6-1 [S100] SPECIFICATIONS AND SERVICE DATA

1. Specifications

1. Specifications
Item Designation
Type Reduction type
MT AT
Model
M000T81681 M001T84481
Manufacturer MITSUBISHI
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load characteris- Current 90 A or less
tics Rotating
Starter 3,000 rpm or more
speed
Voltage 8V 7.7 V
Current 280 A or less 300 A or less
Load characteristics Torque 8.5 N·m (0.87 kg-m, 6.27 ft-lb) 9.8 N·m (1.00 kg-m, 7.24 ft-lb)
Rotating
980 rpm or more 1,000 rpm or more
speed
Voltage 4V
Current 780 A or less 980 A or less
Lock characteristics
17.6 N·m (1.80 kg-m, 13.0 ft-lb) or
Torque 23 N·m (2.3 kg-m, 17 ft-lb) or more
more
Type Rotating-field three-phase type, Voltage regulator built-in type
Model A2TB2991
Manufacturer MITSUBISHI
Voltage and output 12 V — 75 A
Polarity on ground side Negative
Generator Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 30 A or more
Output current 2,500 rpm — 64 A or more
5,000 rpm — 76 A or more
Regulated voltage 14.5+0.3/−0.4 V [20°C (68°F)]
Model FH0137-01R
Manufacturer DEMCO
Ignition coil
Primary coil resistance 0.73 Ω±10%
and ignitor
assembly Secondary coil resistance 12.8 kΩ±15%
Insulation resistance between
More than 10 MΩ
primary terminal and case
Type and manufac- Standard RC10YC4 .......... CHAMPION
turer Alternate BKR5E-11 .......... NGK
Spark plug
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)

2
 COMPONENT PARTS [C100] 6-1
1. Starter

1. Starter

H6M0492B

(1) Sleeve bearing (7) Internal gear ASSY (13) Armature

(2) Front bracket (8) Shaft ASSY (14) Brush holder
(3) Lever set (9) Gear ASSY (15) Brush
(4) Magnet switch ASSY (10) Ball (16) Sleeve bearing
(5) Stopper set (11) Packing (17) Rear bracket
(6) Over running clutch (12) Yoke

3
6-1 [C200] COMPONENT PARTS
2. Generator

2. Generator

H6M0493B

(1) Pulley (5) Rotor (9) Brush

(2) Front cover (6) Bearing (10) Rectifier
(3) Ball bearing (7) Stator coil (11) Rear cover
(4) Bearing retainer (8) IC regulator with brush (12) Terminal

4
 COMPONENT PARTS [C300] 6-1
3. Ignition System

3. Ignition System

S6M0329A

(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kg-m, ft-lb)
(2) Spark plug cord (#1, #3)
T: 22±2 (2.2±0.2, 15.9±1.4)
(3) Ignition coil and ignitor ASSY

5
6-1 [W1A1] SERVICE PROCEDURE
1. Starter

1. Starter 4) Remove starter from transmission.

A: REMOVAL AND INSTALLATION

1. 2200 cc MODEL
1) Disconnect battery ground cable.

G2M0309

5) Installation is in the reverse order of removal.

Tightening torque:
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
G6M0095

2) Remove air intake chamber. <Ref. to 2-7

[W18A0].>

G2M0309

2. 2500 cc MODEL
B2M1679 1) Disconnect battery ground cable.
3) Disconnect connector and terminal from starter.

G6M0095

S6M0002A

(A) Terminal
(B) Connector

6
 SERVICE PROCEDURE [W1B1] 6-1
1. Starter

2) Remove air intake chamber. <Ref. to 2-7 6) Installation is in the reverse order of removal.
[W18A0].> Tightening torque:
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)

S6M0007

3) Remove air intake chamber stay. (AT vehicles G2M0309

only)
B: TEST
1. SWITCH ASSEMBLY OPERATION
1) Connect terminal S of switch assembly to posi-
tive terminal of battery with a lead wire, and starter
body to ground terminal of battery. Pinion should
be forced endwise on shaft.
CAUTION:
With pinion forced endwise on shaft, starter
S6M0023
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
4) Disconnect connector and terminal from starter. a problem.
2) Disconnect connector from terminal M, and
connect positive terminal of battery and terminal M
using a lead wire and ground terminal to starter
body.
In this test set up, pinion should return to its origi-
nal position even when it is pulled out with a screw-
driver.

S6M0002A

(A) Terminal
(B) Connector

5) Remove starter from transmission.

G6M0029

G2M0309

7
6-1 [W1B2] SERVICE PROCEDURE
1. Starter

2. PINION GAP 1) No-load test

With switch on, adjust the variable resistance to
1) With pinion forced endwise on shaft, as outlined
obtain 11 V, take the ammeter reading and mea-
in step 1) before <Ref. to 6-1 [W1B1].>, measure
sure the starter speed. Compare these values with
pinion gap.
the specifications.
Pinion gap:
No-load test (Standard):
0.5 — 2.0 mm (0.020 — 0.079 in)
Voltage / Current
11 V / 90 A or less
Rotating speed
I MT vehicles 2,800 rpm or more
I AT vehicles 2,400 rpm or more
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within specifications.
Load test (Standard):
G6M0030
I MT vehicles
2) If motor is running with the pinion forced end- Voltage / Load
wise on the shaft, disconnect connector from ter- 7.5 V / 8.73 N·m (0.89 kg-m, 6.4 ft-lb)
minal M of switch assembly and connect terminal Current / Speed
M to ground terminal (−) of battery with a lead wire. 300 A / 890 rpm or more
Next, gently push pinion back with your fingertips I AT vehicles
and measure pinion gap. Voltage / Load
3) If pinion gap is outside specified range, remove 7.7 V / 16.00 N·m (1.63 kg-m, 11.8 ft-lb)
or add number of adjustment washers used on the Current / Speed
mounting surface of switch assembly until correct 400 A max. / 740 rpm or more
pinion gap is obtained.
3) Lock test
3. PERFORMANCE TEST With starter stalled, or not rotating, measure the
The starter should be submitted to performance torque developed and current draw when the volt-
tests whenever it has been overhauled, to assure age is adjusted to the specified voltage.
its satisfactory performance when installed on the Lock test (Standard):
engine.
I MT vehicles
Three performance tests, no-load test, load test,
Voltage / Load
and lock test, are presented here; however, if the
4 V / 780 A or less
load test and lock test cannot be performed, carry
Torque
out at least the no-load test.
15.7 N·m (1.60 kg-m, 11.6 ft-lb) or more
For these performance tests, use the circuit shown
in figure. I AT vehicles
Voltage / Current
3.5 V / 940 A or less
Torque
28.9 N·m (2.95 kg-m, 21.3 ft-lb) or more

G6M0031

8
 SERVICE PROCEDURE [W1C1] 6-1
1. Starter

C: DISASSEMBLY 5) Remove packing A, three planetary gears,

packing B and plate.
1. STARTER ASSEMBLY
1) Loosen nut which holds terminal M of switch
assembly, and disconnect connector.
2) Remove bolts which hold switch assembly, and
remove switch assembly, plunger and plunger
spring from starter as a unit.
CAUTION:
Be careful because pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.
G6M0035

6) Remove shaft assembly and overrunning clutch

as a unit.
CAUTION:
Record the direction of lever before removing.

G6M0032

3) Remove both through-bolts and brush holder

screws, and detach rear bracket and brush holder.

