VNX - Su Montero 1987 Service Manual PDF
VNX - Su Montero 1987 Service Manual PDF
VNX - Su Montero 1987 Service Manual PDF
GROUP INDEX
Service
i Manu
,Introduction
and
,Master Troubleshooting
MONTERO
Lubrication
.*.**
and Maintenance
.+....
Front Suspension
1987 : Volume 1
Service
Parking
. . . .. .. . .. . .. ................
~ ..
,.....,..,......,.............................N
BrakesClutch
FOREWORD
<,
,..,*,,.....,.....~...,.*.;
.. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . . .. .. . ..*......
Cqoling
Engine
A .
4ib II
WE SUPPORT
VOLUNTARY
TECHNICIAN
CTF$lFMTlON
THROUGH
e;.*-..
, , :ji
Nat~dnallnsftfute
for
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. ,iXCEL;kEiUCE
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Erfiission
Mitsubishi
Motors
corporation
reserves
ihe right to make changes in
design or to make add&+x
to oi-improvemenfs
in its products
without
imposing
any obliga<&
upon itself to install them on its products
previously
manufact&$d.
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Printed in Japan
0 1986 Mitsubishi
Motors Corporation
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Control
Systems
NOTE
For ElectCcal,
Heater.
ins, refer to . . .
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NOOBAAA
COljlTENtS
?he preceding page contains the GROUP INDEX
which lists the group title and group number.
PAGE NUMBERS
All page numbers consist of two sets of digits
separated by a dash. The digits precding
the dash
-r: identify the number of the group. The digits follow:.ing the dash represent the consecutive page
$.rmber within the group. The page numbers can
be found on the top left or right of each page.
TEXT
Unless otherwise specified, each service procedure
covers all- -models. .*.Procedures covering specific
models are identified by the model codes, or similar
designation (engin-e type, transmission type, etc.).
A descriptjon of these designations is ccvered in
this unit under VEHICLE,IDENTIFICATION.
ig..,,.
Troubleshootings are classified into master troubleshooting .and group troubleshooting and located as
follows:
,...??!$he master troubleshooting is prepared when the
t!ouble symptom relates to two or more groups and
gjven in-MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for
causes of problems related to that individual group
only; a troubleshooting guide is prepared for each
apptopriate group.
:.
3
:..
Installation
SERVICE PROCEDURES
sDEFINITION
.-;
4.
.
19,
k,
! *
:
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OF TERMS
STANDARD VALUE
Indicatesthe value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be keptfunctionally or in strength. It is a value
established outside the range of standard value.
http://vnx.su/
Classification of
SERVICE ROINTS
I)+
*I)
: Installation
: Disassembly
INTRODUCTION
-T
Page number
Group title
Sect@
title
THERMOSTAT
REMOVAL AND INSTALLATION
I*
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Supplying
of the
MAINTENANCE
Coolant
(Refer
- Maintenance
to
W-1: Nm
7-9 fths.
Ser-
Thermostat
kit
-.a
1. Connection
of water temperature
switch
connector
(Vehicles
with an air conditioner)
2. Connection
of radiator
upper
hose
3. Water
outlet
fitting
4. Water
outlet
fitting
gasket
5. Thermostat
I..:.,
NOTE
(1) Reverse the removal procedures
to reinstall
(2) **
: Refer to Service
Points of Installation
(3) p
Non-reusable
parts
INSTALLATION
OF THERMOSTAT
An explanation
of procedures,
regarding removal, installation,
and reassembly.
http://vnx.su/
notes. etc.
disassembly
;* *
:/.
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.? 4
INTRODUCTION
-Vehicle
Identification
VEHICLE IDENTIFKATION
VEHICLE IDENTIFICATION
I
NUMBER
VEHICLE IDENTIFICATION
1st
digit
2nd
digit
3rd
digit
4th
digit
5th
digit
LOCATIOymA
on a plate
The vehicle
type, etc.
6th
digit
7th
digit
8th
digit
9th
digit
10th
digit
11th
digit
12th thru
17th digit
Make
Body
Engine
Check
digit
Feifel
Plant
Serial
number
AMitsu-,
bishi
33-door
metaltop or
van
E2.6 liter.
(155.9
C.I.D.)
H1987
year
JNagoya
-3
00000 1
0
:
3
99&99
7-Truck
9
X
*:
.:
.y?
:
:s/
-. NOTE
*Check digit means a single number or letter X used to verify the accuracy of transcription
number.
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of vehicle indentification
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IDENTIFICATION
NUMBER
Identification
- Vehicle
LIST
FEDERAL
NOOCG-
number)
Engine displacement
Brand
Model code
JA4FJ43EoHJ
I.
L042GVNJLF
JA4FJ43EoHJ
MITSUBISHI
2.555 liters
JA7FJ23EoHJ
MONTERO
(155.9 C.I.D.)
L042GVRJLF
L042GTNSLF
JA7FJ23EoHJ
CALIFORNIA
L042GTRSLF
number)
i. :: .
states.)
Brand
Model code
Engine displacement
JA4FJ43EoHJ
L042GVNJLH
JA4FJ43EoHJ
MITSUBISHI
2.555 liters
JA7FJ23EoHJ
MONTERO
(155.9 C.I.D.)
L042GVRJLH
JB7FJ23EoHJ
VEHICLE
INFORMATION
L042GTNSLH
;
,ei
0:
L042GTNSLH
NOOC+rA,
on the headlight
model,
L042G
-r--r--
2.
G54B
ENGINE
3. TRANS
AX.LE
4.
engine
$p
fry
transmis$on,,
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VNJLF
KM145
COLORTRIM
OPT
876
7
Montone exterior
color code
B21 B76H43
Two-tone color code
Exterior code
E
Two-tone
exterior
is shown
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,ar. 1,-,I
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CODE PLATE
Vehicle information
code plate is riveted
port panel in the engine compartment.
1. MODEL
,p
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f.;. ;.
by the
by the two
INTRODUCTION
CHASSIS
-Vehicle
Identification
NUMBER.
NoacE-A
STAMPING LOCATION
The chassis number is stamped
the right rear shock absorber.
near
IVehicle
line
Et-q
,-J;r,
LABEL
NOOCF-
NOOCG-.
Number
cycling
AA0201 to YY9999
AA0201
---3
AA9999
L ABOOOI
---+
AY9999
L BAOOOl
---3
YY9999
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model
INTRODUCTION
-Vehicle
Identification
?r
7
Nmcn-
Exterior code
Body color
Monotone
676
Cl9
Brown
H43
R52
Silver (Metallic)
s70
Beige
x15
Black
(Metallic)
Red
Two-tone
821 B76H43
Silver (Metallic)/
Dark blue (Metallic)
C38C19X13
Black/
Brown (Metallic)
H15H43X13
Black/
Silver (Metallic)
R06R52X13
Black/Red
Black/Beige
S69S7OX13
X45X1 5H43
Black/
Silver (Metallic).
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PRECAUTIONS
PROTECTING
BEFORE SERVICE
THE VEHICLE
NOODAAC
If there is a likelihood
of damaging
painted or interior parts
protect them with suitable covers
during service operations,
(such as seat covers. fender covers, etc.).
001884
REMOVAL
AND DISASSEMBLY
Fcloo1
SPECIAL TOOLS
If other tools are substituted
for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged,
or the mechanic
might be injured; therefore,
be
sure to use the special tool whenever
doing any work for
which the use of one is specified.
FOOO18
PARTS TO BE REPLACED
If any of the following
parts are removed,
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking
nuts
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they
must
be
--
INTRODUCTION
AND
MASTER
TROUBLESHOOTING
- Precautions
Before Service 9
PARTS
When
replacing
VEHICLE
genuine
parts.
WASHING
If high-pressure
car-washing equipment
or steam car-washing
.I
equipment
is used to wash the vehicle, be sure to maintain th,e,
spray nozzle at a distance of at least 300 mm (11.8 in.) fro,m
any plastic
parts and all opening
parts (doors, lugg$ge
compartment,
etc.).
5
t;
nm
(in.)
so0059
SERVICING
THE ELECTRICAL
When servicing
cable terminal
SYSTEM
disconnect
the negative
,i
. ,.
Caution
Before connecting
or disconnectingthe
negative cable, be
*,
sure to turn off the ignition switch and the lighting switch,;~: * :
(If this is not done, there is the possibility of semicondu~$$r~
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parts being damaged.)
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WIRING
HARNESSES
F16171
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J IO INTRODUCTION
- Precautions
3. When disconnecting
a connector,
connector, not the harness.
Before Service
be sure to pull only the
4.
Disconnect
connectors
the direction indicated
in
,
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.
16R1284
'06347
5. Connect connectors
which have catches
connectors
until they snap.
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by inserting
the
INTRODUCTION
- Precautions
Before Service
11
COMPONENTS
not to
C163Bi
2.
or
..
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4
OOVS66
3. The electronic
parts used for relays, etc., are sensitive to
heat. If any service which causes a temperature
of 80C
(176F) or more is performed,
remove the part or parts in
question before carrying out the service.
I
)j
OOY632
LINKS
10A
Caution
If a fuse is blown-out,
be sure to eliminate
the problem
before installing
a new fuse.
15A
ii:.,
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the cause of
1.
j .
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If additional
optional
equipment
is to be installed
in the
vehicle, follow the procedure
listed in the appropriate
instruction
manual;
however,
be sure to pay careful
attention to the following points:
(1) In order to avoid overloading
the wiring, take the
electrical
current load of the optional
equipment
into
consideration,
and determine
the appropriate
wire size.
(2) Where possible, route the wiring through the existing
harnesses.
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WE569
T
Permissible
Nominal
size
current
2.
SAE
giTe
In engine
compartment
212A
16A
21A
31A
Other
areas
5A
13A
17A
22A
30A
40A
54A
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12 INTRODUCTION
if it
be
LUBRICANTS
In accordance
with the instructions
in this Workshop
Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
FOO028
BRAKE FLUID
Be careful to avoid spilling
any brake fluid, because
if it
adheres to the vehicle body, the paint coat might be discolored.
work is to be done
must be taken.
_ _
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OF TWO OR
by two or more
technicians
INTRODUCTION
- Precautions
NOTE ON INSTALLATION
Before Service
13
OF RADIO EQUlPM$Fz
The computers
of the electronic
control system has been
designed
so that external radio waves will not interfere with
their operation.
However, if antenna or cable of amateur transceiver
etc. is
routed near the computers,
it may affect the operation
of the
computers,
even if the output of the transceiver
is no more
than 25W.
To protect
each of the computers
from interference
by
transmitter
(hum, transceiver,
etc.), the following
should be
observed.
1. Install the antenna on the roof.
2. Because radio waves are emitted from the coaxial cable of
the antenna,
keep it 200 mm (8 in.) away from the,;
computers
and the wiring harness. If the cable must cross I
the wiring harness, route it so that it runs at right angles to
the wiring harness.
3. The antenna and the cable should be well matched,<and
the standing-wave
ratio* should be kept low.
,.t
4. A transmitter
having a large output should not be installed
in the vehicle.
5. After installation
of transmitter,
run the.engine
at idle, emit ._I
radio waves from the transmitter
and make sure that the
.
engine is not affected.
vo,tage,
Voltage
q.;:I,I,,
Cabje
High-frequency
power supply
Antenna
00Y590
<
*STANDING-WAVE
RATIO
If an antenna and a cable having different
impedances
are
connected,
the input impedance
Zi will vary in accordance
with the length
of the cable and the frequency
of the
,.
transmitter,
and the voltage
distribution
will also vary j)~
p ,, ;
accordance with the location.
The ratio between
this maximum
voltage
and minimum.
:
voltage
is called the standing-wave
ratio. It can also be
,
represented
by the ratio between
the impedances
of .$he :
antenna and the cable.
The amount of radio waves emitted from the cable increases
as the standing-wave
ratio increases, and this increase$the
possibility
of the electronic
components
being adver$ely
, .
4, :,*;; ,.f ,
affected.
2,
1,. ;
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14
INTRODUCTION
- ~Z%YZJ%f~~ aStream
AND
SERVICE
BEFORE FORDING
NWFA-
Vehicles
which are driven through
water, or which
may
possibly be driven through water, should be subjected to the
following
inspections
and maintenance
procedures
in advance.
l
Seal the speedometer
cable with a water-resistant
grease
or tape.
0 Inspect the dust boots and breather hose for cracks or
damage, and replace them if cracks or damage are found.
r I ,Steering joint
4ower boot
r,
Steering
OOW521
001525
OOW529
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Speyfometer
cable
\I
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INTRODUCTION
- :;:;~k%~cia
stream
I:5
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16
AND
- ;~:;~;:%$a
SERVICE
AFTER
stream
FORDING
Front differenti
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INTRODUCTION.
AND
MASTER
TROUBLESHOOTING
TOWING
- Towing
AND HOISTING
and
Hoisting
17
NOOGA-
This vehicle can only be towed from the front with conventional sling-type equipment
and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4 x 4 x 55 wood beam) should be placed
forward of under guard and under towing hook/shipping
tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system must be used. This system must be
completely
independent
of the primary
lifting and towing
attachment.
Care must be taken in the installation
of safety
chains to insure they do not cause damage to bumper, painted
surfaces or lights.
LIFTING-GROUND
CLEARANCE
FRONT TOWING
PICKUP
&f
Y
.
SAFETY PRECAUTIONS
The following
precautions
should be taken when towing the.,
:
vehicle.
.,I
1. Remove exhaust tips and any other optional
equipm&nt,.
. .
that interface with the towing sling. Padding (heavy shop ,,
towel or carpeting) should be placed between the towr@g,
sling cross bar and any painted
surfaces, and bump&
.I,
surfaces.
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2. A safety chain system
completely
independent
of the.
i
primary lifting and towing attachment
must be used.
.
3. Any loose or protruding
parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior
to moving the vehicle.
4. Operator should refrain from going under a vehicle unless
L,,
the vehicle is adequately
supported by safety stands.
5. Never allow passengers to ride in a towed vehicle.
6. State and local rules and regulations
must be followed
when towing a vehicle.
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18 INTRODUCTION
- Towing
and Hoisting
HOISTING
POST TYPE
Special care should be ,taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations. (See next page)
Conventional
hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the side
frame.
FLOOR JACK
A regular floor jack may be used under the front crossmember
or rear axle housing.
Caution
1. A floor jack must never be used on any part of the
underbody.
2. Do not attempt
to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice
may result in permanent
damage
to the
body.
.- .
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._ - , ._
EMERGENCY
JACKING
Jack receptacles
are located at the No. 2 crossmember
and
rear axle housing to accept the jack supplied with the vehicle
for emergency
road service. Always block the opposite wheels
and jack only on a level surface.
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INTRODUCTION
FRAME
CONTACT
AND
SUPPORT
MASTER
TROUBLESHOOTING
- Towing
and Hoisting
19
LOCATIONS
2,350
mm (92.5 in.)
Section
A-A
NOTE
The locations of the support point shown as Section A-A are
the same as those of the twin post hoist shown in the
illustration (OOW588) below.
001553
LIFTING
AND JACKING
c
m
SUPPORT
LOCATIONS
Emergency
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20
INTRODUCTION
General
Date
and SpeCifiCatiOnS
N66HA.A
OOW556
Description
L042G
Vehicle dimensions
VNJLFIH
VRJLF/H
TNSLF/H
TRSLFIH
mm (in.)
$ Overall length
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
0
0
3,995(157.3)
1,680 (66,l)
3,995(157.3)
3,995 (157.3)
1,680(66,1)
1,680(66,1)
3,995 (157.3)
1,680(66,1)
0
0
1,840 (72,4)
2,350(92.5)
1,840(72,4)
2.350(92.5)
1,850(72,8)
2.350(92.5)
1,850(72,8)
2.350(92.5)
Front
1,400(55.1)
1,400 (55.1)
1,400(55.1)
Rear
1,375 (54.1)
1,375(54.1)
1,375(54.1)
1,400(55.1)
1,375(54.1)
Front
Go
745(29.3)
745(29.3)
745(29.3)
745(29.3)
900(35.4)
900(35.4)
900(35.4)
900(35.4)
480(18.9)
480(18.9)
480(18.9)
480(18.9)
0
63
440(17.3)
440(17.3)
440(17.3)
210(8.3)
210(8.3)
440(17.3)
210(8.3)
38
38"
38"
38"
@
@
28"
21"
28"
28
28"
21"
21"
21"
1,479(3,260)
1,493 (3,290)
1,440(3,175)
1,460(3,219)
1,910(4,210)
1,100(2,425)
1,910(4,210)
1,100(2,425)
1,450(3,197)
2
1,450(3,197)
$,$ Without
spare tire
Rear
Height at curb weight
Minimum
clearance
(wt.)
running ground
Angle of approach
Angle of departure
Ramp breakover
Vehicle weights
Curb weight
angle
kg (Ibs.)
rating
1,910(4,210)
Gross axle
weight rating
Front
Rear
1,100(2,425)
1,910(4,210)
1,100(2,425)
1,450(3,197)
4
1,450(3,197)
4
Seating capacity
210(8.3)
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~_
~~L
INTRODUCTION
Descrip tiom
L042G
URJLFIH
UNJLFIH
General
21
TRSLF/H
TNSLF/H
Engine
Model No.
G54B
G54B
G54B
Type
Number of cylinders
Bore
In-line OHC
in-line OHC
In-line OHC
4
G54B
In-line OHC
4
Stroke
98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in
2,555 cm3
2,555 cm3
2,555 cm3
2,555 cm3
(155.9 CID)
(155.9 CID)
(155.9 CID)
(155.9 CID)
8.7
8.7
8.7
8.7
Piston displacement
1-3-4-2
1-3-4-2
7 BTDC f 2
1-3-4-2
7 BTDC * 2
1-3-4-2
7 BTDC * 2
7 BTDC + 2
Model No.
KM145
KM148
KM145
KM148
Tvw
5-speed
manual
4-speed
automatic
5-speed
manual
4-speed
automatic
1 st
3.967
2.826
3.967
2.826
2nd
3rd
2.136
2.136
1.360
1.493
1.360
1.493
1.000
4th
5th
1.000
0.856
0.688
-
1.000
0.856
0.688
-
Reverse
High
Low
3.578
1.000
1.944
2.703
1.000
1.944
3.578
2.703
1.000
1.944
1 .ooo
1.944
4.625
4.625
4.625
4.625
Transmission
&transfer
case
Gear ratio
Transmission
Transfer
case
1 .ooo
L
dt
s
R
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Clutch
Dry single
disc &
Type
Dry single
disc &
diaphragm
diaphragm
spring
spring
Chassis
Tire size
Front suspension
P225175R15
We
Spring constant
(Wheel position)
Wishbone compression
22 N/mm (123 Ibs./in.)
type
Rear suspension
Type
Spring constant
Asymmetrical
At load of 1 ,OOO-2,500 N
(220-551 Ibs.)
At load of 4.670-8.870
(1,030-l ,955 Ibs.)
semi-elliptic
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leaf spring
22
INTRODUCTION
Description
--<
General
Date and Specifications/
TighteningTorque
VRJLFIH
TRSLF/H
TNSLFIH
Brakes
Type
Front
Disc
Rear
Drum
(Leading and trailing)
Integral type (Recirculating
ball nut)
16.4
60 liters (15.9 U.S. gaM3.2
eniTIGHTENING
TORQUE
Description
,I
:
,A
.Thread for general purposes
, -(size x pitch) mm
Head mark
8 x 1 .i5
10x 1.25
12x1.25
~:S~$,
14x 1.5
.t*: $\
%,:
5
16x 1.5
.:.
,:: ..,
.
4
;: I*
>y.; ; :.
18x 1.5
. . .I a
.i .,:.
20 x.1.5
P...:
i
:
3 22x1.5
ip
\ 24x1.5
-,
..a
Head mark
ftlbs.
Nm
ft.lbs.
3.0-3.9
7.9-l 2
2.2-2.9
5.8-8.7
4.9-7.8
3.6-5.8
13-19
9.4-l 4
16-23
12-17
27-39
20-29
Nm
6x 1.0
1.
-1
Imp. gal.)
29-43
21-32
47-72
35-53
48-70
67-l 00
35-52
51-77
77-l 10
57-85
130-I 60
90-I 20
100-I 50
150-I 90
74-l 10
180-230
130-170
1 IO-140
160-320
1go-240
200-260
150-I 90
340-430
250-320
260-320
1go-240
420-550
310-410
Nm
ft.lbs.
Description
Remarks
PTlI8
7.9-l 2
16-19
5.8-8.7
12-14
PTlI4
19-30
34-45
14-22
25-33
PT 318
39-54
58-73
29-40
43-54
4.9-7.8
7.9-l 2
3.6-5.8
5.8-8.7
7.9-l 2
16-19
19-13
34-45
5.8-8.7
12-14
14-22
25-33
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INTRODUCTION
- Master Troubleshooting
23
MASTER TROUBLESHOOTING
ENGINE
NOOKAAC
OVERHEATS
Symptom
Reference
page
Remedy
Probable cause
,
Engine
overheats
Cooling system
Incorrect
faulty
Troubleshoot
ignition timing
cooling system
7-5
o-13
Remedy
Reference
paw
I
<r.-.
,
Probable cause
Starting system
Troubleshoot
faulty
starting system
a-94
c
;.
,
i*
;-
!_
OK)
Symptom
Probable cause
Remedy
Reference
page
1485
Carburetor
Troubleshoot
fuel system
14-20
Troubleshoot
ignition system
problems
Ignition system
problems
Vacuum leaks
l
Purge control valve hose
l
Vacuum hoses
l
Intake manifold
l
Carburetor
l
EGR valve
Repair as necessary
Compression
Check compression
(Troubleshoot engine)
too low
9-14
.)
-T
.
1 ST6 Revision
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24
- Master
Troubleshooting
Probable cause
Remedy
Rough idle or
engine stalls
Vacuum leaks
l
Purge control valve hose
l
Vacuum hoses
l
intake manifold
0 Carburetor
l
EGRvalve
Repair as necessary
Ignition system
Troubleshoot
problems
ignition system
Readjust
idle speed
Readjust
Carburetor
Troubleshoot
fuel system
Troubleshoot
fuel system
Engine overheats
Compression
Check compression
(Troubleshoot
engine)
problems
too low
9-14
/
1 STB Revision
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lNTRODUCTlON
ENGINE
HESITATES
Troubleshooting
25
OR POOR ACCELERATION
Symptom
Engine hesitates
poor acceleration
- Master
Probable cause
or
Ignition system
Reference
paw
Remedy
problem
Troubleshoot
ignition system
8-l 09
Vacuum leaks
l
Purge control valve hose
l
Vacuum hoses
0 Intake manifold
l
Carburetor
l
EGRvalve
Repair as necessary
11-4
14-85
Carburetor
Troubleshoot
14-20
problem
Auxiliary accelerator
engine)
fuel system
14-43
25-33
25-34
Engine overheats
Compression
Check compression
(Troubleshoot engine)
9-14
too low
ENGINE DIESELING
Symptom
Probable cause
Remedy
Carburetor
Troubleshoot
Incorrect
problems
ignition timing
Reference;:!
page
1,.
fuel system
14-20
o-13
j ,
i
! ,;7
: ?:
I(, :.
4
kJi
I
%
1 STB Revision
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1,:
i j,;;
i ,:
b-i.cl-:
.i.
..
26
INTRODUCTION
EXCESSIVE
AND MASTER
TROUBLESHOOTING
- Master Troubleshooting
OIL CONSUMPTION
Symptom
Probable cause
Remedy
Reference
page
Excessive oil
consumption
Oil leak
Repair as necessary
o-17
9-45
9-45
9-55
Symptom
Probable cause
Fuel leak
Air cleaner
IRemsd
Reference
we
filter clogged
ignition problems
8-l 09
Carburetor problems
14-20
Check compression
9-14
22-2
Clutch slips
Troubleshoot clutch
6-4
Brakes drag
Troubleshoot brakes
Probable cause
Remedy
Retighten as necessary
Engine noise
Troubleshoot engine
/ ST6 Revision
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Reference
paw
9-l 1
INTRODUCTION
27
- Master Troubleshooting
HARD STEERING
. . NOOKBAC
Symptom
Probable cause
Hard steering
Loose power
steering
steering
system
of upper
No lubricantion
of tie-rod ball
of tie-rod
Remedy
Reference
page
Adjust
19-11
Refill
19-11
Bleed air
19-12
Adjust
22-2
Replace
2-35
2-40
Adjust
19-10
Correct
2-14
Replace
19-40
Lubricate
Replace
No lubrication
Lubricate
of idler arm
19-34
WHEEL TO CENTER
Symptom
Probable cause
Poor return of
steering wheel to
center
Improper
front wheel
Improper
tire pressure
Damaged
Remedy
alignment
Adjust
Adjust
Replace
POOR RIDING
i..
L..
Symptom
Probable cause
Remedy
Reference
we
Poor riding
Improper
tire pressure
Adjust
22-2
wheels
Repair
22-3
lmbalanced
Repair or replace
1.
;
2-14, 17-3:.
Replace
2-35, 174:
Replace
2-51
Replace
2-48
Loose suspension
Retighten
Improper
Malfunctioning
shock absorber
securing
bolt(s)
2-40
Replace
1 STB Revision
1
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28
INTRODUCTION
ABNORMAL
- Master Troubleshooting
TIRE WEAR
Symptom
Abnormal
Reference
page
Remedy
Probable cause
tire wear
Troubleshooting
wheels
and tires
shock absorber
ROAD WANDER
Symptom
Road wander
Probable cause
Remedy
Reference
we
Improper
Adjust
2-14
17-3
Excessive
play of steering
_^
VEHICLE
cj
19-9
wheel
1
1 Retighten
~
or replace
ZI
I
1 22:
wheel bearings
S+ptom
Probable cause
Vehicle pulls to
or& side
Improper
Remedy
Reference
page
Excessive
joint
turning resistance
of lower ball
2-40
2-23
Broken or worn
2-48
torsion bar
2-52
Deformed
2-40
lower arm
STB Revision
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INTRODUCTION
STEERING
- Master Troubleshooting
29
WHEEL SHIMMY
Symptom
Probable cause
Remedy
Reference
iwe
Steering wheel
shimmy
Improper
Adjust
2-14
17-3
Improper
tire pressure
( Adjust
1 22-2
Repair
Replace
2-37
2-40
Repair
19-9
Replace
2-51
Replace
2-40
Malfunctioning
Replace
2-35
Replace
2-48
17-4
Replace
2-23
Symptom
Probable cause
Remedy
Reference,
&;
page
Bottoming
Overloaded
Correct
t.:
Replace
2-48
17-4
t:.
::
f#:
Malfunctioning
Replace
2-35, l+
lmbalanced
wheels
of upper or
Excessive
shock absorber
BOTTOMING
vehicle
shock absorber
) STB Revision
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30
INTRODUCTION
WHEEL BEARING
- Master Troubleshooting
TROUBLESHOOTING
Trouble
Symptom
probable cause
Pitting
Excessive
Excessive
Flaking
Cracking
Chipping
Flat spotting
Excessive
Excessive
Vibration
not used,
shipment
transport
bearing preload
load
when bearings are
such as during
on freight cars,
trucks, etc.
Nicks
Improper
Excessive
Excessive
Faulty oil
grease
bearing preload
load
seal
Smearing
f&St, corrosion
i,q!3j
Appears
or cracking
I$
W)ear
Wear of surface
Improper grease
Foreign matter
Rust or corrosion due to
moisture
Use of grease other than that
specified
Faulty oil eal
,J .
.2
4
3
,I
&coloration
) STB Revision
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bearing preload
load
O-l
LUBRICATION
AND
MAINTENANCE
CONTENTS
GENERAL INFORMATION
.................................
MAINTENANCE
SERVICE
.... .......... . ..................
Air Filter ...........................................................
Automatic
Transmission
.................................
Ball Joint, Steering Linkage
Seals and Drive Shaft Boots ............................
Ball Joints with Grease Nipple
........................
Brake Fluid ......................................................
Brake Hoses ....................................................
Canister
...........................................................
Carburetor Choke Mechanism
and Linkage
.....................................................
Carburetor or Body Mounting
.........................
Cooling System
................................................
Crankcase Emission Control
System (PCV Valve) .........................................
Distributor Cap, Rotor and
Advanced angle System
.................................
Drive Belt .........................................................
EGR Valve ........................................................
Engine Oil ........................................................
Engine Oil Filter ...............................................
Evaporative Emission Control
System (except Canisters)
..............................
Exhaust System (Connection
Portion of Muffler and Pipings
and Keeping Warmth Covers) .........................
Fuel Filter .........................................................
Fuel Hoses, Vapor Hoses, and
Fuel Filler Cap ..................................................
2
9
16
22
26
27
26
26
18
14
21
24
17
19
10
19
9
9
17
28
15
Fuel System
....................................................
Front Axle and Rear Axle .................................
:7
Front Disc Brake Pads .....................................
25
Front Wheel Bearings
.....................................
27\yYl
Ignition Cables ................................................
19!*.:.=:
+: . .I
Inspection
and Adjustment
of Engine Idling
Speed ..............................................................
93 .....:.!.
I,....
Intake Temperature
Control
System
............................................................
~21.~,,.~.~
,
8
Manual Transmission
........................
I.. .......... .$22 : A:
Oxygen Sensor ........................
........................ 2:.)1 g : .Y:i>
Propeller Shaft Joints ......................................
C;,28::.
Rear Axle Oil (Limited Slip
, p;,
Differential)
..........................
~~~~~~~~~~~~~~~.~.~~~~.~~~,~~~~,
1;
.-I
Rear Drum Brake Linings and
Rear Wheel Cylinders ......................................
. 1.25 1; ..
Secondary Air System ............. I.. .................... Fc2,1, :
Solenoid Valve Air Filter of
&
* ;:
Vacuum Control System
.................................
2& .-:
1 f3$, , .::
Spark Plugs .....................................................
Transfer Case ..................................................
23 I$??
Vacuum Hoses, Secondary Air Hoses,
: .
Crankcase Ventilation
Hoses
and Water Hoses
............................................
15
.;
Valve Clearance
...............................................
11
RECOMMENDED
LUBRICANTS
AND
LUBRICANT
CAPACITIES
TABLE
.....................
6
SCHEDULED
MAINTENANCE
TABLE ..............
3
;::
1
16
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o-2
LUBRICATION
AND MAINTIENANCE-General
GENERAL INFORMATION
NOOPA-8
Maintenance
and lubrication
service recommendations have been compiled to provide maximum protection for the vehicle owners investment against all reasonable types of driving conditions.
Since these
conditions vary with the individual vehicle owners
driving habits, the area in which the vehicle is operated
and the type of driving to which the vehicle is subjected, it is necessary to prescribe lubrication
and
maintenance
service on a time frequency as well as
mileage interval basis.
Oils, lubricants and greases are classified and graded
according to standards recommended
by the Society
of- Automotive
Engineers (SAE), the American Petroleum Institute
(API) and the National
Lubricating
Grease Institute (NLGI).
MAINTENANCE
SCHEDULES
Information
for service maintenance
is provided under
SCHEDULED
MAINTENANCE
TABLE.
Three schedules
are provided;
one for Required
Maintenance,
one for General Maintenance
and
one for Severe Usage Service.
SEVERE SERVICE
ENGINE
GEAR LUBWCANTS
The SAE grade number also indicates
Multi-Purpose
Gear Lubricants.
the viscosity of
LUBRICANTS-GREASES
Semi-solid lubricants, bear the NLGI designation
and
are further classified as grades 0, 1, 2, 3 etc..
Whenever
Chassis Lubricant
is specified, MultiPurpose Grease, NLGI grade No. 2, should be used.
MATERIALS
ADDED TO FUEL
Indiscriminate
use of fuel system cleaning agents
should be avoided. Many of these materials intended
for gum and varnish removal may contain highly active
solvents or similar ingredients that can be harmful to
gasket and diaphragm materials used in fuel system
component
parts.
OIL
The SAE grade number indicates the viscosity of en. gine oils, for example, SAE 30, which is a single grade
oil. Engine oils are also identified by a dual number, for
;,:g
example, SAE lOW-30, which indicates a multigrade
oil.
The API classification
system difines oil performance
in terms of engine usage. Only engine oil designed
For Service SF or For Service SF/CC, when available, should be used. These oils contain sufficient:
chemical additives to provide maximum
engine protection. Both the SAE grade and the API designation
can
be found on the container.
mTB
Information
Revision
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LUBRICATION
SCHEDULED
AND MAINTENAN
MAINTENANCE
SCHEDULED MAINTENANCE
PERFORMANCE
Inspection
all vehicle
Emission
nance
E-Scheduled
System
Nooa&-
Mainte-
o-3
Table
TABLE
Maintenance
Kilometers
sands
Service Intervals
Mileage
sands
CONTROL
is observed
in Thouin
Thou-
or suspected.
Retain receipts
24
48
72
80
96
15
30
45
50
60
or
or
at
at
at
Clean Carburetor
Adjust as Required
Choke Mechanism
and Linkage
at
Ventilation Hoses
or
at
Air Filter
Emission Control System (PCV Valve) Every 5 Years
at
at
at
** Every 5 Years
) ST6 Revision
http://vnx.su/
or 1
or
or
or
NOTE
(1) *: Shows recommended maintenance items for California vehicles only, but are required for vehicles
except for California.
(2) l z: Except for California.
or
5 Years
or
at
or
Control System
or
Replace
or
Check Distributor
or
Replace Fuel Hoses, Vapor Hoses and Fuel Filler Cap Every 5 Years
Clean Crankcase
for
LUBRICATION
GENERAL
MAINTENANCE
AND MAINTENAhlCE-Scheduled
Maintenance
General Maintenance
Manual Transmission
in
Service Interval
Oil
Cooling System
,+*
.t.. .,.c NOTE
:!J.;
(l)"f*l:
STB Revision
-1
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Table
PERFORMANCE
o-5
SCHEDULED
MAINTENANCE
The maintenance
Maintenance
Item
items
should
be performed
Service to be
Performed
according
to the following
table:
Replace
Every 6 Months
or
Air Filter
Replace
Crankcase
Emission
Control System
More Frequently
More Frequently
Spark Plugs
Replace at
More Frequently
More Frequently
Engine Oil
Change
Every 3 Months
or
Change
oil at
24 (15)
48 (30)
72 (45)
96 (60)
Severe Usage
Conditions
E
1 STB Revision
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O-6
LUBRICATION
RECOMMENDED
RECOMMENDED
AND MAINTENANCE-R
LUBRICANTS
ecommended
Lubricants
and Lubricant
Capacities
Table
TABLE
LUBRICANTS
NOORA-B
Remarks
API classification
SF or SF/CC
API classification
GL-4 or higher
refer to SAE
sAEgraden
SAE80
75Wl85W
Automatic
Transfer
transmission
case
d
$Front axle
Automatic
DEXRON
transmission
II type
fluid
API classification
GL-4 or higher
SAE 80W or
API classification
GL-4 or higher
API classification
GL-4 or higher
-.
(Rear axle
Conventional
Limited-slip
Power
differential
differential
steering
Automatic
DEXRON
transmission
fluid
or DEXRON II type
r,
+TLakes and clutch
Conforming
,$nt
bearings
Multipurpose
Multipurpose
wheel
, ,J,
. .:
Do,$?hinges,
to DOT 3
DIA-QUEEN LONG-LIFE
COOLANT (Part No. 0103044)
or HIGH QUALITY ETHLENE
GLYCOL ANTIFREEZE COOLANT
.back door hinges
Engine oil
1 ST6 Revision
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LUBRICATION
LUBRICANT
AND MAINTENANCE
CAPACITIES
Recommended
Lubricants
and Lubricant
Capacities
Table
o-7
TABLE
Description
Metric measure
U.S. measure
Imperial measure
5.0 liters
4.4 qts.
0.5 liter
5.3 qts.
.53 qt.
8.0 liters
8.45 qts.
7.04 qts.
Manual transmission
2.2 liters
4.7 pints
3.9 pints
Automatic
Engine oil
Crankcase
Oil filter
Cooling system
tank)
(including
transmission
.44 qt.
7.2 liters
15.2 pints
12.7 pints
Transfer case
2.2 liters
4.7 pints
3.9 pints
Front axle
I. 1 liters
2.3 pints
1.9 pints
1 .I liters
1.8 liters
2.3 pints
3.8 pints
1.9 pints
3.2 pints
0.9 liter
60 liters
1.9 pints
15.9 gals.
1.6pints
Resr axle
Conventional differential
Limited-slip differential
Power
steering
Fuel tank
) STB
Revision
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13.2 gals.
1
T
:.
o-8
LUBRICATION
SELECTION
ENGINE
AND MAINTENANCE-
OF LUBRICANTS
i:
20
38
100
27
60
32
-12
10
-23
-10
-20
-29
SAE viscosity
No.
80
16
Lubricants
FRONT AXLE/REAR
OIL
Anticipated atmospheric
temperature range
Recommended
and
Lubricant
Capacities
AXLE (CONVENTIONAL
Table
DIFFERENTIAL)
Lubricant
API classification
GL-4 or higher
Anticipated tempeature
range
Viscosity
SAE 90
SAE 85W-90
SAE 8OW-90
-23C to -34C
SAE 80W
(- 10F to -30F)
SAE 8OW-90
Below -34C
(-30F)
range
SAE 75W
DIFFERENTIAL)
I:0 P.3-11.
53E531
.i
.-,
: *SAE 5W-20 Not recommended
.-I
:-.1, .\,behicle operation.
i . :;,,
;;,\ .I : 2P
.(.,. .
-I.
I
:..;j .;
*.
.,_
i
y;;:
<,.:I., CGOLANT
,,.
between
s1. , R$ation
,: ,-<
$
s- .
,.
..
.I
: - : :..
,.. ,,.- :,
. .
I
<- .
L.. - .,;
..:<,:..J
-P.; ./a
-. . .
Coolant
?;:
Example
.:. , .. The safe operating temperature
.; c-. (680~).
for sustained
Concentration
high speed
and Specific
Gravity
is - 15C (5F) when the measured specific gravity is 1.058 at the coolant temperature
of 20C
Cautions
1. lf the concentration
of the coolant is below 30%1, the anti-corrosion
property will be adversely affected.
In addition,
if the concentration
is above 60%, both the anti-freeze
and engine cooling properties
will
decrease, affecting the engine adversely. For these reasons, be sure to maintain
the concentration
level
within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
( ST6 Revision
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LUBRICATION
AND MAlNTENANCE-Maintenance
MAINTENANCE
ENGINE
o-9
Service
SERVICE
NOOSMC
OIL (Change)
(1) After warming up the engine, remove the oil filler cap.
(2) Remove the drain plug to allow the engine oil to drain.
(3) Replace the drain plug gasket with a new one and tighten
drain plug.
(4) Pour new engine oil through the oil filler.
Engine
ENGINE
oil total
quantity
: 5.0 liters
Imp.qts.)
(5.3
U.S.
qts.,
the
,; +
:
I*
4.4,
A!
1i
:.
f
,
Cl
.\
.<,
$ ,..
ENGINE OIL FILTER SELECTION
:e f
This vehicle is equipped with a full-flow, throw-away oil filter. the: -;i ;j
same type of replacement filter is recommended
as a replacement
filter for this vehicle. It is possible, particularly in cold weather, that:. -j..
this vehicle may develop high oil pressure for a short duration. Yo&..,?. . :should be sure that any replacement
filter used on this vehicle is I,- ::$
a high-quality filter and is capable of withstanding
a pressure of , :.
1800kPa (256 psi) (manufacturers
specifications)
to avoid filter
and engine damage. The following is a high-quality
filter and is
strongly recommended
for use on this vehicle:
Mitsubishi
t ,:;
Engine Oil Filter Part No. MD084693
or MD031805.
Any replacement
oil filter should be installed in accordance with :<.i
the oil filter manufacturers
installation instructions.
REPLACEMENT
OF ENGINE OIL FILTER
1. Remove the engine oil filler cap.
2. Remove the engine oil drain plug and drain the engine oil.
3. Using the oil filter wrench, remove the engine oil filter.
/ STB Revision
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: MD031805
or equivalent
~~
LUBRICATION
AND MAINTENA
CE - Maintenance
Service
ding
mo54:
Alternator
pulley
Crankshaft
pulley
are clean.
DRIVE
Water pump
pulley
surfaces
BELT (Replace)
NOOSBBA
0400020
Standard
: 9-12
value:
mm
(.35-.47
in.)
REPLACEMENT
OF DRIVE
BELT
Vehicles
without
an air conditioner
1. Loosen the alternator
brace bolt and alternator
nut, and then remove the alternator
drive belt.
2. Install a new alternator
drive belt.
3.
value
: 9-12
mm
(.35-.47
in.)
STB
CL
Revision
support
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support
nut
LUBRICATION
AND
AINTENANCE
- Maintenance
O-II
Service
remove
the
3.
value
: 9-12mm
(.35-.47
in.)
.
...I
VALVE
quired)
CLEARANCE
(Check
and
adjust
as
r&:.. :I.!
NooSA&
Incorrect
valve clearances
will not only result in unsteady
engine operation,
but will also cause excessive
noise and
reduced engine output.
Check the valve clearances
and adjust as required while the
engine is hot.
Valve-to-rocker
Jet valves
Rocker
arm
Auto-lash
adjuster
arm clearances
:
. . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm
(.0098
in.)
VALVE CLEARANCE
ADJUSTMENT
Intake and Exhaust Valves
The auto-lash adjuster is installed to the rocker arm so that the
valve clearance
adjustment
is maintenance-free.
For additional
information
regarding
the auto-lash
adjuster,
refer to GROUP 9 ENGINE.
6EN198
avision
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o-12
LUBRICATION
AND MAINTENANCE
Jet
- Maintenance
valves
Caution
The cyllinder
head bolts
attempting
this adjustment.
I.
2.
3.
4.
5.
Service
should
be
retightened
before
in the forward
Note
If the camshaft
sprockets
mating
opposite position, the No. 4 cylinder
rotation
5EN075
at compression
6.
Standard
: 0.25
by the
Exhaust valves
rant 0
mgine
Note
The valve
value
(when
clearance
when
ct --I-Inlet valves
Inlet valves
5EN2
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warm)
cold
mm
is 0.17
(.0098
mm
(.007
in.)
in.)
LUBRICATION
AND
MAINTENANCE
- Maintenance
o-13
Service
in, because
adjust
the jet
torque.
9.
Coat this area with sealant
10 mm (.39 in.)
10 mm l.39 in.)
..
3EN325
12. Install
13. Install
14. Install
,b\
AND
INSPECTION
ADJUSTMENT
OF
EN
IDLING SPEED
Caution
The improper
setting (throttle
value opening)
will in
exhaust gas temperature
at deceleration,
reducing catalyst
life
greatly
and
deteriorating
exhaust
gas cleanihg
performance.
If also has effect on fuel consumption
and eni
gine braking.
Inspection
1.
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Conditions
85-95C
(185-205F)
Lights and accessories (air-conditioner,
etc.): OFF
l
Transmission:
Neutral
l
Steering wheel: Centered (for power steering equipped vehicles)
1. Prepare a timing light and tachometer.
2. Start the engine and allow it to idle.
3. Inspect the ignition timing. Adjust the ignition timing if necessary.
l
l
Standard
*:
ignition
timing
: 7 BTDC
&2*
When inspecting the standard ignition timing at high altitudes, disconnect the white striped vacuum hose from the
distributor auxilian/ compression
chamber and temporarily
close the end of the hose with a blind plug. (Federal indicated high-altitude
specificatioin
vehicles, California).
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o-14
LUBRICATION
AND
MAINTENANCE
Maintenance
NOTE
Inspect and adjust ignition timing
ELECTRICAL-Ignition
System.
4.
5.
6.
Service
as described
in GROUP
725+15'
-100
800+100
NOTE
M/T : Manual transmlsslon
A/T : Automatic transmission
Caution
DO NOT TOUCH SAS-2. The idle speed adjusting
screw (SAS2) is the preset screw that determines
the relationship
between the throttle
valve and free lever, and has been accurately set at the factory. If this setting is disturbed,
throttle
opener adjustment
and dash pot adjustment
cannot be done
accuratlely.
CARBURETOR
(Clean)
CHOKE MECHANISM
AND LINKAGE
NOOSAEB
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LUBRICATION
AND
ramper Prevention
Concealment
plug
lFU34!
MAINTENANCE
Maintenance
Service
o-15
Caution
1. All carburetors
have a tamper-proof
choke. The chokerelated parts are factory adjusted. The choke adjustment
is
required during service, except when major carburetor
service or overhaul choke calibration
related parts adjustments are needed by state or local inspections.
2. All carburetors
also have a tamper-resistant
idle mixture
adjusting
screw. The CO setting has been done as a factory adjustment.
Neither removal of the plug nor adjustment of Uhe mixture screw is required during service unless a major
carburetor
overhaul,
throttle
body
replacement,
or high idle-CO adjustments
are needed by
state or local inspections.
1FUW
NOOSAFA
FUEL SYSTEM
NC&+
,;
, 1.
VACUUM
HOSES,
SECONDARY
AIR HOSES,
CRANKCASE
VENTILATION
HOSES AND WATER
HOSES (Replace)
Replace them and then make sure that the hoses do not come in
contact with any heat source or moving component which might
cause heat damage or mechanical wear.
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,.
O-16
LUBRICATION
AND
MAINTENANCE
- Maintenance
Service
HOSES AND
FUEL FILLER
Service procedures to check the hoses for damage are the same
as those described in the section Vacuum hoses, secondary air
hoses, crankcase ventilation hoses and water hoses.
NOOSAKC
The air filter will become dirty and loaded with dust during
use, and the filtering
effect will be substantially
reduced.
Replace it with a new one.
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Remove the wing nut. Use pliers only if the wing nut is difficult
to remove.
Unsnap the finger clips.
Remove the filter by hand, and replace it with a new filter.
4.
Install the air filter, and then install the cover and housing,
taking care that the arrows are aligned.
5. Tighten the wing nut by hand.
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LUBRICATION
AND
MAINTENANCE
Maintenance
CRANKCASE EMISSION
valve) (Clean)
o-17
Service
CONTROL
SYSTEM
(PCV
PCV valve
To intake manifold
Air filter
CV
-.
valve
\
Ca;buretor
) M
1 /,I
Rocker
, I I;
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1.
If vacuum is not felt on finger, clean the PCV valve and v&-,
tilation hose in cleaning solvent or replace if necessary.
., :
EVAPORATIVE
EMISSION
CONTROL
SYST&l
(Check for leaks and clogging) - except canister&;.
:,
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1. If the fuel-vapor vent line is clogged or damaged, a fuel-vapor
-.i:
mixture escapes into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean witti:,:, ;:L:
compressed air. Remove the filler cap from the filler pipe and *::+l;i,
.!
check to see if there is evidence that the packing makes improper contact to the filler pipe.
..:T
2. The overfill limiter (2-way valve) installed on the vapor line
:.,.
should be checked for correct operation.
: ._.
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O-18
LUBRlCATlON
MAINTENANCE
AND
Purge
Air filter
control valve
To ther mo
valve
Maintenance
Service
Bowl vent
valve
Canister
Charcoal
uel vapor
-F
---
To carburetor
--I
Purge air
Filter
I----
Fuel tank
Fuel
gauge
unit
03W527
CANISTER
(Replace)
If or when the canister filter becomes clogged, the purge air volume will decrease and consequently,
the canister capacity will be
reduced.
NoQmO
B
1. Spark plugs must fire properly to assure proper engine performance and emission-control.
Therefore,
they should be replaced periodically
with new
ones.
NGK
Other
DENS0
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0.9-I,0
1.0-l
type
ml_
OlR0119
mm (.035-.0.39
in.)
.l mm (.039-.043
in.)
LUBRICATION
Correct
AND
MAlNTENANCE
IG NIT1
Incorrect
- Maintenance
o-19
Service
NOOSAPB
CABLES (Replace)
NOOSARA
-1
Replace EGR valve to a new one.
t, .
A;
REMOVAL OF EGR VALVE
1. Disconnect the vacuum hoses from the EGR valve.
2. Disconnect the EGR valve from the intake manifold.
3. Replace the EGR valve gasket with a new one.
4. Install the EGR valve onthe intake manifold and tighten to th&
specified torque.
Hexagon
Ele
nUt
Housing
OXYGEN
Spring
SENSOR
(Replace)
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Nm
(ft.lbs.)
DISTRIBUTOR
GLE SYSTEM
AN-
system
to
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o-20
LUBRICATION
AND
MAINTIE.NANCE
- Maintenance
Service
INSPECTION
OF DISTRIBUTOR
CAP AND ROTOR
Inspect in accordance with the following procedure. Repair Or replace as necessary.
l
Check the cap for cracks.
l
Check the cap and rotor electrodes
for damage.
Wipe clean the cap and rotor.
INSPECTION
1.
2.
OF CENTRIFUGAL
SPARK
ADVANCE
DEVICE
3.
increasing engine
as engine
speed
NOTE
Centrifugal
properties
(Reference)
Symptom
Probable Cause
Governor
Spring is broken
spring
weak
or missing
rpm
5EL03t
INSPECTION
OF VACUUM
ADVANCE
DEVICE
*:
Disconnect
the vacuum hoses from the main vacuum
chambers, (High-altitude
areas nationwide, California)
Slowly apply vacuum with the vacuum pump and inspect the
advance angle.
3.
increases.
OlRO418
Vacuum properties
(Reference)
NOTE
rSymptom
-13(-l
.9)
-27(-3.9)
Pressure
-4O(-5.8)
kPa
-67(-9.7)
-53(-7.7)
(psi)
Probable Cause
Spring is broken
Angle
is 60
large
1 Diaphragm
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is damaged
LUBRICATION
AND MAINTENANCE
O-21
Service
- Maintenance
INTAKE
(Check)
TEMPERATURE
CONTROL
SYSTEM
?WSATA
SECONDARY
AIR SYSTEM
Refer to GROUP
Emission Control
25 EMISSION
CONTRaL
System, for the inspection
SOLENOlO
Filter
assembly
I
-Filter
opener
(Check)
NWSAUA
SYSTEMS-Exhaust
procedure.
6* j
control
solenoid
valve]
CARBURETOR
OR BODY MOUNTING
(Check) -&
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O-22
LUBRICATION
AND MAINTENANCE
MANUAL
Service
- Maintenance
TRANSMISSION
~00s~
Inspect each component for evidence of leakage, and check the oil
level by remaining the filler plug. If the oil is contaminated,
it is
necessan/ to replace it wi,th new oil.
INSPECTION
l
With the vehicle on a level surface, remove the filler plug and
chelck whether or not the oil is at the same level as the bottom
of the threads.
l
Check whether or not the transmission oil is excessively dirty,
and if the viscosity is normal.
Nm (ft.lbs.)
Drain plug
O!moo21
REPLACING
1. Rernove
2. Replace
3. Fill with
the plug
transmission
Manual
TRANSMISSION
OIL
the drain plug and drain the transmission
oil.
the gasket with a new one and tighten the drain plug.
new oil through the filler plug until the oil level reaches
hole.
transmission
oil capacity
: 2.2 liters
(4.7 U.S.
pints.,
3.9 Imperial
pints.)
03FO12
AUTOMATIC
.
COLD
HOT
372023
TRANSMISSION
Check the fluid level by removing the fluid level gauge. If the fluid
is contaminated,
it is necessary to replace it with new fluid.
1. Place the vehicle on a levei surface.
2. Wipe the area around the oil dipstick to remove accumulated
dirt and then pull out the oil dipstick.
3. Set the selector lever to the P (Park) position and apply the
parking brake. Next, start the engine.
4. Check if the engine idle speed and fluid operating temperature
(50-80C;
122-176F)
are normal.
5. Move the selector lever to each position in turn to fill the
torque convertor and hydraulic system with fluid and then
return the selector lever to the N (Neutral) position.
6. Make sure the fluid level is in the HOT
range of the oil
dipstick . If the fluid level is low, add fluid until it reaches the
ItlOT range.
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LUBRICATION
AND MAINTENANCE
Maintenance
Service
O-23
REPLACEMENT
OF AUTOMATIC
TRANSMISSION
FLUID
Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new .fluid after the cause of any contamination
has
been corrected.
1. Place a large flat container beneath the drain plug.
2. Remove the drain plug and drain the fluid.
3. Replace the gasket with a new one and tighten the drain plug.
4.
TRANSFER
CASE (Change
oil)
NOOSBNB
-)C--Filler
..-.
Pkl
(22-25)
(ft.lbs.1
144003
3. Supply new transfer case oil through the filler plug until it
reaches the same level as the plug hole.
Transfer
vision
capacity
I
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: 2.2
liters
(4.7
U.S.
pints, 3.9 Imp. pints)
j .
., ./-
O-24
kUBRlCATlON
AND
MAINTENANCE
COOLING
quired)
SYSTEM
Maintenance
(Check
Service
and
service
as t-eNOOSBEA
WJ6616
(Refer to GROUP
7 COOLING-Ther-
Inspection
l
Replace the thermostat
if there is even the slightest
opening
of the valve at room temperature.
l
Replace if the exterior of the thermostat
is noticeably
deformed,
or if it is damaged
or broken.
l
Clean away any corrosion
or sediment
adhered to the
valve.
l
Fill a container with water, and immerse the thermostat
in
it; increase the water temperature
and check whether or
not the thermostats
initial opening temperature
and fully
opened temperature
[valve lift amount when fully opened:
8 mm (.31 in.) or more] are the specified
values.
-.
Standard
value
: Initial
valve-opening
temperature:
88 + 1.5% (190 2 3F)
Fully opened
valve temperature:
100C (212F) or higher
NOTE
The lift amount is calculated
by first measuring
the valve
height when fully closed, and then measuring
the height at
the fully open temperature.
ANTIF:REEZE
The engine cooling system is provided with a mixture of 50%
ethylene
glycol anti-freeze
and 50% water at the time of
manufacture.
Since the cylinder head and water pump body are made of
aluminum
alloy casting, be sure to use a 30 to 60% ethylene
glycol antifreeze coolant to provide corrosion
protection
and
freezing prevention.
Caution
If the concentration
of the antifreeze
is below 30%, the
anticorrosion
property
will be adversely
affected. in addition, if the concentration
is above 60%, both the antifreezing and engine cooling
properties
will decrease,
adversely
affecting the engine. For these reasons, be sure to maintain
the concentration
level within
the specified
range.
MEASUREMENT
OF ANTIFREEZE
CONCENTRATION
Run the engine until coolant is fully mixed. Drain some coolant
(antifreeze), and measure temperature
and specific gravity of
the coolant. Determine
concentration
and safe working temperature. If the coolant is short of antifreeze, add antifreeze up
to a concentration
of 50%.
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LUBRICATION
AND MAINTENANCE
- Maintenance
O-25
Service
CHANGING
COOLANT
1. Set the temperature
control lever to the hot position.
2. Remove the radiator cap, radiator drain plug and engine
drain plug to drain the coolant.
Caution
When removing
the radiator
cap, use care to
contact with hot coolant or steam. Place a shop
over the cap and turn the cap counterclockwise
to let pressure
escape through
the vinyl tube.
relieving
the steam pressure, remove the cap by
turning
iP counterclockwise.
avoid
towel
a little
After
slowly
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14K512
Caution
The pads for the right and left wheels should be replaced at
the same time. Never split or intermix
brake pad sets. All
four pads must be replaced as a complete
set.
grease
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: Brake
:
:
grease
SAE 5310,
NLGI
No.1
1.
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O-26
RICATION
BNTENANCE
AND
2.
Maintenance
Service
14KO24
BR
or lea\dm
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..
7
NOOSBIB
brake fluid
: DOT3
2. The reservoir cap must be fully tightened to avoid contamination from foreign matter or moisture.
DO NOT ALLOW PETROLEUM
BASE FLUID TO CONTAMINATE
THE BRAKE FLUID-SEAL
DAMAGE WILL RESULTCaution
Take care in handling
brake fluid as it is harmful
and may also cause damage to painted s&aces.
to the eyes
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NOOSBJA
1. These components,
which are permanently
lubricated at the
factory, do not require periodic lubrication. Damaged seals and
boots should be replaced to prevent leakage or contamination
of the grease.
2. Inspect the dust cover and boots for proper sealing, leakage
and damage. Replace them if defective.
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LUBRICATION
AND
MAINTENANCE
- Maintenance
O-27
Service
IPPLE
GREASE
(Lubricate
NOOSBOB
Fill the specified grease at the grease nipple till the grease come
out of the dust seal of the pitman arm, tie rod, lower control arm
and upper control arm.
Specified
grease
: Multipurpose
No. 2
grease
SAE J310,
(Lubricate
grease)
NLGI
NOOSBKo,.I
for evidence of grease leakage around the hub cap and the
the hub. If there is leakage of grease, remove the hub and
its oil seal for damage. Clean the grease off the hub and
and repack with specified new grease.
grease
: Multipurpose
grease
SAE 5310,
NLGI
I
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No. 2
-1
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NOTE
Refer to GROUP 2 FRONT SUSPENSION-Axle
Hub and Fre$ . .a:
(
_,_
wheeling Hub, for the removal procedures of the front hub.
I
is.
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O-28
LUBRICATION
AND
MAINTENANCE
- Maintenance
REAR AXLE
(Change)
OIL
(LIMITED-SLIP
Oil capalcity
PROPELLER
Service
SHAFT
DIFFERENTIAL)
NooSBaA
(3.2 U.S.pints.,
JOINTS
2.6 Imp.pints.)
(Lubricate
grease
EXHAlJST
MUFFLER
COVERS)
: Multipurpose
No. 2
grease
with
grease)
NOOSBRB
specified
SYSTEM (CONNECTION
PORTION OF
AND PIPINGS AND KEEPING WARMTH
(Check and service as required)
NOOSBLA
1. Check for holes and gas leaks due to damage, corrosion, etc.
2. Check the joints and connections for looseness and gas leaks.
3. Check the hanger rubber and brackets for damage.
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9-l
N09AA--
CONTENTS
CRANKSHAFT,
FLYWHEEL AND DRIVE
PLATE
.................................................................
60
CYLINDER
BLOCK
.............................................
64
CYLINDER
HEAD
................................................
39
CYLINDER
HEAD GASKET
................................
ENGINE
AND TRANSMISSION
ENGINE
MOUNTING
FRONT
SHAFT
ASSEMBLY
17
.... 23
.........................................
50
.................................
GENERAL INFORMATION
Sectional View .................................................
JET VALVE ASSEMBLY
....................................
...............................
PISTON
ROD
ROCKE
AND CONNECTING
ARM AND SHAFT
ASSEMBLY
....................
.............
SERVICE
ADJUSTMENT
20
2
3
48
16
54
36
33
12
13
12
. . . . . . . . . .. . . . . . . .. 14
Checking Compression
Pressure
Replacement
of Engine Oil .,.._.,......................
12
Replacement
of Engine Oil Filter .. . . . . . . . . .. . . . . . . .. 12
t .i
.,
I
Retorquing
of Cylinder Head Bold . . . . .. .. . . . . . . .. . . 13
Silent Shaft Drive Chain
.. .. . . . . . . . . .. . . . . . . . . 14
Tension Adjustment
Procedure
SPECIAL
..,..................s...............m..........
TOOLS
10
4
...............................................
SPECIFICATIONS
....................................
General Specifications
Service Specifications
.....................................
Torque Specifications
.....................................
Sealants and Adhesives
..................................
4
4
9
10
TIMING
28
CHAIN
TRAIN
TROUBLESHOOTING
Excessive Engine
. . . . .. . . . . ..*...............*..........
. . . .. . . . . . . . . . . . .. . . . . . . . . ...*..........
Rolling and Vibration
Compression
Too Low
Connecting
Rod Noise/Main
Noisy Valves
Oil Pressure Drop
Oil Pressure Too High
Timing Chain Noise
VALVE AND VA!,VE
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SPRINGS
Bearing
11
Noise
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. . . . . . . . .. . . . . . . . . .. . . . . . . ,42:,
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ENGINE-General
Information
GENERAL INFORMATION
T
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IJOBBACB
5ENl44
5EN145
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t
9-4
SPECOFIC4TIONS
GENERAL
SPECIFICATIONS
NO9CA-B
Specifications
Items
In-line OHC
Type
Number of cylinders
Bore mm (in.)
4
91 .I (3.5866)
Stroke
98 (3.8583)
mm (in.)
Piston djsplacement
Compression
2555 (155.9)
cc (cu.in.)
7.0
ratio
Firing order
1-3-4-2
Valve timing
Intake valve.
Opens (BTDC)
25
Closes (ABDC)
59
Exhaust valve
Opens (BBDC)
64
Closes (ATDC)
20
Jet valve
Opens (BTDC)
Closes (ABDC)
25
59
Valve overlap
45
264
264
264
:SERVlCE
SPECIFICATIONS
NOSCB-
Specifications
Items
andard value
Cylinder head
Overall height
Flatness
mm (in.)
of gasket
of manifold
Oversize
rework
Intake
Exhaust
Oversize
exhaust)
mm (in.)
surface
Flatness
mounting
dimension
90.0 (3.5433)
surface
mm (in.)
47.300-47.325
(1.8622-1.8632)
47.600-47.625
(1.8740-I
40.300-40.325
(1.5866-1.5876)
40.600-40.625
(1.5984-1.5994)
13.050-13.068(.5138-.5145)
I,
13.250-I
13.500-I
3.268 (.5217-.5224)
3.518 (.5315-.5422)
Timing chain
102
No. of links
mm (in.)Pitch
..
.8750)
;I.
9.5 (.3740)
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ENGINE
9-5
- Specifications
Specifications
Items
I
Timing chain B for silentshaft
drive
90
No. of links
Pitch
mm (in.)
Clearance between
mm (in.)
4;,
8.0 (.3150)
0.2-0.8 (.0079-.0315)
Camshaft
Cam height
mm (in.)
Intake
42.4 (1.6693)
Exhaust
42.4 (1.6693)
37 (1.4567)
mm (in.)
Fuel pump drive cam 0.0.
mm (in.)
Journal diameter
34 (1.3386)
Oil clearance
0.03-0.05
mm (in.)
End play
(.0012-.0020)
.P.
_.i
,t,
0.1-0.2 (.004-,008)
mm (in.)
Rocker arm
I.D.
mm (in.)
18.9 (.7441)
Clearance (Rocker
0.01-0.04
mm (in.)
arm-to-shaft)
(.0004-.0016)
18.9 (.7441)
mm (in.)
Valve
Valve length
mm (in.)
Intake
107.96 (4.2504)
Exhaust
105.86 (4.1677)
Stem 0.D
Intake
mm (in.)
8.0 (.3150)
8.0 (.3150)
Exhaust
4545.30
Face angle
Thickness
Intake
1.2 (.047)
Exhaust
2.0 (.079)
mm (in.)
mm (in.)
Intake
0.03-0.06
(.0012-.0024)
Exhaust
0.05-0.09
(.0020-.0035)
Valve guide
Length
..
mm (in.)
Intake
47 (1.8504)
Exhaust
52 (2.0474)
0.05 (.0020) 0.25 (.OlO) 0.50 (.020)
Oversize
mm (in.)
rework
Intake
Exhaust
_=
c.
I).
0.7-I .2 (.0276-.0472)
mm (in.)
45
mm (in.)
8.2-8.4 (.3228-.3307)
I.
,
1:
._
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9-6
ENGINE
-Specifications
Specifications
Items
Valve spring
Free length
Load
49.8 (1.961)
mm (in.)
N (Ibs.)
at installed height
322.6 (72.5)
Installed height
Out of square
mm (in.)
40.4:1.591)
2
Jet valve
Length
mm (in.)
Stem O.D.
91.58 (3.6055)
mm (in.)
4.3 (.1693)
45
Seat angle
Valve clearance-Hot
engine
Valve clearance-Cold
mm (in)
engine (reference)
0.25 (.OlO)
mm (in)
6.17 (.007)
29.6(1.1654)
Installed height
21.5 (.846)
Max 1.5
34.3 (7.7)
mm (in.)
Out of squareness
at Installed height
Cylinder block
Cylinder bore
Out-of-roundness
Over height
Flatness
91 .l (3.5866)
mm (in.)
and taper of cylinder bore
mm (in.)
316 (12.4409)
mm (in.)
of gasket
surface
mm (in.)
?.
mm (in.)
21 (.8268)
43 (1.6929)
mm (in.)
mm (in.)
0.1 o-o. 13 (.0039-.0053)
.,.. g @ear
Left silent shaft
Front journal diameter
mm (in.)
mm (in.)
Oil clearance
23 (9055)
43 (1.6929)
mm (in.)
Front
0.02-0.06
(.0008-.0024)
Rear
0.10-0.13
(.0039-.0053)
Piston
O.D.
mm (in.)
91 .l (3.5866)
0.02-0.04(.0008?+0016)
mm (in.)
Clearance (Piston-to-cylinder)
mm (in.)
1.5 (.591)
Oil
4.0(.1575)
Compression
Pressure
pressure
difference
Oversize
kPa (psi)
between
cylinders
mm (in.)
Piston ring
Side clearance
mm (in.)
0.05-0.09
0.02-0.06
No. 1
No. 2
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.,-;
_-I
.9
1200(170)960(136)
kPa (psi)
k?,
_I
(.0020-.0035)
(.0008-.0024)
9-7
ENGINE-Specifications
Specifications
Items
End gap
mm (in.)
0.30-0.45
(.0112-.0177)
No. 2
0.25-0.40
(.0098-.0158)
0.30-0.80
(.0118,.031
No. 1
Oversize
mm (in.)
Connecting
!j)..
0.25(.010)0.50(.020)~.75(.030)1.00(.039)
rod
Bend
mm (in.)
0.05(.0020)
Twist
mm (in.)
0.10 (.0039)
Connecting
Piston
pin press-in
Connecting
load
0.1-0.25
mm (in.)
7350-I
N(1b.s.)
(.0039-.0098)
7 150 (1650-3860)
Oil clearance
Under
size
Crankshaft
0.02-0.05
mm (in.)
mm (in.)
(.0008-.0020)
main bearing
Oil clearance
Under
mm (in.)
0.02-0.05
mm (in.)
size
(.0008-.0020)
Crankshaft
Pin O.D.
53 (2.0866)
mm (in.)
Journal
O.D.
End play
60 (2.3622)
mm (in.)
Out-of-roundness
and taper
of journal
mm (in.)
and pin
0.05-0.18
mm (in.)
Undersize
rework
dimension
(.0020-.0071)
mm (in.)
of pin
52.735-52.750
(2.0762-2.0763)
52.485-52.500
(2.0663-2.0669)
52.235-52.250
(2.0565-2.0571)
59.735-59.750
(2.3518-2.3524)
59.485-59.500
(2.3419-2.3425)
59.235-52.250
(2.3321-2.3327)
Undersize
rework
Oil pressure
temperature
dimension
of journal
mm (in.)
Min. 80 (11.4)
Oil
kPa (psi)
Oil pump
Driven
gear
-,
Tip clearance
0.1 l-0.15
mm (in.)
Side clearance
mm (in.)
0.04-O.
(.0043-.0059)
10 (.0016-.0039)
Drive gear
Tip clearance
Side clearance
Load
0.05-O.
mm (in.)
Free height
Relief spring
0.1 I-0.15(.0043-.00;9)
mm (in.)
11 (.0020-.0043)
46.4 (1.8346)
mm (in.)
60(13.4)at40.1
N (Ibs.)
mm (1.5787
in.)
Limit
Cylinder
head
Overall
* Must
height
Flatness
of gasket
Flatness
of manifold
be -0.2
* - 0.2 * ( - .0079)
mm (in.)
surface
mounting
.<
0.2 (.0079)
mm (in.)
mm (in.)
with
0.3 (.0118)
_
the amount ot gnndlng
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blOCkS$asket
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9-8
ENGINE
- Specifications
Items
Camshaft .
Cam height
Specifications
mm (in.)
;
Intake
Exhaust
End play
41.9 (1.6496)
41.9 (1.6496)
,-
mm (in,)
0.4(.016)
Valve
Thickness
mm (in.)
Intake
0.7 (.028)
Exhaust
Valve stem to valve guide clearance
Intake
1.5 (.059)
mm (in.)
0.1 (.0039)
Exhaust
0.15 (.0059)
Valve spring
Free length
Installed
mm (in.)
height
48.8 (1.922)
mm (in.)
41.40 (1.6299)
Out of squareness
Cylinder block
Over height
Flatness
mm (in.1
of gasket surface
* - 0.2 ( - .0079)
,,,.,
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-mm (in.)
0.1 (.0039)
Piston
pressure
kPa (psi)
i &&mpression
.: L.2,. F,&
~j?i&of@ing
..,;.
Side clearance
mm (in.)
-.:
., ..,.
:?
0.12 (.005)
No. 1
No. 2
0.1 (.004)
sEnd gap
..
:.*
960 (136)
mm (in.)
No. 1
0.8 (.031)
No. 2
Oil ring side rail
0.8 (.031)
1.o (.039)
Connecting
rod
,_ Connecting
main bearing
Crankshaft
End play
mm (in.)
mm (in.)
*:
0.4 (.016)
0.1 (.004)
0.1 (.004)
0.4 (.016)
Fly wheel
:Runout
.:,.Oil&~p
mm (in.)
0.13 (.0051)
Driven gear
Tip clearance
Side clearance
mm (in.)
mm (in.)
0.2 (.0079)
0.15 (.0006)
Drive gear
Tip clearance
mm (in.)
0.2 (.0079)
Side clearance ,, mm (in.)
0.15 (.0006)
>-,;..;.
,-i :._
* Must be -0.2 mn-$&0039 . in.) or less,(combined
with the amount of grinding of the cylrnder heads gasket surface.) -
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TORQUE SPECIFICATIONS
Items
Cylinder head bolts-Cold
Cylinder head bolts-Hot
&f+JJ
engine
engine
100-110
<;;
&
7-3-79
15-22
11-15
Camshaft
19-21
14-15
Camshaft
sprocket
50-60
bolts
5-7
3743
,g+>~
18-22
g[+$3;15
8-10
75-85
55-61
Connecting
45-48
33-34
.9-13
110-130
80-94
60-70
44-50
60-70
44-50
4-6
4-5
130-I 40
94-l 01
130-I 40
94-l 01
50-60
37-43
8-10
6-7
bolt
cover bolts
Flywheel
bolts
brackets
bolts
Chain guideB
bolt (Upper)
15-22
II,15
10-12
7.5-8.5
IO-12
IO-12
7.5-8.5
Thrust platebolt
IO-12
7.5-8.5
6-8
4.5-5.5
35-45
26-32
15-22
30-45
mounting
bolt
8-12
nut
16-19
pipe
front insulator
to body
Plate to body
Plate to transfer mounting insulator
Transfer mounting insulator to transfer
Transfer mounting
No. 2 crossmember
mounting
bracket to transfer
to engine mounting
bracket
rear insulator
7.5-8.5
20-30
30-40
13-20
22-29
9-15
55-75
40-54
18-25
13-18
18-25
13-18
30-42
22-29
18-25
13-18
18-25
..
18-25
rear bracket
8-11:
shroud r$unting
3-7
bolts
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13-18
13-18
18-25
18-25
18-25
30-42
,&
i.;,
13-18
,I_;1,3-1 8 +:I
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ENGINE -Specifications
/ Special Tools
Nm
ft.lbs.
16-24
12-17
C&$ol~lWer
assembly to transfer
Cross shaft bracket to body
15-22
11-16
IO-13
7-9
31-42
22-29
50-60
36-43
50-60
36-43
20-25
15-18
30-35
22-25
Items
. . . ..(?i
..-.c,
f :,.
i?d$e.r steering pressure
Air-conditioner
compressor
to discharge
Air-conditioner
compressor
to suction
XSEALANTS
hose
hose
AND ADHESIVES
Items
. -,:<
S: Semi-circular packing
Cylinder block lower surface
Oil pressure
Specified
(4 places)
switch
Quantity
As required
As required
As required
-A
,,
SPECIAL TOOLS
Tool (Number
and name)
;MD998377-01
:kstaller, valve stem seal
NOODA-C
Use
Tool (Number
and name)
MD998250-01
Installer, silent shaft bearing
(For rear bearing)
[Used with MB990938-011
Use
Press-fitting
bearing
&silent
:
St
.[7@
-:
,.
.
4,
.J:;
7.
MD998309
Prier, jet valve ipriiii
Assembling
disassembly
assembly
and
of jet valve
.
MD998443-01
Holder, auto-lash adjuster
MD9981 84-01
Setting tool, piston pin
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ENGINE-Special
Tools /Troubleshooting
I
Use
vlD998308-01
nstaller, jet valve stem seal
MD998376-01
Installer. crankshaft
seal
[Used with
vlD998310
Nrench, jet valve
M B990938-01
Installer, right silent shaft
front bearing
AD998251-01
uller, silent shaft bearing
For rear bearing)
Used with MIT3042041
roof (Number
and name)
TROUBLESHOOTING
L
Probable cause
Co,m@ession
33
.
too low
Reference
page
Replace gasket
9-39
Replace rings
9-56
. 5,
Remedy
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Oil pressure
.f
drop
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Oil pressure
switch-faulty
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Excessive
bearing clearance
.,
Replace bearings
9-54
/ 9-65
_
9-12
9-64
9-50
-.9,5p
1 g-50
.i!
9-50!i
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ENGINE-Troubleshooting/Service
.
Adjustment Procedures 1
,/:
Probable cause
Remedy
Reference
pabe
.,, I
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Oil pressure
too high
Noisy valves
g-50
Incorrect
,9-33.
auto-lash adjuster
..\
/I
Thin or diluted engine oil (low oil pressure)
\
g& I
9-12
or
., ?s..
ia9-1.i, :
_
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*
drop
9-l 1
g-12 ;:.
Excessive
Replace bearings
9-54.
bearing clearance
Incorrect
chain tension
I
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..
Retighten
SERVICE ADJUSTMENT
.CHECKING
ENGINE
Replace
9-28
OIL
9-20,2-l
g-20,21
PROCEDURES
NOSFAAAI
.,
REPLACEMENT
OF ENGINE
Refer
to GROUP
0
Maintenance
Service.
REPLACEMENT
OF ENGINE
Refer
to GROUP
0
Miintenance
Service.
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LUBRICATION
LUBRICATION
OIL.
AND
NO9FBAAl
MAINTENANCf$
OIL FILTER
AND
MWlpAl
MAINTENANCEii
RETORQUING
OF CYLINDER
HEAD BOLTS
NOSFDAD
. s.
head bolts
, *I
bolt (No. 1 to 10)
: 90-100 Nm (65-72 ftlbs.)
: 100-110
Nm (73-79 ftlbs.)
bolt (No. 11)
..
: 15-22 Nm (11-15 ft.lbs.)
: 15-22 (11-15 ftlbs.)
5ENO65
Timing
chain
sequence.
:s:
;; ,
side
NOTE
Run engine u,ntil normal operating temperature
is reach&
c
allow it to cool down, and then retorque bolts to specification
i
for best results.
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5EN016
-;
ADJUSTMENT
OF VALVE CLEARANCE
,Y.( -1
CHECKING
INTAKE AND EXHAUST
VALVES
As the intake and exhaust valves are equipped wifh~fa&lash
._.adjustment mechanisms,
there is no need for valve,clearance. a$~.-~$
justment. The proper functioning of the auto-lash mecha$m
may>~z,,.,$
be determined
by checking for tappet noise. When there IS tappet,:;
4:
noise or any unusual noise, check the the auto-lash.by removing it.
,,
I
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CHECKING
AND ADJUSTING
JET VALVE CLEATLANCE &FJAC.
(1) Idle the engine until radiator coolant reaches 80L90C ...l,-!i!
: ::*;
(176-194Fj:.
(2) Remove all ttie spark plugs$rom
the cylinder head.
,l(3) Remove the rocker co$r... :.
. ..,
i.>
t:
.-.
,( .
r
..:
(-J
Standard
No!1 rd.2
5EN213
value
: 0.25 mm.(.OlO
/.
Caution
As jet valve springtension
the jet valve in.
http://vnx.su/
in.) when
.I
warm.
I< -
is low, be careful not to push
,. [
.
;::
9-14
ENGINE-Service
Adjustment Procedures
(6) When out of specification, loosen the lock nut and adjust clearance with a feeler gauge while turning the adjusting screw.
(7) Holding the adjusting screw with a screwdriver so that it wont
turn, tighten the lock nut to the specified torque.
(8) Turn the crankshaft 360 until the No. 4 cylinder is at compression top dead center.
(9) Measure jet valve clearance where indicated by arrows in the
illustration.
Standard
value
Nb.3
warm
to the procedures
5EN214
TENSION
ADJUSTNOSFIAA
5EN072
2.
3.
Chain guide B
/
torque
:, lo-11
Nm (7.5-8.5
ft. Ibs.)
Projection
5ENOO7
CHECKING
COMPRESSION
PRESSURE
NOSFFM
/ ST6 Revision
-i
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----r
ENGINE-Service
Adjustment
Procedures
9-15
Caution
Cover the spark plug holes with waste cloth, etc., in order
to keep expelled foreign objects from flying out, and keep
away from the holes. When measuring
compression
with
water, oil, or fuel having entered the cylinder through
a
crack, etc., these will come flying out of the spark plug
hole hot and fast, so to sure to take the proper precautions.
(6) Set the compression gauge to the spark plug hole.
(7) Holding the throttle valve full open, crank the engine and measure compression.
1 .?:
FI ; _
..rl
Standard value : 1200 kPa (170 psi) [250400]
rl
Limit
: 960 kPa (136 psi) [250-400
rpm]
$
(8) Perform (6)and(?) above for all the cylinders, ensuring $hat compression for each of the cylinders is within the spec#ed
,
limit.
r t;,1
Limit : Max 100 kPa (14 psi)
(9) If a cylinders compression
or pressure differential exceeds.-:i
the limit, add a small amount of oil through the spark plug
..;. holeand repeat steps (6) to (8).
1 If the addition of oil brings compression
up, it is possible
that there is harmful friction between the piston ring and..
_ .
cylinder wall.
;:.;,.
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..
@ If not compression up, valve seizure, poor valve seating, or
a compression
leak from the gasket are all possible..
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9-16
,I
ENGINE
- On-vehicle
Service
ON-VEHICLE SERVICE
OIL PAN AND SCREEN
3EMOVAL
AND INSTALLATION
NOSHA-
Post-installation
Operation
Installation of the Undercover
and
the Under Skid Plate (Refer to
GROUP 23 BODY - Under Cover.)
l
Supplying of Engine Oil (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Meintenance
Service)
Pre-removal
Operation
l
Removal of the Undercover and the
Under Skid Plate (Refer to GROUP
23 BODY - Under Cover)
l
Draining of the Engine Oil (Refer to
GROUP 0, LUBRICATION
AND
MAINTENANCE
- Meintenance
Service.)
Removal
~~
steps
I.
2.
3.
4.
5.
6.
Drain plug
Drain plug gasket
Oil pan
Oil pan gasket
Oil screen
Oil screen
gasket
35-45
25-32
NOTE
(1) Reverse the removal procedures
(2) l + : Refer to Service Points
parts
(3) q : Non-reusable
Nm
ft.lbs
2
5-8 hm
4.5-5.5 ftlbs
to reinstall.
of Installation.
01 BOO49
INSPECTION
l
l
l
I
I
NOOHCAB
SERVICE
4.
POINTS
INSTALLATION
OF INSTALLATION
OF OIL PAN
NOSHDAI
GASKET
sealant
DEN048
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ENGINE
CYLINDER
IEMOVAL
- On-vehicle
9-17
Service
HEAD GASKET
AND
INSTALLATION
NOSJA--
Pre-removal
Operation
l
Draining of the Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Maintenance
Service.)
16-19
12-14
Post-installation
Operation
l
Supplying of Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
~ Maintenance
Service.)
l
Adjustment
of the Tension of the
Air Conditioner
Drive Belt (Refer to
GROUP 24 HEATERS AND AIR-CONDITIONING - Drive Belt Tension Adjustment.)
Nm
ft.lbs
Cold engine
90-100 Nm
65-72 ft.lbs. -----...
Hot engine
100-110 Nm
23-33
Removal
+I)
I)+
1. Air filter
2. Connection
3.
4.
5.
6.
7.
8.
l 4
4*
+e
+e
I)+
e+
l +
l +
I
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18
ft.lbs.
steps
**
4*
5-7 Nm
3.6-5.0 ft.lbs.
9.
10.
11.
12.
13.
14.
15.
Fixi
16.
17.
18.
19.
of
Radiator
upper
Breather
hose
P.C.V hose
Connection
of
Air-conditioner
Connection
of
accelerator
hose
cable
oxygen
sensor
drive belt
power
steering
pipe
Spark plug cable
Connection
of high tension
Self locking
nut
Connection
of front exhaust
Gasket
Rocker cover assembly
Rocker cover gasket
ng to No. 1 cylinder
TDC
Distributor
Camshaft
sprocket
bolt
Cylinder
head assembly
Cylinder
head gasket
connector
breather
cable
pipe
OlW572
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) +e : Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation.
(4) 8: Non-reusable
parts
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ENGINE
- On-vehicle
SERVICE
1.
:*
Y
Service
POINTS
OF REMOVAL
REMOVAL
OF AIR FILTER
Refer to GROUP 11 INTAKE
Filter
AND EXHAUST
NOSJBAF
SYSTEM
- Air
.
$
7.
REMOVAL
OF AIR-CONDITIONER
DRIVE BELT
Loosen the tension-adjustment
nuts of the air-conditioner
drive belt and remove the air-conditioner
drive belt from
the tension pulley.
FIXING
TO NO.
1 CYLINDER
TDC
17. REMOVAL
OF CAMSHAFT
SPROCKET
BOLT
Pull the camshaft sprocket (with the timing chain attached)
out from the camshaft, and place it on top of the camshaft
sprocket
holder.
Caution
1. The crankshaft
must not be rotated
after the camshaft sprocket
is pulled out from the camshaft.
2. Be careful not to allow the timing
chain to come off
from the camshaft
sprocket.
j.8. REMOVAL
OF CYLINDER
HEAD ASSEMBLY
(1) Disconnect
the fuel hose, vacuum
hose and wiring
harness connected
to the intake manifold and carburetor.
Refer to GROUP 11 INTA E AND EXHAUST - Intake
Manifold
and GROUP
14 UEL SYSTEM-Carburetor.
(2) Loosen the bolts (in the ord r indicated in the figure) in
2 or 3 steps, and remove from the cylinder head.
Front of engine
i
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fit
ENGjNE
- On-vehicle
.li
* SERVICE
Timing
chain
case
Service
POINTS
OF INSTALLATION
NO9JDCE
19. INSTALLATION
OF CYLINDER
HEAD GASKET
Before cylinder head gasket is installed,
apply specified .
sealant to top surface of each butt joint between cylinder..,
block and timing
chain case. ;,;,,
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Specified sealant : 3M ART Part No. 8660 or equivalent
Caution
Be careful not to allow
the cylinder
block.
OlWs53
sealant
to enter
in ,,*. .
Front of engine
5ENCM
18. INSTALLATION
OF CYLINDER
HEAD ASSEMBLY
,.:,
(1) Tighten the bolts (in the order indicated in the figure)in,::
2 or 3 steps, and finally tighten them at the-specified
)
torque.
!:
(2) Connect
the fuel hose, vacuum
hose and wiring *
harness connected
to the intake manifold and carbureiv{.
.s<.
.-.
tor.
-z:-=
Refer to GROUP 11 INTAKE AND EXHAUST - Intake
--$-!
Manifold
and GROUP 14 FUEL SYSTEM - Carburetor.,
:
-17. INSTALLATION
OF CAMSHAFT
SPROCKET
BOLT
Install the camshaft sprocket to the camshaft. Check to be
,:.
sure that the timing chains timing mark and the camshaft
sprockets
timing mark are aligned.
16. INSTALLATION
OF DISTRIBUTOR
Refer to GROUP 8 ELECTRICAL
Sealant
& J:
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.p.
- Ignition Sys$@$&
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- .y.%c(>
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14. INSTALLATION
OF ROCKER COVER ASSEMBLY&:
;::b :,;
Apply a coating of the specified sealant to the semicircular
,;
packing and the cylinder head top surfaces, and then
tighten the rocker cover assembly at the specified torque.
!:
-.: ; J,f-,.
: 3M ART Part No. 8660orequ~valent
i;
Specified sealant
to be applied
f
1.
Cylinder
TL<circular
head
packing
Caution
If they are overtorqued,
leakage could result.
6ENOlZ
2. ADJUSTMENT
Refer to GROUP
a deformed
OF ACCELERATOR
14 FUEL
SYSTEM
1. INSTALLATION
OF AIR FILTER
Refer to GROUP
11 INTAKE AND
1 STB Revision
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rocker
cover
or oil
CABLE
- Accelerator.
EXHAUST
- Air Filter.
,I.
9-20
ENGINE
Service
On-vehicle
ENGINE MOUNTING
REMOVAL
Vehicles
AilID
with
INSTALLATION
a manual
NO9GA-
transmission
18-19
12-14
Nm
ftlbs.
Nm
.- -- .--.-
11-7il
Aa-IE
6-10 Nm
4-7 ftlbs.
\
i,
lation Operation
on of the Under Skid Plate,
Iver, Snow Protection
Underid Transfer Case Protector
3 GROUP 23 BODY - Under
Post-ins
0 lnstal
Unde
cover
(Refe
Covei
Ihc
Nm
ftlbs
18-25
13-18
::s.
-6
22-29
ft.lbs.
184%
13-18
Removal steps
+e e+
+e ~~
l *.
1.
2.
3.
4.
5.
6.
7.
9.
12.
Nm
ft.lbs.
12
A
! .75 Nm
d .54 ft.lbs.
Air filter
Heat protector
Front insulator stopper
Engine mounting front insulator
Plate
Transfer mounting insulator
Transfer mounting, bracket
No. 2 crossmember
Engine mounting rear insulator
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) +e : Refer to. Service Points of Removal.
(3) l + : Refer to Service Points of Installation
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OlW575
ENGINE
Vehicles
with
an automatic
On-vehicle
Service
transmission
16-19
,I&14
Nm
ft.lbs.
6-10 Nm
4-7 ftlbs.
/
J+--Y
13-20
Nm
30-42
22-29
-fjr
3&40
22-29
Removal
+e
e+
+I)
l +
*I)
Nm
ftlbs.
-5
13-18
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Air filter
Heat protector
Front insulator
stopper
Engine
mounting
front insulator
Plate
Transfer
mounting
insulator
Transfer
mounting
bracket
Engine
support
rear bracket
No. 2 crossmember
Rear engine
support
member
Support
plate
Engine
mounting
rear insulator
Nm
ftlbs.
ftlbs.
18-25 Nm
13-18ft.lbs
OlW576
30-42
22-29
Nm
ftlbs.
. - L.
*,b,
NOTE
(I) Reverse the removal procedures
to reinstall.
(2) +*
: Refer to Service Points of Removal.
(3) *+
: Refer to Service Points of Installation.
STB Revision
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55-75
40-54
Nm
ft.lbs.
ENGINE
Service ~
On-vehicle
SERVICE
1. REMOVAL
OF AIR
Refer to GROUP
4.
OF REMC fAL
POINTS
FILTER
11 INTAKE
F D EXHAUST
- Air Filter.
NG FRONT INSULATOR
REMOVAL
OF ENGINE MOUN
(1) Attach a chain to the eng : hangers.
!, hang the engine slightly
(2) Using a chain block-and-tacl
up so that the insulator
is ree of engine weight.
g front insulator.
(3) Remove the engine mounl
NOTE
Hang the engine with a cha
mounting
front insulator.
Caution
Avoid applying
a strain
hoses and cables by rais
6.
NOSGBAD
REMOVAL
(1) Support
NOTE
Support
transfer
until installing
the engine
I the
g the
and fuel
too high.
radiator
engine
OF TRANSFER
the, transfer
f XJNTING
with
jack.
INSULATOR
i jack
the transfer
ing insulator.
(2) Remove
mou
until
installing
the
09wsoi
708.8
INSPECTION
(27.91)
Check the
Check the
Check the
corrosion.
Check the
Check the
sion.
l
l
l
l
l
NOSGCAE
separation or deformation.
)ers for deformation.
racket for deformation
or
or corrosion.
for deformation
or corro-
*- ?
im (in.)
OlW504
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SERVICE
4.
1.
POINTS
OF INST,
LLATION
NOSGDAG
INSTALLATION
OF ENGINE
I OUNTING
FRONT INSULATOR
.:
Make sure that the locating bo: and hole; are in alignment.,
c
\.
... .
Caution
Do not distort rubber portio;
portions
with fuel or oil.
.I)
INSTALLATION
OF AIR FILT
Refer to GROUP 11 INTAKE ,
http://vnx.su/
._
ENGINE
ENGINE
AND TRANSMISSION
REMOVAL
AND
- On-vehicle
9-23
Service
ASSEMBLY
INSTALLATION
NOSSA-B
Pre-removal
Operation
0 Removal of the hood (Refer to
GROUP 23 BODY ~ Hood.)
l
Under Cover, Under Skid Plate,
Transfer Case Protector, Cross Shaft
Protector, Snow-protector
(Refer to
GROUP 23 BODY - Under Cover.)
l
Draining of the Transmission
Fluid
or Oil and Transfer Case Oil (Refer
to GROUP 21 TRANSMISSION
Transmission
and Transfer Oil
Change and Inspection.)
l
Draining of the steering fluid (Refer
to GROUP 19 STEERING ~ Replacement of fluid.)
D Draining of the Refrigerant (Refer to
GROUP 24 HEATERS AND AIR-CONDITIONING - Refrigerant Leak Repair procedure.)
Post-installation
Operation
l
Supplying of Transmission
Fluid or
Transfer Case Oil (Refer to GROUP
21 TRANSMISSION
- Transmission
and Transfer Oil Change and Inspection.)
l
Supplying of Steering Fluid (Refer to
GROlJP 19 POWER STEERING ~
Replacement
of Fluid.)
l
Supplying of Refrigerant (Refer to
GROUP 24 HEATERS AND AIR-CONDITIONING ~ Refrigerant Leak Repair Procedure.)
l
Installation of the Undercover,
Under Skid Plate, Transfer Case Protector, Cross-shaft Protector and
Snow Protector. (Refer to GROUP
23 BODY ~ Under Cover.)
l
Installation of the Hood (Refer to
GROUP 23 BODY - Hood.)
1619
l?-14
Nm
ft.lbs.
I\
8-11 Nm
6-8 ftlbs.
1I
17
15
Removal
~~
l +
l +
e
+e
~~
14
steps
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
12.
13.
Air filter
Connection
of
Radiator
upper
Radiator
lower
Upper shroud
Lower
shroud
Radiator;,.
ZConne@bn
of
hose
Connection
of
Connection
of
Connection
of
Connection
of
Connection
of
16
OlW574
;a,
accelerator
hose
hose
brake
heater
oxygen
control
battery
starter
booster
cable
vacuum
hose
sensor connector
harness
connector
positive
cable
motor connector
http://vnx.su/
14. Connection
of air conditioner
harnness
connector
(Vehicles
with an air conditioner)
15. Connection
of alternator
connector
16. Connection
of water temperature
gauge
unit switch
and sensor connector
17. Connection
of oil pressure
gauge
unit
connecter.
NOTE
(1) Reverse the removal procedures
(2) +e : Refer to Service Points
(3) l + : Refer to Service Points
to reinstall.
of Removal.
of Installation.
._
_
16-24
,12-17
Nm
ftlbs
,-m...
25
0
15-22
11-16
QlW573
30-35
22-25
^^ ^_ Nrn
-.
m-i3
23
Nm
ft.lbs.
30-3I
22-2!
/
k.
/I
30
30-35
22-25
50-60
36-43
Nm
ft.lbs.
Nm
ft.lbs.
01 w577
*1
150-60
3M3
160 Nm
43 ft.lbs.
Nm
ft.lbs.
*2
16-22
13-16
Nm
ftlbs.
nb
+* l * 29.
+* l * 30.
+e l + 31.
32.
Control lever
Rear propeller
Front propelle
Connection of
solenoid valve
33. Connection of
return tube
:: :,.
, ,L
NOTE
(1) Reverse
(2) +e
(3) l *
;sembly
shaft
shaft
the connector for the OD
(4)
(5)
(6)
http://vnx.su/
: Refer to Sen
: Non-reusable
pal
*I : Vehicles with a
2 : Vehicles with al
e Points
;.
of Installation.
ianual transmission.
automatic transmission.
ENGINE
- On-vehicle
9-25
Service
13-18
18-25
13-18
40-54
ftlbs.
Nm
ftlbs.
~~
+e
41)
+e
01W578
x.
10-13
l + 34.
35.
.
~~ 36.
l + 37.
l + 38.
39.
40.
41.
42.
l * 43.
ft.lbs.
NOTE
(1)
Rev&se
the removal
procedures
to reinstall.
(2) 4*
: Refer
to Service
Points
of Removal.
(3)
l + : Refer to Service
Points
of Installation.
(4)
m:
Non-reusable
parts.
(5)
*1 : Vehicles
with
a manual
transmission.
(6)
2 : Vehicles
with
an automatic
transmission.
/ STB Revision
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38*2
owl544
Nm
.;i
ENGINE
On-vehicle
SERVICE
1. REMOVAL
Service
POINTS
OF AIR
Refer to GROUP
7.
OF REMOVAL
N09SBCC
FILTER
11 INTAKE
REMOVAL
OF RADIATOR
Refer to GROUP 7 COOLING
ND EXHAUST
- Air Filter.
- Radiator.
29. REMOVAL
OF CONTROL
LEVER ASSEMBLY
Refer to GROUP 21 TRANSMISSION
- Gearshift
Assembly (Manual transmissior)
or Transfer Control
matic transmission).
Lever
(Auto-
30. REMOVAL
OF REAR PROPE,LER
SHAFT/31.
FRONT
PROPELLER
SHAFT
Refer to GROUP 16 PROPELLE?
SHAFT AND UNIVERSAL
JOINTS - Propeller
shaft.
36. REMOVAL
OF CLUTCH
RELEASE CYLINDER
Refer to GROUP 6 CLUTCH - Clutch Release
37. REMOVAL
OF SELECT CROSS SHAFT/38.
SION CONTROL
ROD
Refer to GROUP
21 TRANSVllSSlON
Control.
43. REMOVAL
BLY
OF ENGINE
AND
Cylinder
TRANSMISTransmission
TRANSMISSION
ASSEM-
SERVICE
..
.
POINTS
OF INST
43. INSTALLATION
OF ENGINE
SEMBLY
(1) While checking
the corm
pipes, hoses, etc., and mak
are being caught, damaged,
transmission
assembly.
(2) Then, after the weight of t
assembly
has been put on
specified
torque.
/
,
STB Revision
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LLATION
ND TRANSMISSION
NOSSDAG
AS-
ENGINE
- On-vehicle
Service
38. INSTALLATION
OF TRANSMISSION
SELECT CROSS SHAFT
Refer to
Control.
GROUP
21
CONTROL
TRANSMISSION
36. INSTALLATION
OF CLUTCH
Refer to GROUP 6 CLUTCH
Transmission
RELEASE CYLINDER
- Clutch Release Cylinder.
34. CONNECTION
OF SPEEDOMETER
Refer to GROUP 21 TRANSMISSION
Speedometer
Cable.
31. INSTALLATION
OF FRONT
REAR PROPELLER
SHAFT
Refer to GROUP 16 PROPELLER
JOINTS - Propeller
shaft.
RODId7.
CABLE
- Replacement
PROPELLER
of the
SHAFT/30.
29. INSTALLATION
OF CONTROL
LEVER ASSEMBLY
Refer to GROUP
21 TRANSMISSION
- Gearshift
Assembly (Manual transmission)
or Transfer Control
matic transmission).
20. CONNECTION
OF THROlTLE
CONTROL
CABLE
Refer to GROUP
21 TRANSMISSION
- Adjustment
Throttle
Control Cable.
7.
INSTALLATION
OF RADIATOR
Refer to GROUP 7 COOLING
- Radiator.
2.
ADJUSTMENT
OF ACCELERATOR
Refer to GROUP
14 FUEL SYSTEM
1. INSTALLATION
OF AIR FILTER
Refer to GROUP 11 INTAKE AND
;.
Lever
(Auto-
of
CABLE
- Accelerator
EXHAUST
- Air Filter.
.
http://vnx.su/
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K(.
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INSTA@$&
50-60
Nm
i\
A-IO
Nm
-0
RI
\
2-7,
II--15
ftlbs.
I
,
. ;..a.
.
-1Nm
ft.lbs.
1 l&l30
80-84
Nm
ftlbs.
12-14
g-10.5
Nm
ftlbs.
.i
5EN195
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,._
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3 ENGINE-Timing
p.
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Removal
Chain Train
Installation
steps
steps
1. Special washer
NOTE
(1)4*
(2) **
(3) m
) STB Revision
http://vnx.su/
..!
r-
ENGINE-Timing
Chain Train
.
SPROCKET/22.
OF CAMSHAm
CHAIN/23.
CRANKSHAFT
SPF 33 ICKET
Remove the timing chain corn1 3r red with camshaft
and crankshaft sprocket.
21. REMOVAL
INSPECTION1
I.
1 ,$
.x1
,I
t *
Camshaft
sprocket
Sprocket
sprocket
NOSWCAA
holder
*Timing
Check the
connected
.Replace if
Check the
damage.
Replace if
TIMING
chain
side-Timing
chajn
auide
side
14. INSTALLATION
(1) Assemble
http://vnx.su/
OF LEFT S!LI
silent shaft&m
UT SHAFT SPROCKET
kets to chain B. Make sure
nment with plated links.
It and left sprockets, as they
ctions.
ENGINE-Timing
9-31
Chain Train
OF CRANKSHAFT
SPROCKET
ES
(for
driving silent
install crankshaft sprocket
12. INSTALLATION
:
&i-
Tiiing
side
Crankshaft
sprocket
Crankshaft
spkocket
stkooq
11. INSTALLATION
Chain
Special
bolt
bolt
guide
Cylinder
Section
Special
shafts) on
crankshaft.
chain
B
block
Y - Y
OF CHAIN
r.
B
Timing
mark
Oil pump
body
plate1
llnk
I
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I
Chain
$
.
T
S,
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I
guide B
Section X - X
pF0
elated
R
Section
8
de
Crankshaft
sorocket
link
_.
.
5EI
{;
P4 P
Specia{bolt
?
Chain and chai>iide
B gap
Standard
value : 0.2 4 fl.8 mm (.0079-.0315
\
5ENOOf
/ STB Revision
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c;
ii&
.. J .
ENGINE-Timing
7.
Chain Train
INSTALLATiON
Using special
OF OIL SEAL
tools, install tt-
oil seal.
MD998376-01
3.
INSTALLATION
OF TIMING
C 4lN CASE
(1) Clean the gasket surfaces o hain case and cylinder block.
and chain case to the cylin(2) Install the chain case gaske
der block.
-.-
1 STB Revision
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ENGINE
- Rocker Arms,
and Camshaft
AND
INSTALLATION
6
h
J.
fs19-20
14-15
Removal
20-26
15-19
Nm
ft.lbs.
Nm
ftlbs.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Breather
hose
Pipe
Oil seal
P.C.V. hose
P.C.V. valve
Oil filler cap
Packing
Rocker cover
Rocker cover gasket
:
I
I!.
~~
11. Auto-lash
adjuster
l + 12. Camshaft
l + 13. Semi-circular
packing
l + 14. Circular
packing
NOTE
Reverse the removal procedures
to reinstall
(2) l * : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation.
(4) m: Non-reusable
parts
(I)
,._
STB Revision
5EN197
http://vnx.su/
..q
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8 $6 .C,
.:
,.Z
9-34
ENGINE-Rocker
M D998443-0
OF REM0
ARM
JAL
\ND SHAFT
NOSLBCA
ASSEMBLY/l
1.
Before removing the rocker an- I and shaft assembly, use the
special tool to ensure that the auto-lash adjuster doesnt fall
out.
Caution
in order in
Put the rocker arms and au1 b-lash adjusters
becylinder No. separated place: , with clear distinction
tween the intake and exhaus : ones to prevent confusion.
INSPECTION
Check camshaft journals for w
essary. If journals are damage
ings for wear or damage. If ci
replace cylinder head.
Check the fuel pump drive cam
for wear or damage. Replace i
in.)
Cam height
Standard value
Intake : 42.4 mm (1.669: I In
- .I
Exhaust : 42.4 mm (1.6E 93 in.)
Limit
Intake : 41.9 mm (1.649r i in.)
Exhaust : 41.9 mm (1.6L 96 in.)
End play
Standard value : 0.1-0.2 I nm (.004-.OOS in.)
L@it : 0.4 mm (016 in.)
1ENOlS
Check for unusual cam face WI Faror damage, replace the part
if required. Measure cam heigt t (i.e., its diameter), replace the
cam if outside of the limit.
rar or damage. Replace if necI. also inspect camshaft bearnshaft bearing is badly worn,
Camshaft
Standard value
HeighU of fuel pump drh e cam : 37 mm (1.4567
Journal diameter
: 34 m n (1.3366 in.)
mm (.0012-.0020
in.)
Oil clearance : 0.03-O.O!
5EN198
NOSLCCA
SERVICE
POINTS
14. INSTALLATION
OF INST 4LLATION
OF CIRCUU
R PACKING
Timing chain
side
Cam
STB Revision
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NOSLDCB
ENGINE-Rocker
13. APPLY
Sealant to be applied
SEALANT
TO SEMI-CIRCULAR
Specified
Cylinder kead
Semi-circular
or breather
9-35
sealant
PACKING
and semi-circle.
packing
6EN013
12. INSTALLATION
OF CAMSHAFT
11. INSTALLATION
OF AUTO-LASH
ARM AND SHAFT ASSEMBLY
MD998443-1
ADJUSTEWlO.
ROCKER
(1) Insert the auto-lash adjuster from below as illustrated, being careful not to spill the diesel oil inside it. Then use the
special tool to prevent adjuster from falling while installing
it.
(2) Place the rocker arm and shaft assembly on the cylinder
head and tighten the bearing cap bolt.
(3) Remove the special tool.
6EN246
1 STB Revision
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9-36
ENGINE-Rocker
Disassembly
NO9NE-B
AND REASSEMBLY
steps
., <*
-I:$C.
NOTE
(1) Reverse the disassembly
prc ,edures to reassemble.
j2).*4
: Refer to Service Poin s of Reassembly.
[ ST6 Revision
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ENGINE-Rocker
9-37
INSPECTION
@ ROCKER
(1) Check
sary.
(2) Check
dil
rocker
arms
to ensure
for wear
Replace
or damage.
if neces-
hole
6EN364
I-
ROCKER
rocker
arm mounting
D
O+J- 0
ARM SHAFT
(1) Check
Oil holes
0
NO9NGADl
ARM
to ensure
Replace
portions
of rocker
arm shaft
as necessary.
,I
I
i
5ENO63
Front
NOSNHCA
GAP/18.
LEFT
ARM SHAFT
the front bearing
arm shaft has a
,.!a:
notch.
Rocker arm shaft, left
Notch
(2) Align the mating mark of the rocker arm shaft front end to
the mating mark of the front bearing cap. Then insert the
bolts to hold shafts in bearing cap.
5EN077
Mating marks
13 mm (1181 in.) dia. hole]
(3) Assemble the rocker arm shaft so that the alignment mark
at the front end matches the alignment mark of the front
bearing cap.
:.
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3,
c
Mating marks
[2 mm (.0787 in.) dia. embossing]
5EN012
Rocker arm
Timing chain m
side
16. INSTALLATION
OF WAVE WASHER
Install the waved washer in the direction
illustration.
http://vnx.su/
shown
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9-38
ENGINE-Rocker
i CAP
13.9.5. INSTALLATION
OF BEARII
Caps 2. 3 and 4 are of similar I li 3pe and require attention
the cap number during assemb 1.
Identification
mark
I
/-
- .
i
:;
9
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:
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Ij
i
1 STB Revision
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to
ENGINE-Cylinder
9-39
Head
CYLINDER HEAD
REMOVAL
NOSOA-S
AND INSTALLATION
Cold engine
90-100
Nm
65-72 ftlbs.
...
Removal steps
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +e
: Refer to Service Points of Rynoval.
(3) l + : Refer to Service Pointsof Installation.
(4) q
: Non-reusable
parts
G..
http://vnx.su/
4.
,i ;p --
8..
ENGINE-Cylinder
Head
INTS OF REMO
INSPECTION
0
l
l
iimjg
12
chain
side
Apply
z.1. , ,,
, :
n
sealaGt>
Ensure tt&?he
sealant
is not allowed
to enter the oil
passages
.*.- .
::
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.ldentification
mark
-XT
A
INSTALLATION
1.
:..
,-:
I,
.- :,a
grind)
LATloN
NWODAB
OF CYLINDER
iEAD GASKET
(1) Clean gasket surfaces of cyl lder head and cylinder block.
(2) Apply a sufficient amount o sealant or similar material .t&K
the two guides on the cylir ler block and chain case r%:.
illustrated.
-:>
. r;
Specified sealant
: 3M Al T Part&l&88.&)
or equiva$,
lent
:.
f
j.
(3; Be sure to position the gasl !t on th.ecyli&er
block with
the identification
mark up.
(
/
.,:., ;j. _
.$2
Idyitificationmark
: 54
(4) Ali;S;; with the mark on the + ,p of the cyli&Jer head when
installing.
Caution
Do not apply
Caution
The cylinder
head gasket su face should be ground to
within
0.2 mm (.0079 in.) e en with the grind of the
cylinder
block gasket surfac
4.
,i
t
I
NOSOCAE
$4
:;.
sealant
5ENO6!
._.
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I_
ENGINE-Cylinder
2.
+
-;::
9-41
INSTALLATION
OF BOLT/l.
CYLINDER HEAD BOLT
Install cylinder head bolts. Starting at tod:center,
tighten aI
Cylinder head bolts to l/2 of specified torque.,in sequence
shown in illustration.
i
<
5EN0!6
Head
,,
1 STB Revision
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9-42
ENGINE-Valves
NOWE-B
AND REASSEMBLY
5EN212
Disassemblysteps
NOTE
(1) Reverse the removal procedur
(2) l * : Refer to Service Points
(3) l a : Refer to Service Points
(4) q
: Non-reusable
parts
.,,i
i
: . I;:.. ,I,.,
1 STB Revision
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i to reinstall.
f Disassembly.
f Reassembly.
ENGINE -Valves
MD99831 0
1.
REMOVAL
9-43
NO9PFAB
3EN324
3EN121
INSPECTION
l
lEN034
NO9PGACl
VALVES
(1) Check each valve for *Lear, damage and deformation
of ,%
i
head and stem at B. Repair or replace excessively worn,
i:
demaged or deformed valves.
(2) If stem tip A has been pitted, correct with oil stone or :I
5
other means. This correction must be limited to a mini1
mum. Also reface the valve.
(3) Replace the valve if the face margin has decreased to less
than limit.
Margin
Standard
value
Intake
: 1.2 mm (.047 in.)
Exhaust
: 2.0 mm (.079 in.)
Limit
Intake
: 0.7 mm (.028 in.)
Exhaust
: 1.5 mm (.059 in.)
1 STB Revision
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9-44
ENGINE-Valves
Lean
t--*O
Valve spring
Standard
value
Free length
: 49.8 n
Load : 322.6 N (72.!
Installed
height
: 4C
Out of squareness
:
Limit
Free length
: 48.8 IT
Installed
height
: 41
Out of squareness
:
m (1.961
in.)
Ibs.) at installed
height
4 mm (1.591 in.)
Within
2
n (1.922 in.)
$0 mm (1.6299
4
VALVE GUIDES
in.)
NO9PGCB
Check the valve stem-to-guide c ?arance. If the clearance exceeds the lirnit, replace the val e guide with new oversize
part.
diameter
lEN323
Valve stem-to-guide
clearance
Standard value
Intake : 0.03-0.06
mm (.O 12-.0024
in.)
Exhaust : 0.05-0.09
mm ( )020-.0035
in.)
Valve Guide Oversizes
4nder head hole size mm (in.)
3.050-13.068
(.5138-.5145)
3.250-13.268
(.5217-.5224)
3.500-13.518
(.5315-.5422)
Limit
Intake : 0.1 mm (.0039 in.]
Exhaust : 0.15 mm (.0059 n.1
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ENGINE-Valves
9-45
PROCEDUR$!&Ac
(1) Check the valve guide for wear. Replace the worn guide.
(2) Reconditon the valve seat with a seat grinder or cutter. The
valve seat contact width should be of the specified size at the
center of the valve face.
(3) The valve and valve seat should be lapped lightly with a lapping
compound.
i
1..
j..
Intake
1 EN036
(4) Check valve seat insert sinkage. If the sinkage exceeds the
service limit, replace the insert with an oversize part as described below.
(5) Measure
the installed height of spring between
the spring
seat and the retainer with the valve spring seat, spring retainer
and retainer lock installed. The amount of sinkage can be
judged from the measured value.
28
0.5-l
mm
(.0197-.0394
VALVE
DURES
in.)
SEAT
INSERT
REPLACEMENT
PROCEL
NoaPlAfi 2.
;
(1) To replace : scrape the inner face of the valve seat to reduce
the wall thickness,
and remove.
0.5-I
mm
(.0197-.0394
in
lEN08;
(2) Adjust the press fit diameter of the valve seat on the cylinder
head side so that it matches the diameter of the oversize valve
seat.
Height of
valve seat
Dia
lEN066
wision
.. .
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/
L.
I
9-46
ENGINE-Valves
Valve
Description
Size mark
Size mm (in.)
Intake valve
seat insert
0.3 (.012)
0,s.
Insert height H
mm (in.)
30
7.9-8.1
(.3110-.3189)
60
8.2-8.4
(.3228-.3307)
30
7.9-8.1
(.3110-.3189)
60
8.2-8.4
(.3228-.3307)
Exhaust valve
seat insert
47.60-47.63
(1.8740-1.8750)
40.30-40.33
(1.5866-1.5876)
40.60-40.63
(1.5984-l
.5994)
-I
150C (480F) and press in an
t bore in the cylinder head at
#hewn in the diagram.
lap the valve.
1 EN036
(9) Ensure that the seat is properly centered on the valve face.
Valve
seat
II
OF VALVE
NO9PKDB
S TEM SEAU13.5.
VALVE
Install the spring seat, then usin! special tool, install the stem
seal by lightly tapping the tool. Seal is installed in specified
position, using the special tool.
Caution
1. Incorrect installation
of the seal wituout using special
tool will result in poor St?i ling and cause oil leakage
down valve guide.
2. Do not reuse stem seal.
14. INSTALLATION
OF EXHAUST
rlALVE/G.
INTAKE
VALVE
Apply engine oil to each valve, insert valves into the valve
guides. Avoid inserting the valve nto the seal with force. After
insertion, check to see if the val le moves smoothly.
1 STB Revision
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12.4. INSTALLATION
Enamel
coated
side
OF VALVE
SPRING
coated
side
r
I $*:,.
6EN024
,g i
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,:<2..... ,,;:p,
(1) Using the valve spring compressor,
compress
the valvy$& ,I)
%g
spring and install the retainer lock.
c, .,$<S
A-:
;
Caution
L
11,
When compressing
the spring with the Valve Spring
.I
Compressor,
check to see that the valve stem seal is
not pressed to the bottom
of the retainer.
Then start
installing
the retainer
lock.
10.2. INSTALLATION
6EN019
1.
INSTALLATION
(1) Apply engine
surface.
Caution
fUlake sure
Apply
engine
OF RETAINER
that retainer
LOCK
locks
OF JET VALVE
installed.
ASSEMBLY
are positively
is a new
and seat
one.
oil
1 EM001
.?
-. rs:..
,,i
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9-48
NWX-0
Disassembly
+**a
AND REASSEMBLY
steps
1. Retainer lock
2. Valve spring retainer
3. Valve spring
4. Jet valve
5. Stem seal
6. O-ring
7. Jet body
l a
*4
l 4
l *
-6U
lEM177
NOTE
(1) Reverse the disassembly
procedures to reassemble.
(2) l * : Refer to Service Points of Disassembly.
(3) l q : Refer to Service Points of Reassembly.
: Non-reusable
parts
(4) q
SERVICE POINTS
1. REMOVAL
OF DISASSEMBLY
OF RETAINER
NOSQFAAl
LOCK
lEMOO5
INSPECTION
,
t
NO9QGAAl
Make sure that the jet valve slides smoothly in the jet body
and has no play.
l
I
Caution
Combination
of the jet valve and jet body should
disturbed
and the jet valve and jet body should
placed as an assembly.
l
l
not be
be re-
Check the valve head and valve seat for damage or seizure.
Check the spring for sag, cracks or breakage.
1 STB Revision
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ENGINE-Jet
Valve Assembly
9-49
Standard value
Jet wafWe
Length : 91.58 mm (3.6055 in.)
Stem O.D. : 4.3 mm (1693 in.)
Seat angle : 45
Jet valve spring
Free length : 29.60 mm (1.1654 in.)
Load : 34.3 N (7.7 Ibs.) at installed
height
: 21.5 mm (.846 in.)
Installed
height
Out of squareness
: Max.l.5
INSTALLATION
OF STEM SEAL
Using special tool, install the stem seal.
4.
INSTALLATION
OF JET VALVE
3.
INSTALLATION
OF VALVE SPRING/Z.
VALVE SPRING RETAINER/l.
RETAINER
LOCK
(1) Mount the valve spring and valve spring retainer on jet
body.
(2) Compress the valve spring with special tool, using care not
to damage the valve stem by the bottom of valve spring
retainer.
(3) While the spring being kept compressed,
install the retainer lock.
\
1 EM005
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8.
:j.
7:
i
i;
6,:
9-50
ENGINE
LENT SHAFT
NOSRA-.
AND INSTALLATION
IO-12 Nm
7.5-8.5 ftlbs. --@
IO-12
Nm
dl2
Nm
7.5-8.5 ft.lbs.
I
@Y.f
10-12
7.5-8.5
bl.4
Nm
77-17
ft
15-22
I 1-15
Nm
,I;ft.lbS. ~ 1.
*/y /
A -
Ihc
Nm
ft.lbs.
,
i
t
.,
.I
6-8-Nm
4.5-5.5
I
p
l +
9.
10.
11.
12.
13.
Relief spring
Relief plunger
Flange bolt
Oil pump body
Pin
,. +
,*4
e-4
+e
54.
15.
16.
-i3:7.
18.
l + 19.
.** 20.
l + 21.
~~ 22.
23.
24.
-,
b.
ftlbs.
5EN205
Removal steps- 1
Driven gear
Drive gear
Woodruff
key
Oil pump cover
Oil pump gasket
Thrust
plate (with front bearing)
.i
-O-ring
Woodruff
key
Left silent sh$t
Right silent shaft
NOTE
1.
(1) Reverse the removal procedures
to reinstall.
Rear bearing
(2) l * : Refer to Service Points of Removal..
(3) **
: Refer to Service Points of Installation.
(4) 8: Non-reusable
parts.
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ENGINE-Front
Thrust
..
OBNTS OF REMOVAL
plate
L OF, THRUST
nt shaft,
8 mm
bolt
(.31/50
in.)
9-51
NOSRBAE
PLATE
left
holes of flange
\ .,\
5EN020
,4x
i
No9RcGB
OIL PUMP
*,I
..,..I
Standard value
Driven gear
Tip clearance
Side clearance
Drive gear
Tip clearance
Side clearance
Limit
Driven gear
Tip clearance
Side clearance
Drive gear
Tip clearance
Side clearance
5EN142
RELIEF PLUNGER
: 0.11-0.15
: 0.04-0.10
mm (.0043-.0059
mm (.0016-.0039
in.)
in.)
: 0.11-0.15
: 0.05-0.11
mm (.0043-.0059
mm (.0020-.0043
in.)
in.)
,,I .%~.
,<c
i.,
,.;>+x>
:.).&gq 1 .
.-;%T $&:-...
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.:.
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NOSACHA
,,p.;\$$;
& ,!,&
AND SPRING
(1) Insert the relief plunger in the front case and qheck to see
I
if it operates smoothly.
(2) Check the relief spring for breakage or sagging.
Standard value
Relief spring
Free length : 46.4 mm (1.8346 in.)
Load : 60 N/40.1 mm (13.4 lbsJ1.5787
SILENT
SHAFT
in.)
NOSRCIA
5EN07
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;
:.I
/.
;
9-52
ENGINE-Front
Cylinder
SHAFT BEARING
block
PROCEDURE N~~REM
REPLACEMENT
5EN022
(2) Apply engine oil to O.D. of bearing, using special tool, install
silent shaft bearing to cylinder block.
tiD990938-07
Cylinder
block
5EN023
engine
oil
OF LEFT SILENT
NOSRDCE
SHAFT
5EN025
20. INSTALLATION
OF O-RING
(1) Install o-ring in groove of thrust plate.
(2) Apply engine oil around O-ring.
New
O-ring
5EN026
19. INSTALLATION
Guide
[6 mm
I
OF THRUST
PLATE
t.2
1
Thrust
blate
,?I4
Cylinjer
block
I STB Revision
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ENGINE-Front
9-53
OF DRIVE
GEAR/14.
DRIVEN
Install oil pump gears to oil pump body and align timing
Driven
gear
Timing
marks
Drive
GEAR
marks.
Caution
If timing marks are out of alignment,
phase of silent shaft
will change and vibration
will result.
gear
5EN028
12. INSTALLATION
OF OIL PUMP
BODY
Place pump assembly in same position as it was installed on ?
engine and put approx. 10 cc (.6 cu.in.) of clean engine oil in ;
delivery port.
3.
.
Apply 10 cc
t.6 cu.in.) of
engine oil
5EN029
Chain
case
and cylinder
4.
blockElde
INSTALLATION
OF OIL PAN
Apply sealant to four places on the cylinder block side of the
hatched area.
Specified
Cylinder
block
and
case
guide
sealant
1~~0%
3.
-tB*
APPLICATION
OF ENGINE OIL TO OIL FILTER
Apply engine oil to surface of packing. But must not protrude
engine oil from case.
\
Apply
oil
6LUO26
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i.r
9-54
ENGINE-Piston
ROD
NOSTA-
AND INSTALLATION
7
8
9
5ENo30
45-43
33-34
Nm /
ft.lbs.
Removal steps
1.
,++e l +2.
.J ,.
t :. .::,,; 3.
> 4.
I)+ 5.
6.
++ l 47.
l e *a 8.
l * 9.
4* ++ 10.
11.
12.
Nut
Connecting
rod cap
Bearing
Bearing
Piston and connecting
Bolt
No.1 piston ring
No.2 piston ring
Oil ring
Piston pin
Piston
Connecting
rod
rod assembly
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +*
: Refer to Service Points of Removal.
(3)*4
: Refer to Service Points of Installation.
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ENGINE-Piston
9-55
number
DEN050
7.
OF CONNECTING
REMOVAL
NOSTBDAl
ROD CAP
rod with
REMOVAL
NO.2 PISTON
Remove
OF NO.1
the piston
PISTON
RING/8.
rings with
a piston
the cylinder
?:.
RING
sF
8,
ring expander.
6ENl
Ident.
10. REMOVAL
mark
OF PISTON
PIN
Ident.
mark
5EN206
(5) Position
ram.
Piston
pin
MD9981
Press
/
/atube
84-01
plates
piston
pin pusher
pin with
Caution
As piston pin is removed,
it must pass through
tube.
Check alignment
and adjust if necessary.
press
receiving
,..,,f
,;i:.
lEN603
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9-56
ENGINE
Rod
INSPECTION
.
NosTcAc1
PISTON
When there are streaks or signs of seizure on the outer suron the thrust side), or if there are
cracks in the outer surface, replace.
Q PISTON PIN
(1) The piston pin should be able to be inserted into the piston
pin hole merely by pushing it in with your finger. If any
resistance is noted or if the pin is loose, replace it.
(2) Piston pins should be replaced as a set.
,face of the piston (especially
PISTON RING
(1) Check for piston ring damage,
the rings if anything unusual
change the piston rings when
(2) Check the clearance between
groove. When it exceeds the
piston, or both.
Piston ring
Standard
No.1 :
No.2 :
Limit
No.1 :
No.2 :
NO9TCBE
side clearance
value
0.05-0.09
mm (.0020-.0035
0.02-0.06
mm (.OOOS-.0024
in.)
in.)
6EN031
;.
