87 Toyota Van Manual

FOREWORD
This manual contains maintenance and repair procedures for

the 1987 VAN.
Applicable models: YR 22, 29, 31, 32 series
The manual is divided into 22 sections and 5 appendixes with a

thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared
as relevant service manuals to the components and systems in
this vehicle.
Manual Name Pub. No.

1987 Van Electrical Wiring Diagram Manual EWD026U
Van & Model-F Collision Damaged Body BRMOO3E
Repair Manual (2WD only)
1987 model New Car Features NCF013U
All information in this manual is based on the latest product

information at the time of publication. However, specifications
and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION

1987 TOYOTA VAN
REPAIR MANUAL
INTRODUCTION 11m
MAINTENANCE mm
ENGINE MECHANICAL 1m
EMISSION CONTROL SYSTEMS lID
EFI SYSTEM II]]
COOLING SYSTEM Km1
LUBRICATION SYSTEM ~
IGNITION SYSTEM .m
STARTING SYSTEM Eli
CHARGING SYSTEM DJJ
CLUTCH lID!
MANUAL TRANSMISSION eli
AUTOMATIC TRANSMISSION Eli
TRANSFER .u
PROPELLER SHAFT En
FRONT AXLE AND SUSPENSION I:E
REAR AXLE AND SUSPENSION 1m
BRAKE SYSTEM 1m:
STEERING II3I
BODY ELECTRICAL SYSTEM .:m
BODY 1m
AIR CONDITIONING SYSTEM lEt!
SERVICE SPECIFICATIONS IEIII
STANDARD BOLT TORQUE SPECIFICATIONS . .
© 1994 TOYOTA MOTOR CORPORATION SSTANDSSM . .
All rights reserved. This book may not be re- AUTOMATIC TRANSMISSION ~
produced or copied, in whole or in part, with-
out the written permission of Toyota Motor
Corporation.
HYDRAULIC CIRCUIT
ELECTRICAL WIRING DIAGRAMS . .
-=-
IN-1
INTRODUCTION
Page
HOW TO USE THIS MANUAL . IN-2
IDENTIFICATION INFORMATION . IN-4
GENERAL REPAIR INSTRUCTIONS . IN-4
PRECAUTIONS FOR VEHICLES EQUIPPED WITH
A CATALYTIC CONVERTER . IN-7
VEHICLE LIFT AND SUPPORT LOCATIONS IN-8
ABBREVIATIONS USED IN THIS MANUAL . IN-10
IN-2 INTRODUCTION - How to Use This Manual
HOW TO USE THIS MANUAL

To assist you in finding your way through the manual, the Sec-
tion Title and major heading are given at the top of every page.
An INDEX is provided on the first page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given
that pertain to al/ repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the system problem and find the cause. The
repair for each possible cause is referenced in the remedy col-
umn to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit
together.
Example:
Backing Plate
+Bearing
Inner Retainer
+Retainer Gasket
+ End Gasket Bearing Outer Retainer
Bearing
'1
l.
I
,-------'-....., I
------. -......... L - -_ _- - - ' I
Brake Dru;;;- "- I

-""""'----J
Rear Axle Shaft

1.050 (76. 103)
t
Hub Bolt
I kg-em (ft-Ib, Nom)1 : Specified torque

RA1141
• Non-reusable part
INTRODUCTION - How to Use This Manual IN-3
The procedures are presented in a step-by-step format:

• The illustration shows what to do and where to do it.
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives
other information such as specifications and warnings.
Example:
~ Task heading: what to do

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a) Place SST and a dial indicator onto the overdrive
brake piston as shown in the figure.
SST 09350-30020 (09350-06120)
Illustration:
what to do and where / ~
Set part No. Component part No,
/ Detail text: how to do it
(b) Measure the stroke applying and releasing the com-

pressed air (4 - 8 kg/cm 2 , 57 - 114 psi or 392 -
785 kPa) as shown in the figure.
Piston stroke: 1.40 - 1.70 mm (0.0551 - 0.0669 in.)
~Specl'f"IcatlOn
This format provides the experienced technician with a FAST

TRACK to the information needed. The upper case task heading
can be read at a glance and only when necessary, the text
below it provides detailed information. Important specifications
and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when they
are required you are given the page to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step. You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A, specifications, for quick reference.
WARNINGS, CAUTIONS, NOTES:

• WARNINGS are presented in bold type, and indicate there is
a possibility of injury to you or other people.
• CAUTIONS are also presented in bold type, and indicate the
possibility of damage to the components being repaired.
• NOTES are separated from the text but do not appear in
bold. They provide additional information to help you effi-
ciently perform the repair.
IN-4 INTRODUCTION - Identification Information, General Repair Instructions
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is on the left top of the
instrument panel.
It is also on the floor pan slope under the front passenger seat
and on the driver's door post.
4Y-E Engine ENGINE SERIAL NUMBER

The engine serial number is stamped on the right side of the
cylinder block.
GENERAL REPAIR INSTRUCTIONS

1. Use, seat and floor covers to keep the vehicle clean and
prevent damage.
2. During disassembly, keep parts in order to facilitate
reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting it or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
other abrasive object.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer to tap the terminal onto the post.
(f) Be sure the cover for the positive (+) terminal is pro-
perly in place.
4. Check hose and wiring connectors to make sure that they
are secure and correct.
INTRODUCTION - General Repair Instructions IN-5
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, a-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the "." symbol.
6. Precoated parts
Seal Lac Adhesive Precoated parts are the bolts and nuts, which have been
coated with a seal lock adhesive at the factory.
(a) If a precoated part is tightened, loosened or caused
to move in any way, it must be recoated with the
specified ad hesive.
(b) Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut or
installation part threads.
IN0036
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
(c)Precoated parts are indicated in the component
illustrations by the "*" symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening tor-
ques. Always use a torque wrench.
9. Use of special service tools (SST) and special service
materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified
and follow the proper work procedure. A list of SST and
SSM can be found at the back of this manual.
10. When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the fuse amp rating
or use one of a lower rating.
11. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the
proper locations (See pages IN-8, 9).
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
the vehicle raised on jack alone, even for a small job
that can be finished quickly.
IN-6 INTRODUCTION - General Repair Instructions
12. Observe the following precautions to avoid damage to the

parts:
(a) To disconnect vacuum hoses, pull on the end, not the
middle of the hose.
~b) \' 0 pu\\ apart e\ectr\ca\ connectors, puH
.. CORRECT J r?Cr~C7C<;7'r- r·.::-,,;;,-o;:;;r,....-'" r7Q"C C"'r~ .--Y-r"'--vo",J' 0

on the con-
(c) Be careful not to drop electrical components, such as

sensors or relays. If they are dropped on a hard floor,
they should be replaced and not reused.
IN0001
(d) When steam c.leaning an engine, protect the IIA, from
water.
(e) Never use an impact wrench to remove or install ther-
mo switches or thermo sensors.
(f) When checking continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
(g) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter instead. Once the hose has been stretched, it
may leak.
13. Tag hoses before disconnecting them:

(a) When disconnecting vacuum hoses, use tags to iden-
tify how they should be reconnected.
(b) After completing a job, double check that the
vacuum hoses are properly connected. A label on the
floor pan shows the proper layout.
IN0002
INTRODUCTION - Precautions for Vehicles Equipped with a Catalytic Converter IN-7
PRECAUTIONS FOR VEHICLES EQUIPPED WITH A

CATALYTIC CONVERTER
WARNING: If large amounts of unburned gasoline flow
into the converter, it may overheat and create a fire hazard.
To prevent this, observe the following precautions and
explain them to your customer.
1. Use only unleaded gasoline.
2. Avoid prolonged idling.

Avoid running the engine at idle speed for more than 20
minutes.
3. Avoid spark jump test.

(a) Spark jump test only when absolutely necessary. Per-
form this test as rapidly as possible.
(b) While testing, never race the engine.
4. Avoid prolonged engine compression measurement.

Engine compression tests must be made as rapidly as
possible.
5. Do not run engine when fuel tank is nearly empty.

This may cause the engine to misfire and create an extra
load on the converter.
6. Avoid coasting with ignition turned off and prolonged

braking.
7. Do not dispose of a used catalyst along with parts con-

taminated with gasoline or oil.
IN-8 INTRODUCTION - Vehicle Lift and Support Locations
VEHICLE LIFT AND SUPPORT LOCATIONS
"'1.
Front
(4-Link Type) (Leaf Spring Type)
.~)\\\ l
~_~_~ID~~~A:\
~ ~.j" \)~
J
..,1I~/
~"","''',.
\~",
.~~.~
~
--~
-
'~
Front Side Rear Side (4-Link Type) Rear Side (Leaf Spring Type)
JACK POSITION ~
Front Center of front suspension crossmember
Rear Center of rear axle housing
PANTOGRAPH JACK POSITION - - - - - , - - - -

SUPPORT POSITION
0
Safety stand ~
601653 601654
601655 601656 ~0107
INTRODUCTION - Vehicle Lift and Support Locations IN-9
VEHICLE LIFT AND SUPPORT LOCATIONS (Cont'd)
SWING ARM TYPE LIFT

PLATE TYPE LIFT
............
':':' .
.:.::::.,::::. .:::::':::'::
:::':~:':':':.::: .
SWING ARM TYPE LIFT PLATE TYPE LIFT

Support position: Do not use a plate type lift as illustrated
Front Engine front mounting member above right as it would damage the battery
Rear '" Lower control arm installation case and rear heater unit.
bracket (4-Link Type)
Leaf spring front hanger (Leaf Spring Type)
601658
IN-10 INTRODUCTION - Abbreviations Used in This Manual
ABBREVIATIONS USED IN THIS MANUAL

A/C Air Conditioner
ALH Automatic Locking Hub
AIT, ATM Automatic Transmission
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
Bo Overdrive Brake
B1 NO.1 Brake
B2 NO.2 Brake
B:l No.3 Brake
BDC Bottom Dead Center
BTDC Before Top Dead Center
BVSV Bimetal Vacuum Switching Valve
Co Overdrive Clutch
C1 Front Clutch
C2 Rear Clutch
DP Dash Pot
ECU Electronic Controlled Unit
EFI Electronic Fuel Injection
EGR Exhaust Gas Recirculation
ESA Electronic Spark Advance
EVAP Evaporative (Emission Control)
EX Exhaust (manifold, valve)
Ex. Except
Fo Overdrive One-way Clutch
F1 No. 1 One-way Clutch
F2 No.2 One-way Clutch
FIPG Formed in Place Gasket
FA, Fr Front
IG Ignition
IN Intake (manifold, valve)
in. Inch
ISC Idle Speed Control
LH Left-hand
LHD Left-hand Drive
Max. Maximum
MP Multipurpose
MIT, MTM Manual Transmission
OD Overdrive
OPT Option
OIS Oversize
PCV Positive Crankcase Ventilation
OWC One-way Clutch
PS Power Steering
RH Right-hand
RHD Right-hand Drive
SSM Special Service Materials
SST Special Service Tools
STD Standard
SIW Switch
TDC Top Dead Center
TWC Three-way Catalyst
UIS Undersize
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
wi With
wlo Without
2WD Two Wheel Drive Vehicles (4 x 2)
4WD Four Wheel Drive Vehicles (4 x 4)
MA-1
MAINTENANCE
Page
MAINTENANCE SCHEDULE . MA-2
MAINTENANCE OPERATIONS . MA-4
GENERAL MAINTENANCE . MA-14 m9
GENERAL NOTES:
• Every service item in the periodic maintenance list must be
performed.
• Failure to do even one item can cause the engine to run
poorly and increase exhaust emissions.
MA-2 MAINTENANCE - Maintenance Schedule
MAINTENANCE SCHEDULE
Maintenance operations: A = Check and adjust if necessary;
R = Replace, change or lubricate;
I =Inspect and correct or replace if necessary
NORMAL CONDITION SCHEDULE
~
Maintenance services beyond 60,000 miles
Service interval (96,000 km) should be performed at the same
(Odometer reading or months, intervals shown in each maintenance schedule.
whichever, comes first) f- ----~---------,--____.----~---_____.__-~_____r--_.--________1 See page
System Miles x 1,000 10 20 30 40 50 60 (item No.)
f- Km x 1,000 16 32 :--~4~_8~-+--+_-6=4=:=8=0=:=~~_6-----i
Maintenance items
\ Months 12 24 36 48 60 72
-- - - ---- -- - - - ------ - - - - - - -- - ---- - - - - -----f------- ---________1--+-------------____j
ENGINE Drive belts(l) I I MA-4 (item 1)
r------------ - ---------------------------~--~--~------- ----- ---f--------- -+-------------
~-~-~g~ne oil and filte~* _ _ _~ R ~_f_______R--R-- ~--f-- MA-5 (item 5)
Engine coolant(2) R MA-5 (item 6)
- - - - - - - - - - - - - f - - - - - - - - ---f_______---+--------------j
Exhaust pipes and mountings I I MA-6 (item 10)

f--- - -- - --- ----- - - --- --- --- - -- - - - ------------
FUEL Idle speed(3) A A A MA-7 (item 12)
f---- --- - c- --- - ----- --------- f--------------________1
Air filter
-
* -- -- - --
R R MA-5 (item 4)
-------~--------j
Fuel line and connections I I MA-6 (item 9)

- - - --- - - - - - -- -- - - - - - ------------------
Fuel filler cap gasket R MA-6 (item 8)
-- - - ---- ----- - - ----- -- -- - -- ---- - -- -- - -- ---------1
IGNITION Spark plugs (Platinum tipped)* R MA-4 (item 2)
-EYA~~ _~_ - __~_~a~~?al c~~_i;!~r - - ---- [Calif. only ~-=-~ _~_~_-~~~~~~--- I MA-6 (item 7) ----
EXHAUST Oxygen sensor*(4) R MA-7 (item 11)
f----~ ------- ---- - - -- - - - -- ---- -- -- --r------- - - - - f - - - - - - - I - - - - - - - - - - - - -
BRAKES Brake lining and drums
-------- -- - - - ----- ----- -- - - - --
I - - -- --
I
---- --- -- ----
I MA-8 (item 14)
~ Brake pads and discs __ _ ___ I ---r-----I-- ----f-------'-- MA-8 (item 15)
; Brake line pipes and hoses I I I MA-8 (item 13)
- - - - -- - - - - - - t - - - - - - - - - -- - - - - - - - - - ---------- --- - ------- f - - - ----f--------+------+----j-----------1
CHASSIS Steering linkage I I I MA-9 (item 16)
r--------- ----- - -- --- - ------- -- - - - - - - - ---+----f------+-----+--------------j
Drive shaft boots 4WD only I I I MA-9 (item 18)
f-------- - - ------- -- ----- ----- ----f---+-----+--------------j
Ball joints and dust covers I I I MA-9 (item 19)
------ ---~--- - - -----+--f------+----+--------'-----------j
Front wheel bearing and thrust bush grease (4WD) R MA-10 (item 20)
}..!.~ering_ ~"ucl<l;;andchassis grease(5) ~WD only R R R MA-l0 (item 21)
Propeller shaft grease(5) 4WD only R R R MA-10 (item 21)
-----------~-----_.,._----- -~ -
Automatic transmission, manual transmission,

MA-9 (item 17)
transfer (4WD), differential and steering gear box
MA-10 (item 22)
oil
f---------- - - - - - - - - - - - - - - - ----- c-_ _ ---+----f---+----+------j--------------t
Bolts and nuts on chassis and body MA-12 (item 25)
Maintenance services indicated by a star (*) or asterisk (*) are required under the terms of the Emission Control Systems
Warranty (ECSW). See Owner's Guide or Warranty Booklet for complete warranty information.
* For vehicles sold in California
* For vehicles sold outside California
NOTE:
(1) After 60,000 miles (96,000 km) or 72 months, inspect every 10,000 miles (16,000 km) or 12 months.
(2) After 60,000 miles (96,000 km) or 72 months, replace every 30,000 miles (48,000 km) or 36 months.
(3) After 60,000 miles (96,000 km) or 72 months, adjust every 30,000 miles (48,000 km) or 36 months.
(4) Replace at 60,000 miles (96,000 km) or 72 months only.
(5) If the upper suspension arm and propeller shaft has been immersed in water, it should be re-greased within daily.
MAINTENANCE - Maintenance Schedule MA-3
Follow the severe condition schedule if vehicle is operated mainly under one or more of the following severe conditions:
• Towing a trailer, using a camper or car top carrier.
• Repeat short trips less than 5 miles (8 km) and outside temperatures remain below freezing.
• Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use.
• Operating on dusty, rough, muddy or salt spread roads.
SEVERE CONDITION SCHEDULE

Maintenance services beyond 60,000 miles
I\~ervice interval
(Odometer reading or months,
(96,000 km) should be performed at the same
intervals shown in each maintenance schedule. See page
System whichever, comes first)
Miles x 1,000 5 10 15 20 25 30 35 40 45 50 55 60 (item No.)
ENGINE
Maintenance items
Drive belts(l)
-------~~-
-----~~
\ Km
Months
x 1,000 8 16 24 32 40 48 56 64 72 80 88 96
6 12 18 24 30 36 ~2 48 54 60 66 72
I I MA-4 (item 1)
Engine oil and oil filter *
r-----------------~---------
R R R R R R R R R R R R MA-5 (item 5)
Engine coolant(2) R MA-5 (item 6)
--_.-------- -~------------- ----_.- ------ - - - - - - - - f - - -
Exhaust pipes and mountings I I I I MA-6 (item 10)
------- - -----_."- - ----------~---
FUEL Idle speed(3) A A A MA-7 (item 12)

- - - - - - - ~ -- - ~ _ . _ ~
Air fi Iter *(6-) I I I I I R I I I I I R MA-5 (item 3, 4)

~-------------- ------- ------ ---------------- --- -- -- -~----
Fuel line and connections I I MA-6 (item 9)

- - - - - - --- - - - - - -------'---_._-_.- ._-~_.
Fuel filler cap gasket R MA-6 (item 8)

-----------.--- ------ - - - - - - - - - - - - - - _ .._- - - --
IGNITION
------
Spark plugs (Platinum tipped)* R MA-4 (item 2)
-- -----
-----~----------------[-~--------
- - - -- - --
EVAP
-----~
~_~~Lco~l_c~rlL~~r _________~alif. only I MA-6 (item 7)
EXHAUST Oxygen sensor*(4) R MA-7 (item 11)
--'---- ----- - --~------- -- --,-------------- ---
---
BRAKES Brake linings and drums I I I I I I MA-8 (item 14)
- '------ ---- --------~.---------_._----- -
Brake pads and discs I I I I I I MA-8 (item 15)

--~-----------------------------
Brake line pipes and hoses I I I MA-8 (item 13)

----,- ------ --------------_.----~ -------"- - ------------ ._~
CHASSIS Steering linkage I I I I I I MA-9 (item 16)

-, .. __ .- -_ .. ~-------
Drive shaft boots I I I I I I MA-9 (item 18)

- - - - - - - - - ~ -- ~ - - - -
-- ----------- - - - - - - - - - - - - - - - - - - - - --
Bail joints and dust covers

- - - - - - - - - - _ .__ ._-_. ~ - - _ . __.-
I I I I I I MA-9 (item 19)
Front wheel bearing and thrust bush grease (4WD) R MA-10 (item 20)
c-----------.-------
Steering knuckle and chassis grease(5) R R R R R R MA-10(item 21)
Propeller shaft grease(5) R R R R R R MA-10 (item 21)
--------------
Automatic transmission, manual transmission, MA-9 (item 17)

transfer (4WD), differential and steering gear box R R R MA-11 (item 23)
oil(8) MA-12 (item 24)
Bolts and nuts on chassis and body(7) I I I I I I MA-12 (item 25)
Maintenance services indicated by a star (*) or asterisk (*) are required under the terms of the Emission Control Systems
Warranty (ECSW). See Owner's Guide or Warranty Booklet for complete warranty information.
*
For vehicles sold in California
* For vehicles sold outside California
NOTE:
(1) After 60,000 miles (96,000 km) or 72 months, inspect every 10,000 miles (16,000 km) or 12 months.
(2) After 60,000 miles (96,000 km) or 72 months, replace every 30,000 miles (48,000 km) or 36 months.
(3) After 60,000 miles (96,000 km) or 72 months, adjust every 30,000 miles (48,000 km) or 36 months.
(4) Replace at 60,000 miles (96,000 km) or 72 months only.
(5) If the propeller shaft has been immersed in water, it should be re-greased within daily.
(6) Applicable when operating mainly on dusty roads. If not follow the normal condition schedule.
(7) Applicable when operating mainly on rough and/or muddy roads. If not, follow the normal condition schedule.
(8) Inspect the steering gear box for oil leakage only.
MA-4 MAINTENANCE - Maintenance Operations
V-Ribbed Type MAINTENANCE OPERATIONS

ENGINE
Cold Engine Operations
1. INSPECT V-RIBBED TYPE DRIVE BELT
(ALTERNATOR) AND CONVENTIONAL TYPE DRIVE
BELTS
(PS PUMP AND AIC COMPRESSOR)
CH0039 CH0004 (a) Visually check the belt for separation of the adhesive
rubber above and below the core, core separation
Conventional Type from the belt side, severed core, separation of the rib
from the adhesive rubber, cracking or separation of
CORRECT WRONG
the ribs, torn or worn ribs or cracks in the inner
ridges of the ribs.
Conventional type only: Check that the belt does
Clearance ::=::t:=t~~ not touch the bottom of the pulley groove.
If necessary, replace the drive belt.
(b) Using a belt tension gauge, check the drive belt
tension.
Belt tension gauge:
Nippondenso BTG-20(95506-00020) or
Borroughs No. BT-33-73F
Nippondenso Borroughs
Drive belt tension:
V-Ribbed type Used belt 115 ± 20 Ib
New belt 175 ± 5 Ib
Conventional type Used belt 80 ± 20 Ib
If necessary, adjust the drive belt tension.
NOTE:
• "New belt" refers to a belt which has been used 5
EC0003 EC0004 ECOOOl
minutes or less on a running engine.
• "Used belt" refers to a belt which has been used on a
V-Ribbed Type running engine for 5 minutes or more.
• After installing the drive belt, check that it fits properly
in the ribbed grooves.
• Check by hand to confirm that the belt has not slipped
out of the groove on the bottom of the pu lIey.
• After installing a new belt, run the engine for about 5
CORRECT WRONG WRONG minutes and then recheck the belt tension.
CH0086
2. REPLACE SPARK PLUGS (PLATINUM TIPPED TYPE)

(a) Disconnect the spark plug wires at the boot.
DO NOT pull on the wires.
(b) Remove the spark plugs.
MAINTENANCE - Maintenance Operations MA-5
(c) Check the gap on the new plugs.

Correct electrode gap: 1.1 mm (0.043 in.)
Recommended spark plugs: ND P16R
NGK BPR5EP11
NOTE: If adjusting the gap of a new plug, bend only the
base of the ground electrode. Do not touch the tip. Never
attempt to adjust the gap on a used plug.
IGOO04
3. INSPECT AIR FILTER

(a) Visually check that the air cleaner element is not
excessively dirty, damaged or oily.
(b) Clean the element with compressed air.
First blow from the back side thoroughly.
Then blow off the front side of the element.
~
4. REPLACE AIR FILTER
Front Back Replace the air cleaner element with a new one.
MA0061
5. REPLACE ENGINE OIL AND OIL FILTER

(See page LU-4)
Engine oil grade:
API grade SF or SFICC, multigrade viscosity and
fuel-efficient oil
Drain and refill with oil filter change capacity:
3.5 liters (3.7 US qts, 3.1 Imp. qts)
6. REPLACE ENGINE COOLANT

(a) Drain the coolant from the radiator and engine drain
cocks. (Engine drain is at left rear of engine block.)
(b) Close the drain cocks.
(c) Fill system with coolant.
Coolant capacity (wi Heater):
2WD wlo Rear heater
7.9 liters (8.3 US qts, 7.0 Imp.qts)
wi Rear heater
MA0088
8.4 liters (8.9 US qts, 7.4 Imp.qts)
4WD wlo Rear heater
wi Rear heater
Use a good brand of ethylene-glycol base coolant, mixed
according to the manufacturer's instructions
7. CALIFORNIA VEHICLES ONLY:

INSPECT CHARCOAL CANISTER
(a) Remove the air cleaner case assembly.
(b) Disconnect the hoses to the charcoal canister.
Label hoses for correct installation.
(c) Plug pipe A with your finger and blow compressed air
(3 kg/cm 2 , 43 psi or 294 kpa) through pipe B (fuel
'-_---'.... C tank side).
Air should flow through freely and
no charcoal should come out MA0089
• Check that air comes out of the bottom pipe C
without resistance.
• Check that no activated charcoal comes out.
If necessary, replace the charcoal canister.
NOTE: Do not attempt to wash the charcoal.
(d) Connect the hoses to the charcoal canister.
(e) Reinstall the air cleaner case assembly.
8. REPLACE GASKET IN FUEL FILLE~ CAP

(a) Remove the old gasket (a-ring) ftom the fuel filler
~
cap. Do not damage the cap.
(b) Install the new gasket by hand.
(c) Inspect the cap for damage or cracks.
~GaSket (d) Install the cap and check the torque limiter.
MA0379
. . Front Fuel Filter Cap

9. INSPECT FUEL LINES AND CONNECTIONS
(See page FI-56)
Visually inspect the fuel lines for cracks, leakage, loose
Fuel connections, deformation or tank bend looseness.
Tank
Check Valve
Throttle Charcoal
Body ~==L) Canister
C=l
MA0082
10. INSPECT EXHAUST PIPES AND MOUNTINGS

Visually inspect the pipes, hangers, and connections for
severe corrosion, leaks or damage.
2WD MIT 11. REPLACE OXYGEN SENSOR

Oxygen (a) Disconnect the oxygen sensor connector.
Sensor (b) Remove the two nuts, heat insulator (2WD MIT),
oxygen sensor and gasket from the exhaust manifold
(2WD MIT) or front exhaust pipe (2WD AIT and 4WD).
(c) Install new gasket, oxygen sensor and heat insulator
with the two nuts.
Torque: 200 kg-em (14 ft-Ib, 20 N'm)
MA0328 (d) Inspect the oxygen sensor operation.
(See pages FI-70 and 71 )
Oxygen
,~ensor
MA0445
Hot Engine Operations

12. ADJUST IDLE SPEED
(a) Preparation
• Air cleaner installed
• All pipes and hoses of air intake system connected
• All vacuum lines connected (Le., ESA, EGR sys-
tems, etc.)
ISC VSV • EFI system wiring connectors fully plugged
EC1996
• Engine at normal operating temperature
• Accessories switches "OFF"
Service Connector
• Transmission in "N" range
(b) Disconnect the ISC VSV connector.
(c) Connect a tachometer to the engine.
Connect the test probe of the tester to the service
connector of the distributor.
CAUTION:
1. NEVER allow the tachometer terminal to touch
ground as it could result in damage to the igniter
EC1828 andlor ignition coil.
2. As some tachometers are not compatible with this
ignition system, we recommend that you comfirm
the compatibility of your unit before using.
(d) Race the engine at 2,500 rpm for about 2 minutes.
(e) Set the idle speed by turning the IDLE SPEED
ADJUSTING SCREW.
Idle speed: MIT 700 rpm
AIT 750 rpm
Idle Speed (f) Reconnect the ISC VSV connector.
Adjusting Screw MA0003 (g) Remove the tachometer.
MA-8 . MAINTENANCE - Maintenance Operations
BRAKES
13. INSPECT BRAKE LINE PIPES AND HOSES
NOTE: Inspect in a well lighted area. Inspect the entire
circumference and length of the brake hoses using a
mirror as required. Turn the front wheels fully right or left
before inspecting the front brake.
(a) Check all brake lines and hoses for:
• Damage • Corrosion
MA0055
• Wear • Leaks
• Deformation • Bends
• Cracks • Twists
(b) Check all clamps for tightness and connections for
leakage.
(c) Check that the hoses and lines are clear of sharp
edges, moving parts and the exhaust system.
(d) Check that the lines installed in grommets, pass
through the center of the grommets.
14. INSPECT REAR BRAKE LININGS AND DRUMS

(See page BR-34)
(a) Check the linings for wear.
Minimum lining thickness: 1.0 mm (0.039 in.)
(b) Check the brake drums for scoring or wear.
Maximum drum inside diameter:
256.0 mm (10.079 in.)
(c) Clean the brake parts with a damp cloth.
MA0057 MA0058 NOTE: Do not use compressed air to clean brake parts.
15. INSPECT FRONT BRAKE PADS AND DISCS

2WD (See page BR-21)
4WD (See page BR-28)
(a) Check the thickness of the disc brake pads and check
for irregular wear.
Minimum pad thickness: 2WD 1.0 mm (0.039 in.)
4WD 3.0 mm (0.118 in.)
NOTE: If a squealing or scraping noise occurs from the
front brake during driving, check the pad wear indicator.
MA0094 MA0093
If there are traces of the indicator contacting the disc rotor,
the disc pad should be replaced.
(b) Check the disc for wear or runout.
Minimum disc thickness:
2WD 19.0 mm (0.748 in.)
4WD 24.0 mm (0.945 in.)
Maximum disc runout: 0.15 mm (0.0059 in.)
BRll07
CHASSIS
16. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay.
Maximum steering wheel freeplay: 30 mm (1.18 in.)
With the vehicle stopped and pointed straight ahead,
rock the steering wheel gently back and forth with
light finger pressure.
(b) Check the steering linkage for looseness or damage.

Check that:
• Tie rod ends, relay rod ends, center arm, idler arm
and drag link do not have excessive play.
• Dust seals are not damaged.
17. INSPECT STEERING GEAR BOX

Check the steering gear box for oil leakage.
SR0373
4WD 18. (4WD)

INSPECT DRIVE SHAFT BOOT
Check the drive shaft boots for clamp looseness, grease
leakage or damage.
MA0447
2WD 19. INSPECT BALL JOINTS AND DUST COVERS

(a) Check the upper and lower ball joints for excessive
looseness.
Dust
Cover 2WD (See pages FA-16)
4WD (See pages FA-99)
Maximum ball joint vertical play:
Lower 0 mm (0 in.)
Upper 2.3 mm (0.091 in.)
MA0448
4WD
Dust
Cover
MA0425
MA·10 MAINTENANCE - Maintenance Operations
20. REPACK FRONT WHEEL BEARINGS AND THRUST

BUSH (4WD)
(a) Change the front wheel bearing grease.
2WD (See page FA-9 to 12)
4WD (See page FA-53 to 56)
Grease grade: Lithium base multipurpose grease
(NLGI No.2)
Wheel bearing friction preload:
2WD at rotating 350 - 870 g
(0.8 - 1.9 Ib, 3.4 - 8.5 N)
4WD at starting 1.0 - 2.4 kg
4WD (2.2 - 5.3 Ib, 10 - 24 N)
~
(b) Repack the drive shaft thrust bush grease.
(See page FA-57 to 61 )
~ '/~~~\, 21. (4WD)

LUBE STEERING KNUCKLE AND CHASSIS GREASE
/ ! \1 1/ (Including Propeller shaft)
) ! (a) (Upper suspension arm)
/ • Remove the three screw plugs.
MA0446
• Repack the suspension arm with grease.
Grease grade: Molybdenum disulphide lithium base
4WD
grease (NLGI No.2)
• Reinstall the three screw plugs.
(b) (Propeller shaft)
Repack the sleeve yoke with grease.
Grease grade: Lithium base multipurpose grease
(NLGI No.2)
MA0426
MIT 22. CHECK TRANSMISSION (A/T OR MIT), TRANSFER

AND DIFFERENTIAL OIL
(a) Visually check the transmission, transfer and dif-
ferential for oil leakage.
If leakage is found, check for cause and repair.
(b) (A/T)
Check the oil level and refill if necessary.
MA0002
AIT
Drain Plug
MA0006
MAINTENANCE - Maintenance Operations MA-ll
Differential (Rear)
MA0091
MIT ~ 23. REPLACE MANUAL TRANSMISSION, TRANSFER

AND DIFFERENTIAL OIL
(a) Remove the filler plug.
(b) Remove the drain plug, and drain the oil.
(c) Reinstall a new gasket and the drain plug.
(d) Add new oil until it begins to run out of the filler hole.
Transmission oil-
Oil grade: API GL-4 or GL-5
MAOOOl
Viscosity: SAE 75W-90
Capacity:
2WD 2.2 liters (2.3 US qts, 1.9 Imp. qts)
Transfer (4WD)-
Capacity: 1 .2 liters (1 .3 US qts, 1.1 Imp. qts)
MA0429
Differential (Front) (4WD) Differential oil-

Oil grade: Hypoid gear oil API GL-S
Viscosity: Above -18°C (0° F) SAE 90
Below -18°C (OOF) SAE 80W-90 or
80W
Capacity:
4WD Front
Rear
MA043CJ
1 .85 liters (2.0 US qts, 1 .6 Imp.qts)
(e) Install a new gasket and the filler plug.
Drain Plug
MACJ063
AfT 24. REPLACE AUTOMATIC TRANSMISSION FLUID

(a) Remove the drain plug, and drain the fluid.
(b) Securely reinstall the drain plug.
(c) With the engine OFF, and new fluid through the
dipstick tube.
Drain and refill capacity:
(d) Start the engine and shift the selector into all positions
from P through L, and then shift into P.
(e) With the engine idling, check the fluid level. Add fluid
AfT up to the COOL level on the dipstick.
CAUTION: Do not overfill.
Add if cool
MAOO99
25. TIGHTEN BOLTS AND NUTS ON CHASSIS AND

BODY
Tighten the following parts:
• Front seat mount bolts
Torque: 375 kg-cm (27 ft-Ib, 37 N'm)
MA0083
2WD • Engine front mounting member-to-body mount

bolts
\ ) Torque: 400 kg-em (29 ft-Ib, 39 N'm)
• (2WD)
Strut bar braeket-to-body mount bolts
Front • Stabilizer bar braeket-to-body mount bolt

MA0098
• (4WD)
Front suspension rear erossmember-to-body
4WD mount bolts
I i
26. FINAL INSPECTION

(a) Check the operation of the body parts:
• Front and rear doors
Door locks operate properly
Doors close properly
• Back door
Door lock operates properly
• Seats
Seats adjust easily and lock securely in any
position
Front seat back locks securely in any position Fold-
down rear seat backs lock securely
(b) Road test
• Check the engine and chassis for abnormal noise.
• Check that the vehicle does not wander or pull to
one side.
• Check that the brakes work properly and do not
drag.
(c) Be sure to deliver a clean car and especially check:
• Steering wheel
• Shift lever knob
• All switch knobs
• Door handles
• Seats
MA-14 MAINTENANCE - General Maintenance
GENERAL MAINTENANCE 8. WARNING LIGHTS AND BUZZERS
These are the maintenance and inspection items Check that all warning lights and buzzers
which are considered to be the owner's respon- function properly.
sibility. They cn be performed by the owner or he
9. HORN
can have then done at a service shop. These items
include those which should be checked on a daily Check that it is working.
basis, those which, in most cases, do not require
(special) tools and those which are considered to be 10. WINDSHIELD GLASS
reasonable for the owner to perform. Check for scratches, pits or abrasions.
Items and procedures for general maintenance are
as follows. 11. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and
OUTSIDE VEHICLE washer.
(b) Check that the wipers do not streak.
1. TIRES
(a) Check the pressure with a gauge. Adjust 12. WINDSHIELD DEFROSTER
if necessary. Check that air comes out from the defroster
(b) Check for cuts, damage or excessive outlet when operating the heater or air condi-
wear. tiorler.
2. WHEEL NUTS 13. REAR VIEW MIRROR

When checking the tires, check the nuts for Check that it is mounted securely.
looseness or for missing nuts. If necessary,
tighten them. 14. SUN VISORS
Check that they move freely and are mounted
3. TIRE ROTATION securely.
It is recommended that tires be rotated every
7,500 miles (12,000 km). 15. STEERING WHEEL
Check that it has specified freeplay. Be alert for
4. WINDSHIELD WIPER BLADES changes in steering condition, such as hard
Check for wear or cracks whenever they do not steering, excessive freeplay or strange noise.
wipe clean. Replace if necessary.
16. SEATS
5. FLUID LEAKS (a) Check that all front seat controls such as
(a) Check underneath for leaking fuel, oil, seat adj usters, seatback recl i ner, etc.
water or other fluid. operate smoothly.
(b) If you smell gasoline fumes or notice any (b) Check that all latches lock securely in any
leak, have the cause found and corrected. position.
(c) Check that the locks hold securely in any
6. DOORS
latched position.
Check that all doors including the slide and
(d) Check that the head restraints move up
back door operate smoothly, and that all
and down smoothly and that the locks
latches lock securely.
hold securely in any latched position.
(e) For folding-down rear seat backs, check
INSIDE VEHICLE
that the latches lock securely.
7. LIGHTS
17. SEAT BELTS
(a) Check that the headlights, stop lights,
(a) Check that the seat belt system such as
taillights, turn signal lights, and other
buckles, retractors and anchors operate
lights are all working.
properly and smoothly.
(b) Check the headlight aiming.
(b) Check that the belt webbing is not cut,
frayed, worn or damaged.
MAINTENANCE - General Maintenance MA-15
18. ACCELERATOR PEDAL lines on the case. If level is low, add distilled
Check the pedal for smooth operation and water only.
uneven pedal effort or catching.
28. BRAKE AND CLUTCH FLUID LEVELS
19. CLUTCH PEDAL (See page CL-3) Check taht the brake fluid level is within 10
Check the pedal for smooth operation. mm (0.39 in.) below the "MAX" line on the
Check that the pedal has the proper freeplay. see-through reservoir.
20. BRAKE PEDAL (See page BR-5) 29. ENGINE DRIVE BELTS
(a) Check the pedal for smooth operation. Check all drive belts for fraying, cracks, wear
or oiliness.
(b) Check that the pedal has the proper
reserve distance and freeplay. 30. ENGINE OIL LEVEL
(c) Check the brake booster function. Check the level on the dipstick with the engine
turned off.
21. BRAKES
At a safe place, check that the brakes do not 31. POWER STEERING FLUID LEVEL
pull to one side when applied. Check the level on the dipstick.
The level should be in the "HOT" or "COLD"
22. PARKING BRAKE (See page BR-7) range depending on the fluid temperature.
(a) Check that the lever has the proper
travel. 32. AUTOMATIC TRANSMISSION FLUID
LEVEL
(b) On a safe incline, check that vehicle is
held securely with only the parking brake (a) Park the vehicle on a level surface.
applied. (b) With the engine idling and the parking
brake applied, shift the selector into all
23. AUTOMATIC TRNSMISSION "PARK" positions from "P" to "L", and then shift
MECHANISM into "P".
(a) Check the lock release button of the (c) Pull out the dipstick and wipe off the fluid
selector lever for proper and smooth with a clean rag. Reinsert the dipstick
operation. and check that the fluid level is in the
(b) On a safe incline, check that vehicle is HOT range.
held securely with the selector lever in (d) Perform this check with the fluid at
the "P" position and all brakes released. normal driving temperature (70 - 80°C or
158 - 176°F).
24. WINDSHIELD WASHER FLUID
NOTE: Wait about 30 minutes before checking
Check that there is sufficient fluid in the tank.
the fluid level after extended driving at high
25. ENGINE COOLANT LEVEL speeds, in hot weather, in heavy traffic or with
a trailer.
Check that the coolant level is between the
"FULL" and "LOW" lines on the see-through 33. EXHAUST SYSTEM
reservoir.
Visually inspect for cracks, holes or loose
26. RADIATOR AND HOSES supports.
If any change in the sound of the exhaust or
(a) Check that the front of the radiator is smell of the exhasut fu mes is noticed, have the
clean and not blocked with leaves, dirt or cause located and corrected.
bugs.
(b) Check the hoses for cracks, kinks, rot or
loose connections.
27. BATTERY ELECTROLYTE LEVEL

Check that the electrolyte level of all battery
cells is between the upper and lower level
I
EM-1
ENGINE MECHANICAL
Page
TROUBLESHOOTING . EM-2
ENGINE TUNE-UP . EM-5
COMPRESSION CHECK . EM-8
CYLINDER HEAD . EM-9
Components . EM-9
Preparation for Removal . EM-10
Removal of Cylinder Head . EM-12
Disassembly of Cylinder Head . EM-13
Inspection, Cleaning and Repair of Cylinder
Head Components . EM-14
Assembly of Cylinder Head . EM-22
Installation of Cylinder Head . EM-23
Post Installation . EM-24
TIMING CHAIN AND CAMSHAFT . EM-27
Components . EM-27
Preparation for Removal . EM-28
Removal of Timing Chain and Camshaft . EM-28
Inspection and Repair of Timing Chain and
Camshaft Components . EM-31
Replacement of Crankshaft Front Oil Seal EM-35
Installation of Timing Chain and Camshaft . EM-36
Post Installation . EM-38
CYLINDER BLOCK . EM-39
Components . EM-39
Removal of Engine . EM-40
Preparation for Disassembly . EM-44
Disassembly of Cylinder Block . EM-44
Inspection of Cylinder Block . EM-49
Disassembly of Piston and Connecting
Rod Assemblies . EM-50
Inspection of Piston and Connecting
Rod Assemblies . EM-51
Boring of Cylinders . EM-54
Inspection and Repair of Crankshaft . EM-55
Inspection and Repair of Camshaft
Bearings . EM-56
Inspection of Valve lifter Bores . EM-57
Replacement of Crankshaft Rear Oil Seal . EM-58
Assembly of Piston and Connecting Rod
Assemblies . EM-59
Assembly of Cylinder Block . EM-60
Post Assembly . EM-63
Installation of Engine . EM-64
EM-2 ENGINE MECHANICAL - Troubleshooting
TROUBLESHOOTING
ENGINE OVERHEATING
Problem Possible cause Remedy Page
Engine overheats Cooling system faulty Troubleshoot cooling system CO-2

Incorrect ignition timing Reset timing IG-14
HARD STARTING
Engine will not crank Starting system faulty Troubleshoot starting system ST-2
or cranks slowly
Engine will not start/ No fuel supply to carburetor Check fuel line
Hard to start No fuel supply to injector Troubleshoot EFI system FI-9
(cranks OK)
• No fuel in tank
• Fuel pump not working
• Fuel filter clogged
• Fuel line clogged or leaking
EFI system problems Repair as necessary
Ignition problems Perform spark test IG-4
• Ignition coil
• Igniter
• Distributor
Spark plugs faulty Inspect plugs IG-5
High-tension cord disconnected or broken Inspect cords IG-5
Vacuum leaks Repair as necessary
• PCV hoses
• EGR valve
• Intake manifold
• Air intake chamber
• Throttle body
• Brake booster line
Pulling in air between air flow meter and Repair as necessary
throttle body
Compression low Check compression EM-8
ROUGH IDLING
Rough idle, stalls or Spark plug faulty Inspect plugs IG-5

misses High-tension cord faulty Inspect cords IG-5
Ignition problems
• Ignition coil Inspect coil
• Igniter Inspect igniter
• Distributor Inspect distributor
ENGINE MECHANICAL - Troubleshooting EM-3
ROUGH IDLING (Cont'd)

Rough idle, stalls or Vacuum leaks Repair as necessary

misses • PCV hoses
• EGR valve
• Intake manifold
• Throttle body
Pulling in air between air flow meter

and throttle body
Incorrect idle speed Adjust idle speed MA-7
EFI system problems Repair as r.ecessary
HAl system faulty Check HAl system
Engine overheats Troubleshoot cooling CO-2
system
EGR valve faulty Check EGR valve
ENGINE HESITATES/POOR ACCELERATION

Engine hesitates/ Spark plug faulty Inspect plugs

poor acceleration High tension cord faulty Inspect cords
• PCV hoses
• EGR valve
• Intake manifold
• Throttle body

throttle body
Fuel system clogged Check fuel system
Air cleaner clogged Check air filter MA-5
Emission control system problem
• EGR system always on (cold engine) Check EGR system
Engine overheats Check cooling system CO-2
EM-4 ENGINE MECHANICAL - Troubleshooting
ENGINE DIESELING
Engine diesels EFI system problems Repair as necessary

(runs after ignition Incorrect ignition timing Reset timing IG-14
switch is turned off)
EGR system faulty Check EGR system
AFTER FIRE, BACKFIRE

Muffler explosion Deceleration fuel cut system always off Check EFI (fuel cut)
(after fire) on system
deceleration only
Muffler explosion Air cleaner clogged Check air filter MA-5

(after fire) all the EFI system problem Repair as necessary
time
Engine backfires EFI system problem Repair as necessary

Vacuum leak Check hoses and repair as
• PCV hoses necessary
• EGR valve
• Intake manifold
• Intake air control valve
• Throttle body

throttle body
Insufficient fuel flow Troubleshoot fuel system FI-9
Carbon deposits in combustion chambers Inspect cylinder head EM-14
EXCESSIVE OIL CONSUMPTION

Excessive oil Oil leak Repair as necessary

consumption PCV line clogged Check PCV system
Piston ring worn or damaged Check rings EM-52
Valve stem and guide worn Check valves EM-15
Valve stem seal worn Check seals
ENGINE MECHANICAL - Troubleshooting, Engine Tune-up EM-5
EXCESSIVE FUEL CONSUMPTION

\
Excessive fuel I Fuel leak Repair as necessary

consumption Air cleaner clogged Check air filter MA-5
• Injector faulty
• Decerelation fuel cut system faulty
Idle speed too high Adjust idle speed MA-7

Spark plug faulty Inspect plugs IG-5
EGR system always on Check EGR system
Tires improperly inflated Inflate tires to proper pressure
Clutch slips Troubleshoot clutch
Brakes drag Troubleshoot brakes
UNPLEASANT ODOR
Unpleasant odor Incorrect idle speed Adjust idle speed MA-7

• PCV hoses
• EGR valve
• Intake manifold
• Throttle body
ENGINE TUNE-UP
INSPECTION OF ENGINE COOLANT
(See steps 1 and 2 on page CO-3)
INSPECTION OF ENGINE OIL

(See steps 1 and 2 on page lU-3)
INSPECTION OF BATTERY
(See steps 1 and 2 on page CH-3)
Standard specific gravity:
1.25 - 1.27 when fully charged at 20°C (68°F)
CLEANING OF AIR FILTER

(See page MA-5)
EM-6 ENGINE MECHANICAL - Engine Tune-up
INSPECTION OF HIGH-TENSION CORDS

(See page IG-5)
Maximum resistance: 25 kfl per cord
INSPECTION OF SPARK PLUGS

(See page IG-5)
Maximum electrode gap: 1.3 mm (0.051 in.)
Correct electrode gap of new plug:
1.1 mm (0.043 in.)
INSPECTION OF ALTERNATOR DRIVE BELT

(See page CH-3)
Drive belt tension:. New belt 175 ± 5 Ib
Used belt 115 ± 20 Ib
ADJUSTMENT OF IGNITING TIMING

(See page IG -14)
Ignition timing: 12° BTDC @ idle
(wI Terminals T and E1 short-circuited)
ADJUSTMENT OF IDLE SPEED

(See page MA-7)
AIT 750rpm
IDLE HC/CO CONCENTRATION CHECK

METHOD
NOTE: This check method is used only to determine
whether or not the idle HC/CO complies with regulations.
1. INITIAL CONDITIONS
(a) Air cleaner installed
(b) Normal engine operating temperature
(c) All pipes and hoses of air intake system connected
(d) All accessories switched off
(e) All vacuum lines properly connected
NOTE: All vacuum hoses for EVAP, etc. should be pro-
perly connected.
(f) EFI system wiring connectors fully plugged
(g) Ignition timing set correctly
(h) Idle speed set correctly
(i) Transmission in N range
(j) Tachometer and HC/CO meter calibrated and at hand
ENGINE MECHANICAL - Engine Tune-up EM-7
2. RACE ENGINE AT 2,500 PRM FOR ABOUT 2

MINUTES
3. INSERT HC/CO METER TESTING PROBE INTO

TAILPIPE AT LEAST 40 em (1.3 ft)
4. CHECK HC/CO CONCENTRATION AT IDLE

Wait at least one minute before measuring to allow the
concentration to stabilize.
Complete the measuring within three minutes.
If the HC/CO concentration does not conform to your
regulations, see the table following for possible causes:
TROUBLESHOOTING
HC
I co Problems Causes
High II Normal Rough idle 1 . Faulty ignition:
I
• Incorrect timing
• Fouled, shorted or improperly gapped plugs
I i • Open or crossed high tension wires
• Cracked lIA cap
I 2. Leaky EGR valve
i
3. Leaky exhaust valves
\
4. Leaky cylinder
I
i
High 1
I
Low Rough idle 1 . Vacuum leak:
I
(Fluctuating) • Vacuum hose

I
I
\HC reading • EGR valve
I
I • Intake manifold
• Throttle body
2. Lean mixture causing misfire
High High Rough idle 1 . Restricted air filter

(Black smoke from exhaust) 2. Faulty EFI system:
• Faulty pressure regulator
• Clogged fuel return line
• Faulty air flow meter
• Defective water thermo. sensor
• Faulty ECU
• Faulty injector
• Faulty cold start injector
• Faulty throttle position sensor
EM-8 ENGINE MECHANICAL - Compression Check
COMPRESSION CHECK
NOTE: If there is lack of power, excessive oil consump-
tion or poor fuel economy, measure the cylinder compres-
sion pressure.
1. WARM UP AND STOP ENGINE
2. DISCONNECT SOLENOID RESISTOR CONNECTOR
3. DISCONNECT COLD START INJECTOR CONNECTOR
4. REMOVE SPARK PLUGS
5. DISCONNECT DISTRIBUTOR CONNECTOR
6. CHECK CYLINDER COMPRESSION PRESSURE

(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle valve.
(c) While crawking the engine with the starter, measure
the compression pressure.
NOTE: Always use a fully charged battery to obtain
engine revolution of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder
Compression pressure:
12.5 kg/cm 2 (178 psi, 1,226 kPa) or more
Minimum pressure:
9.0 kg/cm 2 (128 psi, 883 kPa)
Difference between each cylinder:
1.0 kg/cm 2 (14 psi, 98 kPa) or less
(e) If the cylinder compression in one or more cylinders
is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat
steps (a) through (c) for the cylinder with low com-
pression .
• If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damaged .
• If pressure stays low, a valve may be sticking or
seating improperly, or there may be leakage past
the gasket.
7. RECONNECT DISTRIBUTOR CONNECTOR
8. REINSTALL SPARK PLUGS

9. RECONNECT COLD START INJECTOR CONNECTOR
10. RECONNECT SOLENOID RESISTOR CONNECTOR

ENGINE MECHANICAL - Cylinder Head EM-9
CYLINDER HEAD
COMPONENTS
~---------SealWasher
~---------CylinderHead Cover
:::..-~~---------Gasket
- - - - - - - R o c k e r Arm and Spring
--~----------RockerArm Shaft
Push R o d - - - - - - - - -
Valve Keeper ~ ~
/lA.:
Spark Plug
Spark Plug Tube
Spring Retainer S ~~L-'1---------------.Gasket
Valve Spring I
• Oil Seal ~ . EGR Valve
Spring sea~Cylinder Head
Snap Ring ~
Valve Guide Bushing ~
Water Outlet ~
• Gasket W
• Gasket - - - - - - ,
Heater _ i'l---- • Gasket

Outlet
Valve - - - - - - - - - - - 1
Manifold Stay
Intake and Exhaust Manifold
\kg-cm (ft-Ib, N'm)1 : Specified torque

• Non-reusable part EM3577
EM·10 ENGINE MECHANICAL - Cylinder Head
PREPARATION FOR REMOVAL

(See page EM-g)
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL

OF BATTERY
2. REMOVE RIGHT SEAT
3. REMOVE ENGINE SERVICE HOLE COVER
4. DRAIN COOLANT
Open the radiator and engine drain cocks, and allow coo-
lant to drain into a clean container.
5. DRAIN ENGINE OIL
6. [wi PS]
REMOVE POWER STEERING PUMP
(See page SR-29)
7. REMOVE EXHAUST PIPE AND BRACKET
8. DISCONNECT ACCELERATOR CABLE WITH

BRACKET FROM THROTTLE BODY
/ 9. REMOVE AIR CLEANER PIPE AND HOSES
10. DISCONNECT WATER TEMPERATURE SENDER

GAUGE CONNECTOR FROM CYLINDER HEAD
AT1225
11. DISCONNECT EFI CONNECTORS

(a) Water thermo sensor connector
(b) Cold start injector time switch connector
(c) Cold start injector connector
(d) Air valve connector
(e) Throttle position sensor connector
(f) [2WD MIT]
Oxygen sensor connector
(g) [wi AICl
Water temperature switch connector
12. DISCONNECT HOSES

(a) Radiator inlet hose
(b) Radiator breather hose
(c) Reserve tank hose
(d) Heater outlet hose
(e) PCV hoses
(f) Water by-pass hoses
13. DISCONNECT VACUUM HOSES

(a) Brake booster vacuum hose
(b) Charcoal canister hose
(c) Label and disconnect emission control hoses
EM2747
14. REMOVE THROTTLE BODY

Remove the throttle body from the air intake chamber.
EM1136
15. REMOVE EGR VALVE

(a) Remove the two nuts from the air intake chamber.
(b) Remove the union nut from exhaust manifold and
EGR valve.
EM1137
16. DISCONNECT PIPE AND HOSES

(a)
(a) Cold start injector pipe
(b) Water by-pass hoses
(c) Pressure regulator hose
EMl138
17. REMOVE AIR INTAKE CHAMBER

(a) Remove the air intake chamber brackets.
NOTE: Use a 1 2 mm socket wrench to remove the rear
chamber bracket.
(b) Remove the air intake chamber with the air valve.
NOTE: Use 10 mm and 12 mm socket wrenches to
remove the air intake chamber with the air valve.
EM1139
EM-12 ENGINE MECHANICAL - Cylinder Head
18. DISCONNECT INJECTOR CONNECTOR

(a) Remove the wire clamp bolt.
(b) Disconnect the injector connectors from the injec-
tors.
EM3572
19. REMOVE PARTS

(a) Exhaust manifold bracket
(b) Heater pipe bracket
(c) Fuel inlet pipe union bolt from fuel filter
(d) Fuel outlet hose
REMOVAL OF CYLINDER HEAD

(See page EM-9)
1. REMOVE SPARK PLUGS AND TUBES
2. REMOVE CYLINDER HEAD COVER

Remove the cap nuts, seal washers, cylinder head cover
and gasket.
3. REMOVE ROCKER ARM SHAFT ASSEMBLY

(a) Uniformly loosen and remove the three bolts and two
nuts in several passes, in sequence shown.
(b) Remove the rocker shaft assembly.
4. REMOVE PUSH RODS

NOTE: Keep the push rods in correct order.
1 3 5 4 2
EM2417
5. REMOVE CYLINDER HEAD

6 2
(a) Uniformly loosen and remove the thirteen head bolts
..
in several passes, in the sequence shown.
CAUTION: Head warpage or cracking could result
Fro nt 0 Ii'::oe,'>-------i~-< from bolts removing in incorrect order.
I I
4 10 12 9 7
EM2416
(b) Lift the cylinder head from the dowels on the cylinder
block and place the head on wooden blocks on a
bench.
If the cylinder head is difficult to lift off, pry with a
screwdriver between the cylinder head and block projec-
tion.
CAUTION: Be careful not to damage the cylinder
head and block surface of the cylinder and head
gasket.
EM2415
DISASSEMBLY OF CYLINDER HEAD

(See page EM-g)
1. REMOVE INTAKE AND EXHAUST MANIFOLDS

(a) Remove the inlet and outlet fuel pipes.
(b) Remove the intake and exhaust manifolds from the
cylinder head.
EM3573
2. REMOVE VALVES
SST (a) Using SST, press the valve spring and remove the
I two keepers.
SST 09202-43013
(b) Remove the spring retainer, spring, seat, valve and oil
seal.
EM2413
NOTE: Arrange the disassembled parts in correct order.
~
.~
@)
~~i
(5 Il
IN @)
qQ
\,
EX 61 2 3 4 EMOO25
3. IF NECESSARY, REMOVE PARTS

(a) Water outlet
(b) Heater outlet
(c) Engine rear plate
(d) Engine hanger
INSPECTION AND CLEANING OF CYLINDER

HEAD COMPONENTS
1. CLEAN TOP OF PISTONS AND TOP OF BLOCK
(a) Turn the crankshaft and bring each piston to top
dead center. Using a gasket scraper, remove all the
carbon from the piston top.
(b) Remove all the gasket material from the top of the
block.
EM2532 (c) Blow carbon and oil from the bolt holes.
WARNING: Protect your eyes when using com-
pressed air.
2. REMOVE GASKET MATERIAL

Using a gasket scraper, remove all the gasket material
from the manifold and head surface.
CAUTION: Be careful not to scratch the surfaces.
3. CLEAN COMBUSTION CHAMBERS

Using a wire brush, remove all the carbon from the com-
bustion chambers.
CAUTION: Be careful not to scratch the head gasket
contact surface.
4. CLEAN VALVE GUIDE BUSHINGS

Using a valve guide bushing brush and solvent, clean all
the valve guide bushings.
EM0028
5. CLEAN CYLINDER HEAD

Using a soft brush and solvent, thoroughly clean the head.
CAUTION: Do not clean the head in a hot tank as this
would seriously damage it.
\ \
6. INSPECT HEAD FOR FLATNESS

Using a precision straight edge and feeler gauge, measure
the surfaces contacting the cylinder block and manifolds
for warpage.
Maximum warpage:
Cylinder block side 0.15 mm (0.0059 in,)
Manifold side 0.10 mm (0.0039 in.)
~
o
If warpage is greater than maximum, replace the head.
() 0 0
M2532
EM2533
7. INSPECT CYLINDER HEAD FOR CRACKS

Using a dye penetrant, check the combustion chamber,
intake and exhaust ports head surface and the top of the
head for cracks.
If cracked, replace the head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip any carbon from the
valve head.
(b) Using a wire brush, thoroughly clean the valve.
9. INSPECT VALVE STEMS AND VALVE GUIDE

BUSHINGS
(a) Using a caliper gauge or telescoping gauge, measure
the inside diameter of the valve guide bushing.
Bushing inside diameter:
8.010- 8.030 mm (0.3154 - 0.3161 in.)
EM2407 EM2105
(b) Using a micrometer, measure the diameter of the

valve stem.
Valve stem diameter:
Intake 7.970 - 7.985 mm
(0.3138 - 0.3144 in,)
Exhaust 7.965 - 7.980 mm
(0.3136 - 0.3142 in,)
EM0963 EM0964
(c) Subtract the valve stem measurement from the valve

guide bushing measurement.
Standard oil clearance:
Intake 0.025 - 0.060 mm
(0.0010 - 0.0024 in,)
Exhaust 0.030 - 0.065 mm
(0.0012 - 0.0026 in,)
Maximum oil clearance:
Intake 0.10 mm (0.0039 in.)
Exhaust 0.12 mm (0.0047 in.)
If the clearance is greater than maximum, replace the valve
and valve guide bushing.
Brass Bar 10. IF NECESSARY, REPLACE VALVE GUIDE BUSHING

(a) Using a brass bar and hammer, break the valve guide
bushing.
EM2406
(b) Gradually heat the cylinder head to 80 - 100 0 e (176

- 212°F).
EM2405
(c) Using SST and a hammer, tap out the valve guide
bushing.
SST 09201-60011
EM2404
(d) Using a caliper gauge, measure the bushing bore

diameter of the cylinder head.
\~
EM2403
(e) Select a new valve guide busing. (STD size or O/S

Both intake and exhaust 0.05)
If the bushing bore diameter of the cylinder head is more
Bushing bore diameter mm (in.) Bushing size
than 13.027 mm (0.5129 in.), machine the bore to the
13.000 - 13.027 following dimensions.
Use STD
(0.5118 - 0.5129) Rebored cylinder head bushing bore dimensions:
Over 13.027 13.050 - 13.077 mm (0.5138 - 0.5148 in.)
Use O/S 0.05
(0.5129) If the bushing bore diameter of the cylinder head exceeds
13.077 mm (0.5148 in.), replace the cylinder head.
(f) Gradually heat the cylinder head to 80 - 100°C (176

- 21 2°F).
(g) Using SST and a hammer, tap in a new valve guide
/,
bushing until the snap ring makes contact with the
Snap Ring cylinder head.
SST 09201-60011
EM2402
(h) Using a sharp 8 mm reamer, ream the valve guide

bushing to obtain the standard specified clearance
(See page EM-1 6) between the valve guide bushing
and new valve stem.
EM2401 EM2410
11. INSPECT AND GRIND VALVES

(a) Grind the valve only enough to remove pits and car-
bon.
(b) Check that the valve is ground to the correct valve
face angle.
Valve face angle: 44.5°
44.5°
T
EM0254 EM0180
(c) Check the valve head margin thickness.

Standard margin thickness
Intake 1.0 - 1.4 mm (0.039 - 0.055 in.)
Exhaust 1.3 - 1.7 mm (0.051 - 0.067 in.)
Minimum margin thickness:
Intake 0.5 mm (0.020 in.)
Exhaust 0.8 mm (0.031 in.)
If the valve head margin thickness is less than minimum,
replace the valve.
EM0181
(d) Check the valve overall length.

Standard overall length:
Intake 108.2 mm (4.260 in.)
Exhaust 108.5 mm (4.272 in.)
Minimum overall length:
Length Intake 107.7 mm (4.240 in.)
I Exhaust 108.0 mm (4.252 in.)
If the overall length is less than minimum, replace the
valve.
EM2534
(e) If the valve stem tip is worn, resurface the tip with a
grinder or replace the valve.
CAUTION: Do not grind off more than the minimum
amount.
EM0255
12. INSPECT AND CLEAN VALVE SEATS

(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
EM2535
(b) Check the valve seating position.

Apply a thin coat of prussian blue (or white lead) to
the valve face. Install the valve. While applying light
pressure to the valve, rotate the valve against the
seat.
(c) Check the valve face and seat for the following:
• If blue appears 360° round the face, the valve is
concentric. If not, replace the valve.
• If blue appears 360° around the valve seat, the
EM0183 EM0184 guide and seat are concentric. If not, resurface the
seat.
• Check that the seat contact is on the middle of the
valve face with the following width:
1.2 - 1.6 mm (0.047 - 0.063 in.)
If not, correct the valve seat as follows:
(1) If the seating is too high on the valve face, use
30° and 45 0 cutters to correct the seat.
EM0185
ENGINE MECHANICAL - Cylinder Head EM,-19
Intake (2) [Intake]

Exhaust If the seating is too Iowan the valve face, use
60 0 and 45 0 cutters to correct the seat.
(3) [Exhaust]
If the seating is too Iowan the valve face, use
0
65 and 45 0 cutters to correct the seat.
EM0186
(d) Hand-lap the valve and valve seat together with an

abrasive compound.
(e) After hand-lapping, clean the valve and valve seat.
EM2400
13. INSPECT VALVE SPRINGS

squareness1i
(a) Using a steel square, check the squareness of the
valve springs.
Maximum squareness: 2.0 mm (0.079 in.)
If squareness is greater than maximum, replace the valve
spring.
EM0988
(b) Using calipers, measure the free length of the valve

spring.
Free length: 47.0 mm (1.850 in.)
If the free length is not as specified, replace the valve
spring.
EM0801
(c) Using a spring tester, measure the tension of the

valve spring at the specified installed length.
Installed tension:
28.8 - 35.2 kg (63.5 - 77.6 Ib, 282 - 345 N)
at 40.6 mm (1.598 in.)
If the installed tension is not within specification, replace
the valve spring.
EM0281
14. INSPECT ROCKER ARM AND SHAFT

(a) Inspect the valve contacting surface of the rocker
arm for wear.
EM2399
(b) Inspect the rocker arm-to-shaft clearance by moving

each rocker arm as shown in the figure. If movement
is felt, disassemble and inspect.
(c) Disassemble the valve rocker shaft assembly.
NOTE: Arrange the rocker arms in correct order.
If the contacting surface of the rocker arm is worn, resur-

face it with a valve refacer and oil stone, or replace the
rocker arm.
EM0042
(d) Inspect the oil clearance between the rocker arm and
shaft.
• Using a caliper gauge, measure the inside diameter
of the rocker arm.
Rocker arm inside diameter:
18.500 - 18.515 mm (O.7283 - 0.7289 in.)
EM2397
• Using a micrometer, measure the diameter of the

rocker shaft.
Rocker shaft diameter:
18.474 - 18.487 mm (O.7273 - 0.7278 in.)
EM2396
• Subtract the rocker shaft diameter measurement

from the inside diameter measurement of the
rocker arm.
Standard oil clearance: 0.013 - 0.041 mm
(0.0005 - 0.0016 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the clearance is greater than maximum, replace the
rocker arm and shaft.
(e) Assemble the valve rocker shaft assembly.

Confirm the correct direction of the rocker arm shaft
SST Upward rear end, assemble the rocker arms and springs as
shown and hold them with SST.
SST 09270- 71010
With Protrusion EM2395
15. INSPECT PUSH RODS

(a) Place the push rod on V -blocks.
(b) Using a dial indicator, measure the circle runout at
the center of the push rod.
Maximum circle runout: 0.30 mm (0.0118 in.)
If the circle runout is greater than maximum, replace the
push rod.
(b) Check that the push rod oil hole is not clogged.
L.....- --..,;;..---.;.-.I
EM2536 If clogged, clear it with compressed air.
16. INSPECT INTAKE AND EXHAUST MANIFOLDS

Using a precision straight edge and feeler gauge, measure
the surfaces contacting the cylinder head for warpage.
Maximum warpage: 0.40 mm (0.0157 in.)
If warpage is greater than maximum, replace the manifold.
EM1144
17. INSPECT AIR INTAKE CHAMBER

Using a precision straight edge and feeler gauge, check
the surfaces contacting the intake manifold for warpage.
If warpage is greater than maximum, replace the air intake
chamber.
EM3574
ASSEMBLY OF CYLINDER HEAD

(See page EM-9)
NOTE:
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil to all
sliding and rotating surfaces.
• Replace all gaskets and oil seals with new ones.
. . ~ Keeper 1. INSTALL VALVES

Sprmg Retamer~
(or Valve Rotator) ~V~lve Spring (a) Insert the valves in the cylinder head valve guide
bushing. Make sure the valves are installed in the cor-
Upward
. /~<~
~~:'/@f ~
all Seal
Spring Seat rect order.
t ~:'" ~
/,..~~~?
/
(b) Install the valve spring seat and a new seal.
~ <~>~. (c) Install the spring and spring retainer on the valve.
~ t-valve
Painted White
or Yellow EM0415 EM0416
(d) Using SST, compress the valve spring and place two
SST keepers around the valve stem.
SST 09202-43013
(e) Using a plastic-faced hammer, tap the stem lightly to
assure proper fit.
EM2413
Water Otitlet 2. INSTALL PARTS
-,~'~
(a) Engine hanger
~
, 0r.. :.. . (b) Engine rear plate
(c) Heater outlet
~'.?~., r r I
(d) Water outlet
Engine Rear Plate
Heater Outlet
l c
(
Engine Hanger
EM1146
3. INSTALL INTAKE AND EXHAUST MANIFOLDS

4. INSTALL FUEL PIPES
EM3573
New Gasket
INSTALLATION OF CYLINDER HEAD
(See page EM-9)
10 INSTALL CYLINDER HEAD

(a) Install a new cylinder head gasket on the cylinder
block.
NOTE: Be careful of the installation direction.
EM2393
(b) Place the cylinder head on the cylinder head gasket.

8 13 12 11 9
I
I (c) Apply a light coat of engine oil on the threads and

under the cylinder head bolts.
...
Front
:
0 0
(d)
Torque:
Install and uniformly" tighten the thirteen cylinder
head bolts in several passes, in the sequence shown.
14 mm bolt head 900 kg-em (65 ft-Ib, 88 Nom)

12 mm bolt head 195 kg-em (14 ft-Ib, 19 Nom)
I I
10 2 7
EM2416
20 INSTALL PUSH RODS AND ROCKER SHAFT

Push Rod ASSEMBLY
(a) Make sure the push rods are installed in the correct
order.
(b) Hold the push rod with SST until the rocker shaft
assembly is completely installed.
SST 09270-71010
EM2392
(c) Install the rocker shaft assembly on the cylinder

head.
NOTE: Do not keep the push rods apart from the rocker
arms while tightening the bolts and nuts.
(d) Install and uniformly tighten the two bolts and three
nuts in the several passes, in the sequence shown.
Torque: 240 kg-em (17 ft-Ib, 24 Nom)
(e) Remove the SST from the push rods and rocker shaft
assembly.
EM2417
30 INSTALL CYLINDER HEAD COVER
40 INSTALL TUBES AND SPARK PLUGS

POST INSTALLATION
(See page EM-9)
1. INSTALL PARTS
(a) Exhaust manifold bracket
(b) Heater pipe bracket
(c) Fuel pipe union bolt with new gaskets
(d) Fuel outlet hose
2. CONNECT INJECTOR CONNECTOR

(a) Connect the injector connector to the injector.
(b) Install the wire clamp bolt.
EM3572
3. INSTALL AIR INTAKE CHAMBER

(a) Place on a new gasket and install the air intake cham-
ber with the air valve.
(b) Install the bolt with the bond cable and nuts.
(c) Install the air intake chamber bracket.
EMl139
4. CONNECT PIPE AND HOSES

(a) Cold start injector pipe with new gaskets
(b) Water by-pass hoses
(c) Pressure regulator hose
EMl138
5. INSTALL EGR VALVE

(a) Install a new gasket and the EGR valve with the two
nuts.
(b) Install the union nut to the exhaust manifold.
EM1137
6. INSTALL THROTTLE BODY

Install a new gasket and the throttle body with the nuts.
EM1136
7. CONNECT VACUUM HOSES

(c) Emission control hoses
(
EM2747
(e) 8. CONNECT HOSES

(b) Radiator breather hose
(c) Reserve tank hose
(d) Heater outlet hose
(e) PCV hoses
(f) Water by-pass hoses
9. CONNECT EFI CONNECTORS

(a) Water thermo sensor connector
(b) Cold start injector time switch connector
(c) Cold start injector connector
(d) Air valve connector
(e) Throttle position sensor connector
(f) [2WD M /T]
(g) [wi A/C]
Water temperature switch connector
10. CONNECT WATER TEMPERATURE SENDER GAUGE

CONNECTOR
11. INSTALL AIR CLEANER PIPE AND HOSES
12. CONNECT ACCELERATOR CABLE WITH BRACKET

TO THROTTLE BODY
13. INSTALL EXHAUST PIPE AND BRACKET

Torque the nuts holding the exhaust pipe to the exhaust
manifold.
AT1225
14. [wi PS]

INSTALL POWER STEERING PUMP
(See page SR-37)
15. FILL WITH ENGINE COOLANT (See page CO-3)
16. FILL WITH ENGINE OIL (See page LU-3)
17. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY
18. START ENGINE AND CHECK FOR LEAKS
19. PERFORM ENGINE AND ADJUSTMENT

Adjust the idle speed. (See page MA- 7)
AIT 750 rpm
20. INSTALL ENGINE SERVICE HOLE COVER
21. INSTALL RIGHT SEAT
22. ROAD TEST

Road test the vehicle.
23. RECHECK COOLANT AND ENGINE OIL LEVELS

ENGINE MECHANICAL - Timing Chain and Camshaft EM-27
TIMING CHAIN AND CAMSHAFT

COMPONENTS
Dust S e a l - - - - - - - - - - - - - l
Cylinder Head Cover-----~

(with Gasket)
~-- Rocker Shaft Assembly
~~~p Push Rod
~----\,------Camshaft
(7?; \
Thrust Plate------~---,~ :;:
Chain ------,------tE ~~\J ~vibration Damper

Tensioner n~ ~~
_ _ _--'~ lll~"(\ \..
~_\ \J)~.
Camshaft Sprocket ..
Tim i ng cr in c,--o_v_e_r~-----,
\ \ \ - - - - - - - - - - - - - - T i m i n g Chain
1,600 (116,157)
- - - - - - - - - - - - - C r a n k s h a f t Sprocket
1 - - - - - - - - - - - - - - - - - - . Gasket
.Crankshaft Front Oil Seal

Crankshaft Pulley
Ikg-em (ft-Ib, Nom)l : Specified torque

• Non-reusable part EM1404
EM-28 ENGINE MECHANICAL - Timing Chain and Camshaft
PREPARATION FOR REMOVAL

1. REMOVE RADIATOR (See page CO-8)
2. REMOVE DRIVE BELTS
3. REMOVE FAN AND WATER PUMP PULLEY

(See page CO-4)
4. REMOVE DISTRIBUTOR (See page IG-9)
5. REMOVE COLD START INJECTOR (See page FI-46)
6. REMOVE ROCKER SHAFT ASSEMBLY AND PUSH

RODS (See steps 2 to 4 on page EM-12)
REMOVAL OF TIMING CHAIN AND

CAMSHAFT
(See page EM-27)
1. REMOVE VALVE LIFTERS

Remove the eight valve lifters with a piece of wire or mag-
netic finger.
EM2342 EM2341
CAUTION: Always keep the valve lifters upright, and

in correct order.
EM1142
2. REMOVE CRANKSHAFT PUllEY

(a) Using SST, remove the pulley bolt.
SST 09213-70010 and 09330-00021
(b) Using SST, remove the crankshaft pulley.

SST 09213-31021
EM2343
3. REMOVE TIMING CHAIN COVER

(a) Remove the eleven bolts as shown in the figure.
(b) Using a screwdriver, pry out the chain cover.
4. CHECK TIMING CHAIN SLACK

Using a tension gauge, measure the slack of the timing
chain.
Maximum slack:
13.5 mm (0.531 in.) at 10 kg (22.0 Ib, 98 N)
If the slack is greater than maximum, replace the timing
chain and sprockets.
5. REMOVE CHAIN TENSIONER

Remove the two bolts and chain tensioner.
6. REMOVE TIMING CHAIN AND SPROCKETS

(a) Install the crankshaft pulley to the crankshaft.
(b) Using SST, remove the camshaft sprocket bolt.
SST 09213-70010 and 09330-00021
(c) Remove the crankshaft pulley.
(d) Using SST, uniformly remove the camshaft sprocket

together with the crankshaft sprocket and chain.
SST 09950-20017
7. REMOVE VIBRATION DAMPER

Remove the two bolts and vibration damper.
8. REMOVE THRUST PLATE AND CAMSHAFT

(a) Remove the two bolts and thrust plate.
(b) Carefully pull out the camshaft.
CAUTION: Be careful not to damage the camshaft
bearings.
INSPECTION AND REPAIR OR TIMING

CHAIN AND CAMSHAFT COMPONENTS
1. INSPECT CAMSHAFT
--------~, (a) Place the camshaft on V-blocks and measure the

------~ runout at the center journal.
Maximum circle runout: 0.06 mm (O.0024 in.)
camshaft.
EM0035
(b) Using a micrometer, measure the cam lobe height.

Standard lobe height:
Intake 38.620 - 38.720 mm
(1.5205 - 1.5244 in.)
Exhaust 38.629 - 38.729 mm
(1.5208 - 1.5248 in.)
Minimum lobe height:
Intake 38.26 mm (1.5063 in.)
Exhaust 38.27 mm (1.5067 in.)
EM2011 If the lobe height is less than minimum, replace the
camshaft.
(c) Using a micrometer, measure the journal diameter.
Standard diameter (from front side):
No. 1 46.459 - 46.475 mm
(1.8291 - 1.8297 in.)
No. 2 46.209 - 46.225 mm
(1.8192 - 1.8199 in.)
No.3 45.959 - 45.975 mm
(1.8094 - 1.8100 in.)
No.4 45.709 - 45.725 mm
EM2538
(1.7996 - 1.8002 in.)
No.5 45.459 - 45.475 mm
(1.7897 - 1.7904 in.)
If the journal diameter is not within specification, check
the oil clearance, (See page EM-56)
(d) Install the thrust plate and camshaft sprocket to the
camshaft.
(e) Install and torque the camshaft sprocket mount bolt.
(f) Using a thickness gauge, measure the thrust clearance

between the thrust plate and camshaft.
Standard thrust clearance: 0.07 - 0.22 mm
(O.0028 - 0.0087 in.)
Maximum thrust clearance: 0.3 mm (O.012 in.)
thrust plate. If necessary, replace the camshaft.
2. INSPECT CHAIN AND SPROCKET

(a) Measure the chain length with the chain fully
stretched.
L.. .F."~~~ ·1'=:==

(b) Make the same measurements pulling at three or
\C. ,,·1· H·:;;:;"""::.j

I··F ·"·1·
H
more places selected at random.
Maximum chain elongation:
291.4 mm (11.472 in.)
at 5kg (11.0 Ib, 49 N) tension
If the elongation is greater than maximum, replace the
EM2422
chain.
(c) Using calipers, measure the sprocket diameter with

the chain.
Minimum sprocket diameter (wi chain):
Crankshaft 59 mm (2.32 in.)
Camshaft 114 mm (4.49 in.)
If the diameter is less than minimum, replace the chain and
two sprockets.
3. INSPECT CHAIN TENSIONER

Using calipers, measure the tensioner thickness.
Standard thickness: 15.0 mm (0.591 in.)
Minimum thickness: 12.5 mm (0.492 in.)
If the thickness is less than minimum, replace the ten-
sioner.
4. IF NECESSARY, REPLACE CHAIN TENSIONER

PLUNGER
(a) Using a gasket scraper and hammer, remove the
plate.
CAUTION: Do not bend the plate.
(b) Remove the chain tensioner plunger and spring.
(c) Apply engine oil to the chain tensioner body and

plunger sliding surface.
ENG\NE MECHAN\CAL - T\m\f\g Cha\n and CamsnaH . EM-33
(d) Install the spring and a new chain tensioner plunger

to the chain tensioner body.
(e) Place the plate in position.
EM1397
(f) Using a socket wrench and hammer, tap in the plate.
Socket Wrench
EM1398
5. INSPECT CHAIN VIBRATION DAMPER

Using calipers, measure the damp~r thickness.
Standard thickness: 6.6 mm (0.~60 in,)
Minimum thickness: 5 mm (0.20 in.)
If the thickness is less than minimum, replace the damper.
EM1399
6. INSPECT VALVE LIFTERS

Using a micrometer, measure the valve lifter diameter.
Lifter diameter: 21.387 - 21.404 mm
(0.8420 - 0.8427 in.)
If the diameter is not within specification, check the oil
clearance. (See page EM-57)
EM2389
7. IF NECESSARY, BLEED VALVE LIFTERS

TOYOTA GM
(a) There are two types of valve lifters; Toyota and GM
~ 0 (b)
types, and each has a different method of bleeding.
Immerse the valve lifter into diesel fuel.
~m _ (0.31 in.)
5 mm
(0.20 in.)
EM2390
[TOYOTA Type]
Using SST, pump the plunger several times to bleed the
air from the lifter.
SST 09276-71010
[GM Type]
Disassemble and reassemble the lifter while immersed in
diesel fuel. Use a leak down tester to install the snap ring
and the push rod seat.
8. INSPECT LEAK DOWN TEST

Using a leak down tester, apply 20 kg (44.1 Ib, 196 N) of
pressure to the plunger and measure its slide down time
for 1 mm (0.04 in.) after it has slid down about 2 mm
(0.08 inJ
Leak down time: 7 - 50 seconds/1 mm (0.04 in,)
at temperature 20°C (68 OF)
EM2013
REPLACEMENT OF CRANKSHAFT FRONT

OIL SEAL
NOTE: There are two methods (A and B) to replace the
oil seal.
REPLACE CRANKSHAFT FRONT OIL SEAL
A. If timing chain cover is removed from timing chain

case:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09223-22010
(c) Apply MP grease to the oil seal lip.
EM2351
B. If timing chain cover is installed to timing chain case:

(a) Using SST, remove the oil seal.
SST 09308-10010
(b) Apply MP grease to a new oil seal lip.

(c) Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing chain case edge.
SST 09223-22010
INSTALLATION OF TIMING CHAIN AND

CAMSHAFT
(See page EM-27)
1. INSTALL CAMSHAFT
(a) Carefully insert the camshaft into the cylinder block.
CAUTION: Be careful not to damage the camshaft
bearings.
EM2346
(b) Install the thrust plate with the two bolts.

Front
EM2352
2. INSTALL VIBRATION DAMPER

Install the vibration damper with the two bolts.
EM1394
3. INSTALL TIMING CHAIN AND SPROCKETS

(a) Set the set key of the crankshaft sprocket facing
Camshaft Set Key upward.
(b) Align the set key of the camshaft sprocket with the
mark of the thrust plate.
Crankshaft
Set Key
EM1402
(c) Install the sprockets to the timing chain.

NOTE: Align the timing marks of the timing chain and
sprocket.
(d) Uniformly install the chain together with the
sprockets.
EM0420
(e) Install the crankshaft pulley to the crankshaft.

(f) Apply a light of engine oil on the threads and under
the bolt head of the camshaft sprocket bolt.
(g) Using SST, install and torque the camshaft sprocket
bolt.
SST 09213-70010 and 09330-00021
(h) Remove the crankshaft pulley.
SST EM0421
4. INSTAll CHAIN TENSIONER

Install the chain tensioner with the two bolts.
5. INSTAll TIMING CHAIN COVER

Install a new gasket and the timing chain cover with the
eleven bolts.
Torque: 60 kg-em (52 in.-Ib, 5.9 N'm)
EM2344
6. INSTALL CRANKSHAFT PULLEY

(a) Using a plastic-faced hammer, tap in the crankshaft
pulley.
EM2354
(b) Apply a light coat of engine oil on the threads and

under the bolt heads of the pulley bolt.
(c) Using SST, install and torque the pulley bolt.
SST 09213-70010 and 09330-00021
Torque: 1,600 kg-cm (116 ft-Ib, 157 N'm)
EM0422
7. INSTALL VALVE LIFTERS

Using a wire or magnetic finger, carefully insert the valve
lifters into the valve lifter bore without dropping them.
POST INSTALLATION
1. INSTALL PUSH RODS AND ROCKER SHAFT
ASSEMBLY (See steps 2 and 3 on pages EM-.23)
2. INSTALL COLD START INJECTOR (See page FI-47)
3. INSTALL DISTRIBUTOR (See page IG-15)
4. INSTALL WATER PUMP PULLEY AND FAN

(See step 2 on page CO-6)
6. INSTALL AND ADJUST DRIVE BELTS

Alternator (See page CH-13)
PS pump (See page SR-37)
AIC compressor (See page AC-30)
6. INSTALL RADIATOR (See page CO-g)
7. ADJUST IGNITION TIMING (See page IG-14)

ENGINE MECHANICAL - Cylinder Block EM-39
CYLINDER BLOCK
COMPONENTS
Piston Ring (No, 1 Compression) ~

Piston Ring (No, 2 Compression) P' R' (S'd R 'I)
Piston Ring (Expander)------ __ r - - - - - - Iston mg leal
'------t"'Piston Pi n
Piston---------------i
Ol--------Connecting Rod Bushing
Flywheel
Connecting Rod - - - - - - - - - - - i Rear End Plate
Connecting Rod Bearing----.----
Connecting Rod C a p - - - - - - -
• Gasket Cylinder Block
MIT 850 (61, 83)

AIT 750 (54, 74)
Rear Oil Seal Retainer
i
1185 (13, 18) I
Crankshaft
Timing Chain Case 1 ' I
~ ~------Main Bearing
1185 (13, 18) 1---------, ;---,-----Crankshaft Thrust Washer
f - - - - - - - M a i n Bearing Cap
Oil Pump ------i'."F"1r,~ H--~-..:---"'~--!1800 (58, 78) I
Oil Pan----\..
+Gasket ~
Drain Plug-4
Ikg-cmTtt"=-ib, N'm)1 : Specified torque

+ Non-reusable part EM3578
EM-40 ENGINE MECHANICAL - Cylinder Block
REMOVAL OF ENGINE
OF BATTERY
4. DRAIN ENGINE COOLANT (See page CO-3)
5. DISCONNECT HOSES
(b) Radiator outlet hose
(c) Radiator breather hose
(d) Radiator reservoir tank hose
(e) Heater outlet hose
(f) Brake booster hose

(g) Fuel inlet hose
(h) Fuel outlet hose
(i) Charcoal canister hose
EM1148
6. DISCONNECT CONNECTORS AND WIRES

(a) Water temperature sender gauge connector
(b) Oil pressure switch connector
(c) Distributor connectors
(d) [wi A/C]
AIC compressor connector
(e) [wi A/C]
AIC idle-up VSV connector
EM1149 (f) [w/A IC]
EFI VSV connector
(j) (g) [A/T]
Three connectors
(h) Water temperature switch connector
(i) Alternator connector and wire
(j) Air flow meter connector
(k) Solenoid resistor connectors
(I) Two connectors
EM1150
7. REMOVE AIR CLEANER HOSE
8. [wi PS]
REMOVE POWER STEERING (PS) PUMP
(See page SR-29)
9. DISCONNECT ACCELERATOR CABLE FROM

THROTTLE LINKAGE
10. [A/T]
DISCONNECT THROTTLE CABLE FROM THROTTLE
LINKAGE
11. REMOVE RADIATOR (See page CO-8)
12. DISCONNECT ECU CONNECTORS

(a) Remove the center pillar garnish.
(b) Remove the seat belt retractor and cover.
(c) Disconnect the connectors from the ECU.
EMl157
wi Ale 13. [wi A/C]

REMOVE AIC COMPRESSOR WITHOUT
DISCONNECTING HOSES
(a) Loosen the adjusting bolt and remove the drive belt.
(b) Remove the four compressor mount bolts.
(c) Suspend the compressor with string.
EMl151
14. RAISE VEHICLE ABOUT 1 m (3.28 ft) OF FLOOR

CAUTION: Be sure the vehicle is securely supported.
~ ['-----'\ \'---------"\ 15. DRAIN ENGINE OIL
16. REMOVE PROPELLER SHAFT (S) (See page PR-3)
EMl152
17. REMOVE FRONT EXHAUST PIPE
18. DISNNECT TRANSMISSION CONTROL CABLES
V MIT (See page MT-4)

AIT 2WD (See page AT-30)
\~ AT1225
19. REMOVE CLUTCH RELEASE CYLINDER
20. REMOVE STARTER

(a) Disconnect the connector and wire from the starter.
(b) Remove the two bolts and starter.
wi Rear Heater 21. DISCONNECT SPEEDOMETER CABLE AND GROUND

STRIP
22. DISCONNECT BACK-UP LIGHT SWITCH CONNECTOR
23. [4WD]
DISCONNECT TRANSFER INDICATOR SWITCH
CONNECTOR
24. [wi REAR HEATER]

EM1159
DISCONNECT REAR HEATER CONTROL CABLES
(a) Disconnect the mode sector cable from the damper.
(b) Disconnect the air mix damper cable from the damper.
wi Rear Heater
. . . . Front
EM1158
25. DISCONNECT HEATER HOSES

(a) Heater outlet hose
(b) [wi Rear Heater]
Rear heater hoses
EM'153
26. DISCONNECT GROUND STRAP FROM ENGINE

MOUNTING
27. REMOVE ENGINE UNDER COVER
28. DISCONNECT CONNECTOR OF OIL LEVEL SENSOR
29. [A/T]
DISCONNECT OIL COOLER HOSES
30. [2WD]
REMOVE STRUT BAR (See page FA-27)
31. [4WD]
REMOVE STABILIZER BAR (See page FA-11 0)
32. REMOVE ENGINE AND TRANSMISSION ASSEMBLY

NOTE: In advance, prepare an engine saddle as shown.
EMl154
ENGINE MECHANICAL - Cylinder Block EM-43t /
;.
(a) Support the engine and transmission with engine
saddle and jacks.
EM1155
2WD MIT (b) [2WD MIT]

Remove the bolts holding the engine rear mounting
bracket to the body.
EM1162
(c) [2WD AIT and 4WD]

Remove the through bolt holding the engine mounting
insulator to the transmission.
AT1217
(d) Remove the bolts and nuts holding the engine front
2WD
member to the body.
(e) [4WD]
Remove the bolts, nuts and front suspension rear
crossmember.
(f) Lower the engine and transmission.
(g) Remove the engine mounting member from the
engine.
EMl156 33. SEPARATE ENGINE AND TRANSMISSION
4WD
~€E::::3
EM3593
PREPARATION FOR DISASSEMBLY

1. [MIT]
REMOVE CLUTCH COVER AND DISC
2. [MIT]
REMOVE FLYWHEEL
3. [A/T]
REMOVE DRIVE PLATE
4. REMOVE REAR END PLATE
5. INSTALL ENGINE TO ENGINE STAND FOR

DISASSEMBLY
6. REMOVE ALTERNATOR AND BRACKET
7. REMOVE OIL FILTER BRACKET AND OIL FILTER
8. REMOVE CYLINDER HEAD ASSEMBLY

(See pages EM-12)
9. REMOVE TIMING CHAIN AND CAMSHAFT

(See pages EM-28 to 30)
10. REMOVE ENGINE OIL PAN AND OIL PUMP

(See pages LU-5 and 6)
DISASSEMBLY OF CYLINDER BLOCK

(See page EM-39)
1. REMOVE WATER BY -PASS PIPE

Remove the two nuts and holding bolt, and remove the
water by-pass pipe with the gasket.
2. REMOVE TIMING CHAIN CASE

Remove the nine bolts and one nut, and remove the timing
chain case and gasket.
3. REMOVE REAR Oil SEAL RETAINER

Remove the five bolts, rear oil seal retainer, dust seal and
gasket.
4. CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
(0.0063 - 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the clearance is greater than maximum, replace the con-
necting rod assembly.
5. REMOVE CONNECTING ROD CAPS AND CHECK OIL

CLEARANCE
(a) Using a punch or numbering stamp, place the match-
marks on the connecting rods and caps to ensure
correct reassembly.
(b) Remove the connecting rod cap nuts.

(c) Using a plastic-faced hammer, lightly tap the con-
necting rod bolts and lift off the rod connecting cap.
NOTE: Keep the lower bearing insert with the connecting
rod cap.
(d) Cover the connecting rod bolts with a short piece of

hose to protect the crankshaft from damage.
(e) Clean each crank pin and bearing.

(f) Check each crank pin and bearing for pitting and
scratches.
If the crank pin or bearing are damaged, replace the bear-
ings. If necessary, replace the crankshaft.
EM0210
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap. (See page EM-61)

NOTE: Do not turn the crankshaft.
/ ·0c"-
~
~:j}
EM2560
0) Remove the connecting rod cap.

(j) Measure the Plastigage at its widest point.
Standard clearance: 0.020 - 0.051 mm
(0.0008 - 0.0020 in.)
Maximum clearance: 0.10 mm (0.0039 in.)
bearing. If necessary, replace the crankshaft.
NOTE: If using a standard bearing, rep·lace with one hav-

ing the same number marked on the connecting rod cap.
6,7 or 8 There are three sizes of standard bearings, marked "6",
"7" and "8" accordingly.
Standard sized bearing thickness (at center wall):
Mark "6" 1.486 - 1.490 mm
(0.0585 - 0.0587 in.)
6,7 or 8 Mark "7" 1.490 - 1.494 mm
(0.0587 - 0.0588 in.)
Mark "8" 1.494 - 1.498 mm
EM2031 (0.0588 - 0.0590 in.)
(k) Completely remove the Plastigage.
6. REMOVE PISTON AND CONNECTING ROD

ASSEMBLIES
(a) Remove all the carbon from the piston ring ridge.
(b) Cover the connecting rod bolts. (See page EM-45)
(c) Push the piston, connecting rod assembly and upper
bearing out through the tap of the cylinder.
NOTE:
• Keep the bearings, connecting rod and cap together.
• Arrange the piston and connecting rod assemblies in
correct order.
2 3 4
EM2340
7. CHECK CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
(0.0008 - 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
thrust washers as a set.
Oversize thrust washer: 0/5 0.125, 0.250
8. REMOVE MAIN BEARING CAPS AND CHECK OIL

CLEARANCE
(a) Remove the main bearing cap bolts.
(b) Using the removed main bearing cap bolts, pry the
cap back and forth, and remove the main bearing
caps, lower bearings and lower thrust washers (No.3
main bearing cap only.)
NOTE:
• Keep the lower bearing and main bearing cap together.
EM2022
• Arrange the main bearing caps and lower thrust
washers in correct order.
(c) Lift out the crankshaft.
t--- "- NOTE: Keep the upper bearing and upper thrust washers
-~'- together with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing are damaged, replace the bearing.
If necessary, replace the crankshaft.
EM1498
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each main journals.
@0\
u, /
\
/).
EM1793
(h) Install the main bearing caps. (See page EM-50)

NOTE: Do not turn the crankshaft.
EM2033
(j) Remove the main bearing caps.

(j) Measure the Plastigage at its widest point.
(0.0008 - 0.0020 in.)
If the clearance is greater than maximum, replace the main
bearing. If necessary, replace the crankshaft.
EM1737
NOTE: If using a standard bearing, replace with one hav-

ing the same number marked on the cylinder block. There
are three sizes of standard bearings, marked "1," "2" and
"3" accordingly.
Standard sized bearing thickness (at center wall):
Mark "1" 1.986 - 1.990 mm
~
~~~11l1Em 1, 2 or 3 (0.0781 - 0.0783 in.)
.. ''I
Mark "2" 1.990 - 1 .994 mm
(0.0783 - 0.0785 in.)
Front l
Mark "3" 1.994 - 1.998 mm
NO.1 - No.5 EM2544 (0.0785 - 0.0787 in.)
(k) Completely remove the Plastigage.
Upper (Cylinder Block Side)
9. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust washers
from the cylinder block.
Front NOTE: Arrange the main bearing caps, bearings and
thrust washers in correct order.
Lower (Bearing Cap Side)

EM2323
INSPECTION OF CYLINDER BLOCK

1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
2. CLEAN CYLINDER BLOCK

Using a soft brush and solvent, clean the block.
3. INSPECT TOP OF CYLINDER BLOCK FOR

FLANTNESS
Using a precision straight edge and feeler gauge, check
the surface contacting the cylinder head gasket for war-
page.
If warpage is greater than maximum, replace the cylinder
block.
EM2546
4. INSPECT CYLIN DERS FOR VERTICAL

SCRATCHES
Visually check the cylinders for vertical scratches.
"
y- If deep scratches are present, rebore all four cylinders.

(See page EM-54)
Front . .EB Thrust

Direction
Axial
5. INSPECT CYLINDER BORES
Using a cylinder gauge, measure the cylinder bore
diameter at positions A, Band C in the thrust and axial
t
directions.
Direction
Standard diameter:
10 mm STD size 91.000 - 91.030 mm
]
A (3.5827 - 3.5839 in,)
(0.39 in.)
- Middle Maximum diameter:
B
STD size 91.23 mm (3.5917 in.)
L 10 mm
C O/S 0.50 91.73 mm (3.6114 in.)
(0.39 in.) EM2548
If the diameter is greater than maximum, rebore all four
cylinders. If necessary, replace the cylinder block.
EM0086
/ 6. REMOVE CYLINDER RIDGE

If the wear is less than 0.2 mm (0.008 in.), use a ridge
reamer to machine the piston ring ridge at the top of the
cylinder.
DISASSEMBLY OF PISTON AND
.~,"~",~~:i~,
.. i ,';/ 'I --~)
CONNECTING ROD ASSEMBLIES
1. CHECK FIT BETWEEN PISTON AND PIN
A .-<, --~
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin.
EM2339
2. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the compres-
sion ring.
EM2653
(b) Remove the two side rails and oil ring expander by
hand.
NOTE: Arrange the rings in correct order.
3. DISCONNECT CONNECTING ROD FROM PISTON

Using SST, press the pin out of the piston.
SST 09221-25022 (09221-00020, 09221-00030,
09221-00040, 09221-00071, 09221-00081)
Piston Pin
SST-C)
SST --I
SST---ri
(~ EM2338 EM2324
NOTE:
• The piston and pin are a matched set.
• Arrange the pistons, pins, connecting rods and bearings
in correct order.
EM2655
INSPECTION OF PISTON AND CONNECTING

ROD ASSEMBLIES
1. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the
piston top.
(b) Using a groove cleaning tool or broken ring, clean the

ring grooves.
(c) Using solvent and a brush, thoroughly clean the

piston.
CAUTION: Do not use a wire brush.
2. INSPECT PISTON DIAMETER AND OIL CLEARANCE

(a) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 24 mm
(0.94 in.) from the piston head.
Standard diameter:
STD size 90.925 - 90.955 mm
(3.5797 - 3.5809 in,)
O/S 0.50 91.425 - 91.455 mm
(3.5994 - 3.6006 in,)
EM2745 (b) Measure the cylinder bore diameter in the thrust
L.- ......;.,j directions (See page EM-49) and subtract the piston
diameter measurement from the cylinder bore
diameter measurement.
Oil clearance: 0.065 - 0.085 mm
(0.0026 - 0.0033 in,)
If the clearance is not within specification, replace the
piston, or rebore all four cylinders and replace all four
pistons.
3. INSPECT CLEARANCE BETWEEN WALL OF PISTON

RING GROOVE AND NEW PISTON RING
Using a feeler gauge, measure the clearance between the
ring land and wall of new piston ring groove.
Ring groove clearance: 0.03 - 0.07 mm
(0.0012 - 0.0028 in,)
piston.
4. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond
the bottom of the ring travel, 110 mm (4.33 in,) from
the top of the cylinder block.
(c) Using a thickness gauge, measure the end gap.
Standard end gap:
No.1 0.23 - 0.48 mm (0.0091 - 0.0189 in,)
No.2 0.16 - 0.44 mm (0.0063 - 0.0173 in,)
L.- ~EMO 2......
24 Oil (Side rail)
0.13 - 0.47 mm (0.0051 - 0.0185 in.)
Maximum end gap:
No. 1 1.08 mm (0.0425 in,)
No.2 1.04 mm (0.0409 in.)
Oil (Side rail) 1.07 mm (0.0421 in,)
If the gap is greater than maximum, replace the piston
ring.
If the gap is greater than maximum even with a new piston
ring, rebore all four cylinders and use O/S piston rings.
EM2552
5. INSPECT CONNECTING RODS

I Using a rod aligner and thickness gauge, check the
~
!
connecting rod alignment.

• Check for bend.
Maximum bend:
I, ! 0.05 mm (0.0020 in,) per 100 mm (3.94 in.)
i If bend is greater than maximum, replace the connecting
rod assembly.
EM0287 EM0288
• Check for twist.

Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting
rod assembly.
NOTE: If replacing the connecting rods, replace the
same number of connecting rod bearings as that of new
connecting rod caps.
EM0289 EM0290
BORING OF CYLINDERS
NOTE:
• Bore all four cylinders for the oversized piston's outside
diameter.
• Replace the piston rings with ones to match the over-
sized pistons.
1. KEEP OVERSIZIED PISTONS

Oversized piston diameter.
O/S 0.50 91.415 - 91.445 mm
(3.5990 - 3.6001 in.)
2. CALCULATE DIMENSION FOR BORING CYLINDERS

(a) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 24 mm
(0.94 in.) from the piston head.
(b) Calculate the size each cylinder is to be rebored as
follows:
Size to be rebored = P +C - H
P = piston diameter
C = piston clearance
EM2745 0.065 - 0.085 (0.0026 - 0.0033 in.)
H = allowance for honing
0.02 mm (0.0008 in.) or less
3. BORE AND HONE CYLINDERS TO CALCULATED

DIMENSIONS
Amount of housing: 0.02 mm (0.0008 in.) maximum
CAUTION: Excess honing will destroy the finished
roundness.
INSPECTION AND REPAIR OF CRANKSHAFT

1. INSPECT CRANKSHAFT FOR RUNOUT
~~.\
(a) Place the crankshaft on V-blocks.
•........... (b) Using a dial indicator, measure the circle runout at
---~J the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
crankshaft.
EM2553
2. INSPECT MAIN JOURNALS AND CRANK PINS
-¢-
(a) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD size 57.985 - 58.000 mm
(2.2829 - 2.2835 in.)
H
0/5 0.25 57.745 - 57.755 mm
(2.2734 - 2.2738 in.)
Crank pin diameter:
STD size 47.985 - 48.000 mm
EM0315
(1.8892 - 1.8898 in.)
0/5 0.25 47.745 - 47.755 mm
(1.8797 - 1.8801 in.)
If the diameter is not within specification, check the oil
clearance.
(b) Check each main journal and crank pin for taper and
out-of-round as shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in,)
If taper and out-of-round is greater than maximum, rep-
lace the crankshaft.
3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS

AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
undersized finished diameter.
Install new main journal and/or crank pin undersized bear-
ings.
INSPECTION AND REPAIR OF CAMSHAFT

BEARINGS
1. INSPECT CAMSHAFT OIL CLEARANCE
(a) Using a cylinder gauge, measure the inside diameter
of the camshaft bearing.
Bearing inside diameter (from front side):
No. 1 46.500 - 46.540 mm
(1.8307 - 1.8323 in.)
No.2 46.250 - 46.290 mm
(1.8209 - 1.8224 in.)
No. 3 46.000 - 46.040 mm
(1.8110 - 1.8126 in.)
No.4 45.750 - 45.790 mm
(1.8012 - 1.8028 in.)
No.5 45.500 - 45.540 mm
(1.7913 - 1.7929 in.)
(b) Subtract the journal diameter measurement (See
page EM-31) from the bearing inside diameter
measurement.
(0.0010 - 0.0032 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
camshaft bearings. If necessary, grind or replace the
camshaft.
2. IF NECESSARY, REPLACE CAMSHAFT BEARINGS

NOTE: The outer diameter varies with each bearing.
EM2555
A. Remove expansion plug

Using SST and a hammer, tap out the expansion plug.
SST 09215-00100 (09215-00130, 09215-00150,
09215-00210)
B. Remove the camshaft bearings

Using SST, remove the bearings.
SST 09215-00100 (09215-00120, 09215-00130,
09215-00140,09215-00150,09215-00160,
0921 5-00250)
EM1094
C. Install new camshaft bearing

(a) Align the oil holes of the bearing and cylinder block.
No 1
EM2325
Front .. (b) Using SST, install the bearings.
~
SST 09215-00100 (09215-00120, 09215-00130,
I
~ p 09215-00140, 09215-00150, 09215-00160,

0921 5-00250)
D. Check camshaft oil clearance

(See page EM-56)
E. Install new expansion plug

(a) Apply liquid sealer to the expansion plug surface of
the cylinder block.
(b) Using a hammer, tap in a new expansion plug until its
surface is flush with the cylinder block edge.
EM2326 EM2327
INSPECTION OF VALVE LIFTER BORES

INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using calipers, measure the valve lifter bore diameter.

Bore diameter: 21.417 - 21.443 mm
(0.8432 - 0.8442 in,)
(b) Subtract the valve lifter diameter measurement (See
page EM-33) from the valve lifter bore diameter
measurement.
(0.0005 - 0.0022 in,)
Maximum oil clearance: 0.10 mm (0.0039 in,)
If the clearance is greater than maximum, replace the valve
lifters.
REPLACEMENT OF CRANKSHAFT REAR OIL

SEAL
NOTE: There are two methods (A and B) to replace the
oil seal.
REPLACE CRANKSHAFT REAR OIL SEAL

A. If rear oil seal retainer is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
EM1163
(b) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-63010
'---¥r-~- SST
EM1164
B. If rear oil seal retainer is installed to cylinder block:

(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
CAUTION: Be careful not to damage the crankshaft.
Tape the screwdriver.
(c) Apply MP grease to a new oil seal.

~J (d) Using SST and a hammer, tap in the oil seal until its
~ Ii surface is flush with the rear oil seal retainer edge.
/ SST SST 09223-63010
A
EM1166
ASSEMBLY OF PISTON AND CONNECTING

FrontMark~ ROD ASSEMBLIES
(Cavity) ~
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Align the front marks of the piston and connecting
rod.
Front Mark
(Protrusion)
EM2557
(b) Coat the piston pin and the piston pin hole of the
SST --(; Piston
piston with engine oil.
~. "'........... Pin Piston
~, .~ Pin (c) Using SST, press in the piston pin.
. --l..5 SST 09221-25022 (09221-00020, 09221-00030,
SST~
09221-00040, 09221-00071, 09221-00081)
SST--.~
SST--I
~
SST --------j \
i C_ _
2. PLACE PISTON RINGS ON PISTON

(a) Install the oil ring expander and two side rails by
hand.
(b) Using a piston ring expander, install the two com-

pression rings with the cord mark facing upward.
No.1
~cord
NO.2./Mark
(c) Position the piston rings so that the ring ends are as
shown.
CAUTION: Do not align the ends.
Lower Side Compression

Rail Ring NO.1 and
Expander EM2558
EM-GO ENGINE MECHANICAL - Cylinder Block
3. INSTALL BEARINGS
Install the bearings in the connecting rods and rod caps.
CAUTION: Install the bearing with the oil hole in the
connecting rod.
EM0095
ASSEMBLY OF CYLINDER BLOCK

(See page EM-39)
NOTE:
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil to all
sliding and rotaing surfaces.
• Replace all gaskets, and oil seals with new parts.
1. INSTALL MAIN BEARINGS

(a) Place the upper main bearings in the cylinder block.
(b) Place the lower main bearings in the main bearing
caps.
CAUTION: Install the bearing with the oil hole in the
block.
EM0388
2. INSTALL UPPER THRUST WASHERS

Install the thrust washers under the No. 3 main bearing
cap position of the cylinder block with the oil grooves fac-
ing outward.
3. PLACE CRANKSHAFT ON CYLINDER BLOCK
EM0247
4. INSTALL MAIN BEARINGS CAPS AND LOWER

THRUST WASHERS
NOTE: Each main bearing cap is numbered.
=.
.~
~\
/,9l~
In (a) Install the thrust washers on the No.3 main bearing
cap with the grooves facing outward.
. '\ ...
'=Z~
Oil Groove
EM1703
(b) Install the main bearing caps in their proper location.

Bearing Cap
Bearing Cap No.3
No.1, 2, 4 and 5
j I
.1
J'
,
EM2329
(c) Apply a light coat of the engine oil on the threads and
under the bolt heads of the main bearing caps.
(d) Install and uniformly tighten the ten bolts of the main
bearing caps in sevral pass, in the sequence shown.
(e) Check that the crankshaft turns.
(f) Check the crankshaft thrust clearance.
(See page EM-47)
EM2330
~
5. INSTALL PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Cover the connecting rod bolls with a short piece of
hose to protect the crankshaft and cylinder bore
from damage.
/~I
/
"/3/ I~
I / Il-/~
.--/" ~~ EM2082
(b) Using a piston ring compressor, push the correctly

numbered piston and connecting rod assembly into
each cylinder with the front mark of the piston facing
forward.
6. INSTALL CONNECTING ROD CAPS

(a) Match the numbered connecting rod cap with the
numbered connecting rod.
(b) Install the connecting rod caps with the front mark
facing forward.
EM0253
(c) Apply a light coat of the engine oil on the threads and
under the connecting rod nuts.
(d) Install and alternately tighten the connecting rod nuts
and is several passes.
(e) Check that the crankshaft turns smoothly.
(f) Check the connecting rod thrust clearance.
(See page EM-45)
EM2560
7. INSTAll REAR Oil SEAL RETAINER

8. INSTAll TIMING CHAIN CASE

Install a new gasket and the timing chain case with the
nine bolts and one nut.
EM2321 EM2332
9. INSTAll WATER BY-PASS PIPE

Install a new gasket and the water by-pass pipe.
POST ASSEMBLY
1. INSTALL OIL PUMP AND ENGINE OIL PAN
(See page LU-7)
2. INSTALL TIMING CHAIN AND CAMSHAFT

(See pages EM-36 to 38)
3. INSTALL CYLINDER HEAD

(See pages EM-23)
4. INSTALL OIL FILTER BRACKET AND OIL FILTER

5. INSTALL ALTERNATOR AND BRACKET
6. REMOVE ENGINE FROM ENGINE STAND
7. INSTALL REAR END PLATE
8. [MIT]
INSTALL FLYWHEEL
9. [A/T]
INSTALL DRIVE PLATE
EM0002
10. [MIT]
INSTALL CLUTCH DISC AND COVER
11. INSTALL TRANSMISSION TO ENGINE

INSTALLATION ENGINE
1. ASSEMBLE ENGINE AND TRANSMISSION
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY

(a) Install the engine front member to the engine.
(b) Raise the engine, and install and torque the bolts and
nuts holding the engine front mounting member to the
body.
Torque:
Bolts A 400 kg-em (29 ft-Ib, 39 N'm)
Bolts B 900 kg-em (65 ft-Ib, 88 N'm)
4WD
(c) [4WD]
..~~ Install the front suspension rear crossmember with the

bolt and nuts.
' ..~ ~'\, ' ""
r ~. Torque: 970 kg-em (70 ft-Ib, 95 N'm)
© -j/
EM3593
(d) [2WD MIT]

2WD MIT
Install the bolts holding the engine rear mounting
bracket to the body. Torque the bolt.
EM1162
(e) [2WD AIT and 4WD]

Install the bolt and nut holding the engine rear mount-
ing insulator to the body. Torque the nut.
A1223
3. [2WD]
INSTALL STRUT BAR (See page FA-27)
4. [4WD]
INSTALL STABILIZER BAR (See page FA-11 0)
5. [A/T]
INSTALL OIL COOLER HOSES
6. CONNECT CONNECTOR OF OIL LEVEL SENSOR
7. INSTALL ENGINE UNDER COVER
8. CONNECT GROUND STRAP TO ENGINE MOUNTING

9. CONNECT HEATER HOSES

(a) Heater outlet hose
(b) [wi Rear Heater]
Rear heater hoses
EM1153
w I Rear Heater
10. [wi REAR HEATER]
CONNECT REAR HEATER CONTROL CABLES
(a) Connect the air mix damper cable to the damper.
...... Front
EMl158
wi Rear Heater (b) Connect the mode selector cable to the damper.
EM1159
(c) Move the control levers back and forth, and check for
wi Rear Heater
stiffness and binding through full range of operation.
BE0644
11. CONNECT SPEEDOMETER CABLE AND GROUND

STRAP
12. CONNECT BACK-UP LIGHT SWITCH CONNECTOR
13. [4WD]
CONNECT TRANSFER INDICATOR SWITCH
CONNECTOR
14. INSTALL STARTER
15. INSTALL CLUTCH RELEASE CYLINDER

16. INSTALL EXHAUST PIPE

Torque the nuts holding the exhaust pipe to the exhaust
manifold.
17. CONNECT TRANSMISSION CONTROL CABLES

MIT (See page MT-37)
18. INSTALL PROPELLER SHAFT(S) (See page PR-7)

AT1225
19. LOWER VEHICLE
20. [wi A/C]

INSTALL AIC COMPRESSOR
(a) Install the compressor with the four bolts.
(b) Install the drive belt.
21. CONNECT ECU CONNECTORS

(a) Connect the connectors to the ECU.
(b) Install the cover and seat belt retractor with the bolt and
EM1157 screw.
(c) Install the center pillar garnish.
22. INSTALL RADIATOR (See page CO-9)
23. CONNECT ACCELERATOR CABLE AND ADJUST IT
24. [A/T]
CONNECT THROTTLE CABLE AND ADJUST IT
25. [wi PS]

INSTALL POWER STEERING (PS) PUMP
(See page SR-37)
26. INSTALL AIR CLEANER HOSE
27. CONNECT CONNECTORS AND WIRES

(a) Water temperature sender gauge connector
(f) ~ (b) Oil pressure switch connector
(d)
(c) Distributor connectors
(b) (d) [w/A IC]

Ale compressor connector
(c)
(e) [wi A/C]
EM1149 AIC idle-up VSV connector
(f) [wi A/C]
(j) EFI VSV connector
(g) [A/T]
Three connectors
(h) Water temperature switch connector
(i) Alternator connector and wire
(j) Air flow meter connector
(k) Solenoid resistor connector
(I) Two connectors
EM1150
28. CONNECT HOSES

(b) Radiator outlet hose
(c) Radiator breather hose
(d) Radiator reservoir tank hose
(e) Heater outlet hose

(f) Brake booster hose
(g) Fuel inlet hose
(h) Fuel outlet hose
(i) Charcoal canister hose

BATTERY
31. FILL WITH ENGINE OIL (See page LU-4)
33. PERFORM ENGINE ADJUSTMENT

(a) Adjust drive belt tension.
(See page CH-3, SR-37 or AC-13)
(b) Adjust ignition timing. (See page IG-14)
(wi Terminals T and E1 short-
circuited)
(c) Adjust idle speed. (See page MA-7)
AIT 750 rpm
36. ROAD TEST

Road test vehicle.
37. RECHECK COOLANT AND ENGINE OIL LEVELS

EC-1
EMISSION CONTROL
SYSTEMS
Page
SYSTEM PURPOSE . EC-2
COMPONENT LAYOUT AND SCHEMATIC
DRAWiNG . EC-3
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM . EC-4
FUEL EVAPORATIVE EMISSION CONTROL
(EVAP) SYSTEM . EC-6
DASH POT (OP) SYSTEM . EC-8
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM . EC-10
THREE-WAY CATALYST (TWC) SYSTEM . EC-13
NOTE: TROUBLESHOOTING
See page EM-2
EC-2 EMISSION CONTROL SYSTEMS - System Purpose
SYSTEM PURPOSE
~
System Abbreviation Purpose
Positive crankcase ventilation PCV Reduces blow-by gas (HC)

Fuel evaporative emission control EVAP Reduces evaporative HC
Dash pot DP Reduces HC and CO
Exhaust gas recirculation EGR Reduces NOx
Three-way catalyst TWC Reduces HC, CO and NOx
Electronic fuel injection* EFI Regulates all engine conditions for reduction of
exhaust emissions
* For inspection and repair of the EFI system, refer to the EFI section.
EMISSION CONTROL SYSTEMS - Component Layout and Schematic Drawing EC-3
COMPONENT LAYOUT AND SCHEMATIC DRAWING
EGR Valve
EGR Vacuum
Modulator
Charcoal
Canister
EC1559
Charcoal
Canister
Oxygen
Sensor
(2WD MIT)
Oxygen Sensor
2WD AIT )
( and 4WD
EC2331
EC-4 EMISSION CONTROL SYSTEMS - Positive Crankcase Ventilation (PCV) System
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
---.. Blow-by Gas

--~ Fresh Air
EC0273
To reduce HC emissions, crankcase blow-by gas (HC) is routed through the PCV valve to the intake manifold for
combustion in the cylinders.
Engine not Running or if Backfiring Normal Operation
Surge Tank Side
• PCV VALVE IS CLOSED • PCV VALVE IS OPEN

• VACUUM PASSAGE IS
LARGE
Cylinder Head Side

EC1007 EC1009
Idling or Decelerating Acceleration or Heavy Load
• PCV VALVE IS OPEN • PCV VALVE IS FULLY

• VACUUM PASSAGE IS OPEN
SMALL
EC1008 EC1010
EMISSION CONTROL SYSTEMS - Positive Crankcase Ventilation (PCV) System EC-5
Cylinder Head Side INSPECTION OF PCV VALVE

1. REMOVE PCV VALVE
/
Clean Hose
2.
3.
ATTACH CLEAN HOSE TO PCV VALVE
BLOW FROM CYLINDER HEAD SIDE

Check that air passes through easily.
CAUTION: Do not suck air through the valve.
Petroleum substances inside the valve are harmful.
EC1011
Surge Tank Side

4. BLOW FROM SURGE TANK SIDE
Check that air passes through with difficulty.
If the PCV valve fails either of these checks, replace it.
5. REINSTALL PCV VALVE
EC1012
INSPECTION OF PCV HOSES AND

CONNECTIONS
VISUALLY INSPECT HOSES, CONNECTIONS AND
GASKETS
Check for cracks, leaks or damage.
EC0274
EC-6 EMISSION CONTROL SYSTEMS - Fuel Evaporative Emission Control (EVAP) System
FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM

Purge Port
Check
Valve
*Check
(2) Valve Fuel Filler Cap
(3)
\
\
Check
Valve
Charcoal
Fuel Tank
Canister EC0275
To reduce HC emissions, evaporated fuel from the fuel tank is routed through the charcoal canister to the throttle
body for combustion in the cylinders.
~-----
----- -----,---- ---- - --- ------------
Check Valve in
Charcoal Canister Check Valve in
Condition Fuel Filler Cap Evaporated Fuel (HC)
(1 ) (2) (3)
+ - - - - - - - - - - -~ - - - .------ -- ---------- ~- ------------------
Parking, idling HC from tank is absorbed

and low speed CLOSED - - - in the canister.
- - ---- --
Medium and HC from canister is led
high speed OPEN - - - into throttle body.
High pressure HC from tank is absorbed
- OPEN CLOSED CL.OSED
in tank in the canister.
-f---- --- -f--- --- ----- ------ - --- ---
High vacuum
in tank
- CLOSED OPEN OPEN (Air is led into the tank.)
* This check valve prevents fuel leakage from the fuel tank in event the vehicle rolls over.
INSPECTION OF FUEL VAPOR LINES, FUEL

TANK AND FILLER CAP
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loose connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK

Look for deformation, cracks or fuel leakage.
EC0276
3. VISUALLY INSPECT FUEL FILLER CAP

Look for a damaged or deformed gasket and cap.
If necessary, repair or replace the cap.
Gasket
Check Valve
(Vacuum Valve) EC1102
EMISSION CONTROL SYSTEMS - Fuel Evaporative Emission Control (EVAP) System EC-7
INSPECTION OF CHARCOAL CANISTER

/ 1. REMOVE CHARCOAL CANISTER
2. VISUALLY INSPECT CHARCOAL CANISTER CASE

Look for cracks or damage.
ECll04
3. CHECK FOR CLOGGED FILTER AND STUCK CHECK

VALVE
Tank Pipe (a) Using low pressure compressed air, blow into the
tank pipe and check that the air flows without resis-
tance from the other pipes.
(b) Blow into the purge pipe and check that the air does
not flow from the other pipes.
If a problem is found, replace the charcoal canister.
ECll05
4. CLEAN FILTER IN CANISTER

Clean the filter by blowing 3 kg/cm 2 (43 psi, 294 kPa) of
______ Tank Pipe
compressed air into the tank pipe, while holding the other
upper canister pipe closed.
NOTE:
• Do not attempt to wash the canister.
...
• No activated carbon should come out.
5. INSTALL CHARCOAL CANISTER

ECll06
INSPECTION OF CHECK VALVE

CHECK VALVE BY BLOWING AIR INTO EACH SIDE
(a) Blow air from the fuel tank side and check that the
valve opens with slight resistance.
Charcoal ca~nister
Fuel Tank Side (b) Blow air from the canister side and check that the
Side valve opens without resistance.
-~-
If a problem is found, replace the check valve.
NOTE:
EC0109 1. Care should be taken not to inhale fumes from this
valve, as this could be a health hazard.
2. Care should be taken to install the valve correctly.
EC-8 EMISSION CONTROL SYSTEMS - Dash Pot (DP) System
DASH POT (DP) SYSTEM

(MIT Vehicles only)
DP Diaphragm
EC1561
Normal Driving Deceleration
'1~/ d'
IU"...r-.:J""-l'l/
Filte~
VTV
DP Diaphragm
EC0278 EC0279
To reduce HC and CO emissions, when decelerating the dash pot opens the throttle valve slightly more than at idle.
This causes the air-fuel mixture to burn completely.
Condition Diaphragm VTV Throttle Valve
Pushed in by return force of throttle

Idling CLOSED Idle speed position
valve
I
Normal driving Pushed out by diaphragm spring OPEN High speed position
Pushed in by return force of throttle Slightly opens and then slowly closes
Deceleration CLOSED
valve to idle position
EMISSION CONTROL SYSTEMS - Dash Pot (DP) System EC-9
INSPECTION OF DP SYSTEM
1. WARM UP ENGINE
Cap 2. CHECK IDLE SPEED AND ADJUST IF NECESSARY
3. DISCONNECT THROTTLE CABLES FROM THROTTLE

CAM
4. REMOVE VTV CAP, FILTER AND SEPARATER
EC0280
5. CHECK DP SETTING SPEED

2,500 rpm (a) Maintain engine speed at 2,500 rpm.
.. (b) Plug the VTV hole.
Tachometer
EC0138 EC1966
(c) Release the throttle valve.

1,900 rpm
(d) Check that the DP is set.
DP setting speed: 1,900 rpm
Tachometer
EC0137
If not as specified, adjust with the stopper screw.
EC0281
6. CHECK OPERATION OF VTV

About
•.
~~.
1 Second (a) Set the DP speed in the same procedure as above; (a)
..
'
to (c).
;":'- ;<0 (b) Release the plugged hole and check that the engine
, . Release
returns to idle in about 1 second.
, ~
7. REINSTALL VTV CAP, FILTER AND SEPARATER
Tachometer
EC0282 EC0141
EC-10 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

(1 )
EGR Valve
BVSV
E Port R Port EGR Vacuum
Modulator
Pressure
Chamber
EC1562 EC2365
(2)
BVSV
EGR Valve
(Open)
Pressure
Chamber
EC2366 EC2367
To reduce NOx emission, part of the exhaust gases are recirculated through the EGR valve to the intake manifold to
lower the maximum combustion temperature.
Coolant
Temp.
~
BVSV
-~-
1 Throttle Valve
Opening Angle
----
Pressure in the EGR
Valve Pressure Chamber
EGR Vacuum
Modulator
EGR
Valve
Exhaust Gas
Below 40°C Not

(104°F)
CLOSED - - - CLOSED
recirculated
I
Positioned below Not

I
I
- - CLOSED
recirculated
Above 54°C I
OPEN
I~~~;~ Positioned be-
tween E port
(l)
LOW
·Pressure con-
stantly alter-
OPENS passage
to atmosphere
CLOSED
Not
recirculated
(129°F) i I
. and EGR R port nating between

(2) CLOSES passage
low and high OPEN Recirculated
HIGH to atmosphere
I
I Positioned above ..
CLOSES passage
(3)
_ ..
OPEN
Recirculated
.._.J..
I
R po~t .... _. ___~ HIGH
I to atmosphere (increase)
~---~-
·Pressure increase - Modulator closes - E valve opens - Pressure drops

t EGR valve closes + - Modulator opens ' I
··When the throttle valve is positioned above the R port, the EGR vacuum modulator will close the
atmosphere passage and open the EGR valve to increase the EGR gas, even if the exhaust pressure
is insufficiently low.
EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System EC-11
INSPECTION OF EGR SYSTEM

,. CHECK AND CLEAN FILTER IN EGR VACUUM
MODULATOR
(a) Check the filter for contamination or damage.
(b) Using compressed air, clean the filter.
EC1901
2. PREPARATION
o
Vacuum Gauge
Using a 3-way connector, connect a vacuum gauge to the
hose between the EGR valve and EGR vacuum modulator.
3. CHECK SEATING OF EGR VALVE

Start the engine and check that the engine starts and runs
at idle.
EC1563
COLD 4. CHECK BVSV WITH COLD ENGINE

3,500 rpm Zero Vacuum (a) The coolant temperature should be below 40°C
(104 OF).
(b) Check that the vacuum gauge indication is zero at
3,500 rpm.
Tachometer Vacuum Gauge

ECOl 37 ECOl 28
HOT 5. CHECK BVSV AND EGR VACUUM MODULATOR

3,500 rpm Low Vacuum WITH HOT ENGINE
(a) Warm up the engine.
(b) Check that the vacuum gauge indicates low vacuum
at 3,500 rpm.
Tachometer Vacuum Gauge

EC0137 EC0129
Vacuum Gauge (c) Disconnect the vacuum hose from R port of the EGR
vacuum modulator and connect R port directly to the
intake manifold with another hose.
(d) Check that the vacuum gauge indicates high vacuum
at 3,500 rpm.
NOTE: As a large amount of EGR gas enters, the engine
will misfire slightly.
(e) Disconnect the vacuum gauge and reconnect the
vacuum hoses to the proper locations.
EC1564
EC-12 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System
6. CHECK EGR VALVE

(a) Apply vacuum directly to the EGR valve with the
engine idling.
(b) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses to the proper locations.
IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE

SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART
EC1565
EGRVacuum INSPECTION OF EGR VALVE

Modulator
1. REMOVE EGR VALVE
Check the valve for sticking and heavy carbon deposits. If
a problem is found, replace it.
2. INSTALL EGR VALVE WITH A NEW GASKET
INSPECTION OF EGR VACUUM MODULATOR

R
EC1566 CHECK EGR VACUUM MODULATOR OPERATION
(a) Disconnect the vacuum hoses from ports P, Q and R
EGR Vacuum Air of the EGR vacuum modulator.
Modulator
(b) Plug ports P and R with your finger.
(c) Blow air into port Q. Check that the air passes
through to the air filter side freely.
(d) Start the engine and maintain engine speed at 2,500
rpm.
(e) Repeat the above test. Check that there is a strong
resistance to air flow.
R EC1567 (f) Reconnect the vacuum hoses to the proper locations.
INSPECTION OF BVSV
CHECK BVSV BY BLOWING AI~ INTO PIPE
(a) Drain the coolant froml the radiator into a suitable
container.
Cool (b) Remove the BVSV. I
Water
(c) Cool the BVSV to below 40°C (104°F) with cool
water.
(d) Blow air into the pipe and check that the BVSV is
===~:t:...1 ---l....L.Ll_ EC0122 closed.
Above 54°C (e) Heat the BVSV to above 54°C (129°F) with hot
water.
(f) Blow air into the pipe and check that the BVSV is
open.
(g) Apply liquid sealer to the threads of the BVSV and
-t+--Hot reinstall.
Water
(h) Fill the radiator with coolant.
If a problem is found, replace the BVSV.
-===::::z:::::::::z:::!:....L-- ----l....L.L.l_ ECO 123
EMISSION CONTROL SYSTEMS - Three-Way Catalyst (TWC) System EC-13
THREE-WAY CATALYST (TWC) SYSTEM
Three-Way Catalyst
(Monolithic)
EC2901
To reduce HC, CO and NOx emissions, they are oxidized, reduced and converted to initrogen (N 2 ), carbon dioxide
(C0 2 ) and water (H 2 0) by the catalyst.
~-~~-~_. ---I
Exhaust Port TWC Exhaust Gas
f--
HC, CO. AND NOx

-
1---
J~
~
OXIDATION AND
REDUCTION :> CO 2
H2 O
N2
INSPECTION OF EXHAUST PIPE ASSEMBLY

1. CHECK CONNECTIONS FOR LOOSENESS OR
DAMAGE
2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR

DAMAGE
INSPECTION OF CATALYTIC CONVERTER

CHECK FOR DENTS OR DAMAGE
If any part of protector is damaged or dented to the extent
that it contacts the catalyst, repair or replace it.
EC2902
EC-14 EMISSION CONTROL SYSTEMS - Three-Way Catalyst (TWC) System
INSPECTION OF HEAT INSULATOR

Heat Insulator
1. CHECK HEAT INSULATOR FOR DAMAGE
\i;mm\\~_~~'\E 2. CHECK FOR ADEQUATE CLEARANCE BETWEEN

CATALYTIC CONVERTER AND HEAT INSULATOR
=08 8l=
EC2903
REPLACEMENT OF CATALYTIC CONVERTER

1. REMOVE CONVERTER
(a) Jack up the vehicle.
(b) Check that the converter is cool.
(c) Remove the bolts at the front and rear of the con-
verter.
(d) Remove the converter and gaskets.
EC0292 2. INSTALL CONVERTER

(a) Place new gaskets on the converter front and rear
pipes, and connect the converter to the exhaust
pipes.
(b) Tighten the bolts.
Torque: Catalyst - Exhaust pipe
440 kg-em (32 ft-Ib, 43 N'm)
(c) Reinstall and tighten the bracket bolts.
NOTE: Be sure to install the converter with the delta
mark pointing toward the engine.
FI-1
EFI SYSTEM
Page
SYSTEM DESCRIPTION . FI-2
PRECAUTIONS . FI-4
INSPECTION PRECAUTIONS . FI-4
TROUBLESHOOTING . FI-9
DIAGNOSIS SYSTEM . FI-21
TROUBLESHOOTING WITH
VOLT/OHMMETER . FI-26
FUEL SYSTEM . FI-40
Fuel Pump . FI-40
Cold Start Injector . FI-46
Fuel Pressure Regulator . FI-49
Injectors . FI-51
Fuel Tank and Line . FI-56
AIR INDUCTION SYSTEM FI-57
Air Flow Meter . FI-57
Air Valve . FI-59
Throttle Body . FI-61
ELECTRONIC CONTROL SYSTEM . FI-64
Location of Electronic Control Parts . FI-64
EFI Main Relay . FI-65
Circuit Opening Relay . FI-66
Solenoid Resistor . FI-67
Cold Start Injector Time Switch . FI-68
Water Temperature Sensor . FI-69
Oxygen Sensor . FI-70
Electronic Controlled Unit (ECU) . FI-72
Fuel Cut RPM . FI-74
Idle-up and High-temperature Line Pressure Up
(wi A/C) Systems FI-75
FI-2 EFI SYSTEM - System Description
SYSTEM DESCRIPTION
Fuel Pressure Regulator

Injector
ISC VSV
Water Temp.
Sensor
Distributor and
Ignition Coil
Fuel
Pulsation
Damper
Air Cleaner
Fuel Filter
Ignit
~---"'""
ECU
"CH ECK" Engine

Warning Light
A / C Compressor
Ignition
Switch
Speed
Fuel
Sensor Pump
Check Starter
Engine
Connector
Battery Fuel Tank
FI1517
EFI SYSTEM - System Description FI-3
The EFI system is composed of three basic sub-

systems: Fuel Induction, Air Induction and
Electronic Control Systems.
FUEL SYSTEM
Fuel is supplied under constant pressure to the EFI 3. Diagnosis
injectors by an electric fuel pump. The injectors The ECU detects any malfunctions or abnor-
inject a metered quantity of fuel into the intake malties in the sensor network and lights a
manifold in accordance with signals from the ECU "CHECK" engine warning light on the instru-
(Electronic Control Unit). ment panel. At the same time, the trouble is
identified and a diagnostic code is recorded
AIR INDUCTION SYSTEM by the ECU. The diagnostic code can be read
The air induction system provides sufficient air for by the number of blinks of the "CHECK"
engine operation. engine warning light when terminals T and El
are short-circuited.
(See page FI-21)
ELECTRONIC CONTROL SYSTEM
The 4Y-E engine is equipped with a Toyota Com- 4. Fail-Safe Function
puter Control System (TCCS) which centrally con- In the event of computer malfunction, a back-
trols the EFI, ESA. Diagnosis systems, etc. by up circuit will take over to provide minimal
means of an Electronic Control Unit (ECU - for- drivability. Simultaneously, the "CHECK"
merly EFI computed employing a microcomputer. engine warning light is activated.
By the ECU, the TCCS controls the following func-
tions:
1. Electronic Fuel Injection (EFI)

The ECU receives signals from various sen-
sors indicating changing engine operating
conditions such as:
Intake air volume
Intake air temperature
Coolant temperature
Engine rpm
Acceleration/deceleration
Exhaust oxygen content etc.
These signals are utilized by the ECU to
determine the injection duration necessary for
an optimum air-fuel ratio.
2. Electronic Spark Advance (ESA)

The ECU is programmed with data for
optimum ignition timing under any and all
operating conditions. Using data provided by
sensors which monitor various engine func-
tions (rpm, coolant temperature, etc.), the
microcomputer (ECU) triggers the spark at
precisely the right instant.
(See IG section)
FI-4 EFI SYSTEM - Precautions, Inspection Precautions
PRECAUTIONS
1. Before working on the fuel system, disconnect the
negative cable from the battery.
NOTE: Any diagnostic code retained by the ECU will be
cleared when the battery negative (-) terminal is removed.
Therefore, if necessary, read the diagnosis before remov-
ing the battery terminal.
2. Do not smoke or work on the fuel system near an open

flame.
3. Keep gasoline off rubber or leather parts.
INSPECTION PRECAUTIONS
MAINTENANCE PRECAUTIONS
1. CHECK CORRECT ENGINE TUNE-UP
(See page EM-5)
2. PRECAUTIONS WHEN CONNECTING GAUGE

Service Connector
/ Test Probe (a) Remove the cap of, and connect the test probe of a
tachometer to the service connector of the distribu-
tor.
(b) Use the battery as the power source for the timing
light, tachometer, etc.
EC1828
3. IN EVENT OF ENGINE MISFIRE, CATALYTIC CON-

VERTER MAY OVERHEAT. THEREFORE, PRECAU-
TIONS SHOULD BE TAKEN.
(a) Insure correct drive belt adjustment.
(b) Insure proper connection of battery terminals, etc.
(c) Handle high-tension cords carefully.
(d) After repair work, insure that the ignition coil ter-
minals and all other ignition system lines are re-con-
nected securely.
When cleaning the engine compartment, be especial-
ly careful to protect the electrical system from water.
4. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR

(a) Do not allow the oxygen sensor to drop or hit against
an object.
(b) Do not allow the sensor to come into contact with
water.
EFI SYSTEM - Inspection Precautions FI-5
IF VEHICLE IS EQUIPPED WITH MOBILE

RADIO SYSTEM (HAM, CB, ETC.)
The ECU has been designed so that it will not be affected
by outside interference.
However, if your vehicle is equipped with a CB radio
transceiver, etc. (even one with about 10 W output). it
may, at times, have an affect upon ECU operation,
especially if the antenna and feeder are installed nearby.
Therefore, observe the following precautions.
(a) Install the antenna as far as possible from the ECU.
The ECU is located inside the left Center Pillar so the
antenna should be installed on the rear side of the
vehicle.
(b) Keep the antenna feeder as far away as possible from
the ECU wires - at least 20 em (7.87 in.) - and,
especially, do not wind them together.
(c) Insure that the feeder and antenna are properly
adjusted.
(d) Do not equip your vehicle with a powerful mobile
radio system.
FI0687
INTAKE SYSTEM
1. Separation of the engine oil level gauge, oil filler cap, PCV
hose, etc. may cause the engine to run out of tune.
2. Disconnection, looseness or cracks in the parts of the air
intake system between the air flow meter and cylinder
head will allow air suction and cause the engine to run out
of tune.
FI0714
ELECTRONIC PARTS
1. Before removing EFI wiring connectors, terminals, etc.,
first disconnect power by either turning OFF the ignition
switch or disconnecting the battery terminals.
2. When installing a battery, be especially careful not to
incorrectly connect the positive (+) and negative (-)
cables.
3. Do not permit parts to receive a severe impact during
removal or installation. Handle all EFI parts carefully,
Fll066
especially the ECU.
4. Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can cause damage.
5. Do not open the ECU cover.
6. When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine com-
partment, prevent water from getting on the EFI parts and
wiring connectors.
7. Parts should be replaced as an assembly.
FI-6 EFI SYSTEM - Inspection Precautions
8. Take care when pulling out and inserting wiring connec-

Lock tors.
(a) Release the lock and pull out the connector.
NOTE: Grasp·the connector, not the wire.
FI0092 FI0093
(b) Fully insert the connector and insure that it is locked.
9. When inspecting a connector with a circuit tester.

