Service Manual Introduction and

Master Troubleshooting ***-**0*-**0**~~*

CONQUEST L Lubrication and Maintenance ... .... .

..................................
~. .....h,
mnt Suspension

67$5,21 Rear Axle ............................................

E-
Service ........ . .......................
Brakes - Parking m
Volume-l -~~~~~~- Clutch . .... ... ... ... ..... ... ... .... ... .... .... ... .... .... .
m- i
Engine, -
Cooling .... ... ... ..... .. .... .... ... .... .... .. ....-f....
Chassis & Body -m-~ sic
5 ?L. --
Engine . ... .... ... ... .... ..-’. .... .... ... ... ... .... ..... ... .. 0
._ FoREWoRD . ,. “” 1.“. ‘&I
-jj-“..-y;,.+.,,i ,?;.“I,: -;.q ‘- ~ ; *l .:.>;:q; < .I- E .
-,
Intake and Exhaust System ... .... .. ...
_I ---; mi#
This Service Manual has been prepared with the
latest service information available at the time of Fuel System ... ... ... .... ...<.......................
L-- -- 5
publication. It is subdivided into various group mimpia=
Propeller.. ..Shaft ;===-%
. ... ... ....and Universal
categories and each section contains diagnosis,
disassembly, repair, and installation procedures ..-........i.r......-..r.i.........r...
Joints &I ,b
along with complete specifications and tightening .~ .b --
references. Use, of this manual will aid in properly Rear Suspension . .... .... ... ... ... ....
. . ... ... ...
performG-rg any .servicing’ necessary to maintain or mr
restore the high levels of performance and reliability
designed jnto these outstanding vehicles.
-.. ‘..,Z

Body .. ... ... ... .... .... ... ... ....:_

....I.... ... .... .... ... ..
2. i_...., .c:. .’+ : ; ‘$J!!i!B
... .... .
Heaters and Air Conditioning
_r WZA-;
Emission Control Systems ... .... .. ... pz;
I__

Chrysler Motors reserves the right to make changes in design or~to.

make additions to or improvements in its prodlicts without imposing-
any obligations upon jtself to install them on its products previously
manufactured,*
@ 1987 Mitsubishi Motors Corp&ation Printed in Japan
 _ How to Use This Manual

HOW TO USE THIS MANUAL

’ CONTENTS
The preceding page contains GROUP INDEX which
lists the group title and group number.
*’
- iAGE NUMBERS
All page numbers consist of two sets &digits
p separated by a dash. The digits preceding the dash
-identify the number of the group. The digits follow-
ing the dash represent the consecutive page num-
ber within the group. The page numbers can be
found on the top left or right of each page.

TEXT
Unless otherwise specified, each service procedure
covers all models. Procedures covering specific Repair kit or set parts are
shown. (Only very frequently
models are identified by the model codes or similar used parts are shown.)
designation (engine type, transmission type, etc.). A
description of these designations is covered in this
unit under “VEHICLE IDENTIFICATION”.

TROUBLESHOOTING
Troubleshootings are classified into master trouble- Removal steps:
shooting and group troubleshooting and located as The numbers before part names correspond
follows: to numbers In the illustration. and indicate
The master troubleshooting is prepared when the the order of removal.
Disassembly steps.
trouble symptom relates to two or more groups and The numbers before part names correspond
given in MASTER TROUBLESHOOTING. to numbers In the illustration, and indicate
The group troubleshooting guide is prepared for the order of disassembly.
Installation steps:
causes of problems related to that individual group This is provided if installation cannot be
only; a troubleshooting guide IS prepared for each made in the reverse order of “Remov&
I appropriate group. steps”; omitted if rnstallation in the reverse
order of “Removal steps” is possible.
Reassembly steps:
SERVICE PROCEDURES This IS provrded if reassembly cannot be
made In the reverse order of “Disa$sembly-
The service steps are arranged in numencal order steps” ; omitted If reassembly in the r&
and attentions to be paid in performing vehicle verse order of “Disassembly steps” is
possible.
service are described in detail in SERVICE POINTS.

DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the Classification of
-_value~to which the part or assembly is corrected and SERVICE POINTS
- Removal
adjusted. It is given by tolerance.
LIMIT * Disassembl

Shows the standard for judging the quality of a part

or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be k_ept functionally or in strength. It is a value
~~ esiablished outside the range of standard value.
 INTRODUCTION AND MASTER TROUBLESHOOTING - How*o “se ThisMa”ua’ 3

Indicates the incidental

operation to be. per-
Page number Group title Sectipn title formed before removal
I I or after installation. I

i I
BRAKES - Rear Brake Wheel Cvlinder

REAR BRAKE WHEEL CYLINDER N05”A-

REMOVAL AND INSTALLATION

. Dravvng Brake Fluid

pi2jijq-J
18-21 Nm
,..-/ 13-15ft.lbs. Post-installation Operation

Indicates
non-reusable
part.

- Wheel cylinder kit

1
I
Removal steps
1. Brakedrum
2. Bleeder screw
3. Brake tube NOTE
*+ 4. Wheel cylinder assembly (1) Reverse the removal procedures to reinstall.
+e 5. Wheel cyhnder boot (2) a*: Refer to “Service Points of Removal”.
l * 6. Piston assembly (3) *a: Refer to “Service Points of Installation”.
- - l * l * 7. Piston cup 14) p Non-reusable parts

SERVICE POINTS OF REMOVAL/ NOWBAI

7. REMOVAL OF PISTON CUP
Using a screwdriver, remove the piston cup from the

I
This number corresponds to
the number in “Removal.
steps”, ” Disassembly steps”, installation. disassembly and
“installation steps” or “Reas-
sembly steps.”
 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicte
Identification

VEHICLE IDENTIFICATION NOOCA-

VEHICLE IDENTIFICATION NUMBER LOCATION

The vehicle identification number (V.I.N.) is located on a plate
attached to the left top side of~the instrument panel and visible
through the windshield.

VEHICLE IDENTIFICATION CODE CHART PLATE

NOOCB- -
All vehicle identitication numbers contain 17 diaits. The vehicle =~~
number IS a code which tells countrv, make, vehicle type, etc. ~~~~

0 J 2 000001
: 1988 Okazakl
plant 99E399
3

C’hwk dealt” means a wale number or letter X used lo venfv the accuracy of trarwxptlon of vrlllcle Identifvzatlon number

VEHICLE IDENTIFICATION NUMBER LIST NOOCC- -

V.I.N. Brand Engine

DeStinatiQn Models code
(except sequence number) (Package) displacement
JJ3CC54HOHZ Federal Al 87AMRFGL4
JJXC64HOHZ California* 2.555 liters Al 87AMRFGL9
Chrysler
JJ3CC54NOHZ Federal (155.9 C.I.D.) Al 87AMNFGL4
JJ3CC54NCIHZ California’ Al 87AMNFGL9

- Can also be sold In Federal states,

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle
identification 5

VEHICLE INFORMATION CODE PiATE NOOCD- -

Vehicle information code plate is riveted onto the firewall in the
engine compartment.
The plate shows model code, engine model, transmission
model, final gear ratio, and body color code.

1. MODEL A187AMNFGL4

---lIT~:;:l,,n,,i
2. ENGINE G54B

I Engine model
3. TRANS- KM 132Cl3545
AXLE
-iI Final gear ratio
Blank
T-L Transmission model
4:COLOR, TRIM H84
OPT I
I Monotone exterior
color code

CHASSIS NUMBER NOOCE- .

STAMPING LOCATION
The chassis number is stamped on the top center of the
firewall located in the engine compartment.
CHASSIS NUMBER CODE CHART

A187MJZ000001

Vehicle line Engine Body type

displacement Refer to 10th
thru 17th digits
A18- 7- M- of V.I.N. plate
CONQUEST 2.555 liters 2-door
(155.9 C.I.D.) Hatchback

VEHICLE SAFETY CERTIFICATION LABEL NOOCF- -

The vehicle safety certification label is attached to face of left

door pillar.
This label indicates the month and year of manufacture, Gross
Vehicle Weight Rating (G.V.W.R.), Gross Axle Weight Rating
[(&k$/.R.) front and rear, and Vehicle Identification Number F~
.. ..
xi I
6 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle
identification

ENGINE MODEL STAMPING NOOCG..

The engine model number is stmped at the right front side on

the top edge of the cylinder block as shown in the followlng:

.Engine displacement

The engine serial number is samped near the engin model

number, and the serial number cycles, as shown below.

Engine serial number

e.
BODY COLOR CODE NOOCH- .
K’

Exterior code

R04 Red
R88 Maroon (Metallic)
T87 Blue (Metallic)
wo9 White
x15 Black
Y59 Yellow

Theft protection label NOOClAA

To provide protection against -theft, the vehicle identification

For ori$nal parts number (V.I.N.) is stamped on or its label is affixed ta t_he
following major engine, transmission parts arrd body outer
panels-
Engine cylinder b&k, transmission housing, @rtder,Tquar@r
panel, hood, rear hatch and bumpers.
The theft protection label is aIS_o affixed to each=pf major bociy
outer panels for servicing, while the same information as Ihe
theft protection label is stamped on the engine and tfansmis
OOK619
sion for servicing:
Caution
1. Affix masking tape to the theft protection label before
For replacement parts repainting the original part. After painting, be sure to
remove the masking tape.
2. The theft protection label on the service part has
masking tape affixed to it. Therefore, paint the part as
is and remove the masking tape after painting.
3. Do not remove the theft protection label from the
original or service part.

OOK621
 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification I ’

LOCATIONS

OOLO634

l The theft protection label is affixed to the inside surface.

l The illustration indicates left hand side, outer. Right hand side is symmetrical.
 INTRODUCTION AND MASTER TROUBLESl400TING - Vehicle
kkntification

Part name Target area : for original equipement parts

: for replacement pares

Quarter panel

00L0638

l The theft protection label is affixed to the inside surface.

l The illustration indicates left hand side, outer. Right hand sideis symmetrical.

Hood

OOL0640

l The theft protection label is affixed to the inside surface.

Rear hatch

OOL0639

l The theft protection label is affixed to the insidesurface. _

-__ i ~-~
3umpers Front bumper Rear bumper

0OL0635

D The theft protection label is affixed to the inside surface. OOL0636

 .I
I

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions

beforeService 9

PRECAUTIONS BEFORE SERVICE NOODAAD

PROTECTING VEHICLE
If there is a likelihood of damaging painted or interior parts
during service operations, protects them with suitable covers
(such as seat covers, fender covers, etc.).

OOY684

P?
REMOVAL AND DISASSEMBLY
When checking a malfunction; find the cause of the problem. If
0
0
it is determined that removal and/or disassembly is necessary,
perform the work by following the procedures contained in this
Service Manual.
,,’ s

.a<
&fig
I OOY58? If punch marks or mating marks are made to avoid error in
assembly and to facilitate the assembly work, be sure to make
them in locations which will have no detrimental effect on
performance and/or appearances.
If an area having many parts, similar parts, and/or parts which
are symmetrical right and left is disassembled, be sure to
arrange the parts so that they do not become mixed during the
assembly process.
1. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which are to be
replaced.
3. If. bolts, nuts, etc., are to be replaced, be sure to use only
OOY192 FOO017 the exact size specified.

,SPE(XAL TOOLS
If other tools are substituted for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged, or the technician might be injured; therefore, be sure -s
to use$he special tool whenever doing any work for which the --
use of one is specified.

FOOOll 3

PAR+ TO BE REPLACED
If any rof the following parts are removed, they must be ~_
replaced with new parts.
1. Oil rseals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings

0 000511
5. Lock wa:hers
6. Cotter pins
7. Self-locking nuts i
 -----;
-li_w - I-A.. i

IO INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions

beforeService
PARTS
When replacrng parts, use MCIPAR genurne parts.

=VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the ::
spray nozzle at a distance of at Jeast 300 mm (12in.I from any ‘;~~~ ;~~
plastic parts and al! opening parts (doors, !u.rgg&e @mparJ ---=;-- ~
ment, sunroof, etc.).
mz%
=j_-
c-
a= .-
mw-
w
-
mm (in.) so0059

SERVICING ELECTRICAL SYSTEM -

1. When servicing the electrical system, pay attention to the sI
following.
Never attempt. to modify an electrical unit or to change --_r G-
wirings, which may otherwise cause not only a .vehicle Fe
failure but a vehicle fire due to over-capacity !oad %r Z
short-circuit.
2. Before servicing the- electrical system, disconnect the ‘I., z
negative cables terminal fErn the battery. ’ :Z
_z
Caution G
16C38(
Before connecting or disconnecting the negative cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of semicon-
ductor parts being damaged.)

WIRING HARNESSES
1. Secure the wiring harness9 by using clamps. However, for
any harness which passes to the engine or’other vibrating
parts of the vehicle, allowmVsome slack within a raj-rge that ‘=
Indication ‘mark
\
\
-\
L does not allow the engine_vibrations to cauEe the-harness 11: ~-
-cl6381 to come into .contact with any of the su~F8undEig pa~rts. e -
Then secure the harness- by using a clamp. ’ -em--
In addition, if a mounting indication mark (yeflow Gpe) is on c_
a harness, secure the indication mark in the-;specified -1
location.
2. If any section of a wiring harness contacts theedge of a ~-_
part, or a corner, wrap the section of the harnesswith tape
or something similar in order to protect it ~from damage. _I_

F16171

.-
Correct 3. When disconnecting a-connector, be sure to pull only the --,:
connector, not the harness.

Incorrect 16YO5’

638:

4. Disconnect connectors which have catches by pressing in

the direction indicated by the arrows in the illustration.

Y1634;

5. Connect connectors which have catches by inserting the

connectors until they snap.

OOY58

ELECTRICAL COMPONENTS
1. When installing any of the vehicle parts, be careful not to
pinch or damage any of the wiring harnesses.

Cl6384

.
 _ - ~- --. ~~ ~~~____~ -~~ __ ~~-~~
r RIlc&q

W% __..m----- i =-
T-
: --.__
-- ii&mODUCTION AND IhASTER TROUBLESHOOTING - Precautions
beforeSewice .
2. Sensors, relays, etcr, are sensrtrve to st-rong~rmpacts. =~~=
Handle them with care so that they are not dropped or
mishandled. ~~~

ooY5at

3. The electronic parts used--for relays, etc., are sensrtrve- to. .i_ .,, E
heat. If any service which causes a temperature of 80°C __ e
(176°F) or more is performed, remove the part or parts in = _
question before carrying out the service. . .- ET

!!!5
-.-
zt
E.- --
_a
-.
-
OO’i61
_.- ~~

FUSES AND FUSIBLE LINKS Z~

-~~
I. If a blown-out-fuse is to be replaced, be sure to use only a
fuse of the specified capacity. If a fuse of azapacjty larger
than that specified is used, parts may be damaged and the ~~._
circuit may not be protected adequately.
Caution
1. If a fuse is blown-out, be sure to eliminate the cause
of the problem before installing a new fuse.
IOA 15A 2. Check the condition of fuse holders. If rust or dirt is
OOY58!
found, clean metal parts with a fine-grained sand-
paper until proper metal-to-metal contact is made.
Poor contact of any fuse holder will often lead to
Permissible current
Nominal SAE voltage drop or heating in the circuit and could
size In engine Other result in improper circuit operation.
gXe compartment areas
2. If additional optionafequipment is f0 be installed in the ~~_ =
0.3 mm2 AWG22 - 5A vehicle, follow the procedure listed in the apf%opriate - -~ -~. E
0.5 mm2 AWG 20 7A l3A instruction manual; however, be sure to pay careful
0.85 mmi AWG 18 9A 17A attention to the following: points:
1.25 mm’ AWG 16 l2A 22A (I) In order -to avoid ovrrrloading the !&iJg. J&e.i..,&_ zsI -I=.&
2.0 mm* AWG 14 16A 30A electrical current load_af the optional equipment into mm -
consideration, and determine the appropriate wire size.
3.0 mm2 AWG 12 21A 40A
(2) Where possible, route the wiring through the existing em: ~~ !
5.0 mm2 AWG 10 31A 54A
harnesses,
(3) If an ammeter or srrnrlar Instrument is to~.be connected. --ii F=
to a live-wire crrcurt. use tape to protect the wrre, use a
clamp to secure:the wire, and make sure that there IS .~; E
m&&+
~=
no contactwtth any other parts.
(4) Be sure to provide a fuse for the load circuit of the. -< __.~?-
optronal equipment. m
g*
-5
E
-=a
nm4
z
E
km=
t;:
s-
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions before Service (- lik

TUBES AND OTHER RUBBER PARTS bb

1:
Be careful to avoid spilling any gasoline, oil, etc., because if it -\
adheres to any tubes or other rubber parts, they might be ’
adversely affected.

OOY58F

LUBRICANTS
In accordance with the instructions in this Service Manual,
apply the specified lubricants in the specified locations during ~-
assembly and installation.

FOOOZE

BRAKE FLUID
Be careful to avoid spilling any brake fluid on painted surfaces,
because the paint coat might be discolored or damaged.

OOY58E

DOING SERVICE WORK IN GROUPS. OF TWO OR

MORE TECHNICIANS
If the service work is to be done by two or more technicians
working together, extra caution must be taken.
G,” I4 INTRODUCTION AND MASTER TROUBLESHOOTlNG - Precautions before Service

NOTE ON INSTALLATION OF RADIO EQUIPMENT

NOOEA..

The computers-af the electronic control system has been I

designed so that external radio waves will not interfere with _
their operation.
However, if antenna or cable of amateur transceSer etd. is:-”
routed near the computers, it may affect the operation of the
computers, even- if the output of the transceiver is no more
than 25W.
To protect each of the computers from interference by
transmi‘tter (hum, transceiver: etc.), the following should be
observed.
1. Install the antenna on the roof or rear bumper.
2, Because radio waves are emitted from the coaxial cable of
the antenna,-= keep it 2M mm (8 in.1 away from the
computers and the wiring harness. If the cable must cross
the wiring harness, route it so that it runs at right angles~to
the wiring harness.
3. The antenna and the cableshould be well matched, and the
standing-wave ratio+ should be kept low.
4. A transmitter having a lame output should not be installed in
the vehicle.
5. After installation of transmmer. run the engine at idle, emit-
radio waves from the transmitter and make-sumthat the
engine is not: -affected-
Voltage *STANDING-WAVE RATIO
“o,tageLvz;!;age
If an antenna and a cable having different im@edanties se
connected, the input impedance Zi will vary in accordance with
the length of the cable and the frequency of the transmitter,
and the voltage distribution will also vary in accordancewith the
=- -. -. . location.
Cable
The ratio between~ this maximum voltage and minimum voltage
High-frequency Antenna is called the standing-wave ratio It can also be represented by
power supply the ratio between the impedances of the an‘lenna FU-I~ the
00Y!730
cable.
The amount of radio waves emitted from the cable increases EE
the standing-wave ratio increases. and this increases the
possibility of the electronic -components being adversely
affected.
INTRODUCTION AND MASTER TROUBLESHOOTING - TowingandHoistin< ,$-

TOWING AND HOISTING

WRECKER TOWING
1. This vehicle cannot be towed with sling-type equipmt
2. If a vehicle is towed from the front, use wheel lift or flat be
equipment.
3. If a vehicle is towed from the rear, use flat bed equipment.
SAFETY PRECAUTIONS
1. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior to
moving the vehicle.
2. Operator should refrain from going under a vehicle such as
hood, doors, fenders, trim, etc., unless the vehicle is
adequately supported by safety stands.
3. Never allow passengers to ride in a towed vehicle.
4. State and local rules and regulations must be followed
when towing a vehicle.

HOISTING
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations. (Next page)
Conventional hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the
front/rear crossmembers.
FLOOR JACK
A regular floor jack may be used under the front/rear cross-
members.
Caution
1. A floor jack must never be used on any part of the
underbody.
2. Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.
EMERGENCY JACKING
Jack receptacles are located at the body sills to accept the i
scissors jack supplied with the vehicle for emergency road
service. Always block opposite wheels and jack on level
surface.

-=r=
 INTRODUCTION AND MASTER TROl JBLESHOOTlNG - Towing and Hoisting

ME CONTACT SUPPORT LOCATION

1.225 mm (48 in.)