G6M0036

7) Remove overrunning clutch from shaft assem-

bly as follows:
(1) Remove stopper from ring by lightly tapping
a fit tool placed on stopper.
(2) Remove ring, stopper and clutch from shaft.

H6M0494A

4) Remove armature and yoke. Ball used as a

bearing will then be removed from the end of arma-
ture.
CAUTION:
Be sure to mark an alignment mark on yoke
and front bracket before removing yoke.
G6M0037

H6M0495A

9
6-1 [W1C2] SERVICE PROCEDURE
1. Starter

2. BRUSH HOLDER 3) Depth of segment mold

Check the depth of segment mold.
Slightly open the metal fitting holding the insulating
plate to the brush holder. Remove the insulating Depth of segment mold:
plate. 0.5 mm (0.020 in)
NOTE:
The brush and spring can be easily removed from
the brush holder at this time.

G6M0039

4) Armature short-circuit test

Check armature for short-circuit by placing it on
H6M0497A growler tester. Hold a hacksaw blade against
armature core while slowly rotating armature. A
D: INSPECTION short-circuited armature will cause the blade to
vibrate and to be attracted to core. If the hacksaw
1. ARMATURE blade is attracted or vibrates, the armature, which
1) Check commutator for any sign of burns of is short-circuited, must be replaced or repaired.
rough surfaces or stepped wear. If wear is of a
minor nature, correct it by using sand paper.
2) Run-out test
Check the commutator run-out and replace if it
exceeds the limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in) G6M0040

5) Armature ground test

Using circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There
should be no continuity. If there is a continuity,
armature is grounded.
Replace armature if it is grounded.

G6M0038

G6M0041

2. YOKE
Make sure pole is set in position.

10
 SERVICE PROCEDURE [W1E0] 6-1
1. Starter

3. OVERRUNNING CLUTCH 5. SWITCH ASSEMBLY

Inspect teeth of pinion for wear and damage. Be sure there is continuity between terminals S
Replace if it damaged. Rotate pinion in direction of and M, and between terminal S and ground. Use
rotation (clockwise). It should rotate smoothly. But a circuit tester (set in “ohm”).
in opposite direction, it should be locked. Also check to be sure there is no continuity
between terminal M and B.
CAUTION:
Do not clean overrunning clutch with oil to pre- Terminal / Specified resistance:
vent grease from flowing out. S—M / Continuity
S—Ground / Continuity
4. BRUSH AND BRUSH HOLDER M—B / No continuity
1) Brush length
Measure the brush length and replace if it exceeds
the service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard 17.0 mm (0.669 in)
Service limit 11.5 mm (0.453 in)

G6M0044

E: ASSEMBLY
Assembly is in the reverse order of disassembly
procedures. Observe the following:
1) Carefully assemble all parts in the order of
assembly and occasionally inspect nothing has
H6M0496A been overlooked.
2) Apply grease to the following parts during
2) Brush movement assembly.
Be sure brush moves smoothly inside brush I Front bracket sleeve bearing
holder. I Armature shaft gear
3) Brush spring force I Outer periphery of plunger
Measure brush spring force with a spring scale. If I Mating surface of plunger and lever
it is less than the service limit, replace brush I Gear shaft splines
spring. I Mating surface of lever and clutch
Brush spring force: I Ball at the armature shaft end
Standard I Internal and planetary gears
21.6 N (2.2 kg, 4.9 lb) (when new) 3) After assembling parts correctly, check to be
sure starter operates properly.
Service limit
5.9 N (0.6 kg, 1.3 lb)

11
6-1 [W2A0] SERVICE PROCEDURE
2. Generator

2. Generator 5) Remove bolts which install generator onto

bracket.
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.

H2M1499

6) Installation is in the reverse order of removal.

G6M0095
CAUTION:
2) Disconnect connector and terminal from gen- Check and adjust V-belt tension. <Ref. to 1-5
erator. [G2A0].>

H6M0402 H2M1499

3) Remove V-belt cover.

B: DISASSEMBLY
1) Remove the four through bolts. Then insert the
tip of a flat-head screwdriver into the gap between
the stator core and front bracket. Pry then apart to
disassemble.

B2M0017

4) Remove front side V-belt.

G6M0065

G2M0286

12
 SERVICE PROCEDURE [W2B0] 6-1
2. Generator

2) Hold rotor with a vise and remove pulley nut. 4) Remove screws which secure IC regulator to
rear cover, and unsolder connection between IC
regulator and rectifier to remove IC regulator.

G6M0066

CAUTION: G6M0069

When holding rotor with vise, insert aluminum 5) Remove the brushes by unsoldering at the pig-
plates or wood pieces on the contact surfaces tails.
of the vise to prevent rotor from damage.

G6M0070
H6M0498A
6) Remove the nut and insulating bushing at ter-
3) Unsolder connection between rectifier and sta- minal B. Remove rectifier.
tor coil to remove stator coil.
CAUTION:
Finish the work rapidly (less than three sec-
onds) because the rectifier cannot withstand
heat very well.

G6M0071

G6M0068

13
6-1 [W2C1] SERVICE PROCEDURE
2. Generator

C: INSPECTION AND REPAIR 3) Continuity test

Check resistance between slip rings using circuit
1. DIODE tester. If the resistance is not within specification,
CAUTION: replace rotor assembly.
Never use a megger tester (measuring use for Specified resistance:
high voltage) or any other similar measure for Approx. 2.7 — 3.2 Ω
this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode
Check for continuity between the diode lead and
the positive side heat sink. The positive diode is in
good condition if continuity exists only in the direc-
tion from the diode lead to the heat sink.

G6M0075

4) Insulation test
Check continuity between slip ring and rotor core
or shaft. If continuity exists, the rotor coil is short-
circuited, and so replace rotor assembly.

G6M0072

2) Checking negative diode

Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
good condition if continuity exists only in the direc-
tion from the heat sink to the diode lead.

G6M0076

5) Ball bearing (rear side)

(1) Check rear ball bearing. Replace if it is
noisy or if rotor does not turn smoothly.
(2) The rear bearing can be removed by using
common bearing puller.

G6M0073

2. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any rough-
ness of the sliding surface. Repair slip ring surface
using a lathe or sand paper.
2) Slip ring outer diameter
Measure slip ring outer diameter. If slip ring is worn G6M0077
replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)

14
 SERVICE PROCEDURE [W2C4] 6-1
2. Generator

3. STATOR 2) Checking brush spring for proper pressure

1) Continuity test Using a spring pressure indicator, push the brush
Inspect stator coil for continuity between each end into the brush holder until its tip protrudes 2 mm
of the lead wires. If there is no continuity between (0.08 in). Then measure the pressure of the brush
individual lead wires, the lead wire is broken, and spring. If the pressure is less than 2.648 N (270 g,
so replace stator assembly. 9.52 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 g, 16.58 to 20.81 oz).

G6M0078

2) Insulation test G6M0143

Inspect stator coil for continuity between stator
core and each end of the lead wire. If there is
continuity, the stator coil is short-circuited, and so
replace stator assembly.

