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GI

J100

TO INDEX

GENERAL INFORMATION

IMPORTANT SAFETY NOTICE .................... GI– 2


WARNINGS, CAUTIONS AND NOTES .... GI– 2
HOW TO USE THIS MANUAL ...................... GI– 4
CONTENTS OF EXPLANATION .............. GI– 4
ABBREVIATION CODES ............................. GI– 6
GENERAL SERVICE INSTRUCTION .......... GI– 7
HANDLING INSTRUCTIONS ON
CATALYTIC CONVERTER ......................... GI– 8
JACKING POINTS AND SUPPORTING
POINTS OF SAFETY STANDS ................ GI– 9
MODEL VARIATION ..................................... GI–13
CHASSIS SERIAL NUMBER STAMPED
POSITION ................................................. GI–14
MANUFACTURER’S PLATE POSITION ...... GI–14
CONTENTS OF MANUFACTURER’S
PLATE .................................................. GI–14
ENGINE NUMBER AND ENGINE TYPE
STAMPED POSITIONS ............................ GI–15
BODY COLOR INFORMATION .................... GI–16
TRIM CODE ............................................. GI–16
COLOR CODE IN THE WORLD .............. GI–17
POWER TRAIN SYSTEM ............................. GI–18
AUTOMATIC TRANSMISSION ................ GI–18
PROPELLER SHAFT ................................ GI–23
REAR AXLE ............................................. GI–24
BODY-RELATED ITEMS .............................. GI–25
ELECTRICAL COMPONENTS .................... GI–29
JGI00001-00000

NO. 9711-JE
GI–2 Revised on ’98 Oct.

IMPORTANT SAFETY NOTICE


The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is
potentially hazard. However, one can handle it safely if he has the required knowledge.
Correct service methods and repair procedures are very vital for assuring not only the safety and
reliability of a vehicle, but also the safety of service personnel concerned.
The methods and procedures contained in this manual describe in a general way the techniques
which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of
the products. The contents of the servicing operations come in a wide variety of ways. Moreover,
techniques, tools and parts necessary for each operation are different widely from each other.
This manual does not cover all details of techniques, procedures, parts, tools and handling instruc-
tions which are necessary for these operations, for such coverage is impossible. Hence, any one
who obtains this manual is expected first to make his responsible selection as to techniques, tools
and parts which are necessary for servicing the vehicle concerned properly. Furthermore, he must
assume responsibility for his actions in connection with his own safety.
Therefore, one should not perform any service if he is not capable of making responsible selection
and/or if he can not understand the contents herein described, for this manual has been prepared
for experienced service personnel.

WARNINGS, CAUTIONS AND NOTES


All these symbols have their specific purposes, respectively.
WARNING:
• This symbol means that there is the possibility of personal injury of the operator himself or the
nearby workers if the operator fails to follow the operating procedure prescribed in this manual.
CAUTION:
• This symbol means that there is the possibility of damage to the component being repaired if
the operator fails to follow the operating procedure prescribed in this manual.
NOTE:
• To accomplish the operation in an efficient manner, additional instructions concerning the
operation are given in this section.
The following list describes general WARNINGS:
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires you to be under the vehicle.
• Be sure that the ignition switch is always in the OFF position, unless otherwise required by the
procedure.
• Set the parking brake when working on the vehicle.
• Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
• Keep yourself and your clothing away from moving parts, when the engine is running, especial-
ly from the fan and belts.
• To prevent serious burns, avoid contact with hot metal parts, such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on a vehicle.
• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before
beginning to work on a vehicle.
• Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is mounted
on the radiator and can start to operate at anytime by a rise in coolant temperature or turning ON
of the air conditioner switch in the case of vehicles equipped with an air conditioner. The electric
cooling fan is also mounted on the condenser for air conditioner and starts to operate anytime
when the air conditioner switch is turned “ON”. For this reason care should be taken to ensure that
the electric cooling fan motor is completely disconnected when working under the hood.
Revised on ’98 Oct. GI–3

The UNITS used in this manual are showed as the SI UNIT (International System of Unit), and alter-
natively showed in the metric system.

“Example”
24.5 - 34.3 N·m (2.5 - 3.5 kgf-m)

JGI00002-00000
GI–4 Revised on ’98 Oct.

HOW TO USE THIS MANUAL


CONTENTS OF EXPLANATION
1. Schematic Diagram of Components
(1) The schematic diagram of components that appears at the beginning of each section describes the
nomenclature and installed conditions of each component. Furthermore the tightening torque is
posted in the figure.
(2) Those parts whose reuse is not permitted bear a “★” mark for an identification purpose. Be certain
to replace these parts with new ones during the assembly.
(3) During the assembly, be sure to apply grease to those parts indicated by the mark in the figure.

(Example)

T : Tightening torque
Unit : N·m (kgf-m)
★ : Non-reusable parts

T : 11.80 - 17.7
(1.2 - 1.8)

q Brake master cylinder Ay


w Reservoir tank fill cap
e Reservoir tank cap spacer
r Reservoir tank diaphragm
t Switch operating float
y Master cylinder reservoir tank S/A
u Clamp
i Set bolt
o Gasket
!0 Gasket
!1 Master cylinder repair kit

JGI00003-00001

2. Servicing Procedure
(1) In principle, the servicing procedure is described in the following sequence given below: Removal →
Inspection → Installation, and Disassembly → Inspection → Assembly.
(2) The explanation covers detailed servicing methods, specifications and notes.
(3) The main point of each item explains the servicing section and servicing procedure, using illustrations.