Wheel base
e
2,435mm f95.9in.) ~.” ’ ~;~ 5

LIFTING, JACKING SUPPORT LOCATION

~~~~~~~ Frame contact hoist

m F’oor Jack

0 Twin post hoist or scissors lack (emergency) locatlons

 /If

INTRODUCTION AND MASTER TROUBLESHOOTING - General

DataandSpecifi( <
‘
‘i 4
GENERAL DATA AND SPECIFICATIONS :

OOY653

Items Al 87AMRFGL4 Al 87AMNFGL4

Al 87AMRFGL9 Al87AMNFGL9

Vehicle dimensions mm (in.)

Overall length 0 4,400 (173.2) 4,400 (173.2)
Overall width 0 1,735 (68.3) 1,735 (68.3)
Overall height 0 1,275 (50.2) 1,275 (50.2)
Wheel base 0 2,435 (95.9) 2,435 (95.9)
Tread Front g 1,465 (57.7) 1,465 (57.7)
Rear 1,455 (57.3) 1,455 (57.3)
Overhang Front CD 970 (38.2) 970 (38.2)
Rear @ 995 (39.2) 995 (39.2)
Height at curb mass (wt.)
Front bumper to ground @I 355 (14.0) 355 (14.0)
Rear bumper to ground 63 370 (14.6) 370 (14.6)
Minimum running ground clearance 0 115 (4.5) 115 (4.5)
Angle of approach 0 16” 16”
Angle of departure 0 19” 19”
Ramp breakover angle 63 12” 12”

dehicle weights kg (Ibs.)

Curb weight 1,405 (3,097) 1,375 (3,031)
Gross vehicle weight rating 1,840 (4,056) 1,840 (4,056)
Gross axle weight rating Front 885 (I ,951) 885 (1,951)
Rear 955 (2,105) 955 (2,105)
Seating capacity 5 5
 INTRODUCTION AND MASTER TROUBLESHOOTING - General Data and Specifications -.

Items Al 87AMRFGL4 Al 87AMNFGL4

Al 87AMRFGL9 Al87AMNFGL9
._= .z
Engine
Model No. G54B with turbo G54B with turbo
Type In line OHC In line OHC ==~~~
Number of cylinders 4 4
Bore mm fin.) 91.1 (3.59) 91 .‘I 0.59)
Stroke mm tin.) 98.0 (3.86) 98.0 (3.86)
Piston displacement cm-’ (CID) 2,555 (I 55.9) 2,555 (155.91 1
Compression ratio 7.U 7.0
Firing order 1-3-4-2 l-3-4-2
Basic ignition timing IO” ETDC IO” BTDC
1
Manual transmission
Model No. KM132
Type ~-~ 5-speed manual
Gear ratro 1st 3.369
2nd 2.035
3rd I.366
4th 1.000
5th 0.856
Reverse 3.578

dutomatic transmission
Model No. JMGOD -
Type 4-speed automatic ~~
Gear ratio 1 St 2.458 -
2nd 1.458
3rd 1.000 -
4th 0.686 -
Reverse 2.182 -

‘inal drive gear ratio 3.545 11

._,I-~. -7: .~.~ __
llutch
Type ~~ Dry-single disc & ~ Dry-single disc &
diaphragm spring diaphragm spring
 INTRODUCTION AND MASTER TROUBLESHOOTING - General Data and Specificatib, 6

Items Al 87AMRFGL4 A187AMNFGL4

Al 87AMRFGL9 Al 87AMNFGL9
i
Chassis
Tire Front Rear Front Rear
205/55VR16 225/50VR16 205/55VR 16 225/50VR 16

2257506VR16 245,4:VR 16 225/5%/R 16 245,4%R 16

Radial Radial Radial Radial
Front suspension
Type Independent strut Independent strut
Rear suspension
Type Independent strut Independent strut
Brakes
We Front Disc Disc
Rear Disc Disc
Power steering
Gear type integral type Integral type
(Recirculating ball nut) (Recirculating ball nut)
Gear ratio 14.3 14.3
(Constant ratio gear) (Constant ratio gear)
Fuel tank capacity 75 liters (19.8 gals.) 75 liters (19.8 gals.)
 HTENING TORQUE NOOJA- _

Description

6 x 1.0 2.2-2.9 ~~~

8 x 1.25 5.8-8.7 ~_~~
IO x 1.25
12 x 1.25 35-53 .-
14 x 1.5
16 x 1.5
18 x 1.5 180-230
20 x 1.5

Internal thread: Aluminum ~;

Internal thread:~ Cast irenT
PT I/4 Internal thread: Aluminum
Internal thread: Cast iron ~c
PT 3/8 Internal thread: Aluminum
Internal thread: Cast ircYn. <-

Internal thread: Aluminum

Internal thread: Cast ire17
NPTF ?/8 7.9 - 12 5.8 - 8.7 Internal thread: Aluminum
16- 19 12-14 Internal thread: Cast iron ~.:; -z-
NPTF l/4 19-30 14-22 Internal thread: Aluminum
34-45 25-33 ~~ Internal thread: Cast iren .L-_ ~~~~
 INTRODUCTION AND MASTER TROUBLESHOOTING - MasterTroubleshooting
“-~,

MASTER TROUBLESHOOTING
ENGINE OVERHEATS

Symptom Probable cause Reference page

or remedy

Engine overheats Cooling system faulty 7-6

Incorrect ignition timing 8-l 44

Water leaks
l Loose cylinder head bolt g-30,43
l Damaged cylinder head gasket g-29,42
l Cracked cylinder block 9-65
l Cracked cylinder head 9-42

Loose intake manifold bolts or leaking from gasket 1 l-5

Cracked intake manifold 1 l-6

Faulty automatic transmission oil cooler operation

l Blocked or collapsed hose and pipe 21-76
l Loose hose and pipe connection 21-75

ENGINE WILL NOT CRANK OR CRANKS SLOWLY

Symptom Probable cause Reference page

or remedy

Engine will not crank or cranks Starting system faulty 8-l 29

slowly

ENGINE WILL NOT START OR HARD TO START (CRANKS OK)

Symptom Probable cause Reference page

or remedy

Engine will not start or Ignition system problems 8-l 42

hard to start (Cranks OK)
Compression too low 9-l 5 (9-l 3)

No fuel supply injector 14-81

Injection system problems 14-27

Vacuum leaks Repair as necessary

l Purge control valve hose

l Vacuum hoses

l Intake manifold

l Injection mixer

l EGR valve
 INTRODUCTION AND MASTER TROUBLESHOOTING - MasterTroubleshooting

’ ROUGH IDLE OR ENGINE STALLS

Symptom

Rough idle or engine stalls

l Purge control valve hose

l Vacuum hoses

* Intake manifold
* Injection mixer

ENGINE HESITATES OR POOR ACCELERATION

Symptom Probable cause Reference page

3r remedy

f
Ignition system problem

25-27

Repair as necessary
l Purge control valve hose
l Vacuum hoses
l Intake manifold
l Injection mixer

Refer to “Engine
Overheats”
 t

INTRODUCTION AND MASTER TROUBLESHOOTING - MasterTroubleshoo*ing23

ENGINE DIESELING

Symptom Probable cause Reference page

or remedy

Engine dieseling (runs after Incorrect ignition timing 8-144

ignition switch is turned off)

EXCESSIVE OIL CONSUMPTION

Symptom Probable cause Reference page

or remedy

Excessive oil consumption Positive crankcase ventilation line clogged o-14

Valve stem worn g-45,46

Valve stem seal worn or damaged 9-47

Piston ring worn or damaged 9-53

Oil leak Repair as necessary

L

POOR FUEL MILEAGE

Symptom
I Probable cause Reference page
or remedy

Poor fuel mileage Air cleaner clogged o-13

Brakes drag 5-l 9

Clutch slips 6-5

Ignition problems 8-142

Compression too low 9:15 (9-13)

Fuel injection system problems 14-30

Tires improperly inflated 22-2

Fuel leak Repair as necessary

NOISE

Symptom Probable cause Reference page

or remedy

I Noise Engine noise

Loose bolts and nuts

9-13

Retighten as
necessary
 -.
--..___-

24 INTRODUCTION AND MASTER TROUBLESHOOTING - MasterTroubleshooting

HARD STEERING

POOR RETURN OF STEERING WHEEL TO CENTER

POOR RIDING

Symptom Probable cause

 INTRODUCTION AND MASTER TROUBLESHOOTING - MasterTroubleshooting

ABNORMAL TJRE WEAR

Symptom Probable cause Reference page

or remedy

Abnormal tire wear Improper front or rear wheel alignment 2-7, 17-7

Loose wheel bearings 2-9, 10, 11,

3-20

Malfunctioning shock absorber 2-15, 17-16

Improper tire pressure 22-2,4

lmbalanced wheels

ROAD WANDER

I Symptom Probable cause Reference page

or remedy

Road wander Improper front or rear wheel alignment 1 2-7, 17-7

Poor turning resistance of lower arm ball joint 2-20

Loose or worn lower arm bushing 2-9, 11, 20,22

Loose or worn wheel bearings

Excessive play of steering wheel ) 19-9

Improper tire pressure

VEHICLE PULLS TO ONE SIDE

Symptom Probable cause Reference page

or remedy

Vehicle pulls to one side Improper front or rear wheel alignment 2-7, 17-7

Excessive turning resistance of lower arm ball joint 2-20

Wheel bearing seizure 2-9, 11

Deformed lower arm 2-20

Bend drive shaft 3-25

lmbalanced or worn tires 22-2,4

Uneven tire pressure

 ..A .Y
._ _
*Bs

26 INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting

STEERING WHEEL SHIMMY

Symptom

Steering wheel shimmy

Broken or weakene nt or rear st

BOTTOMING

Symptom Probable cause Reference page

or remedy

Bottoming Broken or weakened coil spring 2-15, 17-16

_
Malfunctioning shock absorber

Overloaded vehicle Correct

 INTRODUCTION AND MASTER TROUBLESHOOTING - MasterTroubleshooting27

WHEEL BEARI.NG TROUBLESHOOTING

Trouble Symptom Probable cause

Pitting Pitting occurs because of uneven rotation of Excessive bearing preload

race and bearing surfaces Excessive load

Flaking The surface peels because of uneven rotation End of bearing life
of the race and bearing surfaces Improper bearing assembly

Cracking Chipping or cracking of cage or roller edges Impact when bearing was installed
(such as being hit with a hammer)

Flat spotting When large load is applied, race and roller Excessive bearing preload
contact surfaces compress, forming Excessive load
indentations Vibration when bearings are not used,
such as during shipment on freight
cars, transport trucks, etc.

Nicks Instead of rolling along race surface, rollers Insufficient grease

slide, thus damaging surface Excessive bearing preload
Excessive load
Faulty oil seal

Smearing Damage or wear caused by minute particles Excessive variation of loads on

adhering to surfaces results in rough move- bearings
ment and such high temperatures that parts Use of grease other than that specified
of surface melt Insufficient grease

Rust, corrosion Appears on various areas of the bearing Use of grease other than that specified
Faulty oil seal
Presence of water or moisture

Wear Wear of surface areas caused by friction Insufficient grease

Foreign matter
Rust or corrosion due to moisture
Use of grease other than that specified
Faulty oil seal

Discoloration Grease discoloration.results from grease Use of grease other than that specified
deterioration which causes particles of pig- Faulty oil seal
ment contained in grease to adhere to surfaces Excessive bearing preload
Heat discoloration will appear as a deep brown Excessive load
or purple
 c

LUBRICATION
AND
MAINTENANCE
CONTENTS
GENERAL INFORMATION . .. .. . . .. .. . .. .._............... 2 Front Wheel Bearings ........................................ 19
Fuel Filter ......... .._.................-.....~............~ ........... 11
MAINTENANCE SERVICE ....... r........................ 8
Fuel Hoses, Vapor Hoses and
Air Cleaner Element ........................................ 13 Fuel Filler Cap .................................................... 12
Automatic Transmission ................................ 16 Fuel System ........................................................ 12
Ball Joint, Steering Linkage Seals Ignition Cables .................................................... 15
and Drive Shaft Boots ........................................ 19
Manual Transmission ........................................ 16
Brake Fluid ................ .._....................~.._.~.....~.~ ... 19
Oxygen Sensor .......... ..-.......-..e.....> .................. 15
Brake Hoses ........................................................ 19
Rear Axle ............................................................. 20
Canister ...................................................... . ..... 14
Spark Plugs ....................................... ..- ...... ..__..... 14
Cooling System ................................................ 17
Turbocharger Air Intake Hoses and
Crankcase Emission Control System Oil Hoses ............................................................ 12
(PCV valve) . ....................................................... 13
Vacuum Hoses, Secondary Air Hoses,
Disc Brake Pads ................................................ 18 Crankcase Ventilation Hoses and
Drive Belt ............................................................ 15 Water Hoses .................................................... 12

Engine Oil ............................................................ 8 Valve Clearance .. .............................................. 9

Engine Oil Filter .................................... ............ 8
RECOMMENDED LUBRICANTS AND
Evaporative Emission Control System LUBRICANT CAPACITIES TABLE . .. .. . .. . .. . ... . . .. . 6
- Except Canisters ............................................ 14
Exhaust System ................................................ 20 SCHEDULED MAINTENANCE TABLE .. .. .. . ..___ 3
 GEAR LUBRICANTS w
GENERAL INFORMATION NOOPA- -

The SAE grade number also indicates the_viacosity 1 -

Maintenance and lubncatron servrce recommenda-
of Multipurpose Gear Lubricants. ~_
tions have been compiled to provide maxrmum The API classification system defrn_es iear Jubrj- Lee. E:
protection for the vehicle owner’s Investment cants in terms of usage. Typically gear lubricants .~i ZZ:
against all reasonable types of driving conditions, conforming to API%L-4 or GL-5Iwith a vj$cosity~of -l ig
Since these condjtrons vary with the individual SAE 89W or SAE 90 are recommended f& rna@al -;a.
vehicle owner’s drivrng habits, the area in which the transmission and rear axle MOPAR Hypoid Lubri- -I FI-
vehrcle is operated and the type of dnvrng to which cant Part No. 4318658 plus MOPAR Hypoid Gear 011 1 Z-=
the vehicle is subjected, it IS necessary to prescribe Additive-Friction Modifier Part No. 4318060 I or Y---
-.z.. _ _s
‘-
lubncatron and marntenance servtce on a time
equivalent.
frequency as well as mileage Interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by the
LUBFilCANfS - GREASES c-P
Society of Automotive Engineers (SAE), the Amer- Semilsolid lubricants, bear the NLGI designation and i-
ican Petroleum Institute (API) and the National are further classified as grades 0, 1, 2, 3 etc, -~- q -
Lubricating Grease Institute (NLGI). Whenever “Chassis Lubricant” is specified, Multi-
purpose Grease, NLGI grade 2, should& used. iz -~ :I q
MAINTENANCE SCHEDULES MOPAR Multi-Mileage Lubricant, ParttNumber .~~ B-
_..
I
2525035 or equivalent, meets these requirement
Informatron for service marntenance is provrded and iS recommended.
under “SCHEDULED MAINTENANCE TABLE”. - _
Three schedules are provided; one for “Required u_
Maintenance”, one for “General Maintenance” and
FUEL USAGE STATEMENT. -
one for “Severe Usage Service”. The use of premium unleaded gasoline having a ;
minimum octane mting~ of 91, (R + -M)/Z 7s recom--7 - --.^.~ .’ L-
SEVERE SERVICE mended for use In this car In order %i. provrde
optimum vehicle performance. The use of premrumZZZ=~- ~’ =I
Vehicles operating under severe service conditions unleaded gasoline having an octanes rating higher -- ..-
will require more frequent service. than 87 may help to obtain improve?d‘ .vef$cle :
Component service rnformation is included in performance.
appropriate unrts for vehicles operating under one or Unleaded gasolines only must be used in vehicles-~ I
more of the followrng conditions: equipped with catalyst emission control systems. mu
1. Trailer towrng or police, taxi, or commercral type All vehicles, so equipped, have labels located on the._, =
operatron Instrument panel and on the back of fuel filler lid that
2. Operation of Vehicle state;“UNLEADED GASOL!NE ON-LLYZ. zh_ese
-jam_ vehi-lg
-=r=-. I’ ‘-; _~g
(1) Short-trip operation at freezing temperature cles also have fuelfiller tubes especially designed to _
(engine not thoroughly warmed up) accept the smaller diameter unl~:adeg_gas~~ne__=_ ~_~ I
(2) More than 500/0 operation in heavy city dispensing nozzles only.
traffic during hot weather above 32°C (90°F)
(3) ExtenGve idling
(4) Driving In sandy areas MATERIALS ADDED TO FUEL
(5) Driving In salty areas Indiscriminate use of fuel System cleaning agents-1 --
(6) Driving In dusty conditions should be avoided. Many of these materials in-
tended for gum and varnish removal r@y contain
ENGINE OIL highly active solvents or srmrlar ingredrents that,_can-_Z __
be harmful to gasket and diaphragm materials used_-
The SAE grade number Indicates the viscosity of ~-.
in fuel system component parts.
engine oils, for example, SAE 30, whrch is a single
grade oil. Engine oils are also identified by a dual
number, for example, SAE 1 OW-30, which indicates
3 tnultigrade 011.
The API classifrcatron system defines oil perform-
ance in terms of engine usage. Only engrne oil
designed “For Service SF” or “For Service SF/CC“,
when available, should be used. These oils contain
sufficient chemical additives to provide maximum
engine protectron. Both the SAE grade and the API
designation can be found on the container.
 LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table

SCHEDULED MAINTENANCE TABLE NOOQA- .

SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER

VEHICLE PERFORMANCE
Inspection and service should be performed any time a malfunction is observed or suspected. Retain receipts
for all vehicle emission services to protect your emission warranty.

Emissidn Coritrol System

Clean Every 5 Years

 ~__
; ,$ f

___A~- --~__---~------------~LFL----.-i _~

LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

General Maintenance

Cochng System

Boots

ransmlssron

Rear Axle Change Oil at X X

-------
Drwe Belt - _ Replace Belt at X X
(for Water Pump and Alternator)
 LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table O-5 ?I,

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS

The maintenance items should be performed according to the following table:

Mileage Intervals
Service to be
Maintenance Item

ICrankcase Emisslon-
Control System Check and Clean as Required More Frequently

Spark Plugs Replace at X X X X X X

IDisc Brake Pads

(Front and Rear)
Inspect for Wear More Frequently
1x1 I I I 1x1 I
Automatic Transmission Change Fluid at X X X x x

Severe usage conditions

A - Driving in dusty conditions E- Driving in sandy areas
B- Trailer towing or police, taxi, or commercial type operation F- Driving in salty areas
C- Extensive idling G- More than 50% operation in heavy city traffic during -
D- Short-trip operation at freezing temperatures hot weather above 32°C (9V’F)
(engine not thoroughly warmed up) H- Driving off-road
6-6 LUBRICATION AND MAINTENANCE - Recommended Lubricants and Lubricant Capacities Table

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE

NOORA-

RECOMMENDED LUBRICANTS

Parts Specifications

Engine oil API classif ication SF or SF/CC” ‘=”

Manual transmission API classification GL-4 or

utomatlc transmlsslon

.,.~(__ ._
* -‘_

Front wheel bearing Multipurpose grease NLGI =’ ‘- -~

Grade 2

Cooling system

Transmission linkage, parking Multipurpose grease NLGI

brake cable mechanism, hood Grade 2
lock and hook, door latch,
hatch latch. seat adjuster

Door hinges, hatch hinges Engine oil

LUBRICANT CAPACITIES TABLE

Metric measure

Crankcase (excludes oil filter)

Automatic Transmission
 LUBRICATION AND MAINTENANCE - Recommended Lubricants and Lubricant Capacities Table O-7

SELECTION OF LUBRICANTS
ENGINE OIL MANUAL TRANSMISSION

“C “F
49 120

38 100 REAR AXLE (limited slip differential)

Refer to P.3-IO.
27 80

16 60

0 32

-12 IO

-23 -10
-29 -20

I 53E531

l Oils of SAE 5W-30 may be used in very cold weather areas where
minimum air temperatures are below-23°C (-1 O’F).

SELECTION OF ENGINE COOLANT

ENGINE COOLANT
Relation between Engine Coolant Concentration and Specific Gravity

,
1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50 %

1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55 %

1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (49) 60 %

Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at the engine
coolant temperature of 20°C (68°F).
Caution
1. If the concentration of the engine coolant is below 30%, the anti-corrosion property will be
adversely affected. In addition, if the concentration is above SO%, both the anti-freeze and engine
cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to
maintain the concentration level within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
O-8 LUBRICATION AND MAINTENANCE - Maintenance Service

MAINTENANCE SERVICE NOOSAAA

ENGINE OIL (Change)

Alwavs use lubricants which contorm 10 the requirements of
the API classrtrcation “For Service SF” or “For Service SF/CC ;.imm
when available, and have the proper SAE grade numberfor the -Y
expected temperature range. -
Never use nondetergent or straight mineral oil. ~~
(1) After warming up the engine, remove the oil tl!@r cap.
C?) Remove the drawn plug to allow the engine oil to drain.
(3) Replace the drain plug gasket with a new one andOtFghten zs.W~
the dram plug.
(4) Pour new engFe 011 through the oil filler.
Engine oil quantity (excludes oil filter): ~~
3.8 lit. (4 qts.)
Oil filter 0.5 lit. (l/z qt.)
Oil cooler 0.4 lit. (Vi2 qt.)

ENGINE OIL FILTER (Change) NOOSASA

The quality of replacement filters varies considerably. Only high

quality filters shoutd be used to assure most efficient serv@. -
Genuine oil filters-require that the filter is capable of withstatid- ~--
ing a pressure of 256 psi and high quality filters are recom- ~~
mended as follows:
Oil Filter Part Number:
Mitsubishi Genuine Parts MD031805
NOTE ~~
Factory installed~ Mitsubishi: Engine Oil Filter Part No. .~~
MD084693 or MD031805.
ENGINE OIL FILTER SELECTION
This vehrcle IS equrpped wrth a tull-flow, throw-away orI filter.
The same type oi replacement filter is recommended as a -=I
replacement triter tor thus vehrcle. It is possible, partrcularly in
I:;old weather, that this vehicles may develop high oil pressure 1
for a short duratrpn. YOU should be sure that any rep%cement ~~-~~~z-m
filter used on thts vehrcle LSa hrgh-quality filter and is capable of
wrthstandrng a pressure of 256 psi (manufacturer’s specifica- ~-
tions) to avord filter and engrne damage. The folloy$ng is a
high-quality triter and IS strongly recommended for use on this ~~-
vehicle: Mrtsubrshr Engine Gil Filter P/N MD084693. .~ or ~j
MD031 805. --I- ;-
Any replacement 011filter should be installed in accordance with
the oil triter manutacturer’s~ specifications and installation ~~T
insrructrons. =
_- ~_
LUBRICATION AND MAINTENANCE - Maintenance Service

(1) Use filter wrench or the like to remove oil filter.

(2) Apply a thin film of engine oil to the surface of gasket
before screwing filter on.
(3) Then tighten filter enough by hand.
(4) Start and run engine and check for engine oil leaks.
(5) After stopping engine, check oil level and refill as neces-
sary.

VALVE CLEARANCE (Check and adjust as re-

quired) NOOSACH

Incorrect valve clearances will not only result in unsteady

engine operation, but will also cause excessive noise and
reduced engine output.
Check the valve clearances and adjust as required while the
engine is hot.
Valve-to-rocker arm clearances:
Jet valves 0.25 mm (.OlO in.)

VALVE CLEARANCE ADJUSTMENT

INTAKE AND EXHAUST VALVES
The auto-lash adjuster is installed to the rocker arm so that the
valve clearance adjustment is maintenance-free.
For additional ‘information regarding the auto-lash adjuster,
refer to GROUP 9 ENGINE.

JET VALVE
Caution
The cylinder head bolts should be retightened before
attempting this adjustment.
(1) Warm up the engine until the engine coolant is heated to 85
to 95°C (185 to 205°F).
(2) Remove all spark plugs from the cylinder head- for easy
operation.
(3) Remove the air intake pipe.
(4) Remove the rocker cover.
O-IO LUBRICATION AND MAlNTENANCE - Maintenance Service

(5) Set the No. 1 piston at top dead center on the compression
stroke.
Turn the crankshaft clockwise until the notch on pulley is
lined up with the “T” mark on timing chain cover. .
In this state, check that themating mark on the camshaft
sprocket is at the position -shown in the illtistratitin.z
Caution
Do not turn the crankshaft counterclockwise.
NOTE
If the mating mark is at the opposite side, No. 4 piston is at
top dead center on the compression stroke. ..

5EN07E

(6) Measure the valve clearanc? at points indicated by arrows.

When No. 1 cylinder is at top dead -.
center on compressidn stroke. Standard value (on hot engine): 0.25 mm (.OlO in.) .-“- Z:
-
Exhaust valves E=
c:
NOTE ~.~~~ .I
.__._ _-_ The valve clearance on cold engine is 0.17 mm (,.!7 in.). %
(7) If the jet valve clearance is not as specified, loosen~the lock -‘-- =-=
Front of
engine nut and adjust the clearance using a feeler gauge while -r
turning the adjusting screw.
Caution
inlet valves The jet valve spring has a small tension and the
5EN221 adjustment is somewhat delicate. Be careful not to
When No. 4 cylinder is at top dead push in the jet valve by turning adjusting screw too
center on compression stroke. much.
Exhaust valves (8) While holding~the adjusting screw with a screwdriver to
prevent it from turning, tighten the lock nut to specified m-f
torque.

Inlet valves

5EN222

(9) Turn the crankshaft through 360” to line up the nofch on the ~z
crankshaft pulley with the “T” mark on timing chain coG2r. T
(10)Check the other valves and if they are out of specification,
readjust according to steps (7) and (8).
 LUBRICATION AND MAINTENANCE - Maintenance Service O-11
(11)Apply specified sealant to the semi-circular packing on the
Apply sealant portions shown in the illustration.
Recommended adhesive: MOPAR Part No. 4318025 or
equivalent
(12)lnstall the rocker cover.
(13)lnstall the air intake pipe.
‘:
-a. .
a.:.:....
. . . . . . . . . . . . . . . . . . . . . . . . . ..- (14)lnstall the spark plugs.
..:.:.:.:.:.:.:.:.:.:..
. .~.~.~.~.~.~.

&id

DEN23C

IOmm

Cylinder head ’ 3EN004)

FUEL FILTER (Replace) NOOSAFA

The fuel filter should be replaced regularly because its

performance is reduced by dirt and water collected over an
extended period of use. Replace as required.
LUBRICATION AND MAINTENANCE - Maintenance Service

FUEL SYSTEM (Check for leaks) NOOSAGA

TANK, LINES AND CONNECTIONS

(I) Check for damage OI leakage in the fuel lines and
connectlons. ~_
(21 inspect the surface of fuel%oses for heat and mechanical
damage. Hard and brittle rubber, cracking, checkit?& tears,
cuts, abrasions and excessrve swelling mdic%te &teriora-
tlon of the rubber.
(3) If the fabric casing of the rubber hose is exposed by cracks
and abrasions In the tuel system, the hoses should be
changed.

VACUUM HOSES, SECONDARY AIR HOSES,

CRANKCASE VENTILATION HOSES AND WATER
HOSES (Replace) NOOSAHA

Replace them and make sure that hoses do not come rn

contact wtth any heat source on moving componefit which
might cause heat damage or mechanical wear.

FUEL HOSES, VAPOR HOSES, AND FUEL FILLER

CAP (Replace) NOOSAIA

Service procedures to check the hoses for damage are the

same as those described rn the section “Vacuum hoses,
secondary air hoses, crankcase ventilation hoses @jd waier
hoses”.
For removal and mstallation procedures, refer to GROUP. 14
FUEL SYSTEM ,~Fuel Tank._ Fuel Line and Vapor -Line.
.- .=_
TURBOCHARGER AIR INTAKE HOSES AND OIL
HOSES (Replace) -for fuel-injection turbocharged
vehicles NOOSAJA

The turbochargers arr mtake_hoses and 011 hoses must be

replaced pertodlcally with new ones. The air ent@ed fr%m
outside the air cleaner filter may make intake a? dirty, resulfing
In engine power less than n_ormal.
The oil leakage from 011 hose may provide improper Tubrication
In the turbocharger, resulting m engine power less than normal.
For removal and mstallatlon procedure, refer to GROUP 11 -IL
INTAKE AND EXHAUST SYSTEM - Turbocharger.
 LUBRICATION AND MAINTENANCE - Maintenance Service O-13
AIR CLEANER ELEMENT (Replace) NOOSAKD

The air cleaner element will become dirty and loaded with dust
during use, and the filtering effect will be substantially reduced.
Replace it with a new one.

(1) Unclamp and remove the cleaner cover.

Caution
Remove the air cleaner cover, paying attention to the
air flow sensor attached to the cover.
(2) Take out the air cleaner element.
(3) Set a new air cleaner element and clamp the cleaner cover.

Rocker cover CRANKCASE EMISSION CONTROL SYSTEM (PCV

Breather hose 1 Injection valve) (Clean) NOOSALA

Jdqocharger The crankcase ventilation system must be kept clean to

maintain good engine performance.
Periodic servicing is required to remove combustion products
from the PCV valve.

I
Oil separator
PCV valve’
Ventilation
/ Intake ma&old
hose 6EM121

(1) Disconnect the ventilation hose from the positive crankcase

ventilation (PCV) valve. Then, remove PCV valve from the
rocker cover and reconnect it to the ventilation hose.
(2) Idle the engine and put a finger to the open end of PCV
valve to make sure that intake manifold vacuum is felt on
the finger.
NOTE
At this time, the plunger inside the PCV valve moves back
and forth.
(3) If vacuum is not felt on finger, clean the PCV valve and
ventilation hose in cleaning solvent or replace if necessary.
“. 2’ 3
!
v,i : -~--.--_i_ ..-.-I_, *-m?s-
-7
-I-
-
--z
-7;
E-
o-14 LUBRICATION AND MAINTENANCE - Maintenance Service

EVAPORATIVE EMISSION CONTROL SYSTEM

(Check for leaks and clogging) - except canisters
NOOSAMA

(1) If the fuel-vapo-r vent line IS clogged or damaged, a

fuel-vapor mixture escapes rnto the atmosphere causrng
excessrve emrssions. Disconnect the line at both ends, and
blow it clean with compressed arr. Remove the filler cap
from the filler pipe and check to see If there isevidencethat
the packing makes Improper contact to the filler. pipe.
(21 The overfill lrmrter (two-way valve) Installed on the vapor
line between the canrster Inlet and feul tank outlet,shau@
be checked for correct operation.

Overfill llmlter
Air intake hose To.thermo valve (Two-wav f&e)

Fuel injector m .
valve

- Fuel vapor
-- - Purge air
5EN026

CANISTER (Replace) NOOSANA

If or when the canister tilter becomes clogged, the purge air

volume will decrease and consequently, the canrster capacity
will be reduced.
For removal and installation procedures, refer to GROUP 14
FUEL SYSTEM --Fuel Line and Vapor Line.

SPARK PLUGS (Replace) NOOSAOA

(‘I 1 Spark plugs must fire properly to assure proper-engine

performance and emrs.on;control.
Therefore, they should be-replaced periodically wTth new
ones. -
Plug gap gauge
NIPPONDENSO (2) The new plugs should bechecked for the.. proper gap.
Spark plug gap:
NGK, CHAMPION
uring
ion 1.0 - 1.1 mm (.039 - .043 in.)
NIPPONDENSO
NGK
W22EP-UIO, W22EPR-U 10
01. 0.9 - 1.0 mm (.035 - .039 in.)
Other type
l-l-f 1.0 - 1.1 mm (.039 - .043 in.)
01R0119
 LUBRICATION AND MAINTENANCE - Maintenance Service o-15
IGNITION CABLES (Replace) NOOSAPA
Correct Incorfect
The ignition cables should be replaced periodically with new
ones. After replacing, make sure that the ignition cables and
terminals are properly connected and fully seated.
NOTE
When disconnecting an ignition cable, be sure to hold cable
bb cap. If the cable is disconnected by pulling on the cable alone,
an open circuit might result.

lEL160 lEL161

OXYGEN SENSOR (Replace) NOOSAQA

The oxygen sensor is a device which controls the fuel mixture.

If the oxygen sensor is damaged, the exhaust-gas cleaning
effect as well as driveability deteriorates. Therefore, it should
be replaced periodically with a new one.

Hexagon nut

03E58(

DRIVE BELT (Replace) NOOSBBA

Replace the drive belts with new ones, and make sure there is
no interference between the belt and other engine compo-
nents.
Then, check the tension of the belt for the water pump and
alternator. The deflection of the belt must be specified listed
below when depressed at a point midway between the water
pump pulley and the alternator pulley with a force of 100 N (22
Ibs.).

(1) Remove the air conditioner compressor belt and/or power

steering oil pump belt if equipped.
(2) Loosen the alternator support bolt nut.
 - .d -a-- -... _.. .-.. -.. _____ ______ ____~__~~__i__-~___ rr.“.

O-16 LUBRICATION AND MAINTENANCE - Maintenance Service

(31 Loosen the belt- tensron adjuster lock bolt. ~~ ~

(4) Turn the adjust bolt to reduce the belt tension; .- =~z-:
(5) Remove the belt.
(6) Install a new belt and turnthe adjust bolt to adjust the belt
.~
tension. ~~
Standard value: 7 - 10 mm (28 - .39 in.)
(7) Tighten the lock bolt. --.
(8) Tighten the a!ternator support bolt nut.

MANUAL TRANSMlSSlbN (Inspect oil I&&)

NOOSBCD

Inspect each component for evidence of leakage, and check

the oil level by removing the filler plug. If the oil is contami-
nated, it is necessary to replace it with new oil.
(1) With the vehicle parked at a level place, remove the filler my
plug and make sure that the oil is at the same level as the --
lower surface of the threaded hoie. ~-~
(2) Check to see that transmission fluid is free of excessive pm-y~~
contamination and has proper viscosity.
- .- _ -- --

Transmission

TRANSMISSION FLUID (Replace)

(1) With the vehicle parked at a level place, remove the oil d~rain -~I
plug to drain transmission fluid.
(2) Replace packing with a new one and install the oil drain
plug.
(3) Pour transmission fluid in the filler plug hole unti!-the fluid is 1
at the same: level as the bottom of the plug hole.
Total transmission fluid capacity: 2.3 lit. (2.4 qts.)

OE
_
AUTOMATIC TRANSfkSlON (Char&? fluid)
NOOSBDC

Drain the flurd and check whether there IS any evtdence of

cotitamrnacron.
Replenrsh with new fluid atter the cause of any conLamination I
has been corrected.
LUBRICATION AND MAINTENANCE - Maintenance Service O-17
(1) Loosen the oil pan screws and tap the oil pan at one corner
to break it loose and allow automatic tra~nsmission fluid to
drain.
(2) Drain automatic transmission fluid remaining in bottom of
oil pan after its removal.
(3) Install oil pan with new gasket and tighten~oil pan screws, 6
to 8 Nm (4.4 to 5.7 ftlbs.).

09Y631

(4) Pour 5 liters (5.3 qts.) of “DEXRON II” ATF into case
through dipstick hole. [Total quantity of ATF required is
approx. 7.2 liters (7.6 qts.).
Actually however, approx. 5.5 liters (5.8 qts.) of fluid can be
replaced because rest of fluid remains in torque converter.]
(5) Start engine and allow to idle for at least two minutes.
Then, with parking brake on, move selector lever momen-
tarily to each position, ending in “N” Neutral position.

(6) Add sufficient ATF to bring fluid level to lower mark.

Recheck fluid level after transmissibn is at normal operating
temperature.
Fluid level should be between upper and lower marks.
Insert dipstick fully to prevent dirt from entering transmis-
sion.

COOLING SYSTEM (Check and service as re-

quired) NOOSBEA

Check the cooling system parts, such as radiator, heater, and

oil cooler hoses, thermostat and connections for leakage and
damage.
Q-18 LUBRICATION AND MAINTENANCE - Maintenance Service

THERMOSTAT (Inspect)
(1) Remove the thermostat. _
(2) Replace the thermostat if-the valve is open-even- slightly: Ii.- 1: -
(3) Replace if greatly deformed, damaged or broken.
(4) Remove rust and fur fron-rthe valve if found on the valve. “T ’ I’
(5) Fill a container with water and immerse the thermostat. I., I~
While stirring water, increase water temperature and check y =
to see that thermostat valve opening temperature and
full-open temperature [valve lift at full open positiori.is 8 mm zzY E
--
(.3 in.) or more] are as specified below. =-
-_.
Standard value: =-
=:~I
Valve opening temperature s-
88 Yl.5”C (190 5 3°F)
Full-open temperature 100°C (212°F) s

NOTE Sk
EL:
Valve lift is calculated by finding difference between the .i E:
valve height measured at full-close state and <the valve __ ~_ E::,
height measured at full-open temperature. _ ~~ mszf

04u001~

Em--
-y”
REPLACE ENGINE COOLANT
(1) Set the temperature control lever to the hot position. :. E
(2) Remove the radiator cap.
(3) Loosen the drain plug to drain the engine-coolant. .~ ...i --
(4) Drain the engine coolant-from the reserve tank. Lack: -: 3~
(5) After draining the engine coolant, tighten the drain $ug mT=
s:
securely.
(6) Supply the engine coolantinto the radiator until it:is filled up .‘~ .. ji c’
to its filler neck. L_
(7) Supply the engine coolant into the reserve tat-&. -~- i Ey
JOOOE (8) After warming the engine until the thermos$& op&$ y- .. E
remove the radiator cap arid check the engine coolant level. _ ~_ G+
(9) Supply the engine coolant&to the radiator until it&.fjlledup ?_ _ _i E
to Its tiller neck, and rnstall the radiator cap sqcurely.
(1O)Fill the reserve tank wrth engine coolant up to the “FULL” 7 _
line. Es=

DISC BRAKE PADS (Inspect for wear)

Check for fluid contaminationand wear. Replace complete set ;

A of pads if defective.
Caution
The pads for the right and left wheels should be replaced at

I
4 14K511
the same time. Never “split” or intermix
four pads must be replaced
Thickness
Limit
of lining (A):
2.0 mm (.08 in.)
brake pad sets. All
as a complete set.
-
LUBRICATION AND MAINTENANCE - Maintenance Service O-19
BRAKE HOSES (Check for deterioration or leaks)
NOOSEHA

Inspection of brake hoses and tubing should be included in all

brake service operations.
The hoses should be checked for:
(1) Correct length, severe surface cracking, pulling, scuffing or
worn spots. (If the fabric casing of the hoses is exposed by
cracks or abrasion in the rubber hose cover, the hoses
should be replaced. Eventual deterioration of the hose may
occur, with possible bursting failure.)
(2) Faulty installation, casing twisting or interference with
wheel, tire or chassis.

BRAKE FLUID (Replace) - including the clutch

fluid NOOSSIA

(1) Check the brake and clutch system for leakage before
replacing brake fluid. Completely drain the brake fluid with
the bleeder screws loosened on each system and refill the
brake and clutch system with new brake fluid.
Specified brake fluid: MOPAR Brake Fluid Part Number
2933249 or equivalent
(2) The reservoir cap must be fully tightened to avoid con-
tamination from foreign matter or moisture.
DO NOT ALLOW PETROLEUM BASE FLUID TO CONTAMI-
NATE THE BRAKE FLUID - SEAL DAMAGE WILL RESULT.
Caution
Take care in handling brake fluid as it is harmful to the eyes
and may also cause damage to painted surfaces.

BALL JOINT, STEERING LINKAGE SEALS AND

DRIVE SHAFT BOOTS (Inspect for grease leaks
and damage) . NOOSSJA

(1) These components, which are permanently lubricated at

the factory, do not require periodic lubrication. Damaged
seals and boots should be replaced to prevent leakage or
contamination of the grease.
(2) Inspect the dust cover and boots for proper sealing, leakage
and damage. Replace them if defective.
,

FRONT WHEEL BEARINGS (Inspect for grease

leaks) NOOSSKE

Inspect for evidence of grease leakage around the hub cap and
the back of the hub. If there is leakage of grease, remove the
hub and inspect its oil seal for damage. Clean the grease off the
hub and bearing, and repack with specified new grease.
Specified grease: MOPAR Multi-mileage Lubricant Part
Number 2525035 or equivalent
O-20 LUBRICATION AND MAINTENANCE - Maintenance Service

EXHAUST SYSTEM (CONNECTION PORTION OF

MUFFLER, PIPINGS AND CONVERTER HEAT
SHIELDS) (Check and service as required) NOOSBLA

(1) Check for holes and gas lqaks due to damage, corrosion,
etc.
(2) Check the joints and connections for looseness and gas ._--
leaks.
(3) Check the hanger rubber and brackets fordamsge. -~_ ~2

REAR AXLE
INSPECT OIL LEVEL
Remove the filler plug and inspect the oil level atbottom of filler
hole. If the oil level is at or slightly below the filler hole, it is”rn FT.=
&
satisfactory condition. .~ .--:
CHANGE OIL
Before changing the rear axle oil, check to make~sure that there ..~
is no oil leakage ~from the re%r axle housing. :
-
Remove the drain plug and drain out all of the oily: .-
Put the oil plug back in place, end then pour new oil in through 1
the filler hole. - _
 FRONT -~--
SUSPENSION ~
CONTENTS
FRONT AXLE HUB .. . .. .. . .. . .. . .. . .. .. . . .. .. ..t..... _._..._...... 9 SPECIAL TOOLS 6
...__..___.._..__..__..__.._...__..._..__..__..._.._

FRONT CROSSMEMBER . . .. .._..._..__..__.__..__.I__..__.. 26 SPECIFICATIONS ................................................ 4

General Specifications .................................... 4
GENERAL INFORMATION . .. ..._.._..__.._.._ _..___.__.__ 2
Lubricants ................................. .__.._._ ... .._............. 5
Adjustable Shock Absorber . .. ._._..__..._.._..___.. . ._ 3
Service Specifications ............... ...” ................. 4
LOWER ARM AND KNUCKLE ARM _...__._...__.._ 20 Torque Specifications ........................................ 5

SERVICE ADJUSTMENT PROCEDURES ..,..._. 7 STABILIZER BAR AND STRUT BAR . .. . .. .. .. . .. .. . 24

Front Wheel Alignment . .. .. . . .. . .. .. . ..._._.._..__._ . .._.. 7
STRUT ASSEMBLY .._..._.._,__..__.
___..._..__..._..._..._... 13
Wheel Bearing Adjustment . . .. ...I.................... 7
 FRONT SUSPENSION - General Information

NOlBAAB

The front suspension is McPherson strut type independent suspension that is simple in constru_ction and light .-->
in unsprung weight.
The tar, end of the strut is supgorted in the wheel house via an insulator and the bottom end is suppe_rted by
the lo&er arm via knuckle aim and ball joint.

Strut assembly

12Y732
Lower am,
Front hub
 i

FRONT SUSPENSION - General Information 2-3

ADJUSTABLE SHOCK ABSORBER (8 LEVELS) NOZBCAA

The adjustable shock absorber can have its damping force adjusted manually to any of eight levels according
to the road surface condition and driving condition. Rotary valve 1 gives the lowest (softest) damping force
and 2, 3, 4, 5, 6, 7 and 8 give increasingly higher (harder) damping force, thus allowing adjustment of the
shock absorber damping force according to the driving condition.

CONSTRUCTION AND FUNCTION

The rotary valve has eight orifices “E” (El to E8) of different
sizes that give different levels of resistance to fluid flow. By
changing the orifices, therefore, the damping force of the
Rotary valve setting shock absorber can be changed.

OPERATION (FLUID FLOW WHEN EXTENDED)

The fluid in chamber B is pressurized and flows to chamber D.
In chamber D, a damping force develops as the fluid flows
through variable orifice E, and this force adds to the damping
force that is generated as the fluid flows to chamber A.
Therefore, by changing the size of orifice E, the damping force
can be changed.

OPERATION (FLUID FLOW WHEN CONTRACTED)

Fluid in chamber A is pressurized and flows to chamber B; the
amount of fluid corresponding to the volume displaced by the
piston rod flows to chamber C. As the base valve is closed, this
same volume flows to chamber D, flowing through variable
orifice E and thus changing the damping force in the same way
as when the shock absorber extended.
Handling Precautions
l Set both right and left damping forces at the same level.
Setting them at different levels adversely affects steering
stability.
l If set midway between numbers, the damper operates at
the hardest level (8).
2-4 FRONT SUSPENSION - Specifications

SPECIFICATIONS NOZCA-

GENERAL SPECIFICATIONS

Suspensron system McPherson strut type

Co11spring
Wire dia. x O.D. x free length 12.8x 142.8x346 12.5 x 142.8 x 327
(.50 x 5.62 x 13.62) (.49x5.62x12.871
Shock absorber
Type Hydraulic, cylindrical, Gas damper type
double-acting type (Adjustable shock absorber)
Max. length mm (in.)
Stroke mm (In.1
Stabrlizer bar
Outside diameter mm (in.)
Front axle hub bearing
Type Taper roller bearing Taper roller bearing
Dimension_sXJ.D_. x I.D.1
Inner

SERVICE SPECIFICATIONS NOZCB- .

Items
-~_ ..-_ ._ i-
Standard value
Toe-in mmljn,)
Recommended setting 0
Acceptable range 5 (.2) toe-in to 5 (.2) toe-out
Camber -0”30’ k 30’ _
Difference between left and right wheels/within .-30’
Caster 5”50’ + 30’ -
Difference between left and right wheels~;within~30
Protruding length of stabilizer bar installation bolt mm (in.) 15-17(.5Ef- .6-T)
Ball joint starting torque Ncm (in.lbs.1 500 - 800 (43 - 69)
Limit
Piston rod O.D. mm (In.) 21.95 t.8642) _~ -~~
 FRONT SUSPENSION - SDecifications 2-5
TORQUE SPECIFICATIONS NOZCC- -
Items Nm ft.lbs.
Tie rod end to knuckle arm 35-45 25-33
Disk cover to strut assembly 8-12 6-9
Strut assembly to brake assembly 80- 100 58-72
Engine mount bracket to crossmember 30-40 22-29
Strut insulator to body 25-35 18-25
Shock absorber ring nut 140- 150 101-108
Strut top end nut 60-70 43-51
Strut bar bracket to frame 35-45 25-33
Stabilizer bar bracket 8-12 6-9
Stabilizer bar to lower control arm IO-20 7-i4
Strut bar to strut bar bracket 75-85 54-61
Strut bar to lower control arm 60-70 43-51
Lower arm shaft (bolt) 80-95 58-69
Knuckle arm to ball joint 60-72 43-52
Knuckle arm to McPherson strut assembly 80- 100 58-72
Lower arm to ball joint 60-70 43 -‘5 1
Crossmember to body 60-80 43-58

LUBRICANTS NOZCD- -

Items Specified lubricant Quantity

Front hub and ball joint MOPAR Multi-mileage Lubricant As required

Part No. 2525035 or equivalent
Front hub inner bearing MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Front hub outer bearing MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Oil seal lip MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Strut insulator MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Shock absorber fluid Repair kit fluid 440 cc (26.85 cu.in.)
2-6 FRONT SUSPENSION - Special Tools

SPECIAL TOOLS NOZDA- -

prong compressor

over and installer

Support ring Preload socket

(CT1 46) (MB9903261

FRONT SUSPENSION - Service Adjustment Procedures 2-7
SERVICE ADJUSTMENT PiiOtEDURES
NOZFCAC

WHEEL BEARING ,ADJUSTMENT

(1) Inspect the play of the bearings while the vehicle is jacked
up and resting on jack stands.
(2) If there is any play, remove the hub cap, cotter pin, and lock
cap, and then loosen the nut.
(3) Tighten the nut by the following procedure.

Tighten to 20 Nm (14 ftlbs.)

J;

Retighten to 5 Nm (4 ft.lbs.)

(4) Install the lock cap and cotter pin. If the position of the
cotter pin is not matched with the holes of the lock cap,
reposition the lock cap so that the holes align. If this cannot
be accomplished, back off the nut by not more than 15’,
align lock cap and install cotter pin.

FRONT WHEEL ALIGNMENT NOZFBAGa

NOTE
The front suspension assembly must be free of worn, loose or
damaged parts prior to measurement of front wheel alignment.
CAMBER
Camber is pre-set at the factory and cannot be adjusted,
NOTE
If camber is not within specifications, replace bent or damaged
parts.
Standard value: -0”30’ IL 30’
Difference between left and right wheels shall be
within 30’
CASTER
Caster, as a rule, requires no adjustment, although it is slightly
adjustable by means of the threaded end of the strut bar.
Standard value: 5”50’ t 30’
Difference between left and right wheels shall be
within 30’
2-8 FRONT SUSPENSION - Service Adjustment Procedures

TOE-IN
If the toe-in is not within~the standard value, make adjvstment
of the toe-in by using the turnbuckle of the left tie rqd. Toe$
increases when the turnbuckle is turned in the direction of the
arrow in the illustration. The difference in the length between
right and left tie rods should not exceed 5 mm (.2 i6T). If the
difference exceeds 5 mm (.2 iri:), remove the right tie food from
the knuckle and adjust its length so that the difference% within
5 mm (.2 in.).
Then make adjustment of toe%. Toe-in changes by about 15
mm (.59 in.) when the turnbuckle of the left tie r0d.j.s turn?d
once.
Standard value:
Recommended setting 0 mm (0 in.)
Acceptable range
5 mm (2 in.) toe-in - 5 mm (2 in.) toe-out
 FRONT SUSPENSION - Front Axle Hub 2-9
FRONT AXLE HUB NOZKA- -

REMOVAL AND INSTALLATION

58-72 ftlbs.

Removal steps
4* 1. Front brake assembly 12Y729
2. Hubcap
3. Cotter pin
l C. 4. Lockcap
I)4 Adjustment of wheel bearing NOTE
5. Nut (1) Reverse the removal procedures to reinstall.
6. Washer (2) l *: Refer to “Service ‘Points of Removal”.
7. Outer bearing (3) I)+: Refer to “Service Points of Installation”.
8. Front axle hub assembly (4) q : Non-reusable parts

SERVICE POINT OF REMOVAL NOZKBAB

1. REMOVAL OF FRONT BRAKE ASSEMBLY

Remove the front brake assembly with the brake hose
connected.
NOTE
To prevent the brake hose from being twisted, suspend the
brake assembly with wires.
Z-10 FRONT SUSPENSION - Front Axle Hub w
f&I;;.
INSPECTION NOZKCAB z=
B&L ;
l Check the 911 seals for crack and damage. :
@ Check the beannss tor seizure, dtscolouratt~on and .__ .z-’
==.i
roughened racewav surtace. -e -i
e Check th.e front axle hub tor cracks.

SERViCE POINTS OF INSTALLATION NOZKDAC

l ADJUSTMENT OF WHEEL BEARING

Tighten the nut by the following procedure.

(1) Tighten to 20 Nrn- (14 ft.1b.s.)

I

I
(2) Loosen to 0 Nm-m(0 ft.lbs.1

(3)I--- Retighten to 5 Nr% (4 ft.lbs.)

4. INSTALLATION OF LOCK CAP

Install the lock-cap and cotter pin. If the posltlon ot the
ccjtter prn IS rrot matched wrth the holes ot the lock cap,
reposItron the lock cap so that the holes align. It this cannot
be accomplished, back otf the nut not more tha.n 15”. Align
lock cap and Install cotter pin.
 FRONT SUSPENSION - Front Axle Hub

DISASSEMBLY AND REASSEMBLY N02HA..

06
/ : s

12Y728

Disassembly steps
1. Snap ring
2. Hub bolts
*I) 3. Brake disc
4. Front axle hub NOTE
5. Outer bearing inner race (I 1 Reverse the disassembly procedures to reassemble..
l 4 6. Oil seal (2) 4*: Refer to “Service Points of Disassembly”.
7. Inner bearing (3) **: Refer to “Service Points of Reassembly”.
(4) q : Non-reusable parts
8. Inner bearing inner race

SERVICE POINT OF DISASSEMBLY NOZHBAS

3. REMOVAL OF BRAKE DISC

Make the mating marks on the brake disc and front hub,
and then separate the front axle hub and brake disc, if
necessary.

luter bearing Inner bearing REPLACEMENT OF BEARING NOZHOAE

(1) Remove the oil seal and inner bearing.

(2) Drive out the bearing outer races by tapping them uniform-
ly.
 FRONT SUSPENSION - Front Axle Hub

3uter bearing Inner bearing (3) Press-fit the bearing outer races with the spectal tools.
(4) Properly pack the bearing with specified grease and install _
n
into hub.

dfL
,c-4171
Specified grease: MOPAR Multi-mileage Lubricant Part
, L-4446 No. 2525035 or equivalent
NOTE
+ The bearing and outer race must be replaced as an ~1~
;,
assembly.

F125i.

SERVICE POINT OF REASSEMBLY NOZHEAE