/
.,,.
..
.,
i
I
,.
putting it
it in. When
gap with a
the piston
1STB Revision
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in.)
ENGINE
- Piston
l
and
Connecting
9-57
Rod
BEARING
WTCDBl
mm (.OOOS-.0020
in.)
NOTE
For the method by which the oil clearance is measured
using a plastigauge, refer to the item on the crankshaft.
NOSTDAI
10. INSTALLATION
OF PISTON PIN
(1) Thread stop plug approximately
half way into the bottom of
the receiving tube.
(2) Select the largest diameter piston pin guide that will pass
through piston and rod. Install spring, spacer, and guide into
receiving tube.
I EN904
Clearance
lENSO
/ STB
(3) With connecting rod removed from piston, insert piston pin
into piston bore. Carefully measure amount of pin that protrudes equally from both sides of piston. Record this measurement for furture use.
(4) Position connecting rod and piston over the anvil. The spring
loaded piston guide will pass through piston and rod and align
it. Lubricate pin and insert it into piston.
(5) Place piston pin pusher on piston pin and push pin through
connecting rod until the pin protrudes some distance measured and recorded above in step 3.
Caution
The piston must be free to float during installation;
check
frequently.
evision
I
.
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,.$
t
!.
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v.
e
i.,
9-58
ENGINE-Piston
e certain
s during
the piston
lnstallaton
and Connecting
Rod
(6) Apply hydraulic pressure to pin and adjust stop plug until stop
Plug comes in contact with spacer.
(7) Remove piston and pin assembly from anvil and check piston
pin to make sure it is centered. If it is not centered, adjust stop
plug up or down to obtain proper centering. The pin stop is
now set for any remaining pistons.
Caution
If the required installation
load is out of specification,
replace piston pin and/or connection
rod.
Piston pin press in load : 7350-l 7150 N (1650-38
Ibs.)
9.
rail
ide
QNSTALLATION
OF OIL RING
(1) Assemble the oil ring spacer into the piston ring groove.
Then, after assembling the upper side rail, assemble the
lower side rail. There is no difference between the upper
and lower side rails or spacers.
pacer
5EN062
End of side
rail
Caution
Do not use piston
rail.
ring expander
when
installing
side
lEN063
Distinguishing
stamped
mark
8.
1
Barrel
shaped
Distinguishing
stamped
INSTALLATION
RING
OF NO.2 PISTON
RING/
7. NO.1
PISTON
Caution
1. Pay close attention
to the differences
in shape
between nos. 1 and 2 to avoid confusing them.
2. Install piston rings 1 and 2 with the maker and size
marks facing up (toward the top of the piston).
mark
Tapered
lENO64
5.
Side
rail
No.
Timing
side
Piston
spacer
alignment
holes
INSTALLATION
OF PISTON AND CONNECTING
ROD ASSEMBLY
(1) Apply plenty of engine oil to the outer piston surfaces, the
piston ring and the oil ring.
(2) Align the mating holes in the piston and oil rings (side rail,
spacer) as illustrated.
6EN641
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ENGINE-Piston
atnd Connecting
9-59
Rod
dentification
the
on
the
into
mark
5EN211
2.
White
paint
;
INSTALLATION
OF CONNECTING
ROD CAP
(1) When the connecting rod is installed, make sure that iden-,,;
tification mark and notch are on same side.
-2
Identification
(Front mark)
mark
Notch
(Front
I
mark
5EN201
Connecting
rod big end side clearance
Standard
value : 0.1-0.25
mm (.OOSS-.0098
Limit
: 0.4 mm (.016 in.)
1 STB Revision
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in.)
9-60
ENGINE
CRANKSHAFT,
FLYWHEEL
IEMOVAL
Crankshaft,
Flywheel
and
Drive Plate
AND INSTALLATION
NOSIJA-
140 Nm
01 ft.lbs.
130-140 Nm
gF1ol
ft*bs.
18
5EN219
Removal
,
.,
steps
1. Ball bearing
2. Flywheel
3. Ring gear
4. Rear plate
5. Bell housing
cover
L 6. Adapter
plate
4, 7. Drive plate
>- &. Crankshaft
adapter
9. Crankshaft
bushing
10. Rear plate
11. Bell housing
cover
12.
13.
l 4 14.
l * 15.
l 4 16.
l 4 17.
18.
l 4 19.
for vehicles
with manual
transmission
for vehicles
with automatic
transmission
gasket
1 STB Revision
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ENGINE-Crankshaft,
9-61
INSPECTION
l
3EN066
Nosucnc
CRANKSHAFT
(1) Check the crankshaft journals and pins for damage, uneven wear and cranks. Also check oil holes for clogging.
Correct or replace any defective part.
(2) ;n;p;;;,
out-of-roundness
and taper of crankshaft journal
Standard value
Cransshaft journal O.D. : 60 mm (2.3622 in.)
Crank pin O.D. : 53 mm (2.0866 in.)
Limit
Out-of-roundness
of journal and pin :
i
0.01 mm (0004 in.)
Taper of journal and pin : 0.01 mm (.0004 in.)
$
MAIN BEARINGS
AND CONNECTING
ROD BEARINGSNosucBA1
:A
Visually inspect each bearing for peeling, melt, seizure and
<,.,,
improper contact. Replace the defective bearings.
NO9UCCDl
OIL CLEARANCE
MEASUREMENT
To check the oil clearance, measure the outside diameter of
the crankshaft journal and the crank pin and the inside diameter of the bearing. The clearance can be obtained by calculating the difference between the measured outside and inside diameters.
Standard value
Crankshaft
main
bearing
: 0.02-0.05
mm
(.OOOS-.0020
Connecting
rod bearing
: 0.02-0.05
(.OOOS-.0020
in.)
mm
in.)
PLASTIGAUGE
METHOD
Plastigauge may be used to measure the clearance.
(1) Remove oil and grease and any other dirt from bearings and
journals.
(2) Cut plastigauge to the same length as the width of the bearing
and place it in parallel with the journal, off oil holes.
6ENO43
1 EN067
*vision
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$-, :
Q; ,,,:
+.
9-62
ENGINE-Crankshaft,
.
with
manual
NO9UCDA
transmission)
NOWCH: 1
Caution
3EN301
SERVICE
(for No.1, 2, 4, 5)
POINTS
OF INSTALLATION
NOSUDAE
19. INSTALLATION
OF UPPER BEARING
When reusing the main bearings, remember to install them by
referring to location marks made at the time of removal.
Be sure oil holes in bearings align with oil hole in block.
17. INSTALLATION
OF LOWER BEARING
Check to ensure that the lower bearing has no oil groove.
[ STB Revision
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ENGINE-Crsnkshaft,
9-63
16. INSTALLATION
OF BEARING
CAP
(1) The caps should be installed with the arrow mark directed
toward the crank pulley side of engine. Cap numbers must
be in correct order.
(2) Tighten cap bolts in sequence : Center, No.2, No.4, front
and rear cap bolts.
(3) Cap bolts should be tightened
evenly in 2 to 3 stages
before they are finally tightened.
(4) Make certain that crankshaft turns freely and has the
proper clearance between the center main bearing thrust
flange and the connecting rod big end bearing.
Standard value : 0.05-0.18
Limit : 0.4 mm (.016 in.)
M B990938-0
mm (.0020-.0071
in.)
15. INSTALLATION
OF OIL SEAL
Using Special Tool, press fit the oil seal all the way in without
tilting it.
Oil seal
MD998376-01
/
Timing
Oil seal
case
chain
case
011 separator
i4
t
$ltiyc;
mounting
5~~140
14. INSTALLATION
OF OIL SEPARATOR
Press the oil separator into the oil seal case. Install it so that
the separator oil hole is on the very bottom, as illustrated.
mm
(1575
in.)
dia. oil hole
6EN048
1 STB Revision
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.
,*
,
.
9-64
ENGINE-Cylinder
Block
CYLINDER BLOCK
REMOVAL
50-60
37-43
NOSVA-A
AND INSTALLATION
Nm
ft.lbs.
6
\
8-12 Nm
6-8 ftlbs.
/
4-6
4-5
Nm
ftlbs.
5EN210
50-6b
37-43
1.
2.
3.
4.
5.
l * l +6.
NOTE
(1) 4*
(2) **
Nm
ftlbs.
: Refer to Service
: Refer to Service
Points of Removal.
Points of Installation.
REMOVAL
OF OIL PRESSURE
NOSWAD
SWITCH
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9-65
INSPIECTION
l
Measuring
NO9VCAD
Visually check the cylinder block for scores, rust and corrosion.
Also check for cracks or any other defects by using a flaw
detecting agent (magnafluxing).
Correct or replace the block if
defective.
Measure the cylinder bore with a cylinder gauge at three levels
in the directions of A and B.
If the cylinder bores show more than specified out-of-round or
taper, or if the cylinder walls are badly scuffed or scored, the
cylinder block should be rebored and honed, and new oversize
pistons and rings fitted.
points are as shown.
Standard value
Cylinder bore : 91.1 mm (3.5866 in.)
Out-of-roundness
and taper of cylinder bore :
Max. 0.02 mm (0008 in.)
If cylinder top ridge is worn in stages, cut away with ridge
reamer.
Oversize pistons are available in four sizes.
6EN66:
-;
i.1.
i,:.
!;
;
a;
I.
r!;..
,:
wall clearance
: 0.02-0.04
mm
(.OOOS-.OOlS in.)
(.0020 in.)
( - .0079
t
.,/ L
t,
in.)
Caution
._ _
The cylinder block gasket surface should be ground to
within 0.2 mm (0079 in.) even with the grind of cylinder
head gasket surface.
1 STB Revision
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9-66
ENGINE-Winder
Block
NOSVEDA
BORING THE CYLINDER
(1) Based on the largest cylinder bore, determine
the over sized
piston to be used.
(2) Measure with the outside diameter of the piston as the datum
measurement
points.
6EN05
NOTE
There are four sizes of oversize piston: 0.25 mm (.OlO in.),
0.50 mm (.020 in.), 0.75 mm (.030 in.), 1.00 mm LO39 in.)
(3) Calculate the reground bore size based on the measured value
of the outside piston diameter.
l
Bore size = outside piston diameter
+ 0.01-0.03
mm
In. ) (gap between cylinder and piston) - 0.02
(.0004-.0012
mm (1.0008 in.) (honing)
(4) Hone each of the cylinders to the calculated measurement.
Caution
In order to avoid uneven boring due to the rise in temperature, bore the cylinders
in the following
sequence:
#2,
#4, #l, and #3.
(5) Hone the cylinders, finishing them to the proper dimension
(outside piston diameter + gap with cylinder).
(6) Check the gap between the piston and cylinder.
Standard
value
: 0.01-0.03
mm (.0004-.0012
in.)
NWVDAF
INSTALLATION
OF OIL PRESSURE
SWITCH
Apply sealant to the screws and install.
Specified
sealant
/
:
Caution
Ensure that the sealant dose not extend beyond
tips.
Be sure not to tighten the screws too tight.
STB Revision
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the screw
14-1
CONTENTS
ENGINE
CONTROL
ACCELERATOR
FBC SYSTEM
. . .. .. . .. . . .. .. . .. . .. ...m...... 84
. .. . . . . . . .. . 84
. . .. .. . .. . ..*............................
CARBURETOR
. .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .. . .
FBC SYSTEM DIAGRAM
. . . . . . . . . . .. .. .. . . . . . . . . . .. .. . .
FUEL LINE AND VAPOR LINE .. . . . . . . . . . . . . . .. .. . . . .
FUEL PUMP
. . . . . . . .. .. . . . . . . .. . . . . . . .. .. . . . . . . . . . . . .. .. .. . . . . . .
FUEL TANK . . . . . . .. . . . . . . . . .. .. . . . . . . .. .. .. . . . . . . . . . . . .. .. . . . . . .
INSPECTION
OF FBC SYSTEM
. . . . . ..a.............
Cautions on Inspection
..............................
Circuit Diagrams
.........................................
Components
Locations and Vacuum
Hoses Layout .............................................
Inspection of Throttle Opener Control
System for Air Conditioner
Load ................
INSPECTION
OF FBC SYSTEM
COMPONENTS
..............................................
Checking the Vacuum Switch ....................
Inspection of Engine Coolant
Temperature
Sensor ..................................
Inspection of Engine Speed Sensor
(Ignition Coil Terminal)
...............................
Inspection of Oxygen Sensor ....................
Inspection of Throttle Opener Control
Solenoid Valve for Air Conditioner
.............
Inspection of Throttle Position
Sensor (TPS) ...............................................
Simple Inspection of Feedback Solenoid
Valve (FBCV) ...............................................
Simple Inspection
of Slow Cut Solenoid
Valve (SCSV) .I.. ...........................................
SERVICE ADJVSTMENT
PROCEDURES
......
Carburetor External View ...........................
Checking the Auxiliary Acceleration
Pump
(AAP) ...........................................................
Checking the Therm0 Valve
(for AAP Control)
........................................
Idle Speed Adjustment
..............................
Idle Speed and Mixture Adjustment
..........
Idle Speed Check Procedure
.....................
Inspection and Adjustment
of Choke
Breaker Opening
........................................
Inspection and Adjustment
of Dash Pot ....
Inspection and Adjustment
of Fast Idle .....
6
61
6
82
77
80
43
43
44
46
53
57
58
57
58
58
59
57
59
59
25
25
41
42
26
26
26
FUEL SYSTEM
...v.....m...m.........................
GENERAL INFORMATION
.............................
SPECIFICATIONS
...........................................
General Specifications
...............................
Lubricant
....................................................
Sealants and Adhesives
.............................
Service Specifications
................................
Torque Specifications
................................
39
30
40
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35
33
34
38
35
30
31
35
36
32
32
42
28
28
24
9
9
13
20
20
23
24
.
:
2
2
3
3
5
5
4
5
..
14-2
FUEL SYSTEM
GENERAL
- General
Information
INFORMATION
N14BA-
The fuel system consists of the fuel tank, the fuel lines (within the fuel return line), the vacuum
fuel pump, the fuel filter, and the carburetor.
The engine
control
is the suspended
type,
and is operated
by the accelerator
pedal
lines, the
and accelerator
cable.
The FBC (Feedback Carburetor) system is a system which functions to regulate the air/fuel mixture ratio.
Input signals from the various sensors enable the electronic
control unit (ECU) to determine
the
operating conditions
of the engine, and, depending
on the operating conditions,
the air/fuel mixture ratio
is regulated by the two solenoid valves (the feedback solenoid valve and the slow cut-off solenoid valve)
equipped
at the carburetor.
The ECU also functions
to control the electric choke, the throttle
opener, etc
3
Feedback solenoid
valve
Fuel pump
t
valve
__----_
Fuel tank
iEngine speed
Throttle position
Oxygen
Engine coolant temperature
sensor
sensor 2
sensor
sensor
ECU
012505
) ,STB Revision
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14-3
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N14CA-
Specifications
Items
Qel
Fu.el tank capacity
60 (15.9, 132)
Provided
Fuel filter
Cartridge type
%el pump
Mechanical
Type
Drive by
diaphragm
type
Camshaft
Discharge
pressure
19.6-29.4
kPa (psi)
(2.84.2)
- 2500 rpm
zarburetor
Down-draft,
2-barrel feedback
Type
Choke type
Automatic
Heater
PTC heater
Identification
(electric type)
model No.
for Federal
for California
Throttle
mm (in.)
bore - primary
secondary
Feedback
mm (in.)
32 (1.26)
35 (1.38)
Duty cycle solenoid
Duty cycle solenoid
Diaphragm
Dash pot
Conventional
Variable resister
Electronic
type
type
type
Vacuum type
Identification
model No.
for Federal
E2T55071 : M/T
E2T55075 : AIT
for California
E2T55071
E2T55075
: M/T
: A/T
Thermistor
type
Input sensors
Coolant temperature
Oxygen sensor
sensor
Zirconia sensor
Control-type
Vacuum switch
Output actuators
Secondary air control solenoid valve
Throttle opener control solenoid valve
switch
ON-OFF
Solenoid valve
ON-OFF
Solenoid valve
NOTE
M/T : Manual transmission
ATT : Automatic transmission
) STB Revision
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type
14-4
FUEL
SERVICE
SYSTEM
- Specifications
SPECIFICATIONS
NMCB-
Specifications
Items
Standard value
Engine adjustments
Approx.
U.S.A. (high
12 BTDC
725+ I50
-100
800 + 100
wm
For the first 500 km (300 miles)
725+15
-100
800 -+ 100
900-950
rpm
rpm
2000
1500
for M/T
for A/T
Throttle-position
sensor (TPS)
Adjustment voltage (throttle valve completely
closed)
0.25
Carburetor
Main jet - primary
# 107.5
secondary
Pilot jet - primary
# 190
# 55
secondary
Enrichment
# 70
# 65
Continuity-approx. 6 fl [at 20C (68PF)l
jet
2.5-2.7(.098-.ld6)
3.2-3.4(.126-,133)
mm (in.)
vm
AIT
rpm
Approx. 2,350 .
Approx. 2,300
(no load, after warm-up, 2nd stage)
R
R
kR
Input sensor
Coolant temperature sensor resistance
kR
20C (68F)
2.5
80C (176F)
0.3
Approx. 1
ON more than 40 kPa (5.8 psi)
OFF less than 26 kPa (3.9 psi)
Vacuum switch
NOTE
M/T : ,Manual transmission
A/T : Automatic transmission
1 STB Revision
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14-5
Items
Output actuator
38 - 44 [2oC (68F)]
38 - 44 [2oC (68F)]
TORQUE SPECIFICATIONS
NMCC-
Nm
ft.lbs.
bolt
15-20
11-14
sensor
20-40
14-29
40-50
29-36
2,5 ~ 4,5
I,8 - 3,2
20-35
Drain plug
Fuel tank to body
15-25
25-30
14-25
II-18
1
16- 19
Items
Carburetor
installation
Coolant temperature
Oxygen sensor
Throttle-position
sensor
installation
screw
18-22
0.7
12-14
LUBRICANT
N14CD-
Specified
Item
Grease for accelerator
spring
SEALANTS
lubricant
Multipurpose grease
SAE J310, NLGI No. 3
Quantity
As required
AND ADHESIVES
N14CE-
Specified
Items
Therm0 valve threads
Coolant temperature
sensor threads
Quantity
As required
As required
/ STB Revision
,&
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14-6
FBC SYSTEM
- FBC System
Diagram
FOR THE
49 STATES
ALTITUDE
SPECIFICATIONS)
OTHER
THAN
( ST6 Revision
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CALIFORNIA
(EXCLUDlNG
HIGH-
FBC SYSTEM
FBC SYSTEM
- FBC System
14-7
Diagram
DIAGRAM
SPECIFICATIONS
r--
3-
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14-8
FBC SYSTEM
- FBC System
FOR CALIFORNIA
I STB Revision
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Diagram
FBC SYS
- Technical
14-9
Description
TECHNICAL DESCRIPTION
COMPONENT
Installation hole
Terminal
2 Terminal
Nl4EBAA
OF FBC SYSTEM
N14BBBA
THROTTLE
POSITION
SENSOR (TPS)
The TPS is a rotation type variable resistor that rotates together
with the carburetor throttle shaft to sense the throttle valve angle.
As the throttle shaft rotates, the TPS output voltage changes and
the ECU detects the throttle valve opening based on the change of
the voltage.
Using the TPS output signal, engine speed signal and other signals, the ECU judges the engine operating mode and controls the
air-fuel ratio, etc. for an optimum air-fuel mixture in that mode.
Throttle shaft
N14BBNC
ENGINE SPEED SENSOR (IGNITION
COIL MEGATIVE
TERMINAL
VOLTAGE SENSOR)
The ignition coil negative terminal voltage makes sudden increase twice per crankshaft revolution synchronously
with ignition timing.
By sensing this ignition coil negative terminal voltage change and measuring the time between peak v,oltages, the
ECU computes the engine speed, judges the engine operating mode and controls the air-fuel ratio.
Ignition switch
Ignition coil
Low rpm
High rpm
One revolution
l-=--i
I ______
------J
A7
of
w
Time
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14-10
FBC SYSTEM
Stoicbiometric
- Technical
Description
OXGENSENSOR
The oxygen sensor installed on the exhaust manifold makes use of
the principles of solid electrolyte oxygen concentration
cell. The
oxygen concentration
cell is characterized by sharp change of the
output voltage in the vicinity of the stoicbiometric
air-fuel ratio.
air-fuel ratio
5
tI/
Lean
13
l6 EC1007 ,
14Air-fuel n tid5
Stoicbiometric
air-fuel ratio
012513
element
-dil&q
Conenctor
03EW
Nl400KA
VACUUM
SWITCH
The vacuum switch is a contact type switch that is operated by
intake manifold vacuum. When the throttle valve closes, the intake
manifold vacuum acts on the vacuum switch to close its contact.
By this action, the voltage on the ECU side is grounded and the
ECU senses that the throttle valve opening is near the idle opening.
012518
Filter
Contact
3EMO62
pm
,evision
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FBC
Control
SYSTEM
rod
IFU219
Duty
100
msec
ratio:
- Technical
14-11
Description
FEEDBACK SOLENOID
VALVE (FBSV)
N14BCAA
The FBSV is installed on the carburetor float chamber cover.
The ECU controls the air-fuel ratio by controlling the duty cycle of
the FBSV.
The higher is the duty ratio, the leaner becomes the air-fuel ratio.
NOTE
The duty cycle control means control of the solenoid valve energization rate by changing the ON time ratio T/T, (called duty ratio)
of 10 Hz pulse.
T,/T,
100 msec
16ZlOOi
N14BCBA
SLOW CUT SOLENOID
VALVE (SCSV)
The SCSV is installed on the carburetor float chamber cover.
The ECU controls the carburetor slow system fuel flow by controlling the duty cycle of the SCSV.
IG.SW.
012519
THROlTLE
OPENER CONTROL
SOLENOID
VALVE
N14BCIC
Refer to section Throttle
opener system for air Conditioning
system on page 14-14.
ELECTRIC
CHOKE RELAY
Refer to section Carburetor
14-18.
electric
choke
system.
on page
SECONDARY
AIR CONTROL
SOLENOID
VALVE
N14BCJA
Refer to GROUP 25 EMISSION
CONTROL SYSTEM-Secondary
air supply system.
1 STB Revision
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:,
4,_
14-12
FBC SYSTEM
- Technical
Description
ELECTRONIC
CONTROL
UNIT (ECU)
Based on the information
from various sensors, the ECU determines
(computes)
operating conditions constantly and accordingly drives the output actuators.
The ECU consists of an 8-bit microprocessor,
random access memory (RAM),
input/output
(I/O) interface.
N14BBDAA
an optimum
(ROM)
IFU350
Connector
Connector
.
// > )
,
A//
c.:
cI.7\
5FUl
ECU Connector
I/O Pin Composition
1. Oxygen sensor
2. Ground for sensor
3. Power supply for sensor
4. 5. Vacuum switch
6. Ground
7. Power supply
8. Power supply
9. Power supply for back-up
10. Engine speed sensor (Ignition coil negative
11. Ground
12. Coolant temperature
sensor
13. Throttle position sensor (TPS)
Pat-t No.
Model
Nc
/
0
L
/
0
5FUl
51.
52.
53.
54.
55.
56.
57.
58.
59.
( ST6 Revision
http://vnx.su/
terminal)
and
FBC SYSTEM
Technical
OPERATION
Jet v
Throttle
position
Oxygen
density-J
Coolant
temperatures
-J
lFU213
Nl4BEM
established
When the FBSV is energized, the main fuel jet is closed to leave
the priman/ main jet passage as the only fuel passage. This will
reduce the amount of fuel, resulting in leaner air-fuel mixture.
To ECU
FBSV
14-13
Description
,!
i:
Priman/
main
iet
lFU21
http://vnx.su/
14-14
THROlTLE
FBC SYSTEM
OPENER
SYSTEM
- Technical
Description
NlUUBB
c\.,;t,.h\
kt%
manifold
=~~r--!rnai;ld
/\
11
Throttle opener
setting screw
/
switch
swlfcn
SAS3
Battery
?
Throttle opener lever
When the engine speed is below the set speed (1,450 rpm), the ECU
when the air conditioner relay is turned on (the air compressor is driven
solenoid valve is energized to introduce intake manifold vacuum to the
slightly, preventing engine speed drop that would otherwise be caused
ST6 Revision
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FBC SYSTEM
4RBURETOR
ELECTRIC
CHOKE
- Technical
SYSTEM
Nl4WBB
Choke
:hoke
14-15
Description
breaker
valve
IFU359
Intake
manifold
vacuum
IFU399
Auto
choke
relay
(ON)
Auto
Engine
speed
Engine
coolant
sensor
temperature
sensor
heater
choke
IFU399
In carburetor
electric choke system, a bimetal which is heated by
an electric heater (PTC heater*) operates the choke valve and fast
idle cam for proper engine warm-up
control.
1 STB Revision
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14-16
FBC SYSTEM
- Technical
Description
Choke
lever
Valve
and
valve
Bimetal
Thiottle
PTC
valve
lFU371
1 STB Revision
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the throttle
FBC SYSTEM
- Technical
2.
3.
Contraction
Description
14-17
1 FU361
4.
5.
Depress the accelerator pedal, and the fast idle cam will turn
counter-clockwise.
Release the accelerator pedal and the lever
will ride on the lower cam of fast idle cam and the throttle
valve will close slightly, decreasing the engine speed. After
warming up the engine for a while, depress the accelerator
pedal and the throttle valve will be further closed.
By repeating this procedure, the fast idle cam is released and
the throttle valve comes to have a normal idle opening.
1 FU362
Expansion
1 FUASII
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14-18
Descrbtion
(Vacuum is created
when coolant temperature
exceeds a certain value.)
If the engine has been started with the throttle valve lever on the
highest fast idle cam detent and left as it is, then the engine speed
increases with the engine coolant temperature
rises, and finally
the engine overruns. In order to prevent such overrun, the choke
opener is provided.
1. When the therm0 valve closes as the engine coolant temperature rises ]65C (149F)], the intake manifold vacuum acts on
the fast idle breaker.
2. The fast idle breaker forces the fast idle cam to turn counterclockwise so that the lever will rest on the lowest cam, closing
the throttle valve to decrease the engine speed.
Choke opener
(Faced fast
idle release)
lFU451
1 FU358
1 STB Revision
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FBC SYSTEM
-Thermovalve
- Technical
Description
14-19
N140TM
Auxiliary Accelerator
Pump (AAP)
The Auxiliary Accelerator Pump is provided to improve driveability
while the engine is still cold. AAP is controlled by a thermo-valve
and intake manifold vacuum and operates in the high load range
while the coolant temperature
is low (approx. 45C/113F).
The thermo-valve
is of the bi-metal type and is mounted on the
intake manifold. The valve opens when the engine coolant temperature is below 45C (113F) and allows the manifold vacuum to
affect AAP chamber [A]. The valve closes when the coolant temperature exceeds 45C (113F) to shut off the manifold vacuum
and stop the operation of the AAP.
The manifold vacuum operates on AAP chamber [Al. When the
diaphragm moves to the right, the fuel pushes check valve 1 open,
flows into and fills chamber [B]. When the throttle valve opens
quickly and the vacuum in chamber [A] lowers, the diaphragm is
pushed to the left by spring pressure. As a result, the fuel in
chamber [B] pushes open check valve 2 and jets into the carburetor, enriching the fuel mixture.
3FU223
A J Manifold
vacuum
With AAP
operating
3FU22d
3FU22:
NllBJAA
The dash pot delays closing of the throttle valve when it closes
from the set opening to the idle opening. This delay absorbs shock
at the time of deceleration for better driving comfort.
Throttle opkner\
)u
1 STB Revision
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14-20
FBC SYSTEM
- Troubleshooting
TROUBLESHOOTING
N14EBM
When checking and correcting engine troubles, it is important to start with inspection of the basic systems. In case
you have such troubles as (1) engine start failure, (2) unstable idling or (3) poor acceleration,
therefore,
you should
first check the following
basic systems.
(1) Power supply
l
Battery
l
Fusible link
l
Fuse
(4) Ignition
system
Spark plug
High-tension
Distributor
Ignition
cable
coil
(6) Others
0
l
Troubles
to check
Ignition timing
Idle speed
with the FBC system are often caused
harness connector
contact.
by poor contact
of harness
connector.
It is, therefore,
important
ZARBURETOR
Symptom
Probable cause
Carburetor
Choke valve remains open-cold
Improper
Remedy
engine
body
1 14-38
and
14-35
sensor
malfunc-
( 14-66
14-57
if
1 Repair or replace
1 14-49
1 Check component
1 14-59
1 Check component
11 Check comoonent
I 14-59
1, 14-58
1 Replace
Repair or replace
I 14-53
-
Vacuum switch
malfunction-cold
enaine
Faulty ECU
Harness broken/short circuited or connector
not connected securely
Rough idle or evgine
stalls
FBC system
Engine coolant temperature
tion
Reference
paae
14-69
Carburetor
Choke valve malfunction
Improper fast idle-cold
14-69
Clean choke bore and link
engine
http://vnx.su/
I 14-40
14-26
14-35
14-68
14-21
FBC SYSTEM-Troubleshooting
Qmptom
iough
tails
Probable
idle or engine
Remedy
cause
Adjust
Engine coolant
malfunction
14-59
valve malfunction
temperature
Vacuum
hose disconnected
Throttle
position
Engine
Throttle
speed
sensor
sensor
opener
or
or damaged
or connector
pump
malfunction
14-49
and adjust
14-28
14-58
Repair or replace
Check pump
open-cold
closed-hot
14-28
engine
engine
valve faulty
discharge
rate
14-69
.I 4-68
Repair or replace
Clean up
14-68
Enrichment
Clean up
14-68
14-36
Secondary
jet clogged
valve operation
Auxiliary acceleration
-cold engine
FBC system
Feedback solenoid
Vacuum
Engine
tion
Throttle
Engine
abnormal
pump
malfunction
coolant
temperature
speed
Check pump
discharge
rate
Check
drive
signal
checker.
Check component
by
14-41
14-59
switch
position
malfunction
valve malfunction
sensor
sensor
using
malfunc-
malfunction
malfunction
Harness broken/short-circuited
not connected
properly
Engine dieseling (runs
after ignition switch is
:urned off)
malfunction
14-57
if
Repair or replace
Check component
malfunction
system
using
malfunction
control
by
14-35
Carburetor
Acceleration
Enrichment
Check
drive
signal
checker.
Check component
sensor
Harness broken/short-circuited
not connected
securely
Ingine
hesitates
)oor acceleration
Reference
paw
14-30
or connector
and adjust
14-58
14-57
if
14-28
14-58
Repair or replace
Carburetor
Engine idle speed
too high
Adjust
14-26
FBC system
Slow cut solenoid
valve malfunction
Check component
idle speed
14-59
1 STB Revision
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14-22
FBC SYSTEM-Troubleshooting
Symptom
Probable cause
Remedy
Reference
paw
14-69
Carburetor
Choke valve operation abnormal
Repair or replace
Auxiliary acceleration
-hot engine
Repair or replace
pump is in operation
FBC system
Engine coolant temperature
tion
sensor malfunc-
Slow-cut
14-26
14-35
1 14-68
drive
signal
by
using
Check comoonents
Check comoonent
14-58
Repair or replace
1 STB Revision
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and adiust
1 14-28
1
I
I
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FUNCTIONS
Slow-cut
Secondary
Throttle
control
switch
Feedback
Air conditioner
Vacuum switch
sensor
sensor (TPS)
Oxygen sensor
Engine-speed
Throttle-position
sensor
Coolant temperature
Air/fuel mixture
ratio control (FBC)
interlock)
Function
NOTE
The * symbol indicates
output
Input
TABLE
Related components
CONTROL
*X
opener
Electric choke
relay control
Secondary
control
air
GROUP 25
EMISSION
CONTROL SYSTEtv
14-36
14-59
14-59
14-59
GROUP 24
HEATERS AND
AIR-CONDITIONIN(
14-58
14-58
14-58
14-57
14-57
Individual unit
description (page)
14-24
/ Special
Tools
N14EAAA
Symptom
Probable cause
Remedy
Reference
paw
Engine malfunctions
due to insufficient
fuel supply
Repair or replace
Clean or replace
Replace
14-80
Evaporative emission
control system
nalfunctions
(When
tank cap is removed,
oressure releasing
noise is heard)
Clean or replace
Malfunctioning
fuel pump
(Clogged filter in the pump)
Replace
14-77
Mispiping
Correct
14-82
Correct
14-82,83
Replace
14-82,83
Replace
Malfunctioning
overfill limiter
(two-way valve)
Replace
14-81
of vapor line
Disconnect
SPECIAL TOOLS
Tool (Number
N14DA..
and name)
Use
Tool (Number
and name)
M D998406
ECI checker
MD 998438
Harness connector
M D998474
Harness connector
(&pin, square)
Adiustment
for FBC
of TPS
1 STB Revision
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Use
Inspection for FBC
system
Use with MD998406
FBC SYSTEM
SERVICE
ADJUSTMENT
CARBURETOR
EXTERNAL
- Service
Adjustment
14-25
Procedures
PROCEDURES
VIEW
N14FJ-.
Mixture
control
Air nipple
chamber
Electrical auto-choke
pump
WP)
View B
Secondary well
bleed nipple
I
A
5FU121
5FU120
View C
5FUlU
Throttle openerDashpot
Accelerator
pump
E\nrichment
,Vacuum nipple E (EGR valve)
View A
5FU122
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http://vnx.su/
14-26
FBC SYSTEM-Service
Adiustment Procedures
PROCEDURE
N14FHAA
AND MINTENANCE-Checkrpm
lFU133
N14FHBA
AND
MAINTENANCE-Idle
(For Un-
1. Remove carburetor
from engine. (Refer to P.14-61,)
2. Clamp carburetor in a vice with idle mixture adjusting screw
(MAS) facing up (protect gasket surface from vice jaws).
3. Drill a 2 mm (5/64 inch) pilot hole in the casting surrounding
the idle mixture adjusting screw (MAX) then redrill the hole to
3 mm (l/8 inch).
4. Insert a blunt punch into the hole and drive out plug.
5. Reinstall carburetor on engine.
6. Run the cold engine at fast idle until the cooling water temperature is raised to 80 to 95C (185 to 205F).
Inspection
Conditions
Engine coolant temperature
: 85-95C
(185-205F)
Light and accessory operation : off
Transmission
: neutral (N or P for automatic
transmission
equipped vehicles)
Steering wheel : center position (power steering equipped vehicles)
7. Prepare a timing light and tachometer.
8. Check the cycle of the timing light. Adjust if necessary.
Timing
light
cycle
: 7 BTDC f2
NOTE
Refer to GROUP 8 ELECTRICAL-Ignition
System,
ing cycle inspection and adjustment
procedures.
FBC SYSTEM-Service
Adjustment
14-27
Procedures
5,
5FU12~
15. Set the idle CO and the engine speed to the specified value by
adjusting the idle speed adjusting screw No. 1 (SAS-1) and the
idle mixture adjusting screw (MAS).
Idle CO : 0.1 to 0.3% at nominal
Curb idle speed :
* 725 :;fi
rpm
/ ** 800 flO0
rpm
NOTE
1. * : For the first 500 km (300 miles)
2. * : After 500 km (300 miles)
3. If the idle CO adjustment fails, suction of secondary
likely. Plug the secondary air hose and try again.
air is
Caution
DO NOT TOUCH SAS-2. The idle speed adjusting
screw
(SAS-2) is the preset screw that determines
the relationship between the throttle
valve and free lever, and has
been accurately
set at the factory. If this setting is disturbed, throttle
opener adjustment
and dash pot adjustment cannot be done accurately.
16. Turn off the ignition switch.
17. Connect the oxygen sensor connector.
18. Install the concealment
plug into the hole to seal the idle mixture adjusting screw.
,, :.
,.i L
t:
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14-28
FBC SYSTEM
- Service Adjustment
Procedures
NOTE
Check the ignition timing and idle speed before performing this
adjustment.
Inspection
Conditions
Engine coolant temperature
: 85 - 95C (185 - 205F)
Lights and accessories : Set to OFF
Transmission
: Neutral
Steering wheel: Straightforward
(vehicles with a power
steering)
(1) Start the engine.
(2) Set the tachometer.
(3) Turn on the air conditioner switch.
NOTE
The solenoid valve will open and the intake manifold
will act on the throttle opener to fully actuate it.
(4) Check the engine
Standard
value
rpm
THROTTLE
MENT
vacuum
POSITION
SENSOR
(TPS)
ADJUSTN14FIBC
cable enough.
(2) Loosen the speed adjusting screw No. 1 (SASl) and No. 2
(SAS2) sufficiently
to close the throttle valve completely.
Record the number of turns loosened.
NOTE
1. Turning
[STB
Revision
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Adjustment
14-29
Procedures
2. At this time, the fast idle control should have been released (the lever not resting on the fast idle cam).
Fast
idle
cam
Lever
1 FU380
(3) Disconnect
the carburetor
connectors.
(4) Connect the special tool (harness connector)
disconnected
connectors.
(5) Connect
a voltmeter
output) and @ (blue:
connectors.
M D998474
Sensor output
(Red teryinal)
(Front view)
8--\
Caution
Use a good,
finely
between
the
between
terminal
0 (red: sensor
sensor ground) of the carburetors
calibrated
digital
type
voltmeter.
5FU125
NOTE
Connection
of FBC connector
as follows:
FBC connector
Terminal
0 (sensor output)
Terminal
@ (sensor ground)
Sensor
power
SUPPlY
(Black
terminal)
Sensor
ground
(Blue
terminal)
and special
tools
terminal
is
Special Tool
and Terminal
Red
and Terminal
Blue
5FU 1YS
Standard
value
: 0.250 V
5FU127
1 STB Revision
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,*
.:
,
i .
!,;.
1
14-30
Adiustment
FBC SYSTEM-Service
INSPECTION
I--
ADJUSTMENT
OF DASH
Pcl-,,
NOTE
Curb idle speed adjustment must be properly adjusted before inspecting dashpot.
Inspection
SAS-2
AND
Procedures
Conditions
3EM07;
SAS3
(3) Close the throttle valve until SAS2 contacts the free lever and
check the engine speed at that moment.
Standard value
Vehicles with a manual
transmission
: 2000 rpm
Vehicles with an automat@
transmission
: 1500 rpm
(4) If engine speed is not as specified, adjust dashpot RPM by
turning SAS3.
(5) Release the free lever and verify that the engine returns to idle
speed slowly.
INSPECTION
OF DISTRIBUTOR
TROL VACUUM (D VACUUM)
Inspection
ADVANCE
Condition
1 STB Revision
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CONNlUlJAA
FBC SYSTEM-s
ervice Adjustment
14-31
Procedures
Vacuum pressure
A
NOTE
For the location of the nipple, refer to the Appearance
buretor (P.14-25)
of Car-
(2) Start and race the engine to make sure that D vacuum
creases with the engine speed.
f
Engine rpm
in-
NOTE
If abnormality is found in change of vacuum, blocked carburetor D port is suspected. Therefore, clean the port as necessary.
lFU445
dacuum pressure
INSPECTION
(E VACUUM)
Inspection
OF EGR VALVE
CONTROL
VACUUM
N14FVAA
Condition
NOTE
For the location of the nipple, refer to the Appearance of Carburetor (P.14-25).
lFU446
(2) Start and race the engine to make sure that E vacuum increases with the engine speed.
NOTE
If abnormality is found in change of vacuum, blocked carburetor E port is suspected. Therefore, clean the port as necessary.
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14-32
FBC SYSTEM-Service
Adiustment Procedures
VACUUM
(A VAC
N14FLAA
Vacuum pressure
A
NOTE
For the location of the nipple, refer to the Appearance of Carburetor (P.14-25)
(2) Start and race the engine to make sure that A vacuum increases gradually with the engine speed.
NOTE
If abnormality is found in change of vacuum, blocked carburetor A port is suspected. Therefore, clean the port as necessary.
>
Engine rpm
lFU447
INSPECTION OF VACUUM
UUM (F VACUUM)
Inspection
Condition
Vacuum pressure
A
nip- .
NOTE
For the location of the nipple, refer to the Appearance of Carburetor (P.14-25).
(2) Start and race the engine to make sure that F vacuum drops
rapidly.
>
Engine rpm
lFlJ448
.I
NOTE
If abnormality
is found in change of the vacuum, blocked carburetor F port and vacuum passage. Therefore, disassemble
and check the carburetor.
1 STB Revision
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FBC SYSTEM-Service
Additional
Adjustment
14-33
Procedures
INSPECTION
OF CARBURETOR
BLEED AIR PASSAGE FOR CLOGGING (INSPECTION
OF CARBURETOR HIGH ALTITUDE COMPENSATION
SYSTEFII
INSPECTION
OF PRIMARY
WELL
CLOGGING-for
California
and high
for the 49 states
BLEED
altitude
NIPPLE
FOR
specifications
Air nipple
NOTE
For the nipple position, refer to the Appearance
(P.14-25).
9
Z!!! i
R P
(1)
(3)
and connect
Disconnect
the vacuum
ple and connect
a hand
well
bleed
nip-
(4) apply vacuum to see that it leaks and does not build up inside
the carburetor.
(5) If vacuum builds up, disassemble and check the carburetor. (Refer to P. 14-63).
PriLary
throttle
valve
(2) Apply vacuum to see that it leaks and does not build up inside
the carburetor.
rimary
main jet
Primary
emulsion
well
Disconnect
the vacuum
hoses from
a hand vacuum pump to the nipple.
of Carburetor
lEU376
f-71
INSPECTION
OF SECONDARY
WELL
CLOGGING-High
altitude
specifications
only (excluding
California)
BLEED NIPPLE
FOR
for the 49 states
N14FRBB
NC11rE
for the nipple position,
(P. 14-25).
Secondarv main /Iiet
ITI
Secondan/ em&ion well / J
Secondary throttle valve
of Carburetor
Disconnect the vacuum hose from the bleed nipple and connect a hand vacuum pump to the nipple.
(2) Apply vacuum to see that it leaks and does not build up inside
carburetor.
(3) If vacuum builds up, disassemble and check the carburetor. (Refer to P.14-63).
(1)
1 STB Revision
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FBC SYSTEM-Service
Adjustment
Procedures
INSPECTION
OF JET AIR NIPPLE FOR CLOGGING-High
altitude specifications
for the 49 states (excluding
California)
NlQFRCA
only
NOTE
For the nipple
(P.14-25).
position,
refer
to the Appearance
of Carburetor
(1) Disconnect
the vacuum hoses from both air nipple and jet air
nipple and connect a hand vacuum pump to the nipples.
(2) Apply vacuum to see that it leaks and does not build up inside
carburetor.
(3) If vacuum
builds up, disassemble
and check the carburetor. (Refer to P.14-63).
Primary
throttle
valve
lFU378
INSPECTION
OF
VALVE OPERATION
(1) Remove
CARBURETOR
SECONDARY
N14FOM
Diaphragm
chamber
OlR0578
(3) With a vacuum of 13.3 kPa (1.9 psi) applied by the vacuum
pump, fully open the primary throttle valve and check that
the secondary
throttle valve also opens fully.
Replace depression
chamber
lFU38E
_ _
Revision
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throttle
valve
14-35
INSPECTION
OF CARBURETOR
ACCELERATION
N14FPM
Primary
Choke
throttle
valve
INSPECTION
valve
OF CHOKE VALVE
Refer
to GROUP
NANCE-Maintenance
0 LUBRICATION
Service
Nl4FQAA
AND
MAINTE-
lFU301
INSPECTION
OF ELECTRIC CHOKE
Electric
N14FOBB
auto-choke
stage
choke
breaker
i
vacuum
pener
lFU359
1 FM95
Caution
All carburetors
have a tamper-proof
choke. The choke-related
parts are factory adjusted.
The choke adjustment
is not required during service, except when major carburetor
overhaul or choke carburetor
related
parts adjustments
are
needed by state or local inspections.
1 STB Revision
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14-36
FBC SYSTEM-Service
Adjustment Procedures
and
NOTE
1. For removal of the bimetal assembly, refer to DISASSEMBLY AND REASSEMBLY
(P. 14-67).
2. Misalignment
and resultant symptom
Symptom
Misalignment
Clockwise
Better startability
but plugs
likely to be sooty
deviation
Counterclockwise
deviation
Poorer startability
to stall
more
choke
body
valve
Gets gradually
start
Opens
rises
hotter
as bimetal
after engine
temperature
(4) If the electric choke body remains cool even after the engine
is started, check the electric choke.
INSPECTION
OF ELECTRIC CHOKE
(1) Disconnect the carburetor connector
the heater.
Normal
N14FacA
and check continuity of
: Should
be conductive
[approx.
6 f3 at
20C (68F)]
(2) If the heater is not conductive, replace the electric choke body
(bimetal assembly).
Carburetor
float
chamber
cover
state
NOTE
For replacement procedures, refer to DISASSEMBLY
ASSEMBLY
OF CARBURETOR
(P.14-67).
5FU
AND RE-
N14FQDA
CHECKING
THE ELECTRIC CHOKE RELAY
(1) Remve the cover of the device box and remove the electric
choke
relay.
/ STB Revision
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FBC SYSTEM-Service
Adjustment
(2) Check
for continuity
flow
is not current
Item
FBC control
unit
Procedures
between
terminals
to the relay coil.
Measured
Between
Ignition
switch
No power flow
-(I%)
t
PTC
(Front
view
of relay
heatel
Auto-choke
PTC heater
Positive
Temperature
Coefficient
Heater
side)
OlR0378
Power flow
14-37
when there is and
terminals
Continuity
terminals 0 - 0
Yes (00)
Between
pp
Between
terminals
0 - 0
No (cdl)
terminals
0 - 0
Between
terminals
0 -0
Yes (00)
Between
terminals
0 - @
No (dl)
NOTE
1. Andicates
the current flow direction.
2. Inspect after checking the infinity of tester.
3. Tonenergize
the relay coil, apply battery voltage directly to
terminals
0-O.
4. Use care as application of battery voltage to incorrect terminals can cause damage to the relay.
(3) If the continuity
choke
relay.
NOTE
If the electric choke body remains cool after engine start although the electric choke heater (PTC heater) and electric
choke relay are normal, check the vehicle body harness circuit.
1 STB Revision
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14-38
FBC SYSTEM-Service
CHECKING
THE CHOKE
BREAKER
Adjustment
Procedures
MECHANlSNs
N14FQEC
At 180C
Stobper
L!
(65F) or higher
Primary throttle
stage)
Intake
manifold
Delay valve
,9
(2nd
1 FU392
Secondary throttle
Manifold /c
vacuum
To intake manifold
lFU391
Engine coolant
temperature
Check
Before
Choke
engine
valve when
normal
Presumed
cause
when abnormal
Fully closed
Malfunction
of
bimetal assembly
Malfunction
of link
Disconnect
the vacuum hose
(yellow stripe) from the choke
breaker during idling.
No movement
Malfunction
of
therm0 valve
Malfunction
of
therm0 valve
Diaphragm
damaged
(chamber
B)
NOTE
For information
concerning
the checking
Exhaust Gas Emission
Control System.
starting
conditions
of the therm0
valve,
refer
1 STB Revision
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to GROUP
25, EMISSION
CONTROL
SYSTEM
FBC SYSTEM-Swvice
INSPECTION
AND
BREAKER OPENING
Choke valve
14-39
Adjustment Procedures
ADJUSTMENT
OF
CHOKE
N14FQFC
Standard
1 FU30
value
: 2.5-2.7
mm (.098-,106
in.)
When removing the bimetal assembly, put a mark on the electric choke body.
NOTE
Rod end opening
Valve clearance
Expected result
Large
Large
Poorer
startability
and stall more likely
Small
Small
(4) Reconnect the removed yellow stripe vacuum hose and measure the choke valve to choke bore clearance as in step (2).
mm (.126-.133
turn-
Clockwise
Counter
clockwise
/ STB Revision
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1
1..
in.)
g
yI
is,
F
p.4:
p...
1.
I!
i
Valve clearance
Expected
result
Small
Better startability
but
plug more likely to
get sooty
Large
Poor startability
stall more likely
and
14-40
FBC SYSTEM-Service
INSPECTION
AND ADJUSTMENT
Adjustment
Procedures
OF FAST IDLE
N14FGGB
Choke breaker
Electric autochoke
Two-st---
-L-,
.age c;rlu<ebreaker
Therm0valve
hifold
vacuum
-Choke
Intake manifoldvacuum
lfU386
lFU360
Inspection
l
8
l
Conditions
transmission)
Steering wheel: Straightforward
ing)
(1) Remove the air filter.
(3) Disconnect
opener.
the vacuum
svision
http://vnx.su/
detent
FBC SYSTEM-Service
14-41
Adjustment Procedures
(5) Start the engine and check the fast idle speed.
Standard value :
2350rpm
[Vehicles with a manual
transmission]
2300rpm
[Vehicles with an automatic
transmission]
(6) If the fast idle speed is out of specification, adjust with the fast
idle adjusting screw.
NOTE
Rotation direction of adjusting screw and fast idle speed
Valve opening
rection
Clockwise
Large
Counter-clockwise
Small
Increases
Decreases
Adjusting
screw
di-
(7) Connect the vacuum hose removed in step (3) to the choke
opener and check that the choke opener cancels fast idle.
CHECKING
THE
PUMP (AAP)
AUXILIARY
ACCELERATION
N14FYAA
NOZZLE
-Therm0
valve
(for AAP)
(Auxiliary Accelerator
Negative
pressure
is felt when the
hose end is covered
by a finger.
Fuel is sprayed
from the nozzle
when the hose is
disconnected.
Negative pressure
Warm-up
the
engine until the
temperature
of
the engine coolant
reaches 50C
(122F) or higher.
3FU22:
Pump)
hose
pressure
Check conditions
7+=7h
*/UP:
Vacuum
negative
Stc ?P
Pump
nozzle
cannot be felt by
the finger.
) STB Revision
http://vnx.su/
14-42
FBC SYSTEM-Service
Adjustment Procedures
CHECKING
THE THERM0
VALVE
TROL)
N14FZAB
(1) Disconnect
the vecuum
hose (black) from the therm0 valve
and connect a manual vacuum
pump to the therm0 valve.
(2) Apply a negative
pressure of 66 kPa (10.0 psi) to the
therm0
valve.
When engine is cold[coolant
temperature 30C (86F) or lower1
Negative pressure
applied (leakage).
Negative pressure is
applied (no leakage).
(3) If incorrect,
replace
the
therm0
adhesive
REPLACEMENT
Refer
Filter
to GROUP
(Replace)
1 ST6 Revision
http://vnx.su/
: 3M Adhesive
Nut
4171 or equivalent
OF FUEL FILTER
0 LUBRICATION
valve.
Caution
1. Do not use a wrench or similar
when removing
or installing
the
2. When installing,
apply a coating
sive to the threaded
part, and then
20-35 Nm (14-25 ftlbs.).
Specified
is not
AND
Locking
No.
N14FCAB
MAINTENANCE-Fuel
FBC SYSTEM-Inspection
of FBC System
14-43
ON INSPECTION
N14PAAC
1 ST6 Revision
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14-44
- Inspection
FBC SYSTEM
CIRCUIT
of FBC System
DIAGRAMS
N 14EG-
Battery
-1.25-B0.5-G
lEi3
A-02
CIRCUIT
Sub fusible
A-23
-15-W
link
Ignition
switch
n5-W
U
z
c:
(u
7
cu
-24 [I
To alternator
[Refer to P.8-37.1
Feed back
solenoid valve
YG
1.25-BW"
Slow cut
solenoid valve
YL
.1.25-BW"
Auto choke
heater
hrottle
#ensor
positio
G
Y
.GF
LI
A-24
Carburetor
assemblv
*;
*i
Remarks
(1) For information concerning
the ground points (example:
q ), refer to P.8-7.
(2) The symbols @I, 0 etc. indicate that the wiring is connected (using the same numerical symbol) to the facing
page. (In other words, 0 on the right page is connected to
0 on the left page.)
1 STB Revision
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FBC SYSTEM
- Inspection
14-45
of FBC System
Ignition
.,
To vacuum
Checker
A-4
A-42
solenoid
[Refer to PI-57.1
A-17
BR
rl
j;
C-24
II
,
I :
I ;
1 0.85-BW
YG,
YL,
I ,
Rb!!,
I '
I '
I
------
I,
2-RL.
x3 B
-----7
-----A
~-----7
B\
GY
YG
------A
r
!R
*4 2-BWl '2-BW
GB,
1
I
IB -,
GB
YG
GY
r
A-4
A-9
A-3
A-6
A-5
B-l 1
B-6
B-9
B-IO
Feed back
carburetor
control unit
B-l
B-2
B-l 2
B-3
B-13
B-8
B-7
3-5
,
I o\o--j
Vacuum
switch
A-46
Water
temperature
sensor
&T[
Oxygen
sensor
-Y
37W612
1 ST6 Revision
http://vnx.su/
14-46
FBC SYSTEM
COMPONENTS
COMPONENTS
LOCATIONS
- Inspection
AND VACUUM
FBC System
of
HOSES
LAYOUT
N14ED-
LOCATIONS
5FU131
Name
Symbol
Engine-speed
Coolant temperature
Oxygen sensor
l-l
Secondary
Electronic
Feedback
Slow-cut
sensor
solenoid valve
solenoid valve
Throttle-position
Vacuum switch
sensor
Name
sensor
(ignition coil@)
j STB Revision
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Symbol
G
FBC SYSTEM
A Throttle
Opener Control
Valve (for air conditioner)
- Inspection
14-47
of FBC System
Solenoid
6 Coolant
Temperature
Sensor
C Feedback
Solenoid
Valve
D Slow-cut
Solenoid
Valve
I I
E Throttle-Positibn
Sensor
F Vacuum
Throttle-PO&ion
Coil
switch
\
sensor
5FUl23
G Ignition
Vacuum
Switch
H Oxygen
(- )
Sensor
u
Oxygen
Sensor
CD
7i
1 STB Revision
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14-48
I Secondary
Valve
FBC SYSTEM
Air Control
- Inspection
of FBC System
Solenoid
J Electric
Secondary
air control
K Electronic
Control
soGid
valve
I:,
Unit
(ECU)
1/
16W1515
1 STB Revision
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Choke
Relay
http://vnx.su/
I
I
L
I
To electrtc choke
I/
5FU115
14-50
Vacuum
FBC SYSTEM-Inspection
Hose Layout..
. vehicles
California
with
high-altitude
of FBC System
specifications
lx
( ST6 Revision
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other
than
FBC SYSTEM-Inspection
Vacuum
Hose Layout
. ..vehicles
for California
STB Revision
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of FBC System
14-51
14-52
FBC SYSTEIVI-Inspection
of FBC System
To secondary
Purge
/..I
Distributor
control
air control
valve
valve*
1/\
///
Therm0 valve
(for AAP control)
Therm0
valve
EGR valve
Vacuum
Device
switch
box %
Secondary
air control
solenoid
valve
.zi- ,_.
1 STB Rewision
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5FU190
FBC SYSTEM-Inspection
14-53
of FBC System
INSPECTION
OF THROTTLE OPENER
SYSTEM FOR AIR CONDITIONER LOAD
Inspection
CONTROL
Nl4PGBB
Condition
Engine speed
switch
OFF
Absent
Idle
Present
ON
Absent
ELECTRONIC
CONTROL UNIT (ECU) CONNECTOR
REMOVAL
AND INSTALLATION
PROCEDURES
Nl4PMA
(1) Disconnect the battery negative (-) terminal connection.
(2) Remove the ECU cover.
unit connector,
steps.
INSPECTION
OF ELECTRONIC
CONTROL
UNIT (ECU) INPUT
AND OUTPUT ELECTRIC SIGNALS
NllPOAB
Inspection and maintenance
of electric system in the FBC system
can be made quickly by inspecting the ECU input and output electric signals with the ECI checker and then by inspecting the component whose signal is abnormal and the harness between the
component
and the ECU.
1 STB Revision
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14-54
FBC SYSTEM-Inspection
CHECK
of FBC System
PROCEDURE
(METHOD
USING
ECI CHECKER)
N14PDAC
http://vnx.su/
FBC SYSTEM
- Inspection
of FBC
14-55
System
FBC SYSTEM
CHECK PROCEDURE
CHART
(Use FBC Harness Connector
MD9984381
,b
0
,ii
-
I
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.!.?
I
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m
-
1 STB Revision
14-56
of FBC System
FBC SYSTEM
CHECK PROCEDURE
CHART
(Use FBC Harness Connector
MD998438)
-
E
1
Y
8
5
a3
J-l
1 STB Revision
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z
-
v
-
FBC SYSTEM-Inspection
14-57
NlUMM
INSPECTION
SENSOR
INSPECTION
(I) Remove engine coolant temperature
sensor from the intake
manifold.
(2) With temperature
sensing portion of engine coolant temperature sensor immersed
in hot water, check electrical resistance. The sensor should be held with its housing 3 mm (.12
in.) away from the surface of the hot water.
16R1251
Temperature
;t;;r&;n\v
Resistance (kfI
C VF)
0 (32)
5.9
20 (68)
2.5
40 (104)
1.1
80 (176)
0.3
(3) If the resistance deviates greatly from the standard value. replace the engine coolant temperature
sensor.
INSTALLATION
(1) Apply specified
adhesive to threaded
portion.
:
3M
Adhesive
Nut
Locking
No.
Specified adhesive
4171 or equivalent
OlR0129
Er-:-:
,?
tE
sensor connector
INSPECTION
VW
OF THROTTLE
POSITION
NlUlQAQ
Sensor
ground
output
Sensor power
OlR049
@
-0
SENSOR
5FU144
TPS installation
torque
NOTE
Refer to P.14-28
procedure.
STB Revision
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sensor
adjusting
14-58
FBC SYSTEM-Inspection
INSPECTION
OF ENGINE
TION COIL 0 TERMINAL)
ess
Ignition
(IGNIN14QCAB
c\btrh
1
I
NOTE
Shake the harness connector
(installed at testing)
5FU145
INSPECTION
OF OXYGEN
SENSOR
N14QDAA
Caution
1.
engine
racing,
the oxygen
sensor
Remarks
Oxygen sensor
output voltage
Approx. 1 V
Racing
measure
eemenyw
Conenctor
03E580
NOTE
For removal and installation
11 INTAKE AND EXHAUST
Oxygen
sensor
CHECKING
installation
THE VACUUM
: 40 - 50 Nm
(36 -36 ft. Ibs.)
SWITCH
N14QIAA
(1) Disconnect
the vacuum
hose (green stripe) from the
device box, and connect a manual vacuum pump to the
device box nipple.
(2) Detach the vacuum switch connector.
(3) Apply negative pressure (vacuum) and check whether or
not there is continuity
between the switch terminals.
5FUW
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FBC SYSTEM-InsPection
14-59
81
40 kPa (5.8 psi) or higher
0 - @
remove the device
switch assembly.
5FU188
t
! L.
$43
36
OF FEEDBACK
SOLENOID
NllQOAB
2 1
7 0
(Front view
at carburetor
side)
5FU147
INSPECTION
(FBSV)
NOTE
For the feedback solenoid valve removal and inspection procedures, refer to CARBURETOR
DISASSEMBLY
AND REASSEMBLY, P. 14-63.
SIMPLE INSPECTION
VALVE (SCSV)
OF SLOW
CUT SOLENOID
Nl4QPAB
(Front view
at carburetor
side)
5FU148
NOTE
For the slow cut solenoid valve removal and inspection procedures, refer to CARBURETOR
DISASSEMBLY
AND REASSEMBLY, P. 14-63.
http://vnx.su/
FBC SYSTEM-Inspection
(4) Apply vacuum and check air tightness for both when battery
voltage is directly applied to the solenoid valve terminal and
when no voltage is applied.
The other nipple of
solenoid valve
Battery voltage
Normal state
5FU150
I
n
(5) Measure
Standard
the solenoid
value
1
I
5FU151
ST6 Revision
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coil resistance.
FBC SYSTEM
14-61
- Carburetor
CARBURETOR
REMOVAL
AND INSTALLATION
N14MA--
16-19
12-14
Nm
ftlbs.
15-20
11-14
11
h$$l:ENANCE
Removal steps
4+ l + 1, Air filter
I)+ Adjusbent
of
2. Connection
3. Connection
4. Connection
5. Connection
l + Adjustment of
6. Snap pin
7. Pin
8. Connection
9. Connection
10. Connection
4*
11. Connection
4*
12. Carburetor
4*
13. Gasket
- Coolant
Replace-
I
Post-installation
accelerator cable
of accelerator cable
of water hose
of fuel vaper hose
of vacuum hoses
throttle cable
of
of
of
of
Operation
Vehicles with an
automatic transmission
throttle cable
control harness connector
main hose
return hose
to reinstall.
of Removal.
of Installation.
03W552
) STB Revision
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FBC SYSTEM
- Carburetor
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
OF AIR
Refer to GROUP
Filter.
N14MBAC
FILTER
11 INTAKE
AND EXHAUST
SYSTEM
11. DISCONNECTION
OF RETURN
HOSE/lo.
MAIN
(1) Before disconnection
of the fuel hose, remove
tank cap to lower the pressure in the fuel
(2) With the receiver placed under the fuel inlet
receive fuel left in the hose, remove fuel hose
carburetor
inlet nipple.
HOSE
the fuel
tank.
fitting to
from the
12. REMOVAL
OF CARBURETOR
NOTE
When the carburetor is removed, keep it horizontally
not to spill fuel from the carburetor.
SERVICE
.
POINTS
OF INSTALLATION
ADJUSTMENT
OF THROTTLE
CABLE
Refer to GROUP
21 TRANSMISSION
Throttle
Cable.
ADJUSTMENT
OF ACCELERATOR
- Air
so as
N14MDAB
- Adjustment
CABLE
of
FREE PLAY
Refer to P.14-84.
1. INSTALLATION
Refer to GROUP
Filter.
/ STB Revision
OF AIR FILTER
11 INTAKE AND EXHAUST
I
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SYSTEM
- Air
FBC SYSTEM
DISASSEMBLY
AND
14-63
- Carburetor
REASSEMBLY
NMME-
7 .
\
-I,
f!sT
Disassembly
steps
1.
2.
3.
4.
5.
+I)
l +
Throttle-return
spring
Damper
spring
Throttle-return
spring
bracket
Throttle
opener/Dash
pot
Bracket
6. Hose
7. Vacuum-delay
valve
8. Hose
9. Screw
IO. Float chamber
cover assembly
11. Float chamber
cover gasket
12. Mixing
body and throttle
body
03W556
Carburetor
assembly
and gasket
kit
NOTE
Reverse the disassembly
procedures
to reassemble.
(2) +e : Refer to Service Points of Disassembly.
(3) q : Non-reusable
parts
(1)
assembly
5FU152
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FBC SYSTEM
14-64
- Carburetor
23
V-lzl17
=-XI18
16
&
&--I5
GDisassembly
13.
+*
14.
15.
4*
4*
16.
17.
18.
19.
de l + 20.
21.
22.
23.
24.
+e ++ 25.
26.
27.
28.
+e ++ 29.
30.
31.
32.
33.
34.
35.
36.
14
k-13
steps
Pin
Float
Needle valve
Needle valve seat
O-ring
Packing
Retainer
Feedback solenoid valve (FBSV)
O-ring
O-ring
Tube
Retainer
Slow-cut
solenoid valve (SCSV)
O-ring
O-ring
Plate
Bimetal assembly
Packing
Connector
Cover
Diaphragm
Spring seat
Spring
Body
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
++ ++ 53.
++ l 4 54.
4~ +4 55.
56.
Spring
Diaphragm
Valve
Mixture control valve (MCV)
Gasket
Cover
Spring
Diaphragm
Body
Spring
Diaphragm
Bracket
Cover
Spring
Diaphragm
Body
Main air jet (primary)
Pilot jet (primary)
Pilot jet (secondary)
Float chamber cover
~~~everse
the disassembly
(2) q+ : Refer to Service
(3) I)+ : Refer to Service
(4) Q: Non-reusable
parts
1 STB Revision
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assembly
procedures
to reassemble.
Points of Disassembly.
Points of Reassembly.
5FU153
FBC SYSTEM
b I
14-65
- Carburetor
-57--0
b---58
OE
Disassembly
I)+
l +
1)4
I)+
I)+
I)+
57.
58.
59.
60.
61.
62.
63.
**
64.
qe I)* 65.
+e I)+ 66.
67.
68.
69.
70.
4*
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
steps
63
Steel ball
2.545
Nm
1 B-3.2 ftlbs
Weight
Ball
Plug
O-ring
Ball
Screw
Gasket
Main jet (primary)
Main jet (secondary)
Cover
Spring
Diaphragm
Enrichment jet valve
Enrichment jet
Spring
Ball
Pump cover assembly
Diaphragm
Spring
Pump body
Gasket
Hose
Auxiliarv acceleration pump cover
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
Spring
Diaphragm
Check valve
Mixing body
Vacuum hose
Depression chamber
Throttle-position sensor (TPS)
Throttle lever
Cam follower
Fast-idle adjustment screw
Free lever
Apartment plate
Idle-speed adjustment screw (SAS-2)
Spring
Secondary lever
Idle-speed adjustment screw (SAS-1)
Plug
Mixture-adjustment screw (MAS)
Throttle body
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) 41) : Refer to Service Points of Disassembly.
(3) I)+ : Refer to Service Points of Reassembly.
(4) -q : Non-reusable
parts
5FU154
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14-66
FBC SYSTEM-Carburetor
NICE
portion
N14MFAA
Caution
1. DO not disassemble
the following
components
at the time
of disassembly.
(1) Choke valve, choke shaft and automatic
choke device
(2) Inner venturi
(3) Throttle valve and throttle
shaft
(4) Fuel inlet nipple
2. When loosening
a Philips screw which has been firmly
tightened,
use a Philips screwdriver
that is an exact fit for
the screw.
10. REMOVAL OF FLOAT CHAMBER
COVER ASSEMBLY
Connector
Stopper
POINITS OF DISASSEMBLY
Pin
Caution
Ensure that the terminal
is not bent during removal of the
connector.
(1) With a pin or the like push the stopper portion to remove
each of the three TPS terminals from the rear of the connectors.
TPS terminals
(three
pieces)
14. REMOVAL
OF FLOAT / 15. NEEDLE VALVE
Remove the pin and then remove the float and needle valve.
Caution
1. Do not let the float drop or apply collapsing
load.
2. Use care not to damage the end of the needle valve.
16. REMOVAL
OF NEEDLE
VALVE
IIKI~ tipped)
SEAT
Caution
Use care not to damage
the float
pushing up the needle valve seat.
Needle
seat
valve
lFU288
( ST6 Revision
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chamber
cover when
FBC SYSTEM-Carburetor
20. REMOVAL
Stopper
Connector
portion
14-67
OF FEEDBACK
SOLENOID
VALVE
(FBSV)
Using a screwdriver or other tool with a thin flat end, push the
stopper portion and remove the two terminals from behind the
connector.
in
Caution
Ensure that the terminal
FBSV terminal
(two pieces)
,
removal
of the
connector.
NOTE
Unless the terminals are removed from the connector, the
feedback solenoid valve cannot be removed from the float
chamber cover.
25. REMOVAL OF SLOW CUT SOLENOID
VALVE (SCSV)
5FU156
(1) Remove
valve.
the retainer
Caution
When removing
hold the body.
the valve,
(2) Using a screwdriver or other tool with a thin flat end, push
the stopper section and remove the two terminals from
behind the connector.
Caution
Ensure that the terminal
the connector.
SCSV terminal
(two pieces)
removal
of
5FU151
Plafe
Bimetal
assembly
(2) Remove
(3) Remove
Stopper
portion
(4) Using a screwdriver or other tool with a thin flat end, push
the stopper section and remove the terminal from behind
the connector.
Connector
in
Caution
Ensure that the terminal
the connector.
Bimetal
assembly
Terminal
5FU154
. .
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removal
of
14-68
FBC SYSTEM-Carburetor
53. REMOVAL
OF MAIN AIR JET (PRIMARY)/54.
PILOT JET
(PRIMARY)/55.
PILOT JET (SECONDARY)
(1) When removing the jets, use a screwdriver that is an exact
fit for their slot and work carefully to prevent damage.
kd
1 FM91
65. REMOVAL
ONDARY)
OF MAIN
JET (PRIMARY)/66.
70. REMOVAL
OF ENRICHMENT
Caution
The valve has many
small
MAIN
JET (SEC-
JET VALVE
parts.
(1) When removing the enrichment jet valve from the mixing
body, use a screwdriver that is an exact fit for its screwdriver slots and work carefully to prevent damage.
(2) Using a screwdriver, loosen the enrichment
jet and take
out the spring and ball from the enrichment
jet valve.
f
Drill
hole
97. REMOVAL
OF PLUG
(1) Clamp carburetor in a vice with idle mixture adjusting
screw (MAS) facing up (protect gasket surface from vice
jaws).
(2) Drill a 2 mm (5/64 in.) pilot hole in the casting surrounding
the idle mixture adjusting screw (MAS) then redrill the hole
to 3 mm (l/8 in.).
(3) Insert a blunt punch into the hole and drive out plug.
lFUl33
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tevision
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FBC SYSTEM-Carburetor
14-69
INSPECTION
N14MGM
GENERAL INSPECTION
Check the following and repair or replace parts if necessary.
(1) Check the fuel paths (jets) and air paths (jets or orifices) for
clogging. If clogged, wash thoroughly with cleaning solvent or
detergent and blow by compressed air. Do not use metal wire
or other metal pieces.
(2) Check the diaphragms for damage and cracks.
(3) Check that the needle valve operates lightly. if the valve is
hard to slide or is binding, repair or replace. If there is overflow,
poor valve to seat contact is suspected. Check thoroughly.
(4) Check the fuel inlet filter (located above the needle valve) for
clogging and damage.
(5) Check the float operation. Check the float and lever for deformation and damage and replace if necessary.
(6) Check operation of the throttle valve, choke valve and link. If
they do not operate lightly, wash well and apply engine oil
sparelingly to their shaft.
(7) Check the float chamber and main body for damage and
cracks.
INSPECTION
OF SLOW CUT SOLENOID
VALVE (SCSV) OPERATION
NllMOBA
(1) Apply battery voltage directly to the slow cut solenoid valve
:,
terminals.
-, . : I_
(2) Check that the valve operates with a click.
1 FU25!
i
MEASUREMENT
OF SLOW CUT SOLENOID
VALVE(SCSV)
RESISTANCE
NuMtxh
(1) Using a circuit tester, check that there is no continuity between the solenoid valve body and terminals.
(2) Measure
Standard
resistance
value
I FU257
1 STB Revision
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between
the terminals.
14-70
FBC SYSTEM-Carburetor
INSPECTION
OF FEEDBACK SOLENOID
VALVE (FBSV) OPERN14MGDA
ATION
(1) Apply batten/ voltage directly to the feedback solenoid valve
terminals.
(2) Check that the valve operates with a click.
1 FU258
lFU294i
MEASUREMENT
OF FEEDBACK
SOLENOID
VALVE (FBSV)
NllMGEA
RESISTANCE
(1) Using a circuit-tester,
check that there is no continuity between the solenoid valve body and terminals.
(2) Measure
Standard
resistance
value
between
the terminals.
MEASUREMENT
OF BIMETAL
Using a circuit tester, measure
and body.
Standard
value
STB Revision
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: Approx.
ASSEMBLY
RESISTANCE
N+lGFA
resistance between the terminal
14-71
FBC SYSTEM-Carburetor
INSPECTION
OF DASH POT
Nl4MGGA
Check that the dash pot operates normally. Resistance must be
felt when the dash pot rod is pulled. When the rod is released, it
must return quickly to the original position. If no resistance is felt
when it is pulled, the diaphragm or the check valve is broken. If the
rod returns slowly, the check valve is binding. In either case, replace the dash pot.
NllMGHA
INSPECTION
OF DEPRESSION
CHAMBER
Check the depression chamber diaphragm for damage. First, push
up the rod fully and closing tightly the nipple with a finger, release
the rod. The diaphragm is intact if the rod does not return to the
initial position while the nipple is held closed with a finger. If the
rod returns, the diaphragm
is broken. Replace the depression
chamber.
MIXTURE
ADJUSTING
SCREW (MAS)
Check the mixture adjusting screw (MA.54 for damage
its taper end by overtightening
etc..
N14MGIA
caused to
1 FlJ367
THROTTLE
POSITION
SENSOR
1. Measure resistance between
position sensor.
2.
(TPS)
terminals
N14MGJA
lFU29l
symbol
6FUW2
L
pm
Nl4MHAE
wision
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FBC SYSTEM-Carburetor
62.
INSTALLATION
OF BALL/Gl.
O-RING/GO.
PLUGI59.
BALL/58. WEIGHT/57.
STEEL BALL
install in correct sequence and at correct positions.
55. INSTALLATION
OF PILOT JET (SECONDARY)/54.
PILOT
JET (PRIMARYV53.
MAIN AIR JET (PRIMARY)
(1) Make sure that correct jets are installed at correct positions. Note the size symbol stamped on each jet for identification.
-
I.
Size
29. INSTALLATION
OF BIMETAL ASSEMBLY
(1) Fit the bimetal end over the choke valve lever.
Bimetal assembly
body
\
\
-__---___---_--
Plate
d
lFU371
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tighten
the screw.
14-73
FBC SYSTEM-Carburetor
Bimetal assembly
Hand rivetter
1 FU372
to the connector
at correct position.
Front view
5FU159
FBSV (yellow)
SCSV (blue)
25. INSTALLATION
OF SLOW
CUT
SOLENOID
VALVE
(SCSV)/SO. FEEDBACK SOLENOID
VALVE (FBSV)
Install terminals to the connector at correct positions.
For TPS
For bimetal
assembly
5FU161
10. INSTALLATION
OF FLOAT CHAMBER
COVER ASSEMBLY
(1) After installing the float chamber cover, install the throttle
position sensor (TPS) terminals (3) to the connector, paying close attention to their positions.
TPS 0 (b&k/red)
5FU16:
INSPECTION
BLY
AND ADJUSTMENT
1 STBI
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AFTER ASSEMN14MIAB
FBC SYSTEM-Carburetor
(2) Measure
the primary
Standard value
Vehicles with
1.21 mm
Vehicles with
1.32 mm
valve to throttle
bore clearance.
:
a manual transmission
(6476 in.)
an automatic
transmission
(.0520 in.)
NOTE
Adjusting
Choke
screw
Adjusting screw
Clockwise
Larger
Increases
Counter clockwise
Smaller
Decreases
UNLOADER
valve
direction
of rotation
OPENING
N14MIBA
(1) Lightly press the choke valve with a finger to fully close it.
(2) In this state, fully open the throttle valve and measure
the
choke valve to choke bore clearance.
Standard
value
- .083 in.)
Lever
NOTE
Lever bending
direction
Clearance
Remarks
UP
Down
Larger
Poor response
Smaller
Lower output
Plug likely to get sooty
1 FU375
CHOKE
BREAKER
Caution
Check and adjust
NUMICB
with
the bimetal
assembly
removed.
(1) Lightly press the choke valve with a finger to fully close it.
(2) Push the choke breaker rod toward the diaphragm
and measure the choke valve to choke bore clearance.
1 FU30
Standard
value :
1st stage : 2.5 - 2.7 mm (.098 - .106 in.)
2st stage : 3.2 - 3,4m
(726 - .133 in.)
ST6 Revision
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FBC SYSTEM-Carburetor
I
u-75
di
adjust by bending
Poorer startability
the
more likely to
N14MIDA
OPERATION
OF CHOKE VALVE
(1) Operate the choke valve with a finger and check for play,
incorrect operation and binding.
(2) If the choke fails to operate smoothly and lightly, wash around
the choke valve.
(3) If the play is excessively large, replace the float chamber
cover.
Nl4MlEA
OPERATION
OF SECONDARY
THROll-LE
VALVE
(1) Fully open the throttle valve and operate the secondary throttle valve lever with a finger to check for play, incorrect operation and binding.
(2) If it fails to operate smoothly and lightly, wash and apply thin
coat of engine oil to th,e shaft.
(3) If the play is excessively large, replace the throttle body.
Nl4MlFA
PORTS
(1) Connect a hand vacuum pump to each port and check for
clogging of the passage.
(2) If there is clogging, clean the port and then blow compressed
air into the port.
STB Revision
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FBC SYSTEM-Carburetor
14-76
Additional
bleed
passage
I
air
Air nipple
bleed
Prin
main
air
Primary
well
bleed nipple
I/ /
jet
Primary
emulsion
i ]
Nl4MlGB
INSPECTION
OF HAC BLEED AIR PASSAGE
Inspection
for Clogging
of Primary Well Bleed Nipple - High
altitude specifications
for the 49 states, California
(1) Connect a hand vacuum pump to the nipple.
(2) Apply vacuum to see that vacuum leaks and does not build up.
(3) If vacuum builds up, disassemble and check the carburetor as
incorrect installation of gasket etc. is suspected.
P;imary<hroitle
valve
well
1 FU37t
Inspection
for Clogging
of Secondary
Well Bleed Nipple N14MIHB
High altitude
specifications
for the 49 states
(1) Connect a hand vacuum pump to the nipple.
(2) Apply vacuum to see that vacuum leaks and does not build up.
(3) If vacuum builds up, disassemble
and check the carburetor as
incorrect installation of gasket etc. is suspected.
Additional
Bleed air
passage
S econdaty
main- jet
5 ;econdary
emulsion
well
Secondary
._
._
r-l
/
throttle
valve
5FU377
., .
,:
Inspection
for Clogging of Jet Air Nipple - High altitude specNllMllB
ifications for the 49 states
(1) Connect a hand vacuum pump to the nipple.
(2) Apply vacuum to see that vacuum leaks and does not build up.
(3) If vacuum builds up, disassemble
and check the carburetor as
incorrect installation of gasket etc. is suspected.
._
TO
cair
Primary
throttle
valv;!
5FU371
p?Ei
levwon
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FBC SYSTEM
Fuel
Pump
FUEL PUMP
REMOVAL
AND
INSTALLATION
1619
12-14
Nm
ftlbs.
\
Removal steps
+e ~~
+*
4*
+e l +
I.
2.
3.
4.
5.
6.
Air filter
Connection of the main hose.
Connection of the return hose.
Fuel pump
Gasket
Insulator
NOTE
(1) Reverse the removal procedures
(2) 4~ : Refer to Service Points
(3) ~~ : Refer to Service Points
(4) m: Non-reusable
parts
03w551
to reinstall.
of Removal.
of Installation
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
N14HBAC
OF AIR FILTER
1 STB Revision
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14-78
FBC SYSTEM-
Fuel Pump
2. DISCONNECTION
Before disconnection
of the fuel hose, remove the fuel
tank cap to lower the pressure in the fuel tank.
4.
REMOVAL
OF FUEL PUMP
(1) Turn the crankshaft to place No. 1 cylinder
center on compression
stroke.
at top dead
NOTE
The above operation
places the lift of fuel pump stroke
at the minimum
position, resulting in ease of fuel pump
removal.
(2) If interference
of pump lever occurs in the cylinder
head, the washer on the cylinder head bolt may be
interfering
with the pump lever. Therefore,
proceed as
follows:
Front of engine
0
0
Remove
the rocker cover.
Loosen cylinder head bolts in the sequence
in the illustration.
>
shown
5EN016
Camshaft
Washer
*
1 1
0380606
INSPECTION
FUEL PUMP
Make the following
checks and replace as necessary.
Note that the fuel pump is a non-maintainable
assembly
must be replaced as an assembly.
l
Oil or fuel leaks from breather hole
l
Damage,
cracks on parts
l
Rocker arm for wear
1 STB Revision
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NllHChC
and
FBC SYSTEM
SERVICE
4.
5EN016
POINTS
OF INSTALLATION
N14HDAC
INSTALLATION
OF FUEL PUMP
(1) Make sure that piston in No. 1 cylinder is in the top
dead center on compression
stroke.
(2) If the washer is moved after loosening of cylinder head
bolt proceed to the following
items.
0 Reinstall
the washer in position.
14-79
- Fuel Pump
torque
1. INSTALLATION
Refer to GROUP
Filter.
1 STB Revision
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OF AIR FILTER
11 INTAKE
AND EXHAUST
SYSTEM
- Air
14-80
FBC SYSTEM
- Fuel Tank
FUEL TANK
REMOVAL
AND INSTALLATION
Pre-removal
Draining
N14GA-
Operation
of the Fuel.
Post-installation
Operation
Supplying of the Fuel.
1 Nm
Z-30
18-22
Nm
ft.lbs.
15-25
11-18
Nm
ftlbs.
Removal steps
l +
l 4
~~
l +
l *
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Drain plug
Fuel filler cap
Fuel filler hose protector
Vapor hose
Check valve
Overfill
limiter (Two-way
Clamp assembly
Fuel filler hose
Breather
hose
Packing
Fuel filler neck
Main hose
Return
hose
valve)
14.
15.
16.
17.
18.
19.
Fuel gauge
unit connector
connection
Fuel tank assembly
mounting
nuts
Fuel tank
Pipe assembly
Separator
tanks
Fuel tank protector
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) l * : Refer to Service Points of Installation.
STB Revision
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FBC SYSTEM
14-81
- Fuel Tank
INSPECTION
Check
Check
Check
Check
l
l
l
l
N14GCAC
NOTE
If the inside of the fuel tank is to be cleaned,
of the following:
(1) Kerosene
(2) Trichloroethylene
(3) A neutral emulsion
type detergent
Check the in-tank fuel filter for damage
Check the check valve for malfunction.
l
l
CHECKING
(TWO-WAY
Outle
side
OVERFILL
VALVE)
or clogging.
LIMITER
may be adopted in
A simple way of inspection, however,
which the overfill limiter is removed and then air is lightly
blown into either the inlet or outlet by month. If the air passes
after a slight resistance, overfill limiter is in good condition.
03ROO21
SERVICE
POINTS
13. INSTALLATION
VAPOR HOSE
OF INSTALLATION
OF RETURN
HOSE/lZ.
N14GDAE
MAIN
HOSE/4.
.I,,.,.......
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m
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9.
INSTALLATION
HOSE
OF BREATHER
INSTALLATION
OF CHECK
HOSE/8.
ends contact
FUEL
FILLER
VALVE
I,\\
03W532
) STB Revision
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14-82
FBC SYSTEM
AND
Line
LINE
INSTALLATION
N14KA-
--------
03w554
l +
e+
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
NOTE
l * : Refer to Service Points of Installation.
STB Revision
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FBC SYSTEM
Fuel
Line
and
Vapor
14-83
Line
INSPECTION
N14KCAB
l
l
l
bends,
CHECKING
PURGE CONTROL VALVE
(1) Make sure that the cooling water is at a temperature
between
80 and 90C (180 and 190F).
(2) Disconnect the purge control hose from the air filter and blow
into the purge hose. If the valve is not open, its operation is
normal. Then start the engine and increase the engine speed
to 1,500 to 2,000 rpm and blow into the purge hose. If the
valve is not open, check for clogged or broken vacuum hose,
or malfunctioning
therm0 valve.
t To carburetor
To air filter
From canister
03E562
SERVICE
7.
POINTS
INSTALLATION
MAIN HOSE
OF INSTALLATION
OF VAPOR
HOSE/4.
N14KDAD
RETURN
HOSE/3.
When attaching
the hose to the pipes, be sure that the
hose is attached
until its end comes in touch with the
bulge of the pipe as shown in the illustration.
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14-84
ENGINE
CONTROL
- Accelerator
Cable
ACCELERATOR
and Pedal
CABLE AND
PEDAL
ADJUSTMENT
OF ACCELERATOR
CABLE FREE PLAY
1. Run the engine until it reaches the specified
idle speed
level.
2. Loosen the locking
bolt or adjusting
nut at the cable
adjusting
portion so that the throttle
lever is free.
3. Move the holder to the position just before the throttle
lever begins to operate, and then return it far enough so
that there is an appropriate
amount of slack in the inner
cable and secure it at this position.
4. Operate the accelerator
arm and confirm that the throttle
valve changes from fully closed to fully open.
STB Revision
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ENGINE CONTROL-Accelerator
REMOVAL
AND
14-85
N14QA-
INSTALLATION
16-19
12-14
Nm
ft.lbs.
\
8
Accelerator
+e l +
~~
~~
*+
l +
**
l +
1. Air filter
Adjustment of accelerator cable free play
2. Accelerator cable
Accelerator
l +
07W532
3.
4.
5.
6.
7.
8.
NOTE
(1)
Reverse
the removal
procedures
(21 CI
: Refer
to Service
Points
64
: Refer
to Service
Points
(4) m:
Non-reusable
parts
i3j
1 STB Revision
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to
of
of
reinstall.
Removal
Installation.
14-86
ENGINE
CONTROL
- Accelerator
SERVICE
Cable
POINTS
and Pedal
OF REMOVAL
1. REMOVAL
OF AIR FILTER
Refer to GROUP 11 INTAKE
Filter.
N140BAA
AND EXHAUST
SYSTEM
INSPECTION
l
l
l
l
l
l
N140CAB
Check the
Check the
Check the
Check the
Check the
Check the
SERVICE
POINTS
OF INSTALLATION
N140DAI
8. APPLICATION
OF GREASE
TO PEDAL17.
ACCELERATOR
ARM/5.
RETURN SPRING/S.
TOR ARM BRACKET
Apply the specified
of the pedal.
Specified
07FOO5
-Air
grease
grease
around
: Multipurpose
No. 3
SPRING/G.
ACCELERA-
grease
SAE J310,
point
NLGI
25
2.
INSTALLATION
OF ACCELERATOR
Make sure that the accelerator
cable
bends.
CABLE
is laid without
ADJUSTMENT
CABLE
OF ACCELERATOR
sharp
FREE PLAY
Refer to P.14-84.
1. INSTALLATION
Refer to GROUP
Filter.
1 STB Revision
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OF AIR FILTER
11 INTAKE AND EXHAUST*SYSTEM
- Air
25-1
EMISSION CONTROL
CONTENTS
COMPONENT LAYOUT AND VACUUM
HOSE PIPING . ..m.......*.............,...,...,.....
COMPONENT
LAYOUT
VACUUM
HOSE PIPING
. . . . . . . . . . . . . . . . . . . . . . . . . ;:
. . . . . . . . . . 23
DIAGRAM
OF POSITIVE CRANKCASE
(PCV) VALVE . . . . . . . . . . . . . . . .
27
27
30
28
28
29
EXHAUST EMISSION CONTROL SYSTEM . . 30
INSPECTION
OF AIR CONTROL
VALVE AND
THERM0
SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSPECTION
OF AIR FUEL RATIO
. . . . . . . . . . . . . . . . . . . . . 30
CONTROL
(FBC) SYSTEM
INSPECTION
OF: CARBURETOR
BLEED
AIR PASSAGE CLOGGING
. . . . . . . . . . . . . . . . . . . . . 38
INSPECTION
OF CHECK VALVE . . . . . . . . . . . . . . 37
INSPECTION
OF EGR VALVE
. . . . . . . . . . . . . . . 33
INSPECTION
OF EGR VALVE
CONTROL
VACUUM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSPECTION
OF ENGINE COOLANT
TEMPERATURE
SENSOR
. . . . . . . . . . . . . . . . . . . . . . 33
INSPECTION
OF ENGINE SPEED SENSOR
33
INSPECTION
OF EXHAUST GAS
RECIRCULATION
(EGR) SYSTEM
. . . . . . . . . . . . . 33
INSPECTION
OF HIGH ALTITUDE
COMPENSATION
SYSTEM
[High altitude specifications
for the 49 states
(excluding California)]
. . . . . . . . . . . . . . . . . . . . . 34
INSPECTION
OF HIGH ALTITUDE
COMPENSATION
SYSTEM
(Vehicles for California)
.. . .
. . . . . . . . . . . 38
N25AA-
INSPECTION
OF HIGH ALTITUDE
C04P/1PENSATOR
(HAC)
[High altitude specifications
for the 49 states
. ... ... ..... .... ..... ... ....
(excluding California)]
INSPECTION
OF HIGH ALTITUDE
COMPENSATOR
(HAC)
(Vehicles for California)
... .... ,... ... ... ......
INSPECTION
OF INTAKE AIR
.. ... ...
TEMPERATURE
CONTROL
SYSTEM
INSPECTION
OF MIXTURE
CONTROL
VALVE (MCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
OF SECONDARY
AIR
CONTROL
SOLENOID
VALVE . . . . . . . . . . . . . . . . .
INSPECTION
OF SECONDARY
AIR
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION
OF SECONDARY
AIR SUPPLY
.. ... ..... .... ... ... ... ..... ... ... .... .....
SYSTEM
INSPECTION
OF THERM0
VALVE . . . . . . . . . . .
INSPECTION
OF THREE CATALYST
CONVERTER
.. .... . .. . . .. .... . ... .... .
INSPECTION
OF VACUUM
REGULATOR
VALVE (VRV) ......................................
INSPECTION
OF VACUUM
SWITCH
........
INSPECTION
OF VACUUM
SWITCHING
VALVE (VSV) [High altitude specifications
......
for the 49 states (excluding California)]
INSPECTION
OF VRV CONTROL
.........................................
VACUUM
GENERAL INFORMATION
.......................
SPECIFICATIONS ...................................
GENERAL SPECIFICATIONS
SERVICE SPECIFICATIONS
TORQUE SPECIFICATIONS
SEALANTS AND ADHESIVES
TECHNICAL DESCRIPTION
http://vnx.su/
40
41
42
(..
32
.:<
31
1
.:,I :
ib
30
33
30
34
33
37
34
2
17
...................
....................
....................
.........................
17
17
17
18
.... . .................
CRANKCASE
EMISSION
CONTROL
SYSTEM
. .. .... .. ..... .. ... ... .... .... ... ... ..
EVAPORATIVE
EMISSION
CONTROL
SYSTEM
..... ... ... .... .... .... ... ... .... .... .... ..
EXHAUST EMISSION
CONTROL
SYSTEM
.. . .. .. ... . . .... . ... .... ... .... ..
TROUBLESHOOTING
36
t.
:.
6
7
9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
$
-?
.-
25-2
EMISSION
CONTROL
SYSTEM-General
GENERAL INFORMATION
Information
N25BEAA
The
(1)
(2)
(3)
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EMISSION
FBC SYSTEM DIAGRAM-vehicles
altitude
specification)
CONTROL
SYSTEM
- General
than
25-3
Information
California
(exclu&g
high-
!
-Ji
:
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25-4
EMISSION
CONTROL
with
SYSTEM
- General
high-altitude
1 STB Revision
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Information
specifications
EMISSION
FBC SYSTEM
CONTROL
DIAGRAM-vehicles
for
SYSTEM
California
tI:
E
1 STB Revision
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- General
Information
25-5
25-6
EMISSION
CONTROL
SYSTEM-Technical
Description
TECHNICAL DESCRIPTION
CRANKCASE
EMISSION
CONTROL
SYSTEM
PCV valve
N25w
Carburetor
Breather hose
ker cover
Intake manifold
To intake manifold
1
5EM081
1 STB Revision
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EMISSION
EVAPORATIVE
CONTROL SYSTEM-Technical
E ISSION CONTROL
Purge
Air cleaner
25-7
Description
N25HBAA
SYSTEM
Fuel check valve
yt?;;lurred by FMVSS
control valve
therm0 valve :
Overfill limiter
I (Two-way valve)
float chamber-
Bowl
Charcoal
-Fuel
vent valve
Canister JlJ-tj
II
II
Thermal
expansion
volume
-~..
I
I
To carburetor
vapor
pi&J
Filter
\
Fuel gauge
unit
Fuel tank
03W527
In order to prevent the loss of fuel vapor from the fuel system into the atmosphere, the evaporative
control system consists of charcoal canister, a bowl vent valve, a purge control valve, etc.
/ STB Revision
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emission
25-8
EMISSION
CONTROL
Canister
SYSTEM-Technical
Description
N25HEEA
CANISTER
While the engine is inoperative, fuel vapors generated inside the
fuel tank and the carburetor float chamber are absorbed and
stored in canister. When the engine is running, the fuel vapors
absorbed in canister are drawn into the intake manifold through
the purge control valve, and an orifice. And the carburetor bowl
vapors flow into the carburetor through the bowl vent valve.
CO3526
t To carburetor
and therm0 valve
To intake
manifold
From canister
03E562
r0 fuel
(:heck valv
To fuel tank
VacuuCn
valve
N25HBEA
OVERFILL LIMITER (TWO-WAY
VALVE)
The overfill limiter consists of a pressure valve and a vacuum
valve. The pressure valve is designed to open when the fuel tank
internal pressure has increased over the normal pressure and the
vacuum valve opens when a vacuum has been producted in the
tank.
\
Pressure valve
03E506
To choke
opener
To purge
control valve
To EGR valve
To choke breaker
THERM0
VALVE
NZBHBFA
The therm0 valve, for sensing the coolant temperature
at the intake manifold, closes the purge control valve when the coolant
temperature
is lower than the pre-set value in order to reduce CO
and HC emissions under engine warm-up conditions, and opens
the purge control valve when the coolant temperature
is above the
pre-set temperature.
Therm0 sensor
for coolant temp.
detection
1 EMZO!
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wision
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Description
FUEL CHECK-VALVE
To overfill
From
fuel
limiter
25-9
NZ5HBGA
The fuel check valve is used to prevent fuel leaks when the car
suddenly rolls over. This valve is connected in the fuel vapor line
(between fuel tank and overfill limiter) and is installed on the fuel
tank.
The fuel check valve contains two balls as shown in the illustration. Under normal conditions, the gasoline vapor passage in the
valve is opened, but if roll-over occurs one of the balls closes the
fuel passage, thus preventing fuel leaks.
tank
03E510
Relief
valve
N25HBHA
the escape
II
, ..i
^i :-
:.:;
03G0002
EXHAUST
EMISSION
CONTROL SYSTEM
N25HcAA )$
intake
stroke
1EMlOf
51
N25HcBA
JET AIR SYSTEM
In addition to the intake valve and exhaust valve, a jet ,valve has
been provided for drawing jet air (super lean mixture or air) into the
combustion chamber.
A jet air passage is provided in the carburetor, intake manifold and
cylinder head. Air flows through the intake openings provided near
the primary throttle valve of the carburetor, goes through the passage in the intake manifold and cylinder head, and flows through
the jet valve and the jet opening into the combustion
chamber.
The jet valve is actuated by the same cam as the intake valve and
by a common rocker arm so that the jet valve and intake valve
open and close simultaneously.
The jet air flowing out of the jet opening scavenges the residual
gases around the spark plug and creates a good ignition condition.
It also produces a strong swirl in the combustion
chamber which
continues throughout the compression stroke and improves flame
propagation after ignition, assuring high combustion
efficiency.
,
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i
a
&:
25-10
EMISSION
CONTROL
SYSTEM-Technical
Description
Refer to GROUP
. .
14 FUEL SYSTEM
- General
Information
for detailed
description
,.:
CATALYTIC
CONVERTER
Exhaust
Cover
Stainless steel
lEM127
Function
The three catalytic converter removes CO, HC and NOx most
effectively in the vicinity of the stoichiometric
ratio. The air fuel
ratio feedback control by oxygen sensor controls the air fuel mixture to the stoichiometric
ratio and the catalytic converter promotes both oxidation and reduction of resultant exhaust gas to
make it clean before it is released to atmosphere.
Stoichiometric
ratio
wision
-7
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EMISSION
CONTROL SYSTEM-Technical
Description
25-11
Caution
The catalytic converters require the use of unleaded
gasoline
only. Leaded gasoline will destroy the effectiveness
of the
catalysts as an emission
control device.
Under normal operating
conditions,
the catalytic
converters
will not require maintenance.
However, it is important
to
keep the engine properly tuned. lf the engine is not kept properly tuned, engine misfiring
may cause overheating
of the
catalysts. This may cause heat damage to the converters
or
vehicle components.
This situation
can also occur during diagnostic testing if any spark plug cables are removed and the
engine is allowed to idle for a prolonged
period of time.
SECONDARY
AIR SUPPLY
SYSTEM
N25HCEC
Seconda
control v
From air
filter
I-
Reed valve
C.C.
C.C. : Catalytic converter
@JJ
1 EM206
c)
The reed valve supplies secondary air into the exhaust manifold for the purpose of promoting oxidation of exhaust
emissions. The reed valve is actuated by exhaust vacuum being generated from pulsation in the exhaust manifold,
and additional air is supplied into the exhaust manifold through the secondary air control valve.
Contents of Control
When the engine coolant is cold (18 - 52C (65 - 125F)J or when the vehicle is decelerating,
the ECU turns on
the power transistor to energize the secondan/ air control solenoid valve.
As a result, the intake manifold vacuum is introduced to the secondary air control valve and the secondary air is
supplied to the exhaust manifold.
1 STB Revision
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?
I>.
P
25-12
EXHAUST
EMISSION
GAS RECIRCULATION
CONTROL
SYSTEM-Technical
Description
(EGR) SYSTEM
N25HCFA
EGR valve
,/
EGR passage
regulator valve
Therm0 valve
Venturi
1 EM207
Operation
During idling or Throttle Wide Open Operation
In this case, the E port vacuum is low and the EGR valve is closed
by spring force. As a result, EGR gas does not flow.
NOTE
The EGR is not made to ensure stable idling operation.
lEMl36
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EMISSION
I
, EGR
valve
/
CONTROL
Description
25-13
spring
Genturi
SYSTEM-Technical
1EM 13t
,VRV
spring
.(*A :
When the venturi pressure drops to near the atmospheric
pre$
sure, the VRV opens to allow the E port vacuum to escape tfi!
f.
atmosphere. Then, the EGR valve closes.
By repeating this cycle (closed loop control), EGR flow rate pro:;
!4
portional to the intake air volume can be obtained.
vk...
Y\
l&
NOTE
By controlling the EGR rate to optimum
level, exhaust emission
(NOx) is minimized without loss of driveability.
lFMlR7
@WV
E port
valve
Throttle
valve
closes
vacuum
to apply
to EGR
1 STB Revision
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EMISSION
HIGH-ALTITUDE
fornia)]
COMPENSATION
CONTROL
SYSTEM
SYSTEM-Technical
[High
altitude
specifications
Description
for the 49 states
(excluding
Cali-
Distributor
High altitude
compensator
Intake manifold
vacuum
Additional
passage
bleed air
------.
Air inlet of
bleed air
7-d
Secondan/ emulsion
Primary throttle valve
bell
1 STB Revision
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EMISSION
CONTROL SYSTEM-Technical
distributor
Check valve yl
compensator
Description
25-15
Primary
jet
Primary /
emission well
1 ENlO%
INTAKE
AIR TEMPERATURE
CONTROL
SYSTEM
Therm0 sensor
Vacuum motor
Air Ifilter
6EM071
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:.
-.I-
25-16
EMISSION
CONTROL
SYSTEM-Technical
Description
Operation
l
MIXTURE
CONTROL
VALVE
(MCV)-VEHICLES
Filter \
WITH
A MANUAL
TRANSMISSION
1 Orifice
Purge jet
Check valve
Throttle valve
Chamber B
Chamber A
Manifold
pressure
negative
Secondary
Primary
5FUO76
When the throttle is closed suddenly during deceleration or shifting, the fuel remaining in the inlet manifold causes
an over rich mixture temporarily.
In order to prevent this, air is supplied temporarily from another passage so as to keep correct air fuel ratio and
reduce emission (HC).
Operation
When the throttle is closed suddenly, the manifold vacuum increases sharply. This increased manifold vacuum acts
on the chamber A of the MCV to open the valve so that air is supplied to the inlet manifold. The vacuum is also
supplied to chamber B but with some delay due to the orifice. When the vacuum is supplied to both chambers B
and A, they are at vacuum and hence the spring causes the valve to close, stopping supply of air. The check valve
located at the diaphragm is to prevent high vacuum from remaining in chamber B when acceleration/deceleration
is repeated successively. (If a high vacuum remains in chamber B, the valve may fail to operate when vacuum acts
on chamber A.)
m
Revision
http://vnx.su/
25-17
SPECIFICATIONS
GENERAL
N25cA--
SPECIFICATIONS
items
Specifications
Crankcase emission
:ontrol system
Positive
Evaporative emission
control system
Canister
2-way valve
Purge control valve (PCV)
Bowl vent valve (BW)
Equipped
Equipped
Single diaphragm
type
Vacuum type
(Purpose:
Control of HC emission)
Exhaust
control
Jet control
emission
crankcase
ventilation
combustion
catalyst
(PCV) valve
type system
system
- FBC system
converter
Monolithic
(Purpose:
Single type
With vacuum
Wax type
Mixture
control valve (MCV)
a manual
transmission
system
- Vehicles
type
Control
valve
of CO emission)
control
COntrOl
(Purpose:
CO, HC emission)
(Purpose:
control
NOx emission)
Bellows
type
Differential
(Purpose:
NZSCB-Specifications
Items
Secondary
air control
valve opening
High altitude
solenoid
temperature
compensator
operating
!.I
18 (64)
65 (149)
C (F)
altitude
Approx.
m (ft.)
1,200 (3,900)
TORQUE SPECIFICATIONS
Nzxc--
Nm
ft.lbs.
50 - 60
37 - 44
70 - 100
52 - 74
bolt
19 - 28
14-
20 - 40
15 - 30
Items
Secondary
Secondary
Of
(Purpose: Control of
CO, HC emission)
SERVICE SPECIFICATIONS
Therm0
Of.
side joint
/ STB Revision
http://vnx.su/
20
.A,
,,:.,
25-18
EMISSION
SEALANTS
CONiROL
SYSTEM -Specifications
AND ADHESIVES
N25CE--
Items
Therm0
/ Troubleshooting
sealants
Spetified
valve
3M,
Adhesive
iNut
Locking
Quantity
and adhesives
As required
4171 or equivalent
TROUBLESHOOTING
N25EA--
Symptom
Probable
cause
Vacuum
hose disconnected
Mixture
control
or damaged
idle or engine
Vacuum
Repair or replace
Replace
~
hose disconnected
~-.
or damaged
Faulty bowl
Mixture
control
Troubleshoot
the system and
check components
under suspicion
25-36
Repair or replace
25-33
Troubleshoot
the system and
check components
under suspicion
25-28
Replace
25-27
Replace
25-42
Replace
25-28
Troubleshoot
the system and
check each component
under
suspicion
25-33
Troubleshoot
the system and
check components
under suspicion
25-36
Replace
25-29
Troubleshoot
the system and
check components
under suspicion
25-41
line clogged
Check positive
tion system
Refer to
GROUP
0
system
Troubleshoot
the system and
check components
under suspicion
25-41
faulty
Troubleshoot
the system and
check components
under suspicion
25-33
Troubleshoot
the system and
check components
under suspicion
25-36
system
vent valve
control
or
Exhaust
gas recirculation
system
Excessive
sumption
oil con-
Positive
crankcase
control
ventilation
Exhaust
faulty
control
gas recirculation
25-33
Repair or replace
Repair or replace
Reference
page
Remedy
system
system
1 ST6 Revision
faulty
faulty
-1
http://vnx.su/
crankcase
ventila-
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1 STB Revision
http://vnx.su/
25-20
EfWSlON
COMPONENT
COMPONENT
CONTROL
SYSTEM-Component
N25EA-A-
LAYOUT
A
5EM082
A PCV valve
B Canister
C Purge control valve
D Bowl vent valve
E Reed valve
F Secondary air control solenoid
G EGR valve
H Vacuum regulator valve
I
J
valve
STB Revision
Therm0 valve
High-altitude
compensator
[High-altitude
specifications
for the 49 states
(ex. California), vehicles for California]
K Vacuum
switching
valve
[High-altitude
specifications
for the 49 states]
L Air control valve
M Mixture control valve
(Vehicles with manual transmission)
rzi
http://vnx.su/
EMISSION
A
PCV valve
Purge
Reed valve
control
CONTROL
SYSTEM-Component
valve
Secondarv
ti
Vacuum
valve
air
STB Revision
http://vnx.su/
valve
regulator
High-altitude
comDensator
-.y
regulator
Vacuum
Therm0
25-21
I!+----
compensator
-I-
8 .
25-22
EMSSION
Vacuum
switching
Mixture
control
CONTROL
SYSTEM-Component
valve
valve (Vehicles
with
a manual transmission)
1 STB Revision
http://vnx.su/
Air control
valve
EMISSION
VACUUM
(excluding
CONTROL
SYSTEM
- c omponent
II
Layout
and
Vacuum
I
h
m
1 STB Revision
http://vnx.su/
Hose
piPin!
other than
25-23
California
25-24
EMlSSlON
CONTROL
SYSTEM
VACUUM
HOSE PIPING DIAGRAM-vehicles
states other than California
Component
Layout
and
with high-altitude
Vacuum
Hose
specifications
r
Ir
STB Revision
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Piping
for the 49
EMlSSlON
VACUUM
CONTROL
HOSE PIPING
SYSTEM
DIAGRAM-vehicles
- component
for
1 CTR Rnvision
http://vnx.su/
Layout
California
and
Vacuum
Hose
PiPing
25-25
u:(~
:. ,
25-26
EMISSION
CONTROL
SYSTEM
Component
/3
Layout
and
Vacuum
Hose
Piping
Therm6 valve
lfor AAP controll
EGRvalve
HAC-California
state, high altitude
specifications for the 49 states
Secondan/
5FU190
/ STB Revision
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,-.,
EMISSION
CONTROL SYSTEM
Crankcase
Evaporative
CAUTIONS
Emission
Emission
Control
Control
System
f
System
25927
ON INSPECTION
N25GALA
CRANKCASE
TEM
EMISSION
N2SlAAA
INSPECTION OF POSITIVE
TION (PCV) VALVE
CRANKCASE
Refer to GROUP
0 LUBRICATION
Maintenance
Service
EVAPORATIVE
SYSTEM
INSPECTION
CONTROL SYS-
EMISSION
AND
VENTILA-
MAINTENANCE-
CONTROL
N2slBM
Caution
Check after the engine is allowed to cool enough. If the engine is not cold, fuel could gush out from the BW.
ST6 Revision
http://vnx.su/
Normal condition
Vacuum leaks
Vacuum holds
25-28 EMISSION
CONTROL
SYSTEM
- Evaporative
Emission Control
System
t
1
l
Therm0 valve
5EMO30
(1) Disconnect the black vacuum hose from the intake manifold
nipple and plug the nipple. Then, connect a hand vacuum
pump to the disconnected black vacuum hose.
(2) Check the following both when the engine is cold [engine
coolant temperature 50C (122F) or less] and when it is hot
[engine coolant temperature 85 to 95C (185 to 205F)J
When
engine
is cold
Normal
F%
:r59d::;zte
When
engine
condition
Vacuum is held
is hot
Vacuum
Engine state
Normal condition
Idling
2,500 rpm
Vacuum is held
Vacuum leaks
INSPECTION
OF PURGE CONTROL
VALVE
(PCVJ,
lEM143
/ STB Revision
-1
http://vnx.su/
-.. ,
EMISSION
CONTROL
SYSTEM
- Evaporative
Emission
Control
System
Z-29
INSPECTION
OF THERM0
NOTE
This therm0 valve
choke
opener.
also controls
VALVE
the choke
N25lBDb
breaker,
EGR and
Caution
1. When removing
or installing
the therm0
valve, do not
use wrenches
or other tools on the resin part.
2. When installing,
apply 3M Adhesive Nut Locking 4171 or
equivalent
to the threads and tighten to 20 to 40 Nm (15
to 30 ftlbs.).
3. When disconnecting
the vacuum
hose, put a mark on
the hose so that it may be reconnected
at original
position.
(1) Disconnect
the vacuum hose (white stripe) from the therm0
valve and connect a hand vacuum pump to the therm0 valve.
(2) Apply vacuum to check therm0 valve condition as follows.
Engine coolant
Normal condition
Vacuum leaks
Vacuum holds
5EMO42
Normal condition
Vacuum leaks
1 STB Revision
http://vnx.su/
Vacuum holds
25-30
HVMSION
CONTROL
SYSTEM
Evaporative
Emission
Control
System
Exhaust Emission
Control
System
INSPECTlON
VALVE)
Refer
OF OVERFILL
LIMITER
(TWO-WAY
N25lBEA
to GROUP
14 FUEL
EXHAUST
TEM
SYSTEM-Fuel
EMISSION
Tank.
CONTROL
SYSN25lCAA
INSPECTION
SYSTEM
(FBC)
Refer to GROUP
14 FUEL SYSTEM-Inspection
of FBC System.
INSPECTION
OF THREE CATALYST
CONVERTTE!
cracks
or fusion
and replace
II
if faulty.
Caution
1. Operation
of any type, including
idling,
should
be
avoided if engine misfiring
occurs. Under this condition
the exhaust
system
will operate
at abnormally
high
temperature,
which may cause damage
to the catalyst
or under-body
parts of the vehicle.
2. Alteration
or deterioration
of ignition
or fuel system, or
any type of operating
condition
which results in engine
misfiring
must be corrected
to avoid overheating
the
catalytic
onveters.
3. Proper maintenance
and tuneup according
to manufacturers
specifications
should
be made to correct the
conditions
as soon as possible.
INSPECTION
TEM
OF SECONDARY
(1) Disconnect
small steel
suction.
Engine coolant
perature
tern-
AIIR SUPPLY
Engine state
Air suction
20-40C
(68 - 104F)
Yes
Idling
Caution
Note that
may blow
/ STB Revision
SYS-
if secondary
back.
-7
http://vnx.su/
air control
valve
is broken,
emission
i \.
EMISSION
CONTROL
SYSTEM
- Exhaust
INSPECTION
VALVE
(1) Remove
Emission
OF
25-31
System
Control
SECONDARY
AIR
,a
:.:
CONTROL
NZSICFA
the secondary
.-
(2) Blow in air from the air filter side to check that air does not:,
i
blow through.
:.
Air filter
lEM150
;;;
I.,
.
Exhaust
manifold side
lEM148
(5) Apply a vacuum of 20 kPa (3.0 psi) and blow in air tocheck
condition as follows.
IAilir
direction
1 Normal
manifold
manifold
condition
Air blows
through
through
1 STB Revision
http://vnx.su/
torque
air
. .
I.
25-32
EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
INSPECTION OF SECONDARY
NOID VALVE
System
NOTE
When disconnecting the vacuum hose, put a mark on the hose so
that it may be reconnected at original position.
(1) Disconnect the vacuum hoses, (red stripe, green stripe) from
the device box.
(2) Separate the harness connector.
Red
e box
5EMlOZ
(3) Connect a hand vacuum pump to the nipple to which red stripe
vacuum hose has been connected.
5EM103
(4) Apply vacuum and check air tighteness both when the battery
voltage is applied directly to the solenoid valve terminal and
when not applied
1 When
not applied
(5) Measure
Standard
solenoid
value
wision
) Open
1 Vacuum
coil resistance.
: 38 - 44 [at 20C (68F)]
http://vnx.su/
holds
\
C..
a, 1.
HWSSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
System
INSPECTION
SENSOR
OF ENGCNE COOLANT
INSPECTION
INSPECTION
OF VACUUM
Refer to GROUP
dures.
14 FUEL SYSTEM
INSPECTION
OF THERM0
Refer
to PURGE
CONTROL
25-33
::
TEMPERATURE
SWITCH
- Service Adjustment
Proce-
VALVE
SYSTEM,
SPECTION OF EXHAUST
(EGR) SYSTEM
P.25-28.
GAS RECIRCULATION
N25lCJA
(1) Disconnect the vacuum hose (green stripe) from the carburetor throttle body and connect a hand vacuum pump to the
vacuum hose.
(2) Check the following both when the engine is cold [engine.
coolant temperature
45F (113F) or less] and when it is hot
[engine coolant temperature
85 to 95C (185 to 205F)l
When
engine
is cold
engine
INSPECTION
Normal condition
Vacuum leaks - from
therm0 valve into atmosphere
Engine state
Vacuum
Apply vacuum
When
3,500 rpm
is hot
N25uxA
OF EGR VALVE
(1) Remove the EGR valve and check it for sticking, deposit of
carbon, etc. If such condition exists, clean with adequate solvent to ensure tight valve seat contact.
(2) Connect a hand vacuum pump to the EGR valve.
(3) Apply a vacuum of 67 kPa (9.7 psi) and check air tightness.
(4) Blow in air from one passage of the EGR to check condition as
follows.
3EM135
Vacuum
Normal condition
Caution
When installing
the EGR, use a new gasket
11 Nm (5 to 8 ftlbs.).
1 STB Revision
http://vnx.su/
>
:1.
and tighten
to 7 to
,
:
25-34
EMISSION
CONTROL
SYSTEM
Exhaust
;;;;fCTl
Emission
system
Control
REGUJLATOR VALVE
N25lclA
OF VACUUM
(1) Disconnect the -vacuum hose (white stripe) from the device
box and connect a hand vacuum pump to the device box.
(2) Apply a vacuum of 53 kPa (7.7 psi) and check VRV condition as
follow.
Normal
5EMl07
condition
Vacuum leaks
IkPECTlON
INSPECTION
Refer to GROUP
dures.
14 FUEL SYSTEM
INSPECTION
OF THERM0
Refer
to PURGE
CONTROL
VACUUJ
- Service Adjustment
Proce-
VALVE
SYSTEM,
P.25-28.
AT ALTITUDE
BELOW
NOTE
When disconnecting
the vacuum hose, put a mark on the t lose so
that it may be reconnected at original position.
Inspection
Condition
Engine coolant temperature:85
- 95C (185 - 205F)
(1) Set the timing light.
(2) Remove the air filter.
Primary emulsion
well bleed nipple
(3) Disconnect the vacuum hoses (black, red stripe, black) from
the carburetor primary emulsion well bleed nipple, secondary
emulsion well bleed nipple and jet air nipple and plug the
nipples.
(4) Connect a hand vacuum pump to the vacuum hoses, one hose
at a time, and check air tightness while running the engine at
idle.
1 ST6 Revision
http://vnx.su/
..
..
-:___.
:
EMISSION
System
25-35
value
: 7BTDC
I..
position.
f 2
i
I,
INSPECTION
AT ALTITUDE
ABOVE
1,200 m (3,900
ft.)
NOTE
When disconnecting
the vacuum hose, put a mark on the hose so
that is may be reconnected
at original position.
Inspection
Condition
Engine coolant temperature
(1) Set the timing light.
(2) Remove the air filter.
(3) Disconnect
the vacuum hoses (black, red stripe, black) from
the carburetor
primary emulsion well bleed nipple, secondary
emulsion well bleed nipple and jet air nipple.
(4) Connect a hand vacuum pump to the vacuum hoses, one hose
at a time, and check air tightness
while running the engine at
idle.
Step 1
Vacuum hose
Primary
(black)
Secondary
(red stripe)
(5) Connect
STB Revision
emulsion
emulsion
the disconnected
http://vnx.su/
Normal condition
well
well
vacuum
Vacuum leaks
hoses
to original position.
..,_
>\,:;.. 8
I,;;,, ;
.
-..
25-36
EMISSION
CONTROL
SYSTEM
Exhaust
Emission
Control
System
value
: Approx.
timing.
1TBTDC
California)
INSPECTION
AT ALTITUDE
BELOW 1,200 m (3,900 ft.)
(1) Disconnect the vacuum hose (yellow stripe) from the HAC and
cennect a hand vacuum pump to the HAC nipple.
(2) Apply vacuum and check that it leaks and does not hold.
(3) Disconnect the vacuum hose (red stripe) from the HAC and
connect a hand vacuum pump to the HAC nipple.
(4) Check that vacuum holds when applied.
INSPECTION
AT ALTITUDE
ABOVE 1,200 m (3,900 ft.)
(1) Disconnect the vacuum hose (yellow stripe) from the HAC and
connect a hand vacuum pump to the HAC nipple.
(2) Check that vacuum holds when applied.
(3) Disconnect the vacuum hose (red stripe) from the HAC and
connect another hand vaccum pump to the HAC nipple.
(4) With vacuum held as in step (2). check that vacuum leaks and
dose not hold.
http://vnx.su/
.~. .~
EMISSION
CONTROL
SYSTEM
Exhaust
Emission
Control
System
25-37
INSPECTION
OF VACUUM
SWITCHING
VALVE
for the 49
(VSV) - High altitude specifications
states (excluding California)
NOTE
When disconnecting
he vacuum hose, put a mark on the hose so
that it may be reconnected at original position.
lEM169
-_
Normal condition
INSPECTION
OF CHECK VALVE - High
specifications
for the 49 states (excluding
nia), and vehicles for California
altitude
CaliforNzslclc
NOTE
When disconnecting
the vacuum hose, put a mark on the hose so
that it may be reconnected at original position.
(1) Remove the check valve.
Vacuum leaks
White
Vacuum holds
6EM969
/ STB Revision
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..
1.
,; t
25-38
EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
INSffECTlON
OF CARBURETOR
SAGE CLOGGING (INSPECTION
HlGk ALTITUDE COMPENSATION
Refer to GROUP
dures.
14 FUEL SYSTEM-Service
System
PEt
AT ALTITUDE
BELOW
NOTi
When disconnecting
the vacuum hose, put a mark on the hose so
that it may be reconnected at original position.
Inspection
Condition
Engine coolant temperature
: 85 - 95C (185 - 205F)
pri-
(4) Connect a hand vacuum pump to the vacuum hose and check
that vacuum is held when applied while running the engine at
idle.
value
wision
: 7BTDC
http://vnx.su/
+ 2
position.
EMISSBQN
CONTROL
SYSTEM
- Exhaust
Emission
Control
System
25-39
(7) While running the engine at idle, disconnect the vacuum hose
(white stripe, two nipples side) from the HAC and hold a finger
at the hose end to check that vacuum is felt.
INSPECTION
AT ALTITUDE
ABOVE
NOTE
When disconnecting
the vacuum hose, put a mark on the hose so
that it may be reconnected at original position.
Inspection
Condition
Engine coolant temperature
: 85-95C(185
-205F)
(1) Set the timing light.
(2) Remove the air filter.
pri-
(4) Connect a hand vacuum pump to the vacuum hose and while
running the engine at idle, apply vacuum to check the pressure
leaks and does not build up.
http://vnx.su/
value
: Approx.
ITBTDC
position.
I
3
!L
25-40
I ..I
EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
*:.
AT ALTITUDE
BELOW
System
COMPENSATOR
+
.?.Y
!.
. .._
:n
\I
I,
: /.R
I
,
(1) Disconnect
the vacuum hose (black) from the HAC and con(3) Disconnect
nect a hand vacuum pump to the HAC nipple.
(4) Check that vacuum holds when applied.
: J
i-8
I
INSPECTION
AT ALTITUDE
ABOVE
(1) Disconnect
the vacuum hose (black) from the HAC and con(3) Disconnect
nect another hand vacuum pump to the HAC nipple.
2, apply vacuum and
(4) Holding the vacuum applied in procedure
check that it leaks and does not hold.
STB Revision-
http://vnx.su/
EMISSION
CONTROL
SYSTEM
- Exhaust
Emission
Control
25-41
System
.i:
,,
CON-
(2) Run the engine at idle and check air control valve condition.
Normal condition
Cold air side inlet closes
5EM122
NOTE
If necessary, apply compressed
hair dryer, etc. to heat.
Compress\ed air/,
INSPECTION
OF AIR
THERM0 SENSOR
INSPECTION
(1) Remove
CONTROL
VALVE
AND +
N25lCTA
OF AIR CONTROL
the air filter.
VALVE
(2) Disconnect the vacuum hose from the air control valve and
connect
a hand vacuum
(3) Apply a vacuum of 67 kPa (9.7 psi) and check air tightness.
5EM123
Normal condition
tion.
5EM124
INSPECTION
OF THERM0
SENSOR
(1) Connect a hand vacuum pump to the therm0
and check air tightness.
Therm0 sensor temperature
30C (86F) or less
45C (113F) or more
Rewision
http://vnx.su/
,.,,
I Normal condition
Vacuum holds
Vacuum leaks
sensor nipple
- ----./.
: 1.
: ._
,,,J 25-42
~~- --
EMISSION
.-- . .
.
CONTROL
SYSTEM
- Exhaust
Emission
Control
System
replace the air filter body.
Valve
Caution
Check the valve after warming
up the engine.
valve quickly
Heard
Remains closed
Not heard
I
..
RJST608009-828
1. STB Revision
:
.:
http://vnx.su/
II-I
INTAKE
CONTENTS
AIR FILTER
..........................................................