(a) For water-proof type connectors, carefully take out
the water-proofing rubber.
FI0095 FI0096
(b) When checking continuity, amperage or voltage,

always insert tester probe into the connector from
the wiring side.
(c) Do not apply unnecessary force to the terminal.
(d) After checking, install the water-proofing rubber on
the connector securely.
FI0097 FI0098
10. Use SST for inspection or test of the injector, cold start
injector or its wiring connector.
SST 09842-30020 and 09842-30050
FI0239
EFI SYSTEM - Inspection Precautions FI-7
FUEL SYSTEM
~PIUg~
1. When disconnecting the connection of the high fuel
pressure line, a large amount of gasoline will come out so
observe the following procedure:
@
o
~ (a) Put a container under the connection.
b (b) Slowly loosen the connection.
4
b (c) Disconnect the connection.
~ FI0419 FI0421
(d) Plug the connection with a rubber plug.
New ---cjJi r
2. When connecting the flare nut or union bolt on the high
pressure pipe union, observe the following procedure:
[Union bolt type]
Gasket
(a) Always use a new gasket.
(b) First tighten the union bolt by hand.
(c) Then tighten the bolt to the specified torque.
GrNew
~;rGaSket
~
[Flare nut type]
(a) Apply a thin coat of oil to the flare and first tighten
the flare nut by hand.
(b) Using SST, tighten the nut to the specified torque.
SST 09631-22020
NOTE: Use a torque wrench with a fulcrum length of 30
cm (11.81 in.).
3. Take the following precautions when removing and install-

O~g 4:rr~ ing the injectors.
(a) Never reuse an O-ring.
~very Pipe,
,
/ \ (b) When placing an O-ring on the injector, take care not
Grommet Injector ~ to damage it in any way.
~. (c) Lubricate the O-ring with spindle oil or gasoline
~ I i Wrong before installing never use engine, gear or brake oil.
~'~ FI0420
4. Install the injector to the delivery pipe and intake manifold

O-Ring
as shown in the figure.
Grommet
Injector
Intake Manifold
FI1522
FI-8 EFI SYSTEM - Inspection Precautions
5. Check that there are no fuel leaks after performing main-

tenance on the fuel system.
(a) With engine stopped, turn the ignition switch ON.
"- (b) Short circuit the terminals of the fuel pump check
Fuel Pump Check
Connector connector with a service wire.
FI0686
(c) When the fuel return hose is pinched, the pressure

within the high pressure line will rise to about 3.1 -
3.2 kg/cm 2 (44 - 46 psi, 304 - 314 kPa), In this
state, check to see that there are no leaks from any
part of the fuel system.
CAUTION: Always pinch the hose. Avoid bending as
it may cause the hose to crack.
FI0685
EFI SYSTEM - Troubleshooting FI-9
TROUBLESHOOTING
TROUBLESHOOTING HINTS
1. Engine troubles are usually not caused by the EFI system.
When troubleshooting, first check the condition of the
following systems:
(a) Electronic source
• Battery
• Fusible links
• Fuses
(b) Body ground
(c) Fuel supply
• Fuel leakage
• Fuel filter
• Fuel pump
(d) Ignition system
• Spark plugs
• High-tension cords
• Distributor
• Ignition coil
• Igniter
(e) Air induction system
• Vacuum leaks
(f) Emission control system
• PCV system
• EGR system
(g) Others
• Ignition timing
• Idle speed
• etc.
2. The most frequent cause of problems is simply a bad con-
tact in wiring connectors. Always make sure that connec-
tions are secure.
When inspecting the connector, pay particular attention to
the following points:
(a) Check to see that the terminals are not bent.
(b) Check to see that the connector is pushed in com-
pletely and locked.
(c) Check to see that there is no signal change when the
connector is slightly tapped or wiggled.
3. Sufficiently troubleshoot for other causes before replac-

ing the ECU. The ECU is of high quality and expensive.
FI-10 EFI SYSTEM - Troubleshooting
Digital Type Analog Type 4. Use a volt/ohmmeter with high impedance (10 kO/V
minimum) for troubleshooting of an electrical circuit.
'" 71
V
D{~+@
""
~ 10 -@
FI0889
TROUBLESHOOTING PROCEDURES
SYMPTOM - DIFFICULT TO START OR NO START
(ENGINE WILL NOT CRANK OR CRANKS SLOWLY)
CHECK ELECTRONIC SOURCE BAD 1. Battery
(1) Connection
(2) Gravity - Drive belt - Charging system
(3) Voltage
2. Fusible link
~OK
CHECK STARTING SYSTEM BAD 1. Ignition switch
2. Neutral start switch (A/T)
3. Clutch start switch (M/T)
4. Starter relay (M/T)
5. Starter
6. Wiring/Connection
SYMPTOM - DIFFICULT TO START OR NO START (CRANKS OK)

CHECK DIAGNOSIS SYSTEI\I, Malfunction Diagnostic code(s) (See page FI-24)
Check for output of diagnostic code. code
(See page FI-24)
Normal Code
CHECK VACUUM LEAKS IN AIR BAD 1. Oil filler cap

INTAKE LINE 2. Oil dipstick
3. Hose connections
4. PCV hoses
5. EGR system - EGR valve stays open
OK
CHECK IGNITION SPARK BAD 1. High-tension cords

(See page IG-4) 2. Distributor
3. Ignition coil
4. Igniter
~ OK CONTINUED ON PAGE FI-11

! OK CONTINUED FROM PAGE FI-1 0
CHECK IGNITION TIMING NO Ignition system

1. Short terminals (T -E1) of check
engine connector.
2. Check ignition timing.
Standard: 12° BTDC @ idle
~ OK
CHECK FUEL SUPPLY TO INJECTOR BAD 1. Fuel line - Leakage - Deformation
1. Fuel in tank 2. Fuses
2. Fuel pressure in fuel line 3. Circuit opening relay (See page FI-66)
(1) Short terminals of fuel pump 4. Fuel pump (See page FI-41)
check connector. 5. Fuel filter
(2) Fuel pressure at fuel hose of fuel 6. Fuel pressure regulator (See page FI-49)
filter can be felt. (See page FI-41)
~ OK
CHECK FUEL PUMP SWITCH IN AIR BAD Air flow meter (See page FI-57)
FLOW METER
Check continuity between terminals FC
and E1 while measuring plate of air flow
meter is open.
CHECK SPARK PLUGS NO 1. Spark plugs

Maximum: 1.3 mm (0.051 in.) 2. Compression pressure
NOTE: Check compression pressure if Minimum: 9.0 kg/cm 2
necessary. (128 psi, 883 kPa)
at 250 rpm
NO 1. Injector(s) - Short circuited

2. Injector wiring between solenoid resistor
All ~ and ECU short circuited
Plugs
( 3. Cold start injector - Leakage
WET
(See page FI-46)
.4. Cold start injector time switch
(See page FI-68)
5. Injector - Leakage (See page FI-54)
~ OK
CHECK AIR VALVE NO 1. Air valve (See page FI-59)
1. Disconnect air hose from air valve. 2. Water hoses
2. Check that the air valve opens when cold. 3. Air hoses
Air valve temp.: Below 20°C (68°F)
~ OK
CHECK EFI ELECTRONIC CIRCUIT NO 1. Wiring connection
Use VOLT/OHMMETER (See page FI-26) 2. Power to ECU
(1) Fusible links
(2) Fuses
(3) EFI main relay (See page FI-65)
3. Air flow meter (See page FI-57)
4. Water temp. sensor (See page FI-69)
5. Injection signal circuit
(1) Injector wiring
(2) Solenoid resistor (See page FI-67)
(3) ECU (See page FI- 72)
SYMPTOM - ENGINE OFTEN STALLS

CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic code(s) (See page FI-24)
Check for output of diagnostic code. code(s)
(See page FI-24)
Normal code

3. Hose connections
4. PCV hoses
OK
CHECK FUEL SUPPLY TO INJECTOR BAD 1. Fuel line - Leakage - Deformation

1. Fuel in tank 2. Fuses
2. Fuel pressure in fuel line 3. Circuit opening relay (See page FI-66)
(1) Short terminals of fuel pump 4. Fuel pump (See page FI-41)
check connector. 5. Fuel filter
(2) Feel pressure at fuel hose of 6. Fuel pressure regulator (See page FI-49)
fuel filter. (See page FI-41)
OK
I
CHECK AIR FILTER ELEMENT BAD IElement - Clean or replace
OK
CHECK IDLE SPEED BAD Idle speed - Adjust

1. Disconnect ISC VSV connector.
2. Check idle speed.
Standard: MIT 700 rpm
AIT 750rpm
OK
CHECK IGNITION TIMING BAD Ignition system

1. Short terminals (T - E1) of check
engine connector.
OK
CHECK SPARK PLUGS NO 1. Spark plugs

necessary. (1 28 psi, 883 kPa)
at 250 rpm
3. Injector - Leakage (See page FI-54)
1OK CONTINUED ON PAGE FI-13

I OK CONTINUED FROM PAGE FI-12
CHECK COLD START INJECTOR BAD 1. Cold start injector (See page FI-46)
(See page FI-46) 2. Cold start injector time switch
(See page FI-68)
0K
1
CHECK AIR VALVE (See page FI-59) BAD 1. Air valve (See page FI-59)
1. Disconnect air hose from air valve. 2. Water hoses
2. Check that the air valve opens when cold. 3. Air hoses
Air valve temp.: Below 20°C (68°F)
RECHECK FUEL PRESSURE BAD 1. Fuel pump (See page FI-41)

(See page FI-41 ) 2. Fuel filter
3. Fuel pressure regulator (See page FI-49)
CHECK INJECTORS BAD Injection condition (See page FI-51)

(See page FI-51)
j OK
CHECK EFI ELECTRONIC CIRCUIT BAD 1. Wiring connection
Use VOLT/OHMMETER (See page FI-26) 2. Power to ECU
(1) Fusible links
(2) Fuses
(4) Circuit opening relay (See page FI-66)
(1) Injector wiring
SYMPTOM - ENGINE SOMETIMES STALLS

(See page FI-24)
1 Normal code
CHECK AIR FLOW METER BAD Air flow meter (See page FI-57)
(See page FI-57)
0K
1
CHECK WIRING CONNECTORS BAD 1. Connector
AND RELAYS 2. EFI main relay (See page FI-65)
Check that there is a signal change when 3. Circuit opening relay (See page FI-66)
the connector or relay is slightly tapped
or wiggled.
SYMPTOM - ROUGH IDLING AND/OR MISSING

(See page FI-24)
Normal code

3. Hose connections
4. PCV hoses
OK
I
CHECK AIR FILTER ELEMENT BAD Element - Clean or replace
OK

STD: MIT 700 rpm
AIT 750 rpm
OK

engine connector.
STD: 12° BTDC @ idle
OK CONTINUED ON PAGE FI-1 5

OK CONTINUED FROM PAGE FI-14
CHECK SPARK PLUGS 1. Spark plugs

BAD
Maximum: 1.3 mm (0.051 in,) 2. Compression pressure
at 250 rpm
OK
(See page FI-46) 2. Cold start injector time switch.
(See page FI-68)
OK
CHECK FUEL PRESSURE BAD 1. Fuel pump (See page FI-41)

OK

(See page FI-51)
OK

Use VOLT/OHMMETER 2. Power to ECU
(See page FI-26) (1) Fusible links
(2) Fuses
5. Air temp. sensor (See page FI-57)
6. Throttle position sensor (See page FI-63)
(1) Injector wiring
8. Oxygen sensor (See page FI- 70)
SYMPTOM - HIGH ENGINE IDLE SPEED (NO DROP)

CHECK ACCELERATOR LINKAGE BAD "I Linkage - Stuck
I
OK
CHECK AIR VALVE BAD Air valve - Always open

(See page FI-58)
I
OK
CHECK AIR CONDITIONER BAD Air valve for air conditioner - Leakage
IDLE-UP CIRCUIT VSV for AIC - Leakage
Water temperature switch - Short
OK

(See page FI-24)
Normal code
CHECK FUEL PRESSURE BAD Fuel pressure regulator - High pressure

(See page FI-41 )
OK
CHECK COLD START INJECTOR BAD Cold start injector - Leakage

(See page FI-46) (See page FI-46)
OK
CHECK INJECTORS (See page FI-51) BAD Injectors - Leakage (See page FI-51)
OK

Use VOLTIOHMMETER 2. Power to ECU
(2) Fuses
(1) Injector wiring
SYMPTOM - ENGINE BACKFIRES-Lean Fuel Mixture

(See page FI-24)
Normal code

3. Hose connections
4. PCV hoses
OK

AIT 750 rpm
OK

engine connector.
OK
(See page FI-68)
OK

OK
CHECK INJECTORS BAD Injectors - Clogged

(See page FI-51 )
I OK CONTINUED ON PAGE FI-18

CONTINUED FROM PAGE FI-17

(2) Fuses
(1) Injection wiring
(3) ECU (See page FI-72)
(4) Fuel cut RPM (See page FI- 74)
8. Oxygen sensor (See page FI- 70)
SYMPTOM - MUFFLER EXPLOSION (AFTER FIRE)-

Rich Fuel Mixture-Misfire
CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic codes (See page FI-24)
(See page FI-24)
Normal code

1. Disconnect the ISC VSV connector.
AIT 750 rpm
OK

engine connector.
OK
(See page FI-68)
OK
CHECK INJECTORS BAD Injectors - Leakage (See page FI-51)

(See page FI-51)
I OK CONTINUED ON PAGE FI-19

CHECK SPARK PLUGS 1. Spark plug

NO
at 250 rpm
OK
CHECK EFI ELECTRONIC CIRCUIT BAD 1. Throttle position sensor (See page FI-63)
Use VOLT/OHMMETER 2. Injection signal circuit
(See page FI-26) (1) Fuel cut RPM (See page FI-74)
(2) Injector wiring
3. Oxygen sensor (See page FI-70)
SYMPTOM - ENGINE HESITATES AND/OR POOR ACCELERATION

CHECK CLUTCH, BRAKE BAD 1. Clutch - Slips
2. Brakes - Drag
OK
CHECK FOR VACUUM LEAKS IN BAD 1. Oil filler cap

AIR INTAKE LINE 2. Oil dipstick
3. Hose connections
4. PCV hoses
OK
I
CHECK AIR FILTER ELEMENT BAD Element - Clean or replace
OK
CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic codes (See page FI-24)

(See page FI-24)
OK
CHECK IGNITION SPARK BAD 1. High-tension cords

(See page IG-4) 2. Distributor
3. Ignition coil
4. Igniter
IOK CONTINUED ON PAGE FI-20


engine connector.
Standard: 12° BTDC @ idling
OK

OK

(See page FI-51 )
OK
CHECK SPARK PLUGS BAD 1. Spark pi ugs

at 250 rpm
OK
(2) Fuses
(1) Injector wiring
Efl SYSTEM - Diagnosis System fl-21
DIAGNOSIS SYSTEM
Description
By analyzing various signals as shown in the later table (See
page FI-24) the ECU detects system malfunctions which are
related to the various operating parameter sensors or to the
actuator. The ECU stores the failure code associated with the
detected failure until the diagnostic system is cleared by
removing the EFI fuse with the ignition switch OFF.
A "CHECK" engine warning light on the instrument panel
informs the driver that a malfunction has been detected.
The light goes out automatically when the malfunction has
been cleared.
IICHECKII ENGINE WARNING LIGHT CHECK

1. The "CHECK" engine warning light will come on when the
CHECK ignition switch is placed at ON and the engine is not run-
ning.
[§] 2. When the engine is started, the "CHECK" engine warning

light should go out.
If the light remains on, the diagnosis system has detected
a malfunction or abnormality in the system.
FI0708
OUTPUT OF DIAGNOSTIC CODES

To obtain an output of diagnostic codes, proceed as follows:
1. Initial conditions:
(a) Battery voltage above 11 volts
(b) Throttle valve fUlly closed (throttle position sensor
IDL points closed)
(c) Accessory switches OFF
(d) Engine at normal operating temperature
(e) AIC switch OFF
2. Turn the ignition switch to ON. Do not start the engine.
3. Short terminals (T - E1) of the check engine connector
~r with a service wire.
Service Wire
FI0684
FI-22 EFI SYSTEM - Diagnosis System
4. Read the diagnostic code as indicated by the number of

flashes of the "CHECK" engine warning light.
FI0707
Diagnostic code (See page FI-24)

No Malfunction
(a) Normal System Operation (code No.1) (no malfunc-
0.5 Seconds tion)
The light will blink once every 4.5 seconds.
4.5 Seconds
FI0117
(b) Malfunction Code Indication

Malfunction
The light will blink a number of times equal to the
malfunction code indication with a 2.5 second inter-
Code No.2 Code NO.4 Code NO.2 val between each indication.
0.5 The diagnostic code series will be repeated as long as the
check engine connector terminals (T - E1) are shorted.
NOTE: In event of a number of trouble codes, indication
will begin from the smaller value and continue in order to
2.5 4.5 the larger.
(Seconds)
FI0483
5. After the diagnosis check, remove the service wire and

install the cap to the check engine connector.
EFI SYSTEM - Diagnosis System FI-23
CANCELLING DIAGNOSTIC CODE

1. After repair of the trouble area, the diagnostic code
retained in memory by the ECU must be cancelled out by
removing the Fuse EFI (15A) for 10 seconds or more,
depending on ambient temperature (the lower the tem-
EFI Fuse
perature, the longer the fuse must be left out) with the
15A
ignition switch off.
FI1537
NOTE:
• Cancellation can also be done by removing the battery
negative (-) terminal, but in this case other memory
systems (radio ETR, clock, etc.) will also be cancelled
out.
• If the diagnostic code is not cancelled out, it will be
retained by the ECU and appear along with a new code
in the event of future trouble.
• If it is necessary to work on engine components requir-
ing removal of the battery terminal, a check must first
be made to see if a diagnostic code has been recorded.
2. After cancellation road test the vehicle, to check that the
"normal" code (No.1) appears on the "CHECK" engine
warning light.
If the same diagnostic code appears, the trouble area has
not been repaired thoroughly.
FI-24 EFI SYSTEM - Diagnosis System
DIAGNOSTIC CODeS
Number of
Code See
CHECK ENGINE System Diagnosis Trouble area
No. Page
blinks
This appears when
ON ON ON ON ON none of the other
1
~ Normal -- -
codes (2 thru 1 1) are
FI0840
identified.
• VC circuit open or VS-E2
1. Air flow meter circuit
Air flow meter short circuited.
2 Jl.JLJULJLLJL signal • E2 circuit open or VC-VS
2. Air flow meter FI-36
3. ECU
FI0841
short circuited.
1. Ignition circuit
No signal from igniter four (+8, IGF, IGT)
3 Ignition signal FI-32
JUlLJlJULJJUL times in succession. 2. Igniter
FI0842
3. ECU
1. Water temp. sensor
Water temp. Open or short circuit circuit
FI-38
4
JUUlJLJlJ1JLLJU sensor signal in water temp. sensor signal. 2. Water temp. sensor
FI0843
3. ECU
1. Oxygen sensor circuit

Oxygen sensor Open circuit in oxygen sensor
-
5 i
!
J1JU1JULJUUUUL signal signal (only lean indication).
2. Oxygen sensor
3. ECU
FI0844
1. Distributor circuit
No Ne signal to ECU while
2. Distributor
6 JUUU1JULJlJUUUU RPM signal
cranking, or Ne value over
1,500 rpm in spite of no
3. Igniter FI-32
4. Starter signal circuit
I Ne signal to ECU.
FI0845
5. ECU
1. Throttle position sensor
Throttle position Open or short circuit in throttle circuit
7 FI-31
JUUUU1JlLJUUUUl sensor signal position sensor signal. 2. Throttle position sensor
FI0846
3. ECU
Intake air temp. Open or short circuit in intake 1. Air temp. sensor circuit
8 FI-37
llilJ1J1JUUl~ sensor signal air temperature sensor. 2. ECU
I
i FI0847
!
No signal for over 8 seconds 1. Vehicle speed sensor
I Vehicle speed when vehicle is travelling circuit
9 -
I J1J1JLJlWJlJLJ1 sensor signal o km/h and engine running 2. Vehicle sensor
FI0848
between 2,800 - 4,.500 rpm 3. ECU
1. Starter relay circuit
No ST A signal to ECU
2. IG switch circuit (starter)
10 Starter signal when vehicle stopped FI-33
JUUUUUUUUULJUl and engine running over.
3. IG Switch
FI0849
4. ECU
1. Air conditioner switch
Air conditioner switch ON, idle
11 J1JUlJlJUUUUlJl Switch signal
switch OFF.
circuit
-
4. Neutral start switch
5. ECU
FI0850
-
EFI SYSTEM - Diagnosis System FI-25
INSPECTION OF DIAGNOSIS CIRCUIT
Fuse ECU
EFI
15A
Fusible BATT
EFI Main Relay
Link Fuse
EFI IGN 2 4
7.5A +B
30A IG2
IG1 3
+ B1
Fuse "CH ECK" engine
Fusible GAUGE Warning Light
Link 7.5A
2.0L W
Battery ~----..---~ ;1
Check
Engine
Connector
FI1503
Yes
1. Does "CHECK" engine warning light come
on when ignition switch is at ON?
System Normal.
I
~ No
Does "CHECK" engine warning light come Check wiring between
Yes OK Try another
on when ECU terminal W is grounded to computer terminal E1
ECU.
the body? and body ground.
! No ! BAD
Check bulb, fuse and wiring between
ECU and ignition switch.
Repair or replace.
I
~ BAD
Repair or replace. I
2. Does "CHECK" engine warning light go
off when the engine is started?
Yes
System Normal. I
~ No
Check wiring between ECU and BAD
Repair.
"CHECK" engine warning light.
I
i OK
Is there diagnosis code output when
No
check engine connector terminals Try another ECU.
(T -E1) are short circuited?
~ Yes
Does "CHECK" engine warning light go No
off after repair according to malfunction Further repair required.
code?
~ Yes
System OK
I
I Cancel out Diagnostic code. I
FI-26 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter
TROUBLESHOOTING WITH
VOLT/OHMMETER
NOTE: The following troubleshooting pro- The following troubleshooting procedures are
cedures are designed for inspection of each separ- based on the supposition that the trouble lies in
ate system, and therefore the actual procedure either a short or open circuit in a component out-
may vary somewhat. However, troubleshooting side the computer or a short circuit within the
should be performed referring to the inspection computer.
methods described in this manual. If engine trouble occurs even though proper
Before beginning inspection, it is best to first make operating voltage is detected in the computer con-
a simple check of the fuses, fusible links and the nector, then that the ECU is faulty and should be
condition of the connectors. replaced.
LOCATION OF FUSES AND FUSIBLE LINKS
Fusible Link
~-~---~,
~~
..
'- li
. ~
Battery
Fuse and Relay
FI0682
EFI SYSTEM - Troubleshooting with Volt/Ohmmeter FI-27
PREPARATION
(a) Remove the center pillar garnish.
(b) Remove the seat belt retractor.
FI0683
EFI SYSTEM CHECK PROCEDURE

NOTE:
• Perform all voltage measurements with the connectors
connected .
• Verify that the battery voltage is 11 V or above when
the ignition switch is at ON.
Using a voltmeter with high impedance (1 OkO /V
minimum), measure the voltage at each terminal of the
wiring connector.
Terminals of ECU
Symbol Terminal Name Symbol Terminal Name
E01 ENGINE GROUND AIC AIC MAGNET CLUTCH
E02 ENGINE GROUND IGF IGNITER
No. 10 INJECTOR E2 SENSOR GROUND
No. 20 INJECTOR OX OXYGEN SENSOR
STA STARTER SWITCH PSW THROTTLE POSITION SENSOR
IGT IGNITER NE ENGINE REVOLUTION SENSOR
VF EFI CHECK CONNECTOR THW WATER TEMP. SENSOR
E1 ENGINE GROUND VC AIR FLOW METER
FPU EFI VSV E21 SENSOR GROUND
V-ISC ISC VSV VS AIR FLOW METER

ACV AIC VSV THA AIR TEMP. SENSOR
W CHECK ENGINE WARNING LIGHT SPD SPEED SENSOR
TSW WATER TEMP. SWITCH BATT BATTERY
T CHECK ENGINE CONNECTOR +B1 MAIN RELAY
IDL THROTTLE POSITION SENSOR +B MAIN RELAY
ECU Terminals
~~~
E01 No
STA VF V- W T IDL IGF NE VC VS THA BAn + B1
10 ISC
No
E02 20 IGT E1 FPU ACV TSW Ale E2 ox PSW THW E21 SPD +8
FI0605
Voltage at ECU Wiring Connectors

[USA]
No. Terminals STD voltage Condition See page

--e-------
+B
1 - E1 10 - 14 Ignition switch ON FI-29
+B1
2 BATT - E1 10 - 14 -- FI-30
IDL - E1 8 - 14 Throttle valve open

3 ~.
Ignition switch ON FI-31
PSW - E1 8 - 14 Throttle valve fully closed
4 IGT - E1 0.7 - 1.0 Idling FI-32
5 STA - E1 6 - 12 Cranking FI-33

----
No. 10 E01
6 - 9 - 14 Ignition switch ON FI-34
No. 20 E02
No trouble ("CHECK" engine warning light off)

7 W - E1 8 - 14 FI-35
and engine running
VC - E2 6 - 10 --
0.5 - 2.5 Ignition switch ON Measuring plate fully closed

8 FI-36
VS - E2 5 - 10 Measuring plate fully open
2 - 8
9 THA - E2 1 - 3 Ignition switch ON Intake air temperature 20°C (68°F) FI-37
10 THW - E2 0.5 - 2.5 Ignition switch ON Coolant temperature 80°C (176°F) FI-38
11 AIC - E1 8 - 14 Ignition switch ON AIC ON FI-39
ECU Terminals
~ ~ ~
No. v- W T IDL IGF NE VC VS THA BATT + B1
E01 10 STA VF ISC
E02
No.
IGT E1 FPU ACV TSW A/C E2 OX PSW THW E2l SPD +B
20
FI0605
No. Terminals Trouble Condition STD Voltage
+8
+81 - E1 No voltage Ignition S/W ON 19-14V
I----'~~~~~~.I.__~ ~ _ _~ - - - - - ' - - ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ L - - ~ ~ ~ ~ ~ ~ ~ ~ - I
EFI Main Relay

Fuse EFI 15A
~......---\----...----o +B
2 4
Fusible Link
EFI 30A
""------() + B1
Fuse IGN 7.5A
Battery
E1
F11504
CD ICD No voltage between ECU terminals + B or +B 1 and E1.

(IG S/W ON)
I® Check that there is voltage between ECU terminal +B or +B 1.

2 and body ground. (IG S/W ON)
NO lOK
® Check wiring between ECU terminal E1 and body
ground.
~ OK 1BAD
Try another ECU. Repair or replace.
Voltmeter
ICheck fuses, fusible links and

ignition switch.
BAD
Repair or replace.
OK
FI1246
ICheck EFI main relay. BAD Replace.
ECU
.--------------,~
~
0K
Ohmmeter L-;~5.,~~~~ I 1
Check wiring between EFI main and
relay and battery.
BAD
Repair or replace.
FI0552
2 BATT - E1 No voltage -- 10-14V
ECU
Fuse EFI 15A

r..
BATT
Fusible Link(
EFI 30A ~
Fusible Link(?
2.0L
Battery
-
_L.-
~
~
-L
-,..
-- I- E1
---
-
1
-
FI1505
CD CD No voltage between ECU terminals BATT and E1.
® Check that there is voltage between ECU terminal BATT and

body ground.
NO
10K
!@ Check wiring between ECU terminal E1 and body
ground.
10K I BAD
Voltmeter I Try another ECU.

I I Repair or replace.
Check fuse and fusible links. I BAD I Replace.

I I
OK
Check wiring between ECU I BAD I

terminal and battery.
IDL - E1 Throttle valve open 8 - 14 V

3 No voltage IG S/W
ON 8 - 14 V
PSW - E1 Throttle valve fully closed
ECU
.n IDL
)+8 (+81)
(~
:El IDL
PSW ,~
PSW
LJ
Throttle Position Sensor
E1
FI1259
CD No voltage between ECU terminals IDL or PSW and El.

(IG S/W ON)
I
® Check that there is voltage between ECU terminal +B or +B 1
and body ground. (IG S/W ON)
NO ~OK
I Check wiring between ECU terminal E 1 and body
ground.
BAD
Repair or replace.
Voltmeter
Refer to No.1. BAD Repair or replace.

(See page FI-29)
OK
® Check throttle position BAD

FI1246 sensor
Ohmmeter ®
BAD ~OK
(See page FI-6l) Replace throttle posi-
Check wiring between ECU and
tion sensor and throt-
throttle position sensor.
tie body assembly.
!OK
El---1~I=b.J.... __ ( Try another ECU. I

IDL
FI0711
4 IGT - E1 No voltage Idling 0.7 - 1.0 V
Ignition Switch Igniter ECU

AM2r
I '"' vTllG2 +B
~) Fusible Link IGF NE IGT

( AM230A
~) Fusible Link
~ 2.0L
-...-
~
~
Battery
IGT
NE
--
-.<1,,"""- IGF
r
I...- I--
E1
_I..-
- --
FI1506
CD CD No voltage between ECU terminals IGT and E1.

(Idling)
cv Check that there is voltage between ECU terminal IGT and

2 body ground. (Idling)
NO OK
FI0191
® Check wiring between ECU
terminal E1 and body ground.
OK
Try another ECU.
Check fusible link and ignition

I---~ Repair or replace.
switch.
OK
FI1143
I-------.l Repair or replace.
ECU ®
Ohmmeter L:=~~~~~:c1 1-------' Repair or replace.
OK
Check igniter. (See page IG- 7) I-=:.:....:.:~ Repair or replace.
FI0552
5 STA - E1 No voltage Cranking 6 - 12 V

ECU
Neutral Start
Ignition Switch Switch (A/T)
AM1 ST1
~I---~---f-o ---....,::).-4.-......------....--------v STA
Fusible Link
AM1 80A Starter
Starter Relay
Fusible Link
(MIT)
1.25B 2 4
Fusible Link
2.0L STA (Terminal 50)
To Circuit Opening Relay

Battery
,----Q E1
FI1507
CD CD There is no voltage between ECU terminals ST A and E1.

(lG S/W START)
Check starter OK Check wiring between ECU terminal STA

~
operation. and ignition switch terminal ST 1.
BAD OK BAD
t
I Repair or replace.
I® Check wiring between ECU terminal E1 and body

ground.
OK ~ BAD
I Try another ECU. Repair or replace.
Check fusible link, battery, wiring,

BAD
ignition switch clutch start switch, Repair or replace.
starter relay and neutral start switch.
OK
Voltmeter ®
® Check that there is voltage at STA (50)terminal of starter.
(lG S/W START) STD voltage: 6 - 12 V
OK NO
Check wiring between ignition switch
Check starter. terminal ST 1 and starter terminal STA
(50).
FI0336
No.10 - E01
6 No voltage IG S/W ON 9 - 14 V
No.20 - E02
ECU
+B Solenoid Resistor
Injector
~-------.-uNo. 20
L..-----------~-uNo.1 0
Battery E
E
FI1509
CD CD No voltage between ECU terminal No.1 0 and/or No. 20

and E01 and/or E02. (lG S/W ON)
@ Check that there is specified voltage between solenoid resistor

terminal +B and body ground. STD voltage: 9-14 V
OK ~ NO
Check fusible link, wiring and BAD Repair or

FI0144
ignition switch. replace.
Check that there is specified voltage between resistor

@ terminal (No.10 or No.20) and body ground.
STD voltage: 9-14 V
OK ~ NO
® Check resistance of magnetic coil in Replace

each injector. STD resistance: 1.5-3.011
I resistor.
OK ~BAD
Ohmmeter
I Replace injector.
Check wiring between ECU BAD I Repair or replace

and resistor.
I wiring.
OK
Try another ECU.
FI0680
No trouble ("CHECK" engine warning light

7 W - E1 No voltage 8 - 14 V
off) and Engine running
ECU
FUSE
W
GAUGE 7.5A "CH ECK" engine
Warning Light
Combination Meter
..---- E1
~
-
FI072a
CD CD No voltage between ECU terminals Wand E1.

(Idling)
cv Check that there is voltage between ECU terminal Wand

body ground.
NO j OK
I@ Check wiring between ECU terminal E1 and body
ground.
~ OK 1BAD
Voltmeter I Try another ECU. Repair or replace.
Check GAUGE fuse 17.5AI and "CHECK"

engine warning light.
1
OK ~ BAD
FI1408
I
ECU ® ~ Fuse blows again
BAD
LlWl~ID~~mlJ
Check wiring between ECU
Ohmmeter Repair or replace.
terminal Wand fuse.
n+
FI0552
No. Terminals Trouble Condition STO Voltage
VC - E2 - 6 - 10 V
VS - E2 IG S/W ON Measuring plate fully closed 0.5 - 2.5 V

8 No voltage
VS - E2 Measuring plate fully open 5 - 10 V
VS - E2 Idling - 2-8V
ECU
+B
C ~
....,
VB
~,.L.
~
;: VC + B1
<~
~
,.. VS VC
1
~
~
...., E2 VS
E2
Air Flow Meter
r -
E1
FI1271
CD No specified voltage at ECU terminals VC and VS and E2.

(IG S/W ON)
cv Check that there is voltage between ECU terminals +B or +B 1

OK ~ NO
Refer to No. 1
(See page FI-29)
Check wiring between ECU terminal E1 or E2

and body ground.
OK I BAD
® Check air flow meter. I Replace or repair.

I
BAD 0K
FI1246 1
Replace air flow Check wiring between ECU and air
meter. flow meter.
Ohmmeter
Air Flow Meter ®
1
0K I BAD
Try another ECU

I I Replace or repair.
(See page FI-57)

Flll03
9 THA - E2 No voltage IG S/W ON 1-3V
ECU
+8
(+ 81)
THA
r---o-t---------------------------6THA
E2
~~I_---------------------_6 E2
Air Temp. Sensor (Air Flow Meter)
E1
FI1256
CD CD No voltage between ECU terminals THA and E2.

UG S/W ON)
I
cv Check that there is voltage between ECU terminal +B or +B 1
and body ground. UG S/W ON)
OK ~NO
Refer to No. 1
(See page FI-29)
Voltmeter Check wiring between ECU terminal E1 and body

ground.
OK ~BAD
v ~
® Check air temp. sensor. I I Replace or repair.
FI1246
BAD
Replace air
iOK
Check wiring between ECU and air

flow meter. temp. sensor.
~OK ~BAD
Air Flow Meter
Ohmmeter
Try another ECU.

II Repair or replace.
(See page FI-57)

FI0330
10 THW - E2 No voltage IG S/W ON I Coolant temp. 80°C (176°F) 0.5 - 2.5 V
ECU
(+8
Water Temp. Sensor (+81)
,...-__r- THW
.----o-----+---------.---~
THW
I aa A
.... yv""
E2
E2
~
.------OE1
FI0487
CD CD No voltage between ECU terminals THW and E2.

(IG S/W ON)
cv Check that there is voltage between ECU terminal +8 or +81

OK ~NO
Refer to No.1.
, (See page FI-29)
-
Check wiring between ECU terminals E1 and body

ground.
OK ~8AD
® Check water temp. sensor. I I Repair or replace.
~8AD OK
Water Temp. Sensor

/
Replace water
temp. sensor.
Check wiring between ECU and
water temp. sensor.
!8AD
I
!OK
I Try another ECU.

I
"-------' (See page FI-69)

11 A/C - E1 No voltage Air conditioning ON 8 - 14 V
ECU
Ale
Amplifier-------.-----------------O A I C
A I C Compressor
1..------{) E1
FI0922
..
CD CD No voltage between ECU terminals A/C and E1.

(Ale ON)
I
Voltmeter @ Check that there is voltage between ECU terminal A/C and
body ground.
NO ~ OK
/
Check wiring between ECU terminal E1 and
FI1265
® body ground.
~ OK ~BAD
Voltmeter
Try another ECU.
V ~* ..J
Check that compressor is running. I OK Check wiring between
ECU terminal A/C
BAD and amplifier.
~BAD
FI1248
Repair or replace.
ECU ® Check that there is voltage between BAD Repair or replace.

amplifier terminal and body ground.
OK
D Check wiring between amplifier and BAD Repair or replace.
n: ECU or compressor.
FI0552
FI-40 EFI SYSTEM - Fuel System
FUEL SYSTEM
Fuel Pump
OUTLET
t
Check Valve
Bearing
Relief Valve
Armature
Casing ---I-
Mag net - - - - - - - i - +
Impeiler - ~ T-
Impeller
Bearing
t
INLET
Ignition Switch
AM2 IG2 Circuit Opening
o-t------, Relay Fuel Pump
AM1 IG1 Fuse
EFI FP
15A
2
EFI AM1 EFI Fuel Pump Switch
30A 80A Main FC (Air Flow Meter)
Relay
4
Fusible 1.258
Link
Starter Neutral
Start Fuel Pump
Relay
(MIT)
Switch Service
(A/T) Connector
Clutch
Start
Switch
FI0530 FI1479
FI1508
EFI SYSTEM - Fuel System FI-41
ON-VEHICLE INSPECTION
1. INSPECT FUEL PUMP OPERATION
(a) Turn the ignition switch ON.
NOTE: Do not start the engine.
(b) Short the terminals of the fuel pump check connec-
tor with a service wire.
(c) Check that there is pressure in the hose.

NOTE: At this time, you will hear fuel return noise.
(d) Remove the service wire.
(e) Turn the ignition switch OFF.
If there is no pressure, check the following parts:
• Fusible link
• Fuse (EFI 15A, IGN 7.5A)
• EFI main relay
FI0678
• Circuit opening relay
• Fuel pump
• Wiring connections
2. INSPECT FUEL PRESSURE

(a) Check the battery voltage above 12 volts.
(b) Disconnect the cable from the negative (-) terminal
of the battery.
(c) Disconnect the wiring connector from the cold start
injector.
(d) Put a suitable container or shop towel under the cold
start injector pipe.
(e) Disconnect the cold start injector pipe.
NOTE: Slowly loosen the union bolt.
(f) Install a gasket, SST, another gasket and union bolt
to the delivery pipe as shown in the figure.
SST 09268-45011
(g) Wipe off any splattered gasoline.
(h) Reconnect the battery cable.
(j) Short the terminals of the fuel pump check connec-

/
Fuel Pump Check"f ~-- (j) Turn on the ignition switch.
Connector .6; >\~
___ Cj
(k) Measure the fuel pressure
Fuel pressure: 2.3 - 2.7 kg/cm 2
(33 - 38 psi, 226 - 265 kPa)
If high, replace the pressure regulator.
Service Wire If low, check the following parts:
//
/
--.---/~
FI0686 • Fuel hoses and connection
• Fuel pump
• Fuel filter
• Pressure regulator
(I) Remove the service wire.
(m) Start the engine.
(n) Disconnect the vacuum sensing hose from the

SST pressure regulator and pinch it off.
(0) Measure the fuel pressure at idling.
(33 - 38 psi, 226 - 265 kPa)
(p) Reconnect the vacuum sensing hose to the pressure

SST regulator.
(q) Measure the fuel pressure at idling.
(27 - 31 psi, 186 - 216 kPa)
If no pressure, check the vacuum sensing hose and
pressure regulator.
(r) Stop the engine. Check that the fuel pressure
remains above 1.5 kg/cm 2 (21 psi, 147 kPa) for 5
L....- F_106.;...7.....
7 minutes after the engine is turned off.
If not within specification, check the fuel pump,
pressure regulator and! or injectors.
(s) After checking fuel pressure, disconnect the battery
ground cable and carefully remove the SST to pre-
vent gasoline from splashing.
(t) Using new gaskets, reconnect the cold start injector
pipe to the delivery pipe.
(u) Connect the wiring connector to the cold start injec-
tor.
(v) Check for fuel leakage. (See step 5 on page FI-8)
3. [wi A/C]
INSPECT HIGH-TEMPERATURE LINE PRESSURE
(a) Ground the idle-up temperature switch terminal.
Idle-up Temp.
Switch FI0676
(b) Start the engine.

(c) Measure the fuel pressure.
(33 - 38 psi, 226 - 265 kPa)
If pressure is low, check the following parts:
• ECU
• EFI VSV
• Wiring
(d) Measure the fuel pressure at idle two minutes later.

SST SST Fuel pressure: 1.9 - 2.2 kg/cm 2
o 0
(27 - 31 psi, 186 - 216 kPa)
~'APProx
2.3 -- 2.7 kg/em' ~ 2.0 kg/em'
After Two Minutes FI0675
(e) Stop the engine.

If the pressure drops quickly, check the fuel pump,
pressure regulator and/or injectors.
(f) After checking fuel pressure, disconnect the battery
ground cable and carefully remove the SST to pre-
vent gasoline from splashing.
(g) Using new gaskets, reconnect the cold start injector
pipe to the delivery pipe.
(h) Reconnect the wiring connector to the cold start
injector.
(i) Check for fuel leakage. (See step 5 on page FI-8)
REMOVAL OF FUEL PUMP
'~~I---------Fuel Hose
-_ .. ~
Fuel Pump Bracket-------\.\

/1\77---_.--..<
• Gasket - - - - - - - - { . " " ' -
0
~
~ ~
fl
II'
I
' t:r---J
- - - - - - F u e l Pump
_ _ _ ~~~.. • Clip
Fuel Pump Filter ~ "
'--= ~.--------RubberCushion
• Non-reusable part FI0738
1. DRAIN FUEL FROM FUEL TANK

WARNING: Avoid smoking and open flame when
working on the fuel pump.
2. REMOVE FUEL TANK
3. REMOVE FUEL PUMP BRACKET FROM FUEL TANK

(a) Remove the seven bolts.
(b) Pull out the fuel pump bracket.
4. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET

(a) Remove the two nuts, and disconnect the wires from
the fuel pump.
(b) Pull aft the bracket from the lower side of the fuel
pump.
(c) Remove the fuel pump from the fuel hose.
5. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
\J~ (a)
(b)
Remove the rubber cushion.
Remove the clip and pull out the filter.
Ou
FI0652
INSTALLATION OF FUEL PUMP

(See page FI-44)
1. INSTALL FUEL PUMP FILTER TO FUEL PUMP
2. INSTALL FUEL PUMP TO FUEL PUMP BRACKET

(a) Insert the outlet port of the fuel pump into the fuel
II i
hose.
Ij ~~,;,
1
. ._\ (b) Install the rubber cushion to the lower side of the fuel
, -~
FI0673
pump.
(c) Push the lower side of the fuel pump, together with
the rubber cushion into the fuel pump bracket.
3. INSTALL FUEL PUMP BRACKET

(a) Place the bracket with a new gasket on the fuel tank.
(b) Install and tighten the seven bolts.
FI0674
4. INSTALL FUEL TANK

Cold Start Injector
Terminal
Solenoid Coil
Ignition
Switch Cold Start
Cold Start Injector Time
ST1 Injector Switch
AM1
Injection
~~-~
~ L.-....::::::::~====~~
...
Fuel
Spring
Solenoid Coil Point
FI0495 FI0496
INSPECT RESISTANCE OF COLD START INJECTOR
(a) Disconnect the cold start injector connector.
(b) Using an ohmmeter, measure the injector resistance.
Resistance: 3 - 5 n
(c) Connect the cold start injector connector.
REMOVAL OF COLD START INJECTOR

OF BATTERY
2. DISCONNECT COLD START INJECTOR CONNECTOR
3. REMOVE COLD START INJECTOR PIPE

(a) Put a suitable container or shop towel under the cold
start injector pipe.
L..-- F1_15---'18 (b) Remove the two union bolts, cold start injector and
gaskets.
4. REMOVE COLD START INJECTOR

Remove the two bolts, cold start injector and gasket.
FI1519
INSPECTION OF COLD START INJECTOR

~Union Bolt INSPECT INJECTION OF COLD START INJECTOR
GaSket<:1~ (a) Install the gasket, SST (two unions), another gasket
and two union bolts to the delivery pipe and injector.
.~~S~T
(b) Connect the SST (hose) to the unions.
SST 09268-41045
(c) Connect the SST (wire) to the injector.
FI0266
SST 09842-30050
NOTE: Position the injector as far away from battery as
possible.
(d) Put a container under the injector.
(e) Turn on the ignition switch ON.
(f) Short the terminals of the fuel pump check connec-
Service Wire
//
/
----~/
FI0686
(g) Connect the test probes of the SST to the battery

and check that the fuel spray is as shown.
SST 09842-30050
CAUTION: Perform this check within the shortest
t'l possible time.
FI0160
(h) Disconnect the test probes from the battery and

SST check that fuel drops one drop or less of fuel per
minute from the injector nozzle.
~SST
FI0161
(j) After checking, restore the following parts to their

original condition:
• Fuel pump check connector
• Ignition switch
• SST
• Cold start injector
• Injector wiring
INSTALLATION OF COLD START INJECTOR

1. INSTALL COLD START INJECTOR
Install a new gasket and the cold start injector with the
two bolts.
Torque: 60 kg-em (52 in.-Ib, 5.9 N·m)
2. CONNECT COLD START INJECTOR PIPE

Using new gaskets, reconnect the cold start injector pipe
to the delivery pipe and cold start injector with the union
bolts.
Torque: 200 kg-em (14 ft-Ib, 20 N·m)
FI1518
3. CONNECT COLD START INJECTOR CONNECTOR

BATTERY
5. CHECK FOR FUEL LEAKAGE

(See step 5 on page FI-8)
Fuel Pressure Regulator
Spring
Diaphragm
IL-_--Valve
FROM
DELIVERY
PIPE
Fuel Pressure
Regulator
TO RETURN PIPE
FI1499 FI0669
CHECK FUEL PRESSURE (See page FI-41)
REMOVAL OF FUEL PRESSURE REGULATOR

1. RAISE VEHICLE
2. DISCONNECT VACUUM SENSING HOSE
3. DISCONNECT FUEL RETURN HOSE

(a) Put a suitable container or shop towel under the
pressure regulator.
(b) Disconnect the fuel return pipe from the pressure
regulator.
NOTE: Slowly loosen the fuel return pipe.
FI-SO EFI SYSTEM - Fuel System
4. REMOVE FUEL PRESSURE REGULATOR

Remove the two bolts and pull out the pressure regulator
from the delivery pipe.
FI0667
CORRECT WRONG WRONG

INSTALLATION OF FUEL PRESSURE
REGULATOR
~ ~~ ~ ~
1. INSTALL FUEL PRESSURE REGULATOR
Install the pressure regulator with the two bolts.
~DeliVery Pipe ~
k-~~~s~~Ring ,.J....
~ Regulator r FI0781
2. CONNECT FUEL RETURN PIPE

3. CONNECT VACUUM SENSING HOSE
4. CHECK FOR FUEL LEAKAGE (See step 5 on page FI-8)
5. LOWER VEHICLE
FI-51
Injectors
Plunger
INJECTION .. INLET
Coil
FI0499
Sound Scope
1. INSPECT INJECTOR OPERATION
Check operation sound from each injector.
(a) With the engine running or cranking, use a sound
scope to check that there is normal operating noise in
proportion to engine rpm.
FI0666
(b) If you have no sound scope, you can check the injector
transmission operation with your finger.
If no sound or an unusual sound is heard, check the wiring
connector, injector, resistor, or injection signal from ECU.
FI0665
Ohmmeter
2. INSPECT INJECTOR RESISTANCE
(a) Disconnect the injector connector.
(b) Using an ohmmeter, measure the resistance between
the terminals.
Resistance: 1 .5 - 3.0 n
If the resistance is not as specified, replace the injector.
(c) Reconnect the injector connector.
REMOVAL OF INJECTORS
OF BATTERY
2. DRAIN ENGINE COOLANT (See page CO-4)

THROTTLE LINKAGE
4. (A/T)
DISCONNECT THROTTLE CABLE FROM THROTTLE
LINKAGE
6. DISCONNECT HOSES AND CONNECTORS

(a) Cold start injector connector
(b) Air valve connector
(c) (2WD MIT)
(d) PCV hoses
(e) Brake booster vacuum hose
(f) Charcoal canister hose
(g) Emission control hoses

(See steps 15 to 17 on page EM-11)
8. DISCONNECT FUEL INLET PIPE

Remove the pulsation damper and two gaskets.
9. DISCONNECT FUEL OUTLET PIPE

Remove the union bolt and two gaskets.
FI0662
10. REMOVE DELIVERY PIPE AND INJECTORS

(a) Disconnect the fuel inlet and outlet pipes from the
Cover delivery pipe.
(b) Remove the bolt, nut and delivery pipe together with
the four injectors.
CAUTION:
• Be careful not drop the injectors, when removing the
delivery pipe.
• Do not remove the injector cover.
~ -----J
FI0221 (c) Pull out the four injectors from the delivery pipe.
Regulator INSPECTION OF INJECTORS

(From Vehicle) ! ~ W 1. INSPECT INJECTOR INJECTION
~J! . ~~
WARNING: Keep clear of sparks during the test.
SST SST
8 ' SST ---lJ ,1. . .
~~
.
~~
g SST WFuel Filter .'"
(On Vehicle) FI2062
Union Bolt i Fuel Hose

(a)
(b)
Disconnect the fuel hose from the fuel filter outlet.
Connect SST (hose) to the fuel filter outlet with SST
SST-~
-u.w
[L ~ (union), new gaskets and the union bolt.
-l.Jl.Q~
(Hose) SST 09268-41045
New Gasket
SST /_~ NOTE: Use the vehicle's fuel filter.
(Union) ~
Fuel
Filter
FI1946
(c) Remove the pressure regulator.

(See pages FI-49 and 50)
(d) Connect the fuel return hose and SST (hose) to the
pressure regulator with SST (union), new gaskets and
union bolt.
SST 09268-41045
(e) Connect SST (hose) to the injector with SST (union),

~I-::~~~~-=---SST and hold the injector and SST (union) with SST
(clamp).
New rt SST (Union)
SST 09268-41045
O'Rin~L- (f) Put the injector into the graduated cylinder.
~ -h SST (Clamp)
nr-~
NOTE: Install the suitable vinyl hose onto the injector to
prevent gasoline from splashing out.
Vinyl Tube (g) Reconnect the battery negative (-) cable.
FI2064 (h) Turn the ignition switch ON.
(i) Using a service wire, short the terminals of the fuel
pump check connector.
NOTE: Fuel pump will operate.
(j) Connect SST (wire) to the injector and battery for 15

seconds, and measure the injection volume with a
graduated cylinder.
Test each injector two or three times.
SST 09842-30020
Volume: 40 - 50 cc (2.4 - 3.1 cu in.) per 15 sec.
Difference between each injector:
5 cc (0.3 cu in.) or less
If the injection volume is not as specified, replace the
FI1279
injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of
SST (wire) from the battery and check the fuel leakage
from the injector.
SST 09842-30020
Fuel drop: One drop or less per minute
(b) Disconnect the battery negative (-) cable.
(c) Remove SST and the service wire.
FI0164 SST 09268-41045
INSTALLATION OF INJECTORS
New O-Ring
1. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Install a light coat of gasoline to a new O-ring and
install it the injector.
Grommet
FI0222
O-Ring ~ ";0IiJ (c) While turning the injector left and right, install it to the
delivery pipe. Install the four injector.
GrommR Delivery Pipe

Injector ~
~,
~ ~ Wrong
'~ FI0420
(d) Place the four insulators and two spacers in position

on the intake manifold.
FI2014
(e) Place the injectors together with the delivery pipe in

position on the intake manifold.
(f) Check that the injectors rotate smoothly.
NOTE: If injectors do not rotate smoothly, the probable
cause is incorrect installation of a-rings. Replace the
a-ring.
(g) Install the delivery pipe with the bolt and nut.
FI2013
2. CONNECT FUEL INLET PIPE

Connect the inlet pipe with the pulsation damper and new
two gaskets. Torque the pulsation damper.
3. CONNECT FUEL OUTLET PIPE

Connect the outlet pipe with the union bolt and new two
gaskets. Torque the union bolt.
FI0662

(See steps 3 to 5 on page EM-24)
5. CONNECT HOSES (See steps 7 to 9 on page EM-25)

(c) Emission control hoses
(d) PCV hoses
(e) Water by-pass hoses
(f) Cold start injector connector
(g) Air valve connector
(h) (2WD MIT)
7. CONNECT ACCELERATOR CABLE, AND ADJUST IT
8. (A/T)
CONNECT THROTTLE CABLE, AND ADJUST IT

BATTERY

FI·56 EFI SYSTEM - Fuel System
Fuel Tank and Line

\so (43 in.-Ib, 4.9) I
Inlet Hose ~ [130 19. 13) i
Tank Protector ~, I 440 (32, 43) I
"f~~/i
Inlet Pipe
Ikg-cm (ft-Ib, N'm)1 : Specified torque Tank Band---~ "~\tJ~

• Non-reusable part FI0661 FI0660
~--'~-''-....
PRECAUTIONS
~<;_. 0 .-----'
1. Always use new gaskets when replacing the fuel tank
, '--'. ~
'"\ L........, _-r-'---:: or component parts.
~-- .~.--
""",.
'-- .. ~
2. When re-installing, be sure to include the rubber pro-
tectors on the upper surfaces of the fuel tank and tank
Rubber Protector
band.
3. Apply the proper torque to all parts tightened.
(2WD and 4WD)
~--(2WD)
FI0740
INSPECT FUEL LINES AND CONNECTIONS

?,---fl,i.--)_ _0 (a) Inspect the fuel lines for cracks, or leakage and con-
nections for deformation.
Crack "-Ieakage (b) Inspect the fuel tank vapor vent system hoses and
connections for looseness, sharp bends or damage.
(c) Inspect the fuel tank for deformation, cracks, fuel
leakage or tank band looseness.
(d) Inspect the inlet pipe for damage or fuel leakage.
2 - 5 mm (e) The hose and tube connections are as shown in the

(0.08 - 0.20 in.) illustration.
Pipe Hose
If problem is found, repair or replace the parts as necess-
ary.
o- 3 mm (0 - 0.12 in.) FU0041

EFI SYSTEM - Air Induction System FI-57
AIR INDUCTION SYSTEM

Air Flow Meter
Compensation Plate
Potentiometer
TO AIR
INTAKE AIR INTAKE
Damping Chamber CHAMBER SIDE
CHAMBER
Return
Spring
Air Temp.--~
Sensor
Air By- Pass

Passage
FROM AIR
CLEANER Measuring Plate
Measuring Air By-pass Passage
Plate FI0448 FI0449
E1 FC E2 VB VC VS INSPECT RESISTANCE OF AIR FLOW METER
THA
(a) Disconnect the wiring connector from the air flow
meter.
each terminal.
Between
Resistance Temperature
terminals
FI0518
E2 - VS 20 - 400 0 -
E2 - ve 100 - 300 n -
r--------------------l
I
I
I
E2 - VB 200 - 400 n -
E2 - THA 10-20kn -20°C (-4°F)
4 - 7 kO ooe (32°F)
FC 2 - 3 kO 20 0 e ( 68°F)
THA
0.9 - 1.3 kO 40°C (104°F)
0.4 - 0.7 kO 60 0 e (140°F)
E1 - Fe Infinity -
L...- ~FIO;;_.72;;.;..,j7 If resistance is not as specified, replace the air flow meter.
REMOVAL OF AIR FLOW METER

1. DISCONNECT AIR FLOW METER CONNECTOR
2. DISCONNECT AIR CLEANER HOSE
3. REMOVE AIR FLOW METER

(a) Remove the bracket bolt.
(b) Remove the four nuts, air flow meter and gasket.
FI1512
FI-58 EFI SYSTEM - Air Induction System
INSPECTION OF AIR FLOW METER

INSPECT RESISTANCE OF AIR FLOW METER
Using an ohmmeter, measure the resistance between each
terminal at different measuring plate positions.
Between Measuring plate

Resistance n
Terminals Opening
Infinity Fully closed
E1 - Fe Other than
Zero
closed position
20 - 400 Fully closed
E2 - VS Fully closed to
20 - 1,000
fully open position
NOTE: Resistance between E2 and VS will change in

accordance with the measuring plate opening.
If resistance is not as specified, replace the air flow meter.
INSTALLATION OF AIR FLOW METER

Measuring Plate FI0480
FI0449
1. INSTALL AIR FLOW METER
(a) Install a new gasket, the air flow meter with the four
nuts.
(b) Install the bracket bolt.
2. CONNECT AIR CLEANER HOSE
3. CONNECT AIR FLOW METER CONNECTOR

Air Valve
AT LOW TEMPERATURE AFTER WARM-UP
TO AIR INTAKE
CHAMBER
Bi-metal
Gate Valve
FROM THROTTLE
BODY FI1494 FI0659
1. INSPECT AIR VALVE OPERATION
Check the engine speed while pinching the air hose.
At low temp. (Coolant temp.: below 60°C (140°F)).
• When the hose is pinched, engine speed should drop.
After warm-up
• When the hose is pinched, check that engine speed
does not drop more than 50 rpm.
If operation is not as specified, replace the air valve.
2. INSPECT AIR VALVE RESISTANCE

Using an ohmmeter, measure the heat coil resistance of
Ohmmeter
the air valve.
.n. Resistance (EP - E1): 40 - 60 n
at coolant temp. 80°C (176°F)
o and air valve closed.

If resistance is not as specified, replace the air valve.
FI0657
REMOVAL OF AIR VALVE

(See steps 1 to 11 on pages FI-51 and 52)
2. DISCONNECT AIR VALVE INLET AND OUTLET HOSES
3. DISCONNECT AIR VALVE BY-PASS HOSES
4. REMOVE AIR VALVE

FI1495
Remove the two bolts air valve.
INSPECTION OF AIR VALVE

INSPECT OPENING CONDITION OF AIR VALVE
Adjusting Screw Check that the valve opens slightly, as illustrated, when
room temperature is about 20°C (B8°F).
FI1503
INSTALLATION OF AIR VALVE

1. INSTALL AIR VALVE
Install the air valve with the two bolts.
2. CONNECT AIR VALVE INLET AND OUTLET HOSES
3. CONNECT AIR VALVE BY-PASS HOSES

(See steps 5 to 16 on page FI-55)
Throttle Body
PSW
E1-------tI
I D L - -...~
FI1504 FI0713
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.
(b) Check the vacuum at each port.

• Start the engine.
• Check the vacuum with your finger.
Port At idling Other than idling
A Vacuum Vacuum
P No vacuum Vacuum
E No vacuum Vacuum
R No vacuum No vacuum
E p FI1505
2. INSPECT THROTTLE POSITION SENSOR

Ohmmeter Check the continuity between the terminals.
(a) Disconnect the sensor connector.
(b) Insert a feeler gauge between the throttle stop screw
and stop lever.
(c) Using an ohmmeter, check the continuity between
( each terminal.
FI0653
FI0711
Continuity between terminals

Clearance between lever and stop screw
IDL - E1 PSW - E1 IDL - PSW
0.57 mm (0.0224 in.) Continuity No continuity No continuity
0.85 mm (0.0335 in.) No continuity No continuity No continuity
Throttle valve fully opened position No continuity Continuity No continuity
If continuity is not as specified, replace the sensor and
throttle body as a set.
REMOVAL OF THROTTLE BODY

OF BATTERY
2. DRAIN COOLANT (See page CO-4)

THROTTLE BODY
5. REMOVE THROTTLE BODY

(a) Disconnect the throttle position sensor connector.
(b) Remove the two by-pass hoses.
(c) Disconnect the vacuum hoses from the throttle body.
(d) Remove four nuts, throttle body and gasket.
EM1136
INSPECTION OF THROTTLE BODY

1. CLEAN THROTTLE BODY BEFORE INSPECTION
(a) Clean the cast parts with a soft brush and carburetor
cleaner.
(b) Using compressed air, blow through all passages and
apertures in the throttle body.
CAUTION: To prevent deterioration, do not clean the
throttle position sensor.
FI1506
2. INSPECT THROTTLE VALVE

Check that there is no clearance between the throttle stop
screw and throttle lever when the throttle valve is fully
closed.
I
Throttle
U Lever
Throttle Stop
No Clearance Screw
FI0650
3. INSPECT THROTTLE POSITION SENSOR

(a) Prepare an angle gauge as shown in figure.
(b) Set the throttle valve opening angle to 64° or 68°
from the vertical position Oncl. throttle valve fully
58° or 62° closed angle 6°).
Throttle Valve
:---._~...~ Angle
Gauge Angle Y'II"~""

12° or 16°
(c) Using an ohmmeter, check the continuity between

Ohmmeter each terminal.
Throttle valve Continuity

opening angle IDL - E1 PSW - E1 IDL - PSW
64° from No No No
vertical continuity continuity continuity
PSW
68° from No No
E1 ---tttItoll:brJ...-_~ Continuity
I DL --~-""';"-_ _- J
vertical continuity continuity
FI0711
(d) Using a feeler gauge, check the continuity between

Ohmmeter terminals IDL and E1.
Clearance between Continuity (IDL - E1)
lever and stop screw
0.57 mm (0.0224 in.) Continuity
0.85 mm (0.0335 in.) No continuity
E1--------jittHi:!::::t-'-_ _
If continuity is not as specified, replace the sensor and
--JJ-----i~----' throttle body as a set.
IDL
FI0653
FI0711
INSTALLATION OF THROTTLE BODY

1. INSTALL THROTTLE BODY
(a) Install a new gasket and the throttle body with the
four nuts.
(b) Connect the vacuum hoses to the throttle body.
(c) Install the two by-pass hoses.
(d) Connect the throttle position sensor connector.
EM1136
3. CONNECT ACCELERATOR CABLE TO THROTTLE

BODY
4. REFILL WITH COOLANT

BATTERY
FI-64 EFI SYSTEM - Electronic Control System
ELECTRONIC CONTROL SYSTEM

Location of Electronic Control Parts
@
®
®
@ 2WD AfT and 4WD

I J
1. Fuel Pump 8 Water Temperature Sensor,

2. ECU 9 Injector
3. Cold Start Injector 10. Air Flow Meter
4. ENGINE Service Connector 11 . Oxygen Sensor
5. Circuit Opening Relay 12. Solenoid Resistor
6. Throttle Position Sensor 13. EFI Main Relay
7. Cold Start Injector Time Switch 14. Distributor (with Ignition Coil)
FI0648
MA0445
EFI SYSTEM - Electronic Control System FI-65
EFI Main Relay

EFI Main Relay
ECU
Fuse EFI 15A 2
r-------------0"""l-o------,r--~ --'0---\----.-----0 +B
Fusible Link
EFI 30A
L...----o+ B1
Fuse IGN 7.5A
Fusible Link
2.0L
Battery
E1
FI1504
No continuity Continuity INSPECTION OF EFI MAIN RELAY

,~ll~J LlD 1. INSPECT RELAY CONTINUITY
La: o
(a)
(b)
Using an ohmmeter, check that there is continuity
between terminals 1 and 3.
Check that there is no continuity between terminals 2
and 4.
If continuity is not as specified, replace the relay.
BEooa9
Continuity
2. INSPECT RELAY OPERATION
CIT::J (a) Apply battery voltage across terminals 1 and 3.

(b) Using ohmmeter, check that there is continuity be-
tween terminals 2 and 4.
If operation is not as specified, replace the relay.
4 3 BEaa1 a
Circuit Opening Relay
----~ To ECU (STA)
To EFI Main Relay~---+----~ToECU (+8)

8 STA
Circuit Opening Relay
~- .... FC E1
Fuel Pump Switch
(Air Flow Meter)
Fuel Pump Fuel Pump
Check Connector
FI0034
INSPECTION OF CIRCUIT OPENING RELAY

1. INSPECT RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity
between terminals STA and E1.
(b) Check that there is continuity between terminals B
and FC.
(c) Check that there is no continuity between terminals B
and FP.
'--- FI_19--'08 If continuity is not as specified, replace the relay.

(a) Apply battery voltage across terminals STA and E1.
(b) Using an ohmmeter, check that there is continuity
between terminals Band FP.
Continuity
FI1909
(c) Apply battery voltage across terminals Band FC.

(d) Check that there is continuity between terminals B
and FP.
Continuity
FI1910
Solenoid Resistor
Ignition Switch
c.r-tt-:-=---=-------------------, Solenoid ECU

AM2 ....._---IIG2 + B Resistor
No. 20 -+-----t~ No.1 0
Injector
L...------.......---u No. 10
"----------------..-----40 No. 20
E01
Battery (E1 )
E02
INSPECTION OF SOLENOID RESISTOR

INSPECT SOLENOID RESISTOR
(a) Disconnect the connectors.
terminal +B and other terminals.
Resistance: 2 - 3 n each
+8 If the resistance is not within specification, replace the

resistor.
FI1538
Cold Start Injector Time Switch
To Ignition S~itch~~~~~~~~~~~~~~~~~~~~~~~~~~To
ECU (STA)
(ST1 )
Cold Start Injector
l _
Cold Start Injector
Time S~itch
FI1273
STtfTJ INSPECTION OF COLD START INJECTOR

TIME SWITCH
INSPECT COLD START INJECTOR TIME SWITCH
(a) Disconnect the connector.
Ohmmeter
(b) Using an ohmmeter, measure the resistance bet~een
each terminal.
o o FI0782
FI0647
Terminals Resistance (n)
20 - 40
Coolant temp.
below 30°C (S6°F)
5TA - 5T J
40 - 60 above 40°C (104°F)
20 - 40 below 30°C (S6°F)
STA - Ground
20 - SO above 40°C (104°F)
If the resistance is not ~ithin specification, replace the

s~itch.
Water Temperature Sensor

40
20
10
8
6
4
c:
~
LU 2
U
Z
«
I-
(J) 1
(J) 0.8
LU
a:::: 0.6
0.2
Thermistor
0.1
-20 a 20 4'0 60 8'0 100 120

(-4) (32) (68) (104)(140)(176)(212)(248)
TEMPERATURE °C CF) FI0515 FI0709
INSPECTION OF WATER TEMPERATURE

SENSOR
INSPECT WATER TEMPERATURE SENSOR
Ohmmeter (a) Disconnect the connector.
~-
both terminals (THW - E2).
Resistance: Refer to the chart.
Black Oxygen Sensor

(E1 )
INSPECTION OF FEEDBACK VOLTAGE (VF)
1. CONNECT SST AND VOLTMETER
Connect SST to the EFI check connector and connect a
voltmeter to SST.
Red SST 09842-14010
(VF) Connect the positive (+) probe to the red wire of the SST
FU0644 IC-4-2 and negative (-) probe to the black wire.
2. WARM UP ENGINE TO NORMAL OPERATING

TEMPERATURE
Warm up the Oxygen sensor with the engine at 2,500

rpm for approx. 90 seconds.
Short terminals T and E1 of the check engine connector. Replace the ECU.
And maintain engine speed at 2,500 rpm.
After replacing
Less than 8 times the oxygen sensor
Check the number of times the voltmeter needle fluctuates in 10 seconds.

1
8 times
Less than 8 times Zero
or more
Warm up the Oxygen sensor with the engine at Normal

2,500 rpm for approx. 90 seconds. And maintain
engine at 2,500 rpm.
8 times or more
Check the number of times the voltmeter
needle fluctuates in 10 seconds. f--------
Zero
Less than 8 times
Unshort terminals T and E1 of the check engine connector

and maintain engine speed at 2,500 prm.
Within 120 seconds, after unshorting terminal T, measure

voltage between terminals VF and E1 of the EFI check
connector.
~OV
More than OV
IRead and record diagnostic codes
I
Normal code Malfunction code(s)
and code 5 (ex. code 5)
Repair the relevent diagnostic code.
m 2 ® 4
CONTINUED ON PAGE FI-71

CONTINUED FROM PAGE FI-70
Repair the relevent diagnostic code

®
Malfunction code(s)
(ex. code 5)
Read and record diagnostic codes (See page FI-24)
Normal code
and code 5
Unshort terminals T and E1 of the check engine

connector. And maintain engine at 2,500 rpm.
Within 120 seconds, after unshorting terminal T, measure

voltage between terminals VF and E1.
lov 5V
Disconnect the pev hose.
Within 120 seconds, after unshorting terminal T,

measure voltage between terminals VF and E1 .
ov IMore than OV
Repair (Over rich)
Disconnect the water temp. sensor connector and

connect resistor with a resistace of 4 - 8 K n or
another coded water temp. sensor.
Short terminals T and E1 of the check engine connector.
Warm up the oxygen sensor with the engine at

2,500 rpm for approx. 90 seconds. And
maintain engine speed at 2,500 rpm.
Measure voltage between terminals VF and E1.
lov 5V
Replace the oxygen sensor Repair (Over lean)
I
FI·72 EFI SYSTEM - Electronic Control System
Electronic Controlled Unit (ECU)

INSPECTION OF ECU
1. INSPECT VOLTAGE OF ECU
NOTE:
1. The ECU, itself, cannot be checked directly.
2. The EFI circuit can be checked by measuring the
resistance and voltage at the wiring connectors of
the ECU.
Check the voltage at the wiring connectors .
• Turn the ignition switch ON.
• Measure the voltage at each terminal.
NOTE: 1. Perform all voltage measurements with the connectors connected.

2. Verify that the battery voltage is 11 V or more when the ignition switch is ON.
Voltages at ECU Wiring Connectors

Terminals Condition Voltage (V)
+B 10 - 14
- E1 Ignition switch ON
+B1
BATT - E1 -- 10 - 14
IDL - E1 Ignition switch ON Throttle valve open 8 - 14
PSW - E1 Ignition switch ON Throttle valve closed 8 - 14
IGT - E1 Idling 0.7 - 1.0
STA - E1 Cranking 6 - 12
No. 10
- E1 Ignition switch ON 9 - 14
No. 20
W - E1 No trouble ("CHECK" engine warning light off) and engine running 8 - 12
VC - E2 Ignition switch ON 6 - 10
Measuring plate fully closed 0.5 - 2.5
E2 Ignition switch ON
VS - Measuring plate fUlly open 5 - 10
E21
Idling 2 - 8
THA - E2 Ignition switch ON Intake temperature 20°C (68°F) 1 - 3
THW - E2 Ignition switch ON Coolant temperature 80°C (176°F) 0.5 - 2.5
AIC - E1 Ignition switch ON Air conditioning ON 10 - 14
Check engine connector (T - E1) not short 10 - 14
T - E1 Ignition switch ON
Check connector (T - E1). short a
ECU Terminals
~ ~ ~
E01 No
STA VF V- W T IDL IGF NE VC VS THA BATT + B1
10 ISC
No.
E02 20 IGT E1 FPU ACV TSW A/C E2 OX IPsw THW E21 SPD +B
FI0605
2. INSPECT RESISTANCE OF ECU

CAUTION:
1. Do not touch the ECU terminals.
2. The tester probe should be inserted into the wir-
Ohmmeter ing connector from the wiring side.
Check the resistance between each terminal of the wiring
connectors.
/
/ • Disconnect the ECU wiring connectors.
FI0197 • Measure the resistance between each terminal of the
wiring connectors.
Resistance at ECU Wiring Connectors
Terminals Condition Resistance (n)

Throttle valve open co
IDL - E1 ~-
Throttle valve fully closed 0

Throttle valve open 0
PSW - E1 f----

~----
+8 - E2 -- 200 - 400
VC - E2 -- 100 - 300
Measuring plate fully closed 20 - 400
VS - E2 f-----
Measuring plate fully open 20 - 1,000

THA - E2 Intake air temperature 20°C (68°F) 2,000 - 3,000
THW - E2 Coolant temperature 80°C (176°F) 200 - 400
ECU Terminals
~ ~ ~
E01 No
STA VF v- W T IDL IGF NE VC VS THA BATT + 81
10 ISC
No
E02 20 IGT E1 FPU ACV TSW A/C E2 OX PSW THW E21 SPD +8
FI0605
Fuel Cut RPM

INSPECTION OF FUEL CUT RPM
INSPECT FUEL CUT RPM
(a) Start and warm up the engine.
(b) Disconnect the connector from the sensor throttle
position sensor.
(c) Short circuit terminals IDL and E1 on the wire con-
J-3-1 nector side.
(d) Gradually raise the engine rpm and check that there
1,800 rpm - 2,200 rpm is fluctuation between the fuel cut and fuel return
points.
NOTE: The vehicle should be stopped.
Fuel cut rpm: 2,200 rpm
Fuel return rpm: 1,800 rpm
FI0037
Idle-up and High-temperature Line

Pressure Up (wi AIC) Systems
Ignition Switch Neutral Start Switch (A/T) ECU
AM1 IG1
0 - + - - - - -__---1--0 -o-+---.--------~ STA
AM2 IG2
Fusible
Link Fuse
AM230A IGN
Fusible 7.5A
Link
1.25B '-+--~EPU
Fusible Fusible
Fusible
Link EFI15A
Link
EFI30A "'--+---~V-ISC
2.0L
Battery
_06-1"'1-- (>--+-----0 TSW
E1
FI1521
INSPECTION OF IDLE-UP AND FUEL

PRESSURE UP SYSTEMS
Ohmmeter 1. INSPECT IDLE-UP TEMPERATURE SWITCH
! iii (a) Using an ohmmeter, check that there is no continuity
between the terminal and body when the oil tempera-
ture is below 103°C (217°F).
(b) Check that there is continuity between the terminal
and body when the oil temperature is above 1-10o C
(230°F).
If operation is not as specified, replace the switch.
~l[J Continuity 2. INSPECT EFI VSV
A. Inspect VSV for open circuit

Using an ohmmeter, check that there is continuity between
terminals.
Resistance (Cold): 37 - 44 n
If there is no continuity, replace the VSV.
EM3125
B. Inspect VSV for ground

No continuity
Using an ohmmeter, check that there is no continuity
between each terminal and the body.
If there is continuity, replace the VSV.
EM3126
C. Inspect VSV operation

(a) Check taht air flows from pipe E to pipe F.
Air
(r....__
(-
ll..-' ~
F ! '.. -
FI1496
(b) Apply battery voltage across the terminals.

(c) Check that air flows from pipe E to pipe G.
If operation is not as specified, replace the VSV.
F113,,5
3. INSPECT ISC VSV

c::::n::::=J 0 h m meter
o A. Inspect VSV for open circuit
o In++-----oo..
Using an ohmmeter, check that there is continuity between
terminals.
Resistance (Cold): 37 - 44 f1
If there is no continuity, replace the VSV.
FI1925
B. Inspect VSV for ground

c::::n::::=J No continuity Using an ohmmeter, check that there is no continuity
between each terminal and the body.
FI1926
C. Inspect VSV operation

(a) Check that air does not flow from pipe E to pipe F.
FI1497
(b) Apply battery voltage across the terminals.

(c) Check that air flows from pipe E to pipe F.
e ffi
FI1356
CO-1
COOLING SYSTEM
Page
TROU BLESHOOTING CO-2
CHECK AND REPLACEMENT OF
ENGINE COOLANT CO-3
WATER PUMP CO-4
THERMOSTAT CO-6
RADIATOR CO- 7
CO-2 COOLING SYSTEM - Troubleshooting
TROUBLESHOOTING
. ~-
I-------.---.-~---_. - - - - - . - - - - - - - - - - - -[ - -.
Engine overheats Fan belt loose or missing Adjust or replace belt CH-3
Dirt, leaves or insects on radiator or Clean radiator or condenser CO-7
condenser
Hoses, water pump, thermostat housing, Repair as necessary
radiator, heater, core plugs or head gasket
leakage
I
Thermostat faulty Check thermostat CO-6

Ignition timing retarded Adjust timing IG-14
Fluid coupling faulty Replace fluid coupling CO-4
Radiator hose plugged or rotted Replace hose
Water pump faulty Replace water pump CO-4
Radiator plugged or cap faulty Check radiator CO-7
Cylinder head or block cracked or plugged Repair as necessary
NOTE: If the engine tends to overheat, removal of the thermostat will adversely effect cooling efficiency.
COOLING SYSTEM - Check and Replacement of Engine Coolant CO-3
CHECK AND REPLACEMENT OF

ENGINE COOLANT
1. CHECK ENGINE COOLANT LEVEL AT RESERVE TANK
The coolant level should be between the "LOW" and
"FULL" lines.
If low, check for leaks and add coolant up to the "FULL"
line.
C00060
2. CHECK ENGINE COOLANT QUALITY

There should not be any excessive deposits of rust or
scales around the radiator cap or radiator filler hole, and
the coolant should be free from oil.
If excessively dirty, replace the coolant.
3. REPLACE ENGINE COOLANT

(a) Remove the radiator cap or water outlet cap.
(b) Drain the coolant from the radiator and engine drain
C00096 cocks. (Engine drain cock is at left front of engine
block.)
(c) Close the drain cocks.
(d) Fill the system with coolant.
Use a good brand of ethylene-glycol base coolant,
mixed according to the manufacturer's directions.
Coolant capacity (w/H eater):
2WD wi 0 Rear heater
wi Rear heater
4WD wlo Rear heater
wi Rear heater
(e) Install the radiator cap (water outlet cap).
(f) Start the engine and check for leaks.
(g) Recheck the coolant level and refill as necessary.
CO-4 COOLING SYSTEM - Water Pump
WATER PUMP
COMPONENTS
Water Pump
Fan
,,&--1
\W I
I
I
I
I
• Gasket
Bolt
Water Pump Pulley
Fluid Coupling
• Non-reusable part C00148
REMOVAL OF WATER PUMP

~. DRAIN COOLANT (See page CO-3)
2. REMOVE DRIVE BELT
3. REMOVE FAN AND WATER PUMP PULLEY

Remove the four nuts holding the fluid coupling to the
pulley seat, and remove the fan and fluid coupling assem-
bly and the pump pulley.
C00004
COOLING SYSTEM - Water Pump CO-5
4. REMOVE WATER PUMP

Adjusting Bar
(a) Remove the bolt and disconnect the drive belt adjust-
ing bar from the water pump.
(b) Remove the nut, four bolts, water pump and gasket.
C00292
INSPECTION OF WATER PUMP

COMPONENTS
1. INSPECT WATER PUMP
Turn the pulley seat and check that the water pump bear-
ing moves smoothly and quietly.
If necessary, replace the water pump.
C00293
2. INSPECT FLUID COUPLING

Check the fluid coupling for damage and silicon oil
leakage.
If necessary, replace the fluid coupling.
C00066
Adjusting Bar
INSTALLATION OF WATER PUMP
(See page CO-4)
1. INSTALL WATER PUMP

Place a new water pump gasket to the timing chain case
and install the water pump and drive belt adjusting bar
with the nut and five bolts.
Torque: Water pump 185 kg-em
(13 ft-Ib, 18 N'm)
C00292 Adjusting bar 400 kg-em
(29 ft-Ib, 39 N'm)
2. INSTALL WATER PUMP PULLEY AND FAN

Install the pump pulley and the fluid coupling and fan
assembly with the four nuts.
C00004
CO-6 COOLING SYSTEM - Water Pump, Thermostat
3. INSTALL AND ADJUST DRIVE BELT

(See page CH-13)
4. REFILL WITH COOLANT (See page CO-3)
THERMOSTAT
REMOVAL OF THERMOSTAT
2. DISCONNECT RADIATOR OUTLET HOSE FROM

WATER INLET
3. REMOVE WATER INLET AND THERMOSTAT

Remove the two nuts, water inlet, gasket and thermostat
from the timing chain case.
INSPECTION OF THERMOSTAT
NOTE: The thermostat is numbered according to the
valve opening temperature.
(a) Immerse the thermostat in water and heat the water
gradually.
C00081
(b) Check the valve opening temperature and valve lift.

If the valve opening temperature and valve lift are not
within the following specifications, replace the ther-
mostat.
Valve opening temperature:
80 - 84°C (176 - 183°F)
Valve lift:
8 mm (0.31 in.) or more at 95°C (203°F)
(c) Check that the valve spring is tight when the ther-
mostat is fully closed. Replace as necessary.
COOLING SYSTEM - Thermostat, Radiator CO-7
INSTALLATION OF THERMOSTAT
1. INSTALL THERMOSTAT AND WATER INLET
(a) Install a new gasket to the thermostat and place the
thermostat with the jiggle valve at the upper left as
shown.
C00297
(b) Install the water inlet with the two nuts.

2. CONNECT RADIATOR OUTLET HOSE TO WATER

INLET
RADIATOR
CLEANING OF RADIATOR
Using water or a steam cleaner, remove any mud and dirt
from the radiator core.
CAUTION: If using a high pressure type cleaner, be
careful not to deform the fins of the radiator core. If
the cleaner nozzle pressure is 30 - 35 kg/cm 2 (427 -
498 psi, 2,492 - 3,432 kPa), keep a distance of at
least 40 - 50 cm (15.75 - 19.69 in.) between the
radiator core and cleaner nozzle.
Radiator Cap Tester

INSPECTION OF RADIATOR
1. INSPECT WATER OUTLET CAP
Using a radiator cap tester, pump the tester until the relief
valve opens. Check that the valve opens between 0.75 kg/
cm 2 (10.7 psi, 74 kPa) and 1.05 kg/cm 2 (14.9 psi, 103
kPa).
Water Outlet Cap
Check that the pressure does not drop rapidly when
pressure on the cap is below 0.6 kg/cm 2 (8.5 psi, 59 kPa).
If either check is not within limits, replace the cap.
CO-8 COOLING SYSTEM - Radiator
2. INSPECT COOLING SYSTEM FOR lEAKS

(a) Fill the radiator with coolant and attach a pressure
7 0 r Cap Tester tester.
(b) Warm up the engine.
(c) Pump it to 1.2 kg/cm 2 (17 psi, 118 kPa), check that
pressure does not drop.
If the pressure drops, check for leaks from the hoses,
radiator or water pump. If no external leaks are found,
check the heater core, cylinder block and head.
C00146
REMOVAL OF RADIATOR
For 2WD
Radiator Inlet Hose
Radiator Fan Shroud
!-------Water Hose
Radiator Outlet Hose

C00149
2. [A/T]
DISCONNECT Oil COOLER HOSES
(a) Remove and lay the washer fluid tank to one side
without disconnecting the hoses.
(b) Disconnect the two cooler hoses from the radiator.
NOTE:
• Be careful as some oil will leak out. Catch it in a suitable
container.
• Plug the hose to prevent oil from escaping.
3. REMOVE FAN SHROUD
4. DISCONNECT RADIATOR HOSES AND COOLANT

RESERVOIR HOSE FROM RADIATOR
5. REMOVE RADIATOR UPPER BOLT
6. RAISE VEHICLE
COOLING SYSTEM - Radiator CO-9
8. REMOVE RADIATOR
Remove the nuts and pull out the radiator from the frame.
INSTALLATION OF RADIATOR
(See page CO-8)
1. INSTALL RADIATOR
3. LOWER VEHICLE
4. INSTALL RADIATOR UPPER BOLT
5. CONNECT RADIATOR HOSES AND COOLANT

RESERVOIR HOSE TO RADIATOR
6. INSTALL FAN SHROUD
7. [AfT]
CONNECT OIL COOLER HOSES
10. [AfT]
CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
Fluid type: ATF DEXRON@ II
MA0099
LU-1
LUBRICATION SYSTEM
Page
TROUBLESHOOTING LU-2
OIL PRESSURE CHECK LU-3
REPLACEMENT OF ENGINE OIL
AND OIL FILTER LU-4
OIL PUMP LU-5
LU-2 LUBRICATION SYSTEM - Troubleshooting
TROUBLESHOOTING
Oil leakage Cylinder head, cylinder block or oil pump Repair as necessary
body damaged or cracked
Oil seal faulty Replace oil seal EM-34, 57
Gasket faulty Replace gasket
Low oil pressure Oil leakage Repair as necessary

Relief valve faulty Repair relief valve LU-5
Oil pump faulty Repair oil pump LU-5
Engine oil quality poor Replace engine oil LU-4
Crankshaft bearing faulty Replace bearing EM-39
Connecting rod bearing faulty Replace bearing EM-39
Oil filter clogged Replace oil filter LU-4
High oil pressure Relief valve faulty Repair relief valve LU-5
LUBRICATION SYSTEM- Oil Pressure Check LU-3
OIL PRESSURE CHECK

1. CHECK ENGINE OIL QUALITY
Recommended Viscosity (SAE):
Check the oil for deterioration, entry of water, discoloring
[
I I r 15W-40 20W-40 20W-50 )
or thinning.
I 10W-30 10W-40 10W-50
i I
<
OF -20
5W-30
20 40
I
60
I I
80
I
100
I I If the quality is poor, replace the oil.
0
°C -29 ~18 -7 4 16 27 38 Use API grade SF or SF/CC, multigrade, fuel-efficient and
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
recommended viscosity oil.
LU0311
2. CHECK ENGINE OIL LEVEL

The oil level should be between the ilL" and "F" marks on
the oil dipstick.
If low, check for leakage and add oil up to the "F" mark.
LU0309
3. REMOVE OIL PRESSURE SWITCH OR SENDER GAUGE

Pressure Gauge
4. INSTALL OIL PRESSURE GAUGE
5. START ENGINE
Start engine and warm it up to normal operating tem-
perature.
6. CHECK OIL PRESSURE

Oil pressure:
L- LU0296
~..:.::.:...:...I
At idle 0.3 kg/cm 2 (4.3 psi, 29 kPa)
or more
At 3,000 rpm 2.5 - 5.0 kg/cm 2
(36 - 71 psi, 245 - 490 kPa)
NOTE: Check for oil leakage after reinstalling the oil
pressure switch or sender gauge.
LU-4 LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filter
REPLACEMENT OF ENGINE OIL

AND OIL FILTER
1. DRAIN ENGINE OIL
SST (a) Remove the oil filter cap.
(b) Remove the oil drain plug and drain the oil into a con-
tainer.
2. REPLACE OIL FILTER

LU0297
(a) Using SST, remove the oil filter.
SST 4WD AIT (w/Oil cooler) 09228-44011
Others (w/o Oil cooler) 09228-22020
(b) Check and clean the oil filter installation surface.

(c) Apply clean engine oil to the gasket of a new oil filter.
LU0004 LU0005
(d) Lightly screw in the oil filter by hand to where you

feel resistance.
(e) Then, using SST, tighten it another 3/4 turn.
SST 4WD AIT (w/Oil cooler) 09228-44011
Others (w/o Oil cooler) 09228-22020
3. FILL WITH ENGINE OIL

(a) Clean and install the oil drain plug with a new gasket.
(b) Fill the engine with new oil, API grade SF or SF/CC
LU0006 LU0007
multigrade, fuel-efficient and recommended viscos-
ityoil.
Capacity:
Drain and refill
wi Oil filter change
wlo Oil filter change
Dry fill 4.2 liters (4.4 US qts, 3.7 Imp. qts)
5. RECHECK ENGINE OIL LEVEL (See page LU-3)

LUBRICATION SYSTEM- Oil Pump LU-5
OIL PUMP
COMPONENTS
Oil Pump Body-~~~~
1l~~~~~--[185(13,18Il
,-
Relief Valve Cd
Relief Valve Spring-\ ~--------OilPump Drive Rotor
Relief Valve Plu9~ f -- ~-------Oil Pump Driven Rotor
~~--Oil Pump Cover
[aD (69 in.-~~, 7.Sll-------iJ ~--;;; Oil Strainer
[g-':'_~~t-I~, N~r-nlJ : Specified torque LU0124
REMOVAL OF OIL PUMP

1. RAISE VEHICLE
2. DRAIN ENGINE OIL (See page LU-4)
3. REMOVE RIGHT AND LEFT STIFFENER PLATES
4. DISCONNECT CONNECTOR OF OIL LEVEL SENSOR
Oil Lever Sensor 5. IF NECESSARY, REMOVE OIL LEVEL SENSOR
Protector
I
Gasket
LU0315
LU-6 LUBRICATION SYSTEM- Oil Pump
6. REMOVE OIL PAN

(a) Remove the eighteen bolts.
(b) Insert the blade of SST between the cylinder block
and oil pan, cut off applied sealer and then remove
the oil pan.
SST 09032-00100
NOTE:
• Do not use SST for the timing chain cover side. If
necessary, use a screwdriver.
LU0272 LU027 1
• When removing the oil pan, be careful not to damage
the oil pan flange.
7. REMOVE OIL PUMP

Remove the bolt and pullout the oil pump.
DISASSEMBLY OF OIL PUMP

(See page LU-5)
1. CHECK OIL PUMP OPERATION

(a) Using a screwdriver, immerse the oil strainer in oil
and turn the oil pump shaft clockwise. Oil should
come out of the oil outlet hole.
LU0305
(b) Close the oil outlet hole with your thumb and turn the
oil pump shaft as before. The oil pump shaft should
be difficult to turn.
LU0306
2. REMOVE RELIEF VALVE

Remove the relief valve plug, spring and valve.
Relief Valve 3. REMOVE OIL PUMP COVER

spring~ Remove the three bolts and oil pump cover.
?
Relief Valve Plug LU0304
4. REMOVE DRIVE AND DRIVEN ROTORS
INSPECTION OF OIL PUMP

1. INSPECT RELIEF VALVE OPERATION
Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If necessary, replace the valve and/or pump assembly.
LU0299
2. INSPECT DRIVE AND DRIVEN ROTORS

A. Inspect Rotor Body Clearance
driven rotor and body.
(0.0039 - 0.0059 in,)
Maximum clearance: 0.2 mm (0.008 in,)
rotors. If necessary, replace the oil pump assembly.
LU0300
B. Inspect Rotor Body Clearance

Using a feeler gauge, measure the clearance as shown.
(0.0012 - 0.0028 in.)
LU0302
C. Inspect Rotor Tip Clearance

drive rotor and driven rotor.
(0.0028 - 0.0047 in,)
LU0301
LU-8 LUBRICATION SYSTEM- Oil Pump
ASSEMBLY OF OIL PUMP

(See page LU-5)
1. INSTALL DRIVE AND DRIVEN ROTORS

Install the rotors so the punch marks are facing upward
toward the pump body.
Punch Marks
2. INSTALL OIL PUMP COVER
Install the oil pump cover with the three bolts. Torque the
LU0303 bolts.
Torque: 80 kg-cm (69 in.-Ib, 7.8 N'm)
3. INSTALL RELIEF VALVE, SPRING, AND RELIEF VALVE

PLUG
Relief Valve
Insert the relief valve and spring, and install the relief valve
Spring ' \ plug.
~~
4. CHECK OIL PUMP OPERATION

~
Relief Valve Plug
(See page LU-6)
LU0304
INSTAtLATION OF OIL PUMP

1. INSTALL OIL PUMP
(a) Align the governor shaft protrusion of the IIA with
the drive rotor slot of the oil pump.
(b) Install the oil pump with the bolt.
Torque the bolt.
LU0298 2. INSTALL OIL PAN

(a) Remove any oil packing material and be careful not to
drop any oil on the contacting surfaces of the oil pan
and cylinder block.
• Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket
surfaces and sealing groove.
• Thoroughly clean all components to remove all the
loose material.
• Clean both sealing surfaces with a non-residue
solvent.
CAUTION: Do not use a solvent which will affect the
painted surfaces.
(b) Apply seal packing to the oil pan as shown in the

o o o o
figure.
\ Seal packing: Part No. 08826-00080 or equivalent
Seal breadth approx.
3 mm (0.12 in.)
• Install a nozzle that has been cut to the 3 mm
(0.12 in.) opening.
NOTE: Avoid applying an excess amount to the surface.
Be especially careful near oil passages.
• Parts must be assembled within 15 minutes of
application. Otherwise, the material must be
LU0307
removed and reapplied.
• Immediately remove nozzle from tube and reinstall
cap.
(c) Install the oil pan with the eighteen bolts.
Torque: 130 kg-cm (9 ft-Ib, 13N'm)
3. INSTALL OIL LEVEL SENSOR

(a) Install a new gasket and the oil level sensor with the
,]/f
Oil Level Sensor
four bolts. Torque the bolts.
Protector Torque: 55 kg-cm (48 in.-Ib, 5.4 N'm)
(b) Install the protector of the oil level sensor with the
two bolts.
CAUTION: Be careful not to drop the oil level sensor
<lllJ1zIItl when installing it.
Gasket
LU0315 4. CONNECT CONNECTOR OF OIL LEVEL SENSOR
5. INSTALL RIGHT AND LEFT STIFFENER PLATES
6. LOWER VEHICLE
7. FILL WITH ENGINE OIL (See step 3 on page LU-4)
9. CHECK ENGINE OIL LEVEL (See page LU-3)

IG-1
IGNITION SYSTEM
Page
PRECAUTIONS IG-2
TROUBLESHOOTING IG-2
ELECTRONIC SPARK ADVANCE (ESA) IG-3
ON-VEHICLE INSPECTION IG-4
DISTRIBUTOR ............................ IG-8
IG-2 IGNITION SYSTEM - Precautions, Troubleshooting
Service Connector
Test Probe PRECAUTIONS
3. NEVER allow the tachometer terminal to touch ground

as it could result in damage to the ignition coil.
4. Do not disconnect the battery while the engine is run-
ning.
5. Make sure that the igniter is properly grounded to the
body.
TROUBLESHOOTING
Engine will not start/ Incorrect ignition timing Reset timing IG-14
hard to start Ignition coil faulty Inspect coil IG-6
(cranks ok)
Igniter faulty Inspect igniter IG-7
Distributor faulty Inspect distributor IG-7
High-tension cord faulty Inspect high-tension cords IG-5
Spark plug faulty Inspect plugs IG-5
Ignition wiring disconnected or broken Inspect wiring
Rough idle or stalls Spark plug faulty Inspect plugs IG-5

Ignition wiring faulty Inspect wiring
Ignition coil faulty Inspect coil IG-6
Igniter faulty Inspect igniter IG-7
Distributor faulty Inspect distributor IG-7
High-tension cord faulty Inspect high-tension cords IG-5
Engine hesitates/ Spark plug faulty Inspect plugs IG-5

poor acceleration Ignition wiring faulty Inspect wiring
Engine dieseling Incorrect ignition timing Reset timing IG-14

(runs after ignition
switch is turned off)
Muffler explosion Incorrect ignition timing Reset timing IG-14

(after fire) all the time
Engine backfires Incorrect ignition timing Reset timing IG-14
Poor gasoline mileage Spark plug faulty Inspect plugs IG-5

Incorrect ignition timing Reset timing lG-14
Engine overheats Incorrect ignition timing Reset timing IG-14

IGNITION SYSTEM - Electronic Spark Advance (ESA) IG-3
ELECTRONIC SPARK ADVANCE

(ESA)
The ECU is programmed with data for optimum ignition timing
under any and all operating conditions. Using data provided by
sensors which monitor various engine functions (rpm, intake air
volume, eng. temperature, etc.) the microcomputer (ECU) trig-
gers the spark at precisely the right instant.
ESA SYSTEM CIRCUIT
Distributor
AM2 (Black)
(Brown)
Ignition Cap and Rotor
Switch
Fusible
Link
AM2
Spark
Plug (Blue) I
Signal Rotor Service
Fusible Firing Order: I
2.0L Connector
Link 1-3-4-2
Pickup Coil
.-+-~'""" Distributor
T' ,+-~...J Connector
I Battery
i-
ECU Igniter
To Tachometer
IG0550
IG-4 IGNITION SYSTEM - On-Vehicle Inspection
SPARK TEST
CHECK THAT SPARK OCCURS
(a) Disconnect high-tension cords from spark plugs.
(b) Remove the spark plugs.
(c) Install the spark plugs to each high-tension cord.
(d) Ground the spark plug.
(e) Check if spark occurs while engine is being cranked.
NOTE: To prevent gasoline from being injected from
injectors during this test, crank the engine for no more
than 1 - 2 seconds at a time.
If the spark does not occurs, perform the test as follows:
SPARK TEST
I
NG
CHECK RESISTANCE OF HIGH-TENSION CORD

(See page IG-5) hG---1 Replace the cord (s).
I
OK
r
]
CHECK POWER SUPPLY TO IGNITION COIL Check wiring between
1. Ignition switch turn to ON. ignition and ignition coil.
2. Check that there is battery voltage at ignition NG
--
coil positive (+) terminal.
OK
I
CHECK RESISTANCE OF IGNITION COIL Replace the ignition coil.

(See page IG-6) (See page IG-9)
Resistance (cold): Primary 1.2 - 1.5 n NG
Secondary 7.7 - 10.4 kn
OK
I
CHECK RESISTANCE OF SIGNAL GENERATOR Replace the distributor

(PICKUP COIL) (See page IG-7) -.. housing assembly.
Resistance: 140 - 180 n NG (See page IG-9)
OK
II
CHECK AIR GAP OF DISTRIBUTOR Replace the distributor

housing assembly.
(See page IG- 7) NG (See page IG-9) 1
OK
I
TRY ANOTHER IGNITER
IGNITION SYSTEM - On-Vehicle Inspection IG-5
INSPECTION OF HIGH-TENSION CORDS

1. CAREFULLY REMOVE HIGH-TENSION CORDS BY
THEIR RUBBER BOOTS FROM SPARK PLUGS
CAUTION: Pulling on or bending the cords may
damage the conductor inside.
MA0004
2. INSPECT HIGH-TENSION CORD RESISTANCE

Using an ohmmeter, measure the resistance without dis-
connecting the cap.
Maximum resistance: 25 k11 per cord
If resistance is greater than maximum, check the ter-
minals. If necessary, replace the high-tension cord and/or
distributor cap.
INSPECTION OF SPARK PLUGS

[Platinum Tipped Type]
CAUTION:
• Never use a wire brush for cleaning.
• Never attempt to adjust the electrode gap on used
spark plug.
• Spark plug should be replaced every 96,000 km
(60,000 miles)
1. INSPECT ELECTRODE
Megger
(a) If using a megger (insulation resistance meted.
Measure the insulation resistance.
Correct insulation resistance: 10M 11 or more
If less than 10M 11, clean the plug.
IG0147
(b) If not using a megger.

Quickly race the engine to 4,000 rpm five times.
Visually inspect the spark plugs.
If the electrode is dry Okay
If the electrode is wet Clean the plug
2. REMOVE SPARK PLUGS
IG0148
IG-6 IGNITION SYSTEM - On-Vehicle Inspection
3. VISUALLY INSPECT SPARK PLUGS

Check the spark plug for thread for insulation damage.
If abnormal replace the plug.
Spark plug: NO P16R
NGK BPR5EP11
IG0149
4. INSPECT ELECTRODE GAP

Maximum electrode gap: 1.3 mm (0.051 in.)
If the gap is greater than maximum, replace the plug.
Correct electrode gap of new plug:
1.1 mm (0.043 in.)
If adjusting the gap of a new plug, bend only the base of
the ground electrode. Do not touch the tip.
5. CLEAN SPARK PLUGS

If the electrode has traces of wet carbon, allow it to dry
and then clean with a spark plug cleaner.
Air pressure: Below 6 kg/cm 2 (85 psi, 588 KPa)
Duration: 20 seconds or less
NOTE: If there are traces of oil, clean it off with gasoline
before using the spark plug cleaner.
6. INSTALL SPARK PLUGS

L-.. 15~2
I..;..;GO__ Torque: 180 kg-cm (13 ft-Ib, 18 N'm)
INSPECTION OF IGNITION COIL

1. INSPECT PRIMARY COIL RESISTANCE
Using an ohmmeter, measure the resistance between the
positive (+) and negative (-) terminals.
Primary coil resistance (cold): 1.2 - 1.5 n
If the resistance is not within specification, replace the
ignition coil.
IG0559
2. INSPECT SECONDARY COIL RESISTANCE

positive (+) terminal and high-tension terminal.
Secondary coil resistance (cold): 7.7 - 10.4 k n
ignition coil.
IG0560
IGNITION SYSTEM - On-Vehicle Inspection IG-7
INSPECTION OF DISTRIBUTOR
1. INSPECT AIR GAP
Using a feeler gauge, measure the gap between the signal
rotor and pickup coil projection.
Air gap: 0.2 mm (0.008 in.) or more
If the gap is less than specified, replace the distributor
housing assembly.
IG0551
2. INSPECT PICKUP COIL

Using an ohmmeter, check the resistance of the pickup
coil.
Pickup coil resistance: 140 - 180 n
distributor housing assembly.
IG0552
INSPECTION OF IGNITER
(See procedure Spark Test on page IG-4)
IG-8 IGNITION SYSTEM - Distributor
DISTRIBUTOR
COMPONENTS
y-:;.;;r----.:,---------- Distributor Cap

(with High-tension Cord)
~-----Gasket
----Rotor
Gasket
Distributor Wire -----r'
-r-.~ Ignition Coil

Dust Cover
I-----Ignition Coil
----' ~1iIW-----++.....,.h;~-
T hru s t
Washer
-----+---Distributor Housing Assembly
@ Plate Washer
~--. O-Ring-----+
~~. Straight Pin
~. Driven Gear
• Non-reusable part IG0553

IGNITION SYSTEM - Distributor IG-9
REMOVAL OF DISTRIBUTOR
OF BATTERY
4. DISCONNECT DISTRIBUTOR CONNECTORS
5. DISCONNECT HIGH-TENSION CORDS FROM SPARK

PLUGS
6. REMOVE DISTRIBUTOR
Remove the mount bolt and pull out the distributor.
IG0566
DISASSEMBLY OF DISTRIBUTOR
(See page IG-8)
1. REMOVE DISTRIBUTOR CAP WITHOUT

DISCONNECTING HIGH-TENSION CORDS
2. REMOVE ROTOR
3. REMOVE IGNITION COIL DUST COVER
4. REMOVE IGNITION COIL

(a) Remove the nuts and disconnect the wires from the
terminals of the ignition coil.
(b) Remove the four screws, ignition coil and gasket.
5. REMOVE DISTRIBUTOR WIRE
6. REMOVE CONNECTOR LAMP

INSPECTION OF DISTRIBUTOR
1. INSPECT AIR GAP
Using a feeler gauge, measure the gap between the signal
rotor and pickup coil projection.
Air gap: 0.2 mm (0.008 in.) or more
If the gap is less than specification, replace the distributor
housing assembly.
IG0577
2. INSPECT GOVERNOR SHAFT

(a) Turn the governor shaft and check that it is not rough
or worn.
If it feels rough or worn, replace the distributor housing
assembly.
IG0576
(b) Using a feeler gauge, measure the governor shaft

thrust clearance.
Thrust clearance: 0.15 - 0.50 mm
(0.0059 - 0.0197 in.)
If the clearance is within specification, adjust with a thrust
washer. (See page IG-11)
IG0514
ADJUSTMENT OF GOVERNOR SHAFT

THRUST CLEARANCE
(OR REPLACEMENT OF DRIVEN GEAR)
1. REMOVE DRIVEN GEAR
(a) Using a grinder, grind the driven gear and straight
pin.
CAUTION: Be careful not to damage the governor
shaft.
IG0156
IG0154
(b) Using a pin punch and hammer, tap out the straight
pin.
(c) Remove the drive gear and plate washer.
2. REMOVE GOVERNOR SHAFT

Remove the governor shaft and thrust washer.
IG0155
3. INSTALL GOVERNOR SHAFT
Thrust Washer
(a) Lightly coat the gover shaft with high-temperature
grease.
(b) Slide the thrust washer onto the governor shaft.
(c) Push the governor shaft into the housing.
4. INSTALL NEW DRIVEN GEAR

~
Plate Washer-------@ (a) Slide the plate washer and a new driven gear onto the
~~ IG0578
governor shaft.
(b) Align the drill mark on the driven gear (not driven
gear straight pin hole) with the groove of the hous-
Groove ing.
CAUTION: Be sure to check the governor shaft
cutout is positioned as shown.
(c) Install a new straight pin.
IG0579
(d) Using a feeler gauge, measure the governor shaft

y' thrust clearance.
\
Thrust clearance: 0.15 - 0.50 mm
=IJ (0.0059 - 0.0197 in,)
If the clearance is not within specification, adjust with a
thrust washer.
Thrust washer thickness:
0.3 mm (0.012 in.)
0.4 mm (0.016 in.)
0.5 mm (0.020 in.)
'-------------------' IG0514
0.6 mm (0.024 in.)

(e) Secure the ends of the straight pin in a vise.
IG0517
ASSEMBLY OF DISTRIBUTOR
(See page IG-8)
1. INSTALL CONNECTOR CLAMP

(a) Align the housing protrusion with the clamp groove.
(b) Install the clamp with the screw.
2. INSTALL DISTRIBUTOR WIRE
IG0574
3. INSTALL IGNITION COIL

(a) Install the gasket and ignition coil with the four
screw.
Red
Black (b) Connect the three wires to the terminals of the igni-
tion coil with the two nuts as shown.
~~~---l\\ Ittl1t7- Brow n
IG0575
CAUTION:
• When connecting the wires to the ignition coil, insert
both properly into their grooves found on the side of
the ignition coil.
• Be sure that the wires do not contact with signal rotor
or distributor housing.
4. INSTALL IGNITION COIL DUST COVER
IG0656
5. INSTALL ROTOR
6. INSTALL DISTRIBUTOR CAP AND HIGH-TENSION

CORDS
(a) Place the gasket in position on the distributor hous-
ing.
(b) Install the distributor cap with the three bolts.
7. INSTALL NEW O-RING TO HOUSING

NOTE: Lightly coat the new a-ring with engine oil.
IG0522
INSTALLATION OF DISTRIBUTOR
Hole of NO.1 Spark Plug
I J) ,,0 1. SET NO.1 CYLINDER TO TDC/COMPRESSION'
..
~--=-~JF"'=~·~·· ~ ~ ~ Set to TDC/compression in the following manner. .,
Yo;:)! '/~ ir.~ (a) Remove the No.1 spark plug. ~..~.,<\~~-
?'
elf I ):B (b) Place your finger over the hole of the No. 1 spark~.'~::'\'
plug and rotate the crankshaft clockwise to .......
TDC. If,:, '. "-
pressure is felt on your finger, this is TDC/compres-i~ '-,
sian of the No. 1 cylinder. If not, repeat the process. ,/~
IG0082 IG0083
(c) Install the No. 1 spark plug.
2. SET OIL PUMP DRIVE ROTOR SLOT

Position the slot on the top end of the drive rotor in the
direction shown in the figure.
3. INSTALL DISTRIBUTOR
(a) Align the groove of the housing with the drill mark of
the driven gear (not driven gear straight pin).
(b) Insert the distributor, aligning the center of the flange
with that of the bolt hole on the cylinder block.
(c) Lightly tighten the hold-down bolt.
4. CONNECT HIGH-TENSION CORDS

Firing order: 1-3-4-2
5. CONNECT DISTRIBUTOR CONNECTORS

BATTERY
7. WARM UP ENGINE
Allow the engine to reach normal operating temperature.
8. CONNECT TACHOMETER
Remove the connector cap and connect the test probe of
the tester to the service connector of the distributor.
CAUTION:
• NEVER allow the tachometer terminal to touch
ground as it could result in damage to the igniter
and/or ignition coil.
• As some tachometers are not compatible with this
ignition system, we recommend that you confirm
EC1828 the compatibility of your unit before using.
9. ADJUST IGNITION TIMING
Check (a) Using a service wire, short the terminals of the check
Engine engine connector.
Connector
Service
Wire
EC1709
(b) Using a timing light, check the ignition timing.

(c) Loosen the mount bolt of the distributor.
(d) Adjust the turning the distributor.
(e) Tighten the mount bolt, and recheck the ignition tim-
ing.
IG0682
(f) Remove the service wire, install the connector cap.
EC1756
10. FURTHER CHECK IGNITION TIMING

Ignition timing: Approx. 20° BTDC @ idle
\\
'\\
/! )
~~ IG0682

ST-1
STARTING SYSTEM
I
Page
TROUBLESHOOTING . ST-2
STARTER . ST-3
STARTER RELAY (MIT ONLy) . ST-12
CLUTCH START SWITCH (MIT ONLY) . ST-12
ST-2 STARTING SYSTEM - Troubleshooting
TROUBLESHOOTING
--e---------
Engine will not crank Battery charge low Check battery specific gravity CH-3
Charge or replace battery
Battery cables loose. corroded or worn Repair or replace cables
Neutral start switch faulty (A/T) Adjust or repair switch
Fusible link blown Replace fusible link
Starter faulty Repair starter ST-3
Ignition switch faulty Replace ignition switch
Engine cranks slowly Battery charge low Check battery specific gravity CH-3
Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
Starter faulty Repair starter ST-3
---_.
Starter keeps running Starter faulty Repair starter ST-3

Ignition switch faulty Replace ignition switch
Short in wiring Repair wiring
~
--
Starter spins - engine Pinion gear teeth broken or starter faulty Repair starter ST-3
will not crank Flywheel teeth broken Replace flywheel
STARTING SYSTEM - Starter ST-3
STARTER
COMPONENTS
r~(,~!1"~~ar1:aring
I
Front Bearing
• O-Ring
.O-RlT1g
Pinion Gear
Magnetic SWitch
I
• Non-reusable part 5T0231
REMOVAL OF STARTER
OF BATTERY
2. DISCONNECT CONNECTOR AND WIRE FROM

STARTOR
3. REMOVE STARTER
Remove the two bolts, and them remove the starter from
the flywheel bell-housing.
51·4 STARTING SYSTEM - Starter
DISASSEMBLY OF STARTER
(See page ST-3)
1. REMOVE FIELD FRAME AND ARMATURE ASSEMBLY

(a) Disconnect the lead wire from the magnetic switch
terminal.
(b) Remove the two through bolts. Pullout the field
frame together with the armature from the magnetic
switch.
5T0232 5T0233 (c) Remove the O-ring.
2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY

AND GEARS
(a) Remove the two screws.
I
\-------~-----~-----,
5T0248
(b) Remove the following parts from the magnetic

switch:
(1) Starter housing
(2) Pinion gear
(3) Bearing
(4) Idler gear
(5) Clutch assembly
(6) Return spring
5T0234
3. REMOVE STEEL BALL

Using a magnetic finger, remove the steel ball from the
clutch shaft hole.
5T0009
4. REMOVE BRUSH HOLDER

(a) Remove the two screws and end cover from the field
frame.
(b) Remove the O-ring.
(c) Using a screwdriver, hold the spring back and dis-

connect the brush from the brush holder. Disconnect
the four brushes and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME
INSPECTION OF STARTER
Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity bet-
ween the segments of the commutator.
If there is no continuity, replace the armature.
5T0012
2. INSPECT COMMUTATOR FOR GROUND

J Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
ST0011
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, correct with sandpaper (No.
400) or on a lathe.
ST-6 STARTING SYSTEM - Starter
2. INSPECT COMMUTATOR CIRCLE RUNOUT

Maximum circle runout: 0.05 mm (0.0020 in,)
If the circle runout is greater than maximum, correct it on a
lathe.
S T (lCll:,
3. INSPECT DIAMETER OF COMMUTATOR

Standard diameter: 30 mm (1.18 in.)
Minimum diameter: 29 mm (1.14 in.)
If the diameter of the commutator is less than minimum,
replace the armature.
S T (1(114
4. INSPECT UNDERCUT DEPTH

Check that the undercut depth is clean and free of foreign
material. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in,)
Minimum undercut depth: 0.2 mm (0.008 in,)
If the undercut depth is less than minimum, correct it with
a hacksaw blade.
ST004()
Field Coil (Field Frame)

1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
\
SH)015
2. INSPECT FIELD COIL FOR GROUND

Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, repair or replace the field frame.
ST0016
Brushes
INSPECT BRUSH LENGTH
Standard length: 15.5 mm (0.610 in,)
Minimum length: 10.0 mm (0.394 in,)
If the length is less than minimum, replace the brush
holder and field frame.
S T (1(' 1 1 S T(l(ll 8
Brush Springs
INSPECT BRUSH SPRING LOAD WITH PULL SCALE
Spring installed load:
1.79 - 2.41 kg (3.9 - 5.3 Ib, 18 - 24 N)
NOTE: Take the pull scale reading the instant the brush
spring separates from the brush.
If the reading is is not within specification, replace the
brush springs.
S 1,'1(11 l j
Brush Holder
INSPECT INSULATION OF BRUSH HOLDER
tween the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
ST0062
Clutch and Gears

1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and
clutch assembly for wear or damage. Replace if damaged.
If damaged, also check the flywheel ring gear for wear or
damage.
2. INSPECT CLUTCH PINION GEAR

Rotate the pinion gear clockwise and check that it turns
freely. Try to rotate the pinion gear counterclockwise and
check that it locks.
If necessary, replace the clutch assembly.
/
I
ST0020
STARTING SYSTEM - Starter
Bearings
1. INSPECT BEARINGS
Turn each bearing by hand while applying inward force.
If resistance is felt or if either bearing sticks, replace the
bearing.
5T0041
2. IF NECESSARY, REPLACE BEARINGS

(a) Using SST, remove the bearing from the armature
shaft.
(b) Using SST, remove the other bearing on the opposite
side.
SST 09286-46011
5T0042
(c) Using SST and a press, press in a new front bearing.

SST 09201 -41 020
(d) Using a press, press in a new rear bearing.
SST
Magnetic Switch
Terminal 50
1. PERFORM PULL-IN COIL OPEN CIRCUIT TEST
tween terminals 50 and C.
If there is no continuity, replace the magnetic switch.
"~~
Terminal C
5 TO 137
2. PERFORM HOLD-IN COIL OPEN CIRCUIT TEST

Switch Body Using an ohmmeter, check that there is continuity be-
Terminal 50
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
5T0138
ASSEMBLY OF STARTER
~;,~~
" --------._-
(See page ST -3)
NOTE: Use high-temperature grease to lubricate the

bearings and gears when assembling the starter.
a 1. PLACE ARMATURE INTO FIELD FRAME
Apply grease to the armature bearings and insert the
armature into the field frame.
2. INSTALL BRUSH HOLDER

(a) Using a screwdriver, hold the brush spring back, and
connect the brush into the brush holder. Connect the
four brushes.
NOTE: Check that the positive (+) lead wires are not
grounded.
(b) Place a new a-ring in position on the field frame.

(c) Install the end cover with the two screws.
/ \ ST()23~
3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE

Apply grease to the ball, and insert it into the clutch shaft
hole.
S T11('44
4. INSTALL CLUTCH ASSEMBLY AND GEAR

(a) Apply grease to the clutch assembly, gears, bearing
and return spring.
(b) Insert the return spring into the magnetic switch.
ST-l0 STARTING SYSTEM - Starter
(c) Place the following parts in position on the starter

(4)
housing.
(2)
(1) Clutch assembly
(2) Idler gear
(3) Bearing
(4) Pinion gear
5T024(J
-~
(d) Assemble the starter housing and magnetic switch
with the two screws.
5T0248
5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY

(a) Place a new O-ring in position on the field frame.
(b) Align the protrusion of the field frame with the
cutout of the magnetic switch.
\
(c) Install the two through bolts.

(d) Connect the lead wire to the magnetic switch ter-
minal, and install the nut.
5T0233 5T0232
PERFORMANCE TEST OF STARTER

Terminal C CAUTION: These tests must be performed within 3
to 5 seconds to avoid burning out the coil.
1. PERFORM PULL-IN TEST

(a) Disconnect the field coil lead from terminal C.
(b) Connect the battery to the magnetic switch as
shown. Check that the pinion gear moves outward.
If the pinion gear does not move, replace the magnetic
5T0140
switch assembly.
2. PERFORM HOLD-IN TEST

While connected as above with the pinion gear out, dis-
connect the negative (-) lead from terminal C. Check that
the pinion gear remains out.
If the pinion gear returns inward, replace the magnetic
switch assembly.
3. INSPECT PLUNGER RETURN

Disconnect the negative (-) lead from the switch body.
Check that the pinion gear returns inward.
If the pinion gear does not return, replace the magnetic
switch assembly.
4. PERFORM NO-LOAD PERFORMANCE TEST

(a) Connect the battery and ammeter to the starter as
Terminal 50 shown.
(b) Check that the starter rotates smoothly and steadily
with the pinion gear moving out. Check that the
ammeter reads the specified current.
Specified current: gOA or less at 11.5V
5T0143
INSTALLATION OF STARTER
1. INSTALL STARTER
(a) Place the starter in position in the flywheel bell hous-
ing.
(b) Install and torque the two bolts.
2. CONNECT CONNECTOR AND WIRE TO STARTER
5T0249
ST-12 STARTING SYSTEM - Starter Relay, Clutch Start Switch
STARTER RELAY (MIT ONLY)

LOCATION: In the engine compartment on the left side.
INSPECTION OF STARTER RELAY

(a) Using an ohmmeter, check that there is continuity
(b) Check that there is no continuity between terminals 2
and 4.
5T0322

(a) Apply battery voltage across terminals 1 and 3.
5T0323
CLUTCH START SWITCH

(MIT ONLY)
(See page CL-4)
CH-1
CHARGING SYSTEM
Page
PRECAUTIONS CH-2
TROUBLESHOOTING CH-2
ON-VEHICLE INSPECTION CH-3
ALTERNATOR CH-6
IGNITION MAIN RELAY CH-14
CH-2 CHARGING SYSTEM - Precautions, Troubleshooting
PRECAUTIONS
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is

given a quick charge.
3. Do not perform tests with a high voltage insulation

resistance tester.
4. Never disconnect the battery when the engine is run-

ning.
TROUBLESHOOTING
i
Discharge warning Fuse blown· I Check "IGN", "CHARGE" and

light does not light "ENGINE" fuses
with ignition ON and Light burned out Replace light
engine off
Wiring connection loose Tighten loose connections
IC regulator faulty Replace IC regulator CH-6
------ - --------
f- t ---------- - --- - ----
Discharge warning Drive belt loose or worn Adjust or replace drive belt CH-3
light does not go out Battery cables loose, corroded or worn Repair or replace cables
with engine running
(battery requires fre- Fuse blown Check" ENGINE" fuse
quent recharging) Fusible link blown i Replace fusible link
I
IC regulator or alternator faulty Check charging system CH-4

I Wiring faulty I Repair wiring I
CHARGING SYSTEM - On-Vehicle Inspection CH-3
1. CHECK BATTERY SPECIFIC GRAVITY AND
ELECTROL YTE LEVEL
(a) Check the specific gravity of each cell.
Upper Level Standard specific gravity:
1.25 - 1.27 when fully charged at 20°C (68°F)
Lower Level
(b) Check the electrolyte quantity of each cell.
If insufficient refill with distilled (or purified) water.
CH()()1 2
2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND

FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
CHOL78
(b) Check the fusible link and fuses for continuity.

Fusible link:
O.5G
1.25B
2.0L
AM180A
AM230A
Fuse: CHARGE 7.5A
ENGINE 15A
IGN 7.5A
3. INSPECT DRIVE BELT

(a) Visually check the belt for separation of the adhesive
rubber above and below the core, separating from
the belt side, severed core, separation of the rib from
the ad hesive rubber, cracking or separation of the
ribs, torn or worn ribs or cracks in the inner ridges of
the ribs.
If the belt has any of the above defects, replace it.
(b) Using a belt tension gauge, check the drive belt ten-
~" Nippondenso Borroughs sion.
~~
~ : ~ Belt tension gauge:
'v " I
Nippondenso BTG-20 (95506-00020) or
~
Borroughs No. BT -33-73F
t Drive belt tension: New belt 175 ± 51b
/(~'
rc*1 Used belt 115 ± 20lb
If the belt tension is not within specification, adjust it.
FC!)(!():', fC()On4 fCi)!!i!!

CH-4 CHARGING SYSTEM - On-Vehicle Inspection
NOTE:
• "New belt" refers to a belt which has been used less
than 5 minutes on a running engine.
running engine for 5 minutes or more.
• After installing the drive belt, check that it fits properly
in the ribbed grooves.
CORRECT WRONG • Check by hand to confirm that the belt has not slipped
out of the groove on the bottom of the crank pulley.
CH0086 • After installing the belt, run the engine for about 5
minutes and then recheck the tension.
4. VISUALLY CHECK ALTERNATOR WIRING AND

LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the alter-
nator while the engine is running.
CH0282
5. CHECK CHARGE LIGHT CIRCUIT

(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch to "ON". Check that the
charge light is lit.
(d) Start the engine. Check that the light goes out.
If the light does not go off as specified, troubleshoot the
charge light circuit.
6. CHECK CHARGING CIRCUIT WITHOUT LOAD

NOTE: If a battery/alternator tester is available, connect
the tester to the charging circuit as per manufacturer's
instructions.
(a) If a tester is not available, connect a voltmeter and
ammeter to the charging circuit as follows:
~
Batter21..- • Disconnect the wire from terminal B of the alterna-

tor and connect it to the negative (-) probe of the
ammeter.
CH0008 • Connect the test probe from the positive (+) ter-
minal of the ammeter to terminal B of the alterna-
tor.
• Connect the positive (+) probe of the voltmeter to
terminal B of the alternator.
• Ground the negative (-) probe of the voltmeter.
CHARGING SYSTEM - On-Vehicle Inspection CH-5
(b) Check the charging circuit as follows:

With the engine running from idling to 2,000 rpm,
check the reading on the ammeter and voltmeter.
Standard amperage: 10A or less
Standard voltage: 13.5 - 15.1 V at 25°C (77°F)
If the voltage reading is not within standard voltage, re-
place the IC regulator.
CH0205 CH0010
If the voltage reading is less than standard voltage, check

the IC regulator and alternator as follows:
• With terminal F grounded, start the engine and
check the voltage reading of terminal B.
CH0185
• If the voltage reading is greater than standard

voltage, replace the IC regulator.
• If the voltage reading is less than standard voltage,
check the alternator.
7. CHECK CHARGING CIRCUIT WITH LOAD

(a) With the engine running at 2,000 rpm, turn on the
high beam headlights and place the heater fan con-
trol switch on "HI".
(b) Check the reading on the ammeter.
Standard amperage: 30A or more
If the ammeter reading is less than 30A, repair the alterna-

tor. (See page CH-6)
NOTE: With the battery fully charged, the indication will
sometimes be less than 30A.
CH-6 CHARGING SYSTEM - Alternator
ALTERNATOR
COMPONENTS
Wave Washer
Rotor
Retainer
Drive End Frame
Pulley
~~ ~
~
! ,;1 /-:",_.
J -./_ _ _ _ _ : ~)
15'\ l \) l
Rear Bearing
. , ;rJ~ I c, ~ •. , "{j
~
~ \f\
\J~\ ~Q-';"'r-_1~ T
'11 J
]
JI
"
I
Front Bearing
Bearing Cover
Rubber Insulator
Terminal Insulator Brush Holder

(with Cover)
I@ l'~"i.~
cov~ ,-..<;l~' " :t'.-;.·. .,?,.I~,'~~-~··· ~-
IC Regualtor
Rectifier End
.. .. -·--Rear End Frame
~~~. ,""'* ~ \C~ ~) -/'.)
121 ~ I(; '. 'v:~ ~
-------Spring
Rectifier Holder
CH0411
REMOVAL OF ALTERNATOR
OF BATTERY
2. DISCONNECT CONNECTOR AND WIRE FROM

AL TERNATOR
CH0282
3. DISCONNECT DRIVE BELT FROM ALTERNATOR

/,.~ Adjusting Bolt
c'5Ff/~~~i a .
(a) Loosen the adjusting lock, pivot and adjusting bolts.
. .I .~ ~ (b) Disconnect the drive belt.
Adjusting Lock BOlt0~,.,.
. .' ~
~<)\~
c
4. REMOVE ALTERNATOR
p~ \V
l
(c' . J> ::<, /.
(a) Remove the adjusting lock and pivot bolts.
-~ r-.!
~ ;j-
(b) Remove the alternator.
Pivot Bolt "')'~ ._'"'.{~
~ ....
,
.:...;y
~~~~J
.
CH0283
CHARGING SYSTEM - Alternator CH-7
DISASSEMBLY OF ALTERNATOR
(See page CH-6)
1. REMOVE REAR END COVER

(a) Remove the nut and terminal insulator.
(b) Remove the three nuts and end cover.
CH0212
2. REMOVE BRUSH HOLDER

Remove the two screws, brush holder and cover.
'"r---'
_T:,r='i~ ~
CH0083
3. REMOVE IC REGULATOR
Remove the three screws and IC regulator.
CH0061
4. REMOVE RECTIFIER HOLDER

(a) Remove the four screws and rectifier holder.
(b) Remove the four rubber insulators.
CH0188
5. REMOVE PU LLEY
(a) Hold SST (A) with a torque wrench, and tighten SST
(8) clockwise to the specified torque.
SST 09820-63010
(b) Check that SST (A) is secured to the rotor shaft.
(c) As shown in the figure, mount SST (C) in a vise, and

install the alternator to SST (C).
(d) To loosen the pulley nut turn SST (A) in the direction
shown in the figure.
CAUTION: To prevent damage to the rotor shaft, do
not loosen the pulley nut more than one-half of a turn.
(e) Remove the alternator from SST (C).
(f) Turn SST (B) and remove SSTs (A and B).
(g) Remove the pulley nut and pulley.
6. REMOVE RECTIFIER END FRAME

(a) Remove the four nuts.
(b) Using SST, remove the rectifier end frame.
SST 09286-46011
7. REMOVE ROTOR FROM DRIVE END FRAME
CH0187
INSPECTION AND REPAIR OF ALTERNATOR

Rotor
1. INSPECT ROTOR FOR OPEN CIRCUIT
tween the slip rings.
Standard resistance (cold): 2.8 - 3.0 n
If there is no continuity, replace the rotor.
CH0190
2. INSPECT ROTOR FOR GROUND

tween the slip ring and the rotor.
If there is continuity, replace the rotor.
CH0191
3. INSPECT SLIP RINGS

(a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(b) Using calipers, measure the slip ring diameters.
Standard diameter: 14.2 - 14.4 mm
(0.559 - 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.
Stator
1. INSPECT STATOR FOR OPEN CIRCUIT
tween the coil leads.
If there is no continuity, replace the drive end frame
assembly.
CH0193
2. INSPECT STATOR FOR GROUND

tween the coil leads and drive end frame.
If there is continuity, replace the drive end frame assemb-
ly.
CH0194
Brushes
1. INSPECT EXPOSED BRUSH LENGTH
(a) Using a scale, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.0059 in.)
If the exposed length is less than minimum, replace the
brushes.
2. IF NECESSARY, REPLACE BRUSHES

(a) Unsolder and remove the brush and spring.
(b) Run the wire of the brush through the hole in the
brush holder, and insert the spring and brush into the
brush holder.
CH0196
(c) Solder the brush wire to the brush holder at the

exposed length.
Exposed length: 10.5 mm (0.413 in.)
(d) Check that the brush moves smoothly in the brush
holder.
(e) Cut off the excess wire.
(f) Apply insulation paint to the soldered point.
\ )
Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
M~8~- .
<;/
--~/-4 \ CH0227
2. IF NECESSARY, REPLACE FRONT BEARING

(a) Remove the four screws, bearing retainer and bear-
ing.
CH0/28
(b) Install the bearing.

(c) Align the claws of the bearing retainer with the slots
of the drive end frame.
(d) Install the bearing retainer with the four screws.
CH0216
3. INSPECT REAR BEARING

Check that the bearing is not rough or worn.
4. IF NECESSARY, REPLACE REAR BEARING

(a) Using SST, remove the bearing cover and bearing.
SST 09820-00021
CAUTION: Be careful not to damage the fan.
CH0200
(b) Using SST and a press, press in a new bearing and

bearing cover.
SST 09285-76010
CH0201
ASSEMBLY OF ALTERNATOR
(See page CH-6)
1. INSTALL ROTOR TO DRIVE END FRAME
2. INSTALL RECTIFIER END FRAME

(a) Using a plastic-faced hammer, lightly tap in the end
frame, together with the wave washer.
(b) Install the four nuts.
CH()218
3. INSTALL PULLEY
SST (A)--~+
(a) Install the pulley to the rotor shaft by tightening the
SST (B)----+-~
pulley nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST
(B) clockwise to the specified torque.
SST 09820-63010
(c) Check that SST (A) is secured to the pulley shaft.
(d) As shown in the figure, mount SST (C) in a vise, and

install the alternator to SST (C).
(e) To torque the pulley nut turn SST (A) in the direction
Torque: 1,125 kg-em (81 ft-Ib, 110 N'm)
(f) Remove the alternator from SST (C).
(g) Turn SST (B) and remove SSTs (A and B).
4. INSTALL RECTIFIER HOLDER

(a) Install the four rubber insulators on the lead wires.
(b) Install the rectifier with the four screws.
CH0188
5. INSTALL BRUSH HOLDER AND IC REGULATOR

(a) Install the brush holder cover to the brush holder.
(b) Install the IC regulator together with the brush holder
horizontally as shown.
(c) Install the five screws.

(d) Check the clearance between the brush holder and
connector is 1 mm (0.04 in.) or more.
(e) Install the brush holder cover to the rear end frame.
CH02l9
6. INSTALL REAR END COVER

(a) Install the end cover with the three nuts.
(b) Install the terminal insulator with the nut.
7. MAKE SURE ROTOR ROTATES SMOOTHLY
INSTALLATION OF ALTERNATOR
~l~~ 1. INSTALL ALTERNATOR
u=== Mount the alternator on the engine bracket with the pivot
I
Adjusting Lock ~_~_I!-_-/ ) and adjusting lock bolts. Do not tighten the bolts yet.
CH0283
2. INSTALL AND ADJUST DRIVE BELT

(a) Install the drive belt.
(b) Move the alternator over by hand until the belt
tightens, then lightly tighten the adjusting bolt until it
touches the engine bracket.
;v-~""
/
Engine Bracket CH0284
(c) Tighten the adjusting bolt the specifield number of

revolutions.
Adjusting bolt revolutions:
New belt 8 revolutions
Used belt 5 revolutions
(d) Check the drive belt tension. (See page CH-3)
CH0285
3. CONNECT CONNECTOR AND WIRE TO ALTERNATOR

BATTERY
5. PERFORM ON-VEHICLE INSPECTION

(See steps 5 to 7 on pages CH-4 to 6)
CH0282
CH-14 CHARGING SYSTEM - Ignition Main Relay
IGNITION MAIN RELAY

Main Relay LOCATION: Under the instrument panel in the relay box.
CH0413
No continuity Continuity INSPECTION OF IGNITION MAIN RELAY

{) {)
o (a) Using an ohmmeter, check that there is continuity

and 4.
Continuity 2. INSPECT RELAY OPERATION

BF0010
CL-1
CLUTCH
Page
TROUBLESHOOTING CL-2
CHECK AND ADJUSTMENT OF
CLUTCH PEDAL CL-3
BLEEDING OF CLUTCH SYSTEM CL-3
INSPECTION OF CLUTCH START SYSTEM CL-4
CLUTCH MASTER CYLINDER CL-5
CLUTCH RELEASE CYLINDER CL-8
CLUTCH UNIT CL-10
CL-2 CLUTCH - Troubleshooting
TROUBLESHOOTING
Hard to shift or will not Clutch pedal freeplay excessive Adjust pedal freeplay CL-3
shift Air in clutch lines Bleed clutch system CL-3
Clutch release cylinder faulty Repair release cylinder CL-8
Clutch master cylinder faulty Repair master cylinder CL-5
Clutch disc out of true, runout is excessive or Inspect clutch disc CL-l0
lining broken
Splines on input shaft or clutch disc dirty or Repair as necessary CL-l0
burred
Clutch pressure plate faulty Replace clutch cover CL-l0
Transmission jumps out Clutch pilot bearing worn Replace pilot bearing CL-l0
of gear
-~ _.
Clutch slips Clutch pedal freeplay insufficient Adjust pedal freeplay CL-3
Clutch disc lining oily or worn out Inspect clutch disc CL-l0
Pressure plate faulty Replace clutch cover CL-l0
Release fork binding Inspect release fork CL-l0
CI utch grabs/ chatters Clutch disc lining oily or worn out Inspect clutch disc CL-l0
Pressure plate fa ulty Replace clutch cover CL-l0
Clutch diaphragm spring bent Align clutch diaphragm CL-l0
Engine mounts loose Repair as necessary
Clutch pedal spongy Air in clutch lines Bleed clutch system CL-3
Clutch release cylinder faulty Repair release cylinder CL-8
Clutch master cylinder faulty Repair master cylinder CL-5
CI utch noisy Loose part inside housing Repair as necessary
Release bearing worn or dirty Replace release bearing CL-l0
Pilot bearing worn Replace pilot bearing CL-l0
CLUTCH - Check and Adjustment of Clutch Pedal, Bleeding of Clutch System CL-3
Push Rod Play and Freeplay Adjust Point CHECK AND ADJUSTMENT OF
CLUTCH PEDAL
/;
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet: 171 - 181 mm
(6.73 - 7.13 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT

(a) Loosen the lock nut and turn the stopper bolt until the
~'\j~_ Pedal Height
Adjust Point
height is correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal height, check the pedal
freeplay.
3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD

PLAY ARE CORRECT
Push in on the pedal until the beginning of clutch resistance
Push Rod is felt.
Play
Pedal freeplay: 5 - 15 mm (0.20 - 0.59 in.)
Push rod play at pedal: 1 - 5 mm (0.04 - 0.20 in.)
CL0205
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND

PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the
freeplay and push rod play are correct.
\~( (c) After adjusting the pedal freeplay, check the pedal
/' height.
Pedal Freeplay
BLEEDING OF CLUTCH SYSTEM

NOTE: If any work is done on the clutch system or if air is
suspected in the clutch lines, bleed the system of air.
CAUTION: Do not let brake fluid remain on a painted
surface. Wash it off immediately.
1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID

Check the reservoir frequently. Add fluid if necessary.
2. CONNECT VINYL TUBE TO BLEEDER PLUG

81979
Insert the other end of the tube in a half-full container of

brake fluid.
3. BLEED CLUTCH LINE

(a) Slowly pump the clutch pedal several times.
(b) While depressing the pedal, loosen the bleeder plug
until the fluid starts to run out. Then close the bleeder
plug.
(c) Repeat this procedure until there are no bubbles in the
fluid.
~ CL0004
----J NOTE: Do not reuse the fluid that was bled. It contains air.
CL-4 CLUTCH - Inspection of Clutch Start System
INSPECTION OF CLUTCH START

SYSTEM
CHECK CLUTCH PEDAL
(See page CL-3)
2. CHECK THAT PEDAL FREEPLAY AND PUSH ROD

PLAY ARE CORRECT
(See page CL-3)
CHECK CLUTCH START SYSTEM

CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch
Clearance "A"
pedal is released.
(b) Check that the engine starts when the clutch pedal is
fully depressed.
(c) Check that clearance "A" is greater than 1 mm (0.04
in.) when the clutch pedal is fully depressed.
CLll190
If necessary, adj ust or replace the cl utch start switch.
10.0 ± 0.5 mm (0.394 ± 0.020 in.)

INSPECTION AND ADJUSTMENT OF CLUTCH
START SWITCH
INSPECT CONTINUITY OF CLUTCH START SWITCH
(a) Check that there is continuity between terminals
when the switch is ON (pushed).
(b) Check that there is no continuity between terminals
when the switch is OFF (free).
If continuity is not as specified, replace the switch.
ADJUST CLUTCH START SWITCH

(a) Measure the pedal stroke, and check the switch
clearance "A" using the chart left.
(b) Loosen and adjust the switch position.
CL0154
mm 160.0 '" I (c) Recheck that the engine does not start when the
~
(in.) (6.300)
clutch pedal is released.
155.0 - ,
(6102)
Q)
..::t:.
2
150.0
(5.906)
I
i ~
en ~
I
-co 145.0 I
~
(5.709) I
"'0
Q) j
a... 140.0
(5.512) I I
i I
6.0 8.0 10.0
(0.236) (0.315) (0.394)
Clearance "A" mm(in.) CL0191
CLUTCH - Clutch Master Cylinder CL-5
CLUTCH MASTER CYLINDER

COMPONENTS
Cluster Finish P a n e l - - - - - - - - - · - / I
Combination Meter--~to --Reservoir Cap
No.3 Air Duct NO.1 Air Duct Reservoir Hose
Washer
Union~
•
•
@
(SJ
'6l
J -----,
155(11,15)
Clevis
C~.:
Mounting Bolt
Cylinder
Clevis Pin
Clip Snap Ring
I kg-em (ft-Ib, N·m) I: Specified torque

• Non-reusable part CL0357
REMOVAL OF MASTER CYLINDER

1. DISCONNECT NEGATIVE CABLE FROM BATTERY
2. REMOVE CLUSTER FINISH PANEL

(a) Remove the reservoir cap.
(b) Remove the five screws and pull the panel toward you.
~r
I
I B01868
CL-6 CLUTCH - Clutch Master Cylinder
3. REMOVE COMBINATION METER

(a) Remove the four screws and combination meter.
(b) Disconnect the speedometer cable and wiring con-
nectors.
4. REMOVE NO.3 AIR DUCT
5. REMOVE NO.1 AND NO.2 AIR DUCTS
6. DISCONNECT RESERVOIR HOSE FROM MASTER

801869
CYLINDER, AND PLUG RESERVOIR HOSE
7. REMOVE CLIP AND CLEVIS PIN
8. DISCONNECT CLUTCH LINE UNION

Using SST, disconnect the union.
SST 09751-36011
9. REMOVE MASTER CYLINDER

Remove the mounting bolts and pull out the master
cylinder.
DISASSEMBLY OF MASTER CYLINDER

(See page CL-5)
1. REMOVE PUSH ROD

(a) Pull back the boot, and using a screwdriver, remove
the snap ring.
(b) Pull out the push rod assembly.
2. REMOVE PISTON
L-- CL_OO--'48 Using compressed air, remove the piston from the cylinder.
3. REMOVE UNION
INSPECTION OF MASTER CYLINDER

NOTE: Clean the disassembled parts with compressed air.
1. INSPECT MASTER CYLINDER BORE FOR SCORING
OR CORROSION
If a problem is found, clean or replace the cylinder.
2. INSPECT PISTON AND CUPS FOR WEAR, SCORING,
CRACKS OR SWELLING
If either one requires replacement, use the parts from the
cylinder kit.
3. INSPECT PUSH ROD FOR WEAR OR DAMAGE
If necessary, replace the push rod.
CLUTCH - Clutch Master Cylinder CL·7
~ap Base Glycol Grease

.......... ASSEMBLY OF MASTER CYLINDER
(See page CL-5)
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL

GREASE, AS SHOWN
J H\ \ 2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING

~
~ CLOO10
4. INSTALL UNION
(a) Install the union as shown and tighten the union bolt
by hand.
(b) Torque the union bolt.
INSTALLATION OF MASTER CYLINDER

(See page CL-5)
1. INSTALL MASTER CYLINDER WITH MOUNTING

BOLTS
2. CONNECT RESERVOIR HOSE
3. CONNECT CLUTCH LINE UNION

First finger-tighten the union nut and then tighten it to
specified torque with SST.
SST 09751-36011
4. INSTALL PUSH ROD ASSEMBLY TO CLUTCH PEDAL

Secure the clevis pin with a clip.
5. INSTALL NO.1 AND NO.2 AIR DUCTS
6. INSTALL NO.3 AIR DUCT
7. INSTALL COMBINATION METER

601869
8. INSTALL CLUSTER FINISH PANEL
9. BLEED CLUTCH SYSTEM

(See page CL-3)
10. CHECK FOR LEAKS
11. CHECK AND ADJUST CLUTCH PEDAL

(See page CL·3)
12. CONNECT NEGATIVE CABLE TO BATTERY

CL-8 CLUTCH - Clutch Release Cylinder
CLUTCH RELEASE CYLINDER

COMPONENTS
~ Bleeder Plug
~ 110{8.11) I
Cylinder Spring Piston Boot Push Rod
I kg-cm (ft-Ib, N·m) I: Specified torque CLOOll
REMOVAL OF RELEASE CYLINDER

1. DISCONNECT CLUTCH LINE UNION
Using SST, disconnect the union.
SST 09751-36011
2. REMOVE BOLTS AND PULL OFF RELEASE CYLINDER
DISASSEMBLY OF RELEASE CYLINDER

1. PULL OUT PUSH ROD WITH BOOT
2. REMOVE PISTON AND SPRING

Using compressed air, remove the piston and spring from
the cylinder.
CL0235
INSPECTION OF RELEASE CYLINDER
NOTE: Clean the disassembled parts with compressed air.
1. INSPECT RELEASE CYLINDER BORE FOR SCORING
OR CORROSION
If a problem is found, clean or replace the cylinder.
2. INSPECT PISTON AND CUPS FOR WEAR, SCORING,
CRACKS OR SWELLING
If either one requires replacement, use the parts from the
cylinder kit.
3. INSPECT PUSH ROD FOR WEAR OR DAMAGE
If necessary, replace the push rod.
CLUTCH - Clutch Release Cylinder CL-9
y~
\.' I Lithium Soap Base
Glycol Grease
ASSEMBLY OF RELEASE CYLINDER
(See page CL-8)
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL

GREASE, AS SHOWN
~ 2. INSERT SPRING AND PISTON INTO CYLINDER
~ CL0313
3. INSTALL PUSH ROD WITH BOOT
INSTALLATION OF RELEASE CYLINDER

(See page CL-8)
1. INSTALL RELEASE CYLINDER WITH BOLTS
2. CONNECT CLUTCH LINE UNION

First finger-tighten the union nut and then tighten it to
specified torque with SST.
SST 09751-36011
3. BLEED CLUTCH SYSTEM

(See page CL-3)
4. CHECK FOR LEAKS

CL-10 CLUTCH - Clutch Unit
CLUTCH UNIT
COMPONENTS
Flywheel
Clutch Disc
Release Bearing
Release Fork
Clip Boot
850 (61.83) ~
Pilot Bearing
Clutch Cover Release Bearing Hub
I kg-cm (ft-Ib. N·m) I : Specified torque

CL0356
REMOVAL OF CLUTCH UNIT

1. REMOVE TRANSMISSION
(See page MT-3)
NOTE: Do not drain the transmission oil.
2. REMOVE CLUTCH COVER AND DISC

(a) Place the matchmarks on the clutch cover and fly-
wheel.
D7017
(b) Loosen each set bolt one turn at a time until the spring
tension is released.
(c) Remove the set bolts and pull off the clutch cover and
disc.
3. REMOVE RELEASE BEARING, FORK AND BOOT

FROM TRANSMISSION
(a) Remove the clips and pull off the bearing and hub.
(b) Remove the fork and boot.
CLUTCH - Clutch Unit CL-11
INSPECTION OF CLUTCH PARTS

1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If a problem is found, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT

Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If runout is excessive, replace the disc.
=p ·1
_L~c~~~ ~-. M1257
3. INSPECT FLYWHEEL RUNOUT

Using a dial indicator, check the flywheel runout.
If runout is excessive, replace the flywheel.
08386
4. INSPECT PILOT BEARING

Turn the bearing by hand while applying force in the axial
direction.
If the bearing sticks or has much resistance, replace the
pilot bearing.
07489
5. IF NECESSARY, REPLACE PILOT BEARING

(a) Using SST, remove the pilot bearing.
SST 09303-35011
07490
(b) Using SST, install a new pilot bearing.