G6M0079

4. BRUSH
1) Measure the length of each brush. If wear
exceeds the service limit, replace the brush. Each
brush has the service limit mark on it.
Brush length:
Standard
18.5 mm (0.728 in)
Service limit
5.0 mm (0.197 in)

H6M0499A

15
6-1 [W2C5] SERVICE PROCEDURE
2. Generator

5. BEARING (FRONT SIDE) D: ASSEMBLY

1) Check front ball bearing. If resistance is felt To assemble, reverse order of disassembly.
while rotating, or if abnormal noise is heard, 1) Pulling up brush
replace the ball bearing. Before assembling, press the brush down into the
2) Replacing front bearing brush holder with your finger and secure in that
(1) Remove front bearing retainer. position by passing a [2 mm (0.08 in) dia. length 4
(2) Closely install a fit tool on the bearing inner to 5 cm (1.6 to 2.0 in)] wire through the hole shown
race. Press the bearing down out of front in the figure.
bracket with a hand press or vise. A socket CAUTION:
wrench can serve as the tool. Be sure to remove the wire after reassembly.

G6M0144 G6M0146

(3) Set a new bearing and closely install a fit 2) Heat the rear bracket [50 to 60°C (122 to
tool on the bearing outer race. Press the bear- 140°F)] and press the rear bearing into the rear
ing down into place with a hand press or vise. bracket. Then lubricate the rear bracket.
A socket wrench can serve as the tool. CAUTION:
(4) Install front bearing retainer. Grease should not be applied for the rear bear-
ing.
Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.

G6M0145

16
 SERVICE PROCEDURE [W3A1] 6-1
3. Spark Plug

3. Spark Plug (3) Remove air intake duct as a unit.

A: REMOVAL AND INSTALLATION

CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
NGK: BKR5E-11
(Alternate)
CHAMPION: RC10YC4
B2M2012
1. #1 SPARK PLUG
1) Disconnect battery ground cable. (4) Remove resonator chamber.

G6M0095 B2M2306

2) Remove air intake duct and resonator chamber. 3) Remove air cleaner upper case and air cleaner
(2200 cc California SPEC. vehicle) element. (Except 2200 cc California SPEC.
vehicle)
(1) Remove bolt which installs air intake duct
(1) Disconnect mass air flow sensor connector.
on the front side of body.

B2M2018
S6M0708
(2) Remove two clips securing air cleaner
(2) Remove bolt which installs air intake duct upper cover.
on body. (3) Loosen the clamp screw and separate air
cleaner upper cover from air intake duct.

B2M2284
B2M2290

17
6-1 [W3A2] SERVICE PROCEDURE
3. Spark Plug

(4) Remove air cleaner element. 2. #2 SPARK PLUG

4) Remove #1 spark plug cord by pulling boot, not
1) Disconnect battery ground cable.
cord itself.

G6M0095
B6M0922A

5) Remove spark plug with the spark plug socket. 2) Remove #2 spark plug cord by pulling boot, not
cord itself.

B6M0923
B6M0927A
6) Installation is in the reverse order of removal.
Tightening torque (Spark plug): 3) Remove spark plug with the spark plug socket.
20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)

B6M0924

4) Installation is in the reverse order of removal.

Tightening torque (Spark plug):
20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)

18
 SERVICE PROCEDURE [W3A3] 6-1
3. Spark Plug

3. #3 SPARK PLUG (4) Remove resonator chamber.

1) Disconnect battery ground cable.

B2M2306

G6M0095 3) Remove air cleaner upper case and air cleaner

element. (Except 2200 cc California SPEC.
2) Remove air intake duct and air chamber. (2200
vehicle)
cc California SPEC. vehicle)
(1) Disconnect mass air flow sensor connector.
(1) Remove bolt which installs air intake duct
on the front side of body.

B2M2018

S6M0708 (2) Remove two clips securing air cleaner

(2) Remove bolt which installs air intake duct upper cover.
on body. (3) Loosen the clamp screw and separate air
cleaner upper cover from air intake duct.

B2M2284
B2M2290
(3) Remove air intake duct as a unit.
(4) Remove air cleaner element.

B2M2012

19
6-1 [W3A4] SERVICE PROCEDURE
3. Spark Plug

4) Remove #3 spark plug cord by pulling boot, not 2) Disconnect washer motor connector.
cord itself.

S2M0546
B6M0928A
3) Disconnect rear window glass washer hose
5) Remove spark plug with the spark plug socket. from washer motor, then plug connection with a
suitable cap.
4) Remove the two bolts which hold the washer
tank, then take the tank away from the working
area.

B6M0925

6) Installation is in the reverse order of removal.

Tightening torque (Spark plug):
B2M2023
20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb) 5) Remove #4 spark plug cord by pulling boot, not
cord itself.
4. #4 SPARK PLUG
1) Disconnect battery ground cable.

B6M0929A

G6M0095
6) Remove spark plug with the spark plug socket.

B6M0926

20
 SERVICE PROCEDURE [W3B0] 6-1
3. Spark Plug

7) Installation is in the reverse order of removal. B: INSPECTION

Tightening torque (Spark plug): Check electrodes and inner and outer porcelain of
20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14 plugs, noting the type of deposits and the degree
ft-lb) of electrode erosion.
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.

G6M0086

1) Normal
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.

G6M0087

2) Carbon fouled
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.

G6M0088

21
6-1 [W3C0] SERVICE PROCEDURE
3. Spark Plug

3) Oil fouled C: CLEANING AND REGAPPING

Wet black deposits show excessive oil entrance
into combustion chamber through worn rings and Clean spark plugs in a sand blast type cleaner.
pistons or excessive clearance between valve Avoid excessive blasting. Clean and remove car-
guides and stems. If same condition remains after bon or oxide deposits, but do not wear away por-
repair, use a hotter plug. celain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing sur-
face of electrodes with file. Then correct the spark
plug gap using a gap gauge.
Spark plug gap: L
1.0 — 1.1 mm (0.039 — 0.043 in)

G6M0089

4) Overheating
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance
results from incorrect ignition timing, loose spark
G6M0091
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.

G6M0090

22
 SERVICE PROCEDURE [W4B0] 6-1
4. Ignition Coil and Ignitor Assembly

4. Ignition Coil and Ignitor B: INSPECTION

Assembly Using accurate tester, inspect the following items,
and replace if defective.
A: REMOVAL AND INSTALLATION 1) Primary resistance
1) Disconnect battery ground cable. 2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73 Ω±10%
Between terminal No. 2 and No. 4
0.73 Ω±10%
G6M0095

2) Disconnect spark plug cords from ignition coil

and ignitor assembly.
3) Disconnect connector from ignition coil and
ignitor assembly.

B6M0931A

[Secondary side]
Between (A) and (B)
12.8 kΩ±15%
Between (C) and (D)
B6M0932 12.8 kΩ±15%
4) Remove ignition coil and ignitor assembly.

B6M0773C

B6M0930 3) Insulation between primary terminal and case:

10 MΩ or more.
5) Installation is in the reverse order of removal.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.

23
6-1 [W5A0] SERVICE PROCEDURE
5. Spark Plug Cord

5. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
5.12 — 12.34 kΩ

S6M0337

24
 DIAGNOSTICS [K100] 6-1
1. Starter

1. Starter
Trouble Probable cause
Magnet switch poor contact or disconti-
Magnet switch does not operate. nuity of pull-in coil circuit
(no clicks are heard.) Improper sliding of magnet switch
plunger
Poor contact of magnet switch’s main
contact point
Starter does not start. Layer short of armature
Magnet switch operates. Contaminants on armature commutator
(clicks are issued.) High armature mica
Improper grounding of yoke field coil
Insufficient carbon brush length
Insufficient brush spring pressure
Worn pinion teeth
Failure of pinion gear to engage ring
Improper sliding of overrunning clutch
Starter starts but does not crank engine. gear
Improper adjustment of stud bolt
Clutch slippage Faulty clutch roller spring
Poor contact of magnet switch’s main
contact point
Layer short of armature
Discontinuity, burning or wear of arma-
Starter starts but engine cranks too slowly. ture commutator
Poor grounding of yoke field coil
Insufficient brush length
Insufficient brush spring pressure
Abnormal brush wear
Starter overruns. Magnet switch coil is a layer short.