6. INSTALLATION OF OIL SEAL

(I) Apply the specified grease to the oil seal lip and insrde
surface of_ the front axle hub.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
(2) Apply the specified grease to the inner- bearim int--er _
race and install the inner race into the front axle hub. _p
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
(3) Press-fit the new oil seal Into the front axle hub-by usrng
the special tools, unttl It IS Hush with the tront.axle hub .-.I
end face.
 FRONT SUSPENSION - Strut Assembly 2-13

STRUT ASSEMBLY NOPLA- -

REMOVAL AND INSTALLATION

25-35 Nm
18-25 ft.lbs.

8-12 Nm
6-9 ft.lbs.

80-I 00 Nm
58-72 ft.lbs.

Removal steps
l + ’ 1. Brake plate
*+ 2. Front brake assembly
3.. Hubcap
4. Cotter pin
5. Lockcap NOTE
6. Nut (I) Reverse the removal procedures to reinstall.
7. Washer (2) C+: Refer to “Service Points of Remyl”.
8. Froht axle hub assembly (3) I)*: Refer to “Service Points of Installation”.
9. Dust cover (4) q : Non-reusable parts
*C 10. Strut’assembly
2-14 FRONT SUSPENSION - Strut Assembly

SERVICE POINTS OF REMOVAL

1. REMOVAL OF BRAKE PLATE / 2. FRONT BRAKE s:
B’
ASSEMBLY
m i
Remove the brake plate from the strut and then remove VS _ :Z
brake attaching bolts. Raisethe brake assembly and hold-it sm
in ralsed positjon using wires, etc. M
Caution
Do not pull or kink the brake hose firmly. W&:

14Y76E
m
SERVICE POINT OF INSTALLATION N02LDAD

10. INSTALLATION OF STRUT ASSEMBLY

When the knuckle arm is installed to the strut, apply
semi-drying sealant to the flange of the knuckle. arm.. .=_ .~_=

12Y67:
 FRONT SUSPENSION - Strut Assemblv 2-15
DISASSEMBLY AND REASSEMBLY NOILE- -

Hydraulic type Gas damper type

(Adjustable shock absorber)
60-70 Nm
140-150 Nm 43-51 ft.lbs.
101-108 ft.lbs.

60-70 Nm
G------l
43-51 fi.1bs.v 2m
m

8
6

12Y723
121735

Disasseinbly steps Reassembly steps

1. Insulator cap I)+ 14. Outer shell
(I* 2. Top end nut (Self-locking nut) I)*’13. Cylinder
3. Insulator I)+ 1.1. Piston
4. Spring seat I)+ 12. Piston guide
5. Rubber helper *C IO. Square section O-ring
6. Dust cover l * 9. Oil seal assembly
7. Coil spring 8. Strut assembly
8. Strut assembly 7. Coil spring
4* 9. Oil seal assembly 6. Dust cover
4* 10. Square section O-ring ,** 5. Rubber helper
4* 11. Piston I)* 4. Spring seat
12. Piston guide *C 3. Insulator
13. Cylinder 2. Top end nut (Self-locking nut)
14. Outer shell 1. Insulator cap

NOTE
(1) +*: Refer to “Service Points of Disassembly”.
(2) I)*: Refer to “Service Points of Reassembly”.
(3) q : Non-reusable parts
 -

Z-16 FRONT SUSPENSION - Strut Assembly

SERVICE POINTS OF DISASSEMBLY NOZLFAH

2. REMOVAL OF TOP END NUT

(1) Compress -the coil spring with the special tool.
(2) Remove the insulatorzap from the insulator: -‘I

Y1262t

(3) Using power tool, remove the top end nut.

Y12627(

9. REMOVAL OF OIL SEAL-ASSEMBLY

(1) To prevent entry of foreign material into the cylinder, ~ ~F:eE
shock absorber fluid, etc. during disassembly, thorough-
ly clean the external surface. of the strut before, =ri, _ -id
disassembly.
(2) Lightly hold the strut upright in a vice, hanging down the
piston rod to the bottom. ~=e-~.
NOTE _~~ -
When securing the strut in the vice, close the. vice on i
the knuckle part, not -the outer shell.
Y 12035 (3)~ Remove the oil seal assembly. . ~r.z Lo-
IO. REMOVAL OF SQUARE SECTION O-RING
Remove the square section O-ring;

11. REMOVAL OF PISTON

(1) Slowly withdraw the piston rod from~ the.. cylinder
together with the piston guide.
Caution
Because the piston rod has a highly precise surface,
handle it carefully.
(2) Drain the shock absorber fluid.
(3) Remove the piston guide from the piston rod. ~.
(4) Remove the cylinder from the strut outer shell,.
 FRONT SUSPENSION - Strut Assembly 2-17
NOTE
The gas damper type shock absorber (adjustable shock
absorber) cannot be disassembled. When replacement is
necessary, replace the strut assembly.

INSPECTION NOZLGAC

l Check that the piston outer diameter has not been reduced
to specified limit.
Limit: 21.95 mm (.8642 in.)
+ 12Y711
NOTE
Measure at six points illustrated.
If the value is below the limit at any of these points, replace
the shock absorber assembly.
l Check the insulator for wear, crack and peeling.
F12030 l Check the rubber helper, dust cover and rubber helper seat
for crack and damage.
l Check the coil springs for crack, damage and weakness.

SERVICE POINTS OF REASSEMBLY NOZLHAI

14. INSTALLATION OF OUTER SHELL / 13. CYLINDER / 11.

PISTON
(1) Install the cylinder and piston assembly into the strut
outer shell.

(2) Gradually pour specified shock absorber fluid into the

cylinder while slowly moving the piston up and down.
NOTE
The above quantities are the capacities when the
cylinder, piston and outer shell are completely dry. Be
sure to take the amount of fluid adhering to the walls
into consideration.
Specified fluid: Repair kit fluid
440 cc (26.85 cub.)
 FRONT SUSPENSION - Strut Assembly
ET

12. INSTALLATION OF PISTON GUIDE m-F?

With the flange of the piston guide facing upward, insert .- B-
the piston guide to the piston rod until it con&ts the i- z e.
.y:-
cylinder end.
--~
-
a--
K&r
I
#ma;
UT
-~
n
Ed
F1256t

IO. INSTALLATION OF SQUARE SECTION O-RING ~-- -. Zrmm

Install the new square section O-ring to the pisto_? guide. r
NOTE
When the O-ring is set on the periphery of the piston guide,
press the O-ring down evenly, taking care to prevent =
~- .~
inclination and doubling.

Egz
Y12581 --
sr
.._
9. INSTALLATION OF OIL SEAL ASSEMBLY
(1) Attach the cover to the piston rod end.
(2) Apply shock absorber fluid to the cover and ins_t_allth&oil zI
seal assemblv.

(3) Tighten the 011 seal assembly until its edge contacts the _:I Em
strut outer cylinder. -

12YO3!

5. APPLICATION OF ADHESIVE ~0 RUBBER HELPER z “’

Bond the spring seat to the rubber helper with a drying F==
adhesive.

l?Y67!
FRONT SUSPENSION - Strut Assemblv z-19
4. INSTALLATION OF SPRING SEAT
Align the D-shaped hole in the spring seat with the fiat on
the piston rod. Align the projections on the dust cover with
the holes in the spring seat.

3. APPLICATION OF GREASE TO INSULATOR

Pack the specified grease in the strut insulator and install
the cap.
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent
NOTE
Do not apply grease to the rubber parts.
 FRONT SUSPENSION - Lower Arm and Knuckle Arm

LOWER ARM AND KNUCKLE ARM NOZNA-

REMOVAL AND INSTALLATION

1 O-20 Nm
7-14ft.lbs.

35-45 Nm
25-33 ft.lbs. -

60-72 Nn

\ ’
I -J
‘* 80-g; Nm \
-2- ” 7, r
58-69 ft.ibs.

60-70 Nm
43-51 ft.lbs.

60-70 Nm
Removal steps 43-51 ft.Ibs. 12Y725

1. Cotter pin
*I) 2. Tie rod end assembly connection
I)+ 3. Strut assembly connection -

4. Strut bar connection

+4 5. Stabilizer bar mounting nut (Self-locking nut)
6. Stabilizer bar connection NOTE
N 7. Lower arm (I) Reverse the removal procedures ta reinstall: - q
8. Self locking nut (2) +*: Refer to “Service Points of Removal”.
+* 9. Knuckle arm (3) l +: Refer to “Service PoinfsDf Installation”.
10. Ball joint (4) I[ifl: Non-reusable parts
11. Lower arm shaft bushing (5) *: Must be tightened while vehicle iS unladen.
 FRONT SUSPENSION - Lower Arm and Knuckle Arm 2-21
SERVICE POINTS OF REMOVAL NOPNBAE

2. DISCONNECTION OF ROD END ASSEMBLY

Disconnect the tie rod end assembly from the knuckle arm
using the special tool.

7. REMOVAL OF LOWER ARM

Remove the idler arm attaching bolts, -slide the steering
linkage backward and remove the lower arm shaft (bolts).
Then, remove the lower arm.

12Y734

MB991113 9. REMOVAL OF KNUCKLE ARM

Remove the knuckle arm .from the lower arm ball joint by
using the. special tool.

INSPECTION NOPNCAC

l Check the bushing for wear.

l Check the lower arm for bend or breakage.
l Check the ball joint dust cover for cracks.
l Check all bolts for condition and straightness.

CHECKING OF BALL JOINT STARTING TORQUE

Measure the starting torque of the ball joint.
Standard value: 500 - 800 Ncm (43 - 69 in.lbs.)
NOTE
If ball joint starting torque exceeds the upper limit of standard
value, replace the ball joint.
Even if ball joint starting torque is below the lower limit of
standard value, the ball joint may be reused unless it has
excessive play or a drag is felt.
I Y12062
 FRONT SUSPENSION - Lower Arm and Knuckle Arm

BALL JOINT DUST COVER REPLACEMENT NOZNEAC

(1) Remove the dust cover. ~

(2) Apply semi-drying sealant to the metal ring part of the new
dust cover.
(3) Drive in the dust cover with the special tooiuntil i;t is fully
seated.

13Ytw7

(4) Exchange the ball joint plug with a grease nipple.

(5) Shape the dust cover to dimensions shown and pack with
specified grease until it takes the form as- indicated by
Grease broken line. -1L
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent
(6) Apply semi-drying sealant to plug and reinstall plug.
Cap

12Y72>

LOWER ARM BUSHING REPLACEMENT NOZNDAB

Caution
Do not remove the lower arm bushing unless absolutely
necessary.
(1) Press out the lower arm bushing with the special tool.

Y12564

(2) Press-fit the neti~lower arm bushing with the special tool
until it is fully seated in the lower arm.

Mb90799
Y12565
FRONT SUSPENSION - Lower Arm and Knuckle Arm 2-23
SERVICE POINTS OF INSTALLATION NOPNFAF

5. INSTALLATION OF STABILIZER BAR MOUNTING NUT

Tighten the nut on the stabilizer bar bolt to the specified
distance.
Standard value: 15 - 17 mm (.59 - .67 in.)

12Y67;

3. INSTALLATION OF STRUT ASSEMBLY

When the knuckle arm is installed to the strut, apply
semi-drying sealant to the flange of the knuckle arm.

12Y673
 : ”

pH_-pe_ ~-- -~~ ~~--

2-24 FRONT SUSPENSION - Stabilizer Bar and Strut Bar

STABILIZER BAR AND STRUT BAR NOZTA- .

REMOVAL AND INSTALLATION

Pre-removal Operation
l Removal of Under Cover

stallation Operation
llation of Under Cover n-1-w lLlLJ5.
l .InsPection and Adjustment of Wheel Alignment
(Refer to P.2-7.)

* 75-65 Nm
54-61 ft.lbs.
2533 ft.lbs.

2
60-70 Nm
43-51 ft.lbs.

Strut bar removal steps

*+ 1. Strut bar
2. Bushing
3. Strut bar bracket
Stabilizer bar removal steps NOTE
(I ) Reverse the~removel procedures to reinstall.
4. Lower fixture (2) *+: Refer to “Service Points of Installation”
5. Upper fixture (3) q : Non-reusable parts
I)+ 6. Stabilizer bar mounting nut (Self-locking nut) (4) *: Must be tightened while vehicle is unladen.
7. Stabilizer bar
12~668

INSPECTION NOZTCAB

* Check the stabilizer bar for deformation or weakness. __

* Check the rubber bushing for cracks and damage. :
e Check the strut bar for cracks or bend.
@ Check the strut bar bracket for deformation ordamage.. :
@ Check the bushing for cracks~~or damage.
 FRONT SUSPENSION - Stabilizer Bar and Strut Bar 2-25
SERVICE POINTS OF INSTALLATION NOZTDAD

6. INSTALLATION OF STABILIZER BAR MOUNTING NUT

Tighten the nut on the stabilizer bar bolt to the specified
distance.
Standard value: 15 - 17 mm (.59 - .67 in.)

12Y672

1. INSTALLATION OF STRUT BAR

Identification mark
Left side - “L” or white mark (1) When installing the strut bar, verify the identification
Right side - “d” or no mark mark stamped on it.

F1254(

(2) Tighten the nut on the strut bar so that the distance
between the end of the strut bar and the front surface
of the lock nut has the dimension shown in the
illustration.

12Y68E

(3) The front and rear strut bar bushings are different in
shape. Install them as shown in the illustration.
(4) The top end nut should be torqued with the vehicle
lowered to the ground and unloaded. After installing the
strut bars, measure the caster.

12Y66
2-26 FRONT SUSPENSION - Front Crossmember

FRONT CROSSMEMBER
REMOVAL AND INSTALLATION

1 O-20 Nm
7-14 ftlbs.
/

3040 Nm
/ 22-29 ft.lbs.

12Y726

Removal steps
1. Cotter pin
+I) 2, Tie rod end assembty connection
3. Strut bar connectron
l + 4. Stabilizer bar mounting nut (Self-locking nut)
5. Stabilizer bar connection NOTE
+* 6. Lower arm connection (i 1 Reverse the removal procedures to reinstall.
+I) 7. Front crossmember mounting nuts (Self- (2) ++: Refer to “Service Points of Removal”.
locking nut) (3) *+: Refer tb “Service Points of Installation”.
8. Bolt assembly (4) 8: Non-reusable parts
9. Front crossmember (5) *: Must be tightened while vehicle is unladen.
 FRONT SUSPENSION - Front Crossmember 2-27
SERVICE POINTS OF INSTALLATION NOZYBAB

2. DISCONNECTION OF TIE ROD END ASSEMBLY

Disconnect the tie rod end assembly from the knuckle arm
using the special tool.

6. DISCONNECTION OFT LOWER ARM

(I) Remove the idler arm attaching bolts, slide the steering
linkage backward and remove the lower arm shaft
(bolts).
(2) Remove the lower arm from the front crossmember.

7. REMOVAL OF FRONT CROSSMEMBER MOUNTING

NUT
(1) Support the engine to such a degree that the engine
load does not act on the engine mounting.
(2) Remove the engine mounting-to-front crossmember
attaching bolts.
(3) Remove the front crossmember mounting nuts.

INSPECTION NOZYCAB

l Check the crossmember for cracks or damage.

l Check the crossmember for dimension.

mti (in.) 12Y67E

SERVICE POINT OF INSTALLATION NOZYEAB

4. INSTALLATION OF STABILIZER BAR MOUNTING NUT

Tighten the nut on the stabilizer bar bolt to the specified
distance.
Standard value: 15 - 17 mm (.59 - .67 in.1

12Y672
 REAR AXLE
CONTENTS
AXLE SHAFT .._..__.__.
__.__._ _.._..__.__..__.18
__.._..._.__.__._..___. TROUBLESHOOTING . .. ..__.I_.._..t_.._.............~.... _. 13
Axle Shaft, Axle Housing
DIFFERENTIAL CARRIER . . ..._._____.._.__.___..____.__..__.
33
Grease Leakage
DRIVE SHAFT . . . .. . .. ...t_..._._.._..._..._.__.._
__.____.
__.___._..__23 Noise While Wheels are Rotating
Differential
GENERAL INFORMATION . . .. . .. . .. .._.._.._.._.._.._.._. 2
Abnormal Noise During Driving or Gear
SERVICE ADJUSTMENT PROCEDURES . .. . ..__ 15 Changing
Checking Axle Shaft for Axial Play . .. .. .. .._.._... 15 Abnormal Noise When Cornering
Checking Gear Oil Level . . ..._.__._......_.__._... __.__._.__ 15 Breakdown
Checking Rear Axle Total Backlash ......_.t_..._.. 15 Gear Noise
Differential Carrier Oil Seal Replacement _._. 16 Gear Oil Leakage
Limited Slip Differential Preload Seizure
Measurement .._.._..._..._._. .._.._.._..._.._.._..._.t_......_.. 16 The Limited Slip Differential Does Not
Function (On Snow, Mud, Ice, etc.)
SPECIAL TOOLS . .. .._._._....__.__.___
_._.__._.____.__
_.._t....... _ 11 Drive Shaft
SPECIFICATIONS .. ..__........_.___.._._.. __._..,_..__.__.,..__ _ 8 Noise
General Specifications . . . .. . .. .. .. . .. . ..__.._............. 8 Torque Tube
Lubricants ..______....
______.._..__....._.._.....t_......_.__.._,.._.. IO Noise
Sealants and Adhesives . .. . .._..._.._._......._.._..__...._ 10
Service Specifications . .. . .. .. . .. . .. . .. . . .. .. .. . . .. . .. .. . . 9
Torque Specifications . . .._.._............_.....__.._.._..__.. 9

TORQUE TUBE . . .. .._..................................._......... 28

3-2 REAR AXLE - General Information

GENERAL INFORMATION NOBBAAF

The rear axle consists of torque tube, differential, drive shaft, axle housing and axle shaft.
The differential is of a limited slip type.

Torque tube
 REAR AXLE - General information 3-3
LIMITED SLIP DIFFERENTIAL NOBBBAA

A limited slip differential is an anti-slipping device which functions as a differential during cornering to allow
the outer wheel to turn at a faster speed than the inner wheel. In the event that one wheel begins spinning
(driving on slippery road surfaces, one wheel leaves the road surface. etc.), it automatically functions to
prevent such spinning.
CONSTRUCTION AND FUNCTION
With a conventional differential, in the event that one wheel of the vehicle is on ice, mud, or some other
slippery surface, the wheel will spin and the drive force of the vehicle will be greatly reduced. If this happens,
the speeds of the differential case and of the side gear (axle shaft) are different because of differential
operation. The limited slip function acts to limit this differential operation. The construction is shown in the
illustration. The multi-plate clutches engage with the differential case and with each of the side gears. If
spinning causes a difference in component speeds, the frictional force between the clutch plates will cause
the speed of the side gear to become closer to that of the differential case, and thus the limited slip function
will control the spinning. In addition, the purpose of the pressure rings inside the differential case is to the
driving force to the pinion gear, and the reason for the separation is to provide an increase in the clutch plate
pressing force through the leverage of the pinion shaft.

Pinion shaft

Pinion shaft
Drive gear \
Differential case (B)

plate

_,,._,
nifff - .._.-. ,. , (B)
11S675

Friction disc Friction plate

I 11 S653
 REAR AXLE - General Information

OPERATION (TORQUE TRANSMISSION) DURING STRAIGHT DRIVING

When the differential case is turned the drive pinion vra the drive gear, the pressure rings which are :
interlocked with the differential case will also turn at the same -speed. [The projections located on the outs@e i.I
of the pressure rings engage (with some play) the grooves located on the inside of the differentral case]. _ -
When the pressure rings move in the direction or rotatron, they contact the tapered portion of the pin?on shaft,’ ES.
and thereby receive reaction force in both the lateral direction and the direct@n of rotation. The reaction focce A&
in the lateral direction presses the clutch plates together, and marntarns straight driving. During su$ driving,
because the road surface gives.equal resistance to both the left and right wheels, equal resistances@ applied --
to the left and right side gears. Therefore, the pinion gear does not revolve, and the drive gear, the 6fferentiaf 1
case, the pinion shaft, the pinion gear, and the left and right side~gear-s all turn as one unit.- =yF

Pinion 100%
shaft
Input tot-clue
Left pressure ring Right pressure ring
-~~=-

Direction of rotation
of the pressure ring I“I (IIt:
Fjytion
p,
of rotation
^ . . . ..^^^.,“,. A..-
t2zJ>L Ilt: 1 !, ry
during straight driving during straigl 7t dl 9vir

I
Reaction force symbol code
P= Pressing force of the press ilre rings
on the clutch plates
F= Pressing force of the press1 xe rings
on the pinton shaft
N= Resultant, force of P +F
 REAR AXLE - General Information 3-5
OPERATION (TORQUE TRANSMISSION) WHEN THE SPEEDS OF THE LEFT AND RIGHT WHEELS ARE
DIFFERENT
When one wheel is in contact with a concrete road surface (which has high coefficient of fridtio?) and the
other wheel is in contact with a muddy or other slippery road surface (which has low coefficient of friction),
the differential operation will cause the speed of the wheel in contact with the slippery surface to be faster
than the speed of the drive gear, lowering the maximum drive force. If this occurs, the limited slip function will
control the differential operation and increase the driving force,
The transmission of torque through the limited slip device in this event is as follows:
When the differential case is turned by the drive gear and the drive pinion, the pressure rings which are
interlocked with the differential case will turn at the same speed. Also, the difference in the road surface
resistances will cause differential operation and the left and right side gears will revolve at speeds different
from that of the differential case. Because of the friction produced between the clutch plates in mesh with
both the side gear and differential case, one of the pressure rings increases its rotating speed, whereas the
other reduce5 its rotating speed. The pressure rings press the tapered portion of the pinion shaft with which
they are in contact, and thereby receive reaction force in both the lateral direction and the direction of rotation.
The reaction force in the lateral direction causes the clutch plates to mesh, increasing the frictional and the
drive force.

Left pressure ring Right pressure ring

Direction of ring
frictional force
1 Direction of
pressure ring
frictional force
(decelerating (accelerating
direction) direction)

J
Low-speed side High-speed side
llF109 50+15=65% 50-15=35%

Opposing force symbol code

P, P’ = Pressing force of the pressure rings
on the clutch plates
F, F’ = Pressing force of the pressure rings
on the pinion shaft
N, N’.= Resultant force of P + F and P’ + F’
llW511
3-6 REAR AXLE - General Information

FEATURES OF THE LIMITED SLIP DIFFERENTIAL

(I) When one wheel of the vehicle IS in contxt with a road
surface which has poor tractron, the limited slip different%
in comparrson to a cor-rventronai differential, supplies
additional torque to the wheel which has the betters traction
conditrons by utilizing clutch plates, thus i~mproving the
tractron capacity. Moreover, the effect of the limited sIip
differential is to prevent the vehicle trom becoming stuck,
even if the traction of one uf the wheels becomegradica!ly
reduced. ~~
(2) When one wheel moves -from a road surface which has
poor traction onto one which has good tractron, or when the
wheels are constantly leaving the road .surfaGwhile driving
on a rough, bumpy road, the clutch plates of the limited sjip
differential allow the torque to absorb the differences
between the revolutron speeds of the right and left wheels.
In addition, the sudden changes (jolting) in the drive force
are also absorbed, thus preventing skrddrng.
(3) Because in the limtted slip differential, the differential
operation is slightly restricted during normal cornering, the
understeer tendency (the tendency for the cornering of the
vehicle to exceed the turnrng of the steenng wheel)
becomes greater, however, this does not have .my c&t:
rimental effect on the driving of the vehicle. Moreover, in
the event that the Inside wheel lifts up (the tire leaves the
road surface) during high speed cornering, the clutch plates
function to limit differential operation which would simul-
taneously decrease the drive force of the outside wheel;
therefore, the Irmrted slip drfferentral moderates sudden
speed reductions during vehicle cornering, and thereby
provides greater cornering capability than a conventional
differential.
 REAR AXLE - General Information 3-7
MAKING EFFECTIVE USE OF A LIMITED SLIP DIFFEREN-
TIAL
Total drive torque Effective Use in Combination with the Brakes
I(1 +1)x2-I]+[(1 +I)-I]=4 If a wheel is in contact with a slippery road surface and has
begun to spin, using the brakes in combination with the limited
slip differential will provide even greater traction capability. The
resistance caused by the brakes will further increase the drive
torque of the engine, and this increased torque will increase the
clutch plate pressing force of the pressure ring, thus increasing
the traction. also, the drive force transmitted to the brakes will
not function as real drive force. This is shown in the illustration
at right. The application rate is Rt = 2, and, supposing the
= 2 ..::::::::::::. torque from the brake operation is 1, a drive torque of 1 + 1 = 2
will be applied to the spinning wheel (the right wheel), and a
(1 +1)x2-11 I(1 + I)-11 drive torque of twice that which is applied to the spinning
*2 *I “2 Cl wheel, or (1 -I- 1) x 2 = 4, will be applied to the wheel which is
not spinning (the left wheel). However, because the brake
force of 1 is a negative value with regard to the propulsion
“I. Negative torque from the brake operation torque of each wheel, the propulsion torque actually obtained
*2. Supposing that the braking torque for both
wheels is 1. by the right wheel is (1 + 1) - 1 = 1, and that obtained by the
left wheel is [(I + I) x 2 - I] = 3.
IlFlOC
Therefore, the total drive torque is 1 + 3 = 4. In the same
circumstances, the total drive torque of a conventional differen-
tial is 1 + 1 = 2, and that of a limited slip differential when the
brakes are not used in combinadon is 1 + 2 = 3. This
represents an increase in the traction by a factor of 2 over that
of a conventional differential, and by a factor of 1.3 over that of
a limited slip differential when the brakes are not used.
NOTES REGARDING SERVICE PROCEDURES FOR THE
LIMITED SLIP DIFFERENTIAL
_ (1) The engine must never be operated while only a single
wheel is jacked up. Doing so is extremely dangerous; if the
differential functions while the engine is operated at high
speed, the oil film between the clutch plates will decrease,
thus causing the friction coefficient to increase, the
prescribed torque ratio will be exceeded, an excessive
amount of torque will be applied to the stationary wheel,
and the vehicle will move forward. Also, resistance must
never be applied to the spinning wheel.
(2) In the event that one of the wheels comes in contact with a
slippery road surface and begins to spin, if the engine
continues to be operated at high speed for too long, the
clutch plates might become abnormally worn; such action
must be avoided.
(3) As gear oil, use MOPAR Hypoid Gear Lubricant (part
number 4318058) to which MOPAR Hypoid Gear Oil
Additive/Friction Modifier (part number 4318060) has been
added. When changing the oil, the oil which is removed will
appear considerably blacker than ordinary oil. This, howev-
er, is not a change in color due to the deterioration of the oil,
but rather the oil has become mixed with worn particles of
the special treatment on the clutch plates.
3-8 REAR AXLE - Specifications

SPECIFICATIONS N03CA-- _

GENERAL SPECIFICATIONS

Axle shaft
Type Semi-floating type
Shaft dimension
Outer bearing portion dia. mm (in.)
Inner bearing portion dia. mm (in.)
Center portion dia. mm (in.)
Overall length mm (in.)
Bearing
72 x 35 (2.83 x 1.38)

Joint type inner Double offset joint ~

Outer

Reduction gear type

Reduction ratio
Differential lock type Disc type mm
Differential gear type and configuration
Side gear Straight bevel gear x 2
Pinion gear Straight bevel gear x 4
Number of teeth
Drive gear
Drive pinion
Side gear
 REAR AXLE - Smcifications
SERVICE SPECIFICATIONS NOBCE- _

Items Specifications
Standard value
Limited slip differential axle shaft turning 39 (28) or more
torque Nm (ft.lbs.)
Setting of D.O.J. boot length mm (in.) 83 3~3 (3.3 + .12)
Final drive gear backlash mm (in.) 0.13 - 0.18 (005 - .007)
Drive pinion rotating torque
with oil seal Ncm (in.lbs.) 40 - 50 (3.5 - 4.3)
without oil seal Ncm (inlbs.) 15 - 25 (1.3 - 2.2)
Difference in total thickness between left and 0.05 (.002)
right clutch plate mm (in.)
Clearance betweenAh; ;$ch plates and the
differential case 0.06 - 0.20 (002 - .008)
Clutch plate preload
when equipped with new clutch plates
Nm (ft.lbs.) 50 - 80 (36 - 58)
when equipped with old clutch plates
Nm (ftlbs.) 35 - 80 (25 - 58)
Limit
Rear axle total backlash mm (in.) 5 (2)
Drive gear runout mm (in.) 0.05 (002)
Axle shaft end play mm (in.) 0.8 (031)
Torque tube companion flange runout mm (in.) 0.1 (004)
Spline coupling runout mm (in.) 0.1 (004)
Clutch plate wear
Difference in the thicknesses of the friction
surface and the projection mm (in.) 0.1 (004)
Flatness of the friction plates and friction
discs mm (in.) 0.08 (.003)

TORQUE SPECIFICATIONS NOBCC- -

Items Nm ft.lbs.

Axle shaft companion flange 260 - 300 188-217

Drive shaft to axle shaft companion flange 55-65 40-70
Rear axle housing to caliper support 40-50 29-36
Torque tube companion flange 160-220 116- 159
Propeller shaft to torque tube 50-60 36-43
Torque tube to front support 35-45 25-33
Torque tube to differential carrier 70-85 51 -61
Lower control arm shaft 70-80 51-58.
Axle housing to lower control arm 15-20 II-14
Strut assembly to axle housing 50-70 36-51
Axle housing mounting nut 50-70 36-51
Rear support protector to insulator 30-35 22-25
Rear insulator to crossmember 25-30 18-22
Differential carrier to spline coupling 190-250 137- 181
 REAR AXLE - SDecifications

FiTTerplug
Drain plug
Bearing cap
Differential case-to drive gear
Cover

LUBRICANTS NO3CD-.

Axle housing grease MOPAR Multi-Mileage Lubricant

Part No. 2525035 orequivalent _
Axle shaft oil seal lip MOPAR Multi-Mileage Lubricant _~
Part No. 2525035 arXquivalent
Differential case oil seal lip MOPAR Multi-Mileage Lubricant .~ As required
Part No. 2525035 or equivalent
Differential side spline and pocket MOPAR Multi-Mileage Lubricant As required
of extension shaft Part No. 2525035 or equivalent mm
Contact surfaces of spline coupling and MOPAR Multi-Mileage Lubricant .~
washer Part No. 2525035 orequivalent
Washer of special tools for pinion height MOPAR Multi-Mileage Lubricant _~
adjustment Part No. 2525035 or-equivalent -
D.O.J. boot grease Repair kit grease
Overall capacity 110-?30g(3.9~4.502)
Within D.O.J. 65 - 75 g (2.3 - 2.6 oz)
Within D.O.J. boot 45 - 55 g (1.6 - 1.9 oz)
B.J. boot grease
Overall capacity 95-115g(3.3-4.1 oz)
Within B.J. 55 - 65 g (2.0 - 2.3 oz)
Within B.J. boot

NOTE
D.OL: Double offset joint
B.J.: BirfTeldTornt

SEALANTS AND ADHESIVES NOJCE- - -

Items Specified sealants and adhesives_ Quantity

Differential cover MOPAR Part No. 4318034 or _ .~

equivalent
Drive gear threaded hole MOPAR LOCTTTE 277 or equivalent As required
 REAR AXLE - Special Tools 3-11
SPECIAL TOOLS NOJDA- -

Tool (Number and name) Use Tool (Number and name) Use

C-4381 Removal of the axle DT-1007-B Insertion of the axle

Spanner wrench shaft outer bearing Axle shaft oil seal installer shaft oil seal
Press-fitting of the oil
seal of the drive pinion
[I @ q Press-fitting of the oil
seal onto the side of the
Q differential carrier

C-293-PA Removal of the axle c-4171 Press-fitting of the oil

Bearing puller shaft outer bearing Drive handle seal onto the side of the
differential carrier
Press-fitting of the axle
shaft inner bearing
Press-fitting of the drive
pinion bearing

~~_..
C-637 Removal of extension MB990906 Removal and insertion
Sliding hammer set, shaft bearing Drive shaft, torque tube re- of the drive shaft
mover and installer attach- assembly

be bearing installer

Side bearing puller bearing inner race Bearing remover pinion rear bearing inner
3-12 REAR AXLE - Soecial Tools

Tool (Number and name) Use Tool (Number and name!_ Use
q-k: -_
MB990802 -- Press-fitting of the drive C-4626 -- - - y Measurement of the
Bearing installer pinion rear bearing inner Pinion height gauge unit- drive pinion height
race
Press-fitting of the side
bearing inner race

p MBgg09& =_ = -~-
MB9905j2 .- 1’ Measurement of the Measurement of the
Cylinder gauge drive pinion height Side gear holding tool s@t clutch plate preload

Tool

MB%0989
MB9.9!0767 -.-~ il -i Measurement of the li- B
End yoke holder mited slip differential
preload
 REAR AXLE - Troubleshooting 3-13
TROUBLESHOOTING NOBEAAF

Symptom Probable cause Remedy

AXLE SHAFT,
AXLE HOUSING
Noise while wheels Brake drag Replace
are rotating Bent axle shaft
Worn or scarred axle shaft bearing

Grease leakage Worn or damaged oil seal Replace

Malfunction of bearing seal

DRIVE SHAFT
Noise Wear, play or seizure of ball joint Replace
Excessive drive shaft spline looseness

TORQUE TUBE
Noise Wear, play or seizure of bearing Replace

DIFFERENTIAL
Abnormal noise Excessive final drive gear backlash Adjust
during driving Insufficient drive pinion preload
or gear changing
Excessive differential gear backlash Adjust or replace

Worn spline of a side gear Replace

Loose spline coupling self-locking nut Retighten or replace

NOTE
In addition to a malfunction of the differential carrier components, abnormal noise can also be caused by the
universal joint of the propeller shaft, the axle shafts, the wheel bearings, etc. Before disassembling any parts, take
all possibilities into consideration and confirm the source of the noise.

Abnormal noise Damaged differential gears Replace

when cornering Damaged pinion shaft
Nicked and/or abnormal wear of inner and outer
clutch plates
Contaminated gear oil

Insufficient gear oil quantity Refill

Gear noise Improper final drive gear tooth contact adjustment Adjust or replace

Incorrect final drive gear backlash Adjust

Improper drive pinion preload adjustment

Damaged, broken, and/or seized tooth surfaces Replace

of the drive gear and drive pinion
Damaged, broken, and/or seized drive pinion
bearings
Damaged, broken, and/or seized side bearings
Damaged differential case
Contaminated gear oil

Insufficient gear oil quantity Refill

NOTE
Noise from the engine, muffler vibration, transmission, propeller shaft, wheel bearings, tires, body, etc., is easily
mistaken as being caused by malfunctions in the differential carrier components. Be extremely careful and
attentive when performing the driving test, etc.
Test methods to confirm the source of the abnormal noise include: coasting, acceleration, constant speed driving,
raising the rear wheels on a jack, etc. Use the method most appropriate to the circumstances.
 =-xc, _= ~_~_E
__-

REAR AXLE - Troubleshooting

Loose filler or drain plug Retighten or apply adhesive

Clogged or damaged vent plug Clean or replace

Seizure Adjust
Excessive drive pinion preload
Excessive side bearing preload
Improper differential gear backlash
Excessive clutch plate preload

Contaminated gear oil Replace

.._ I-
Insufficient gear oil quantity Refill
L
NOTE ~.
In the event of seizure, disassemble and replace the parts involved, and also be sure to check all components for
any irregularities and repair or replace as necessary.

Breakdown incorrect final drive gear backlash Adjust

Incorrect drive pinion preload
Incorrect side bearing preload
Excessive differential gear backlash
Insufficient clutch plate preload

Loose drive gear clamping bolts Retighten

.r
Operational malfunction due to overloaded’~~ ’ Avoid excessively rough operation
clutch

In addition to drsassembling and replacing the failed parts, be sure to check all components for irregularities and
repair or replace as necessary.

The limited slip The limited slip device 1sdamaged ~- Drsassemble, check the functioning,
differential does not and replace the damaged parts
function (on snow,
mud, ice, etc.)
 REAR AXLE - Service Adjustment Procedures 3-15
SERVICE ADJUSTMENT PROCEDURES
NOBFAAC

CHECKING REAR AXLE TOTAL BACKLASH

1. If the vehicle vibrates and produces a booming sound due
to the imbalance of the driving system, measure the rear
axle total backlash by the following procedures to see if the
differential carrier assembly requires removal.
(I) Place the gearshift lever in the neutral position, apply
the parking brake and jack up the vehicle.

Mating marks (2) Turn the companion flange fully clockwise. Make the
mating mark on the dust cover of the companion flange
and on the torque tube.

) I 11’1687

(3) Turn the companion flange fully counter-clockwise, and

measure the amount of distance through which the
mating marks moved.
Limit: 5 mm (.2 in.)
2. If the backlash exceeds the limit, remove the differential
carrier assembly and adjust the backlash.

CHECKING AXLE SHAFT FOR AXIAL PLAY NOJFBAC

1. Measure the axle shaft for axial play by using a dial

indicator.
Limit: 0.8 mm (.031 in.)
2. ‘If the axle shaft axial play exceeds the limit, replace the
bearing.

CHECKING GEAR OIL LEVEL NOBFCAA

1. Remove the level plug, and check the oil level.

2. The oil level is sufficient if it reaches the level plug hole.

DO903;
3-16 REAR AXLE - Service Adjustment Procedures

LIMITED SLIP DIFFERENTIAL PRELOAD

MEASUREMENT NOWDAA

1. To measure the preload of the limited slip differential, set

the shift lever of the tran_smrssion to the neutral-position,
lock the tront wheels, and fully release the parking brake. -!
One of the rear wheels should be ~marntarned in contact ~1:
with the ground surface, and the other should be rarsed up. ~~_

2. Measure the startrng torque at the side on which th,e wheel, _- _

is in the raised position by using the following prcrcedures: -z
(1) Remove the wheel.
(2) Mount the special tool to the hub bolts by using the hub Yimm
nuts.
(3) Find the limited slip differential preload by measuring 1
the axle shaft starting-torque in the forward direction
with a torque wrench.
Standard value: 39 Nm (28 ft.lbs.) or more

This valuejncludes thedragging torque 4 NmJ3 ftlbs.) ~~

of the disc brake.
(4) If the torque is less than the standard value, remove the mLr
limited slip differential from the-vehicle and @sassem- =i
ble it. .__

-I
DIFFERENTIAL CARRIER OIL SEAL REPLACE-
MENT NOBFGAA

1. Detach the drive shaft and the companion flange.

TQv779 C-637
2. Pull the drive shaft out from the differential carrieryby using ,“--Z.
-1s
the special tools.
Caution
When pulling the drive shaft out from the differential
carrier, be careful that the spline part of the drive shaft
does not damage the oil seal.

3. Remove then oil seal from the differential carrier.

REAR AXLE - Service Adjustment Procedures 3-17
4. Press-fit the oil seal positively with the special tool and
apply the specified grease to the oil seal lip.
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent

5. Drive the drive shaft into the differential carrier by using the
special tools.
Caution
1. Be careful not to damage the lip of the oil seal.
2. Replace the circlip which is attached to the B.J. side
spline with a new one.
6. Install the drive shaft to the companion flange.
 REAR AXLE - Axle Shaft

AXLE SHAFT NOBHA-.

REMOVAL AND INSTALLATION

55-65 Nm
4047 ft.lbs.

I 50-70 Nm
36-5 1 ft.lbs.

40-50
29-36

‘4
I
70-80 Nm \
51-58 ftlbs. 15-20 Nm
1 l-14 ft.lbs.

6
I llY701

Removal steps
1. Cotter pin
2. Parking brake cable connection
3. Rear brake assembly connection
4, Brake disc
5. Drive shaft connection NOTE F-m- ~
6. Lower control arm connection (1) Reverse the removal procedures to relnstall.
7. Strut assembly connection (2) *I): R&%to “Service Points of Removal”. _
8. Axle housing assembly (3) q : Non-reusable parts
 REAR AXLE - Axle Shaft

SERVICE POINT OF REMOVAL NOBHBAC

3. DISCONNECTION OF REAR BRAKE ASSEMBLY

Hold the caliper body by suspending it with wires or other
suitable method so that the brake hoses are not twisted.

INSPECTION NOBHCAB

l Check to assure that the axle shaft end play is within the
limit.
Limit: 0.8 mm (.031 in.)

llY206
 ; .;~-; -_L-.----
.--.“.....

3-20 REAR AXLE - Axle Shaft

AXLE SHAFT NOIHE- -

DISASSEMBLY AND REASSEMBLY

260-300 Nm
186-217 ftlbs.

qi

Disassembly steps
I. Companion flange mounting nut (self-locking
nut)
4+ 2. Axle shaft
3. Spacer
4. Outer bearing
5. Dust cover
6. Companion flange
7. Dust cover NOTE
44 8. Oil seal (1) Reverse the disa&embly procedures toEassemble.
9. Inner bearing (2) +I): Refer to “Service Points of Disassembly”.
IO. Axle housing (3) I)+: Refer to “Service Points of Reassembly”, --;
11. Dust cover (4) q : Non-reusable parts

SERVICE POINT OF DlSiSSEMBLY NOSWAA

2. REMOVAL OF AXLE SHAFT

Loosen the companion flange mounting nut, and then tap
the axle shaft out of the:axle housing by using-a plastic e
hammer.
Caution
Be careful not to scratch the oil seal.
 REAR AXLE - Axle Shaft 3-21
INSPECTION NOJHGAA

l Check companion flange for wear and damage.

l Check dust cover for deformation and damage.
l Check oil seal for damage.
l Check inner and outer bearings for seizure, discolouration
and rough raceway surface.
l Check axle shaft for cracks, wear and damage.

INNER AND OUTER BEARING REPLACEMENT

NOBHHAB

(1) Remove the rear axle bearing with the special tool and
Bearing Puller.

(2) Drive out the inner bearing from the axle housing and oil
seal by using a bar.

(3) Press-fit the new outer bearing to the axle shaft.

NOTE
The seal side of the outer bearing should face the flange
side of the axle shaft.
(4) Apply specified grease to the inside surface of the axle
housing.
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent

(5) Position the new inner bearing so that the seal side faces
the companion flange, and then press-fit the bearing.
(6) Apply the specified grease to the area of the axle housing
where the oil seal is to be press-fitted, and then use the
07. special tool to drive the oil seal in until it comes into contact
with the edge of the axle housing.
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent
 -___- ~- -__j- -~c~~-~ _c__
y‘

&-

REAR AXLE - Axle Shaft

=::;
__L
1 SERVICE POINT OF REASSEMBLY NOJHIPA

8. APPLICATION OF GREASE TO OIL SEAL

”
Apply specified grease ta:the oil seal lip. ~_ --
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent
 REAR AXLE - Drive Shaft 3-23
DRIVE SHAFT N03JA- -

REMOVAL AND INSTALLATION

40--47ftJbs.

Removal steps
41) I)* 1, Drive shaft assembly NOTE
2. Circlip (I) Reverse the removal, procedures to reinstall.
I)+ 3. Oil seal (2) +*: Refer to “Service Points of Removal”.
(3) **: Refer to “Service Points of Installation”.
(4) q : ‘Non-reusable parts

SERVICE POINT OF REMOVAL N03JBAA

1. REMOVAL OF DRIVE SHAFT ASSEMBLY

Pull the drive shaft out from the differential carrier by using
the special tools.
Caution
When pulling the drive shaft out from the differential
carrier, be careful that the spline part of the drive shaft
does not damage the oil seal.
SERVICE POINTS QF INSTALLATION NOJJCAA

3. INSTALLATION OF OIL SEAL

(1) If the oil seal is to be replaced because of-damage, drive
it in by using the special tool.
(2) Apply the specified grease to the oil seal lip.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No. 2525035 or equivalent

_- -
1. INSTALLATION OF DRIVE SHAFT ASSEMBLY -
Drive the drive shaft into the differential carrier by using the,
special tools. I .~
Caution
1. Be careful not to damage the lip of the oil seal.
2. Before and after connecting the drive shaft with the
companion flange, slide the drive shaft axially to
check that it does not come off the differential
carrier.
 REAR AXLE - Drive Shaft 3-25
DRIVE SHAFT
DISASSEMBLY AND REASSEMBLY

UL
d 111692
HY690

Joint &shaft kit (B.J.) Boot kit (B.J.)

Disassembly steps
l + 1. Boot bands (for D.O.J. boot)
2. Circlip
I)* 3. D.O.J. outer race
l 4 4. Balls MY697
l * I)+ 5. D.O.J. cage llY691
6. Snap ring
I)+ 7. D.O.J. inner race Joint kit (D.O.J.) Boot kit (D.O.J.)
8. Circlip
c* 9. D.O.J. boot
IO. Boot bands (for B.J. boot) NOTE
(1) Reverse the disassembly procedures to reassemble.
** I)* 11. B.J.boot (2) ++: Refer to “Service Points of Disassembly”.
l + 12. B.J. and shaft assembly (3) +*: Refer to “Service Points of Reassembly”.
13. Dust cover (4) The drive shaft joint requires special grease. Do not use any
14. Circlip other type.
15. End plate (5) q : Non-reusable parts
3-26 REAR AXLE - Drive Shaft s-
sgr
SERVICE POINTS OF DISASSEMBLY NOBJEAA

5. REMOVAL OF D.O.J. CAGE

Remove the D,O.J. tags from the D,O.J. inner race in the -E
direction of the B.J.

9. REMOVAL OF D.O.J. BOOT / 11. B.J. BOOT

Wrap vinyl tape around the.spline part on the D.O*J- side of _
the drive shaft so that theD.0.J. and B.J. boots are not ~~
damaged when they are removed.
Caution
B.J. and shaft assembly cannot be disassembled. Do
not attempt to disassemble.

Yllos 7
A

INSPECTION NOBJFAA

* Check drive shaft for bend and wear.

@ Check B.J. for entry of water, toreign matter and rust. 1
@ Check B.J. ball for damage.
l Check D.O.J. cage, D-0.3. inner race~and ball for rust, wear 1
and damage.
* Check D.O.J. outer race for wear and damage.

SERVICE POINTS OF REASSEMBLY NOBJGAC

12. APPLICATION OF GREASE TO B.J. AND SHAFT ASSEM-

BLY / 11. B.J. BOOT
If the B.J. is to-be reused, pack the specified grease into the r
B.J. boot. . -
Specified grease: Repair kit grease
Overall capacity 95- 115 g (3.4-4.1 02)
Within B.J. 55 - 65 g (2.0 - 2.3 oz)
Within B.J. boot 40-5Og(1.4-1.802)

7. INSTALLATION OF D.O.J. INNER RACE / 5. D.O.J. CAGE ~--

Inner race (1) Install the D.O.J. cage~onto the drive shaft so that the ~_
Drive shaft /-< smaller diameter side of the cage is~instal!ed first. ..;r
(2) Install the circlip on the drive shaft.
(3) Install the D.O.J. inner- race on the drive shaft with~its :I
smaller chamfering angle (17”) side on the B.J. side, and -:
then secure with the-snap ring. _..I

:*
llY702
 REAR AXLE - Drive Shaft 3-27
Cage (4) Apply specified grease to the D.O.J. inner race and the
D.O.J. inner race
D.O.J. cage, and then fit them together.
Specified grease: Repair kit grease

4. APPLICATION OF GREACE TO BALLS

Apply specified grease to the ball insertion parts of the
D.O.J. inner race and D.O.J. cage, and insert the balls.
Specified grease: Repair kit grease

3. INSTALLATION OF D.O.J. OUTER RACE

(1) Apply 65 to 75 g (2.3 to 2.6 oz) of specified grease to the
D.O.J. outer race.
(2) Fit the drive shaft into the D.O.J. outer race.
(3) Apply 45 to 55 g (1.6 to 1.9 oz) of specified grease to the
D.O.J. outer race.
Specified grease: Repair kit grease
Overall capacity IIO- 130 g (3.9-4.5 oz)
Within D.O.J. 65 - 75 g (2.3 - 2.6 oz)
Within D.O.J. boot 45-55g(1.6-1.9oz)

1. INSTALLATION OF BOOT BANDS (FOR D.O.J. BOOT)

(1) Install the circlip onto the D.O.J. outer race.
(2) Place the D.O.J. boot over the D.O.J. outer race, and
then use boot band (1) to secure the boot.
(3) Place boot band (2) at the specified distance in order to
adjust the amount of air inside the D.O.J. boot, and then
tighten the boot band (2).
Standard value (A): 83 f 3 mm (3.3 +_ .I2 in.)
3-28 REAR AXLE - Torque Tube

TORQUE TUBE NOBKA- .

REMOVAL AND INSTALLATION

3545 Nm
25-33 ft.lbs.

70-65 Nm
-^ ^--. I 51-61 ft.lbs.
!3u-tN Nrn

160-220 Nm \

Removal steps
1. Propeller shaft
I)* Measurement of companion flange runout NOTE
++ 2. zit;7panion flange mounting nut (Self-locking (1) Reverse the w&oval procedures to reinsta!l.
(2) ++: Refer to “Service Points of Rem@“.
I)* 3. Torque tube assembly to front support bolt (3) I)+: Refer to “Service Points of Installation”.
++ I)+ 4. Torque tube assembly (4) m: Non-reusable parts
REAR AXLE - Torque Tube 3-29
SERVICE POINTS OF REMOVAL NOBKBAA

2. REMOVAL OF COMPANION FLANGE MOUNTING NUT

Hold the extension shaft by applying the parking brake, and
loosen the companion flange mounting nut.
NOTE
The nut should only be loosened, not removed.

4. REMOVAL OF TORQUE TUBE ASSEMBLY

(1) Disconnect the extension shaft spline from the spline
coupling by using the special tools.
(2) Disconnect the special tools from the torque tube, and
pull the torque tube assembly out toward the rear.
Caution
Whenever the torque tube assembly is removed, be
sure to disassemble and install them in accordance
with the specified procedure. Otherwise the dam-
aged bearing will result.

SERVICE POINTS OF INSTALLATION NOBKCAA

4. INSTALLATION OF TORQUE TUBE ASSEMBLY

Drive the extension shaft in the differential spline coupling
by using the special tools until the surface oft the torque
tube flange comes fully in contact with the surface of the
differential carrier flange.
Caution
1. Do not hit the torque tube flange and the bracket
when driving in the torque tube.
2. If a clearance between the torque tube flange and
the differential carrier flange exists, and the torque
tube and the differential carrier are connected to
each other, the ball bearing may be pre-loaded and
seizured.
If there is clearance between the torque tube and differen-
tial carrier flange, proceed as follows:
(1) Remove the torque tube assembly.
(2) Disassemble the torque tube assembly. (Refer to
P.3-31.)
(3) Apply the specified grease to the pocket and the spline
part of the differential side of the extension shaft. (Refer
to P.3-32.)
Specified grease: MOPAR Multi-Mileage Lubricant
Part No. 2525035 or equivalent
(4) Insert the extension shaft into the torque tube.
(5) Drive the extension shaft into the differential spline
coupling.
(6) Install the torque tube onto the differential carrier and
front support.
 =- __ -__ __ - - ,i-- -:-

REAR AXLE - Torque Tube Ed

ET:
(7) Drive the bearing into the extension shatt by using the
special tool. (Refer to P.3-32.)
a,;:
D
NOPE
Continue driving the b&ring in until the flange-surface < Ed
of the,sp&al tool comes in contact with the edge
- of the .I Em
torque tube. ~~ YL
-- m
(8) Install the snap ring by using snap rrng pljers to secure G =
the bearing In place.
(9) Install the companion flange by properly aligning the ~-I
mating marks. !!!!sez-

3. APPLICATION OF OIL TO TORQUE TUBE ASSEMBLY r

TO FRONT SUPPORT BOLT
Apply oil to -the bolt on-its entire surface bef.sre its, is _ i ~~
installed.

‘, MEASUREMENT OF COMPANION FLANGE RUNOUT -

(1) Hold the extension shaft by applying the parking brake,
and tighten the companion flange mounting nut.
(2) Measure companion flange runout with a dial indicator. ...i
(3) If the companion flange runout exceeds the standard I -
value, change the phase of the companion flange and
extension shaft and measure the runout once again, ,,-
Standard value: 0.1 mm (.004 in.)
 REAR AXLE - Torque Tube 3:
1
TORQUE TUBE N03KD- --\

DISASSEMBLY AND REASSEMBLY

160-220 Nm
116-159 ft.lbs.

Disassembly steps Reassembly steps

1. Companion flange mounting nut 6. Torquetube
(Self-locking nut) l + 5. Bearing
+I) 2. Extension shaft I)+ 2. Extension shaft
+* 3. Companion flange 4. Snap ring
4. Snap ring l + 3. Companion flange
+* 5. Bearing *(1 1. Companion flange mounting nut
6. Torque tube (Self-locking nut)

lp’:*: Refer to “Service Points of Disassembly”.

(2) l 4: Refer to “Service Points of Reassembly”.
(3) m: Non-reusable parts. llY154

SERVICE POINTS OF DISASSEMBLY NOBKEAA

2. REMOVAL OF EXTENSION SHAFT / 3. COMPANION

FLANGE
(1) Make the mating marks to the extension shaft and
companion flange.
