn c u t
C,iscolorar!cn
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
hlark E
Mark 7
51,j.L 8
kqsrt: 9
k k r ~,' (;
contact arz* on
,7,79,
:: * < , 7
-'<,.
,.=
.-je:,
c o u ! - . ~ ? r : ~ , d,.+ ~,a,=,
,,
<? ,-
2 : : v ~ 3 3 ,0) . 3 : $ - - ; . : , " i t , ,
7i!..cciorat:ci;
2 2 SS9-22 '?93, C . % i 4 7 - :
i 9C52:
Wear oi dernage
.,:,.. t:?
"
,,
?:it
. i ? '5:~>c!!
,.
,7 . - , ? - .
1 , .,'i..'
-";P_-- -
.,,I.
j;
*is:
"i
-5:1.:;
'-,,-,.. ,
,;,
3%
:!(ts
3f;
,,
5;
h~
-,
5 1 e,:.,
' J i e ~ sor
C~I?-~?~!;C
(con: dl
3-5
I-
MEASUREMENT
-Diameter o f needle bearing c o q t a c t diea
i o ~ n t e r s h ~3~r d{ tgedr
D i j n i z t e r of r i . e d t l:e,jr!rv> r--i:t,,-~ ,irf:d
c o u n t e r s h a f t 4 t h gear
Dlameter o f ~ e e d l euearing c o n t a c t area
c o u n r e r s h a f t reverse gear collar
Diameter o f needle bearing c o n t a c t area
c o u n r e r s h a f t L gear collar
Diameter o f needle beari!:g c o n r a c t area
reverse idle gear
Reverse idle1 :,t:dft i:uIdei d i i i i , ~ f e i
M a i n s h a f r 2 n d gear I D
M a l n s h a f ? 1 s t gear I D
C o u n t e r s h a f t 4 t h gear I D
C o u n t e r s h a f ? 3 r d gear I D
C o u n t e r s h a f t 2 n d gear I D
C o u n t e r s h a f t 1 st gear l D
C o u n t e r s h a f t reverse gedr I D
Reverse idle gear I i)
M a i n s h a f t 4 t h gear e n d play
M a i n s h a f t 2 n d gear e n d play
M a i n s h a f t 1 st gear e n d play
C o u n t e r s h a f t 3 r d gear e n d play
C o u n t e r s h a f t 2 n d gear e n d play
Reverse idler gear e n d play
C o u n t e r s h a f r reverse gear e n d play
Reverse gear h u b 0 D
Thrust wdshpl tnickrc.ss
M a i n s t i d f t 2 r d gear
-------
S T A N D A R D (NEW1
SERVICE LIMIT
on
or>
on
on
on
Wear or damage
Wear or damage
Wear or damage
B
C
D
E
F
G
H
I
Counterst-aft 41)- gear cclldr t h i c ~ r e s sA
R
C
D
E
F
G
Thrust washer t h i c k ~ e s1wzinshafl
~
1 st gear L side,
M a i n s h a f t 1 s t gear ccliar l z , , y t h
?,:.qn:h3tt
1 st gnar collar flange thicnness
1 4 ( 0 055,
Wedr or damage
Vvedr or damage
Wear or damage
U~ameto
~ fr c o u n t e r s h a f t o n e w a y c l u t c h
c o n t a c t area
Diameter o f parkiqg gesr o r e w a y c l u t c h
Wear or damage
--
c o p t a c t area
M a i n s h a f l f e e d pipe 0 D Iar 2 0 r n m f r 3 m end)
Counrershaft f e e d plpe
0 D l a t 2 0 r n m f r o m end1
M a i r s h a f t s e a i i r g ririg 3 2 mrr i b i c k n e s s
M a i n s h a f t b,:shiny I D
66 635
1 980
6 018
0 31421
1 995 I0 0780 0 07851
6 0 3 0 10 2 3 6 9 - 0 2 3 7 4 1
b8ainsha!t b b s h i n g I D
C o u ~ i t ? : s h n f r bushing I D
9 GOO
6000
2025
9 0 1 5 10 3 5 4 3 0 3 5 4 9 1
8 0 1 5 r 0 3 1 5 0 031561
2060100797 008111
66 695 2 6254
6 9
F 9 8 10 2 7 4 4
7 97
7 9 8 10 3 1 3 8
2 6258
0 27481
,
j
Wear or d a m a g e
6 9 5 ( 0 2741
7 9 5 10 3 1 ,
1 8 10 0 7 1 1
6 04510 2381
9 0310 3 5 6 )
8 0 3 1 0 3 1 61
2 0810 0821
--
MEASUREMENT
Seal~ngrlng contdct area diameter
-
brake control
I
I
servo body
--
---
5 9 - - 6 0 ( 0 232- 0 2361
18 5 - 1 8 6 10 728-0 7321
5 4 ( 0 211
Wear or other defect
Wear or other defect
B
C
Shift fork shaft valve bore I D
Valve body
Wear or damage
Wear or damage
Wear or damage
Wire Dla.
'Selective-fit at factory
Wear or damage
0.0
No of coils
Free Length
-1
Transmisston oil
MEASUREMEKT
-
.-.-
.. -
Lrne pressure
--
a?
SER\V!CE LI.MIT
STANDARD iNEinl!
-..-
- -
I
I
Hydraultc
pressure
I
1
2 00C r ~ m
4 ?b c i c r z r picssLte
2.500 rpi-r;
2:
( h . 5 - 2 5 k g crn', ? E l : ? p s 8 i
F 3 9 8 3 4 ltPa
5 7 6 . 5k g , c m - , 7 6 - 1 2 1 psi1
?.I?-834 kFa
,, ' - ' .
6 5 K g , ( . v , , , -, .d " ", - ', psi,
., -
785-8-14 k?a
o a ;j I..;,can-, 1 1 4 - 1 2 1 PSI)
;?E-;'.IT;
4%)
!.? ;
: -:ls :,I;r2,
3: - 3 3 PSI!
505 L A q ,;"fo
,5,7';--i; ;a kg,c;n', 7 3 ~ ~ psi)
7 5
t8
Governor p r e s i i r i i: 60 h i : h
Throttle pressurt. B
7e4
-- --
--
Stall speed
f3 --
- .--
? $1
!):i
Ti.) iG.316-0.326,
0.6:
i:.gC: (0C26-0.031i
t3.i. !C,!)ld-0 0 2 4 !
t ,L,*.,
C I i t c h disc th~chnes?,
Clutch plbte l h ~ c l ~ n ~ r c
Clutch end pi,:i? :hicl,:-i\;:
Mar;'. ?
:u?drk 2
Mzrit S
V<iik A
?Jar!: 5
Xrsk d
!!,l<-rk 7
4: 6:K 5
iiinrk 9
"ark 10
c;:-?
,:re3
;:.,,I
;;,?a
. "~:i,b,li?'t
.
'/I
.,J
j.?. i
'3
I:
;I
C ~ ~ i , ; ~ t s k . . qf ~t . 3 .;*a'
'
'&{P
.<?
'
, . .3
'3
i?,,:!1
.;cc>.< #,., ,,,:,.
,, : , , L ., , .'. ! ,.,- :"p;,->:!.,$" ;
8:t'L"
C ~ u r t c i ~ l ? ~2r.:
? i :q i i : r
p",:.., .,>
1r8G
::re 41,
Ci~slchrc?,i:i: sc-inr. ii.b,r :e.,:;t'~.
E~^.t.c.~
:sw
!v;i.;isl;;,';
034 s ? a
-,n ;c:~cli;r!::,nii
C!~!?ch
ir.!i:;!i cicarancr
:s _
9;
".:,t'
,,'
c,',,
e7.,3 r . j \
lb-
30 5
i:
27.: ,: "1
: d e 2 . : ? :C.i374-0.0791
1 :)C-2.05 10.077-0.081:
. ,
!0,CSO---00 9 4 )
2 $--2.5
2 5- 2 6
2.6-2 7
2 7--2.8
10.094-0.098,
(0.098--0.102)
l0.102--!2.1r)bi
iO.l(3G-Q.?It?,
7 8 - 2 9 (0.I 11;- 0.i ; A ;
2 . 9 - 3 0 ,':.:I.$
-C.',
18)
0 - 21 8
0 122)
-.
3 . i - 2.2 ~ 0 , ? 2 2 0 . 1 2 6 i
3 . 2 2 3 ( 0 126- 0 ? 3 0 1
---
28.5 ! 7 . ? 2 1
32.C r S , . - 9 1
i i i i t l l groos,es ih/orn out
1D~scolsra:ion
A
Unit: mm (in.)
--- -- -
STANDARD (NEW]
MEASUREMENT
--
--
SERVICE LIMIT
-
0.05 0 . 1 8 1 0 . 0 0 2 0 007)
0 1 0 - 0 . 2 0 10 0 0 4 - 0 0 0 8 )
51 8 7 5 1 . 9 0 12 0 4 2 1 - 2 . 0 4 3 3 1
Wear or damage
A
8
L
n
E
.-
Wear or damage
Wear or damage
A
B
C
D
E
F
G
H
Countershdft 4rh gear colidr thickness
I
A
B
C
D
E
F
G
T r r u s t nsasher thickness imainshafr 1st gear
L side1
Mainshafr 1st gear collar length
Mairishaft 1st gear collar flange thickness
Countershaft reverse gear collar length
Coun!ershafr reverse gear coilar flange
th~ckness
Countershaft 1st gear collar length
Countershaft 1st gear collar flange
th~ckness
Diameter of counrershaft o n e ~ w a yclutch
contact area
Diameter of parking gear one-way clutch
contact area
Malnshaft and coilntershaft feed pipe 0 D
fa: 2 0 m m from end!
M a ~ n s h a f tsealing ring 3 2 m m Th~ckness
Mainshaf: bushing I D
Mainshafr bushing I D .
Countershaft bushing I.D.
Mainshaft sealing ring groove w i d t h
I
I
Regulator valve
Wear or damage
/
1
+i
t
-,
Reverse sh~f: fork th~ckness
3 2 0 0 0 - 3 2 0 2 5 11 2 5 9 8 - 1 26081
-.
5 9
-.
6 0 10 2 3 2 - 0 2361
Wear or damage
Wear or damage
Shifting oevice
and p r r k ~ r ~ g
brake ccntrol
1 4 ( 0 0551
Wear or damage
I
/
Wear or damage
3 2 . 0 5 11.261
5 4 (0.211
Wear or other defect
Wear or other defect
A
8
L
/
I
j
Stator cdrnsiiafl r e c d k o?ar,f?g bore I D
Stdtor c;ini:ihrift rieed!~?b c ~ r i n gcSr,!act
arid 0 3
9tl purn? dr:,>,crt qcd; ! 9
011punip chdft C D
0 0 3 0 0 5 10 0 0 1 2 0 00201
Drive.021027
10008 0011:
Driven.
o 05
0.09
!O 0 0 2 0 0041
2 4 0 0 0 2 4 0 7 1 10 9 4 4 9
26 0 0 0
l&016
7 3 950
0 94571
Wear or damage
26 0 1 3 11 G236
1 0241 1
14 034 ' 0 5 5 1 8
13 9 9 0 10 550.1
0 55251
Wear or darndpe
Wear or ddrnage
ih'rar or damage
0 55081
MEASUREMENT
Springs
1I
i
1
1
11
/!
1
:
1
1
,-
i/
i
1
1
/
I
Rtrlo qear
1
1
0 8 1003)
0 . 8 10.031
10.041
0.8 10.03)
? 4 10.06i
0.45 10.02)
1.0 (0.041
0.45 10.021
0 9 i0.04)
0.5 10.021
2.3 10.091
2 6 1010)
395 r 2 3
1016 x 0.091
3.95 x 2.3
10.16 x 0.091
10.041
1 . 0 10.0A)
1 0 10.04)
1 . 4 ioosi
2 . 6 iO 10)
1.0 10.04)
0 . 8 (0.03)
1.1 10.041
0.8 (0.03)
1 2 10.051
I
/
iuo, of coils
15.1 10.591
9 6 ( 0 381
38.4 " 5 1 1
8.4 10.331
8 4 10 331
6.1 10.241
8.5 10.331
6 2 10.241
9 . 5 10.33i
6.8 16.26)
4.5 10 I81
7.6 10.30)
4.5 i0.181
9 . 6 10.381
4.5 10.181
20 10.791
18.6 10.731
20 10.791
!1
i
1
'1
2
12
15
20.7
5 5
/
I
25
11
31
8
'I
79
13.8
16
20.4 10.801
ij
9.6 (0.38)
9.6 10.381
6.8 10.27)
9 . 4 10.32;
28811131
18.8 10.741
Free Length
71.2 (2.801
44.0 11 73)
3031119)
36.4 11.431
47 7 11.881
38.3 (1.51)
20.7 10.81)
30.0 11.181
30.7 11.21)
38.711.501
15.0 10.58)
64.4 12.491
13.3 10.521
35.3 11.371
10.5 10.401
49.8 11.96)
96.4 13.801
81.2 13.20)
14
88.1 13.47)
17 5
17.5
59 9
56.5
29.5
33.0
40.3
41.2
22.9
38.9
26.9
27.2
l3
10.5
33
/
1
11.8 10.46!
8 . 3 !0.331
6.8 (0.271
9.4 1037)
4
7
12.3
20
8
*.
: Fuei-Injected Englne
Backlash
1
,
STANDARD (NEW1
0 1 4 - 0 20 ' G 0 0 6 - 0 008)
Dtfferential
Carrier
D~fferential
Backlash
0.05-0.15
plnion gear
0.057-0.093
Carbureted E n g ~ n e
(0.002-0.006!
18.041-18.061
SERVICE LIMIT
S e l e c t i o n with 8 t y p e s of
washers
0.15 (0.006)
'
(0.7103-0.71 11)'
10.0022-0.0037')
Fuel-Injected E n g ~ n e
MEASUREMENT
R,gh: h o o t
A s instali?d
A s installed
MT
AT
STANDARD :NEW)
0 25 ; 0 0 1 0 )
Carbureted Englne
Left b o o t
(2.32)
12.191
11.16)
(1.301
11.59)
11.62)
10.901
11.50)
11.061
11.05)
MEASUREMENT
- Driveshaft --Section 17
2.0 10.081
1 8 10.07,
.
2
I
]
Wire Dia,
STANDARC (NEW1
SERVICE LIMIT
MEASUREMENT
Steer~ngwheel
+Carbureted Engtne
STANDARD (NEW)
SERVICE LIMIT
10 10 39) Max
1 0 1 0 ( 0 10 0 72)
Play
P l n ~ o nstartlng torque N.m (kg-m, ft-lb)
Suspension - Section 20
MEASUREMENT
Front
Wheel al~gnment
o0 00'
Camber
Caster
Toe-ln
Wheel
0 2 3
( 0 2 0.1181
0 6 O 50' *6'518
Steertng angle
RIL
lnstde
Outs~de
Rtm runout
Steel
Axla1
Radtal
Ax~al
Alurntnum
I
1/
SERVICE LlMlY
Iear
o O - 1 / 2 2l o
Kingpin tnclination
STANDARD (NEW)
?09
:;
&
0.079)
38O
30
0-1
0-1
0-0
0-0
0
0
7
7
(0-0
(0-0
(0- 0
10-0
39)
39)
0281
028)
--
Brake - Section 21
k-k
MEASUREMENT
STANDARD (NEW)
Parklng brake
lever
Foot brake
pedal
Pedal h e ~ g h t
Free play
Master cvlinder
Disc brake
Disc thickness
Front
Rear
DISC runout
Disc parallelism
Pad thickness
Brake booster
'
Front
Rear
19.0 (0.75)
10.0 (0.39)
1
9.5 (0.371
Vacuum i m m Hgl
0
300
500
20 (44)
20 (441
20 (44)
!
Characterist~cs
SERVICE LIMIT
17,O (0.67)
8.0 (0.311
0.15 (0,006)
0.015 (0.0006)
3.0 10.11i
1.6 (0.06)
Llne Pressure kglcm* (PSI)
0 12.0 (171) m ~ n
0 48.6 !6911 mln
G 72.9 11.037) mln
*
*
13 (1851
53 1754)
65 (924)
* Carbureted Englne
Fuel-Injected Englne
MEASUREMENT
Rated
voltage
--
--
.-
1.06
Alternator
..
+ 2O BTDC
20
+ Z0
BTDC
2.8-3.0 ohms
32.5 (1.281
0 10.5 (0.411
15
50 ~ m b e r eHours
8 . 5 V minimum at 150 Ampere draw
Output at no-load
-.
---
--.
1.24 ohms
l g n ~ t ~ otlmtng
n
Battery
STANDARD (NEW1
+
i
*
!-?!
-
--
U n ~ tm m ( ~ In
--.
15.5 (0.611
t 0 . 1 ohms
3 2 1 (1.261
-.-
--
1.4 KW IMITSUBAI
Startlng motor
k a d e p t h - - - - -
-I
MEASUREMENT
Commutator 0 D
STANDARD (NEW)
0 4 - 0 5 ( 0 0 1 6 - 0 0201
0 - 0 0 2 ( 0 00081
28 0 ( 1 10)
SERVICE LIMIT
--
0 15 ( 0 0061
---
0 0 5 ( 0 0021
--
--
27 5 11 081
Design Specifications
ITEMS
Overall Length
DIMENSIONS
Curb We~ght
Five
Si
Dx
36.6139.2in.
3501376in.
W~thoutAIC 5-MT Si
ox
4-AT Si
Dx
With AIC
5-MT Si
Dx
4-AT Si
Dx
2.379
2,293
2,423
2,317
2,425
2.344
2,469
2,368
1,515kg
1,474kg
TYpe
Cylinder Arragement
Bore and Stroke
Valve Train
Lubrication System
Fuel Required
2841b.
Gear reductton
Gear dlrect
1.4KW
12v
3 0 seconds
Clockwise as vlewed from gear end
9.9lb.
4.5kg
3.7kg
8.11b.
ND
MITSUBA
Normal output
Nomlnal voltage
Hour rating
Direction of rotation
Weight
991b.
SI
129kg
STARTER
ND
MITSUBA
Clutch
5 MT
Primary Reduction
Gear Ratlo
Flnal Reduct~on
Ib.
Ib.
Ib.
Ib.
Ib.
Ib.
Ib.
Ib.
Si
Dx
SI
Dx
Si
Dx
Compression Ratio
Includes bumper
3,3401b.
45kg
Displacement
TRANSMISSION
NOTE
172.21n.
169. l i n .
66.9in.
51 .Om.
96.5in.
57 9/57.9in.
5.91n
I
ENGLISH
SI
Dx
Overall Width
Overall He~ght
Wheelbase
Tread FIR
Ground Clearance
Seatlng Capaclty
Overhang FiR
WEIGHTS
METRIC
I
11
Ill
IV
V
Reverse
5MT
4AT
SI
Dx
SI
Dx
4 AT
SI
Dx
SI
1 000
3 181
1 842
1 250
0 937
0 771
3 000
i 000
3181
1944
1 250
1 000
2529
1481
1 060
0 734
1 000
2 380
1 560
1032
0 777
1 904
1 954
1
I
3 000
Single
Slngle
Slngle
Slngle
176cm'
160cm-
helical
hellcat
helical
helical
gear
gear
gear
gear
4
3
4
4
Dx
066
875
066
071
27 3sq In
24 8sq In
(cont'd)
AIR
CONDITIONER
Coollng capactty
- Condltlons
Compressor rpm
Outs~dealr temperature
Outslde alr humldlty
Condenser atr temperature
Condenser alr veloctty
Blower capacity
35OC
4 5 m sec
3 9 0 m'lh
Compressor
Radial tvpe
Recelver Dryer
WI.4EEL
ALIGNMENT
Type
Power consumptton
Refrigerant
Type
Quantity
slrocco fan
145 W (12 V )
Infmtely variable
390 1nJ,h
1
1 3 , 7 7 3 cu, ft:h
I
/
BRAKE SYSTEM
R-12
0,8
0.05 kg
1
iI
1 7 6 r 0.1 1 b s
FrontiRear
Front
Rear
Front
Front
Rear
370 mm
1 4 . 6 in
1 . 6 US. q t , I 3 Imp q t
1.5 11t.
FONDA Genuine Power Steerlng Fluld
Ktngpln lncllnation
Front
Rear
Parking Brake Kind and Type
Spare
0
0
O0
0 an.
0 . 0 8 0 tn
6"50'
Type, Front
Type, Rear
Llnlng Surface Area. FrontrRear
FrontiRear
Omm
2 mm
St
Dx
SI
Dx
'
I
185170 Fi 1 3 86H
1 8 5 7 0 SR13
T I 0 5 80D13
---
Effect~veDISC Dta.
TIRES
Overall Ratlo
Turns, lock-to-lock
Steertng Wheel Dta.
Power Steerlng Oil Capacity
Power Steering 011
Caster
Toe-ln
Wheel ai,gr;msnt
Camber
Air-mix type
Comp. Clutch
Type, Front
Type, Rear
Shock Absorber
02.
/~ype
SUSPENSION
SYSTEM
13773cufth
Temp. Conrrol
95OF
Evaporator
STEERING
SYSTEM
81 5'F
7 , 0 0 0 rpm
8 0 cc
I
2 . 7 US
Includes fusible safety plug.
Condenser
Blowr
1 8 0 0 rptn
I
5 0 '0
27 5C
Ty~e
No of cyltnders
Plston
displacement
Max rpm
Lubncant caparlty
Wnth dess~cant
NOTE
ENGLISH
METRIC
ITEMS
I
1
I
ITEMS
METRIC
1
ELECTRICAL
SYSTEM
I
I
1
/
Battery
Starrtnq Motor
Generator
M a ~ nF J S ~
Fuses
Headltghts
Turn S ~ g n a Llghts
l
i
/
I
Stop Taill~ghts
Stde Marker Ltghls
Back up Lights
L~censePlate Llghts
Dome llght
Trunk Llght
Glove @ O X Light
lllurntnatton Ltghts
ENGLISH
12 V-50 AH
1 2 v 1 4 Kw
12V - 65A 12V-60A
I
Front
Rear
Front Rear
6 5 A x 1 3 5 A x l
20Ax6 15Ax9 10Ax8
20Ax6 15Ax6 10Ax7
1 2 V -65 35 W
1 2 V - 3 2 CP
1 2 V - 32CP
1 2 V - 3 2 1 3 CP
1 2 V - 3 CP
1 2 V - 3 2 CP
1 2 V - 4 CP
12 V - 8 W
12V 3 4 W
12 v - 3 4 W
14 V-3 4 W
14V-1 4 W
' 2 V - 1 4 W 1 4 V - 1 4 Vd
1 2 V - 3 411 4 1 2 W
12V-3414W
1 2 V - 1 4W 1 2 V - 1 2 W
Carbureted Enqine
Fuel Injected Englne
II
1
1281)
(SAE1156 1 9 4 )
(SAE1156'
iSAE1156 1 9 4 )
(SAE 1941
lSAE11561
(SAE671
Body Specifications
I
Si:
Unit: mm (in.)
Dx:
Untt. mrn ( i n . )
Maintenance
Lubrication Points ............................ 4-2
Maintenance Schedule ...................... 4-4
Lubrication Points
i
No.
LUBRICATION
POINTS
LUBR~CANT
Engine
--
Manual
Transmission
Automatic
--
k
5
6
7
'
--8
9
10
11
12
13
1
1
10
Brake reservoir
Brake f l u ~ dD O T 3 or D O T 4
Multipurpose Grease
--
-.-
--
Piston seal
Dust seal
Caliper p i n
Piston
S h i f t r o d clevis bushings
D o o r hinges upper and lower
D o o r opening detentr
Engine h o o d latch
H o o d hinges
Fuel filler door
T r u n k hinges
F r o n t upper a r m
S ~ l i c o n eGrease
Multipurpose Grease
--
- --
- ----
--
Multipurpose Grease
Calipers
t e m p e r a t u r e ranges.
S t e e r ~ n ggearbox (Power)
F R O N T WHEEL BEARINGS -,
and SEALS
and SEALS
8 STEERING
GEAR BOX
'\
i/
1
,
LOWER A R M B A L L J O I N T
12 P E D A L L I N K A G E
13 H E A D L i G H T RETRACTORS
"-"a,*'A,:@'..*?
4,
//
G
'/
2.-
CALlPERS
Stl~conegrease
+$
~y-5-3
43.
,'
15
o . 'B , \F
..ti
17
DOOR HINGES
ENGINE HOOD
L A T C H -,
16
DOOR OPENING
DETENTS
;C ENGINE HOOD
2i
F U E L F I L L E R DOOR
23 F R O N T UPPER A R M
Maintenance Schedule
R
C
I
T h e maintenance l ~ s t e db e l o w m u s t b e p e r f o r m e d a t m ~ l e a g eIntervals
s h o w n t o ensure safe a n d e f f l u e n t operattng condrtrons and proper emlssron levels T h l s c h e c k lrst 1s arranged In h o t i c o l d i h o t s e q u e n c e s o y o u
c a n w o r k o n a hot e n g l n e w h ~ l ewartrrlg f o r ~tt o cool, a n d t h e n r u n c o l d
a n d h o t e m r s s ~ o n sc h e c k s
MAINTENANCE ITEM
Replace
= Clean
-
Inspect
A f t e r rnspectlon, clean, adjust, repalr or
replace ~f n e c e s s a r y
MAINTENANCE tNTERVALS
1I
x 1,000 miles
95
30
45
60
75
x 1,000 k m
24
48
72
96
120
12
24
36
48
60
,
'
NOTES
months
'
Parkinq brake
Brake pads
Suspens~onmountlng bolts
21-4
25,37,58
M l n thickness:
21-7,
35.40.66
'
11-41, 9 0
19 26
I
I
II
I
I
I
I
11 41
--
1 1 2, 13
121-32
20-3,4,5
79 3
i1 I i
Il
I*
'
19 8
Carbureted Engine
i *
CAUTION: The following items must be serviced more frequently on cars normally used under severe driving conditions.
Refer to the chart below for the appropriate maintenance intervals.
S e v e r e drtving c o n d i t i o n s i n c l u d e :
A : Repeated s h o r t d i s t a n c e d r i v i n g
B: D r i v i n g i n d u s t y c o n d i t i o n s
C: D r i v i n g i n severe c o l d w e a t h e r
2 0 10, 21
9-5, 6
4-3
21 3
Front 3 m m (0.12 ~ n . )
Rear 1.6 m m 10.06 in.)
15 8, 78
Min. thickness:
1
I
1
1 , (
Inspect every 7,500 miles
(12,000 k m ) or 6 months
!I
1 4 2
D : D r i v i n g i n areas u s i n g r o a d s a l t o r o t h e r c o r r o s i v e materials
E: D r i v i n g o n r o u g h a n d l o r m u d d y r o a d s
1
]
MAINTENANCE ITEM
x 1.000 miles
MAINTENANCE INTERVALS
15
30
45
60
NOTES
75
I SEC
& PAGE
months
Brake fluid
1
I 1
(020-0.25 i n )
13-3
Radiator coolant
system capaclty
6 8 1' ( 1 . 8 US gals)
'Manual
' Automattc 6 7 Y ( 1 8 US gals)
*Manual
6 4 S ( 1 7 US gals)
*Automattc 7 1 t' ( 1 9 US gals)
Check spectfic g r a v ~ t yfor freezing p o ~ n t
1~:
Alternator d r ~ v ebelt
Crankcase em~ssioncontrol
system
P C V valve
* -Blow-by
1
/
6 - 9 m m ( 0 . 2 4 - 0 . 3 5 in.)
@ l o kg ( 2 2 I ~ s tension
)
* 7 - 1 0 m m ( 0 . 3 - 0 . 4 in.)
@ l o kg ( 2 2 Ibs) tension.
12-25
12-25
lgnttion w i r ~ n g
10-8, 9
Z 12-64
filter
10-2, 3
I iR1 IR
In: 0 . 1 2 - 0 . 1 7 m m ( 0 . 0 0 5 - 0 . 0 0 7 In.)
EX: 0 , 2 5 - - 0 . 3 0 m m ( 0 . 0 1 0 - 0 . 0 1 2 in.)
6-22
l C l
1
-
Fuel-Injected Eng~ne
Carbureted Eng~ne
'
1
1
012-27
* 12-64
12-27
MAINTENANCE ITEM
i
I
MAINTENANCE INTERVALS
::
~ 1 , 0 0 0 r n 1 l e r, 1 5 3
x1.000km
months
0 4
48 7
I
24
60
2 9
36
48
-1 6 0
---
12-35
i 25-27
7 5 0 i- 5 0 rpm
OAutomatic 7 5 0 i 5 0 rpm (in "N" or "P")
" Manual 8 0 0 ? 5 0 rpm
* Automatic 8 0 0 i 5 0 rpm (in gear)
0 Manual
ldle speed
'
I' 0 11-85
1*
11-27
ldle CO
--
Evaporat~veem~ssion
control system (hot)
1 12-47
I
,
Draw 5- 1 5 m m (0.2-0.6 in.) Hg vacuum.
Pressurize t o 2 5 - 5 5 m m 11.0-2.2 in) Hg.
* -Inner
vent cut-off
solenold valve
I
Catalytic converter heat sh~eld
-Two-way valve
0 Fuel-Injected Engine
" Carbureted Engine
1
1
NOTES
6 /I20
1 7 5I
+--7--~----
I
I
Check c o n d ~ t ~ oand
n t~ghtness
1 0 12-63
" 12-48
Engine
Engine Removal/lnstallation ............... 5-2
Engine Lubrication
Illustrated Index ............................... 8-2
............. 6-1 1 Oil Level Inspection ...........................8-3
Valves ...........................
.
....... 6-1 2 Oii Replacement ............................... 8-3
Valve Seats ..........................
.
Valve Guides ...................................6- 14 Oil Filter Replacement ....................... 8-4
Valve Springs and Valves ................... 6-16 Oil Pressure Test .............................. 8 - 4
Oil Pump Illustrated Index .................. 8 - 5
CamshaftjRocker Arms and
Camshaft SealsIPulley ............. 6-1 7 Oil Pump Removal/lnspection ............. 8-6
Cylinder Head Installation .................. 6-18 Oil Filter Base Inspection .................... 8-7
Timing Belt ...................................... 6-1 9
lntake manifold1Exhaust System
Valve Clearance Adjustment .............. 6 - 2 2
Intake Manifold Illustrated Index ......... 9-2
Engine Block
Exhaust manifold Illustrated Index ....... 9-3
Illustrated Index ...............................7-2
Exhaust Pipe and
Muffler Replacement ............... 9 - 5
Flywheel and
Drive Ptate Replacement ........... 7 - 4
Main Bearings and Rod Bearings .......... 7-5
Engine Removalllnstallation
Engine Removal/lnstallation
4.
Make sure jacks and safety stands are placed
properiy (pages 1-6thru $1, and hoist brackets
are attached t o correct positions on the engine
(page 5 - 7 ) .
Apply parking brake and block rear wheels, so
car will not roll off stands and fa!! on you while
working under it.
I
@
1.
6.
THROTTLE CA
CONTROL
IGNITION PRlMARV LE
7.
6 x l.O mm
12 N-m (1.2 kg-m.
ENGINE COMPARTMENT
TROL
-:
,. , ,
,
.
'\
,,-. .-yj
\-~--,
MEA'rEW HOSE
B x 1.3mm
12 ?q'\i.rrs( 1 . 2 kg-m,
6 x 1.Ornrn
9
@
L
@
VOTE: O n ~ e a s s e m b i ?check
~,
t h e cable adjusfment
{sectiot-~? 5).
SKIB r ROD YOKE a ;i ACb!VEN f BOLT
Px125rn~t
2 2 F4.m :2 2 kg-m WCBtP ;rl
'\
!
6 x 4.6 mmr
CLUTCH CABLE
THROTTLE CONTROL
CABLE (A!T Orilv)
. .
5-5
PUMP
AlC COMPRESSOR
@ Loosen the belt adjusting bolt.
@
Loosen the compressor mount bolts and adjusting bolt then remove the compressor belt.
NOTE: The compressor can be moved without discharging the air conditioner system.
BELT ADJUSTIN@BOLT
4 Remove the compressor mounting bolts, then
10 x 1.25 mm
48 Nsm (4.8 kg-m, 35 Ib-ftl
ALTERNATOR
4 Disconnect the alternator wire harness connectors.
ALTERNATOR
BELT
ADJUSTING BOLT
8 x 1.25 mm
26 N-m
(2.6 kg-m, 18 Ib-ft)
WIRE HARNESS
/
ALTERNATOR NUT
ALTER^^^^^
ALTERNATOR BOLT
1 0 x 1.25mm
4 5 N-m (4.5 kg-m, 33 Ib-h)
smoothlv.
0 Check that the spring clip on the end of each
V-belt.
CAUTION: Use new spring clips on installation.
0 Clean battery posts and cable terminals with
@
@
@
a 12 x 1.25 mrn
75 N-rn (7.5 kg-rn, 54 Ib-ftl \_L
2 10 x
1.25 mm
12x 125mm
Tighten snug only
75 N-m (7.5 kg-m, 54 ~b-ft)
NOTE
Use n e w 0 r l n g s a n d g a s k e t s w h e n e v e r r e a s s e m b l i n g
CROWN NUT 6 x 1 . 0 mm
1 0 N - m ( 1 . 0 kg-m, 7 Ib-ft)
W
-WASHER
CYLINDER HEAD
BOLTS
1 0 %1 . 2 5 m m
6 8 N - m (6.8 kg-m. 49 Ib-ft)
Apply cledn englne 011
t o threads and
under the bolt heads.
and GROMMET
VALVE COVER
SPECIAL WASHER
UPPER BELT
OIL CONTROL
8 x 1.25 mm
28 N.m ( 2 . 8 kg-m, 2 0 Ib-ft)
TIMING BELT
Replacement, page 6-19
Inspection!Ad~ustment,
page 6 - 2 1
ADJUSTMENT BOLT
43 N - m ( 4 3 kg-m. 31 Ib-fti
Loosen, but d o n e t remove
'
BYPASS OUTLET
8 x 1 . 2 5 rnm
22 N.m ( 2 . 2 kg-m, 16 Ib-ft)
Garhureted Engine:
NOTE: Use new O-rings and gaskets whenever reassembling.
-----CYLINDER H E A D
BOLT
40 x l,25mrn
68 N m (6.8 kg-m. 49 Ib-ft)
Apply clean engine 0 1 1 to
screw threads and under
heads
SPECIAL WASHER
10 m m
- V A L V E COVER
V A L V E COVER GASKET
---
CONTROL
TIMING BELT
lnspectionIAdjustrnent,
page 6-21
BYPASS OUTLET
ADJUSTMENT BOLT
(cont'd)
8 x 1.25 m m
6 x 1.0 mm
12 N , m ( 1 . 2 kg-rn. 9 Ib-ft)
2 2 N . m ( 2 . 2 kg-m, 16 Ib-ft)
ROCKER ARM ASSEMBLY
Overhaul, page 6 - 9
Inspection, page 6-10
6 x I .O mrn
CAMSHAFT PULLEY
Removal, page 6-7
VALVE KEEPERS
ISTRIBUTOR
ee Section 25
Replace
INTAKE VALVE
SPRING RETAINER
SPRING RETAINE
Replace
INTAKE VALVE
Removal, Inspection,
Dimension, page 6 - 1 1
Recondit~oningvalve
seat, page 6 - 12
Valve Clearance
Adjustment, page 6 - 2 2
'
EXHAUST VALVE
Carbureted Engine:
8 x 1 . 2 5 mm
2 2 N , m ( 2 . 2 kg-m, 16 Ib-ft)
6 x 1 .Q mm
12 N , m 11.2 kg-m. 9 Ib-ft)
6 x 1 .O mm
DlSTRlBUTOR
8 x 1.25 mm
38 N.m 13.8 kg-m. 2 7 i b - f t l
I
Installation, page 6-17
SPECIAL
WASHER
EXHAUST VALVE
SPRING RETAINER
l d e n t ~ f y ~ ndots
g
on exhaust
sprlng retarner only
Removal, page 6 - 7
-*~
i Installation. page 6 - 1 7
QQ-
VALVE SPRING
OUTER SPRING
INNER SPRING
VALVE STEM S
VALVE SPRING SEAT
--------*
Inspection, page 6 - 1 3
Replacement and Reamrng,
page 6 - 1 4 and 1 5
THERMOSTAT
HOUSiNG
CYLINDER HEAD
Rernoval, page 6-6
2 2 N . m ( 2 . 2 kg-m. 16 Ib-ft)
Warpage, page 6 13
Installatron, page 6 18
INTAKE VALVE
Removal, lnspe
Dlmenslons, page 6-1 1
Recond~t~oning
valve
seat, page 6 1 2
Installat~on,page 6 16
Valve Clearance
Adjustment, page 6 22
11
/1
EXHAUST VALVE
Cylinder Head
I-I
1
2
3.
4.
5
Camshaft Pulley
!I
1.
Fuel-injected Engine:
I.
2.
"UP', mark
play.
Camshaft End Play:
Standard ( N e w ) : 0 . 0 5 - 0 . 1 5 m m
( 0 . 0 0 2 - 0 . 0 0 6 in.)
Service Limit:
0 . 5 m m ( 0 . 0 2 in.)
Unscrew the adjust~ngscrews
Carburered Engine:
CAMSHAFT
I
I
RETAlNlNG BOLT
SPEC'AL
WASHER 8 rnm
NOTE S e f d r ~ -emovlnq
~
rocker
c h e c t c ~ m ~ h a rl n: d pldv
'ircri
Clean the camshaft bearing surfaces i n the cylirider head, then set camshaft back i n place.
,~~sernbiy,
icont'd)
Camshaft
- Inspection (cont'd)
4.
If the total runout of the camshaft is within tolerance, replace the cylinder head.
--
PLASTIGAGE STRIP
whtle measurtng
Rocker Arms
- Overhaul
ROCKER ARM
SPRING A
(4 olaces)
SPRING B
( 4 places)
ROCKER ARM B
(6 places)
COLLAR A
(4 places)
ROCKER SHAFT B
NOTE:
9 Identify parts as t h e y are removed t o ensure reinstallation i n original locations.
9 Inspect rocker shafts and rocker arms (page
6-10).
if reused.
ROCKER ARM A
(6 places)
I
LEFT END
BEARING CAP
Rocker Arms
1.
'Iearance -
NOTE: This procedure requires a commerciallyavailable valve spring compressor. A typical style is
illustrated.
I
I
1.
2.
2.
GAUGE
3.
4.
5.
11
Inspect rocker
Replace
Replace
(BLACK SPRING)
(WHITE SPRING)
Valves
0
2.
lNTAKE EXHAUST
!IALVES
VALVE
(Typical)
(Typical)
PLASTIC
MALLET
A I
INTAKE VALVE
STEMS
U
:3:S
(T
VALVE
Valve Seats
2.
5.
Renew t h e i~al,~,i;l
SeLys i n :hc zy11nc:er head using a
valve seal grinder.
NOTE:
If gaides aro 1' 1!o:.? ipsge 6-13), rey;:ac?
t h e m !page 6-14) before ijrindin:; !~ai\le seats.
r-"L
6.
2.
lr , i a ! :;ten?
~ ~ in:;tallcd heisht is over s e w i c e Iirnit,
i.i:::I~c? v ~ l v etind recheck. If still i)\/er service limit,
:rpi,rci? c\/iind!>r "7eJ;t l ? valve
~
seat !n the head ::I
iI
Cylinder Head
- Valve Guide-to-Valve Stem
Clearance
1.
If warpage is b e t w e e n 0 . 0 5 m m ( 0 . 0 0 2 in.) a n d
resurface cylinder head.
0 . 2 m m ( 0 . 0 0 8 11-1.1,
within
Valve Guides
1.
4.
(3.43 in.)
(2.24 in.)
(0.44 in.)
11.3 mrn
2,
3.
CAUTION:
6 Always wear safety goggles or a face shield
when using the air hammer.
@ Hold the air hammer directly i n line w i t h the
valve guide t o prevent damaging the driver.
5.
CAUTION:
@ Do not use a torch; it may warp the head.
@ Do n o t get the Read hotter than 150C (300F);
excessive heat may loosen the valve seats.
@ T o avoid burns, use heavy gloves when handling
the heated cylinder head.
6.
- Reaming
1
I
7.
Slip a 6 m m steel washer and ?he correct driver a:tachment over the end of the driver (The washer
w i l l absorb some of the impact and extend the life
of the driver).
2.
/Exhausti
DRIVER
8.
6 mrn WASHER
ATTA~HMENT
[Intakel
VALVE GUlDE REAMER, 6 . 6 rnm
5 7 9 8 4 - 6 1 1 0 0 0 0 or 0 7 3 8 4 - 6 5 7 0 1 0 A
/
,,--,
Turn reamer in
clockwise direction
only
installation
Intake: 15.5 rnm (0.61 in.)
Exhaust: 15.5 rnm (0.61 in.)
VALVE GUIDE
5.
Measure here
,VALVE
SPRING
R E ,
[INTAKE]
y6f
A
I
SEATS
'=G4
Valve installation
W h e n installing valves in cylinder head, coat valve
stems w i t h oil before inserting into valve guides, and
make sure valves m o v e u p and d o w n smoothly.
W h e n valves and springs are in piace, lightly tap the end
o f each valve s t e m t w o or three times w i t h a plastic
mallet t o ensure proper seating of valve and valve keepers.
INTAKE
VALVES
EXHAUST
VALVE
PLASTIC
2.
6.
Tighten each bolt t w o turns at a time in the sequence shown below t o erisure that the rockers do
not bind on the valves.
6 x 1.0x40mm
12 N.m
( 1 . 2 kg-m, 9 Ib-ftl
8x 1.257
~7 m m
2 2 N-m
(2.2 kg-m, 16 Ib-ft)
4.
5.
/\
7.
8.
CAMSHAFT PULLEY
/
RETAINING BOLT
8 x 1.25 mm
38 N-rn
(3.8 kg-m, 27 Ib-ft)
WASHER 8 mm
,-
Cylinder Head
Installation
9.
aligned.
~~
Fuel-Injected Engine:
8 x 1.25 mrn
/
CYLINDER HEAD
GASKET
O-RING
I
I
JET
4---
1
mrn
2.2 kg-m,
5
6
Carbureted Engine:
8 x 1.25 rnm
7.
8 x 1.25 rnm
Timing Belt
r Replacement --I
--
---
TlMlMG BELT
VALVE COVER
B x 1.0rnm
WATER PUMP
6 x 1 .O mm
ADJUSTMENT BOLT
43 N-m
(4.3 kg-m, 31 Ib-f'il
For adjustment only,
do not remove
5 2 x 1.25rnrn
115 N.m
(11.5 ks-m, 83 Ih-ft)
Timing Belt
MANUAL TRANSMISSION:
POINTER ON
"UP" MARK
i
I
T.D.C. MARK
(Painted Whtte)
AUTOMATIC TRANSMISSION:
- Inspection
- Pension Adjustment
I
NOTE:
Replace belt ~f o ~ soaked.
l
a Remove any oil or solvent t h a t gets on the belt.
1.
2.
Loosen adjusting b o l t .
Inspect this
area for wear
Rotate pulley
and inspect belt
ADJUSTING BOLT
43 N.m
(4.3kg-rn, 31 Ib-ft)
4.
T ~ g h t e nadjusting bolt.
Valve Clearance
1.
5.
6.
INTAKE
7-
Number 3 piston at T O @
INDENTATION
GROOVE
;\
No.l
7.
8.
EXHAUST
2.
Number 1 piston at TD
"UP" OR ROUND
MARK
GROOVE
Engine Block
Engine Block
Illustrated Index
Fuel-injected Engine Shown; Carbureted Engine Similar:
Lubricate all internal parts w i t h engine oil
during reassembly.
6 x 9.0 m m
14 N - m (1.4 kg-m, 1 0 Ib-ft)
FLYWHEEL COVER
E PLATE COVER
Apply sealant at
6 x 1.0 rnm
12 N.m (1.2 kg-m, 9 Ib-ft)
1 2 x l.Omm
7 5 N-rn ( 7 . 5 kg-m. 5 4 Ib-hl
Torque sequence, page 7 - 4
"
BAFFLE PLATE
1 0 x 1.25rnm
AUTOMATIC TRANSMiSSlON
DRIVE PLATE
Check for cracks.
1 2 x 1.0 m m
1 0 5 N-m (10.5 kg-m, 76 Ib-h)
Torque sequence, page 7 - 4
-\ MANUAL TRANSMISSION
FiYWHEEL
Runout, section 1 3
MAIN BEARINGS
Radial clearance, page 7-5
Selection, page 7 - 6
NOTE: New main bearings
must be selected by matching
crank and block indentification
markings.
CRANK SEAL
Installation, page 7-1 7
CRANKSHAFT
End play, page 7-4
Runout, Out-of-Round, and
Taper, page 7-8
Installation, page 7- 16
CRANK SEAL
Installation, page 7- 1 7
DEFLECTOR
Apply sealant at
these po~nts.
Apply sealant at
these points.
THRUST WASHERS
Replacement, page 7 - 4
Grooved sides face outward.
NOTE: Thrust washer thickness
is f ~ x e dand must not be changed
by grinding or sh~mming.
NOTE: New rod bearings must be selected by rnatching connecting rod and crankshaft identification
markings (page 7-61.
PISTON RINGS
Replacement, page 7-1 4
Measurement, pages 7- 14 and 1 5
Alignment, page 7-1 5
PISTON PIN
Removal, page 7-1 1
Installation, page 7-1 2
Inspection, page 7-1 3
PISTON
Removal, page 7 - 7
Measurement, pages 7-9
NOTE:
Before removing piston, inspect the top
CONNECTING ROD
End play, page 7 - 4
Selection, page 7-1 2
Small end measurement, page 7-13
CONNECTING ROD
BEARINGS
Clearance, page 7 - 5
Selection, page 7-6
bore inspection,
Engine Block
- Flywheel Wepilacement
(Manual Transmission)
Remove the eight flywheel bolts, then separate the
flywheel from the crankshaft flange, After installation,
tighten the bolts in the sesquence shown.
42 x 1.0 rnrn
1 0 5 N-rn
(10.5 kg-m, 7 6 Ib-ft)
CONNECTING ROD
CRANKSHAFT
Main Bearings
Rod Bearings
r
1.
2.
3.
Clearance
1.
2.
3.
4.
4.
6.
7.
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color
listed above or below that one), and check clearance again.
NOTE: If the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crank and start over.
I
I
Rod Bearings
Main Bearings
Half of number is
stamped on bearing
cap and the other
half is stamped on
rod.
Bearing identification
Bearing Identification
Color code IS on the
edge of the beartng
A or l
B or li
C or Ill
D or Ill1
II
1 or l
P~nk
Yellow
Plnk
Yellow
Green
Smaller
main
journal
Smaller
bearing
(thicker)
Yellow
G e e
Green
Brown
/
/
Green
Brown
B l a q
Blue
Brown
, Black
2 or ll
Red
Plnk
Pink
Yellow
Green
I Brown
3 or Ill
4 or Ill1
Smaller bear~ng(thicker)
r Red
,Larger
Smaller
bearlng
Yellow
Green
Green
Brown
Brown
Black
Blue
1 Black
89L SCREEN
6.
7.
6, I f y o u (:an feel
BAFFLE PLATE
2.