(Example)

What to do How to do it
What to do and where

3. Brake tube installation


(1) Install the brake tube to the wheel cylinder temporarily
by hands.
(2) Tighten the brake tube to the wheel cylinder, using
the following SST. 09751-36011-000
SST: 09751-36011-000

JGI00004-00002
Revised on ’98 Oct. GI–5
(4) The inspection in this manual describes only checking operation. Therefore, if you find any malfunc-
tion, replace any defective parts with new ones.

3. SST
For those operations which require the use of any SST, the SST numbers concerned are given in bold
letters.

4. Service Specifications
Service specifications are indicated in bold letters or enclosed by heavy lines. Be certain to confirm the
specifications concerned.

5. Tightening Torque
For those operations which require the control of tightening torque, the relevant tightening torque is
given in bold letters. Be certain to confirm the tightening torque concerned.

6. Definitions of Terms
Specified Value …… A value which represents the allowable range during the inspection
and adjustment.
Limit ………………… A maximum or a minimum limit which the value should not exceed or fall below.
JGI00005-00000
GI–6 Revised on ’98 Oct.

ABBREVIATION CODES
The abbreviation codes that appear in this workshop manual stand for the following, respectively.
Abbreviation code Original word Meaning
A/C Air Conditioner Refers to air conditioner.
A/T, AT Automatic Transmission Refers to automatic transmission
A/Y or Ay Assembly Refers to an assembled component comprising more than two single parts or sub-assembly
parts.
API American Petroleum The standards set forth by the American Petroleum Institute (abbreviated as API
Institute Classification) have been employed to evaluate and classify properties of various oils.
Engine oils for gasoline engines are classified as SF, SG, SH and so on, whereas engine oils
for diesel engines are classified as CC, CD and so on.
ECU Electronic Control Unit Refers to electronic control unit.
Electronic Refers to electronic fuel injection.
EFI Fuel Injection
F/L Fusible Link Refers to fusible link.
L.H.D. Left-Hand Drive Left-hand drive vehicle.
LH Left Hand Refers to left side.
M/T, MT Manual Transmission Refers to manual transmission.
MP Multipurpose Means that the following item has multi-purposes.
O/S Oversize In instances where fitting becomes too loose due to wear resulting from use for a long period
of time or due to frequent removal/installation operations, if the fitting part (e.g. piston) is
replaced with a part having larger dimensions, the other mating part may be put into use
again. “Oversized” parts denote those parts having larger dimensions compared with the
standard parts.
PR Ply Rating Represents strength of tires.
The larger the ply rating number, the stronger the tire strength.
R.H.D. Right-Hand Drive Right hand drive vehicle
RH Right Hand Refers to right side.
S/A Sub-Assembly Refers to a component comprising more than two single parts which are welded, staked, or
studded to each other to form a single component.
SAE Society of Automotive For example, automotive oils are designated as SAE so and so number.
Engineers These designation numbers have been set forth by the Society of Automotive Engineers in the
United States of America (SAE). The larger the SAE number, the higher the oil viscosity.
Conversely, the smaller the SAE number, the lower the oil viscosity.
SST Special Service Tool Refers to a tool designed for a specific purpose.
STD Standard When referring to automotive parts, “standard” represents those parts which have been
installed originally by the manufacturer and which have standard dimensions.
T Torque Refers to tightening torque.
U/S Under Size In the same manner as with the “oversized” parts, if fitting part (e.g. bush and bearing) is
replaced with a part having smaller bore dimensions, the other mating part may be put into
use again. “Under sized” parts denote those parts having smaller dimensions compared with
standard parts.
VSV Vacuum Switching
Refers to vacuum switching valve.
Valve
W/ With Denotes that the following part is attached.
ETR Electronic Tuning Radio which incorporates variable capacitance, etc. which varies the value according to an
Radio applied voltage or current.
JGI00006-00000

The abbreviation codes that appear in the figure stand for the following, respectively.
B Bolt S Screw

N Nut W Washer
JGI00007-00000
Revised on ’98 Oct. GI–7
GENERAL SERVICE INSTRUCTION
1. Use fender covers, seat covers and floor sheets so that the vehicle may not get dirty or be scratched.

2. Jacking up
(1) When only the front section or rear section of the vehicle is jacked up, be sure to place chocks at
the wheels so as to insure safe operations.
(2) When the vehicle has been jacked up, be sure to support the vehicle at the specified section using
safety stands. (See page GI–9)

3. Handling instructions related to battery.


(1) Before you start performing the electrical works, make certain to disconnect the battery ground
cable terminal from the negative (–) terminal of the battery.
NOTE:
• Before disconnecting the battery ground cable terminal from the negative (–) terminal of the battery,
be sure to read out the diagnosis code of the EFI, Airbag and immobilizer system etc., if the vehicle
is equipped with such systems, when necessary.
• After reconnecting the battery ground cable terminal to the negative terminal of the battery, be sure to
reset the watch or radio, if the vehicle is equipped with such equipment.