25
6-1 [K200] DIAGNOSTICS
2. Generator

2. Generator

B6M0771

26
6-2 [S100] SPECIFICATIONS AND SERVICE DATA
1. Body Electrical

1. Body Electrical
Type MT model: 55D23L (MF) AT model: 75D23L (MF)
Battery Reverse capacity MT model: 100 minutes AT model: 120 minutes
Capacity
Cold cranking ampere MT model: 430 amperes AT model: 520 amperes
Speedometer Electric pulse type
Temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Tachometer Electric impulse type
Turn signal indicator light 12 V — 1.4 W
Charge indicator light 12 V — 1.4 W
Oil pressure indicator light 12 V — 1.4 W
ABS warning light 12 V — 1.4 W
Combination CHECK ENGINE warning light (Malfunc-
12 V — 1.4 W
meter tion indicator light)
HI-beam indicator light 12 V — 3.4 W
Door open warning light 12 V — 1.4 W
Seat belt warning light 12 V — 1.4 W
Brake fluid and parking brake warning light 12 V — 3.4 W
FWD indicator light 12 V — 1.4 W
AIRBAG warning light 12 V — 1.4 W
Meter illumination light 12 V — 3.4 W
AT OIL TEMP. warning light 12 V — 1.4 W
Headlight 12 V — 60/55 W (Halogen)
Front fog light 12 V — 55 W
Front turn signal light 12 V — 27 W
Side turn signal light 12 V — 3.8 W
Side marker/Parking light 12 V — 3.8 W
Tail/Stop light 12 V — 8/27 W
Rear combination light Turn signal light 12 V — 27 W
Back-up light 12 V — 27 W
License plate light 12 V — 3.8 W
High-mount stop light Sedan: 12 V — 18 W Wagon: 12 V — 13 W
Room light 12 V — 8 W
Spot light 12 V — 8 W
Trunk room light 12 V — 5 W
Luggage room light 12 V — 5 W
Front wiper
Input 12 V — 54 W or less
motor
Rear wiper motor Input 12 V — 42 W or less
Front washer Pump type Centrifugal
motor Input 12 V — 36 W or less
Rear washer Pump type Centrifugal
motor Input 12 V — 36 W or less
Horn 12 V — 350 Hz
Accessory socket Input 12 V — 120 W
Rear window Input 12 V — 160 W
defogger Indicator light 12 V — 50 mA
Cargo socket Input 12 V — 120 W

2
 SERVICE PROCEDURE [W2B0] 6-2
2. Battery

1. Precautions 2. Battery
I Before disassembling or reassembling parts, A: REMOVAL AND INSTALLATION
always disconnect battery ground cable. When
repairing radio, control units, etc. which are 1) Disconnect the positive (+) terminal after dis-
provided with memory functions, record connecting the negative (− ) terminal of battery.
memory contents before disconnecting battery 2) Remove flange nuts from battery rods and take
ground cable. Otherwise, these contents are off battery holder.
cancelled upon disconnection.
I Reassemble parts in reverse order of disas-
sembly procedure unless otherwise indicated.
I Adjust parts to specifications contained in
this manual if so designated.
I Connect connectors and hoses securely dur-
ing reassembly.
I After reassembly, ensure functional parts
operate smoothly.
CAUTION:
I Airbag system wiring harness is routed near G6M0102
the electrical parts and switch.
I All Airbag system wiring harness and con- 3) Remove battery.
nectors are colored yellow. Do not use electri- 4) Installation is in the reverse order of removal.
cal test equipment on these circuits. Tightening torque:
I Be careful not to damage Airbag system wir- 3.4±1.0 N·m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
ing harness when servicing the ignition key
cylinder. NOTE:
I Clean battery cable terminals and apply grease
to retard the formation of corrosion.
I Connect the positive (+) terminal of battery and
then the negative (− ) terminal of the battery.
B: INSPECTION
WARNING:
I Electrolyte has toxicity; be careful handling
the fluid.
I Avoid contact with skin, eyes or clothing.
Especially at contact with eyes, blush with
water for 15 minutes and get prompt medical
attention.
I Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
I Ventilate when charging or using in enclosed
space.
I For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a
battery.
I Do not let battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.
I To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle
because a short circuit will be caused.

3
 SERVICE PROCEDURE [W2B0] 6-2
2. Battery

1. Precautions 2. Battery
I Before disassembling or reassembling parts, A: REMOVAL AND INSTALLATION
always disconnect battery ground cable. When
repairing radio, control units, etc. which are 1) Disconnect the positive (+) terminal after dis-
provided with memory functions, record connecting the negative (− ) terminal of battery.
memory contents before disconnecting battery 2) Remove flange nuts from battery rods and take
ground cable. Otherwise, these contents are off battery holder.
cancelled upon disconnection.
I Reassemble parts in reverse order of disas-
sembly procedure unless otherwise indicated.
I Adjust parts to specifications contained in
this manual if so designated.
I Connect connectors and hoses securely dur-
ing reassembly.
I After reassembly, ensure functional parts
operate smoothly.
CAUTION:
I Airbag system wiring harness is routed near G6M0102
the electrical parts and switch.
I All Airbag system wiring harness and con- 3) Remove battery.
nectors are colored yellow. Do not use electri- 4) Installation is in the reverse order of removal.
cal test equipment on these circuits. Tightening torque:
I Be careful not to damage Airbag system wir- 3.4±1.0 N·m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
ing harness when servicing the ignition key
cylinder. NOTE:
I Clean battery cable terminals and apply grease
to retard the formation of corrosion.
I Connect the positive (+) terminal of battery and
then the negative (− ) terminal of the battery.
B: INSPECTION
WARNING:
I Electrolyte has toxicity; be careful handling
the fluid.
I Avoid contact with skin, eyes or clothing.
Especially at contact with eyes, blush with
water for 15 minutes and get prompt medical
attention.
I Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
I Ventilate when charging or using in enclosed
space.
I For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a
battery.
I Do not let battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.
I To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle
because a short circuit will be caused.