9.
4.
5.
PISTON
1 1 . Mark p i s t o n i c o n n e c t i r ~rod
~ zssemblies w i t h cylinder numbers t o avoie m i x u p o n reassembly.
Crankshaft
@
Alignment
@
Journal Out-of-Round:
Standard (New): 0 . 0 0 5 mm (0.0002 in.)
Service Limit:
0 . 0 1 0 rnrn (0.0004 in.)
Measure in two
places a t middle.
DIAL INDICATOR
Measure taper
at edges.
Journal Taper:
Standard (New): 0.005 rnrn ( 0 . 0 0 0 2 in.)
Service Limit:
0.010 rnrn (0.0004 in.)
Cylinder Block
Pistons
Piston-to-Block Clearance
1.
1.
2.
Fuel-injected Engine:
Piston A Diameter
Standard (New): 82.68-82.69 rnm
(3.2554 - 3 . 2 5 5 5 in.)
8 2 . 6 7 m m (3.2547 in.)
Service Limit:
Piston B Diameter
Standard (New): 8 2 . 6 7 - 8 2 . 6 8 rnm
(3.2547-3.2557 in.)
8 2 . 6 6 m m ( 3 . 2 5 4 3 in.)
Service Limit:
Carbureted Engine:
Piston A Diameter
Standard (New): 7 9 . 9 8 - 9 9 . 9 9 mrn
( 3 . 9 4 8 8 - 3 . 7 4 9 2 in.)
Service Limit:
79.97 m m ( 3 . 1 4 8 4 in.)
Piston B Diameter
Standard (New): 7 9 . 9 7 - 7 9 . 9 8 rnm
(3."1884-3.9488
in.)
79.96 mm (3.3480 in.)
Service Limit:
2.
Calculate difference between cylinder bore diameter on page 7 - 1 0 and piston diameter.
SKIRT
Piston-to-Cylinder Clearance:
Standard (New): 0.02-0.04 m m
(0.0008-0,0016 in.)
Service Limit:
0 . 0 8 mm (0.003 in.)
Fuel-injected Engine:
Standard 0.30
82.98--82.99 mrn
(3.2689-3,2673 i w , )
Carbureted Engine:
Standard 0.25:
3.
$0.22-80.23 m m
(3.1583-3.1 5 8 7 in.)
Standard 0.5:
8 0 . 4 7 - 8 0 . 4 8 rnrn
(3.1681 -3.1685 in.)
Check the piston p~n-to-pistonclearance. Coar the
piston pin w i t h engine oil.
It should then be possible t o push the piston pin
into the piston hole w i t h thumb pressure.
Piston Pin-to-Piston Clearance:
Service limit: 0.01 2 - 0 . 0 2 4 m m
( 0 . 0 0 0 % - 0 . 0 0 0 9 in.)
--------.,--
"-J
.
Cylinder Block
lnspection
1.
Bore Taper
Limit: (Difference between first and third measurement) 0 . 0 5 m m (0.002 in.)
If measurements in any cylinder are beyond
Oversize Bore Service Limit, replace the block.
If block is t o be rebored, refer t o Piston Clearance lnspection (page 7-9) after reboring.
NOTE: Scored or scratched cylinder bores must be
honed.
Out-of -Round
Service Limit: 0.05 m m (0.002 in.)
Check the top of the block for warpage.
Measure along the edges and across the center as
shown.
SURFACES TO BE MEASURED
Fuel-Injected Engine:
Cylinder Bore Size A
Standard (New): 82.71 -82.72 m m
(3.2562-3.2566 in.)
82.75 m m (3.2578 in.)
Service Limit:
Cylinder Bore Size B
Standard (New): 82.70-82.71 m m
(3.2559-3.2562 in.)
82.74 m m (3.2574 in.)
Service Limit:
Carbureted Engine:
Cylinder Bore Size A
Standard (New): 80.01 -80.02 m m
(3.1500-3.1504 in.)
80.05mm(3.1516in.)
Servicelimit:
Cylinder Bore Size B
Standard (New): 80.00-80.01 m m
(3.1496-3.1 5 0 0 in.)
Service Limit:
80.04 m m (3.151 2 in.)
Oversize
Fuel-injected Engine:
Standard 0.30 (New): 83.01 -83.02 m m
(3.2681 -3.2685 in.)
Carbureted Engine:
Standard 0.25 (New): 80.25-80.26 m m
(3.1594-3.1598 in.)
Standard 0.5 (New): 80.50-80.51 m m
(3.1693-3.1697 in.)
Piston Pins
- Bore Honing
1.
2.
1.
3.
4.
07973-6570002
or 07973-6570001
2.
ENGINE BLOCK
CYLINDER HONE
ADJUSTABL
PlSTON PIN DRIVER
07973-PE00302
or 07973- BE03301
PILOT COLLAR
07973-SB00200
NOTE:
@ After honing, clean the cylinder thoroughly w i t h
soapy water.
@ Only scored or scratched cylinder bore must be
honed.
Connecting Rods
- Selection
Each rod is sorted into one of four tolerance ranges
(frorn+0.006 t o 0 . 0 0 2 4 rnrn, in 0 . 0 0 6 rnrn increments)
depending on the size of its big end bore. It's then
stamped w i t h a number ( 1 , 2, 3, or 4 ) indicating that
tolerance. You may find any combination of 1, 2, 3, or
4, in any engine.
Piston Pins
Installation
1.
1
i
Fuel-Injected Engine:
CONNECTING ROD
OIL HOLE
Carbureted Engine:
Install piston w i t h marks
on same side as oil hole
REFERENCE
MARKS
CONNECTING ROD
PISTON PIN
OIL HOLE
ADJUSTABLE
PISTON PIN DRIVER
0 7 9 7 3 - PE00302
or 07973-PE00301
Turn the handle of the p l s t o ~
pin driver so that the end
1IJ
Embossed mark
facing up.
\ L j l
PISTON PIN
:k
PILOT COLLAR
07973-SBOO200
-.u&
f---BASE IS PART OF
L.-
TOOL SET
07973-6570002
or
07973 -6570001
- Inspection
1.
3.
2.
4.
Piston Rings
- Replacement
1.
1,
2.
2.
Fuel-injected Engine:
Top Ring
Standard (New): 0 . 2 0 - 0 . 3 5 m m
( 0 . 0 0 8 - 0 . 0 1 4 in.)
0 . 6 0 m m (0.02 in.)
Service Limit:
Second Ring
Standard (New): 0.30-0.42 m m
(0.012-0.017 in.)
0.6 m m ( 0 . 0 2 in.)
Service Limit:
Oil Ring
Standard (New): 0.2-0.9 m m (0.008-0.035
1.1 m m ( 0 . 0 4 in.)
Service Limit:
Carbureted Engine:
Top and Second Ring
Standard (New): 0.1 5-0.35 mm
(0.006-0.0114 in.)
in.)
PISTON RlNG
RlNG EXPANDER
- Land Clearances
After installing a new set of rings, measure ring-toland clearances:
1.
Fuel-Injected Engine:
Standard (New): 0.030-0.060m m
(0.0012-0.0024in.)
0.13 m m (0.005in.)
Service Limit:
Carbureted Engine:
Standard (New):0.020-0.045 mm
(0.0008-0.0018 in.)
Service Limit: 0.13 mm (0.005 in.)
2.
3.
MARK
TOP RlNG ,
SECOND RING -+
-+---
OIL RING
4.
SPACER
GAP
\
\
OIL RING GAP
,-
Crankshaft
Pistons
lnstallat ion
Installation
2.
1.
2.
CONNECTING ROD 1
CONNECTING ROD 3
Carbureteia E n ~ i n e :
P i l c n msiks and
oil hole must both
face the ~ntake
Fuel-lnjecfed Engine:
t !4d
THRUST WASHERS
MQTE: Mainrail? downward force on ring compressor t o pieven? rings from expanding befoce en:ering
the cyiider bore.
Use the wooden handle
of a hammer to push, or
tap the piston into rhe
cylinder bore.
4.
5.
6.
CAUTION: Whenever any crankshaft or connecting rod bearing is replaced, after reassembly run
the engine at idling speed until it reaches normal
operating temperature, then continue to run for approximately 15 minutes.
RING CONPRESSOR
Oil Seals
installation
NOTE: install the seals before you tighten the main
bearing cap bolts.
3.
1.
CAP
SEAL DRIVER
0 7 9 4 7 -SB00200
Apply sealant.
4.
NO. 1 CAP
NO. 5 CAP
1
DRIVER
07749 -001 0000
2.
Engine Lubrication
Engine Lubrication
Fuel-injected Engine Shown; Carlsureted Engine Similar
NOTE:
@ Use new O-rings whenever reassembling.
@ Apply oil to O-rings before installation.
6 x 1 .O mrn
1 2 N.m (1.2 kg-m, 9 Ib-ft)
OIL FILTER
Replacement, page 8-4
Replace every 12,000 km (7,500 mile)
Tighten according t o instructions
@ @
DRAIN PLUG
2 0 x 1 . 5 mm
45 N-rn ( 4 . 5 kg-m, 33 Ib-ft)
Oil Level
1
I
1.
2.
Make certain that the oil level indicated on the dipstick is between the upper and lower marks.
Engine Oil
1.
2.
I Requirement /
Capacity
/
Oil Pressure
Oil Filter
Test
1.
CAUTION: After the engine has been run, the exhaust pipies will be hat; be careful when working
around the exhaust manifold.
7.
2.
3.
I
I
01912-64 16001
22 N o ~ n12.2 kg-rrp, 'l6 ib-tt)
2.
ADAPTER
Oil Pump
Illustrated index
GASKET
Replace
I
O-RING
Replace
INNER ROTOR
Inspection, page 8-6
6 x 1.0mm
12 N-m (1.2 kg-m,
Oil Pump
1.
2. Remove the three bolts and one nut that secure the
Housing-to-Rotor Radial Clearance
Standard (New): 0.1 -0.18 rnm
(0.004-0.007 in.)
0.2 m m (0.008 in.)
Service Limit:
3.
PUMP
INNER ROTOR
4.
PUMP WOUSiNG
Apply sealant.
RELIEF VALVE
Valve must slide freely
in oil filter base bore.
If valve is scored.
1 8 x 1.5mm
Intake Manifold
!illustrated Index
Fuel-Injected Engine:
EGR VALVE
Inspection, Secti
8 x 1.25 mm
22 N-m ( 2 . 2 kg-rn. 16 Ib-ft)
GASKET
Replace
TA SENSOR
8 x 1.25 mm
22 N-m (2.2 kg-rn, 16 Ib-ft)
Exhaust Manifold
-
Illustrated Index
Fuel-Injected Engine:
6 x f.Qrnrn
12 N.m (1.2kg-m, 9 lb-ft)
50 Narn
(5.0 kg-m, 36 Ih-ft)
OXYGEN'SENSOW
45 N.rn (4.5 kg-rn. 33 Ib-fr)
SELF-LOCKINGNUB
? O x 1.25rnrn
B x 1.0mm
12 RI-m (1.2 kg-m, 9 Ib-ftl
AIR SUCTION T
8 x 1.25 mm
To Air Cleaner
6 x 1 . 8 mrn
Replace
I'
TEMPERATU
SENDING UN
if
cracked or
m s t l n g surfaces a r e
damaged
BRACKET
8x1.25mm
,
H E A D E R PIPE
Replacement
Fuel-injected Engine:
SELF-LOCKING NUTS
10 x 1.25 mm
5 5 N-rn (5.5 kg-m, 40 Ib-ft)
Replace
HEADER PIPE
8 x 1.25 mm
22 N-rn (2.2 kg-m. 16 Ib-ft)
MUFFLER
6 x 1.0 mm
CATALYTIC CONVERTER
Inspectton, Sect~on1 2
Replacement, page 9-7
10 x 1.25 mm
6 x l.Omm
10 N.m (1.0 kg-m,
GAS ET
G
R
Replace
SELF-LOCKING NUT
10 x 1.25 mm
55 N-m (5.5 kg-rn, 40 Ib-ft)
Replace
8 x 1.25 mm
22 N-m (2.2
2 kg-m, 16 Ib-ftl
Replace
Catalytic Converter
Replacement
r
I Fuel-injected Engine:
1.
TOP
3.
0
RIGHT
SIDE
4.
LEFT
SIDE
Q
CAUTION: Torque the converter flange nuts in the
sequence shown.
10 x 1.25 mm
-m, 16 lb-ft)
8 x f . 2 5 mm
22 M-rn (2.2 kg-m, 16 Ib-f
(cont'd)
Catalytic Converter
-
- ,
.I
I\
Replacement tconx ar
Carbureted Engine:
1
2.
3.
4.
1 0 x 125mm
34 N m (3.4 kg-m, 25 Ib-ft)
16 x 1.25 mm
34 N.m (3.4 kg-m, 25 Ib-ftl
Cooling
Radiator
Replacement .......................
.
......
Refilling and Bleeding ......................
Cap Testing ...................................
Radiator Testing .............................
10-2
10-4
10-5
10-5
Thermostat
Replacement .................................10-6
Testing .........................................10-7
Water Pump
Replacement .................................10-7
Belt Adjustment ............................. 10-8
Radiator
Fuel-Injected Engine:
System is under high pressure when engine is
hot. To avoid danger of releasing scalding coolant, remove cap only when engine is cool.
Total Cooling System Capacity (Incl. heater, and
reservoir tank:
6.8liter (1.8U.S. gal.)
Manual:
Automatic: 6.7 liter (I .8 U.S. gal.)
CAUTION: If any coolant spills on painted portions
of the body, rinse it off immediately.
RADIATOR
Refilling and bleeding, page 10-4
Leak test, page 10-5
Inspect soldered joints and
seams for leaks.
Blow dirt out from between
cc;e fins w i t h compressed a!r.
If insects, etc., are clogglng
radiator, wash them off w l t h
l o w pressure water
NOTE:
Check all cooling system hoses for damage,
leaks or deterioration and replace if necessary.
Check all hose clamps and retighten if necessary.
Use new O-rings whenever reassembling.
RADIATOR CAP
Pressure test, page 10-5
6 x 1.0rnrn
10 Nern ( 1.O kg-rn, 7 Ib-ft)
FAN MOTOR
Test for operation
w i t h 1 2 V DC applie
RADIATOR
HOSE
Carbureted Engine:
System i s under high pressure when engine is hot.
T o avoid danger of releasing scalding coolant,
remove cap only when engine i s coo!.
Total Cooling System Capacity (Incl. heater, and
reservoir tank):
Manual:
6.8 liter (1.8 U.S. gal.)
Automatic: 7.5 liter (2.0 U.S. gal.)
CAUTION: I f any coolant spills on painted portions of the body, rinse it off immediately.
RADIATOR
Refilling and bleeding, pag, 10-4
Leak test, page 10-5
Inspect soldered joints and
seams for leaks.
Blow dirt out from between
core fins with compressed air.
If insects, etc., are clogging
radiator, wash them off with
low pressure water
RADlATOR CAP
Pressure test, page 1
Radiator
4.
5.
CAUTION:
@ Do not mix different brands anti-freezelcoolants.
@ Do not use additional rust inhibitors or anti-rust
products; they may not be compatible with the
recommended coolant.
BLEED BOLT
10 x 1.25 rnm
10 N-rn (1.0 kg-rn, 7 Ib-h)
7.
With the radiator cap off, start the engine and let it
run until warmed up (fan goes on at least twice).
Then, if necessary add more coolant mix t o bring
the level back up to the bottom of the filler neck.
8. Put the radiator cap on, then run the engine again
Radiator Coolant Refill Capacity
Fuel-Injected Engine:
3.7liters(l.OU.S.gal.)
Manual:
Automatic: 4 . 5 liters ( 1 . 2 U.S. gal.)
Carbureted Engine:
4 . 3 liters (1.1 U.S. gal.)
Manual:
Automatic: 5.0 liters ( 1 . 3 U.S. gal.)
Cap Testing
I
1.
2.
Apply a pressure of 7 4 - 1 0 3
kg/cm2, 1 1 - 1 5 psi).
kPa ( 0 . 7 5 - 1 . 0 5
PRESSURE CAP
,-
"
Radiator Testing
1.
4.
---______
Thermostat
Replacement
NOTE: Use new gaskets and O-rings whenever reassembling.
Fuel-lnjected Engine:
TW SENSOR
18 N*m (1.8 kg-m, 13 ab-ft)
THERMO SWITCH
A-108
28 N-m (2.8 kg-m, 20 Ib-ft)
I /
&'
BLEED BOLT
10 x 1.25 mm
>O N.m (1.O kg-m, 7 lb-ftl
8 x 1.25 mm
22 N.m (2.2 kg-m, 1 6 Ib-ftl
THERMO
9 N-m (0.9 kg-m, 7 Ib-ft)
GASKET
rd\
6 x 1.0
12 N-m
(1.2 kg.
THERMOSTAT HOUSING
OUTLET
Carbureted Engine:
THERMOSTAT
i n s t . with o n up
,/----'.
"
,/-
THERMOSTAT HOUSING
oesf
LET
i--
6 x 1.0 mm
12 N m
(1.2 kg-m, 9 lb-ft)
I
\
BLEED BOLT
10 x 1.25 mm
10 N.m (1.0 kg-m, 7 Ib-ft)
TEMPERATURE
SENDING UNIT
9 N.m
(0.9 kg-m, 7 Ib-ft)
HERMOSTAT
ThermostatIWater Pump
Thermostat Testing
1.
II
THERMOSTAT
STANDARD THERMOSTAT
Lift height:
8 mm ( 0 . 3 1 in.)
Starts opening:
82OC 2 2 (180F 2 3)
Primary:
Secondary: 85OC 2 (185OF 2 31
Fully open:
95OC (203OF)
OPTIONAL THERMOSTAT
Lift height:
8 mm (0.31 in.)
Starts opening: 8 6 - 9 0 C (187- 194OF)
Fully open:
1 0 0 C (212OF)
r Water
Pump Replacement
Fuel-Injected Engine:
DRAIN PLUG
32 N-m (3.2 kg-m, 2 3 Ib-ft
bearing deterioration.
NOTE: Small amount of
"weeping" from bleed
hole is normal.
12 N.m
(1.2 kg-m, 9 Ib-ftl
ALTERNATOR BELT
6x1.0mm
12
(1.2 kg-m, 9 Ib-ft)
0-RI
r Replacement (cont'd)
Carbureted Engine:
DRAIN PLUG
3 2 N . m (3.2kg-rn, 23 lb-ft)-
Replace
WATER PUMP P U L L E Y
"'
~
~ q
n w-. O .a B .8 .
"a
8."
,I
\\
ALTERNATOR B E L T
,/
beartng deterioratian
NOTE: Small amount of
"weeping" from bleed
hole i s normal.
6 x 1.0 rnrn
12 N.rn
(1.2 kg-rn, 9 Ib-ft)
O-RING
Replace
Belt Adjustment
Fuel-Injected Engine:
1.
2.
3.
Move the alternator t o obtain the proper belt tension and retighten the adjusting nut, bolt and
mounting nut.
4.
ADJUSTING NUT
6 x 1.0mrn
1 0 N-rn (1.0 kg-rn, 7 Ib-ft)
Belt Adjustment
Carbureted Engine:
1.
ADJUSTING BOLT
8 x 1 . 2 5 mm
2 6 N - m (2.6 kg-m, 18 Ib-ft)
2.
3.
Move the alternator to obtain the proper belt tension and retighten the adjusting nut, bolt and
mounting nut.
4.
ADJUSTING N U T
6 x 1.0 mm
10 N.m (1.0 kg-m, 7 Ib-ft)
MOUNTING
10 x 1.25 mrn
45 N.m (4.5 kg-rn, 33 Ib-ft)
ALTERNATOR1
WATER PUMP BELT
Fuel
Carbureted Engine ......................... 1 1.1
Fuel- Injected Engine ....................... 1 1-39
Fuel
Index ............................................ 1 1-2
Throttle Cable ................................. 1 1-4
Automatic Choke ............................. 1 1-6
Fuel Cut-off Solenoid Valves .............. 1 1-12
Fuel Filters ...................................... 1 I - 13
Fuel Tank ....................................... 1 1-14
Fuel Gauge Sending Unit ................... 1 1 .14
Fuel Pump ..................................... 1 1-15
Carburetor:
Removal/lnstallation ...................... 1 1 .16
Replacement of Attached Parts ....... 1 1.19
Separation ................................... 1 1-20
Overhaul ...................................... 1 1-22
Assembly .................................... 1 1-25
Adjustment:
Synchronization ............................ 1 1-26
Idle SpeedJMixture ........................ 1 1-27
Tailpipe Emission .......................... 1 1-30
Idle Boost (AIC) ............................. I 1-34
Fast Idle ....................................... 1 1-33
Thermowax Valve ......................... 1 1-34
Float Level ................................... 11-35
Power Valve ................................. I 1-36
Index
Fuel System
LOW-FUEL W A R N I N G
LIGHT
/'
ACCELERATOR PEDAL
A d l u r t r n e ' : t Paae 1 1 - 5
R e p ~ e i n e n t Page
,
11-i6
CARBURETOR ASSEMBLY
Rernoval~lnstallation,Page 1 1-16
Separation, Pages 1 1 - 2 0 to 1 1-22
Overhaul, Pages 1 1-22 t o 1 1-25
A I R C L E A N E R CASE
Throttle Cable
Replacement
NOTE: Cetacf; cable in the ncimbeied seqirence shown.
1.
2.
3.
THROTTLE
CABLE
2.
Check pedal free-play at the pedal. To adjust freeplay, loosen the locknut and turn the stopper bolt.
STANDARD: 6
THROTTLE CABLE
LOCKNUT
4.
5.
0-9 mm
10-0.35 in.)
Automatic Choke
- Description
This system provides easy engine starting under a wide range of alr temperatures.
fl
H E A T RISER
B I M E T A L L I C COIL
THERMOVALVE
To Regulator
CHOKE V A L V E
MAIN
CHOKE
HEATER
As the choke heater warms the bimetallic coil spring, i t s lever turns clockwise to open the choke valve The fast idle
cam and lever will remain where originally set unless the throttle I S depressed to wide open, or the coolant temperature
r~sesenough to cause the thermowax valve piston to extend, which rotates the fast idle cam and causes the lever to step
down and decrease the idle speed.
During cold accelerailon, i f the throttle i s opened, with the choke valve still closed, the unloader rod will adjust the
choke valve opening with that of the throttle to prevent an over-r~ch
condition
CHOKEVALVE
Automatic Choke
Co01~irittemperdture ,s 1~1onl;oredby lhermovalve A , if the cooldnt temperdture i s below i t s set ternperdture, ther
m0balve A i s open and bleeds off mdnifold vdcuunl rhdt ~ v o u i dnormally open the choke valve
When the ignicior; w i t c h i s in the start position, The crankrng leak solenoid
vacuum that would nornidily open the choke valve.
is
On cold stdrt:
Once the engi:ie starts, arid the lanlt!on switch i s returned to the run positlon, the cranking leak solenold I S de-energized; the crdrik.ing ieak solenoid i s n o n closed anci manifold vacuum oper?s the choke valve a f i x e d amount. The
amount that ;he choke valve car: open i s determined b y the balance of rnanifoid vacuurn and choke opener snritlg ten.
sion. As ?he coolant wdrms, dnd exceeds thern:ovaive A,s sel temperature, iherinov;llve A \r;ill close causing fu!! man!fold vacuum to be applied t o the choke opeper.
011vvdrm sraits (above ?hermov;llvc A s set temperalure but sfill below normal cooidnt
operating temperature)
D a r ~ n qcranking, the cr;inkinq leak s o l ~ n o i dI S eneroized so the choke remalns in rts pdr trailb/ ciosed positlon
Once the eqgine starts, and the ignitiorj s ~ v ~ t cISh returned to the run position, the cranklng ledk solenoid i s d~ ener
gized and thermobal\/e A i s closed so fill1 m a n ~ f o l dvacuum i s dppiied to the choke opener
CHOKE OPENER
LEAK SOLENOID
THERMO.
VALVE A
(Open)
T O IGNITION SWITCH
THROTTLE
CiiOKE
FULL
OPEN
THERMOVALVE A
- - Choke Opener
-- -
.-
2810 ENGINE -
1.
1.
2.
2.
3.
CHOKE OPENER
INDEX
MARKS
, ,
/CHOKE
COVER
Automatic Choke
Choke Coil Heater
HOT ENGINE --Start the engine and let it run. As the engine reaches
normal operating temperature, the choke blade should
fully open:
@
I f the choke still does not open all the way, disconnect the whitelblue choke cover wire from the
engine compartment wire harness and check for
voltage.
1.
2.
W i t h the ignition off, apply vacuum t o that hose using a vacuum pump.
20 #'VACUUM HOSE
If voltmeter reads 0 volts, check for an open circuit in the whitelblue wire between the choke
cover connector and voltage regulator connector,
then check the charge warning light circuit.
I
.
1.
2.
3.
6.
BLEED V A L V E
5.
HOKE D R I V E LEVER
4.
TAB B
7.
CHOKE OPENER
LEVER
CHOKE
LEVER
Measure here
?
CHOKE V A L V E
<
\-
---
CHOKE D R I V E LEVER
SPRING
M,'T
-I
A/T
3.1 1 i: 0 07 mm ( 0 122
-
- -
* 0 003 1n.1
1
I
-1
- --
TAB C
Automatic Choke
$- Choke Cower Replacement
1.
2.
3.
4.
Fuel Cut-off
Solenoid Valves
,-
Inspection
1.
1
FUEL CUT-OFF SOLENOID VALVE
2.
8\
RIVETS
Fuel Filters
Replace both front and rear filters every 4 years or
6 0 , 0 0 0 miles ( 9 6 , 0 0 0 km), whichever comes first.
3.
4.
Front
1. Use fuel line clamps t o pinch o f f the fuel lines.
2.
CAUTION :
5. Jack up the front of the car, and support w i t h safet y stands. Block rear wheels and set the parking
brake.
6.
Place the shift or selector lever in second or 2 position and accelerate, then suddenly release the
throttle and check for voltage during deceleration
above 15 mph.
There should be no voltage.
@
3.
4.
5.
I
II
Rear
1. Block front wheels.
2.
3.
4.
5. Attach fuel line cla~npst o the fuel lines and disconnect the lines from the filter.
6.
F U E L LINE CLAMP
07614-0050100
Fuel Tank
i- Replacement
1.
2.
3.
Remove ~ n drain
e
bolt and drain the fuel ~ n t o
an approved container.
4.
5.
1.
3. Remove fuel
Idirk.
6.
7.
Remove the strap nuts and let the straps fall free.
8.
9.
---
PACKING
8 x 1.25 rnm
2 2 N.m (2.2 kg-m, 16 Ib-it)
Fuel Pump
I
Output Test
NOTE: See Body Electrical for Test of Fuel Pump
Cut-off Relay.
1.
Check for a clogged fuel filter andior fuel line before checking file1 pump pressure.
5.
Remove pressure gauge and hold a graduated container under the hose.
BLACK/
LLOW
I
I
BLACKiYELLOW
FUSE BOX
3.
GRADUATED
L lPER OR QUART
CONTAINER
4.
!
I
Carburetor
Fuel Pump
!-
Rep'acement
Do not smoke during this procedure. Keep
any open flame away from your work area.
I1
1.
2.
3.
4.
I
I
I
1.
2.
3.
#r8 V A C U U M
/
HOSE
AIR CLEANER
COV R
CENTER B O L T
-'
HOT A I R I N T A K E
HOSE
4.
5.
6.
7.
8.
9.
6 x 9.0 k m
1 Q N.m (1.0 kg-rn. 7 Ib-ft)
6.
7.
8.
\
AIR CLEANER BASE
1~
I
18. Loosen the insulator bands and remove the carburetor with the vacuum tube manifold attached.
CARBURETOR
Carburetor
19. install the carburetors in the ievt?rseorder, checking
the following Items:
@
as Check ~ I soerrd
G
fuplia~rmixture and carburetor
synchron~zation,,rnd adjust ~f necessary
@
T H R O T T L E OPENER
DlAPHRAGM
Remove the f r o n t b - a c k ~ t
w ~ t hrhe didphracm In pidce
REAR BRACKET
PIPE
CARBURETOR
CHOKE CAP
11-19
Carburetor
r Separation
3.
1.
FUEL LINE
UPPER V A C U U M
TUBE M A N I F O L D
2.
4.
WASHER
CONNECTOR
CONNECTORS
SCREWS
COTTER'PIN
Replace
SCREWS
RETAINER PLATES
T H R O T T L E OPENER
DlAPH,RAGM
SCREW
SCREWS
I
I
COTTER PIN
I
SCREW
CROSSOVER PIPE
Replace
i t then discon-
8.
F R O N T BRACKET
COTTER PIN
Replace
THERMOWAX
WASHER
SCREWS
Overhaul
1.
SCREWS
VACUUM CHAMBER
2.
VACUUM PISTON
STOPPER
NEEDLE H O L D f R
O-RING
3.
6.
4.
7.
JET C O V E R S
r'
DIAPHRAGM
SPRING
COVER
SEAL R I N G
O-RING
5.
8.
S E C O N D A R Y M A l N A I R .JET
SLOW A I R J E T
PRIMARY M A l N
A I R JET
COVER
(cont'd)
Carburetor
r Overhaul (comt'd)
9.
12. Remove the float arm pin, float and float valve.
SCREWS
16. Remove the needle jet, primary slow jet (underneath primary main jet) and power valve nozzle
(underneath power valve jet).
SECONDARY M A I N JET
N E E D L E JET H O L D E R
PRIMARY
SLOW JET
POWER V A L V E JET
POWER
VALVE
NOZZLE
SCREW
1.
2.
I
I
4.
SPR!NG SEAT
0-
STOPPER
HOLDER
!
3
JET H O L D E R
SECONDARY
M A I N JET
PRIMARY
POWER V A L V E
e2
t3
&+
6%
VALVE
SEAT
V~CUUM
PISTON
5.
6.
VALVE
C o ~ n e cthe
t choke shaft spring
instail rhe rear bracket but don't tighten its screws
yet
'
FLOAT
7.
8.
~~~~-
0 0
PUMP
DIAPHRAGM
II
%)
REAR
BRACKET
F R O N T BRACKET
9.
Carburetor
Synchronization InspectionIAdjustment
1.
2.
5.
- I f the flow rates are identical, remove the synchronizer, adapters and reinstall the remsining
parts in the reverse order of disassembly.
FLANGES
- If the air flow rates are different, loosen the adjusting screw lock nut and adjust as necessary.
The adjusting screw only affects the right carburetor; turning the screw clockwise decreases
air flow and counterclockwise increases air
flow.
If the flow rates can't be balanced, check for air
leaks or carbon build-up on a throttle valve.
S Y N C H R O N I Z A T I O N SCREW
3.
,.
4.
r,
\\
CARBURETOR
SYNCHRONIZER
6.
7.
NOTE :
This procedure requires a propane enrichment kit.
Check that the carburetors are synchronized properly before making idle speed and mixture
~nspections.
1.
FREQUENCY
SOLENOID
VALVE A
Start engine and warm up to normal operating temperature; the cooling fan will come on.
3.
Connect a tachometer.
4.
CA L
49 ST and
6.
Iingearl
800 2 50 rpm
/ 700 +. 50 rpm
NOTE:
I t isn't necessary to disconnect the intake tube;
its opening is just behind the right headlight.
Check that propane bottle has adequate gas
before beginning test.
Insert the propane enrichment hose into the opening of the intake tube about 4-inches.
Carburetor
9.
3 mm
(118 in.)
k\
CAUTION: If you drill deeper than this measurement, the bit may damage the mixture adjusting
screw.
Maximum RPM
/
I
Full
PRQPANE V O L U M E
k::a
Transmission
RPM increase
65 _c 20
t ic
8.
I f the propane enriched speed is too high, mixture i s too lean: turn b o t h mixture screws 1/4t u r n counterclockwise and recheck
VACUUM PUMPlGAUGE
A973X-041 -XXXXX
Carburetor
Tailpipe Emission inspectian
Do not ?make during this procedure.
pen flame away from your work area.
1.
2.
3.
Turn t i l e engine ~ f i ;iesrart the e n g i ~ s3126 t3.wplete the idle CO check within three minutes of
re-starting, iyith the headlights, heater blower,
window defroster, cooling fan and air conditioner
off.
I--
Description
This system prevents the idle speed from dropping when the AiC compressor is turned on.
When the compressor is on, manifold vacuum is introduced into the diaphragm chamber of the idle controller through the
idle control solenoid valve which is activated by the compressor switch. The idle controlier's diaphragm rod is retracted
t o open the throttle valve a certain amount. The amount of this throttle valve opening is adjusted w i t h the idle control
screw on the idle controller t o maintain the original idle speed.
When the compressor is off, or engine coolant temperature, vehicle speed, and engine speed are above the set value, the
idle control solenoid valve is deactivated t o close the vacuum passage and the vacuum stored in the controller is released
through the filter on the solenoid valve.
'1
2,500 rpm
AND
COOLANT TEMPERATURE
ABOVE 7 0 " ~
(158'~)
AND
VEHICLE SPEED ABOVE
15 MPH
--___-A
A/CSWlTCHON
--
ALL CONDITIONS
APPLICABLE
I,
-,
F R O M SPEED SENSOR
CONTROL-
A/C IDLE
SOLENOID V A L V E
OFF
i
-
'BI'
CONDITIONS
NOT APPLICABLE
AIC ~ D L E
CONTROL~
SOLENOID V A L V E
I
ON
L
P
Carburetor
- Idle Boost Control (AIC) (cont'd)
l nspection
HOT E NG l NE
2.
4.
5.
Mdnuai
Automatic
i ~ gear)
n
'
CAL
800
I 50
rpm
/,
49 ST and
750
50 rpm
800 i- 5 0 rpm
800
50 rpm
7 5 0 z 50 rpm
I f the speed cannot be adjusted w i t h the adjusting screw, check for voltage at the idle control
solenoid valve with the A/C on.
There should be voltage
-
3.
D ~ x e o n e c both
t
c o o l a n t lloses t r o m t h e rhermowdx
R e m o v e t h e i o c k n u t dr>d ph~ilipsmews, t h e n re
m o v e the valba
W A X CASE
ASSET$ISLY
Float Bevel: 16
4.
Adlusi as ne:essai y
--
Carburetor
rI
Power
Description
This system provides supplementary fuel into the primary main fuel passage when the car is run in the power mode.
When the ignition switch is turned on, the power valve lock solenoid valve opens, and the power valve control solenoid
valve i s operated by the control unit.
1
I
'
TEMPERATURE I OR
BELOW ISOC
1
(64"~)
VACUUM SWITCH A
ON
AND
ENGINE SPEED ABOVE:
Manual 3,000 rpm
Automatic 2,900 rom
POWER VALVE
I 1--
b@- FROM
2w
POWER V A L V E CONTROL
SOLENOID V A L V E OFF
VEHICLE SPEED
BELOW 15 MPH
AND
VACUUM SWITCH C
0N
AND
COOLANT TEMPERATURE
BELOW:
Manual 7 0 ' ~( 1 5 8 ' ~ )
Automatic 5 0 ' ~(122F)
3.
inspection
Check for vacuum between the power valve control solenoid valve and lock solenoid valve.
HOT ENGINE
1.
Disconnect the hose from the power valve and connect a hand vacuum pump t o the valve. Draw
vacuum.
V A C U U M PUMPIGAUGE
A973X-041-XXXXX
4.
5.
POWER V A L V E
2.
Fuel-Injected Engine
Index .............................................
1 1 -40
Interconnect Diagram ....................... 1 1-42
Vacuum and Electrical Connections .... 1 1-45
Description
PGM-FI Control System ................. 1 1-46
Fuel System ................................1 1-51
Air Intake System .........................1 1-54
Idle Control
Troubleshooting ...........................11-76
Index
CONTROL BOX
page 1 1-43
INJECTOR
COOLANT TEMPERATURE
(TW) SENSOR
Troubleshooting, page 2 1-67
Test, page 1 1-74
THROTTLE ANGLE
SENSOR
Troubleshooting, page 1 1-68
Test, page 1 1-74
SENSOR
Troubleshoot~ng,page 1 1-57
\
'
'\
FUEL INJECTOR
Test, page 1 1-87
Replacement, page 1 1-88
PRESSURE REGULATOR
Test, page 1 1-89
IUEL
FEED PIPE
Interconnect Diagram
Control Box
Manual Transmission
IGNITION CONTROL
SOLENOID VALVE
FAST IDLE CONTROL
SOLENOID VALVE
Troubleshooting, page 1 1-82
Test, page 1 1-83
EGR CONTROL
SOLEN01D VALVE
MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSOR
Troubleshoot~ng,page 1 1-65
CHECK VALVE
A/6: IDLE BOOST
SOLENOID VALVE
AIR CHAMBER
Interconnect Diagram
Control Box
Automatic Transmission
52
fa
-
13A/C
8 SPEED SENSOR
@ MAIN RELAY
$3 IGNITION SWITCH
@j
Description
PGM-FI Control System
INPUTS
MAP Sensor
TW Sensor
TA Sensor
Throttle Angle Sensor
Oxygen Sensor
PA Sensor
EGR Lift Sensor
Vehicle Speed Signal
Starter Signal
Alternator FR Signal
Air Conditioning Signal
AIT Shift Position Signal
Battery Voitage (lGN.1)
BCfl'PLrT
injector
Main Relay (Fuel Pump)
PGM-FI W a r n ~ n gt . i ~ h t
,413- ldle Control Soieno,d \/dive
ldle Control S o l ~ n o r dValve
Fast ldle Control Solenold \Ialvc
AiG ldlr R q o s ~S o I ~ > n o ~Valve
d
lgrlitiorl Control Sotenold i / d l d ~
EGR Control Solenoid Valve
iI
I
IF-
-----
i
-
2.
S t a r t ~ n gConrrsi
When the engine IS started, the ECU provides a rich mtxture
Fuel Pump Control
When the i g n ~ t i o ns w ~ t c hIS initially turned on, the ECU suppl~esground t o the main relay w h c h suppifes current t o
the fuel pump for 2 seconds t o pressurlne the fuel system,
When the engtne IS runnlng the ECU supplies ground t a tne main relay whrch siappires current to the fuel pijrnp
When the engine IS not running and the ignition is on, the ECU cuts ground t o the main relay w h c h cuts current
t o the fuel pump
Fuel Cut-off Control
D u r ~ n gdeceleratton w16h the throttle valve closed, current t o the injectors is cut-off at speeds cver 4,4Q:3 rpm,
t o tmprove fuel economy
Fuel c u t of action also rakes place when englne speed exceeds 6,7063 rpm regardless of :be positron o t the ti--rottle valve $0 psotect engfne from over running.
@
3.
5.
Tile
k C b cu"
around t o r h e
2. Back-up Function
W h e n an abnormality occurs i n the ECU itself, the injections are controlled by a back-up circuit independent of the
main system in order t o t permit minimal driving.
ECU
Description
r PGM-FI
TDC SIGNAL
No 2
No. 1
vb
vA
CYL SIGNAL
No. 3
vA
No. 4
No. 2
No 1
vA
vA
YA
vA
No. 1 TDC
ROTORS
MAP SENSOR
VACUUM CAVITY
OUTPUT
VOLTAGE
(V)
I
3.5
/-
\SlLlCOhl
DIAPHRAGM
(in. Hg)
GAUGE
(mmWg) READING
PA SENSOR
OUTPUT
VOLTAGE
(V9
3.5
10
15
20
25
L-2-
30
TOR
Description
- PGM-FI Control System (eont'd)
'OR
THROTTLE SHAFT
CONNECTING LEVER
Qxygen
tJ
( 0 2 ) Sensor
The oxygen sensor, detect the oxygen content in the exhaust gas, and inputs the ECU. In operation, the ECU receives the
signals from the sensor and varies the duration during which fuel is injected. The oxygen sensor is located in the exhaust
manifold.
The sensor is a hollow shaft of zirconia w i t h a closed end. The inner and outer surfaces are plated w i t h platinum, thus
forming a platinum electrode. The inner surface or chamber is open t o the atmosphere whereas the outer surface is exposed t o the exhaust gas flow through the manifold.
CAUTION: Keep all cleaning materials away from the sensor; they could contaminate it and make it stop working.
Voltage is induced a t the platinum electrode when there is any difference in oxygen concentration between the t w o
layers of air over the surfaces. Operation of the device is dependent upon the fact that voltage induced changes sharply
as the stoichiornetric air-fuel ratio is exceeded when the electrode is heated above a certain temperature.
EXHAUSTGAS
ZIRCONIA
VOLTAGE ( V )
ATMOSPHERE
RICH
Starter Switch
STOlCHlOMETRlC
AIR FUEL RATIO
RATIO
-a-
LEAN
The air-fuel mixture must be rich for starting. During cranking, the ECU detects signals from the starter switch and increases the amount of fuel injected into the manifold according t o the engine temperature. The amount of fuel injected is
radually reduced when the stzrter switch is turned OFF.
The fuel pump is an in-line, direct drive type. Fuel is drawn into the piimp through a filter, f l o w s around the armature
through the check valve and is delivered t o the engine compartment. A pulsation damper is provided t o prevent fuel
pulsation. The fuel pump has a relief valve t o prevent excessive pressure. It opens if there is a blockage in the discharge
side, Wixr, the relief valve opens, fuel just flows from the high pressure side t o the l o w pressure side.
A check ./alve is provided t o maintain fuel pressure in the line after the pump is stopped. This is t o ease re-starting.
The ;;Lmp se-tton 1s c o ~ p o s e d3f a rotor, rollers, and pomp spacer as shown.
'When the rotor Turns, the rollers ?br;> and travel along the Inner surface of the pump spacer by centrifugal force
The voluwe of tht? cavity ei-iclosea by these three parts changes, draw~ngand pressurizing the fuel.
ARMATURE
ROLLER
MAGNET
PlJLSAf [ON
DAMPER
'\
RELIEF VALVE
Description
Pressure Regulator
The fuet pressure regulator maintains a constant fuel pressure to the injectors. When the difference between the fuel
pressure and manifold pressure exceeds 2.55 kg/cm2 (36 psi), the diaphragm is pushed upward, and the excess fuel is
fed back into the fuel tank through the return line.
OPEN
CLOSE
MANIFOLD +VACUUM
MANIFOLD +-
FUEL INLET
FUEL RETURN
Fuel Injector
The injector is of the solenoid-actuated constant-stroke pintle type consisting of a solenoid, plunger needle valve and
housing. When current is applied t o the solenoid coil, the valve lifts up and pressurized fuel is injected close t o the intake
va!ve. Eecause the needle valve lift and the fuel pressure are constant, the injection quantity is determined by the length
of time that the valve is open, (i.e., the duration the current is supplied t o the solenoid coil). The injector is sealed by an 0ring and seal ring at the top and bottom. These seals also reduce operating noise.
FUEL PIPE
CORE
PLUNGER
SEAL RING
Injector Resistor
For the best possible injector response, it is necessary t o shorten the current rise time when voltage is applied t o the injector coil. Therefore, the number of windings of the injector coil is reduced. This, however, makes l o w resistance in the
coil. Flow of current i n the coil is therefore restricted by a resistor installed in series between the electric power source
and the injector coil.
-_I_
INJECTOR
INJECTORS
Main Relay
The main relay actually contains t w o individual relays. This relay is installed at the left side of the cowl. One relay is
energized whenever the ignition is on which supplies the battery voltage t o the ECU, power t o the injectors, and power
for the second relay.
The second relay is energized for 2 seconds, when the ignition is switched on and when the engine is running which Supplies power t o the fuel pump.
MAIN RELAY
Description
I-
Air intake System --The system s u p p l i ~ sair for dl! engine needs It corissta of the air cleaner, air intake pipe, throttle body, idle control
system fast idle meciranism 2nd iniake manifold A resonator in the air intake pipe provides r d d i t o n a l silencing as alr 1s
drawn into the system
Throttle Body
The t h m t t ! ~body is n single-barrel side-draft type. The lower portion of the throttle valve is heated by engine coolant
which is led from the cylinder head. The idle adjusting screw which increasestdecreases bypass air and the
canisteripurge port are located on the top of the throttle body. A dashpot is used t o slow the throttle as it approaches the
closed position.
DASHPOT CHECK VALVE
DASHPOT DIAPHRAGM
DASHPOT PORT
THROTTLE VALVE
THROTTLE ANGLE
SENSOR
LE ADJUSTING SCREW
Dashpot System
The dashpot is employed t o slow the closing of the throttle valve during gear shifting or deceleration.
L__
r'
->
--- -
Isensor
PA
-I-+I
u
p
-
Starter S ~ g n a l
Alternator FR
-- Term~nalS ~ g n a-_ l _I
----4-
ECU
&
t-7
1
_
-J
--
Description
I
I
CAUSAL PART
Ecu
SYMPTOM
FUEL PUMP
INJECTOR
--
FAULTY ECU
'OPEN SHORT
.FAULTY
FILTER
DIFFICULT TO START
ENGINE WHEN COLD
FILTER
I
AFTER
WARMING UP
IRREGULAR
IDLING
.IDLE
ADJUSTING
SCREW OUT OF
ADJUSTMENT
HOSE
FREQUENT
STALLING
1
-
IDLE ADJUSTING
SCREW OUT OF
ADJUSTMENT
STUCK AIR
BYPASS VALVE
'OPEN SHORT
CIRCUIT
'FAULTY
SENSOR
t
POOR PERFORMANCE
1
'
LACK OF
POWER A T
LOW RPM
i
I
.OPENlSHORT
CIRCUIT
.BROKEN OIS-
CONNECTED
HOSE
.FAULTY
SENSOR
I
WARNING1
INDICATOR
LIGHT TURNS
ON
PGM FI
WARNING
LIGHT
; INDICATOR
.OPEN SHORT
CIRCUIT
.FAULTY
SENSOR
ATMOSPHERIC
PRESSURE
SENSOR
0 2 SENSOR
I
T W SENSOR
I
;-~-;--
THROTTLE
ANGLE
SENSOR
EGR
CONTROL
IMPORTANT POINTS
L--~.
.
2 ...._--p.-~.p-
IDLE
CONTROL
SYSTEM
.+
TASENSOR
FAULTY
ECR CONTROL
SYSTEM
SOLENOID
I
I
SENSOR
!
.CHECK IDLE SPEED
CIRCUIT
SOLENOID
'
.F4ULvY
,
I
SENSOR
C.3
(2pause
second)
);l
2
pause
..
\"I
The quick reference chart on the next page covers the failure modes and possible causes for the PGM-FI.
If you run through all the possible causes listed and the problem is still unsolved, go on t c the more detailed troubleshooting on the following pages.
Sometimes the PGM-FI warning light and/or ECU LED display will come on, indicating a system problem, when, in fact,
there is a bad or intermittent electrical connection. To troubleshoot bad connections, note the ECU LED display blink frequency, refer t o the diagnosis chart on page 11-61 and check the connectors associated w i t h the items mentioned in the
"Possible Cause" column. Clean or repair connections if necessary.
NOTE.
The ECU's memory is retained even w i t h the ignition off. It is necessary, therefore, t o reset the memory after
making repairs by disconnecting Hazard fuse for at least 1 0 seconds.
After reconnecting the Hazard fuse, check that the LED display is turned off.