(2) When it becomes necessary to disconnect the battery power supply for the purpose of carrying out
checks or repairs, always disconnect the battery ground cable terminal from the negative terminal
of the battery first.
(3) To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery
ground cable terminal straight upward, rather than turning or prying the terminal.
NOTE:
• Be sure to employ a battery terminal puller (commercially available) to remove the battery ground
cable terminal from the negative terminal of the battery, if encountered any difficulty.

(4) Clean the battery terminal posts or battery ground terminals, using a cloth. Never use a file or other
adhesive agents.
(5) When connecting the battery ground cable terminal to the battery, first the battery ground cable ter-
minal should be fitted onto the battery post with the attaching nut in a loose state.
Then, tighten the nut. Never tap the terminal onto the battery post, using a hammer or spanner wrench
or the like.
(6) As for the cover at the positive (+) terminal side, be sure to install it at the correct position.

4. Repairs of fuel system


(1) The EFI equipped vehicles employ a high fuel pressure. Therefore, the following notes should be
observed.
q Be sure to prevent the fuel from splashing with a cloth or the like, when the union bolt or other
connected section of the fuel line is loosened or slackened.
(2) When connecting/disconnecting the fuel line.
q Tighten each connecting section to the specified torque.
w Attach new specified clips to each connecting section.
e Be certain to place a suitable container or a cloth, etc. under the connected section of the fuel
line before disconnecting the fuel line.
r Before the fuel line is disconnected, be sure to release the inner pressure of the fuel tank by
detaching the fuel filler cap.
t Be sure to follow the instruction mentioned in the main text when disconnect or connect the
quick type connectors.
(3) Never work near open flames.

5. For increased work efficiency and improved accuracy, be sure to utilize SSTs (Special Service Tools) ef-
fectively.
JGI00008-00000
GI–8 Revised on ’98 Oct.

HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER


WARNING:
• When a great amount of unburnt gas is admitted into the catalytic converter, overheating is prone to
occur, resulting in a fire hazard.
To avoid such trouble in advance, be certain to observe the following precautions. Also, be sure to
explain such precautions to your customers.

1. Use only unleaded gasoline.

2. Avoid idling the engine for a prolonged length of time.


Do not run the engine continuously at idle speed for more than 20 minutes.
WARNING:
• Immediately check and repair the vehicle if the fast idle speed or idle speed is unstable or the system
exhibits malfunction. Failure to observe this warning may result in a fire hazard.

3. Be sure to observe the following points when performing the spark jump tests.
(1) The spark jump test must be limited to cases where such test is absolutely necessary. Also, be sure
to finish the test in the shortest possible time.
(2) Be sure to shut off the fuel supply when performing the spark jump test in advance.

4. Do not run the engine when the fuel tank becomes nearly empty.
Failure to observe this caution will cause misfiring. Also, it will apply excessive load to the catalytic con-
verter, even leading to catalyst damage.

5. Do not dispose of the waste catalyst along with parts contaminated with gasoline or oil.
JGI00009-00000
Revised on ’98 Oct. GI–9
JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS
CAUTION:
• Be sure to support the vehicle at the flat surface of the rocker panel.
• Do not support the vehicle at the edge part rocker panel.

• Jacking Points
Front side ………… Differential mount bracket
Rear side ………… Rear axle housing
Front side Rear side

Supporting points

Garage jack Garage jack

• Supporting points of safety stands


Four supporting points are located at the right and left sides. (The supporting points have been
strengthened by spot-welding reinforcements. Never support the vehicle at points other than the
specified points.)

• Supporting points of tow-post lift


Align the supporting pads of a two-post lift with the supporting points of safety stands, as indicated in
the figure above.

• Supporting points of plate supporting type lift


A vehicle should be placed at the center of the supporting plates of the lift.
When lifting up the vehicle, be sure to support the front section of the vehicle.

JGI00010-00003
GI–10 Revised on ’98 Oct.

TOWING INFORMATION
When towing the model J100 follow the manner mentioned below.
CAUTION:
• Never perform towing, using sling type equipment.
Failure to observe this caution may lead to severe damage on the vehicle body.
JGI00011-00000

Flat bed type


We recommend this as the most desirable method.
CAUTION:
• Apply the parking brake securely.
• Be sure to tie-down the vehicle body to the carrier,
using a tie-down wires. However, never apply exces-
sive force to each hook on the vehicle body, for vehicle
body may be severely damaged.

Wheel lift type JGI00012-00004

Use a towing dolly when towing the vehicle with the front
wheels or rear wheels on ground.
WARNING:
• Never allow anyone to be in the vehicle being towed.

CAUTION:
• Be sure to secure the front or rear tires on the towing
dolly.
• Never perform the towing, using sling type equipment.
Failure to observe this caution may severely damage
the vehicle body. JGI00013-00005

Emergency towing
This manner can be employed if the vehicle is equipped with
a manual transmission and the road surface is hard and
smooth. In this case, be certain to follow the WARNING and
CAUTION mentioned below.
WARNING:
• The driver in the vehicle to be towed should always
keep in mind that braking will require more force than
usual when the engine is stopped, because the brake
booster is not functioning when the engine is stopped. JGI00014-00006
Revised on ’98 Oct. GI–11
• Never tow the vehicle at speed more than 30 km/h.
• Turn the ignition switch of the vehicle to be towed in the “ACC” position during the towing. Never pull
out the key or turn the ignition switch to the “LOCK” position during the towing. Failure to observe this
warning will loose controllability, causing an accident.
• Never tow the vehicle in this manner unless the wheels, axles, drive train, steering, and brakes are in
a good condition.