EXHAUST
MANIFOLD
EXHAUST
GENERAL
INFORMATION
INTAKE
MANIFOLD
.......................................
...................
.................................
...........................................
4
11
13
2
6
I;
Nl lAA--
SPECIFICATIONS
...............................................
General Specifications
....................................
Sealants and Adhesives
..................................
Service Specifications
.....................................
Torque Specifications
.....................................
2
2
3
........................................
TROUBLESHOOTING
Abnormal Noise
Exhaust Gas Leakage
http://vnx.su/
2
3
.
.
11-2
- General
/ Specifications
Information
GENERAL INFORMATION
NllBAAD
The exhaust
manifold,
to reduce exhaust
interference.
:!; SPECIFICATIONS
i GENERAL
SPECIFICATIONS
NllCA-
Specifications
items
Air filter
Type
Heated air intake
Dry type
Vacuum motor type
Exhaust system
Front exhaust
pipe
Dual type
Expansion
Muffler
Coupling
Suspension
resonance
type
Spherical coupling
Rubber hangers and suspenders
system
SERVICE SPECIFICATIONS
Specifications
Items
Standard value
Intake and exhaust
manifold
surface
distortion
mm (in.)
surface
distortion
mm (in.)
Limit
Intake and exhaust
manifold
( STB Revision
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11-3
- Specifications
TORQUE SPECIFICATIONS
NllCC--
Nm
ft.lbs.
16-19
12-14
15-20
11-14
15-20
11-14
IO-13
7-9
20-40
14-29
19-28
14-20
8-12
6-9
12-15
IO-13
9-l 1
7-9
6-9
4-7
8-10
6-7
20-40
14-29
20-40
14-29
12-15
9-11
70-100
51-72
Items
15-20
11-14
20-30
14-22
20-30
14-22
15-25
11-18
40-60
29-43
8-12
6-9
Suspender to frame
Center exhaust pipe to main muffler
8-12
6-9
20-30
14-22
5-10
4-7
Hanger to frame
5-10
4-7
Oxygen sensor
40-50
29-36
SEALANTS
AND ADHESIVES
Nl lCD-
Items
Quantity
As required
As required
As required
As required
As required
3M AdhesiveNut
locking
4171 or equivalent
As required
( ST6 Revision
http://vnx.su/
11-4
/ Air Filter
-Troubleshooting
TROUBLESHOOTING
NllEAAA
Symptom
Probable cause
Remedy
Reference
we
Loose joints
Retighten
II-13
Repair or replace
11-13
Broken separator
Replace
11-13
Replace
11-13
Interference
body
Correct
11-13
Repair or replace
II-13
Abnormal
noise
in muffler
; AIR FILTER
REMOVAL
AND
INSTALLATION
NllFA-
Removal
1.
2.
3.
4.
5.
6.
7.
8.
Wing nut
Connection
of breather hose
Air duct
Connection
of air hose
Air filter mounting nut
Heat duct
Connection
of vacuum hose
Air filter
NOTE
(1) Reverse the removal procedures to reinstall.
(2) l + : Refer to Service Point of Installation
SERVICE
2.
POINT
INSTALLATION
NOTE
Be careful,
when
1 STB Revision
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OF INSTALLATION
OF BREATHER
installing,
NllFDAA
HOSE
not to apply
INTAKE
DISASSEMBLY
AND EXHAUST
- Air
II-5
Filter
NllFEAA
AND REASSEMBLY
6
Disassembly
steps
I.
2.
3.
4.
5.
6.
Air filter
Air filter
Secondary
Secondary
Air filter
Air filter
cover
element
air case
air filter
gasket
body
NOTE
(1) Reverse the disassembly
parts
(2) q : Non-reusable
procedures
to reassemble.
i.
-:
1 ST6 Revision
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11-6
INTAKE
AND
EXHAUST
- Ontake Manifold
INTAKE MANIFOLD
REMOVAL
AND INSTALLATION
Pre-removal
Operation
Draining of coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Maintenance
vice.)
Post-installation
Operation
0 Supplying of Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
- Maintenance
Service.)
l
Checking and adjustment
of idling
rpm and ignition timing (Refer to
GROUP 9 ENGINE - Service Adjustment Procedures.)
Ser-
15-20 Nm
1 I-14 ft.lbs
16-19 Nm
12-14 ft.lbs.
\
15-20 Nm
1 l-14 ftlbs
,,,i
1 l-14
12
ft.lbs.
04W569
Removal steps
+e
+I)
e+
e+
1.
2.
3.
4.
5.
6.
7.
8.
Air filter
Carburetor
Gasket
Connection
Connection
Water hose
Connection
Connection
hose
9. Connection
10. Connection
connector
tioner)
11. Connection
of
connector
12. Connection
of
unit connector
13. Connection
of
(Vehicles
with
14. Intake manifold
15. Intake manifold
assembly
of radiator
upper
of water
by-pass
hose
hose
of heater
of brake
vacuum
hose
booster
of vacuum
hose
of water temperature
switch
(Vehicles
with an air condi-
water
temperature
sensor
water
temperature
gauge
therm0
switch
connector
an automatic
transmission)
gasket
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +e : Refer to Service Points of Removal.
(3) l + : Refer to Service Points of installation
(4) q
: Non-reusable
parts
1 STB Revision
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INTAKE
AND
EXHAUST
SERVICE
- Intake
POINTS
1. REMOVAL
11-7
Manifold
OF REMOVAL
OF AIR
NllMBAD
FILTER
INSPECT10
NllMCAD
Check
found.
the following
INTAKE
MANIFOLD
points;
replace
is
;z
i
SERVICE
2.
POINTS
OF INSTALLATION
INSTALLATION
OF CARBURETOR
ASSEMBLY
Refer to GROUP 14 FUEL SYSTEM - Carburetor.
1. INSiALLATlON
Refer to P.l l-4.
1 STB Revision
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OF AIR
FILTER
NllMDAC
5I
11-8
INTAKE
DISASSEMBLY
AND
AND
EXHAUST
- Intake
Manifold
REASSEMBLY
NllME--
8-9 Nm
5-6 ft.lbs.
10-14 Nm
7-10 ftlbs.
/
IO-13 Nm
7-9 ftlbs.
20-40
14-29
,----
Nm
ftlbs.
8-12 Nm
8-9 ft.lbs.
14-29 ftlbs.
14-20 ftlbs.
8-10 Nm
6-7 ftlbs.
04W567
Disassembly steps
l +
l +
l
l
l
l
+4
+
+
+
+
1. Water temperature
switch
(Vehicles
with
an air conditioner)
2. Plug (Vehicles
without
an air conditioner)
3. Joint
4. Engine
hanger
5. Vacuum
hose assembly
6. Joint
7. Therm0
valve assembly
8. Water temperature
sensor
9. Water temperature
gauge
unit
10. P.C.V. nipple
11. Therm0
switch
(Vehicles
with an automatic transmission)
l +
12.
13.
14.
15.
16.
17.
NOTE
(1) Reverse
(2)
(3)
1 STB Revision
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: Refer
to Service
: Non-reusable
parts
assembly
procedures
Points
of
to reassemble.
Reassembly.
INTAKE
AND EXHAUST
SERVICE
- Intake
POINTS
16. INSTALLATION
Refer to GROUP
Il.
APPLICATION
11-9
Manifold
OF REASSEMBLY
NllMHAB
OF THERMOSTAT
7 COOLING -Thermostat
OF ADHESIVE
TO THERM0
SWITCH
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04W563
9.
APPLICATION
TURE GAUGE
Apply a coating
part, and then
Specified
OF ADHESIVE
TO WATER
TEMPERAUNIT
of the specified adhesive to the threaded
tighten at the specified
torque.
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04w550
8. APPLICATION
OF ADHESIVE
TO WATER
TEMPERATURE SENSOR
Apply a coating of the specified adhesive to the threaded
part, and then tighten at the specified torque.
Specified
04w559
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
7. APPLICATION
OF SEALANT
TO THERM0
VALVE ASSEMBLY
Apply a coating of the specified adhesive to the threaded
part, and then tighten at the specified torque.
Specified
04W564
j STB Revision
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adhesive
: 3M Adhesive
equivalent
Nut
Locking
4171 or
1:
:
*
I
II-10
INTAKE
AND
EXHAUST
- Intake
6. APPLICATION
Manifold
OF ADHESIVE
TO JOINT
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04W562
3. APPLICATION
OF ADHESIVE
TO JOINT
Apply a coating of the specified adhesive to the threaded
part, and then tighten
at the specified
torque.
Specified
adhesive
1. APPLICATION
TURE SWITCH
Apply a coating
part, and then
Specified
OF ADHESIVE
STB Revision
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TO
Nut
Locking
WATER
4171 or
TEMPERA-
adhesive
04W.560
: 3M Adhesive
equivalent
: 3M Adhesive
equivalent
Nut
Locking
4171 or
INTAKE
EXHAUST
AND EXHAUST
- Exhaust
II-II
Manifold
MANIFOLD
REMOVAL
AND
INSTALLATION
NllNA-
16-19 Nm
12-14 ft.lbs.
10-13 Nm
j-9 ftlbs.
12-15 Nm
15-20 klm
11-14 ft.lbs.
40-50
29-36
Nm
ftlbs.
/
80
04W566
Removal steps
+e
l +
I.
2.
3.
4.
5.
Air filter
Air duct
Heat duct
Air pipe assembly
Reed valve B bracket
6.
Exhaust
manifold
10.
11.
12.
13.
Gasket
Engine
Exhaust
Exhaust
hanger
manifold
manifold
cover
7. Oxygen
sensor
8. Self-locking
nut
9. Connection
of exhaust
front exhaust
pipe
gasket
,\
manifold
and
NOTE
(1)
Reverse
the removal
procedures
(2)
l * : Refer to Service
Points
(3)
l + : Refer to Service
Points
(4)
: Non-reusable
parts
/ STB Revision
http://vnx.su/
to reinstall.
of Removal.
of Installation.
11-12
INTAKE
AND EXHAUST
SERVICE
- Exhaust
POINTS
Manifold
OF REMOVAL
NllNBAA
1. REMOVAL
OF AIR FILTER
Refer to P.l l-4.
INSPECTION
Check
found.
NllNdAD
the following
points;
replace
is
EXHAUST
MANIFOLD
(1) Check for damage
or cracking of any part.
(2) Check for obstruction
of the negative pressure (vacuum)
outlet port, and for obstruction
of the water passage or gas
passage.
(3) Using a straight edge and a thickness
gauge, check for
distortion
of the cylinder head installation
surface.
Standard value : 0.15 mm (.006 in.) or less
Limit
: 0.3 mm (.OlZ in.) or less
EXHAUST
Check
for flaking
SERVICE
1.
MANIFOLD
or damage
POINTS
INSTALLATION
Refer to P.ll-4.
1 STB Revision
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GASKET
of the gasket.
OF INSTALLATION
OF AIR
FILTER
NllNDAB
INTAKE
EXHAUST
REMOVAL
AND
EXHAUST
- Exhaust
II-13
INSTALLATION
N1lRA--
40-60
29-43
Nm
ftlbs.
5-10 Nm
4-7 ft.lbs.
8-12 Nm
-22 ftlbs.
-30 Nm
15-22 ftlbs.
15-25
11-18
l +
~~
~~
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
iO0
8-l>
Nm
6-9 ft.lbs.
io
Nm
ft.lbs.
\
20-30 Nm
15-22 ft.lbs.
05W521
:
,
*
I
Gasket
Front exhaust
pipe
Spring
Suspender
Hanger
bracket
Center exhaust
pipe
Hanger
Main muffler
Catalytic
converter
assembly
Self-locking
nut
NOTE
(1) l + : Refer to Service Points of Installation
(2) q : Non-reusable
parts
1 STB Revision
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II-14
INTAKE
AND
EXHAUST
- Exhaust Pipes
and
Mufflers
INSPECTION
NllRCAE
SERVICE
POINTS
OF INSTALLATION
NllRDAE
2. INSTALLATION
OF FRONT EXHAUST
PIPE/G. CENTER
EXHAUST
PIW8.
MAIN MUFFLER /9. CATALYTIC
CONVERTER ASSEMBLY
(1) Temporarily
install the front exhaust pipe, the catalytic
converter assembly,
the center exhaust pipe, and the
main muffler in that order.
Caution
With temporarily
tightened,
no distortion
of the hangers.
is
STB Revision
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7-1
COOLING
CONTENTS
COOLING
FAN
GENERAL
INFORMATION
RADIATOR
SERVICE
.. . . . . . . . . .. . . .. . . . . . . .. . . . . . . . . . . . . .. .. . . . . . . . . . ..
. . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . ..
. . . .. .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . ..
ADJUSTMENT
PROCEDURES
. . . . . . . . . . .._...._...._.....
Coolant
Concentration
Coolant
Leak Check
. . . . . .. .. . . . . . . . . . . .. ..._........._...._
Coolant
Replacement
.._.........._....._,,.._.,.,..._..,
Test
. . . . . . . . ..
SPECIAL
Cap Pressure
TOOL
Test
. ... ..
....................................
Specifications
3
4
...........................................................
Sealants
3 ;,
4
.......................................................
Lubricants
Service
Specifications
.....................................
Torque
Specifications
.....................................
. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . 10
TROUBLESHOOTING
General
THERMOSTAT
.._.......
Adjustment
...............................................
SPECIFICATIONS
.. . . . . . . . . .. . . . . . . .. .. . . . . . . . . ...s......
No Rise in Temperature
Overheat
.. ... . . .
WATER
. . .. . . . . . . . . . . .. .. . . . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . .
WATER
PUMP
WATER
TEMPERATURE
http://vnx.su/
. . . . . . . .. .. . . . . . . . . .. .. . . . . . . . . .. . . 15
. .. . . . . . . . . . . . .. . . . . . . . . .. . . . . . ..~..........~.......
GAUGE
UNIT
12
. . . . .. .. . . . . 17
7-2
COOLING
GENERAL
- General
Information
INFORMATlON
N07BABB
Carburetor
Thermostat
pump
Water
At cold
Radiator
ooling
fan
Carburetor
/
Thermostat
\
IHeater
At hot
-.i:-:
J
Radiaior
)
Cooling
0480047
fan
1 STB Revision
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7-3
COOLBNG -Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NO7CA-
items
Specifications
Cooling method
Water-cooled,
pressurized,
forced circulation
Radiator
Pressurized
Type
Performance
corrugated
fin type
transmission
Type
Water pump
Thermostatic
Type
Thermostat
Impeller of centrifugal
type
Type
Identification
mark
88 (Stamped on flange)
Drive belt
We
Water temperature
V-belt
gauge unit
Thermistor
Type
Thermoswitch
for automatic
Type
Water temperature
transmission
Thermo-ferrite
type
sensor
Thermistor
We
Thermoswitch
type
type
Type
thermistor
type
SERVICE SPECIFICATIONS
N07CB--
Specifications
Items
Standard value
Opening
pressure
Range of concentration
Alternator
of anti-freeze
valve
%
in coolant
kPa (psi)
Thermostat
full-opening
temperature
9-12 (.35-.47)
88(190)
C (F)
C (F)
Limit
Opening
pressure
I-15)
30-60
mm (in.)
Thermostat
75-105(1
valve
kPa (psi)
) ST6 Revision
http://vnx.su/
65 (9.2)
7-4
COOLING
- Specifications
TORQUE SPECIFICATIONS
N07CG
Alternator
ft.lbs.
Nm
Items
12-15
9-l 1
20-22
14-16
3-7
2-5
Alternator
Radiator
brace bolt
nut
support
8-l 1
6-8
IO-12
7-9
8-10
IO-13
6-7
pump pully
bolt
7-9
16-19
12-14
10-13
7-9
flare nut
70-l 00
51-72
Exhaust manifold
cover
12-15
9-l 1
15-20
20-30
11-14
14-22
IO-12
7-9
6-9
4-7
IO-14
7-10
bolt
Thermoswitch
Nater temperature
switch
JVater temperature
sensor
20-40
14-29
Water temperature
gauge unit
8-10
6-7
LUBRICANTS
NOICD--
lit.(U.S.qts.,
Items
Recommended
DIA QUEEN LONG-LIFE
-, (Part No. 0103044)or
Engine coolant
antifreeze
Imp.qts.1
*Quantity
COOLANT
8.0 (8.5,7.0)
..
..
;
NOTE : * Includes
SEALANTS
0.57 Imp.qts.)
in reserve tank
AND ADHESIVES
Items
N07CE-
Specified
sealants
and adhesive
Quantity
Water temperature
gauge unit
As required
Water temperature
sensor
As required
Water temperature
switch
As required
As required
Therm0 switch
1 STB Revision
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COOLING
7-5
SPECIAL TOOL
Tool (Number
NQIDA-
and name)
Use
MIT2 10863
Radiator cap test adapter
:
,
TROUBLESHOOTING
NO7EBAA
Symptom
Probable cause
Remedy
Reference
we
Overheat
Improper
Replenish
7-6
Correct
7-6
Replace
7-6
Inoperative
fan clutch
Replace
7-9
Correct
coolant
Coolant concentration
Water leaks
Damaged
too thick
Replace
7-8
Replace
7-8,15
Correct or replace
7-l 0
Correct or replace
7-12
Replace
7-6
Correct
9-39
9-17
Cracked
cylinder block
cylinder head
Replace
Replace
9-64
Cracked
Replace
7-10
Replace
7-12
Faulty thermostat
Faulty water
No rise in
temperature
bolt or
operation
pump operation
Replace
Clean
Faulty thermostat
Replace
1 STB Revision
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9-39
7-10
1:
f
7-6
COOLING
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
CbOLANT
PROCEDURES
LEAK CHECK
NOIFAAD
.
!,
.-*.
.I
A
4.
.[
If there
is leakage,
repair
or replace
the appropriate
part.
.(
RADIATOR
1.
2.
CAP PRESSURE
3.
N07FBAC
TEST
kPa (11-15
stops
psi)
at
NOTE
Be sure that the cap is clean before testing, since rust or
other foreign
material
on the cap seal will cause an
improper indication.
COOLANT
REPLACEMENT
N07FCAA
Refer to GROUP
0 LUBRICATION
Maintenance
Service.
AND
COOLANT
TEST
CONCENTRATION
Refer to GROUP
0 LUBRICATION
Maintenance
Service.
DRIVE
DURE
BELT
DEFLECTION
AND
MAINTENANCE
N07FDAC
MAINTENANCE
CHECKING
PROCEN07FEAE
installed
in the
Caution
If there is belt squeal or slippage,
check the amount
deflection,
check for wear, damage
or deterioration
the surface of contact
with the pulley, and check
scars on the pulley.
1 STB Revision
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of
at
for
COOLING
Service
2.
Water pump
pulley
Adjustment
Crankshaft
pulley
04B0028
7-7
Alternator
pulley
Procedures
value
: 9-12
mm
(.35-.47
in.)
Caution
Measure the amount
of belt deflection
between the
designated
pulleys.
An overtensioned
belt could cause not only premal
ture belt wear but also noise and damage to water
pump bearing
and alternator
bearing.
A loose belt also could cause failure of the alternator
to generate
enough
power
and consequently
a
rundown
battery.
l
-1
DRIVE
BELT DEFLECTION
ADJUSTMENT
Vehicles
without
an air conditioner
1. Loosen the alternator brace bolt and the alternator
nut.
2.
3.
Vm (ft.lbs.1
(14-16)
support
04w551
Vehicles
with an air conditioner
1. Loosen the alternator support nut and the bolt holding the
alternator.
2. Adjust the amount of deflection
of the belt by using the
tension-adjustment
bolt.
3. Tighten the alternator support nut and the bolt holding the
alternator.
http://vnx.su/
N07FFAD
rvrsron
,,.+
!,
:
.
;
,f, ,
/:
7-8
COOLING
- Radiator
RADIATOR
REMOVAL
AND INSTALLATION
NOIQA-
8-11 Nm
6-8 ftlbs.
Operation
IPre-removal
,l Draining of the Coolant (Refer to
GROUP 0 LUBRICATION AND
I
MAINTENANCE - Maintenance Ser- 1
vice.)
,l Draining of the Automatic Transmission Fluid (Refer to GROUP 0 LUBRICATION AND MAINTENANCE Maintenance Service.)
Post-installation
l
w
I
\
3-7 Nm
2-5 ftlbs.
04W572
Operation
INSPECTION
l
l
l
l
l
l
l
Check
Check
Check
Check
tion.
Check
Check
Check
NOIQCAB
1 STB Revision
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COOLING
COOLING
RAMOVAL
7-9
- Cooling Fan
FAN
AND
INSTALLATION
NOIHA--
8-10
Nm
6-7 ft.lbs.
Removal
2-5
steps
1. Radiator
upper
2. Cooling
fan
3. Fan clutch
ft.lbs.
NOTE
Reverse the removal procedures
shroud
INSPECTION
COOLING
l
l
04BOO24
to reinstall.
?
N07HCAA
FAN
FAN CLUTCH
l
Check fan clutch for fluid leaks from case joint and seals. If
fluid quantity
decreases
due to leakage, fan speed will
decrease and engine overheating
might result.
l
When a fan attached to an engine is turned by hand, it
should give a sense of some resistance. If fan turns lightly,
it is faulty.
l
Check bimetal strip for damage.
Bimetal
6COOlO
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Revision
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>:
;
I
c,
2
7-10
COOLHW
- Thermostat
THERMOSTAT
REMOVAL
Draining
AND INSTALLATION
of the Coolant
MAINTENANCE
Post-installation
(Refer to
~ Maintenance
N07GL
Ser-
Operation
(Refer to
GROUP 0 LUBRICATION AND
MAINTENANCE
- Maintenance
Service.)
-4
IO-13 Nm
7-9 ft.!bs.
5
0480031
Thermostat
kit
0400030
Removal steps
1. Connection of water temperature switch
connector (Vehicles with an air conditioner)
2. Connection of radiator upper hose
3. Water outlet fitting
4. Water outlet fitting gasket
l + 5. Thermostat
1 STB Revision
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NOTE
(1) Reverse the removal procedures to reinstall.
(2) l + : Refer to Service Points of Installation
(3) q : Non-reusable
parts
COOLING
7-11
- Thermostat
INSPECTION
N07GDAC
I.
88C ( 190F)
100C (212F) or more
NOTE
The height of the valve when fully opened
calculated
by first measuring
its height when
and determining
the difference.
5.
POINTS
OF INSTALLATION
INSTALLATION
OF THERMOSTAT
Install the thermostat
to the intake
manifold
N07GEAA
as illustrated.
Caution
The thermostat
flange
fits over the manifold
seat;
ensure that the thermostat
is not installed
at an angle.
77
Must
6e hmost
parallel
STB Revision
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c
.(
.$
0..I
y;.:
04UOO18
SERVICE
si
7-12
COOLING
- Water Pump
WATER PUiVlP
REMOVAL
AND INSTALLATION
Draining
of the Coolant
MAINTENANCE
NOIMB-
(Refer to
- Maintenance
Ser-
3-7 Nm
2-5 ft.lbs.
4*
l +
l +
a*
l +
2
1. Radiator upper shrouu
2. Radiator lower shroud
3. Cooling fan clutch assembly
Adjustment of air conditioner compressor
drive belt deflection
4. Air conditioner compressor drive belt
(Vehicles with an air conditioner)
Adjustment of alternator drive belt deflection
drive belt
of power
steering
oil pump
4*
Removal steps
5. Alternator
Adjustment
8. Connection
9. Connection
of radiator
of heater
lower
hose
hose
( STB Revision
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COOLING
7-13
- Water Pump
SERVICE
POINTS
OF REMOVAL
N07MCAC
4.
REMOVAL
OF AIR CONDITIONER
COMPRESSOR
DRIVE
BELT
(1) Loosen the nut holding the tension pulley.
(2) Loosen the nut for tension
adjustment,
and then
remove the drive belt.
5.
REMOVAL
OF ALTERNATOR
DRIVE BELT
Vehicles without
an air conditioner
Loosen the alternator brace bolt and the alternator
nut, and then remove the alternator
drive belt.
r :
support
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!,
04w557
Vehicles
with
an air conditioner
(1) Loosen the bolt holding the alternator and then loosen
the alternator
support nut.
(2) Loosen the bolt for deflection
adjustment,
and then
remove the alternator
drive belt.
6.
REMOVAL
OF POWER
STEERING
OIL
BELT
Loosen the bolt holding the power steering
then remove the drive belt.
INSPECTION
BELT
l
Check surface for damage, peeling or cracks.
l
Check surface for presence of oil or grease.
l
Check rubber for wear or hardening.
I STB Revision
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PUMP
DRIVE
oil pump,
and
NOIMDAC
+I
it.
;
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5
7-14
COOLING
- Water
WATER
l
l
l
l
Pump
PUMP
1 coo05
SERVICE
POINTS
10. INSTALLATION
7J
f
7%
j-
OF WATER
N07MEAE
PUMP
The dimension
of the water pumps
installation
bolt differs
according
to the installation
location,
so care must be
taken to avoid incorrect
installation.
e
Strength classification indication
OF INSTALLATION
I /
No.
Strength classification
(Head mark)
I 1 I
4T
dxe
mm (in.)
II
8x23(.31
x.90)
8x28(.31
x1.10)
4T
4T
8x88(.31
x3.46)
4T
8x78(.31
x3.07)
ADJUSTMENT
OF POWER
BELT DEFLECTION
Refer to GROUP
Procedures.
I
I
I
I 2 I
ADJUSTMENT
TION
STEERING
19 STEERING
OF ALTERNATOR
OIL PUMP
Service
DRIVE
DRIVE
Adjustment
BELT
DEFLEC-
Refer to P.7-7.
l
ADJUSTMENT
DRIVE BELT
OF AIR CONDITIONER
DEFLECTION
COMPRESSOR
1 STB Revision
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COOLING
- Water
and Pipe
Hose
AND
INSTALLATION
16-19
12-14
IO-13 Nm
7-9 ft.lbs.
Draining
of the Coolant
MAINTENANCE
Draining
MAINTENANCE
4-i
t
(Refer to
- Maintenance
of the Coolant
Nm
ftlbs.
Ser-
04w570
(Refer to
- Maintenance
Ser-
I)+
1.
2.
3.
4.
5.
6.
7.
8.
Air filter
Reed valve and air pipe assembly
Reed valve bracket
Exhaust manifold cover
Engine hanger
Connection of oxygen sensor connector
Self-locking nut
Connection of exhaust manifold and exhaust pipe
9. Gasket
10. Exhaust manifold
11. Exhaust manifold gasket
12.
13.
14.
Water hose
) STB Revision
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,i.
,:
7-16
COOLING
- Water
SERVICE
OF REMOVAL
N07lB-
SERVICE
POINTS
11. INSTALLATION
Replace
Refer to GROUP
) STB Revision
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AND
EXHAUST
OF INSTALLATION
OF EXHAUST
the gasket
1. INSTALLATION
(?
11 INTAKE
if there
N071DAD
MANIFOLD
is peeling,
- Air Filter.
flaking
GASKET
of damage.
OF AIR FILTER
11 INTAKE
AND
EXHAUST
- Air Filter.
COOLING
WATER TEMPERATURE
REMOVAL
AND
- Water Temperature
7-17
Unit
Gauge
GAUGE UNIT
INSTALLATION
Pre-removal
Operation
l
Draining of the Coolant (Refer
GROUP 0 LUBRICATION
AND
MAINTENANCE
~ Maintenance
vice.)
N070B-
to
Ser-
Post-installation
Operation
Supplying of the Coolant (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE
~ Maintenance
Service.)
1
k
6-9 Nm
4-7 ft.lbs.
/?-
8-10 Nm
6-7 ft.lbs.
2040
14-29
+$
Nm
ft.lbs
04w573
il.
1. Therm0 switch
(Vehicles
with
an automatic
transmission)
r
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!
NOTE
l + : Refer to Service
SERVICE
POINTS
4. APPLICATION
GAUGE UNIT
,/
Points
OF INSTALLATION
OF SEALANT
TO WATER
N070EAF
TEMPERATURE
Specified
sealant
wision
part,
http://vnx.su/
kc
of Installation.
7-18
COOLING
- Water
Temperature
3. APPLICATION
TURE SENSOR
Gauge
Unit
OF ADHESIVE
TO
WATER
TEMPERA-
part,
Apply
Specified
adhesive
: 3M Adhesive
equivalent
Nut Locking
4171 or
04W55!
2. APPLICATION
OF SEALANT
TO WATER TEMPERATURE
SWITCH
Apply a coating of specified sealant to the threaded part,
and then tighten to the specified
torque.
Specified
: 3M ART
sealant
No. 8660
or equivalent
04W560
1. APPLICATION
OF ADHESIVE
TO THERM0
SWITCH
adhesive
04W563
) STB Revision
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: 3M Adhesive
equivalent
Nut
Locking
part,
4171 or
6-1
CONTENTS
CLUTCH
FORK
CLUTCH
MASTER
AND TUBE
CLUTCH
PEDAL
CLUTCH
RELEASE
GENERAL
CYLINDER
................
.......
.................................................
CYLINDER
INFORMATION
..........................
.................................
SERVICE
ADJUSTMENT
PROCEDURES
..........
..........................................................
Bleeding
Inspection and Adjustment
of Clutch Pedal ...
14
8
7
12
2
6
6
6
SPECIFICATIONS
General
Lubricants
2
3
...............................................
....................................
Specifications
.......................................................
Service Specifications
Torque Specifications
TROUBLESHOOTING
Clutch Chattering
. . . . . . . . .. .. . . . . . . . . . .. .. . . . . . . .. . . . .
.. .. .. . . . . . . .. . . . . . . . . . . . .. . . . . . . . . ..
. . . . . . . .. ..*...*...................*....
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2 ;
3 I.!
4
6-2
/ Specifications
CAUTION
When
servicing
clutch assemblies
or components,
do
dust by sanding,
grinding
or by cleaning
clutch parts with a dry brush or with compressed
air. (A
water dampened
cloth should be used.) The clutch disc
contains Asbestos
Fibers which can become airborne if
dust is created during service operations.
Breathing
dust
containing
Asbestos
Fibers may cause serious bodily
harm.
NOT create
GENERAL INFORMATION
The clutch is the dry single-plate
diaphragm
type; hydraulic pressure
is used for the clutch control.
>,i The clutch control is composed
of the clutch pedal, the clutch master cylinder, the clutch tube,
1: cylinder, etc. Note that the clutch pedal is the suspended
type.
?
the release
t,,.lSPECIFICATIONS
1.I
j
.
GENERAL
SPECIFICATIONS
NOGCA-
Specifications
Items
Clutch operating
Inside diameter
Hydraulic type
method
mm (in.)
15.87 (.6248)
Clutch disc
Type
Facing Size (outside
Number
x inside)
mm (in.)
of torsion springs
N (Ibs.)
mm (in.)
264 (10.4)
Type
Free travel
mm (in.)
Self-centering
type
0 (O)-Constant
contact type
19.05 (.75)
mm (in.)
11
SERVICE SPECIFICATIONS
NOBCB-
Specifications
Items
Standard values
186-191 (7.3-7.5)
mm (in.)
mm (in.)
Clutch pedal clevis pin play
l-3 (.04-.12)
8-16 (.31-.63)
Clearance
floorboard
Limit
Master
mm (in.)
mm (in.)
mm (in.)
35 (1.38) or more
0.15 (.0059)
0.3(.012)
/ STB Revision
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6-3
CLUTCH - Specifications
TORQUE SPECIFICATIONS
Items
~
T 15522
31-42
Clutch to flywheel
Release cylinder to transmission
Fulcrum
case
ft.lbs.
Nm
1 l-16
22-30
31-42
22-30
25-35
18-25
20-25
13-17
15-18
IO-12
5-7
7-9
18-25
8-12
6-9
13-18
LUBRICANTS
NOGCD-
Items
Specified
lubricants
Quantity
Fluid
DOT 3
As required
As required
Multipurpose
NLGI No.3
As required
As required
As required
As required
DOT 3
As required
1 STB Revision
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6-4
CLUTCH - Troubleshooting
TROUBLESHOOTING
NOBEAAF
Symptom
Probable cause
Remedy
Reference
we
Clutch slipping
l
Vehicle will not
respond to
engine speed
during
acceleration.
0 Improper
vehicle speed
0 Lack of power
during uphill
driving
Improper
Adjust
6-6
Excessive
Replace
6-l 4
Hardened
surface
Replace
6-14
Damaged
pressure
Replace
6-l 4,9-60
Replace
6-14
Adjust
6-6
Correct
6-6
Replace
9-57
Replace
6-14
Replace
6-14
Repair or replace
6-6
Adjust
6-6
Repair or Replace
6-6
Replace
6-14
Replace
6-14
Adjust
6-6
Replace
6-14
plate or flywheel
Excessive
spring
Interference
between
Excessive
Hydraulic system
mixed in
When
clutch is
not used
Improper
Excessive
bearing
vibration
of clutch disc
(distortion)
of clutch
A noise is
heard after
clutch is
disengaged
Replace
6-14
A noise is
heard when
clutch is
disengaged
Repair
6-14
Repair
6-14
A noise
is heard
when
vehicle
is suddenly rolled of with
clutch
partially
engaged
Damaged
Replace
9-60
Improperly
bearing
or
pilot bearing
1 STB Revision
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6-5
CLUTCH -Troubleshooting
Symptom
Clutch
cause
Remedy
Refernce
we
Facing
hardened
Replace
6-l 4
Facing
stained
Repair or replace
6-l 4
Replace
6-14
Replace
6-14
Replace
6-l 4,9-62
Probable
chatters
Clutch operation
erratic or rough
oil or grease
Weak or broken
disc damper
Improper
facing
contact
Pressure
plate or flywheel
Loose
Hard pedal effort
with
engine
springs
or disc runout
warped
mounting
Repair
or replace
g-20.21
Improper
shaft
lubrication
of clutch
pedal
Repair
6-7
Improper
spline
lubrication
of clutch
disc
Repair
6-17
Improper
lubrication
lever shaft
of clutch
release
Repair
6-12
Improper
retainer
of front bearing
Repair
Refer to
GROUP 21.
lubrication
Facing
stained
Facing
worn
Torsion
Improper
spring
with grease
or oil
Repair
or rivet loose
deteriorated
lubricant
on clutch
or broken
pedal
pivot
STB Revision
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or replace
6-14
Replace
6-l 4
Replace
6-14
Lubricate
6-7
.I
6-6
(lutch
CLUTCH
pedal height
Clutch pedal
clevis pin play
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
INSPECTION
PEDAL
1.
ADJUSTMENT
OF CLUTCH
N06FAAi-l
Measure
the clutch pedal height (from the face of the
pedal pad to the floorboard)
and the clutch pedal clevis pin
play (measured at the face of the pedal pad).
Standard
Standard
2.
AND
PROCEDURES
in.)
oawso3
3.
After completing
the adjustments,
confirm that the clutch
pedal free play (measured at the face of the pedal pad) and
the distance
between the clutch pedal (the face of the
pedal pad) and the floorboard
when the clutch is disengaged are within the standard value ranges.
Standard
Standard
4.
value
value
If the clutch pedal free play and the distance between the
clutch pedal and the floorboard
when the clutch
is
disengaged
do not agree with the standard values, it is
probably the result of either air in the hydraulic system, or
a faulty master
cylinder
or clutch.
Bleed the air, or
disassemble
and inspect the master cylinder or clutch.
BLEEDING
NO6FBAB
Whenever
the clutch tube, the clutch hose, and/or the clutch
master cylinder have been removed,
or if the clutch pedal is
spongy, bleed the system.
Caution
Use the specified
brake fluid. Avoid
specified
fluid and other fluid.
Specified
brake fluid
STB Revision
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: DOT
using
a mixture
of the
CLUTCH
- Clutch
6-7
Pedal
CLUTCH PEDAL
REMOVAL
AND
INSTALLATION
Post-installation
Operation
0 Adjustment
of Clutch Pedal
(Refer to P.6-6.)
,
25-35
18-25
Nm
ft.lbs.
Removal steps
I)+
*+
1.
2.
3.
4.
Return spring
Cotter pin
Washer
Clevis pin
6. Pedal
shaft
7. Clutch pedal
l + 8. Bushing
l + 9. Spacer
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) l * : Refer to Service Points of Installation.
(3) m : Non-reusable
parts
INSPECTION
l
SERVICE
POINTS
OF INSTALLATION
9. APPLICATION
OF GREASE
PEDAL SHAFT
Apply specified
bushings.
Specified
II
08Y5
FTB
Grease
19
Revision
http://vnx.su/
grease
NOBPDAK
TO SPACER/8.
to the
: Multipurpose
NLGI No. 3
pedal
shaft,
grease
BUSHING/G.
spacer
SAE
and
J310,
.,
CLUTCH
- Clutch
Pedal/Clutch
Master
4. APPLlCATlON
Cylinder
OF GREASE TO CLEWS
and Tube
grease to the
surface
of the
: Wheel
bearing
NLGI No. 2
outer
CLUTCH
t!,, REMOVAL
MASTER
AND
CYLINDER
grease
AND TUBE
INSTALLATION
i
,
;.
.:
.
I
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Pre-removal
l
Draining
Cotter pin
Washer
Clevis pin
Clutch master cylinder
5. Sealer
Clutch line removal steps
l +
l *
I.
2.
3.
4.
Operation
of Clutch Fluid
Post-installation
Operation
Supplying Clutch Fluid
Bleeding
(Refer to P.6-6.)
l
Adiustment
of Clutch Pedal
(Refer to P.6-6.)
l
l
6. Eye bolt
~~ l +
I)+
,
7.
8.
9.
10.
Gasket
Clutch hose
Hose clip
Clutch tube
FFEeverse
the removal procedures
to reinstall.
(2) l + : Refer to Service Points of Removal.
(3) ~~ : Refer to Service Points of Installation.
(4) q : Non-reusable
parts
1 STB Revision
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surface
of the
bushing.
Grease
-1
PIN/3. WASHER
SAE
J310,
CLUTCH
Clutch
Master
Cylinder
SERVICE
POINTS
8. REMOVAL
and
6-9
Tube
OF REMOVAL
OF CLUTCH
NOGMBAD
HOSE
the flare
14w593
Clutch
clip and
remove
the
clutch
hose
14UOO87
INSPECTION
l
l
Check
Check
SERVICE
NOGMCAA
POINTS
10. INSTALLATION
OF INSTALLATION
OF CLUTCH
TUBE/8.
CLUTCH
NOGMDAE
HOSE
(1) Temporarily
tighten the clutch tube flare nut by hand;
and then tighten
it to the specified
torque,
being
careful that the clutch hose does not become twisted.
Secure
side
ot3wsa
(2) Connect
the clutch hose to the release cylinder at the
stepped
portion shown
in the illustration.
(3) After tightening
the clutch tube flare nut and eye bolt,
check to be sure there is no leakage of the clutch fluid.
1 STB Revision
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:
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;,
6-10
CLUTCH
Clutch
Master
Cylinder
3. APPLICATION
Apply
spacer
and
OF GREASE
Tube
TO CLEVIS
PIN/2.
WA;tMHEE
the specified
grease to the outer surface
and the inner surface of the bushing.
Specified
: Wheel
bearing
NLGI No. 2
grease
grease
SAE
of the
J310,
Grease
08W521
DISASSEMBLY
Disassembly
l *
++
~~
AND
REASSEMBLY
steps
Reservoir
rod
cap
5. Reservoir
l + 6. Reservoir
band
7. Master cylinder
body
\7
NOTE
(1)
(2)
(3)
Reverse
the
4~
: Refer
l + : Refer
disassembly
to Service
to Service
procedures
Points
of
Points
of
to reassemble.
Disassembly.
Reassembly.
SERVICE
\\
POINTS
08W513
OF DISASSEMBLY
1.
REMOVAL
OF PISTON
STOP
Remove the piston stop ring.
3.
REMOVAL
OF PISTON
ASSEMBLY
Pull out the piston assembly.
RING
Caution
1. Do not damage the master cylinder body
assembly.
2. Do not disassemble
piston
assembly.
08YO3
INSPECTION
l
l
l
Revision
http://vnx.su/
NOSNBAA
and piston
NOGNCAB
CLUTCH
Clutch
Master
Cylinder
and
6-11
Tube
CLEARANCE
BETWEEN
MASTER CYLINDER
TER AND PISTON
OUTER DIAMETER
(1) Measure
the master cylinder
piston outside
diameter
with
micrometer.
Limit
: 0.15 mm
(.0059
DIAME-
inside diameter
and the
a cylinder
gauge and a
in.)
NOTE
Measure
the inside diameter
three-places
(bottom,
middle,
perpendicular
directions.
14E108
INNER
4..
3
=,
;.
i :,
.
SERVICE
POINTS
6. INSTALLATION
OF REASSEMBLY
OF RESERVOIR
After installing
the reservoir, tighten
the range shown in the figure.
NOGNDAG
BAND
the reservoir
band in
06R0005
r-l
r-l
3. APPLICATION
BLY
OF CLUTCH
FLUID
TO PISTON
ASSEM-
Apply specified
clutch fluid to the inner surface of the
cylinder and to the entire periphery of the piston assembly.
)
;
Specified
I?
clutch
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fluid
: DOT
:1
6-12
CLUTCH
- Clutch
Release
AND INSTALLATION
Pre-removal
0 Draining
Removal
CylindQr
NOGHA-
Operation
of Clutch Fluid
31-42
22-30
steps
1.
2.
3.
++. 4.
.i+ 5.
Nm
ft.lbs.
Bleeder screw
Eye bolt
Gasket
Connection of clutch hose
Clutch release cylinder
NdTE
(1) Reverse the remqval procedures
(2) w+ : Refer to Service Points
(3) [iIl
: Non-reusable
parts
to reinstall.
of Installation.
20-25
14-18
08W520
INSPECTION
NO6HCAA
l
l
SERVICE
5.
POINTS
APPLICATION
INDER
OF INSTALLATION
OF GREASE
TO CLUTCH
NOGHDAE
RELEASE
CYL-
Specified
4.
Grease
CONNECTION
: MITSUBISHI
No. 0101011
OF CLUTCH
Genuine
Grease
Part
HOSE
Revision
I
http://vnx.su/
-.
..
,:,
I,
..
,,
4
CLUTCH
DISASSEMBLY
AND
+*
1.
2.
3.
4.
l + 5.
6.
7.
8.
9.
Clutch
Release
6-13
Cylinder
REASSEMBLY
9-13 Nm
7-9 ft.lbs.
Disassembly
NOGM--
*
\
steps
00W523
Valve plate
Spring
Push rod
Boots
Piston and cup
Conical
spring
Cap
Bleeder
plug
Release
cylinder
I..
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) +e : Refer to Service Points of Disassembly.
(3) I)+ : Refer to Service Points of Reassembly.
SERVICE
5.
POINTS
REMOVAL
OF DISASSEMBLY
OF PISTON
AND
NOILBAA
CUP
i
using corn-
Caution
1. Cover with rags to prevent the piston from popping
out.
2. Apply compressed
air slowly to prevent brake fluid
from splashing.
INSPECTION
l
l
Cylinder gauge
N06LCAA
Limit
: 0.15
14UOO63
1 STB Revision
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mm
(.006
in.)
;
.I
;
(.
SERVICE
POINTS
5. APPLlCATlON
OF REASSEMBLY
OF FLUID
TO
NOGLDAB
PISTON
AND
CUP
After applying
brake
fluid
: DOT
DCLOOG
::
fs,, REMOVAL
Post-installation
l
AND INSTALLATION
Operation
6\
15-21Nm
11-15 ft.lbs.
31-42
22-30
\
Nm
ftlbs.
06W524
(1)
(2)
(3)
SERVICE
1.
POINTS
REMOVAL
OF REMOVAL
OF TRANSMISSION
Refer to GROUP
Assembly.
1 ST6 Ftgvision
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21 TRANSMISSION
NOGOBAB
CASE
ASSEMBLY
- Transmission
case
CLUTCH
Clutch
2.
Disc
and
Release
ASSEMBLY
(1) Insert clutch disc guide, or main drive gear of transmission in center spline to prevent dropping of clutch disc.
(2) Diagonally
loosen bolts retaining clutch cover to flywheel.
Back off bolts, one or two turns at a time, in succession, to avoid bending cover flange.
REMOVAL
OF CLUTCH
Caution
DO MOT clean
cleaning
7.
6-15
Fork
REMOVAL
COVER
clutch
disc
OF RELEASE
bearing
with
FORK
in direction
AND
of arrow
to disengage
INSPECTION
fork by sliding
to clip.
it in other
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I.
T
4
1:Iv,.
N060CAB
1 STB Revision
;*
.
Caution
Attempting
to remove
release
direction
will result in damage
CLEANING
or release
solvent.
.4
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;*
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;,
:,.;,
CLUTCH
Clutch
Disc and
CLUTCH
Release
Fork
DlSC
: 0.3 mm
from the
in.)
(3) If the measured value is below the limit, replace the clutch
disc,
(4) The hub splines and splines on transmission
input shaft
should be a snug fit without
signs of excessive wear.
(5) Metallic portions of disc assembly should be dry and clean
and show no evidence
of having been hot. Each of the
arched springs between facings should be unbroken
and
all rivets should be tight.
SERVICE
Clutch release bearing
(.012
touching
of grease
POINTS
7. APPLICATION
6.
OF INSTALLATION
OF GREASE
TO RELEASE
fork fulcrum
Specified
: MITSUBISHI
No. 0101011
grease
APPLICATION
ING
Pack specified
I.D.
Specified
OF GREASE
grease
grease
NOBQDAC
FORK
TO CLUTCH
in groove
: MITSUBISHI
No. 0101011
on clutch
grease.
Grease
Part
RELEASE
BEAR-
release
bearing
Genuine
Grease
or equivalent
Part
fork
kl
DCLOOE
Release
fork
4.
\%
APPLICATION
OF GREASE TO CLUTCH
RELEASE CYLINDER
Apply specified
grease to release fork to release cylinder
push rod contacting
surfaces.
Specified
grease
1 STB Revision
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: MITSUBISHI
No. 0101011
Genuine
Grease
Part
CLUTCH
- Clutch
3.
Disc
and Release
INSTALLATION
6-17
Fork
OF CLUTCH
ASSEMBLY
are oils or greases on clutch facing and
pressure plate, throughly
wipe away with a dry cloth.
(2) Lightly specified grease clutch disc spline.
(1) If there
Specified
grease
: MITSUBISHI
Genuine
Part No. 0101011
Grease
(3) Using clutch disc guide, or main drive gear of transmission, install clutch disc and clutch cover assembly on
flywheel.
(4) When installing clutch disc, be sure that surface having
manufacturers
stamped mark is on pressure plate side.
Pressure plate
6CLOO4
1 STB Revision
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OF TRANSMISSION
CASE
21 TRANSMISSION-Transmission
the
the
the
ASSEMBLY
case
21-48
AUTOMATIC
TRANSMISSION
- General
Information
GENERAL INFORMATION
Safety
goggles
should
be worn
NZlBABE
at all times
when
working
on these
transmissions,
converter,
transmission
The transmission
oil sump and the transfer oil sump of model
Accordingly,
the filling of oil is necessary to perform separately
in an integral
aluminum
die casting.
KM148-4WD
transmission
are separated.
to the transmission
and to the transfer.
/ ST6 Revision
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Torque converter
Oil pump
Over drive clutch
Over drive brake
Over drive planetary
Forward clutch
Direct clutch
Brake No.1
Brake No.2
gear
10.
11.
12.
13.
14.
15.
16.
17.
18.
Brake No.3
Front planetary gear
Rear planetary gear
Brake No.3 piston
Governor
Transfer control lever
Input gear
High-low clutch
Low speed gear
19.
20.
21.
22.
23.
24.
25.
2WD-4WD
clutch
Drive sprocket
Chain
Rear output shaft
Front output shaft
Counter gear
Valve body
21-50
AUTOMATIC
TRANSMISSION
- General
Information
TORQUE CONVERTER
Front
cover
Turbine
Impeller
Stator
_ One-way
clutch
372070
TRANSMISSION
POWER TRAIN
The transmission
power train consists
of three sets of multiple
disc clutches, four sets of multiple disc brakes, three sets of oneway clutches, and a single-row
and a double-row
Simpson planetary gear set. The three sets of clutches
are an element that
controls the input to the planetary gear set, while the four sets of
brakes and three sets of one-way clutches act to hold some of the
elements
of the planetary gear set stationary
or prevent them
from turning. An appropriate
gear ratio for each driving condition
can thus be obtained through the operation
of these elements
which select the point from which the driving force is input and
points to be held stationary
in the planetary gear set.
The following
Table TABLE
FOR OPERATION
ELEMENTS
AT
EACH POSITION
OF SELECTOR
LEVER shows
particular elements in action in different selector lever positions.
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AUTOMATIC
TRANSMISSION
FO Over
drive planetary
- General
F,
gear
F,
Information
21-51
C,:
C,:
C,:
B,:
B, :
B,:
B,:
.,
-*
G:;
,;,, 1
(,:.I
372071
1 ST6 Revision
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>i
AUTOMATIC
TRANSMISSION
- General
Information
OVERDRIVE CLUTCH
Plate
Cylinder
hub
Piston
Ieturn spring
FORWARD
Plate
CLUTCH
Ieturn spring
Iclutch
hub
DIRECT
Plate
n
Disc
Return
spring
CLUTCH
The multiple-disc direct clutch, actuated in the 3rd and 4th speeds
and in reverse, transmits the input force to the sun gear, driving
the pinions of the front planetary gear set.
Cylinder
372005
OVERDRIVE
BRAKE
BRAKE
Center support
Plate
No.1
MT
In -
Plate
Disc
Brake
1 No.2
Piston
NO.1
The brake No.1, actuated in the 2nd speed of the 2 range, holds
the sun gear stationary.
BRAKE
NO.2
The brake No.2, actuated in the 2nd, 3rd, and 4th speeds of the
D range and in the 2nd speed of the 2 range, holds the outer
race of one-way clutch No.1 stationary, allowing the one-way
clutch No.1 to act as an overrunning clutch.
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AUTOMATIC
Plate
Reaction
TRANSMISSION
General
Information
21-53
BRAKE NO.3
sleeve
piston
372008
Free
Outer race
(9D planetary
carrier)
I
InnfG race
(OD sun gear)
355032
Outer
4.---
race
Lock
-
Free
Outer
355034
race
I
carrier)
;g+LGV
\
u
ONE-WAY CLUTCH
The three sets of one-way clutches are of the sprag type. The
overdrive (OD) one-way clutch is operated during gearshifting between 3rd and 4th (OD) speeds, ensuring smooth selection between the OD clutch and OD brake.lt is in free state when the
carrier of the OD planetary gear set rotates clockwise and locks
when the sun gear turns clockwise.
The one-way clutch No.2 prevents the front planetary carrier from
turning counterclockwise,
actuated in the 1st speed. So, no engine braking is given in the 1st speed of the D as well as 2
range. Engine braking is, however, given in the L range in which
the carrier is held stationary by the brake No. 3.
Wag
.!..u
\
Wk
Case
(skationary
side)
355032
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21-54
AUTOMATIC
TRANSMISSION
General
Information
OVERDRIVE
PLANETARY
GEAR
The planetary gear, of a single-row type, consists of the sun gear,
pinion, carrier, and ring gear. The input from the OD input shaft is
imparted to the carrier.
Ring gear
OD one-way
clutch
372009
PLANETARY
GEAR SET
This planetary gear set called the Simpson type is made up of two
planetary gear sets, each consisting of pinions, carrier, and sun
gear. The sun gear is connected to the direct clutch, front carrier
to brake No.3, and the rear ring gear to forward clutch. The front
ring gear and rear carrier are coupled to the output shaft.
output
shaft
Sun gear
372010
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2 ,
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AUTOMATIC
TABLE
FOR OPERATION
REMARKS:
IP=lnner
TRANSMISSION
ELEMENTS
Piston.
- General
AT EACH POSITION
OP=Outer
OF SELECTOR
LEVER
Piston
Clutch
ielector
3D-OFF
3ver po- switch
sition
Gear
shift
stage
Engine Parking
mechastart
nism
Gear
ratio
21-55
Information
C2
co
One-way clutcm
Brake
IP
63
OP
B0
B,
B,
IP
OP
F0
Neutral
OK
Reverse
2.703
Neutral
OK
1st
2.826
2nd
1.493
3rd
1.ooo
4th
0.688
1st
2.826
2nd
1.493
3rd
1.000
1st
2.826
2nd
1.493
1st
1 2.826
ON
OFF
POWER
F,
F2
I
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FLOW
The following is the description of the element operation and the power transmission at each gear shift stage. As
for the element operation at each gear shift stage, it is summarized on the above table.
Brake
6)
clutch
(FJ
planetary
No.1
clutch
(F,)
gear
gear
1 ST6 Revision
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No.2
ront
planetary
gear
planetary
gear
372071
372072
21-56
nee
AUTOMATIC
TRANSMISSION
Outer race
(Front planetary carrier)
Swg
35503;
.\.
Information
First in D range
When the vehicle speed is relatively low with a greater throttle
valve opening angle, which requires a greater acceleration, the OD
clutch (C,), OD one-way clutch (F,), forward clutch (C,), and oneway clutch No.2 (F,) operate to shift gears into the 1st speed
position, the output shaft turning clockwise at a gear ratio of
2.826.
In the forward (excluding 4th speed of ID range) and reverse
ranges, Co and F, are actuated to transmit the input to the forward
clutch cylinder via the OD input shaft. As Co and F, are actuated,
the OD planetary carrier and sun gear are locked together to rotate
bodily. This causes the turning force of the OD input shaft to be
transmitted
to the planetary carrier, allowing the carrier to rotate
clockwise together with the sun gear, thus holding the pinion to a
standstill.Now,
the entire planetary gear set rotates bodily, which
couples the OD input shaft directly to the forward clutch cylinder
to allow them to rotate clockwise.
In the 1st speed, C, is also actuated allowing the turning force of
forward clutch cylinder to be transmitted
via the intermediate
gear
to the rear planetary carrier (output shaft), which turns the carrier
clockwise. The sun gear (rotating counterclockwise)
in mesh with
the pinion of the rear planetary gear set, on the other hand, tends
to turn the front planetary carrier counterclockwise;
however, F,
acts to prevent the carrier from rotating, hence the turning force in
the clockwise direction is transmitted
to the output shaft.
Though acting to prevent the front planetary carrier from rotating
counterclockwise,
F2 is driven from the axle shaft end during engine braking, thus allowing its outer race to rotate in the direction
to free the clutch. Hence, no engine braking. This also applies
when the shift is in the 1 st speed of 2 range. F, functions in the
same manner in the 2nd speed of D range.
In the L range, the brake No.3 (B,) is actuated to hold the front
planetary carrier stationary, thus providing engine braking.
6, (L range only)
D or 2 Range-1st
Input
output
2.826
D Range-1st
General
372073
1.000
F,
,
/,.:.:.::,.:./:::::/::::~:~i::I:i~i~iii:i:~:.i:,:.i:,i::~
:/.
/:::::f,
x/jf/:.g.j::::
,:,:.,,,,
>::.:.:.:.:
.A.,...
.,.....
:.,:..,::
::I./:,: .,,:.,. :, ,,,::,,I:.
/,.:.A,/..,,, .
372074
L Range-1st
372075
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AUTOMATIC
Outer
race
(combined
with
(combined
TRANSMISSION
brake
No.2)
with
\
4=---
or 2
Lock
Free
355034
- General
Information
21-57
Second in D range
As the vehicle speed is accelerated from the 1 st speed, the brake
No.2 (B2) is actuated to shift into the 2nd gear, allowing the output
shaft to rotate clockwise at a gear ratio of 1.493. The OD planetary
gear set operates in the same way as in the 1st speed. In 2nd
speed, C, is actuated, which causes the turning force of forward
clutch cylinder to be transmitted, via the intermediate
shaft and
rear planetary ring gear to the pinion. Then, the sun gear, which is
in mesh with the pinion, receives a turning force in the counterclockwise direction; however, since F,, activated by BP, prevents
the sun gear from rotating, the pinion moves around the sun
gear.This motion causes the carrier to rotate, transmitting
a rotating force in the clockwise direction to the output shaft. No rotating
force is transmitted
to the front planetary gear as the sun gear
does not turn. In the 2nd speed of 2 range, the brake No.1 (B,)
is actuated to hold the sun gear stationary, thus providing engine
braking.
(2
RANGE-2nd
range
only)
372076
D
RANGE-2nd
372077
RANGE-2nd
372078
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21-58
AUTOMATIC
TRANSMISSION
- General
Information
Third in D range
As the vehicle is further accelerated, the direct clutch (C,) comes
into play to shift into the 3rd speed. In 3rd speed, both C, and C2
operate, allowing the intermediate
shaft and sun gear to rotate in
the same direction. So, the pinion is locked causing the entire
planetary gear set to rotate bodily. This couples the input shaft to
the output shaft directly giving a l-to-l gearing.
D RANGE-3rd
c,
c2
82
Output
Input
372079
Fourth (overdrive)
in D range
When the vehicle is further accelerated with the OD-OFF switch
turned ON, the OD clutch (C,) is released and, at the same time,
the OD brake (B,) is actuated to shift into the 4th speed, allowing
the output shaft to rotate in the clockwise direction at a ratio of
0.688.
In this gear position, B, holds the OD sun gear stationary. The
rotating force of the OD input shaft is therefore transmitted via the
OD planetary gear pinion to the ring gear and the forward clutch
cylinder, which is accelerated in reference to the OD input shaft,
rotates clockwise. The rotating force of the forward clutch cylinder
is transmitted
to the output shaft in the same way as in the 3rd
speed of D ranae.
Bo
D RANGE-4th
c,
c*
B, -
lnpu
372081
372082
;;E
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AUTOMATIC
TRANSMISSION
General
21-59
Information
Reverse
When the shift is in reverse gear, the OD clutch (C,), OD one-way
clutch (F,), direct clutch (C,), and brake No.3 (B,) are actuated and
the rear output shaft rotates counterclockwise
at a ratio of 2.703.
The operation of the OD planetary gear set is the same as in the
1st speed of D range.
Since C, is activated, the rotating force of the input shaft is transmitted to the front planetary gear pinion via the sun gear. As the
front planetary carrier is held stationary by BB, the rotating force of
the sun gear is transmitted to the ring gear via pinion, turning the
output shaft in the counterclockwise
direction.
REVERSE
CO
b
I
utput
Carrier fixed
1.000
372083
372084
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21-60
AUTOMATIC
TRANSMISSION
General
Information
SELECT PAlTERN
Select pattern refers to the indication of transmission positions to
be manually selected by the driver. This transmission
is provided
with six positions; P-R-N-D-2-L.
The following text explains the function of each position selected.
P-Parking
All elements do not operate at all, and the engine output is not
transmitted
to the output shaft.
The output shaft is mechanically
locked and the vehicle does
not move either in the forward or reverse direction.
The engine can be started.
R-Reverse
The vehicle is in the reverse range.
The engine cannot be started.
N-Neutral
The engine output is not transmitted
to the output shaft as in
the case of P.
The engine can be started.
D-Drive
Corresponding
to the degree that the accelerator pedal is
pressed down (throttle valve opening angles) and vehicle
speed, D automatically
shifts between the four forward
speeds, or three forward speeds when the OD-OFF switch is
in OFF position.
The automatic shifting is performed according to the shift pattern shown on P.21-61.
The vehicle is started with the gear in first speed position.
Kickdown refers downshifting
accomplished
when the accelerator pedal is depressed while the vehicle is in motion in 2nd.
3rd. or 4th speed. In the shift pattern, it occurs when the load
exceeds the downshift point.
This function is useful when the driver is accelerating to pass
another vehicle.
No engine braking is given when the shift is in 1st speed.
2-Second
The 2 automatically
shifts between the 1 st and 2nd speeds,
and no shifting into 3rd will be performed.
The vehicle is started with the gear in 1st speed position.
When the 2 range is selected while the vehicle is in motion
in the 3rd or 4th speed of D range, gear is downshifted to
2nd or 3rd speed as the vehicle speed reaches predetermined
levels.
As in the case of D range, no engine braking is given when
the shift is in 1st speed position.
L-Lockup
While L performs downshifting
from 2nd to 1st. it does not
shift into high, from 1st to 2nd or to 3rd. This is what we call
the 1st gear holding.
The vehicle is started with the gear in 1st speed position,
when the engine braking is given.
If the L range is selected while the vehicle is in motion in
D or 2 range, downshifting
from 4th to 3rd, 3rd to 2nd. or
2nd to 1st is performed as the vehicle reaches the respective
speeds predetermined
for each gear.
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AUTOMATIC
TRANSMISSION
General
lnforrmation
21-67
Low coast
modulator
pressure
(from modulator
In L
range
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21-68
AUTOMATIC
TRANSMISSION
- General
Information
1rhrottle
Fxessure
T..LGovernol
I
I
In case
of low
governor
pressure
11
pressure
(2nd)
355059
ntermediate
I shift valve
coast
From
B,
Throttle
Ipressure
In case
of high
governor
pressure
(3rd)
355060
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AUTOMATIC
TRANSMISSION
General
Information
21-69
Throttle
Dressure
In 2 and L range
355051
Throttle pressure
Sprn~
3-4-L
valve
From
Line
pressure
In case of low governor pressure
35507t
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AUTOMATIC
Throttle
TRANSMISSION
General
Information
pressure
To C,
To B,
In case
governor
of high
pressure
Line
(When
switch
And
Line
pressure
pressure
Throttle
Governor
pressure
II
t
355071
pressure
OD-OFF
is in
in 2
_ Third coast
shift valve
I <I:.IY
To C,
To B,
In case of OD-OFF
switch
OFF
pressure
355072
Cut-Back
l-1
Valve
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AUTOMATIC
Line
pressure
(from 2-3
shift valve)
In R
In D
range
Line pressure
(from manual
range
and
TRANSMISSION
Reverse
valve)
355063
3rd speed
Clutch
a-71
Valve
355064
Timing
Valve
The D-2 down timing valve ensures that engine braking is given
mildly when the select lever is shifted into the 2 range during
4th speed (OD) mode. Gear is shifted from OD to 3rd and to 2nd.
instead of directly from OD into 2nd.
While the vehicle is in motion in 4th speed, this valve is located on
the top end. When gear is shifted into 2 range, the line pressure
from the manual valve pushes down the 3-4 shift valve setting the
3rd speed. At the same time, the line pressure
is also applied to
the top of D-2 down timing valve, pushing the valve down because
of the difference
in land diameters
(#1=#2>#3).
This opens the
circuit to the intermediate
shift valve, allowing the line pressure to
be applied to push down the 2-3 shift valve, thus setting the 2nd
speed.
N+driving
To intermedlate
shift valve
In 2
Sequence
Information
The reverse clutch sequence valve, acting to dampen shocks generated when the gear is shifted into I? range, is controlled by the
line pressure applied to the inner piston of direct clutch (C,). With
the shift in R range, the line pressure
is applied both to the
circuits A and B; however,
since the circuit B does not open
before the pressure
A being applied to this valve, i.e. the line
pressure
applied to the inner piston, overcomes
the spring tension, the outer piston operates with a lag behind the inner piston.
With the shift in 3rd speed in D range, the circuit B is closed by
the manual valve, allowing only the inner piston to apply pressure.
At the time, the circuit B acts to release hydraulic pressure to be
applied to the outer piston.
D-2 Down
FEZsure
- General
range
355074
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21-72
AUTOMATIC
TRANSMISSION
General
Information
GOVERNOR
, Weights
f+-+&,
Shaft
Spring
Drain
-output
_-.I
In case
of low
shaft
vehicle
speed
aI+
,LEsure
4Governo1
pressure
In case
of high
vehicle
speed
372027
Operation
ACCUMULATOR
side
C2
To inner
piston
side
I (from
Oil pump)
Accumulators
are provided for C,, C,, and B,, respectively,
to
dampen shocks when each is actuated.
The area of the pressure receiving side of the accumulator
piston
is made greater than that of the back pressure
side. The line
pressure is always applied to the back pressure
side, keeping the
piston in up position. When the circuit to the pressure
receiving
side opens causing the line pressure
to be applied to the piston,
the piston is slowly pushed downward,
thus dampening
shocks
when each device is operated.
355067
FOURTH
(OD) CONTROL
SYSTEM
372028
OD-OFF Switch
3-4 shift
valve
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AUTOMATIC
TRANSMISSION
OD Solenoid
355018
- General
Information
21-73
Valve
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21-74
AUTOMATIC
TRANSMISSION
- General
N (Neutral)
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Information
AUTOMATIC
TRANSMISSION
General
Information
21-75
P (Parking)
,.,3.
[
I
!,:;
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JalOO3
01
680ZLE
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Throttle
valve
_
III i-xl
I(-lh
II %!!EJl
Cut
back
valve
~~~~~~~~
II I lregurarorll
Overdrive
brake
I
shift
II II II%%
Direct
clutch
II II II II
lUIIF=l####F
valve
II ~i----xlh7
I! II IU imllu
II IIIIII //llll II v
Nor3
Brake
modulator
modulator
valve
II medite
<,
r,
In
M%i
I/ / 1solenoid
0
0
n
valve
pressure
pressure
oressure,
Cut back
Governor
Converter
II
2ND)
II
Lubrication
Third
coast
oil pressure
pressure,
Intermediate
Low coast
modulator
D-2 (DRIVE
III1
fl h)
Line pressure
Detent
regulator
modulator
pressure,
pressure
Throttle
pressure
0
(
II
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372091
Ill/-.
II -
II
=
!
I!
coasr
valve
w
Intermediate
modulator
Reverse
seauence
valve
clutch
valve
I
0
0
0
0
I
II
IIII
oil pressure
3RD)
II II I11
Lubrication
pressure,
Inten--:-*Low
coast
mooulator
D-3 (DRIVE
Line pressure
Detent
regulator
modulator
pressure,
pressure
Throttle
pressure
Cut back oressure
Governor
pressure
Converter
pressure,
http://vnx.su/
\\I
Overdrive
brake
UK,,
I
Direct
clutch
-. -..No.1
I
II II IIIIII IIIIII II w
u,umce
No.2
I
Brake
No.3
Intermediate
modulator
modulator
valve
valve
oil pressure
3RD)
valve
OFF
11 3-4 shift11
Lubrication
pressure,
Intermediate
Low coast
modulator
D-3 (DRIVE
OD solenoid
Throttle
pressure
Cut back pressure
Governor
pressure
Converter
oressure,
a
n
n
m
so,lenoid
Line pressure
Detent
regulator
modulator
pressure,
pressure
[
0
http://vnx.su/
II u
To cooler
372093
ZIIZIZ
I,
II II
JI
Torque
converter
I
II valve
III-
11
II ffC?l
I I I ( regulatol
11 Check
valve
Overdrive
h
Overdrive
brake
Brake
No.1
II lkhl
Forward
clutch
Direct
Cl Ui tch
Brake
No.2
Brake
No.3
Ill
Intermediate
modulator
Reverse
sequence
valve
=T
D-4
I:
pressure
pressure
pressure,
(DRIVE
Third
JJ
coast
oil pressure
3-4 shift
c7?
valve
4TH)
Lubrication
pressure,
Intermediate
Low coast
modulator
L-J
snlrt
dl
valve
Cut back
Governor
Converter
0
0
0
clutch
valve
Throttle
pressure
Line pressure
Detent
regulator
modulator
pressure,
pressure
0
0
:
A
?
P
AUTOMATIC
TRANSMISSION
- General Information
l-l
http://vnx.su/
21-81
21-82
AUTOMATIC
TRANSMISSION
- General
2 (SECOND 2ND)
I
1
http://vnx.su/
Information
http://vnx.su/
372096
-&IT
To cooler
Ivalve II
rc
IIll
ih
Overdrive
clutclyl
Overdrive
brake
Forward
clutch
Direct
clutch
Brake
Brake
Brake
No.3
modulator
Reverse
0
n
m
valve
clutch
Throttle
Cut back
Governor
Converter
L (LOCK
pressure
pressure
pressure,
pressure
Line pressure
Detent
regulator
modulator
pressure,
pressure
L
a
UP)
Lubrication
D-2 down
timing valve
oil pressure
pressure,
Intermediate
Low coast
modulator
I-
21-84
AUTOMATIC
TRANSMISSION
- General
Information
R (REVERSE)
I
http://vnx.su/
AUTOMATIC
TRANSFER
14.
15.
16.
17.
18.
19.
20.
21.
- General
21-85
Information
2?
22
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TRANSMISSION
Rear cover
Chain cover
Drive sprocket
Clutch hub (2-4WD)
Clutch sleeve (2-4WD)
Low speed gear
Clutch hub (for H-L)
Clutch sleeve (for H-L)
21 20 19 18 17
33 34 35 32
\I
dv/
22.
23.
24.
25.
26.
Control housing
Control lever
Control sleeve
Control shaft
Shift lug (2-4WD)
27.
28.
29.
30.
31.
http://vnx.su/
32.
33.
34.
35.
36.
cover
148001
148002
148003
148004
21-86
AUTOMATIC
TRANSMISSION
General
Information
POWER FLOW
ZWD-H
Sleeve
ZWD-H
When the H-L selector sleeve is shifted forward and engaged with
the clutch gear of input gear, the input gear is directly coupled to
the rear output shaft, thus transmitting
power to the rear wheels.
This is the power transmission
of 2WD-H, which involves no other
gears, making for quiet driving.
14ACl40
4WD-H
1.000
--
3\
To rear
wheels
4WD-L
Sleeve for
changeover
H-L
4WD-H
When
mesh
mitted
chain,
If the
mode
the 2WD-4WD
selector sleeve is shifted to the rear and in
with the clutch gear of the drive sprocket,
power is transfrom the drive sprocket
to the front output shaft via the
thus driving the front wheels.
H-L selector sleeve is in the forward position at the time, the
is 4WD-H.
4WD-L
When the H-L selector
sleeve is shifted toward
rear, power is
imparted from the input gear to counter gear and to low speed
gear and the rear and front wheels are driven by the rear and front
output shaft, respectively.
This mode is 4WD-L.
http://vnx.su/
AUTOMATIC
TRANSMISSION
TRANSFER
General
CONTROL
21-87
Information
MECHANISM
Control
lever
Control
Shift
Shift
fork
shaft
Set
Control sleeve
(H-L)
rail (H-L)
Front
Shift
Shift
Switch
rail (24WD)
fork
(2-4WD)
Spring
A
Poppet
lug
Shift
B
Switch
Select
ball
http://vnx.su/
plunger
21-88
UTOMATIC
TRANSMISSION
2WD-4WD
- General
Information
Shift Mechanism
In the 2WD-4WD
shift mechanism,
the shift lug and shift fork are
separate. The shift lug is fastened to the shift rail with a spring pin,
while the shift fork is not secured but can slide over the shift rail,
which ensures smooth shifting from 4WD-H into 2WD-H.
Drive
sprocket
(24WD)
144045
144046
Select
Plunger
The select plunger and select spring push the control finger tightly
against the H-L shift fork when the control lever is in the 4WD-H
position, thereby preventing
the lever from oscillating or coming
off position. They also provides
a resistance
when shifting into
2WD-H.
Select
In case
4WD-H
of
spring
In case
4WD-L
of
144047
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AUTOMATIC
TRANSMISSION
4WD Indicator
- General
Information
21-89
Light Switch
There are two switches installed that control the 4WD indicator
light which tells the driver that the vehicle is in 4WD mode.
When shift is mode from 2WD-H to 4WD-H or between 4WD-H
and 4WD-L, the 4WD indicator light comes on. When shifting from
4WD-H to 4WD-L, or vice versa, the switch B causes the light to
go off in the mid shift motion, allowing the driver to know that a
selection has been completed.
Switch A
Switch A
ON
OFF
144048
144049
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21-90
AUTOMATIC
TRANSMISSION
-Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NZlCA-
Items
Automatic
Torque
transmission
and transfer
case model
Specifications
~~
(Ml48
converter
We
Stall torque
One-way
1 elements,
1 -step 2-phase
system
1I .96
ratio
!jprag
clutch
type
Transmission
I-orward 4 gears, reverse 1 gear, single-line
planetary gear
!Jear and Simpson
Type
Control
planetary
elements
3 pairs
Clutch
IVlultiple
Brake
4 pairs
Ivlultiple disc tyep
,Sprag type
3 pairs
One-way
clutch
disc type
Gear ratios
1st gear
2.826
2nd gear
1.493
3rd gear
1.000
4th gear
(3.688
Reverse
2.703
Shift control
Select
method
pattern
and overdrive
switch
Oil pump
ISear type
Type
Drive system
Hydraulic
control
Oil-cooling
system
system
IDirectly
coupled
to engine
Throttle
opening
and vehicle
I4ir-cooled
(lsecondary
system
cooling
I4lwaysengaged
method
Single-lever
Shift ratios
LOW
1.944
HIGH
1 .ooo
Speedometer
gear ratio
2618
http://vnx.su/
speed
+ water-cooled
method)
Transfer
Type
Shift control
via torque
type
floor-shift
type
converter
detection
system
oil cooler
AUTOMATIC
TRANSMISSION
NUMBER
MARKING
TRANSMISSION
POSITION
AND DESIGNATION
1 Serial number
per month1
Fixed number
(Mitsubishi
exclusive
J-&--j
Transmission
21-91
Specifications
number
148013
-1
head number)
Classification
N: AW372
of type
1 Manufacturing
month
year
A: January
v: April
4
I
1
M : December
B
http://vnx.su/
Manutacturlng
87: 1987
21-92
AUTOMATIC
TRANSMISSION
- Specifications
SERVICE SPECIFICATIONS
NZlCB--
Specifications
Items
Standard value
Stall speed
Governor
rpm
pressure
2 100-2400
kPa (psi)
1000 rpm
138-l 66 (20-24)
2000 rpm
246-284
(36-41)
3200 rpm
402-460
(59-66)
When idling
452-529
(66-76)
During stall
991-1166(144-169)
Line pressure
D range
kPa (psi)
R range
When idling
687-804
During stall
1471-1863
mm (in.)
Overdrive
brake clearance
Overdrive
Free length
Overdrive
mm (in.)
(100-l
16)
(214-270)
0.3-0.9 (.012-,035)
0.35-I .6 (.0143-,062)
14.9(.587)
mm (in.)
Free length
Sleeve and selector
16.1 (.634)
mm (in.)
lever clearance
15.2-15.9
(.60-.62)
Transfer
H-L clutch hub end play
mm (in.)
O-0.08 (O-.003)
O-0.06 (O-.002)
O-0.06 (O-.002)
Limit
Overdrive
mm (in.)
14.5 (.571)
15.7(.618)
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AUTOMATIC
TRANSMISSION
21-93
-Specifications
TORQUE SPECIFICATIONS
NZlCC-
Items
Nm
ft.lbs.
Transmission
Converter
housing
installation
bolt
27-42
20-30
48-68
35-49
18-25
13-18
6-9
24-28
4.3-6.5
27-42
20-30
screw
6-9
4.3-6.5
bolt
5-6
6-9
3.6-4.3
4.3-6.5
8-12
5.8-9
5-6
3.6-4.3
6-9
4.3-6.5
4-5
2.9-3.6
Union
Elbow connector
20-30
20-30
14-22
14-22
6-9
18-23
4.3-6.5
13-17
IO-16
IO-16
7-12
14-18
IO-13
IO-13
7-9
IO-13
7-9
installation
bolt
installation
installation
bolt
installation
bolt
Overdrive
bolt
bolt
bolt
bolt
bolt
Plug
Manual lever installation
Transmission
nut
17-20
7-12
Transmission
18-24
13-17
Transmission
30-35
22-25
20-27
14-20
50-60
36-43
Front exhaust
20-30
15-22
pipe mounting
IO-12
7-9
No. 2 crossmember
55-75
40-54
IO-13
7-9
bolt
to body
member to body
18-25
13-18
Transmission
to starter motor
to transmission
43-55
31-40
Transmission
to engine
A, B
43-55
31-40
20-27
14-20
35-42
2
25-30
0.4
Transmission
40-50
29-36
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21-94
AUTOMATIC
TRANSMISSION
- Specifications
NPlCC-
Items
Nm
ft.lbs.
ransfer
Transfer case installation
bolt
30-42
22-30
nut
30-42
;!2-30
31-42
22-30
8-10
5.8-7
15-22
1 I-16
Cover bolt
15-22
11-16
Control housing
bolt
15-22
11-16
30-35
22-25
Drain plug
30-35
22-25
Select plug
30-35
;!2-25
15-22
11-16
100-I 30
72-94
Speedometer
1.5-2.2
1 .I-1.6
Seal plug
30-42
22-30
4WD switch
30
22
8-10
5.8-7
8-10
5.8-7
50-60
36-43
Transfer
mounting
bracket
18-25
13-18
Transfer
mounting
bracket to pipe
30-42
22-29
to control housing
to transfer
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TIC
TRANSMISSION
- SDecifications
LUBRICANTS
NZlCD--
Items
Automatic
Transfer
Specified
transmission
fluid
Automatic
II type
oil
Propeller
Transmission
part
control
sliding
Adaptor
MOPAR
2525035
Multi-Mileage
or equivalent
installation
MOPAR
3744994
(press-in
Chain cover
gasket
gasket
Cover gasket
housing
only)
Part
Approx.
pints)
Small quantity
Small quantity
Small
quantity
Quantity
MOPAR
or equivalent
as required
crrcumference)
MOPAR
or equivalent
as required
MOPAR
or equivalent
as required
MOPAR
or equivalent
as required
MOPAR
or equivalent
as required
MOPAR
or equivalent
as required
4171 or
as required
or equivalent
as required
sides)
sides)
gasket
(cover
side
3M Adhesive
equivalent
cable
and adhesives
SH 780 (TORAY
(both
(both
sealants
sides)
(both sides)
grommet
12.7 Imp.
NZlCE--
Specified
Bolt (threads)
Speedometer
Part No.
bolt (threads)
(both
Air breather
Control
surface
lubricant
Approx.
pints)
AND ADHESIVES
gasket
Rear cover
fluid DEXRON
MOPAR
3744994
Items
Oil pump
transmission
Quantity
MOPAR Multi-Mileage
Lubricant
No. 2525035
or equivalent
SEALANTS
lubricants
MOPAR
as required
SILICONE)
Nut Locking
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21-96
AUTOMATIC
TRANSMISSION
- Special Tools
SPECIAL TOOLS
NZlDA-
nstallation
(includes MD9983311
Oil pressure gage
http://vnx.su/
of oil pump
AUTOMATIC
Tool (Number
and name)
TRANSMISSION
Use
Tool (Number
MD99821 0
Bolt
Disassembly
and
assembly of No. 3 brake
spring
Torque
MD99821 1
Retainer
Disassembly
and
assembly of No. 3 brake
spring
and name)
MD998353
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21-97
- SDecial Tools
driver set
Use
Tightening of valve body
screw
21-98
AUTOMATIC
TRANSMISSION
- Troubleshooting
SHQOTING
N21 EBAE
GENERAL
Automatic
transmission
lowing conditions:
malfunctions
may be caused
by the fol-
COLD upper
COLD lowelCrnif
limit
COLD
HOT lower
limit
HOT
372029
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AUTOMATIC
TRANSMISSION
21-93
- SDecifications
TORQUE SPECIFICATIONS
NZlCC-
Items
Nm
ft.lbs.
Transmission
Converter
housing
installation
bolt
27-42
20-30
48-68
35-49
18-25
13-18
6-9
4.3-6.5
Center support
24-28
17-20
2742
20-30
screw
6-9
bolt
5-6
6-9
4.3-6.5
3.64.3
installation
Adapter installation
bolt
bolt
installation
8-12
5.8-9
bolt
5-6
3.6-4.3
6-9
4.3-6.5
4-5
2.9-3.6
Union
Elbow connector
20-30
20-30
14-22
14-22
6-9
4.3-6.5
18-23
13-17
IO-16
7-12
IO-16
14-18
7-12
IO-13
Overdrive
bolt
4.3-6.5
bolt
Plug
Manual lever installation
Transmission
bolt
nut
IO-13
7-9
IO-13
Transmission
18-24
7-9
13-17
30-35
22-25
Transmission
20-27
14-20
50-60
36-43
20-30
15-22
IO-12
No. 2 crossmember
to body
Rear engine support member to body
55-75
7-9
40-54
IO-13
7-9
No. 2 crossmember
18-25
13-18
43-55
31-40
43-55
20-27
31-40
14-20
35-42
25-30
0.4
40-50
29-36
to transmission
Transmission
to starter
Transmission
to engine
Torque converter
bolt
motor
A, B
D
to drive plate
) STB Revision
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21-94
AUTOMATIC
TRANSMISSION
- Specifications
NZlCC--
Items
Nm
ftlbs.
Transfer
Transfer case installation
Transfer case installation
bolt
nut
3042
30-42
22-30
22-30
3142
22-30
8-10
5.8-7
15-22
11-16
Cover bolt
15-22
15-22
11-16
11-16
30-35
22-25
Drain plug
30-35
22-25
Select plug
Locking plate bolt
30-35
15-22
22;25
11-16
100-l 30
1.5-2.2
72-94
Seal plug
3042
22-30
4WD switch
30
22
8-10
8-10
5.8-7
5.8-7
50-60
3643
18-25
13-18
Transfer
30-42
22-29
mounting
to control housing
bracket to pipe
STB Revision
http://vnx.su/
1.1-1.6
AUTOMATIC
TRANS
21-95
ISSION - SDecifications
LUBRICANTS
NZlCD--
Items
Automatic
Transfer
transmission
Specified lubricants
Automatic
fluid
fluid DEXRON
II type
Multipurpose
Small quantity
Transmission
Multipurpose
Small quantity
Transfer
oil
transmission
Quantity
SEALANTS
O-ring
Small quantity
AND ADHESIVES
Items
NPlCE-
specrrrea
sealants
ana aanewves
Uudrltlty
As required
As required
bolt (threads)
As required
As required
As required
As required
As required
Bolt (threads)
3M Adhesive
As required
As required
Speedometer
cable grommet
1 STB Revision
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21-96
AUTOMATIC
TRANSMISSION
-Special
Tools
SPECIAL TOOLS
NZlDA-
Tool (Number
Use
MD998218
Wrench
Inspection
converter
of torque
MD998212
Oil pump puller
MD998219
Stopper
Inspection
converter
of torque
M D998335
Oil pump band
Assembly
M D998330
Iincludes MD998331)
Oil pressure gage
:3000 kPa)
1427 psi)
Measurement
pressure
MD99841 2
Guide
Installation
of oil
and name)
Use
of oil punTP
of oil pl JmP
VI D999563
includes MD998331
3il pressure gage
1000 kPa)
142 psi)
Measurement
pressure
of oil
MD99821 7
Gage
9
/
M D998206
Adapter
Connection of oil
pressure gage
M D998207
Spring compressor
1 STB Revision
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Disassembly
and
assembly of clutct- I and
brake
AUTOMATIC
Tool (Number
and name)
TRANSMISSION
-Special
Use
Tool (Number
MD99821 0
Bolt
Disassembly
and
assemblv of No. 3 brake
spring
M D998353
Torque driver set
MD99821 1
Retainer
Disassembly
and
assembly of No. 3 brake
spring
1 STB Revision
http://vnx.su/
21-97
Tools
and name)
Use
Tightening
screw
of valve body
21-98
AUTOMATIC
TRANSMISSION
- Troubleshooting
TROUBLESMOOTING
NZlEBAE
GENERAL
Automatic transmission
malfunctions
may be caused by the following conditions:
(1) Improper maintenance
and adjustment
(2) Mechanical malfunctions
(3) Hydraulic malfunctions
(4) Poor engine performance
Troubleshooting
in the event of any such malfunctions
should
begin by checking fluid level, ATF condition, manual linkage adjustment, throttle control cable adjustment
and other conditions
whose deviation from standards can be readily known.
Then, road test shall be performed to determine whether or not
the problem has been corrected or more diagnosis is necessary. If
the problem still persists after these tests and corrections, hydraulic tests should be performed for further troubleshooting.
upper
bve:mit
COLD
HOT
limit
HOT
upper
bvel\
Y
HOT
37202!l
1 STB Revision
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AUTOMATIC
TRANSMISSION
MANUAL
- Troubleshooting
21-99
LINKAGE
The inhibitor switch is installed on the selector lever. After checking normal.operation
of this switch, place the selector lever in the
N position. If the notch of the seletor lever on the transmission
side faces directly down, the linkage has been adjusted correctly.
THROlTLE
CONTROL
CABLE
INHIBITOR
L
.,
,
i
SWITCH
Check to see that the engine starts only when the selector lever
is in the N or P position and that it does not start when the
selector lever is in other positions.
SELECTOR LEVER
(1) Check to see that the vehicle moves forward when the selector lever is shifted from the N position to the D range and
that the vehicle reverses when the lever is shifted to the R
range.
(2) Stop the engine.
(3) Shift the selector lever from the N position to the D range
and then to the 2 position to check that the lever can be
operated smoothly and engage at each position with reasonable firmness.
(4) Check to see that shifting to each of the P, R, 2 and
L positions can take place only when the selector lever is
pushed in.
ROAD TEST
Prior to performing
road test, be sure to make basic checks including check and adjustment
of fluid level and condition and adjustment of the throttle cable. For road test, the transfer must be
placed in the 2H (2WD-high) position.
In road test, various changes such as slips in transmission
and
shifting conditions are checked and hence the transmission
operation at each shift position must have been checked.
1 STB Revision
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5
.,I(-
? _
75
,.:
21-100
D RANGE
AUTOMATIC
TRANSMISSION
- Troubleshooting
TEST
Start with throttle valve 50%/full open and check shifting from 1st to 2nd
speed, 2nd to 3rd speed and 3rd to 4th speed and compliance of shift point
with shift pattern.
Low
coast
modulator
too low
During acceleration
pressure
to check engine
1
Large shock
1
Line pressure too high.
Accumulator or check ball faulty.
/ STB Revision
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AUTOMATIC
TRANSMISSION
- Troubleshooting
21-101
NOTE
Drive at D range 3rd speed and check for abnormal noise and
vibration. Check carefully as abnormal noise and vibration are
sometimes
caused by unbalanced
propeller shaft, differential,
tires, torque converter, engine, etc.
2 RANGE TEST
(1) Shift to 2 position and start with throttle valve 50%/full open
and check if 1st to 2nd speed upshift point at these throttle
openings meets the shift pattern.
(2) Kickdown at 2nd speed in 2 range to check that 2nd to 1st
kickdown speed limits meet shift pattern.
(3) Check for abnormal noise during acceleration/deceleration
and
check for shock during up/downshift.
L RANGE TEST
(1) Drive at the L range and check that upshift to 2nd speed
does not take place.
(2) Check for abnormal noise during acceleration/deceleration.
R RANGE TEST
(1) Shift to the R range and start forward with full throttle to
check for slip.
(2) While the vehicle is running, lightly depress the accelerator
pedal to check for slip.
7 RANGE TEST
With the vehicle parked on a slope (about 5 degrees or steeper),
shift to the P range and release the parking brake to check to
see that the parking brake system functions to keep the vehicle
stationary.
CONVERTER
STALL TEST
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(.
I
y.
I.
21-102
Judgement
Stall speed
AUTOMATIC
of Stall
in D
Test
and R
TRANSMISSION
- Troubleshooting
Results
range
GOVERNOR
- I \
Line pressure
pick up
PRESSURE
TEST
138-l 66 kPa
(20-24 psi)
2000 rpm
246-284
kPa
(36-41 psi)
3200
402-460
kPa
(59-66 psi)
rpm
STB Revision
http://vnx.su/
pressure
ATIC TRANSMISSION
21-103
- Troubleshooting
LINE PRESSURE
TEST
chassis dynamometer.
the line pressure takeoff port.
gauge using Adapter MD998206
(spegauge into the inside of the vehicle.
(7) Depress the brake pedal firmly by the left foot and operates
the accelerator
pedal by the right foot to measure
the line
pressure at each engine rpm. If the measured
pressure
is not
nominal, check adjustment
of the throttle cable and readjust if
necessary
before conducting
the test again.
(8) Place the selector lever in the R range and test as above.
Standard .value
Judgement
Line pressure
R range
D range
At idle
452-529 kPa
66-76 psi
At stall
991-1166
144-169
kPa
psi
687-804
100-116
1471-1863
214-270
by Line Pressure
Hydraulic pressure
Hydraulic pressure
Hydraulic pressure
Hydraulic pressure
(1)
(2)
(3)
(4)
(5)
range
(1)
(2)
(3)
(4)
adjusted
adjusted
[ ST6 Revision
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kPa
psi
kPa
psi
21-104
CIRCUIT
AUTOMATIC
- Troubleshooting
i..rr :
DIAGRAMS
OVERDRIVE
Battery
T;Rq?JSMISSION
NZlEC--
CONTROL -SYSTEM
-1.25-B
Sub
A-02
-5
3
Main
link
CIRCUIT
5 WA-23
-5-w
fusible
link
Ignition
0.5-G
2-w
switch
/T
fusible
cf3
3
(\:I
r
L
A-22
bM STIG
_
c4
1 c-55
szz
mm
4,:
(VW)
2-BY
To combination
meter
[Refer
to P.8-52.1
To alternator
[Refer
to P.8-37.1
0.85-N
0.85-W
2
z
TO column
[Refer
to
switch
P.8-51.1
Remarks
(I)
For information
concerning.,the
ground
points
(example:
0).
refer
to P.8-7.
(2)
The
symbols
0,
0,
etc.
indicate
that
the
wiring
is
connected
(using
the same
numerical
symbol)
to the
facing
page.
(In other words,
0 on the right page is connected
to 0 on
the left page.)
Combination
RL]
1 ]
ST6 Revision
http://vnx.su/
w
YR
meter
LQ
1 1 ]
AUTOMATIC
TRANSMISSION
Inhibitor
Water
temperature
switch
switch
A-51
RL
*
21405
- Troubleshooting
OD-OFF
relay
To back-up
lrght
[Refer
to P.8-45.1
Z-BY,
To starter
[Refer
to
@4
*
R
YR
(Lg)
I
1
relay
P.8-34,
35.
A-10
cl c
JO
c
C
ii!3
ii
Automatic
transmission
oil temperature
swatch
OD-OFF
switch
Wiring
color
code
Br:
B: Black
LI: Light
blue
0:
Brown
Orange
OD-OFF
solenoid
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
Lg:
W:
1 STB Revision
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Light
White
green
37W619
21-I 06
AUTOMATIC
TRANSMISSION
- Service
Adjustment
procedures
SERVICE ADJUSTMENT
PRQCEDUREsF+
CHECKING
CHANGING
FLUID
TRANSMISSION
FLUID
LEVEL
AND
(3) Check the transfer case oil level with the filler plug removed.
(4) The fluid level is okay if it is at the same level as the lowest
point of the filler plug hole.
I
,
:.
: i
0
>
-
--
-_
ATF CHANGING
PROCEDURES
Caution
If ATF change is required due to damage
be sure to clean the cooler system.
to the transmission,
~
14
COLD upper
HOT upper
limit
limit
COLD lower
HOT lower
limit
limit
Y
.
Y
COLD
HOT
(5) Start the engine and allow to idle for at least two minutes.
Then, with the parking brake and service brake applied, move
the selector lever through all positions and finally place in the
N or P position.
(6) After the transmission
is warmed up to the normal operating
temperature,
recheck the fluid level, which must be between
the HOT upper limit and HOT lower limit marks.
(7) Insert the dipstick fully to prevent dirt from entering the
transmission.
372029
rST
Revision
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AUTOMATIC
TRANSMISSION
- Service
TRANSFER
(1)
(2)
(3)
(4)
Adjustment
21-107
procedures
PROCEDURES
ADJUSTMENT
BLE
OF THE THROTTLE
52-53
mm
(2.047-2.086
level.
CONTROL
If necessary,
CA-
readjust.
:.
: ,:
(idle adjustment)
has been
the throttle
control
cable.
in.)
Standard
value:
52-53
mm (2.047-2.085
in.)
IO-14Nm
w
8- 10 ftlbs.
372098
Front
REPLACEMENT
SEALS
OF THE PROPELLER
SHAFT
OIL
NPlFGABl
or a similar
tool, remove
Caution
Use a new oil seal.
(3) Apply a coating
seals.
Specified
1 ST6 Revision
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grease
of the specified
: Multipurpose
No. 2
:.
.
\
21-I
08
AUTOMATIC
TRANSMISSION
- Service
REPLACEMENT
Adjustment
procedures
OF THE
SPEEDOMETER
CAWIID
sealant
: 3M ART
equivalent
Part
No.
8001
or 8011,
or
1 STB Revision
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AUTOMATIC
TRANSMISSION
REMOVAL
AND
TRANSMISSION
- Transmission
CONTROL
INSTALLATION
N21 IA-
012,
21-109
Control
25\
/:4\Ybs.
IO-13 Nm
ft.lbs.
- ~7-9
25
012
IO-13 Nm
23
/
F9
ft.bs*
21
24
09w542
Removal
steps
I. Plate B
Floor console
3. Overdrive
switch
connection
4. Selector
handle
5. Overdrive
switch
harness
and front wiring harness
connection
6. Cover
7. Inhibitor
switch
and front wiring
harness
connection
8. Position
indicator
light and front wiring
harness
connection
9. Indicator
panel
10. Bracket
assembly
11, Heat protector
12. Cotter pin
13. Transmission
control
rod (B)
14. Dust cover
2.
+e
l +
+e
+e
++
l +
l +
l +
l +
15.
16.
17.
18.
19.
20.
21.
~~
l +
l +
w+
l +
22.
23.
24.
25.
26.
Snap ring
Spring
Cross shaft
Cross shaft
Select cross
Transmission
Cap
Bushing
Cross shaft
Cross shaft
Bushing
Pin
bushing
boot (B)
shaft
control
rod
bracket
boot
NOTE
(1)
Reverse
the removal
procedures
(2)
+e
: Refer
to Service
Points
(3)
l + : Refer to Service
Points
(4)
: Non-reusable
parts
1 STB Revision
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(A)
(A)
to
of
of
reinstall.
Removal.
Installation.
AUTOMATIC
TRANSMISSION
SERVICE
4.
- Transmission
POINTS
REMOVAL
Control
OF REMOVAL
OF SELECTOR
HANDLE
(3) Remove
the selector
N2lIBAF
handle
from
connector
from
the shift
the
lever.
13. DISCONNECTION
OF TRANSMISSION
CONTROL
ROD
(B)
(1) Disconnect
the transmission
control rod (B) from the
transmission
control arm by lossening
the nut from
under the floor.
(2) Disconnect
the select cross shaft from the heat
protector.
(3) Disconnect
the select cross shaft from transmission
control rod B.
19. REMOVAL
OF SELECT CROSS
SION CONTROL
ROD (A)
(1) Disconnect
the select
control rod A.
I-V-)
09w521
STB Revision
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cross
SHAFT/PO.
TRANSMIS-
shaft from
transmission
AUTOMATIC
TRANSMISSION
Transmission
21-111
Control
(2) Remove the dust cover, and then remove the snap ring
that holds the spring.
(3) Remove the cross shaft bracket mounting
bolts from
the transfer assembly.
(4) Detach the cross shaft bracket from the bracket on the
No. 1 crossmember
side.
Cross
shaft
bracket
(A) v
09~011
(5) Remove
sion.
Transmission
control
rod
transmission
control
(A)
SERVICE
POINTS
OF INSTALLATION
NPlDAH
26. APPLICATION
OF GREASE
TO PIN/25.
BUSHING/24.
CROSS
SHAFT
BOOT/23.
CROSS
SHAFT
BRACKET
(A)/22. BUSHING/20.
TRANSMISSION
CONTROL
ROD
(A)/19. SELECT CROSS SHAFT/18.
CROSS SHAFT BOOT
(B)/17. CROSS SHAFT BUSHING/lG.
SPRING
Apply a coating of the specified
grease to the bushing
inner surface and the sliding parts shown in the figure.
Specified
grease
13. INSTALLATION
: Multipurpose
No. 2
OF TRANSMISSION
grease
09w523
FRevision
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y,
c;-
:,
CONTROL
ROD (B)
\\\
2.
21-112
AUTOMATIC
DISASSEMBLY
AND
TRANSMISSION
- Transmission
Control
REASSEMBLY
N21lE.-
3
6
18-24
13-17
/
Nm
ftlbs.
09w5.43
Removal steps
l +
l +
l +
l +
f Overdrive
\
1.
2.
3.
4.
5.
6.
7.
8.
9. Shift
Position
indicator
light
Inhibitor
switch
Overdrive
switch
Pushbutton
Spring
Selector
handle
Bushings
Transmission
control
arm
lever
l * 10. Sleeve
l + 11. Spring
l + 12. Rod assembly
13. Bracket
NOTE
(I)
(2)
Reverse
the disassembly
l + : Refer to Service
procedures
to reassemble.
Points of Reassembly.
INSPECTION
switch
l
l
l
l
l
l
N211GAA
When
When
. .
the
the
overdrive
overdrive
1 STB nevmon
http://vnx.su/
switch
switch
is OFF:
is ON:
continuitv
non-continuity
TRANSMISSION
AUTOMATIC
- Transmission
Overdrive
relay
Check
21-113
Control
relay
the continuity
between
terminals
during
no current
flow
Inhibitor
Check
Continuity
Between
lW1575
Continuity
1 and 3
terminals
2 and 4
Between
terminals
1 and 3
Non-continuity
switch
the continuity
with
the select
09w513
NOTE
o-o indicates
between
the terminals.
NZllHAE
12. APPLICATION
OF GREASE TO ROD ASSEMBLY/l
ING/10.
SLEEVE/8.
TRANSMISSION
CONTROL
BUSHINGS/4.
PUSHBUlTON
Apply the specified
Specified
09w54:
Pushbutton side
: Multipurpose
No. 2
grease
10. INSTALLATION
OF SLEEVE
Move the selector lever to the N position, and turn the
sleeve so that the angled surface of the sleeve is at the
pushbutton
side. At this time, adjust the clearance between the sleeve and the selector lever so that it is the standard value.
B part
Selector lever
Standard
value
: 15.2-15.9
mm (.60-.62
NOTE
Move the B part of the sleeve
(drivers seat side).
09R0070
fpN
grease
1. SPRARM17.
pushbutton
side
2. INSTALLATION
OF INHIBITOR
SWITCH
(1) Temporarily
install the inhibitor switch.
(2) Set the shift lever so that the pin at the end of the rod is
at the position shown in the figure.
position
im (in.)
to the
in.)
Revision
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AUTOMATIC
TRANSMISSION
Transmission
Control
1 STB Revision
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AUTOMATIC
TRANSFER
REMOVAL
Removal
+I) l +
~~
TRANSMISSION
Transfer
21-115
Control
CONTROL
AND
INSTALLATION
steps
1.
2.
3.
4.
5.
NOTE
(1)
Reverse
the
(2)
e+
: Refer
l * : Refer
(3)
removal
procedures
to Service
Points
to Service
Points
to
of
of
reinstall.
Removal.
Installation.
SERVICE
3.
POINTS
REMOVAL
OF REMOVAL
OF CONTROL
LEVER
SERVICE
4.
POINTS
APPLICATION
GASKET
http://vnx.su/
and remove
OF INSTALLATION
surfaces
to both
OF CONTROL
LEVER
the
N21KDAA
sealant
Check to be sure
tion (transmission
illustration.
1 STB Revision
position
TO CONTROL
INSTALLATION
0980027
ASSEMBLY
OF SEALANT
Apply semi-drying
housing
gasket.
3.
NPlKBAA
HOUSING
of the control
ASSEMBLY
21416
AUTOMATIC
DISASSEMBLY
Disassembly
+*
1.
2.
3.
4.
5.
6.
TRANSMISSION
Transfer
Control
AND REASSEMBLY
NZlKE--
0980045
steps
Reassembly
Spring pin
Set screw
Control lever assembly
Control finger
O-ring
Control housing
3.
+* 5.
6.
4.
WC 1.
2.
steps
NOTE
(I)+*
(2)*+
(30
REMOVAL
OF SPRING
N21KFAA
PIN
(1) Drill 12 mm (.47 in.) diameter hole in the center of the boss
16 mm (63 in.) diameter on the control housing not to
damage the control finger and control lever assembly.
(2) Draw out the spring pin using a punch.
Lf
09BOO4C
APPLICATION
OF LUBRICANT
TO O-RING
oil
N2lKHAA
and apply a
: Hypoid
Gear Oil API Classification
GL-4
or higher SAE viscosity
No. 8OW, 75W85W
1. INSTALLATION
OF SPRING PIN
(1) Drive the spring pin using a punch so that the cut out
portion of the spring pin is in the axial direction of the
control lever assembly.
(2) Apply the sealant in the inner surface of the worked hole
and drive the sealing cap up to the dimension shown in the
figure.
1.5-2.0
Control
housing
mm
(.06-.08
in.1
09l30032
evision
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AUTOMATIC
TRANSMISSION
REMOVAL
AND
TRANSMlSSlON
- Transmission
21-117
Oil Cooler
OIL COOLER
INSTALLATION
Pre-removal
Operation
Removal of Under Cover and Under
Skid Plate (Refer to GROUP 23
BODY-Under
Guard)
l
Bleeding
of the automatic transmission fluid. (Refer to GROUP 0 LUBRICATION AND MAINTENANCEMaintenance
Service)
NZlSA-
Post-installation
Operation
l
Installation of Under Cover and Under Skid Plate (Refer to GROUP 23
BODY-Under
Guard)
l
Supplying of Automatic
Transmission
Fluid. (Refer to GROUP 0 LUBRICATION AND MAINTENANCE-Maintenance Service)
18W831
46-50
26-36
Nm
ftlbs.
04w571
Removal
l *
l +
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Radiator
grille
Eye bolts
Gaskets
Oil cooler assembly
Hose clamp
Hose
Oil cooler
tube clamp
Feed tube
Return tube
NOTE
(1) Reverse the removal procedures
(2) +e : Refer to Service Points
(3) I)+ : Refer to Service Points
(4) q
: Non-reusable
parts
1 STB Revision
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to reinstall.
of Removal.
of installation.
21-118
AUTOMATIC
TRANSMlSSlON
SERVICE
- Transmission
POINTS
2. REMOVAL
Oil
Cooler
OF REMOVAL
NZlSSAS
OF EYE BOLTS
while
tightening
the weld
nut of
INSPECTION
l
l
0
l
Check the oil cooler fins for bend, damage and foreign
matters caught between fins.
Check the oil cooler tubes for crack, damage, clogging and
deterioration.
Check the gaskets for damage
and deformation.
Check the eye bolts for clogging
and deformation.
SE&ICE
9.
NZlSCAD
POINTS
INSTALLATION
OF INSTALLATION
OF RETURN
TUBE/%
NZlSDAA
FEED TUBE
For installation
of the feed tube and return tube to the
transmission,
first loosely
tighten
each coupling
and
clamp, and then make the final tightening
in sequence
from the feed tube and return tube coupling.
1 STB Revision
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AUTOMATIC
TRANSMISSION
REMOVAL
AND
TRANSMISSIO
Transmission
and
Transfer
Assembly
21-I
19
N21 LA-
Pre-removal
Operation
Removal of Cross Shaft Protector
Removal of Transfer Case Protector
Bleedina of Automatic
Transmission
Fluid atd Transfer Oil (Refer to
GROUP 0 LUBRICATION
AND
MAINTENANCE-Maintenance
Service)
Post-installation
Installation
Installation
l
l
l
l
l
Operation
of Cross Shaft Protector
of Transfer Case Protec-
1
20-27
14-20
Nm
ft.lbs.
35 Nm
22-25 ft.lbs.
50-60
35-43
16-22
13-16
,i$
Nm
ftlbs.
IO-13 Nm
7-9 ftlbs.
09w544
Removal
l +
steps
1.
2.
3.
4.
5.
6. Connection
l +
l 4
of overdrive
solenoid
valve
4*
l *
4*
l *
l 4
I)*
l 4
l *
0.
1.
2.
3.
NOTE
connector
7. Speedometer cable
8. Oil filler tube
9. O-ring
(1)
(2)
(3)
(4)
Reverse the
+e : Refer
l + : Refer
a
: Non
STB Revision
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removal procedures
to Service Points
to Service Points
resusable parts
to reinstall.
of Removal.
of Installation
21-120 AUTOMATIC
14
XI-30
E-2?
Nm
ftlbs.
TRANSMISSION
35-42
25-30
- Transmission
and
Transfer
Assembly
Nm
ftlbs.
22-29
ftlbs.
\
..
7-gqi$y i
18-25
13-18
55-75
40-54
Nm
ftlbs.
Nm
ftlbs.
NOTE
Reverse the removal procedures to reinstall.
(1)
(2)
(3)
+*
) STB Revision
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: Refer
: Refer
to
to
Service
Service
Points
Points
of
of
Removal.
Installation
AUTOMATIC
TRANSMISSION
- fransmission
SERVICE
POINTS
10. REMOVAL
PROPELLER
and
Transfer
21-121
OF REMOVAL
OF REAR
SHAFT
12. REMOVAL
OF SELECT
SION CONTROL
ROD
NZlLBAG
PROPELLER
Refer
Assembly
SHAFT/ll.
SHAFT
CROSS
AND
SHAFT/13.
FRONT
UNIVERSAL
TRANSMIS-
to P.21-110.
17. REMOVAL
OF SPECIAL
23. REMOVAL
SEMBLY
bolts
BOLTS
(six) coupling
OF TRANSMISSION
the torque
AND
convert-
TRANSFER
AS-
(1) Disconnect
the transmission
and transfer
assembly
from the engine by pulling it slowly toward
the rear of
the vehicle.
(2) When lowering
the transmission
and transfer
assembly, tilt the front of the transmission
downward
and
slowly
lower forward,
while using care to make sure
that the rear of the transmission
does not hit the No. 4
crossmember.
NOTE
Detach so that the torque
the engine side.
SERVICE
POINTS
23. INSTALLATION
ASSEMBLY
converter
does
OF INSTALLATION
OF TRANSMISSION
not remain
at
NPlLDAG
AND
TRANSFER
IRevision
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21-122
AUTOMATIC
TRANSMISSION
- Transmission
13. INSTALLATION
OF TRANSMISSION
SELECT CROSS SHAFT
Refer to P.21-11 I.
11. INSTALLATION
OF FRONT
REAR PROPELLER
SHAFT
RLfer to GROUP 16 PROPELLER
JblNTS
- Propeller
Shaft.
9. APPLICATION
Automatic
transmission
PROPELLER
SHAFT/IO.
OF LUBRICANT
TO O-RING
transmission
CONNECTION
fluid
: ATF
OF SPEEDOMETER
DEXRON
transmis-
II Type
CABLE
Refer to P.21-108.
Oil filler tube O-ring
5.
CONNECTION
OF THROlTLE
Refer to P.21-107.
/ STB Revision
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CONTROL
CABLE
AUTOMATIC
TRANSMISSION
Transmission
and
Transfer
DISASSEMBLY
Assembly
23
21-I
NzlLE--
Caution
1. When removing
the transmission
assembly from the vehicle, use care so that the oil pan is not hit by the transmission jack.
2. The automatic
transmission
is built of accurately
machined parts which should be handled during disassembly
with utmost care to prevent damage.
3. When separating
light alloy metal parts such as the case,
do not pry with a screwdriver
but tap lightly with a soft
headed hammer
(plastic hammer).
4. Place rubber mat on the work bench and keep it clean.
5. During disassembly,
do not wear cloth gloves or use rags.
If necessary, use nylon cloth or paper towel.
6. Clean all parts that have been disassembled.
Ordinary detergent may be used for cleaning metallic parts but after
washing, be sure to dry with air.
7. Wash the clutch disc, brake disc, resin and rubber parts in
ATF (automatic
transmission
fluid) and keep them free
from dust.
8. If the transmission
itself is damaged,
disassemble
and
clean the cooler system.
(1) Remove sand and dirt from the outside of the transmission.
(2) Remove the transfer (P.21-174).
(3) Place the transmission
assembly on a bench with the oil pan
down.
L1.
f
P
iz;
i!,I
4::
;G;
!.
>
i
,
I:
.i-:
E
St!
-If
Caution
Do not place the assembly with the oil pan up before theit:
J
oil pan is removed.
This is necessary to prevent foreign
1
;
matter in the oil pan from entering the valve body.
1.
!,
(4) Remove the torque converter.
(5) Remove
valve.
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and
21-124
AUTOMATIC
Oil screen
\
Oil pipe
/I
TRANSMISSION
- Transmissioti
and Transfer
Assemblv
(9) With the oil pan down, remove the oil pan bolts and then
remove the oil pan and gasket.
(10)Place the assembly with the valve body up.
(1 l)Remove
the oil pipe, prying with a screwdriver and using care
not to cause deformation.
(12)Remove the oil screen.
(13) Remove
17 bolts attaching
the throttle
cable
le vision
-1
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AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-125
(17)Drive out spring pin 1 and remove shaft 2 and manual valve
lever 3.
(18)Remove
the oil seal from the manual valve shaft using a
screwdriver.
When installing the oil seal, do so evenly.
Caution
Use care as the piston and fluid pops and gushes out.Pistons for B,, C,, and C, have been installed from the front
to rear in the order shown. Store the removed pistons and
springs arranged in this order.
(20)Remove
(21)Remove
(22)Remove
(23)Holding
housing.
the
the
the
the
..
3
I.
355212
(25)Remove
1 ST6 Revision
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21-I 26 AUTOMATIC
- Transmission
TRANSMISSION
and Transfer
(26)Remove
the foward
(27)Remove
(28)Remove
Assembly
clutch assembly.
attaching
bolts.
ring
3551oa
I
vision
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together
carrier by using
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
21-127
(32)Remove
case.
(33)Remove
355102
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21-I 28 AUTOMATIC
- Transmission
TRANSMISSION
and
Transfer
Assembly
REASSEMBLY
NZlLF--
Caution
1. The automatic
transmission
is built of accurately
maichined parts which should be handled during reassembly
Iwith utmost
care to prevent
damage.
Damaged
parts
could cause fluid leaks or affect performance.
Check the
parts carefully before reassembly.
2. Clean all parts that are to be reassembled.
Ordinary detergent may be used for cleaning metallic
parts but after
washing, be sure to dry well with air.
3. Wash the clutch disc, resin thrust plate and rubber parts in
ATF and keep them free from dust.
4. Do not reuse gasket, oil seal and other rubber parts. At
reassembly,
replace them with new ones.
5. Never use grease other than petrolatum
or industrial
petrolatum.
6. Apply ATF to friction elements,
rotating
parts and sliding
parts before installation.
7. New clutch disc and brake disc should be immersed
in
ATF for more than two hours before installation.
8. Do not apply sealer or adhesive to gaskets.
9. When bushing must be replaced, replace assembly which
includes it.
10. Tighten parts to specified torque.
(2) Install output shaft thrust bearing race #21 and thrust bearing
#20 in the case.
Caution
When installing
the thrust bearing
direction,
referring to the illustration.
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their
AUTOMATIC
TRANSMISSION
#4
#!i#7
#9
- Traunsmission
#lO
#12
#13
#15
#I6
and Transfer
#I7
#18
#19
Assembly
21-129
#20
372034
(3) Install the apply tube in the case. Make sure that the paw1 at
the end of the tube is inserted to inside of the piston.
carrier, seating
its
(5) Install the rear planetary gear and output shaft assembly in the
case. Insert slowly and taking care not to hit at the bearing.
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^,,i
21-I 30
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
(6) Install the backing plate in the case. Insert firmly until it comes
into contact with the apply tube.
(7) Apply grease to the thrust washer and attach it to the front
planetan/ gear carrier. Then install the front planetary gear
assembly in the ring gear.
(8) Install the clutch discs and plates alternately in this order on
the backing plate.
355194
to make
sure that
(12)lnstall the center support assembly in the case, checking correct seating of the one-way clutch on the center support and
pushing the center support while pulling the sun gear.
The center support will not be installed completely
in the case
if the one-way clutch is floating.
(13)Pushing the center support backward, tighten the bolts alternately on side (A) in about 7 Nm (5 ft.lbs.) increments.
Finally
tighten to specified torque.
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ATIC TRANSMISSION
- Transmission
and
Transfer
21-I 31
Assembly
(15)Attach thrust race #14, bearing #15 and thrust race #16 onto
the rear of the forward clutch hub using petrolatum and noting
the direction of the thrust bearing race.
(16)lnstall the forward clutch assembly, using care not to drop the
thrust bearing attached in the step above.
value
: Approx.
1.5 mm
(.059
in.)
372038
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21-I
32 AUTOMATIC
TRANSMISSION
- Transunission
(19)lnstalf
MD99841
and Transfer
Assembly
case.
(20)Along the guides, install the O.D. case assembly in the transmission case, positioning the O.D. case notch as illustrated.
(2l)lnstall
Planetary
carrier
gear.
side
355247
1 STB Revision
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gear assembly
carrier and
with the
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-133
(24)Check that the O.D. clutch and planetary gear set assembly
has been installed completely
by using the special tool.
Measured value - gauge thickness = O.D. clutch assembly
installed height
Standard
value : Approx.
2 mm LO8 in.)
MD99821 7
355248 I
position
the
O-ring
355249
(26)lnstall
37204C
: C.
4
(27)Apply petrolatum
I
I
U
MD99841 2
372041
sealant
: SH700 (Toray)
) STB Revision
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value : 0.3-0.9
mm (.012-.035
in.)
21-I
34 AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
by
O.D. clutch
Forward clutch
Brake No.1
Brake No.2
Direct clutch
Brake No.3
(33)Place parking
spring 3.
(34)lnstall the cam plate, making sure that the parking rod assembly protrudes from the cam plate.
Cam
III
plate
372042
,kze
1
--- I STB Revision
355204
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AUTOMATIC
TRANSMISSIO
- Transmission
and Transfer
Assembly
(36)lnstall accumulator
pistons and springs;
and No.3 (Cl) from front side.
Accumulator
No. 1 (82)
No. 2 (C2)
No. 3 (Cl)
Pistons
IIII
No. 2
31.8 mm
(1.252 in.)
45 mm
(1.772 in.)
No. 3
31.8 mm
(1.252 in.)
49.5 mm
(1.949 in.)
Springs
Identification
Wire
diameter
Ident.
color
Free
length
O.D.
No. 1
66.7 mm
(2.626 in.)
17.3 mm
(.681 in.)
2.8 mm
(.I 10 in.)
No. 2
55.2 mm
(2.173 in.)
16.4 mm
(.646 in.)
2.3 mm
(.091 in.)
No. 3
64.7 mm
(2.547 in.)
17.5 mm
(.689 in.)
2.0 mm
(.079 in.)
(37)lnstall throttle
assembly.
Length
48.5 mm
(1.909 in.)
Accumulator
A3
Identification
O.D.
34.8 mm
(1.370 in.)
Pin
No. 1
372099
ml
21-135
Red
Ial valve
ii,
355254
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uniformly
to
__
21-136 AUTOMATIC
Oil screen
TRANSMISSION
,pipel
Transmission
and
Transfer
Assembly
(43)Attach the magnet to the oil pan (to area directly below the oil
screen).
(44)lnstall the oil pan with oil pan gasket attached. First tighten 14
bolts temporarily
and then tighten to specified torque uniformly.
(45)lnstall
(48)lnstall
Caution
Be sure to use two O-rings.
(49)lnstall torque converter to transmission.
(50)lnstall
the transfer assembly
(P.21-178).
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AUTOMATIC
TRAlWWSSION
- Oil Pump
21437
OIL PUMP
18-25
Nm
1. Oil seal
2. Oil pump body
6. Stator support
7. Seal ring
8. Thrust bearing race #l
9. Thrust bearing #2
10. Thrust bearing race #3
355104
DISASSEMBLY
&,;
INSPECTION
Wash the parts and dry with air. Then, check the following and
replace if faulty.
(1) Oil seal damage
(2) Ridged wear on body and drive gear contact surfaces and
damage to the body crescent portion (indicated by arrow)
35510!
355104
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21-138
AUTOMATIC
TRANSMISSION
- Oil Pump
REASSEMBLY
(1) Apply ATF to the drive and driven gears and install them in the
body.
(2) Assembly the body and stator support and tighten the six bolts
finger-tight.
(3) Tighten outside of the cover and support by using the special
tool.
(4) Tighten the bolts to specified torque.
(5) After reassembly, check with a screwdriver that the drive gear
turns lightly.
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AUTOMATIC
TRANSMISSION
Overdrive
OD clutch cylinder
OD clutch piston
O-ring
O-ring
Return spring
Spring retainer
Snap ring
Clutch plate
Clutch disc
Snap ring No.1
OD brake hub
Snap ring No.2
Snap ring No.3
One-way clutch retainer
One-way clutch assembly
One-way clutch outer race
Thrust washer
Thrust bearing #4
Thrust bearing race #5
Pinion shaft plug
OD planetary gear
Thrust washer
15
16
Clutch
and
Planetary
GEAR SET
17
Gear
Set
21-139
NZlLHE4
22
18
19
<'
:
372045
i,,
Ir
DISASSEMBLY
(1) Remove snap ring No.2 and remove the O.D. brake hub. Then,
disassemble
the O.D. planetary gear set and O.D. clutch assembly.
(2) Remove snap ring No.3 from the O.D.planetary
gear assembly
and remove the thrust washer,
O.D. one-way
clutch, outer
race, thrust bearing and four pinion shaft plugs.
355216
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wision
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21-140
AUTOMATIC
TRANSMISSION
Overdrive
Clutch
and
Planetary
Gear
Set
the piston
with
hand to prevent
it from
pop-
INSPECTION
Wash the disassembled
parts and dry with air before checking the
following. Replace parts that are found faulty.
(1) Check the O.D. planetary gear for pinion wear, damage, turning condition, spline wear and damage.
(2) Check the O.D. one-way clutch for wear and damage of
spring, ribbon spring and outer race.
(3) Check the O.D. clutch cylinder for wear and damage of the
O.D. sun gear and piston slinding surface (cylinder). Also
check for wear and damage of the thrust washer and one-way
clutch contact surfaces and seal ring slinding surface.
(4) Check the clutch disc and plate for wear and damage of the
friction surfaces and of cylinder to hub engaging portions.
(5) Check the clutch piston for wear and damage of its outside
and inside surfaces.
(6) Check the spring for damage and deterioration.
Free length
Standard value : 14.9 mm (.587 in.)
Limit : 14.5 mm (.571 in.)
(7) Shake the piston to check that the check ball is not binding.
Also apply air pressure to the piston to see that it is free from
leaks. Apply air pressure to the piston inside.
355218
In case of no
clutch actuation
In case of clutch
actuation
355116
The O.D. clutch, forward clutch and direct clutch have a check
ball installed inside as illustrated. This is to prevent oil remaining in the cylinder from working to actuate the clutch by centrifugal force that develops when the clutch cylinder is rotated
at high speed. Namely, the centrifugal force developed at high
speed rotation causes the ball to separate from the, seat, thus
opening the oil path to release oil pressure that would otherwise actuate the clutch.
(8) Check the O.D. brake hub for abnormal tooth wear and damage.
(9) Check the bearings, races and thrust washers for wear and
damage.
\ ST6 Revision
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AUTOMATIC
TRANSMISSION
Overdrive
Clutch
and
Planetary
Gear
Set
21-141
REASSEMBLY
(1) Fit new O-rings in inside and outside grooves of the piston.
(2) Apply ATF to the O-rings and insert the piston into the O.D.
clutch cylinder using care not to damage the O-rings.
(3) Install the return spring and spring seat in the clutch cylinder.
Then, place the clutch assembly on a press bench and install
the snap ring by using the special tool.
(4) Install the clutch plates and clutch discs in the clutch cylinder
and fit snap ring No.1 (narrower one).
(5) Install the O.D. brake hub and then fit snap ring No.2 (wider
one).
Clutch disc
(7) Assemble
assembly
noting the
(8) Install the
(9) Install the
bly.
Front -
of the O.D.
race, thrust
:,
directing
355221
(1O)Check operation of the one-way clutch. With the clutch cylinder held by hand, turn the input shaft clockwise to see that the
shaft turns smoothly and turn it counter-clockwise
to see that
the shaft is locked.
!