3
6-2 [W2B1] SERVICE PROCEDURE
2. Battery

1. BATTERY I Observe instructions when handling battery

charger.
1) External parts: I Before charging the battery on vehicle, dis-
Check for the existence of dirt or cracks on the connect battery ground terminal. Failure to fol-
battery case, top cover, vent plugs, and terminal low this rule may damage alternator’s diodes
posts. If necessary, clean with water and wipe with or other electrical units.
a dry cloth. Apply a thin coat of grease on the ter-
minal posts to prevent corrosion. 1. NORMAL CHARGING
2) Electrolyte level: Charge the battery at current value specified by
Check the electrolyte level in each cell. If the level manufacturer or at approximately 1/10 of battery’s
is below MIN LEVEL, bring the level to MAX ampere-hour rating.
LEVEL by pouring distilled water into the battery
cell. Do not fill beyond MAX LEVEL. 2. QUICK CHARGING
3) Specific gravity of electrolyte: Quick charging is a method in which the battery is
(1) Measure specific gravity of electrolyte using charged in a short period of time with a relatively
a hydrometer and a thermometer. Specific grav- large current by using a quick charger. Since a
ity varies with temperature of electrolyte so that large current flow raises electrolyte temperature,
it must be corrected at 20°C (68°F) using the the battery is subject to damage if the large current
following Equation: is used for prolonged time. For this reason, the
S20 = St + 0.0007 x (t − 20) quick charging must be carried out within a current
S20:Specific gravity corrected at electro- range that will not increase the electrolyte tem-
lyte temperature of 20°C perature above 40°C (104°F). It should be also
St :Measured specific gravity remembered that the quick charging is a temporary
t :Measured temperature (°C) means to bring battery voltage up to a fair value
Determine whether or not battery must and, as a rule, a battery should be charged slowly
be charged, according to corrected spe- with a low current.
cific gravity. CAUTION:
Standard specific gravity: 1.220 — 1.290 I Observe the items in 1. NORMAL CHARG-
[at 20°C (68°F)] ING.
I Never use more than 10 amperes when
charging the battery because that will shorten
battery life.
3. JUDGMENT OF BATTERY IN
CHARGED CONDITION
1) Specific gravity of electrolyte is held at a spe-
cific value in a range from 1.250 to 1.290 for more
than one hour.
2) Voltage per battery cell is held at a specific
G6M0103 value in a range from 2.5 to 2.8 volts for more than
one hour.
(2) Measuring the specific gravity of the elec-
trolyte in the battery will disclose the state of 4. CHECK HYDROMETER FOR STATE OF
charge of the battery. The relation between the CHARGE
specific gravity and the state of charge is as
shown in figure. Hydrometer indi-
State of charge Required action
cator
C: CHARGING Green dot Above 65% Load test
Dark dot Below 65% Charge battery
WARNING:
Replace battery*
I Do not bring an open flame close to the bat- Clear dot Low electrolyte (If cranking com-
tery at this time. plaint)
CAUTION: *: Check electrical system before replacement.
I Prior to charging, corroded terminals should
be cleaned with a brush and common baking
soda solution.
I Be careful since battery electrolyte over-
flows while charging the battery.

4
 SERVICE PROCEDURE [W4A1] 6-2
4. Lighting

3. Ignition Switch 4. Lighting

A: REMOVAL AND INSTALLATION A: ADJUSTMENT
1) Remove screws, separate upper column cover 1. HEADLIGHT AIMING
and lower column cover.
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check
aiming, do not turn on for more than two min-
utes.
NOTE:
Before checking the headlight aiming, be sure of
the following:
I The area around the headlight has not sustained
any accident, damage or other type of deformation.
G6M0104 I Vehicle is parked on level ground.
I The inflation pressure of tires is correct.
2) Remove knee protector.
I Vehicle’s gas tank is fully charged.
3) Remove meter visor.
4) Disconnect ignition switch connector from body I Bounce the vehicle several times to normalize
harness. the suspension.
5) Using a drift and hammer, hit the torn bolt head I Make certain that someone is seated in the driv-
to loosen and remove the ignition switch. er’s seat.
1) Place a cloth over the headlight that does not
require aiming adjustment.
2) Turn the headlights on. Perform the aiming
adjustment for the other headlight as follows:
CAUTION:
Do not perform lateral headlight aiming adjust-
ment.

G6M0020

6) Installation is in the reverse order of removal.

NOTE:
When installing, tighten the connecting bolt until its
head twists off.

G6M0105

H6M0709A

5
 SERVICE PROCEDURE [W4A1] 6-2
4. Lighting

3. Ignition Switch 4. Lighting

A: REMOVAL AND INSTALLATION A: ADJUSTMENT
1) Remove screws, separate upper column cover 1. HEADLIGHT AIMING
and lower column cover.
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check
aiming, do not turn on for more than two min-
utes.
NOTE:
Before checking the headlight aiming, be sure of
the following:
I The area around the headlight has not sustained
any accident, damage or other type of deformation.
G6M0104 I Vehicle is parked on level ground.
I The inflation pressure of tires is correct.
2) Remove knee protector.
I Vehicle’s gas tank is fully charged.
3) Remove meter visor.
4) Disconnect ignition switch connector from body I Bounce the vehicle several times to normalize
harness. the suspension.
5) Using a drift and hammer, hit the torn bolt head I Make certain that someone is seated in the driv-
to loosen and remove the ignition switch. er’s seat.
1) Place a cloth over the headlight that does not
require aiming adjustment.
2) Turn the headlights on. Perform the aiming
adjustment for the other headlight as follows:
CAUTION:
Do not perform lateral headlight aiming adjust-
ment.

G6M0020

6) Installation is in the reverse order of removal.

NOTE:
When installing, tighten the connecting bolt until its
head twists off.

G6M0105

H6M0709A

5
6-2 [W4B1] SERVICE PROCEDURE
4. Lighting

W H L h I Attach the rubber cap with letters TOP on the

Except 1,070 630 569 114
top so that the drain hole will be on the lower
OUTBACK (42.13) (24.80) (22.40) (4.49) side.
1,070 650 569 114
OUTBACK
(42.13) (25.59) (22.40) (4.49)
Unit: mm (in)

B: REMOVAL AND INSTALLATION

1. HEADLIGHT BULB
1) Disconnect the connector from inside of the
engine compartment.
2) Remove rubber cap.
3) Remove the light bulb retaining spring to M6A0140
remove the bulb.
I To keep water out, correctly engage the
groove portion of the rubber cap.
2. HEADLIGHT AND SIDE MARKER LIGHT
1) Remove front grille and disconnect connector
from headlight.
2) Remove screw then remove side marker light
while disconnecting connector.

H6M0400

4) Replace the bulb with a new one and hook the

spring.
5) Attach the rubber cap and connect the connec-
tor.
CAUTION:
I Since the tungsten halogen bulb operates at
high temperature, dirt and oil on the bulb sur- H6M0398

face decreases the bulb’s useful life. When

3) Remove screws and bolts which secure head-
replacing the bulb, hold the flange portion and
light and remove headlight.
do not touch the glass portion.

H6M0399
M6A0139

4) Installation is in the reverse order of removal.

Tightening torque:
6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
NOTE:
When installing, securely fit clip (on fender side)
into locating (on side marker light side).

6
 SERVICE PROCEDURE [W4B4] 6-2
4. Lighting

3. REAR COMBINATION LIGHT 4) Remove screws which secure switch and

remove switch.
1) Remove rear trim.
2) Remove nuts and disconnect connector.

S6M0046

G6M0097 5) Installation is in the reverse order of removal.

3) Attach adhesive cloth tape to body area around
rear combination light.
4) Using a standard screwdriver, carefully pry rear
combination light off and away from the front of
vehicle.
5) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
CAUTION:
I Do not pry rear combination light forcefully
as this may scratch vehicle body.
I Remove all traces of adhesive tape from
body before installation.
I Attach butyl rubber tape to back of rear com-
bination light before installing rear combina-
tion light on body for sealing purposes.
4. COMBINATION SWITCH
1) Remove instrument panel lower cover. <Ref. to
5-4 [W1A0].>
2) Remove screws which secure upper column
cover to lower column cover.

S6M0042

3) Disconnect connector from combination switch.