CAUTION:
• Never tow an automatic transmission vehicle in this manner. Be sure to always use a towing dolly.
• Always pull the hook in a straight-ahead direction to prevent it from being damaged. Never pull it
from side or in a vertical direction. Also, never pull it sharply.
• Never connect the towing rope, cable or such to the parts other than the hooks provided on the vehi-
cle shell. Connection of the towing rope, cable or such to other pants than hooks may damage these
components
• Ensure that the hooks are installed on the vehicle shell securely before towing.

1. Attach a sturdy rope, towing strap or cable to the towing hook.


2. A driver must ride in the vehicle being towed and control it.
3. Release the parking brake and shift the shift lever of manual transmission to the neutral position.
4. Select the center differential lock switch in the free position.
NOTE:
• If you cannot start the engine, ensure that the center differential lock mechanism is free by jacking up
one of the wheels and making sure that the wheel turns freely.
Even if the indicator lamp in the combination meter shows that the differential lock is free, there is the
possibility that it is not free actually.

5. Set the ignition switch to the “ACC” position.


6. Perform the towing.
JGI00015-00000

DIAGNOSIS CONNECTOR
The diagnosis connector is provided under the instrument
panel at the driver’s seat side as shown.
Terminal table
Terminal number and name
q IG For DS-21 o T (ITC)
e ABST !0 SIO For DS-21
r ECUT !1 EFIT
i REV !3 Body ground
!6 VF JGI00016-00007

1. Be sure to connect the following SST when utilizing this


connector, in order to prevent the terminals in the diagno-
sis connector from being damaged.
The shape of the SST end is the same as the diagnosis
connector.
SST: 09991-87404-000

JGI00017-00008
GI–12 Revised on ’98 Oct.

2. When measuring the engine tachometer, connect the fol-


lowing SST to the No. 8 (REV) terminal of the above SST.
REV
SST: 09991-87402-000

JGI00018-00009

3. Utilize the following SST when connecting the terminals in


the SST for the diagnosis connector which is specified in
the main text.
SST: 09991-87403-000

CAUTION:
• Never connect the terminals other than that specified in
the main text in each section. Failure to observe this
caution may lead to serlus damage or malfunction.

JGI00019-00010

4. Reference
(1) Output of diagnosis code of EFI system.
Connect the 11(EFIT) and 13 (Body ground)
(2) Output of diagnosis code of ABS system.
Connect the 4(ECUT) and 13 (Body ground)
(3) Switching to the test of ABS system. 1 2 3 4 5 6 7 8
Connect the 3(ABST) and 13 (Body ground) 9 10 11 12 13 14 15 16
(4) Vf output (oxygen sensor function)
Connect the 16(VF) and 13(body ground)
(5) Output of diagnosis code of air bag system.
Connect the 4(ECUT) and 13 (Body ground) JGI00020-00011

(6) To connect the tachometer


Connect a tachometer to 8(REV) terminal.
(7) Connection of the DS–21
Connect the DS–21 utilizing the following SST. The fol-
lowing SST is provided with the terminal for DS–21.
SST: 09991-87404-000

CAUTION:
• Never connect the DS–21 in another way than that
manner specified.
Revised on ’98 Oct. GI–13
MODEL VARIATION
Specification General AUS EC
Engine Handle position RHD LHD RHD RHD LHD
Grade Lo Hi Lo Hi Lo Hi Lo Hi Lo Hi
Model code J100RG J100LG J100RG J100RG J100LG
HC-EJ 5MT GMDE GMXE GMDE GMXE GMDEQ GMXEQ GMDEW GMXEW GMDEW GMXEW
4AT GPDE GPXE GPDE GPXE GPDEQ GPXEQ GPDEW GPXEW GPDEW GPXEW
JGI00021-00000

Explanation of vehicle model code


J1 0 0 L G - G M D E W
Model code
J1 : TERIOS

Drive system
0 : Four-Wheel Drive Vehicle (Full-time 4WD)

Engine type
Body type 0 : Type HC-EJ engine
G : Station
wagon Steering position
Number of doors L : Left-Hand Drive Vehicle
G : Five Door R : Right-Hand Drive Vehicle

Transmission Fuel supply


M : Five-speed Manual Transmission E : EFI-equipped Engine
P : Four-speed Automatic Transmission
Destination
Grade of model Non : General Specifications
D : Low grade W : European Specifications
X : High grade Q : Australian Specifications
JGI00022-00000
GI–14 Revised on ’98 Oct.

CHASSIS SERIAL NUMBER


STAMPED POSITION
The chassis number is stamped on the cowl panel at the right Serial number
side in the engine compartment.