The memory for the "PGM-FI" warning light will be erased when the ignition switch is turned off; however, the
memory for the LED display will n o t be cancelled. Thus, the warning light will not come on when the ignition is
again turned on unless the trouble is once more detected. Troubleshooting should be done according t o the LED
display even if the warning light is OFF.
If the LED display fails t o come on when the ignition switch is turned on again, check for:
- Blown Hazard fuse ( 1 0 A ) .
- Open circuit in WhiteJYellow wire between ECU A 1 7 terminal and Hazard fuse.
Then, if there is no problem, substiute a known-good ECU and re-check.
Turn the ignition switch ON. The PGM-FI warning light should come on for about 2 seconds.
If the warning light w o n ' t come on, check for:
- Blown No. 5 fuse (also the fuse for the back-up lights, seat belt alarm, and clock)
- Open circuit in Yellow wire between No. 5 fuse and combination meter.
- Open circuit in GreeniRed wire between combination meter and ECU 5 6 terminal.
- Open circuit in Black wires between ECU A2, A 4 and ground 1.
- Blown warning light bulb.
Then, if there is no problem, substitute a known good ECU and re-check.
Symptom
not slart
Warnlng light on
.
I
.
,
1
"
"Faulty ECU
1
1
1.
" Hesitat~on
Fuei fouled plug
" Frequent engine stsil~ng
1
1
Page,
Possible cause
7-
I
I
______i_--______
PO
11 -
opening thrcitle
'
"
* Same as above
/I
i
i *
Erratic idling
rapidly
High Idle speed
* Engine does not rev up when cola
'
,
1
sensor wire
*Crank angie sensor wire interfering with
spark plug wires
" Crank angle sensor at fault
1
1
i
-d
I
1
1
,
69
i
j
+----
Faulty ECU
"
"
"
I
i
,
Di?cai?i?r?cted
PA sensor connecTcr
o r d,scoznec?-d PA sensor wtre
F,.,!ty PA s*:ii;o,-
". Sl-o.:rd
NOTE:
@ If the number of blinks bstweer 2 :;e,:or;c pz+js.:z exceeds 13, cr if Ci~t:: LZB l,?dics.:sr sts.?'s oil, the ECU is faulty.
@ Some failure indications ( s u c h 85, cne blink) require the full test procedures oi? t h e fo:io5aing;>ages 10 cogfirm that
the failure has or has not been eiimlnatcd.
-.-
\
DIGITAL
MULTIMETER
KS-AHM-32-003
.
\
--I
-;=ii
\-1
I
\
-g
------
v-1
!--_
TERMINAL
_
LOCWHION
__
-_
1I _
AZ AP
J
.
.L
L
1
.
I
<-c,nt,n,.,,v,
1
L
YES
Substitute a known-goo9 FGU srrd lecheck. If symptom goes f w a y , replace t h e
o r ~ g ~ n ECU
al
IS symptom does not go atway, check t o see
IZ the warninq I~ghtts on ?rid the LED rndlcator ~sn o w blinktng, a i d trouhlesi:oot
the true cause
-m
_
,
qpl.i:- diagnosis indicator remains off
--
__--
-._ --
Connect the system checlcer harness between the ECU and connector.
I
/
;
1
/I-___-
- The dash
j
A16
L.--
LTurri
NG
--
YES
I -'
\>---
-- - -
(To pa:Je ? 2 - 6 3 )
,-.AlSRIr
i
I
j
;\iiitch
ON.
the ionition3
c,,or, ,s,i:
--
A.---
~ - 2
1
I
--
- -
TZ
r,(2(2
!?
OC,S
n"'-,"-'""
/-\
-\#-!,-,
-,
-, ,u
V'C/VC, - ) V L
1I
(
7Fuse ( 1 5
A) blown
Open circuit in YellowiBEue wire bstween
Fuse ( 1 5 A ) and main relay
Faulty main relay
- Open circuit i n YellowiBiack wire between
main reiay and ECU
Regulator fuse (10 A) b l o w n (fuel pump is
not working).
Open circuit in BlackIYelfow wire between
Regulator fuse and main relay
Open circi~id i n main relay ground wire
(Black)
Faulty ECU.
Is 12 V available?
1-
/ YES
NOTE: No
voltage
available.
-T----------
)L
Faulty circuit or combination meter.
YES
Substitute a known-good ECU and re-check.
Ef symptom/indication goes away, replace the
original ECU.
< T g S e l f
Stsp engine.
Connect system checker harness between /
I
ECU and connector.
I
--
'
I
/
Attach positive probe of voltmeter to C 1 6 term i n d (White (+I) of checker, and negative pro-'
I
be t o A 18 (Black/Red i-))
terminal.
A 1 8 (--i
--
--
below 0.4
I
i
YES
(To page 1 1-64)
Y ~
Stop engins
~ L I
---- -- I
---..-.i
Discsnnect engine wir;. narne- '
i
1 ss from oxygen sensor.
i
r
I
--
I
I
YES
I Check for open or short cir- I
I cuit in White wire between II
oxvaen sensor and ECU.
1
_i_____
Faulty wire,
-___-___A
/
/
1
I
7-
YES
Subsrituts 3 known-good ECU and
re-check, repeating the above five
steps.
If symptomlindication goes away
replace the original ECU.
;
I
-i~Ik-
Count the number of blinks again. If the LED is, in fact, blinking t w i c e between pauses, substitute a knowngood ECU and re-check.
If the indication goes away, replace the original ECU.
NO
YES
L-.-.2
cl, !-I
2 76296V)
I
C'4!
NO
Is voltage between 2,
YES
L-
-{Tb
Count the number of b l ~ n k sagain. If the LED is, in fact, blink~ngfour times, substitute a known-good ECU and
re-check.
If the indication goes away, replace the original ECU.
371
1
1 -
(
/
) No
Is routing norma!?
Reconnect routing.
_
_
_
_
_
_
A
1 YES .
1
Oiscorinect pipe fro[)? tho MAP sensor
and plug open end.
Disconnect # 2 1
throttle body.
I
I
vacuum
hose from
- _ _ A
_
-L
____-_-.-.-.--
J ~ - -
Is vacuum maintatned?
---
_---_I_.
--
YES
__1_.---
m
-( en
11
YES
_____-L--Connect vacuum pump t o the M A P
sensor.
--
I
i
r ~ h e c that
k
voitage changes as vacuum is
---I
__
Or 'luel
White wire between M A P NOTE: f f there is no voltsensor and ECU.
age or if voltage is low,
check for a shorted wire.
if voltage is high, wire may
be open or bad contact.
- Faulty MAP sensor.
If wire is normal, the M A P
sensor is at fault.
r p E /
-----7
1\10
i-----
/ YES
Substitute a known-good ECU and
re-check.
If symptomiindieation goes away, replace
the original ECU.
1----
---
7--
------
.---2
_____-
-,
---
ts voltage betwee13 0 . 5 0
\
and 0.98 V?
\.---- -.
r--/ YES
Substitute a known-gdod ECU and re-check
If ~ ~ ~ r n p t o m / i ? d ~ c agoes
t r o n away, replace
the oprgrnai EClJ
-~
,-,
-,
c\
9 nq
-. <./,JLJ(,''\~G
n,
~d
,-
.
.
A
op engine.
/---.?L..----- T--------i
-2
----Check TW sensor
71-94)
-----
7
---l
I
----
IS seasor ncrwal;
---1
(page
I
\,-%-
Faulty TW sensor
YES
NOTE:
I
-i
i
i
L----
--
If there is
niay be open
bad contact.
.--
--A__. _
Are wiu-es riorrmal?
1, NO Faulty ,atires
I-----
i YES
Stibstitr~tea kriown-good ECU sncj" re-ci:eck.
If symp:orn:indication goes aulay, replace
the original ECU.
or
-I
?7--?'~
+T-+
--
__A
I
F
!MeaJYG-
voT&ge - k i e e n c I 3 terminal
(Yellow!White (+)I of system checker harness and C 1 2 terminal (GreenlWhice (-)I.
_______--I__---
(-
1 t o C l 2 terminal
I
,
11
of
_ _ _ -
)--
Is 4.75-5.25 V attained?
?---
_--______
-v
Check that 0.4--0.6 V is ai8a3ableat fully
i
closed, and 4.3-4.8 V at fully open.
-I
7
-
J-i
YES
1\1
/I
YES
- NO
-\+--
Faulty throttle
angle sensor
--
-r
!
-
NO
7
-
'
Faulty wires
(--_--____,
Are wires ~norrnal?
YES
Subst~;:,t$ a known-good
ECLJ anci re-check. if
symptcrn/indication goes
airdzy, replace the original
ECcl.
jTc
11
II
1
J NO
I YES
NO
322-
(
(
Replace wires.
IS
sensor n
1 YES
Substitute a know;-good
ECU and recheck. If syrnptomlindication goes away,
replace the original ECU.
NO
Connect system checker harness between the ECU and harness connector.
(,-
>
Is voltage correct?
YES
Substitute a known-good ECU and recheck. If symptomlindication goes away, replace the original ECU.
NO
I1
I
Is sensor normal?
L ~ u r ignition
n
switch OFF.
'
AIR TEMPERATURE
1I
'
I YES
Faulty TA sensor.
NOTE: If voltage is
low, or there is no
voltage, check wires
for short circuit. If
voltage is high, probability is open or
bad contact.
Faulty wires.
Count the number of blinks again. If the LED is, in fact, blinking eleven times between pauses, substitute a
known-good ECU and re-check.
If the indication goes away, replace the original ECU.
3Tk
[ T Lignition
~ switch OM.
r
C 1 3 (*I
!
2
Is 4.75-5.25 V available? yo-
5 25V
i l 2 l
'
-I
(+I
2 7b2 963'
I
_____i___
!-
Faulty PA sensor.
C12 1 I
NOTE: If the number of blinks between 2 second par:ses exceeds 13, or if the LED indicator stays on, the ECU is
Sensors
r(
02
Sensor Test
TA Sensor Test
-I=-0 2
sensor.
1 1
1.
NOTE: If it takes more than one minute t o cornplete the checks, warm up the engine as in step 2
before continuing.
4.
5.
TA SENSOR
OXYGEN SENSOR
45 N.m (4.5 kg-m, 33 Ib-ft)
@
6.
6b sb
-20 0 20 40
100 1 2 0 ("C)
-4 32 68 104140176212248("F)
NOTE:
@
@
NOTE:
@ Don't let the sensor touch the bottom of the
container.
During the test, stir the water in the container t o
ensure even temperature.
Sensors
r TW Sensor Test
1.
1.
2.
WHITE
-ITE
*
over a range of coolant temperature.
COOLANT TEMPERATURE
DISTRIBUTOR
kQ
O-RING
Replace
SENSOR
ASSEMBLY
Installation:
1
lnstall a new 0 - i ~ n g .
2. lnstall the sensor t o the distrrbutor.
D i s c o ~ n e c the
t
connector of the distributor.
L/,
3.
Idle Control
Troubleshooting
/
I
p
I
Idle control
solenoid valve 1
a
Symptom
g
80
Fast idle
control
7
A/T idle
control
boost
81
81
I
I
iI
vacuum hose
--1i
I
I
Leaky
solenold valve
solenoid valve
98
Leaky
solenold valve
Valve failure
++
I
1
1
I
Valve fallurel
p~nched
vacuum hose
'
1 Valve failure1
1 pinched
/
I
I
vacuum hose
I
I
!
!
Valve fa~luruer
p~nched
vacuum hose
adjustment
I bolt out of
I
I Adjust~ng
Valve fallure:
pinched
vacuum hose
I
Valve failure
- - \ ,
i
1
Valve stuck
I+-p
I
Idle s ~ e e ddrops
when bllpplng throttle w ~ t helectr~cal
load
Adjusting screw
out of
adjustment
Throttle
body
82
1
1
A/C idle
1I
I
1
Throttle
angle sensor
out of
Idle Control
1
/
/
----.
--
I
Turn i g n i t ~ o nswitch t o START
,
r
-8-
A
i
-Start engine.
L--
AIBI
814 ( + I
i-. .-.-A
r---__lj
/ p - T u r n i i a d l i n h t s ON and OFF.
/1
--
1
NO
--
engine'
r ~ h e c k for continuity i n
White/ Red wire between al- j
ternator and ECU.
j
1
(IJthereconrinuiryly\
/
YES
Faulty voltage regulator or alternator
NOTE: FR terminal
diode is faulty if continuity or no continui t y exists in b o t h directions between F
and FR terminals of
voltage regulator.
Open circuit in barness
/
j
1
I
7
-
1
I
/
1
-__i__--._
DO-
]
,
1
Open circuit in Green wire between
AIT position indicator and ECU.
TYES
_ _ _ _ _ _ I - - -
--
!" 'P
1
-
1
I
L-
0 , nc.9'
-- ,
1-
I
I
A18
1___--
11
_____A
7i
Move shift lever into qear.
.cu
1.1 ochers 5 Y
I
-1.-
,
A
Check that more than 5 V appears in positions other than "P" ( 0 V in "P").
1
I
7---__L_
Is correct voltage available?
-----
--
,-r
NO
ldle Control
1
/
Start engine.
Blower switch ON.
'
Attach positwe probe of ~ o l t m c t etio A ? 1 terminal (GreenIBlack (+)I and negative probe t o A
18 terminal (BlackiRed (-)I of system checker
harness.
:-
p a r t engine.
<
NOTE: Measure
within 1 0 seconds.
A181
r 5v 4,
,id"
"9,
!I
Raise engine speed over 1,500 rpm.
NO
Faulty ECU.
/
.\
Start engine.
A14 l + l A18
L-J
0
<
'
5")
1
Is 0- 1.5 V available?
Start engine.
2
7
II
I
I
--
A181 i
NOTE: No voltage
Idle Control
Tr~ubleshootingFlow Chart IcontRd%
/
1
1
1
I
I
,
-
1
--
A101 1
0 4 I+
I
,
I
(
Is 6- 1.5 V available?
NOTE: No voltage
available.
1.
2.
3.
Fast
1 Test
1.
2.
3.
4.
4.
5.
5.
GREENIBLACK
BLACKIYELLOW
#23 NOSE
Attach the battery positive terminal t o the
Black!Yellow terminal of the control box connector
and battery negative terminal to the Orange
terminal.
Apply vacuum t o the hose.
It should not hold vacuum.
If it holds vacuum, replace the valve and retest.
r
I
Test
When the solenoid valve is energized, vacuum is
directed from #12 vacuum hose t o the AIC idle boost
valve through vacuum hose # I 9. 9V or higher should
be detected betwen the Black/Yellow terminal ( + ) and
Red terminal ( - ) of the main harness at the control
box.
1.
2.
3.
1.
I
I
VACUUM PUMPIGAUGE
VACUUM PUMPIGAUGE
A 9 7 3 X - 0 4 1 -XXXXX
4.
I
4.
I.
2.
Connect a tachometer.
3.
Disconnect the upper vacuum hose of the idle control solenoid valve (between the valve and intake
manifold) from the intake manifold.
4.
Adjust idle speed, if necessary, b y turning the adjusting bolt on the AIC idle boost valve.
IDLE CONTROL
SOLENOID VALVE
VACUUM HOSE
5.
\
ADJUSTING BOLT
-Manual
7 5 0 t 5 0 rpm
Automatic
750
7.
or "P")
ADJUSTING SCREW
9.
Fuel Pressure
- Weliewing
1.
2.
3.
I.
Disconnect the battery negative cable from the battery negative terminal.
2.
3,
4.
VACUUM
PRESSURE
SERVICE BOLT
12 Al-rn (1.2 kg-m, 9 Ib-ft)
I
FUEL
FILTER
NOTE:
@ A fuel pressure gauge can be attached at the 6
m m service bolt hole.
@ Always replace the washer between the service
bolt and the special banjo bolt, whenever the
service bolt is loosened t o relieve fuel pressure.
@ Replace all washers whenever the bolts are
removed to disassemble parts.
Fuel Injectors
2.
INJECTOR
Fuel Injectors
D o n o t smoke during the work. Keep
open flames away f r o m your work area.
1.
12. Coat new seal rings w i t h clean engine oil and press
them into the intake manifold.
5.
6.
7.
8.
FUEL PIPE
-MARKINGS
I
Injector Resistor
1.
2.
Pressure Regulator
I
1.
07406 - 040801
VACUUM
HOSE
- -
2.
PRESSURE
PRESSURE
REGULATOR
/
RETURN HOSE
\SHOP TQWEL
If the pressure does not rise, replace the regulator and re-test.
Pressure Regulator
Fuel Filter
- Replacement
Do n o t smoke while working o n fuel
system. Keep open flame away from work area.
2.
OK.
1.
(I
5.
BANJO BOLT
SERVICE BOLT
12 N.m (1.2 kg-m, 9 Ib-ft)
NOTE:
@ Replace the O-rings.
0 When assembling the regulator, apply clean
engine oil t o the O-ring and assemble i t into its
proper position, taking care not t o damage the
O-ring.
I
I
Fuel Pump
Do not smoke during the test. Keep open
flame away from your work area.
1.
With the ignition switch OFF, disconnect the connector from the main relay near the under-dash
fuse box.
Connect the YellowiBlack wire and Black/Yellow
wire with a jumper wire.
2.
1.
YELLOWIBLACK
3.
pump.
If there is no voltage, check the main relay and
wire harness (page 1 1-93).
Fuel Pump
Main Relay
Rep'acement
Do n o t smoke while working en fuel
system. Keep open flames away from your work area.
1. Relieve fuel pressure (page 1 1-86).
2. Block front wheels. Jack up the rear of the car and
Test
1.
2.
support w ~ t h
jackstands.
3 . Remove left rear wheel.
4. Remove the fuel pump cover.
5 . Remove the three bolts, then remove the fuel pump
w i t h its mount.
6. Disconnect the fuel lines and 2-P connector.
IG. SW.
BAT. @
GROUND
ST. SW.
the pump.
FLR
FUEL
PUMP
PULSATION
3.
4.
- Harness Test
1.
2.
7.
'5
0.
1
I
@ in
4.
i3.
8.
5.
(3
e.
51,
6.
9.
@'
The :i.iel
Fuel Tank
6.
1.
7.
Remove the strap nuts and let the straps fall free
8.
2.
4.
5.
9.
"
TANK STRAPS
&
TANK
Y M o C i N T l i v G NUT
Fuel Gauge
1.
1.
2.
@R WIRE
3.
--
1
1
2.
Measure the resistance between A and B terminals a? E (EMPTY), I j 2 (HALF FULI-) and F (FULL)
by moving tEie float.
+
Resistance
d)
The iu6.l u n ~ m
t ~ t h3
- Replacement
- Test
Park car on level ground
1.
1.
2.
2.
3.
4.
Throttle Cable
r lnspectionlAdjustment
Replacement
r
I
1.
Warm up the engine t o normal operating ternperature (cooling fan comes on).
1.
2.
2.
CABLE
LOCKN'UT
4.
CABLE BRACKET
ADJUSTING NUT
CABLE BRACKET
ADJUSTING
3.
4..
5,
Throttle Body
- Inspection
CAUTION: D o n o t adjust the throttle stop screw since
it can n o t be reset except a t the factory.
5.
2.
VACtlUMlPRESSURE
GAUGE
A9295-237-81167
4.
THROTTLE LEVER
Disassembly
GASKET
CAUTION:
e The throttle valve stop screw 1s non-adjustable.
o On cars w i t h A/T, adjust the throttle cable (page 1 1-97) and AIT throttle control cable (sectton 151 after reassembly.
DASHPOT DIAPHRAGM
Test, page (17-101)
/
THROTTLE ANGLE SENSOR
Troubleshoottng, page 1 1-68
Test, page 1 1-74
II
O-RING'
Replace
IDLE ADJUSTING
SCREW
inspection
NOTE:
The fast idle valve is factory adjusted, it should
not be disassembled.
Check the PCV (engine breather) circuit hoses
for proper connection and condition.
@ Check that the throttle valve is fully closed.
If idle speed is too high after engine is warmed up:
I
I
1.
2.
3.
4.
"Pa'!
1.
2.
3.
Ib-ft)
If air does not flow or the resistance is large, replace the fa.: idie valv-. and adjust idle speed.
( p a g e 11 -821
Dashpot System
1.
DASHPOT DIAPHRAGM
2.
Emission Controls
Carbureted Engine .. .. . . . . . . . .. . . . . . . . . . . .. 1 2-1
Fuel-Injected Engine . .. . . . . . . .. . .. . . . . . . . . . 12-55
Carbureted Engine
System Description ........................ 12-2
Inspection ... ... ..... .. ............*........... 12-25
Description
Interconnect Diagram
Control Box
,//--.
--
vka.cuub..SWITCB-I4
/L
."-
iJuwtnv n t v t
CONTROL SULENOlD
AIR FILTER
VALVE
EGRGONTROL
SOLENOID VALVE A
i
\ P
\.I- b
r l I { inn rnnt-rnnr
VV",r,
L.","
l nu,"
CRANKING
LEAK SOLENOLD
SOLENOID VALVE
?&wflgP
CHECK VALVE H
1
.
\,,
AIR SUCTION
SOLENOID
PQWR VALVE
LOCK SOLENO
VALVE
VACUUM SWDTCH B
Control Box - 2
-53
\V
.
i
,
\\>,
\.
COIUSTANT
\.
/-----
CHECK
I<
,/
//
ANTI-AFTERBURN
VALVE
\;
;;;;;"
'
FREQUENCY
SOLENOID VALVE
SOLENOID VALVE
CHECK VALVE D
Description
Vacuum and Electrical Connections
,c2
.'
3,
la
27
5%
@
36,
3-7
JS
$9,
40,
@
42
43
k
65
4&
47
@
4
5Q
5
7
52
53
C4
55
56
57
58
59
60
61
62
@
64
@
63
@'
A I R SUCTION V A L V E
CHOKE OPENER
T H R O T T L E CONTROLLER
I N T A K E A I R TEMPERATURE SWITCH
TWEXMCSEPJSOX
CONTROI. U N I T
SPEED SENSOR
A I R JET CONTROLLER
C A T A L Y T I C CONVERTER
O X Y G E N SENSOR
CHECK V A L V E D
DISTRIBUTOR V A C U U M A D V A N C E
DISTRIBUTOR
SURGE T A N K A
SURGETANKB
l G N l T l O N SWITCH
INNER V E N T SOLENOID V A L V E
A I R V E N T CUT-OFF SOLENOID V A L V E
POWER V A L V E
CANiSTER
TWO-WAY V A L V E
PCVVALVE
BLOW-BY F I L T E R
V A C U U M TANK A
lGNlTlON COIL
AIR FILTER
A I R CHAMBER A
A I R CHAMBER B
A U X I L I A R Y COIL
CHECK VALVE G
CHECK VALVE H
AIR BLEED VALVE B
V A C U U M TANK B
THERMOVALVE C (in the air cleaner case)
AIR LEAK SOLENOID VALVE
Crankcase Control
The p o i r i v e crankcase ventilation (PCV) system i s drsignid to pi-eveni blow-by gas from escaping to the atmosphere,
The PCV valve contains a spring loaded plunger. When the engine starts, the plunger in the PCV valve is lifted in proportion t o intake manifold vacuum and the blow-by gas is sucked directly into the intake manifold.
FRESH AIR
BLOW-BY VAPOR
Description
BREATHER
CHAMBER
CRANK-
CASE
INTAKE
MANIFOLD
PCV
VALVE
- --
--
VALVE
COVER
AIR
CLEANER
INTAKE M A N I F O L D
BREATHER HOSE
A I R CLEANER
PCV V A L V E
slow-BY
L I OUI DIVAPOR
SEPARATOR
~ - - - -(Breather
d
Chamber)
',
-_
FRESH AIR
BLOW-BY VAPOR
BREATHER
lNTAKE
I
MANIFOLD
- -
CRANK
CASE
COVER
-4-
AIR
CLEANER
.
A
INTAKE M A N I F O L D
.-----I
FRESH AIR
BLOW BY VAPOR
i
-
"&
.-"-
- Evaporative Controls
Fuel Tznk Venting
A two-way valve regulates the pressure or vacuum caused by changes in ternperature and fuel level inside the tank.
( 1 ) Pressure relief
IS
IS
Thermovalve B
When the engine coolant temperature i s above the s e t temperature of thermovalve B, i t closes and the purge control diaphragm valve in the canister is opened by intake manifold vacuum. Fuel vapor is purged from the charcoal canister
through the purge control diaphragm valve b y venturi vacuum
Carburetor Venting
(I)The air vent cut-off solenoid valve regulates air flow t o the carburetor float bowls.
When the engirie i s not running, the outer air vent passage opens, so that fuel vapor in the float bowls can be vented
into the charcoal canister. When the engine speed is above 500 rpm, the air vent cut-off solenoid valve opens the
inner air vent passage, so that fuel vapor- in the float bowls can be vented into the air cleaner.
When the engine is hot started, with the coolant ternperature above 7 0 ' ~( 1 5 8 ~ )the
, opening of the inner air vent
passage i s delayed momentarily t o ease engine start up.
D E L A Y TIMER
'
,
1
OR
AND
COOLANT TEMPERATURE
ABOVE 70 C 1758 F )
L
-
V A C U U M SWITCH A O N
AND
COOLANTTEMPERATURE
ABOVE 70 C (158 F I
OR 1
-____a
--.--__-_--_-J
( 2 ) There i s also an inner vent solenoid valve to control air flow to the carburetor float bowls. When the engine speed is
above 500 rpm, the innei- vent solenoid valve normally opens the sub inner air vent passage, but will only allow fuel
vapor to be vented t o the air cleaner.
Description
IGNITION
SWITCH
*Located in control box -r 1
- Exhaust Controls
1
Control Systems
The ten systems used to control exhaust emissions are:
Description
Intake Air Controls
This system maintains uniform air temperature inside the air cleaner (approximately 1 0 0 ' ~ ) .The carburetor receives
fresh air, controlled within a narrow temperature range, regardless of outside temperature.
HOT
.L
t
I
-
R BLEED V A L V E
FIXED ORIFICE
CHECK V A L V E
e+----Vacuum
=: : : :<
Outside
'I
COOLANT TEMPERATURE
BELOW 60C (140'F)
AND
I N T A K E AIR TEMPERATURE
I
BELOW
1 8 " (64F)
~
L--
'
--
k---
- I COOLANT TEMPERATURE
(
- 1-
--
BELOW 7 0 " ~
(158"~)
I
AM D
I VACUUM SWlTCH C OFF
AND
I
! VEHICLE SPEED BELOW 15 MPH
AND
1.000
!-r
LENGINE SPEED BELOW_ -
7
I
1p
-------------- L - - I
COOLANT TEMPERATURE^
BELOW 7 0 ' : ~(158F)
1
AN D
VACUUM SWlTCH C ON
AND
I
VEHICLE SPEED BELOW 15 MPH
AND
ENGINE SPEED OVER 1.20a rpm
7------i
BELAY TIME+
I
1
'
-7
VACUUM CONTROL
SOLENOID V A L V E ON
r-4L_
_A
Description
DISTRIBUTOR
SPEED SENSOR
Description
Catalytic Converter
---
The catalytic converter i s used rc eorivert hydlocarbons (MC), caibon rr;o;:oxic+e (CO) and oxides of nltrogen (NGx) in
t h e cxhaust gas, to carbon dioxrcle (CO: ), drn~trogen(N:) and water vapor
12-14
- EGR
The EGR System is designed to reduce oxides of nitrogen emissions (NOx), by recirculating exhaust gas through the
EGR valve and the intake manifold into the combustion chambers. It is composed of an EGR valve, EGR control valves
A and 5,EGR control solenoid valve A, thermosensor, and vacuum switch C.
The EGR valve is operated by vacuum from the carburetor port and provides EGR volume proportional to engine loads (intake air volume) by the operation of the EGR control valves A and 5.
The EGR system recirculates exhaust gas only after the engine is up to normal operating temperature and then only
while accelerating or crusing; these two conditions create the majority of NOx emissions. EGR flow IS cut off during
idle, deceleration, and cold engine operation to assure good combustion during these conditions.
@
The vacuum signal is ported above the idle throttle valve position t o eliminate EGR a t idle.
The control unit senses the engine coolant temperature and intake manifold vacuum, and EGR flow is cut off by the EGR
control solenoid valve A from the signal of control unit.
When engine coolant temperature is cold, EGA flow is cut off in order to malntain driveability, and when the engine
coolant temperature is hot, EGR flow is cut off during deceleration or idling.
~ ECuT-OFF
R
1
,
1 (EGR CONTROL S O L E N O I D ,
'
V A L V E A ON)
L---
------
L
COOLANT TEMPERATURE
BELOW 50C 1122 FI
i
-
--T--7 - .--___
r-_-I_-_,
OR
,VVF:UM
:
__--l
SWITCH
____
- Anti-Afterburn Valve
The anti-afterburn valve lets fresh a i r into the intake manifold when manifold vacuum suddenly increases; such as, during
deceleration.
When manifold vacuum suddenly increases (i.e. sudden deceleration), the diaphragm/valve unit is pulled downward.
Air flow from the air chamber to the sensing charriber is restricted by an orifice, creating a pressure differential on the
diaphragm, which holds the valve open. This unbalanced condition lasts for a I-evv seconds until the pressure in both
chambers is equalized by air entering through the orifice, then the spiing pushes the diaphragm up, closing the valve.
The anti-afterburn control solenoid valve is designed to cut off manifold vacuum f!ow to the top side cf the anti-afterburn valve diaphragm.
When the anti-afterburn confro! solenoid valve opens, the anti-afterburn valve does not open because there is no vactium
difference on both sides of the diaphragm.
M A N U A L TRANSFJIiSSlON
'1
ANTI-AFTERBURN CONTROL
SOLENOID V A L V E O N
_--
1
_
r-I
-1
A N T I - A F T E R B U R N CCNI'ROL
SOLENOID V A L V E O N
7-
--,
--
'
--
/<EKE
SPEED BELOW 1
I
---A
5
s
I
AND
COOLANT TEMPERATURE
BELOW 70'C (l58'F )
+"ANTI-AFTERBURN
CONTROL SOLENOID
VALVE
NTI-AFTERBURN
I CONTROL
UNIT
k t ! ! ! ?
BSlV
F R Q M I G N l T I O N COlL
--4---+-+---jllk
SPEED SENSOR
\ -
---
-a----
Description
To maintain optimum air-fuel ratio, the main air jet control system controls air flow into the main air jets of the carburetor throats. When the car is being started, or running in the power mode, the control unit energizes the main air
jet solenoid valve in the air cleaner to close the extra air passage, increasing fuel flow.
M A N U A L TRANSMISSION
7- - ---
AUTOMATIC TRANSMISSION
--
TEMPERATURE 1 OR
1 BELOW 18C
j
-1
I
+
1v ~ c u u a
1 SWITCH A /
F~G~A?
i ON
TEMPERATURE
BELOW 18C
(64'FI
OR
SWITCH A O N
I VEHICLE SPEED
BELOW 16 MPH
*VACUUM SWITCH A
CONTROL U N I T
..---
~------m~a--mw,-
P h ~ ssystem makes use of vacuum pulses in the exhaust man~foldto draw air from the a i r -1eancr t n i'lc 0xha:rct man~foid
to promote oxidation of hydrocarbons
The controi unit energizes the alr suctlon control solenold valve to apply manlfold vacuum to tkle air suctfiori cut-off
d~aphragrnvalve, which opens the secondary air passage When negative pressure, created by exhaust pidlses, opens the
air suct~onreed valve, fresh alr pours ~ n t o
the exhaust manifold
The alr chambers act as silencers to reduce exhaust noise and the delay valve rnalntains th? proper a l r ' f i i ~ ITI>,~LYF!
l
when
shifting gears or during decelerat~on.
ILr----
E-
-.
--
--
I
!
,
1
1
1
I
/
,
---- 1
I N T A K E AIR TEMPERATURE
ABOVE 1 8 ' C ( 6 4 ' F )
AND
VACUUMSWITCHAOFF
AN0
ENGINE SPEED BELOW;
Manual Transm~ssion3,OQQ rprn
Autornat~cTransrn~ssion:2,900 rprn
AND
COOLANT TEMPERATURE BELOW;
PNT-ATE
A I R TEMPERATURE
'/
'
ABOVE 18 C ( 6 4 F )
AND
V A C U U M SWITCH C Q F F
AND
VEHICLE SPEED ABOVE 15 M P M
AND
I
COOLANT TEMPERATURE AEf4VE.
I
,
T-------I
CAL
and 49 ST
- - -' _
-_____J
i
C
W l ALT
and 4 9 S T I
-1
--+---r7
1 AutoI
L-nlatlc
35 C
i95'F)
65' c
(149F)
I, kt:;
I ,",",:.",,
L . - - _____-i
_r
,749jF)
11
,
- Feedback Contra[
The Feedback Control System maintams the proper airifuel mixture ratio by alicjwtng air into the intake manifaid, as is
necessary, t o adjust a temporarily fuel-rrch condit~on.This system is made up sf Three subsystems: the X-system, the Nsystem and the Idle Feedback Control system.
The X-system consists of Air Contro! Valve B, F r e q ~ e n c ySolenoid Valve B, Constant Vacuum Vaive, Check Vaives A,
13, C and E, Surge Tanks A and B, and the Con.trol Unit. W h e i ~Frequency Solenoid Valve B i s opened by rhe Control
Unit, manifold vacuom, which is constantly modulated by the Constant Vacuum Valve, is applied t o Air Control Valve
3. When Valve B opens, it allows the correct amount of air to be Fed into the intake manifold.
Surge Tank A and check valves act as a vacuum reservoir while Sijrgc Tank B darnpeas the vacuum pulses so rhrjt reiativel y steady vacuum is applied t o Air Cor:troi Vaive B.
The h"lsystern consists of 191sControl Valve A Freqr~enfySolencrd '*'alve d mr' the i'nntrul U n ~ t Whe?
.
Fsequer;cjr
Solenold Valve A rs opened by the Control bnir A s sCsntroi k a h e A, w1a1cht79s D ~ E I : alieadv opened %)I V B C L I U ~from tbe
carburetor port, feeds t h e correct amount of air wra, rha !ni-ake ma4fo:d The amount of air I S proportronai t o intake alr
volume.
I Manual
BOW OT'ti'GEe\l
CONCENTRATION
QR
- - ----
'
---
--
VACUUM SWITCH C2
OK<-\L
OR
,
r
--*
0R
7---
/ VEHICLE
,--
eoworT,oMs
,'gFT--^.
------
COMBITIONS L E F T
N3T APailEE
APPLIED
0W
------
'
PNTAKE A I R TEMPERATURE
BELOW 18'6 (64 F)
-
'1
OR
VEHlCkE SPEED BELQt% 15 RID;
1 A T COLD STARTING
{COOLANT T E M P E R A T U R E
BELOW 70'C (158 Fli
___
FFIEI14UtibCY SC?LE!I';I%$
SIALVEC A a n d B O F F
r---__L
---
OR
7
-
AkiTBb$ATiC Q N L V
45 mph
AND
E N G i M E SPEED BkLOW 'l.003rDrn
_L
17
FREQUENCY SQLENOYD
ValP L ~ I E SS 3r?a B OIJ
Description
Feedback Control (csratld)
The idle feedback control system consists of thermovalve C and the air leak solenoid valve. Thermovalve C, located
in the air cleaner case, senses intake air temperature and opens t o introduce air t o the air leak solenoid valve. The air
leak solenoid valve is activated by a control unit, which processes the signals from the ignition coil (engine speed),
vacuum s w i t c h C (carburetor vacuum), and oxygen sensor (oxygen content). The engine speed and carburetor
vacuum signals are used t o identify idiing conditions. The solenoid valve opens and allows air into the carburetor
primary slow air jet depending on the oxygen content i n the exhaust gas. This idle feedback control system operates
and decreases idle emissions when air injection t o the exhaust manifold is cut off.
VACUUM SWITCH
HIGH OXYGEN
CONCENTRATION
1
ENGINE SPEED BELOW
1,300 rpm
Description
Feedback Control (cont'd)
Description
- Speed Sensor
The speed sensor which is essentially a photointerrupter, is mounted in the speedometer. I t is actuated at a predetermined vehicle speed by the sealed
plate rotating w i t h the speedometer shaft as shown.
SPEEDOMETER
;'
,Li i
O D 0 & TRIP
M E T E R ASSY.
VALVE
ACTUATOR
.,
AMPLIFIER
Inspection
Crankcase Controls
1.
Check the crankcase ventilation hoses and connections for leaks and clogging.
2.
1.
3.
4.
Place your finger over the PCV valve and listen for a
clicking noise from ?he PCV valve.
PCV V A L V E
BLOW-BY FILTER
5.
Inspection
r Intake Air Controls
1.
3.
4.
2. With the engine cold, start the engine, let i t run for
AIR INTAKE
5.
6.
INTAKE AIR
CONTROL DOOR
AIR CONTROL DIAPHRAGM
BLEED V A L V E
CHECK V A L V E
-I
7.
Evaporative Controls
-----
..~
COLD ENGINE
Charcoal Canister
-
COLD ENGlNE - - - -
1.
1.
#16 HOSE
Disconnect vacuum hose a19 at purge control diaphragm valve (on the charcoal canister) and connect
vacuum gauge to the hose.
P U R G E CONTROL
DlAPHRAGM V A L V E
2.
VACUUM PUMPIGAUGE
A973X--041-XXXXX
2.
- If there is voltage, replace EGR control solenoid valve A (Box s f l ) and re-test.
-- If there is no voltage, go t o troubleshooting
on page 12-50.
inspection
--
COLD ENGINE
1.
D~sconnectvaruurr hose -1;.8 from the vacuum ddvance didphragm B on the drstribulor and connect
a vacuum E;aLlye To Ihe kiose
VACUUM PUMPIGAUGE
A973X -041-XXXXX
DIAPHRAGM EX
0 1 7 page
'I 2-47)
2.
i f fhpl+? V~C~IJZTI, go
engine ii-;spection.
f:~:
?B ;age
12-45 fcr h a t
1
5
_-
, :here
/
is nc \,gb;eg:",
gfi
;$;
;..i),,-ir^t::.ij;?c,?':?g
GT:
page 'I 2 - 5 0
II
!
I
- it' there i s
q;:
!
Icocf'd)
I
i
Anti-Afterburn Valve
COLD ENGINE
4.
Disconnect the vacuum hose #5 from the air suction cut-off diaphragm and connect a vacuum gauge
to the disconnected hose. Check for vacuum.
I f there i s vacuum, replace the air suction control solenoid valve and re-test.
0
5.
1.
Disconnect the intake air temperature switch connector and check for a bubbling noise from the air
suction port at idle.
ANTI-AFTERBURN VALVE
"12-29
Inspection
Anti-Afterburn Valve (contld)
--
--
i f no vacuum, check for leaks or disconnected hose. I f there are no defects, replace the anti-afterburn control solenoid
valve and re-test.
4.
Place the sh!ft b~ selector lever In second or 2 posrt ~ o n and arcelerale, then suddenly release the
throttle a i d circck for vacuum during decelerat~on
above 3,000 rpm for i-rrenual or above 15 mph for
automatic.
If no vacuum, check for voltage a t .the antlafterburn control <olenoid valve above 3,000 rpm
for marlual or above 15 mph for automatic.
- 1: there is voitage, go t o iroubleshooting or1
page 12-50.
- If there i s no voltage, disconnect vacuum
hose a21 from the anti-afterburn valve and
check for vacuum above 3,000 rpm for
manual or above 15 mph for automatic
Inspection
HOT ENGINE
'r
1.
I
ANTI.AFTERBURN V A L V E
1.
VACUUM PUMPIGAUGE
A973X-041-XXXXX
I f no vacuum, go on to step 4.
Inspection
Main Air Jet Control -System (contrd)
4.
r
I
Throttle Controlls
HOT ENGINE
Connect a tachometer, start the engine and allow it
to reach normal operating temperature (cooling fan
comes on).
1.
i f vacuum remains steady, disconnect the vacuum gauge and reconnect rlie hoses.
Install the filter element and air cleaner cover.
2. Disconnect vacuum hose #6 from the throttle controller, connect a hand vacuum pump t o the controller and apply 200 mmHg (8 in. Hg) vacuum.
V A C U U M PUMPIGAUGE
A97JX-041-XXXXX
500 rpm, go
4.
VACUUMIPRESSURE GAUGE
A9295- 237 - 81 167
ADJUSTING SLOT
OPENER LEVER
3.
Inspection
-- Throttle Controls (contdd)
I
HOT ENGINE
1.
1
3.
CRANKING OPENER
SOLENOID V A L V E
MOT E N G I N E ---
1.
EGR VALVE
AIR INTAKE
DUCT
INTAKE AIR
/ C O N T R O L DOOR
A I R BLEED VALVE
HOT A I R DUCT
F I X E D ORIFICE
\
,
'\\/
2.
CHECK V A L V E
3.
2.
--
-m,
Vacciurn a t
EGR Hose
Conditior,
I f the control door now closes, I-eplace the a!,bleed valve and re-test.
I t the control aoov does not clost, correct n h d t
ever i s caus~nr;rhe door to b ~ n d ,and or rtpI2te
nir control didpbrdgm Re test
r
I
216
-
7--
--
--
idle
i-
-";jiaTeF
yellow/white
wlre of EGR
1
control solenold
valve k
- -- --
No
Yes
d
4,5GO rpm
yes
2-6'
Wq
No
Evaporative Controls
HOT ENGINE
Charcoal Canister
1.
1.
2.
2.
3.
PURGE CONTROL
DIAPHRAGM VALVE
VACUUMIPRESSURE GAUGE
89295-237-82 367
HOSE $19
PURGE A I R
HOSE
4.
3.
5.
Inspection
fitting.
Connect hand vacuum pump t o canister "purge"
fitting as shown, and draw vacuum.
"PCV" F I T T I N G
"PURGE" FITTING
8.
"TANK"
fitting as
I
V A C U U M PUMPIGAUGE
A973X-041-XXXXX
7.
litllll$,.
I f there
re-test
IS
Two-Way Vaive
1.
2.
4.
5.
VACUUMIPRESSUR GAUGE
A9295-237-81167
VAPOR LINE F R O M
F U E L T A N K TO
TWO-WAY V A L V E
3.
0.6 in.Hg).
*
@
Inspection
1.
2.
HOT ENGINE
NOTE: Engine coolant temperature must be below 7 0 ' ~
(158"~).
1.
V A C U U M PUMPIGAUGE
A973X-041-XXXXX
,,y&7-
"\\
7 ,/
1
,
-
tJ&d
\
74
,'
V A C U U M PUMPfGAUGE
A973X-041-XXXXX
3.
AIR V E N T CUT-OFF
SOLENOID V A L V E
2.
4.
3.
Vacuum should drop t o zero
0
I f vacuum does not drop to zero, check for voltage a t air vent-cut-off solenoid valve.
-
. . ., .. .,.
... . .. ..,
Feedback Control
HOT ENGINE
1.
2.
Start the engine and check that the frequency solenoid valves A and B are operating while runnlng the
engine at approximately 2,500 rpm.
and install
conditioner off, if so equipped, check that frequency solenoid valves A and B are not operating
while idling the engine.
NOTE:
I t may be easier to determine if the valves are
working by placing your hand on each valve
individually.
*
*
*
go
on t o
Inspection
rI
1.
2.
A.
When vacuum is released, air should flow with resistance; the pressure gauge should register pressure.
A.
2.
AIR CONTROL V A L V E A
VACUUM PUMPIGAUGE
A973X-041 -XXXXX
AIR CONTROL V A L V E 5
1.
2.
valve
FREQUENCY SOLENOID V A L V E A
F R E Q U E N C Y SOLENO\ID V A L V E B
VACUUM PUMPlGAUGE
A973X-041 -XXXXX
VACUUM~PRESSUREGAUGE
d.CIr,P.C-
ee.1
e-.r.eTr-P
HOSE .=31
\
HOSE =30
2.
4.
I f vacuum remains steady, the frequency soienoid v a l v e i s OK. Reconnect the hoses ~ 3 and
0
~ 3 to1 the valve.
If vacuum IS not ava~lable,replace the freqbency
solenoid valve.
(cont'd)
Inspection
rFeedback
Control (con%")
Thermovalve C
I.
1.
2.
FREQUENCY SOLENOID V A L V E 5
V A C U U M PUMP:GAUGE
A973X-041-XXXXX
I
HOSE 130
repiace the
CB
4.
1.
2.
3.
HOT ENGINE
--
1.
#22 HOSES
DIAPHRAGM B
VACUUM PUMPiGAUGE
A973X-041-XXXXX
AIR LEAK
SOLENOID VALVE
4.
5.
2.
I1
4.
P ~ n c hthis hose
I f timing advances more than previous test, disconnect tachometer and reconnect advance hoses
to distributor. Test is complete.
If timing does not advance more than you
recorded on step 3 or will not stay advanced,
replace advance diaphragm and re-test.
1.
4.
Place the shift or selector lever in second or 2 position and accelerate above 15 mph, then release the
throttle and check for a bubbling noise from the
air suction port at idle.
Inspection
----
Control Unit
SPEED
IGNITION
- COIL
1 r
i SOLENOID VALVE
1 1 - E G R CONTROL
l ISOLENOID
---____-__2 VALVE A
I
y i E c i X r n T ~
(Air suction)
$1
I
i SOLENOID VALVE
INTAKE AIR
IDLE CONTROL
CRANKING LEAK
1
Ill
1
-
i SOLENOID VALVE
Inspection
r Troubleshooting
I f there is no voltage from the control unit when there should be voltage or if there is voltage from the unit when there
/ shouldn't
be voltage, inspect as follows and if no defects can be found, replace the control unit and re-test.
--
PROBLEMATIC CIRCUIT
To a ~ vent
r
cut-off solenoid
valve (GreeniYellow wire)
REFERTQ
CHECK NUMBER:
11
2,4, 6, 10,1 1
1
I
___1
u
p
-
'
TO anti-afterburn control
soleno~dvdiule
(Blue/Yellow wire)
it-
2,3,4,10,11
___(
'
2,3,4,5,6, 7, 10, I
11
1
Ik-
1
-
CHECK
4,7, 10. 1 I
I5.
1
I
-- -
2, 10, 11
3,5,6,10, 1 1
To vacuum control
solenold valve
(BlueIBlack wire)
1
I
/
1
To frequency solenoid
valves A and B
(Green wire)
~ c ~ - o
valves A and 5
(Yellow wire)
To ~ d l econtrol
solenold valve
1
1
Manual.
4,5, 10,1 1
Automatic
2, 3 , 4 , 5, 7, 10,
11
I, 2,3,4.5.6.7,
10,ll
I
f
1
1
1
I
I
~2,3,4,6,8,10.11
e ~ d7
--
2,3, 4,9,10, 1 1
I
1 , 2 , 7 , 70,1 1
Speed Sensor
1.
1.
2.
YELLOWIBLACK
WHITE
r--'
#J
-i_l
2.
3.
O X Y G E N SENSOR
45 N.m (4.5kg-m, 33 Ib-ftJ
4.
5.
Stop the engine, lower the car to ground, and disconnect the voltmeter.
Inspection
- Thermosensor
The chart below shows the change in resistance over a
range of coolant temperatures.
1.
2.
Vacuum Switches
Vacuum Switch A
1
VACUIJM S W I T C H
I
t
I
---
-%
<>
>
-_
d
--- .