SST 09304-3001 2
07491
6. INSPECT DIAPHRAGM SPRING FOR WEAR

Using calipers, measure the diaphragm spring for depth and
width of wear.
Limit: Depth 0.6 mm (0.024 in.)
Width 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING

Turn the bearing by hand while applying force in the axial
direction.
If the bearing sticks or has much resistance, replace the
release bearing.
NOTE: The bearing is permanently lubricated and re-
quires no cleaning or lubrication.
07492
8. IF NECESSARY, REPLACE RELEASE BEARING

(a) Using SST and a press, press out the release bearing
hub from the release bearing.
SST 09315-00010
SST
07608
(b) Using SST and a press, install a new release bearing

to the release bearing hub.
• SST 0931 5-00021

(c) After installing the bearing, check that there is no drag
on the bearing when it is turned under pressure.
07609
CLUTCH - Clutch Unit CL-13
INSTALLATION OF CLUTCH UNIT

(See page CL-10)
Flywheel
1. INSTALL CLUTCH DISC ON FLYWHEEL
Side
Using SST, install the disc on the flywheel.
SST 09301-20020
81998 CL0156
2. INSTALL CLUTCH COVER

(a) Align the matchmarks on the clutch cover and fly-
wheel.
(b) Tighten the bolts evenly and gradually. Make several
passes around the cover until the cover is snug.
Torque the bolts.
NOTE: Tighten the topmost bolt from the three near the
knock pins first.
3. CHECK DIAPHRAGM SPRING TIP ALIGNMENT

Using a dial indicator and measuring point, check the
diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (O.020 in.)
If non-alignment is excessive, adjust as follows.
D8387
4. IF NECESSARY, ADJUST SPRINGS

Using SST, bend the springs until alignment is correct.
SST 09333-00013
D7027
6. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE (NLGI NO.2) OR MP GREASE
(a) Apply molybdenum disulphide lithium base grease to
the following parts:
• Release fork and hub contact point
• Release fork and push rod contact point
• Release fork pivot point
82001 82000
• Clutch disc spline

• Release bearing hub inside groove
(b) Apply MP grease to the front surface of the release

bearing.
E2769
6. INSTALL BOOT, FORK AND RELEASE BEARING ON

TRANSMISSION
7. INSTALL TRANSMISSION
(See page MT-36)
MT-1
MANUAL TRANSMISSION
Page
TROUBLESHOOTING . MT-2
G53 TRANSMISSION . MT-3
Removal of Transmission . MT-3
Components . MT-6
Disassembly of Transmission . MT-8
Inspection of Transmission Components . MT-17
Assembly of Transmission . MT-23
Installation of Transmission . MT-36
SHIFT LEVER AND CONTROL CABLE . MT-39
MT-2 MANUAL TRANSMISSION - Troubleshooting
TROUBLESHOOTING
Hard to shift or will Splines on input shaft dirty or burred Repair as necessary
not shift Transmission faulty Disassemble and inspect MT-6
tra nsm ission
Transmission jumps Transmission faulty Disassemble and inspect MT-6

out of gear transmission
MANUAL TRANSMISSION - G53 Transmission MT-3
G53 TRANSMISSION
REMOVAL OF TRANSMISSION
1. DISCONNECT BATTERY CABLE FROM NEGATIVE
TERMINAL
2. RAISE VEHICLE
3. DRAIN TRANSMISSION OIL
4.-1 (2WD)
REMOVE PROPELLER SHAFT
Matchmarks
(a) Place the matchmarks on the differential and propeller
shaft flanges.
(b) Remove the four bolts and nuts, disconnect the
propeller shaft from the differential.
(c) Pull out the propeller shaft yoke from the transmission
and insert SST into the extension housing.
SST 09325-20010
PROOOl
4.-2 (4WD)
REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR-4)
Matchmarks
\ PR0124
5. DISCONNECT BACK-UP LIGHT SWITCH CONNECTOR
MT0230
6. (4WD)
DISCONNECT TRANSFER INDICATOR SWITCH
CONNECTOR
MT031 a
MT-4 MANUAL TRANSMISSION - G53 Transmission
2WD 4WD 7. DISCONNECT SPEEDOMETER CABLE AND GROUND

STRAP
MT0319 MT0239
8. DISCONNECT TRANSMISSION CONTROL CABLES

(a) Remove the nuts.
(b) Remove thE3 retainers from the bracket.
9. (4WD)
DISCONNECT TRANSFER CONTROL CABLE
(a) Disconnect the clip and washer.
(b) Remove the retainer from the bracket.
E0848
10. REMOVE CLUTCH RELEASE CYLINDER
MT0233
11. DISCONNECT EXHAUST FRONT PIPE

(a) Remove the exhaust front pipe clamp from the bracket.
(b) Disconnect the exhaust front pipe from the exhaust
manifold.
12. REMOVE STARTER AND CONTROL CABLE BRACKET
MT0234
13.-1 (2WD)
JACK UP TRANSMISSION SLIGHTLY
Raise the transmission enough to remove the weight from
the rear mounting.
13.-2 (4WD)
JACK UP TRANSMISSION AND TRANSFER SLIGHTLY
Raise the transmission and transfer enough to remove the
weight from the rear mounting.
MT0299
'I~ /, 14.-1 (2WD)

l .~ DISCONNECT ENGINE REAR MOUNTING
14.-2 (4WD)
REMOVE ENGINE REAR MOUNTING BOLT
15. REMOVE TRANSMISSION MOUNTING BOLTS
16.-1 (2WD)
REMOVE TRANSMISSION
Pullout the transmission down and toward the rear.
16.-2 (4WD)
L-- MT0314
---J REMOVE TRANSMISSION WITH TRANSFER
Pull out the transmission with the transfer toward the rear.
17. (4WD)
REMOVE TRANSFER FROM TRANSMISSION
(a) Remove the engine rear mounting.
MT0237
(b) Stand the transmission with the transfer and remove

the transfer mounting bolts.
(c) Pull the transfer straight up and remove it from the
transmission.
MT0238
COMPONENTS
\~--Extension Housing
(4WD)
Front Bearing Retainer

380 (27,37)
Synchronizer Ring
Rear Bearing Retainer
Input Shaft
'~~
e~---4.·1 1,200 (87,118)
.~
~ ~~)
~~ 1 No.5 Gear Spline Piece
Counter Gear 0 ~~~ Synchronizer Ring
l.~ 1 Spacer Counter 5th Gear

~!,? Counter Rear
~' Bearing
*Straight Screw Plug r;;J ~
Spring
Ball
'J ~
\ 0
No.1 Shift Fork Shaft... ~ - - - - - - - - - - N o . 1 Shift Fork
1st and 2nd Shift~ @> ... ~~-----------NO.2 Shift Fork Shaft
Head ~" .. Q10"" Reverse Shift Fork
~
0 ///~ReverseShiftArmBracket
No.2 Shift Fork :J '" t't> IIIJo... .-
',- ~ \ ~
No.3 Shift Fork Shaft 1;) ~, ~Reverse Shift Arm
~ lIf)
Reverse Shift Head ~ ~

oo~
!
.° ~ ~,-
(;r\
0
~
'• ( _
No.3 Shift Fork
~ No.4 Shift Fork Shaft

Ikg-cm (ft-Ib, N.m)1 : Specified torque
* Precoated part GM0302
MANUALT RANSMISSION - G53 Trans miSSion
" .
COMPONEN TS (Con1'd)
.,.~~ <Jl Shift Outer Lever
Select Outer L
ever~ ~ t;---j-;;~~and <Jl
U
Select Lever
1?J. *
~:
lD'" e
~
~ H~: l }r
~
I
~r--; ~~';
__ and Sp'
Restrict Pin
Reverse Idler Gear and Shaft Rever5e
... _>
r;;, r J
Shift ..• -.: rmg
ever
and Select~
Seat~ ~ :
rc
--
__ ~~V.·-
~~;"S Vl\ HhiftLeverShatt
Cll oil'L . ,,-,,: ? ",,-. - ousing
~;I))~,~) ~ ~SP"ng---'j'QO;.
I
Input Shaft
Synchronizer R"
mg (4WD)
2?I
Select Lever Shaft
-
Output Shaft
Synchronizer R" (2WD)
~W\·\~~1
No 2 H 3rd Gear
speedomlDrive Gear
N " u b Sleeve Inner Race
,~ ~2WD~
o. 2 Clutch Hub
S No.1 Clutch H S:nchronizer Ring
5th Gear
I I
No " 1 Hub Sleeve 15t Gear
2 nd Gear
DISASSEMBLY OF TRANSMISSION
(See pages MT-6,7)
1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH AND

SPEEDOMETER DRIVEN GEAR (2WD)
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION

CASE
r GM0245
4. REMOVE SHIFT LEVER SHAFT HOUSING ASSEMBLY
GM0270
5.-1 (2WD)
REMOVE EXTENSION HOUSING
NOTE: Leave the gasket attached to the intermediate
plate.
'" ~ GM0271
5.-2 (4WD)
REMOVE TRANSFER ADAPTOR
plate.
GM0307
6. REMOVE FRONT BEARING RETAINER
GM0308
7. REMOVE BEARING SNAP RINGS

Using snap ring pliers, remove the two snap rings.
GM0012
8. SEPARATE INTERMEDIATE PLATE FROM

TRANSMISSION CASE
(a) Using a plastic hammer, carefully tap off the trans-
mission case.
(b) Remove the transmission case from the intermediate
plate.
plate.
GM0272
9. MOUNT INTERMEDIATE PLATE IN VISE

(a) Use the two clutch housing bolts, plate washers and
suitable nuts as shown.
CAUTION: Install the plate washers in reverse of
normal position. Increase or decrease plate washers so
that the bolt tip and front tip surface of the nut are
aligned.
(b) Mount the intermediate plate in a vise.
GM0212
10. REMOVE STRAIGHT SCREW PLUGS, LOCKING

BALLS AND SPRINGS
(a) Using a torx socket wrench, remove the four plugs.
,~ GM0273
(b) Using a magnetic finger, remove the springs and balls.
GM0309
11. REMOVE SLOTTED SPRING PINS AND BOLT

(a) Using a pin punch and hammer, drive out the four
pins.
GM0274
(b) Remove the bolt from NO.1 shift fork.
12. REMOVE E-RINGS

Using a screwdriver, remove the four E-rings.
13. REMOVE NO.4 SHIFT FORK SHAFT AND NO.3 SHIFT

FORK
(a) Pullout No.4 shift fork shaft from the intermediate
plate.
(b) Remove No.3 shift fork.
(c) Using a magnetic finger, remove the locking balls from
the reverse shift head and intermediate plate.
GM0210
14. REMOVE REVERSE SHIFT HEAD

15. REMOVE NO.3 SHIFT FORK SHAFT

(a) Pullout No.3 shift fork shaft from the intermediate
plate.
(b) Using a magnetic finger, remove the interlock pins
from the shaft and intermediate plate.
GM0278
16. REMOVE NO.2 SHIFT FORK SHAFT

(a) Pull out No. 2 shift fork shaft from the intermediate
plate.
(b) Using a magnetic finger, remove the interlock pins
from the shaft and intermediate plate.
17. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 AND NO.2

SHIFT FORKS AND FIRST AND SECOND SHIFT HEAD
Pull out No.1 shift fork shaft and remove No.1 and No.2
shift forks and 1st and 2nd shift head.
GM0280
18. REMOVE REVERSE IDLER GEAR AND SHAFT

(a) Remove the reverse idler gear shaft stopper.
(b) Remove the reverse idler gear and shaft.
GMOO26
19. REMOVE REVERSE SHIFT ARM FROM REVERSE

SHIFT ARM BRACKET
GMOO27
20. MEASURE COUNTER FIFTH GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust
clearance.
(0.0039 - 0.0118 in.)
GM0028
21. REMOVE NO.5 GEAR SPLINE PIECE,

SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS
AND COUNTER FIFTH GEAR WITH NO.3 HUB SLEEVE
(a) Engage the gear double meshing.
(b) Using a hammer and chisel, loosen the staked part of
the nut.
GMOO29
(c) Remove the lock nut.

(d) Disengage the gear double meshing.
GM0030
(e) Using SST, remove No. 5 gear spline piece, syn-

chronizer ring, needle roller bearings and counter 5th
gear.
SST 09213-27010
22. REMOVE SPACER AND BALL

(a) Remove the spacer.
(b) Using a magnetic finger, remove the ball.
GM0033
23. REMOVE REVERSE SHIFT ARM BRACKET

Remove the two bolts and reverse shift arm bracket.
GMOO34
24. REMOVE REAR BEARING RETAINER

Using a torx socket wrench, remove the four screws.
I
\ '
1 GM0035
25. REMOVE BEARING SNAP RING

Using snap ring pliers, remove the snap ring.
GMOO36
26. REMOVE OUTPUT SHAFT, COUNTER GEAR AND

INPUT SHAFT AS A UNIT FROM INTERMEDIATE
PLATE
(a) Remove the output shaft, counter gear and input shaft
as a unit from the intermediate plate by pulling on the
counter gear and tapping on the intermediate plate
with a plastic hammer.
(b) Remove the input shaft with the 13 needle roller
bearings from the output shaft.
GMOO37
27. REMOVE COUNTER REAR BEARING FROM

SST INTERMEDIATE PLATE
Using SST, remove the counter rear bearing.
SST 09608-12010 (09608-00020, 09608-00050)
GM0230
28. (2WD)
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using snap ring pliers, remove the rear snap ring.
(b) Remove the speedometer drive gear.
(c) Using a magnetic finger, remove the steel ball.
(d) Using snap ring pliers, remove the front snap ring.
GMOO38
29. MEASURE EACH GEAR THRUST CLEARANCE

3rd
Measure the thrust clearance of each gear.
(0.0039 - 0.0098 in.)
1 st 2nd GM0040
30. REMOVE FIFTH GEAR, REAR BEARING, FIRST GEAR,

INNER RACE AND NEEDLE ROLLER BEARING
(a) Using two screwdrivers and a hammer, tap out the
snap ring.
GM0041
(b) Using a press, remove the 5th gear, rear bearing, 1st
gear and inner race.
(c) Remove the needle roller bearing.
(d) Remove the synchronizer ring.
GM0282
31. REMOVE LOCKING BALL

Using a magnetic finger, remove the locking ball.
/
GMOO45
32. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND

SECOND GEAR
(a) Using a press, remove NO.1 hub sleeve, synchronizer
ring and 2nd gear.
(b) Remove the needle roller bearing.
GM0283
33. REMOVE NO.2 HUB SLEEVE ASSEMBLY AND THIRD

GEAR
(a) Using snap ring pliers, remove the snap ring.
GMOO47
(b) Using a press, remove NO.2 hub sleeve, synchronizer

ring and 3rd gear.
(c) Remove the needle roller bearing.
WMOO55
34. REMOVE SELECT OUTER LEVER AND LEVER SHAFT

(a) Remove the lever lock pin and nut.
(b) Remove the select outer lever, plate washer and lever
shaft from the shift lever shaft housing.
GM0304
35. REMOVE SHIFT OUTER LEVER AND BOOT

Remove the lever lock pin and pull out the shift outer lever
and boot.
GM0284
36. REMOVE SHIFT AND SELECT LEVER AND SHAFT

(a) Using a pin punch and hammer, drive out the slotted
spring pin.
GM0285
\
(b) Remove the shift and select lever and shaft.
'\
'\
GM0286
37. REMOVE SEAT AND COMPRESSION SPRING

~-~~
r----r
/\_---
/
GM0247
38. REMOVE REVERSE RESTRICT PIN AND

COMPRESSION SPRING
(a) Using a hammer, drive a screw extractor into the
slotted spring pin. Pull out the slotted spring pin.
GM0250
(b) Remove the reverse restrict pin and compression

spring.
GM0251
INSPECTION OF TRANSMISSION
COMPONENTS
1. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using calipers, measure the output shaft flange
thickness.
GM0048
(b) Using calipers, measure the inner race flange thick-

ness.
GM0287
(c) Using a micrometer, measure the outer diameter of

the output shaft journal.
Minimum diameter:
2nd gear 37.984 mm (1.4954 in.)
3rd gear 34.984 mm (1.3773 in.)
GMOO49
(d) Using a micrometer, measure the outer diameter of

the inner race.
Minimum diameter: 38.985 mm (1.5348 in.)
WMOO59
(e) Using a dial indicator, check the shaft runout.

GM0288
2. CHECK OIL CLEARANCE OF FIRST GEAR

Using a dial indicator, measure the oil clearance between
the gear and inner race with the needle roller bearing
installed.
(0.0004 - 0.0013 in.)
If the clearance exceeds the limit, replace the gear, inner
race or needle roller bearing.
WM0061
3. CHECK OIL CLEARANCE OF SECOND, THIRD AND

COUNTER FIFTH GEARS
the gear and shaft with the needle roller bearing installed.
Standard clearance:
2nd and 3rd gears 0.009 - 0.033 mm
(0.0004 - 0.0013 in.)
Counter 5th gear 0.009 - 0.032 mm
(0.0004 - 0.0013 in.)
L-- GM0051
-----J Maximum clearance:
2nd and 3rd gears 0.033 mm (0.0013 in.)
Counter 5th gear 0.032 mm (0.0013 in.)
If the clearance exceeds the limit, replace the gear, needle
roller bearing or shaft.
4. INSPECT SYNCHRONIZER RINGS

(a) Turn the ring and push it in to check the braking
action.
(b) Measure the clearance between the synchronizer ring

back and the gear spline end.
(0.039 - 0.079 in.)
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the limit, replace the syn-
chronizer ring.
5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB

SLEEVES
hub sleeve and shift fork.
If the clearance exceeds the limit, replace the shift fork or
hub sleeve.
WMOO66
6. IF NECESSARY, REPLACE INPUT SHAFT BEARING

WM0266
(b) Using a press, remove the bearing.
WM0267
(c) Using SST and a press, install a new bearing.

SST 09506-35010
SST
III
WM0268
(d) Select a snap ring that will allow minimum axial play
and install it on the shaft.
Mark Thickness mm(in.)
0 2.05 - 2.10 (0.0807 - 0.0827)

1 2.10-2.15 (0.0827 - 0.0846)
2 2.15 - 2.20 (0.0846 - 0.0866)
3 2.20 - 2.25 (0.0866 - 0.0886)
4 2.25 - 2.30 (0.0886 - 0.0906)
WM0269 5 2.30 - 2.35 (0.0906 - 0.0925)
7. IF NECESSARY, REPLACE FRONT BEARING

RETAINER OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
ri
/ I
GM0310
(b) Using SST, drive in a new oil seal.

SST 09223-50010
Drive in depth: 12.2 - 13.2 mm (0.480 - 0.520 in.)
Transmission case installation surface
SST---t i
(c) Coat the lip of the oil seal with MP grease.
GM0311
8. IF NECESSARY, REPLACE COUNTER GEAR FRONT

BEARING
-1 SST (b) Using SST and a socket wrench, press out the bearing.
r---- SST 09950-00020
t-
(c) Replace the side race.
D6623
(d) Using a socket wrench, press in the bearing and inner

race.
---j
--l
1 -
--}-~-~
RM0013
(e) Select a snap ring that will allow minimum axial play
and install it on the shaft.

1 2.05 - 2.10 (0.0807 - 0.0827)
2 2.10- 2.15 (0.0827 - 0.0846)
3 2.15 - 2.20 (0.0846 - 0.0866)
4 2.20 - 2.25 (0.0866 - 0.0886)
5 2.25 - 2.30 (0.0886 - 0.0906)
WMoon 6 2.30 - 2.35 (0.0906 - 0.0925)
9. (2WD)
IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921 -00010
WM0108
(b) Using SST, drive in a new oil seal into the sleeve.
SST 09201 -60011
20 mm Drive in depth: 20 mm (0.79 in.)
k=sB~=
I
SST
WM0109
10. IF NECESSARY, REPLACE SELECT OUTER LEVER OIL

SEAL
GM0289
(b) Using a socket wrench and hammer, drive in a new oil

seal.
GM0290
11. IF NECESSARY, REPLACE SHIFT OUTER LEVER OIL

SEAL
GM0237

seal.
GM0236
12. (2WD)
SST
IF NECESSARY, REPLACE EXTENSION HOUSING OIL
SEAL AND BUSHING
SST 09308-00010 or
09308-10010 with output shaft installed
(b) Heat the extension housing end to 80 - 100°C (176
- 212°F) in an oil bath.
WMOll0
(c) Using SST, remove the bushing and install a new

SST bushing.
SST 09307-30010
WMOlll
(d) Using SST, drive in a new oil seal.

SST SST 09325-20010
(e) Coat the lip of the oil seal with MP grease.
WM0112
ASSEMBLY OF TRANSMISSION
(See pages MT-6,7)
1. INSTALL REVERSE RESTRICT PIN AND

COMPRESSION SPRING
(a) Install the reverse restrict pin and compression spring.
GM0291
(b) Using a pin punch and hammer, drive in the slotted

spring pin.
GM0248
2. INSTALL SEAT AND COMPRESSION SPRING
GM0247
3. INSTALL SHIFT AND SELECT LEVER AND SHAFT

(a) Install the shift and select lever and shaft to the shift
lever shaft housing.
NOTE: One of the spline teeth of the shaft has been
eliminated. Therefore, be certain to correctly align this
portion to the matching portion on the lever during
assembly.
GM0286

spring pin.
GM0285
4. INSTALL SHIFT OUTER LEVER AND BOOT

Install the shift outer lever and boot to the shaft with the
lever lock pin and nut. Torque the nut.
GM0284
5. INSTALL SELECT OUTER LEVER AND LEVER SHAFT

Install the select outer lever, plate washer and lever shaft
with the lever lock pin and nut. Torque the nut.
GM0304
6. INSERT NO.1 AND NO.2 CLUTCH HUBS INTO HUB

SLEEVES
(a) Install the clutch hub and shifting keys to the hub
sleeve.
. . Front (b) Install the shifting key springs under the shifting keys.
CAUTION: Install the key springs positioned so that
their end gaps are not in line.
NO.1 No.2
GM0059
7. INSTALL THIRD GEAR AND NO.2 HUB SLEEVE

ASSEMBLY ON OUTPUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys.
(c) Install the needle roller bearing in the 3rd gear.
WM0114
(d) Using SST and a press, install the 3rd gear and NO.2
hub sleeve.
SST 09506-35010
SST
GM0292
8. INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play.

---- -~---~-- -f---~-~~- - ----~~~~~~~~---~-.~~
C-1 1.75 - 1.80 (0.0689 - 0.0709)

D 1.80 - 1.85 (0.0709 - 0.0728)
D-1 1.85 - 1.90 (0.0728 - 0.0748)
E 1.90 - 1.95 (0.0748 - 0.0768)
E-1 1.95 - 2.00 (0.0768 - 0.0787)
WM0116
F 2.00 - 2.05 (0.0787 - 0.0807)
F-1 2.05 - 2.10 (0.0807 - 0.0827)
(b) Using snap ring pliers, install the snap ring.
GM0047
9. MEASURE THIRD GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 3rd gear thrust
clearance.
(0.0039 - 0.0098 in.)
10. INSTALL SECOND GEAR AND NO.1 HUB SLEEVE

ASSEMBLY
(b) Place the synchronizer ring on the gear and align the
ring slots with the shifting keys.
(c) Install the needle roller bearing in the 2nd gear.
GMOO61
(d) Using SST and a press, install the 2nd gear and NO.1
hub sleeve.
SST 09316-60010 (09316-00020)
GM0293
11. INSTAll lOCKING BAll AND FIRST GEAR

ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the needle roller bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller
bearing and bearing inner race.
GM0063
(d) Install the assembly on the output shaft with the

synchronizer ring slots aligned with the shifting keys.
(e) Turn the inner race to align it with the locking ball.
GM0064
12. INSTAll OUTPUT SHAFT REAR BEARING

Using SST and a press, install the bearing on the output
shaft with the outer race snap ring groove toward the rear.
NOTE: Hold the 1st gear inner race with a screwdriver to
prevent it from falling.
SST 09316-60010 (09316-00020)
1 __ .----55T
GM0294
13. MEASURE FIRST AND SECOND GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the 1st and 2nd gear thrust
clearance.
(0.0039 - 0.0098 in.)
2nd GMOO40
14. INSTALL FIFTH GEAR

Using SST and a press, install the 5th gear.
SST 09506-35010

Mark Thickness mm(in.) Mark Thickness mm(in.)
A 2.67-2.72(0.1051 -0.1071) G 3.03 - 3.08 (0.1193 - 0.1213)

B 2.73 - 2.78 (0.1075 - 0.1094) H 3.09 - 3.14 (0.1217 - 0.1236)
C 2.79 - 2.84 (0.1098 - 0.1118) J 3.15 - 3.20 (0.1 240 - 0.1260)
D 2.85 - 2.90 (0.1122 - 0.1142) K 3.21 - 3.26 (0.1264 - 0.1 283)
E 2.91 - 2.96 (0.1146 - 0.1165) L 3.27 - 3.32 (0.1287 - 0.1307)
F 2.97 - 3.02 (0.1169 - 0.1189)
GM0067
(b) Using a screwdriver and hammer, install the snap

ring.
GM0068
16. (2WD)
INSTALL SPEEDOMETER DRIVE GEAR
(a) Using snap ring pliers, install the front snap ring.
(b) Install the ball and drive gear.
(c) Using snap ring pliers, install the rear snap ring.
GMOO38
17. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE

Install the output shaft into the intermediate plate by pulling
on the output shaft and tapping on the intermediate plate.
GM0295
18. INSTALL INPUT SHAFT

(a) Apply MP grease to the 13 needle roller bearings and
install them into the input shaft.
GMOOn
(b) Install the input shaft to the output shaft with the
synchronizer ring slots aligned with the shifting keys.
GM0074
19. INSTALL COUNTER GEAR

Install the counter gear into the intermediate plate while
holding the counter gear, and install the counter rear
bearing with a plastic hammer.
GM0312
20. INSTALL BEARING SNAP RING

Using snap ring pliers, install the snap ring.
NOTE: Be sure the snap ring is flush with the inter-
mediate plate surface.
GM0036
21. INSTALL REAR BEARING RETAINER

Using a torx socket wrench, install and torque the screws.
GM0035
22. INSTALL REVERSE SHIFT ARM BRACKET

Install the reverse shift arm bracket and torque the bolts.
Torque: 185 kg-ern (13 ft-Ib, 18 N'm)
GMOO34
23. INSTALL BALL AND SPACER
GM0239
24. INSERT COUNTER FIFTH GEAR INTO NO.3 HUB

SLEEVE
(a) Install the shifting keys and No.3 hub sleeve onto the
counter 5th gear.
_ Front (b) Install the shifting key springs under the shifting keys.
GM0077
25. INSTALL COUNTER FIFTH GEAR WITH NO.3 HUB

SLEEVE ASSEMBLY AND NEEDLE ROLLER
BEARINGS
(a) Apply gear oil to the needle roller bearings.
(b) Install the counter 5th gear with No.3 hub sleeve and
needle roller bearings.
GMOO78
26. INSTALL SYNCHRONIZER RING, NO.5 GEAR SPLINE

PIECE AND LOCK NUT
(a) Engage the gear double meshing.
(b) Install the synchronizer ring onto No. 5 gear spline
piece.
GMOO29
(c) Align the synchronizer ring slots with the shifting keys.
Install a new lock nut on the end of the counter gear
and press fit the gear spline piece to the counter gear.
Torque: 1,200 kg-em (87 ft-Ib, 118 N 'm)
(d) Stake the lock nut.
GMOO30
(e) Disengage the gear double meshing.
GM0029
27. MEASURE COUNTER FIFTH GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust
clearance.
(0.0039 - 0.0118 in.)
GMOO28
28. INSTALL REVERSE SHIFT ARM TO REVERSE SHIFT

ARM BRACKET
Install the reverse shift arm to the pivot of the reverse shift
arm bracket.
GMOO27
29. INSTALL REVERSE IDLER GEAR AND SHAFT

(a) Install the reverse idler gear on the shaft.
(b) Align the reverse shift arm shoe to the reverse idler
gear groove and insert the reverse idler gear shaft to
the intermediate plate.
(c) Install the reverse idler gear shaft stopper and torque
the bolt.
GMOO26
30. INSTALL NO.1 SHIFT FORK SHAFT, NO.1 AND NO.2

SHIFT FORKS AND FIRST AND SECOND SHIFT HEAD
Place No.1 and No.2 shift forks into the groove of NO.1 and
NO.2 hub sleeves, and install No.1 fork shaft to NO.1 fork
and the 1st and 2nd shift head through the intermediate
plate.
GM0280
c GM0296
31. INSTALL NO.2 SHIFT FORK SHAFT
a (a) Apply MP grease to the interlock pins.

o o (b) Using a magnetic finger and screwdriver, install the
o
a interlock pin into the intermediate plate.
7~ GM0081 GMOO82
(c) Install the interlock pin into the shaft hole.
GM0265
GM02S8
(d) Install No.2 fork shaft to No.2 shift fork through the
intermediate plate.
32. INSTALL NO.3 SHIFT FORK SHAFT

(a) Using a magnetic finger and screwdriver, install the
interlock pin into the intermediate plate.
GM0266
(b) Install the interlock pin into the shaft hole.
Ct @b GM0305
GM0299
(c) Install No.3 fork shaft to the reverse shift arm through
the intermediate plate.
GM0306
33. INSTALL NO.4 SHIFT FORK SHAFT, NO.3 SHIFT

FORK AND REVERSE SHIFT HEAD
(a) Using a magnetic finger and screwdriver, insert the
locking ball into the intermediate plate.
GM0267
(b) Place No. 3 shift fork into the groove of No. 3 hub
sleeve and install NO.4 fork shaft to No.3 shift fork.
C;" iIl>\D r 9GM0210

""'--~_--------"-----~GM0303
(c) Install the reverse shift head to No.3 fork shaft.
(d) Using a magnetic finger and screwdriver, insert the

locking ball into the reverse shift head hole and install
NO.4 fork shaft to the reverse shift head.
- -', GM0200
34. CHECK INTERLOCK

(a) Shift No.1 fork shaft to the 1st speed position.
(b) No.2, NO.3 and No.4 fork shafts should not move.
35. INSTALL SLOTTED SPRING PINS AND BOLT

(a) Install the bolt to No.1 shift fork.
GM0275

spring pins to the reverse shift arm, 1st and 2nd shift
head, No.2 and NO.3 shift forks.
GM0274
36. INSTALL E-RINGS

Using pliers, install the four E-rings.
-<) GM0300
37. INSTALL LOCKING BALLS, SPRINGS AND STRAIGHT

SCREW PLUGS
(a) Apply sealant to the plug threads.
Sealant: Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the locking balls, springs and screw plugs, and
then torque the screw plugs with a torx socket
wrench.
NOTE: Install the short spring into the bottom of the
intermediate plate.
38. REMOVE INTERMEDIATE PLATE FROM VISE

(a) Remove the intermediate plate from the vise.
(b) Remove the bolts, nuts, plate washers and gaskets.
39. INSTALL TRANSMISSION CASE WITH NEW GASKET

TO INTERMEDIATE PLATE
Align each bearing outer race, each fork shaft end and
reverse idler gear shaft end with the case installation holes,
and install the case. If necessary, tap on the case with a
plastic hammer.
40. INSTALL BEARING SNAP RINGS

Using snap ring pliers, install the two snap rings.
GMOO12
41. INSTALL FRONT BEARING RETAINER WITH NEW

GASKET
(a) Install the bearing retainer with a new gasket.
(b) Apply sealant to the bolt threads.
(c) Install and torque the bolts.
42.-1 (2WD)
INSTALL EXTENSION HOUSING WITH NEW GASKET
(a) Install a new gasket to the intermediate plate.
(b) Install the extension housing and torque the bolts.
GM0165
42.-2 (4WD)
INSTALL TRANSFER ADAPTOR WITH NEW GASKET
(a) Install a new gasket to the intermediate plate.
(b) Apply sealant to the three bolt threads of adaptor
inner.
(c) Install the transfer adaptor and torque the bolts.
GM0307
43. INSTALL SHIFT LEVER SHAFT HOUSING ASSEMBLY

WITH NEW GASKET
(a) Install a new gasket to the transmission case.
(b) Apply sealant to the threads of all bolts except the two
L-j)=J black bolts.
1l..lI-+f-*-..:::...Black
Bolts LOCTITE 242 or equivalent
(c) Install the shift lever shaft housing and torque the
bolts.
GM0270
44. AFTER INSTALLING SHIFT LEVER SHAFT HOUSING,

CHECK FOLLOWING ITEMS:
(a) Check to see that the input shaft and output shaft
rotate smoothly.
(b) Check to see that shifting can be made smoothly to all
positions.
45. INSTALL CLUTCH HOUSING

(a) Install the clutch housing.
(b) Install and torque the bolts.
Torque: 380 kg-em (27 ft-Ib, 37 N 'm)
46. INSTALL BACK-UP LIGHT SWITCH

47. (2WD)
INSTALL SPEEDOMETER DRIVEN GEAR
48. INSTALL RELEASE FORK AND BEARING

the following parts:
• Release bearing hub inside groove
• Input shaft spline
• Release fork contact surface
(b) Apply MP grease to the front surface of the release
bearing.
INSTALLATION OF TRANSMISSION
1. (4WD)
INSTALL TRANSFER TO TRANSMISSION WITH NEW
GASKET
(a) Place a new gasket to the transfer adaptor.
(b) Install the transfer to the transmission.
(c) Apply sealant to the two front bolt threads.
< ) Sealant: Part No. 08833-00080, THREE BOND 1344,

MT0238 LOCTITE 242 or equivalent
(d) Install and torque the bolts.
(e) Install the engine rear mounting.
2. PLACE TRANSMISSION AT INSTALLATION POSITION

AND INSTALL TRANSMISSION MOUNTING BOLTS
(a) Align the input shaft spline with the clutch disc, and
push the transmission fully into position.
MT0237 (b) Install and torque the transmission mounting bolts.
'--------------------'
Torque:
Transmission mounting bolt 730 kg-em
(53 ft-Ib, 72 N'm)
Stiffener plate bolt 380 kg-em (27 ft-Ib, 37 N'm)
3.-1 (2WD)
CONNECT ENGINE REAR MOUNTING
MT0317
3.-2 (4WD)
INSTALL ENGINE REAR MOUNTING BOLT
4. INSTALL STARTER AND CONTROL CABLE BRACKET
MT0314
5. CONNECT EXHAUST FRONT PIPE

(a) Connect the exhaust front pipe to the exhaust
manifold.
(b) Install the exhaust front pipe clamp to the bracket.
MT0234
6. INSTAll CLUTCH RELEASE CYLINDER
MT0233
7. (4WD)
CONNECT TRANSFER CONTROL CABLE
(a) Install the control cable to the bracket and clip.
(b) Connect the control cable to the outer lever.
E0848
8. CONNECT TRANSMISSION CONTROL CABLES

(a) Install the control cables to the bracket and clip.
(b) Connect the control cables to the outer levers.
2WD 4WD 9. CONNECT SPEEDOMETER CABLE AND GROUND

STRAP
MT0319 MT0239
10. (4WD)
CONNECT TRANSFER INDICATOR SWITCH
CONNECTOR
MT0318
11. CONNECT BACK-UP LIGHT SWITCH CONNECTOR
MT0230
12.-1 (2WD)
Matchmarks INSTALL PROPELLER SHAFT
(a) Remove SST and insert the yoke into the transmission.
SST 09325-20010
(b) Align the match marks on the flanges and connect the
propeller shaft with the four blots and nuts.
(c) Torque the bolts and nuts.
PROOOl
12.-2 (4WD)
INSTALL FRONT AND REAR PROPELLER SHAFTS
(See page PR-6)
Matchmarks
PR0124
13. FILL TRANSMISSION WITH OIL

Capacity:
14. LOWER VEHICLE
15. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL
16. PERFORM ROAD TEST

Check for abnormal noise or operation.
MANUAL TRANSMISSION - Shift Lever and Control Cable MT-39
SHIFT LEVER AND CONTROL CABLE

COMPONENTS
Shift Lever
Select Control Cable
Shift Control Cable
MT0321
ADJUSTMENT OF SHIFT LEVER NEUTRAL

POSITION
1. REMOVE CONSOLE ASSEMBLY
2. CONFIRM THAT SHIFT LEVER IS IN NEUTRAL

POSITION
3. CHECK SHIFT LEVER NEUTRAL POSITION

Check that the guide pin inserts smoothly into the shift lever
MT0320 retainer hole and shift lever inspection hole.
NOTE: Use a 6 mm (0.24 in.) diameter guide pin.
f\,
' 4. IF NECESSARY, ADJUST SHIFT LEVER NEUTRAL
POSITION
(a) Loosen the adjusting nut lock nuts and adjust the
length of the select control cable so that the guide pin
inserts smoothly into the holes.
(b) Tighten the lock nuts.
5. INSTALL CONSOLE ASSEMBLY

MT0320
AT-1
AUTOMATIC
TRANSMISSION
Page
THOUBLESHOOTING . AT-2
ATF INSPECTION . AT-4
ADJUSTMENTS . AT-4
TESTS . AT-5
AUTOMATIC SHIFT DIAGRAM . AT-13
ELECTRIC CONTROL . AT-14
ON-VEHICLE REPAIR . AT-19
REMOVAL OF TRANSMISSION (2WD) . AT-30
REMOVAL OF TRANSMISSION (4WD) . AT-33
DISASSEMBLY OF TRANSMISSION . AT-37
COMPONENT GROUP DISASSEMBLY,
INSPECTION AND ASSEMBLY . AT-43
Oil pump . AT-44
Overdrive Input Shaft and Clutch . AT-47
Overdrive Case and Brake . AT-52
Front Clutch . AT-55
Rear Clutch '" . AT-59
Center Support Assembly . AT-62
Planetary Gear Output Shaft . AT-68
Transmission Case and Rear Brake Pistons . AT-73
Valve Body . AT-76
Governor Body . AT-99
Extension Housing (2WD) . AT-101
Torque Converter . AT-101
Electrical Parts . AT-102
ASSEMBLY OF TRANSMISSION . AT-103
INSTALLATION OF TRANSMISSION (2WD) AT-114
INSTALLATION OF TRANSMISSION (4WD) .... AT-118
AT-2 AUTOMATIC TRANSMISSION - Troubleshooting
TROUBLESHOOTING
f------ ---",---- ~-- --- --._--._---------- - _ . ~ - - - _ .
--I--
Fluid discolored or Fluid contaminated Replace fluid MA-11

smells burnt Torque converter faulty Replace torque converter
Transmission faulty Disassemble and inspect AT-37
transmission
Vehicle does not move Manual shift cable out of adjustment Adjust shift cable ATA
in any forward range Valve body or primary regulator faulty Inspect valve body AT-19,76
or reverse
Parking lock pawl faulty Inspect parking lock pawl AT-23
Torque converter faulty Replace torque converter

Converter drive plate broken Replace drive plate AT-114, 118
Oil pump intake strainer blocked Clean strainer AT-19
Shift lever position Manual shift cable out of adjustment Adjust shift cable AT-4
incorrect Manual valve and lever faulty Inspect valve body AT-19,76

transmission
Harsh engagement Throttle cable out of adjustment Adjust throttle cable AT-4
into any drive range Valve body or primary regulator faulty Inspect valve body AT-19,76
Accumulator pistons faulty Inspect accumulator pistons AT-110
transmission
Delayed 1-2, 2-3 or Throttle cable out of adjustment Adjust throttle cable AT-4
3-00 up-shift, or Throttle cable and cam faulty Inspect throttle cable and cam AT-22
down-shifts from OD-3
Governor faulty Inspect governor AT-99
or 3-2 then shifts back
to 00 or 3 Valve body faulty Inspect valve body AT-29,76
Slips on 1 -2, 2-3 or Manual shift cable out of adjustment Adjust shift cable AT-4
3-00 up-shift, or Throttle cable out of adjustment Adjust throttle cable AT-4
slips or shudders on
Valve body faulty Inspect valve body AT-19,76
take-off
transmission
Drag, binding or tie-up Manual shift cable out of adjustment Adjust shift cable AT-4
on 1-2, 2-3 or 3-00 Valve body faulty Inspect valve body AT-19,76
up-shift
transmission
AUTOMATIC TRANSMISSION - Troubleshooting AT-3
TROUBLESHOOTING (Cont'd)
!
Problem Possible cause I
Remedy Page
r-~------~-~---- ------- - ~ -f - - ~ ~ - - - - - -
I
Harsh down-shift Throttle cable out of adjustment I, Adjust throttle cable AT-4
Throttle cable and cam faulty , Inspect throttle cable and cam AT-22
I
Accumulator pistons faulty Inspect accumulator pistons AT-110

I

Transmission faulty i Disassemble and inspect AT-37
: transmission
No down-shift when Governor faulty [Inspect governor AT-99
I
coasting Valve body faulty AT-19,76
[Inspect valve body
Down-shift occurs too Throttle cable out of adjustment Adjust throttle cable AT-4
quick or too late while Throttle cable faulty Inspect throttle cable AT-22
coasting
Governor faulty Inspect governor AT-99
transmission
00-3, 3-2 or 2-1 Throttle cable out of adjustment Adjust throttle cable AT-4
kick-down Governor faulty Inspect governor AT-99
No engine braking in I Valve body faulty Inspect valve body AT-19,76

"2" range , Transmission faulty Disassemble and inspect AT-37
I
I transmission
I
Vehicle does not hold Manual shift cable out of adjustment Adjust shift cable AT-4
in "P" Parking lock pawl cam and spring faulty Inspect cam and spring AT-23
NOTE: See page AT -14 for inspection procedures for electrical controls of automatic transmission with
overdrive.
AT-4 AUTOMATIC TRANSMISSION - ATF Inspection, Adjustments
ATF INSPECTION
OK if hot
1. CHECK FLUID LEVEL (See page MA-15)
2. CHECK FLUID CONDITION

If the ATF smells burnt or is black, replace it.
3. REPLACE ATF (See page MA-12)
MA0156
ADJUSTMENTS
ADJUSTMENT OF THROTTLE CABLE
1. DEPRESS ACCELERATOR PEDAL ALL THE WAY AND
WHEN THROTTLE VALVE IS CHECK THAT THROTTLE VALVE OPENS FULLY
FULLY OPENED
If the throttle valve does not open fully, adjust the
accelerator link.
Outer Cable
Rubber Boot
2. FULLY DEPRESS ACCELERATOR
1
3. LOOSEN ADJUSTING NUTS
4. ADJUST THROTTLE CABLE

(a) Adjust the cable housing so that the distance be-
tween the end of the boot and the stopper on the
cable is correct.
Distance: 0 - 1 mm (0 - 0.04 in,)
(b) Tighten the adjusting nuts.
(c) Recheck the adjustments.
Adjusting Nut
Cable Stopper ADJUSTMENT OF FLOOR SHIFT CABLE
(or Painted Mark)
1. LOOSEN NUT ON SHIFT CABLE
ATl721
2. ADJUST SHIFT CABLE

(a) Push the manual lever fully rearward.
~~/L~
..•,.~,
.. , .. (b) Return the lever two notches to the NEUTRAL posi-
@5. ~. I ' , tion.
1
\0 ,:,
(c) Set the shift selector in "N".
l (d) While holding the selector lightly toward the "R"
range side, tighten the shift cable nut.
ADJUSTMENT OF NEUTRAL START SWITCH

L- A_Tl_75--J9 If the engine will start with the shift selector in any range
other than "N" or "P", adjustment is required.
1. LOOSEN NEUTRAL START SWITCH BOLT AND SET

SHIFT SELECTOR IN "N" RANGE
2. ADJUST NEUTRAL START SWITCH

(a) Align the groove and neutral basic line.
(b) Hold in position and tighten the bolt.
3. TORQUE NEUTRAL START SWITCH BOLT
AT1760
Torque: 55 kg-cm (48 in.-Ib, 5.4 N·m)
AUTOMATIC TRANSMISSION - Tests AT-5
TESTS
STALL TEST
The object of this test is to check the overall performance of the transmission and engine by measuring the
maximum engine speeds in the "0" and "R" ranges.
CAUTION: EVALUATION
(a) Perform the test at normal operation fluid (a) If the engine speed is the same for both
temperature (50 - 80°C or 122 - 176°F). ranges but lower than specified value:
(b) Do not continuously run this test longer • Engine output is insufficient.
than 5 seconds. • Stator one-way clutch is not operating pro-
perly.
MEASURE STALL SPEED
NOTE: If more than 600 rpm below the specified
(a) Chock the front wheels. value. the torque converter could be faulty.
(b) Mount an engine tachometer. (b) If the stall speed in "0" range is higher than
(c) Fully apply the parking brake. specified:
(d) Step down strongly on the brake pedal with • Line pressure too low
your left foot. • Front clutch slipping
• One-way clutch No. 2 not operating pro-
(e) Start the engine.
perly
(f) [4WD] • 00 one-way clutch not operating properly
Turn off the 4WD control switch.
(c) If the stall speed in "R" range is higher than
(g) Shift into "0" range. Step all the way down on specified:
the accelerator pedal with your right foot.
Quickly read the highest engine rpm at this • Line pressure too low
time. • Rear clutch slipping
• Brake No. 3 slipping
Stall speed: 2,100 ± 150 rpm • 00 one-way clutch not operating properly
(h) Perform the same test in "R" range. (d) If the stall speed at "R" and "0" range is
higher than specified:
• Line pressure too low
• Improper fluid level
• 00 one-way clutch not operating properly
AT1206
AT-6 AUTOMATIC TRANSMISSION - Tests
TIME LAG TEST

If the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock
can be felt. This is used for checking the condition of the OD clutch, front clutch, rear clutch and brake NO.3.
MEASURE TIME LAG EVALUATION

(a) Fully apply the parking brake. (a) If "N" - "0" time lag is longer than specified:
(b) Start the engine and check the idle speed. • Line pressure too low
Idle speed: 750 rpm • Front clutch worn
(c) [4WD] • 00 one-way clutch not operating properly
Turn off the 4WD control switch. (b) If "N" - "R" time lag is longer than specified:
(d) Shift the shift lever from "N" to "0" range.
• Line pressure too low
Using a stop watch, measure the time it takes
from shifting the lever until the shock is felt. • Rear clutch worn
Time lag: Less than 1 .2 seconds • Brake No. 3 worn
(e) In same manner, measure the time lag for "N" • 00 one-way clutch not operating properly
- "R".
Time lag: Less than 1 .5 seconds
CAUTION:
(a) Perform the test at normal operation fluid
temperature (50 - 80°C or 122 - 176°F).
(b) Be sure to allow one minute interval be-
tween tests.
(c) Make three measurements and take the
average value.
Shock Noise
~[~
o•
0 R
1 12 14
2 // I {
3 / 0 /3
II 13
•
~[~ -'
-
~,
I t \
Shock Noise
AT0837
HYDRAULIC TEST
1. PREPARATION (b) Measurement can be made with the
(a) Warm up the transmission fluid. 1,000 rpm test, but if tests are to be
made at 1,800 and 3,500 rpm, it would
(b) [4WO] be safer to test on a road or chassis
Turn off the 4WD control switch. dynamometer because an onstand test
(c) Chock the front wheels. could be hazardous.
(d) Jack up rear of the vehicle and support it
2. MEASURE GOVERNOR PRESSURE
on stands.
(a) Fully apply the parking brake.
(e) Remove the transmission case test plugs
and mount hydraulic pressure gauges. (b) Start the engine.
SST 09992-00093 (c) Shift into "0" range and measure the
governor pressures at the speeds specified
CAUTION: in the table.
(a) Perform the test at normal operation fluid
temperature (50 - 80°C or 122 - 176°F). EVALUATION
If governor pressure is defective.
• Line pressure defective
• Fluid leakage in governor pressure circuit
• Governor valve operation defective
~
Vehicle speed
Output shaft Govenor pressure
(Reference only)
A45DL 1,000 rpm 26 km/h (16 mph) 1.4 - 1.7 kg/cm 2 (20 - 24 psi, 137 - 167 kpa)
Tire size 175R 14 1,800 rpm 48 km/h (30 mph) 2.2 - 2.6 kg/cm 2 (31 - 37 psi, 216 - 255 kpa)
Differential gear ratio 4,300 3,500 rpm 94 km/h (58 mph) 4.5 - 5.3 kg/cm 2 (64 - 75 psi, 441 - 520 kpa)
-
A45DL 1,000 rpm 27 km/h (17 mph) 1.4 - 1.7 kg/cm 2 (20 - 24 psi, 137 - 167 kpa)
Tire size P195/75R 14 1,800 rpm 50 km/h (31 mph) 2.2 - 2.6 kg/ cm 2 (31 - 37 psi, 216 - 255 kpa)
A45DF 1,000 rpm 26 km/h (16 mph) 1.4 - 1.7 kg/cm 2 (20 - 24 psi, 137 - 167 kpa)
Tire size P205/75R 14 1,800 rpm 46 km/h (29 mph) 2.2 - 2.6 kg/cm 2 (31 - 37 psi, 216 - 255 kpa)
AT1207
3. MEASURE LINE PRESSURE EVALUATION

(a) Fully apply the parking brake and chock (a) If the measured values at all ranges are higher
the four wheels. than specified:
(b) Start the engine. • Throttle cable out-of-adjustment
(c) [4WD] • Throttle valve defective
Turn off the 4WD control switch. • Regulator valve defective
(d) Shift into "D" range and step down (b) If the measured values at all ranges are lower
strongly on the brake pedal with your left than specified:
foot and, while manipulating the accele-
rator pedal with the right foot, measure • Throttle cable out-of-adjustment
the line pressures at the engine speeds • Throttle valve defective
specified in table. • Regulator valve defective
(e) In the same manner, perform the test in • Oil pump defective
"R" range.
• OD clutch defective
Line pressure kg/cm 2 (psi) [kPa] (c) If pressure is low in "0" range only:
Engine
speed • "D" range circuit fluid leakage
"0" range "R" range
• Front clutch defective
4.5 - 5.1 6.8 - 7.6
Idling (64 - 73) (97 - 108) • OD clutch defective
[441 - 500] [667 - 745] (d) If pressure is low in "R" range only:
10.1 - 11.9 15.0 - 19.0 • "R" range circuit fluid leakage
Stall (144 - 169) (213-270)
[990 - 1,167] [1,4 71 - 1,863] • Rear clutch defective
• Brake NO.3 defective
(f) If the measured pressures are not up to • OD clutch defective
specified values, recheck the throttle
cable adjustment and retest.
AT1208
ROAD TEST
CAUTION: Perform the test at normal operation fluid
temperature (50 - 80°C or 122 - 176°F).
1. "0" RANGE TEST

Shift into "0" range and, while driving with the accelera-
tor pedal held constant at specified points (throttle valve
opening 50% and 100%) and the 00 switch "ON", check
the following points.
(a) A t each of the above throttle openings, check to see
that 1 -+2, 2 -+3 and 3 -+00 up-shift take place and
~.~.~
also that the shift points conform to those shown in
the automatic shift diagram.
Full Open
NOTE: 3-+00 up-shift does not take place with a throt-
Q.) tle valve opening of more than 86% or coolant tem-
2
perature below 50°C (122°F).
); 100°,
3rd
0'>
Q.) 86 -- ~-: ----'--
E.~ 00 EVALUATION
e~
..co. (1) If there is no 1 -+2 up-shift:
~O 0-
Vehicle Speed • Governor valve is defective
TE0014
• 1-2 shift valve is stuck
(2) If there is no 2 -+3 up-shift:
(3) If there is no 3 -+00 up-shift (throttle valve opening
of less than 86%):
(4) If the shift point is defective:
• Throttle cable is out-of-adjustment
• Throttle valve, 1-2 shift valve, 2-3 shift valve, 3-
00 shift valve etc., are defective
(b) In the same manner, check the shock and the slip at
8J) 8 1 -+2, 2 -+3 and 3 -+00 up-shifts.
EVALUATION
8 If the shock is severe:

• Line pressure is too high
• Accumulator is defective
• Shock
• Slippage
8 61459
• Check ball is defective
(c) In "0" range 3rd gear or 00, check for abnormal

noise and vibration .
•
NOTE: Check for cause of abnormal noise and vibration
must be made with extreme care as they could also be due
to unbalance in propeller shaft, differential, tire, torque
converter, etc. or insufficient bending rigidity, etc., in the
•
power train .
• Abnormal Noise
• Vibration
61460
(d) While running in "0" range 2nd, 3rd gears and 00,
~ • • • ~r>~ Full Open

check to see that the possible kick-down vehicle
speed limits for 2-1, 3-1, 3-2, 00-3 and
00-2 kick-downs conform to those indicated in the
100% automatic shift diagram.
Q) r-1 5t-1 5t 2nd-2nd 3rd
1
~
ro
>
Q)C)
-c
'I 11-'
:2nd
1 t
3rd//[ t
(e) Check for abnormal shock and slip at kick-down.
~'E OD
eQ) : 3rd: OD
..co.
1-0 o
Vehicle Speed 81456
NOTE: 00-3 kick-down is always possible with a
~.~.~
throttle valve opening of more than 86%.
~ Full open
Q)
ro>
>Q)C> 100%Lt::rd
86 ------:.:',-------
....
-
"'c
c
0Q)
- / : OD
1:0. o ;
1-0
Vehicle Speed TE0030
(f) While running in "0" range 3rd gear or 00 gear, shift

to "2" and "L" ranges and check the engine braking
.. (2)
effect in each of these ranges.
EVALUATION
(1) If there is no engine braking effect in "2" range:
• Brake No. 1 is defective
If there is no engine braking effect in "L" range:
• Engine Braking • Brake No.3 is defective
.. ~~
81458
(g) While running in "0" range, release your foot from
~.
the accelerator pedal and shift into "L" range. Then
,
check to see if 00-3, 3-2 and 2-1 down-shift
points conform to those indicated in the automatic
~ shift diagram.
([D I
I
I
I
I
-+--
8
•
I
I
I
I
I
1.
o TE0045
(h) While driving in "0" range, overdrive, at a steady

speed (lock-up ON) of about 80 km/h (50 mph),
lightly depress the accelerator pedal and check that
the engine rpm does not change abruptly.
NOTE: If the lock-up is not operating, drive power will
not be transmitted via the torque converter fluid. Conse-
quently, the torque converter will slip when the pedal is
depressed, causing an abrupt change in engine rpm.
~.~~~
~ ~~~
p
o
~
100 %
@
...
Half Open (50%)
Full Open (100%)

,
2. "2" RANGE TEST
(a) Shift to "2" range and run with the throttle valve
opening at 50% and 100% respectively. Then check
the 1-2 up-shift points at each of the throttle valve
openings to see that it conforms to those indicated in
pUP~ft ~
1 the automatic shift diagram.
• 50 \ ..)
.. \i(
Oint Q) :
~ 0 _: ;
~ Vehicle Speed
TEOO15
(b) While running in "2" range, 2nd gear, release the

accelerator pedal and check the engine braking
effect.
• Engine Braking
81463
(c) Perform a kick-down from the "2" range and check

the possible 2-1 kick-down vehicle speed limit to
see if it conforms to that indicated in the automatic
shift diagram.
Vehicle Speed TEOO16
(d) Check for abnormal noise at acceleration and
~~
. Acceleration deceleration, and for shock at up-shift and down-
C\ ~ • Abnormal shift.
,- DeceleratioJ Noise
_UP-Shift]
• Shock
• Down-shift
AT0776
3. ilL" RANGE TEST

(a) While running in "L" range, check to see that there is
no up-shift to 2nd gear.
Oc¢>@
No Up-shift
AT0778
(b) While running in "L" range, release the accelerator

pedal and check the engine braking effect.
• Engine Braking
AT0779
(c) Check for abnormal noise at acceleration and

deceleration.
Acceleration
Deceleration
• Abnormal Noise
TE0018
4. "R" RANGE TEST

Shift into "R" range and check for slipping while running
at full throttle.
Full Throttle
• Slippage
~ AT0780
5. lip" RANGE TEST

Stop the vehicle on a gradient (more than 9%) and after
shifting into "P" range, release the parking brake. Then
EW
~p
.• ~
G)i
R
• Parking Lock
@~
6~', I~
check that the parking lock pawl prevents the vehicle from
moving .
Pawl Engaged Vehicle on Gradient
AT0781
AUTOMATIC TRANSMISSION - Automatic Shift Diagram AT-13
AUTOMATIC SHIFT DIAGRAM
%
100
90
r-------------
80 I
0>
C
1 -.1-2
c 70
Q)
c. 60
0
Q)
~ 50
co
>Q)
40
-;:; Up-shift
2
..c
30
- - - - - Down-shift
I- 20
10
0 '-------''"-------..L-..--L- ,---=-0'-=-0--=-0---~----:2::----,0-,,-l0-=-0----=-----'---'-----=-3-,0....L.0:-:0,.-------4-,0.L..0-0--- 0 utput Shaft
1
rpm
Differential Vehicle
gear ratio speed
10 20 30
, 40
, 50 60 70 80 90 100 110 120 km/h
4.300 0 ~ 1L.-----r-----..L_
r
! _--I......,_ _L--_....---1-_
I i
! _- l! . - - - - r - _I L - - _ - - 4_ _----'--_,.--..L..-_---.L....,-_--J''--_
I I I
I
I I
I
10 20 30 40 50 60 70 mph
10 20 30 40 50 60 70 80 90 100 110 km/h

4.778 0, !
I
I I
r
I
I I I
I
I
I I
I
I I
10 20 30 40 50 60 70 mph
km/h (mph)
"0" range (throttle valve fully open) "L" range

Differential
gear ratio 1 ~ 2 2~3 3~ 00 Lock-up Lock-up
OD~ 3 3~2 2~ 1 2 ~ 1
ON OFF
44-53 87-98 *140-50 *169-78 *163-73 82-95 37-49 37-49

4.300 *2
(27-33) (54-61 ) (25-31 ) (43-48) (39-45) (51-59) (23-30) (23-30)
39-50 81-92 *135-45 *163-72 *158-68 76-88 34-44 33-46

4.778 *2
(24-31 ) (50-57) (22-28) (39-45) (36-42) (47-55) (21-27) (21-29)
*1 With closed throttle valve.

*2 00 ~ 3 down shift possible up to maximum speed. AT2497
AT2548
AT-14 AUTOMATIC TRANSMISSION - Electric Control
ELECTRIC CONTROL
CIRCUIT (2WD)
Ignition Fuse
Switch Gauge
AM, IG, 7.5A
00 OFF Indicator
Fusible Link
AM,60A
2 3
Fusible Link
1.25B
00 Relay
Fusible Link
2.0L 4
'T"
I Battery
~
Water
00 Solenoid Thermo 00 Main Switch
Switch
Overdrive Main Switch Overdrive Relay Overdrive Solenoid Water Thermo Switch
AT249'
GA-4-' H-4-2 IC-2-2 IH-'-2-A
AUTOMATIC TRANSMISSION - Electric Control AT-15
CIRCUIT (4WD)
Ignition Fuse
Switch Gauge
r-o-_---;.-------------.--------------,
ATFThermo
Indicator
Fusible Link
AM 1 60A
2 Charge
Fusible Link
1.25B
ATF
Thermo
Sensor9 ATM Control
Fusible Link 4
Computer
2.0L
3
10 11
~ Battery
00 Main
1
Switch
3 00 Water 4WO
Solenoid Thermo Indicator
Switch Switch
00 Main Switch 00 Solenoid Water Thermo Switch ATF Thermo Sensor
4WO Indicator Switch ATM Control Computer
AT2027
GA-4-1 IC-2-2 IH-1-2-A IH-2-2
IH-1-25-12-2
INSPECTION ELECTRIC CONTROL

COMPONENTS
1. INSPECT OVERDRIVE RELAY (2WD) OR ATM
CONTROL COMPUTER (4WD) AND SOLENOID
(a) Turn on the ignition switch.
(b) Disconnect the connector from the thermo switch.
(c) Repeatedly turn OD main switch ON and OFF.
AT1750
(d) At this time, check that an operation sound from the

solenoid and overdrive relay (2WD) or ATM control
computer (4WD) can be heard.
If there is no sound from either the solenoid, overdrive relay
(2WD) or ATM control computer (4WD), check them.
AT1763
2. INSPECT OVERDRIVE RELAY (2WD)

(a) Remove the console box.

EL0010
(c) Apply 1 2 V battery voltage across terminals 2 and 4.

2 Using an ohmmeter, check that there is no continuity
(d) Install the overdrive relay.
3 (e) Install the console box.
ELOOO1
AUTOMATIC TRANSMISSION - Electric Control AT-17
3. INSPECT ATM CONTROL COMPUTER (4WD)

(b) Measure the voltage at each terminal.
No. Terminal Measuring condition Voltage (V)

f---- --
1 2- Ground Ignition switch ON 12 V
--
Engine not running OV

2 7- Ground f-------------
Engine running 12 V
------- -- ~- -----~._---,_._---
Engine not running OV

3 6- Ground -----
Engine running 12 V
------- ~- ---------------- ----------------
Ignition switch OFF OV

4 1- Ground ---~
Ignition switch ON 5V
~
---- ---'- -------- ---- --
DO switch OFF OV
5 3- Ground - - - - - - - - - - - - - - - - --
DO switch ON 5V
-------- 1------ --------~ --
DO switch OFF OV
6 11 - Ground
00 switch ON 12 V
- - - - - -------~------
Coolant temperature below 43°C (109°F) OV

7 4- Ground
Coolant temperature above 55°C (131°F) 12 V
4. INSPECT OVERDRIVE SOLENOID

(a) Disconnect the solenoid connector and apply a 12 V
battery voltage to the solenoid.
Check that the solenoid operation sound is heard.
AT1763
(b) Using an ohmmeter, measure the solenoid coil re-

sistance.
Resistance: 13 n
(c) Connect the solenoid connector.
5. INSPECT WATER THERMO SWITCH

(a) Disconnect the thermo switch connector.
the terminal and ground.
(c) Connect the thermo switch connector.
Coolant temperature Resistance (Point)
-
Below 43°C (109°F)
------- ----- ----- -
on (Closed)
------------._---------------- ---
EL0005
Above 55°C (131°F) n (Open)
OCJ
6. INSPECT OVERDRIVE MAIN SWITCH

(b) Using an ohmmeter, check the continuity of the
terminals for each switch position.
o----D: Continuity
'--- T..::-er'--...m inal
2 3 4
Switch position
ON
OFF
(c) Install the console box.
7. INSPECT 00 OFF INDICATOR

(a) Turn on the ignition switch.
(b) Check that the 00 OFF indicator does not light, when
the 00 main switch is turned ON.
(c) Check that the 00 OFF indicator lights, when the 00
main switch is turned OFF.
8. INSPECT ATF THERMO INDICATOR LIGHT (4WD)

(a) With the ignition switch ON, check that the indicator
light inside the combination meter lights.
(b) Check that when the engine is started, the indicator
light goes out.
RD0074
9. INSPECT ATF THERMO SENSOR (4WD)

(a) Place the sensor in a container filled with ATF
(DEXRONR> 11) up to the point shown in the illustration.
(b) As the fluid is warmed, measure the resistance
between the terminals.
Resistance: 541.7 - 689.5 n (120°C or 248°F)
NOTE: As the resistance is measured, check that the
resistance value gradually drops as the temperature falls
from 120°C to 25°C (248°F to 77°F).
D2239
AUTOMATIC TRANSMISSION - On-Vehicle Repair AT-19
15 mm
(0.59 in.)
ON-VEHICLE REPAIR
4 65
mm (026 In! IT·· REMOVAL OF VALVE BODY
r--.. 68mm
I
(2.68 in.)
- +
20 mm
-~65 mm
(2 56' )
. In.
1. MAKE PLATE TO RETAIN ACCUMULATOR PISTONS
A retainer is helpful for holding accumulator pistons in the
case during removal and installation of the valve body. The
(0.79 in.)
plate may be made of aluminum or plastic.
r----~-
I
115 mm --- i
(4.53 in.) AT0782
2. CLEAN TRANSMISSION EXTERIOR

To help prevent contamination, clean the exterior of the
transmission.
3. DRAIN TRANSMISSION FLUID

Remove the drain plug and drain the fluid into a suitable
container.
4. REMOVE OIL PAN, FILLER TUBE AND GASKET

CAUTION: Some fluid will remain in the oil pan. Be
careful not to damage the filler tube and O-ring.
Remove all pan bolts, and carefully remove the pan
assembly. Discard the gasket.
5. REMOVE OIL TUBES

Pry up both tube ends with a large screwdriver and
remove the tubes.
OROO01
6. REMOVE OIL STRAINER

Remove the six bolts, and the oil strainer.
CAUTION: Be careful as some oil will come out with
the filter.
81481
AT·20 AUTOMATIC TRANSMISSION - On-Vehicle Repair
7. REMOVE VALVE BODY

(a) Remove the seventeen bolts.
NOTE: Bolt lengths will be shown for installation, so
there is no need to mark them now.
(b) Lower the valve body slightly, and install the

accumulator piston retaining plate. Hold it in place
with two pan bolts. Hand tighten the bolts with a
socket driver.
(c) Disconnect the throttle cable from the cam and

remove the valve body.
DISASSEMBLY, INSPECTION AND

ASSEMBLY OF VALVE BODY
(See page AT-76)
INSTALLATION OF VALVE BODY

1. CONNECT THROTTLE CABLE TO CAM
Push the cable fitting into the cam.
2. ALIGN MANUAL VALVE LEVER WITH MANUAL

VALVE AND LOOSELY INSTALL SEVERAL BOLTS IN
VALVE BODY
Leave the bolts loose so that the accumulator retaining
plate can be removed.
81485
3. REMOVE ACCUMULATOR RETAINING PLATE

Remove the two pan bolts, and slide out the plate.
AT0995
4. INSTALL VALVE BODY BOLTS

Install the bolts as shown. Tighten the bolts evenly.
5. INSTALL OIL STRAINER

Be sure the strainer is clean. Torque the bolts.
61481
6. INSTALL OIL TUBES

Press the tubes by hand into the positions indicated in the
figure.
OR0002
7. INSTALL PAN WITH NEW GASKET

Be sure the pan is clean and the magnets are in place.
CAUTION: Do not use gasket sealer.
Tig hten the bolts evenly.
8. INSTALL DRAIN PLUG

Torque the drain plug.
9. FILL TRANSMISSION WITH ATF

Add only about four liters of ATF.
Fluid type: ATF DEXRON® II
10. CHECK FLUID LEVEL

(See page MA-15)
AT1213
AT-22 AUTOMATIC TRANSMISSION - On-Vehicle Repair
REMOVAL OF THROTTLE CABLE

1. DISCONNECT THROTTLE CABLE
(a) Disconnect the cable housing from the bracket.
(b) Disconnect the cable from the throttle linkage.
2. REMOVE VALVE BODY (See page AT-19)
3. PUSH THROTTLE CABLE OUT OF TRANSMISSION

CASE
Using a 1O-mm socket, push the throttle cable out.
INSTALLATION OF THROTTLE CABLE

1. INSTALL CABLE IN TRANSMISSION CASE
Be sure to push it in all the way.
2. INSTALL VALVE BODY (See page AT-20)
OROO16 C3579
3. IF THROTTLE CABLE IS NEW, PAINT MARK ON

INNER CABLE
0.8 -1.5 mm
(0.031 - 0.059 in.) NOTE: New cables do not have a cable stopper installed.
Therefore, to make adjustment possible, paint a mark as
described below.
(a) Pull the inner cable lightly until a slight resistance is
Painted Mark felt, and hold it.
(Width: 4 mm)
(b) Paint a mark as shown, about 4 mm (0.16 in.) in
Outer Cable width.
OR0021
4. CONNECT THROTTLE CABLE

(a) Connect the cable to the throttle linkage.
(b) Connect the cable housing to the bracket.
5. ADJUST THROTTLE CABLE (See page AT-4)
6. TEST DRIVE VEHICLE

REMOVAL OF PARKING LOCK PAWL

1. REMOVE VALVE BODY (See page AT-19)
2. REMOVE PARKING LOCK PAWL BRACKET

Remove the two bolts and the bracket.
3. REMOVE SPRING FROM PARKING LOCK PAWL

PIVOT PIN
4. REMOVE PIVOT PIN AND PARKING LOCK PAWL
INSTALLATION OF PARKING LOCK PAWL

1. INSTALL PARKING LOCK PAWL AND PIVOT PIN
2. INSTALL PIVOT SPRING
3. INSTALL PARKING LOCK PAWL BRACKET

(a) Push the lock rod fully forward.
(b) Install the two bolts finger tight.
(c) Check that the pawl operates smoothly.
(d) Torque the bolts.
4. INSTALL VALVE BODY (See page AT-20)
REPLACEMENT OF REAR OIL SEAL (2WD)

1. RAISE VEHICLE, AND POSITION PAN TO CATCH ANY
FLUID THAT MAY DRIP
2. REMOVE PROPELLER SHAFT
SST 3. REMOVE REAR DUST SEAL AND OIL SEAL

CAUTION: Clean the extension housing before
removing the seal.
Using SST, remove the two seals.
SST 09308-10010
4. INSTALL NEW OIL SEAL AND DUST SEAL

Using SST, drive in the oil seal as far as it will go. Drive in
the dust seal flush with the housing.
SST 09325-20010
5. INSTALL PROPELLER SHAFT
6. LOWER VEHICLE AND CHECK FLUID LEVEL

(See page MA-15)
Add fluid as necessary.
REPLACEMENT OF REAR OIL SEAL (4WD)

1. RAISE VEHICLE, AND POSITION PAN TO CATCH ANY
FLUID THAT MAY DRIP
2. REMOVE TRANSFER (See page TF-5)
3. REMOVE REAR OIL SEAL

CAUTION: Clean the transfer adaptor before removing
the oil seal.
L-- A_T2_01--l4 Using SST, remove the oil seal.
SST 09308-00010
4. INSTALL NEW OIL SEAL

Using SST, drive in a new oil seal.
SST 09350-20015 (09388-20010)
SST
AT2015
5. INSTALL TRANSFER (See page TF-52)

(See page MA-15)
REMOVAL OF GOVERNOR ASSEMBLY (2WD)

1. RAISE VEHICLE AND POSITION PAN TO CATCH ANY
FLUID THAT DRIPS
3. SUPPORT TRANSMISSION WITH JACK
AT1214
4. DISCONNECT SPEEDOMETER CABLE
5. REMOVE SPEEDOMETER DRIVEN GEAR

Remove the bolt and locking tab. Pry out the speedometer
gear with a screwdriver.
6. REMOVE TRANSMISSION MOUNTING THROUGH

BOLT
(a) Remove the two fuel tank mount bolts and support
the fuel tank.
(b) Remove the transmission mounting through bolt.
AT1217
7. REMOVE EXTENSION HOUSING AND GASKET

Remove the six bolts. If necessary, tap the extension
housing with a soft-faced hammer or block of wood to
loosen it.
AT1218
8. REMOVE SPEEDOMETER DRIVE GEAR

(b) Slide off the speedometer gear.
(c) Remove the lock ball and the other snap ring.
AT1219
9. REMOVE GOVERNOR FROM OUTPUT SHAFT

(a) Using a larger screwdriver, lift the retaining clip.
(b) Unstake the lock plate, remove the bolt and lock
plate.
(c) Remove the governor.
INSPECTION AND REPAIR OF GOVERNOR

ASSEMBLY (2WD)
(See page AT-99)
INSTALLATION OF GOVERNOR ASSEMBLY

(2WD)
1. INSTALL GOVERNOR ON OUTPUT SHAFT
(a) Using a large screwdriver, lift the retaining clip, and
slide the governor on the shaft with the retaining ring
facing the end of the shaft.
(b) Release the retaining clip into the hole in the output
shaft. Check that the governor assembly is secure.
L-...- D_ 7b--'41 (c) Install the bolt and lock plate, stake the lock plate.
2. INSTALL SPEEDOMETER DRIVE GEAR

(a) Install the snap ring and lock ball.
(b) Slide the speedometer gear onto the shaft.
(c) Using snap ring pliers, install the outer snap ring.
AT1221 ATl222
3. INSTALL NEW GASKET AND EXTENSION HOUSING

ON TRANSMISSION
(a) Clean the threads of the@ bolt and bolt hole with
white gasoline.
(b) Coat the threads of the@ bolt with sealer.
Sealer: Part No. 08833-00080, THREE BOND 1344,
(c) Install the extension housing over a new gasket with
bolts, and then torque them.
NOTE: The two lower bolts are shorter.
4. INSTALL TRANSMISSION MOUNTING THROUGH

BOLT
(a) Raise the transmission with the jack to allow installa-
tion of the transmission mounting through bolt.
(b) Torque the through bolt.
(c) Install the two fuel tank set bolts.
AT1223
5. INSTALL SPEEDOMETER DRIVEN GEAR

(a) Install a new O-ring on the shaft sleeve.
(b) Install the lock plate with a bolt and washer.
6. CONNECT SPEEDOMETER CABLE

Place the felt dust protector and washer on the end of the
cable. Tighten the collar with pliers.
AT1216 AT1224

PROOOl

(See page MA-15)
Fluid type: ATF DEXRON@ II
AT1213
MA0156
REMOVAL OF GOVERNOR ASSEMBLY (4WD)

1. RAISE VEHICLE AND POSITION PAN TO CATCH ANY
FLUID THAT DRIPS
2. REMOVE TRANSFER (See page TF-5)
3. REMOVE TRANSFER ADAPTOR

Remove the six bolts. If necessary, tap the transfer adaptor
with a soft-faced hammer or brock of wood to loosen it.
NOTE: When removing the transfer adaptor, be careful
not to damage the oil seal.
AT2016
4. REMOVE GOVERNOR BODY FROM OUTPUT SHAFT

(a) Using a larger screwdriver, remove the retaining clip.
AT2017
(b) Unstake the lock plate, remove the bolt and lock plate.
(c) Remove the governor body.
AT2018
INSPECTION AND REPAIR OF GOVERNOR

ASSEMBLY (4WD)
(See page AT-99)
INSTALLATION OF GOVERNOR ASSEMBLY

(4WD)
1. INSTALL GOVERNOR BODY ON OUTPUT SHAFT
(a) Align the governor body and bolt hole on the output
shaft.
(b) Install the bolt and lock plate, stake the lock plate.
A T201 9
(c) Using a large screwdriver, install the retaining clip into

the hole in the output shaft.
(d) Check that the governor assembly is secure.
AT2017
2. INSTALL NEW GASKET AND TRANSFER ADAPTOR

ON TRANSMISSION
(a) Clean the threads of the ® bolt and bolt hole with
white gasoline.
(b) Coat the threads of the ® bolt with sealer.
(c) Install the transfer adaptor over a new gasket with
bolts and then torque them.
A T2016
NOTE: When installing the transfer adaptor, be careful
not to damage the oil seal.
3. INSTALL TRANSFER (See page TF-52)

(See page MA-15)
AT1213
MA0156
AT-3D AUTOMATIC TRANSMISSION - Removal of Transmission (2WD)
(2WD)
1. DISCONNECT BATTERY CABLE FROM NEGATIVE (-)
TERMINAL
2. DISCONNECT TRANSMISSION THROTTLE CABLE

(a) Loosen the adjusting nuts, and disconnect the cable
housing from the bracket.
Connectors 3. DISCONNECT WIRING CONNECTORS

Disconnect the neutral start switch, back-up light and
overdrive solenoid connectors.
4. RAISE VEHICLE AND DRAIN TRANSMISSION

6. DISCONNECT EXHAUST PIPE CLAMP FROM

TRANSMISSION HOUSING
7. REMOVE EXHAUST PIPE CLAMP
8. DISCONNECT SHIFT CABLE FROM TRANSMISSION
AT1761
AUTOMATIC TRANSMISSION - Removal of Transmission (2WD) AT-31
9. DISCONNECT SPEEDOMETER CABLE AND BOND

CABLE
AT1215
10. DISCONNECT TWO OIL COOLER LINES

(a) Loosen the two nuts.
(b) Remove the two clamps and disconnect the two oil
cooler lines.
11. REMOVE STARTER

(a) Remove the mounting bolts, and pull the starter
toward the front of the vehicle.
(b) Lay the starter alongside the engine.
AT1938

If a transmission jack is not available, be sure to put a
wooden block between the jack and the transmission pan
to prevent damage.
AT1214

BOLT
(a) Remove the two fuel tank mount bolts and support
the fuel tank.
(b) Remove the transmission mounting through bolt.
A T1 217
14. REMOVE BOTH STIFFNER PLATES FROM

AT1762
AT-32 AUTOMATIC TRANSMISSION - Removal of Transmission (2WD)
15. REMOVE SIX TORQUE CONVERTER MOUNTING

BOLTS
(a) Pry out the service hole cover at the rear of the
engine.
(b) Turn the crankshaft to gain access to each bolt.
Remove the six bolts.
AT1000
16. REMOVE TRANSMISSION HOUSING MOUNTING

BOLTS
17. REMOVE TRANSMISSION ASSEMBLY

Draw out the transmission down and toward the rear.
CAUTION: Do not catch the throttle cable or neutral
start switch cable. Keep the oil pan positioned down-
ward.
18. PLACE PAN UNDER CONVERTER HOUSING, AND

REMOVE CONVERTER
Pull the converter straight off, and allow the fluid to drain
into the pan.
AT1942
19. REMOVE FILLER TUBE
20. REMOVE TRANSMISSION MOUNTING

(4WD)
1. DISCONNECT BATTERY CABLE FROM NEGATIVE (-)
TERMINAL
2. DISCONNECT TRANSMISSION THROTTLE CABLE

(a) Loosen the adjusting nuts, and disconnect the cable
housing from the bracket.
Connectors 3. DISCONNECT THE THREE WIRING CONNECTORS

Disconnect the three connectors located near the starter.
4. RAISE VEHICLE AND DRAIN TRANSMISSION AND

TRANSFER
5. DISCONNECT ATF THERMO SENSOR CONNECTOR
6. REMOVE FRONT AND REAR PROPELLER SHAFTS

(See page PR-3)
7. DISCONNECT EXHAUST PIPE FROM MANIFOLD

(a) Remove the exhaust pipe clamp from the transmission
housing.
(b) Disconnect the exhaust pipe from the manifold.
AT2030
8. DISCONNECT TRANSMISSION SHIFT CABLE FROM

TRANSMISSION OUTER LEVER
AT1761
9. DISCONNECT VACUUM HOSES FROM VACUUM

ACTUATOR
10. DISCONNECT SPEED SENSOR AND 4WD

INDICATOR CONNECTORS
AT2394
11. DISCONNECT SPEEDOMETER CABLE, GROUND

STRAP AND TRANSFER INDICATOR SWITCH
CONNECTOR
AT2285
12. DISCONNECT OIL COOLER LINES

(a) Loosen the two union nuts.
(b) Remove the two clamps and disconnect the two oil
cooler lines.
AT2032
13. REMOVE CONTROL CABLE BRACKET FROM

AT2279
14. REMOVE STARTER

(a) Remove the mounting bolt and pull the starter toward
the front of the vehicle.
(b) Lay the starter alongside the engine.
AT2283

If a transmission jack is not available, be sure to put a
wooden block between the jack and the transmission pan to
prevent damage.

BOLT
AT2286
17. REMOVE BOTH STIFFENER PLATES FROM

(
II
\i
Iii
"·'L
j~
AT1762
18. REMOVE TORQUE CONVERTER MOUNTING BOLTS

(a) Pry out the service hole cover at the rear of the engine.
(b) Turn the crankshaft to gain access to each bolt.
Remove the six bolts.
AT1000
19. REMOVE TRANSMISSION HOUSING MOUNTING

BOLTS
20. REMOVE TRANSMISSION ASSEMBLY

Draw out the transmission down and toward the rear.
CAUTION: Do not entangle the throttle cable of
neutral start switch cable. Keep the oil pan positioned
downward.
AT2284
21. PLACE PAN UNDER CONVERTER HOUSING, AND

REMOVE CONVERTER
Pull the converter straight off, and allow the fluid to drain
into the pan.
AT1942
22. REMOVE FILLER TUBE
23. REMOVE TRANSMISSION MOUNTING
AT2391
24. REMOVE TRANSFER

(a) Remove the eight bolts.
(b) Remove the transfer.
AT2281
AUTOMATIC TRANSMISSION - Disassembly of Transmission AT-37
DISASSEMBLY OF TRANSMISSION
SEPARATE BASIC SUBASSEMBLY
1. REMOVE CLAMP FOR WIRING AND THROTTLE
CABLE
2. REMOVE SOLENOID AND O-RINGS
3. REMOVE SHIFT HANDLE
4. REMOVE NEUTRAL START SWITCH
C4138 C4139
5. [2WD]
REMOVE SPEEDOMETER DRIVEN GEAR
C4141 C4142
6. REMOVE Oil PUMP

(a) Remove the seven bolts.
(b) Position SST on shaft in back of the spline.
SST 09610-20012
CAUTION: Do not damage the shaft bushing surface.
Turn the end bolt of SST to free the pump.
(c) Grasp the front pump stator shaft and pull the pump
from the case.
7. BE CAREFUL OF BEARING BEHIND Oil PUMP
C4697
AT-38 AUTOMATIC TRANSMISSION - Disassembly of Transmission
8. REMOVE CONVERTER HOUSING

(a) Remove the two 12-mm bolts and four 1O-mm bolts.
(b) While holding the input shaft, remove the converter
housing.
9. [2WD]
REMOVE EXTENSION HOUSING
10. [4WD]
REMOVE TRANSFER ADAPTOR
(See page AT-28)
11. [2WD]
REMOVE SPEEDOMETER DRIVE GEAR
12. REMOVE GOVERNOR BODY FROM OUTPUT SHAFT

(a) Loosen the staked part of the lock plate.
(b) Remove the governor body lock bolt.
(c) While lifting the retaining clip with a larger
screwdriver, slide off the governor body.
13. IF NECESSARY, REMOVE GOVERNOR STRAINER

(a) Remove the three screws and plate.
(b) Remove the strainer from the case.
AT1039 AT1038
14. REMOVE PAN AND GASKET

(a) Remove the fourteen bolts.
(b) Remove the pan by lifting the transmission case.
CAUTION: Do not turn the transmission over as this
will contaminate the valve body with the foreign material
in the bottom of the pan.
15. EXAMINE PARTICLES IN PAN

Remove magnets and use them to collect any steel chips.
Lock carefully at the chips and particles in the pan and on
the magnets to anticipate what type of wear you will find
in the transmission:
Steel (magnetic) = bearing, gear and clutch plate
wear
Brass (nonmagnetic) = bushing wear
16. TURN TRANSMISSION OVER AND REMOVE TUBES

Pry up both tube ends with a large screwdriver and
remove the tubes.
17. REMOVE STRAINER AND GASKET
18. REMOVE VALVE BODY

(a) Remove the seventeen bolts.
(b) Disconnect the throttle cable from the cam and

remove the valve body.
C4156
19. REMOVE THROTTLE CABLE AND RETAINER

Using a 10-mm socket, push the plastic throttle cable
retainer out of the transmission case.
C4158
20. COVER PISTON WITH A RAG AND, REMOVE

ACCUMULATOR PISTONS AND SPRINGS
WARNING: Keep face away to avoid injury. Do not
use regular high-pressure air.
Position a rag to catch each piston. Using low-pressure
compressed air (1 kg/cm 2 , 14 psi, or 98 kPa, max.). pop
each piston into the rag. Force air into the holes shown,
and remove the pistons and springs.
AT1244
21. REMOVE PARKING LOCK PAWL BRACKET AND ROD
22. REMOVE SPRING, PIVOT PIN AND PARKING LOCK

PAWL
23. IF NECESSARY, REMOVE MANUAL LEVER AND

SHAFT
(a) Using a hammer and screwdriver, pry and shift the
collar.
(b) Using a hammer and punch, drive out the pin.
(c) Slide the shaft out of the case and remove the detent
plate.
A T0852 A T0853
24. PLACE TRANSMISSION CASE ON CYLINDER

Place the transmission on a cylindrical stand for more effi-
cient work.
CAUTION: Place shop rags between the case and
stand to avoid damaging the case.
AT0856
25. MEASURE DISTANCE BETWEEN TOP OF CASE AND

CLUTCH DRUM
Set SST on the case as shown in the figure.
SST 09350-20015 (09370-12010)
Make a note of the distance for reassembly.
26. REMOVE OVERDRIVE CLUTCH

Grasp the shaft and pullout the overdrive clutch assembly.
Be careful of the bearings and races on both sides of the
assembly.
C4162
27. REMOVE OVERDRIVE CASE AND BRAKE

Hold both sides of the overdrive case and pull it out of the
transmission case. Be careful of the bearings and races on
both sides of the assembly.
28. MEASURE DISTANCE BETWEEN TOP OF CASE

FLANGE AND CLUTCH DRUM
Set SST on the case as shown in the figure.
SST 09350-20015 (09370-12010)
Make a note of the distance for reassembly.
29. REMOVE FRONT CLUTCH AND BEARINGS

Grasp the shaft and pull out the front clutch assembly.
Be careful of the bearings and races on both sides of the
assembly.
30. REMOVE BEARING AND RACE
C4209
31. REMOVE REAR CLUTCH

Grasp the clutch hub and pull it out of the case.
32. REMOVE CENTER SUPPORT AND SUN GEAR

(a) Remove the two center support bolts.
A T1 059
(b) Grasp the assembly and pull out the center support
( with the sun gear.
C4212
33. REMOVE REACTION PLATE RETAINING RING

Using a long screwdriver, compress the snap ring and lift it
above the groove with a wire hook.
C4214
34. REMOVE REAR PARTS GROUP

Grasp the intermediate shaft and pull out the rear parts
group.
If the brake apply tube and rear thrust bearing and races
do not come out with the assembly, remove them from
the case.
35. BASIC DISASSEMBLY IS COMPLETE

The transmission is now in basic component subassem-
C4215 blies. Next, you will disassemble, clean, inspect, repair and
assemble each of these component groups.
AUTOMATIC TRANSMISSION - Component Groups AT-43
COMPONENT GROUP DISASSEMBLY, INSPECTION AND

ASSEMBLY
The instructions here are organized so that you As much as possible, complete the inspection,
work on only one component group at a time. repair, assembly before proceeding to the next
This will help avoid confusion of similar-looking component group. If a component group cannot
parts from different subassemblies being on be assembled because parts are being ordered,
your workbench at the same time. be sure to keep all parts of that group in a
The component groups are inspected and separate container while proceeding with dis-
repaired from the converter housing side. assembly, inspection, repair and assembly of
other component groups.
GENERAL CLEANING NOTES:

1. All disassembled parts should be washed 3. When using compressed air to dry parts,
clean and the fluid passages and holes blown avo;d spraying ATF or kerosene in your face.
through with compressed air to make sure
they are not clogged.
2. Cleaning solvent used should be the recom-

meded automatic transmission fluid or
kerosene.
PARTS HANDLING NOTES:
1. After cleaning, the parts should be arranged 3. New brakes and clutches that are to be used
in proper order to allow performing the for replacement must be soaked in transmis-
inspection, repairs, and reassembly with effi- sion fluid for at least two hours before
ciency. assembly.
2. When disassembling a valve body, be sure to

keep each valve together with the corres-
ponding spring.
GENERAL ASSEMBLY NOTES:
1. All oil seal rings, clutch discs, clutch plates, 4. If a worn bushing is to be replaced, the re-
rotating parts, and sliding surfaces should be placement must be made with the subassem-
coated with transmission fluid prior to bly containing that bushing.
reassembly.
5. Check thrust bearings and races for wear or
2. All gaskets and rubber O-rings should be re- damage. Replace if necessary.
placed.
6. Use petroleum jelly to keep parts in their
3. Make sure that the ends of a snap ring are not places.
aligned with one of the cutouts and are
installed in the groove correctly.
AT-44 AUTOMATIC TRANSMISSION - Component Groups (Oil Pump)
Oil Pump
Pump Body Drive Gear Pump Cover

• O-Ring
Oil Seal Ring
• Oil Seal Driven Gear
• Non-reusable part ATOOOl
DISASSEMBLY OF OIL PUMP

1. USE TORQUE CONVERTER AS WORK STAND
2. REMOVE TWO OIL SEAL RINGS FROM PUMP COVER
3. REMOVE PUMP COVER

(a) Remove the six bolts.
(b) Remove the pump cover.
4. REMOVE O-RING FROM PUMP
5. LIFT PUMP OFF CONVERTER AND REMOVE Oil

PUMP DRIVE GEAR AND DRIVEN GEAR
Identify the top and bottom and keep in assembly order.
AUTOMATIC TRANSMISSION - Component Groups (Oil Pump) AT-45
INSPECTION OF OIL PUMP

1. CHECK BODY CLEARANCE OF DRIVEN GEAR
Push the driven gear to one side of the body. Using a
feeler gauge, measure the clearance.
Standard body clearance: 0.07 - 0.15 mm
(0.0028 - 0.0059 in.)
Maximum body clearance: 0.3 mm (0.012 in.)
If the body clearance is greater than maximum, replace the
C4717 drive gear, driven gear or pump body.
2. CHECK TIP CLEARANCE OF BOTH GEARS

Measure between the gear teeth and the crescent-shaped
part of the pump body.
Standard tip clearance: 0.11 - 0.14 mm
(0.0043 - 0.0055 in.)
Maximum tip clearance: 0.3 mm (0.012 in.)
If the tip clearance is greater than maximum, replace the
drive gear, driven gear or pump body.
C4718
3. CHECK SIDE CLEARANCE OF BOTH GEARS

Using a steel straightedge and a feeler gauge, measure the
side clearance of both gears.
Standard side clearance: 0.02 - 0.05 mm
(0.0008 - 0.0020 in.)
Maximum side clearance: 0.1 mm (0.004 in.)
If the side clearance is greater than maximum, replace the
drive gear, drive gear or pump body.
C4719
4. INSPECT FRONT OIL SEAL

Check for wear, damage or cracks.
If necessary, replace the oil seal as follows.
(a) Pry off the oil seal with a screwdriver.
AT0849
(b) Using SST and a hammer, tap in a new oil seal.

The seal end should be flush with outer edge of pump
body.
SST 09350-20015 (09388-20010)
AT-46 AUTOMATIC TRANSMISSION - Component Groups (Oil Pump)
ASSEMBLY OF OIL PUMP

(See page AT-44)
1. INSTALL DRIVEN GEAR AND DRIVE GEAR AND SET

PUMP BODY ON TORQUE CONVERTER
Make sure the top of the gears is facing upward.
2. LOOSELY INSTALL PUMP COVER

Align the bolt holes and drop the pump cover into the
place. Install the six bolts with the wave washers finger
tight.
3. ALIGN PUMP BODY AND PUMP COVER

Install the SST around body and cover.
Tighten SST to align the body and cover.
SST 09350-20015 (09363-20010)
4. TIGHTEN SIX PUMP COVER BOLTS

5. REMOVE SST
SST 09350-20015 (09363-20010)
6. INSTALL TWO OIL SEAL RINGS ON PUMP COVER

Spread apart and slide into the groove.
Hook both ends by ha nd.
Wipe off any excess petroleum jelly.
NOTE: After installing the oil seal rings, check that they
move smoothly.
7. INSTALL NEW O-RING ON PUMP

Make sure the a-ring is not twisted and is fully seated in the
groove.
8. CHECK DRIVE GEAR ROTATION

Turn the drive gear with SST and make sure it rotates
smoothly.
SST 09350-20015 (09397 -22020)
CAUTION: Be careful not to damage the oil seal lip.
AUTOMATIC TRANSMISSION - Component Groups (Overdrive Input Shaft and Clutch) AT-47
Overdrive Input Shaft and Clutch

Disc
Plate
Snap Ring
Piston Return Spring
• a-Ring
00 Clutch Drum
Race
Snap Ring
aD Brake Hub
Thinner Snap Ring
Cushion Plate
Spring Retainer Thrust Washer
~
00 Clutch Piston
Planetary Gear
Thrust Washer
One-Way Clutch
Thrust Washer
• Non-reusable part AT2427
DISASSEMBLY OF OVERDRIVE INPUT SHAFT

AND CLUTCH
1. REMOVE RACE FROM OVERDRIVE INPUT SHAFT
(a) Slide off the race from the clutch side by hand. Note
the position of the race.
(b) Using a screwdriver, pry off the thrust washer from
the planetary gear side.
AT0865
2. PULL OVERDRIVE CLUTCH ASSEMBLY FROM INPUT

SHAFT
CAUTION: Be careful that the thrust bearing and
race do not fall out.
AT-48 AUTOMATIC TRANSMISSION - Component Groups (Overdrive Input Shaft and Clutch)
3. REMOVE SNAP RING AND HUB FROM OVERDRIVE

CLUTCH ASSEMBLY
4. REMOVE DISC
5. REMOVE THINNER SNAP RING, PLATE AND

CUSHION PLATE
AT2448
6. COMPRESS PISTON RETURN SPRINGS AND REMOVE

SNAP RING
Place SST on the spring retainer and compress the springs
with a shop press. Using a screwdriver, remove the snap
ring.
SST 09350-20015 (09369-20040)
7. REMOVE SPRING RETAINER AND EIGHTEEN

SPRINGS
4/ AT2446
8. ASSEMBLE OVERDRIVE CLUTCH ON OIL PUMP AND

BLOW OUT PISTON
(a) Slide the overdrive clutch onto the oil pump.
(b) Apply compressed air to the oil pump to remove the
piston. (If the piston does not come out completely,
use needle-nose pliers to remove it.)
(c) Remove the overdrive clutch from the oil pump.
9. REMOVE CLUTCH PISTON O-RINGS
10. REMOVE SNAP RING FROM OVERDRIVE

PLANETARY GEAR ASSEMBLY
11. REMOVE THRUST WASHERS AND ONE-WAY

CLUTCH FROM PLANETARY GEAR ASSEMBLY
CAUTION: Be careful not to lose the four plugs.
12. REMOVE BEARING

Note the direction of the bearing.
C4731
13. REMOVE ONE-WAY CLUTCH FROM OUTER RACE

Note the direction of the one-way clutch.
C4733
INSPECTION OF OVERDRIVE INPUT SHAFT

AND CLUTCH
1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the
piston.
(b) Check that the valve does not leak by applying low-
pressure compressed air.
AT2447
2. INSPECT DISC, PLATE AND CLUTCH HUB

Check that the sliding surface of disc is not worn or burnt.
If the disc is worn or burnt, replace the disc.
Then check that the sliding surfaces of plate and hub are not
worn or bu rnt.
If necessary, replace them.
NOTE: Do not allow the disc to dry out.
Prepare a new disc by soaking it at least two hours in ATF.
AT2486
ASSEMBLY OF OVERDRIVE INPUT SHAFT

AND CLUTCH
(See page AT-47)
1. INSTALL BEARING
(a) Coat part with petroleum jelly to keep it in place.
(b) Slip in the bearing as shown in the figure.
AT2444
Front 2. INSTALL ONE-WAY CLUTCH

• (a)
(b)
Install the one-way clutch into the outer race.
Install the retainer on both sides of the one-way
clutch.
NOTE: Remember that the spring cage side of the one-
way clutch faces toward the front of the transmission.
ATOO32 C4733
3. INSTALL THRUST WASHER AND ONE-WAY CLUTCH

(a) Install the thrust washer, facing the grooves upward.
(b) Install the one-way clutch in correct direction.
(c) Install the thrust washer.
(d) Install the snap ring.
AT2416
AT-50 AUTOMATIC TRANSMISSION - Component Groups (Overdrive Input Shaft and Clutch)
4. INSTALL CLUTCH PISTON IN OVERDRIVE CLUTCH

DRUM
(a) Install new O-rings on the piston. Coat the O-rings
with ATF.
(b) Press the piston into the drum with the cup side up,
being careful not to damage the O-rings.
5. INSTALL EIGHTEEN PISTON RETURN SPRINGS AND

SPRING RETAINER AND SNAP RING IN PLACE
6. COMPRESS RETURN SPRINS AND INSTALL SNAP

RING IN GROOVE
(a) Place SST on the spring retainer, and compress the
springs on a shop press.
SST 09350-20015 (09369-20040)
(b) Using a screwdriver, install the snap ring.
@ Be sure the end gap of snap ring is not aligned with

the spring retainer claw.
7. INSTALL CUSHION PLATE AND PLATE
Plate
Cushion
Plate
AT2547
8. INSTALL THINNER SNAP RING IN OVERDRIVE

CLUTCH DRUM
Compress and lower the snap ring into the groove by hand.
Check that the ends ofthe snap ring are not aligned with one
of the cutouts.
9. INSTALL DISC
Using low-pressure compressed air, blow all excess ATF
from the disc.
AT2443 CAUTION: High-pressure air will damage the disc.
10. INSTALL HUB AND OUTER SNAP RING

Check that the ends of the snap ring are not aligned with
one of the cutouts.
AT2448
11. CHECK PISTON STROKE OF OVERDRIVE CLUTCH

Install the front clutch drum onto the oil pump body. Using a
dial indicator as shown, measure the stroke applying and
releasing the compressed air (4 - 8 kg/cm 2 , 57 - 114 psi
or 392 - 785 kPa).
Standard piston stroke: 1.77 - 2.58 mm
(0.0697 - 0.1016 in.)
If the stroke exceeds the limit, the clutch pack is probably
worn. If the stroke is less than the limit, parts may be
misassembled or there may be excess ATF on the disc.
12. ASSEMBLE OVERDRIVE CLUTCH DRUM AND

OVERDRIVE PLANETARY GEAR
Mesh the hub with the disc, twisting and jiggling the hub
as required.
13. CHECK OPERATION OF ONE-WAY CLUTCH

Hold the clutch drum and turn the input shaft. The input
shaft should turn freely clockwise and should lock coun-
terclockwise.
14. KEEP THRUST WASHER AND RACE
AT2435
AT-52 AUTOMATIC TRANSMISSION - Component Groups (Overdrive Case and Brake)
Overdrive Case and Brake
Cush ion Plate

Plate
Disc
Clutch Flange
Snap Ring
-----<
I
I
I
I
I OD Case
J
Bearing
Brake Piston
Spring Retainer
Oil Seal Ring

~
Race
T •
O-Ring
Snap Ring
Race
Thrust Washer
DISASSEMBLY OF OVERDRIVE CASE AND

BRAKE
1. REMOVE OUTER SNAP RING FROM OVERDRIVE
CASE
2. REMOVE CLUTCH FLANGE, DISCS PLATES AND

CUSHION PLATE
C4741
3. REMOVE RING GEAR AND THRUST WASHER
4. REMOVE THRUST BEARING AND RACES FROM

OVERDRIVE CASE
Note the position of the races.
AT2489
AUTOMATIC TRANSMISSION - Component Groups (Overdrive Case and Brake) AT-53
5. REMOVE SNAP RING, SPRING RETAINER AND

RETURN SPRINGS
C4229
6. REMOVE BRAKE PISTON

Blow compressed air through the case hole indicated in
the figure to pop out the brake piston.
If piston does not pop out, lift it out with needle nose
pliers.
7. REMOVE TWO OIL SEAL RINGS FROM OVERDRIVE

CASE
C4742
8. REMOVE O-RINGS FROM PISTON
INSPECTION OF OVERDRIVE CASE AND BRAKE

INSPECT DISC, PLATE AND FLANGE
If a disc is worn or burnt, replace all discs.
Then check that the sliding surfaces of plate and flange
are not worn or burnt.
AT2486
NOTE: Do not allow the discs to dry out.
Prepare new discs by soaking them at least two hours in
ATF.
ASSEMBLY OF OVERDRIVE CASE AND BRAKE

(See page AT-52)
1. INSTALL TWO OIL SEAL RINGS ON OVERDRIVE CASE

Spread apart and slide the rings into the groove. Hook
both ends by hand.
move smoothly.
AC4743
2. INSTALL NEW O-RINGS ON PISTON
3. INSTALL BRAKE PISTON IN OVERDRIVE CASE

Install the piston with the cup side up, being careful not to
damage the a-rings.
4. INSTALL RETURN SPRINGS AND SPRING RETAINER

AND SNAP RING IN PLACE
Check that the ends of snap ring are not aligned with one
of the cutouts.
AT2441
AT-54 AUTOMATIC TRANSMISSION - Component Groups (Overdrive Case and Brake)
5. INSTALL THRUST BEARING AND RACES TO RING

GEAR, AND SET RING GEAR IN OVERDRIVE CASE
NOTE: Make sure that the races are installed in correct
direction.
AT0867
6. INSTALL CUSHION PLATE, DISCS, PLATES AND