JGI00023-00012

MANUFACTURER’S PLATE POSITION


The manufacturer’s plate is attached on the cowl panel.
Manufacturer’s
plate

JGI00024-00013

CONTENTS OF MANUFACTURER’S PLATE

(1) General, Australian, Norwegian and Finnish specifications

q
w
e
r t

u
y !4 q Manufacturer’s name, Country
w Vehicle model
i e Chassis No.
r Engine type
o t Engine displacement
y Body colors
u Trim code
(2) European Specification (except for Norway and Finland) i Engine number
o Manufacturer’s name in Japanese
q !0 Gross vehicle weight
!1 Gross combination weight
!5 !2 Maximum permissible front axle weight
e !3 Maximum permissible rear axle weight
!4 Production month-year (Only for AUS spec.)
!0
!5 Authorized number of W.V.T.A.
!1 (Only for European specification.)
!2
!3
w
r y

JGI00025-00014
Revised on ’98 Oct. GI–15
ENGINE NUMBER AND ENGINE TYPE
STAMPED POSITIONS
• The engine number is stamped on the cylinder block. Serial number
• The engine type is indicated by embossed letters on the stamped
cylinder block. position

JGI00026-00015
GI–16 Revised on ’98 Oct.

BODY COLOR INFORMATION


In line with the improvements of the Terios of this time, the quality of the vehicle exterior color has been en-
hanced in order to appeal a casual feeling of the vehicle. For this end, the following two vehicle colors have
been changed.
From “Turquoise mica metallic” to “Jade green metallic;
From “Red mica metallic” to “Maple red mica metallic.”
Moreover, a new color of “Sea sapphire blue mica metallic” has been added.
Color code
Body color name
Mono-tone color Two-tone color
Silver Metallic S07 NF7 (S07/S07)
Black Metallic 6A5 NF2 (6A5/S07)
Purplish blue mica Metallic B38 NG1 (B38/S07)

Jade green Metallic G31 NH4 (G31/S07)

Sea sapphire blue mica Metallic B44 NG5 (B44/S07)

Maple red mica Metallic R27 NH9 (R27/S07)
Violet Metallic P05 NG2 (P05/S07)
White W19 NJ0 (W19/S07)

; New additional color
JGI00027-00000

TRIM CODE
F C S5 Trim color code (Serial code)
Serial code
Seat main material
F: Fabric
S: Gray
JGI00028-00000
Revised on ’98 Oct. GI–17
COLOR CODE IN THE WORLD

SPIES
DAIHATSU AKZO DUPONT ICI STNDOX
HECKER
Silver Metallic S07 DAHS07 L8842 B127B 97097 S07
Black Metallic 6A5 DAH6A5 G8742 A403B 96326 6A5
Purplish blue mica Metallic B38 DAHB38 F3425 JNE4B 55603 B38

Mono- Jade green Metallic G31 DAHG31 F5146 NMH2B 65649 G31
tone Sea sapphire blue mica Metallic B44 DAHB44 F5147 NMH3B 56715 B44
Maple red mica Metallic R27 DAHR27 F7151 MCE2B 34314 R27
Violet Metallic P05 DAHP05 F3426 JNE5B 40868 P05
White W19 DAHW19 M0004 RAA7 23024 W19
NF7 DAHS07 L8842 B127B 97097
Silver Metallic (S07/S07) /DAHS07 /L8842 /B127B /97097 S07/S07

NF2 DAH6A5 G8742 A403B 96326


Black Metallic (6A5/S07) /DAHS07 /L8842 /B127B 97097 6A5/S07

NG1 DAHB38 F3425 JNE4B 55603


Purplish blue mica Metallic (B38/S07) /DAHS07 /L8842 /B127B /97097 B38/S07

NH4 DAHG31 F5146 NMH2B 65649


Jade green Metallic (G31/S07) /DAHS07 /L8842 /B127B /97097 G31/S07
Two-
tone NG5 DAHB44 F5147 NMH3B 56715
Sea sapphire blue mica Metallic (B44/S07) /DAHS07 /L8842 /B127B /97097 B44/S07

NH9 DAHR27 F7151 MCE5B 34314


Maple red mica Metallic (R27/S07) /DAHS07 /L8842 /B127B /97097 R27/S07
NG2 DAHP05 F3426 JNE5B 40868
Violet Metallic (P05/S07) /DAHS07 /L8842 /B127B /97097 P05/S07

NJ0 DAHW19 M0004 RAA7 23024


White (W19/S07) /DAHS07 /L8842 /B127B /97097 W19/S07
JGI00029-00000
GI–18 Revised on ’98 Oct.