A
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<:
21-142
OVERDRIVE
AUTOMATIC
TRANSMISSION
- Overdrive
Brake
N2llMA
BRAKE
16
/
1. Snap ring
2. Backing plate
3. Brake disc
4. Brake plate
5. Cushion plate
6. Spring retainer
7. Return spring
8. Brake piston
9. O-ring
10. O-ring
11.. Thrust race
12. Planetary ring
13. Thrust bearing
14. Thrust bearing
15. Thrust bearing
$ 16. OD case
:( 17. Thrust bearing
,# 18. Thrust bearing
19. Seal ring
13 15
gear
race #6
#7
race #8
race #9
#lO
355223
DISASSEMBLY
(1) Remove the snap ring and take out the backing plae, brake
discs, brake plates, cushion plate, thrust washer, planetary
ring gear, bearing and race from the O.D. case.
(2) Remove the snap ring and take out the spring retainer and
return spring.
355224
(3) Blow air into the O.D. case through the oil hole to remove
piston.
(4) Remove the O-ring from the piston.
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the
AUTOMATIC
TFZANSMI
N - Overdrive
21-143
Brake
INSPECTION
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
(1) Check the O.D. case for wear and damage of the piston sliding
surfaces, seal ring and ring groove.
(2) Check the piston for wear and damage of its outside (surface
in contact with the case).
(3) Check the spring for damage and deterioration.
Free length
Standard value : 16.1 mm (.634 in.)
Limit : 15.7 mm (.618 in.)
(4) Check the discs and
surfaces. Also check
and damage.
(5) Check the planetary
surfaces and splines.
(6) Check the bearings,
damage.
of tooth
REASSEMBLY
l
(1) Install new O-rings in the piston outside and inside grooves.
(2) Apply a light coat of ATF to the O-rings and install the piston in
the case, using care not to damage O-rings.
(3) Install the return spring and spring retainer and fit the snap
ring.
Caution
1. Make sure that the springs is installed
nation.
2. Make sure that the snap ring is seated
correctly.
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(4) Install bearing races #6 and #8, thrust bearing #7, planetary
ring gear and thrust washer in the O.D. case. Thrust bearing
races #6 and #8 should be installed in the illustrated direction.
without
(5) Install the cushion plate and then install the brake plates and
brake discs alternately. Then, install the backing plate and fit
the snap ring.
Brake plate
Braky d,/sc ,,/ $shion,plate
Caution
Note the direction
j ST6 Revision
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of the cushion
plate.
21-144
AUTOMATIC
TFIANSMISSIO
Overdrive
Brake
/ Forward
Clutch
value
: 0.35-1.6
mm (M-.062
in.)
=ORWARD CLUTCH
1
I
2
I
11 12111211
12
13
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
14 15
16
372100
DISASSEIUIBLY
(1) Remove the snap ring (for installation of the direct clutch hub)
and remove the direct clutch hub, forward clutch hub and
clutch disc from the clutch cylinder.
(2) Remove the needle bearing and thrust bearing races.
(3) Remove the snap ring and remove the clutch plates and clutch
discs.
MD998207
(4) Place the front clutch cylinder on a press bench and compress
the clutch return spring by using the special tool. Remove the
snap ring.
(5) Remove the spring retainer and return spring.
1 STB Revision
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AUTOMATIC
TRANSMISSION
- Forward
21-145
Clutch
(6) Install the clutch cylinder in the O.D. case and blow air into the
O.D. case through the oil hole to remove the piston from the
clutch cylinder.
(7) Remove the O-ring from the piston.
INSPECTION
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
(1) Check the input shaft and clutch cylinder for excessive wear
and binding of thrust bearing contact surface 1 and bushing
sliding surface 2, for damage of splines 3 and for wear of O.D.
case seal ring contact surface 4.
372049
(2) Check
clutch
surface
surface
(3) Check the front clutch for abnormal wear and damage of teeth
1 and splines 2 and for wear, binding and damage of hub thrust
surface 3.
Coil
STB Revision
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value
: 8.0 mm
value
: 15.1 mm
(.315
(.594
in.)
in.)
21-146
AUTOMATIC
TRANSMISSION
- Forward
Clutch
(6) Check the clutch piston for wear and damage of the outside
(surface in contact with the cylinder). Shake the piston to
check for binding check ball. Also apply air pressure to the
piston inside to check for air leaks.
of
35511'
REASSEMBLY
(1) Install new O-ring in the piston outside and inside grooves.
(2) Apply a light coat of ATF to the O-rings and install the piston in
ttie case, using care not to damage O-rings.
(3) Install the return spring and spring retainer in the clutch cylinder and compress the spring by using the special tool. Fit the
snap ring.
STB
Revision
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AUTOMATIC
TRANSMISSION
- Forward
Clutch
21-147
Plate
37210
(7) The snap ring should be located with its ends as illustrated.
(8) Install one clutch disc and then install the direct clutch hub and
fit the snap ring (wider one) at illustrated location.
,.,J-!
355121
( STB Revision
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21-148
AUTOMATIC
TRANSMISSION
DIRECT CLUTCH
- Direct Clutch
Nz1LHcB
,
45676767
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
372053
DISASSEMBLY
(1) Remove the snap ring and remove the clutch backing plate,
clutch discs and clutch plates from the direct clutch cylinder.
(2) Place the rear clutch on a press bench by using the special
tool, compress the return spring to remove the snap ring.
Then, remove the spring retainer and piston return spring.
(3) Install the clutch cylinder in the center support and blow air
through the oil hole of the center support to remove the piston
from the cylinder.
(4) Remove the O-rings from the piston.
INSPECTION
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
(1) Check the clutch cylinder for wear and damage of grooves 1
and piston sliding surface 2, for wear and damage of thrust
bearing surface and for wear and damage of seal ring sliding
surface.
(2) For inspection of the clutch disc, plate, piston and spring, see
FRONT CLUTCH.
355125
1 ST6 Revision
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AUTOMATIC
TRANSMISSION
Direct
21-149
Clutch
REASSEMBLY
(1) Fit new O-rings in inside and outside grooves of the piston.
(2) Apply a light coat of ATF to the O-rings and insert the piston
into the cylinder using care not to damage the O-rings.
(3) Place the clutch cylinder on a press bench and install the
clutch return spring and spring retainer.
(4) Compress the return spring, fit the snap ring by using the
special tool.
Plate
(5) Install the clutch plates, clutch discs and clutch backing plate
in the clutch cylinder and fit the snap ring.
Disc
Caution
Note the direction
Backing
plate
/ ST6 Revision
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of installation
of the backing
plate.
21450
AUTOMATIC
TRANSMISSION
I- Center Support
CENTER SUPPORT
1.
2.
3.
4.
5.
6.
Seal ring
Snap ring
Snap ring
Clutch backing plate
Clutch disc
Clutch plate
N21LU--
7.
8.
9.
10.
11.
12.
Spring
Brake
Brake
O-ring
O-ring
Center
retainer
return spring
piston
support
DISASSEMBLY
372055
OF BRAKE NO.1
(1) Remove the snap ring from the front of the sun gear and
remove the sun gear (with one-way clutch) from the center
support.
(2) Remove the snap ring from the center support and remove the
backing plate, clutch discs and clutch plates.
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.f
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:- L
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(3) Plate the center support on a press bench by using the special
tool. Compress the spring, remove the snap ring. Then, remove the spring retainer and 12 brake return springs.
Blow air into the oil way of the center support to remove
brake No.1 piston.
(5) Remove the O-rings from the piston.
(6) Remove the seal rings from the center support.
355130
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the
AUTOMATIC
TRANSMlSSlON
21-151
- Center Sumort
INSPECTI(IN
355131
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
(1) Check the center support for damage and deterioration
of the
seal rings, for abnormal wear and ridge wear of seal ring
groove, for abnormal wear and binding of bushing and for wear
of clutch plate slot (section A).
(2) Check the brake piston for damage of its outside (surface in
contact with the center support cylinder). For inspection of the
disc and plate, see FRONT CLUTCH.
(3) Check the brake return spring for damage, squareness and for
compliance with the spring specifications.
Coil
0-D.
Standard
value
Free leng!h
Standard
value
Load at height
Standard
value
REASSEMBLY
.
: 8.0 mm
(.315
: 16.1 mm
(.634
in.)
in.)(reference)
: 21-23N
(4.7-5.2
Ibs.)(reference)
;,
..!.
OF BRAKE NO.1
DISASSEMBLY
For disassembly
REASSEMBLY
of installation
of the backing
AND INSPECTION
and inspection,
plate in the
plate.
OF BRAKE NO.2
OF BRAKE NO.2
(1) Install new O-rings on outside and inside of the No.2 brake
piston.
(2) Apply a light coat of ATF to the O-rings and insert the piston in
the cylinder, using care not to damage the O-rings.
(3) Place the center support on a press bench and fit 12 brake
return springs in recesses of the piston. Then place the spring
retainer thereon.
1 STB Revision
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, %
21-152
AUTOMATIC
TRANSMISSION
Center
Support
(4) Compress the springs and fit the snap rings by using the special tool.
(5) Install the clutch plates, clutch discs and backing plate in the
support and fit the snap ring.
I
Caution
Note the direction
of installation
of the backing plate.
Plate
Backing
Disc
\
plate
372102
INSPECTION
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
Caution
When drying the one-way
is likely to pop out.
clutch
(1) Fix the brake No.2 hub (outer race) and check that the sun gear
(inner race) turns smoothly when rotated clockwise and that it
locks securely when rotated counter-clockwise.
If the one-way clutch is found faulty, replace the brake No.2
hub and one-way clutch assembly.
(2) Remove the sun gear from the one-way clutch 1 and check for
wear and damage of its surface contacting with the one-way
clutch springs. Also check for wear and damage of the seal
ring and ring groove and for damage of the sun gear teeth 3
and splines 4.
REASSEMBLY
Seal ring
groove
372056
r
) STB Revision
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ATIC TRANSMISSIO
One-Way
Clutch
No.
2 and
Front
Planetary
Gear
Set
21-153
NZILK-
4. Thrust washer
5. Front planetary gear
6. Thrust washer
355136
DISASSEMBLY
(1) Disassemble the one-way clutch inner race and front planet&-y
,.r,
carrier.
(2) Remove the retaining ring from the front planetary carrier and
remove the one-way clutch No.2 assembly and thrust washers.
355137
INSPECTION
i.
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
Caution
When drying the one-way
is likely to pop out.
clutch
(1) Check the thrust washers 1 and 2 for wear, bend and binding.
(2) Check the front planetary gear for wear of carrier thrust surface 3, for wear and damage of pinion 4 and for wear of the
one-way clutch outer race surface.
(3) Check one-way clutch No.2 for wear and damage of springs,
ribbon and sprag.
355136
1 STB Revision
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21 -I 54
AUTOMATIC
TRANSMISSION
one-way
Clutch
Planetary
Gear
set
(4) Check the one-way clutch inner race for wear and damage of
teeth 1 and disc sliding surface 2 and for wear and damage of
inner race surface 3.
355139
REASSEMIBLY
(1) Install the thrust washer (front) on the planetary gear.
(2) Install two end bearings on the one-way clutch and noting the
direction, install the clutch on the front planetary gear and fix
with the retaining ring.
(3) Install the one-way clutch inner race on the front planetary
carrier.
(4) Fix the inner race and check that the outer race (planetary gear
carrier) turns smoothly when rotated counter-clockwise
and
that it locks securely when rotated clockwise.
(5) Apply Vaseline to the thrust washer (rear) and attach it to the
front planetary gear carrier.
STB Revision
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AUTOMATIC
IEAR PLANETARY
TRANSMISSIO
Rear
Planetary
Gear
and
Output
Shaft
21-155
N21 LZ--
#18
372057
lb
1. Thrust
2.
3.
4.
5.
washer
6.
7.
8.
9.
10.
Intermediate shaft
Thrust bearing #17
Rear planetary ring gear
Retaining ring
Thrust bearing race #18
11.
12.
13.
14.
15.
DISASSEMBLY
:I:
(1) Loosen the retaining ring and remove the intermediate
shaft
1
(front planetary ring gear and rear planetary gear) from the
i
output shaft assembly.
(2) Remove the front planetary ring gear, thrust washer
and rear +
planetary gear from the intermediate
shaft.
i
i
INSPECTION
Wash the removed parts and dry with
ing and replace faulty parts.
the follow-
(1) Check the front planetary ring gear for wear and damage
internal gear teeth 1 and parking pawl teeth 2.
1 STB Revision
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of
>iI*
21456
AUTOMATIC
TRANSMISSION
Rear
Planetary
Gear
and
Output
Shaft
(3) Check the rear planetary gear for wear of the carrier thrust
surface, for wear, damage and play in thrust direction of the
pinion.
(4) Check the rear planetary ring gear for wear and damage of the
internal gear teeth and internal splines.
of flange thrust
surface 2 and for
way 4.
wear and binding
Also check the
REASSEMBLY
(1) Install thrust bearing #17 on the intermediate
shaft and then
install the rear planetary ring gear and fix with the retaining
ring.
/ STB Revision
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AUTOMATIC
TRANSMISSION
Rear
Planetary
Gear
and
Output
Shaft
2%157.
(5) Install the retaining ring on the front planetary ring gear and
install the ring gear on the output flange while compressing
the retaining ring.
Caution
Pay attention
1 STB Revision
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to location
of retaining
ring ends.
21458
AUTOMATIC
TFtANSMlSSOON
- Brake No. 3
BRAKE NO. 3
1.
2.
3.
4.
5.
Retaining ring
One-way clutch inner race
Clutch disc
Clutch plate
Backing plate
N21uaA
6.
7.
8.
9.
10.
11. O-ring
12. Reaction sleeve
13. Brake No.3 secondary piston
372050
DISASSEMBLY
(1) Compress the :spring and remove the snap ring by using the
special tools.
(2) Remove the spring retainer and 16 piston return springs.
For inn,er
piston
usand
and
rag
(4) Remove primary piston 2 and secondary piston 3 from reaction sleeve 1.
(5) Remove O-rings from the pistons and reaction sleeve.
STB Revision
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AUTOMATIC
TRANS
ISSION
- Brake
No. 3
21-159
INSPECTION
Wash the removed parts and dry with air. Then, check the following and replace faulty parts.
(1) Check the clutch discs and clutch plates for wear and binding
of the friction surfaces and for wear of parts in engagement
with the transmission
case and hub.
(2) Check the backing plate for wear and binding of disc friction
surface and for wear and damage of brake apply tube contact
surface.
355158
REASSEMBLY
(1) Install new O-rings on the primary and secondary
reaction sleeve.
(2) Apply ATF to the O-rings and push inner piston 2
sleeve 1 and then install outer piston 3.
(3) Slide the pistons and reaction sleeve assembled
above into the cylinder, using care not to damage
355159
(4) Apply grease to 16 brake return springs and install them on the
outer piston. Then, install the spring retainer.
(5) Compress the springs and fit the snap ring by using the special
tools.
Sna? ring
M D998207
MD99821 1
355154
( ST6 Revision
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21-160
AUTOMATIC
TRANSMISSION
- Valve Body
VALVE BODY
NzllO--
7776
6
da
I
3@so
R~k-3
72
&
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71
70
Q A
372061
AUTOMATIC
ISSION
TRA
1. Throttle cam
2. Cam spacer
3. Return spring
4. Throttle valve
5. Throttle valve primary spring
6. Kickdown valve
7. Upper front valve body
8. Check valve
9. Check ball
10. Throttle valve keep plate
11. Secondary regulator valve spring
12. Secondary regulator valve
13. Front valve end cover
14. 1-2 shift valve
15. l-2 shift valve plug
16. Valve retainer
17. 3-4 shift valve
18. 3-4 shift valve plug
19. Locating pin
20. D-2 down timing valve
21. D-2 down timing valve plug
22. Valve retainer
23. Primary regulator valve
24. Primary regulator valve Spring
25. Primary regulator valve plunger
26. Primary regulator valve sleeve
27. Valve retainer
28. Check valve
29. Check valve
30. Manual valve
31. Plate
32. Oil screen gasket
33. Oil screen
34. Pressure relief valve
35. Pressure relief valve spring
36. Retainer
37. Detent spring
38. Detent spring plate
39. Lower valve body cover gasket (upper)
40. Lower valve body cover plate
41. Lower valve body cover gasket (lower)
42. Lower valve body cover
- Valve Body
21-161
.. )
1:
I
..:
j.
ST6 Revision
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21-162
AUTOMATIC
TRANSMISSION
- Valve
Bodv
DISASSEMBLY
For disassembly, observe the precautions given below.
(1) Keep the disassembled
parts orderly for efficient reassembly
operation. Attach tags to springs for identification.
(2) When disassembling
the valve, do not attempt to remove the
valve with undue force. The valve and valve hole could be
damaged or burred, leading to faulty valve operation.
(3) When removing the front upper and rear valve bodies from the
lower valve body, use care not to lose check balls and springs.
INSPECTION
Wash the removed
ing checks.
Caution
When making ctnecks, use care not to damage
side and valve body holes.
Throttle valve
Kick-down
valve
I
Secondan/ regulator valve
355161
STB Revision
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AUTOMATIC
TRANS
ISSION
21-163
- Valve Body
Intermediate
modulator
valve
*-
valve
dete-zf
1,
!
.5.
timing valve
mllml
t
Primary regulator
valve plunger
Manual valve
372063
ST6 Revision
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:.(
<i
21-164
Valve Spring
AUTOMATIC
TRANSMISSION
Identification
~TB
Revision
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- Valve
Body
AUTOMATIC
TRA
ISSION
Body
- Valve
21-165
REASSEMBLY
Caution
Before reassembly,
wash the parts in a clean detergent
and
dry with air. Do not wipe with rags for drying. Entry of dust
could cause faulty valve operation.
(1) Install primary regulator valve 1, spring 2, plunger 3 and sleeve
4 in the lower valve body in the order shown and insert retainer 5 to prevent the valve and other parts from coming
loose.
(2) Install l-2 shift valve 1 and valve plug and insert retainer 3 to
prevent the valve from coming loose.
'3
355165
(3) Install 1-2 shift valve spring 1, low coast shift valve 2 and plug
3 and fit low coast shift valve cover 4.
372064
(5) Install spring, check valve and check valve spring at illustrated
locations.
/;
STB Revision
1
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,.,.:
?:.
21466
AUTOMATIC
Plug
TRANSMISSION
- Valve Body
(6) Install the spring, 3-4 shift valve and plug and then inset-t the
locating pin.
355234
D-2 down
hole ~~,:,
ys
Seat /355235
(8) install 2-3 shift valve spring 1, 2-3 shift valve 2, 2-3 shift valve
plug 3 and retainer 4 in the upper rear valve body.
(9) Install intermediate
coast shift valve 5, plug 6 and retainer 7.
3 in the
(1l)lnstall
low coast modulator valve 1, plug 2, reverse brake sequence valve 3 and intermediate
coast modulator valve 4.
(12)lnstall valve springs.
(13)lnstall rear valve cover 5.
372065
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evision
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AUTOMATIC
TRA
ISSION
21-167
- Valve Body
locations
in oil ways in
(15)When installing the lower valve body cover, use the correct
gasket. One with oval holes for check balls is for the lower
valve body.
COVW
gasket 355233
.,
(16)lnsert secondary regulator valve spring 1 and secondary reg:.^.
ulator valve 2 in the front upper valve body and install front
valve end cover 3.
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3
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35517:
1,
(18)lnstall the throttle cam and spring on the upper front valve
body and tighten bolts temporarily.
When installing, note the
location of the spring end on the body side. Then, hook the
other end of the spring to the cam and bolt the cam to the
valve body. After installation, check that the throttle cam turns
through full stroke smoothly.
Caution
Hook the spring
!J
1 ST6 Revision
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to the correct
hole.
21-168
AUTOMATIC
TRANSMISSION
- Valve Body
(19)lnstall cut back valve 1, valve plug 2 and retainer 3. Install the
cut back plug with the larger land end facing out.
355176
(20)lnstall
location.
355177
(21) Place a new lower valve body gasket on the lower valve body.
NOTE
Do not use gasket for the upper valve body.
355237
bolts at illustrated
loca-
(23)Piace a gasket for upper valve body, aligning with the separator plate.
(24)While using care not to disturb check valve position on the rear
upper valve body, install the lower valve body onto the rear
upper valve body and tighten the bolts (indicated by (A)) temporarily from the lower valve body side.
(25)Remove the two bolts tightened in step (22).
(26) Install the lower valve body onto the rear upper valve body and
tighten the bolts (indicated by (B)) temporarily from the lower
valve body side.
(27) Install the detent plate.
[ ST6 Revision
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AUTOMATIC
TRA
ISSION
- Valve Body
21-169
(28)lnstall the lower valve body onto the upper front valve body
and temporarily tighten the bolts shown at left from the lower
valve body side.
355240
tighten
the
(30)Then, temporarily
tighten the remaining valve body bolts as
,!
illustrated.
FI
(31)Tighten all bolts of the valve body to specified torque.
$:
(32) Install the manual valve.
;
.
Fi
le
1 STB Revision
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21-170
AUTOMATIC
TRANSMISSION
- Governor
GOVERNOR
&a-3
1.
2.
3.
4.
5.
6.
7.
8.
9.
E-ring
Governor weight
Governor valve
Outer governor spring
Inner governor spring
Secondary weight
Governor valve shaft
Governor body
Governor retaining ring
DISASSEMBLY
(1) Remove the E-ring 1 and remove governor weight 2.
(2) Remove governor shaft 3, spring and governor valve in the
direction of arrow. Remove the governor valve from the output
shaft hole.
INSPECTION
Wash removed parts and dry with air. Then, make the following
checks.
(1) Check the governor valve for damage and wear and check that
it slides smoothly while rotating it in the body.
(2) Check the governor body for damage and wear of the valve
sliding surface and for clogging of the oil hole and oil way.
(3) Check the governor spring.
Outer
Inner
mm (in.)
15.34 (.604)
11.55 (.455)
Free length
mm (in.)
12.76 (.520)
11.49 (.452)
Wire diameter
mm (in.)
0.85 (.034)
0.85 (.034)
White
White
Identification
color
REASSEMBLY
Reassemble
the governor
verse order.
) STB Revision
-/
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following
the disassembly
steps in re-
AUTOMATIC
TRANSMISSION
Transmission
Case / Manual
Valve Lever /
Parking
System / Throttle
Control
Cables
TRANWHSSION
CASE
21-171
umu0--
INSPECTION
Make the
(1) Check
(2) Check
(3) Check
(4) Check
(5) Check
following checks
the bushing for
the accumulator
the brake No.3
the case inside
mating surfaces
MANUAL
VALVE LEVER
INSPECTION
Make the following checks and replace faulty parts.
(1) Check the lever detent spring collar contact surface 1 for wear
and damage.
(2) Check manual valve lever pin 2 for wear.
(3) Check shaft 3 for wear.
(4) Check slotted spring pin 4 for wear.
Caution
When disassembled,
spring
pin.
.{
,2;
.8
?
3.
PARKING SYSTEM
2
i
INSPECTION
1
a=D
4
d
8:
+\3
QQ
372057
THROlTLE
CONTROL CABLES
INSPECTION
Make the
(1) Check
(2) Check
(3) Check
(4) Check
355188
/
levision
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.,i-.
3
21-172
AUTOMATIC
TRANSMISSION
Th rust
Bearings
and
Thrust
Washers
/ Adapter
INSPECTION
(1) ~Check the thrust bearings and thrust washers
binding and replace if faulty.
ADAPTER
INSPECTION
(1) Check the adaoter rear end for leaks and check the oil seal lip
for damage anb replace the oil seal if faulty.
When installing the oil seal, apply grease to its lip.
1. Oil seal
2. Gasket
3. Adapter
372068
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AUTOMATIC
T ANSMISSION
21473
Transfer
TRANSFER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Snap ring
Spring retainer
Shift rail assembly
Cotter pin
H-L shift fork
Spring
Steel ball
Stopper plate
Clutch sleeve
Clutch hub
Bearing
Rear output shaft
NZIND--
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26,
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
STB Revision
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Buffle plate
Side cover gasket
Dust seal guard
Oil seal
Transfer case
Chain cover gasket
O-ring
Thrust washer
Needle bearing
Bearing spacer
Counter gear shaft
Counter gear
Lock plate
Dust seal guard
Dust seal
Rear cover
Rear cover gasket
Steel ball
4WD lamp switch
Seal plug
Poppet spring
Steel ball
Cord fastener
50.
51.
52.
53.
Interlock plunger
Ball bearing
Steel ball
Chain
54.
55.
56.
57.
Needle bearing
Sprocket sleeve
Drive sprocket
Bearing
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
j:
2
i
(
:
;
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i.;
148014
?LE
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21-174
AUTOMATIC
TRANSMISSION
- Transfer
REMOVAL
(1) Remove
take out
(2) Remove
ket.
(3) Remove
(4) Pull the
the plug from the right side of the transfer case and
the select spring and select plunger.
the control lever housing assembly, cover and gasthe transfer case to adapter attaching bolts and nuts.
transfer case back to separate from the adapter.
DISASSEMBLY
(1) Remove two 4WD light switches.Take
out two steel balls.
(2) Remove the speedometer
sleeve clamp and remove the
speedometer
sleeve assembly.
(3) Remove the rear cover attaching bolts and remove the spacer
and gasket.
(4) Remove the cover (front output shaft portion) and take out the
wave spring, spacer (if inserted) and gasket.
(5) Remove the side cover and gasket.
(6) Drive out the spring pin from the H-L shift fork by using the
special tool or a pin punch (commercially
available).
(7) Remove the two seal plugs and take out the two poppet
springs and balls.
(8) Pull out the H-L shift rail rearward.
(9) Take out the interlock plunger.
(lO)Remove
the snap ring from the rear output shaft rear bearing.
(1 l)Remove
the chain cover.
(12)Remove the oil guide.
(13)Remove
the countershaft
countershaft.
j STB Revision
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locking
plate
and pull
out the
AUTOMATIC
Thrust\ washer
Counter gear
TRANSMISSION
21475
- Transfer
and needle
144011
(15) Remove the snap ring from the 2-4WD shift rail and remove
the two spring retainers and spring from the shift rail.
i,.
d
J-
(17)Remove
(18)Remove
(19)Remove
(20)Remove
the
assembly.
http://vnx.su/
remove
the input
gear
21-176
AUTOMATIC
TRANSMilSSlON
DISASSEMBLY
- Transfer
OF REAR OUTPUT
SHAFT
(1) Remove the snap ring from the rear output shaft front end and
remove the H-L clutch hub, low speed gear, thrust washer and
needle bearing.
(2) Pry up the staked portion of the rear output shaft lock nut and
loosen and remove the lock nut.
(3) Remove the ball bearing from the rear end using a bearing
puller (commercially
available) or a press.
(4) Remove the sprocket spacer and steel ball.
(5) Remove the drive sprocket, two needle bearings, sprocket
sleeve and steel ball.
(6) Remove the 24WD clutch sleeve, hub and stop plate and pull
out the ball bearing using a puller or press.
456
123
13
14
15 16
1. Snap ring
2. H-L clutch hub
3. Low speed gear
4. Ball bearing
5. Stop plate
6. 24WD clutch sleeve
9 10
78
7.
8.
9.
10.
11.
12.
17
11
12
18
Thrust washer
Needle bearing
Needle ball
Sprocket sleeve
17. Needle bearing
18. Steel ball
13.
14.
15.
16.
144616
ST6 Revision
-1
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AUTOMATIC
TRANSMISSION
21-177
- Transfer
Also check
The clutch
Front
1
For H-L
For 2-4WD
144023
148012
(4) Install a snap ring for H-L clutch hub on the front end of the
1,
rear output shaft. Use the thickest snap ring that fits in the
groove.
(:
H-L clutch hub end play
Standard value: O-0.08
mm (O-.003
in.)
(5) Tighten the lock nut to specified torque and then stake at the
illustrated location, aligning with the groove.
(6) Check that the low speed gear and drive sprocket ball bearing
rotate smoothly.
] STB Revision
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21-178
AUTOMATIC
TRANSMISSION
- Transfer
REASSEMBLY
(1) Press fit new oil seals in the input gear portion and front output
shaft portion of the transfer case. Fit the baffle plate on the
input shaft side. Apply specified oil to the oil seal lips.
Specified
gear oil
: Hypoid
Gear Oil API Classification
GL-4 or higher
SAE viscosity
No.
mw, 75w-a5w
14800E
value
: 0 - 0.06 mm (O-.002
in.)
(4) Insert the input gear assembly in the transfer case and fit a
snap ring. Use the thickest one that fits in the groove.
Standard
value : 0 - 0.06 mm (O-.002 in.)
(5) Insert the needle bearing in the input gear.
1 ST6 Revision
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AUTOMATIC
TRANSMISSION
21-179
- Transfer
(8) Engage chain securely with the rear output shaft and front
output shaft sprockets. Then, install the rear and front output
shafts and chain together, while sliding the 2-4WD shift fork
with the clutch sleeve attached over the 2-4WD shift rail.
..
;
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(9) Install two spring retainers and spring over the 2-4WDshift
and fit a snap ring.
rail
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. :,
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;
Thrust
Counter
washer
(10) Insert two needle bearings and spacer in the counter gear and
install the assembly in the transfer case. Install a thrust
washer on each of the counter gear.
gear
(1l)lnser-t
the countershaft
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plate.
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,
.
21-180
AUTOMATIC
TRANSMISSION
- Transfer
g>
144626
sealant
(14)Tighten
the chain cover bolts to specified torque. Apply
a,dhesive to threads of bolts fitted in holes that go through
the case.
Nut Locking
4171 or
Specified adhesive
: 3M Adhesive
equivalent
(15)Fit a snap ring in the groove of the bearing at the rear end of
the rear output shaft.
Spring pin
r( d
(19)Aligning the spring pin holes of the H-L shift fork and shift rail,
drive in the spring pin by using the special tool or a pin punch
(commercially
available). When installing the spring pin, face
its slit toward the shift rail center.
(20)Measure
the output shaft rear bearing protrusion A and rear
cover recess B to calculate the end play. Select the spacer that
gives specified end play.
(21)Apply sealer to a new rear cover gasket and attach it to the
chain cover side.
Specified
) STB Revision
sealant
-1
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AUTOMATIC
TRANSMISSION
21-181
- Transfer
(22)lnstall the selected spacer on the rear of the output shaft rear
bearing.
(23)lnstall
the rear cover and tighten the bolts to specified
torque. Apply adhesive to threads of bolts fitted in holes
that go through the case.
Specified
Nut Locking
4171 or
/144Q28j
I A
(.
2
A Gasket
Specified
sealant
Specified
(26)lnstall the wave spring spacer (if necessary) on the rear of the
bearing.
(27)lnstall the cover and tighten the bolts to specified torque.
Apply adhesive to threads of bolts.
: 3M Adhesive
equivalent
adhesive
adhesive
: 3M Adhesive
equivalent
Nut
Locking
I
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@
4171 0;:.
..:T
>.:
I+.
Wave spring
Spacer
II
148011
Extension
housing
Mating mark
13404!i
1 ST6 Revision
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light switches,
making
21-182
AUTOMATIC
TRANSMISSION
- Transfer
REASSEMBLY
For reassembly,
follow the removal
steps in reverse order,
paying attention
to the following.
1. Apply sealer to one side of the two control housing
gaskets and attach them to both sides of the control
liousing
cover.
Specified
2. Apply
sealant
sealer
Specified
to the adapter
sealant
( ST6 Revision
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gasket.
21-l
TRANSMISSION
MANUAL AND
UTOMATIC
CONTENTS
AUTOMATIC
TRANSMISSION
.........................
48
ADAPTER
.............................................................................
BRAKE NO. 3 .......................................................................
CENTER SUPPORT
.............................................................
DIRECT CLUTCH .................................................................
FORWARD CLUTCH
...........................................................
GENERAL INFORMATION
..................................................
GOVERNOR
.........................................................................
MANUAL VALVE LEVER ....................................................
OIL PUMP ............................................................................
ONE-WAY CLUTCH NO. 2 AND FRONT PLANETARY
GEAR SET ............................................................................
OVERDRIVE BRAKE ............................................................
OVERDRIVE CLUTCH AND PLANETARY GEAR SET .......
PARKING SYSTEM .............................................................
REAR PLANETARY GEAR AND OUTPUT SHAFT .............
SERVICE ADJUSTMENT
PROCEDURES
...........................
SPECIAL TOOLS
.................................................................
SPECIFICATIONS
................................................................
General Specifications
..................... ..............................
Lubricants
................ ...................... . .............................
Sealants and Adhesives
...... .............. ........................
Service Specifications
............. ................................ ....
.....................................................
Torque Specifications
172
158
150
148
144
48
170
171
137
THROl7LE
CONTROL CABLES .........................................
THRUST BEARINGS AND THRUST WASHERS
................
TRANSFER
...........................................................................
TRANSFER CONTROL
........................................................
TRANSMISSION
AND TRANSFER ASSEMBLY
................
TRANSMISSION
CASE .......................................................
...............................................
TRANSMISSION
CONTROL
...........................................
TRANSMISSION
OIL CoO&R
TROUBLESHOOTING
.........................................................
Circuit Diagram .................... .........................................
Converter Stall Test ........................................................
Fluid Level and ATF Condition
..... .............. .................
171
172
173
115
119
171
109
117
98
104
101
98
153
142
139
171
155
106
96
90
90
95
95
92
93
NZlAA-
General ...........................................................................
..............................................
Governor Pressure Test
Inhibitor Switch ...............................................................
........................................................
Line Pressure Test
Manual Linkage ...............................................................
Road Test ........................................................................
.............................................................
Selector Lever
Throttle Control Cable .....................................................
VALVE
BODY
MANUAL
TRANSMISSION
..*...................,
........
98
102
99
103
99
99
99
99
160
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42
31
11
18
9
21-2
GENERAL
MANUAL
TRANSMISSION
- General
Information
INFORMATION
NPlBAAF
within
an
145110
( STB Revision
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MANUAL
TRANSMISSION
21-3
- Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NZlCA--
Specifications
Items
Model
KM145
Transmission
5-speed 4-wheel
Type
Gear ratio
1 st
3.967
2nd
2.136
3rd
4th
1.360
1.000
5th
0.856
Reverse
3.578
4.625
4.875 (Option)
2618 ,,, Final gear ratio 4.625
2718 ._. Final gear ratio 4.875 (Option)
drive
gear ratio
Transfer case
Constant
Type
Gear ratio High
1.000
1.944
Low
Drive system
mesh type
Front wheel
Chain drive
Rear wheel
Direct drive
2.30
2.35
2.40
2.45
2.50
No.
(.091 )-White-MD701729
(.093)-Brown-MD701730
(.094)-None-MD701731
(.096)-Blue-MD701732
(.098)-Yellow-MD701733
No.
0.84(.033)-Black-MD701845
0.93 (.037)-None-MD701839
1.02 (.040)-Red-MD701840
1 .ll (.044)-White-MD701841
1.20 (.047)-Yellow-MD701842
1.29 (.051)-Blue-MD701843
1.38 (.054)-Green-MD701844
No.
2.15(.085)-Blue-MD701761
2.22 (.087)-None-MD701762
2.29 (.090)-Brown-MD701763
2.36 (.093)-White-MD701764
Thickness
mm (in.)-ldent.
1 STB Revision
http://vnx.su/
21-4
MANUAL
TRANSMISSION
- Specifications
Specifications
Items
Snap ring for input gear assembly
mm (in.)-color
Thickness
2.70 (.106)-Purple
2.75(.108)-Pink
2.80(.1 IO)--Yellow
2.85 (.I 1.&-White
2.90 (.I 14)~-Blue
mm (in.)-color
2.14
2.21
2.28
2.35
2.42
(.084)--None
(.087)--Yellow
(.090)--White
(.093j-Blue
(.095t-Red
2.30
2.35
2.40
2.45
2.50
(.091 )--None
(.093)--Red
(.094)--White
(.096)--Blue
(.098)--Green
mm (in.)-color
SERVICE
0.84 (.033)-Black
0.93 (.037)--None
1.02 (.040)--Red
1.11 (.044)--White
1.20 (.047)-Yellow
1.29(.051)-Blue
1.38(.054)-Green
SPECIFICATIONS
Specifications
Items
Standard value
Front bearing retainer and bearing clearance
mm (in.)
Main drive gear end play
Counter gear end play
Input gear end play
Output shaft end play
nchronizer
mm (in.)
O-O.1 (O-.004)
mm (in.)
mm (in.)
mm (in.)
by spacer
by snap ring
:.
-1
http://vnx.su/
by snap ring
0.5 (.020)
STB Revision
.C
by spacer
mm (in.)
Adjustment
Adjustment
by spacer
MANUAL
TRANSMISSION
21-5
- Specifications
TORQUE SPECIFICATIONS
NPlCC-
Items
Nm
ft.lbs.
Manual transmission
Transmission
mounting
bolts
43-55
32-39
22-32
16-23
250-270
20-60
181-195
15-43
8-10
160-I 90
5.8-7.2
116-737
20-60
15-43
30
22
bolts
60
43
30-35
22-25
15-22
11-16
15-22
11-16
IO-13
IO-12
7.2-9.4
15-22
11-16
15-22
11-16
bolt
bolts
bolt
7-9
Transmission
control lever mounting bolt
Rear propeller shaft to rear differential
15-22
11-16
50-60
36-43
Front exhaust
20-30
15-22
55-75
31-42
40-54
22-29
18-25
13-18
18-25
13-18
A, B
43-55
31-40
D. E
20-27
15-20
pipe mounting
bolt
No. 2 crossmember
to body
Clutch release cylinder mounting
Engine mounting
Engine mounting
Transmission
bolt
to engine
/ STB Revision
http://vnx.su/
21-6
MANUAL
TRANSMISSION
Items
Transfer
-Specifications
Nm
ftlbs.
15-22
11-16
IO-13
7.2-9.4
30-42
22-30
22-30
case
bolt
bolt
Adapter to transfer
case mounting
30-42
8-10
5.8-7.2
15-22
11-16
Cover bolt
15-22
11-16
15-22
11-16
30-35
22-25
Drain plug
30-35
22-25
30-35
22-25
15-22
100-l 30
11-16
72-94
Speedometer
15-22
11-16
30-42
light switch
30
IO-13
22-30
22
Seal plui
4WD indicator
Transfer
7-9
50-60
18-25
3643
13-18
Transfer
18-25
13-18
mounting
bracket to body
1 STB Revision
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MANUAL
TRANSMISSION
21-7
-Specifications
LUBRICANTS
NBlCD-
Items
Specified
lubricant
Quantity
Transmission
3.9 Imp.
Transfer
3.9 Imp.
Multipurpose
No. 2
grease
SAE J310,
NLGI
As required
Multipurpose
No. 2
grease
SAE J310,
NLGI
As required
case
Sliding
lever
Sliding
SEALANTS
control
control
lever
AND ADHESIVES
Items
NZlCE-
Specified
seatants
and adhesives
Quantity
Control
housing
or equivalent
As required
Control
lever gasket
or equivalent
As required
or equivalent
As required
Housing
cover gasket
Stopper
bracket
installation
bolt
As required
Stopper
bracket
installation
bolt (threads)
3M Scotch
As required
Extension
Adapter
gasket
gasket
Front bearing
retainer
or equivalent
As required
As required
As required
As required
Cover gasket
As required
3M Adhesive
As required
Cover installation
Rear cover gasket
bolt (threads)
Nut Locking
4171 or equivalent
As required
:.
.,. i
http://vnx.su/
21-8
MANUAL
TRANSIWSSION
-Special Tools
SPECIAL TOOLS
Tool (Number
and name)
NZlDA--
I
Use
Tool (Number
MD998020
Bearing puller
M D998067-0 1
Mainshaft bearing installer
Driving in of mainshaft
bearing
M D998029-0 1
Main drive gear bearing
installer
M D998200-0 1
Front bearing retainer oil seal
installer
VlD998348-0 1
Taper bearing puller
lqemoval
MB990938-01
Handle
vl IT4336
Searing driver handle
IJse with
Pvl D998067-0 1,
rvl D998029-01
[Iriving in of main drive
Eyear and mainshaft
tIearing
M D998245-01
Lock pin installer
MD998028
Bearing puller adapter
of counter
shaft bearing
http://vnx.su/
and name)
Use
MANUAL
TRANSMISSION
- Troubleshooting
TROUBLESHOOTING
21-9
NZlEAAC
..
,-*::
_
1 STB Revision
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:i
-: ..
MANUAL
TRANSMISSION
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
PROCEDURES
NZlFFM
CHANGING
AND INSPECTION
SION AND TRANSFER OIL
OF TRANSMIS-
1.
2.
Drain dua
n!mnn71
GL-4
or higher
3.9 Imp.
3.9 Imp.
pints)
pints)
098002;
6. Tighten
098002:
REPLACEMENT
Rear
or a similar
Caution
Use a new oil seal.
(3) Apply a coating of the specified
seals.
Specified
Grease
OBW528
( ST6 Revision
/
http://vnx.su/
tool, remove
: Multipurpose
NLGI No. 2
grease
SAE
J310,
MANUAL
TRANSMlSSlON
TRANSMISSION
REMOVAL
AND
20-30
- Transmission
AND TRANSFER
and
Transfer
21-11
Assembly
ASSEMBLY
NZIMA--
INSTALLATION
Nm
30-35
Nm
ft.lbs.
18-25
,13-18
50-60
36-43
Nm
ft.lbs.
Nm
ft.lbs.
/
18-25
13-18
Nm
ft.lbs.
Nni
ft.lbs:
55-75. Nm
40-54 ft.lbs.
qemoval
l *
w
+I)
l 4
l +
steps
I,
2.
3.
4.
5.
6.
7.
8.
9.
10.
+e l + 11.
12.
13.
14.
l e e+ 15.
Transmission
shift lever knob
Transfer
shift lever knob
Front floor console
Speedometer
cable
Rear propeller
shaft
Front propeller
shaft
Front exhaust
pipe mounting
bolt
Bell housing
cover
Connection
of 4WD indicator
light
stiitch
f$haust
pipe mounting
bracket
Clutch release
cylinder
Transfer
mounting
bracket
No. 2 crossmember
Engine
mounting
rear insulator
Transmission
and transfer
assembly
NOTE
(1) Reverse the removal procedures
to reinstail.
(2) l * : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installat,i$n.
, e
Nm
ft.lbs.
O.D. x Length
.*.
STB Revision
http://vnx.su/
-.,
-.-I--
21 -12
MANUAL
TRANSMISSION
- Transmission
SERVICE
POINTS
and Transfer
Assembly
OF REMOVAL
5. REMOVAL
OF REAR PROPELLER
PELLER SHAFT
Refer to GROUP 16 PROPELLER
JOINTS - Propeller
Shaft
11. REMOVAL
Refer
OF CLUTCH
to GROUP
SHAFT/G.
SHAFT
RELEASE
6 CLUTCH
NZlMEAG
FRONT
AND
PRO-
UNIVERSAL
CYLINDER
- Clutch
Release
Cylinder.
15. REMOVAL
OF TRANSMISSION
AND TRANSFER
Caution
When removing
the transmission
from the engine, care
must be taken not to shake or rock with force, because
to do so might
cause damage
to the end of the main
drive gear, the pilot bearing,
or the clutch disc, etc.
(1) Disconnect
the transmission
and transfer
assembly
from the engine by pulling it slowly toward
the rear of
the vehicle.
(2) When
the transmission
and transfer
assembly
are
lowered,
tilt. the front of the transmission
downward
and slowly
lower forward,
while
using care to make
sure that the rear of the transmission
does not interfere
with the No. 4 crossmember.
SERVICE
POINTS
15. INSTALLATION
ASSEMBLY
OF INSTALLATION
OF TRANSMISSION
NZlMDAH
AND
TRANSFER
http://vnx.su/
MANUAL
TRANSMISSION
- Transmission
and Transfer
11. INSTALLATION
OF CLUTCH
Refer to GROUP 6 CLUTCH
Assemblv
21-13
RELEASE CYLINDER
- Clutch Release Cylinder.
6. INSTALLATION
OF FRONT PROPELLER
SHAFT/5.
REAR
PROPELLER
SHAFT
Refer to GROUP 16 PROPELLER
SHAFT AND UNIVERSAL
JOINTS - Propeller
Shaft.
2.
INSTALLATION
Refer to P.21-43.
http://vnx.su/
OF TRANSFER
SHIFT
LEVER
KNOB
-r__._
j@-
21-14
MANUAL
TRANSMISSION
DISASSEMBLY
TRANSMISSION
Transmission
and
Transfer
Assembly
NZlMEC
AND REASSEMBLY
07
/
Nm
30-35
22-25
ft.lbs.
\?*
22-25
30-42
22-30
Disassembly
Nm
ft.lbs.
!
145075
steps
.$
4.
.-
2.
3.
4.
5.
.I 6.
l * 7.
8.
9.
ftlbs.
16.
17.
18.
19.
Seal plug
Neutral return spring
Neutral return plunger (B)
Neu&l return plunger (A)
NOTE
(1) Reverse the disassemblyproceduresto reassemble.
(2) l + : Refer to Service Points of Reassembly.
(3) q
: Non-reusableparts
http://vnx.su/
95-22
11-16
Nm
ft.lbs.
13--LL
Nrn
11-16
klbs.
30 Nm
22 ft.lbs.
6dNm
43 ftlbs.
146076
Disassembly
steps
,.F
NOTE
(1) Reverse the disassembly procedure&
(2) W : Refer to Service Points of Disassembly.
(3) l + : Refer to Service Points of Reassemblp::?
S,<
(4) q
: Non-reusable parts
http://vnx.su/
21 - 16 .:,c.&IIANUAL
$pq3
TRANSMISSION
- Transmission
and
Transfer
Assembly
OF TRANSFER
NZlMWD
ADAPTER
Turn the control shaft to the left and remove the control finger
from the groove in the shift lug, then remove the transfer
adapter from the transmission.
N21MGBG
27. INSTALLATION
OF EXTENSION
GASKETI26.
TRANSFER
ADAPTER
(1) Apply sealant to both sides of the extension gasket and
affix the gasket to the rear surface of the transmission
case.
Specified
sealant
(2) Turn the control shaft to the left and install the transfer
adapter.
(3) Turn the control shaft to the right and insert the control
finger in the groove of the shift lug.
24. INSTALLATOCDN
Identification
marl
Install
rear.
OF BREATHER
the breather
12. ASSEMBLY
OF
ASSEMBLY/lo.
(1) Apply sealant
rear surface
mark toward
the
ADAPTER GASKETIll.
TRANSFER
CASE
CHANGE SHIFTER
to both sides of the gasket and affix it to the
of the adapter.
&?i. ._
Specified sealant
: 3M,AFJT Part No. 8001 or equiva
leni&,<
(2) Install the transfer case $stalling the change shifter to the
control shaft.
r:.;
;,Z
,$$
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MANUAL
TRANSMISSION
- Transmission
7.
DRIVING
and
IN OF SPRING
Center
control
line of
shaft
Transfer
tool
Assembly
21-17
PIN
to drive
in the spring
pin.
(2) Drive the spring pin in with the slit in the spring pin parallel
to the shaft center of the shift rail, so that the
birnensions
are as shown in the illustration.
NOTE
Do not reuse spring pin
145034
1 STB Revision
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1
t
.-
--- ..
21-18
:
MANUAL
TRANSMISSION
ISASSEMBLY
.
+a~&b~y&&f
,i . .
: : .c:p .<$,
TRANSMISSION
- Transmission
Assembly
ASSEMBLY
N2lME-D
AND REASSEMBLY
I
I)
1.
.-%-,
2.
. .;.
f:
3.
I& l . * 4.
g, l + 5.
:**4
6.
7.
Under covei
i
Under cover ask@
$
Plug
Poppet spring 1 q
Steel ball
Spr.ing.pin
l-2 speed shift rail
NO<E ].
(1)
(2)
(3j
(4)
http://vnx.su/
MANUAL
..
TRANSMISSION.
- Transmission
21-y; :
Assembly
i.
,!$/
4
Disassembly
steps
+**+13.
Main shaft lock nut
+e l +l 4. Countershaft
lock nut
4*
15. Counter rear bearing
l *
16. Counter overdrive gear
17.Spacer
18. Reverse idler gear
19. Spacer
20. Sleeve
21. Steel ball
22. Overdrive gear
250-270
Nm
181-195
ft.lbs.
-.a
&Ty
,y,.Y. -,-. j-
-0
i
I( 055*
;:;
7>
.:; .
, _(/: -c .I. ..
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i
._
118-137
18,
4o
;s
15-22
11-18
ftlbs.
3,36
3
20-60 Nm
I w-55-43
ft.lbs.
Nm
ftlbs.
.*..q.
(2) 4,
(3) l 4
(4) q
http://vnx.su/
MANUAL
TRANSMISSION
- Transmission
Assembly
42
lo-13
Nin
7.5-9.4 ftlbs.
Disadkhly
56
145099
steps
+***42.
Main shaft bearing
l *43. Spacer
44. Counter rear bearing outer race
l +45. Front bearing retainer
, b ~46. Front bearing retainer gasket
+47.Spacer
,
l +%3~OilSeal
491 Spacer
50. Counter front bearing outer race
l * l *51 . Main drive gear assembly
52. l-2 speed shift f,ork
53. Countershaft assembly
NOTE
(1) Reverse the disassemblyprocedures to reassemble.
(2) 0 l : Referto Service Points of Disassembly.
(3) 04 : Refer to Service Points of Reassembly.
(4) l : Non-reusableparts
--I
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,$y.
5
-I-y-
MANUAL
TRANSMISSION
SERVICE
6.
- Transmission
POINTS
Assembly
OF DISASSEMBLY
/9. REMOVAL
OF SPRING
PIN
Drive the spring pin out using the special
NZlMFBE
,.-
-
too.!;,,,,.
13. REMOVAL-;;
MAIN SHAFT LOCK NUT/14.
COUNTER
SHAFT LOCK NUT
(1) As shown in the illustration,
use the front edge of the
blade of a chisel or a blunt punch to loosen the baffle on
the main shaft and counter shaft lock nuts.
(2) Shift the OD-R synchronizer sleevelto the reverse side,
then shift the 1-2 synchronizer sleeve to the 2nd speed
side.
(3) Remove the main shaft lock nut and the counter shaft lock
nut.
15. REMOVAL
OF COUNTER
OVERDRIVE
GEAR
Pull off counter overdrive
suitable puller.
REAR ,BEARING/lG.
,$; I* * o( : :
gear, and ba):l!bearing
COUNTER
by using8 a
i-e
.
-
wision
http://vnx.su/
pipi
4
II
:;,
SERVICE i0I~~s
,.
. .
0~ REASSEMBLY*
NZlMGBH
51. INSTALLATION
OF MAIN DRIVE GEAR ASSEMBLY
Hold the counter gear upward in the case&nd install the main
>
drive gearassembly.
::,
>
IN~TALLATI&&OF
$~&ER/~B:
ER~NT&@@ING
RE-TAINER GASKEX#&$RONT
BEARING RWAINER
1.1) Before ins&?&the-frpnt
bearing retainer, select a spacer
which will bringhe
&earance:(c) <:Q;y.
to the
: .:i .,standard value.
-1
-$
- -;*: >F;@:
Standard value $0-0.1
mm (Of. 004 in.)
y%-
http://vnx.su/
.*
MANUAL
TRANSMISSION
- Trah%mission
Assembly
21-i-3
-y
sealant
,
..:;.
. .:
L.
43. INSTALLATION
OF SPACER
(1) Hold down counter gear and bearing outer race (in the
direction of arrovyshown in illustration).
..i
i
. ,
,
iy
(3) Put straight edge on spacer and try to turn spacer byindex
finger. If spacer turns lightly, replace it with spacer one
rank (0.03 mm (0012 in.)] thicker, and similarly turn this
spacer. In this manner, choose and instG&a-spacer which
makes clearance between sstyaight $&%.and.spacer
closest to 0. Make sure that ; .the*beanngs~q@$.OT
preloaded.
p*.-& 3 . k
.&;__..~-13Standard
value
: O-045
#fk
k.
I
\
42.lNSTALLATlON.OF
MAIN
SHAFT
BEAPING
After installingthe
snap ring on,ihe ma% shaf$.bearing, drive
the main shaft bearing into theltiansmission
case using the
special tool.
1 STB Revision
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,
;
MANUAL
TRANSMISSION
Transmission
Assembly
40. INSTALLATION
OF REVERSE IDLER GEAR SHAFT
Position the reverse idler gear shaft with bolts and drive it in.
30. INSTALLATION
OF SYNCHRONIZER
HUB/ZS. SYNCHRONIZER KEY/28. SYNCHRONIZER
SPRINGI27.
OD-R SYNCHRONIZER
SLEEVE
(1) Assemble synchronizer hub and sleeve. Make sure that
hub and sleeve slide smoothly.
(2) Insert three keys into groove of hub. Assemble hub and
keys as shown in illustration
since they have a definite
direction to be assembled.
Front a
II
Hub
SleevB
3132031
..!
j
Step of
26. INSTALLATION
OF SYNCHRONIZER
RING
14. INSTALLATION
MAIN SHAFT
OF COUNTER
LOCK NUT
SHAFT
LOCK
NUT/lB.
(I) Tighten main shaft and counter gear lock nut to specified
torque.
(2) Stake the area as shown in illustration without fajl,to prevent lock nut from loosening.
(3) Ensure that OD gear rotates smoothly.
.:
- STB Revision
: dWiMh~b,:
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MANUAL
TRANSMISSION
- Transmission
9. INSTALLATION
Shift
21-25
Assembly
tool to drive
in OD-R
shift
fork
spring
fork
NOTE
Do not reuse
spring
pin.
Slit
14501t
-,
/ STB Revision
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,Y
.._
: MANUAL
TRANSMISSION
- Main Drive
Gear Assembly
NZlMQAB
AND REASSEMBLY
116636
Disassembly
l *l
**1)*2.
3.
steps
NOTE
(1) Reverse the disassemblyprocedures to reassemble.
(2) +*
: Refer to Service Points of Disassembly.
(3) l + : Refer to Service Points of Reassembly.
Snap ring
Bearing
Main dri@gear
.
REMOVAL
OF BEARING
134616
SERVICE POINT?
2.
INSTALLATION
OF REASSEMBLY
OF BEARING
MIT4336
MD998029-01
116616
1.
INSTALLATION
OF SNAP
RING
Select and install main drive gear snap ring of such thickness
that will minimize clearance between snap ring and bearing. In
other words, install the thickest snap ring that can fit in snap
ring groove.
Standard
value
j STB hevwon
_. -:.:.,
http://vnx.su/
: O-0.06
mm (O-.002
in.)
MANUAL
TRANSMISSION
Main
Shaft
21-27
Assembly
Disassembly
l *
l
l
l
l
+*
l
l
l
l
l
1.
2.
3.
4.
+ 5.
6.
+ 7.
+ 8.
+ 9.
10.
11.
W2.
13.
+l 4.
W 5.
+16.
417.
18.
19.
20.
N2lPE-c
AND REASSEMBLY
steps
::
\
sleeve
hub
145103
hub
sleeve
NOTE
(1) Reverse the disassemblyproceduresto reassemble.
(2)+*
: Refer to Service Points of Disassembly.
4
(3)**
: Refer to Service Points of Reassembly.
i,
http://vnx.su/
21-28
MANUAL
TRANSMISSION
- Main Shaft
Assembly
NzlPFAAZ
1. lNSTALLATlON
OF BALL BEARING INNER RACE/lo. SECOND SPEED GEAR
Holding second speed gear on press base, push rear end of
main shaft to remove bearing inner race (double bearing only),
gear bearing sleeve, first speed gear, 1-2 speed synchronizer
and second speed gear.
145102
INSPECTION
l
Limit
Synchronizer
ring
Gear
110003
N2lPHAM
17. ASSEMBLY
OF 3-4 SPEED SYNCHRONIZER
SLEEVE/lG.
3-4 SPEED SYNCHRONIZER
HUB/Il5.
SYNCHRONIZER
KEY/14. SYNCHRONIZER
SPRING
(1) Mate synchronizer hub with sleeve using mark made at
disassembly.
Make sure that hub and sleeve slide
smoothly. If they slide unsmoothly,
replace hub and sleeve
assembly.
(2) 3-4 synchronizer sleeve has teeth missing at six portions.
Assemble hub to sleeve in such a way that center tooth T
between two missing teeth will touch synchronizer key.
Synchronizer
WlPGAA2
Check synchronizer
ring for worn and damaged
internal
threads.
With synchronizer assembled to cone of each gear check dimension A. If dimension A exceeds the limit, replace the
synchronizer ring and/or gear.
key
110012
(3) Use care when installing 3-4 synchronizer hub since only
3-4 synchronizer is directional. Smaller diameter side A
of center boss is front of 3-4 synchronizer hub.
Front
145025
. .
( STB Ftevrslon
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MANUAL
3-4
speed
r\
TRANSMISSION
Main
Shaft
Assembly
21-29
16. INSTALLATION
OF 3-4 SYNCHRONIZER
HUB/lZ.
SNAP
RING
(1) Assemble 3-4 synchronizer positioning hub toward correct
direction.
(2) As for main shaft front end snap ring. select and install one
of such thickness that will minimize clearance between
snap ring hub. In other words, install the thickest snap ring
that fits in snap ring groove.
(3) Make sure that 3rd speed gear turns%moothly.
Main shaft
134024
9.
SYN1-2
as for
.*
http://vnx.su/
.:
21-30
MANUAL
TRANSMISSION
- Counter
Shaft
Assembly
N21XE-B
AND REASSEMBLY
Disassembly
l **+1
+**+2.
steps
. Counter
Counter
3. Counter
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) +*
: Refer to Service Points of Disassembly.
(3) e+ : Refer to Service Points of Reassembly.
front bearing
center
bearing
shaft gear
132069
Taper bearing
Press
/
1. REMOVAL
OF COUNTER
CENTER
BEARING
MD998348-01
FRONT
BEARING/S.
N2iXFAB
COUNTER
Removal the taper roller bearing from the end of the counter
shaft gear using the special tool.
Counter gear
dylinder
PrRs
c)
,320,8
Steel pipe
(Inner diameter:
26 mm (1.02 in.)
Outer Diameter:
30 - 31 mm
(1.18 - 1.22 in.)
U2IXHAAl
1. PRESSURE INSERTION
OF COUNTER FRONT BEARING/Z.
COUNTER
CENTER
BEARING
Pressure insert the taper roller bearing using a steel pipe with
the dimensions
shown in the illustration.
Set the steel pipe so that it presses on the inner race only and
doesnt contact the bearing cage.
1 STB Revision
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15-22
11-16
Nm
ft.1b.s.
16
I
15-22
11-16
C4
30-42 Nm
22-30
ft.lbs.
16-22
11-16
Disassembly
l q
l +
l +
l +
l 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Nm
ft.lbs.
steps
Sleeve clamp
Speedometer
gear assembly
4WD indicator
light switch
Gasket
Steel ball
Rear cover
Rear cover gasket
Spacer
Dust seal guard
Oil seal
Spring
pin
Seal plug
Poppet
spring
Steel ball
H-L shift rail
l
l
l
l
+
*
*
*+
l +
l +
l +
NOTE
http://vnx.su/
16. Interlock
plunger
17. Cover
18. Cover gasket
19. Spacer
20. Wave spring
21. Pulse generator
22. Cover
23. Cover gasket
24. Spacer
25. Wave spring
26. Pulse rotor
KM 145-9-FL
KM 145-9-FSL
Nm
ft.lbs.
MANUAL
TRANSMISSION
- Transfer
Assembly
30-42
22-30
28
Nm
ft.lbs.
27
.I
5.6-7.2
15-22
11-16
Nm
ftlbs.
\
44
145083
Disassembly
steps
r
27. Snap
<.;
*k
@:+e
%+e
ring
~~
e+
31.
32.
33.
34:*
.,:
gasket
+e
Side cover
Side cover gasket
Lock plate
Counter
gear shaft
42.
43.
l + 44..
45.
46.
l + 47.
l + 48.
49.
Spring
Spring
retainer
Output
shaft assembly
2-4WD shift fork
2.4WD
shift rail
H-L shift fork
H-L clutch sleeve
Needle
bearing.
NOTE
(I)
Reverse the disassembly
(2) +e : Refer to Service
;.
y,
(3)
(4)
I)+
m
http://vnx.su/
procedures
to reassemble.
Points of Disassembly.
: Refer
to Service
Points
: Non-reusable
parts
of
Reassembly.
.;:-.
.
MANUAL
- Transfer
,j!
TRANSMISSION
Assembly
-;
Disassembly
steps
145084
l + $0. Snap
l + 51. Input
e+
52.
53.
54.
l + 55.
56.
ring
gear assembly
Oil seal
Baffle plate
Dust ieal guide
Oil seal
Transfer
case
i
, .,s-.4
NOTE
(I) Reverse the disassembly
procedures
to reassemble....,?
. .,.*
i^;----rLIIL
(2) l + : Refer to Service Points of Reassembly.
(3) q : Non-reusable
parts
OF LOCK PLATE/34.
COUNTER
GEAR SHAFT
Remove the lock plate and pull out the counter gear shaft.
Thrust washer
WASHER/38.
Counter gear
http://vnx.su/
;I
44. REMOVAL
OF OUTPUT
SHAFT
ASSEMBLY
Specified oil
oil
144018
52. INSTALLATION
OF OIL SEAL (INPUT GEAR)
Apply the specified oil to the lip of the oil seal and pressure
insert it.
Specified
..
oil
xi.<.
i
\t, * ,j <
1
51. INSTAl$&ON
OF INPUT GEAR/SO. SNAP RING
(1) Inset-&e
input gear assembly into the transfer case and
fasten it with the snap ring.
(2) Select the thickest snap ring that will fit into the groove
and install it.
Standard
value
48. INSTALLATKjN.
OF H-L CLUTCH SLEEVE/47.
H-L SHIFT
FORK
.:.
(1) Install the H-L clutch.sleeve
and H-L shift fork
ion
http://vnx.su/
MANUAL
TRANSMISSION
21-35
Assembly
(2) Make sure the direction of the sleeve is correct. The.direction of the sleeve is the same for both 2WD and 4WD.
Front
Clutch
- Transfer
sleeve
145090
44. INSTALLATION
OF OUTPUT SHAFT ASSEMBLY
(1) Engage the chain precisely with the sprockets of the rear
output shaft and the front output shaft.
(2) Install the 2-4WD shift fork on the 2-4WD clutch sleeve.
While passing them along the 2-4WD shift rail, install the
rear and front output shaft and chain.
Thrust
washer
Counter
39. INSTALLATION
OF BEARING SPACER/38.~NEEDLE
BEARING/37. THRUST WASHER/36.
COUNTER G-EAR
(1) Assemble the needle bearings (2 PCS) in the counter gear,
then after inserting the spacer, install the counter gear
inside the transfer case.
(2) Place thrust washers on the front and rear of the counter
gear.
\.
gear
34. INSTALLATION
OF COUNTER
GEAR SHAFr/33.
LOCK
~I
.. ,..
PLATE
es.: >
1
(1) Insert the counter shaft, being careful of the direction.of
the groove in the locking plate
:J.
,>\\, , ,
(2) Install the lock plate.
,y>
$.,,.
30. INSTALLATION
KET/28. CHAIN
OF OIL GUIDe/29.
COVER
_ _
sealant
http://vnx.su/
COVER
GAS-
1 STB Revision
CHAIN
.:
21-36
MANUAL
TRANSMISSION
- Transfer
Assembly
(3) Install the chain cover so that the end of the oil guide
enters the window in the chain cover.
25. INSTALLATION
OF THE WAVE
COVER GASKET/22.
COVER
SPRING/24.
SPACER123.
sealant
HWave
spring
4
M i#
Specified
adhesive
: 3M Adhesive
or equivalent
Nut Locking
4171
Spacer
145105
20. INSTALLATION
OF WAVE
COVER GASKET/17.
COVER
I I
SPACER/18.
Gasket
2E(
SPRING/lS.
Wave
Specified
sealant
Specified
adhesive
spring
Spacer
148011
/ STB Revision
http://vnx.su/
: 3M Adhesive
or equivalent
Nut Locking
4171
ANUAL
Spring
TRANSMISSION
- Transfer
11. INSTALLATION
pin
21-37
Assembly
OF SPRING
PIN
(1) Align the H-L shift fork and shift rail spring pin hole,.and
then use the special tool to drive it in.
(2) Drive in so that the slit is parallel with the axial direction
of the shift rail.
8.
Gasket
INSTALLATION
OF SPACER/7.
REAR COVER GASKET/G.
REAR COVER
(1) Measure the amount of protrusion of the rear output shaft
rear bearing A and the amount of inset in the cover B.
Select a spacer which adjusts the end play to the standard
value.
Standard
value
-___
148010
(2) Apply sealant to both sides of the rear cover gasket and
affix the rear cover gasket to the chain cover.
Specified
Extension
housi
2.
Sleeve
INSTALLATION
sealant
OF SPEEDOMETER
GEAR ASSEMBLY
Mating marks
1 STB Revision
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21-38
MANUAL
TRANSMISSION
>=
-2
.>
DISASSEMBLY
;;.
14,.
AND REASSEMBLY
8
72-94
21
ft.lbs.
Disassembly steps
,416. Clutch hub (2-4WD)
17. Stopper plate
l *
18. Bearing
19. Rear output shaft
l *
20. Bearing
21. Front output shaft
I. Chain
l + 2. Snap ring
~~ 3. Clutch hub (H-L)
4. Bearing spacer
5. Low speed gear
6. Needle bearing
~~ 7. Lock nut
l *
8. Radial ball bearing
9. Sprocket spacer
10. Steel ball
II. Drive sprocket
12. Needle bearing
13. Sprocket spacer
14. Steel ball
l *15. Clutch sleeve
NOTE
(1) Reverse the disassemblyproceduresto reassemble.
(2) 40 : Refer to Service Points of Disassembly.
(3) 60 : Refer to Service Points of Reassembly.
(4) q
: Non-reusableparts
I ST6 Revision
http://vnx.su/
MANUAL
TRANSMISSION
Output
Shaft
21-39
Assembly
n-
8.
REMOVAL
OF RADIAL
BALL BEARING/18.
BEARING
20. REMOVAL
OF BEARING
145107
Front
16. INSTALLATION
SLEEVE
OF CLUTCH
HUB
(2-4WD)/15.
CLUTCH
Hub
2l
eeve
145093
7.
INSTALLATION
OF LOCK NUT
After tightening the lock nut at the proper torque, crimp the
lock nut in the groove in the output shaft at the location shown
in the illustration.
148008
1 STB Revision
http://vnx.su/
':
. .
ri
21-40
MANUAL
Front
TRANSMISSION
3.
- Output
INSTALLATION
Shaft
Assembly
OF CLUTCH
HUB (H-L)/2.
SNAP RING
shown
in the illustra-
144023
(2) Select the thickest snap ring that will fit into the groove
the front end of the rear output shaft and install it.
http://vnx.su/
in
MANUAL
TRANSMISSION
Input
Shaft
21-41
Assembly
NZlMlBA
AND REASSEMBLY
Disassembly
l 41.
+**+2.
3.
4.
5.
6.
7.
steps
Snap ring
Bearing
Spacer
Snap ring
Cone spring
Sub gear
Input gear
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) +e : Refer to Service Points of Disassembly.
(3) l + : Refer to Service Points of Reassembly.
(4) q : Non-reusable parts
REMOVAL
OF BEARING
145108
PRESSURE
INSERTION
OF BEARIN&
1.
INSTALLATION
OF SNAP
RING
Select the thickest snap ring that will fit into the grooie
front end of the input gear and install it.
1 STB Revision
http://vnx.su/
in the
21-42
MANUAL
TRANSMISSION
- Speedometer
Sleeve Assembly
Disassembly
l + 1. Spring
2.
3.
4.
5.
Driven
Sleeve
O-ring
O-ring
NZlRE-C
AND REASSEMBLY
steps
pin
gear
110008
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) l *
: Refer to Service Points of Reassembly.
: Non-reusable
parts
(3) q
OF SPRING
PIN
Spring
NOTE
Do not reuse spring pin.
110919
( STB Revision
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N21RHAAZ
MANUAL
TRANSMISSION
- Gearshift
21-43
Lever Assembly
AND
INSTALLATION
NZlGA-
15-22
Nm
OQW541
Removal steps
1.
2.
3.
4.
+e l + 5.
6.
7.
8.
9.
+e ~~ 10.
11.
12.
13.
14.
15.
16.
~~
NOTE
(1)
Reverse
the removal
procedures
(2)
+e
: Refer
to Service
Points
(3)
*+
: Refer
to Service
Points
(4)
liTJ
: Non-reusable
parts
http://vnx.su/
to
of
of
reinstall.
Removal.
Installation.
21-44
MANUAL
TRANSMISSION
SERVICE
5.
Gearshift
Lever
Assembly
POINTS
OF REMOVAL
NZlGBAD
REMOVAL
OF TRANSMISSION
CONTROL
SEMBLY/TO.
TRANSFER
CONTROL
LEVER
Remove the control lever attaching
control lever assembly.
LEVER ASASSEMBLY
the
Caution
When the control lever assembly
is removed,
keep the
transmission
control lever and the transfer control lever
in the following
positions.
Transmission
control lever - Neutral
position
2H
(2-wheel
drive - high
Transfer control lever
range) position
After the control
lever assembly
has been removed,
cover with a cloth to prevent entry of fforeign substances
into the extension
housing.
INSPECTION
Control
lever
I lever
cover
l
NzlGcMl
SERVICE
POINTS
10. INSTALLATION
SEMBLY
OF INSTALLATION
OF TRANSFER
(2) When
Apply
assembling,
the specified
Specified
sealant
.
--
.,
Control
housing
Specified
ogBoo,
/ ST9 Revision
http://vnx.su/
grease
LEVER
AS-
of gasket.
Ii3
CONTROL
NZlGDAF
grease
surface.
generously
: Multipurpose
NLGI No. 2
grease
to transfer
SAE
J310,
WIANUAL
TRANSMISSION
5.
Gasket
Gearshift
INSTALLATION
ASSEMBLY
Lever
21-45
Assembly
OF TRANSMISSION
CONTROL
LEVER
Specified
sealant
iousina
I
-knob
Transfer
shift lever
Specified
1
2.
/
/
Nut
Transfer
INSTALLATION
grease
: Multipurpose
NLGI No. 2
OF TRANSFER
SHIFT
grease
LEVER
SAE
5310,
KNOB
(1) After manually screwing the nut all the way to the end
of the threaded part of the shift lever, return it about a
half turn and install the spring washer.
shift lever
09wo32
Vehicle
(2) After turning the shift lever knob about one turn
beyond where the spring washer begins to yield, screw
in further and adjust until the shift pattern on the knob
faces the front of the vehicle.
front
Shift pattern
\
NOTE
If the adjustment cannot be made as described in (2)
above, first screw the shift lever all the way in, and
then return about one turn to make the adjustment.
'
09wo3:
1 STB Revision
http://vnx.su/
21-46
MANUAL
TRANSMISSION
- Control
Lever
Assembly
NZlGE-
AND REASSEMBLY
IO-13 Nm
7-9 ftlbs.
Disassembly
l
l
2\
31
steps
1. Bolt
2. Control housing cover
+ 3. Control housing cover gasket
:. 4. Transfer control lever
5. Transmission control lever
+ 6. Gasket
7. Stopper plate
8. Nut
9. Spring washer
41 0. Stopper bracket assembly
11. Return spring
a12. Special bolt
13. Control housing
9----@
8
16-22
11-16
Nm
ft.lbs.
145042
NC)TE
(1) Reverse the disassemblyprocedures to reassemble.
(2) l + : Refer to Service Points of Reassembly.
(3) liTJ : Non-reusablepans
INSPECTION
l
If
play is evident replace lever assembly.
Push control lever in and check to ensure that it moves
smoothly up and down.
Check cover for damage and replace if necessan/. To remove
cover, cut away with knife. To install new cover, first apply thin
coat of oil to periphery of control lever B. Then install by
sliding it down from top of lever B.
Check lever bushing for wear and replace if necessary.
Control I*
Control lever cover
Spring cover
U21GGAC
Lever bushing
STB Revision
http://vnx.su/
lever B.
MANUAL
TRANSMISSION
- Control
Lever
21-47
Assembly
bracket
assembly
NZlGHAF
STOPPER
12. INSTALLAUION
OF
SPECIAL
BOLT/lo.
BRACKET ASSEMBLY
(1) Apply sealant to peripheries (except threaded portions) of
two special bolts and install them to cover. Do not wipe
away excess sealant from cover.
Specified
sealant
sealant
: 3M Scotch
equivalent
Grip
No.
2353
to
or
6.
Adz
-_
:
._.
INSTALLATION
OF GASKET/3.
COj@&&WSING
yy=yf
I- e .~g$&r
COVER GASKET
(1) Apply specified
sealant to both su?faF& of thegas5-q; ;,.;c.
kets.
Specified
1 STB Revision
http://vnx.su/
sealant
16-1
PROPELLER SHAFT
AND
UNIVERSAL JOINTS
CONTENTS
GENERAL
INFORMATION
PROPELLER
SPECIAL
SHAFT
TOOL
SPECIFICATIONS
General
. . . . . . . . . . . . . .. .. . . . . . . . . . . . .. . . .
N16AA--
Lubricants
. . . . . . . . . . . . .. .. .. . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. .. .
Service
Specifications
Torque
Specification
. . . ..*............m...........s............
. . . . . . . . . . . .. .. .. . . . . . . . . . . .. .. . . . . . . . . . . .. . . . . . . . .
. . . . . . . . . .. .. . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . .
Noise
and Vibration
Noise
at Start
Specifications
.._______._._....,.,,,,...,,...,.._.
TROUBLESHOOTING
http://vnx.su/
. . . . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . . .. .
,......................................
. . . . . . . .. .. . . . . . . .. .. . . . . . . . . . . .. .. . . . . .
at High Speed
2
2
2
16-2
JOINTS
G eneral
Information
/ Specifications
GENERAL INFORMATION
The Z-joint
lubrication.
type propeller
NlGBAAE
The universal
joint
includes
a grease
nipple
for easy
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N16CA--
Items
2-joint type
2-joint type
Propeller shaft
Type
Length
x O.D.
mm (in.)
Front
665 x 50.8(26.2
x 2.0)
741 x 50.8(29.2
x 2.0)
Rear
522 x 71.8(20.6
x 3.0)
Cross type
Cross type
14.7 (.58)
14.7 (.58)
Universal joint
We
Bearing
Journal O.D.
mm (in.)
SERVICE SPECIFICATIONS
N16CB--
Items
Specifications
Standard value
Journal end play
mm (in.)
0.06 (.0024)
Limits
Propeller shaft runout (Dial indicator
Front
reading)
mm (in.)
0.5 (.OZO)
Rear
0.6 (.024)
TORQUE SPECIFICATION
NlGCC--
Item
1 Flange yoke attaching
Nm
ft. Ibs.
bolts
LUBRICANTS
Items
Universal
joint
Specified
Multipurpose
NLGI No. 2
lubricant
( STB Revision
http://vnx.su/
Quantity
As required
As required
JOINTS-s
pecial
Tool
16-3
/Troubleshooting
SPECIAL TOOL
Tool (Number
and name)
Mi3990840-01
Universal joint
installer set
remover
NlGDA-
Use
Removal and installation
of journal bearing
and
TROUBLESHOOTING
NlGEAAA
Symptom
Probable
Noise at start
Worn
Worn
journal
sleeve
Loose
Noise and vibration
high speed
at
cause
propeller
Unbalanced
Improper
Worn
bearing
yoke spline
shaft installation
propeller
shaft
Reference
page
Replace
16-6
Retighten
16-4
Replace
16-4
Adjust
journal
Remedy
Replace
bearing
1 STB Revision
http://vnx.su/
the clearance
16-8
7 6-6
16-4
PROPELLER
SHAFT
AND
UNIVERSAL
JOINTS
Propeller
Shaft
PROPELLER SHAFT
REMOVAL
NlIGA--
AND INSTALLATION
Pre-removal
Draining
Operation
of the Transfer
0 Supplying
the Transfer
Transmission
Gear Oil
and Transfer
Case.)
50-60 Nm
36-43 ftlbs.
lOG0004
Removal steps
+e
+e
l +
l +
1. Rear propeller
2. Front propeller
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +I) : Refer to Service Points of Removal.
(3) ~~ : Refer to Service Points of Installation
shaft
shaft
SERVICE
POINTS
OF REMOVAL
N16GBAE
1. REMOVAL
OF REAR PROPELLER
SHAFT/P.
FRONT PROPELLER SHAFT
(1) Place the free wheel hubs in the FREE position and set
the transfer lever to 2H.
(2) Make mating
marks on the flange
yoke and the
differential
companion
flange.
evision
http://vnx.su/
\tic
PROPELLER
SHAFT
AND
UNIVERSAL
Propeller
16-5
Shaft
Caution
1. Be careful not to damage the lip of the transmission oil seal or the lip of the transfer case oil seal.
2. Do not allow foreign matter to enter the transmission or transfer.
Front
Lip
JOINTS
l@
09w529
091528
INSPECTION
l
l
l
N16GCAB
Check the sleeve yoke and flange yoke for wear, damage
or cracks.
Check the propeller
shaft yokes for wear, damage
or
cracks.
Check the propeller shaft for bends, twisting or damage.
Check the
directions.
universal
joints
CHECKING
PROPELLER
Measure propeller
shaft
Limits
Front propeller
Rear propeller
SERVICE
2.
0.5 mm
0.6 mm
1 STB Revision
http://vnx.su/
(.020
(.024
gear oil
in all
in.)
in.)
OF INSTALLATION
INSTALLATION
OF FRONT
PROPELLER
SHAFT
lOGO
operation
SHAFT RUNOUT
runout with a dial indicator.
shaft
shaft
POINTS
Specified
for smooth
PROPELLER
hypoid
NlGGDAC
SHAFT/l.
REAR
16-6
PROPELLER
SHAFT
AND
UNIVERSAL
JOINTS
Propeller
Shaft
install
the propel-
Caution
Degrease
the thread of the mounting
bolts and nuts
before tightening
these parts. Otherwise,
they could
become loose.
DISASSEMBLY
AND
Front
REASSEMBLY
propeller
NlGGE-
shaft
Rear propeller
Disassembly
l +
4*
+w
l +
l +
l +
shaft
steps
Adjustment
of journal
1. Snap ring
2. Grease nipple
3. Journal bearing
4. Journal
5. Flange yoke
6. Sleeve yoke
end play
lOW501
NOTE
(1)
(2)
SERVICE
POINTS
1. REMOVAL
procedures
to reassemble
Points of Disassembly.
Points of Reassembly.
OF DISASSEMBLY
N16GFAC
OF SNAP RING
REMOVAL
OF JOURNAL
BEARING
Revision
http://vnx.su/
shaft
PROPELLER
SHAFT
AND
UNIVERSAL
JOINTS
16-7
Shaft
Propeller
bearing
in the same
NOTE
If the journal bearing is hard to remove,
with a plastic hammer
as illustrated.
manner
YlOOOS
SERVICE
4.
POINTS
INSTALLATION
OF REASSEMBLY
OF JOURNAL/3.
lQY6cK
JOURNAL
Specified
grease
N16GHAC
BEARING
parts;
of journal
: Multipurpose
NLGI No. 2
grease
SAE
J310,
Caution
Use of excessive amounts
of grease may result in
difficulty
in assembling
unit and incorrect
selection
of snap rings.
NOTE
When the journal
obtain the universal
and journal
joint kit.
bearing
propeller
shaft
2.
INSTALLATION
OF GREASE
Rear propeller
shaft
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are replaced,
NOTE
Be sure to align the mating
Front
bearing
tool
NIPPLE
directed
as shown
in the illustra-
PROPELLER
SHAFT AND
UNIVERSAL
.
JOINTS
ADJUSTMENT
- Propeller
OF JOURNAL
END PLAY
and journal
Shaft
(3) Measure
the clearance
shown in the illustration
with a
feeler gauge. If the clearance exceeds the standard value,
the snap rings should be replaced.
Standard
value
lOBOOl5
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3-1
CONTENTS
,
.*
NOBAA!,
,
AXLE ASSEMBLY
AXLE SHAFT
......................................................
DIFFERENTIAL
GENERAL
SERVICE
..............................................
CARRIER
INFORMATION
20
22
...................................
27
.................................
PROCEDURES
..........
Axle Shaft for End Play ....................
Gear Oil Level ..................................
Rear Axle Total Backlash
.................
17
17
18
18
Checking
Checking
Checking
SPECIAL
ADJUSTMENT
TOOLS
................................................
SPECIFICATIONS
General
...............................................
....................................
Specifications
.......................................................
Lubricants
......................................
Sealant and Adhesive
Service Specifications
.....................................
.....................................
Torque Specifications
14 i.
. . . . . . .. . . . . . . . . . . ..*................m..
TROUBLESHOOTING
AXLE SHAFT, AXLE HOUSING
. . . . . . . . .. .. . . . . . . .. .. . . 14 <;,
17
17
12
9
9
11
11
10
11
http://vnx.su/
Grease Leakage
Noise While Wheels
$
are Rotating
DIFFERENTIAL
(CONVENTIONAL
DIFFERENTIAL)
. . . . .. . . . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . . .. . . . . 14
Bearing Noise While Driving or Coasting
Constant Noise
Gear Noise While
Coasting
3-2
REAR AXLE
General
Information
GENERAL INFORMATION
N03BAAB
The banjo-type,
semi-floating
type of rear axle has been adopted.
In order to improve the river-crossing
ability of this model, a vent hose has been installed from the axle
housing, and a differential
breather (air bleeder) has been used within the frame crossmember.
There are two types of differential;
conventional
differential
and limited slip differential.
The limited
slip
differential
is of great help when driving on muddy and other slippery ground.
Axle housing
llW508
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REAR AXLE
LIMITED
General
3-3
Information
SLIP DIFFERENTIAL
NOBBBAB
Pinion
Pinion
shaft
Differential
Friction
lifferential
shaft
\ Pressure
case (A)
disc
case
Friction
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disc
ring
3-4
ring
Right pressure
ring
-f-----T
Direction of rotation
of the pressure ring
during straight driving
$y~~;no*>
Direction of rotation
of the txessure ring
during straight drivkg
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--A
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3-5
Information
OPERATION
(TORQUE
TRANSMISSION)
WHEN THE SPEEDS OF LEFT AND RIGHT WHEELS
ARE
DIFFERENT
When one wheel is in contact with a concrete road surface (which has high coefficient
of friction) and the
other wheel is in contact with a muddy or other slippery road surface (which has low coefficient
of friction),
the differential
operation will cause the speed of the wheel in contact with the slippery surface to be faster
than the speed of the drive gear, lowering the maximum
drive force. If this occurs, the limited slip function
will control the differential
operation and increase the driving force. The transmission
of torque through the
limited
slip device in this event is as follows:
When the differential
case is turned by the drive gear and the drive pinion, the pressure rings which are
interlocked
with the differential
case will turn at the same speed. Also, the difference
in the road surface
resistances will cause differential
operation and the left and right side gears will revolve at speeds different
from that of the differential
case. Because of the friction produced between the clutch plates in mesh with
both the side gear and differential
case, one of the pressure rings increases its rotating speed, whereas the
other reduces its rotating speed. The pressure rings press the tapered portion of the pinion shaft with which
they are in contact, and thereby receive reaction force in both the lateral direction
and the direction
of
rotation. The reaction force in the lateral direction causes the clutch plates to mesh, increasing the frictional I:
and the drive force.
Left
ring
frictional
pressure
Right
ring
pressure
ring
Low-speed
50 + 15
force
F;flsing
side
65%
High-speed
50 - 15
symbol
P,P
F,F
= Pressing force of
N.N
Pressing
pressure
on the
force
force
rings
clutch
of
the
plates
the
pressure
rings
on the pinion
shaft
= Resultant
force
of P +
F and P + F
llF109
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llW511
side
35%
3-6
Information
FEATURES
OF LIMITED
SLIP DIFFERENTIAL
(1) When one wheel of the vehicle is in contact with ;3 road surface which has poor traction, the limited slip
differential,
in comparison
to a conventional
differential,
supplies additional
torque to the wheel which
has the better traction conditions
by utilizing clutch plates, thus improving
the traction
capacity.
Moreover, the effect of the limited slip differential
is to prevent the vehicle from becoming
stuck, even if
the traction of one of the wheels becomes
radically reduced.
(2) When one wheel moves from a road surface which has poor traction onto one which has good traction,
or when the wheels are constantly
leaving the road surface while driving on a rough, bumpy road, the
clutch plates of the limited slip differential
allow the torque to absorb the differences
between the
revolution speeds of the right and left wheels. In addition, the sudden changes (jolting) in the drive force
are also absorbed,
thus preventing
skidding.
(3) Because in the limited
slip differential,
the differential
operation
is slightly restricted
during normal
cornering, the understeer tendency (the tendency for the cornering of the vehicle to exceed the turning
of the steering wheel) becomes
greater; however, this does not have any detrimental
effect on the
17
driving of the vehicle. Moreover,
in the event that the inside wheel lifts up (the tire leaves the road
.
c,
.,
surface) during high speed cornering,
the clutch plates function to limit differential
operation
which
the limited
slip
would simultaneously
decrease
the drive force,= of the outside wheel; therefore,
i
differential
moderates
sudden speed reductions
during vehicle cornering, and thereby provides greater
i $ cornering
capability
than a conventional
differential.
Id
pTB
Revision
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..
I.
Effective
Use
in Combination
with
SLIP
Brakes
Information
3-7
DIFFERENTIAL
If a wheel is in contact with a slippery road surface and has begun to spin, using the brakes in combination
with the limited slip differential
will provide even greater traction capability. The resistance caused by the
brakes will further increase the drive torque of the engine, and this increased torque will increase the clutch
plate pressing force of the pressure ring, thus increasing the traction. Also, the drive force transmitted
to the
brakes will not function
as real drive force. This is shown in the illustration
below.
In the illustration,
the application
rate is Rt = 2, and, supposing the torque from the brake operation is 1. a
drive torque of 1 + 1 = 2 will be applied to the spinning wheel (the right wheel), and a drive torque of twice
that which is applied to the spinning wheel, or (1 + 1) x 2 = 4, will be applied to the wheel which is not
spinning (the left wheel). However, because the brake force of 1 is a negative value with regard to the
propulsion
torque of each wheel, the propulsion
torque actually obtained by the right wheel is (I + 1) - 1
= 1, and that obtained
by the left wheel is [(I + 1) x 2 - I] = 3.
Therefore,
the total drive torque is 1 + 3 = 4. In the same circumstances,
the total drive torque of a
conventional
differential
is 1 + 1 = 2, and that of a limited slip differential when the brakes are not used in *.,
combination
is 1 + 2 = 3. This represents
an increase in the traction by a factor of 2 over that of a.?
conventional
differential,
and by a factor of 1.3 over that of a limited slip differential when the brakes are not,
used.
,..1.
Torque
doubling
rate
..::::.,:::::.
*I.
llF103
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3-8
NOTES
REAR AXLE
REGARDING
SERVICE
PROCEDURES
- General
Information
FOR LlMlTED
SLIP
DIFFERENTIAL
(1) The engine must never be operated while only a single wheel is jacked up. Doing so is extremely
dangerous;
if the differential
functions while the engine is operated at high speed, the oil film between
the clutch plates will decrease, thus causing the friction coefficient
to increase, the prescribed torque
ratio will be exceeded, an excessive amount of torque will be applied to the stationary wheel, and the
vehicle will move forward. Also, resistance
must never be applied to the spinning
wheel.
(2) In the event that one of the wheels comes in contact with a slippery road surface and begins to spin, if
the engine continues
to be operated
at high speed for too long, the clutch plates might become
abnormally
worn; such action must be avoided.
(3) As gear oil, use MITSUBISHI
Genuine Gear Oil (part number 8149630 EX) or equivalent.
MITSUBISHI
Genuine Gear Oil was especially developed
for limited-slip
differential
use, and is different from ordinary
gear oil. When changing the oil, the oil which is removed will appear considerably
blacker than ordinary
oil. This, however, is not a change in color due to the deterioration
of the oil, but rather the oil has
mixed with worn particles of the special treatment
on the clutch plates.
*11\*7,?d become
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3-9
SPECIFICATIONS
GENERAL
M13cA.-
SPECIFICATIONS
Items
Banjo type
Banjo type
Semi-floating type
Semi-floating type
40 (1.57)
40(1.57)
34.5 (1.358)
34.5 (1.358)
703.5 (27.700)
703.5 (27.700)
80 x 40 x 19.75
(3.15 x 1.57 x .7776)
80x40x
19.75
(3.15 x 1.57 x .7776)
Axle shaft
Supporting type
Shaft dimensions
Bearing portion dia.
Center portion dia.
Overall length
mm (in.)
mm (in.)
mm (in.)
Bearing
O.D. x I.D. x width
mm(in.)
Differential
Reduction gear type
Reduction ratio
Hypoid gear
Hypoid gear
4.625
-
4.625
Side gear
Pinion gear
Drive gear
Drive pinion
37
37
Side gear
Pinion gear
14
10
16
Disc type
Number of teeth
10
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3-10
SERVICE SPECIFICATIONS
Vehicles with conventional
differential
0.05-0.20
-
0.05-0.20
Items
Standard values
Axle shaft end play
mm (in.)
(.0020--.0079)
4-6 clicks
0.1 I-0.16(.0043--.0063)
Differential
mm (in.)
mm (in.)
(.0020-.0079)
4-6 clicks
O.ll-0.16(.0043-.0063)
-
0.4-0.5 (3.5-4.3)
0.4-0.5 (3.5-4.3)
0.65-0.75
-
0.65-0.75
without
oil seal
Nm (in. Ibs.)
Nm (in. Ibs.)
(5.6-6.5)
(5.6-6.5)
0.06-.20
0.05-0.20
65-l 00 (47-72)
35-100 (25-72)
5 (.20)
5 (.20)
0.05 (.0020)
0.2 (.008)
0.05 (.0020)
-
0.08 (.0031)
0.1 (004)
(.0024-.0079)
(.0020-.0079)
preload
Limits
Differential
mm (in.)
mm (in.)
gear backlash
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3-11
NOBCG-
Items
Shackle assembly
attaching
Nm
nut
ft. Ibs.
45-60
33343
18825
85-l 10
13-18
61-80
13-17
9-12
50-60
36-43
36-43
50-60
180-220
40-60
Drain plug
60-70
43-5 1
25-30
1go-250
18-22
137-181
80-90
55-65
58-65
i
i
Lock plate
15-22
II-16
Shock absorber
attaching
U-bolt attaching
nut
nut
nut
130-I 59
29-43
40-47
LUBRICANTS
Items
-.
Specified
lubricants
Quantity
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Differential
Multipurpose
NLGI No. 2
As required
Companion
flange washer
Multipurpose
NLGI No. 2
As required
Conventional
differential
SEALANT
AND ADHESIVE
Item
Specified
carrier gasket
hole
or equivalent
Quantity
As required
As required
As required
IYL
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3-12
SPECIAL TOOLS
NOBDA--
Tool (Number
e housing
and name)
M B990799-0 1
Axle bearing remover and
installer
Adjustable
Removal and
adjustment of side
wrench
M B990339-0 1
Pinion carrier bearing puller
Pressing of axle shaft
bearing outer race
Pressing of axle shaft oil
Pressing
Use
of drive pinion
wrench
MB99081 I-01
Side bearing cup remover
remover
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REAR
AXLE - Special
3-13
Tools
Use
Use
Tool (Number
M B990767-0 1
End yoke holder
Holding of companion
flange
MIT3041 80
Handle
Pressing
oil seal
of drive pinion
MB990901-01
Pinion height gauge set
Measurement
height
MB990031-01
Drive pinion oil seal installer
Pressing
oil seal
of drive pinion
MB990802-01
Bearing installer
M B990988
Side gear holdins tool
Measurement
of limited
slip differential preload
Tool (Number
and name)
of pinion
and name)
- r-1
Tool
A
-J
389
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3-14
TROUBLESHOOTING
NOBEAAA
Probable cause
Remedy
Reference
paw
Brake drag
Bent axle shaft
Worn or scarred axle shaft bearing
Replace
3-22
Grease leakage
Replace
3-22
Correct or replace
3-29
Replace
3-32,35
Foreign material
3-32,35
No oil
Fill or change
3-17
Correct or replace
3-29,37
Damaged gear
Replace
3-32,35
Foreign material
3-32,35
Insufficient
Fill or change
3-17
Symptom
AXLE SHAFT,
AXLE HOUSING
DIFFERENTIAL
[CONVENTIONAL
DIFFERENTIAL)
Constant
noise
?.
Gear noise while
driving
oil
3-32,351
Improper
Correct or replace
3-37
Damaged
gear
Replace
3-32,35
Replace
3-32, 35
Cracked
bearing
Replace
3-32, 35
Heat
Adjust
3-29
Insufficient
Fill or change
3-l 7
oil
STB Revision
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REAR
Symptom
Oil leakage
3-15
-Troubleshooting
Remedy
Reference
paw
Clean or replace
3-20
3-27
Replace
3-32,35
Excessive
3-17
Probable cause
Clogged breather
Cover tightened
Seal malfunction
DIFFERENTIAL
(LIMITED SLIP
DIFFERENTIAL)
Abnormal noise
during driving or
gear changing
AXLE
hose
not
oil
h ..A
.r
Adjust
3-29,47
Excessive
Adjust or replace
3-29
Replace
3-42.45
differential
gear backlash
nut
Retighten
or replace
3-42.45
NOTE
In addition to a malfunction of the differential carrier components,
abnormal noise can also be caused by the
universal joint of the propeller shaft, the axle shafts, the wheel bearings, etc. Before disassembling
any parts, take
all possibilities into consideration
and confirm the source of the noise.
. Abnormal noise
when cornering
Gear noise
Replace
3-42.45
3-51
Improper
Refill or replace
3-17
Adjust or replace
3-29
Adjust
3-29.47
Replace
3-42,45
Improper
Refill or replace
3-17
NOTE
Noise from the engine, muffler vibration, transmission,
propeller shaft, wheel bearings, tires, body, etc., is easily
mistaken as being caused by malfunction in the differential carrier components.
Be extremely careful and attentive
when performing the driving test, etc.
Test methods to confirm the source of the abnormal noise include: coasting, acceleration, constant speed driving,
raising the rear wheels on a jack, etc. Use the method most appropriate to the circumstances.
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.>
i$ : .,
r -( ,..
._
,._-
I.
3-16
Symptom
Gear oil leakage
Seizure
Remedy
Reference
page
Replace
3-42,45
Retighten
or replace
3-42,45
Retighten
or apply adhesive
3-27
Clogged or damaged
Clean or replace
3-20
Adjust
3-29,47,
Improper
gear oil
Replace
3-17
Improper
Refill or replace
3-17
nut
breather hose
NOTE
In the event of seizure, diassemble and replace the part:s involved, and also be sure to check all components
any irregularities and repair or replace as necessary.
Breakdown
incorrect
Incorrect
Incorrect
Excessive
Incorrect
malfunction
bolts
due to overloaded
Adjust
3-29,47,5
Retighten
3-42,45
Avoid excessively
operation
rough
I
NOTE
In addition to disassembling
and replacing the failed parts, be sure to check all components
repair or replace as necessary.
The limited slip device is damaged
/ STB Revision
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for
for irregularities
and
51
REAR AXLE
- Service
Adjustment
3-17
Procedures
SERVICE ADJUSTMENT
CHECKING
llY503
REAR AXLE
PROCEDUREEZ&
TOTAL
BACKLASH
the parking
,.
>.
r;
: 5 mm
(.20 in.)
CHECKING
AXLE
SHAFT
remove
the differential
NOBFBAB
value
: 0.05-0.20
mm
(.0020-.Od79
in.)
,;
\ :
CHECKING
NOJFCAC
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(1.
3-18
Adjustment
LIMITED
SLIP
SUREMENT
Procedures
DIFFERENTIAL
PRELOAD
MEANOJFDAD
value
: 35 Nm
(25 ftlbs.)
turn
the
axle
or more
REPLACEMENT
OF AXLE
1. Disconnect
the parking
and then remove
the
cables. (Refer to GROUP
..
:.
1
NOTE
Do not disconnect
connection.
HOUSING
OIL
S$All~
the parking
2. Before disconnecting
the brake tube, drain the brake fluid
from the bleeder screw at the left side of the rear brake.
3. Pull the rear axle shaft with rear brake assembly attached.
If the rear axle shaft is hard to remove, use the special
tools.
/B
Revision
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REAR AXLE
- Service
Adiustment
4. Use special
3-19
Procedures
grease
to remove
area of the
..t.*
: Multipurpose
No. 2
grease
SAE J310,
6. Drive the new oil seal into the rear axle housing
using the special tools.
7. Apply the specified grease to the oil seal lip.
Specified
grease
: Multipurpose
No. 2
grease
Standard
value
(Refer to GROUP
dures.) *
BSTB Revision
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end by;,,,.,
:r,.
. .
SAE J310,
NLGl
NLGl
and rear
housing.
(Refer to
,.
stroke
of
: 4-6 clicks
5 BRAKES-Service
Adjustment
Proce-
3-20
AXLE ASSEMBLY
REMOVAL
N03GA-
AND INSTALLATION
33-43
ft.lbs.
l 45-60
3343
I
I
Nm
ftlbs.
Ii
llW602
85-l 10 Nm
61-80 ft.lbs.
j18-25 Nm
13-18 ft.lbs.
Post-installation
Operation
Air Bleeding from Brake Lines (Fiefer to GROUP 5 BRAKES - Service
Adjustment
Procedures)
l
Adjustment
of Parking Brake Lever
Stroke (Refer to GROUP 5 BRAKES
- Service Adjustment
Procedures)
l
Removal steps
l *
ae
I)+
1. Adjuster
(Parking
brake cable)
2. Parking
brake cable attaching
bolts
3. Parking
brake cable heat protector
(right side only)
4. Connection
of parking
brake cables
equalizer
5. Connection
of brake hose
6. Connection
of breather
hose
7. Rear propeller
shaft
4*
l +
4*
and
8. Connection
of shock absorbers
part only)
9. U-bolts and bump stopper
10. Shackle
assembly
11. Axle assembly
(lower
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +e : Refer to Service Points of Removal.
(3) l + : Refer to Service Points of installation.
(4)
The
part
with
lowered
to the
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* must
ground.
be
tightened
with
the
vehicles
REAR AXLE
- Axle
3-21
Assemblv
N03GBAB
5.
DISCONNECTION
OF BRAKE HOSE
Before disconnecting
the brake tube, drain the brake fluid
from the bleeder screw at the right side of the rear brake.
7.
REMOVAL
OF REAR
PROPELLER
SHAFT
REMOVAL
OF U-BOLT AND BUMP STOPPER
IBefore removing the U-bolt and the bumper stopper, place
the jack underneath
the center of the axle assembly
to .6
x
hold it slightly upward.
h
%,I.,
,L
I*,
11. REMOVAL
OF AXLE ASSEMBLY
Draw out the axle assembly toward the reaf of the vehicle..
li3,
iv! ,,,,.
Caution
The axle assembly
is unstable on the jack; be careful not
to allow it to fall.
SERVICE
POINTS
OF INSTALLATION
10. INSTALLATION
OF SHACKLE
ASSEMBLY
Install the shackle assembly from the outside
inside of vehicle.
c3
Inside
vehicle
of
7.
NOBGDAB
toward
the
INSTALLATION
OF REAR PROPELLER
SHAFT
Align the mating
marks on the flange yoke and the
companion
flange to install the rear propeller
shaft.
12w514
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3-22
AXLE
SHAFT
REMOVAL
AND l.NSTALLATlON
180-220
130-159
NO3HA-
Nm
ftlbs.
Post-installation
ODeration
l
Air Bleeding from Brake Lines (Refer to GROUP 5 BRAKES - Service
Adjustment
Procedures)
l
Adjustment
of Parking Brake Lever
Stroke (Refer to GROUP 5 BRAKES
- Service Adjustment
Procedures)
Removal steps
94
1. Adjuster
(Parking
brake cable)
2. Parking
brake cable attaching
bolts
3. Parking
brake cable heat protector
(right side only)
4. Connection
of parking
brake cable and
equalizer
5. Brake drum
6. Connection
of brake tubes
7. Nuts
8. Rear axle shaft assembly
(with parking
brake cable)
9. Shims
10. O-ring
Adjustment
of axle shaft end play
+e
+e
l
l
l
l
+
+
+
+
~~
*a
~~
l * l +
+e
11.
12.
13.
14.
15.
16.
17.
18.
19.
Lock nut
Lock washer
Washer
Rear axle shaft
Bearing
inner race
Bearing
case
Oil seal
Bearing
outer race
Oil seal
NOTE
(1) Reverse the removal procedures to reinstall.
(2) C& : Refer to Service Points of Removal.
(3j
(4)
64
I
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: Refer to Service
Points
: Non-reusable
parts
of Installation.
REAR AXLE
3-23
- Axle Shaft
SERVICE
POINTS
OF REMOVAL
N03HBAB
6.
DISCONNECTION
OF BRAKE TUBES
Before disconnecting
the brake tube, drain the brake fluid
from the bleeder screw at the right side of the rear brake.
8.
REMOVAL
OF REAR AXLE SHAFT ASSEMBLY
Pull the rear axle shaft with rear brake assembly attached.
If the rear axle shaft is hard to remove, use the special
tools.
NOTE
Do not damage
its removal.
11. REMOVAL
OF LOCK NUT
jr.:
Remove the lock nut by following
the steps below.
(1) Straighten
the bent tab of the lock washer with the ,
screwdriver.
,
Il.
1
e-
i
;*&, ,
yy+ +,
MB9907\85-01
(2) Remove
(3) Remove
14. REMOVAL
OF REAR AXLE SHAFT
(1) Reinsert the lock nut on the axle shaft approximately
three turns.
(2) Install the special tool as figure to remove the rear axle
shaft from the bearing case.
Be sure to install nuts and washers diagonally.
(3) Turn nuts with equal pressure
to ensure smooth
removal of the wheel bearing.
18. REMOVAL
OF BEARING
Using a hammer
bearing case.
OUTER
RACE
bearing
19. REMOVAL
OF OIL SEAL
Remove the oil seal from the end of rear axle housing
the special tool, if necessary.
1 STB Revision
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with
1(
f
i
3-24
Shaft
INSPECTION
l
l
l
l
NOBHCAA
SERVIICE
POINTS
OF INSTALLATION
NOBHDAD
19. INSTALLATION
OF OIL SEAL
(1) Apply the specified grease to the oil seal fitting
the rear axle housing.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE J310,
(2) Drive the new oil seal into the rear axle housing
using the special tools.
(3) Apply the specified
Specified
MB990938-01
grease
grease
11 BOO45
: Multipurpose
NLGI No. 2
grease
/MB990937-01
17. INSTALLATION
grease
,Specified
11 BOO4f
5310,
periphery
SAE
of
J310,
case by
OF OIL SEAL
lontact
: Multipurpose
NLGI No. 2
SAE
MB990938-01
end by
18. INSTALLATION
OF BEARING
OUTER RACE
(1) ,Apply the specified grease to the external
the bearing outer race.
Specified
area of
grease
grease
to the external
: Multipurpose
NLGI No. 2
grease
periphery
SAE
of
5310,
(2) Press-fit the new oil seal into the bearing case until it is
.flush with the face of the bearing case by using special
.too1s.
(3) ,4pply the specified
grease to the lips of the oil seal.
:Specified
1 STB Revision
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grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
3-25
grease
: Multipurpose
NLGI No. 2
grease
SAE
REAR
of the
5310,
118021
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
,ii
t
13. INSTALLATION
OF WASHER/12.
LOCK WASHER/ll.
LOCK NUT
Install these parts with cares described below.
(1) Apply the specified grease to the thread portion of the
axle shaft, to which the locking nut is installed.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
5310,
the axle.shaft
to
by using
NOTE
If the slot in the lock nut and the tab of the lock washer
are out of alignment,
turn the lock nut in until they are
in alignment.
1 STB Revision
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!I
:
::
3-26
ADJUSTMENT
OF AXLE SHAFT END PLAY
Adjust the clearance between the bearing case and rear
axle housing end by the following procedure.
(1) Insert a 1 mm (.04 in.) thick shim and O-ring into the left
side rear axle housing.
(2) Apply the specified sealant to the mating. surface of
bearing case, install the left axle shaft into rear axle
housing and tighten the nuts.
NOTE
Tighten
!$pecified
sealant
sequence.
: 3M ART
equivalent
Part
No 8663,
8661
or
(3) Install the right axle shaft without a shim (s) and O-ring
and temporarily
tighten to about 6 Nm (4.3 ft.lbs.).
(4) Measure the clearance between the bearing case and
rear axle housing end with a feeler gage.
(5) Select shims of the thickness
which is equal to the
sum of the measured
clearance
and 0.05-0.20
mm
(.0020-.0079
in.)
(6) Remove the right axle shaft, and install shim (s) and Oring on the right side rear axle housing end.
(7) Apply the specified
sealant to the mating surface of
bearing case, install the right axle shaft into rear axle
housing and tighten the nut.
NOTE
Tighten
Specified
sealant
sequence.
: 3M ART Part
equivalent
No. 8663,
8661
the standard
Standard
1160671
1 ST6 Revision
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or
value
: 0.05420
mm (.0020-.0079
in.)
DIFFERENTIAL
REMOVAL
3-27
Carrier
CARRIER
NONA-
AND INSTALLATION
13-17
Nm
9-I:
ft.lbs
50-60
36-43
3u-ou
36-43
Nm
ft.lb,s.
Ivrn
ft.,bs.
18-22
40-60
29-43
n@
Nm
ft.lbs.
ft.lbs.
5
llW615
Pre-removal
l
Operation
Drain of Differential
to P.3-17.)
Post-installation
ODeration
.I
,
c
2
<
Removal steps
l *
1. Adjuster
(Parking
brake cable)
2. Parking
brake cable attaching
nuts
3. Parking
brake cable heat protector
(right side only)
4. Connection
of parking
brake cable
equalizer
5. Brake drums
6. Connection
of brake tubes
7.
+e
+e
+e
l +
l +
Nuts
i\
and
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +w : Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation.
SERVICE
POINTS
OF REMOVAL
N0316AB
6.
DISCONNECTION
OF BRAKE TUBES
Before disconnecting
the brake tube, drain the brake fluid
from the bleeder screw at the right side of the rear brake.
8.
REMOVAL
OF REAR AXLE SHAFT ASSEMBLY
Pull out the right and left axle shafts by about 70 mm (2.8
in.). If it is hard to pull out, use the special tools.
STB Revision
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I'*
3-28
Carrier
OF REAR
PROPELLER
SHAFT
10. REMOVAL
OF DIFFERENTIAL
CARRIER
NOTE
Do not remove the uppermost
the way to the stud bolt end.
Caution
Use care not to strike
SERVICE
t-3 mm
.08-.12 in.)
POINTS
part of
several
the companion
all
flange.
OF INSTALLATION
NOBIDAB
10. APPILICATION
OF SEALANT TO DIFFERENTIAL
CARRIER
When the differential
carrier is installed,
apply specified
sealant to the differential
carrier mounting
surface of the
axle housing as illustrated
in either of the illustrations.
Specified
sealant
: 3M ART
equivalent
Part
No.
8663,
8661
or
11 BOO51
9.
INSTALLATION
OF REAR PROPELLER
SHAFT
Align the mating
marks on the flange yoke and the
companion
flange to install the rear propeller
shaft.
STB Revision
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3-29
Carrier
BEFORE DISASSEMBLY
N03lEAA
Secure the working base in a vice and then install the removed
differential carrier assembly.
or more
on the circumference
:1:
,>
of the<
t.
Standard
value
: 0.1 l-0.16
mm (.0043-.0063
at the shoulder
in.)
on the reverse
DIFFERENTIAL
GEAR BACKLASH
(CONVENTIONAL
DIFP-
bi,
FERENTIAL)
While locking the side gear with the wedge, measure the \I
differental
gear backlash with a dial indicator
on the pinion ;. .
gear.
;
1 STB Revision
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Carrier
condition
NOTE
Chec:king the tooth contact pattern is the way to confirm
that the adjustments
of the pinion height and backlash
have been done properly. Continue
to adjust the pinion
height and backlash until the tooth contact pattern resembles the standard pattern.
If, after adjustments
have been made, the correct tooth
contact pattern cannot be obtained,
it means that the drive
gear and the drive pinion have become worn beyond the
allowable
limit. Replace the gear set.
Caution
If either
replaced,
1 STB Revision
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be
REAR
Standard
1
2
3
tooth
contact
AXLE
- Differential
3-31
Carrier
pattern
Toe
Drive-side
Heel
Coast-side
-1
Problem
Tooth contact
ion height
pattern
resulting
from
excessivb
Solution
pin-
Tooth
height
contact
pattern
resulting
from
insufficient
position
the
drive
gear
pinion
llS641
/ STB Revision
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3-32
Carrier
(Conventional
Type)
DISASSEMBLY
Inspection
l
Before
Disassembly
P.3-29.)
l
l
(Refer to
P.3-29.)
56
15-22 Nm
/ / ?514,
80-90
190-250
137-181
Disassembly
Nm
58-65 ftlbs.
Nm
ft.lbs.
steps
lW546
1. Lock plates
2. Side bearing nuts
3. Bearing caps
4. Differential case assembly
5. Side bearing outer races
6. Side bearing inner races
7. Bolts (10)
8. Drive gear
9. Lock pin
IO. Pinion shaft
11. Thrust block
12. Pinion gears
13. Pinion washers
14. Side gears
15. Side gear thrust spacers
16. Differential case
17. Self-locking nut
18. Washer
l *
4*
NOTE
(1) +e
(2)
: Non-reusable
SERVICE
2.
POINTS
parts
OF DISASSEMBLY
REMOVAL
OF SIDE BEARING
Using the special tool, remove
1 STB Revision
--
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NUT
the side bearing
NOOIGAA
nut.
REAR AXLE
Differential
4.
Carrier
REMOVAL
Take out
handles.
(Conventional
3-33
Type)
OF DIFFERENTIAL
CASE ASSEMBLY
the differential
case assembly
with
hammer
NOTE
Keep the right and left side bearings and side bearing nuts
separate, so that they do not become mixed at the time of
reassembly.
6.
MB990339-0
REMOVAL
OF SIDE BEARING INNER RACE
Pull out the side bearing inner races by using the special
tools.
#l.
8.
REMOVAL
OF DRIVE GEAR
(1) Make the mating marks to the differential
case and the
drive gear.
(2) Loosen the drive gear attaching
bolts in diagonal
sequence to remove the drive gear.
9.
DRIVE-OUT
OF LOCK PIN
Drive out the lock pin with a punch.
NOTE
The removed side gears and side gear thrust
and right, should be retained for reassembly.
17. REMOVAL
OF SELF-LOCKING
NUT
Use the special tools to hold the companion
remove the companion
flange self-locking
nut.
1 STB Revision
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:.
>
2:
,
spacers,
left
flange
and
1;.
Carrier
(Conventional
Type)
pinion
and
Caution
The mating
mark made on the companion
flange
Imust not be on the coupling surface of the flange
yoke and the rear propeller shaft.
(2) Drive out the drive pinion together with the drive pinion
spacer and drive pinion front shims.
20. REMOVAL
RACE
OF DRIVE
28. REMOVAL
RACE
Brass rod
PINION
pinion
OF DRIVE
REAR
rear bearing
PINION
FRONT
front bearing
BEARING
inner
INNER
race by using
BEARING
OUTER
29. REMOVAL
OF DRIVE PINION
REAR BEARING
OUTER
RACE
Drive out the drive pinion rear bearing outer race from the
gear carrier.
INSPElCTlON
l
l
l
l
l
l
l
N03lHAA
STB Revision
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REAR AXLE
- Differential
Carrier
(Conventional
3-35
Type)
REASSEMBLY
N0311.-
11
80-90 Nm
58-65 ftlbs.
190-250 Nm
137-181 ftlbs.
11-16
lW546
Reassembly steps
I, Differential carrier
1)4 2. Drive pinion rear bearing outer race
I)*
3. Drive pinion front bearing outer race
l + Adjustment of pinion height
l +
4. Drive pinion
5. Drive pinion rear shim (for pinion height
adjustment)
l *
6. Drive pinion rear bearing inner race
l +
l + Adjustment of drive pinion preload
7. Drive pinion front bearing inner race
l +
8. Oil seal
9. Drive pinion front shim (for preload adjustment)
~~
10. Drive pinion spacer
l +
11. Drive pinion assembly
12. Companion flange
13. Washer
14. Self-locking nut
NOTE
15. Differential case
(I) l +
(2) q
16. Side gear thrust spacers
1 STB Revision
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3-36
REAR AXLE
- Differential
Carrier
SERVICE
2.
MB990936-01
(Conventional
POINTS
INSTALLATION
ER RACE
Type)
OF REASSEMBLY
OF DRIVE
PINION
REAR BEARING
press-fitting
carefully
NOBIJAB
outer
OUT-
llYO53
3.
INSTALLATION
OF DRIVE PINION
OUTER RACE
Press-fit the drive pinion front bearing
carrier by using the special tools.
NOTE
Perform
race.
press-fitting
carefully
FRONT
outer
BEARING
llW595
MB990905-1-01
HW518
OF PINION
HEIGHT
Adjustment
the drive pinion
height
by the following
procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races to the gear carrier in the sequence
shown in the illustration.
MB990901-0
lit-
AD.JUSTMENT
NOTE
Apply a thin coat of the specified grease
face of the washer of the special tool.
Specified
grease
: Multipurpose
NLGI No. 2
to the mating
grease
SAE J310,
(2) Tighten the handle of the special tool until the standard
value of drive pinion turning torque is obtained.
(3) Measure
seal).
torque
value
NOTE
Gradually
checking
http://vnx.su/
Nm (3.5-4.3
(without
Standard
1 STB Revision
: 0.4-0.5
turning
the oil
in.lbs.)
tool while
REAR AXLE
Differential
Carrier
(Conventional
3-37
Type)
(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion rear shim of
a thickness which corresponds
to the gap between the
special tools.
NOTE
Be sure to clean the side bearing seat thoroughly.
When positioning
the special tool, be sure that the cutout sections
of the special tool are in the position
shown in the illustration,
and also confirm
that the
special tool is in close contact with the side bearing
seat.
When selecting the drive pinion rear shims, keep the
number of shims to a minimum.
,P
(5) Fit the selected drive pinion rear shim(s) to the drive !
pinion, and press-fit the drive pinion rear bearing inner J
4
race by using the special tool.
i
!.a..
ADJUSTMENT
OF DRIVE
Adjust the drive pinion
following procedure:
Without
PINION
turning
PRELOAD
torque
by using
the
Oil Seal
(1) Fit the drive pinion front shim(s) between the drive
pinion spacer and the drive pinion front bearing inner
race.
(2) Tighten the companion
flange to the specified torque
by using the special tools.
NOTE
Do not install the oil seal.
(3) Measure
seal)
Standard
value
: 0.4-0.5
turning
torque
Nm (3.5-4.3
(without
the oil
i
i
i.
;i
in.lbs.)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque by
replacing
the drive pinion front shim(s) or the drive
pinion spacer.
.
NOTE
When selecting
the drive pinion front shims, if the
number of shims is large, reduce the number of shims
to a minimum
by selecting
the drive pinion spacers.
(5) Remove
again.
/ STB Revision
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the companion
flange
,:/
/.
once
:t
3-38
Carrier
(Conventional
Type)
d
J
grease
: Multipurpose
NLGI No. 2
grease
SAE
5310,
grease
: Multipurpose
NLGI No. 2
grease
-
SAE
J310,
llD554
(5) Measure the drive pinion turning torque (with oil seal)
to verify that the drive pinion turning torque complies
with the standard value.
Standard
value
: 0.65-0.75
Nm (5.6-6.5
in.lbs.)
111223
ADJUSTMENT
OF DIFFERENTIAL
GEAR BACKLASH
(1) ,4ssemble
the side gears, side gear thrust spacers,
ipinion gears, and pinion washers into the differential
(case.
(2) Temporarily
install the pinion shaft.
NOTE
00 not drive in the lock pin yet.
1 STB Revision
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Carrier
3-39
Type)
(Conventional
(3) Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
(4) While locking the side gear with the wedge, measure
the differential
gear backlash with a dial indicator
on
the pinion gear.
Standard
value : 0.01-0.076
Limit
: 0.2 mm (.008 in.)
mm
(.0004-.0030
in.)
llS606
*<
22. INSTALLATION
OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.
23. INSTALLATION
OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhered to the threaded holes of
the drive gear by turning the tap tool (Ml0 x 1.25),eand
then clean the threaded holes by applying compressed
air.
adhesive
adhesive
to the threaded
: 3M adhesive
or equivalent
holes of
stud locking
4170
1 STB Revision
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.
4;.
:
,
Carrier
(Conventional
Type)
28. INSTALLATION
OF BEARING
CAP
Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.
ADJUSTMENT
OF FINAL
DRIVE
GEAR
BACKLASH
-8,
ri,
:,
3-t
(2) Measure
<Standard
,
?
: 0.11-0.16
mm (.0043-.0063
in.)
,?+5
When
backlash
is in-
tool (MB990201-Ol),
adjust the
value by moving the side bearing
NOTE
First turn the side bearing nut for loosening,
and then
turn (by the same amount)
the side bearing nut for
tightening.
LWhen
badladh
cessive
is ex110267
STB kevision
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REAR
AXLE
- Differential
Carrier
(Conventional
Type)
3-41
(4) Using the special tool, to apply the preload, turnn down
both right and left side bearing
nuts on half the
distance between centres of two neighbouring
holes.
MB092153
MB092154
: 0.05
mm
is evident,
(.OOZO in.)
1 STB Revision
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3-42
REAR AXLE
- Differential1
Carrier
(Limited
Slip Type)
DISASSEMBLY
NOBISA-
Inspection
Before Disassembly
Final Drive Gear Backlash (Refer to
Contact
(Re-
15-22 Nm
11-16 ft.lbs.
55-65 Nm
40-47 ftlbs.
80-90 Nm
58-65 ft.lbs.
Disassembly
steps
1,
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Lock plates
Side bearing
nuts
Bearing
caps
Differential
case assembly
Side bearing
outer races
Side bearing
inner races
Bolts
Drive gear
Limited
slip differential
case assembly
Self-locking
nut
Washer
Drive pinion assembly
Drive pinion
rear bearing
inner race
Drive pinion
rear shim (for pinion
height
adjustment)
/ STB Revision
15.
16.
17.
18.
l *
4*
NOTE
(1) qe
(2) m
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19.
20.
21.
22.
23.
Drive pinion
Companion
flange
Drive pinion
spacer
Drive pinion front shim (for preload
adjustment)
Oil seal
Drive pinion front bearing
inner race
Drive pinion front bearing
outer race
Drive pinion
rear bearing
outer race
Differential
carrier
Carrier
(Limited
SERVICE POINTS
Slip
REMOVAL
Take out
handles.
3-43
OF DISASSEMBLY
2. REMOVAL
OF SIDE BEARING
Using the special tool, remove
4.
Type)
NOllLAA
NUT
the side bearing.
OF DIFFERENTIAL
CASE ASSEMBLY
the differential
case assembly
with
hammer
,.1.
NOTE
Keep the right and left side bearings and side bearing nuts;
separate, so that they do not become mixed at the time of :.
reassembly.
e,
6.
REMOVAL
OF SIDE BEARING
INNER RACE
Pull out the side bearing inner races by using the special
tools.
8.
REMOVAL
OF DRIVE GEAR
(1) Make the mating marks to the differential
case and the r,
Y
drive gear.
(2) Loosen the drive gear attaching
bolts in diagonal
.;
..
sequence to remove the drive gear.
10. REMOVAL
OF SELF-LOCKING
NUT
Use the special tools to hold the companion
remove the companion
flange self-locking
nut.
1 STB Revision
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flange
and
REAR
AXLE
Differential
Carrier
(Limited
Slip
Type)
12. REMOVAL
OF DRIVE PINION ASSEMBLY
(1) Make the mating
marks to the drive
companion
flange.
pinion
and
Caution
The mating
mark made on the companion
flange
must not be on the coupling
surface of the flange
yoke and the rear propeller
shaft.
(2) Drive out the drive pinion together with the drive pinion
spacer and drive pinion front shims.
13. REMOVAL
OF DRIVE PINION
REAR BEARING
RACIE
Pull out the drive pinion rear bearing innerrace
the special tools.