Flange FLANGE
Using low-pressure compressed air, blow all excess A TF
~~~~--I--Disc from the discs.
Plate ---+-i,
CAUTION: High-pressure air will damage the discs.
Cushion Install in order: Cushion plate (rounded end down)-plate-
Plate disc - pi ate-d isc - plate-d isc- flang e
AT2357

Check that the ends of the snap ring are not aligned with
one of the cutouts.
C4741
8. MEASURE BRAKE CLEARANCE

Measure the distance between the snap ring and flange.
(0.0256 - 0.0870 in.)
9. KEEP THRUST WASHER FOR ASSEMBLY

The thrust washer left over will be installed later, as the
transmission is assembled.
C4740
AUTOMATIC TRANSMISSION - Component Groups (Front Clutch) AT-55
Front Clutch
Snap Ring
Front Clutch Piston

Front Clutch Drum
Bearing
Plate
Spring Retainer
Bearing
Race • O-Ring Snap Ring
Front Clutch Hub
Bearing
Race
Rear Clutch Hub

Race
• Non-reusable port AT2428
DISASSEMBLY OF FRONT CLUTCH

1. REMOVE THRUST BEARINGS AND RACES FROM
BOTH SIDES OF CLUTCH
2. REMOVE SNAP RING FROM FRONT CLUTCH DRUM
C4762
3. REMOVE FRONT AND REAR CLUTCH HUB

Lift out the two clutch hubs together.
C4763
AT-56 AUTOMATIC TRANSMISSION - Component Groups (Front Clutch)
4. REMOVE THRUST BEARING AND RACES

5. REMOVE DISC
C4764
6. REMOVE THINNER SNAP RING
7. REMOVE REMAINING CLUTCH PLATES AND DISCS

SNAP RING
with a shop press.
Using a screwdriver, remove the snap ring.
SST 09350-20015 (09369-20040)
9. REMOVE SPRING RETAINER AND TWENTY

SPRINGS
C4768
10. ASSEMBLE FRONT CLUTCH ON OVERDRIVE CASE

AND BLOW OUT PISTON
(a) Slide the front clutch onto the overdrive case.
(b) Apply compressed air to the overdrive case to
remove the piston. (If piston does not come out com-
pletely, use needle-nose pliers to remove it.)
(c) Remove the front clutch from the overdrive case.
11. REMOVE O-RINGS FROM PISTON

C4769
INSPECTION OF FRONT CLUTCH

1. INSPECT FRONT CLUTCH PISTON
(a) Check that check ball is free by shaking the piston.
A T2440 A T2484
AUTOMATIC TRANSMISSION - Component Groups (Front Clutch) AT-57
2. INSPECT DISC, PLATE AND FLANGE

If the disc is worn or burnt, replace all discs.
NOTE: Do not allow the discs to dry out. Prepare new
discs by soaking them at least two hours in ATF.
AT2486
ASSEMBLY OF FRONT CLUTCH

(See page AT-55)
1. INSTALL NEW O-RINGS ON PISTON
2. INSTALL PISTON IN FRONT CLUTCH DRUM

Press the piston into the housing with the cup side up
(check ball down).
Be careful not to damage the O-rings.
3. INSTALL TWENTY PISTON RETURN SPRINGS,

SPRING RETAINER AND SNAP RING IN PLACE
4. COMPRESS RETURN SPRINGS AND INSTALL SNAP

RING IN GROOVE
SST 09350-20015 (09369-20040)
(b) Using a screwdriver, install snap ring.
Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.
5. INSTALL DISCS AND PLATES WITHOUT

ASSEMBLING THINNER SNAP RING
(a) Do not assemble the thinner snap ring yet.
(b) Using low-pressure compressed air, blow all excess
A TF from the discs. For measurement of the clutch
pack, install all plates and discs (temporarily without
thinner snap ring).
Install in order: Plate-disc-plate-disc-plate-disc-plate-disc
AT2417
6. CHECK PISTON STROKE OF FRONT CLUTCH

(a) Install the rear clutch hub and outer snap ring.
(b) Install the front clutch drum onto the overdrive case.
Using a dial indicator as shown, measure the stroke
applying and releasing the compressed air (4 - 8 kg/
cm 2 , 57 - 114 psi or 392 - 785 kPa).
Cutout (0.0520 - 0.1047 in.)
(=.-'IU"j--7'4-~r-Porti on
C4766
misassembled or there may be excess A TF on the discs.
AT-58 AUTOMATIC TRANSMISSION - Component Groups (Front Clutch)
7. INSTALL THINNER SNAP RING IN CLUTCH DRUM

(a) Remove the snap ring and rear clutch hub to allow
installation of the inner snap ring.
(b) Compress and lower into groove by hand. Check that
the ends of the snap ring are not aligned with one of
the cutouts.
8. INSTALL INNER THRUST BEARING AND RACES

IMPORTANT: Coat parts with petroleum jelly to
keep them in place.
Install the inner race, needle bearing and outer race. Press
them into place.
NOTE: Face the race lip toward the front clutch body.
A T2492
9. INSTALL FRONT CLUTCH HUB

Align the disc lugs with the hub teeth. Make sure the hub
meshes with all the discs and is fully inserted.
10. INSTALL REAR CLUTCH HUB AND OUTER SNAP RING

Check that the snap ring ends are not aligned with one of
the cutouts.
NOTE: Note the position of the thrust bearing and races,
and keep them together until assembly.
11. KEEP THRUST BEARINGS AND RACES TOGETHER
C4762
AUTOMATIC TRANSMISSION - Component Groups (Rear Clutch) AT-59
Rear Clutch
Disc
Plate
Plate
Snap Ring
Rear Clutch Drum
Rear Clutch Piston

• O-Ring
Spring Retainer
Snap Ring
DISASSEMBLY OF REAR CLUTCH

1. REMOVE SNAP RING FROM DRUM
2. REMOVE CLUTCH FLANGE, DISCS AND PLATES
/
AT0845

SNAP RING
with a shop press.
SST 09350-20015 (09369-20040)
4. REMOVE SPRING RETAINER AND EIGHTEEN

RETURN SPRINGS
C4781
J.\T-60 AUTOMATIC TRANSMISSION - Component Groups (Rear Clutch)
5. ASSEMBLE REAR CLUTCH ON CENTER SUPPORT

AND BLOW OUT PISTONS
(a) Slide the rear clutch onto the center support.
(b) Apply compressed air to the center support to remove
the piston. (If the piston does not come out completely,
use pliers to remove it.)
(c) Remove the rear clutch from the center support.
6. REMOVE O-RINGS FROM REAR CLUTCH PISTONS

C4782
INSPECTION OF REAR CLUTCH

1. INSPECT REAR CLUTCH PISTON
(a) Check that check ball is free by shaking each piston.
AT2439 AT2484

If the disc is worn burnt, replace all discs.
Then check that sliding surfaces of plate and flange are
not worn or burnt.
If necessary replace them.
AT2486
ASSEMBLV OF REAR CLUTCH

(See page AT-59)
1. INSTALL NEW O-RINGS ON PISTONS
2. INSTALL REAR CLUTCH PISTONS IN DRUM

Press the rear clutch pistons into the drum with the cup
side up, being careful not to damage the O-rings.·
C4784
3. INSTALL EIGHTEEN PISTON RETURN SPRINGS AND

SET RETAINER WITH SNAP RING IN PLACE

RING IN GROOVE
~
SST 09350-20015 (09369-20040)
C4781 C4774 Be sure the end gap of the snap ring is not aligned
AUTOMATIC TRANSMISSION - Component Groups (Rear Clutch) AT-61
5. INSTALL DISCS, PLATES AND FLANGE

from the discs.
CAUTION:I High-pressure air will damage the discs.
I
Install in or~er: Plate-disc-plate-disc-plate-disc-flange
I (rounded edge down)
6. INSTALL
the cutout.
7. CHECK PI TON STROKE OF REAR CLUTCH

Install the ar clutch onto the center support. Using a dial
indicator s shown, measure the stroke applying and
releasing t e compressed air (4 - 8 kg/cm 2 , 57 - 114 psi,
or 392 - 85 kPa).
Standard iston stroke: 1.06 - 2.14 mm
(0.0417 - 0.0843 in.)
If the strole exceeds the limit, the clutch pack is probably
worn. If t e stroke is less than the limit, parts may be
C4778 misassem led or there may be excess A TF on the discs.
I
AT-62 AUTOMATIC TRANSMISSION - Component Groups (Center Support Assembly)
Center Support Assembly
No.2 Brake Piston
Oil Seal Ring

No.1 Brake Piston
Spring Retainer
Plate
Disc
Snap Ring
Center Support
Piston Return Spring Oil Seal Ring
sunGear~ ~
Snap Ring
4WD only
J,
Flange One-way Clutch
Brake Hub
Snap Ring
9
Snap Ring
+Retainer
Retainer
+ Retainer
Flange
+ Non-reusable part AT2422
DISASSEMBLY OF CENTER SUPPORT

ASSEMBLY
1. REMOVE SNAP RING FROM END OF SUN GEAR
SHAFT
2. PULL CENTER SUPPORT ASSEMBLY FROM SUN

GEAR
3. REMOVE SNAP RING FROM FRONT OF CENTER

SUPPORT ASSEMBLY (NO.1 BRAKE)
4. REMOVE CLUTCH FLANGE, DISC(S) AND PLATE(S)

(NO.1 BRAKE)
AUTOMATIC TRANSMISSION - Component Groups (Center Support Assembly) AT-63

SNAP RING
SST
with a shop press.
Using a screwdriver, remove snap ring.
SST 09350-20015 (09369-20040)
6. REMOVE SPRING RETAINER AND TWELVE SPRINGS
C4791
7. REMOVE NO.1 BRAKE PISTON

Blow compressed air through the center support oil hole
~~.. to remove the No. 1 brake piston.
If the piston does not pop out, lift it out with needle-nose
pliers.
8. REMOVE NO. 1 BRAKE PISTON O-RINGS
A 12419
9. TURN CENTER SUPPORT ASSEMBLY OVER AND

REMOVE REAR SNAP RING (NO.2 BRAKE)
10. REMOVE CLUTCH FLANGE, DISCS AND PLATES

(NO.2 BRAKE)
C4796

SNAP RING
with a shop press.
Using a screwdriver, remove snap ring.
SST 09350-20015 (09369-20040)
12. REMOVE SPRING RETAINER AND TWENTY SPRINGS
C4798
13. REMOVE NO.2 BRAKE PISTON

Blow compressed air through the center support oil hole
to remove the NO.2 brake piston.
If the piston does not pop out, lift it out with needle-nose
pliers.
14. REMOVE NO.2 BRAKE PISTON O-RINGS
C4800
15. REMOVE THREE OIL SEAL RINGS FROM CENTER

SUPPORT
AT2396
16. REMOVE ONE-WAY CLUTCH ASSEMBLY AND OIL

SEAL RINGS FROM SUN GEAR
~1
AT0794 AT1062
INSPECTION OF CENTER SUPPORT

~-~'"
~ ~
ASSEMBLY
~~--="1-J----
\1 1. CHECK OPERATION OF ONE-WAY CLUTCH
~
Hold the No. 2 brake hub and turn the sun gear. The sun
gear should turn freely counterclockwise and should lock
clockwise.
~ If the one-way clutch does not work properly, replace it.
AT1063
2. IF NECESSARY, REPLACE ONE-WAY CLUTCH

(a) Bend several tabs back with a tapered punch.
(b) Pry off the retainer with a screwdriver. Leave the
other retainer on the hub.
(c) Remove the one-way clutch.
C4803
..
Front (d) Install one-way clutch into the brake hub, facing the
spring cage toward the front.
AT0032 C4812
(e) Hold the brake hub in a soft jawed vise, and flatten the
ears with a chisel.
(f) Check to make sure that the retainer is centered.
AT2355

NOTE: Do not allow the discs to dry out.
Prepare new discs by soaking them at least two hours in
AT2486
ATF.
ASSEMBLY OF CENTER SUPPORT

ASSEMBLY
(See page AT-62)
1. INSTALL TWO OIL SEAL RINGS AND ONE-WAY

CLUTCH ASSEMBLY ON SUN GEAR
move smoothly.
2. INSTALL THREE OIL SEAL RINGS ON CENTER

SUPPORT
Spread apart and slip them into the groove.
Hook both ends by hand.
move smoothly.
3. INSTALL NEW O-RINGS ON NO.1 BRAKE PISTON
4. INSTALL NO.1 BRAKE PISTON IN CENTER SUPPORT

Press No. 1 brake piston into the center support with the
cup side up, being careful not to damage the O-rings.
AT2418
5. INSTALL TWELVE PISTON RETURN SPRINGS AND


RING IN GROOVE
springs on shop press.
SST 09350-20015 (09369-20040)
C4791 ATO030 Be sure the end gap of the snap ring is not aligned
7. INSTALL NEW O-RINGS ON PISTON AND CENTER

SUPPORT
8. TURN CENTER SUPPORT OVER AND INSTALL NO.2

BRAKE PISTON
Press the No.2 brake piston into the center support with
the cup side up, being careful not to damage the O-rings.
9. INSTALL TWENTY PISTON RETURN SPRINGS AND


RING IN GROOVE
SST 09350-20015 (09369-20040)
Be sure the end gap of the snap ring is not aligned

BRAKE PISTON PLATE(S), DISC(S) AND FLANGE
from the discs.
CAUTION: High-pressure air will damage the disc(s).
Install in order:
2WD - Plate-disc-flange (rounded edge down)
4WD - Plate-disc-plate-plate-disc-flange (rounded
edge down)
12. INSTALL SNAP RING IN CENTER SUPPORT

cutouts.
13. CHECK PISTON STROKE OF NO.1 BRAKE

Using a dial indicator as shown, measure the stroke apply-
ing and releasing the compressed air (4 - 8 kg/cm 2 , 57 -
114 psi, 392 - 785 kPa).
Standard piston stroke:
2WD 0.78 - 1.50 mm (0.0307 - 0.0591 in.)
4WD 0.80 - 1.73 mm (0.0315 - 0.0681 in.)
C4788
misassembled or there may be excess A TF on the discs.

BRAKE PLATES, DISCS AND FLANGE
Using the low-pressure compressed air, blow all excess
ATF from the discs.
Install in order: Plate-disc-plate-disc-plate-disc-flange
(flat end down)
A11263
15. INSTALL SNAP RING IN CENTER SUPPORT

the cutouts.
16. CHECK PISTON STROKE OF NO.2 BRAKE

Using a dial indicator as shown, measure the stroke apply-
ing and releasing the compressed air (4 - 8 kg/cm 2 , 57 -
114 psi, or 392 - 785 kPa).
C4 79~ (0.0398 - 0.0886 in.)
misassembled or there may be excess ATF on the discs.
17. ASSEMBLE CENTER SUPPORT AND SUN GEAR

(a) Align the brake NO.2 disc flukes.
(b) Mesh the brake hub with the discs, twisting and jig-
gling the hub as required.
C4815
18. INSTALL SNAP RING ON END OF SUN GEAR

. . MATIC TRANS MISSION - Component G roups (Planetary G
68___A_U=-T.O
Planet ear Output Shaft)
ary Gea r 0 utput Shaft
Front PI anetary G ear
O ne-wa C
ressure PI y lutch
P ate
Snap Ring
Output Shaft
Plate
Race
Disc
r Thrust Bearing
Set Ring
Planetary R"mg Gear
DISASSEMBLY
OUTPUT SHAFTOF PLANETARY GEA
1. REMO
VE NO 3
R
FRONT PLANET:=AKE DISC/PLAT
Grasp th Y GEAR E PACK AND
e comp
output
B asht f. onents and pull off
e careful not to d the front end of th
rop the be anng
. on th e output shaft. e
2. REMOVE TH
PLANETARY ~UE~RWASHER FROM FR
NOTE: The t ONT
planetar y gear hrust
case. washe r may stick to the' .
REMO inside of th
VE BRA e
PLANETARY G~~~ISCS AND PLATES F
3.
REMOVE RE ROM FRONT
PLANETARY ~~~~N PLATE FROM FRONT

4.
AUTOMATIC TRANSMISSION - Component Groups (Planetary Gear Output Shaft) AT-69
5. REMOVE SNAP RING AND ONE-WAY CLUTCH FROM

FRONT PLANETARY GEAR
6. REMOVE THRUST WASHER FROM FRONT

PLANETARY GEAR
AT0795 A T0796
7. REMOVE APPLY TUBE AND CLUTCH PRESSURE

PLATE
8. COMPRESS SHAFT SNAP RING AND REMOVE FRONT

PLANETARY RING GEAR
(a) While pulling up the ring gear, compress the snap ring
with needle-nose pliers and remove it from the
groove.
(b) Pull out the ring gear by hand.
9. REMOVE INTERMEDIATE SHAFT FROM OUTPUT

SHAFT ASSEMBLY
10. REMOVE THRUST BEARING AND RACE FROM

OUTPUT SHAFT ASSEMBLY
Note the position of the race.
11. REMOVE THREE OIL SEAL RINGS FROM OUTPUT

SHAFT
AT2392
12. REMOVE NYLON WASHER FROM INTERMEDIATE

SHAFT ASSEMBLY
13. REMOVE PLANETARY SUN GEAR
C2424
AT-70 AUTOMATIC TRANSMISSION - Component Groups (Planetary Gear Output Shaft)
14. INVERT INTERMEDIATE SHAFT AND REMOVE SET

RING
15. REMOVE REAR PLANETARY RING GEAR AND

BEARING FROM INTERMEDIATE SHAFT
Note the direction of the bearing.
INSPECTION OF PLANETARY GEAR OUTPUT

SHAFT
INSPECT DISC, PLATE AND FLANGE
A 12485
ASSEMBLY OF PLANETARY GEAR OUTPUT

SHAFT
(See page AT-69)
1. INSTALL THRUST BEARING AND REAR PLANETARY

RING GEAR ON INTERMEDIATE SHAFT
Slip the thrust bearing and ring gear onto the shaft with the
C40li4
exterior splines upward as shown.
2. INSTALL SET RING ON INTERMEDIATE SHAFT

Push down the set ring and wind it into the place. Check to
make sure it is secure.
3. INSTALL REAR PLANETARY GEAR, NILON WASHER

ON REAR PLANETARY RING GEAR
Install the washer with the lugs downward, fitting it into the
rear planetary gear.
CAUTION: Make sure the different lug shapes match
the openings on the plate.
4. INSTALL THREE OIL SEAL RINGS ON OUTPUT SHAFT

Spread the rings apart and slide them into the groove.
Hook both ends by hand.
move smoothly.
5. INSTALL THRUST BEARING AND RACE ON OUTPUT
SHAFT
Hold the cup of the race toward the bearing.
AT2392
AUTOMATIC TRANSMISSION - Component Groups (Planetary Gear Output Shaft) AT-71
6. INSTALL REAR PLANETARY GEAR WITH

INTERMEDIATE SHAFT ASSEMBLY IN OUTPUT
SHAFT
Slide it into place, and make sure that the lugs interlock.
C4506
7. INSTALL PLANETARY SUN GEAR
8. SET FRONT PLANETARY RING GEAR IN PLACE

Slide the snap ring downward, and align the lugs with the
notches.
Align the ends of the snap ring with the wide gap between
the teeth.
9. INSTALL FRONT PLANETARY RING GEAR WITH

SNAP RING
While pushing down the ring gear, squeeze the snap ring
end with, needle-nose pliers and install it into the groove.
NOTE: When the snap ring is fully seated, the gap is the
width of one lug.
10. INSTALL NYLON WASHER IN FRONT PLANETARY

GEAR
Face the lugs downward and match them with the slots in
back of the planetary gear.
AT2421
•
Front
11. INSTALL ONE-WAY CLUTCH
Install the one-way clutch into the outer race, facing the
spring cage toward the front.
ATOO27 C4061
AT-72 AUTOMATIC TRANSMISSION - Component Groups (Planetary Gear Output Shaft)
13. TEMPORARILY INSTALL REACTION PLATE ON

FRONT PLANETARY GEAR
Insert it into place for test of the one-way clutch.
14. TEST ONE-WAY CLUTCH

The planetary gear must rotate freely counterclockwise
and lock clockwise.
If the clutch does not work correctly, it must be replaced.
C4066 15. REMOVE REACTION PLATE
16. INSTALL THRUST WASHER ON FRONT PLANETARY

GEAR
Apply petroleum jelly to washer to hold it in place during
later assembly. Match the lugs with the planetary gear
while installing.
17. INSTALL FRONT PLANETARY GEAR ASSEMBLY TO

INTERMEDIATE SHAFT
C4067
18. INSTALL PRESSURE PLATE

Install the pressure plate, facing the flat surface toward
the intermediate shaft.
19. INSTALL NO.3 BRAKE CLUTCH PACK

Using low-pressure compressed air, blow all excess A TF
from the discs.
Install in order: Disc-plate-disc-plate-disc-plate-disc-
plate-disc
20. KEEP REACTION PLATE, APPLY TUBE, THRUST

BEARING AND RACE TOGETHER
AUTOMATIC TRANSMISSION - Component Groups
(Transmission Case and Rear Brake Pistons) AT-73
Transmission Case and Rear Brake

Pistons
Transmission Case
+O-Ring
NO.3 Brake Outer Piston
Spring Retainer
Piston Return Spring Inner Piston

Sleeve
Snap Ring
• Non-reusable part ATOO12
DISASSEMBLY OF TRANSMISSION CASE

SST
AND REAR BRAKE PISTONS
1. COMPRESS RETURN SPRINGS AND REMOVE SPRING
RETAINER SNAP RING
(a) Install the SST. Gradually and evenly tighten the bolt
to compress the springs, being careful not to damage
the transmission case with SST.
SST 09350-20015 (09369-20040)
L..-- Z2_11--14 (b) Using the screwdriver and a hook, remove the snap
ring.
2. REMOVE SPRING RETAINER AND SIXTEEN SPRINGS

AT-74 (Transmission Case and Rear Brake Pistons)
3. REMOVE OUTER PISTON AND REACTION SLEEVE

WITH COMPRESSED AIR
(a) Turn the case over face down on a workbench. Place
several clean shop rags under the case to catch the
piston and sleeve. To pop them out, apply com-
pressed air to the outer and inner piston oil holes.
If the piston and sleeve do not pop out with compressed

air:
(b) Using needle-nose pliers, lift the outer piston from
the case.
AT0876
(c) Insert two long hooks behind the reaction sleeve and
slowly lift it out of the case.
(d) Using hooks, lift the inner piston out of the case in
the same manner.
4. REMOVE O-RINGS FROM OUTER AND INNER

PISTONS AND REACTION SLEEVE
AT0877
INSPECTION OF CASE COMPONENT GROUP

REPLACEMENT OF MANUAL SHAFT OIL SEALS
(a) Remove the manual shaft oil seals with a screwdriver.
(b) Drive in new left and right oil seals with SST.
SST 09350-20015 (09361-30011)
(See page AT-73)
1. INSTALL NEW O-RINGS ON REACTION SLEEVE AND

PISTONS
CAUTION: The thinner O-ring goes on the outside of
the reaction sleeve.
2. INSTALL INNER AND OUTER PISTONS IN REACTION

SLEEVE
(a) Push the inner piston into the cupped side of the
Thinner reaction sleeve.
AT0878 AT0879
(b) Push the outer piston onto the other side of the reac-
tion sleeve.
(Transmission Case and Rear Brake Pistons) AT-75
3. INSTALL PISTONS AND SLEEVE IN CASE

CAUTION: Be careful not to damage the O-rings.
Hold the assembly with the outer piston up (spring seats
visible), and push the assembly into its bore in the case.
4. INSTALL SST BASE UNDER CASE

SST 09350-20015 (09369-20040)
AT2488 A T0031
5. INSTALL SIXTEEN PISTON RETURN SPRINGS AND

NOTE: Springs are visible through cutout in the case,
which helps to position them more easily.
C4071
6. COMPRESS PISTON RETURN SPRINGS TO ALLOW

SST INSTALLATION OF SNAP RING
CAUTION: Avoid bending the spring retainer by
overtightening the bolts.
(a) Carefully position the spring compressor on the
spring retainer.
(b) Gradually and evenly tighten the bolt to compress the
springs, being careful not to damage the transmis-
sion case with SST.
Z2114
SST 09350-20015 (09369-20040)
@ (a)
(b)
Push it into place by hand. Visually check to make
sure it is fully seated and centered by the three lugs
on the spring retainer.
Remove the SST.
SST 09350-20015 (09369-20040)
A T0030 A T0821
AT-76 AUTOMATIC TRANSMISSION - Component Groups (Valve Body)
Valve Body
t
Upper Rear
J-----Valve Body
Upper Front
Valve Body
~------.Gasket
~---ManualDetent Spring
(Disassembly of Valve Body)

1. REMOVE DETENT SPRING
2. REMOVE MANUAL VALVE
C4236
3. TURN ASSEMBLY OVER AND REMOVE TEN BOLTS

FROM UPPER FRONT VALVE BODY AND UPPER REAR
VALVE BODY
C4238
AUTOMATIC TRANSMISSION - Component Groups (Valve Body) AT-77
4. TURN ASSEMBLY OVER AND REMOVE SET BOLTS

FROM LOWER VALVE BODY
C4240
5. LIFT OFF LOWER VALVE BODY AND PLATE AS

SINGLE UNIT
NOTE: Be careful that none of the valves or balls fallout.
C4241
(Lower Valve Body)
1-2 Shift Upper Valve
_~o~e DO
~~O
3-4 Shift Valve
~rnJ 0
D-2 Down Timing Valve
cn--Jb:o ~ D
~-.
Lock-up Signal Valve
p&;;;:va~L
~
Plunger
J
Sleeve
0
~ CJ r1lflit::Jl []:tlfiJ
r- ~ ~Lock-upRelay Valve
Pressure Relief Valve

our~ Sleeve
I--------Manual Valve
AT2424
DISASSEMBLY OF LOWER VALVE BODY

1. REMOVE LOWER VALVE BODY PLATE AND
GASKETS
AT1042
2. REMOVE DAMPING CHECK BALL, COOLER RETURN

CHECK BALL, COOLER BY-PASS VALVE AND
SPRINGS
AT2487
3. TURN ASSEMBLY OVER, REMOVE SET BOLT AND

REMOVE LOWER BODY COVER, PLATE AND
GASKETS
C4325
4. REMOVE CHECK BALLS

Remove check balls, being careful not to scratch the
grooves. Keep the balls together to prevent losing them.
o~
00
AT2332
5. REMOVE SPRING RETAINER FROM PRESSURE RELIEF

ASSEMBLY
CAUTION: Cover the spring four hand. Then, using
needle-nose pliers, slowly pull out the spring seat,
being careful not to bend the spring.
6. REMOVE PRESSURE RELIEF SPRING AND BALL
C4327
7. REMOVE PLATE AND GASKET
8. REMOVE LOCK-UP RELAY VALVE

(a) Remove plug retainer and plug.
C4328 C4329
(b) Remove sleeve with lock-up relay valve, control valve

and spring.
AT1883
9. REMOVE SPRING RETAINER FROM PRIMARY

REGULATOR VALVE
WARNING: Highly compressed spring inside - keep
away from face.
C4344
10. REMOVE SLEEVE, PLUNGER, SPRING AND PRIMARY

REGULATOR VALVE
AT1006
11. REMOVE LOCATING PIN FOR LOCK-UP SIGNAL

VALVE
12. REMOVE PLUG, SPRING AND LOCK-UP SIGNAL

~ VALVE
~e~
I® C4331 C4332
13. REMOVE PLUG RETAINER FOR 0-2 DOWN TIMING

VALVE
14. REMOVE PLUG AND 0-2 DOWN TIMING VALVE
C4334
15. REMOVE PLUG LOCATING PIN FOR 3-4 SHIFT VALVE

16. REMOVE PLUG, 3-4 SHIFT VALVE AND SPRING
C4335 C4336
AUTOMATIC TRANSMISSION - Component Groups (Valve Body) AT-a1
17. REMOVE PLUG RETAINER FOR 1-2 SHIFT VALVE
18. REMOVE PLUG, 1-2 SHIFT VALVE AND SPRING
19. REMOVE COVER PLATE
AT2331 A12330
20. REMOVE REVERSE BRAKE SEQUENCE PLUG
21. REMOVE lOW-COAST SHIFT VALVE
AT2335 AT2334
22. REMOVE lOCATING PINS FOR THIRD-COAST VALVE
23. REMOVE PLUGS, THIRD-COAST VALVE AND 3-4

CONTROL VALVE
C4340 C4341
INSPECTION OF LOWER VALVE BODY

INSPECT VALVE SPRINGS
Check for damage, squareness, rust and distorted coils.
Measure the spring free height and replace it if less than
--------
that shown below.
Free length mm (in.) Color

(1) (2) (3) (4) (5) (6) (7) (8) (9)
(1) Primary regulator valve 61.20 (2.4094) White
AT2426 (2) 1-2 shift valve 34.62 (1.3630) None
(3) 3-4 shift valve 36.28 (1.4283) Red

(4) Oil cooler by-pass valve 28.90 (1 .1378) Orange
(5) Pressure relief valve 32.14 (1.2654) None
(6) Damping check ball 20.00 (0.7874) None
(7) Lock-up relay valve 18.50 (0.7283) White

(8) Lock-up signal valve 38.60 (1.5197) Light Blue
(9) Cooler return ball 13.70 (0.5394) None

ASSEMBLY OF LOWER VALVE BODY

(See page AT-78)
1. INSTAll REVERSE BRAKE SEQUENCE PLUG
2. INSTAll lOW-COAST SHIFT VALVE

Carefully insert the low-coast shift valve with the small
end first.
3. INSTAll 3-4 COAST SHIFT VALVE AND

THIRD-COAST VALVE
(a) Insert the 3-4 coast shift valve with the cup side first.
(b) Insert the 3rd-coast valve with the small end first.
C4351
4. INSTAll TWO PLUGS AND lOCATING PIN

(a) Insert the inside plug with the thick face first.
(b) Using needle-nose pliers, insert the locating pin.
(c) Insert the outside plug, and then insert the locating
pin.
ATl025
5. INSTAll COVER PLATE

6. INSERT SPRING, 1-2 SHIFT UPPER VALVE, LOWER

VALVE AND PLUG
Set the valve body on edge and carefully insert the spring,
1-2 shift upper valve, lower valve and plug.
7. INSTALL 1-2 SHIFT VALVE PLUG RETAINER
C4356 C4357
8. INSERT SPRING, 3-4 SHIFT VALVE AND PLUG

Set the valve body on edge and carefully insert the spring,
3-4 shift valve (small end first) and plug.
9. INSTALL 3-4 SHIFT VALVE PLUG LOCATING PIN
10. INSTALL 0-2 DOWN TIMING VALVE AND PLUG

Insert the D-2 down timing valve with the small end first
and then the plug with the large end first.
11. INSTALL 0-2 DOWN TIMING VALVE RETAINER
AT1026
12. INSERT LOCK-UP SIGNAL VALVE, SPRING AND PLUG

Insert the lock-up signal valve (large end first), spring and
plug with the small end first.
13. INSTALL LOCK UP SIGNAL VALVE LOCATING PIN
14. INSERT PRIMARY REGULATOR VALVE AND SPRING

Set the valve body on the edge and drop in the valve with
the large end first and the spring.
15. CHECK VALVE POSITION

Make sure that the primary regulator valve fits flush with
the valve body.
16. INSERT REGULATOR VALVE PLUNGER INTO SLEEVE

Insert with the rounded end first. Make sure that it is fully
~~
inserted: the plunger should be recessed inside the sleeve.
17. INSERT SLEEVE WITH PLUNGER
18. INSTALL REGULATOR VALVE SPRING RETAINER

/
/
/ AT2442 C4350
19. INSERT LOCK-UP RELAY VALVE

(a) Assemble the spring, lock-up relay control valve,
lock-up relay valve and plug into the sleeve.
Insert . . . . . . Insert
AT1884
(b) Insert the sleeve into the bore.

Smaller Hollow NOTE: Insert the sleeve with the smaller hollow on the
sleeve top side facing upward as shown in the figure.
(c) Install the plug retainer.
AT2420
20. INSTALL PRESSURE RELIEF BALL, SPRING AND

RETAINER
21. CHECK RETAINERS AND LOCATING PINS

Make sure that the retainers and pins are installed correct-
ly.
AT1028
22. INSTALL FOUR CHECK BALLS
C4362
23. INSTALL PLATE WITH GASKET

Tighten the four bolts.
Torque: 55 kg-em (48 in-Ib, 5.4 N'm)
24. INSTALL LOWER BODY COVER

Body Side Cover Side
Install in the following order.
Gasket-plate-gasket-cover.
NOTE: The two gaskets are not interchangeable.
C4364 C4366
25. INSTALL LOWER BODY COVER SET BOLTS

C4368
26. INSTALL CHECK BALL, (¢5.5 mm/O.217 in.)

<b6.35 DAMPING CHECK BALL, (1)6.35 mm/O.250 in.)
<b5.5
SPRING, OIL COOLER BY-PASS VALVE, SPRING,
<1>9.5
CJ
COOLER RETURN BALL (¢9.5 mm/O.375 in.) AND
SPRING
A T1888
27. INSTALL LOWER VALVE BODY GASKET

00. OO~C::::>Oo 0
o
0"0
00' ••
.00.
~
0 Note that the two gaskets are not interchangeable. The
~ ~ ~~ 0 0 :. a 0 0 0
gasket must lay flat on the valve body.
• 00 ~oo 0 = 0
0'0= • O. =. CAUTION: Make sure that the new gasket matches
o 0 00 ' 0 : • o· 0'.
c 0 0 0° 0 <=> 0 the old one.
o o' 00 0 0 00 0; •0
00 0 0 ~01;J° •
o
o
0 0 0 00U 0
°oooo~~o
Lower Valve Body Side
28. INSTALL LOWER VALVE BODY PLATE

Set the plate into place. Temporarily install the two short
bolts finger tight to compress the plate against the spring-
loaded check valve.
NOTE: Use the bolt for the oil strainer.
(4248
(Upper Front Valve Body)
Retainer
Cut-back Valve
Plug
i
~ThrottleCam
~ Cam Pin
Retainer-----D EJ Spring
Throttle Valve
Down-shift Spring
Secondary Regulator Valve
Cover
A T1251
DISASSEMBLY OF UPPER FRONT VALVE

BODY
1. REMOVE RETAINER FOR CUT-BACK PLUG AND
THROTTLE VALVE RETAINER
2. REMOVE PLUG AND CUT-BACK VALVE
AT2478 AT2490
3. REMOVE SECONDARY REGULATOR VALVE AND

SPRING
(a) Remove one bolt from the plate over the valve and
loosen the other one. Slowly rotate the plate to
uncover the valve.
WARNING: The valve is spring loaded.
(b) Remove the valve and spring. Keep the spring with
the valve.
(c) Remove the other bolt and remove the cover plate.
C4267 C4269
AT-SS AUTOMATIC TRANSMISSION - Component Groups (Valve Body)
4. PUSH DOWN-SHIFT PLUG INTO VALVE BODY AND

TEMPORARILY HOLD IN THROTTLE VALVE
Temporarily hold the throttle valve in position with the
cut-back valve plug retainer.
5. REMOVE THROTTLE CAM
C4270 C4271
6. REMOVE DOWN-SHIFT PLUG AND SPRING

Press on the down-shift plug so that the temporary
retainer falls out.
C4272
7. REMOVE THROTTLE VALVE
S. REMOVE SPRING AND ADJUSTING RINGS

Note the number of adjusting rings installed.
C4273
INSPECTION OF UPPER FRONT VALVE BODY

es INSPECT VALVE SPRINGS
ss Check for damage, squareness, rust and collapsed coils.

Measure the spring free height and replace if less than that
s
I --------
shown below.
B a§
B
~
8
~
Free length mm (in.) Color
(1) Secondary regulator valve 71.27 (2.8059) Green
(1 ) (2) (3)
AT2358 (2) Down-shift plug 39.76 (1.5654) Purple
(3) Throttle valve 21.94 (0.8638) None
ASSEMBLY OF UPPER FRONT VALVE BODY

(See page AT - 78)
1. INSERT THROTTLE VALVE

Note the arrangement in the photo. Make sure that the
valve is inserted fully into the bore.
2. INSTALL THROTTLE VALVE RETAINER

Coat the clip with petroleum jelly to keep it in place. Note
C4276 C4277 position of the tabs in the figure. Slip the retainer into place
in the valve body.
3. INSTALL ADJUSTING RINGS AND SMALL SPRING

ON THROTTLE VALVE SHAFT
(a) Slip the spring over the end of the valve shaft.
Compress and slide it into place.
(b) Install the same number of adjusting rings as were
removed during disassembly.
C4279 C4278
4. INSERT SPRING AND DOWN-SHIFT PLUG
5. TEMPORARILY INSTALL RETAINER OF CUT-BACK

PLUG TO HOLD DOWN-SHIFT PLUG IN PLACE
Push the down-shift plug into the valve body and tem-
porarily install the retainer.
C4280
6. ASSEMBLE THROTTLE CAM

~----
(a) Install the spring with the hook through the hole in
the cam.
(b) Insert the sleeve through one side of the cam.
AT2363 AT2362
7. INSTALL CAM ASSEMBLY ON UPPER FRONT VALVE

BODY
Check the position of the spring ends against the figure.
Tighten the bolt.
8. REMOVE TEMPORARILY INSTALLED RETAINER

NOTE: After assembly, check that the cam rotates
smoothly throughout its full stroke.
C4283
9. INSTALL SECONDARY REGULATOR VALVE

(a) Partially install the cover plate and insert the spring
and secondary regulator valve.
(b) Compress the spring and swing the cover plate into
place.
(c) Install the second bolt in the cover plate and tighten
both bolts.
C4286
10. INSERT CUT-BACK VALVE AND PLUG

Install the valve with the smaller end first.
11. INSTALL CUT-BACK VALVE RETAINER

Coat the valve with petroleum jelly to keep in place.
C4290
(Upper Rear Valve Body)
Plug
=~
2-3 Shift
Valve
---tr8
Intermediate_ _ ~
I o
-l
..,1
I I
I I
I I
Shift Valve t::;;j I I
I I
I I
o 0 0 0
o Check Ball
I I
I L ~ Governor Modulator Plug
I
Lu? IftIMM
I
Plug Low-coast
Modulator Valve
AT2299
DISASSEMBLY OF UPPER REAR VALVE BODY

1. REMOVE CHECK BALLS WITH TWEEZERS
Three rubber balls and one steel ball.
C4294
2. REMOVE INTERMEDIATE SHIFT VALVE RETAINER
3. REMOVE PLUG, INTERMEDIATE SHIFT VALVE AND

~~< SPRING
o~~c
< "1
C4295 C4296
AUTOMATIC TRANS MISSION
4 - Component G roups (Valve Body)
. REMOVE
(a) R 2 -3 SHIFT VALVE
emove th e 2-3 shift v
(b) Remove the plu alve retainer
9 and 2-3 shofI t valveo
C4297 C4298
5.
MODU~~~~~TATE
REMOV E ONE BOLT FRO
SLIGH M VALVE BOD
6. COVER TO R Y SIDE-COAST
COVER
VALVE ONLY ELEASE LOW
7. REMOVE SPRING AND LOW-COAST MODULATOR

VALVE
8.
GOVERNOR ~~~~~~~~RRA
ROTATE COV ND
p LUG REMOVE
C4303
AND REAR CLU~C~U~~~~~NAND

9. ROTATE COVE
CE VALVE
REMOVE SPRING
10. REMOVE COVER PLATE, SPRING AND

INTERMEDIATE MODULATOR VALVE
C4305
11. REMOVE DETENT REGULATOR VALVE RETAINER

/
12. REMOVE SPRING AND DETENT REGULATOR VALVE
of'
~~ AT2366 AT2367
INSPECTION OF UPPER REAR VALVE BODY

INSPECT VALVE SPRINGS
~ g
I II
Check for damage, squareness, rust and collapsed coils.
~
~
~
8
i~ Measure the spring free height and replace it if less than
that shown below.
8
(1 ) (2) (3)
-="
(4) (5)
~ Free length mm (in.) Color
(1) Low-coast modulator valve 42.35 (1.6673) None
AT2333 (2) Rear clutch sequence valve 37.55 (1.4783) Red
~-
(3) 2-3 shift valve 35.10 (1.3819) White

(4) Detent regulator valve 32.08 (1.2630) None
--
(5) Intermediate modulator valve 27.26 (1.0732) Green

ASSEMBLY OF UPPER REAR VALVE BODY

(See page AT-91)
1. INSTALL DETENT REGULATOR VALVE, SPRING AND

RETAINER
Insert the valve (round end first) and spring into the bore.
Compress the spring with a large screwdriver and slip the
retainer over the edge of the spring. Then compress the
spring and allow the retainer to fall into place.
C4309 C431 () NOTE: Make sure that the retainer fully covers the end of
the spring.
2. INSERT INTERMEDIATE MODULATOR VALVE AND

SPRING
Insert the valve with the round end first, and then insert
the spring.
(;4311
3. INSTALL VALVE BODY SIDE COVER WITH ONE BOLT
4. INSERT REAR CLUTCH SEQUENCE VALVE AND

SPRING
the spring.
C4312
5. INSERT GOVERNOR MODULATOR PLUG
C4314
6. INSERT LOW MODULATOR VALVE AND SPRING

the spring.
7. POSITION COVER AND INSTALL SECOND BOLT

Install the 2nd bolt, and then tighten both bolts.
C4315 C4316
8. INSERT 2-3 SHIFT VALVE

(a) Insert the 2-3 shift valve with the smaller end first,
and then insert the plug.
(b) Compress plug and install the intermediate shift
valve retainer in the valve body.
C4317 C4318
9. INSERT SPRING AND INTERME:OIATE SHIFT VALVE

INTO BORE
Insert valve with the round end upwards.
10. INSERT PLUG AND RETAINER
C4319 C4320
11. INSTALL CHECK BALLS AS SHOWN

Install the steel ball in the position shown in the figure.
The three rubber balls are identical and may be installed in
Steel any other of the positions.
Ball
C4243
(Assembly of Valve Body)

1. POSITION NEW GASKET ON UPPER REAR VALVE
BODY
Make sure that the new gasket matches the old gasket
before installation. Align the gasket at the lower right cor-
ner.
AT1030
2. PLACE lOWER VALVE BODY WITH PLATE ON TOP

OF UPPER REAR VALVE BODY
Align the right edge.
AT1031
3. INSTAll AND FINGER TIGHTEN THREE BOLTS IN

lOWER VALVE BODY TO SECURE UPPER REAR
VALVE BODY
NOTE: Each bolt length (mm) is indicated in the figure.
4. TURN ASSEMBLY OVER, CHECK GASKET

ALIGNMENT AND FINGER TIGHTEN FIVE BOLTS IN
UPPER REAR VALVE BODY
5. REMOVE TEMPORARY BOLTS FROM PLATE
C4355
6. PLACE LOWER AND UPPER REAR VALVE BODY

ASSEMBLY ON TOP OF UPPER FRONT VALVE BODY
C4256
7. FINGER TIGHTEN SET BOLTS IN LOWER VALVE

BODY TO SECURE UPPER FRONT VALVE BODY
C4258
8. TURN ASSEMBLY OVER AND FINGER TIGHTEN FIVE

BOLTS IN UPPER FRONT VALVE BODY
C4259
9. TIGHTEN BOLTS IN UPPER FRONT AND REAR VALVE

BODIES
Recheck alignment of the gaskets. Tighten the bolts.
C4260
10. TURN ASSEMBLY OVER AND TIGHTEN BOLTS IN

LOWER VALVE BODY
Tighten the bolts.
11. INSERT MANUAL VALVE
AT 1032
12. INSTALL DETENT SPRING

Tig hten the bolts.
40 mm (1.57 in.)
C4263
AUTOMATIC TRANSMISSION - Component Groups (Governor Body) AT-99
Governor Body
~ E-Ring
® Governor Weight
Q Governor Valve
I Spring
I Spring
D Secondary Weight
dl; Governor Valve Shaft
~-----Retaining Clip
~----.Lock Plate
DISASSEMBLY OF GOVERNOR BODY

1. REMOVE E-RING AND GOVERNOR WEIGHT
Compress the spring by pushing up on the shaft and down
on the weight. Remove the E-ring with a screwdriver. Lift
off the governor weight.
2. REMOVE GOVERNOR VALVE

Slide it down through the bore.
C2414
3. REMOVE RETAINING CLIP

Remove the clip end, indicated by the arrow, being careful
not to scratch the governor body.
C2415
AT-100 AUTOMATIC TRANSMISSION - Component Groups (Governor Body)
INSPECTION OF GOVERNOR BODY

ASSEMBLY OF GOVERNOR BODY
(See page AT-99)
1. INSTALL RETAINING CLIP

Install the clip end, indicated by the arrow, being careful
not to scratch the governor body.
C2415
2. INSTALL GOVERNOR VALVE, WEIGHT, SPRINGS

AND SHAFT
(a) Install the secondary weight to the shaft.
(b) Install the two springs.
(c) Slide down the governor valve through the bore.
C2416
(d) Slide down the springs and shaft through the bore.
C2419
3. INSTALL GOVERNOR WEIGHT AND E-RING ON

SHAFT
Compress the spring, and install the E-ring on the shaft
with needle-nose pliers. Make sure that it is fully seated in
the groove.
NOTE: Make sure that the valve moves smoothly.
(Extension Housing, Torque Converter) AT-101
Extension Housing (2WD)
1t-:~ INSPECTION OF SPEEDOMETER GEAR AND

EXTENSION HOUSING
1. IF NECESSARY, REPLACE SPEEDOMETER GEAR OIL
(Install) 19.7 - 20.3 mm SEAL
(0.776 - 0799 in.)
~~':-cr~~SST
~4_~ SST 09921-00010
WM0108
WM0109 (b) Using SST, install a new oil seal.
SST 09201-60011
2. IF NECESSARY, REPLACE OIL SEAL AND DUST SEAL

SST 09308-10010
(b) Using SST, drive in a new oil seal and dust seal.
SST 09325-20010
OR0004 OR0005
Torque Converter
CLEAN TORQUE CONVERTER
.s~~ If the transmission is contaminated, the torque converter

and transmission cooler should be thoroughly flushed,
with Toyota Transmission Cleaner.
. . " • )
INSPECTION OF TORQUE CONVERTER
AT0952
1. INSERT SST IN END OF TORQUE CONVERTER
(a) Insert a turning tool in to the inner race of the one-
way clutch.
(b) Insert the stopper so that it fits in the notch of the
converter hub and other race of the one-way clutch.
SST 09350-20015 (09397-22020)
AT0953
2. TEST ONE-WAY CLUTCH

The clutch should lock when turned counterclockwise,
and should rotate freely and smoothly clockwise. Less
than 25 kg-cm (22 in.-Ib, 2.5 N'm) of torque should be
required to rotate the clutch clockwise. If necessary, clean
the converter and retest the clutch. Replace the converter
if the clutch still fails the test.
AT0954
AT-102 AUTOMATIC TRANSMISSION - Component Groups (Electrical Parts)
Electrical Parts
1. INSPECT OVERDRIVE SOLENOID
Check the resistance between the terminals.
Ohmmeter Standard resistance: About 13 n
~
o
ATl228
2. INSPECT NEUTRAL START SWITCH

Using an ohmmeter, check the continuity of the terminals
for each switch position shown in the table below.
Ohmmeter If continuity between the terminals is not as specified, re-
~l place the switch.
~---------,-------r-------,--------,---.--,
Terminal
B N RB RL
Range
ELOOO7 p 0 -0
R 0 --0
N 0 D
AUTOMATIC TRANSMISSION - Assembly of Transmission AT-103
ASSEMBLY OF TRANSMISSION
Disassembly, inspection and assembly of each If something wrong is found in a certain compo-
component group have been indicated in the nent group during assembly, inspect and repair
preceding chapter. this group immediately.
Before assembly, make sure again that all com-
ponent groups are assembled correctly.
GENERAL ASSEMBLY NOTES:

1. The automatic transmission is composed of 5. Do not use adhesive cement on gaskets and
highly precision-finished parts, necessitating similar parts.
careful inspection before assembly because
even a small nick could cause fluid leakage or
affect performance.
2. Before assembling new clutch discs, soak 6. When assembling the transmission, be sure
them in automatic transmission fluid for at to use new gaskets and O-rings.
least two hours.
3. Apply automatic transmission fluid on sliding 7. Dry all parts by blowing with compressed air.
or rotating surfaces of the parts before Never use shop rags.
assembly.
4. Use petroleum jelly to keep the small parts in 8. Be sure to install the thrust bearings and
their places. races in the correct direction and position.
D E F G H
B
c F G H
D E
..
Front
AT2425
AT2477
AT-104 AUTOMATIC TRANSMISSION - Assembly of Transmission
1. PLACE TRANSMISSION CASE ON CYLINDER

Place the transmission on a cylindrical stand for more effi-
cient work.
CAUTION: Place shop rags between the case and
stand to avoid damaging the case.
A T0897
2. INSTALL THRUST WASHER AND BEARING

Install the thrust washer, facing the cup side downward.
Z2138
C4464
3. INSTALL APPLY TUBE ONTO OUTER PISTON OF

Brake NO.3 Piston REAR BRAKE PISTONS
Install the tube, aligning its locking tab (part A) with part B
of the case.
NOTE: Make sure that the lips of the tube end are com-
pletely inserted onto the outer piston.
4. PARTIALLY INSERT OUTPUT SHAFT ASSEMBLY

INTO CASE
5. CHECK CLUTCH PACK CLEARANCE

With the case in upright position, make sure that the
clutch pack is lower than the ledge below the snap ring
groove.
If the clutch pack is not lower than the ledge, components
may be misassembled or there may be excess A TF on the
discs.
Standard clearance:
0.61 - 2.64 mm (0.0240 - 0.1039 in.)
AT0016 C4876
6. INSTALL REACTION PLATE

Position the notched tooth of the reaction plate toward
the valve body side of the case. Push it into place.
NOTE: The reaction plate is correctly installed if the snap
ring groove is fully visible.

Use a large screwdriver to compress the snap ring. Push it
into the place by hand. Work around the case. Visually
check to make sure that the ring is fully seated. Make sure
that the ends of the snap ring are between the lugs.
8. PUSH CENTER SUPPORT ASSEMBLY INTO CASE

II
Align the oil hole and bolt hole of the center support with
those of the body side and insert.
C4468
9. INSTALL TWO CENTER SUPPORT BOLTS WITH

WAVE WASHERS
Align the center support with holes in case and install the
two bolts finger tight.
AT0899
10. INSTALL REAR CLUTCH IN CASE

Rotate the clutch to mesh the hub with the center support.
11. CHECK FOR CORRECT INSTALLATION OF REAR

CLUTCH
If the rear clutch is fully meshed with the center support,
the splined center of the clutch will be flush with the end
of the sun gear shaft.
C4210 C4880
12. INSTALL THRUST BEARING RACE OVER SPLINED

END OF REAR CLUTCH IN CASE
Coat parts with petroleum jelly to keep them in place.
Position the lip of the race toward the rear clutch.
Z2139
13. INSTALL THRUST BEARING AND RACE ON FRONT

CLUTCH
Coat parts with petroleum jplly to keep them in the place.
Position the lip of the race ou'tward.
;
14. INSTALL FRONT CLUTCH ASSEMBLY IN CASE
Align the flukes of the rear clutch discs and mesh them
with the front clutch hub. Push the front clutch assembly
into the case.
CAUTION: Be careful that the thrust bearing does
not fa II out.
C4881 C4471
15. CHECK CORRECT INSTALLATION OF FRONT CLUTCH

Set SST on the transmission case as shown in the figure.
Measure the distance between the top surface of SST and
front clutch assembly. If the distance corresponds to that
during disassembly, the front clutch is installed correctly.
SST 09350-20015 (09370-12010)
Height: Measured value minus SST width =
Approx. 2 mm (0.08 in,)
16. INSTALL SST ON CASE

SST Finger tighten the SST on the transmission case.
SST 09350-20015 (09362-30011)
17. INSTALL THRUST BEARING ON FRONT CLUTCH

Coat the thrust bearing with petroleum jelly and set it into
place.
C4474
18. INSTALL OUTER RACE ON OVERDRIVE CASE END

Coat the outer race with petroleum jelly and set it into place
facing lip side toward the overdrive case.
A T0825
19. INSERT OVERDRIVE CASE INTO TRANSMISSION

CASE
Insert the overdrive case gently through the two guide bolts
(SST) with cut out portion of the case facing the direction
shown in illustration.
SST 09350-20015 (09362-30011)
C4415
20. INSTALL THRUST WASHERS

Coat the thrust washers with petroleum jelly. Install thrust
washer on the overdrive planetary carrier.
NOTE: The washer lugs should be inserted in the holes.
AT0826 AT0827
21. INSTALL OVERDRIVE CLUTCH IN CASE

Align the flukes of the discs in the overdrive case. Align
the flukes with the slots of the overdrive clutch and press
the overdrive clutch into the overdrive case.
CAUTION: Be careful that the thrust washer does
not fall out.
C4883 C4477
22. CHECK CORRECT INSTALLATION OF OVERDRIVE
.,
~SST
",':.:
I
:
CLUTCH
Set SST on the overdrive case as shown in the figure.
Measure the distance between the top surface of SST and
overdrive clutch. If the distance corresponds to that during
disassembly, the overdrive clutch is installed correctly.
SST 09350-20015 (09370-12010)
Height: Measured value minus SST width =
Approx. 3.5 mm (0.138 in,)
23. INSTALL O-RING ON OVERDRIVE CASE
24. INSTALL CONVERTER HOUSING

Install the two 1 2 mm bolts at B and four 10 mm bolts at
A and tighten them.
Torque: A bolts 345 kg-em (25 ft-Ib, 34 N·m)
B bolts 580 kg-em (42 ft-Ib, 57 N·m)
AT262(i
25. INSTALL OUTER RACE ON OVERDRIVE CLUTCH

Coat the outer race with petroleum jelly. Install the thrust
washer facing the lip side outward inside.
26. INSTALL THRUST BEARING ON OIL PUMP

Coat the thrust bearing with petroleum jelly and set into
place.
AT0829
27. INSTALL OIL PUMP

(a) Install the oil pump gently through the two guide
bolts, being careful that the thrust washer does not
fallout.
(b) Coat the five set bolts with seal packing and finger
tighten them.
Seal packing: Part No. 08833-00080, THREE BOND
1344, LOCTITE 242 or equivalent
(c) Using a screwdriver, remove the SST. In the place of
it, install the two set bolts coated with seal packing.
SST 09350-20015 (09362-30011)
(d) Tighten the set bolts gradually and evenly.
28. TIGHTEN TWO CENTER SUPPORT BOLTS

Tighten the bolts alternately in 70 kg-cm (61 in.-Ib, 6.9
N'm) increments.
NOTE: First tighten the accumulator piston side.
29. CHECK OPERATION OF PISTONS
(3) ----0 f-~~l j Blow low-pressure compressed air into the passages indi-
cated in the illustration and listen for noise from piston
(6) 141 ~~o 171 movement.
(2) (1 ) Overdrive clutch
(2) Front clutch
(5) ~o (3) Overdrive brake
~~J
o 0 0 0
(4) Rear clutch
(5) Brake NO.1
(6) Brake NO.2
(7) Brake NO.3
If the pistons do not move, disassemble and inspect.
30. CHECK INPUT SHAFT AND OUTPUT SHAFT

(a) Make sure that the input shaft has play in axial direc-
tion and that it turns.
(b) Make sure that the output shaft has thrust play in
axial direction.
AIOB3D AIDB31 Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 in.)
31. IF NECESSARY, INSTALL MANUAL VALVE LEVER

SHAFT INTO CASE
(a) Assemble a new collar to the manual valve lever.
NOTE: Always replace the collar and roll pin with new
ones. Never reuse a pin after it has been removed.
(b) Install the manual valve lever shaft to the transmis-
sion case through the manual valve lever.
(c) Drive in a new roll pin with the slot at a right angle to
the shaft.
(d) Match the collar hole to the lever calking hollow and
calk the collar to the lever.
32. INSTALL PARKING LOCK PAWL, PIVOT PIN AND

SPRING IN CASE
33. INSTALL PARKING LOCK ROD PAWL BRACKET ON

CASE
(a) Hook the parking lock rod to the manual valve and place
it on the parking lock pawl.
(b) Install the parking lock pawl bracket with the two bolts.
(c) Check that the pawl moves smoothly.
NOTE: It is possible for the bracket to be installed too far
forward, where it will bind the pawl.
C4492
34. CHECK OPERATION OF PARKING LOCK PAWL

Make sure the planetary gear output shaft is locked when
the manual valve lever is in "P" range.
35. INSTALL NEW O-RING ON THROTTLE CABLE FITTING
36. INSTALL THROTTLE CABLE IN CASE

Push the cable through the case, being careful not to
damage the O-ring. Check for full seating.
CAUTION: In subsequent work, do not roll the case
over the cable and possibly break the cable fitting.
37. INSTALL ACCUMULATOR PISTON AND SPRINGS

mm (in.)
Wire
Spring Free length Outer diameter No. Color
diameter
55.18 (2.1724) 18.32 (0.7213) 11.0 2.6 (0.102) Light green

82
35.13 (1.3831) 16.16 (0.6362) 6.0 1.3 (0.051) Red
C) 59.82 (2.3551) 16.57 (0.6524) 12.5 2.7 (0.106) Green
C] 64.68 (2.5465) 17.50 (0.6890) 18.5 2.0 (0.079) None
38. PLACE VALVE BODY ON TRANSMISSION

Make sure the accumulator pistons are pressed fully into
the bore. Align the manual valve with the pin on the
manual valve lever, and lower the valve body into place.
39. LIFT SIDE OF VALVE BODY AND ATTACH THROTTLE

CABLE
While holding the cam down by hand, slip the cable end
into the slot.
C4156
'-----------~-----
40. INSTALL BOLTS IN VALVE BODY

Install the bolts as shown.

Install the small plate and oil strainer
A 11034
42. INSTALL OIL TUBES

Using a plastic-faced hammer, install the tubes into the
position indicated in the photo.
CAUTION: Be careful not to bend or damage the
tubes.
43. PLACE MAGNETS IN PAN AND INSTAll Oil PAN

WITH NEW GASKET
(a) Install the magnets in the pan.
CAUTION: Make sure that the magnets do not inter-
fere with the oil tubes.
AT1037
(b) Align the cut part of the gasket and case.

44. INSTAll DRAIN PLUG WITH NEW GASKET

46. INSTAll GOVERNOR LINE STRAINER

(a) Install the strainer onto the case.
(b) Install the plate.
AT1038 AT1039
46. INSTAll GOVERNOR BODY ON OUTPUT SHAFT

(a) While lifting the retaining clip with a large
screwdriver, slide the governor body and insert the
retaining clip end into the hole on the output shaft.
(b) Install the lock plate and bolt, and then stake the lock
plate.
47. [2WD]
INSTAll SPEEDOMETER DRIVE GEAR
(a) Install the snap ring and lock ball.
(b) Slide the speedometer gear on the shaft.
(c) Using snap ring pliers, install the outer snap ring.
\
~
)
48. [2WD]
C4147
INSTAll REAR EXTENSION HOUSING WITH NEW
GASKET
(a) Clean the threads ofthe A bolt and bolt hole with white
gasoline.
(b) Coat the threads of the A bolt with sealer.
lOCTITE 242 or equivalent
(c) Install the extension housing over a new gasket with
bolts, and then torque them.
NOTE: The two lower bolts are shorter.
49. [2WD]
INSTALL O-RINGS, BUSHING AND SPEEDOMETER
DRIVEN GEAR TO SHAFT SLEEVE
50. [2WD]
INSTALL SPEEDOMETER DRIVEN GEAR ASSEMBLY
IN EXTENSION HOUSING
Insert the shaft sleeve assembly into the housing. Install the
lock plate with a bolt and lock washer.
C4141
51. INSTALL NEUTRAL START SWITCH

(a) Slide the neutral start switch onto the control shaft.
(b) Install the grommet, facing the groove toward the
switch body, and then install the washer and nut.
Torque: 70 kg-em (61 in.-Ib. 6.9 N·m)
52. INSTALL SHIFT HANDLE
53. ADJUST NEUTRAL START SWITCH

C4138 (See page AT-4)
Torque: 55 kg-em (48 in.-Ib, 5.4 N·m)
54. INSTALL SOLENOID

Install the solenoid on the body with two O-rings.
AT-114 AUTOMATIC TRANSMISSION - Installation of Transmission (2WD)
(2WD)
1. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator and measure the drive plate runout.
If runout exceeds 0.20 mm (0.0079 in.) or if the ring gear
is damaged, replace the drive plate. If installing a new drive
plate, note the orientation of the spacers and tighten the
'---- B_15---J04 bolts.
Runout: 0.20 mm (0.0079 in,) or less
2. MEASURE TORQUE CONVERTER SLEEVE RUNOUT

(a) Temporarily mount the torque converter to the drive
plate. Set up a dial indicator.
If runout exceeds 0.30 mm (0.0118 in.), try to correct it by
reorienting the installation of the converter. If excessive
runout cannot be corrected, replace the torque converter.
Runout: 0.30 mm (0.0118 in,) or less
B 1 ~05
NOTE: Mark the position of the converter to ensure cor-
rect installation.
(b) Remove the torque converter.
3. INSTALL TRANSMISSION MOUNTING ON

EXTENSION HOUSING
Inspect the rubber mounting for deterioration and replace
it if necessary.
4. INSTALL FILLER TUBE

Replace the a-ring and push the tube into place.
AT2391
5. APPLY GREASE TO CENTER HUB OF TORQUE

CONVERTER AND PILOT HOLE IN DRIVE PLATE
AT0767
AUTOMATIC TRANSMISSION - Installation of Transmission (2WD) AT-115
6. INSTALL TORQUE CONVERTER IN TRANSMISSION
AT2393
7. CHECK TORQUE CONVERTER INSTALLATION

Using calipers and a straight edge, measure from the
installed surface to the front surface of the transmission
housing.
Correct distance: 26 mm (1.02 in.)
Al1941
8. ALIGN TRANSMISSION AT INSTALLATION

POSITION
CAUTION: Be careful not to tilt the transmission for-
ward because the torque converter could slide out.
Align the two sleeves on the block with the converter
housing.
AT1943
9. INSTALL BOLTS IN CONVERTER HOUSING

Install the filler tube bracket with the upper right-hand bolt
and tighten bolts.
10. INSTALL STARTER

14. INSTALL BOTH STIFFNER PLATES

AT1762

BOLT
AT1223
16. CONNECT TWO OIL COOLER LINES

17. INSTALL TWO COOLER LINE CLAMPS
RI0003
18. CONNECT SPEEDOMETER CABLE AND BOND CABLE
AT1215
19. CONNECT SHIFT CABLE TO TRANSMISSION

(See page AT-4)
20. INSTALL EXHAUST PIPE CLAMP
AT1761

PROOOl
22. LOWER VEHICLE AND CONNECT WIRING

CONNECTORS
RI0002
23. CONNECT AND ADJUST TRANSMISSION THROTTLE

CABLE
(c) Adjust the transmission throttle cable.
(See page AT -4)
24. CONNECT BATTERY CABLE TO NEGATIVE (-)

TERMINAL

Total capacity: 6.5 liters (6.9 US qts, 5.7 Imp. qts)
AT1213
OK if hot 27. ROAD TEST VEHICLE

Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
Add if hot
MA0156
~"- (4WD)
1. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator and measure the drive plate runout.
If runout exceeds 0.20 mm (0.0079 in.) or if the ring gear is
damaged, replace the drive plate. If installing a new drive
plate, note the orientation of the spacers and tighten the
81504
bolts.
Runout: 0.20 mm (0.0079 in.) or less
2. MEASURE TORQUE CONVERTER SLEEVE RUNOUT

(a) Temporarily mount the torque converter to the drive
plate. Set up a dial indicator.
If runout exceeds 0.30 mm (0.0118 in.), try to correct it by
reorienting the installation of the converter. If excessive
runout cannot be corrected, replace the torque converter.
Runout: 0.30 mm (0.0118 in.) or less
81505
NOTE: Mark the position of the converter to ensure
correct installation.
(b) Remove the torque converter.
3. INSTALL TRANSMISSION MOUNTING ON

TRANSFER ADAPTOR
Inspect rubber mounting for deterioration and replace if
necessary.
4. INSTALL FILLER TUBE

Replace the a-ring and push the tube into place.
5. INSTALL TRANSFER WITH NEW GASKET

(a) Install the transfer to the transmission with a new
gasket.
(b) Apply seal packing to the two front bolts.
1344, LOCTITE 242 or equivalent
A T2281
6. APPLY GREASE TO CENTER HUB OF TORQUE

CONVERTER AND PILOT HOLIN DRIVE PLATE
AT0767
7. INSTALL TORQUE CONVERTER IN TRANSMISSION
AT2393
8. CHECK TORQUE CONVERTER INSTALLATION

Using scale and straight edge, measure from the installed
surface to the front surface of the transmission housing.
Correct distance: 27.1 mm (1.067 in.)
AT1941
9. ALIGN TRANSMISSION AT INSTALLATION POSITION

CAUTION: Be careful not to tilt the transmission for-
ward because the torque converter could slide out.
Align the two sleeves on the block with the converter
housing.
AT1943
10. INSTALL BOLTS IN TRANSMISSION HOUSING

AT2284

BOLT
AT2286
12. INSTALL TORQUE CONVERTER BOLTS

(a) Align the drive plate and converter holes.
(b) First install the gray bolt, then other bolts. Turn the
crankshaft to gain access.
(c) Tighten the six bolts evenly.
13. INSTALL SERVICE HOLE COVER
J AT1236
14. INSTALL BOTH STIFFENER PLATES

AT1762
15. INSTALL STARTER
AT2283
16. INSTALL CONTROL CABLE BRACKET
AT2279
17. CONNECT OIL COOLER LINES

18. INSTALL COOLER LINE CLAMPS
AT2032
19. CONNECT SPEEDOMETER CABLE, GROUND STRAP

AND TRANSFER INDICATOR SWITCH CONNECTOR
AT2285
20. CONNECT SPEED SENSOR AND 4WD INDICATOR

CONNECTOR
21. CONNECT VACUUM HOSES TO VACUUM

ACTUATOR
AT2394
22. CONNECT EXHAUST PIPE TO MANIFOLD

(a) Connect the exhaust pipe to the manifold.
(b) Install the exhaust pipe clamp.
. /~
AT2030
23. CONNECT TRANSMISSION SHIFT CABLE TO SHIFT

;-__ ~I
LEVER
24. CONNECT ATF THERMO SENSOR CONNECTOR
25. INSTALL FRONT AND REAR PROPELLER SHAFTS

(See page PR-4)
26. FILL TRANSFER WITH OIL

Oil type: API GL-4 or GL-5
AT1761 Viscosity: SAE 75W-90
Capacity: 1.2 liters (1.3 US qts, 1.1 Imp.qts)
27. LOWER VEHICLE AND CONNECT WIRING

CONNECTORS
RlOO02
28. CONNECT AND ADJUST TRANSMISSION THROTTLE

CABLE
(c) Adjust the transmission throttle cable.
o- 1 m m (0 - 0.04 in.) 29. CONNECT BATTERY CABLE TO NEGATIVE (-)

TERMINAL
ATl721

Total capacity: 6.5 liters (6.9 US qts, 5.7 Imp. qts)
Q"'4r~ AT1213
32. ROAD TEST VEHICLE

Check for abnormal noise, shock, slippage, correct shift
points and smooth operation.
Add if hot
MA0156
TF -1
TRANSFER
Page
PRECAUTIONS TF-2
TROUBLESHOOTING TF-2
ON-VEHICLE REPLACEMENT OF OIL SEAL TF-3
REMOVAL OF TRANSFER TF-5
DISASSEMBLY OF TRANSFER TF-7
COMPONENT GROUP DISASSEMBLY, INSPECTION
AND ASSEMBLY TF-17
Vacuum Actuator . . . . . . . . . . . . . . . . . . . .. . . . . . TF-17
Oil Pump Body TF-19
Front Output Assembly TF-23
Rear Output Assembly TF-29
Input Shaft TF-33
Planetary Gear ...... TF-35
High and Low Shift Fork Shaft and
Shift Lever Shaft . TF-38
Front Case and Extension Housing . TF-40
ASSEMBLY OF TRANSFER . TF-43
INSTALLATION OF TRANSFER . TF-52
ADJUSTMENT OF TRANSFER SHIFT LEVER
FREEPLAY . TF-53
ELECTRICAL SHIFT TYPE . TF-55
TF-2 TRANSFER - Precautions, Troubleshooting
PRECAUTIONS
When working with FIPG material, you must be observe the fonowing.
• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket
surfaces.
• Thoroughly clean all components to remove all the loose material.
• Clean both sealing surfaces with a non-residue solvent.
• Apply the seal packing in approx. 1 mm (0.04 in.) bead along the sealing surface.
• Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must
be removed and reapplied.
TROUBLESHOOTING
1------------ --- -- - - - -- --------------- - - - - - - - - - - - - - - - - - - - - -- -
Hard to shift or will not Transfer faulty Disassemble and inspect TF-5
shift transfer
- - - - - -- --- - --- -------- ---- --- -------------~.---~ ~--------
Transfer jumps out of Transfer faulty Disassemble and inspect TF-5

gear transfer
TRANSFER - On-Vehicle Replacement of Oil Seal TF-3
ON-VEHICLE REPLACEMENT OF
OIL SEAL
(FRONT OIL SEAL)
1. REMOVE TRANSFER CASE PROTECTOR
2. DRAIN GEAR OIL FROM TRANSFER
3. REMOVE FRONT PROPELLER SHAFT

PR0124
(See page PR-4, 5)
4. REMOVE OIL SEAL

Using SST, remove the front output shaft oil seal.
SST 09308-10010
TF0262
5. INSTALL OIL SEAL

(a) Using SST, drive in a new oil seal.
SST 09325-20010
Oil seal depth: 9.5 - 10.5 mm (0.374 - 0.413 in.)
(b) Coat the lip of the oil seal with MP grease.
TF0263
6. INSTALL FRONT PROPELLER SHAFT

(See page PR-6)

Capacity: 1.2 liters (1.3 US qts, 1.1 Imp. qts)
8. INSTALL TRANSFER CASE PROTECTOR

PR0124
(REAR OIL SEAL)

2. DRAIN GEAR OIL FROM TRANSFER
3. REMOVE REAR PROPELLER SHAFT

(See page PR-4)
PR0123
TF-4 TRANSFER - On-Vehicle Replacement of Oil Seal
4. REMOVE COMPANION FLANGE

(a) Using a hammer and chisel, loosen the staked part of
the nut.
(b) Using SST to hold the companion flange, remove the
companion flange lock nut.
SST 09330-00021
SST
TF0264
(c) Using SST, remove the companion flange.

SST 09950-20017
fF0265
5. REMOVE OIL SEAL

Using SST, remove the rear output shaft oil seal.
SST 09308-10010
TRANSFER - Removal of Transfer TF-5
Matchmarks REMOVAL OF TRANSFER

TERMINAL
2. RAISE VEHICLE
PROOOl 4. DRAIN TRANSFER OIL
5. REMOVE FRONT AND REAR PROPELLER SHAFTS

(See page PR-4, 5)
6. DISCONNECT TRANSFER INDICATOR SWITCH

CONNECTOR
7. (w/SPEED SENSOR)
DISCONNECT SPEED SENSOR CONNECTOR
rF0438
8. DISCONNECT SPEEDOMETER CABLE AND

GROUND STRAP
MT0239
A/T 9. (A/T)
\ DISCONNECT VACUUM HOSES FROM VACUUM
ACTUATOR
, O. (MIT)
DISCONNECT TRANSFER CONTROL CABLE
(a) Remove the clip and washer.
(b) Remove the retainer from the bracket.
E0848
TF-6 TRANSFER - Removal of Transfer
11. DISCONNECT EXHAUST FRONT PIPE

(a) Remove the exhaust front pipe clamp from the bracket.
(b) Disconnect the exhaust front pipe from the exhaust
manifold.
MT0234
12. JACK UP TRANSMISSION SLIGHTLY

Raise the transmission enough to remove the weight from
the rear mounting.
13. REMOVE ENGINE REAR MOUNTING BOLT
MT0314
14. REMOVE TRANSFER MOUNTING BOLTS
15. REMOVE TRANSFER

Pull out the transfer toward the rear.
TF0440
16. REMOVE ENGINE REAR MOUNTING
MT0237
TRANSFER - Disassembly of Transfer TF-7
DISASSEMBLY OF TRANSFER
COMPONENTS (MIT)
MIT Planetary Gear Spline Piece
')
')
*~ I
I
I
I Oil Receiver
i~
L..--
No.1 Shift ark
I
Transfer Case Protector
Companion
Flange
Transfer Drive Chain
Rear Output Assembly
Thrust Bearing Race
115 (8. 11) I
_-G» ~ Extension Housing
_--@l ~
[kg-em (ft-Ib, N·m) I: Rear Case

Front Output Assembly
* Precoated part TF0445
TF-8 TRANSFER - Disassembly of Transfer
COMPONENTS (AfT)
AfT Planetary Gear Assembly

Transfer Indicator Switch
Fron~ '- g
I
I"
I
NO.1 Shift Fork
')
')
*~ I
I
I Oil Receiver
!b
I --- - ~~
I 50 (43 in.-Ib. 4.9) I

Speedometer Driven Gear
Companion Flange
Transfer Case Protector
• I 1.250 (90. 123)
~
Transfer Drive Chain
----~*.. I 115 (8. 11) I
Extension Housing
Speed Sensor Cover
Rear Case
Vacuum Actuator
Speed Sensor
I kg-cm (ft-Ib, N· m) I: Specified torque

* Precoated part TF0408
DISASSEMBLY OF TRANSFER
(See page TF-7,8)
1. (AfT)
REMOVE VACUUM ACTUATOR
(See page TF-17)
2. REMOVE SPEEDOMETER DRIVEN GEAR
3. REMOVE TRANSFER INDICATOR SWITCH
4. (AfT)
AIT REMOVE SPEED SENSOR
Remove the bolt, the cover and the speed sensor.
TF0409
5. REMOVE OIL PUMP BODY ASSEMBLY

(a) Remove the seven bolts and remove the oil pump body
assembly.
TF0269
(b) Remove the two pins from the input shaft.
H0270

(a) Using a hammer and chisel, loosen the staked part of
the nut.
TF0271
(b) Using SST to hold the flange, remove the companion

flange lock nut.
SST 09330-00021
SST
TF0272

SST 09950-20017
TF0273
7. REMOVE SPEEDOMETER DRIVE GEAR FROM

COMPANION FLANGE
8. REMOVE EXTENSION HOUSING

Remove the five bolts and remove the extension housing.
TF0275
9. REMOVE TRANSFER REAR CASE

"
_~~~_,~/ c
TF0391
(b) Remove the eleven bolts and rear case.

NOTE: Using a screwdriver, pry at the portions indicated
in the illustration to remove the rear case.
TF0277
10. REMOVE SPRING AND WASHER FROM FRONT

DRIVE SHIFT FORK SHAFT
snap ring.
TF0278
(b) Remove the washer and spring.
TF0279
11. REMOVE FRONT AND REAR OUTPUT ASSEMBLY

(a) Remove the front and rear output assembly with the
transfer drive chain and No.1 shift fork.
(b) Remove the transfer drive chain and No.1 shift fork.
TF0281
(c) Remove the thrust bearing.
TF0282
(d) Remove the thrust bearing race from the rear output
assembly.
(e) Remove the needle roller bearing from the input shaft.
TF0283
(f) Remove No. 1 hub sleeve from the rear output

assembly.
TF0284
12. REMOVE Oil STRAINER

(a) Using a torx socket wrench, remove the screw and oil
strainer.
(b) Remove the O-ring from the oil strainer.
TF0285
13. REMOVE Oil RECEIVER

Using a torx socket wrench, remove the screw and oil
receiver.
MIT 14. (MIT)

REMOVE SHIFT OUTER LEVER
(a) Remove the nut and lever lock pin.
(b) Remove the shift outer lever and plate washer.
TF0287
15. REMOVE STRAIGHT SCREW PLUGS, SPRINGS AND

LOCKING BALLS
(a) Using SST, remove the plug on the upper side.
SST 09313-30021
(b) Using a magnetic finger, remove the spring and ball.
TF0288
(c) Remove the plug, spring and ball on the lower side in
the same procedure.
TF0289
MIT 16. REMOVE FRONT DRIVE SHIFT FORK SHAFT

(a) Pullout the front drive shift fork shaft.
TF0290
All
TF041 0
(b) Using a magnetic finger, remove the interlock pin from

the front case.
TF0291
17. REMOVE HIGH AND LOW SHIFT FORK SHAFT

Remove the high and low shift fork shaft with No.2 shift
fork and high and low hub sleeve.
/ TF0292
MIT 18. (MIT)

REMOVE SHIFT LEVER SHAFT
Remove the shift lever shaft from the front case.
19. REMOVE PLANETARY GEAR ASSEMBLY WITH INPUT

SHAFT
TF0294
(b) Remove the planetary gear assembly with the input

shaft by tapping on the input shaft with a plastic
hammer.
TF0295
MIT
20. REMOVE INPUT SHAFT
(a) (MIT)
TF0296
MIT
(b) (MIT)
Remove the planetary gear spline piece and input
shaft.
TF0297
A/T (c) (A IT)

Remove input shaft.
TF0412
(d) Remove the thrust bearing from the planetary gear.
TF0298
(e) Remove the thrust bearing race from the input shaft.
TF0299
21. (MIT)
MIT
REMOVE RING GEAR
(a) Using a screwdriver, remove the snap ring.
TF0300
(b) Remove the ring gear from the front case.

MIT
TF0301
TRANSFER - Component Groups (Vacuum Actuator) TF-17
COMPONENT GROUP
DISASSEMBLY, INSPECTION AND
ASSEMBLY
Vacuum Actuator
COMPONENTS
l----- Diaphragm Cylinder Body
• O-Ring
~ ~1175113.17} I
~Clamp
175 (13,17)
Shift Link Lever
• Gasket
Ikg-em (ft-Ib, N·m) I: Specified torque
• Non-reusable part Diaphragm Cylinder Cover TF0413
DISASSEMBLY OF VACUUM ACTUATOR

1. REMOVE DIAPHRAGM CYLINDER COVER
(a) Remove four bolts and the cover.
(b) Remove the gasket.
TF0414
2. REMOVE SHIFT LINK LEVER
TF0415
TF-18 TRANSFER - Component Groups (Vacuum Actuator)
3. REMOVE DIAPHRAGM CYLINDER BODY

(a) Remove three bolts and diaphragm cylinder body from
the transfer case.
(b) Remove the O-ring from the diaphragm cylinder body.
4. INSPECT DIAPHRAGM CYLINDER BODY

(a) With 500 mmHg (19.7 in.Hg, 66.7 kPa) of vacuum in
diaphragm upper port, confirm that the push rod is
pulled upward.
(b) With 500 mmHg (19.7 in.Hg, 66.7 kPa) of vacuum in
diaphragm lower port, confirm that the push rod is
pulled downward.
(c) On the same condition, check the gauge needle is
stable for about 30 seconds.
ASSEMBLY OF VACUUM ACTUATOR

1. INSTALL DIAPHRAGM CYLINDER BODY
(a) Install a new O-ring to the diaphragm cylinder body.
(b) Install diaphragm cylinder body to the transfer case.
Torque the three bolts.
2. INSTALL SHIFT LINK LEVER
TF0415
3. INSTALL DIAPHRAGM CYLINDER COVER

Install the diaphragm cylinder cover with a new gasket to
the diaphragm cylinder body.
Torque the four bolts.
TF0414
TRANSFER - Component Groups (Oil Pump Body) TF-19
Oil Pump Body

COMPONENTS
Oil Pump Cover
Driven Rotor
Oil Pump Body Pin
MIT
Oil Pump Plate
Drive Rotor
• Oil Seal
*~
Of----Ball
a
.~
Spring
~ Straight Screw Plug

~
1175 (13, 1711
Ikg-cm (h-Ib, N·m) I : Specified torque
* Precoated part El058
DISASSEMBLY OF OIL PUMP BODY

1. REMOVE STRAIGHT SCREW PLUG, SPRING AND
BALL
(a) Using SST, remove the straight screw plug.
SST 09313-30021
TF0302
(b) Using a magnetic finger, remove the spring and ball.
TF0303
TF-20 TRANSFER - Component Groups (Oil Pump Body)
2. REMOVE OIL PUMP COVER

(a) Using a torx socket wrench, unscrew the torx screws.
(b) Remove the oil pump cover.
TF0304
3. REMOVE OIL PUMP PLATE
4. REMOVE OIL PUMP DRIVE AND DRIVEN ROTORS
TF0306
INSPECTION OF OIL PUMP BODY

1. CHECK BODY CLEARANCE OF DRIVEN ROTOR
Push the driven rotor to one side of the body.
Using a feeler gauge, measure the clearance.
(0.0028 - 0.0067 in.)
If the clearance exceeds the limit, replace the driven rotor or
TF0307
pump body.
2. CHECK TIP CLEARANCE OF BOTH ROTORS

Using a feeler gauge, measure the clearance between both
rotor tips.
(0.0039 - 0.0087 in.)
If the clearance exceeds the limit, replace the drive or driven
rotor.
TF030B
TRANSFER - Component Groups (Oil Pump Body) TF-21
3. CHECK SIDE CLEARANCE OF BOTH ROTORS

rotors and oil pump plate.
(0.0012 - 0.0051 in.)
If the clearance exceeds the limit, replace the drive rotor,
driven rotor or oil pump plate.
TF0309
4. IF NECESSARY, REPLACE OIL PUMP BODY OIL SEAL

TF0310
---
MIT
SST Nc ;:JP11 SST 09316-60010 (09316-00010, 09316-00060) for MIT
AIT
09316-60010 (09316-00010,09316-00040) for AIT
(Lf"b- -_ .riJl
- ~,
TF0311
ASSEMBLY OF OIL PUMP BODY

1. INSTALL OIL PUMP DRIVE AND DRIVEN ROTORS
(a) Apply gear oil to the both rotors.
(b) Install the oil pump driven rotor.
El062
(c) Install the oil pump drive rotor.
El069
TF-22 TRANSFER - Component Groups (Oil Pump Body)
2. INSTALL OIL PUMP PLATE

Install the oil pump plate.
NOTE: Facing the side marked with a 'R' upwards, align
the elongated hole of the oil pump plate with the matching
hole on the oil pump body.
E1073
3. INSTALL OIL PUMP COVER

(a) Install the oil pump cover.
NOTE: Align the notched portion of the oil pump cover
with the pump body oil hole.
E1074
(b) Using a torx socket wrench, tighten the torx screws.

4. INSTALL BALL, SPRING AND STRAIGHT SCREW

PLUG
(a) Install the ball and spring.
(b) Apply liquid sealer to the plug.
(c) Using SST, torque the plug.
SST 09313-30021
L- -.:- T_F0_30-...l2 Torque: 175 kg-em (13 ft-Ib, 17 N'm)
5. CHECK DRIVE ROTOR ROTATION

Turn the drive rotor and make sure it rotates smoothly.
E1076
TRANSFER - Component Groups (Front Output Assembly) TF-23

COMPONENTS
Transfer Driven Sprocket
No.2 Hub Sleeve

1
Shifting Key
Clutch Hub
;)
I
Synchronizer Ring j
Shifting Key Spring

B' Speed Sensor Rotor (A/T)
~ r~ ~
Shifting Key Retainer
r
Bearing I E-Ring (AIlI
I
I
I
I
I
l----~
~ Bal/(A/T)
Spacer
f
Needle Roller Bearing
Front Output Shaft

TF0418
A/T DISASSEMBLY OF FRONT OUTPUT

ASSEMBLY
1. (A/T)
REMOVE SPEED SENSOR ROTOR
(a) Using two screwdrivers and hammer, tap out the
E-ring.
TF0419
(b) Remove the speed sensor rotor and ball.

A/T
TF0420
TF-24 TRANSFER - Component Groups (Front Output Assembly)
2. MEASURE DRIVEN SPROCKET THRUST CLEARANCE

Using a feeler gauge, measure the driven sprocket thrust
~77!'1i
~; ~ ~--
i /. ',' /,: \,
clearance.
~"'!'.'
'.iL". ., . ,.\.
(0.0039 - 0.0098 in.)
\--~
TF0400
3. REMOVE FRONT OUTPUT SHAFT FRONT BEARING

snap ring.
TF0313
(b) Using SST and a press, remove the bearing.

SST SST 09950-00020
TF0314
4. REMOVE SPACER AND SHIFTING KEY RETAINER
TF0315
5. REMOVE NO.2 HUB SLEEVE ASSEMBLY AND

TRANSFER DRIVEN SPROCKET
(a) Using a press, remove No. 2 hub sleeve assembly,
synchronizer ring and transfer driven sprocket.
(b) Remove the spacer and needle roller bearing.
--f'
TF03 1 6
INSPECTION OF FRONT OUTPUT ASSEMBLY

1. INSPECT FRONT OUTPUT SHAFT
Using a micrometer, measure the outer diameter of the
front output shaft journal surface.
, 11,','/ _ , " Minimum diameter: 36.930 mm (1.4539 in.)
TF0401
2. CHECK OIL CLEARANCE OF DRIVEN SPROCKET

the sprocket and shaft with the needle roller bearing
installed.
(0.0004 - 0.0022 in.)
If the clearance exceeds the limit, replace the driven
sprocket, front output shaft or needle roller bearing.
[,110l
3. INSPECT SYNCHRONIZER RING

(a) Turn the ring and push it in to check the braking
\ action.
/ El091
(b) Measure the clearance between the synchronizer ring

back and the sprocket spline end.
Standard clearance: 1.1 - 1 .9 mm
(0.043 - 0.075 in.)
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the limit, replace the syn-
chronizer ring.
TF031B
4. MEASURE CLEARANCE OF NO.1 SHIFT FORK AND

NO.2 HUB SLEEVE
Using a feeler gauge, measure the clearance between No.1
shift fork and No.2 hub sleeve.
hub sleeve.
E 1093
5. IF NECESSARY, REPLACE FRONT OUTPUT SHAFT

REAR BEARING
(a) Using SST and a socket wrench, press out the bearing.
SST 09950-00020
TF0319
(b) Using SST and a press, install a new bearing.

SST 09506-30012
ASSEMBLY OF FRONT OUTPUT ASSEMBLY

1. INSERT CLUTCH HUB INTO NO.2 HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub
sleeve.
Front . . (b) Install the shifting key springs under the shifting keys.
TF0321
2. INSTALL NO.2 HUB SLEEVE ASSEMBLY AND

TRANSFER DRIVEN SPROCKET
(b) Install the needle roller bearing and spacer in the
driven sprocket.
TF0322
(c) Place the synchronizer ring on the sprocket and align

the ring slots with the shifting keys.
(d) Using SST and a press, install the driven sprocket and
1----55T NO.2 hub sleeve assembly.
SST 09316-60010 (09316-00010, 09316-00070)
TF0323
3. MEASURE DRIVEN SPROCKETTHRUST CLEARANCE

Using a feeler gauge, measure the driven sprocket thrust
clearance.
(0.0039 - 0.0098 in.)
TF0400
4. INSTALL SHIFTING KEY RETAINER AND SPACER
/ TF0315
5. INSTALL FRONT OUTPUT SHAFT FRONT BEARING

Using SST and a press, install the bearing.
SST 09506-30012
NOTE: Hold the spacer with a screwdriver to prevent it
from falling.

Mark Thickness mm(in.) Mark Thickness mm(in.)
1 1.95-2.00 (0.0768-0.0787) 7 2.25-2.30 (0.0886-0.0906)

2 2.00-2.05 (0.0787 -0.0807) 8 2.30-2.35 (0.0906-0.0925)
3 2.05-2.10(0.0807-0.0827) 9 2.35-2.40 (0.0925-0.0945)
4 2.10-2.15 (0.0827-0.0846) 10 2.40-2.45 (0.0945-0.0965)
5 2.15-2.20 (0.0846-0.0866) 11 2.45-2.50 (0.0965-0.0984)
TF0325 6 2.20-2.25 (0.0866-0.0886) 12 2.50-2.55 (0.0984-0.1004)
(b) Using a screwdriver and hammer, install the snap

ring.
7. (AfT)
AfT
INSTALL SPEED SENSOR ROTOR
(a) Install the ball, then turn the speed sensor rotor to
align it with the ball.
TF0420
(b) Using a screwdriver and hammer, install the E-ring.

AfT
TF0421
TRANSFER - Component Groups (Rear Output Assembly) TF-29

COMPONENTS
Bearing
Transfer Drive Sprocket
Ball
1
Thrust Washer
Rear Output Shaft

Neelde Roller Bearing
E1109
DISASSEMBLY OF REAR OUTPUT ASSEMBLY

1. MEASURE DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust
clearance.
/ ) (0.0039 - 0.0098 in.)
-/ /) Maximum clearance: 0.40 mm (0.0157 in.)
TF0327
2. REMOVE O-RING
TF0328
TF-30 TRANSFER - Component Groups (Rear Output Assembly)
3. REMOVE REAR OUTPUT SHAFT BEARING

SST
Using SST and a press, remove the bearing.
SST 09950-00020
hl----I/ :: !,', '.L-
M __ -I:-L-TFo329
4. REMOVE THRUST WASHER AND BALL
TF0330
5. REMOVE TRANSFER DRIVE SPROCKET

Remove the transfer drive sprocket and needle roller
bearing.
\. )
~
.
TF0331
INSPECTION OF REAR OUTPUT ASSEMBLY

1. INSPECT REAR OUTPUT SHAFT
Using a micrometer, measure the outer diameter of the rear
output shaft journal surface.
Minimum diameter:
Part A 27.930 mm (1.0996 in.)
B 38.900 mm (1.5315 in.)
C 36.930 mm (1.4539 in.)
El116
2. CHECK OIL CLEARANCE OF DRIVE SPROCKET

the sprocket and shaft with the needle roller bearing
installed.
(0.0004 - 0.0022 in.)
If the clearance exceeds the limit, replace the drive
sprocket, rear output shaft or needle roller bearing.
TF0332
TRANSFER - Component Groups (Rear Output Assembly) TF-31

NO.1 HUB SLEEVE
Using a feeler gauge, measure the clearance between NO.1
shift fork and hub sleeve.
~~ If the clearance exceeds the limit, replace the shift fork or
\ hub sleeve.
( E 1118

HIGH AND LOW HUB SLEEVE
Using a feeler gauge, measure the clearance between No.2
shift fork and high and low hub sleeve.
hub sleeve.
TF0333
ASSEMBLY OF REAR OUTPUT ASSEMBLY

1. INSTALL TRANSFER DRIVE SPROCKET
(b) Install the needle roller bearing in the drive sprocket.
(c) Install the drive sprocket with the needle roller

bearing.
TF0331
2. INSTALL THRUST WASHER AND BALL

Turn the thrust washer to align it with the ball.
TF0330
TF-32 TRANSFER - Component Groups (Rear Output Assembly)
3. INSTAll REAR OUTPUT SHAFT BEARING

Using SST and a press, install the bearing.
SST 09506-30012
NOTE: Hold the thrust washer with a screwdriver to
prevent it from falling.
TF0334
4. MEASURE DRIVE SPROCKET THRUST CLEARANCE

Using a feeler gauge, measure the drive sprocket thrust
clearance.
(0.0039 - 0.0098 in.)
TF0377
5. INSTAll NEW O-RING
TF0328
TRANSFER - Component Groups (Input Shaft) TF-33
Input Shaft
COMPONENTS
MIT
Snap Ring
Sun Gear
Input Shaft E 1126
DISASSEMBLY OF INPUT SHAFT

REMOVE SUN GEAR
1. Using snap ring pliers, remove the snap ring.
TF0335
2. Remove the sun gear from the input shaft.
INSPECTION OF INPUT SHAFT

-
t:rl~ INSPECT INPUT SHAFT
- Using a micrometer, measure the outer diameter of the
input shaft journal surface.
0 A 0
Minimum diameter:
Part A 47.540 mm (1.8716 in.)
.... L.......-
.J)-f---,
r:::=
- E1128
TF-34 TRANSFER - Component Groups (Input Shaft)
ASSEMBLY OF INPUT SHAFT

INSTALL SUN GEAR
1. Install the sun gear to the input shaft.
E 1130
2. Using snap ring pliers, install the snap ring.
TF0335
TRANSFER - Component Groups (Planetary Gear) TF-35
Planetary Gear
COMPONENTS
Bearing
• Needle Roller Bearing Planetary Gear Assembly
Snap Ring
• Non-reusable part El131
INSPECTION OF PLANETARY GEAR

1. MEASURE PLANETARY PINION GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the planetary pinion gear
thrust clearance.
(0.0079 - 0.0295 in.)
E1135 If the clearance exceeds the limit, replace the planetary
gear assembly.
2. CHECK OIL CLEARANCE OF PLANETARY PINION

GEAR
Using a dial indicator, measure the oil clearance of the
planetary pinion gear.
(0.0004 - 0.0015 in.)
If the clearance exceeds the limit, replace the planetary
El136
gear assembly.
TF-36 TRANSFER - Component Groups (Planetary Gear)
3. IF NECESSARY, REPLACE PLANETARY GEAR OUTER

BEARING
\
)
(b) Using SST and a press, remove the bearing.

SST 09554-30011 and 09555-55010
- TF0338
l, (c) Using SST and a press, install a new bearing.

\
SST 09223-15010
SST
J:(t,-,
--- -j,- n
I ,I
--11 l- --- TF0339
(d) Select a snap ring that will allow minimum axial play.
Mark Thickness mm (in.)

--------- - - -- f--
1 1.45 - 1.50 (0.0571 - 0.0591)

2 1.50 - 1.55 (0.0591 - 0.0610)
3 1.55 - 1.60 (0.0610 - 0.0630)
4 1.60 - 1.65 (0.0630 - 0.0650)
/-
5 1.65 - 1.70 (0.0650 - 0.0669)
TF0340
(e) Using snap ring pliers, install the snap ring.
TF0337
TRANSFER - Component Groups (planetary Gear) TF-37
4. IF NECESSARY, REPLACE PLANETARY GEAR INNER

BEARING
(a) Using SST and a press, remove the bearing.
~-SST
SST 09550-10012 (09252-10010, 09557 -10010)
E 1134
(b) Using SST and a press, install a new bearing.

SST 09550-10012 (09252-10010, 09557 -10010)
Bearing depth: 5.5 - 6.1 mm
(0.217 - 0.240 in.)
11
I
E 1137
TF-38 TRANSFER - Component Groups (High and Low Shift Fork Shaft and Shift Lever Shaft)
High and Low Shift Fork Shaft and

Shift Lever Shaft
COMPONENTS (MIT)
MIT
I' - ---- -- - ------ J --1
Shift Lever Shaft
// ~ ~
/ ~ Shift Inner Lever
/
/
/
/
/ - - - - Slotted Spring Pin
/
/
/
I JV'~--- No.2 Shift Fork
/
/
/
-~-
/ j
----
High and Low Shift Fork Shaft
TF0444
COMPONENTS (A/T)
AIT
- - - Slotted Spring Pin
t----No. 2 Shift Fork
High and Low Shift Fork Shaft
TF0422
TRANSFER - Component Groups (High and Low Shift Fork Shaft and Shift Lever Shaft) TF-39
DISASSEMBLY OF HIGH AND LOW SHIFT

FORK SHAFT AND SHIFT LEVER SHAFT
1. DISASSEMBLE HIGH AND LOW SHIFT FORK SHAFT
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the high and low shift fork shaft.
TF0341
MIT
2. (MIT)
DISASSEMBLE SHIFT LEVER SHAFT
(a) Using a screwdriver, remove the E-ring.
(b) Remove the shift inner lever from the shift lever shaft.
TF0342
ASSEMBLY OF HIGH AND LOW SHIFT FORK

SHAFT AND SHIFT LEVER SHAFT
1. ASSEMBLE HIGH AND LOW SHIFT FORK SHAFT
(a) Install No.2 shift fork to the high and low shift fork
shaft.
E1144

spring pin.
TF0341
MIT 2. (MIT)
ASSEMBLE SHIFT LEVER SHAFT
(a) Install the shift inner lever to the shift lever shaft.
(b) Using pliers, install the E-ring.
El145
TF-40 TRANSFER - Component Groups (Front Case and Extension Housing)
Front Case and Extension Housing

COMPONENTS
• Oil Seal
Extension Housing
Front Case
• Non-reusable part E1146
INSPECTION OF FRONT CASE AND

SST EXTENSION HOUSING
1. IF NECESSARY, REPLACE FRONT OUTPUT SHAFT
OIL SEAL
SST 09308-00010
TF0343

SST 09325-20010
Oil seal depth: 9.5 - 10.5 mm
(0.374 - 0.413 in.)
TF0344
TRANSFER - Component Groups (Front Case and Extension Housing) TF-41
MIT 2. (MIT)
IF NECESSARY, REPLACE SHIFT LEVER SHAFT OIL
SEAL
TF0345

seal.
Oil seal depth: 1 .0 - 1 .6 mm
(0.039 - 0.063 in.)
TF0346
3. IF NECESSARY, REPLACE EXTENSION HOUSING OIL

SEAL
TF0347

SST 09316-60010 (09316-00010,09316-00020)
TF0348
4. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN

GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921-00010
WM0108
TF·42 TRANSFER - Component Groups (Front Case and Extension Housing)
(b) Using SST, drive a new oil seal into the sleeve.
SST 09201-60011
20 mm
Oil seal depth: 20 mm (0.79 in.)
k-=ct3,~
SST
WMOi09
TRANSFER - Assembly of Transfer TF-43
ASSEMBLY OF TRANSFER
(See page TF-7,8)
1. (MIT)
INSTALL RING GEAR
(a) Install the ring gear into the front case.
(b) Install the snap ring.
TF0349
2. INSTALL INPUT SHAFT TO PLANETARY GEAR

ASSEMBLY
(a) Apply MP grease to the thrust bearing.
(b) Install the thrust bearing in the planetary gear as-
sembly.
TF0298
(c) Install the thrust bearing race to the input shaft.
TF0299
(d) Apply gear oil to the needle roller bearing and install it
into the input shaft.
I TF0350
TF-44 TRANSFER - Assembly of Transfer
(e) Apply gear oil to the planetary gear inner bearing.

(f) (MIT)
Install the input shaft and planetary gear spline piece
to the planetary gear assembly.
TF0297
(g) (A/T)
A/T
Install the input shah to the planetary gear assembly.
TF0412
MIT (h) (MIT)

Install the snap ring.
NOTE: Put the opened portion to the location as shown in
the illustration.
TF0351 TF0361
3. INSTALL PLANETARY GEAR ASSEMBLY WITH INPUT

MIT
SHAFT
(a) Install the planetary gear assembly with the input
shaft in the front case.
NOTE: It is recommended that the planetary gear as-
sembly be rotated slightly as it is installed.
All
TF0411
TF0294
4. (MIT)
MIT INSTALL SHIFT LEVER SHAFT
Install the shift lever shaft to the front case.
TF0293
5. INSTALL HIGH AND LOW SHIFT FORK SHAFT WITH

HUB SLEEVE
(a) Install the high and low hub sleeve to No.2 fork.
El047
(b) Align No.2 shift fork groove and the shift inner lever
tip, and insert the shift fork shaft fully into the front
case with the hub sleeve.
NOTE: Install the notched end of the shift inner lever to
No.2 shift fork.
TF0292
6. INSTALL FRONT DRIVE SHIFT FORK SHAFT

(a) Using a magnetic finger and screwdriver, install the
interlock pin into the front case.
TF0352
MIT (b) Align the front drive shift fork shaft groove and shift
inner lever tip, and insert the shift fork shaft into the
front case.
TF0290
AIT
TF0410
7. INSTALL STRAIGHT SCREW PLUG, SPRING AND

LOCKING BALL FOR HIGH AND LOW SHIFT FORK
SHAFT
(a) Apply liquid sealer to the plug.
(b) Install the locking ball and spring (red).
(c) Using SST, torque the plug (the plug of AIT is yellow).
TF0289
SST 09313-30021
8. INSTALL STRAIGHT SCREW PLUG, SPRING AND
LOCKING BALL FOR FRONT DRIVE SHIFT FORK
SHAFT
(a) Apply liquid sealer to the plug.
(b) Install the locking ball and spring.
(c) Using SST, torque the plug.
TF0288 SST 09313-30021
MIT 9. (MIT)
INSTALL SHIFT OUTER LEVER
(a) Install the plate washer and shift outer lever to the
lever shaft.
TF0353
MIT (b) Install the lock pin and nut. Torque the nut.
10. INSTALL OIL RECEIVER

(a) Install the oil receiver.
(b) Using a torx socket wrench, tighten the screw.
TF0286

(a) Install a new O-ring to the oil strainer.
(b) Install the oil strainer.
(c) Using a torx socket wrench, tighten the screw.
TF0285
12. INSTALL FRONT AND REAR OUTPUT ASSEMBLY

(a) Apply MP grease to the thrust bearing.
(b) Install the thrust bearing to the input shaft rear end.
TF0282
(c) Install No.1 hub sleeve to the rear output assembly.
TF0284
(d) Install the thrust bearing race to the rear output

assembly.
TF0283
(e) Assemble the front and rear output assembly, No.

shift fork and drive chain.
TF0281
(f) Install the front and rear output assembly with the
drive chain and NO.1 shift fork.
13. INSTALL SPRING AND WASHER TO FRONT DRIVE

SHIFT FORK SHAFT
(a) Install the spring and washer to the front drive shift
fork shaft.
TF0279
(b) Using pliers, install the snap ring.

14. INSTALL TRANSFER REAR CASE

(a) Apply seal packing to the rear case as shown in the
figure.
1281 or equivalent
TF0355
(b) Install the rear case to the front case. If necessary, tap
on the rear case with a plastic hammer.
TF0356

/ Torque: 380 kg-cm (27 ft-Ib, 37 N'm)
TF0277
~- (d) Using snap ring pliers, install the snap ring.
TF0391
15. INSTALL EXTENSION HOUSING

(a) Apply seal packing to the extension housing as shown
in the figure.
1281 or equivalent
(b) Install the extension housing.
TF0357
(c) Apply liquid sealer to the bolts.

(d) Install and torque the bolts.
TF0275
16. INSTALL SPEEDOMETER DRIVE GEAR TO

COMPANION FLANGE
TF0274
17. INSTALL COMPANION FLANGE

(a) Install the companion flange to the rear output shaft.
(b) Using SST to hold the flange, install the companion
flange lock nut.
SST 09330-00021
"'- Torque: 1,250 kg-em (90 ft-Ib, 123 N'm)
TF0407
(c) Stake the lock nut.
TF0271
18. INSTALL OIL PUMP BODY ASSEMBLY

(a) Install the two pins to the input shaft.
TF0270
(b) Apply seal packing to the oil pump body assembly as

1 281 or equivalent
(c) Install the oil pump body assembly with the drive rotor
slots aligned with the two pins.
o
TF0359
(d) Apply liquid sealer to the bolts.

(e) Install and torque the bolts.
TF0269
19. AFTER INSTALLING OIL PUMP BODY ASSEMBLY

CHECK FOLLOWING ITEMS:
(a) Check to see that the input and output shafts rotate
smoothly.
(b) Check to see that shifting can be made smoothly to all
positions.
20. (A/T)
A/T
INSTALL SPEED SENSOR
Install the bolt, cover and speed sensor.
21. INSTALL TRANSFER INDICATOR SWITCH
22. INSTALL SPEEDOMETER DRIVEN GEAR
23. (A/T)
TF0409
INSTALL VACUUM ACTUATOR
(See page TF-17)
TF-52 TRANSFER - Installation of Transfer
INSTALLATION OF TRANSFER
1. INSTALL TRANSFER TO TRANSMISSION WITH NEW
GASKET
(a) Install the engine rear mounting.
(b) Place a new gasket to the transfer adaptor.
(c) Align the input shaft spline with the transmission
output shaft, and push the transfer fully into position.
MT0237
(d) Apply sealant to the two front bolt threads.
LOCTITE 242 or equivalent.
(e) Install and torque the bolts.
TF0440
2. INSTALL ENGINE REAR MOUNTING BOLT

MT0314
3. CONNECT EXHAUST FRONT PIPE

(a) Connect the exhaust front pipe to the exhaust
manifold.
(b) Install the exhaust front pipe clamp to the bracket.
MT0234
4. (MIT)
CONNECTTRANSFER CONTROL CABLE
(a) Install the control cable to the bracket and clip.
(b) Connect the control cable to the outer lever.
E0848
TRANSFER - Installation of Transfer, Adjustment of Transfer Shift Lever Freeplay TF-53
A/T 5. (A/T)
CONNECT VACUUM HOSES TO VACUUM ACTUATOR
TF0439
6. CONNECT SPEEDOMETER CABLE AND GROUND

STRAP
MT0239
7. CONNECT TRANSFER INDICATOR SWITCH

CONNECTOR
8. (wi SPEED SENSOR)

CONNECT SPEED SENSOR CONNECTOR
~l TF0438
9. INSTALL FRONT AND REAR PROPELLER SHAFTS
(See page PR-6, 7)

11. INSTALL TRANSFER CASE PROTECTOR
12. LOWER VEHICLE
13. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL

PROOOl
14. PERFORM ROAD TEST
Check for abnormal noise or operation.
s .. 2- 4 kg ADJUSTMENT OF TRANSFER
SHIFT LEVER FREEPLAY
ADJUST SHIFT LEVER FREEPLAY
1. Shift the transfer shift lever into the H4 position.
2. Loosen the three detent plate installation bolts.
3. Pull the top of the shift lever with a force of 2 - 4 kg (4.4-
TF0442
8.8 Ib, 20 - 39 N).
TF-54 TRANSFER - Adjustment of Transfer Shift Lever Freeplay
4. Adjust the clearance between the detent plate H4 stopper

surface and the shift lever so that it is 1 mm (0.04 in.) or
less. Then tighten the detent plate installation bolts.
1 mm or less
TF0443
TRANSFER - Electrical Shift Type TF-55
ELECTRICAL SHIFT TYPE

ELECTRONIC CONTROL COMPONENTS
A/T
*Vehicle Speed Sensor 4WD Indicator
4WD Control Switch
*4WD Control
Computer
4WD Indicator Switch
Vacuum Actuator
/
*Locking Hub
(Automatic or Manual) VSV
*Transfer Speed Sensor
Ignition Switch
*Vehicle Speed
Sensor
I_
(In Combination
Meter)
TIM
Transfer
~-~~--......-r-~
Rear \
Differential
*Locking Hub (Automatic or Manual)
*With locking hub vehicle

TF0423
TF0424
TF-56 TRANSFER - Electrical Shift Type
ELECTRONIC CONTROL CIRCUIT
With Locking Hub (Automatic) Vehicle
Ig n ition Switch
GAUGE ECUIG
7.5A 15A
From Tail Fuse ~-..()----, 4WD 4WD Indicator

[L, Control
u Switch
Rheostat
4WD Control Computer
.,...
I
---L
4WD Indicator
NO.1 NO.2
r-+--+....,VSV Switch
VSV
o
Speed Sensor
(Transfer)
Without Locking Hub Vehicle (A/T)
Ignition Switch
GAUGE
7.5A
From Tail Fuse
4WD Control Switch
ON
I
I 4WD Indicator
--J-
OFF
T
I
---l-
4WD Indicator
Rheostat Switch
No.1 No.2
VSV VSV
TF0425
TF0426
TRANSFER - Electrical Shift Typ~ TF-57
TROUBLESHOOTING
VEHICLES WITH AUTOMATIC OR MANUAL LOCKING HUB
Trouble No.1: Shifting between 2WD and 4WD impossible
Is it possible to perform the shifting from 2WD to On switching ON the 4WD control switch, does
4WD while vehicle stopped (0 km/h or 0 mph)? the 4WD indicator light for several seconds while
running at vehicle speed above 10 km/h (6 mph)?
j NO
YES I NO
While the engine is idling, on switching ON the
4WD control switch, does it make a sound of I Try another computer. I
vacuum change?
YES
BAD
Check the automatic locking : Repair
While the engine is idling, does the vacuum reach hub or manual locking hub.
above a standard value? (See FA section)
STD: above 500 mm/Hg (See page TF-60)
OK
YES JNO
The transfer speed sensor or
Check and repair the leak of the combination meter speed
vacuum hose and tank. sensor faulty.(See page TF-59)
BAD
Check 4WD control switch, light and the circuit of Check the leak of vacuum hose and tank. IRepair I
these. (See page TF-59)
OK I BAD OK
BAD
Transfer faulty I I Repair Check No.1, No.2 VSV and the circuit of : Repair
I
these.(See page TF-59, 60)
OK
BAD
Check the 4WD control switch and the
circuit of these.(See page TF-56, 59)
: Repair
I
OK
BAD
Check the circuit of computer. : Repair
(See page TF-61 )
I
I OK
Try another computer.

I
Trouble No.2: When vehicle restart after parking in 4WD condition, it change in 2WD condition.
NO
In 4WD condition, does the 4WD indicator light? Check and repair the 4WD indicator light, the 4WD
control switch and the circuit of these. (See page
t YES TF-56,59)
Check and repair the circuit between the 4WD

control switch and the computer.
VEHICLES WITHOUT AUTOMATIC OR MANUAL LOCKING HUB

Trouble: Shifting between 2.WD and 4WD impossible
While the engine is idling, on switching ON-OFF-

ON the 4WD control switch, does it make a sound
NO
Check the leak of vacuum hose and tank.
BAD
: Repair 1
of vacuum change? OK
YES
t BAD 1I Repair 1
Check the No.1, No2 VSV and the
circuit of these. (See page TF-59)
While the engine is idling, does the vacuum reach
above a standard value?
STD: above 500 mm/Hg (See page TF-60)
t OK
YES ! NO
4WD control switch faulty
Check and repair vacuum

I hose and tank.
Check the 4WD control switch, light and the circuit

of these. (See page TF-56)
OK BAD
t
Transfer faulty
I I Repair
4WD Control Switch

INSPECTION OF 4WD CONTROL SWITCH
INSPECT SWITCH CONTINUITY
(a) Check that there is continuity between terminals 2
and 6 while turning on.
~
~ If continuity is not specified, replace the switch.
TF0427

and 6 while turning off.
If continuity is not specified, replace the switch.
~
~
TF0428
Speed Sensor
INSPECTION OF TRANSFER SPEED SENSOR
INSPECT SWITCH RESISTANCE
Measure the resistance between terminals 1 and 2, while
rotating the output shaft.
Resistance: 360 ± 30 n
NOTE: At the same time, confirm that a index of the
l.- TF0429
--l ohmmeter swings a little.
INSPECTION OF VEHICLE SPEED SENSOR

(See BE-53)
No.1 and No.2 VSV

o o INSPECTION OF NO.1 AND NO.2 VSV
1. INSPECT SWITCH RESISTANCE
Measure the resistance between terminal 1 and 2.
Resistance: 39 ±3 n
TF0430
2. INSPECT VSV OPERATION

(a) Check that air flows from port B to port C. Check that
air does not flow from port B to port A.
B
~
TF0431
(b) Apply the battery voltage across terminals 1 and 2.

Check that air flows from port A to port B. Check that
air does not flow from port A to port C.
8 EEl
TF0432
Vacuum Tank and Line

INSPECTION OF VACUUM TANK AND LINE
1. AIR TIGHTNESS TEST
(a) Disconnect the vacuum hose from the vacuum line.
(b) Apply 500 mmHg (19.7 in.Hg, 66.7 kPa) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
TF0433
2. INSPECT VACUUM LINE

(a) Disconnect the vacuum line from the vacuum tank.
(b) Connect the vacuum gauge to the vacuum line.
(c) Start the engine and run it at idle.
(d) Check that the vacuum gauge indicates about 400
mmHg at idle.
TF0434
4WD Indicator Switch

o
INSPECTION OF 4WD INDICATOR SWITCH
o o INSPECT SWITCH CONTINUITY
(a) Check that there is continuity between terminal and
switch bodY.,when the switch is pushed.
(b) Check that there is no continuity between terminal
and switch body when the switch is free.
L.- __
TF0435 If continu ity is not as specified, replace the switch.
4WD Control Computer

o INSPECTION OF 4WD CONTROL COMPUTER
o o
INSPECT 4WD CONTROL COMPUTER CIRCUIT
(a) Disconnect the computer and inspect the connector on
the wire harness side as shown in the table below.
TF0436
Terminal Check Item Tester connection Condition Voltage Value
I
Turn 4WD control switch on Battery voltage
1 Voltage I
1- 10
i
Turn 4WD control switch off No voltage
Transfer gear 2WD position Battery voltage

4 Voltage 4 -10
Transfer gear 4WD position No voltage
I
--
5 Voltage 5 -10 Turn ignition switch on Battery voltage

6 Voltage 6 -10
I
I
11 Voltage 11 - 10
I
(b) Disconnect the connector from the computer and

inspect the wire harness as shown in the table below.
TF0437
Terminal Check Item Tester connection Resistance Value
4 Resistance 4-10 about 35n

8 Resistance 8-9 about 360 n
--
10 Continuity 10- Body Ground Continuity
11 Resistance 11 - 10 about 35 n
PR-1
PROPELLER SHAFT
Page
PRECAUTIONS PR-2
TROUBLESHOOTING PR-2
PROPELLER SHAFT PR-3
PR-2 PROPELLER SHAFT - Precautions, Troubleshooting
PRECAUTIONS
Be careful not to grip the propeller shaft tube too tightly in the
vise as this will cause deformation.
TROUBLESHOOTING
Noise Sleeve yoke spline worn Replace propeller shaft PR-3

Spider bearing worn or stuck Replace propeller shaft PR-3
Vibration Propeller shaft runout Replace propeller shaft PR-3

Propeller shaft imbalance Balance propeller shaft
Transmission extension housing or Replace extension housing bushing
transfer front case bushing worn or transfer front case
Sleeve yoke spline stuck Replace propeller shaft PR-3
PROPELLER SHAFT - Propeller Shaft PR-3
PROPELLER SHAFT
COMPONENTS
(2WD) Propeller Shaft
I
I
~-j
MIT 750 (54, 74)

AIT 430 (31, 42)
(4WD) Front Propeller Shaft
Rear Propeller Shaft
Rear Propeller Shaft

Sleeve Yoke
430 (31.42)
750 (54,74)
750 (54. 74)
I kg-cm (ft-Ib. N·m) I : Specified torque PROl16

PR0120
PR0121
(2WD)
Matchmarks
REMOVAL OF PROPELLER SHAFT
1. DISCONNECT PROPELLER SHAFT FROM
DIFFERENTIAL
(a) Place the match marks on the differential and propeller
shaft flanges.
(b) Remove the four bolts, washers and nuts, disconnect
the propeller shaft from the differential.
PROOOl
PR-4 PROPELLER SHAFT - Propeller Shaft
2. REMOVE PROPELLER SHAFT FROM TRANSMISSION

(a) Pull out the propeller shaft yoke from the transmis-
sion.
(b) Insert SST in the transmission to prevent oil leakage.
SST 09325-20010
SST
PR0004
(4WD)
REMOVAL OF REAR PROPELLER SHAFT
1. DISCONNECT REAR PROPELLER SHAFT FROM
01 FFER ENTIAL
shaft flanges.
PR0122
2. REMOVE REAR PROPELLER SHAFT

(a) Place the match marks on the transfer and propeller
shaft fla nges.
(b) Remove the four nuts and washers, remove the
propeller shaft from the transfer.
PRO'23
(4WD)
REMOVAL OF FRONT PROPELLER SHAFT
1. DISCONNECT DIFFERENTIAL SUPPORT MEMBER
FROM BODY
(a) Remove the two bolts from the bracket.
(b) Remove the four bolts and nuts, disconnect the
differential support member from the body.
2. DISCONNECT FRONT PROPELLER SHAFT FROM

DIFFERENTIAL
shaft flanges.
PRO'24
3. REMOVE FRONT PROPELLER SHAFT

"''- ......-----... (a) Pull out the propeller shaft yoke from the transfer.
,'. r-
~>/ / (b) Insert SST in the transfer to prevent oil leakage.
~_f-==:::-~/ \
- I \,' /
SST 09325-20010
I if \.Q~~:"~\~
• '7 j' ~-:::-~.~~§-
SST
PR0126
INSPECTION OF PROPELLER SHAFT

1. INSPECT PROPELLER SHAFT RUNOUT
If shaft runout is greater than maximum, replace the
propeller shaft.
PROl18
2. INSPECT SPIDER BEARINGS

Check the spider bearing axial play by turning the yoke or
flange while holding the shaft tightly.
Bearing axial play: 0 mm (0 in.)
PROl17
(4WD)
Matchmarks DISASSEMBLY AND ASSEMBLY OF REAR
PROPELLER SHAFT
1. REMOVE YOKE FROM PROPELLER SHAFT
(a) Place the matchmarks on the sleeve yoke and shaft.
(b) Pull out the sleeve yoke from the shaft.
PROl27
2. INSERT SLEEVE YOKE INTO PROPELLER SHAFT

(a) Apply MP grease to the propeller shaft spline and
sleeve yoke sliding surface.
(b) Align the matchmarks on the sleeve yoke and shaft.
(c) Insert the sleeve yoke into the shaft.
PR-6 PROPELLER SHAFT - Propeller Shaft
(2WD)
INSTALLATION OF PROPELLER SHAFT
1. INSERT PROPELLER SHAFT YOKE INTO
TRANSMISSION
(a) Remove SST from the transmission.
SST 09325-20010
SST (b) Insert the yoke into the transmission.

PR0004
2. CONNECT PROPELLER SHAFT TO DIFFERENTIAL

Matchmarks
(a) Align the match marks on the flanges and connect the
flanges with the four bolts, washers and nuts.
(b) Torque the bolts and nuts.
Torque: MIT 750 kg-em (54 ft-Ib, 74 N'm)
AIT 430 kg-em (31 ft-Ib, 42 N'm)
PROOOl
(4WD)
INSTALLATION OF FRONT PROPELLER SHAFT
1. INSERT PROPELLER SHAFT YOKE INTO TRANSFER
(a) Remove SST from the transfer.
SST 09325-20010
(b) Insert the yoke into the transfer.
PR0126
2. CONNECT FRONT PROPELLER SHAFT TO

DIFFERENTIAL
PR0124
3. CONNECT DIFFERENTIAL SUPPORT MEMBER TO

BODY
(a) Connect the differential support member to the body
with the four bolts and nuts.
(b) Install the two bolts to the bracket. Torque the bolts.
PR0147
(4WD)
INSTALLATION OF REAR PROPELLER SHAFT
1. CONNECT REAR PROPELLER SHAFT TO TRANSFER
FLANGE
flanges with the four nuts and washers.
(b) Torque the nuts.
PR0123
2. CONNECT REAR PROPELLER SHAFT TO

DIFFERENTIAL
(a) Align the matchmarks on the flanges and connect the
PROl22
FA-1
FRONT AXLE AND

SUSPENSION
Page
(2WD)
TROUBLESHOOTING . FA-2
FRONT WHEEL ALIGNMENT . FA-3
FRONT AXLE HUB AND STEERING
KNUCKLE . FA-8
Front Axle Hub . FA-9
Steering Knuckle . FA-10
FRONT SUSPENSION . FA-15
Ball Joints . FA-16
Torsion Bar Spring . FA-18
Lower Suspension Arm and Shock
Absorber . FA-20
Upper Suspension Arm . FA-24
Strut Bar . FA-27
Stabilizer Bar . FA-28
(4WD)
TROUBLESHOOTING . FA-29
FRONT WHEEL ALIGNMENT . FA-30
FREE WHEELING HUB . FA-36
AUTOMATIC LOCKING HUB . FA-42
KNUCKLE . FA-52
Front Axle Hub . FA-53
Steering Knuckle . FA-57
FRONT DRIVE SHAFT . FA-62
FRONT DIFFERENTIAL . FA-69
FRONT SUSPENSION . FA-98
Ball Joints FA-99
Torsion Bar Spring . FA-101
Lower Suspension Arm . FA-103
Upper Suspension Arm . FA-106
Shock Absorber . FA-109
Stabilizer Bar . FA-110
FA-2 FRONT AXLE AND SUSPENSION - Troubleshooting (2WD)
TROUBLESHOOTING (2WD)
-------------------f-- ----- - ~---~----------~---------- ------+------------ - --------------------+--------1
Wanders/pulls Tire worn or improperly inflated Inflate tires to proper pressure or FA-3
replace tires
Alignment incorrect Check front alignment FA-3
Wheel bearing adjusted too tight Adjust wheel bearing FA-8
Front or rear suspension parts loose or broken Tighten or replace suspension part FA-15
Steering gear out of adjustment or broken Adjust or repair steering gear SR-14,
38,58
~ - - - - - - - - - - - - t - - - - - - - - - ------ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - t - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Bottoming Vehicle overloaded Check loading

Springs weak Replace spring FA-15
Sways/pitches Tires improperly inflated Inflate tires to proper pressure FA-3

Stabilizer bar bent or broken Inspect stabilizer bar FA-28
------------------- ---------
Front wheel Ti res worn or improperly inflated Replace tire or inflate tires to proper FA-3
shimmy pressure
Wheels out of balance Balance wheels
Alignment incorrect Check front alignment FA-3
Wheel bearings worn or improperly adjusted Replace or adjust wheel bearings FA-8
Ball joints or bushings worn Inspect ball joints and bushings FA-15
Steering gear out of adjustment or broken Adjust or repair steering gear SR-14
38,58
f - - - - - - - - - - - - - - - - - - - - - + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - _ + _ _ ----
Abnormal tire wear Tires improperly inflated Inflate tires to proper pressure FA-3
Alignment incorrect Check toe-in FA-3
Suspension parts worn Replace suspension part FA-15
FRONT AXLE AND SUSPENSION - Front Wheel Alignment (2WD) FA-3
FRONT WHEEL ALIGNMENT (2WD)

1 MAKE FOLLOWING CHECKS AND CORRECT ANY
PROBLEMS
(a) Check the tires for size, wear and proper inflation.
Cold tire inflation pressure:
kg/cm 2 (psi, kPa)
Tire Size Front ! Rear
175R146PRLT 2.8 (41, 280) 2.8 (41, 280)
P195/75 R14 2.4 (35, 240) 2.4 (35, 240)
(b) Check the wheel runout.

Lateral runout: 1.2 mm (0.047 in.) or less
(c) Check the front wheel bearings for looseness.
(d) Check the front suspension for looseness.
(e) Check the steering linkage for looseness.
(f) Check that the front absorbers work properly by using
the standard bounce test.
FA1455
2. MEASURE CHASSIS GROUND CLEARANCE

Chassis ground clearance:
mm(in.)
Tire Size Front Rear
175 R14 6PRLT 234 (9.21) 254 (10.00)
*1 264 (10.39)
P195/75 R14 234 (9.21)
*2 254 (10.00)
FA0888 * 1 Four link type rear suspension

*2 Leaf spring type rear suspension
Four link suspension If the clearance of the vehicle is not standard, try to level the
vehicle by rocking it down.
If still not correct, check for bad springs or suspension parts.
NOTE: When measuring the chassis ground clearance,
measure from the ground to the center of the lower
suspension arm front mounting bolt.
Leaf spring suspension
FA1521
FA0890
FA-4 FRONT AXLE AND SUSPENSION - Front Wheel Alignment (2WD)
3. INSTALL WHEEL ALIGNMENT EQUIPMENT

Follow the specific instructions of the equipment manu-
facturer.
FA0241
4. INSPECT WHEEL ANGLE

Remove the caps of the knuckle stopper bolts and check the
wheel angles.
Wheel angle:
Max. at 20° (Outside wheel)

----- -- ----- -""-,--
A: Inside Inside wheel Outside wheel Inside wheel

1------ ------ --+--- --
B: Outside
37000,+1 ° 33°00' 22°00'
FA0018 -2
NOTE: When the steering wheel is fully turned, make

sure that the wheel is not touching the body or brake
flexible hose.
If maximum wheel angles differ from the standard value,
adjust the wheel angle.
5. ADJUST WHEEL ANGLE

(a) Remove the caps of the knuckle stopper bolts.
(b) Loosen the knuckle stopper bolt lock nuts, and tighten
the stopper bolts by hand.
FA 1290
(c) Remove the boot clips and loosen the tie rod clamp
bolts and nuts.
(d) Adjust maximum wheel angle by turning the left and
A=B right rack ends an equal amount.
(e) Check that the lengths of the left and right tie rods are
the same as shown.
Left-right error: 1 .5mm (0.059 in.) or less
(f) Torque the tie rod clamp bolts and nuts.
FA 1267
(g) Install the boot clips.
NOTE: Check that the boots are not twisted.
(h) Turn the steering wheel fully, and loosen the knuckle
stopper bolt until it touches to the lower arm.
(i) Torque the knuckle stopper bolt lock nuts.
(j) Install the caps of the knuckle stopper bolts.
Axis Camber 6. ADJUST CAMBER,STEERING AXIS INCLINATION

Inclination AND CASTER
Camber: Inspection standard - 5' ± 45'
Adjustment standard - 5' ± 30'
Left-right error 30' or less
Caster: Inspection standard 2°30' ± 45'
Adjustment standard 2°30' ± 30'
Steering axis inclination:
FA0012 Inspection standard 10°35' ± 45'
Caster
Front ...
FA0013
If camber or caster is not within specification, adjust by

turning the adjusting cam or strut bar nut.
--------
Each graduation of the
adjusting cam
---- --------- -------
Each turn of the strut

bar nut
------
Camber changes
~---
13'50"
-
Caster changes
12'
25'
NOTE:
FA0723
• The adjusting cam should not be turned more than 4.5
graduations from the neutral position.
• Do not turn the strut bar nut more than 3 threads from
the original position.
Torque: Adjusting cam
1,550 kg-cm (112 ft-Ib, 152 N'm)
Strut bar nut
1,230 kg-cm (89 ft-Ib, 121 N· m)
If steering axis inclination is not as specified after camber
and caster have been correctly adjusted, recheck the
steering knuckle and front wheels for bending or looseness.
FA 1332
7. ADJUST TOE-IN
Adjust toe-in with a toe-in gauge in the following proce-
dure.
(a) Rock the vehicle up and down to stabilize the suspen-
sion.
(b) Move the vehicle forward about 5 m (16.4 ft) with the
front wheels in the straight-ahead position on a level
place.
RA0793
(c) Mark the center of each rear tread and measure the
distance "8" between the marks of the right and left
tires.
FA 1269
(d) Advance the vehicle until the marks on the rear sides
of the tires come to the measuring heights of the
gauge on the front side.
\
\~
NOTE: If the tire rolls too far, repeat from step (b).
" I . . Advance the vehicle
'- ~O""'~~f,~a~
~~~~'
FA 1270
(e) Measure the distance "A" between the marks on the

front of the tires.
FA 1271
(f) Measure the toe-in.

Toe-in = 8 - A
Inspection standard: 0 ± 2 mm (0 ± 0.08 in.)
If toe-in is not as specified, adjust the left and right tie rods.
FAOO18
(g) Remove the boot clips and loosen the tie rod clamp
bolts and nuts.
(h) Adjust toe-in by turning the left and right rack ends an
equal amount.
\
\ Adjustment standard: 0 ± 1 mm (0 ± 0.04 in.)
FA1291
(i) Insure that the lengths of the left and right tie rods are
the same.
A=B
Left-right error: 1.5 mm (0.059 in.) or less
(j) Torque the tie rod clamp bolts and nuts.
(k) Install the boot clips.
FA 1267
8. INSPECT SIDE SLIP WITH SIDE SLIP TESTER

Side slip: 3.0 mm/m (0.118 in./3.3 ft) or less
If the side slip exceeds the limit, the toe-in or other front
wheel alignment may not be correct.
FA0459
FA-8 FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD)

KNUCKLE (2WD)
COMPONENTS
n------ Disc Brake Caliper
- - - + Cotter Pin
\ - - - - - - Steering Knuckle
1.050 (76. 103)
+Oil Seal
Dust Cover
Outer Bearing
Hub with Disc
+ Cotter Pin
I kg-cm (ft-Ib, N·m) I : Specified torque
+ Non-reusable part FA1531
FRONT AXLE AND SUSPENSION - Front Axle Hub and Steering Knuckle (2WD) FA-9
Front Axle Hub

(See page FA-8)
DISASSEMBLY OF FRONT AXLE HUB

1. REMOVE DISC BRAKE CALIPER
(a) Remove the three bohs and disc brake caliper.
FA 1553
(b) Suspend the disc brake caliper with wire.

NOTE: Do not disconnect the brake tube and hose.
FA0791
2. REMOVE AXLE HUB WITH DISC

(a) Remove the cap, cotter pin, nut lock and nut.
(b) Remove the hub with disc together with the outer
bearing and thrust washer.
NOTE: Be careful not to drop the outer bearing.
FAQ020
3. REMOVE OIL SEAL AND INNER BEARING

(b) Remove the inner bearing from the hub.
FA0021
INSPECTION AND REPAIR OF FRONT AXLE

HUB
1. INSPECT BEARINGS
Clean the bearings and outer races and inspect them for
wear or damage.
2. REPLACE BEARING OUTER RACES

(a) Using a brass bar and hammer, drive out the bearing
outer race.
(b) Using SST, carefully drive in a new bearing outer race.

SST 09608-30022
Inside race (09550-00050, 09608-05010)
Outside race (09608-05010, 09608-05040)
FA1287
ASSEMBLY OF FRONT AXLE HUB

(See page FA-8)
1. PACK BEARINGS WITH MP GREASE

(a) Place MP grease in the palm of your hand.
(b) Pack grease into the bearing, continuing until the
grease oozes out from the other side.
(c) Do the same around the bearing circumference.
2. COAT INSIDE OF HUB AND CAP WITH MP GREASE
FA 1286
3. INSTALL INNER BEARING AND OIL SEAL

Place inner bearing into the hub. Using SST, drive the oil
seal into the hub. Coat the oil seal with MP grease.
SST 09608-30022 (09550-00050, 09608-05010)
4. INSTALL AXLE HUB ON SPINDLE

(a) Place the axle hub on the spindle.
(b) Install the outer bearing and thrust washer.
FA 1285
5. ADJUST PRELOAD
(a) Install and torque the nut.
FA 1284
(b) Snug down the bearing by turning the hub several

times.
FA 1283
(c) Loosen the nut until it can be turned by hand.
FA 1282
(d) Using a spring tension gauge, measure and make a

note of the frictional force of the oil seal.
FA1281
(e) Tighten the nut until the preload is within specifica-

tion.
Preload (starting)
Add oil seal frictional force
350 - 870g (0.8 - 1.9 Ib, 3.4 - 8.5 N)
FA 1280
(f) Measure the hub axial play.

Axial play: 0.05 mm (0.0020 in.) or less
FAl279
6. INSTALL NUT LOCK, COTTER PIN AND HUB GREASE

CAP
7. INSTALL DISC BRAKE CALIPER

Install the brake caliper to the steering knuckle with the
three bolts.
FA1551
Steering Knuckle
(See page FA-8)
REMOVAL OF STEERING KNUCKLE

1. REMOVE FRONT AXLE HUB
(See page FA-8)
FA0651
2. REMOVE DUST COVER AND KNUCKLE ARM

Remove the cotter pin, nut and bolt and remove the dust
cover and knuckle arm from the steering knuckle.
FA1456
3. REMOVE STEERING KNUCKLE

(a) Support the lower arm with a jack.
(b) Remove the two cotter pins and two nuts.
FA0793
(c) Using SST, disconnect the steering knuckle from the

lower ball joint.
SST 09628-62011
(d) Using SST, disconnect the steering knuckle from the
upper ball joint.
SST 09628-62011
(e) Remove the jack.
(f) Remove the nuts, retainers and bushing from the
FA0896 shock absorber.
(g) Push the lower arm and strut bar down and remove
the steering knuckle.
FA0794
INSPECTION OF STEERING KNUCKLE

INSPECT STEERING KNUCKLE
Using a dye penetrant, check the steering knuckle for
cracks.
If crack is found, replace the steering knuckle.
FA0928
INSTALLATION OF STEERING KNUCKLE

(See page FA-8)
1. INSTALL STEERING KNUCKLE

(a) Install the steering knuckle to the upper ball joint and
install the nut.
(b) Push the lower arm and strut bar down and install the
steering knuckle to the lower ball joint. Install the nut.
(c) Support the lower arm with a jack.
FA0794
(d) Torque the upper ball joint nut.

(e) Torque the lower ball joint nut.
(f) Install new cotter pins.
NOTE: If the cotter pin hole does not line up, correct by
tightening the nut by the smallest amount possible.
(g) Install the bushing, retainers and nuts to the shock
absorber.
2. INSTALL KNUCKLE ARM AND DUST COVER

(a) Install the knuckle arm and dust cover with the bolt
and nut.
(b) Torque the bolt and nut.
(c) Secure the nut with a new cotter pin.
FA 1550 tightening the nut by the smallest amount possible.
3. INSTALL FRONT AXLE HUB AND DISC BRAKE

CALIPER
(See page FA-1 0)
4. CHECK FRONT WHEEL ALIGNMENT

(See page FA-3)
FA0651
FRONT AXLE AND SUSPENSION - Front Suspension (2WD) FA-15
FRONT SUSPENSION (2WD)

COMPONENTS
Retainer
Rear BUShin~
Upper Arm Shaft I
r-- 1--,.550 (112. 152) ~ € €} •
o '--1 480 (35, 47) I

~-TOrqUeArm
AnChorArm
: 1300122.291 1 ~ I
\
~-upper Ball Joint ~

e [ 260 (19, 25) ~ ~,f, E158. 78) I ~ 6>
~
~~r
Retainer 6 Retaine'r
Cushion-----eJ cushion~ _Adjusting Nut
~
CUShion Retainer~
Stabilizier
Bar
~Retalner Cushion
o-collar
' ~
:
Retainer
e
f
Boot
Torsion Bar Spring
Retainer ~ Shock Absorber washer~

Cushion---e f&lf-
Q Cushion COllar-~
~
~ w-l
I 1,230(89,121) I
.
Bracket~ cus~ion=» ~~l----Retainer
~ v~~ ~Retainer Retainer ~ ~~'--.- - - Cushion
~
~
~~ /" ....
1'95('4.19) I <..... // >
.... .... ...." "
~~" - - - Retainer
~ ~ Cus hion '-1-8-0-(1.1-3-,-18-)---'
U Retainer
Strut Bar
Lower Suspension Arm
Bushing ~ fi\--@00(152, 206) I
~~ ~ <>
-- .
Adjusting Cam
~ 1,.050176.,031 I
C9 Lower Ball Joint

II
• Non-reusable part FA1468
FA-16 FRONT AXLE AND SUSPENSION - Front Suspension (2WD)
Ball Joints
(See page FA-15)
INSPECTION OF BALL JOINTS

1. INSPECT LOWER BALL JOINT FOR EXCESSIVE
LOOSENESS
(a) Jack up the front of the vehicle and support it with
stands.
L..- F_AO_92---19 (b) Make sure the front wheels are in a straight-forward
position, and depress the brake pedal.
(c) Move the lower suspension arm up and down and
check that the lower ball joint has no play.
Maximum vertical play: 0 mm (0 in.)
2. INSPECT UPPER BALL JOINT FOR EXCESSIVE

LOOSENESS
Move the wheel up and down and check that the upper ball
joint has no excessive play.
Maximum vertical play: 2.3 mm (0.091 in.)
FA0930
3. INSPECT BALL JOINT FOR ROTATION CONDITION

(a) Remove the ball joint.
(b) As shown, flip the ball joint stud back and forth 5 times
before installing the nut.
(c) Using a torque gauge, turn the nut continuously one
turn every 2-4 seconds and take the torque reading on
the 5th turn.
Torque (turning): Lower ball joint
FA1278
15 - 30 kg-cm
(13 - 26 in.-Ib, 1.5 - 2.9 N·m)
Upper ball joint
10 - 35 kg-cm
(9 - 30 in.-Ib, 1.0 - 3.4 N·m)
REMOVAL OF BALL JOINTS

(See page FA-15)
(See page FA-13)
2. REMOVE LOWER BALL JOINT FROM LOWER

SUSPENSION ARM
FA0797
3. REMOVE UPPER BALL JOINT FROM UPPER

SUSPENSION ARM
FA0796
INSTALLATION OF BALL JOINTS

(See page FA-15)
1. INSTALL UPPER BALL JOINT TO UPPER

SUSPENSION ARM
FA0798
2. INSTALL LOWER BALL JOINT TO LOWER

SUSPENSION ARM
FA0801

(See page FA-14)
FA0794
Torsion Bar Spring

(See page FA-15)
REMOVAL OF TORSION BAR SPRING

1. JACK UP AND SUPPORT FRAME ON STANDS
2. PLACE MATCHMARKS ON TORSION BAR SPRING,

ANCHOR ARM AND TORQUE ARM
Remove the boots and place match marks on the torsion bar
spring, anchor arm and torque arm.
3. REMOVE LOCK NUT AND MEASURE PROTRUDING

BOLT END "A", AS SHOWN
NOTE: Use this measurement for reference when adjust-
ing the chassis ground clearance.
FA 1324
4. REMOVE ADJUSTING NUT
5. REMOVE ANCHOR ARM AND TORSION BAR SPRING
INSTALLATION OF TORSION BAR SPRING

(See page FA-15)
NOTE: There are left and right identification marks on the
rear end of the torsion bar springs. Be careful not to
interchange the torsion bar springs.
FA1277
1. INSTALL TORSION BAR SPRING AND ANCHOR ARM

If Reusing Torsion Bar Spring:
(a) Apply a light coat of molybdenum disulphide lithium
base grease to the spline of the torsion bar spring.
(b) Align the match marks and install the torsion bar
spring to the torque arm.
(c) Align the match marks and install the anchor arm to
the torsion bar spring.
FA0904 FA1331
(d) Tighten the adjusting nut so that the bolt protrusion is

equal to that before removal.
FA1324
If Using a New Torsion Bar Spring:

(a) Check that the upper and lower arms rebound.
(b) Remove the front wheel.
(c) Apply a light coat of molybdenum disulphide lithium
(d) Install one end of the torsion bar spring to the torque
arm.
FA0904
(e) Install the torsion bar spring on the opposite end to the
anchor arm as shown in the figure.
(f) Finger tighten the adjusting nut.
A = About 10 mm (0.39 in.)
FA 1276
(g) Tighten the adjusting nut. (Reference)

B =About 70 mm (2.76 in.)
(h) Install the wheel and remove the stands. Bounce the
vehicle up and down to stabilize the suspension.
(i) Adjust the chassis ground clearance turning the
adjusting nut.
mm(in.)
Tire size Front Rear
175R146PRLT 234 (9.21) I

254 (10.00)
*1 264 (10.39)
P195/75 R14 234 (9.21)
*2 254 (10.00)
* 1 Four link type rear suspension

*2 Leaf spring type rear suspension
2. TORQUE LOCK NUT

3. INSTALL BOOTS
Lower Suspension Arm and Shock

Absorber
(See page FA-15)
REMOVAL OF LOWER SUSPENSION ARM
AND SHOCK ABSORBER
1. REMOVE WHEEL
FA0800 FA0790
2. REMOVE SHOCK ABSORBER
3. DISCONNECT TIE ROD

(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod.
SST 09610-20012
SR1375
4. DISCONNECT STABILIZER BAR WITH BRACKET

FROM LOWER SUSPENSION ARM
FA1457
5. DISCONNECT STRUT BAR FROM LOWER

SUSPENSION ARM
6. DISCONNECT LOWER BALL JOINT

Remove the two bolts and nuts holding the ball joint to the
lower suspension arm.
NOTE: Be careful not to damage the ball joint boot.
FA1458
7. REMOVE LOWER SUSPENSION ARM

(a) Place a matchmark on the adjusting cam.
FA0723
(b) Remove the nut and adjusting cam and remove the
FA1460
REPLACEMENT OF LOWER SUSPENSION

ARM BUSHING
1. REMOVE BUSHING
r--"-7'SST Using SST and a press, press out the bushing from the
lower arm.
SST 09726-27011
(09726-02030, 09726-02060, 09726-02090)
--====:':L.---l------l:::::=====_ FA0907
2. INSTALL BUSHING
Using SST and a press, press a new bushing into the lower
SST arm.
SST 09726-27011 (09726-02030, 09726-02040,
09726-02060,09726-02090)
NOTE:
• Do not apply grease or oil to the bushing.
• Do not press on the inside flange of the bushing.
FA 1527
INSTALLATION OF LOWER SUSPENSION ARM

Matchmark
AND SHOCK ABSORBER
(See page FA-15)
1. TEMPORARILY INSTALL LOWER SUSPENSION ARM

(a) Install the lower arm.
(b) Align the match mark and finger tighten the nut.
FA0723
2. TEMPORARILY CONNECT LOWER SUSPENSION

ARM
Connect the lower suspension arm to the ball joint and
finger tighten the bolts and nuts.
FA1461
3. TEMPORARILY CONNECT STRUT BAR TO LOWER

ARM
Connect the strut bar and finger tighten the bolt and nuts.
FA1462
4. CONNECT STABILIZER BAR WITH BRACKET TO

LOWER ARM
() FA1457
5. TORQUE LOWER BALL JOINT AND STRUT BAR

6. CONNECT TIE ROD

(a) Connect the tie rod to the knuckle arm and torque the
nut.
(b) Secure the nut with a new cotter pin.
SR1379
7. INSTALL SHOCK ABSORBER

(a) Position the shock absorber and install the bushings,
retainers and nut.
(b) Install the lower mounting bolts.
FA0799
8. INSTALL WHEEL AND LOWER VEHICLE
9. STABILIZE SUSPENSION
Bounce the vehicle up and down to stabilize the suspension.
RA0793
10. TORQUE ADJUSTING CAM NUT

FA1463

(See page FA-3)
FA0241
Upper Suspension Arm

(See page FA-15)
REMOVAL OF UPPER SUSPENSION ARM

1. REMOVE TORSION BAR SPRING
(See page FA-18)
2. REMOVE COOL AIR INTAKE DUCT
3. DISCONNECT UPPER SUSPENSION ARM

Remove the four bolts, spring washers and nuts disconnect
the upper arm from the upper ball joint.
NOTE: Be careful not to damage the ball joint boot.
FA1464
4. REMOVE UPPER SUSPENSION ARM

Remove the bolts and remove the upper arm from the
frame.
FA0915 FA0916
REPLACEMENT OF UPPER SUSPENSION ARM

BUSHINGS
1. REMOVE TORQUE ARM
2. REMOVE COTTER PINS, NUTS AND WASHERS
FA0803
3. REMOVE FRONT BUSHING

Using SST and a press, remove the front bushing.
SST 09726-27011 (09726-02020, 09726-02030,
09726-02040,09726-02090)
L=..J"""""""'r'<--- Bush i ng 4. REMOVE UPPER ARM SHAFT
FA0806
5. REMOVE REAR BUSHING

Using SST and a press, press out the rear bushing.
SST 09726-27011 (09726-02030, 09726-02050,
09726-02070, 09726-02090)
SST
Bushing
~ ------,
FA0807
6. INSTALL REAR BUSHING

Using SST and a press, press in a new rear bushing.
SST 09726-27011 (09726-02050, 09726-02060,
09726-02070, 09726-02090)
SST NOTE: Do not apply grease or oil to the bushing.
7. INSTALL UPPER ARM SHAFT TO UPPER ARM
FA0808
8. INSTALL FRONT BUSHING

Using SST and a press, press in a new front bushing.
SST 09726-27011
(09726-02030, 09726-02040, 09726-02090)
FA0809
9. TORQUE UPPER ARM SHAFT

(a) Install the washers and nuts.
Ball Joint Center NOTE: Position the upper arm shaft so that the frame
installation surface is at right angle to the arm.
FA0684
(b) Torque the shaft nuts.

Torque: Rear side 975 kg-em (71 ft-Ib, 96 N'm)
Front side 800 kg-em (58 ft-Ib, 78 N'm)
NOTE: First torque the rear side nut and then the front
one.
(c) Secure the nuts with new cotter pins.
FA0804
10. INSTALL TORQUE ARM TO UPPER ARM

FA0805
INSTALLATION OF UPPER SUSPENSION ARM

(See page FA-15)
1. TORQUE UPPER ARM TO FRAME

Torque the upper arm mounting bolts.
Torque:
Front side 900 kg-em (65 ft-Ib, 88 N'm)
Rear side 1,550 kg-em (112 ft-Ib, 152 N'm)
FA0917 FA0918
2. CONNECT UPPER SUSPENSION ARM

Connect the upper suspension arm to the upper ball joint
with the four bolts, spring washers and nuts.
FA 1464
3. INSTALL COOL AIR INTAKE DUCT
4. INSTALL TORSION BAR SPRING

(See page FA-18)

(See page FA-3)
Strut Bar
Matchmarks
(See page FA-15)
REMOVAL OF STRUT BAR

1. REMOVE STABILIZER BAR
(See page FA-28)
2. REMOVE STABILIZER BAR BRACKET FROM LOWER

ARM
FA0685
3. PLACE MATCHMARKS ON STRUT BAR
4. REMOVE REAR NUT FROM STRUT BAR
5. REMOVE STRUT BAR FROM LOWER SUSPENSION

ARM
Remove the nuts holding the strut bar to the lower arm, and
remove the strut bar.
INSTALLATION OF STRUT BAR

Matchmarks
1. ASSEMBLE FRONT NUT
If Reusing Strut Bar:
332 mm Install the front nut and align the matchmarks on the strut
bar.
If Using New Strut Bar:
Install the front nut.
Standard distance: 332 mm (13.07 in.)
FA0685 FA0687
2. INSTALL STRUT BAR TO BRACKET

(a) Install the washer and bushing to the strut bar and
install it to the bracket.
(b) Install the collar, bushing and washer to the strut bar.
(c) Finger tighten the rear nut.
3. CONNECT STRUT BAR TO LOWER SUSPENSION ARM

Torque: 680 kg-em (49 ft-Ib, 67N'm)
FA1467
4. TORQUE REAR NUT

(a) Remove the stands and bounce the vehicle up and
down to stabilize the suspension.
(b) Torque the rear nut.
5. INSTALL STABILIZER BAR BRACKET AND

STABILIZER BAR
FA 1332
(See page FA-3)
Stabilizer Bar
(See page FA-15)
REMOVE STABILIZER BAR

REMOVE STABILIZER BAR FROM LOWER SUSPENSION
ARMS
(a) Remove the nuts and cushions holding both sides of
the stabilizer bar to the lower arms.
FA1446
(b) Remove both stabilizer bar bushings and brackets, and

remove the stabilizer bar.
FA 1465
INSTALLTION OF STABILIZER BAR

13 - 16 mm
1. POSITION STABILIZER BAR
Place the stabilizer bar in position and install both stabilizer
bar bushings and brackets to the frame.
Finger tighten the bolts.
2. CONNECT STABILIZER BAR TO LOWER SUSPENSION

ARMS
FA0690
Connect the stabilizer bar on both sides to the lower arms
with bolts, cushions and new nuts as shown. Tighten the
nuts.
Distance: 13 - 16 mm (0.51 - 0.63 in.)
3. TORQUE BRACKET SET BOLTS

FA 1330
FRONT AXLE AND SUSPENSION - Troubleshooting (4WD) FA-29
TROUBLESHOOTING(4WD}
Problem Possible Remedy Page
Wanders/pulls Tires worn or improperly inflated Inflate tires to proper pressure or FA-3D
replace tires
Alignment incorrect Check front wheel alignment FA-3D
Wheel bearing adjusted too tight Adjust wheel bearing FA-52
Front or rear suspension parts loose or broken Tighten or replace suspension parts FA-98
Steering gear out of adjustment or broken Adjust or repair steering gear SR-4D,
58
Bottom Vehicle overloaded Check loading
Shock absorber worn out Replace shock absorber FA-98
Spring weak Replace spring FA-98
Sways/ pitches Tires improperly inflated Inflate tires to proper pressure FA-30
Stabilizer bar bent or broken Inspect stabilizer bar FA-98
Front wheel Tires worn or improperly inflated Replace tire orinflate to proper FA-30
shimmy pressure
Wheels out of balance Balance wheels
Alignment incorrect Check front wheel alignment FA-30
Wheel bearing worn Replace wheel bearings FA-52
Ball joints or bushings worn Inspect ball joints and bushings FA-93
Steering gear out of adjustment or broken Adjust or repair steering gear SR-40,
58
Abnormal tire wear Tires improperly inflated Inflate tires to proper pressure FA-30
Shock absorbers worn out Replace shock absorber FA-98
Alignment incorrect Check toe-in FA-30
Suspension parts worn Replace suspension parts
Oil leak from drive Oil level too high or wrong grade Drain and replace oil
pinion
Oil seal worn or damage Replace seal FA-69
Companion flange loose or damaged Tighten or replace flange FA-69
Oil leak from side Oil level too high or wrong grade Drain and replace oil
gear shah Oil seal worn or damaged Replace oil seal FA-76
Noise in front axle Oil level low or wrong grade Drain and replace oil
Excessive backlash between pinion and ring Check backlash FA-76
or side gear
Ring, pinion or side gears worn or chipped Inspect gears FA-76
Drive pinion bearing worn Replace bearing FA-76
Side gear shaft bearing worn Replace bearing FA-76
Differential side bearing loose or worn Adjust or replace bearings FA-76
FRONT WHEEL ALIGNMENT(4WD)

1. MAKE FOLLOWING CHECKS AND CORRECT ANY
PROBLEMS
(a) Check the tires for size wear and proper inflation.
Tire size: P205/75 R 14
Cold tire inflation pressure:
2.4 kg/ cm 2 (35 psi, 240 kPa)
(b) Check the wheel runout.

Lateral runout: 1.2 mm (0.047 in.) or less
(c) Check the front wheel bearings for looseness.
(d) Check the front suspension for looseness.
(e) Check the steering linkage for looseness.
(f) Check that the front absorbers work properly by using
the standard bounce test.
2. MEASURE CHASSIS GROUND CLEARANCE

mm(in.)
~.~ Front Rear
YR31LG 256 (10.09) 284 (11.17)

~-- ---"-----,-~
YR32LV 253 (9.44) 305 (11.99)

•
If the clearance of the vehicle is not standard, try to level the

vehicle by rocking it down.
If still not correct, check for bad springs or suspension parts.
NOTE: When measuring the chassis ground clearance,
measure from the ground to the center of the lower
suspension arm front mounting bolt.
--'- .:.::...-_...::::-;....- FA1521
3. INSTALL WHEEL ALIGNMENT EQUIPMENT

Follow the specific instructions of the equipment manu-
facturer.
FA 1266
4. INSPECT WHEEL ANGLE

Remove the caps of the knuckle stopper bolts and check the
Front wheel angles.
t Wheel angle:
Max. at 20° (Outside wheel)

f-----
A: Inside Inside wheel Outside wheel Inside wheel
B: Outside
34000'+ 0° 32°00' 20°50'
FAOO18
- 3°
NOTE: When the steering wheel is fully turned, make

sure that the wheel is not touching the body or brake
flexible hose.
If maximum wheel angles differ from the standard value,
adjust the wheel angle.
6. ADJUST WHEEL ANGLE

I (a) Remove the caps of the knuckle stopper bolts.
/ (b) Loosen the knuckle stopper bolt lock nuts, and tighten
the stopper bolts by hand.
FA 1268
(c) Remove the boot clips and loosen the tie rod clamp
bolts and nuts.
(d) Adjust maximum wheel angle by turning the left and

right rack ends an equal amount.
A=B
(e) Check that the lengths of the left and right tie rods are
the same as shown.
Left-right error: 1.5 mm (0.059 in.) or less
(f) Torque the tie rod clamp bolts.
(g) Install the boot clips.
L-- F_Al_26---l7 NOTE: Check that the boots are not twisted.
(h) Turn the steering wheel fully, and loosen the knuckle
stopper bolt until it touches the lower arm.
(i) Torque the knuckle stopper bolt lock nuts.
(j) Install the caps of the knuckle stopper bolts.
FA 1268
Axis 6. ADJUST CAMBER,STEERING AXIS INCLINATION

Inclination Camber Caster AND CASTER
.. ¢)
Camber: Inspection standard 0°10' ± 45'
Adjustment standard 0° 10' ± 30'
Front Left- right error 30' or less
Caster: YR31 LG
Inspection standard 2°50' ± 45'
FA1790 FA1791 YR32LV
Inspection standard 2°10' ± 45'
Front Adjusting Cam
JJ
Increase
Steering axis inclination:
Inspection standard
Left-right error
12°25' ± 45'
30' or less
If the steering axis inclination is not as specified after
camber and caster have been correctly adjusted, recheck
the steering knuckle and front wheel for bending or
looseness.
FA0965
If camber and/or caster are not within specification, adjust
by front and/or rear adjusting cams.
(See Adjustment Chart)
Rear Adjusting Cam
D\~~
Incr~1 ~~ t Decrease
~O
- <= ~
FA0964
How to Read Chart

(a) Refer to the service specifications for the adjustment
oc9 standards and then mark them on the graph.
____--+-:-'---+---'<-.....-.+---++--"r-t-~,
Example: Camber 0°10'
f-r-,,<-+----+-+----l<->"'--+--""""7't-'" be<O Caster 2°50'
~.,..Ll-~++--+-~'t---+-,),
FA1621
(b) Then mark on the graph the measurements taken

from the vehicle.
Example: Camber 0°15'
Caster 3°30'
FA1621
(c) As shown in the illustration, read from the graph the

amounts by which the front and/or rear cams are to
be adjusted.
Example: Front cam + 3.0
Rear cam - 1 .3
(d) Loosen and adjust the front and/or rear cam.
(e) Torque the front and/or rear cam nuts.
FA 1621
Adjustment Chart
----Camber
- - - - - - - - -Caster
Increase Front Cam
o~/
a
~/
"
,,<:'
r-e/ /
/
/
/1 0 0
~
t>,<O /
/
r-e/ /
" "
/
ot><<:'
"/
f'l:>0 /
0" ~
/
" "" /
Decrease Increase
Rear Cam Rear Cam
f'l:>0
~/
/
"
,,<:'
c::SS / ,0/ "
~/ /
/
/
t>,<O" "
r-e "
"
/
"
/
/ "
Decrease Front Cam
FA1620
7. ADJUST TOE-IN
Adjust toe-in with a toe-in gauge in the following pro-
cedure.
(a) Rock the vehicle up and down to stabilize the suspen-
sion.
(b) Move the vehicle forward about 5 m (16.4 ft) with the
front wheels in the straight-ahead position on a level
place.
RA0793
(c) Mark the center of each rear tread and measure the
distance "8" between the marks of the right and left
~
tires.
Front" A FA1269
(d) Advance the vehicle until the marks on the rear sides
of the tires come to the measuring heights of the
gauge on the front side.
NOTE: If the tire rolls too far, repeat from step (b).
FA 1270
(e) Measure the distance "A" between the marks on the

front of the tires.
FA1271
(f) Measure the toe-in.
----A------..l Toe-in =B - A
Front Inspection standard: 0 ± 2 mm (0 ± 0.08 in.)
If toe-in is not as specified, adjust the left and right tie rods.
- t H H + - - - - - . - - . ---#-+#--
B- A = Toe-in
----B---~
FAOO18
(g) Remove the boot clips and loosen the tie rod clamp
bolts and nuts.
(h) Adjust toe-in by turning the left and right rack ends an
equal amount.
Adjustment standard: 0 ± 1 mm (0 ± 0.04 in.)
FA1070
(i) Insure that the lengths of the left and right rack ends
are the same.
A=8
Left-right error: 1 .5 mm (0.059 in.) or less
FA 1267
(j) Torque the tie rod clamp bolts and nuts.

(k) Install the boot clips.
8. INSPECT SIDE SLIP WITH SIDE SLIP TESTER

Side slip: 3.0 mm/m (0.118 in.l3.3 tt) or less
If the side slip exceeds the limit, the toe-in or other front
wheel alignment may not be correct.
FA1272
FA-36 FRONT AXLE AND SUSPENSION - Free Wheeling Hub (4WD)
FREE WHEELING HUB (4WD)

COMPONENTS
.Gasket
Snap Ring
Spacer
Free Wheeling Hub Body
Snap Ring
r--_
I Free Wheeling Hub Ring
I
Clutch
Inner Hub
Pawl
Snap Ring
Steel Ball and Spring
p
• Gasket
Spring
Spring
Control Handle and Seal
Free Wheeling Hub Cover

FRONT AXLE AND SUSPENSION - Free Wheeling Hub (4WD) FA-37
REMOVAL OF FREE WHEELING HUB

! (See page FA-36)
o 1. REMOVE FREE WHEELING HUB COVER
(a) Set the control handle to FREE.
(b) Remove the cover mounting bolts and pull off the
cover.
~I
I FA0054
2. REMOVE BOLT WITH WASHER
FA1411
3. REMOVE FREE WHEELING HUB BODY

(a) Remove the mounting nuts and washers.
(b) Using a brass bar and hammer, tap on the bolt heads
and remove the cone washers.
(c) Pull off the free wheeling hub body.
FA1412
DISASSEMBLY OF FREE WHEELING HUB

(See page FA-36)
1. REMOVE CONTROL HANDLE FROM FREE WHEELING
HUB COVER
(a) Compressing the spring, remove the pawl tab from the
handle cam, and remove the clutch.
(b) Using snap ring pliers, remove the snap ring.
(c) Remove the control handle.
FA 1273 FAOO57
(d) Remove the steel ball and spring from the control
handle.
2. REMOVE INNER HUB AND FREE WHEELING HUB

RING FROM FREE WHEELING HUB BODY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the inner hub and free wheeling hub ring.
FA0058
3. REMOVE FREE WHEELING HUB RING FROM INNER

HUB
(b) Remove the free wheeling hub ring and spacer.
FAOO59
INSPECTION OF FREE WHEELING HUB

1. INSPECT COVER, HANDLE AND SEAL
Temporarily install the handle in the cover and check that
the handle moves smoothly and freely.
FAOO60
2. INSPECT BODY AND CLUTCH

Check that the clutch moves smoothly in the body.
FA0213
3. MEASURE OIL CLEARANCE BETWEEN INNER HUB

AND FREE WHEELING HUB BODY
Oil clearance (A - B): 0.3 mm (0.012 in.)
ASSEMBLY OF FREE WHEELING HUB

(See page FA-36)
1. APPLY MP GREASE TO SLIDING SURFACE OF PARTS
6
FA0210
2. INSTALL CONTROL HANDLE TO COVER

(a) Install the seal, spring and steel ball to the handle.
(b) Insert the handle in the cover and install the snap ring
with snap pliers.
3. INSTALL TENSION SPRING IN CLUTCH

Install the tension spring in the clutch with the spring end
aligned with initial groove.
FAOO63
4. INSTALL FOLLOWER PAWL TO CLUTCH

(a) Place the follower pawl on the tension spring with one
of the large tabs against the bent spring end.
(b) Place the top ring of the spring on the small tabs.
FAOO64
5. INSTALL CLUTCH AND SPRING INTO COVER

(a) Place the spring between the cover and clutch with
the large spring end toward the cover.
(b) Compress the spring and install the clutch with the
pawl tab fit to the handle cam.
FA0065
6. INSTALL SPACER AND FREE WHEELING HUB RING

TO INNER HUB
(a) Install the spacer and free wheeling hub ring to the
inner hub.
FAOO58
7. INSTALL INNER HUB AND FREE WHEELING HUB

RING IN FREE WHEELING HUB BODY
(a) Insert the inner hub and free wheeling hub ring in the
body.
8. TEMPORARILY INSTALL COVER TO BODY AND

CHECK FREE WHEELING HUB
(a) Set the control handle and clutch to the FREE position.
FAOO60 FA0066
(b) Insert the cover in the body and verify that the inner
hub turns smoothly.
(c) Remove the cover from the body.
INSTALLATION OF FREE WHEELING HUB

(See page FA-36)
1. INSTALL FREE WHEELING HUB BODY

(a) Place a new gasket in position on the front axle hub.
(b) Install the free wheeling hub body with the six cone
washers and nuts.
FA1413
2. INSTALL BOLT WITH WASHER

FA1414
3. APPLY MP GREASE TO INNER HUB SPLINES
FAOO70
4. INSTALL FREE WHEELING HUB COVER WITH NEW

GASKET
(a) Set the control handle and clutch to the FREE position.
(b) Place a new gasket in position on the cover.
FAOO60 FAOO66
(c) Install the cover to the body with the follower pawl
tabs aligned with the non-toothed portions of the body.
(d) Tighten the cover mounting bolts.
FA0071
FA-42 FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD)
AUTOMATIC LOCKING HUB (4WD)

TROUBLESHOOTING

- ,-~- - -------~--
Will not lock Brake shoe worn or damaged Replace brake assembly FA-43
Will not unlock Brake spring weak Replace brake assembly FA-43
Rubbing between the inner hub and clutch Replace hub assembly FA-43
Engage/disengagement between the clutch Replace hub assembly FA-43
and hub body not smooth
f - - - - - - - - - - - - - - ----
Abnormal noise Body and clutch loose or damaged Replace hub assembly FA-43
Loose set bolt on axle shaft and inner hub Tighten or replace hub as- FA-43
sembly
Loose brake assembly set screw Replace brake assembly FA-43
- - ---~~ - - - - - - - - - ~ - ~ - - - - -
Brake drag (ALH) Outer cam worn or damaged Replace hub assembly FA-43
Front brake dragging Replace hub assembly FA-43
SUSPENSI O N - Autom atic Lockl·ng Hub (4WD,)~~_ _ FA-43
FRONT AXLE AND COMPONENTS
Adjusting Nut k Drum
Bra e Thrust Plate
Brake Shoe Snap Ring
Preset Spring
R6~gJ~g Clutch
+ Gasket
Thrust Washer . o
Snap RmgB~ing~nih~aSh~ Ring
+Gasket
Cover
f Ib , N·m)
k -cm (t- Specified torque
g rt
Non- reu sable pa
REMOVAL OF AUTOMATIC LOCKING HUB

(See page FA-43)
CAUTION: The brake shoe and brake drum grease is a
special type and should not be substituted when it is
necessary to change the grease, replace the brake drum
and/or hub body and brake assembly.
1. REMOVE HUB COVER

Using a torx socket, remove the screws and hub cover.
2. REMOVE AXLE BOLT WITH WASHER
3. REMOVE HUB BODY

(b) Using a brass bar and hammer, tap on the bolt heads
CAUTION: Do not tap the hub body when removing
the cone washer. If the stud bolt is damaged or de-
formed, replace with a new one.
(c) Pull off the hub body.
4. REMOVE BRAKE SUBASSEMBLY

(a) Using a screwdriver, pry out the snap ring.
CAUTION: Never strike brake shoe with the screw-
driver, always apply the screwdriver to the brake drum to
remove the snap ring.
FA1578
(b) Using a screwdriver, pry off the brake subassembly.

CAUTION: Do not drop the brake shoe subassembly.
FA 1655
FRONT AXLE AND SUSPENSION - Automatic Locking Hub (4WD) FA-45
5. REMOVE BRAKE DRUM

Using a torx socket, remove the screws and the drum.
FA 1579
6. IF NECESSARY, REMOVE ADJUSTING NUT

Using SST, remove the adjusting nut.
SST 09607 -60020
SST
FA 1039
DISASSEMBLY OF AUTOMATIC LOCKING HUB

(See page FA-43)
1. REMOVE INNER HUB SUBASSEMBLY FROM HUB

BODY
(b) Remove the inner hub subassembly from the hub.
FA0176
2. REMOVE OUTER CAM
FA0572
3. REMOVE CLUTCH WITH JOINT SPRING, PRESET

SPRING AND SPRING RETAINER
(a) Using snap ring pliers, extend the joint spring and
release it from the cam follower claw.
NOTE: Do not stretch the spring more than necessary.
(b) Remove the clutch with the joint spring, preset spring
and spring retainer.
FA0573
4. REMOVE INNER CAM, CAM FOLLOWER AND

RETURN SPRING
-~ / (a) Using SST, attach SST to the cam follower claw and
compress the return spring.
SST 09950-20017
(c) Remove the inner cam, cam follower and return
SST
,/ spring.
FA0574
INSPECTION OF AUTOMATIC LOCKING HUB

1. MEASURE BRAKE SHOE THICKNESS
(a) Remove the thrust plate from the brake subassembly.
NOTE:
• Do not wipe off the grease on the brake drum or brake
shoe.
• Do not remove the spring inside the brake shoe.
FA0575
(b) Measure the shoe thickness.
If the shoe thickness is less than minimum, replace the
brake drum assembly.
2. INSPECT HUB BODY AND CLUTCH

(a) Check to see that the hub body and clutch engage and
disengage smoothly.
(b) If engage/disengagement are not smooth, replace the
hub assembly.
3. INSPECT OTHER PARTS

(a) Check for abnormal wear or scratches on each part.
(b) If there is abnormal wear or scratches, replace the hub
FA0587
assembly.
ASSEMBLY OF AUTOMATIC LOCKING HUB

(See page FA-43)
1. ADJUST HEIGHT OF SST

(a) Position SST, place the clutch hub above it and insert
the cam follower.
SST 09950-20017
(b) Adjust the height of the SST so the cam follower
meshes with the inner hub spline and also so the cam
FA0576
follower claw aligns with the claw of SST.
(c) Remove the cam follower.
2. ASSEMBLE RETURN SPRING, CAM FOLLOWER AND

INNER CAM TO INNER HUB
(a) Install the return spring.
NOTE: Set the follower claw to the spring end of the
return spring.
(b) Compress the return spring and attach the cam
follower claw to SST.
FA0577
SST 09950-20017
(c) Using snap ring pliers, secure the snap ring.
FA0574
3. INSTALL CLUTCH, JOINT SPRING, PRESET SPRING,

SPRING RETAINER TO INNER HUB
(a) Install the joint spring to the clutch.
(b) Insert the spring retainer and preset spring to the
clutch.
(c) Install the joint spring with the clutch to the inner
hub. Using snap ring pliers, expand the spring and
attach it to the cam follower.
FA0573
4. INSTALL INNER HUB ASSEMBLY TO HUB BODY

(a) Install the thrust washer to the inner hub.
(b) Install the hub body to the inner hub.
(c) Install the thrust washer.
(d) Using snap ring pliers, secure the snap ring.
FA0176
5. INSTALL OUTER CAM TO INNER CAM
FA0572
INSTALLATION OF AUTOMATIC LOCKING HUB

(See page FA-43)
1. IF NECESSARY, INSTALL ADJUSTING NUT

CAUTION: When converting to an automatic locking
type from a type without free wheeling hubs or a manual
locking type, a thrust washer must not be installed.
2. ADJUST PRELOAD
(a) Using SST, torque the adjusting nut.
SST 09607 -60020
(b) Turn the hub right and left two or three times.
(c) Using SST, loosen the adjusting nut until it can be
turned by hand.
SST 09607 -60020
FA1040
(d) Using SST, retighten the adjusting nut.

SST 09607 -60020
(e) Using a spring tension gauge, check the preload.
Preload (starting): 2.1 - 3.6 kg
(4.6 - 7.9 Ib, 21 - 35 N)
FA1041
3. INSTALL BRAKE ASSEMBLY

(a) Tighten the adjusting nut by the smallest amount
possible and align it in either position shown left.
(b) Align the brake hub with the spindle groove and insert
until it is up against the adjusting nut.
Then confirm that the holes of the brake hub and
adjusting nut are aligned.
FA0179 FA0178
(c) Using a spring tension gauge, check the preload.

(4.6 - 7.9 lb. 21 - 35 N·m)
If not within specification, adjust with the adjusting nut.
FA1041
(d) Install the brake drum.

(e) Using a torx socket, torque the three screws.
Torque: 70 kg-em (61 in.-Ib. 6.9 N·m)
/' FA1580
(f) Install the snap ring.
\ FA1581
NOTE: Do not align the snap ring gap and the notch of the
brake drum.
Snap Snap
Ring Ring
Gap Gap
FA0579
(g) Align the tabs of the thrust plate with the groove of the
thrust plate and assemble.
FA0580
FA-50 FRONT AXLE AND SUSPENSION - Automatic Locki~g Hub (4WD)
Correct (h) Install the brake subassembly to the brake drum.
Wrong
~ FA 1656 ~~g~~;
4. INSTALL AUTOMATIC LOCKING HUB

MP Grease
(a) Install a new gasket to the axle hub.
(b) Apply MP grease to the splines of the automatic
locking hub body.
(c) Align the spring ends of the brake assembly with the
knock pin.
D5180FA1321
Knock Pin Hole (d) Check that the outer cam stopper is securely in the
inner cam groove.
\
(e) Position the inner cam protrusion so it is centered
between the outer cam protrusions and aligned with
the knock pin hole of the hub body.
Outer Cam Stopper /

D9674 FA 1325
(f) Install the aoutomatic locking hub body to the axle hub
so that the inner cam protrusion is set between the
ends of the brake spring. Then install to the drive shaft
spine.
(g) Check that the hub body fits perfectly on the axle hub,
and install the six cone washers and nuts.
NOTE: If the hub body and axle hub do not fit perfectly,
reinstall them.
FA 1582
If the splines are not aligned, turn the propeller shaft to align
them.
(
Torque the bolt.
\
6. INSTALL COVER
\
\
\ Using a torx socket, install the cover.
\\ Torque: 100 kg-em (7 ft-Ib, 10 N'm)
\
\ FA 1583
OPERATION CHECK
CAUTION: When assembling the automatic locking
hub, the locking of the left and right hubs may not be
identical, so shift to "H4" in the first run after assembly.
Perform this check with two persons.
1. CONFIRMATION OF FORWARD MOTION
.
Check Lock Operation:
(a) Push on the 4WD control switch to "H4" and shift into
"1 sf', and slowly proceed for several meters.
(b) Stop the vehicle.
FA1152
(c) For transfer, push off the 4WD control switch to "H2"
and proceed slowly while an assistant checks under
the vehicle to see that the propeller shaft is rotating. If
• the propeller shaft rotates, the automatic locking hub

is locked.
FA1153
Check Free Operation:

(a) Transfer is done in "H2'", shifting to reverse position
and backing up several meters.
While shifting, have an assistant check under the
®® vehicle to see that the propeller shaft is not rotating.
FA1154
2. CONFIRMATION OF REVERSE MOTION

Reverse is checked in the same manner as forward motion.
In the event of any abnormalities, recheck the assembly
and/or installation.