'
\
'
f
'
IS
above 2 v C
IS
below 4 5 G
Vacasum Switch B
I
is
nor as specifled
*- *--
--=-a=-
-"-2>--mm-o%p>-~-~-h~w~"wm~e---~~~
Inspection
2.
Fuel-Injected Engine
Interconnect Diagram ....................... 12-56
Vacuum and Electrical connections .....
Description ...........................
.
.
....
Tailpipe Emission .............................
Catalytic Converter .......................
Positive Crankcase Ventilation
System ......................................
Evaporative Emission Controls ...........
EGR Control system .........................
Ignition Timing Controls ....................
12-58
12-59
12-63
12-63
12-64
12-64
12-67
12-70
Insterccsnnect Diagram
3) FCV VALVE
13THERMOVALVE
'7 FUEL TANK
TWO-WAY VALVE
CHARCOAL CAMlSlER
7; CATALYTllC COhlVERTEW
8 CHECK VALVE
$3lGN!TlON CONTROL SOLENOID VALVE
c!,'s
Description
Positive Crankease Ventilation
T h e 3-way catalytic converter is used t o convert hycarbon monoxide (CO), and oxides of
drocarbons (He),
nitrogen (NOx) in the exhaust gas, t o carbon dioxide
(C021, dinitrogen (N2) and water vapor.
PCV VALVE
2:FRESH AIR
*:BLOW-BY VAPOR
Description
Evaporative En3ission Controls
The evaporative controls are designed t o rn~nimizethe amount of the fuel vapor escaptncj t o the atmosphere. The system
consists of the following components:
Charcoal Canister
A canisrer fcr rhe t e m p o ~ a r ystorage of fuel vapor untii the fuel vapor can be purged frorn the canister into the engine
and burned.
B.
C.
TWO-WAY VALVE
--FUEL TANK
ADVANCE
SOLENOID VALVE
Description
--
L____-__
--
r MAP Sensor
L---
I_TW
Sensor
[ T h r o t t l e Angle Sensor--
I --
memories)
PA Sensor
Vacuum regulated by the Constant Vacuum Control (CVC) valve is directed to the EGR valve b y the EGR control solenoid
valve. When the EGR control solenold valve is energized from the ECU, vacuum is supplied t o the EGR valve.
Tailpipe Emission
Catalytic Converter
I
I
1.
2.
Connect a tachometer.
3.
4.
10 x 1.25 mm
34 Marn 13.4 kg-m, 25 Ib-ft)
RUBBER
MOUNTS
\
x 1.25 mm
GASKET
Replace.
CONVERTER
Removal/lnstallation, section
Inspect housing for cracks
or other damage.
Inspect element for clogging
by looking through the inside
8 x I .25 rnrn
24 N-m (2.4 kg-rn, 17 Ib-ft)
@
8 x 1.25 mm
26 N-m
12.6 kg-m, 19 Ib-ft)
Positive Crankcase
Ventilation System
Evaporative Emission
Controls
Test
Test
/I
I.
Check the crankcase ventilation hoses and connections for leaks and ciogging.
I.
BREATHER HOSE
PURGE CONTROL
DIAPHRAGM VALVE
\
V A C U U M PUMPIGAUGE
A973X-04: - X X X % %
2.
2.
@
@
I
#3 HOSE
--- HOT
1.
ENGINE
7.
8.
1
VACUUM PUMPIGAUGE
A973X-041-XXXXX
I
#3 HOSE
2.
operating
"PURGE" FITTING
"PCV" FITTING
\\
3.
4.
5.
VACUUM PUMPIGAUGE
A973X-041 -XXXXX
VACUUMIPRESSURE GAUGE
A9295-237-81167
0
9.
Evaporative Emission
Controls
- Test (cont'd)
Two-Way Valve
1.
2.
(a/
T-FIT~ING
4.
PRESSURE SIDE
VACUUM GAUGE
A9295-237-81167
-&-
VACUUM PUMPIGAUGE
A973X-041 -XXXXX
3.
5.
4.
2.
*?
V A C U U M PCIMP!GAUGE
A973X-041 - X X X X X
Hu)
3.
idle.
--
6.
-._
# 2 1 HOSE
2.
Disconnect the lower vacuum hose of the EGR control solenoid valve (between the EGR control
solenaid valve a d the air chamber), from the air
chamber.
3.
vacuum
the hose'
4.
5.
1.
2.
If it holds vacuum, replace the EGR control solenoid valve and re-test.
EGR Valve
VACUUM puMP/GAUGE
A ~ ~ ~ X - - Q L-XXXXX
II
If it does not hold vacuum, replace the EGR con:rol solenoid valve and re-test.
3.
Cb
1
NO
-If
--~
1 . 0 -~1 . 4 ~ 7 (VI ~
-1
NO
-
-Faulty
wires.
i
1
Faulty EGR
valve lift
serrsor.
Substitute a knokn-good ECU and retesr EGR components as on page 1267. If EGR n o w operates properly,
replace the original ECU.
#12 HOSE
4.
VACUUM PUMP!GAUGE
A973X-041 --XXXXX
5.
ADVANCE DIAPHRAGM A
2.
6.
@
3.
%15 WOSE
ADVANCE DIAPHRAGM S
7.
r-
T h e ignition control solenoid valve is activated by commands from the ECU. When the solenoid valve opens,
t h i s causes vacuum in the # 1 5 vacuum hose and sends
vacuum t o advance diaphroagm B t o improve cold
engine performance under the following conditions:
6.
7.
1.
2,
4.
8.
5.
9.
Transaxle
Clutch
Illustrated Index ............................. 13-2
Clutch Adjustment ......................... 13-3
Release Bearing .............................. 1 3 - 4
Pressure Plate ..............................
13-6
Clutch Disc ....................................13-7
Flywheel .......................................1 3 - 8
hlanual Transmission
Removal .......................................
Illustrated Index .............................
Disassembly ..................................
Reassembly ...................................
Installation .............................
......
Automatic Transmission
(Fuel-Injected Engine)
Description .................................... 15-2
Troubleshooting ............................. 1 5-4
Road Test ..................................... 15-6
Pressure Test ................................. 15-7
Fluid Level ....................................... 15-8
Illustrated Index ...............................15-10
Torque Converter ............................. 15-63
Installation ...................................... 15-64
Shift Position Switch .........................15-67
Shift Cable Adjustment ..................... 15-71
Throttle Control Cable
Adjustment/lnstallation .................. 1 5-72
(Carbureted Engine)
Description .................................. 15-74
Troubleshooting ........................... 15-76
Road Test .................................... 15-78
Pressure Test ............................... 15-79
Fluid Level .....................................15-80
Illustrated Index ........................... 15-82
Torque Converter ......................... 15-12 7
Installation .................................. 1 5-1 2 8
Shift Position Switch ....................... 1 5-1 3 0
Shift Cable Adjustment .................. 1 5-1 3 3
Throttle Control Cable Bracket
Adjustmentllnstallation ................ 1 5-1 34
Differential
Illustrated Index ........................... 16-2
Inspection/Disassembly ................. 16-5
Reassembly ................................. 16-6
Installation .................................. 16-8
Driveshafts
Removal ..................................... 17-2
Disassemblyllnspection ................. 17-3
Reassembly ................................. 17-4
Illustrated Index
ROTE: W h e r ~ e v e rthe transrnrssion is removed, the release bearing sliding surface should be cleaned and greased.
CLUTCH PEDAL
RETURN SPRING
CLUTCH PEDAL
Adjustment, page 1 3 3
CLUTCH CABLE
26 N.m (2 6 kg-m, 19 Ib f t )
i
'Y
Rernoval/lnspect~on,page 43%
Instaliatcon, page 13-8
CLUTCH DISC
Removal, page 13-7
lnspect~on,page 1 3 7
I n ~ t ~ ~ l l a tpage
~ o n ,13 8
PRESSURE PLATE
Removal, page 1 3 4
Inspect#on,page 1 3 6
l n s t a l l a t ~ o npage 13 8
TRANSMISSION
Rernovai, S e c t ~ o n14
i n s t a l i a t ~ o n ,Sectrol l 4
RELEASE BEARING
Removalllnspect~on,page 13-4
Installat~on,page 1 3 5
RELEASE A R M CLIP
page 134
Insrallat~on,page 13 5
Adjustment
STROKE AT PEDAL:
CLUTCH CABLE
ADJUSTING NUT
Turn in or out to get
specified free play at
tip of release arm.
RELEASE ARM
A T PEDAL
(0.06-0.100
Release Bearing
1.
Remove t h e 8 m m s p e c ~ a bolt
l
4.
5.
8 rnm BOLT
RELEASE A R M
RELEASE BEARING
2.
3.
Separate t h e release a r m frorrr the bearing b y rem o v i n g t h e clip from t h e holes i n t h e release bearing.
RELEASE A R M CLIP
RELEASE
ARM
----I\
RELEASE BEARlNG
Installation
1.
3.
(Molybdenum Disulfide)
/
(Molybdenum Disulfide)
(Molybdenum Disulfide)
4.
shown.
RELEASE ARM
RELEASE ARM CLIP
I
SPRING WASHER
Replace
8 x 1.25 mm
26 N-m (2.6 kg-m, 14 Ib-fa)
Y\
RELEASE BEARING
5.
Pressure Plate
Rernoval/lnspection
1.
2.
II
4.
5.
CLUTCH DISC
ALIGNMENT TOOL
07974-6890100
DIAPHRAGM
SPRING
3.
4 5 N - m ( 4 . 5 kg-m, 3 2 Ib-ft)
Clutch Disc
1.
3.
4.
--
Engine
.-
Standard
(New)
-.- -- -.---
Fuel-injected
8 . 3 - 9 . 0 rnm
(0.33-0.35 in )
.-
Carbureted
--
Engine
1
+
Flywheel
rI
,-
InspectionIRemovaI
1.
2,
Inspect the clutch disc mating surface on the flywheel for wear, cracks or burning.
3.
Installation
1.
2.
Install the Ring Gear Holder, then torque the flywheel bolts in a crisscross pattern, as shown.
RlNG GEAR HOLDER
07324- PD20002
MAGNETIC STAND
FLYWHEEL
3.
DIAL lNDlCATOR
12 x 1.0 mm \
105 N.m (10.5 kg-m. 76 Ib-ft)
4.
PRESSURE PLATE
FLYWHEEL
MOUNTING BOLTS
.-
7-
" "-
__I
4.
(Molybdenum Disulfide)
5.
/'
8 x 1.25 mrn
26 R1.m (2.6 kg-m, 19 Ib-ft)
7.
Manual Transmission
Maintenance .................................................
14-2
Transmission
....................... 14-2
Removal ....................
Illustrated Index ...........................................
14-4
Transmission Housing
Disassembly ...............................................14-6
Reverse Fork
Shift Shaft Clearance ................................... 14-8
Differential Oil Seal
. . 14- 10
Removal ......................................
Bearings and Seals
Replacerraent (Clutch Housing) ...................... 14- 10
.
.
.
.
Bearings
Replacement (Trans Housing) ........................14-12
Mainshaft Index .............................................14-13
.....
..
2 4-14
Countershaft Index .....................
Synchronizer Sleeve. Shift Shaft ....................... 14-16
Mainshaft Inspection ......................................14-17
Countershaft Ifispeceion ..................................14-17
MainshaftICounterskaft
ReassembSy and M e a s i i ~ e r n e......................
n~
74-18
...........
7 4-22
....................
Shift Arm Hc!der index
Shift Asm,'Seiscro< Arm ................... ............ 14-23
Shifl[ Rod and Shift Arm bd~lder ......................... '1 4-23
..
.
.
Maintenance
Transmission
II
3.
Oil Change
Change oil every 48,000 k m (30,000 miles).
Use only SAE30, 1OW-30, 1OW-40, or 20W-40 weight
oil rated SE or SF grade.
Car on Ground
1 . Disconnect ground cable at battery and at transmission.
2. Release steering lock and place gear selector in
neutral position.
3. Disconnect engine compartment wiring as follows:
0 Battery positive cable from starter motor.
@ Black,white wire from starter solenoid.
@ Greewblack and yellow wires from back-up light
switch.
4. Release engine sub-wire harness from clamp at
clutch housing.
5. Disconnect clutch cable at the release arm.
6. Remove the t w o upper transmission mounting
bolts.
1.
2.
Oil Capacity
2.3P (2.4 U.S. qt.) after drain.
2.4P (2.5 U.S.qt.) after overhaul.
81L FILLER PLUG
32 x 1.5 nim 70 N-m (7.0kg-rn, 51 Ib-ft)
TORQUE ROD
SHIFT ROD
1 5. Turn each steering knuckle t o its most outboard position. With screwdriver, pry right-side CV joint out
approximately l i 2 " , then pull sub-axle out of transm i s s ~ o nhousing. Repeat on opposite side.
Remove the right-side radius rod.
R E A R TRANSMISSION
MYLINTING B R A C K E T
18 x 1.25 mm
1 7 . Remove the darnper bracket from the transmission.
_ _ DAMPER B R A C K E T
- --
-=-I
-'
--
'
lllustaated Index
Clean all parts thoroughly in solvent and dry w i t h
compressed air.
Lubricate all parts w i t h oil before reassembly
,,
$, Replace
J,
--
f7
31
,4,
I\
g
?
&
ENDCOVER
Removal, Page 14-6
Installation Page 14 29
GASKET
LOCKNUT
R e n o ~ a iPage 14 6
Installarcon Page 1 4 29
SPRING WASHER
F I F T H G E A R SVNCHRO SLEEVE
Remdvai Page 14 7
l r s t a l l a t ~ o n Pas: 14 29
FIFTH G E A R SHIFT e m #
Rerroval Page 14 7
lnstallat~on Page 14 29
SPRING PiM
F I F T H G E A P SYNGRO HUB
Rnrroval P a g ~14 7
Instal atto- Page 14 28
SYNCHRO SPRING
(3
n
'
3
21
4' L
L
,:
Gi;
L
'9
,)
42
(&
17
(irz
2,
3
P
23
%
,
SPRING WASHER
COUNTERSHAFT F I F T H
GEAR
DRAINPLUG
4 0 N,rn (4.0 kg-rn, 29 ~ b - f t )
WASHERri4mm
B A L L BEARING
Replacement, Paye 14 12
OIL SEAL
Removal, Page 14 10
irstallatlon, Page 14 30
O I L FILLER BOLT
45 N.rn (4.5 kg-rn, 33 fb-ft)
WASHER 20 mm
TRANSMISSION HOUSING
D~jassembly Page 14-6
lnstallatfon Page 14 27
GASKET
SNAP R I N G 80 mm
@ OIL SEAL
@ MAENSHAFT
@ BOOT
@ SHIFT ROD
@ DOWEL PIN 14 x 20 mrn
@ DIFFERENTIAL ASS\(
Removal, Page 14-10
Overhaul, Sec 17
Installa?~on,Page 14-25
@ OIL BARRIER PLATE
@ COUNTERSHAFT BEARING
Replacement, Pages 14-10, 1 1
@ BEARING RETAINER PLATE
I@ COUNTERSHAFT ASSY
Removal, Page 14-9
inspect~on,Page 14-17
Installat~on,Page 1 4 - 2 5
Measurements, Page 14-21
Q FIRST & SECOND
GEARSHIFT SHAFT
$$ SHIFT A R M HOLDER
Measurements Pages 14 22, 23
Removal, Page 14 23
Instollat~on,Page 14 25
A 12 N-m ( 1 2 kg rn, 9 lb-fit
B 1 5 h i - m ( 1 5 kg m , 11 !b-fti
@ SPRING
@ SPRING COLLAR
J$ CLUTCH HOBPSfNG
66 BREATHER CHAILqBER
PLATE
Transmission Housing
r Disassembly
1.
3.
MAINSHAFT HOLDER
E N D COVER
07923-68901 01
(8bolts, 6 x 1.0mm)
S H I F T ROD
4.
5.
Remove locknuts.
CAUTION: The mainshaft locknut has left-hand
threads.
30 rnrn SOCKET
6.
Remove ~nalnshaffholder.
5 mm PIN PUNCH
SPRING PIN
8. Remove mainshaft fifth gear, shift fork, synchronizer sleeve, hub, ring and spring as a unit.
SHIFT FORK
COUNTERSWAFT
F I F T H GEAR
RETAINING
SCREWS
BACK-UP L I G H T S W I T C H
07936-6340000
Reverse Fork
Countershaft/Mainshaft
Wemowali
1.
2.
PIN-TIP-FORK CLEARANCE
Standard (New): 0.05-0.35 rnm
10.082-0.014 in.)
Service Limit:
0.5 rmm (0.02 in.)
-3
FIFTHIREVERSE
I
1
I [
Gear Clearance
1.
I
I
GEAR-TO-FORK CLEARATaiGE
Standard (New): 0.2- 1 .Q mm (0.008-0 04 in.)
Service Limit:
% .7 rnm (0.07in )
2.
\
.
I
R E V E R S E IDLER GEAR
-t
8.
lst12nti
SHIFT SHAFT
7.
F I FTHIREVERSE
SHIFT SHAFT
SHIFT GUIDE
~NTERLOCK
C O U N T E R S H A F T ASSY
MAINSHAFT ASSY
2.
BEARING RETAINER
PLATE
2.
3.
4.
into
ADJUSTABLE BEARING
REMOVER
ATTACHMENT
80 m n SNAP R I N G
07936-6890101
4.
I
\
5.
7.
M A I N S H A F T OIL SEAL
6.
M A I N S H A F T O I L SEAL
/
52 x 55 mrn
07746- 0010400
BEARING
DRIVER
07947- 6340000
- '
PLATE
Bearings
4.
Bedrlng
L--
1
I
D ~ m e n s ~ oAn as ~ n s t a l l e d
"
--
Countershaft
--------
3 0-8 0 m m
( 0 7 18-0 314 in)
-- -
- --
7 0 - 7 1 mm
(0 2 7 6 - 0 279 i n )
2.
3.
INSTALL
,
'
I
-
I N S T A L L BEWWlldG W I T H $!+&
N U M B E R SIDE F A C I N G Q t J Y .
PART
IS
Index
NOTE:
@ Clean all parts thoroughly in solvent and dry w i t h compressed air
Third, fourth and fifth gear needle bearings are identical.
Lubricate all parts w i t h oil before reassembly
NEEDLE BEARING
Check for wear, f a u l t y
roller movement
MAINSHAFT
Inspectton, page 14-17
B A L L BEARING
SPACER C O L L A R
NEEDLE BEARING
Check f o r wear, f a u l t y
roller movement
SPACER WASHER 28 mm
Inspectton, page 1 4 - 2 0
SYNCHRONIZER
SLEEVE
l n s p e c t ~ o n page 14 1 5
S N A P R I N G 28 mrn
SYNCHRONIZER
THIRD GEAR
Inspeci~on.
page 1 4 - 1 9
FORTH GEAR/
I n s p e c t ~ o n page
,
14-19
/'
SYNCHRONIZER RING
Inspection, page 1 4 - 1 5
S Y N C H R O N I Z E R SPRING
Replace
SPRING WASHER
\
SPRING
Replace
SYNCHRONIZER
RING
Inspect~on,
page 14-15
SYNCHRONIZER
I n s p e c t ~ o n page
,
1 4 - i5
SYNCHRONIZER
HUB
SPACER C O L L A R
NEEDLE
LOCKNUT
SYNCHRONIZER
SLEEVE
Inspectton page 14 15
M
AA
I NRSI N
HG
A
BE
SYNCHRONIZER
HUB
/
F I F T H GEAR/
Inspection, page 14.20
LNEEDLE BEARING
Check for wear, faulty
roller movement
YJ,
MAINSHAFT NEEDLE
B E A R I N G OUTER RACE
Reptacement, p a q e 14 1 2
Countershaft
Index
NOTE:
e Clean all parts thoroughly in solvent and dry w i t h compressed air.
@ F ~ r s and
t
second gear needle bearlngs are not identical.
Lubricate all parts w i t h oil before reassembly
REVERSE GEAR S Y N C H R O N I Z E R
\
SLEEVE
SYNcHRON'ZER
SYNCHRONIZER
Inspection,
F I R S T GEAR
e 14.21
T H R U S T WASHER
Measurement,
selection, page 14-21
COUNTERSHAFT
Inspection, page 14-1 7
NEEDLE BEARING
Check f o r wear, faulty
roller n3ovement.
SPRING WASHER
\
BALL BEARING
F O U R T H GEAR
T H I R D GEAR
Clearance, page 14-19
LOCKNUT
90 N m (65 Ib-ft)
SPACER COLLAR
31 x 38 x 30.5 nrn
SNAP R I N G 6 8 mm
SPACER C O L L A R C
SECOND GEAR
Measurement, page 14-21
the ~ n s l d eo f synchrontzer
Wear
--.---
6.
GEAR
Ring-to-Gear Clearance:
Standard ( N e w ) :0 . 7 3 - 4.18 rnm
(0.629-0.047 in.)
Service Limit:
0.4 mrn (6.856i n . )
7.
8.
9.
rI
2.
Hub Inspections
1.
2.
THREE
SLEEVE
HUB
SHIFT
- Installing Sy%irc=hronizer
Hubs in Sleeves
Each synchron!zer sleeve has three sets o f longer teeth
(120 degrees apart) tha? m u s t be m a t c h e d w i t h the
three sets of deeper grooves In t h e h u b w h e n assembled
SYNCHRQ
SLEEVE
LONGf R TEETH
SYNcHRo
SHAFT-TO-GUIDE CLEARANCE
Standard (New): 0 . 2 - 0 . 5 mrn ( 0 . 0 0 8 - 0 . 0 2 in.)
Service Limit:
0 . 8 mm ( 0 . 0 3 in.)
2.
SHIFT SHAFT
Mainshaft
Countershaft
I
Outside Diameter:
Standard (New): A : 26.004- 26.01 7 rnm
(1.0238- 1.0243 in.)
B: 31.984-32.000 rnrn
(1.2592- 1.2598 in.)
C: 24.980-24.993 rnrn
(0.9835-0.9840 in.)
Service Limit:
A: 25.95 m m (1.022 in.)
B: 31.93 m m (1.257 in.)
C: 24.93 m m (0.98 in.)
Inspect.o~l
passages
for restr~ctlons
Inspection
Wear
Outside Diameter:
Standard (New): A: 33.000-33.015 mrn
(1.2992- 1.2998 in.)
B: 33.984-34.000 mrn
(1.3380- 1.3386 in.)
C: 24.980-24.993 mrn
(0.9835--0.9840in.)
Service Limit:
A: 32.95 mrn (1.297 in.)
B: 33.93 rnrn (1.336 in.)
C: 24.93 m m (0.981 in.)
Support with
lathe type tool
or V-blocks
Support with
lathe type tool
or V-blocks
Mainshaft Measurements
7.
9.
FOURTHGEARCLEARANCE
Service Limit:
(0.0012-0.0071 in.)
0 . 3 rnm (0.012 in.)
FOURTH GEAR
SPACER C O L L A R
THIRD G E A R
SECOND GEAR
8.
SPACER WASHER 28 mm
\
SPACER COLLAR
BALL BEARING
F I F T H GEAR
IDENTIFICATION
THICKNESS
1 . 8 8 - 1.92 mni ( 0 . 0 7 4 - 0 . 0 7 5 ~ n . )
1.94- 1 . 9 8 rnm ( 0 . 0 7 6 - 0 . 0 7 8 In.)
2 . 0 0 - 2 . 0 4 m m ( 0 . 0 7 9 - 0 . 0 8 0 1n.1
2.06-2.10mm(0.087-0.0821n.)
2.1 2 - 2 . 1 6 rnm ( 0 . 0 8 3 - 0 . 0 8 5 ~ n . )
Countershaft Measurements
gear
thrust
Service Limit:
(0.0012-0.004in.)
0.18mm (0.007in.)
T H I R D GEAR
LSECOND GEAR
IDENTIFICATION
THICKNESS
+
I
-- -------
2.02-2.04
2.00-2.02
1.98-2.00
1.96- 1 . 9 8
THRUST WASHER
mm
mm
mm
mm
(0.080-0.081
(0.079-0.080
(0.078-0.079
(0.077-0.078
in.)
in.)
~n.)
in.)
MICROMETER
0-25 mm
CLEARANCE
Standard (Mew): 0.03 -0.2 rnm
(0.0004-0.008 in.)
2.
IDENTIFfCATlON
TMlCKNESS
-
1L
p
p
p
p
p
-
08mrn(O0311r.)
1 0 m m ( 0 0 3 9 in )
1 2 rnrn ( 0 047 ~n
1 .1- mrr, 10 0 5 5 ~n i
7 6 mrn 1
0 063 in i
/
l
SELECTOR A R M
- Removal
2.
3.
1.
BO b TS
- Interlack Clearance
2.
I
C h e c k hole for wear
1.
SHOULDER BOLT
SELECTOR ARM
Shift Arm/
Gear Selector Arm
Shift Rod
2.
3.
- Installation
1.
2.
3.
SHIFT A R M
SPRlNGiDETENT B A L L
\
SHIFT ROD
F T ROD
GUIDE
/.Af
i
0
8 x 1.25 mm
ft)
S H I F T ROD
GUIDE
SHIFT ROD
Transmission
- Installation
- Reassembly
1.
SHIFT A R M HOLDER
1.
SELECTOR A R M
ewnx
/
D I F F E R E N T I A L ASSY
2.
HOUSING
2.
15 N.m (1.5 kg-m, 11 Ib-ft)
FIRST/SECOND
GEAR SHIFT SHAF
M A I M S H A F T ASSV
THIRD/"OUAYH
G E A R SHIF7- SHAFT
(ccnt'd'
Transmission
Reassembly (cantVd)
3.
6.
F I FTHIREVERSE
SWIFT SHAFT
SELECTOR A R M
7.
4.
5.
Hook interlock i n t o selector arm, firstisecond gears h i f t s h a f t and thrrd'fourth gearshift shaft. Hook
s h i f t guide i n t o shift arm.
SELECTOR A R M
INTERLOCK
SHIFT A R M
SWIFT GUIDE
\-
A = 12 mrn (8.5in)
INTERLOCK
TR;ANSMISSION HOUSING
DOWEL PIN
GASKET
DOWEL P I N
REVERS^ IDLER
GEAR SHAFT
REVERSE IDLER
GEAR
Transmission
Reassembly ( c ~ n t ' d )
1 5 . Install three defent balls, washers, and retaining
screws.
M A I N S H A F T F I F T H GEAR
DETENT
BALL
SPRING
DETENTBALL
HOLE
SCREW
12 x 1.0 mrn
22 N.rn (2.2 kg-rn, 16 Ib-ft)
SPRING WASHER
SYNCHRONIZER HUB
SYNCHRONIZER SLEEVE
NEEDLE BEARING
COUNT RSHAFT
F I F T H GEAR
SYNCHRONIZER SPRING
SPACER COLLAR
SYNCHRONIZER RING
FIFTH
S#(FI F O R K
.7"
,.*.
-I c r c ~ i i c::?~insk:>ii
;in-! colintershd"
locknuts.
Tighccr, tc7 t--p.::ified ti:i-qiis, :hen iooseri a n d retiyhri-.n to sr n;t: lorquc
._ --
--.
\___
.-
f RANSWlllSSlON HOUSING
SNAP R l N C
3.
D R I V E R ATTACHMENT
07947-61 10500
2.
DRIVER
07749-604 0060
D R I V E R ATTACHMENT
07947-61 10500
Transmission
Installation
--I
Shown
1.
2.
3.
4.
5.
6.
7.
3,
-C
> I
'
--
,
1
.
\-
TRANSMISSION
12 x 1 25 mrn
75 N r n 17 5 kg m, 54 ~b f t )
l o x 1 25 mm
65 Y m (6 5 kg-rn, 47 Ib f t )
FRONT TRANSNlSSlON
MOUNT
10 x 1.25 rnm
45 N . m (4.5 kg-m. 33 Ib-ft)
Car an Ground
R E A R TRANSMISSION
M O U N T I N G BRACKET
2).
23. Check transmission for snloodh operation.
45 N . m (4.5 kg-m, 33 Ib-ft)
*
-
Gearshift Mechanism
i-
Qverhau'
/ S H I F T KNOB
SNAP R I N G
SHIFT LEVER
OUST
@/
\
S H I F T LEVER
B A L L STOPPER
THRUST
SHIFT LEVER
,GEARSHIFT
\\
LEVER
JOjNT COLLAR
Replace
OUST SEAL
-@0
'" @
12
THRus.wr,HER
T H R U S T RUBBER
0,:
,<y
.RINGS
eplace
8 x 1.25 rnrn
22 N . m ( 2 2 k g m , 16 Ib-ftl
6 x 1.0 mm
10 N . m ll .O kg-m, 7 Ib-ft)
/
r
1
Testing
1.
2.
3.
This washeirnust
always be replaced
for switch to
function properly
and to prevent
o i l leaks.
4.
\
BACK-UP
LIGHT St71
Automatic Transmission
(Fuel-Injected Engnie)
Description ................................. "1-2
Troubleshooting
Symptom-to-system ................. 75-11.
Road Test .................................. 1 5-6
Pressure Test .......................,..
1 5-7
Stall Speed ................................. li' 5-8
Maintenance ...................
......
1 5-8
Transmission
R e m ~ v a l...................
.,.
. ... 15-9
illustrated Index .......................... 1 5-1 0
Transmission Housing
Removal .......................... .
.
.. 15-1 2
MainshaftICountershaft
Removal ....................
.
.
........ 4 5-1 5
Governor Valve
....
...*.. 15-16
Removal ....................
Main Valve Body
Removal ...............................
1 5- 4 6
Control Shaft ..................... .....
15,-20
O n e - w a y Clutch/Parking Gear ....... 2 5-2 1
Main Valve Bcdy
Disassembly ........................... 15-22
Secondary Valve .....am.................,1 5-23
Valve Body ................................ 1 5-24
Main Valve Body
Reassembly ........................ ....15-25
Regulator Valve Body ................... 7 5-27
bock-Up Shift Valve Body ............. 15-28
Reassembly .............................75-30
Mainshaft
Disass<3ru.3b/y!'tr1syectI<:iti/
Reassembly ............................1 5-3i
Caaen.r.ershaft
Disassembly!I~~~;peclloni
Reassemhty ............................1 5-32
@sun?er~i?af
t;Mssiil~;C'i~?f;~
CIeare~nce8t7easi.sra:~~ents.......... "e-33
Cliirch ....................................... 15-36
Differential artd Seei .....................:? 5-45
- .
Bearings and ssaes .......................15-46
", .,K - 4 8
En6 Caver .................................
Throt.tie Con'rrei Shaft ................,. 15-43
Transmission
Reassembty ..........................9 5-45
Torque G m v e r t e r .......................1 5-63
Transmission
installation ............................15-454
Shift Position Svvil:;:? . . . . . . . . . . . . . . . . . .1 5-67
,c:
Shift Indicator i.Egh: ..................... ! ,fi-?,?>
Shift lnefica~or%"r.lt..;i . . . . . . . . . . . . . . . . . . .-*-:-. p a
; 'P'
Gearshift Seiectzsr ........................;,>4 .;
".',x
Shift Cable ................................ 2 - 8
Tkrottie Cc?ntrc;i C,?il?ie ................. !5-72
'
#
>-
Description
Tho Horid;c Autoniatic Traiismission is s combindtiori of a 3-aiernent Torque convertc'r and dual-shaft automatic transmission which provides 4 speeds forward and 1 speed reve!se. The entire unit is pcciticned in lint. with e?(;ine.
WYDRAUUCCOMTROL
I ne valve assembly i ~ c l u d e s
the main valve body, secondary valve body. servo valve body, modulator valve body, regulator valve body and lock-up shift
valve body, through the respective sepsrator plc,,!es.
They are bolted t o the torque copverter case as a r assembly.
The main valve body contains the manual valge, 1-2 shift valve, 2-3 shift valve, 3 4 shift valve, pressure relief valve. 2nd orifice control valve, and oil pump
Ths secondary valve body includes The CBC vaivn, REV con*rci valve, lock-up cut valve, kickdown valve, 3-2 timing valve and shift timing valves.
The servo kalve body contains the acci~mu!atorps:ons. 3rd orifice control valve, throttle 4 and B valves, and the modulator valve. The regulator valve body
ccntains the lock-.up timlng valves, precsiure r r 3 : i l ~ l o rvaive 8nd lock-up ~ ~ ' i t r voal l v ~ Fluid
.
irom the regulator passes through the manua! valve t o the various cor>l;oI Vailes.
The lock-bp shift valve Do6y corti.!n:, a lock-cp t;mirg va!:e bnd iock-up shif: valve. The 1 st. 3rd and 4th cluches receive oil from their respective feed pipes.
LOCK-GP MECHAIMISM
1,i 0 4 , In 2nd. 3rd end 4th, press1;rizt.c lluio is <:rained from tbi? back of the torque converter through an oil passage, causing the lock-up piston t o be held
aaains! the rornue coi2vcrtei. ~covzi.A S this i h k i 3 place, the r,a;rshaf; rotates at the same speed as the engine crankshaft.
The lock-up shrft \,alve body ciintrots rhc range of lock-up acco-d:ng to vehicle speed and throttle pressure. The lock-up timing valve controls the flow of oil
t o the lock-up shift valve in 2nd. 3rd n?d &i? gears iiri D J range).
The lock-un cut valve is housed In 'the secondary valve boay and prevenrs lock-up from taking place when the throttle is not opened sufficiently.
GEAR SELECTION
The selector lever has six positions: P PARK, R fiEWERSE, N NEUTRAL. D 4 ? s t through 4 t h gear ranges, D3 1 st through 3rd gear ranges, and 2 2nd
34
CRiVE
...
f
1
N ?roiis"i list of
POSITlON INEICATOR
P oosi:ior
ind!ce?or
11
t h r il-'et:.k!r:-tn:
an:-.! i h c w ~ ,**:ha:
;
*;LOT
II
B
p
m
7
,
"
<
.
,
u
p
-
3rd GEAR
END COVER
CLUTCH PLATE
'
'
CLUTCH
l
DISC
COUNTERSHAFT
PARKING GEAR
/
LOCK-UP
CLUTCH
REVERSE SELECTOR HUB
* --
~,\
;\
~\
- -.
7-
-+--
4th GEAR
RtNG GEAR
-------
RELlEF VALVE
Keeps constant fluid pressur
for lubrication.
/-'
REGULATOR V & i V E
STATOR SHAFT
i i a n s m r t s torque ccnverter
ret?ction tc the irgu!c.tor 3~elve.
. ACCUMULATOR
Changes ciuech pressure to
absorb shock i r i h e r the clutch
GOVERNOR VALVE
Changes vehicle speed into
hydraulic pressure and
selects optimum gear.
SERVO VALVE
e.
MANUAL VALVE
=
--.-
v;-,isa.
p
.
p
p
v
-
Troubleshooting
C l r ~ c xtneie
SYMPTOM
',
___----
f
I
,li.J P bur
- .........
Czr , F i v e s 111DT, G 4 ,:nil 2, bd:
Car ~ c b e : ; n 03,3 4
PROBABLE
On
C/ALSE LIST
I*OTES PAGE
-.___A
6 7 '6;
K. L 9, S
1
,I,-I ,n
9, >C,
,-
4,;
~-.--i......
:L*'
:'L
, ,
Car ,n?ovii cn N
1
j
-- -
9, ,
3:
I
The foliowing symptoms can be caused
by tmpropcr ratpati or assembly
; It,,
:',
Ad
A,-
..
2 3 ?,
I
_
_
.
,
lock up ~nR
'ians
ITEMS O N
NOTES
R5
'
....
A3
.I
1 A8
C,"
PROBABLE
CAUSE DUE
TO IMPROPER
REPAIR
on
R1, R 2
C2r creeps ~n N
ixcess,kc v i b r a t ~ c r ,~ p related
n
%oi:f
!I-
;/-
t.+ar:,i, ~,;,sl-~~ts.
A,K
R7
---
Items
,:t: 'K
Check these
I,
i,
c
' , ' . , :.
22.
.>:+,4,:
:i3
- -..-,
I,
Check these
items o n
r , L. ld
I?
PROBABLE CAUSE
1
-- . -__ia
/
1
2
Throi:lP
/_
1-
-.
.-.
.
.
.
.
.?
\iVicng typa ATF
i
'
NNI ~ 3 o w 1 l i t ~t ~c 1 f t
Late upshift.
' C C C ~ C ~
-__L:l:l?
-c?.,i
--
-.--._4-_-.--
3
~
_____: I ..L
'
---:.-:'-/L.
,i$ 4
1 Thrctt!e 8 \ , ~ ; b estbck
/
.!..
I
/
..+
.- _,
.B
!.
---- -------
i
-
'
. -c ~ ~ . v_e r fdefecCtl~e
oi
I
-
Tc:rq.~t
.
-.
-
:8.
-.
r n
i
-0
.
,
I 3'
.- .
x: z,13,e:,,
>
2-2
i,;.fi ,.
.' 61uCh
,cive
--
.-
I 3 - - 4 ~hi!' ~ a l v ' s r ~ c k
C
.-
i 22
Re,,ecj
23
C,,tci:
2.1
,^.kc:
..'. !.F,-"
"I;'"'
'"'""
'".",".' ,
3'.
.:;
,..C
'1
stuck
________I----I
! S - o C e ~ o n t ~~ohl i k rstuck
2C,
'
27
Kl:k,rfown
28
S h ~ f timing
?
i.alveiaccumuIator stuci,
vaive stuck
25
FO
Z y E h
accumulator defective
I L O C ~ J Pc1,:c1-
VIY;'
..
iC
^r
k.
CCI:~PCI
I rr,ng v a l v ~B stuck
--I
PROBABLE CAUSE
!
r
-1-1
1
49
Sealing rings
worn
- quide
.
50.
51
--
ID the end cover is scored by the malnshaft, inspect the ball bearlng for excessive movement In t h e transmcssion housing. If OK, replace the end cover as !t is dented. The 0-r,ng
under the gulde IS probably broken.
--
--.
0
Replace the mainshaft if the bushings for the low and 4 t h feedpipe are
loose or damaged If the low feedpipe is damaged or out o f round, replace it. If the 4th feedp~peis damaged or out of round, replace the end
cover.
- .- -- - .-.-.
-A horn or camd(;rc spra,? c8-tcn s most \, + .c-sult cr i 5 , f t . n g tnr. trans
r D3 or Di a n :t- t r n .vrcers .otJ:e n rr iric sLcn 3 s r o c s ~ n g!ne car
--
b+-e
NOTES
H-
Install the rnaln seal flush with the torque converter case.
If you push it into the torque converter case until ~tb o t t o m s out, it will
block the oil relurn passage and result ~ndamage.
if the large clutch prston O-ring IS broken, Inspect the plston groove for
rough machining.
-E
, 11
"
/
I
j
Throttle cable adtustment is essentta' for proper operation of the transmtsslon Not only does ~taffect the shlft oolnts i f misadlusted but also
the s h ~ f quality
t
and locktip clutch operation.
A too long adjusted cable will result In throttle pressure being too low
for the amount of englne torque input Into the transmlss~on,and may
cause clutch sllppage A too short adjusted cable will result i n too high
throttle pressures which rnay cause harsh shtfts, erratbc s h ~ f t sand
torque converter hunttng
/
i
If the 3rd orlflce control valve is stuck, Inspect the 3rd and 4th clutch
wear
packs for
-
If the clutch pressure control vaive is stuck closed. the transmissaon will
not shift out of low gear
Check I' servo valve check valve stopper cap 1s ~nstailed.If it was not
~nstalled,the check valve may have been pushed out by hydraul~coressure causing 3 leak t!nternPll affecting all forward gears
7
D
NOTES
improper alignment of main valve body and torque converter case may
cause orl pump selzure The symptoms are mostly a n rpm-related
ticking nolse high p~tchedsqueak. In severe instances, i t may stall the
engtne Follow instruction procedure on oaae 15-51
j
j
Road Test
NOTE. After transmlsslon IS installed;
e Make sure the floor mat does not interfere w i t h accelerator pedal travel. Fully depress accelerator pedal and
check t o make sure the throttle lever I S fully opened.
@ Release the accelerator pedal and check both Inner control cables t o be sure they have slight play.
Warm up the engine t o operating temperature
and I
D---4 Range
--
2.
Apply parking brake and block the wheels. Start the engine, then move the selector t o w while depressing the
brake pedal. Depress the accelerator pedal, and release it suddenly. Engine should not stall.
Check that shift points occur at approximate speeds shown. Also check for abnormal noise and clutch slippage.
Upshift
I.
I st
-,
2nd
2nd
-,
3rd
3rd
4th
LC. ON
Full-throttle
Acceleration from a stop
Half-throttle
Acceleration from a st00
I
ting d o w n - h ~ lfrom
l
a stop
10-12rnphj
1 9 - 2 3 rn
Downshift
4th
I Closed-throttle
11
3rd
1 5 - 1 9 mphj
I
3rd
-,
2nd
5-8 mph
2nd
1st
3.
r - - - -
kd (2nd Gear)
U
1.
Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage.
2. Upshifts and downshifts shouid not occur w ~ t hthe selector in this range.
Accelerate from a stop at full throttle, an3 check for abnorwai noise and clutch slippage.
' P : (Park)
i
Park car on a slope (approx. 16'), apply the psrking brake, and shift into Park. Then release The brake; the car should
n o t move.
Pressure Pest
NOTE:
@ Stop engine when attaching hoses for pressure
tests.
Torque hose fitting t o 18 Nsrn (1.8 kg-rn, 12 Ibft).
D o n o t reuse aluminum washers.
@ For throttle and governor test, use Low Pressure
Gauge, 07406-0070000.
LINE PRESSURE
B PRESSURE
PRESSURE
HOSE FITTING
PRESSURE
MEASUREMENT
POSUION
LINE
N or P
1st
0 3 or 0 4
SYMPTOM
Z%","afE:::ke
applied r a w front
wheels off ground and support with safety
Stands
4th
1.
j
1 .
/ .
/
1 i .
1
.
/
8
GOVERNOR
'
0 3 or 0 4
~tsndsrd
THROTTLE
FLUID PRESSURE
PROBABLE CAUSE
NO 101 low1
LINE pressure
No ior low!
First pressure
1st clutch
0 rlngr
No lor low1
SECOND pressure
2nd clutch
0 r nga
No lor law!
3rd clutch
NO
,orlow!
THROTTLE
pressure
Throttle vaive A
Thfottle modulator valve
i/
1
1
7hrottle vaive 8
!
1
i
i
opentng
Servo valve
Ith
clu'ch
Service Limit
785 kPa 18 0 kg
114 psll
THIRD pressure
I
/
834-883 kPa i 8 5 - 9 0
kg cm2 121 - 128 psti
/
Nc
tar l c w i GOVER
NOR pressure
Covetnor vaive
ZJE! 1j
490 k P a i 5 00 kg:cm2.
~ ~ ~ , : 0 , ~ ~ & $
71 psi! with lever in fdli
510 kpa, 15 05-5 20
kg,cm2 72- 74 ps,, w ~ t h, tnrotflo Dasltion
lever ,n full throttle
!
0 kPa 10 hg,cm2.
0 psl! with iever released
334-883 kPa i 8 5 - 9 0
kylcm2 ' 2 1 - 1 2 8 orii
with lever in fuil throitle
Stall Speed
Maintenance
r CheckinglChanging
Test
Checking
1.
2.
m.
a,
a,
BfiOBABLE CAUSE
TROUBLE
--
m,
Stall rpm l o w
i n m , @,,
&
B.
1.
j5141
-- -
L----
DRAIN PLUG
40 N-m (4.0 kg-m, 29 Ib-ftI
Transmission
1 . Disconnect ground cable at battery and transmission.
2. Release steering lock, and shift gear selector to N.
3. Disconnect wiring:
Battery positive cable from starter.
@ Blackiwhite wire from starter solenoid.
4. Disconnect cooler hoses, and wire them up next t o
the radiator so ATF won't drain out.
5. Remove starter mounting bolts and t o p transmission mounting bolt.
6. Loosen front wheel nuts.
7. Apply parking brake, block rear wheels, then raise
front end on jack stands and remove front wheels.
8. Drain transmission. Reinstall drain plug w i t h a new
washer.
9. Remove throttle control cable:
Remove the cable end from the throttle lever.
e Loosen the lock nut A only.
Remove the cable from bracket.
15. Turn right side steering knuckle t o its m o s t outboard position. With screwdriver, pry CV joint out
approximately 112", then pull C V joint o u t of transmission housing.
1 SHIF,T L E V E R
THROT'TLE
CABLE
(LOCK NUT 6)
ADJUSTER
THRQTTLE
CONTROL
LEVER
SHIFT CABLE
Replace G
"
ILO I L
@ C [ e ; rall
~ rm~tsthrough \I ir L U I V ~ FGI~ ~P c ~ r j ? ~ r t : c ~
cleaner <3r;d drv with cornpi e ;sac a r Blobzl oi?
@
sli uass;.gcs.
Coar all pFr'is w i t h A7-F b ~ l a r c-rassc~r,hi\
? s t CLUTCH
Disassembi,
1 9 x 1 2 5 mm
F\eecscmbly ,?.ice
35
3C
>5 di
WASHER 26 n-rn
-i THRUST
THRUST P\Es'"BL."
3
5,
;;'
,
7
.s
BEARING 38 Y 47 x 2 n n
NEEDLE BEARING
34 x 36 x 98 5 rnm
MAINSHAFT Ice GEAR
THRUST !hlASL-OER
COLLAR 26 nzw
SNAP RLNG C: ma?
MRlNSHPFT BEBRII~G
Reprazernz.-t
pay
*'
2' HANGER
\,
PAWL ROLLER
REVERSE ICLER
ARJNG bQL3ER
WOV i
p.gr-
' 5 14
Ti-IRBTTLE COrqTROL
SHAFT SPRiNG
R,r,ol,al pase i 5 1 1
I ~ ~ s * a l l a t i o pagi
n
15 56
TRANSMlSSlON
HOUSfMG
THROTTLE CONTROL
SHAFT SEAL
LOCK PLATE
THROTTLE CONTROL
CABLE BRACKET
DOWEL PIN 14 x 25 rnrn
LOCK UP SHIFT
3 SPRING
13
3rd CLUTCH PlPE
VALVE BODY
6 DOWEL PIN
4th ACCUMULATOR COVER
bC COUNTERSHAFT
Removal, page 15- 18
@
/ MAIN VALVE SEPARATOR F! O-RING
REVERSE GEAR
D~sassernbly,page i5 - 2 8
PLATE
2ndi3rd ACCUMULATOR
SELECTOR HUB
@< MAINSHAFT ASSY
(93COTTER PIN
COVER
'i' REVERSE GEAR
Disassembly lnspectron page 15-31 3 WASHER
3 SERVO VALVE BODY ASSY
SELECTOR
A
$ 1 ROLLERS
@: REGULATOR VALVE BODY
Removal, 15-1 7
$8 COUNTERSHAFT ASSY
Removal, page 1 5- 1 8
'7' CONTROL SHAFT
Dlsassembly, 15-29
Dlsassembly Inspection,
Repalr, page 1 5 - 2 4
MANUAL VALVE PIN
(2 TIMING ACCUMULATOR
page 15 32
Dlsassembly, page 15-27
^i BAFFLE PLATE
PISTON
~s COUNTERSHAFT NEEDLE
& STOP PIN
\? FILTER SCREEN
SPRlNG
BEARING
@ O-RING
("-CLIP
STEEL BALLS
,OIL GUlDE PLATE
9 STATOR SHAFT
THROTTLE CONTROL SHAFT
SPRING
,
' DIFFERENTIAL
@ STEEL BALLS
r
21
\ DOWEL PIN
LC' SECONDARY FILTER
3 SNAP RING 80 mm
1st CLUTCH PlPE
I - J SERVO SEPARATOR PLATE
SECONDARY VALVE BODY
TOROUE CONVERTER
~2' MAIN VALVE BODY
I.!DOWEL
.