POWER TRAIN SYSTEM


For enhanced driving stability, reliability and quietness, the automatic transmission, propeller shaft and rear
axle of the power train system have been improved as the measures for appealing the product quality.
JGI00030-00000

AUTOMATIC TRANSMISSION
1. Outline
The basic construction of the automatic transmission remains the same as the hitherto-employed transmis-
sion mounted on the Terios. However, for improved transmitting efficiency and enhanced durability, reliabili-
ty and quietness, the hitherto-employed automatic transmission for the Terios has been further improved.
In line with the rolling-off of the new Terios of this time, modifications have been made on the following com-
ponents with an asterisk mark (*) indicated in the sectional view of the automatic transmission for the Terios.
Furthermore, the parking brake mechanism, etc. indicated in the following page has been modified.
JGI00031-00000

SECTIONAL VIEW OF AUTOMATIC TRANSMISSION

q w e r t y u i o !0

!1 !2 !3 !4 !5 !6 !7 !8 !9

*q Torque converter *!0 Output shaft


*w Oil pump *!1 Input shaft
*e Direct clutch *!2 Valve body
*r Forward clutch *!3 2nd brake band
*t Rear clutch *!4 Front planetary sun gear
*y One-way clutch *!5 Planetary short pinion
*u 1st & reverse brake *!6 Planetary output shaft
*i Planetary long pinion *!7 Intermediate shaft
*o Rear planetary sun gear *!8 Parking lock gear
*!9 Governor drive gear
*: Modification has been made on the components with an asterisk mark indicated.
JGI00032-00016
Revised on ’98 Oct. GI–19
PARKING BRAKE MECHANISM

Parking lock gear

Output shaft
Parking rod
Cam spring

*Parking lock pawl

Parking cam

*: Modification has been made on the components with an asterisk mark indicated.
JGI00033-00017
GI–20 Revised on ’98 Oct.

2. Specifications
Transmission Type A4JA
Transmission ID code F64
Driving method 4WD
Engine type HC-EJ
Torque Type Three-element, one-stage, two-phase type
converter Stall torque ratio 2.0
Type Four forward speed, one reverse gear
Wet type multiple clutch: 3 set
Band type brake: 1 set
Control element
Wet type multiple brake: 1 set
One-way clutch: 1 set
1st 2.730
Trans- 2st 1.526
mission Gear ratio 3rd 1.000
type
4th 0.696
R 2.290
Speed meter gear ratio 24/5
Fluid to be used ATF DEXRON 3
Fluid capacity litter 4.2
Cooling method Water-cooled (radiator built-in type)
Control Gear shift control method Four forward speeds, full automatic shift
system Manual control pattern P-R-N-D-2-L (with over drive switch)
JGI00034-00000

3. Improvement of transmitting efficiency


1. Oil pump Oil pump driven gear
For reduced load at the time of oil pump driving and im-
proved fuel efficiency, the crescent has been abolished Oil pump drive
from the trochoid type gear oil pump. gear

Oil pump body

JGI00035-00018

2. Forward clutch
For improved transmitting efficiency, the number of teeth
of the forward clutch disc No. 2 and forward clutch hub
has been increased from 20 to 35.

JGI00036-00019
Revised on ’98 Oct. GI–21
4. Enhanced quietness
1. Reduction of gear noise Planetary Intermediate shaft
short pinion
For reduced gear noise, the profile and number of teeth of
each gear of the planetary long pinion, rear planetary sun
gear, front planetary sun gear, planetary short pinion and Planetary
output shaft
planetary output shaft.
Rear planetary
Number of teeth
Planetary gear sun gear
Former New
Front planetary Planetary long
Planetary long pinion 36 31 sun gear pinion
Rear planetary sun gear 24 20 JGI00038-00021

Front planetary sun gear 30 26


Planetary short pinion 23 19
Planetary output shaft 84 71

2. Securing of oil tube


Formerly, the oil tube was secured by applying it to the oil
pan. However, in this method, abnormal noise can be
emitted due to the difference in behavior between the oil
pan and the tube. Therefore, the tube is secured to the
valve body with the bolts so that a clearance may be
made between the oil pan and the oil tube.

JGI00039-00022

5. Improvement of durability and reliability Thrust needle bearing


1. Intermediate shaft
The journal diameter of the intermediate shaft has been
reduced so as to increase the rolling area of the thrust
needle bearing relative to the sun gear as well as to pre-
vent the bearing from flaking.
Dimensions of Thrust Needle Bearing
Outer Diameter: 32 mm
Inner Diameter: 14 mm
Thickness: 4.1 mm Thrust bearing race
JGI00040-00023
GI–22 Revised on ’98 Oct.

2. Parking brake mechanism


For easier operation and enhanced durability & reliability of the parking brake mechanism, the sheet
thickness of the parking lock pawl has been increased from 7 mm to 10 mm. Also, the set load of the
set spring of the parking lock pawl has been reduced by 30%.

Parking lock gear

Output shaft
Parking rod
Cam spring

*Parking lock pawl

Parking cam

*: Modification has been made on the components with an asterisk mark indicated.
JGI00041-00024

6. Reduction of number of parts


1. Output shaft
The oil lubrication hole of the shaft has been abolished.

JGI00042-00025
Revised on ’98 Oct. GI–23
2. Abolishment of oil cooler hose
In order to reduce the number of components of the oil cooler piping, the automatic transmission tube
has become integral with the engine side tube. Consequently, the oil cooler hose has been abolished.

This illustration shows specifications except


for the EU specifications

Oil cooler front hose

Front tube

A/T tubes

Oil cooler inlet hose

Oil cooler outlet hose

JGI00043-00026

PROPELLER SHAFT
1. Enhanced quietness
In order to reduce the bead noise that is emitted at the time of shaft rotation, the shape of the propeller
shaft bearing center support housing has been changed.

[Former] [New]

JGI00044-00027
GI–24 Revised on ’98 Oct.