KNUCKLE (4WD)
COMPONENTS

~
~
~
G
Cushion ----8
Retainer ?&iii Drive Shaft
Bushing
• Cotter Pin
1
Disc Brake Caliper
Shock
Absorber
Dust
Deflector I
1!30 (67. 91) :

Steering
I
Dust Cover I
Knuckle
Lower Suspension
" Arm
I
l.-
Tie Rod
Hub with Disc
Outer Bearing
I
I
l
.Oil Seal " I
I
I
Adjusting Nut " "" I
--J
~~ LockNut
')
,r, '" :
" Lock Washer :
a- ', •
f
Gasket \
Free Wheeling ~
Hub Body :
• Gasket "'", :
Ikg-cm (ft-Ib, N·m) I: Specified torque Free Wheeling
'-J
Hub Cover
Front Axle Hub

(See page FA-51)
DISASSEMBLY OF FRONT AXLE HUB

1. REMOVE DISC BRAKE CALIPER
Remove the disc brake caliper from the steering knuckle
and suspend it with wire.
NOTE: Do not disconnect the brake hose.
2. REMOVE FLANGE, FREE WHEELING HUB OR

AUTOMATIC LOCKING HUB
Flange
(a) Remove the hub grease cap from the flange.
(b) Remove the bolt with washer.
(c) Remove the mounting nuts.
FAl27~
(d) Using a brass bar and hammer, tap the bolt heads and
\ remove the cone washers.
I
-~ )
/
.- ... ~ 4,'
FA1151
(e) Install and tighten the two bolts to the flange and
remove the flange.
Free wheeling hub
(See page FA-37)
Automatic locking hub
(See page FA-44)
FAll72
3. REMOVE AXLE HUB WITH DISC

(a) (w/o Automatic locking hub)
Using a screwdriver, release the lock washer.
(b) (w/o Automatic locking hub)
Using SST, remove the lock nut and lock washer.
SST 09607 -60020
(c) Using SST, remove the adjusting nut.
SST 09607-60020
(d) Remove the axle hub with disc together with the
SST
L-- ---'
FA1039 bearings.
4. REMOVE OIL SEAL AND INNER BEARING

(b) Remove the inner bearing from the hub.
FA0782
INSPECTION AND REPAIR OF FRONT AXLE

HUB
1. INSPECT BEARINGS
Clean the bearings and outer races and inspect them for
wear or damage.
2. REPLACE BEARING OUTER RACES

(a) Using a brass bar and hammer, drive out the bearing
FA 1275
outer race.
(b) Using SST, carefully drive in a new bearing outer race.

SST Outside race
09608-35014(09608-06020,09608-06200)
Inside race
09608-28010 and
09608-35014 (09608-06020)
FA0942
ASSEMBLY OF FRONT AXLE HUB

(See page FA-51)
1. PACK BEARING WITH MP GREASE

(a) Place MP grease in the palm of your hand.
(b) Pack grease into the bearing, continuing until the
grease oozes out from the other side.
MP Grease
(c) Do the same around the bearing circumference.
FA0944
2. COAT INSIDE OF HUB WITH MP GREASE
MP Grease
FA1180
3. INSTALL INNER BEARING AND OIL SEAL

(a) Place the inner bearing into the hub.
(b) Using SST, drive in a new oil seal into the hub.
SST 09608-10010 and
09608-35014 (09608-06020)
(c) Coat the oil seal lip with MP grease.
4. INSTALL AXLE HUB TO STEERING KNUCKLE

(a) Place the axle hub to the steering knuckle.
(b) (w/o Automatic locking hub)
Install the outer bearing and thrust washer.
(wi Automatic locking hub)
Install the outer bearing.
FA1044
5. ADJUST PRELOAD
(a) Using SST, torque the adjusting nut.
SST 09607 -60020
(b) Turn the hub right and left two or three times to allow
the bearing to settle.
(c) Using SST, loosen the adjusting nut until it can be
turned by hand.
SST
L- FA_l0--.l40 SST 09607-60020
(e) Check that the bearing has no play.
(f) Using a spring tension gauge, check the preload.
Prelod (starting): 2.1 - 3.6 kg
(4.6 - 7.9 Ib, 21 - 35 N)
FA1041
6. (w/o Automatic locking hub)

INSTALL LOCK WASHER AND LOCK NUT
(a) Install a new lock washer and the lock nut.
(b) Using SST, torque the lock nut.
~\
. <!.
SST 09607 -60020
(c) Using a spring tension gauge, recheck the preload.
FA1040 (4.6 - 7.9 Ib, 21 - 35 N)
If not within specification, adjust with the adjusting nut.
(d) Secure the lock nut by bending one of the lock washer
teeth outward and the other lock washer teeth inward.
FA0771
7. INSTALL FLANGE, FREE WHEELING HUB OR

Flange
(a) Place a new gasket in position on the axle hub.
(b) Install the flange to the axle hub.
(c) Install and torque the six nuts with cone washers.
FAOO83
(d) Install the bolt with washer in the drive shaft.

(e) Install the hub grease cap to the flange.
Free wheeling hub
(See page FA-41 )
Automatic locking hub
(See page FA-48)
FA1274
8. INSTALL DISC BRAKE CALIPER

Install the brake caliper to the steering knuckle, and torque
the bolts.
Torque: 850 ± 100 kg-em
(61 ± 7 ft-Ib, 83 ± 10 N'm)
FA1045
Steering Knuckle
(See page FA-52)
REMOVE OF STEERING KNUCKLE

1. REMOVE FRONT AXLE HUB
(See page FA-53)
2. REMOVE DUST COVER

\
~ ------'- FA 1046
3. DISCONNECT TIE ROD FROM STEERING KNUCKLE

(b) Using SST, disconnect the tie rod from the steering
knuckle.
SST 09628-62011
FA0946
4. DISCONNECT STABILIZER BAR FROM LOWER

SUSPENSION ARM
Remove the two bolts and disconnect the stabilizer bar from
the lower suspension arm.
FA1047
5. CHECK STEERING KNUCKLE BUSHING THRUST

CLEARANCE
(a) Install a bolt in the drive shaft.
(b) Using a feeler gauge, measure the front drive shaft
thrust clearance between the steering knuckle outside
bushing and spacer, by pulling the bolt and applying
10 kg (22.0 Ib, 98 N) of pressure.
Front drive shaft thrust clearance:
/ Standard clearance 0.075 - 0.690 mm
---~
FA 1298 (0.0030 - 0.0272 in.)
Maximum clearance 1.0 mm (0.039 in.)
If the measurement more than maximum, replace the
steering knuckle outside and inside bushings.
6. REMOVE SNAP RING AND SPACER

Using snap ring pliers, remove the snap ring and spacer.

(a) Remove the cotter pin and nut from the upper ball
joint.
(b) Using SST, disconnect the steering knuckle from the
upper suspension arm.
SST 09628-62011
FA1048
(c) Remove the four bolts holding the lower ball joint to
the steering knuckle.
FA0949
(d) Push the lower suspension arm down and remove the
steering knuckle.
FA1049
INSPECTION AND REPLACEMENT OF

STEERING KNUCKLE
1. INSPECT STEERING KNUCKLE
Using a dye penetrant, check the steering knuckle for cracks.
If cracks are found, replace the steering knuckle.
FA0950
2. REMOVE DUST DEFLECTOR

Using a screwdriver, pry out the deflector from the steering
knuckle.
FA0951
3. REMOVE STEERING KNUCKLE BUSHING

(a) Using SST, pullout the steering knuckle outside
bushing.
SST 09308-00010
)-----55T
FA0952
(b) Using a brass bar and hammer, drive out the steering
knuckle inside bushing.
FA0953
4. INSTALL STEERING KNUCKLE BUSHING

(a) Using SST and a hammer, tap in a new steering
knuckle outside bushing.
SST 09608-35014 (09608-06020, 09608-06090)
NOTE: When installing the bushing to the spindle, make
sure the flat portion of the bushing is aligned with the
spindle groove as shown in the figure.
FA0954 FA0812
(b) Using SST and a hammer, tap in a new steering knuckle

inside bushing.
SST 09608-35014 (09608-06020, 09608-06090)
FA0955
(c) Apply molybdenum disulphide lithium base grease to

the steering knuckle bushings.
FA0956
5. INSTALL DUST DEFLECTOR TO STEERING KNUCKLE

Using SST and a hammer, tap in a new dust deflector to the
steering knuckle.
SST 09608-35014 (09608-06020,09608-06180)
FA0957
INSTALLATION OF STEERING KNUCKLE

(See page FA-52)

the drive shaft.
FA1050
(b) Push the lower suspension arm down and install the
steering knuckle.
(c) Connect the lower ball joint to the steering knuckle,

and install and torque the four bolts with washers.
FA0958
(d) Connect the upper suspension arm to the steering

knuckle, and install and torque the nut.
(e) Install a new cotter pin.
2. INSTALL SPACER AND SNAP RING

Install the spacer to the front drive shaft and using snap
ring pliers, install the snap ring.
If you replace the steering knuckle bushing, recheck the
front drive shaft thrust clearance.
(a) Install the bolt in the shaft.
(b) Using a feeler gauge, measure the front drive shaft

thrust clearance between the steering knuckle outside
bushing and spacer, by pulling the bolt and applying
10 kg (22.0 Ib, 98 N) of pressure.
Front drive shaft thrust clearance:
0.075 - 0.690 mm (0.0030 - 0.0272 in.)
spacer.
Spacer thickness
1.80 mm (0.0709 in.)
[ 2.25 mm (0.0886 in.)
- - - -
3. CONNECT STABILIZER TO LOWER SUSPENSION
ARM
Torque: 195 kg-cm (14 ft-Ib, 19 N·m)
FA1047
4. CONNECT TIE ROD TO STEERING KNUCKLE

(a) Connect the tie rod to the steering knuckle and torque
the nut.
(b) Install a new cotter pin.
FA0959
5. INSTALL DUST COVER
6. INSTALL FRONT AXLE HUB AND DISC BRAKE

CALIPER
(See page FA-54)

(See page FA-30)
FA 1046
FA-52 FRONT AXLE AND SUSPENSION - Front Drive Shaft (4WD)
FRONT DRIVE SHAFT (4WD)

COMPONENTS
~'-, ------li 700 (50.69) I
~
"'~l~(~r,
- Free Wheeling
Hub Body
'~~ <:--~
700(50'6~"""""'"
Drive Shaft fi'--------
~f
Spacer
Tripod Joint
Snap Ring
Free Wheeling
Boot Hub Cover
+Clamp
+Clamp
Boot
+ Non-reusable part FA1530
REMOVAL OF FRONT DRIVE SHAFT

1. DISCONNECT DRIVE SHAFT FROM SIDE GEAR
SHAFT
Remove the six bolts and nuts holding the drive shaft and
side gear shaft.
2. REMOVE FLANGE, FREE WHEELING HUB OR

See pages ( Flange FA-52 )
\ FA1087
Free wheeling hub FA-37
Automatic locking hub FA-44
3. REMOVE SNAP RING AND SPACER

Using snap ring pliers, remove the snap ring from the drive
shaft.
FRONT AXLE AND SUSPENSION - Front Drive Shaft (4WD) FA-53
4. REMOVE FRONT DRIVE SHAFT

(a) Jack up the lower suspension arm.
CAUTION: If the vehicle is not steady, support the
chassis with stands.
FA 1297
(b) Remove the drive shaft.

NOTE: To prevent damage to the boot, place a shop rag
between the lower suspension arm and front drive shaft.
DISASSEMBLY OF FRONT DRIVE SHAFT

(See page FA-52)
1. CHECK DRIVE SHAFT

(a) Check to see that there is no play in the inboard and
outboard joints.
(b) Check to see that the inboard joint slides smoothly in
the thrust direction.
(c) Check to see that there is no play in the radial direction
of the universal joints.
(d) Check for damage to the boots.
2. REMOVE INBOARD JOINT BOOT CLAMPS
FA0899
3. DISASSEMBLE INBOARD JOINT TULIP

(a) Place matchmarks on the inboard joint tulip and tripod.
CAUTION: Do not punch the marks.
(b) Remove the inboard joint tulip from the drive shaft.
FA0844
4. DISASSEMBLE TRIPOD JOINT

Matchmarks
(b) Using a punch and hammer, place match marks on the
shaft and tripod.
RAl134
(c) Using a brass bar and hammer, remove the tripod joint
from the drive shaft.
FA0863
5. REMOVE INBOARD JOINT BOOT
FA0924
6. REMOVE OUTBOARD JOINT BOOT CLAMPS AND

BOOT
CAUTION: Do not disassemble the outboard joint.
FA0840
7. REMOVE DUST DEFLECTOR

Using a screwdriver and hammer, remove the dust
deflector.
FA0841
ASSEMBLY OF FRONT DRIVE SHAFT

(See page FA-52)
1. INSTALL DUST DEFLECTOR

Using a screwdriver and hammer, install a dust deflector.
FA0843
2. TEMPORARILY INSTALL BOOT AND NEW BOOT

CLAMPS TO OUTBOARD JOINT
NOTE: Before installing the boot, wrap vinyl tape around
//(h.,~--VinylTape
the spline of the shaft to prevent damaging the boot.
FA1704
3. TEMPORARILY INSTALL BOOT AND NEW BOOT

CLAMPS FOR INBOARD JOINT TO DRIVE SHAFT
FA0924
4. ASSEMBLE TRIPOD JOINT

(a) Place the beveled side of the tripod axial spline toward
Beveled Side the outboard joint.
Outboard
Joint
FA1401
(b) Align the matchmarks placed before disassembly.
FA1402
(c) Using a brass bar and hammer, tap in the tripod joint
to the drive shaft.
FA0864
(d) Using snap ring pliers, install a new snap ring.
FA0865
5. ASSEMBLE BOOT TO OUTBOARD JOINT

Before assembling the boot, pack in grease.
NOTE: Use the grease supplied in the boot kit.
Grease capacity: 195 - 205 9 (0.42 - 0.45 Ib)
FA0842
6. ASSEMBLE INBOARD JOINT TO INBOARD JOINT

TULIP
(a) Pack in grease to the inboard tulip and boot.
NOTE: Use the grease supplied in the boot kit.
Grease capacity: 215 - 225 9 (0.47 - 0.50 Ib)
FA0766
(b) Align the matchmarks placed before disassembly.

(c) Install the inboard tulip to the drive shaft.
(d) Temporarily install the boot to the inboard tulip.
FA0844
7. ASSEMBLE NEW BOOT CLAMPS TO BOTH BOOTS

(a) Be sure the boot is on the shaft groove.
(b) Bend the band and lock it as shown in the figure.
FA1400
(c) Insure that the boot is not stretched or contracted

when the drive shaft is at standard length.
Standard length: 378.0 ± 1.5 mm
(14.482 ± 0.059 in.)
378.0 ± 1.5 mm
FA 1506
INSTALLATION OF FRONT DRIVE SHAFT

(See page FA-62)
1. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE
Apply molybdenum disulphide lithium base grease to the
outboard joint shaft.
FA0881
2. INSTALL FRONT DRIVE SHAFT

Insert the front drive shaft to the steering knuckle, and
temporarily connect the front drive shaft to the side gear
shaft with the six bolts and nuts.
3. INSTALL SPACER AND SNAP RING

Install the spacer to the front drive shaft, and using snap
ring pliers, install the snap ring.
4. INSTALL FLANGE, FREE WHEELING HUB

See pages (Flange FA-56)
Free wheeling hub FA-41
Automatic locking hub FA-48
FA1036
5. TORQUE FRONT DRIVE SHAFT MOUNTING BOLTS

AND NUTS
FA1087
FRONT AXLE AND SUSPENSION - Front Differential (4WD) FA-69
FRONT DIFFERENTIAL (4WD)

ON-VEHICLE REPLACEMENT OF REAR OIL
SEAL
Front Differential
• See page FA-71
Companion Flange
Dust Cover
Oil Slinger
Plate Washer
Rear Bearing
Ikg-cm (ft-Ib, N·m) r : Specified torque

1. DISCONNECT FRONT PROPELLER SHAFT

(a) Place matchmarks on the flanges.
(b) Remove the four bolts and nuts and disconnect the
front propeller shaft.
Matchmarks
PR0124

(a) Using a chisel and hammer, loosen the staked part of
nut.
(b) Using SST, to hold the flange, remove the nut and
plate washer.
SST 09330-00021
8405684057
FA·70 FRONT AXLE AND SUSPENSION - Front Differential (4WD)
Hold (c) Using SST, remove the companion flange.

SST 09557-22022
3. REMOVE OIL SEAL AND OIL SLINGER

SST 09308-10010
(b) Remove the oil slinger.
4. REMOVE REAR BEARING AND BEARING SPACER

(a) Using SST, remove the rear bearing from the drive
pinion.
SST 09556-22010
(b) Remove the bearing spacer.
5. INSTALL NEW BEARING SPACER AND REAR

BEARING
(a) Install a new bearing spacer on the drive pinion with
the large end toward the differential carrier.
(b) Install the rear bearing on the drive pinion.
FA1080
6. INSTALL OIL SLINGER AND NEW OIL SEAL

(a) Install the oil slinger.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09554-22010
Oil seal drive in depth: 2.0 mm (0.079 in.)

(a) Using SST, install the companion flange on the drive
pinion.
SST 09557-22022
(b) Place the plate washer on the companion flange.
FA1082
(c) Apply light coat of gear oil on the threads of a new

companion flange nut.
(d) Using SST to hold the flange, torque the nut.
SST 09330-00021
FA1083
8. ADJUST DRIVE PINION PRELOAD

Using a torque meter, measure the preload of the backlash
between the drive pinion and ring gear.
Preload (starting):
5 - 8 kg-em (4.3 - 6.9 in.-Ib, 0.5 - 0.8 N'm)
If the preload is greater than specification, replace the
bearing spacer.
If the preload is less than specification, retighten the nut
130 kg-cm (9 ft-Ib, 13 N'm) a little at a time until the
FA1084
specified preload is reached.
If the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload
procedure. Do not back off the pinion nut to reduce the
preload.
Maximum torque: 2,400 kg-em (174 ft-Ib, 235 N'm)
9. STAKE DRIVE PINION NUT
/
FA1157
FA-72 FRONT AXLE AND SUSPENSION - Front Differential (4WD)

COMPANION FLANGE
(a) Align the match marks and connect the propeller shaft
to the companion flange with the four bolts, spring
washers and nuts.
Matchmarks PR0124
11. CHECK DIFFERENTIAL OIL LEVEL

Fill with hypoid gear oil if necessary.
Oil type: Hypoid gear oil API G L-5
Recommended oil viscosity:
Above - 1SoC {0° F) SAE 90
Below - 1SoC (OaF) SAE SOW or SOW-90
REMOVAL OF FRONT DIFFERENTIAL
RH Drive Shaft ~50.68)

~"
I Front Differential Front Propeller Shaft
I
430 (31. 42)
RH Support (~
I
r--------, I
730 (53. 72) I
690 (50. 68)
970 (79.95)
690 (50. 68) Engine Under Cover
Ikg-cm (ft-Ib, N·m) I: Specified torque FA1335
1. DRAIN DIFFERENTIAL OIL
2. DISCONNECT FRONT PROPELLER SHAFT

front propeller shaft.
Matchmarks PR0124
3. DISCONNECT DRIVE SHAFTS FROM SIDE GEAR

SHAFTS
(a) Remove the six bolts and nuts holding the drive shaft
and side gear shaft.
FA1087
(b) Disconnect the drive shaft and suspend it to the upper

suspension arm with string.
FA1088

Remove the five bolts and engine under cover.
FA1089
5. REMOVE FRONT SUSPENSION REAR

CROSSMEMBER
(a) Hold the front differential with a jack.
(b) Disconnect the surge tank stay bolts of the air
conditioner.
FA1090
(c) Remove the rear support bolt and cushion.
FA1091
(d) Remove the four bolts, plate washers, spring washers,

nuts and rear crossmember.
6. REMOVE SUPPORT BOLTS

Remove the bolts, cushions and retainers holding the RH
support and LH support to the crossmember.
FA1093
7. REMOVE FRONT DIFFERENTIAL ASSEMBLY

Lower the jack and remove the front differential assembly.
8. REMOVE SUPPORT BRACE

Remove the three bolts and support brace.
FA1094
9. REMOVE DIFFERENTIAL SUPPORTS

(a) Remove the four bolts and RH support.
(b) Remove the two bolts and LH support.
COMPONENTS
Plate Washer
RH Side
Gear Shaft
Differential
Tube
900 (65. 88)
+ See page FA-93
_ - - - -Companion Flange
+Oil Seal----------"
Bleeder P l u g - - - - - - -
Carrier Cover - - - - -.....
I
I
,------------------,1
~O(30.40) ~~11l)
+Gasket
800 (58. 78)
Bearing Cap
Ikg-cm (ft-Ib. N.m] : Specified torque

+ Non-reusable part
FA1705
DISASSEMBLY OF FRONT DIFFERENTIAL

(See page FA-76)
1. REMOVE DIFFERENTIAL CARRIER COVER

(a) Remove the eight bolts.
FA 1097
(b) Using a brass bar and hammer, carefully tap off the
carrier cover.
FA1098
2. CHECK SIDE GEAR BACKLASH

Using a dial indicator, measure the side gear backlash while
holding one pinion gear toward the differential case.
Side gear backlash: 0.05 - 0.20 mm
(0.0020 - 0.0079 in.)
If the backlash is not within specification, replace the thrust
washers.
FA0933
3. CHECK DEVIATION OF SIDE GEAR SHAFTS

Using a dial indicator, measure the longitudinal and
latitudinal deviation of the side gear shaft.
Maximum longitudinal deviation: 0.20 mm
(0.0079 in.)
Maximum latitudinal deviation: 0.20 mm
(0.0079 in.)
FA1099
4. REMOVE SIDE GEAR SHAFTS

(a) Using needle-nose pliers, remove the snap ring.
(b) Remove the side gear shaft.
FA1502
5. REMOVE DIFFERENTIAL TUBE

Remove the four bolts and differential tube.
FA1100
6. CHECK DEVIATION OF COMPANION FLANGE

latitudinal deviation of the companion flange.
(0.0039 in.)
(0.0039 in.)
RA0096
7. CHECK RING GEAR RUNOUT

Using a dial indicator, measure the ring gear runout.
If the runout is greater than maximum, replace the ring gear
and drive pinion as a set.
FAll01
8. CHECK RING GEAR BACKLASH

(a) Fix the dial indicator on the tooth surface at a 90 0
angle.
(b) Holding the drive pinion flange, measure the ring gear
backlash.
Ring gear backlash: 0.13 - 0.18 mm
(0.0051 - 0.0071 in.)
If the backlash is not within specification, adjust the ring
gear backlash.
FAll02
NOTE: Measure from three or more places on the cir-
cumference of the ring gear.
9. INSPECT TOOTH CONTACT BETWEEN RING GEAR

AND DRIVE PINION (See step 6 on page FA-92)
FA1103
10. CHECK DRIVE PINION PRELOAD

Preload(starting}:
5 - 8 kg-em (4.3 - 6.9 in.-Ib, 0.5 - 0.8 N'm)
11. CHECK TOTAL PRELOAD

With the drive pinion and ring gear meshed, using a torque
meter, measure the total preload.
FA1158
Total preload (starting):
Add drive pinion preload
3 - 5 kg-em (2.6 - 4.3 in.-Ib, 0.3 - 0.5 N'm)
12. REMOVE SIDE GEAR OIL SEALS

Using SST, remove the oil seal.
SST 09308-00010

(a) Using a chisel and hammer, unstake the nut.
FAl159
(b) Using SST to hold the flange, remove the nut and plate
washer.
SST 09330-00021

SST 09557 -22022

(a) Using SST, remove the oil seal from the differential
carrier.
SST 09308-10010
15. REMOVE REAR BEARING AND BEARING SPACER

(a) Using SST, remove the rear bearing from the drive
pinion.
SST 09556-22010
16. REMOVE DIFFERENTIAL CASE ASSEMBLY AND

RING GEAR
(a) Place match marks on the bearing cap and differential
carrier.
(b) Remove the four bolts and two bearing caps.
FAl106
(c) Using SST and a screwdriver, remove the teeth side

plate washer.
SST 09504-22011
FAl107
(d) Remove the differential case with the bearing outer

races from the differential carrier.
NOTE: Tag the bearing outer races to show the location

for reassembly.
QfLH]
QfB---H]
FA1109
17. REMOVE DRIVE PINION FROM DIFFERENTIAL

CARRIER

DIFFERENTIAL COMPONENTS
1. REPLACE DRIVE PINION FRONT BEARING
(a) Using SST and a press, press out the front bearing
from the drive pinion.
SST 09950-00020
NOTE: If the drive pinion or ring gear are damaged,
replace them as a set.
(b) Install the plate washer on the drive pinion with the
chamfered end facing the pinion gear.
(c) Using SST and a press, press in the front bearing onto
the drive pinion.
SST 09506-30012
--rt:::::::::J1==--- SST
FA1112
2. REPLACE DRIVE PINION FRONT AND REAR

BEARING OUTER RACES
(a) Using a brass bar and hammer, drive out the outer
race.
(b) Using SST and a press, press in a new outer race.
SST 09608-30012
Front outer race (09608-04020, 09608-04100)
Rear outer race (09608-00060, 09608-04020)
.---'L_-.lL-__ ~
FA1113 FAl114
3. REMOVE RING GEAR

(a) Place matchmarks on the ring gear and differential
case.
(b) Using a screwdriver, unstake the lock plates.
(c) Remove the eight bolts and four lock plates.
FA1116
(d) Using a plastic-faced hammer, tap on the ring gear to

separate it from the differential case.
FA1160
4. CHECK DIFFERENTIAL CASE RUNOUT

(a) Place the bearing outer races on their respective
bearings.Check that the left and right outer races are
not interchanged.
(b) Install the differential case in the differential carrier.
(c) When there is no play left in the side bearings, install
the plate washers.
(d) Align the matchmarks on the bearing cap and dif-
ferential carrier.
FAl149
(e) Install and uniformly tighten the four bearing cap bolts
in several passes.
(f) Using a dial indicator, measure the differential case
runout.
(g) Remove the differential case.
(See procedure step 16 on page FA-80)
5. REMOVE SIDE BEARINGS

/ Using SST, remove the side bearing from the differential
case.
SST 09950-20017
NOTE: Fix the claws of SST to the notches in the
differential case.
6. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY

(a) Using a pin punch and hammer, drive out the straight
pin.
FAll19
(b) Remove the following parts:
~(31 (1)
(2)
Pinion shaft
Pinion gears
~
~
) ~~
(3) Side gears
(4) Side gear thrust washers
(2)
10th)
~ x0
(1)
FA1706
7. ASSEMBLE DIFFERENTIAL CASE

(a) Install the side gear thrust washers to the side gears.
FA1121
(b) Install the side gears with the thrust washers, pinion
gears and pinion shaft.
~FA1707
(c) Check the side gear backlash.

• Temporarily install the side gear shaft.
• Measure the side gear backlash while holding one
pinion gear toward the case.
(0.0020 - 0.0079 in.)
washers.
FA1389
Thrust washer thickness mm(in.)
0.92 - 0.98 (0.0362 - 0.0386)

0.97 - 1.03 (0.0382 - 0.0406)
1.02 - 1.08 (0.0401 - 0.0426)
1.07 - 1.13 (0.0421 - 0.0445)
1.12 - 1.18 (0.0441 - 0.0465)
1.1 7 - 1.23 (0.0461 - 0.0484)
NOTE: Select the same sized thrust washers for both the
left and right sides.
FRONT AXLE AND SUSPENSION - Front Differential (4WD) FA-8S
(d) Using a pin punch and hammer, drive the straight pin
through the holes in the differential case and pinion
shaft.
FAl124
(e) Using a chisel and hammer, stake the outside of the

differential case pin hole.
FA1125
8. INSTALL RING GEAR

Ring Gear
(a) Heat the ring gear to about 100°C (212°F) in an oil
bath.
CAUTION: Do not heat the ring gear above 110°C
Oil Bath
(230°F).
(b) Clean the contact surface of the differential case.
(c) Clean the contact surface of the ring gear with
cleaning solvent.
FAl126
(d) Align the match marks on the ring gear and differential
case.
(e) Then quickly install the ring gear on the differential
case.
(f) Place the four lock plates on the differential case.
(g) Install and uniformly tighten the eight bolts in several
passes.
FAl127
(h) Using a chisel and hammer, stake the lock plates.

NOTE: Stake one claw flush with the flat surface of the
nut. For the claw contacting the protruding portion of the
nut, stake only the half on the tightening side.
dTI ~eA"28 F Al129

9. INSTALL SIDE BEARINGS

Using SST and a press, press the bearing into the
~-- SST differential case.
SST 09710-22020(09710-01030) and
09950-20017
_.--:::t:==::t====-- SST FAl130

bearings. Check that the left and right outer races are
not interchanged.
(c) When there is no play left in the side bearings, install
the plate washers.
(d) Align the matchmarks on the bearing cap and
differential carrier.
FAl13l
in several passes.
(f) Using a dial indicator, measure the ring gear runout.
(g) Remove the differential case.
(See procedure step 16 on page FA-BO)
FAll33
11. REPLACE RH SIDE GEAR SHAFT BEARING AND

DUST COVER
FAll32
(b) Using SST and a press, press out the bearing.

SST 09950-00020
FAl134
(c) Using a screwdriver, remove the dust cover.
" ---".
--~~~--( _J
~>,-
I"~
\ FAl135
(d) Using a press, press a new dust cover onto the RH side
gear shaft.
FA1136
(e) Using a press, press a new bearing onto the RH side

gear shaft.
FA1137
(f) Using snap ring pliers, install the snap ring.
FA1132
FA-SS FRONT AXLE AND SUSPENSION - Front Differential (4WD)
ASSEMBLY OF FRONT DIFFERENTIAL

(See page FA-76)
1. TEMPORARILY ADJUST DRIVE PINION PRELOAD

(a) Install the drive pinion, rear bearing and oil slinger.
NOTE: After adjusting the gear tooth contact, assemble
the spacer and oil seal.
FAl138
(b) As the spacer is not installed, using SST, install the

Hold
companion flange until a small clearance remains on
the drive pinion.
SST 09557-22022
(c) Place the plate washer on the companion flange.
(d) Apply a light coat of gear oil on the threads of the

companion flange nut and drive pinion.
(e) Using SST to hold the flange, adjust the drive pinion
preload by tightening the companion flange.
SST 09330-00021
CAUTION: As there is no spacer, tighten a little at a
time, being careful not to overtighten.
(f) Rotate the flange left and right to seat the bearings.
(g) Using a torque meter, measure the preload.
Preload(starting):
New bearing
10 - 16 kg-cm
(8.7 - 13.9 in.-Ib, 1.0 - 1.6 N'm)
Reused bearing
5 - 8 kg-cm
(4.3 - 6.9 in.-Ib, 0.5 - 0.8 N-m)
~ F_Al_15---,8 NOTE: In order to measure the total preload, record the
preload reading.
2. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL

CARRIER
not interchanged.
3. ADJUST RING GEAR BACKLASH

(a) Install only the plate washer on the ring gear back
side.
NOTE: Check that the ring gear has backlash.
(b) Snug down the washer and bearings by tapping on the

ring gear with a plastic-faced hammer.
(c) Fix the dial indicator on the tooth surface at a 90 0

angle.
(d) Hold the side bearing boss on the teeth side of the ring
gear and measure the backlash.
Backlash (reference): 0.13 mm (0.0051 in.)
FA1102
(e) Select a ring gear back side plate washer, using the
backlash as reference.
Plate washer thickness mm(in.)

2.21 - 2.23 (0.0870 - 0.0878) 2.72 - 2.74 (0.1071 - 0.1079)
2.24 - 2.26 (0.0881 - 0.0890) 2.75 - 2.77 (0.1083 - 0.1091)
2.27 - 2.29 (0.0894 - 0.0902) 2.78 - 2.80 (0.1095 - 0.1102)
2.30 - 2.32 (0.0906 - 0.0913) 2.81 - 2.83 (0.1106 - 0.1114)
2.33 - 2.35 (0.0917 - 0.0925) 2.84 - 2.86 (0.1118 - 0.1126)
2.36 - 2.38 (0.0929 - 0.0937) 2.87 - 2.89 (0.1130 - 0.1138)
2.39 - 2.41 (0.0941 - 0.0949) 2.90 - 2.92 (0.1142 - 0.1150)
FA1140
2.42 - 2.44 (0.0953 - 0.0961) 2.93 - 2.95 (0.1154 - 0.1161)
2.45 - 2.47 (0.0965 - 0.0972) 2.96 - 2.98 (0.1165 - 0.1173)
2.48 - 2.50 (0.0976 - 0.0984) 2.99 - 3.01 (0.1177 - 0.1185)
2.51 - 2.53 (0.0988 - 0.0996) 3.02 - 3.04 (0.1189 - 0.1197)
2.54 - 2.56 (0.1000 - 0.1008) 3.05 - 3.07 (0.1201 - 0.1209)
2.57 - 2.59 (0.1012 - 0.1020) 3.08 - 3.10 (0.1213 - 0.1220)
2.60 - 2.62 (0.1024 - 0.1031) 3.11 - 3.13 (0.1224 - 0.1232)
2.63 - 2.65 (0.1035 - 0.1043) 3.14 - 3.16 (0.1236 - 0.1244)
2.66 - 2.68 (0.1047 - 0.1055) 3.17 - 3.19 (0.1248 - 0.1256)
2.69 - 2.71 (0.1059 - 0.1067) 3.20 - 3.22 (0.1260 - 0.1268)
(f) Select a ring gear teeth side plate washer with a

thickness which eliminates any clearance between
the outer race and differential carrier.
(g) Remove the plate washers and differential case.
(h) Install the ring gear back side plate washer in position
in the differential carrier.
FA1143
(i) Place the other plate washer onto the differential case
together with the outer races, and install the dif-
ferential case with the outer races into the carrier.
(j) Using a plastic-faced hammer, snug down the

washers and bearings by tapping the ring gear.
(k) Using a dial indicator, measure the ring gear backlash.

(0.0051 - 0.0071 in.)
If the backlash is not within specification, adjust by either
increasing or decreasing the washer thickness on both
sides by an equal amount.
NOTE: There should be no clearance between the plate
washer and case.
FAll02
4. ADJUST SIDE BEARING PRELOAD

(a) Remove the ring gear teeth side plate washer and
measure the thickness with a micrometer.
(b) Install a new plate washer of 0.06 - 0.09 mm (0.0024-

0.0035 in.) thicker than the removed plate washers.
NOTE: Select a washer which can be pressed in 2/3 of
the way with your finger.
(c) Using SST and a hammer, tap in the plate washer.
SST 09504-22011
FAl144
(d) Align the matchmarks on the bearing cap and

differential carrier.
in several passes.
FAl131
(f) Recheck the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
If the backlash is not within specification, adjust by either
increasing or decreasing the washer thickness on both
sides by an equal amount.
NOTE: The backlash will change about 0.02 mm (0.0008
in.) with 0.03 mm (0.0012 in.) alteration of the side washer.
FAll02

Using a torque meter, with the drive pinion and ring gear
meshed, measure the total preload.
3 - 5 kg-em (2.6 - 4.3 in.-Ib, 0.3 - 0.5 N'm)
If the total preload is not within specification, replace the
ring gear teeth side plate washer.
FAl158

AND DRIVE PINION
(a) Coat 3 or 4 teeth at three different positions on the
ring gear with red lead.
(b) Hold the companion flange firmly and rotate the ring
gear in both directions.
(c) Inspect the tooth pattern.
FA1103
Heel contact
Face Contact
Select an adjusting shim that will bring the drive

pinion closer to the ring gear.
Proper contact
Toe Contact Flank contact
Select an adjusting shim that will shift the drive

pinion away from the ring gear.
RAOO29
If the tooth pattern is not proper, replace the drive pinion

plate washer.

2.26 - 2.28 (0.0890 - 0.0898) 2.50 - 2.52 (0.0984 - 0.0992)
2.29 - 2.31 (0.0902 - 0.0909) 2.53 - 2.55 (0.0996 - 0.1004)
2.32 - 2.34 (0.0913 - 0.0921 ) 2.56 - 2.58 (0.1008 - 0.1016)
2.35 - 2.37 (0.0925 - 0.0933) 2.59 - 2.61 (0.1020 - 0.1028)
2.38 - 2.40 (0.0937 - 0.0945) 2.62 - 2.64 (0.1031 - 0.1039)
Plate Washer
2.41 - 2.43 (0.0949 - 0.0957) 2.65 - 2.67 (0.1043 - 0.1051)
2.44 - 2.46 (0.0961 - 0.0969) 2.68 - 2.72 (0.1055 - 0.1063)
FAl145
2.47 - 2.49 (0.0972 - 0.0980)
7. REMOVE COMPANION FLANGE AND OIL SLINGER

(See step 13 on page FA-79)
8. REMOVE REAR BEARING

9. INSTALL NEW BEARING SPACER AND REAR

BEARING
(b) Install the rear bearing on the drive pinion.

(a) Install the oil slinger.
SST 09554-22010
[2.0 mm
Drive in Depth FA1081

pinion.
SST 09557-22022

(d) Using SST to hold the flange, tighten the nut.
SST 09330-00021
SST RA0031

Preload( starting):
New bearing
10 - 16 kg-em
(8.7 - 13.9 in.-Ib, 1.0 - 1.6 N'm)
Reused bearing
5 - 8 kg-em
FA1158
(4.3 -- 6.9 in.-Ib, 0.5 - 0.8 N'm)
If the preload is greater than specification, replace bearing

spacer.
preload.
13. RECHECK TOTAL PRELOAD

Total preload(starting}:
3 - 5 kg-em (2.6 - 4.3 in.-Ib, 0.3 - 0.5 N'm)
14. RECHECK RING GEAR BACKLASH

Ring gear backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in.)
15. RECHECK TOOTH CONTACT BETWEEN RING GEAR

AND DRIVE PINION (See step 6 on page FA-92)

(0.0039 in.)
Maximum latitudinctl deviation: 0.10 mm
(0.0039 in.)
RA0096

Using a punch and hammer, stake the drive pinion nut.
""'IlII
RAOO32
18. INSTALL NEW SIDE GEAR SHAFT OIL SEALS

(a) Using SST and a hammer, tap in a new oil seal until its
surface is flush with the differential carrier end.
SST 09550-22011 (09550-00020, 09550-00031 )
(b) Apply MP grease to the oil seal lip.
FAl147
19. INSTALL DIFFERENTIAL TUBE

Install the differential tube to the differential carrier with
the fou r bolts.
FAll00
20. INSTALL SIDE GEAR SHAFTS

Install the side gear shaft to the differential carrier and
secure the shaft with a new snap ring.
FA1099
21. CHECK DEVIATION OF SIDE GEAR SHAFTS

latitudinal deviation of the side gear shaft.
(0.0079 in.)
(0.0079 in.)
FA0933
22. INSTALL DIFFERENTIAL CARRIER COVER

(a) Remove any old packing material and be careful not to
drop oil on the contact surfaces of the differential
carrier and carrier cover.
(b) Apply seal packing to the carrier cover as shown in the
figure.
o 0 0 1281 or equivalent
Seal Width Approx.
NOTE: Install the carrier cover as soon as the seal packing
1- 2 mm (0.04 - 0.08 in.) FAl148
is applied.
(c) Install and torque the eight bolts.
FA 1097
INSTALLATION OF FRONT DIFFERENTIAL

(See page FA-72)
1. INSTALL DIFFERENTIAL SUPPORTS

(a) Install the RH support with the four bolts.
(b) Install the LH support with the two bolts.
FA1095 FA1096
2. INSTALL SUPPORT BRACE

(a) Install the support brace with the three bolts.
(b) Torque the bolts.
Torque:
Support side 195 kg-em (14 ft-Ib, 19 N'm)
Differential side 130 kg-em (9 ft-Ib, 13 N'm)
3. INSTALL FRONT DIFFERENTIAL ASSEMBLY

Jack up the front differential assembly and install the
cushions, retainers and bolts holding the RH support and
LH support to the crossmember.
FA1093
4. INSTALL FRONT SUSPENSION REAR

CROSSMEMBER
(a) Temporarily install the crossmember with the four
bolts, plate washers, spring washers and nuts.
(b) Install the surge tank stay bolts of the air conditioner.
(c) Install the cushion and rear support bolt.

(d) Torque the RH and LH support bolts.
(e) Torque the rear crossmember mounting bolt and nuts.
FA1091

Install the engine under cover with the five bolts.
FA1089
6. CONNECT DRIVE SHAFTS TO SIDE GEAR SHAFTS

(a) Connect the drive shaft to the side gear shaft with the
six bolts and nuts.
FA1087

COMPANION FLANGE
(a) Align the matchmarks and connect the propeller shaft
washers and nuts.
PR0124
8. FILL DIFFERENTIAL WITH GEAR OIL

Fill with hypoid gear oil.
Oil type: Hypoid gear oil API GL-5
Above - 18°C (OOF) SAE 90
Below - 18°C (OOF) SAE 80W or 80W-90
Capacity: 1 .2 liters (1.3 US qts, 1.1 Imp. qts)
FA1085
FRONT SUSPENSION(4WD)
COMPONENTS
Torsion Bar Spring
Boot
Torque Arm
...,
I
~,~'-~~
1.550 (112.152) I Anchor Arm
I;J ...... -
~
~
~
~
cushionl---~
sr
• Cotter Pin
Retainer----~ 1.150 (83. 113)
Shock - - - - - - - - \ @ - - Retainer
Absorber
C3
~Bracket
i@
Front Axle Hub Assembly c:3 Cushion
~
~ ~ f):
~LinkROd
970 (70. 95) Stabilizer Bar
I
I
~~Bracket
I
I Lower Suspension Arm
I
• Front Bushing
I
I
I
I
I
~
'f>
---t ~
Cushion
-lIIII:@r---1'95 (14, 19) I
~~
Cushion
~
~ Lower Ball Joint
Cam Plate
2.100 (152. 206)

\! I 590 (43. 58) I
\
'-'--....\
'-.I
1,150 183, 113Di'"
.Cotter Pin
Ikg-cm (ft-Ib, N.m)l: Specified torque

Ball Joints
(See page FA-98)
INSPECTION OF BALL JOINTS

1. INSPECT LOWER BALL JOINT FOR EXCESSIVE
LOOSENESS
(a) Jack up the front of the vehicle and support it with
stands.
FA1057 (b) Make sure the front wheels are in a straight forward
position, and depress the brake pedal.
(c) Move the lower suspension arm up and down and
check that the lower ball joint has no play.
Maximum vertical play: 0 mm (0 in.)
2. INSPECT UPPER BALL JOINT FOR EXCESSIVE

LOOSENESS
Move the vehicle up and down and check that the upper ball
joint has no excessive play.
Maximum vertical play: 2.3 mm (0.091 in.)
FA1058
3. INSPECT BALL JOINT FOR ROTATION CONDITION
~
~'
\\\ ,/,/ (a) Remove the ball joints.
.. ..
(b) As shown in the figure, flip the ball joint stud back and
forth 5 times before installing the nut.
(c) Using a torque gauge, turn the nut continuously one
L
turn every 2-4 seconds and take the torque reading on
the 5th turn.
Torque (turning):
Lower ball joint
FA 1278
15 - 30 kg-cm (13 - 26 in.-Ib, 1.5 - 2.9 N·m)
REMOVAL OF BALL JOINTS

(See page FA-57)
2. REMOVE LOWER BALL JOINT FROM LOWER

SUSPENSION ARM
(b) Using SST, remove the lower ball joint from the lower
suspension arm.
FA0960
SST 09628-62011
3. REMOVE UPPER SUSPENSION ARM WITH UPPER

BALL JOINT
(a) Remove the torsion bar spring.
(See page FA-1 01 )
(b) Remove the upper suspension arm with upper ball
joint. (See page FA-1 06)
FA1071
INSTALLATION OF BALL JOINTS

1. INSTALL UPPER SUSPENSION ARM WITH UPPER
BALL JOINT
(a) Install the upper suspension arm with upper ball joint.
(See page FA-1 06)
(b) Install the torsion bar spring.
(See page FA-1 01 )
2. INSTALL LOWER BALL JOINT TO LOWER

SUSPENSION ARM
(a) Install the lower ball joint to the lower suspension arm
and torque the nut.
FA0819

(See page FA-60)
Torsion Bar Spring

(See page FA-98)
REMOVAL OF TORSION BAR SPRING

1. PLACE MATCHMARKS ON TORSION BAR SPRING,
ANCHOR ARM AND TORQUE ARM
Remove the boots and place matchmarks on the torsion bar
spring, anchor arm and torque arm.
FA0961 FA0962
2. REMOVE LOCK NUT
FA1059
3. MEASURE PROTRUDING BOLT END "A", AS SHOWN

NOTE: Use this measurement for reference when ad-
justing the chassis ground clearance.
4. REMOVE ADJUSTING NUT
5. REMOVE ANCHOR ARM AND TORSION BAR SPRING
FA0963
INSTALLATION OF TORSION BAR SPRING

(See page FA-98)
NOTE: There are left and right indication marks on the
rear end of the torsion bar spring. Be careful not to
interchange the torsion bar springs.
FA1277
1. INSTALL TORSION BAR SPRING AND ANCHOR ARM

If Reusing Torsion Bar Spring:
(a) Apply a light coat molybdenum disulphide lithium base
grease to the spline of the torsion bar spring.
(b) Align the matchmarks and install the torsion bar
spring to the torque arm.
(c) Align the match marks and install the anchor arm to
the torsion bar spring.
FA0961 FA0962
(d) Tighten the adjusting nut so that the bolt protrusion is

equal to that before removal.
FA1073
If Using a New Torsion Bar Spring:

(a) Check that the upper and lower arms rebound.
(b) Apply light coat of molybdenum disulphide lithium
(c) Install the two boots onto the torsion bar spring.
(d) Install one end of the torsion bar spring to the torque
arm.
(e) Install the torsion bar spring on the opposite end to the
anchor arm as shown in the figure.
(f) Finger tighten the adjusting nut.
A =About 40 mm (1.57 in.)
------_..-/ (g) Tighten the adjusting nut.(Reference)

YR31 LG B = About 63 mm (2.48 in.)
YR32LV B =About 61 mm (2.40 in.)
(h) Install the wheel and remove the stands. Bounce the
vehicle up and down to stabilize the suspension.
(i) Adjust the chassis ground clearance turning the
-8 adjusting nut.
;</ Chassis ground clearance:
FA0963 FA0967
mm(in.)
----------
YR31LG
YR32LV
Front
256 (10.09)
253 (9.94)
Rear
284 (11.17)
305 (11.99)
2. TORQUE LOCK NUT

3. INSTALL BOOTS
FA1059
Lower Suspension Arm

(See page FA-98)
REMOVAL OF LOWER SUSPENSION ARM

1. DISCONNECT SHOCK ABSORBER FROM LOWER
SUSPENSION ARM
FA 1525
2. DISCONNECT STABILIZER BAR FROM LOWER

SUSPENSION ARM
FA 1526
3. DISCONNECT LOWER SUSPENSION ARM FROM

LOWER BALL JOINT
(b) Using SST, disconnect the lower suspension arm from
the lower ball joint.
SST 09628-62011
FA1294
4. REMOVE LOWER SUSPENSION ARM

(a) Place match marks on the front and rear adjusting
cams.
FA0965 FA0964
(b) Remove the nuts and adjusting cam, and remove the
REPLACEMENT OF LOWER SUSPENSION

ARM BUSHING
1. REMOVE FRONT AND REAR BUSHINGS
(a) Using a screwdriver, remove the bushing retainer.
(b) Cut off the flange tip of the bushing as shown in the
figure.
FA1326 FA1328
(c) Using SST and a press, press out the front and rear
bushing from the lower suspension arm.
SST 09710-28020
(09710-08020,09710-08030,09710-08040)
2. INSTALL FRONT AND REAR BUSHINGS

Using SST and a press, press a new front and bushings to
the lower suspension arm.
SST 09710-28020 (09710-09030,09710-08040)
NOTE: Do not apply grease or oil to bushing.
FA 1329
INSTALLATION OF LOWER SUSPENSION ARM

(See page FA-98)
1. INSTALL LOWER SUSPENSION ARM

(a) Install the lower suspension arm to the frame with the
adjusting cams.
(b) Temporarily install the two nuts to the front and rear
adjusting cams.
2. CONNECT LOWER SUSPENSION ARM TO LOWER

BALL JOINT
(a) Connect the lower suspension arm to the lower ball
joint and torque the nut.
FA 1520
3. CONNECT STABILIZER BAR TO LOWER

SUSPENSION ARM
Jack up the stabilizer bar and install the cushions, retainers
and collar, and install and torque the two bolts.
FA1526
4. CONNECT SHOCK ABSORBER TO LOWER

SUSPENSION ARM
Install the shock absorber to the lower suspension arm
bracket with the bolt, washer and nut.
FA1525
5. TORQUE ADJUSTING CAM NUTS

(a) Install the wheel, and remove the stands and bounce
the vehicle up and down to stabilize the suspension.
RA0793
(b) Align the matchmarks on the front and rear adjusting
~\--JII~
cams.
)! ~O
0
- = rj
FA0965 FA0964
(c) Torque the nuts.


(See page FA-30)
FA1586

(See page FA-98)
REMOVAL OF UPPER SUSPENSION ARM
:...J9''''',..------Console Box
Front RH Seat-~
Sheet Floor Panel
15! Fan Shroud
Ikg-cm (ft-Ib, N·m) I: Specified torque

FA1739
1. REMOVE TORSION BAR SPRING

(See page FA-1 01)
2. REMOVE RH FRONT SEAT
3. REMOVE CONSOLE BOX
4. REMOVE TRANSMISSION AND TRANSFER SHIFT
LEVERS WITH RETAINER
Disconnect the control and shift cables from the shift levers.
5. REMOVE PARKING BRAKE LEVER
Disconnect the brake cable from the brake lever, and
remove the brake lever assembly.
6. REMOVE PARKING BRAKE AND SHIFT CABLES
(a) Disconnect the brake cable from the intermediate
lever and remove it.
(b) Disconnect the shift cable from the transmission and
remove it.
7. REMOVE SEAT FLOOR PANEL
9. REMOVE RADIATOR MOUNTING BOLT AND NUTS
NOTE: Do not drain coolant.
10. DISCONNECT SHOCK ABSORBER FROM FRAME

Remove the nuts, cushion and retainers, and disconnect
the shock absorber from the frame.
NOTE: Do not disconnect the shock absorber from the
11. DISCONNECT UPPER SUSPENSION ARM FROM

STEERING KNUCKLE
Remove the cotter pin and nut, and using SST, disconnect
the upper ball joint from the steering knuckle.
SST 09628-62011
FA1522
12. REMOVE UPPER SUSPENSION ARM

Remove the two bolts, and remove the upper suspension
arm from the frame.
FA1071
REPLACEMENT OF UPPER SUSPENSION ARM

IF NECESSARY, REPLACE UPPER SUSPENSION ARM
ASSEMBLY
(a) Remove the two bolts and torque arm.
FA1074
(b) Install the torque arm to a new upper suspension arm,

and torque the bolts.
Torque: 1,250 kg-em (90 ft-Ib, 123 N·m)
INSTALLATION OF UPPER SUSPENSION ARM

(See page FA-98)
1. INSTALL UPPER SUSPENSION ARM
Install the upper suspension arm and torque the mounting
bolts.
2. INSTALL AND TORQUE RADIATOR MOUNTING BOLT

AND NUTS
3. CONNECT UPPER SUSPENSION ARM TO STEERING

KNUCKLE
(a) Connect the upper suspension arm to the steering
knuckle and torque the nut.
FA1519
4. CONNECT SHOCK ABSORBER TO FRAME

Connect the shock absorber to frame with the cushions and
retainers, and install and tighten the nuts.
5. INSTALL FAN SHROUD
6. INSTALL SEAT FLOOR PANEL
7. INSTALL PARKING BRAKE CABLE AND SHIFT CABLE

(a) Connect the shift cable to the transmission.
(b) Connect the brake cable to the intermediate lever.
8. INSTALL PARKING BRAKE LEVER

Install the parking brake lever assembly and connect the
brake cable to the brake lever.
9. INSTALL TRANSMISSION AND TRANSFER SHIFT

LEVER ASSEMBLY
Install the transmission and transfer shift lever assembly,
and connect the cables.
10. INSTALL CONSOLE BOX
11. INSTALL FRONT SEAT
12. INSTALL TORSION BAR SPRING

(See page FA-1 01)
Shock Absorber
(See page FA-9a)
REMOVAL OF SHOCK ABSORBER

REMOVE SHOCK ABSORBER
(a) Remove the lock nut and nut.
(b) Remove the retainers and cushion.
FA1065
(c) Remove the bolt, spring washer and nut.

(d) Remove the shock absorber.
FA 1525
INSPECTION OF SHOCK ABSORBER
, 1. INSPECT OPERATION OF SHOCK ABSORBER

(a)
(b)
While pushing the shock absorber, check that the pull
throughout the stroke is even, and there is no
abnormal resistance or noise.
Push the shock absorber in fully and release it. Check
that it returns at a constant speed throughout.
RA0850
2. DISCARD SHOCK ABSORBER

Before discarding the cartridge, drill a hole 2 - 3 mm (0.08
10- 20 mm (0.39 - 0.79 in.) - 0.12 in.) in diameter at the location shown in the figure
to release the gas inside.
q.------JC--[p:mu CAUTION:
• When drilling, chips may fly out, work carefully.
• The gas is coloress, odorless, and non-poisonous.
RA0806
INSTALLATION OF SHOCK ABSORBER

(See page FA-9a)
INSTALL SHOCK ABSORBER

(a) Connect the shock absorber to frame with the
cushions and retainers, and install and tighten the lock
/ nut and nut as shown in the figure.
(b) Install the shock absorber to the lower suspension arm

with the bolt, spring washer and nut.
FA 1525
Stabilizer bar
(See page FA-98)
REMOVAL OF STABILIZER BAR

REMOVE STABILIZER BAR
(a) Remove the bolts and disconnect the stabilizer bar
from the lower suspension arm.
(b) Remove both stabilizer bar brackets and cushion, and

remove the stabilizer bar.
INSTALLATION OF STABILIZER BAR

(See page FA-98)
1. PLACE STABILIZER BAR BODY

Place the stabilizer bar in position and install both stabilizer
bar cushion and brackets to the stabilizer bar. Torque the
bolts.
2. CONNECT STABILIZER BAR TO LOWER

SUSPENSION ARMS
Connect the stabilizer bar on both sides to the lower
suspension arms with the bolts, cushions and retainers.
Torque the bolts.
RA-1
REAR AXLE AN D
SUSPENSION
Page
TROUBLESHOOTING RA-2
REAR AXLE SHAFT RA-3
DIFFERENTIAL RA-8
4-LlNK TYPE REAR SUSPENSION RA-26
Coil Spring and Rear Shock Absorber RA-27
Lateral Control Rod RA-31
Upper and Lower Control Arms RA-33
Rear Stabilizer Bar RA-38
LEAF SPRING TYPE REAR SUSPENSION RA-39
Leaf Spring and Rear Shock Absorber RA-39
RA-2 REAR AXLE AND SUSPENSION - Troubleshooting
TROUBLESHOOTING
Oil leak at rear axle Oil seal worn or damaged Replace oil seal RA-3
Bearing retainer loose Replace retainer RA-3
Rear axle housing cracked Repair as necessary
Oil leak from drive Oil level too high or wrong grade Drain or replace oil
pinion Oil seal worn or damaged Replace oil seal RA-8
Companion flange loose or damaged Tighten or replace flange RA-8
Noises in rear axle Oil level low or wrong grade Fill or replace oil
Excessive backlash between pinion and Check backlash RA-12
ring or side gear
Ring, pinion or side gears worn or chipped Inspect gears RA-12
Pinion shaft bearing worn Replace bearing RA-15
Axle shaft bearing worn Replace bearing RA-3
Differential bearing loose or worn Tighten or replace bearings RA-15
Bottoming Vehicle overloaded Check loading

Shock absorber worn out Replace shock absorber RA-26,39
Springs weak Replace spring RA-26,39
REAR AXLE AND SUSPENSION - Rear Axle Shaft RA-3
REAR AXLE SHAFT

COMPONENTS
Backing Plate
• Bearing
Inner Retainer
• Retainer Gasket
Wf
Bearing Outer Retainer
r-- ......... • End Gasket
I "
I ..............
.........
I ...................
I ...........................
I .................... Bearing
.........
..,
~ ...................
......... ..........
.............
I
...---_--1..---, I
l--_I
Brake Dru~ ................... I
....J
Rear Axle Shaft

1,050 176, 103)
I kg-cm (ft-Ib, N·m) I: Specified torque

RA1141
REMOVAL OF REAR AXLE SHAFT

1. JACK UP AND SUPPORT VEHICLE
2. REMOVE WHEEL AND BRAKE DRUM
3. REMOVE BRAKE RETURN SPRING

Using SST, remove the return spring.
SST 09703-30010
BR1114
4. REMOVE BACKING PLATE MOUNTING NUTS
RA1146
RA-4 REAR AXLE AND SUSPENSION - Rear Axle Shaft
5. DISCONNECT BRAKE TUBE

Using SST, disconnect the brake tube. Use a container to
catch the backing plate.
SST 09751-36011
RA1196
6. REMOVE REAR AXLE SHAFT

(a) Using SST, pull out the rear axle shaft.
SST 09520-00031
CAUTION: Be careful not to damage the oil seal.
(b) Remove the backing plate assembly.
(c) Remove the end gasket from the rear axle housing.
RA1143
Limit Limit INSPECTION AND REPAIR OF REAR AXLE

1.5 mm 0.1 mm SHAFT COMPONENTS
1. INSPECT REAR AXLE SHAFT AND FLANGE FOR
WEAR, DAMAGE OR RUNOUT
Maximum shaft runout: 1.5 mm (0.059 in.)
Maximum flange runout: 0.1 mm (0.004 in.)
If the rear axle shaft or flange is damaged or worn, or if
runout is greater than maximum, replace the rear axle shaft.
RA0005
2. INSPECT REAR AXLE BEARING FOR WEAR OR

DAMAGE
If the bearing is damaged or worn, replace it.
3. REMOVE BEARING INNER RETAINER

(a) Using a grinder, grind down the inner retainer.
(b) Using a hammer and chisel, cut off the retainer and
remove it from the shaft.
RA0160 RA0161
REAR AXLE AND SUSPENSION - Rear Axle Shaft RA-5
4. REMOVE BEARING AND OUTER RETAINER FROM

AXLE SHAFT
SST (a) Using SST and a press, press the bearing off the shaft.
SST 09527 -21011
(b) Remove the outer retainer from the shaft.
RA1051
5. INSTAll BEARING OUTER RETAINER AND NEW

BEARING ON AXLE SHAFT
Using SST and a press, press in the bearing outer retainer
and a new bearing.
SST 09515-21010
RA0804
6. INSTAll BEARING INNER RETAINER ON AXLE

SHAFT
(a) Heat the bearing inner retainer to about 150°C
(302°F) in an oil bath.
RA0854
(b) Using SST and a press, press the inner retainer onto
the shaft while the inner retainer is still hot.
SST 09515-21010
NOTE:
• Be sure that there is no oil or grease on the rear axle
SST shaft or retainer.
• Face the non-beveled side of the inner retainer toward
the bearing.
RA0805
7. INSPECT OIL SEAL FOR WEAR OR DAMAGE

If the seal is damaged or worn, replace it.
8. REMOVE Oil SEAL FROM AXLE HOUSING

Using SST, remove the oil seal.
SST 09308-00010
RA-6 REAR AXLE AND SUSPENSION - Rear Axle Shaft
9. INSTALL NEW OIL SEAL IN AXLE HOUSING

(a) Apply MP grease to a new oil seal lip.
(b) Using SST and a hammer, tap in the oil seal to a depth
of 6.0 mm (0.236 in.).
SST 09517-30010
RA1144
INSTALLATION OF REAR AXLE SHAFT

(See page RA-3)
1. CLEAN FLANGE OF AXLE HOUSING AND BACKING

PLATE
2. INSTALL REAR AXLE SHAFT

(a) Apply seal packing to both sides of a new end gasket.
RA1143
1281 or equivalent
(b) Place the end gasket onto the end of the axle housing
with the notch faci ng downward.
(c) Install the backing plate to the axle housing.
(d) Apply seal packing to both sides of a new retainer
gasket.
1281 or equivalent
(e) Align the notch of the outer retainer with the oil hole
of the retainer gasket.
RA1128
(f) Install the rear axle shaft with the notch of the outer
retainer facing downward, and torque the four nuts.
NOTE:
• Be careful not to damage the oil seal.
• When inserting the axle shaft, be careful not to hit or
deform the oil deflector inside the axle housing.
RA1145
3. INSTALL BRAKE RETURN SPRING

Using SST, install the brake return spring.
SST 09703-30010
~~~-SST
BR1118
RA-8 REAR AXLE AND SUSPENSION - Differential
DIFFERENTIAL
COMPONENTS
Adj usti ng Nut @

Side Gear Thrust Washer
Side Gear Pinion Gear
Side Bearing
Ring Gear
Differential Case
0" ~ .~~
Thrust Washer
(/'
~ I
f 6D~
//0 985 (71, 97)
1 Washer
Rear Bearing
Drive Pinion
130 (9.13) I
• Bearing Spacer
Companion Flange
------~I 800(58.78) I
Washer
,~s~:
.Nut~ ')
~ ,)rJ,) Bearing Cap

') Bearing
• Oil Seal
kg-cm (ft-Ib, N·m) I: Specified torque
• Non-reusable part RA1249
ON-VEHICLE REPLACEMENT OF OIL SEAL

1. DISCONNECT PROPELLER SHAFT
propeller shaft.
PRO'22

(a) Using a chisel and hammer, loosen the staked part of
nut.
(b) Using SST, to hold the flange, remove the nut and
plate washer.
SST 09330-00021
84056 84057
REAR AXLE AND SUSPENSION - Differential RA-9

SST 09557-22022

SST 09308-10010
4. REMOVE FRONT BEARING AND BEARING SPACER

(a) Using SST, remove the front bearing from the drive
pinion.
SST 09556-22010
5. INSTALL NEW BEARING SPACER AND FRONT

BEARING
New Spacer
..60
(b) Install the front bearing on the drive pinion.
RA1058

(a) Install the oil slinger facing as shown.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09554-30011
=-~---II
j'~1.5 mm
Drive in Depth RA1055
RA-'O REAR AXLE AND SUSPENSlON - Differential

pinion.
SST 09557-22022

companion flange nut.
(d) Using SST to hold the flange, torque the nut.
SST 09330-00021
FA1083

Preload(starting):
6 - 10 kg-em (5.2 - 8.7 in.-Ib, 0.6 - 1.0 N·m)
If the preload is greater than specification, replace the
bearing spacer.
FA1084
preload.
Maximum torque: 2,400 kg-em (174 ft-Ib, 235 N·m)
/
FA1157
10. CONNECT PROPELLER SHAFT TO COMPANION

FLANGE
washers and nuts.
Torque: 2WD MIT 750 kg-cm (54 ft-Ib, 74 N'm)
2WD AIT 430 kg-cm (31 ft-Ib, 42 N'm)
4WD 750 kg-cm (54 ft-Ib, 74 N'm)
PR0122
11. CHECK DIFFERENTIAL OIL LEVEL

Fill with hypoid gear oil if necessary.
Above -18°C (O°F) SAE 90
Capacity:
2WD 1 .45 liters (1.53 US qts, 1.28 Imp. qts)
0-5 mm (0 - 0.20 in.) 4WD 1.85 liters (1.96 US qts, 1.63 Imp. qts)
RA10n
REMOVAL OF DIFFERENTIAL
1. DRAIN DIFFERENTIAL OIL
2. REMOVE REAR AXLE SHAFTS

(See page RA-3)
3. DISCONNECT PROPELLER SHAFT

propeller shaft.
PR0122
4. REMOVE DIFFERENTIAL CARRIER ASSEMBLY

Remove the nuts, washers and differential carrier as-
sembly.
CAUTION: Be careful not to damage the installation
surface.
RA1068
DISASSEMBLY OF DIFFERENTIAL
(See page RA-8)

(0.0039 in.)
RAOO96
(0.0039 in.)

Using a dial indicator, measure the ring gear runout.
If the runout is greater than maximum, replace the ring gear
and drive pinion as a set.
RA1073
3. CHECK RING GEAR BACKLASH

(a) Fix the dial indicator on the tooth surface at a 90°
angle.
(b) Holding the drive pinion flange, measure the ring gear
backlash.
(0.0051 - 0.0071 in.)
If the backlash is not within specification, adjust the ring
gear backlash.
RA1052
NOTE: Measure from three or more places on the cir-
cumference of the ring gear.

AND DRIVE PINION (See step 7 on page RA-22)
RA1059
5. CHECK SIDE GEAR BACKLASH

Using a dial indicator, measure the side gear backlash while
holding one pinion gear toward the differential case.
(0.0020 - 0.0079 in.)
washers.
RA1049

Preload( starting):
6 - 10 kg-em (5.2 - 8.7 in.-Ib, 0.6 - 1.0 N'm)

With the drive pinion and ring gear meshed, using a torque
meter, measure the total preload.
L-- FA:..:....
-.:..:... 11..:..:J58 Total preload(starting):
4 - 6 kg-em (3.5 - 5.2 in.-Ib, 0.4 - 0.6 N'm)

(a) Using a chisel and hammer, unstake the nut.
FAl159
(b) Using SST to hold the flange, remove the nut and plate
washer.
SST 09330-00021

SST 09557 -22022

(a) Using SST, remove the oil seal from the differential
carrier.
SST 09308-10010
10. REMOVE FRONT BEARING AND BEARING SPACER

(a) Using SST, remove the front bearing from the drive
pinion.
SST 09556-22010
11. REMOVE DIFFERENTIAL CASE ASSEMBLY AND

RING GEAR
(a) Place matchmarks on the bearing cap and differential
carrier.
(b) Remove the two adjusting nut locks.
(c) Remove the two bearing caps and two adjusting nuts.
(d) Remove the differential case with bearing outer races

from the carrier.
NOTE: Tag the disassembled parts to show the location

for reassembly.
RA0644
12. REMOVE DRIVE PINION FROM DIFFERENTIAL

CARRIER
RA1213

DIFFERENTIAL COMPONENTS
1. REPLACE DRIVE PINION REAR BEARING
(a) Using SST and a press, press out the rear bearing from
the drive pinion.
SST 09950-00020
NOTE: If the drive pinion or ring gear are damaged,
replace them as a set.
(b) Install the reused washer on the drive pinion with the
chamfered end facing the pinion gear.
(c) Using SST and a press, press in the rear bearing onto
the drive pinion.
SST 09506-30012
FAll12
2. REPLACE DRIVE PINION FRONT AND REAR

BEARING OUTER RACES
(a) Using a brass bar and hammer, drive out the outer
race.
(b) Using SST and a press, press in a new outer race.
SST 09608-30012
Front outer race (09608-04020,09608-04100)
Rear outer race (09608-04020,09608-04110)
3. REMOVE RING GEAR

(a) Place match marks on the ring gear and differential
case.
(b) Using a screwdriver, unstake the lock plates.
RA1075
(c) Remove the ten bolts and five lock plates.
RA1071
(d) Using a plastic-faced hammer, tap on the ring gear to

separate it from the differential case.
RA1077
4. CHECK DIFFERENTIAL CASE RUNOUT

(a) Install the differential case in the differential carrier
and tighten the adjusting nut just to where there is no
play in the bearing. (See page RA-20)
(b) Using a dial indicator, measure the differential case
runout.
(c) Remove the differential case.
(See procedure step 11 on page RA-14)
RA1050
5. REMOVE SIDE BEARINGS

Using SST, remove the side bearing from the differential
case.
SST 09950-20017
NOTE: Fix the claws of SST to the notches in the
differential case.
RA1069
6. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY

(a) Using a pin punch and hammer, drive out the straight
pin.
RA1070
(b) Remove the following parts:

@-tr-~-(5) (4) . (1) Pinion shaft
(2) Pinion gears
~ @®
(3) Pinion gear thrust washers
~~
". J (4) Side gears
(1) R (5) Side gear thrust washers
(3) (2) ~@
FAl120
7. ASSEMBLE DIFFERENTIAL CASE

(a) Install the side gear thrust washers to the side gears.
FA1121
(b) Install the side gears with the thrust washers, pinion
gears, pinion gear thrust washers and pinion shaft.
FAl122
(c) Check the side gear backlash.

• Measure the side gear backlash while holding one
pinion gear toward the case.
(0.0020 - 0.0079 in.)
washers.
Thrust washer thickness mm(in.)
0.96 - 1.04 (0.0378 - 0.0409)

1.06 - 1.14 (0.0417 - 0.0449)
1.16 - 1.24 (0.0457 - 0.0488)
1.26 - 1.34 (0.0496 - 0.0528)
NOTE: Select the same sized thrust washers for both the
left and right sides.
(d) Using a pin punch and hammer, drive the straight pin
through the holes in the differential case and pinion
shaft.
FA1124
(e) Using a chisel and hammer, stake the outside of the

differential case pin hole.
'A1125
8. INSTALL RING GEAR

(a) Heat the ring gear to about 100°C (212°F) in an oil
bath.
CAUTION: Do not heat the ring gear above 110°C
(230°F).
(b) Clean the contact surface of the differential case.
(c) Clean the contact surface of the ring gear with
cleaning solvent.
(d) Align the matchmarks on the ring gear and differential

case.
(e) Then quickly install the ring gear on the differential
case.
(f) Place the five lock plates on the differential case.
(g) Install and uniformly tighten the ten bolts in several
passes.
RA1076
(h) Using a chisel and hammer, stake the lock plates.

NOTE: Stake one claw flush with the flat surface of the
nut. For the claw contacting the protruding portion of the
nut, stake only the half on the tightening side.
9. INSTALL SIDE BEARINGS

Using SST and a press, press the bearing into the dif-
ferential case.
!IIIII------..,SST
SST 09550-10012
(09252-10010, 09557-10010, 09558-10010)
SST
RA1074

(a) Install the differential case in the differential carrier
and tighten the adjusting nut just to where there is no
play in the bearing. (See page RA-20)
(b) Using a dial indicator, measure the ring gear runout.
(c) Remove the differential case.
(See procedure step 11 on page RA-14)
RA1067
ASSEMBLY OF DIFFERENTIAL
(See page RA-8)
1. TEMPORARILY ADJUST DRIVE PINION PRELOAD

(a) Install the drive pinion, front bearing and oil slinger.
NOTE: After adjusting the gear tooth contact, assemble
the spacer and oil seal.
RA1056
(b) As the spacer is not installed, using SST, install the

companion flange until a small clearance remains on
the drive pinion.
SST 09557-22022
(c) Place the plate washer on the companion flange.
FAl139
(d) Apply a light coat of gear oil on the threads of the

(e) Using SST to hold the flange, adjust the drive pinion
preload by tightening the companion flange.
SST 09330-00021
CAUTION: As there is no spacer, tighten a little at a
time, being careful not to overtighten.
(f) Rotate the flange left and right to seat the bearings.
(g) Using a torque meter, measure the preload.
Preload(starting):
New bearing
12 - 19 kg-cm
(10.4 - 16.5 in.-Ib, 1.2 - 1.9 N'm)
Reused bearing
6 - 10 kg-cm
(5.2 - 8.7 in.-Ib, 0.6 - 1.0 N'm)
NOTE: In order to measure the total preload, record the
~ FAl158
.--J preload reading.
2. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL

CARRIER
not interchanged.
RA1066
3. INSTALL ADJUSTING NUTS

Install the adjusting nuts on their respective carrier,
making sure the nuts are threaded properly.
NOTE: Check that there is backlash between the ring gear
and drive pinion.
4. INSTALL BEARING CAPS

Align the match marks on the cap and carrier. Screw in the
two bearing cap bolts two or three turns and press down
the bearing cap by hand.
NOTE: If the bearing cap does not fit tightly on the carrier,
the adjusting nut threads are not threaded properly.
Reinstall the adjusting nuts if necessary.
5. ADJUST SIDE BEARING PRELOAD AND RING GEAR

BACKLASH
(a) Torque the bearing cap bolts.
(b) Loosen the bearing cap bolts until the adjusting nuts
can be turned with SST.
SST 09504-00011
RA1060
(c) Using SST, tighten the adjusting nut on the ring gear
side until the ring gear has a backlash of about 0.2 mm
(0.008 in.).
SST 09504-00011
RA1062
(d) Using SST, firmly tighten the adjusting nut on the

drive pinion side.
SST 09504-00011
(e) Check that the ring gear has backlash.
If tightening the adjusting nut creates ring gear backlash,
loosen the nut so that backlash is eliminated.
RA1064
(f) Place a dial indicator on the top of the adjusting nut on

the ring gear side.
(g) Loosen the adjusting nut on the drive pinion side.
(h) Adjust the side bearing for zero preload by tightening
the other adjusting nut until the pointer on the
indicator begins to move.
RAOO28
(i) Tighten the adjusting nut 1 - 1 1/2 notches from the

zero preload position
RA1064
(j) Using a dial indicator, adjust the ring gear backlash

until it is within specification.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
NOTE: The backlash is adjusted by turning the left and
right adjusting nuts equal amounts. For example, loosen
the nut on the left side one notch and tighten the nut on the
right side one notch.
RA1061
(k) Torque the bearing cap bolts.

RA1060
(I) Recheck the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
RA1052

Using a torque meter, with the drive pinion and ring gear
meshed, measure the total preload.
4 - 6 kg-cm (3.4 - 5.2 in.-Ib, 0.4 - 0.6 N'm)
FA1158

AND DRIVE PINION
(a) Coat 3 or 4 teeth at three different positions on the
ring gear with red lead.
(b) Hold the companion flange firmly and rotate the ring
gear in both directions.
(c) Inspect the tooth pattern.
RA1059
Heel Contact Face Contact
Select an adjusting shim that will bring the drive

pinion closer to the ring gear.
Proper Contact
Toe Contact Flank Contact
Select an adjusting shim that will shih the drive

pinion away from the ring gear.
RAOO29
If the tooth pattern is not proper, replace the drive pinion

plate washer.
2.23 - 2.25 (0.0878 - 0.0886) 2.50 - 2.52 (0.0984 - 0.0992)

2.26 - 2.28 (0.0890 - 0.0898) 2.53 - 2.55 (0.0996 - 0.1 (04)
2.29 - 2.31 (0.0902 - 0.0909) 2.56 - 2.58 (0.1 008 - 0.1 016)
2.32 - 2.34 (0.0913 - 0.0921) 2.59 - 2.61 (0.1020 - 0.1 028)
Plate Washer 2.35 - 2.37 (0.0925 - 0.0933) 2.62 - 2.64 (0.1031 - 0.1 039)
FA1145 2.38 - 2.40 (0.0937 - 0.0945) 2.65 - 2.67 (0.1 043 - 0.1 051)
2.41 - 2.43 (0.0949 - 0.0957) 2.68 - 2.70 (0.1 055 - 0.1 063)
2.44 - 2.46 (0.0961 - 0.0969) 2.71 - 2.73 (0.1 067 - 0.1 075)
2.47 - 2.49 (0.0972 - 0.0980)
8. REMOVE COMPANION FLANGE AND OIL SLINGER

(See step 8 on page RA-13)
9. REMOVE FRONT BEARING

10. INSTALL NEW BEARING SPACER AND FRONT

BEARING
(b) Install the front bearing on the drive pinion.
RA1058

(a) Install the oil slinger facing as shown.
SST 09554-30011
Oil seal drive in depth: 1 .5 mm (0.059 in.)
Drive in Depth RA1055

pinion.
SST 09557-22022

(d) Using SST to hold the flange, tighten the nut.
SST 09330-00021
RAOO31

Preload (starting):
New bearing
12 - 19 kg-em
(10.4 - 16.5 in.-Ib, 1.2 - 1.9 N'm)
Reused bearing
6 - 10 kg-em
FA1158
(5.2 - 8.7 in.-Ib, 0.6 - 1.0 N'm)
If the preload is greater than specification, replace bearing
spacer.
preload.
14. RECHECK TOTAL PRELOAD

Total preload(starting}:
4 - 6 kg-em (3.4 - 5.2 in.-Ib, 0.4 - 0.6 N'm)
15. RECHECK RING GEAR BACKLASH

Ring gear backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in.)
16. RECHECK TOOTH CONTACT BETWEEN RING GEAR

AND DRIVE PINION (See step 7 on page RA-22)

(0.0039 in.)
(0.0039 in.)
RAOO96

Using a punch and hammer, stake the drive pinion nut.
RAOO32
19. INSTALL ADJUSTING NUT LOCKS

NO.1 No.2
,~
(a) Select either a lock No. 1 or No.2, whichever will fit
the adjusting nuts.
(b) Install the lock nut on the bearing caps.
RA1057
INSTALLATION OF DIFFERENTIAL
1. INSTALL NEW GASKET TO AXLE HOUSING
2. INSTALL DIFFERENTIAL CARRIER ASSEMBLY

Install the differential carrier assembly in the axle housing
with the ten nuts.
RA1068
3. CONNECT PROPELLER SHAFT TO COMPANION

LANGE
washers and nuts.
Torque: 2WD MIT 750 kg-em (54 ft-Ib, 74 N'm)
( i 2WD AIT 430 kg-em (31 ft-Ib, 42 N'm)
~/~ PR0122
4WD 750 kg-em (54 ft-Ib, 74 N'm)
4. FILL DIFFERENTIAL WITH GEAR OIL

Fill with hypoid gear oil.
Above - 18°C (O°F) SAE 90
Capacity:
2WD 1.45 liters (1 .53 US qts, 1.28 Imp. qts)
0-5 mm (0 -0.20 in.) 4WD 1.85 liters (1.96 US qts, 1.63 Imp. qts)
RA1072
RA-26 REAR AXLE AND SUSPENSION - 4-Link Type Rear Suspension
4-LINK TYPE REAR SUSPENSION

COMPONENTS
~---------------I 280(20,27) I
- - - - - - Retainer
- - - - - Cushion
4WD
Rea r Shock ~-----------------\
Absorber
Upper Insulator ~ 1-------__
,
1,300 (94,127)
Bumper ~
Bushing ~
I
1 11~,~ 5~ ~~
@) ~---I 375 (27, 37)
~ Spacer
Coil Spring ~ wat:'lg (43.
Lateral Control Rod

Lower Insulator ~
Upper Control
Ar~~
1,125 (81, 110)
Stabilizer1
Link
Retainer --e
Cushion --e
e
e
9
e Bushing
2WD
Lower Control Arm
I kg-em (h-Ib, N·m) I: Specified torque

• Non-reusable part RA1214
REAR AXLE AND SUSPENSION - 4-Link Type Rear Suspension RA-27
Coil Spring and Rear Shock Absorber

(See page RA-26)
REMOVAL OF COIL SPRING AND REAR

SHOCK ABSORBER
Jack up the rear axle housing and support the body with
stands. Leave the jack under the rear axle.
2. REMOVE WHEEL
3. DISCONNECT REAR SHOCK ABSORBER

(a) (2WD)
Remove the bolt holding the shock absorber to the rear
axle housing and disconnect the shock absorber.
RAl153
(4WD)
Remove the nut, washer and bolt holding the shock
absorber to the lower control arm and disconnect the
shock absorber.
RA1207
(b) If replacing the shock absorber, remove the nut

holding the shock absorber to the body, and remove
the shock absorber.
NOTE: Use a screwdriver to keep the shaft from turning.
4. REMOVE STABILIZER BAR BUSHING BRACKETS

Remove the bolt holding the stabilizer bar bushing to the
rear axle housing.
RAl149
5. DISCONNECT LATERAL CONTROL ROD FROM REAR

AXLE HOUSING
Remove the nut holding the lateral control rod to the rear
axle housing and disconnect the lateral control rod.
RA1158
6. REMOVE COIL SPRING

(a) Begin to lower the rear axle housing.
NOTE: Be careful not to snag the brake line and parking
brake cable.
(b) While lowering the rear axle housing, remove the coil
spring and upper and lower insulators.
RA0363
INSPECTION OF REAR SHOCK ABSORBER

1. INSPECT OPERATION OF SHOCK ABSORBER
(a) While pushing the shock absorber, check that the pull
throughout the stroke is even, and there is no
abnormal resistance or noise.
(b) Push the shock absorber in fully and release it. Check
that it returns at a constant speed throughout.
RA0851
2. DISCARD SHOCK ABSORBER

Before discarding the cartridge, drill a hole 2 - 3 mm (0.08
10- 20 mm (0.39 - 0.79 in.) - 0.12 in.) in diameter at the location shown in the figure
q -L no
to release the gas inside.
CAUTION:
• When drilling, chips may fly out, work carefully.
• The gas is color less, odorless, and non-poisonous.
RA0807
INSTALLATION OF COIL SPRING AND REAR

SHOCK ABSORBER
(See page RA-26)
1. PUT LOWER INSULATOR ON AXLE HOUSING
RA0306
2. PUT UPPER INSULATOR ON COIL SPRING
RA0596
3. INSTALL COIL SPRING
4. JACK UP REAR AXLE HOUSING
5. CHECK POSITION OF LOWER INSULATOR

Check that the lower insulator is installed correctly.
If the insulator is not in correct position, reinstall the coil
spring.
RAl136
6. CONNECT LATERAL CONTROL ROD

In this order, install a washer, bushing, spacer, lateral
control rod, bushing, washer and nut on the rear axle
housing.
NOTE: Do not tighten the nut.
7. INSTALL SHOCK ABSORBER

(a) Connect the shock absorber to the body with the nut.
Hold the shaft with a screwdriver. Torque the nut.
(b) (2WD)
Connect the shock absorber to the rear axle housing
with the bolt. Torque the bolt.
RA1152
(4WD)
Connect the shock absorber to the lower control arm
RA1206
8. INSTALL STABILIZER BAR BUSHING BRACKETS TO

REAR AXLE
RA1150
t
(a) Install the wheels.
(b) Bounce the vehicle up and down to stabilize the
suspension.
RA0793
11. TIGHTEN LATERAL CONTROL ROD NUT

(a) Raise the axle housing until the body is free from the
stands.
(b) Torque the lateral control rod nut.
Lateral Control Rod

(See page RA-26)
REMOVAL OF LATERAL CONTROL ROD

1. JACK UP AND SUPPORT BODY
Jack up the rear axle housing and support it with stands.
2. DISCONNECT LATERAL CONTROL ROD FROM REAR

AXLE HOUSING
Remove the nut holding the lateral control rod to the rear
axle housing, and disconnect the lateral control rod.
3. DISCONNECT LATERAL CONTROL ROD FROM

BODY
Remove the bolt and nut holding the lateral control rod to
the body and remove the lateral control rod.
REPLACEMENT OF LATERAL CONTROL ROD

Remove BUSHING
~ 1. REMOVE BUSHING
SST
YO Chamfer
Using SST and a press, press out the bushing from the
lateral control rod.
SST 09710-30020
(09710-03020,09710-03120,09710-03130)
NOTE: When inserting and removing the bushing, press
RA0834 RA 1254 or pull from the chamfered side as shown in the figure.
2. INSTALL BUSHING
Install Using SST and a press, press a new bushing into the lateral
control rod.
SST Chamfer ~
SST 09710-30020
~OO57
(09710-03020,09710-03070,09710-03120)
NOTE: Do not use a lubricant when pressing in the
bushing.
(-U; SST
INSTALLATION OF LATERAL CONTROL ROD

(See page RA-26)
1. CONNECT LATERAL CONTROL ROD TO BODY

(a) Raise the axle housing until the body is free from the
stands.
(b) Install the lateral control rod to the body with the nut.
2. INSTALL LATERAL CONTROL ROD TO REAR AXLE

HOUSING
(a) In this order, install the washer, bushing, spacer,
lateral control arm, bushing, washer and nut on the
rear axle housing.
RA1157
(b) Remove the stands and bounce the vehicle to stabilize

the suspension.
t
RA0793
(c) Jack up the axle housing.

(d) Torque the nuts.
Torque: Body side
1,125 kg-em (81 ft-Ib, 110 N ·m)
Axle housing side
600 kg-em (43 ft-Ib, 59 N·m)
Upper and Lower Control Arms

(See page RA-26)
REMOVAL OF UPPER AND LOWER CONTROL

ARMS
Jack up the vehicle and support the body with stands.
Hold the rear axle housing with a jack.
2. DISCONNECT PARKING BRAKE CABLE FROM

LOWER CONTROL ARM
3. (4WD)
DISCONNECT REAR SHOCK ABSORBER
Remove the bolt, spring washer and nut holding the shock
absorber to the lower control arm and disconnect the shock
absorber.
RA1204
4. REMOVE UPPER CONTROL ARM

(a) Remove the bolt, spring washer and nut holding the
upper control arm to the body.
(b) Remove the bolt, spring washer and nut holding the
upper control arm to the rear axle housing, and
remove the upper control arm.
RA1162
5. REMOVE LOWER CONTROL ARM

(a) Remove the bolt and nut holding the lower control arm
to the body.
(b) Remove the bolt and nut holding the lower control arm
to the rear axle housing, and remove the lower control
arm.
RAl151
Remove
REPLACEMENT OF UPPER AND LOWER
CONTROL ARM BUSHINGS
J 1. REMOVE BUSHING
cO
SST Chamfer
Using SST and a press, press out the bushing from the
control arm.
SST 09710-14012
(09710-00010, 09710-00020, 09710-00050)
NOTE: When inserting and removing the bushing, press
RA0834 RA 1254 or pull from the chamfered side as shown in the figure.
2. INSTALL BUSHING
Install Using SST and a press, press a new bushing into the
control arm.
Chamfer ~
SST 09710-14012
SSTdO (09710-00010,09710-00020,09710-00050)
NOTE: Do not use a lubricant when pressing in the
bushing.
RA0834 RA0657
INSTALLATION OF UPPER AND LOWER

CONTROL ARMS
(See page RA-26)
1. INSTALL UPPER CONTROL ARM
(a) Install the upper control arm on the body with the bolt,
spring washer and nut.
(b) Install the upper control arm on the rear axle housing
RA1164
2. INSTALL LOWER CONTROL ARM

(a) Install the lower control arm on the body with the bolt,
spring washer and nut.
RA1199
(b) Install the lower control arm on the rear axle housing
\
3. (4WD)
CONNECT REAR SHOCK ABSORBER
Connect the rear shock absorber to the lower control arm
RA1205
4. CONNECT PARKING BRAKE CABLE TO LOWER

CONTROL ARM
Remove the stands and bounce the vehicle to stabilize the
suspension.
t
RA0793
6. JACK UP VEHICLE
Raise the axle housing until the body is free from the stands.
7. TIGHTEN BOLT AND NUT HOLDING UPPER

CONTROL ARM TO BODY
8. TIGHTEN BOLT AND NUT HOLDING UPPER

CONTROL ARM TO REAR AXLE HOUSING
RAl163
9. TIGHTEN BOLT AND NUT HOLDING LOWER

CONTROL ARM TO BODY
RA120l
10. TIGHTEN BOLT AND NUT HOLDING LOWER

CONTROL ARM TO REAR AXLE HOUSING
RAl155
Rear Stabilizer Bar

(See page RA-26)
REMOVAL OF REAR STABILIZER BAR

1. REMOVE STABILIZER BAR BUSHING BRACKETS
RAl149
2. REMOVE REAR STABILIZER BAR FROM BODY
3. DISCONNECT STABILIZER BAR END FROM LINK
INSTALLATION OF REAR STABILIZER BAR

1. INSTALL STABILIZER LINK TO BODY
Install the link onto the body as shown.
RAl142
2. INSTALL STABILIZER BAR TO LINK

(a) Connect the stabilizer bar on both sides to the links
with the bolts, collars, cushions, nut and new cotter
pins.
(b) Install new cotter pins.
3. INSTALL BRACKETS TO BODY

RAl150
REAR AXLE AND SUSPENSION - Leaf Spring Type Rear Suspension RA-39
LEAF SPRING TYPE REAR

SUSPENSION
Shackle Pin
~ Shackle Plate
~(®, c ~ '-6-00-(-43-.5-9---")
u-BOlt----~nn sulng· ,@@®.
Spring Upper seat~ Leaf Spring

375 (27. 37)
Spring Pad---~
Shock Absorber
+Bushing---
Hanger Pin Bolt ~
kg-cm (ft-Ib, N·m) I : Specified torque

+ Non-reusable part
RA1138
Leaf Spring and Rear Shock Absorber

REMOVAL OF LEAF SPRING AND REAR
SHOCK ABSORBER
1. JACK UP AND SUPPORT BODY
2. REMOVE WHEEL
3. DISCONNECT PARKING BRAKE CABLE

RA0769
4. REMOVE SHOCK ABSORBER

(a) Remove the bolt holding the shock absorber to the
spring seat and disconnect the shock absorber from
the spri ng seat.
(b) If replacing the shock absorber, remove the bolt
holding the shock absorber to the body, and remove
the shock absorber.
RA0772
RA-40 REAR AXLE AND SUSPENSION - Leaf Spring Type Rear Suspension
4. REMOVE U-BOLTS
(a) Remove the U-bolt mounting nuts and spring washer.
(b) Remove the spring lower seat and spring pad.
(c) Remove the two U-bolts.
RA0773
5. REMOVE LEAF SPRING

(a) Remove the hanger pin nut, spring washer and bolt.
(b) Disconnect the leaf spring from the bracket.
RA0771
(c) Remove the two shackle pin nuts spring washers and
shackle plate.
(d) Remove the shackle pin and leaf spring from the
bracket.
(e) Remove the upper seat and spring pad.
6. REMOVE BUSHINGS FROM BODY
RA0770
REPLACEMENT OF EVE BUSHING

REPLACE EYE BUSHINGS WITH PRESS
Using a press and socket wrench, replace the eye bushings.
RA0457
REPLACEMENT OF LEAF SPRING

1. BEND OPEN SPRING CLIP
Using a chisel, pry up the spring clip.
2. REMOVE CLIP BOLT

Remove the clip bolt, collar and nut from the clip.
FA0156
3. REMOVE CENTER BOLT

Hold the spring near the center bolt in a vise and remove
the center bolt.
\ ~ -
FA0157
4. REPLACE SPRING CLIP

(a) Drill off the head of the rivet, and drive it out.
(b) Install a new rivet into the holes of the spring leaf and
cl ip. Then rivet with a press.
FA0158 RA0460
5. INSTALL SPRING CENTER BOLT

(a) Align the leaf holes and secure the leaves with a vise.
(b) Install and tighten the spring center bolt.
6. INSTALL CLIP BOLT

Position the collar and install the clip bolt and nut.
7. BEND SPRING CLIP

Using a hammer, bend the spring clip into position.
RA0461
RA-42 REAR AXLE AND SUSPENSION - Leaf Spring Type Rear Suspension
INSPECTION OF REAR SHOCK ABSORBER

INSPECT OPERATION OF SHOCK ABSORBER
While pushing the shock absorber, check that the pull
throughout the stroke is even, and there is no abnormal
resistance or noise.
RA0851
INSTALLATION OF LEAF SPRING AND REAR

SHOCK ABSORBER
(See page RA-39)
1. INSTALL BUSHINGS TO BODY
2. INSTALL LEAF SPRING

(a) Install the spring pad and upper seat onto the leaf
spring.
(b) Place the front end of leaf spring in the front bracket
and install the hanger pin bolt.
(c) Install the spring washer and finger tighten the hanger
pin nut.
(d) Place the rear end of leaf spring in the rear bracket,
and install the shackle pin.
(e) Install the shackle plate and spring washers, and
finger tighten the nuts.
RA0788
3. INSTALL U-BOLTS
(a) Install the two U-bolts onto the axle housing.
(b) Install the lower seat with pad and install the spring
washers and nuts.
(c) Tighten the U-bolt mounting nuts.
RA0773
NOTE: Tighten the U-bolts so that the length of all the

U-bolts under the spring seat are the same.
RA0774
4. INSTALL REAR SHOCK ABSORBER

5. CONNECT PARKING BRAKE CABLE
RA0772
Bounce the vehicle up and down to stabilize the suspension.
1
RA0793
8. TIGHTEN HANGER PIN AND SHACKLE PIN

(a) Torque the hanger pin nut.
RA0789
(b) Torque the two shackle pin nuts.

RA0790
BR-1
BRAKE SYSTEM
Page
PRECAUTIONS BR-2
TROUBLESHOOTING BR-2
CHECKS AND ADJUSTMENTS BR-5
MASTER CYLINDER BR-8
BRAKE BOOSTER BR-14
FRONT BRAKE BR-18
2WD BR-18
4WD BR-24
REAR BRAKE BR-31
LOAD SENSING PROPORTIONING
AND BY-PASS VALVE (LSP & BV) BR-40
BRAKE HOSES AND TUBES BR-47
BR-2 BRAKE SYSTEM - Precautions, Troubleshooting
PRECAUTIONS
1. Care must be taken to replace each part properly as it
could affect the performance of the brake system and
result in a driving hazard. Replace the parts with parts
of the same part number or equivalent.
2. It is very important to keep parts and the area clean
when repairing the brake system.
TROUBLESHOOTING
Low or spongy Linings worn Replace brake shoes or pads BR-18, 24, 31
pedal Leak in brake system Locate and repair
Master cylinder faulty Repair or replace master cylinder BR-8
Air in brake system Bleed brake system BR-6
Wheel cylinder faulty Repair wheel cylinder BR-31
Piston seals worn or damaged Repair brake calipers BR-18,24
Rear brake automatic adjuster faulty Repair or replace adjuster BR-31
Brakes drag Parking brake out of adjustment Adjust parking brake BR-7
Linkage binding Repair as necessary
Booster push rod out of adjustment Adjust push rod BR-16
Return spring faulty Replace spring BR-31
Brake line restricted Repair as necessary
Lining cracked or distorted Replace brake shoes and pads BR-18, 24, 31
Wheel cylinder or caliper piston sticking Repair as necessary BR-18, 24, 31
Automatic adjuster broken Replace adjuster BR-31
Master cylinder faulty Repair or replace master cylinder BR-8
Brakes pull Tires improperly inflated Inflate tiers to proper pressure FA-3
Oil or grease on linings Check for cause/Replace shoes BR-18, 24, 31
Brake shoes distorted, linings worn or Replace brake shoes BR-31
glazed
Drum or disc out of round Replace drum or disc BR-18, 24, 31
Return spring faulty Replace spring BR-31
Piston frozen in caliper Repair caliper BR-18,24
Disc brake pad stickig Replace pads BR-18,24
Brakes grab/ Oil or grease on linings Check for cause/Replace shoes BR-18, 24, 31
chatter Drum or disc scored or out of round Replace drum or disc BR-18, 24, 31
Brake shoes distorted, linings worn or Replace brake shoes BR-31
glazed
Disc brake pad sticking Replace pads BR-18,24
Brake booster faulty Replace booster BR-14
BRAKE SYSTEM - Troubleshooting BR-3
Hard pedal but brakes Oil or grease on linings Check for cause. Replace shoes BR-18, 24, 31
inefficient Brake shoes distorted, linings worn or BR-31
Replace brake shoes
glazed, drums worn
Disc brake pads worn Replace pads BR-18,24
Piston frozen in caliper Repair caliper BR-18,24
Brake booster faulty Repair booster BR-14
Brake line restricted Repair as necessary
Snapping or clicking Drum brakes-brake shoes binding at Lubricate BR-31

noise when brakes are backing plate ledges
applied Drum brakes-backing plate ledges Replace and lubricate ledges BR-31
worn
Drum brakes-loose or missing hold- Replace BR-31
down spring
Drum brakes-loose set bolt at backing Tighten BR-31
plate
Disc brakes-rust on front edge of Inspect, lubricate or replace if BR-18,24
inboard shoes necessary
Disc brakes-loose or missing pad Replace BR-18,24
support plate
Disc brakes-loose installation bolt Tighten BR-18,24
Disc brakes-wear on slide bushing Replace BR-18,24
Scraping or grinding Worn brake linings Replace, refinish drums or rotors if BR-31
noise when brakes are heavily scored
applied Caliper to wheel or rotor interference Replace as required BR-18,24
Dust cover to rotor or drum interference Correct or replace
Other brake system components: Inspect and repair BR-18, 24,31
Warped or bent brake backing plate,
cracked drum or rotor
Tires rubbing against chassis and body Inspect and repair
Squealing, groaning or Brake drums and linings, rotors and pads Inspect, repair or replace BR-18, 24, 31
chattering noise when worn or scored
brakes are applied Disk brakes-missing or damaged brake BR-18,24
Replace
NOTE: Brake friction pad anti-squeal shim
materials inherently Disc brakes-burred or rusted calipers BR-18,24
Clean or deburr
generate noise and
heat in order to dis- Dirty, greased, contaminated or glazed Clean or replace BR-31
sipate energy. linings
As a result, occasional Improper lining parts Check for correct parts/Replace BR-31
squeal is normal and is Maladjustment of brake pedal or Inspect and adjust BR-5, 16
aggravated by severe booster push rod
environmental condi-
tions such as cold, Drum brakes-weak damaged or Inspect, repair or replace BR-31
heat, wetness, snow, incorrect shoe hold-down springs, loose
salt, mud, etc. or damaged shoe hold-down pins and
springs and grooved backing plate
This occasional squeal ledges
is not a functional pro-
blem and does not
indicate any loss of
brake effectiveness
BR-4 BRAKE SYSTEM - Troubleshooting
Squealing noise Bent or warped backing plate causing Repair or replace BR-31
when brakes are interference with drum
not applied Improper machining of drum causing Replace drum BR-31
interference with backing plate or shoe
Maladjustment of brake pedal or booster Inspect and adjust BR-5, 16
push rod
Poor return of brake booster or master Inspect, repair or replace BR-8, 14, 18,
cylinder or wheel cylinder 31
Disc brakes - rusted, stuck Inspect. Lubricate if necessary BR-18,24
Other brake system components: Inspect, repair or replace as required BR-31
Loose or extra parts in brakes
Rear drum adjustment too tight causing
lining to glaze
Worn, damaged or insufficiently
lubricated wheel bearings
Drum brakes - weak, damaged or Inspect, repair or replace BR-31
incorrect shoe return springs
Drum brakes - grooved backing plate BR-31
ledges
Improper positioning of pads in caliper Inspect and service BR-18,24
Outside diameter of rotor rubbing caliper Inspect, correct or replace BR-18,24
housing
Housing installation of disc brake pad Correct BR-18,24
support plate
Groaning, click- Stones or foreign material trapped inside Remove foreign material
ing or rattl ing wheel covers
noise when Loose wheel hub nuts Tighten to correct torque. Replace if
brakes are not stud holes are elongated
applied
Disc brakes-failure of shim Inspect. Replace if necessary BR-18,24
Disc brakes-wear on slide bushing Inspect. Replace if necessary BR-18,24
Disc brakes-loose installation bolt Inspect. Tighten if necessary BR-18,24
Maladjustment of brake pedal or booster Inspect and adjust BR-5, 16
push rod
Disc brakes-poor return of piston Inspect, repair or replace BR-18,24
Drum brakes-loose or extra parts Inspect, remove or repair BR-31
Worn, damaged or dry wheel bearings Inspect, lubricate or replace FA-8,52
RA-3
BRAKE SYSTEM - Checks and Adjustments BR-5
CHECKS AND ADJUSTMENTS

CHECK AND ADJUSTMENT OF BRAKE PEDAL
Pedal height from asphalt sheet: 148 - 158 mm
(5.83 - 6.22 in.)
If incorrect, adjust the pedal height.
2. IF NECESSARY, ADJUST PEDAL HEIGHT

(a) Sufficiently loosen the stop light switch and the
brake cancel switch for the cruise control.
(b) Adjust the pedal height by turning the pedal push
rod.
(c) Return the stop light switch until its body lightly con-
tacts the pedal stopper.
(d) After adjusting the pedal height, check and adjust the
Pedal Height
pedal freeplay.
BR0936
3. CHECK PEDAL FREEPLAY

(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the
booster.
(b) Push in the pedal until the beginning of resistance is
felt. Measure the distance, as shown.
Pedal freeplay: 1 - 3.5 mm (0.04 - 0.138 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY

(a) Check that the pedal height is correct.
(b) If incorrect, adjust by turning the pedal push rod.
(c) Adjust the stop light switch position until its body
slightly contacts with the stopper rubber.
BR0937
5. CHECK THAT PEDAL RESERVE DISTANCE IS

CORRECT
Pedal Reserve Distance
Release the parking brake. With the engine running,
depress the pedal and measure the pedal reserve distance,
as shown.
Pedal reserve distance from floor panel at 50 kg
,,
'>
" \
,
(110.2 Ib, 490 N): More than 60 mm (2.36 in.)
'< //",,- v
If incorrect, troubleshoot the brake system.
\ ... -_/
//7//////Y///J.,?
BR1083
BR-6 BRAKE SYSTEM - Checks and Adjustments
OPERATIONAL TEST OF BRAKE BOOSTER

NOTE: If the booster leaks or lacks vacuum, repair
before testing.
1. OPERATING CHECK
(a) Depress the brake pedal several times with the
engine off, and check that there is no change in the
pedal reserve distance. .
(b) Depress the brake pedal and start the engine. If the
pedal goes down slightly, operation is normal.
GOOD NO GOOD 2. AIR TIGHTNESS

(a) Start the engine and stop it after one or two minutes.
Depress the brake pedal several times slowly. If the
pedal goes fartherest down the first time, and gra-
dually rises after the second or third time, the booster
is air tight.
(b) Depress the brake pedal while the engine is running,
and stop it with the pedal depressed. If there is no
change in pedal reserve travel after holding the pedal
B1526 for thirty seconds, the booster is air tight.
BLEEDING OF BRAKE SYSTEM

NOTE: If any work is done on the brake system or if air is
suspected in the brake lines, bleed the system of air.
CAUTION: Do not let brake fluid remain on a painted
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID

Check the reservoir after bleeding each wheel. Add fluid, if
necessary.
BR1568
2. BLEED MASTER CYLINDER

NOTE: If the master cylinder was disassembled or if the
reservoir becomes empty, bleed the air from the master
cylinder.
(a) Disconnect the brake tubes from the master cylinder.
(b) Depress the brake pedal and hold it.
BR0938
(c) Block off the outlet holes with your fingers, and
release the brake pedal.
(d) Repeat (b) and (c) three or four times.
II '
I ,
I ,
I I
, ,
¢ ""'" " 's'
,-_..IJ \ \
BR0939
BRAKE SYSTEM - Checks and Adjustments BR-7
3. CONNECT VINYL TUBE TO WHEEL CYLINDER

BLEEDER PLUG
Insert other end of the tube in a half-full container of brake
fluid.
NOTE: Begin air bleeding from the wheel cylinder with
the longest hydraulic line.
4. BLEED BRAKE LINE

(a) Slowly pump the brake pedal several times.
L...-- B_15---l28 (b) While an assistant depresses the pedal, loosen the
bleeder plug until fluid starts to run out. Then close
the bleeder plug.
(c) Repeat this procedure until there are no more air bub-
bles in the fluid.
Bleeder plug tightening torque:
Front cylinder 85 kg-cm (74 in.-Ib, 8.3 N'm)
LSP & BV 85 kg-cm (74 in.-Ib, 8.3 N'm)
Rear cylinder 110 kg-cm (8 ft-Ib, 11 N'm)
5. REPEAT PROCEDURE FOR EACH WHEEL
6. BLEED LOAD SENSING PROPORTIONING AND

BY-PASS VALVE
BR0341
CHECK AND ADJUSTMENT OF PARKING

BRAKE
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the
number of clicks.
Parking brake lever travel
at 20 kg (44.1 Ib, 196 N):
BR1082 YR 22, 31, 32 series: 7 - 9 clicks
YR 29 series: 6 - 8 clicks
2. IF NECESSARY, ADJUST PARKING BRAKE

NOTE: The rear brake shoe clearance should be adjusted
before adjusting the parking brake.
For shoe clearance adjustment, see step 9 on page BR-39.
Adjust the parking brake lever travel by turning the ad-
justing nut.
BR1130
BR-8 BRAKE SYSTEM - Master Cylinder
MASTER CYLINDER
REMOVAL OF MASTER CYLINDER
Speedometer Cable Combination Meter

Wiring Connector Cluster Finish Panel
Vacuum Check Valve Bracket---
Master Cylinder _
Cluster Finish Lower Panel
Reservoir Hose _ _---1..----1
Air Duct No. 1
Air Duct No.2
Air Duct No. 3

I kg-em (ft-Ib, N'm)1 : Specified torque SRl569
,. DISCONNECT NEGATIVE CABLE FROM BATTERY

TERMINAL
2. REMOVE FOLLOWING PARTS:

(a) Cluster finish panel (See page CL-4)
(b) Combination meter
(c) Cluster finish lower panel
(d) Air duct No. 3
(e) Air duct No. 1 and No.2
BRAKE SYSTEM - Master Cylinder BR-9
3. TAKE OUT FLUID WITH SYRINGE

CAUTION: Do not let brake fluid remian on a painted
4. DISCONNECT TWO BRAKE TUBES

SST Using SST, disconnect the two brake tubes from the master
cylinder.
SST 09751 -36011
BR1570
5. DISCONNECT TWO RESERVOIR HOSES FROM

MASTER CYLINDER
Using pliers, disconnect the two reservoir hoses from the
master cylinder.
BR1571
6. REMOVE BRAKE MASTER CYLINDER

Remove the mounting nuts and vacuum check valve
bracket, and then pull out the master cylinder.
COMPONENTS
i~
@
~
Union Bolt
1550 (40, 54) I
• G a s k e t - - - - -.....I-~~ ~ • Gasket
~ ~lnletUnion
~ • Gasket
Stopper Bolt - - - - - - - - - - - - - - '

I 100 (7, 10) I
I~~f---snap Ring
Spring No 2 Piston Spring No. 1 Piston
I kg-cm (ft-Ib, N·m~ : Specified torque

• Non-reusable part BR1573
DISASSEMBLY OF MASTER CYLINDER

1. PLACE CYLINDER IN VISE
2. REMOVE INLET UNIONS
BR1574
3. REMOVE PISTON STOPPER BOLT

Using a screwdriver, push the pistons in all the way and
remove the piston stopper bolt.
BR0668
4. REMOVE TWO PISTONS AND SPRINGS

BR0669
(b) Remove two pistons and springs from the master

cylinder.
NOTE: It may be necessary to inject compressed air in
'<, the hole to force out the No.2 piston, as shown.
BR0670
INSPECTION OF MASTER CYLINDER

NOTE: Clean the disassembled parts with compressed
air.
1. INSPECT CYLINDER BORE FOR RUST AND

SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE

If necessary, clean or replace the cylinder.
ASSEMBLY OF MASTER CYLINDER

(See page BR-9)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO

RUBBER PARTS OF PISTON
2. INSTALL TWO SPRINGS AND PISTONS

CAUTION: Be careful not to damage the rubber lips
on the pistons.
BR0616 (a) Insert two springs and pistons in the master cylinder
housing as shown.
\
t
BR0669
3. INSTAll PISTON STOPPER BOLT

Using screwdriver, push the pistons in all the way and
in$tall the piston stopper bolt over the gasket.
Torque the bolt.
BR0668
4. INSTAll TWO INLET UNIONS

Install the inlet union over the gaskets.
BR1575
INSTALLATION OF MASTER CYLINDER

(See page BR-8)
1. ADJUST lENGTH OF BRAKE BOOSTER PUSH ROD

BEFORE INSTALLING MASTER CYLINDER
(See step 1 on page BR-16)
BROO20
2. INSTAll MASTER CYLINDER

Install the master cylinder to the brake booster with four
nuts. Torque the nuts.
BR1572
3. CONNECT TWO RESERVOIR HOSES TO MASTER

CYLINDER
'~ Using pliers, connect the two reservoir hoses to the master
cylinder.
o
t
~..~
l~
~~ BR1571
4. CONNECT TWO BRAKE TUBES

First, tighten the nuts by finger, then with SST.
SST 09751-36011
BR1570
5. INSTALL FOLLOWING PARTS

(a) Air duct No. 1 and No.2
(b) Air duct No.3
(c) Combination meter
(d) Cluster finish panel
(e) Cluster finish lower panel
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND

BLEED BRAKE SYSTEM (See page BR-6)
8. CHECK FOR LEAKES
9. CHECK AND ADJUST BRAKE PEDAL

(See page BR-5)
BR-14 BRAKE SYSTEM - Brake Booster
BRAKE BOOSTER
REMOVAL OF BRAKE BOOSTER
Cluster Finish Panel
tQb-1
Air Duct No.3
Reservoir Hose I ...
Air Duct No.2
Air Duct NO.1
Ikg-cm (ft-Ib, N·m) I Specified torque

BR1576
1. REMOVE MASTER CYLINDER

(See page BR-8)
2. DISCONNECT VACUUM HOSE FROM BRAKE

BOOSTER
3. REMOVE STEERING COLUMN ASSEMBLY

(a) Remove the cluster finish lower panel.
(b) Remove the steering column assembly.
(See page SR-4)
4. DISCONNECT CONNECTORS
Disconnect the four connectors.
5. PERFORM FOLLOWING STEPS

(a) Loosen the clutch pedal installation nut and bolt.
Remove the nut and pull out the bolt until the bolt
head goes in.
(b) Loosen the two clutch master cylinder installation
bolts and pull out them until brake pedal bracket is free
from the clutch master cylinder.
BR1577
(c) Pull out the throttle cable from the cable hook.
BRAKE SYSTEM - Brake Booster BR-15
6. REMOVE BRAKE BOOSTER WITH PEDAL BRACKET

(a) Remove the three mounting bolts of the pedal bracket
lower side.
BR1578
(b) Remove the two mounting bolts of the pedal bracket

upper side.
(c) Pull out the brake booster with bracket to underside.
BR1579
7. REMOVE BRAKE BOOSTER FROM PEDAL BRACKET

(a) Remove the cotter pin and clevis pin.
(b) Remove the four nuts and remove the booster from
the bracket.
BR1580
BR-16 BRAKE SYSTEM - Brake Booster
INSTALLATION OF BRAKE BOOSTER

(See page BR-14)
1. ADJUST LENGTH OF BOOSTER PUSH ROD

(a) Set SST on the master cylinder, and lower the pin until
its tip slightly touches the piston.
SST 09737-00010
BR0419
(b) Turn SST upside down, and position it on the booster.

SST 09737-00010
(c) Measure for clearance between the booster push rod
f------SST
and pin head (SST).
Clearance: 0 mm (0 in.)
B1255
(d) Adjust the booster push rod length until the push rod
lightly touches the pin head.
BR0020
2. INSTALL BRAKE BOOSTER TO PEDAL BRACKET

(a) Install the brake booster to the pedal bracket with the
four nuts.
(b) Connect the brake pedal and clevis with the clevis pin
and new cotter pin.
BR15BO
3. INSTAll BRAKE BOOSTER WITH PEDAL BRACKET

(a) Insert the booser with bracket from the underside.
(b) Tighten the two mounting bolts of the pedal bracket
uppers ide.
BR1579
BRAKE SYSTEM - Brake Booster BR-17
(c) Tighten the three mounting bolts of the pedal bracket

lowers ide.
BR1578
4. PERFORM FOLLOWING STEPS

(a) Tighten the clutch master cylinder installation bolts.
(b) Install the clutch pedal return spring and tighten the
pedal installation bolt and nut.
(c) Hook the throttle cable to the cable hook.
BR1577
5. CONNECT CONNECTORS
Connect the four connectors.
6. INSTALL STEERING COLUMN ASSEMBLY

(a) Install the steering column assembly.
(See page SR-13)
(b) Install the cluster finish lower panel.
SR2091
7. INSTALL MASTER CYLINDER

(See page BR-12)
8. CONNECT VACUUM HOSE TO BRAKE BOOSTER

10. CHECK FLUID LEAKAGE
11. CHECK AND ADJUST BRAKE PEDAL

(See page BR-5)
12. PERFORM OPERATIONAL CHECK

(See page BR-6)
BR-18 BRAKE SYSTEM - Front Brake
FRONT BRAKE
(2WD)
COMPONENTS
~.~"'I------Disc Brake Cylinder
p-Installation Bolt
[ 200 (1 ~,_ 20) ]
\tP ~ Torque Plate Bleeder Plug
1--J Pad Guide Plate

Main Pin Boot IS5 (74 in.-Ib, 8.31 1
Anti-Rattle Spring
Pad Support Plate
Anti-Squeal Shim
Piston
SealI
~ \ \\ \ fl~
Pad
Anti-Squeal Shim
/
[k9-~cm(ft=Tb, N'~
: Specified torque ~slBushing BR1581
BR1582
REPLACEMENT OF BRAKE PADS

NOTE: If a squealing noise occurs from the front brakes
while driving, check the pad wear indicator. If there are
Pad Wear traces of the indicator contacting the rotor disc, the brake
Indicator
pad should be replaced.
Rotor Disc
BROO04
1. INSPECT PAD LINING THICKNESS

Check the pad thickness through the cylinder inspection
hole and replace the pads if not within specification.
BR1583
BRAKE SYSTEM - Front Brake BR-19
2. REMOVE CYLINDER INSTALLATION BOLT

Hold the sliding bushing and remove the bolt.
BR1584
3. LIFT UP CYLINDER
(a) Lift up the cylinder.
(b) Insert a bolt into the torque plate hole to secure the
cylinder.
BR1585
4. REMOVE FOLLOWING PARTS

(a) Two anti-squeal shims
(b) Two brake pads
(c) Three anti-rattle springs
(d) Pad guide plate
(e) Pad support plate
BR1645
5. INSTALL PAD SUPPORT PLATE, PAD GUIDE PLATE

AND ANTI-RATTLE SPRINGS
(a) Pad support plate
(b) Pad guide plate
BR1097
Outside Inside 6. INSTALL NEW PADS AND ANTI-SQUEAL SHIMS

(a) Install the pads onto each spring or plate.
NOTE: Install the outside pad so the wear indicator is at
the lower side.
BR1586
(b) Install the anti-squeal shims to the pads as shown.
BR1646
7. LOWER CYLINDER
NOTE: Insert the cylinder carefully so the boot is not
wedged.
8. INSTALL CYLINDER INSTALLATION BOLT

Install and torque the cylinder installation bolt.
BR1588
REMOVAL OF CYLINDER
(See page BR-18)
1. DISCONNECT BRAKE LINE

Remove the union bolt and disconnect the brake line.
Use a container to catch the brake fluid.
BR1587
2. REMOVE CYLINDER
Remove the cylinder installation bolt.
Remove the cylinder from the main pin of the torque plate.
3. REMOVE PADS AND ANTI-SQUEAL SHIMS

(See page BR-19)
4. REMOVE ANTI-RATTLE SPRINGS, PAD GUIDE PLATE

AND SUPPORT PLATE
BR1584BRll01
DISASSEMBLY OF CYLINDER
(See page BR-18)
1. REMOVE SLIDING BUSHING AND BOOT
BR1589 BR1590
2. REMOVE MAIN PIN BOOT

Using a chisel and hammer, remove the main pin boot.
3. REMOVE SET RING AND CYLINDER BOOT FROM

CYLINDER
BR1591
4. REMOVE PISTON FROM CYLINDER

Use compressed air to remove the piston from the cylinder.
WARNING: Do not place your fingers in front of the
piston when using compressed air.
5. REMOVE PISTON SEAL FROM CYLINDER
BR1592 B1022
INSPECTION OF FRONT BRAKE

COMPONENTS
1. MEASURE PAD LINING THICKNESS
M inimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the thickness is less than the minimum
(the 1.0 mm slit is no longer visible) or if it shows sign of
uneven wear.
BR0791
2. MEASURE ROTOR DISC THICKNESS

Standard thickness: 20.0 mm (0.787 in,)
Minimum thickness: 19.0 mm (0.748 in,)
If the disc thickness is less than minimum, replace the
disc.
BR1107
3. MEASURE ROTOR DISC RUNOUT

Measure the rotor disc runout at 10 mm (0.39 in.) from the
outer edge of the rotor disc.
Maximum disc runout: 0.15 mm (0.0059 in,)
If the runout is greater than the maximum, replace the
disc.
NOTE: Make sure the front bearing is adjusted correctly
before measuring the runout.
BR 1108
4. IF NECESSARY, REPLACE ROTOR DISC

(a) Remove the torque plate from the knuckle.
(b) Remove the axle hub. (See page FA- 7)
(c) Remove the disc from the axle hub.
(d) Install a new rotor disc. Torque the four bolts.
(e) Install the axle hub and adjust the front bearing
preload. (See page FA-8)
BR0651
(f) Install the torque plate onto the knuckle.
Grease ASSEMBLY OF CYLINDER

(See page BR-18)

FOLLOWING PARTS
(a) Main pin boot
Grease (b) Sliding bushing and boot

BR1582 (c) Piston seal and piston
(d) Dust boot
2. INSTALL PISTON SEAL AND PISTON IN CYLINDER
3. INSTALL CYLINDER BOOT AND SET RING IN

CYLINDER
BR0564 B 1020
4. INSTALL MAIN PIN BOOT

Using a 22-mm socket, install the boot.
BR1593
5. INSTALL DUST BOOT AND SLIDING BUSHING

(a) Install the dust boot.
NOTE: Be careful that the seal does not fold under.
(b) Install the bushing into the boot, facing the flange
toward the inside.
BR15B9
INSTALLATION OF CYLINDER
(See page BR-18)

(b) Pad guide plate
(d) Two brake pads
BR1645 (e) Two anti-squeal shims
2. INSTALL CYLINDER
(a) Install the cylinder onto the main pin.
NOTE: Make sure that the boot end is installed into the
groove of the main pin.
(b) Install the cylinder over the brake pads.

Install the cylinder installation bolt and torque it.
NOTE: Insert the installation bolt into the cylinder
carefully so as not to wedge the boot.
BR1588
4. INSTALL FLEXIBLE HOSE TO BRAKE CYLINDER

Set the flexible hose and new gaskets in position and install
the union bolt.

6. CHECK FOR FLUID LEAKAGE
BR 1587
FRONT BRAKE
(4WD)
COMPONENTS
Brake Hose
Rotor Disc ---Ir
370 ± 50 (27 ± 4, 36 ± 5)
t::::=l
Pad Guide Plate ~~
:::-:::~:r::::~ (\.'~~ ~~_squeal .. \ Shim Main Pin Biot

Bleeder Plug
85 (74 in.-Ib, 8.3)
Pad ~~~ Torque Plate ~
Anti-Rattle Spring
Anti Squeal Spring t ~ o~
~ Sliding Bushing
I kg-cm (ft-Ib, N·m) I: Specified torque Boot
BR1370
REPLACEMENT OF BRAKE PADS

NOTE: If a squealing noise occurs from the front brakes
-Pad Wear while driving, check the pad wear indicator plate. If there
~~===-'I Indicator are traces of the indicator contacting the rotor disc, the
brake pad should be replaced.
Rotor Disc
BROO04
1. INSPECT PAD LINING THICKNESS

Check the pad thickness through the cylinder inspection
hole and replace pads if not within specification.
BR1371
2. REMOVE CYLINDER INSTALLATION BOLT

Hold the sliding bushing and remove the bolt.
~
~ BR1372
3. LIFT UP CYLINDER
(a) Lift up the cylinder.
(b) Insert a bolt into the torque plate hole to secure the
cylinder.
BR1373
4. REMOVE ANTI-SQUEAL SPRINGS, PADS AND

ANTI-SQUEAL SHIMS
5. REMOVE ANTI-RATTLE SPRINGS, PAD GUIDE PLATE

AND SUPPORT PLATE
BR1374

(b) Pad guide plate
BR1375
7. INSTALL NEW PADS AND ANTI-SQUEAL SHIMS

(a) Install the pads onto each spring or plate.
(b) Install the anti-squeal shims as shown.
(c) Install the anti-squeal springs.
. d;/ . V
Y j)
BR1677
8. LOWER CYLINDER
NOTE: Insert the cylinder carefully so the boot is not
wedged, and check that the dust b,Jot is not folded into the
bushing groove.

Install and torque the cylinder installation bolt.
Torque: 370 ± 50 kg-em (27 ± ft-Ib, 36 ±5 N'm)
BR1377
REMOVAL OF CYLINDER
(See page BR-24)
1. DISCONNECT BRAKE HOSE

(a) Disconnect the clip.
(b) Using SST to hold the tube, and a wrench to hold the
hose, disconnect the tube and hose.
BR1378
(c) Disconnect the brake hose from the brake cylinder.
BR1379
2. REMOVE CYLINDER
(a) Remove the cylinder installation bolt.
(b) Remove the cylinder from the main pin of the torque
plate.
BR1372
3. REMOVE FOLLOWING PARTS

(a) Two anti-squeal springs
(b) Two anti-squeal shims
(c) Two brake pads
(d) Three anti-rattle springs
(e) Pad guide plate
(f) Pad support plate
BR1678
DISASSEMBLY OF CYLINDER
(See page BR-24)
1. REMOVE SLIDING BUSHING AND BOOT
BR13B1 BR1382
2. REMOVE MAIN PIN BOOT

Using a chisel and hammer, remove the main pin boot.
BR 1383
3. REMOVE SET RINGS FROM CYLINDER

Using a screwdriver, remove the two set rings.
BR1384
4. REMOVE PISTONS FROM CYLINDER

Use compressed air to remove the pistons from the cylinder.
WARNING: Do not plate your fingers in front of the
piston when using compressed air.
5. REMOVE CYLINDER BOOTS FROM EACH PISTON
BR1385
6. REMOVE PISTON SEALS FROM CYLINDER

Using a screwdriver, remove the two piston seals from the
brake cylinder.
BR 1386
INSPECTION OF FRONT BRAKE

COMPONENTS
1. MEASURE PAD LINING THICKNESS
Replace the pad if the thickness is less than the minimum
(the 1.0 mm slit is no longer visible) or if shows signs of
uneven wear.
BR0791
2. MEASURE ROTOR DISC THICKNESS

If the disc thickness is less than minimum, replace the disc.
BR1387
3. MEASURE ROTOR DISC RUNOUT

Measure the rotor disc runout at 10 mm (0.39 in.) from the
outer edge of rotor disc.
Maximum disc runout: 0.15 mm (0.0059 in.)
If the runout is greater than the maximum, replace the disc.
NOTE: Make sure the front bearing is adjusted correctly
before measuring the runout.
BR1388
4. IF NECESSARY, REPLACE ROTOR DISC

(a) Remove the torque plate from the knuckle.
(b) Remove the axle hub.
(c) Remove the disc from the axle hub.
BR1151
(d) Install a new rotor disc. Torque the five bolts.

Torque: 650 ± 100 kg-cm (47 ± 7 ft-Ib, 64 ± 10 N'm)
(e) Install the axle hub and adjust the front bearing
preload.
(f) Install the torque plate onto the knuckle.
Torque: 850 ± 100 kg-cm (61 ± 7 ft-Ib, 83 ± 10 N'm)
BR1152
ASSEMBLY OF CYLINDER
(See page BR-24)
c ~o
FOLLOWING PARTS
(a) Main pin boot
(b) Sliding bushing and boot
(c) Piston seals and pistons
(d) Cylinder boots
BR1389
2. INSTALL PISTON SEALS AND PISTONS IN CYLINDER

Install the two piston seals and two pistons into the brake
cylinder.
BR1390 BR1391
3. INSTALL CYLINDER BOOTS AND SET RINGS IN

CYLINDER
Install the cylinder boot and set ring to each piston.
BR 1392
4. INSTALL MAIN PIN BOOT

Using a 22 mm socket wrench, press in the boot.
BR1393
5. INSTALL DUST BOOT AND SLIDING BUSHING

(a) Install the dust boot.
NOTE: Be careful that the seal does not fold under.
(b) Install the bushing into the boot facing the flange
toward the inside.
NOTE: Check that the dust boot is not folded into the
bushing groove.
BR1382 BR1381
INSTALLATION OF CYLINDER
(See page BR-24)
(b) Pad guide plate
(d) Two brake pads
BR1678
(e) Two anti-squeal shims
(f) Two anti-squeal springs
2. INSTALL CYLINDER
(a) Install the cylinder onto the main pin.
NOTE: Make sure that the boot end is installed into the
groove of the main pin.
(b) Install the cylinder over the brake pads.
NOTE: Check that the dust boot is not folded into the
bushing groove.
BR 1394

Install the cylinder installation bolt and torque the bolt.
Torque: 370 ± 50 kg-em (27 ± 4 ft-Ib, 36 ± 5 N'm)
NOTE: Insert the installation bolt into the cylinder care-
fully so as not to wedge the boot.
BR1377
4. CONNECT BRAKE HOSE

(a) Connect the brake hose to the brake cylinder.
BR 1379
(b) Connect the hose and tube by hand.

(c) Using SST to hold the tube, and a wrench to hold the
SST hose, torque the connection.
SST 09751-36011

BR1378
BRAKE SYSTEM - Rear Brake BR-31
REAR BRAKE
COMPONENTS
Bleeder Plug
I 110 (8, 11) I
Backing Plat~ '~It;'~de~r~~~~~~~~~~~~~~~~~~~=:i:::n

100 (7.
• ~Q)r . 1/ ~----------Piston
~---------------4l
•• C-Washer
Cup
Spring /
I
@r'
w__ Adjusting Washer
i l-........ Parking Brake Lever
Rear Shoe / /./ ~& Automatic Adjusting
~ , ~ ~~~waSher
-', i-~- "~\l\
~J@~~~~
"
__ Spring
AdjUster
Front Shoe
Anchor spring~§~
:::J~ -
Cup
Shoe Hold-Down Spring
Return Spring
Brake Drum
kg-cm (ft-Ib, N·m) : Specified torque
Non-reusable part BR1112
REMOVAL OF REAR BRAKE

1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than minimum, replace the shoes.
2. REMOVE REAR WHEEL

BR1594
3. REMOVE BRAKE DRUM

NOTE: If the brake drum cannot be removed easily,
perform the following steps.
(a) Insert a screwdriver through the adjusting hole in the
backing plate, and hold the automatic adjusting lever
away from the adjuster.
(b) Using another screwdriver, reduce the brake shoe
adjustment by turning the front shoe.
BRll13
BR-32 BRAKE SYSTEM - Rear Brake
4. REMOVE FRONT SHOE

(a) Using SST, remove the return spring.
SST 09703-30010
BRll14
(b) Remove the shoe hold-down spring, cups and pin.

(c) Disconnect the anchor spring from the front shoe and
remove the front shoe.
(d) Remove the anchor spring from the rear shoe.
BR0530 BR0531
5. REMOVE REAR SHOE

(a) Remove the shoe hold-down spring, cups and pin.
(b) Using a screwdriver, disconnect the parking brake
cable from the anchor plate.
(c) Using pliers, disconnect the parking brake cable from
the lever and remove the rear shoe together with the
adjuster.
6. REMOVE ADJUSTER FROM REAR SHOE

(a) Remove the adjusting lever spring.
(b) Remove the adjuster.
BR0533 BR0534
7. DISCONNECT BRAKE TUBE FROM WHEEL CYLINDER

Using SST, disconnect the brake line. Use a container to
catch the brake fluid.
SST 09751-36011
B1042
8. REMOVE WHEEL CYLINDER

Remove the two bolts and the wheel cylinder.
E0540
9. IF NECESSARY, DISASSEMBLE WHEEL CYLINDER

Remove the following parts from the wheel cylinder.
@t,~~~Q.
~
• Two boots
• Two pistons
'
~9'~PistonReturn Spring • Two piston cups
• Spring
I Piston Cup
Piston
Boot
BRll15
INSPECTION AND REPAIR OF REAR BRAKE

COMPONENTS
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS

If the shoe lining is less than minimum or shows signs of
uneven wear, replace the brake shoes.
NOTE: If any of the brake shoes have to be replaced,
replace all of the rear shoes in order to maintain even
braking.
B0930
3. MEASURE BRAKE DRUM INSIDE DIAMETER

Standard inside diameter: 254.0 mm (10.000 in.)
Maximum inside diameter: 256.0 mm (10.079 in.)
If the drum is scored or worn, the brake drum may be lathed
to the maximum inside diameter.
4. INSPECT REAR BRAKE LINING AND DRUM FOR

PROPER CONTACT
If the contact between the brake lining and drum is
improper, repair the lining with a brake shoe grinder, or
replace the brake shoe assembly.
B1045 5. MEASURE CLEARANCE BETWEEN BRAKE SHOE

AND LEVER
Shim
Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within specification, replace the shim
with one of the correct size.
Thickness mm(in.)
Clearance 0.2 (0.008) 0.5 (0.020)

0.3 (0.012) 0.6 (0.024)
0.4 (0.016) 0.9 (0.035)
BR0535 D0608
6. IF NECESSARY, REPLACE SHIM

(a) Remove the parking brake lever, and install the correct
size shim.
BROO87
(b) Install the parking brake lever with a new C-washer.

(c) Remeasure the clearance.
BROO88
INSTALLATION OF REAR BRAKE

(See page BR-37)
NOTE: Assemble the parts in the correct direction as
shown.
Right-Hand Threads Left-Hand Threads
Front .. . . Front
Left Wheel Right Wheel BR1595
1. ASSEMBLE WHEEL CYLINDER

(a) Apply lithium soap base glycol grease to the cups and
pistons as shown.
(b) Assemble the wheel cylinder.
NOTE: Install in proper direction only.
• Spring
• Two cups
• Two pistons
BR1115
• Two boots
2. INSTALL WHEEL CYLINDER

Install the wheel cylinder on the backing plate with two
bolts.
E0540
3. CONNECT BRAKE TUBE TO WHEEL CYLINDER

Using SST, connect the brake tube.
SST 09751-36011
B1042
4. APPLY HIGH TEMPERATURE GREASE TO BACKING

PLATE AND ADJUSTER
(a) Apply high temperature grease to the brake shoe
contact surfaces as shown.
BRl117
(b) Apply high temperature grease to the adjuster bolt

threads and ends.
BR0397
5. INSTALL ADJUSTER ONTO REAR SHOE

Set the adjuster in place and install the adjusting lever
spring.
BR0534 BR0533
6. INSTALL REAR SHOE

(a) Using pliers, connect the parking brake cable to the
lever.
(b) Pass the parking brake cable through the notch in the
anchor plate.
(c) Set the rear shoe in place with the end of the shoe
inserted in the wheel cylinder and the other end in the
anchor plate.
(d) Install the shoe hold-down spring, cups and pin.

CAUTION: Do not allow oil or grease to get on the
rubbing face.
BR0537
7. INSTALL FRONT SHOE

(a) Install the anchor spring between the front and rear
shoes.
(b) Set the front shoe in place with the end of the shoe
inserted in the wheel cylinder and the adjuster in
place.
BR0531 BR0538
(c) Install the shoe hold-down spring, cups and pin.

CAUTION: Do not allow oil or grease to get on the
rubbing face.
J~.~_"\\.'~. rJ
-~
".1./
, i
4 l-
8R0530
(d) Using SST, install the return spring.

SST 09703-30010
-SST
BR1118
8. CHECK OPERATION OF AUTOMATIC ADJUSTING

MECHANISM
(a) Move the parking brake lever of the rear shoe back and
forth, as shown. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation
of the rear brakes.
8R1119
(b) Adjust the adjuster length to the shortest possible

amount.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a
cliking sound can no longer be heard.
8Rl08281059
9. CHECK CLEARANCE BETWEEN BRAKE SHOES AND

DRUM
(a) Remove the brake drum.
(b~ Measure the brake drum inside diameter and diameter
of the brake shoes. Check that the difference between
the diameters is the correct shoe clearance.
Shoe clearance: 0.6 mm (0.024 in.)
If incorrect, check the parking brake system.
B 1043 BR0543
10. INSTALL BRAKE DRUM
11. INSTALL REAR WHEEL

BLEED BRAKE SYSTEM
(See page BR-6)
13. CHECK FOR FLUID LEAKAGE

BR-40 BRAKE SYSTEM - LSP & BV
LOAD SENSING PROPORTIONING

AND BY-PASS VALVE (LSP & BV)
COMPONENTS
Valve Bracket r, _ r---G95 (14,19) I

" ~:'~ ~ 155(11,15) I
I I
I
I
I
I
I
I
I
'1 @ ---:-------
J --- "..j Laod Sensing Proportioning
C 01-------- and By-pass Valve
'fii)
~~--------1130(9,13) 1
Bleeder Plug
85 (74 in.-Ib, 8.3) ~r-----------,__C-lip--
1"--------1 185 (13, 18) 1
"'4E"'''''':::------Load Sensing Spring Assembly
Plate Washer
Head Insulator
@b ® 1 185 (13,18) I
- - - - - - - - - .....•
Load Sensing Valve Boot
~@@))
~ShaCkleNo. 1
~~collar
@~, -Bushing
!250(18,25J]---@
~
~-----ShackleNo.2
• Cotter Pin
<"-~-
- Load Sensing
Spring
Rubber Plate
Bushing ~~ @j))0
SenSing~
195 (14,19)
, Load
L.... Spring Boot - - - - ..... ~
Cushion Retainer
kg-cm (ft-Ib, N·m) I: Specified torque
Shackle Bracket
• Non-reusable part BR1445
CHECK AND ADJUSTMENT OF FLUID

PRESSURE
1. SET REAR AXLE LOAD
Rear axle load (include vehicle weight):
2WD 950 kg (2,094 Ib)
4WD 900 kg (1,984 Ib)
BRl121
BRAKE SYSTEM - LSP & BV BR-41
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR

SST
SST 09709-29017
BRl122
3. RAISE FRONT BRAKE PRESSURE TO 50 kg/em

(711 psi, 4,903 kPa) AND CHECK REAR BRAKE
PRESSURE
Rear brake pressure: 29.0 ± 5 kg/em 2
(412 ± 71 psi, 2,844 ± 490 kPa)
NOTE: The brake pedal should not be depressed twice
and/or returned while setting to the specified pressure.
Read the value of rear pressure two seconds after adjusting
the specified fluid pressure.
BRl142
4. RAISE FRONT BRAKE PRESSURE TO 100 kg/em 2

(1,422 psi, 9.807 kPa) AND CHECK REAR BRAKE
PRESSURE
Rear brake pressure: 34.0 ± 7 kg/em 2
(484 ± 100 psi, 3,334 ± 686 kPa)
If the brake pressure is incorrect, adjust the fluid pressure.
BRl143
5. IF NECESSARY, ADJUST FLUID PRESSURE

(a) Adjust the length of the No.2 shackle.
Low pressure - Lengthen A
High pressure - Shorten A .
Initial set: 78 mm (3.07 in.)
Adjusting range: 72 - 84 mm (2.83 - 3.31 in.)
NOTE: One turn of the No.2 shackle changes the fluid
pressure about 1.0 kg/cm 2 (14.2 psi, 98 kPa).
BROO63
(b) In event pressure cannot be adjusted by the No. 2

t shackle, raise or lower the valve body.
Low pressure - Lower
High pressure - Raise
(c) Torque the nuts.
, BRl125
Torque:
(d)
130 kg-em (9 ft-Ib, 13 N'm)
Adjust the length of the No.2 shackle again.
If it cannot be adjusted, inspect the valve housing.
6. IF NECESSARY, CHECK VALVE BODY

(a) Assemble the valve body in the upper most position.
NOTE: When the brakes are applied, the piston will move
down about 1 mm (0.04 in.). Even at this time, the piston
should not make contact with or move the load sensing
spring.
(b) In this position, check the rear brake pressure
kg/cm 2 (psi, kPa)
BRl125 BR0218
Front brake pressure Rear brake pressure
5 (71,490) 5 (71,490)
5.0 - 9.0
25 (356, 2,452)
5, 25, 60 kg/cm 2 (71 - 128, 490 - 883)
7.0 - 14.0
60 (853, 5,884)
(100 - 199, 686 - 1,373)
If the measured value is not within standard, replace the

valve body.
BR1142
REMOVAL OF lSP & BV

(See page BR-40)
1. DISCONNECT SHACKLE NO.2 FROM BRACKET

(a) Remove the cotter pin.
(b) Remove the nut and disconnect the shackle NO.2 from
the bracket.
(c) Remove the retainer, two bushings and collar.
BR1596
2. REMOVE LSP & BV ASSEMBLY

(a) Using SST, disconnect the brake tubes from the valve
body.
SST 09751-36011
SST .~.
~
BRl126
(b) Remove the valve bracket mounting bolts and remove

the LSP & BV assembly.
BR1127
DISASSEMBLY OF lSP & BV ASSEMBLY

1. REMOVE VALVE BRACKET
(a) Remove the nut and bolt as shown.
(b) Remove the two nuts, and remove the bracket and set
plate from the valve body.
BR 1597
2. DISCONNECT SPRING FROM VALVE

Using a pliers, remove the clip, and remove the spring from
the valve.
BR1290
3. REMOVE SHACKLE NO.1 AND NO.2

Remove the nut and bolt, and then remove the shackle No.
1 and No.2 and two plate washers from the load sensing
spring assembly.
03711
4. DISASSEMBLE LOAD SENSING SPRING

Disassemble the following parts.
(a) Bushings
(b) Collars
(c) Rubber plates
(d) Load sensing valve boot
(e) Load sensing spring boot
BR0589
INSPECTION OF LSP & BV

INSPECT VALVE PISTON PIN AND LOAD SENSING
SPRING CONTACT SURFACE FOR WEAR
Wear limit: 0.7 mm (0.028 in.)
Wear Limit 0.7 mm
BR0218 BROO68
ASSEMBLY OF LSP & BV ASSEMBLY

(See page BR-40)
1. ASSEMBLE FOLLOWING PARTS TO LOAD SENSING

SPRING
(a) Load sensing valve boot
(b) Load sensing spring boot
(c) Collars
(d) Rubber plates
BROO69
(e) Bushings
NOTE: Apply lithium soap base glycol grease to all
rubbing areas.
Do not mistake the valve side for the shackle side of the load
sensing spring.
Valve Side Shackle Side
BROO70
2. INSTALL SHACKLE NO.1 AND NO.2 TO LOAD

SENSING SPRING
Install the shackle to the load sensing spring through the
t.wo plate washers.
D3715
3. INSTALL LOAD SENSING SPRING TO VALVE BODY

Install the load sensing spring assembly to the valve body
with a clip.
BR1290
4. INSTALL VALVE BRACKET

(a) Install the set plate to the valve assembly and
temporarily tighten the two valve body mounting nuts.
BR1598
(b) Install the valve assembly to the bracket and torque

the bolt and nut of load sensing spring boot through
the two plate washers.
BR1597
INSTALLATION OF LSP & BV

1. INSTALL LSP & BV ASSEMBLY
Install the LSP & BV assembly to the frame with four bolts.
BR1127
2. CONNECT BRAKE TUBES

Using SST, connect the brake tubes.
\ BRl126
3. CONNECT SHACKLE NO.2 TO BRACKET

(a) Set the dimension A by turning shackle No.2.
Initial set: 78 mm (3.07 in.)
BROO63
(c) Install the two bushings and a collar to the load

sensing spring shackle.
(d) Install the load sensing spring to the shackle bracket
with a retainer and nut.
(e) Install the new cotter pin.
4. SET REAR AXLE LOAD

(See page BR-40)
BR 1596
5. SET VALVE BODY

(a) When pulling down the load sensing spring, confirm
that the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly
contacts the load sensing spring.
BR0218
(c) Tighten the valve body mounting nuts.

BR1125
6. BLEED BRAKE SYSTEM

(See page BR-6)
8. CHECK AND ADJUST LSP & BV FLUID PRESSURE

(See page BR-41)
BRl122
BRAKE SYSTEM - Brake Hoses and Tubes BR-47
BRAKE HOSES AND TUBES
t- TUbe
DISCONNECT AND CONNECT HOSE AND
TUBE
1. DISCONNECT HOSE AND TUBE
(a) Remove the clip.
(b) Using SST to hold the tube and a wrench to hold the
hose, disconnect the tube and hose.
Hose BR0795 SST 09751-36011
2. CONNECT HOSE AND TUBE

(a) Connect the hose and tube by hand.
(b) Using SST to hold the tube and a wrench to hold the
hose, torque the connection.
SST 09751-36011
(c) Install a hose clip.
BR0287
INSEPCTION OF BRAKE HOSES AND TUBES

1. INSPECT BRAKE HOSES
~\
(a) Inspect the hose for damage, cracks or swelling.
(b) Inspect the threads for damage.
~---------
BR0591
2. INSPECT BRAKE TUBES

(a) Inspect the tube for damage, cracks, dents or cor-
rosion.
(b) Inspect the threads for damage.
BR0592
SR-1
STEERING
Page
PRECAUTIONS . SR-2
TROUBLESHOOTING . SR-2
ON-VEHICLE INSPECTION . SR-3
STEERING COLUMN ASSEMBLY WITH TILT
STEERING . SR-4
STEERING GEAR HOUSING . SR-14
POWER STEERING . SR-25
On-Vehicle Inspection . SR-25
Bleeding of Power Steering System . SR-27
Oil Pressure Check . SR-27
Power Steering Pump . SR-29
Gear Housing . SR-38
STEERING BEVEL GEAR HOUSING . SR-58
SR-2 STEERING - Precautions, Troubleshooting
PRECAUTIONS
Care must be taken to replace each part properly because it
could affect the performance of the steering system and
result in a driving hazard.
TROUBLESHOOTING
Hard steering Tires improperly inflated Inflate tires to proper pressure FA-3,30
Wheel alignment incorrect Check front wheel alignment FA-3,30
Upper or lower arm ball joints worn Replace ball joints FA-16,99
Steering gear out of adjustment or Adjust or repair steering gear SR-14,38,
broken 58
Power steering belt loose Adjust belt SR-25
Fluid level in reservoir low Add power steering fluid SR-25
Insufficient lubricant Lubricate suspension and
steering linkage
Power steering unit faulty Replace power steering unit SR-29
Poor return Tires improperly inflated Inflate tires to proper pressure FA-3,30
Insufficient lubricant Lubricate suspension and
steering linkage
Wheel alignment incorrect Check front wheel alignment FA-3,30
Steering gear out of adjustment or broken Adjust or repair steering gear SR-14,38,
58
Excessive play Steering gear housing loose Tighten gear housing SR-24,56
mounting bolts
Upper or lower arm ball joints worn Replace ball joints FA-16,99
Steering gear out of adjustment or broken Adjust or repair steering gear SR-14,38,
58
Power steering noisy Fluid level in reservoir low Add power steering fluid SR-25
Power steering belt loose Adjust belt SR-25
Air in power steering system Bleed air SR-27
Fluid foamy or emulsified Bleed air SR-27
PS pump faulty Repair or replace PS pump SR-29
Power steering gear housing faulty Replace gear housing SR-38
STEERING - On-Vehicle Inspection SR-3
,
1. CHECK THAT STEERING WHEEL FREEPLAY IS
Maximum
CORRECT
Freeplay
With the vehicle stopped and wheels in straight ahead
position, rock the steering wheel gently back and forth
with light finger pressure. Freeplay should not exceed the
t maximum limit.
30 mm
Maximum play: 30 mm (1.18 in,)
'-- .::.c...SRc.:....01--J51 If incorrect, repair.
2. CHECK STEERING LINKAGE AND GEAR HOUSING

(a) Check the steering linkage for looseness or damage.
Also check that:
• Tie rod ends do not have excessive play.
• Boots are not damaged.
• Boot clamps are not loose.
(b) Check gear housing for grease leakage or oozing.
SR-4 STEERING - Steering Column Assembly with Tilt Steering
STEERING COLUMN ASSEMBLY WITH TILT STEERING

REMOVAL OF STEERING COLUMN ASSEMBLY
Steering Wheel - - - - - / ,~WheeIPad
'----1 350 (25. 34)
Combination Switch - - - - r
~---columnCover
~.
1195 (14. 19) 1~------dilI
1 250 ( 1 8 . 2 5 1 1 - - - -
~---InstrumentLower Cover
Ikg-cm (ft-Ib, N'm)1 : Specified torque

SR0923
2. REMOVE UNIVERSAL JOINT BOLT

(a) Place match marks on the intermediate shaft and
bevel gear to ensure correct reassembly.
(b) Remove the universal joint bolt.
SRl221
STEERING - Steering Column Assembly with Tilt Steering SR-5
3. REMOVE STEERING WHEEL

(a) Remove the steering wheel pad with the screw.
(b) Disconnect the horn connector.
(c) Remove the steering wheel nut.
(d) Using SST, remove the steering wheel.
SST 09609-20011
4. REMOVE INSTRUMENT LOWER COVER
5. REMOVE COLUMN COVERS AND COMBINATION

SWITCH
6. REMOVE TWO COLUMN TUBE BOLTS
7. REMOVE COLUMN BRACKET MOUNTING BOLTS

AND COLUMN TUBE MOUNTING NUTS
8. PULL OUT COLUMN TUBE AND SHAFT
SR2091
COMPONENTS
* 80 (69 in.-Ib, 7.9)
Main Shaft Upper Bracket
Tilt Steering Support

. . Cord I r250l18. 25)1 1 - - Snap Ring
Tension Spnng ~-- ._~J
V
Column Bracket
Column No.1 Ring
Column Tube
Retainer
Lower Bearing
~
Dust Cover
Intermediate Shaft
• [225116:22T]
Tilt Lev~rI
I Tilt Lever Retainer
55 (48 in.-Ib. 5.4)
-~ -
. . _..
Tension Spnng-------w_---
. @
1195(1~. . 19)l------------f - ~
~- - - 1!S.J!.~.29ll~~
@ ::
~
' '"
0
.@;
'-,- ~
":
'"
"'-"
1@.----------CollarNo.1
'~
:
~,
:
,~
:~ : - ,
l~N~'1 ':@=*
Serration Bolt
Column Cover Plate
Release Pin I ~ ~ I I ~
(jt): " , t2' " Tilt Steering Support
@~ f' 0 0 q
~ \ ,
&,
. I ~ :
:
: ,. ~'"~Column Cover Support
Tilt Pawl I QOJ I , . . ". .~
I e v r-::,--=-=-:i
Collar ~:
~ r \
1;-11018. "L!
~.Ll25 (16. 22) I
I
Column Bracket -----~
Shim
[kg-cm (ft-Ib, N'm)! : Specified torque Collar NO.2
* Precoated part Tilt Lever Subassembly
DISASSEMBLY OF STEERING COLUMN

ASSEMBLY AND TILT MECHANISM
(See page SR-6)
1. REMOVE IGNITION KEY CYLINDER

(a) Place the ignition key at the ACC position.
(b) Push down the stop key with a thin rod, and pull out
the key cylinder.
2. REMOVE IGNITION SWITCH
3. REMOVE TENSION SPRINGS AND CORDS

(a) Fully tilt the main shaft upward.
(b) Release the cord from the hook.
(c) Using a screwdriver, pry out the cord tip and remove
the spring and cord.
4. REMOVE COLUMN COVER PLATE
5. DISCONNECT INTERMEDIATE SHAFT AND MAIN

SHAFT
(a) Place match marks on the intermediate shaft and
universal joint.
(b) Remove the joint bolt.
(c) Remove the four bracket bolts.
(d) Remove the column tube with the intermediate shaft.
6. REMOVE UPPER BRACKET WITH MAIN SHAFT

FROM COLUMN BRACKET
7. REMOVE MAIN SHAFT FROM UPPER BRACKET

(a) Using a soft jaws vise and snap ring pliers, remove
the snap ring.
(b) Pullout the main shaft from the bracket.
8. REMOVE TILT LEVER

(a) Remove the tension spring.
(b) Remove the E-ring and bushing.
(c) Remove the nut, plate washer and nylon bushing.
(d) Remove the lever, bushing, wave washer and nylon
bushing.
9. REMOVE TilT lEVER RETAINER

(a) Remove the bolt, two nuts and two washers.
(b) Remove the lever retainer and collar.
10. REMOVE TilT PAWL

Pullout the release pin and remove the tilt pawl.
11. REMOVE SERRATION BOLT

Temporarily install another nut flat with the end of the bolt
and tap it in with a hammer.
12. REMOVE TILT LEVER SUBASSEMBLY
/
/
13. REMOVE COLUMN COVER SUPPORT

Remove the following parts:
(a) Nuts
(b) Bolts
(c) Collars
(d) Washers
14. REMOVE TILT STEERING SUPPORT
15. REMOVE PAWL SET BOLT
16. REMOVE INTERMEDIATE SHAFT

(a) Remove the clamp bolt and pull out the intermediate
shaft from the upper tube.
(c) Remove the lower bearing from the shaft.
(d) Pull out the shaft from the lower tube.
SR2092
INSPECTION AND REPAIR OF STEERING

COLUMN ASSEMBLY
1. IF NECESSARY, REPLACE BEARING IN UPPER
BRACKET
(a) Remove the bearing with a hammer and SST.
SST 09620-30010 (09623-30010)
A-_
- .-
(b) Pack MP grease into a new bearing.

SST (c) Using SST and a hammer, drive the bearing into the
bracket.
SST 09620-30010 (096:i 1-00020, 09624-30010)
2. IF NECESSARY, REPLACE LOWER BEARING

(a) Using SST and a press, remove the lower bearing
from the main shaft.
SST 09527-20011
(b) Pack MP grease into a new bearing.
(c) Using SST and a press, assemble the lower bearing

and main shaft.
SST 09236-00101 (092:37-00010)
09612-22011
SST
ASSEMBLY OF STEERING COLUMN
~./
/. ;.:~
ASSEMBLY AND TILT MECHANISM
~ . .. v..:.
(See page SR-6)
1. APPLY MP GREASE TO ALL RUBBING PARTS
2. ASSEMBLE TILT LEVER SUBASSEMBLY AND

COLLARS NO. 1 AN 0 NO.2
(a) Select a collar No. 1 which will eliminate all play.
Outer diameter mm (in.)

17.989-17.996 (0.7082-0.7085)
17.996 -18.003 (0.7085-0.7088)
18.003-18.010 (0.7088-0.7091 )
18.010-18.017 (0.7091 -0.7093)
18.017-18.024 (0.7093-0.7096)
(b) Install the tilt lever subassembly and collar No. 1 to

the support.
(c) Select a collar No. 2 which will eliminate all play.
Outer diameter mm (in.)

f------~~ --------------------l
17.982 -18.000 (0.7080-0.7087)

18.000-18.018 (0.7087 -0.7094)
(d) Install collar No. 2 to the support.
3. INSTALL PAWL SET BOLT

Install the pawl set bolt and torque the nut.
4. INSTALL TILT STEERING SUPPORT TO COLUMN

BRACKET
Install the tilt steering support to the column bracket and
drive in the serration bolt.
5. INSTALL SHIM AND BOLT

(a) Select a shim which fits snugly when pressed in by
hand.
Thickness mm (in.)
0.2 (0.008) 1.4 (0.055)
0.5 (0.020) 1.8 (0.071)
0.8 (0.031)
(b) Install the shim and bolt.
6. INSTALL COLUMN COVER SUPPORT

Install the following parts:
(a) Column cover support
(b) Bolt and collar
(c) Washers and nuts
7. INSTALL TILT PAWL

Install the tilt pawl and the release pin.
;:J
,,---
8. INSTALL TILT LEVER RETAINER

(a) Install the collar and lever retainer.
(b) Install the bolt, two nuts and washers.
9. INSTALL TILT LEVER

(a) Install the nylon bushing, wave washer, bushing and
lever.
(b) Install the nylon bushing, plate washer and nut.
(c) Install the bushing and E-ring.
(d) Install the tension spring.
10. INSTALL MAIN SHAFT TO UPPER BRACKET

(a) Insert the main shaft to the upper bracket.
(b) Using a soft jaws vise and snap ring pliers, install the
snap ring.
11. INSTALL IGNITION SWITCH
12. INSTALL IGNITION KEY CYLINDER
13. INSTALL UPPER BRACKET WITH MAIN SHAFT TO

COLUMN BRACKET
(a) Apply sealant to 1 or 2 threads of the bolt end.
Sealant: Part No. 08833-00070, THREE BOND
1324 or equivalent
(b) Install the two bolts; one with a wiring clamp.
14. INSTALL INTERMEDIATE SHAFT TO COLUMN TUBE

(a) Insert the intermediate shaft into the lower tube.
(b) Install the lower bearing.
(c) Using snap ring pliers, install the snap ring.
(d) Install the upper tube and tighten the clamp bolt.
I SR2092
15. INSTALL COLUMN TUBE TO COLUMN BRACKET

Install the three bolts; one with a wiring clamp.
16. CONNECT INTERMEDIATE SHAFT TO MAIN SHAFT

Align the matchmarks on the universal joint and inter-
mediate shaft and tighten the bolt.
17. INSTALL COLUMN COVER PLATE

(a) Apply sealant to 1 or 2 threads of the bolt end.
Sealant: Part No. 08833-00070, THREE BOND 1324
or equivalent
(b) Install the column cover plate with the bolt and nut.
SR2093
18. INSTALL TENSION SPRINGS AND CORDS

(a) Connect the spring and cord, and hook the spring to
the hanger.
(b) Hook the cord end to the tilt steering support.
(c) Hook the cord to the tilt steering support hook.
INSTALLATION OF STEERING COLUMN

ASSEMBLY
(See page SR-4)
1. PLACE COLUMN AND SHAFT IN INSTALLED

POSITION
2. CONNECT UNIVERSAL JOINT

Line up the marks on the universal joint and bevel gear.
SR1221
3. INSTALL COLUMN BRACKET MOUNTING BOLTS

AND COLUMN TUBE MOUNTING NUTS BY HAND
4. INSTALL COLUMN TUBE BOLTS

5. TORQUE COLUMN BRACKET MOUNTING BOLTS

6. TORQUE COLUMN TUBE MOUNTING NUTS

7. INSTALL COUPLING SET BOLT

SR2094
8. INSTALL COMBINATION SWITCH AND COLUMN

COVERS
9. INSTALL INSTRUMENT LOWER COVER
10. INSTALL STEERING WHEEL

(a) Position the front wheels straight ahead and install
the steering wheel in neutral position.
(b) Tighten the nut.
(c) Install the steering wheel pad with the screw.

SR-14 STEERING - Steering Gear Housing
STEERING GEAR HOUSING

REMOVAL OF GEAR HOUSING
"=~--. Cotter Pin

~f------I 600 (4_3, 59)]
Rack Housing
~-----'-------Bracket
~ i........ ....... ..JI

I
t
I
I
I
I
(ftAr----------Grommet
[~7Ol56:76lJ~
I
I
I
I
I
1 ' / . / " 1 . - - - - - - - - - - - - Gear Housing
[kg=cr:Tllf1:=ib~ : Specified torque

• Non-reusable part SR1306
1. REMOVE FRONT WHEEL
2. DISCONNECT TIE ROD FROM KNUCKLE ARM

(a) Remove the cotter pin and set nut.
(b) Using SST, disconnect the tie rod from the knuckle
arm.
SST 09610-2001 2
3. DISCONNECT TORQUE SHAFT FROM GEAR

HOUSING
(a) Place matchmarks on the torque shaft and pinion
shaft.
(b) Remove the set bolt.
SR1376
STEERING - Steering Gear Housing SR-15
Remove the three bolts and bevel gear.

Disconnect the torque shaft from the pinion shaft.
SR1222
4. REMOVE GEAR HOUSING

Remove the four bolts and gear housing.
COMPONENTS
~elod
~I 195 114. 191 I
!'-.
@"' ~,~) 'I
Tie Rod
I ',- I
I', I
I ' , I
I " I
I " I
I " I
L'f "
CliP~rI Rack End
1850 (61. 83)
~
~
~~awwaSher i
Rack Boot I ~
ciampi
Rack Bushing
Dust Cover =~ ,~ W C\--~----Gear Housing

* Lock Nut
~ 50 (83. 113) I
* Pin~~~iO;e:r~:Mft
Adjusting Screw
~
------ 1250 (18. 25) I ~ --- Rac~ Guide
Ikg-cm (ft-Ib. N'm)1 : Specified torque. 0'1 S I Spring . .
ea ~
@
* Rack GUide Spring Cap
* Lock Nut 700 (51, 67) I
I
I
• Non-reusable part Rack Guide Seat ~
* Precoated part ~ SR1450
DISASSEMBLY OF GEAR HOUSING

1. CLAMP GEAR HOUSING IN VISE
Using SST, secure the steering gear in a vise.
~---SST
SST 09612-00012
SR1439
2. REMOVE TIE RODS

(a) Place match marks on the tie rod and rack end.
(b) Loosen the clamp bolt and remove the tie rod from the
rack end.
3. REMOVE CLIPS, CLAMPS AND RACK BOOTS

4. REMOVE RACK ENDS AND CLAW WASHERS

(a) Unstake the claw washer.
CAUTION: Avoid any impact to the rack.
/
SR143l
(b) Using SST, remove the rack ends.

SST 09612-24013 (09617-24010,09617-24030)
NOTE: Mark the left and right rack ends.
(c) Remove the claw washer.
D0018
5. REMOVE RACK GUIDE SPRING CAP LOCK NUT

Using SST, remove the rack guide spring cap lock nut.
SST 09612-24013 (09617-24020)
6. REMOVE RACK GUIDE SPRING CAP

Using SST, remove the rack guide spring cap.
SST 0961 2-24013 (09612-10022)
7. REMOVE RACK GUIDE SPRING
8. REMOVE RACK GUIDE AND RACK GUIDE SEAT

9. REMOVE PINION BEARING ADJUSTING SCREW

LOCK NUT
Using SST, remove the pinion bearing adjusting screw
lock nut.
SST 09612-10093 (09617-10010)
~~)----SST
SR1434
10. REMOVE PINION BEARING ADJUSTING SCREW

Using SST, remove the pinion bearing adjusting screw.
SST SST 09612-10093 (09628-10020)
SR1459
11. REMOVE PINION WITH BEARING

NOTE: Be careful not to damage the serrations.
(a) Fully pull the rack from the pinion side and align the
rack notched portion with the pinion.
(b) Remove the pinion together with the upper bearing.
SR1460
12. REMOVE RACK

Remove the rack from the pinion side without revolving it.
NOTE: If the rack is pulled from the tube side, there is
possibility of damaging the bushing with the rack teeth
surface.
INSPECTION AND REPAIR OF GEAR

HOUSING COMPONENTS
1. INSPECT RACK
(a) Check the rack for runout and for teeth wear or
damage.
(b) Check the back surface for wear or damage.
If faulty, replace it.
CAUTION: Do not use a wire brush when cleaning.
2. IF NECESSARY, REPLACE RACK BUSHING

(a) Using SST, remove the rack bushing.
SST 09612-24013 (09613-22011)
08143
(b) Align the three rack bushing claw to the rack housing
hole and install the rack bushing.
NOTE: Be careful not to damage the inside of the bush-
ing.
3. IF NECESSARY, REPLACE PINION OIL SEAL

(a) Using a socket wrench, drive out the oil seal.
D8548
(b) Using SST, drive in a new pinion oil seal until it is

protruding 0.5 mm (0.020 in.).
SST 0961 2-10093 (09612-10050)
gSST
08549
ASSEMBLY OF GEAR HOUSING

(See page SR-16)
1. PACK MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE ON PARTS SHOWN
. . : Molybdenum Disulphide Lithium Base Grease SR1450
2. INSTALL RACK INTO RACK HOUSING

(a) From the pinion side, install the rack into the rack
housing.
(b) Set the rack notched portion so that the pinion can
be positioned inside.
SR1443
3. INSTALL PINION INTO HOUSING

Insure that the pinion end is securely in the lower bearing.
SR1460
/ 4. INSTALL PINION BEARING ADJUSTING SCREW

(a) Apply liquid sealer onto the screw threads.
(b) Using SST, install the pinion bearing adjusting screw.
SST 0961 2-10093 (09628-10020)
SR1435
5. INSTALL PINION BEARING ADJUSTING SCREW

LOCK NUT
(a) Apply liquid sealer onto the lock nut threads and
housing contacting surface.
(b) Using SST, install and torque the lock nut.
SST 09612-10093 (09617-10010)
SR1444 Torque: 1,150 kg-em (83 ft-Ib, 113 N'm)
6. INSTALL RACK GUIDE AND SPRING
7. INSTALL RACK GUIDE SPRING CAP

(a) Apply liquid sealer onto the spring cap threads.
(b) Temporarily install the spring cap and mesh the rack
with the pinion.
8. ADJUST TOTAL PRELOAD

(a) Using SST, torque the rack guide spring cap.
SST 09612-24013 (09612-10022)
(b) Return the rack guide spring cap 30°.
(c) Using SST and torque meter, adjust the total preload
until within specification.
SST 09612-24013 (09612-10022,09616-10010)
Preload (turning): 5 - 13 kg-em
~."....---SST (4.3 - 11.3 in.-Ib, 0.7 - 1.3 N'm)
SR1442
9. INSTALL RACK GUIDE SPRING CAP LOCK NUT

(a) Coat liquid sealer onto the lock nut thread and hous-
ing surface.
\~~--SST
(b) Using SST, torque the lock nut.
SST 0961 2-24013 (09612-10022, 0961 7 -24020)
SR1461 (c) Recheck the total preload.
10. INSTALL DUST COVER
11. INSTALL CLAW WASHERS AND RACK ENDS

(a) Install a new claw washer.
NOTE: Align the claw of the claw washer with the rack
groove.
(b) Using SST, install and torque the rack end.
SST 09612-24013 (09617-24010,09617-24030)
(c) Stake the claw washer.
SR1441
12. INSTALL RACK BOOTS

(a) Install the rack boots.
NOTE: Be careful not to damage or twist the boots.
The left and right boots are different. Be careful not to
~
~1I1 interchange them.
SR1372
(b) Install the clamps and clips.

(c) Using pliers, stake the clamps and bend to upward.
NOTE: Face the open ends outward to avoid damage to
the boots.
SR1438
13. INSTALL TIE RODS
ar k s (a) Screw the tie rods onto the rack ends until the
matchmarks are aligned.
Ma:l___ - ". . JiJ

P.....
PP......
(b)
Torque:
After adjusting toe-in, torque the clamp bolts.
195 kg-em (14 ft-Ib, 19 N'm)
08338
INSTALLATION OF GEAR HOUSING

(See page SR-14)
1. INSTALL GEAR HOUSING

Install the gear housing with the four bolts to the body and
torque the four bolts.
SR1378
2. CONNECT TORQUE SHAFT TO GEAR HOUSING

(a) Align the matchmarks on the torque shaft and pinion
shaft.
(b) Install the bevel gear with the three bolts and torque
the three bolts.
(c) Torque the coupling bolts.

SR1376
3. CONNECT TIE ROD TO KNUCKLE ARM

(a) Install the tie rod to the knuckle arm and torque the
mount nut.
4. INSTALL WHEEL
5. CHECK STEERING WHEEL FREEPLAV
6. CHECK TOE-IN (See page FA-6)
7. CHECK STEERING WHEEL CENTER POINT

STEERING - Power Steering SR-25
[ } { - Nipponqenso Borroughs POWER STEERING

On-Vehicle Inspection
CHECK OF DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Borroughs No. BT -33- 73F
ECOOO3 ECOOO4 ECOO01
Drive belt tension:
New belt 125 + 25 Ib
;-- .......
If necessary, adjust the drive belt tension.

NOTE:
FLUID LEVEL CHECK
1& 1.
2.
KEEP VEHICLE LEVEL
BOOST FLUID TEMPERATURE

With the engine idling at 1,000 rpm or less, turn the steer-
~
ing wheel from lock to lock several times to boost fluid
temperature.
Fluid temperature: 60°C (140°F)
O il Temp.
3. CHECK FOR FOAMING OR EMULSIFICATION

NOTE: Foaming and emulsification indicate the exis-
tence of air in the system or that the fluid level is low.
4. CHECK FLUID LEVEL IN RESERVOIR

Check the fluid level and add fluid if necessary.
Fluid: ATF DEXRON® or DEXRON® II
NOTE: Check that the fluid level is within the HOT LEVEL
of the dipstick. If the fluid is cold, check that it is within
the COLD LEVEL of dipstick.
SR-26 STEERING - Power Steering
REPLACEMENT OF POWER STEERING FLUID

1. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH
STANDS
2. REMOVE FLUID RETURN HOSE FROM OIL

RESERVOIR AND DRAIN FLUID INTO A CONTAINER
3. WITH ENGINE IDLING, TURN STEERING WHEEL

FROM FULL LEFT TO FULL RIGHT WHILE DRAINING
FLUID
4. STOP ENGINE
5. FILL RESERVOIR WITH FRESH FLUID

Fluid: ATF DEXRON® or DEXRON® IT
6. START ENGINE AND RUN IT AT 1,000 RPM
Blind Plug After 1 or 2 seconds, fluid will begin to discharge from the
return hose. Stop the engine immediately as soon as fluid
begins to discharge.
7. REPEAT STEPS 5 AND 6 FOUR OR FIVE TIMES UNTIL

THERE IS NO MORE AIR IN FLUID
8. CONNECT RETURN HOSE TO OIL RESERVOIR
9. BLEED POWER STEERING SYSTEM

Bleeding of Power Steering System

1. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
NOTE: Check that the fluid level is within the HOT LEVEL
of the dipstick. If the fluid is cold, check that it is within
the COLD LEVEL of the dipstick.
2. START ENGINE AND TURN STEERING WHEEL

FULLY IN BOTH DIRECTIONS THREE OR FOUR
TIMES
Run the engine at 1,000 rpm or less.
3. CHECK THAT FLUID IN RESERVOIR IS NOT FOAMY

OR CLOUDY AND DOES NOT RISE OVER
MAXIMUM WHEN ENGINE IS STOPPED
Measure the fluid level with the engine running. Stop the
engine and measure the fluid level.
Maximum rise: 5 mm (0.20 in.)
If a problem is found, repeat steps 6 and 7 on page SR-26.
Repair the PS pump if the problem persists.
Oil Pressure Check

1. CONNECT PRESSURE GAUGE
(a) Using SST, remove the pressure line from the PS
pump.
SST 09631-22020
(b) Connect the gauge side of the pressure gauge to the
PS pump.
(c) Connect the valve side of the pressure gauge to the
pressure line.
(d) Bleed the system. Start the engine and turn the wheel
~- -
1(;/ -~
\ (e)
fully in both directions two or three times.
Check that the fluid level is correct.
(£'-\\-
-_._--
2. CHECK THAT FLUID TEMPERATURE IS AT LEAST
60°C (140°F)
bQ
Oil Temp.
3. START ENGINE AND RUN IT AT IDLE

~ Min. 75
\,7:=;=========~
kg/cm 2
4. CHECK FLUID PRESSURE READING WITH VALVE
1'1
CLOSED
Close the pressure gauge valve and observe the reading
Closed on the gauge.
Idle Minimum pressure: 75 kg/cm 2 (1,067 psi, 7,355 kPa)
~ ~
NOTE: Do not keep the valve closed for more than 10
seconds.
SR0539
SR0440 If pressure is low, repair or replace the PS pump.
5. OPEN VALVE FULLY
6. CHECK AND RECORD PRESSURE READING AT 1,000

m RPM
Open 7. CHECK AND RECORD PRESSURE READING AT 3,000

1,000 2,000 RPM
§3 SR0539
SR0442
Check that there is less than 5 kg/cm 2 (71 psi, 490 kPa)
difference in pressure between the 1,000 rpm and 3,000
rpm checks.
If the difference is greater, repair or replace the PS pump
flow control valve.
Min. 75 kg/cm 2 8. CHECK PRESSURE READING WITH STEERING

y;<:::C<==========~::2J WHEEL TURNED TO FULL LOCK
Be sure the pressure gauge valve is fully opened and the
Open engine idling.
Lock Position Minimum pressure: 75 kg/cm 2 (1,067 psi, 7,355 kPa)
[S If pressure is low, the gear housing has an internal leak and

must be repaired or replaced.
~ SR0539
SR0444
9. MEASURE STEERING EFFORT

Center the steering wheel and run the engine at idle.
Using a scale, measure the steering effort in both direc-
tions.
Maximum steering effort: 4 kg (8.8 Ib, 39 N)
If steering effort is excessive, repair the power steering
unit.
NOTE: Be sure to consider tire type, pressure and con-
tact surface before making your diagnosis.
Power Steering Pump

REMOVAL OF POWER STEERING PUMP
~----IdlerPulley
~ ---~r-4-0-0-(2-9.-3-9)~1
I 400 (20ill~
Bracket----~
c ~Return Hose
~ I 450 (33. 44) I
e ~
\\[ ( ~~ III
I 440 (32. 43) I Air Hose

I PS Pump
Drive Pulley
Ikg-cm (ft-Ib, N·m~ : Specified torque SR0924
1. DISCONNECT AIR HOSES FROM AIR CONTROL

/
/~ VALVE
2. DRAIN FLUID FROM RESERVOIR TANK
3. DISCONNECT RETURN HOSE FROM POWER

STEERING PUMP
4. DISCONNECT PRESSURE TUBE FROM POWER

STEERING PUMP
Using SST, loosen and disconnect the pressure tube.
SST 09631-22020
5. REMOVE DRIVE BELT AND PULLEY

(a) Push on the drive belt to hold the pulley in place and
remove the pulley set nut.
(b) Loosen the drive belt adjust bolt.
(c) Remove the drive belt.
(d) Remove the pulley and woodruff key.
6. REMOVE POWER STEERING PUMP

Remove the PS pump mount bolts, and remove the PS
pump from the bracket.
COMPONENTS
Bearing
Rotor Shaft
I
I 470 (34. 46) I
Snap Ring
l
i
ront Housing
• O-Ring
.Oil Seal
~-----Suction Port Union

- ~ Uff?A
S·· nap R"Ing \\,,, / . • O-Ring
PIUg~~
Spring-----
Flow Control Valve
- - - - - - - . O-Ring
Pin
~ ~:::J------ • O-R ing
Pressure Port Union
., I~,~ I 700 (51, 69) I
.1
1
Vane Plate
Rotor
O-Ring
Cam Ring Rear Plate

+Seat
Rear Housing
Air Control Valve

Ikg-cm (ft-Ib, N·m~ : Specified torque
[ 370 (27, 36) I
Matchmarks DISASSEMBLY OF POWER STEERING PUMP

1. CLAMP POWER STEERING PUMP IN VISE
CAUTION: Do not tighten the vise too tight.
2. REMOVE AIR CONTROL VALVE FROM REAR

HOUSING
3. REMOVE UNION FROM REAR HOUSING
4. MARK FRONT AND REAR HOUSINGS TO INSURE

CORRECT REASSEMBLV
5. REMOVE FRONT HOUSING

(a) Remove the four front housing bolts.
(b) Using a plastic hammer, tap off the front housing.
CAUTION: Be careful that the vane plates, rotor and
cam ring do not fall out.
6. REMOVE CAM RING, ROTOR AND VANE PLATES

CAUTION: Be careful not to scratch the cam ring,
rotor or vane plates.
7. REMOVE ROTOR SHAFT

(a) Clamp the front housing in a vise.
CAUTION: Do not tighten the vise too tight.
(b) Using a chisel and hammer, pry off the oil seal.
(c) Using snap ring pliers, remove the snap ring.
(d) Using a plastic hammer, lightly tap the rotor shaft out
of the front housing.
8. REMOVE REAR PLATE AND SPRING

Using a plastic hammer, tap the bottom end of the rear
housing, and remove the rear plate and spring.
CAUTION: Avoid gripping the rear plate with pliers
as this could damage it.
9. REMOVE FLOW CONTROL VALVE

(a) Temporarily install a bolt to the plug.
(b) Push the bolt and remove the snap ring with snap
ring pliers.
(c) Pullout the bolt and remove the plug.
(d) Remove the spring and flow control valve by hand.
CAUTION: Use care not to drop, scratch or nick this
valve.
10. REMOVE PRESSURE PORT UNION

INSPECTION OF POWER STEERING PUMP

1. INSPECT BUSHING AND MEASURE BUSHING OIL
./~
CLEARANCE
I
(a) Check the bushing for wear or damage. The bushing
cannot be replaced separately.
If wear or damage is found, replace entire housing.
(b) Check the oil clearance between the bushing and
rotor shaft.
Maximum oil clearance: 0.07 mm (0.0028 in,)
2. IF NECESSARY, REPLACE ROTOR SHAFT B'EARING

(b) Using a press, press out the bearing.
(c) Using a press, press in the bearing.
(d) Using snap ring pliers, install the snap ring.
3. INSPECT AND MEASURE VANE PLATES

(a) Check the vane plates for wear or scratches.
(b) Measure the length, height and thickness of the vane
plates.
Minimum length: 14.97 mm (0.5894 in,)
Minimum height: 7.8 mm (0.307 in,)
Minimum thickness: 1.7 mm (0.067 in,)
(c) Measure the clearance between the vane plate and
rotor groove.
NOTE: There are five vane lengths with the following
rotor and cam ring numbers:
Rotor and cam

Vane length mm On.)
ring number
None 14.996-14.998 (0.5904-0.5905)
1 14.994-14.996 (0.5903-0.5904)
2 14.992 -14.994 (0.5902-0.5903)
3 14.990-14.992 (0.59016-0.59024)
4 14.988-14.990 (0.5901 -0.5902)
4. IF NECESSARY, REPLACE UNION SEAT

(a) Using a screw extractor, remove the union seat.
Screw (b) Install a new union seat.

Extractor NOTE: Only floating type parts are available.
SR0090
5. INSPECT FLOW CONTROL VALVE AND MEASURE

Compressed Air SPRING
(a) Check the flow control valve for wear or damage.
x (b)
(c)
Apply fluid to the valve and check that if falls
smoothly into the valve hole by its own weight.
Check the flow control valve for leakage.
• Close one of the holes and apply compressed air
[4 or 5 kg/cm 2 (57 or 71 psi, 392 or490 kPa)] into
the opposite side.
• Confirm that air does not come out from the end
hole.
If necessary, replace the valve with one having the same
letter as on the rear housing.
(d) Check that the spring is within specification.
Standard length: 50.0 mm (1.969 in.)
Minimum length: 47.0 mm (1.850 in.)
If the spring is not within specification, replace it.
ASSEMBLY OF POWER STEERING PUMP

(See page SR-30)
1. INSTALL FLOW CONTROL VALVE

NOTE: Be sure the letter inscribed on the flow control
valve matches the letter stamped on the rear of the pump
body.
Inscribed mark: A, B, C, 0, E or F
Install the flow control valve, spring, plug and snap ring.
2. INSTALL PRESSURE PORT UNION

Install and torque the union.
3. INSTALL ROTOR SHAFT TO FRONT HOUSING

Install the rotor shaft into the front housing by tapping it in
with a plastic hammer.

Using snap ring pliers, install the snap ring to the front
housing.
~
/\
i \ 5. INSTALL OIL SEAL
(a) Apply a light coat of MP grease to a new oil seal lip.
(b) Using SST and a hammer, install the oil seal.
SST 09608-30012 (09608-04020)
6. INSTALL O-RING
7. INSTALL CAM RING

Align the fluid passages of the cam ring and front housing,
and install the cam ring.
8. INSTALL ROTOR
Install the rotor with the chamfered end facing toward the
..
front.
NOTE: Be sure the letters inscribed on the cam ring and
Front rotor match .
Inscribed mark: 1, 2, 3, 4 or None
9. INSTALL VANE PLATES

Install the vane plates with the round end facing outward.
Round End
Outside
~
-
10. INSTALL REAR PLATE AND SPRING
(a) Align the fluid passages of the rear plate and cam
ring, and install the rear plate with the spring.
(b) Place the spring on the rear plate.
11. INSTALL REAR HOUSING

(a) Align the match marks on the front and rear housing,
and assemble them.
(b) Tighten the front and rear housing mount bolts by
hand.
12. TIGHTEN FOUR HOUSING BOLTS

(a) Clamp the rear housing in a vise.
CAUTION: Do not tight the vise too tight.
(b) Tighten the four housing bolts evenly in 3 or 4
passes.
13. INSTALL UNION TO REAR HOUSING

Insert and tighten the union.
14. INSTALL AIR CONTROL VALVE TO REAR HOUSING

Install and tighten the air control valve.
15. CHECK ROTOR SHAFT ROTATION CONDITION

(a) Check that the rotor shaft rotates smoothly without
abnormal noise.
(b) Provisionally install the pulley nut and check the rota-
tion torque.
Rotation torque: Less than 2.8 kg-em
(2.4 in.-Ib, 0.3 N'm)
INSTALLATION OF POWER STEERING PUMP

(See page SR-29)
1. INSTALL POWER STEERING PUMP

Place the PS pump in position and torque the mount bolts.
2. INSTALL PULLEY AND DRIVE BELT

(a) Install the woodruff key, pulley and set nut.
~ Nippondenso Borroughs (b) Install the drive belt.
cr (c) Turn the adjusting bolt until the belt tension is at

specified value.
(d) Using a belt tension gauge, check the drive belt ten-
sion.
Belt tension gauge:
Borroughs No. BT -33- 73F
Drive belt tension: New belt 125 ± 25 Ib
If necessary, adjust the belt tension.
NOTE:
(e) Tighten the idler pulley nut.
(f) Push down on the drive belt to hold the pulley in
place and torque the pulley set nut.
3. CONNECT PRESSURE TUBE TO POWER STEERING
PUMP
Using SST, torque the flare nut.
SST 09631-22020
4. CONNECT RETURN HOSE TO RESERVOIR TANK
5. CONNECT AIR HOSES TO AIR CONTROL VALVE
6. FILL RESERVOIR WITH FLUID

7. BLEED POWER STEERING
8. CHECK FOR FLUID LEAKS

Steering Gear Housing

REMOVAL OF GEAR HOUSING (2WD)
• Cotter Pin
~
rR;~'i'r1-----~0 (43. 59) I r-- I G
!~~~met ~_--1-- Rack Housing
Bracket
r----...... I
I ...... .J
I
I 1-------[ 770 (56. 76) I
I
I
~--------Grommet
I
i //' Pressure and

I ~ Return tube
I // I 450 (33, 44) I
Gear Housing----------~A.m
---/
/
Torque Shaft - - - - - - - - - - r '
I kg-cm (ft-Ib, N'm)1 : Specified torque

/
1
I 360 (26. 35l]
• Non-reusable part SR1308
1. REMOVE FRONT WHEEL
2. DISCONNECT TIE ROD FROM KNUCKLE ARM

(b) Using SST, disconnect the tie rod from the knuckle
arm.
SST 09610-20012

HOUSING
(a) Place match marks on the torque shaft and pinion
shaft.
(b) Remove the set bolt.
/~/ SR1376
(c) Remove the three bolts and bevel gear.

(d) Disconnect the torque shaft from the pinion shaft.
SR1222
SST 4. DISCONNECT PRESSURE AND RETURN TUBES

Using SST, disconnect the pressure and return tube.
SST 09631-22020
SR1380

Remove the four bolts and gear housing.
REMOVAL OF GEAR HOUSING (4WD)
700 (50,69)
Front Differential Assembly
Bracket
Grommet
+Cotter Pin~
[ 930(67,91) ~
Gear Housing------lJ
~~ ~ @ 430 (31, 42)
rf!II
." ~JL .l--~90150.6811
~(Jf((f/,;W~ ~ 450 (33, 44) I
~
~
Engine Under Cover
690 (50, 68) I

Torque Shaft~ ,
r----'---~ Under Cover

360 (26, 35)
I kg-cm (ft-Ib, N· m) I: Specified torque

+ Non-reusable part SR 1830
1. REMOVE FRONT DIFFERENTIAL ASSEMBLY

(See page FA-73)
2. DISCONNECT TIE ROD END FROM KNUCKLE ARM

(b) Using SST, disconnect the tie rod end from the knuckle
arm.
SST 09610-20012

HOUSING
(a) Remove the two bolts and under cover.
(b) Place the match marks on the torque shaft and pinion
shaft.
(c) Remove the set bolt.
SR1832
(d) Remove the three bolts and bevel gear.

(e) Disconnect the torque shaft from the pinion shaft.
4. DISCONNECT PRESSURE AND RETURN TUBES

Using SST, disconnect the pressure and return tubes from
the gear housing.
SST 09631-22020

Remove the two bolts, two nuts and gear housing.
SR1835
COMPONENTS
Tie Rod 195 (14. 19)
e. ClalP ~ ~
~ @J",
1',
I
I
,
'........
'I
I
.Teflon Ring
I '" I • a-Ring
I " I
I ',I
I "
I ........ ,JI
l,
-.....:
Clip
Rack End
I 1.050 (76. 103)
• Claw Washer
Rack
'~-----JL-----TurnPressure Tube
I 250 (18. 25) I
Spacer----------------
Clamp
• a-Ring
Rack Boot
6~9)~
Control Valve Housing
•
Bearing
Oil Seal
.T fl R" Bearing Guide
Spring
~RaCk*
~ ~Rack Guide
~
Guide
SealC:
Rack Guide
Ikg-cm (ft-Ib. N"m)1 : Specified torque e on mg N_u_t _ Spring Cap
• Non-reusable part I 250 (18. 2ill ~ *I Lock Nut
* Precoated part 700 (51. 69) ISR1451
SST DISASSEMBLY OF STEERING GEAR

HOUSING
(See page SR-42)
1. CLAMP GEAR HOUSING IN VISE

Using SST, secure the steering gear in a vise.
SST 09612-00012
SRl187
2. REMOVE RIGHT AND LEFT TURN PRESSURE TUBES

~. Using SST, remove the pressure tubes.
SST 09633-00020
SR1303
3. REMOVE TIE RODS

(a) Place matchmarks on the tie rod and rack end.
(b) Loosen the clamp bolt and remove the tie rod from the
rack end.
4. REMOVE CLIPS, CLAMPS AND RACK BOOTS
5. REMOVE RACK ENDS AND CLAW WASHERS

(a) Unstake the claw washer.
CAUTION: Avoid any impact to the rack.
SR1302
(b) Using SST, remove the rack ends.

SST 09612-24013(09617-24010,09617-24030)
NOTE: Mark the left and right rack ends.
(c) Remove the claw washer.
00923
6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
.~. Using SST, remove the rack guide spring cap lock nut.
SST 09612-24013 (09617-24020)
ST
~-1J--t+----S
SR1462
7. REMOVE RACK GUIDE SPRING CAP

Using SST, remove the rack guide spring cap.
SST 0961 2-2401 3 (0961 2-10022)
8. REMOVE RACK GUIDE, SPRING AND SEAT
SR1301
9. REMOVE CONTROL VALVE AND HOUSING

(a) Place matchmarks on the valve housing and rack
housing.
(b) Remove the two bolts.
(c) Pull out the valve with the valve housing.
(d) Remove the O-ring.
10. REMOVE CYLINDER END STOPPER NUT

Using SST, remove the stopper nut.
SST 09631-20120
C0928
11. REMOVE OIL SEAL, RACK END GUIDE AND

STEERING RACK
Using a press and SST, remove the oil seal, rack end guide
and rack.
SST 0961 2-24013 (09612-10061)
CAUTION: Be careful not to damage the inside of the
cylinder tube.
12. REMOVE CONTROL VALVE

(a) Remove the dust cover.
(b) Using SST, loosen the bearing guide nut.
SST 09631 -20060
(c) Using a plastic hammer, tap out the control valve

with the bearing guide nut.
(d) Remove the O-ring.
SR1432
INSPECTION AND REPAIR OF GEAR

HOUSING COMPONENTS
1. INSPECT RACK
(a) Check the rack for runout and for teeth wear or
damage.
(b) Check the back surface for wear or damage.
If faulty, replace it.
D2798
2. INSPECT NEEDLE ROLLER BEARING

(a) Check for wear or damage.
(b) If necessary, replace the cylinder housing assembly.
D0930
\-_ . j 3. IF NECESSARY, REPLACE CONTROL VALVE

BEARING AND OIL SEAL
(a) Using SST, press out the oil seal and bearing from
U the control valve housing.
SST 09630-24013 (09620-24010)
'------".55T 09631-1 2020
(b) Coat the oil seal lip with power steering fluid.
A9352
(c) Using SST, press a new oil seal into the control valve
\.--.. -j-' housing.
SST --t:i SST 09630-24013 (09620-24020)
09631 -1 2020
A9353
(d) Using SST, press a new bearing into the control valve
housing.
SST 09630-24013 (09620-24030)
55T--------
09631 -1 2020
IL..I!I~....LI_---L.I@
. . . .I +
D0932
4. IF NECESSARY, REPLACE CYLINDER HOUSING OIL

SEAL
(a) Using SST, remove the oil seal with the spacer.
I----~SST
SST 09630-00011 (09631-00080)
09631 -1 2020
D1224
(c) Install the oil seal and spacer to SST, and insert it to
the rack housing.
Rack End Guide SST 09630-24013 (09631-24070)
09631 -1 2020
SST
(d) To prevent the spacer and oil seal from being installed
slantwise, install the rack end guide to the rack
housing.
(e) Tap SST with a plastic hammer.
SR2104
5. IF NECESSARY, REPLACE BEARING GUIDE NUT OIL
~,'~,.""""'-,",<"~
SEAL
(a) Using SST, press out the oil seal.
rr----r~L2fbW SST 09630-24013 (09620-24020)
o 09631-1 2020
~-----,=- SST
D8229
(c) Using SST, press a new oil seal into the guide nut.
SST 09631-20040
SST - - - - - - . . . . . <
..---1-_---1..---,
A9351
6. IF NECESSARY, REPLACE TEFLON RING AND O-RING

(a) Using a screwdriver, remove the teflon ring and
O-ring.
CAUTION: Be careful not to damage the steering rack.
(b) Install a new O-ring.
(c) Expand a new teflon ring with your fingers.
CAUTION: Be careful not to over-expand the teflon
ring.
Z5646 (d) Install a new teflon ring.
(e) Coat the teflon ring with power steering fluid and
snug it down with your fingers.
7. IF NECESSARY, REPLACE CONTROL VALVE TEFLON

RING
(a) Using a screwdriver, remove the teflon ring.
CAUTION: Be careful not to damage the control
valve.
87397
(b) Install a new teflon ring to SST and expand it.

SST 09631 -20070
..
87398
(c) Install the expanded teflon rings to the control valve

and snug it down with your fingers.
CAUTION: Be careful not to damage the teflon rings.
87399
(d) Coat the teflon ring with power steering fluid, -and
carefully slide the tapered end of SST over the teflon
ring to seat the ring.
~~~-7SST
SST 09631-20081
87400
8. IF NECESSARY, REPLACE UNION SEAT