(2) Drive out the extension shaft from the torque tube with
a plastic hammer.

5. REMOVAL OF BEARING
Pull out the bearing from the torque tube by using the
special tool.
 REAR AXLE - Torque Tube

INSPECTION
e Check bearing for looseness and rotatron.
@ Check torque tube for cracks.
l Check extension shaft for bend, wear and damage. Lo 2

SERVICE POINTS OF REASSEMBLY NOBKGAA

5. INSTALLATION OF BEARING
Drive the bearing into the extension shaft by using the I
special tool.
NOTE
Continue driving the bearing in untjl the flange surface of -z
the special tool comes in contact with the edge of the .s :
torque tube..-~

2. APPLICATION OF GREASE TO EXTENSION SHAFT

Apply the specified grease to the pocket and the spline part
of the differential side of the extension shaft.
Specified grease: MOPAR Multi-Mileage Lubricant Part ~=~-
No. 2525035 or equivalent
3. INSTALLATION OF COMPANION FLANGE
Install the companion ~flange with mating marks~properly
aligned.
1. INSTALLATION OF COMPANION FLANGE MOUNTING
11YlOI
NUT
Temporarily tighten the companion flange by usmg the
companion flange mountmg nuts.
NOTE
After mounted to the vehi-cle, trghten the campar-rron flange _ _.
mountmg nut.
 REAR AXLE - Differential Carrier 37
i
--
DIFFERENTIAL CARRIER NOBJA- - =---
_

REMOVAL AND INSTALLATION

Pre-removal Operation
l Draining Gear Oil I

Post-installation Operation
l Filling Gear Oil

3035 Nm
s,’ 22-25 ft.lbs.

2530 Nm
70-85 Nm
9JT Alznl-lYl,l 51-61 ft.lbs.
33-a

25-33 ft.lbs.

50-60 Nm
36-43 ft.lbs.

60-70.Nm
43-51 ft.lbs. 55-65 Nm
40-47 ft.lbs.

llY705

Removal steps
1. Drive shaft NOTE
.2. Circlip (I 1 Reverse the removal procedures to reinstall.
3. Torque tube (2) l *: Refer to “Service Points of Removal”.
4* 4. Differential carrier assembly (3) q : Non-reusable parts
REAR AXLE - Differential Carrier
SERVICE POINT OF REMOVAL NOBBAC

4. DIFFERENTIAL CARRIER ASSEMBLY E!zE!F

my’
Dismount the ditterential_ carrier from the rear-support BI
rnsulators bv rarsrng the drtterentral earner with-a jack. .-z _Z%:

INSPECTION BEFORE DISASSEMBLY NO31EAE

a-
Remove the rear supports and cover. Secure the working base -.~:
in a vice and then install the removed differential carrier 1
assembly.

.
-.

'16E
-
UT
-~
FINAL DRIVE GEAR BACKLASH c
With the drive pinion locked in place, measure the final drive ~~
gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumferentie of the yii ~~ 5
drive gear.
Standard value: 0.13 - 0.18 mm (.005 - .007 in.)
F-

DRIVE GEAR RUNOUT --

Measure the drive gear runoot at the shoulder on the reverse -i ~~. +
side of the drive gear.
Limit: 0.05 mm (.002 in.)

SPLINE COUPLING RUNOUT

Measure the spline coupling runout with a dial indicator. __=
Standard value: 0.1 mm (.004 in.)

-1lY242
-.
--
 REAR AXLE - Differential Carrier 3-35
FiNAL DRIVE GEAR TOOTH CoNTACT
Check the final drive gear tooth contact as follows:
(1) Apply a thin, uniform coat of machine blue to both surfaces
of the drive gear teeth.

(2) Insert a brass rod between the differential carrier and the
differential case, and then rotate the spline coupling by
hand (once in the normal direction, and then once in the
reverse direction) while applying a load to the drive gear so
that the rotating torque [approximately 2.5 to 3.0 Nm (1.8 to
B rass rod 2.2 ft.lbs.)] is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
(3) Check the tooth contact condition of the drive gear and
drive pinion.
NOTE
Checking the tooth contact pattern is the way to confirm
that the adjustments of the pinion height and backlash have
been done properly. Continue to adjust the pinion height
and backlash until the tooth contact pattern resembles the
standard pattern.
If, after adjustments have been made, the correct tooth
contact pattern cannot be obtained, it means that the drive
gear and the drive pinion have become worn beyond the
allowable limit; replace the gear set.
llS67t
Caution
If either the drive gear or the drive pinion is to be
replaced, be sure to replace both gears as a set.
 3-36 REAR AXLE - Differential Carrier

Standard tooth contact pattern

1 Toe
2 Drive-side
3 Heel
4 Coast-side

Problem

Tooth contact patter-n resulting from exces-

sive pinion height

The drive pinion is positioned too far from the center of increase the thickness of the pinion height adjusting
1:he drive gear. shim, and position the drive pinion closer to thecenter
of the drive gear.
Also, for backlash adjustment, position the drive gear
farther from the drive pinion.
.
t:ient pinion height

1-he drive pinion is positioned too close to the center of Decrease the thickness of the pinion height adjusting
t he drive gear. shim, and position the drive pinion farther from the
center of the drive gear.
Also, for backlash adjustment, position the dFive gear
closer-to the drive pinion. .

11 S642
-
 REAR AXLE - Differential Carrier 3-37
DIFFERENTIAL CARRIER N03lV- -

DISASSEMBLY AND REASSEMBLY

Inspection Before Disasse mbly

l Final Drive Gear Backlash (Refer to P.3-34)
l Drive Gear Runout (Refer to P. 3-34)
l FinaLDrive Gear Tooth Contact (Refer to P. 3-35)
55-65
l Spline Coupling Runout (Refer to P. 3-34) 1,. 1- Nm
r. . .

70 Nm 6
51 ft.lbs. \

190-250 Nm
137-181 ftlbs.

SO-90.Nm 55-65 Nm
58-65 ftlbs. 40-47 ft.lbs.
4b-60 Nm
29-43 ftlbs.
I I

Disassembly steps
1. Rear supports 18. Drive pinion front bearing inner race
I)* 2. Vent plug *I) *(1 19. Drive pinion front bearing outer race
l C 3. Cover +* *+ 20. Drive pinion rear bearing outer race
4. Bearing cap 21. Oil seal
4* 5. Differential case assembly 22. Gear carrier ’
I)4 Final drive gear backlash adjustment
6. Side bearing adjusting spacer NOTE
7. Side bearing outer race (1) Reverse the disassembly procedures to reassemble.
l * I)* 8. Side bearing inner race (2) +I): Refer to “Service Points of Disassembly”.
*I) ** 9. Drive gear (3) I)*: Refer to “Service Points of Reassembly”.
4* IO. Spline coupling mounting nut (Self-locking (4) q : Non-reusable parts
nut)
4* 11. Drive pinion
12. Drive pinion rear shim (for pinion height
adjustment)
I)4 Drive pinion preload adjustment
*c Pinion height adjustment
13. Drive pinion spacer
14. Drive pinion front shim (for preload adjust-
ment)
15. Spline coupling
4* 16. Drive pinion rear bearing inner race
c* 17. Oil seal ;
SERVICE POINTS OF DISASSEMBLY NOBILBA

5. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY

Take out the differential case assembly with a hammer
handle. ~~
NOTE y.
Keep the right and left side bearingsand sides bearing E-
adjusting spacers separate, so that they do not-become -! E
mixed at the time of reassembly.

_
8. REMOVAL OF SIDE BEARING INNER RACE ’ -* Eg
Pull out the Sde bearing -inner races by using the special --L- &g
tools. -+
c
NOTE EELS
__~
Attach the prongs of the special tool to the inner race ofThe -1 zII
side bearing through the openings in the differential case.

9. REMOVAL OF PRIVE GEAR

(1) Make the mating mar&s to the differential -= case
~~ and the=,
drive gear.
(2) Loosen the drive gear attaching bolts inn: diagonal -{
sequence to remove the drive gear. ~~-
NOTE ‘-
An anti-looseness agent has been used on the bolts. [f~_:
they cannot be loosened, heat the area-to approximate--~-~-
ly 150°C (302°F) vvlth a propane torch, and then loosen ’
them. ~-

10. REMOVAL OF SPLINE COUPLING MOUNTING NUT i

Use the special tools to hold the spline coupling and .
remove the spline coupling mounting nut.

.~ - .._
SC
11. REMOVAL OF DRIVE PINION L
(1) Make the mating marks to the drive pinion land spline
coupling.
(2) Drive out the drive pinion together with the drive pinion
spacer and drive pinion front shims. =

. -
--
REAR AXLE - Differential Carrier 3-39
16. REMOVAL OF DRIVE PINION REAR BEARING INNER
RACE
Pull out the drive pinion rear bearing inner race by using the
special tools.

17. REMOVAL OF OIL SEAL / 19. DRIVE PINION FRONT

BEARING OUTER RACE / 20. DRIVE PINION REAR
BEARING OUTER RACE
Drive out the oil seal, drive pinion front and rear bearing
outer races from the gear carrier by using a bar.

INSPECTION NOBIMBA

Wash the disassembled parts in cleaning solvent, dry them

using compressed air, and then check the following areas:
l Check companion flange for wear or damage.
l Check oil seal for wear or deterioration.
l Check bearings for wear or discoloration.
l Check gear carrier for cracks.
l Check drive pinion and ring gear for wear or cracks.
 REAR AXLE - Differential Carrier

_C-3893
SERVICE POINTS OF REASSEMBLY
20. INSTALLATION OF DRIVE PINION
OUTER RACE / 19. DRIVE PINION FRONT BEARING
REAR BEARING
NO3lNBD

OUTER RACE
Press-fit the drive pinion front and rear bearing quter races ~.;
into the gear carrier by using the special tools. -
Caution
Perform press-fitting carefully so as not to tilt the outer
race.

l PINION HEIGHT ADJUSTMENT

Adjust the drive pinion height by the following procedure: I
(1) Install special tools and drive pinion front and rear-
bearing inner races tcrthe gear carrier in the sequence
shown in the illustration.
NOTE
Apply a thin coat of the specified grease to ihe mating-.=:
face of -the washer of the special tool.
Specified grease: MOPAR Multi-Mileage Lubricant -
Part No. 2525035 or equivalent
11 --~
(2) Tighten the nut of the specral tool until the standard--,
value of -drive pinion- preload is obtained. _ _

(3) Measure the drive prnron rotatrng torque (wrthout the oil
seal).
Standard value: 15 - 25 Ncm (1.3 - 2.2 in.lbs.1
-
NOTE
Gradually tighten the nut of the special tool while?
checking the drive pinion rotating torque. ~.

llY21i

(4) Positionthe special tool in the side beanng.seat of the ;

gear carrier, and thenselect a drive pinion rear shim of a
thickness which corresponds to the gap between the
special tools. _~ --
NOTE
Be sure to clean the side bearing seat thoroughly. When
position&g the spec$al tool, be sure that the c&ou~~ _ --
sections of the special tool are in the position shown in l
the illustration, and also confirm that the special tool is
Drive pinion rear shim r in close. contact with the side bearing seat.
When selecting the drive pinion rear shims, keep the” ~’
REAR AXLE - Differential Carrier 3-41
(5) Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
race by using the special tool.

. DRIVE PINION PRELOAD ADJUSTMENT

Without Oil Seal
Adjust the drive pinion rotating torque by using the
following procedure:
(1) Fit the drive pinion front shim(s) between the drive
pinion spacer and the drive pinion front bearing inner
race.

(2) Tighten the spline coupling by using the special tools.

NOTE
Do not install oil seal.

(3) Measure the drive pinion rotating torque (without oil

seal).
Standard value: 15 - 25 Ncm (1.3 - 2.2 in.lbs.1
(4) If the drive pinion rotating torque is not within the range
of the standard value, adjust the turning torque by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE
When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims
@,a minimum by selecting the drive pinion spacers.
(5) Remove the spline coupling and drive pinion once again.
3-42 REAR AXLE - Differential Carrier

(6) Place the~front bearing inner race in the gear carrier. Z

(7) Drive the oil seal into the gear carrier front lip by using 1
the special tool.
(8) Apply specified grea& to the oil seal lip.
Specified grease: Multipurpose grease SAE J310,
NLGI No. 2

With Oil Seal

(1) Apply a thin coat of -specified grease~to t& spline
coupling contacting surface of the washer before -z
installing drive pinion assembly.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No. 2525035 or equivalent

Y1153i

(2) Install the~drive pinion assembly and Splin& coupling

with mating marks properly aligned, and tighten the
spline coupling mounting nut by using the special tools. 1

(3) Measure the drive pinion rotating torque (with oil seal)
to verify that the drive pinion rotating torque complies _
with the standard value.
Standard value: 40 - 50 Ncm (3.5 - 4.3 in.lbs.1

-
(4) Measure the spline coupling runout.
Standard value: 0.1 mm (.004 in.)
If the spline coupling runout exceeds the standard, .._
value, change the phase of the spline coupling and drive
pinion afterdisassembling the different@! carrier and L
-_
measure the runout once again.

llY24:
REAR AXLE - Differential Carrier 3-43
9. INSTALLATION OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhered to the threaded holes of
the drive gear by turning tap (Ml0 x 1.25), and then
clean the threaded holes by applying compressed air.

(3) Apply the specified adhesive to the threaded holes of

the drive gear.
Specified adhesive: MOPAR LOCTITE 271 or equiva-
lent
(4) Install the drive gear onto the differential case with the
mating marks properly aligned. Be sure to tighten the
bolts in a diagonal sequence.

8. PRESS-FIT OF SIDE BEARING INNER RACE

Press-fit the side bearing inner races to the differential case
by using the special tool.

. FINAL DRIVE GEAR BACKLASH ADJUSTMENT

Adjust the final drive gear backlash by the. following
procedure:
(1) Install the side bearing adjusting spacers, which are
thinner than those removed, to both the pinion gear and
the drive gear sides of the differential case assembly,
and then mount the differential case assembly into the
gear carrier.
NOTE
Select side bearing adjusting spacers with the same
thickness for both the drive pinion side and the drive
gear side.
(2) Push the differential case assembly to one side, and
measure the clearance between the gear carrier and the
side bearing adjusting spacer with a feeler gauge.
 REAR AXLE - Differential Carrier

(3) Measure the thickness of the stde bearing sdjustrng ~I

spacers on one side, select two pairs of spacers which
correspond to that thickness plus one half of the 1:
clearance~plus 0.05 mm LOO2 in.), and then install one ;
pair each to the drive pinion side and the~drive gear side.
NOTE
Be sure that there isDo clearance betweenAh-e gear ..-3---
0.05 mm
+ l.002 in.) carrier and the side bearing adjusting spacer.
-A = il~~ngs of the spacer on
1 lY2L

(4) Install the side bearing-adjusting spacers and differential -.I

case assembly, as shown in the illustration, to the gear ~_
carrier. -

(5) Tap the side bearing adjustrng spacers with a brass bar T
to fit them to the side bearing outer race.

(6) Align the mating marks on the gear carrier and ~the =+
bearing czp, and then tighten the bearing cap.

(7) Measure the final drive gear backlash.

Standard value: 0.13 - 0.18 mm (.005 - .007 in.)
 REAR AXLE - Differential Carrier

If backlash is too small (8) Change the side bearing adjusting spacers as illus-
trated, and then adjust the final drive gear backlash
between the drive gear and the drive pinion.
NOTE
Be sure to change the side bearing adjusting spacers on
the drive pinion side and on the drive gear side so that
the total thickness is equal to that obtained from the
calculation in item (3).
When selecting the side bearing adjusting spacers,
keep the number of spacers to a minimum.
If backlash is too larae llY19

(9) Check the drive gear and drive pinion for tooth contact.
If poor contact is evident, make adjustment. (Refer to
P.3-36.)
(lO)Re-measure the backlash to verify that the
backlash complies with the standard value.
NOTE
There is a correlation between the backlash and tooth
contact of the final drive gear. Coordinate their adjust-
ment, while checking both, until a point of compromise
is found. If correct adjustment cannot be made by only
moving the drive gear sideways, adjustment of the
drive pinion height is required.
(11)Measure the drive gear runout. -
Limit: 0.05 mm (.002 in.)
If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential
case, and re-measure.

llY161

3. INSTALLATION OF COVER
Section A-A
Apply specified sealant to the cover flange surface (surface
2-3(.08-.12) which contacts the carrier) as illustrated and attach it on the
carrier.
Specified sealant: MOPAR Part No. 4318034 or equiva-
lent

mm (in.) llY703

2. INSTALLATION OF VENT PLUG

When installing vent plug, apply semi-drying sealant to the
mating surfaces of the vent plug and the cover.
Caution
Do not apply sealant to the part shown in the illustra-
tion.
 ~-~~-~~-_ --L ==
e-;

&;g
=&-
3-46 REAR AXLE - Differential Carrier

DIFFERENTIAL CARRIER NOJIW.

OVERHAUL

‘1
Differential gear set

llY694

Disassembly steps
I)+ Adjustment of clutch plate preload 16. Friction plate
++ 1. Screw 17. Friction disc
2. Differential case (A) 18. Friction plate ~
3. Spring plate 19. Spring disc
4. Spring disc 20. Spring plate E
5. friction plate I)* Adjustment of clutch plate friction force
6. Friction disc 21, Differential case (B)
7. Friction plate
8. Friction disc
9. Pressure ring
10. Side gear
11. Differential pinion gear NOTE
(I) Reverse the disassembly proceduresto reassemble.
12. Differential pinion shaft (2) l *I Refer to “Service Points of Disassembly”.
13. Side gear 13) I)+: Flefer to “Service Pornts of Reassembly”. ,~
14. Pressure ring
15. Friction disc
REAR AXLE - Differential Carrier 3-47
SERVICE POINT OF DISASSEMBLY NOBIPBA

1. REMOVAL OF SCREW
(1) Loosen screws of the differential cases (A) and (B)
uniformly a little at a time.
(2) Separate differential case (A) from differential case (B).
(3) Remove the components from differential case (B).
NOTE
Keep the right and left parts separate in order to be able
to distinguish them for reassembly.
11 Y641

INSPECTION NOBIQBA

l Check side gears, pinion gears and pinion shaft for wear or
damage.
l Check the side gear spline for wear or damage.

INSPECTION OF THE CONTACT AND SLIDING SURFACES

OF PARTS
(1) Inspect the friction plate, friction disc, spring plate, spring
disc and pressure ring.
A. The friction surfaces of the friction plate, friction disc,
spring plate, and spring disc.
If there are any signs of seizure, severe friction, or
colour change from the heat, it will adversely affect the
locking performance; replace the part with a new one.
NOTE
The strong contact on the inner circumference of the
friction surfaces is because of the spring plate and the
spring disc; this wear is not abnormal.
B. The six projections on the inner circumference of the
friction disc.
If there are nicks and dents, it will cause abnormalities
in the clutch pressure.
Repair the parts by using an oil stone; if the parts
cannot be repaired, replace them.
C. The four projections on the outer circumference of the
friction disc.
If there are nicks and dents, it will cause abnormalities
in the clutch pressure.
Repair the parts by using an oil stone; if the parts
cannot be repaired, replace them.
D, The friction surface of the friction disc of the pressure
ring.
If there are nicks or scratches, repair the part by first
grinding with an oil stone and then polishing with
rubbing compound on a surface plate.
NOTE
The strong contact on the inner circumference of the
friction surface is because of the spring plate and the
11 S65E spring disc; this wear is not abnormal.
3-48 REAR AXLE - Differential Carrier

(2) Inspect the contact and &ding surfaces listed below, and _.I
repair any nicks and burrs by using an oil stone. _~_
E. The spring contactingxrrface- of the differer-&al case; ...I
F. The contact surfaces of the outer circumference of jhe
pressure {ring and the inner circumference of the ..-t
differential case. ’
G. The sliding surface .of the thrust washer.
H. The sliding surfaces of~the hole in the pressure ring and -1
the outer circumference of the side gear.
I. The projection on the outer circumference of the .,
pressure ring. .~~
J. The spherical surface Qf the differential pTnion~gear and ;
-E
the inner-diameter of- the pressure ring.
K. The V-shaped grooven the pressure ring, and the
V-shaped part in the pinion shaft.
L. The outer diameter offthe pinion shaft and the hole in ..z
K the differential pinion gear.
J I M. The outer circumference groove of the side..gear, 1
N. The inner~circumference groove of the differential case, _ -;

M
\ J llS662
11 S657
118658
-.
INSPECTION FOR WARPING-OF THE FRICTION PLATE AND
FRICTION DISC
Using a ~dial indicator, measure the amount of warping (the .~
flatness) of the friction plate and the friction dTsc on a surface .z
plate by turning the friction plate or disc.
Limit: 0.08 mm (.0031 in.)

,3G li

INSPECTION FOR WEAR OF THE FRICTION PLATE AND

FRICTION DISC
(1) In order to measure the wear, measure the thickness of the =
friction surfaces and prelections of the friction disc and 1
plate, and then find the difference. -4

Limit: 0.1 mm (.0039 in.)

- -
NOTE
Make the measurement at several different points. -=
(2) If the parts are~worn beyond the allowable limit, replace
llS659 them with new parts.
 REAR AXLE - Differential Carrier 3-49
SERVICE POINTS OF REASSEMBLY NOBIRBA

. CLUTCH PLATE FRICTION FORCE ADJUSTMENT

Before assembly, use the following method to adjust
clearance between the spring plates and differential cases
(for clutch plate frictional force adjustment) when installing
the internal components into the differential case.

(1) Stack up the friction discs and friction plates two each
on each side as illustrated. Find combination that gives
standard difference in thickness between the two
sides.
Standard value: 0.05 mm (.0020 in.)
NOTE
The thickness of new friction plate and friction disc is
1.70 mm (.0669 in.).

I 11 S674

(2) Stack up spring disc and spring plate one each on each
side as illustrated. Find combination that gives smallest
difference in thickness between- the two sides.
NOTE
The thickness of new spring disc and spring plate is
1.70 mm (.0669 in.).

I
11 S673

(3) Assemble the pressure ring internal parts (differential

pinion shaft, differential pinion gear and side gear),
friction discs and friction plates and measure the overall
width as illustrated.
(4) Determine the sum (C) of thickness of spring discs and
spring plates and measurement taken in step (3) above.

(5) Determine the dimension (D) between contact surfaces

of spring plates when differential cases (A) and (B) are
combined.
D=E+F-G
(6) Adjust the spring disc thickness so that the spring plate
to differential case clearance (D - E) becomes the
standard value.
Standard value:
0.06 - 0.20 mm (.0024 - .0079 in.)
 REAR AXLE - Differential Carrier

Spring plate (7) Place parts in the drtferentral case (BJ In the illustrated .-
direction.

-I~
NOTE
(a) Before assembly, apply the specified gear oil to 1
each component being especially careful to coat all I
contact surfaces and sliding surfaces. _
Specified gear oil:
MOPAR Hypoid Gear Lubricant Part No.
4318058 plus MOPAR Hypoid Gear Oil Addi-
tive - Friction Modifier, Part No. 4318060 or
llS671
equivalent
(b) Be careful not to Insert the trrction plates and tnction
discs rn the Incorrect order and to rnstall the spring 1
plates and spring discs in Incorrect direction, iy

l CLUTCH PLATE PRELOAD ADJUSTMENT

(1) Align mating marks (same numeral on each case) on . ..-
differential case (A) and differential caz (B),
(2) Tighten screws with a screwdriver in several steps until .-I
the cases-are brought into close contact.
NOTE
If end faces of cases (A) and (B) do not come into close _
contact when screws are tightened, incorrect engage- 2
ment of preload spring and outer clutch plate or sprk-rg or
plate with groove is suspected. Assemble again.
llS66f

(3) After assembly, in order to check the frictronal.force of -‘_”

the clutch plate, use the special tools to measure the -1
starting torque.
NO-j-E --~
Slightly rotate the unit before measuring the torque. ’
Standard value:
When a new clutch plate is used
50 - 80 Nm (36 - 58 ft.lbs.)
When an old clutch plate is used
35 - 80 Nm (25 - 58 ft.lbs.)
 5-1

BRAKES
SERVICE AND PARKING
CONTENTS
BRAKE BOOSTER ................................................ 43 SPECIAL TOOLS .. .. . .. .. . . .. . ..._.._............_.____.._.......... 18

BRAKE LINE ........................................................ 45 SPECIFICATIONS ................................................ 14

General Specifications .................................... 14
BRAKE MASTER CYLINDER ............................ 38
Lubricants ............................................................ 17
BRAKE PEDAL .................................................... 35 Sealants and Adhesives .................................... 17
Service Specifications .................................... 15
FRONT DISC BRAKES ........................................ 47
Torque Specifications ........................................ 16
GENERAL INFORMATION ................................ 2
TROUBLESHOOTING _............. _. .. . .. . .. .. .. . . . .. .. .. . . . 19
PARKING BRAKE CABLE .................................... 68 Brake Drag
Groaning, Clicking or Rattling Noise When
PARKING BRAKE LEVER .................................... 66 Brakes Are Not Applied
REAR BRAKE LOCK-UP CONTROL Increased Pedal Stroke
SYSTEM ................................................................ 58 (Reduced Pedal to Floorboard Clearance)
Insufficient Braking Power
REAR DISC BRAKES ............................................ 52 Insufficient Parking Brake Function
SERVICE ADJUSTMENT PROCEDURES ........ 24 Rear Brake Lock-up Control System
Bleeding ................................. .._........................ 29 Scraping or Grinding Noise When B~rakes
Are Applied
Brake Booster Operating Tests ........................ 25
Squealing Noise When Brakes Are Not Applied
Brake Fluid Level Sensor Check .................... 24
Squealing, Groaning or Chattering Noise
Brake Pedal Inspection and Adjustment ........ 24 When Brakes Are Applied
G-sensor Installation Levelness Check ........ 29 Vehicle Pulls to One Side When Brakes
Modulator Operating Test ................................ 28 Are Applied
Pad Assembly Inspection and
Replacement .................................................... 29
Parking’Brake Lever Stroke Check ................ 33
Parking Brake Switch Check ............................ 34
Proportioning Valve Function Test ................ 27
Rear Brake Lock-up Control System
Function Check ................................................ 27
 ,,

I
‘7

z=:
f@

mm-
5-2 BRAKES - General Information
-E .-~z
_~
f!g!~
CAUTION m--
When servicing brake assemblies or compo-
nents, do not create dust by sanding, grinding
or by cleaning brake parts with a dry brush or E
with compressed air. A WATER DAMPENED
CLOTH SHOULD BE USED. Many brake com-
ponents contain asbestos fibers which can -
become air-borne if dust is created during ‘?&
service operations. Breathing dust which con-
tains asbestos fibers can cause serious bodily
harm.
a:=;
IF-.
BE%
=y-i
BZT
&=:
GENERAL INFORMATION NOSBA..
gx
E&h-=
The serViG brakes on all four wheels (front and rear) are disc brakes (ventilaed type) that feature outstanding I =
braking effect and heat dissipation.
Abrake booster is also added to reduce the force required for braking. ._
A proportioning valve is provided for improved stability during braking.
g+z--A
s--f
p=--
&;;-
--;--
g&
v-K--;-
L:
--;=-i
-=
ET.
m-3
h--~~
Es?’
m--
e5. fizm
c-_I
s;,
-._e-~ f-:
s*.
E
E.
&; 2

-~=

i : -__
A& :

Rear-AD type disc brake

(ventilated) --
-MY815
-
Front - FSI 7 type disc brake
(ventilated) s-I
E-
z

se

I%-
E*
m-
 BRAKES - General Information 5-3
The parking brake is a mechanical brake acting on rear wheels. The parking brake lever is installed offset
toward the driver’s seat so that it is easy to manipulate. The brake cable arrangement is V-type. The parking
brake lever stroke is adjustable by means of the equalizer installed beneath the floor console.

Parking brake lever

5-4 BRAKES - General Information
REAR BRAKE LOCK-UP CONTROL SYSTEM
Direction is stabilized
SUMMARY
Handling is stabilized
This system is anautomatic brake control system designed to -,,
achieve maximum braking efficiency for quick stops on wefor =
icy road surfaces; and to red&e the possibility-of the vehicle
skidding. If the wheels become locked when the bi%kes are _
applied suddenly while driving on roads slippery with snoti or _
rain, the braking efficiency w-ill be drastically reduced, and in
Vehicle equipped wrth rear Other vehicle addition, the driver could possibly lose complete control of the .;
brake lock-up control system vehicle. The rear-brake lock-up control system is designed, to
14Y69
reduce the possrbrlity of these-dangerous conditions occurring I pi
by automatrcally maintaining~~optimum control of braking in X
accordance wrth the road-conditions. This system, however, is -
designed for t-m wheel control only. If the front wheels Y
become locked, the brakes will not be automatically controlled. i
THE PRINCIPLES OF THE REAR BRAKE LOCK-UP CONTROL * &;
R~
S’
SYSTEM ax-
The rear brake lock-up control system is designed to control the ZC
physical characteristics of th_e relationship between the tjres 2 EI
and the road surface (the friction factor be.tween the tires and m~I E
the road surface and the slrpprng rate of the tires*).
The illustration shows the ba=sic curves of f~ versus s”* ZE
._ and of :
lateral stability.
From the illustrati’on, It can clearly be seen that, by maintaining Em
control in the area of 1~max (the maximum fricfion factor), the 7 -m
braking distance can be reduced, and in addition, lateral stability -
can be maintained.
This rear brake lock-up control system has been designed to-~;
implement these pnncrples~>n the braking function. :’ -. =-
5peed af The speed of ..:
the vehicle - the wheels
+ Slrpprng rate (s) = 1 -4%
Speed of the vehicle
*. The curve ot p versus s IS determrned by the relatronship between .I
the road surface tnctton facto_r and the slipping rate.

Ia Range of stability during wet condittons

0.8 [:I Range of stability during icy conditions

0.6
E-
E.

p versus s curve -

ability curve

Slipping rate (s)

 BRAKES - General Information 5-5
COMPONENTS

Fail indication light G-sensor

Pulse generator

14Y692

The rear brake lock-up control system is composed of the

following five units:
PULSE GENERATOR
Generates a rotation pulse in accordance with the speed of the
rear wheels.
G-SENSOR
Generates a voltage in accordance with the reduction of the
vehicle speed.
CONTROL UNIT
Controls each of the signals.
MODULATOR
Controls the pressure of the brake fluid.
FAIL INDICATION LIGHT
Illuminates in the event of a malfunction of the control unit.

DIAGRAM OF THE FLUID PRESSURE AND VACUUM CIRCUITS

Modulator
m Fluid pressure circuit -1
!ZZJ Vacuum circuit IJ

Vacuum source
Engine
Intake manifold

I ~~~\qGcyind>
Master cylinder
Front brakes Rear brakes 14Yfi94
5-6 BRAKES - General Information

ELECTRIC CIRCUIT DIAGRAM

To fuse box 13 (3G)

Tofuse box 11 (ACC)

To fuse box 2 (B)

P Modulator

141706 SSF==
-
- .- : i --i:-g *
OPERATION DESCRIPTION
Pulse Generator (Detection of the Speed of the Wheels)
The pulse generator is composed of a permanent magnet, a ~~
coil and a rotor. E 1; installed:at the s@eedometer exit poti of ~
the transmission;:The rotor IS rorared~by the speedometer drjve ~.I
gear. The magn@c flux generared from the per-tianetit magnet I
varies accordingto the rotatron of the rotor, and an AC voltage ET
is generated In the coil (El&tromagnetic inductioti~ action?).
The AC voltage~(s proportlonate to the rotating speed of the .~~~
rotor, and the frequency varies. Accordingly, the speed of the _-
wheels is detected by using Jhe frequency variafions of the AC T
voltage generated by the pulse generator.
The frequency of the generated voltage is the average valti6 of eY
-
the speeds of tie -left and Light wheels.
5.~..
--
Construction of the pulse generator zy
I

Speedometer drive gear

(inside the transmission)

Speedometer cable +--

-
-
 BRAKES - General Information 5-7
G-Sensor (Detection of the Reduction of the Vehicle
Printed Speed)
The G-sensor is composed of a differential transformer, a
Ioil assembly, control circuit (in the form of a printed circuit board), etc. It is
installed on the floor of the baggage compartment.
The core within the differential transformer is usually stationary
Core- at the center of the coil; however, when a reduction in speed is
applied, the core moves and a voltage corresponding to the
amount of displacement of the core is generated. In other
words, the extent of the reduction in the vehicle speed is
Construction detected.

Reduction of the vehicle speed

Output characteristic
14Y70E

- Control Unit (Signal Control)

1 The control unit is installed inside the baggage compartment. It
receives the signals from the pulse generator, the G-sensor,
and the brake switch (which is also used as the stop light
nnn switch), and transmits the brake fluid pressure control signal to
JWVL the modulator. If there is a malfunction in either the control unit
Pulse generator G-sensor II Brake
-___---- - --- pedal or the modulator (the solenoid valve section), or in the event of
-u an open circuit, the condition is detected. The brake system is
returned to conventional operation, and the fail indication light
Control unit illuminates to warn the driver of the existence of a malfunction.
(Determination of the
optimum condition) In addition, if an open circuit occurs in the wiring of the control
unit power supply, the G-sensor, the inside of the pulse
--: il generator, or the brake switch (input wiring), or if all the stop
---T----- light bulbs burn out, the brake system is returned to conven-
tional operation, and the fail indication light illuminates in the
same way to warn the driver.
The signal to lower the brake fluid pressure of the rear brakes
indication causes the modulator release valve (the valve used to lower the
light
brake fluid pressure) to operate in the event that the amount of
slipping of the tires on the road surface becomes greater than
the specified value which is determined in accordance with the
speed reduction of the wheels and also in the event that the
14Y69G speed reduction of the wheels becomes greater than the
specified value in relationship to the reduction of the vehicle
speed. Note that there is no lock-up control of the rear brakes
when the speed of the vehicle is approximately 8 km/h (5 mph)
or less.
5-8 BRAKES - General Information
OUTLINE OF OPERATIQN ~
Operation curve The control unit determines the~ideal vehicle speed reduction
Curve of the actual curve in accordance with the input signals from-the G-sensor
and the pulse generator. As sh@n in the operation curve, the
ideal vehicle speed reduction ar@ the actual speed reduction of
the wheels are compared. If the actual speed reduction of the
wheels is greater (if the rotationspeed of the wheels is slowing
down too rapidly), the brake fluid pressure for the rear brakes is
2
- Curve of the ideal rate decreased, the rate of speed reduction of the wheels.is also
2 of vehicle speed reduction
G Decrease decreased, and &e ideal vehicle ~speed reduction rate is
&signal S restored. On the other hand, if the actual speed reduction of
the wheels is smaller (if the rctation speed of the wheels is
slowing down too slowly), the brake fluid pressure for the rear
brakes is increased, the rate oFspeed reduction of the wheels
is also increased, -and the ideaf wheel speed reduction rate is
1110 second
restored. In this way, the whee% are controlled to maintain the
ideal rate of speed reduction..
The slope of the Ideal rate of vehicle speed
reduction is maintained at the optimum FAIL-SAFE FUNCTION
level by a constant feedback of the rate of
speed reduction of the wheels. The fail-safe function causes the control unit to cease opera-
[Points (1). (2) and (3) in the graph] tion, the brake system to return to conventional operation, and
the fail indication light to illuminate in the event that any of the
14y70!
following malfunctions occur in the rear brake lock-qYcontr6l
system : .~
1, The wrnng of the solenord valve used for vacuum control of
the modulator_ becomes disconnected. . ’
-.‘S The wiring of the solenord valve used for vacuum control ‘of
the modulator operates cenrinuously for five seconds or
longer.
3. The wiring of the brake switch becomes disconnected.
4. A problem occurs rnsrde the pulse generator, or fie wiring
of the pulse generator becomes disconne@d.
5, A problem occurs In the G-sensor, or the wit?ii - of the. i
G-sensor becomes drsconnected.
6. The power supply line ot the control ~unit becomes
drsconnected.
7. The wirrng of the stop lriht becomes. disconne?ted.
If the fail indication light illumrnates, refer to the troubleshoot-
rng sectron.
CONTROL UNIT FUNCTION ICHECK
Run the engine for five secor& or longer while thevehicle is
not rn motion. Next, set the ignition key to- the “LOCK”
posrtion, depress~the brake pedal, and then, while keeping the
brake pedal depressed, set the ignition key back to the I’ON”
positron. At this time, confirm that the operation sound of the
modulator solenoid valve can be heard. If this-sound can. be
heard, then the control unrt IS functioning normally.
In other words, self-diagnoses of the control unit is done by
causing the release solenord valve to operate.
 BRAKES - General Information 5-9
Modulator (Vacuum-servo Type Brake Fluid Pressure Con-
trol)
The modulator receives the control signal (electrical signal)
from the control unit, and controls the brake fluid pressure for
the rear brakes.
The modulator is composed of a brake fluid pressure control
section to control the brake fluid pressure for the rear brakes, a
vacuum drive section to drive the brake fluid pressure control
section, and a solenoid valve to control the vacuum of the
vacuum drive section.
OPERATION DESCRIPTION
Non-operating Condition
When the solenoid valves (the release solenoid valve and the
build-up solenoid valve) are not in the operating condition, the
pressures in compartments A and B become equal because of
the opening of release seat B. For this reason, the brake fluid
plunger is pressed to the right through the vacuum piston by
the main spring, the check valve opens, and continuity exists
for the master cylinder and the rear brake circuit.

Char nber B (vacuum) Joints

Main spring \ Release valve seat B Release valve seat A
ChamberA (vacuum)
\
From the master

Release
solenoid
valve

.A III
I Ill1 Chamber B (vacuum)

Check valve Build-up

1 / II solenoid
Brake fluid pressure valve
control section
Brake fluid pressure plunger
To vacuum source
Vacuum piston

Vacuum drive section 14Y700

5-10 BRAKES - General Information RI
m!E&2:
w..
During Operation
1. Reduction of the brake fluid pressure for the rear brakes
If the signal for reductron of the brake fluid @%sur$; is I!!
output from the control unrt, the electrrc current will flow to pi
the release solenord valve, the release plunger will move to 1
the left, release valve seati will open, and, simul%neousJy, m7
release valve seat B will close. Air will flow hto chamber B _
through the art- filter, to the air Intake port, and io release i-y
valve seat A. When chamber B reaches atmospheric ~-
pressure, the pressure drtference between chamber A G
(vacuum condition) and chamber B will cause the vacuum
piston to move to the left, compressing the main spring. ~*
The brake fluid pressure plunger will move t0 the left I
simultaneously with the vacuum piston and close the ch.eck ._=
valve. Whenthe check valve IS closed, the flow of brake z
fluid from the master -cylinder to the rear brakes is 1
disrupted, and, at the same time, the brake fluid pressure is?
decreased b.ecause of the. increase in the capacity of brake .-~~ ’
fluid rn chamber C. _ _

Main spring
Chamber 6 Joints Release valve seat B Release valve seat A
Chamber A (vacuum) \ (atmospheric pressure) /\ \ /

\ \
From the master ! par

plu1nger =_

rake fluid chamber C

Brake fluid pressure plunger

To vacuum source
14'1698
- -
 BRAKES - General Information 5-l 1

2. Slow restoration of the brake fluid pressure for the rear

brakes to a normal level
Once the brake fluid pressure to the rear brakes has been
reduced, the brake fluid pressure reduction signal will cease
to be output, the release solenoid valve will return to its
non-operating condition, and the air intake to chamber B will
be stopped. Because the atmospheric pressure of chamber
B passes through the orifice, the pressure in chamber B will
gradually change from atmospheric pressure to a vacuum,
and, as a result, the pressure difference between chamber
A and chamber B will gradually disappear. The brake fluid
plunger will be pressed back to the right by the force of the
main spring, the condition will be the same as when not
operating, and the normal level of brake fluid pressure will
be supplied to the rear brakes.
3. Quick restoration of the brake fluid pressure for the rear
brakes to normal level
The electric current will flow to the build-up solenoid valve,
the build-up plunger will move to the right, and the build-up
valve seat will open. Because the pressure reduction of
chamber B is done through both the orifice and the build-up
valve seat, the pressure of chamber A and chamber B will
quickly equalize.
NOTE
If the brake fluid pressure is reduced too much and the level
of wheel speed reduction becomes significantly lower than
the desired level, the build-up solenoid valve will operate to
rapidly achieve the desired level of speed reduction.

Chamber B (vacuum)

Main T:‘g \ lar::refilease valve seat B Release valve seat A

Chamber A (vacuum)
\
\ \ ’
Release
solenoid
valve

j j,i i Chamber B (vacuum)

rake fluid pressure

control section
rake fluid pressure plunge
_-____ To vacuum source

Vacuum drive section \

Vacuum piston

14Y699
5-12 BRAKES - General Information

CHECK VALVE FUNCTIONS -

From the master cylinder 1. .When the brake fluid pressure for the rear brakes s to be
To the rear brakes I
t Checkvalve body 1 i 1 decreased, the brake fluid pressure plunger moves to the
left. At this time. the checkvalve body also moves to the
left, the brake fluid line is closed by the seal and baTf valve,
and the rear brake fluid pressure is decreased. ~~__
2. When the brake fluid pressure for the rear brakes is to be
restored to normal, a sudden increase in the brake fluid
pressure plunger sgal / \- pressure is avoided as follows: The brake fluid pressure
Ball valve Orifice plunger moves to the right, pushing on the ballvalve which
CIAY 707
opens the brake fluid line, allowing the brake fluid from the
master cylinder to pass through the orifice and @adually
flow to the rear brakes. ~.
CHOKE VALVE FUNCTION _
Extreme Increase m the master cylrnder brake fluid pressure
will occur when the brake pedal IS operated suddenfy during
ourck stops etc. The choke valve prevents sudden increase in
the rear brake fluid pressure toallow the system to correctly
perform the control function even during. sudden braking. Th.e
brake fluid flows freely to the rear brakes until the brake fluicl
pressure~of the master cylinder reaches 4,903 kPa (711~ psi), as
shown rn the qrapt

Plug
From the master cylinder

d
2
3
>
--

Master cylinder
brake fluid pressure

I-
1,800

1.500
2?
N-shaped groove) 2
gh 1,200
2
is 900 6
-2
& 750 5
600 4

I Time

To the brake fluid pressure control section

(to the rear brakes)
BRAKES - General Information 5-13
When the brake fluid pressure reaches 4,903 kPa (711 psi), the
stepped diameter piston will press the cut-in spring upward,
and contact the plug. The brake fluid will pass only through the
V-shaped groove, thus limiting the rate of increase of the brake
fluid pressure to the rear brakes.
Fail Indication Light
If any malfunction occurs in the rear brake lock-up control
system, a signal from the control unit will cause the fail
indication light to illuminate to warn the driver of the malfunc-
tion. In addition, the light will illuminate for approximately three
seconds when the ignition key is set to the “ON” position in
order to provide confirmation that the light is connected and
functioning properly.
If the light does not illuminate, there is a malfunction of the light
or the light circuit.
If the light remains on, there is a malfunction of the rear brake
lock-up control system.
Notes Regarding Handling
1. Because there is such a large number of transistor circuits,
the system could be easily and instantly damaged if a
terminal is improperly contacted during a check for a
malfunction; handle with care.
2. Do not open the cover of the control unit to inspect the
internal parts. The unit might easily be damaged if a part is
mistakenly touched, or if dust or other foreign particles
enter the unit.
3. The connections of the battery MUST NEVER be reversed.
During replacement of the battery, be sure to set the
ignition key to the “LOCK” position, and connect the new
battery carefully so that there are no mistakes.
4. During removal and installation, be careful not to expose
any of the components to any violent shaking or impacts.
Special care must be observed in the handling of the
G-sensor; however, all of the other components of the rear
brake lock-up control system should also be handled with
care.
5. When checking the system with a circuit tester, be careful
not to mistakenly touch an adjacent terminal, or to connect
the tester to the wrong terminal. If this occurs, the system
could be easily and instantly damaged.
6. If the system is being checked during rainy weather, be
careful not to allow water to get into any of the compo-
nents.
7. The G-sensor is filled with a special oil. If it is opened, it can
no longer be used.
5-14 BRAKES - Specifications

SPECIFICATIONS NOSCA..

GENERAL SPECIFICATIONS

Brake booster
Type
Effective dia. of power cylinder mm (in.)
Boosting ratio
[Brake pedal depressi

Type
276 (I 0.87) ~
Pad thickness mm (In.)

Disc 0.D. mm (in.)

Pad thickness mm (In.)
Cylinder I.D. mm (in.) 41.3(1.631

3.58 - 4.27 (519 -. 619)

Type ~-~ Vacuum booster type

Pulse generator
Type
Parking brake
Type Mechanical br_ake acting on rear wheels
Brake!ever.type
Cable arrangement
 BRAKES - Specifications 5-15
SERVICE SPECIFICATIONS NOSCB- _

Items Specifications

Standard value
Brake pedal height mm (in.) 177 - 183 (7.0 - 7.2)
Brake pedal free play mm (in.) IO-15(.4-.6)
Brake pedal to’toeboard clearance mm (in.) 80 (3.1) or more
Booster push rod to master cylinder piston clearance
mm (in.) 0.7 - 1 .I (.028 - ,043)
Brake drag force
(tangential force of wheel mounting bolts) N (Ibs.) 70 (15.4) or less
[Brake dragging torque Nm (ft.lbs.)] 14 (3) or less]
Modulator resistance fi
Release solenoid valve side 3.8 - 4.8
Build-up solenoid valve side 4.5 - 5.5
Pulse generator resistance fi ,600 - 800
G-sensor installation levelness Within f I0
G-sensor output voltage ‘V
At 0” inclination 1.1-1.5
At 90” inclination 4.6 - 5.0
Modulator fluid pressure kPa (psi)
Split point fluid pressure 4,903 (711)
Set master cylinder fluid pressure 11,768 (1,707)
Max. cut fluid pressure 9,807 (1,422)
Brake booster operating test
Air-tightness test with no load kPa (mmHg) 3.0 (25)
Air-tightness test under load kPa (mmHg) 3.0 (25)
Booster function test M Pa (psi)
At 100 N (22 Ibs.) foot force 2.5 - 4.0 (355 - 570)
At 300 N (66 Ibs.) foot force 6.0 - 8.0 (850 - 1,140)
Non-boosting function test MPa (psi)
At 100 N (22 Ibs.) foot force 0.2 (28) or less
At 300 N (66 Ibs.) foot force 1.5 (213) or less
Proportioning valve split point MPa (psi) 3.58-4.27 (519-619)
Output pressure at proportioning valve input pressure
of 6.86 MPa (996 psi) MPa (psi) 4.80 -. 5.48 (696 - 795)
Parking brake lever stroke clicks 4-5

-imit
Master cylinder to piston clearance mm (in.) 0.15 (.006)
Brake pad thickness mm (in.) 2.0 (.08)
Brake disc thickness mm (in.)
Front 22.4 (.88)
Rear 16.4 (.65)
Brake disc runout mm (in.) 0.15 (006)
TORQUE SPECIFICATIONS NKXG.

Items

Brake pedal to pedal support

Nm

25-35
ft,lbs.

18-25
I
Brake booster to pedal support 8-12 6-9
Reservoir band 2.5 - 4.0 1.8 - 2.9
Check valve case 40 - 50 29-36
Check valve cap 25- 35 18-25
Piston stopper 1.5 --3.0 1.1 -2.2
Master cylinder to brake booster 8- 12 6-9
Fitting 1 5 -.- 18 II-13
Master cylinder to brake line connector 25-35 17-25
Brake line flare nut 13-17 9-12
Proportioning valve to body 5.5 -8.5 4.0 - 6.0
Combination valve to body 8-12 6-9
Front disc brake hub to disc 35-40 2529 ~~~
Front disc brake dust cover 8-12 6-9
Front brake to knuckle 80 - l-00 58-72
Slide pm 85-95 61 -69
Rear axle housing to calrper support 40-50 29-36
Parking brake bracket to caliper body 40-55 29-40 ~~
Guide pin and lock pin 50-60 36-43
Bleeder screw 7-9 5-7
Bleeder cap 20-30 14-22
Hydraulic cylinder mounting bolts 5510 4-7
Valve cap 30 -- 40 22-29
Pulse generator clamp IO-13 7-9
Steering shaft to gear box 20-25 15- 18
Steering column mounting special bolt 8-11 6-8
Front wheel bearing nut 2040-5 14-+0-+4
Rear strut to axle housing 50-70 36-51
Drive shaft to axle housing 55-65 40-47
4xle shaft to axle housing 260 1300 188-217
Lower arm~shaft Iholt) 70-80 31 -58
Lower arm to axle housing 15-20 11-13
 BRAKES - Specifications 5-17
LUBRICANTS NOSCD- -

Items ~~ -~~ Specified lubricants Quantity

Brake pedal bushing and spacer MOPAR Multi-mileage Lubricant As required

Part No. 2525035 or equivalent
Brake fluid MOPAR Brake Fluid As required
Part No. 2933249 or equivalent
Lip of cylinder (Front brake assembly) Repair kit grease (pink) As required
Front brake caliper plug seat surface Repair kit grease (pink) As required
Front brake caliper slide pin hole Repair kit grease (pink) As required