INNER
by using
21. REMOVAL
OF DRIVE PINION
FRONT BEARING
OUTER
FUKIE
Drive out the drive pinion front bearing outer race from the
gear carrier.
llWS94
22. REMOVAL
OF DRIVE PINION
REAR BEARING
OUTER
RACIE
Drive out the drive pinion rear bearing outer race from the
gear carrier.
INSPECJTON
NOBIMAA
1 STB Revision
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Carrier
(Limited
Slip
3=45
Type)
REASSEMBLY
NOBIT-
15-22 Nm
11-16 ft.lbs.
55-65 Nm
40-47 ftlbs.
190-250
137-181
Nm
ft.lbs.
/
80-90 Nm
58-65 ftlbs.
HBOO97
Reassembly steps
1. Differential carrier
1)4 2. Drive pinion rear bearing outer race
l + 3. Drive pinion front bearing outer race
l a Adjustment of pinion height
4. Drive pinion
5. Drive pinion rear shim (for pinion height
adjustment)
6. Drive pinion rear bearing inner race
w+ Adjustment of drive pinion preload
7. Drive pinion front bearing inner race
8. Oil seal
9. Drive pinion front shim (for preload adjustment)
IO. Drive pinion spacer
11. Drive pinion assembly
12. Companion flange
3. Washer
4. Self-locking nut
5. Limited slip defferential case assembly
6. Drive gear
7. Bolts
8. Side bearing inner races
19. Side bearing outer races
20. Differential case assembly
l + 21. Bearing caps
l + Adjustment of final drive gear backlash
22. Side bearing nuts
23. Lock plate
NOTE
(1) l + : Refer to Service Pointsof Reassembly
(2) q : Non-reusableparts
/ STB Revision
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,,
::
>
3-46
REAR AXLE
- Differential
-
Carrier
SERVICE
(Limited
POINTS
Slip Type)
OF REASSEMBLY
NOBINAB
2. INSTALLATION
OF DRIVE PINION
REAR BEARING
OUTER RACE
Pressfit the drive pinion rear bearing outer race into the
gear carrier by using the special tools.
MB990938-01
NOTE
Perform
race.
press-fitting
carefully
llYO53
3.
MB990938-01
MB990934-01
INSTALLATION
OF DRIVE PINION
OUTER RACE
Press-fit the drive pinion front bearing
carrier by using the special tools.
NOTE
Perform
race.
press-fitting
carefully
FRONT
outer
BEARING
llW595
ADJUSTMENT
OF PINION
HEIGHT
grease
: Multipurpose
NLGI No. 2
grease
SAE
5310,
(2) Tighten the handle of the special tool until the standard
value of drive pinion turning torque is obtained.
MB990905-1-01
(3) Measure
seal).
: 0.4-0.5
turning
torque
Standard
value
NOTE
Gradually
checking
1 STB Revision
http://vnx.su/
Nm (3.543
(without
the oil
in.lbs.)
tool while
REAR AXLE
- Differential
Carrier
(Limited
3-47
Slip Type)
(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion rear shim of
a thickness which corresponds
to the gap between the
special tools.
NOTE
Be sure to clean the side bearing seat thoroughly.
When positioning
the special tool, be sure that the cutout sections
of the special tool are in the position
shown in the illustration,
and also confirm that the
special tool is in close contact with the side bearing
seat.
When selecting
the drive pinion rear shims, keep the
number of shims to a minimum.
(5) Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
i
race by using the special tool.
i.
.
MB990767-01
ADJUSTMENT
OF DRIVE PINION
PRELOAD
Adjust the drive pinion turning
torque
by using the
following
procedure:
Without
Oil Seal
(1) Fit the drive pinion front shim(s) between the drive
pinion spacer and the drive pinion front bearing inner
race.
(2) Tighten the companion
flange to the specified torque
by using the special tools.
NOTE
Do not install
(3) Measure
seal).
Standardvalue
llY223
, I!
: 0.4-0.5
turning
torque
(without
Nm
(3.5-4.3
in.lbs.)
the oil ?,
t
..>
(4) If the drive pinion turning torque is not within the range
of the standard
value, adjust the turning torque by
replacing
the drive pinion front shim(s) or the drive
pinion spacer.
NOTE
When selecting
the drive pinion front shims, if the
number of shims is large, reduce the number of shims
to a minimum
by selecting
the drive pinion spacers.
(5) Remove
again.
/ STB Revision
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the companion
flange
and drive
pinion
once
Carrier
Slip Type)
(Limited
MIT304180
Specified
: Multipurpose
NLGI No. 2
grease
MB990031-01
grease
SAE J310,
llV224
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
llD554
(5) Measure the drive pinion turning torque (with oil seal)
to verify that the drive-pinion
turning torque complies
with the standard value.
Standard
value
: 0.65475
Nm (5.6-6.5
in.lbs.)
16. INSTALLATION
OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhered to the threaded holes of
the drive gear by turning the tap tool (Ml 0 x 1.25), and
then clean the threaded holes by applying compressed
air,
llVl96
1 STB Revision
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- Differential
REAR AXLE
Carrier
(Limited
3-49
Slip Type)
adhesive
to the threaded
holes of
adhesive
: 3M Adhesive
or equivalent
stud locking
4170
18. PRESS-FIT
OF SIDE BEARING
INNER RACE
Press-fit the side beating inner races to the
case by using the special tool.
21. INSTALLATION
OF BEARING
differential
,!,.,
T.i;
CAP
Align the mating marks on the gear carrier and the beating
cap: an.d&then tighten the bearing cap.
ADJUSTMENT
OF FINAL DRIVE GEAR BACKLASH
(1) Using the special tool temporarily
tighten
the side
bearing nut until it is in the state just before preloading
of the side bearingL
lW522
(2) Measure
Standard
STB Revision
http://vnx.su/
: 0.11-0.16
mm (.0043-.0063
in.)
I,
3-50
R@R
When
backlash
AXLE
- Differential
Carrier
(Limited
Slip
Type)
is in-
NOTE
First turn the side bearing nut for loosening,
and then
turn (by the same amount)
the side bearing nut for
.tightening.
cessive
(4) Using the special tool, to apply the preload, turn down
both right and left side bearing
nuts on half the
distance between centres of two neighbouring
holes.
MB092153
: 0.05
mm
(.0020
is evident,
in.)
1 STB Revision
I
http://vnx.su/
REAR AXLE
- Differential
Carrier
(Limited
Slip
3-51
Type)
OVERHAUL
I
I
Differential
gear set
Disassembly steps
l * *+
I. Screw
2. Differential case (A)
3. Thrust washer
4. Spring plate
5. Spring disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure ring
11. Side gear
12. Thrust block
13. Differential pinion gear
14. Differential pinion shaft
15. Thrust block
16.
17.
18.
19.
20.
21,
22.
23.
24.
l + 25.
Side gear
Pressure ring
Friction disc
Friction plate
Friction disc
Friction plate
Spring disc
Spring plate
Thrust washer
Differential case (6)
NOTE
(I) Reverse the disassembly procedures to reassembly
(2) *e
: Refer to Service Points of Disassembly.
(3) l + : Refer to Service Points of Reassembly.
1 STB Revision
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3-52
Carrier
SERVICE
(Limited
POINTS
Slip Type)
OF DISASSEMBLY
NOBIPAA
1. REMOVAL
OF SCREW
(1) Loosen screws of the differential
cases (A) and (B)
uniformly a little at a time.
(2) Separate differential
case (A) from differential
case (B).
NOTE
Before disassembling
the differential
cases, confirm
that the mating rnarks (numbers) on case A and case B
are the same.
1lSBBC
(3) Remove
the components
from differential
case (B).
NOTE
Keep the right and left thrust washers, spring plates,
spring discs, friction plates, and friction discs separate
in order to be able to distinguish
them for reassembly.
INSPECTION
l
l
NO3lClAA
Check the side gears, pinion gears and pinion shaft for
wear or damage.
Check the side gear spline for wear or damage.
INSPECTION
PARTS
OF CONTACT
AND
SLIDING
SURFACES
OF
(1) Inspect the friction plate, friction disc, spring plate, spring
disc: and pressure ring.
A The friction surfaces of the friction plate, friction disc,
spring plate, and spring disc. If there are any signs of
seizure, severe friction, or color change from the heat, it
will adversely affect the locking performance;
replace
the part with a new one.
NOTE
The strong contact on the inner circumference
of the
friction surfaces is because of the spring plate and the
spring disc; this wear is not abnormal.
6
D
G
\
D
llS659
NOTE
.The strong contact on the inner circumference
of the
.friction surface is because of the spring plate and the
spring disc; this wear is not abnormal.
1 STB Revision
http://vnx.su/
I N
(Limited
Slip
3-53
Type)
(2) Inspect the contact and sliding surfaces listed below, and
repair any nicks and burrs by using an oil stone.
E The sliding surfaces of the thrust washer and the case.
F The spring contacting
surface of the differential
case.
G The contact surfaces of the outer circumference
of the
pressure
ring and the inner circumference
of the
differential
case.
H The sliding surface of the thrust washer.
I The sliding surfaces of the hole in the pressure ring
and the outer circumference
of the side gear.
J The projection
on the outer circumference
of the
pressure ring.
K The spherical
surface of the differential
pinion. gear
)
and the inner diameter
of the pressure ring.
L The V-shaped groove in the pressure ring, and the V- ,,.,,:
ir
shaped part in the pinion shaft.
M The outer diameter of the pinion shaft and the hole of ii
!
the differential
pinion gear.
;,
N The outer circumference
groove of the side gear.
0 The inner circumference
groove of the differential
!,- ,
case.
P The sliding surface of the thrust block.
llS658
Carrier
L
lS662
INSPECTION
FOR WARPING
OF FRICTION
PLATE AND
FRICTION
DISC
Using a dial indicator,
measure the amount of warping (the
flatness) of the friction plate and the friction disc on a surface
plate by turning the friction plate or disc.
Limit
: 0.08
mm
(.0031
in.)
INSPECTION
FOR WEAR OF FRICTION
PLATE AND FRICTION DISC
(1) In order to measure the wear, measure the thickness
of
the friction surfaces and projections
of the friction disc and
plate, and then find the difference.
(The same procedure is used for the spring discs and the
spring plates.)
Limit
: 0.1 mm
(.004
NOTE
Make the measurement
11swo
in.)
at several
STB Revision
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different
the allowable
points.
limit,
replace
.:
i.
!
REAR AXLE - Differential
Carrier
SERVICE
Slip Type)
(Limited
POINTS
OF REASSEMBLY
NOBIRAC
25. INSTALLATION
OF DIFFERENTIAL
CASE (6)
Before assembly,
use the following
method to adjust the
clearance between the spring plates and differential cases
(for adjustment
of the clutch plate friction force), and to
adjust the axial clearance of the side gear when installing
the internal components
into the differential
case.
value
IVOTE
IFor new ones, there is one type of friction plate: 1.75
mm (.0689 in.); there are two types of friction disc:
1.75 mm (.0689 in.) and 1.85 mm (.0728in.).
(2).Arrange one spring disc and one spring plate for each
side, one on top of the other, so that the difference
,between the left and the right thickness
is minimized.
IPJOTE
IFor new ones, there is one type
spring plate: 1.75 mm (.0689 in.).
of spring
disc and
(3),Assemble
the pressure
rings internal
components
(differential
pinion shaft and pressure
ring) and the
friction discs and friction plates, and then, as shown in
the figure, measure the overall width.
of the
(4 .)Calculate the total value (C) of the thickness
spring discs and spring plates plus the value measured
in (3) above.
(5)Obtain
the dimension
(D) between
the spring plate
contact surfaces when differential
cases (A) and (B) are
combined.
(D=E+F-G)
(6)Change the thickness
of the friction disc so that the
clearance (D - C) between the differential
case and
the spring plate becomes the standard value.
!Standard
evision
value
: 0.06-0.20
-http://vnx.su/
mm (.0024-.0079
in.)
REAR AXLE
Differential
Carrier
(Limited
Slip
3-55
Type)
(7)Remove
the spring plates, spring discs, friction plates
and friction disc.
(8)lnstalI the thrust washer as shown in the figure, and
then select a thrust washer so that the difference
between
the left and right dimensions
from the
pressure ring rear face to the thrust washer end face is
the standard value.
Standard
Thrust
washer
value
NOTE
Measure the distance
groove manually.
115654
while
squeezing
the V-shaped
end
:,.
l.&
Thrust
washer
1,cIIs4
(10)Obtain
the dimension
(I) between the thrust washer
contact surfaces when differential
cases (A) and (B) are
combined.
(I=J+K+L)
NOTE
Dimension
J is the distance between the spring plate
contact surfaces when differential
cases (A) and (B) are
combined.
(Refer to P.3-54.)
(1 l)Change
the thickness of the thrust washer so that the
clearance ( I - H ) between the thrust washer and the
differential
case is the standard value.
Standard
value
: 0.05-0.20
mm
(.0020-.0079
in.)
NOTE
I. Select the thrust washer so that the difference
between the left and right dimensions
from the
pressure ring rear face and the thrust washer end
surface are the standard
value even when the
thrust washer is changed.
2. There are three sizes of new thrust washers: 1.50
mm (.0591 in.), 1.60 mm (.0630 in.), and 1.70 mm
(.0670 in.)
ng
Spri
plate
Friction
(12)Place
the each part in the differential
directions shown in the figure.
plate
case
(B) as
NOTE
1. . Before assembly,
apply the specified
gear oil to
each component
especially careful to coat contact
surfaces and sliding surfaces.
1
spring
disc
Fribtion
disc
llsst
1STBsion
http://vnx.su/
3-56
Carrier
(Limited
!jpecified
gear oil:
MITSUBISHI
Genuine
or equivalent
2.
Slip Type)
Gear Oil Part No. 8149630
EX
1. INSTALLATION
OF SCREW
(1) Align the mating
marks (the same numeral
on each
case) of differential
case (A) and differential
case (B).
(2) Turning the screwdriver
slowly several times, tighten
the screw so that the cases are in close contact.
i s66a
Tool
MB990!
NOTE
If, even though
the screw is tightened,
the end
surfaces of case (A) and case (B) do not come into
close contact, probably the thrust washer and spring
plate are not fit correctly into the groove, so make the
assembly
again.
(3) After assembly, in order to check the frictional force of
the clutch plate, use the special tools to measure the
starting torque.
38 G
Standard
value:
When a new clutch plate is used
65-100 Nun (47-72 ft.lbs.)
When an old clutch plate is used
35-100 Nun (25-72 ftlbs.)
NOTE
Measure
the starting
torque
after rotating
slightly.
When measuring
the torque, do so at the beginning
of
movement.
1 STB Revision
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22-1
wti&LS
AND
CONTENTS
GENERAL
INFORMATION
. . . . .. .. .. . . . . . . . . .. .. . . . . . . .. . . .
SERVICE ADJUSTMENT
PROCEDURES
. . . . . .. . . .
Checking Tire Inflation Pressure
,......,.............
Checking Tire Wear . . .. . . . . . . . . . . . . . .._..................
. . . . . . . . . . . . . . . . .. . . . .
4
4
4
. . . . . . . . . . . .. .. .. . . . . . . .. .. . . . . . . . . .. .. .
.*.....................................a.......
SPECIFICATIONS
General Specifications
. . . . . . . . . . . . . .. .. .. . . . . . . . . .. .. . . . . .
Sealant and Adhesive
. . . .. .. . . . . . . . . . . .. . . . . . . . . .. .
Service Specifications
. .. .. .. . . . . . . . . . . . . . .. . . . . . . . . . . .. . . .
2
2
2
2
Checking
Wheel
Runout
Torque
Specifications
. . . . . .. . . . . . . . . . .. . . . . . .. .
N22AA--
TROUBLESHOOTING
Bald Spots
Cracked Treads
. . . . . . . . . . . .. . . . . . . . . . . . .. .. . . . . . . .. .. . .
Feathered Edge
Rapid Wear at Center
Rapid Wear at Shoulders
Scalloped Wear
Wear on One Side
WHEELS
http://vnx.su/
AND TIRES
. . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .
4, .
1..
i IT
>\ :
c,
I&.
22-2
WHEELS
/ Specifications
GENERAL INFORMATION
All models
are equipped
with tubeless
N22BAAD
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N22CA-
Specifications
Items
Wheel
Tire size
P225ff 5R-15
Wheel type
Steel type
Wheel size
6JJx 15
Amount
of wheel
mm (in.)
offset
22 (.87)
kPa (psi)
Front wheels
180 (26)
Rear wheels
NOTE
*Minimum
for improving
ride comfort
N22CB.-
Specifications
Items
I
* Limit
Wheel runout
Radial
3(.12)
mm (in.)
3 (.12)
1.6 (.06)
Lateral
mm (in.)
Tread depth of tire
mm (in.)
TORQUE SPECIFICATIONS
Items
Hub nuts for steel wheel
Spare tire bracket
SEALANT
to body
AND ADHESIVE
N22CD.-
Item
Spare tire bracket
mounting
Specified
bolts
pTB
Revision
http://vnx.su/
Quantity
As required
22-3
TROUBLESHOOTING
N22EA-
Symptom
Probable cause
Remedy
Reference
Rapid wear
at shoulders
Underinflation
or lack of
rotation
22-2
Rapid wear
at center
Overinflation
or lack of
rotation
Cracked
treads
Under-inflation
Wear on
one side
Excessive
camber
2-l 5
Feathered
edge
Incorrect
toe
2-l 5
Bald spots
Unbalanced
wheel
Adjust the
imbalanced
wheels
Scalloped
wear
22-6,
2-l 5
1 ST6 Revision
page
http://vnx.su/
22-4
WHEELS
Adjustment
procedures
/ Wheels
SERVICE ADJUSTMENT
CHECKING
TIRE
Measure
Tires
PROCEDURES
INFLATION
PiRESSURE
CHECKING
and
make
the
N22FDAA
necessary
TIWE WEAR
N22FBAB
53Y510
Limit
If the remaining
tire.
tread depth
NOTE
When the tread depth of tires is reduced
less, wear indicators will appear.
CHECKING
WMEEL
replace
the
RUNOUT
N22FCAB
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with a
dial indicator.
i
34,
5
Limit
If wheel
runout
exceeds
the
limit,
replace
the wheel.
AND
INSTALLATION
NZZGA-
Removal steps
1.
2.
l + 3.
4.
Center cap
Hub nut
Center cap holder
Balance
weight
5. Steel wheel
6. Tire
11w599
100-120
72-87
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +e : Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation.
1 STB Revision
---I
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Nm
ft.lbs.
WHEELS
AND TIRES
SERVICE
Wheels
POINTS
and
22-5
Tires
OF REMOVAL
1. REMOVAL
OF CENTER CAP
(1) Using the vehicle equipped
wheel nut wrench), remove
NZZGBAB
Caution
Use a piece of cloth or other, similar
material
prevent scratching
the wheel when the wheel
wrench or wheel nut wrench is used.
or
to
cap
0
0
For front
wheel
SERVICE
3.
Remove
the wheel cap wrench
or wheel nut
1
J
wrench and use it at the opposite side.
Move each tool as shown in the figure so as to $ ;$
remove the wheel cap.
.
4t
POINTS
INSTALLATION
OF INSTALLATION
OF CENTER
N22GDM
CAP HOLDER
NOTE
Note that the center cap attaching
metal fittings
front and rear wheels are different in shape.
for the
C;t ends
Front
wheel
Flea! wheel
( STB Revision
i
http://vnx.su/
22-6
WHEELS
/ Spare
Tire Carrier
ROTATION
N22GE.-
TIRE CHAINS
03-W
AND SNOW
TIRES
N22GGAB
1. Use tire chains only on rear wheels. Do not use tire chain
on front wheels.
2. When using snow tires, use them on all four wheels for
maneuverability
and safety.
60E501
AND
INSTALLATION
N22HA-
8-10 Nm
6-7 ftlbs.
llW600
Removal
steps
1. Hub nut
NOTE
(1) Reverse the removal procedures to reinstall.
(2) **
: Refer to Service Points of Installation
2. Spare tire
l + 3. Spare tire bracket
SERVICE
POINTS
OF INSTALLATION
3. APPLICATION
OF SEALANT
Apply a coat of the specified
bracket mounting
bolts.
Specified
sealant
STB Revision
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N22HDAC
2-1
SUSPE
CONTENTS
AXLE HUB AND FREE-WHEELING
DIFFERENTIAL
CARRIER
DRIVE SHAFT
FRONT
INNER
KNUCKLE
LOWER
...................................
MOUNTING
INFORMATION
SHAFT
...........
52
.................................
2
62
44
ARM
......................................................
Replacement
of Lower Arm Bushing
.............
Replacement
of Lower Ball
Joint Dust Cover ..............................................
SERVICE ADJUSTMENT
PROCEDURES
..........
Checking Drive Shaft End Play ........................
Checking Front Axle Total Backlash
...............
..................................
and Adjustment
of Wheel
........................................................
Replacement
of Differential Carrier Oil Seal
ABSORBER
Replacement
SPECIAL
TOOLS
AND UPPER
ARM
SPECIFICATIONS
...............................................
General Specifications
....................................
Lubricants
.......................................................
42
42
14
16
15
14
... 17
............
....................
................................................
40
16
Inspection
Alignment
SHOCK
STABlLlZER
TORSION
.....................................................
.. . . . . . . . . . . .. .. . . . . . . . . .. . . . . . . .. . .
. . . . . . . . . .. .. . . . . . . . . .. .. . . . . . .. . . . . .
. . . . . . . .. . . . . . . .. .. . . . . . . . .. . . . . .
7
!?I
6 ,-.
. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . .. . . . . 51
66
................
...........................................................
Checking
16
68
.....................................................
DIFFERENTIAL
GENERAL
HUB
35
37
8
4
4
7
BAR
TROUBLESHOOTING
. . .. . . . . . . . . .. .. . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . .. . . . . 48
.. ..a...................................
AUTOMATIC
FREE WHEELING
Does not lock
Locks but does not become
HUB
11
. . .. .. . . . . . . . 11
free
:
,-,,.t
Ratcheting
readily occurs
-$ I ;j;;.
.. . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .. . . . . . . . . . I$ -:Y+:
DIFFERENTIAL
II. ,;.
Bearing noise while driving or. coasting
: , ,.;,
;
Constant noise
i t
.:I
. ,;J.;
Gear noise while coasting
.a
*;,*.,..,.f. .
Gear noise while driving
:.
k
Heat
j L.t
Noise while turning
Oil leakage
DRIVE SHAFT, INNER SHAFT . . .. . .. . . . . . . .. .. . . . . . . . 12
Noise due to excessive play of wheel in
turing direction
Noise due to excessive wheel end play
Noise during wheel rotation
MANUAL FREE WHEELING
HUB,
FRONT AXLE HUB, KNUCKLE
. . . . . .. .. . . . . . . . . .. .. . . . 11
Noise due to excessive play of wheel in
turning direction
Noise due to excessive wheel end play
http://vnx.su/
?i
,;
2-2
FRONT
GENERAL
SUSPENSION
Information
- General
I FORMATION
The-front suspension
torsion bar spring.
NOZBBAA
is an independent
suspension
which
is a combination
of the double-wishbone
and
Drive
sh
Torsion
Shock
absorber
Free-wheeling
Drive
if.
I i
Follower
Clutch
shaftL.H.
Lower
MANUAL
bar
hub
arm
FREE-WHEELING
HUB
OPERA-K)ly
I_...
lS063
;,;a F
PJ
>
Tension/spring
11 SO63
wision
http://vnx.su/
FRONT
SUSPENSION
General
AUTOMATIC
Information
FREE-WHEELING
2-3
HUB OPERATlq$m
state
Locked
state
~04:
llWO23
Lug
Locked
state
of the
retainer
(A)
Meshed
state
llWO44
wision
http://vnx.su/
2-4
FRONT SUSPENSION
- Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOZCA-
Specifications
Items
Suspension
system
Torsion bar
Length x O.D.
mm (in.)
Spring constant
N/mm (Ibs./in.)
22 (123)
Shock absorber
Hydraulic cylindrical
Type
Maximum
length
Compressed
Stroke
mm (in.)
length
mm (in.)
215 (8.46)
120 (4.72)
mm (in.)
double-acting
335(13.19)
(.984 ft./set.)]
1,940-2,560
N (Ibs.)
C,o$Wion
Front axie hub bearing
(428-564)
Type
Dimensions
(O.D. x I.D.)
mm (in.)
Outer
,. Inner
Drive shaft
. Joint type
Length
$ (Joint to joint)
Outer
Inner
Right
Left
mm (in.)
mm (in.)
294(11.6)
Q&-rer shaft
x
;:(Shaft
overall length
mm (in.)
,.&earing
$3s O.D. x I.D.
mm (in.)
Differential
432 (17.0)
62 x 35 (2.44 x 1.38)
Hypoid gear
4.625
ratio
gear type
of teeth
Drive gear
Drive pinion
37
8
Side gear
Pinion gear
I 4
I 0
rSTB
Revision
http://vnx.su/
type
FRONT SUSPENSION
2-5
- Specifications
SERVICE SPECIFICATIONS
NOZCE-
Items
Specifications
Standard values
Toe-in
mm (in.)
2-9 (.08-.35)
Camber
lt30
Caster
257 i 30
0.2-0.5 (.008-.020)
Automatic
free-wheeling
mm (in.)
hub
height
thickness
Stabilizer attaching
dimension
mm (in.)
dimension
dimension
(.465-,480)
10.5 (.41)
Ncm (in.lbs)
and bump stopper
bump stopper
attaching
11.8-12.2
mm (in.)
mm (in.)
80-350 (7-30)
bracket
mm (in.)
71 (2.80)
7-8 (.27-.31)
mm (in.)
6-8 (.24-.31)
..:
mm (in.)
L.H.
135.2-143.2
R.H.
mm (in.)
(5.323-5.638)
77-83 (3.03-3.27)
Differential
Final drive gear backlash
Differential
mm (in.)
gear backlash
0.1 l-0.16
mm (in.)
O-0.076 (O-.0030)
oil seal
(.0043-.0063)
0.6-0.7 (5.2-6.1)
Nm (inlbs.)
0.4-0.5 (3.5-4.3)
Limits
Front axle total backlash
Automatic
mm (in.)
free-wheeling
Free-wheeling
hub
9.6 (.378)
35 (1.38)
mm (in.)
mm (in.)
30(1.18)
Nm (ft.lbs.)
15(11)
N (Ibs.)
mm (in.)
100 (8.7)
14(3.1)
mm (in.)
Ncm (in.lbs.)
N(lbs.)
Lower
14(.55)
6.8 (1.5)
0.5 (.020)
Differential
Drive gear runout
Differential
mm (in.)
gear backlash
0.05 (.0020)
mm (in.)
0.2 (.008)
) STB Revision
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2-6
FRONT SUSPENSION
- Specifications
TORQUE SPECIFIC
NOZCC-
Nm
Items
Automatic
free-wheeling
hub cover
ft.lbs
18-35
13-25
Manual free-wheeling
hub cover
Free wheeling jub body or drive flange
Front hub to brake disc
Knuckle to front brake assembly
IO-14
7-10
50-60
50-60
80-100
36-43
100-120
72-87
Rebound
8-12
6-9
43-65
36-43
58-72
60-90
12-18
15-22
120-180
87-130
140-160
101-116
54-75
20-30
39-54
Anchor arm B
95-l 20
69-87
40-50
29-36
8-12
6-9
45
50-60
33
36-43
Left diffefential
mounting
bracket to differential
carrier
carrier
carrier
bolts
flange
3earing cap
9-13
11-16
14-22
80-100
80-100
58-72
80-110
80-100
58-80
58-72
80-110
58-80
50-60
100-120
36-43
58-72
60-70
72-87
43-51
40-60
2943
160-220
15-22
116-159
11-16
55-65
40-47
80-90
58-65
18-25
IO-13
13-18
7-9
13-17
9-12
Differential
LSTB Revision
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FRONT SUSPENSION
LUBRICANTS
2-7
- Specifications
\
Items
NOZCD-
Quantity
Specified lubricants
1.10 lit.
(1.16 U.S. qts., 0.97 Imp. qts.)
As required
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Multipurpose
grease
SAE J310, NLGI No. 2
As required
hub
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Needle bearing
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Multipurpose
grease
SAE J310, NLGI No. 2
As required
110g(1.902.)
110g(1.90z.)
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Multipurpose
grease
SAE J310, NLGI No. 2
As required
Automatic
free wheeling
hub
SEALANTS
and
, .,. : #I
..,
.I
Items
Specified
I
f
AND ADHESIVES
hole
Gasket
f STB Revision
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2-8
FRONT SUSPENSION
- Special Took
SPECIAL TOOLS
NOZDA-
Tool (Number
and name)
MB990955-01
Oil seal installer
attachment
Use
Pressing of front a
hub oil seal
Sliding hammer
Disassembly
and
reassembly of
automatic
free-wheeling
hut
Removal of side
bearing inner race
set
Pressing
of differential
MB990778-01
Ball joint remover
Removal of knuck
Disconnection
of
upper ball joint
MB990799-01
Ball joint remover
and installer A
Removal and
installation of upr
MB990800-01
MB990840-01
Universal joint remover
and installer
ustment
of lock
ME3990809-01
Pitman arm puller
1 STB Revision
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Removal of knuck
Disconnection
of
FRONT SUSPENSION
Tool (Number
and name)
MB990958-01
Torsion bar bushing
and installer
remover
M B990883-0 1
Arbor
Use
2-9
- Special Tools
Tool (Number
and name)
Use
MD998348-01
Bearing separator
M B990339-0 1
Pinion carrier bearing
puller
Removal of knuckle
Disconnection
of tie rod
MIT3031 73
Insert
of
of
/I
M B990635-0 1
Steering linkage puller
Q
BJ
M B990956-0 1
Needle bearing instal1e.r
Pressing of knuckle
needle bearing
MIT44801
Collet set
CJ
e!J
cc
M B990985-0 1
Oil seal installer
Pressing
oil seal
of knuckle
(?
\
$
,.,J
,,
.
.I
Holding of end yoke 7, i
M B990767-0 1
End yoke holder
4. ..
$..
- .,
k,
6
63
G2J
MB991 150
Dust cover installer
Pressing of drive
shaft dust cover
Qs!@%l
Qaz
MB990901-01
Pinion height gauge set
/ STB Revision
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Adjustment of
pinion height
2-10
FRONT SUSPENSION
- Special Tools
Use
Use
MB990802-01
Bearing installer
Pressing of drive
pinion front bearing inner
race
Pressing of side
bearing inner race
M IT3041 80
Handle
klB990031-01
Irive pinion oil seal installer
Pressing of drive
pinion oil seal
1 ST6 Revision
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2-11
FRONT SUSPENSION-Troubleshooting
TROUBLESHOOTING
Symptom
NOZEA-
Remedy
Reference
page
Replace
2-33
2-l 5
2-23
Replace
2-46
Free wheeling
hub serration
Replace
2-33
Free wheeling
hub looseness
Tighten or replace
2-29
2-2 1
2-25
Replace parts
2-25
Probable cause
MANUAL FREE
WHEELING HUB,
FRONT AXLE HUB,
KNUCKLE
Noise due to excesFree wheeling
sive play of wheel in
turning direction
Noise due to excessive wheel end play
hub serration
play
play
AUTOMATIC FREE
WHEELING HUB
Does not lock
Automatic
loose
Locks but does not
become free
free wheeling
hub attaching
Ratcheting
occurs
readily
bolt
front power
Retighten
attaching
bolts
Replace parts
of
2-l 8
2-25
or replace
of
train resistance
Adjust differential
preload
Replace parts
hub attaching
1 STB Revision
http://vnx.su/
bolts
2-2 1
2-25
2-l 8
., ;
-.. 2-12
FRONT SUSPENSION
ymptom
-Troubleshooting
-lizRemedy
Probable cause
Reference
we
Replace
2-62
Replace
2-64
Check or replace
2-52
Replace
2-62
2-74
Replace
2-52
2-74
Replace
2-52
2-62
Adjust or replace
2-J 6
Tighten or replace
2-62
Correct or replace
2-68
side bearing
Correct
or replace
2-73,76
drive pinion
Correct
or replace
2-73,
2-76
pounding
play
noise
Correct or replace
2-73,76
Replace
2-73,76
Replace
2-73, 76
Replace
2-73, 76
Foreign material
2-73,
2-76
No oil
Fill or change
2-l 6
Correct
or replace
2-69
Improper
gear adjustment
Correct
or replace
2-69
Improper
Correct
or replace
2-77
or pinion
Deformed
Damaged
gear
Damaged
case
gear
Replace
2-73,76
Foreign material
2-73,
2-76
Insufficient
Fill or change
2-16
oil
bTB
Revision
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T.
.
FRONT SUSPENSION
symptom
Gear noise while
coasting
2-13
-Troubleshooting
Probable cause
Remedy
Reference
page
Correct or replace
2-77
Damaged
gear
Replace
2-73,76
Replace
2-73,
2-76
differential
Cracked
bearing
Replace
2-73, 76
Damaged
shaft
Replace
2-73,
2-76
Adjust
2-69
Fill or change
2-16
2-73,
2-76
Replace
2-73,76
Excessive
2-l 6
Heat
Improper differential
Excessive preload
Insufficient
Oil leakage
or damaged
gear backlash
oil
oil
/ STB Revision
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2-14
FRONT
SlJSPiENSlON
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
INSPECTION
ALIGNMENT
AND
PROCEDURES
NOZFBAC
ADJUSTMENT
OF WHEEL
the toe-in.
value
: 2-9 mm (.08-.35
in.)
2.
If the toe-in does not agree with the standard value, use
the left and right tie rod turnbuckles
to adjust it.
3. Make the adjustment
by turning the left and right turnbuckles the same amount
in opposite
directions.
The toe-in
value will decrease if the left turnbuckle
is turned toward
the front of vehicle and the right one is turned toward the
rear, and vice a half-turn of the turnbuckles
will result in an
approximately
15 mm (.59 in.) adjustment
in the toe-in.
CAMBER
I. Remove the free-wheeling
hub.
2. Measure the camber with a camber/caster/kingpin
Standard
3.
value
gauge.
: 130
Make adjustment
of the camber by incerasing
or decreasing the thickness
of the adjusting
shims between
the
upper arm shaft and the crossmember.
A total of 4 mm (.I6 in.) shim thickness is normally required
for standard camber. A 1.0 mm (.039 in.) adjustment
in
thickness
of shims will provide about 13 minutes
adjustment of camber.
Camber
adjustment
1 STB Revision
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shim
(yellow
plating)
FRONT
SUSPENSIO
- Service
Adjustment
2-15
Procedures
CASTER
I.
2.
Leir
To increase
To increase
To reduce
caster
caster
value
: 257
gauge
and a
t 30
12w529
CHECKING
FRONT
AXLE
TOTAL
BACKL/iSi
1
http://vnx.su/
2-16
FRONT
SUSPENSION
Service
Procedures
Adjustment
: 14 mm ($5 in.)
CHECKING
NOZFEAB
Remove the filler plug and check the oil level. The oil level
should be somewhere
within 8 mm (.31 in.) from the bottom
of the filler plug hole.
Specified
gear oil
CHECKING
DRIVE
SHAFT
END PLAY
NOZFFAA
VEHICLES
WITH AUTOMATIC
FREE-WHEELING
HUBS
I. Place the free-wheeling
hubs in the free condition.
NOTE
The free condition
can be obtained by shifting the transfer
shift lever to the 2H position and then moving in reverse
for 1 to 2 m (3.3 to 6.5 ft.).
2.
3.
4.
5.
6.
value
: 0.2-0.5
mm (.008-.020
value,
in.)
adjust
by adding
or
llWO2!
value
: 0.2-O-5 mm (.008-.020
http://vnx.su/
value,
in.)
adjust
by adding
or
FRONT
SUSPENSION
Service
Adjustment
REPLACEMENT
SEAL
1. Remove
2. Remove
3. Remove
2-17
Procedures
OF DIFFERENTIAL
CARRIER
OIL
NOZFGAB
Caution
When pulling
the left drive shaft from the differential
carrier assembly,
be careful that the drive shaft spline
does not damage the oil seal.
4. Remove
bly.
5. Remove
tools.
the right drive shaft from the inner shaft assemthe inner
shaft
assembly
by using
Caution
When pulling the inner shaft assembly
tial carrier, be careful that the spline
does not damage the oil seal.
the special
i
6. Remove
the differential
mounting
bracket
(R.H.)
housing tube. (Refer to 2-66, 68.)
7. Use the special tool to remove the oil seal.
grease
: Multipurpose
No. 2
and
NOTE
On R.H. side, after installation
of the oil seal, install the
housing tube and differential
mounting
bracket (R.H.).
Install the inner shaft with care not to damage the oil seal
lip, and install the drive shaft.
Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached
to the B.J. side spline with
a new one.
1 STB Revision
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ii
?
,,,+$-
assembly.
2-18
FRONT SUSPENSION
AXLE
- Axle
REMOVAL
AND
B&j00
58-72
INSTALLATION
(Vehicles,
Hub
and
Free-Wheeling
Hub
HUB
with
Automatic
Free-Wheeling
Hubs) NOZGA--
Nm
ft.lbs.
,13-25
80-100 Nm
58-72 klbs.
-T
/
130-200 Nm+ONm+25
Nm
94-145 ft.lbs.+Ofit.lbs+lB
ft.lbr
_c
Removal
.5040
3643
steps
1. Cover
l + Adjustment of drive shaft end play
2. Snap ring
l *
3. Shim
4. Front brake assembly
++
l + Adjustment
of automatic
free-wheeling
hub
turning resistance
5. Bolts
+*
l + 6. Automatic
free-wheeling
hub assembly
I)* Height adjustment of brake contact surface
+*
7. Shim
4*
4*
8. Lock washer
l 4 Adjustment of wheel bearing preload
9. Lock nut
10. Front hub assembly
NOTE
(1) Reverse the removal procedures to reinstall.
(2) ++ : Refer to Service Points of Removal.
(3) l * : Refer to Service points of installation
1 ST6 Revision
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Nm /
ft.lbs.
,k.
FRONT
SUSPENSION
Axle
SERVICE
Hub
and
POINTS
2-19
Hub
Free-Wheeling
OF REMOVAL
1. REMOVAL OF COVER
(1) Place the free-wheeling
NOZGBAB
NOTE
The free condition
can be obtained
by shifting the
transfer shift lever to the 2H position and then moving
in reverse for 1 to 2 meters (3.3 to 6.5 ft.).
(2) Remove
the automatic
free-wheeling
hub cover.
NOTE
When the cover cannot be loosened by hand, use an oil
filter wrench with a protective
cloth in between not to
damage the cover.
..
:::
__
,,#..f
.-..c
2.
4.
5.
Hexagonal
wrench
REMOVAL
OF SNAP RING
Using a snap ring pliers, remove
drive shaft.
,+. .
the sna$ ring from
r S&f;
the
:
REMOVAL
OF FRONT BRAKE ASSEMBLY
(1) Remove the front brake assembly with the brake hose
I .3;;: :
connected.
(2) Use wire to suspend the front brake assembly from thei,,,*
.i
upper arm so that the front brake assembly wont fall.
Ai
.,-iII-1:
Caution
I ._1
Do not twist the brake hose.
2.
REMOVAL
OF BOLTS
Remove tha automatic
hexagonal wrench.
1 STB nevlslon
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free-wheeling
hub
by using
the
FRONT SUSPENSION
- Axle
9.
Hub
and
Hub
Free-Wheeling
REMOVAL
OF LOCK NUT/IO.
FRONT HUB ASSEMBLY
(1) After the lock washer has been removed, remove the
lock nut with the Ispecial tool.
(2) Remove
the front hub assembly
from the knuckle
together with the inner and outer bearings.
4
r
5!
INSPECTION
l
l
l
SERVICE
.
N02GCAA
POINTS
OF INSTALLATION
AD.JUSTMENT
OF WHEEL BEARING
(1) Using the special tool, tighten
following procedures.
PRELOAD
the lock nut
and
N02GDAB
by the
11568
Retighten
value
Standard
value
http://vnx.su/
: 30-130 Ncm
.
(2.6-l 1.3 in.lbs.)
.:. ,
[Spring scale reading]
5-18 N (I.140
Ibs.)
: 0.05 mm (.0020 in.) or less
FRONT
SUSPENSION
- Axle
Hub
and
Free-Wheeling
2-21
Hub
NOTE
If adjustment
is not possible,
the bearing
may
incorrectly installed; check and, if necessary, repair.
The lubrication
condition should also be checked.
be
(3) Mount the lock washer. If the lock washer holes do not
align with the lock nut holes, loosen the lock nut (no
more than 30 to 40 degrees) to align them.
HEIGHT ADJUSTMENT
OF BRAKE CONTACT
SURFACE
Measure the height of brake contact surface.
,p +
0 Using a depth gauge, measure the dimension
A shown f
1.
in illustration
at two points.
8:.*
T.
Standard
value : 11.8-12.2 mm (.465-.480
in.)
1,
0
6.
If the average
of the measured
values
standard value, adjust by inserting shims.
INSTALLATION
ASSEMBLY
OF AUTOMATIC
is out
FREE-WHEELING
..
ok
$
vjj 1
.%;::
HUB
sealant
Caution
Make sure that there is no excess
on the hub outside
surface,
8661
specified
or No.
sealant
,.
I 2.
(2) Align the key of the brake (B) and the keyway of,
knuckle spindle and loosely install the automatic
free-l: t !,,..:$
5 ;*i;:wheeling hub assembly.
(3) Check that the hub proper and automatic
free-wheeling
-:I~,,$$+
hub assembly are brought into intimate
contact when
,,.:
the assembly is fored lightly against the hub proper. If
:,;.,
not; turn the hub until intimate. contact is achieved.
ADJUSTMENT
OF AUTOMATIC
FREE-WHEELING
HUB
TURNING
RESISTANCE
Check the automatic
free-wheeling
hub turning resistance
by the following procedure.
0 Use a spring scale to measure the front hub turning
resistance again. Subtract the value measured
in step
(1) from
that measured
here to find the turning
resistance of the free-wheeling
hub.
j STB Revision
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2-22
RONT SUSPENSION
Hub
If the free-wheeling
limit, disassemble
hub again.
ADJUSTMENT
OF DRIVE SHAFT END PLAY
After the installation
of shim and snap ring, check the drive
shaft end play by the following
procedure.
0 Rotate the drive shaft forward, and backward and then
set the drive shaft to the position (the position where
end play is maximum)
mid-way between
where the
for each (where there is a
rotation
feels heavy
stopping
feeling).
Set the dial gauge as shown in the figure; then move
the drive shaft in the axial direction
and measure the
play.
!Standard
0
value
: 0.2-0.5
1 STB Revision
http://vnx.su/
mm
(.OO&.020
value, adjust
in.)
by adding
or
DISASSEMBLY
AND
REASSEMBLY
50-60
3643
Disassembly
1. Outer
bearing
NOTE
(1) Reverse the disassembly
procedures
to reassemble.
(2) +e : Refer to Service Points of Disassembly.
(3) ++ : Refer to Service Points of Reassembly.
(4) @I : Non-reusable parts
3. Inner bearing
4. Brake disc
5. Front hub
4.
Iuter bearing
NOPHA-
Nm
ft.lb
SERVICE
)uter bearing
Hub)
steps
l 4 2. Oil seal
*I)
(Front Axle
Inner bearing
Inner bearing
f=i
POINTS
OF DISASSEMBLY
1
4
NOZHBAA
REMOVAL
OF BRAKE DISC
Make the mating marks on the brake disc and front hub,
and then separate
the front hub and brake disc, if
necessary.
REPLACEMENT
OF BEARING
NOZHDAB
di,
(1) Remove the oil seal.
4.;
(2) Wipe off grease from the front hub interior.
(3) Using the drift against,
drive out the inner and outer CT,,,:i
ri ,
bearing outer races by tapping them uniformly.
(4) Apply the specified grease to the outside surface of the
. .,
new inner and outer bearing outer races.
T
Specified grease : Multipurpose
grease SAE 5310, NLGI
No. 2
(5) Press-fit the inner and outer bearing
the special tools.
NOTE
The bearing inner race and bearing
replaced as an assembly.
evision
http://vnx.su/
outer
races by using
outer
race should
be
2-24
FRONT SUSPENSION
SERVICE
POINTS
Hub
OF REASSEMBLY
NOMEAB
2. INSTALLATION
OF OIL SEAL
(1) Apply the specified grease to the oil seal lip and inside
surface of the front hub.
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE 5310,
grease
: Multipurpose
NLGI No. 2
grease
SAE
inner
5310,
(3) Press-fit the new oil seal into the front hub by using the
special tools, until it is flush with the front hub end
face.
STB Revision
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FRONT SUSPENSION
DISASSEMBLY
Disassembly
AND
REASSEMBLY
Free-Wheeling
Hub
Hub)
steps
1. Cover
2. O-ring
3. Housing
4.Housing
C ring
4*
l 4 5.Brake (B)
6. Brake (A)
7. Brake spring
8.Housing
snap ring
41)
9.Retainer
(B) C ring
41)
IO.
Drive
gear
assembly
4*
II.
Slide
gear
assembly
41)
4* +4 12. Return spring
l 4 13.Retainer
(B)
14. Retainer bearing
4*
4+
NOTE
(1) Reverse the disassembly
procedures
to reassemble.
(2) C) : Refer to Service Points of Disassemblv.
i3j 64 : Refer to Service points of Reassembly
(4) m
: Non-reusable
parts
1 STB Revision
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2-25
NOWA-
2-26
FRONT SUSPENSION
- Axle
Hub
SERVICE
4.
and
Hub
Free-Wheeling
POINTS
OF DISASSEMBLY
OF HOUSING
c RING
REMOVAL
Remove the housing
C ring.
NOTE
The ring is easily removable by pushing
using asmall-end
screwdriver, etc.
8.
REMOVAL
Remove
9.
OF HOUSING
the housing
NOlJBAA
SNAP
RING
snap ring.
REMOVAL
OF RETAINER
(B) C RING
Using a special tool, lightly push the drive
remove the retainer(B)
C ring.
gear
in and
NOTE
Since the return spring relaxes approx. 40 mm (1.57 in.),
the stroke of the press should be set to more than 40 mm
(1.57 in.)
Caution
1. Place a protective
cover not to damage
the cover
attaching
surface of the housing
before setting
on
the press table.
2. Make sure that the pressing force does not exceed
200 N (44.1 Ibs.).
10. REIMOVAL
OF DRIVE GEAR ASSEMBLY/l
ASSEMBLY/lZ.
RETURN SPRING
Slowly reduce the pressure
spring fully relaxes.
1. SLIDE
the return
Caution
When the pressure of the press is removed,
make
that the retainer
(A) is not caught by the retainer
/
llWO2C
r-STB
I tvision
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GEAR
sure
(B).
FRONT
SUSPENSION
- Axle
Hub
2-27
Hub
Free-Wheeling
15. REMOVAL
Remove
and
Caution
When the drive gear snap ring is removed,
replace it with a new one.
18. REMOVAL
be sure to
,.3
, .
!-
llWOl8
INSPECTION
l
l
o
l
l
, Brake (B)
E
-
NOZJCAA
Check the
Check the
damage.
Check the
Check the
damage.
Check the
wear and
B and
housing
contact
surfaces
for
surfaces
for
,.?pZ
c, :;
4:. . .t:
./,:
Check the brake assembly
thickness
by following
the steps (j,:.:,zji ,j
! . .:,
below.
(1) Assemble
brake (A) and brake (B) and then use slide
k;y$
calipers to measure the thickness
of the assembly
at the
,-,,f
two lugs on brake (A).
.$
BRAKE ASSEMBLY
THICKNESS
NOTE
Measure
STB Revision
http://vnx.su/
the limit,
replace
brake (A)
2-28
FRONT
SUSPENSION
AxIf:
Hub
and
Free-Wheeling
Hub
DETERIORATION
OF RETURN SPRING
Check the return spring for deterioration
by following
the
steps below.
(1) Measure
the dimension
A shown in illustration
at the
opposite side of spring end.
Limit
: 35 mm (1.38 in.)
Caut:ion
To measure
the dimension
A shown
in illustration,
measure the dimension
from the outermost
extremity
of
one wire diameter
to that of the other wire diameter.
llW567
replace
the spring.
SPRING
Limi,t
: 30 mm (1.18 in.)
llW566
Cau,tion
To measure
the dimension
B shown
in illustration,
mealsure the dimension
from the outermost
extremity
of
one wire diameter
to that of the other wire diameter.
(2) If the measured
SERVICE
POINTS
grease
replace
the spring.
OF REASSEMBLY
grease
NOPJDAB
to the attaching
: Multipurpose
No. 2
grease
surfaces
SAE
of all
J310,
NLGI
13. AWLICATION
OF GREASE TO RETAINER
(B)
Pack the grooves of retainer (B) with the specified
Specified
grease
: Multipurpose
No. 2
grease
12. INSTALLATION
OF RETURN SPRING
Install the return spring with the smaller
toward the cam.
5.
APIPLICATION
OF GREASE
TO BRAKE
of brake
Specified
: Multipurpose
No. 2
grease
1 STB Revision
1
http://vnx.su/
grease.
coil diameter
side
(B)
grease.
FRONT
REMOVAL
AND
SUSPENSION
INSTALLATION
with
(Vehicles
Manual
2-29
IHubS
Free-Wheeling
Hubs)
80-100 Nrb
58-72 ftlbs.
Removal steps
1. Free-wheeling hub cover
2. Gasket
+a Adjustment of drive shaft end play
3. Snap ring
*I)
4. Shim
5. Front brake assembly
+I)
+4 6. Manual free-wheeling hub assembly
7. Lock washer
+*
I)+ Adjustment of wheel bearing preload
a. Lock nut
l *
9. Front hub assembly
l *
*+
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +* : Refer to Service Points of Removal.
(3) ++ : Refer to Service Points of Installation.
(4) m:
Non-reusable
parts
1 STB Revision
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Nm
ft.lbs.
lo-14 Nm
7.10 ftlbs.
N02GA-
Z-30
FRONT SUSPENSION
- Axle
SERVICE
POINTS
Hub
OF REMOVAL
NOZGBBA
1. REMOVAL
OF FREE-WHEELING
HUB COVER
(1) Set the control handle to the FREE position.
(2) Remove the free-wheeling
hub cover.
3.
5.
REMOVAL
OF FRONT
the snap
ring from
the
BRAKE ASSEMBLY
(1) Remove the front brake assembly with the brake hose
connected.
(2) Use wire to suspend the front brake assembly from the
upper arm so that the front brake assembly wontt fall.
Caution
Do not twist
8.
the brake
hose.
REMOVAL
OF LOCK NUT/S. FRONT HUB ASSEMBLY
(1) After the lock washer has been removed,
remove the
lock nut with the special tool.
(2) Remove
the front hub assembly
from the knuckle
together with the inner and outer bearings.
118695
INSPECTION
l
l
l
1 STB Revision
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NOZGCAA
and
FRONT SUSPENSION
- Axle
SERVICE
Q
Hub
and
Free-Wheeling
POINTS
ADJUSTMENT
2-31
Hub
OF INSTALLATION
OF WHEEL
BEARING
tool,
tighten
NOZGDBB
PRELOAD
the
lock
nut by the
ft.lbs.)
w
Loosen to 0 Nm (0 ft.lbs.)
Retighten to 25 Nm (18ft.lbs.)
Standard
value
Standard
value
f"
,:I
: Ii .L
be{
1:
Cc.F
T :~~~~
. _*
(3) Mount the lock washer.
If the lock washer
holes do not
L .y
align with the lock nut holes, loosen the lock nut (no
more than 30 to 40 degrees)
to align them.
NOTE
If adjustment
is not possible,
the bearing
may
incorrectly
installed;
check and, if necessary,
repair.
The lubrication
condition
should also be checked.
6.
INSTALLATION
ASSEMBLY
OF
MANUAL
FREE-WHEELING
HUB
Specified
---
sealant
Caution
Make sure that there is no excess
the hub outside surface.
/ STB Revision
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specified
sealant
on
2-32
FRONT SUSPENSION
- axle
l
Hub
and
ADJUSTMENT
Free-Wheeling
OF DRIVE
Hub
SHAFT
END
PLAY
and then the snap
Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction
and measure the play.
Standard
wo70
value
: 0.2-0.5
mm
~STB Revision
http://vnx.su/
(.008-.020
value,
adjust
in.)
by adding
or
FRONT
SUSPENSION
- Axle
Hub
and
DISASSEMBLY
Hub)
Refer
DISASSEMBLY
8
Disassembly
l d
l +
1.
2.
3.
4.
5.
6.
~~
7.
8.
*I)
l + 9.
10.
l +
+4 11.
12.
AND
REASSEMBLY
Free-Wheeling
AND
2-33
Hub
REASSEMBLY
(Front
NOZHA-
to P.2-23.
(Manual
free-Wheeling
Hub)
N02JA-
90
steps
Free wheeling
hub
Gasket
Free wheeling
hub
Compression
spririg
Follower
Tension spring
Free wheeling
hub
Wheel snap ring
Inner hub
Shaft snap ring
Free wheeling
hub
Spacer
Axle
cover
llW574
L
\
i, . j;
< ,..$,Z.f~
I
;. :?.:i,r.
clutch
:iq;
body
r: .p,
1,:
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) +e : Refer to Service Points of ,Disassembly.
(3) l + : Refer to Service Points of Reassembly.
(4) m:
Non-reusable parts
ring
SERVICE
8.
POINTS
REMOVAL
RING
OF DISASSEMBLY
OF WHEEL
SNAP
RING/lo.
NOPJBBA
SHAFT
SNAP
ring pliers.
1 STB Revision
http://vnx.su/
2-34
NT SUSPENSION
- Axle
Hub
and
Free-Wheeling
Hub
INSPECTION
0
0
0
NOZJCBA
SERVICE
POINTS
OF REASSEMBLY
NOZJDBB
11. APPLICATION
OF GREASE TO FREE WHEELING
HUB
RING/g.
INNER HUB17. FREE WHEELING
HUB BODY/3.
FREIE WHEELING
HUB CLUTCH/l.
FREE WHEELING
HUB COVER
(1) Apply the specified grease to the entire periphery of
the free wheeling hub ring, inner hub and free wheeling hub clutch, free wheeling hub cover and the inside
of the free wheeling hub body.
hub clutch
Specified
Grease
,Drive shaft
llWO7E
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
(2) Check to be sure that the hub body assembly and hub
cover assembly ;are coated (at the positions shown in
the figure) with a sufficient coating of the specified
grease.
(3) ,4dd more grease if necessary.
IVOTE
,4 liberal amount of grease should be applied, especially when grease is wiped away or a new free-wheeling
hub is installed.
/ STB Revision
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RONT
SUSPENSION
Shock
Absorber
and
Upper Arm
2-35
AND
IO&120
INSTALLATION
N02MA--
Nm
72-87 ft.bls.
8-
6-12 Nm
6-9 ft.lbs.
60-90
43-65
Shock
absorber
l +
Upper
removal
1. Shock
arm
removal
Nm
ftlbs
15-22
11-16
401
-- 50 Nm
29-36 ft.lbs.
Nm
ft.lbs.
steps
absorber
steps
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) l * : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation.
(4) q
: Non-reusable
parts
STB Revision
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2-36
FRONT SUSPENSION
- Shock Absorber
SERVICE
POINTS
OF REMOVAL
NOZMBAA
2. LOOSENING
OF ANCHOR
ARM ASSEMBLY
ADJUSTING NUT
Loosen the anchor bolt of the torsion bar all the way.
NOTE
When the anchor arm assembly adjusting nut is loosened,
use a jack to support the lower arm of the side to be
loosened, thus the work easier.
6.
DISCONNECTION
1OF UPPER
BALL
KNUCKLE
(1) Loosen the nut tightening
the upper
knuckle.
NOTE
The nut should
removed.
be partially
loosened
disconnect
JOINT
FROM
ball joint
to the
and should
not be
the upper
Caution
Tie the special tool to the upper
with a string to prevent bouncing.
arm,
ball joint
for example,
10. REMOVAL
OF UPPER ARM
Remove the upper arm from the crossmember.
NOTE
The camber
adjustment
shims
should
be stored
reference at assembly.
Do not turn the upper arm shaft, as it changes caster.
12W5lC
INSPECTION
l
l
for
NOZMCU
SHOCK: ABSORBER
Expand and contract
the shock absorber
damage, oil leakage or abnormal
noise.
wision
http://vnx.su/
to check
it for
FRONT SUSPENSION
Shock
UPPER
Absorber
ARM SHAFT
and
Upper
STARTING
2-37
Arm
TORQUE
2.
: 15 Nm (1 lftlbs.)
[Spring scale reading]
6.8 N (1.5 Ibs.)
UPPER
BALL JOINT
STARTING
torque
exceeds
the limit,
TORQUE
f .
72.5(2.854)
2.
72.5(2.854)
UPPER
ARM SHAFT
TIGHTENING
Give appropriate
amount
the specified dimension.
Caution
The dimensions
shown
dimensions
that determine
REPLACEMENT
torque
is out of specification,
AMOUNT
in the illustration
the caster.
are
important
NOZMDAB
t:
.,: 2;
,:. <.i,%
120079
MB990840-01
Upper
arm
128055
3.
I
Press the upper ball joint out of the upper arm by using the
special tools.
ball joint
STB Revision
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2-38
FRONT
SUSPENSION
- Shlock Absorber
4.
and Upper
Arm
tools aligning
the mating
,---
&tltf$f
.-
-01 C-+-+
upper arm=
MB990800
-3-01
5.
Specified
sealant
i ;/:,,,,
7.
8.
grease
sealant
: Multipurpose
No. 2
sealant
POINTS
the interior
grease
to the grooves
of dust
SERVICE
in the
ball joint
No. 8661 or
with a ring.
OF INSTALLATION
NOZMEAA
10. INSTALLATION
OF UPPER ARM
When the upper arm assembly
is installed
to the crossmember,
insert the upper arm shaft attaching
bolts from
outside the crossmember
and put adjusting
shims between the crossmember
and upper arm shaft.
ADJUSTMENT
OF CLEARANCE
BETWEEN
PER TO BUMP STOPPER
BRACKET
Refer
to P.2-49.
1 STB Revision
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BUMP
STOP-
FRONT
SUSPENSION
- Shock Absorber
1.
and Upper
Arm
2-39
INSTALLATION
OF SHOCK ABSORBER
(1) Tighten the shock absorber installation
nut so that the
dimension
shown in the figure is the standard value.
Standard
value
: 7-8 mm (.27-.31
in.)
12W533
(2) Install the shock absorber so that the white paint mark
at the lower side of the shock absorber faces the outer
side of the vehicle.
p :I
,!
r
-1
,.b
t
i.1
12W54:
/ STB Revision
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2-40
FRONT
SUSPENSllON
- Lower
Arm
LOWER ARM
REMOVAL
AND
INSTALLATION
NOPNA-
18-25
13-18
Nm
ftlbs.
18W654
1
15-22
Nm
11-16
ft.lbs.
IO-13 Nm
7-9 ft.lbs.
12W541
Nm
ft.lbs.
b%?
63
e3
40-50
29-36
120-180 Nm
87-130 ftlbs.
12W556
14-22
ftlbs.
!S4-75
139-54
Removal
steps
Nm
ftlbs.
7. Stabilizer
bar
8. Shock absorber
mounting
bolts
ball
joint
mounting
nuts
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +*
: Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation.
(4) m : Non-reusable
parts
(5)
[ STB Revision
: Must
II
http://vnx.su/
be
tightened
while
vehicle
is unladen.
FRONT
SUSPENSION
SERVICE
3.
POINTS
REMOVAL
Refer
5.
- Lower
OF REMOVAL
OF TORSION
NOZNBAA
BAR
to P.2-48.
DISCONNECTION
OF LOWER
BALL
KNUCKLE
(1) Loosen the nut tightening
the lower
knuckle.
NOTE
The nut should
removed.
be partially
loosened
JOINT
FROM
ball joint
and should
to the
A.:*
I.
+::
*I.
not be
!\4.
51 Iii:
2-41
Arm
disconnect
the lower
ball joint
REMOVAL
OF SHOCK ABSORBER
MOUNTING
BOLTS
Remove the shock absorber lower part and compress the
shock absorber.
INSPECTION
l
l
l
: 0.5 mm
(.020
http://vnx.su/
in.)
end play exceeds
the limit,
replace
2-42
FRONT SUSPENSION
- Lower Arm
OF LOWER ARM BUSHING
REPLACEMENT
1.
Using a special
bracket.
tool,
remove
the
bushing
NOTE
When removing
the left hand bushing
differential
carrier. (Refer to P.2-69.)
2.
Using a special
bracket.
tool,
3.
Remove
the
special tools.
4.
bushing
NOZND~
A from
the
A, detach
the
press-fit
the
bushing
B from
the
lower
A into
arm
the
by using
MB990883-01
12SO71
REPLACEMENT
COVER
OF LOWER
BALL
2.
3.
wision
grease
Secure
sealant
: Multipurpose
No. 2
sealant
grease
to the grooves
DUST
http://vnx.su/
to
NOZNEAB
JOINT
side
ball joint
No. 8661 or
with
a ring.
FRONT
SUSPENSION
SERVICE
- Lower
POINTS
2-43
Arm
OF INSTALLATION
NOZNFAA
7. INSTALLATION
OF STABILIZER
BAR
Install the stabilizer bar to the lower arm in such a way that
the amount of protrusion
of the stabilizer bar installation
bolt is the standard value.
Standard
value
: 6-8
NOTE
The dimension
show
bushing is used.
3.
.
mm
(.&l-.31
in figure
in.)
is the value
INSTALLATION
OF TORSION
BAR
Refer to P.2-48.
ADJUSTMENT
OF CLEARANCE
BETWEEN
PER AND BUMP STOPPER
BRACKET
Refer to P.2-49
1 STB Revision
http://vnx.su/
when
..
a n&V
+. .
BUMP
STbP-
T.
,:
vi
2-44
-.
FRONT
SUSPENSION
- Knuckle
KNUCKLE
REMOVAL
AND INSTALLATION
60-90
43-65
NOZPA-
Nm
ft.lbs.
80-100 Nm
58-72 ftlbs.
33 ftlbs.
18-35
120-180
Nm
87-130
ft.lbs.
36-43
ftlbs.
Nm
80-100 Nm
58-72 ft.lbs.
130-200 Nm + 0 Nm i, 25 Nm
94-145 ft.lbs. + 0 ft.lbs. $ 18 ftlbs.
lW14Nm
7-10 ft.lbs.
Manual
hub
i
11W611
Removal steps
+e 1)4 1.
2.
3.
4.
4*
4*
4*
5.
6.
7.
8.
9.
Front axle
Dust cover
Cotter pin
Connection
knuckle
Cotter pin
Connection
Cotter pin
Connection
Knuckle
free-wheeling
hub
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +*
: Refer to Service Points of Removal.
(3) I)4 : Refer to Service Points of Installation.
(4) m
: Non-reusable parts
/ STB Revision
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FRONT SUSPENSION
SERVICE
2-45
- Knuckle
POINTS
1. REMOVAL
HUB
OF REMOVAL
OF FRONT
AXLE
NOZPBAA
.4.
6.
DISCONNECTION
KNUCKLE
Disconnect
the
special tool.
I/
TIE
ROD
the
ASSEMBLY
knuckle
FROM
by using
the +, :
pf
Q
$i
Caution
1. Use cord to bind the special tool closely so it wo&
become separated.
2. The nut should be loosened only, not removed.
DISCONNECTION
OF LOWER
BALL
JOINT
FROM
KNUCKLE/8.
UPPER BALL JOINT
FROM KNUCKLE
Using
upper
j663
OF
the special
ball joint.
tool,
remove
the
lower
ball joint
and
Caution
1. Support
the lower arm with a jackwhen
removing
the knuckle from the lower ball joint or the upper
ball joint.
2. After the knuckle has been removed,
lower the jack
slowly.
12W524
INSPECTION
l
l
l
Check
Check
Check
SERVICE
the needle
the knuckle
the knuckle
POINT
NOZPCAA
OF INSTALLATION
1. INSTALLATION
OF
WHEELING
HUB
FRONT
AXLE
NOZPDAA
HUB
AND
FREE-
For mddels
equipped
with the automatic
free-wheeling
hub, refer to page 2-18; for models equipped
with the
manual free-wheeling
hub, refer to page 2-29.
/ STB Revision
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I\.
!
./I,
2-46
FRONT SUSPENSION
DISASSEMBLY
Disassembly
+ee+
AN
- Knuckle
REASSEMBLY
NOZPE-
steps
I)+
1. Oil seal
**
2. Spacer
3. Needle
4. Knuckle
bearing
llW605
NOTE
(1) Reverse the disassembly
procedures
to reassemble
(2) 41) : Refer to Service Points of Disassembly.
(3) l rC : Refer to Service Points of Reassembly.
(4) q
: Non-reusable
parts
SERVICE
3.
POINTS
REMOVAL
OF DISASSEMBLY
OF NEEDLE
NOZPFAA
BEARING
(1) Remove the oil seal and take out the spacer.
(2) Drive out the needle
bearing
by tapping
uniformly.
Caution
Once removed,
reused.
SERVICE
3.
POIINTS
the
needle
bearing
needles
must
not
OF REASSEMBLY
NOZPGAB
INSTALLATION
OF NEEDLE BEARING
(1) /4pply the specified grease to the roller surface
new needle bearing.
Specified
grease
: Multipurpose
NLGI No. 2
grease
1 STB Revision
http://vnx.su/
driving
the needle
of the
SAE J310,
be
bearing
tools,
too
FRONT SUSPENSION
2.
INSTALLATION
2-47
Knuckle
OF SPACER
Specified
grease
grease
to the knuckle
: Multipurpose
NLGI No. 2
grease
1. INSTALLATION
with
the
attaching
SAE
J310,
chamfered
OF OIL SEAL
(1) Press-fit
the new oil seal by using the special tools,
until it is flush with the knuckle end face.
(2) Pack the specified
grease in the oil seal inside and lip,.!,
Specified
grease
: Multipurpose
grease
:.
No. 2
,
/ STB Revision
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2-48
FRONT SUSPENSION
- Torsion
Bar
TORSION BAR
REMOVAL
AND
lNSTALLATlON
NOZSA--
iNl-50 Nm
12W558
Removal
I)+
l *
I)+
steps
1. Heat
Adjustment
stopper
2. Anchor
3. Dust
4. Heat
5. Torsion
protector
(right side only)
of clearance
between
bump
and bump stopper
bracket
arm assembly
covers
cover (left side only)
bar
NOTE
(1) Reverse the removal procedures to reinstall.
(2) 4*
: Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation
SERVICE
2.
POINTS
OF REMOVAL
N02SBAA
REMOVAL
OF ANCHOR ARM ASSEMBLY
Support the lower arm from which the torsion
removed, with a jack.
bar is to be
INSPECTION
NOZSCAA
l
l
SERVICE
POINTS
OF INSTALLATION
NOZSDAB
grease
1 STB Revision
: Multipurpose
No. 2
http://vnx.su/
grease
SAE
5310,
NLGI
FRONT
SUSPEIWION
5.
Mating
mark
Whie
Identification
mark
mark
M\ating rn,:,J
- Torsion
2-49
Bar
INSTALLATION
OF TORSION
BAR
(1) Identify the right and left torsion bars referring to the
identification
mark put on the torsion bars.
Face the end having identification
mark forward, and
align the mark on anchor arm B with the mating mark
on torsion bar when the torsion bar is inserted in the
anchor arm B.
NOTE
When installing
a new torsion bar, align the serration
painted white with the mark on anchor arm 9.
(2) Select the relative position of the torsion bar serrations
and the anchor arm serrations so that the length shown
:I-
in the illustration
may have specified dimension
when
the torsion bar and the anchor arm are assembled,
with ,
the upper arm rebound
stopper in contact with the:;.
crossmember.
Standard
12s6oo
value
: L.H. 135.2-143.2
in.)
R.H. 124.3-132.3
in.)
mm
(5.323-5.638
mm
(4.894-5.210
ADJUSTMENT
OF CLEARANCE
BETWEEN
PER AND BUMP STOPPER BRACKET
BUMP
:;:
STOP-
of anchor
NOTE
The anchor bolt projection
amount
is a reference
dimension
used when the torsion bar spring is installed.
Finally, adjust so that the distance to the bump stopper
bracket is the standard value.
,
This method can also be used to make the adjustment
,!,
on previously sold vehicles.
;. !, ai::.
I.
..
Example
.;?
For a vehicle with a curb weight of 1,440 kg (3,175 lbs.),
the table shows the following
left and right anchor bolt5 p, .:!
projections.
i; ; $5.
h*t!;
Left
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.36 in.)
k,
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 mm (2.80 in.)
NOTE
For curb weights of the various models, refer to INTRODUCTION
AND MASTER TROUBLESHOOTING
- General
Date and Specifications.
80 (3.15)
I r nlgnr s
70 (2 76)
60 (2.36)
50 (1.97)
14wo31
40 (1.57)
1618 1712
1312 1316 141.0 14.4 14:8 1512 15:6 Id.0 Id4
(29.1 )(30.0)(30.8)(31.7)(32.6)(33.5)(34.4)(35.3~(36.2)(37.0)(37.9)(38.8~~39.7~l40.6
STB Revision
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1716
18!.0
1d.4
.:
2-50
FRONT SUSPENSION
Torsion
Bar
value
:: 71 mm (2.80 in.)
ii-J
12woo
/ STB Revision
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nut
FRONT SUSPENSION
Stabilizer
2-51
Bar
STABILIZER BAR
REMOVAL
AND
INSTALLATION
NOZTA-
7-9 ft.lbs.
Removal
I)+
steps
1.
2.
3.
4.
5.
6.
7.
8-12 r&l
6-9 ftlbs.
12W555
NOTE
(I 1 Reverse the removal procedures to reinstall.
(2) l + : Refer to Service Points of Installation.
(3) q : Non-reusable
parts.
p
$jfJ / ;..
N02T& -.I;j
INSPECTION
l
l
l
SERVICE
POINTS
7. INSTALLATION
OF INSTALLATION
OF STABILIZER
BAR
value
When installing
arms, tighten
dimension.
Standard
value
: 6-8 mm (.24-.31
http://vnx.su/
tighten
in.)
NOTE
The dimension
shown
new bushing is used.
;
N02TOAA
in the figure
in.)
2-52
FRONT SUSPENSION
- Drive
shaft
DRIVE SHAFT
REMOVAL
NOPClA-
AND INSTALLATION
Left drive
shaft
lo-13 Nm
7-9 ft.lbs.
Nm
ft.lbs.
50-60
35-43
Removal steps
4*
4*
4*
4*
4*
4*
4*
+e
1. Under cover
2. Cover
(automatic
free-wheeling
hub)
3. Free-wheeling
hub cover
(manual
free-wheeling
hub)
4. Gasket (manual
free-wheeling
hub)
1)4 Adjustment
of driveshaft
end play
5: Snap ring
6. Shim
7. Front brake assembly
8. Cotter pin
9. Connection
of tie rod assembly
and
knuckle
10. Cotter pin
11. Connection
of lower
ball joint and
knuckle
12. Cotter pin
13. Connection
of upper ball joint and
knuckle
14. Front hub and knuckle assembly
l + 15. Left drive shaft
16. Circlip
17. Right drive shaft
llW581
NOTE
(1) Reverse
(2)
(3)
(4)
l
l
e
+
m:
/ STB Revision
the removal
: Refer to Service
: Refer to Service
Non-reusable
parts
http://vnx.su/
procedures
Points
Points
to reinstall.
of Removal.
of Installation.
SUSPENSION
SERVICE
2.
2-53
- II wive shaft
POINTS
OF REMOVAL
NOZOBAC
the automatic
free wheeling
hub cover.
NOTE
When the cover cannot be loosened by hand, use an oil
filter wrench with a protective
cloth in between not to ,jJ.,JJ,
damage the cover.
J3:
3.
REMOVAL
OF FREE WHEELING
HUB COVER
free wheeling
hub)
(1) Set the control handle to the FREE position.
(2) Remove the free wheeling hub cover.
(Manual
>
,,..
; y
9,
i9,
5.
REMOVAL
OF SNAP RING
Using a snap ring pliers, remove
drive shaft.
the snap
llWO50
7.
REMOVAL
OF FRONT
BRAKE ASSEMBLY
(1) Remove the front brake assembly with the brake hose
connected.
(2) Use wire to suspend the front brake assembly from the
upper arm so that the front brake assembly wont fall.
Caution
Do not twist
1 STB Revision
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the brake
hose.
; j
5
,.:
ring from the;
~::
1.
:( ,I I
.,, 1
hr%.
>-.
c
2-54
FRONT SUSPENSION
9.
Drive
shaft
DISCONNECTION
OF TIE ROD
ASSEMBLY
FROM
KNUCKLE
Disconnect
the tie rod from the knuckle
by using the
special tool.
Cuation
1. Use cord to bind the special tool closely so it wont
become separated.
2. The nut should Ibe loosened only, not removed.
11. DISCONNECTION
OF LOWER
BALL
JOINT
FROM
KNIUCKLE/13.
UPPER BALL JOINT FROM KNUCKLE
Using the special tool, remove the lower ball joint and
upper ball joint.
Caution
1. Support
the lower arm with a jack when removing
the knuckle from the lower ball joint or the upper
ball joint.
2. After the knuckle has been removed,
lower the jack
slowly.
15. REMOVAL
OF LEFT DRIVE SHAFT
Pull the drive shaft out from the differential
carrier.
Caution
When pulling
the drive shaft out from the differential
carrier, be careful Uhat the spline part of the drive shaft
does not damage the oil seal.
INSPECTION
l
l
l
NOZCXAB
SERVICE
POINTS
OF INSTALLATION
15. INSTALLATION
OF LEFT DRIVE SHAFIDrive the drive shaft into the front differential
plastic hammer.
and excessive
NOZQDAC
carrier with a
Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached
to the D.O.J. side spline
part with a new one.
( STB Revision
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FRONT SUSPENSION
.
- Drive
ADJUSTMENT
Vehicles with
2-55
shaft
value
: 0.2-0.5
mm (.008-,020
value, adjust
in.)
by adding
or
r
value
: 0.2-0.5
1 STB Revision
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mm (.008-.020
value, adjust
in.)
by adding
or
,L
2-56
FRONT SUSPENSION
DISASSEMBLY
AND
Drive
Shaft
REASSEMBLY
NOZCIE-
I In--_
l?
16
11 BOO25
17ilj
llW60E
*5
llW609
11 W602
I
Disassembly
Reassembly
steps
Boot band A
Boot band B
Circlip
D.O.J. outer race
5. Balls
6. D.O.J. cage
7. Snap ring
9.
10.
11.
12.
13.
14.
15.
16.
17.
NOTE
(1) +e
(2) e+
inner
steps
1.
2.
3.
4.
8. D.O.J.
D.O.J. kit
race
D.O.J. boot
Dust cover
Boot protector band
Boot protector
Boot band A
Boot band B
B.J. boot
Drive shaft and B.J.
Circlip
: Non-reusable parts
: Birfield Joint
B.J.
D.O.J. : Double Offset Joini
(3) ml
: Refer to Service Points of Disassembly.
: Refer to Service Points of Reassembly.
(4)
(5)
1 STB Revision
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FRONT SUSPENSION
Right
Drive
2-57
Shaft
drive shaft
llBOO25
UJ
llW60
llW609
,.
D.O.J. kit
.*.
Reassembly steps
Disassembly steps
l *
l *
l *
l *
l *
*I)
c*
NOTE
(1) 4I)
(2) ++
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
13.
14.
15.
16.
Boot band A
Boot band B
Circlip
D.O.J. outer race
Balls
D.O.J. cage
Snap ring
D.O.J. inner race
D.O.J. boot
Dust cover
Boot protector
band
Boot protector
Boot band A
Boot band B
B.J. boot
Drive shaft and B.J.
: Refer to Service
: Refer to Service
l
l
l
l
l
+
+
+
+
+
~~
l +
e+
l +
l +
l +
~~
l +
Points of Disassembly.
Points of Reassembly.
(3)
(4)
(5)
16.
15.
13.
14.
2.
9.
1.
6.
8.
7.
5.
4.
3.
12.
11.
10.
: Non-reusable parts
B.J.
: Birfield Joint
D.O.J. : Double Offset Joint
1 STB Revision
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:i
I-
2-58
FRONT
SUSPENSION
SERVICE
5.
6.
Shaft
- Drive
POINTS
OF DISASSEMBLY
REMOVAL
OF BALLS
Rernove the balls from
REMOVAL
Remove
direction
OF D.O.J.
the D.O.J.
NOZQFAB
cage.
CAGE
7.
9.
RElMOVAL
1 lY09E
OF D.O.J.
BOOT
(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaft so that the D.O.J. boots are not
damaged
when they are removed.
(2) Withdraw
the D.O.J. boots from the drive shaft.
..
i
llYO97
10. REiMOVAL
Remove
OF DUST
COVER
wision
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FRONT
SUSPENSION
Drive
Shaft
2-59
15. REMOVAL
OF B.J. BOOT
(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaft so that the B.J. boot are not
damaged when they are removed.
,
:,
(2) Withdraw the B.J. boot from the drive shaft.
_I
;
Caution
Do not disassemble
the B.J.
e.
llW604
INSPECTION
l
l
0
o
l
l
NOPOGAB
h,,.Gi.
()I;i.*(
_
/ &,:
,.
SERVICE
POINTS
15. INSTALLATION
BOOT BAND
BOOT BAND
(1) Apply the
vinyl tape
the drive
Specified
OF REASSEMBLY
NOZQHAB
(2) Install the B.J. boot, boot bands (new ones), and D.O.J.
boot on the drive shaft, in that order.
Caution
The B.J. and D.O.J. boots are different
shape, so make sure they are correct.
~STB Revision
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i.
in size and
2-60
FRONT SUSPENISION
Shaft
Drive
(3) Apply all the specified grease, half of it to the inner side
of the B.J., and the other half to the inner side of the
B.J. boot.
Specified
?p
4I,
;
:,.:
: Repair
kit grease
iI&
grease
Caution
Be sure that the
bands is correct.
Boot b
installation
[llO
gr (3.9 oz.)]
by boot bands A
direction
of the
boot
/ ;
,*A
; I (I
1180076
6.
Cage
\
INSTALLATION
OF D.O.J. CAGE / 8. D.0.J INNER RACE
(1) Install the D.O.J. cage onto the drive shaft so that the
smaller diameter
side of the cage is installed
first.
(2) Apply the specified grease to the D.O.J. inner race and
the D.O.J. cage, and then fit them together.
Specified
grease
: Repair
kit
grease
5.
I
APPLICATION
OF GREASE TO BALLS
Apply the specified grease to the ball insertion parts of the
D.O.J. inner race and D.O.J. cage, and insert the balls.
Specified
4.
grease
: Repair
kit grease
INSTALLATION
OF D.O.J. OUTER RACE
(1) Apply the specified
grease to the D.O.J.
Specified
grease
wision
grease
http://vnx.su/
race.
outer
race.
outer
race.
FRONT
SUSPENSION
- Drive
Caution
Be sure that the
bands is correct.
(6) Replace
installation
direction
race, and
of the
boot
Caution
Do not secure the boot
2-61
Shaft
band A
(7) Secure the driveshaft, and then move the D.O.J. outer
q:
race until it is at the position where the D.O.J. bootgV3
assembly
dimension
is the standard value.
\5
. I.
t,f
Standard value : 77-83 mm (3.03-3.27
in.)
..
.
fr,
(8) Remove a part of the D.O.J. boot from the D.O.J. outer b:,
race and release the air within the boot.
(9) Secure the boot band A on D.O.J. boot.
Boot band B
Bo
band A
llYO99
Caution
Be sure that the
bands is correct.
installation
direction
of the
boot
g,
:,
12. INSTALLATION
OF BOOT
PROTECTOR
/ 11. BOOT f: ,:.$:j
.i>;
PROTECTOR
BAND
CA
(1) After installating
the boot protector to the B.J., secure\., : ~~
by the boot protector
band.
c,
is,.,, ;
Caution
Be sure that the installation
direction
of the boot
.
bands is correct.
(2) Securely
protector.
llB0017
10. INSTALLATION
Using
cover
Steel pipe
OF DUST
COVER
wision
http://vnx.su/
below,
force
the dust
2-62
FRONT SUSPENSION
- Inner
Shaft
INNER SHAFT
REMOVAL
AND
INSTALLATION
80-100 Nm
58-72 ftlbs.
80-110 Nm
58-80 ft.lbs.-
58-72
50-50
3543
ftlbs.
Nm
ftlbs,
10-13 Nm
7-9 ftlbs.
Removal
+e
l *
+e
steps
1.
l + 2.
3.
l * 4.
~~ 5.
6.
7.
8.
9.
llW582
Under cover
Front hub and knuckle
assembly
Shock absorder
lower
mounting
bolts
Drive shaft assembly
(R.H.)
Inner shaft
Circlip
Self locking
nut
Differential
mounting
bracket
(R.H.)
Housing
tube
NOTE
(1) Reverse the removal procedures to reinstall.
(2) l I) : Refer to Service Points of Removal.
(3) *+
: Refer to Service Points of Installation.
(4) m
: Non-reusable
pans
1 STB Revision
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FRONT
SUSPENSION
SERVICE
2.
POINTS
2-63
Shaft
OF REMOVAL
NOZRBAB
REMOVAL
OF FRONT HUB AND KNUCKLE
BLY/4. DRIVE SHAFT ASSEMBLY
(R.H.)
Refer
5.
Inner
to 2-44,
REMOVAL
ASSEM-
52.
OF INNER
SHAFT
Attach the special tools to the flange of the shaft, and drive
the inner shaft out from the front differential
carrier.
, _.\
,C
Caution
1. Being careful
not to scratch
or scar the shocki
absorber
with the special tool, remove
the lower a
mounting
bolts of the shock absorber, and compress
the shock absorber as much as possible.
2. When pulling
the inner shaft out from the front
differential
carrier, be careful that the spline part of
the inner shaft does not damage the oil seal.
INSPECTION
l
l
l
l
Check
Check
Check
Check
SERVICE
5.
NOZRCAA
POINTS
INSTALLATION
OF INSTALLATION
OF INNER
NO2DAf
I.
,
SHAFT
the front
differential
carrier
by d
7
1
Caution
1. Replace the circlip which is attached
to the inner
shaft spline part with a new one.
2. Be careful not to damage the lip of the dust seal and
oil seal.
4.
INSTALLATION
FRONT HUB
Refer
to 2-44,
STB Revision
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<
(R.H.)/2.
:.
2-64
FRONT SUSPENSION
DISASSEMBLY
AND
- Inner
Shaft
REASSEMBLY
NOZRE-
.,
$,
:rrr
?
Disassembly
1.
+e I)+ 2.
+e l + 3.
4.
ae ~b+ 5.
1
_.
: I
4
steps
llW597
Inner shaft
Bearing
Dust cover
Housing tube
Dust seal
NOTE
(1) Reverse the disassembly
procedures
to reassemble.
(2) +e : Refer to Service Points of Disassembly.
(3) I)+ : Refer to Service Points of Reassembly.
(4) q
: Non-reusable parts
SERVICE
2.
POINTS
OF DISASSEMBLY
REMOVAL
OF BEARING
(1) 13end the outside periphery
hammer.
NOZRFAB
Q
118727
) STB Revision
II
http://vnx.su/
FRONT SUSPENSION
3.
REMOVAL
Inner
2-65
Shaft
OF DUST
COVER
5.
REMOVAL
OF DUST
SEAL
l-
llW56
SERVICE
5.
POINTS
INSTALLATION
OF REASSEMBLY
OF DUST
NOZRHAD
SEAL
(1) Press-fit the new dust seal into the housing tube by
using the special tools, until it is flush with the housing
tube end face.
(2) Apply the specified grease to the dust seal lip.
MB990938-01
MB990955-01
Specified
grease
: Multipurpose
NLGI No. 2
grease
SAE
J310,
lW561
l-l
Steel pipe
3.
INSTALLATION
OF DUST
COVER
,.
Using a steel pipe, force a new dust cover onto the inner:
i\
shaft.
mm (in.)
Steel pipe
Overall length
50 (1.97)
Outside diameter
/ 75 (2.95)
Wall thickness
1 4i.16)
NOTE
After the dust cover has been installed,
grease to the inside of the dust cover.
Specified
2.
grease
INSTALLATION
: Multipurpose
No. 2
http://vnx.su/
OF BEARING
STB Revision
grease
apply specified
2-66
FRONT
SUSPENSION
FRONT DIFFERENTIAL
REMOVAL
AND
Front
Differential
Mounting
MOUNTING
INSTALLATION
NOZUA-
q 10 ~E;ft%i.
80-110
Nm
13
CY
8
ICE%,&
80-100 Nm
58-72 ft.lbs.
^^ _--
3042
22-30
_.
UU-100
Nm
58-72
ftlbs.
Nm
ft.lbs.
12W554
lo-13 Nm
7-9 ft.lbs.
Removal steps
+e
l +
+e
l +
l *
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
Under cover
Drive shaft
Circlip
Inner shaft
Circlip
Self-locking
Differential
Differential
Differential
Self-locking
Differential
Differential
13.
14.
15.
16.
nut
mounting
mounting
mounting
nut
mounting
mounting
rubber
rubber
bracket
rubber
rubber
A
B
(L.H.)
A
Differential
Self-locking
Differential
Differential
mounting
nut
mounting
mounting
bracket
rubber
rubber
(R.H.)
C
D
NOTE
(I)
(2)
(3)
(4)
: Refer to Service
Points
: Non-reusable
parts
STB Revision
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of Installation.
FRONT
SUSPENSION
Front
SERVICE
Differential
POINTS
OF REMOVAL
2. REMOVAL
OF DRIVE
Refer to P.2-52.
4.
2-67
Mounting
NOZUBAB
SHAFT
REMOVAL
OF INNER SHAFT
Attach the special tools to the flange of the shaft, and drive
the inner shaft out from the front differential
carrier.
Caution
1. Being
careful
not to scratch
or scar the shock
absorber
with the special tool, remove
the lower
mounting
bolts of the shock absorber, and compress
the shock absorber
as much as possible.
2. When pulling
the inner shaft out from the front
,, I
differential
carrier, be careful that the spline part of $
the inner shaft does not damage
the oil seal.
d
;
9.
REMOVAL
OF DIFFERENTIAL
MOUNTING
BRACKET::
(L.H.) / 13. DIFFERENTIAL
MOUNTING
BRACKET
(R.H.)
:.
While supporting
the differential
carrier with a jack, remove
the differential
mounting
bracket.
NOTE
Support the differential
carrier with
the differential
mounting
bracket.
a jack until
INSPECTION
installing
NOZUCAA
l
l
l
SERVICE
4.
POINTS
INSTALLATION
OF INSTALLATION
INNER
2.
not to damage
INSTALLATION
Refer to P.2-52.
1 STB Revision
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OF DRIVE
, :
l-r
SHAFT
NOPUDAA
differential
carrier
b\l;.
j I .+
1, .:
;;, ,yf
SHAFT
2-68
FRONT SUSPENSION
- Differential
Carrier
DIFFERENTIAL CARRIER
REMOVAL
AND
INSTALLATION
NOZVA-
mg,
PILlIll
Qz&&y
11 El/
-iJ..,
Nm
80-I 10 Nm
/ 58-80 ft.lbs.
50-60 NIY
/36-43
fds.
100-120 Nm ---------i
72-87 ft.lbs.
i2
80-100 Nm
58-72 ft.lbs.
80-106 Nm
58-72 ft.lbs.
IO-13 Nm
7-9 ft.lbs.
Removal steps
I+*
~~
4*
4*
1.
2.
l +
3.
I)+
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Under cover
Drive shaft
Circlip
Inner shaft
Circlip
Front propeller
shaft
Self-locking
nut
Differential
mounting
bracket
(L.H.)
Self-locking
nut
Front suspension
crossmember
and
differential
carrier assembly
Self-locking
nut
Front suspension
crossmember
Differential
mounting
bracket (R.H.)
Housing
tube
Front differential
carrier assembly
Pre-removal
Draining
Operation
of Gear Oil (Refer to P.2-
16.)
Post-installation
Operation
l
Supplying Gear Oil (Refer to P.2-16.)
front
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +e : Refer to Service Points of Removal.
(3)
l * : Refer to Service Points of Installation.
(4) q
: Non-reusable
parts
/ STB Revision
http://vnx.su/
FRONT SUSPENSION
Differential
Carrier
2-69
NOZVBAB
2.
REMOVAL
OF KNUCKLE
Refer to P.2-44, 52.
ASSEMBLY
4.
REMOVAL
OF INNER SHAFT
Attach the special tools to the flange of the shaft, and pull
the inner shaft out from the front differential
carrier.
Caution
1. Being careful
not to scratch
or scar the shock
absorber
with the special tool, remove
the lower
mounting
bolts of the shock absorber, and compress
the shock absorber as much as possible.
2. When pulling
the inner shaft out from the front
differential
carrier, be careful that the spline part of
the inner shaft does not damage the oil seal.
6.
REMOVAL
Make the
differential
Detach the
assembly.
,I.<I
...
+,.
p
q
\
*ll.
L,
OF FRONT PROPELLER
SHAFT
mating
marks on the flange yoke and the
companion
flange.
propeller shaft from the front differential
carrier
,,r:' bb
1'
8.
REMOVAL
OF DIFFERENTIAL
MOUNTING
BRACKET ;:. _:
(L.H.)
g,. .i,,:.,
While supporting
the differential
carrier with a jack, removei< *I..:{
,5. .)I
the differential
mounting
bracket.
?->
::
<5
i ,
INSPECTION
BEFORE DISASSEMBLY
NOZVCAA
Remove the cover and gasket. Hold the working base in a vice,
and install the differential
carrier assembly
to the working
base.
evision
http://vnx.su/
z-70
FRONT
SUSPENSION
FINAL
- Differential
DRIVE
GEAR
Carrier
BACKLASH
llV16i
value
or more
: 0.11-0.16
mm
on the circumference
(.0043-.0063
in.)
: 0.05
mm
(.0020
GEAR
it by
below.
on the
in.)
DIFFERIENTIAL
of
for improper
case.
BACKLASH
should
be made
Standard
value : O-0.076 mm
Limit : 0.2 mm (.0079 in.)
(2) If the backlash exceeds
gear thrust spacers.
I STB Revision
http://vnx.su/
the limit,
for both
(O-.0030
adjust
pinion
gears
in.)
FRONT SUSPENSION
FINAL
Differential
DRIVE
GEAR
2-71
Carrier
TOOTH
CONTACT
Check the tooth contact of the final drive gear by following the
steps below.
(1) Apply a thin, uniform
coat of machine
blue to both
surfaces of the drive gear teeth.
contact
condition
of th drive
gear and
NOTE
1. Checking
the tooth contack
pattern is the way to
confirm that the adjustments
of the pinion height and
backlash have been done properly.
2. Continue to adjust the pinion height and backlash nutil
the tooth contact
pattern
resembles
the standard
pattern.
3. If, even after adjustments
have been made, the correct
tooth contact pattern cannot be obtained, it means that
.the drive gear and the drive pinion have become worn
beyond the allowable limit; replace the gear set.
Caution
If either
replaced,
,:
:.
i: :
/ ST6 Revision
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2-72
FRONT
Standard
tooth
1 Toe
2 Drive-side
3 Heel
4 Coast-side
contact
SUSPENSIOPIJ
Differential
Carrier
pattern
Solution
Problem
Tooth
pinion
contact
height
pattern
resulting
Tooth
pinion
contact
height
pattern
excessive
resulting
from
from
improper
118642
SERVICE
4.
OF
INSTALLATION
INSTALLATION
OF INNER SHAFT
Drive the inner shaft into the front
using the special tools.
Caution
Be careful
seal.
2.
POINTS
not to damage
INSTALLATION
Refer to P.2-52.
Revision
http://vnx.su/
OF DRIVE
N02VDAB
differential
carrier
by
FRONT SUSPE
SOON - Differential
2-73
Carrier
160-220
116159
Nm
ft.lbs.
170
31
25
\I*:
8
\
40-60
2643
Nm
ft.lbs.
do-70
43-51
15-22
11-16
Nm
ft.lbs.
Nm
ft.lbs.
aI
Disassembly steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Cover
Gasket
Bearing caps
Differential case assembly
Side bearing adjusting spacers
Side bearing outer races
Side bearing inner races
Bolts (IO)
Drive gear
Lock pin
Pinion shaft
Pinion gears
Pinion washers
Side gears
Side gear thrust spacers
Differential case
Companion flange self-locking nut
Washer
Drive pinion assembly
Drive pinion front bearing inner race
21. Drive
22.
23.
24.
25.
pinion
front
bearing
outer
NOTE
(1) ++
(2) q
STB Revision
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of Disassembly.
race
,/- L
.i
.
!b<. .:
2-74
FRONT SUSPENSION
SERVICE
4.
- Differential
POINTS
Carrier
OF DISASSEMBLY
NOZVFAA
REMOVAL OF DIFFERENTIAL
CASE ASSEMBLY
Take out the differential
case assembly
with a hammer
handle.
Caution
When taking
out the differential
case assembly,
be
careful not to drop and damage the side bearing outer
races.
NOTE
Keep the right and left side bearings
and side bearing
adjusting
spacers separate, so that they do not become
mixed at the time of reassembly.
MB990339-01
7.
REMOVAL
OF SIDE BEARING
INNER RACES
Pull out the side bearing inner races by using the special
tools.
9.
801
10. REMOVAL
OF LOCK PIN
Drive out the lock pin with a punch.
NOl-E
The removed side gears and side gear thrust
and right, should be retained for reassembly.
17. REIWIOVAL
NUT
OF COMPANION
ST6 Revision
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FLANGE
spacers,
left
SELF-LOCKING
flange
and
FRONT
SUSPENSION
Differential
19. REMOVAL
OF DRIVE
2-75
Carrier
PINION
ASSEMBLY
and companion
Caution
The mating
mark made on the companion
flange
must not be on the coupling
surface of the flange
yoke and the front propeller
shaft.
(2) Drive out the drive pinion together
spacer and drive pinion shims.
20. REMOVAL
OF DRIVE PINION
FRONT BEARING
INNER
RACE
Pull out the drive pinion front bearing inner race by using
the special tools.
MIT303173
llS732
28. REMOVAL
RACE
ss rod
OF DRIVE
PINION
REAR
BEARING
outer
OUTER
118596
29. REMOVAL
OF DRIVE PINION
FRONT BEARING
OUTER
RACE
Drive out the drive pinion front bearing outer race from the
gear carrier by using the brass rod.
INSPECTION
l
l
l
l
l
l
l
NOZVGAA
1 STB Revision
http://vnx.su/
$
:,
1.
.z
2-76
FRONT
SUSPENSION
- Differential
Carrier
N02VH.-
EASSEMBLY
160-220
1%159\
40-60
26-43
11
Nm
ft.lbs.
TV \
16El
\
Nm
ft.lbs.
Pi-22
11-16
Nm
ftlbs.
511134
Reassembly
l *
l +
~~
l +
l +
steps
1 STB Revision
http://vnx.su/
FRONT
w/
SUSPENSION
MB990938-01
- Differential
2-77
carrier
MB990934-01
INSTALLATION
OF OIL SEALS
Install the oil seal with the special tool and apply a thin coat
of specified grease to the lip of the oil seal.
Specified
4.
0938-01
N02VlAB
grease
: Multipurpose
No. 2
grease
INSTALLATION
OF DRIVE
PINION
OUTER RACE
Press-fit the drive pinion front bearing
gear carrier by using the special tools.
FRONT
BEARING
0936-01
NOTE
Perform
race.
5.
4
MB990938-01
MB990934-01
press-fitting
carefully
J
,i
.
INSTALLATION
OF DRIVE PINION
REAR BEARING OUTER RACE
Press-fit the drive pinion rear bearing outer races into the
gear carrier by using the special tools.
NOTE
Perform
race.
press-fitting
carefully
11 w593
, jj$(%lB990905-4-01
MB990905-3-01
MB990905-2-01
MB990901-01
ADJUSTMENT
Adjustment
procedures:
OF PINION HEIGHT
the drive pinion
height
.I
by the
following
,
\
!,
(1) Install special tools and drive pinion front and rear ,
bearing inner races to the gear carrier in the sequence
!
shown in the illustration.
(2) Tighten the handle of the special tool until the standard
value of drive pinion rotation torque is obtained.
MB990905-l-01
llW518
1 STB Revision
http://vnx.su/
value
: 0.4-0.5
Nm (3.54.3
torque
(without
in. Ibs.)
the
.
.$
:g.
2-78
FRONT SUSPENSION
Differential
Carrier
NOTE
I, Gradually
tighten
the hardle of the special tool
while checking the drive pinion preload.
2. Because one rotation
cant be made when the
special tool is in contact with the gear carrier, move
it a few times
and, after seating
the bearing,
measure the rotation torque.
(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion front shim of
a thickness which corresponds
to the gap between the
special tools.
NOTE
1. Be sure to clean the side bearing seat thoroughly.
When positioning
the special tool, be sure that the
cut-out
sections
of the special tool are in the
position shown in the illustration,
and also confirm
that the special tool is in close contact with the side
bearing seat.
2. When selecting the drive pinion front shims, keep
the number of shims to a minimum.
(5) IFit the selected drive pinion front shim(s) to the drive
pinion, and press-fit the drive pinion front bearing inner
race by using the special tool.
ADJUSTMENT
OF DRIVE
Adjust the drive pinion
following
procedure:
PINION
turning
PRELOAD
torque
by
using
the
Without
Oil Seal
(1) Insert the drive pinion into the gear carrier, and then
install, from the front side of the carrier, the drive
Ipinion spacer, the drive pinion rear shim; the drive
pinion rear bearing
inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.
(2) Tighten the companion
flange
by using the special tool.
1 STB Revision
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to the specified
torque
FRONT SUSPENSION
Differential
(3) Measure
oil seal).
Standard
2-79
Carrier
rotation
value
Nm (3.5-4.3
: 0.4-0.5
torque
(without
the
in.lbs.)
With
the companion
flange
once
T
?
?
Oil Seal
(1) After setting the drive pinion rear bearing inner race, drive
the oil seal into the gear carrier front lip by using the
special tool.
(2) Apply the specified grease to the oil seal lip.
Specified
MB990031-01
grease
: Multipurpose
No. 2
grease
grease
: Multipurpose
No. 2
grease
,
$
1 s
.SAE 5310, NLGI :.
li.,. :
i;?.
wision
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2-80
FRONT
SUSPENSION
- Differential
Carrier
(5) Measure the drive pinion rotation torque (with oil seal)
to verify that the drive pinion preload complies with the
standard value.
!standard
value
: 0.647
Nm
(5.2-6.1
in.lbs.)
ADJUSTMENT
OF DIFFERENTIAL
GEAR BACKLASH
(1) Assemble
the side gears, side gear thrust spacers,
pinion gears, and pinion washers into the differential
case.
(2) Temporarily
install the pinion shaft.
NOTE
Do not drive in the lock pin yet.
(3) Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
(4) Measure
the differential
gear backlash
with a dial
indicator on the pinion gear.
Standard
value : O-0.076 mm
Limit : 0.2 mm (.008 in.)
(O-.0030
in.)
23. INSTALLATION
OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.
wision
http://vnx.su/
FRONT
SUSPENSI
h! - Differential
2-81
Carrier
24. INSTALLATION
OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhered to the threaded holes of
the drive gear by turning the tap tool (Ml0 x 1.25), and
then clean the threaded holes by applying compressed
air.
adhesive
adhesive
to the threaded
: 3M Adhesive
or equivalent
holes of
stud locking
4170
{*
/.
26. INSTALLATION
OF SIDE BEARING
INNER RACES
Press-fit the side bearing inner races to the differential
case by using the special tool.
.I fE!-.:
.i:
ADJUSTMENT
OF FINAL DRIVE GEAR BACKLASH
f :.,:
(1) Install the side bearing adjusting
spacers, which areFd, ::;;
tinner than those removed, to the side bearing outer\,
;
races, and then mount the differential
case assembly \,,
-3
into the gear carrier.
:;: 2
I ,
NOTE
Select side bearing adjusting
spacers with the same
I.
thickness
for both the drive pinion side and the drive
gear side.
1 STB Revision
http://vnx.su/
2-82
FRONT
+ Clearance + 0.05
2
SUSPENSIO
Differential
Carrier
(3)Measure
the thickness
of the side bearing adjusting
spacers on one side, select two pairs of spacers which
correspond
to that thickness
plus one half of the
clearance plus 0.05 mm (.002 in.), and then install one
pair each to the drive pinion side and the drive gear
side.
mm
(.002 in.)
= Thickness
of the
spacer on one side
llY241
value
evision
or more
: 0.11-0.16
http://vnx.su/
mm
on the circumference
(.0043-.0063
in.)
FRONT
SUSPENSION
Differential
2-83
Carrier
mm
(.0020
on the
0.
..11
..:
in.)
31. APPLICATION
OF SEALANT
TO GASKET
llSO58
1 STB Revision
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sealant
: 3M ART Part
or equivalent
No. 8661
and
or No. 8663,
t
I,
i, G
17-1
REAR
SUSPE
CONTENTS
GENERAL
INFORMATION
REAR SUSPENSION
SERVICE
ADJUSTMENT
Inspection
. . . . . . . .. .. . . . . . . . .. . . . . . .. .. . . . .
ASSEMBLY
. . . . . .. . . . . . . . . . . .. . .
PROCEDURES
2
4
. . . . .. .. . .
. . .. . . . . . . . . ..
N17AA-
SPECIFICATIONS
. . ..a..........................................
General Specifications
. . . . . . . . . . . . . . . .. .. . . . . . . . .. .
Service Specifications
Torque Specifications
http://vnx.su/
. . . . . . . .. .. . . . . . . . . . . . .. . . . . . . . . . .
. . . . . . . .. .. . . . . . . . . . .. .. . . . . . . . . . . .
2
2
3
3
17-2
REAR SUSPENSION
- General
Information
/ Specifications
GENERAL INFORMATION
N17BAAB
Shock absorber
hock absorber
lW614
SPECIFICATIONS
GENERAL SPECIFICATIONS
Nl7CL
Specifications
Items
Suspension
system
Leaf springs
Number of leaf springs
4
1,196.5-l ,203.5 (47.106-47.382)
mm (in.)
Straight span
Camber (unladen)
mm (in.)
73.5-82.5 (2.894-3.248)
N/mm (Ibs./in.)
Spring constant
-as installed
22 (123)
50 (280)
Shock absorbers
Type
Max. length
Min. length
Stroke
mm (in.)
mm (in.)
mm (in.)
Damping force
[at 0.3 m/set. (0.984 ft./set.)]
Expansion
N (Ibs.)
Compression
1.580-2.100 (348-463)
590-850 (130-I 87)
N (Ibs.)
/ ST6 Revision
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SUSPENSION
SERVICE
- Specifications
/ Service
Procedures
Adjustment
SPECIFICATIONS
Items
Specifications
Standard value
Toe-in
mm (in.)
0 (Non adjustable)
Camber
0 (Non adjustable)
TORQUE SPECIFICATIONS
Items
Nm
ft.lbs.
45-60
33-43
45-60
18-25
33-43
13-18
14-20
85-l 10
IO-14
Shackle assembly
U-bolt attaching
attaching
attaching
nut
bolt
nut
61-80
SERVICE ADJUSTMENT
INSPECTION
PROCEDURE$,.
value
: Toe-in 0 mm (0 in.)
Camber 0
NOTE
Toe-in
and
camber
are
set
at the
factory
and
cannot
be
adjusted.
If toe-in
or camber
replace
bent
is not within
or damaged
/ STB Revision
http://vnx.su/
the standard
parts.
value,
check and
17-4
- Rear Suspension
REAR SUSPENSldN
REAR SUSPENSION
REMOVAL
Assembly
ASSEMBLY
N17GA-
AND INSTALLATION
18-25
13-18
45-60
33-43
Nm
ft.lbs.
14-20
IO-14
llW613
Nm
ftlbs.
61-80
Post-installation
l
Operation
Removal
~~
l +
l +
l +
l +
ft.lbs.
Alignment
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Il.
Parking
brake cable
Shock absorber
U-bolt seat
U-bolts
Bump stopper
Front pin assembly
Rubber
bushings
Shackle
plate
Shackle
assembly
Rubber
bushings
Rear spring
attaching
bolt
NOTE
(1) Reverse the removal procedures to reinstall.. ,,
(2)
** : Refer to Servrce Pornts of lnstallatron
: Tighten when the vehicle is unloaded.
(3)
1 STB Revision
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REAR SUSPENSION
Rear
&pension
17-5
Assembly
INSPECTIQN
Check the shock absorbers
for oil leakage,
malfunction.
Check the leaf springs for damage or deterioration.
Check the U-bolt for cracks or bends.
Check the rubber parts for cracks or deterioration.
l
l
l
l
SERVICE
VehE
POINTS
noise
OF INSTALLATION
or
Nl7GDAE
11. INSTALLATION
OF REAR SPRING
Install the spring assembly to vehicle. Make sure the front
end (front pin side) to center bolt distance is shorter than
the rear end to center bolt distance.
front
NllGCh0
Center
bolt
125566
Front
Shackle
pin side
Inside of ~3
vehicle
9.
side
Inside of e
vehicle
12w515
INSTALLATION
ASSEMBLY
(1) Install the
the inside
(2) Install the
the inside
OF SHACKLE
front pin assembly
of vehicle.
shackle assembly
of vehicle.
ASSEMBLY/G.
FRONT
PIN
toward
from
toward
the outside
12W51.
4.
INSTALLATION
OF U-BOLT/S.
U-BOLT SEAT
Before the U-bolts
are tightened
to specified
torque,
confirm the relative position
of the center bolt and axle
housing and that of the center bolt and the hole in the Ubolt seat.
1 STB Revision
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li
.1
;:
19-1
POWER
TEERING
CONTENTS
GENERAL
INFORMATION
OIL PUMP
POWER
.................................
...........................................................
STEERING
SERVICE
GEAR BOX
ADJUSTMENT
Air Bleeding
PROCEDURES
Fluid Level
Checking
Stationary
Checking
Steering
Angle
Checking
Steering
Gear Backlash
Checking
Steering
Wheel
Free Play
Checking
Steering
Wheel
Return
Checking
Drive-Belt
Pressure
..........
.....................................................
.......................................
Steering
Ball Joint
Effort
End Play
...............
................................
Tension
23
.........................
Checking
Measuring
33
...................
...............
to Center
9
12
11
10
10
9
9
... 11
...........................
11
........................
10
..............................
13
NlSAA--
Replacement
Steering
SPECIAL
Wheel
Centering
TOOLS
SPECIFICATIONS
General
Lubricants
Sealants
Service
Torque
..............................
...... .........................................
....................................
and Adhesives
Specifications
Specifications
STEERING
HOSES
STEERING
LINKAGE
TROUBLESHOOTING
14
.......................................................
COLUMN
11
........... . ....................................
Specifications
STEERING
http://vnx.su/
......................................
of Fluid
..................................
2
5
5
.....................................
.....................................
AND SHAFT
....................
16.
.............................................
3%
..........................................
39
. . . . . . . . . .. . . . . ..*......................
, 912
;::;< I,:!.
/ Specifications
GENERAL INFORMATION
NlSBABB
A tilt steering system in which the steering column can be adjusted in four steps of 3 each for the most
suitable driving position has been adopted.
A ball-and-nut type (variable-ratio
gear) manual steering gear box has been adopted;
it features excellent wear
resistance and withstand
resistance
to impact shocks from the road surface, and assures
excellent operation
of the steering system.
In addition, an integral type of power steering
gear box has been adopted
ing force during full-angle turns and during low-speed
driving.
which
reduces
the required
steer-
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NlOCA--
Specifications
Items
Steering wheel
diameter
Power
gear box
steering
mm (in.)
380 (14.9)
SERVICE
Vane type
cc/:ev. (cu.in./rev.)
9.6 (.59)
SPECIFICATIONS
NlOCB--
items
Specifications
Standard value
mm (in.)
3230..0,,
Outer wheel
29OO
steering
25 (.98) or less
mm (in.)
effort
25 l.98)
N (Ibs.)
mm (in.)
37 (8.2)
9-l 2 (.35-.47)
kPa (psi)
7,500-8,200
Ncm (in.lbs.)
Mainshaft starting torque
Cross-shaft
end play
mm (in.)
25-65 (2-6)
Mainshaft
50-90 (4-8)
Backlash between
balls
mm (in.)
Ncm (in.lbs.)
Ncm (in.lbs.)
Ncm (in.lbs.)
N (Ibs.)
(1,067-l
0.05 (.0020)
0.05-o. 1 (.0020-,004)
100-300
(8.9-26)
300-900
(26-78)
25-75 (5.5-16.5)
1 ST6 Revision
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,I 66)
POWER
STEERING
-Specifications
Items
Specifications
Limit
Steering wheel free play
Steering gear backlash
Bail joint end play
mm (in.)
50 (2.0)
mm (in.)
0.5 (.02)
mm (in.)
1.5 (.06)
kPa (psi)
Gauge hose valve closed
Backlash between ball groove of rack piston and balls
Clearance
TORQUE
between
1,500 (218)
mm (in.)
0.2 (.008)
mm (in.)
0.1 (.004)
SPECIFICATIONS
NlOCC--
Items
Nm
ft.lbs.
35-45
25-33
20-25
14-18
8-10
6-7
3-5
2-4
11-15
Joint assembly
30-35
22-25
22-25
18-25
13-18
55-65
30-35
40-47
22-25
45
40-50
33
29-36
30-40
22-29
Side cover
45-55
33-40
30-45
22-33
Breather plug
3-4
2-3
130-I 50
94-l 08
Circulators
Plate
Power steering
Adjusting
to steering
column
gear box
15-20
30-35
gear box
3.5-4.5
2.5-3.2
Valve housing
installation
45-55
33-40
Lock nut*
180-230
130-I 66
NOTE
* If the special tool is used to measure the tightening
/ STB Revision
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is 135-175
Nm (98-l 27 ftlbs.).
1.4
1~ :p
POWER STEERING
,9-4
-Specifications
ftlbs.
Nm
Items
il pump
Oil pump bracket to engine
Front
14-21
IO-15
Front
14-21
IO-15
Rear
Right side
27-41
20-30
16-24
12-17
6-10
4-7
18-22
13-16
25-33
40-60
2943
6-10
4-7
18-22
13-16
18-25
13-18
IO-13
7-9
18-24
eering hoses
Under skid plate
Front
Rear
Pressure hose
Oil pump side
Gear box side
16-24
12-17
30-40
21-29
Return tube
40-50
29-36
Clip
8-10
6-7
8-12
6-9
8-12
6-9
16-24
12-17
Tube clip
8-12
6-9
Breather pipe
8-12
6-9
18-25
13-18
IO-13
7-9
45
33
45
33
65-80
47-58
45
33
45
33
40-60
29-43
55-65
40-47
eering linkage
Underskid plate
Front
Rear
( STB Revision
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Items
Quantity
lubricant
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Between
spring
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Installation locations
column A bushings
Multipurpose
grease SAE J310,
NLGI No. 2
Automatic transmission
fluid
DEXRON type
As required
Multipurpose
NLGI No. 2
As required
U-packing
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Multipurpose
NLGI No. 2
As required
Power steering
of steering
fluid
of side cover
SEALANTS
AND ADHESIVES
NlSCE--
Specified
Items
Dash panel cover bolt installation
Inside steering
Installation
column
hole
sealant
B nut
/ STB Revision
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; .j :
19-6
"
TROUBLESHOOTING
NlSEABB
Symptom
Probable cause
Excessive play of
steering wheel
Excessive
play in steering
Loose steering
Loose or worn
Steering wheel
operation is hard
(insufficient power
assist)
gear box
gear mounting
bolts
Shrill noise
Hissing
Whistling
noise
noise
19-25, 28
Retighten
19-23
Retighten
necessary
or replace as
19-39
19-11
19-12
Twisted
19-38
Damaged
belt
or damage hoses
Malfunction
of gear box
19-23
Malfunction
of oil pump
19-l 3
Loose installation
Retighten
box
and
1g-23., 33
19-38
Abnormal
pump
19-23.33
19-11,38,
19-33
19-33
Loose belt
19-11
19-33
Air sucked
19-II,38
19-23
Malfunction
of return hose
19-38
Malfunction
19-23
Air sucked
noise
Repair
19-I 1
Reference
page
Loose belt
Fluid leakage
Rattling noise
Remedy
1 STB Revision
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ii
Droning noise
Loose mounting
Interference
connectron
Improperly
welded
pipe
Overflow
19-33
19-II,12
or adjust the
Malfunction
19-33
Malfunction
19-34
19-23
Malfunction
19-25, 28
NOTE
* A slight beat noise is produced by the oil pump; this is not a malfunction.
(This noise occurs particularly when a
stationary steering effort is made.)
** A slight vibration may be felt when the stationary steering effort is made due to the condition of the road surface. To
check whether the vibration actually exists or not, test-drive the vehicle on a dry concrete or asphalt surface.
Moreover, a very slight amount of vibration is not a malfunction.
1 STB Revision
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SPECIAL TOOLS
NlSDA--
Steering
linkage puller
MB990778-01
Ball joint remover
M B990228-01
Preload socket
Measurement of the
mainshaft starting
M B990853-01
Top cover remover
M B990662-0 1
Oil pressure gage
M B9908540 1
Snap ring installer
pressure gage
pressure gage
1 STB Revision
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..
<.
_
POWER
STEERING
Service
Adjustment
Procedures
19-9
SERVICE ADJUSTMENT
PROCEDURES
CHECKING
FREE PLAY
STEERING
WHEEL
NlSFABD
value
: 50 mm
: 25 mm
(2.0
in.)
13K706
2.
If the measured
value exceeds the repair limit, check the
steering gear backlash and linkage ball joint end play.
CHECKING
STEERING
GEAR BACKLASH
NlSFOAB
to bind
become
separated.
The
should
nut
the special
be loosened
tool
only,
closely
not
wheel in
so it wont
removed.
135742
3.
4.
: 0.5 mm
(.02
at the pitman
arm top
in.)
If the measured
value exceeds the limit, screw in the
steering gear box adjusting
bolt until steering wheel free
play is within the range of standard value.
Caution
1. Be sure to make the adjustment
with the steering
wheel
in the straight-ahead
position.
2. If the adjusting
bolt is over-tightened,
more steering
effort will be required,
and return
of the wheel
will
be adversely
affected.
I STB Revision
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1940
._
POWER
STEERING
- Service Adjustment
MEASURING
Procedures
BALL JOINT
END PLAY
NlSFPAA
\
L-.
: 1.5 mm
If the measured
ball joint.
CHECKING
(.06 in.)
displacement
STEERING
ANGLE
value
: Inner wheel
Outer wheel
radius
gauge
NOTE
After adjusting
the
jam bolt so that the
head of the stop
direction, and then
specified
grease.
Specified
grease
Caution
Be sure
adjusting
that
the
CHECKING
steering
edge of
bolt are
pack the
and
3230 -%
29OO
the
NlSFDAC
replace
the stop
: Multipurpose
No. 2
grease
the toe-in
is properly
steering
angle.
STATIONARY
adjusted
STEERING
before
EFFORT,,,,,,,
4.
value
: 37 N (8.21
Ibs.) or less
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-1
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POWER
STEERING
- Service
-.
*
Adjustment
CHECKING
CENTER
.:
;*,r
19-11
Procedures
STEERING
WHEEL
RETURN
TO
N19FGAD
CHECKING
131613
DRIVE-BELT
TENSION
NlSFHAD
value
: 9-12mm
(.35-.47
FLUID
of IOON
in.)
If the measured
tension
is different
value, adjust the drive belt tension.
CHECKING
pressure
from
the standard
LEVEL
NlBFlAF
fluid
: Automatic
Type
REPLACEMENT
transmission
fluid
OF FLUID
DEXRON
NlOFJAF
Bleed
fluid
: Automatic
Type
the system
1 STB Revision
http://vnx.su/
and check
transmission
the fluid
fluid
pressure.
DEXRON
19-12
POWER STEERING
- Service
Adjustment
Procedures
AIR BLEEDING
NlSFKAD
Check stationary
s#teering effort. If it is different
standard value, air in the system is suspected.
system.
1. Make certain the reservoir is filled up.
2. Jack up the front wheels.
3. Remove the high tension cable.
from
Bleed
the
the
8. Loosen the breather plug, and then turn the steering wheel
completely
to the right and left continuously
until air
bubbles no longer appear in the fluid coming out of the
tube.
Caution
Do not hold the steering
completely
for 10 seconds
or more.
9. After completion
of the bleeding, tighten the breather plug.
Check the fluid level, and refill if necessary.
10. When turning the steering wheel right and left fully, check
that the fluid level variation is less than 4 mm (.I6 in.)
/ ST6 Revision
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POWER
STEERING
Service
Adjustment
PRESSURE
MB990662
NOTE
Use the adapter
M B990662
19-13
Procedures
1. Disconnect
the pressure
connect the special tool
s
Lf/
Thermometer
to connect
NlSFlAD
oil
pump
and
3s(w
MB990994-01
Caution
Do not close the shut-off
more than 3 seconds.
Standard
Valve
Valve
Limit
:
Valve
valve
of the special
value :
closed 4,900-7,800
kPa (711-1,138
opened 980 kPa (142 psi)
opened
6.
1,500
tool
for
psi.)
1 STB Revision
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POWER
STEERING
Tape or mark
on steering
column cover
Tape or mark
on steering
wheel hub
13W584
Distance
Service
STEERING
Adjustment
Procedures
WHEEL
CENTERING
SMilPLlFlED
STEERING
WHEEL CENTERING
,:
DETERMINING
STEERING
WHEELS
OFF CENTER
1. For the road test, take along chalk or tape and a ruler.
2. Drive straight ahead on an uncambered
level surface.
3. When the vehicles
wheels are pointing
straight ahead,
mark the steering wheel hub and column
cover with a
chalk or tape line.
4. Stop the vehicle and line up the marks on the hub and
column cover.
5. Place a tape strip or mark on the steering wheel rim.
6. Hold a ruler next to the rim as shown in the illustration,
and
then steer the steering wheel until it is in the desired
centered
position.
7. Record the distance
the strip or mark on the rim has
moved. This is how far the steering wheel is off center. If it
is more than16 mm (5/8 in.) off center, it can be centered
by indexing
it ten degrees towards the center.
off-center
INDEXING
STEERING
WHEEL TO CENTER IT
The steering wheel shaft has 36 splines, allowing
wheel to be indexed in ten-degree
increments.
the steering
36 splines
13W589
16 mm (5/8 in.
NlBFNAB
16 mm (5/8 in.)
13W582
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POWER
STEERING
Service
Adjustment
19-15
Procedures
PRECISION
STEERING
WHEEL CENTERING
In general, the tie rods are adjusted to steer the front wheels
in
the same direction that the steering wheel is off center. If the
steering wheel is off center to the left, center it by adjusting
steer toward
13W586
I.
2.
desired number
same direction
of turns. Adjust
to center
the steering
in the
wheel.
NOTE
I
13W587
1 STB Revision
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. ,.I
19-16
POWER
STEERING COLUMN
REMOVAL
STEERING
- Steering
Column
and Shaft
AND SHAFT
AND INSTALLATION
NlSGA-
3545
25-33
22-25
Nm
ft.lbs.
ftlbs.
13W644
Removal steps
++
I.
2.
3.
l + 4.
5.
6.
7.
8.
9.
10.
Bolt
Horn pad
Jam nut
Steering
wheel
assembly
Lower
column
cover
Upper column
cover
Lap heater duct
Cable band
Column
switch
Ignition
switch
l 4
l +
l 4
1.
2.
3.
4.
5.
6.
Key remained
switch
Brake pedal return spring
Clutch pedal return spring
Washer
bolts
Bolts
Steering
column
and shaft
assembly
NOTE
(1)
(2)
(3)
Reverse
l
l
*
+
1 STB Revision
the removal
: Refer
: Refer
to
to
procedures
Service
Service
http://vnx.su/
Points
Points
to reinstall.
of
of
Removal.
Installation
POWER
STEERING
Steering
SERVICE
4.
Column
and
POINTS OF REMOVAL
REMOVAL
OF STEERING
WHEEL
Remove the steering wheel.