(a) Using a screw extractor, remove the union seat.
00933
(b) Using a plastic hammer and extension bar, tap in a

new union seat.
00933
ASSEMBLY OF GEAR HOUSING

(See page SR-42)
1. COAT POWER STEERING FLUID OR GREASE ON

FOLLOWING PARTS:
. . Molybdenum Disulphide Lithium Base Grease

¢J Power Steeri ng FI uid
SR1458
2. INSTALL RACK
(a) Install SST to the rack.
SST 09631 -20110 (For 2WD)
09631-20111 (For 4WD)
NOTE: If necessary, scrape the burrs off the rack teeth
end and burnish.
(b) Coat SST with power steering fluid.
(c) Insert the rack into the cylinder.
A0811 (d) Remove SST.
3. INSTALL RACK END GUIDE

Install the rack end guide to the rack and slide it into the
housing.
08232
4. INSTALL CYLINDER END STOPPER, OIL SEAL AND

SPACER
(a) Coat the oil seal with power steering fluid.
(b) Clean the end stopper and apply liquid sealer to the
two or three threads of the end stopper.
/ Sealant: Part No. 08833-00080, THREE BOND 1344,
(c) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(d) Install the oil seal by pushing into the cylinder in the
direction shown in drawing, without tilting.
(e) Using SST, torque the end stopper.
SST 09631-20120
(f) Using a pin punch and hammer, stake the housing

and stopper.
D8234
5. INSTALL CONTROL VALVE INTO HOUSING

(a) Install a new O-ring to the control valve.
(b) Coat the teflon ring and O-ring with power steering
fluid.
(c) Push the control valve into the housing.
SR1465
(d) Using SST, install the bearing guide nut.

SST 09631-20060
SR1466
(e) Using a hammer and chisel, stake the nut.

(f) Install the dust cover.
6. AIR TIGHTNESS TEST

(a) Install SST to the union of the cylinder housing.
SST 09631 -1 2070
(b) Apply 400 mmHg (15.75 in.Hg, 53.3 kPa) of vacuum
for about 30 seconds.
(b) Check that there is no change in the vacuum.
7. INSTALL CONTROL VALVE

(a) Install a new O-ring to the valve.
(b) Align the marks on the valve housing and rack hous-
ing.
(c) Torque the two bolts.
8. INSTALL RACK GUIDE, SEAT AND RACK GUIDE

SPRING
9. INSTALL RACK GUIDE SPRING CAP

Apply liquid sealer to the threads of the spring cap.
SR1469

(a) Using SST, torque the rack guide spring cap.
SST 0961 2-24013 (0961 2-10022)
SR1470
(b) Using SST, return the rack guide spring cap 30°.
SST 0961 2-24013 (09612-10022)
(c) Turn the control valve shaft right and left one or two
times.
(d) Loosen the spring cap to when the rack guide com-
pression spring is not functioning.
SR1471
(e) Using SST and a torque meter, tighten the rack guide
spring cap until the preload is within specification.
SST 0961 2-2401 3 (0961 2-10022)
0961 6-00010
Preload (turning): 9 -13 kg-em
(7.8 - 11.3 in.-Ib, 0.9 - 1.3 N'm)
SR1472
11. INSTALL RACK GUIDE SPRING CAP LOCK NUT

(a) Apply liquid sealer to the screws of the spring cap lock
nut.
SST 09612-24013 (09612-10022,09617-24020)
(d) Using a pin punch and hammer, stake the lock nut
and cap.
SR1474
12. INSTALL CLAW WASHERS AND RACK ENDS

(a) Install a new claw washer.
NOTE: Align the claw of the claw washer with the rack
groove.
(b) Tighten the rack end and torque it with SST.
SST 0961 2-24013 (0961 7 -24010, 09617-24030)
D0945
(c) Using a hammer and brass bar, stake the claw

washer.
00946
13. INSTALL RACK BOOTS, CLAMPS AND CLIPS

(a) Insure that the tube hole is not clogged with grease.
NOTE: If the tube hole is clogged, the pressure inside the
boot will change after it is assembled and the handle
turned.
A0570
(b) Install the boots.

NOTE: Be careful not to damage or twist the boots.
(c) Install the clamps.
(d) Install the clips.
NOTE: Face the open ends outward to avoid damage to
the boots.
08242
14. INSTALL TIE RODS

(a) Screw the tie rods onto the rack ends until the
~ ~m_ar_k_s
matchmarks are aligned.
atDch -..,................. A (b) After adjusting toe-in, torque the clamp bolts.
~ IDDn!~
08338
15. INSTALL RIGHT AND LEFT TURN PRESSURE TUBES

Using SST, tighten the nuts and torque them.
NOTE: First torque the nuts of the cylinder housing.
SST 09633-00020
\
08244
INSTALLATION GEAR HOUSING (2WD)

(See page SR-38)

Install the gear housing with the four bolts to the body and
torque the four bolts.

(a) Align the match marks on the torque shaft and pinion
shaft.
the three bolts.
(c) Torque the coupling bolts.

SR1376
SST 3. CONNECT RETURN LINE AND PRESSURE LINES
'-~
~~ ~,
Using SST, connect the return and pressure tube.

> •• ':~ :1?- ~>-l,~
k
~
SST 09631-22020
~ I G\~ ~II~ Torque: 450 kg-em (33 ft-Ib, 44 N'm)

~~~
~' --;:,
~,----
£'> '1::; yo _ 4. CONNECT TIE ROD TO KNUCKLE ARM
_____--------- _ L
(a) Install the tie rod to the knuckle arm and torque the
mount nut.
SR1380 Torque: 600 kg-em (43 ft-Ib, 59. N'm)
5. INSTALL WHEEL
----------,~'\
-~(
6. FILL RESERVOIR TANK WITH FLUID
-- \ ~
~ •.~ I Fluid: ATF DEXRON® or DEXRON® IT
7. BLEED POWER STEERING SYSTEM (See page SR-27)
--/
y 9. CHECK TOE-IN (See page FA-6)
SR1379

INSTALLATION OF GEAR HOUSING (4WD)

(See page SR-40)
(a) Install the two grommets to the gear housing.
(b) Install the gear housing with the brackets, and torque
the two bolts and two nuts.
SR1835
2. CONNECT PRESSURE AND RETURN TUBES

Using SST, connect the pressure and return tubes to the
gear housing.
SST 09631-22020

(a) Aligh the matchmarks on the torque shaft and pinion
shaft.
the bolts.
(c) Torque the set bolt.

(d) Install the under cover with the two bolts.
4. CONNECT TIE ROD END TO KNUCKLE ARM

(a) Install the tie rod end to the knuckle arm and torque
the mount nut.
SR 1836
5. INSTALL FRONT DIFFERENTIAL ASSEMBLY

(See page FA-96)
6. FILL RESERVOIR TANK WITH FLUID

7. BLEED POWER STEERING SYSTEM
9. CHECK TOE-IN
(See page FA-34)

SR-58 STEERING - Steering Bevel Gear Housing
STEERING BEVEL GEAR HOUSING

REMOVAL OF BEVEL GEAR HOUSING
Steering Main S h a f t - - - - - - - - f
OL----- [~~o (29. ~~iJ
---+---- I
----+-----
n
/
:
I
--JG27/ Torque Shaft

(
I
Bevel Gear Housing
I
[400 (29. } 9 ) _ ] - -
Jf}----I! 400 (29. 3YU [360 (26. 35) I

[kg-em (ft-Ib. N'm)] : Specified torque @ SR1309
1. REMOVE TWO UNIVERSAL JOINT BOLTS
SR1221
2. REMOVE BEVEL GEAR HOUSING WITH BRACKET

(a) Remove the three bolts.
(b) Remove the bevel gear with bracket.
SR1222
STEERING - Steering Bevel Gear Housing SR-59
COMPONENTS
Bracket
Dust Cover
Bevel Gear Housing
Spring Retainer
Spring
Thrust Washer------@)
No. 1 Bevel Gear - - - - - - - l

Seat ()
Plate~...~
L_ockl3~_ t ' ~ Bearing Dust Cover

[1Q2 (_~10) i-~- ----1 80 (69 in.~
* Lock Nut
I I
~ :'c:_~_c-
1,100 (80. 108)
. .__ * Adjusting Screw
~J_ .~
'~~-
'~~ ~
~"
... '._.
~~
Spring
No.2 Bevel Gear
- "" Spring Holder

* Housing Cover &> \80 (69 in.-Ib, 7.9) I
~c:m-(ft-It),t-.!~r:6] : Specified torque
* Precoated part SR1223
DISASSEMBLY OF BEVEL GEAR HOUSING

1. CLAMP BEVEL GEAR HOUSING BRACKET IN VISE
2. REMOVE TWO DUST COVERS
SRl224
3. REMOVE ADJUSTING SCREW LOCK NUT

SST Using SST, remove the adjusting screw lock nut.
_?- I SST 09612-10093 (09617 -10010)
". I
SR1225
4. REMOVE ADJUSTING SCREW

(a) Using SST, remove the adjusting screw.
SST 0961 2-10093 (09616-10020)
(b) Pull out the spring from the adjusting screw.
SR1226
5. REMOVE HOUSING COVER

Remove the five bolts and housing cover.
SR1227
I
6. REMOVE PLATE, SEAT, SPRING AND SPRING
HOLDER
(a) Loosen the lock nut and unscrew the adjusting bolt.
(b) Remove the two plate set bolts and plate.
(c) Take out the adjusting bolt seat, spring and spring
holder.
SR1228
7. WIPE OFF GREASE OF GEAR TEETH
8. INSPECT TOOTH CONTACT BETWEEN NO. 1 AND

NO.2 BEVEL GEAR
(See step 9 on page SR-65)
SR2214
9. REMOVE NO.1 AND NO.2 BEVEL GEAR

(a) Push in the No.2 bevel gear.
If necessary, tap the No.2 bevel gear with a plastic ham-
mer.
(b) Pull out the No.1 bevel gear and thrust washer.
SR1229
(c) Using a plastic hammer, tap out the No.2 bevel gear.
(d) Remove the bearing and spring retainer.
INSPECTION AND REPAIR OF BEVEL GEAR

HOUSING COMPONENTS
/-~
~
1. INSPECT NO.1 AND NO.2 BEVEL GEAR
~\b (a) Check the needle roller bearing contacting surface
i~~~v_,
'-~7/' (b)
for wear or damage.
Check the gear teeth for wear or damage.
/
2. INSPECT NEEDLE ROLLER BEARING
SR1231
Check for wear or damage.
3. IF NECESSARY, REPLACE NO.1 BEVEL GEAR OIL

SEAL
SR1232

SST 0961 2-10093 (0961 2-10050)
SR1233
4. IF NECESSARY, REPLACE NO.2 BEVEL GEAR OIL

SEAL
(a) Using a screwdriver and hammer, drive out the oil
\ . seal.
SR1234

SST 0961 2-10093 (0961 2-10050)
SR1235
STEERING - Steering Bevel Gear SR-63
ASSEMBLY OF BEVEL GEAR HOUSING

(See page SR-59)
1. PACK FOLLOWING PARTS WITH MOLYBDENUM

DISULPHIDE LITHIUM BASE GREASE:
SR1223
/~
2. INSTALL NO.2 BEVEL GEAR AND BEARING
"~ ~ ...
,,-2
J~ "i \-
::. A
'~,
\
(a) Insert No.2 bevel gear into the housing.
~~- ',-,.. ~(
. <--\)
~..L--~"', '-, 'I
(b) Using SST, press in the bearing.
oJ~.;.T_,-;~. ~1
'i~--1
SST 0961 2-10093 (09612-10061 )
SST
'>l
SR1236
3. INSTALL NO.1 BEVEL GEAR AND THRUST WASHER

(a) Install the thrust washer to the No. 1 bevel gear.
(b) Install the NO.1 bevel gear into the housing.
NOTE: Line up the cutout portion of the NO.1 and No.2
bevel gear.
SRl229
4. INSTALL SPRING AND SPRING HOLDER TO NO.2

BEVEL GEAR
Install the spring with the spring holder to the No.2 bevel
gear.
SR1237
5. INSTALL PLATE, ADJUSTING BOLT AND SEAT

(a) Install the plate with two bolts.
SR1238
(b) Install the adjusting bolt seat.

(c) Screw the adjusting bolt, until touch to the seat.
! ---- l
- ! ---y
~ SR1239
6. ADJUST NO.1 BEVEL GEAR PRELOAD

(a) Using a screwdriver and SST, adjust the NO.1 bevel
gear preload, and then NO.1 bevel gear is no axial
play.
SST 09612-10093 (09616-10010)
Preload (turning): 0.8 - 1.5 kg-em
(0.7 -1.3 in.-Ib, 0.08 - 0.15 N'm)
SR1240
(b) Using a screwdriver, holding the adjusting bolt, and

install and torque the lock nut.
(c) Recheck the NO.1 bevel gear preload.
SR1241
7. INSTALL SPRING RETAINER, SPRING AND

ADJUSTING SCREW
(a) Install the spring retainer into the housing.
(b) Install the spring to the adjusting screw.
(c) Coat liquid sealer to the adjusting screw.
(d) Install the adjusting screw to the housing.
\
SR1242

(a) Using SST and dial indicator, tighten the adjusting
screw, until the No. 1 and No.2 bevel gear back lash
is O.
SST 0961 2-10093 (09616-10020)
(b) Turn the No. 1 bevel gear left and right 5 times and
snug it.
SR1475
(c) Using SST, unscrew the adjusting screw little by little

and measure the total preload within specification.
SST 0961 2-1 0093 (0961 6-1 001 0, 0961 6-10020)
Preload (turning): 1.5 - 4.0 kg-cm
(1.3 - 3.5 in.-Ib, 0.15 - 0.39 N'm)
CAUTION: When loosening the adjusting screw, take
care that the back lash is not more than 0.36 mm
(0.0142 in.).
SR1245
9. INSPECT TOOTH CONTACT BETWEEN NO.1 AND

NO.2 BEVEL GEAR
(a) Coat two teeth at symmetrical position on the No.
bevel gear with red lead.
SR2214
(b) Using SST, turn the No.2 bevel gear in both directions.
SST 09612-10093 (09616-10010)
(c) Inspect the tooth pattern of the No.2 bevel gear.
If incorrect, reassemble the bevel gear housing.
SST
SR2215
[Tooth Pattern of No.2 Bevel Gear]
~
washer
No.2 Bevel ~ear
Heel Contact Face Contact
Select a more thick washer
Proper Contact
Toe Contact Flank Contact
~ No.2 Bevel Gear

Washer
Select a thinner washer

SR2216
If the teech are not contacting properly, use the following

chart to select a proper washer for correction.
Mark Thrust washer thickness mm(in.)
2 1.875 - 1.925 (0.0738 - 0.0758)

3 1.925 - 1.975 (0.0758 - 0.0778)
4 1.975 - 2.025 (0.0778 - 0.0797)
Mark 5 2.025 - 2.075 (0.0797 - 0.0817)
6 2.075 - 2.125 (0.0817 - 0.0837)
SR2217
7 2.1 25 - 2.175 (0.0837 - 0.0856)
8 2.175 - 2.225 (0.0856 - 0.0876)
10. INSTALL ADJUSTING SCREW LOCK NUT

, SST (a) Coat liquid sealer to the lock nut thread and housing
surface.
Sealant: Part No. 08833-00080,THREE BOND 1344,
/ll~ SST 09612-10093 (09616-10020,09617-10010)
/ (;V' Torque: 1,100 kg-em (80 ft-Ib, 108 N'm)
~\
11. PACK MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE INTO GEAR HOUSING
12. INSTALL HOUSING COVER

(a) Coat liquid sealer to the contacting surface of hous-
ing cover.
(b) Install the housing cover with five bolts and torque
bolts.
L-- 12:....:..:....J47
---=..:..SR.c.:...: 13. INSTALL TWO DUST COVERS
INSTALLATION OF BEVEL HOUSING

(See page SR-58)
1. CONNECT BEVEL GEAR TO TWO UNIVERSAL JOINTS

Line up the cutout portion to the bevel gear and universal
joint, and connect them.
2. INSTALL BEVEL GEAR HOUSING TO FRAME

(a) Install the bevel gear housing with the bracket to the
frame.
(b) Install and torque the three bolts.
3. INSTALL AND TORQUE TWO UNIVERSAL JOINT

BOLTS
Torque:
Main shaft side 250 kg-em (18 ft-Ib, 25 N'm)
Torque shaft side 360 kg-em (26 ft-Ib, 35 N'm)
SR1221
BE-1
BODY ELECTRICAL
SYSTEM
Page
GENERAL INFORMATION . BE-2
LOCATION OF SWITCHES AND RELAYS . BE-7
IGNITION SWITCH . BE-12
LIGHTING . BE-13
WIPERS AND WASHERS . BE-18
INSTRUMENTS, GAUGES AND
WARNING LIGHTS . BE-23
REAR WINDOW DEFOGGER . BE-34
HEATERS . BE-36
POWER WINDOW . BE-41
DOOR LOCK . BE-43
REAR SUN ROOF . BE-44
REMOTE CONTROL MIRROR . BE-45
CRUISE CONTROL SYSTEM . BE-46
RADIO, STEREO TAPE PLAYER AND
ANTENNA . BE-65
CLOCK . BE-74
BE-2 BODY ELECTRICAL SYSTEM - General Information
Example: GENERAL INFORMATION

WIRING COLOR CODE
I
d Wire colors are indicated by an alphabetical code.
Red
B = Black L = Light Blue R = Red
R-G d
BR = Brown LG = Light Green V = Violet
I i G = Green 0 = Orange W= White
Red Green
GR = Gray P = Pink Y = Yellow
BE1359
The first letter indicates the basic wire color and the
second letter indicates the color of the stripe.
CONNECTOR
1. PIN NUMBER OF FEMALE CONNECTOR
~
. 32 1. Numbered in order from upper left to lower right.
XII> 2. PIN NUMBER OF MALE CONNECTOR
Female Male Numbered in order from upper right to lower left.
BE0832
3. DISTINCTION OF MALE AND FEMALE CONNECTORS

Male and female connectors are distinguished by shape of
their internal pins.
(a) All connectors are shown from the open end, and the
lock is on top.
Female Male
BE0833
(b) To pull apart the connectors, pull on the connector

itself, not the wires.
WRONG CORRECT
IN0001
REPLACEMENT OF COMBINATION SWITCH

REMOVE TERMINALS FROM CONNECTOR
(a) From the open end, insert a miniature screwdriver
between the locking lugs and terminal.
BE0163
BODY ELECTRICAL SYSTEM - General Information BE-3
(b) Pry up the locking lugs with the screwdriver and pull
the terminal out from the rear.
M94B4
INSTALL TERMINALS TO CONNECTOR

(a) Push in the terminal until it is securely locked in the
connector lug.
(b) Pull on the wire to confirm that it is securely locked.
B0797
.. RESET CIRCUIT BREAKER

1. REMOVE CIRCU IT BREAKER
(a) Remove the kick panel.
(b) Remove the circuit breaker.
B079B
2. RESET CIRCUIT BREAKER

(a) Insert the needle into the reset hole and push it.
.... ~ between both terminals of the circuit breaker.
~/
If there is no continuity, replace the circuit breaker.
BE0015 BE0014
3. INSTALL CIRCUIT BREAKER

(a) Install the circuit breaker.
NOTE: If a circuit breaker continues to cut out, a short
circuit is indicated. Have the system checked by a qualified
technician.
(b) Install the kick panel.
B0798
REPLACEMENT OF FUSES
Install new fuses with correct amperage ratings.
CAUTION:
1. Turn off all electrical components and the ignition
switch before replacing a fuse. Do not exceed the
fuse amp rating.
2. Always use a fuse puller for removing and insert-
ing a fuse. Remove and insert straight in and out
without twisting. Twisting could force open the
terminals too much, resulting in a bad connection.
If a fuse continues to blow, the circuit is probably shorted.
Have the system checked by a qualified technician.
BODY ELECTRICAL SYSTEM - General Information BE-5
To Ignition S/W
VOLTAGE CHECK
IG Terminal
(a) Establish conditions in which voltage is present at the
check point.
Fuse Example:
® - Ignition S/W on
A ® - Ignition S/W and S/W 1 on
© - Ignition S/W, S/W 1 and Relay on (S/W 2 off)
Voltmeter (b) Using a voltmeter, connect the negative lead to a
good ground point or negative battery terminal, and
a the positive lead to the connector or component ter-
minal. This check can be done with a test light
v instead of a voltmeter.
Relay ® 8
t
S/W 2
-=- -=-
Solenoid
1
BE0819
CONTINUITY AND RESISTANCE CHECK

(a) Disconnect the battery terminal or wire so there is no
voltage between the check points.
Ohmmeter ~------1
(b) Contact the two leads of an ohmmeter to each of the
check points.
BE0820
If the circuit has diodes, reverse the two leads and check
~
~
I I
again.
Ohmmeter ! J When contacting the negative lead to the diode positive
/ \
side and the positive lead to the negative side, there
Idl. kCl
ffi 8 ® 8 should be continuity.
L..,..J y When contacting the two leads in reverse, there should be
no continuity.
~
~ ~
Diode ~
I~ ~ BE0821
(c) Use a volt/ohmmeter with high impedance (10 kO/V

Digital Type
Analog Type minimum) for troubleshooting of the electrical circuit.
r;: 7\
,~
'-' I
-I-
I'
/
Dr~+@
c-r
'"
vt,o -@
FI0889
FINDING A SHORT CIRCUIT

(a) Remove the blown fuse and disconnect all loads of
the fuse.
Test Light Fuse Case (b) Connect a test light in place of the fuse.
Short A (c) Establish conditions in which the test light comes on.
Example:
® - 19 nition S/W on
Short ~
® - Ignition S/W and S/W 1 on
Disconnect © - Ignition S/W, S/W 1 and Relay on (Connect
Disconnect the Relay) and S/W 2 off (or Disconnect S/W
2)
(d) Disconnect and reconnect the connectors while
watching the test light.
The short lies between the connector where the test
Disconnect light stays lit and the connector where the light goes
out.
(e) Find the exact location of the short by lightly shaking
the problem wire along the body.
BE0822
BODY ELECTRICAL SYSTEM - Location of Switches and Relays BE-7
LOCATION OF SWITCHES AND RELAYS

ENGINE AND PASSENGER COMPARTMENT
SWITCHES AND RELAYS
Water Temperature
Sender Gauge
Oil Pressure
Sender Gauge
Oil Pressure --~----f-1---~..:YI

Switch
Oil Level Switch----+-----~~I
Neutral Start Switch (A/T)
Oil Level Warning Computer
Turn Signal Flasher

Wiper Control Relay
Taillight Control Relay //
Seat Selt Warning Relay
~ CIS
~(Power
~ Window)
"to-- CIS
(Rear Heater)
~ CIS (Front Heater)
Dome Light Control Relay

Rear Heater Relay
EFI Main
Relay
Heater Relay
Power Main Relay
co
Headlight Control Relay
BE0635
BE1551
BE-8 BODY ELECTRICAL SYSTEM - Location of Switches and Relays
DASH AND STEERING COLUMN

SWITCHES
II-----No. 1 Rear Heater

/
SW~Ch II
Outer Mirror Master Switch (MIT) Front Heater Blower Switch
I
Defogger Switch Rear Wiper Switch I
I
@
\~
Light Control Rheostat ~
~
Outer Mirror Master Switch (A/T)
Fog Light Switch

,~
Radio Remote Control Switch
Ignition Switch
Key Unlock Warning Switch
Headlight Dimmer Switch
Wiper and Cruise Control Switch
Turn Signal and Hazard

Warning Switch
Light Control Switch
Horn Contact
BE1552
BE1022
PASSENGER COMPARTMENT SWITCHES
Stop Light Switch
~
II r"
Front Door Courtesy Switch
~____
.
e
~rking Brake Switch
~ I I ~NO. 2 Rear Heater Switch
J3
"'--Rear Heater Blower Switch
~ Slide Door
Courtesy Switch
-+----\-+~~
Back Door Courtesy Switch
BR0647
BE-10 BODY ELECTRICAL SYSTEM - Location of Switches and Relays

(Cont'd)
Rear Sun Roof Switch

Power Window Master Switch
I
/ I
Slide D~oor
Lock cO,.lntrql Motor
I
. I
I
: i
Washer Change Valve------'"I
~
-,,? '~.)
I ! ~
I I ,I
~ (~ "\ I
c\ ~/
ff
, I 1
~I
Back Door Lock

Control Motor
Front Washer Motor
Rear Washer Motor
BE0860

(Cont'd)
Cruise Control
Cruise Control Main Relay
Main Switch
Computer
Actuator
BE1015
BE-12 BODY ELECTRICAL SYSTEM - Ignition Switch
IGNITION SWITCH
INSPECTION OF IGNITION SWITCH
:i:
ill B Inspect the switch continuity between terminals.
~
Switch
position
LOCK
ACC
4
0- iO
3 2 1 8 7 5 9 10
ON O- f-{)- ~ 0- -0
START C 0- ~ cr- -0-- f--O
ffi
Cl
c: Normal
'Eco
... ... ~
Push 0- ~
10
l
H-8-2
H-2-2
BODY ELECTRICAL SYSTEM - Lighting BE-13
LIGHTING
Troubleshooting
Only one light does Light bulb burned out Replace bulb
not light Socket, wire or ground faulty Repair as necessary
Headlights do not HEAD fuse blown Replace fuse and check for short BE-4
light Fusible link blown Replace fusible link
Headlight control relay faulty Check relay BE-15
Light control/dimmer switch faulty Check switch BE-14
Wiring or ground faulty Repair as necessary
High beam headlights Light control/dimmer switch faulty Check switch BE-14
or headlight flasher Wiring faulty Repair as necessary
does not operate
Cornering light Cornering light control relay faulty Check relay BE-16
does not light Turn signal switch faulty Check switch BE-17
Fog lights do not FOG fuse blown Replace fuse and check for short BE-4
light Fog light switch faulty Check switch BE-15
Tail, parking and T AIL fuse blown Replace fuse and check for short BE-4
license lights do not Fusible link blown Replace fusible link
light
Taillight control relay faulty Check relay BE-15
Light control switch faulty Check switch BE-14
Stop lights do not STOP fuse blown Replace fuse and check for short BE-4
light Stop light switch faulty Adjust or replace switch
Stop lights stay on Stop light switch faulty Adjust or replace switch
Instrument lights do Light control rheostat faulty Check rheostat BE-16

not light (taillights Wiring or ground faulty Repair as necessary
light)
Turn signal does not Turn signal switch faulty Check switch BE-17
flash on one side Wiring or ground faulty Repair as necessary
Turn signals do not TURN fuse blown Replace fuse and check for short BE-4
operate Turn signal flasher faulty Check flasher BE-17
Turn signal/hazard switch faulty Check switch BE-17
BE-14 BODY ELECTRICAL SYSTEM - Lighting
Light Control Switch and Headlight

Dimmer Switch
INSPECTION OF LIGHT CONTROL SWITCH
AND HEADLIGHT DIMMER SWITCH
INSPECT CONTINUITY OF LIGHT CONTROL SWITCH AND
HEADLIGHT DIMMER SWITCH
Inspect the switch continuity between terminals.
Light control switch
~
10 11 4
(Wire Tor EL ELorT H
Swi.t~h color) (W) (W) (R)
position
OFF
TAIL
HEAD
Headlight dimmer switch
BEQlll
~~ Terminal 13 6 5 12
'~ire color) ED HL Hu HF
(W-B) (R-G) (R-Y) (R-W)
Switch "',
I
position ··~i
Flash
~-_._---
.~ ~.- f-------------~~---- f--.-
!
Low Beam 0--- f-----Q
High Beam 0
REPLACEMENT OF LIGHT CONTROL SWITCH

AND HEADLIGHT DIMMER SWITCH
REPLACE LIGHT CONTROL SWITCH AND HEADLIGHT
DIMMER SWITCH
(a) Remove the terminals from the connector.
" (See pages BE-2, 3)
(b) Remove the light control switch.
(c) Remove the headlight dimmer switch.
BE0198
(d) Install the headlight dimmer switch.

(e) Insert the spring into the lever and install the lever
with the set screw and nut.
BE0092 BE0093
(f) Place the ball on the spring, position the lever at

"High Beam" and install the plate with the screws.
BE0094 BE0095
(g) Insure that the switch operates smoothly.

(h) Connect the terminals to the connector.
(See pages BE-3, 14)
No continuity Continuity Light Control Relays

[::K:J [::K:J
o (Headlight and Taillight)
INSPECTION OF LIGHT CONTROL RELAYS
3 2 and 2.
BE0083
and 3.
Continuity
~ 2. INSPECT RELAY OPERATION
0
0 0 (b) Check that there is continuity between terminals 2
and 3.
BE0082
Fog Light Switch
INSPECTION OF FOG LIGHT SWITCH
~ Switch
position
ON
1 3 2
r; ~.n
\.. v
4
OFF r:t\
\,~
BEOB61
If continuity is not as specified, replace the switch or bulb.
BE-16 BODY ELECTRICAL SYSTEM - Lighting
Cornering Light Control Relay

INSPECTION OF CORNERING LIGHT
CONTROL RELAY
Continuity INSPECT RELAY OPERATION
[][] (a) Connect the positive (+) lead from the battery to
1
terminals 4 and 1, then connect the negative (-) lead to
1°0++
10
1
, °
- -
terminal 3, and check that there is continuity between

terminals 4 and 5.
BEOB63
(b) In approximately 2 seconds after disconnecting the

Approx. 2 sec.
positive (+) lead from terminal 1, check that terminals 4
Q)
and 5 show no continuity.
~
°
0
°
BE1372
(c) Connect the positive (+) lead from the battery to

terminals 2 and 4, then connect the negative (-) lead to
terminal 3, and check that there is continuity between
terminals 4 and 6.
Continuity
3
[][]
°
Ol~----
°
Approx. 2 sec. (d) In approximately 2 seconds after disconnecting the

positive (+) lead from terminal 2, check that terminals 4
and 6 show no continuity.
If operations are not as specified, replace the relay.
010++-----
°
BE1373 Light Control Rheostat
INSPECTION OF LIGHT CONTROL RHEOSTAT
INSPECT RHEOSTAT OPERATION
Connect the positive (+) lead from the battery to terminal
2. Connect the negative (-) lead from the battery to ter-
minal 3, and connect a 3.4W test bulb between terminals
1 and 2.
3 Gradually slide the rheostat knob toward the bright side
and/or dark side and check that the test bulb brightness
changes.
L- B
=EO=8=65 If operation is not as specified, replace the rheostat.
Turn Signal and Hazard Warning

Switch
INSPECTION OF TURN SIGNAL AND HAZARD
WARNING SWITCH
INSPECT TURN SIGNAL AND HAZARD WARNING SWITCH
BEOlll
Terminal 3
9 8 2 7 1
(Wire
TL T8 TR
color) (G-B) (G-W) (G-Y)
B} F B2
Switch (G-U (G) (G-O)
position
L
Turn Signal N
R
Hazard ON
REPLACEMENT OF TURN SIGNAL AND

HAZARD WARNING SWITCH
REPLACE TURN SIGNAL AND HAZARD WARNING
SWITCH
(See pages BE-2, 3)
(b) Remove the turn signal and hazard switch.
(c) Install the turn signal and hazard switch.
(d) Install the terminals to the connector.
BE0199
(See pages BE-3, 17)
Turn Signal Light Bulbs (27W)

Turn Signal Flasher
INSPECTION OF TURN SIGNAL FLASHER
INSPECT FLASHER OPERATION
(a) Connect the positive (+) lead from the battery to
terminal 3 and the negative (-) lead to terminal 2.
3 (b) Connect the two turn signal light bulbs parallel to each
2
other to terminals 1 and 2.
BE0127 Check that the bulbs turn on and off.
NOTE: The turn signal lights should flash 60 to 120 times
per minute.
If one of the front or rear turn signal lights has an open
circuit, the number of flashes will be more than 140 per
minute.
If operation is not as specified, replace the flasher.
BE-18 BODY ELECTRICAL SYSTEM - Wipers and Washers
WIPERS AND WASHERS

Troubleshooting
Page
Problem Possible cause Remedy
Front Rear
Wipers do not WIPER fuse blown Replace fuse and check for short BE-4 BE-4
operate or return Wiper motor faulty Check motor BE-20 BE-21
to off position
Wiper switch faulty Check switch BE-18 BE-21
Wipers do not operate Wiper control relay faulty Check relay BE-19
/
at INT position Wiper switch faulty Check switch BE-18
Wiper motor faulty Check motor BE-20
Washers do not Washer hose or nozzle clogged Repair as necessary
operate Washer relay faulty Check relay BE-22 BE-22
Washer motor faulty Replace motor
Washer change valve faulty Check valve BE-22 BE-22
Washer switch faulty Check switch BE-18 BE-21
Wiring faulty Repair as necessary
Front Wiper and Washer Switch

INSPECTION OF FRONT WIPER AND
WASHER SWITCH
- - ~Iflr~
~ ~15I"ll·lsl·~ V' 121 'lb
ili~
~ 13Il22121Jl20flls\1I1 \I2JllJIOJ\.sIIl17J ,.-,
1
-
BEQ111 G-5-2
~
20 21 17 22 19 14 15 VR VR
Switch
Switch +S +1 +8 +2 Cj EW W
position
OFF
i
INT
!
Wiper
LO
HI I
\ \
I
OFF I
i i i :
Washer I
ON i
i
I
SLOW 50 kf1 I
I
•
I
INT I I 34.25 kf1

Time
Control • I
15.75 kf1
FAST Okf1
\

BODY ELECTRICAL SYSTEM - Wipers and Washers BE-19
REPLACEMENT OF FRONT WIPER AND

WASHER SWITCH
REPLACE FRONT WIPER AND WASHER SWITCH
(See pages BE-2, 3)
(b) Remove the terminal from the horn contact.
(c) Remove the windshield wiper and washer switch.
(d) Install the windshield wiper and washer switch.
BE0200
(e) Install the terminal to the horn contact.
3 2 (f) Install the terminals to the connector.

I (See pages BE-3, 19)
Front Wiper Control Relay

(INT. Invariable Type)
INSPECTION OF FRONT WIPER CONTROL
4 RELAY
BE0866 INSPECT RELAY OPERATION
(a) With terminal 1 connected to the battery positive (+)
3 to 5 seconds
terminal. Check that there is a relay operation noise
when terminal 4 is connected to the battery negative
(-) terminal.
(b) Connect terminal 2 to the battery positive (+) ter-
minal.
(c) Check that there is a relay operation noise when
changing terminal 2 to the battery negative (-) ter-
minal and another operation noise 3 to 5 seconds
later.
l.....-- BE_08--'67 If operation is not as specified, replace the relay.
3 2
(INT. Variable Type)
INSPECTION OF FRONT WIPER CONTROL
RELAY
I
5 4
BE0868
INSPECT RELAY OPERATION
@..Q)..@
About 2 seconds
(a) With terminal 1 connected to the battery positive (+)
terminal. Check that there is a relay operation noise
when terminal 4 is connected to the battery negative
(-) terminal.
(b) Connect terminals 5 and 6.
(c) Check for a relay operation noise about every 2
seconds.
BE0869
Front Wiper Motor

INSPECTION OF FRONT WIPER MOTOR
1. INSPECT THAT MOTOR OPERATES AT LOW SPEED
(a) Disconnect the connector from the wiper motor.
(b) Connect the positive (+) lead from the battery to ter-
minal 2. Connect the negative (-) lead to the motor
ffi 8 body.
(c) Check that the motor operates at low speed.
2. INSPECT THAT MOTOR OPERATES AT HIGH SPEED

(a) Connect the positive (+) lead from the battery to ter-
body.
(b) Check that the motor operates at high speed.
ffi 8
BE0295
3. INSPECT THAT MOTOR OPERATES, STOPPING AT

STOP POSITION
(a) Operate the motor at low speed.
(b) Stop motor operation anywhere except stop position
by disconnecting terminal 2.
ffi 8
(c) Connect terminals 2 and 3.

(d) Connect the positive (+) lead from the battery to ter-
minal4.
(e) Check that the motor stops running at stop position
after the motor operates again.
If operation is not as specified, replace the motor.
BODY ELECTRICAL SYSTEM - Wipers and Washers BE-21
Rear Wiper and Washer Switch

INSPECTION OF REAR WIPER AND WASHER
SWITCH
1 u------tt1e-+--4 INSPECT SWITCH CONTINUITY
2 u---++I---+- 5
Inspect the continuity between terminals for each switch
u---++t---t- 7
3 11--------.4-11--+-- 8 position shown in the table below.
Terminal Illumination
BE1016
Switch 3 2 7 8 5 4
position
OFF
ON
Washer
If continuity is not as specified, replace the switch or bulb.
Rear Wiper Motor

2
I
INSPECTION OF REAR WIPER MOTOR
1. INSPECT THAT MOTOR OPERATES
body.
(b) Check that the motor operates.
BE0384
2. INSPECT THAT MOTOR OPERATES, STOPPING AT

STOP POSITION
body. Operates the motor.
(b) Stop motor operation anywhere except stop position
e ® by disconnecting terminal 3.
Wiper Motor'---------'
Body BE0385
(c) Connect terminals 3 and 4.

(d) Connect the positive (+) lead from the battery to
terminal 2.
(e) Check that the motor stops running at stop position
after the motor operates again.
BE 1346
No continuity Continuity Washer

INSPECTION OF WASHER RELAY
o 1. INSPECT RELAY CONTINUITY
and 3.
and 4.
(c) Check that there is no continuity between terminals 3
and 4.
Continuity If continuity is not as specified, replace the relay.

(b) Check that there is continuity between terminals 2
and 4.
and 4.
8 If operation is not as specified, replace the relay.
4 3 BE1375
INSPECTION OF WASHER CHANGE VALVE

CHECK FLUID CIRCUIT CONTINUITY IN VALVE BY
BLOWING AIR INTO PIPE
(a) Blow into pipe "A" and check that air does not come
out of pipe "B".
(b) Apply battery voltage across terminals 1 and 2.
Blow into pipe" A" and check that air comes out of
pipe "B".
L.- BE1385
---' If a problem is found, repair or replace the valve.
BODY ELECTRICAL SYSTEM - Instruments, Gauges and Warning Lights BE-23
INSTRUMENTS, GAUGES AND WARNING LIGHTS

Troubleshooting
Problem ! Possible cause Remedy Page
I
Tachometer does GAUGE fuse blown Replace fuse and check for short BE-4
not work I
Tachometer faulty Check tachometer BE-26
I
!
I Wiring faulty Repair as necessary
I
Fuel gauge does not GAUGE fuse blown Replace fuse and check for short BE-4
work Fuel gauge faulty Check gauge BE-27
Sender gauge faulty Check sender gauge BE-27
~- -
Fuel level warning GAUGE fuse blown Replace fuse and check for short BE-4
light does not light I
Bulb burned out Replace bulb

!
I
Fuel level warning switch faulty Check switch BE-28
I

--- -~
Water temperature GAUGE fuse blown Replace fuse and check for short BE-4
gauge does not work Water temperature gauge faulty Check gauge BE-28
I
Water temperature sender gauge faulty Check sender gauge BE-29
~iring or ground faulty Repair as necessary
Oil pressure gauge GAUGE fuse blown Replace fuse and check for short BE-4
does not work Oil pressure gauge faulty Check gauge BE-29
Sender gauge faulty Check sender gauge BE-30
1-----
Low oil pressure GAUGE fuse blown Replace fuse and check for short BE-4
warning light does Bulb burned out Replace bulb
not light
Oil pressure switch faulty Check switch BE-30
Oil level warning GAUGE fuse blown Replace fuse and check for short BE-4
light does not light Bulb burned out Replace bulb
!
i
Oil level warning computer faulty Check computer BE-32
Oil level switch faulty Check switch BE-32
I
--
Brake warning light r<;AUGE fuse blown Replace fuse and check for short BE-4
does not light Bulb burned out Replace bulb
Brake fluid level warning switch faulty Check switch BE-30
,-----
Radiator coolant level GAUGE fuse blown Replace fuse and check for short BE-4
warning light does Bulb burned out Replace bulb
not light
Radiator coolant level warning Check switch BE-31
!
switch faulty
I
BE-24 BODY ELECTRICAL SYSTEM - Instruments, Gauges and Warning Lights
Combination Meter and Gauge

(w/o Tachometer)
Connector "0"
10
9-
8-
r
6-
5 .....
4~
3~,
2 ,
1
G-3-2
BE0650
COMBINATION METER CIRCUIT

No. Wiring connector side
C-5 0----0~C-IO-C_k------oC-4 1 Turn Signal Switch Terminal 6
2 EFI ECU and Cruise Control Computer Terminal 7
~ Speed Sensor
A-3 ~~-------oA-2 3 Ground
A 5 TAIL Fuse
C-1 8 Turn Signal Switch Terminal 8
9 Ground
C-2 C-7
Water Temperature 10 Turn Signal Switch Terminal 9
C-8 :j Gauge
1 EFI ECU
Beam 2 Parking Brake Switch and Brake Fluid Level Warning
A-9 A-1
Switch
Right Turn Signal
A-8 3 Oil Pressure Sender Gauge
Left Turn Signal B 4 IGN Fuse
A-10
Fasten Belts
5 CHARGE Fuse
B-6 6 Seat Belt Warning Relay
Low Oil Pressure 7 DOME Fuse
B-3
OD OFF 8 Door Courtesy Switch
C-6
Fuel Level Warning 1 Fuel Sender Gauge Terminal 2
C-3
2 Ground
Brake Warning
B-2 3 Fuel Level Warning Switch Terminal 1
Check Engine 4 Ground
B-1
5 DOME Fuse
C
RADIATOR 6 00 OFF Switch
C-9 7 GAUGE Fuse
Discharge Warning
B-5 B-4 8 Water Temperature Sender Gauge
o----@Door 9 Radiator Coolant Level Warning Switch
B-7 o B-8
10 Light Control Rheostat
o-----@ Illumination
r
A-5 o C-10
1 4WO Indicator Light Switch
D_1~4WD D-2 D 2 GAUGE Fuse
ATF 3 ATF Thermo Sensor
D-3
BE 1377
(wi Tachometer)
Connector "D" Connector "E"
~on~o:~\~or
"A"
6 /
5
4
.__---..r 3
2 ,
Q~
2-H-2 G-3-2
BE1376
COMBINATION METER CIRCUIT
No. Wiring connector side

1 Turn Signal Switch Terminal 6
~ Speed Sensor
::----+---'-----~o A - 2
A - 3 o.------tc:::::::::::;7--: 2 EFI ECU and Cruise Control Computer Terminal 7
3 Ground
}-----........----'-T.::;.;ac::..;..h:..:.o-'-'-m...:.e_te_r ---Q C- 6 5 TAIL Fuse
C-8
A
6 Seat Belt Warning Relay
A_9lr-----4-----J(~ 7 Oil Pressure Sender Gauge
~~IIl.jJ.--=.=.:..:~-----O A-1 8 Turn Signal Switch Terminal 8
Fuel C-1 Right Turn Signal A-8 Ground
Gauge
9
C-2 o-~----ll~
Left Turn Signal A-10 10 Turn Signal Switch Terminal 9
Water 8-1 ~F..::.a::..;st..::.en:..;....:;.8.;:.cel..;...:ts,---o A - 6 1 Water Temperature Sender Gauge
Temperature 2 Parking Brake Switch and Brake Fluid Level Warning
Gauge
A-7 Switch
B 4 CHARGE Fuse
5 IGN Fuse
'-~aI+--";:";';""::':"'"'-"-'---O 0-1 7 EFI ECU
~~IU"l-....:C;.;..h:..:.ec=k-,-,-E_n....:..q,-i
n_e_-o 8- 7 8 DOME Fuse
....-----¥'v'#------.=----o 8- 2 1 Fuel Sender Gauge Terminal 2

2 Ground
C- 5 O-~V 'l-~
3 Door Courtesy Switch
4 Fuel Level Warning Switch Terminal 1
C 5 Radiator Coolant Level Warning Switch
8-4 8-5 6 GAUGE Fuse
C-3 0
@} Door
08-8
8 IIA
9 Light Control Rheostat
C-9 0
@ Illumination
o A-5 10 Back Door Unlock Switch
E-l :
E-3
~ :~FD jE-2
D
1
2
Oil Level Warning Switch
00 OFF Switch
1 4WD Indicator Light Switch
E 2 GAUGE Fuse
3 ATF Thermo Sensor
BE 1378
Speedometer
ON-VEHICLE INSPECTION OF SPEEDOMETER
(a) Using a speedometer tester, inspect the speedometer
for allowable indicating error and check the operation
of the odometer.
NOTE: Tire wear and tire over or under inflation will
increase the indicating error.
(b) Check the speedometer for pointer vibration and
abnormal noises.
NOTE: Pointer vibration can be caused by a loose
speedometer cable.
Standard indication Allowable error

(km/h) (km/h)
20 18 - 23
40 40 - 44
60 60 - 64.5
80 80 - 85
100 100 - 105
120 120 - 125.5
140 140 - 146
160 160 - 167
Standard indication Allowable error

(mph) (mph)
20 20 - 23
40 40 - 43.5
60 60 - 64
80 80 - 84.5
100 100 - 105
Tachometer
ON-VEHICLE INSPECTION OF TACHOMETER
(a) Connect a tachometer, and start the engine.
(b) Compare the tester and tachometer indications.
If the error is excessive, replace the tachometer.
CAUTION:
• Reversing the connection of the tachometer will
damage the transistors and diodes inside.
• When removing or installing the tachometer, be
careful not to drop or subject it to heavy shocks.
Standard indication (rpm)

I 700 I 3,000 ! 5,000 7,000
I I I
Allowable range (rpm) I + 20 I ±200 : ±200 ±300

I -120 I I
Fuel Gauge
INSPECTION OF FUEL GAUGE
1. INSPECT RECEIVER GAUGE OPERATION
(a) Disconnect the connector from the fuel sender
gauge.
(b) Turn the ignition switch on. Check that the receiver
gauge needle moves to the empty position.
(c) Connect a 12V, 3.4W test bulb between terminals 2

Test Bulb 3AW and 3. Check that the bulb lights and that the receiver
.~2~.1/,,~
SWit~ -V
Ignition Fuel Gauge
c ~-'j!r
gauge needle operates.
NOTE: Because of the silicon oil in the gauge, it will take
Connect~r about 90 seconds for the needle to stabilize.
If indications are not correct, remove and test the receiver
gauge.
2. INSPECT RECEIVER GAUGE RESISTANCE

Measure the resistance between terminals.
Between Resistance (0)
terminals w/o Tachometer wi Tachometer

IG - FU Approx. 125 Approx. 64.3
FU - E Approx. 55 Approx. 169.0
IG - E Approx. 70 Approx. 233.3
If each resistance value is not as specified, replace the

wi Tachometer receiver gauge.
3. INSPECT SENDER GAUGE OPERATION

(a) Connect a series of three 1.5V dry cell batterys.
(b) Connect the positive (+) lead from the dry cell batterys
to terminal 2 through a 3.4W test bulb and the
negative (-) lead to terminal 3.
(c) Check that the voltage rises between terminals 2 and
3 as the float is moved from the top to bottom position.
BE1379
(d) Measure the resistance between terminals 2 and 3 for

each float position.
Float position mm(in.) Resistance (0)

2WD 55 - 61 (2.1 7 - 2.40)
F 3.0 ±1
4WD 35.4 - 41.4 (1.394 - 1.630)
2WD 233.5 - 239.5 (9.193 - 9.429)

E 110.0±7.7
4WD 231.4 - 237.4 (9.110 - 9.346)
BE13BO

sender gauge..
Ignition Fuel Level Warning Light
Switch
Fuel Level Warning Light
Connector INSPECTION OF FUEL LEVEL WARNING
1. INSPECT WARNING LIGHT OPERATION
(a) Disconnect the connector from the warning switch.
Connect the terminals 1 and 2 of wire harness side
connector.
(b) Turn the ignition switch on. Check that the warning
light lights.
2. INSPECT WARNING SWITCH OPERATION

(a) Apply battery voltage between terminals 1 and 3
Battery through a 3.4W test bulb. Check that the bulb lights,
:+ NOTE: It will take a short time for the bulb to light.
I
T
(b) Submerge the switch in gasoline. Check that the bulb
goes out.
If operation is not as specified, replace the switch,
Battery
+
Water Temperature Test Bulb 3.4 W

Gauge
Water Temperature Gauge
Ignition ........, \ I 1/
...; INSPECTION OF WATER TEMPERATURE
Switch .'
GAUGE
Connector
(a) Disconnect the connector from the sender gauge.
Ground the terminal through a 12V, 3.4W test bulb
as shown.
(b) Turn the ignition switch on. Check that the bulb
lights and that the receiver gauge needle operates.
wlo Tachometer 2. INSPECT RECEIVER GAUGE RESISTANCE

Measure the resistance between terminals.
Resistance (0)
Between
terminals I
wlo Tachometer wi Tachometer
i
1- TU Approx. 55 -
IG- TU - Approx. 55
TU-E - Approx. 125
IG- E - Approx. 70
wi Tachometer
~---_._---~-
( ~@: I:@E receiver gauge.
/~ \~:u~
( ~@@~@@ @ @
LJ
3. INSPECT SENDER GAUGE RESISTANCE
Measure the resistance between the terminal and body
ground.
Water temperature °C (OF) Resistance (0)
50 l122) 2260 + 33.6

. - 36.6
115 (239) 264+ 1 .71

. - 2.21
If resistance value is not as specified, replace the sender

gauge.
Oil Pressure Gauge
Ignition
Switch ,0 Oil Pressure Gauge
INSPECTION OF OIL PRESSURE GAUGE
Ground the terminal through a 12V, 3.4W test bulb
as shown.
(b) Turn the ignition switch on. Check that the bulb
lights and that the receiver gauge needle operates.
§~ ~OU© @
§ 2. INSPECT RECEIVER GAUGE RESISTANCE
~ IG© @ Measure the resistance between terminals IG and au.
\~@@ @@ Resistance: Approx. 42 fl
If resistance value is not as specified, replace the receiver
gauge.
~~@®~~~
LJ
3. INSPECT SENDER GAUGE OPERATION

(b) Connect a 12V battery through a 12V, 3.4W test
bulb as shown.
(c) Check that the bulb does not light when the engine is
stopped, and flashes when the engine is running. The
number of flashes should vary with engine speed.
_ Battery
If operation is not as specified, replace the sender gauge.
I
Ignition Oil PresStJre Warning Light Low Oil Pressure Warning
Switch
I INSPECTION OF LOW OIL PRESSURE
Connector WARNING
(a) Disconnect the connector from the pressure switch.
Ground the terminal.
1 (b) Turn the ignition switch on. Check that the warning
light lights.
2. INSPECT PRESSURE SWITCH OPERATION

(a) Check that there is continuity between the terminal
and body ground with the engine stopped.
(b) Check that there is no continuity between the ter-
minal and body ground with the engine running.
NOTE : After the eng ine has started, oil pressure should
be over 0.3 kg/cm 2 (4.3 psi, 29 kPa).
If operation is not as specified, replace the switch.
Brake Fluid Level Brake Warning

Ignition Warning Light
Switch INSPECTION OF BRAKE WARNING
Connector 1. INSPECT WARNING LIGHT OPERATION
(a) Disconnect the connectors from the level warning
switch and parking brake switch.
(b) Connect the terminals on the wire harness side of the
level warning switch connector.
1 (c) Remove CHARGE fuse and turn the ignition switch
ON. Check that the warning light lights.
If the warning light does not light, test the bulb.
2. INSPECT OPERATION OF BRAKE FLUID LEVEL

WARNING SWITCH
(a) Check that there is no continuity between terminals
when the warning switch is OFF (float up).
(b) Check that there is continuity between terminals
when the warning switch is ON (float down).
If operation is not as specified, replace the warning switch.
3. INSPECT PARKING BRAKE OPERATION

(a) Check that there is continuity between the terminal
n. and screw hole with the parking brake lever pulled
up.
o (b) Check that there is no continuity between the ter-

minal and screw hole with the parking brake lever
returned.
If operation is not correct, replace the switch.
BE0504
Ignition
Radiator Coolant Level
Warning Light
Radiator Coolant Level Warning
Switch Light
Connector INSPECTION OF RADIATOR COOLANT LEVEL
WARNING LIGHT
(a) Disconnect the connector from the warning switch.
1 (b)
Connect the terminals of the wiring connector.
Turn the ignition switch on. Check that the warning
light lights.
2. INSPECT WARNING SWITCH OPERATION

(a) Check that there is no continuity between terminals
OFF
when the warning switch is OFF (float up).
t
rCJ',
~
(b) Check that there is continuity between terminals
ON~ when the warning switch is ON (float down).
If operation is not as specified, replace the warning switch.
Oil Level Warning Light

WIRING DIAGRAM
GAUGE Oil Level Warning Light
Ignition Switch Fuse 7.5A
O.....--------<O""'--O~---------_6___---->-'L---____.,
.----------~ 6 )-------4 Delay

Circuit
- ----- - ------4
T
I Battery Oil Level Oil Level Computer
---.1..- Switch
l
Ignition Oil Level Warning Light INSPECTION OF OIL LEVEL WARNING LIGHT
Switch IQl
:----~--~ i 1. INSPECT WARNING LIGHT OPERATION
(a) Disconnect the connector from the oil level computer
c:§l
Computer
(b)
connector. Connect terminal 2 to the body ground.
Turn the ignition switch on. Check that the warning
Connector
light lights.
BE0697
2. INSPECT OIL LEVEL COMPUTER

(a) Connect the bulb lead wires to terminal 2 and the
battery (+).
(b) Connect the positive (+) lead from the battery to ter-
minal 1. Connect the negative (-) lead from the bat-
tery to terminal 5.
(c) Check that the bulb lights within 1 5 to 30 seconds
after connecting.
BE0640
(d) Next, connect the negative (-) lead from the battery
to terminal 6, and check that the bulb goes out.
(e) Disconnect the terminal 6 lead wire, and recheck that
the bulb lights within 15 - 30 seconds after discon-
necting.
BE0641
(f) Disconnect the lead wires connected in step (b).

(g) Connect the negative (-) lead from the battery to ter-
minal 3, and check that the bulb lights.
,-_._---
BE0645
3. INSPECT OIL LEVEL SWITCH

To
ground • (a) With the float facing down and lowered, check that
W1 2 To
Computer terminals 1 and 2 are continuous.
Level
rL-~..r--Switch
Float
BE0643
Temperature Switch BEl139
(b) With the float facing down, place the switch in warm
(65°C or 149°F) engine oil and check the float floats
up. Then check that terminals 1 and 2 are con-
tinuous.
/ 3JtmOtOmmoOtl~
8E1140
(c) With the float facing up, resubmerge switch and

check the float floats up On opposite direction from
before).
Then check that there is no continuity between ter-
minals 1 and 2.
NOTE: The temperature switch OFF temperature varies
within 50 - 60°C (122 - 140°F), but the ON temperature
varies from 1 - 15°C (34 - 59°F) below the OFF tem-
perature.
8E1141
BE-34 BODY ELECTRICAL SYSTEM - Rear Window Defogger
REAR WINDOW DEFOGGER

Troubleshooting
Rear window defogger DEFOG fuse blown Replace fuse and check for short BE-4
does not work Defogger switch faulty Check switch BE-34
Defogger wire broken Check wires BE-34
Wiring and ground faulty Repair as necessary
Rear Window Defogger Switch

INSPECTION OF REAR WINDOW DEFOGGER
SWITCH
Terminal Illumination
Switch
BE1381 BE1382
position 4 5 3 2
OFF
ON
If continuity is not as shown, replace the switch or bulb.
Rear Window Defogger Wires

CAUTION:
• When cleaning the glass, use a soft, dry cloth, and
Testerp~.
~'.
wipe the glass in the direction of the wire. Take care
Heat Wire not to damage the wires.
• Do not use detergents or glass cleaners with
abrasive ingredients.
Tin Foil
• When measuring voltage, wind a piece of tin foil
around the tip of the negative probe and press the
56161
foil against the wire with your finger as shown.
INSPECTION OF REAR WINDOW DEFOGGER

WIRES
1. INSPECT FOR WIRE BREAKAGE
(a) Turn the ignition switch to ON.
(b) Turn the defogger switch to ON.
BODY ELECTRICAL SYSTEM - Rear Window Defogger BE-35
(c) Inspect the voltage at the center of each heat wire as

shown.
Voltage Criteria
r-
Approx. 5V Okay (No break in wire)
1---
Approx. 1OV or OV Broken wire
NOTE: If there is 10V, the wire is broken between the

center of the wire and positive (+) end. If there is no
voltage, the wire is broken between the center of the wire
and ground.
2. INSPECT FOR WIRE BREAKAGE POINT

Several (a) Place the voltmeter positive (+) lead against the
o volt Volts defogger positive (+) terminal.
(b) Place the voltmeter negative (-) lead with the foil
strip against the heat wire at the positive (+) terminal
end and slide it toward the negative (-) terminal end.
v
(c) The point where the voltmeter deflects from zero to
o BE0124
several volts is the place where the heat wire is
broken.
NOTE: If the heat wire is not broken, the voltmeter will

indicate OV at the positive (+) end of the heat wire but
gradually increase to about 1 2V as the meter probe is
moved to the other end.
REPAIR OF REAR WINDOW DEFOGGER

WIRES
1. CLEAN BROKEN WIRE TIPS WITH CLEANER
/ \ 2. PLACE MASKING TAPE ALONG BOTH SIDES OF

WIRE TO BE REPAIRED
/ ../" '--.../ ]Broken Wire
.~I~_ ~
Masking Tape
BE0150
3. REPAIR DEFOGGER WIRES

(a) Thoroughly mix the repair agent (Dupont paste No.
4817).
p-
~4,~~.. rrr'.~' (b) Using a fine tip brush, apply a small amount to the
wire.
~~" (c) After a few minutes, remove the masking tape.
'\
(d) Allow to stand at least 24 hours.
~=I
BE0151
BE-36 BODY ELECTRICAL SYSTEM - Heaters
HEATERS
Troubleshooting
Page
Problem Possible cause Remedy
Front Rear
Blower does not work Heater circuit breaker OFF Reset breaker and check for BE-3 BE-3
when fan switch is on short
Heater blower motor relay Check relay BE-37
faulty
Heater blower switch faulty Check switch BE-36 BE-39
Heater blower resistor faulty Check resistor BE-37 BE-39
Heater blower motor faulty Replace motor
.- lncorrect Control cables broken or Check cables BE-38 BE-40

temperature output binding
Heater hoses leaking or Replace hoses
clogged
Water valve faulty Replace valve
Air dampers broken Repair dampers
Air ducts clogged Repair ducts
Heater radiator leaking or Replace radiator
clogged
Heater control unit faulty Repair control unit
Front Heater Blower Switch

INSPECTION OF HEATER BLOWER SWITCH
Terminal
Switch 2 3 5 6 7* 8*
position
OFF
LO
II
III
HI
* For illumination light

BEl017
0-B-2
BODY ELECTRICAL SYSTEM - Heaters BE-37
Front Heater Blower Motor Relay

INSPECTION OF FRONT HEATER MAIN
RELAY
BE0908
No continuity Continuity 1. INSPECT RELAY CONTINUITY

and 3.
and 4.

fi- Connect the positive (+) lead from the battery to terminal
1 and connect the negative (-) lead from the battery to
terminal 3. Then, check that there is continuity between
terminals 2 and 4.
If operation is not as described, replace the relay.
BE0010
Front Heater Blower Resistor

2
INSPECTION OF HEATER BLOWER RESISTOR
INSPECT RESISTOR CONTINUITY
Check that there is continuity between terminals 2 and 4.
If continuity is not as specified, replace the resistor.
4 3
Front Heater Control

ADJUSTMENT OF FRONT HEATER CONTROL
FRESH 1. ADJUST AIR INLET DAMPER
Set the air inlet damper and control lever to "FRESH".
2. ADJUST MODE SELECTOR DAMPER

Set the mode selector and control lever to "FACE".
3. ADJUST AIR MIX DAMPER

Set the air mix damper and control lever to "COOL".
Adjustment Clip
I I
Push the outer 4. ADJUST WATER VALVE

CO~OLI cable in the direction Set the water valve and control lever to "COOL".
of the arrow.
til i' NOTE: Place the water valve lever on "COOL" and while
Adjustment ,..', -: . ~ pushing the outer cable in the "COOL" direction, clamp
the outer cable to the water valve bracket.
Clip _~(Z-01'
--~J~~~ L
BE0654
5. TEST HEATER CONTROL CABLE OPERATION

Move the control levers right and left, and check for stiff-
ness and binding through the levers full range of opera-
tion.
BODY ELECTRICAL SYSTEM - Heaters BE-39
No. 1 and No.2 Rear Heater

-~- ~
Switch
~ I
---i:O LJ~~, ~r .
L I.
~ -j 2 1
INSPECTION OF NO.1 AND NO.2 REAR
! I
HEATER SWITCH
~~'
.. ,
·~T-~cr~
t~' Inspect the switch continuity between terminals.
4 3
~.~~
BE 103 7
Switch 1 2 3 4
position
OFF
~
ON \::../
Rear Heater Blower Switch

INSPECTION OF REAR HEATER BLOWER
SWITCH
3-~-~
BE1038
~Switch
position
LO
1 2 3
•
HI
Rear Heater Blower Motor Relay

REFER TO FRONT HEATER BLOWER MOTOR RELAY
(See page BE-37)
Rear Heater Blower Resistor

INSPECTION OF HEATER BLOWER RESISTOR
Continuity
INSPECT RESISTOR CONTINUITY
Check that there is continuity between terminals 2 and 3.
If there is no continuity, replace the resistor.
BE1039
Rear Heater Control

ADJUSTMENT OF REAR HEATER CONTROL
1. ADJUST MODE SELECTOR DAMPER
Set the mode selector and control lever to "FACE".
Adjustment Clip ~
2. ADJUST AIR MIX DAMPER

Set the air mix damper and control lever to "WARM".
~
. . . Front
3. TEST HEATER CONTROL CABLE OPERATION

Move the control levers back and forth, and check for
stiffness and binding through the levers full range of
operation.
BODY ELECTRICAL SYSTEM - Power Window BE-41
Armrest Type POWER WINDOW

Power Window Master Switch
3nrlf 2 1
INSPECTION OF POWER WINDOW MASTER
8 7 6 5 4 SWITCH
13 12 1 1 10 9 INSPECT SWITCH CONTINUITY
S-13-2 Armrest type terminal 9 7 5 4 9 12 10 4
Door trim type terminal 4 1 8 3 4 6 5 3
Door Trim Type
1\ Operation window
Driver's side Passenger's side
Switch position \
~
UP 0- -D 0- ~ 0- f-O 0-k)
o~
"'0 u
c:,S2 OFF 0- f-()- f-O 0- k>- f-O
.- c:
S :::J DOWN 0 D 0 D
0 0 0 {)
UP 0- k) 0- -0 0- -0
~
0
GA-B-2A
-g~
.- u
OFF 0- k:>- -0 0- ro
S,S2 0 D 0 D
DOWN
Armrest Type 0 D
Power Window Door Switch

INSPECTION OF POWER WINDOW DOOR
SWITCH
G-5-2-A
Door Trim Type Armrest type 2 1 5 4 3

Door trim type 5 1 4 3 2
UP
c:
..co
B:~ OFF
.~ ~
CfJQ..
-0
DOWN

G-5-2
No continuity Continuity Power Main Relay

n. r n. 1
I
INSPECTION OF POWER MAIN RELAY

- 2- 1- and 3.
~h (b) Check that there is no continuity between terminals 2
-
IP
4- 3 -
BE090B BE0009
and 4.
BE-42 BODY ELECTRICAL SYSTEM - Power Window

1 and connect the negative (-) lead from the battery to
terminal 3. Then, check that there is continuity between
terminals 2 and 4.
Power Window Motor
Ifil\ t?1 -11 INSPECTION OF POWER WINDOW MOTOR

1. INSPECT CIRCUIT BREAKER OPERATION
I Within 4 to 40 seconds (a) With the window in the full closed position, hold the
power window switch at "UP" position and check
IR tY1 Jl\
that there is a circuit breaker operation noise within 4
to 40 seconds.
(b) With the window in the full closed position, hold the
switch at "DOWN" and check that the window
begins to descend within 60 seconds.
If operation is not as described, replace the motor.
. . Within 60 seconds
2. INSPECT MOTOR OPERATION

(a) (b)
terminal 1 and negative (-) lead to terminal 2, and
check that the motor turn.
r::::::=:)-++-- 1 (-) (b) Connect the positive (+) lead from the battery to
(+) 1
(-) 2 --+-f---------i --2 (+) check that the motor turns the opposite way.
BODY ELECTRICAL SYSTEM - Door Lock BE-43
Instrument Panel Type DOOR LOCK

2~----+--+l
Door Lock Control Switch
INSPECTION OF CONTROL SWITCH
4 3 ~Terminal
Switch ~~ 2 1 4 3
position ~
1--------- - - -
Armrest Type
LOCK
3nJlf 2 1 OFF
UNLOCK
8 7 6 5 4
13 12 1 1 10 9 If continuity is not as specified, replace the switch.
5-13-2
Front and Slide Door Door Lock Control Motor

(a) (b)
INSPECTION OF CONTROL MOTOR
l::::::::J--+-+-- 1 (- ) terminal 1 and negative (-) lead to terminal 2, and
check that the motor turns.
(-)2-J.-------..I - 2 (+)
(b) Connect the positive (+) lead from the battery to
check that the motor turns the opposite way.
Back Door If operation is not as specified, replace the motor.
Withdraws Protrudes
(+) (-) (-) (+)
2. INSPECT ROD STROKE

Stroke: 30 ± 2 mm (1.18 ± 0.08 in.)
If there is not within specification, replace the motor.
30 ± 2 mm
BE-44 BODY ELECTRICAL SYSTEM - Rear Sun Roof
REAR SUN ROOF

Rear Sun Roof Switch
INSPECTION OF REAR SUN ROOF SWITCH
~
I
4 3
Switch 2 1 4 3
position
OPEN
OFF
CLOSE
Power Main Relay

(See page BE-41)
Rear Sun Roof Motor

INSPECTION OF REAR SUN ROOF MOTOR
J Within 4 to 40 seconds 1. INSPECT CIRCU IT BREAKER OPERATION
.
~~~-~->~-~-~-~\ Jl i
(a) With the sun roof in the full closed position, hold the
sun roof switch at "CLOSE" position and check that
there is a circuit breaker operation noise within 4 to
40 seconds.
(b) With the sun roof in the full closed position, hold the
~~~Jl
sun roof switch at "OPEN" and check that the win-
dow begins to descend within 60 seconds.
If operation is not as described, replace the sun roof
J Within 60 seconds
motor.
....• ~
I,~~~
... -~~S~~~ H
~~

(a) (b)
check that the motor turns.
(+) 1 --t--t--r-_ _ +-f--- 1 (-)
check that the motor turns the opposite way.
(-) 2 -I-+-~ 2 (+)
BODY ELECTRICAL SYSTEM - Remote Control Mirror BE-45
REMOTE CONTROL MIRROR

Outer Mirror Master Switch
INSPECTION OF OUTER MIRROR MASTER
SWITCH
Mirror Left mirror Right mirror

I
~
Switch
position
7 6 2 1 3
I
I
1 2 I
I
5 4
2 Up I
Down
5 4 0- f-o:o- k)
I
-0
Left
I
I
I
I
Right
0- ~ I
0-hJ
0- t-o:o-1-0
I I
Remote Control Mirror

ON-VEHICLE INSPECTION OF MIRROR
INSPECT MIRROR OPERATION
2 3 (a) Connect the positive (+) lead from the battery to
terminal 3 and negative (-) lead to terminal 2, check
that the mirror moves upward.
Then, reverse the polarity, and check that the mirror
revol ution is reversed.
terminal 1 and negative (-) lead to terminal 2, check
that the mirror moves to the left.
Then, reverse the polarity, and check that the mirror
revolution is reversed.
If there is no mirror operation, replace the mirror.
BE-46 BODY ELECTRICAL SYSTEM - Cruise Control System
CRUISE CONTROL SYSTEM

Wiring Diagram
Ignition Switch
ST j
Fuse ECU-IG 10A
Fuse GAUGE 7.5A
Stop
Light
Clutch Switch
Fusible Computer
Link
= Battery
Taillight
I
Relay
)--------~00 Relay
2 1
Computer
~
W:llij
Actuator ~)g
Alternator Main Relay
Wire Harness Side
~ 32
9 Control Switch (SPE) (RS)
Speed Sensor
~
Clutch Switch
~
Brake Cancel
Switch
fa
• Stop Light Switch
• Brake Fluid Level
~ OJ
Parking Brake
Switch Neutral
Start Switch
Warning Switch BEl043
BODY ELECTRICAL SYSTEM - Cruise Control System BE-47
Troubleshooting
Problem Inspection item
f------- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - e----------
Cruise control does not operate. Inspection of power source circuit A

-_._- - - - - - - - - - - - - - _.. _------- "---- - - - - - - - - - - - - f----
Vehicle speed does not fluctuate when set switch

turned on.
Vehicle speed does not decrease when

coast switch turned on.
Inspection of control switch and circuit B
Vehicle speed does not accelerate when accel Inspection of actuator and circuit C
switch turned on.
Vehicle speed does not return to memorized

speed when resume switch turned on.
-------------
Set speed deviates on high side.

~------- --
Inspection of actuator and circuit C
Set speed deviates on low side. Inspection of speed sensor and circuit H
Setting speed does not cancel when brake Inspection of actuator and circuit C
pedal depressed. Inspection of stop light switch and circuit 0
f----------- -
Setting speed does not cancel when Inspection of actuator and circuit C
parking brake pulled. Inspection of parking brake switch and circuit E
-
Setting speed does not cancel when clutch Inspection of actuator and circuit C
pedal depressed (MIT only). Inspection of clutch switch and circuit F
Setting speed does not cancel when Inspection of actuator and circuit C
shifted to "N" range (A/T only). Inspection of neutral start switch and circuit G
;--------------------
Speed can be set about 40 kmlh (25 mph) or below.

1----- -------------- Inspection of actuator and circuit C
Cruise control will not disengage even Inspection of speed sensor and circuit H
below 40 km/h (25 mph).
o INSPECTION OF SOURCE CIRCUIT
Turn ignition switch on.
No No
Is ECU-IG fuse normal? Replace fuse. The short circuit wire harness
Is operation normal? between fuse and terminal 2
Yes of the main switch.
Yes
IFuse faulty.
MAIN S/W
INSPECT POWER SOURCE No Open circuit in wire harness between fuse

Is there battery voltage between terminal 2 ......--~~ and terminal 2 of main switch.
of main switch and body ground?
Yes
INSPECT GROUND CONNECTION • Open circuit in wire harness between

Disconnect connector from main switch. No terminal 4 of main switch and body ground.
Is there continuity between terminal 4 of wire • Body ground faulty.
harness side connector and body ground?
Yes
•
INSPECT SWITCH OPERATION Inspect main switch.
No
Is there battery voltage between terminal 3
and body ground with main switch turned on?
Yes
MAIN RELAY
INSPECT POWER SOURCE No Open circuit in wire harness between terminal

Is there battery voltage between terminal 2 ......-- -t 2 of main relay and fuse.
and body ground?
Yes
Is there battery voltage between terminal 3 No Open circuit in wire harness between terminal
and body ground with main switch turned on ?I--------.~ 3 of main switch and terminal 3 of main relay.
,
INSPECT GROUND CONNECTION Open circuit in wire harness between terminal
No
Is there continuity between terminal 1 and 1 and body ground.
body ground?
Yes
CONTINUED ON PAGE BE-49
CONTINUED FROM PAGE BE- 48
INSPECT RELAY OPERATION Replace relay.

No
Is relay operation normal?
(See page BE-54)
Yes
CO NTROL S/W
INSPECT GROUND CONNECTION Open circuit in wire harness between terminal

Disconnect connector from control switch. No 9 of control switch and body ground.
Is there continuity between terminal 9 of wire
-
I
, Yes
t
INSPECT SET/COAST SWITCH OPERATION No Inspect control switch.
Is there continuity between terminal 2 and -
body ground with set/coast switch turned on?
I
Yes
t
Is there no continuity between terminal 2 and No _ Inspect control switch.
body ground with set/coast switch turned
off?
, I
Yes
1
INSPECT RESUME/ACCEL SWITCH Inspect control switch.

OPERATION No
Is there continuity between terminal 1 and
body ground when resume/accel switch
turned on?
II
Yes
,
I
BRAKE CANCEL S/W I
INSPECT CANCEL CIRCUIT • Severed wire between brake cancel switch

Is there continuity between terminal 1 No terminal 2 and actuator terminal 5.
of brake cancel switch and body ground • Check actuator.
when brake pedal is not depressed?
I
~ Yes
Disconnect actuator and brake cancel switch Short in wire harness between brake cancel
connector. Is there continuity between Yes _ switch terminal 2 and actuator terminal 5.
brake cancel switch terminal 2 and body
ground?
No
CONTINUED ON PAGE BE-50
CONTINUED FROM PAGE BE-49
STOP UGHT S/W ~
INSPECT STOP LIGHT SWITCH Inspect stop light switch.

OPERATION No _
Is there continuity between terminals 1 and 2
with brake pedal depressed?
Yes
Disconnect stop light switch and computer Open circuit in wire harness between
connector. Is there continuity between stop No _ terminal 12 of computer and terminal 1 of
light switch terminal 1 and computer terminal stop light switch.
12?
I
Yes
~
I
CO MPUTER
Disconnect computer and inspect connector

on wire harness side as follows.
INSPECT POWER SOURCE Open circuit in wire harness between

Is there battery voltage between terminal 10 No _ terminal 10 of computer and terminal 4 of
and body ground with main switch turned main relay.
on?
Yes
•
body ground?
No
- terminal 13 and body ground.
• Body ground faulty.
Yes
I
INSPECT SET/COAST SWITCH CIRCUIT • Open circuit in wire harness between

Is there continuity between terminal 1 7 and No terminal 1 7 of computer and terminal 2
body ground with set/coast switch turned of control switch.
on? • Inspect control switch.
Yes
Is there continuity between terminal 1 7 and • Short circuit in wire harness between
body ground with set/coast switch turned Yes terminal 1 7 of computer and terminal 2
off? of control switch.
• Inspect control switch.
I
I
No
~ CONTINUED ON PAGE BE-51
INSPECT RESUME/ACCEL SWITCH • Open circuit in wire harness between

CIRCUIT No _ terminal 16 of computer and terminal 1
Is there continuity between terminal 16 and of control switch.
body ground with resume/accel switch turned • Inspect control switch.
on?
Yes
r
Is there continuity between terminal 16 and • Short circuit in wire harness between
body ground with resume/accel switch turned Yes terminal 16 of computer and terminal 1
off? of control switch.
• Inspect control switch.
No
INSPECT ACTUATOR MOTOR CIRCUIT • Severed wire between computer terminal

Is there continuity between computer 2 and actuator terminal 1.
No
terminals 2 and 4? • Severed wire between computer terminal
4 and actuator terminal 6.
• Inspect actuator.
, Yes
INSPECT POTENTIOMETER CIRCUIT • Severed wire or short between computer

Is there 2 k n resistance between computer terminal 3 and actuator terminal 3.
No _
terminals 1 and 3? • Severed wire or short between computer
terminal 1 and actuator terminal 4.
Yes
I
Is there continuity between computer No _ • Severed wire or short between computer

terminals 6 and 3? terminal 6 and actuator terminal 2.
Yes
Disconnect actuator connector. Yes Short circuit in wire between computer

Is there continuity between computer terminal terminal 3 and actuator terminal 3.
3 and body ground?
No
Disconnect actuator connector. Short circuit in wire between computer

Yes
Is there continuity between computer terminal terminal 6 and actuator terminal 2.
6 and body ground?
No
10 CONTINUED ON PAGE BE-52
•
Disconnect actuator connector.
Is there continuity between computer terminal
Yes
Short circuit in wire harness between
computer terminal 1 and actuator terminal 4.
1 and body ground?
No
INSPECT CLUTCH SWITCH CIRCUIT (MIT) Yes • Short circuit in wire harness between
body ground with clutch pedal returned?
- terminal 14 of computer and body ground.
• Inspect clutch switch.
No
INSPECT NEUTRAL START SWITCH • Short circuit in wire harness between

CIRCUIT (A/T) terminal 14 of computer and terminal 1 of
No
Is there battery voltage between terminal 14 neutral start switch.
and body ground when shifted, except to • Inspect neutral start switch.
"N" range?
Yes
INSPECT PARKING BRAKE SWITCHCIRCUIT • Short circuit in wire harness between

Remove the CHARGE fuse. No terminal 15 of computer and parking
Is there battery voltage between terminal 15 - brake switch terminal 1.
and body ground with parking brake lever • Inspect parking brake switch.
returned?
Yes
INSPECT SPEED SENSOR CIRCUIT Open circuit in wire harness between

Disconnect connector from combination meter. No _ terminal 2 of combination meter and
Is there continuity between terminal 2 of wire terminal 7 of computer.
harness side connector and terminal 7 of
computer?
I
~ Yes
Disconnect connector from combination meter. No _ Short circuit in wire harness between
Is there continuity terminal 2 and body terminal 7 of computer and terminal 2 of
ground? combination meter.
Yes
SPEED SENSOR

Disconnect connector from combination terminal 3 and body ground.
No •
meter. Is there continuity between terminal 3 • Body ground faulty.
of wire harness side connector and body
ground?
I
Yes
, CONTINUED ON PAGE BE-53
+
INSPECT SPEED SENSOR OPERATION No Speed sensor faulty.
Is speed sensor operation normal?
I
I
i Yes
ACTUATOR I
•
INSPECT ACTUATOR OPERATION No _ Replace actuator.
Is actuator operation normal?
(See page BE-52)
I
Yes
I Replace computer. I
INSPECTION OF CONTROL SWITCH CIRCUIT
co NTROL S/W
t
Disconnect connector from control switch. No terminal 9 of control switch and body
Is there continuity between terminal 9 of wire ground.
harness side connector and body ground? • Body ground faulty .
~Yes
INSPECT CONTROL SWITCH OPERATION I Replace control switch.
No
Is control switch operation normal?
(See page BE-64)
~Yes
Connect connector to control switch.
COMPUTER ~
Disconnect connector from computer and
inspect on wire harness side as follows.
I
~
INSPECT SET/COAST SWITCH CIRCUIT Open circuit in wire harness between terminal
Is there continuity between terminal 17 and No 17 of computer and terminal 2 of control
body ground when set/coast switch turned switch.
on?
I

Yes
I
Short circuit in wire harness between terminal
body ground when set/ coast switch turned f----___ 17 of computer and terminal 2 of control
off? switch.
~-
INSPECTRESUME/ ACCELSWITCHCIRCUIT Open circuit in wire harness between terminal

Is there continuity between terminal 16 and No 16 of computer and terminal 1 of control
body ground when resume/accel switch switch.
turned on?
!
~Yes
Is there continuity between terminal 16 and Short circuit in wire harness between terminal
Yes
body ground when resume/accel switch 16 of computer and terminal 1 of control
turned off? switch.
~NO
I Replace computer.
I
o INSPECTION OF ACTUATOR CIRCUIT
Turn ignition switch off I
CONTROL CABLE
Yes
Are there damage on the control cable? ~--~ Replace control cable.
No
ACTUATOR
INSPECT ACTUATOR OPERATION Replace actuator.

No
Is actuator operation normal?
(See page BE-62)
BRAKE CANCEL Yes

S/W
INSPECT CANCEL CIRCUIT Open circuit in wire harness between terminal

Disconnect connector from brake cancel 2 of brake cancel switch and terminal 5 of
No
switch. actuator.
Is there continuity between terminal 2 of wire
Yes
Disconnect connector from actuator. Short circuit in wire harness between terminal
Yes
Is there continuity between terminal 2 of wire 2 of brake cancel switch and terminal 5 of
harness side connector and body ground? actuator.
No
INSPECT BRAKE CANCEL SWITCH Replace brake cancel switch.

OPERATION No
Is brake cancel switch operation normal?
(See page BE-63)
Yes
Connect connector to brake cancel switch and

actuator.
COMPUTER
Disconnect connector from computer and

inspect connector on wire harness side as
follows.
INSPECT CONTROL MOTOR CIRCUIT Open circuit in wire harness between terminal
No
Is there continuity between terminals 2 and 4? 1--------. 2 of computer and terminal 1 of actuator or
terminal 4 of computer and 6 of actuator.
\ Yes
'CONTINUED ON PAGE BE-56
~ CONTINUED FROM PAGE BE-55
Disconnect connector from actuator. Short circuit in wire harness between terminal
Yes
Is there continuity between terminal 5 and 2 of computer and 1 of actuator.
body ground?
! No
Is there continuity between terminal 4 and Yes Short circuit in wire harness between terminal
body ground? 4 of computer and 6 of actuator.
~ No
INSPECT POTENTIOMETER CIRCUIT Open circuit in wire harness between terminal

Is there 2 Kfl resistance between terminals 1 No 3 of computer and terminal 3 of actuator or
and 3? terminal 1 of computer and terminal 4 of
actuator.
~ Yes
Is there continuity between terminals 3 and 6? No Open circuit in wire harness between terminal
6 of computer and terminal 2 of actuator.
~ Yes
Disconnect connector from actuator. Yes Short circuit in wire harness between terminal
Is there continuity between terminal 3 and 3 of computer and terminal 3 of actuator?
body ground?
! No
Is there continuity between terminal 6 and Yes

t - - . - - -__ Short circuit in wire harness between terminal
body grou nd? 6 of computer and 2 of actuator.
~ No
Is there continuity between terminal 1 and Yes Short circuit in wire harness between terminal
body ground? 1 of computer and 4 of actuator.
~ No
INSPECT BRAKE CANCEL SWITCH CIRCUIT Open circuit in wire harness between terminal
No
Is there continuity between terminal 5 and 5 of computer and terminal 1 of brake cancel
body ground when brake pedal released? switch.
! Yes
Is there continuity between terminal 5 and Short circuit in wire harness between terminal
Yes
body ground when brake pedal depressed? 5 of computer and terminal 1 of brake cancel
switch.
~ No
I Replace computer. I
INSPECTION OF STOP LIGHT SWITCH CIRCUIT
Turn ignition switch on.

I
Is stop fuse normal? No • Short circuit in wire harness between

terminal 12 of computer and fuse.
I
I Yes
COMPUTER I
•
INSPECT ACTUATOR CIRCUIT Inspect brake cancel

Disconnect computer connector. Is there Yes switch.
continuity between connector terminal 5 on
wire harness side and body ground when
brake pedal is depressed?
I No
~
INSPECT STOP FUSE CIRCUIT No Open circuit in wire harness between
Is there battery voltage between terminal 12 terminal 12 of computer and STOP fuse.
and body ground?
I
, Yes
INSPECT STOP LIGHT SWITCH CIRCUIT Open or short circuit in wire harness
Is there battery voltage between terminal 11 No between terminal 11 of computer and
and body ground with brake pedal terminal 2 of stop light switch.
depressed?
Yes
o INSPECTION OF PARKING BRAKE SWITCH
Turn ignitioQswitch on. I

co MPUTER
INSPECT PARKING BRAKE SWITCH • Open circuit in wire harness between 15

CIRCUIT No of computer and parking brake switch.
Is there battery voltage between terminal 15 • Inspect parking brake switch.
and body ground?
Yes
IReplace computer. I
INSPECTION OF CLUTCH SWITCH CIRCUIT (MIT)
CLUTCH S/w
INSPECT GROUND CONNECTION No Open circuit in wire harness between

Is there continuity between terminal 3 and terminal 3 and body ground.
body ground?
I
I Yes
COMPUTER •

INSPECT CLUTCH SWITCH CIRCUIT • Open circuit in wire harness between

Is there continuity between terminal 14 and No terminal 14 of computer and terminal 2
body ground with clutch pedal depressed? of clutch switch .
• Inspect clutch switch.
I
i Yes
t
I Replace computer.
INSPECTION OF NEUTRAL START SWITCH CIRCUIT (AfT)
NEUTRAL START S/W
INSPECT GROUND CONNECTION No Open circuit in wire harness between

Is there continuity between terminal 2 and terminal 2 and body ground.
body ground?
I
I,
I Yes
COMPUTER

\
•
INSPECT NEUTRAL START SWITCH • Open circuit in wire harness terminal 14
CIRCUIT No of computer and terminal 1 of neutral start
Is there continuity between terminal 14 and switch.
body ground when shifted to uN" range? • Inspect neutral start switch.
Yes
t
I Replace computer.
BE-GO BODY ELECTRICAL SYSTEM - Cruise Control System
[H] INSPECTION OF SPEED SENSOR CIRCUIT

SPEED SENSOR
INSPECT GROUND CONNECTION Open circuit in wire harness between

Disconnect connector from combination terminal 3 and body ground.
No
meter. Is there continuity between terminal 3
of wire harness side connector and body
ground?
Yes
CO MPUTER

I
INSPECT SPEED SENSOR CIRCUIT Open circuit in wire harness between

Disconnect connector from combination No terminal 2 of combination meter and terminal
meter. Is there continuity between terminal 2 7 of computer.
of wire harness side connector and terminal
7 of computer?
Yes
INSPECT SPEED SENSOR OPERATION Speed sensor faulty.

Does circuit between terminal 7 of computer No
and body ground repeat from "ON" to "OFF"
about every 40 cm (15.75 in,) vehicle
moves?
Yes
IReplace computer. I
Cruise Control Computer Circuit

INSPECTION OF COMPUTER CIRCUIT
Disconnect the computer connector and inspect the con-
nector on the wire harness side as shown in the chart
below.
Connection of Voltage or
erminal Tester connection Condition
measure item resistance value
-11
- - - - - _ ._ _._----- ------- ---------_. - - - -- ------------._-------+------
Actuator
1_=-~ _
Approx. 2 kH
2 - Tester (+) Control plate at max. acceleration No continuity

2 fActuator 4 - Tester (-)
- _ _~I _
Continuity
- -- - ---- ----
3 Actuator 3-1 Approx. 2 kH

- -- ---+ - ---------
4 - Tester (+) Control plate at max. deceleration No continuity
4 I Actuator - - - - - - - - -------- - - - - - - - - - - - - - - 1 - - - - - - -
2 - Tester (-) Continuity
-+--- ----+- ---_._----
I
Other
Brake cancel Brake pedal released Continuity

5
I
i switch
15 - Body ground ------------------.--.-.---+----------1
Brake pedal depressed No continuity

t ------+------.--
Move control plate slowly from
6-3
acceleration to deceleration side. Resistance slowly
6 Actuator
Move control plate slowly from rises
3-1
! deceleration to acceleration side.
-t-- - -------------------------
1 pulse each 40 cm
7 Speed sensor 7- Body ground Vehicle moving slowly
(15.75 in.)
i
1- - ----t------- ---- -+--- - - -.-------------1
I 8 - Body ground : ..
8 Battery voltage
!
I 00 relay (Ignition switch ON) 00 main SWitch ON

-t'
I
10
--- ---
, _M
__ ain switch
10- Body ground I :Main switch OFF
- - + - - - . - - - - - - - . - - - - - - - - - t - - - - - - - - - - - - - - - .. - - - - -
OV
~(Ignition switch ON)
I
__ ~!in s~it~__~~ _ Battery voltage
Stop light switch 11 _ Body ground ~i Brake pedal released OV

11 I,.
Brake pedal depressed Battery voltage

-- -----+-- - - - - - . - - - - ------- --------------+-------------4
12 : Stop light fuse 12 - Body ground Battery voltage
---~--- . _ - - -----~-- - - - - - - - - - - - - --- ------
13 ,Body ground 13 - Body ground Continuity

----1--------
I
Clutch pedal depressed

Clutch switch or Continuity
Shih into P or N range
14 I neutral start I 14 - Body ground ----- -------------------1
switch Clutch pedal released

No continuity
Shih into except P or N ra nge
. _ - - - , - - - - - - - - - - - - - - 1 - - -----------.--- .- - - - - .--- ...- - - - - - - - - 1 - - - - - - - - - - - -
Remove CHARGE fuse and ignition
switch turned on with parking brake Battery voltage
lever pulled up.
15 Parking brake 15 - Body ground -- - --------~-"._---------------_.-
Remove CHARGE fuse and ignition

switch turned on with parking brake OV
lever released.
r- -------- - ---- t- ---
Control switch OFF No continuity
Control switch i 16 - Body ground 1 - - - - - - - - - - -.. - - - - - - - - - - - - - -
RESUMEI ACCEL switch ON Continuity
------ --- --- ---------
Control switch OFF No continuity

17 Control SWitch 17 - Body ground
SET ICOAST switch ON Continuity
Main Switch
INSPECTION OF MAIN SWITCH

terminal 2 and the negative (-) lead to terminal 4.
and 3 with the main switch turned on.
S 6 2
and 3 with the main switch turned off.
Actuator
INSPECTION OF ACTUATOR
1. INSPECT CONTROL CABLE FREEPLAY
Inspect that the control cable freeplay is less than 2 mm
(0.08 in.).
If necessary, adjust the control cable freeplay.
2. INSPECT ACTUATOR OPERATION

minal 5 and connect the negative (-) lead from the
battery to body ground.
(b) Apply voltage to each terminal and check the motor
3 2 operation
~e:,~1
6 5 4 Battery Battery
1 6
Operation I (+) (-)
direction \
I
Acceleration I
Deceleration i
(c) Check that the motor stops at the fully open and fully
closed positions.
3. INSPECT ACTUATOR RESISTANCE

(a) Measure the resistance between terminals 3 and 4.
Resistance: About 2 k n
(b) Check that the resistance between terminals 2 and 3
or 4 changes when the plate is moved.
Speed Sensor
INSPECTION OF SPEED SENSOR
INSPECT SPEED SENSOR CONTINUITY
tween terminals 2 and 3 four times per each revolution of
the magnet shaft.
Brake Cancel Switch

INSPECTION OF BRAKE CANCEL SWITCH
Inspect the continuity between terminals 1 and 2.
Switch free: No continuity
Switch pushed: Continuity
Parking Brake Switch

(See page BE-31)
Neutral Start Switch

(See page AT-1 02)
Stop Light Switch

INSPECTION OF STOP LIGHT SWITCH
'-8-'
...,
2
r'
Inspect the continuity between terminals 1 and 2 .
Switch free: Continuity
I Switch pushed: No continuity
Clutch Switch
o INSPECTION OF CLUTCH SWITCH

rn
Inspect the continuity between terminals 2 and 3.
Switch free: Continuity
Switch pushed: No continuity
Cruise Control Switch

Cruise Control Switch
INSPECTION OF CRUISE CONTROL SWITCH
INSPECT CRUISE CONTROL SWITCH CONTINUITY
;~~
9 2 1 9
(Wire color)
Ew S5 SR EW
Switch
(G) (R) (8)
position
SET/COAST
OFF
RESUME/ACCEL
No continuity Continuity Power Main Relay

Ii. n.
INSPECTION OF POWER MAIN RELAY
and 3.
and 4.

o 1 and connect the negative (-) lead from the battery to
o terminal 3. Then, check that there is continuity between
terminals 2 and 4.
BEOOlO
BODY ELECTRICAL SYSTEM - Radio, Stereo Tape Player and Antenna BE-65
RADIO, STEREO TAPE PLAYER

AND ANTENNA
Troubleshooting
DESCRIPTION OF SYMBOLS
D Inspection
o Check or replace part
@ Test by operating radio
1. DEAD RADIO AND TAPE PLAYER

(a) No power to radio or tape player, or power but no
sound.
Possible causes:
• Blown RADIO fuse
• Short circuit or broken wire in power source wire
harness
• Loose connectors behind radio and tape player
• Loose speaker connector
• Defective speaker
• Broken wire in speaker wire harness
• Improperly installed radio or tape player
• Defective radio or tape player
TEST 1
OK
: Check RADIO fuse. f-I -----------------~Qroceed
to Test 2.
I
I Blown
(
~
RePlace] fuse
Does not blow
~------------------~O\---------..-IL__
_ ___J
,-------''---------------
t
Blows again
Check for short circuit in

power source wire harness.
No short
-----------.,
~
GReplace radio and tape
player.
'----_-----,.-- . -----.J _""'
,I
Short
BE-66 BODY ELECTRICAL SYSTEM - Radio, Stereo Tape Player and Antenna
TEST 2
Proceed to _T est-3~
Yes
Are all connectors behind radio and Yes .. l i s there power to radio and I Yes Are radio and player
tape player properly connected? f-------~Iayerconnectors 7 properly connected?
~ ,--- --J I
, No
I--
~ ,! No
~( Inspect and repair power wire

--....
No
Connect properly. Properly reinstall

, harness to radio and player.
TEST 3
Are speaker connectors connected? ~~:~~;ariIY install another ~O~_R_e_p_l_ac_e_s_p_e_ak_e_r_.__)

No No
Is there continuity in speaker Yes Replace radio and

Connect properly. wire harness? tape player.
No w/o Player
Inspect and repair speaker wire Ij Proceed to Test 1 of

harness. following item.
(b) Tape player okay but no sound from either the AM or

FM band.
Possible causes:
• Antenna disconnected
• Antenna plug not properly connected
• Defective antenna
• Defective antenna cable
• Defective radio or tape player
• Blown HAZ-HORN fuse
• Short circuit or broken wire in wire harness for
back-up power source
TEST 1
! -Is
I
1- .
~l;~ -_-- - -' ---~-.I
radio electronic sear;;!;
type
7
Yes
Is either AM or FM okay?
Yes
Proceed to Test 2.
No
Proceed to Test 3,
TEST 2
~---
, Check HAZ-HORN OK Is there back-up power to connectors

behind radio? Proceed to Test 3.
fuse.
No
No
I Blown Inspect and repair back-up power
( wire harness.
~------------
i
r=-~--~ OK
< Replace fuse, r - --------~---------------------~~
~
!
Blows again
Check for short circuit in back-up OK ( )

power source wire ha_rn_e_s_s_, r-----------I~- Replace radio.
Short
Inspect and repair wire harness l

for back-up power source. I
!
NOTE: Back-up power refers to the storage voltage for

preset tuning. This is applied even when ignition switch is
OFF.
TEST 3
Check that antenna plug is

secure in radio.
OK
~----i
I
Reinsert plug. Okay?
: OK r: ~
-------.-<\(nspect antenna PluV
f-;
'--------.--L-o-o-s-e-----~ ~--.~ No -
Properly insert. Does radio alone wor~f---Y-e-s------i._CReplace tape Player.)

I
No
Or--------------I
TEST 4
Temporarily install another OK Inspect antenna and antenna cable, and

antenna. Okay'? replace as necessary.
No
'- Replace rad!R)

(c) No sound from one speaker.

Possible causes:
• Loose speaker connector
• Broken wire in speaker wire harness
• Defective radio and tape player
TEST 1
Pull out connector and] OK ( )

~_ls_t_h_e_s_p_e~a_k_er~co_n_n_e_c_t_ed_7_.~~~~~~~_re_i_n_se_r_t.~~~~~~_~~~~~~~~ Inspect connecto~
No
No
TEST 2
Temporarily install anot~r-~~_~~Y_e_s~~_~.(RePlaces peaker. )

speaker. Okay? ~
~---
No
t
Check for continuity in speaker
wire harness.
I-- O_K~_ _ ~( Replace radio and tape
---t. . player.
'-------~------r--~-------.J
No
Inspect and repair for speaker

wire harness.
"--~----_._--- - - - - - - '
2. FAINT RECEPTION
Possible causes:
• Incorrectly adjusted antenna trimmer
• Defective antenna cable or antenna
• Defective radio
TEST
Are both reception and static faint with I~ Temporarily install another speaker.
~Replace speake,)
antenna fully lengthened? I I Okay?
No
~
~~
Adjust AM antenna trimmer.
(See illustration.)
Temporarily install another O_K_ _---.l.,I Inspect antenna and cable and repair
j
I
antenna. Okay? '~s necessary.
INa
t
(Ex. Electronic Search Type)

NOTE: Adjustment of the antenna trimmer.
(1) Fully lengthen the antenna.
(2) With volume and tone at maximum, turn the dial to
around 1,400 kHz where there is no reception.
(3) Adjust the trimmer to where static is loudest.
3. BAD SOUND QUALITY

(a) Sound quality bad when radio played.
Possible causes:
• Multipath interference excessive interception
• Tuner dial not synchronized with station
• Defective antenna and cable
• Speaker improperly installed
• Vibration sound from components near speaker
• Defective radio
TEST 1
-------------- -----------------------------.
. . .. Yes . FM multipath interference and excessively strong

Is sound quality bad In certain f---------------( AM reception near broadcasting station which
areas on Iy 7 __ ~_ _ _J \,-----ca n not be a~oide_d_i_n_m_o_s_t_ca_s_e_s_. _
No
~-- --.-----._-----.1- - -- - 7 l Yes c- Temporarily Install anotherl Yes ( Inspect antenna cable, and
Is t~ner_~~I~rOperly s~~chron~e~~ ~ _ant_enn~_~ka__/-7------J~", repair as necessary
No No
~_ _------L'__ . t
::~operly Syn_C_h~oniz~)_-----------L~!~~eed~T~st__2~_J
TEST 2
Yes ~he-re a vibration sound-l9

0 - TempOrarilY~es
L-~ coming from components
. I
Is speaker Installed correctly Install another --' Replace

_-.:ot IOO~~~:~O_:9ht)7 _~ L~ear ~eaker!_ speaT Okay~ ~s~eaker
No Yes No
~operly
_ _---L-t ._
install. If ;pea~
f rame b ent rep Iace.
//;0
.. _
0
___ .l~
R_epa__ir.
// ~
Replace radio.
NOTE: FM distortion tends to increase sharply if the

tuner is not synchronized.
(b) Sound quality bad when tape player played.

Possible causes:
• Bad tape
• Dirty head
• Incorrectly installed speaker
• Vibration noise from around speaker
• Defective tape player
TEST 1
Does sound improve with Yes

another tape?
Yes
OK
TEST 2
--
Yes Does vibration sound No Temporarily install Yes
Is speaker correctly installed ~ come from around another speaker. Replace
(loose or too tight)? speaker? Okay? speaker.
No Yes No
Install correctly. If speaker

frame bent, replace. Repair. Replace tape player.
NOTE: Head cleaning procedure.

Pinch Roller Capstan
(1) Raise the cassette door with your finger. Next using a
Head
pencil or like object, push in the guide as shown.
(2) Using a cleaning pen or cotton applicator soaked in
alcohol, clean the head surface, pinch rollers and
capstans.
(3) Push in the "eject" button.
C0192
4. DEFECTIVE AUTO-SEARCH MECHANISM

Manual search possible but automatic search mechanism
does not function or does not stop at all receivable sta-
tions.
Possible causes:
• Poor search sensitivity (SENS button)
• Defective radio
TEST
Does needle move when Yes Is desired broadcast receivable Yes ~

search button is pushed? t----~~
when button is at "OISTANT" position?
,No
i
_----I-N-o-- _____
( Replace radio. \, , /Check if desired broadcast can
'- ./
actually be received in the area.
If receivable, replace radio.
Radio Remote Control Switch

INSPECTION OF RADIO REMOTE CONTROL
SWITCH
and 6.
NOTE: The resistance reading will vary depending on the
BE1550, U·10·2 direction the tester is connected.
and 6.
NOTE: The resistance reading will vary according to
direction the tester is connected or position to which the
volume knob has been turned to.
(c) Check that there is continuity between terminals 10
and 2.
(d) Check that there is continuity between terminals 5
and 2 when power switch pushed on.
(e) Connect the positive (+) lead from the battery to
terminal 5 and negative (-) lead to terminal 2.
(f) Check that there is continuity between terminals 4
and 2 when FM/AM switch pushed on.
(g) Check that there is continuity between terminals 9
and 2 when pushed tune switch to UP.
(h) Check that there is continuity between terminals 3
and 2 when pushed tune switch to DOWN.
BE-74 BODY ELECTRICAL SYSTEM - Clock
CLOCK
Troubleshooting
CLOCK WILL NOT OPERATE
Locate trouble and repair or

Check to see if fuse is blown.
Blown fuse ---- replace fuse as necessary.
~OK
Check to see if clock adjusting
Repair if necessary or replace
knob is binding in position and
clock.
has failed to return. Adjusting knob
not returned
~OK
Check to see if battery voltage
is over 11 V with no load.
!OK
Below 11 v---1 Recharge or replace battery.
I
+
Check to see if connector on
clock side is loose or rusted. Loose or rusted --1 Repair
I
~OK
Check to see if there is voltage
at terminal B or connector or Locate cause and repair.
clock side. No voltage
~OK
Check to see if clock ground
wire is loose or rusted. Loose or rusted
---j Repair
I
OK
I
I.
t
Replace clock.
CLOCK LOSES OR GAINS TIME
Check amount of time the clock loses or gains per day or a week against the allowable error table .
• Exceeds allowable error
Check to see if there is 11 V -1 5V

Locate cause and repair, or
on terminal B of connector on
Below 11 V recharge battery.
clock side.
_----,-O-K--------
Adjust or replace clock.
BODY ELECTRICAL SYSTEM - Clock BE-75
1. INSPECT ALLOWABLE ERROR OF CLOCK

I
Type • Allowable error (per day)
r--- ----L---------------t
~nd q~_~_~_ _ ± 4.0 second~_

Digital quartz I ± 2.5 seconds
2. ADJUSTMENT OF CLOCK
Adjustment of the quartz clock requires a precise digital
counter. Adjustment must be made in a shop specified by
the manufacturer.
3. STARTING OF CLOCK
(a) Connect the battery terminal.
(b) Check the clock to see that it is running, and then set
it to the correct time.
NOTE: Whenever the battery terminal is disconnected,
make sure to set the clock to the correct time after recon-
necting it.
BO-1
BODY
Page
FRONT DOOR . BO-2
SLIDE DOOR . BO-9
BACK DOOR . BO-15
MOULDING . BO-18
WINDSHIELD . BO-29
SIDE WINDOW . BO-35
BACK DOOR WINDOW GLASS . BO-37
FRONT TILT ROOF . BO-41
REAR SUN ROOF . BO-44
SAFETY PAD . BO-48
SEAT . BO-52
SEAT BELT . BO-56
BODY DIMENSIONS . BO-59
BODY- Front Door
FRONT DOOR
COMPONENTS
Fran t Lower Fra me r-~ear~wer Frame
- 4SO Door Lock Striker

Door Hinge
Door Lock
Door Lock Motor
~
r
~:
I e-
o ow I I . '
Power Wmd -- . . '. Regulator

Motor 6 :' Wmdow
(J Ga, ,: ~
Window Regulator
~ArmrestBase Wmdow Regulator

o
DoorTrim
o o
@jIID Courtesy Light
@"-
"n
~~"~
i[l Armrest
Lower Door Trim tator Handle

Window Reg
801964
BODY - Front Door BO-3
DISASSEMBLY OF FRONT DOOR

(See page 80-2)

(a) Door inside handle bezel
(b) Armrest or pull handle
2. REMOVE WINDOW REGULATOR HANDLE

(w/o POWER WINDOW)
'-- B_O_OO---'20 Pull off the snap ring with a cloth and remove the regulator
handle and plate.
3. REMOVE DOOR TRIM

o (a) Remove the courtesy light.
@) (b)
NOTE:
Insert a screwdriver between the retainers and the
door panel to pry it loose.
Tape the screwdriver tip before use.
(c) Disconnect the wiring connector (with power win-
dow) and remove the door trim.
B01565 4. REMOVE ARMREST BASE
-~-~~----- --- 5. REMOVE INSIDE HANDLE

(b) Disconnect the control link from the handle and
remove the handle.
6. REMOVE SERVICE HOLE COVER
7. REMOVE REAR VIEW MIRROR

(a) Pry loose the retainer and remove the cover.
NOTE: Tape the screwdriver tip before use.
(b) Remove the three screws and the mirror.
(c) Disconnect the connector from the mirror.
8. REMOVE DOOR GLASS

(a) Raise the window 80 - 120 mm (3.15 - 4.72 in.).
(b) Remove the two guide set bolts.
BO-4 BODY - Front Door
(c) Remove the door glass by pulling it upward.
62169
9. REMOVE INNER WEATHERSTRIP

Pry loose the clips from the edge of the panel and remove the
(~, weatherstrip.
~" ~''''
,/
Outer Weatherstrip 10. REMOVE OUTER WEATHERSTRIP OR BELT

MOULDING
[Outer Weatherstrip]
Pry loose the clips from the edge of the panel and remove
the weatherstrip or moulding
600426
[Belt Moulding]
Belt Moulding
(See page 80-23)
600763
11. REMOVE REGULATOR

(a) Disconnect the wiring connector. (wi Power window)
(b) Remove the regulator mounting bolts.
(c) Remove the regulator through the service hole.
12. REMOVE REAR LOWER FRAME

Remove the frame from the glass run.
13. REMOVE FRONT LOWER FRAME

(a) Pull out the glass run from the frame.
(b) Remove the two screws under the weatherstrip.
(c) Remove the two bolts and pull out the frame.
14. DISCONNECT FOLLOWING LINKAGES:

(a) Door inside opening control link
(b) Door outside opening control link
(c) Door outside locking control link
15. REMOVE DOOR LOCK CYLINDER
16. REMOVE DOOR LOCK

(a) Disconnect the connector from the door lock motor.
(wi Power door lock)
(b) Remove the door inside locking knob.
(c) Remove the three screws, two bolts and door lock.
(wI Power door lock)
(d) Remove the three screws, two bolts and door lock with
800035
the motor. (wi Power door lock)
c F .__
~-=::Ji ~~.n,
~\ / ""i \y'. ./ 17. REMOVE OUTSIDE HANDLE
-------'
~ (~)i
I /
~'I"I
~~ '--7 1
0,
'1
•... liI ",

'~
\,
i . \. f
//(C{
./ /.,
~
\.. ,
1'"
J'
REPLACEMENT OF GLASS
1. REMOVE GLASS CHANNEL WITH SCREWDRIVER OR
SUCH
2. APPLY SOAPY WATER TO INSIDE OF

WEATHERSTRIP
3. INSTALL CHANNEL BY TAPPING IT WITH PLASTIC

HAMMER
254 mm (1 0.00 in.)
ASSEMBLY OF FRONT DOOR

(See page BO-2)
1. APPLY MP GREASE TO PARTS BEFORE INSTALLING

(a) Apply MP grease to the sliding surface and gear of the
t window regulator.
CAUTION: Do not apply MP grease to the spring of the
window regulator.
(b) Apply MP grease to the sliding surface of the door lock.
801477 801539
2. INSTALL OUTSIDE HANDLE
3. INSTALL DOOR LOCK

(a) Install the door lock with three screws and two bolts.
(J (w /0 Power door lock)
(b) Install the inside locking knob.
(c) Connect the connector to the door lock motor.
(w/o Power door lock)
4. INSTALL DOOR LOCK CYLINDER
5. CONNECT FOLLOWING LINKAGES:

(a) Door outside locking control link
(b) Door outside opening control link
(c) Door inside locking control link
800035
6. ADJUST OUTSIDE HANDLE

(a) Disconnect the control link.
(b) Raise the handle 2.0 - 2.5 mm (0.079 - 0.098 in.)
from the rest position.
(c) Fit the pin into the hole by turning the adjuster.
7. INSTALL FRONT AND REAR LOWER FRAMES
Z6286
8. INSTALL REGULATOR
(a) Install the regulator with the mounting bolts.
(b) Temporarily tighten the equalizer arm bracket mounting
bolts.
(c) Connecttheconnectortothe motor.(w/ Power window)
9. INSTALL INNER WEATHERSTRIP

Outer Weatherstrip 10. INSTALL OUTER WEATHERSTRIP OR BELT

MOULDING
[Outer Weatherstrip]
Insert the claw of the clips into the upper panel hole and
push the weatherstrip onto the panel.
[Belt Moulding]
~
Belt Moulding -......;:;:::::----- Tap the moulding onto the upper panel by hand.
BB95B
11. INSTALL DOOR GLASS

(a) Place the glass in the door cavity.
(b) Install the glass to the regulator with two mounting
bolts.
12. ADJUST DOOR GLASS

Adjust the equalizer arm up or down and tighten it where
dimensions A and S, as shown, are equal.
A --.---------I/-~---------::-=:_ttt_rB
A=B
I II
B00033

(a) Connect the wire harness connector.
(b) Seal the service hole cover with adhesive.
(c) Insert the lower edge of the service hole cover into
the panel slit.
I
(d) Seal the panel slit with cotton tape.

CAUTION: Do not block the trim clip seating with the
tape.
14. INSTALL REAR VIEW MIRROR

(a) Connect the connector to the mirror.
(b) Install the mirror with the three screws.
(c) Install the cover.
15. INSTALL INSIDE HANDLE
16. INSTALL DOOR TRIM

(a) Connect the wiring connector. (wi Power windows)
(b) Install the door trim.
(c) Install the courtesy light.
17. INSTALL ARMREST BASE
18. INSTALL WINDOW REGULATOR HANDLE

(w/o POWER WINDOW)
With door window fully closed, install the window regulator
handle and plate with a snap ring as shown.
Front . . 19. INSTALL FOLLOWNG PARTS:

(a) Armrest or pull handle
(b) Door inside handle bezel
B001B1
ADJUSTMENT OF FRONT DOOR

1. ADJUST DOOR IN FORWARD/REARWARD AND
VERTICAL DIRECTIONS
Using SST, adjust the door by loosening the body side
hinge bolts.
SST 0981 2-00010
2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL

DIRECTIONS
Adjust the door by loosening the door side hinge bolts.
SST 0981 2-00010
BODY - Slid e Doar
SLIDE DOOR
COMPONENTS
Upper Roller
Outside Handle
Rear SI"d
I e Door Lock
Door Lock Striker
Inside Handle
Front Slide Center Roller
Door Lock
Upper Door Trim
Door Lock
Striker
Y'"",
~~-~
Child Proof
Lock
Door Trim
Down Female
Stopper
~
"~O
ri
__ J(}
~Down Male
'I ~
"J lJ Stopper Rail Moulding
BO-10 BODY - Slide Door
DISASSEMBLY OF SLIDE DOOR

(See page BO-9)
1. REMOVE DOOR TRIM

(a) Remove door locking button.
(b) Remove slide door open stopper.
(Broon:nc
• [C a],
'-:-J' ~ (c)
(d)
Remove the upper door trim.
Remove the door trim.
3. REMOVE CENTER ROLLER

(a) Remove the three set bolts.
NOTE: Place a wooden block under the door panel and
support it with a jack.
(b) After removing the rail moulding, remove the roller
toward the rear.
4. REMOVE DOOR PANEL

(a) Remove the three set bolts of the lower roller.
NOTE: Place a wooden block under the door panel and
support it with a jack.
(b) Slide the door toward the rear side.
(c) Remove the upper roller from the cut-out part of the
upper rail.
5. REMOVE UPPER RAIL
6. REMOVE CENTER RAIL

x
(a) Insert a screwdriver between the retainers and the
door panel to pry it loose.
NOTE: Tape the screwdriver top before use.
(b) After removing the set bOlts, remove the rail.
7. REMOVE UPPER ROLLER

Remove the roller from the door panel.
8. REMOVE LOWER ROLLER

Remove the roller from the rail.
BODY - Slide Door BO-11
9. REMOVE DOOR LOCK REMOTE CONTROL AND DOOR

LOCK MOTOR
Remove the seven mounting bolts.

(a) Rear slide door lock cylinder link
(b) Front slide door lock open control link
~ (c) Door motor control link
'\
801458 11. REMOVE SLIDE DOOR OUTSIDE HANDLE
12. REMOVE SLIDE DOOR INSIDE HANDLE
13. REMOVE REAR SLIDE DOOR LOCK
14. REMOVE FRONT SLIDE DOOR LOCK
ASSEMBLY OF SLIDE DOOR

(See page BO-9)
1. INSTALL FRONT SLIDE DOOR LOCK
2. INSTALL REAR SLIDE DOOR LOCK

After connecting the cable, install the door lock assy.
{
/
3. INSTALL SLIDE DOOR INSIDE HANDLE
4. INSTALL SLIDE DOOR OUTSIDE HANDLE
5. CONNECT FOLLOWING LINKAGES:

(a) Rear slide door lock cylinder link
(b) Front slide door lock remote control link
(c) Door motor control link
6. INSTALL DOOR LOCK REMOTE CONTROL AND DOOR

LOCK MOTOR
801458
7. ADJUST SLIDE DOOR LOCK REMOTE CONTROL

About 5 mm (0.20 in.)
(a) Adjust the remote control so there is about 5 mm
---\;- (0.20 in.) play in the inside handle.
(b) Loosen the rear lock cable adjusting screw and lightly
pull the cable until it is sung. Then return it about 1
Rear Lock Cable Remote Control Cable mm (0.04 in.) and tighten it down.
(c) Loosen the remote control cable adjusting screw and
lightly pull the cable until it is sung. Then return it
about 1 mm (0.04 in.).
NOTE: Make adjustment without the clamp for the cable
and inner panel installed. Allow it to hang loose.
(d) While operating the outside and inside handles,
check that the front and rear locks release smoothly.
8. INSTALL LOWER ROLLER
9. INSTALL CENTER ROLLER
10. INSTALL CENTER RAIL
11. INSTALL UPPER RAIL

12. INSTALL DOOR PANEL
(a) Install the bolts of the lower roller.
(b) Install the upper roller from the cut-out part of the
upper rail.
13. INSTALL CENTER ROLLER

While pulling on the door panel, install the center roller
parallel with the rail.

BODY - Slide Door 80-13
15. INSTALL DOOR TRIM

(a) Install the door trim and upper door trim.
(b) Install the slide door open stopper.
(c) Install the door locking button.
ADJUSTMENT OF SLIDE DOOR

1. DOOR REAR VERTICAL AND HORIZONTAL
ADJUSTMENT
(a) Adjust the door lock striker.
(b) With the door closed, adjust so the center roller is 0
- 1 mm (0 - 0.04 in,) above the race.
(c) Adjust the center roller bracket.

i;
NOTE: The center roller is installed parallel with the rail.
2. DOOR FORE-AFT ADJUSTMENT

Adjust by moving the center roller fore and aft.
NOTE: The center roller is installed parallel with the rail.
3. DOOR FRONT VERTICAL ADJUSTMENT

Adjust with the lower roller.
4. DOOR FRONT HORIZONTAL ADJUSTMENT

(a) Adjust with the upper and lower rollers.
I . . . . .
(b) Insure that the clearance between the upper roller

and rail is as shown in the figure throughout the
entire stroke.
5. DOWN MALE STOPPER ADJUSTMENT

2 ± 1.0 mm (a) Finger tighten the male stopper on the body side,
(0.08 ± 0.039 in,) close the door and determine the door position.
(b) Adjust the lower male stopper.
it
6. DOOR LOCK ADJUSTMENT
Adjust the clearance between the striker and ratchet.
Clearance: 2 - 6 mm (0.08 - 0.24 in,)
BODY - Back Door BO-15
BACK DOOR
COMPONENTS
Door Hinge
I----Damper Stay
~ -- - -- "~I \
. \ _ ~:J,.li-:;:::~=-=---------t---Door Lock Control

Inside Handle \.~, ~, ,r" ~~
, 'R.~~~,~"."" ""
-t//
L 'R. . . ~': <>., ~
ll
:001
Child Lock - 'R.: . ~-1L';}--~-=-----~_/-1 _-_-----@-DoorLOck
-- -~--- '/
~
V
~~---------Door Lock Striker
Service Hole Cover-------1
Door Trim - - - - - - - - - - - \ \
800819
BO-16 BODY - Back Door
DISASSEMBLY OF BACK DOOR

(See page BO-15)

(a) Back door locking knob
(b) Back door inside handle
(c) Back door inside handle bezel
2. REMOVE DOOR TRIM

(a) Back door control motor link
(b) Back door lock cylinder control link
(c) Back door lock remote control link
(d) Back door open control link
5. REMOVE BACK DOOR INSIDE HANDLE ASSEMBLY

Remove the three set bolts.
6. REMOVE BACK DOOR LOCK CONTROL

(a) Remove the three set bolts.
.=--n=\ (b) Disconnect the connector.
7. REMOVE BACK DOOR LOCK MOTOR

(b) Remove the two set bolts.
8. REMOVE CHILD PROOF LOCK
9. REMOVE OUTSIDE HANDLE

Remove the eleven nuts and five clips.
ADJUSTMENT OF BACK DOOR

1. ADJUST DOOR IN FORWARD/REARWARD AND
LEFT/RIGHT DIRECTIONS
Loosen the hinge bolts to adjust.
2. ADJUST DOOR LOCK STRIKER

Loosen the striker set screws and tap the striker with a
hammer to adjust.
ASSEMBLY OF BACK DOOR

(See page BO-15)
ASSEMBLE PARTS IN REVERSE SEQUENCE
OF DISASSEMBLY
BODY - Back Door BO-17
REMOVAL OF DAMPER STAY

1. DISCONNECT DAMPER STAY FROM BACK DOOR
2. REMOVE DAMPER STAY FROM BODY
3. HANDLING OF BACK DOOR DAMPER

(a) Do not disassemble the damper because the cylinder
is filled with gas.
(b) If the damper is to be replaced, drill a 2.0 - 3.0 mm
(0.079 - 0.118 in.) hole in the bottom of the
removed damper cylinder to completely release the
high-pressure gas before disposing of it. (The gas is
colorless, odorless and non-toxic. However, when
10- 20 mm drilling, chips may fly out so work carefully!).
t= I~nl~...-::Ul;
(0.39 - 0.79 in.)
(c) Handle the damper carefully. Be careful not to score
or scratch the exposed part of the piston rod, and
never allow paint or oil to get on it.
(d) Do not turn the piston rod and cylinder with the
Hole Here Cylinder Piston Rod damper fully extended.
INSTALLATION OF DAMPER STAY

1. INSTALL DAMPER STAY TO BODY
2. CONNECT DAMPER STAY TO BACK DOOR

BO-18 BODY - Moulding
MOULDING
Windshield Outside Moulding
COMPONENTS
Upper Moulding
~JOint Cover
~(--
/I----Side Moulding
/
Lower Moulding
CACACACACAC REMOVAL OF OUTSIDE MOULDING

~f(
ell
\:C.~A There are two types of clips for moulding installation.
A/I C Locations of these clips and fasteners are as shown in the
C
,
AI.!;
CA
i
lA\e.~ figure.
Carefully apply adhesive tape to protect the body.
BOBOBOBOBOBOB
Clips Fasteners
~ ~ c-rc=J ~
(A) (B) (C) (0)
1. PREPARE A SMALL SCREWDRIVER

Bend a screwdriver at right angle as shown.
--'~m--------',JI;::::::=====lru"-----~(O
-30
~.~
-1r--
I
3 mm
(012 in.)
800027
BODY - Moulding BO-19
2. REMOVE WIPER ARM

A
3. REMOVE UPPER MOULDING
(a) Insert the tip of the screwdriver between the mould-
ing and clip, and twist it to pry loose the clips (A) on
the window side.
(b) Pry loose the fasteners and remove the moulding.
4. REMOVE JOINT COVER

(a) Remove the joint cover from the upper moulding.
800100
(b) Slide the moulding out.

NOTE: Do not bend the moulding.
5. REMOVE SIDE AND LOWER MOULDINGS

Remove the side and lower mouldings in the same direc-
tion as the upper moulding.
REPLACEMENT OF FASTENER AND CLIP

Replace any damaged fasteners.
\----Knife 1. REMOVE DAMAGED CLIP
2. CUT OFF OLD ADHESIVE AROUND CLIP

INSTALLATION AREA
(a) Grind a notch into the clip so it latches onto the glass
edge.
800095
(b) Temporarily install the clip and insure that it is firmly

attached to the glass.
Remove any damaged clips.
3. REPLACE FASTENER
Fastener
(a) Remove any damaged fasteners.
(b) Cut off old adhesive around fastener installation area.
(c) Install fastener onto body with double-stick tape.
Z5829
INSTALLATION OF OUTSIDE MOULDING

1. INSTALL NEW CLIP INTO MOULDING
Install the moulding to the body so that the clips and
fasteners are not in a position where they will contact each
other.
800097
2. APPLY ADHESIVE AT CLIP INSTALLATION AREA
Adhesive
800098
3. INSTALL UPPER MOULDING

(a) Place the moulding onto the body.
(b) Pry up the clips on the body side and install them to
the moulding.
600273
600190
(c) Tap the moulding with your hand to fasten the clips
at the glass edge.
At the same time, tap on the fasteners by hand.
600101 600144
(d) If the moulding is not at the same level as the body,

insert a scraper between them and tap on the mould-
ing while pushing on the fastener.
600103
4. INSTALL JOINT COVER

Install the joint cover to the upper moulding.
5. INSTALL SIDE AND LOWER MOULDINGS IN SAME

MANNER AS FOR UPPER MOULDING
6. INSTALL WIPER ARM

80-22 BODY - Moulding
Side Moulding
COMPONENTS
Door Belt Moulding

Joint
Roof Drip Moulding
-------- REMOVAL OF ROOF DRIP MOULDING

1. REMOVE JOINT
Latch the SST to the bottom side of the joint and remove
it.
SST 09806-30010
801422
2. REMOVE MOULDING
Latch the SST to the bottom side of the moulding and
remove it.
SST 09806-30010
801423
INSTALLATION OF ROOF DRIP MOULDING

(See page BO-22)
1. INSTALL MOULDING
Suspend the upper side of the moulding to the roof drip
and tap it on by hand.
801424
2. INSTALL JOINT
F 801425
REMOVAL OF DOOR BELT MOULDING

1. REMOVE DOOR GLASS
(See steps 1 to 7 on page BO-3)
2. REMOVE DOOR BELT MOULDING

Pry loose the clips from the edge of the panel and remove
the moulding.
800763
INSTALLATION OF DOOR BELT MOULDING

1. INSTALL BELT MOULDING
Tap the moulding onto the clips by hand.
2. INSTALL DOOR GLASS

(See steps 11 to 17 on pages BO- 7, 8)
Side Body Moulding

COMPONENTS
Front Door Moulding

Quarter Moulding Rear Moulding
Rear Moulding Center Pillar Moulding

Slide Door Moulding Front Door Moulding
~ Adhesive
• Clip
)( Nut
801459
BODY - Moulding 80-25
TOOLS AND SUPPLIES
Part No. Part name Quantity
08850-00051 Adhesive (Super special) 209 (0.71 oz.) 1
Cleaner (for cleaning body and removing body 011 stains)

Heat light
Precautions for storing moulding material:

• Store in cool place, and avoid direct sunlight, high tem-
perature or dust.
• The moulding is of polyvinyl chloride, so do not allow it
to come in contact with thinner or other solvent, open
flame, or boiling water.
• The storage time for the moulding and adhesive is
limited to about 9 months.
REMOVAL OF FRONT DOOR MOULDING

REMOVE MOULDING
(a) Remove the nut from the door inside.
(b) Pry loose the adhesive and clips with a scraper, and
remove the moulding.
NOTE: Apply tape to the scraper blade to prevent
scratching the vehicle body.
801445
INSTALLATION OF FRONT DOOR

MOULDING
1. CLEAN MOULDING MOUNTING SURFACE
Wipe off the remaining adhesive with cleaner.
801446
2. INSTALL NEW CLIPS AND RETAINERS TO

MOULDING
3. HEAT BODY MOUNTING SURFACE

Using a heat light, heat the body mounting surfaces to 40
- 60°C (104 - 140°F).
CAUTION: When the moulding is installed, the tem-
perature of the mounting surface should be 20°C
(68°F) or higher.
801447
80-26 BODY - Moulding
4. HEAT MOULDING
Using a heat light, heat the moulding to 20 - 30°C (68 -
86°F).
CAUTION: Do not heat the moulding excessively.
The temperature should not be higher than 30°C
(86°F).
801448
5. APPLY ADHESIVE TO MOULDING

Apply adhesive to the moulding between the adhesive
tape.
CAUTION: Install the moulding within 7 minutes
after applying the adhesive.
6. LIFT MOULDING RELEASE SHEET FROM FACE OF

-0 0
~----
a 0 a MOULDING
CAUTION: When the moulding release sheet is
801449 removed, be sure that no dirt or dust can get onto the
uncovered area.
7. INSTALL MOULDING
(a) Push the moulding onto the panel by hand.
(b) Install the nut.
CAUTION:
• Be sure that the body and moulding are heated to
the proper temperature.
• Do not depress the adhesive-coated parts exces-
sively, just hold them down with your thumb.
801450
• Scrape off any overflowing adhesive with a plastic
spatula and clean the surface with a dry rag.
• After installation do not wash the vehicle for 24
hours.
REMOVAL OF CENTER PILLAR MOULDING

REMOVE MOULDING
Using a scraper, pry loose the clips and remove the
moulding.
801451
\':--- --\
INSTALLATION OF CENTER PILLAR
'\
\\,,\,a MOULDING
Wipe off with a rag.
2. INSTALL MOULDING
Install the clips to the moulding and push the moulding
onto the panel by hand.
REMOVAL OF SLIDE DOOR MOULDING

REMOVE MOULDING
(a) Remove the two nuts from door inside.
(b) Using a scraper, pry loose the clips and remove the
moulding.
801453
INSTALLATION OF SLIDE DOOR

MOULDING
2. INSTALL MOULDING
(a) Install the clips to the moulding and push the mould-
ing onto the panel by hand.
801454 (b) Install the two nuts.
REMOVAL OF QUARTER MOULDING

REMOVE MOULDING
(a) Remove the two nuts from the panel inside.
(b) Using a scraper, pry loose the clips and remove the
moulding.
801455
INSTALLATION OF QUARTER MOULDING

2. INSTALL MOULDING
(a) Install the clips to the moulding and push the mould-
ing onto the panel by hand.
(b) Install the two nuts.
REMOVAL OF REAR MOULDING

REMOVE MOULDING
(a) Remove the nut from the panel inside.
(b) Pry loose the adhesive and clips with a scraper, and
remove the moulding.
INSTALLATION OF REAR MOULDING

(See page BO-25)
BODY - Windshield 80-29
WINDSHIELD
TOOLS AND SUPPLIES
Part name and Part No. I

Contents of set Quantity
~._~--_.--_.--- ----- ~---
Adhesive set Main agent 500 g (1 7.64 oz,) 1 can

08850-00070 Hardening agent 75 g (2.65 oz.) 1 ea.
[0 - 15°C (32 - 59°F)] Primer G [for glass] 20 g (0.71 oz.) 1 ea.
08850-00080 Primer M [for body] 20 g (0.71 oz.) 1 ea.
[15 - 35°C (59 - 95°F)] Sponge for applying primer 2 ea.
08850-00090 Piano wire 0.6 mm dia. x 1 m (0.024 in. dia. x 39.37 in,) 1 ea.
[35 - 45°C (95 - 113°F)] Cartridge 1 set
--~ .••._.- ._--_ •.• - - ..• .~
Dam kit Dam

04562-30040 Double-stick tape (for sticking on dam)
-----
-t I
Sealant gun (for applying adhesive)
Glass or steel sheet (for mixing adhesive)
Putty spatula (for mixing adhesive and correcting adhered parts)
Cleaner (for cleaning adhering surfaces)
Ambient
I
1. CHOOSE AN ADHESIVE SET

Part No. Part name
temperature
--_._-~-
Use an adhesive set suitable for the ambient tem-
Windshield glass perature.
08850-00070 adhesive set
No. 15
~-_.- ~--_._. -~.--_. _ _. _ - -
Windshield glass
15 - 35°C
08850-00080 adhesive set
(59 - 95°F)
No. 35
f------- - .--- - - - - - . - - - . - - - - - - - - - j
35 - 450C Windshield glass

(95 - 1130F) 08850-00090 adhesive set
No. 45
2. CHECK ADHESIVE USABLE TIME

(min,)
After the mixing the main and hardening agents, finish
glass installation within the specified time as shown.
Example:
For glass installation in an ambient temperature of 25°C
(77°F), apply adhesive set No. 35 within 45 minutes.
10 20 30 40 (CO)
Ambient Temperature
3. CHECK ADHESIVE HARDENING TIME

(min.)
600 A leak tests should be made only after the hardening
Q,) time has elapsed.
E
~ Example:
0) The hardening time for adhesive set No. 35 with an
c
c ambient temperature of 25°C (77°F) is 2 V2 hours.
Q,)
"E CAUTION: Do not drive the vehicle until at least

ctl 120
I double the hardening time has elapsed.
o 10 20 30 40 (CO)
Ambient Temperature
BO-30 BODY - Windshield
COMPONENTS
Joint Cover Upper Moulding Inner Rear View Mirror

Assist Grip
Side Moulding
Windshield Glass Roof Headliner
Front Trim
/
I
I
I
I
Wiper Arm Lower Moulding Dam Front Pillar Garnish

BODY - Windshield BO-31
REMOVAL OF WINDSHIELD
(See page 80-32)

(a) Wiper arm
(b) Inner rear view mirror
(c) Assist grip
(d) Front pillar garnish
NOTE: Tape the screwdriver tip before use.
2. REMOVE WINDSHIELD MOULDING (See page BO-18)
3. REMOVE CLIPS
Be careful not to damage the clips when removing them from
around the glass.
NOTE: It is not necessary to remove the fasteners but
damaged fasteners should be replaced.
4. REMOVE WINDSHIELD GLASS

(a) Push piano wire through from the interior.
(b) Tie both wire ends to a wooden block or equivalent.
CAUTION: When separating, take care not to
damage the paint and interior and exterior ornaments.
To prevent scratching the safety pad when removing
the windshield, place a plastic sheet between the
piano wire and safety pad.
(c) Cut the adhesive by pulling the piano wire around it.
(d) Remove the glass.
CAUTION: Leave as much of the urethane layer on
the body as possible.
INSPECTION AND CLEANING

1. CLEAN CONTACT SURFACE OF BODY
(a) Remove any dam remaining on the body.

NOTE: Leave as much urethane layer on the body as
possible.
80-32 BODY - Windshield
(b) Clean the cutting surface of the urethane gum with a

Urethane Gum
piece of cloth saturated in cleaner.
2. IF FASTENERS ARE DAMAGED

Fastener
1
(a) Remove any damaged fasteners.
I,
(b) Cut the old adhesive off around the fastener installa-
tion area.
(c) Install a new fastener.
3. CLEAN REMOVED GLASS BEFORE INSTALLATION
~ret~ane .)
(a) Using a scraper, remove the urethane gum sticking to
the glass.
de (b) Clean the glass with cleaner.
4. POSITION GLASS
(a) Replace any broken rubber spacers.
(b) Place the glass in correct position onto the rubber
spacers.
Position Mark (c) Check that all contacting parts of the glass rim are
perfectly even and do not make contact with the
fasteners.
(d) Make reference marks between the glass and body.
Spacer Spacer (e) Remove the glass.
5. CLEAN CONTACT SURFACE OF GLASS

Using cleaner, clean the contact surface 15 - 30 mm (0.59
-1.18 in.) wide around the entire glass rim.
15 - 30 mm
BODY - Windshield BO-33
Dam INSTALLATION OF WINDSHIELD

1. INSTALL DAM
(a) Apply double-stick tape at a point 7 mm (0.28 in.)
Glass 7 mm from the glass rim.
(b) Place the dam on the double-stick tape.
NOTE: Cut a V-wedge into the corner folds of the dam.
CAUTION: Do not touch the glass face after cleaning
it.
2. COAT CONTACT SURFACE OF BODY WITH PRIMER

"M"
Using a brush, coat the contact surface on the body with
(,~ /
Primer M.
CAUTION:
Primer M r • Let the primer coating dry for 10 minutes or more.
Make sure that the installation of the glass is
finished within 2 hours.
I0thane
~'~ /
• Use care not to leave any part of the contact surface
uncoated or excessively coated, as Primer M and G
Primer Mr serve to boost the adhesive power of the urethane

to the glass or body.
• Do not keep any of the opened Primer M and G for
later use.
3. COAT CONTACT SURFACE OF GLASS WITH PRIMER

"G"
(a) Using a brush or sponge, coat the edge of the glass
and the contact surface with Primer G.
(b) Before the primer dries, wipe it off with a clean cloth.
CAUTION: Be sure that installation of the glass is
finished within 70 minutes.
4. MIX ADHESIVE COATING

CAUTION:
• Be sure that installation of the glass is finished with-
in usable time. (See step 2 on page BO-27)
• The mixture should be made within 5 minutes.
(a) Thoroughly clean the glass plate and putty spatula
with cleaner.
(b) Using a putty spatula, thoroughly mix the main 500g
(17.64 oz.) and hardening agents 75g (2.65 oz.) on a
glass plate or such.
5. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle to make a hole
5 mm (0.20 in.) in diameter. Fill the cartridge with
adhesive.
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive on all contact surfaces
along the ridge.
Adhesive height:
If adhesive remains on body 3.5 - 5.0 mm
(0.138 - 0.197 in.)
If no adhesive remains on body 8 - 10 mm
(0.31 - 0.39 in.)
BO-34 BODY - Windshield
6. INSTALL GLASS
(a) Position the glass so that the reference marks are
aligned, and press in gently along the rim.
(b) Using a spatula, apply adhesive on the glass rim.
(c) Use a spatula to remove any excess or protruding
adhesive. ..
(d) Fasten the glass securely until the adhesive sets.
7. INSPECT FOR LEAKS AND REPAIR

(a) Perform a leak test after the hardening time has
elapsed.
(b) Seal any leak with auto glass sealer.
Part No. 08833-00030 or equivalent
CAUTION: Wait at least twice the hardening time
before driving the car.
8. INSTALL OUTSIDE MOULDING

(a) Using a knife, remove the adhesive around the
installation area of the clips.
(b) Apply adhesive to the installation area of the clips.
sJ \
Remove Adhesive
NOTE: Loosely install the clips and confirm that the clip
arm is not protruding above the surface.
(c) Install the clips into the moulding.

When installing the moulding, be sure that the clips
and fasteners on the body side do not make contact.
(d) Install the outside moulding.
9. INSTALL FOLLOWING PARTS:

(a) Roof headliner front trim
(b) Inner rear view mirror
10. INSTALL WIPER ARM
11. INSTALL FRONT PILLAR GARNISH

BODY - Side Window BO-35
SIDE WINDOW
COMPONENTS
Packing
Sash Clip
Sash Assembly
!I Glass Run
I
Moulding
Pad
~
Glass
f
r
~
I ~
I ~ m
Weatherstrip l.!J ~
Channel
REMOVAL OF SIDE WINDOW

1. REMOVE SASH CLIP
2. REMOVE SIDE WINDOW

(a) Cut the adhesive with a screwdriver.
NOTE: Do not bend the body or frame edge.
(b) Remove the sash with the glass.
(c) Wipe off any adhesive left on the sash.
NOTE: After wiping off the adhesive, use adhesive tape
to pull off any remaining pieces.
BO-36 BODY - Side Window
(d) After removing the channel set screw, remove the

glass.
(e) Pull apart the sash and remove the glass channel.
INSTALLATION OF SIDE WINDOW

(See page 80-35)

(a) Side window glass
(b) Side window glass channel
(c) Side window glass channel weatherstrip
2. INSTALL SIDE WINDOW

(a) Wipe off any adhesive left on the body.
(b) Apply adhesive tape around the body.
(c) Install the frame onto the body.
(d) To compress the butyl tape, squeeze the frame and
body edge portion together with a pair of pliers.
(e) Install the clip on the body and frame edge.
BODY - Back Door Window Glass 80-37
BACK DOOR WINDOW GLASS

COMPONENTS
Weatherstrip
~ -I --=--=--=-_ -.~~-"----"~----BackDoor Window
~I '\\
--~
c:::::iii!!s:::!r:r=:::s==-\\~--WiperA rm
--- --\ ~--

80-38 BODY - Back Door Window Glass
REMOVAL OF BACK DOOR WINDOW GLASS

1. REMOVE TRIM
2. REMOVE REAR WIPER ARM
3. DISCONNECT DEFOGGER WIRE CONNECTOR
4. APPLY ADHESIVE TAPE TO PROTECT BODY
5. REMOVE GLASS
If reusing weatherstrip:
(a) Working from the vehicle outside with a screwdriver,
loosen the weatherstrip lip from the body.
(b) Force the weatherstrip lip from the interior to the out-
side body flange. Pull the glass outwards and remove
it with the weatherstrip.
If not reusing weatherstrip:

(a) From the outside, cut off the weatherstrip lip with a
knife.
(b) From the vehicle interior, push out the glass with an
even force.
(c) Pull off the weatherstrip from the body.
BODY - Back Door Window Glass 80-39
INSTALLATION OF BACK DOOR WINDOW

GLASS
(See page 80-37)
1. CLEAN BODY AND GLASS
Using cleaner, wipe off any adhesive left on the body or
glass.
2. INSTALL WEATHERSTRIP ON GLASS

(a) Attach the weatherstrip to the glass.
CAUTION: If the weatherstrip has hardened, it may
develop water leaks. Use a new one if possible.
(b) Install a working cord along the weatherstrip groove
as shown.
3. INSTALL GLASS
(a) Apply soapy water to the contact face of the
weatherstrip lip and to the body flange.
NOTE: Begin installation from the lower center part of

the glass.
(b) Hold the glass in position on the body.
(c) Install the glass by pulling the string from the interior,
while pushing on the outside of the weatherstrip with
your open hand.
(d) To snug the glass in place, tap from the outside with
your open hand.
80-40 BODY - Back Door Window Glass
4. INSPI;CT LEAKS AND REPAIR

(a) Perform a leak test.
(b) Seal any leak with auto glass sealer.
Part No. 08833-00030 or equivalent

(a) Window defogger wire connector
(b) Back door trim
(c) Rear wiper arm
BODY - Front Tilt Roof BO-41
FRONT TILT ROOF

COMPONENTS
,=------Tilt Roof Panel Cover
Tilt Roof Hin g e - - 4 , :;;-"7-----Tilt Roof Glass
~~~?----Tilt Roof Guide Rail
~
~------Spacer
- - - - - - T i l t Roof Lock Handle
~-----Sun Shade Trim Protector
-.>----- Front Sun Shade Trim
800820
BO-42 BODY - Front Tilt Roof
DISASSEMBLY OF FRONT TILT ROOF