Front brake slide pin Repair kit grease (pink) As required
Front brake bushing inner surface Repair kit grease (pink) As required
Opposing surfaces of front brake inner shims Repair kit grease As required
and pad side surfaces of inner and outer shims
Rear brake dust boot fitting groove Repair kit grease (orange) As required
Rear brake contact surface of caliper body and Repair kit grease (orange) As required;
spring washers
Rear brake lever cap inner surface and lip of Repair kit grease (orange) As required
lever cap
Rear brake guide pin and lock pin Repair kit grease (orange) As required
Parking brake lever bearing Repair kit grease (orange) As required
Rear brake caliper support guide pin and lock Repair kit grease (orange) As required
oin boot
Dust seal of modulator Repair kit grease (silicone grease) As required
Zlevis pin, bushing and ratchet plate Multi-mileage Lubricant As required
Part No. 2525035 or equivalent

SEALANTS AND ADHESIVES NOBCE- -

Items Specified adhesives Quantity

Front brake slide pin bushing lip section Repair kit adhesive As required
5-20 BRAKES - Troubleshootina

Squealing, groaning or
chattering noise when
brakes are applied
 BRAKES - Troubleshooting 5-21

CIRCUIT DIAGRAM

Diode
1-

I I E
3
i
(Y

Combination meter

‘o turn signal flasher 0.85~~

[nit
L
4
r
A-L-L

Modulator
Rear brake lock-up
control relay

-------m---------------------7
I

Pulse generator .*.1

B-l 1

.*‘p
Remark
rJ For details of grounding
Stop light B points (ex.: I), refer to
switch 12 page 8-l 0.
.
I
-27

Resistor Hazard cluster

switch (R.H.)

Lg: Light green

R: Red W: White Y: Yellow

 BRAKES - Troubleshooting

REAR BRAKE LOCK-UP CONTROL SYSTEM - CONTROL PARTS LAYOUT

ENGINE COMPARTMENT

INSTRUMENT PANEL
 BRAKES - Troubleshooting 5-23

TRANSMISSION

09Y665

LUGGAGE COMPARTMENT

/
14Y677
5-24 BRAKES - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

NOSFAAJ

BRAKE PEDAL INSPECTION AND ADJUSTMENT

1. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, adjust as -~ .~~
foflows. ~_
Standard value (A): 177 - 183 mm (7.0 - 7.2 in.)
\
I 14F51E

(1) Disconnect the stop lrght switch and loosen the Locke-1
nut. Then, move the stop light switch to a position
Pedal where it does not contact the brake pedal arm. ~-~:
) down (2) Adjust the brake pedal height by turning the:Ioperating
rod with pliers (with the operating rod locking nut
loosened), until then- correct brake pedal ~height is .I
obtained- .
c

Locking nut

2. While the engine IS stopped, depress the brake- pedal two

or three times. After thus eliminating the vacuum in the r
brake booster, press the pedal down by h_a_nd,a~nd confirm-z ,
that the amo-unt of movement before resistance is met (the
free play) is within the standard value range. ~~
Standard value (B): IO - 15 mm (.4 - .6 in.)
(I) If the free play is less than the standard value, check to
make sure that normal clearance is maintained between _~
the stop light switch and the pedal arm.
(2) If the free play exceeds the standard value, largeplay f
between the clevis pm and brake pedal arm is sus:~-
petted. Check and replace faulty parts if any.
3. Start the engine, depress the brake pedal with a force off
approximately 500 N (110 Ibs.), and measure the distance I
between the upper face of the brake pedal and the floor-
sheet.
Standard value (C): 80 mm (3.1 in.) or more
If the clearance is smaller than the standard value, check for:
air trapped in the brake line or brake fluid leaks and repair as
needed.
F145

BRAKE FLUID LEVEL SENSOR CHECK NOSFBAD

1. Connect an ohmmeter to the brake fluid level sensor

connector.
2. Move the float vertically to check continuity. The brake fluid
level sensor is okay if it IS confirmed that there ia no_ ,
continuity when the float top is above “A” and there is .
continuity when the float top is below “A”.

14W581 0
 0
BRAKES - Service Adiustment Procedures 5-25

When engine When engine

BRAKE Boos-rE~ OPERATING TESTS NOSFCAG

is stopped is started TEST WITHOUT A TESTER

v
For simple checking of the brake booster operation, carry out
the following tests:
1. With the engine stopped, step on the brake pedal several
times with the same foot pressure to make sure that the
pedal height will not change.
Then step on the brake pedal and start the engine.

0
If the pedal moves downward slightly, the booster is in
14UOO6C
good condition.
If there is no change, the booster is defective.
2. Run the engine for one or two minutes, and then stop it.
Step on the brake pedal several times with normal

w
Good No godd
pressure.
If the pedal depress fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly.
If the pedal height remains unchanged~, the booster is
faulty.

14UOO61 14110062

3. With the engine running, step on the brake pedal and then
stop the engine. Hold the pedal depressed for 30 seconds.
If the pedal height does not change, the booster is in good _
condition. If the pedal rises, the booster is faulty.
If the above three tests are okay, the booster performanc,e can
be determined as good.
If one of the above three tests is not okay at last, the check
valve, vacuum hose or booster will be faulty.
TEST USING SIMPLE TESTERS

- Air-tightness Test with No Load

and then measure the decrease in vacuum.

Standard value: 3.0 kPa (25 mmHg) or less --
(3) If the vacuum decrease exceeds the standard value. check ~__ ??
the vacuum hoses, and the brake booster, and make any 7 -’ 5:’
necessary corrections, : B&3
Test 2 - Air-tightness Test Under Load &i
m-3
aEs
(I) Start the engine. -
(2) Depress the brake pedal at a force of approximately 200 N - g
(44 Ibs.). m=
Stop the engine when the-vacuum gauge reachesapprox- %
rmately 68 kPa (500 mmHg).
(3) After stoppmgthe engine,wart approxrmately 15.seconds, = E
-n- ~.
and then measure the decrease In vacuum. -EEr-
Standard value: 3.0 kPa (25 mmHg) or less
(4) If the vacuum-decrease exceeds the standard value, check, _-
the check valve, the vacuum hoses, and the- brake booster, --
and make any necessarycorrectrons. m i
Test 3 - Boosting Function Test eln
ST--
(I) Start the engine.
(2) Depress the brake pedal &hen the vacuum gaugesreaches 1 T
approxrmately 68 kPa (5013 mmHg).
(3) Check to be sure that the brake-fluid pressure is the _
standard value when the brake pedal is depressed-at a foot mm::
tome of 100. N (22 Ibs.) -and 300 N (66 Ibs.). I pi ,;_
Standard value: -v
m;
At 100 N (22 Ibs.) foot force
2.5 - 4.0 MPa (355 - 570 psi)
At 300 N (66 Ibs.) foot force
6.6 - 8.0 MPa (850 - 1,140 psi)
Test 4 - Non-boosting Function Test
(I) Stop the engine.
(2) Depress the brake pedal several times.
(3) Confirm thatthe vacuum gauge Indicates 0 kPa (O-mmHg). -1
(4) Check to be sure that the brake fluid pressure is the
standard value when the brake pedal is depressed-at a foot -~r
force of lOCEF(22 Ibs.) -and 300 N (66 tbs.). ~.
Standard value:
At 100 N (22 Ibs.) foot force
6.2 MPa (28 psi) or less
At 300 N (66 Ibs.) foot force
1.5 MPa (213 psi) or less
BRAKES - Service Adjustment Procedures 5-27
PROPORTIONING VALVE FUNCTION TEST NOBFKAG

1. Connect two pressure gauges, one each to the input side

and output side of the proportioning valve, as shown in the
illustration.
2. With the brake pedal depressed, make the following
measurements and check to be sure that the measured
values are within the allowable range.
(1) Output pressure begins to drop relative to input
pressure (split point)
Y14531
Standard value: 3.58 - 4.27 MPa (519 - 619 psi)
(2) Relationship between input pressure and output pres-
sure
Standard value:
Rear brake lock-up control system at input
pressure of 6.86 MPa (996 psi)
4.80 - 5.48 MPa (696 - 795 psi)
3. If the measured pressures are not within the standard
value, replace the proportioning valve.

REAR BRAKE LOCK-UP CONTROL SYSTEM

FUNCTION CHECK NOBFFAA

SELF-DIAGNOSIS CHECK
1. Operate the engine for five seconds or longer while the
vehicle is not moving, turn the ignition key to the “LOCK”
position, and then depress then brake pedal.
2. Turn the ignition key from the “LOCK” position to the “ON”
position, and confirm that the sound of the modulator
operating can be heard. If the operating sound can be
heard, the solenoid valve is functioning properly.
NOTE
The sound of the modulator operating should be a dull
clicking sound.
FUNCTION CHECK
1. Raise the vehicle on a jack (the rear wheels should be
completely off the ground), and then support the vehicle on
rigid racks. Block the front wheels.
2. Warm up the engine, see the shift lever to the second gear
position, depress the accelerator pedal, and maintain the
speedometer reading at approximately 30 km/h (19 mph).
3. Keep the accelerator pedal depressed in the same position,
and then depress the brake pedal suddenly.
4. The brakes will attempt to stop the rotation of the rear
wheels; however, because the operation of the anti-skid
brake system will cut off the supply of brake fluid pressure,
the rotation of the rear wheels will be restored. This
reduction and increase process should keep repeating
itself.
5-28 BRAKES - Service Adjustment Procedures

MODULATOR OPERATING TEST NOBFGAB -~

1. Connect pressure gauges [(A) and (B) with ranges of 0 to

15,000 kPa (0 to 2,100 pslf or more], one to the rear-brake -
Master exit point of the modulator, and the other between the
ge (A) cylinder master cylinder and the modulator.
2. Let the engine run at idling speed.
3. Hold the brake pedal at the point which will result in a
reading of about 4,903 kPa (711 psi) on pressure-@uge(B)
connected to the rear-brake exit point of the modulator. __
4. While watching pressure-gauge (B), operate the release _
solenoid valve.
The condition is normal-if the reading sudde_n!y drops --
almost to 0 kPa (0 psi). ~
BatteW
5. While maintaining the condition in step 4, operate the -1
build-up solenoid valve.
6. Then, while in- the condition in step 5, stop the operation of
- Connections during operation of the release solenoid valve while watching the pressure ~;
the release solenoid valve gauge.
----- Connectrons during operation of If the pressure suddenly rises to about 4.903 kPa (71 1 psi), ~_
the build-up solenoid valve the condition is normal.
14Y68L
Standard value:
Split point fluid pressure 4,903 kPa (711 psi)
7. Repeat step 4 and then, v&h the build-up solenoid valve in ._
the non-operating condition, stop the operation of the -
release solenoid valve while watching pressure gauge (B). If -
[Master cylinder brake the pressure~rises about one second later to about 4,900 .~
fluid pressure] kPa (710 psi), the condition is normal.
Master cylinder brake 8. With both solenoid valves in the non-operating condition,
fluid pressure (Al increase the fluid pressure of the master cylinder, and 1
/__--_L_
:’ check the relationship with the rear brake fluid pressure.
10. I’I r-f- NOTE
: Check to be sure that gauge (B) show a reading of 9,807
ET- : r/‘/Rear wheel cylinder
kPa (1,422 psi) when the brake pedal is depressed until ~-
: ,/’ brake fluid pressure
fi- /,,’ (BI gauge (A) shows a reading of 11,768 kPa (1,707 psi).
5- “[Maximum cut fluid pressure] If these values cannot be satisfied, replace the modulator. -.
4.
Standard value:
300
2 I/ Split point Set master cylinder fluid pressure
1 1 11,768 kPa (1,707 psi)
01 oe Max. cut fluid pressure 9,807 kPa (1,422 psi)
Time
BRAKES - Service Adiustment Procedures 5-29
G-SENSOR INSTALLATION LEVELNESS CHECK
N05FHAB

1. Position the unladen vehicle on a level place.

2. Use .a spirit level to measure levelness of the G-sensor in
lateral and longitudinal directions and check to see that it is
within the standard value range.
Standard value: Within +I”
3. If it is out of the standard value, use adequate shim to
adjust to the standard value.

BLEEDING NOBFYAE

1. The brake hydraulic system should be bled whenever the

brake tube, brake hose, master cylinder or wheel cylinder
has been removed or whenever the brake pedal feels
spongy when depressed.
2. Bleed the brake system in the sequence shown in the
illustration.
3. Purge air from the modulator before purging air from the
front wheel cylinders.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified brake fluid and other fluid.
If brake fluid is exposed to the air, it will absorb
moisture; as water is absorbed from the atmosphere,
the boiling point of the brake fluid will decrease and the
braking performance will be seriously impaired. For
this reason, use a hermetically sealed 1 lit. (1.06 qt.) or
0.5 lit. (0.53 qt.) brake fluid container.
Firmly close the cap of the brake fluid container after
use.

PAD ASSEMBLY INSPECTION AND REPLACE-

MENT NOBFZAG

FRONT
(1) Remove the lower slide pin.
NOTE
The slide pin is coated with a special grease. Be careful to
avoid wiping away this special grease or getting the slide
pin dirty.

(2) Raise the caliper body and hold it in a raised position.

(3) Remove the pad retainers, outer shim, inner shim and pad
assemblies from the caliper support.
 BRAKES - Service Adjustment Procedures ~-
(4) Measure thickness of the pad assembly at a portron where
wear is severest,
(5) If the pad assemblies are worn beyond the limit, replace
them.
Limit: 2.0 mm (.08 in,)
(6) Check pads for deformation, metal backing for damage, and
oil on the linings.
Replace the pad assemblies If necessary.

(7) Measure pad assembly slrdrng sectton of brake disc at tour

or more points.
Limit: 22.4 mm (.88 in.)
(8) Replace the brake disc if the brake disc thickness is smaller
than specified limit even at one point.

14F61'

(9) Measure the brake disc runout at rts peripheral end tace.
Limit: 0.15 mm I.006 in.)
(10)lf the brake disc runout exceeds the limit, change its
position on the hub a~ndi’or retorque evenly.
(11 )Check the runout again. lfjt cannot be corrected, replace
the brake disc. Do not resurface it.
-
NOTES

il
Before measurement of brake disc runout, check wheel
bearing for play and correctif necessary. Also clean-the disc
14F61: surface to remove dirt and rust before runout measure-
ment
(12)To determine the dragging torte of the pad, measure the
rotational force of the hub with the pad removed.

.-
li*..
(13)Push in the piston by using the specral, tool.
NOTE
Be sure that the dust~bootdoes not protrude from the end ,I
of the piston.
If the reservoir is full of brake fluid, pushing in of the piston ~~_
will cause overflow of fluid from the reservoir-. Drain --~
somewhat, therefore, before operation.
Before setting the special tool, clean the piston.

14Y22t
BRAKES - Service Adjustment Procedures 5-31

(14)lnstall the pad retainer to the caliper support.

1 (15)lnstall the inner and outer shims to the pad assembly.

(16)lnstall the assemblies
Caution
to the caliper support.

The pad assemblies should be replaced as sets (inner

and outer) for both the left and right wheels at the
same time.

(17)Mount the caliper body to the caliper support.

(18)Measure the brake dragging torque by starting the engine,
maintaining the brake pedal in the depressed position for
approximately 5 seconds while the vehicle is not moving:
and then rotating the disc ten revolutions in the forward
direction and using a spring balance to measure the brake
drag in the forward direction.
Standard value: 70 N (15.4 Ibs.) or less
[Brake dragging torque: 4 Nm (3.0 ft.lbs.) or less]
(19)lf the difference between the value measured while the
brake pads are mounted and that obtained while they are
removed exceeds the standard value, disassemble the
caliper assembly, and check for dirt and/or corrosion on the
sliding part of the piston, and also for deterioration of the
piston seal.

REAR
(1) Disconnect the parking brake cable.
(2) Remove the lock pin.
NOTE
The lock pin is coated with a special grease. Be careful to
avoid wiping off this grease or getting the lock pin dirty.
(3) Raise the caliper body and hold it in a raised position.
(4) Remove the pad clips, shim and pad assemblies from the
caliper support.
 _~___
_.
EC
Gz
&
---
5-32 BRAKES - Service Adjustment Procedures

(5) Measure thickness of the pad assembly at a portion where - B

wear is severest.
(6) If the pad assemblies are worn beyond the limit, replace I Em
them.
Limit: 2.0 mm (.08 in.)
(7) Check pads for deformation, metal backing for damage, and go
oil on the linings.
Replace’the pad assemblies if necessary.
Egs
--
14Y791

EiE&
(8) Measure pad assembly sliding section of brake disc at tour -s-
or more points.
Limit: 16.4 mm (.65 in.)
(9) Replace the brake disc if the brake disc thickness is smaller
than specified-limit even at one point. ~~

u 14F61'

(lO)Measure the brake disc runout at Its perrpheral end face.

Limit: 0.15 mm (.006 in.)
(11)lf the brake disc runout -exceeds the limit, change its
position on the hub and/or retorque evenly.
(12)Check the runout again. If it cannot be corrected, replace
the brake disc. Do not r&urface it.
NOTE
Before measurement of brake disc runout, check wheel
bearing for play and correct if necessary. Also clean the disc
14F61: surface to remove dirt and rust before runput measure-,
=-~_
ment.
(13)To determineIthe dragging force of the pad, measure the
rotational force of the hub with the pad removed.

(14)Screw in the piston by using the special tool and then Install ~= I
the caliper body.
NOTE
At this point, set the piston stopper grooves, as shown by
the arrow in the illustration, so that they will interlock with
the projections on the rear of the pad assembly.
If the reservoir is full of brake fluid, pushing in of the piston
will cause overflow of fluid from the reservoir. Drain
somewhat, therefore, before operation.
Before setting the special tool, clean the piston.
 BRAKES - Service Adiustment Procedures 5-33
(15)lnstall the pad clip to the caliper support.

Pad clip
I-

(16)lnstall with shim paw1 engaged with the pad assembly as

illustrated.
(17)lnstall the pad assemblies to the caliper support.
Caution
The pad assemblies should be replaced as sets (inner
and outer) for both the left and right wheels at the
same time.
(18)Lower the caliper body, and install the lower lock pin.

(19)Measure the brake drag by starting the engine, maintaining

the brake pedal in the depressed position for approximately
5 seconds while the vehicle is not moving, and then rotating
the disc ten revolutions in the forward direction and using a
spring balance to measure the brake drag in the forward
directio~n.
Standard value: 70 N (15.4 Ibs.) or less
[Brake dragging torque 4 Nm (3.0 ft.lbs.) or IessJ
(20)lf the difference between the measured value obtained
while the brake pads are mounted and that obtained while
.~ they are removed exceeds the standard value, disassemble
the piston, and check for dirt and/or corrosion on the sliding
part of the piston, and also for deterioration of the piston
seal.

PARKING BRAKE LEVER STROKE CHECK NOBFEAD

1. Pull the brake lever with a force of approx. 200 N (45 Ibs.),
and count the number of notches.
Standard value: 4 - ,5 clicks
2. If the parking brake lever stroke exceeds the standard
* value, adjust it by turning the cable adjuster.
 ; c

-~.

mzz
5-36 BRAKES - Brake Pedal
.______~~_ zEcc<

SERVICE POINT OF REMOVAL NOSGBAE

12. REMOVAL OF STEERING COLUMN ASSEMBLY

Refer to GROUP 19 STEERING - POWER.

INSPECTION NO5GCAF

* Check the spacer and bushing for wear.

Shaft l Check the brake pedal for bend or twisting. ~~~~ .= _
l Check the brake pedal return spring for damage.
STOP LIGHT SWITCH
Operate the switch and check for continuity between the
terminals.

SERVICE POINTS OF INSTALLATION NOCGDAT

12. INSTALLATION OF STEERING COLUMN ASSEMBLY

Refer to GRQUP 19 STEERING - POWER. ~_ ~~
9. APPLICATION OF GREASE TO SPACER / 8. BUSHINGS
Apply the specified grease to the bushing and the spacer.
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent

Y1459C

5. APPLICATION OF GREASE TO CLEVIS PIN / 4. WASHER

Apply specified grease to clevis pin and washer and insert a _
clevis pin and bend the cotter pin tightly.
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent
 BRAKES - Brake Pedal 5-37
2. INSTALLATION OF RETURN SPRING
Install the return spring at illustrated position.

7i

1. ADJUSTMENT OF STOP LIGHT SWITCH

(1) Temporarily install the stop light switch.
(2) Turn the operating rod until the brake pedal height
becomes the standard value.
zrrating’
Standard value (A): 177 - 183 mm (7.0 - 7.2 in.)

Operating
rod lock n

14F51E

(3) Screw in the stop light switch until it contacts the brake
pedal stopper (just before the brake pedal starts to
move), back it off one turn, and secure it with the lock
nut.
(4) Connect the stop light switch connector.
(5) Check that the stop light does not come on unless the
brake pedal is depressed.

\
mm (in.) F145171
BRAKE MASTER CYLINDER
REMOVAL AND INSTALLATION

25-35 Nm
18-25 ft.lbs.
13-17 Nm
9-12 Mbs.
‘B

8-12 Nm
69 ftlbs.

Removal steps
I. Brake fluid level sensor connection _
2. Brake tube NOTE ~I
3. Brake fluid reservoir assembly (I) Reversethe removal procedures to reinstall.
I)+ 4. Brake master cylinder assembly (2) I)+: Refer to “Service Points of Installation”.
lb772 -_

Es
SERVICE POINT OF INSTALLATION NOBIDAK

4. INSTALLATION OF BRAKE MASTER CYLINDER E;;

ASSEMBLY
Measure the clearance (A) between the brake boaster pcrsh ~-
rod and the primary pisUn by using the following proce-
dure:

(I) Measure master cylinder end to piston dimension (61. ._

NOTE 4
Measure ~with a straightedge applied to the master I
cylinder xnd face and determine dimension (6) by
subtracting the straightedge thickness from reading. ~4

14lJOO64 14KOlE
BRAKES - Brake Master Cvlinder 5-39
(2) Measure master cylinder’s brake booster mounting
surface to end face dimension (C).

14KOlE

(3) Measure brake booster’s master cylinder mounting

surface to push rod end dimension (D).
(4) From values obtained in (I), (2) and (31, determine brake
booster push rod to primary piston clearance (A).
Standard value: 0.7 - 1.1 mm (.028 - .043 in.)
[A=B-C-D]

14KOl!

(5) If the clearance is not within the standard value range,

adjust by changing the push rod length by turning ,the
screw of the push rod.
Caution
Insufficient clearance may cause excessive brake
drag.
 ..-_. --n _,
m
S’;?
Es:
5-40 BRAKES - Brake Master Cylinder
zz,
G=-
DISASSEMBLY AND REASSEMBLY NOBHAAE
zz=
SC-

16

40-50 Nm
2S-36ft.lbs. Iill 24 u--fj \
@=-7
3--0 ea - 2.5-4.0 Nm
@I--8 1 B-2.9 ft.lbs.
4-J 8
25-35 Nm
16-25 ft.lbs.

1.5-3.0 Nm
1.1-2.2 ft.lbs.

Brake master cylinder disassembly steps

1. Checkvalvecase --
2. Gasket
3. Check valve
4. Check valve spring
5. Check valve cap
6. Tube seat
7. Check valve
8. Check valve spring
+I) 9. Secondary piston stopper
10. Gasket
+* 1 I. Piston stopper ring
12. Piston stopper plate
*I) *+ 13. Primary piston
+I) I)+ 14. Secondary piston
I)* 15. Brake master cylinder body

Brake fluid reservoir disassembly steps

+* 16. Nipple
17. Reservoir band NOTE -m ~-
18. Brake fluid level sensor switch (I) Reverse the disassembly procedures to reassemble.
19. Reservoir hoses (2) +I): Refer to “Service Points of Disassembly”.
20. Reservoir bracket (3) I)+: Refer to “Service Points of Reassembly”.
(4) q : Non-reusable parts
*+ 21. Reservoircap
22. Reservoir tank
14Y561
 BRAKES - Brake Master Winder 5-41

/I SERVICE POINTS OF DISASSEMBLY

9. REMOVAL OF SECONDARY
Remove the secondary piston
PISTON STOPPER
stopper while pushing
NOSHBAB

the
&I piston.

11. REMOVAL OF PISTON STOPPER RING

Remove the piston stopper ring while pushing the piston.

13. CAUTION OF PRIMARY PISTON

Caution
Do not disassemble the primary pistons.
14. REMOVAL OF SECONDARY PISTON
NOTE
If the secondary piston is hard to remove, slowly apply
compressed air from the secondary side outlet port of the
master cylinder.
Caution
Do not disassemble the secondary piston.
16. REMOVAL OF NIPPLE
When removing the nipple, lift it straight up.

INSPECTION NOSHDAA

l Check the check valve and check valve spring for weak-
ness.
l Check the gasket and tube seat for damage.
l Check the master cylinder body for rust and scars of inner
surface.
l Check the primary and secondary pistons for rust, scars,
wear and deformation.
l Check the piston cup for damage.
l Check the primary and secondary pistons for weakness of
springs.
5-42 BRAKES - Brake Master Cylinder

I CLEARANCE BETWEEN MASTER CYLINDER INNER DIA-

METER AND PISTON OUTER DIAMETER
(1) Measure approximately three positions of the. master
cylinder inner diameter [bottom (A), middle (B) and top (C)l
by using a cylinder gauge:
(2) Measure O.DI of pistonsat illustrated location using~ a ~~_
micrometer. -
NOTE
Measure the inner diameter of master cylinder at the two :
places described above and at D and E,shown In the z
Primary piston illustration. ~~~ .-
(3) If the difference between-these-inner diameters and the, ~
piston outer diameter exceeds the limit, replace the master _;
cylinder and the piston assembly as set.
Limit: 0.15 mm (.006 in.)
Secondary piston

14Y77!
14UOOE

SERVICE POINTS OF REASSEMBLY NOBHCAH

21. APPLICATION OF BRAKE FLUID TO RESERVOIR CAP

DIAPHRAGM SURFACE
Apply specified brake fluid to the diaphragm surface of the mzI
reservoir cap and tighten the cap, taking care not to distort _
the diaphragm.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent

15. APPLICATION OF BRAKE MASTER CYLINDER BODY TO

BRAKE FLUID / 14. SECONDARY PISTON / 13. PRIM-
ARY PISTON
Apply the specified brake fluid ~sufficiently to the inner
surface of the master cylinder body and to the entire
periphery of the secondary and primary pistons.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent

I Y146191
 BRAKES - Brake Booster 5-43
B.RAKE BOOSTER NOIJA- -

REMOVAL AND INSTALLATION

71 fg@gg=j
(Refer to P.5-29.)

4 6

25-35 Nm
IS-25 ft.lbs.

8-12 Nm
8-9 ft.lbs.
8-12 Nm 14Y814
6-9 fklbs.

Removal steps
1. Brake tube
2. Reservoir hose
l * 3. Brake master cylinder
I)* 4. Vacuum hose
l + 5. Checkvalve
6. Vacuum pipe
l * 7. Fitting
8. Cotter pin
*41 9. Clevis pin NOTE
(1) Reverse the removal procedures to reinstall.
I)* IO. Washer (2) I)+: Refer to “Service Points of Installation”.
Il. Brake booster (3) q : Non-reusable parts
12. Sealer
13. Spacer
14. Sealer
 INSPECTION NOSJCAD

Check the check- valve operation as follows.

l Blow into the-check valves If the air passes through when I
you blow from the booster side, but not when you blow -
from the. engine side, the check valve his functioning 1:
properly.

SERVICE POINTS OF INSTALLATION N05JDAK

10. APPLICATION OF GREASE TO WASHER / 9. CLEVIS PIN

Apply specified grease to devis pin and wash_er. Then insert _*
clevis pin an’d bend the 7zotter pin tightly.
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent

14u0050

7. APPLICATION OF SEALANT TO FITTING

When installing the fitting,apply the semi-drying sealant to --
its threaded portion.

14Y62f 3

5. INSTALLATION OF CHECK VALVE

Install the check valve, noting the direction of installation. -;
Brake bQQSter Engine side
side-

14E517

4. INSTALLATION OF VACUUM HOSE

Fasten the v!uum hose securely to prevent air leaks from --
the connections.

Insert the vacuum hosexntil~ it is seated on the fitting s-i

flange.
3. INSTALLATION OF BRAKE MASTER CYilNDkR
Check the booster push rod to brake master cylinder piston
clearance. zr
Standard value: 0.7 - 1.1 mm (-028 - .043 in.)
 BRAKES - Brake Line 5-45
BRAKE LINE NOIKA- -
REMOVAL AND INSTALLATION

Post-installation Operation
l Refilling Brake Fluid
l Bleeding Brake Line
(Refer to P.529.)

25-35 Nm
R 18C25 ft.lbs.

15

14Y815

+* I)+ 1. Front brake hoses (L.H.)

2. Front brake tube (L.H.)
+* I)+ 3. Front brake hoses (R.H.)
4. Front brake tube (R.H.)
5. Front brake tube
6. Connector attaching bolt
7. Gasket
8. Connector
9. Gasket
IO. Pil3e
4* 11. Pfoportioning valve NOTE
4* l 4 12. Rear brake hoses (L.H.) (1) Brake hose flare nut tightening torque is 13 - 17 Nm (9 - 12
13. Rear brake tube (L.H.) ft.lbs.).
4* I)4 14. Rear brake hoses (R.H.) (2) +I): Refer to “Service Points of Removal”.
15. Rear brake tube (R.H.) (3) I)*: Refer to “Service Points of Installation”.
16. 3-way connector (4) a: Non-reusable parts

L
5-46 BRAKES - Brake Line
SERVICE POINTS OF REMOVAL NffiKBAJ

1. REMOVAL OF FRONT BRAKE HOSES (L.H.) / 3. FRONT

BRAKE HOSES (R.H.) / 12. REAR BRAKE HOSES (L.H.) /
14. REAR BRAKE HOSES (R.H.)
For disconnection of braketube and brake hose, proceed-as -
follows: ~~
(1) Drain brake fluid from the bleeder plug of each brake. i
(2) While holding the nut B-r the brake hose side, loosen .-I
the brake tube flare nut. _ -
14YJ8

(3) Pull out the brake hoseclip and remove the brake hose ,:
from the bracket.

Clip 14Y78E ,

11. CAUTION OF PROPORTIONING VALVE

Caution
1. Do not disassemble the proportioning valve be-
cause its performance depends on the set load of
the spring.
2. Use the proportioning valve bearing marked A123.

Y14532

INSPECTION NOSKCAD

a Check the brake tubes foEcracks, breakage or corrosron. ..-;

@ Check the brake hoses-for cracks, damage, leakagepr ooze.. 6
c Check the brake tube flare nuts for damage or leakage., ._

SERVICE POINTS OF INSTALLATION NOBKDAE

14. INSTALLATION OF REAR BRAKE HOSES (R.H.) / 12.

REAR BRAKE HOSES (L.H.) / 3. FRONT BRAKE HOSES
(R-H.) / 1. FRONT BRAKE HOSES (L.H.)
Install the brake hoses without twisting them.
NOTE
Make sure that the hoses are not in contactwith the edge,. ;-I=
welding beads or movrng parts.
 BRAKES - Front Disc Brakes 5-47
FRONT DISC BRAKES NOSLA- -

.
REMOVAL AND INSTALLATION

Pre-removal Operation

l Refilling Brake Fluid

l Bleeding Brake Line

6-9 ft.lbs /
8

Removal steps
l * 1. Brake hose
2. Front brake assembly
3. Hubcap
I)* 4. Cotter pin
l * 5. Lockcap
I)4 Adjustment of wheel bearing
6. Nut NOTE
7. Washer (1) Reverse the removal procedures to reinstall.
l + 8. Brake disc (2) *I): Referto “Service Points of Removal”.
4* 9. Front axle hub (3) l *: Refer to “Service Points of Installation”.
10. Dust cover (4) [iIl : Non-reusable parts

I llY787
 s-2
e

E
5-48 BRAKES - - Front Disc Brakes -.Bpf

SERVICE POINT OF REMOVAL NOBLBCB

9. REMOVAL OF FRONT AXLE HUB

Do not drop the outer bearing when removing the hub. =;

14Y818

SERVICE POINTS OF INSTALLATION NOBLDCC

8. INSTALLATION OF BRAKE DISC

(1) Confirm that there is no rust or foreign matter on the
contact surfaces of the brake disc and the front hub,
before instaliation. -
(2) install the-front hub assembly and measure the brake
disc runout with a diaT indicator.
Limit: 0.15 mm (.006 in.)
(3) If the brake disc runout exmeds the limit, shift the,
14F61: phase of the front hub and brakedisc, reinstall the front
hub assembly and m,easure the brake disc runout again.
(4) Until the brake disc runout is within the limit. shift the :I
phase by 90”, 180” and 270” in that order.
(5) If the brake disc runoutwithin the limit is not obtained .i
by the above-mentioned procedure, measure the brake ~.
disc runoutand the front hub runout separately and ~~
replace the part showing the larger runout. : ~ ~_

@ ADJClSTMENT OF WHEEL BEARING

Tighten the nut by the following procedures.

(2) Loosen to 0 Nm (O- ft.lbs.)

I
I

F1253C
L
(3) Retighten to 5 Nm (4 ft.lbs.)

5. INSTALLATION OF LOCK CAP / 4. COlTER PIN

Fit the lock cap and cotter pin. If the position of the cotter
pin is not matched with the~holes of the lock cap, back off
the nut by 15” at maximum.
1. INSTALLATION OF BRAKE HOSE
After the brake hose is_‘installed, make the following
operatron.
(I) Bleed the hydraulic system.
(2) Check the-brake dragging torque. (Refer to P.5-31.)
 BRAKES - Front Disc Brakes 5-49
DISASSEMBLY AND REASSEMBLY NOSLE- -

7-9 Nm

85-95 Nm
61-69 ft.lbs.

Disassembly steps
++ 1. Slide pin
2. Inner shim
3. Outer shim
4. Pad assembly
5. Pad retainer
++ ++ 6. Bushing
++ 7. Pin boot
I)4 8. Cap
9. Caliper support
10. Bleeder screw NOTE
++ Il. Dust cover (I) Reverse the disassembly procedures to reassemble.
l + +C 12. Piston (2) 4*: Refer to “Service Points of Disassembly”.
** l * 13. Piston seal (3) ++: Refer to “Service Points of Reassembly”.
14. Caliper body (4) q ,: Non-reusable parts

14Y313

SERVICE POINTS OF DISASSEMBLY NOBLFCA

6. REMOVAL OF BUSHING
Push out the bushing from the caliper support by using the
slide pin.
 BRAKES - Front Disc Brakes

12. REMOVAL OF PISTON

Remove the piston by applying compressed air through the z
brake hose fitting hole.
Caution
Place a piece of cloth in front of the piston, and slowly
increase the force of the compressed air to prevent the
piston from springing out abruptly.

13. REMOVAL OF PISTON SEAL

Remove the ~piston seal.
Caution
Be careful not to damage the caliper bore.

14Y7% I

INSPECTION NO5LGCA

CALIPER ASSEMBLY
@ Check the caliper suppon for cracks.
l Check the caliper body for cracks and cylinder for rust,
@ Check the piston for rust.
Caution
The bushing, pin boot, cap, dust boot and piston seal must
all be replaced with ne&~ parts.

SERVICE POINTS OF REASSEMBLY NOBLHCA

13. APPLICATION OF GREASE TO PISTON SEAL m--z:

(1) Apply the-~specified brake fluid to the cylinder walls. E

Specified brake fluid: MOPAR Brake Fluid Part No. ZK_-
m-
2933249 or equivalent ---:e
(2) Fit a new piston seal into the cylinder.
NOTE --
The piston seal in the-repair kit is coated with special r
grease. Be careful noito wipe off this grease. 7- E
(3) Apply the~specified grease to the lip of the cylinder.
Specified grease: Repair kit grease (pink)
 BRAKES - Front Disc Brakes 5-51
12. INSTALLATION OF PISTON / 11. DUST COVER
(1) Apply the specified brake fluid to the external surface of
the piston.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
(2) Install a new dust boot onto the piston end as shown in
the illustration.

Y145

(3) Fit the forward end of the dust boot into the caliper
body groove and gently insert the piston into the
cylinder by hand. ’
NOTE
Take care not to twist the piston.
(4) Make certain that the end of the dust boot is fitted into
the piston groove.

8. APPLICATION OF GREASE TG CAP / 7. PIN BOOT

Apply the specified grease to the contact surface of the

I slide pin, the seat surface of the cap of the caliper support,
and the inside surface of the pin boot.
Specified grease: Repair kit grease (pink)
P-i
C:ap
Pin boot

Caliper support 14Y66E

6. APPLICATION OF GREASE TO BUSHING

(1) Apply the specified grease to the inside surface of the
bushing.
Specified grease: Repair kit grease (pink)
(2) Apply the specified adhesive furnished in the repair kit
to the lip of a new bushing, and insert the bushing into
the caliper support by using the slide pin.
Specified adhesive: Repair kit adhesive

D1462;

1. APPLICATION OF GREASE TO SLIDE PIN

(1) Apply the specified brake fluid to the threaded portion
of the slide pin.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
(2) Apply a thin coat of the specified grease to the slide pin,
and then install the caliper body to the caliper support.
Specified grease: Repair kit grease (pink)
5-52 BRAKES - Rear Disc Brakes
m
REAR DISC BRAKES NOSMA- -
REMOVAL AND INSTALLATION

13-17 Nm
S-12 ft.lbs.
50-70 Nm
\ I\ 35-51 ftlbs.

55-55 Nm
40-47 ft.lbs.

188-217 ftlbs.

40-50 Nm

51-58 ft.lbs. ’ /

15-20 Nm
II-14klbs.

Removal steps
++ 1. Brake hose
2. Dust cover
3. Cotter pin
4* 4. Parking brake cable
5. Rear brake assembly
NOTE
l + 5. Brake disc (I) Reverse the removal procedures to reikstail.
+I) ++ 7. Axle housing (2) +I): Refer to “ServicePoints of Removal”.
4* .+ 8. Nut (3) l +: Refer to “Service Points of Installation”.
++ ++ 9. Axle shaft (4) q : Non-reusable pa&
7 0. Dust cover
14’1-796
BRAKES - Rear Disc Brakes 5-53
SERVICE POINTS OF REMOVAL N05MBAB

4. REMOVAL OF PARKING BRAKE CABLE

Disconnect the parking brake cable from the rear brake
assembly.
7. REMOVAL OF AXLE HOUSING / 8. NUT / 9. AXLE
SHAFT
Refer to GROUP 3 REAR AXLE - Axle Shaft.

SERVICE POINTS OF INSTALLATION NOBMCAB

9. INSTALLATION OF AXLE SHAFT / 8. NUT / 7. AXLE

HOUSING
Refer to GROUP 3 REAR AXLE - Axle Shaft.
6. INSTALLATION OF BRAKE DISC
(1) Install the brake disc and measure the brake disc runout
with a di.al indicator. (Refer to P.5-32.)
(2) If the brake disc runout exceeds the limit, shift the
phase of the axle shaft and brake disc, reinstall the
brake disc and measure the brake disc runout again.
Shift the phase to 90”, 180” and 270”, in that order, until
the brake disc runout is within the limit.
(3) If the brake disc runout within the limit is not obtained
by the above-mentioned procedure, measure the brake
disc runout and the axle shaft runout separately and
replace the part showing the larger runout.
1. INSTALLATION OF BRAKE HOSE
After installation of the brake hose, perform the following
operations.
(1) Bleed the hydraulic system.
(2) Check the brake dragging torque. (Refer to P.533.)
5-54 BRAKES - .~.__~~
Rear Disc
..~ Brakes
REAR DISC BRAKES NOSNA- .
DISASSEMBLY AND REASSEMBLY

158 ‘f:6 18 19 ‘1
7-9 Nm
5-7 ftlbs.

50-60 Nm
35-43ft.lbs.

40-55
I
Nm ’ I 5”
29-40 ft.lbs.
5040 Nm
36-43 ft.lbs.

Disassembly steps
r)* 1. Lock pin
1)+1 2. Guide pin
3. Pad assembly
4. Shim
5. Pad clip
I)4 6. Caliper support
*C 7. Guide pin boot
g. FiTt retainer

*+ IO: Lock pin boot

4* Il. Retaining ring
** 12. Parking lever assembly
13. Garter spring
*+ 14. Lever cap
15. Cap ring
16. Return spring
17. Connecting link
+I) *+ 18. Spindle
*+ 19. Spring washer
*+ 20. Spindleseal
21. Boot ring
.+ 22. Dust boot
+I) *+ 23. Piston
NOTE
a* *+ 24. Piston seal (1) Reverse the disassembly procedures to reassemble.
25. Parking cable bracket (2) ++: Refer to “Service Points of Disassembly”.
26. Bleeder screw (3) **: Refer to “Service Points of Reassembly”.
+* ** 27. Bearing (4) q : Non-reusable parts
** 28, Caliper body
14Y242
 BRAKES - Rear Disc Brakes 5-55
SERVICE POINTS OF DISASSEMBLY NOSNBAB

11. REMOVAL OF RETAINING RING

To remove the retaining ring, disengage the cap ring from
the lever cap groove and slide the lever cap away.

18. REMOVAL OF SPINDLE

Remove the spindle by unscrewing it.

23. REMOVAL OF PISTON

Push out the piston from the caliper body.

J -J

Piston seal
14Y2’

14Y8( 11
\I24. REMOVAL OF PISTON SEAL
Remove the piston seal.
Caution
Be careful not to damage

27. REMOVAL OF BEARING

the caliper bore.

Press out the bearings by using the special tool.

14Y20:
5-56 BRAKES - Rear Disc Brakes

INSPECTION NOSNCAB

* Check the connecting ljnk and spindle for wear and

damage. -: -
l Check the caliper body for cracks and rust.
l Check the parking lever assembly for rust. _
l Check the bearing for wear and rust. .r*
l Check the proton for rust.
Caution
The guide pin boot, lock pin boot, garter spring, cap ring,
lever cap, spindle seal, boot ring, dust boot and piston seal
must all be replaced with new parts.
SERVICE POINTS OF REASSEMBLY NOBNDAB

28. INSTALLATION OF CALIPER BODY

Clean the caliper body bore with trichloroethylene, alcohol _
or brake fluid.
27. INSTALLATION OF BEARING
(1) Apply the specified grease to the bearing.
Specified grease: Repair kit grease (orange)
(2) Press in the bearings by using the special tool until it
becomes flush with the caliper body.
- .-
NOTE ;: -
Insert the bearings so that the depressed marks on the _ :
bearings -face outward.
24. INSTALLATION OF PISTON SEAL
(1) Apply the specified brake fluid to the piston seal and ~1
inside surface of the- cylinder.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
(2) Fit a piston seal into the cylinder.

23. INSTALLATION OF PISTON

Gently insert the piston assembly into the cylinder by hand,
being careful not to twist the piston assembly.

22. APPLICATION OF GREASE TO DUST BOOT

(1) Apply the specified grease to the dust boot fittingg:
groove in the caliper body.
Specified grease: Repair kit grease (orange)
(2) Install anew dust boot and boot ring. .~ .i - ~1
 BRAKES - Rear Disc Brakes 5-57
20. INSTALLATION OF SPINDLE SEAL / 19. SPRING
WASHER / 18. SPINDLE
(1) Apply the specified brake fluid to the spindle seal.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
(2) Paying attention to the proper direction of installation,
install the spring washers onto the spindle.
(3) Apply the specified grease to the contact surface of the
caliper body and spring washers.
Specified grease: Repair kit grease (orange)
(4) Carefully screw the spindle into the caliper body until it
rotates freely.
(5) Using the special tool, push the spring washers, and
screw the spindle in with a screwdriver or other suitable
tool.
(6) Set the connecting link and return spring on the spindle.

14y20;
Y h 14Y20f

14. INSTALLATION OF LEVER CAP / 12. PARKING LEVER

ASSEMBLY
(1) Install the lever cap to the parking lever assembly, and
then insert them in the caliper body.
(2) Hold the parking lever assembly with the retaining ring.
(3) Apply plenty of the specified grease to the lever cap as
well as to the lip section.
Specified grease: Repair kit grease (orange)
NOTE
Apply grease amply to the contact and sliding surfaces
of spindle, connecting link and spring washer, etc.
(4) Install the lever cap to the caliper body assembly.
lO.APPLlCATlON OF GREASE TO LOCK PIN BOOT / 7.
GUIDE PIN BOOT / 6. CALIPER SUPPORT
Apply specified grease to lock pin, boot inside, guide pin
boot mounting surface and caliper support and guide pin
contact surface.
Specified grease: Repair kit grease (orange)

14Y8Oi

2. APPLICATION OF GREASE TO GUIDE PIN / 1. LOCK PIN

Apply a thin coat of specified grease to the guide pin and
lock pin, and then install the caliper body to the caliper
support.
Specified grease: Repair kit grease (orange)
5-58 BRAKES - Rear Brake Lock-up Control System

REAR BRAKE LOCK-UP CONTROL SYSTEM NO’SOA- -

REMOVAL AND INSTALLATION

IO-13 Nm
7-9 ft.lbs.

+* I, Modulator NOTE
41, *+ 2. Pulsegenerator (1) *I): Refer to “Service Points of~Remqv$“.
+e ++ 3. G-sensor (2) ++: Refer to “%wice Points crf lnstallatlon”. :
+, 4, Control unit

SERVICE POINTS OF REMOVAL NOWBAA

1. REMOVAL OF MODULATOR
Remove the modulator a-s described below: ._~ ~_-
(1) Remove the heat protector. . _ 2

(2) Removethe vacuumihose, the brake tube, and the _

connector for the solenoid valves.
(3) Remove the moduJato_r bracket from the toebbard, “ndiz
then remove the madulator. --
BRAKES - Rear Brake Lock-up Control Svstem 5-59
2. REMOVAL OF PULSE GENERATOR
After disconnecting the speedometer cable at the pulse
generator side, remove the pulse generator.

3. REMOVAL OF G-SENSOR
Remove the G-sensor from its position on the baggage
compartment floor.
Caution
When removing the G-sensor, be careful not to subject
it to any impact or violent shaking.

4. REMOVAL OF CONTROL UNIT

Remove the control unit from beneath the high floor side
panel on the right side of the baggage compartment.

INSPECTION NOSOCAB

MODULATOR
Measure the resistance value between the terminals with an
ohmmeter.
Standard value:
Between terminals 1 - 3 (release solenoid valve)
3.8 - 4.8 fl
Between terminals 2 - 4 (build-up solenoid valve)
4.5 - 5.5 R

PULSE GENERATOR
Measure the resistance value between the terminals with an
ohmmeter.
Standard value: 600 - 800 n

14Y675
 -~ ---if&G - --;
Es-
=&
-pi
c-=
5-60 BRAKES - Rear Brake Lock-up Control System G=-
EL”
E=e-
c=.
G-SENSOR -.
Measure the voltage of the G-sensor when it is laid down in I z
accordance with the following procedure.
(1) Check voltage across R wire of G-sensor and ground for 7.0 i z
to -7.5 V:Voltage other than 7.0 to 7.5 V indicates faulty ’ ~1
-
control unit.
_-
--
w I”.
E!!r-

Voltage characteristic of G-sensor (2) Remove G-sensor and ground to vehicle body by wire.
(3) Measure voltage across G wire of G-sensor and ground. 7
Standard value: 1 .I - 1.5 V
(4) Turn G-sensorwith mark upward. Measure voltage across I
G wire of G-sensor and ground. ~~~
Standard value: 4.6 - 5.0 V
If the voltage-is out of standard value, replace the G-sensor, 1

0
Lav the G-sensor down SIOWIY so
that the mark faces upward.

REAR BRAKE LOCK-UP CONTROL RELAY

(1) Remove the rear brake lock-up control relay.
 BRAKES - Rear Brake Lock-up Control System 5-61
(2) Check continuity between terminals when the battery
voltage is applied to the terminal 2 and the terminal 4 is
grounded.

I Voltage applied 1 Terminals 1 - 3 1 Conductive I

Voltage not Terminals 1 - 3 Non-conductive
applied
Terminals 2 - 4 Conductive

16LO312 16W90E

SERVICE POINTS OF INSTALLATION NOBODAA

3. INSTALLATION OF G-SENSOR
Install the G-sensor while using a level to be sure that it is
perfectly horizontal.

I Transmission’ A-A cross-section 2. INSTALLATION OF PULSE GENERATOR

(1) Align the mating marks of the pulse generator and the
transmission.
(2) Securely fit the clamp in the grooves in the pulse
generator body.

generator
Rear eigine Clar&
mounting 14Y678 14Y27E
 1-

__ - - __~

5-62 BRAKES - Rear Brake Lock-w Control Svstem

DISASSEMBLY AND REASSEMBLY NOBOEAA

Disassembly steps
+I) 1. Hydraulic cylinder
++ 2. Plunger
+I) I)+ 3. Dust seal
++ I)+ 4. Snap ring
I)+ 5. Cup retainer
6. Back-up ring
++ I)+ 7. Seal cup
+* 8. Bleeder cap
*I) I)+ 9. O-ring
10. Check valve piston spring
Il. Check valve piston
I)+ 12. Check valve seal
I)+ 13. Valve cap
14. Gasket 30-40 Nm
15. Choke valve spring 22-29 ftlbs.
16. Spring seal
++ I)+ 17. Bushing
+I) l + 18. Choke valve piston
++ ** 19. O-ring
20. Vacuum cylinder assembly

NOTE 20
(1) Reverse the disassembly procedures to reassemble.
(2) **: Refer to “Service Points of Disassembly”.
(3) I)+: Refer to “Service Points of Reassembly”.
(4) q : Non-reusable parts
14Y292

SERVICE POINTS OF DISASSEMBLY NOSOFAA

1. REMOVAL OF HYDRAULIC CYLINDER

Remove the hydraulic cylinder assembly from the modula-
tor by pulling out straight. -
NOTE
After removal of the hydraulic cylinder, be sure to prevent
dust and dirt from enteringthe vacuum cylinder assembly. 1

2. REMOVAL OF PLUNGER
Pull out the plunger from the hydraulic cylinder assembly.
NOTE
When pulling out the plunger, do not damage the plunger
surface. -
BRAKES - Rear Brake Lock-up Control System 5-63
3. REMOVAL OF DUST SEAL
Use trim stick to remove the dust seal.

14Y29f

4. REMOVAL OF SNAP RING

Finish the ends of snap ring pliers as shown and use the
pliers to remove the snap ring.
NOTE
Do not damage the inner surface of the hydraulic cylinder.

7. REMOVAL OF SEAL CUP

Remove the seal cup from the hydraulic cylinder with a wire
having an L-shaped end.

8. REMOVAL OF BLEEDER CAP

Hold the hydraulic cylinder in a vice and remove the bleeder
cap.
NOTE
When the hydraulic cylinder is held in a vice, be sure to hold
the portion painted black.

9. REMOVAL OF O-RING
Use trim stick to remove O-ring from the bleeder cap.
 ~ L/,-
_____

5-64 BRAKES - Rear Brake Lock-up Control System

Bushing 17. REMOVAL OF BUSHING / 18. CHOKE VALVE PISTON

r
/ I (1) Hold the end of choke~valve piston with a long-nosed I
pliers or the like and remove the choke valve piston and ~
bushing at-the same time from the hydraulic cylinder.
(2) Push the choke valve ptiton out with fingers to remove 11
it from the bushing.
Choke valve piston ’

.-
19. REMOVAL OF O-RING
n Trim stick Remove 0rrng from the choke valve piston with the trim -I
stick.

INSPECTION N050GAA

l Check the each valve spring for weakness.

0 Check the hydraulic cylinder tor rust and scars on lnslde .-f
surface.
* Check the check valve piston and choke valve prston for _
rust, scars, wear and weakness.

SERVICE POINTS OF REASSEMBLY N050HAD

19. INSTALLATION OF O-RING / 18. CHOKE VALVE PISTON

Choke valve piston / 17. BUSHING
(1) Coat O-ring with specifEd brake fluid and install it to the __
choke valve piston.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
(2) AssembMhe choke valve piston to the bushing before -;
installing it to the hydraulic cylinder.

13. INSTALLATION OF VALVE CAP

After tightening the valvezap, clearance (A) of 0.5 to 1.0 ~~-I1
mm (.02 to .04 in.) mustie left. .=

Valve
cap
14y30:
 BRAKES - Rear Brake Lock-up Control System 5-65
12. INSTALLATION OF CHECK VALVE SEAL
piston) I After coating the check valve seal with specified brake fluid,
\ Check valve install with its larger inner diameter end towards outside.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
Caution
If the check valve seal is installed in the reverse
direction, the brake will become inoperative.

14Y290

9. APPLICATION OF FLUID TO O-RING

Coat O-ring with specified brake fluid and install it to the
bleeder cap.
Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent

14Y30E

7. APPLICATION OF FLUID TO SEAL CUP

Coat the seal cup with rust preventive agent and install it
with its concave side directed towards the hydraulic
cylinder.
-, Seal cup Specified brake fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
5. INSTALLATION OF CUP RETAINER
Install the cup retainer, with its large outer diameter end on
the hydraulic cylinder side.
14Y306

4. INSTALLATION OF SNAP RING

Fit the snap ring securely in the snap ring groove.
NOTE
After installation of the snap ring, hold the cup retainer
lightly with a long-nosed pliers’and pull it to make sure that
the snap ring is positively installed.

Dust seal 1 3. INSTALLATION OF DUST SEAL

(1) Apply the specified grease to the dust seal.
Specified grease: Repair kit grease (silicone grease)
(2) While holding it with fingers, install it to each of the cup
retainer and hydraulic cylinder.
Caution
Do not force the periphery of the dust seal inward,
Snap ring because a specified clearance is provided between
dust seal and snap ring.
14Y307
 ~~~
~ ____.-.I_p----