PIN
ASSY
HOUSING
ASSY
(? O-RING
Removal, 15-1 7
3 GOVERNOR VALVE
Remove, 1 5- 19
? SERVO VALVE
Dlsassembly Inspect 1 5 - 2 3
Removal, 15- 1 6
Dlsassembly, 1 5 - 2 2
r) RETURN SPRING
BOWEL PINS
Dlsassernbly !nspect.on, 15 30 6 DRIVEN GEAR SHAFT
,
CHECK VALVE STOP PLATE
SECONDARY SEPARATOR
2 LOCK PLATE
q, PUMP DRIVEN GEAR
SEPARATOR PLATE
PLATE
3 REVERSE SHlFT FORK
;5 PUMP DRIVE GEAR
? 4th CLUTCH PlPE
MAINSHAFT BEARING
-' LOCK PLATE
9
4
DOWEL
PIN
r;' MODULATOR VALVE BODY
MAINSHAFT 01L SEAL
DOWEL PIN
TORQUE CONVERTER
Removal, page 15-1 7
Y
.
DIFFERENTIAL 0th SEAL
? SEPARATOR PLATE
CHECK VALVE
2 MAGNET
(<
WASHER
i+ OIL SEAL
Y NEEDLE BEARING
(2
.
2
'
2
\-I
Transmission Housing
Removal
1.
rings.
2.
6.
DIPSTICK
END COVER
3.
GASKET
7.
6 x 2.3 rnm
Replace
MAINSHAFT HOLDER
07GAB-PF50100
MAINSHAFT
MAINSHAFT LOCKNUT
STOP PIN
1st CLUTCH
SPRBNG
\
THRUST WASHER
2 6 rnm
THRUST NEEDLE BEAR1
3lx47x2rnm
1st GEAR
-----------.----g
NEEDLE BEARING
31 x 3 6 x 48.5 mrn
11. Pry the staked edge of the locknut out of the notch
in the parking gear.
Transmission Housing
Removal (eorntyd)
4 5. From the countershaft, remove the needle bearing
and Ist gear collar. From the mainshaft, remove
the I st gear collar.
NEEDLE BEARlNG
39, x 38 x 14rnm
O-RINGS
19.8 x 1.9 mrn
COUNTERSHAFT
I
R
1st GEAR COLLAR
1
/
LOCK
PLATE
REVERSE IDLER
BEARING HOLDER
SPRING
'
\
THROTTLE CONTROL
LEVER
1st GEAR
COOLAR
THROTTLE CONTROL
BRACKET
IDLER BEARlNG
HOLDER ASSEMBLY
- STEEL BALL
7 7. Bend d o w n the tab on the lock plate under the parking shift arm bolt.
18. Remove the bolt, then remove the parking shift
arm.
Mainshaft/
Countershaft
22. install the transmission housing puller over the
countershaft w i t h four bolts and tighten securely.
Then sciew in the puller bolt against the end of the
countershaft until the transmission housing comes
loose.
1.
COUNTERSHAFT
REVERSE GEAR
NEEDLE BEARING
REVERSE GEAR
SELECTOR HUB
REVERSE GEAR --iv
SELECTOR
NEEDLE BEARING
28 x 33 x 20 mrn
LOCK PLATE
COUNTERSHAF
4th GEAR--
HOUSING PULLER
c\
COUNTERSHAFT
a":<:,--7
\\:--:p
;48
p?&
.'
L"
l4\;-&&&Ji
-',
>:
7,:
+.:
"
/J
L/
3.
4.
/'---'
5.
I
TRANSMISSION
TERSHAFT
TORQUE CONVERTER
HOUSING
Governor Valve
- Removal
I
1.
BAFFLE PLATE
GOVERNOR
2.
LOCK PLATES
3.
4th ACCUMULATOR
COVER
4th A C C U ~ U L A T O RSPRING
OD: 18.6 mm (0.73 in9
4.
THROTTLE CONTROL
SHAFT
$1
VALVE BODY
BALL
SPRING
TIM1NG ACCUMULATOR
PlSTOM
Removal (cont'd)
11. Remove the separator plate and dowel pins.
BOWEL PlNS
REGULATOR
VALVE BODY
SEPARATOR PLATE
14. Remove the stator shaft arm, dowel pins and stop
pin.
LC-SHIFT
VALVE BODY
STATOR SHAFT ARM
STOP PIN
- -
4
'
DOWEL PlNS 8 x 14 mm
PIN
FILTER SCREEN
WASHER
\-
COTTER PIN
OIL PASSAGE
STEEL BALLS 5.5 mm (0.22 in) MAIN VALVE BODY
PUMP DRIVE
GEAR
<,-,
,-
SEPARATOR PLATE
Control Shaft
1.
/
<
'
r'
----
r----lL--
\-hi,
CABLE HOLDER
CONTROL LEVER
ROLLER
CONTROL LEVER
i-
LEVER
4.
--
LOCK PLATE ,
Separate the countershaft Ist gear from the parking gear by turning the parking gear in the direction
shown.
PARKING GEAR
COUNTERSWAFT
1 s t GEAR
2.
PARKING GEAR
ONE-WAY CLUTCH
COUNTERSHAFT
1 s t GEAR
COUNTERSHAFT
I st GEAR
SHlFT VALVE
STEEL BALLS
(4.76 mm, 0.187 in.)
BALL SPRING
FT BALL SPRING
1
1-2 SHIFT VALVE
t-2 SHlFT SPRING
2-3 SHlFT SPRING
'ALVE SPRING CAP
I
RELIEF VALVE
SPRING
3-4 SHIFT
-----
c;^
TORQUE CONVERTER
CHECK VALVE
VALVE
3-4 SHIFT BALL SPRING
ORIFICE CONTROL
SPRING
STEEL BALLS
SPRING
2nd GEAR ORlFlCE
CONTROL VALVE
Inspect for scoring
or damage.
SHIFT VALVE
MANUAL VALVE
/
ROLLER
SHIFT VALVE
COVER
1
5 x 0.8 x 1 2 m m
8 N-m (0.8 kg-m,
6 Ib-ft)
U
CPC VALVE CAP
--3
REV CONTROL
CPC VALVE SPRING
SECONDARY FILTER
LC CUT SPRING
SECONDARY VALVE
LCCUTVALVE
VALVE SPRING
SEAT
SLEEVE
7 1 mm
KICK DOWN
VALVE CAP
Valve Body
NOTE: This repair is only necessary if one or more
of the valves in a valve body do not slide smoothly
in their bores, You may use this procedure t o free
the valves in the main valve body, regulator valve
body, lock-up shift valve body, and servo valve
body. DO NOT use this procedure t o free the valves
in the governor; if any governor valves are stuck,
the governor must be replaced as an assembly.
1.
2.
5.
6,
VALVE
3.
4.
VALVE
BODY
Inspect the valve for any scuff marks. Use the ATFsoaked # 5 0 0 paoer t o polish off any burrs that are
on the valve, then wash the valve in solvent and
dry it w ~ t hcompressed air.
Roll up half a sheet of ATF-soaked paper and insert
burrs.
ATF-soaked
#600 abrasive
paper
7.
Slide the spring into the hole in the big end of the
shift valve.
While holding the steel balls w i t h the tips of your
fingers, put the sleeve over the shift valve.
STEEL BALLS
t4.76 mm, 0.187 in.)
Place spring between
steel balls.
3.
4.
RELIEF SPRING
DETENT ROLLERS
SHIFT VALVE
SHIFT VALVE
r Reassembly (cont'd)
6.
8.
'I
VALVE BODY
clearance of
the
gear-to-valve body.
driven
DRIVE GEAR
Inspect teeth
for wear or damage
DisassemblylBnspectio~;s
--NOTE
a Clean PI: parts ~ h c r o t j g r l l yi n S ~ I L F Q nr
: c: rbilretor cleaner
@ i i e p b c e valve booy as ac,sernblv bf 3 r - 1 ~parrs are worn cr damaged
R r p ~ 1 orb
8 aae.7 15-24.
@ Check all valdes for f l e e movemenr if ,3nv fa,! i3 s?ide freely, see 'v'd1s.e E c d ~
$C See Sectref. 3 for s7ring s ~ e c i f i c a l ~ o r i '
@ Cost ail parts *vt?h ATF be+o:e reassemoty
/, RETWBNER
,id,
"\k/
A*
@q%)*k
sP~lhlG
I@$
@
SEAT
\ a;, t . S I A I O R R E l i C T I O N
SPWLNG
OUTER SFRBbSG
PRESSURE
WEGULA'888
Inspect for werr
scratcnes, or scGr ?F
PRES%i;WE 4EGULB'km0&$
VALVE
T?pASNGVALVE Si"lpQ(P2G
LC TlMlNC VALVE 9
1,
2.
3.
4.
rlvltll
APF
LOCK BOLT
7 2 Neni r l . 2 kg-m,
ROLLER
PARKING BOLT
LC SHIFT VALVE
LOCK-UP SHIFT
VALVE BODY
Inspect for scoring
LC TIMING VALVE B
Inspect for scoring or scratches.
r DisassemblyllnspectionlReassembly
NOTE:
0 Clean all parts thoroughly i n solvent or carburetor cleaner, a n d d r y w i t h compressed air.
B l o w o u t all passages.
If any fail t o slide freely, see Valve Body Repair o n page 15-24.
3 for spring specifications.
0 See Section
4th ACCUMULATOR
COVER
2nd
CLUTCH PIPE
PLATE
TRANS-MAGNET
f fl
,31
O-RING
x 2.7 mm
MODULATOR VAL$E
Inspect for scorlng or
scratches.
SPRING HOLDER
/'
8-
THROTTLE VALVE-A
SET
21.2 x 2.4 mm
Replace
4th ACCUMULATOR
PISTON
EL,
,
/'
SLEEVE
2nd ACCUMULATOR SPRING
3rd ACCUMULATOR SPRING
O-RING 18.3 x 2.4 mm
-0
Replace
!"
O-RING 24.4
u ~n
r I~
ADJUSTMENT
BOLTS
..--NU I : DO not adjust or
remove these bolts; they are
adjusted at the factnrv.
for proper shift poinrs.
Governor Valve
Disassembly/Inspection/ Reassembly
NOTE:
0 Clean all Darts thoroughly
- . s;olvent or carburetor cleaner, and dry w i t h compressed air. Blow out all passages.
0 Check that the governor works smoothly; replace it if it does not.
0 See Section 3 for spring specifications.
0 Coat all parts w i t h ATF before reassembly.
WOODRUFF
KEY 3 mm
Inspect
FILTER
Clean
HOLDER
Inspect for
scoring or
warpage.
SNAP RING
LOCK PLATES
Redace
THRUST WASHERS 14 mm
Inspect face for wear or damaae.
GOVERNOR HOUSING
NOTE: Check that governor works smoot
I
GOVERNOR VALVE
lnspect for wear, scratches, scoring.
SECONDARY WEIGHT
lnspect for wear, scratches, or scoring.
__,
GOVERNOR SPRING B
PRIMARY WEIGHT
lnspect for wear, scratches, or scorlng.
GOVERNOR
SPRING A
SNAP RING 28 mm
SNAP RING 20 mm
Push down on secondary
weight t o ease snap ring
removal.
E-RING 5 mm
Disassemblyllnspectionl Reassembly
NOTE:
Lubricate all parts w i t h ATF during reassembly.
Install thrust needle bearings w i t h unrolled edge of bearing retainer facing washer.
SPACER COLLAR
23 mm
MAINSHAFT
splines for excessive
--
__-
--
THRUST WASHER
36 5 mm
Measurement,
selectron, page 15-35
O-RINGS
19.8 x 1 2 rnm
Replace
THRUST NEEDLE
BEARING
36x52x2rnm
4th GEAR
/
/
THRUST NEEDLE
BEARING
32x44x2mm
inspect tor gailtng
and rough mobernenr
THRUST NEEDLE
BEARING
39x54x2rnrn
MEEDLE
BEARINGS
32 x 38 x 20 rnm
Inspect for gall~ng
WASHER
26ie45x3mm
SNAP RING
26 mrn
Countershaft
NOTE:
NEEDLE BEARING
3 2 x 3 8 ~
14mm
Inspect for galling and
rough movement
VERSE GEAR
SELECTOR HUB
Groove faces
reverse gear
NEEDLE BEARING
28 x 33 x 20 mm
SPACER COLLAR 28 mm
Measurementiselect~ofi,
THRUST NEEDLE
39x54x2mm
lnspect for gall~ng
and rough movement
SPLINED THRUST
WASHER 35 mm
Measurementlselect~on
COUNTERSHAFT
Check splines for excessive wear or damage.
Check bearing surface for scoring, scratches or
excessive wear.
Clearance Measurements
--
I
Remove both the mainshaft and countershaft bearings from the transmission housing.
Assemble the mainshaft and the counrershaft including bearings and ali parts shown below.
lnstall the mainshaft and countershaft assernbiies
into the torque converter housing.
OllE WAY
r
EEDLE BEARING
6BEARING
7
' w 39
1st GEAR
p
+
NEEDLE BEARLNG
3 2 x 3 8 x 4 4 r n m , , ,=,
x 52 x 2 rnm
SPLiNED
SPLiNED
WASHER
{Selective)
{Select~ve)
9Rki.O.P REP&,
RlkG
RC66 mr6l.si
mhl.si
,
p
2
dd
q
&WR
,
$
2
q'NR
REVFRSEGEaR
____
NEEDLE BEARtPJG
32 x 38 x 14 mrn
SELECTOR HUB
r??versC:i j d s
REVERSE GEAR
---
3rd
3rd CLUTCH
CLUTCH
I-
8.
9. Slide the 3rd gear out fully. Measure and record the
clearance between the 2nd and 3rd gears w i t h a
On the countershaft, rrleasure the clearance between the shoulder on the selecior hub and the
shoulder on 4 t h gear.
feeler gauge.
3rd GEAR
SELECTOR HUB
FEELER
GAEJGE
-
SELECTOR
"1J"
--
s,
ii
(Select fit)
4th GEAR
2nd GEAR
SPACER
COLLAR
PUSH
'b
FEELER GAUGE
3rd GEAR
CLASS
PIN
/ 90503-PC9--030
! 90504-PC9-OCiD
C
D
/ 90505-
PC9-000
; 90507-PC9-000
90509-PC9--90B
,
G
90510--PC9-000
T H = ~ ~ I
''\\
2nd GEAR
FEELER
GAUGE
38.97--39.00 mrn
(1.534.- 9.535 in.)
39.02-39.05 rnm
('I ,536-1.537 in.)
39.07-39.1 0 rnm
(1.538-1.539 in.)
THICKNESS
CLASS
39.12-39.15 mrn /
(1.540- - 1 . 5 4 1 in.)
32.1 7-39.20 m m
(1.542--?,543 in.)
39 22-39.25 mm
(1.54.4-1.545 in.)
39.27--39.30 mrn
2.97-3.00 m m
(0.117-0.1 18 in.)
3.02-3.05 rnrn
(0.119-0.120 in.)
3.07-3.10 rnrn
(0.121 -0.1 22 in.)
3.12-3.15 rnrn
(0.123-0.1 24 in.)
3,17-3.20 m m
(0.125-0.1 26 in.)
3.22-3.25 rnm
(0.127-0.1 28 in.)
3.27-3.30 m m
(0.129-0.130 in.)
3.32-3.35 m m
(0.131-0.132 in.)
3.37-3.40 m m
(0.133-0.134 in.) I
Mainshaft Assemblv
LOCK NUT
J
-
I
1st CLUTCH
NEEDLE BEARING
36 x 41 x 18.3 mm
THRUST NEEDLE
THRUST WASHER
biz&++
--
(0.003-0.006in.)
THRUST NEEDLE
BEARING
31 x 4 7 ~ 2 m m
/-----
Id
NEEDLE BEARING
31 x 36 x 18.5 mm
MAINSHAFT
a---- I s t GEAR
SPLINED WASHER
&
26 mm COLLAR
SNAP RlNG 75 mm
@--BALL BEARING
a-
SNAP RING
WASHER
THRUST NEEDLE
BEARING
32x44x2mm
-+--4th GEAR
i
L
NEEDLE BEARINGS
32 x 38 x 20 mm
r-GLASS
-PIN-
(J
--
-I
THICKNE
3.97-4.00 mrn
THRUST NEEDLE
BEARING
39x54x2mm
%'
THRUST WASHER
LJ
2nd14th
CLUTCH
ASSEMBLED MAIMSHAFT
THRUST WASHER
(Selective)
THRUST NEEDLE
BEARING
36x52x2mm
90446 F F 4 - 0 0 0
(0.164-0.165 rn.) I
4.22-4.25 mm
Clutch
NOTE:
@ The 7 s t and 3rd ciiatci.les arc? idenricat except foi'
t h e piston plate Ins"iaiied In the I st c i u ~ c h .
@ To disassemble :he
2nd,4tk1 clutch, use the
special tooi in Step 3 ir: the szi-ne? manner as for
the 1st and 3rd clulc!?as
1.
3.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07GAE-PG40100
SET MERE
2.
DO N O ~ S E T
HERE
(Retainer unstlpported
by spring)
plate.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07GAE-PG40100
CLUTCH SPRING
COMPRESSOR ATTACHMENT
07960-6120108
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
07GAE-PG40200
II
2ndI4th Clutch
@
2ndl4th CLUTCH
\
CLUTCH RETURN SPRING
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07GAE-PG40100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07960-6120100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07GAE-PG40100
C L ~ ~ C
SPRING
H
COMPRESSOR
BOLT ASSEMBLY
07GAE-PG40200
\
CLUTCH RETURN
SPRING
Clutch
I s t Clutch
NOTE: Piston plate is installed in the 1st clutch
CLUTCH
PLATES
O-RING
SNAP RING
125 mrn
CLUTCH
' /
O-RING
110 x 2.2 rnrn
Replace
Clutch
CHECK VALVE
Clean thoroughly with
solvent or carburetor cleaner.
PISTON
CHECK VALVE
Inspect for restriction,
Clean thoroughly with
loose check valve, or
or carburetor cleaner,
rough O-ring groove.
Replace
I
I
END
PLATE
PISTON
SPRING
RETAINER
CLUTGH
DISCS
O-RING
39.8 x 2.2 mm
naplace
Clutch
r(
Disassembly/Inspection (contra
2ndl4th Clutch
CLUTCH DISCS
1~
END PLATE
CLUTCH PLATES
RETURN SPRING
SNAP RING
SNAP RING
1 2 5 rnm
110 x 2 . 2 mm
2 . 2 mm
39.8 x 2 . 2 rnm
SNAP RING
1 2 5 mm
or rough 0 - r ~ n ggroove.
NOTE:
@ The 1st and 3rd clutch assemblies are identical
except installirrg the clutch piston plate in the
Is t clutch.
@ To reassemble the 2ndl4th clutch, use the
special tosi in Step 7 in the same manner as for
the ? s t and 3rd clutches.
1.
2.
O-RING
7 4 0 x 2.2 mnf
3.
SPRING WASHER
(2ndI4th and 3rd ClutthesJ
* 1st ciutch has no spring washer.
4.
f l 0 x 2.2 mm
\
.
CLUTCH
SPRING
WASHER
(2ndi4th and
3rd Clutches)
CLUTCH DRUM
Clutch
P Reassembly (contVd2.--------I
5.
6.
311 The
drun~.
sprii;r; retainer
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
37GAE-PG404 0 0
$NAP RING
--
/"
/'
CLUTCH SPRING
COMPRESSOR
-/
ATTACHMENT
.---
07968-6420100
C L U f Cad SPRING
COMPRESSOR
ASSEMBLY BOLT
7.
8.
CAUTION: 14 either end of the carrapvessar attachment is set aver an area of t h e retainer which is uasupported by t h e spring, the retaincs. m a y be damaged.
CLUTCH SPMEdQ
COMPRESSOR
/ ATTkChiMEFdT
/'"
~JGAE-~a.$c:
ijo
CLUTCH SPRING
COMPRESSOR SET
W7GAE-PG4QQOO
2nd14th Clutch
Assemble the spring compressor on the clutch
drum.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07GAE-PG40100
SNAP RING
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07960-6120100
CLUTCH SPRING
COMPRESSOR
ASSEMBLY BOLT
07GAE-PG40200
@
CLUTCH RETURN
SNAP RING
\
END PLATE
Clutch
Reassembly (esntY1
14. If not within service limit, select a n e w clutch end
plate from the following table.
22551 -PF4-000
22552-PF4-000
22553-PF4-000
22554-PF4-000
22555-PF4-080
22556-PF4-000
22557-PF4-000
22558-PF4-000
22559-PF4-000
,j
1
!
1
2
3
4
5
6
7
8
9
2.3
i 2.4
2.5
2.6
2.7
2.8
! 2.9
mm
mm
n7rn
rnm
mm
mrn
mm
(0.090 in.)
(0.094 in.)
( 0 . 8 9 8 in.)
10.182 in.)
(0.106 in.)
10.1 10 in.)
(0.314 in.)
NUMBER
2ND
dTH
0.50-0.70 m m
0.40-0.60 m m
0.40-020 m m
1
1
(0.020-0.028 in.)
(0.016-0.024 in.)
(0.016-0.024 in.)
1
15. Check the clutch engagement by blowing air into
the oil passage in the clutch drum hub. Remove the
air pressure and check that the clutch releases.
OSHA-APPROVED
CLUTCH ASSEMBLY
30 psi NOZZLE
4.
ATTACHMENT
07947 -6340500
3.
5.
Remove the differential seal from the transmission
housing in the same way.
DRIVER
'\-/
DIFFERENTIAL SEAL
DIFFERENTIAL SEAL
Replace if removed.
ATT~CHMENT
07947 - 6 1 10500
r Replacement
Torque converter housing
1.
4.
rn
ADJUSTABLE BEARING
REMOVER
2 5 - 4 0 mm
07736-A01000A
or
ATTACHMENT
07GAC-PF40210
TORQUE CONVERTER
HOUSlNG
0 7 9 4 7 --6340500
ATTACHMENT
6 2 x 6 8 mm
07746-0010500
ATTACHMENT
6 7 9 4 7 - 6340263
TORQUE CONVERTER
BEARING
flush with housing surface.
3,
OIL GU~DEPLATE
Transmission housing
1.
To remove the mainshaft and countershaft bearings from the transmission housing, expand each
snap ring w i t h snap ring pliers, then push the bearing out by hand.
MAINSHAFT
SNAP RlNG
out.
MAINSHAFT
BEARING
COUNTERSHAFT
COUNTERSHAFT
BEARING
AP
RlNG
PLIERS
INSTALL
Install with
part number out
SNAP' RING
REMOVE
3.
End Cover
- Disassembly/Inspection
I
STEEL
BALL
1st CLUTCH
FEED PlPE
Replace
PIN 1 9 . 8 mm
Sx14mm
OUTER SPRING
19.8 x 1.9 mm
INNER SPRING
3rd CLUTCH
FEED PlPE
Inspect for
damage t o ends.
22.7 x 2.7 mm
26 mm
3 8 mm
1st ACCUMULATOR
COVER
1.
2.
Seat a new O-ring in the groove of the 1st accumulator, and slide the accumulator piston into the right
side transmission cover. lnstall the outer spring,
inner spring, another new O-ring and the accumulator cover, in that order.
3rd CLUTCH-
6.
8 mm SNAP RING
9.
STOP PIN
6 rnm BOLTS
12 N-m (1.2 kg-m, 9 Ib-ft)
REGULATOR
VALVE
Transmission
r Reassembly 9contYd)
6 mrn BOLTS
//
OIL PASSAGE
REGULATOR
CONTROL VALVE
1
OIL PASSAGES
(Steel bals here)
SEALING BOLT
BOWEL PINS
8 x 40 mrn
DOWEL PINS
SERVO SEPARATOR
PLATE
STEEL BALLS
ACCUMULATOR
BOLTS
12 N-rn (1.2 kg-rn, 9 Ib-ftl
VALVE SPRING
SECONDARY
FILTER
NOTE: The ball for the top oil passage has a spring
t o press the ball against the separator plate.
SERVO VALVE
BODY
r Reassembly (cont'd)
19. Put the rollers on each side of the manual valve
stem, then attach the valve t o the lever w i t h the
pin. Secure w i t h the lock pin.
PIN
6 mm BOLTS
WASHER
6 mm BOLTS
12 N - m (5.2 kg-m, 9 Ib-ft)
4th CLUTCH
FEED PIPE
3rd CLUTCH
FEED PlPE
6 mrn BOLT
12 N-rn ( l 2 kg-m,
9 Ib-ftt
MQDULATO~SEPARATOR
PLATE
MODULATOR
VALVE BODY
6 mm BOLTS
I
25. Install the governor valve using new lock plates,
and the three 6 m m bolts.
GOVERNOR
LOCY PLATES
BOLTS
M6 x 1.0 mm, 12 N-m (1.2 kg-m, 9 Ib-ftl
REVERSE GEAR
SELECTOR HUB
REVERSE GEAR
SELECTOR
REVERSE
SHIFT FORK
NEEDLE BEARING
28 x 33 x 20 mm
COUNTERSHAFT
4th GEAR
DISTANCE
LOCK PLATE
65
COUNTERSHAFT
29. lnstall the reverse shift fork over the servo valve
stem. Align the hole in the stem w i t h hole in fork as
shown, and install the boit and new lock plate.
Bend the lock tab against the boit head.
Transmission
r
i
Reassembly (eont'd)
30. Install the countershaft reverse gear,
bearing, and reverse gear collar.
needle
REVERSE GEAR
COLLAR
COUNTERSHAFT
REVERSE GEAR
NEEDLE BEARING
.
-
6 mm BOLT
1 4 x 25mm
DOWEL PIN
RETAINING
BOLT
12 N.m (1.2 kg-m.
9 Ib-ft)
WASHER
REVERSE
1 4 x 25 mm
DOWEL PIN
-_
I
GASKET
STEEL BALL
4.
38. lnstall the spring and then tighten the retaining bolt
w i t h sealed washer.
6 x I .O mm
12 N.m 11.2 kg-m,
9 Ib-ftl
NEEDLE
BEARING
4'
r Reassembly (cont'd)
39. Piace the transmission housing on the torque
converter housing.
42. Install the bolt and new lock plate. Bend the lock
tab against the bolt head.
NEW 'OCK PLATE
BOLT
9 N-m (0.9 kg-m,
SPRING PIN
SPRING
THROTTLE CONTROL
LEVER
TORQUE CONVERTER
HOUSING
PARKING
PARKING LEVER
1//
ARM
THROTTLE CONTROL
BRACKET
6xl.Omm
1 4 N.m (1.4 kg-m. 10 Ib-ft)
'
44" instail the Ist gear eoiiar a n d needle bearing or1 :he
countershaft. instsl! the 26 mrn collar on the
mainshaft.
4 .-l .
45. Install n e w
mainshaft.
?9,8 x
? .3 rnm 8-rifigs
o n rhe
NEEDLE BEARING
32 x 3%x 14 nrn
COUNTERSWAFT
i
'Ist GEAR
COLLAR
REVERSE IDLER
BEARING
this h o i ~ ,
I
@
I
46. install t h e countershaft 1st gear and parking gear
on the countershait.
.-----
FAWKSKG GEAR
gear.
Transmission
rI Reassembly (cant'd)
/
BARKING PAWL
RELEASE SPRING
COUNTERSHAFT
LOCKNUT
23 x 1.25 mm
140
0 140 N.m
(14.0 0
14.0 kg-m,
102
0 1Q2Ib-ft)
Replace
+
-.
wRErH
1st CLUTCH
SOCKET WRENCH
22 rnm
THRUST WASHER
26 rnrn
THRUST NEEDLE BEARING
3lx47x2rnm
1st GEAR
NEEDLE BEARING
31 x 36 x 18.5 rnrn
THRUST WASHER
-*
LOCKNUT 19 mm
95
0 -. 95 N-m (9.5 -. 0
70
0
70 Ib-ft)
Replace
-+
9.5 kg-rn,
56. Stake the locknut flange into the groove in the 1st
clutch.
Transmission
Reassembly (cont'd)
5 7 , Install the gasket, dowel pins, and O-rings on the
transmission hous~ng.
BANJO BOLT
2 9 N.m ( 2 . 9 kg-m, 2 1 Ib-ft)
COOLER HOSE FITTING
2 9 N-m ( 2 . 9 kg-m, 2 1 Ib-ftl
DOWEL PIN
GASKET
DOWEL PIN
TRANSMISSION
OIL COOLER PIPE
Torque Converter
Transmission
Installation
I
TRANSMISSION
1 0 x 1.25 mm
3 9 N.m ( 3 . 9 kg-m, 2 8 Ib-ft)
6 x 1 .O mm
1 2 N-m (1.2 kg-m, 9 Ib-ft)
O-RING
3 2 x 1.9 mm
Replace
0
1 0 x 1 . 2 5 mm
3 9 N.m
( 3 . 9 kg-m, 2 8 Ib-ftl
c-
DRIVE PLATE
Inspect for cracks
RING GEAR
7 5 N.m
( 7 . 5 kg-m,
5 4 Ib-ft)
1
i
@
\
TAB
GblP
8 x 1.25 rnm
31 N m (3.1kg-rn, 22 ib-b'r)
I
6
1
12 x 9.25 mrn
75 M o r n ( 7 . 5 kg-rn. 64 Ib-ftt
SE-6 cE-IB":~
2 2 . i r i ~ I ~i ?: i~ ; - , wheels,
t
lower car to ground, and
"trqilc ilLq?A to 1 10 h1.m ( 1 1 .0 kg-m, 80 Ib-ft).
iI
I
I
30. Start engine, set parking brake, and shift transmission through all gears three times. Check for proper
shift cable adjustment (page 15-71).
31. Let englne reach operating temperature w i t h transmission In Neutral or Park, then turn it off and
check f l u ~ dlevel
32. Install throttle control cable and adjust.
33. Road test as descr~bedon page 15-6.
Replacement (esnt'd)
4.
rn
6
Transmission housing
1.
/
1
,
ADJUSTABLE BEARING
REMOVER
25-40 mm
07736-A0100OA
or:
COUNTERSHAFT
NEEDLE BEARING
Replace w ~ t hn e w
bear~ngrf removed.
ATTACHMENT
0 3 9 3 6 - 6 8 9 0 4 01
5.
ATTACHMENT
52 x 55
07746-00 10400
DRIVER
07749-0010800
MAINSHAFT BEARING
(60 rnrn snap ring)
3.
On the torque converter housing, install the differential 80 mrn snap ring if removed.
2.
SNAP RING
80mrn
5.
Install the differential seals into the torque converter housing and transmission housing.
DRIVER
ATTACHMENT
07947-6340201
DIFFERENTIAL
SEAL
Replace i f removed
ATTACHMENT
07947-61 10560
TORQUE CONVERTER
BEARING
End Cover
Disassembly/lnspeclion
CAUTION: Remove and instaii parts carefully to avoid
1S t CLUTCH
SNAP RING
38mm
+
-
END COVER
Inspec? for cracks,
grooving, scorivg.
Blow o u t all passages.
1.
2.
3.
4.
1st Accumulator
DisassemblylBnspe6tion
@
@
The 1st accumulator can be removed with the end cover installed.
See Section 3 for spring specifications.
OW1 FlCE B O L T
N,rn (1.8 kg-m, "12b-ft)
a$
I.
2.
3.
O-RINGS
8.5 x '3.9 mm
ACCUMULATOR
BOLT
12 fx4.A ( I . ? kg-m, 53 Lbbal
Transmission Assy
NOTE: Lubricate all parts w i t h ATF during
reassembly.
1.
2.
I I
SUCTION PIPE
FlLTER SCREEN
All way replace
MANUAL
VALVE
@ONTW& SHAFT
LEVER
CONTROL SHAFT
Transmission Assy
,-=
Reassembly (cont'd)
7 . Tighten the 4 vaive body bolts in the sequzfice
shown. Make sure the pump drive gear rotates
smoothly in the normal operating direction and
the pump shaft moves smoothly in both the axial
and normal operating directions.
STOP PIN
STATOR
SHAFT ARM
D O W ~ LPINS 8 x 14 rnm
13.instali the
TOP O I L PASSAGE
NOTE: The ball for the top oil passage has a spring
to press the ball against the separator plate.
12. Install the separator plate and dowel pins.
DOWEL PINS
PIN
8 x, 14 mm
\'
2
I
WASHER
COTTER PIN
Transmission Assy
r Reassembly (contld)
1 5 , lnstall the throttle control shaft and E-c11p.
16. install t h e o ~pass
i
pipes ( 8 x 50 rnm and 8 x 29.5
mml.
3 7 . lnstalt t h e clutch pressure control valve bady,
b o d y cover and separator piate a n t h e servo
body.
18. Install t h e clutch pressure control valve body
bolts a n d torque to 4 2 N-m (4.2kg-m, 9 ib-ftl.
LOCKUP SHIFT
VALVE BODY
EPARATOR PLATE
E-CLIP
STEEL BALL
CLUTCH PRESSURE
CONTROL VALVE BODY
cross pattern.
GOVERNOR
I
JMU LATO W
Transmission Assy
Reassembly (esnt'd)
29. Install 4th gear and i t s needle bearing, and the
countershaft 4th gear and its selector hub.
REVERSE GEAR
COLLAR
COUNTERSHAFT
REVERSE GEAR
NEEDLE BEARING
REVERSE GEAR
SELECTOR HUB
REVERSE GEAR
SELECTOR
REVERSE
SHIFT FORK
NEEDLE BEARING28 x 33 x 20 mrn
COUNTERSHAFT
4th GEAR
LOCK PLATE
33. Install the new gasket and three dowel pins in the
torque converter housing.
14 x 2 5 m m
DOWEL PIN
1 4 x 20 rnm
DOWE! PIN
31. install the reverse shift fork over the servo valve
stern. Align the hole in the stem with hole in fork
as shown, and install the bolt and new lock plate.
Bend the lock tab against the bolt head.
--/
14 x 25 mrn
DOWEL PIN
GASKET
/h/
Chmferpad end
Transmission Assy
r Reassembly (cont'd)
44. instaii the pariting shiit arm and spring on the shift
shaft with the bolt and a new lock plate. Bend the
lock tab against the bolt head.
NOTE: The spring should put clockwise tension on
the shift arm, forcing it against the stop pin.
PARKING LEVER
Flat pad faces
closed end of
shift
PARKING
SHIFT A R M
6 x 1.0mm
14 Narn (1.4 kg-m, 10 Ib-ft)
43. lnstall the bolt and new lock plate, Bend the lock
46. lnstall new 19.8 x 1.9 mm O-rings on the mainshaft.
NEEDLE BEARING
3Ox35xllmrn
COUNTERSHAFT
19.8 x 1.9 mm
i
I
/
SPRING
'
THROTTLE CONTROL
LEVER
1st GEAR
COLLAR
COLLAR
26 rnm
REVERSE iDLER
BEARING
30 m m SOCKET WRENCH
07907-6890188
PARKING GEAR
COUNTERSHAFT
PARKING PAWL
RELEASE SPRING
COUNTERSHAFT LOCKNUT
95+0+95 N - m (9.5-+0--99.5kg-m,
70+0470 Ib-ft)
Replace
PARKING PAWL
STOP PIN
NOTE:
One end of the parking pawl release spring fits
into the hole in the parking pawl, the other end
into the hole in the transmission howsing as
shown.
@ The release spring should put clockwise tension
on the pawl, forcing it away from the parking
gear.
@
Transmission Assy
Reassembly (cont'd)
52. lnstall 31 x 36 x 18.5 mm needle bearing and thrust
washer on the mainshaft.
53. lnstall 1st gear, thrust needle bearing, and the
thrust washer on the mainshaft.
THRUST WASHER
26 mm
THRUST NEEDLE
BEARING
31 x 37 x 7: mm
SOCKET WRENCH
22 mrn
LOCKNUT 19 mm
95-0-95
N-m (9.5+0-9.5
70-0-70
Ib-ft)
Replace
kg-m.
57. Stake the locknut flange into the groove in the 1st
clutch.
Torque Converter
Disassembly
58. Install the gasket. dowel pins, and O-rings on the
transmission housing.
59. lnstall the end cover and torque all bolts (9)to 12
N.m (1.2 kg-m, 3 Ib-ft).
O-RING
32 x 1.9 mm
Replace
R I N G GEAR
D R I V E PLATE
Inspect f o r cracks
BANJO FITTING
BAN30 BO L T
HOSE F l T T l N G
cross pattern
1 2 x 1.25mm
75 N.rn
54 Ib-("t)
6 x 1.0 mm
12 N.m
( 1.2 kg-rn, 9 Ib-h)
Transmission
Installation
1 Attach shift cable to shift arm with pin, then secure
cable to edge of hous~ngwith cable holder and
bolts, 12 N,m (1.2 kg-m, 9 Ib-ft).
O-RING
3 2 x 1.9 rnrn
Replace
8. Fit the left axle into the differential as you raise the
transmission up to the engine.
t
D R I V E PLATE
Inspect for cracks.
12 x 1.0 rnm
7 5 N.m
(7.5 kg-m,
54 Ib-ft)
10 x 1.25 mm
39 N.n (3.9 kg-m, 2 8 Ib-ft)
11. lnsrall the front transmission mount bolts and torque to 39 N.m (3.9 kg-m, 28 Ib-ft).
FRONT TRANSMISSION
MOUNT
8 x 1.25 mrn
3 1 N.m (3.3kg-m, 22 Ib-ftl
TRANSMlSSlQlU
10 x 1.25 mm
39 N.m (3.9 kg-m, 28 Ib-ft)
rnm
65 N.rn (6.5 kg-m, 46 ~b-fa\,,
c 1.25
31
6:; descr~bedan
pege 15-78.
INHIBITER SWITCH
[RI
Wire color
View from
v~irrside
Black1
White
Blacki
White
1.
2.
\
White
Yeilevv
Wire color
7
-
03
D4
GND
Green/
Yellow
' O
To-~'o-~
L
P
-
1
----L
i
I
___1-
Gr~eniI
Blue
,
-I-
Greanl
Black
Green
-----+
White
t-7
'
'
A G T U A ~ O RPIN
i
I
(2
___t-----
; ; i
'
, b !
Creend
1
,
1
,
----?------C--
'
3.
Gearshift SeBectar
4 x ti mtm SCREW
* Apply non-harden~ngthread
s~>alant
SELECTOR LEVER
15-132
Shift Cable
-- Adjustment
7.
4.
CONSOLE
SHIFT GABLE
Cable
Too Short:
Cable
Too Long
Exact
Alignment
1
SHIFT LEVER
(In D, or 0 4 )
LOCK BIN
6.
7.
II
I
SWIFT CABLE
QBGK NUT
Adjustment
1.
2.
3.
4.
5.
Tolerance Factor:
T H R O T T L E CONTROL
CABLE BRACKET
1.
2.
3,
&ITTHROTTLEGAUGE
4.
Remove the
air intake hose.
/-
LOCK
6.
.-
mm (3.346-
6-3.366 in.)CABLE E N D
R O T T L E CONTROL
BLE BRACKET
CONTROL LEVER
LOCKNUT '@
,
7.
8.
Differential
illustrated Index ............................... 1 6 - 2
lnspection1Disassembly .................... 1 6 - 5
Reassembly .................................... 1 6 - 6
Installation ...................................... 1 6 - 8
----.,-------.--.----------.--
----
CLUTCH HOUSlNG
Removal, Section 14.
i n s ~ i i l i a t i o n ,Section 1 4
SNAP WfNG, 80 mm
Seicst,on, T 6-40
R e n o v s i , Section lib.
lnstallat:on, Section 'i4.
SEAL
Replacement.
Section 14.
*,
CARRIER
R ~ N GGEAR
riemok;lI, page 7 9-5
i;?s:aiiat:on. pege 16-7
weir
~ for
D excessive
~ c ~
BALL BEARING
Replacement, page 16-4
Inspect for faulty m o v e m e n t
Differential
r!
1
i
I!
1
DIAL INDICATOR
Bearing Replacement -
I/
NOTE Check bearings for we;.? and rough rotation if bearinds ar? CK, removal IS n o t necessdrv
7.
BEARiNG PULLER
Ii
i
f
2.
Iristall n e w bearings.
DRIVER
07746-8030100
II
inspection1Disassembly
1.
3.
.
-
RING GEAR
2.
A u t o m a t i c Only:
Pry snap ring o f f carrier, then remove speedometer
drive gear and d o w e l pin.
4.
PINION SHAFT
Inspect for scoring
and burrs.
PINION GEARS
SNAP RING
5.
16-5
Differential
1.
CAUTION: Coat all gears with molybdenum disulfide grease on all sides.
3.
4.
2.
holes
SHAFT
SIDE GEARS
pin
Thrust Washers
I
11
PART NUMBER
THICKNESS
41 3 5 i - 6 8 9 - 0 0 0
41 355-PC8-000
41 3 5 2 - 6 8 9 0 0 0
41 356 PC8-000
41353-689-000
41357-PC$-000
41354--689-000
0 7 ( 0 028 in)
0 75 ( 0 029 in)
0 8 ( 0 031 in!
0 85 ( 0 032 in)
0 . 9 (0.035 i n )
0.95 (0.036 in)
1 . 0 10.039 in)
1
1
j
I
I
1
1
PINION GEAR
I
I
THRUST WASHER
7.
A u t o m a t i c Only:
Install speedometer drive gear w i t h i t s chamfer ( o n
inside diameter) facing carrler and secure w i t h snaw
ring.
9.
Manual
SNAP RING
carrier.
8.
A u t o m a t i c Only:
Align snap ring or: carrier as s h o w n .
DOWEL PIN 5 x 10 m m
Automatic
Chamfer on inside diameter
of ring gear faces carrier.
+i----END GAP
SNAP RlNG
\k
,-
Differential
Installation
1.
Automatic Only:
Install 80 m m snap ring in clutch/torque converter
housing. Do not install oil seal yet.
3.
!nstall all transmission gear assemblies in clulchitorque converter housing. Refer t o Section 14
(Manual) or Section 15 (Automatic).
4.
Manual Only:
Shift transmission into 3rd gear t o position shift
guide shaft for reassembly.
5.
Place new gasket on clutch:torque converter housing and install both dowel pins, then carefully lower
the transmission housing into place.
TRANSMISSION HOUSING
HOUSING
2.
Install differential assembly in clutch torque converter housing using driver. Tap on differential w i t h
driver and attachment t o seat the snap ring in
clutch/ torque converter housing.
DOWEL PIN
6.
DRIVER
07749-0010000
DIFFERENTIAL ASSV.
ATTACHMENT E
07947-6340500
CLUTCHlTORQUE
CONVERTER MOUSING
GASKET
DOWEL PIN
Manual Only:
Bolt housings together and torque all thirteen bolts
to 27 Nam (2.7 kg-m, 20 Ib-ft) in sequence shown.
7.
Automatic Only:
(Carbureted Engine)
Torque bolts t o 27 IV-rn (2.7
kg-n?, 20 Ib-lt! i n order
in t w o or more steps.
(Fuel-Injected Engine)
Torque bolts tc 45 N - m (4,E kg-rn, 33 lb-f?) i n order
i n t w o or more steps.
9.
THROTTLE
CONTROL BRACKET
DRIVER
07749--0010000
8.
Manual Only
Install 80 mrn snap rltig ~n xrsrsrnts.,vn
housing
80 mm SNAP RING
Installation (csnt'd)
10. Measure clearance between snap ring and outer
race of bearing in transmission housing (Manual),
or torque converter housing (Automatic].
SNAP RING
07749-0010000
TRANSMISSION
HOUSING
(Manual)
Part Number
90414-PC8-000
9041 5-PC8-000
90416-PC8-000
90417-PC8-000
90418-PC8-000
'
,
1
i
Thickness
2 50
2.60
2.70
2.80
2.90
mm
mm
mm
mm
mm
(0.098 in.)
(0.102 In.)
( 0 106 in.)
(0.110 In.)
( 0 . 114 in.)
Automatic only:
Thickness
1
I
Driveshafts
Removal ........................
.
........... 17-2
Disassembly/lnspection .................. 17-3
Reassembly ............................
.
.
.. 17-4
I.
i-oosri~the
12.
fit.js?C
vvki;i~i
!l;ij D u t y
6.
KNUCKLE
20i.
5.
8,
C i i JGINT
SCREWDRIVER
CAUTION :
@
r Reassembly
1.
2.
Install the rollers and bearing races on the spider shafts, then slide the spider assembly into the inboard shaft joint
CAUTION : Avoid getting oil or grease on the rubber parts.
Slide the boots lritu pldce and lnstaii Ilew novt bands C on
SNAP R l N G
BOOT B A N D B
Bend both sets
BOOT B A N D A
Bend b o t h sets
o f locktng tabs.
OUTBOARD CV J O I N T
Pack cavltv w > t bgrease
4.
6.
I
CAUTION :
@
L E F T DRlVE SHAFT
Carburated Engine.
MiT: 800-804.5
AIT: 809-813.5
Fuel Injected Engine
MIT: 805-809.5
AlT 812-816 5
*
mm 131.5-31.7 in.)
mrn 131.6-32.0 in.)
mm 131.7-31.9 in.)
mm 132.0-32 1 in.)
-i
RIGHT DRIVESHAFT
-t
Carburated Enaine
514-518.5 mm 120.2-20.4 in.)
Fuel Injected Engine
506-510.5 mrn 119.9-20.1 in.)
GROOVE
7.
5.
NOTE
Be sure to bend both sets of the locking tabs.
Lightly tap on the doubled-over portions to
reduce therr height.
*
*
CAUTION:
L O C K I N G TABS
Power Steering
index .............................................19-2
Troksbleshsstirsg .............................W-3
Maintenance ................................."B-8
Steering hlheel ..............................19-1 2
Coi;umn ........................................19-1 3
Pump ...........................................1 9-1 8
Gearbox .=......a.e............................1 9-26
Operation ......................................19-49
Power Steering
Troubleshooting
Check the 6oilow:ng before y o u begin
@
@
Bt
@
@
@
Was the suspension been modified in a %ay that would affect steering?
Are tire sizes and air pressure as specified:
i s the steering wheei original equipment or equivaient?
I s the power steering pump beit properly adjusted?
Is steering fldid reservoir liiied to proper level?
i s ?he engine idle speed correct and steady?
Hard steering
I
-L
I
_
.
_
.
.
.
_
/L
I
i
Low or n o assist in one directi*mor car steers in one direr,tion by itself ( a difference of
up ro 4.9 N (0.5 kg, 1.4 Ibs)
botvveei~right and left t u r n e f fort i?aea:ured with a spring
scaie.
-
..
I------------
,.---
-.