(See page 80-41)
1. REMOVE TILT ROOF OPENING TRIM MOULDING
2. REMOVE BOTH SIDE TILT ROOF LOCK HANDLES
:. -------- -- ----
I
---- -----~'
800821
3. REMOVE TILT ROOF GLASS

(a) Remove the four mounting nuts.
800822
(b) Remove the hinge subassembly.
800823
4. REMOVE TILT ROOF GUIDE RAIL

(a) Remove the four mounting screws.
800824
(b) Carefully apply adhesive tape to protect the body.

NOTE: Do not damage the body.
BODY - Front Tilt Roof BO-43
ASSEMBLY OF FRONT TILT ROOF

(See page BO-41)
1. INSTALL TILT ROOF GUIDE RAIL
>~ Install the six set screws.
/~~--~
/" --- - -- ~
r-- - - -- -------
-----------._--- ---
,/ ,.-- ~-- --- -- -- ~:_~:---
!~~
BOOB24
2. INSTALL TILT ROOF GLASS

(a) Install the hinge subassembly.
B00823
(b) Install the four set nuts.
B00822
3. INSTALL BOTH SIDE TILT ROOF LOCK HANDLES
B00821
4. CHECK TILT ROOF LOCK
Spacer Check the tilt roof lock.

/ If it does not lock properly insert a spacer between the
handle and link.
5. INSTALL TILT ROOF OPENING TRIM MOULDING
B00832
BO-44 BODY - Rear Sun Roof
'REAR SUN ROOF

COMPONENTS
Sliding Roof Weatherstrip
Protector - - - , . . . - - - - 1
I
'" r-----------Shim
~--~-----FrontShoe
~--Shim
---Rear Shoe
_ _ _ Sliding Roof Drive

Cable Subassembly
BODY - Rear Sun Roof BO-45
REMOVAL OF REAR SUN ROOF

(See page BO-44)
1. REMOVE REAR SUN ROOF SWITCH
2. REMOVE SLIDING ROOF DRIVE GEAR

SUBASSEMBLY
3. REMOVE SLIDING ROOF HEADLINING

(a) Pry loose the clips.
(b) Face the headlining toward the rear side.
4. REMOVE SLIDING ROOF PANEL

(a) Remove the eight set bolts and shims.
(b) Remove the sliding roof panel.
5. REMOVE SLIDING ROOF DRIVE CABLE

SUBASSEMBLY
(a) Carefully apply adhesive tape to protect the body.
(b) Remove the cable subassembly set screws.
(c) Remove the cable subassembly with the roof head-
lining.
NOTE: Do not damage the body.
DISASSEMBLY OF REAR SUN ROOF PANEL

1. REMOVE SLIDING ROOF GUIDE RAIL
Remove the two screws.
2. REMOVE SLIDING ROOF WEATHERSTRIP RETAINER

AND PROTECTOR
3. REMOVE SLIDING ROOF WEATHERSTRIP

BO-46 BODY - Rear Sun Roof
ASSEMBLY OF REAR SUN ROOF PANEL

1. INSTALL SLIDING ROOF WEATHERSTRIP
2. INSTALL SLIDING ROOF WEATHERSTRIP HOLDER

AND PROTECTOR
3. INSTALL SLIDING ROOF GUIDE RAIL
A
INSTALLATION OF REAR SUN ROOF
(See page BO-44)
1. INSTALL SLIDING ROOF DRIVE CABLE

SUBASSEMBLY
A=B (a) Install the sliding roof headlining to the cable sub-
assembly.
(b) Dimensions A and S, as shown, are equal.
8
2. INSTALL SLIDING ROOF PANEL
3. INSTALL SLIDING ROOF HEADLINING
4. INSTALL SLIDING ROOF DRIVE GEAR

SUBASSEMBLY
5. INSTALL SLIDING ROOF SWITCH
ADJUSTMENT OF REAR SUN ROOF
I
I
= ~~ ~ IF NECESSARY, ADJUST GAP BETWEEN SLIDING ROOF

PANEL AND BODY
Insert the shim into Insert the shim into
the front shoe. the rear shoe. (a) Adjust by increasing or decreasing the number of
shims between the front and rear shoes and roof
panel.
(b) Minute adjustments of the fore-aft/left-right sides of

the sliding roof are done with the set screws.
BODY - Rear Sun Roof 80-47
1\ (c) If there is a difference in the left and right clearances,

loosen the rear shoe nuts, slide the sun roof fore-
and-aft once and then retighten the nuts.
The rear shoe has a 1.5 mm (0.059 in.) margin, per-
Na rrovv, Wid e mitting automatic adjustment when the roof is slid.
Wide (d) If the roof is slanted with the front end about 2 mm
(0.08 in.) out of place, the drive gear has slipped one
tooth. Therefore, remove the gear subassembly and
advance the cable one tooth on the side with the
larger clearance [one tooth = 2.5 mm (0.098 in.)).
If the difference is only about 1 mm (0.04 in.), loosen
the rear shoe nuts and adjust the sliding roof to the
proper position.
The shoe set screw hole has a 0.5 mm (0.020 in.)
margin.
BO-48 BODY - Safety Pad
SAFETY PAD
COMPONENTS
Safety Pad
@ Instrument Cluster Finish Panel
Bracket
I------Instrument Panel
Glove Compartment Door
(8)
LH Speaker_ _i l l
Panel
Combination Meter if
Under Tray
~ Ash Tray Retainer

~
~ Cover
Steering Column ~_RadioandStereo
~
@ f
c ~ © Instrument Cluster Center Panel
@
Steering Wheel
Instrument Finish Lower Panel

~A sh Tray
801875
BODY - Safety Pad BO-49
NOTE: Screw sizes in the previous illustration are indicated

by following the code below for remove and installation of
safety pad.
mm(in.)
Code Shape Size Code Shape Size Code Shape Size
¢ =5 (0.20) ¢ =5 (0.20) ¢ =6 (0.24)
-
A
L = 14 (0.55)
[Gray]
B
L = 16 (0.63)
[Black]
C
~ L = 16 (0.63)
¢ =5 (0.20) ¢ =5 (0.20) ¢ =6 (0.24)

0
~ L = 14 (0.55)
[Black]
E
~ L = 12 (0.47)
[None]
F
ilwmm L =20 (0.79)
-
¢ =5 (0.20) ¢ =5 (0.20)
G H
L = 16 (0.63) L = 12 (0.47)
[None] [Black]
REMOVAL OF SAFETY PAD

(See page BO-48)

TERMINAL
2. REMOVE STEERING WHEEL

(See page SR-5)
3. REMOVE INSTRUMENT FINISH LOWER PANEL

Remove the four screws and finish lower panel.
4. REMOVE STEERING COLUMN COVER

BO-50 BODY - Safety Pad
5. REMOVE LH SPEAKER PANEL

(b) Remove the LH speaker panel with the two clips.
B01867
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL

(a) Remove the five screws.
(b) Remove the finish panel with the three clips.
7. REMOVE COMBINATION METER

(a) Remove the four screws.
(b) Disconnect the speedometer cable and connectors.
(c) Remove the combination meter.
8. REMOVE INSTRUMENT CLUSTER CENTER PANEL

(a) Remove the ash tray.
(b) Remove the four screws.
(c) Remove center panel with the two clips.
(d) Disconnect the connector and illumination wire from
the cigarette lighter.
(e) Remove the two screws and ash tray retainer.
B01870
9. REMOVE RADIO AND STEREO

(a) Remove the four screws, radio and stereo.
(b) Disconnect the antenna cable and connectors.
10. DISCONNECT HEATER CONTROL

Remove the three screws and disconnect the heater
control.
B01871
BODY - Safety Pad 80-51
11. REMOVE UNDER TRAY AND GLOVE COMPARTMENT

DOOR
(a) Remove the two screws and under tray.
(b) Remove the two screws and glove compartment door.
-~--:::::-\
~-::_-~:
B01872
12. REMOVE SAFETY PAD

(a) Remove the six screws and two bolts.
(b) Remove the safety pad with the two clips.
B01873
13. REMOVE INSTRUMENT PANEL

Remove the four bolts, two screws and instrument panel.
1\
I
\
\
\
\
I
\
\
\
\
I
It
i B01874
INSTALLATION OF SAFETY PAD

(See page BO-48)
INSTALL SAFETY PAD PARTS FOLLOWING REMOVAL

SEQUENCE IN REVERSE
BO-52 BODY Seat
SEAT
Front Seat
COMPONENTS
Armrest
Headrest
Bushing
.....
.....
l!rt
[400 (29. 39) I ..........
l '/ '.....
......
..... ../
I
I
I
I
.... "
,
'1'---"
Bushing
1 - - - - - - - Seat Back
~I 375 (27. 37) I

Seat Cushion
Seat Reclining
~
~-'~-'"
I
) I
I 375 (27. 37) I_ _~...... ~-~~C"
:
>,
Seat Track - - - - - - - - - - - - - ! I "
Ikg-cm (ft-Ib. Nom)1 : Specified torque 800827

BO-53
Rear Seat
COMPONENTS
Rear No. 1 Sea t (Standar d Seat}
Bushing
Headrest
[37? 127.371
Armrest
lfi,,
Seat Back
Seat Cushion
Seat Track -
Seat Leg
Striker
I 185 (13, 18) I

BO-54 BODY - Seat
COMPONENTS (Cont'd)
Rear No. 1 Seat (Swivel Seat)
q----Headrest
I - - - - - - - - - - S e a t Back
Armrest-------------i
~-----€-Bushing
~ @.({) ~ ~ 375127.371 !
Seat Reclining---------V'"~
I ~r-------I 375 (27. 37) I
Seat Cushion------------"\
I '"0
I
L
Seat Turn T able ---------f~ --....-~_=____. . . . . -~~----I 375 (27. 37) I
~e ---:
I ~
~ ~r-----------I 375 (27. 37) I
~-------~(27. 37) I
Seat L e g - - - - - - - - -
[i75 (27. 37)]
Ikg-cm (ft-Ib. Nom)1 : Specified torque

601282
BODY - Seat BO-55
COMPONENTS (Cont'd)
Rear No.2 Seat
Headrest
I 375 (27.37) ] - - - -
Seat cushion~ Seat Back Lock

Lock ~:
1185 (13. 1 8 ) V ~ (,l -f-------Striker

l, W (f;;
Seat Cushion----~ '-
'~>-----------I 210 (15. 21) I
I - - - - - - - - - S e a t Hinge
I
I
I
Striker - - - - - - - - - , I
I
I",~
:'~--I 210 (15. 21) I
~~1185113. 181 I
Ikg-cm (ft-Ib, Nom)1 : Specified torque 800829

BO-56 BODY - Seat Belt
SEAT BELT
COMPONENTS
Front Seat
Front Seat
Outer Belt ~_ _-----,
.' ~ Front Seat

/ Inner Belt ~
C:....
.,' ~. ~: - L
........ ~.
I/(
I 440 (32. 43) I
Front Seat - - - - - - - - + J I " ' : : l l
Inner Guide
[440 (32. 43)
[ 440 (32. 43) I 440 (32.~ Retractor Cover

Rear No. 1 Seat Belt
(Standard Seat) (Swivel Seat)
1440 (32.~
ALR Type
~
lf'rJ
r- • . . l'
I ~ . .-: :
I 440 (32. 43) I
I
1
440 (32. 43) I
Ikg-cm (ft-Ib. Nom)1 : Specified torque 800830

800826 801217
BODY - Seat Belt BO-57
COMPONENTS (Cont'd)
Rear No.2 Seat Belt
ALR Type
I 440 (32. 43) I
I kg-cm (ft-Ib. Nom)1 : Specified torque B01204

BO-58 BODY - Seat Belt
FRONT SEAT BELT

[Emergency Locking Retractor (ELR) Type]
1. RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belt.
(b) Drive the car at 10 mph (16 km/h) and make a very
hard stop.
(c) Check that the belt is locked and cannot be extended
at this time.
800632
NOTE: Conduct this test in a safe area. If the belt does
not lock, remove the belt mechanism assembly and con-
duct the following static check. Also, whenever installing a
new belt assembly, verify the proper operation before
installation.
2. STATIC TEST
(a) Remove the locking retractor assembly.
(b) Tilt the retractor slowly.
(c) Verify that the belt can be pulled out at an angle of
15 degrees or less to the mount verify that it cannot
be pulled out at an angle greater than 45 degrees to
the mount.
If a problem is found, replace the assembly.
OUTBOARD REAR SEAT BELT

[Automatic Locking Retractor (ALR) Type]
~~,
~ "'.~.,
.. "--
I,,/' TESTING
". I
(a) Pull out the belt, release it slightly and then pull it out
~ (b)
again.
Verify that the belt cannot be extended further.
If a problem is found, replace the assembly.
800634
CENTER REAR SEAT BELT

(Manual Type)
TESTING
(a) Adjust the belt to the proper length.
(b) Apply a firm load to the belt.
(c) Verify that the belt does not extend.
800635
~
Do)
CQ
o:;]
I.. 1.625 (63.98) --I
*1: C-c 786 (30.94)
N
:E
-
a
A
RH
Fr..-f
LH a m
o
OJ o
o -<
c I
-< OJ
o
c..
c -<
o
.625 (63.98) ~
s:
m 3
co
[YVheel-base---L~.?~5T87~9 gT] :2 :J
en
en
-
o
O·
:J
en
:2
~ I ~""""! iii'
Imaginary
Standard
en
Line
C.c D,I d
181 181 F, f
(7.13) (7.13) 255
(10.04)
The dimensions in the following drawing

indicates actual distance.
Therefore, please use the dimensions as a
reference. mm(in.l
Symbol Nomenclature Hole dia. Symbol Nomenclature Hole dia.

Aa Front bumper installation hole 17 (0.67) E, e Front side member standard hole 18(0.71)
B.b Front bumper installation hole 17 (0.67) F, f Lower control link inner bracket hole 15 (0.59) m
c. c Front side member working hole 18 (0.71) G. g Upper control link inner bracket hole 14.5 (0.57)
o
I
C1I
D.d Engine support member installation hole - front 13 (0.51) H.h Rear floor side member bumper installation nut 12(0.47) (D
OJ
<
Q)
o
0)
I
::J
N
o
* 1 : C-c 786 (30.94) 1,148 (45.20) --~-~ ~
o
RH 1,914/
(75.35)
Fr..J 61
(~~~~-tU-++- --
1,010
(39.76)
946
(37.24)
1,914
(75.35)
~.
LH OJ
=r o
~ ')~nnnn_J.- -~ ,/;n===~~, \~
q5 . ~~- --- ~~j 1i ~.~••••~ ••• ~ •••~.~ ~ ~ .~ ~ ~ ~
a
o _~ i \ r i •
:)~ ;~l~ ~ G~~~ ~ ,
c
-<
I I I
I
OJ
o
c.
-<
I.. 1,148(45.20) ., o
3
CD
[\,\theel b~s~ J]~i30 (87:-80) I :::J
CJ)
0'
o:::J
CJ)
rtf: ::0: ':==~~"

~--t--t_==~_::~::::::=t .J-- _ _ _ __
J, nT=iQ:1:~~~~~~c
-11 -- ~~~ ~_ .
\~~:~~na~d
~
\_-~-~ Line
G. 9 H. h
C. c D,d 95 61
181 F. f (3.74) (2.40)
(7.13) 181 265
(7.13) (10.43)

indicates actual distance.
reference. mmOn.l
A, a Front bumper installation hole 17 (0.67) E, e Front side member standard hole 18 (0.71)
B, b Front bumper installation hole 17 (0.67) F, f Rear spring front hanger hole-inner 14 (0.55)
C,c Front side member working hole 18 (0.71) G, g Rear spring rear hanger hole-inner 30 (1.18)
D, d Enaine support member installation hole-front 13 (0.51) H, h Rear floor side member bumper installation nut 12 (0.47)
~
~
-
C
Fr;
A,
RH
I
1,013 i
. (39:mJt,
LH a
OJ
o
c
-<
I
OJ
o
a.
-<
I Wheel Base I 2,235 (87.99) I o
3
CD
indicates actual distance. ::l
en
O·
reference. ::l
en
Imaginary
Standard
A,a B,b D,d G,g
217 239
Line
191 191 E,e
(7.52) (7.52) (8.54) 5 (9.41)
(0.20)

A, a Front bumper installation hole 17 (0.67) E, e Lower control link inner bracket hole 15 (0.59)
B,b Front bumper installation hole 17 (0.67) F, f Upper control link inner bracket hole 14.5 (0.57) OJ
c, c Engine support member installation hole - front 13 (0.51) G, g Rear floor side member bumper installation nut 12 (0.47) o
I
D,d Front side member standard hole 18(0.71) en

~
AC-1
AIR CONDITIONING
SYSTEM
Page
PRECAUTIONS . AC-2
TROUBLESHOOTING . AC-2
Checking of Refrigeration System
with Manifold Gauge . AC-4
SPECIAL TOOLS AND EQUIPMENT . AC-8
AIR CONDITIONING SYSTEM CIRCUIT . AC-9
ON-VEHICLE INSPECTION . AC-13
REFRIGERATION SYSTEM . AC-14
Checking of Refrigerant Charge . AC-14
Installation of Manifold Gauge Set . AC-14
Discharging of Refrigeration System . AC-15
Evacuating and Charging of
Refrigeration System . AC-15
Performance Test . AC-18
SYSTEM COMPONENTS . AC-20
COMPRESSOR . AC-24
CONDENSER . AC-36
RECEIVER . AC-38
FRONT COOLING UNIT . AC-39
Evaporator . AC-41
REAR COOLING UNIT . AC-42
REFRIGERATOR . AC-45
REFRIGERANT LINES . AC-46
AIC SWiTCH . AC-46
NO.1 REAR HEATER BLOWER SWITCH . AC-47
AIC RELAY . AC-47
CONDENSER FAN MOTOR . AC-49
MAGNETIC VALVE . AC-52
PRESSURE SWITCH . AC-52
THERMISTOR . AC-53
AIR CONDITIONER AMPLIFIER . AC-53
VACUUM SWITCHING VALVE (VSV) . AC-55
AC-2 AIR CONDITIONING SYSTEM - Precautions, Troubleshooting
PRECAUTIONS
1. When handling refrigerant (R-12) the following precautions should be observed:
I
(a) Always wear eye protection.

(b) Keep the refrigerant container (service drum) below 40°C (104°F).
(c) Do not handle refrigerant in an enclosed area or near an open flame.
(d) Discharge refrigerant slowly when purging the system.
(e) Be careful that liquid refrigerant does not get on your skin.
2. If liquid refrigerant gets in your eyes or on the skin:

(a) Do not rub.
(b) Wash the area with a lot of cool water.
(c) Apply clean petroleum jelly to the skin.
(d) Rush to a physician or hospital for immediate professional treatment.
(e) Do not attempt to treat yourself.
3. When tubing:
(a) Apply a few drops of refrigeration oil onto the O-ring fittings.
(b) Tighten the nut using two wrenches to avoid twisting the tube.
(c) Tighten the O-ring fitting to the specified torque.
Tightening torque for O-ring fittings
Fitting size Torque
0.31 in. Tube 135 kg-cm (10 ft-Ib, 13 N'm)
0.50 in. Tube 225 kg-cm (16 ft-Ib, 22 N'm)
0.62 in. Tube 325 kg-cm (24 ft-Ib. 32 N'm)
Bolted Type 250 kg-cm (18 ft-Ib, 25 N·m)
TROUBLESHOOTING
No cooling or Magnetic clutch does not engage
warm air (a) Heater circuit breaker blown Reset circuit breaker and check AC-9 to 12
for short
(b) Magnetic clutch faulty Check magnetic clutch AC-24
(c) A/C switch faulty Check A/C switch AC-46
(d) Thermistor faulty Check thermistor AC-53
(e) A/C amplifier faulty Check amplifier AC-53
(f) Wiring or ground faulty Repair as necessary AC-9 to 12
(g) Refrigerant empty Check refrigerant pressure AC-14
(h) Main relay faulty Check main relay AC-9 to 12
(i) Pressure switch faulty Check pressure switch AC-52
Compressor does not rotate properly
(a) Drive belt loose or broken Adjust or replace drive belt AC-13
(b) Compressor faulty Check compressor AC-24
Expansion valve faulty Check expansion valve AC-39
Leak in system Test system for leaks AC-16
Fusible plug on receiver blown or clogged Check receiver AC-38
screen
AIR CONDITIONING SYSTEM - Troubleshooting AC-3
No cooling or warm air Blower does not operate

(Cont'd) (a) Heater circuit breaker blown Reset circuit breaker and check for AC-9 to 12
short
(b) A/C switch faulty Check A/C switch AC-46
(c) Main relay faulty Check main relay AC-9 to 12
(d) Blower motor faulty Check blower motor
(e) Wiring faulty Repair as necessary AC-9 to 12
(f) Magnetic valve faulty Check magnetic valve AC-52
f-----
Cool air comes out Magnetic clutch slipping Check magnetic clutch AC-24
intermittently Expansion valve faulty Check expansion valve AC-39
Wiring connection faulty Repair as necessary AC-9 to 12
A/C amplifier faulty Check amplifier AC-53
Excessive moisture in the system Evacuate and charge system AC-4, 15
Limited amount of cool Thermistor faulty Check thermistor AC-53

air at high speed Idling stabilizer amplifier faulty Check amplifier AC-53
r---
Cool air comes out only Condenser clogged Check condenser AC-36
at high speed Condenser fan motor faulty Check fan motor AC-49
Drive belt slipping Check or replace drive belt AC-13
Insufficient or too much refrigerant Check refrigerant charge AC-6,14
Air in system Evacuate and charge system AC-7, 15
Insufficient cooling Condenser clogged Check condenser AC-36

Condenser fan motor faulty Check fan motor AC-49
Drive belt slipping Check or replace drive belt AC-13
Magnetic clutch faulty Check magnetic clutch AC-24
Compressor faulty Check compressor AC-24
Expansion valve faulty Check expansion valve AC-39
Thermistor faulty Check thermistor AC-53
Idling stabilizer amplifier faulty Check amplifier AC-53
Insufficient or too much refrigerant Check refrigerant charge AC-6,14
Air or excessive compressor oil in system Evacuate and charge system AC-7,15
Receiver clogged Check receiver AC-38
Water valve set faulty Reset water valve cable BE-38
Insufficient velocity of Evaporator clogged or frosted Clean evaporator fins or filters AC-41
cool air Air leakage from cooling unit or air duct Repair as necessary
Air inlet blocked Repair as necessary
Blower motor faulty Replace blower motor
Insufficient cooling Expansion valve faulty Check expansion valve AC-39

(Refrigerator) Thermistor faulty Check thermistor AC-53
Evaporator clogged frosted Clean evaporator fins AC-41
AC-4 AIR CONDITIONING SYSTEM - Troubleshooting
Checking of Refrigeration System

with Manifold Gauge
This is a method in which the trouble is located by using a
manifold gauge.
Read the manifold gauge pressure with the following
established conditions:
(a) Temperature at the air inlet is 30 - 35°C (86 - 95
OF)
(b) Engine running at 2,000 rpm
(c) Blower speed set at high
(d) A/C switch ON
(e) Temperature control lever set at cool
NOTE: The gauge indications may vary slightly due to
ambient temperature conditions.
1. NORMALLY FUNCTIONING REFRIGERATION

SYSTEM
Gauge reading:
AC0067 Low pressure side 1.5 - 2.0 kg/cm 2
(21 - 28 psi, 147 - 196 kPa)
High pressure side 14.5 - 15.0 kg/cm 2
(206 - 213 psi)
(1,422 - 1,471 kPa)
2. MOISTURE PRESENT IN REFRIGERATION SYSTEM

Condition: Periodically cools and then fails to cool
AC0068
Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system
During operation, Moisture entered in Drier in oversaturated (1) Replace receiver

I
pressure on low I refrigeration system state drier

pressure side some- freezes at expansion
1 (2) Remove moisture
I
times becomes a valve orifice and I

I
in cycle through
vacuum and some- temporarily stops Moisture in refrigeration repeated vacuum
times normal cycle, but normal system freezes at purging method
state is restored expansion valve orifice
I
after a time when and blocks circulation (3) Charge refrigerant to
I the ice melts of refrigerant proper amount
I
3. INSUFFICIENT REFRIGERANT
Condition: Insufficient cooling
AC0069
Symptom seen in
Pressure low on both Gas leakage at some Insufficient refrigerant (1) Check with leak
low and high pressure place in refrigeration in system detector and repair
sides system
! (2) Charge refrigerant to
Bubbles seen in sight Refrigerant leaking proper amount
glass
Insufficient cooling
performance
4. POOR CIRCULATION OF REFRIGERANT

AC0069
Symptom seen in
I
Pressure low on both !
Refrigerant flow Receiver clogged Replace receiver

low and high pressure obstructed by
. sides dirt in receiver
Frost on tubes from

receiver to unit
i
AC-6 AIR CONDITIONING SYSTEM - Troubleshooting
5. REFRIGERANT OVERCHARGE OR INSUFFICIENT

COOLING OF CONDENSER
Condition: Does not cool sufficiently
AC0070
Symptom seen in
Pressure too high on Unable to develop Excessive refrigerant (1) Clean condenser
both low and high sufficient performance in cycle - refrigerant
pressure sides due to excessive overcharged (2) Check fan motor
refrigerant in system operation
Condenser cooling Condenser cooling (3) If (1) and (2) are

insufficient insufficient - con- normal, check amount
denser fins clogged of refrigera nt
or fan motor faulty
Note: Vent out
refrigerant through
gauge manifold low
pressure side by
gradually opening
valve.
6. EXPANSION VALVE IMPROPERLY MOUNTED/HEAT

SENSING TUBE DEFECTIVE (OPENS TOO WIDE)
AC0070
Symptom seen in
c---~_.~~- -------
Pressure too high on

~--- I
i
I
Probable cause
------- -
Trouble in expansion
- ------------------ - ----- --- --
Diagnosis
Excessive refrigerant
-------------~--_._- ------ .---
Remedy
(1) Check heat sensing

both low and high i
valve or heat sensing in low pressure piping tube installed
pressure sides tube not installed condition
i
correctly 1
I
(2) If (1) is normal. test
Frost or large amount Refrigerant flow out Expansion valve opened expansion valve in
of dew on piping at low of adjustment too wide unit
pressure side
Replace if defective
7. AIR PRESENT IN REFRIGERATION SYSTEM

Condition: Does not cool down sufficiently
NOTE: These gauge indications are shown when the
refrigeration system has been opened and the refrigerant
charged without vacuum purging.
AC0155
Symptom seen in
-~ --I- -- ------------------- --- --
Pressure too high on Air entered refrigeration Air present in (1) Replace receiver
both low and high system refrigeration system and drier
pressure sides 1 (2) Check compressor
Insufficient vacuum oil to see if dirty or
purging insufficient
(3) Vacuum purge and
charge new
refrigerant
8. REFRIGERANT DOES NOT CIRCULATE

Condition: Does not cool (Cools from time to time in
some cases)
AC0156
Symptom seen in
~-~-- - - - - - - - - - - ~-- - - - - ---~-~-~- - - ~ - - - - - - - ~ ~ - - - -
Vacuum indicated on Refrigerant flow ob- Expansion valve Allow to stand for
low pressure side, very structed by moisture orifice clogged some time and then
low pressure indicated or dirt in refrigerant 1 restart operation to
on high pressure side freezing or adhering Refrigerant does not determine if trouble
to expansion valve flow is caused by
Frost or dew seen on orifice moisture or dirt.
piping before and
after receiver and drier Refrigerant flow ob- If caused by moisture,
or expansion valve structed by gas leak- refer to procedures
age from expansion step 2 on page AC-4.
valve heat sensing
tube If caused by dirt, remove
expansion valve and
clean off dirt by blowing
with air. If unable to
I I
remove dirt. replace
! valve.
I
I
Vacuum purge and

i charge new refrigerant
to proper amount.
I
\
For gas leakage from
'I
heat sensing tube, replace
~ expansion valve.
AC-8 AIR CONDITIONING SYSTEM - Troubleshooting, Special Tools and Equipment
9. INSUFFICIENT COMPRESSION
Condition: Does not cool
AC0157
Symptom seen in
Pressure too high on Internal leak in Compression Replace compressor
low pressure side compressor defective
!
Pressure too low at Valve leaking or broken
high pressure side sliding parts
(piston, cylinder, gasket
etc.,) broken
SPECIAL TOOLS AND EQUIPMENT

Tool SST No. Use
f...----------
Manifold gauge set 07117-78010 To evacuate and charge system

Ohmmeter - To perform electrical diagnosis
Magnetic clutch tool set 07110-77011 General set for magnetic clutch
Pressure plate remover 07112-71010 To remove pressure plate
Snap ring pliers 07114-84020 To remove pressure plate
Key remover 07112-45021 To remove key
Shaft plate remover 07112-15010 To remove shaft plate
Shaft seal remover 07112-25010 To remove shaft seal
Hexagon wrench set 07110-61050 To remove service valves and front housing
Shaft plate installing tool 07114-15010 To install shaft plate
Key press tool 07114-45010 To install key
N
~
C
r--;-~~:~l~---J.:=~--------------------=:--------J.....q~o--_Ao..~Battery
-.
en
F.L 60A AM1 (3) 11111- F.L F.L . ~
Rear Blower (,;;\ Rear Blower
Motor ~ Resistor :::;,
r--------------~ 1.258 20L IG COil-
@~
ce
c::IL §:
-=-
®
0 Magnetic Clutch
Throttle Sensor
'DJI[ »
ClB20~
Front
Blower
~re..ur.
t=====[§~witch
:IJ
n
Switch EFI Computer o
' "__l...--
~ h
:2
C
@
@)~
Condenser
3
Fan Motor
M o
Idle·up 2
~t=mA/T VSV
I~ »
Model 2
@~ -
~ Neutral
C)
@'1
C Start
2
en
~ Switch
::t1 -<
en
n -f
m
o s:
z I
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~
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-,
L-1'® -t n
-
I
I I Bl@'121
L..-J
o
G)~ ~
:::J
o Q.
~:
15A 2=f! Condenser

Fan Relay
"" CD ®
Rear
Fan
Rear
Main
Switch Switch z- o·
:::J
I~ z :::J
=eldle-up
@ CO
G). U>
~ :;~a:ut Relav
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en
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m
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~ ~ ~
[8J rn CD
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14685329
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-
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AIC Amplifier ~5 45 7 • 9 1illt

3 .. n I
-t (0
AC-10 AIR CONDITIONING SYSTEM - Air Conditioning System Circuit
AIR CONDITIONING SYSTEM CIRCUIT (Cont'd)

2WD (Dual)
II :;
~ ~
t
~ ~ t!1r IV
: !~~L--~-----__
j I
~ @
1IlI0
o ·
1~ . - IJ
~ i!L
' ...~
-!CI..
::1 ~-----~-++++h o
w 1-:
m ~-
~ ~------+-+--+-4
~
.. -
.-
CD ~ @
""""- "'~~---++---++-+-_-----.I
~ .'~+----~---+-+--+---------'
~ ".~~--++---++--+--------'
~ !~.a.------H---++-+---_----t
~ ~~+----+-6----++-+--- _ _----t
~:~ I~
-~:'0-4--+-----+-----4J
~-++--+-++---+-------+- .......
__ - - _---4---4 :~
~~-~-----~
AC1287
AIR CONDITIONING SYSTEM - Air Conditioning System Circuit AC-11
AIR CONDITI-ONING SYSTEM CIRCUIT (Cont'd)

4WD (Single)
(j) Rear Main Switch
i
@Rr. @ Rr. Fan Switch (Rear)
~ 01~1~
Resistor
Compressor @ :0 Rr. M
Blower Motor
1 2 2 1 3
Battery
D
Dual
Pressure ~"="I-----t+-----JTI ~~~ °IWI
-~EFI
Throttle
Fl
20l"
3 Sensor
Switch
, cPu
IGCoil L.J I r+-----Ir----+---++----------~
0~
@ Condenser
®Fr.
Mg Valve
~
rmIl
L---------1I-+-----+-+----------+++-++------,
®
@)Idle-Up~
VSV ~t----+++++---~r+---++--~
~
Fan Motor
M M
8mB
rt~- - -<1.- - - - '- -'-2
__
4-=-"""""""-1
3_ _- - - - - , r+++++---++++=-=-----=-=--~ 2
---'31 l' Ale
0~
L-- ---. I 1L..-....H+t+-t++1 I ~ ~n Motor Relay No.1 _ ST
0.
II ,~~ Fan Motor Relay No.2"
0~
1
Cut
@Fr. (DRear \ '16) Main Relay Relay
Blower 0 G)Fr. Main Switch \~
Idle-Up ~elay
Motor
1 2
Fr.
Resistor
2 1 3 4
Fan Switch
~rm1TA%fil ~
17816532 SW..!...1..l~
(Front) . '\. '-'-,
rr1 f[;l ~l
6513423142314
nrn
2 1714169
rnl
513612@
I ~~ ~~ II~ I 0~
n ~ lW
G~
0~
"--------4=7~~~-+-+-+-~+++__, G ~
erm
Neutrl'
8
Stlrt SIW 2 ~t-+-+-~-+-t
,~~~~~~~~~--I
I I
~~~ r---t---+-----+-+---+-+--+------+---+----------l=~~~--+~---+-+--++---+-'
IGSW 6~
8 @
~
ACcD , C-~.~.
L-_ ~ r-------~ ; ~=~~~__+__++--+-++-+---.
6 ~_+_-__+__++___.
7 t-----+-----+----++---+-_+_'
8 ~_+__---+----+-+___+---'
A~A'rllr 1
1~
"--~
I~I ~
A7C;J Rr.~av @..-.. 5_2_34_7_6_9_8-1
L ----
Main Relay SPeedF~.nsing~
~ '.J I I
CB20 ~
~~
L""" H hlO
L ...--
Temperlture SensinG
Ale Amplifier
III!
___'
G o
~ 01'2l ER 82:G
~ 'EET 'EEY ~
AC1302
AIR CONDITIONING SYSTEM - On-Vehicle Inspection AC-13
1. CHECK CONDENSER FINS FOR BLOCKAGE OR
DAMAGE
If the fins are clogged, clean them with pressurized water.
CAUTION: Be careful not to damage the fins.
Nippondenso Borroughs 2. CHECK DRIVE BELT TENSION

Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Drive belt tension:
NOTE:
than 5 minutes on a running engine .
3. START ENGINE
4. TURN ON AIC SWITCH

Check that the AIC operates at each position of the
blower switch.
5. CHECK MAGNETIC CLUTCH OPERATION

~.\\\\\~
- Circuit Breaker for Heater . If the magnetic clutch does not engage, check the circuit
~\ ~ ~~J~~(~I
breaker.
6. CHECK THAT IDLE INCREASES

---.,
When the magnetic clutch engages, engine revolution
d, should increase.
Standard idle-up rpm: 950 ± 50 rpm
7. CHECK AMOUNT OF REFRIGERANT

If you can see bubbles in the sight glass, additional
refrigerant is needed. (See page AC-14)
8. IF NO OR INSUFFICIENT COOLING, INSPECT FOR

LEAKAGE
Using a gas leak detector, inspect each component of the
refrigeration system.
AC-14 AIR CONDITIONING SYSTEM - Refrigeration System
(2WD) (4WD) REFRIGERATION SYSTEM

Checking of Refrigerant Charge
1. RUN ENGINE AT FAST IDLE
2. OPERATE AIR CONDITIONER AT MAXIMUM

COOLING FOR A FEW MINUTES
3. CHECK AMOUNT OF REFRIGERANT

1.- A_Cl_23_7_A_Cl_15--J6 Observe the sight glass beside the receiver.
Item Symptom Amount of refrigerant Remedy
1 Bubbles present in sight glass Insufficient Check for leak with gas leak detector
2 No bubbles present in sight glass Empty, proper or sufficient Refer to items 3 and 4
3 No temperature difference Empty or nearly empty Evacuate and charge system

between compressor inlet and Then check for leak with gas leak
outlet detector
4 Temperature between compressor Proper or too much Refer to items 5 and 6

, inlet and outlet is noticeably
different
5 Immediately after the air Too much Discharge the excess refrigerant to
conditioner is turned off, specified amount
refrigerant in sight glass stays
clear
6 When the air conditioner is Proper

turned off, refrigerant foams --
and then stays clear
(2WD)
.I~
_
Suction Tube
Installation of Manifold Gauge Set
Low Pressure - ' - . " J'
Charging Valve-.......,,~~~~ NOTE: Fittings for attaching the manifold gauge set are
located on the discharge line tube and the suction line tube
charging valves.
1. CLOSE BOTH HAND VALVES OF MANIFOLD

GAUGE SET
2. INSTALL CHARGING HOSES OF GAUGE SET TO

AC0737
CHARGING VALVES
Connect the low pressure hose to the low pressure
charging valve and the high pressure hose to the high
pressure charging valve. Tighten the hose nuts by hand.
NOTE: Do not apply compressor oil to the seat of the
connection.
AIR CONDITIONING SYSTEM - Refrigeration System AC-15
Discharging of Refrigeration System

1. INSTALL MANIFOLD GAUGE SET
(See page AC-14)
2. PLACE FREE END OF CENTER HOSE IN A SHOP

TOWEL
3. DISCHARGE SYSTEM
(a) Slowly open the high pressure hand valve to adjust
the refrigerant flow. Do not open the valve very
much.
CAUTION: If refrigerant is allowed to escape too
fast, compressor oil will be drawn out of the system.
(b) Check the shop towel to make sure no oil is being
discharged.
If oil is present, partially close the hand valve.
(c) After the manifold gauge reading drops below 3.5
kg/cm 2 (50 psi, 343 kPa), slowly open the low
pressure valve.
(d) As the system pressure drops, gradually open both
high and low valves until both gauges read 0 kg/cm 2
(0 psi, 0 kPa),
Evacuating and Charging of

Refrigeration System
NOTE:
• Whenever the air conditioning system has been
exposed to the atmosphere, it must be evacuated .
• After installation of a component, the system should
be evacuated for approximately 15 minutes. A com-
ponent in service that has been opened for repair
should be evacuated for 30 minutes.
Pressure
Gauge
1. EVACUATE SYSTEM
Vacuum (a) Connect a manifold gauge set. (See page AC-14)
Pump
(b) Install the center hose of the gauge set to the
vacuum pump inlet.
(c) Run the vacuum pump, and then open both hand
valves.
(d) After about ten minutes, check that the low pressure
AC0407 gauge reads more than 600 mmHg (23.62 in. Hg,
80.0 kPa) of vacuum.
If the reading is not more than 600 mmHg (23.62 in.Hg,
80.0 kPa), close both valves and stop the vacuum pump.
Check the system for leaks and repair as necessary.
If no leakage is found, continue evacuating the system.
(e) After the low pressure gauge indicates more than

700 mmHg (27.56 in. Hg, 93.3 kPa) of vacuum, con-
tinue evacuating for 1 5 minutes.
(f) Close both hand valves, and stop the vacuum pump.
Disconnect the hose from the vacuum pump.
The system is now ready for charging.
2. INSTALL REFRIGERANT CONTAINER TAP VALVE

CAUTION: Observe the precautions listed in the
front of this section.
(a) Before installing the valve on the refrigerant con-
tainer, turn the handle counterclockwise until the
valve needle is fully retracted.
(b) Turn the disc counterclockwise until it reaches its
highest position.
Screw down the valve on the refrigerant container.
(c) Connect the center hose to the valve fitting. Turn the
disc fully clockwise by hand.
Disc-~~~21
(d) Turn the handle clockwise to make a hole in the
sealed tap.
AC0160 (e) Turn the handle fully counterclockwise to fill the
center hose with gas. Do not open the high and low
pressure valves.
(f) Loosen the center hose nut connected to the center
fitting of the manifold gauge until a hiss can be
heard.
Allow air to escape for a few seconds, and then
tighten the nut.
3. TEST SYSTEM FOR LEAKS

NOTE: After evacuating the system, check for leaks.
(a) Install the refrigerant can tap valve as described in
step 2.
(b) Open the high pressure valve to charge the system
Open with refrigerant vapor.
(c) When the low pressure gauge reads 1 kg/cm 2 (14
psi, 98 kPa), close the high pressure valve.
(d) Using a halide gas leak detector, propane torch, or
electric leak detector, check the system for leaks.
I
If a leak is found, repair the faulty component or connec-
,f tion.
(Liquid (e) After checking and repairing the system, perform the
Tube) (Suction Tube) AC0408 following:
• Turn the container tap handle fully clockwise.
• Disconnect the center hose from the can valve fit-
ting.
• Evacuate the system for at least 1 5 minutes.
(See step 1 on page AC-1 5)
4. CHARGE EMPTY SYSTEM (LIQUID)

NOTE: This step is to charge an empty system through
the high pressure side with refrigerant in a liquid state.
When the refrigerant container is held upside down,
refrigerant will enter the system as a liquid.
CAUTION:
• Never run the engine when charging the system
,-._<}(j Open through the high pressure side.
(------
Close I
I • Do not open the low pressure valve when the
I
I
I
system is being charged with liquid refrigerant.
I I I t
I \
: '--i:---/
I
(a) Close both high and low pressure valves completely
after the system is evacuated.
~\11D '----fi-- -~-_-_1)- -_-
" I \
(Liquid (b) Install the refrigerant can tap valve as described in

Tube) ~-r:- --- -- --_/ == ==:C)::~ -_-_cc
step 2.
:: ~ (Suction Tube) AC0409
(c) Open the high pressure valve fully, and keep the con-
tainer upside down.
(d) Charge the system with more than one container
(400 g, 0.9 Ib) to the specified amount. Then, close
the high pressure valve.
Specified amount:
Single AIC 600- 750g(1.3-1.7Ib)
Dual AIC 1,350 - 1,450 g (3.0 - 3.2 Ib)
NOTE:
• A fully charged system is indicated by the receiver
sight glass being free of any bubbles.
• If the low pressure gauge does not show a reading,
the system is clogged and must be repaired.
5. CHARGE EMPTY OR PARTIALLY CHARGED SYSTEM

(VAPOR)
NOTE:
• This step is to charge the system through the low
pressure side with refrigerant in a vapor state. When
the refrigerant container is placed rightside up,
refrigerant will enter the system as a vapor.
• Put the refrigerant container in a pan of warm water
(maximum temperature 40°C (104°F) to keep the
vapor pressure in the container slightly higher than
Open vapor pressure in the system.
(a) Install the refrigerant can tap valve as described in
step 2.
Open: (b) Open the low pressure valve. Adjust the valve so that
I
I
the low pressure gauge does not read over 4.2 kg/
I
I cm 2 (60 psi, 41 2 kPa).
(Liquid l~:
I.
:: I I
t\~
,..
J.
"':
_
(c) Run the engine at fast idle and "'perate the air condi-
tioner.
Tube) T/~~---------) ~;:-:t~~;;=
(Suction Tube) AC0410 CAUTION: Be sure to keep the container in the
upright position to prevent liquid refrigerant from
being charged into the system through the suction
side, resulting in possible damage to the compressor.
(d) Charge the system with more than one container
(400 g, 0.9 Ib) than the specified amount. Then,
close the low pressure valve.
Specified amount:
Single AIC 600 - 750 g (1.3 - 1.7 Ib)
Dual AIC 1,350 - 1,450 g (3.0 - 3.2 Ib)
NOTE: A fully charged system is indicated by the
receiver sight glass being free of any bubbles.
6. IF NECESSARY, CHARGE SYSTEM WITH ANOTHER

REFRIGERANT CONTAINER
(a) When the refrigerant container is empty, close the
pressure valves.
(b) Remove the can tap valve from the container.
(c) Attach the can tap valve to a new refrigerant con-
tainer.
(d) Purge the air from the center hose by barely opening
the low pressure valve and loosening the valve disc.
AC0164
(e) Make a hole in the sealed tap of the new container
and charge the system.
CAUTION: Be careful not to overcharge the refri-
gerant as it could cause failure of the bearings and
belt.
7. WHEN SYSTEM IS FULLY CHARGED, DISCONNECT

MANIFOLD GAUGE SET
(a) Close both low and high pressure valves.
(b) Close the valve of the refrigerant container. If using
one pound containers of R-l 2, allow the remaining
refrigerant to escape by slowly removing the charge
line.
(c) Turn off the engine.
(d) Using a shop rag, quickly remove both hoses from
the each service valve.
WARNING: Care must be taken to protect eyes and
skin when removing the high pressure hoses.
(e) Put the cap nuts on the service valve fittings.
Performance Test
(See page AC-14)
Dry-bulb Thermometer
2. RUN ENGINE AND OPERATE AIR CONDITIONER
(a) Run the engine at 2,000 rpm.
(b) Set the blower switch at HI, AIC switch ON, tem-
perature control at COOL, and air flow control at
VENT.
(c) Keep all windows and doors open.
3. POSITION THERMOMETERS
(a) Place a dry-bulb thermometer in the cool air outlet.
(b) Place a psychrometer close to the inlet of the cooling
unit.
4. WAIT UNTIL AIR CONDITIONING SYSTEM

STABILIZES
(a) Check that the reading on the high pressure gauge is
14.0 - 15.5 kg/cm 2 (199 - 220 psi, 1,373 - 1,520
kPa).
If the reading is too high, pour water on the condenser. If
the 'reading is too low, cover the front of the condenser.
(b) Check that the reading on the bulb thermometer at
the air inlet is 25 - 35°C (77 - 95 of).
5. CHECK PERFORMANCE OF AIR CONOJIIONING

SYSTEM
(a) Calculate the relative humidity from the psychro-
metric graph by comparing the wet- and dry-bulb
readings of the psychrometer at the air inlet.
HOW TO READ THE GRAPH:

After measuring the temperature of the wet- and dry-
bulb thermometers at the evaporator air inlet, relative
humidity (%) can be obtained.
Example: Supposing dry- and wet-bulb temperatures (77)
at the evaporator air inlet are 25°C (77°F) and 19.5°C 25
EXAMPLE
(67°F) respectively. The point of intersection of the
~~\
dotted lines in the graph is 60%. oC
~
~0~ (68)
~~~tr"- (67) 20
~~~ 19.5
·~S\;~
:\;«)
~<i,
-5 o 5 10 15 20 25 30
(23) (32) (41 ) (50) (59) (68) (77) (86)
- - - . - - DRY-BULB TEMPERATURE °C (OF) AC0174
(b) Measure the dry-bulb temperature at the cool air out-

22 °C
(I)] let, and calculate the difference between the inlet
u -::J
C 20 I-t~~~~-=::Ji------+----+---.j dry-bulb and outlet dry-bulb temperatures.
(1)0
.... -0 18 r---t~~~~~~~~d----1 (c) Check that the intersection of the relative humidity
~ C
.-
0_
t'O 16 t--t---""""'~~~~~ and temperature difference is between the two
(I)~ 14~-+--+-~~~
.... C hatched lines.
::J-
12 t--t-+----t-------I----4---....:~iiiiiiiiiH
eC
-
(I)
(I) (I) 10 t--t-+---t-----1----4-~_+---!
If the intersection is within the two lines, cooling perfor-
a.~ mance is satisfactory.
E
(I) -(I)
l- aJ
50 60 70
Relative Humidity (%) AC0547
AC-20 AIR CONDITIONING SYSTEM - System Components
SYSTEM COMPONENTS
2WD Single Air Conditioner
Cooling Unit
Expansion Valve
Evaporator
Discharge Hose
Cooling Unit Suction Hose
Compressor
Liquid Tube ----------I\.,o~:;::::;__

Pressure Switch
Low Pressure Charging Valve
Resistor - - - - - - - - - - - - - ,
Condenser (Rear)
Condenser Fan Motor

Condenser (Front)
Receiver
High Pressure Charging Valve
Ae0738
AIR CONDITIONING SYSTEM - System Components AC-21
SYSTEM COMPONENTS (Cont'd)

2WD Dual Air Conditioner
Rear Cooling Unit
Expansion
Valve Expansion Valve
Evaporator Rear Cooling Unit Discharge Pipe
~-- Magnetic Valve

Refrigerator
Suction Pipe
,-----Suction Hose
,~--:::::-"-::;;I;\'\'[J.~ I---A:T"\-..L - Discharge Hose
Front Cooling Unit----I
Compressor
Low Pressure Charging Valve---~~:;::::::::::-;:;-~--........::S)J==::::::-

Pressure Switch
Magnetic V a l v e - - - - - - /
--Condenser (Rear)
Resistor -------
High Pressure Charging Valve

Cooling Fan Motor---~
Condenser (Front)
Refrigerator
Amplifier j(. Thermistor

Evaporator Expansion Valve
AC1282
AC1204
AC-22 AIR CONDITIONING SYSTEM - System Components

4WD Air Conditioner
Cooling Unit
Expansion Valve
Discharge Hose
Evaporator
Receiver
Suction Hose
A~~~"-_ _ Compressor
Front Cooling Unit~~----I
r--.. . . . " , } - - - - - - - - Surge Tank

'-------Suction Hose
Liquid Tube---------......
Suction Tube-------~
\,~---------- Magnetic Valve
Sight Glass---------
~----------Condenser Fan Motor

Low Pressure Charging Valve--~
Condenser
AC1294
AIR CONDITIONING SYSTEM - System Components AC-23

4WD Air Conditioner
Rear Cooling Unit
Expansion
Valve
Expansion Valve
Rear Cooling Unit

/Al------ Liquid Tube
)Q....----- Magnetic Valve
'J}.------Discharge Tube
~---Discharge Hose
Refrigerator - - - - - - - - {
Suction Hose
~~~~r-- Compressor
Front Cooling Unit
~\'~f,]}..------Surge Tank
" - - - - - - - - Suction Hose
Liquid Tube----""'- ~~~~~ffi~~L_-----Receiver
Suction Tube -------tI......_'S:K ~~~~iS~~---------MagneticValve
Sight Glass - - - - - - - -
---------Condenser Fan Motor

Low Pressure Charging Valve
Condenser
Refrigerator
Evaporator
Amplifier . V I
X
Expanslon a ve
Thermistor
AC1295
AC1204
AC-24 AIR CONDITIONING SYSTEM - Compressor
COMPRESSOR
(See page AC-14)
2. RUN ENGINE AT FAST IDLE
3. CHECK COMPRESSOR FOR FOLLOWING:

(a) High pressure gauge reading is not low and low
pressure gauge reading is not higher than normal.
(b) Metallic sound.
(c) Leakage from shaft seal.
If defects are found, repair the compressor.
4. CHECK MAGNETIC CLUTCH

(a) Inspect the pressure plate and the rotor for signs of
oil.
(b) Check the clutch bearings for noise and grease
leakage.
(c) Using an ohmmeter, measure the resistance of the

stator coil between the clutch lead wire and ground.
Standard resistance: 2.9 ± 0.2 n at 20°C (68°F)
If resistance is not as specified, replace the coil.
lo~1
~J.r--J---t--~-I n
AC0762
AIR CONDITIONING SYSTEM - Compressor AC-25
Crankshaft Pulley
Drive Belt
~FR
250 (18.25)
375 (27. 37)
I kg-cm (ft-Ib. N"m) I: Specified torque

AC0763 AC0764
REMOVAL OF COMPRESSOR
1. RUN ENGINE AT IDLE WITH AIR CONDITIONING ON
FOR 10 MINUTES
3. DISCONNECT CLUTCH LEAD WIRE FROM WIRING

HARNESS
4. DISCHARGE REFRIGERANT FROM

REFRIGERATION SYSTEM (See page AC-15)
5. DISCONNECT TWO HOSES FROM COMPRESSOR

SERVICE VALVES
Cap the open fitting immediately to keep moisture out of
the system.
6. REMOVE COMPRESSOR
(a) Loosen the drive belt.
(b) Remove the compressor mounting bolts and the
compressor.
AIR eo NDITIONING SYSTEM - Compressor
Rotor Sea'nng
Pressure Plate
Compressor
DISASSEMBLY OF
1. REMOVE PRESSUR MAGNETIC CLUTCH
(a) U. E PLATE
SST sing a socket
1 and SST e shaft nut.
07110-7701 ' remove th
(b) Using a
SST 071 12 _71 0 10 and SST ' remove th e pressure plate.
socket
(c) Remo ve the sh'Ims from th e shaft.

2. REMOVE ROTOR
(a) Using SST. remove the snap ring.
SST 07114-84020
ACOOOl
(b) Using a plastic hammer, tap the rotor off the shaft.
CAUTION: Be careful not to damage the pulley when
tapping on the rotor.
3. REMOVE STATOR
(a) Disconnect the stator lead wires from the com-
pressor housing.
AC0767
(b) Using SST, remove the snap ring. Remove the stator.
SST 07114-84020
AC0768
4. REMOVE ROTOR BEARINGS

NOTE: Press the bearings out only if they are to be re-
placed.
(a) Remove the bearing snap ring from the rotor.
(b) Using SST, press out the two bearings.
SST 07110-77011
ACOOll AC0542
~
[ 2E)O (19, 25)
I I
I
I
Cylinder Block
DISASSE M BLY 0 F *00 not d"lSassemble
1. REMOVE FELT COMPRESSOR
2. RE.MOVE SNAP RIN

USing SST, remove th G
SST 07714-84020 e snap ring.
AC0770
3. REMOVE KEY
Remove the key from the shaft.
SST 07112-45021
AC0015
4. APPLY COMPRESSOR OIL TO INNER BORE

Apply compressor oil to the inner bore of the compressor.
. 5. REMOVE SHAFT PLATE

(a) Insert SST against the shaft. Then push the holder
ring downward.
SST 07112-15010
AC0772
(b) Pull up the remover bar, and remove the shaft plate.
SST
6. REMOVE SHAFT SEAL

Insert SST against the shaft, and turn it to the right while
pressing on the remover.
Then remove the shaft seal.
SST 07114-15010
7. REMOVE SERVICE VALVE

(a) Using SST, remove the bolts holding the service
valve.
SST 07110-61050
(b) Remove the O-rings from the service valves and dis-
card them.
8. DRAIN COMPRESSOR OIL INTO MEASURING FLASK

Measure the quantity of drained oil because the same
amount should be replaced later.
AC1337
9. REMOVE FRONT HOUSING

(a) Using SST, remove the five through bolts.
NOTE: Do not reuse the five washers.
SST 07110-61050
AC0022
(b) Using a screwdriver, remove the front housing.

CAUTION: Be careful not to scratch the sealing sur-
face of the front housing.
AC0023
10. REMOVE FRONT VALVE PLATE

Remove the two pins from the front housing. Discard the
pins.
AC0153
11. REMOVE REAR HOUSING

Using a screwdriver, remove the rear housing.
CAUTION: Be careful not to scratch the sealing sur-
face of the rear housing.
AC0024
12. REMOVE FRONT AND REAR O-RINGS FROM

CYLINDER BLOCK
Discard the O-rings.
ASSEMBLY OF COMPRESSOR
(See page AC-28)
1. INSTALL REAR VALVE PLATE ON REAR CYLINDER

(a) Install two pins in the rear cylinder.
(b) Lubricate a new O-ring with compressor oil. Install
the O-ring in the rear cylinder.
AC0026
(c) Install the rear suction valve over the pins on the rear
cylinder.
NOTE: The front and rear suction valves are identical.
AC0027
(d) Install the rear valve plate together with the dis-
charge valve over the pins on the rear cylinder.
NOTE: The rear valve plate is marked with an "R".
(e) Lubricate the gasket with compressor oil. Install the
gasket on the valve plate.
AC0028
2. INSTALL REAR HOUSING ON REAR CYLINDER
ACOOO6
3. INSTALL FRONT VALVE PLATE ON FRONT

CYLINDER
(a) Install the two pins in the front cylinder.
(b) Lubricate a new O-ring with compressor oil. Install
the O-ring in the rear housing.
(c) Install the front suction valve over the pins on the
front cylinder.
(d) Install the front valve plate together with the dis-
charge valve over the pins on the front cylinder.
ACOO29
NOTE: The front valve plate is marked with a "F".
(e) Lubricate the gasket with compressor oil. Install the
gasket on the valve plate.
4. INSTALL FRONT HOUSING ON FRONT CYLINDER

AND TIGHTEN FIVE THROUGH BOLTS
Using a torque wrench and SST, gradually tighten the five
through bolts in two or three passes.
SST 07110-61050
ACOO22
5. INSTALL SHAFT SEAL

SST
(a) Fit the shaft seal onto SST.
SST 07114-15010
AC0152
(b) Apply oil to the bore.

Insert SST, and turn it counterclockwise while lightly
SST pressing in.
Then pull up the SST.
SST 07114-1 5010
ACOO]O
6. INSTALL SHAFT PLATE

(a) Put in the shaft plate.
(b) Press in SST.

SST 07112-25010
AC0776
7. INSTALL KEY IN SHAFT GROOVE

Using a plastic hammer and SST, tap the key lightly.
SST 07114-45010
Place the felt inside the bore.
(Refer to page AC-28)
8. POUR COMPRESSOR OIL INTO COMPRESSOR

Add the same quantity plus 20 cc of oil into the com-
pressor.
Compressor oil: DENSOOIL 6, SUNISO No.5 GS or
equivalent
AC0034
9. INSTALL SERVICE VALVES

(a) Lubricate new O-rings with compressor oil. Install the
O-rings in the service valves.
(b) Install the service valves on the compressor. Using a
torque wrench and SST, tighten the bolts.
SST 07110-61050
AC0779
10. CHECK SHAFT STARTING TORQUE

Torque: 30 kg-cm (26 in.-Ib, 2.9 N'm) or less
AC0036
ASSEMBLY OF MAGNETIC CLUTCH

(See page AC-26)
1. INSTALL TWO BEARINGS IN ROTOR

(a) Using SST, press a shield ring and two new bearings
into the rotor boss until fully seated.
SST 07110-77011
(b) Install the bearing snap ring into the rotor groove.
2. INSTALL STATOR
(a) Install the stator on the compressor.
(b) Using SST, install the snap ring.
SST 07114-84020
(c) Connect the stator lead wires to the compressor
housing.
AC0768
3. INSTALL ROTOR
(a) Install the rotor on the compressor shaft.
SST
(b) Using SST, install the snap ring.
SST 07114-84020
AC0001
4. INSTALL PRESSURE PLATE

(a) Adjust the clearance between the pressure plate and
rotor by putting shims on the compressor shaft.
(0.024 - 0.039 in.)
If the clearance is not within tolerance, add or reduce the
number of shims to obtain the standard clearance.
(b) Using a torque wrench and SST, install the shaft nut.
SST 07110-77011
SST
AC0007
5. CHECK CLEARANCE OF MAGNETIC CLUTCH

Check the clearance between the pressure plate and rotor,
using thickness gauge.
Standard clearance: 0.6 - 1.0 mm (0.024 - 0.039 in.)
If the clearance is not within standard clearance adjust the
clearance using the shims to obtain the standard
clearance.
Thickness Gauge
AC0800
PERFORMANCE TEST OF COMPRESSOR

3 kg/cm 2
1. PERFORM GAS LEAKAGE TEST
(a) Install the inspection service valve on the service
valve.
NOTE: Use only a TOYOTA supplied inspection service
valve for the perform gas leakage test.
Part No. Suction side 88376-17010
Discharge side 88376-22030
""--- ...:....:A.;;,.:;Co:.:...:78~O (b) Charge the compressor with refrigerant through the
charge valve until the pressure is 3 kg/cm 2 (43 psi,
294 kPa).
(c) Using a gas leak detector, check the compressor for
leaks.
If leaks are found, check and replace the gasket, O-ring, or
shaft seal.
2. EVACUATE COMPRESSOR AND CHARGE WITH

REFRIGERANT (See page AC-15)
Make sure the caps are tight and the compressor is free
from moisture and contamination.
NOTE: When storing a compressor for an extended
period, charge the compressor with refrigerant or dry
nitrogen gas to prevent corrosion.
AC-36 AIR CONDITIONING SYSTEM - Compressor, Condenser
INSTALLATION OF COMPRESSOR
(See page AC-25)
1. INSTALL COMPRESSOR WITH MOUNTING BOLTS
2. INSTALL DRIVE BELT

(a) Install the drive belt to the pulley.
(b) Tighten the belt with the adjusting bolts.
Belt tension gauge:
Nippondenso Borroughs Drive belt tension:
NOTE:
3. CONNECT TWO HOSES TO COMPRESSOR SERVICE

VALVES
EC0003 EC0004 EC0001
Torque:
Discharge line 250 kg-cm (18 ft-Ib, 25 N'm)
Suction line 250 kg-cm (18 ft-Ib, 25 N'm)
4. CONNECT CLUTCH LEAD WIRE TO WIRING

HARNESS
6. EVACUATE AND CHARGE AIR CONDITIONING

SYSTEM (See page AC-15)
CONDENSER
1. CHECK CONDENSER FINS FOR BLOCKAGE OR
DAMAGE
If the fins are clogged, wash them with water and dry with
compressed air.
CAUTION: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or
pliers.
2. CHECK CONDENSER FITTINGS FOR LEAKAGE

Repair as necessary.
REMOVAL OF CONDENSER
(See pages AC-20 to 23)
(2WD)
1. DISCHARGE AIR CONDITIONING SYSTEM
(See page AC-15)
3. REMOVE RADIATOR MOUNT BOLTS

AIR CONDITIONING SYSTEM - Condenser AC-37
4. DISCONNECT DISCHARGE HOSE FROM

CONDENSER INLET FITTING
5. DISCONNECT LIQUID LINE HOSE FROM

CONDENSER OUTLET FITTING
6. REMOVE FRONT CONDENSER

Remove four bolts and two nuts.
7. DISCONNECT LIQUID HOSE FROM SIGHT GLASS
8. DISCONNECT THREE DISCHARGE HOSES FROM

CONDENSER INLET FITTING AND DISCHARGE TUBE
9. DISCONNECT PRESSURE SWITCH LEAD WIRE
10. REMOVE REAR HOUSING

Remove four bolts.
(4WD) (4WD)
2. DISCONNECT DISCHARGE HOSE FROM

CONDENSER INLET FITTING
3. DISCONNECT LIQUID LINE HOSE FROM

CONDENSER OUTLET FITTING
4. DISCONNECT CONDENSER FAN MOTOR

CONNECTOR
AC1158
5. REMOVE CONDENSER
Remove four bolts.
INSTALLATION OF CONDENSER
(2WD)
1. INSTALL CONDENSER
Install in the reverse sequence of removal.
2. CONNECT LIQUID HOSE AND DISCHARGE HOSE TO

CONDENSER
Torque:
Liquid hose 135 kg-em (10 ft-Ib, 13 N'm)
Discharge hose 225 kg-em (16 ft-Ib, 22 N'm)
3. IF CONDENSER WAS REPLACED, ADD

COMPRESSOR OIL TO COMPRESSOR
Add 40 - 50 ee (1.4 - 1.7 fl.oz.)
4. EVACUATE, CHARGE AND TEST REFRIGERATION

AC-38 AIR CONDITIONING SYSTEM - Condenser, Receiver
(4WD)
1. INSTALL CONDENSER
2. CONNECT CONDENSER FAN MOTOR CONNECTOR
3. CONNECT LIQUID HOSE AND DISCHARGE HOSE TO

CONDENSER
Torque:
Liquid hose 135 kg-em (10 ft-Ib, 13 N'm)
Discharge hose 226 kg-em (16 ft-Ib, 22 N'm)
4. IF CONDENSER WAS REPLACED, ADD

Add 40 - 60 ee (1.4 - 1.7 fl.oz.)

RECEIVER
CHECK SIGHT GLASS, FUSIBLE PLUG AND FITTINGS FOR
LEAKAGE
(2WD) Use a gas leak detector. Repair as necessary.
Liquid Tube Condenser
REMOVAL OF RECEIVER

(See page AC-15)
2. REMOVE CONDENSER (4WD only, See page AC-36)

Receiver
L- A_CO_78--l5 3. DISCONNECT TWO LIQUID TUBES FROM RECEIVER
NOTE: Cap the open fittings immediately to keep moisture
(4WD) out of the system.
Condenser
4. REMOVE RECEIVER FROM RECEIVER HOLDER
INSTALLATION OF RECEIVER
1. INSTALL RECEIVER IN RECEIVER HOLDER

NOTE: Do not remove the blind plugs until ready for
connection.
ACl159
2. CONNECT TWO LIQUID TUBES TO RECEIVER

3. IF RECEIVER WAS REPLACED, ADD COMPRESSOR

OIL TO COMPRESSOR
Add 20 ee (0.7 fl.oz.)
4. REINSTALL CONDENSER (4WD only, See page AC-36)
5. EVACUATE, CHARGE AND TEST AIR CONDITIONING

AIR CONDITIONING SYSTEM - Front Cooling Unit AC-39
FRONT COOLING UNIT

ON-VEHICLE INSPECTION OF EXPANSION
VALVE
1. CHECK QUANTITY OF GAS DURING REFRIGERATION
CYCLE

(See page AC-14)
3. RUN ENGINE
Run the engine at 2,000 rpm for at least 5 minutes.
4. CHECK EXPANSION VALVE

If the expansion valve is clogged, the low pressure reading
will drop to 0 kg/cm 2 (0 psi, 0 kPa), otherwise it is OK.
ACl190
REMOVAL OF COOLING UNIT

2. DISCHARGE REFRIGERATION SYSTEM

(See page AC-15)
3. DISCONNECT SUCTION TUBE FROM COOLING UNIT

OUTLET FITTING
4. DISCONNECT LIQUID TUBE FROM COOLING UNIT

AC0786
INLET FITTING
out of the system.
5. REMOVE GROMMETS FROM INLET AND OUTLET

FITTINGS
6. REMOVE GLOVE BOX AND UNDER COVER
8. REMOVE COOLING UNIT

Remove three screws, two bolts and a nut.
AC-40 AIR CONDITIONING SYSTEM - Front Cooling Unit
DISASSEMBLY OF COOLING UNIT
(d) eli p --T----T--1
(9) Thermistor ---",,-..,...........'-~v
) - Expansion Valve
(b) Amplifier
(c) Wire Harness
AC1171
1. REMOVE LOWER AND UPPER UNIT CASES

(a) Disconnect connectors.
(b) Remove amplifier.
(c) Remove wire harness.
(d) Remove seven clips.
(e) Remove two screws.
(f) Remove upper unit case.
(g) Remove thermistor with thermistor holder.
(h) Remove lower unit case.
2. REMOVE EXPANSION VALVE

(a) Disconnect the liquid tube from the inlet fitting of the
expansion valve.
(b) Remove the packing and heat sensing tube from
suction tube of evaporator.
AIR CONDITIONING SYSTEM - Front Cooling Unit AC-41
(c) Remove expansion valve.
Evaporator
INSPECTION OF EVAPORATOR
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
CAUTION: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES

ASSEMBLY OF COOLING UNIT

INSTALL COMPONENTS ON EVAPORATOR
(a) Connect the expansion valve to the inlet fitting of the
evaporator. Torque the nut.
NOTE: Be sure that the a-rings are positioned on the tube
fitting.
(b) Install the holder to the suction tube with heat
sensitizing tube.
~
-~)
(c) Connect the liquid tube to the inlet fitting of the
.~~~
,/ expansion valve. Torque the nut.
(d) Install lower unit case to the evaporator.

(e) Install thermistor to the evaporator.
(f) Install upper u nit case.
(g) Install two screws.
(h) Install seven clips.
(i) Install harness.
(j) Install amplifier.
(k) Connect connectors.
,
Screw
@
INSTALLATION OF COOLING UNIT
1. INSTALL COOLING UNIT
Install the cooling unit with three screws, two nuts and bolts.
2. CONNECT CONNECTORS
3. INSTALL GLOVE BOX AND UNDER COVER
AC1202
AC-42 AIR CONDITIONING SYSTEM - Front Cooling Unit, Rear Cooling Unit
4. INSTALL GROMMETS ON INLET AND OUTLET FITTINGS
5. CONNECT LIQUID TUBE TO COOLING UNIT INLET

FITTING
6. CONNECT SUCTION TUBE TO COOLING UNIT OUTLET

FITTING
AC0786 7. IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR

OIL TO COMPRESSOR
Add 40 - 50 cc (1.4 - 1.7 fl.oz.)