5-66 BRAKES - Parking Brake Lever

PARKING BRAKE LEVER NOSWA- ~

REMOVAL AND INSTALLATION

14'1812

Removal steps
+* *+ 1. Rear floor console
I)+ Adjustment of parking brake lever stroke
2. Adjuster
3. Equalizer
4. Stay
I)* 5, Bushing - NOTE
I)+ 6. Parking brake lever (I) Reverse the removal procedures to reinstall,
(21~ *I): Refer to “Service Points of Removal”.
7. Parking brake switch (3) I)+: Refer to “Service Points of installation”.
8. Cotter pin (4) q : Non-reusable parts
l + 9. Clevis pin

SERVICE POINT OF REMOVAL NOSWRAA

1. REMOVAL OF REAR FLOOR CONSOLE

Refer to GROUP 23 BOW - Roor Console.
BRAKES - Parking Brake Lever 5-67
INSPECTION N05WCA8

l Check the bushing for wear.

l Check the parking brake switch for malfunction.
l Check the parking brake lever ratchet for wear.

SERVICE POINTS OF INSTALLATION NOSWDAC

9. APPLICATION OF GREASE TO CLEWS PIN / 6. PARKING

BRAKE LEVER / 5. BUSHING
Apply specified grease to the clevis pin, bushing and ratchet

fied grease: MOPAR Multi-mileage Lubricant Part

No. 2525035 or equivalent

14Y761

. ADJUSTMENT OF PARKING BRAKE LEVER STROKE

Adjust the adjuster to make sure that the number of clicks
is within specification when the lever is pulled with.200 N
(45 Ibs.) force. (Refer to P.5-33.)
Standard value: 4 - 5 clicks
1. INSTALLATION OF REAR FLOOR CONSOLE
Refer to GROUP 23 BODY - Floor Console.
5-68 BRAKES - Parking Brake Cable

PARKING BRAKE CABLE NO!XA.-

REMOVAL AND INSTALLATION

141813
Removal steps p&
+* +* I. Rear floor console II-
I)+ Adjustment of parking brake lever stroke .-m .~
2. Adjuster
a+ 3. Rear seat cushion
T-r-
4. Dust cover ssfs~”
** --
-mEiE~
5. Cotter pin NOTE
++ 6. Washer (1 I Reverse the removal procedures to reinsfall.
+I) 7. Clevis pin (2) +I): Refer to “Serwce Points of Removal”.
+I) 8. Clip (3) *+:Refer to “Service Points of Installation”. ;~ 2 -m
+I) I)+ 9. Parking brake cable (4) 8: Non-reusable parts

SERVICE POINTS OF REMOVAL NffiXBAfl

1. REMOVAL OF REAR FLOOR CONSOLE

Refer to GROUP 23 BODY - Floor Console. ~~
3. REMOVAL OF REAR SEAT CUSHION
Refer to GROUP 23 BQDY - Seat.
BRAKES - Parking Brake Cable 5-69
5. REMOVAL OF COTTER PIN / 6. WASHER / 7. CLEVIS
PIN / 8. CLIP
(1) Remove the cotter pin, clevis pin and washer.
(2) Remove the clip by pulling downward, and remove the
parking brake cable out of the groove in the brake body.

9. REMOVAL OF PARKING BRAKE CABLE

(1) Remove the parking brake cable mounting bracket from
the lower control arm.
(2) Pull the parking brake cable out of the vehicle.

INSPECTION NOBXCAB

Check the parking brake cable for damage and operation.

SERVICE POINTS OF INSTALLATION NOlXDAB

9. APPLICATION OF SEALANT TO PARKING BRAKE

CABLE
Apply drying sealant to the grommet and body panel
contact surface.

Y14512

. ADJUSTMENT OF PARKING BRAKE LEVER STROKE

Adjust the adjuster to make sure that the-number of clicks
is within specification when the lever is pulled with 200 N
(45 Ibs.) force. (Refer to P.5-33.)
Standard value: 4 - 5 clicks
1. INSTALLATION OF REAR FLOOR CONSOLE
Refer to GROUP 23 BODY - Floor Console.
 6-l

CLUTCH
CONTENTS
CLUTCH DISC AND RELEASE FORK .. . .. . .._......_ 16 SPECIFICATIONS .. .. . ..._........._..................._.._...... 2 -
General Specifications _._..._...... . .. . .. .. . .. .. . .. . .. .. . . 2
CLUTCH MASTER CYLINDER AND
Lubricants . .. .. .. . .. . .. .._......._.................................... 3
LINE .._.........................................................._.__._ _.. . . 9
Service Specifications .. . .. .._............................ 3
CLUTCH PEDAL . . .. .. . . .. . .. .. . .._................. _.. .. . .. . .. . .. . . 7 Torque Specifications . .._._.._......._.................._.._. 3

CLUTCH RELEASE CYLINDER .. .. . . .. . .. .. .. . ..___.__ 13

TROUBLESHOOTING . .. .. . . .. .. . .. .. . .. . .. .. . .. .. . .. . .. . .. .. 4

GENERAL INFORMATION . .. . .. .. . . .. .. . .. . .. . .. .. . .. . .. . 2 Clutch Chatters

Clutch Drags or Does Not Release
SERVICE ADJUSTMENT PROCEDURES . . .._... 5 Clutch Noises
Bleeding .. . .. . . .. ..._..._._._._.___....._.___.________......._______ 6 Clutch Operation Erratic or Rough
Clutch Pedal Inspection and Adjustment . . .. .._. 5 Clutch Slips
SPECIAL TOOL .. .._............._....................___.____.__.. 4
6-2 CLUTCH - General Information / SDecifications

CAUTION
When servicing clutch assemblies or compo-
nents, do NOT create dust by sanding, grind-
ing or by cleaning clutch parts with a dry brush
or with compressed air. (A water dampened
cloth should be used). The clutch disc contains
“Asbestos Fibers” which can become airborne
if dust is created during service operations.
Breathing dust containing “Asbestos Fibers”
may cause serious bodily harm.

GENERAL INFORMATION NOIBAAE

The clutch is dry single plate diaphragm type with hydraulicclutch control.
The clutch control consists of clutch pedal, clutch master cylinder, clutch tube, release cylinder, etc. The
clutch pedal is suspended type.

SPECIFICATIONS NO6CA--

GENERAL SPECIFICATIONS

Clutch disc
Single dry disc type
Facingdiameter (outside x inside) mm (in.) 240 x 160 (9.45 x 6.30)
Number of torsion springs
Clutch cover assembly
Type Diaphragm spring, strap drive type
Setting load N (Ibs.)
Mounting bolt circle diameter mm (in.)
Clutch release bearing
Type Self-centering type
Free travel 0 (Zero) - CotWant

Clutch release cylinder

 CLUTiH - Specifications 6-3
SERVICE SPECIFICATIONS NOBCB- _

mm (in.)

Items Specifications

Standard value
Clutch pedal height 187 - 193 (7.3 - 7.6)
Clutch pedal play (at clevis pin) l-3 (.04-.lO)
Clutch pedal free play (total) 6 - 13 (.2 - .5)
Distance between pedal pad upper surface and 35 (1.4)
floorboard measured with clutch disengaged
Limit
Master cylinder to piston clearance . 0.15 (.006)
Clutch disc Rivet sink 03 LOI 2)

TORQUE SPECIFICATIONS NOGCC- _

Items Nm ft.lbs.

Clutch to flywheel 15-21 II-15

Release cylinder to transmjssion case 30-42 22-30 _~
Transmissron-. __~
to engine 43-53 32-39
Fulcrum 30-42 22-30
Eye bolt _ E 20-25 14-18
Clutch tube flare nut 5 13-17 9.4- 12.3
Clutch hose bracket 8 5.8
Clutch ._master cylinder to toeboard IO-15 7.2 - 10.8

LUBRICANTS NOBCD- -

Items Specified lubricants Quantity

Clutch fluid MOPAR Brake Fluid As required

Part No. 2933249 or equivalent
Grease for clutch pedal shaft, bushings, MOPAR Multi-Mileage Lubricant As required
return spring, and clevis pin Part No. 2525035 or equivalent
Release cylinder push rod and release MOPAR Multi-Mileage Lubricant As required
fork surfaces making contact with Part No. 2525035 or equivalent
each other
Clutch release bearing inner surface .: MOPAR Multi-Mileage Lubricant As required
Part No. 2525035 or equivalent
Clutch disc spline inner diameter MOPAR Multi-Mileage Lubricant As required
Part No. 2525035 or equivalent
Release fork and fulcrum arm surfaces MOPAR Multi-Mileage Lubricant As required
making contact with each other Part No. 2525035 or equivalent
Release bearing and release fork surfaces MOPAR Multi-Mileage Lubricant As required
making contact wifh each other Part No. 2525035 or equivalent
Release cylinder inner diameter MOPAR Brake Fluid As required
and piston assembly Part No, 2933249 or equivalent

P‘
6-4 CLUTCH - Special Tool / Troubleshooting

SPECIAL TOOL NOGDA- .

s: 7

E?

Tool (Number and name) Use =_~

g&r
-~ cz.-
MD998272 Alignment of clutch disc x
Clutch disc center guide center hole
c
_-.

Symptom Probable cause Remedy

r I
Clutch slips Insufficient clutch pedal free play 1 Adjust

Oil or grease on clutch facing Replace

Clutch facing worn
Pressure spring deteriorated

Pressure plate or flywheel runout Repair or replace

Hydraulic system failure

Clutch dragsordoes Excessive clutch pedal free play Adjust

not release
Interference between pedal and floor panel Correct

Pilot bearing worn or broken .~ &pIace

Clutch disc warped
Pressure plate, disc or thrOWQUt bearing damaged

Hydraulic system failure Repair or replace

Clutch chatters Facing hardened Replace

Facing stained with oil or grease
Weak or broken disc damper springs .~~
Improper facing contact or disc runout
Pressure plate orflywheel warped

Clutch noises Release bearing broken, worn or poorly lubricated Replace

Pilot bearing worn
Disc hub loose
Disc plate cracked
Torsion springs deteriorated or broken __

Clutch operation Facing stained with grease or oil Replace

arratic or rough Facing worn or rivet loose
Torsion spring deteriorated or broken ~_

Insufficient lubricant on clutch pedal pivot Lubricate

 CLUTCH - Service Adiustment Pr.ocedures 6-5
Pedal height Clevis pin play SERVICE ADJUSTMENT PROCEDURES
NOGFAAF

CLUTCH PEDAL INSPECTION AND ADJUSTMENT

1. Measure the clutch pedal height and clutch pedal clevis pin
play. If the clutch pedal height and clutch pedal clevis pin
play are not within the standard value, adjust it by using the
following procedure:
Standard value:
08YO4: (A) 187 - 193 mm (7.4 - 7.6 in.)
(W 1 - 3 mm (.04 - .I2 in.)
2. Disconnect the clutch switch connector and turn the switch
Clutch switch for standard clutch pedal height, Then lock with the lock
nut.

Lock nut

08Y62C

-
3. Turn the push rod so as to adjust so that the play at clutch
pedal clevis pin becomes within the standard value, and
then secure with the lock nut.
Caution
Do not push the push rod in when making the
adjustment of clutch pedal clevis pin play.

-
4. After depressing the clutch pedal a few times, confirm that
the distance between the clutch pedal and the floorboard is
more than the standard value when the clutch is disen-
gaged.
Standard value (C): 35 mm (1.4 in.)

5. Then, measure the clutch pedal free play (including the play
at the clutch pedal clevis pin) and confirm that it is within
the standard value.
Standard value (D): 6 - 13 mm (.2 - .5 in.)
If the clearance and/or the clutch pedal free play do not
meet the standard value, probably there is air in the
hydraulic system or a malfunction of the clutch itself, so
bleed out the air or disassemble and inspect the clutch.

08YO43
 ____~.

6-6 CLUTCH - Service Adjustment Procedures

BLEEDING
Whenever the clutch tubing, the clutch hose, and/or the clutch
master cylinder have been removed, or if the clutch pedal is
spongy, bleed the system.
1. Loosen the bleeder screw~at the clutch release -cylinder.
2. Push clutch pedal down slowly until all air is expelled.
3. Hold clutch pedal down until bleeder screw is ret&htened.
4. Refill clutch master cylinder with specified clutch fluid.
Caution
Use the specified clutch fluid only.
Specified clutch fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent
 CLUTCH - Clutch Pedal 6-7

CLUTCH PEDAL NOGPDAH

REMOVAL AND INSTALLATION

IO-15 Nm
/ 7.2-10.8 fklbs.

08Y636

Removal steps
1. Clutch switch
2. Clip
I)+ 3. Return spring
4. Return spring bushing
5. Cotter pin
I)+ 6. Clevis pin
l a 7. Pedal shaft
I)+ 8. Pedal shaft bushing lykevarse the removal procedures to reinstall.
I)* 9. Spacer (2) *a: Refer to “Service Points of Installation”.
IO. Clutch pedal (3) a: Non-reusable parts
11. Clutch pedal bracket
 CLUTCH - Clutch Pedal

INSPECTION NOWCAE

CLUTCH SWITCH
Check the clutch switch operation as follows:
Check with a circuit tester -connected to the clutch switch l
terminal. The switch is normal if there is continuity when the ~_
switch plunger ispushed jn and no continuity when the plunger
is released. t:~ ~~
e Check the bushing for wear.
0 Check the pedal arm for bend or torsion.
nm OSY62: l Check the return spring for damage.
=
SERVICE POINTS OF INSTALLATION NO6PDAH

9. APPLICATION OF GREASE TO SPACER / 8. PEDAL

SHAFT BUSHING / 7. PEDAL SHAFT
Apply specifiid grease ta;the spacer, pedal shaft bushing _
and pedal shaft.
Specified grease: MOPAR Multi-Mileage Lubricant Part -
No. 2525035 or equivalent

I I YO851!

6. APPLICATION OF GREASE TO CLEVIS PIN

r, Brake pedal Apply specified grease to the clevis pin.
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent

Washer Cl&s pin

1411004~
-
3. APPLICATION OF GREASE TO RETURN SPRING
Apply specified grease to the return spring.
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent
NOTE
When installing the returnspring, install the pedal side first 4
and then depress the pedal and install the pedal support
side. -
 CLUTCH - Clutch Master Cylinder and Line 6-9

CLUTCH MASTER CYLINDER AND LINE NOGMA- -

re
REMOVAL AND INSTALLATION

l Refilling Clutch Fluid

l Bleeding Clutch Line

l Adjustment of Clutch Pedal IO-15 Nm

(Refer to P.6-5.) 7.2-10.8 ft.lbs.

20-25 Nm 8Nm 08Y 637

14-18 ftlbs. 5.8 ft.lbs.

Clutch master cylinder removal steps

1. Split pin
I)* 2. Clevis pin
4I) 3. Brake fluid reservoir
4. Clutch tube connection
4* 5. Clutch master cylinder
6. Gasket
Clutch line removal steps
NOTE
4* 7. Clutch tube (1) Reverse the removal procedures to reinstall.
4* ;. y&:t (2) l *: Refer to “Service Points of Removal”.
(3) l +: Refer to “Service Points of installation”.
I)4 IO: Clutch hose (4) a: Non-reusable parts
11. Clip
 CLUTCH - Clutch Master Cvlinder and Line

SERVICE POINTS OF REMOVAL NOGMBAC

3. REMOVAL OF BRAKE FLUID RESERVOIR

Remove the-brake fluid reservoir bracket ..attachjng bolts _~~
and slide the reservoir aside. i --f
Caution
Do not pull the brake hoses firmly or kink them.

L /..f---u P8Y62E

5. REMOVAL OF CLUTCH MASTER CYLINDER

Remove the-clutch master cylinder. _
NOTE ~
The master cylinder attaching nut (lower) is- located in the i
compartment.

~_~ .-
7. REMOVAL OF CLUTCH TUBE
Holding the ~elutch hose side nut, loosen the clutch tube --::
flare nut.

Pull out the clutch hose=olrp and remove‘ the clutch h~ose =;
from the bracket. -

8. REMOVAL OF EYE BOLT

Refer to P.613. _

INSPECTION NIKMCAC

@ Check the clutch tube for cracks, crimps and corrosron.

@ Check the clutch hose for cracks, damage and leakage._.:
Q Check the clutch tube flare nuts for damage and leakage. my
 CLUTCH - Clutch Master Cylinder and Line 6-11
SERVICE POINTS OF INSTALLATION NOBMDAD
Stopper
10. INSTALLATION OF CLUTCH HOSE
When connecting the clutch hose to the release cylinder,
install as illustrated, making sure it is not twisted.

OBY63L

2. INSTALLATION OF CLEVIS PIN

Refer to P.6-8.

CLUTCH MASTER CYLINDER AND LINE NOGNA- -

DISASSEMBLY AND REASSEMBLY

I\
7

-\

08Y628
Disassembly steps
4* 1. Piston stop ring
2. Damper and push rod
** I)* 3. Piston assembly
4. Reservoir cap
5. Reservoir bracket
6. Reservoir NOTE
l * 7. Nipple (1) Reverse the disassembly procedures to reassemble.
8. Reservoir band (2) +I): Refer to “Service Points of Dkassembly”.
9. Master cylinder body (3) I)+: Refer to “Service Points of Reassembly”.
6-12 CLUTCH - Clutch .~~~
Master ...~~
Cylinder
~~ and Line
SERVICE POINTS OF DISASSEMBLY NOGNBAA

1. REMOVAL OF PISTON STOP RING

Remove the piston stop ring.
3. REMOVAL OF PISTON ASSEMBLY
Pull out the piston assembly.
Caution
Do not damage the master cylinder body and piston
assembly.
Do not disassemble the piston assembly.

INSPECTION NOGNCAA

3 Check for rust or scars iriside~cylinder body.

* Check piston cup for wear or deformatron. ~~ x
l Check piston -or rust or scars. - .=

CLEARANCE BETWEEN MASTER CYLINDER INNER DIA-

METER AND PISTON OUTER DIAMETER
(1) Measure the master cylinder inside diameter-and the piston
outside diameter with a cylinder gauge and a micrometer. 1
Limit: 0.15 mm (.006 in.)
NOTE
Measure the inside diameter of the master cylinder at three ~_
places (bottom, middle, and top), each in two perpendicular
directions.
14ElOE (2) If the master Glinder-to-p&on c!earance exceeds the limit, . _
replace the master cylinder and/or piston assembly.

SERVICE POINTS OF REASSEMBLY NOGNDAD

7. INSTALLATION OF NIPPLE
Install the nipple and band as shown in the illu_stration. ~_

YO8518

3. APPLICATION OF CLUTCH FLUID TO PISTON ASSEM-

BLY
Apply specified clutch fluid to the inner surface of the .=
cylinder and to the entire periphery of the piston assembly.
Specified clutch fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent

08Y51
 CLUTCH - Clutch Release Cylinder 6-13

CLUTCH RELEASE CYLINDER NOGHA- _

REMOVAL AND INSTALLATION

Pre-removal Operation
0 Draining Clutch Fluid

l Refilling Clutch Fluid

l Bleeding Clutch Line
(Refer to P.6-6.)
l Adjustment of Clutch Pedal
22-30ftJbs.

Removal steps
NOTE
+* *C 1. Eye bolt (I) Reverse the removal procedures to reinstall.
2. Gasket (2) *I): Refer to “Service Points of Removal”.
I)+ 3. Clutch hose connection (3) *a: Refer to “Service Points of Installation”.
I)* 4. Clutch release cylinder (4) q : Non-reusable parts

08W520

SERVICE POINT OF REMOVAL NOGHBAB

1. REMOVAL OF EYE BOLT

Disconnect the eye bolt from the release cylinder.

INSPECTION NOGHCAA

l Check the clutch release cylinder for fluid leakage.

l Check the clutch release cylinder boot for damage.

SERVICE POINTS OF INSTALLATION NOGHDAC

4. APPLICATION OF GREASE TO CLUTCH RELEASE

CYLINDER
Apply specified grease to release fork to release cylinder
push rod contacting surfaces.
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent
6-14 CLUTCH -- Clutch Release Cylinder

3. INSTALLATION OF CLUTCH HOSE

Connect the Clutch hose -to the release cylinder at the ..- z-
- I_
-E-_~
stepped portion shown in the illustration.
1. INSTALLATION OF EYE BOLT
Bleed the syste~m. (Refer to P.6-6.)

08Y63
-* _~
mBz--
CLUTCH RELEASE CYLINDER NOUA-- FEE
m”
DISASSEMBLY AND REASSEMBLY 92

Disassembly steps
1. Valve plate
2. Spring
3. Push rod
4. Boot
+I) l + 5. Piston and cup
6. Conical spring NOTE
7. Bleeder screw (I) Reverse the disassembly procedures t6 reassembIe. .-
8. Bleeder plug (2) **: Refer t0 “F&vice Points of Disassembly”.
9. Release cylinder (3) *+: Refer to “Serwce Points of Reassembly”. -

SERVICE POINT OF DISASSEMBLY NOGLBAC

5. REMOVAL OF PISTON AND CUP

Use compressed air to remove the piston and cup from the :
release cylinder.
Caution
1. Cover the cylinder bore with rag to prevent the
piston from jumping out of the bore.
2. Apply compressed air gradually to avoid possible
scattering of clutch fluid.
 CLUTCH - Clutch Release Cvlinder 6-15
INSPECTION NOBLCAA

l Check the inner surface of release cylinder for rust and

damage.
Use cylinder gauge to measure the inner diameter of
,di
‘/,,’
l
release cylinder at three locations (bottom, mid and brim). If
the clearance between piston and release cylinder exceeds
T the limit, replace the release cylinder assembly.
Cylindk gauge3
Limit: 0.15 mm (.006 in.)

14UOO6C

SERVICE POINT OF REASSEMBLY NOGLDAC

5. INSTALLATION OF PISTON AND CUP

Apply specified clutch fluid to the inner surface of release
cylinder body and the peripheries of piston and piston cup
before inserting the piston and cup assembly.
Specified clutch fluid: MOPAR Brake Fluid Part No.
2933249 or equivalent

DCLOOE
6-16 CLUTCH - Clutch Disc and Release Fork

CLUTCH DISC AND RELEASE FORK N06OA-- ~~;

REMOVAL AND INSTALLATION

Post-installation Operation
l Refilling Clutch Fluid
l Bleeding Clutch Line
(Refer to P.66.)
l Refilling Transmission Oil
(Refer to GROUP 21 TRANSMIS-
SION -Service Adjustment Proce-
dures.)

2 #
30-42 Nm
22-30 ft.lbs.

6 \ .

@
15-21 Nm
II-15 ft.lbs. 7

Removal steps
4+ I. Transmission assembly
+* I)+ 2. Clutch cover assembly
I)+ 3. Clutch disc
4, Return clip
I)+ 5. Clutch release bearing NOTE
++ I)+ 6. Release fork (1) Reverse the removal procedures to reinstall.
7. Release fork boot y (2) +I): Referto “Service Points of RemoV9l”.
8. Fulcrum (3) ++: RefeFto “Service Points of installation”.

SERVICE POINTS OF REMOVAL NOGOBAA

1. REMOVAL OF TRANSMISSION ASSEMBLY

Refer to GROUP -21 TF@NS!yllSSlON -~~ranspt~s.s~o~. z;
 CLUTCH - Clutch Disc and Release Fork

2. REMOVAL OF CLUTCH COVER ASSEMBLY

(1) Insert clutch disc center guide (MD998272), or main
drive gear of transmission in center spline to prevent
dropping of clutch disc.
(2) Diagonally loosen bolts retaining clutch cover to fly-
wheel.
Back off bolts, o%e or two turns at a time, in succession,
to avoid bending ,cover flange.
Caution
ch disc center guide
DO NOT clean clutch disc or relegse bearing with
cleaning solvent.
5: REMOVAL OF RELEASE FORK
Slide release fork in direction of arrow to disengage fulcrum
from clip.
Caution
Attempting to remove release fork by sliding it in other
direction will result in damage to clip.

..
DCLOO 2

CLEANING AND INSPECTION NOGQCAA

(1) Clean clutch dust from clutch housing with vacuum brush
or shop towel. Do not use compressed air. Inspect for oil
leakage through engine rear main bearing oil seal and
transmission front oil seal. If leakage is noted, it should be
corrected at this time.
(2) Friction face of pressure plate should be have a uniform
appearance throughout entire disc contact area. If there is
evidence of heavy contact on one portion of wear circle and
a very light contact 189 degrees from that portion, pressure
plate may be improperly mounted or sprung.
(3) Friction face of flywheel should also be free from excessive
discoloration, burned areas, small cracks, deep grooves, or
.
ridges.
(4) The disc assembly should be handled without touching~
facings. Replace disc if facings show evidence of grease or
oil soakage.
(5) Measure rivet sink, and if it is below the limit, replace clutch
disc.
Limit: 0.3 mm (.012 in.)
The hub splines and splines on transmission input shaft
6CL003 should be a snug fit without signs of excessive wear.
Metallic portions of disc assembly should be dry and clean
and show no evidence of having been hot. Each of the
arched springs between facings should be unbroken and all
rivets should be tight.
(6) Wipe friction surface of pressure plate with a cleaning
solvent.
(7) Using a straight edge, check pressure plate for flatness.
The pressure plate friction area should be flat within 0.5
mm (.020 in.) and free from discoloration, burned area,
cracks, grooves or ridges.
(8) Visually inspect the cover outer mounting flange for
flatness. It should be free of nicks, burrs, dents or other
damage.
kz - g
 CLUTCH - Clutch Disc and Release Fork _~
Es
(9) The three dowels on the flywheel should be trght and e
undamaged.
The cover stamprng should be a snug frt on the dowels. ~c
(I O)lf the clutch assembly does not meet these requirements, it
should be replaced.
(1 IKheck the clutch releasekylrnder for fluid leakage.
(12Kheck the clutch releaseylinder boot tar damage.

SERVICE POINTS OF INSTALLATION NOIQDAA

Release bearing f-
6. APPLICATION OF GREASE TO RELEASE FORK
Pack the release fork fulcrum hole and release cylinder _<
push rod hole with grease. -
-Grease
Specified grease: MOPAR Multi-Mileage Lubricant Part -I=
No. 2525035 or equivalent
5. APPLICATION OF GREASE TO CLUTCH BEARING
Pack grease in groove on release bearing I.D. a=
Specified grease: MOPAR Multi-Mileage Lubricant Part
No. 2525035 or equivalent

Grease ----u
DCLOO!
-
3. INSTALLATION OF CLUTCH DISC / 2. CLUTCH COVER .-
ASSEMBLY
(1) If there are oils or greases on clutch facing and pressure ==
plate, thoroughly wipe away with a dry cloth.
(2) Lightly apply specified grease to clutch disc spline and I
Flywhel
J main drive gear spline of transmission.
Clutch disc
Specified grease: MOPAR Multi-Mileage Lubricant
This surface has Part No. 2525035 or equivalent
a manufacturers
(3) Using clutch disc center guide (MD9982721, or main _
drive gear of transmis$ion, install clutchIdisc~-and clutch pi
cover assembly on flywheel.
(4) When installing clutch disc, be sure that surface having ;;
manufacturers stamped mark is on pressure plate si;de.
Caution
When installing transmission, do not shake it nor
install in such a manner that main drive gear is
unduly stressed.
Make sure that main drive gear enters clutch disc
squarely.
 7-I

COOLING
CONTENTS
COOLING FAN .. . . ..._._._.____._....._____........____._........_
13 SPECIFICATIONS . .. . ..._........_.....__.__.__._.
_. .._.__...._.. 4
General Specifications .. .. .. . . .. .. . .. . .. .. . .. . .. .. .. . .. . . . 4 i-~
ENGINE COOLANT TEMPERATURE
GAUGE UNIT .. . . .. .. .. . . .. . .. . .._._._._..____._.__t._________..__.
__ 22 Lubricants .. . .. . .. .._..........__.__.__.__..........~ ..__.___......... 5~
Sealants ..._......_.______._____ _. . ..._........._..........._....... 6
GENERAL INFORMATION .. . .. .. . ..._....._______.....__. 2 Service Specifications . . .. . .. .. .. ....I.................... 5
RADIATOR .. . . .. .. .. . . .. . .. . .. . .. ..._.........___.__.......___........ 16 Torque Specifications _.__.__.__.__............._..__......... 5

SERVICE ADJUSTMENT PROCEDURES . .. . ..._ 8 THERMOSTAT . . .. .._....__...............__.._........_.__.._.._. 11

Drive Belt Tension Check and TROUBLESHOOTING ........................................ 6
Adjustment ........................................................ 10
No Rise in Temperature
Engine Coolant Leak Check ............................ 8
Overheat
Radiator Cap Pressure Test ............................ 8
Specific Gravity Test ........................................ 8 WATER HOSE AND PIPE .................................... 21

WATER PUMP . .. . . .. .. . .. . .. ..._..___

_I.___
__.__
__. .._._._.__.__. 19
7-2 COOLING - General Information

GENERAL INFORMATION N07BAAI

=&y
The cooling system consrsts of a radiator, tan, electric fan motor, water pump, thermostat, hose, radiator cap -’ E;
(pressure cap), engine coolant reserve tank, engine coolant temperature sensor, electric fan motor-relay and EE
automatic transmission 011 cooler. a-
-~
SYSTEM OPERATION
When the cold and hot engines are operated, engine coolant IS controlled as shown I~I the tollowlng
illustration.

ENGINE COLD
Thermostat
-closed
I n

Heater

Radiator and electric

motor fan

ENGINE HOT
Thermostat
- opened

Heater

Radiator
motor fan
 COOLING - General Information 7-3
The routing and plumbing for turbocharger coolant are as shown below.
To maintain turbocharger, engine coolant is constantly kept flowing through the turbocharger-bearing housing
water jacket. Water hoses and pipes are laid to provide closed loop flow of engine coolant from the intake
manifold to the turbocharger housing to the water inlet pipe.

i ‘\
\ Water outlet Engine
coolant

Engine
coolant
~I
ICTLUIII

Sectional view of turbocharger

water jacket
From aV
radiator 6lNO38

THERMOSTAT
The thermostat housing is located near No. 1 port in the intake manifold so that the thermostat may be
removed and inspected easily.
The thermostat is a wax pellet type. The jiggle valve is installed in the air vent located in the thermostat fla.nge. -.I
When the engine is not running, it makes easy the bleeding of air from engine coolant. When the engine is
running (the thermostat is in closed state), the jiggle valve is closed to reduce the time required for engine
warm-up and prevent the engine from overcooling.

WATER PUMP
The water pump consists of a diecast aluminum body, stamped steel impeller, seal and grease-filled bearing
shaft. It is driven by the crankshaft pulley through the V-ribbed belt.

ELECTRIC FAN
The electrically driven cooling fan is installed to control the engine coolant temperature efficiently and reduce
loss of engine output.
7-4 COOLING - Specifications

SPECIFICATIONS NO’ICA- .
GENERAL SPECIFICATIONS

Pressurized corrugated fin type

Radiator cap
High pressure valve opening pressure
Vacuum valve opening pressure kPa (psi)
Radiator fan motor No. 1
Direct current ferrite magnet type
Rated load torque Ncm (inlbs.)
rpm (with the fan attached) rpm 1,750-2,250 :
Current A
Radiator fan motor No. 2
(Vehicles with a manual transmission)
Direct current ferrite magnet type
Rated load torque Ncm (in.lbs.)
rpm (with the fan attached) wm
Current A
Radiator fan motor No. 2
[Vehicles with an automatic transmission)
Type Direct current ferrite magnet type
Rated load torque Ncm (in.lbs.)
rpm (with the fan attached) rpm 1,750 - 2,250
Current A
Thermosensor No. 2
Operating temperature “C (“F)
OFF -+ ON 82-88(180-190)
ON + OFF 78- 87 (172 - 189)
Thermosensor No. 2
Operating temperature “C (“F)
OFF% ON 97- 103 (207 --Zl7)
ON + OFF 9X- 102 (199-216)
?adiator fan motor relay
Excitingcoil rated current A 0.074 - 0.106 -~
Maximum contact current capacity A
Range of voltage used V
Voltage drop between terminals V 0.2 or less +
Water pump ’ Impeller of centrifugal type
Thermostat
Type Wax type with jiggle valve
Valve opening temperature “C (“F) 88(190)
Full-opening temperature “C (“F) 1 OII (212) at valve lift of 8 mm (.3l in.)
Identification mark 88 (Stamped on flange)
Xve belt
Length mm (in.) 964 (37.95) HM type
 COOLING - SDecifications 7-5

Engine coolant temperature gauge unit

Type Thermistor type
Resistance fl 104 at 70°C (158°F)
24 at 115°C (284°F)
Engine coolant temperature sensor for ECI system
Type Thermistor type
Resistance fi 16,200 at -20°C (-4°F)
2,450 at 20°C (68°F)
296 at 80°C (176°F)

SERVICE SPECIFICATIONS N07CB. -

Items Specifications

Standard value
Opening pressure of radiator cap high pressure valve
kPa (psi) 75-105(11-15)
Engine coolant concentration % 30-60
Drive belt deflection mm (in.) 7-10(.28-.39)
Thermostat
Opening valve temperature “C (“F) 88 (190)
Full-open temperature “C (“F) 100 (212)
Limit
Opening pressure of radiator cap high pressure valve
kPa (psi) 65 (9.2)

TORQUE SPECIFICATIONS N07CG _

Items Nm ftlbs.

Shroud to radiator 11-14 8-10

Thermosensor ‘14- 16 IO-12
Alternator support bolt and nut 20-24 15-18
Alternator brace bolt 12-14 9-10
Water pump 12- 15 9-10
Water pump pulley bolt and nut IO- 12 7.3 - 8.6
Engine coolant temperature gauge unit 30-40 22-28
Engine coolant temperature sensor 20-40 15-28
Water outlet fitting 17-20 13-14
Eye bolt for water pipe 35-50 25-36
Engine coolant temperature switch (Vehicles with an,air conditioner) IO- 14 7-10

LUBRICANTS NOTCD- _

Items Specified lubricants Quantity

Engine coolant lit. (qts.) High quality ethylene glycol * 8.73 (9.22)

NOTE
* Includes 0.70 liter (0.74 qt.) in reserve tank
7-6 COOLING - Specifications / Troubleshooting

SEALANTS NOJCE-.

Items ~~ Specified sealant Quantity

Engine coolant temperature gauge unit MOPAR Part No. 4378034 or equivalent As required
Engine coolant temperature sensor MOPAR Part No. 4318034 or equivalent As required
Engine coolant temperature switch MOPAR Part No, 4318033 or equivalent As required

TROUBLESHOOTING NOJEAAG

ermosensor

radiator core joint

Corroded or cracked hoses
(radiator hose, heater hose, etc.)
Loose bolt or leaking gasket in water outlet Correct or replace
fitting (thermostat)
Loose water pump mounting bolt or leaking Correct or replace

Faulty radiator cap valve or setting of spring

 COOLING - Troubleshootina 7-7

CIRCUIT DIAGRAM

Battery Sub fusible link 2

Therm0 sensor
P No. 1
I
1 2-F Radiator fan
id y---JM motor No. 1

B -

2-P
1.25LW
A-51

Radiator Radiator
fan motor fan motor
relay No. 1 relay No. 2
For details of grounding points (ax.: a). refer to page 8-10.

WY603
Wire color code
B: Black Br: Brown G: Green g: pdY L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink Y: Yellow W: White

OPERATION
l With the ignition switch at the “ON” position, let the engine coolant temperature reach 85°C (185”F), and
the thermosensor No. 1 will be turned “ON” and current will flow from the radiator fan motor relay No. 1
(contacts) to thermosensor No. 1 to ground to close the contacts of radiator fan motor relay No. 1.
l Then current flows from the radiator fan motor relay No. 1 (contacts) to radiator fan motor No. 1 to ground
to run the radiator fan motor No. 1.
l When engine coolant temperature reaches 100°C (212°F). the thermosensor No. 2 is turned “ON”, and
current will flow from radiator fan motor relay No. 2 (coil) to thermosensor No. 2 to ground to close the
contacts of radiator fan motor relay No. 2.
l So, current flows from radiator fan motor relay No. 2 (contacts) to radiator fan motor No, 2 to ground to run.
the radiator fan motor No. 2.
7-8 COOLING - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

N07FAAB

ENGINE COOLANT LEAK CHECK

1. Loosen radiator cap.
2. Confirm that the engine coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and
apply 150 kK(21 psi) pressure, Hold for two minutes in -
that condition; while checking for leakage from the radiator,
hose or connections. z _
Caution
Be sure to completely clean away any moisture from
the places checked.
When the tester is removed, be careful not to spill any
coolant from it.
Be careful, when installing and removing the tester and
when testing, not to deform the filler neck of the
radiator.
4. If there is leakage, reparr or replace the approprrate part.

RADIATOR CAP PRESSURE TEST NO’IFBAE

1. Use an adapter to attach the cap to the tester.

2. Increase the pressure until the indicator of the gauge stops
moving.
High pressure valve opening pressure:
Limit 65 kPa (9.2 psi)
Standard value 75 - 105 kPa (11 - 15 psi)
3. Check that the pressure level ismaintained at or above the ~-
limit.
4. Replace the radiator cap if the reading does not remain at or
above the limit. - -
NOTE
Be sure that~ the cap is clean before testing, since rust or
other foreign- material on the- cap seal will cause an
Improper Indication.

SPECIFIC GRAVITY TEST NO’IFDAD

1. Measure the specific gravity of the engine coolant with a

hydrometer.
2. Measure the engine coolant temperature, and calculate the
concentrationfrom the relation between the specific gravity -
and temperature, using the following table for reference.
Standard value: 30 - 60 %
 COOLING - Service Adjustment Procedures 7-9
RELATION BETWEEN ENGINE COOLANT CONCENTRATION AND SPECIFIC GRAVITY
The following table is applicable only to the specified engine coolant, HIGH QUALITY ETHYLENE GLYCOL
(ANTIFREEZE) COOLANT.

1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55 %

1.103 1.098 1.092 1.084 1.076 -Sp (-58) -45 (49) 60 %

Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at the engine
coolant temperature of 20°C (68°F).
Caution
1. If the concentration of the engine coolant is below 30%, the anti-corrosion property will be
adversely affected. In addition, if the concentration is above 60%, both the anti-freeze and engine
cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to
maintain the concentration level within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
 COOLING - Thermostat
Standard value:
Opening valve temperature 88°C (190°F)
Full-open temperature 100°C (212°F)
NOTE
Measure valve height when fully closed. Calculate lift: by
measuring the height when fully open.

04UOOlE
il
/ SERVICE POINT OF INSTALLATION
\ IJ-
NO’IGEAA
b - Proiection of -2
5. INSTALLATION OF THERMOSTAT
IOk, intake manifold /
Install the thermostat to the intake manifold as illustrated. ~_ _
Caution
Be careful not to install the thermostat obliquely by
fitting the thermostat flange in the spot facing provided
in the intake manifold.

between these
 COOLING - Coolina Fan 7-13
COOLING FAN
REMOVAL AND INSTALLATION

5
4 ’ 11-14 Nm
\ I I / 8-10 ft.lbs.

Removal steps
1. Fan motor connection
2. Connector cap
** l * 3. Shroud
4* 4. Fan
4* 5. Motor No. 1 \ 1 I-14 Nm
6. Air duct
2 8-10 ft.lbs.

Air conditioner fan removal steps

7. Fan motor connection
8. Connector cap 8
l * I)* 9. Shroud
4* 10. Fan
4* 11. Motor No. 2 04Y662
12. Air duct 9 12

NOTE
(I) Reverse the removal procedures to reinstall.
(2) (I*: Refer to “Service Points of Removal”.
(3) I)*: Refer to “Service Points of Installation”.

SERVICE POINTS OF REMOVAL N07HBAB

3. REMOVAL OF SHROUD ,/ 9. SHROUD

Disconnect the radiator fan motor connectors, remove the
shroud mounting bolts, then remove the radiatorfan motor
from the radiator.

4. REMOVAL OF FAN / 10. FAN

Separate the fan from the fan motor.
 __- -

COOLING - Cooling Fan

5. REMOVAL OF MOTOR NO. 1 / 11. MOTOR NO. 2

Remove the motor from-the shroud,

16'0795
. .

INSPECTION N07HCAE

RADIATOR FAN MOTOR NO. 1 AND NO. 2

Apply the battery voltage to the terminal “1” and sound the
terminal “2”, then make surEthat the moror tu~rns smoothly. f

RADIATOR FAN- MOTOR RELAY

(1) Remove the- radiator fan motor relay.
/Raaator fan

(2) Check c on t’Inuity between terminals when the battery

voltage is applied to the Lerminal 1 and the terminal ? is ~I
grounded.

Voltage applied Terminal 3- 4 Condtictiv6~.

Voltage not _ Non-conductive
applied “.
Terminals I - 2 Conductive
16G02U8
 COOLING - Cooling Fan 7-15
I I SERVICE POINTS OF INSTALLATION NO’IHDAB

3. INSTALLATION OF SHROUD / 9. SHROUD

When installing the shroud, tighten also the radiator motor
ground wires with the bolts.
7-16 COOLING - Radiator

RADIATOR N07QA..

REMOVAL AND INSTALLATION

10-12 ft.lbs.

64Y663

Radiator
removal steps
1. Radiator cap
+I) 2. Drain plug
3. Overflow tube connection
9. Fan motor connection
10. Connector cap
4. Thermosensor No. 1
5. Thermosensor No. 2 Reserve tank removal steps
6. Radiator upper hose connection 3 Overflow tube connection _I
7. Radiator lower hose connection 17. Overflow tube
8. Radiator 18. Reserve tank
+* *+I 11. Shroud 19. Reserve tankbracket
12. Fan motor connection
13. Connector cap NOTE :I
*I) I)* 14. Shroud (1) Reverse the removal procedures to rernstall.
15. Radiator bracket (2) +I): Refer to “Service Points of Removal”.
16. Radiator support insulator (3) I)+: Refer to “Service Points of lnstallation”.~~
 COOLING - Radiator 7-17
SERVICE POINTS OF REMOVAL N07QBAD

2. REMOVAL OF DRAIN PLUG

Set the temperature control lever of heater control to the
hot position and drain engine coolant.

11. REMOVAL OF SHROUD / 14. SHROUD

Disconnect the thermosensor and radiator fan motor
connectors, remove the shroud mounting bolts, then
remove the radiator fan motor from the radiator.