- -_A
--
----
, _
I
'
I
---
--
----
19-25).
'
--.
- -- -1
(80-90
1
-
1
1
,
1
Troubleshooting
General (cont'dl
Belt slipping on pulley.
Adjust belt tension. Replace belt
if necessary (page 79-81.
I I
k-d
I I'
Uneven or rough steering.
---i
it
as
necessary
(page
__1__1
--
I
I
adjust
belt
H
Wheel w i l l n o t return smoothly.
-I,
guide;
ti
Troubleshooting
i
1 1
i
I
) 1
Lines
touch.
OF
1-
Humming
I
i
then compare.
-)
I
Grating noise
Squeaking
(cavitation
Horn
or under too much pressure;
grease the contact, or bend
i t to reduce the pressure.
'
II
off.
fluid.)
o
ri
, !
1
chattering
/
I
'I
for
r crushed
~
x suction
c
k
- Fluid Leaks
Leaking from cylinder end seal
into tie-rod boots; replace
/
Steering gearbox
I L e a k i n g f r ~ mtop (gearbox f a c e ) T
or either side of valve body;
replace all control unit seais and
O-rings,
replace
it
{+
pump
/
/
Speed sensor
[
j
Reservoir
- -1
I!
1I
II
Maintenance
1.
1.
I
14 mm WRENCH
10 mm FLANGE BOLT
(PIVOT BOLT)
39 N.m
39 N-m
(3.9kg-m, 28 ft-lb)
2.
LQCKNUT WRENCH 46 mm
8791 6-SA50001
Om-Car Check
Measure the pump belt tension by pushing on it 7 5 rnm
( 2 . 9 5 in) from the center of the pump pulley w i t h a
force of about 1 0 0 N ( 1 0 kg, 2 2 Ibs).
Pump belt should deflect about 14-17
0 . 6 7 in).
2.
m m (0.55--
3.
ANKSHAFT PULLEY
On-Car Checks
Fluid Replacement
Check the fluid pressure as follows t o determine whether the trouble is in the pump or gearbox.
3.
2. Start the engine, let it run at idle, and turn the steerNOTE: I f p o w e r steering gauge ( 0 7 4 0 6 0 0 1 0 0 0 0 ) is used, the pressure control valve
( 0 7 4 0 6 - 0 0 7 03001 and pressure gauge ( 0 7 4 0 6 0 0 1 0 4 0 0 ) must be installed as shown.
\
HOSE JOlNT ADAPTOR
OUTLET HOSE
SHUT-OFF VALVE
PRESSURE GAUGE
07406.-0016400
CONTROL VALVE
10300
3.
4.
5. Start the engine and run it at fast idle, then turn the
steering from lock-to-lock several times t o bleed air
from the system.
1.
8.
9.
VALVE
tension.
SPEEDOMETER CABLE
2. Start the engine, let it warm up t o normal temperature, and turn the steering wheel lock-to-lock a f e w
times t o warm up the fluid.
4.
2.
3.
4.
Steering Wheel
Carbureted Model
1
2
3
4
SLIP R I N G
STEERlNG SHAFT N U T
5 0 N . m 15.0 kg-m. 36 Ib-ft)
STEERING WHEEL
H O R N COVER
CENTER PAD
1.
2.
3.
4.
5.
6.
7.
8.
STEERING WHEEL
I
I
UPPER C O L U M N B R A C
LOWER C O L U M N B R A C K E T
C O L U M N LOWER
PANEL
S T E E P I N G JOINT B O L T
LOWER COVER
TRIM
S T E E R I N G J O l N T COVER
/*
Column
- DisassemblyIlnspectisn
C A U T I O N : Do not drop the steering shaft; the impact may break the shear pins.
1.
2.
3.
4.
5.
6.
Remove the
Remove the
Remove the
Remove the
Remove the
Remove the
CAUTION
: Don? disassembie the tilt mechanism and steering shaft from the column assembly.
TENSION
ADJUSTlNG
BOLT
C h e c k f o r wear or damage
T I L T LOCK L E V E R
C h e c k t o r b e n d ~ n gor damage.
GUARD
"U" P L A T E
C h e c k f o r damage.
T U R N SIGNAL
CANCEL KEY
LOCKNUT
STEEL B A L L
UPPER C O L U M N C O V E R
C O L U M N ASSEMBLV
L I G H T I T U R N SIGNAL
D I M M E R SWITCH
SLIDE PLATE
C h e c k f o r damage
Column
I
I
Reassembly (csnt'd)
9.
TENSION BOLT
UPPER COLUMN
COVER
GUARD
II
4
LOCK LEVER
BRACKET
LOWER
COLUMN
COVER
LEVER STOP
"U" PLATE
LOCKNUT
43 N.m (4.3 kg-m, 31 Ib-ft)
TENSION
ADJUSTING
BOLT
PLATE
'
1. Siip he upper ilonger) end of the jolnt onio the bottom end of the steering shaft, so its bolt hole lines up w i t h the
f i a r part of the shaft.
2. Siip the lower end of the joint onto the pinion shaft (line up its bolt hole with the groove around the shaft), install
?he bottom bolt.
3. Make sure that the sliding plates are in place, then hold the column in position while you loosely attach its upper
bracket to the mounting studs.
4. Loosely insta!l the lower bracket.
5 . Puii up the column to be sure the mounting hole ends of the upper mount are seated against the mounting studs,
then torque the upper mount nuts to 13 N.m (1.3 kg-m, 9 Ib-ft).
6 , 'Toraue the !ower bracket bolts to 22 M,m (2.2 kg-m, 16 Ib-ft).
7. Reconnect the wire harness connectors.
8. Pvil down on the column joint, then tighten top joint bolt and bottom bolt to 23 N,m (2.3 kg-rn, 16 Ib-ft).
9 . Instali the steering jo~nt.cover.
10. lnstaii the column lower panel, !ower cover trim and the coin pocket.
T 4 Install the steering wheel.
MOUNTING STUD
UPPER B R A C K E T
UPPER C O L U M N BRACKE
LOWER COLUMN B R A C K E T
8 x 1 . 2 5 mm
13 N.m (1.3 kg-m, 9 Ib-ft)
STEERING
JOINT COVER
8 x 1.25 mm
22 N m (2.2 kg-m, 96 Ib-it)
Pump
--
Inspection
Use only STEERING GREASE
CAUTION: Pump cornpasenas are made zst aluminum. Bo carefa! not t o damage them when servicing.
Replace ail O-rings i f i d seals Do not dip new 0-rlrrgs and seals in sotderl:, cost 9-rings with steering grease
and makt. %re t h e y s t - 3 ~n place duflng resssen3bly
before 11;staIi~tt31?,
The shaded parts are seie-,:~vei.d trpted, and should not be d~sasscn?biedexcept t o replace seais. if any one of
t h e w IS faillty, replace the whole pump as a r assef-nbly.
9 PORT H814SBNG
Check tor d a m a g e ic
seal~ngface
YOUSING SEAL
,
G . . . .
,-.*:-
VILIWlt' R W W 3 . l i V U
DRIVEN GEAR
Check tor damage
DRFVE GEAR
lNkET FITTING
Checlc tor darnage
t o si:all~ifl face.
e mnn
PI-AIYU~I. BWL I
8 n l n ~FLANGE BOLT
12 N-ne { I .2 kg-rn, 9 Ib-fc)
Replace.
PULLEY e m f
(Left hand threads)
33 [\%em(3.3kg-m,
24 Ib-ftl
1.
2.
3.
(7.1 kg-m,
8 Ib-at)
b
'
r
I
\
\
'\-
39 N.rn
(3.9 kg-rn. 28 Ib-ft)
4.
8.
Start the engine and let it run a t fast idle while turni n g the steering wheel lock-to-lock several times t o
bleed air from the system.
39 N-m
(3.9 kg-rn.
28 Ib-ft)
Replace.
Preload Inspection
Pump
Pulley Replacement
I
1.
1.
PORT HOUSING
12 N.m
(1.2 kg-m, 9 ib-ft)
UNIVERSAL HOLDER
I
2.
3.
f6
Check
damage to edges
~DENVIFICAT~ON
MARK
' Part2mber ,
Mark
Part Namo
--i_
Without
1 56360-PC1
mark
-010
'ONTRoL
VALVE
,
''
16 000-16 0 0 6
( 0 6 2 9 9 - 0 6302)
Pump
Control Valve Inspection and Replacement (csntrd)
i6.
HOSE
9.5 mm 814 (0.374 in)
(The power steering
return hose is
recommended .)
SEAT
13 N-rn
(1.3 kg-m,
9 Ib-ft)
RELIEF VALVE
if used.
\
CONTROL VALVE
CONTROL VALVE
Clamp this end in
a vise with soft jaws
RELIEF VALVE
SPRING
10. Clean all the parts in solvent, dry them off, then reassemble and re-test the valve.
NOTE: If necessary, relief pressure is adjusted at
the factory by adding shims under the check ball
seat. If you found shims in your valve, be sure y o u
reinstall as many as you took out.
POWER STEERING
FLUID or SOLVENT
Resealing
CAUTOORI: The pump components are made of
aluminum, be casefull not to damage them when
servicing.
1.
7.
20).
2.
3.
DRIWE GEAR
4.
PORT
6.
HOUSlNG
SEAL
PUMP HOUSING
8.
9.
Reassembling Qesnt'd)
HOUSING SEAL
PORT
8 x 10 mm DOWEL PINS
16. Grease the new plunger seal and install it over the
plungers.
17. lnstall the dowel pins.
18. Fill the groove of the pump housing w i t h grease and
install the new housing seal in the pump housing.
19. Grease the n e w O-ring and install it in the pump
housing.
20. lnstall the pump front cover w i t h the five 6 m m
bolts and tighten them in the order shown below.
21. lnstall the inlet fitting.
8 x 10mm
DOWEL PtNS
INLET
FITTING
1
12 N-rn
(1.2 kg-m, 9 Ib-ft)
PLUNGER
SEAL
22. Loosely install the new oil seal in the pump front
cover.
Gearbox
@
Before disassembling the gearbox, wash i t off with solvent and a brush.
Do not dip seals and O-rings in solvent; coat O-rings with grease, and make sure they stay in position during
reassembly.
The shaded parts (valve body, control valve, cut-off valve) are a matched set; if any of them are faulty, replace
all of them.
@
ST EERlNG GREASE
RACK BUSHING
Inspect for damage
CYLINDER SPRING
CYLINDER
Inspect Inner wall
CYLINDER END
SEAL
Replace (White)
6 x 1.0 x 60 mm
PINION HOLDER
CIRCLlP 15 mm
ClRCLlP 32 mm
V A L V E BODY
CAP
PRESS-ON TYPE:
B A L L JOINT BOOT
I
\
TIE-ROD E N D
AIR-BLEEDING
CLlP G U I D E B
BOLT
07974-SA50800
07974-6790000
T I E - R O D SEAL D R I V E R
Gearbox
2.
3.
4.
7.
6 x 1.0 x 60 mm BOLTS
D:
T:
From pump
To speed sensor
To reservoir thru speed sensor
To reservoir thru cooler
14 n~rriwrench
12 m m wrench
12 m m wrench
17 m m wrench
V A L V E BODY
8.
5.
CAP
V A L V E BODY
CAP SEAL
Replace.
CONTROL U N I T
ORIFICE A & B
x 18 mm BOLTS
' 1
SPRING
49.5 mm O - R I N G
Replace
CUT-OFF V A L V E
V A L V E BODY
CAP
,
9. Remove the cap seal from the valve body cap.
10. Remove the cut-off valve and spring from the valve
body .
PORT HOUSING
Inspect ~ t surface
s
for scoring or scratches.
Slip it back into the valve body, and make sure it
slides smoothly without drag and side play.
NOTE:
The cut-off valbe I S s~zedto fit the valve body,
so, ;f you replace it, make sure the new valve
has the same identification mark on it.
@ If the valve body IS damaged, replace all three
parts (valve body, cut-off valve and control valve)
as a set.
!
V A L V E BODY
12. Remove the seal and dowel pins from the valve port
housing.
SEAL
V A L V E PORT
Replace
CUT.OFF V A L V E
lDEMTlFlCATlON MARK
D O W E L PINS
CONTROL
VALVE
l'i mm O - R I N G
Replace
1 ldenfificaOutside diameter
tlon mark
lo
000--10.005 mm
( 0 3937-0.3939 in.)
Part number
4
53650-SA5-9500
Gearbox
r
I
h O T E h h e n rernouing the rollers, hold the plungf i i i g ~ r sto keep them from popplng
ers b ~ ~ your
i h
ROLLER
ROLLER
PLUNGERS
Check for scoring or
scrntches, and rough
PORT H O U S I N G
SlDE
CONTROL V A L V E
CAP SIDE
CONTROL V A L V E
V A L V E B O D Y , C O N T R O L V A L V E , PLUNGERS and
R E L A T E D PARTS
PLUNGERS
Check for scortng or
scrsiches, and rough
sliding.
V A L V E BODY
,/
CONTROL V A L V E
I
ROLLER
1 1 rnm 0 R I N G
Ren,d~c
Repl~ce
SENSOR ORIFICE
NOTE
e The control valve 1s s~zedto frt the v a l v e body,
so, if you repldce ~ t make
,
sure the new valve has
the same identif~cationmark on rt
@
V A L V E BODY
V A L V E BODY
3 rnm 1118") B R I L L B I T
19. Using a 7.5 m m (1; 16") drill bit, push the damping
orrfice and 3.4 m m O-ring out of the valve body.
CAUTION : Grind the shank end of the drill bit flat
before using.
DAMPING ORIFICE
CONTROL V A L V E
Check for smooth
operation
Grind f l a t
IDENTlFlCATlON MARK
-r
O.D.
1I ltlon
dentfica
mark
Ovtrd~
ddrneirr
Par? number
3 4 m m O RlNG
Firpi 3t e
i
1 5 rnm D R I L L B I T
Gearbox
3.
CAP
R E T U R Y SPRINGS
DAMPING ORIFICE
CUT-OFF V A L V E
VALVE
SENSOR ORIFICE
O-RING I 1 mmm
PORT HOUSING
4.
8. Connect
P:
S:
D:
T:
From pump
To speed sensor
To reservoir thru speed sensor
To reservoir thru cooler
14 mrn wrench
12 mm
12 mm
17 mrn
5.
6.
22 N.m
37 N-m
(2.2 kg-m, 16 lb-tt) (3.7 kg-m, 27 Ib-ft
10. Make sure there are no fluid leaks, then install the
shield.
11. Recheck the fluid level in the reservoir.
CONTROL UNIT
7.
Gearbox
1
CONTROL CABLE
I
TOP BOLT
8 x 125mm
22 N m ( 2 2 kg m
B O T T O M BOLT
8 x 125mm
22 N m ( 2 2 k g m,
SHAFT
CONTROL CABLE H O L D E R
3.
19-9.
4.
6.
7,
CASTLE N U T
44 N , m ( 4 . 4 k$.m, 32 lb-ftl
SELF-LOCKING N U T S Replace
50 N , m (5.0 kg-m, 36 Ib-ft)
(cont'd)
MOUNTING B R A C K E T
JOINT N U T S
22 P4.m (2.2kg-n?, 16 ib-ft;
97 rnm W R E N C H
12 mrn W ~ E N C W 44 rn;
WRENCH
Gearbox
-----
.-.---
Resealing
I.
2.
5.
", /
b"@
3.
SNAP R I N G 32
Woid ?hr; r x k with a 19 rnm wrench, and unscrew the tie-rods with another 19 mrn wrench
n?13
6.
7.
R I G H T END OF 8 A G K
4.
R A C K G U I D E LOCKNUT W R E N C H
07976--SA50001
ti!E
8.
GEARBOX
CYLINDER
CYLINDER
E N D SEAL (BLACK)
9.
CYLINDER BARREL
GEAR HOUSING
STEERING
RACK
C Y L I N D E R CAP
SEAL
RETAINER
CYLINDER
BARREL
Gearbox
Resealing (esntYd)
12. Remove the retainer washer from the gear housing
O - R I N G 46.5 rnrn
GEAR HOUSING
Replace
SNAP R I N G 31 rnrn
R E T A I N E R WASHER
P I N I O N I-iOLDER
14. Remove the bolts, ?hen remove the pinion dust seai
retainer from the gear housing. Remove the dust
seal and 46 mm O-ring from the retainer.
Remove the pinion holder from the gear housing.
P I N I O N DUST SEAL
P I N I O N HOLDER
Repiace
O-RING 46 mm-Replace
I
G E A R HOUSING
GEAR HOUSING
I
ATTACHMENT
42 x 47 mm
07746-0010300
DRIVER
PINION UPPER
BEARiNG
NEEDLE ROLLER
BEARING
GEAR HOUSING
NEEDLE ROLLER
BEARING
/
PINION HOLDER
(cont'd)
Gearbox
I- Resealing (cantYd)
@
SNAP R I N G 31 mm
24.5 mrn
CYLINDER CAP
PINION HOLDER
C Y L l N D E R BARREL
SEAL R E T A I N E R
C Y L I N D ~ REND
SEAL ( W H I T E )
RACK
20. Carefully pry the piston ring and the O-ring under
PISTON RING
I
PISTON R I N G
PISTON R I N G
f a c ~ n gout.
I
23. Coat the piston ring and the inside of the sizing tool
with power steering fluid.
Carefully slide the tool onto the rack and over the
piston ring, then rotate the tool as you move it up
and down to seat the piston ring.
RACK
Gearbox
Resealing (eont'd)
2 . 2 Coat new G-iintjs with grease and iqstcill them on
the cyl~ndercap.
C Y L I N D E R CAP
GEAR H O U S I N G
RETAlNEW WASHE R
SEAL R E T A I N E R
',
CY LtMDE R
CAP
31. Press the seal retainer into the gear housing and
2 7 . Install
CAUTION
@
@
C Y L t N D E R END SEAL
Install wlrh groove side
,-"-"-z
-\
CYLIhDER
END SEAL
SkAb RETAINER
/
GEAR
32. Coat the end real slider tool with grease, and make
sure its surface is not damaged. Then install on the
seal retainer.
ir
SEAL R E T A I N E R
GEAR H O U S I N G
wH
33. Coat the rack and fill its teeth with grease, then
insert the rack into the seal retainer.
CAUTION:
Gearbox
rResealing (cant'd)
36. Install the cylinder spring over the rack, then coat
the rack bushing with power steering fluid, and
install i t on the spring.
/p
E N D SEAL GUIDE
07911-SA.0400
, -
Fi
E N D SEAL GUIDE
GEAR HOUSING
37. Coat the end seal guide tool with grease and slip it
onto the end of the rack.
40. Slip the end seal guide off the rack.
41. Lay the gearbox down, and push the right end of
the rack back into the cylinder housing so its
smooth surface won't be damaged.
CYLINDER
Install wl!h the groove
f a c ~ n gout
GEAR l
PINION
15 mrn S N A P R I N G
R HOUSING
I
PINION LOWER BEARING
6 x 18rnrn
10 R1.m 11.0 kg-rn, 7 Ib-ft)
I?
turns
smoothly.
housing.
I
P I N I O N HOLDER
4 2 x 4 7 mrn
PINION
Gearbox
r Resealing (cont'd)
I
47. Install the 32 mrn snap ring with irs tapered side
facing out in the groove in the pinion holder from
the unders~deof the gear housing.
P I N I O N HOLDER
PlMlON S E A L R E T A l N E R
46 mrn O - R I N G
P l N l O M SEAL
PSPdLON
P I N I O N DUST SEAL
P I N I O N D U S T SEAL
SEAL R E T A I N E R
'\
LOCKNUT
2 5 N . m ( 2 . 5 ky-m, 78 Ib f t i
//
6 x 18mm
10 N . m (1.0 kg-m, 7 Ib-ft)
GEAR H O U S I N G
RACK GUlDE
LOCKNUT W R E N C H
07916-SA50001
BOOT BAND
5 5 N . m ( 5 . 5 kg-m, 40 lb-ft)
screw threads
LOCKNUT
GI?
Gearbox
r Resealing (cont'd)
A I R T R A N S F E F TUBE
RUBBER M O U N T S
M O U N T I N G BRACKETS
69. Check the control unit for leaks, then reinstall the
shield.
7 0 . Reinstall the front wheels
Sy stern Description
--.
i
1
I
1/
1
I
1
Th?
i i - ; e i i ~ ~ !iru p o l i i s
poiri:r sfec:lng fluid To i h e pump, the p u m p pressurizes t h e fluid t o about 8001' LPa ( 1 200 psi),
5ai;ieF i q l i ~ d e ;f l o w s back through the control valve and out t o t h e reservoir through the cooler,
Fit16
::::
:ICV.
~ X S ?iiii
it
II
Y : ? V B i i i t i ; : IESFIYO~I
r - ! r i ~ : 8:~~c)rdii'lg
to
SPEED SENSOR
--
The p o w e r steering p u m p is m o u n t e d a t t h e left front corner of the englne and is driven b y a V-belt f r o m the crankshaft
pulley. It uses a combination flow-control,relief valve t o keep o u t p u t pressure b e t w e e n 7839-8825 kPa 180 -90
kg;crnz, 1 1 3 5 1 2 8 Q p s i ) . The p u m p is made of aluminum to reduce its weight and help it r u n cooier. I t uses the a
pressure balance s y s t e m w h i c h allows fluid pressurized b y the p u m p t o f l o w behind t w o "floating" plungers,
automatically maintaining the correct c!earance b e t w e e n the other ends of t h e plungers, and the p u m p gears. This n o t
only increases p u m p efficiency, b u t alscj imprcves durability, since the p!unuers can :cove to compensate for the
expansion caused b y high temperatures; otherwise t h e clearance w o u l d decrease. uiiowing mare rapid p u m p wear.
Flow Control
F L O W C O N T R O L V A L V E OPEN
PUMP
METERING
ORIFICE
1
I
TROL
I r-TO C O N T R O L U N I T
Pressure Relief
As pressure on the control unit side builds u p i t pushes
the relief valve ball (inside the flow control valve) up
against its spring, and excess fluid returns t o the pump
inlet. As the pressure under the flow control valve
drops, the relief valve ball is closed by its spring, and the
flow control valve is forced down again, allowing excess
fluid from the pump side to return to the inlet.
T h ~ sflow control valve-relief valve cyl~nderkeeps pump
output pressure between 7839- 8825 kPa (80-90 kg cm2,
1136-1280 psi)
R E L l E F V A L V E OPEN
DAMPING ORIFICE
from
from
Operation
r Control Valve
Msunted on the lowe; side of the gearbox is a control valve, that is moved horizontally by a pin ori the piniori holder
t o shift fluid pressure t o the right or left side of the Power Cylinder when the steering wheei is turned.
It has thrust pins a t both ends, and two inter.connected reaction chambers, one on each side.
Each reaction chamber contains a pair of spring !oaded plungers that ride against right and ieft thrust pins.
The following valve body fluid passages are controlled by the control valve.
P:
Fiom pvmp
T: TO reservoir
A : To right side of cylinder
B: Po left side of cylinder
/
PlNlOM HOLDER PIN
CONTROL VALVE
I n the power steering unlt, the method used t o direct a single source of fluid pressure in either of two directions (for left
or right turns) involves the pinion gear transferring a "message" of direction t o the fluid Control Valve.
The pinion is mounted slightly off-center in a pair of bearings, which are in turn mounted in a Pinion Holder cylinder
that rotates, centered in its own outer bearings. A t the bottom of the Pinion Holder is a pin,which fits in a slot in the
Control Valve.
As the pinion i s turned ( t o turn left or right), because i t is off-centered it also moves slightly along the rack. This movement 1s transferred to the holder. The pln in the holder then moves the Control Valve, to direct fluid pressure t o elther
side of the rack Power Cylinder.
The back edges of the pinion holder (facing away from the rack) hit stops cast into both sides of the gear housing t o
avoid push~ngthe control valve too far in either direction. The front edge of the pinion holder cuts off assist a t full lock
as described on the next page.
CONTROL V A L V E
Operation
r-
glnloader System
ONE-WAY VALVE
INNER ROTOR
OUTER ROT
SPEEDOMETER
GEAR
It turns only when the car IS movlng, controll~ngthe cutoff valve by regulat~ngf l u ~ dpressure In the control unit
accord~ngto the speed of the car.
With the engine running in a parked car, fluid flow
through the sensor rotors is blocked because the rotors
are not turning.
INLET
(From the
cut-off valve),
Driving Forward:
Driving in Reverse:
RELIEF VALVE
L-J
.-J
RESERVOIR
RELIEF VALVE
Suspension
Illustrated index ............................. 20-2
Wheel Alignment ...................
.....
20-3
Front Suspension ...................
.....
20-8
Rear Suspension .................go.........20-2 0
FRONT D A M P E R
Fit I T ~ * , paqe 20 II
D ~ ~ a s s ~~
n ~~( a~ L
~ ' ~L ~
i piqc
I o T I20
,
18
Rc?ssernbip 2 n d i n ~ t ~ l l d t i o v
P'qc 20 19
-1
FRONT wt-4EE~A L I G N M E N T
Adju,tmenr
pages 20 3 4 5
I
S p r ~ n qH c ~ q h It n s n e ~ t ~ opage
r
20 6
L-___
UPPER A R M
Inspectton pc7cie70-16
Aernoval page 20 8
D t s a s s e ~ h l yileassembli aage 20 16
REAR GAlHFEt2
R t rno\,al . sacre
20 22
.
--'
D ~ s a s s r r n b l yl n s p ~ c c i o n '
R E A R W H E E L ALIGNMENT
Aajustmenr, page 20-5
!
Sprtng Height inspec:ion, page 20-6
L
-
-2
BEARING
h ' t ? ~ ! a c e ~ ; c rj rj ,j ~ c2C 2 4
\WHEEL
Wheel Alignment
r Camber InspectioniAdjalstment
6.
2.
3.
WHEEL ALLGNMERIT
GAUGE ATT. B
07410-0080200
SPINDLE NUT
185 Nam (W.5 kg-m,
'1 34.Ib-ft)
W H E E L ALIGNMENT
GAUGE AT+. B
07410-0510200
CWMBE RICASTE W
GAUGE
8.
5.
Wheel Alignment
- Caster Inspectisn/Adjustment
1.
2.
3.
4.
6.
7.
16 rnm N U T
' C
Caster angie: 0
35'
WHEEL A L I G N M E N T
GAUGE A T T . 5
074 10-001 0200
SELF-LOGKING N U T
R A D I U S 8014 ADJUSTER
8.
5.
2.
3.
4.
II
1.
II
II
2.
TIE-ROD
II
I I
Release park~ngbrake.
4.
AQJUSTiNG BOLT
I
I
Spring Height
Wheel Measurement
Standard: SteelAluminum-
0-1.0 mm (0.039in.)
0-0.7 mm (0.028 in.)
Front Suspension
Disassembly and Inspection
i
I
NOTE
Rcpldce
SELF LOCKING N U T
12 x 1 2 5 m m
83 N.m 18 3 kg-m, 60 Ib f t )
Repl~ce
I
UPPER A R M ASSY
3rl,pecf i o n Gisassernbiy
Rr~ssefrbly page 20 16
SELF LOCKING N U T
12 x 1 2 5 m m
STABILIZER BUSHING A
Check for deterlor ~ t l o n
10 x 1 25 m m
44N.m ( 4 4 k g m . 3 2 I b f t )
STABILIZER
SELF-LOCKING N U T
12 x 1.25 m m
5 N m (6 5 kg m, 47
10 x 1.25 m m
55 N.m ( 5 5 kg-m,
ILIZER BAR
FRONT LOWER A R M
Check fot damdye
SELF L O C K I N G NUT
l o x 125mm
45 N m (4.5 kg-m, 33 I b - i t )
RUBBER BUSHING
Check i c j - deter c i , t ~ o r .
o - d, nc,ae
SILICONE GREASE
S P I N D L E NUT
22 x 1.5 mrn
185 N.m (18.5kg-m, 134 lb-fti
L U G NUT
12 x 1.5 mm
7 10 N.m ( 1 1.0 kg-tn, 79 Ib-fti
Front Suspension
NOTE: Replace the self-locking bolts ~f you can
easily thread a n u t past their nylon locking inserts.
N Y L O N INSERT
SELF-LOCKING NUT
14 x 1.5 m m
30 N,m (3.0 kg-m, 22 Ib.ft1
Replace.
10x1.25mm
40 N.m (4.0 kg-m, 29 I b - f t )
I
/
SELF-LOCKING NUT
12 x 1.25 m m
83 N
, (8.3
~ kg-m, 6 0 1b-ft)
SELF-LOCKING NUT
70 x 1.25 rnm
1
55 N.m (5.5 kg-m, 40 Ib-ft)
SELF-LOCKING NUT
12 x 1.25 m m
55 N.m (5.5 kg-m, 40 I b - f t )
1
CASTLE NUT
12 x 1.25 m m
44 N,m (4.4 kg-m, 32 I b - f t )
6 x 1 .O mm
18 N,m 11.8 kg-m, 13 I b - f t )
SELF-LOCKING B O L T -
8 x 1.25 m m
22 N,m (2.2 kg-m, 16 Ib-ft)
8 x 1.25rnm
22 N.m (2.2 kg-m, 16 l b - f t )
6 x l.0mm
1 0 N " m ( 1.O kg-m, 7 l b - f t )
CASTLE NUT
10 x 1.25 mrn
44 N.m ( 4 . 4 kg-m, 32 Ib
LOCKING NUT
1 6 x 1.5mm
83 N,m (8.3 kg-m. 6 0 ib-it)
,/"
9 2 x 1.25mm
7 8 N.m 17.8 kg-m, 56 I b - f t )
'\
CASTLE NUT
12 x 1.25 m m
55 N,m (5.5 kg-m, 40 I b - f t )
SPINDLE NUT
2 2 x 1.5 m m
185 N.rn (18.5 kg-m, 134 Cb-ft)
Replace.
1.
07965-SB00200
Pos~tionthe special tool between the ball jolnt housIng and knuckle and set them in a vtse Press the ball
joint o u t of the knuckle
07965-SBOO
BALL JOINT
INSTALLATION BASE
07965-SB00300
CLIP G U I D E A
07974-SA50700
Front Suspension
i-
Knuckle/Hub Replacement
1
--
m
p
6.
7.
TO
prr-
32 mm SOCKET
2,
BOLTS FQR
DISC REMOVAL
8 ~ 2 . 2 152 ~m m
( 1 2 mm is minimum length)
in DroDer
locations.
.
.
4.
5.
8,
BRAKE D l S C
Remove the cotter pit-, from the tie-rod i:nd and remove the castle nut.
CAUTBOPB
I
1
C A L I P E R MOUNTING BOLTS
78 N,m (7.8 kg-m, 55 Ib-ft!
TIE R O D E&D
BALL JOINT
10. Pry the cotter pin off and looscn the lower arm ball
joint nut h a i f the leriyth o f the joint threads.
11. Separate the ball joint and lower arm using a puller
with the pav\ds applied to the lower arm.
LOWER A R M
4
1
r
L
SCREWS
PULLER
CAUTION :
Take care not to distort the splash guard.
@
Hold onto the hub to keep it from failing when
pressed clear.
NOTE: If necessary, apply penetrating type lubricant t o loosen the ball joint.
DRIVER
07965-6340 7 00
07941 -6920002
Front Suspension
rI
Removal
1.
2.
Installation
1.
3.
PRESS
DRIVER
07749-0010000
DRIVER
07749-001 0000
FRONT H U B D I S I
ASSEMBLY TOOL D
DISIASSEMBLY
TOOL C
07965-6920300
DISIASSEMBLY TOOL BASE A
07965-6340301
4.
2.
HUB
Fd
NOTE: Pack both wheel bearings with grease before installation. Also apply grease to the outer
race and both inner races.
3.
F R O N T H U B DIS/
ASSEMBLY TOOL A
07965-69201 0 0
FRONT HUB
DISIASSEMBLY TOOL B
07965-6920200
7 2 rnm SNAP R I N G
B E A R I N G INNER RACE
"1 OUTBOARD
DUST SEAL
FRONT H U B
DISIASSEMBLY TOOL B
07965-6920201
5.
4.
5.
8.
r
1
I
DRIVER
07749-001 0000
FRONT HUB DiS/
ASSEMBLY TOOL E
07965-6920500
--__
'
"
----
t-
--
P7+----
''
FRONT HUB
FRONT HUB
DISIASSEMBLY
TOOL 5
07965--6920201
DRIVER
07749-0010000
I
FRONT HUB TOOL F
07965- SA00600
9.
70. Drive the inboard dusr seal into the knuckle using
special tools.
INBOARD
BUST SEAL
7.
Turn the knuckle upside d o w n and install the inboard ball bearing and its inner race.
/
DRIVER
07749-001 0000
DUST
ASSEMBLY TOOL B
07965-6920201
Front Suspension
r
I
2.
6.
7.
UPPER A R M
UPPER A R M
BUSHINGS
B A L L JOINT
"
4.
8.
9.
H O U S I N G SEAL
1
H O U S I N G SEAL
COLLAR
c-
UPPER A R M B O L T
Replace.
I
1
I
SELF-LOCKING N U T
55 N m (5.5 kg-rn, 40 Ib-ft)
UPPER A R M BUSHING
Replace
5.
10 x 1.25 rnrn
55 N . m (5.5 k g - r n , 4 0 I b - f t )
UPPER A R M
BOOT
10. Coat the ends and insides of the upper arm bushings
and sealing lips of the upper arm bushing seals with
grease.
Damper Removal
1.
2.
----
D A M P E R ASSY
UPPER A R M BOLT
3.
Front Suspension
DAMPER CAP
4 0 N , m (4.0 kg-m, 29 Ib-ft)
-7
CAUTION
SEAL
M O U N T BASE
iF!*
DAMPER MOUNTlNG
COLLAR
DUST COVER
SLEEVE
UPPER SPRING SEAT
Check for damage.
BOOT
'A-
2.
Ll
(Commercially ava~lable)
3.
4.
BUMP STOP
Check for weakness
or damage.
COIL SPRING
Check for weakened
compression or damage.
--
NE EDS
NORMAL
II
REPLACEMENT
il
DAMPER U N I T
Check for leaks and
faulty operation
SELF-LOCKING NUT
Replace.
3 0 N.nl 13.0 kg-m.
22 Ib-ft,
AMPER M O U N T
DAMPER BUSHINGS
Check for weakness
Or
damage
- Damper Reassembly
I
1.
2.
lnstall the bump stop, boot, upper spring seat, collar and bushing on the damper shaft.
3.
Damper installation
1.
2.
4 0 N , m ( 4 . 0 kg-m, 29 Ib-ft)
I
'-----
M O U N T BASE
SPRING
COMPRESSOR
ALIGNING TAB
4.
SELF-LOCKING N U T
30 M.m (3.0 kg-m, 22 Ib-ft)
DAMPER SHAFT
IS
NYLON INSERT
SILICONE GREASE
RUBBER BUSHING
Check for deterioration
o r damage.
\
\
BAR
8 x 1.25mm
22 N.m (2.2 kg-m, 16 Ib-ft)
LOWER A R M
Check f o r damage.
SELF-LOCKING N U T
83 N.m (8.3kg-m, 60 I b - f t )
REAR WHEEL
HUB CARRIER
Check for d a m a g e
Refer to p a g e 20-23
BUSHING A
SILICONE
GREASE
10 x 1.25 mm
65 N.m (6.5 kg-m, 47 Ib-ft)
'.
12x 125mm
I
70 N.m (7 0 kg-m, 51 I b - i t )
12 x 1.25 m m
83 N m (8.3kg-m, 60 I b - f t )
RUBBER BUSHING A
Check for deterlorallon
or damaqe
I
I
RADIUS ROD
ADJUSTING BOLT
GREASE
Rear w h e e l alignment,
see page 20-5.
RUBBER BUSHING A
Check for d e t e r ~ o r a t ~ o n ,
RADIUS ROD
Check for bending or
damage.
SILICONE GREASE
Rear Suspension
8 x 1.25 m m
2 2 N . m (2.2 kg-m, 16 I b - f t )
MOUNT
----a
1.
I1
1
/ WASHER
SELF-LOCKING N U T
Replace
2.
DAMPER RUBBER
BUSHINGS
4.
5.
6.
7.
O U N T BASE
8.
9.
SPRING M O U N T
RUBBER
D U S T COVER
Compress the damper spring ilsing Spring Compressor and remove t h e self-locking nut.
Follow spring compressor
acturer s instructions carefully.
manu-
BOOT
Replace ~fcut open
o r torn.
CAUTION
Repljce
COIL SPRING
Check tor damage.
BUMP STOP
Check icjr cracks or
damanr.
DAMPER U N I T
Check for ieaks; ~ i s ofor ---------a,
f n u l : ~ opt:ration, cee
pace 20-23
Damper installation
NOTE: Install the rear suspension in the reverse
order of removal, noting the following:
1.
2.
1.
I 3.
4.
5.
Compress the damper spring in the Spring Compressor and install the spring on the damper.
I
DAMPER ASSEMBLY
HUB CARRIER
2.
3.
COMPRESSOR
SPRING
07959-A50000
8.
&
LOWER A R M BOLT
10 x 1.25 mm
65 N.m (5.5 kg-m, 40 Ib-ft)
ALIGNING TAB
DAMPER SHAFT
4.
Place jack under the hub carrier and raise until the
car just lifts off of safety stand.
5.
6.
7.
Rear Suspension
Wheei Bearing and Seal
1 . Remove the rear brake callper ( s e c t ~ o n21 ) .
2
Removc the
3.
4.
I P ~ hub
I
cdp
SPINDLE N U T
Tiqhpen)ni: paoe 20 2 5
9.
WHkEL BEARINGS A
5.
PINHOLDER
K- :I>/
i
DRIVER
01749-001 0000
12. Si,p the disc owet the spindie, then 1ns:ai' :he out
board bearlna, hub washer-, and sptndie nut.
EARING DRIVER
7946-69201 00
7.
I.
2.
11-~sfaii
and tighten the spindle nut t o 2 5 N - i n (2.5
kg-m, 18 fb-fT! and rotate the brake disc 2-3 turns
by h a r d , tlren re:ighten t h e spindle nut to 25 lai-rn
12.5 kg-m, if3 { b i t ) .
Repeat s?ep 2 :inti1 r h e sgi!~dle n u t holds that
/I
/
3 . -~.cique.
4.
II
1
07,
PIN HOLDER
1.
2.
Brakes
Carbureted Model
............................... 2 1 - 2
Front Brakes ................................... 2 1 - 4
Master Cylinder .............................
2 1.10
Brake Booster .................................. 2 1.1 4
Rear Brakes ..................................... 2 1 - 2 3
Brake S w i t c h ................................... 2 1 - 3 3
Parking Brake ................................
21-34
Illustrated Index
.
.
- - . . - ...... 2 1 - 5 6
Carbureted Model
Brakes
Index
MASTER C Y L I N D E R
~ 2 1g- 3 2~
D U A L PROPORTIONING V A L V E
Removal Inspect~on,paqe 21-10
REAR BRAKE
DISC BRAKE
Index/lnspection, page 21 -23
Pad Inspec?~onlReplacement.page 21 24
Callper Disassembly, page 21 -26
DISC Inspect~on,page 21 -31
PARKING BRAKE
Adjusrrnenr, page 21-3
D i s a s s e m b l y : l n s t r ? l ~ a ~ i ~p na ,c e 21 - 3 4
S w i t c h Tes?, page 2 1 - 3 3
F R O N T BRAKE
BRAKE BOOSTER
Removal,'lnsrnlIat~on,pdge 21-112
index! 1 ns?ecti@n, Page 21-74
D~sasscmbly,Reass~mbly,
page 21-16
Rebuild k i t , page 21-17
A d ~ u s t m e n t ,page 21-22
Pedal Height
Parking Brake
- Adjustment
1.
PUSHROD LOCKNUT
SWITCH
'
PEDAL HEIGHT
176 mrn ( 7 in.)
2.
BRAKE L I G H T
SWITCH L O C K N U T
PEDAL PLAY
1-5 mm (3164-13164 1n.1
NOTE: When the rear brake caliper has been serviced, depress the brake pedal several times t o set the
self-adjusting brakes before adjusting t h e parking
brake cable.
1.
2.
3.
4.
5.
EQUALIZER
3.
I
I
I
I
Front Brakes
NOTE
Coat piston, piston seal, and callper bore w i t h
clean brake fluid
@
Replace ~ l rubber
l
parts w i t h new ones when
ever disdssernbled
@
Brake Pad
1.
CWLiPEFk
5.
BODY
3.
4.
6.
7.
PAD
Apoly anri-seize:
compccqa.
C A L [PER BRACKET
SHOE
I1
P A D RETAINERS
Brake Pad
InspectionlRepllacement (con%")
8.
,-
Brake Caliper
Disassembly
1
2.
P A D SHIM
Apply anti-seize compound.
PADS
9.
CALIPER P I N B B O L T
19 N . m (1.9 kg-m, 14 Ib-ft)
CALIPER BODY
CALIPER P I N A BOLT
18 N , m (1.8 kg-m, 73 Ib-ft)
NOTE: Install the inner pad with pad wear indicator on the inside.
INNER PAD
3.
D U S T COVER
>
OUTER P
P A D SHlM
I 1
PAD SPRING
4.
5.
2.
I I
3.
4.
bore.
DUST S E A L
PISTON SEAL
Replace.
$BSIQM
SILICONE G R E A S E
2.
t i l t : front of
1.
car n
,
2.
$Jc?vi ?lit calipe~ ;.,-;d pdds o u i of thc way as described In t5e prccediny column.
3.
io.39 i n , '
3.
4.
MlCROMETER
Measure a t 10 mm
(0.39 i n . ) f r o m edge
5.
iii
O ? C mrr:
{t004 rn.)
Bral.,e Dtsc P ~ r a i ! e i ~ s m :
T h e difference betweerr any thickness measrsrelnenls shouid not be mare than 8.13185 mrn
( 8 8886 in.).
Bleeding
NOTE: The
I
I
2,
securi.;iy
Bleeding Sequence
3.
Repeat tnr procedure f o r e j c h wheei ,n the sequence shown above, i ~ n r l lair bubblts nc longtr
appebr rn t h e f!uid.
FRONT
BRAKE ELEED SCREW
10 x 1.0mm 18.39 x 0.84 in.)
9 N.m (0.9kg-m, 7 l b - f t i
1
I
""MR
MASTER CY LlNDER
To I c f t
rear b l , i k ~
O ~ ~ - t h , u lInspi c t i o n p m i 2 1 1 i
(1.3 kg-tn,
10 N.m ( 1 . 0 k g - m , 7 Ib-f?)
1 5 N m ( 1 . 5 k g ~ m ,10 Ib-ft)
B R A K E BOOSTER
Inde.<,'l~,sr~ection,
psye 2 1 - 1 4
Tesi, ado? 21-7 5
3 , s ? s s e i v b l y , P J ~ E21-16
R c b ' i h d k t * , page 2 1 - 1 7
? c r s s c n : i l , y , p , i ~ c21.18
Master Cylinder
NOTE:
CAUTION :
/*'rT'
g_____L-
RESERVOIR CAP
C ~ P iCo l~ ~ I O C ~ J ~ P
c f vent holes
--
F L U I D L E V E L SENSOR
Check operdtlon o f
float and reed switch
//I>
</-_J------
E3/
R E S E R V O I R SEAL
--/
FILTER
Remove ?ed~rner>t
3'
p&w
RESERVOIR
PISTON CUP
PRIMARY
PRESSURE CUP
MASTER CYLINDER
Check bore for wear or
CUP STOPPER
,
'
,,
M E T A L GASI<ET
SNAP R I N G
STOP B O L T
9 N rn (0.9 kg-rn, 6 Ib-h)
SNAP R l N G
/
'S E C O N D A R Y
SPRING
I n s p e ~ for
l
wear or damage
CUPS
\
SECONDARY PISTON A
STOPPER
SECONDARYS C R E W
1.3 N m
!0.13kg-m, 1 i b - f t i
1.
3.
5.
ASSEMBLY
2.
SNAP R I N G
M E T A L GASKET
STOP PLATES
SNAP R I N G
Brake Booster
Scr~bean aligning mark across the front and rear housings so you can reassemble in their original positions (page
21-16).
BOOSTER SPRING
OUTER V A L V E
SPRING
Check for f a t ~ g u e
R E A C T I O N lDISC@>
/
,
'
BOOSTER CHECK V A L V E
',*\
'*$\
BOOSTER
F PISTON
'$,
Check f o r cracks,
d e c e r ~ o r s t ~ oorr
A-..~,.~
R E A R HOUSING
Check for d ~ s t o r t ~ o n
PIN
Replace
0 RING
BUSHING R E T A I N E R
SNAP RING"
THROUGH BOLT
Functional Test
1.
beak Test
1
2.
VACUUM HOSE
,-
Brake Booster
Disassembly
2.
3.
E-CLIP
6.
RETAlNER
F R O N T BOOSTER
BOLT BOOTS
HOUSING
4.
Remove the washers and seals from the rear housIng, then remove the snap ring.
7.
DIAPHRAGM
SNAP R I N G
SE'AL
5.
BOOSTER SPRING
WASHER
SPRING R E T A I N E R
,3
E-CLIP
6-9
SEAL
assembly.
b
SNAP
RING
E-CLIP
FILTER B
ADJUSTER
REACTION DISC
BOOT
STAR
DIAPHRAGM
@
POPPET
VALVE
SILENCER A
E-CLIP
(Felt)
SNAP
RING
BUSHING
PISTON S E A L
RETAINER
SNAP
RING
O-RING
SILICONE
GREASE
5.
7.
8.
L,
L l c o N E GREASE
PISTON SEAL
SILICONE GREASE
6.
DRIVER
//P7749-0010000
LOCK U T
RETAINER
ATTACHMENT C
07947-671 01 00
07965-6920500
or
i 6 rnm(0.24
in.)
BUSHING
SILICONE GREASE
L.
REAR H O U S I N G
--A
(cont'd)
Brake Booster
SNAP R I N G
BOOT
BOOSTER
THROUGH
B'OLT
PISTON
THROUGH BOLT
O-RING
REACTION
TABS
GREASE
SLOT
OUTPUT-ROD
BOOSTER S P R I N G
E-CLIP
F R O N T ROQSf ER HOUSING
SPRING R E T A I N E R
BOOSTER SPRING
SNAP R i N G
--
--
--
29 -21
3rake Booster
- Pushrod Clearance
Adjustment
6.
7.
must be checked and adjustments made, if necessary, before installing master cylinder.
1.
SECONDARY PISTON
'b--q
ADJUSTING N U T
\
2.
3.
4.
VACUUM GAUGE
(0-30 in Hgl
LOCKNC
NGlNE
ACUUM
m
Clearance:
0-0.4 mm (0-0.016 in.)