REAR AXLE
1. Improvement of driving stability
For enhanced roll rigidity, the rebound spring built-in type shock absorber has been adopted for the rear
shock absorber so as to improve the driving stability, while maintaining the driving comfort.

JGI00045-00028

2. Enhanced quietness
For reduced differential noise, the sheet thickness of the rear
axle housing has been increased and the reinforcement has
been abolished.

JGI00046-00029
Revised on ’98 Oct. GI–25
BODY-RELATED ITEMS
With regard to the body-related items, the following design changes have been made as the measures for
appealing the product quality so that the ODB conformity collision safety body may be attained, the physi-
cal comfort may be improved and any deficiency encountered in the market may be eliminated.
JGI00047-00000

1. Attainment of ODB conformity collision safety body


1. Reinforcement of front pillar and rocker section
For the reinforcement of sections around the front pillar, reinforcements (“A” pillar corner reinforcement
and “A” pillar lower reinforcement) have been enlarged and an inner rocker reinforcement has been
added.

[Former] [New]

JGI00048-00030

2. Reinforcement of body undermembers


For the reinforcement of body undermembers, reinforce-
ments have been added to the body underbody structure
(front side member reinforcements at the front right and
left). Furthermore, the reinforcements have been enlarged
(at the front side member No. 3, right and left). Moreover,
the outriggers have been further strengthened (outrigger
No. 1 FR at the right and left, outrigger No. 3).

JGI00049-00031

3. For assured rescuability of occupants at the time of colli-


sion, a “Z”-shaped hem has been employed at the front
side of the right rear door.

JGI00050-00032
GI–26 Revised on ’98 Oct.

2. Improvements of physical comfort


1. Seat arrangement
(1) Increased sliding amount of front seat
For improved physical comfort of the front seat, the seat sliding amount has been increased 15 mm
forward; 60 mm backward.
(2) Length of front seat cushion
For improved physical comfort, the length of the front seat cushion has been increased 10 mm.
(3) Height of rear seat cushion
For improved physical comfort, the forward edge of the seat cushion has become 20 mm higher.

10mm
20mm

JGI00051-00033

2. Assurance of accommodating space at rear floor


An accommodating space has been provided at the rear floor section by setting deck boards of two
kinds, respectively; One is of a high grade and the other is of a low grade.
170

195

446 (X670)

*246 (X556)

(Hi Grade)

60 53
0 3
134

159

446 (X670)

*246 (X556)

(Lo Grade)

JGI00052-00034
Revised on ’98 Oct. GI–27
3. Enhanced performance of vehicle interior ventilation
In order to assure adequate ventilating performance, a
ventilation valve has been provided at two points behind
the rear combination lamp of the left side “D” pillar and
behind the right bumper.

JGI00053-00035

4. Reduction of transmitting noise into vehicle interior


(1) Adoption of high-density, thicker dash silencers;
(2) Adoption of double steel sheets at the inner cowl and
dash panel;

JGI00054-00036

(3) Adoption of hood silencer and dash outer silencers;

JGI00055-00037

(4) Adoption of high-density, floor silencers.

JGI00056-00038
GI–28 Revised on ’98 Oct.

5. Reduction of wind noise level


Weatherstrip
(1) Employment of inner and outer, double weatherstrips Shelf
(The wind noise level has been further reduced by en- Front
door
hancing the sealing characteristics and by providing a
larger air layer between the weatherstrips.)
(2) A shelf for preventing wind noise has been provided at
the front pillar so that no air stream may be admitted
deeply.
Front pillar
Weatherstrip
JGI00057-00039

3. Improvements of deficiencies encountered in the market


1. Assurance of adequate rigidity of back door
For improved rigidity of the backdoor, the following measures given below have been taken as the mea-
sures for complaints for poor opening/closing of the back door due to insufficient rigidity.
(1) Adoption of large-sized reinforcements (lock reinforcement integral type reinforcement & spare tyre
carrier reinforcement);
(2) Enhanced rigidity of hinges;
(3) Optimization of hinge offset amount;
(4) Adoption of lighter hinges (employment of pressed hinges);
(5) Assurance of adequate pitch between upper hinge and lower hinge.

JGI00058-00040
Revised on ’98 Oct. GI–29
2. Improvements of installation method of roof mouldings
The following measures given below have been taken as
the measures for complaints for floated roof mouldings.
(1) Improvements of shape of mouldings
The shape of mouldings has been altered into such a
shape in which the floating or bend of mouldings may
not become conspicuous by setting the moulding in-
stallation seating surface at a point lower than the
body surface.
(2) Installation method of mouldings
In order to prevent the mouldings from being floated, JGI00059-00041

the front side of the roof moulding is secured by insert-


ing the moulding into the T-shaped studs provided at
the body side, whereas the rear side of the roof mould-
ing is secured by inserting the moulding into the rear
combination lamp housing.

ELECTRICAL COMPONENTS
For enhanced safety and improved physical comfort, the following design changes enumerated below
have been made on the electrical components.