I 04Y64

INSPECTION N07QCAF

l Check the radiator fins for bends, breaks, or plugs.

l Check the radiator for corrosion, damage, rust or scale.
l Check the radiator hoses for cracks, damage or wear.
l Check the reserve tank for damage.
l Check the radiator cap spring for damage.
l Check the radiator cap seal for cracks or damage.
l Check the engine coolant for contamination,

THERMOSENSOR
Check for continuity with the thermosensor in hot water.

J
16UO328
Thermosensor No. i.
, 4f3(7-t5)

--%x&35 z!I 5)
-Water
temperature
Thermosensor NO. 2 16Y1190
, 4f3(755)

:;pp
100+3(212f5)
_ Water
“C (“F) temperature
16Y1190
7-18 COOLING - Radiator
I SERVICE POINTS OF INSTALLATION NO’IQDAD

11. INSTALLATION OF SHROUD / 14. SHROUD

When installing the shroud to the radiator, be sure to 1
tighten the ground wires with the bolts which senses also I-
for mounting the shroud.-
Connect the thermosensoFto the connector and iiistall the 2
cap on the thermosensor to project it from water. ~-
NOTE
1. Fill the radiator and reserve tank with clean engine _,
coolant. =
2. Run the engine until the engine coolant has warmed wp -
enough so_ that the thermostat valve opens, and then
stop the engine.
3. Remove the radiator &p, pour in the engine coolant
until it is up to the filler neck of the radiator, and then fill .i
the reserve tank to the upper level.
4. Check to be sure that there is no leakagefrom the mL
radiator, hose or connections. -. :
 COOLING - Water Pump 7-19

WATER PUMP NQ7MB- -

REMOVAL AND INSTALLATION

Post-installation Operation
l Refilling Engine Coolant
l Installation of Batterv
l Adjustment of Air Conditioner Compressor V-belt Tension
(Refer to GROUP 24 HEATERS AND AIR CONDITIONING -
Service Adiustment Procedures.)
l Adjustment of Power Steering dil Pump V-belt Tension
(Refer to GROUP 19 STEERING-POWER-Service
Adjustment Procedures.)
l Adjustment of Alternator and Water Pump Drive Belt
Tension (Refer to P.7-IO.)

041665

04Y666

Water pump kit

Removal steps
1. Radiator lower hose connection
2. Air conditioner compressor V-belt
3. Alternator and water pump drive belt NOTE
4. Power steering oil pump V-belt (1) Reverse the removal procedures to reinstall.
5. Water pump pulley (2) *e: Refer to “Service Points of Installation”.
6. Heater hose connection (3) q : Non-reusable parts
(4) For torque required for tightening the water pump bolts
*(I 7. Water pump marked with *, refer to Installation of Water Pump.
8. Water pump gasket
 -.-- ~~~-

7-20 COOLING - Water Pump

INSPECTION NO’IMDAH

DRIVE BELT FOR ALTERNATOR

A belt which has following defects should be replaced. I
* Damaged, peeled or cracked surface.
@ Oily or greasy surface.
+ A belt worn to such an extent that it is in con-Erct with l
bottom of V groove in pulley.
l Worn or hardened rubber.

WATER PUMP
e Check each part for cracks, damage or wear, and replace =
the water pump assembly if necessary.
l Check the bearing for damage, abnormal noise and sluggish
rotation, and replace the water pump assembly if neces-
sary.
l Check the seal-unit for leaks, and-replace the water pump
assembly if necessary. -_
l Check for water leakage. lfwater leaks from hole ‘YA”. seal =
unit is leaking. Replace as an assembly.

SERVICE POINT OF INSTALLATION N07MEAI

7. INSTALLATION OF WATER PUMP

Water pump installatio~n bolt size are different and-caution _
must be paid to ensure that they are properly installed. I

Hardness
(!I!7 foW
No. category Torque
d x l mm (in.)
hardness category (Head mark) Nm (ft.lbs.1
04lJoo25
1 4T 8x 23 (.31 x .90) 12-15
(9- 10)
2 4T 8x28(.31 x 1.10)

3 4T 8 ~88 (.31 x 3.46)

4 4T 8 x 78 (.31 x 3.07)
 COOLING - Water Hose and Pipe 7-21
WATER HOSE AND PIPE N071A- -

REMOVAL AND INSTALLATION

26-36 ft.lbs.

8\ R \

Removal steps
1.. Air cleaner
2. Heat protector
3. Oxygen sensor harness connector
4. Heat insulator
5. Water hose \I-
6. Water pipe “9”
7. Water hose
8. Water pipe “A”
9. Water hose
10. Water hose
11. Water hose A (heater) connection
12. Heater pipe assembly NOTE
13. Water hose B (heater) (1) Reverse the removal procedures to reinstall.
14. Water hose connection (2) q : Non-reusable parts
OlY706
- = ...-

7-22 COOLING - Engine Coolant Temperature Gauge Unit

ENGINE COOLANT TEMPERATURE GAUGE UNIT N070B-- ~~

REMOVAL AND INSTALLATION

Removal steps
OlY705
I, Engine coolant temperature switch harness -
connection (Vehicles with an air conditioner)
4* l + 2. Engine coolant temperature switch (Vehicles
with an air conditioner)
3. Engine coolant temperature gauge unit har-
ness connection
+I) l + 4. Engine coolant temperature gauge unit
5. Engine coolant temperature sensor harness NOTE
(1) Reverse the re%~al procedures to reinstail
connection (2) *I): Refer to “Service Points of Removal”.
++ ++ 6. Engine coolant temperature sensor (3) **: Refer to T&vice Points of Instaltation”. -
--

SERVICE POINTS OF REMOVAL NO’IOCAC

2. REMOVAL OF ENGINE COOLANT TEMPERATURE

SWITCH (Vehicles with an air conditioner) / 4. ENGINE
COOLANT TEMPERATURE GAUGE UNIT / 6. ENGINE
COOLANT TEMPERATURE SENSOR
(1) Drain coolinqsystem dawn to gauge unit level or below.
(2) DisconneCT the battery ground cable and disconnect mm
harness from the gauge unit.
(3) Remove the engine coolant temperature gauge unit. -
COOLING - Engine Coolant Temperature Gauge Unit 7-23
INSPECTION N07QDAE

ENGINE COOLANT TEMPERATURE GAUGE UNIT

Refer to GROUP 8 ELECTRICAL - Meters and Gauges.
ENGINE COOLANT TEMPERATURE SENSOR
Refer to GROUP 14 FUEL (ECI) SYSTEM.
ENGINE COOLANT TEMPERATURE SWITCH (VEHICLES
WITH AN AIR CONDITIONER)
Refer to GROUP 24 HEATERS AND AIR CONDITIONING -
Service Adjustment Procedures.

SERVICE POINTS OF INSTALLATION N070EAS

6. INSTALLATION OF ENGINE COOLANT TEMPERATURE

SENSOR / 4. ENGINE COOLANT TEMPERATURE
GAUGE UNIT / 2. ENGINE COOLANT TEMPERATURE
SWITCH (Vehicles with an air conditioner)
(1) Apply sealant to threaded portion and tighten.
Specified sealant: MOPAR Part No. 4318034 or
equivalent
(2) Connect the harness to engine coolant temperature
gauge’ unit.
(3) Connect battery ground. cable.
(4) Refill cooling system.
Caution
Do not use an impact wrench to install the engine
coolant temperature gauge unit, engine coolant
temperature sensor, and engine coolant tempera-
ture switch.
 9-l

CONTENTS
CRANKSHAFT, FLYWHEEL AND DRIVE OIL PAN AND OIL SCREEN . .. .. . .. ...__..._....._. . . .. .. .. 25
PLATE .. .._...__..___..._t_.__.._...___.._...___..__..
__.___.._._.___
_.___ 60
PISTON AND CONNECTING ROD .. . .. ..__..._. . .. . .. 55
CYLINDER BLOCK .. . .. . .. .. . .. . . .. .. . .. . .. . .. .. . . .. . .. ..__....... 64
ROCKER ARM AND SHAFT ASSEMBLY ..,..... 38
CYLINDER HEAD . .. . .. . .. . .. . .. ..._...........__.t_...._........ 41
ROCKER ARMS, ROCKER ARM SHAFTS
CYLINDER HEAD GASKET .. ..__..__..___ .___...__..._ 26
____ AND CAMSHAFT ..,...._._..__...__..._....._...._......._...._. 35

ENGINE ADJUSTMENT . .._.__.___..__... __..._...__..._... 14 SPECIAL TOOLS _.___...__..._.......... 12

.. . .. ..._...._..._....___.__
Compression Pressure Check ,._..___..__...__ _.._... 15
SPECIFICATIONS ................................................. 5
Engine Oil~Filter Replacement . . .. .. . .. . . .. ..._....... 14
General Sp.ecifications .................................... 5 -
Engine Oil Inspection . .. .. . . .. .. . .. . .. . .. . .. . .. . .. .. . .. . ..~.. 14
Sealants ... ........................................................ 1 11
Engine~Oil Replacement . . ..._.._..._...._...__..__...__..__ 14
Service Specifications .................................... 6 ":
Retorquing Cylinder Head Bolts .. . .. . .. . .. .._....-. 14
Torque Specifications .. . ........... l..... .................... IO -
Silent Shaft Drive Chain Tension
Adjustment Procedure _....._..__...._........_..._..._... 15 TIMING CHAIN TRAIN . .. .._.__.__...._..........._.I......... 31
Valve Clearance Adjustment ._...._...._...__..__. .._._. 14
TROUBLESHOOTING . . .. .. . ...__..___.._......~............. 13
ENGINE AND TRANSMISSION Compression Too Low
ASSEMBLY . .. .. . ._.. . . .. _.._.. . .. .. . . .. . .. .. . ._.I.... _.. . ._._......... 19
Connecting Rod Noise/Main Bearing Noise
ENGINE MOUNTING 17
. .. .._.___..__...__...__..__..___..____. Excessive Engine Rolling and Vibration
Noisy Valves
ENGINE OIL COOLER . .. ..._................................. 24
Oil Pressure Drop
FRONT CASE, OIL PUMP AND SILENT Oil Pressure Too High
SHAFT . .. .._.____.._ _..._..___.___...__..._...._..51
______...__..._...._.... Timing Chain Noise .

GENERAL INFORMATION . .. .. . .. _..._. . .. .. . .. . .. . .._.._ 2 VALVES AND VALVE SPRINGS _......___..__...._..... 44

JET VALVE .,......_...__..._.............. _..._. . .. .. . . ._.. . .. _.. . ...I 49

9-2 ENGINE - General Information

GENERAL INFORMATION NOSBACD

The 2.61 (159 cum.) displacement engine is a four cylrnder overhead camshatt power plant with a cast Iron .-=
cylinder block, an aluminum cylinder head and a silent shaft_ system.
The forged steel crankshaft is supported by five main bearings. 1 -
The cylinder block has a Siamese type water jacket which ensures high cooling efficiency and uniform cooling -1
of the cylinders. -w
Two counterbalance shafts (silent shafts) are incorporated in the cylinder block to reduce engine noise and ~~
vibration.
The prstons are made of alumrnum alloy casting.
The piston pin IS floatrng In the piston and pressed-in to the forged steel connecting rod. The piston pink is !
offset from the prston center toward the thrust side.
The oil pump is a gear type pump and also drives the right (front[silent shaft.Lhe oil pump and left (rear) silent
shaft are chain driven through sprockets by crankshaft. -
The silent shaft-system cancels the vertical vibration force of the engrne and-secondary vibrating forces such -1
as the vibrating moment in the rolling direction. The silent shafts are located~ in the upper teft (rearward side)
and lower right (forward side) of the cylinder block. The left shaft. rotates in ‘the same direction as the
crankshaft while the rrght shaft rotates in the opposite direction at twice the crankshaft speed. .~=. E$h silent Yti
shaft is supported by two aluminum bearings.
The cylinder head is an aluminum alloy casting with compact type comb@stion. chambers. The intake and 1
exhaust valves are made of heat-resistant steel and arranged in a ‘Iv” with asamshaft on center. The let valve
assemblies, consrsting of the let valve, jet body, stem seal, spring, retainer GYd retainer lock, are screwed into ~5
the cylinder head.
The cast iron camshaft is supported by five bearing journals and is driverrby the crankshaft sprocket and .I
camshaft spracket by the trmrng charn. The distributor drive gear is mounted on the front of the camshaft. -I=
The camshaft drive chain IS a double roller type chain. To provide the chain vvi_th the proper tension and ensure ’
quiet operation at all times, tensloner is installed on the slack side, :
Two rocker arms are used with one for actuating the exhaust-valves and the other For actuating the -_ intake y
valves and jet valves.
The rocker arms are aluminum alloy die-castings with cemented carbide alloy slippers. By using the auto lash ;
adjuster, the rocker arms eliminate the need for adjustment of intake 2nd exhaust valve clearance. :-
The oil pump IS an internal-external involute gear type pump and is driven cy crankshaft. The oil filter, paper f
filter element cartridge type, is mounted on the front facing side of the engine. ~-
L
 ENGINE - General Information 9-3
SECTIONAL VIEW

5GE019-A :-

5EN0019
 -

3 L..

._
-
- -. I __ ,,“-

ENGINE - General Information

LUBRICATION SYSTEM
 ENGINE - Specifications 9-5
SPECIFICATIONS NOPCA- -

GENERAL SPECIFICATIONS

terns Specifications

rwe In-line, OHC

dumber of cylinders 4
3ore mm (in.) 91 .I (3.587)
;troke mm (in.) 98.0 (3.858)
‘iston displacement cc (cu.in.) 2,555 (155.9)
Iompression ratio 7.0
Yring order I-3-4-2
lalve timing
Intake valve
Opens (BTDC) 25”
Closes (ABDC) 59”
Exhaust
Opens (BBDC) 64”
Closes (ATDC) 20”
Jet valve
Opens (BTDC) 25
Closes (ABDC) 59”
Valve overlap 45”
Intake valve duration 264’
Exhaust valve duration 264’
Jet valve duration 264”
9-6 ENGINE - Specifications

SERVICE SPECIFICATIONS

Overall height mm (in.)

Flatness of gasket surface Less than 0.05 (.002OT

Flatness of manifold mountrng surface
mm tin.) Less than 0.15 (.00591
Oversize rework drmensron of valve
seat hole mm (in.)
Intake 0.3 mm (.0118 in.) OS. 47.300 -47.325 (I .8622 7 1.8632)
0.6 mm t.0236 in.) O.S. 47.600-47.625 (1.8740- 1.8750)
Exhaust 0.3 mm (.I 18 in.) O.S. 40.300 - 40.325 (1.5@6- ‘I .5876) :
0:6 mm t.0236 in.) O.S. 40.600 - 40.625 (1.5%34- 1.5994) 1;

0.05 mm t.002 in.) O.S. 13.050- 13.068(.5138-.5145)

0.25 mm t.010 in.) 0.S. 13.250 - 13.268 l.5227 G.5224)

No. of links
Pitch mm (In.1

Pitch mm (in.)
etween chain and chain guide

Cam herght mm (in.)

Intake 42.43 (1.6705)
Exhaust 42.43 (1.6705) ~~
Height of fuel pump drive cam
Journal diameter mm (In.)
Oil clearance mm (in.) 0.05 - 0.09 t.0020 --a0351

Rocker arm-to-shaft)
 ENGINE - Specifications

Items Standard value Limit

Valve
Valve length mm (in.)
Intake 107.96 (4.2504)
Exhaust 105.86 (4.1677)
Stem O.D. mm (in.)
Intake 8.0 (.315)
Exhaust 8.0 (.315)
Face angle 45” - 45”30’
Thick;;;.yf valve head (Margin)

Intake 1.2 (.047) 0.7 (028)

Exhaust 2.0 f.079) 1.5 (.059)
Valve stem to valve guide clearance
mm (in.)
Intake 0.03 - 0.06 (.0012 - .0024) 0.10 f.0039)
Exhaust 0.05 - 0.09 (0020 - .0035) 0.15 f.0059)
Valve guide
Length mm (in.)’
Intake 47 (1.85)
Exhaust 52 (2.05)
Oversize mm (in.) 0.05 (.002), 0.25 (.OlO),
0.50 (.020)

Valve seat
Width of seat contact mm (in.) 0.7 - I .2 (028 - ,047) I
Seat angle 45”
Oversize rework of valve seat insert
height mm (in.)
Intake 0.3 mm (.012 in.) 7.9-8.1 (311 -.319) ,
0.6 mm (024 in.) 8.2 - 8.4 (323 - .331)
Exhaust 0.3 mm (.012 in.) 7.9 - 8.1 (311 - .319)
0.6 mm (024 in.) 8.2 - 8.4 (323 - ,331)

Jalve spring
Free length mm (in.) 49.8 (I ,961) 48.8 (1.922)
Load N (Ibs.) 329 (73) at installed height
Installed height mm (in.) 40.4 (1.591) 41.4 (1.630)
Out of squareness Less than 2” 4”

Jet valve
Length mm (in.) 92.53 (3.6429)
Stem O.D. mm (in.) 4.3 (. 169)
Seat angle 45”
Valve clearance - Hot engine mm (in.) 0.25 (.0098)
Valve clearance-Cold engine
(Reference) mm (in.) 0.17 (0067)
a:
-2
_____ _p__--____i----L---

9-8 ENGINE - Specifications

Limit

Free length mm (in.)

Load N (IbsJ 35 (7.7) at installed height

Cylinder bore mm (in.) 91.1 (3.5871 -----

Out-of-roundness and taper of cylinder
bore mm (in.) Max. 0.02 (.0008)
Overall height mm (in.) “-0.2 (*-,008)
*Limit must be --0.2
(-.008) combined with
amount of grinding of
cytinder head gasket
surface.
0.1 (.004)

Front jdurnal diameter

Rear journal diameter
Oil clearance mm (in.)

Front journal diameter

Rear journal diameter I
Oil clearance mm (in.)
Front 0.020 - 0.062 (0008 r .6024)

Clearance (Piston-to-cylinder) 0.03 - 0.05 (.0012 -~;pozo) -

Ring groove width mm (in.)
No. 1 and No. 2
011
Compressp-pressure 1,000 (142) (250 - 400 rpm)
Oversize mm (in.) 0.25 (.OlO), 0.50 (.026),
0.75 (.030), 1 .oo (.039T -

0.05 - 0.09 (.OOZO- .0035) -= 0.12 (.0047) ~~

No. 2 0.02 - 0.06 (.0008 - .0024) ~: 0.10 (.0039)
End gap mm (in.)
No. 1 0.30 - 0.45 LO1 18 -~.0177) 0.8 (.031 I
No. 2 0.25 - 0.40 (0098 -2lf57) 0.8 (.031)
-
Oil ring side rail 0.30 - cJ.go (.0118 -,Q315) 1 .o f.039)
Oversize mm (In.) 0.25 (.OlO), 0.50 (.CDO),
0.75 (.030), I .oo (.039)
 ENGINE - Specifications

Items Standard value Limit

Connecting rod
Bend mm (in.) 0.05 (.0020) or less per 100 (3.937)
Twist mm (in.) 0.10 t.0039) or less per 100 (3.937)
Connecting rod big end to crankshaft
side clearance mm (in.) 0.10-0.25 (.0039- .0098) ’ 0.4 f.016)
Piston pin press-in load N (Ibs.) 7,500- 17,500 (1,653-3,858)

Connecting rod bearing

Oil clearance mm (in.) 0.02 - 0.05 (0008 - .0020) 0.1 (.004)
Undersize mm (in.) 0.25 (.OlO), 0.50 (.020),
0.75 (.030) c_
Crankshaft main bearing
Oil clearance mm (in.) 0.021 - 0.046 (.0008 -~.0018)- -
Undersize mm (in.) 0.25 (.OlO), 0.50 (.020), 0.75 (030)

Zrankshaft
Pin O.D. mm (in.) 53 (2.09)
Journal O.D. mm (in.) 60 (2.36)
0ut;fmm;;dness of journal & pin
Less than 0.015 (0006)
Taper of journal & pin mm (in.) Less than 0.005 (0002)
End play mm (in.) 0.05-0.18(.0020-.0071) 0.4 (.016)
Undersize rework dimension of pin
mm (in.)
0.25 m-i-r-i(.OlO in.) U.S. 52.735 - 52.750 (2.0762 - 2.0768)
0.50 mm (.020 in.) U.S. 52.485 - 52.500 (2.0663 -2.066-g).
-r T
0.75 mm (.030 in.) U.S. 52.235 - 52.250 (2.0565 - 2.0571) &-
Undersize rework dimension of journal
mm (in.)
0.25 mm (.OlO in.) U.S. 59.735 - 59.750 (2.3518 - 2.3524)
0.50 mm (.020 in.) US. 59.485 - 59.500 (2.3419 i 2.3425) ,.. _
0.75 mm (.030 in.) U..S 59.235 - 59.250 (2.3321- 2.3-327) :
,.
:lywheel c 7
Runout mm (in.) i Less than 0.13 (.-065’1)

Iii pressure at curb idle speed kPa (psi) Min. 80 (11.4) -

Conditions: Oil temperature is 75 to 90°C ‘2.
167 to 194”F)l I
~-- -
Xl pump
Drivengear
Tip clearance mm (in.) 0.11 -0.15(.0043-.0059) 0.20 (.0079)
Side clearance mm(in.) 0.04-0.10 (.0016-.0039) ~. 0.15 (.D060) ~-
Drive gear
Tip clearance mm (in.) 0.11 - 0.15 (0043 - .0059) 0.20 (.0079)
Side clearance mm (in.) 0.05 - 0.11 (.0020 - .0043) 0.15 (.0060)
9-10 ENGINE - Smxifications

NOTE
0.D. = Outer Diameter
I.D. = Inner Diameter
OS. = Oversize Diameter
U.S. =~Undersrze Drameter

TORQUE SPECIFICATIONS NOSCC- .

Cylinder head bolts - Hot engine

Cylinder head bolt (M8 bolt)
Camshaft bearing cap bolts
Camshaft sprocket bolts
Rocker cover bolts
Jet valve assembly
Engine oil cooler eye bolt
Intercooler air hose band
Accelerator cable lock nut
Rear catalytrc converter to front catalytrc converter nut
Turbocharger oil pipe flare nut
Engine mounting front rnsulator to engine nut
Engine mounting front rnsulator to cross member bolt

Engine mounting rear rnsulator to engine nut

Engine support bracket to body bolt
Power steering oil pump to bracket bolt
Air conditioner compressor to bracket bolt
Automatic transmrssion oil cooler eye bolt
Clutch tube flare nut
Propeller shaft to torque tube companion flange bolt
Rockzr arm adjusting nuts for let valve
Main bearing cap bolts
Connecting rod cap nuts
Dumper pulley bolts
011pump sprocket bolt
Srlent shaft sprocket bolt
Timing chain case bolt
Srlent shaft camber cover bolts
Flywheel bolts
Engine support brackets bolts
Chain guide “B” bolt (Upper)
 ENGINE - Specifications 9-11

Items Nm ftlbs

Oil pump driven gear bolts 60-70 44-50

Oil pump cover bolts IO- 12 7.3 - 8.6
Oil pump assembly mounting bolt IO-12 . 7.3-8.6
Thrust plate bolt IO? 12 7.3 - 8.6
Oil pan bolt 6-8 4.4- 5.7
Oil pan drain plug 35-45 26-32
Oil screen bolt 15-22 11-15
Oil filter 11-12 8.0 - 8.6
Oil relief valve plug 30-45 22-32
I

SEALANTS i_ NOSCE- .

Items Specified sealant

Oil pressure switch No. 4318034 or equivalent

Cylinder block lower surface, 4 pos\tions As required ~=~.~.

Semi-circular packing

_..
9-12 ENGINE - Special Tools

SPECIAL TOOLS NOSDA..

Tool (Number and name) Use Tool (Number and name) Use

lnstallatron of jet valve MD998309 - Disassembly and reas-

Jet valve stem seal installer stem seal Jet valve spring prier sembly of jet valve

Removal and installation C-3422-E Removal and installation

Jet valve wrench of jet valve assembly Valve spring compressor of valve and related
parts

MD998251 Removal of silent shaft Press-fitting of silent

Silent shaft bearing puller bearing Silent shaft bearing rnstaller shaft bearing
(For rear bearing) [For rear bearing)

MD998376 Installation of crankshaft MD998_443 Retaining the auto-lash

Crankshaft rear oil seal installer rear oil seal 4uto-lash adjusterholder adjuster

Installing valve stem

Valve stem seal installer [Used seals
with valve spring seat]
 ENGINE - Troubleshootina 9-13
TROUBLESHOOTING

Symptom Probable cause Remedy

Compression too low Cylinder head gasket blown Replace gasket

Piston ring worn or damaged Replace rings

Piston or cylinder worn Repair or replace piston and/or

cylinder block

Valve seat worn or damaged Repair or replace valve and/or seat

ring

Oil pressure drop Engine oil level too low Check engine oil level

Oil pressure switch faulty Replace oil pressure switch

Oil filter clogged Replace oil filter

Oil pump gears or body worn Replace gears and/or body

Oil relief valve stuck (opened) Repair relief valve

Excessive bearing clearance Replace bearings

Oil pressure too high Oil relief valve stuck (closed) Repair relief valve

Noisy valves Incorrect auto-lash adjuster Replace auto-lash adjuster

Valve stem or valve guide worn or damage Replace valve and/or guide

Connecting rod Insufficient oil supply Check engine oil level

noise/main
bearing noise Low oil pressure Refer to “Oil pressure drop”

Excessive bearing clearance Replace bearings

Timing chain noise Incorrect chain tension Adjust chain tension

Excessive-engine Loose engine support bracket Retighten bracket

rolling and vibration
Broken engine mounting front insulator Replace insulator

Broken engine mounting rear insulator Replace insulator

 ___- ____

ENGINE - Engine Adjustment

ENGINE ADJUSTMENT NOSFAAAa

ENGINE OIL INSPECTION

(1) Check that the engine oil level is within the range shown on ~_
the dipstick. _ ~~
(2) Check that the engine oil is not excessively conGminated ~z
and is free from engine coolant or gasoline. Also check that :
it has appropriate viscostiy.

_i
-z

ENGINE 01~ REPLACEMENT NOSFBAAa

Refer to GROUP Q LUBRICATION AND MAINTENANCE - z

Marntenance Service.

ENGINE OIL FILTER REPLACEMENT NOSFCAAa

Refer to GROUPS -LUBKlCATlON AND MALNTENANCE .. -~

Maintenance Servrce. :

RETORQUING CYLINDER HEAD BOLTS NOSFDAB

(1) Using torque wrench. first slightly loosen cylinder head ~~

bolts and thentighten to specified torque.
Tightening torque:
Cylinder head bolt (No. 1 to IO)
Cold engine 90 - 100 Nm (65 - 72 t=t.lbs.
Hot engine 100 - 110 Nm (73 - 79 ftlbs.
Cylinder head bolt (No. 11)
Cold engine 15-22Nm (II-15ft.lbs.
Hot engine 15-22Nm(ll-15fklbs.
\ (2) Be sure to-follovv the specific torquing sequence.
5EN06E
-
@ Timirig belt side NOTE
Run engine until normal operating temperature is reached, I
allow it to cool down, and then retorque bolts to specifica- 1
tion for best results.

5ENOlE
-
VALVE CLEARANCE AbJlJ&MENT NOSFEAAa

Refer to GROUP 0 LUBRICATION AND MAINTENANCE -_~~

Maintenance Se~rvice. :
 ENGINE - Engine Adjustment 9-15
SILENT SHAFT DRIVE CHAIN TENSiON ADJUST-
MENT PROCEDURE NOSFIAA

When a loose slilent shaft drive chain is suspected as the

probable cause of abnormal noise, the tension must be
readjusted.
Tension of silent shaft drive chain can be adjusted without
removing timing chain cover as follows.
(1) Remove cover from access hole provided at center of chain
case (under water pump).

\ iEN

(2) Loosen special bolt “B”.

Chain guide “B”
(3) Using your finger, push projection on chain guide “B” in ,
direction of arrow. Do not push projection with a screwdriv-
“B” er or other tool. Improper chain tension will cause abpormal
noise.
(4) Tighten special bolt “B”.
(5) Install cover. Do not reuse damaged gasket.
Cover bolt tightening torque:
10 - 12 Nm (7.3, - 8.6 ftlbs.)
Projection
5ENOO;

COMPRESSION PRESSURE CHECK NO9FFAA

(1) Before inspection, check that the engine oil, starter motor
and batery are in normal state.
(2) Start and run the engine until the engine coolant tempera-
ture rises to 80 to 90°C (176 to 194°F).
(3) Stop the engine and disconnect the spark plug cables.
(4) Remove the spark plugs.
(5) Crank the engine to drive out foreign matter from cylinders.-
Caution
Cover the spark plug holes with cloth to prevent
scattering of foreign matter. Also keep away from the
spark plug holes. This operation is necessary to be
performed before compression pressure check to pre-
vent danger of exposure to hot water, oil, fuel or other
foreign matter that could enter the cylinders through
cracks etc.; as they will gush out from the spark plug
holes at the time of compression pressure check.
(6) Set a compression gauge at the spark plug hole.
(7) With the throttle valve held fully open, crank the engine and
measure the compression pressure.
Standard value: 1,000 kPa (142 psi) [250 - 400 rpm]
Limit: 800 kPa (113 psi) [250 - 400 rpm]
(8) Repeat steps (6) and (7) ‘on all cylinders to check that the ~~
compression pressure difference among all cylinders is. .- -1
within the following limit.
Limit: Max. 100 kPa (14 psi)
9-16
EL -
(9) If any of cylinders has a compressron pressure and/or %
pressure difference that-exceeds the limits, add a small zi
amount of engine oil throqh the spark plug hole and repeat -T E
--
_
steps (6) through (8) onthat cylinder. -.
t-i, If addition of engine Causes an increases ofcompres-
sron pressure, the piston and/or cylinder wall may have -’
been wornor damaged. .-
i2i If addition of engine oil does not cause any Increase of .Tz
compressron pressure, valve seizure, poor valve con-
tact, pressure leaks through gasket are surected. -~-- .-
 ENGINE - Engine Mounting 9-17

ENGINE MOUNTING NOSGA- -

REMOVAL AND INSTALLATION

^13-20 Nm . .
13-20 Nm
9.4-14 ft.lbs.
4
\ 20-24 Nm
-1 .l-DfiII

IONm
7 7 ft Ihc

Front mounting
1. Heat protector
2. Front insulator stopper
l * ** 3. Engine mounting front insulator

Rear mounting
4* 4. Engine mounting rear insulator
5. Engine support bracket
l C 6. Lockwasher
7.~ Plate NOTE
8. Lower cushion (1) **: Refer to “Service Points of Removal”.
9. Upper cushion (2) *a: Refer to “Service Points of installation”.
 9-18 ENGINE - Engine Mounting

SERVICE POINTS OF REMOVAL NOSGBAC

3. REMOVAL OF ENGINE MOUNTING FRONT INSULA-

TOR
(1) Remove the engine mounting nuts and bolts from the -.;:
front insulators. ~. E
(2) Attach a chain to theengine hangers. --
(3) Using an engine~hoist, -raise the engine and remove the ~2
insulators ~~
Caution
Avoid applying a strain on the radiator and fuel
hoses and cables by raising the engine too high.
4. REMOVAL OF ENGINE MOUNTING REAR INSULATOR ~-
(1) Support the transmission with a jack.
(2) Remove the supportbrakcet and insulator assembly. 1

INSPECTION NOSGCAB

a Check the insulators for cracks, separatron. and deforma- 2

tron.
o Check the cushion pad for cracks and wear. . . .
l Check the engine support bracket for deformation and 1.:
corrosron.

I SERVICE POINTS OF INSTALLATION NOSGDAC

6. INSTALLATION OF LOCK WASHER

Install the rear insulator and bend the lock washer tabs to .
keep the engine support bracket mountrng bolts from 1
turning.
Caution
1.---)
Do not distort rubber portions, and never stain rubber
portions with fuel or oil.

Fololc
t
I
3 !f$X$;o~TION OF ENGINE MOUNTING FRONT IN-

Make sure that the locating boss and hole are in alignment. ~
Caution
Do not distort rubber portions, and never stain rubber
portions with fuel or oil.
 ENGINE - Engine and Transmission Assembly 9-19
ENGINE AND TRANSMISSION ASSEMBLY NOSSA- -
3EMOVAL AND INSTALLATION
Pre-removal Operation
l Draining Engine Coolant
l Draining Engine Oil
0 Removal of Residual Pressure in Fuel High
Pressure Hose (Refer to GROUP 14 FUEL
SYSTEM - Service Adjustment Procedures.)
l Draining Transmission Oil or Fluid
l ;;rdo;/al of Hood (Refer to GROUP 23 BODY -

l Draining Clutch Fluid

1. Air cleaner
2. Heat protector
3. Oxygen sensor harness connector
4. Intercooler air hose A connection 2
Intercooler air hose D connection
:: Power brake booster vacuum hose connec-
tion
Heater hose connection
Power steering oil pump V-belt
Air conditioner compressor
Power steering
oil pump
(I* 11. Air conditioner
compressor 2-4 ft.lbs. -
12. Rear catalytic
converter connection
VOTE
(I*: Refer to “Service Points of Removal”.

25-33 Nm
18-24 Mbs.
\

Post-installation Operation
l Refilling Engine Coolant l Adjustment of Accelerator Cable Free Play (Ref&oGROUP
l Refilling Engine Oil 14 FUEL SYSTEM -Service Adjustment ProceduSes.)
l Refilling Transmission Oil or Fluid l Adjustment of Clutch Pedal Cable Free Play (Refe!&
l Refilling Clutch Fluid GROUP 6 CLUTCH -Service Adjustment Procedures.)
l Installation of Under Cover (Refer to GROUP 23 BODY - l Adjustment of Hood (Refer to GROUP 23 BODY - Service
Loose Panel.) Adjustment Procedures.)
l Installation of Hood (Referto GROUP 23 BODY - Hood.) l Adjustment of Engine (Referto GROUP 0 LUBRICATION
l Bleeding Clutch Line (Refer to GROUP 6 CLUTCH-Service AND MAINTENANCE - Maintenance Service.)
Adjustment Procedures.) l Checking Oil, Engine Coolant or Fluid Leaks
l Adjustment of Air Conditioner Compressor V-belt Tension l Checking Meter and Gauge Operation
(Refer to GROUP 24 HEATERS AND AIR CONDITIONING - l RodTest
Service Adjustment Procedures.) (1) Steering Wheel Operation
l Adjustment of Power Steering Oil Pump V-belt (Refer to (2) Transmission Gear Shift Lever Operation
GROUP 19 STEERING - POWER-Service Adjustment (3) Clutch Operation
Procedures.) (4) Brake Operation
 -_____
ENGINE - Engine and Transmission Assembly

30-35 Nm
22-25 ftlbs.

13
\ /

- 30-50 Nm
22-36 ft.lbs. 01y74’

23

13. Eye bolt

14. Gasket
15. Radiator
16. Accelerator cable connection
17. Fuel high pressure hose connection
18. O-ring
19. Fuel return hose connection
20. Clutch tube connection
21. High tension cable connection
22. Speedometer cable connection
23. Vacuum hose connection

NOTE ~~
8: Non-reusable parts
 ENGINE - Engine and Transmission Assemblv 9k21

OOY642

24. Water temperature unit harness connector 34. Ground cable connector connection
connection 35. Alternator harness connector connection
25. Water temperature sensor harness connec- 36. Oil pressure gauge unit harness connector
tor connection connection
26. Water temperature switch harness connec- 37. Starter motor harness connector connection
tor connection 38. Detonation sensor harness connector con-
27. Secondary air solenoid valve harness con- nection
nector connection 39. Back-up light switch harness connector con-
28. EGR solenoid valve harness connector con- nection
nection 40. O.D. cancel solenoid harness connector con-
29. Injector harness connector connection nection
30. Throttle position sensor harness connector 41. Downshift solenoid harness connector con- .
connection nection
3L ISC servo harness connector connection 42. Inhibitor switch harness connector connec-
32. Motor position sensor harness connector tion
connection
33. Distributor signal generator harness connec-
tor connection
 ENGINE - Engine and Transmission Assembly

OlY696

*r) I)+ 43. Propeller shaft

4a 44. Gear shift lever assembly
l + 45. Rear mounting NOTE
46. Nut (I) +I): Refer to “Service Points of Removal.“.
47. Engine and transmission assembly (2) I)+: Refer to “S&vice Points of Installation”. ~~.

SERVICE POINTS OF REMOVAL NOSSWA

IO. REMOVAL OF POWER STEERING OIL PUMP / 11. AIR

CONDITIONER COMPRESSOR
Hold.the power steering-oil pump and air compressor by
wires since-they are removed with hoses as connected. ~_
43. REMOVAL OF PROPELLER SHAFT
Refer to GROUP 16 PROPELLER SHAFT AND UFjlVERSAL ~;
JOINTS - Propeller ShafI and Universal Joints
ENGINE - Engine and Transmission Assembly 9-23
44. REMOVAL OF GEAR SHIFT LEVER ASSEMBLY
Refer to GROUP 21 TRANSMISSION - MANUAL AND
AUTOMATIC - Gear Shift Lever Assembly.

SERVICE POINTS OF INSTALLATION NOSS&iC

45. INSTALLATION OF REAR MOUNTING

Refer to P.9-17
43. INSTALLATION OF PROPELLER SHAFT
Refer to GROUP 16 PROPELLER SHAFT AND UNIVERSAL
JOINTS - Propeller Shaft and Universal Joints.

2’
9-24 ENGINE - Engine Oil Cooler

ENGINE OIL COOLER NOBMA-.

REMOVAL AND INSTALLATION

30-35Nm ~
22-25 fklbs.

Yost-installation Operation

Removal steps
+* 1. Eye bolt
2. Gasket
3. Engine oil return hose assembly
NOTE ’
4. Engine oil feed hose assembly (I 1 Reverse the removal procedures to reinstall,
5, Engine oil cooler (2) **: Refer to “Service Porn& of RemovaT”I~

SERVICE POINT OF REMOVAL N09MEiAA

1. REMOVAL OF EYE BOLT

Caution
Be sure to hold the weld nut of the oil cooler while
loosening the eye bolt.
INSPECTION NOSMCAA

l Check the engine oil cooler fins for bends, breaks or plugs.
l Check the engine oil cooler hoses for cr&ks, damage,
clogging or c&tenoratron.
@ Check the gaskets for damage or deformatron;- .I
r Check the eve bolWfor clogging or deformation. 1
 ENGINE - Oil Pan and Oil Screen 9-25
OIL PAN AND OIL SCREEN NOSHA- -

REMOVAL AND INSTALLATION

Post-installation Operation
l Refilling Engine Oil

Removal steps
1. Oil drain hose 15-22 Nm
2. Oil pan
3. Oil pan gasket
I)+ Application of sealant to cylinder block
4. Oil screen
5. Oil screen gasket

TE
Reverse the removal procedures to reinstall.
**: Refer to “Service Points of Installation”.
I: Non-reusable parts

26-32 fklbs.

OlY704

INSPECTION NOSHCAA

l Check the oil pan for faiure, damage and cracks. Replace if
defective.
l Check the oil screen for clogging, damage and cracks and
replace if defective.

Cylinder block SERVICE POINT O’F INSTALLATION NOSHDAB

n
. APPLICATION OF SEALENT TO CYLINDER BLOCK
Apply specified sealant to four places shown in illustration.
Specified sealant: MITSUBISHI GENUINE Part No.
MZ100168 or equivalent
Caution
Do not apply sealant to oil pan gasket.

case Oi! seal case

f
9-26 ENGINE
- - - Cylinder Head Gasket ._

CYLINDER HEAD GASKET NOSJA..