7
6-2 [W4C1] SERVICE PROCEDURE
4. Lighting

C: INSPECTION 2. HEADLIGHT RELAY

1. COMBINATION SWITCH (LIGHTING) Check continuity between terminals when terminal
No. 4 is connected to battery and terminal No. 3 is
Move combination switch to respective positions grounded.
and check continuity between terminals.
When current Between terminals
Continuity exists.
flows. No. 1 and No. 2
Between terminals Continuity does
When current No. 1 and No. 2 not exist.
does not flow. Between terminals
Continuity exists.
No. 3 and No. 4

S6M0048A

3. TAIL AND ILLUMINATION RELAY

Check continuity between terminals (indicated in
table) when terminal No. 4 is connected to battery
H6M0500B
and terminal No. 3 is grounded.
When current Between terminals
Continuity exists.
flows. No. 1 and No. 2
Between terminals Continuity does
When current No. 1 and No. 2 not exist.
does not flow. Between terminals
Continuity exists.
No. 3 and No. 4

S6M0048A

S6M0136A

8
 SERVICE PROCEDURE [W5B3] 6-2
5. Front Wiper and Washer

5. Front Wiper and Washer B: REMOVAL AND INSTALLATION

A: ADJUSTMENT 1. BLADE
1) Turn the wiper switch to OFF position. 1) Pull out blade following the arrow direction,
2) Adjust blades in original position as shown in from arm while pushing up locking clip.
figure by changing wiper arm installation.
Original position:
A: 22.5±7.5 mm (0.886±0.295 in)
B: 32.5±7.5 mm (1.280±0.295 in)

B6M0107A

2) Installation is in the reverse order of removal.

2. WIPER ARM
G6M0115 1) Open front hood.
2) Remove cap. Remove the nut which secure
3) Adjust washer ejecting point on windshield wiper arm, and remove wiper arm.
glass as shown in figure when vehicle stops.
Ejecting point:
A: 375 mm (14.76 in)
B: 150 mm (5.91 in)
C: 350 mm (13.78 in)

G6M0118

3) Installation is in the reverse order of removal.

Tightening torque:
14±2N·m (1.4±0.2 kg-m, 10.1±1.4 ft-lb)
G6M0116
3. WIPER MOTOR AND LINK
1) Detach weatherstrip and cowl panel. <Ref. to
5-1 [W11A0].>
NOTE:
Apply silicone oil or soap water to both sides of
cowl net to facilitate removal.

9
6-2 [W5B3] SERVICE PROCEDURE
5. Front Wiper and Washer

2) Disconnect electric connector, and remove 5) Remove wiper link from service hole in front
motor attaching bolts. panel.
Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)

G6M0121

6) Installation is in the reverse order of removal.

G6M0119

3) Remove nut securing motor link on the back

side of motor.
Tightening torque:
15±3 N·m (1.5±0.3 kg-m, 10.8±2.2 ft-lb)

G6M0120

4) Remove nuts which secure sleeve unit.

Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)

G6M0021

10
 SERVICE PROCEDURE [W5C2] 6-2
5. Front Wiper and Washer

C: INSPECTION 2. WIPER MOTOR

1. COMBINATION SWITCH (ON-CAR) 1) Check wiper motor operation at low speed:
Connect battery to wiper motor. Check wiper motor
Set wiper switch to each position and check conti- for proper operation at low speed.
nuity between terminals.

G6M0122

2) Check wiper motor operation at high speed:

Connect battery wiper motor. Check wiper motor
for proper operation at high speed.

H6M0501B

G6M0123

3) Check wiper motor for proper stoppage:

Connect battery to wiper motor. After operating
wiper motor at low speed, disconnect battery to
stop it.

G6M0124

S6M0137

11
6-2 [W6A0] SERVICE PROCEDURE
6. Rear Wiper and Washer

4) Reconnect battery and ensure that wiper motor 6. Rear Wiper and Washer
stops at “AUTO STOP” after operating at low
speed. A: ADJUSTMENT
1) Adjust wiper blade in original position as shown
in figure by changing wiper arm installation.
Original position:
A: 30±5 mm (1.18±0.20 in)

G6M0125

G6M0126

2) Adjust washer ejecting point on rear gate win-

dow as shown in figure when the vehicle stops.
Ejecting point:
A: 25 mm (0.98 in)
B: 200 — 300 mm (7.87 — 11.81 in)

G6M0127

B: REMOVAL AND INSTALLATION

1. BLADE
1) Pull out blade following the arrow direction,
from arm while pushing up locking clip.

B6M0107A

2) Installation is in the reverse order of removal.

12
 SERVICE PROCEDURE [W6B4] 6-2
6. Rear Wiper and Washer

2. WIPER ARM 5) Remove attaching screws and take out wiper

motor assembly.
1) Remove head cover.
2) Remove nut and wiper arm. CAUTION:
Be careful not to damage O-ring when remov-
ing wiper motor assembly.

G6M0128

3) Installation is in the reverse order of removal. G6M0130

Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb) 6) Installation is in the reverse order of removal.
3. WIPER MOTOR Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
1) Remove cap and special nut.
4. WASHER TANK
CAUTION:
Be careful not to strike service tool against 1) Remove rear quarter trim.
nozzle during removal. 2) Disconnect washer hose and connector.
3) Remove attaching bolts.
Tightening torque:
7.4±1.5 N·m (0.75±0.15 kg-m, 5.4±1.1 ft-lb)

G6M0022

G6M0129 4) Installation is in the reverse order of removal.

2) Remove rear gate trim. <Ref. to 5-2 [W3A0].> Tightening torque:
3) Undo clips which secure harness, and discon- 5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
nect connector of wiper motor.
4) Separate washer hoses at joint.

13
6-2 [W6C1] SERVICE PROCEDURE
6. Rear Wiper and Washer

C: INSPECTION 2) Check wiper motor for proper stoppage:

After operating wiper motor, disconnect battery
1. COMBINATION SWITCH (ON-CAR) from wiper motor.
Set rear wiper and washer switch to each position
and check continuity between terminals.

G6M0132

3) Reconnect battery and ensure that wiper motor

H6M0502B
stops at “AUTO STOP” after it has been operated.

G6M0133

S6M0137

2. WIPER MOTOR
1) Operational check:
Connect battery to wiper motor and check opera-
tion of wiper motor.

G6M0131

14
 SERVICE PROCEDURE [W7A1] 6-2
7. Rear Window Defogger

3. REAR WIPER RELAY 7. Rear Window Defogger

1) Connect battery to terminal No. 1 and ground
terminal No. 2. A: INSPECTION
2) Check continuity between terminals. 1. HEAT WIRES
Between terminals Continuity does 1) Start the engine so that battery is being
When current No. 3 and No. 4 not exist. charged.
flows. Between terminals 2) Turn defogger switch ON.
Continuity exists.
No. 3 and No. 5 3) Check each heat wire at its center position for
Between terminals
Continuity exists.
discontinuity by setting direct current voltmeter.
No. 3 and No. 4
NOTE:
When current Between terminals Continuity does
does not flow. No. 3 and No. 5 not exist.
I Normal indication is about 6 volts.
Between terminals
Continuity exists.
No. 1 and No. 2

G6M0135

I When measuring voltage, wind a piece of tin foil

around the tip of the tester probe and press the foil
against the wire with your finger.

S6M0075A

G6M0136

15
6-2 [W7B0] SERVICE PROCEDURE
7. Rear Window Defogger

4) When tester indicates 12 volts when its probe B: REPAIR

reaches point “A”, a broken circuit occurs between
point “A” and the negative terminal. Slowly move 1) Clean broken wire and its surrounding area.
tester probe toward the negative terminal while 2) Cut off slit on (used) thin film by 0.5 mm (0.020
contacting it on heat wire to locate point where in) width and 10 mm (0.39 in) length.
tester indication changes abruptly (0 volts). This is 3) Place the slit on glass along the broken wire,
the point where a broken circuit occurs. When and deposit conductive silver composition
tester indicates 0 volts when its probe reaches (DUPONT No. 4817) on the broken portion.
point “A”, a broken circuit occurs between point “A”
and the positive terminal. Locate a point where
tester indication changes abruptly (12 volts) while
slowly moving tester probe toward the positive ter-
minal.