ADJUSTING N U T
Rear Brakes
RETURN SPRING
27 N.rr~(2.7 k g m , 20 Ib-ft)
LEVER G U i D E
BLEED SCRE%'
RUBBER GREASE
HONDA Cylinder Grease
(PIN 0 8 7 3 3 - BO20E) or
equivalent rubber grease
C A M BOOT
e
3
/
"
SEALING WASHERS
5 N.nl (3.5 kg-m, 25 Ib.ft)
RUBBER GREASE
HONDA CyBinder
Grease (PIN 0 8 7 3 3 BOZOE) or equivalent
rubber grease
B R A K E PADS
CYLINDER
Check for scoring
on cyl~nderwall
Cl RGLIP
RUBBER GREASE
HONDA Cylinder Grease
(PIN 0 8 7 3 3 - - 5 0 2 0 E ) or
equivalent rubber grease
Check l ~ n ~ n
th~ckness.
g
See page 2 1-24
B A L L BEARING
GUIDE
Check for weakness
or damage
PIN BOOT
Check for deterio-atron
or damaye
PISTOW
'I
check io,
sror,ng
o r c~,.f+ce
RUBBER GREASE
HOMDA Cylinder
PIN A h
Grease (PIN 08733.slblGOIdE GREASE
PIN 5
PISTON BOOT
RUBBER GREASE
WON194 Cylinder Grease
(PI& 08733-BOZQE) or
equivalent rubber grease
39 N.m (3.9kg-m, 28 Lb f t )
CALIPER BRACKET
Check for cracks
Brake Pad
r InspectioniRepiacement
1.
3.
CALIPER
CALIPER SHIELD
2.
4.
LOCK PIN
SHOE
5.
6.
/--
,
I
9.
- ,. *
OUTER P A D
Brake Caliper
I-- Disassembly
7.
3.
35 N m (3.5kg m, 25 Ib-ft)
.
-
I
CALIPER SHIELD
6 x 3.0 m m
Avoid spilling brake fluid on paint and instrument lenses as i t may damage the finish.
@ After disconnecting the brake hose, plug the end
with a shop rag to prevent brake fluid from f l ~ w ing out.
Thoroughly clean the outside of the caliper before disassembly to prevent dust and dirt from
entering inside.
Remove the piston and piston boot while rotating
the piston.
@
2.
BARKING B R A K E C A B L E
I
5.
PIN
boot.
PISTON
PISTON BOOT
6.
7.
B A L L BEARING
ADJUSTER N U T
PLAINWASHER
PISTON
,-
c---
P L A I N WASHER
WAVE WASHER
SNAP R I N G PLIERS
07914-SA50000
8.
9.
RETAINING R I N G
SPRING COVER
bore.
SPRING SEAT
PISTON SEAL
SPRlNG COVER
Brake Caliper
r Reassembly
Disassembly (contrd)
1.
2.
O-RING
KEY PLATE
RETAINING RING
C A M BOOT
-/-,
'&
16. Remove the return spring, nut, lever, cam and cam
boot.
R E T U R N SPRING
i/
CAM
3.
LEVER
LEVER
4.
R E T U R N SPRING
5.
8.
SNAP R I N G PLIERS
07914-SA50000
IT+
9.
6.
;I
SLITS
REAR CALIPER
GUIDE
07973-Sf
NOTE: Align the lug on the key plate with the hole
in the cylinder.
7.
EAR CALIPER
7973-SA50000
Brake Caliper
Reassembly (cont'd)
11. Remove the Caliper Gu~de.Check that the flared
end of the spring cover 1s below the c ~ r c l ~
groove
p
as
PISTON BOOT
07914-SA5000
RUBBER GREASE
PLAIN WASHER
WAVE WASHER
RUBBER GREASE
CAUTION :
I.
B~OCK
the front wheels, support the rear of rrie car
on safety stands, then remove the rear wheels.
2.
2.
Move the caliper and pads out sf the way as described i n the preceding column.
4.
3.
4,
5.
Brake HoseslPipes
1.
2.
Check the brake l~rlesfor damage, rusting or leakage Also check for bent brake I~nes.
3.
Check for leaks at hose and line jotnts or connections, and ret~ghten~f necessary.
BLEED SCREW
9 N.m (0.9 kg-m, 7 Ib-ft)
DISC BRAKE
BRAKE HOSE-TO-CALIPER
35 N.m (3.5 kg-m, 25 Ib-ft)
1.
2.
RESERVOIR CAP
2V-33
MASTER CYLINDER
Overhaul/lnspection, page 2 1 - 4 1
Disassembly!Reassembly, page 2 1-42
FRONT BRAKES
Inspection, page 2 1 - 3 6
Pad inspeciion,'Replacement, page 21 -37
Caliper disassembly, page 21 -38
Caliper reassembly, page 2 1-39
Disc Inspection, page 2 1 - 4 0
REAR BRAKES
Inspection, page 21 - 5 6
Brake pad, page 21-57
Brake caliper
Disassembly, page 27-59
Reassembly, page 21 -61
Installation, page 21-61
Disc inspection, page 21 -65
BRAKE BOOSTER
Index and Inspection, page 21-44
Tests, page 2 1 - 4 5
Disassembly, page 21 - 4 6
,
21-49
Rebuild k ~ t page
Reassembly, page, 21 - 5 0
Adjustment, page 2 1 - 5 4
Front Brakes
NOTE:
@ C0a.t piston, piston seal, and caliper bore w i t h
clean brake fluid.
9 Replace all rubber parts w i t h n e w ones whenever disassembled.
:2 mtn BOLT
7 8 N-m
( 7 . 8 kg-m. 53 Ib-ft)
CALIPER PIN
BRACKET
r cracks.
PAD RETAINER
Apply anti-seize
compound t o the back
of the oads.
PIN BOOT
Check for deterioration
'PAD RETAINER
Check for weakness or damage.
BLEED SCREW
9 Nern
(09 kg-m, 6 Ib-ft)
ALIPER BODY
N//
\T-
45 N.rn
(4.5kg-rn. 33 Ib-ftl
PISTON BOOT
Replace.
Chl
SLEEVE BOOB B
Check for deterioration
or damage.
PISTON SEAL
Replace.
Brake Pad
- InspectionlReplacement
1.
04
6.
3.
18 N-m
(1.0 kg-m, 7 Ib-ft)
CALIPER BOLT
8.
4,
Apply anti-seize
compound.
pne RETAINERS
NOTE: Measuremer7t does not include pad backing
th~ckness.
Brake Caliper
Brake Pad
Inspection/Replacement {ccsnt'd)9.
CAUTION:
@ Avoid spilling brake fluid on painted, plastic, or
rubber parts as it may damage the finish.
s Plug the end of the brake hose w i t h a shop rag to
prevent brake fluid from flowing out of the brake
hose after disconnecting.
@ Clean all parts thoroughly w i t h the clean brake
fluid. Blow out all passages w i t h compressed
air.
e Do n o t allow the foreign matter to enter the system.
10. Install the brake pads, inner pad shim A and B, and
outer pad shim.
NOTE: Install the pad w i t h the wear indicator on
the inside.
OUTER PAD
SHIM
1.
BANJO BOLT
35 Nem
(3.5 kg-m,
25 Ib-ft)
1 1 . Push in the piston so tha? the caliper will fit over the
pads. Keep the boot in position t o prevent damaging the boot when pivoting the caliper down.
CALlPER BOLT
SEALING WASHERS
CAUTION:
@ Make sure a
BB parks are clean before reassembly.
@ Use only new replacement parts.
@ Use only new clean brake fluid.
@ Do not allow dirt or other foreign mattes t o con
taminate the brake fluid.
e Do not mix different brands of brake fluid,
@ Avoid spilling brake fluid on painted, plastic or
rubber surfaces as its can damage the finish.
Wash spilling brake fluid off immediately w i t h
clean water.
4.
1.
2.
3.
4.
PISTON BOOT
Run-our
1. Remove the front wheels, and support the front of
car on safety stands.
2.
Move the caliper and pads out of the w a y as described in the precegding column.
3.
3.
4.
If the disc is beyond the limits for thickness or parallelism, refer to ihe Honda Brake Disc Grinder
Manual t o see if it can be ground. If it can't be
ground, remove it and install a new one.
Master Cylinder
NOTE:
@ Wash all removed parts in brake fluid and b l o w
dry w i t h compressed air. Blow open all passages.
@ Replace all rubber parts w ~ t hnew ones whenever the cylinder is disassembled.
@ To prevent damage, liberally apply clean brake
fluid t o the piston cups before installation. Use
special tool t o install the cups.
CAUTION:
e Avoid spilling brake fluid on painted surfaces as
severe damage can result. Wipe up spilled fluid
at once and rinse well with clean water.
9
RESERVOIR CAP
Check operation of
float and reed s w i t c h .
FILTER
R e m o v e sediment.
SEAL
^..I^_^
PRIMARY
CIIP S T ~ P P F R
PRESSURE CUP
- .
METAL GA
R ~ n l a r ~
\
SECONDARY PISTON B
ear or damage.
STOP BOL
9 N-rn
(0.9 kg-IT!.
6.5 Ib-ft)
SECONDARY SCREW
12 N-rn
( 1 . 2 kg-m,
9 I$-fri
A p p l y sealant.
PISTON CUP
Replace.
PISTON
STOPPER
SECONDARY
SPRING
\,
SECONDARY PISTON A
Inspect for wear or darnage
Replace.
RINd
SECONDARY CUPS
Replace
Master Cylinder
CAUTION:
@ Avoid spilling fluid on painted, pgastic, or rubber
parts as it may damage the finish.
@ Plug %he
end of the brake hose with a shop rag t o
prevent brake fluid from flawing out of the brake
hose after disconnecting,
@ Do not mix different brands of brake fluid.
@ Use only new clean brake fluid.
@ Clean all parts thoroughly with the brake fluid.
Blow out a!! passages with compressed air.
@ DO not use high air pressure; use an OSHAapproved 30 psi nozzle.
@ Do net allow foreign matter PO enter the system.
@ Be careful not to bend or damage the brake pipe
when removing the master cylinder.
7.
Remove the stop bolt while pushing in the secondary piston assembly.
Remove the p~stonguide, secondary piston assembly and primary piston assembly.
ROD SEAL
5. Remove The screw from the secondary piston assembly, then remove the secondary spring.
2.
SECONDARY SPRING
2.
CAUTION:
@ Make sarre all parts are clean before reassembly.
@ Use only new replacement parts.
@ Use only new clean brake fluid.
@ Do n o t aliow dirt or other foreign matter to contaminate the brake fluid.
@ Do n o t mix different brands of brake fluid.
e Avoid spilling brake fluid o n painted, plastic or
rubber surfaces as it can damage the finish.
Q Wash spilled brake fluid off immediately w i t h
clean water.
1.
3.
PRESSURE CUP
I
4.
P ~ S TCUP
~N
SPRING
PISTON
STOPPER
SECONDARY
PISTON B
CUP
RING
I
5.
Brake Booster
lrsdex and inspection
Booster resting is on next page.
Pards marked'"
(page 2 1-46).
BOOSTER CHECK VALVE
Test as described on next page.
VALVE BODY
VALVE HOLDER
VALVE SPRING
FLANGE LOCKNUT"
5.5 N-rn i0.55 kg-m.
PUSH ROD LOCKNUT
15 Nern ( 1 . 5 kg-m, l l Ib-ft)
- Tests
Functional Test
1. W i t h the engine stopped, depress the brake pedal
several times, then depress the pedal hard and hold
t h a t pressure for 15 seconds. If the pedal sinks, the
master cylinder, brake line or a wheel cylinder is
faulty.
Leak Test
1.
2.
CHECKVALVE
I
Brake Booster
1 . Scribe an aligning mark across the front and rear
booster housings t o ensure proper positioning of
parts on reassembly.
2.
3.
6.
6 mm FLANGE LOCKNUT
FRONT HOUSING
REAR HOUSING
REAR
7.
4.
SNAP RINGS
\ [!\,l:\dG$?
'SPRING RETAINER
w\/'
BOOT
I
THROUGH BOL?
SNAP RING
PISTON SEAL
BOOSTER PLATE
BUSHING RETAINER
BUSHING
REAR HOUSING
I
(cont'd)
Brake Booster
Disassembly (csntrd)
13. Remove the output rod, reaction disc and reaction
REACTION DISC
REACTION PLATE
I
VALVE BODY
PUSH ROD LOCKNUT
ADJUSTER
STAR LOCKNUT
I
PUSH ROD YOKE
E-CLIP
Rebuiid Kit
17. Remove filter A. t h e spring seat, valve springs,
valve holder and poppet valve from t h e push rod.
PUSH ROD
VALVE HOLDER
8
E-CLIP
SNAP RING
SEAL
REACTION
D1SC
BOOT
DIAPHRAGM
FILTER A
(Felt)
FILTER A i ~ e l t t
PUSH ROD
RETAINER
'
LOCKNUT
rnm
BUSHlNG
RETAINER
SILICONE GREASE
Brake Booster
---
Weassew~bly
I.
3.
->r
FILTER A
(Felt)
VALVE HOLDER
2.
NOTE: install the spring seat w i t h its short end fating the filter side.
4.
PUSH ROD
Apply silicone grease to the inner and outer srsfaces of :he vaive body tube. Press the push rod
assembly into the valve body tube, and instal! the
push rod retainer.
R VALVE SPRING
SPRING SEAT
,
PUSH ROB WfTAlPdER
FILTER A
(Felt)
5.
7.
Install the piston seal and bushing In the rear houstng, and gently drive t h e retarne: rn until it IS 6 rnm
below the edge of the rear h a u s ~ n g
FILTER B
(Sponge1
STAR LOCKNUT
@
1
PUSH ROB
ATTACHMENT C
RETAINER
ADJUSTER
.24in.)
REAR HOUSiNG
D
GREASE
8.
O-RING
SILICONE GREASE
THROUGH 80i.T
PISTON SEAL
Brake Booster
Reassembly Ccont'd)
9. Install the diaphragm on the booster plate.
DIAPHRAGM
BOOSTER PLATE
BOOT
THROUGH BOLT
10. Attach the booster plate t o the rear housing, aligning their tabs and slots.
12. Apply silicone grease t o the bore of the rear housing and the outer surface of the valve body
asssembly. lnstall the valve body assembly in the
rear housing.
BOOSTER PLATE
REAR HOUSING
REAR HOUSING
SILICONE GREASE
BOOSTER SPRING
16. Install the spring retainer on the through bolts aligning the square portions of the bolts and retainer.
14. Install the set plate, and tighten the four 6 m m
flange nuts.
6 rnm FLANGE N U T
5.5N*m 10.55 kg-m.
SET PLATE
ib-fti,/
RING
BOOSTER GPRIMG
SPRING RETAINER
Brake Booster
Reassembly Icoralt'd)
NOTE: Master cylinder pushrod-to-piston clearance must be checked and adjustments made, if
necessary, before installing master cylinder.
SEAL
1.
TER
NDER
ONDARY PISTON
ADJUSTER LOCKNUT
BOLT
2.
4.
5.
6.
With a feeler gauge, measure the clearance between the gauge body and the adjuster locknut as
shown.
Clearance: (3-0.4mm (0-0.016 in.)
7.
8.
STAR LOCKNUT
22 N.m (2.2 kg-m, 16 Ib-ft)
Pushrod-to-Piston clearance:
0-0.4 mm (0-0.46 in.)
Pushrod Adjustment
Install the locknut and pushrod yoke on the pushrod;
adjust the pushrod length as shown.
Rear Brakes
lnspectiogl
BREAK PADS
Check l ~ n i n gthickness.
2 3 N-m
( 2 . 3 kg-m, 17 Ib-ft)
3 9 N-m
(3.9 kg-m, 2 8 Ib-ft)
PARKING NUT
28 N.m
RUBBER GREASE
HONCBA Cylinder
Grease (PIN 08733B020E) or equivaaenr
rubber grease
USTING SPRING B
SLEEVE PISTON
Check for scoring
on surface or damage.
SPRING COVER
Check for damage.
CALIPER BODY
Check for scoring
on cylinder wail.
Replace.
SILICONE
GREASE
PISTON BOOT
Replace.
SILICONE GREASE
Brake Pad
Inspection1Replacement
1. Remove the caliper shield.
3.
CALIPER SHIELD
/5=F%
2.
PARKING BRAKE
CABLE
4.
CALIPER MOUNTING
Remove the pads and, using a vernier caliper, measure the thickness of each brake pad lining.
Brake Pad
ly.
1 I . lnstall the brake caliper.
6.
7.
8.
RETAINERS
9.
Brake Caliper
- Disassembly
CAUTION:
e Make sure all parts are clean before reassembly.
@ Use only new replacement parts.
@ Use only new clean brake fluid.
Do not allow dirt or other foreign matter to contaminate the brake fluid.
9 Do not mix different brands of brake fluid.
0 Avoid spilling brake fluid on painted, plastic or
rubber surfaces as its can damage the finish.
Wash spilling brake fluid off immediately with
clean water.
1.
2.
3.
4.
Remove the caliper shield and disconnect the parking brake cable.
Remove the banjo bolt and remove the brake hose
from the caliper.
Remove the t w o caliper mounting bolts, and
remove the caliper from the caliper bracket.
CAUTION: Thoroughly clean the outside of the
caliper t o prevent dust and dirt from entering.
Replace.
CALIPER
Brake Caliper
Disassembly 6cont"sB)
6. Remove the circlip, then washer, adjusting spring
A, and the adjusting nut from the piston.
8.
ADJUSTING
SPRING A
-
BRAKE SPRING
COMPRESSOR
07960- SA50002
2 4 rnm ClRCLlP
/'
ADJUSTING
NUT
WASHER
YZ9'
BEARING A
ADJUSTING
- Reassembly
CAUTION:
@ Make sure all parts are clean before reassembly.
@ Use only new replacement parts.
@ Use only new clean brake fluid.
@ Do not allow dirt or other foreign matter to contaminate the brake fluid.
0 Do not mix different brands of brake fluid.
@ Avoid spilling brake fluid on painted, plastic or
rubber surfaces as its can damage the finish.
Wash spilling brake fluid off immediatery with
clean water.
1.
2.
3.
SLEEVE PISTON
PIN
HONDA Brake
Cylinder Grease
RETURN SPRING
PARKING
NUT
\@
,
,
CAM
C A M BOOT
SPRING
WASHER
NEEDLE BEARING
Brake Caliper
- Reassembly (eont")
4.
5.
----
9. lnstall the new cup w i t h its groove f a c ~ n gthe bearing A side on the adjusting bolt.
10. Fit bearing A, the spacer, adjusting spring B and
spring cover on the adjusting bolt, and install in the
caliper cylinder.
RETURN SPRING
PARKING N U T
28 N-rn
( 2 8 kg-m, 2 0 ib-ft)
,SPRlNG WASHER
_/'
\\
6.
7.
8.
--+--
O-RING
HOLE
HOLE
BRAKE SPRING
COMPRESSOR
07960-A50002
I
ADJUSTING
-->:
,+
GROOVE
17. Coat the new piston seal and piston boot with silicone grease and install them In the caliper.
PISTON SEAL
PISTON BOOT
Brake Caliper
I-
1.
1.
2.
3.
5.
Body
Doors ..............................
........... 22-2
Windshield and Windows .................. 22-1 1
Interior Trim .....................
.
..... .
.
,
.. 22-2 1
Seats ..................................=..........22-21
Console ......................................... 22-26
Carpet ................................
.
.
...... 22-26
Sunroof ........................
.
.
.
........
22-27
Instrument Panel and Gauges ............. 22-34
Dashboard .....a,...........m...................
22-39
Bumpers ................... .
.
...............
22-42
Hood .................... .
.
..
.
.
. . . . . . . 22-44
Trunk Lid ....................
.
.......
.
...... 22-45
Fuel Door Opener ....................... ....... 22-47
Frame Repair Chart .......................... 22-48
Boors
illustrated Index
HEAR VIEw MlRRO
Replacement, page
Adjustment, page
REGULATOR HANDLE
Removal, page 2 2 - 3
Removal, page 2 2 - 3
LATCH ASSY
Removal. page 22-4
Removal, page 2 2 - 4
- Disassembly
1.
Push the clip off the regulator handle with a screwdriver, or pull it off from the other direction with a
wire hook. Remove the regulator handle.
3.
To remove the door panel, insert a stiff putty knife between the panel and the plastic shield, slide it around the
edge until it hits a retainer clip, then pry it up sharply t o
remove the clip. Repeat at all clip locations until the
panel is free, then lift it straight up off the window sill,
and disconnect the courtesy light and power window
wires. Peei off the plastic shieid without tearing it.
CLIP
L
mm
L
f-
DOOR PANEL
2. Remove the cap from the trim plate and remove the
screw. Then pull the handle and remove the trim
plate.
TRIM PLATE
CAP
'
95 rnrn
11
Doors
5.
Si:
7.
8.
9.
COVER PANEL
mounting bolts.
\
i
.-
,I-,1-
,
--
c---_---'
- -
__---GUIDE
11. Loosen the door mounting bolts and slide the guide
forward. Remove the glass from the guide, then
remove two bolts from the glass.
12. Lower the glass, disengage the front side from the
channel, and remove the glass.
OUTER M O L D I N G
- Assembly
Assemble the door in the
disassembly, and also:
1.
reverse order
of
3.
4.
Manual:
Power:
2.
Position the motor on its mount by aligning the pinion w i t h the sector, and install using the three
mount bolts. Move the window regulator t o the
original position by connecting a 1 2 V battery t o the
motor.
MOTOR
Doors
r- Assembly (contrd)
4.
the courtesy
light
TO
DOORSEAL
1.
2.
3.
4.
SPEAKER
5.
1
[
- D s s r Striker Adjustment------
4.
Draw
2.
DOOR HBNGE
3.
DOOR HINGE
Boor Mirror
r , ~
50 rnrn
2.
NARROW END
3.
UPPEq MOLDING
e w HOLDER
WlNDSHlELD
WER JOINT CLIP A
CORNER MOLDING
cement. page 2 2 - 1 3
DAM
MOLDING
MOLD~N'GCLIP A
Replacement, page 22-1 2
LOWER MOLDlNG
Front
TO
-
M O L D I N G CLlP B
Rear
MOLDING
1.
BODY
GLASS
I
3.
2.
4
7 mm ( 0 . 2 8 in.)
-38 mm -2
(1.5 in.)
I.
M O L D I N G CLIP A
Remove the quarter window upper and lower moldings by sliding them to the side.
2.
CLlP
UPPER MOLDING
TOP CLlP
CLIP
3.
Body side
CLIP
For replacement, the two lower clips can be removed by turning them 90".
Replacement
1.
CAUTION: Do not scrape down t o the painted surface; adhesive will not bond t o damaged paint.
air gun.
3.
4.
6.
GLASS
NEW ADHESI
'/
7.
Windshield:
EXISTING
\
ADHESIVE
7.
i
1
- Removal
- - - -s- - - - -
NOTE: W~ndsh~eid
removal
removal of other glass
1.
is
IS shoSwn;piocedu:e for
slm~lar.
Apply protective tape along the edge of the dashboard and body next to the windshield ds shown.
PROTECTIVE
TAPE
WINDSHIELD
-----+
WINDSHIELD
L+'
\
QTECTIVE
PE
DASHBOARD
BODY
4.
i
I
PROTECTIVE TAPE
Cut t h e ~vindshie~ci
moidlng cl~psand rubber spacers
away f r o v she body, they are cemented In p/ace.
NOTE: Windshield and rear window glass replacement is shown; the procedure for quarter glass
replacement is similar.
NOPE:
@
4.
SPACERS
ALIGNMENT MARKS
5.
6.
8.
Front
CLlP H O L D E R
MCBhDlRdG
Front
Rear
- . . +
230mm 155mm
(9.1 in.) (6.3 in.)
CLIP HQLDERS
SIDE MOLDING
l PLACE
Rear
7.
UPPER MOLDING
M O L D I N G CLlP B
L+
.
.
.
.
4
200 mm 150 mm
(7.9 in.) (5.9 in.)
140 rnm
LUG
105 rnm
(4.1 ID.)
Body side
r
I
instaleation Ccsnt'd)
----.---.----
Glass side
WINDSHIELD
Clean a 60 mm wide
strip along the bottom
10, Then glue the rubber dam onto the inside of the
glass according to the measurements shown.
EDGE OF WINDSHIELD
NOTE:
Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.
16, Use suction CUDS to hold the glass over the opening,
align it with the marks made in step 4 and set it
down on the adhesive. Lightly push on the glass
until its edge is fully seated on rhe adhesive all the
way around.
13. Thsrobyhly mix all the adhesive and hardener together on a glass or metal plate with a putty knife.
NOTE:
Clean the plate with a sponge and alcohol before
mixing.
Follow the instructions that come with the
adhesive.
ALlGN M A R K S
15. Pack adhesive into the cartridge, without air pockets, to ensure continuous delivery. Put the cartridge
in a caulking gun, and run a bead of adhesive around
the edge of the glass as shown.
CLIP HOLDER
Smooth, continuous
bead, 10 mm thick.
ADHESIVE
18. Spray water on the windshield 1 - 2 hours after installing the glass. Mark any leaks and let the windshield dry, then seal leaking area with urethan
windshield adhesive.
NOTE:
@ Do nor squirt water on freshly applied adhesive.
Quarter
Interior Trim
- Replacement
FRONT PILLER T R l M
1 . Remove the door trim.
2. Remove the grab rail
(only passenger side).
3. Insert a t h i n plate between
garnish and front pillar, remove
the 3 clips, and remove the
garnish.
4. Slide the garnish t o the rear, and
remove i t f r o m the roof clip.
DOOR TRIM
REAR SHELF
1 Remove the quarter w ~ n d o wt r l m
and speakers
2 Remove the cl~psb y h ~ t t l n gthem l ~ g h t l y
w~th
a plastic hammer f r o m the unders ~ d eof the rear shelf
CAUTION:
Do not bend the rear shelf excesr~veily,
as it breaks easily.
At the tlme of tnrtallatton, check the
wtring for the rear w ~ n d o wdefroster
wtres.
Rear Seat
- Replacement
1.
2.
Pull the seat back all the way down, and pull the
trunk floor rnat from the trunk to the inside.
4.
Rear view
6 x 1.0 mrn
10 N.m (1.0 kg-m, 7 Ib-ft)
\
G x 4.0mm
CLIP PIN
3.
RUBBER BUMPER
7.
CUSHION M O U N T BOLT
6 x 4.0 mm
40 N.m (1.0 kg-m, 7 Ib-ft)
TRUNK SIDE
GARNISH
LOCK CYLINDER
RUBBER MBUMT
LATCH
Seat Cover
rI Replacement
Front seat bask
1.
2.
- Replacement
1.
2.
Other seats
1.
II
3.
4.
RETRACTOR
RETRACTOR
LOWERANCHORBOLT
Replacement (corst")
5.
Slide the front seat foward until the seat belt center
anchor bolt is accessible, then remove the bolt and
the center anchor
1.
2.
3.
6.
I
I
ELR
Q
NOTE: When installing belt, make sure it i s not
twisted behind the seat.
COLLARS
P L A I N WASHER
LOCK WASHERS
PLAIN WASHERS A
BEARDRiG
UPPER
/ ANCHOR
ANCHOR
BEARING
W A V E WASHER
f
I
ANCHOR
LOWER
BOLT
32 P4.m 13.2kg-m, 23 Ib-ft)
1.
2.
Remove:
@
BASE
SCREWS
3.
4.
Sunvisors
Console
P Replacement
1.
2.
Carpet
Replacement
Remove:
3.
Sunroof
Illustrated Index
SLIDING GLASS
Adjustment, page 22- 2 8
Replacement, page 22-29
ROOF MOLDENG
/"
MOUNT BRACKET
COVER
SUNSHADE
Replacement, page 2 2 - 2 9
/
WIND DEFLECTOR
Adjustment, page 22-29
Installation, page 22-32
SUNROOF FRAME
Replacement, page 22-30
Sunroof
7.
1.
-~
F------
f
.>
.. .
.
.
--- -
L, ---.
-.
---- _--
i
:
:
-
_
,
-
R A I L COVER
;I.
'
LIFT-UP GUIDE
?:?f
r Glass Side
Clearance Aaustment
3.
4.
Tighten nuls.
ds
nec~ssary.
3.
LIFT-UP GUIDE
\
ADJUSTER
5.
Opzn the surroof and pry the rail covers off both
sides.
2,
4.
2.
MOUNT B R A C K E T C O V E R
PLUG
1I
3.
3.
4.
MOUNT NUTS
5.
NOTE The height ot t h e drfiectai when open cannot oe adjusred. If damaged or deformed, replace ~t
- Cable Replacement
-.
With the sun roof out of the car, remove the guide 1 3 1 1
rnourtlng nuts, i ~ f ot f f the gu~dera~ls,and remove the
cables.wlth the rear mounts arrached.
2.
OUTERCABLE
6;WQMMET
,y
>,I
,5'
,+yIIz-=-.
7
I
,/Y
,/P
,//'
//
Sunroof
LOCKWASHER
USTlMG N U T
increase force
To decrease force
3.
CLUTCH
LOCKWASI-IER
/
ADJUSTING NUT,
Engine compartment
RELAY
.\
j--
Water leak
Deflector noise
Motor noise
1
I
2.
3.
1.
Loose motor.
1.
P
A
-
3.
1
I
2,
3.
4.
5.
1.
--- -
2
3
4
Wind noise
Probable Causes
-- Gap between glass weatherstrlp and roof panel
Deflectwe or ~mproperlyInstalled glass weatherstr~p
Clogged d r a ~ ntube.
Gap between glass weatherstr~pand body
---
I - -
Symptom
-
Troubleshooting
3
4
-
Blown fuse
Faulty r w ~ t c h
Battery run down
Defect~vemotor
-
__
----
- - --
- --- ---
--
10P COUPLER
ARDtREAR WINDOW
ROSTER SWITCH
E LIGHTER ASSEMBLY
rlng n u t a n d rewove the
22-35
Gauges
DX:
CAUTION:
0
Do not touch the printed circuits.
Avoid damaging coupler terminals.
COVER
AMPLIFIER
RESET KNOB
GAUGE VISOR
UNDER VISOR
Si:
NOTE: A v o i d damaging terminals and printed circuit.
COVER
RESET KNOB
GAUGE VlSOR
UNDER VISOR
Glove Box
'a! u! ~ ~ !o!pe.i
i s a43 ~I!M laued
ayl at\owad pue 'euuaaue pue o!peJ 'aqS!~ Ae~iqse
'246!1 xoq an016aqi
BU!J!Mayi 13auuo3s!p ' u a q l
.pued qsep zyfi!~JaMol aqa WQJ) sljoq ayl a/boulau 'g
.Aa~iqseaqi anowad pua xoq an016aql uado
'5
S P A E ~ A ~ ~ J2
'2
'I,
Dashboard
Replacement (cant") ----9. Remove the 9 dashboard mounting boils.
10. Lift the dahbaard as you pull so it will slide off the guide pin a t the middle; hold it from underneath so it won't fall
when it comes off the pin.
Front Bumper
Repiacement
FRONT BUMPER
Slide the bumper to the front
Dx:
MOUNT BOLT
8 X 1.25 mm
22 N.m
(2.2 kg-m. 16 Ib-ft)
CORNER SLIDE
8 x 1.25 mm
22 N.m (2.2 kg-m, 16 Ib-ft)
BUMPER
MOLDING
Rear Bumper
r Replacement
Si:
LICENSE PLATE
M O U N T BOLT
REeR BUMPER
BUMPER BEAM
'
BUMPER STAY
MOUNT BOLT
8 x 1.26 mrn
2 2 N-rn
12.2 kg-rn, 16 Ib-ft)
Dx:
BEAR BUMPER
BUMPER STAY
M O U N T BOLT
8 x 1 . 2 5 mrn
2 2 N.rn 12.2 kg.
BUMPER MOLDING
'runk Lid
Replacement
1.
2.
3.
Remove the ititch and lock cylinder, then disconnect the wire harness and cable.
4.
5. Remove t h e hir:ge bracket mounting bolts, then remove t h e hinges from t h e trunk.
6.
Before tightening tht? hinge bolts, check the adjustments shown below:
Q7GAZ-SE30100
'
d fi- flusb w t h t h e
\
6x50rnm
10 N rn ( 1 0 k~ rn, 7 Ib-ft)
'CY
A d i u ~ tr t r ~ b e ru p c 2 n dd c n n .
dnd right and left untll trunk
id 1 5 f l u s h witr; t h e ,ca- edge
o f the body
--,
'-9
t h e handle.
2.
3.
4.
CLAMP
I.
2.
/
'
' ' A
I,
Si:
Unit: mm
Heater
Illustrated Index ............................
...23-2
Heater and Blower Boor Positions ....... 23-3
Circuit Diagram ......................
.
...... 23-4Troubleshooting/Connector Informa.
.
.
................ 23-5
tion ....................... .
Blower
.
.
.... 23-6
Replacement .......................
Overhaul ....................
.
.............a 23-6
Heater Assembly
Replacement ................................ 23-7
Heater Core
ReplacementlOverhaL81
................... 23-8
23-9
Control Panel
Replacement ................................ 23-9
Overhaul ...................................... 23- 10
.............. 23- 4 0
Test ......................
.
.
.
Test
...23-1 1
Solenoid Valve Test ................... .
Diaphragm Test ............................ 23-1 2
Relay Test . ................................... 23-12
Vent/Heat/Befrost Switches ........... 23-12
Power Transistor Test .................... 23-4 3
Heater
BLOWER
Replacement, page 2 3 - 6
D~sassernbl\/,page 2 3 - 6
POWER TRANSISTOR
Test~ng,page 2 3 - 1 3
H E A T E R V A L V E CABLE
Adjustment, page 2 3 - 9
Test~ng,page 2 3 - 1 2
23-2
Recirculatiorr w i t c h OFF
Recirculation switch ON
OUTSIDE A I R
Heater
Door positions shown
according t o which
function button is
pushed.
AIR MI
DOOR
(Cold)
NOTE: This diagram shows the air mix doors in the most appropriate position for each heater control position. The position of the air mix door is controlled by the TEMP lever and is independent of the heater control position.
Circuit Diagram
- TroublshootinglConnector
1.
2.
.
.
.
.
.
3.
Information
page 2 3 - 1 0
page
page
page
page
page
23-1 1
2 3 - 12
23-1 2
23-1 1
23- 1 2
Wire harness.
- Replacement
1.
2.
3.
6.
=
=
=
=
=- - - /
.
~ 3
I'
BLOWER D U C T
SOLENOID
FAN
BLOWER
MOTOR
TRANSISTOR
BLOWER R E L A Y
CALITlON:
Heater Assembly
- Replacement
2.
3.
4.
i
1
7.
8.
9.
10.
5.
HEATER DUCT
II
Heater Core
Heater Care Replacement
RETAINING
PLATE
1
2
3
4
VENTIDEF
SWITCH
HEATER SUB
HARNESS
SOLENOID V A L V E
O L E N O I D V A L V E (VENTIDEFROST)
HEATER PIPE
COVER
CAUTION.
@
2.
3.
SWITCH
- lest
Using the chart below for the pin location, check for
and 51 lead
continuity between the pin marked "0"
when the respective mode switch is pushed in.
NOTE:
@
BI
Test
II
Continuity Test:
Check for continuity between the G and BI, BI and Y
and Y and G terminals.
Recirculation Solenoid
Continuity Test:
Check for continuity between the terminals.
Make sure the fuse is in good condition.
1.
2.
Draw vacuum
1.
3.
2.
Draw vacuum.
3.
4.
4.
5,
\/
v A(R'I-)
BI ( B A T T E R Y )
Test
I
11
1
Diaphragm Test
2.
i!
Coririec:
;ivacuum
3.
i?t h e I C doer
~
not reiurr! l u l i y replace t h e diaph~agrn.
I
1
CAUTlON
Don't rnest'a? the linkage rod by hand.
TRc draphragm may be diitvaged.
5f~:-~>i;7~j~.
Thei-t si.~ould ue
2.
Disconnect the wire harness from the power transistor. Pull out the LGIBI lead from the connector
and connect a 1.2-3.4 watt bulb as shown. Then,
reconnect the wire harness to the transistor.
3.
1.2-3.4 W
BULB
Air Conditioner
System Index ..................................
Evaporator ......................
,
.
..........
Condensor ........................ .
.
Performance Test ................... .
.
.
...
Service Tips ...................
........
.....
.....we...
24-2
24-3
24-3
24-4
24-5
Compressor
Troubleshooting .....................
.
.... 24-6
Replacement ....................
.........
24-7
Clutch Inspection .......................... 24-8
Clutch Overhaul ............................ 24-9
Shaft Seal Removal ....................... 24-10
Shaft Seal Installation .................... 24-1 1
Evaporator
Replacement ......................
....
... 24-1 3
Overhaul ..................................... 24-1 4
Condensor
Replacement
..................... .
.
.
..... 24-1 5
Test
Thermostat Test ........................... 24-1 6
Relay Test .................................... 24- 16
A/C Control Switch Replacement ..... 24- 16
A/C Control Switch Pest ................. 24-1 6
Pressure Test .................................. 24-1 7
Discharge Procedure ........................ 24- 1 7
System Evacuation .......................... 24-1 8
beak Test ....................................... 24- 18
System Charging ............................. 24-1 9
Idle Boost
Diaphragm and Solenoid ................. 24-20
Adjusment ..................................2 4 - 2 0
Air Conditioner
System Index
EVAPORATOR
As refrigerant c ~ r c t ~ l a t e sheat
,
I S absorbed f r o m the surrouritiing
passerigt'r c o r n p a r t n i r n t air.
Replacement, page 2 4 - 1 3
Overhaul, page 2 1 - 1 4
BLOWER
CONDENSE P
D~sstpatest h e heat w h ~ c h
was absorbed b y t h e refrtgerant
Replacement, Dage 2 4 - 1 5
COMPRESSOR
Compresses t h e refrigerant a n d t h e n
forces ct t h r u t h e condenser.
Compressor troubleshooting, page 2 4 - 6
Compressol replacement, page 2 4 - 7
COMPRESSOR C L U T C H
Overhaul, page 2 4 - 9
Fieiav tes?, page 24-16
Compressor
--
TEST RESULTS
Ii
II
2
i!
RELATED %VMPXO&?S
-.---.-a
PROBABLE CASE
,_
,i
_ ____-__-
_
I
I
.
_
.--
kine rc condenser
Discl-:;:?-ge pressuri:
abncrrnaily Icw
-.I--
.
I in system.
! ,#ccELtdf3?.
.-~&.
I
. . -- ..--.-...I-.-_.-------.--..--.--.-! Exce:.zEve t:ubbI~"s
ir: ';'pi:~ gi,a~r;
.L C O P ~ M I Ii sS r.3l
~~
i---.--.--.I---..-...----.---..--_-.-
Clean,
Check voltage and fan rpm.
heated.
!
1i
: Repair or repiace.
?!OW.
,..__I__-_
if-"--Excanl:i.c;r: *~;iiii!i : n f a t i ,
i !ow pressure hose i s cocler thar,
'
pa""',,pic,..sio~
?.- rr.
valve ovlcler and cvapo:-a' pt>r.
- i..eaki~gt 3 ? ~ i m 0 ~ t a t .
- -1
1
A
1- - . - - - - . - I"- -
'
Frorep e x p ~ n s i o nva!vt..
Fau;"~ ~ - < p a l s i ovelve
i~
1
2-4.
Check for leaks.
' Charge as required
LL
t~~r~ffi~ii?n":rtl-grigerant.
c
i
: Heplace compressor.
-t-
P\~.
.
~ u t l e aC
t expamion valve is riot
----
I
/
I O O ~ )after
---4
radiator fins.
1 Higii 2nd
ii;
--
1 required.
...--- .-
I Excessivtr i.e*r!gersnt in
REMEDY
i-__-.:___-:
*
a
i-eoking thssrnos?af.
I Replace expansion valve.
F i ~ z e nexpansion vaiwe.
F ~ l . ! b $~ X P L ~ T : Sv/ O
~~
T :v F ? .
F7oyi.n eviporatcr.
off.
-v-Clogged expansion vaive.
: CIe6t.i or replace.
.-----
"-
repair or repiace.
S ~ c r i o n{itow) pre-,E-c,&
pressure hose and check joint
st^^.: +iis:;c.rmai;y
k'yh , G;B 6300ltlr dhao around eBiapcr&tor.
Excessive refregerapi in
SvL.TEri:.
1 I-recessary.
Faulty gasket,
i Replace compressor.
Fairlry hi@ pressure valve. j
Foreign particle s:iici< in
i
tligh preswre va!ve.
I
'
- Replacement
1. Run the englne at idle speed and turn on the air
conditioner for a few minutes.
2. Shut the engine off and disconnect the battery negarlve terminal.
3. Disconnect the compressor clutch lead.
4. D~scharge the refrigerant very slowly from the
system.
5. On a car with power steering, loosen the steering
pump adjusting and mounting bolts.
6. i i f t the power steering belt off the pulley.
7. Remove the power steering oil pump.
8. Disconnect the suction and discharge hoses from
the compressor.
10 x 27 rnm BOLT
47 N m (4.7 kg-m, 34 Ib-ft)
92 x 1.25 x 52 mm
48 M.m (4.8 kg-m, 35 Ib-ft)
Compressor
CEuteh inspection
Check pulley bearing play a ~ ddrag by rotating the
pulley by hand. Replace the pulley with a new one i f
it i s noisy or has excessive play and drag.
24-8
- Clutch Overhaul
1.
3.
Use snap ring pliers to take off the snap ring, then
remove the pulley from the shaft with a 2 or 3 jaw
puller.
CAUTION: When removing the snap ring, be careful not to damage the aluminum compressor snout.
4.
AIR CONDITIONER
PULLEY HOLDER
07923-PB80001
I
CLUTCH
cTIL
SHIM
PULLEY
2.
BOLT
SNAP
RING
3"""""
SNAP R l N G
6 rnrn BOLTS
Compressor
2.
5.
32 mm SNAP R I N G
3.
7.
8.
Rotate the Shaft Seal Remover clockwise or counterclockwise to make sure that the cutout is engaged
with the metal pawl.
S H A F T SEAL R E M O V E R
H07934-SB20000
WOODRUFF
1 1
M E T A L PAWL
----
1
I
1.
solvent.
N QTE :
@ Use only clean refrigeran.t ail,
e Do not touch the sealing surfaces of aha shaft
seal a f t e r lubricating.
CAUTION:
@
Keep the cleaning solvent and dirt wt of the
compressor.
6
@
r Do not spiDi the refrigerator oil from the cornpressor. ReFiEI the same amshsnd of t h e oil if the
oil is spillad out.
NOTE:
3.
4.
SEAL
FLAT
f
I
Compressor
'
13. Press the snap ring with the grip side of the remover.
:-71
METAL PAWL
1
14. Install the shirn(s) and woodruff key
WOODRUFF KEY
m /
11. Press the seal seat with the grip side of the remover.
CAUTION: Be careful not to damage the compressor.
Evaporator
1
2
9.
SEALING
BAND
Evaporator
'B
2.
3.
4.
5
ID
the hotisirgs
R~ienbte
the evaporator in the reverie of dtsassembik, and
anshali the exparlsmn cover capillary l ~ b againsr
e
the suction [ I F ~ and
,
wrap it wlth tape
@ Re~nstail
the thermostat caprllarf tube IP Irs original locat~on
@ Rcassswble t h e upper a ~ In~*vev
d
housings w t h !he ciij3s, in;kie Z i l T i :he,e i;~e ?a g d p b Lrb:if~t'trl f l i t i i
@
EVAPORATOR
Blow dirt out of fins
rni~thcompresced alr
CAUTION D o not
damage capt[ldry tube
when remowirsg from
eraooratur (ins
TAPE
Replace
Make sure there I S ns f o r e ~ y nmatter stuck
betwcen the captilary tube ailc outlet 11,ie
EXPANSlON
VALVE
Condenser
Replacement
1.
CAUTION :
9
5.
Cap the open fittings immediately to keep moisture and dirt out of tlie system.
Be careful not to damage the condenser fins and
tubes.
----
M O U N T I N G BOLTS
RUBBER MOUNTS
6.
Test
A/"CCoritrcsi SwiPei-1Replacement
Thermostat Test
D , p rkae therm:::tat
capillary tube into a pan filled with
ice water, and check for continuity,
. . . . . . . . . . 1.5-0.5'~ (35-33'~)
Cut-in . . . . . . . . . . . 3.0-5.0'~ (37-41~~1
Cur-off
1
I
I.
2.
3.
4.
5.
6.
II
I
CONTROL PANEL
16E WATER
TEMPERATURE
60NTROb LEV
BRACKET
-..-
1.
2.
2
Thc:e slicrr~dbe con~inuitybetweer tne terminals 3
-=-
Discharge Procedure
Pressure Test
1.
2.
3.
4.
Keep away from open flames. The refrigerant, although nonflammable, will produce a poisonous gas
if burned.
Work in a well-ventilated area. Refrigerant evaporates
quickly, and can force ail the air out of a small enclosed area.
1.
2.
CAUTION:
4.
LOW PRESSURE
VAL
HIGH PRESSURE
(Close)
LOW PRESSURE
VALVE
HlGH PRESSURE
VALVE
Leak Test
System Evacuation
NOTE: When an A/C System has beep opened to the
atmosphere, such as dur~ngtnstallat~onor repair, it must
be evacuated uslng a vacuum pump (If the system has
been open for several days, the receiver-dryer should be
replaced).
9
2.
3.
H I G H P R IESSURE
LOW PRESSURE
1.
,,
HIGH
PRESSURE
VACUUM
PUMP
I
'
J,
25
1
REFRIGERANT
CYLINDER
System Charging
Always wear eye protection when charging
the system.
The A/C system may be charged with refrigerant by
either Vapor or Liquid niethod:
1,
2.
3.
RE
LOW PRESSURE
------
5.
LOW PRESSURE
VALVE
For vapor charging
HiGH PRESSURE V A L V E
For ~ t q u i dcharging
Catbureted Engine:
Atter ci-rarging. check thc idfe $peed *n,itrPI rRe &ir sonditia~;ei cn:
Fuel-Injected Engine:
1.
2.
Connect a tachometer.
3.
4.
Adji.1~; idle saaeed, if s~ecc-saari,by turning the adCP the bi!C idt? cciitroi a/ai!!e.
i ~ : ~ t i nbait
g
SOLE%SQI@.
VALVE
5.
'7.
n~bz??dj
speed.
11
D
I
r
d
Electrical
Engine Electrical ............................ 25-2
B o d y Electrical .............................. 26-2
Harness. Fuses. and Diagram .......... 27-2
Engine Electrical
Illustrated Index .............................25-2
Starter
Illustrated Index ..........................25-3
Test ..........................................~ 5 - 5
Replacement ..............................25-8
Reassembly .............a.m..............s
25-1 2
lgnition System
Wire Inspection and Test ............... 25- ;3
Coil Test ....................................25- 1 3
Condenser Test ..........................2 5- 1 4
Distributor Removal ....................25- 1 7
Distributor Installation .................ec-38
Distributor Overhaul ................... 25-22
Ignition Timing ...........................25-25
Spark Plug Inspection ..................25-27
Charging System
Battery InspectioniCharging ............25-28
Warning Light Test ....................25-29
Condenser Test ..........................25-29
Voltage R e g ~ ~ l a t oTest
r
...............25-38
Alternator Output Test ................25-32
Alternator Replacement ...............25-34
Alternator Belt Adjustment ...........25-35
G,- 3 G
Alternator Overhaul .....................2
Alternator Brush Inspection .............25-38
Rotor Slip Ring Test .................... 25-39
RectifierIStator Test
Garbbereted Engine
25-40
Fuel-Injected Engine ................. 25-42
Alternator Rmssembly ................. 25-43
BE
+ -b
.........a,.......z.