SERVICE
19-17
Shaft
POINTS
NlSGBAH
ASSEMBLY
OF INSTALLATION
NlBGDAE
13. APPLICATION
OF SEALANT
TO WASHER
BOLTS
Attach the dash panel cover and apply a coating of the
specified
sealant in the bolt installation
hole from inside
the vehicle.
Specified
sealant
Caution
Do not loosen the column tube clamp bolts. If the clamp
bolts should be loosened,
retighten
them securely while
pulling the steering
shaft out fully toward the interior
side.
13. INSTALLATION
OF CLUTCH
/12.BRAKE
PEDAL RETURN
Install the return
figure.
4.
spring
PEDAL
SPRING
to the position
RETURN
SPRING
as shown
in the
INSTALLATION
OF STEERING
WHEEL ASSEMBLY
Position the front wheels in the straight-ahead
position and
install the steering wheel.
If the center of the steering wheel is not in alignment,
make the steering wheel centering
adjustment.
(Refer to
19-14.)
1 STB Revision
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19-18
POWER
DISASSEMBLY
AND
STEERING
REASSEMBLY
NlSGE-
2510
/
--
15
\4
20-25
14-18
Nm
ft.lbs.
8-10 Nm
5-7 ftlbs.
i6
Disassembly
l 4
l * l +
l +
l +
~~
4*
l +
I)+
l +
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
1 3.
1 4.
1 5.
1 6.
1 7.
1 8.
19.
20.
21.
22.
steps
Bolt
Return springs
Clevis pin
Bolts
Bolt
Bushings
Snap ring
Stopper
Spacer
Steering shaft A
Dust seal
Bushing
Steering column A
Special bolts
Steering lock assembly
Dash panel cover
Column tube clamp
Steering column B
Column bushing
Column tube
Steering shaft B
Snap ring
+e l +
+e l +
l +
l +
l +
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Clip
Bearing
Special bolts
Plate
Nut plate
Snap pin
Lever assembly
Snap ring
Plate assembly
Lower boot
Upper boot
Dust cover
Spring
Steering shaft C
Steering shaft D
Joint assembly
NOTE
(1)
(2)
(3)
(4)
Reverse
the disassembly
procedures
+e
: Refer
to Service
Points
of
l + : Refer to Service
Points
of
: Non-reusable
parts
1 STB Revision
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to reassemble
Disassembly.
Reassembly.
POWER STEERING
- Steering
Column
and
19-19
Shaft
7.
REMOVAL
OF CLEWS PIN
Knock the clevis pin out from
column.
REMOVAL
OF SNAP
the inside
NISGFAF
of the steering
RING
Using the snap ring pliers, remove the snap ring from
steering shaft A and extract steering shaft A from the
bottom
of steering
column A.
NOTE
Release
the steering
14. REMOVAL
SEMBLY
OF SPECIAL
lock to extract
steering
BOLTSI15.STEERING
shaft A.
LOCK AS-
25. REMOVAL
OF SPECIAL
BOLTW26.PLATE
If it is necessary to remove the plate of steering column B,
cut a groove on the head of each special bolt with a metal
saw, and remove the plate with a screwdriver.
INSPECTION
l
l
l
l
l
l
l
l
NlSGGAF
1 STB Revision
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19-20
POWER
STEERING
Steering
SERVICE
Column
POINTS
and
Shaft
OF REASSEMBLY
NlSGHAK
38. INSTALLATION
OF JOINT
ASSEMBLY
(1) Plate the upper boot over steering shaft C assembly
the lower boot and dust cover over steering
shaft
NOTE
Leave the upper and lower boots
assembling
them to the universal
Steering
Steering
shaft D
Steering
shaft C
\
Steering
/
grease
to the steering
: Multipurpose
NLGI No. 2
without
shaft C and D.
grease
SAE
5310,
shaft C
Caution
After inserting
steering shaft D make sure that the tilt of
the yoke of steering
shaft D in relation
to the yoke of
steering shaft C is within the angle measurement
shown
in the illustration.
shaft D
(3) Assemble
upper
Q
(0i
III
Q
Lower
grease
on the shafts
joint.
and
D.
the upper
and lower
boots
NOTE
Align the arrows on the upper and lower boots to the slits
on the yokes in order to assemble.
Slit
S/it
13S699
31. APPLICATION
OF GREASE
LEVER ASSEMBLY
TO PLATE
ASSEMBLY/28
When installing
the lever assembly
and the plate assembly, apply the specified grease to the following
locations:
Specified
grease
: Multipurpose
No. 2
grease
spring,..-,:...=-;7;;:
-. ..-
STB Revision
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POWER
STEERING
- Steering
Column
and
19-21
Shaft
26. INSTALLATION
OF PLATE/25.SPECIAL
BOLTS
When mounting
the plate onto the steering
column
tighten the special bolts until the heads twist off.
16. APPLICATION
OF GREASE
Apply the
grommet.
Specified
specified
grease
15. INSTALLATION
SPECIAL
BOLTS
TO DASH
grease
to
the
PANEL
dash
B.
COVER
panel
cover
: Multipurpose
No. 2
OF STEERING
LOCK
ASSEMBLY/14.
13W605
12. APPLICATION
Dust, seal
l.DUST
SEAL
of the
Specified
OF GREASE
grease
TO BUSHING/l
: Multipurpose
No. 2
10. INSTALLATION
STEERING
SHAFT A
Align the projection
of the dust seal and the notch of
steering
column A, and then install steering
shaft A to
steering column A.
Iion
http://vnx.su/
POWER
STEERING
Steering
Column
6. APPLICATION
5.
Yellow
line
Shaft
OF GREASE
and
grease
TO BUSHINGS
grease
to th,e bushings
: Multipurpose
No. 2
grease
and install
SAE J310,
NLGI
INSTALLATION
OF BOLT
Assemble
steering column A and steering column B by
aligning the yellow line on the serrated part of steering
shaft B with the yoke groove in steering shaft A.
13W604
4. APPLICATION
OF ADHESIVE
adhesive
TO BOLTS
: 3M Adhesive
equivalent
Caution
If there is any adhesive
hardened
tap to remove
it before applying
3.
stud
locking
column
4170
or
use a
INSTALLATION
OF CLEVIS PIN
Insert a new clevis pin until the tip of the pin is flush with
steering column
B.
1. INSTALLATION
OF BOLT
line
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::
POWER STEERING
POWER STEERING
REMOVAL
Bleeding
AND
Power
Steering
Gear
19-23
.
Box
GEAR BOX
INSTALLATION
of the Power
NlONA-
Steering
30-40
22-29
Nmy
ft.lbs.
30-35
22-25
Nm
ft.lbs.
:\\I--
55-65
4047
Nm
ft.lbs.
Removal
+*
l *
l *
~~
45 Nm/
33 ft.lbs.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Bolt
Connection
of pressure
hose
Connection
of return hose
Cotter pin
Slotted
nut
Connection
of relay rod
Self-locking
nuts
Connection
of joint assembly
Power
steering
gear box
13W64i
40
,,:: . .
*, _;I., /, <i!
; &. <:, . y!.*
.:-&
., c%$&$;<,;:
.:. -..;,
:,?
\
\..~
, I,:-J
y .;,.4- , .y., ,:
NOTE
:,
.I tfli. ,+r$
(1) Reverse the removal procedures
to reinstall.
(2) +I) : Refer to Service Points of Removal.
Iii ,s:: I ,.
YR
(3) l * : Refer to Service Points of Installation.
(4) q
: Non-reusable
parts
:*q.
:i.
?
( ST6 Revision
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.,
aib4
;:o, I
: f
P'2
f
POWER STEERING
Power
SERVICE
2.
Steering
POINTS
Gear
Box
OF REMOVAL
DISCONNECTION
OF
HOSE
Disconnect
the pressure
gear box.
NlONBAC
PRESSURE
HOSE/3.
RETURN
hose from
the
Caution
Use waste cloth to close the end of each hose in order to
prevent escape of fluid and entrance
of dirt and other
foreign material.
6.
DISCONNECTION
OF RELAY
ROD
Caution
1. Use cord to bind the special
ifl~.4@ijme
separated.
2. /The nut should be loosened
tool
closely
only,
not
so it wont
removed.
MB990635-01
SERVICE. POINTS
9.
INSTALLATION
OF INSTALLATION
OF POWER
STEERING
N19NDAB
GEAR
BOX
( STB Revision
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POWER
STEERING
- Power
Steering
Gear
Box
DISASSEMBLY
33-40
Disassembly
ft.lbs.
steps
1. Jam nut
2. Pitman arm
3. Dust cover
4. Breather
plug cap
5. Breather
plug
6. Washer
bolts
.7,. ,,Side cover
8,:Adjusting
bolt lock
9. Cross-shaft
,lO. Adjusting
bolt
11. Adjusting
plate
12. O-ring
13. U-packing
14. Valve housing
lock
15. Bolts
16. Valve housing
17. Rack piston
18. Seal ring
l *
nut
l *
l *
nut
c.1.
x-t
.gi.
.-*
NOTE
, 1, (1) l *
(2) q
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
O-rings
Screws
Circulator
holder
Circulators
Balls
Top cover
Main shaft
Thrust
needle
bearings
Ball bearing
Oil seal
O-rings
.
Seal, rings
Oil seal
Upacking
Gear box housing
Y 7.
T>,
.%i
1 STB Revision
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;,
. .
._
..
~~.~,.:~;~,
, r;
>
of 6isasse;i7bQ~~.
- .
-2.
:z-$-$
.y
.
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: .
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-.
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b
- -.
19-26
-
POWER STEERING
\p,
MB990809-01
Power
SERVICE
2.
REMOVAL
Steering
POINTS
Gear
BOX
OF DISASSEMBLY
OF PITMAN
NlSNFAC
ARM
8.
REMOVAL
OF BREATHER
PLUG
Remove the breather plug, and drain the steering
REMOVAL
OF ADJUSTING
BOLT
LOCK
by
gear oil.
NUT
9.
REMOVAL
OF CROSS-SHAFT
With the mainshaft
and cross-shaft placed in the straight
ahead position,
tap the bottom
of the cross-shaft with a
plastic hammer to take out the cross-shaft together
with
the side cover.
10. REMOj/AL
OF ADJUSTING
BOLT
.+gg~Remove the side cover by turnrng3be
_ IXT
13. REMOVAL
;.$-a
;y..
bolt.
OF U-tiAC$%JG
adjusting
U-packing
at the rear of the needle
is fluid leakage from the threads of
If there is leakage,
replace the Uone.
. :
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MB990852-01
\
14. REMOVAL
OF VALVE HOUSING
LOCK NUT
Remove the valve housing lock nut by using the special
tool.
REMOVAL
OF VALVE HOUSING
Remove the valve housing together
Caution
Use care not
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to drop
the
rack
piston.
POWER
STEERING
- Power
17. REMOVAL
Steering
Gear Box
OF RACK
PISTON
Caution
Be careful
piston
from
the mainshaft
24. REMOVAL
OF TOP
19-27
inside
by turning
it
COVER
Remove the top cover by using the special tool, and take
out the mainshaft,
together
with the top cover, from the
valve housing.
27. REMOVAL
OF BALL
BEARING/28.0lL
SEAL
(1) Temporarily
attach the top cover to the valve
(2) Drive out the ball bearing
and the oil seal.
housing.
13YO24
INSPECTION
l
l
l
l
l
NIONGAA
CHECKING
BACKLASH
PISTON
AND BALLS
BETWEEN
BALL GROOVE
OF RACK
mm
Standard valud : 0.05-0.1
Limit
: 0.2 mm (.008 in.)
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,;
(.0020-.004
I&-
in.)
and
19-28
POWER
STEERING
- Power
Steering
Gear Box
REASSEMBLY
NlSNE--
26
30
/2g
3.04.0
Nm
, Nm
ftlbs.
L
-25
'--45-55
\ -
3340
17nl
hm
ftlbs.
13W609
Reassembly steps
Gear box housing
:_
U-packing
Oil seal
Seal rings
O-rings
l + 6. Oil seal
l + 7. Ball bearing
l + 8. Thrust needle bearings
9. Main shaft
l + Adjustment
of main shaft starting
10. Top cover
1. Valve housing
lock nut
2. O-rings
3: Seal ring
4. Rack piston
5. Balls
6. Circulators
7. Circulator
holder
l +
l Q
1.
2.
3.
4.
5.
l + 19. Valve
l + 21. U-packing
l * 22. O-ring
l + Adjustment
of cross-shaft
play
l
l
l
l
starting
+
+
+
+
torque
housing
l +
NOTE
(1) l *
(2) q
(3)
*
20. Bolt
STB Revision
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end
23. Adjusting
plate
24. Adjusting
bolt
25. Cross-stiaft
26. Adjusting
bolt lock nut
27. Side cover
Adjustment
of main shaft total
torque
28. Washer
bolts
29. Breather
plug
30. Breather
plug cap
31. Dust cover
32. Pitman
arm
33. Jam nut
POWER
STEERING
- Power
Steerina
Gear
19-29
Box
INSTALLATION
OF UPACKING/3.
6.
INSTALLATION
N19NHAB
OIL
SEAL
OF OIL
SEAL17.
BALL
the oil
BEARING
(1) Press-fit
the ball bearing and oil seal into the top cover.
(2) Apply specified
grease to the oil seal of the top cover.
Specified
8.
INSTALLATION
grease
: Multipurpose
NLGI No. 2
OF THRUST
NEEDLE
grease
SAE J310,
BEARING
,,
Caution
Be careful that the thrust
plates and the thrust
needle bearing
do not come off the top cover.
L,
C1318
Thrust
needle
bearing
o
240
mm
(9.4
in.)
ADJUSTMENT
thrust
plate, thrust
needle bearing
plate to the mainshaft
in that order
illustration.
OF MAINSHAFT
STARTING
TORQUE
Caution
After tightening
the top cover, rotate
to confirm
that there is no torque
abnormal
noise.
1 STB Revision
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the mainshaft:
fluctugtion
or
!
:
;!.
i
.I.,.
: ,i
-.+
19-30
POWER
STEHBING
Power
Steering
Gear
BOX
(4) Tighten
torque
while
the
Caution
Be sure that the top cover does
with the lock nut at this time.
MB990852-01
measuring
value
: 25-65
starting
Ncm
not turn
torque
(2-6
together
by using
the
in.lbs.)
MB990228-01
14. INSTALLATION
OF RACK PISTON
Install the rack piston until it comes in contact with the
edge of the mainshaft.
Rotate the mainshaft to align the ball raceway with the ball
insertion
hole.
Yw
15. INSTALLATION
OF BALLS
(1) Insert 19 balls into the ball-insertion
gently with a brass bar.
Caution
Do not
balls.
rotate
(2) Measure,
by
surface of the
holes.
(3) If the distance
figure, remove
(4) Insert 7 balls
STB Revision
.iA
the
rack
while
inserting
them
the
using calipers,
the distance
from the
rack-piston
to the ball top point at both
differs from the value shown in the
the rack piston and reinsert the 19 balls.
into the circulators.
J
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piston
hole, pushing
POWER
STEERING
- Power
Steering
16. INSTALLATION
lnstal
Gear
OF CIRCULATORS
the circulators
19. INSTALLATION
of the
rack
OF VALVE
fluid
piston.
HOUSING
Specified
19-31
Box
transmission
: Automatic
transmission
RON Type
21. APPLICATION
OF GREASE
Apply specified
and the needle
Specified
: Multipurpose
No.
22. APPLICATION
TO O-RING
seal
surface
fluid
OF AUTOMATIC
grease
: Automatic
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NOTE
Install the adjusting
plate
faces the contact
surface
Standard
wision
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FLUID
trarh$@n
(2) Measure
gauge.
of U-packing
TRANSMISSION
.I!
:
.i
fluid
DEXRON
.I
bolt with
: 0.05
mm (.0020,,iy.)
,
.,i;,,
.(2.. ;:,.
<
side
a feeler
1
:
value
to the
Apply specified
automatic
transmission
and attach it to the side cover.
i ,:
Specified
moves
DEX-
TO U-PACKING
grease
to the
bearing.
grease
fluid
or I&
; i:
.
s
19-32
POWER
- Power
STEERING
Steering
Gear Box
25. INSTALLATION
OF CROSS
SHAFT/26.
ADJUSTING
BOLT LOCK NUT
Install the cross-shaft to the side cover, and then temporarily tighten the adjusting
bolt lock nut.
27. INSTALLATION
OF SIDE
COVER
to the
NOTE
Apply specified automatic
transmission
fluid to the teeth
and shaft areas of the rack piston, and apply specified
grease to the oil seal lip.
Specified
fluid
: Automatic
Type
Specified
grease
transmission
: Multipurpose
No. 2
grease
fluid
DEXRON
Caution
Do not rotate the side cover during
installation.Take
care not to damage
the cross-shaft
oil seal.
-.
ADJUSTMENT
TORQUE
OF
MAINSHAFT
TOTAL
STARTING
NOTE
^. Position
the
measurement.
MB990228-01
Mating
value
(2) Tighten
torque.
marks
the
: 50-90
mainshaft
adjusting
Ncm
in the -center
bolt
lock
32. INSTALLATION
OF PITMAN
ARM
Install the pitman arm to the gear
marks aligned.
.-
/ STB Revision
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(4-8
in.lbs.)
position
nut to the
box with
during
specified
the mating
POWER STEERING
Oil
Pump
OIL PUMP
REMOVAL
AND
INSTALLATION
NlSRA-
Post-installation
Operation
Supplying of Power Steering Fluid
(Refer to P.19-11.)
l
Bleeding of the Power Steering
Fluid Line (Refer to P.19-12.)
6-10 Nm
4-7 ft.lbs.
16-24
12-17
Nm
ftlbs.
13W634
3\
/l
8
13-16
14-21
/ IO-15
25-33
18-24
Nm
ft.lbs.
Nmft.lbs.
25-33
18-24
14-21
IO-15
Nk
ftlbs.
-2&l
Nm
ftlbs.
Nm
ftlbs.
Nm
13W648
SERVICEPOINTS
8.
:?rar,
REMOVAL
OF DRIVE VELT
When removing the.,drive belts, remove
compressor
drive belt (models equipped
er) and the alternator
drive belt.
SERVICEPOINTS
8.
.I*NlSRBAD
OF REMOVAL
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OF INSTALtAtION
ADJUSTMENT
OF DRIVE
Refer to P.19-11.
STB Revision
( $$
.<
TENSION
- NlSRDAD
:>,.
..I-.-.~
:e.
POWER STEERING
DISASSEMBLY
AND
- Oil Pump
REASSEMBLY
NlSRE--
13w945
Oil pump
cartridge
kit
Oil pump
9
Pulley assembly
seal kit
13W646
kit
40-60
Nm
6-10 Nm
4-7 ftlbs.
16-2;
13-16
130
.I8
40
Nm
ftlbs.
7
13W636
Disassembly steps
5;
.i,
. :i.
l *
l +
l +
1. Reservoir bracket
2. Pump cover
3. Cam case
l *
4. O-ring
5.
6.
l * l *
7.
l + 8.
9.
4* .
-10.
_
;,-a%,__ _I
I. .:: 11.
: ; 12.
Cam ring
Vanes
Snap ring
Rotor
Pulley assembly
Plate
Suction plate
Suction tube
1 STB Revision
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POWER STEERING
SERVICE
7.
19-35
- Oil Pump
POINTS
REMOVAL
OF DISASSEMBLY
OF SNAP
NlSAFdE
RING
9.
REMOVAL
OF PULLEY ASSEMBLY
Tap the rotor side of the shaft lightly with
hammer,
and take out the pulley assembly.
16. REMOVAL
OF FLOW CONTROL
VALVE/17.FLOW
TROL SPRING
Remove the flow-control
valve and the flow-control
from the oil pump body.
Caution
Do not
disassemble
the
flow
control
INSPECTION
l
l
l
l
l
l
l
Check the
Check the
Check the
Check the
Check the
stepped
Check the
Check the
with rotor
a plastic
CONspring
valve.
NlSRGAD
CHECKING
CLEARANCE
BETWEEN
SHAFT
AND PUMP
BODY
Check the clearance between pulley assemblys
shaft and the
pump body.
(1) Place the dial gauge against
the end of the pulley
assemblys
shaft.
(2) Move the pulley assembly up and down;anb
measure the
.i
play.
Limit
: 0.1 mm
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(.004
in.)
I:
_
-=G
;,f.,
19-36
POWER STEERING
SERVICE
- Oil Pump
18. INSTALLATION
TROL VALVE
Mark A, B or C
l-t
OF OIL
PUMP
NlBRHAH
BODY/lG.FLOW
CON-
13v902
Mark A, 6 or C
OF REASSEMBLY
POINTS
Specified
13W623
: Automatic
transmission
RON Type
fluid
MB990938-01
13. INSTALLATION
OF OIL
8.
INSTALLATION
control
DEX-
valve and
SEAL
fluid
the flow
control
tools.
valve.
OF ROTOR
7.
side.
INSTALLATION
OF SNAP RING
(1) Install the snap ring with the special
tool
(2) Lift the rotor and check to be sure that the snap ring
has entered the countersunk
part.
STB Revision
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POWER STEERING
5. INSTALLATION
When
pump
install
body
19-37
- Oil Pump
OF CAM
RING
4. APPLICATION
OF FLUID
TO O-RING
Apply the specified automatic transmission fluid to the Oring, and then install it to the cam case.
Specified
Direct round edge
the cam ring
fluid
to
3.
: Automatic
Type
INSTALLATION
OF CAM
transmission
fluid
DEXRON
CASE
ring
Specified
Cl3217
1 STB Revision
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fluid
: Automatic
transmission
RON Type
fluid
DEX-
19-38
POWER
STEERING
REMOVAL
STEERING
- Steering
Hoses
HOSES
AND
INSTALLATION
NlSTA-
S&&ing
of Power
Steering
Fluid
8-12 Nm
&IO Nm
6-7 ftlbs.
8-12 Nm
6-9 ftlbs.
40-50 Nm
/29-36 ft.lbs.
13W617
Removal steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
10-13 Nm
7-9 ft.lbs.
16W654
NOTE
Reverse
) STB Revision
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the removal
procedures
to reinstall
POWER
STEERING
REMOVAL
55-65
40-47
Steering
19-39
Linkage
LINKAGE
AND
Nm
ftlbs.
\
STEERING
INSTALLATION
NlSVA--
8lIl
/
18
17
18
45 Nm
33 tklbs.
45 Nm
33 ftlbs.
45
Nrh
33 ftlbs.
\
45 Nm
33 ftlbs.
5ml
4
65-80
47-58
Nm
ftlbs.
13W637
18-25
13-18
/
Nm
ftlbs.
10-13 Nm
7-9 ftlbs.
16W654
Removal steps
+e
**
64
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
II.
12.
13.
14.
15.
16.
17.
18.
a:
.zq
Dust cover
O-ring
Self-locking
Washer
Idler arm
Bushings
nut
NOTE
(I)
Reverse the removal procedures
(2) l * : Refer to Service Points
(3) l * : Refer to Service Points
(4) q
: Non-reusable
parts
( STB Revision
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to reinstall.
of Removal.
of Installation
19-40
POWER
STEERING
SERVICE
4.
- Steering
Linkage
POINTS
DISCONNECTION
OF REMOVAL
OF THE
ROD
NlSVBAC
ENDS
tool
closely
only,
not
so it wont
removed.
7. DISCONNECTION
OF RELAY ROD
Using the special tool, disconnect
the connecting
of the idler arm and the steering
gear box,
remove the relay rod.
INSPECTION
l
l
l
l
l
l
Standard
CHECKING
Standard
portions
and then
NlSVCAB
Check the
Check the
Check the
Check the
Check the
Check the
CHECKING
and
BALL
value
JOINT
: 100-300
IDLER
value
Revision
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ARM
: 300-900
(5.5-16.5
STARTING
Ncm
STARTING
Ncm
Ibs.)]
TORQUE
(8.9-26
inIbs.)
TORQUE
(26-78
in.lbs.)
[25-75
POWER STEERING
Steering
REPLACEMENT
(1) Remove
arm
grease
/
OF DUST COVER
arm,
Specified
grease
also remove
grease
the O-ring.
: Multipurpose
No.
Specified
NlBVEAB
the dust cover from the tie rod end or the idler
NOTE
For the idler
Pack
19-41
Linkage
grease
SEA J310.jl$LGl.
._
.-; :
grease
of the dust
inside
the dust
: Multipurpose
grease
cover.
No. 2
13W556]
sealant
REPLACEMENT
: 3M ART Part
OF IDLER ARM
BUSHING
NlSVFAE
grease
: Multipurpose
No.
grease
of the
SAE J310,
NLGI
SERVICE
4.
R,elay
rod
side
Knuckle
side
POINTS
INSTALLATION
OF INSTALLATION
OF TIE
ROD
NlSVDAA
ENDS
end
tightness,
left
and
right,
should
be
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BRAKE
SERVICE AND PARKING
CONTENTS
BRAKE
BOOSTER
BRAKE LINE
BRAKE PEDAL
FRONT
GENERAL
..............................................
...................
.m...................................
....................................................
........... . ..............
.................................
..........................................
25
Inspection
and Adjustment
of
Brake Pedal . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . .
27
18
29
2
MASTER
CYLINDER
PARKING
BRAKE CABLE
...................................
40
PARKING
BRAKE LEVER
...................................
39
21
...........................................
33
CYLINDER
36
......................
SERVICE
ADJUSTMENT
PROCEDURES
..........
..........................................................
Bleeding
Blend Proportioning
Valve
Function Test ..................................................
Brake Booster Operating Test ........................
Checking and Adjustment
of Parking
Brake Lever Stroke ..........................................
Checking Brake Fluid Level Sensor
................
Checking Parking Brake Switch ......................
NowA.-
10
14
14
12
11
12
12
SPECIAL
TOOLS
. . . . .. . . . . . . .. . . . . . . . ..a........................
15
7
SPECIFICATIONS
. . . . . . . . . . . .. . . . . . . . . . . .. .. . . . . . . . . . .. . . . . . ...*
. . . . . . .. .. . . . . . . . . .. .. . . . . . . . . . . . .. .
General Specifications
. .. .. . . . . . . . . .. . . . . . . . . . . .. . . . . . . .. . .. . . . . . . . . . . .. .. .._
Lubricants
braking
parking
.. . . . . . . . . .. . . . . . . . . . . . .. . . .. . . . . . . ... . .
or rattling
noise
power
brake function
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,noise
81
li .j
5-2
BRAKES - General
Information
CAUTION
do not create dust by sanding,
servicing
brake bssemblies
or compqnents,
cleaning brake parts dith a dry brush or with compressed
air.
A WATER DAMPENED
bLOTH
SHOULD
BE USED. Many brake components
contain
which can become airdorne
if dust is created during service operations.
Breathing
dust which hontains
asbestos
fibers c,an cause serious bodily
harm.
When
GENERAL
SERVICE
grinding,
or by
asbestos
fibers
BNFOfSMATlON
BRAKE
Brake
booster
Blend
Fro&
disc bl
proportioning
14W614
From ma_ster,
To
BLEND PROPORTIONING
far brake
VALVE
, w501
( STB Revision
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BRAKES
PARKING
- General
Information
5-3
BRAKE
Floor
\
I.
?i.
..
1 STB Revision
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5-4
BRAKES - Specifications
SPECIFICATIONS
GENERAL
Master
SPECIFICATIONS
NOICA-
I
hems
Specifications
cylinder
Type
I.D.
Tandem type
mm (in.)
Brake booster
Type
Effective
Boosting
dia. of power
ratio [Brake pc
inder
vacuum type
203.2 (8.0)
mm (in.)
II depressing
4.0
force]
Front brakes
F-type disc
Type
Disc O.D.
Disc thickness
Pad thickness
Cylinder I.D.
Clearance
mmi
255 (10.0)
20 (.79)
mm (8
10.5 (.413)
mm (in.)
53.97 (2.1248)
mm (in
Automatic
adjustment
Rear brakes
Leading and trailing shoe type drum
Type
Drum I.D.
Lining thickness
Cylinder I.D.
Clearance
254(10.0)
mm (in.)
mr
4.6(.18)
n.)
20.64(13/16)
mm (in
Automatic
adjustment
Parking brakes
Type
Brake engagement
Mechanical
Lever type
Cable routing
V-type
/ STB Revision
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,---
5-5
BRAKES -Specifications
SERVICE SPECIFICATIONS
N05CB--
Items
andard Value
Brake pedal height
mm (in.)
191-196 (7.5-7.7)
operating
Air-tightness
function
mm (in.)
0.5-I .o (.020-,039)
1O-l 5 (.39-.59)
95 (3.74) or more
4-6 clicks
test
Air-tightness
Boosting
Specifications
kPa (mmHg)
kPa (mmHg)
test
MPa (psi)
At 100 N (22 Ibs.) foot force
3.0-4.0 (427-570)
6.5-8.0 (925-l
Non-boosting
function
test
MPa (psi)
0.2 (28)
0.4 (57)
valve function
138)
test
MPa (psi)
3.325-3.725
(472.9-529.8)
4.725-5.325
(672.0-757.4)
N (Ibs.)
57(13.l)orless
Nm (ft.lbs.)
push rod to master cylinder piston clearance
[4 (3) or less)]
mm (in.)
0.1-0.5 (.004-,020)
nit
Pad thickness
Disc thickness
mm (in.)
1 .o (.039)
18.4 (.724)
mm (in.)
mm (in.)
Master cylinder body to piston clearance
Lining thickness
Drum I.D.
0.15 (.0059)
mm (in.)
mm (in.)
0.15 (.0059)
1 .o (.039)
mm (in.)
256.0 (10.079)
mm (in.)
1 STB Revision
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0.15 (.0059)
5-6
BRAKES - Specifications
TORQUE SPECIFICATIONS
NOBCC-
Items
8-12
25-35
6-9
8-12
6-9
18-25
13-18
Reservoir
1.5-3.0
l-2
Piston stopper
Master cylinder to brake booster
Fitting
1.5-3.0
8-12
15-18
l-2
Master
25-35
11-13
18-25
13-17
9-12
Bleeder screw
7-9
5-7
80-I 00
58-72
18-21
13-15
,_.,i
ftlbs.
Nm
stopper
cylinderto
member
bolt
18-25
6-9
LUBRICANTS
Items
Specified
Quantity
lubricant
Brake fluid
DOT 3
Chassis
plug
at the shoe assemblies
cylinder
As required
grease SAE J310, NLGI No. 0
Small quantity
Small quantity
As required
Small quantity
Small quantity
As required
Chassis
As required
Small quantity
;i SEALANTS
AND ADHESIVES
NOBCE-
Specified
Items
sealants
and adhesives
As required
As required
As required
I Both sides
of the sealer
or equivalent
Quantity
/ ST6 Revision
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As required
BRAKES -Special
Tools
5-7
/ Troubleshooting
SPECIAL TO
1 Tool (Number
NOCDA-
and name)
1 Use
Installation of rear wheel
cylinder piston cap
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Reference
paw
Replace
5-15
Inadequate
Correct
5-15,34
Adjust
5-33
Replenish
Auto adjuster
malfunction
Drum eccentricity
Improper
power
braking
NOBEAAB
or uneven wear
Low or deteriorated
brake fluid
or change
Bleed air
5-14
Correct
Replace
5-15
Inadequate
Correct
5-l 5,34
Replace
5125
Adjust
Replace
5-27
Bleed air
5-14
Replace
5-l 5,34
Replace
5-25
Correct
Adjust
Excessive
clearance
Adjust
5-23
Replace
5-21
contact
Brake booster
Auto adjuster
of pad or lining
malfunction
malfunction
2
F
<
Lb,.
i
valve malfunction
1 STB Revision
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1 5-27
5-8
BRAKES -Troubleshooting
Symptom
Probable cause
Remedy
Reference
page
Brake drag
Incomplete
Correct
Adjust
Replace
5-18
Replace
5-33
Lack of lubrication
Lubricate
5-35
Adjust
5-23
Replace
5-21
Correct
5-21
Replace
5-33
Excessive
Replace
5-l 5,34
Auto adjuster
Adjust
Replace
5-40
Replace
5-29,36
Replace
5-l 5,34
Correct
or replace
5-29
Correct
or replace
5-33
Correct
or replace
5-33
Cracked
Correct
or replace
5-29,33
Incorrect
Improper parking
brake function
Scraping or grinding
noise when brakes
3re applied
Squealing, groaning
lr chattering noise
when brakes are
applied
malfunction
Disc brakes-missing
outer shim
Replace
5-15
Correct or replace
5-l 5,34
Improper
or damaged
brake pad
Correct or replace
5-29,33
Clean or deburr
5-29
Clean or replace
5-29,33
Drum brakes-weak
damaged or incorrect
shoe hold-down springs, loose or
damaged shoe hold-down pins and springs
Correct or replace
5-33
incorrect adjustment
booster push rod
Adjust
lining parts
Disc brakes-burred
Dirty, greased,
linings
.:
in sliding parts
or rusted calipers
contaminated
or glazed
of brake pedal or
1 STB Revision
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.
5-10
5-9
BRAKES - Troubleshooting
Remedy
Reference
we
plate causing
Replace
5-33
Improper
machining
of drum causing
interference
with backing plate or shoe
Replace
Disc brakes-rusted,
Lubricate
or replace
5-29
Worn, damaged
or insufficiently
lubricated
wheel bearings
Drum brakes-weak,
damaged
or incorrect
shoe return spring
Lubricate
or replace
5-33
Loose
Retighten
of pads in caliper
Correct
5-29
of support
Correct
5-29
Replace
5-21,25
Adjust
5-IO,23
Symptom
Probable
cause
Squealing
noise
when brakes are not
applied
Bent or warped
backing
interference
with drum
stuck
Improper
positioning
Improper
installation
and caliper body
Stones or foreign
wheel covers
Loose
wheel
material
brake
trapped
of shim
Disc brakes-loose
installation
damaged
or dry wheel
of brake
inside
brake
stones,
etc.
Replace
5-15
bolt
Retighten
5-29
bearings
Lubricate
pedal or
or replace
Adjust
5-IO,23
Replace
5-33,40
5-39
surface
malfunction
parking
Remove
Retighten
nuts
Incorrect adjustment
booster push rod
Poor parking
function
or master
of brake pedal or
Disc brakes-failure
Worn,
mounting
5-33
drum
lever stroke
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BRAKES
Service
Adjustment
Procedures
PROCEDURES
SERVICE ADJUSTMENT
INSPECTION
DAL
NOSFAAA
AND ADJUSTMENT
OF BRAKE PE-
(1) Disconnect
loosen the
Move the
not contact
(2) Adjust the
rod with
loosened),
obtained.
mm (7.5-7.7
in.)
value
(B) : 0.5-l
.O mm (.020-.039
in.)
value
in.)
If the free play is less than the standard value, confirm that
the clearance
between the outer case of the stop light
switch and brake pedal is within the standard value.
If the free play exceeds the standard value, the clearance
between the clevis pin and the brake pedal arm might be
excessive. Check and replace the faulty parts if necessary.
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BRAKES
- Service
Adjustment
5-11
Procedures
Standard
value
(D) : 95 mm
(3.74
in.) or more
OF PARKING
NO5FUB
2.
value
ZOON $4
&
i.4,
;L
: 4-6 clicks
is secured
Caution
If the number
of brake lever clicks engaged
is less
than the standard
value, the cable has been pulled
excessively,
and failure of the automatic
adjuster
mechanism
will result. Be sure to adjust it to within
the standard value.
3.
Caution
If the parking brake cable is pulled too far, the adjuster
lever does not fit the adjuster,
resulting
in faulty
operation
of the brake shoe adjuster.
4.
.d
Jr It 1
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!
. ..
542
BRAKES
- Service
Adjustment
CHECKING
Procedures
BRAKE
FLUID
LEVEL
SENSOR
N~J~FBAA
1. Connect an ohmmeter
to the connector
of the brake fluid
level sensor.
2. Move the float from top to bottom and check for continuity. The brake fluid level sensor is in good condition
if there
k no continuity
when the float surface is above A, and if
there is continuity
when the float surface is below A.
,
CHECKING
PARKING
BRAKE
SWITCH
NOSFDAA
Good
_.
When engine
stopped
14uoo59
Good
is
0I
k
No good
BOOSTER
TEST WITHOUT
OPERATING
TEST
NOSFCAD
A TESTER
14UOO62
When engine
started
BRAKE
is
3.
No good
I
running,
depressed
for 30 seconds.
If the pedal
change, the booster is in good condition,
if
the booster is faulty.
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BRAKES
Service
Adjustment
TEST
WITH
5-13
Procedures
A SIMPLE
TESTER
Prior to the test, remove the check valve from the brake
booster and check the check valve for operation.
(Refer to P.526.)
With the check valve removed, make connections
as shown,
using another check valve (MB238892,
etc.), vacuum gauge,
pressure gauges and foot pressure gauge, bleed the pressure
gauges, and proceed as follows:
Test with No Load
Test 1 - Air-tightness
(1) Start the engine.
(2) Stop the engine when the vacuum gauge reaches approximately 68 kPa (500 mmHg).
After stopping the engine, wait approximately
15 seconds,
and then measure the decrease in vacuum.
Standard
value
4:
<
or less
ME109
,--b
..
.:
* t.,.:
Test 2 - Air-tightness
Test Under Load
(1) Start the engine.
(2) Depress the brake pedal at a force of approximately
200 N
(44 Ibs.).
Stop the engine when the vacuum gauge reaches approximately 68 kPa (500 mmHg).
(3) After stopping the engine, wait approximately
15 seconds,
and then measure the decrease in vacuum.
Standard
value
or less
3 - Boosting
Function
/
I
Test
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value,
:I
.
5-14
BRAKES
- Service Adjustment
Procedures
Function
Test
4 - Non-boosting
(1) Stop the engine.
(2) Confirm that the vacuum gauge indicates 0 kPa (0 mmHg).
(3) Check to be sure that the brake fluid pressure is the
standard value when the brake pedal is depressed at a foot
force of IOON (22 Ibs.) and 300N (66 Ibs.)
Test
Standard
value :
At 100 N (22 Ibs.) foot- force
0.2 MPa (28 psi)
At 300 N (66 Ibs.) foot force
0.4 MPa (57 psi)
(4) If the output.fluid
pressure agrees with the standard
the brake booster is functioning
properly.
BLEND PROPORTIONING
TEST
value
VALVE FUNCTION
N05FKAB
Standard value :
At 6.0 MPa (853 psi)
3.325-3.725
MPa
(472.9-529.8
psi)
At 9.0 MPa (1,280 psi)
4.725-5.325
MPa
(672.0-757.4
psi)
1:
k:
.
.+
3.
_-
If the measured
pressures are not within the permissible
ranges, replace the blend proportioning
valve.
Caution
Do not
depends
disassemble
the B.P.V. since
on preset load of the spring.
BLEEDING
its performance
N05FYE.a
brake fluid
evision
: DOT 3
1
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BRAKES
- Service
Adjustment
$915
Procedures
c ;, ..+qj 4
Caution
1. Use the specified
brake fluid. Avoid using a rni&$
of
the specified brake fluid and other fluid.
2. Of brake fluid is exposed
to the, air, it will absorb
moisture;
as water is absorbed
from the atmosphere,
the boiling point of the brake fluid will decrease and the
braking performance
will be seriously impaired.
For this
reason, use a hermetically
sealed 1 lit. (1.06 U.S.qt., 0.88
Imp.qt.) or 0.5 lit. (0.52 U.S.qt., 0.44.Imp.qt.)
brake fluid
container.
3. Firmly close the cap of the brake fluid container
after
use.
h,
INSPECTION
1.
Limit
2.
: 1.0 mm
condition
of the brake
in the caliper body.
(.039
NOTE
Hold the front brake assembly
wires
or other suitable
means
the brake hose is not twisted.
Outer
rsad clb
(4)Remove
anti-rattle
Anti-
&+.p.~
~-7
rattle
wring
ad
zip
B
14W608
----
) ST6 Revision
http://vnx.su/
through
the
f.
;.
,..
a
,
II 1
.,7
beyond
(3)Remove
downward
pads
in.)
(1)Pull
(2)Use
AND REPLACEMENT
plug
the limit,
replace
by moving
it upward
or
6
by suspending
it with.
in such a manner that
.
!k.
outer
mounting
shim, pad
support.
clips,
-..
.
--J,&.
BRAKES
Servic6
%djustm,ent
(5)Check
(6)Check
Procedures
the brake
the brake
disc thickness.
(Refer to P.5-31.)
disc runout. (Refer to P.5-32.)
(7)Measure
the rotational force of the hub, with the pad
removed so as to measure the pad dragging force after
installation.
4:
Then, gently
taking care to
Caution
If it is hard to push the piston with the hammer
handle, loosen the bleeder screw, and the piston will
go in easily. After the piston has been set in this
manner,
be sure to bleed the system. (Refer to P.514.)
(9)lnstall
(1O)lnstall
Anti-rattle
spring
u
w
14W552
(11)Attach
the tabs of the new outer shim to -the outer
brake pad at three places, and install the outer shim to
the brake pad.
.*
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lvision
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BRAKES
Service
Adjustment
Procedures
(12)Install
the
support.
new
pad
assemblies
to
the
mounting
Caution
The pad assemblies
should be replaced as sets (inner
and outer) for both the left and right wheels at the
same time.
.-
(14) Install
grease
the caliper
: Brake grease
No. 1
SAE J310,
NLGI
I:.,
.,*..
1:
,!. ;.
assembly.
) STB Revision
value
If the difference
exceeds the standard value, remove the caliper body and disassemble
it. Check
the piston and seal for deterioration,
corrosion, dirt
or scoring. (Refer to P.5-29.)
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,;
/
* a
5-18
BRAKES
- Brake Pedal
BRAKE PEDAL
REMOVAL
AND INSTALLATION
NO5GA--
14W604
13. Brake
Removal steps
1. Meter cover
2. Combination
screw
+*
3.
4.
5.
6.
7.
l + 8.
l * 9.
10.
l + 11.
** 12.
.,.
meter
installation
bolt
17. Pedal
(under
18. Pedal
and
support
member
the combination
support
member
installation
meter)
installation
bolt
bolt
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ES
- Brake
5-19
Pedal
REMOVAL
OF COMBINATION
METER
Refer to GROUP 8 ELECTRICAL-Meter
NOBGBAB
ASSEMBLY
and Gauges.
INSPECTION
l
l
l
NOIGCAD
4. .f
{.
k
CHECKING
STOP LIGHT SWITCH
Connect an ohmmeter
to the connector
of the stop light
switch, and then check for continuity
when the plunger of the
stop light switch is pressed
in and when it is released
outward.
The stop light switch is in good condition
if there is no
continuity
when the plunger is pressed in, and if there is
continuity when the plunger is released outward.
Plunger
3t
----
No
A,
continuity
Continuity
SERVICE
Steering
column
assembly
$edal
support
POINTS
OF INSTALLATION
NOIGDAG
20. INSTALLATION
OF PEDAL SUPPORT
MEMBER
After temporarily
fastening
the installation
bolts and~r;ldts~..~~
of the pedal support member,
tighten
them in the&quence shown by the numbers in the figure.
member
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STB Revision
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5-20
OF GREASE
TO SPACER/15.
grease
: Chassis
grease
BUSHING
surface
of the
14W596
12. APPLICATION
OF GREASE TO CLEVIS PIN/l 1. WASHER
After applying the specified
grease to the clevis pin and
washer, insert a clevis pin and bend the cotter pin tightly.
Specified
grease
: Wheel
bearing
NLGI No. 2
grease
SAE
J310,
Grease
9.
INSTALLATION
DAL/8. RETURN
Install the return
figure.
14w59
1 STB Revision
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OF RETURN
SPRING
spring
SPRING
to the position
OF CLUTCH
as shown
PEin the
5-21
MASTER
REMOVAL
Pre-removal
l
Draining
CYLINDER
AND
12
INSTALLATION
-@?9
Operation
Brake Fluid
1.5-3.0 Nm/
l-2 ftlbs.
12
13-17 Nm
9-12ft.lbs.
14W567
Removal steps
l *
1. Connection
of brake
connector
2. Connection
of brake
3. Connector
4. Master
cylinder
5. Reservoir
cap
6. Diaphragm
7. Oil reservoir
float
8. Reservoir
installation
9. Reservoir
10. Reservoir
seal
fluid
level
18-25 ftlbs.
9-12 ftlbs.
sensor
+e
tube
NOTE
Reverse the removal procedures
to reinstall.
(2) 4*
: Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation
screw
(I)
SERVICE
9.
POINTS
REMOVAL
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NOBIBAD
OF RESERVOIR
When removing
1 STB Revision
OF REMOVAL
the reservoir,
upward.
5-22
BRAKES
Master
Cylinder
depressing
depressing
14. REMOVAL
OF PRIMARY
Caution
Do not disassemble
15. REMOVAL
PISTON
the primary
OF SECONDARY
the
the
ASSEMBLY
piston
PISTON
assembly.
ASSEMBLY
NOTE
If the secondary
piston
is difficult
to remove,
apply
compressed
air gradually from the secondary
side outlet
port of the master cylinder, and then remove the secondary piston from the cylinder.
Caution
Do not disassemble
the secondary
piston
assembly.
INSPECTION
Check the
scars.
Check the
ing, wear,
Check the
l
l
l
NO5ICAA
inner surface
of master
cylinder
CLEARANCE
BETWEEN
MASTER
CYLINDER
TER AND PISTON
OUTER DIAMETER
Primary
INNER
DIAMENOBICBC
(1) Measure
approximately
three positions
of the master
cylinder inner diameter
[bot=to&(A),
middle (B) and top (C)]
by using a cylinder gauge.
(2) Measure
O.D. of pistons at illustrated
location
using a
micrometer.
piston
NOTE
Measure the inner diameter
of master cylinder at the two
places described
above and at D and E shown in the
illustration.
B
Secondary
piston
: 0.15 mm
wision
(.0059
in.)
I
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BRAKES
- Master
SERVICE
5-23
Cylinder
POINTS
OF INSTALLATION
N05lDAH
15. APPLICATION
OF BRAKE FLUID TO SECONDARY
PISTON ASSEMBLY/14.
PRIMARY PISTON ASSEMBLY
Apply the specified
brake fluid sufficiently
to the inner
surface of the master cylinder body and to the entire
periphery of the secondary and primary pistons.
Specified
brake fluid
: DOT 3
14KO28
ADJUSTMENT
OF
BOOSTER PUSH ROD
Check and adjust the
booster push rod and
steps below.
(1) Measure
master
CLEARANCE
BETWEEN
BRAKE.
AND PRIMARY
PISTON
clearance
(A) between the brake r.P
the primary piston by following the?
<I
ii.
Lk
the dimension
(B) from
cylinder to the piston.
the
edge
of the
NOTE
Obtain the dimension
(B) by first placing a straight
scale against the edge of the master cylinder, and then
measuring
and subtracting
the thickness of the straight
scale.
i;
.
) STB Revision
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2,
5-24
BRAKES
Master
Cylinder
value
: 0.1-0.5
mm
(.00&.020
in.)
ST6 Revision
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clearance
brake
drag.
BRAKES
5-25
- Brake Booster
BRAKE BOOSTER
REMOVAL
AND
INSTALLATION
N05JA..
5-9 ftlbs.
14W616
5-9 ftlbs.
9-12 ft.lbs.
18-25 ft.lbs.
Removal steps
l +
~~ l +
l +
l *
l +
Pre-removal
l
Draining
Operation
of Brake Fluid
/ozz;i;:gy4,,
l
Adjustment
NOTE
(1) Reverse the removal procedures to reinstall.
(2) 4)
: Refer to Service Points of Removal
(3j 64 : Refer to Service Points of Installation.
(4) q
: Non-reusable parts
SERVICE
POINTS
5 . REMOVAL
OF REMOVAL
OF VACUUM
N06JBAD
HOSE
Caution
1. When removing
the vacuum hose from the brake
booster, pull it out straight.
2. The check valve installed on the brake booster will
be damaged if the vacuum hose is forced up and
down or to the left and right.
1 STB Revision
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5-26
BRAKES
Brake
Booster
INSPECTION
NO5JCAB
CHECKING
CHECK VALVE
Blow into the check valve. If the air passes through when you
blow from the booster side, but not when you blow from the
engine side, the check valve is functioning
properly.
14W523
SERVICE
POINTS
OF INSTALLATION
NO5JDAG
15. INSTALLATION
OF FITTING
When installing the fitting, apply the specified
threaded portion.
Fitting
Specified
sealant
: 3M ART
equivalent
Part
No.
sealant
8663,
to its
8661
or
Sealant
14V626
9. APPLICATION
OF GREASE TO CLEVIS PIN/8. WASHER
After applying the specified
grease to the clevis pin and
washer, insert a clevis pin and bend the split pin tightly.
Specified
grease
: Wheel
bearing
NLGI No. 2
grease
SAE
5310,
Grease
5.
Clio
Vacuum
hose
Check valve
INSTALLATION
OF VACUUM
HOSE
Fasten the vacuum hose securely to prevent
the connections.
NOTE
When the hose clip on the brake booster side is installed,
fix it on the brake booster pipe and do not bring it into
contact with the check valve.
Brake
booster
side
14KOQS
ADJUSTMENT
OF CLEARANCE
BETWEEN
BOOSTER
PUSH ROD AND PRIMARY
PISTON
Refer to P.5-23.
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BRAKE
5-27
BRAKE LINE
IEMOVAL
AND INSTALLATION
Flare
nut
13-17 Nm
9-12 ft.lbs.
14FO38
.
I
,I
Pre-removal
l
Draining
Operation
of Brake Fluid
,
<I
>
:
Bi
14W578
Removal steps
++
4*
l +
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
NOTE
(1) *I)
: Refer to Service Points of Removal.
(2) l + : Refer to Service Points of Installation.
STB Revision
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POINTS
OF REMOVAL
NO5KBAD
14wss3
tube
Brake hose
7.
REMOVAL
Caution
Do not
depends
OF BLEND
disassemble
on preset
PROPORTIONING
the B.P.V.
load of the
VALVE
INSPECTION
l
0
l
SERVICE
2.
POINTS
INSTALLATION
Install
r
i
NO5KCAB
the brake
NOTE
When installing,
contact edges,
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OF INSTALLATION
OF BRAKE
hoses
NO5KDAB
HOSE
without
twisting
them.
BRAKES
Front
Disc
Brake
5-29
Caliper
AND INSTALLATION
W-100
N05LA-
Nm
ft.lbs.
58-72
80-100
ft.lbs.
58-72
14W610
Pre-removal
l
Draining
Operation
of Brake Fluid
18
11
4*
*+
l +
l *
l *
l e I)+
l * l +
+* l 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Il.
12.
Connection
of brake hose
Clip
Spigot
pin
Stopper
plug
Plug plate
Caliper assembly
Brake tube
Boot ring
Piston boot
Piston
Piston seal
Mounting
support
and brake
bly
pad
l 4
l 4
++
I)+
3.
4.
5.
13.
14.
15.
16.
17.
18.
19.
Spigot
pin
Stopper
plug
Plug plate
Pad assembly
Outer shim
Outer pad clip
Inner pad clip
Pad clip B
Anti-rattle
spring
Mounting
support
i5
l-8
l-3
17
1518 13
Brake
pad kit
NOTE
Reverse the rE:moval procedures to reinstall.
(2) l * : Refert 0 Service Points of Removal.
(3) *+
: Refer to Service Points of Installation.
(4)
q : Non-re usable part
(1)
ST6 Revision
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14
14W607
assem-
17
sea ana Do
.:
...>
-ft
;
5-30
BRAKES
Front
Disc
SERVICE
Brake
Caliper
POINTS
1. DISCONNECTION
OF REMOVAL
OF BRAKE
NOBLBCA
HOSE
Refer to P.5-28.
4.
REMOVAL
OF STOPPER
PLUG
6. REMOVAL
OF CALIPER ASSEMBLY
Remove the caliper assembly
by moving
downward at an angle.
it upward
or
NOTE
Hold the front brake assembly by suspending
it with wires
or other suitable means in such a manner that the brake
hose is not twisted.
8.
REMOVAL
OF BOOT RING
Remove the boot ring by using a screwdriver.
9.
REMOVAL
OF PISTON BOOT/IO.
PISTON
Remove
the piston and piston boot by applying
pressed air through the brake hose fitting hole.
com-
Caution
Place a piece of cloth in front of the piston, and slowly
increase the force of the compressed
air to prevent the
piston from springing
out abruptly.
14E619
Il.
REMOVAL
OF PISTON
(1) Remove the piston
SEAL
seal from the cylinder
by hand.
Caution
Never use a screwdriver
or similar
tools,
doing so could damage the cylinder surface.
(2) Clean the caliper
brake fluid.
zvision
because
alcohol
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or
BRAKES
5-31
Caliper
OF PAD ASSEMBLY
Remove
downward
NOTE
Hold the front
wires or other
the brake hose
(2) Remove
brake assembly
suitable means
is not twisted.
the brake
by moving
it upward
by suspending
it with
in such a manner that
pad assembly.
INSPECTION
N05LCAB
l
l
0
e
l
CHECKING
BRAKE
PAD THICKNESS
Measure
the thickness
wear is the greatest.
/,6
A
or
Limit
: 1.0 mm
(.039
in.)
are worn
beyond
them.
14110072
CHECKING
BRAKE
(1) Clean
the brake
DISC
disc
THICKNESS
surface
to remove
dirt
and rust.
(2) Measure
the thickness
of the brake disc at least four
places on the sliding surface of the brake disc and the pad.
Limit
I.2
14F611
: 18.4 .mm
(.724
in.)
If the thickness
of the brake disc is less than the limit (even
at only one location)
or there is wear, replace the brake
disc. (for removal
of the brake disc, refer to GROUP 2
FRONT SUSPENSION-Axle
Hub and Free-Wheeling
Hub.)
STB Revision
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-t, :.:! -
5-32
BRAKES
- Front
CHECKING
BRAKE DISC RUNOUT
Measure the runout of the brake disc at the edge of the brake
disc circumference.
Limit
: 0.15 mm
(.0059
in.)
If the brake disc runout exceeds the limit, change its position
on the hub and/or retorque evenly.
Check the runout again, and if it cannot be corrected,
replace
the brake disc. Do not resurface it. (for removal of the brake
disc, refer to GROUP 2 FRONT SUSPENSION-Axle
Hub and
Free-Wheeling
Hub.)
NOTE
Before measuring the runout of the brake disc, check the play
of the wheel bearing and, if necessary,
correct it.
SERVICE
POINTS
13. INSTALLATION
Refer
\\
Grease
OF PAD
ASSEMBLY
OF PISTON
SEAL
NOBLDCB
to P.5-15.
11. INSTALLATION
Piston
OF INSTALLATION
brake
fluid
with
the
10. APPLICATION
OF BRAKE FLUID TO PISTON
Apply brake fluid to the outside surface of the piston and
slowly insert the piston by hand, while using care not to
twist it.
14Y184
Specified
9.
: DOT 3
APPLICATION
OF GREASE TO PISTON BOOT
Apply the specified
grease to the piston boot
groove in the caliper body.
Specified
5.
brake fluid
grease
: Repair
kit grease
mounting
(orange)
APPLICATION
OF GREASE TO PLUG PLATE/4.
STOPPER
PLUG
Apply a thin coat of the specified grease to the plug plate
and stopper plug contact surface.
Specified
grease
: Brake
grease
1. CONNECTION
OF BRAKE
Refer to P.5-28.
evision
I
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HOSE
SAE J310,
NLGI
No. 1
5-33
AND
Post-installation
l
INSTALLATION
NO!iUA-
Operation
Adjustment
of Parking Brake Lever
Stroke (Refer to P.5-11,)
14Wf99
Removal
steps
*I)
1. Brake drum
++
2. Shoe
return
spring
with
brake
shoe
ad-
juster
NOTE
(1) Reverse the removal procedures to reinstail.
(2) 4* : Refer to Service.Points
of Remc~val.
(3) l + : Refer to Service Points of Installation.
3. Adjusting
spring 4. Shoe retainer
spring
5. Shoe hold-down
spring
SERVICE
e+
e+
(I)+
POINTS
OF REMOVAL
MQSJ0Af)
1. REMOVAL
OF BRAKE DRUM
If the brake drum is difficult to remove, follow either of the
steps described below.
(1) When using the brake shoe adjuster.
0 Remove the adjusting hole cover at the muside of
the backing plate.
0 Insert a screwdriver
into the adjustment
hole and
use it to separate the adjustment
lever from the
brake shoe adjuster.
0
Brake shoe
14W602
wision
1
http://vnx.su/
, 1
,.
..
,a
BRAKES
INSPECTION
NOIUCAD
CHECKING
BRAKE LINING THICKNESS
(1) Measure the wear of the brake lining
most.
Limit
14110075
holes
: 1 .O mm (.039 in.)
replace
CHECKING
BRAKE DRUM INSIDE DIAMETER
(1) Measure the inside diameter
of the drum at more than two
positions by using a caliper gage.
Limit
: 256.0 mm (10.079
in.)
(2) If the internal diameter of the brake drum is the limit value
or more, or if there is noticeable
abnormal
wear, replace
the brake drum.
CHECKING
BRAKE
LINING
AND
BRAE
DRUM
CONTACT
(1) Apply chalk powder to the inner surface of the brake drum
and turn the brake drum so that it rubs against the shoe
assembly.
(2) If places of noticeably
poor contact are discovered,
replace
the shoe assembly and/or brake drum.
SERVICE
8.
OF INSTALLATION
APPLICATION
OF GREASE TO SHOE HOLD-DOWN
Apply the specified
sealant to the shoe hold-down
inserting portion of the backing plate.
Specified
POINTS
sealant
: 3M Sealant
lent
140612
1 STBi% evision
I
http://vnx.su/
NOSUDAH
PIN
pin
5-35
7. APPLICATION
OF SEALANT
TO SHOE AND LEVER
ASSEMBLY/G.
SHOE AND LINING ASSIEMBLY
Apply the specified grease to the contacting
surfaces of
the shoes and backing
plate, anchor plate and wheel
cylinder piston ends.
Specified
grease
: Brake
lent
grease
SAE 5310,
NLGI
. ;I
.:
No. 1
Cl4074
2.
Grease
INSTALLATION
OF SHOE
RETURN
SPRING
BRAKE SHOE ADJUSTER
(1) Apply the specified grease to the thread portion
adjuster.
Specified
Identification
groove
14W581
grease
: Brake grease
No. 1
SAE
brake adjuster
brake adjuster
5310,
WITH
-,!
of the
;ri:
1;
I:
NLGI i;i,.
I.,<..
qroove
to be directed
ou<warA
14w504
253.1 -mm976
in.) ,4w503
1 STB Revision
http://vnx.su/
the outside
will facilitate
diameter
adjustment
the
outside
of brake shoe as
of the shoe clear-
t (:
1
L.
i:
1..
1
5-36
BRAKES
Cylinder
AND INSTALLATION
18-21 Nm
13-15 ft.lbs.
Pre-removal
l
Draining
l
l
Operation
of Brake Fluid
Removal
steps
l *
1.
2.
3.
4.
~~
14W600
Brake drum
Bleeder screw
Brake tube
Wheel cylinder assembly
NOTE
(1) Reverse the removal procedures to reinstall.
(2) l * : Refer to Service Points of Remova,l.
(3) l + : Refer to Service Points of Installation
SERVICE
1.
POINTS
OF REMOVAL
REMOVAL
OF BRAKE
Refer to P.5-33.
SERVICE
POINTS
NO6VBAB
DRUM
OF INSTALLATION
NOBVDAE
4. APPLICATION
OF SEALANT
TO WHEEL CYLINDER
ASSEMBLY
Apply the specified sealant to the wheel cylinder assembly
fitting surface before installation
to the backing plate.
Specified
sealant
http://vnx.su/
: 3M Sealant
lent
BRAKES
DISASSEMBLY
AND
5-37
REASSEMBLY
NOBVE-
I
Disassembly
l +
l +
l * l *
1.
2.
3.
4.
5.
Wheel
cylinder
kit
steps
Wheel
Piston
Piston
Piston
Wheel
cylinder
assembly
boot
NOTE
Reverse the disassembly
procedures
to reassemble
(2) ~~ : Refer to Service Points of Disassembly.
(3) l + : Refer to Serwce Points of Reassembly.
(4)
q : Non-reusable parts
(I)
cup
cylinder
body
SERVICE
4.
POINT
REMOVAL
OF PISTON
Remove the
screwdriver.
OF DISASSEMBLY
piston
NOlVFAB
f:
>
CUP
cup from
the
piston
by using
4:
A.
,.
i
it
..
INSPECTION
Check the piston
damage.
CHECKING
CYLINDER
NOBVGAB
and wheel
AND PISTON
cylinder
CLEARANCE
Measure in two perpendicular directions to figure the clearance between the wheel cylinder inner diarneter (max. value)
and the piston outer diameter (min. value).
Limit
NOTE
If the difference is more than the limit, replace the piston and
wheel cylinder as an assembly.
wision
http://vnx.su/
.
-.: :1
.:,
5-38
BRAKES
Rear
Brake
SERVICE
Wheel
Cylinder
POINTS
OF REASSEMBLY
N05VHAD
4. INSTALLATlON
OF PISTON CUP
(1) Wash the inner surface of the wheel cylinder and outer
surface of the piston with trichloroethylene,
alcohol or
brake fluid.
(2) Apply the specified
brake fluid to the entire surface of
the piston cups and to the external periphery of the
special tool.
Specified
brake fluid
: DOT 3
Caution
Use a repair kit to replace
cylinder boot.
the piston
(3) Attach the special tool to the piston, fit the piston cup
onto the special tool with the lips of the piston cup
directed upward, and push down (with finger tips) to
let it slide along the outer surface of the special tool
until it fits into position.
Face iip upward
Caution
When pushing down the piston cup, push uniformly
and slowly with both hands, without
stopping,
so
that deformation
or turning over will not result.
14uoo93
2. APPLICATION
OF BRAKE
Apply the specified brake
wheel cylinder and to the
cups, and install the piston
Specified
brake fluid
1. APPLICATION
: DOT 3
OF GREASE
TO WHEEL
CYLINDER
Grease
(orange)
Specified
grease
/ STB Revision
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: Repair
kit grease
BOOT
(orange)
BRAKES
PARKING
- Parking
5-39
Brake Lever
:j
BRAKE LEVER
REMOVAL
AND
INSTALLATION
NOBWA-
14W613
17
Removal
12. Parking
lever bushing
13. Connection
of parking
brake
nectar
brake lever assembly
l 4 14. Parking
15. Parking
brake switch
++ 16. Cover
17. Sealer
18. Cotter pin
19. Clevis pin
20. Parking
brake cable
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Rear console
panel
Inner box
Floor console
assembly
Floor console
bracket
Cable adjuster
Connection
of parking
brake
Lever pin
Nut holder
Cable equalizer
Parking
brake shaft cover
Parking
lever stay
cables
NOTE
Reverse the removal procedures to reinstall.
(2) ~~ : Refer to Service Points of Installation
(3) q
: Non-reusable
parts
(I)
/ STB Revision
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switch
con-
BRAKES
- Parking
Brake
INSPECTION
l
Check
SERVICE
NOBWCAA
the brake
POINTS
16. APPLICATION
lever
ratchet
OF INSTALLATION
OF SEALANT
Specified
,PARKING
REMOVAL
TO COVER
sealant
pin
BRAKE CABLE
AND INSTALLATION
NOSXA-
14W561
Removal
steps
+w
1. Brake drum
2. Cable adjuster
3. Parking
cable
4. Parking
brake
l *
NOIWDAB
14. APPLICATION
OF GREASE TO PARKING
BRAKE LEVER
ASSEMBLY/lZ.
PARKING
LEVER BUSHING
Apply the specified grease to the clevis pin, bushing and
ratchet plate.
Bushing
Clevis
sealant
for wear.
heat protector
cables
NOTE
(1)
Reverse
the
(2)
+e
: Refer
(3)
l + : Refer
/ STB Revision
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removal
procedures
to Service
Points
to Service
Points
to reinstall.
of Removal.
of Installation.
BRAKES
,Shoe
retainer
Parking
Brake
SERVICE
4.
POINTS
REMOVAL
5-41
Cable
OF REMOVAL
OF PARKING
N05XBAA
BRAKE CABLE
spring
Parking
brake
cable
1Nr
NOTE
Push the offset box-end
stopper is pushed in.
14W60
wrench
until
the parking
SERVICE
POINTS
4.
mm (9.965 -9.976
in.)
14~503
NOlXCAA
Check
253.1 -253.4
i-V 1.
INSPECTION
INSTALLATION
(1) Install the
(2) Install the
(3) Turn the
diameter
brake
cable
for operation
OF INSTALLATION
or damage.
N05XOAA
OF PARKING
BRAKE CABLE
cable end to the brake shoe assembly.
brake shoe assembly.
brake shoe adjuster to adjust the outside
of brake shoe as shown in the illustration.
NOTE
Adjusting the outside diameter
in the illustration
will facilitate
clearance.
/ STB Revision
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1
f
I
23-1
BODY
CONTENTS
BACK DOOR ASSEMBLY
..................................
BACK DOOR HANDLE AND LATCH
.................
BACK DOOR LOCK SWITCH
.............................
BACK DOOR TRIM
.............................................
BACK DOOR WINDOW
GLASS
........................
.............................................
BODY MOUNTING
...........................................................
BUMPERS
............................................
CENTER CONSOLE
DOOR ASSEMBLY
.............................................
DOOR HANDLE AND LATCH
............................
DOOR TRIM AND WATERPROOF
FILM ...........
FENDERS
............................................................
..............................................
FLOOR CONSOLE
FRONT DOOR GLASS AND REGULATOR
.......
FRONT SEATS ....................................................
...........................................
FUEL FILLER DOOR
.................................
GENERAL INFORMATION
.............................................
GRILLE, GARNISH
..................
HEADLINING
AND ASSIST STRAP
HOOD ..................................................................
INSTRUMENT
PANEL ........................................
LOOSE PANEL ....................................................
......................................................
MUD GUARD
.............................................
OUTSIDE
MIRROR
............................
QUARTER WINDOW
GLASS
REAR SEAT .........................................................
SEAT BELTS .......................................................
..........
SERVICE ADJUSTMENT
PROCEDURES
.............
Adjustment
of Back Door Installation
Adjustment
of Door Glass ...............................
......................
Adjustment
of Door Installation
Adjustment
of Fuel Filler Door Hook Fit ..........
Adjustment
of Hood Fit ...................................
47
50
52
49
31
18
57
66
32
44
33
24
67
35
75
22
2
59
68
20
61
55
54
60
29
77
78
15
17
16
15
15
15
..........................
Adjustment
of Inside Handle
Adjustment
of Outside Handle
.......................
..................
Adjustment
of Ventilator Window
................................................
SPECIAL TOOLS
...............................................
SPECIFICATIONS
....................................
General Specifications
Lubricants
.......................................................
Sealants and Adhesives
..................................
Service Specifications
.....................................
.....................................
Torque Specifications
.................................................................
TRIMS
........................................
TROUBLESHOOTING
Back Door ........................................................
Hard back door operation, abnormal noise
from hinges
.............................
Back Door Locking System
Back door fails to unlock or lock
Back door is locked but cannot be unlocked
Back door is unlocked but cannot be locked
Front Door .......................................................
Hard door glass operation
No door glass operation
Power Windows
..............................................
Door windows cannot be operated
Door windows do not operate smoothly
Front door windows cannot be operated
None of the windows can be operated
Wind Noises ....................................................
Wind noise from around the door
Wind noise from back door
..................................................
UNDER GUARD
WINDOW
GLASS RUNCHANNEL
AND DOOR
...............................
OPENING
WEATHERSTRIP
.....................................................
WINDSHIELD
http://vnx.su/
N23AA--
16
16
16
8
6
6
:.
(
.:*
7
8
6
7<
71 vt
g (
9::
$
,
I{?
.:;
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3
q.
%,.&.$
9
14
9
53
45
26
BODY
23-2
GENERAL
- General
Information
INFORMATION
BODY
The body and frame construction is the independent division type.
N23BAAB
The body form is the tumble type, and the frame is the ladder type.
For body mounts, the compression
type, with t&o body mount rubber
frame, is employed.
pieces
fit between
Rear
shock
absorber
bracket,
right
I
Engine
Stabilizer
mounting
bracket
bradket
Lower
arm
Body
bracket
No.
mounting
bracket
Rear
1 crossmember
shock
absorber
bracket,
left
15w519
BODY
Body
rubber
MOUNTING
mounting
STB Revision
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BODY - General
SHEET
23-3
Information
METAL
The instrument
panel is made of sheet metal to which urethane padding is attached.
The adhesive-type
of headlining is used.
The injection-type
of trim is used.
Separate,
low-back
front seats are equipped;
suspension
seats are available as an option.
For the metal-top
van, the rear seat is a front-facing
seat for two passengers.
The front seat belts are 3-point seat belts with E.L.R.
The rear seat belts for the metal-top
van are 2-point retractable
seat belts.
Front
Front
pillar
seat
trim
Instrument
panel
I
trim
wheelhouse
Rear
seat
belt
Rearseat
Rear\
(metal
pillar trim
top-van)
19W665
1 STB Revision
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23-4
BODY - General
SUSPENSION
Information
SEAT
I
seat offers the following
features:
Pantograph
type link mechanism
Optimum
combination
of coil spring and shock absorber
More comfortable
ride by adjust body weight meter to drivers weight
Fixed position of seat can be adjusted in three height levels
The components
of the suspension
seat are as follows:
1'
1. Lock lever
2. Guide 6
3. Coil spring
4. Link
5. Upper
6.
7.
8.
9.
10.
19W696
bracket
Shock absorber
Link
Handle
Lower
bracket
Guide A
jpper bracket
Pantograph
OPERATION
type link
Front
_ower
bracket
Royler
Whenthere
is no
load
Suspension
Mechanism
The suspension
mechanism
is constructed
as shown.
The lower and upper brackets of the link are coupled by hinges
at one end and by rollers at the other, allowing forward and
backward sliding. If a force in the direction
of the arrow is
exerted to the link (pantograph),
the upper bracket is moved
downward, so the shock absorbers hinge-coupled
to the lower
and upper brackets absorb vibration.
19W606
pm
wision
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BODY - General
23-5
Information
NOTE
The illustration above shows the top view
of the body weight adjusting mechanism.
Thecshows
the working
of each part
when the spring force is increased.
Suspension
Lock Mechanism
The suspension
lock mechanism
is constructed
as shown
the illustration
at left. The seat lock position can be selected
three levels by a lock lever.
Upper bracket
Lock lever
, 1,
When lock
is OFF
bracket
b,.
.:.
lock poiition
,
Lower
in ..?
in >,
Wh\en lock is ON
l9W667
1 STB Revision
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23-6
BODY
- Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N23CA--
Specifications
Items
Hood
Type
Front door
Construction
Regulator system
Locking system
X-arm type
Pin-fork type
3ack door
Construction
Locking system
Pin-fork type
Slass installation
method
Windshield
Weatherstrip
type
Quarter window
Front door window
Weatherstrip
type
Weatherstrip
type
Weatherstrip
type
;lass thickness
mm (in.)
5.7 (.22)
Windshield
Quarter window
4.0(.16)
glass
4.0(.16)
glass
4.0 (.16)
Ventilator
glass
4.0(.16)
window
Irame Type
Ladder type
Sectional form
j&pension
seat
Box type
Suspension
Up-and-down
Body weight
mechanism
movement
adjustment
70 (2.76)
mm (in.)
stroke
kg (Ibs.)
50-I 00 (110.2-220.5)
3 levels
SERVICE SPECIFICATIONS
Specifications
Items
Standard values
mm (in.)
Front door glass holder mounting position
Distance between the glass holder (A) and (B)
Distance
between
466.5-467.5
76.5-77.5
(18.367-l
(3.012-3.051)
5-l 0 (.20-.40)
4-l 0 (. 16-.40)
mm (in.)
mm (in.)
1 ST6 Revision
http://vnx.su/
8.406)
BODY
23-7
- Specifications
TORQUE SPECIFICATIONS
23CG-
ft.lbs.
Nm
Item
Body to frame
Hood hook to hood
28-32
20-23
4.0-6.0
2.94.3
4.0-6.0
2.9-4.3
3.5-4.0
2.5-2.9
18-25
IO-13
IO-13
18-25
13-18
7-9
IO-13
7-9
IO-13
7-9
17-26
35-55
12-19
to frame
installation
bolts
window
assembly
to door panel
Front seatback
to seat cushion
adjuster side)
to body
to seat cushion
bolts
13-18
25-40
6
6
4.3
4.3
25-40
4.3
35-55
7-9
8-10
6-7
4-6
3-4
9-14
6.5-I 0
35-55
9-14
25-40
6.5-10
45-60
33343
IO-15
9-14
7-11
6.5-10
45-60
35-55
33-43
25-40
LUBRICANTS
23CD.
Specified
Items
Back door hinges
Sliding parts of front seat adjuster
Sliding parts of rear seat leg bracket,
stopper striker
rear seat
lubricants
Quantity
Multipurpose
As required
Multipurpose
As required
Multipurpose
As required
( STB Revision
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23-8
BODY - Specifications
SEALANTS
/ Special Tools
AND ADHESIVES
23CE.-
Items
Specified
Quantity
As required
weatherstrip
and windshield
glass
Windshield
weatherstrip
As required
As required
As required
As required
and quarter
As required
Quarter window
As required
As required
As required
3M Adhesive
As required
weatherstrip
and back
film
Door window
runchannel
Door window
assembly
runchannel
and ventilator
sash
sash
EC-870 or equivalent
As required
As required
and ventilator
As required
and ventilator
As required
As required
As required
As required
\
I
ieadlining
and back
SPECIAL TOOLS
Tool (Number
IB990900-01
oor adjusting
and name)
23DA--
Use
Tool (Number
Adjustment
and name)
of door fit
wrench
Windshield
STB Revision
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moulding
remover
Use
23-9
BODY-Troubleshooting
TROUBLESHOOTING
FRONT DOOR
N23EAAC
Remedy
Reference
page
Adjust
Attach
Broken sash
Replace
Collapsed
sash
Repair or replace
Collapsed
window
Repair or replace
Replace
Adjust
23-16
Symptom
Probable cause
Dismount
window
Detached
sash
Broken window
Door glass operates
up and down hardly
Improper
window
Collapsed
sash
i Collapsed
glass regulator
glass position
Repair or replace
window
Broken window
regulator arm
regulator
handle
Repair or replace
Replace
BACK DOOR
; y.
Symptom
Probable cause
Remedy
Insufficient
Apply chassis
grease on hinges
grease
23-48
. ..;,,,
;
WIND NOISES
Remedy
Reference
page
holding force
23-l 5
installed, or de-
Repair or replace
23-45
Adjust
Improper
Adjust
23-l 5
Adjust
Repair or replace
holding force
23-l 7
installed, or de-
Repair or replace
23-47
Uneven
Adjust
23-l 7
Repair or replace
Symptom
Probable cause
Insufficient
weatherstrip
Weatherstrip
teriorated
improperly
door position
Uneven clearance
runchannel
Deformation
Wind noise from back
door
li .
4
Insufficient
Weatherstrip
teriorated
between
of the door
weatherstrip
improperly
( STB Revision
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.*
23-10
BODY
- Troubleshooting
HOW TO LOCATE WIND
NOISES
18W809
(3) Then remove the strips of tape one by one, making a road
test after each is removed,
until a wind noise source is
discovered.
nemove
18W809
are found,
(7) Check to confirm that wind noise occurs when the last
remaining
tape is removed, and that noise does not occur
when it is re-attached.
(8) When the source(s) of the wind noise is finally located,
attach butyl tape, body sealer or similar
material
to
obstruct this source as much as possible.
wision
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23-11
BODY - Troubleshooting
BACK DOOR LOCKING
T\
SYSTEM
Inspection
items
Symptom
j;
CIRCUIT
but can-
inspection
sequence.
DIAGRAM
1.25F-G
cz
J
N
-1.25-G
1.25F-R
2-I-R
-To
heater relay
[Refer to P 8.551
2-B
-To
column
switch
[Refer to PM11
1.25-R
B-12
CC
I
Rkc
--
0
R
EE%3
M
Back door
lock aCtato,
Whng
color code
B Black
Br Brown
LI Light blue
0 Orange
Hemark
For InformatIon
refer lo P 8-7
G Green
P Pink
Gr Gray
R Red
concerning
L Blue
Y Yellow
1 STB Revision
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Lg
W
the ground
Light green
Whlre
pants
37W302
(example
23-12
BODY - Troubleshooting
POWER WINDOW
CIRCUIT
DIAGRAM
Ignition
WA
Battery
A-02
-
Sub fusible
switch
link
5-W
U
1.25-B
Main
lrnk
fusible
3
m
c:
Multipurpose
fuse
z
d
[Refor to P.8-491
Power window
main switch
Remarks
(1) For information
concernina
the around pornts (example:O), refer to P.8-7.
(2) The symbols 0, 0, etc. indicate
that the wiring
is
connected
(usina the same numerical
symbol) to the
facing page.
(In other words, 0 on the right page is connected to 0 on
the left page.)
ST6 Revision
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(RL)
2-I-R :g
BODY
2-B
R
B0
Power
motor
23-13
- Troubleshooting
To colunm switch
[Refer to P.8-511
window
(L.H.)
2-B
MU,
B-31 1
c!
Ll
C-Y
0.:2-LR
(RL)
To headlight
washer relay
[Refer to P.8-581
Power
7-
motor
'
c+l~
(R.H.)
window
relay
tr,
1 '
2-RL,ZF-G
Z-LB
ZF-L
Z-GL
ZF-R
I
I
(y
c-30
\
0
Power window
sub switch (R.H.)
37W603
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
/ ST6 Revision
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L: Blue
Y: Yellow
23-14
POWER
BODY - Troubleshooting
WINDOWS
23EAAD
Inspection items
a
.-8
.L
Symptom
done of the door windows can be
operated.
Co
STB Revision
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BODY
Service
Adjustment
23-15
Procedures
SERVICE ADJUSTMENT
ADJUSTMENT
OF HOOD
PROCEDURES
FIT
N23FAAC
l.
18W50!
3.
the rotating
P
II,
.. ,
ADJUSTMENT
FIT
OF FUEL
FILLER
DOOR
HOOK.
N23FDAB
ADJUSTMENT
1.
OF DOOR INSTALLATION
rSTB
N23FEAC
Revision
http://vnx.su/
tape
hinge
to the fender
is installed.
edges
near
the
23-16
BODY - Service
Adjustment
Procedures
2.
ADJUSTMENT
OF DOOR GLASS
NZOFFAB
I,
ADJUSTMENT
OF VENTILATOR
WINDOW
N23FJAA
Lock
[mm
NOTE
Fix the adjusting
adjustment.
washer
(in.)
18W561 I
ADJUSTMENT
I.
2.
nut by bending
OF INSIDE
HANDLE
after the
N23FGAB
value
: 4-10
mm
(.16-.40
in.)
@J+
1880033
ADJUSTMENT
FRONT
OF OUTSIDE
HANDLE
NZBFHAB
DOOR
v
16Y 066
1857481
Caution
The rod
snap
Standard
value
STB Revision
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must
: 5-10
be replaced.
mm
(.20-.40
in.)
BODY
Service
Adjustment
BACK
23-17
Procedures
DOOR
2.
film.
(Refer to
Disconnect
the outside handle from
rod, and turn it right to left to adjust
play.
the outside
the outside
Standard
(.20-.40
in.)
DOOR
INSTALLA;l02
value
ADJUSTMENT
: 5-10
OF
mm
BACK
handle
handle
(3) At the
door,
(4) Adjust
latch
shims,
( STB Revision
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j:.
i
4
i
1
:.
I
23-18
BODY - Body
Mounting
BODY MOUNTING
REMOVAL
AND
INSTALLATION
N23GW
1.
2.
3.
4.
5.
6.
7.
8.
9.
Special bolt
Plain washer
Body mounting rubber
Spacer
Body mounting rubber
Washer
Self locking nut
Body shim
Mounting bolt
NOTE
m :Non-reusable parts
28-32Nm
20-23ftJbs.
28-32Nm
20-23ft.lbs.
28-32Nm
20-23ft.lbs.
1 STB Revision
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28-32Nm
20-23ftlbs.
(A)
(6)
23-19
REMOVAL
(1) Remove or disconnect
the following - parts:
0
Air filter
0
Accelerator cable
0
Vapor hose
0
Heater hoses
0
Brake booster vacuum hose
0
Starter motor wiring harness
0
Alternator wiring harness
0
Engine ground (on body side)
0
Steering shaft joint
0
Fuel cut solenoid valve connector
0
E.S.S. solenoid valve connector
0
High-tension
cable
0
Water temperature
gage connector
0
Power steering pump
0
Oil pressure switch harness
0
Transmission
oil cooler
0
Radiator assembly
0
Oxygen sensor connector
0
Hydraulic clutch hoses
0
Brake pipes
l
Speedometer
cable (transmission
side)
0
Carburetor
control wiring harness
0
Air temperature
sensor connector
0
Water temperature
sensor connector
0
Backup light switch connector
0
4WD indicator light switch connector
0
Pulse generator connector
0
Fuel pipe
0
Filler hose protector
0
2-way va Ive
0
Rear combination
light connector
0
Filler neck
0
Transmission
gearshift lever
0
Transfer gearshift lever
0
Parking brake cable
0
Front and rear seats
0
Door opening trim
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23-20
BODY - Hood
HOOD
REMOVAL
AND INSTALLATION
4.0-6.0
2.943
Kim
ftlbs.
3.5-4!0
2.5-2.9
Nm
ftlbs.
18W731
1. Hood
2. Hood
3. Hood
hook
hinge
latch
latch
release
release
handle
cable
NOTE
(1) Reverse the removal procedures to reinstall.
(2) *+
: Refer to Service Points of Installation
SERVICE
POINTS
7. APPLICATION
STRIP
OF INSTALLATION
OF SEALANT
TO HOOD
REAR WEATHER-
sealant
http://vnx.su/
: 3M ART Part
23-21
BODY - Hood
4.
ADJUSTMENT
OF HOOD
LATCH
/2. HOOD
HOOK
(1) Loosen the hood latch and hood catch stay attaching
bolts.
(2) Adjust the position of the hood latch and hood hook to
align the lock with the hook.
NOTE
Apply chassis grease to the sliding portion,
portion of the hood hook and hood lath.
I~_
--
the rotating
1. ADJUSTMENT
OF HOOD
(1) Adjust the longitudinal
and lateral positions of the hood
by utilizing the oblong holes in the hinge.
(2) Adjust the vertical position of the hood by adjusting the
hood bumper either up or down.
--
STB Revision
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j .
1..
,
23-22
AND
INSTALLATION
N23JAAD
Fuel filler
cable con-
NOTE
(1) Reverse the removal procedures to reinstall.
(2) I)+ : Refer to Service Points of Installation.
[ STB Revision
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23-23
Door
10. INSTALLATION
OF FUEL FILLER DOOR LOCK RELEASE
CABLE
Install so that the installation
position mating mark (yellow
paint) on the release cable is aligned with the position
shown in the figure.
.i
.
-I
IT
1. ADJUSTMENT
OF FUEL FILLER
DOOR PANEL
( STB Revision
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v, . ) _
23-24
BODY - Fenders
FENDERS
REMOVAL
Removal
l +
AND
INSTALLATION
N23KAAE
steps
1.
2.
3.
4.
5.
6.
7.
8.
Radiator
grille
Front combination
Headlight
bezel
Grille filler panel
Front mud guard
Partial wheel
lip
Splash
shield
Front fender
light
NOTE
(1)
(2)
*4
STB Revision
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181111824
23-25
BODY - Fenders
Cross-section
(Iross-section B-B
A-A
Specified
sealant
ONSTALLATION
OF FRONT FENDER
tape
Specified sealant
fully to the
top
part of
equivalent
i
-J-J
Adhesive
lent
EC-5310,
or equiva-
STB Revision
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23-26
BODY - Windshield
WINDSHIELD
3EMOVAL
AND INSTALLATION
Removal
steps
+*
4*
1.
2.
3.
4.
5.
6.
7.
8.
4*
4*
4*
4*
4*
4*
h*
+e
++
I)+
N23LBAD
9. Windshield
IO. Windshield
18W723
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) a*
: Refer to Service Points of Removal.
(3) +*
: Refer to Service Points of Installation
(4) m: Non-reusable
parts
weatherstrip
SERVICE
POINTS
1. REMOVAL
MOULDING
OF REMOVAL
OF UPPER
MOULDING
JOINT/2.
JOINT/3.
TO 8. MOULDINGS
after sliding
the
moulding
WINDSHIELD
WEATH-
http://vnx.su/
the mould-
joint.
OF WINDSHIELD/lO.
Push the windshield
remove
LOWER
along
the entire
BODY -
23-27
Windshield
INSPECTION
l
Check
SERWCE
the body
POINTS
flange
for deformation.
OF INSTALLATION
10. INSTALLATION
OF WINDSHIELD
WEATHERSTRIP/S.
WINDSHIELD
(1) Fill the weatherstrip
with the specified adhesive and fit
it to the windshield.
Specified
adhesive
18W776
jt.: :
strings
in the weatherstrip
groove.
(
NOTE
Make certain that the strings
ends.
mm (in.)
105711
.1
f
hi?!&
Soap solution
18W774
STB Revision
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hold
the
glass
against
the
the
the
body
df :4
1
,v
!I:
:
,
<
!
23-28
BODY
- Windshield
(6) Apply specified
adhesive
between
and the body flange at the locations
illustration.
Specified
,/
I
. .
.L
adhesive
18W55E
1 ST6 Revision
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adhesive
the weatherstrip
indicated
in the
of the specified
adhesive all
between
it and the body
or No.
BODY - Quarter
QUARTER
REMOVAL
WINDOW
AND
Window
23-29
Glass
GLASS
INSTALLATION
N23LEBFJ
181773
Removal
+e
4*
4*
I)+
steps
Slide glass
(parts
lock removal
11. Connector
12. Packing
13. Slide glass
steps
lock
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) 4*
: Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation.
(4) m : Non-reusable
parts
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
AND WEATHERSTRIP
ASSEMBLY
With the glass in position, push the quarter
window
assembly outward while raising the lip of the weatherstrip
http://vnx.su/
OF GLASS
23-30
BODY - Quarter
9.
Window
Glass
REMOVAL
OF QUARTER
WINDOW
FRONT GLASS/IO.
QUARTER
WINDOW
REAR GLASS
Move the quarter window glass to the middle position and
remove it by opening the weatherstrip
up and down.
SERVICE
POINTS
OF INSTALLATION
1. APPLICATION
OF ADHESIVE
TO GLASS AND WEATHERSTRIP
ASSEMBLY
(1) Apply the specified adhesive to the weatherstrip
at the
location indicated
in the illustration.
Specified
adhesive
or No.
16W717
Quarter
(2) After the quarter window rear glass has been installed,
install the stopper by applying the specified adhesive.
window
Specified
adhesive
: 3M Adhesive
lent
EC-870 or equiva-
1 ED586
Specified
16W662
mm
(in.)
18W716
(TB
Revision
-1
http://vnx.su/
adhesive
the weatherstrip
indicated
in the
or No.
BODY - Back
AND
Door Window
23-3 1
Glass
GLASS
INSTALLATION
N23LDAD
7-10 Nm
5-7 ft.lbs.
18W610
Removal
1
2
3
*+
steps
4
5
Spare
Wiper
with
Rear
rear
Back
Back
tire
arm and blade assembly
a rear wiper)
defogger
terminal
(Vehicles
defogger)
door window
weatherstrip
door window
glass
1
.
f< .;,.;:;$
(Vehicles
with
NOTE
(1)
Reverse the removal procedures
to reinstall.
(2) l 4 : Refer to Service Points of Installation.
I;,,
..
*\
i. ,;
t I
..
OF ADHESIVE
the specified
Specified
adhesive
adhesive
or No.
18W752
levision
http://vnx.su/
the
23-32
DOOR ASSEMBLY
REMOVAL
AND
INSTALLATION
N23MAAF
Nm
ft.lbs.
35-55
25-40
17-26 Nm
12-19 ft.lbs.
Removal
steps
Nm
ft.lbs.
3&55
25-40
18W792
NOTE
(I) Reverse the removal procedures
(2)
cap
I)4
: Refer
to
Service
Points
to reinstall.
of
Installation.
INSPECTION
l
Check
noise.
the
door
hinges
for
cracks,
damage
or abnormal
DOOR SWITCH
Operate
minals.
the switch,
and check
the continuity
between
the ter-
Y16885
Release
Push
NOTE
O-O indicates that there is continuity
SERVICE
OF GREASE
HINGE
-m
\ ST6 hevmon
the terminals.
POINTS OF INSTALLATION
8. APPLICATION
DOOR UPPER
10w722
between
-I
http://vnx.su/
grease
TO DOOR
LOWER
HINGE/G.
to the sliding
part
of the door
BODY
- Door
Trim
AND
Removal
steps
4*
1.
2.
3.
4.
5.
6.
7.
*+
INSTALLATION
trim
film
23-33
Film
FILM
(Vehicles
Clip
Regulator
handle
Escutcheon
Armrest
Inside handle
cover
Door trim
Trim clip
8. Door upper
9. Waterproof
and Waterproof
without
/-
a Power
Window)
N23MBAE
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) l * : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation
(4) CI : Clipping position
1auo392
remove
the
18UO43C
7.
REMOVAL
OF TRIM CLIP
If trim clips remain at the door side when the door trim is
removed, improvise a tool (such as shown in the figure) to
remove them.
wision
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23-34
BODY - Door
Trim
and
Waterproof
Film
Specified
REMOVAL
I
Removal
l *
l +
AND INSTALLATION
(Vehicles
OF ADHESIVE
TO WATERPROOF
FILM
a coating
of specified
adhesive
to the position
in the illustration,
and then attach the waterproof
adhesive
: 3M ART
Adhesive
. !;
steps
1.
2.
3.
4.
5.
6.
7.
Armrest
Inside handle cover
Power window
switch
Door trim
Trim clip
Door upper trim
Waterproof
film
cover
I\IIC
a*
+*
: Refer
: Refer
to Service
to Service
Points
Points
of Removal.
of Installation
SERVICE
5.
REMOVAL
POINTS OF REMOVAL
OF TRIM
1 STB Revision
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CLIP
at the door side when
a tool (such as shown
BODY -
Door
Trim
and
Waterproof
Film
SERVICE
7.
/ Front
Door
POINTS
Grass
and
OF INSTALLATION
APPLICATION
Apply
OF ADHESIVE
a coating
of specified
shown
in the
23-35
Regulator
illustration,
TO WATERPROOF
FILM
adhesive
to the position
then attach
the waterproof
and
film,
Specified
adhesive
: 3M ART
Adhesive
AND
INSTALLATION
N23MCAE
2L6
Removal
steps
+e
l *
2. Outer weatherstrip
3. Inner weatherstrip
4. Center sash protector
l + Adjustment
of ventilator
window
5. Ventilator
window
assembly
6. Glass holder
7. Door glass pad
w+ 8. Door window
glass
l + 9. Window
regulator
**
+e
+I)
Nm
4 .3 ft.lbs.
film
glass
18W781
*g
assembly
NOTE
(1) Reverse the
(2) l * : Refer
(3) +*
: Refer
(4) * : Vehicles
) STB Revision
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removal procedures
to reinstall.
to Service Points of Removal.
to Service Points of Installation.
with a power window
23-36
BODY - Front
SERVICE
POINTS
OF REMOVAL
1. REMOVAL
OF DOOR
Refer to P.23-33.
TRIM
AND
WATERPROOF
FILM
..
1
2. REMOVAL
OF OUTER
WEATHERSTRIP
5.
REMOVAL
(1) Remove
window
(2) Pull
8.
OF VENTILATOR
WINDOW
ASSEMBLY
the screws and bolts mounting
the ventilator
assembly.
window
assembly
upward.
REMOVAL
OF DOOR WINDOW
GLASS
(1) Lower the door glass to the access hole position.
(2) Peel the waterproof film off with care not to damage it.
(3) Remove
the glass mounting
bolts from the glass
holder.
NOTE
When removing
glass to avoid
18WSl7~
1 STB Revision
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bolts,
support
the
23-37
(4) Gently pull out the door glass upward while tilting it so
that the rear end of the glass comes up to the top.
9. REMOVAL OF WINDOW
REGULATOR
Vehicles without
a Power Window
(1) Remove the window regulator
mounting
NOTE
Hold the regulator assembly
when bolts are removed.
(2) Take
hole.
bolts.
, ito
regulator
through
the
access
_
;::
:;v
a!
,,.I.:
t+J \( I.3
! ;:.:-
i-,
(2) Disconnect
tor.
the power
window
motor
Caution
Because the force of the regulator
spring may cause the
regulator
arm to jump up when the screws attaching
the
motor to the window
regulator
are removed,
remove
the regulator
spring before removing
the screws.
18K324
1 STB Revision
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23-38
MAIN SWITCH
Operate the switch,
terminals.
and check
the continuity
between
the
lBW023
I\
Terminal
L.H. side
NOTE
O--O indicates
that there
is continuity
between
the terminals.
STB Revision
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R.H. side
LOCK
23-39
and check
the continuity
between
the
UP
16W972
NOTE
O-O indicates that there is continuity
POWER WINDOW
(1) After removing
window relay.
between
RELAY
the
cowl
side
between
trim,
ED
2
the
power
2
,
3
I
4
I
NOTE
(1) M
indicates that there is continuity between the terminals.
(2) O----O indicates the connection with the power supply.
10W906
T
3
1
1
remove
the terminal.
Terminal
the terminals.
6 1
lBW909
wision
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6 ..
*F ..,i
2:. I. ..1
!:
.:.:
(I I..
.*t ,,!,$
4. Y,
_
I+4
.G.i;p-.$.&,,~y
:-
~~
--;,,;-<,-~
II
23-40
BODY - Front
Door
Glass
and
SERVICE
9.
POINTS
lNSTALLATlON
Regulator
OF INSTALLATION
OF WINDOW
REGULATOR
Vehicles without
a Power Window
Apply a coating chassis grease to the sliding
rotating parts of the window regulator.
parts and
INSTALLATION
OF DOOR WINDOW
GLASS
When the door glass has been removed
from the glass
holder, install to the position
shown in illustration.
Standard
value
Distance
Distance
:
X 466.5-467.5
mm (18.366-18.406
Y 76.5-77.5
mm (3.012-3.051
in.)
ADJUSTMENT
OF VENTILATOR
Refer to P.23-16.
ADJUSTMENT
OF DOOR
Refer to P.23-16.
1. INSTALLATION
OF DOOR
FILM
Refer to P.23-33. 34.
http://vnx.su/
WINDOW
TRIM
WINDOW
GLASS
AND
WATERPROOF
in.)
BODY
Door
Front
Glass
and
23-41
Regulator
DISASSEMBLY
AND REASSEMBLY
(Ventilator
Window Assembly)
Disassembly
l +
steps
1. Door window
2. Screw
3. Screw
glass runchannel
h?
4. Washer
l +
l +
~~
I)+
l +
l a
Q
6
0
14
5. Packing
6. Hinge
7. Pin
8. Ventilator window lock handle
9. Push button
10. Push button spring
11. Wave washer
12. Screw
13. Ventilator open handle
Adjustment of ventilator window
14. Ventilator sash spring kit
15. Ventilator sash
16. Ventilator window glass pad
17. Door ventilator window glass
18. Ventilator window weatherstrip
19. Ventilator sash assembly
8
z
0
jaw797
NOTE
(1) Reverse the disassembly
(2) l + : Refer to Service
1 STB Revision
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procedures
to reassemble.
Points of Reassembly.
23-42
BODY
- Front
SERVICE
POINTS
19.APPLlCATlON
ASSEMBLY/18.
OF REASSEMBLY
OF ADHESIVE
VENTILATOR
TO VENTILATOR
SASH
WINDOW
WEATHERSTRIP
adhesive
adhesive
: 3M Super Weatherstrip
Adhesive
8001 or 8011 or equivalent
adhesive
to the place
: 3M ART
Adhesive
marked
B in
17. APPLICATION
OF ADHESIVE
TO DOOR VENTILATOR
WINDOW
GLASS/lG.
VENTILATOR
WINDOW
GLASS
PAD/15.
VENTILATOR
SASH
(1 ) The SECT. A-A and VIEW B parts in the illustration are to be
coated with the specified
adhesive.
Specified
adhesive
: 3M Super Weatherstrip
Adhesive
8001 or 8011 or equivalent
(21) The SECT. C-C and SECT. D-D parts in the illustration
be coated
Specified
SECT. A-A
Apply the
adhesive so that
with
adhesive
VIEW 0
the specified
: 3M ART
Adhesive
without ripples,
-high
parts, etc.
18W799
SECT. C-C
SECT. D-D
Specified
adhesive
18W804
16W805
4
_i
wision
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are to
adhesive.
Part No. 8080 or 3M
EC-1368,
or equivalent
BODY - Front
Door
Glass
and
ADJUSTMENT
sash assembl
23-43
Regulator
OF VENTILATOR
WINDOW
Refer to P.23-16.
Door
window
glass
runchannel
1. APPLICATION
OF ADHESIVE
GLASS RUNCHANNEL
mm (in.)
18W800
DOOR
WINDOW
adhesive
: 3M ART
Adhesive
Door window
glass runchannel
Ventilator
window
1. y eatherstrp
TO
SpeGfied
adhesive
SECT. A-A
[ STB Revision
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23-44
and latch
AND INSTALLATION
N23MDAD
18W741
Removal
ae
l +
l *
l +
steps
1. Door trim and waterproof
film
Adjustment
of outside
handle
Adjustment
of inside handle
2. Inside lock knob
3. Outside
handle
4. Door latch
5. Inside handle
NOTE
(I 1 Reverse the
(2)
O*
: Refer
(3)
l + : Refer
SERVICE
1.
removal procedures
to Service
to Service
POINTS
TRIM
ADJUSTMENT
OF INSIDE
Refer to P.23-16.
ADJUSTMENT
OF OUTSIDE
Refer to P.23-16.
1. INSTALLATION
OF DOOR
FILM
Refer
to P.23-33,
III1
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AND
WATERPROOF
FILM
OF INSTALLATION
1 STB Revision
to reinstall.
of Removal.
of Installation.
POINTS OF REMOVAL
REMOVAL
OF DOOR
Refer to P.23-33.
SERVICE
Points
Points
34.
HANDLE
HANDLE
TRIM
AND
WATERPROOF
BODY -
WINDOW
STRIP
REMOVAL
Window
GLASS
AND
Glass
and
Runchannel
RUNCHANNEL
Door
Opening
23-45
Weatherstrip
WEATHER-
INSTALLATION
N23MEAD
6Nm
4.3 ft.lbs.
Removal steps
+e l +
41) l +
41) l +
+e l +
4*
1.
2.
3.
4.
5.
10w705
NOTE
(1) Reverse the removal procedures to reinstall.
(2) 4*
: Refer to Service Points of Removal.
(3) l 4 : Refer to Service Points of Installation.
REMOVAL
AND WATERPROOF
OF VENTILATOR
WINDOW
FILM
ASSEMBLY
Refer to P.23-36.
4.
REMOVAL
Refer
5.
OF DOOR WINDOW
tto P.23-36.
REMOVAL
Remove
GLASS
OF WINDOW
the window
http://vnx.su/
GLASS
glass
RUNCHANNEL
runchannel
by pressing
both
23-46
BODY - w. In d ow
Glass Runchannel
7.
and Door
Opening
Weatherstrip
WEATHERSTRIP
weatherstrip
with
the tool
5. APPLICATION
OF ADHESIVE
TO WINDOW
GLASS RUNCHANNEL
Apply the specified
adhesive to the positions
shown in
illustration
and install the window glass runchannel.
Specified
; ..,.2
ii
;
I
\
?
,
. .
;,L
I
I
adhesive
: 3M Adhesive
4.
INSTALLATION
OF DOOR WINDOW
Refer to P.23-40.
2.
INSTALLATION
OF VENTILATOR
Refer to P.23-35.
1. INSTALLATION
OF DOOR
FILM
Refer to P.23-33, 34.
STB Revision
IIIII
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TRIM
EC-870
or equivalent
GLASS
WINDOW
AND
ASSEMBLY
WATERPROOF
23-47
AND
INSTALLATION
N230AAE
35-55 Nm
25-40 ft.lbs.
Back
door
removal
steps
1. Spare tire
2. Spare tire carrier
3. Rear opening
trim
4.
Quarter
trim
l *
5. Rear pillar lower trim
l *
l + Adjustment
of back door installation
6. Cotter pin
7. Clevis pin
8. Connection
of rear washer
tube
cles with a rear wiper)
9. Connection
of back door wiring
harness
connectors
l + 10. Door upper hinge
~~ 11. Door lower
hinge
12. Back door
l *
Striker
(Vehi-
removal steps
13. Striker
14. Striker
shim
l + 15. Door
opening
:
NOTE
(1) Reverse the removal procedures to rein&II.
(2) +I) : Refer to Service Points of Removal.
(3) l 4 : Refer to Service Points of Installation.
(4) a : Non-reusable parts
weatherstrip
SERVICE POINTS
4.
REMOVAL
OF REMOVAL
OF QUARTER TRIM
Refer to P.23-73.
5.
REMOVAL
Refer
to P.23-74.
1 STB Revision
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23-48
OF DOOR OPENING
Remove
the door opening
shown in the illustration.
WEATHERSTRIP
weatherstrip
with
the tool
(in.)
WWK?
adhesive
11. APPLICATION
QF GREASE TO DOOR LOWER HINGE /
10. DOOR UPPER HINGE
Supply specified grease from the grease holes of the door
hinges.
Specified
grease
: Multipurpose
No. 3
grease
NOTE
The nozzle of the grease gun should
tip.
SAE J310,
have a small-diameter
ADJUSTMENT
OF BACK DOOR INSTALLATION
Refer to P.23-17.
2.
INSTALLATION
Refer to GROUP
Carrier.
STB Revision
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OF SPARE
NLGI
TIRE CARRIER
22 WHEELS
AND
TIRES
- Spare
Tire
AND
Removal
steps
4*
1.
2.
3.
4.
5.
6.
l *
N230BAB
INSTALLATION
,
:
NOTE
(1) Reverse the removal procedures to reinstall.
(2) ~~
4* : Refer to Service Points of Removal.
(3) ~)a
*a : Refer to Service Points of Installation
(4) l
: Clipping position
i.,
10w794
REMOVAL
OF TRIM
CLIP
If trim clips remain at the door side when the back door
in the
trim is removed,
improvise
a tool (such as shown
figure) to remove them.
APPLICATION
OF ADHESIVE
TO WATERPROOF
Apply specified
adhesive
at the positions
shown
illustration,
and then attach the waterproof
film.
Specified
adhesive
1 STB Revision
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FILM
in the
: 3M ART Part
No. 8626 or
Adhesive
EC-5310, or equivalent
3M
23-50
BODY - Back
Door
Handle
and
Latch
AND
INSTALLATION
N230CAA
18W795
Removal
+e
l +
~~
**
*I)
a*
a*
4*
steps
1. Back
Adjustment
2. Back
3. Back
4. Outside
5. Inside
6. Back
7. Back
door
film
NOTE
(1) Reverse the removal procedures to reinstall.
(2) q*
: Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation
L
//
II I I
SERVICE POINTS
OF REMOVAL
REMOVAL
OF BACK
FILM
Refer to P.23-49.
DOOR
TRIM
AND
REMOVAL
OF BACK
DOOR
GARNISH
BACK DOOR GARNISH
Remove the back door garnish installation
and then remove the back door garnish.
http://vnx.su/
WATERPROOF
BRACKET/3.
nuts and bolts,
BODY - Back
4.
6.
Door
Handle
and
23-51
Latch
REMOVAL OF OUTSIDE
HANDLE
Disconnect
the outside
handle rod from
handle, and then remove the outside handle.
REMOVAL
OF BACK
LOCK ACTUATOR
DOOR
LATCHI7.
the
outside
BACK
DOOR
(1) Disconnect the outside lock rod and the inside lock rod
from the lock cylinder.
(2) Disconnect the actuator rod from the outside lock rod.
(3) Remove
(4) Remove
with
the rods.
18W757
INSPECTION
16WO46
Refer
OF OUTSIDE
HANDLE
to P.23-16.
1. INSTALLATION
PROOF FILM
Refer to P.23-49.
1 STB Revision
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OF BACK
DOOR
TRIM
AND
WATER-
:.
.
1
3,.
43
23-52
AND
INSTALLATION
II
,
\
SERVICE
IPOINTS
18iV802
OF REMOVAL
INSPECTION
BACK DOOR LOCK SWITCH
Operate the switch, and check
the continuity
between
the
terminals
16W974
J
OFF
LOCK
NOTE
0-C indicates that there is continuity between the terminals.
STB Revision
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BODY
Under
23-53
Guard
UNDER GUARD
REMOVAL
AND
Vehicles
with
transmission
INSTALLATION
N23WW
a manual
18-25
13-18
Nm
ft.lbs.
y13Nm
7-9 ft.lbs.
lo-13 Nm
7-9 ft.lbs.
Vehicles
with
transmission
l&l3
Nm
7-9 ftlbs.
18-25 Nm
13-18 ftlbs.
16W787
an automatic
IO-13 Nm
7-9 ft.lbs.
I.
2.
3.
4.
5.
Snow-protection
under
Under cover
Under skid plate
Transfer
case protector
Cross shaft protector
cover
l&l3
Nm
7-9 ft.lbs.
1 STB Revision
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~~
,r
23-54
MUD GUARD
REMOVAL
AND
INSTALLATION
NZBWBAA
( STB Revision
-1
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23-55
LOOSE PANEL
REMOVAL
AND INSTALLATION
2.943
Waterproof
+e
l +
e+
NPJSAAC
ft.lbs.
removal
steps
l + 12. Hood
latch
13. Hood catch bracket
14. Bridge
panel cover
1. Front fender
2. Waterproof
pad
3. Air duct
4. Floor
5. Front
console
floor cover
l + 16. Splash
grille
grille
6.
8.
9.
10.
11.
Radiator
grille
Front combination
light
Head light bezel
Grille filler panel assembly
Hood catch stay
lip
bracket
wheel
shield
Shield rubbers
assembly
assembly
Rear ventilator
with
an automa-
(Vehicles
without
cover
cover
NOTE
(1) Reverse the removal procedures to reinstall.
(2) +*
: Refer to Service Points of Removal.
(3) l + : Refer to Service Points of Installation.
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23-56
OF REMOVAL
1. RFMOVAL
OF FRONT
Rbfer to P.23-24.
FENDER
4.
CONSOLE
REMOVAL OF FLOOR
Refer to P.23-67.
2. APPLICATION
OF SEALANT
Apply the specified
sealant
figure.
Specified
sealant
1. INSTALLATION
Refer
to P.23-25.
STB Revision
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SHIELD
LATCH
TO WATERPROOF
PAD
to the places marked in the
OF FRONT
FENDER
23-57
BODY - Bumpers
BUMPERS
REMOVAL
AND
INSTALLATION
(Front
N23ZBAB
Bumper)
18W820
1. Front
DISASSEMBLY
bumper
assembly
AND REASSEMBLY
Disassembly steps
1.
2.
3.
4.
NOTE
Reverse
Bumper
stay assembly
Front bumper
side
Bumper
guard (metal
Front bumper
center
the disassembly
procedures
/3
top-van)
to reassemble.
1 STB Revision
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23-58
BODY - Bumpers
REMOVAL
AND INSTALLATION
(Rear Bumper)
18W821
1. Rear bumper
DISASSEMBLY
Disassembly
AND REASSEMBLY
steps
1.
2.
3.
4.
5.
6.
7.
NOTE
Reverse
assembly
the
Rear
Rear
Rear
Rear
Side
Rear
Rear
bumper
bumper
bumper
bumper
bumper
bumper
bumper
disassembly
stay
reinforcement
plate
side
stay
stay
face
procedures
to
181772
reassemble
1 STB Revision
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23-59
GRILLE, GARNISH
REMOVAL
AND
INSTALLATION
NZJRAAF
q
18W826
18W828
/,
18W827
rille removal
steps
1. Radiator
grille
2. Front combination
3. Headlight
bezel
light
+*
4. Upper quarter
trim (metal top-van)
5. Rear ventilator
cover (except
for metal
top-van)
6. Air outlet garnish
NOTE
Reverse the removal procedures to reinstall.
+*
: Refer to Service Points of Removal..
(3) l + : Refer to Service Points of Installation
(1)
(2)
REMOVAL
Refer to P.23-73.
INSTALLATION
OF UPPER QUARTER
Refer to P.23-74.
1 STB Revision
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TRIM
?3-60
BODY
- Outside
Mirror
OUTSIDE MIRROR
REMOVAL
AND INSTALLATION
N23QBAB
18W789
1. Rearview
mirror
1 STB Revision
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BODY - Instrument
INSTRUMENT
Panel
PANEL
For installation
of the instrument
panel, the bolts, screws and nut described below are used.
They are indicated by symbols in the illustration in the section SERVICE POINTS OF REMOVAL.
/ STB Revision
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23-61
23-62
REMOVAL
BODY
AND
- Instrument
Panel
INSTALLATION
16
\-
19W690
Removal
12. Connection
of recirculation/fresh
air
changeover
control wire
13. Connection of mode selection control
wire
14. Connection
of water valve control wire
15. Center reinforcement
16. Horn pad
17. Steering wheel
18. Fuse box cover
19. Fuse box assembly
20. Instrument
panel
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
4*
4*
+*
NOTE
(1)
(2)
(3)
/ STB Revision
*4
-1
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to reinstall.
of Removal.
of Installation
BODY - Instrument
SERVICE
23-63
Panel
POINTS
OF REMOVAL
1. REMOVAL
OF LAP HEATER DUCT (B)/3.HOOD
RELEASE
CABLE BRACKET
Remove the lap heater duct B and hood release cable
bracket.
4.
REMOVAL
OF DEMISTER
GRILLE (L.H.) /5. DEMISTEb.
i,,:
GRILLE (R.H.)
.
Remove the right and left demister
grilles by raising the<
5;
attaching
projections
with a screwdriver.
t..
Caution
Use care not to break
6.
REMOVAL
(1) Remove
(2) Remove
the
projections.
OF GLOVE BOX
the glove box stopper.
side lap heater duct(C) on the assistants
,,..:
seat.
19W52(
7.
REMOVAL
OF METER COVER
Remove the meter cover with a screwdriver.
19W66:
1 STB Revision
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23-64
BODY - Instrument
Panel
8. REMOVAL
OF METER
(1) Remove
(2) Remove
CASE
(3) Disconnect
the speedometer
cable from the meter
case by pushing
the stopper
of the plug on the
speedometer
cable side of the connection.
(4) Disconnect
the connectors
of the meter harness and
also of the body harness.
(5) Disconnect
the connectors
(all located
behind the
meter case at the bottom)
of the hazard switch, the
rear window defogger,
rear fog lamp switch, electric
tailgate
locking
switch,
and the rear wiper/washer
switch, and then remove the meter case.
9.
F~EMOVAL 0F COMBINATION
METER
Remove the combination
meter pad.
10. REMOVAL
OF COMBINATION
METER
PAD
CASE
harness
Caution
To prevent internal
trouble,
the meter must not be
dropped
or subjected
to shock or must
not be
abruptly
inclined
to the extent that the maximum
indication
angle is exceeded.
19WE14
15. REMOVAL
OF CENTER
REINFORCEMENT
(1) Remove
the center console.
(Refer to P.23-66.)
(2) Remove
the center reinforcement
attaching
screws.
(3) Remove the center reinforcement,
radio and car stereo
player as a unit.
(4) Disconnect
the radio and car stereo player from the
front harness and feader wire.
wision
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BODY - Instrument
23-65
Panel
N23UAAE
17. REMOVAL
OF STEERING
WHEEL
Remove the steering wheel.
NOTE
Before removal, make the mating
shaft and steering wheel.
marks
on both steering
20. REMOVAL
OF INSTRUMENT
PANEL
Remove the instrument
panel attaching
bolts and nuts,
and withdraw
and remove the instrument
panel toward
you.
SERVICE
POINTS
20. INSTALLATION
OF INSTRUMENT
all of the connectors
(1) Connect
(2) Make sure
19w701
DISASSEMBLY
OF INSTALLATION
that
PANEL
securely.
harnesses
pinched.
:,;
b.
! ;rI:*
I..
AND REASSEMBLY
lQW692
1.
2.
3.
4.
5.
are not
Assist grip
Instrument
pad B
Switch holder
Instrument
pad A
Instrument
panel
1 STB Revision
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23-66
CENTER CONSOLE
REMOVAL
AND
INSTALLATION
N23UBAD
Removal steps
1. Knob
2. Plug
3. Center panel
4. Connection
of center
panel wiring
harness to front wiring
harness. connector
NOTE
Reverse the removal procedures
DISASSEMBLY
to reinstall.
AND REASSEMBLY
N23UBAE
7
Disassembly steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
Plug
Center panel pad
Cigarette
lighter
Clock (Vehicles
with a clock)
Ashtray
Ashtray
bracket
Cigarette
lighter
bracket
Lamp holder
Heater control
panel
Center panel wiring
harness
Box panel
Center panel
19W695
NOTE
Reverse
( STB Revision
the disassembly
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procedures
to reassemble.
BODY - Floor
23-67
Console
FLOOR CONSOLE
REMOVAL
AND INSTALLATION
Vehicles
manual
Removal
Vehicles
automatic
with a
transmission
with an
transmission
,1
I?
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
NOTE
Reverse the removal procedures
19W696
to reinstall.
1 STB Revision
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23-68
BODY
- Headlining
HEADLINING
REMOVAL
INSTALLATION
AND
NZBUDAF
19W669
Assist
strap
1. Assist
2. Assist
3. Hook
strap
grip
a*
40
+O
~~
l +
(metal
top-van)
l *
1.
4.
5.
6.
Assist strap
Door opening
trim
Front side roof rail trim (metal top-van)
Inside rear view mirror
7. Sun visor
8. Front roof rail trim (metal top-van)
9. Rear opening
trim
INOTE
(1) Reverse the removal procedures to reinstall.
(2) 4*
: Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation.
1 STB Revision
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BODY
Headlining
and
Assist
23-69
Strap
REMOVAL
OF FRONT
Refer to P.23-72.
8.
REMOVAL
OF FRONT
Refer to P.23-72.
11. REMOVAL
OF REAR HEADLINING/12.
ING
(1) Remove the dome light.
(2) Slowly peel the headlining
away,
corner of the roof panel.
FRONT
HEADLIN-
beginning
with
the
Caution
Make sure that the headlining
is removed slowly;
the sponge portion of the headlining
is left behind
the roof panel.
as
on
(3) Thoroughly
remove the drying sealant and sponge left
behind on the roof panel by using a toluol solution, etc.
Caution
Make sure that all remaining
sealant and sponge are
thoroughly
removed,
as they produce
uneven surfaces when the headlining
is bonded
to the roof
panel.
1 STB Revision
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23-70
BODY - Headlining
and
Assist
Strap
sealant
TO FRONT
HEADLINING/
: 3M ART
Adhesive
\
Roof
panel
flange
10w547
(front)
Dome
Headlining
light
(rear)
1ew540
1 STB Revision
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edges as shown.
23-7 1
BODY - Trims
TRIMS
REMOVAL
AND
INSTALLATION
N23UCAF
6
I
18
10
Front
4*
4,. . ,4
4*
Cowl
. Center
4*
t Quarter
4*
pillar
1.
2.
3.
4.
5.
6.
7.
8.
trim
removal
removal
steps
trim
removal
10. Ashtray
12. Quarter
steps
(metal
trim
Rear wheelhouse
~~
only)
top-van)
trim
Upper
quarter
trim
removal
2.
12.
14.
15.
16.
41) l + 17.
Rear
rail
4*
steps
side
steps
side trim
(Left
roof
Rear pillar
4,
lower
http://vnx.su/
trim
removal
steps
NOTE
(1)
Reverse
the
(2)
++
: Refer
(3)
l + : Refer
1 ST6 Revision
trim
removal
procedures
to Service
Points
to Service
Points
to reinstall.
of Removal.
of Installation
23-72
BODY - Trims
dlining
Cross section
marked
4.
REMOVAL
OF FRONT SIDE ROOF RAIL TRIM
Remove the front side roof rail trim
5.
REMOVAL
OF FRONT PILLAR
Remove the front pillar trim.
8.
REMOVAL
OF FRONT ROOF RAIL TRIM
Remove the front roof rail trim
9.
REMOVAL
C
lQW64C
portion I-
Cross section of
portion marked C
Headlining
Front roof rail trim
Front roof rail
TRIM
1QW641
OF COWL
SIDE TRIM
(1) Insert
portion
marked-
t:he cowl
side
trim
and
11. REMOVAL
OF CENTER PILLAR TRIM
(1) On vehicles with cassette stereo player, remove the
rear speaker. (Refer to GROUP 8 ELECTRICAL-Radio
and Stereo.)
(2) Remove the clips at two places (upper and lower) at
the foremost
part of the quarter trim.
(3) Insert the tip of a flat-tip (-) screwdriver or similar tool
beneath the center pillar trim and cut the top part of
the clips.
NOTE
When cutting
body panel.
/evision
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the clips,
be careful
not to scratch
the
23-73
BODY - Trims
3oss section
narked C
of portion
12. REMOVAL
OF QUARTER
TRIM
the body
19W552
13. REMOVAL
OF REAR WHEELHOUSE
TRIM
(3) Remove the rear seat. (Rear to P.23-77.)
(2) Remove the hooks and the rear wheelhouse
Cross section of
portion marked e
Uppe;
trim
Cross section of
portion marked e
trim.
17. REMOVAL
OF UPPER QUARTER TRIM
(1) Insert the special tool under the upper quarter
remove the clips.
(2) Remove the upper quarter trim.
quarter
lBW544
18. REMOVAL
OF REAR ROOF RAIL TRIM
Remove the rear roof rail trim.
774
1 STB Revision
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trim and
,
.:
23-74
BODY - Trims
19. REMOVAL
OF REAR PILLAR
LOWER
TRIM
(I)
,-w
I
a
L
SERVICE
Clip
-
POINTS
17. INSTALLATION
Long
hole
OF INSTALLATION
OF UPPER
QUARTER
TRIM
When attaching
clips to the upper quarter trim, attach so
that the clip is at a right angle relative to the long hole of
the body panel.
19W630
19W627
13. INSTALLATION
OF REAR WHEELHOUSE
5.
trim
TRIM
INSTALLATION
OF FRONT PILLAR TRIM
When attaching
clips to the front pillar trim, attach so that
the
clap
IS
at
a
right
angle relative to the long hole 0 f the
front IlIar,
STB Revision
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BODY - Front
23-75
Seats
FRONT SEATS
DISASSEMBLY
N23UEAD
AND REASSEMBLY
Suspension
seat
Normal
seat (L.H.)
45-60
33-43
Nm
ft.lbs.
35-55
Nm
.I,. -,
35-55
25-40
Nm
ft.lbs.
Normal
seat (R.H.)
33-43
Disassembly
e+
l +
ftlbs.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Parallel
link assembly
Seat support
bracket
Suspension
seat assembly
Seat adjuster
Adjuster
cover
Reclining
lever knob
Front seatback
Head restraint
Front seat cushion
35-55
25-40
Nm
ft.lbs.
NOTE
Reverse the disassembly
(2) l + : Refer to Service
(1)
1 STB Revision
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procedures
to reassemble.
Points of Reassembly.
23-76
BODY - Front
APPLICATION
OF GREASE TO SEAT ADJUSTER/l.
PARALLEL LONK ASSEMBLY
(1) Apply the specified grease to the following points.
I
I
links
Specified
0
0
0
Sliding
Sliding
Sliding
grease
: Multipurpose
NLGI No. 2
grease
WE
5310,
(2) After the seat has been installed, check to ensure that
the seat adjusters lock at all lock positions when the
seatback is moved slowly.
(3) Check to ensure that the forward folding and return
mechanisms
of the parallel links operate smoothly
and
lock securely.
Seat adjusters
Parallel
Seats
lQW693
INS+ECTION
l
l
l
l
l
l
l
l
Check
Check
Check
Check
Check
Check
damage
Check
Check
1 STB Revision
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bends,
23-77
REAR SEAT
DISASSEMBLY
AND REASSEMBLY
N23UFAF
33-43 ft.lbs.