SYSTEM
Cooling Unit (Rear) . . ~ REAR COOLING UNIT

~:e ~_
1 -~ REMOVAL OF COOLING UNIT
Liquid Tube
(See page AC-15)
4. DISCONNECT LIQUID TUBES
5. REMOVE MAGNETIC VALVE

Suction Tube
~~~ ''-~.
6. REMOVE REAR BLOWER UNIT
Bolt ) 7. DISCONNECT SUCTION TUBE
8. REMOVE REAR COOLING UNIT

Bolt Remove four bolts.
AIR CONDITIONING SYSTEM - Rear Cooling Unit AC-43
DISASSEMBLY OF REAR COOLING UNIT
(f) Upper Unit Case

(c) Screw - - - - - « I
Evaporator
ACl170
REMOVE LOWER AND UPPER CASES

(a) Remove thermistor.
(b) Remove expansion valve.
(c) Remove two screws.
(d) Remove four clips.
(e) Remove two screws.
(f) Remove upper unit case.
(g) Remove lower unit case.
Evaporator
INSPECTION OF EVAPORATOR
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
CAUTION: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES

AC-44 AIR CONDITIONING SYSTEM - Rear Cooling Unit
ASSEMBLY OF COOLING UNIT

INSTALL COMPONENTS ON EVAPORATOR
(a) Install lower unit case.
(b) Install upper unit case.
(c) Install two screws.
(d) Install four clips.
(e) Install two screws.
(f) Connect the expansion valve to the inlet fitting of the
evaporator. Torque the nut.
NOTE: Be sure that the O-rings are positioned on the tube
fitting.
Bolt (g) Install the holder to the suction tube with heat
];
sensitizing tube.
(h) Install thermistor.
ff
··~
-::.,~ . Cooling Unit
l(~
-~, . (Rear)
j>
Cooling Unit (Rear) INSTALLATION OF REAR COOLING UNIT

1. INSTALL REAR COOLING UNIT
Install the rear cooling unit with four bolts.
, Liquid Tube
I 2. CONNECT SUCTION TUBE TO REAR COOLING UNIT
OUTLET FITTING
3. INSTALL REAR BLOWER UNIT
4. INSTALL MAGNETIC VALVE
5. CONNECT LIQUID TUBES

6. IF EVAPORATOR WAS REPLACED, ADD

Add 40 - 50 ee (1.4 - 1.7 fl.oz.)

SYSTEM
AIR CONDITIONING SYSTEM - Refrigerator AC-45
REFRIGERATOR
REMOVAL OF REFRIGERATOR
AC1205
1. REMOVE THREE SCREWS
2. REMOVE SIDE COVER
I J /'
/' ..
AC0044
2-pin 6-pin
3. REMOVE 2-PIN, 3-PIN AND 6-PIN CONNECTORS
3-pin
AC0045
4. REMOVE SUCTION AND LIQUID TUBES
5. REMOVE REFRIGERATOR MOUNTING BOLTS

AC-46 AIR CONDITIONING SYSTEM - Refrigerant Lines, AIC Switch
REFRIGERANT LINES
1. INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak detector. Replace, if necessary.
2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT

LOOSE
Tighten or replace, as necessary.
REPLACEMENT OF REFRIGERANT LINES


(See page AC-15) .. ""
2. REPLACE FAULTY TUBE OR HOSE

out of the system.
3. TIGHTENING TORQUE FOR O-RING AND BOLTED

TYPE FITIINGS
(See page AC-2)

Ale SWITCH
AIC Switch
1. DISCONNECT NEGATIVE CABLE FROM BATIERY
2. REMOVE CENTER CLUSTER
3. DISCONNECT AIC SWITCH CONNECTOR
4. CHECK AIC SWITCH FOR CONTINUITY

Using an ohmmeter, check continuity between the ter-
minals for each switch position shown in the table.
[819 1EG:E1 5.
If there is no continuity, replace the AIC switch.
CONNECT AIC SWITCH CONNECTOR
6. INSTALL CENTER CLUSTER
~SWItch
position
LW G LR
Some
17
OFF of
rrflL
4? AICResistance
ON
Continuity Switch
AIR CONDITIONING SYSTEM - No.1 Rear Heater Blower Switch, AIC Relay AC-47
NO. 1 REAR HEATER BLOWER

(
I
I
I m 0
--
I SWITCH
~ lS::_:
2. REMOVE NO.1 REAR HEATER BLOWER SWITCH
3. DISCONNECT NO.1 REAR HEATER BLOWER SWITCH
)~I
No.1 Rear Heater Blower Switch AC0354
4. CHECK NO.1 REAR HEATER BLOWER SWITCH

Using an ohmmeter, check continuity between the ter-
minals for each switch position shown in the table.
Terminal
If there is no continuity, replace the No. 1 rear heater
Switch
position blower switch.
OFF 5. CONNECT NO.1 REAR HEATER BLOWER SWITCH
ON
6. INSTALL NO.1 REAR HEATER BLOWER SWITCH
Ale RELAY
INSPECTION OF RELAY
1. REMOVE GLOVE BOX AND UNDER COVER
2. REMOVE RELAYS
AC0790
(4WD) Condenser Fan

Condenser Fan Relay No.2
Relay No.1
~----- ~~
AIC Cut Amplifier AC1238 ACl160
3. INSPECT CLUTCH RELAY CONTINUITY

and 2.
Continuity No continuity (b) Check that there is continuity between terminals 1
4~11 and 3.
l~
and 4.
BEOO12
AC-48 AIR CONDITIONING SYSTEM - AIC Relay
4. INSPECT CLUTCH RELAY OPERATION

No continuity
n. (a) Apply battery voltage across terminals 6 and 2.
o (b) Check that there is no continuity between terminals 1

and 3.
(c) Check that there is continuity between terminals
and 4.
BEOOll
5. INSPECT CONDENSER FAN RELAY CONTINUITY

and 3.
No and 4.
continuity If continuity is not as specified, replace the relay.
4 3 BEOOO9
Continuity 6. INSPECT CONDENSER FAN RELAY OPERATION

~.!l _ (a) Apply battery voltage across terminals 1 and 3.
:--101 (b) Check that there is continuity between terminals 2
:0
'~
1 :
and 4.
If there is no continuity, replace the relay.
BEOO1O
Continuity Continuity 7. INSPECT AIC CUT RELAY (2WD), CONDENSER FAN

RELAY NO.1, NO.2 (4WD) CONTINUITY
I n I n
0
and 2.
0 0 0
and 4.
If there is no continuity, replace the relay.
BEOO99
8. INSPECT AIC CUT RELAY (2WD), CONDENSER FAN

RELAY NO.1, NO.2 (4WD) CONTINUITY
and 4.
If there is continuity, replace the relay.
BE0100
AIR CONDITIONING SYSTEM - AIC Relay, Condenser Fan Motor AC-49
9. INSPECT CONDERNSER FAN RELAY NO.3

CONTINUITY (4WD only)
3/~
con.t~n.,-.D,u"~"i~r
<.1 (a) Check that there is continuity between terminals 2
and 4.
No ,',/4 CO,nt, inuity
,0., 2 . ~
5
i
~r~ . ~ and 5.
~~J9J r C0~,J: ' \ (c) Check that there is no continuity between terminals 1
, 1~
and 2.
jgJf'
Continuity If continuity is not as specified, replace the relay.
ACl161
10. INSPECT CONDENSER FAN RELAY NO.3

OPERATION (4WD only)
1 3
contl~,t~,'ICO~.
4 ,.' . (b) Check that there is continuity terminals 1 and 2.

E' 'H-' ,-
~ 2 5 ~ i
'L --~
Battery
ACl162
(2WD) CONDENSER FAN MOTOR

INSPECTION OF CONDENSER FAN MOTOR

(2WD)
2. DISCONNECT CONNECTOR OF FAN MOTOR
l-- A_CO_79---J3 3. CHECK FAN MOTOR

(a) Using the wire harness, apply battery voltage to the
connector.
(b) Confirm smooth rotation of the motor within the
specified current flow.
Standard current: 8.3 ± 0.8 A
If current is not as specified, replace the motor.
(2WD) 4. CHECK RESISTOR

Resistor (a) Using an ohmmeter, measure the resistance of re-
sistor.
Standard resistance: 0.9 ± 0.1 kfl at 20°C (68°F)
If resistance is not as specified, replace the resistor.
5. CONNECT CONNECTOR OF FAN MOTOR

AC0794
AC-50 AIR CONDITIONING SYSTEM - Condenser Fan Motor
(4WD)
(4WD)
2. DISCONNECT CONNECTOR OF FAN MOTOR
Connector
3. CHECK FAN MOTOR
(a) Using the wire harness, apply battery voltage to the
connector.
(b) Confirm smooth rotation of the motor within the
L-- A_C _"---J63 specified current flow.
Standard current: 6.7 ± 0.7 A
If current is not as specified, replace the motor.
4. CHECK RESISTOR
(4WD)
Using an ohmmeter, measure the resistance of resistor
e:
Vehicle Side between terminals Band b" D and d,.
Harness c t-----~c' Harness Standard resistance: 0.24 - 0.30 n at 20°C (68°F)
Resistor b @ If resistance is not as specified, replace the resistor.
d, ~ 5. CONNECT CONNECTOR OF FAN MOTOR

AC1'64
AIR CONDITIONING SYSTEM - Condenser Fan Motor AC-51
7. CHECK FAN MOTORS OPERATION

Condenser Condenser Fan Motor NOTE: The fan motors operate at two speeds depending
on the refrigerant pressure.
AIC switch Pressure switch Fan motor

(Magnet clutch relay) (Refrigerant pressure) speed
Connector
OFF
Pressure is approx.
16.5 kg/cm 2 (235 psi, LO
1,610 kPa) or less
ACl163
ON
ON
Pressure is approx.
16.5 kg/cm 2 (235 psi, HI
1,610 kPa) or more
(Example) Ale Switch: ON Pressure Switch,: ON Fan Motor Speed: HI
Amplifier
Main Magnetic
Relay '--+-4-...J Clutch Relay
Fan Motor
Relay No.2
'--.........-I-~
Pressure
Switch
AC1201
AC-52 AIR CONDITIONING SYSTEM - Magnetic Valve, Pressure Switch
MAGNETIC VALVE
INSPECTION OF MAGNETIC VALVE
CHECK MAGNETIC VALVE OPERATION
(a) A/C ON, Refrigerator OFF
~~
Air temp,
and device
1 2 3 4
ci. Cooling unit (Front) Low Low High High

E
$
"-
~ Cooling unit (Rear) Low High Low High
Open Open Shut Shut

Magnetic valve (Front)
(ON) (ON) (OFF) (OFF)
Q)
u Open Shut Open Shut
'>
Q)
Magnetic valve (Rear)
(ON) (OFF) (ON) (OFF)
0
Compressor
On On On Off
magnetic cI utch
(b) A/C ON, Refrigerator ON

Front Rear
Unit Unit Refrigerator
Nonreturn Valve : 15 sec. Magnetic Valve shut Refrigerator

operate
&CJ Refrigerator
60 sec. Magnetic Valve open Refrigerator
Ice non-operate
Maker
Receiver Expansion Valve
AC0047
PRESSURE SWITCH
Magnetic Valve INSPECTION OF PRESSURE SWITCH
1. CHECK REFRIGERANT PRESSURE
(a) Connect the hoses of the manifold gauge set to the
compressor service valves and observe the gauge
reading.
(b) The gauge reading must be more than 2.1 kg/cm 2
(30 psi, 206 kPa) when the ambient temperature is
higher than O°C (32°F).
AC0403
If the pressure is less than 2.1 kg/cm 2 (30 psi, 206 kPa),
charge the refrigerant. (See page AC-14)
(2WD) (4WD)
2. CHECK PRESSURE SWITCH
Dual Pressure Switch
(a) Remove the glove box.
(b) Remove the cooling unit.
(c) Disconnect the lead wire of the pressure switch.
(d) Check the continuity between the lead wires of the
~ / pressure switch with an ohmmeter.
Pressu re Switch Pressure Switch The ohmmeter must indicate zero ohms.
If there is any resistance, replace the pressure switch with
AC 1239 AC 11 65
a new one.
AIR CONDITIONING SYSTEM - Thermistor, Air Conditioner Amplifier AC-53
THERMISTOR
REMOVAL OF THERMISTOR
2. REMOVE GLOVE BOX
3. REMOVE COOLING UNIT
4. REMOVE THERMISTOR
Thermometer (b) Remove the screw and thermistor from the cooling
unit.
INSPECTION OF THERMISTOR
CHECK THERMISTOR OPERATION
(a) Place the thermistor in cold water. While varying the
temperature of the water, measure the resistance at
the connector and, at the same time, measure the
temperature of the water with a thermometer.
(b) Compare the two readings on the chart.
If the intersection is not in the shaded area replace the
5,5 00 ~--+-----+--+---+-+-----+---I thermistor.
2 5 ,000 INSTALLATION OF THERMISTOR

~ 4,500~-+----" 1. INSTALL THERMISTOR
c
ro (a) Install the thermistor with a screw.
tl 4, 000 ~--+------+--+-----F
'eQ)n (b) Connect the connector.
a: 3,5 00 ~-+----1--+----1--+----+--=
-1 Q 2 45°C 2. INSTALL UNDER TRAY
30 32 34 36 38 40°F
Temperature AC0548
Wire Harness Side AIR CONDITIONER AMPLIFIER

AIC Amplifier (Single Type)
INSPECTION OF AMPLIFIER
INSPECT AMPLIFIER CIRCUIT
Disconnect the amplifier and inspect the connector on the
wire harness side as shown in the chart below.
AIC Amplifier (Dual Type)
Test conditions:
(1) Ignition switch: ON
(2) Temperature control lever: MAX COOL
AIC Cut Amplifier (3) Blower switch: HI
Refrigerator Amplifier
591
K-17-1, H-l-1
K51
5H-ll1
AC-54 AIR CONDITIONING SYSTEM - Air Conditioner Amplifier
A/C amplifier (Single type)

Check for Tester connection Condition Specified value
r - - - - - - - - - - - - e----------
Continuity 6- Ground - Continuity
- - - - - - ~ _ . _ - - -
r------
Turn ignition switch on. Battery voltage
2-6
Turn ignition switch off. No voltage
---- - - - - - - - - - - - - - - - - ~-

3-6 f--

Voltage --
4-6
r----
Start the engine. Approx. 10 to 14 V
5-6
Stop the engine. No voltage
f--------------------- -- -----------f--
7- Ground - Continuity
Continuity
8-9 - Continuity
f - - - - - - - - - - - - - - - - ~- --
Resistance 9-6 - Approx. 1.7 kfl at 25°C (77°F)
If circuit is correct, replace the amplifier.

A/C amplifier (Dual type)
--
Continuity 13 - Ground - Continuity
1---------
Turn A/C switch on. Battery voltage

Voltage 4-13
Turn AIC switch off. No voltage
Turn rear A/C switch on. Continuity
Continuity 7-8
Turn rear AIC switch off. No continuity
----------------- ----

1- 13
--

2- 13 f-------

r-----
3 -13
--
5 -13 r--
----
Voltage 6-13
1----
10 - 13
--
14 - 13
f---------

18 - 13
-
Start the engine. Approx.1 0 to 14 V
9 - 13 f-----
Stop the engine. No voltage
I----
17 - 16 - Approx. 0 - 3 kfl
--
Resistance 8 -12 - Approx. 100 - 4,000 n
e-------- -
16 - 12 - Approx. 100 - 4,000 n

AIR CONDITIONING SYSTEM - Air Conditioner Amplifier, Vacuum Switching Valve (VSV) AC-55
AIC cut amplifier

f-------------.
Continuity 4 - Ground - Continuity

--
Turn AIC switch on. Battery voltage
Voltage 2-4
Turn AIC switch off. No voltage
---- -----~---------- ------ ---~--- -----
Turn acceleration switch on. Continuity

1- Ground --
Continuity Turn acceleration switch off. No continuity

----
Refrigerator amplifier
--
4 - Ground - Continuity
Continuity
8-4 ~-

!------- -
Turn ICE switch on. Battery voltage

3-4 r----
Turn ICE switch off. No voltage
Voltage ---
Turn COOL switch on. Battery voltage

1-4
Turn COOL switch off. No voltage
~-_._--
Turn HOT switch on. Battery voltage

10-4 e--------
Turn HOT switch off. No voltage
-- -----
Continuity 8-5 - Continuity

- - - - - - - - - - - - - - - - - - t - - - - - - - - - - . - - - - - -f---
Resistance 7- 11 - Approx. 1.5 kD
VACUUM SWITCHING VALVE

(VSV)
INSPECTION OF VSV
1. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY
BLOWING AIR INTO PIPES
(a) Connect the VSV terminals to the battery terminals as
~ ........----~AC0182
----J illustrated.
(b) Blow into pipe "F" and check that air comes out of pipe
(c) Disconnect the battery.

(d) Blow into pipe "E" and check that air comes out of
pipe "G". -- not out of pipe "F".
If a problem is found, repair or replace the VSV.
1.-- .... AC0183

AC-56 AIR CONDITIONING SYSTEM - Vacuum Switching Valve (VSV)
2. CHECK FOR SHORT CIRCUIT

Ohmmeter
Using an ohmmeter, check that there is no continuity
between each terminal and the VSV body.
ACOll0
3. CHECK FOR OPEN CIRCUIT

Ohmmeter
two terminals.
Resistance: 38 - 44 n at 20°C (68°F)
If resistance is not as specified, replace the VSV.
AC0109
A-1
SERVICE SPECIFICATIONS
Page
MAINTENANCE . A-2
ENGINE MECHANICAL . A-3
EFI SYSTEM . A-7
COOLING SYSTEM . A-9
LUBRICATION SYSTEM . A-9
IGNITION SYSTEM . A-10
STARTING SYSTEM . A-10
CHARGING SYSTEM . A-11
CLUTCH . A-11
MANUAL TRANSMISSION . A-12
AUTOMATIC TRANSMISSION . A-14
TRANSFER . A-17
PROPELLER SHAFT . A-20
FRONT AXLE AND SUSPENSION . A-20
REAR AXLE AND SUSPENSION . A-25
BRAKE SYSTEM . A-27
STEERING . A-29
BODy . A-32
LUBRiCANT . A-33
A-2 SERVICE SPECIFICATIONS - Maintenance
MAINTENANCE
Engine
Drive belt tension

Alternator (V-ribbed) New belt 175 ± 5 Ib
PS pump and AIC compressor New belt 125 ± 25 Ib
Used belt 801: 20 Ib
Coolant capacity wi heater or air conditioner
2WD wlo Rear heater 7.9 liters 8.3 US qts 7.0 Imp. qts
wi Rear heater 8.4 liters 8.9 US qts 7.4 Imp. qts
4WD wlo Rear heater 7.0 liters 7.4 US qts 6.2 Imp. qts
wi Rear heater 7.5 liters 7.9 US qts 6.6 Imp. qts
Engine oil capacity Drain and refil
wi Oil filter change 3.5 liters 3.7 US qts 3.1 Imp. qts
Spark plug Type NO P16R
NGK BPR5EP11
Gap 1.1 mm 0.043 in.
Firing order 1-3-4-2
Idle speed MIT 700 rpm
AIT 750 rpm
Chassis
Front brake
Pad thickness 2WD Limit 1.0 mm 0.039 in.
4WD Limit 3.0 mm 0.118in.
Disc thickness 2WD Limit 19.0 mm 0.748 in.
4WD Limit 24.0 mm 0.945 in.
Disc runout Limit 0.15 mm 0.0059 in.
Rear brake
Lining thickness Limit 1.0 mm 0.039 in.
Drum inner diameter Limit 256.0 mm 10.079 in.
Front axle and suspension
Ball joint vertical play Lower Limit 2.3 mm 0.091 in.
Upper Limit Omm o in.
Wheel bearing friction preload
2WD at Rotating 350 - 870 g 0.8 - 1.9 Ib 3.4 - 8.5 N
4WD at Starting 1.0 - 2.4 kg 2.2 - 5.3 Ib 10 - 24 N
Steering wheel freeplay Less than 30 mm (1.18 in.)
Torque specifications:
Front seat mounting bolts or nuts 375 kg-em 27 ft-Ib 37 N·m
Engine front mounting member x Body 400 kg-cm 29 ft-Ib 39 N·m
Strut bar bracket (2WD) x Body 900 kg-cm 65 ft-Ib 88 N·m
Stabilizer bar bracket x Body 900 kg-cm 65 ft-Ib 88 N·m
SERVICE SPECIFICATIONS - Engine Mechanical A-3
ENGINE MECHANICAL
Specifications
Intake at Idle speed 400 mmHg (15.75 in.Hg, 53.3 kPa) or more
manifold
vacuum
I--------------j----- ----------------------------+----------------------1
Compression Engine revolution at 250 rpm STD
12.5 kg/cm 2 (178 psi, 1,226 kPa) or more
pressure Limit 9.0 kg/cm 2 128 psi 883 kPa
Difference of pressure between each cylinder 2
1.0 kg/cm (14 psi, 98 kPa) or less
1---------+--- - - - - - - - - - - - - - - - - - + - - - - - - - - - - - - - - - - - - - - - 1
Cylinder head Cylinder block side warpage Limit 0.15 mm 0.0059 in.
Manifold side warpage Limit 0.10 mm 0.0039 in.
Valve seat Refacing angle Intake 30°, 45°, 60°
Exhaust 30°, 45°, 65°
Contacting angle 45°
Contacting width 1.2 - 1.6 mm 0.047 - 0.063 in.
Valve guide Inner diameter 8.010 - 8.030 mm 0.31 54 - 0.3161 in.

bushing Outer diameter STD 13.040 - 13.051 mm 0.5134 - 0.5138 in.
OIS 0.05 13.090 - 13.101 mm 0.5154 - 0.5158 in.
Valve Valve overall length STD Intake 108.2 mm 4.260 in.

Exhaust 108.5 mm 4.272 in.
Limit Intake 107.7 mm 4.240 in.
Valve face angle IN & EX 44.5°
Stem diameter Intake 7.970 - 7.985 mm 0.3138 - 0.3144 in.
Exhaust 7.965 - 7.980 mm 0.3136 - 0.3142 in.
Stem oil clearance STD Intake 0.025 - 0.060 mm 0.0010 - 0.0024 in.
Exhaust 0.030 - 0.065 mm 0.0012 - 0.0026 in.
Margin thickness STD Intake 1.0 - 1.4 mm 0.039 - 0.055 in.
Exhaust 1.3 - 1.7 mm 0.051 - 0.067 in.
Valve spring Free length 47 mm 1.85 in.

II Installed load at 40.6 mm (1.598 in.) 28.8 - 35.2 kg
~
(63.5 - 77.6 Ib, 282 - 345 N)
1--__ --+-I-S-q-u_areness Limit 2.0 mm 0.079 in.
Rocker arm Rocker arm inside diameter STD 18.500 - 18.515 mm 0.7283 - 0.7289 in.
and shaft Rocker shaft diameter STD 18.474 - 18.487 mm 0.7273 - 0.7278 in.
Rocker arm to shaft oil clearance STD 0.013 - 0.041 mm 0.0005 - 0.0016 in.
Limit 0.08 mm 0.0031 in.
Push rod Circle runout 0.30 mm 0.0118 in.
Intake and Manifold surface warpage Limit IN & EX 0.4 mm 0.016 in.
exhaust
manifold
Air intake Air intake chamber surface warpage Limit 0.3 mm 0.012 in.
chamber
A-4 SERVICE SPECIFICATIONS - Engine Mechanical
Specifications (Co nt' d)
Chain and Chain slack at 10 kg (22.0 Ib, 98 N)

sprocket Limit 13.5 mm 0.531 in.
Chain elongation Limit 291.4 mm 11.472 in.
Crankshaft sprocket wear Limit 59 mm 2.32 in.
Camshaft sprocket wear Limit 114 mm 4.49 in.
Tension and Tensioner head thickness STO 15.0 mm 0.591 in.

damper Limit 12.5 mm 0.492 in.
\
Oamper thickness STO 6.6 mm 0.260 in.
Limit 5.0 mm 0.197 in.
Valve lifter Lifter diameter 21.387 - 21.404 mm 0.8420 - 0.8427 in.
Cylinder block lifter bore diameter 21.41 7 - 21.443 mm 0.8432 - 0.8442 in.
Oil clearance STO 0.012 - 0.056 mm 0.0005 - 0.0022 in.
Leak down test at 20 kg (44.1 Ib, 196 N) 7 - 50 seconds/1 mm (0.04 in.)
Camshaft Thrust clearance STO 0.07 - 0.22 mm 0.0028 - 0.0087 in.

Journal oil clearance STO 0.025 - 0.081 mm 0.0010-0.0032 in.
Limit 0.10 mm 0.0039 in.
Journal diameter STO No.1 46.459 - 46.475 mm 1.8291 - 1.8297 in.
No. 2 46.209 - 46.225 mm 1.8192 - 1.8199 in.
No.3 45.959 - 45.975 mm 1.8094 - 1.8100 in.
No.4 45.709 - 45.725 mm 1.7996 - 1.8002 in.
No.5 45.459 - 45.475 mm 1.7897 -1.7904 in.
Bearing inside diameter STO No.1 46.500 - 46.540 mm 1.8307 - 1.8323 in.
No. 2 46.250 - 46.290 mm 1.8209 - 1.8224 in.
No. 3 46.000 - 46.040 mm 1.8110-1.8126 in.
NO.4 45.750 - 45.790 mm 1.8012 - 1.8028 in.
No. 5 45.500 - 45.540 mm 1.7913 - 1.7929 in.
Circle runout Limit 0.06 mm 0.0024 in.
Cam lobe height STO Intake 38.620 - 38.720 mm 1.5205 - 1.5244 in.
Exhaust 38.629 - 38.729 mm 1.5208 - 1.5248 in.
Cylinder block Cylinder head surface warpage Limit 0.05 mm 0.0020 in.
Cylinder bore diameter STO STO 91.000 - 91.030 mm 3.5827 - 3.5839 in.
Limit 91.23 mm 3.5917 in.
G/S 0.50 Limit 91.73 mm 3.6114 in.
Piston and Piston diameter sro 90.925 - 90.955 mm 3.5797 - 3.5809 in.
piston ring GIS 0.50 91.425 - 91.455 mm 3.5994 - 3.6006 in.
Piston to cylinder clearance STO 0.065 - 0.085 mm 0.0026 - 0.0033 in.
Ring to ring groove clearance 0.03 - 0.07 mm 0.0012 - 0.0028 in.
Piston ring end gap STO NO.1 0.23 - 0.48 mm 0.0091 - 0.0189 in.
No.2 0.1 6 - 0.44 m m 0.0063 - 0.0173 in.
Oil 0.13 - 0.47 mm 0.0051 - 0.0185 in.
Limit No.1 1.08 mm 0.0425 in.
No.2 1.04 mm 0.0409 in.
Oil 1.07 mm 0.0421 in.
SERVICE SPECIFICATIONS - Engine Mechanical A-5
Connecting Thrust clearance STO 0.160-0.312 mm 0.0063 - 0.0123 in.

rod Limit 0.35 mm 0.0138 in.
Connecting rod bearing center wall thickness
STO No.6 1.486 - 1.490 mm 0.0585 - 0.0587 in.
No. 7 1.490 - 1.494 mm 0.0587 - 0.0588 in.
No. 8 1.494 - 1.498 mm 0.0588 - 0.0590 in.
Bearing oil clearance STO 0.020 - 0.051 mm 0.0008 - 0.0020 in.
Limit 0.10 mm 0.0039 in.
Rod bend Limit per 100 mm (3.94 in.) 0.05 mm 0.0020 in.
Rod twist Limit per 100 mm (3.94 in.) 0.05 mm 0.0020 in.
Crankshaft Thrust clearance STO 0.020-0.220 mm 0.0008 - 0.0087 in.
Limit 0.30 mm 0.0118 in.
Thrust washer thickness STO 2.440 - 2.490 mm 0.0961 - 0.0980 in.
DIS 0.125 2.503 - 2.553 mm o 0985 - 0.1 005 in.
DIS 0.250 2.565 - 2.615 mm 0.1010-0.1030 in.
Main journal oil clearance STO 0.020 - 0.051 mm 0.0008 - 0.0020 in.
Limit 0.10 mm 0.0039 in.
Main journal diameter STO 57.985 - 58.000 mm 2.2829 - 2.2835 in.
U/S 0.25 57.745 - 57.755 mm 2.2734 - 2.2738 in.
Main bearing center wall thickness
STO No.1 1.986 -1.990 mm 0.0781 - 0.0783 in.
No. 2 1.990 - 1.994 mm 0.0783 - 0.0785 in.
No. 3 1.994 - 1.998 mm 0.0785 - 0.0787 in.
Crank pin diameter STO 47.985 -48.000 mm 1.8892 - 1.8898 in.
U/S 0.25 47.745 -47.755 mm 1.8797 - 1.8801 in.
Main journal taper and out-of round Limit 0.02 mm 0.0008 in.
Crank pin journal taper and out-or round
Limit 0.02 mm 0.0008 in.
Torque Specifications
Part tightened kg-cm ft-Ib N'm

Manifold x Cylinder head 500 36 49
Cylinder head x Cylinder block 12 mm bolt head 195 14 19
14 mm bolt head 900 65 88
Valve rocker shaft x Cylinder head 240 17 24
Air intake chamber x Manifold 120 9 12
Exhaust pipe x Exhaust manifold 630 46 62
Camshaft thrust plate x Cylinder block 185 13 18
Vibration damper x Cylinder block 185 13 18
Camshaft sprocket x Camshaft 920 67 90
Chain tensioner x Cylinder block 185 13 18
Timing chain cover x Chain case 60 52 in.-Ib 5.9
Crankshaft pulley x Crankshaft 1,600 116 157
Main bearing cap x Cylinder block 800 58 78
Connecting rod cap x Connecting rod 500 36 49
A-6 SERVICE SPECIFICATIONS - Engine Mechanical
Torque Specifications (Cont'd)
Part tightened kg-em ft-Ib N·m
Rear oil seal retainer x Cylinder block 120 9 12

Timing chain case x Cylinder block 185 13 18
Flywheel x Carnkshaft 850 61 83
Drive plate x Crankshaft 750 54 74
Engine front mounting member x Body 400 29 39
Strut bar bracket (2WD) x Body 900 65 88
Stabilizer bar bracket (4WD) x Body 900 65 88
SERVICE SPECIFICATIONS - EFI System A-7
EFI SYSTEM
Specifications
Fuel pressure Fuel pressure at No vacuum 2.3 - 2.7 kg/cm 2

regulator (33 - 38 psi, 226 - 265 kPa)
Cold start Resistance 3 - 5 f!

injector Fuel leakage One drop or less of fuel per minute
Injector Resistance 1.5 - 3.0 f!

Injection volume 40 - 50 cc/15 sec (2.4 - 3.1 cu in.!1 5 sec)
Difference between each injector 5 cc (0.3 cu in.) or less
Fuel leakage One drop or less of fuel per minute
Auxiliary air valve Resistance (EP - E1) 40 - 60 f!

Temperature wi Valve closed About 80°C (176°F)
Throttle body Throttle valve fully closed angle
Throttle position Throttle opening angle Clearance between psw- E1

IDL - E1 IDL - PSW
sensor (from Vertical) stop screw and lever
I---------------+-----------+--------+------t-----------I
0.57 mm 0.0224 in. Continuity No continuity No continuity

0.85 mm 0.0335 in. No continuity No continuity No continuity
Fully opened position No continuity Continuity No continuity
64° No continuity No continuity No continuity
68° No continuity Continuity No continuity
EFI main relay Resistance 1 - 3 40 - 60 f!

2 - 4
Circuit opening Resistance STA - E1 17 - 25 f!

relay 8 - Fe 88 - 112 f!
8 - FP
Solenoid resistor Resistance 2 - 3 f! each
Cold start Resistance ST A - STJ 20 - 40 f! below 30°C (86°F)

injector time 40 - 60 f! above 40 0 e (104°F)
switch ST A - Ground 20 - 40 f! below 30°C (86°F)
20 - 80 f! e
above 40 0 (104°F)
Air flow meter Resistance E2 - VS 20 - 400 f!

(Measuring plate fully closed)
20 - 1,000 f!
(Measuring plate fully open)
E2 - VC 100 - 300 f!
E2 - +8 200 - 400 f!
E1 - FC 00 (Measuring plate closed)
o (Measuring plate open)
E2 - THA 10 - 20 kf! at -20°C (-4°F)
4 - 7 kf! at O°C (32°F)
2 - 2.7 kf! at 20°C (68°F)
0.9 - 1.3 kf! at 40 0 e (104°F)
0.4 - 0.7 kf! at 60°C (140°F)
A-a SERVICE SPECIFICATIONS - EFI System
Specifications (Cont'd)
Water temp. Resistance (THW - E2) 10-20kf1 at -20°C (-4°F)
sensor 4 - 7 kf1 at O°C (32°F)
2 - 3 kf1 at 20°C (68°F)
0.9-1.3kf1 at 40°C (104°F)
0.4 - 0.7 kn at 60°C (140°F)
0.2 - 0.4 kf1 at 80°C (176°F)
Computer NOTE: 1. Perform all voltage and resistance measurements with the ECU connected.
2. Verify that the battery voltage is 11 V or above when the ignition switch is
ON.
~-
Terminals Terminals Condition Voltage (V)

voltage +8
+81
BATT - E1 - 10- 14
IDL - E1 Ignition switch ON Throttle valve open 8 - 14
PSW - E1 Ignition switch ON Throttle valve closed 8 - 14
IGT - E1 Idling 0.7 - 1.0
STA - E1 Cranking 6 - 12
NO.10
NO.20
W - E2 No throttle and engine running 8 - 12

VC - E2 Ignition switch ON 6 - 10
Measuring plate fully closed 0.5 - 2.5
E2 Ignition switch ON
VS - Measuring plate fully open 5 - 10
E2l
Idling 2-8
D
THA - E2 Ignition switch ON Intake air temp. 20°C (68 F) 1 - 3
THW - E2 Ignition switch ON Coolant temp. 80°C (176°F) 0.5 - 2.5
AIC - E1 Ignition switch ON AIC ON 10 - 14
Check engine connector not short 10 - 14
I T - E1 Ignition switch ON
Check engine connector short 0
I Resistance Terminals Condition Resistance (n)

Throttle valve open 00
IDL - E1
Throttle valve fully closed
I
Throttle valve fully open

°
0
PSW - E1
+8 - E2 - 200 - 400
VC - E2 - 100 - 300
Measuring plate fully closed 20 - 400
VS - E2
Measuring plate fully open 20 - 1,000
D
THA - E2 Intake air temp. 20 C (68°F) 2,000 - 3,000
D
THW - E2 Coolant temp. 80 C (176°F) 200 - 400
Fuel cut rpm (wi Vehicle speed 0 km/h and
coolant temp. 80°C (176°F))
Fuel cut rpm 2,200 rpm
Fuel return rpm 1,800 rpm
SERVICE SPECIFICATIONS - EFI System, Cooling System, Lubrication System A-9
Part tightened kg-cm ft-Ib N·m
Fuel sender gauge 35 30 in.-Ib 3.4

Fuel pump x Fuel tank 50 43 in.-Ib 4.9
Fuel drain plug 130 9 13
Fuel tank band x Body 440 32 43
Cold start injector x Air intake chamber 60 52 in.-Ib 5.9
Cold start injector pipe x Cold start injector 200 14 20
Cold start injector pipe x Delivery pipe 200 14 20
Fuel pressure regulator x Delivery pipe 60 52 in.-Ib 5.9
Fuel inlet pipe x Delivery pipe 300 22 29
Fuel return pipe x Fuel pressure regulator 200 14 20
Throttle body x Air intake chamber 120 9 12
COOLING SYSTEM
Specifications
Engine coolant capacity See page A-2

f - - - - - - - - - . - - . - .. --.---~---------------.- ---.---.-------------. --.----- .-
Radiator Relief valve opening pressure STD 0.75 - 1.05 kg/ cm 2

(10.7 - 14.9 psi, 74 -103 kPa)
Limit 0.6 kg/cm 2 8.5 psi 59 kPa
~ _ . _ . - . _ - - - - - - - ~ - _ . _ - - - - - - - - - - - - - - - - - - - ~ . _ - - - - - - - - - - .-
- .- _ . .- ' --_
... _-- ~
Thermostat Valve opening temperature 80 - 84°C 176 - 183°F

Valve opening travel at 95° (203°F) 8 mm (0.31 in.) or more

f - - - - - - - - - - - - - - - - - - - - - - - - - - - - . - - ..- - - - - - - - j - - - - - - - - - - - - . - - - - - - -.... ---~------.------- ------------
Water pump x Cylinder block 185 13 18

Water pump x Timing gear case 185 13 18
Alternator adjusting bar x Cylinder block 400 29 39
Water inlet x Timing chain case 120 9 12
LUBRICATION SYSTEM
Specifications
Engine oil capacity See page A-33
Oil pressure at Idle speed 0.3 kg/cm 2 (4.3 psi, 2.9 kPa) or more
at 3,000 rpm 2.5 - 5.0 kg/cm 2
(36 - 71 psi, 245 - 490 kPa)
Oil pump Body clearance STD 0.10 - 0.15 mm 0.0039 - 0.0059 in.
Limit 0.20 mm 0.0079 in.
Tip clearance STD 0.07 - 0.12 mm 0.0028 - 0.0047 in.
Limit 0.20 mm 0.0079 in.
Side clearance STD 0.03 - 0.07 mm 0.0012 - 0.0028 in.
Limit 0.15 mm 0.0059 in.
Relief valve operating pressure 3.6 - 4.4 kg/cm 2
(51 - 63 psi, 353 - 431 kPa)
A-10 SERVICE SPECIFICATIONS - Lubrication System, Ignition System, Starting System
Oil pump relief valve spring plug x Oil pump body 375 27 37
Oil pump cover x Oil pump body 80 69 in.-Ib 7.8
Oil pump x Cylinder block 185 13 18
Oil pan x Cylinder block 130 9 13
Oil pan x Timing chain case
. 130 9 13
Oil pan x Rear oil seal retainer 130 9 13
Oil level sensor x Oil pan 55 48 in.-Ib 5.4
IGNITION SYSTEM
Ignition timing (wi Terminals T - E1 short circuited) 12° BTDC @ Idle
Spark plug See page A-2
Firing order 1-3-4-2
High-tension Resistance Limit 25 kf1 per cord

cord
Ignition coil Primary coil resistance 1.2 - 1.5 f1

Secondary coil resistance 7.5 - 10.5 kf1
IIA Air gap 0.2 mm (0.008 in.) or more

Pickup coil resistance 140 - 180 f1
Governor shaft thrust clearance 0.15 - 0.50 mm 0.0059 - 0.0197 in.
Governor shaft thrust washer thickness 0.3 mm 0.012 in.
0.4 mm 0.016 in.
0.5 mm 0.020 in.
0.6 mm 0.024 in.
STARTING SYSTEM
Starter Rated voltage and output power 12V 1.4 kw

No-load characteristic Current 90A or less at 11.5V
rpm 3,000 rpm or more
Brush length STD 15.5 mm 0.610 in.
Limit 10.0 mm 0.394 in.
Commutator Outer diameter STD 30 mm 1.18 in.
Limit 29 mm 1.14 in.
Undercut depth STD 0.6 mm 0.236 in.
Spring installed load 1.79-2.41 kg 3.9 - 5.3 Ib 18 - 24 N
SERVICE SPECIFICATIONS - Charging System, Clutch A-11
CHARGING SYSTEM
Battery specific gravity When fully charged at 20°C (68°F) 1.25 - 1.27
Drive belt tension See pge A-2
Alternator Rated output 12V 70A

Rotor coil resistance 2.8 - 3.0 n
Slip ring diameter STD 14.2 - 14.4 mm 0.559 - 0.567 in.
Limit 12.8 mm 0.504 in.
Brush exposed length STD 10.5 mm 0.413 in.
Alternator Regulating voltage at 25°C (77°F) 13.5-15.1V

regulator
CLUTCH
Specifications
Pedal height (from asphalt sheet) 171 - 181 mm 6.73-7.13in.
Push rod play at pedal top 1 - 5 mm 0.04 - 0.20 in.
Pedal freeplay 5 - 15 mm 0.20 - 0.59 in.
Disc rivet head depth Limit 0.3 mm 0.012 in.
Diaphragm spring out of alignment Limit 0.5 mm 0.020 in.
Diaphragm spring finger wear Depth Limit 0.6 mm 0.024 in.
Width limit 5.0 mm 0.197 in.
Flywheel runout Limit 0.2 mm 0.008 in.
Master cylinder union bolt 550 40 54

Clutch cover x Flywheel 195 14 19
Clutch line union 155 11 15
Bleeder plug 110 8 11
Flywheel set bolt 850 61 83
A-12 SERVICE SPECIFICATIONS - Manual Transmission
MANUAL TRANSMISSION
Specifications
Output shaft
2nd gear journal diameter Limit 37.984 mm 1.4954 in.
3rd gear journal diameter Limit 34.984 mm 1.3773 in.
Flange thickness Limit 4.80 mm 0.1890 in.
Runout Limit 0.05 mm 0.0020 in.
Inner race flange thickness Limit 3.99 mm 0.1571 in.
Inner race outer diameter Limit 38.985 mm 1.5348 in.
Gear thrust clearance
1st 2nd & 3rd STO 0.10 - 0.25 mm 0.0039 - 0.0098 in.
Limit 0.25 mm 0.0098 in.
Counter 5th STO 0.10 - 0.30 mm 0.0039 - 0.0118 in.
Limit 0.30 mm 0.0118 in.
Gear oil clearance
1st & counter 5th STO 0.009 - 0.032 mm 0.0004 - 0.00 13 in.
Limit 0.032 mm 0.0013 in.
2nd & 3rd STO 0.009 - 0.033 mm 0.0004 - 0.00 13 in.
Limit 0.033 mm 0.0013 in.
Shift fork to hub sleeve clearance Limit 1.0 mm 0.039 in.
Synchronizer ring to gear clearance STO 1.0 - 2.0 mm 0.039 - 0.079 in.
Input shaft snap ring thickness Mark
a 2.05 - 2.10 mm 0.0807 - 0.0827 in.
1 2.10-2.15mm 0.0827 - 0.0846 in.
2 2.15 - 2.20 mm 0.0846 - 0.0866 in.
3 2.20 - 2.25 mm 0.0866 - 0.0886 in.
4 2.25 - 2.30 mm 0.0886 - 0.0906 in.
5 2.30 - 2.35 mm 0.0906 - 0.0925 in.
Output shaft snap ring thickness
Front Mark
C-l 1.75 - 1.80 mm 0.0689 - 0.0709 in.
o 1.80 - 1.85 mm 0.0709 - 0.0728 in.
0-1 1.85 - 1.90 mm 0.0728 - 0.0748 in.
E 1.90-1.95mm 0.0748 - 0.0768 in.
E-l 1.95 - 2.00 mm 0.0768 - 0.0787 in.
F 2.00 - 2.05 mm 0.0787 - 0.0807 in.
F-l 2.05 - 2.10 mm 0.0807 - 0.0827 in.
SERVICE SPECIFICATIONS - Manual Transmission A-13
Output shaft snap ring thickness

Rear Mark
A 2.67 - 2.72 mm 0.1051 - 0.1071 in.
B 2.73 - 2.78 mm 0.1075 - 0.1094 in.
C 2.79 - 2.84 mm 0.1098 - 0.1118 in.
o 2.85 - 2.90 mm 0.1122 - 0.1142 in.
E 2.91 - 2.96 mm 0.1146 - 0.1165 in.
F 2.97 - 3.02 mm 0.1169 - 0.1189 in.
G 3.03 - 3.08 mm 0.1193 - 0.1213 in.
H 3.09 - 3.14 mm 0.121 7 - 0.1 236 in.
J 3.15 - 3.20 mm 0.1240 - 0.1260 in.
K 3.21 - 3.26 mm 0.1264 - 0.1283 in.
L 3.27 - 3.32 mm 0.1287 - 0.1307 in.
Counter gear snap ring thickness
Front bearing Mark
1 2.05 - 2.10 mm 0.0807 - 0.0827 in.
2 2.10 - 2.1 5 mm 0.0827 - 0.0846 in.
3 2.15 - 2.20 mm 0.0846 - 0.0866 in.
4 2.20 - 2.25 mm 0.0866 - 0.0886 in.
5 2.25 - 2.30 mm 0.0886 - 0.0906 in.
6 2.30 - 2.35 mm 0.0906 - 0.0925 in.
Straight screw plug 190 14 19

Extension housing x Transmission case (2WD) 380 27 37
Transfer adaptor x Transmission case (4WD) 380 27 37
Front bearing retainer x Transmission case 170 12 17
Rear bearing retainer x Intermediate plate 185 13 18
Reverse shift arm bracket 185 13 18
Counter gear rear lock nut 1,200 87 118
Reverse idler gear shaft stopper bolt 175 13 17
Clutch housing x Transmission case 380 27 37
Shift lever shaft housing x Transmission case 170 12 17
Shift outer lever lock pin nut 120 9 12
Select outer lever lock pin nut 80 69 in.-Ib 7.8
Shift fork x Shift fork shaft 200 14 20
Back-up light switch 380 27 37
A-14 SERVICE SPECIFICATIONS - Automatic Transmission
AUTOMATIC TRANSMISSION
Specifications
Governor pressure
Output shaft rpm (Vehicle speed reference)
1,000 (approx. 26 km/h, 16 mph) 1.4 - 1.7 kg/cm 2 20 - 24 psi 137 - 167 kPa
1,800 (approx. 48 km/h, 30 mph) 2.2 - 2.6 kg/cm 2 31 - 37 psi 216 - 255 kPa
3,500 (approx. 92 km/h, 57 mph) 4.5 - 5.3 kg/cm 2 64 -75 psi 441 - 520 kPa
Line pressure (wheel locked)

Engine idling "0" range 4.5 - 5.1 kg/cm 2 64 -73 psi 441 - 500 kPa
"R" range 6.8 - 7.6 kg/cm 2 97 - 108 psi 667 - 745 kPa
At stall "0" range 10.1 - 11.9 kg/cm 2 144 - 169 psi 990 - 1,167 kPa
"R" range 15.0 - 19.0 kg/cm 2 213 - 270 psi 1,471 - 1,863 kPa
Engine stall revolution 2, 100 ± 50 rpm

Time lag "N" range - "0" range Less than 1.2 seconds
"N" range - "R" range Less than 1.5 seconds
Engine idle speed "N" range 750 rpm
Throttle cable adjustment

Throttle valve fully opened Between boot end face and inner cable stopper
0-1 mm 0 - 0.04 in.
Torque converter runout Limit 0.30 mm 0.0118 in.
Drive plate runout Limit 0.20 mm 0.0079 in.
Shift point "0" range (throttle valve fully open) "L" range
Differential
schedule Lock-up Lock-up
gear ratio 1-2 2-3 3- 00 00- 3 3-2 2- 1 2-1
km/h (mph) ON OFF
44-53 87-98 *140-50 *169-78 *1 63-73 82-95 37-49 37-49

4.300 (27-33) (54-61) (25-31) (43-48) (39-45)
*2
(51-59) (23-30) (23-30)
39-50 81-92 *135-45 *163-72 *1 58-68 76-88 34-44 33-46

4.778 (24-31) (50-57) (22-28) (39-45) (36-42)
*2
(47-55) (21-27) (21-29)
*1 With closed throttle valve

*2 00 - 3 down shift possible up to maximum speed
Valve body Coil outer No.

Spring Free length Wire diameter Color
spring diameter coils
mm(in.)
Lower va Ive body
1-2 shift valve 34.62 (1.3630) 7.56 (0.2976) 13 0.56 (0.0220) None
Pressure relief valve 32.14 (1.2654) 13.14 (0.5173) 9 2.03 (0.0799) None
Primary regulator valve 61.20 (2.4094) 17.20 (0.6772) 13 1.80 (0.0709) White
3-4 shift valve 36.28 (1 .4283) 10.60 (0.4173) 14.5 1.10(0.0433) Red
Oil cooler by-pass valve 28.90 (1.1378) 13.80 (0.5443) 6.5 1.60 (0.0630) Orange
Damping check ball 20.00 (0.7874) 4.97 (0.1957) 16 0.40 (0.0157) None
Lock-up relay valve 18.50 (0.7283) 5.20 (0.2047) 13 0.55 (0.0217) White
Lock-up signal valve 38.60 (1.5197) 9.70 (0.3819) 13.5 1.10(0.0433) Light
Blue
Cooler return ball 13.70 (0.5394) 10.50 (0.4134) 10 0.50 (0.0197) None
SERVICE SPECIFICATIONS - Automatic Transmission A-15

Valve body Coil outer No.
Spring Free length Wire diameter Color
spring diameter coils
mm(in.)
Rear upper valve body
(cont'd)
2-3 shift valve 35.10 (1.3819) 8.96 (0.3528) 12.5 0.76 (0.0299) White
Sequence valve 37.55 (1.4783) 9.20 (0.3622) 14 1.20 (0.0472) Red
Low coast modulator valve 42.35 (1.6673) 9.24 (0.3638) 15 0.84 (0.0331) None
Detent regulator valve 32.08 (1.2630) 8.85 (0.3484) 13.5 0.90 (0.0354) None
Intermediate modulator valve 27.26 (1.0732) 9.04 (0.3559) 9.5 1.10 (0.0433) Green
Front upper valve body
Throttle valve 21.94 (0.8638) 8.58 (0.3378) 8 0.71 (0.0280) None
Down-shift plug 39.76 (1.5654) 10.83 (0.4264) 11.5 1.20 (0.0472) Purple
Secondary regulator valve 71.27 (2.8059) 17.43 (0.6862) 15 1.93 (0.0760) Green
Oil pump Side clearance STD 0.02 - 0.05 mm 0.0008 - 0.0020 in.
Body clearance STD 0.07 - 0.15 mm 0.0028 - 0.0059 in.
Tip clearance Driven gear STO 0.11 - 0.14 mm 0.0043 - 0.0055 in.
Limit 0.3 mm 0.0012 in.
Clutch and Front clutch (C l ) STO 1.32 - 2.66 mm 0.0520 - 0.1047 in.
brake piston Rear clutch (C.) STD 1.06 - 2.14 mm 0.041 7 - 0.0843 in.
stroke 00 clutch (Co) STD 1.77 - 2.58 mm 0.0697 - 0.1016 in.
NO.1 brake (B 1 ) 2WO STO 0.78 - 1.50 mm 0.0307 - 0.0591 in.
4WO STO 0.80 - 1.73 mm 0.0315 - 0.0681 in.
NO.2 brake (B 2 ) STD 1.01 - 2.25 mm 0.0398 - 0.0886 in.
Brake clearance No.3 brake (B 3 ) STO 0.61 - 2.64 mm 0.0240 - 0.1039 in.
00 brake (B o) STD 0.65 - 2.21 mm 0.0256 - 0.0870 in.
Accumulator Length Outer diameter

~
piston
B2 Front 48.5 (1.909) 34.8 (1.370)
mm (in.)
C'2 Center 45.0 (1.772) 31.8 (1.252)
Cl Rear 49.5 (1.949) 31.8 (1.252)
Accumulator No.
Free length Coil outer diameter Wire diameter Color
piston spring coils
mm (in.)
55.18 18.32 2.6 Light
11.0
(2.1724) (0.7213) (0.102) Green
82 Front
35.13 16.16 1.3
6.0 Red
(1.3831) (0.6362) (0.051 )
-
59.82 16.57 2.7
C2 Center (2.3551 ) (0.6524) 12.5 (0.106) Green
-
64.68 17.50 2.0
C1 Rear 18.5 None
(2.5465) (0.6890) (0.079)
A-16 SERVICE SPECIFICATIONS - Automatic Transmission
Bushing bore Bushing Length Finished bore Bore limit

mm(in.)
9.70 21.501 -21.527 21.577
Front
(0.3819) (0.8465 - 0.8475) (0.8495)
Stator support
17.45 21.501 - 21.527 21.577
Rear
(0.6870) (0.8465 - 0.8475) (0.8495)
13.46 38.11 3 - 38.1 38 38.188

Oil pump body
(0.5299) (1.5005 - 1.5015) (1.5035)
9.70 23.062 - 23.088 23.138

OD sun gear Front & Rear
(0.3819) (0.9080 - 0.9090) (0.9109)
9.00 11.200-11.221 11.271

aD input shaft
(0.3543) (0.4409 - 0.441 8) (0.4437)
13.50 21.501 - 21.527 21.577

Sun gear Front & Rear
(0.5315) (0.8465 - 0.8475) (0.8495)
60.07 36.386 - 36.411 36.461

Center support
(2.3650) (1.4325 - 1.4335) (1.4355)
13.46 38.11 3 - 38.1 38 38.188

Transmission case
(0.5299) (1.5005 - 1.5015) (1.5035)
9.70 18.001 - 18.026 18.076

Output shaft
(0.3819) (0.7087 - 0.7097) (0.7117)
29.75 38.010 - 38.035 38.085

Extension housing
(1.1713) (1.4965 - 1.4974) (1.4994)
Engine x Transmission 650 47 64

Transmission housing 12 mm 580 42 57
10 mm 345 25 34
Extension housing x Transmission (2WD) 345 25 34
Transfer adaptor x Transmission (4WD) 345 25 34
Transfer x Transmission (4WD) 380 27 37
Transmission mounting through bolt 500 36 49
Drive plate x Crankshaft 750 54 74
Torque converter x Drive plate 280 20 27
Oil pump 215 16 21
Center support 260 19 25
Upper valve body x Lower valve body 55 48 in.-Ib 5.4
Valve body 100 7 10
Oil strainer 55 48 in.-Ib 5.4
Oil pan 45 39 in.-Ib 4.4
Oil pump cover bolt 75 65 in.-Ib 7.4
Cooler pipe union nut 350 25 34
Testing plug 75 65 in.-Ib 7.4
Stiffener plate 375 27 37
Parking lock pawl bracket 75 65 in.-Ib 7.4
Exhaust pipe x Exhaust manifold 630 46 62
Neutral start switch (bolt) 55 48 in.-Ib 5.4
Neutral start switch (nut) 70 61 in.-Ib 6.9
Propeller shaft x Rear differential 2WD 430 31 42
4WD 750 54 74
SERVICE SPECIFICATIONS - Transfer A-17
TRANSFER
Specifications
Oil pump body Body clearance STD 0.07 - 0.1 7 m m 0.0028 - 0.0067 in.
Limit 0.40 mm 0.0157 in.
Tip clearance SrD 0.10 - 0.22 mm 0.0039 - 0.0087 in.
Limit 0.40 mm 0.0157 in.
Side clearance STD 0.03 - 0.13 mm 0.0012 - 0.0051 in.
Limit 0.40 mm 0.0157 in.
Front output Drive sprocket thrust clearance STD 0.10 - 0.25 mm 0.0039 - 0.0098 in.
assembly Limit 0.40 mm 0.0157 in.
Driven sprocket oil clearance STD 0.010- 0.057 mm 0.0004 - 0.0022 in.
Limit 0.15 mm 0.0059 in.
Front output shaft journal diameter Limit 36.930 mm 1.4539 in.
Synchronizer ring to sprocket clearance
STD 1.1 - 1.9 mm 0.043 - 0.075 in.
No.1 shift fork to No.2 hub sleeve clearance
Front output shaft snap ring thickness
Mark
1 1.95 - 2.00 mm 0.0768 - 0.0787 in.
2 2.00 - 2.05 mm 0.0787 - 0.0807 in.
3 2.05 - 2.10 mm 0.0807 - 0.0827 in.
4 2.10- 2.15 mm 0.0827 - 0.0846 in.
5 2.15 - 2.20 mm 0.0846 - 0.0866 in.
6 2.20 - 2.25 mm 0.0866 - 0.0886 in.
7 2.25 - 2.30 mm 0.0886 - 0.0906 in.
8 2.30 - 2.35 mm 0.0906 - 0.0925 in.
9 2.35 - 2.40 mm 0.0925 - 0.0945 in.
10 2.40 - 2.45 mm 0.0945 - 0.0965 in.
11 2.45 - 2.50 mm 0.0965 - 0.0984 in.
12 2.50 - 2.55 mm 0.0984 - 0.1004 in.
Rear output Drive sprocket thrust clearance STD 0.10 - 0.25 mm 0.0039 - 0.0098 in.
assembly Limit 0.40 mm 0.0157 in.
Drive sprocket oil clearance STD 0.010- 0.057 mm 0.0004 - 0.0022 in.
Limit 0.15 mm 0.0059 in.
Rear output shaft journal outer diameter
Part
A Limit 27.930 mm 1.0996 in.
B Limit 38.900 mm 1.5315 in.
C Limit 36.930 mm 1.4539 in.
No.1 shift fork to NO.1 hub sleeve clearance
No.2 shift fork to high and low hub sleeve
clearance Limit 1.0 mm 0.039 in.
A-18 SERVICE SPECIFICATIONS - Transfer
Input shaft Input shaft journal outer diameter
Part A Limit 47.540 mm 1.8716 in.
Planetary gear Pinion gear thrust clearance STD 0.20 - 0.75 mm 0.0079 - 0.0295 in.
Limit 1.00 mm 0.0394 in.
Pinion gear oil clearance STD 0.009 - 0.038 mm 0.0004 - 0.0015 in.
Limit 0.C8 mm 0.0031 in.
Outer bearing snap ring thickness Mark
1 1.45 - 1.50 mm 0.0571 - 0.0591 in.
2 1.50 - 1.55 mm 0.0591 - 0.0610 in.
3 1.55 - 1.60 mm 0.0610 - 0.0630 in.
4 1.60 - 1.65 mm 0.0630 - 0.0650 in.
5 1.65 - 1.70 mm 0.0650 - 0.0669 in.
Inner bearing depth 5.5 - 6.1 mm 0.217 - 0.240 in.
The detent plate H4 stopper surface to shift lever clearance
Limit 1 mm 0.04 in.
Speed sensor Switch resistance 1-2 360 ± 30 f1
(While rotating the output shaft)
No.1 and No.2 Switch resistance 1-2 39 ± 3 f1
VSV
4WD control Connector Terminals Condition Voltage value

computer voltage
Turn 4WD control switch on Battery voltage
1 -10
Turn 4WD control switch off No voltage

4 -10
5 -10 Turn ignition switch on Battery voltage

6 -10

10 - 11
Wire harness Terminals Resistance value
_.
resistance
4 -10 about 35 f1
8-9 about 360 f1

10 - 11 about 35 f1
-_._--
Wire harness 10- Body ground Continuity
continuity
SERVICE SPECIFICATIONS - Transfer A-19
Diaphragm
cylinder body
--------
Diaphragm cylinder body air
thickness
---
Condition
Vacuum in diaphragm
500 mmHg (19.7 in.Hg,
66.7 kPa) for 30 seconds No charge
Vacuum tank Vacuum tank air thickness Vacuum in vacuum tank

and line 500 mmHg (19.7 in.Hg,
66.7 kPa) for 30 seconds No charge
-~-
Vacuum line air pressure Engine idling About 400 mmHg

(15.75 in.Hg, 53.3 kPa)
Diaphragm cylinder x Rear case 175 13 17

Diaphragm cylinder cover 175 13 17
Oil pump cover 75 65 in.-Ib 7.4
Straight screw plug for oil pump body 175 13 17
Straight screw plug for high and low shift fork shaft 175 13 17
Straight screw plug for front drive shift fork shaft 175 13 17
Oil receiver 50 43 in.-Ib 4.9
Oil strainer 50 43 in.-Ib 4.9
Rear case x Front case 380 27 37
Extension housing x Rear case 115 8 11
Companion flange lock nut 1,250 90 123
Oil pump body x Front case 115 8 11
Speed sensor x Rear case 115 8 11
Engine rear mounting x Transfer 290 21 28
Transfer x Transmission adaptor 380 27 37
Engine rear mounting 500 36 49
Exhaust front pipe x Exhaust manifold 630 46 62
A-20 SERVICE SPECIFICATIONS - Propeller Shaft, Front Axle and Suspension
PROPELLER SHAFT
Specifications
Spider bearing axial play Omm o in.

Runout Limit 0.8 mm 0.031 in.
Torq ue specifications

--------_. ----_. ---
(2WD)
Propeller shaft x Differential MIT 750 54 74
AIT 430 31 42
(4WD)
Front propeller shaft x Front differential 430 31 42
Rear propeller shaft x Rear differential 750 54 74
Rear propeller shaft x Transfer 750 54 74
FRONT AXLE AND SUSPENSION

Specifications (2WD)
Cold tire Inflation pressure kgl cm 2 (psi, kPa)

inflation Tire size
Front Rear
pressure --
175R146PRLT 2.8 (41, 280) 2.8 (41, 280)
f- -------~---~~---
P195/75 R14 2.4 (35,240) 2.4 (35, 240)

1---- - - - - - _ . - - r-=.----.- - ------ - - ~ - - " - , -
Front wheel Inspection STD Adjustment STD

f- ---._--------~._- '-- --------_.-------
alignment
Toe-in o ± 2 mm (0 ± 0.08 in.) 0±1 mm (0 ± 0.04 in.)
-- -------_.,._-_.-.---- --~---
Camber -5' ± 45' -5' ± 30'

Left-right error 30' or less 30' or less
f-- --.- - - - _ . _ - - - ~ - - - _ . _ - -
Steering axis inclination 10°35' ± 45'

-
_ .. _- ------ ------ --,-------,,-------
Caster 2°30' ± 45' 2°30 ±30'

---- - --------~------------
Side slip 3.0 mm/m (0.118 in./3.3 ft) or less

I- - - - - - - - - - - - - - - - ------ --- - - - - -
0
Inside wheel 37000' +1
-2°
Wheel angle ~----------
Outside wheel 33°00'

--
at 20° outside wheel 22°00' inside wheel

_ _ _ _ _ _ _ _ _ _ _ _ _. _ _ _ L. __ _ _ _ _ _ _ .. _ _ _ L-_ _ _ _ _ _ _ _ _ ..
Disc wheel lateral runout Limit 1.2 mm 0.047 in.

Wheel bearing preload Add oil seal frictional force
(starting load at hub bolt) 350 - 870 g 0.8 -1.9Ib 3.4 - 8.5 N
Hub axial play Limit 0.05 mm 0.0020 in.
Upper ball joint vertical play Limit 2.3 mm 0.091 in.
Lower ball joint vertical play Limit Omm o in.
Ball joint turning torque Lower ball joint 15 - 30 kg-cm 13 - 26 in.-Ib 1.5 - 2.9 N·m
Upper ball joint 10 - 35 kg-cm 9 - 30 in.-Ib 1.0 - 3.4 N·m
•
SERVICE SPECIFICATIONS - Front Axle and Suspension A-21
Specifications (4WD)
Cold tire Inflation pressure kg/cm 2 (psi, kPa)

inflation Tire size
Front Rear
pressure
_
e--------- - - l--------- - --- - - - - - - - - - - - - - - - - - - e - - - - - - - - - - - - - - - - - - - - ~
P205/75 R14 2.4 (35, 240) 2.4 (35, 240)

~ - - - - - - - ------I-~---- ------------------- ------ --- --- --- ---~- ---
Chassis ground
clearance
f-=~----- ~ront mm (in.) Rear mm (in.)
YR31 LG 256 (10.09) 284 (11.17)
1-------- - - - - - - - - ------- - - - - - c----- ------~
YR32LV 253 (9.44) 305 (11.99)
'~~tm:~~~;------4-f----=-~c----
~-~--~ _ -r-- _ _ 'n~~-;~~~TD- l___ AdjustmentSTD
Toe-in 0 ± 2 mm (0 ± 0.08 in.) 0 ± 1 mm (0 ± 0.04 in.)
Camber 0°10' ± 45' 0°10' ± 30'

----- ---- ----------1------- - - -------
Steering axis inclination 12° 25' ± 45'

1------- ---- - - - - - - - - ---+-- ----------------- ------+-----------------1
Caster 2°50' ± 45' 2°50' ± 30'

1------- ------------------------ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ' - - - - - - - - - - - - - - - ---1
Slide slip 3.0 mm/m (0.118 in./3.3 ft) or less
1------- - - - - - - - - - - - - - - - ---------------------------------------------~
Wheel angle
Max. Inside wheel 34°00'~~~
Outside wheel 32°00'
At 20° (Outside wheel) 20°50' (Inside wheel)
~--------'------ -- -1---------- _
Disc wheel lateral runout Limit 1.2 mm 0.047 in.

Wheel bearing preload 2.1 - 3.6 kg 4.6 -7.9Ib 21 - 35 N
(rotating load at hub bolt)
Free wheeling hub ring oil clearance 0.3 mm 0.012 in.
Automatic locking hub brake shoe thickness Minimum 1.5 mm 0.059 in.
Drive shaft thrust clearance STD 0.075 - 0.690 mm 0.0030 - 0.0272 in.
Drive shaft thrust clearance adjusting shim thickness 1.80 mm 0.0709 in.
2.25 mm 0.0886 in.
Drive shaft standard length 378.0 ± 1.5 mm 14.882 ± 0.059 in.
Drive shaft grease capacity Inboard joint 195 - 205 g 0.42 - 0.45 Ib
Outboard joint 215 - 225 g 0.47 - 0.50 Ib
A-22 SERVICE SPECIFICATIONS - Front Axle and Suspension
Specifications (4WD) (Cont'd)
Front differential rear oil seal drive in depth 2.0mm 0.079 in.
Front differential drive pinion bearing preload (starting)
New bearing 10- 16 kg-em 8.7 - 13.9 in.-Ib 1.0 -1.6 N·m
Reused bearing 5- 8 kg-cm 4.3 - 6.9 in.-Ib 0.5 -0.8 N·m
Front differential side gear shaft deviation
Maximum longtudinal deviation 0.20 mm 0.0079 in.
Maximum latetudinal deviation 0.20 mm 0.0079 in.
Front differential companion flange deviation
Maximum longtudinal deviation 0.10 mm 0.0039 in.
Maximum latetudinal deviation 0.10 mm 0.0039 in.
Front differential ring gear runout 0.07 mm 0.0028 in.
Front differential ring gear backlash 0.1 3 _. 0.1 8 m m 0.0051 - 0.0071 in.
Front differential preload (starting) Total preload Add drive pinion preload
3- 5 kg-em 2.6 - 4.3 in.-Ib 0.3 - 0.5 N·m
Front differential case runout 0.07 mm 0.0028 in.
Front differential side gear backlash 0.05 -·0.20 mm 0.0020 - 0.0079 in.
Front differential side gear backlash thrust washer 0.92 -·0.98 mm 0.0362 - 0.0386 in.
thickness
0.97 _. 1.03 mm 0.0382 - 0.0406 in.
1.02 _. 1.08 mm 0.0401 - 0.0426 in.
1.07 -·1.13 mm 0.0421 - 0.0445 in.
1.12 -·1.18 mm 0.0441 -0.0465 in.
1.17 _. 1.23 mm 0.0461 - 0.0484 in.
Front differential backlash or side bearing 2.21 -·2.23 mm 0.0870 - 0.0878 in.
preload thrust washer thickness
2.24 _. 2.26 mm 0.0881 - 0.0890 in.
2.27 _. 2.29 mm 0.0894 - 0.0902 in.
2.30 _. 2.32 mm 0.0906 - 0.0913 in.
2.33 -·2.35 mm 0.0917 - 0.0925 in.
2.36 _. 2.38 mm 0.0929 - 0.0937 in.
2.39 _. 2.41 mm 0.0941 - 0.0949 in.
2.42 -- 2.44 mm 0.0953 - 0.0961 in.
2.45 -- 2.47 mm 0.0965 - 0.0972 in.
2.48 -- 2.50 mm 0.0976 - 0.0984 in.
2.51 -- 2.53 mm 0.0988 - 0.0996 in.
2.54 -- 2.56 mm 0.1000 - 0.1008 in.
2.57 -- 2.59 mm 0.1012 - 0.1020 in.
2.60 -- 2.62 mm 0.1024 - 0.1031 in.
2.63 -- 2.65 mm 0.1035 - 0.1043 in.
2.66 -- 2.68 mm 0.1047 - 0.1055 in.
2.69 -- 2.71 mm 0.1059 - 0.1067 in.
2.72--2.74mm 0.1071-0.1079in.
2.75 -- 2.77 mm 0.1083 - 0.1091 in.
2.78--2.80mm 0.1095-0.1102 in.
2.81 -- 2.83 mm 0.1106 - 0.1114 in.
2.84 -- 2.86 mm 0.1118 - 0.1126 in.
2.87 -- 2.89 mm 0.1130 - 0.1138 in.
2.90 -- 2.92 mm 0.1142 - 0.1150 in.
2.93--2.95mm 0.1154-0.1161 in.
2.96 -- 2.98 mm 0.1165 - 0.1173 in.
2.99--3.01 mm 0.1177-0.1185in.
SERVICE SPECIFICATIONS - Front Axle and Suspension A-23
Specifications (4WD) (Cont'd)

Front differential backlash or side bearing 3.02 - 3.04 mm 0.1189 - 0.1197 in.
preload thrust washer thickness (cont'd) 3.05 - 3.07 mm 0.1 201 - 0.1 209 in.
3.08 - 3.10 mm 0.1213 - 0.1220 in.
3.11 - 3.13 mm 0.1224 - 0.1232 in.
3.14 - 3.16 mm 0.1236 - 0.1244 in.
3.17 - 3.19 mm 0.1248 - 0.1256 in.
3.20 - 3.22 mm 0.1260 - 0.1268 in.
Front differential drive pinion plate washer thickness 2.26 - 2.28 mm 0.0890 - 0.0898 in.
2.29 - 2.31 mm 0.0902 - 0.0909 in.
2.32 - 2.34 mm 0.0913 - 0.0921 in.
2.35 - 2.37 mm 0.0925 - 0.0933 in.
2.38 - 2.40 mm 0.0937 - 0.0945 in.
2.41 - 2.43 mm 0.0949 - 0.0957 in.
2.44 - 2.46 mm 0.0961 - 0.0969 in.
2.47 - 2.49 mm 0.0972 - 0.0980 in.
2.50 - 2.52 mm 0.0984 - 0.0992 in.
2.53 - 2.55 mm 0.0996 - 0.1004 in.
2.56 - 2.. 58 mm 0.1008 - 0.1016 in.
2.59 - 2.. 61 mm 0.1020 - 0.1028 in.
2.62 - 2.. 64 mm 0.1031-0.1039in.
2.65 - 2.. 67 mm 0.1043-0.1051 in.
2.68 - 2.. 70 mm 0.1055 - 0.1063 in.
Lower ball joint vertical play Omm o in.
Upper ball joint vertical play 2.3 mm 0.091 in.
Lower ball joint turning torque 15 - 30 kg-cm 13 - 26 in.-Ib 1.5 - 2.9 N·m
Torque Specifications (2WD)
Tie rod clamp bolt 195 14 19

Knuckle stopper bolt lock nut 350 25 34
Steering knuckle x Upper ball joint 800 58 78
Steering knuckle x Lower ball joint 1,050 76 103
Steering knuckle x Knuckle arm x Dust cover 1,060 77 104
Upper ball joint x Upper arm 300 22 29
Lower ball joint x Lower arm 680 49 67
Shock absorber x Lower arm 180 13 18
Shock absorber upper mounting lock nut 260 19 25
Lower arm x Body (Adjusting cam nut) 2,100 152 206
Upper arm shaft x Rear side nut 975 71 96
Upper arm shaft x Front side nut 800 58 78
Upper arm x Torque arm 480 35 47
Upper arm x Frame front side 900 65 88
Upper arm x Frame rear side 1,550 112 152
A-24 SERVICE SPECIFICATIONS - Front Axle and Suspension
Torque Specifications (2WD) (Cont'd)

r-----
Strut bar x Lower arm 680 49 67
Strut bar x Strut bar bracket (Rear nut) 1,230 89 121
Stabilizer bar bracket x Body 195 14 19
Tie rod cia mp bolt 195 14 19
Disc brake caliper x Steering knuckle 1,060 77 104
Wheel hub nut 1,050 76 103
Torque Specifications (4WD)

t-------
Knuckle stopper bolt lock nut 350 25 34

Tie rod clamp bolt 195 14 19
Free wheeling hub body x Drive shaft 185 13 18
Free wheeling hub cover x Free wheeling hub body 100 7 10
Axle hub bearing preload lock nut 480 35 47
Free wheeling hub body x Axle hub 315 23 31
Steering knuckle x Upper suspension arm 1,150 83 113
Stabilizer bar bracket x Lower suspension arm 195 14 19
Lower suspension arm x Front shock absorber 970 70 95
Steering knuckle x Tie rod 930 67 91
Lower suspension arm x Lower ball joint 1,150 83 113
Drive shaft x Front differential 700 50 69
Torsion bar spring lock nut 800 58 78
Lower ba II joi nt x Steeri ng kn uckle 590 43 58
Lower suspension arm x Body 2,100 152 206
Torque arm x Upper suspension arm 1,250 90 123
Upper suspension arm x Body 1,550 112 152
Stabilizer bar bracket x Body 195 14 19
Differential carrier x Carrier cover 475 34 47
Differential carrier x Differential tube 900 65 88
Ring gear x Differential case 985 71 97
Drive pinion x Companion flange See page FA-71
Differential support x Differential tube 730 53 72
Support bolt 690 50 68
SERVICE SPECIFICATIONS - Rear Axle and Suspension A-25
REAR AXLE AND SUSPENSION

Specifications
Rear axle Rear axle shaft bearing inner retainer

shaft installation temperature 150°C 302°F
Rear axle shaft runout Limit 1.5 mm 0.059 in.
Rear axle shaft flange runout Limit 0.1 mm 0.004 in.
- -
Differential Drive pinion bearing preload (starting)
New bearing 12 - 19 kg-cm
(10.4 - 10.5 in.-Ib, 1.2 - 1.9 N·m)
Reused bearing 6 - 10 kg-cm
(5.2 - 8.7 in.-Ib, 0.6 - 1.0 N·m)
Total preload (starting) Add drive pinion bearing preload
4 - 6 kg-cm 3.4 - 5.2 in.-Ib 0.4 - 0.6 N·m
Drive pinion to ring gear backlash 0.13-0.18 mm 0.0051 - 0.0071 in.
Pinion gear to side gear backlash 0.05 - 0.20 mm 0.0020 - 0.0079 in.
Ring gear runout Limit 0.07 mm 0.0028 in.
Companion flange deviation Limit
Radial 0.10 mm 0.0039 in.
Lateral 0.10 mm 0.0039 in.
Ring gear installation temperature 90 - 110°C 194 - 230°F
Oil seal drive in depth 1.5 mm 0.059 in.
Side gear thrust washer thickness 0.96 - 1.04 mm 0.0378 - 0.0409 in.
1.06 - 1.1 4 m m 0.0417 - 0.0449 in.
1.16 - 1.24 mm 0.0457 - 0.0488 in.
1.26 - 1.34 mm 0.0496 - 0.0528 in.
Drive pinion adjusting plate washer thickness 2.23 - 2.25 mm 0.0878 - 0.0886 in.
2.26 - 2.28 mm 0.0890 - 0.0898 in.
2.29 - 2.31 mm 0.0902 - 0.0909 in.
2.32 - 2.34 mm 0.0913 - 0.0921 in.
2.35 - 2.37 mm 0.0925 - 0.0933 in.
2.38 - 2.40 mm 0.0937 - 0.0945 in.
2.41 - 2.43 mm 0.0949 - 0.0957 in.
2.44 - 2.46 mm 0.0961 - 0.0969 in.
2.47 - 2.49 mm 0.0972 - 0.0980 in.
2.50 - 2.52 mm 0.0984 - 0.0992 in.
2.53 - 2.55 mm 0.0996 - 0.1004 in.
2.56 - 2.58 mm 0.1008 - 0.1016 in.
2.59 - 2.61 mm 0.1020 - 0.1028 in.
2.62 - 2.64 mm O.1031-0.1039in.
2.65 - 2.67 mm 0.1043-0.1051 in.
2.68 - 2.70 mm 0.1055 - 0.1063 in.
2.71 - 2.73 mm 0.1067 - 0.1075 in.
A-26 SERVICE SPECIFICATIONS - Rear Axle and Suspension
Rear axle shaft Part tightened kg-cm ft-Ib N·m
Bearing retainer x Backing plate 730 53 72
Differential Propeller shaft x Companion flange

2WD MIT 750 54 74
AIT 430 31 42
4WD 750 54 74
Drive pinion x Companion flange See page RA-1 0
Ring gear x Differential case 985 71 97
Side bearing cap x Differential carrier 800 58 78
Side bearing adjusting nut lock 130 9 13
Differential carrier x Axle housing 315 23 31
Suspension Shock absorber x Body 280 20 27

(4-Link type) Shock absorber x Rear axle housing (2WD) 375 27 37
Shock absorber x Lower control arm (4WD) 1,300 94 127
Lateral control rod x Rear axle housing 600 43 59
Lateral control rod x Body 1,125 81 110
Upper control arm x Rear axle housing 1,450 105 142
Upper control arm x Body 1,450 105 142
Lower control arm x Rear axle housing 1,450 105 142
Lower control arm x Body 1,450 105 142
Stabilizer bracket x Rear axle housing 375 27 37
Stabilizer link x Stabilizer bar 260 19 25
Suspension Shock absorber x Body 375 27 37

(Leaf spring Shock absorber x Spring seat 375 27 37
type) Leaf spring x Hanger pin 1,000 72 98
Leaf spring x Shackle pin 600 43 59
Leaf spring xU-bolt 1,250 90 123
SERVICE SPECIFICATIONS - Brake System A-27
BRAKE SYSTEM
Specifications
Brake pedal Pedal height (from asphalt sheet) 148 -158 mm 5.83 - 6.22 in.
Pedal freeplay 1- 3.5 mm 0.04 - 0.138 in.
Pedal reserve distance
at 50 kg (11 0.2Ib, 490 N) More than 60 mm (2.36 in.)
Brake booster Booster push rod to piston clearance

wi SST Omm o in.
Front brake Pad th ickness STD 10.0 mm 0.394 in.
Limit 2WD 1.0 mm 0.039 in.
4WD 3.0 mm 0.118in.
Disc thickness STD 2WD 20.0 mm 0.787 in.
4WD 25.0 mm 0.984 in.
Limit 2WD 19.0 mm 0.748 in.
4WD 24.0 mm 0.945 in.
Rear brake Drum inner diameter STD 254.0 mm 10.000 in.

Limit 256.0 mm 10.079 in.
Lining thickness STD 5.0 mm 0.197 in.
Shoe to parking brake shoe lever clearance 0-0.35 mm 0 - 0.0138 in.
Parking brake shoe lever shim thickness 0.2 mm 0.008 in.
0.3 mm 0.012 in.
004 mm 0.016 in.
0.5 rTIm 0.020 in.
0.6 mm 0.024 in.
0.9 mm 0.035 in.
Drum to shoe clearance 0.6 mm 0.024 in.
Parking brake Lever travel at 20 kg (44.1 Ib, 196 N)

YR22, 31, 32 series 7- 9 clicks
YR29 series 6- 8 clicks
A-28 SERVICE SPECIFICATIONS - Brake System

-~-~--
Bleeder plug
(on front cylinder and LSP & BV) 85 74 in.-Ib 8.3
(on rear wheel cylinder) 110 8 11
Master cylinder x Brake booster 130 9 13
Piston stopper bolt x Master cylinder 100 7 10
Master cylinder union bolt 550 40 54
Brake booster clevis lock nut 260 19 25
Brake booster x Pedal bracket 130 9 13
Disc brake cylinder x Torque plate 2WD 200 14 20
4WD 370 ± 50 27 ± 4 36 ± 5
Torque plate x Steering knuckle 2WD 1,060 77 104
4WD 850 ± 100 61 ± 7 83 ± 10
Rotor disc x Front axle hub 2WD 900 65 88
4WD 650 ± 100 47 ± 7 64 ± 10
Flexible hose x Brake cylinder 2WD 310 22 30
4WD 235 17 23
Brake tube union nut 155 11 15
Drum brake backing plate x Rear axle housing 670 48 66
Rear brake wheel cylinder x Backing plate 100 7 10
LSP & BV bracket x Frame 195 14 19
LSP & BV x LSP & BV bracket 130 9 13
LSP & BV spring x LSP & BV bracket 185 13 18
LSP & BV spring x Shackle No.1 185 13 18
LSP & BV shackle lock nut 250 18 25
LSP & BV shackle x Shackle bracket 130 9 13
LSP & BV shackle bracket x Rear axle housing 195 14 19
SERVICE SPECIFICATIONS - Steering A-29
STEERING
Specifications
Steering Steering wheel freeplay 30 mm (1.18 in.) or less
Tilt steering Collar No. 1 outer diameter 17.989 - 17.996 mm 0.7082 - 0.7085 in.
17.996 - 18.003 mm 0.7085 - 0.7088 in.
18.003 - 18.010 mm 0.7088 - 0.7091 in.
18.010 - 18.0 17 mm 0.7091 - 0.7093 in.
18.017 - 18.024 mm 0.7093 - 0.7096 in.
Collar NO.2 outer diameter 17.982 - 18.000 mm 0.7080 - 0.7087 in.
18.000 - 18.018 mm 0.7087 - 0.7094 in.
Tilt steering support shim thickness 0.2 mm 0.008 in.
0.5 mm 0.020 in.
0.8 mm 0.031 in.
1.4 mm 0.055 in.
1.8 mm 0.071 in.
Steering gear Steering rack runout Maximum 0.3 mm 0.0 12 in.

housing Total preload at Turning 5 - 13 kg-cm 4.3 - 11.3 in.-Ib 0.7 - 1.3 N'm
Power steering Drive belt tension

Nippondenso BTG-20 or
Borroughs gauge No. BT-33-73F
Maximum rise of oil level Below 5 mm (0.20 in.)
Oil pressure at Idle speed More than 75 kg/cm 2 (1,067 psi, 7,355 kPa)
Variation in vane pump discharge pressure Less than 5 kg/cm 2 (71 psi, 490 kPa)
(at 1,000 rpm and 3,000 rpm)
Steering effort at Steering wheel Less than 4 kg (8.8 Ib, 39 N)
Shaft to bushing clearance STD 0.010 - 0.030 mm 0.0004 - 0.0012 in.
Limit 0.07 mm 0.0028 in.
Vane plate Height STD 8.2 mm 0.323 in.
Thickness STD 1.8 mm 0.071 in.
Length STD 15.00 mm 0.5906 in.
Limit 14.97 mm 0.5894 in.
Rotor to cam ring difference Limit 0.06 mm 0.0024 in.
Vane plate to vane plate groove clearance
Limit 0.06 mm 0.0024 in.
Vane length
Rotor and cam ring mark None 14.996 - 14.998 mm 0.5904 - 0.5905 in.
1 14.994 - 14.996 mm 0.5903 - 0.5904 in.
2 14.992 - 14.994 mm 0.5902 - 0.5903 in.
3 14.990 - 14.992 mm 0.59016 - 0.59024 in.
4 14.988 - 14.990 mm 0.5901 - 0.5902 in.
Flow control valve spring length STD 50.0 mm 1.969 in.
Limit 47.0 mm 1.850 in.
Pump rotating torque Less than 2.8 kg-cm (2.4 in.-Ib, 0.3 N·m)
A-30 SERVICE SPECIFICATIONS - Steering

Power steering Steering rack runout Maximum 0.3 mm 0.012 in.
(cont'd) Total preload at Turning 9 - 13 kg-cm 7.8 - 11.3 in.-Ib 0.9 -1.3 N'm
Bevel gear No. 1 bevel gear preload at Turning 0.8 - 1.5 kg-cm 0.7 - 1.3 in.-Ib 0.08 - 0.15 N·m
housing Total preload at Turning 1.5 - 4.0 kg-cm 1.3 - 3.5 in.-Ib 0.15 - 0.39 N'm
Thrust washer thickness Mark
2 1.875 - 1.925 mm 0.0738 - 0.0758 in.
3 1.925 - 1.975 mm 0.0758 - 0.0778 in.
4 1.975 - 2.025 mm 0.0778 - 0.0797 in.
5 2.025 - 2.075 mm 0.0797 - 0.0817 in.
6 2.075 - 2.1 25 mm 0.0817 - 0.0837 in.
7 2.125 - 2.175 mm 0.0837 - 0.0856 in.
8 2.175 - 2.225 mm 0.0856 - 0.0876 in.
Tilt steering Part tightened kg-cm ft-Ib N·m
Pawl set bolt 195 14 19

Tilt lever retainer Bolt 195 14 19
Nut 225 16 22
Tilt steering support stopper bolt 110 8 11
Tilt lever x Tilt lever retainer 55 48 in.-Ib 5.4
Upper bracket x Tilt steering support 80 69 in.-Ib 7.9
Column tube x Column bracket 195 14 19
Main shaft x Intermediate shaft 250 18 25
Intermediate shaft x Bevel gear shaft 250 18 25
Column bracket x Body 260 19 25
Column tube x Body 330 24 32
Column hole cover x Body 195 14 19
Main shaft x Steering wheel 350 25 34
Steering gear Pinion bearing adjusting screw 250 18 25

housing Pinion bearing adjusting screw lock nut 1.150 83 113
I
Rack guide spring cap lock nut 700 51 69
Steering rack x Rack end 850 61 83
Gear housing x Body 770 56 76
Gear housing x Torque shaft 360 26 35
Tie rod x Knuckle arm 600 43 59
Tie rod end clamp 195 14 19
Power steering Pressure port union x Rear housing 700 51 69

i Front housing x Rear housing 470 34 46
Union x Rear housing 130 9 13
Air control valve x Rear housing 370 27 36
PS pump x Bracket 400 29 39
Pressure tube x PS pump 450 33 44
Pump pulley x Rotor shaft 440 32 43
Cylinder housing x Cylinder. end stopper 800 58 78
SERVICE SPECIFICATIONS - Steering A-31
Torque Specifications (Cont'd)
Power steering Part tightened kg-cm ft-Ib N·m

(cont'd)
Bearing guide nut x Control valve housing 250 18 25
Cylinder housing x Control valve housing 185 13 18
Rack guide spring cap lock nut 700 51 69
Steering rack x Rack end 1,050 76 103
Turn pressure tube x Control valve housing 250 18 25
Turn pressure tube x Cylinder housing 250 18 25
Gear housing x Body 770 56 76
Return and pressure line x Gear housing 450 33 44
Tie rod x Knuckle arm 2WD 600 43 59
4WD 930 67 91
Tie rod end clamp 195 14 19
Torque shaft x Pinion shaft 360 26 35
Bevel gear Plate x Bevel gear housing 80 69 in.-Ib 7.8

housing Adjusting bolt lock nut 100 7 10
Adjusting screw lock nut 1,100 80 108
Bevel gear housing x Housing cover 80 69 in.-Ib 7.8
Bevel gear housing bracket x Body 400 29 39
Bevel gear shaft x Torque shaft 360 26 35
Bevel gear shaft x Steering main shaft 250 18 25
A-32 SERVICE SPECIFICATIONS - Body
BODY
~------------
SEAT
Front Seat
Armrest x Seat back 375 27 37
Seat back x Seat cushion 400 29 39
Seat back x Seat reclining 375 27 37
Seat cushion x Seat reclining 375 27 37
Seat track x Seat cushion 185 13 18
Seat track x Body 375 27 37
Rear No. 1 Seat
(Standard Seat)
Seat track x Seat cushion 185 13 18
Seat track x Seat leg 375 27 37
Seat leg x Seat cushion lock 210 15 21
Seat cushion lock striker x Body 185 13 18
(Swivel Seat)
Seat turn table x Seat cushion 375 27 37
Seat leg x Sent turn table 375 27 37
Seat leg x Body 375 27 37
Rear NO.2 Seat
Seat back lock x Seat back 210 15 21
Seat back x Seat hinge 375 27 37
Seat cushion x Seat hinge 375 27 37
Seat cushion lock x Seat cushion 210 15 21
Seat cushion lock striker x Body 185 13 18
SEAT BELT
Front Seat
ELR x Body Lower side 440 32 43
Outer belt shoulder anchor x Body 440 32 43
Outer belt lower anchor x Body 440 32 43
Inner belt x Seat cushion Driver's side 440 32 43
Inner belt x Body Passenger's side 440 32 43
Rear No. 1 Seat Belt
(Standard Seat)
ALR x Body Lower side 440 32 43
Seat belt hook x Body 440 32 43
(Swivel Seat)
ALR x Seat cushion 440 32 43
Seat belt anchor x Seat cushion 440 32 43
Rear NO.2 Seat Belt
ALR x Seat cushion Lower side 440 32 43
Seat belt hook x Body 440 32 43
SERVICE SPECIFICATIONS - Lubricant A-33
LUBRICANT
Capacity
Item Classification
Liters US qts Imp. qts
1----- - - - - - - - - - - - - --~~---- e---
Engine oil API grade SF or SF/CC, multigrade,
Dry fill 4.2 4.4 3.7 fuse-efficient and recommended viscosity
Drain and refill oil
w/Oil filter change 3.5 3.7 3.1
wlo Oil filter change 3.0 3.2 2.6
~----~- - - - _ . _ - - I---~--------- --
Manual transmission oil API GL-4 or GL-5, SAE 75W-90

2WD 2.2 2.3 1.9
4WD 2.6 2.7 2.3
-------- - - - - - ----- --1----
Automatic tra nsm ission fl uid ATF DEXRON@ II

Dry fill 6.5 6.9 5.7
Drain and refill 2.5 2.6 2.2
- - - - - -- - -
Transfer oil 1.2 1.3 1.1 API GL-4 or GL-5, SAE 75W-90
--,,-~._---- -----_.-
Front differential oil 1.2 1.3 1.1 Hypoid gear oil API grade GL-5
Above -18°C (OOF) SAE90
Below -18°C (OOF) SAE80W
or 80W-90
-- ------
Rear differential oil 2WD 1.45 1.5 1.3 Hypoid gear oil API grade GL-5
4WD 1.85 2.0 1.6 Above -18°C (OOF) SAE90
Below -18°C (O°F) SAE80W
or 80W-90
-- ------- ~. -_.
Power steering fluid ATF DEXRON@ or DEXRON@II

Reservoir tank 350 cc 21.4 cu in.
Total 785 cc 48.0 cu in.
- - - - - f--.-
Steering gear housing grease Molybdenum disulphide lithium base,

-
NLGI No.2
-- - - - - - - ---------~
Ball joint grease Molybdenum disulphide lithium base,

-
NLGI No.1 or NO.2
1---- -~------ - - - - -f - - - - - - - - - - - - - -
Wheel bearing grease - Lithium base multipurpose, NLGI No.2

- - - - - - f-
Brake fluid - SAE J 1703, DOT3

B-1
STANDARD BOLT
TORQUE SPECIFICATIONS
Page
STANDARD BOLT TORQUE SPECIFICATIONS ..... B-2
B-2 STANDARD BOLT TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS

HOW TO DETERMINE BOLT STRENGTH
Mark Class
~-- Mark Class
------------
Hexagon Bolt 4- 4T Stud bolt
head bolt
~headNO.5- 5T ,-.. .------- Nom ark
6- 6T
~I
7- 7T ~
4T
0 No mark 4T
Hexagon
flange bolt
w/washer
hexagon bolt
Hexagon
0 No mark 4T
I~
I
-'(J'
~
~Grooved
6T
(])
head bolt Two
protruding 5T
lines
Hexagon Welded bolt

flange bolt
w/washer (!) Two
protruding
lines
6T
~
hexagon bolt
4T
Hexagon
0
head bolt Three
protruding 7T
lines
STANDARD BOLT TORQUE SPECIFICATIONS B-3
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
Class Diameter Pitch Hexagon head bolt Hexagon flange bolt
mm mm
kg-cm ft-Ib N'm kg-cm ft-Ib N'm
6 1 55 48 in.-Ib 5.4 60 52 in.-Ib 5.9
8 1.25 130 9 13 145 10 14
10 1.25 260 19 25 290 21 28

4T
I
12 1.25 480 35 47 540 39 53
14 1.5 760 55 75 850 61 83
16 1.5 1,150 83 113 -
6 1 65 56 in.-Ib 6.4 -
-
1
8 1.25 i 160 12 16
i
I
10 1.25 330 24 32 -
I
5T I
12 1.25 600 43 59 -
I
14 1.5 930 67 91 -
I 101 137 -
16 1.5 I 1 AOO
I 6 1 80 69 in.-Ib 7.8 90 78 in.-Ib 8.8

I
I
8 1.25 195 14 19 215 16 21
6T 10 1.25 400 29 39 440 32 43
12 1.25 730 53 72 810 59 79
14 1.5 - 1,250 90 123
6 1 110 8 11 120 9 12
8 1.25 260 19 25 I 290 21 28

I
10 1.25 530 38 52 590 43 58

7T
12 1.25 970 70 95 1,050 76 103
14 1.5 1,500 108 147 1,700 123 167
16 1.5 2,300 166 226 -

I
C-1
SST AND SSM

Page
SST (SPECIAL SERVICE TOOLS) C-2
SSM (SPECIAL SERVICE MATERIALS) C-18
..
C-2 SST AND SSM - SST (Special Service Tools)
SST (SPECIAL SERVICE TOOLS)

NOTE: Classification
A =
SST required for vehicle inspections and minor repairs and
multipurpose SST.
B = SST required for major repairs involving disassembly of
components.
C = SST required for rather special, less frequent work not of
classifiable as either A or B.
Section
Classification
.... .... LL
~
Part Name ~ ::::> ....en J: ....I a: « « a: a: 0
w u: ....I (J (J ~ « .... Q. LL a: co en co
Part No.
Illustration \
T 09032-00100 ( Oil Pan seal)
Cutter
A
•
~ 09201-41020 (valve Stem Oil)
Seal Replacer B
•
~ •
*1
•••
( Valve Guide BUShing) *1 *2
09201-60011 A
Remover & Replacer
~ •
( Valve Spring)
09202-43013 A
Compressor
~ 09213-27010 (Gear Removed B

•
~-I I
I
09213-31021 ( Crankshaft PUlley)
Puller A
•
~ !
!
I
I
09213-70010 ( Crankshaft PUlley)
Holding Tool A
•
t---------.- ~
~e I
~~
-
ieCl ( Camshaft Bearing )
r- - -~
- - - -- - - _ _
09215-00100
1_ - - - --
Remover & Replacer
Set "A"
f--------_
C
r-
•
~ (09215-00120) (Gate "A")
•
~ (09215-00130) (Bolt)
•
Remarks:
*1 Speedometer driven gear oil seal (2WD only)
*2 Speedometer driven gear oil seal
SST AND SSM - SST (Special Service Tools) C-3
SST (SPECIAL SERVICE TOOLS) (Cont'd)
Section
Classification
« «
\
Part Name ~ ::::> I- ::I: ...J l- I- LL. a: a: a: 0
w u: ...J en u u ~ « l- e.. a:
LL. m en m
Part No.
Illustration \
€B (09215-00140) (Nut)
•
(Do -1Ml (09215-00150) (Shaft "A")
•
~ (09215-00160) (Pin)
•
~ (09215-00210) (Remover & Replacer)
•
~ (09215-00250) (Remover & Replacer)
•
®~"·I~
~e~
bfifi
1-----------
~
09221-25022
-----;-
(Piston Pin
Remover & Replacer
--------
)
8
-
•
~ (09221-00020) (Body)
•
I (09221-00030) (Spring)
•
~ (09221-00040) (Bushing" A")
•
~ (09221-00071 ) (Guide "A")
•
fj (09221-00081 ) (Guide "B")
•
~ •
( Crankshaft Rear )
*1
09223-15010
Oil Seal Replacer
8
Remark:
*1 Planetary gear outer bearing
Section
Classification
.... .... LL
~
Part Name ~ ....CJ) :I: ..J a: <t <t a: a: 0
~ <t ....
::)
w u:: ..J U U Q. LL a: m CJ) m
Part No.
Illustration \
~ 09223-2201 0 ( Crankshaft Front)
Oil Seal Replacer
B
•
~
*1
09223-50010 ( Crankshaft Front)
Oil Seal Replacer
B
•
~ 09223-63010 (crankshaft Rear Oil)
Seal Replacer
B
•
~
*2
09228-22020 (Oil Filter Wrench) A
•
~ •
*3
09228-44011 (Oil Filter Wrench) A
~
"
I-- -
~
o~c:?
-
cc?_""
- -- -
®"'"
- -
c::::?
- - -
09236-00101 (water Pump overhaul)
Tool Set
------- --------
B
-
•
~ •
*4
(09237-00010) (water Pump Bearing)
Remover & Replacer
~
.:~
e- eo- e-" e:-".. "1;""
09268-41045 (Injection MeaSUring)
Tool Set
B
•
~'~
. :.. . ~ ~;y-
<:.~~
09268-45011 ( EFI Fuel pressure)
Gauge
A
•
~~
.. ~- ~~ 09270-71010 ( Rocker Arm support)
Tool Set
B
•
~ 09276-71010 (Valve Lifter Tool) B
•
~
(iy'i~;;.;~ 09285-7601 0 ( Injection Pump
. ~"J)I)))))j)j)JJI)/J.
Ca ms haft Bearing
Cone Replacer
C
•
Remarks:
*1 Front bearing retainer oil seal
*2 wlo oil cooler
*3 wi oil cooler
*4 Tilt steering main shaft lower bearing
Section
Classification
.... .... ....
~
Part Name ~ ::> .... ::J: ...I u.. a: « « a: a: 0
w u.. ...I en U U ~ « Q. u.. a: m en m
Part No.
Illustration \ \
~ 09286-46011 ('niochon Pump
Spline Shaft Puller
)
C
••
-
1cn11 J Y,ijjjjjjj 09301-20020 (Clutch Guide Tool) A
•
09303-35011
,nput Shaft Front)
( Bearing Puller A
•
Input Shaft Front)
( Bearing Replacer A
•
(Exte~sion HOUSing) *1
09307-30010
Bushmg Replacer
8
•
••• ••
*1
09308-00010 (Oil Seal Puller) A
••• ••
*1
09308-10010 (Oil Seal Puller) A •
09313-30021
Detent Ball PlUg)
( Socket A
•
Clutch Release )
09315-00010
(
Bearing Remover
& Replacer
A
•
Clutch Release )
09315-00021
(
Bearing Remover,
& Replacer '
A
•
• •
Transmission & )
09316-60010 ( Transfer Bearing , '
8
Replacer
f- - - - - - - - - - - - - - - - - - - - - - - - - I- -r--t-----t------ir---t---t---t----+--+---+--+---+-+--t--+---t
(09316-00010) (Replacer Pipe)
Remarks:
*1 2WD only
*2 Rear output shaft oil seal, oil pump body oil seal, driven sprocket and
extension housing oil seal
Section
Classification
~
Part Name ~
w u:: ...J
t- J:
::> (J)
U
...J
U
t-
~
t-
«
LL.
t-
a:
o.
~
LL.
«
a:
a: a: 0
co (J) co
Part No.
Illustration \
*1
@ (09316-00020) (Replacer "A")
• •
~ •
*2
(09316-00040) (Replacer "C")
@ (09316-00060) (Replacer "E")

•
*3
e
I
•
*4
(09316-00070) (Replacer "F")
f--
@},~ _IIII'!!!.! "

09325-20010 ( Transmission Oil)
Plug A
••••
*5 *6
~ • • ••
*7
( Companion Flange)
09330-00021 Holding Tool
A I
•
I
( Clutch DiaPhragm)
b;;;;;Zl 09333-00013 Spring Aligner
B
~ ~~
~ ~
~
'1/1",11111,
~o; r~-4J3
1---------
09350-20015
- - ~ - -
(TOYOTA Automatic )
Transmission Tool Set
f-------- -
B
•
~
(ManUal Valve Leve' )
(09361-30011 ) Shaft Oil Seal
Replacer •
~
~ (09362-30011) (Guide Bolt)
•
~ (09363-20010) ( Oil Pump BOdY)
Setting Band •
0!1
a~
~ (09369-20040)
(Piston Spring
Compressor Set.
)
•
Remarks:
* 1 Rear output shaft oil seal and extension housing oil seal
*2 Oil pump body oil seal (A/T)
*3 Oil pump body oil seal (MIT)
*4 Driven sprocket
*5 2WD only
*6 Front output shaft oil seal
*7 4WD only
Section
Classification
~
Part Name ~
w LL.
::::>
...J
~
en
::I:
U
...J
U
~
~
~
«
LL.
~
a:
Q.
« «
LL. a:
a: a: 0
m en m
Part No.
Illustration \ \
~ •
(Clutch Drum Thrust)
(09370-12010) Play Gauge
~ (09388-20010) (Oil Seal Replacer)

•
~
=
~ (09397-22020) (one-way Clutch Test)
Tool Set
•
~
(D;fferentia'S;de )
--------------
-
09504-00011 Bearing Adjusting
Nut Wrench
B
•
~
( D;fferent;a' S;de ) *1
09504-22011 Washer Remover &
Replacer ,
B
•
~ • ••
(D;ffe,.nt;a, Dr;ve ) *2 *1
09506-30012 Pinion Bearing B
Cone Replacer
~
(D;fferent;a, Dr;ve ~
•
*3
09506-35010 Pinion Rear Bearing B
Replacer
Gf$~ 09515-21010 (Rear Axle Shaft )

Bearing Replacer
B
•
()JtJiii 09517-30010 ( Rear Axle Shaft )
Oil Seal Replacer
B
•
JJII '
09520-00031 (Rear Axle Shaft )
Puller
A
•
~ ~
*4
09527-20011 (Rear Axle Shaft )
Bearing Remover
B
•
~ 09527-21011 (Rear Axle Shaft )
Bearing Remover
B
•
Remarks:
*1 4WD only
*2 Front output shaft rear bearing, front output shaft front bearing and
rear output shaft bearing
*3 Input shaft bearing, No.2 hub sleeve assembly and 5th gear
*4 Tilt steering main shaft lower bearing
Section
Classification
« «
\
Part Name :!: ::> ~ J: ...I ~ ~ u.. a: a: a: 0
w u:: ...I en u u :!: « ~ 0- u.. a: a:l en a:l
Part No.
Illustration \
~~®~
~ ~~~~
09550-10012 B
• •
--
C ~ ~~ @tl (Replacer Set "B")
I
-------- -- -- ------- -
VJr·~ ~
J:~';;~Jii'; (09252-10010) (No.1 Replacer Handle)
• •
•
(Differential Drive ) *1
@ (09557-10010) Pinion Front Bearing.
Replacer
•
~ •
( Rear Axle Shaft Oil)
(09558-10010) Seal Replacer
~
~~
~
.@ 09550-22011
.Rear Axle Bearing)
( & Differential Tool
Set
B
•
1 - - - - - - - - - -1 - - - - - - ------- -
~
*2
(09550-00020) (Handle)
•
*2
~ (09550-00031 ) (Replaced
•
~
*2
•
. ~~
(Differential Oil)
;'// .
09554-22010 Seal Replacer
A
~
*3
09554-30011 (Differential Oil)
Seal Replacer
A
• •
~
(Differential DriVe)
•
*3
09555-55010 Pinion Bearing B
Replacer
~
*2
09556-22010
(Drive Pinion Front)
Bearing Remover
B
••
~oo-~
-- .
~~ -~
0-"""'":
09557-22022 ( Companion Flange )
.Remover & Replacer
A
*2
••
Remarks:
*1 Planetary gear inner bearing
*2 4WD only
*3 Planetary gear outer bearing
Section
Classification
Part Name ~ ::::> ....U) J: ...I .... .... u. a: « « a: a: 0
w u: ...I () () ~ « .... Q. u. a: co U) co
Part No.
Illustration \ \
a 09607-60020
cmntWheel
Adjusting Nut
Wrench
)
A
•
*1
>:"
E9
~ , ~
09608-10010
( Steering Knuckle Oil )
Seal Replacer
B
•
.... ~~~
'----=-..=-------
~~ ~
~
"
~
09608-1201 0
1 - - - - - - - - - - - -f - - - - - - - 1 - - - - -
(' Front Hub & DriVe)
Pinion Bearing
Replacer Set
- I---
B
•
~
*2
•
(Remover & RePlacer)
(09608-00020)
Handle
*2
@ (09608-00050)
(DriVe Pinion Front
Bearing Cup Replacer
)
•
0 09608-28010
(Front Hub & Bearing)
Replacer
B
*1
•
Front Hub & \
c---~000
~--r~,g~
__ c__ ~
I-- _ _ _ _ _ _ _ _._
~~'
-
09608-30012
---
( Drive Pinion Bearing)
Tool Set
f------- -
B
•• • *3
~
*1
(09608-00060) (Replacer)
•
~
*1
(09608-04020) (Handle)
•• •
~g?J
*1
(09608-04100) (Drive Pinion Front
)
••
~ •
(Drive Pinion Rear )
(09608-04110)
~~ ~.- -<= ~~
I
I
09608-30022 (Front Hub Bearing)
Replacer Set
B
•
Remarks:
*1 4WD only
*2 Counter gear rear bearing
*3 PS pump shaft oil seal
Section
~
Classification
Part Name :2
w u:: ::>
...J
~
V)
:I:
U
...J
u :2
~ ~
«
u. a::
~
« «
c. u. a::
a:: a::
a:1 V)
0
a:1
Part No.
Illustration \
I
•
*1
~
I
(09550-00050) (Replacer)
*1
~ (09608-050 Hl) (Handle)

•
*1
@ (09608-05040) (Replacer)
•
E6~g. (~(';lQ~0
(AXle Hub &
~ Qe
I--~--------
09608-35014
------
. Drive Pinion Bearing )
Tool Set
------ - -
B
-
•
~
*2
(09608-06020) (Handle)
•
! Front Hub Outer & *2
@ (09608-06090) \ Steering Worm
Bearing Replacer
)
•
*2
~ •
( Drive Pinion Rear )
(09608-06180)
Bearing Cup Replacer,
@ (09608-06200) ( Rear Axle Bearing)

Replacer
*2
•
~ •
( Steering Wheel) A
09609-20011 Puller
-~ - - . __ . ~ - .
~ • •
*3 *4
09610-20012 (Pitman Arm Puller) A
•
~
Rack & Pinion .
09612-00012 ( Steering Rack )
Housing Stand
B
•
~c~~~=F'~~
~ ~.~-~
..
OQ~~
09612-10093 (Steering Gear HOUSing)
Overhaul Tool Set
B
•
Remarks:
*1 2WD only
*2 4WD only
*3 Oil pump
*4 Tie rod end
Section
~
Classification
Part Name ~
w u:: ::J
...J
t-
en
:I:
(,)
...J
(,)
t-
~
t-
«
LL
t-
a:
o.
« «
LL a:
a: a: 0
cc en cc
Part No.
Illustration \
*1
~ (09612-10050) ( Steering Rack Shaft )

Bushing Replacer
•
(Steering Pinion ) *2
~ "'))hi~lIiil/l11l1111
(09612-10061 )
Bearing Replacer.
•
Steering Pinion
I JiI~IWJl!W)!~w. (09616-10010) i Bearing Adjusting
Socket •
. Steering Pinion ) *3
~ (09616-10020) ( Bearing Adjusting
Screw Wrench •
~
( Steering Pinion Bear-) *4
(09617-10010) ing Adjusting Screw
Lock Nut Wrench •
~
*5
(09628-10020)
.----~._~
( Ball Joint Lock Nut)
Wrench
•
~ •
(Tilt Handle Bearing)
09612-22011 Replacer
B
~,:",-:.:J ll1J.
•
..... ~::a""i7'
.". ( Steering Gear HOUSing) B
-
_ ..... ~ ~~ 09612-24013
"~ --- ~ 0 Overhaul Tool Set
C-v==
.... ..
~~~
,
---------
y))))))))))l
~.----
(09612-10022)
- - - -
(Hexagon Wrench)
- - '-
•
~»)ljliJ/llilill/liJliill/lll
(09612-10061 ) (Steering Pinion )
Bearing Replacer
•
*6
~~ (09613-22011 ) (Steering Rack Shaft )

Bushing Puller
•
! Steering Pinion,
1)))~iiJJJ)JI!;JJ (09616-10010) ( Bearing Adjusting)

Socket •
Remarks:
*1 Pinion oil seal and bevel gear oil seal
*2 Bevel gear bearing
*3 Bevel gear bearing adjusting screw
*4 Bevel gear bearing adjusting screw lock nut
*5 Pinion bearing adjusting screw
*6 Steering rack end guide
Section
~
Classification
Part Name :E cr: ::;) ....en J: ......I .... .... LL a:: « « a:: a:: 0
Part No.
w ......I U u :E « .... c. LL a:: m en m
Illustration \
~ (09617-24010) (Steering Rack Wrench)
•
( St••,;ng P;n;on B.,,· )
~ •
*1
(09617-24020) \ ing Adjusting Screw
Lock Nut Wrench
~ (09617-24030) (Steering Rack End)

Wrench
•
([I) 09616-00010
Steering Worm )
( Bearing Adjusting.
Socket
B
•
~ ee~
~e
---------- -
09620-3001 0
-- --
(Steering Gear BOX)
Replacer Set
---------1-
B
•
~
~
( Steedng Wo'm
•
*1
(09623-30010) Bearing & Oil Seal
. Replacer
eat (09624-3001 0) ( Steering Sector Shaft)

Oil Seal Replacer
*2
•
~
*2
(09631-00020) (Handle)
•
~~3 09628-62011 (Ball Joint Pulled A
•
---~ GAO Power Steering Gear)
~ ~ ~ g 09630-00011
~~~EJ~~
( Housing Overhaul
Tool S e t '
~---------~-----~--------~
B
•
~ (09631-00080) (Replacer "B")
•
~@j@~(~r-.
~o~~eA~
'_.- u
'---'~
~
09630-240 13 (Steering Rack Oil)
Seal Tool Set
B
•
Remarks:
*1 Rack guide spring cap lock nut
*2 Tilt steering main shaft upper bearing
Section I I
I I
I
Classification I
... ... «... ... « «
\
Part Name ~ ::> ::I: ...J LL. a: a: a: 0
w u::: ...J en u u ~ a- LL. a: l:Q en l:Q
\
Part No.
I
Illustration \ I
!
I !
EJ •
I
( Valve Cap Oil Seal)
I (09620-24010)
Remover /
*1
@ (09620-24020) ( Valve Cap Oil Seal )
Replacer
•
@ (09620-24030) (ValVe Cap Bearing)
, Replacer
•
@ (09631-24070) (Oil Seal Replacer) B I
•
I
I I
{:-
f---------.
) I 09631-12020 (Handle) B
•
d~
..
<~
109631-12070
,
,
(Steering Rack Oil)
Seal Test Tool
B
•
~
i
•
I
I 09631-20040 (Oil Seal "B" Replacer) B

I
C
,
09631-20060 (Bearing Guide Nut)

Wrench
B
•
QJ I
09631-20070 (Seal Ring Guide) B
•
~
I
•
I
1 09631-20081 (Seal Ring Tool) B

I
I,
I
~
*2
'I
09631-20110
( Steering Rack" F" )
Cover
I
I B I •
~I 09631-20111
Steering Rack
Cover "G"
B
*3
•
Remarks:
* 1 Bearing guide nut oil seal
* 2 2WD only
*3 4WD only
Section
I
Classification
- -
.... .... .... u.. «

c.. «
\
Part Name ~ ::;) ::I: ...J ~ ~ ~ 0
w u::: ...J en U U ~ « .... u.. ~ m en m
Part No.
\-~-\
Illustration
~
I
-- ~~----~--
09631-20120 I(
fNutW,ench
Cylinder End Stopper) 8
•
~
. Power Steering
1------ --~ --------.-

09631-22020
- ---
I(Hose Nut 14 , 17 )
Wrench
- ------ --- ---~
A • •
~
e - - - - - - - _________ ._~
09633-00020
_____ ~ ~~_
I(~owe, Stee,;ng Hose)
Nut Wrench
_____________
A
- ---
•
~
_
1 - - - - -- - - - - - - - - - - - - - - -
09703-30010 I (B,ake Shoe Retum )
1----_______ _
Spring Tool
_ _ _ _ ______ _
A
••
~ ~ 09709_2901~L:~V I Gauge Setl C
•
--~<:::<:
. - - . I
~~-~-~--t---
'J:'=J 09710-14012 (Rea, suspenSion)
~ '!j ~ ~
-- - - - - - - -
I
---- - -
BUShing Tool Set
~ ------ - - - f-
8
•
*1
@ (09710-00010) (Replacer)
i
•
~ •
*1
(09710-00020) (Pipe)
~
*1
(09710-00050) (Handle)
•
~ C("~~
•
Front Suspension )
c:= ~~~ ::S
09710-22020 Bushing Tool Set
8
1------ --- f--- _ _ _ _
- -- - - - -
•
*2
( Upper Arm BUShing)
~------------
e:J (09710-01030)
1-----
Replacer
--------+-
~B©G •
I
I (hont Suspens;on)
09710-28020 Bushing Tool Set
8 I I
i
i 1
i
! I I I
I
Remarks-
*1 4-link type rear suspension
*2 Front differential side bearing (4WD only)
I
Section I
Classification i
Part Name l- a: « « a: a: 0
~
I- J: ...J I- LL.
'I • Li:1 3 en u u ::E « I- Q. LL. a: cc en cc
Part No.
\
\\
I,
Illustration -~'\
I
\ i
*1
® (09710-08020)! (Bushing Removerl I,
I
•
8 •
*1
(09710-08030) (Base)
§ •
'I
*1
(09710-08040) (Bushing Replacer) I
i
I
i
~~P'~'_-_') tf: ~~~<CD

•
I
( Suspension )
09710-30020 8
i
~- -pt ~ ~. ,~,---,
~~.==F- ~ ~ ® t5=J ~
i
Bushing Tool Set.
I
f--- - - - - - - -- - - - - - - - - - - - - - -
!
•
! *2
(jfIJf!lI!JDJ (09710-03020) (Handle) I
*2
•
Front Suspension
EJ (09710-03070) ! Lower Arm Bushing

Remover
i
( Re" Sospension ) *2
L:J (09710-03120) Upper & Lower Arm

Bushing Removing
Base I
•
*2
tj (09710-03130)
( Lateral Rod BUShing)
Remover
:
•
~
r
•
Front Lower Arm
~~'a~ 09726-27011 Bushing Remover B I
13 ~ (9 ~~
I,
i
& Replacer i
!
'- - --~----- -----+--------- f--
~ •
*3
(09726-02020) (Remover)
g (09726-02030) (No.1 Base)

*3
•
~ •
I *3
I
(09726-02040) i IReplace" I
Remarks
*1 4WD only
*2 4-link type rear suspension
*3 2WD only
Section
~
Classification
Part Name ~ :::::> ~ J: ...J ~ ~ LL ex: <t <t ex: ex: 0
w L!: ...J tJ) U U ~ <t ~ Q. LL ex: CQ tJ) CQ
Part No.
\ \
i·
Illustration
*1
~ (09726-02050) IRemove' & Replace" I
I
I
1
I
I
I I
1
C?3 (09726-02060) (No.2 Base)

*1
•
((J (09726-02070) (No.3 Base)
•
*1
a:DJi18'. ;1£7f'f®
*1
(09726-02090) (Handle)
•
~ 09737-00010 (Brake Booster
Push Rod Gauge
) A
•
/ I
09751-36011 (Brake Tube Union
Nut 10 x 12 Wrench
) A
• ••
~ ' . 09806-30010 (Windshield MOUlding)
Remover
C
•
~
•
i (Door Hinge Set )
~- 09812-00010 C
Bolt Wrench
~ 09820-00021 ( Alternator Rear)

Bearing Puller 8
•
00 09820-63010 (Alternator Pulley set)
Nut Wrench
8
•
c!D~
I
09842-14010 ('d'e Adjusting )

Wiring Harness A
•
a 09842-30020 (Wiring :'C"
Inspection
EFI ) 8
•
Remark:
*1 2WD only
SST AND SSM - SST (Spedal Service Tools) C-17
Section
~
Classification
Part Name ~
w u:: :::>
...J
...en ::I:
U
...J
U
... ... ...u.
~ ~
a::
~
~ ~
u. a::
a:: a:: 0
m en m
Part No.
Illustration \
~
I
:'A" EFI)
I
09842-30050 (Wiring
Inspection
B
•
~
*2
•••
*1 *1
09921-0001 0 (Spring Tension Tool) A
~
C'~~J'"
~,
C
.............. 09950-00020 (Bearing Remover) B
• • ••
c-.~~~
•
*3
~~o~'J
~=s-~.~:
c-->,~ -.J~
09950-20017 (Universal Puller) A
• ••
~I
.~--~~
•
(Oil Pressure Gauge)
09992-00093 Set A
~T.::::!D~~j
Remarks:
*1 Speedometer driven gear oil seal (2WD only)
*2 Speedometer driven gear oil seal
*3 4WD only
C-18 SST AND SSM - SSM (Special Service Materials)
SSM (SPECIAL SERVICE MATERIALS)

Part Name Part No. Sec. Use etc.
Seal packing or equivalent 08826-00080 LU Engine oil pan
Transfer rear case

TF Extension housing
Seal packing 1281, Oil pump body
08826-00090
Three bond 1281 or equivalent
FA Differential carrier cover
RA Rear axle shaft gaskets
Adhesive 1324,
08833-00070 SR Upper bracket
Three bond 1324 or equivalent
Straight screw plug for shift fork shaft

locking ball
Front bearing retainer set bolt
Shift lever shaft housing set bolt (Ex.
MT two black bolts)
Transfer adaptor set bolt (Three adaptor
inner bolts) (4WD only)
Transfer mount bolt (Two front bolts)
(4WD only)
Oil pump installation bolt

Extension housing installation bolt
AT (one bolt, 2WD)
Transfer adaptor installation bolt (one
bolt, 4WD)
Adhesive 1344, Straight screw plug for oil pump body

Three bond 1344, 08833-00080 Straight screw plug for high and low
Loctite 242 or equivalent shift fork shaft locking ball
Straight screw plug for front drive shift
TF
fork shaft locking ball
Extension housing set bolt
Oil pump body set bolt
Transfer x Transmission bolts
Pinion hearing adjusting screw

Pinion bearing adjusting screw lock
nut
Rack guide spring cap
Rack guide spring cap lock nut
SR
Cylinder end stopper
Bevel gear housing cover
Bevel gear bearing adjusting screw
Bevel gear bearing adjusting screw
lock nut
Dupont paste No. 4817 - BE Rear window defogger wire
Super adhesive 08850-00051 BO Side body moulding

SST AND SSM - SSM (Special Service Materials) C-19
SSM (SPECIAL SERVICE MATERIALS) (Cont'd)

Part Name Part No. Sec. Use etc.
}-------------- ------------------- --~---------~- --- - - - - - - - - - - - - - - - - ---------~---------------j
Windshield glass
Windshield glass adhesive set No. 15 08850-00070 80 Rear window glass
(0 - 15°C or 32 - 59°F)
I-- -------- - ---------- -t--
Windshield glass
Windshield glass adhesive set No. 35 08850-00080 80 Rear window glass
(15 - 35°C or 59 - 95°F)
---- - - - + - - - - - - - - - - - - - - - - - - - - - j
Windshield glass
Windshield glass adhesive set No. 45 08850-00090 BO Rear window glass
(35 - 45°C or 95 - 113°F)
f------- ---------- - - ------------- - - - ~ - - - - ~ - -- ---j-----r-----------------------j
Windsh ield glass

Dam kit 04562-30040 BO
Rear window glass
- ----- -- ---- -- ---- - --- -- -- - --- ------- --------~-----------------------------~--
Windshield glass
Three cement black 08833-00030 80
Back door window glass
0-1
AUTO'MATIC
TRANSMISSION
HYDRAULIC CIRCUIT
Page
A45DL, A45DF HYDRAULIC CIRCUIT 0-2
CI
N
"p" RANGE CIRCUIT
Ovt'rdr Ive Clutch From Clutch No Brake No.3 Brake Governor Valve
Line Pressure
Overdrive Bratte Aear Clutch No 2 Brake
I Detent Regulator Pressure
Lock up 2 Low Cost Modulator Pressure
CIUICh
• Throt11e Pressure
TOIQue
o Torque Converter Pressure and Lubrication
Convpr let
Throttl
Valve
DampIng
Check
Strainer
Valve
"R" RANGE CIRCUIT
Overdrive Clutch Front Clu,ch No Brake No.3 Brake Governor Valve
• LIne Pressure
Lock up
Overdrive Brake Rear CIU1Ch No 2 Brake
o I Detent Regulator Pressure
2 Low Coast Modulator Pressure
Clutch
_ Throttle Pressure
Torque
o Torque Converter Pressure and LubricatIon
Convpr tet
DOMainS W
Damping
Check
Valve
CI
W
o
"N" RANGE CIRCUIT
~
Overdrive Clutch F font Clutch No 1 Brake No.3 Brake Governor Valve
Ove,drove Bra.e Rear Clutch No 2 Brake I I • Line Pressure
Lock up . . . .;-----.j---J--~ LJ Detent Regulator Pressure

Clutch -
• Throttle Pressure
~ I 0 Torque Converter Pressure and Lubrtcalton
TOIQut·
ConVf"Il"
r -> =1II=r------.. 1
00 Main S/W
Low Coa,
/fI'ifflv;-...ll.lJ!.J-,.j.J Modu lato
Valve
Governor Intermediate
Modulator ShIft Valve
Plug
Detent
DampIng Regulator 34 ShIft
Check Valve Valve
---J Valve Strainer 1 2 ShIft
Valve
"0" RANGE
FIRST GEAR CIRCUIT
Overdrive Clutch F font Clutch No Brake No.3 Brake Governor Valve
• Line Pressure
Lockup
Clutch
I I
. ,
Overdrive Brake Rear Clutch No 2 Brake
o Detent Regulator Pressure
• Governor Pressure
Torque
Converter o Cut Back Pressure
o Torque Converter Pressure and lubrication
~ Reverse
. &A Brake
Sequence
Plug
Stramer 12 ShIft
Valve
.
c
U1
CI
"0" RANGE O'l
SECOND GEAR CIRCUIT
Overdrive Clutch Front Clutch No 1 Brake No.3 Brake Governor Valve
_ Line Pressure
Lock up
Clutch
Torque
Conver lef o Cut Back Pressure

"0" RANGE
THIRD GEAR CIRCUIT
Overdrive Clutch Front Clutch No No.3 B,ake (0/0 Main S/W OFF)
Overdrive Brake I Rea, Clutch

11 Brak:
o 2 Brake I "'' 00'1 ",.. LIne Pressure
Lock-up
Clutch I Detent Regulator Pressure
Governor Pressure
~.
TorQue Throttle Pressure
Con vel tel
Cut Back Pressure
Torque Converter Pressure and Lubrication
CI
"
CI
"0" RANGE 00
THIRD GEAR CIRCUIT
(OlD Main S/W ON)
Overdr Ive Clutch Front Clutch No Brake No J Brake Governor Valve
• Line Pressure
Lock up
Clutch
I
•
I !IU~
,.,,~
Overdllve Bra~e Rear CIU1Ch No 2 Brake
Torque
Converter o Cut Back Pressure

"0" RANGE
DID GEAR CIRCUIT
LOCK-UP OFF
Overdr Ive Clutch Front CIUICh No 1 Brake No 3 Brake Governor Valve
• Line Pressure
Lock up
Clutch
OVetd,lve Brake Real Clutch No 2 Brake
Torque
COflV('IIt'1 o Cut Back Pressure
D 2 Down
TIming Valve
o
I
CD
"0" RANGE ...oC
I
0/0 GEAR CIRCUIT

LOCK-UP ON
Ove,d,lve Clutch No Brake No.3 Blake Govemor Valve
• L,ne Pressure
Lock up
Clutch
Overdllve Brake Rea' Clutch No 2 Brake
Torque
Conyer te, o Cut Back Pressure
o Torque Converter Pressure and LubricatIon
fLo""~ 00 MaIO 5 W
11
Damping
Check
Valve
"0" RANGE
KICK DOWN (00-3) CIRCUIT
OverdrIve Clutch Front Clutch No B'ake No 3 B'ake Governor Valve
Lock up
OverdrIve Brake I Rea, C,ulch No 2 i,ake I •
o
line Pressure
Detent Regulator Pressure
Clutch
Torque
o Cut Back Pressure
o
Conv('1 tfl
Torque Converter Pressure and lubricatIon
00 Main S/W
o
o
~
~
c,
~
"2" RANGE N
SECOND GEAR CIRCUIT
Overdr Ive Clutch Front Clutch No Brake No.3 Brake
Go~,"O'1 "'~ • Line Pressure
Overd1lve Brake Rear Clutch No 2 Brake
I Detent Regulator Pressure
Lock up O 2 Intermediate Modulator Pressure
Clutch
TOfQue
Conver tl'I o Cut Back Pressure
- Torque Converter Pressure and Lubrication
DampIng
Check
Valve
"l" RANGE CIRCUIT
Overdrive Clutch Front Clutch No Brake No.3 Brake Governor Valve
• Line Pressure
Overdrive Brake Rear Clutch No 2 Brake 1 Detent Regulator Pressure
Lock·up
Clutch ! !! !!!'QD)
O 2 Intermediate Modulator Pressure
3 Low Coast Modulator Pressure
Torque
o
Converter
Cut Back Pressure

OD Main S/W
Sol enOl d _
Damping
Check
Valve
...o,
W
E-1
ELECTRICAL WIRING
DIAGRAMS
HOW TO READ THIS SECTION

JUNCTION BLOCK OR RELAY BLOCK
Wire Color Block No. Wire Color
I
R-G
I
2 R
I
( >
Block Inside
WIRE COLOR
Wire colors are indicated by an alphabetical code.
B= Black L= Light Blue R= Red
BR= Brown LG= Light Green V= Violet
G= Green 0= Orange W= White
GR= Gray P= Pink Y= Yellow
The 1st letter indicates the basic wire color and the 2nd indicates the stripe color.
Example: R-G indicates a Red wire with a Green stripe.
ABBREVIATION
wi =
wlo =
2WD =
4WD =
..
SYSTEM INDEX
VAN 1987 Model (Page 1 to Page 5)
SYSTEMS LOCATION SYSTEMS LOCATION
~ ~
Air Conditioner, Cooler Radio and Tape Player 3-6
4-3,5-4
and Heater
J,~R
Back-up Lights
~
1-8 Rear Window Defogger
~ 2-5
Charging
4lI 1-5 Rear Wiper and Washer
~ 2-7
Cigarette Lighter
~ 3-8 Remote Control Mirrors
~ 3-7
Clock
~ 3-6 Starting
6 1-1
Combination Meter
~ 1-6 Stop Lights
t: 2-5
Cru ise Control

~ 2-4 Sun Roof
~ 2-1
Door Locks
~ 2-2 Taillights and Illumination
~ 3-1
4.
EFI I[gGSo~ 1-3 Turn Signal and Hazard ~~ ~~
..
2-6
Qi ~
Unlock
Fog Lights 4-5 3-3
and Seat Belt Warning
~r\
Front Wiper and Washer
~ 2-8 4WD
...... 4-6
Headlights
~ 3-2
Horn
~ 2-7
Ignition
~ 1-4
Interior Lights
~ 3-4
Overdrive
m 1-8,4-8
Power Sou rce

~ 1-1
Power Windows
~ 2-2
2 VAN (Cont'd) •
~ Sun Roof /11, Power Windows
~ Door Locks
1 2 3
C
D-~
E
F--
G
G
~
E
20A
PWR
CB
;:g
::l
U.
g~
« ~.w
-----~~--- . ~
'"
~. W-R
~ To 4WD Control Compuier (4-7)
P
E
e
u..
W-R
a::l
~ 1 POWER MAIN
RELAY
r----
I I I ~
3: ~
tIl
•
L
0
a:
1-)-
z«
" ~
0
a:
I-
~I
O~
Uw
wa: )- )- 0
z
0
u~
f\
SUN ROOF S/W POWER WINDOW MASTER s/w ~ I DOOR LOCK CONTROL S/W
-,
~z
:::>-
a: « tIl
cD
" " ~(/)
bm I
U~ ~ 3~ '-
a: I-
UCfl
~!T\1 Cl.
1 1 z Cl.
1z ~
1
~
~l ~
tIl
...J
I~
:::> ~ :::> ~ ~ tn
o ~ 0 Cfl
...J
() I W-B
0
0 0
W-B W-B I g ; z
«
~
0
a:
I-
~ Z
(])
~ 0
U
~
0
..J a: w
>- a: a: ~ I- B-Y Cfl
..J ..J z
0 :::>
l-R U a: -'-
M
L-B
w
U - '-
~
40J-
SUN ROOF
FRONT LH :::>
a:
U
...
~
r
MOTOR
If
tn a:
"'~~
l-R
~
0
I ..---...
0
Z Cl.
C\
z FRONTRH ~
O~0
~ :::>0 U
a: 0
w ...J
~ a:
0 Q) 0
a.
"~O
L-R
Cl.
-- >-
I- M 0
OJ
OJ
a. :;; SLIDE
a: >- Cl.
a:1 ~I
..J ~ l-
e:
OJ
E
4E£-J L0-
a:
E ~ L-R
~ L-B
~ ..::
"-'
~I
a::l co POWER WINDOW MOTOR tIl co
BACK
3: ~ ~ ~ tIl tIl
~ ~
~f 1 I t=t=f I 1 ~
.
Ground points a = located on cowl left b = Located on wiper bracket set bolt C = Located on cowl right f = Located on left rear fender
I I ------ I
i:4oSET~~
Cruise Control '~ St()p Light, Rear ~ogger ~ Turn Signal and Hazard
1 4 I 5 I 6 Ii
>-
.,j
a:
01 I ~ ~I 0 To Radio & Tape Player (3-G)
~H
RIGHT
CRUISE CONTROL COMPUTER
1 I \1J 111 1
TURN OFF
co -l To Light Contrll
a: LEFT
~I co ~ ci: (3-2)
a: OFF
(AfT) 0 HAZARD
ON
] ~f1
STOP
01
co >- G
a:
"-l >- co ~
~
ci: > -l
0
co
~
~ LIGHT
~
6 0 0 From "TAIL" Fuse (3-1)
• I
~
" s/w ci:
I I
G·Y G-Y
Gl
s: >- CORNERING
0 ci: G-W G-B G-B LIGHT RELAY
6t
I
~'~
-=
C}{J U LJ:J I
1-- Cl? TURN SIGNAL
Z~
0--
UUl
~
Ul
I I r I ~ FLASHER
I I 0\ a:
0
wI
I I UlU
-I-
:::>:::>
til'"
0~
a: -l co
UU ~
Ul
INDJCATER LH INDICATOR RH I-
teOMB. METER) I
(COMB. METER)
S?
~I
CRU ISE CONTROL ACTUATOR
:" >-1
II W-B G-B G-Y W-S
LH
-l
{,7
~
CXl a:
w
-l FRONT LH FRONT RH ~ Z
0 G-Y a::
" ro
~
;;riD
=~ j:: I I G-B W-B 0
U
ro I co
~ e~ a:i ~ S? ~ ~
- Ow 0 REAR RH
I
Ul REAR LH
~~ 0
::> ::>
OJ
~
~
a. a.
EE
Ull-
ZW
~~
" ICXl
Oa:
Zw
-" I I W-S t:::::\ G-B I G-Y C\ W-S
as'" Ul
ci
a a
UU
oa:i
LH
,,~
-0
RH
~"
en
c E u:~ w~
-lu a:o
<tLL
~
~ we
E
wo
c..u &0:: CXl WW
a:: I I I TURN SIGNAL LIGHTS
c..'" OJ
a
aU
Ul_
tiES ~ OJ
0
a U:O
I- ~ ~
a '1"
l-
E
a
u: I I I I OJ
~
~
~I ~I ~I ~I
Back Door Right
~I ~I ~l
co
~I ~I ~I ~I
CXl
~
I , I I
~ Horn
~ Rear Wiper and Washer ~ Front Wiper and Washer
7 8
-J=:=======~~~=====~~ ,
E
F
G
....J ....J ....J >-

...J
WASHER WASHER
CHANGE RELAY
VALVE
" S/W ~ CD
...J ?;
....J
REAR WIPER WIPER AND WASHER S/W ~

....J ....J (COMB. S/W) ...J
0: AND WASHER S/W
o S I +1 B E B
OFF
INT
LOW
HIGH
HORN S/W
91
....J
ll?
....J
>-
...J
CD
~
WASHER
CD CD
INTERMITTENT TIME S/W ...J ~I ~ ~

ICOMB. S/W)
~
RH
W-L
>- L-R
«
....J
w
a:
a:
w
0-
~I ~I
0
...J
L -.L. I I I L
CD CD
CD
?; ?;
?;
----------1 1 E~
VAN ELECTRICAL WIRING DIAGRAM-1987 Model (Page 1 to Page 5)
~ Power Sou rce

6 ~~[pU~
EFI
2 3
A
B
c
D
E
c;J
~I c;J
W-G
B
a:
...J
W-R
sl ~I a: ~
c;J a:
~
I To/'MAGNET CLUTCH"
(4-3)
a: '" B-R S B-R

m I
B-R
0
.....,
l~
~~~
i<! ~ a:
UJ
...J
I
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tI)
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en s S
u. u. u. 0:
<! <! <! WATER r-B"ATT
<!
g ~ 0
to
l-
(J)
THERMO SENSOR
...J
<!
a:l EFI MAIN RELAY BR I .... a .. I G
THW
a:
en
LD
W
t-~
53 t: en
Zt! .8-R It' ToA/CCutAeiay
(4-1)(5·1)
B
J+81 +B TSW
L IDLE-UP TEMP. S/V
C'!
~
...J B -::
U. STA
enl I (.J c;J c;J1

SPD
IG-L
• To Spee
AIR FLOW METER

>- a:
B
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til
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u.
0
I-
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f-
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w
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,
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w
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a;w ::J
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Q U ~ co
<!: CO
a: co co
o
f-f-
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U ~
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a.. ~ ~ OX SENSOR OX SENSOR ::J
U
co ....J CHECK CONNECTOR w
w
ci: RESISTOR ::J OX u:: I B
a: u. w
B PSW
0 THR
I-
u W-B SEN
UJ IDL
~~
Il
BATTERY CHECK CONNECTOR
I-cn
O:w BR
~ (.J!
<!~
t--
<nI-
INJECTOR
l co ~ I B I ~ ~ GR IVF IGF
Y
IGT~
CHECK ENGINE
col col l'J1 (.JI 'r CONNECTOR
a.. NE W
UJ
~ GR-B
>
...J ::J I I IT
a..
<!
gl ~ I~I ~ Igl ~ Igi ~ I >
a:
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W
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en
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sl >-~
Y
I
#20
w
#10
E1
E01
co E02
co
~ ::i:
a::
en
e • • • •
f Ground points a" Located on cowl left h ~ Located on wiper bracket set bolt c = Located on cowl rl,1
~ Ignition
~ Charging
~
Combination Meter
4 5 6 7
B-R To 4WO ControlS!W (4-6)

....I. R-L To Power Main Relay (2·1)
ci: • .. To Seat Belt Warning Relay (3-3) To AIT 0
• I • .. To Seat B
>-
::5 I I l-
l.I.J I ..Y.
a::: ~ c~
OIL (OX) OIL PRESSURE S/W (OX) OIL (LE)
Z ....I
c.:J
~; Y-B I Y-B
« z :o~
~, I 1 ' 'Via:!
c.:J z~ :::J1.!'l
LL N a:!
a:::l.I.J
-
~
«I- E""': OIL (LE)
3:l.I.J 0....1
..... LL
l.I.J~ LL~
<.::Jeri
a:~
«0 ENGINE OIL
Iu LEVEL S!W
B-R u- WATER TEMP.
I Sensor (2·4)
B YoW
3:
Ignet Clutch (4·3)(5-4) CHECK
>-
CONNECTOR
FUEL FUEL SENDER FUEL

C Idle-up VSV (4-4)(5·5)
a::: From A!T Oil Temp. Y-L L .. ~_IW-B
en aJ Indicator (OX)(4·8)
C Cut Relay (4-3)(5-4)

IGNITER
S
OTTLE POSITION >-It::lI3: I a:! DISTRIBUTOR ri: BRAKE -=
;OR FLUID LEVEL S!W TACH
>- $1 $ >-
R-W R-W I'\Akl"ol W-B
dJ
B L RADIATOR
• .. To A!e Amplifier (4.4)(5-5) $
RADIATOR FLUID LEVEL SIW
co ci:
From AIC Oil Temp.
Indicator (LE)(4-8) ~~ CD a:
CD
CHECK ENGINE
ALTERNATOR
GR-R From Cruise
(WI IC Regulatorl
Control Computer
(2-4)
GR-R
CD a:! a:!
~ ~
a:
~ co
Iht d = Located on engine compartment left e = Located on under chamber f = Located on left rear fender
2
~ r
-n >
-l
'l
::lJ
C m m
m :n en
r en
en -l C
m m :n
Z S m
om 'l en
m
en
:n m 2
Z o
o m
BR m :n
::lJ
r
W-B m
'I
r
I BACK-UP LIGHT S/W
W-B (Van) W-B R-B R-B R-L
~ BACK-UP LIGHTS
; (RR. COMB. LIGHT)
~ 1It-- --W--B-+"\ ur+_R_-B_---'

?;[.
~
~:p
rr
~N
~:e -i
0
~g
•
0
2;
Y-L 0
0
3
'0
S
~
~
~
VAN (Cont'd)
2 3
• Air Con
D • ...
G ... 1 I
From "FL 1.25B" ~ • I To "FOG" Fuse ( 4 - 5 ) . .. ..
( 1-1)
From "STARTER" Fuse _ ••_ - - - - - - ,

( 1-1)
o
..J
a::
..J
a.a
>- a:l
>-
0:
..J ....J a:l ~I J ci
0: ~
0:
..J
a:l
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a:
o
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t-
UJ
0: en W-B ~
en .....1...-
a:
UJ Z 0
a:: :::>>- 0: Z t-
UJ ci
IJ.JJ~~
AIC SIW ~
a::
UJ
I-:-
(WI Heater) I cia:
t-
ci
UJ
:2:
0: .... L L :2:
a:-
O
:2:
z
I ci §
$' I I' UJ'- ci C1l ci
a:
;1
~
I a:l a:l a:!::; UJ<ll u.. a:
~ ' ci a:~
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0
..J
a: (fJ
Z
LlJ
Y-B 0
Z
C? 0
>- a: ~u
..J
I I ;1 a:l
~
a:
...J
REAR
BLOWER MICRO
MOTOR (W/O Heated ~ BLOWER
MOTOR
0: 0
..J ..J
Y-B
I L
REAR
BLOWER RESISTOR BLOWER RESISTOR
L-R I ___ . . . I W-B

0
~ L-O LAAAAAMI\JLb
..J
>-
..J
ql
....J
>;-
....J
~~~~
REAR
HEATER
HEATER BLOWER S/W
BLOWER S/W
a:l a:l a:l a:l
a:l a:l
~ ~ ~ ~ ~ ~ ~
d , . • 1 l' 1 1
Ground points c~ Located on cowl right d= Located on engine compartment left

~
LG-B
.-+
G-R
0
:J
CD
.......
H I-LOW CHANGE
RELAY ()
W-B W-B 0
0
CD
L-R .......
HIGH PRESSURE S/W
III
:J
0-
HI-LOW RELAY CONDENSOR FAN
RELAY I
CD
W-B W W III
.-+
CD
.......
LG-B L-Y L-Y
~
:2:
0
W-B W-B L-Y

»
R n BR L-W
0
C
-l MAGNET CLUTCH
J)
r m RELAY
OJ r
»
LG -<
II
-I-l
o 0 MAGNET CLUTCH
-lm L-R
::r T!
(3 -
... m
=-0
roc
BR
~=
~.~
6- L-W
:::J L-W
~ L-B
L-R
~
~
W-L
MAGNETIC VALVE
-IT! (Front)
o ~
0 r
LG
~~ ~
:0
co
m:::J :0 VOLUME S/W
()~ (Rear) W
c::; MAGNETIC VALVE
(Rear)
~
~ ~
~~ J)
W-R L-W
W-G W-G
THERMISTOR ~
» L-R
(Dual A/C) C! n
»
~ -< (J1
\J
r W Y-R :0 Y-R
-< THERMISTOR Ti
C!
-<
-<
~»
Y-G
m
JJ FAN MOTOR
~ I
~
C! or
C
0
I
~
»
ttl
w m W n
~ -< roC/)
2.-~
C! »
( -<
~ Y-G
n
»
~
\J
Y-B ~
m
JJ
G Y G
W-B W-B Y-W Y-G
B-Y Y-L
~ THERMISTOR
Co
W-B
Tr o
r o
~
r+
...
C.
........
r; HEATER RELAY
r
~a. L-R
S
L-O
0
:J r:-
n r :n SW
0 :n Or -<
~ -j0
,0. O~ Co
I JJm
;r S JJ
I'V
L-O JJro
mr
W-B (/)0
S (fi~
WI L-Y -jm 11
rm
O~
OJJ
JJ Y-B L-R o
~-j 3
mm
:n:n
(f) -s
~-
~ -< "--n
r
Co -< OJJ
Co
11
C
ttl
C. W-B
II
r Y-R Y-R
~
n- W-B W-B B-W B-R
o
:J
ttl
~:J A/C CUT

RELAY
ttl
n
0
3
~ Y-B L-R
~
~ L-O L-O L-R L-R L
S
~ r
o sroJJ REAR HEATER RELAY
Orm
-jO~
O~JJ
r JJm REAR MAIN S/W
o JJ (Front)
OJ:n
rm L-R
~~r---------+-----+-hDr+l~---'
m
L-Y JJ
JJ
m Y-B
(f)
(f)
-j
o
JJ
W-B »
0
,
Y-B Y-B L-R a
::J
0-
~
REAR MAIN S/W a

::J
(Rear)
~
CONDENSOR FAN 0
RELAY
a
0
W-B W-B L-B R-W ~
OJ
W-B ::J
0-
CONDENSOR FAN MOTOR W I
CD
Q.)
MAGNET CLUTCH ~
C'll
"""I
LG W W L-B
~
~
n BR L-W ~
To EFI-ECU n 0
(1-4) -.--+-+-+----------~ c-j
MAGNET
To Throttle R JJ CLUTCH
m
Position r RELAY
Sensor (1-4) ~
W-B W-B -<
L-R
L-W L-W
To EFI-ECU L-B
(1-4)
L-R
From Igniter B
(1-5l LOW PR ESSLJR F S'W
W-L
MAGNETIC VALVE
LG ....
(Front)
--~
MAGNETIC VALVE
(Rear)
W-R
}>
o
}>
$ Y-R
\l
r
"Tl
m W Y-R L-B
J)
FAN MOTOR
}>
W
o
}>
$
\l
r
"Tl
m
J)
Y G
Y-B Y-R Y-G
B-Y Y-L
THERMISTOR
W-B
(Jl
FOG LIGHT S/W

W-B
W-B G-O R-Y
W-B
W-B
FOG LIGHTS
G
G-W
FOG LIGHT
RELAY
G-R
G-R ."
r
o
c.e
(C'
:r-
tt
~
r-+
V)
W-B W-B R-G

....-+------...----+~ooor - f - - - - - - - - - - - - . . . . J . , j n 2WD
(AfT W/O Free Wheel Hub) R-L
R-W
4WD CONTROL SOLENOID ------I~ 4WD
W-B
4WD INDICATOR S/W
R R R-L
4WD INDICATOR S/W 4WD INDICATOR LIGHT

(COMB. METER) "Tl
o
3
R W-L ci
R-L R-L »
To Speed Sensor (2_4)_.... G_-L..... W-G

~...-+----...----- c
t
Cl
m
"Tl
,..-. ~
;
}> C
~ ~
(j)
m
~
W-B 4WD CONTRO L S/W ~
R-G ~
=2:
o :2:
n
o ~
z I
-l
£.
I __
u
Z
-l ~
R-W JJ 0-
0
r
(")
0
$
"'0
R-Y R-L c
-j
111
m
J) 0
SPEED SENSOR 3
(Transferl
m
(")
R-Y W-R
<;=
Cl
11
W-B W-B
~
t::J
W
010 MAIN SIW

W-B W-B 0
0/0 SOLENOID
8
11t---+-""1iIiu.....-+-----------~
Y-L Y
A/T OIL TEMP,

SENSOR
WATER TEMP. SIW
11t--Kl"""'-U-t-Y--R-------e-------I
-<
:il
From Cruise Control_~_ _--,
Computer (2-4)
VAN (Cont'd)
~
Taillights and Illumination
~ Headl ights
~
~seat Unlock and
BeltWarning
1 2 3
D;;;;;==+:======r=====~Rt-------~~-=----
c
F
G
•
t
• I
I
c
To Cornering Light
Relay (2--6)
t:l
-I
t:ll <.? 0:1 a:,
~ ~
To Clock (Degital)
(3-6)
~ 3l
:::l
u.. u..
~RH~
a:
.....:t
(/)
w tu
~
~I I
l- l-
I (!) t:l
I
(9 ::> ::>
<:} S2 ::::i « <r l-
.... > -1>- I
d:5 O<!
LH 0
4:
P f' (9
«W <!-I W
~ u:0
E -I
~I ~t~1
WW
.1--0: Ia: I a:
a: a: a: u.. I- Q
J:
c.? a:
W
::::i ~ I-
t:l OC Ci5 ~
...J 5= Z
<.? I-
o From Cornering
ri: Z
a: .... Z z
0w
-
RADIO Light Relay (2-7) R-Y I R-Y <rOC Z a:
3: uJ 0:
« u..::!.
G ~ W·G 1-1-
-I
uJ 3:
uJ~ :lC
REAR WIPER S/W s: l]]a:i 0
0
r:i: I-~
G G
~ R-W «0
R-G R-G -I
w<.J :z
(1)- ::>
FRONT FOG LIGHT S/W
TAIL RH G C\. W-G ...J ...J ~
(9
ci: 0.. <:I
CIGARETTE LIGHTER ci:

~ LD
SEAT BELT
WARNING RELAY
R ROOM LIGHT
CONTROL
HIGH BEAM RELAY
G G COMB. METER INDICATOR LIGHT i
<.? 1 G ti1iUr~ (COMB. METER) s
;n
l]]
t:l
l]]
Q)
~ d: CJ?I
TAIL LH ~
CD
~
a: s:CJ?
HEATER CONTROL ...J S >;-1 ~ ~
0 ci: .:i
~
G W·B a: a:
O"l
o
T EL H HF HU I HL I ED u.
DEFOGGER S/W o W-B
I-
G C\. W-G OFF FLASH
~ TAIL LOW
~
HEAD HIGH
LICENCE PLATE
LIGHT DIMMER S/W co
G W-B CRUISE CONTROL CONTROL SIW (COMB. S/W) ~
MAIN S/W (COMB. S/W)
co CJ
~ ~
I- ~
4: C/)
Back Door Center tn. • G W

-I
0 ~
W U
I ::>
a: co
CLOCK
G C'\ W-B
---
aJ co en co en a:l
r
~ ~ ~ ~ ~ ~
Ground points a '"

~!F
Located on cowl left
1
b "" Located on wiper bracket set bolt ('
1
Located on cowl right d
1 1--
Located on engine compartment left
W-B ~ W-B R
--------
(LE) W R-W
'-,
II
r
g JJ 0
~ ~
*
a.
0
~
FRONT INTER lOR LIGHT
~ (OX)
FRONT LH
II
CD
a>
R-B JJ R R
CD
~
II to
~ JJ
JJ JJ
~
0
0 FRONT RH JJ JJ ~
r DOOR COURTESY LIGHT LH
0 ~ ~
~
JJ R-W R-W
R-W R R
n II
g
JJ JJ
--1
C/l ~
-< DOOR COURTESY LIGHT RH
C/l
BACK DOOR r
~ i2:'
0
X
R-W R
W-B R-L ::l
r-t
~ ro
r ~
0
REAR INTERIOR LIGHT ~
C
SLIDE DOOR JJ II R
CO
-::r
~ ~
R-B JJ ~
II ~
JJ BACK DOOR LIGHT

~
R-W II R
01
R-G
STEP LIGHT
R-B R
OPEN DOOR WARNING LIGHT
~
(COMB. METER)
R-L R R
0
0
~
i W-B
BACK DOOR
UNLOCK S!W
R-W R-Y
BACK DOOR WARNING LIGHT
(COMB. METER)
R-W
CLOCK (Analog)
- - - -...- --.'_B-I~ -I-___-4l--

WB o
W R R
_._-I--I----..- - - - - - - - - - - - - - - - - - - - - -
- --I
CLOCK (Digital) ~
~
L- W B...
_-_ .... R--.._........
I-- ()
<;:? 0"
(")
G-1 o G-R '"

From "TAIL" Fuse (3-11- ----:.. o
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....._ _ - ~~~:(;~~Z-HOR N"
r
BR BR BR :D
SATELLITE S!W
~
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Cl
JJ
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01 P-L RADIO AND TAPE PLAYER RADIO
m -l
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U
< \J r
ro
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C/l C/l
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m m
JJ JJ
01 JJ
JJ m
r 0 JJ r :t>
I JJ
Z I I JJ I
--1
W-B (Console Box Type) r :D

:r: I
W-B (Instrument Panel Type)
r JJ 0 C r JJ 0 C
m C) 0 "'U m Q 0 "'U
"Tl ."
--1 :r: ~ -l I ~
-l 2 -l 2
L-W
G-R
CD
r
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L-R W-B JJ ::0
m ro
~
0 3
L-W -l
I
r m S
ro
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L-R 0 ()
JJ < Z
0
JJ r -l
0 JJ ::l
r-t
JJ L "- L 0
~
n r (3
0 ~
-l L-Y $
0 r < JJ
JJ
JJ JJ
C/l 0 """
(3
L-B JJ
....,
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~
(/l
JJ
L-Y
JJ
I
L-B
CIGARETTE LIGHTER FRONT
L-R G-R 00
W-B
CIGARETTE LIGHTER REAR

L-R L-R
W-B
SA-8 SUSPENSION AND AXLE (Front) - Free Wheeling Hub
FREE WHEELING HUB

COMPONENTS
Cone Washer
~: -l 311315. 231
@)
.Gasket
Free Wheeling
Hub Cover
Free Wheeling
Hub Body 10 (100.7)
.Gasket
Spring
Clutch
Snap Ring
o--Ball
Follower Pawl
I-----Spring
Free Wheeling
Hub Cover
K961
IN'm (kgf'cm, ft·lbf) I Specified torque K961
SUSPENSION AND AXLE (Front) - Free Wheeling Hub SA-9
REMOVAL OF FREE WHEELING HUB

1. REMOVE FREE WHEELING HUB COVER
(a) Set the control handle to FREE position.
54
(b) Remove the cover mounting bolts and pull off the
cover.
2. REMOVE BOLT WITH WASHER
3. REMOVE FREE WHEELING HUB BODY

(b) Using a brass bar and hammer, tap on the bolts head
(c) Pull off the free wheeling hub body.
DISASSEMBLV OF FREE WHEELING HUB

1. REMOVE· CONTROL HANDLE FROM FREE WHEELING
HUB COVER
(a) Compressing the spring, remove the pawl tab from
the handle cam, and remove the clutch.
(c) Remove the control handle.
(d) Remove the steel ball, spring and seal from the con·
trol handle.
o 0)))))))))) - -
SA0321
INSPECTION OF FREE WHEELING HUB

1. INSPECT COVER, HANDLE AND SEAL
Temporarily install the handle in the cover and check that
the handle moves smoothly and freely.
ASSEMBLY OF FREE WHEELING HUB

1. APPLY MP GREASE TO SLIDING SURFACE OF PARTS
SA 1378
2. INSTALL CONTROL HANDLE TO COVER

(a) Install the seal, spring and steel ball to the handle.
SA0321
(b) Install the handle in the cover and snap ring with
snap ring pliers.
FA0057
3. INSTALL TENSION SPRING IN CLUTCH

Install the tension spring in the clutch with the spring end
aligned with the initial groove.
AOO63
4. INSTALL FOLLOWER PAWL TO CLUTCH

(a) Place the follower pawl on the tension spring with
one of the large tabs against the bent spring end.
(b) Place the top ring of the spring on the small tabs.
A0064
5. INSTALL CLUTCH AND SPRING INTO COVER
1t (a) Place the spring between the cover and clutch with
the large spring end toward the cover.
SA0323
(b) Compress the spring and install the clutch with the
pawl tab fit to the handle cam.
FAOO65
6. TEMPORARILY INSTALL COVER TO BODY AND CHECK

FREE WHEELING HUB
(a) Set the control handle and clutch to the FREE posi-
tion.
(b) Install the cover in the body and verify that the inner
hub furns smoothly.
(c) Remove the cover from the body.
INSTALLATION OF FREE WHEELING HUB

1. INSTALL FREE WHEELING HUB BODY
(a) Place a new gasket in position on the front axle hub.
(b) Install the free wheeling hub body with six cone
washers and nuts. Tighten the nuts.
Torque: 31 N'm (315 kgf'cm, 23 ft-lbf)
K7526

Torque: 18 N'm (185 kgf'cm, 13 ft-lbf)
K9564
3. APPLY MP GREASE TO INNER HUB SPLINES
FA0070
4. INSTALL FREE WHEELING HUB COVER WITH NEW GAS~

KET
(a) Set the control handle and clutch to the FREE posi·
tion.
(b) Place'S new gasket in position on the cover.
FA0060 FAO066
(c) Install the cover to the body with the follower pawl
tabs aligned with the non-toothed portions of the
body.
FA0324
(d) Tighten the cover mounting bolts.

Torque: 10 N'm (100 kgf'cm, 7 fHbf)
K7522

87 Toyota Van Manual

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87 Toyota Van Manual

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FOREWORD

This manual contains maintenance and repair procedures for

Applicable models: YR 22, 29, 31, 32 series

The manual is divided into 22 sections and 5 appendixes with a

Manual Name Pub. No.

All information in this manual is based on the latest product

TOYOTA MOTOR CORPORATION

HOW TO USE THIS MANUAL

+ End Gasket Bearing Outer Retainer

Brake Dru;;;- "- I

Rear Axle Shaft

I kg-em (ft-Ib, Nom)1 : Specified torque

The procedures are presented in a step-by-step format:

~ Task heading: what to do

/ Detail text: how to do it

(b) Measure the stroke applying and releasing the com-

This format provides the experienced technician with a FAST

WARNINGS, CAUTIONS, NOTES:

4Y-E Engine ENGINE SERIAL NUMBER

GENERAL REPAIR INSTRUCTIONS

12. Observe the following precautions to avoid damage to the

~b) \' 0 pu\\ apart e\ectr\ca\ connectors, puH

.. CORRECT J r?Cr~C7C<;7'r- r·.::-,,;;,-o;:;;r,....-'" r7Q"C C"'r~ .--Y-r"'--vo",J' 0

(c) Be careful not to drop electrical components, such as

13. Tag hoses before disconnecting them:

PRECAUTIONS FOR VEHICLES EQUIPPED WITH A

1. Use only unleaded gasoline.

2. Avoid prolonged idling.

3. Avoid spark jump test.

4. Avoid prolonged engine compression measurement.

5. Do not run engine when fuel tank is nearly empty.

6. Avoid coasting with ignition turned off and prolonged

7. Do not dispose of a used catalyst along with parts con-

VEHICLE LIFT AND SUPPORT LOCATIONS

(4-Link Type) (Leaf Spring Type)

PANTOGRAPH JACK POSITION - - - - - , - - - -

VEHICLE LIFT AND SUPPORT LOCATIONS (Cont'd)

SWING ARM TYPE LIFT

SWING ARM TYPE LIFT PLATE TYPE LIFT

ABBREVIATIONS USED IN THIS MANUAL

NORMAL CONDITION SCHEDULE

Exhaust pipes and mountings I I MA-6 (item 10)

Fuel line and connections I I MA-6 (item 9)

Automatic transmission, manual transmission,

SEVERE CONDITION SCHEDULE

FUEL Idle speed(3) A A A MA-7 (item 12)

Air fi Iter *(6-) I I I I I R I I I I I R MA-5 (item 3, 4)

Fuel line and connections I I MA-6 (item 9)

Fuel filler cap gasket R MA-6 (item 8)

Brake pads and discs I I I I I I MA-8 (item 15)

Brake line pipes and hoses I I I MA-8 (item 13)

CHASSIS Steering linkage I I I I I I MA-9 (item 16)

Drive shaft boots I I I I I I MA-9 (item 18)

Bail joints and dust covers

Automatic transmission, manual transmission, MA-9 (item 17)

V-Ribbed Type MAINTENANCE OPERATIONS

2. REPLACE SPARK PLUGS (PLATINUM TIPPED TYPE)

(c) Check the gap on the new plugs.

3. INSPECT AIR FILTER

5. REPLACE ENGINE OIL AND OIL FILTER

6. REPLACE ENGINE COOLANT

7. CALIFORNIA VEHICLES ONLY:

8. REPLACE GASKET IN FUEL FILLE~ CAP

. . Front Fuel Filter Cap