1. Enhanced safety
1. Improvements of airbag system
In addition to the installation of an airbag on the driver’s seat as well as on the front passenger seat,
seat belts equipped with a pretensioner & force limiter have been mounted on all vehicles.
As a result of this change, the airbag ECU and cowl wire have been altered.
At the same time, changes have been effected on the steering wheel (from the two-spoke with airbag to
the three-spoke with airbag).Furthermore, the roll connector has been modified.
JGI00060-00000
OC3 F/L ABS 50A OC6 ABS
Head lamp 30A O69 H/L
Tail 40A OF1 TAIL
ALT Back up 10A C90 B/U
GI–30

Horn, Hazard 15A F69 HRN/HAZ


F/L AM 60A O31
ACC R01 ACC
R/B IG No. 1 N01 IG1
O12 IG No. 2 N30 IG2
IG SW ST

Wire F/L 2.0


Junction block N60 N59 N60

10 A
10 A

10 A
Engine

ECU IG
Air bag
AIRBAG SYSTEM CIRCUIT DIAGRAM

Battery
QB2 N31 T45
H61

T37
Air bag ECU
Warning lamp
(Combination meter)
T26 W DC-DC Back-up Safing
circuit condenser sensor
A Roll
connector
Z08
B
DB+ T11
Driver's
DB— T12 air bag
T01 IG1 Control Drive
circuit circuit PB+ T09
Diagnosis connector T02 IG2 Passenger's
PB— T10 air bag
IG ECU IMB T28 TC CPU
REV
T W DP+ T48
ITC E G sensor Driver's
VF
T SIO DP— T47 pretensioner
Diagnosis Drive
code circuit PP+ T29
memory Passenger's
Air bag ECU connector (at cowl wire harness side) T44 SIO PP— T13 pretensioner
T14 E1
T10 T09 T44 T26 T12 T11 T28

A B
T14 T13 T29 T47 T48 T02 T01

JGI00061-00042
Revised on ’98 Oct.
Revised on ’98 Oct. GI–31
STEERING
A new three-spoke type steering wheel with air bag has been
employed.

JGI00062-00043

ROLL CONNECTOR
The full stroke of the roll connector from the lock to the lock
TOP mark
has been increased from five turns to six turns. Consequently,
in the former setting during the roll connector installation, the
roll connector was set after it is backed off 3.0 turns from the
lock point, while in the new setting, it is necessary that this ini-
tial setting is made after the roll connector is backed off 3
turns.

JGI00063-00044

1. Addition of fuel cut system


The fuel cut function has been added to the impact sens-
ing safety system.
As a result of this change, a fuel cut sensor and a fuel cut
sensor circuit have been added.

JGI00064-00045
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
GI–32

Back up 10A B/U


Horn,Hazard 15A HRN/HAZ
ACC ACC
IG No. 1 IG1
IG No. 2 IG2
ST ST
IG SW
Main MAIN

Junction block OF2 N59 F70 N59 CA2

F/L AM 60A
Buzzer

20 A
Stop 10 A

Wiper/Turn

Door lock 15 A
locking switch alone was mounted.

Gauge 10 A

Wire F/L 2.0


Q17 H67 F65 F66 E44

F47 F32 F60


RH LH

Battery
Courtesy SW
HZD TRN

RH LH
Turn signal lamp OFF
Room lamp
2. Employment of two-contact points on door lock switch

Flasher relay
F48 Multi-use lever

Turn signal indicator


ON DOOR
SW

ITC ECU Q47 QB3 QC7 QB7 QB5 QC4 QB9 QC5 QB4 QB6
+B IG1 CHZD T/H CHR CHL CFL FL+ DCSD CRL
Buzzer

SPD CS1 CS– LKS UKS E1 ULM LKM T

Q34 QC3 QC2 #02 QB8 ZT3 Q51 Q50 QC1

ITC ECU connector (wire harness side) Door lock Diagnosis connector
D motor
CHL FL+ T/H T LKS IG1 E1 LKM ABS ECU IMB
CSD M IG REV

S
Collision T T W

N
C

N
CHR CFL CRL UKS SPD CS1 +B CS– ULM ITC EFI

S
HZD sensor SIO E VF

Vehicle
M T T
M

speed sensor
Door lock M
Switch
M
that the locking/unlocking state of the door may be detected accurately. In the former system, the un-

JGI00065-00046
For improved safety, a lock switch has been added to the impact sensing door lock release system so
Revised on ’98 Oct.
Revised on ’98 Oct. GI–33
3. Enhanced conspicuousness of switches
In order to enhance conspicuousness of the switches during night driving, night illumination has been
added to the following switches listed below:

ON

Indicator OFF
light

Rear defogger switch Rear wiper switch

ON

OFF

Front fog lamp switch Rear fog lamp switch.

JGI00066-00047

4. Improvement of combination meter


The illumination method of the combination meter has been changed from the indirect illumination type
to the transmitting illumination type so that the conspicuousness of meters may be further enhanced.
Furthermore, the glow method of the seat belt warning lamp has been altered to the flashing type so as
to protect the circuit.
IC

Seat belt Sw
A13

LED

JGI00067-00048
GI–34 Revised on ’98 Oct.

1. Improvement of physical comfort


1. Employment of compact power window control switch
For improved physical comfort, the power window control
switch has become smaller, resulting in roomier space
around the knee of the driver, thereby making it possible
for the driver to take an easier driving posture.
(EC specifications: LHD vehicle only)

L.H.D.
JGI00068-00049

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