Engine Electrical
Illustrated index
While you're working:
Before Troublesho~ting
:
0
@
CAUTION: Do not pull on the wires when disconnecting a connector; pull only on the connector
housings.
CAUTION:
o Do not quick-charge a battery unless the battery
ground cable has been disconnected, or you will
damage the alternator diodes.
CHARGE WARNING
LIGHT
IGNITION COIL
Test, pages 25-1 3 and 14
RADIO NOISE
CONDENSER
Test, page 25-29
VOLTAGE
REGULATOR
Test, page 2 5 - 3 0
STARTER
Index, pages 25 3 and
Tesr, page 25-5
Replacement, page 25-8
Reassembly page 25 12
--I\
/'
dm>
_i
- ,-__
--
DISTRIBUTOR
Removalllnstallation, pages 2 5 - 1 7 and 18
GverXaiil, pages 25-22, 2 3 and 2 4
Timing, page 2 5 - 2 5
BATTERY
Inspection and Charging,
page 2 5 - 2 8
Replacement, page 2 5 34
Belt Adjustment, page 2 5 3 5
Overhaul, pages 25-36 and 37
SPARK PLUG
Inspect~on,page 2 5 - 2 7
Starter
Iliustreted Elndsx [Gear Reduetion 1.4 kw, ND)
CAEbeF!QN: D~sconnectthe ground cable from tile bat-
rsry
DO56
QVERRUMNlMG
CLUTCH ASSY
STARTER
SOLENOBO
YHalDlrGGS HOUSlNG
URE HOUSING)
tBhER GEAR
CAGE
ARMATVW E
Inspectton and
Test, page 25-9
HARNESS CLIP
Starter
Illustrated Index (Gear Reduction 11.4 kw, MitsulSa)
CAUTION: Disconnect the ground cable from the battery post before removing the starter.
OVERRUNNING
CLUTCH ASSY
STARTER
SOLENOID
GEAR'HQUSING
COVER
HARNESS CblP
END COVER
RUSH HOLDER
Inspection, p ~ g e
25-11
ARMATURE
lnspecrion and
Test, page 25-9
ARMATURE HBCdSlNQ
Test, page 25-12
j-- Test
5
2.
3 8 " (59
~ dnd 100F) before testrng.
Alternate Procdurs:
GROUND
Ammeter, 0-400 A
3,
e Tachometer 0-1 200 rpm
2.
Starter
4.
I f the starter engages, but cranks the engine erratically, remove the starter motor. Inspect ehe
starter, drive gear, and flywheel ring gear far
damage.
CI-iectc the drive gcar overrunning ciutci.3 for
binding or slipping when the armaature i s rotated
w i t h the drive gear held. Replace the gears if
damaged. See page 25-1 I ,
~3
25-10),
@
7.
- Soienoid Test
1.
Check puii-in coii for continuity between the soienoid terminal and any convenient ground. Coil is
OK if there is continuity.
2.
Cheek hold-in coii for continuity between the soienoid terminal and the motor terminal on the solenoid. Coil is OK i f there is continuity.
Nippon Denso:
Nippon Denso:
SOLENOID T E R M I N A L
\
SOLENOID T E R M I N A L
Mitsuba:
Mitsuba:
SOLENOID T E R M I N A L
SOLENOID T E R M I N A L
2.
3.
4.
5.
1.
MARMESS CLIP
(M/Ponly)
STARTER CABL
M/T: 10 x 1.25 x 85
A n : 10 x 1.25 x 125
45 N.rn (4.5kg-m, 32 I b - h )
-9
3.
If surface IS d ~ r ~ recondrt~on
y,
it w ~ t i ?a $505 or
#600 sandpaper Then, check mica depth If necessary, undercut mica wrth a hacksaw bisde to ach~eve
proper depth as shown
Inspect for
damage.
2.
SANDPAPER
MBCA DEPTH
Standard (New):
ND: 0.5-0.8 mrn i6.020-0.031 in.)
Mitsuba: 0.4-0.5 m m (0.016-0.020 in.)
COMMUTATOR
Service Limit:
ND: 0.2 mm (0.008 in.)
Mitsurba: 0.15 mrn (0.8306 in,)
V E R N I E R CALIPER
Starter
Armature lnspeetisn and Test Ceorrtrd)
5. Place the armature on an armature tester. Hold a
COMMUTATOR
SEGMENTS
SHAFT
COMMUTATOR
8.
li
Brush inspection
Measure brush length. ? f not within service iimir, replace
the armature housing and brush holder assembly.
Standard (New):
ND: 14.5-15.5 mm (0.57-0.61 in,)
Mitsuba: 14.3-14.7 mrn (0.57-0.58in.)
Sesv~ceLimit:
ND: 8.5 rnm (0.33 in.)
Mitsuba: 9.3mm (0.37in.)
@ BRUSH HOLDER
BRUSH HOLDER
@ BRUSH MOLDER
--
Starter
Starter Reassembly 1-
2.
RUSHES
2.
ARMATURE
HOUSING
lgnition
---
1.
Check condition of the wire terminals. If any terminal is corroded, clean it, and if i t is broken or
distorted, replace the wire.
rI
Carbureted Engine:
1.
corroded, or bent
terminals.
2.
2.
Ignition
r Ignition Coil Test (cant"]
Test
Fuel-injected Engine:
1.
W i t h the ignition switch OFF, disconnect the primary connectors and the coil wire.
2.
NOTE: 86slstance will v a r y w ~ t hthe cod temperature. Resistances are for 20C 1703F)
Primary Winding Resistance (between the A and B
terminals):
a 2- 4.5 ohms
Ssscor-adsary Winding Resistance (between the A and
secondary winding ferminaisJ:
1 1,074- 'I1.%26ohms
Resistance beaween the B and D termined!~:
Approx. 2.200 ohms
SECONDARY
WINDING
TERMINAL
3. Check lor continuity between the A and C terminals. Replace the coil if there is no continuity.
Circuit Diagram
PRIMARY WINDLNO
SECONDARY
WIMDlNG
/ 7
4.
(&
COVER
WIRE
HARNESS CLIP
2.
@ terminal,
and negative probe t o the igniter unit (ground),
then measure resistance on the igniter input.
-PICK-UP COlL
3.
Measure resistance between the G and Bu2 terminals on the pick-up coil. Replace the pick-up coil if
t h e resistance is n o t within specifications.
NOTE: Resistance will vary w i t h the coil temperature.
Pick-up Coil Resistance:
Apprax. 750 ohms at 20C (70F)
(cont'd)
Ignition
igniter Unit Test (contrd)
1.
I-
-,
1.
2.
STATOR
SCREWS
RELUCTOR
2.
3.
4.
SILICONE
GREASE
CAP
Distributor Removal
Carbureted Engine:
1.
1.
2.
2.
3.
4.
PR~MARY'
LEAD WlRE
4.
PRIMARY L E A D WIRES
VACUUM HOSES
HOLD-DOWN BOLTS
COIL WIRE
VACUUM HOSES
Ignition
rI
I1
Distributor installation
Fuel-injected Engine:
Carbureted Engine:
1.
1.
2.
DlSTRlBUTOR E N D
NEW O-RING
'//
DISTRIBUTOR
GROOVES
CAMSHAFT END
3.
4.
CONDENSER
4.
IGNITION COIL
,IGNITION COIL
Bu
BI/Y
I.
1
1
Carefully pry up ti-ts ielvcror by using two screwdr,rers as s~owift:.Do srct damage the relbctor arid
stator.
RAG
2.
Ignition
2.
Disconnect the diaphragm arm then pull the diaphragm out of the distributor.
I
I G N I T E R UNIT
lGNlTER COVER
GROUND W I R E
2.
,--
Distrii~u-ova ~ i e r l - ~ a{Cavb~rraaed
~l!
Engine]
--------.
--
D1AMAGNETIC SCREW
MAGNET SET
BRIFAKER PLATE
RELUCTOR
CAP
Check for cracks, wear.
damage, or fouling.
Clean o r replace.
ROTOR
B A L L BEARING
\
THRUST WASHER
I
SHAFT
THRUST PLATE
C-CLIP
Replace
a /AS
RUBBER CAP
MOLYBDENUM
DlSULFlDE
GOVERNOR SPRINGS
IGNITER COVER
IGNITER
MOLYBDENUM
DlSULFlDE
VACUUM ADVANCE
DIAPHRAGM
THRUST WASHER
PIN RETAINER
Replace
COUPLING
t
I
IGNITER SEAL
O-RING
Check f o r damage.
O-RING
CAP SEAL
Replace
/
DISTRIBUTOR
HOUSING
Check f o r cracks
o r damage.
/
O I L SEAL
Replace
\
\
Ignition
DIAMAGNETIC SCREW
CAP
Check for cracks,
SET PLATE
THRUST PLATE
ROTOR SHAFT
IGNITER SEAL
MOLYBDENUM
VACUUM ADVANCE
DIAPHRAGM
IGNITER COVER
IGNITER UNIT
3.
Disconnect the vacuum hoses from the vacuum advance diaphragm and, while the engine idles, check
each hose for vacuum.
The inside hose (#2 for Carbureted engine)
should have vacuum.
The outside hose ( # I 5 for Fuel-Injected engine)
or #28 for Carbureted engine) should not have
vacuum.
I
5. Adjust ignition timing, if necessary, to the following specifications.
Ignition Timing
Carbureted engine:
Manual Transmission:20 + 2' BTDC (Red) at
8 0 0 + 5 0 rpm in neutral.
Automatic Transmission: 12Of 2' BTDC (Red) at
800 + 50 rpm in gear.
Fuel-Injected engine:
All models: 15O + 2' BTDC (Red)
at 7 5 0 + 5 0 rpm in neutral.
Automatic Transmission
Red mark
FLYWHEEL
DRIVE PLATE
ADJUSTlNG BOLTS
TIMING LIGHT
9.
ADJUSTING NUT
Disconnect the vacuum hoses from the vacuum advance diaphragm and p ~ n c hthe end of the hoses
using fuel iine clamps ( 0 7 6 14 - 0 0 5 0 1 00).
The tlrnlng should be 4OBTDC.
TO RETARD
ADJUSTING BOLTS
7.
Tighten the adjusting bolts (and nut for FuelInjected engine), recheck the timing.
8.
1.
011
Standard plug:
ga P
'
foul~ng
B Carbon
ciepostts
e Cracked
center
electrode
~nsulator 1
Carbureted Engine:
BPRBEY-14 (NGK), W20EXR-U11 (ND)
Fuel-hjectesl Engine:
BPR5EV-3 1 [NGK), W15EXR.blll [ND)
(for all notrnai driving)
BPR6EV-11 (NGK), WSUEXR-U^I 4 (ND)
(for hob climates or continuous high speed d ~ v i n g )
Cracked
insUlatOr
2.
in.)
4.
5.
NOTE: App!y a srnali quantity of anti-seize cornpound to tho plug threads before installing.
Charging
3.
IaATSUSI-IBTA or FURUKAWA:
Peel off the strip of tape aver the caps, then
$,emobJethe capo and add elecuolyte until the
level rises ta tEw !$%PER ?7IarK or indicator turns
blue (see NOTE its step 3).
DELGO or HBNBA:
Electrolyte cannot be added because these batterics are perrsrd"aentv yealed
:iilASA.
I
NOTE: On a sealed battery, check the specific
gravity s f the electrolyte by looking at the indicator
on the top of the battery. Charge the battery if the
indicator is white. Follow the indicator description
on the battery for other conditions.
INDICATOR
4.
1.140
1.100
1.060
0 2 , 4 6 8 10 12 14 16 18
-I
NOTE: Before resting, cneck the wire hart%?!::; connections and alternator bell: tension.
I.
1
1
1
IB
~~'___YL_I__^--7--4
----------7
is
11
Charging
Voltage Regulator f est
Caabureted Engine Only:
1.
CONDENSER
2.
QV
,-_-
---
~Batreryvolfage
7.5 V aggrox.
I Battery voltage
1
9.- 11 V
r---
3.
4.
5-7.5 V
Check the alternator belt tension, and adjust or replace the belt as necessary.
2.
1I
ALTERNATOR 5
If there is no battery voltage, check the IG terminal wire (blackiyellow) and No. 4 fuse ( 1 0 A ) .
@
5.
3.
Charging
4.
CAUTION: Don't let the v ~ l t a g ereading at the battery exceed 19 volts. If i t does, shut the engine off,
and then replace the voltage regulator.
5.
Turn on the:
e Headlight switch (high beam).
Rear window defroster switch.
@ Heater blower switch (HI).
6.
Fuel-Injected Engine:
1.
2.
4.
5.
Turn on:
Headlight switch (high beam).
Rear window defroster switch.
Heater fan switch (Ill).
6.
Charging
r Alternator Wepiacement
I
I
Fuel-Injected Engine:
1.
Disconnect the ground cable from the battery negative post (-).
1.
2.
3.
3.
Disconnect the ground cable from the battery negative post (-1.
B TERMINAL
TERMINAL NUT
WHITE WIRE
HARNESS CLIP
I1
'
4.
'
NGlNE WlRE
HARNESS
4.
ADJUSTING BOLT
B x 1.25mm
24 N.m (2.4 kg-m, 17 Ib-ft)
\:'\
ADJUSTING NUT
ALTERNATOR
THROUGH BOLT
ALTERNATOR NUT
MOUNT BRACKET BOLT
1 0 x 1.25 mm
1 0 x 1.25 mm
4 5 N.m (4.5 kg-me 33 Ib-ft) 4 5 N-m (4.5 kg-m, 33 Ib-ft)
\
ALTERNATOR NUT
10 x 1.25 mm
45 N.m (4.5 kg-m, 33 Ib-ft)
ALTERNATOR BOLT
l o x 1.25mm
4 5 N.m (4.5 kg-m, 33 Ib-ft)
7.
1.
NOTE: On a brand-new
~6
nlrii
ADJUSTING R4UT
6 x 3 .Q n$!n
70 ?cd*:mi4.0 ?~-rn,7 It:.".lPj
ALTERRATOW BOLT,
8 x "?25 aawn
24 Mwm 12.4kg-r~i,
?gy$*l-EB
PUMP
PULLEY
:.- .
--
--"
AL'TEHNAIOR NU?'
2.
3. f $ ~ v eshe ai+czrnar~rto &stain .rhe proper- be!? tension and ~.etiqhtenthe bolt and nilt.
belt.
Charging
Fuel-Injected Engine:
NOTE: It is only necessary t o separate the pulley,
drive end housing and rotor when the front bearing
needs replacement.
To remove the pulley and rotor, use 10 m m and 22 m m
box wrenches t o loosen the pulley locknut. Use an impact wrench t o remove the nut if necessary.
TERMINAL INSULATION
kd
PULLEY LOCKNUT
7 3 him 17.3 kg-rn, 53 Ib-f0
VOLTAGE REGULATOR
Test, page 25-31
DIODE (RECTIFIER) ASSY
Test, page 25-42
HARNESS CLIP
REAR HOUSING
INSULATION
SLEEVE
REAR BEARING
BEARING
RETAlNER
SPACER RING
//
FRONT BEARING
/"
ROTOR
Test, page 25-39
STATOR THROUGH
BOLT
STATOR ASSYi
DRIVE END HOUSING
Test, page 25-43
i
\
PULLEY
PULLEY LOCKNUT
73 R1.m (7.3kg-rn, 63
Charging
Fuel-Injected Engine:
1.
2.
V E R N I E R CALIPER
VERNIER CALIPER
2.
If the brushes are not within the service limit, replace them.
3. If the brushes are not within the service limit, replace them.
SOLDERING IRON
BRUSHES
Garbuaeted Engine:
1.
Fuel-injected Engine:
1.
2,
2.
ROTOR SHAFT
3.
138TOR SHAFT
m
p
p-p- - -
Charging
RectifierIStatsr f est (Carbureted Engine)
NOTE: To test the rectifier or stator, you must separate
them by unsoldering the connecting wires.
1.
Rectifier Test:
NOTE: The diodes are designed to pass current in one
direction and block current in the opposite direction.
Since the alternator rectifier is made up of six diodes
( 3 pairs), each diode must be tested for continuity in
both directions; a total of 12 checks.
3.
RECTIFIER ASSY
'
2.
4.
Stator Test:
6.
LEAD W I R E S
GROUND STUD
7.
w
GROUND STUD
5.
COIL CORE
8.
Charging
Car-mezt NEGATIVE test probe t o sreuna terminal and POSITIVE probe to P terrntnal of each
diode par
If any of the 16 checks sho~msconti!xjity ii: both directions, or no continuity in both directicns, the
diode is defectjve and the rece!t(isr assembly must
be replaced, {Diodes are no: availabie separately.)
Alternator Reassembly
Reassemble the alternator in the reverse order of disassembly.
I.
INSULATOR W A S H E R S
REC
+ STUDS
2.
LEAD WIRE
3.
BRUSHES
Charging
Alternator Reassembly (canted)
3.
4.
CONDENSER
Body Electrical
Illustrated Index ....................................26-2
............ 26-1 5
Trunk LightISwitch Test ........................26-1 5
Trunk Latch Switch Test .......................26-1 5
Seat Belt Switch ..................................26-1 6
Key Switch Replacement ......................26-1 6
Key Switch Test ..................................26-1 6
Horn Switch Test .................................26-1 7
................
26-7
............................... 26-1 8
Ashtray Light Bulb Replacement ................ 26-1 8
........ 26-4 2
Gauge Light Replacement ......................26-1 2
Dashboard Light Bulb Replacement
........................ 26-1 4
......................... 26-14
..................26-1 8
...................26-1 9
....................26-1 9
Headlight Adjustment ...........................26-1 9
License Plate Light Replacement ............ 2 6 - 2 0
Front Turn Signal Light Replacement ...... 2 6 - 2 0
Sealed Beam Replacement
....................................2 6 - 2 0
Taillight Replacement ............................2 6 - 2 8
Gauges ...............................................26-21
Power Door Mirror Troubleshooting .......... 2 6 - 2 2
Cruise Control Troubleshooting ................ 26-23
Power Window Troubleshooting ............... 2 6 - 2 9
High Mount Brake Light Replacement ......... 2 6 - 3 3
Replacement
Body Electrical
Bilasstrated Index-
- .
Before troubleshooting;
oi rece;7tiicl~s.
silicove grease.
Pack with s ~ ' , c o f i eyre;.se
RETRACTABLE B-IEQDLIGCIT
SUNROOF PAOTOW
/'
T r s r , page 26-1 5
TAILLIGHT
MOT0W
R e p l z c e m ~ n l ,~ n a e26-7 i
Test, pzge 266-1 1
LICENSE P L A T E L I G H T
Rc:piacemenr, oayc- 26-20
!
I
T U R N S I G N A L LIGHT
F e p ~ ~ c c r n e n :page
,
26-33
DGOR SWITCH
-T,~s:, E ; ~ Q P 26-1.1
lRepiucernent, page 26-'4
ANTENtVA
Rep;accmen:,
pagc 2 6 13
SAFETY l M 5 l C A f Q R
Bulb Replacement, page 26-13
H&ZARD/DEFROSTER SWITCH
Hazard Switch, Test, page 2 6 - 8
Rear Defroster Switch, Test, page 26--8
W A R N I N G DISPLAY
8uIb Replacement,
HORN W I T C H
Test, page 2 6 - 1 7
L I G H T BRIGHT-
~ e s t page
,
26-5
K E Y SWITCH
Replacement, page 26-16
C O M B l N W l l O N S W i f CM
( L I G H T I N G , T U R N SIGNAL/
DIMMER1
Test, page 26-6
Body Electrical
Relay, Amplifier and Control Unit Location
CRUISE CONTROL
UMlP
SUNROOF MOTOR
I
DOME LIGHT
TIMER
RETRACTABLEHEADLIGHT
CONTROL UNIT
I
4.
I I
'
r'qrrnical
ACC
BAT
6. lnsert the ignition key and check for proper operation of the steering wheel lock,
7.
SHEAR SCREW
/
TWIST-OFF PORTION
Body Electrical
Combination Switch Test
Check for continuity between the terminals in each
switch position according t o the table.
Dimmer Switch
Headlight Switch
To intermittent
-RETRACT
'8
: Wiy
* TURN:
HORN: Bu/R
i G i : GI51
& * TURN: GlBl
Lo: Bu
RETRdCT
INT A : Bulw
Xi: Buiy
Tc Side Vv'ire Harness
GMD: BI
26-fi
'3
: WiB
II
1.
I-
I/
2. Connect the voltmerer positive probe tc> the terminal A ( R lead) and negative probe to the termiral
B
3.
EBI lead).
Dimmer Reiay Test -There sl?nuid be no continslty between the B and 9 teririinals atid continuity between rhe A and D terminals,
wher: the battery positive cable is ccnnected to the E
terminal and nea;bi.de cable tc the F terminal.
There skouici be csntinuity between tile B and D teirninals and no continuity betweeri the X and 9 terminals
with the battery disco~ctected,
Turn th~1
controllet. i?dji:stmen: kgob.
ADJUSTMENT KNOB
f" Lighting Relay Test--There should be continu~rybetween the A and B Perininais, when applyrng battery voltage to the C (posrtive) and D (negative) terminals There should be no
continuirbp wnen the battery is drscornected,
>:Of E : 'i.r:is
relay i s I O C Z T <ir:
~
t k ~ irelay
box, in the
Body Electrical
Retractable HeadiightiSunroof
Switch Test
Check for continuity according t o the table felow
Retractable Headlight
Switch
Hazard Switch
Termtnal
U'
'
'
DEF
!
RELAY
RELAY
1641
!3
ID)
62
GND: BI
RELAY (L):Buly
RELAY: BuiG
ILLUMINATION @: RIB1
ILLUMINATION
:R
DEF RELAY: G
% a: W I ~
ILLUMINATION @ : RIB1
IG?(B): GIBI
82:
WlBu
BI @ : WIR
I81
OFF
1!
OPEN
CLOSE
wire
'
IG-I
Position
II
-
OPEN
IP!
'
CLOSE
ICI
-+-I
Body Electrical
1
I
Replacement
1.
4.
El x 1.25 mrn
14 N.rn
(1.4 kg-rn, 10 Ib-ft)
2.
3.
1
CLIP
Test
1.
Test the motor low speed by applying battery voitabe: Positive to the G/BI lead and negative to the
Bu lead.
2.
Test the motor high speed by applying battery voltage: Positive to the G/BI lead and negative to the
Bu/Y lead.
3.
\ , s J L L L t
S: 5u/W
View from
wire srde
B: G/BI
-Windshield Washer
Test the reeracror motor bv applying battery voltage to the Bu/R (positive) and 81 (negative) leads.
2.
4.
RepEacemenr
1. Remove the front bumper
no co:i"rnur"
CAUTION :
repealedly.
15A fuse.
/<-i
c'
MOTOR
CLAMP
3.
,'
tes+. ~ f l ~ r i e ba:tety
ct
oos,tlve d \ i r t . to this
tei~i~val
WASHER MOTOR
Best
Test the motor speed by applying SaTtery voltage to i t s
terminals.
For right w<jtnlnqcircuit check, move t h a
a a l t e r y po61;1~t.
cable t c I termlri
s t m e proocdcire cis for the left cl
NOTE
Body Electrical
Retractor Relay Testing
--
There should be no curlrinulty berween the i3 and B tetminals and conrinu~tybetween the C and A terrn~najs,
when the battery posrtlve cable IS connected to the E
terminal and negative cable to the F terrn~nal.
There should be continu~tybetween the C and 5 terminals and no continuity between the C and A terminals with the battery disconnected.
h u g e Light Replacement
1
TO
26-72
antenna Replacement
1.
2.
BULB
4.
ANTENNA
C!oek Replacement
1.
2.
PANEL
Body Electrical
,
Dome Light Replacement
1.
2.
4.
BULB
\,
2.
HOUSING
-b &-
SCREW
1.
LENS
E
To Door Switch
From B a t r e v
LENS
Body Electrical
-Seat Belt Switch
Check for continuity.
@
2.
3.
SWITCH LEADS
Use an ohmmeter
There sr~ouldbe continuity between the contact ring and
hub cure when the horn s w ~ t c h 1s depressed, and no
continully when reledsed.
7.
2.
CONTACT
'
----
Body Electrical
Fuse Box Light Replacemeat
7.
3.
BUSH ROD
I-
counterclockw~srand rernodc
2.
-I
I I
I
2.
3.
4.
R E T A I N I N G Wlh%O
H E A D L I G H T CASE
BRACKET \
M O U N T I N G BOLTS
8 x 1.25mm
22 N , m ( 2 . 2 kg-m, 16 Ib-ft)
5.
6.
Headlight Adjustment
Adjust the headlights to local requirements.
HORIZONTAL
ADJUSTING SCREW
VERTICAL
ADJUSTING SCREW
Body Electrical
License Plate Light Replacement
I
1
Align
LENS
Taillight Replacement
Unscrew the nuts and remove the taillight.
COVER
Gauges
LIGHT (1.4 W1
Body Electrical
Power Door Mirror
Troubleshootirag
The power door mirror system uses No.9 110A) fuse
(REAR DEFROSTER @IG2).
- Pawer
Mirror Test
Replacement
1.
1.
2.
Clear the tab of The switch rear end from the door
panel.
2.
3.
Connect the barterv to rhe R'J or LV and R or h termicals. The mirror I S normal if rT moves sn7oofhiy.
4.
IS
norrnai if
I?
moves smootlsiy.
- Cruise Coa.etso&
Trouhlesh~oting--------NOTE 8 4 u r e v o u t r y t o d ~ a c n o s e31 rcpalr the probiem, cneck
@ Throttle cable free piey
@ For a Fuil-systen- check, basen c n controi unit ~ r ~ p l j tplease?
s
see page 26-28
@ Actuator cable free plav
@ Throttle linkage oparatiorr
@ W1r3harness ccnnectors
O b'iacuIJQ7 lines
l
if all possibie scurces of rna'functton check OK, replace t h e c o ~ t r o untt.
Body Electrical
Cruise Control Main Switch
Replacement
1.
2.
rI
RESUME
SWITCH
I,
ON
I
+
+
OFF
,
1
c--- ------ L1
Wire Color
SLIP RING
CONNECTOR
C
D4, D3 and 2 position: There should be continuity between the A and B terminals.
ROD
TERMINALS
- Brake bight Switch Test There should be continuity between the A and D terminals, and no continuity between the B and C terminals,
w h e n the rod is pushed in.
There skotild be no c o ~ t i n u i t ybetween the A and D terminals, and continuity between the B and C terminals,
w h e n the switch IS free.
- Cruise Actuator
Solenoid Test
TERMINALS
(A)-(D)
(C)-(Dl
RESISTANCE
40-60R
3 0 - 5 8 11
43-60 II
V ~ e wfrom pln side
5
D
[COMMON
POSITIVE)
A [SAFETY GROUND)
SAFETY VALVE
C (VENT1
VENT
VALVE
-
L-,
4-
VACUUM
VALVE
Body Electrical
r
I
I
ActuatorlCable Replacement
1.
Pull back the boot and loosen the locknut, then dis
connect the cable from the bracket.
4.
TO VA
TANK
With voltage and vacuum still applied, try to pull the actuator rod out by hand.
It should not be able to be pulled. If it can be, it is defective.
Clean the vent tube and the actuator filter then disconnect the battery negative terminal from the terminals
(A) and (B).
The actuator rod should return.
If actuator rod does not return, the solenoid valve is defective.
Body Electrical
r
I
Wire
I
l
Test condit~on
Black
BrownIWhlte
l
1
Test: oes~redresult
lgnttion s w ~ t c hOFF
Possible cause
Llght Blue
1
1
Gray
1
1
1
;hie
I
Green/
8
Red
A n o p e n o r short rn t h e wire
Faultv actuator
b s w t t c k pushed.
1
i
1.-
j
---~
+ght
/
1
1 ohms
1 C o X z t a g e t o g r o u n d
I should b e 12 volts
lgnltlori swttcb ON
j and rnaln s w ~ t c h
1 ON
-1
1
I
--------T-----5
Faulty actuator
w ~-r -e-should-.
b e 40-60
ohms
- - --
t
I
Poor ground.
An open In the 81 wire
--d-
Poor ground.
An open in the wlre.
Misadjusted brake s w ~ t c ho r f a u l t y
- - -.
Light Green/
Black
Faulty s l ~ pring.
wanI
.-LL ,
!
I
selector ~n0 3 , D4 or 2
IA'TI.
lgn~tionswitch ON
and ground the red
wire
Poor ground.
Ciutch switch misadjusted.
i
/ Check the pilot light: ?he pilot
'
A
~
.
-
term~nals.should be 0-12-0.-
12V repeatedly
1
-
View
---
<ram wire s , d t
Faulty bulb.
An open In the wire.
Faulty lgnitlon system.
-.
I
The power window system uses a 35 A main fuse and 15A AUXILIARY Fuse Holder No.1 (front left door), No.2 (front
right door).
I.
2.
-2
i
-
1.
TAB
--
- /
DOOR PANEL
-X
Body Electrical
Power Window Switch Test
--
UP
OFF
DOWN
DOWN
MAIN
Switch
Color
--
(AUTO)
81 y
,
-
-I_i__i--,Wy
BY G
RIG BulBI Bu y
Bi
84 6
B i
Driver s Door:
For t h e a r ~ v e r ' saoor, ccn~iec'ia battery posltlve lead t o
the B u / R and a g r o ~ i r dlead t o :he Bu,W. Theti reverse
the leads to b ~ sure
thz; the m o w will run In both
directions.
There should he continuity between the A and B terminals, when the battery is cont~ectedto the C (positive)
and D (negative) terminals.
There should be no continuity when the battery is disconnected.
Bu'W
f
Passenger's Door:
For the passenger door, c u q r e c l a barrery positive
lead to ope Inire and ci g r o r i i d icad t o i h e other wire
Then reverse the leads :o be sure ;hat t h e motor w ~ lrun
l
iil b o t h dlreCllOr!S
Body Electrical
Black (81)
1
1
WhiteiYellow (WIY)
WIY
( V I E W F R O M W l R E SIDE)
BlIG
Output Test: The control unit couplers are reconnected and the control unit ground wire is disconnected with ignition
switch ON.
Wire: test condition
GROUND WIRE
(VIEW F R O M WlRE
SIDE)
Connector Directory
Fuel-Injected Engine
Engine Wire Harness ..............................27-1 1
Main Wire Harness ................................27-1 1
Left Side Wire Harness ...........................27-13
Heater Wire Harness ..............................27-14
Dashboard Wire Harness ........................ 27-1 5
Trunk Wire Harness ...............................27-16
Door Wire Harness ................................ 27- 16
Fuel Unit Wire Harness ...........................27-1 6
Roof Wire Harness ................................27-7 6
Dashboard Wire Harness B ......................27-1 7
Heater Control Panel Wire Harness ........... 27-1 7
Rear Defroster Ground Wire .................... 27-1 7
Carbureted Engine
Engine Wire Harness .............................. 27- 18
A/C Wire Harness ................................. 27-18
Carburetor Wire Harness ........................27-18
Main Wire Harness ................................ 27-19
Left side Wire Harness ............................ 27-20
Heater Wire Harness .............................. 27-20
Dashboard Wire Harness ........................ 27-21
Trunk Wire Harness ...............................27-22
Door Wire Harness ................................27-22
Fuel Unit Wire Harness ........................... 27-22
Roof Wire Harness ................................ 27-22
Dashboard Wire Harness B ...................... 27-23
Heater Panel Wire Harness ......................27-23
Rear Defroster Ground Wire ..................... 27-23
Lb -Light Blue
Lg -Light Green
Br -Brown
GND-9 and
C-79
Fuel-injected Engine:
HEATER WlRE
WlRE HARNESS
SUNROOF WlRE
\
DRIVER'S
DOOR WIRE HARNESS
27-5
NK WlRE HARNESS
HARNESS
DOME LIGHT
WIRE HARNESS
DASHBOARD
WlRE HARNESS B
GND-13
C-761
- Connector Directory
Fuel-injected Engine:
Engine Wire Harness
CONNECTOR
TERMINAL
NUMBER
1
1
NUMBER
OF
PlNS
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
Alternator
Oil pressure switch
Starter niotor
No. 1 lnjector
No. 2 lnjector
No. 3 lnjector
No. 4 lnjector
EGR valve lift sensor
Throttle angle sensor
Intake air temperature sensor
Back-up light switch '
M i T only
Back-up light switch ,
Oxygen sensor
Crank angle sensor
Temp. unit
Thermosensor
Thermoswitch
Main wire harness (C-75)
Resistor
Left side wire harness (C-102)
Left side wire harness iC-101)
Main fuse box
Alternator
Engine ground
Enqine qround
CONNECTOR
TERMINAL
NUMBER
NUMBER
OF
PlNS
LOCATION
Left front
Left front
Left front
Left front
Left front
Left front
Left front
engine
engine
engine
engine
engine
engine
enaine
compartment
compartment
compartment
compartment
compartment
compartment
comnartment
DESTINATION
To
To
To
To
To
To
To
II
C-58
C-59
C-60
C-6 1
C-62
C-63
C-64
C-65
C-66
C-67
C-68
C-69
'2-70
C-71
C-72
C-73
C-74
C-75
C-76
c-77
C-78
C-79
C-86
C-8 1
C-82
C-83
C-84
C-85
C-86
C-87
C-88
T-3
GND-3
GND-4
NUMBER
OF
PINS
I
1
1
1
2
3
3
2
2
6
*
I
i
I
i~
2
8
6
3
2
4
4
1
1
I
I
I
I
I
I
1
2
7
20
24
LOCATION
DESTINATION
To A C Pressure s w ~ t c h
To AIC Pressure s w ~ t c h
1 To AIC Compressor clutch
T o Washer motor
/ To Left horn
1 To Left horn
I
To Left headl~ght
To Left s~demarker llght
To Left front turn s ~ g n a l
To R ~ g h horn
t
I To R ~ g h horn
t
1 To R ~ g h headlight
t
To R ~ g h st ~ d emarker l ~ g h t
1 To R ~ g h front
t
turn s ~ g n a l
1 To R ~ g h headlight
t
retractable motor
To Coollng fan motor
1 To Coollng fan s w ~ t c h
I
To Eng~newire harness (C-18)
To Control box
TO M a n ~ f o l dalr pressure sensor
To EGR valve l ~ f sensor
t
I
To Condenser
To Condenser
To AIC D ~ o d e
To AIC Compressor clutch relay
TO l g n ~ t ~ oCOII
n
To l g n ~ t ~ ocod
n
To Sunroof wire harness (C-736)
To Heater wrle harness (C-'I 8 3 )
To Heater wrle harness (C-186)
To Heater wrle harness (C-185)
To Alternator
To Body ground
To Body ground
1I
1
1
,
CONNECTOR
TERMINAL
NUMBER
NUMBER
PINS
'
LOCATION
Left center engine compartment
Left center engine compartment
Left center engine compartment
Left center engine compartment
Left center engine compartment
Left rear engine compartment
Left rear engine compartment
Left rear engine compartment
Center floor
Center floor
Left floor
Left floor
Rear left window
Left front trunk
Fuel tank area
Fuel tank area
Left floor
Left floor
Left floor
Left floor
Rear shelf
Left door
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left under dash
Left center engine compartment
Left trunk
DESTINATION
To Engine wire harness (C-21)
To Engine wire harness (C-20)
To Cruise control actuator
To Main wire harness (C-53)
To M a ~ nwire harness ((2-54)
To Brake fluid level switch
To Windshield wiper motor
To Air control solenoid valve
To Parking brake switch
To Seat belt switch
To Power window control unit
To Power window control unit
To Rear window defroster
To Rear wire harness (C-251)
To Fuel pump
TO Fuel unit wire harness (C-711)
To PGM-FI control unit
To PGM-FI control unit
To PGM-FI control unit
To Atomospheric sensor
To Rear tray wire harness ('2-200)
To Left door switch
To Door wire harness (C-3011
To Door wire harness (C-302)
To Seat belt timer unit
To Key light timer unit
To Brake light switch
To Clutch switch
To Heater wire harness (C-152)
To Heater wire harness (C-154)
To Heater wire harness (C-153)
To Combination switch
To Combination switch
To Fuse box
To Dashboard wire harness (C-205)
To Side marker control unit
To Dome light wire harness (C-731)
To Body ground
To Body ground
NUMBER
OF
PINS
LOCATION
DESTlNATlON
1
I
I
I
/
1
I
'
r-zGGGTGW
i
NUMBER
OF
PlMS
TERM~NAL
RlEJMBER
1
LOCATDON
DESIlNWTlOM
-
1
1
I
'
I
/i
C-193
C-104
C 195
C-196
6-197
C - I 98
C-20C
C-207
GND 3
END ?O
Trunk
Trunk
Trunk
Trunk
,
I
i
i
I
I
Trunk
Trunk
Rcar shelf
Center rear shelf
R~ghtupper trunk
Trunk lid
-..-.---J
- --
CONNECTOR
TERMINAL
NUMBER
C-203
C 204
C-205
C-206
C-207
(2-208
C-2C9
C-210
C-211
C-2'12
@-213
C-214
6-24 5
C-246
C-217
C-218
C-219
C-221
C-722
C-224
GND-1 1
/-E&);----
NUMBER
OF
PlNS
------
18
2
10
14
18
2
13
I
I
I
1
1
3
3
10
12
8
10
16
1C
6
13
3.
I
I_*_
/
I
1
I
_L_-----------------
--
----
- -
--
'
I
I
1
10
I
DESTINATION
LOCWTlON
--
__ - -__- _
-To Heater wire harness ( C - 1 6 4 i
To
To
To
To
Chime
Healer wire harness ( C i 58)
Left slde wire Parness (C 135)
Fuse b o x
1c9 Fuse box 11ghZ:
T9 Retractable h e a d l ~ y h tzontrol u r l t
P o illurn~nationcontroller
T o Crurse control maln s w i t c h
To Retractable headl~gh?/sunroofs w ~ t c h
T o Gauge
To Gauge
t
indicatcr ( A l l )
T o S h ~ f posltlon
T o Safety indicator
To Gauge
T o Clock
T o Heater wlra harness !G-165)
To Dashboard wire harness B (C-741)
To C ~ g a r e t t elrghter
To Cigarette Ilghter
1 3 Hazerairear defroster s w i t c h
To Body ground
--
----I
NUMBER
OF
1
+-!?EL
C-251
C-252
C-253
C-254
C 255
C-256
C 257
GND-12
I
I
8
8
2
2
8
'
I
I
LOCATION
DESTINATION
Left trunk
Left trunk
Center trunk
Center trunk
Right t r u ~ k
Under rear bumper
Under tear bumper
Left trunk
/
I
1
1
To
To
To
To
To
To
To
To
CONNECTOR
TERMlNAL
NUWlBER
1
1
I
I
NUMBER
OF
PINS
DESTINATION
LOCATION
Left under dash
Left undei dash
Left under dash
Left under dash
Right under dash
Right under dash
Left door
Left door
Left door
Righr door
Righr door
Right door
Left door
Left door
Right door
Righr door
Left door
C-304
C-302
C-303
C-304
C-305
C-306
C-307
C-308
C 309
C-310
C-311
C-312
C-313
C-37 4
C-34 5
6-316
C-377
CONNECTOR
TERMINAL
NUMBER
1
1
NUMBER
OF
PiNS
3
3
_i___-___
--
NIJMBER
OF
PINS
LOCATIBY
DESTINATION
I
I
DESTINATION
I
I
1-
C-711
C-7 12
LOCATION
/
I
CONNECTOR
TERMINAL
NUMBER
NUMBER
I
L-To Main w ~ r eharness (C-85)
I
LOCATION
Right under dashboard
Front center rcof
DESTlNATlON
I
--*
To Sunroof motor
a
--- ---
CONNECTOR
TERMINAL
NUMBER
C-741
C-742
C-743
C-744
C-745
C-746
C-747
CONNECTOR
TERMINAL
NUMBER
NUMBER
I
I
I
C-761
GND-13
C-751
C-752
CONNECTOR
TERMINAL
NUMBER
NUMBER
OF
PINS
10
10
/
!
LOCATION
Center
Center
Center
Center
Center
Center
Center
dashboard
dashboard
dashboard
dashboard
dashboard
dashboard
dashboard
LOCATION
Center dashboard
Center dashboard
DESTINATION
To
To
To
To
To
To
To
DESTINATION
T o Heater wire harness (C- 170)
T o Heater control panel
NUMBER
OF
LOCATION
DESTINATION
PINS
Right rear w i n d o w
Right rear w i n d o w
T o Rear w i n d o w defroster
T o Body ground
NUMBER
OF
PINS
+
LOCATION
REMARKS
To Alternator
To Thermosensor
To Automatic choke
To Temperature gauge sender unit
To Carburetor wire harness (C41)
To Back-up light switch
To Back-up light switch
To Temperature sensor
To Temperature sensor
To Frequency solenoid
To Starter motor
To Main wlre harness (C77)
To Main wire harness (C76)
To Main wire harness (C75)
To Oil pressure sender
To Alternator
To Junction box
To Engine ground
MIT only
MIT only
TERMiNAL
NUMBER
,,
NUMBER
OF
PINS
,
i
6
C32
C33
1I
1
C35
C36
C37
GND-2
4
4
/
I
CONNECTOR
TERMINAL
NUMBER
I
I
LOCATION
--
I NUMBER 1
'1 PINS
OF
/
1
I
DEs-rlNATloN
,i
1
1
LOCATION
REMARKS1
To
To
To
To
' To
To
To
1 To
DESTINATION
To Engine wire harness (C5)
To inner vent solenoid valve
To Main air jet solenoid valve
To Main air jet solenoid valve
To Air vent cut-off solenoid valve
To Primary slow mixture cut-off
solenoid valve
To Primary slow mixture cut-off
solenoid valve
To Auxiliary slow mixture cut-off
solenoid valve
NUMBER
OF
PINS
__I
REMARKS
LOCATION
To Left side wire harness (C-181)
To No. 2 control box
To Frequency solenoid valve
To At6 solenoid valve
To Retractor relay
To Retractor relay
To Left headeight retractor motor
To Horn
To Horn
To Left turn signal
To l e f t side marker light
To Left headiight
To Oxygen sensor
To Horn
To Horn
To Right headlight
To Right side marker light
To Right turn signal
l o Washer motor
To AIC wire harness 1C-31)
To Cooling fan motor
To Cooling fan switch
To Right headlight retractor motor
To Engine wire harness ( C - i 51
To Engine wire harness (C-141
To Engien wire harness (C-13)
To Condenser
To IC. regulator
To Ignition coil
To Radio noise condenser
To Radio noise condenser
To Emission control box
To Emission curitrol box
To Emissiori control unit
To Heater wire harness (@-I 5 3 )
To Heater wire harness (C-75%)
To Sunroof wire harness ((3-736)
To Emission control unit
To Junction box
To Body ground
To Body groc~nd
r(
CONNECTOR
TERMINAL
N
U
'
NUMBER
OF
PINS
!
i
LOCATION
Left front engine compartment
Left rear engine compartment
Left rear engine compartment
Left rear engine compartment
Behind fuse box
Behind fuse box
Behind fuse box
Behind fuse box
Behind fuse box
Left fuse box
Behind fuse box
Left fuse box
Left fuse box
Under driver's seat
Under driver's seat
Left door area
Left fuel tank
Left fuel tank
Rear left window
Left front trunk room
Rear shelf
Behind fuse box
Left front engine compartment
Left trunk room
I
I
1I
DESTINATION
REMARKS
I
I
1
1
CONNECTOR I NUMBER
TERMINAL
OF
NUMBER
PINS
C 1 5 2 -14
C153
/
C154
1
C155
C156
C157
C158
C159
C160
C161
(2162
C164
C165
C166
1
1
i
i
LOCATION
-
3
4
16
6
/'
1
i/
DESTINATION
REMARKS
--___t__---
1i
A/T only
AIT only
CONNECTOR I NUMBER
TERMINAL
NUMBER
LOCATION
,PLs
C177
C178
C179
C180
GND7
GND8
Center console
Center console
Center console
Right door area
Right under dashboard
Center dashboard
2
2
10
DESTINATION
To
To
To
To
To
To
REMARKS
A / T only
A I T only
A I T only
NUMBER
OF
PlNS
LOCATION
DESTINATION
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
To
Center dashboard
Behind right gauge panel
Center dashboard
Center dashboard
Center dashboard
Behind gauges
Behind gauges
Behind gauges
Behind gauges
Center dashboard
Behind right gauge panel
Behind warning light
Behind warning light
Behind fuse box
Left kick panel
Under left dashboard
Behind fuse box
Behind fuse box
Behind fuse box
Behind fuse box
Under left dashboard
C212
C213
C214
C215
C216
C218
C219
C220
C222
C223
C224
GNDl 1
REMARKS
Clock
Hazardlrear defroster switch
Dashboard wire harness B ('2-741)
Cigarette lighter
Cigarette lighter light
Speed sensor
Safety indicator
AIT indicator
Combination meter
Heater wire harness (C-167)
Headlightlsunroof switch
Warning light
Dashlight brightness controller
Fuse box light
Key-onwarning chime
Retractable headlight control unit
Fuse box
Left side wire harness (C-105)
Heater wire harness (C-169)
Heater wire harness (C-170)
Body ground
NUMBER
0F
PINS
LOCATION
REMARKS
DESTINATION
I To
To
/ To
/ To
To
To
To
To
To
To
To
/ To
j
i
I
1r
CONNECTOR
TERMINAL
NUMBER
--
C-251
C-252
C-253
C-254
NUMBER
OF
PINS
-- -
8
8
2
2
8
2
2
C-257
?1
'
1
GND-12
LOCATION
I
I
DESTINATION
--
Left trank
Lefr trunk
Center trunk
Center trunk
?;:rt:Crkbumper
Under rear bumper
Left trunk
CONNECTOR
TERMINAL
NUMBER
NUMBER
OF
PINS
C-303
C 305
C-313
C-? 14
C-315
C-316
DESTlNATlON
'
'/
Right door
---- --
Ii
CONNECTOR
TERMINAL
I
1
NUMBER
OF
/!-
NLIMBER
PENS
I
I
I
LOCATION
DESTINATION
-----C 731
L-1 - C-732 -
_
_
I
-
NUMBER
OF
LOCATlON
I
L
-
I
1
3
___
To Dome light
1;
I
CONNECTOR
TERMINAL
NUMBER
/-C-736
1 C-737
--
'
NUMBER
2
2
or
PINS
1
1
LOCATION
Right under dashboard
Front center roof
DEsTiNATloN
C-741
C-742
C-743
C-744
C-745
C-746
C-747
NUMBER
OF
PINS
LOCATION
DESTINATION
-.--
Center
Center
Center
Center
Center
Center
Center
dashboard
dashboard
dashboard
dashboard
dashboard
dashboard
dashboard
To
To
To
To
To
To
To
I
1
C-751
C-752
NUMBER
OF
PINS
1
/
10
10
I
1
LOCATION
Center dashboard
Center dashboard
1
/
1
DESTlNATlON
To Heater w ~ r ehdrness (C-166)
C-761
GND-13
NUMBER
OF
PINS
I
LOCATION
DESTINATION
To Rear w ~ n d o wdefroster
To Body ground