Disassembly steps
19W684
l +
1.
2.
3.
4.
NOTE
(I) Reverse the disassembly
(2) l + : Refer to Service
procedures
to reassemble
Points of Reassembly.
19w510
grease
place.
1 STB Revision
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23-78
SEAT BELTS
REMOVAL
AND
INSTALLATION
35-55
Nm
N23UGAD
35-55 Nm
25-40 ft.lbs.
-------
19W699
Removal
steps
l *
1.
2.
3.
4.
+e
l +
I)+
pillar trim
Center
Sash guide cover
Front seat belt assembly
Connection
of seat belt
tor
5. Buckle stalk
35-55 Nm
25-40 ft.lbs.
switch
connec-
NoTE
(1) Reverse the removal procedures to reinstall.
(2) 4*
: Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation
SERVICE
POINTS OF REMOVAL
1. REMOVAL
OF CENTER
Refer to P.23-72.
3.
REMOVAL
OF FRONT
Caution
Special
bolts (l-in.
mounting
bolts.
Do not disassemble
SERVICE POINTS
5.
PILLAR
TRIM
bolts)
are used
for
http://vnx.su/
seat
belt
the retractor.
OF INSTALLATION
INSTALLATION
OF BUCKLE STALK
Install the seat belt buckle stalk in parallel
line of the vehicle.
evision
the
23-79
REMOVAL
l +
AND INSTALLATION
1. Rear
seat
19W602
belt
35-55 Nm
25-40 ft.lbs.
NOTE
(1) Reverse the removal procedures to reinstall.
(2) l + : Refer to Service Points of Installation.
Paral
/ STB Revision
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bolts)
are used
for the
the
anchor
seat
belt
._ -..
23-80
light
Buzzer
OFF
ON-
SYSTEM
When the seat belt switch in ON (seat belts not buckled) with
the i$nition key in the ON position, the seat belt warning timer
caus& the seat bel-t warning light to illuminate
and the buzzer
to sobnd for 4 to 8 seconds. If the seat belts switch is set to
OFF (the seat belts buckled) during the seat belt warning timer
interval, only the buzzer is cancelled.
4,to
8 set
I
16Y1805
SYSTEM
INSPECTION
1. Disconnect the seat belt warning timer connector.
2. When the YG wire (terminal 2) and B wire (terminal
3) are
connected
with a jumper wire, the seat belt warning light
should illuminate.
If it fails to illuminate,
check the bulb,
key-reminder
switch and fuse.
3. Also the buzzer should sound when the RB wire (terminal
4)l and B wire (terminal
3) are connected
with a jumper
wire. In this condition,
fasten the buckle;
if the buzzer
stops sounding, the seat belt switch is good.
.,
16C953
3
L
18UO385
4.
I Terminal
Buckle unlock
1 Buckle lock
16UO368
+o
I
I
NOTE
0-C
indicates
that there
is continuity
5. After performing
the above inspections,
reconnect the seat
belt warning timer.
6. With the ignition switch turned to IG, verify the function of
the seat belt warning system.
/ STB Revision
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..-.
BODY - Seat
23-81
Belts
Type
Part number
M B544777
lQW666
:
Caution
1. The seat belt extender is intended for use only when the
seat belt is not long enough to fit around an occupant.
It
must be renioved and stowed when not required by that
occupant.
2. Incorrect
use of seat belt extender
or other extender
which is not specified
may result in serious injury.
SEAT
hide
seat belt
BELT
EXTENDER
INSTRUCTIONS
1. To use the extender, insert and latch the tip of the vehicle
seat belt in the buckle of the extender.
19W668
Vehicle
seat belt
Seat belt extender
FTB
Revision
http://vnx.su/
6;
13-1
NMENT
FRAME ALI
!(
CONTENTS
BODY DIMENSIONS
AND MEASUREMENT
METHODS
. . . .. . . . . . . . . . . . .. .. . . . . . . .. . . . . . . . . . . .. . . . . . . . . .. .. . . . . . .
. . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . .
Body Center Points
TYPE A (PROJECTED
2
3
Are Indicated
Indication of Reference
Measurement
Methods
Dimensions
. . . . . . .. . . . . . . . . .. .. . . . . . .. . . .
. . .. .. . . . . . . . . .. . . . . . . . . .. . . . . . . .. .. . .
3
2
FRAME CENTERING
GAGE INSTALLATION
POSITIONS
. . . . . . .. . . . . . . . . . .. .. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . .
Measurement
Points
. . . . . . .. . . .
. . . . . . . . .. . . .
NlBAA-
2
2
DIMENSIONS)
.. . . . . . . .. . . . . .
<
1,
c
I
TYPE B (ACTUAL-MEASUREMENT
....................................................
DIMENSIONS)
......................................
Engine Compartment
.............................................................
Interior
http://vnx.su/
Side Body
........................................................
Upper Body .....................................................
10
12
16
16
12
13-2
BODY AND
FRAME
mm (in.)
ALIGNMENT
Bodv
Dimensions
and
Measurement
Methods
MEASURE-
BODY DIMENSIONS
MENT METHODS
AND
ARE INDICATED
INDICATION
OF REFERENCE
NlOGAAC
when the
reference
used for
distance
reference
measure-
DIMENSIONS
32WO65
MEASUREMENT
Hecenu.
POINTS
Measurement
points are used to indicate the following:
(1) Hole centers
If a measurement
is to be made at a hole center, the point
of the surface from which the measuring
instrument
is
applied is the measurement
point.
-+
Q
I
yiIr....
Hole civmference
..
32UO13:
/
svision
I
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BODY AND
FRAME
ALIGNMENT
Body
Dimensions
MEASUREMENT
ww)
and
gage
13-3
Methods
METHODS
NOTE
Make sure that the tracking
between its body and probes.
robe
Measurement
(using
used
a tracking
is free from
play
32UO141
dimensions)
both probes to the same length
,:(*
j
!
2UO142
Dimensions
1Hole circumference
Desired
L=
dimensions:
Example:
Reference
Measured
e+y
1 = 600 (23.6)
D = 20 (.79)
d = 10(.39)
Desired measu
+ 20(.79);10(.39)
= 605 (23.8)
32110144
svision
http://vnx.su/
Z~
%
dimensions:
L = 600(23,6)
.,
mm (in.)
dimensions:
hole diameters:
Desired
;:
;.:
13-4
BODY AND
FRAME
FRAME CENTERING
ALIGNMENT
Frame
Centering
GAGE INSTALLATIIQN
indicated
at locations
Frame centering
gage
in illustration
Gage
Installation
Positions
POSITIONS
N13HA-
and vertical
y
mm (in.)
32WO53
32WO52
NOTE
Dimensions shown
the panel thickness.
1 STB Revision
http://vnx.su/
BODY AND
FRAME
ALIGNMENT
Frame
Centering
Gage
Installation
Positions
13-5
31
15w512
hole [diameter
hole [diameter
hole [diameter
1 STB Revision
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hole [diameter
http://vnx.su/
;.
.._
(l/2)
NlUA-
mm (in.)
32WO52
32WO53
BODY AND
FRAME
ALIG
1 STB Revision
http://vnx.su/
Dimensions)
13-7
http://vnx.su/
:-
(2/2)
mm (in.)
Y AND
FRAME
ALIGNMENT
Type
A (Projected
Dimensions)
13-9
%k
&g
Fs
se
1 STB Revision
/
http://vnx.su/
http://vnx.su/
710
(27.95)
(41.36)
1,051
No.
Length
No.
Length
(45.28)
1,150
817
(32.16)
@)*
(65.23)
1,657
o*
762
(30.00)
@*
(60.75)
1,543
a*
840
(33.07)
(44.42)
1,128
1,031
(40.58)
a*
(50.39)
1,280
707
(27.84)
a*
(41.44)
1,053
CT
522
(20.55)
TYPE B (ACTUAL-MEASUREMENT
@*
(9.53)
242
a*
959
(37.77)
(3??8)
758
(29.83)
a*
870
(34.25)
@
695
(27.38)
o*
DIMENSIONS)
0
439
(17.28)
@I*
1,344
(52.90)
a*
1,031
(40.59)
43
266
(10.47)
1,251
(49.23)
Nl3KA.m
0
(I+:&
$3
(3y;l)
8
1262
(4b.68)
1598
(6i.93)
CD*
mm (in.)
BODY
AND
FRAME
if?
5.
VD
ALIGNMENT
1 STB Revision
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Type
B (Act&measurement
Dimensions)
13-11
13-12
- Type
1 STB Revision
http://vnx.su/
B (Actual-measurement
Dimensions)
http://vnx.su/
5 (Body center
Front
pillar
lower
part
of accelerator
C enter
hi ale [diameter
: 9 mm
I L
I
I -
[diame-
cable
mounting
(.35 in.)]
point)
support
of roof
10I
Joint
and
Center
of fender
ter : 6.6 mm (.26
I6
front
pillar
mounting
in.)]
Center
of fender
mounting
ter : 9 mm (.35 in.)]
hole
hole
[ diame-
[diame-
Joint
-I11
Headlight
of side
roof
mounting
Center
of fender
ter : 6.6 mm (.26
rail
and
hole
mounting
in.)]
quarter
hole
panel
[diame-
of
of
Body center
eter : 5 mm
mounting
in.)]
point)
point reference
(.20 in.)]
center
hole
front
fender
mounting
: 10 mm (.39 in.)]
weatherstrip
: 5.5 mm (.22
12 (Body
Center
[diameter
Center
[diameter
[ diam-
hole
hole
13-14
- Type
6 (Actual-measurement
Dimensions)
--z
\
\
\
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m
0
~a------
BODY AND
FRAME
ALIGNMENT
Type
B (Actual-measurement
Dimensions)
13-15
http://vnx.su/
13-16
TvDe B (Actual-measurement
n?I
STB Revision
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Dimensions)
BODY AND
FRAME
ALIGNMENT
Type
0al
6
3
#
1 STB Revision
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B (Actual-measurement
Dimensions)
13-17
GROUP/SECTION
INDEX kme-.
Service Manual
..............................
INTRODUCTION
MONTERO
...........................................
Electrical
1987 : Volume
Charging
FOREWORD
This Service Manual has been prepared with the
latest service information
available at the time of
publication.
It is subdivided
into various group
categories
and each section contains
diagnosis,
procedures
disassembly,
repair, and installation
along with complete
specifications
and tightening
references.
Use of this manual will aid in properly
performing
any servicing necessary to maintain
or
restore the high levels of performance
and reliability
designed into these outstanding
vehicles.
..........................
System
Starting
System
............................
Ignition
System
.............................
......................
.............................
System
..........
...............................................
Accessory
......................................
Audio System
................................
WE SUPPORT
VOLUNTARY
TECHNICIAN
CERTIFICATION
THROUGH
.........
..........................................
Air-conditioning
............................
MITSUBISHI
MOTOR SALES
OF AMERICA.
Inc.
Mitsubishi
Motors
corporation
reserves
the right to make changes
in
design or to make additions
to or improvements
in its products without
imposing
any obligations
upon itself to install them on its products
previously
manufactured.
0 1986 Mitsubishi
Motors
Corporation
Printed
For Engine
**,
in Japan
http://vnx.su/
Chassis
& Body
refer
to
INTRODUCTION
NOOBAAK
CONTENTS
The preceding
page contains
the GROUP
which lists the group title and group number.
INDEX
PAGE NUMBERS
All page numbers
consist of two sets of digits
separated by a dash. The digits preceding the dash
identify the number of the group. The digits following the dash represent
the consecutive
page
number within the group.
The page numbers can
be found on the top left or right of each page.
piiiKL=lIndicates
TEXT
Unless otherwise specified, each service procedure
covers all models.
Procedures
covering specific
models are identified by the model codes, or similar
designation
(engine type, transmission
type, etc.).
A description
of these designations
is covered in
this unit under VEHICLE IDENTIFICATION.
SERVICE
PROCEDURES
OF TERMS
Reassembly
STANDARD
VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection
or the
value to which the part or assembly is corrected and
adjusted.
It is given by tolerance.
operation
DEFINITION
incidental
if installation
cannot be made in the reverse
order of Removal steps; omitted if installation in the reverse
order of Removal
steps is
possible.
.
steps : I his IS provided It reassembly
cannot be made in the reverse
order of Disassembly
steps;
omitted if reassembly
in the
reverse order of Disassembly
steps is possible.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum
value within which the part or assembly
must be kept functionally
or in strength.
It is a value
established
outside the range of standard value.
http://vnx.su/
Classification of
SERVICE ROINTS
Oe : Removal
**
: Installation
Oe : Disassembly
I)+ : Reassembly
Page number
INTRODUCTION
Group title
Section title
THERMOSTAT
REMOVAL
AND
INSTALLATION
1 torque
-L
0480031
Thermostat
kit
Repair
kit or set
parts
are
Removal
+
I s
B~C
1. Connectw
of water
temperature
switch
connector
(Vehicles
with an air condltloneri
2 Connection
of radiator
upper
hose
3 Water
outlet
fitting
4 Water
outlet
fitting
gasket
5. Thermostat
SERVICE
45.
POINTS
OF lNSTALLATlON--
INSTALLATION
Install
the
OF
thermostat
Caution
The
thermostat
ensure
that
the
THERMOSTAT
to the
flange
thermostat
fits
Intake
over
is not
manifold
as illustrated.
the
manifold
installed
at an
seat;
angle.
An explanation
of procedures,
notes, etc.
regarding removal installation
disassembly
(and reassembly.
-1
http://vnx.su/
INTRODUCTION
Vehicle
Identification
VEHlCLE IDENTIFICATION
&LE
IDENTIFICATION
NUMBER
LOCATIOyo(lcAmm
VEHICLE
lDENTlFlCATlON
\
6th
digit
Country
Make
JJapan
AMitsubishi
Vehicle
type
4-
Multipurpose
vehicle
(MPW
numbers
contain 17 digits.
tells country, make, vehicle
7th
digit
8th
digit
9th
digit
10th
digit
Price
class
Body
Engine
Check
digit
Model
year
2-
3-
Low
or more TERO
with
hydraulic
brakes
4-
3-door
metaltop or
van
E2.6 liters
(155.9
C.I.D.)
Line
High
0
1
2
3
on a plate
Plant
The vehicle
type, etc.
1 ZZ-Zer
H1987
year
7-Truck
9
X
NOTE
*Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle indentification
number.
1 STB Revision
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INTRODUCTION
VEHICLE
IDENTIFICATION
NUMBER
- Vehicle Identification
LIST
FEDERAL
NOOCC-
number)
Model code
Engine displacement
Brand
L042GVNJLF
L042GVRJLF
JA4FJ43EoHJ
JA4FJ43EoHJ
MITSUBISHI
JA7FJ23EoHJ
MONTERO
2.555 liters
(155.9 C.I.D.)
L042GTNSLF
L042GTRSLF
JA7FJ23EoHJ
CALIFORNIA
number)
states.)
Model code
Engine displacement
Brand
L042GVNJLH
JA4FJ43EoHJ
JA4FJ43EoHJ
JA7FJ23EoHJ
L042GVRJLH
2.555 liters
MITSUBISHI
MONTERO
L042GTNSLH
(155.9 C.I.D.)
1 L042GTNSLH
JB7FJ23EoHJ
VEHICLE
INFORMATION
CODE PLATE
Vehicle information
code plate is riveted
port panel in the engine compartment.
The plate shows
model code, engine
model, and body color code.
1.
MODEL
L042G
2.
ENGINE
G54B
on the headlight
model,
Engine
COLOR,
transmission
model
KM145
TRANS
AXLE
Transaxle
4.
sup-
VNJLF
I
3.
NOOCO-A
TRIM
OPT
model
876
Montone
exterior
color code
OOK520
B2 1 B76H43
Two-tone
color code
Exterior code
Two-tone
exterior is shown
by the
exterior code followed
by the two
color codes.
._:
) STB Revision
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INTRODUCTION
- Vehicle
Identification
CHASSIS
NUMBER
STAMPING
LOCATION
NOOCE-A
The chassis
number is stamped
the right rear shock absorber.
CHASSIS
NUMBER
near
CODE CHART
LO4
HJOOOOOl
VEHICLE
SAFETY CERTIFICATION
LABEL
NOOCF-
ENGINE
MODEL STAMPING
NOOCG-
1 Engine displacement
1 2.555 liters (155.9 C.I.D.)
Number
model
cycling
AA020toYY=
/ STB Revision
--I
http://vnx.su/
j . f
.,,.
..-.
INTRODUCTION
- Vehicle
Identification
NOOCH-
Body color
Exterior code
Monotone
B76
Cl9
Brown
H43
Silver (Metallic)
R52
Red
s70
x15
Beige
(Metallic)
Black
Two-tone
B21 B76H43
Silver (Metallic)/
Dark blue (Metallic)
C38C19X13
Black/
Brown (Metallic)
H15H43X13
Black/
Silver (Metallic)
R06R52X13
Black/Red
S69S7OX13
Black/Beige
X45X1 5H43
Black/
Silver (Metallic)
1 STB Revision
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INTRODUCTION
PRECAUTIONS
PROTECTIN
BEFORE SERVICE
THE VEHICLE
NOODAAC
If theIre is a likelihood
of damaging
painted or interior parts
during service operations,
protect them with suitable covers
(such as seat covers. fender covers, etc.).
REMOVAL
AND DISASSEMBLY
oorn,
FOOOl;
SPECIAL TOOLS
If other tools are substituted
for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged,
or the mechanic
might be injured;
therefore,
be
sure to use the special tool whenever
doing any work for
which the use of one is specified.
FOOOl8
r
DO05111
STB Revision
they
,j
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must
be
INTRODUCTION
- Precautions
Before Service
PARTS
When
replacing
VEHICLE
parts,
use MITSUBISHI
genuine
parts.
WVASHING
If high-pressure
car-washing
equipment
or steam car-washing
equipment
is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance
of at least 300 mm (1 1.8 in.) from
any plastic
parts
and all opening
parts
(doors,
luggage
compartment,
etc.).
nm
(in.)
so0059
SERVICING
THE ELECTRICAL
When
cable
the electrical
system,
from the battery.
servicing
terminal
SYSTEM
disconnect
the negative
Caution
Before connecting
or disconnecting
the negative
cable, be
sure to turn off the ignition
switch
and the lighting
switch.
(If this is not done, there is the possibility
of semiconductor
parts
being damaged.)
WIRING
HARNESSES
1.
2.
If any section
of a wiring
harness
contacts
the edge of a
part, or a corner, wrap the section of the harness with tape
or something
similar in order to protect
it from damage.
F161711
:,
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INTRODUCTION
- Precautions
Before
Service
3. When disconnecting
a connector,
connector, not the harness.
4.
Disconnect
connectors
the direction indicated
5.
Connect connectors
which have catches
connectors
until they snap.
in
16Rl263
16R1264
Y16347
by inserting
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the
INTRODUCTION
- Precautions
Before
ELECTRICAL COMPONENTS
1. When installing any of the vehicle
pinch or damage
2.
Sensors,
relays, etc., are sensitive
Handle them with care so that
mishandled.
3.
11
Service
parts, be careful
harnesses.
not to
to strong impacts.
they are not dropped
or
The electronic
parts used for relays, etc., are sensitive
to
heat, If any service
which causes
a temperature
of 80C
(176F) or more is performed,
remove the part or parts in
question
before carrying out the service.
OOY63:
LINKS
If a blown-out
fuse is to be replaced,
be sure to use only a
fuse of the specified
capacity.
If a fuse of a capacity
larger
than that specified
is used, parts may be damaged
and the
circuit may not be protected
adequately.
Caution
If a fuse is blown-out,
be sure to eliminate
the problem
before installing
a new fuse.
15A
IOA
the cause
of
oOY58S
Permissible
current
Nominal
size
0.3 mm2
05mm
0.85 mm2
1.25 mm2
2.0 mm2
AWG22
AWG 20
AWG18
AWG 16
AWG14
~
I
5A
13A
17A
22A
30A
zi
12A
16A
If additional
optional
equipment
is to be installed
in the
vehicle,
follow
the procedure
listed in the appropriate
instruction
manual;
however,
be sure to pay careful
attention to the following
points:
(1) In order
to avoid overloading
the wiring,
take the
electrical
current
load of the optional equipment
into
consideration,
and determine
the appropriate
wire size.
(2) Where
possible,
route the wiring through
the existing
harnesses.
Revision
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12
INTRODUCTION
- Precautions
Before
Service
(3) If an ammeter
or similar instrument
is to be connected
to a live-wire
circuit, use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
,i no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
if it
be
LUBRICANTS
In accordance
with the instructions
in this Workshop
Manual,
apply the specified
lubricants
in the specified
locations
during
assembly
and installation.
FooO281
BRAKE FLUID
Be careful
to avoid spilling
adheres
to the vehicle body,
ored.
IN GROUPS
work is to be done
must be taken.
by two
OF TWO OR
or more
-FOOO3OI
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technicians
INTRODUCTION
- Precautions
IKITE
13
Before Service
ON INSTALLATION
OF RADIO
EQUIPMW&
The computers
of the electronic
control
system
has been
designed
so that external
radio waves
will not interfere
with
their operation.
However,
if antenna
or cable of amateur
transceiver
etc. is
routed near the computers,
it may affect the operation
of the
computers,
even if the output of the transceiver
is no more
than 25W.
To protect
each of the computers
from
interference
by
transmitter
(hum, transceiver,
etc.), the following
should be
observed.
1. Install the antenna
on the roof.
2. Because radio waves are emitted from the coaxial cable of
the antenna,
keep
it 200 mm (8 in.) away
from
the
computers
and the wiring harness.
If the cable must cross
the wiring harness,
route it so that it runs at right angles to
the wiring
harness.
3. The antenna
and the cable should be well matched,
and
the standing-wave
ratio* should
be kept low.
4. A transmitter
having a large output should not be installed
in the vehicle.
5. After installation
of transmitter,
run the engine at idle, emit
radio waves
from the transmitter
and make sure that the
engine is not affected.
High-frequency
power supply
_.
If an antenna
and a cable having different
impedances
are
connected,
the input impedance
Zi will vary in accordance
with
the length
of the cable and the frequency
of the
transmitter,
and the voltage
distribution
will also vary in
accordance
with the location.
The ratio between
this maximum
voltage
and minimum
voltage
is called the standing-wave
ratio. It can also be
represented
by the ratio between
the impedances
of the
antenna and the cable.
The amount of radio waves
emitted from the cable increases
as the standing-wave
ratio increases,
and this increases
the
possibility
of the electronic
components
being
adversely
affected.
r.
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INTRODUCTION
- Towing
TOWING
and Hoisting
AND HOISTING
NOOGA-
This vehicle can only be towed from the front with conventional sling-type
equipment
and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4 x 4 x 55 wood beam) should be placed
forward
of under guard and under towing
hook/shipping
tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system
must be used. This system
must be
completely
independent
of the primary
lifting and towing
attachment.
Care must be taken in the installation
of safety
chains to insure they do not cause damage to bumper,
painted
surfaces
or lights.
LIFT!NG-GROUND
CLEARANCE
FRONT TOWING
PICKUP
SAFETY PRECAUTIONS
The following
precautions
should be taken when towing
the
vehicle.
1. Remove
exhaust
tips and any other optional
equipment,
that interface
with the towing
sling. Padding (heavy shop
towel or carpeting)
should be placed between
the towing
sling cross
bar and any painted
surfaces,
and bumper
surfaces.
2. A safety
chain system
completely
independent
of the
primary lifting and towing
attachment
must be used.
3. Any loose or protruding
parts of damaged
vehicle such as
hoods, doors, fenders,
trim, etc., should be secured
prior
to moving the vehicle.
4. Operator
should refrain from going under a vehicle unless
the vehicle is adequately
supported
by safety stands.
5. Never allow passengers
to ride in a towed vehicle.
6. State and local rules and regulations
must be followed
when towing
a vehicle.
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INTRODUCTION
- Towing
and
15
Hoisting
HOISTING
POST TYPE
Special care should
be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped
with the
proper adapters
in order to support
the vehicle at the proper
locations.
(See next page)
Conventional
hydraulic
hoists may be used after determining
that the adapter
plates will make firm contact
with the side
frame.
FLOOR
JACK
crossmember
Caution
1. A floor jack must
never
be used on any part of the
underbody.
2. Do not attempt
to raise one entire side of the vehicle by
placing a jack midway
between
front and rear wheels.
This practice
may result
in permanent
damage
to the
body.
EMERGENCY
JACKING
Jack receptacles
are located at the No. 2 crossmember
and
rear axle housing
to accept the jack supplied
with the vehicle
for emergency
road service. Always
block the opposite
wheels
and jack only on a level surface.
.::
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.
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16
FRAME
INTRODUCTION
CONTACT
SUPPORT
support
of the
below.
and
Hoisting
LOCATIONS
2,350
NOTE
The locations
of the
the
same
as those
illustration
(OOW588)
Towitng
point
twin
shown
as Section
post
hoist
shown
mm
A-A
in
(92.5
in.)
Section
A-A
are
the
oow553
LIFTING
AND JACKING
c
m
@B
SUPPORT
Twin
post
Floor
lack
Emergency
LOCATIONS
hoist
jacking
(jack
supplied
with
the
vehicle)
OOW588
http://vnx.su/
INTRODUCTION
GENERAL
- Geraeral
17
NOOHA-A
OOW556
L042G
Description
Vehicle dimensions
VNJ LFIH
VRJLFIH
TRSLF/H
TNSLFIH
mm (in.)
Overall length
Without spare tire
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
3,960 (155.9)
0
0
3,995 (157.3)
1,680 (66.1)
3,995 (157.3)
1,680 (66.1)
3,995 (157.3)
1,680 (66.1)
3,995 (157.3)
1,680 (66.1)
Overall height
1,840 (72.4)
1,840 (72.4)
1,850 (72.8)
1,850 (72.8)
Wheelbase
2,350 (92.5)
2,350 (92.5)
2,350 (92.5)
2,350 (92.5)
Front
1,400 (55.1)
1,400 (55.1)
1,400 (55.1)
1,400 (55.1)
Rear
1,375 (54.1)
1,375 (54.1)
1,375 (54.1)
1,375 (54.1)
Front
745 (29.3)
745 (29.3)
745 (29.3)
745 (29.3)
Rear
900 (35.4)
900 (35.4)
900 (35.4)
900 (35.4)
480 (18.9)
480 (18.9)
480 (18.9)
440(17.3)
210 (8.3)
440(17.3)
440(17.3)
210 (8.3)
480(18.9)
440(17.3)
210 (8.3)
210 (8.3)
@
@
38
28
38
28
38
28
38
28
21
21
21
21
1,479 (3,260)
1,493 (3,290)
1,440 (3,175)
1,460 (3,219)
I,91 0 (4.210)
Tread
Overhang
Height at curb weight
(wt.)
angle
kg (Ibs.)
rating
Front
1,910 (4,210)
1 ,I 00 (2,425)
I,91 0 (4,210)
1 ,I 00 (2,425)
1,910(4,210)
1 ,I 00 (2,425)
weight ratin!g~:+y~
Seating,c&ac&~
.
:I ;.,* . ..,,
VU.,
,: ,_.: .,
,_;. ,; ,: 3,. r
Rear
1,450 (3,197)
4
1,450 (3,197)
4
1,450 (3,197)
2
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1,100 (2,425)
1,450 (3,197)
2
18
INTRODUCTION
L042G
Description
- General
VNJLFIH
TNSLFIH
VRJ L.F/H
TRSLFIH
Engine
Model
G54B
No.
Type
Number
i In-line
4
of cylinders
G54B
G54B
OHC
In-line
4
G54B
In-line
OHC
OHC
In-line
OHC
Bore
Stroke
98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.)
Piston
displacement
Compression
ratio
Firing
order
Basic
ignitron
Transmission
Model
trming
&transfer
2,555 cm
(155.9 CID)
8.7
2,555 cm
(155.9 CID)
2,555 cm3
(155.9 CID)
2,555 cm3
(155.9 CID)
8.7
8.7
8.7
I-3-4-2
I-3-4-2
1-3-4-2
7 BTDC
? 2
7 BTDC
? 2
1-3-4-2
7 BTDC
2 2
7 BTDC
case
No.
KM145
KM148
KM145
KM148
5-speed
manual
4-speed
automatic
5-speed
manual
4-speed
automatic
1 st
3.967
2.826
3.967
2.826
1.493
Type
Cear ratio
Transmjssion
Transfer
case
2nd
2.136
1.493
2.136
3rd
1.360
1 .ooo
1.360
1.000
4th
5th
1.000
0.856
0.688
-
1 .ooo
0.856
0.688
-
Reverse
3.578
2.703
3.578
2.703
High
1.000
1.000
1.000
1 ,040
Low
1.944
1.944
1.944
1.944
4.625
4.625
4.625
4.625
Dry single
Dry single
disc &
disc &
diaphragm
diaphragm
spring
spring
Chassis
Tire size
Front suspension
P225/75R15
Type
Spring
constant
Wishbone
compression
(Wheel
position)
22 N/mm
(123 Ibs./in.)
type
Rear suspension
Type
Spring
Asymmetrical
semi-elliptic
leaf spring
constant
At load of 1 ,OOO-2,500
(220-551
Ibs.)
22 N/mm
(123 Ibs./in.)
At load of 4,670-8,870
(1,030-I
,955 tbs.)
50 N/mm
(280 Ibs./in.)
..,j ;
* :
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? 2
INTRODUCTION
Description
m--__
L042G
Data and
General
Specifications
VRJLFIH
VNJLFIH
/ Tightening
Torque
TNSLFIH
19
TRSLFIH
Brakes
We
Power
Front
Disc
Rear
Drum
(Leading
steering
Gear type
Integral
Gear ratio
16.4
NOOJA-
Head mark
Head mark
Nm
07
ft.lbs.
ft.lbs.
Nm
2.2-2.9
4.9-7.8
3.6-5.8
5.8-8.7
13-19
9.4-14
purposes
I
6x 1.0
3.0-3.9
8x 1.25
7.9-I
10x 1.25
16-23
12-17
27-39
20-29
12 x 1.25
29-43
21-32
47-72
35-53
14x 1.5
48-70
35-52
77-l
16x 1.5
677100
51-77
130-I
18x1.5
100-l
50
74-I
150-I
90
20x
1.5
10
10
57-85
60
90-I
20
180-230
130-170
1 IO-140
160-320
1 go-240
22 x 1.5
200-260
150-I
340-430
250-320
24x
260-320
1 go-240
420-550
310-410
Nm
ft.lbs.
1.5
Description
Tape
ball nut)
TORQUE
Description
type (Recirculating
TIGHTENING
Taper
and trailing)
thread
for pipes
90
Remarks
(size)
PT l/8
Internal
Internal
thread:
thread:
Aluminum
Cast iron
PT l/4
Internal
Internal
thread:
thread:
Aluminum
Cast iron
PT 318
Internal
Internal
thread:
thread:
Aluminum
Cast iron
thread
pipes (size)
NPTF l/16
4.9-7.8
7.9-I 2
3.6-5.8
5.8-8.7
Internal
Internal
thread:
thread:
Aluminum
Cast iron
NPTF l/8
7.9-I 2
16-19
5.8-8.7
12-14
Internal
Internal
thread:
thread:
Aluminum
Cast iron
NPTF l/4
19-13
34-45
14-22
25-33
Internal
Internal
thread:
thread:
Aluminum
Cast iron
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8-1
ELECTRICAL
CONTENTS
ACCESSORY
......................................................
188
Cigarette Lighter
............................................
,190
Clock ...............................................................
,191
AUDIO SYSTEM
................................................
.192
AUTOMATIC
FREE-WHEELING
HUB
INDICATOR
SYSTEM
........................................
208
Automatic
Free-wheeling
Hub
Indicator Control Unit .....................................
,216
Pulse Generator
..............................................
215
BACK DOOR WINDOW
DEFOGGER
................ .203
Defogger switch
............................................
,206
Printed Heater Lines ......................................
,207
CHARGING
SYSTEM
.........................................
71
Alternator
........................................................
83
Service Adjustment
Procedures
.....................
77
Battery Charging
........................................
82
Inspection
of Battery ..................................
81
Output Current Test ...................................
78
Regulated Voltage Test ..............................
79
Voltage Drop Test of Alternator Output
Wire ............................................................
77
ELECTRICAL
SYSTEM PARTS LOCATION
...... 2
Diode ...............................................................
5
Fusible Link and Fuse .....................................
6
.......................................................
Grounding
7
Relay and Control Unit ....................................
2
Sensor .............................................................
4
HORN ..................................................................
184
Horn Switch
....................................................
187
IGNITION
SYSTEM
............................................
105
Ignition Switch ................................................
122
Ignition System
...............................................
1 14
Service Adjustment
Procedures
.................... .l 1 1
Checking Ignition System
..........................
11 1
Checking Ignition Timing
...........................
11 1
Spark Plug Cable Test ................................
1 12
Spark Plug Test ..........................................
1 12
NOBAA-
......
9
INSPECTION
OF HARNESS CONNECTOR
Check for Improper Engagement
of
..........................................................
9
Terminal
Continuity and Voltage Test for Connector
.... 9
Engaging and Disengaging
of Connector
Terminal
..........................................................
9
143
LIGHTING
SYSTEM
...........................................
Column Switch ................................
. .............. .I59
Dimmer Control Switch .................................
.I62
Hazard Warning Switch .................................
.I61
Headlight
........................................................
,158
Service Adjustment
Procedures
.................... .I57
Headlight Aiming
.......................................
157
METERS AND GAUGES
....................................
123
Service Adjustment
Procedures
.................... .I30
Fuel Gauge Simple Test .................................
.I31
Fuel Gauge Unit Inspection
...........................
.I31
Oil Pressure Gauge Simple Test .................... .I32
Oil Pressure Gauge Unit Simple Test ............ ,132
Speedometer
Inspection
.I30
...............................
Tachometer
Inspection
..................................
,130
Voltage Meter Simple Test ............................
.I33
Water Temperature
Gauge Simple Test ....... ..I3 1
Water Temperature
Gauge Unit Inspection
. ..I3 2
..........................................
91
STARTING
SYSTEM
97
Starter Motor ............ .......................................
WIPER AND WASHER SYSTEM
.163
.......................
WIRING
HARNESS
............................................
13
Centralized Junction
.......................................
69
Circuit Diagram
...............................................
34
27
Configuration
Diagram
....................................
How to Read Wiring Diagrams
.......................
20
Troubleshooting
..............................................
13
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8-2
ELECTRICAL
ELECTRICAL
SYSTEM
- Relay
and Control
Unit
IPARTS LOCATION
NOIBAB-A
--
Symbol
D
Air conditioner
relay
-Auto choke relay
-Automatic
free-wheeling
unit
16W722
n 17
Heater relay
F
I
F
Automatic free-wheeling
2
\ hub indicator control unit
carburetor
control unit
Air conditioner
d---
Blower
assembiy&
v/i
16W152B
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Jr
relay
I-
EvaporatorE
ELECTRICAL
FI)I
-Headlight h
k\\\
washer
SYSTEM
PARTS LOCATION
relay
Hazard warnina
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8-3
8-4
ELECTRICAL
- Sensor
SENSOR
Symbol
Items
Oxygen
sensor
Pulse generator
--
~~
Water
temperature
sensor
ltw722
Throttle
Ileedometer
16W1506
p
Revision
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position
sensor.
ELECTRICAL
SYSTEM
PARTS LOCATION
8-5
- Diode
DIODE
transmission
1 @NJ22
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light)
oil
ELECTRICAL
SYSTEM
PARTS LOCATION
Symbol
Dedicated
Dedicated
circuit)
I E
A
Multipurpose
fuse
NOTE
For detailed information
concerning
fuses, refer to the section regarding
TION (P.8-69, 70.)
16W722
/ STBI
-Evaoorator
circuit)
levision
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D
the fusible links and
CENTRALIZED
JUNC-
ELECTRICAL
8-7
-Grounding
GROUNDING
Headlight
washer relay,
h
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!Ja
_ .-----
-/
8-8
ELECTRICAL
\\/
16W1512
SYSTEM
PARTS LOCATION
-Grounding
5.
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:.,
INSPECTION
OF HARNESS
CONNECTOR
Inspection
of Harness
8-9
Connector
INSPECTION OF HARNESS
CONNECTOR
CONTINUITY
TOR
AND VOLTAGE
NOECAM
Connect
harness
to
16UO500
ENGAGEMENT
OF TERMI-
16R1317
ENGAGING
TERMINAL
AND DISENGAGING
OF CONNECTOR
COMPUTER
CONNECTOR
(1) Insert screwdriver [1.4 mm (06 in.) width] as shown
figure, disengage front holder and remove it.
8;
:
4
.j _.
16R1319
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in the
8-10
INSPECTION
OF HARNESS
CONNECTOR
Inspection
of Harness
Connector
(3) Insert tip of screwdriver [1.4 mm (.06 in.) width] into connector
in a manner as shown in the figure, raise housing lance slightly
with it and pull out harness.
Housing lance
NOTE
Tool No. 753787-l
of screwdriver.
-5
supplied
16R1321
Needle
16Ffi322
ROUND
WATERPROOF
CONNECTOR
Housing lance
16R1323
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INSPECTION
OF HARNESS
CONNECTOR
RECTANGULAR
Inspection
WATERPROOF
(1) Disengage
front
of Harness
Connector
8-71
CONNECTOR
and remove
it.
Housing
lance
16R13
26
(3) Press contact point of male terminal down by holding a screwdriver [1.4 mm (.06 in.) width] in a manner as shown
in the
figure.
16R1329
INJECTOR
(1) Remove
CONNECTOR
waterproof
cap.
16R1326)
Terminal
lance
16Rl330
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8-12
INSPECTION
OF HARNESS
CONNECTOR
Inspection
of Harness
Connector
(3) Press contact point of male terminal down by holding a screwdriver Il.4 mm (.06 in.) width] in a manner as shown in the
figure.
Caution
Correct lancer to be in proper
inserted into connector.
I
16R132i
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condition
before terminal
is
WIRING
HARNESS
8-13
- Troubleshooting
WIRING HARNESS
TROUBLESHOOTING
NO8DAAA
TROUBLESHOOTING
STEPS
1 1 1 Observation
of Problem
Symptoms
Observe
the symptom
problems.
carefully.
for troubleshooting,
the causes correctly
Check
if there
the problem
and making
b
0,
Determination
of Probable
In determining
the probable causes, it is necessary
to check the
wiring diagram to understand
the circuit as a system.
Knowledge
of switches,
relays and other parts is necessary
for accurate determination.
The causes of similar problems
in the past must be
taken into account.
Causes
Checking
14
1 Repair
of Parts
and
Confirmation
Associated
Troubleshooting
is carried out by making step by step checks until
the true cause is found. Always go through the procedures
considering what check is to be made where for the best results.
with
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8-14
WIRING
HARNESS
- Troubleshooting
INSPECTION
1. Visual and aural checks
Check relay operation, blower motor rotation, light illumination, etc. visually or aurally. The flow of current is invisible but
can be checked by the operation of the parts.
I
2. Simple checks
For example, if a headlight does not come on and a faulty fuse
or poor grounding is suspected, replace the fuse with a new
one or ground the light to the body by a jumper wire to determine which part is responsible for the problem.
1680222
3.
Changeover
knob
1680224
INSPECTION
INSTRUMENTS
instruments.
1680225
2.
Self-power
test lamp
A self-power test lamp consists of a bulb, battery and lead
wires connected in series. It is used to check continuity or
grounding.
,.!?i,
,,
1680226
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WIRING
HARNESS
3.
8-15
- Troubleshooting
Jumper wire
A jumper wire is used to close an open circuit. Never use one
to connect a power supply directly to a load.
1660227
4.
Voltmeter
A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) probe is applied to the point of voltage
measurement and the negative (black lead) probe to the body
ground.
Ground
1680228
5.
Ohmmeter
An ohmmeter is used to.check continuity or measure resistance of a switch or coil. If the measuring range has been
changed, the zero point must be adjusted before measurement.
CHECKING
SWITCHES
ON
ax
Current does not flow
Current flows
ON
-op--
l-2
Current flows
IX
Current does not flow
1680229
pm
#vision
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8-16
WIRING
HARNESS
- Troubleshooting
2.
CONNECTION
SWITCH
figure
illustrates
a complex switch. The switch plates
indicated by solid lines move in the direction of the arrow
when operated.
The continuity between terminals at each position is as indicated in the table below.
This
OFF
1st
stage
2nd stage
3rd stage
1
--_
4th stage
1660230
NOTE
M
denotes
continuity
between
terminals.
16W896
CHECKING
Cover
Coil
Spring
Iron
core
Iron
piece
RELAYS
Contact
1660231
2.
Relav
l-
Battery:
-I
d
T
1660232
3. The relays may be classified into the normal open type and the
normal close type by their contact construction.
state
Energized
I
ED
1
2
3
4
CurreZ!
not flow
state
1
BP
NOTE
The deenergized
state means that no kurrent is flowing
through the coil and the energized state means that current is
flowing through the coil.
2
3
4
1 YZZZw;6B0233
J
.
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WIRING
Normal
Deenergized
close
state
INC) type
Energized
state
Current
-flows
Current
does
HARNESS
8-17
- Troubleshooting
not flow
1680234
CHECKING
FUSES
checking
of
block. The
one lead is
other lead is
so that the
=
1680235
State
of fuse
blown
CAUTIONS
due to overcurrent
IN EVENT
OF BLOWN
FUSE
1660237
State
of fuse
blown
due to thermal
fatigue
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WIRING
HARNESS
- Troubleshooting
CHECKING
1660236
HANDLING
ON-VEHICLE
BAlTERY
When checking or servicing does not require power from the onvehicle battery, be sure to disconnect the cable from the battery
(-)terminal.
This is to prevent problems that could be caused by
shorting of the circuit. Disconnect the (-) terminal first and reconnect it last.
TROUBLESHOOTING
supply
Power
/----
Fuse
ON
Motor
1660239
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WIRING
Power
HARNESS
supply
Fuse block
(remove
fuse)
Test
light
rTJ Switch
Illumination
light
- Troubleshooting
8-19
2. CHECKING
SHORTCIRCUITS
(1) Remove the blown fuse connect the test light to the
disconnected
terminal. The test light should not come
on.
(2) Connect a lead wire of the test light to the power side
of the connector 0. The test light should not come on.
(3) Connect a lead wire of the test light to the load side of
the connector 0. The test light should come on and the
load light should also come on.
(4) Disconnect
the load at the connector
0 and connect
the test light lead wire to the load side of the connector
CD.
The test light should come on and the load light should
also come on.
(5) Connect the test light lead wire to the switch side of
the connecotr
0. The test light should come on.
(6) If the test conforms
to any of the above conditions,
there is a shortcircuit
in the wiring between
the
connector
0 and the connector
0.
4,
1680241
3.
Self
power
test
light
Switch
ON
OFF
CHECKING
CONTINUITY
(I) When the switch is in the OFF position, the self power
test light should come on or the ohmmeter
should read
0 R only when the terminals
2 and 3 are interconnected.
(2) When the switch is in the ON position, the self power
test light should come on or the ohmmeter
should read
0 LR only when the terminals
1 and 4 are interconnected.
1680242
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8-20
WIRING
HARNESS
NOEDBAE
DIAGRAMS
Exampe
: p.!-
f.~~~~
~;~~o,
Connectors unique number
(serial number)
A : Engine compartment
B : Interior and frame
C : Instrument
panel
Main
fusible
link
A-03
A-o4 > 4WD indicator switch
A-05
Automatic
transmission
temperature
switch
oil
indicates
I
Same
diagram
connector
and
the circuit
diagram.
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is located
in the
WIRING
HARNESS
Diagrams
8-21
(2) Identification
of connectors
differing according
to different vehicle specifications
Without wiring harness connectors, the inter-device or -wiring harness connectors which vary in shape or
position on different vehicle specifications are given the specification-dependent
connector identification svmbol (lower case alphabet) after a serial number.
For detailed information on this specification-dependent
symbol, refer to Item (8) under HOW TO READ
CIRCUIT DIAGRAMS.
(3) Indication of standard mounting positions of harnesses
The standard mounting positions of harnesses are shown with the mark * in wiring harness configuration
diagrams.
(4) Indication of ground point
The position of ground points are shown in wiring harness configuration diagrams. For detailed information on
the ground portion, refer to ELECTRICAL SYSTEM PARTS LOCATION (Grounding).
Ground symbol
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8-22
WIRING
HARNESS
How
to
Read
Wiring
Diagrams
DIAGRAMS
are functionally
separated.
Indicates
direct grounding
the device to the bodv.
tion type.
Ignition
*I RL **2-RL
1
BI
L
r------B-39
43
Refer to item
Indicates
that
nectar.
(3)
this
connector
switch
RL
Z-RL
B
BRL*I
RL*2
is a B-39
con-
Dome
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/
/B-6&
RB-
(RG) - (RB)
(REV 1 I (GR)
B-68b
L-2
B-35
I
I
--------_
---__---___----
--------
31103LI
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17
from
WIRING
HARNESS
BO Read
HOW
Wiring
8-23
Diagrams
of centralized
junction
symbol:
A - 01 x
Centralized junction
Connectors unique
Connector symbol
indication symbol
number (serial number)
to CENTRALIZED
1shaoe. etc.
JUNCTION
for connector
-I
Headlight
ignition switch
relay
Dome light
B-68b
II
B-35
P:8-47)
I
BI
0
III-
L
B-39
RL
2-RL
B
IEU
2I
-----____________
- - - - - _ _ _ _ _ __
_ _ _ _ _
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8-24
WIRING
HARNESS
- How
to
Read Wiring
Diagrams
A - Ola
Specification
a : Vehicles
b : Vehicles
c : Vehicles
d : Vehicles
- dependent
connector
identification
with a manual transmission
with an automatic
transmission
with a power window
without a power window
marks.
For distinction
symbol
between
is a specification-dependent connector
identification symbol and indicates that
Ignition switch
Headlight
relay
the connector
is used for vehicles
automatic transmission.
Dome light
B-68a
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with
WIRING
HARNESS
How
to
Read
IDENTIFYING
Position
improper
of guide to prevent
connection
8-25
Diagrams
CONNECTORS
In circuit diagrams,
the connectors
are indicated
by symbolic
marks which show the number of their wires and whether
they
are male,or female connectors.
(1) Number of connector
wires
The number of divisions
in the connector
diagram indicates
the number of wires. A cross in a division, however,
indicates
the position of a guide to prevent improper connection.
The
connector
shown here, therefore,
is a g-wire connector.
fl!liB
9-wire
Wiring
connector
1680219
(2) Identification
of male and female connectors
Connectors
drawn with double outer lines are male, and those
with single outer lines are female.
jpg$&
R
-y
Male
On-vehicle
terminal
connector
Female
terminal
Connector
in
wiring diagram
(3) Connector
direction
The connector
marks show on-vehicle
from the direction shown here.
connectors
as viewed
1680220
(4) Identification
of
The color codes
viewed
at their
illustrated
here.
joining surfaces
so the terminals
NOTE
The color codes
identical.
connector
terminals
of a pair of connectors
(male and female), if
joining surfaces,
will appear symmetrical
as
When the connectors
are connected,
their
are put together in the way a book is closed,
of identical codes are connected
together.
connectors
16R0459
Guide to prevent
connection
Double
male.
@
lines
indicate
(5) Identification
of sealed connectors
Identification
of round, sealed connectors
(water-proof
pin terminal connectors)
used in radiator fan motor circuits, turbo
circuits,
etc. is accomplished
by the same
method
as
described
above.
improper
Numb&ions
Indicates
number
of wires
36KO37
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8-26
WIRING
SYMBOLIC
Various
HARNESS
Diagrams
MARKS
equipment
is indicated
Battery
Body ground
Fuse
Equipment
Fusible link
Motor
symbolically
in circuit idiagrams
as shown
Single bulb
Resistor
Speaker
Coil
below.
Capacitor
Diode
ground
Transistor
4
Crossing of lines
with conron
-1~
1.25 - GB
Code
Wire color
Code
Wire color
Black
Brown
LI
Light blue
Oranqe
Br
1 Gr
Grav
Blue
Light green
Lg
1.25: Wire size (mm2)
F: Flexible wire
T: Twisted wire
I
1
P
R
i
1
I Y I
W
Red
Yellow
White
NOTE
If a cable has two colors, the first of the two color code characters
indicates the basic color (color of the cable coating) and the second indicates the marking color.
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WIRING
OVERALL
WIRING
HARNESS
- Overall
DIAGRAM
Wiring
Diagram
8-27
NOBDC-3
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8-28
WIRING
HARNESS
- Engine
Compartment
1 ENGINE COMPARTMENT
Connector
symbol
AA156
;:::I Main
fusible link
A-53
A-54
A-52
A-28
A-29
A-34
A-35
A-40
Condenser
A-55
A-l 7 Checker
A-18 Diode
A-19 Brake fluid level sensor
A-20 Front harness and back-up light
A-21 land 4WD indicator wiring
harness combination
Sub
fusible link
it;;>
A-24 Carburetor assembly
A-25 Control wiring harness and air
conditioner wiring harness
combination
A-26 Front wiring harness and control
wiring harness combination
A-27 Device box
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A-30
A-31
A-32
A-33
WIRINGA-06
;
,.
,I
A-48
HARNESS
A-14
1 A-15
I,
- Engine
8-29
Compartment
WI
&-ii&
A-39
A-37
A-35
A41
i-$
Ignition coil
A-44
A-45 Magnetic clutch
A-46 Water temperature
sensor (FBC circuit)
;rii}Alternator
A-49 Water temperature switch (Air conditioner circuit)
A-50 Water temperature gauge unit
A-51 Water temperature switch (OD control circuit)
A-52 Oil pressure gauge or oil pressure switch
Low pressure switch
$3
Ai34
A!33
J-3:
36W618
A-55
A-56
A-57
A-58
A-59
Headlight (R.H.)
Front harness and air conditioner
combination
Front combination
light (R.H.)
Front washer motor
Oxygen sensor
wiring harness
Remarks
(1) The mark * shows the reference mounting
position of
wiring harness.
(2) For information
concerning
the ground points (example: q ), refer to P.8-7.
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8-30
WIRING
HARNESS
- Interior
B-01
Be03
and Frame
symbol
B
B-32
B-33
\
B-29
-I2
B-05
\
B-06
B-08
\ B-p7 \
B-p9
B-l 0
1
AB-26
B-27
B-22
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36W617
WIRING
HARNESS
the reference
mounting
position
- Interior
/&}License
plate light (L.H.)
B-19 Back door lock actuator
B-20 Rear combination
light (L.H.)
B-21 Fuel gauge unit
B-22 Rear side marker light (L.H.)
B-23 Front wiring harness and frame wiring
combination
;:g
E$
:::g>
B-30
B-31
B-32
B-33
of wiring
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8-31
and Frame
harness
8-32
WIRING
3 INSTRUMENT
Connector
HARNESS
- Instrument
Panel
PANEL
c-04
symbol
C-06
C
C-65
C-64
C-63
C-61
Remarks
For information
refer to P.8-7.
concerning
the ground
points
(example:
d54
c!5
),
C-08 Diode
C-09 Rear wiper and washer switch
r&~}Oil
pressure gauge
C-12 f;hybination
gauge illumination
$:;;IThermostat
$:;;IFeed back
meter
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WIRING
cy50
C149
Cl48
HARNESS
- Instrument
Panel
c-47
El$,}Cigarette
lightet
C-43 Cigarette lighter illumination light
E::$ Radio
C-46 Shift position illumination light
C-47 Inhibitor switch
C-48 OD-OFF switch
C-49 Parking brake switch
C-50 Seat belt switch
C-51 Hazard switch
Column switch
C-54 Key reminder switch
C-55 Ignition switch
C-56 Stop light switch
E3
Ision
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8-33
8-34
WIRING
MARNESS
1 STARTING CIRCUIT
(VEHICLES WITH A MANUAL
- Starting
Circuit
TRANSMISSION)
Ignition
switch
TA RT
Battery
Main
link
@.25B+
L1!
zcl
fusible
A-23
mw BY
M
2
M
I
7 A-15
BIT/B
F=
Starter
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37W620
WIRING
HARNESS
Battery
-p
8-35
Circuit
TRANSMISSION)
A-23
Main
fusible
link
- Starting
Ignition
switch
lrrilI
1.25-B
-5-w
A-02
U
c-47
a 1 2-BY
Ia- 1
2-BY
1
Inhibitor
switch
N
2-BY,2-BY*2
2-BY
2-BY*l
P
BYBY
fTl
37W613
Remark
For information concerning
the ground
refer to P.8-7.
Wiring color code
Br: Brown
8: Black
LI: Light blue
0: Orange
points (example:
G: Green
P: Pink
0 ).
Gr: Gray
R: Red
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L: Blue
Y: Yellow
8-36
WIRING
2 IGNITION
HARNESS
- Ignition
Circuit
CIRCUIT
A-23
Main
fusible
link
Batterv
Sub fusible
(IGN * SW)
link
Ignition
switch
IR
I
i
r
mw
Distributor
To combination
meter
(TACHO)
[Refer to P.8-52.1
J A-44
37W609
Remark
For information
refer to P.8-7.
concerning
the ground
Br: Brown
0: Orange
points
(example:
G: Green
P: Pink
),
Gr: Gray
R: Red
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L: Blue
Y: Yellow
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WIRING
3 CHARGING
HARNESS
- Charging
8-37
Circuit
CIRCUIT
Ignition
switch
.n
Main
fusible
link
Battery
I
3
cl
m L
A-02
A-23
,
I81
m
3
c:
-22
3
c!J
t
El
A-48
Alternator
Comornatron
Remark
For information
refer to P.8-7.
concerning
the ground
Br: Brown
0: Orange
points (example:
3
a
I
6
Multipurpose
fuse
meter
37W605
),
Gr: Gray
R: Red
G: Green
P: Pink
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L: Blue
Y: Yellow
8-38
WIRING
HARNESS
Battery
Main
fusible
link
Feed
Back
Carburetor
Circuit
CIRCUIT
m
A-02
efl
EEI
j
i
-1.25-B-
Sub fusible
link
Ignition
BW
switch
uA-2i
I
I:
h
A-28
zix--I
c:
qi
To alternator
[Refer to P.8.37.1 1
-26c-1
ziE2
BW ".
r
Feed back
solenoid valve
YG
1.25-BW"'
Slow cut
solenoid valve
2-BW wQ
I
I
YL
1.25-BW*'
yL ,0
P
Auto choke
heater
-hrottle
iensor
position
1 A-24
Carburetor
assembly
Remarks
(1) For information
concerning
the ground points (example:
0). refer to P.8-7.
(2) The symbols 0, 0 etc. indicate that the wiring is connected (using the same numerical symbol) to the facing
page. (In other words, 0 on the right page is connected to
0 on the left page.)
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WIRING
HARNESS
8-39
Circuit
Ignition
coil
) _ ,E3
$-To
A-42
A-4
vacuum
solenoid
BR
cl
c-2 Af r
I
I
I
I
I
;
:
;
:
0.85-BW
YG
YL.
I
RW,
II
II
(I
A-4
A-9
A-3
A-6
A-5
B-l 1
B-6
B-9
B-IO
I
I I- - - - -. -_ __ __
L---__._._
1I ! !
I i-----,
+L----J
Feed back
carburetor
control unit
B
B-l
B-2
B-l 2
B-3
B-13
B-8
B-7
B-5
Vacuum
switch
Device
box
control
A-46
Water
temperature
sensor
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solenoid
8-40
WIRING
HARNESS
- Layout
of Components
WC)
CD
II
\\
5FU131
Items
Items
Symbol
Slow-cut
solenoid valve
(Ignition coil 0)
control unit
Throttle
Oxygen sensor
Vacuum switch
Secondary
Throttle
solenoid
opener
valve
position sensor
1 Water temperature
contr
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Symbol
sensor
D
A
WIRING
sensor
US) /
control
HARNESS
- Layout
of Components
5FUl
unit
w1515
1/
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(FBC)
8-41
8-42
WIRING
5 OVERDRIVE
HARNESS
CONTROL
- Overdrive
Control
System
Circuit
SYSTEM CIRCUIT
/ Sub
fusible
link
Ignition
$in
switch
fusible
To combination
meter
[Refer
to P.8-52.1
To alternator
[Refer
to P.8-37.1
0.85-W
To column
[Refer
to
0.85-RL
switch
P.8-51.1
0.85-W
i
Remarks
(I)
For information
concerning
the ground
points
(example:
0).
refer
to P.8-7.
(2)
The
symbols
0,
0,
etc.
indicate
that
the
wiring
is
connected
(using
the same
numerical
symbol)
to the
facing
page.
(In other words,
0 on the right page is connected
to 0 on
the left page.)
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Combination
RLI
1 IyRw
-7
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meter
4
1 1 I
WIRING
HARNESS
- Overdrive
Control
System
8-43
Circuit
*I
Inhibitor
Water
temperature
switch
OD-OFF
relav
C--63
RL
)
To back-up light
[Refer to P.8-45.1
2-BY
9
3
4
5
To starter relay
[Refer to P.8-34, 35.1
IA-12 @@
VRR
r
A-05
Automatic
transmission
oil temperature
switch
switch
OD-OFF
solenoid
llR)3
[RILRI
-10
G: Green
P: Pink
G;; ;ZJ
L: Blue
Y: Yellow
1 STB Revision
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37w019
8-44
WIRING
HARNESS
Sub
EiT
n1.25-Bn
fusible
link
II
Main
fusible
link
To turn-signal
flasher
unit
O-85-RL
i
I
I
I
Inhibitor
switch
A-09
combination
i
1
I
I
combination
000
Back-up
switch
light
Em
Wiring
color
code
g: Black
Ll: Light
blue
Br:
0:
Brown
Orange
G: Green
P: Pink
Gr: Gray
R: Red
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
WIRING
HARNESS
Tail Light,
Position
License
Plate
Light
Light,
Rear
and Back-Up
Side Marker
Light.
Light Circuit
8-45
fl!FEEl
Column
switch
Lighting
switch
Light control
relay
F-GW -GW
B-l 2
B-l 1
Tail light
Tail light
Back-up
light
Rear
$ combination
light
(R.H.)
RG
RI.G
El3
Tail light
Tail light
Back-up
light
I
Remarks
(1) The broken lines are applicable to models equipped wrtn
an automatic transmission.
(2) For information
concerning
the ground
points (example: 0 ). refer to P.8-7.
(3) The symbols
0, 0, etc. indicate that the wiring is
connected
(using the same numerical
symbol) to the
facing page.
(In other words, 0 on the right page is connected to 0 on
the left page.)
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GW
IBl
Rear side
B-22
37W023
Rear
combination
fight
(L.H.)
8-46
WIRING
HARNESS
Headlight
Circuit
1
7 HEADLIGHT
CIRCUIT
M-!l
Battery
-1.25-B1
Main
link
R
YR
il II viI!Ii
Sub fusible
link
A-02
5-w
5-w m5-w
M 0.5-G
2-R
U
A-23
fusible
2-B
71' 0
[ES
$$J
A-33
Dedicated
1 c-05
fuse
BEAM
1 ('R;
J
Combination
meter
I w
C-52
-32
A-34
Light
relay
control
Lighting
switch
Dimmer
switch
Column
Remark
For information
concerning
the ground
POintS
(example: 0 ), refer to P.8-7.
Wiring color code
B: Black
Ll: Light blue
A-55
Br: Brown
0: Orange
Passing
switch
(L.H.)
switch
(R.H.)
Headlight
37W621
9
G: Green
P: Pink
x2
m
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
WIRING
HARNESS
- Dome
8-47
Circuit
Light
A-02
Battery
1.25-B
\
3
Main
fusible
Sub
5-w rl5-w
u
2-w
fusible
link
0.5-G
2-R
A-23
link
To column
[Refer
to
Multi-purpose
fuse
switch
P.8-46.1
1.25-GB
2-R
&
m
At
Combination
meter
1.25-GB
To hazard
flasher
unit
[Refer
to P.8.49.1
I--
C-27
B-01
Dome
light
(L.H.)
(R.H.)
Door
switch
37W620
Remark
For information
refer
to P.8-7.
Wiring
B: Black
LI: Light
color
blue
concerning
the
ground
points
(example:
),
code
Br: Brown
0: Orange
G:
P:
Green
Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
8-48
WIRING
HARNESS
9 TURN-SIGNAL
AND
A-02
a3
1.25-B-
Main
fusible
Hazard
Light
Circuit
LIGHT CIRCUIT
Sub fusible
link
0.5-G
A-23 5-W
l-l
(5-W
Turn-Signaland
HAZARD
1
m
Battery
1 81
El3
Ignition
2-R
switch
2-W
link
A-32
GW To lighting
switch
e [Refer to P.8-46.1
2-R
2-RW
I-
2-B
To column switch
[Rear to P.8-461
'I
7
l.ZS-tit3
0.85-GY
+a
I_ \
(Bl -6
0.85-GL
LO
Gw -@
rn&
lzil
A-57
Turn-signal
and
hazard light
Front
Turn-signal
and
hazard light
Front
combination
light (R.H.)
el
n00
STB Revision
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b-d
5
c-05
J CL
--.
I- \I--
IG
Combination
meter
WIRING
HARNESS
- Turn-Signal
and
OR
0 RI.
Turn-signal
Turn-signal
flasher
unit
I
I
switch
Hazard
GO
0 0.3
iazard
Hazard
flasher
unit
r
E
L:
ci
Light
8-49
Circuit
switch
*2
C-62
Turn-signal
and hazard
->
&
light
Rear Combination
light (R.H.)
light
Rear combination
light (L.H.)
mm
c-57
Dimmer
switch
control
OL
Em B
WL
EJ
Br: Brown
0: Orange
37W825
-2
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
STB Revision
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8-50
WIRING
HARNESS
- Stop Light
Circuit
1
In3
Sub
fusible
link
A-07
Main
link
fusible
Multi-purpose
fuse
0.85-GR
0.85-G
c-51
0.85-G
Hazard
switch
1.85-WG
$R
WL
1 1 1
,I
,I
Turnsignal
switch
Rear
light
Remark
For information
refer
to P.8-7.
concerning
Wiring
color
code
B: Black
LI: Light
blue
the
Br: Brown
0: Orange
ground
points
(example:
G: Green
P: Pink
cdmbination
(L.H.)
Rear
light
c:mbination
(R.H.)
),
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
WIRING
HARNESS
11 INSTRUMENT
Instrument
Panel
Wumination
PANEL ILLUMINATION
Battery
CIRCUIT
Sub fusible
5-w
Main
fusible
5-w l-75-W
LA-23
8-51
Circuit
link
0.5-G
2-R
link
@L
CA
M
A
A-22
rx
c-l
Y$lO
I
Optical
fiber
Multi-purpose
fuse
control
illumination
0
3
a
.ight contr
clay
c-4o1l
knob
light
Combination
gauge
Illumination
ligl
control
switch
&01BY
7t
Shift-position
lmer
C-38
4
Ashtray
illumination
Cigaretty
lighter
minagn
n+
Hegpane
illumination
light
63
_
Clock I
illumination
1 STB Revision
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Combination
illumination
light
meter
light
37w '62;
L: Blue
Y: Yellow
WIRING
HARNESS
- Meter
Circuit
12 METER CIRCUIT
1
m
A-02
Sub fusible
link
Ignition
switch
15-w
Main
link
fusible
--
A-22
1
m
-ffiFirmer
control
[Refer to P.8-511
I 0 column :
[Refer to P.E
BY
4
@/
Multi-purpose
fuse
To turn,signal
switchfd,,, (bYI ,
[Refer to P.8-491
1
To seat belt timer
[Refer to P.8-661
G 1
To seat belt warning
buzzer [Refer to P.8-661 M
I
To alternator
0.85tW
fRefer to P.8-371 41D\ 1
o dimmer, passir, ,, ,
witc :h and light control Ir r n ! , I
~ -_
clay [Refer to P.8461
Kb
To dome light
[Refer to P.8-471 4
To door yi~,h,,_(RG)
I
I
ID,.&-* +,.
YBdD
q
3_---_-ly-J
Ir
t
Combination
1 STB Revision
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meter
WIRING
HAFNESS
Meter
8-53
Circuit
O&y-ssure
[Eal
> El
Oil pressure
gauge unit
YRB BRYR
ElxQ
A-20
I.+
A-03
A-06
4WD
indicator
--
.-
I
I
I
E
I
I
*
- -,,-
--
YB
L,
I
4
Brake fluid
level sensor
0.85-B
Jo
cigarette lighter
[Refer to P.8-621
-I m-w
I
I
k-1
A-04
A-07
rA
fs
Ei
switch
Parking
switch
? I
brake
I
I
I
I
I
I
1
' 1
I
I I
I 1
B-23
, I I I
I !
Fuel gauge
unit
Water
temperature
gauge unit
37W617
Combination
gauge
to@ontheleft page.)
Wiring color code
B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
8-54
HARNESS
WIRING
- Horn Circuit
13 HORN CIRCUIT
/I
1
m
Battery
Sub fusible
A-23
5-w/-75-w
m 0.5-G
Main
fusible
link
Ignition
switch
Z-W
link
OFF
]AM
ACC]
Multi-purpose
fuse
a
-i
::
C
To wiper motor
[Refer to P.8-59.1
A-3
Column
A-39
switch
37W608
Remark
For information concerning
the ground
refer to P.8-7.
Wiring color code
Br: Brown
B: Black
LI: Light blue
0: Orange
points (example:
G: Green
P: Pink
),
GI.: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
WIRING
HARNESS
Heater
8-55
Circuit
14 HEATER CIRCUIT
*I BI
l!zEl
lonition
switch
Battery
0
(Ignition
switch)
Multi-purpose
fuse
To turn
signal
flasher
[Refer
to P.8-49.1
unit4
-P---
H
M2
Ml
bFF
0.85-RL
Blower
motor
C-18
Blower
!!
i
\
Blower
resistor
switch
motor
LBLI
LRLW
El3
I
Heater
relay
8L
LRLR
El *2
*1
37W614
Remark
For information
concerning
refer
to P.8-7.
Wiring
color
code
B: Black
LI: Light
blue
the
Br: Brown
0: Orange
ground
points
G:
P:
(example:
Green
Pink
),
Gr: Gray
R: Red
STB Revision
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L: Blue,
Y: Yellow
Lg:
W:
Light
White
green
8-56
WIRING
HARNESS
15 AIR CONDITIONER
- Air Conditioner
Circuit
CIRCUIT
Ignition
Main
fusible
I;..,,
Sub fusible
(Fuse B)
m
1
switch
link
+2
0.85-R
(lonition
switch)
,!..I
unit ~ 0.85-RL
L
I
3-LRwQ
,0.85-LW
To cigarette
lighter
[Refer to P.8-62.1
0.85-WB@
FA2
Ml
Ii
Blower
Br: Brown
0: Orange
1C-18
bFF
Blower
motor
8
I
IY4JYl!!!a
f
1
switch
G: Green
P: Pink
lower
motor
Gr: Gray
I?: Red
T-
L: Blue
Y: Yellow
Heater
relay
STB Revision
II/
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WIRING
HARNESS
- Air
Conditioner
8-57
Circuit
B 0.3
LvfL
ElFI
Air conditioner
relay
*2
Air :on!$!er
85-Bw:o.85-Bw
0
0:
) control
u
A-25
(Bl
rela
Lw
20.85-BWr
ll 10.85-BWL&
A-13
Vacuum
valve
solenoid
@,0.85-WB
A-45
0.85-BWnBW
Is*la
Magnetic
clutch
(compressor)
Condenser
blower motor
Condenser
blower
motor relay
Water temperature
switch
BY
rl
-I37W611
Remarks
(1) For information
converning
the ground
points (example:(l)n),
refer to P.8-7.
(2) The svmbols
0, 0, etc. indicate that the wiring
is
connedted
(using the same numerical
symbol) to-the
facing page. (In other words, 0 on the right page is
connected
to 0 on the left page.)
) STB Revision
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8-58
WIRING
HARNESS
- Wiper
Circuit
Washer
LW
1
m
CIRCUIT
IL&
Battery
and
Sub fusible
Ignition
link
-1.25-BAs2
Main
fusible
switch
2-R
5-w r--(5-w
Z-W
link
To lighting
switch
Light
control
relay
Multi-purpose
fuse
I-2-B
Intermittent
wiper
control
relay
Remarks
(1) For information concerning the
ground points (example: q ).
refer to P.8-7.
(2) The symbols 0.0, etc. indicate
that the wiring is connected (using
the same numerical symbol) to the
facing page.
(In other words, 0 on the right
page is connected to 0 on the left
page.)
C-64
Headlight
washer motor
Wiring
I
1
Headlight washer
motor relay
color code
B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
/ STB Revision
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WIRING
HARNESS
m --
- Wiper
and
Column switch
FronthiDer
switch
Washer
8-59
Circuit
-1
BP
118 B
f!EEl
Headlight
washer
switch
I
-_I
z-09
c-53
@4-zo-(YL)
@JY'
@- BR
@- Lw
-1 j
A-14
I
1A-58
Frontwasher
motor
Front wiper
motor
Rearwasher
motor
WB
Q I.
Rear wiper
motor
37W024
1 STB Revision
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S-60
WIRING
HARNESS
17 RADIO/CASSETTE
Battery
A-02
/ Cassette
Deck
Circuit
DECK CIRCUIT
L1
1
EQ3
1
lm
Ignition
Sub fusible
1.25-B
A-23
\
rlin
- Radio
5-*5-w
link
0.5-G
2-w
fusible
To light control
relay
[Refer to P.8-461
To air conditioner
[Refer to P.8-561
To combination
4
meter
[Refer to P.8-521
BY
DIN Cable
JC
3:
A-C-1
Tape
Radio
player
1 STB Revision
-7
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switch
WIRING
HARNESS
- Radio / Cassette
8-61
Deck Circuit
(R.H.)
Front speaker
1
(L.H.)
Rear speaker
37W618
Remarks
(1) For information
concerning
the ground points (example: 0 ), refer to P.8-7.
(2) The symbols 0, 0, etc. indicate that the wiring
is
connected
(using the same numerical
symbol) to the
facing page.
(In other words, 0 on the right page is connected to 0 on
the left page.)
Wiring color code
Br: Brown
G: Green
Gr: Gray
B: Black
I?: Red
P: Pink
LI: Light blue
0: Orange
1 STB Revision
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L: Blue
Y: Yellow
8-62
WIRING
18 CIGARETTE
HARNESS
Cigarette
Lighter
/ Clock
Circuit
fusible
r-l E-f?
Ignition
link
)
switch
-u
yn;in
fusible
7-R
To light control
[Refer
to P.8-461
To radio
[Refer
to
To hazard
[Refer
to
flasher
P.8-491
\*I
relay
GW
P&601-,
unit4
3FI .LJ-
Pm
G
Multi-purpose
II
illumination
fuse
light
To heater
illumination
[Refer
to
control
light
P.8-511
Clock
1
J
h
6
CT
0:
Jc-36
To combination
[Refer
to P.8-521
Wiring
B:
Br:
G:
Gr:
L:
Lg:
Black
Brown
Green
Gray
Blue
Light
color
mete&
BY
code
green
LI:
0:
P:
H:
Y:
W:
Light
Orange
Pink
Red
Yellow
White
blue
To dimmer
[Refer
to
control
P.8-511
switch
Remark
For information
refer
to P.8-7.
http://vnx.su/
BY
concerning
the
ground
points
(example:
1,
WIRING
19 DEFOGGER
HARNESS
- Defogger
CIRCUIT
Sub fusible
A-23
5-wn5-w
ynlin
8-63
Circuit
0.5-G
I ml
EEH
link
Ignition
fusible
switch
z-w ,
A
I
l%
7
N
(#IO
-22
To light control
~-RN
w
relay
[Refer to P.8-461
+!I00
Defogger
1.25-B
m
I
Ki .
4
1.25-BR
B-05 /
B
Q
z
A
pFJ
Bg
L-l
2-FB m
Multi-purpose
@fuse
3-B
B-13
BR
Q
m
of
A
To column switch
[Refer to P.8-461
LY!ii!T
Rheostat
x7.
Remarks
For information
refer to P.8-7.
concerning
the ground
points
Detogger
*I
switch
(example:a),
37W62
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
8-64
WIRING
20 POWER WINDOW
HARNESS,
Power
Window
Circuit
CIRCUIT
w
EEH
Ignition
- ..
I
81
switch
II
1.25-B
Main
link
fusible
Multipurpose
fuse
[Refor to P.8-491
, I-
(RL)
2-LR bg
Power window
main switch
-I
*1 1.25-R
*2 1.25-G
Remarks
(I) For information
concerning
the ground
points (example:m). refer to P.8-7.
(2) The symbols 0, 0, etc. indicate
that the wiring
is
connected
(using the same numerical
symbol) to-the
facing page.
(In other words, 0 on the right page is connected to 0 on
the left page.)
1 STB Revision
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1.25-R
1.25-G
,@
,@
WIRING
R
B0
Power
motor
window
(L.H.)
bM
B-31
c
::
r
HARNESS
- Power
2-B
,
r
>
.I.
-I
Window
8-65
Circuit
To colunm switch
[Refer to P.8-511
washer relay
[Refer to P.8-581
Power
window
relay
IRL)
:=2-L,
04 2-L
g:
2-B
2-RL
Power window
sub switch (R.H.)
1.25-R
@*1.25-G
8*
37w003
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
8-66
WIRING
HARNESS
Buzzer
Circuit
21 BUZZER CIRCUIT
nil1
Battery
-1.25-B
A-02
Sub fusible
I 01
IT8
link
Ignition
switch
0
Main
link
fusible
dhm
b-
Multi-purpose
OR Key reminder
A0 switch
[Refer to P.8-491
c-03 r
C
-CCl
z-CY
z-
m
c-50
P-P
mm-l
aa-cd
-.A
IC
-J
ski&t
switch
I.5
bb
Key reminder
and seat belt
warning
buzzer
Combination
meter
Seat belt
warning timer
Remark
For information
refer to P.8-7.
37W607
concerning
the ground
Br: Brown
0.: Orange
points
(example:
G: Green
P: Pink
),
Gr: Gray
R: Red
1 ST9 Revision
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L: Blue
Y: Yellow
WIRING
HARNESS
Automatic
Free-Wheeling
FREE-WHEELING
Battery
-5-w
Main
link
Indicator
System
HUB INDICATOR
Sub
171.
Hub
fusible
Circuit
B-67
SYSTFM
link
1 m2-G
fusible
rgntrron
Iz-w
- _I
swrtcn
ON
Pulse
generator
Multi-purpose
fuse
To column
[Refer
to
switch
P.8-461
::
0:
2I
I++m
c-07
Vehicle
speed
detective
circuit
Pulse
detective
circuit
EleAtrir
circuit
power
d&V+
LR
m
m
,:cAcJl
!!I
T-r-
q OE!
z-
C-06
-.I;
c-04
Combination
meter
Automatic
indicator
For information
refer
to P.8-7.
Wiring
B: Black
LI: Light
color
blue
free-wheeling
control
unit
concerning
the
ground
hub
37W610
points
(example:
).
code
Br: Brown
0: Orange
G: Green
P: Pink
,;:
;;;Y
STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
WIRING
HARNESS
Battery
Sub fusible
link
Multi-purpose
fuse
1.25F-G
-1.25-G
1.25F-R
2-LR -To
1.25-R
2-B
B-l 2
cza
I I
xx. .
77
B-24 [
cLL3
ALA
CVN
. .
77
-To
heater relay
[Refer to P.8-551
column switch
[Refer to P.8-511
Back door
lock actuator
Remark
For information
refer to P.8-7.
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
/ STB Revision
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37W602
concerning
the ground
points (example:
),
WIRING
HARNESS
- Centralized
896!
Junction
CENTRALIZED JUNCTION
Main
Fusible
Link
Circuit
Cable color
mm (ir?.)
continuous
Fusing current
Sub Fusible
current
40
190
Link
Circuit
Cable color
Fusible link size
mm7 (in.2)
continuous
Fusing current
Dedicated
1.25 (.0019)
A
Item
Permissible
circuit
Black
Alternator
Main circuit
current
Lighting circuit
Ignition circuit
Green
0.5(.0008)
Red
Green
0.85(.0013)
27
34
0.5(.0008)
27
100
150
100
Power window
circuit
Green0.5(.0008)
27
100
Fuse
Upper beam indicator circuit
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Air conditioner
cixit
WIRING
Multi-purpose
Power
- Centralized
Junction
Fuse
supply circuit
Battery
Headlight
HARNESS
relay
Ignition switch
(IG)
Battery
Ignition switch
(ACC)
Fuse No.
Rated
capacity A
Applicable
20
10
10
IO
15
20
15
Key-reminder
15
Windshield
Intermittent
10
Rear window
10
15
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circuits
switch,
flashers
Headlight
washer
relay,
and washer
CHARGING
CHARGING
SYSTEM
General
8-71
Information
SYSTEM
GENERAL INFORMATION
NOBEMD
light
:--\;-----------I
I.C.
-A
I.C.
regulator
alternator
-y
I
6EL239
Drive
-belt
Brush
heat
-sink
pulley
Rotor
assembly
Stator
6EN246
1 STB Revision
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6EN211
8-72
CHARGING
SYSTEM
- General Information
MAINTENANCE
Test indicator
The maintenace-free
battery is, as the name implies, totally
maintenance
free and has no removable
battery cell caps.
Water
never needs to be added to the maintenace-free
battery.
The battery is completely
sealed, except for small vent holes in
the cover, These vent holes allow what small amount
of
gasses are produced
in the battery to escape. The special
chemical composition
inside the battery reduces the production of gas to an extremely
small amount at normal charging
voltages. The battery contains a visual test indicator
which
indicates
the condition
of the battery.
( ST6 Revision
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CHARGING
SYSTEM -Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
ALTERNATOR
NOOEB-B
Specifications
~-Battery voltage sensing
Items
Type
Model No.
A2T03477
Part No.
MD1 10318
Rated output
12150
VIA
Voltage regulator
BAlTERY
Specifications
Items
Type
Ampere hours (5 HR) Ah
55824R (S)-MF
36
Cranking
420
75
NOTES
1. CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 or
greater at a specified temperature.
2. RESERVE CAPACITY RATING is the amount of time a battery can deliver 25 A and maintain a minimum terminal
voltage of 10.5 at 26.7C (80F).
SERVICE SPECIFICATIONS
NOBEC-
Specifications
Items
Standard values
Regulated voltage
Ambient
- 20C ( - 4F)
14.2-15.4
20C (68F)
13.9-14.9
60C (140F)
13.4-14.6
80C (176F)
13.1-14.5
23 (.906)
mm (in.)
3.1
Limit
Output current
Slip ring O.D.
Min. 35
22.2 (.874)
mm (in.)
[ STB Revision
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8-74
CHARGING
SYSTEM -Specifications
TORQUE SPECIFICATIONS
items
__-
Nm
ft.lbs.
Alternator
brace bolt
12-15
9-l 1
Alternator
support
20-22
14-16
bolt nut
High pressure
hose nut
20-25
14-18
Low pressure
hose nut
30-35
22-25
1 STB Revision
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CHARGING
8-75
SYSTEM -Troubleshooting
TROUBLESHOOTING
NOBEH-
Symptom
Probable cause
Remedy
Reference
we
Fuse blown
Check fuses
8-70
Replace light
loose
8-79
Refer to
GROUPS.
8-8 1
Fuse blown
Check fuses
8-70
8-69
Electronic
faulty
Test alternator
8-77
8-79
Wiring faulty
Repair wiring
Refer to
GROUP 9.
Wiring connection
t
Run-down
or worn
battery
or
Poor grounding
1 Repair
I
Overcharge
8-69
I-I
Electronic
faulty
Test alternator
8-77
8-79
Decrease
in life of battery
Replace battery
8-81
8-79
STB Revision
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8-76
CHARGING
3 CHARGING
SYSTEM
- Circuit
Diagram
CIRCUIT
Ignition
switch
OFF
IAM
Main
fusible
link
fl.3-Br
Battery
3
A
m L
A-02
1~5~~
Sub fusible
(IGN . SW)
A-23
IG
] c-55
m
A
link
Multin, Irnn4P
ComSeter
Remark
For information
refer to P.8-7.
concerning
the ground
Br: Brown
0: Orange
points (example:
G: Green
P: Pink
37W605
),
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
CHARGING
SYSTEM
Service
Adjustment
SERVICE ADJUSTMENT
INSPECTION
8-77
Procedures
OF THE CHARGING
PROCEDUREswmAB
SYSTEM
Preparation
(1) Turn the ignition switch to OFF.
(2) Disconnect the battery ground cable.
(3) Disconnect the alternator output lead from the alternator B
terminal.
(4) Connect a DC ammeter
(0 to 100 A) in series to the B
terminal and the disconnected
output lead. Connect the (+)
lead of the ammeter to the B terminal and the (-) lead to
the disconnected
output wire.
lEL15I
NOTE
Use of a clamp type ammeter that can measure current without disconnecting
the harness is preferred. The reason is that
when checking a vehicles that has a low output current due to
poor connection of the alternator B terminal, such poor connection is corrected as the B terminal is loosened and a test
ammeter is connected in its place and as a result, causes for
the trouble may not be determined.
(5) Connect a digital voltmeter between the alternator B terminal and battery (+) terminal. Connect the (+) lead wire of the
voltmeter
to the B terminal and the (-) lead wire to the
battery (+) terminal.
(6) Connect the battery ground cable.
(7) Leave the hood open.
Test
(1) Start the engine.
(2) Turn on or off the headlights and small lights and adjust the
engine speed so that the ammeter reads 20 A and read off the
voltmeter indication under this condition.
Result
(1) It is okay if the voltmeter indicates the standard value.
( STB Revision
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8-78
CHARGING
SYSTEM
- Service Adiustment
Procedures
OUTPUT CURRENT
TEST
This test judges whether or not the alternator
current that is equivalent to the nominal output.
gives an output
Preparation
(1) Prior to the test, check the following items and correct as
necessary.
(a) Check the battery installed in the vehicle to ensure that it
is in sound state*. The battery checking method is described in BATTERY.
NOTE
*The battery that is used to test the output current should
be one that has been rather discharged.
With a fully
charged battery, the test may not be conducted correctly
due to an insufficient load.
(b) Check tension of the alternator drive belt. The belt tension
check method is described in GROUP
7 COOLING
Service Adjustment
Procedures.
(2) Turn off the ignition switch.
(3) Disconnect the battery ground cable.
(4) Disconnect the alternator output wire from the alternator B
terminal.
80A
Iad
Voltmeter
Ammeter
176
as a heavy
[ STB Revision
--I
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CHARGING
SYSTEM
- Service Adjustment
8-79
Procedures
Result
(1) The ammeter reading must be higher than the limit value. If it
is lower but the alternator output wire is normal, remove the
alternator from the vehicle and check it.
Limit
value
: 31 A min.
Caution
1. The nominal
output
current value is shown on the
nameplate
affixed to the alternator
body.
2. The output current value changes with the electrical
load and the temperature
of the alternator
itself.
Therefore, the nominal
output current may not be obtained if the vehicle electrical load at the time of test is
small. In such a case, keep the headlights
on to cause
discharge of the battery or use lights of another vehicle as a load to increase the electrical load. The nominal output current may not be obtained if the temperature of the alternator
itself or abmient temperature
is
too high. In such a case, reduce the temperature
before testing again.
(2) Upon completion of the output current test, lower the engine
speed to the idle speed and turn off the ignition switch.
(3) Disconnect
the battery ground cable.
(4) Remove the test ammeter
and voltmeter
and the engine tachometer.
(5) connect the alternator output wire to the alternator
B terminal.
(6) Connect the battery ground cable.
REGULATED
VOLTAGE
TEST
voltage
Preparation
(1) Prior to the test, check
essary.
the following
items
and correct
if nec-
1 ST6 Revision
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8-80
CHARGING
SYSTEM
- Service
Adjustment
Procedures
e
Ignition
switch
Load
Alternator
Ammeter
Voltmeter
I
@
lid-hi!
6EK52
1 STB
voltage
table
Regulating voltage V
(-4)
14.2-15.4
20 (68)
13.9-14.9
60 (140)
13.4-14.6
80 (176)
13.1-14.5
Revision
http://vnx.su/
CHARGING
SYSTEM
- Service Adjustment
Procedures
8-81
INSPECTION
VISUAL
OF BATTERY
INSPECTION
OF BATTERY
NOBEIBA
(1)
The batten/ contains a visual test indicator which gives blue signal
when an adequate charge level exists, and white signal when
charging is required.
VISUAL
ll3Y1848
INSPECTION
OF BAlTERY
(2)
Make sure ignition switch is in Off position and all battery feed
accessories are Off.
1. Disconnect ground cable from battery before disconnecting
(+) cable.
2. Remove battery from vehicle.
Caution
White
I
Blue
I
3.
4.
5.
6.
7.
8.
9.
10.
1 STB Revision
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8-82
CHARGING
SYSTEM
- Service
BATTERY
Adjustment
Procedures
CHARGING
NOEEICDZ
Caution
When batteries
are being charged, an explosive
gas forms
beneath the cover of each cell. Do not smoke near batteries
on charge or which have recently
been charged.
Do not
break live circuits
at the terminals
of the batteries
on
charge. A spark will occur where the live circuit is broken.
Keep all open flames away from the battery.
Battery electrolyte
temperature
may temporarily
be allowed to
rise to 55C (131F). Increase of electrolyte
temperature
above
55C (131F) is harmful to the battery, causing deformation
of
battery cell, decrease in life of battery, etc.
CHARGE
RATE
If the test indicator is white, the battery should be charged as
outlined
below.
When the dot appears or when maximum
charge shown
below is reached, charging
should be stopped.
NOTE
If the indicator does not turn to blue even after the battery is
charged, the battery should be replaced;
do not overcharge.
Charge
Rate Chart
Battery
55B24R (S)-MF
(420 amps)
Slow Charging
Fast Charging
/ STB Revision
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CHARGING
SYSWVI
- Alternator
8-83
ALTERNATOR
REMOVAL
AND
INSTALLATION
(Vehicles
without
Air Conditioner)
NOEEJAE
0 Adjustment
of the Drive Belt Tenslon (Refer to GROUP 7 COOLINGService Adjustment
Procedures)
Removal
I)+
steps
1. Connection
of alternator
connector
2. Alternator
3. Shim
4. Support bolt
5. Brace
NOTE
(I) Reverse
(2)
the removal
: Refer
to
Service
9-11
<I
16W1565
procedures
Points
ft.lbs.
to
of
reinstall.
installation.
SERVICE
POINTS
OF INSTALLATION
2. INSTALLATION
OF ALTERNATOR
(1) Position the alternator and insert the support bolt. (Do not
attach the nut.)
(2) Push the alternator
forward and determine
how many
spacers
[thickness:
0.198 mm (.0078 in.)] should
be
inserted between the front leg of the alternator
and the
front case (space A in the illustration).
(There should be
enough spacers so that they do not fall out when you let
go of them.)
(3) Insert the spacers (space A in the illustration),
attach the
nut, and complete
the installation.
ST6 Revision
http://vnx.su/
8-84
CHARGING
REMOVAL
AND
INSTALLATION
SYSTEM
(Vehicles
with
- Alternator
Air Conditioner)
30-35
D Draining
of Refrigerant
CONDITIONING
(Refer to
- Service Adjust-
ost-installation
Operation
1 Charging of Refrigerant (Refer to
GROUP 24 HEATERS AND AIR
CONDITIONING
- Service Adjustment Procedures)
D Adjustment
of Drive Belt Tension
(Refer to GROUP 7 COOLING and
GROUP 24 HEATERS AND AIR
CONDITIONING
~ Service Adjustment Procedures)
:emoval
~~
Nm
20-22
14-16
Nm
ft.lbs.
16W1566
steps
1.
2.
3.
4.
5.
6.
Connection
Connection
Connection
Compressor
Connection
Alternator
of high pressure
hose
of low pressure
hose
of compressor
connector
of alternator
OTE
) Reverse the removal procedures
I) e+ : Refer to Service Points
connector
to reinstall.
of installation
/ STB Revision
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CHARGING
SYSTEM
SERVICE
6.
- Alternator
POINTS
INSTALLATION
8-85
OF INSTALLATION
OF ALTERNATOR
(1) Position the alternator and insert the support bolt. (Do not
attach the nut.)
(2) Push the alternator
forward and determine
how many
spacers [thickness:
0.198 mm (.0078 in.)] should
be
inserted between the front leg of the alternator
and the
front case (space A in the illustration).
(There should be
enough spacers so that they do not fall out when you let
go of them.)
(3) Insert the spacers (space A in the illustration),
attach the
nut, and complete
the installation.
; .-:,
i
) STB Revision
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CHARGING SYSTEM-Alternator
10
\I
11
14
I
1 EL666
Disassembly
4*
1.
2.
l a 3.
4.
5.
6.
4*
7.
8.
9.
10.
4*
11.
12.
13.
14.
4,
steps
Pulley
Seal
Rotor assembly
Rear bearing
Bearing retainer
Front bearing
Front bracket
Stator
Terminal
Plate
Regulator and brush holder
Brush
Brush spring
Slinger
NOTE
(1) Reverse the disassembly
(2) +e : Refer to Service
(3) l + : Refer to Service
1 STB Revision
http://vnx.su/
procedures to reassemble.
Points of Disassembly.
Points of Reassembly.
CHARGING
8-87
SYSTEM-Alternator
SERVICE
POINTS
OF DISASSEMBLY
7. REMOVAL OF FRONT BRACKET/lG.
(1) Insert plain screwdriver
core and pry downward.
between
Caution
Do not insert screwdriver
of damage to stator coil.
REAR BRACKET
front bracket
and stator
1.
REMOVAL
OF PULLEY
11. REMOVAL
OF REGULATOR
(1) Unsolder
rectifier.
(2) Unsolder
three
two
stator
soft jaws.
AND BRUSH
leads
plates soldered
soldered
HOLDER
to main diodes
on
to rectifier.
Caution
1. When soldering
or unsoldering,
use care to make
sure that heat of soldering
iron is not transmitted
to diodes for a long period. Finish soldering
or unsoldeing in as short a time as possible.
2. Use care that no undue force is exerted to leads of
diodes.
INSPECTION
ROTOR
l
Standard
value
: 3.1 f2
6ELllt
.
1 STB hewsion
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8-88
CHARGING
l
SYSTEM-Alternator
Check rotor coil for grounding. Check to ensure that there is no
continuity between slip ring and core. If there is continuity,
replace rotor assembly.
6EL115
STATOR
l
Make continuity test on stator coil. Check to ensure that there
is continuity between coil leads.
If there is no continuity, replace stator assembly.
3ELOlO
l
RECTIFIERS
l
Positive rectifier test
Check for continuity between positive rectifier and stator coil
lead connection terminal with a circuit tester. If there is continuity in both directions, diode is shorted.
Replace rectifier assembly.
lELll0
l
lELll1
Negative
rectifier test
Check for continuity between negative rectifier and stator coil
lead connection terminal. If ther is continuity in both direction,
diode is shorted, and rectifier assembly must be replaced.
) STBRc evision
-7
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8-89
CHARGING SYSPE
l
lELll2
REPLACEMENT
OF BRUSH
A brush worn away to the limit
below.
is replaced
(1) Remove
spring.
the pigtail
solder
1 STB Revision
1
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8-90
CHARGING SYSTEM-Alternator
SERVICE POINTS OF REASSEMBLY
3. REASSEMBLY
OF ROTOR
ASSEMBLY
6EL122
Rear bracket
6EL123 I
STB Revision
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STARTING
SYSTEM-General
STARTING SYSTEM
GENERAL INFORMATION
Information
8-91
NOBFAAJ
The electrical circuit of the starter system consists of battery, starter motor, solenoid switch, ignition switch,
inhibitor switch, connecting wire and battery cable.
In the starter system and electrical circuit, electricity flows to activate the coils of the starter motor solenoid when
the ignition switch is turned to the start position. In so doing, the solenoid plunger and clutch shift lever move, the
clutch pinion engages with the ring gear and then the solenoid contacts shut and the starter motor cranks.
As soon as the engine begins to run and, in order to prevent damage due to over-revolution
by the armature starter,
the running clutch pinion gear over-rides, Thus in order not to cause damage to the starter motor once the engine
is running, the ignition switch must be immediately
turned back to the ON position.
The starter motor is the reduction-drive
type, and is compact and lightweight.
Inhibiter
-
switch
lEL151
1 STB Revision
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8-92
STARTING
terminal
SYSTEM
General
terminal
\
Sole;oid
Information
coil
clutch
Brush
gear
type
reduction
1 ST6 Revision
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STARTING
8-93
SYSTEM - Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOIFB-
Items
Specifications
Starter motor
Type
Model No.
Reduction
Part No.
M DO99667
Rated output
drive
MIT70481
kW1 v
I.2112
SERVICE SPECIFICATIONS
Items
Standard
Specifications
values
Starter motor
Free running characteristics
Terminal voltage
11
Current
Max. 90
Speed
r.p.m
Min. 3000
0.5-0.8(.020-,031)
mm (in.)
Under-cut depth
Commutator diameter
mm (in.)
Pinion gap
Commutator
mm (in.)
runout
29.4(1.157)
0.5-2.0(.020-,079)
mm (in.)
0.05(.0020)
mm (in.)
28.8(1.134)
Limit
Commutator
diameter
Commutator
runout
mm (in.)
0.1 (.004)
'_'
TORQUE SPECIFICATIONS
Items
Starter motor mounting
Air filter mounting
bolts
nuts
1 STB Revision
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Nm
ftlbs.
27-34
16-19
20-24
12-14
8-94
STARTING
SYSTEM
-Troubleshooting
TROUBLESHOOTING
NOFH-
Remedy
Reference
paw
8-81
8-82
8-81
Refer to
GROUP 21.
8-69
Repair starter
8-97
Ignition switch
8-l 22
8-8 1
8-82
8-8 1
Repair starter
motor
8-97
Repair starter
motor
8-97
Ignition switch
Symptom
Probable cause
,
I
Engine cranks
slowly
transmission
__~
only)
faulty
or worn
or worn
faulty
Short in wiring
Starter spins but enJine will not crank
motor
-7
http://vnx.su/
8-l 22
I
Repair wiring
1 STB Revision
motor
8-97
Replace flywheel
torque converter
Refer to
GROUP 9.
ring gear or
STARTING
1 STARTING
(VEHICLES
SYSTEM
CIRCUIT
WITH A MANUAL
- Circuit
8-95
Diagram
TRANSMISSION)
Ignition
switch
Ik
\
OFF
START
ON
9
w
11171
$in
ACC
c-55
ST
fusible
.I
Sub fusible
BY
link
37W626
Starter
/ STB Revision
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8-96
STARTING
SYSTEM
Circuit
Diagram
Sub
(IGN
A-23
_ 5-WI-754
L-l m
fusible
. SW)
link
0.5-G
Ignition
switch
1, 1,
1L-W
Battery
c-47
2-BY-Z-BY*2
!-BY
N
Z-BY1
L-l
(Z-BY*]
BYBY
R
I
Remark
For information
refer
to P.8-7.
concerning
Wiring
color
code
B: Black
LI: Light
blue
the
Br: Brown
0: Orange
ground
points
(example:
G: Green
P: Pink
),
Gr: Gray
R: Red
STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
STARTING
WSTEM
- Starter
Motor
8-97
STARTER MOTOR
REMOVAL
AND
INSTALLATION
16-19
12-l?
12-14
NOBFJAE
Nm
ft.lbs.
15W1564
Removal
steps
1. Air filter
2. Connection
of starter
l * 3. Starter motor
NOTE
(1) Reverse the removal procedures
(2) ++ : Refer to Service Points
motor
connector
to reinstall.
of Installation
INSPECTION
PINION GAP ADJUSTMENT
I,
6EL05(
Caution
This test must be performed quickly
onds) to prevent coil from burning.
Revision
http://vnx.su/
8-98
Motor
Pinion
value : 0.5-2.0
clearance
mm (.020-.079
in.)
6EL003
5.
If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket.
lEL113
/
Field
3.
coil wire
Caution
This test must be performed
quickly (in less than 10 seconds) to prevent coil from burning.
If pinion moves out, then pull-in coil is good. If it doesnt,
replace magnetic switch.
3.
Field
coil wire
Caution
This test must be performed
quickly (in less than 10 seconds) to prevent coil from burning.
If pinion remains out, everything is in order. If pinion moves in,
hold-in circuit is open. Replace magnetic switch.
1 ST6 Revision
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WEEM -Starter
I-
Carbon-pile
rheostat
6EL07
8-99
Motor
FREE RUNNING
TEST
1. Place starter motor in a vise equipped with soft jaws and
connect a fully-charged 12-volt battery to starter motor as follows :
2. Connect a test ammeter (loo-ampere
scale) and carbon pile
rheostat in series with battery positive post and starter motor
terminal.
3. Connect a voltmeter (16volt scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative post to starter
motor body.
6. Adjust rheostat until battery voltage shown on the voltmeter reads 1 IV.
7. Confirm that the maximum
amperage
is within the standard value and that the starter motor turns smoothly
and
freely.
Standard
value
Max. 90A
Min. 3,000 rpm
: Current
Speed
INSTALLATlON
OF STARTER MOTOR
Clean both surfaces of starter motor flange and rear plate.
[ ST6 Revision
1
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Disassembly
+*
4*
+*
+*
Motor
AND REASSEMBLY
steps
1. Screw
2. Magnetic switch
3. Screw
4. Screw
5. Rear bracket
6. Brush holder
7. Brush
8. Rear bearing
9. Armature
10. Yoke assembly
11. Ball
12. Packing A
13. Packing B
14. Plate
15. Planetary gear
16. Lever
l d 17. Snap ring
l a 18. Stop ring
19. Over running clutch
20. -Internal gear
21. Planetary gear holder
22. Front bracket
6ELlSS
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) a+: Refer to Service Points of Disassembly.
(3) l O: Refer to Service Points of Reassembly.
] STB Revision
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STARTING SYSTEM-Starter
8-101
Motor
OF ARMATURE/ll.
BALL
When removing the armature, do not lose the ball which acts
as a bearing for the armature and tip.
17. DISASSEMBLY
OF SNAP RING/18.
STOP RING
(1) Push the stop ring towards the snap ring using the proper
socket.
(2) After removal of the snap ring with the snap ring pliers,
remove the stop ring and the over-running clutch.
Snap
Armature
CLEANING
STARTER MOTOR PARTS
1, Do not immerse parts in cleaning solvent. Immersing the yoke
and field coil assembly and/or armature will damage insulation.
Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated
at the factory and solvent will wash
lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened with
cleaning solvent and wiped dry with a cloth.
INSPECTION
CHECKING
COMMUTATOR
(1) Place the armature on a pair of V blocks and check run-out with
a dial gauge.
Standard value : 0.05 mm (-0020 in.)
Limit : 0.1 mm (.0039 in.)
1ELlO
pi-
wision
I
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8-102
STARTING SYSTEM-Starter
Motor
lEL116
value
: 0.5-0.8
between
mm (.020-.031
segments.
in.)
lEL66
BRUSH HOLDER
Check conductivity
between the brush holder
holder. If there is no conductivity this is normal.
Brush
holder
OVERRUNNING
CLUTCH
1. While holding clutch housing, rotate the pinion. Drive pinion
should rotate smoothly in one direction, but should not rotate
in opposite direction. If clutch does not function properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning
clutch assembly. If pinion is damaged,
also inspect ring gear for wear or burrs.
1 STB Revision
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8-103
REPLACEMENT
OF BRUSHES AND SPRINGS
1. Brushes that are worn beyond limit line, or are oil-soaked,
should be replaced.
2. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail.
i&l
E
-Limit
Motor
line
1ELOlI
New brush
Soidered
(Make sure that
there is no excess
solder on brush
surface)
3. Sand
4. Insert
Make
brush
5. When
holder
brush
Surface marked If
1ELM
TESTING
ARMATURE
TESTING ARMATURE
FOR SHORT-CIRCUIT
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace shorted
armature.
6EL082
TESTING ARMATURE
FOR GROUNDING
Check the insulation in the space between the segments of the
commutator
and the armature and coil core. If there is no conductivity this is normal.
1FL
108
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8-104
STARTING SYSTEM-Starter
Motor
1 STB Revision
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IGNITION
SYSTEM -General
Information
8-105
IGNITION SYSTEM
GENERAL INFORMATION
NOUGAAB
(igniter-integrated)
cable,
Ignition
switch
1 AMR
1Gl
Ignition
coil
Ignite;
Distributor
lEL117
The distributor is composed of signal generator (signal rotor and igniter internalized pickup), linear current control
unit (igniter) advance control unit (governor and vacuum controller) and distribution unit (rotor plus distributor cap).
http://vnx.su/
IGNITION
SYSTEM-General
Information
IISTRIBUTOR
Vacuum
controller
lEL153
IGNITER
OPERATION
(1) When the signal rotor revolves a projection inside the signal rotor alternately moves away from and faces
towards the core detector inside the igniter.
(2) When the projection is separated from the core, an oscillating electrical circuit begins to oscillate, and when it
faces, magnetic flux issuing from the core moves across the inside of the signal rotor, so when loss increases,
oscillation ceases.
(3) This oscillation introduces power to the oscillation detector circuit, and after output is amplified it drives the
power transistor. During oscillation (when the projection and core are apart) electricity flowing through the
ignition coil and when oscillation stops (when the projection and core are facing) the electric current is interrupted.
(4) The electrical detection circuit, in preventing excessive electrical flow to the power transistor, protects the
transistor.
Ignition
switch
Sig,nal
rotor
Detection
coil
-I-
and core
-.IT1 Battery
----
Power
Oscillation
detector
Amplifier
Oscillation
Current
ditector
Igniter
1 STB Revision
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-7
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- I
IGNITION
8-107
SYSTEM - Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
DISTRIBUTOR
N08GB.B
Items
California
Federal
pointless
Contact pointless
T3T61980A
Part No.
Igniter
MD109013
Built-in type
Built-in type
Firing order
1-3-4-2
1-3-4-2
IGNITION
type
Contact
Type
Model No.
T3T65571
MD1 10264
COIL
Specifications
Items
Type
Model No.
Oil filled
Part No.
M DO73079
SPARK
type
E-089
PLUG
Model No.
Items
W20EP-U 10
W20EPR-Sll
Manifacturer
NIPPON DENS0
BURGEA-1 1
Alternate
plug
IGNITION
BPGES-1 1
BPRGES-1 1
BUGEA-11
NGK
W20EPR-U
W20EPSll
NIPPON DENS0
IO
SWITCH
Specifications
Items
ignition switch
Load capacity
AM-ACC
15A
AM-IG
30A
AM-ST
15A
AM-R
15A
0.1 V or less
switch
Rated load
IW
Voltage drop
0.2 V or less
) STB Revision
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8408
IGNITION
SYSTEM - Specifications
SERVICE SPECIFICATIONS
N08GC-B
Specifications
Items
Basic ignition timing at curb idle speed
7BTDC
Distributor
Federal
Governor
Initial
(crank deghpm)
O/l 600
1 9/2800
Middle
Final
1g/6000
O/80
Middle
12/I 50
231280
Final
California
Governor
(crank deghpm)
initial
O/l 600
Middle
912800
Final
1g/6000
O/80
Middle
8/l 50
Final
201360
O/60
Final
5180
Ignition coil
Primary resistance
at 20C (68F)
TORQUE
1.1-1.3
14.5-19.5
1R
mm (in.)
1.22-1.48
1.0-I .I (.039-,043)
SPECIFICATIONS
NOBGD-
Items
Spark plug
1 STB Revision
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Nm
ft.lbs.
20-30
15-21
IGNITLON
8-109
SYSTEM -Troubleshooting
TROUBLESHOOTING
NOBGH--
Symptom
Probable
cause
Incorrect
ignition
Ignition
coil faulty
Inspect
ignition
Ignition
faulty
Inspect
igniter
8-120
Inspect
distributor
8-120
Inspect
cord
high tension
8-116
Replace
plugs
Distributor
Remedy
timing
Adjust
faulty
High tension
cord faulty
idle or stalls
wiring
wiring
Replace
plugs
Ignition
Inspect
wiring
Adjust
ignition
wiring
Engine
mileage
overheats
faulty
timing
timing
8-111
coil
8-116
8-115
8-115
-
Incorrect
ignition
Ignition
coil faulty
Inspect
ignition
Ignition
faulty
Inspect
igniter
8-120
Inspect
cord
high tension
8-116
cord faulty
Replace
plugs
Ignition
Inspect
wiring
Incorrect
Poor gasoline
or broken
ignition
Inspect
High tension
Engine hesitates/poor
acceleration
disconnected
Reference
paw
wiring
faulty
ignition
Spark plugs
timing
Adjust
faulty
Replace
timing
8-111
coil
8-116
8-115
-
timing
8-111
8-115
plugs
Incorrect
ignition
timing
Adjust
ignition
timing
8-111
Incorrect
ignition
timing
Adjust
ignition
timing
8-111
1 STB Revision
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8-110
IGNITION
2 IGNITDN
SYSTEM
- Circuit
Diagram
CIRCUIT
Sub fusible
(IGN - SW)
A-23
5-wn5-wu
0.5-G
link
Ignition
switch
1
Z-W
63-I
IAT
Main
fusible
link
Rnttprv
64-b
ze
cj _-
3m
A:p
N
CL
m
I
Ei I
Disi
To combination
meter
(TACHO)
[Refer to P.8-52.1
A-an
Ignition
coil
37 w009
Remaik
-For information
refer to P.8-7.
concerning
the ground
Br: Brown
0: Orange
points (example:
c
G: Green
P: Pink
),
Gr: Gray
R: Red
L: Blue
Y: Yellow
1 STB Revision
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IGNITION
SYSTEM
Service Adjustment
SERVICE ADJUSTMENT
CHECKING
IGNITION
IGNITION
TIMING
8-111
Procedures
PROCEDURES
TIMING
NOEGIBA
ADJUSTMENT
Adjustment
conditions:
Coolant temperature:
80-90C
(170-I
Lights and all accessories:
Off
Transmission:
N (Neutral)
90F)
1. Connect
tachometer
and timing light.
2. Start eng.ine and run at curb idle speed.
725';;;
After 500 km
(300 mile)
800 ?I00
3.
4.
Basic
ignition
timing:
7 + 2BTDC
CHECKING
CHECKING
1.
2.
3.
4.
IGNITION
SYSTEM
CENTRIFUGAL
ADVANCE
NOBDIDB
EQUIPMENT
Assumed causes
Excessive advance
Broken spring
5.
6.
7.
1 STB Revision
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8-112
IGNITION
SYSTEM
- Service
Adjustment
CHECKING
NEGATIVE
Procedures
PRESSURE
ADVANCE
EQUIPMENT
Symptom
Excessive
advances
Weakness
spring
Broken spring
Insufficient
hysteresis
Impaired movement
base
5.
6.
7.
cable
~~
8.
advance or large
\
5ELO45
If the malfunction
indicators
above are confirmed,
dismantle
and check the distributor.
Allow the engine to idle and then turn the ignition switch to
OFF.
Remove the vacuum pump and attach the vacuum hose to the
vacuum controller
nipple.
Remove the timing light.
NOUGIHB
Connect the spark plug to the high tension cable, ground outer
electrode (main body), and crank engine. In the atmosphere,
only
short sparks are produced because of small discharge
gap. If the
spark plug is good, however,
sparks will occur in discharge
gap
(between
electrodes).
In a defective
spark plug, no sparks will
occur because of leak of insulation puncture.
plug
5ELO46
Iefective
NWGIGB
of breaker
Cylinder
block
6-8
mm
(.24-.31
in.)
controller
Broken diaphragm
Primaw
cable
of vacuum
No advance
Secondary
causes
insula
5ELO47
/
fvision
I
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IGNITION
SYSTEM-Service
Adjustment
Procedures
CANNOT
8-113
BE CRANKED
1.
2.
3.
Disconnect
the high tension cable from the center tower of
the distributor
cap, and hold the end of the cable about 5 - 10
mm (.2 - .4 in.) away from the cylinder block of the engine.
Turn the ignition switch to ON. Then, when a piece of metal
(the tip of a screwdriver
for instance) is inserted into the detection coil of the pick-up and then moved away, a spak can be
generated.
4.
Secondary
+
!:
cable
5-10
(.2-.4
km
in.)
5EL0
1 STB Revision
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8-114
IGNITION
IGNITION
SYSTEM
- Ignition
System
SYSTEM
REMOVAL
AND
INSTALLATION
NOEGJAE
20-30
Spark
+e
~~
+e
*e
plug
l +
~~
e+
e+
removal
1.
2.
3.
4.
5.
Distributor
~~
l +
+*
de l q
Ignition
Spark
Spark
Spark
Spark
Spark
steps
plug
plug
plug
plug
plug
removal
cable
cable
cable
cable
No.
No.
No.
No.
removal
1
2
3
4
16W1563
steps
Nm
connector
hose
steps
7. High tension
cable
10. Connection
of ignition
11. Ignition
coil
coil
connector
NOTE
(1) Reverse
(2)
(3)
+e
1 STB Revision
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the removal
: Refer
: Refer
to
to
Service
Service
procedures
Points
Points
to reinstall.
of
of
Removal.
Installation
IGNITION
Ignition
8-115
Svstem
No good
Good
SYSTEM
l-4. CAUTION
CABLE
OF SPARK
PLUG
CABLES17.
721017
HIGH
TENSION
72T06t
9.
16W947
REMOVAL
OF DISTRIBUTOR
Before removing the distributor,
position the piston in No.
1 cylinder at the top dead center on compression
stroke by
the following
procedure.
(1) Remove the cap from the distributor.
(2) Turn the crankshaft
until the distributor
rotor lines up
with the No. 1 spark plug cable electrode
on the
distributor
cap.
(3) Align the notch on the crankshaft pulley with the timing
mark T on the timing indicator to set the engine SO
that the piston in No. 1 cylinder is at the compression
top dead center.
INSPECTION
CLEANING
1. Pull the
2. Using a
cylinder
AND INSPECTION
OF SPARK PLUGS
spark plug cables out of the spark plugs.
spark plug wrench, take all the spark plugs out of the
head.
Caution
Ensure that no foreign bodies fall from the spark plug
holes.
3. Using the following criteria check that there is no electrode
spark loss, that there is no damage to the outer insulation, and
that sparking is good.
l
Existence of insulation damage
l
Spark dissipation
l
Carbon accumulation
Using either plug cleaner or wire brush, clean both the upper part and the glass part.
l
Damage to or breakage of gaskets
l
Spark action in spark glass area
In cases where there are black deposits due to carbon, this
indicates excessive passage of mixed gases so that air intake becomes extremely deficient.
Owing to the excessively large spark gap, spark loss and so
on can be expected.
In case of white scorching, this indicates an excessively
thin gas mixture and prolongment
of sparking time, which
suggests poorly fitted plugs.
/ STB Revision
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8-116
IGNITION
SYSTEM-Ignition
System
4.
5.
Plug
cleaner
OlUOO89
NIPPON
Plug gap
gauge
termine
direction
Standard
rl
CHECKING
value
SPARK
: 1.0-1.1
PLUG
mm (.039-.043
in.)
CABLE
(1) Check that there are no cracks in the cap or in the insulating
coating.
(2) Ctieck the resistance value.
High tension
cable
I
CHECKING
1 No.2
No.1
9
THE IGNITION
11
1 No.3
I
13
Standard
value
14
COIL
(1) Measurement
of the resistance
of the external
Measure
the resistance
of the external resistor.
High voltage
terminal
1 No.4
: 1.2-1.4
resistor
IR
(2) Measurement
of the resistance
of the primary coil
Measure the resistance between the positive (+) terminal
and the negative
(-) terminal
of the ignition
coil.
Standard
value
: 1.1-1.3
IR
(3) Measurement
of the resistance
of the secondary
coil
Measure the resistance between the high voltage terminal
and the positive (+) terminal
of the ignition
coil.
Standard
value
: 14.5-19.5
01R0234
wision
http://vnx.su/
kfl
IGNITION
SYSTEM-Ignition
SERVICE
9.
POINTS
INSTALLATION
8417
System
OF INSTALLATION
OF DISTRIBUTOR
Notch on
crankshaft
pulley
Stud
housing
with
mating
mark
l-4.
INSTALLATION
OF SPARK
Improper arrangement
between
the cables,
surge at acceleration
careful to arrange the
lowing procedure.
1.
2.
3.
PLUG
CABLE
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8-118
SPARK
IGNITION
PLUG CABLE
SYSTEM
- Ignition
System
INSTALLATION
I(1
3
-4
-3
-1
-2
3
I
View
5EL04
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1
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IGNITION
SYSTEM
8-119
- Distributor
DISTRIBUTOR
DISASSEMBLY
Disassembly
AND REASSEMBLY
steps
1. Breather
2. Distributor cap
3. Packing
4. Contact carbon
5. Rotor
6. Vacuum control
7. Ground wire
8. Lead wire
l + Adjustment
of air gap
9. Igniter
10. Rotor shaft
4*
+***
11. Signal rotor
l * 12. Breaker plate
13. Spring retainer
4*
4*
14. Governor spring
15. Governor weight
16. Lock pin
4**+
17. Driven gear
18. Washer
19. 0 ring
20. Distributor shaft
21. Washer
22. Oil seal
23. Distributor housing
Vehicles for
California
Vehicles except
for California
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) +e : Refer to Service Points of Disassembly.
(3) Hw: Refer to Service Points of Reassembly.
(4) q : Non-reusable
parts
1 STB Revision
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lEL104
8-120
IGNITION
SYSTEM
Distributor
13. DISASSEMBLY
SPRING
OF SPRING
RETAINERI14.
GOVERNOR
Remove two spring retainers with pliers and then remove two
governor springs.
6ELO6i
ti
II
17. DISASSEMBLY
Pin punch
OF DRIVEN
GEAR
INSPECTION
Check according to the following provisions and repair or replace
anything faulty.
CAP ROTOR
(1) Ensure there are no cracks in the cap.
(2) Ensure that the electrodes of the cap and of the rotor are
undamaged.
(3) Wipe off any dirt from the cap or the rotor.
1ELlOi
1 STB Revision
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IGNITION
8-121
SYSTEM-Distributor
17. REASSEMBLY
Install driven
location.
Distributor
OF DRIVEN
GEAR
marked
6EL093
12. REASSEMBLY
/ A
OF BREAKER
PLATE
I -1--
11. REASSEMBLY
OF SIGNAL
ROTOR
Socket
ADJUSTMENT
OF AIR GAP
Standard
value
1 STB Revision
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8-122
IGNITION
IGNITION
REMOVAL
Removal
SYSTEM
- Ugnition
Switch
SWITCH
AND INSTALLATION
NOEGLAE
steps
16W1557
1. Lower
column
cover
2. Upper column
cover
3. Cable band
4. Ignition
switch
5. Key remaind
switch
NOTE
Reverse
the
removal
procedures
to reinstall
INSPECTION
(1) Disconnect
connect
Ignition
16UO36C
switch
!I
START
NOTE
O-C indicates
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that there
-7
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is continuity
between
the terminals.
8-123
SPECIFICATIONS
AND GAUGES
NOEHB-
Specifications
Items
Speedometer
Electromagnetic
Type
Tachometer
Type
Detection
type
Pulse type
Ignition coil
source
Fuel gauge
Bimetal type (constant-voltage
Type
Fuel gauge unit
Variable resistance
Type
Water temperature
Type
Oil pressure
type
type
gauge
Bimetal type
gauge unit
Bimetal type
Type
Inclinometer
Type
Damping
for 7V)
gauge
Type
Water temperature
Type
Oil pressure
relay incorporated
Gravity type
Oil-filled system
system
Voltage meter
Bimetal type
Type
INDICATOR
AND WARNING
LIGHTS
NOEHC-B
Specifications
Items
Turn signal indicator
lights
light
Door-ajar warning
light
1.4 (74)
1.4 (74)
1.4 (74)
W
W
1.4 (74)
1.4 (74)
light
1.4 (74)
1.4 (74)
W
light
1.4 (74)
1.4 (74)
Charging warning
4WD indicator
light
1.4 (74)
1.4 (74)
Free-wheeling
1.4 (74)
warning light
light
W
hub indicator light
NOTE
The values in parentheses
1 STB Revision
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8-124
METERS
AND
GAUGES - Specifications
BUZZER
Specifications
Items
Range of voltage used
IO-16
dB
frequency
53-7
goo* 150
Hz
SERVICE SPECIFICATIONS
Specifications
Items
Standard values
Speedometer
indication error
indication
km/h
f4
-1
+4
0
+5
0
+5.5
+0.5
20 km/h
40 km/h
80 km/h
120 km/h
Meter with mph
indication
mph
10 mph
+- 1.5
25 mph
+ 1.5
50 mph
75 mph
+I.5
Tachometer
k 1.5
indication
error
r/min
1,000 r/min
3,000 r/min
*IO0
+150
5,000 r/min
f 250
terminals
terminals
value
1 (power
R
supply) and 2 (fuel gauge unit)
122-l 48
value
Float point E
Fuel gauge unit float position
23-27
100-l 20
R
14.9-19.1
113.5-l 26.5
mm (in.)
Float point F
29.7-34.7
Float point E
183.8-185.8(7.236-7.315)
Water temperature
Between terminals
temperature
gauge
Water temperature
resistance value R
gauge resistance
value
R
50-60
90.5-I 17.5
45-55
1R
IOV
to.5
k 0.5
16V
( ST6 Revision
(1.169-l
-7
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.366)
8425
/Troubleshooting
TORQUE SPECIFICATIONS
Items
Water temperature
SEALANTS
gauge unit
Nm
ft.lbs.
8-10
6-7
AND ADHESIVES
Items
Water temperature
portion
Quantity
As required
TROUBLESHOOTING
TACHOMETER
NOBHH-
Inspection
Symptom
The tachometer
I The tachometer
NOTE
Number
fails to operate
pointer is faulty
in circle indicates
inspection
sequence.
FUEL GAUGE
Inspection
Symptom
The fuel gauge fails to operate
The fuel gauge pointer is faulty
NOTE
Number
in circle indicates
inspection
sequence.
1 STB Revision
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items
items
8-126
WATER TEMPERATURE
GAUGE
-0
c
2
(5
Symptom
The water temperature
0
a
NOTE
Number in circle indicates inspection sequence.
OIL PRESSURE
GAUGE
jnspection items
Symptom
The oil pressure gauge fails to operate
The oil pressure gauge pointer is faulty
NOTE
Number in circle indicates inspection sequence
( STB Revision
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8-127
LIGHT
Inspection
Symptom
items
\
starting the
go
in circle indicates
EGR WARNING
inspection
Other inspection
items
t
c
Co
sequence.
LIGHT
U
5
P
Co
The EGR warning indicator fails to illuminate after the car has travelled
every 50,000 miles (Light bulb is OK.)
NOTE
Number
in circle indicates
inspection
sequence.
[ STB Revision
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8-128
METERS
AND
GAUGES
- Circuit
Diagram
CIRCUIT DIAGRAM
METER CIRCUIT
Ignition
[Refer to P.8-511
To turn-signal
switch
[Refer to P.8-491
I
To seat belt timer
[Refer to P.8-661
To seat belt warning
buzzer [Refer to P.8-661
To alternator
48,5!W
IRefer to P.8.371
D
-0 dimmkr, passinq
I+,:
!
;witch and light control \ y K
clay [Refer to P.8-461
To dome liaht
5--hIIII
[Refer to P&47] -w
switch
1.25-GBA
, ^.
III
I
-1
I
r I
I
I
I
I
/
II
II
1
-I
YI
1 '----f--d+ii$$j
I
I
----m-w-
Combination
( STB Revision
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meter
.I_
METERS
AND GAUGES
011 pressure
switch
A-52
\
(
UY
>
I
H
> Oil A-52
pressure
gauge
unit
A-20
r..,
8-129
Diagram
YB
YR mYR
B
-0.85-B
Circuit
A-06
A-03
YR,RL
RL
El
switch
--
I I 1
L7
I I I I I
I
1 !
1 1
8-23
Fuel gauge
unit
YB
g--
4WD
indicator
L
WL/B
YL
y
1I I1
I'4 . I. 'I8. ;
LY)T~
OD OFF switch
[Refer to P.8-431
1 I
Combination
Br: Brown
0: Orange
Remarks
(I) The broken line indicates vehicles with combination gauge.