G6M0138

4) Dry out the deposited portion.

5) Inspect the repaired wire for continuity.

G6M0137

16
 SERVICE PROCEDURE [W8B0] 6-2
8. Combination Meter

8. Combination Meter B: BULB REPLACEMENT

A: REMOVAL AND INSTALLATION
1) Move steering wheel most down.
2) Remove screws which secure visor and
remove visor.

H6M0524A

(1) Speedometer and tachometer

(2) HI-beam
(3) Turn RH
(4) Turn LH
H6M0522A (5) Airbag
(6) Temperature gauge
3) Remove screws which secure combination (7) ABS
meter, and pull combination meter out. (8) Low fuel
(9) FWD
(10) AT oil temp.
(11) Speedometer and temperature gauge
(12) Seat belt
(13) Door open
(14) Check engine
(15) Charge
(16) Tachometer
(17) Brake
(18) Oil pressure
H6M0523

4) Disconnect connector from back of combination

meter.
5) Installation is in the reverse order of removal.
CAUTION:
When installing combination meter, be sure to
connect connectors to backside of combina-
tion meter.

17
6-2 [W9A1] SERVICE PROCEDURE
9. Radio, Speaker and Antenna

9. Radio, Speaker and Antenna 10. Front Fog Light

A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION
1. RADIO BODY 1) Disconnect ground cable from battery.
2) Remove front fog light cover.
1) Remove console box. <Ref. to 5-4 [W1A0].>
2) Remove AT cover (AT model).
3) Remove center panel.
4) Remove fitting screws, and slightly pull radio
out from center console.

H6M0525

3) Remove the two screws, then draw out the front

fog light from front bumper.

S5M0048A

5) Disconnect electric connectors and antenna

feeder cord.
6) Installation is in the reverse order of removal.
2. FRONT SPEAKER
1) Remove front door trim and disconnect connec-
tor. <Ref. to 5-2 [W2A2].>
2) Remove screws which secure front speaker.
3) Remove speaker and disconnect connector. H6M0526

4) Installation is in the reverse order of removal. 4) Disconnect the connector.

3. REAR SPEAKER (SEDAN) 5) Installation is in the reverse order of removal.
1) Remove rear shelf trim panels.
2) Remove screws which secure rear speakers.
3) Disconnect connector and remove speakers.
4) Installation is in the reverse order of removal.
4. REAR SPEAKER (WAGON)
1) Remove rear door trim and disconnect connec-
tor. <Ref. to 5-2 [W2A2].>
2) Remove screws which secure rear speaker.
3) Remove speaker and disconnect connector.
4) Installation is in the reverse order of removal.

18
6-2 [W9A1] SERVICE PROCEDURE
9. Radio, Speaker and Antenna

9. Radio, Speaker and Antenna 10. Front Fog Light

A: REMOVAL AND INSTALLATION A: REMOVAL AND INSTALLATION
1. RADIO BODY 1) Disconnect ground cable from battery.
2) Remove front fog light cover.
1) Remove console box. <Ref. to 5-4 [W1A0].>
2) Remove AT cover (AT model).
3) Remove center panel.
4) Remove fitting screws, and slightly pull radio
out from center console.

H6M0525

3) Remove the two screws, then draw out the front

fog light from front bumper.

S5M0048A

5) Disconnect electric connectors and antenna

feeder cord.
6) Installation is in the reverse order of removal.
2. FRONT SPEAKER
1) Remove front door trim and disconnect connec-
tor. <Ref. to 5-2 [W2A2].>
2) Remove screws which secure front speaker.
3) Remove speaker and disconnect connector. H6M0526

4) Installation is in the reverse order of removal. 4) Disconnect the connector.

3. REAR SPEAKER (SEDAN) 5) Installation is in the reverse order of removal.
1) Remove rear shelf trim panels.
2) Remove screws which secure rear speakers.
3) Disconnect connector and remove speakers.
4) Installation is in the reverse order of removal.
4. REAR SPEAKER (WAGON)
1) Remove rear door trim and disconnect connec-
tor. <Ref. to 5-2 [W2A2].>
2) Remove screws which secure rear speaker.
3) Remove speaker and disconnect connector.
4) Installation is in the reverse order of removal.

18
 SERVICE PROCEDURE [W11A0] 6-2
11. Cruise Control

11. Cruise Control

A: ADJUSTMENT

S6M0138A

19
6-2 [W11B1] SERVICE PROCEDURE
11. Cruise Control

B: REMOVAL AND INSTALLATION 5) Disconnect cruise control vacuum hose from

intake manifold.
1. ACTUATOR
1) Remove air intake chamber.

S6M0089

6) Remove actuator attaching bolts.

S6M0007
7) Disconnect connector from actuator, then
2) Remove air intake chamber stay. remove the actuator.
3) Remove clip bands from cruise control cable.

S6M0090
S6M0087
8) Installation is in the reverse order of removal.
4) Remove cruise control cable end from throttle Tightening torque:
cam. 7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
CAUTION:
When inserting vacuum hose to intake
manifold, apply sealant to the fitting hose.
Fluid packing:
THREE BOND 1105 or equivalent
CAUTION:
I Be careful not to apply excessive load to the
wire cable when adjusting and/or installing;
otherwise, the actuator may be deformed or
S6M0088
damaged.
I Do not bend cable sharply with a radius less
than 100 mm (3.94 in); otherwise, cable may
bend permanently, resulting in poor perfor-
mance.
I When installing cable, be careful not to
sharply bend or pinch the inner cable;
otherwise, the cable may break.

20
 SERVICE PROCEDURE [W11B3] 6-2
11. Cruise Control

2. CRUISE CONTROL MAIN SWITCH 4) Using TORXT BIT T30 (Tamper resistant type),
remove two TORXT bolts which secure driver’s air-
1) Remove screws and clip from instrument panel
bag module.
lower cover.
2) Remove panel lower cover.

S6M0094A

S6M0091 5) Disconnect airbag module connector on back of

airbag module.
3) Disconnect connector from cruise control main
6) Remove horn switch from steering wheel as
switch.
shown.

S6M0092A
S6M0095

4) Remove main switch by pushing it outward.

7) Disconnect horn and cruise control command
switch connector, then remove cruise control com-
mand switch.

S6M0093

5) Installation is in the reverse order of removal.

S6M0096
3. CRUISE CONTROL COMMAND SWITCH
8) Installation is in the reverse order of removal.
CAUTION:
Before starting operation carefully read the
notes given in Chapter 5-5 for proper handling
of the airbag module. <Ref. to 5-5 [W3A0].>
1) Set front wheels in straight ahead position.
2) Turn ignition switch OFF.
3) Disconnect battery ground cable from battery
and wait for at least 20 seconds before starting
work.

21
6-2 [W11B4] SERVICE PROCEDURE
11. Cruise Control

4. CRUISE CONTROL MODULE

1) Remove front pillar lower trim.

S6M0097

2) Disconnect connector from cruise control mod-

ule.
3) Remove bolt, then remove cruise control mod-
ule.