(2) The dash and dot line (-.-) indicates vehicles
with automatic free-wheeling
hub indicator.
(3) For information concerning the ground points
(example: 0 ). refer to P.8-7.
(4) The symbols @I,@, etc. indicate that the wiring
is connected (using the same numerical
symbol) to the facing page.
(In other words, 0 on the right page is
connected to 0 on the left page.)
gauge
G: Green
P: Pink
Water
temperature
gauge unit
Gr: Gray
R: Red
/ STB Revision
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L: Blue
Y: Yellow
8430
METERS
AND
GAUGES
- Service
Adjustment
Procedures.
BJUSTMENT. PROCEDURES
SERVICE
SPEEDOMETER
INSPECTION
NOSHIAA
I.
value :
with km/h
40 km/h
80 km/h
120 km/h
10
25
50
75
with
mph
mph
mph
mph
km/h
+4
-1
+4
0
+5
0
+ 5.5
+0.5
20 km/h
Meter
indication
mph
indication
mph
+I.5
21.5
+I.5
&I.5
Caution
1 When
using a speedometer
tester to inspect
the
speedometer,
be sure to chock the non-drive
wheels
to prevent the vehicle from moving.
Also be sure to
set the transfer
shift lever to 2H.
2 If there
is a special
regulation
for speedometer
indication
error in the area where the vehicle
is
operated,
be sure to meet the requirement
of the
regulation.
TACHOMETER
INSPECTION
NOBHIBA
Connect a tach-dwell
meter, and then compare
the meter
readings at various engine speeds with the values indicated on
the tachometer.
Standard
value:
1,000 r/min
3,000 r/min
5,000 r/min
Tgch-dwell
meter
f 100 r/min
2150 r/min
&250 r/min
Caution
The tachometer
is the negative-ground
type, and therefore
should not be connected
in reverse polarity
to the battery.
If the tachometer
is connected
in reverse
polarity,
the
transistors
and diodes will be damaged.
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METERS
AND GAUGES
- Service
Adiustment
FUEL GAUGE
(harness
side)
16W834
SIMPLE
(upper)
TEST
UNIT
INSPECTION
NOEHIIF
To check the fuel gauge unit, first remove it from the fuel tank.
For detailed
information
concerning
installation
of the fuel
gauge unit, refer to GROUP 4, FUEL SYSTEM - Fuel Tank.
FUEL GAUGE
UNIT FLOAT
Check to be sure that the
(relative to the center part of
standard value range when
(upper limit) and E position
NOEHICE
(1) Disconnect,
from below the vehicle, the wiring connector
from the fuel gauge unit.
(2) Ground the connector
at the harness through a test light.
(3) Turn the ignition
key to the ON position.
(4) Check to be sure that the test light flashes and the fuel
gauge indicator
moves.
(5) If both the test light and gauge operate, the circuit to the
gauge unit is normal and the gauge unit itself is faulty.
If the test light flashes but the gauge does not operate, the
gauge is faulty.
If neither the test light nor the gauge operates, the fuel
gauge circuit is faulty.
FUEL GAUGE
Stopper
8-131
Procedures
POSITION
CHECK
height of the fuel gauge float
the fuel gauge unit) is within the
the float is at the F position
(lower limit).
Standard
value:
A 29.7-34.7
mm (1.170-I .366 in.)
B 183.8-185.8
mm (7.236-7.315
in.)
FUEL
GA&E
UNIT
RESISTANCE
CHECK
Confirm that the resistances when the float of the fuel gauge
unit is at the F position (top) and the E position (bottom)
are within the standard value ranges.
Standard
Float
Float
WATER
value:
position
position
F point
E point
TEMPERATURE
14.9-19.1
IR
113.5-126.5
IR
GAUGE
SIMPLE
T,5$2
(1) Disconnect
the wiring connector
from the water temperature gauge unit inside the engine compartment.
(2) Ground the connector
at the harness through a test light.
(3) Turn the ignition
key to the ON position.
(4) Check to be sure that the test light flashes and the water
temperature
gauge indicator
moves.
,
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8-132
METERS
AND
GAUGES
- Service
Adjustment
Procedures
(5) If both the test light and gauge operate, the circuit to the
gauge unit is normal and the gauge unit itself is faulty.
If the test light flashes but the gauge does not operate, the
gauge is faulty.
If 1neither the test light nor the gauge operates, the water
temperature
gauge circuit is faulty.
VVATER TEMPERATURE
TION
Se
GAUGE
UNIT
ONSPECNOBHIKD
TEMPERATURE
GAUGE
UNIT
RESISTANCE
CHECK
Immerse
measure
Standard
value:
OIL PRESSURE
90.5
GAUGE
SIMPLE
- 117.5
TEST
and
LR
NOEHIFA
(1) Disconnect
the wiring connector
from the oil pressure
gauge unit inside the engine compartment.
(2) Ground the connector
at the harness through a test light.
(3) Turn the ignition
key to the ON position.
(4) Check to be sure that the test light illuminates
steadily and
the indicator
of the oil pressure gauge moves.
(5) If both the test light and gauge operate, the circuit to the
gauge unit is normal and the gauge unit itself is faulty.
If the test light flashes but the gauge does not operate, the
gauge is faulty.
If neither the test light nor the gauge operates,
the oil
pressure gauge circuit is faulty.
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METERS
IOil
Oil pressure
p ressure
gauge unit
\
AND
\ 1 I Test light
@(12V
- 3.4 W)
GAUGES
I
Service
Adjustment
OIL PRESSURE
GA
Procedures
GE UNIT
CURRENT
8-133
CHEC,l<,
(1) Disconnect
the wiring connector
from the oil pressure
gauge unit inside the engine compartment.
(2) Apply battery voltage (through the test light) to the gauge
unit side terminal.
(3) Check to be sure that the test light switches OFF when the
engine is stopped, and that it flashes while the engine is
running.
16W1576
VOLTAGE
METER
SIMPLE
TEST
value
1 STB Revision
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: 1OV
16V
+ 0.5v
+ 0.5v
NOEHIGC
and of
8-134
METERS
COMBINATION
METER
REMOVAL
Removal
AND
GAUGES
- Combination
AND INSTALLATION
Meter
NOBHJAF
steps
1. Meter cover
of speedometer
l 4 2. Connection
3. Meter asset nbly
NOTE
(I)
Reverse
the
l + : Refer
(2)
removal
procedures
to Service
Points
to
of
reinstall.
Installation.
cable
16W1553
INSPECTION
REED SWITCH
Using an ohmmeter,
check that continuity and discontinuity
alternate between terminals 1 and 2 four times at every
rotation of the shaft of the speedometer
cable connection.
I
BUZZER
Check to be sure that buzzer sounds when the batterys
positive (+) terminal is connected
to terminal 2 and the
batterys negative (-) terminal is connected
to terminal 1.
16W1645
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METERS
AND GAUGES
Combination
FUEL GAUGE
Measure the resistance
an ohmmeter.
.3
Standard
value
l-2 terminals:
2-3 terminals:
l-3 terminals:
8-135
Meter
value between
t.he terminals
by using
:
23-27 R
122-148 Sz
100-120 IR
16WQ25
Caution
If there is a malfunction
of the ground
contact of the
voltage
regulator
even once during vehicle operation,
the excessive current flowing
through
the heat coil of
the water temperature
gauge and the fuel gauge will
cause permanent
distortion
of the bimetal,
resulting
in
the indications
being consistently
lower than the actual
value.
For this reason, therefore,
be sure to make the earth
contact
securely.
16W925
WATER TEMPERATURE
Measure the resistance
an ohmmeter.
GAUGE
value between
the terminals
by using
Standard
value:
Bimetal
type
l-2 terminals:
50-80 n
10W926
SERVICE
2.
POINTS
INSTALLATION
OF INSTALLATION
OF SPEEDOMETER
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its stopper
CABLE
properly
fits
to the
8-136
METERS
DISASSEMBLY
AND
AND
GAUGES
- Combination
Meter
REASSEMBLY
I
10
16W1664
Disassembly
steps
1.
2.
3.
4.
5.
6.
7.
Meter cover
Buzzer
Fuel and water
Tachometer
Speedometer
Indicator panel
Meter glass
temperature
8. Window
plate
9. Meter case
10. Printed circuit boad
gauge
NOTE
Reverse
1 STB Revision
the disassembly
-1
http://vnx.su/
procedures
to reassemble.
METERS
3-METER
REMOVAL
Removal
AND
GAUGES
3-meter
Unit
lJN(IT
AND
INSTALLATION
steps
1. Meter
pad
2. Gauge assembly
NOTE
Reverse
the removal
procedures
16W1560
to reinstall
INSPECTION
OIL PRESSURE
Measure
ohmmeter.
Standard
GAUGE
the resistance value
value
: Approx.
between
the terminals
with an
the terminals
with an
50 CR
lBW077
VOLTAGE
METER
value
1 STB Revision
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value between
: 380-4601(1
8-138
METERS
AND GAUGES
- s-meter
Unit
INCLINOMETER
(1) Check
to be sure
that
operation
is smooth
when
the
inclinometer
is tilted up/down
and to the left and right.
(2) The i,nclinometer
can be considered
to be in good condition If the pointer
indicates
the spherical
dial horizontal
centre
line when
the meter case is placed
on a level
surface.
16W678
DISASSEMBLY
AND
REASSEMBLY
Disassembly
1.
2.
3.
4.
5.
6.
7.
NOTE
Reverse
the
steps
Oil pressure gauge
Inclinometer
Voltage meter
Meter glass
Window
plate
Meter case
Meter harness
disassembly
procedures
to
reassemble.
16W1561
1 ST6 Revision
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METERS
Center shaft of
pitching damper
AND
GAUGES
s-meter
Unit
8-139
INCLINOMETER
plate
OUTLINE
inclinometer
is an instrument
which indicates the forward
or backward inclination
(pitching)
or side to side inclination
(ding)
of vehicle.
Motion
of a pendulum
in the system
is displayed
on the
system. The pitching
and rolling pointer is supported
by a
double support mechanism
in which the rolling fulcrum
is
supported in such a way as to be rotative around the case and
the pitching fulcrum supported
on the rolling system
The
16W 600
Pointer
Spherical
dial
Spherical
horizontal
16W966
Spherical
\
Gxizontal
dial
Dial support
/
plate
Oil case
centerlinewtationaryframe
Blind plate
Forward
CONSTRUCTION
The inclinometer
consists of an outer case which inclines with
the vehicle, a pointer which is provided
in an oil case and
always maintains
a level position,
and a spherical
dial. The
spherical dial is coupled through the dial support plate to the
rolling damper plate. The rolling damper plate is swivel bearing
coupled to a stationary
frame by the center axis, so it can
incline side-to-side,
but is always held in a level position by a
pendulum.
The pointer is coupled with the pitching damper
plate.
Since the pitching damper plate is swivel bearing coupled to
the rolling damper
plate by the center axis, it can incline
forward and backward,
but is always maintained
in a level
position
by the pendulum.
16W627
or backwarc
OPERATION
The side-to-side
inclination
angle should be read on a scale of
the front panel as indicated
by the horizontal centerline
of the
spherical dial, whereas the forward or backward inclination
angle should be read on a scale of the spherical
dial as
indicated
by the pointer.
Hokizontal
line
Horizbntal
line
[ STB Revision
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8-140
AND GAUGES
METERS
Side-to-Side
- 3-meter
Unit
Inclination
The front panel inclines with the vehicle, but the spherical dial
maintains
a horizontal condition,
so the horizontal centerline of
the s&lerical
dial shows the side-to-side
inclination
angle.
Inclined
15"
to right
16W969
Forward
or Backward
Inclination
The spherical
dial inclines
forward
or backward
with the
vehicle,
but the pointer
maintains
a level position,
so the
pointer indicates
the forward or backward inclination
angle.
Combined
Forward
or Backward
and Side-to-Side
Inclination
The forward or backward inclination
angle and the side-to-side
inclination
angle are indicated by the pointer and spherical dial.
@
10 d15
15 downhill
Inclined
IO
to
left
16W968
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METERS
INDICATORS
AND
GAUGES
AND WARNING
Symbol
and Warning
8-141
Lights
LIGHTS
Operation
This indicator
beam.
Door-ajar warning
+e3
=
=
- Indicators
light
illuminates
on when
are on high
*
Fasten seat belt indicator
Brake warning
4
light
BRAKE
Charging warning
III
light
This warning
light comes on
ON position, and goes off
This warning
light comes on
or the trouble occurs in the
Oil pressure
warning
light
P
Overdrive
00
indicator
control
OFF
68R0133
warning
light
A/T
TEMP
warning
light comes on when
fluid temperature
becomes abnor-
68WO68
Free-wheeling
hub indicator
YEL
free-wheeling
68WO80
4WD indicator
This indicator will light up when the transfer case shift lever is
shifted to the four wheel driving position (either the 4H or the
4L position) and the ignition key is in the ON position.
z4
EGR warning
light
CHECK
EGR
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8-142
METERS
AND
GAUGES
- EGR Warning
EGR WARNING
System
SYSTEM
RESET SWITCH
Use the switch on the back of the odometer
warning system.
NOTE
If the speedometer
the same reading
1 STB Revision
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is to be replaced,
as the odometer
to
LIGHTING
8-143
SYSTEM - Specifications
LIGHTING SYSTEM
SPECIFICATIONS
GENERAL
EXTERIOR
SPECIFICATIONS
AND INTERIOR
LIGHTS
NOEIB-
Specifications
Items
Exterior lights
Head lights
60/50
Front combination
Turn-signal
lights
cp
lights
32
lights
cp
light
32
32/3
32
Back-up lights
Rear side marker lights
3.8(194)
6
Interior lights
Dome light
W
Heater panel illumination
10
light
1.4 (74)
illumination
Shift illumination
light
1.4 (74)
1.4 (74)
light
W
light (automatic
3.4 (158)
transmission)
NOTE
The values in parentheses
UNIT
1.4 (74)
Specifications
Items
Light control relay
Rated load
Max. 200
IO-16
V
terminals
0.2 or less
flasher unit
Type
Rated load
W
Blinking frequency
Condenser type
84.4
[I 2.8 V, 20C (68F)l
cycle/min
85210
cycle/min
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902 10
8-144
SYSTEM -Specifications
LIGHTING
COLUMN
SWITCH
Specifications
Items
Lighting switch
Rated load
A
Voltage drop (at 12V and the rated load)
Dimmer-passing
0.17-0.27
V
0.2 or less
switch
Dimmer switch
Rated load
Upper bearm
16.1-18.7
Lower
9.4-10.8
beam
0.2 or less
Passing switch
Rated load
Upper beam
Lower
beam
16.1-18.7
0.17-0.27
0.2 or less
TB-FL, TB-FR
2.2-2.8
TB-RL, TB-R R
4.2-4.8
ST-RL, ST-RR
4.2-4.8
HAZARD
WARNING
0.2 or less
SWITCH
Specifications
Items
I Voltage
DIMMER
CONTROL
0.1 or less
SWITCH
Items
Specifications
Variable-resistance
Type
Rated load
15 (Min.)-26.6
type
(Max.)
0.15 or less
SERVICE SPECIFICATIONS
Items
Specifications
Limit
Headlight
intensity
cd
20,000 or more
TORQUE SPECIFICATIONS
N08lb
Items
I
Steering wheel
Nm
35-45
lock unt
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ft.lbs.
I.
26-33
LIGHTING
SYSTEM
SPECIAL TOOLS
Tool
(Number
MB990784
Ornament
NOIIG-B
and name)
Use
Removal
warning
remover
of hazard
switch
TROUBLESHOOTING
HEADLIGHT
Inspection
1Symptom
Headlights
-0
K
2
t
do not illuminate,
It is not possible
items
to change
or illuminate
the headlights
intermittently
beam
Headlights
arm dim
Headlights
NOTE
Number
in circle indicates
inspection
sequence.
( STB Revision
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8-146
LIGHTING
SYSTEM -Troubleshooting
PLATE LIGHT
Symptom
Lights fail to illuminate
Lights on only one side illuminate
NOTE
Number
in circle indicates
BACK-UP
inspection
sequence.
LIGHT
-0
c
c-a
Il
5
m
Back-up
in circle indicates
inspection
sequence.
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I
0
LIGHTING
SYSTEM
8-147
- Troubleshooting
DOME LIGHT
Inspection
The dome light does not illuminate when the door is opened (illuminates
the borne light switch is ON)
in circle indicates
TURN SIGNAL
inspection
sequence.
LIGHT
Inspection
items
Symptom
All turn signal lights fail to flash
The turn signal light will not flash
(illumination
remained)
in circle indicates
inspection
when
I
0
items
sequence
1 STB Revision
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8-148
LIGHTING
SYSTEM
-Troubleshooting
STOP LIGHT
Other inspection
items
0
A
NOTE
Number
in circle indicates
INSTRUMENT
inspection
sequence
PANEL ILLUMINATION
CIRCUIT
Inspection
iterns
Symptom
Illumination
Illumination
Illumination
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0 Installation parts
of the stop light
switch
LIGHTING
SYSTEM
CIRCUIT DIAGRAM
HEADLIGHT CIRCUIT
Circuit
Battery
Sub
link
A-02
5-v m5-w
L-l
Main
lrnk
8-149
Diagram
fusible
0.5-G
2-R
A-23
fusible
z
A
2-B
r
2-B
ItfYH
A-33
Dedicated
c-05
dl
dl
fuse
YR[
11.25-Y
1-1
I
Combination
meter
I
n
*
Wlir,L
A .-32
Lrght
relay
control
A-55
Lighting
switch
Dimmer
switch
Passing
switch
(LTH.)
(R.H.)
R R RL
FP
x2
Remark
For information
points
(example:
Wiring
B: Black
LI: Light
color
blue
Column
concerning
), refer
Headlight
switch
XI
37W621
the ground
to P.8-7.
code
Br:
Brown
0:
Orange
G:
P:
Green
Pink
Gr: Gray
R: Red
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
8-150
LIGHTING
SYSTEM
- Circuit
Diagram
CIRCUIT DIAGRAM
TAIL LIGHT, POSITION LIGHT, REAR Sl!DE MARKER LIGHT,
LICENSE PLATE LIGHT AND BACK-UP LIGHT CIRCUIT
Battery
Sub fusible
A-02
link
-1.25-B3
1
Main
fusible
link
A-02
mw
3
cl
1m
-22
To turn-signal
flasher unit
[Refer to P.8-49.]-
0.85-RL
T
I
lB-@
A-57
Position
light
Front
- .
combination
light (L.H)
Position
v
light
A-08
Front
_ _
combination
Ii-h+ IQ LA\
Backy
switch
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
A-09
Inhibitor
switch
light
i
/ STB Revision
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LIGHTING
Column
SYSTEM
- Circuit
8-154
Diagram
switch
Light control
relay
1
-32
C-52
J
F-GW -GW
F-B
B
L
B-06
B-12
B-14
Tail light
Tail lrght
Rear
combination
light
(R.H.)
Back-up
light
Tail light
Tail light
Rear
combination
light
(L.H.)
Back-up
light
L-l5
B-20
Rear side
marker light
(L.H.)
Remarks
with
(1) The broken lines are applicable to models~equipped
an automatic transmission.
concerning
the ground points (exam(2) For information
ple: 0 ). refer to P.8-7.
0, 0, etc. indicate that the wiring
is
(3) The symbols
connected
(using the same numerical
symbol) to the
facing page.
(In other words, 0 on the right page is connected to 0 on
the left page.)
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B-22
37W823
8-152
LIGHTING
SYSTEM
CIRCUIT DIAGRAM
TURN-SIGNAL
AND HAZARD
A-02
63
-1.25-BMain
fusible
Circuit
Diagram
LIGHT CIIRCUIT
I
lml
Battery
Sub fusible
1BI
m
link
Ignition
switch
link
II I z I
Multi-purpose
fuse
2-B
To column switch
[Rear to P.8-461
'I
0.85-RL
1.25-GB
0.85-GY
I_\
0.85-GL
-o
ao
(BJ -0
Gw -@
I
3
cs
I
z
dm
A-31 1
1.I
I-
000
Turn-signal
and
hazard light
Turn-signal
and
hazard light
Front
combination
Front
combination
light (R.H.)
light
(L.H.)
Combination
w
q
1 STB Revision
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meter
I IGYIa.
LIGHTING
SYSTEM
- Circuit
Diagram
8-153
I
Turn-srgnal
Turn-signal
flasher
unit
I
r
switch
iazard
Hazard
flasher
unit
l!d
switch
C-62
-W\*1W++
\&VB/
aI
::
I v-l--c
n
c
I
::
nC
*
o- 0.85-RL
1 ')r rTurn -signal
and hazard
a-
Y-
light
Rear Combination
light (R.H.)
Rear combination
light (L.H.)
Dimmer
switch
control
OL
EZB B
WL
-
Br: Brown
0: Orange
37W029
B-20
G: Green
P: Pink
Gr: Gray
R: Red
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L: Blue
Y: Yellow
to 0 on
8-154
LIGHTING
SYSTEM
Circuit
Diagram
CIRCUIT DIAGRAM
DOME LIGHT CIRCUIT
v
I=32
A-02
Battery
Sub
5-w
Main
fusible
Combination
To
5-w r-l5-w
u
fusible
0.5-G
*
63
column
2-R
A-23
IInk
link
switch
To
meter
hazard
RB
B
ElRF
EL
B-01
RB
B
RG
H-28
(L.H.)
Door
(R.H.)
switch
37W020
Remark
For information
refer
to P.8-7.
Wiring
B: Black
LI: Light
color
blue
concerning
the
ground
points
(example:
),
code
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
LIGHTING
SYSTEM
- Circuit
8-155
Diagram
CIRCUIT DIAGRAM
STOP LIGHT CIRCUIT
Sub
fusible
link
-1
Main
link
3-w
fusible
07
Multr-purpose
fuse
c-51
-0.85-G
2-B
Hazard
switch
To column
*[Refer
to
switcf
P.8-461
0.85-WG
d
B-20
]B-14
Turnsignal
switch
Stop
Rear
light
Remark
For information
refer
to P.8-7.
concerning
Wiring
color
code
B: Black
Ll: Light
blue
the
Br: Brown
0: Orange
ground
points
(example:
G: Green
P: Pink
light
cdmbination
(L.H.)
Stop
Rear
light
light
c;mbination
(R.H.)
).
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y. Yellow
Lg:
W:
Light
White
green
8-156
LIGHTING
SYSTEM
- Circuit
CIRCUIT DIAGRAM
INSTRUMENT PANEL ILLUMINATION
CORCUIT
-1.25-B0
Battery
.5-w
5-w 15-w
0.5-G
2-R
A-23
A-02
Main-Err
fusible link
Diagram
Sub fusible
z
A
cy]llo
link
a
I
N
A-22 [
CY
c-i
Optical
fiber
Heater
control
Heater
control knob
illumination
light
Multi-purpose
fuse
Combination
gauge
Illumination
ght control
lay
knob
B01 0
light
c
Cn
/
-
Lighting
switch
ti
Dimmer
illumination
0
QBY
switch
rel
lighter
Remarks
(1) The broken lines are applicable to models eouipped
an automatic
transmission.
(2) For information
concerning
the ground
points
ple: 0 1, refer to P.8-7.
Wiring color code
6: Black
Br: Brown
G: Green
Ll: Light blue
0: Orange
P: Pink
control
c-57
Combination
illumination
with
meter
light
37W822
(exam-
Gr: Gray
R: Red
1 ST6 Revision
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L: Blue
Y: Yellow
LIGHTING
SYSTEM
- Service
Adjustment
Procedures
E ADJUSTMENT
8-157
PROCEDURES
T AIMING
PRE-AIMING
J;it A:I w
Targets
Must be used
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Calibration fixture
Thumb adjusting screws
Level vial
Floor level offset dial
Horizontal dial knob
Vertical dial knob
Aimer level vial
Level vial bubble
Top port hole
Viewing port
Split image
not aligned
1660245
INSTRUCTIONS
LUMINOUS
Split image
aligned
INTENSITY
MEASUREMENT
Bubble centered
1660246
Limit
: 20,000 cd or more
NOTE
1. When measuring the luminous
engine at 2,000 rpm and have
2. If there are specific regulations
lights in the region where the
that the intensity conforms to
ulations.
pTB
Revision
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8-158
LIGHTING
SYSTEM
- Headlight
HEADLIGHT
REMOVAL
AND INSTALLATION
Post-installation
Operation
Adjustment
of Headliaht
( fer to P.8-157.)
l
Aimina
NOBIJAE
Removal steps
1.
2.
3.
4.
5.
NOTE
Reverse
Radiator grille
Front combinatior I light
Headlight bezel
Retaining ring
Headlight
the removal
procedure
to reinstall.
16W963
INSPECTION
HEADLIGHT
CONTROL
RELAY
Remove the headlight
control relay from the inner side of the
left fender shield.
For models
equipped
with headlight
washers,
remove the
headlight washer tank, and then remove the headlight
control
relay.
while
Terminal
power
is
Battery voltage
not applied
Battery voltage
applied
iswasa
NOTE
(I 1 C-C
(2) O--O
ewision
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LIGHTING
COLUMN
SYSTEM
Column
8-159
Switch
SWITCH
REMOVAL
AND
INSTALLATION
NOBIPAG
3
Removal
*I)
16W1569
steps
I.
2.
3.
4.
5.
6.
Steering
wheel
Steering
wheel
Lower
column
Upper column
Column
switch
Cable band
center
pad
cover
cover
I\IIC
hlnTC
(I)
(2)
SERVICE
2.
POINTS
REMOVAL
Remove
puller.
OF REMOVAL
OF STEERING
the
steering
wheel
WHEEL
by
using
the
steering
wheel
Caution
Do not hammer on the steering wheel to remove
doing so may damage the collapsible mechanism.
) STB Revision
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it;
LIGHTING
SYSTEM
- Column
Switch
INSPECTION
Rem&e
the steering lower column cover, and then detach the
conn&tor
of the column
switch from the wiring harness.
Operate the switch and check the continuity
between the
terminals.
LIGHTING
SWITCH
16W1530
IO
NOTE
GO
DIM$ER*PASSING
between
SWITCH
Terminal
Switch
the terminals.
14
.,O
position
D2
1-1
Pl
P2
NOTE
GC
TURN
SIGNAL
SWITCH
Termina 2
Switch positi&?Left
3
n
22
0
21
o-----o
NOTE
0-C indicates that there is continuity between the terminals.
/ STB Revision
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16
LIGHTING
SYSTEM
- Hazard Warning
8-161
Switch
HAZARD WARNING
REMOVAL
AND
INSTALLATION
NOBICLAC
SERVOCE POINTS
1.
OF REMOVAL
HAZARD WARNING
SWITCH
Insert the special tool into the switch and pry the switch
remove it from the instrument
panel.
to
INSPECTION
Operate
minals.
the switch
between
16W1531
NOTE
CC
indicates
that there
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is continuity
between
the terminals.
the ter-
8-162
LIGHTING
DIMMER
CONTROL
REMOVAL
AND INSTALLATION
Removal
SYSTEM
- Dimmer
Control
Switch
SWITCH
NOBIRAB
steps
1. Knob
2. Ring
nut
3. Dimmer
control
NOTE
Reverse
switch
the removal
procedures
to reinstall.
16W936
INSPECTION
(1) Measure
the continuity
between
the dimmer
control
switch terminals
with an ohmmeter.
(2) If the resistance value varies smoothly between 0 and 10 IR
throughout
the entire operation
range, the dimmer
control
switch is functioning
properly.
1 STB Revision
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8-163
SYSTEM -Specifications
SYSETM
SPECIFICATIONS
GENERAL
SPECIFICATIONS
WINDSHIELD
WIPERS
AND WASHER
NOBKB-
Sbecifications
Items
Windshield
wiper
motor
Type
Speed control system
ermanent-magnet
Braking system
3524
45?8
wiper
type
13(g)
blade
Wiping angle
35.5 & 1.5
11451.5
Drivers side
Passengers
side
mm (in.)
washer
401 (16)
Motor type
Iirect
Pump type
Zentrifugal
3.5 or less
Power consumption
A
Allowable period of continuous
With washer
Max. 20
kPa (psi)
relay
time
load
HEADLIGHT
1.5~0.7-10.5~3
sec.
,-
70 (12.8) or more
1.5 (1.6, 1.3) or more
Tank capacity
Intermittent wiper
type
sec.
fluid
Intermittent
use
moving
0.4-I .2
sec.
60
WASHER
Specifications
Items
Washer
Motor type
Pump type
Centrifugal
21 or less
Power consumption
kPa (psi)
Nozzle injection pressure
lit.
(U.S.
qts.,
Imp.qts.)
Tank capacity
Headlight
washer
Time setting
Check valve
Valve opening
control unit
sec.
and closing pressure
type
0.52 -+ 0.1
kPa (psi)
49-108(7.1-15.6)
1 STB Revision
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8-164
COLUMN
SYSTEM
-Specifications
SWITCH
Specifications
Wiper-washer
switch
Wiper switch
Rated load
Low
3.5
intermittent
0.17-0.27
High
4.5
18
Lock
Voltage drop (at 2V and the rated load)
Washer
switch
Rated load
washer
Rated load
0.2 or less
switch
/
I
0.5 or less
0.5
A
V
REAR WIPER
0.2 or less
AND WASHER
Specifications
Items
Wiper motor
Motor type
Braking system
Revolution under no-load
4025
Nm (ftlbs.)
Nominal torque
Wiper blade
8 (6)
108
Wiping angle
Blade length
Window
380(15)
mm (in.)
washer
Motor type
Pump type
Centrifugal
Power consumption
3.5 or less
Allowable
period of continuous
With washer
use
sec.
Max. 60
Max. 20
fluid
Empty operation
Nozzle jet-spray
Tank capacity
REAR WIPER
pressure
78 (11.4) or more
1 .I (1.2, 1 .O) or more
kPa (psi)
lit. (U.S.qts.,
AND WASHER
Imp.qts.)
SWITCH
Specifications
Items
Rated load
type
Wiper switch
Washer
5
0.1 or less
switch
1 STB Revision
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WIPER
AND
WASHER
SYSETM
- Specifications
/ Special
TORQUE SPECIFICATIONS
TOOIS
8-165
N08KLb-
Nm
Items
Windshield wiper pivot shaft installing
Windshield wiper arm locking nut
IO-16
nut
IO-16
7-10
35-45
8-12
7-10
7-10
SPECIAL TOOLS
NOEKG-B
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8-166
TROUBLESHOOTING
WINDSHIELD/REAR
N08KW
/
Inspection
items
Other inspectior
items
co ~
2s
a, al
2 2
Ll-LL
1
T
+c
E
&
.;
1
0
E
-0 i;
6%
Symptom
Wiper fails to operate
Even when the wiper switch
wiper continues to operate
is at OFF, the
is operated
the wiper
*The wiper
The washer
fails to operate
0
0
NOTE
(1) Number in circle indicates inspection sequence.
(2) The *symbol indicates vehicle with intermittent wipers
1 STB Revision
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8-167
WASHER
Inspection
Other inspection
items
Symptom
Headlight washer
fails to operate
NOTE
Number in circle indicates
inspection
sequence.
1 STB Revision
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items
8468
WIPER
AND
CIRCUIT DIAGRAM
WIPER AND WASHER
lattery
WASHERS SYSTEM
Diagram
- Circuit
CIRCU
Sub
-1.SBAz2
A-23
fusible
Ignition
link
0.5-G
2-R
5-w m5-w
Z-W
U
Main
fusible
Light
control
relay
link
switch
IL
P1 I?
J.
-RW
,
Multi-purpose
fuse
JA
:
II,
.
C>
L
0.85-L
'
I-2-B
Intermittent
wiper
control
relay
-r
,m:
JJ-.
Remarks
(I)
For information
concernina
the
ground
points
(example:
a ),
refer to P.8-7.
(2)
The svmbols
0.0.
etc. indicate
that the wiring
is connected
(using
the same numerical
symbol)
to the
facing
page.
(In other words,
0 on the right
page is connected
to 0 on the left
page.)
1 C-64
a
c:
Headlight
washer
motor
relay
EEEI
m
Wiring
B: Black
LI: Light
color
blue
code
Br: Brown
0: Orange
G: Green
P: Pink
Gr:
R:
Gray
Red
/ STB Revision
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L:
Y:
Blue
Yellow
Lg:
W:
LB
L1
Light
White
green
Column
--
SYSTEM
Circuit
8469
Diagram
switch
Front-koer
-1
switch
Headlight
washer
switch
Rear wiper
and
washer
switch
r
I
o-(YL)
@JYJ
(+
BR
@- Lw
w2-B
B-l 2
)1L
!(
7
A-58
1
washer
81
B-07
>
Front
motor
A-14
Front
motor
wiper
GE&washer
motor
I
Rear
motor
wiper
37W124
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8-170
WIPER
AND WASHER
SYSTEM
- Service
Adjustment
SERVICE ADJUSTMENT
WIPE#l BLADE
WINdSHIELD
RUBBER
Procedures
PROCEDURES
REPLACEMENT
NOBKIAA
WIPER
and backing
blade
from
the stopper
Back&g
blade
REAR WIPER
1. Pull out one
stopper.
2.
3.
side
of the wiper
blade
rubber
from
the
Pull out the wiper blade rubber, and then remove the blade
rubber.
Installation
of the new blade rubber
is the reverse
procedure
of removal.
( ST6 Revision
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WIPER AND
WINDSHIELD
WIPE
REMOVAL
INSTALLATION
AND
WASHER
SYSTEM
- Windshield
8-171
Wipers
NOBKJAD
16W961
Removal
steps
1. Wiper
l + 2. Wiper
4*
3.
4.
5.
6.
Wiper
Wiber
Wiper
Wiper
blades
arms
pivot shield
pivot collars
motor
link
caps
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) 4* : Refer to Service Points of Removal.
(3) I)* : Refer to Service Points of Installation
SERVICE
5. WIPER
POINTS
OF REMOVAL
MOTOR
Uncouple
the
pulled
slightly
linkage
outward).
and
motor
(with
the
Caution
Because the installation
position
of the crank
motor determine
the wiper auto stop angle,
semble them unless it is necessary to do so. If
must be removed
from the motor,
remove
marking
their mounting
positions.
svision
I
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wiper
motor
8-172
WIPER
AND WAsHER
SYSTEM
SERVICE
2.
POINTS
INSTALLATION
Wipers
Windshield
OF INSTALLATION
OF WIPER
ARMS
Install the wiper arm to the pivot shaft so that the wiper
blades stop position is the position shown in the illustration.
nm (in.1
16Y1568
INSPECTION
WIPER
MOTOR
Disconnect
the wiring connector
from the wiper motor
connect battery to the wiper motor connector
to check
the @viper motor runs.
LOW
SPEED
OPERATION
CHECK
(v
and
that
L
I
Battery
to terminal
+
Battery
II
16W1538
AUTOMATIC
STOP OPERATION
CHECK
(1) Connect
battery ( +) to terminal
1 and battery ( -) to
terminal
3 to run the motor at low speed.
(2) Disconnect
terminal
1 during operation
to stop the motor.
bv
J
.jr
2.
Battery
16W1539
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WIPER
AND WASHER
SYSTEM
- Windshield
8-173
Wipers
To wiper
motor
bracket
16W1540
INTERMITTENT
WIPER RELAY
Remove the intermittent
wiper relay (located
of the left side cowl side trim).
16W1524
CONTINUITY
CHECK
Check to see that there
5.
16UO373
) STB Revision
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is continuity
between
terminals
2 and
a-174
WIPER AND
WASHER
$YSTEM
INTERMITTENT
OPERATION
CHECK
(1) Cpnnect the battery and the test light to the relay, as
shown in the figure.
(2) l&ert a variable resistance between terminal 8 and battery
(1) (VR = O-50 kfl)
(3) The condition is normal if, when the batterys negative (-)
terminal is connected
to terminal
7, the test light illuminates at the same time, and thereafter,
in accordance with
the value of the variable resistance,
stops illumination
(approx. 1.5 sec. - approx. 10.5 sec.) and then illuminates
(approx. 1 sec.) over and over again.
7-est
- Windshield
WASHER
INTERLOCK
OPERATION
CHECK
(1) Connect the battery and the test light to the
shown in the .figure.
light
relay,
as
16K1920
REAR WIPtER
REMOVAL
AND
INSTALLATION
NOOKKAC
16W962
Removal
+e
steps
film
1 STB Revision
NOTE
Reverse the removal procedures to reinstall.
(2) 4* : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation.
(1)
-7
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WIPER
AND WASHER
SYSTEM
SERVICE
2.
POINTS
REMOVAL
FILM
3.
2.
16K394
Rear
POINTS
8-175
Wiper
OF REMOVAL
OF BACK
Refer to GROUP
proof Film.
SERVICE
DOOR
TRIM
AND
WATERPROOF
and Water-
OF INSTALLATION
INSTALLATION
Install the wiper
the lower edge
OF WIPER BLADE
arm so that the wiper blade
of the window glass.
INSTALLATION
PROOF FILM
Refer to GROUP
proof Film.
OF BACK
DOOR
TRIM
is parallel
AND
to
WATERand Water-
INSPECTION
WIPER MOTOR
Disconnect
the wiring connector
from the wiper motor
connect battery to the wiper motor connector
to check
the wiper motor runs.
I STB Revision
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and
that
8476
WIPER
AND WASHER
SYSTEM
- Rear Wiper
OPERATION
CHECK
Connect battery (+ :I to terminal 1 and battery
to check that the motor runs.
( -) to terminal
16W1541
AUTOMATIC
OPERATION
CHECK
(1) Connect
battery (+) to terminal
1 and. battery ( - ) to
terminal
3 to run the motor.
(2) While the motor is running, disconnect
terminal
1 to stop
the motor.
Battery
2.3
To wiper
motor
bracket
+
10w1543
1 STB Revision
-7
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WIPER
AND WASHER
WINDSHIELD
WASHER
REMOVAL
INSTALLATION
AND
SYSTEM
- Windshield
8-177
Washer
N08KlAD
16W1556
1.
2.
3.
4.
INSPECTION
::I:;rl
_
+
WASHER
MOTOR
AND
PUMP
1
2
18K1514
negative
( -)
[ STB Revision
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terminal
is connected
to terminal
I.
8-178
SYSTEM
- Rear Washer
REAR WASHER
REMOVAL
AND INSTALLATION
N08KLCA
16W1669
Removal
steps
+e
1.
2.
3.
4.
5.
~~
Rear wheelhouse
trim and quarter
Rear washer tank
Washer motor and pump
Washer tube
Washer nozzle and tube
trim
NOTE
(1)
(2)
(3)
SERVICE
1.
Reverse
POINTS
REMOVAL
TER TRIM
Ravisinn
procedures
Points
Points
-7
http://vnx.su/
to reinstall.
of Removal.
of Installation.
OF REMOVAL
OF REAR WHEELHOUSE
Refer to GROUP
1 STR
the removal
l * : Refer to Service
l + : Refer to Service
23 BODY
- Trims.
TRIM
AND
QUAR-
WIPER
AND WASHER
+1
li.if
I
SYSTEM
- Rear Washer
/ Headlight
Washer
8-179
INSPECTION
SERVICE
POINTS
1. INSTALLATION
OF INSTALLATION
OF
REAR
WHEELHOUSE
TRIM
AND
QUARTER TRIM
Refer to GROUP
HEADLIGHT
REMOVAL
Removal
AND
23 BODY - Trims.
WASHER
INSTALLATION
NOEKPAA
steps
1.
2.
3.
4.
5.
Radiator grille
Front combination light
Headlight bezel
Headlight washer nozzle
Washer tube
6. Check valve
7. Headlight washer tank
8. Washer motor and pump
16W1562
NOTE
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WIPER AND
WASHER
SYSTEM
Headlight
Washer
INSPECTION
WASHER
16Wl544
MOTOR
AND
PUMP
HEADLIGHT
WASHER
RELAY
WASHER
OPERATION
part
CHECK
(1) Connect the battery and the test light to the relay as
,shown in the figure.
(2) If, when terminal
1 is connected
to the negative
(-)
terminal of the battery, the light illuminates
(for about 0.5
second), the unit is operating
normally.
18W943
Test light
16W945
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WIPER
COLUMN
AND
WASHER
SYSTEM
8-181
Switch
Column
SWITCH
REMOVAL
AND
INSTALLATION
NOBKMAE
35-45 Nm
3
Removal
l *
16W1569
steps
1.
2.
3.
4.
5.
6.
pad
NOTE
(1)
Reverse
the
(2)
*I)
: Refer
SERVICE
2.
removal
procedures
to Service
Points
POINTS
REMOVAL
Remove
to
of
reinstall.
Removal
OF REMOVAL
OF STEERING
the steering
WHEEL
wheel
by usiing
the steering
wheel
puller.
Caution
Do not hammer
doing so many
) STB Revision
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on the
damage
steering
wheel
the collapsible
to remove
mechanism.
it;
8482
between
the
16W1530
WIPER-WASHER
SWITCH
20
1 OFF
Ip-I
18
15
HI
14
19
o-t--t-o
v
o-
13
- -
-0
NOTE
(1) GC
indicates that there is continuity
between
the terminals.
(2) The dotted lines indicate that the washer switch ON.
HEADLIGHT
WASHER
Terminal
.,2
Switch Poisition
OFF
ON
NOTE
C-C indicates
that there
16W153C
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is continuity
between
the terminals.
WIPER
AND
WASHER
SYSTEM
4*
AND
- Rear Wiper
and
Washer
8-183
Switch
SWITCH
INSTALLATION
I. Rear wiper
NOTE
l * : Refer to Service
SERVICE
POINTS
1. REMOVAL
OF REMOVAL
OF REAR
WIPER
AND
WASHER
SWITCH
Insert the special tool into the switch and pry the switch to
remove it from the instrument
panel.
INSPECTION
Operate
minals.
the switch,
16W944
) STB Revision
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between
the ter-
8-184
HORN
Specifications
/ Troubleshooting
HORN
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOBLE--
Specifications
Items
Effective
Power
sounding
voltage
consumption
Sound level
Fundamental
(at 12V)
11-14.5
A
Max. 3.5
dB
100-7 10
frequency
Hz
High
sound
400--440
Low
sound
340--380
TORQUE SPECIFICATIONS
Items
Steering wheel
lock nut
Nm
ft.lbs.
35-45
26-33
TROUBLESHOOTING
HORN
NOBLH-
in circle indicates
inspection
0
sequence.
1 STB Revision
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@I
0
Horn contact
plate
HORN - Circuit
8485
Diagram
CIRCUIT DIAGRAM
HORN CIRCUIT
fusible
link
OFF
Multi-purpose
fuse
I r
m
I
2
d
t
1
mm
I
I
mm
2%
$2
dd
dd
A-37
Horn switch
Column switch
To wiper motor
[Refer to P.8-59.1
A-36
A-38
A-39
I--J!
(H)
(U
37W608
Remark
For information
concerning the ground
refer to P.8-7.
Wiring color code
Br: Brown
B: Black
LI: Light blue
0: Orange
points (example:
G: Green
P: Pink
Gr: Gray
R: Red
1 STB Revision
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L: Blue
Y: Yellow
8486
HORN - Horn
HORN
REMOVAL
Removal
AND INSTALLATION
NOBWAE
steps
1. Radiator grille
2. Horn (High)
3. Horn (Low)
NOTE
INSPECTION
o
o
l
HORN ADJUSTMENT
169744
1 ST6 Revision
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the
HORN - Horn
8-187
Switch
HORN SWITCH
REMOVAL
AND
INSTALLATION
NOILKAE
T--J2
Removal
+I)
steps
1.
2.
3.
4.
5.
Steering wheel pa
Steering wheel
Steering bossplate
Steering wheel cover
Horn switch
16W1570
I IL
(1)
(2)
SERVICE
2.
POINTS
REMOVAL
Remove
puller.
OF REMOVAL
OF STEERING
the steering
to reinstall.
of Removal.
wheel
WHEEL
by using
the steering
wheel
Caution
Do not hammer
on the steering
wheel to remove
doing so may damage
the collapsible
mechanism.
INSPECTION
l
l
l
1 STB Revision
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contact.
it;
8-188
ACCESSORY
- Specifications
/ Troubleshooting
ACCESSORY
SPECIFICATIONS
GENERAL
SPECIFICATIONS
CIGARETTE
LIGHTER
NOBMB-
Specifications
Items
Maximum
current
Return time
A
I
I
sec.
10
18 or less
CLOCK
Items
Specifications
Crystal oscillating type
Fluorescent digital display
Type
Display type
TROUBLESHOOTING
ZIGARETTE LIGHTER AND CLOCK
Inspection
Symptom
Cigarette
Clock stopped
NOTE
Number
in circle indicates
inspection
sequence.
MB
Revision
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items
ACCESSORY
- Circuit
8-189
Diagram
CIRCUIT DIAGRAM
CIGARETTE LIGHTER / CLOCK CIRCUIT
Sub
,-fs
M
Main
link
15-W
fusible
5-W 25-W
I I
fusible
LW
w
EB
Ignition
link
switch
;I;
3e
I
NN
I
,
To- .J
linht . cnntrnl
__._ [Refer
to P.8-461
To radio
[Refer
to
To hazard
[Refer
to
illumination
flasher
P.8-491
P.8-601
r&v
-.,
GW
1 .25-
Z-RW
I 4
I 4
L-K
GB
unit4
Multi-purpose
fuse
light
r
To heater
illumination
[Refer
to
control
light
P 8-511
iI
I
-I To combination
[Refer
to P.8-521
Wiring
B: Black
Br: Brown
G: Green
Gr: Gray
L: Blue
Lg: Light
color
green
meter
BY
m
I
N
Q-
code
LI: Light
0: Orange
P: Pink
R: Red
Y: Yellow
W: White
To dimmer
[Refer
to
blue
control
P 8-511
switch
.I
BY
37W615
Remark
For information
refer
to P.8-7.
1 STB Revision
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concerning
the
ground
points
(example:
).
8-190
ACCESSORY;
CIGARETTE
REMOVAL
Lighter
LIGHTER
AND
Removal
- Cigarette
INSTALLATION
NOEMJAE
steps
1. Knob
Plug
3. Center
4. Plug
5. Nut
6. Socket
2.
7.
Outer
panel
case
8. Cigarette
lighter
NOTE
Reverse
bracket
the
removal
procedure
to
reinstall.
16W1555
INSPECTION
l
l
l
CAUTIONS
FOR USE OF THE CIGARETTE
AS AUXILIARY
POWER SOURCE
LIGHTER
SOCKET
overloaded
1 STB Revision
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ACCESSORY
Clock
8-191
CLOCK
REMOVAL
Removal
AND
INSTALLATION
NOBMKAD
steps
1. Knob
2. Plug
3. Center
4. Clock
panel
16W1558
NOTE
Reverse
the removal
procedures
to reinstall
1 STB Revision
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8-192
AUDIO
I/
SYSTEM
SPECIFICATIONS
GENERAL
SPECIFICATIONS
NOENB-
Items
Spe,cifications
Radio
Model
AR-7 127PY
AR-7 177PY
Receiving band
AM/ FM
AMI FM
Tape player
Model
-_-
CX-25Y
Speaker
Instrument
panel
-
Model
SR-28A4-Y K-2
5W (Max. 7W)
SG-13SL4-G2 (GRAY) or
SG-13SL4-BE87 (BEIGE)
SG-13SL4-G2 (GRAY) or
SG-13SL4-BE87 (BEIGE)
Pole antenna
Pole antenna
Antenna
Type
TROUBLESHOOTING
Symptom
NOTE
Number
in circle indicates
inspection
sequence
( STB Revision
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8-193
of Electrical
System
Noise
Ignition system
Power generation
system
(3) Distributor
(1) Armature
motors.
of wiper,
blower
and other
switch
(4) Horn
(5) Contact of turn signal
(6) Loose contact of wiring
!
Noise
Sourse
of Vehicle
harness
Equipment
Kind of noise
Equipment
Symptom
Whistling
Alternator
Scratching
sound
sound
Water temperature
gauge unit
of noise generation
Jarring
Oil pressure
Wish-wash,
wish-wash
Flasher relay
Noise is produced
signal light
Buzz, click
Horn
Whinning
Wiper motor
Noise is generated
Washer
switch
motor
STB Revision
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with operation
of turn
8-194
AUDIO
SYSTEM
Diagram
- Circuit
CIRCUIT DIAGRAM
I
RADIO/CASSETTE
DECK CIRC,UIT
LW
w
033
Ignition
A-02 IL-
Battery
Sub fusible
1.25-B
5-w
Main
link
A-23
5-w ll5-w
u
switch
link
0.5-G
2 w
-
fusible
Z-RW,,: 3
To air conditioner,LW
[Refer to P.8-561
To combination
4
meter
[Refer to P.8-521
By
DIN Cable
Tape
I
I
/
J
It, /II
=z
c- 45
player
Radio
[ STB Revision
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AUDIO
SYSTEM
- Circuit
8-195
Diagram
Front
speaker
(L.H.)
C-65
B-03
YL
Gr,=:
(L.H.)
B-04
Rear
speaker
B-29
YR c
GrRC+
(R.H.)
B-2?
Remarks
(1)
For information
concerning
the
ground
points
(example: 0 ), refer
to P.8-7.
(2) The
symbols
0,
0,
etc.
indicate
that
the
wiring
is
connected
(using
the same
numerical
symbol)
to the
facing
page.
(in other words,
0 on the right page is connected
to 0 on
the left page.)
Wiring
color
B: Black
LI:
Light
blue
code
Br:
0:
Brown
Orange
G: Green
P: Pink
Gr: Gray
R: Red
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L: Blue
Y: Yellow
Lg:
Light
W:
White
green
8-196
AUDIO
SYSTEM
- Service
Adjustment
Procedures
SERVICE ADJUSTMENT
ANTkNNA
PROCEDURES
TRUMMER
NOBNIAA
1. The antenna
TRIMMER
ADJUSTMENT
2.
70R0351
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of an electronic
tuning
AUDIO
RADIO
REMOVAL
SYSTEM
e-197
Player
INSTALLATION
NOINJAF
16W1519
Post-installation
Operation
l
Adjustment
of Antenna
(Refer to P.8-196.)
Trimmer
Removal steps
1. Knob
2. Plug
3. Center console
7. Radio
8. Tape player
9. Box (Vehicles without tape player)
4. Connection
of center panel wiring
harness to front wiring
harness
connector
5. Radio panel
6. Radio bracket
NOTE
Reverse
1 STB Revision
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the removal
procedures
to reinstall.
8-198
AUDIO
SYSTEM
- Front
Speaker
/ Rear Speaker
FRONT SPEAKER
REMOVAL
AND INSTALLATION
Removal
NOONMAE
steps
1. Mounting screws
2. Front speaker
NOTE
Reverse
16W1520
the
removal
procedures
to
reinstall.
REAR SPEAKER
REMOVAL
AND
INSTALLATION
16Wl570
Removal
steps
1. Mounting screws
2. Rear speaker
NOTE
Reverse
the
removal
procedures
to
reinstal
1 STB Revision
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AUDIO
SYSTEM
8-199
- Antenna
ANTENNA
REMOVAL
AND
NOSNPAC
INSTALLATION
16W1579
Removal
4*
+e
w+
steps
1.
2.
3.
4.
5.
Mounting nut
Antenna mast
Front fender panel
Ground base
Antenna base
NOTE
(1)
(2)
(3)
SERVICE
POINTS
OF REMOVAL
1. REMOVAL
OF MOUNTING
NUT
Hold the antenna mast, and then
http://vnx.su/
remove
the mounting
8-200
AUDIO
SYSTEM
3.
Antenna/Noise
REMOVAL
OF FRONT
Refer to GROUP
SEFiVlCE
3.
Suppression
ff OINTS
FENDER
23 Body-Front
PANEL
Fender
OF INSTALLATION
IbSTALLATION
OF FRONT FENDER PANEL
Refer to GROUP 23 Body-Front
Fender.
NOISE SWPRESSION
N08NOAA
I.
Noise interfering
with radio reception
may be roughly
classified
as follows:
(1) Noise produced
by the vehicle itself
Noise from the ignition circuit, alternator
circuit, etc
(2) Noise generated
in the radio itself
Thermal
noise from transistors,
IC, resistor, etc.
(3) Atmospheric
noise
Noise from other cars, neon signs, etc.
2. The radio has devices to suppress noise of the radio itsel f
and atmospheric
noise, but it is difficult to eliminate
them
completely.
Noise produced by the vehicle includes whining from the alternator
system, and a strong, impulsive,
fast popping
noise from the ignition
system.
3. Before performing
any checking
or adjustments,
first
confirm the following
points.
Adjust the antenna trimmer
completely.
Set the push buttons (tuning) properly.
Extend the antenna all the way.
PREVENTION
OF IGNITION
CIRCUIT
NOISE
A resistance-equipped
cable is used for the high-tension
cable
in order to prevent noise; however, if any noise from the
ignition
circuit does occur, check the tightness
and ground
connection
of the positive (+) terminal of the noise filter, and,
if necessary,
check the noise filter.
Caution
Be careful not to connect the noise filter to the hightension
cable; doing so could damage
the noise filter.
PREVENTION
OF OTHER CIRCUIT
NOISE
1. For other noises, take necessary
corrective
actions
in
accordance
with the following
items and the NOISE
SUPPRESSION
CHART.
2. Polish the grounding
cable terminal, and connect it properly.
3. Polish the pillar antenna ground terminal,
and connect it
properly.
4. Ground electric parts completely.
5. Keep the antenna cable and speaker lead wire away from
other electric wiring.
STB Revision
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SUPPRESSION
8-201
Suppression
CHART
Symptom
Remedy
Unusual noise
engine speed.
related
to
Securely
hood.
ground
the engine,
frame
and/or
Ground wire
16E71C
Clatter
flashing
Turn signals
?L
capacitor
to the 6 terminal
Abnormal
noise when
the horn is operated.
Horn
1.
2.
Horn
LC filter
16E71:
Washer
motor
1.
2.
the
capacitor
to the terminal
1 STB Revision
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8-202
AUDIO
NOISE SUPPRESOR
SYSTEM
- Noise Suppression
LOCATION
16W722
--I
1
Grou:d
cable
- Noise condenser
1 STB Revision
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16W1580
DEFOGGER - Specifications
/ Special Tools
8-203
DEFOGGER
SPECIFICATIONS
( ;ENERAL
SPECIFICATIONS
NOOPB-B
Specifications
Items
Back door window
defogger
switch
Type
Seesaw
Rated current
20A
defogger
timer
-
Timer
Back door window glass with defogger
No. of printed heater lines
Power consumption
11
112-148W
[2OC (68F)]
SPECIAL TOOLS
Tool (Number
MB990784
Ornament
type
and name)
remover
NOBPG-B
Use
Removal of back door
window defogger
switch
1 STB Revision
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8-204
I
DEFOGGER-Troubleshooting
TROUBLESHOOTING
functions,
NOBPH-B
defogger
function.
defogger
does not
.--Number
in circle indicates
inspection
sequence.
/ STB Rqvision
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0
0
BACK
DOOR WINDOW
CIRCUIT DUAGRAM
DEFOGGER CIRCUIT
-
8-205
- Circuit Diagram
-t IDI L
H-ULm
Ll&J
5-w
Main
link
DEFOGGER
Sub fusible
A-23
5-w"5'w
fusible
link
0.5-G
ignition
switch
z-w ,
To light control
zmR~
w
relay
[Refer to P.8-461
q--l-
Multi-purpose
@fuse
1.25-B
m
E
c:
To column switch
[Refer to P.8-461
a
c!
\
Rheostat
Defogger
Remarks
For information
refer to P.8-7.
concerning
the ground
points
switch
a
cl
(example:D).
31 W02:
Br: Brown
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
STB Revision
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L: Blue
Y: Yellow
8-206
DEFOGGER SWITCH
REMOVAL
AND
OEFOGGER
I
- Defogger Switch
INSTALLATION
NOEPJAB
\
A
w
I_
1. Defogger
NOTE
+* : Refer.to
switch
SERVICE
1.
POINTS
REMOVAL
16W932
OF REMOVAL
OF DEFOGGER
SWITCH
lr@rt the special tool into the switch and pry the switch
remove it from the instrument
panel.
to
INSPECTION
DEFOGGER
SWITCH
(1) Remove the defogger
switch from the instrument
panel
and connect an ohmmeter
to the switch side connector.
(2) Operate the switch and check the continuity
between the
terminals.
* : Indicator light
** : Illumination light
16W976
NOTE
0-C indicates that there is continuity between the terminals.
1 STB Revision
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BACK
Normal
characteristic
DOOR WINDOW
DEFOGGER
INSPECTION
I;\\
Abnormal
Printed
heater
line
characteristic
Negative
terminal
curve
Voltage
Tf
IZV
I Open-circuit
I point
I
6V
ov :Positive
terminal
Printed
heater
line
Printed
Heater
Lines
B-207
curve
Voltage
Positive
terminal
Negative
terminal
N08PKAA
161332
Alignme.nt
REPAIR
holes
I.
Masking
tape
16FfiSCl
2.
3.
4.
Caution
After repair, clean the glass with a soft dry shop towel
or wipe along the printed
heater line with a slightly
moistened
shop towel.
1 STB Revision
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8-208 AUTO
ATIC FREE-WHEELING
GENERAL INFORMATION
HUB INDICAUOR
SYSTEM
General
Information
N08RAAA
Automatic
free-wheeling
hub
16W1567
hub indicator
16W1506
1 STB Revision
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AUTOMATIC
OPERATIONAL
FREE-WHEELING
CHARACTERISTICS
HUB INDICATOR
SYSTEM
General
Information
8-209
OF THE SYSTEM
Time-----w
16W1548
Symbols used in
above diagram
No illumination of the indicator light when the ignition key is turned from OFF to ON,
regardless of the condition of the automatic free-wheeling hub.
The indicator light illuminates when the automatic free-wheeling hub is locked and pulse
signals are output from the pulse generator, and when, in addition, the vehicle-speed sensor
detects a vehicle speed of approximately 2.5 mph (4 km/h) or higher.
The locked condition is entered in the memory even if the vehicle is stopped (with ignition
key still at ON) while the automatic free-wheeling hub is in the locked condition, and the
indicator light illumination continues.
After the automatic free-wheeling hub is changed from the locked condition to the free
condition (the pulse signals from the pulse generator cease), the indicator light remains
illuminated until the vehicle-speed sensor detects a vehicle speed of approximately 2.5 mph
(4 km/h) or higher.
1 STB Revision
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8-210
AUTOMATIC
EXPLANATION
FREE-WHEELING
OF INDICATOR
HUB INDICATOR
SYSTEM
General
Information
OPERATION
1. Automatic
free-wheeling
hub in locked condition
The output of the pulse generator
is input to $ertninal
4 of the control
unit, and the output signals from
the vehicle-speed
sensor are input to termi#al
3 of the control unit.
Only when there are pulse signals from the pulse generator,
and when, moreover, the vehicle-speed
signals indicate a vehicle speed of approximatkly
2.5 mph (4 km/h) or highter does the control unit judge
that the automatic
free-wheeling
hub is the locked condition
at the lock-discrimination
circuit of the
control unit, and therefore the set signal (locked condition)
is output.
This signal is entered into the memory
circuit, thus causing the indicator
light to illuminate.
Speed sensor
(Reed switch)
Pulse generator
use No. 3
Ignition
n
J 2
switch
I_
Power-supply
Pulse-detection
circuit
link
Main
link
1
1
Vehicle-speed
detection
circuit
circuit
Sub fusible
fusible
)1
Battery
Memory
circuit
rp*
I
Automatic
free-wheeling
indicator control unit
2.
hub
Lock-discrimin&ion
circuit
16W1535
Pulse generator
sense
use
No. 3
Ignition
switch
10~ Automatic
free3; wheeling
hub
I/\ indicator light
Sub fusible
Power-supply
Pulse-detecti:
Lock-discrimination
Memory
ci~uit~~I~
circuit
detection
circuit
Automatic
free-wheeling
indicator control unit
hub
[ STB Revision
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circuit
circuit
Main
fusible
link
link
AUTOMATIC
3.
FREE-WHEELING
HUB INDICATOR
SYSTEM
8-211
Generallnformation
Automatic
free-wheeling
hub in free condition
For the free condition,
although there are (when the vehicle is traveling)
output signals from the vehiclespeed sensor,
there are no signals from the pulse generator,
with the result that the memory
circuit is
erased (because
reset signals are output from the lock-discrimination
circuit), and so the indicaotr
light
does not illuminate.
ipeed
Ignition
sensor
Automatic
switch
free-
Sub fusible
link
i
link
detection
IUse-detection
Lock -discrimination
circuit
circuit
Memory
circuit
Automatic
free-wheeling
indicator control unit
Pulse
generator
cross-sectional
Coil
PULSE
view
hgnet
16W1547
rator
hub
GENERATOR
16W1546
STB Revision
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8-212 AUTOMATIC
FREE-WHEELING
Speedometer
I
iensor
SENSOR
(REED-TYPE
SWITCH)
The vehicle-speed
sensor functions to substitute
pulse signals
for the rotations (vehicle speed) of the transmissions
output
gear;/ it is located within the speedometer.
Pulse signals are generated
when the speedometer
cable
rotates.
Vehicle-speed
sensor
12R0058
16W1506
AUTbMATlC
FREE-WHEELING
CONTROL UNIT
Circuit
HUB
INDICATOR
The control unit is located at the upper part of the right cowl
side.
The control unit is composed
of the pulse-detection
circuit
(which receives the input signals from the pulse generator),
the vehicle-speed-detection
circuit (which receives the input
signals from the vehicle-speed
sensor), the lock-discrimination
circuit (which, based on both of these input signals, judges the
condition
of the automatic
free-wheeling
hub and then transmits indicator output signals to the memory
circuit), and the
memory
circuit (which
memorizes
the indicator
output
signals from the lock-discrimination
circuti).
Diagram
16W153
SPECIFICATIONS
GENERAL
SPECIFICATIONS
Specifications
Items
Automatic free-wheeling
Pulse generator
W (SAE
trade number)
Type
Vehicle-speed
1.4(74)
sensor
Reed switch
Type
Pulse generation
4 pulses/
type
rotation
SERVICE SPECIFICATIONS
NOORG-
Specifications
Items
Standard values
Pulse generator
Vehicle-speed
resistance
215-275
1 STB Revision
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When
OFF
4 or more
When
ON
AUTOMATIC
FREE-WHEELING
HUB
INDICATOR
SYSTEM
-Troubleshooting
8-213
TROUBLESHOOTING
Inspection
NOIRH-
items
Symptom
Reference
page
3-21E
in circle indicates
inspection
sequence.
/ STB Revision
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Cc
8-214 AUTOM
TIC FREE-WHEELING
VU6
INDICATOR
SYSTEM
Circuit
Diagram
CIRCUIT DIAGRAM
AUTOMATIC FREE-WHEELING
CIRCUIT
F==e=%
HUB INDICATOR
lu-!
A-02
Battery
Main
link
Sub fusible
15-w
r-)5-w
I I
SYSTEM
link
0.5-G
I
Ignition
2-w
switch
fusible
7
N
-22
Pulse
generator
3
c:
h
IA-21 m
v?~
r:
BI I
= 9i
To column switch
[Refer to P.8-461
A
m
c:
2
CT
I
z
d
LR
I
!J
q IIEI
Automatic
free-wheeling
indicator control unit
Combination
meter
hub
37W610
1 B R
El1 Y L
Em
Remark
For information
refer to P.8-7.
concerning
the ground
Br: Brown
0: Orange
points (example:
G: Green
P: Pink
),
,r: RG,dY
1 STB Revision
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L: Blue
Y: Yellow
AUTOMATIC
FREE-WHEELING
HUB INDICATOR
SYSTEM
Pulse
Generator
8-215
PULSE GENERATOR
REMOVAL
Removal
AND
INSTALLATION
NOBRJM
steps
I. Pulse
2. O-ring
generator
NOTE
(1) Reverse the removal procedures
(2) q : Non-reusable
parts
to reinstall
l
l
CHECKING
PULSE GENERATOR
RESISTANCE
value
: 215 - 275 LR
16WO92
i
1 STB Revision
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8-216 AUTOMATIC
AUTOMATIC
REMOVAL
Removal
FREE-WHEELING
FREE-WHEELING
HUB INDICATOR
SYSTEM
HUB INDICATOR
AND INSTALLATION
Control
CONTROL
Unit
UNIT
NOBRKAA
steps
/
16W1568
1
NOTE
Standard
values
Vehicle-speed
Vehicle-speed
:
sensor
sensor
OFF : 4V or higher
ON : OV
If there is a malfunction
of the vehicle-speed
sensor,
replace it by replacing the speedometer
assembly.
( STB Revision
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24-1
AIR-CO
IONING
CONTENTS
AIR-CONDITIONING
AIR CONDITIONER
CIRCUIT DIAGRAM
SWITCH
.........................
......................................
42
.. 26
COMPRESSOR
...............................................
EVAPORATOR
............................................
....
GENERAL INFORMATION
.............. . ....... . . . ....
RECEIVER DRIER, CONDENSER,
COMPRESSOR
CLUTCH ASSEMBLY
..........
SAFETY PRECAUTIONS
................................
SERVICE ADJUSTMENT
PROCEDURES
......
Compressor
Compressor
Noise
.....................................
Handling
Tubing
and Fittings
Manifold
Gauge
Set Installation
Performance
Refrigerant
Test
Testing
.....................
System
SPECIAL TOOLS
SPECIFICATIONS
................
......................................
Test Procedures
...........
...........
.........................................
for Leaks
46
43
19
45
28
29
40
Is Intermittent
Insufficient
Air Flow
Insufficient
Cooling
HEATERS
14
BLOWER ASSEMBLY
. . .. . . . . . . . . .. .. . . ..a...............
CIRCUIT DIAGRAM
. . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. .. . . . . . . 4
GENERAL INFORMATION
. . . . . . . . . .. . . . . . . . . . . . .. . . . . . 2
. . . . . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . .. .. . . 9
HEATER CONTROL
.
.
.
.
.
.
.
.
.
.. . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . .. . . 12
HEATER UNIT
SERVICE ADJUSTMENT
PROCEDURES
. . . . .. 5
41
39
Temperature
Adjustment
29
Water
34
Control System
. . .. .. .. . . . . . . . . . . .. .. . . . . . . . . . . . .. .. . . . . . . . . .. .
Valve Replacement
Blower
Motor
29
Blower
Speed
Motor
Only
..........................
33
............................................
...... . . .. .................................
22
21
Specifications
...............................
21
Service
Specifications
................................
21
Torque
Specifications
................................
21
....................................
22
Improper
. . . . . . . . . . . . .. . . . . . . . ..
. .. .. . . . . . . . . . . . .. .. . . . . . . . . .. . . . . . .
TROUBLESHOOTING
34
General
TROUBLESHOOTING
Air is Emitted
5
8
Inoperative
Operates
on High
Heat
No Ventilation
Even When Mode
Selection Lever Is Operated
VENTILATORS
http://vnx.su/
. . . . . . .. .. . . . . . . . . . . .. . . . . . ..a..... .. .. . . . . . . .. 16
24-2
HEATERS
GENERAL
- General
Information
INFORMATION
24BAAD
The heater unit and the blower motor are the separate type.
For temperature
control of the heater, the blend air system is used for excellent
response and easy
temperature
adjustment.
Because the damper in the blend air system controls the warm air, which passes through the heater core,
of the temperature
are
and fresh (cool) air, which does not pass througlh the core, minor adjustments
therefore
possible,
and the temperaturecan
be ,set to the optimum
level.
The lap heater ducts (which provide warm air to th$ knee area for the front seats)
(which provide warm air to the foot area for the rebr seats) from the heater unit,
rear heater, assure
heating comfort
throughout.
:
Blower motor
/
;;eselection
Mode selection lever
I
2OW640
Blower
To defroster and
Blend
air
damper
demister
Air selection
damper
Fresh air
Mode selection
damper (VENT)
To foot area
ro
rear heater
duct
Mode
To rear heater
duct
selection
damper (FOOT/DEF)
1 ST6 Revision
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2OW706
switch
58W540
Temperature
contra
lever
24-3
HEATERS -Troubleshooting
TROUBLESHOOTING
Symptom
Improper
N24EAAC
Probable
heat
cause
Obstructed
Correct
24-5
malfunction
Replace
heater
Replace
24-l 2
Adjust
24-5
Clean or replace
24-l 3
Adjust
24-5
Adjust
24-5
hoses
adjusted
control
cables
Plugged
or partially
plugged
heater
Incorrect
pers
adjustment
of changeover
Incorrect
wire
installation
mode
Broken
blower
motor
Broken
blower
switch
Blower
erative
Burnt-out
inop-
, Thermostat
selection
motor
adjusted
Correct
dampers
Improperly
improperly
Reference
paw
Changeover
or binding
Obstructed
No ventilation
even
when mode selection
lever is operated
floor outlets
Remedy
core
damcontrol
con-
resister
fuse
Poor grounding
Repair
or replace
Replace
24-l 5
Replace
24-l 0
Replace
Correct
Malfunction
blower
switch
Replace
24-l 0
Malfunction
blower
motor
Replace
24-l 4
1 STB Revision
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24-4
HEATERS
CIRCUIT
DIAGRAM
c Circuit
Diagram
I
1 El1
El3
lanition
Battery
link
Sub fusible
(Fuse
B)
m-
switch
link
(Ignition
switch)
Multi-purpose
fuse
$5
LA,:
a3 M
To turn
sional
flasher
[Refer
to P.8-49.7-
(Init
- d
0.85RI
f-Y
I I
-r
Blower
-18
Blower
Remark
For information
concerning
refer
to P.8-7.
Wiring
color
code
B: Black
LI: Light
blue
the
Br. Brown
0: Orange
ground
Blower
resistor
switch
CJ
points
(example:
G: Green
P: Pink
motor
Heater
r&v
Lg:
W:
Light
White
),
Gr: Gray
R: Red
1 STB Revision
http://vnx.su/
L: Blue
Y: Yellow
green
HEATERS
Service
Adjustment
SERVICE
24-5
Procedures
DJUSTMENT
TEMPERATURE
ENT
CONTROL
PROCEDURES
SYSTEM
ADJUSTN24FAAD
MODE SELECTION
LEVER
1. Move the mode selection lever to each position and check
the air flow with the blower operating.
2. If the air flow is not correct for any position of the mode
selection lever, adjust the mode selection control wire. If
this adjustment
does not help, adjust the damper.
Adjustment
of the Mode Selection
1. Disconnect
the defroster duct and
at the drivers seat side from the
2. Disconnect
the mode selection
mode selection
damper
lever and
Control
Wire
the lap heater duct (B)
heater unit.
control wire from the
the heater unit,s clip.
3.
that
when
to the
in the
mode
heater
clipping.
6.
Adjustment
of the Damper
1. Disconnect
the. mode selection
control wire from the
mode selection
damper lever and the heater units clip.
2. Adjust the VENT damper as described
below:
(1) Unfasten the clip of the mode selection damper lever,
and disconnect
the link for the VENT damper from
the mode selection
damper
lever.
1 STB Revision
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24-6
HEATERS
Service
Adjustment
Procedures
(2) Turn the mode selection damper lever all the way in the
direction
of the arrow.
(3) Pull the VENT damper lever completely
downward
and move the VENT damper
to the position
(not
visible) shown in the figure.
(4) Attach the end of the link for the VENT damper to the
: mode selection
damper
lever.
3.
damper
NOTE
When attaching it, pull the lever end (A in the figure)
the direction
of the arrow.
4.
in
1 STB Revision
http://vnx.su/
HEATERS
- Service
Adjustment
Procedures
TEMPERATURE CONTROL
24-7
LEVER
Adjustment
Damper
I.
Move the warm water flow control lever to the extreme left
position.
2. Disconnect the water valve control wire from the blend air
damper
lever and the heater units clip.
3. Remove the water valve cover.
h?*
IWater
4.
valve lever
Unfasten
the clip of the blend air damper
lever, and
disconnect
the link for water valve lever from the blend air
damper
lever.
5.
Push the water valve lever all the way inward so that the
water valve is at the closed position.
6. Turn the blend air damper lever all the way in the direction
of the arrow so that the blend air damper is completely
closed at the lower most position.
Blend
air d
7. Attach the end of the link for the water valve lever to the
blend air damper lever.
8. Install the water valve cover.
9. After connecting
the water valve control wire to the blend
air damper lever, connect to the clip part of the heater unit.
Caution
Be careful that the lever does not move when clipping.
1 STB Revision
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the temperature
control
lever
position. Also check to be sure
is completely
closed when the
is moved to the extreme
left
right position.
24-8
HEATERS
- Service
WAiER
Adjustment
VALVE
Procedures
REPLACEMENT
N24FBAC
I.
5.
Disconnect
the water valve control wire from the blend air
damper lever and the heater units clip.
6. Remove the water valve cover.
7.
8.
9.
10.
11.
12.
2OW751
13.
1 STB Revision
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HEATERS
24-9
Heater Control
HEATER CONTROL
REMOVAL
AND
N24GA-
INSTALLATION
2QW824
Removal
steps
4+
++
~~
EyTEeverse
the removal procedures
to reinstall.
(2) 4+ : Refer to Service Points of Removal.
(3) eq : Refer to Service Points of Installation.
SERVICE
POINTS
1. REMOVAL
OF GLOVE
(2) Remove
BOX
STOPPERS
box lid.
the glove
http://vnx.su/
OF REMOVAL
box stopper.
box outward.
N24GBAE
24-10
HEATERS
I- Heater
Control
VIOVAL
OF AIR
SELECTION
CONTROL
WIRE
Use a screwdriver
to pry and remove the clip that holds
the outer cable of the air selection
control wire.
Disconnect
the inner cable of the air selection
control
wire from the end of the recirculation/fresh-air
changeover damper
lever.
9.
REMOVAL
OF MODE
SELECTION
CONTROL
10. REMOVAL
OF WATER
VALVE
WIRE
CONTROL
WIRE
INSPECTION
BLOWER
SWITCH
Operate
minals.
the switch,
N24GCAC
and check
the continuity
Terminal
Switch
position
between
the ter-
214567
OFF
2ow7a7
o--O
.
NOTE
O-O indicates that there is continuity
/ STB Revision
-7
http://vnx.su/
between
0
0
the terminals.
HEATERS
Top view
Bottom
Heater
SERVICE
view
I
POINTS
11. APPLICATION
SEMBLY
24-11
Control
OF INSTALLATION
OF GREASE
N24GDAD
TO HEATER
CONTROL
2OW553
AS-
parts of the
2OW534
10. lNSTALLATlON
OF WATER
VALVE
CONTROL
WIRE
2OW750
9.
INSTALLATION
OF MODE
SELECTION
CONTROL
WIRE
2.
INSTALLATION
OF AIR SELECTION
CONTROL
WIRE
1 STB Revision
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24-12
HEATERS
I
- Heater Unit
HEATER UNBT
REMOVAL
AND
INSTALLATION
Pre-removal
Operation
0 Draining of Coolant
(Refer to GROUP 0 LUBRICATION
AND MAINTENANCE-Maintenance
Service)
Post-installation
Operation
0 Supplying of Coolant
(Refer to GROUP 0 LUBRICATION
AND MAINTENANCE-Maintenance
Service)
2OW823
Removal steps
l *
+* l 4
I, Heater
hose
connection
2. Instrument panel
3. Duct
4. Center
5. Heater
ventilator
unit
duct
NOTE
(1) Reverse the removal procedures
to reinstall.
(2) +e : Refer to Service Points of Removal
(3) l + : Refer to Service Points of Installation
SERVICE
POINTS
1. DISCONNECTION
OF REMOVAL
OF HEATER
N24lBAE
HOSES
ETB
Revision
http://vnx.su/
HEATERS
2.
24-13
- Heater Unit
REMOVAL
OF INSTRUMENT
PANEL
Refer to GROUP 23 BODY-Instrument
Panel.
INSPEGTION
l
l
l
N24cAa
Remove
2.
3.
Remove
the FOOT/DEF
damper
link from the mode
selection
damper
lever.
Move the damper lever to the position at which the mode
selection damper lever does not protrude very much to the
heater core side.
Remove the heater core. If at this time the damper lever
and heater core are in contact, making removal difficult,
remove the damper
lever.
4.
5.
the water
valve
cover.
parts
to remove
the water
Caution
To prevent
interference
between
the heater
case, use care not to peel the heater core
when the heater core is removed.
valve.
core and
felt away
6. After installing the heater core and water valve, install the
link for each damper
after referring
to the Service
adjustment
procedures
section.
SERWOCE POINTS
2.
INSTALLATION
Refer
to GROUP
1 STB Revision
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OF INSTALLATION
OF INSTRUMENT
23 BODY-Instrument
N241EAD
PANEL
Panel.
24-14
HEATERS
+ Blower
Assembly
BLOWER ASSEMBLY
REMOVAL
Removal
+*
+e
4*
NXKA-
AND INSTALLATION
steps
1.
2.
l + 3.
4.
5.
6.
7.
8.
9.
10.
2oWBO6
NOTE
(1)
Reverse
the
removal
procedures
to
relnstall.
SERVICE
2.
REMOVAL
POINTS
OF REMOVAL
OF GLOVE
BOX
3.
REMOVAL
OF AIR
N24KBAE
SELECTION
hinge.
CONTROL
WIRE
http://vnx.su/
HEATERS
Blower
24-15
Assembly
5. REMOVAL
OF BLOWER
ASSEMBLY
--I
harness
2OW537
INSPECT00
N24KCAD
RESISTOR
Connect an ohmmeter to each terminal
measure the resistance.
Terminal
2OW768
BLOWER
connections
Resistance
1 -2(M1)
Approx. 1.22R
1 -3(M2)
Approx. 0.41 R
I-4(Low)
Approx. 2.25112
1 - 5 (High)
Approx. OlR
MOTOR
2OW779
SERVICE
3.
POINTS
INSTALLATION
OF INSTALLATION
OF AIR
SELECTION
N24KDAC
CONTROL
WIRE
1 STB Revision
http://vnx.su/
24-16
HEATER?
- Ventilators
VENTILATORS
REMOVAL
AND
INSTALLATON
(Ventilators
of instrument
panel)
N24MA-
16
zowaa
Removal
I4
steps
1.
2.
3.
4.
5.
6.
7.
8.
Demister
grill
Lap heater garnish
Lap heater duct (B)
Lap heater duct (C)
Defroster
duct (L.H.)
Lap heater duct (A)
Defroster
duct (R.H.)
Air duct (R.H.) (Only vehicles
conditioner)
9. Lap heater duct (A)
10. Air duct (L.H.) (Only vehicles
conditioner)
11.
12.
13.
14.
15.
16.
17.
with
with
Instrument
panel
Defroster
duct
Center ventilator duct
Center air outlet
Knob
Air duct
Side air outlet
air
air
SERVICE
NOTE
(1)
Reverse
the
(2)
+e
: Refer
POINTS
removal
procedures
to Service
Points
OF REMOVAL
to
of
reinstall.
Removal
N24MBAG
levision
http://vnx.su/
HEATERS
24-17
- Ventilators
2.
REMOVAL
OF LAP HEATER GARNISH
While using a screwdriver to pry the lock of the lap heater
garnish, use another screwdriver to pry the end of the lap
heater garnish to remove it.
6.
REMOVAL
OF LAP HEATER
DUCT (A)
Remove the screw at the side of the instrument
then remove the lap heater duct (A).
2OW75l
panel, and
2OW759
7.
REMOVAL
(R.H.)
OF DEFROSTER
DUCT
(R.H.)/8.
AIR
DUCT
9.
REMOVAL
OF LAP HEATER DUCT (A)
(1) Remove the center panel. (Refer to GROUP 23 BODY Floor console)
(2) Remove the heater control assembly. (Refer to P.24-9)
(3) Insert a hand through
the heater control assembly
installation
hole in the instrument
panel, and remove
the installation
screw of the lap heater duct (A).
10. REMOVAL
OF AIR DUCT (L.H.)
(1) Remove the combination
meter. (Refer to GROUP
ELECTRICAL-Meters
and Gauges)
(2) Remove the air duct (L.H.).
11. REMOVAL
OF INSTRUMENT
PANEL
Refer to GROUP 23 BODY-Instrument
1 STB Revision
http://vnx.su/
Panel.
8 HI
24-18
HEATERS
REMOVAL
AND INSTALLATION
[Rear heater
1
REMOVAL
ducts)
'f------A
7F-T
Removal
- Ventilators
steps
1.
2.
3.
4.
5.
6.
Floor console
Front seat
Rail cover
Carpet
Rear heater duct (B)
Rear heater duct (A)
AND
2ow.307
NOTE
Reverse
INSTALLATION
the removal
(Rear ventilator
procedures
to reinstall.
duct)
N24MA-
1 (L042GT)
18W825
Removal
*I)
steps
1. Upper quarter trim (L042GV)
Rear ventilator cover (L042GT)
2. Nut
3. Screw
4. Air outlet garnish
5. Screw
6. Rear ventilator duct
2OW796
NOTE
(1) Reverse the removal procedures
(2) +e : Refer to Service Points
SERVICE
POINTS
1. REMOVAL
OR REAR
OF REMOVAL
OF UPPER
VENTILATOR
Refer to GROUP
( STB Revision
http://vnx.su/
to reinstall.
of Removal.
QUARTER
COVER
23 BODY-Trims,
N24MBAI
TRIM (L042GV)
(L042GT)
Loose Panel.
AIR-CONDITIONING-General
24-19
Information
GENERAL INFORMATION
N2400AC
$;e;election
Mode
lever
Blower
sditch
selection
I
Air-cdnditioner
switch
Temberature
control lever
58W539
Mode selection
damper (VENT)
Heater
core
Fresh air
selection
Mode selkction
damper
(FOOT/DEF)
Evapdrator
Blower!
motor
2OW830
STB Revision
http://vnx.su/
damper
24-20
AIR-CONDITIONING
AIR-CONDITION!NG-General
I
SYSTEM COMPO
MDuct,
Information
N24BBBB
joint (Blower
side)
oint (Heater
unit side)
Condenser
Condenser
2OWB31
Suction
Pipe
Receiver
bracket
COMPRESSOR
- The prime purpose of the compressor
is to compress the low pressure refrigerant vapor
from the evaporator
into a high pressure, high temperature
vapor. The 6 cylinder 6P148 compressor
is used.
MAGNETIC
CLUTCH is mounted
on the compressor
providing
a convenient
way to drive and disengage
compressor
in accordance
to the cooling needs. CONDENSER
is located in front of the radiator. Its function
is to cool the hot, high pressure refrigerant gas causing it to condense into high pressure liquid refrigerant.
RECEIVER DRIER is used to remove any traces of moisture from the refrigerant
system. This component
incorporates
the sight glass and fusible plug. SIGHT GLASS at the top of the receiver drier is provided as a
diagnostic
tool to observe refrigerant
flow and observe refrigerant
level. THE FUSIBLE PLUG is located on
the receiver drier. Its function
is to prevent damage
to the air conditioning
system in the event that
excessive pressure develops due to condenser air flow being restricted by, for example, leaves, newspaper,
an overcharge
of refrigerant,
or air in the system.
LOW PRESSURE
SWITCH
prevents damage
to the
compressor
in case of system loss of refrigerant charge. EXPANSION
VALVE - The expansion valve is used
for all applications.
Its function
is to meter refrigerant
into the evaporator
in accordance
with cooling
requirements.
EVAPORATOR
COIL is located in the unit and its function is to cool and dehumidify
the air
before it enters the vehicle. FREEZE UP CONTROL
FIN THERMOSTAT
SENSOR is installed at the heater
side of evaporator.
The main function of a freeze control is to keep condensate
water on the face of the
evaporator
coil from freezing
and restricting
air flow. WATER TEMPERATURE
SWITCH
- When the
temperature
of the radiator coolant became high, this switch functions to stop the compressor
and prevent
engine overheating.
SERVICE VALVE at the compressor
and the discharge line. The valves are used to test
and service the refrigerant
system. REFRIGERANT
R-12 is used maximum
amount 907 g (32 oz.) R-12.
COMPRESSOR
OIL is used DENS0 oil 6 maximum
amount
110 cc (3.7 U.S.fl.oz.,
3.9 Imp.fl.oz.).
/ STB Revision
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AIR-CONDITIONING
24-2 1
-Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
N24CA-
Items
Specifications
Compressor
Model
6P148lnclined-plate
6 cylinders
110 (3.7,3.9)
ON:4.5 (39)
ON:230 (33)
C(F)
OFF:210 (30)
kPa (psi)
Water temperature
switch
Freezor prevention
Fusible plug
Refrigerant
C (F)
Air temperature
OFF:3 (37.4)
C (F)
6,148 (208,216)
DENS0 oil 6
Low pressure
switch
type
ON:106(222)
thermostat
ON:5 (41)
106 (222)
Burn out temperature
R-l 2
600-900 (1.3-2.0)
C (F)
and quantity
g (Ibs.1
SERVICE SPECIFICATIONS
N24CE-
Items
Specifications
Standard value
Drive belt deflection
Pressure
mm (in.)
17.20 (.7-.8)
mm (in.)
0.4-0.7
(.02-.03)
TORQUE SPECIFICATIONS
N24CG
Items
Nm
ftlbs.
30-35
22-25
12-15
12-15
9-l 1
9-l 1
30-35
12-15
22-25
9-l 1
20-25
15-18
30-35
22-25
20-25
15-18
20-25
15-18
15-17
11-13
Through bolt
25-26
18-20
/ STB Revision
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24-22
AIR-CONDITIONING
Special
TOOIS
/ Troubleshooting
SPECIAL TOOLS
N24DA.-
Use
MB990783-01
Steering/pinion
remover/installer
Installation
of seal plate
gear
TROUBLESHOOTING
Before replacing or repairing air
charge, air flow, or compressor
The following diagnostic charts
malfunction.
If these charts do
explanation.
After correcting the malfunction,
MALFUNCTION
CAUSES
Air is
emitted
but is
1 not cool
N24EBAE
conditioning
compofents,
first determine
if the malfunction
related.
have been developed as a quick reference aid in determining
the cause of
not satisfactorily
describe the problem, refer to appropriate
section for detailed
check out the complete
AND REMEDIES
system
(Numbers
indicate
to assure satisfactory
performance.
checking/inspection
order.)
Replace
1. Magnetic clutch is
not switched ON
-4 2.Check
I
the fuse (IOA)
t-l
I
I
Replace
the air-conditioner
(P.24-32)
__)
Replace
4.Check
switch
Replace
Replace
Replace
-i
6.Check
switch
the blower
(P.24-10)
1 STB Revision
http://vnx.su/
I,
3,Check
switch
relay
Replace
M
clutch
Replace
I
24-23
AIR-CONDITIONING-Troubleshooting
1 CONTINUED
FROM
--)
PREVIOUS
2lnsufficient
PAGE]
refrigerant
Check the
(P.24-29)
refrigerant
amount
_1
Supply
refrigerant
.--+
Replace
__)
Adjust
belt
?
--)
3.Receiver
--.
4.Abnormal
rotation
compresspor
i-
5.Expansion
drier clogged
of
*
valve clogged
6.Poor compression
compressor
of
drier
1 STB Revision
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valve
Replace
Replace
the
1
AIR-CONDITIONING-Service
SERVICE ADJUSTMENT
MANIFOLD
GAUGE
Adjustment Procedures
PROCQDURES
SET INSTALLATUON
24-29
N24FDAD
Discharge
gauge
Suction
gauge
Suction
gauge
valve
The receiver drier assembly consists of; Drier reservoir, Refrigerant level sight glass and Fusible plug.
glass
Drier
2OW724
SIGHT
GLASS
REFRlGERANT
LEVEL TEST
The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass and start the
vehicle engine. Push the air conditioner button to operate the compressor, place the blower switch to high and
move the temperature lever to extreme left.
After operating for a few minutes in this manner, check the sight glass.
(1) If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm and the
compressor inlet line is cool; the system has a full charge.
(2) If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature difference
between compressor inlet and discharge lines; the system has lost some refrigerant.
(3) If the sight glass is clear and the magnetic clutch is disengaged; the clutch is faulty or, the system is out of
refrigerant. Perform low pressure switch test to determine condition. Check low pressure switch and clutch coil
for electrical continuity.
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AIR-CONDITIONING
lnsuffi
cient air
flow
1 .Leakage
joint
at a duct
2.Evaporator
frost
3.Blower
motor
function
mal-
24-25
- Troubleshooting
.
Replace
Replace
Measure
(P.24-34)
Apply
vacuum;
supply
refrigerant
Replace
motor
+
Cool air
flow is
intermittent
i--)
1 .Air in refrigerant
2.Expansion
valve
malfunction
the pressure
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valve
24-26
AIR-CONDITIONING
CIRCUIT DIAGRAM
Diagram
Circuit
N24ZB-I
Ignition
Main
Sub fusible
(Fuse
B)
link
Battery
switch
link
To turn
signal
flasher
[Refer
to P.8-49.1
0.85-RL
unit ~
,0.85-LW
1
yl
lLG1
[Refer
to
P.8-62.1
0.85-WB*
C-C
Blower
motor
IA2
Ml
kFF
switch
Blower
resistor
motor
LBLY
LRLI
El3
B: Black
LI: Light
color
blue
-18
BI ower
Wiring
E!!
i
\
Heater
relav
B L
LRLR
EEJ
x,
$2
code
Br:
0:
Brown
Orange
G: Green
P: Pink
Gr: Gray
R: Red
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L: Blue
Y: Yellow
Lg:
W:
Light
White
green
AIR-CONDITIONING
- Circuit
24-27
Diagram
Air
conditioner
relay
El
Low
pressure
switch
El
A-54
85-BW:0.85-BW
u
A-25
*20.85-BWr
*10.85-BWi&
A-13
@,0.85-WB
To feed
back
carburetc
control
unit
[Refer
to P.8-39.1
Vacuum
valve
solenoid
++
A-45
Magnetic
clutch
(compressor)
A
Condenser
blower
motor
Condenser
motor
relay
blower
z-
BY
rl
37W611
Remarks
(1)
For
information
ple.(l)m),
refer
(2) The
symbols
0,
connected
(using
facing
page
(In
connected
to 0
( STB Revision
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converning
the
ground
points
(examto P.8-7.
0,
etc
indicate
that
the
wiring
is
the same
numerical
symbol)
to the
other
words,
0 on the right
page
is
on the left page.)
24-28
AIR-CONDITIONING-Safety
Precautions
SAFETY PRECAUTIONS
SAFETY
N24PAAB
PRECAUTIONS
Caution
Wear safety goggles when servicing the refrigeration
system.
R-12 evaporates so rapidly at normal atmospheric
pressures and temperatures
that it tends to freeze anything it
contacts. For this reason, extreme care must be taken to prevent any liquid refrigerant from contacting the skin and
especially the eyes.
Always wear safety goggles when servicing the refrigeration part of the air- conditioning
system. Keep a bottle of
sterile mineral oil handy when working on the refrigeration system. Should any liquid refrigerant get into the eyes,
use a few drops of mineral oil to wash them out. RI12 is rapidly absorbed by the oil. Next, splash the eyes with
plenty of cold water. Call your doctor immediately
even though irritation has ceased after treatment.
Caution
Do not heat R-12 above 52C (125F).
In most instances, moderate heat is required to bring the pressure of the refrigerant in its container above the
pressure of the system when charging or adding refrigerant. A bucket or large pan of hot water not over 52C
(125F) is all the heat required for this purpose. Do not heat the refrigerant container with a blow torch or any other
means that would raise temperature
and pressure above this temperature.
Do not weld or steam clean on or near
the system components
or refrigerant lines.
Caution
Keep R-12 containers
upright when charging the system.
When metering
R-12 into the refrigeration
system, keep the supply tank or cans in an upright position. If the
refrigerant container is on its side or upside down, liquid refrigerant will enter the system and damage the
compressor.
Caution
Always work in a well-ventilated
room.
Good ventilation is vital in the working area. Always discharge the refrigerant into the service bay exhaust system
or outside the building. Large quantities of refrigerant vapor in a small, poorly ventilated room can displace the air
and cause suffocation.
Although R-12 vapor is normally nonpoisonous,
contact with an open flame can cause the vapor to become very
poisonous. Do not discharge large quantities of refrigerant in an area having an open flame. A poisonous gas is
producted when using the flame-type leak detector. Avoid inhaling the fumes from the leak detector.
Caution
Do not allow liquid refrigerant
to touch bright metal.
Refrigerant will tarnish bright metal and chrome surfaces, and in combination
all metal surfaces.
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with moisturecan
severely
corrode
AIR-CONDITIONING-Service
SERVICE ADJUSTMENT
MANIFOLD
GAUGE
Adjustment Procedures
PROCQDURES
SET INSTALLATUON
24-29
N24FDAD
Discharge
gauge
Suction
gauge
Suction
gauge
valve
The receiver drier assembly consists of; Drier reservoir, Refrigerant level sight glass and Fusible plug.
glass
Drier
2OW724
SIGHT
GLASS
REFRlGERANT
LEVEL TEST
The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass and start the
vehicle engine. Push the air conditioner button to operate the compressor, place the blower switch to high and
move the temperature lever to extreme left.
After operating for a few minutes in this manner, check the sight glass.
(1) If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm and the
compressor inlet line is cool; the system has a full charge.
(2) If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature difference
between compressor inlet and discharge lines; the system has lost some refrigerant.
(3) If the sight glass is clear and the magnetic clutch is disengaged; the clutch is faulty or, the system is out of
refrigerant. Perform low pressure switch test to determine condition. Check low pressure switch and clutch coil
for electrical continuity.
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24-30
AIR-CONDITIONING
-Service
Adjustunent
Procedures
(4) If the sight glass shows foam or bubbles, the systpm could be low on charge. Occasional foam or bubbles are
normal when the ambient temperature
is above 43C(110F) or below 21C(7OF).
Adjust the engine speed to 1,500 rpm. Block the airflow through the condenser to increase the compressor
discharge pressure to 1,422 to 1,520 kPa (20$ to 220 dsi). If sight glass still shows bubbles or foam, system charge
level is low.
The refrigerant system will not be low on charge unless there is a leak. Find and repair the leak. If the leak can be
repaired without discharging the system an oil level check is not necessary. Use the procedure for correcting low
refrigerant level found in the Refrigerant Sy$em Service Procedure Section.
FUSIBLE PLUG
When ambient temperature
of the fusible plug reach& 105~221~F),
the fusible plug melts and the refrigerant
the system is released.
Once the fusible plug is operated, it cannot be used again.
SO, it is necessary to install new one and charge the refrigerant in the system.
in
LOW PRESSURE
SWITCH
The Low Pressure Switch, located on the liquid line, is wired in
series with the magnetic clutch. It cuts off the electrical power
supply to the clutch when refrigerant pressure drops below the
cont$ol point of the switch. Whenever the system is inactivated by
the low pressure switch due to refrigerant loss, the refrigerant oil
may have been lost. Therefore, to prevent damage to the compressor due to operation without sufficient lubrication, the leak
must be repaired and the compressor oil level checked before final
charge of the system. The switch is a sealed, factory calibrated
unit. No attempt should be made to adjust or otherwise repair it.
If it is found to be faulty it must be replaced.
Low pressure
switch
,
To
(1)
(2)
(3)
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AIR-CONDITIONING-Service
Adiustment
Procedures
24-31
FREEZE UP CONTROL
Evaporator freeze up is controlled by a thermistor attached to the
evaporator fins. The control is an electronic type and consists of
two parts_(thermo
relay and thermistor.)
It is connected to the
magnetic clutch of the compressor in series. When the temperature of the evaporator drops below 3C (37.4F), the compressor is
turned OFF.
WATER TEMPERATURE
SWITCH
The water temperature
switch is located on the thermostat
housing. The water temperature
switch is connected
to the clutch
in series. When the coolant
temperature
in the radiator
reaches above 113C (235F), it turns the compressor
OFF.
This is to prevent engine overheating.
When the water temperature
switch is activated and the clutch is
OFF, check the surface of the condenser and radiator, the belt
tension, and the coolant volume in the radiator, and return to the
normal condition.
To Test the Water Temperature
Switch
(1) Remove wire from water temperature
switch and jump lead
wires.
(2) Press the air conditioner switch and blower switch on.
(3) Momentarily
turn the ignition switch on (do not crank the engine), listen for the clutch engaging.
(4) If the clutch does not-engage, the fin thermistor, low pressure
switch, wiring or fuse may be faulty.
(5) If clutch engages, replace the switch.
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24-32
AIR-CONDITIONING-Service
i->
9
Procedures
AIR CONDITIONER
SWITCH
To jest the Air Conditioner
Switch
(1) Disconnect the harness connector
for the air conditioner
switch.
(2) Jump the lead wires as shown.
(3) Turn the blower switch ON.
(4) Momentarily
turn the ignition switch on (do not crank the engine), listen for the clutch engaging.
(5) If the clutch does not engage,
fin thermostat,
water
temperature
switch, wiring or fuse may be faulty.
(6) If clutch engages,
replace the air conditioner
switch.
2ouo319
Adjustment
MAGNETIC
CLUTCH
(1) Disconnect the wiring to the magnetic clutch.
(2) Connect battery (+) voltage directly to the wiring for the magnetic clutch.
(3) If the magnetic clutch is normal, there will be a click. If the
pulley and armature do not make contact (click), there is a
malfunction.
Suction gauge
2OW627
Discharge
/
Suction
ww
w-w
Discharge
w-w
2OUO306
Suction
w-w
COMPRESSOR
(1) Install the manifold gauge set, and run the air conditioner.
(2) If a pressure of approx.490 kPa (71 psi) is indicated on the
suction gauge side and a pressure of approx.883 kPa (128 psi)
is indicated on the discharge gauge side, the compressor has
abnormal compression.
Replace the compressor.
(3) If a pressure of 294 to 392 kPa (43 to 59 psi) is indicated on the
suction gauge side and a pressure of approx.1961
kPa (284
psi) is indicated on the discharge gauge side, it is suspected
that air is present in the air conditioning
system.
Discharge the system, evacuate and recharge with specified
amount of refrigerant.
(4) During operation of the air conditioner, cold air may stop flowing after the elapse of time and this state is maintained before
cold air flows out again. If cold air stops flowing out with
negative pressure indicated on the suction gauge side and a
pressure of 588 to 980 kPa (85 to 142 psi) indicated on the
discharge gauge side, it is suspected that water is present in
the air conditioning
system.
Discharge the system. Replace receiver drier. Evacuate and
check for leaks, and recharge with specified amount of refrigerant.
Discharge
gauge
2OUO307
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AIR-CONDITIONING-Service
TESTING
Adjustment
SYSTEM
24-33
Procedures
FOR LEAKS
N24FFA8
2080113
Compressor
6
T-7
Cl
Refrigerant
tester
Leak
, tester
pick up
tube
b/
while
torch is lighted
or in the
2OUO316
(7) Examine all tube connectors and other possible lead points by
moving the end of the sampling hose from point to point.
Always keep torch in upright position. Since R-12 is heavier
than air, it is good practice to place the open end of sampling
hose directly below point being tested. Be careful not to pinch
sampling tube since this will shut off air supply to flame and
cause a color change.
(8) Watch for a change in the color of the flame. Small leaks will
produce a green color and large leaks a bright blue color. If
leaks are observed at tube fittings, tighten the connection,
using the proper flare wrenches, and retest.
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24-34
AIR-CONDITIONING-Service
Adiustment Procedures
PEAFORMANCE
TESI
r---:ES :
Dry
bulb therr&neter
TEST
N24FWAB
NOTE
Air temperature in test room must be 21C (70F) minimum for this
test.
(1) Connect a tachometer and manifold gauge set.
(2) Set air conditioner controls to Max air conditioner, temperature lever on full cool, and blower on high.
(3) Turn engine on 1000 rpm with air conditioner clutch engaged.
(4) Engine should be warmed up with doors, windows, and hood
open.
(5) Insert a thermometer in the left center air conditioner outlet
and operate the engine for 5 minutes.
(6) Note the discharge air temperature.
2OW825
NOTE
If the clutch cycles, take the reading before the clutch disengages.
Performance
Garage ambient
temperature
Discharge air
temperature
21 C
(70 F)
1.7-4.4
(35-40
Temperature
26.5 C
(80 F)
C
F)
1.7-5.0
(35-41
Chart
32 C
(90 F)
C
F)
1.7-5.6
(35-42
C
F)
37.5 C
(100 F)
1.7-6.1
(35-43
C
F)
40.6 C
(I 05 F)
1.7-6.7
(35-44
C
F)
Compressor
discharge pressure
1.069-1.547 kPa
(152-220
psi)
1,209-1,772 kPa
(172-252
psi)
1,336-1,969 kPa
(190-280 psi)
1,406-2,109 kPa
(200-300
psi)
Evaporator suction
pressure
127-148 kPa
(18-21
psi)
131-162 kPa
(18.6-23
psi)
134-176 kPa
(19-25 psi)
136-194 kPa
(19.4-27.6 psi)
REFRIGERANT
N24FnAB
LOST CHARGE
If the system has lost all charge due to a leak:
(1) Evacuate the system. (See the procedure).
(2) Charge the system with approximately one pound of refrigerant.
(3) Check for leaks.
(4) Discharge the system.
(5) Repair leaks.
(6) Replace receiver drier.
Caution
Replacement
filter-drier
units must be sealed while in storage. The drier used in these units will saturate water quickly
upon exposure to the atmosphere.
When installing
a drier,
have all tools and supplies
ready for quick reassembly
to
avoid keeping the system open any longer than necessary.
Refrigerant
leak tester
LOW CHARGE
tester
up
2OUO316
If the system has not lost all of its refrigerant charge; locate and
repair all leaks. If it is necessary to increase the system pressure
to find the leak (because of an especially low charge) add refrigerant. If it is possible to repair the leak without discharging the
refrigerant system, use the procedure for correcting low refrigerant level.
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AIR-CONDITIONING-Service
CORRECTING
LOW
REFRIGERANT
Adiustment
Suction
gauge
\-
LEVEL
Discharge
gauge
a/
Discharge
gauge
24-35
Procedures
gauge
valve
II
II
Ho\t water
52C i 125F)
2OUO325
(7) Place the refrigerant in a large pan of water heated to 52C (125F). Place pan of water containing the refrigerant
can on an accurate scale so the amount of refrigerant added can be weighed. Open the refrigerant manifold
valve.
(8) Purge all air from test hoses. Air in the system will be trapped in the condenser causing abnormally
high
discharge pressures and interfering with condensing of the refrigerant.
(9) Slightly loosen both test hoses at the gauge set manifold. Tighten the hoses as soon as the air is purged.
(10)Slightly loosen charging hose connection at gauge set manifold. This will purge air from the charging hose.
Tighten connection as soon as air is purged.
(1l)With vehicle windows open and hood up, operate engine at 1,500 rpm and jump the switch terminals located
on so the clutch will remain engaged.
(12)Place air conditioner control on air conditioner and place the blower switch on high.
(13)lf necessary, block the condenser to maintain a discharge pressure of 1,422 to 1,520 kPa (206 to 220 psi.).
System must be charged through the evaporator suction service ports as follows:
(a) Slowly open the suction service gauge valve. Meter flow of refrigerant by adjusting the suction service
gauge valve so that pressure registered at the suction service gauge does not exceed 345 kPa (50 psi).
Keep refrigerant
container
upright.
(b) Add refrigerant gas until there is no foam visible at the sight glass.
(c) Close the suction gauge valve.
Caution
Too much refrigerant in the system can cause abnormally high discharge pressures. Care must be
used so that the exact recommended
amount of refrigerant is added after foam clears in the sight
glass.
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24-36
AIR-CONDITIONING-Service
COllector
can
2OUO315
2OUO31
/vision
Adjustment
Procedures
D&ARG,NG
THE SYSTEM
Since the air conditioning
refrigerant system is pressurized, it will
be necessary to completely discharge the system (in a well ventilated area) before replacing any refrigerant component.
The procedure is as follows:
(1) Install manifold gauge set. Make sure the gauge set valves are
closed before attaching the hoses to the refrigerant system.
(2) Install a long hose to the manifold gauge set connector. Run
this hose to the oil collector can near a shop exhaust system.
A good oil collector can may be made from a large empty
coffee can with a plastic top. Slit the plastic top in the form of
a Y to make an entrance for the refrigerant hose and an exit for
the gas.
(3) Open the compressor
discharge and suction line pressure
valves and blow the refrigerant into the oil collect can. Watch
to make sure the hose does not blow out of the collector can.
(4) When the system has been completely
discharged, measure
the amount of oil collected in the can. The amount of oil measured should be added to the refrigerant system before it is
re-charged. Add new oil-discard
the used oil.
Caution
It is important
to have the correct amount of oil in the refrigerant system.
Too little oil will provide inadequate compressor
lubrication and
cause a compressor failure. Too much oil will increase discharge
air temperature.
When a 6P148 compressor
is installed
at the factory, it
contains 110 c.c. (3.7 U.S.fl.oz., 3.9 Imp.fl.oz.) of refrigerant oil.
While the air conditioning
system is in operation,
the oil is
carried through the entire system by the refrigerant.
Some of
this oil will be trapped and retained in various parts of the
system.
When the following system components
are changed, it is necessary to add oil to the system to replace the oil being removed
with the component.
Compressor
- 4Occ (1.4 U.S.fl.oz.,
1.4 Imp.fl.oz.)
Condenser
- 30 cc (1.0 U.S.fl.oz.,
1.1 Imp.fl.oz.)
Evaporator
- 60 cc (2.0 U.S.fl.oz.,
2.1 Imp.fl.oz.)
Piping - 10 cc (.3 U.S.fl.oz.,
.4 Imp.fl.oz.)
Receiver drier - 0 cc (0 U.S.fl.oz.,
0 Imp.fl.oz.)
EVACUATING
THE SYSTEM
Whenever the system has been opened to the atmosphere,
it is
absolutely essential that the system be evacuated or vacuumed
to remove all the air and moisture. Air in the refrigerant system
causes high compressor
discharge pressures, a loss in system
performance,
and oxidation of the compressor oil into gum and
varnish. Moisture in the refrigerant system can cause the expansion valve to malfunction.
Under certain conditions,
water can
react with the refrigerant to form destructive acids. It is necessary
to adhere to the following procedure to keep air and moisture out
of the system.
(1) Install manifold gauge set. Make sure the gauge set valves are
closed before attaching the hoses to the refrigerant system.
(2) Discharge the system if the manifold gauge set indicates pressure in the system.
(3) Connect a long test hoses from gauge set manifold center
connection to vacuum pump.
(4) Open both manifold gauge set valves.
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AIR-CONDITION1
G-Service
Adjustment
24-37
Procedures
(5) Start the vacuum pump and operate until the evaporator
suction gauge registers
at least-101
kPa (29.9 in.of vacuum).
If at least-101
kPa (29.9 in. of vacuum) cannot be obtained,
either the system has a leak or the vacuum pump is defective.
Check the vacuum pump. If the pump proves to be functioning
properly, the system has a leak. Charge the system with one
pound of refrigerant.
Locate and repair all leaks. Discharge the
refrigerant and evacuate the system.
(6) Continue to operate the pump for at least five minutes.
(7) Close manifold valves. Turn off the vacuum pump and observe
evaporator
suction gauge for two minutes. The vacuum level
should remain constant.
If the vacuum level falls off, the system has a leak. Charge the
system with one pound of refrigerant.
Locate and repair all
leaks. Discharge the system and repeat evacuation procedure.
CHARGING
THE SYSTEM
The refrigerant
system must have been evacuated using the previous procedure
before charging. Charge using only R-l 2 refrigerant R-l 2 is available in bulk tanks or small cans. Follow the safety
precautions
for handling R-12 as listed in the beginning of this
group.
Charging
with
Small
Cans
carefully
the can
2OUO326
Caution
Never use these cans to charge into the high pressure side of
the system (compressor
discharge port) or into a system that
is at high temperature,
because the high system pressures
could be transferred
into the charging can causing it to explode.
Keep the refrigerant
manifold valves capped when not in use.
Keep a supply of extra refrigerant-can-to-refrigerant-manifold
gaskets on hand so that gaskets can be replaced periodically. This will
insure a good seal without
excessive
tightening of the can or the
manifold nuts.
(1) Attach center hose from manifold gauge set to refrigerant
dispensing
manifold. Turn refrigerant
manifold valves completely counterclockwise
so they are fully open. Remove protective caps from refrigerant
manifold.
(2) Screw refrigerant
cans into manifold. Be sure manifold-to-can
gasket is in place and in good condition. Tighten can and manifold nuts to 8 to 11 Nm (6 to 8 ft.lbs.)
(3) Turn refrigerant
manifold
valves completely
clockwise
to
puncture the cans and close the manifold valves.
/ ST6 Revision
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24-38
AIR-CONDITIONING-Service
Adjustment
Procedures
(4) Purge the air from the charging line by loosening the charging
hose at the gauge set manifold and turning one of the refrigerant valves counterclockwise
to release refrigerant. When
the refrigerant gas starts escaping from the loose connection,
re-tighten the hoses.
Caution
Never heat small
mad explode.
refrigerant
(5) qully open all refrigerant manifold valves being used and place
the cans of refrigerant into a pan containing 52C (125F) water
will warm the charging can and aid in the transfer of the charge
into the system. Place the water pan and refrigerant cans on
a scale and note the weight.
(6) Jump the low pressure switch terminals
located on the receiver drier so the clutch will remain engaged.
(7) Start the engine and move the controls to air conditioner
switch on and low blower position.
The low pressure switch will prevent the clutch from engaging
until refrigerant is added to the system. If the clutch does
engage, replace the switch before proceeding any further.
(8) Charge through the suction side of the system by slowly opening the suction manifold valve. Adjust the valve as necessary
so charging
pressure does not exceed 345 kPa (50 psi).
Maintain the temperature
of the water in the pan by adding
warm water as necessary.
Note the weight
of water
added, to ensure accuracy when determining
amount
of
refrigerant
added to system.
(9) Adjust the engine speed to a fast idle of approximately
1500
rpm.
(IO) When specified refried refrigerant charge 730 (1.6 Ibs.) has
entered the system, close the gauge set manifold valves,
refrigerant
manifold
valves, and reconnect
wiring. Each
can contains 397 g (14 oz.) of R-12. Use 2 l/2 cans.
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AIR-CONDITIONING-Service
HANDLING
TUBING
Adjustment
24-39
Procedures
AND FllTlNGS
N24FlAA
12-15 Nm
9-l 1 ft.lbs.\
20-25
15-18
Nm
ftlbs.
\
22-25
15-18
ftlbs.
ft.lbs.
20-25
Nm 15-18
ft
2080122
Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the
entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised
to make sure that all connections are pressure tight.Dirt and moisture can enter the system when it is opened for
repair or replacement of lines or components. The following precautions must be observed.
The system must be completely discharge before opening any fitting or connection in the refrigeration system.
Open fittings with caution even after the system has been discharged. If any pressure is noticed as a fitting is
loosened, allow trapped pressure to bleed off very slowly. Never attempt
to rebend formed lines to fit. Use the
correct
A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose.
Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that they are at least
80 mm (3 in.) from the exhaust manifold. It is good practice to inspect all flexible hose lines at least once a year
to make sure they are in good condition and properly routed.
Unified plumbing connections with O-rings. These O-rings are not reusable.
1 STB Revision
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24-40
AIR-CONDITIONING-Service
Nut
I
Adjustment Procedures
O-RING INSTALLATION
(1) Clean sealing surface.
(2) Make sure O-ring does not have any scratches.
(3) Connect fitting, install fastener, and torque to amount shown
in illustration.
The internal part of the refrigeration system will remain in a state
of chemical stability as long as pure-moisture-free
R-l 2 and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can
upset the chemical stability and cause operational troubles or even
serious damage if present in more than minute quantities.
When it is necessary to open the refrigeration system, have everything you will need to service the system ready so the system
will not be left open any longer than necessary. Cap or plug all
lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components
in parts stock
should be capped or sealed until they are ready to be used.
All tools, including the refrigerant dispensing manifold, the gauge
set manifold and test hoses should be kept clean and dry.
Union
20110267
COMPRESSOR
Tension pulley
Crankshaft
pulley
2OY907
N24FJAE
1 STB Revision
value
-7
http://vnx.su/
: 17-20
mm (.67-.78
in.)
AIR-CONDITIONING
COMPRESSOR
-Service
Adjustment
NOISE
Procedures
24-41
NWLM
When investigating
an air conditioning
related noise, you must first know the conditions when the noise occurs.
These conditions
are: weather, vehicle speed, in gear or neutral, engine temperature
or any other special
conditions.
Noises that develop during air- conditioning
operation can often be misleading.
For example: what sounds like a
failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose clutch
assembly. Verify accessory drive belt tension (power steering,
alternator or air pump). Improper accessory drive belt
tension can cause a misleading noise when the compressor is engaged and little or no noise when the compressor
is disengaged.
Drive belts are speed sensitive. That is, at different engine speeds, and depending upon belt tension, belts can
develop unusual noises that are often mistaken for mechanical problems within the compressor.
Adjustment
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Procedures
Select a quiet area for testing. Duplicate conditions as much as possible. Switch compressor on and off several
times to clearly identify compressor noise.
To duplicate
high ambient
conditions
(high head pressure), restrict air-flow through condenser. Install
manifold
gauge set to make sure discharge
pressure does not exceed 2,070 kPa (300 psi).
Tighten all compressor mounting bolts, clutch mounting bolt, and compressor drive belt. Check to assure clutch
coil is tight (no rotation or wobble).
Check refrigerant hoses for rubbing or interference that can cause unusual noises.
Check refrigerant charge (See Charging the System).
Recheck compressor noise as in Step 1.
If noise still exists, loosen compressor mounting bolts and retorque. Repeat Step 1.
If noise continues, replace compressor and repeat Step 1.
1 STB Revision
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24-42
AIR-CONDITIONING
AIR CONDITIONER
REMOVAL
AND
- Air Conditioner
Switch
SWITCH
INSTALLATION
N24CLA-
2ow929
Removal
steps
1. Lap heater duct (C)
2. Glove box stoppers
3. Knobs
4. Plugs
5. Center panel
6. Connection
of center panel wiring harness to front wiring harness connector
7. Air conditioner
switch
NOTE
(1)
Reverse
the
(2)
+e
: Refer
SERVICE
POINTS
1. REMOVAL
removal procedures
to
Service
Points
OF REMOVAL
OF GLOVE
BOX
STOPPERS
1 STB Revision
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to reinstall.
of
Removal
AIR-CONDBTIONI
G - Evaporator
EVAPORATOR
REMOVAL
Operation
Discharge
P.24-36)
Removal
~~
l +
N24RA--
AND INSTALLATION
Pre-removal
l
24-43
the refrigerant.
(Refer
to
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
NOTE
(I) Reverse the removal procedures
to reinstall.
(2) l * : Refer to Service Points of Installation.
N24MAC
Caution
If the hoses or pipes are disconnected, cap the hoses or pipes:
with a blank plug to prevent entry of dust, dirt, and water.
Union
/
SERVICE
2OUO267
POINTS
OF INSTALLATION
N24AOAE
2. APPLICATION
OF COMPRESSOR
OIL TO SUCTION
HOSE/l.
LIQUID PIPE
Apply specified
compressor
oil to portions indicated
before installing the liquid pipe (C) and suction flexible
hose.
Specified oil : DENS0 oil 6
!vision
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24-44
AIR-CONDOTIONING-Evaporator
DISASSEMBLY
N24RE--
AND REASSEMBLY
1
\
Disassembly
4*
+e
l +
1.
2.
3.
4.
5.
6.
7.
8.
steps
Air conditioner
relay
Thermostat
Screw
Clip
Evaporator
case (upper)
Evaporator case (lower)
Evaporator assembly
Expansion valve
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) +e : Refer to Service Points of Disassembly.
(3) l + : Refer to Service Points of Reassembly.
-6
2OW828
SERVICE POINTS
4.
REMOVAL
OF DISASSEMBLY
N24RFAB
OF CLIP
2OW718
8.
REMOVAL
OF EXPANSION
VALVE
Use two wrenches to loosen the flare nut on the pipe connection (for both the inlet and outlet).
2ow722
SERVICE
0-rina
8.
Expansion
valve
O-rim
POINTS
APPLICATION
VALVE
OF REASSEMBLY
OF COMPRESSOR
OIL
N24RHAE
TO EXPANSION
Specified
oil
1 STB Revision
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: DENS0
oil 6
AIR-CONDITIONING
RECEIVER
REMOVAL
Receiver
DRIER, CONDESER,
AND
drier,
Condenser,
Compressor
COMPRESSOR
Clutch
24-45
Assembly
CLUTCH ASSEMBLY
INSTALLATION
N24TA--
Pre-removal
Operation
Discharge the Refrigerant.
(Refer to
P.24-36)
l
Remove the Radiator Grille. (Refer
to GROUP 23 BODY-Grille, Garnish,
Moulding)
l
Disconnect the Liquid Pipes and
Hoses.
Post-installation
Operation
l
Install the Radiator Grille. (Refer to
GROUP 23 BODY-Grille, Garnish,
Moulding)
l
Charge the Refrigerant. (Refer to
P.24.37)
l
Adjustment
of the Tension of the
Air Conditioner
Drive Belt. (Refer to
P.24-40)
2OW832
8. Drive belt
9. Compressor clutch assembly mounting
bolt
10. Compressor clutch assembly
NOTE
Reverse
the removal
procedures
to reinstall.
N24TBAB
Caution
If the hoses or pipes are disconnected,cap
the hoses or pipes
with a blank plug to prevent entry of dust, dirt, and water.
1 STB Revision
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24-46
AIR-CONDITIONING
- Compressor
COMPRESSOR
DISASSEMBLY
AND
REASSEMBLY
N24TE-
16
15-h
11-13
Nm
ftlbs
26-26
16-20
Nm
ftlbs.
\
l5Dl
2QY947
Magnetic
4*
1. Nut
~~ Adjustment of clutch clearance
2. Clutch hub
3. Shims
4. Snap ring
5. Rotor assembly
6. Snap ring
7. Ground terminal
l + 8. Clutch coil
Compressor front
sembly steps
**
o+
04
NOTE
(1) Reverse the disassembly
(2) +e : Refer to Service
(3) e+ : Refer to Service
(4) q : Non-reusable
parts
1 STB Revision
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procedures
to reassemble.
Points of Disassembly.
Points of Reassembly.
AIR-CONDITIONING
SERVICE
5.
24-47
- Compressor
POINTS
OF DISASSEMBLY
N24TFAE
REMOVAL
OF ROTOR ASSEMBLY
It may be necessary to lightly tap the rotor with
hammer.
a plastic
2OY713
INSPECTION
l
l
l
Shaft pl&e
Check the
Check the
Check the
tion.
Check the
surfaces.
Check the
SERVICE
Front housing
N24TGAC
POINTS
MB990?83-01
OF REASSEMBLY
N24THAH
14. INSTALLATION
OF SHAFT PLATE
(1) Lubricate
the shaft plate and a new O-ring with
compressor
oil. Push the shaft plate and O-ring into the
front housing.
2OY789
plate
into
the
front
housing
with
2OY790
13. INSTALLATION
OF SHAFT
Lubricate
the shaft seal with
shaft seal on the shaft.
SEAL
compressor
oil. Install
NOTE
Rotate the shaft seal lightly by hand to check that
fitted into the notch on the compressor
shaft.
the
it is
2OY788
evision
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,: 24-48
AIR-CQNDITIONING
- Compressor
REFILL
OF COMPRESSOR
OIL
assembly.
Specified
8.
: DENS0
oil
INSTALLATION
The clutch
compression
oil 6
OF CLUTCH
coil
must
be
COIL
aligned
with
the
pin
in the
housing.
2OY717
ADJUSTMENT
(1) Check
trated.
OF CLUTCH
the
Pressure
pressure
plate
plate
CLEARANCE
to rotor
clearance
as illus-
to rotor clearance
:
mm (.016-.028
in.)
0.4-0.7
NOTE
Remove
clearance
adjusting
shims to decrease
clearance.
Add shims selected
from the following
iOY718
to increase
Clearance
clutch
Adjustment
Part No.
clutch
table
clearance.
Shims
Thickness
RSI 3023A
RSI 3023B
RSI 3024
by hand to confirm
that it rotates
freely.
RJST608009-284
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