S6M0098

4) Installation is in the reverse order of removal.

5. STOP AND BRAKE SWITCH
Disconnect connector from switch, then remove
the switch. <Ref. to 4-5 [C100].>
6. CLUTCH SWITCH
Disconnect connector from switch, then remove
the switch. <Ref. to 4-5 [C100].>

22
 DIAGNOSTICS [K1A0] 6-2
1. AT Shift Lock System

1. AT Shift Lock System

A: WIRING DIAGRAM

H6M0503

23
6-2 [K1B0] DIAGNOSTICS
1. AT Shift Lock System

B: BASIC DIAGNOSTICS CHART

H6M0504

24
 DIAGNOSTICS [K1C0] 6-2
1. AT Shift Lock System

C: DIAGNOSTICS PROCEDURE NO. 1

H6M0505

25
6-2 [K1D0] DIAGNOSTICS
1. AT Shift Lock System

D: DIAGNOSTICS PROCEDURE NO. 2 (SHIFT LOCK DOES NOT RELEASE.)

H6M0506

26
 DIAGNOSTICS [K1E0] 6-2
1. AT Shift Lock System

E: DIAGNOSTICS PROCEDURE NO. 3 (KEY INTERLOCK DOES NOT

OPERATE.)

H6M0507

27
6-2 [K1F0] DIAGNOSTICS
1. AT Shift Lock System

F: DIAGNOSTICS PROCEDURE NO. 4 (KEY INTERLOCK DOES NOT

RELEASE.)

H6M0508

28
 DIAGNOSTICS [K2A3] 6-2
2. Combination Meter

2. Combination Meter 2A2 : CHECK GROUND CIRCUIT OF COM-

BINATION METER.
A: DIAGNOSTICS PROCEDURE
If speedometer does not operate, or operates 1) Turn ignition switch to OFF.
abnormally, check combination meter circuit. 2) Measure resistance of harness between com-
CAUTION: bination meter connector and chassis ground.
Make sure that trouble code of vehicle speed Connector & terminal
sensor 2 system appears in electrical system (i12) No. 13 (+) — Chassis ground (−):
on-board diagnosis.

2A1 : CHECK POWER SUPPLY FOR COM-

BINATION METER.

1) Remove combination meter.

2) Turn ignition switch to ON.
3) Measure voltage between combination meter
connector and chassis ground.
Connector & terminal
H6M0594A
(i12) No. 8 (+) — Chassis ground (−):
: Is the resistance less than 10 Ω?
: Go to step 2A3.
: Repair harness and connector.

2A3 : CHECK TRANSMISSION TYPE.

: Is the transmission type MT?

: Go to step 2A4.
H6M0593A
: Go to step 2A9.
: Is the voltage more than 10 V?
: Go to step 2A2.
: Repair harness and connector.
NOTE:
In this case, repair the following:
I Open circuit in harness between combination
meter and battery.
I Poor contact in coupling connectors (i12) and
combination meter connector. <Ref. to FORE-
WORD [T3C0].>

29
6-2 [K2A4] DIAGNOSTICS
2. Combination Meter

2A4 : CHECK HARNESS CONNECTOR 2A6 : CHECK HARNESS CONNECTOR

BETWEEN COMBINATION METER BETWEEN VEHICLE SPEED SENSOR
AND VEHICLE SPEED SENSOR 2. 2 AND ENGINE GROUND.

1) Disconnect connector from vehicle speed sen- 1) Turn ignition switch to OFF.
sor 2. 2) Measure resistance between vehicle speed
2) Measure resistance of harness connector sensor 2 connector (B17) and engine ground.
between vehicle speed sensor 2 and combination Connector & terminal
meter. (B17) No. 2 (+) — Engine ground (−):
Connector & terminal
(B17) No. 1 — (i12) No. 10:

B6M0946A

H6M0595A
: Is the resistance less than 10 Ω?
: Go to step 2A7.
: Is the resistance less than 10 Ω? : Repair harness connector between
: Go to step 2A5. vehicle speed sensor 2 and engine
ground.
: Repair wiring harness.

2A5 : CHECK HARNESS CONNECTOR

BETWEEN BATTERY AND VEHICLE
SPEED SENSOR 2.

1) Turn ignition switch to ON.

2) Measure voltage between vehicle speed sensor
2 connector (B17) and chassis ground.
Connector & terminal
(B17) No. 3 (+) — Chassis ground (−):

B6M0945A

: Is the voltage more than 10 V?

: Go to step 2A6.
: Repair harness connector between bat-
tery and vehicle speed sensor 2.

30
 DIAGNOSTICS [K2A8] 6-2
2. Combination Meter

2A7 : CHECK VEHICLE SPEED SENSOR 2. 2A8 : CHECK VEHICLE SPEED SENSOR 2.

NOTE: 1) Connect connector to vehicle speed sensor 2.

I If resistance between terminals of vehicle speed 2) Set the vehicle on free roller, or lift-up the
sensor 2 is out of specification, the sensor may vehicle and support with safety stands.
have a failure. WARNING:
I If resistance is OK and voltage between termi- Be careful not to be caught up by the running
nals of vehicle speed sensor 2 is out of wheels.
specification, mechanical trouble may be present
between vehicle speed sensor 2 and speedometer 3) Drive the vehicle at speed greater than 20 km/h
shaft in transmission. (12 MPH).
4) Measure voltage between vehicle speed sensor
Measure resistance between terminals of vehicle 2 connector (B17) and chassis ground.
speed sensor 2.
Connector & terminal
Terminals (B17) No. 1 (+) — Chassis ground (−):
No. 2 — No. 3:

B6M0947A
B3M0289

: Is the voltage more than 4 V?

: Is the resistance between 350 and
450 Ω? : Repair or replace speedometer.
: Go to step 2A8. : Replace vehicle speed sensor 2.
: Replace vehicle speed sensor 2.

31
6-2 [K2A9] DIAGNOSTICS
2. Combination Meter

2A9 : CHECK HARNESS CONNECTOR 2A10 : CHECK AUTOMATIC TRANSMIS-

BETWEEN COMBINATION METER SION CONTROL MODULE.
AND AUTOMATIC TRANSMISSION
CONTROL MODULE. 1) Connect connector to automatic transmission
control module.
1) Disconnect connector from automatic transmis- 2) Set the vehicle on free roller, or lift-up the
sion control module. vehicle and support with safety stands.
2) Measure resistance between combination WARNING:
meter connector (i12) and automatic transmission Be careful not to be caught by the running
control module connector (B55). wheels.
CAUTION: 3) Drive the vehicle faster than 20 km/h (12 MPH).
To measure the voltage and/or resistance, use 4) Measure voltage between automatic transmis-
a tapered pin with a diameter of less than 0.64 sion control module connector (B55) and chassis
mm (0.025 in). Do not insert the pin more than ground.
5 mm (0.20 in). CAUTION:
Connector & terminal To measure the voltage and/or resistance, use
(i12) No. 10 — (B55) No. 13: a tapered pin with a diameter of less than 0.64
mm (0.025 in). Do not insert the pin more than
5 mm (0.20 in).
Connector & terminal
(B55) No. 13 (+) — Chassis ground (−):

H6M0596A

: Is the resistance less than 10 Ω?

: Go to step 2A10.
B6M0949A
: Repair harness connector between
combination meter and automatic trans-
: Is the voltage more than 4 V?
mission control module.
: Repair or replace speedometer.
: Replace automatic transmission control
module. <Ref. to 3-2 [W22A0].>

32