REMOVAL AND INSTALLATION

3-5 Nm
2-I ft.lbs. \

Removal steps
1. Brake master cylinder heat protector
2. Oxygen sensor harness connector connection +
3. Heat protector
4. Air cleaner
5. Air hose A connection
6. Air hose D connection
7. Boost hose connection
8. lntakeairtemperature ~ .-
sensor B connector
connection
9. Radiatorupper hose connection
IO. Air intake pipe
11 Secondary air cleaner
12. PCV valve hose connection
~~~13. Accelerator cable connection
Pre-removal Operation 14. Bolt
l Draining Engine Coolant 15. Reeker c&er
l Draining EngTne Oil 16. Rocker crFjvergasket
l Removal of Residual Pressure in Fuel High *+ 17. Semi-circular packing
Pressure Hose (Refer to GROUP 14 FUEL 4* Alignment of timing mark
SYSTEM -Service Adjustment Procedures.)
l Removal of Air Conditroner Compressor V-belt
NOTE =-mm -
(Refer to GROUP 24 HEATERS AND AIR
CONDITIONfNG - Receiver, Condenser, Corn- (I) Reverse the remova procedures to reinstall.
pressor, Clutch Assembly.) (2) **Xefer to “Service Points of Removal’7
(3) *+: Refer to “Service Points of Installation”.
 EhlGINE - Cvlinder Head Gasket 9-27

26
22-29fLlbs.

33

18. High tension cable connection ECl73;

19. Spark plug cable connection
20. Fuel high pressure hose connection
21. O-ring
22. Fuel return hose connection
23. Power brake booster hose connection
24. Heater hose connection
25. Water hose connection
26. Engine oil level gauge guide
27. O-ring
28. Turbocharger oil pipe connection
29. Turbacharger oil return hose connection
30. Turbocharger water hose connection - I\JQTE
31. Rear catalytic converter connection (7) Reverse the removal procedures to reinstall.
I)* 32. Distributor (2) *+: Refer to “Service Point5 of Installation”.
33. Vacuum hose connection (3) q : Non-reusable parts :m~
9-28 ENGINE - Cylinder Head Gasket

Hot engine
100-110 Nm
73-79 ft.lbs.

Cold engine _
15-22 Nm
11-15 ft.lbs.
-39
Hot engine
15-22 Nm
11-15 ft.lbs.

42

Post-installation Operation
l Adjustment of Air Conditioner 36 3
CompressorV-belt (Refer to GROUP 24
HEATERS AND AIR CONDITIONING -
Service Adjustment Frocedures.)
l Adjustment of Accelerator Cable Free Play
(Refer to GROUP 14 FUEL SYSTEM -
Service Adjustment Procedures.)
l Refilling Engine Oil
l RefiKng Engine Coolant

50-60 Nm
37-43 ft.lbs

34. Water temperature unit harness connector

connection
35. Water temperature sensor harness connec-
tor connection --
36, Water temperature switch harness connec- _ .-.
tor connection
37. Secondary air solenoid valve harness con- -244. Ground cable connector connection
nectar connection 45 Camshaftsprocket to camshaft bolt
38. EGR solenoid valve harness connector con- :: I)+ 46’ Bolt
nection +I) I)+ 47: Cylinder head bolt
39. Injector harness connector connection ---48. Cylinder head
40. Throttle position sensor harness connector +I) I)+ 49. Cylinder head gasket
connection
41, ISC servo harness connector connectlon NOTE -
42. Motor position sensor harness connector (1) Reverse the removal procedures to reinstall.
connection (2) +*I Refer to “Service Points of Removal”
43. Distributor signal generator harness connec- (3) l *! Refer to “Service Points of Installation”.
tor connection (4) q : Non-reusable parts
 ENGINE - Cvlinder Head Gasket 9-29
SERVICE POINTS OF REMOVAL NOSJBAB

. ALIGNMENT OF TIMING MARK

Turn the crankshaft clockwise to align the timing marks.
Caution
Always turn the crankshaft clockwise.

45. REMOVAL OF CAMSHAFT SPROCKET TO CAMSHAFT

BOLT
(1) Remove the cam sprocket installation bolt, and remove
the distributor gear.
(2) Pull the camshaft sprocket (with the timing chain
attached) out from the camshaft, and place it on top of
the camshaft sprocket holder.
Caution
1. The crankshaft must not be rotated after the
camshaft sprocket is pulled out from the cam-
shaft.
2. Be careful not to allow the timing chain to come
off from the camshaft sprocket.

46. REMOVAL OF BOLTS / 47. CYLINDER HEAD BOLTS

Loosen the bolts (in the order indicated in the figure) in 2 or
@ Front of engine 3 steps, and remove from the cylinder head.
49. REMOVAL OF CYLINDER HEAD GASKET
Remove gaskets from the cylinder head and block corn- ~~
pletely using a gasket scraper, etc.
Caution
Be careful not to scratch the surfaces. Do not allow
gasket fragments to fall into the cylinder.
5ENOi E

Idenyfication mark SERVICE POINTS OF INSTALLATION NOSJDCA

49. INSTALLATION OF CYLINDER HEAD GASKET

(1) Clean the cylinder block and head surfaces in contact
with gasket.
(2) Lay the cylinder head gasket on the cylinder block with
the identification mark at front top.
Caution
Do not apply sealant to cylinder head gasket.
L
- Front of engine 5EN069
9-30 ENGINE - Cylinder Head Gasket

(3) Before cylinder head gasket rs rnstalled, apply specified

Timin
chain sealant to top surface of each butt ioint betww z
case cylinder blocky and timing chain case. .. = --
Specified sealant: MOPAR Part No. 4318034 or ,
equivalent
Caution
Be careful not to allow sealant to enter the oil hole
in the cylinder block.

47. INSTALLATION OF CYLINDER HEAD BOLTS / 46. -

BOLTS
0 Front of engine
Tighten the bolts (in the order indicated in the.illustration) in 4
2 or 3 steps, and finally tighten- them-af?the specified
-
torque.
-
@y?J??J

5ENOlt
:^ . .
32. INSTALLATION OF DISTRIBUTOR
Befer to GROUP 8 ELECJRICAL - Distributor,_

17. APPLICATION OF SEALANT TO SEMI-CIRCULAR PACK-

ING
Sealant to be applied
Apply a coating of the specified sealant to the semi-cjrcular

-. ‘:
gasket and the cylinder bd top surfaces, and then tighten -1

.:.:..
.
..:.:.:.:.:,........:.::::,.~
..:::::::::::::::::::..
d ...
the rocker cover assembly
Specified

Caution
sealant:

If they are overtorqued,

at the speCFfied torque.
MOPAR Part No. 4318034 or equiva- ‘-’
lent

a deformed rocker cover or oil

DEN231 leakage could result.
.. ^.

Cylinder head
 ENGINE - Timing Chain Train
+--..~
TIMING CI-IXIN TRAIN NOSWA--

REMOVAL -AN,D INS’ TALLATION 50-60 Nm

37-43 ftlbs.

60-70 Nrnv 18
44-50 ft.lbs.
8 \

Nm
ftlbs.

7.3-8.6 ftlbs.

Installation steps
26. Sprocket holder
25. Tension side chain guide c
110-130 Nm 24. Loose side chain guide _~~ ~_I
80-94ftJbs. - =’ l * 18. Tensioner spring
I)+ 17. Rubber sheet :
W 16. Tensioner sleeve -_ tzr&
Removal steps 23. Crankshaft sprocket .
1. Special washer I)+ 22. Timing chain
2. Damper pulley 21. Camshaft sprocket
3. Timing chain case 20. Spring pin
4. Chain case gasket 19. Distributor gear
5. Chain guide access hole cover , 15. Spacer
6. Chain guide access hole gasket I)+ 14. Left silent shaft sprocket
7. Oil seal 13. Oil pump sprocket
8. Chain guide “B” I)+ 12. Crankshaft sprocket “B” ..i
9. Chain guide “A” l a 11. Chain “8”
10. Chain guide “C” 10. Chain guide “C”
11. Chain ’ B’: 9. Chain guide “A”
12. Crankshaft sprocket “B” 8. Chain guide “B”
13. Oil pump sprocket *C 7. Oil seal
14. Left silent shaft sprocket 6. Chain guide accesshole gasket
15. Spacer 5 Chain guide access hole cover
16. Tensioner sleeve 4. Chain case gasket -:I:-- ~~~~ m_z:zTin L-Y
17. Rubber sheet l * 3. Timing chain case in.~_ ~~ _ ~-~ _ _~
18. Tensioner spring 2. Damper pulley
19. Distributor gear 1. Special washer - C~
- ---r-
20. Spring pin
4* ‘21. Camshaft sprocket
4* 22. Timing chain
4* 23. Crankshaft sprocket NOTE
24. Loose side chain guide (1) +I): Refer to “Service Point? of RemovalI:,
(2) I)+: Refer to I’S&ice Points-of Installation’~L_
25. Tension side chain guide
26. Sprocket holder (3) q : Non-reusable parts
 ENGINE - Timing Chain Train

SERVICE POINTS OF REMOVAL NOSWESU

21. REMOVAL OF CAMSHAFT SPROCKET / 22. TIMING

CHAIN / 23. CRANKSHAFT SPROCKET
Remove the tlm1r-q chain combined with camshaft~sprocket
and crankshaft sprocket. -

INSPECTION NOSWCAA

l Check the tlmxq chain for roller play, wear, damage or

disconnected links. -
Replace if tiessary.
@ Check the tensroner and chain guide rubber shoe for wear ~~
or damase.
Replace if necessary. Y

SERVICE POINTS OF INSTALLATION NOSWDAA

18. INSTALLATION OF TENSIONER SPRING / 17. RUBBER

SHEET / 16. TENSIONER SLEEVE
Install tensioner spring sleeve and rubber sheet to oil pump, -
and then install the oil pump.
22. INSTALLATION OF TIMING CHAIN
(1) Turn crafiksfiaft until piston of No.1 cylinder is at top
dead center. _
(2) Line up plated links of timing chain and timinsmarks on ~;
sprockets as chain and sprockets are-assembled.
Chain (3) While sli-ding crankshaft sprocket onto ~wnkshaft, ;
a,u,ide,
install chain and sprocket. Place cams&&sprocket on
sprocket holder,

bd Plated link

5ENiXli

_--
<=, -$$%I chain e Timing chain side 14. INSTALLATION OF LEFT SILENT SHAFT SPROCKET
(1) Assemble silent shaft sprockets to chain “B”. Make .
sure that timing mar&s are in alignment with plated -zz
links. I
(2) Use care~hot to confuse right and left sprockets, as they
are installed in opposite directions.

when sprocket when sprocket

IS installed boil is bstalled to
pump drive gear left silent shaft
Right side Left side 5EijQQ4
i
 ENGINE - Timing Chain Train

12. INSTALLATION OF CRANKSHAFT SPROCKET “B” ‘b-.&a_

-_m
..-. _:
Install crankshaft sprocket “B” (for driving silent shafts) %%,-Yi3T
Timing chain crankshaft.
side
1~

Crankshaft sprocket
Crankshaft .sprocket \
5EN003

-*
11. INSTALLATION OF CHAIN “B”
Chain guide “B”
(1) Holding assembled sprockets and chain “B”, align -:-
Special bolt “A” /Cylinder block timing mark on crankshaft sprocket “B” with that on
. % chain “B”, and install sprockets to oil pump drive gear
Section Y -Y and left silent shaft. Partially, tighten bolt.
Specjal bolt “B” Timina mark Plated
Oil pump body

Chain guide “B”

Section X -X

ckc

Plated link
!iENO(

(2) Rotate both silent shaft sprockets slightly to position

0.2-0.8 mm chain slack at point P.
(.008-.031 in.) (3) Adjust position of chain guide “B” so that when chain is;.
Chain guide “Btf@X pulled in direction of arrow with finger tips, clearance
83 between chain guide “F” and links of chain “B” will be ~:-
Section P-P as shown below.
Special bolt “A” Clearance between chain and chain guide “B”:
Standard value
0.2 - 0.8 mm (.OOS - .031 in.)

5ENOOE
 ~-~ -_-
E ;

@c:.
-e,.
9-34 ENGINE - Timing Chain Train _
sx;
7. INSTALLATlON OF OIL SEAL
Using the special tool, install the oil seal.
Oil
seal MD998376
\

Timing chain case 5EN14C I _-

:
I*

3. INSTALLATION OF TIMING CHAIN CASE

(I) Clean the gasket surfmes of chain case and~cylinder ~~
block.
(2) ‘Install the chain case gaskets and chain case to the .;
cylinder block.
 ENGINE - Rocker Arms, Rocker Arm Shafts and Camshaft 9-35
ROCKER ARMS, ROCKER ARM SHAFTS AND CAMSHAFT NOSLA- _

REMOVAL AND INSTALLATION

Removal steps
1. Breather hose
2. Pipe
3. Oil seal
4. P.C.V. hose
5. P.C.V. valve
6. Oil filler cap

I 7.
8. Rocker
Packing cover
9. Rocker cover gasket
+* I)* 10. Rocker arm and shaft assembly
+I) l * 11. Auto-lash adjuster
I)+ 12. Camshaft
I)+ 13. Semi-circular packing
I)* 14. Circular packing

NOTE
(1) Reverse the removal procedures to Leinstall.
(2) l *: Refer to “Service Points of Removal”.
*C: Refer to “Service Points of Installations.
: Non-reusable parts
 ENGINE - Rocker Arms. Rocker Arm Shafts and Camshaft

M D998443 SERVICE POINTS OF REMOVAL N09LBCA

10. REMOVAL OF ROCKER ARM AND SHAFT ASSEMBLY /

11. AUTO-LASH ADJUSTER
Before disasSam.bling the-rocker arm and shaft assembly, G
hold the auto-lash adjuster using the special tool.
Caution
Put the rocker arms and auto-lash adjusters in order in
cylinder No. separated places with clear distinction
between the intake and exhaust ones to prevent
6EN24t confusion.
-

Fuel pump drwe cam

INSPECTION NOBLCCA

l Check camshaft journals for wear or damage. Replace if

necessary. If journals arerlamaged, also inspect camshaft I
bearings for-wear or damage. If camshaft bearing is badly _
worn, replace cylinder head. -
l Check the fuel pump drive cam and distributor drive gear ,-
teeth for wear or damage. Replace if necessary.
Camshaft:
Standard value
5EN19E
Height of fuel pump drive cam
- 37 mm (1.46 in.)
Journal diameter 34 mm (1.34 in.)
Oil clearance 0.05 - 0.09 mm (.OOZO - .0035 in.)

@ Check the car% surface forabnormal wear and damage and ~_

replace if faulty. Measure the cam height (cam major
diameter) and replace if it exceeds the service limit..- -=-
Cam height:
Standard value
Intake 42.43 mm (1.6705 in.
Exhaust 42.43 mm (1.6705 in.
Limit
Intake 41.93 mm (1.6508 in.)
Exhaust =- 41.93 mm (1.6508 in.)
End play:
Standard value 0.1 - 0.2 mm (.004 - .008 in.)
Limit 0.4 mm (.016 in.)
 .

ENGINE - Rocker Arms, Rocker Arm Shafts and Camshaft $37 .~“i

-x5 .
~-J-

Rear bearing cap SERVICE POINTS OF INSTALLATION NO@2i ~51”;

I* T= -.-*p-$
Front 14. INSTALLATION OF CIRCULAR PACKING -y-W .-i
Set circular packing on cylinder head as illustrated and
install cam cap.

To be flush Cylinder head !iFN175

13. APPLICATION OF SEALANT TO SEMI-CIRCULAR PACK-

ING
Sealant to be applied
Apply specified sealant to portions indicated in illustration.
I
Specified sealant: MOPAR Part No. 4318034 or equiva-
lent
1:
‘::.:.. .
..*.-.-.a.
. . . . . . .. .. .. . .. . .. . .. .. .. .. .. .... . ..*
. . ...:.::::::i::::::.:..

62

DEN23

IOmm

\x in,w ALdY
\Y x \ sk&nt

,~~

Semi-circular
packing
A\\
Cylinder head RFN004r

12. INSTALLATION OF CAMSHAFT

Apply engine oil to the journals of camshaft and install it to ~.it
cylinder head.

MD998443 11. INSTALLATION OF AUTO-LASH ADJUSTER / 10. ROCK-

I ER ARM AND SHAFT ASSEMBLY
(1) Insert the auto-lash adjuster from below as illustrated,
using care not to spill light oil from the adjuster. Then, fit
the special tool to prevent the adjuster from dropping.
(2) Place the rocker arm and shaft assembly on the cylinder
head and tighten the bearing cap bolt.
(3) Remove the special tool.
 -Ie__-_-.-
-____

ENGINE - Rocker Arm and Shaft Assemblv

ROCKER ARM AND SHAFT ASSEMBLY NOSNE- -

DISASSEMBLY AND REASSEMBLY

16 S-i0 Nm
5.8-7.2 ftlbs.

Disassembly steps
1. Rear bearing cap
2. Rocker arm “C”
3. Rocker arm “A”
4. Rocker shaft spring
++ 5. Bearing cap No. 4
6. Rocker arm “C”
7. Rocker arm “A”
8. Rocker shaft spring
I)+ 9. Bearing cap No. 3
10. Rocker arm “C”
Y 11, Rocker arm “A”
12. Rocker shaft spring
I)+ 13. Bearing cap No. 2
14. Rocker arm “C”
15. Rocker arm “A”
l + 16. Wave washer
I)+ 17, Right rocker arm shaft
+* 18. Left rocker arm shaft
++ 19. Front bearing cap NOTE
20. Nut (I 1 Reverse the disassembly procedures to reassemble
b 21, Adjusting screw (2) l +: Refer to “Service Points of Reassembly”.
 ENGINE - Rocker Arm and Shaft Assembly 9-39
INSPECTIONS NOSNGAB

ROCKER ARM
(1) Check rocker arms for wear or damage. Replace if
necessary.
(2) Check to ensure that oil holes are clear.

Oil hole
lEN012-P

ROCKER ARM SHAFT

(1) Check rocker arm mounting portions of rocker arm shaft for
wear or damage. Replace as necessary.
Oil holes
(2) Check to ensure that oil holes are clear.
0
0 O-0

5EN06:

Front SERVICE POINTS OF REASSEMBLY NOSNHCA

(r 19. IhiSTALLATlON OF FRONT BEARING CAP / 18. LEFT

ROCKER ARM SHAFT / 17. RIGHT ROCKER ARM SHAFT
(1) Insert the left and right rocker shafts into the front.
bearing cap. The rear end of left (intake) rocker arm
shaft has a notch.
(2) Align the mating mark of the rocker arm shaft front end _
to the mating mark of the front bearing cap. Then insert ~~
Rocker arm shaft, left
the bijlts to hold shafts in bearing cap.
Notch 5EN077

(3) Assemble ‘the rocker arm shaft so that~the alignment _~

mark at the front end matches the alignment -mark of
the front bearing cap.

Mating marks”
[2 mm (.08 in.) dia. embossing] 5~~01:

Rocker arm 16. INSTALLATION OF WAVE WASHER

Install the waved washer in the direction shown. in the
Timingchain si
illustration.
+

Front bearing cap 5EN07

 ~~ ~~ __. ---~-
_~ ~~
E+
-6

ENGINE - Rocker Arm and Shaft Assembly

lb ~~TiniinCjbelt side Identification

mark
13.9. 5. INSTALLATION OF BEARING CAP

I
Rocker cover
mountinq stamped cap No. when assembling.

Rocker cover mounting

bolt hole 5ENZlE
 ENGINE - Cylinder Head 9-41
CYLINDER HEAD N090A-.

REMOVAL AND INSTALLATION

Cold engine
90-I 00 Nm
65-72 ftlbs.

Removal steps
+* I)+ 1. Cylinder head bolt
4* I)4 2. Bolt
3. Cylinder head
+4 4. Cylinder head gasket

NOTE
(I) Reverse the removal procedures to reinstall.
(2) +3: Refer to “Service Points of Removal”.
(3) I)*: Refer to “Service Points of Install$ion”.
(4) q : Non-reusable fiat-&
 ENGINE - Cylinder
- Head

SERVICE POINT§ OF REMOVAL

1. REMOVAL OF CYLINDER HEAD BOLT / 2. BOLT ETI
s;
<=7 Timing chain side
Remove cylinder head bolts in sequence shown in illustra-
tion.

INSPECTION
* R&move sea%, sealing compound and carbon deposits
completely. After cleaning oil passages, apply compressed
air to make certain that the passages are not clogged.
l Check the jet air passage and EGR gas passage for
ctogging. ~~ =~~~ =
l Visually check the cylinder head for cracks, damage and
,water leakage.
l Check cylinder head gasket surface for flatness with a
straight edges as shown in illustration.
l If flatness exceeds. service limit in any direction, either
replace cylinder head or lightly machine the cylinder head
gasket surface.
Flatness of cylinder head gasket surface:
Standard value Max. 0.05 mm (.0020 in.)
Limit 0.2 mm t.008 in.)
Overall height:
Standard value 90.0 mm (3.543 in.)
Limit . 89.8 mm (3.535 in.)
Caution
if cylinder block gasket surface has already been
ground, thickness of the removed stock should be
included in the grinding limit of -0.2 mm l-.008 in.).

~_ em~Sealant appllcatlon
@ Timing chain side position
SERVICE POINTS OF INSTALLATION NOIODAB

4. INSTALLATION OF CYLINDER HEAD GASKET

(I) Clean gasket surfaces- of cylinder head- and cylinder ~ ZZ
block.
(2) Apply sealant oc equivalent at two positions- upper
ends of the cylinder ~block and chain case- mating I
Zare for not surface, as shown in the iHustration. ~
:o clog the
)il hole with Specified sealant: MOPAR Part No. 4318034 or
seatant equivalent
5EN20’
 ENGINE - Cvlinder Head 9-43
Identification mark. (3) Be sure to position the gasket on the cylinder block with
the identification mark up.
Identification mark: “54”
(4) Install aligning with the dowel pin on the cylinder block
top surface. -
Caution
Do not apply sealant to cylinder head gaskdt. _

- Timing chain side 5EN06f

2. INSTALLATION OF BOLT / 1. CYLINDER HEAD BOLT

Install cylinder head bplts. Starting at top center, tighten all
@ Timing chain side cylinder head bolts to l/2 of specified torque in sequence
shown in illustration. ._
.

5ENOiE
..-.- -_- ._
9-44 ENGINE - Valves and Valve Springs

VALVES AND VALVE SPRINGS NOSPE- .

DISASSEMBLY AND REASSEMBLY

Nm
ft.lbs.

5EN212

Disassembly steps
+* ++ 1. Jet valve assembly
C* *+ 2. Retainer lock
3. Valve spring retainer
++ 4. Valve spring
Ib+ 5. Valve spring seat
*C 6. Intake valve
+r) l + 7. Valve stem seal
8. Intake valve guide
9, Intake valve seat
+r) 04 10. Retainer lock
11. Valve spring retainer
*)+ 12. Valve spring
I++ 13. Valve springseat NOTE
I)+ 14. Exhaust valve (I) Reverse the disassembly procedures to reassemble.
*I) +* 15. Valve stem seal (2) +I): Refer to “Service.Pokits of Disassembly”.
16. Exhaust valve guide (3) l +: Refer-to “Service PoTiTts of Reassembly”.Y
17. Exhaust valve seat (4) q : Non-reusable parts
 ENGINE - Valves and Valve Springs 9-45
MD99831 0 \ \ SERVICE POINTS OF DISASSEMBLY NOSPFAB

1. REMOVAL OF JET VALVE ASSEMBLY

Using the special tool, remove the jet valve assembly.
Caution
When the special tool is used, make certain that the
wrench is not tilted with respect to the center of the jet
valve. If the tool is tilted, the valve stem might be bent
by the force exerted on the valve spring retainer,
resulting in defective jet valve operation.

2. 10. REMOVAL OF RETAINER LOCK

(1) Using the special tool, compress the valve spring and
remove the retainer locks.
(2) Keep these parts in order so that they can be reinstalled
in their original positions.

3EN324

7.. 15. REMOVAL OF VALVE STEM SEAL

Remove the valve stem seals with pliers and discard them.

3EN128

INSPECTION NOSPGAA

VALVES
(1) Check each valve for wear, damage and deformation of
head and stem at “B”. Repair or replace excessively worn,
damaged or deformed valves.
(2) If stem tip “A” has been pitted, correct with oil stone or
other means. This correction must be limited to a minimum.
Also ,reface the valve.
(3) Replace the valve if the face margin has decreased to less
Margin than limit.
1 EN03
Margin:
Standard value
Intake 1.2 mm (.047 in.)
Exhaust 2.0 mm (.079 in.)
Limit
Intake 0.7 mm (028 in.)
Exhaust 1.5 mm (059 in.)
9-46 ENGINE - Valves and Valve Springs

VALVE SPRINGS N09PGBA

-iI--
Out of square
(1) Check free length or each valve spring and replace if
necessary.
(2) Using a square, test squareness of each valve spring. ~~~
If spring .is excessively out of square, replace it.
Valve spring:
Free length Standard value
Free length 49.8 mm (1.961 in.)
Load 329 N (73 Ibs.) at installed height
Installed height 40.4 mm (1.591 in.)
1 EN035
Out of squareness within 2”
Limit
Free length 48.8 mm (1.922 in.)
Installed height 41.4 mm (1.630 in.)
Out of squareness 4”

VALVE GUIDES NOSPGCA

Check the valve stem-to-guide clearance. If the clearance

exceeds the service limit, replace the valve guide with new
oversize part: =
Valve stem-to-guide clearance:
Standard value
Intake 0.03 - 0.06 mm (.0012 - .0024 in.)
Exhaust 0.05 - 0.09 mm (.0020 - .0035 in.)
Limit
Intake 0.10 mm (.0039 in.)
Exhaust 0.15 mm (.0059 in.)
Valve Guide Oversizes

0.05 (.002) OS. 13.050 - 13.068

i.5138 - .5145)

0.25 f.0101 O.S. 25 13.25G 13.268

(.5217 - .5224

0.50 (.020) O.S. 50 13.500 - 13.518

t.5315 - .54z-2)
 . ,.

ENGINE - Valves and Valve Springs 9-47

SERVICE POINTS OF REASSEMBLY NOSPKCA

15.7. INSTALLATION OF VALVE STEM SEAL / 13. 5.

VALVE SPRING SEAT
Install the spring seat, then using the special tool, install the
stem seal by lightly tapping the tool. Seal is installed in
specified position.
Caution
1. Incorrect installation of the seal without using the
special tool will result in poor sealing and cause oil
leakage down valve guide.
2. Do not reuse stem seal.
14. INSTALLATION OF EXHAUST VALVE / 6. INTAKE
VALVE
Apply engine oil to each valve. Insert valves into the valve
guides. Avoid inserting the valve into the seal with force.
After insertion, check to see if the valve moves smoothly.

12.4. INSTALLATION OF VALVE SPRING

* Spring retainer
Enamel Valve springs should be installed with the enamel.coated
coated side toward the valve spring retainer.

zziSL-- Valve stem

sea’

10.2 * INSTALLATION OF RETAINER LOCK

(1 ) Using the special tool, compress the valve spring and
install the retainer lock.
Caution
When compressing the spring with the Valve
Spring Compressor, check to see that the valve
stem seal is not pressed to the bottom of the
retainer. Then start installing the retainer lock.
(2) Make certain that retainer locks are positively installed.
3EN32.r

1. INSTALLATION OF JET VALVE ASSEMBLY

(1) Apply engine oil to the O-ring, jet body threads and seat
surface.
Caution
Make sure that the O-ring is a new one.
 __.________-____-
e=:
9-48 ENGINE - Valves and Valve Springs e;

(2J Screw th--e jet valve assembly into cylinder head by

hand. Tighten the jet valve to the specified torque with ~.
the special tool and a-torque wrench while holding the r
special tonI in line with the jet valve canterline. _
 ENGINE - Jet Valve 9-49

JET VALVE NOSQE- -

DISASSEMBLY AND REASSEMBLY

Disassembly steps NOTE

(1) Reverse the disassembly procedures to reassemble.
+* l * 1. Retainer lock (2) *I): Refer to “Service Points of Disassembly”.
I)+ 2. Valve spring retainer (3) l 4: Refer to “Service Points of Reassembly”.
l + 3. Valve spring (4) q : Non-reusable parts
I)+ 4. Jet valve
l + 5. Stem seal
6. O-ring
7. Jet body
lEM177

SERVICE POINT OF DISASSEMBLY NO9QFAA

1. REMOVAL OF RETAINER LOCK

Using the special tool, remove the retainer lock.

MD998309
 ENGINE - Jet Valve
INSPECTION NOSQGAA

l . Make sure that the jet valve slides smoothly in the jet body
and has no play.
Caution
Combination of the jet valve and jet body should not be
disturbed and the jet valve and jet body should be
replaced as an assembly.
* Check the valve head andvalve seat for damage or seizure. ~~
l Check the spring for sag, cracks or breakage.
Standard value:
Jet valve
Length 92.53 mm (3.6429 in.)
Stem O.D. 4.3 mm (.I69 in.)
Seat angle 45”
Jet valve spring
Free height 29.60 mm (1.1654 in.)
Load 35 N (7.7 Ibs.) at installed height
Installed height 21.50 mm (.8465 in.)
Out of squareness Max. 1.5”

SERVICE POINTS OF REASSEMBLY NOSQHAB

5. INSTALLATION OF STEM SEAL

Using the special tool, ir%tall the stem seal.

4. INSTALLATION OF JET VALVE

(1) Apply engine oil to the stem of the jet valve.
(2) Use care~yo--prevent damage to the new seal lips. 1
(3) Check to ensure that the valve slides smoothly.

3. INSTALLATION OF VALVE SPRING / 2. VALVE SPRING

RETAINER / 1. RETAINER LOCK
(1) Mount the valve spring and valve spring retainer on jet
body.
(2) Compress-the valve spring with the special tool, using
care not to damage the valve stem by the bottom of
valve spring retainer.
(3) While the-spring being kept compressed, install the ~~
retainer lock.
MD998309
1EMOOF
 ENGINE - Front Case. Oil Puma, and Silent Shaft 9-51

FRONT CASE, OIL PUMP AND SILENT SHAFT NOSRA- -

REMOVAL AND INSTALLATION

hman 40-50 Nm
I 29-36 ft.lbs.

kW\
27-34 Nm 4
20-24 ft.lbs. ‘/xl-4

5.8-8.6 ft.lbs. I Id/-

IO-12 Nm
7.3-8.6 ft.lbs.*

26

m-m
“VP,”
Nm
. . . . .
23

IL-., . . ..I
7.3-8.6 ft.

\-
8-10 Nm -r
5.8-7.2 ft .Ibs. 30-45 Nm
19 \
60-70 N
44-50 ft
60-70 Nm 22-32 ft.lbs.
44-50 ft.lbs.
lo-12 Nm
7.3-8.6 ft.lbs. 0
Removal steps 4
97
1. Oil pum upsprocket 3W4Nm 5m
2. Left silf ?nt shaft sprocket 4.4-5.7 ft.lbs.
2632 ft.lbs.
3. Sbacer
4. dil drain plug
5. Oil drain plug gasket --
l + 6. Oil filter 24. Pin
7. Oil cooler by-pass valve I)4 25. Driven gear
8. Oil pipe joint I)+ 26. Drive gear
9. Oil pressure gauge unit 27. Woodruff key
10. Knock bushing 28. Oil pump cover
1 1. Oil filter bracket bolt 29. Oil pump gasket
12. Oil filter bracket +I) I)+ 30. Thrust plate
13. O-ring *C 31. O-ring
14. O-ring 32. Woodruff key
l * 15. Oil pan l 33. Left silent shaft
16. Oil pan gasket 34. Right silent shaft..
17. Oil screen 35. Rear bearing
18. Oil screen gasket
19. Plug NOTE
20. Relief spring (1) Reverse the~remcval procedures to reinstall
21. Relief plunger (2) l *: Refer to “Service Points of Removal”*.-.
22. Flange bolt (3) *4: Refer to “Service Points of Installation”.
l * 23. Oil pump body (4) q : Non-reusable parts
5EN0026
9-52 ENGINE - Front Case, Oil Pump and Silent Shaft

Thrust plate SERVICE POINT OF REMOVAL NOSRBAB

30. REMOVAL OF THRUST PLATE

It shaft, left Install 8 mm (.3’l in.) dia. bolts into threaded holes of flange :
and turn bolts in to remove the thrust plate.

1 t.31 In.1 bolt 5EN02(

_ ~ - ~

INSPECTION NOSRCGB

OIL PUMP
(1) Check gear contacting surfaces of cover for step wear.
(2) Check the clearance of drive and driven gears. If clearance _
is excessive, replace case and cover assemblyPor gears. ~:
Standard value:
Driven gear
Tip clearance 0.11 - 0.15 mm (.0043 - .0059 in.)
Side clearance O-04- 0.10 mm (.0016- .0039 in.)
5EN142 Drive gear
Tip clearance 0.11 - 0.15 mm (.0043 - .0059 in.)
Side clearance 0.05 - 0.11 mm (.0020 - .0043 in.)
Limit:
Driven gear
Tip clearance 0.20 mm (0079 in.)
Side clearance 0.15 mm (.OOSO in.)
Drive gear
Tip clearance 0.20 mm (.0079 in.)
Side clearance 0.15 mm (.OOSO in.)
RELIEF PLUNGER AND SPRING NOSRCHA

(1) Insert the relief plunger ITthe oil pump body and check to
see it It operates smoothly.
(2) Check the relief spring for breakage or saggrng.
Standard value:
Relief spring
Free length 46.6 mm (1.835 in.)
Load 61 N/40.1 mm (13 lbsJ1.579 in.)

SILENT SHAFT NOSRCIA

(1) Check journals for wear, damage and seizure. If. excessive 2
damage or seizure is evjdent, check bearing as well. If ~-
necessary, replace silentshaft or bearing or both. ~~_
(2) Check oil hole (passage) for clogging. ~-
Clean or repair as necessary.

5EN071
 ENGINE - Front Case, Oil Pump and Silent Shaft 9-53
SlLENT SHAFT BEARING REPLACEMENT PROCE-
DURE NOSREAA
Cylinder block MD998251 Beiring (1) Using the special tool, remove silent shaft rear bearing.
front surface

Cylinder block
5ENOZ

(2) Apply engine oil to O.D. of bearing. Using the special tool,
install silent shaft bearing to cylinder block.

Cylinder block
5EN023

,
SERVICE POINTS OF INSTALLATION NOSRDCA

33. INSTALLATION OF LEFT SILENT SHAFT

Apply engine oil
(1) Apply engine oil to journal of left silent shaft.
(2) Insert left silent shaft into cylinder block. Insert silent
shaft carefully to prevent damage to the bearing.

5ENOZt

31. INSTALLATION OF O-RING

(1) Install O-ring in groove of thrust plate. l +

(2) Apply engine oil around O-ring.

O-ring

5EN02E
L

30. INSTALLATION OF THRUST PLATE

(1) Install two guides in threaded holes for mounting thrust
: shaft plate. Guides should be fabricated by cutting off
hexagon heads of bolts 6 mm (.24 in.) in diameter and
50 mm (1.97 in.) long.
(2) Install thrust plate into cylinder block -along guides. em
Without use of guide, threaded holes will be hard to
der block
align.

5EN02:
 ENGINE - Front Case, Oil Pump and Silent Shaft
I 26. INSTALLATION OF DRIVE GEAR / 25. DRIVEN GEAR
Install oil pump gears to-oil pump body and align titning
marks.
Driven gear Caution
If timing marks are out of alignment, phase of silent
Timing marks shaft will change and vibration will result.
Drive gear

5EN02F

23. INSTALLATION OF OIL PUMP BODY

Apply 10 cc
(0.6 cu.in.) of Place pump assembly in the same position as it was .
engine oil installed on-engine and put approx. 10 cc (0.6 cu.inJ of _
clean engine oil in delivery port.

5ENOZC
--
15. APPLICATION OF SEALANT TO OIL PAN
Cylinder block t-l
Apply sealant to the cylinder block at four positions which _
corresponds to the hatched area of the-oil pan in the ~~
illustration. 1 -
Specified sealant: MITSUBISHI GENUINE Part No. -
MZ100168 or equivalent

case Oil seal case 1 EN054

6. APPLICATION OF ENGINE OIL TO OIL FILTER

Apply thin coat of engine oil to the packing surface.

-ED*
\
Apply engine oil

6LU02E ,
 , ENGINE - Piston and Connecting Rod 9-55
PISTON AND CONNECTING ROD NOSTA: -

REMOVAL AND INSTALLATION

4528 Nm
33-34 ft.lbs.

Removal steps
FyTFeverse the removal procedures to reinstall.
1. Nut (2) ail): Refer to “Service Points of Removal”.
+I) ++ 2. Connecting rod cap (3) +4: Refer to “Service Points of Installation”.
3. Bearing
4. Bea.ring
I)+ 5. Piston and connecting rod assembly
6. Bolt
7. No. 1 piston’ring
8. No. 2 piston ring
9. Oil ring
10. Piston pin
11. Piston
12. Connecting rod

5EN030
 E
9-56 ENGINE - Piston and Connecting Rod
Bz
SERVICE POINTS OF REMOVAL NOSTECA

2. REMOVAL OF CONNECTING ROD CAP

Before remoying the bearing cap, stamp cylinder number ~=
- E
on connecting rod big end for reassembly.

DENOS( 1

EEL,
1. ;3cGOVAL OF NO. 1 PISTON RING / 8. NO. 2 PISTON ~:m
w
Remove the--piston ringF with a piston ring expander.
- ~_ z~m

- --
e,
INSPECTION NOSTCAA E=
&f%
PISTON AND PISTON PIN z-
(1) Replace the piston If It has marks ot streaks or seizure on -2
the outside, thrust surtace in particular. Also replace if it-has
cracks on the outside. =
(2) If the piston prn can be-inserted Into the prston prn hole ‘r
snugly with a thumb, rt Isreusable. It it isir-iserted with no
resistance orthere IS a play, replace the piston and pin as a ~~
set,

PISTON RING NOYTCBB

(1) Check the piston ring for damage, abnormal wear and
breakage arrd replace if defective. If the piston itself is i
replaced, also replace the piston ring. _
(2) Check the piston ring to ring groove clearance. If-i{ exceeds -,
the limit, replace the ring and/or piston.
Piston ring side clearance:
Standard value
No. 1 0.05 - 0.09 mm (.0020 - .0035 in.)
No. 2 0.02 - 0.06 mm (.0008 - .0024 in.)
Limit
No. 1 0.12 mm I.0047 in.)
No. 2 0.10 mm l.0039 in.)
 ENGINE - Piston and Connecting Rod 9-57
(3) Insert a piston ring into cylind& bore..Correctly position the
ring at right angles to the cylinder wall by gently pressing it
down with a piston.
Draw the piston up and out, then measure the gap with a
feeler gauge. If the gap exceeds the limit, replace the piston
ring.
Piston ring end gap:
Standard value
No. 1 0.30-0.45 mm (.0118- .0177 in.)
No. 2 0.25 - 0.40 mm I.0098 - .0157 in.)
Piston ring 6EN03: Oil ring 0.30-0.80 mm (.0118- .0315 in.)
IJmit
- No. I’ 0.8 mm (.031 in.)
No. 2 0.8 mm (.031 in.)
Oil ring 1.0 mm (.039 in.)

BEARING NOSTCDA

(1) Visually check the bearing surface and replace the bearing if ’
there is uneven contact, streak, scratch or burn. If there is
heavy streak or burn, also check the crankshaft. Replace
the crankshaft or machine it to an undersize if damaged.
(2) Measure the connecting rod bearing I.D. and crankshaft pin
O.D. and if the clearance exceeds the limit, replace the
bearing and, if necessary, also replace the crankshaft, Or
machine the crankshaft to an undersize and replace the
bearing with an undersized one.
Standard value: 0.019 - 0.056 mm I.0007 - .0022 in.)
Limit: 0.1 mm (.004 in.)
NOTE
Refer to CRANKSHAFT for measurement of oil clearance
with plastic-gauge.

r SERVICE POINTS OF INSTALLATION NO9TDAC

9. INSTALLATION OF OIL RING

(1) First, install the oil ring spacer in the piston ring groove.
Next, install the upper side rail and then the lower side
rail.
Both upper and lower side rails may be installed with
their either side facing up.
9-58 ENGINE - Piston and Connecting Rod

End of (2) To install-the srde rai!, trrst place oneLend Ln the gap =
side rail betweenthe groovezrnd the spacer.
While holding the end firmly, press the portion to be 11
inserted with finger as illustrated until the side rail is in ~
position.:-- : -
Caution
Do not use piston ring expander to install the side
rail.

1 ENOGS
--
8. INSTALLATION OF NO. 2 PISTON RING / 7. NO. 1
PISTON RING
Using a piston ring expander, install No. 2 and No. 1 piston
ring. “.
Caution
1. The No. 1 and No. 2 piston rings have a different
cross section. Be sure to install them in correct
positions.
2. Install the No. 1 and No. 2 piston rings with the size
mark and maker mark on ring surface toward the
1 EN061
piston top.
5. INSTALLATION OF PISTON AND CONNECTING ROD
Side rail
ASSEMBLY
(1) Apply engine oil amply to the piston.-rcr_utside, piston ~
rings and- oil ring. -
(2) Position the gaps of the pistonr&@s?EdoTT ring (side r
rails, spacer) as illustrated. ~~~~~~~ ~. .=

spacer 6EN04’ I
- s ~-

(3))fnsert~the piston and conne&rg rod assembly from the ~1

cylinder top with the front marks on piston top and T
connecting rod facingthe timing belt side of engine. -

‘iEN
F~ er

2. INSTALLATION OF CONNECTING ROD CAP I

White pant When new connecting rod is installed, make sure that
identification mark and notch- are on same side.

(Front m%k) Notch (Front mark)

5EN30;
ENGINE - Piston and Connecting Rod 9-59
Check the connecting rod big end side clearance.
Standard value: &IO - 0.25 mm t.0039 - .0098 in.)
Limit: 0.4 mm (.016 in.)

. I
-.&A ‘.

S-69 ENGINE - Crankshaft, Flywheel and Drive Plate

CRANKSHAFT, FLYWHEEL AND DRIVE PLATE NOSUA..

REMOVAL AND INSTALLATION

130-140 Nm
M-101 ft.lbs.

130-140 Nm
94-101 ft.lbs.
18

Removal steps
I. Ball bearing -18. Crank shaft
*+ 2. Flywheel I)+ 19. Upper bearing
3, Ring gear 20,mCheck valve
4. Rear plate 21. Gasket _
5. Bell housing cover 22. Oil jet y
6. Adapter plate 23. Spring pin-
7. Drive plate 24. Gasket
8. Adapter plate 25. Check valve
9, Crank shaft bushing 26, Gasket ~
10. Rear plate 27. Oil jet
11. Bell housing cover Z-Spring pin
12. Oil seal case 29.-Gasket 1
13. Oil seal case gasket
*+ 14. Oil separator
I)+ 15, Oil seal NOTE ~~
I)+ 16. Bearing cap (I) Reversethe remova procedures to reinstall.
*+ 17. Lower cap bearing (2) I)+: R&r to “Service f%int oflnstallation”.
(3) a: Non-reusable parts

5EN218
 ENGINE - Crankshaft, Flvwheel and Drive Plate 9-61
INSPECTION NOLIUCAA

CRANKSHAFT
(1) Check the crankshaft journals and pins for damage, uneven
wear and cracks. Also check oil holes for clogging. Correct
*or replace any defective part.
(2r Inspect out-of-roundness and taper of crankshaft journal
and pin.
Standard value:
Crankshaft journal O.D. 60 mm (2.36 in.)
/ \’ 3EN05E Crank pin O.D. 53 mm (2.09 in.)
Out-of-roundness of journal and pin
0.015 mm (.0006 in.)
Taper of journal and pin 0.005 mm (.0002 in.)

MAIN BEARINGS AND CONNECTING ROD BEARINGS

NOSUCBA

Visually inspect each bearing for peeling, melt, seizure and

improper contact. Replace the defective bearings.

OIL CLEARANCE MEASUREMENT NOSUCCB

3EN055
, ‘To check the oil clearance, measure the outside diameter of the :..-
crankshaft journal and the crank pin and the inside diameter of
the bearing. The clearance can be obtained by calculating the
difference between the measured outside and inside dia-
meters.
Oil clearance:
Crankshaft main bearing
0.021 - 0.046 mm (.OOOS - .0018 in.)
Connecting rod bearing
0.019 - 0.056 ,mm (.0007 - .0022 in.)
I .

Plastic-gauge may be used to measure the clearance.

Plastic-gauge i (1) Remove oil and grease and any other dirt from bearings and
journals.
(2) Cut plastic-gauge to the same length as the width of the
bearing and place it in parallel with the journal, off oil holes.
(3) Install the crankshaft, bearings and caps and tighten them
to the specified torques. During this operation, do NOT turn
the crankshaft.
(4) Remove the caps. Measure the width of the plastic-gauge
at the widest part by using a scale printed on the
6EN04: plastic-gauge sleeve.
(5) If the clearance exceeds the repair limit, the bearing should
be replaced or an undersize bearing used.
When installing a new crankshaft, be sure to use standard
size bearings.
(6) Should the standard clearance not be obtained even after
bearing replacement, the journal should be ground to
undersize and a bearing of the same size should. be
installed.

1EN061
9-62 ENGINE - Crankshaft, Flywheel and Drive Plate

OIL SEAL NO9UCDA

Check front and rear oil seals fork damage or worn 11~s. i
Replace any seat that IS defective.

RING GEAR
(for vehicles with a manual transmission) NOBUCEA

Check the ring gear for worn, damaged or broken teeth,

Replace the ring-gear if teeth are defective, and also check the 1
starter motor pinion.
Ring Gear Replacement Procedure
(1) Strike outer circumferenceof ring gear at several points and ~_
remove the gear. -=
Caution
3EIV30’ I The ring gear cannot be removed if it is heated.
(2) Install the ring gearonflywheel after heating the ring gear 1’
to 260 - 28OT(500 - 536°F) for shrink fjt.

FLYWHEEL
(for vehicles with a manual transmission) NOSIJCFA

(I) Visually check the clutch disc friction surface of flywheel for
ridge wear, streaks and seizure.
Replace as necessary.
(2) If the flywheel runout exceeds the limit,. replace it.
Limit: 0.13 mm (.0051 in.)

DRIVE PLATE
(for vehicles with an automatic transmission) NOSUCGA

Replace if deformed, damaged or cracked.

SERVICE POINTS OF INSTALLATION NOSUDAB

19. INSTALLATION OF UPPER BEARING

When reusing the main bearings, remember to install them ._
Lower bearmg- Upper bearing by referring to location marks made at the time of removal.
Ifor No. 1, 2,4, 5) -(for No. 1, 2,4. 6) Be sure oil holes in bearings align with oil hole in block.
17. INSTALLATION OF LOWER BEARING
Install bearings-without grooves (lower bearing) on main
bearing cap side. ~~
Upper and lower bearings
(for center) 1 ENOSe
 ENGINE - Crankshaft, Flvwheel and Drive Plate 9-63
Arrow mark towqrd 16. INSTALLATION OF BEARING CAP
(1) The caps should be installed with ,the arro.~.__mark
directed toward the crank pulley side of engine.. Cap
numbers must be in correct order.
(2) Tighten cap bolts in sequence: center, No. 2, No. 4,
front and rear cap bolts.
(3) Cap bolts should be tightened evenly in 2 to 3 stages.
before they are finally tightened.
(4) Make certain that the crankshaft. turns freely and has
the proper clearance between the ce,nter main bearing
thrust flange and the connecting rod big end bearing.
Crankshaft end play:
Standard value 0.05 - 0.18 mm (.OOZO - .007’l in.)
Limit 0.4 mp (.016 in.)

15. INSTALLATION OF OIL SEAL

Using the special tool, press fit the oil seal all the way in
without tilting it.
1I
I MD998376

5EN20!

14. INSTALLATION OF OIL SEPARATOR

Oil seal case Oil separator
Force the oil separator into the oil seal case, making sure
that the oil hole in the separator is positioned at the bottom
(indicated by an arrow in the illustration).

iole
6EN041

2. INSTALLATION OF FLYWHEEL
Install the flywheel with the crankshaft dowel pin aligned _
with the dowel pin hole in ,the flywheel.
 50-60 Nm
37-43ft.lbs.

I
5-7 Nm
3.7-5.0 ft.lbs.

Removal steps
I. Right engine support bracket
2. Left engine support bracket
3. Silent shaft chamber cover -50-40 Nm
4. Chamber cover gasket 3743 ft.lbs.
5. Cylinder block

NOTE -:I
q : Non-reusable parts
 ,
ENGINE .- Cylinder Block 9-65
INSPE,CTION
l Visually check the cylinder block for scores, rust and
corrosion. Also check for cracks or any other defects by
using a flaw detecting agent (magnafluxing). Correct or
replace the block if damaged.
l Measure the cylinder bore with a cylinder gauge at three
levels in the directions of A and B. If the cylinder bores.
show more than specified out-of-round or taper or if the
cylinder walls are badly scuffed or scored, the cylinder block
should be rebored and honed, and new oversize pistons
and rings fitted.
Measuring points are as shown.
I Cylinder bore: 91.1 mm (3.587 in.)
i ’ Out-of-roundness and taper of cylinder bore:
Max. 0.02 mm (.OOOS in.)
l If cylinder top ridge is worn in stages, cut away with ridge
reamer.
l Oversize pistons are available in four sizes.
Piston service size and mark:
0.25 mm (.OlO in.) O.S. 0.25
0.50 mm (.020 in.) O.S. 0.50
0.75 mm (.030 in.) O.S. 0.75
1.00 mm (.039 in.) O.S. 1 .oo
l To rebore the cylinder bore to oversize, keep the specified
clearance between the oversize piston and the bore, and
make sure that all pistons used are of the same oversize.
The standard measurement of the piston outside diameter
is taken at a level 2 mm (.08 in.) above the bottom of the
piston skirt and across the thrust faces.
Piston-to-cylinder wall clearance:
0.03 - 0.05 mm (.0012 - .0020 in.)

l Check for damage and cracks.

l Check top surface for flatness. If excessive flatness is
evident, grind to minimum limit or replace.
Flatness of gasket surface:
Standard value Max. 0.05 mm (0020 in.)
Limit 0.1 mm (.004 in.)
Overall height:
Standard value 316 mm (12.44 in.)
Limit 315.8 mm’(12.433 in.)
Caution
/ 6EN05:
If cylinder head gasket surface has already been
ground, the thickness of the removed stock should be
included in the grinding limit .of -0.2 mm (-.008 in.).
9-66 ENGINE - Cylinder Block

REBORING CYLINDER NO9VEAA

(1) Determine the oversize p~istons to be used with reference ~;~

to the cylinder with the largest bore.
(2) There are four kinds of oversized piston available; 0.25 mm ?
(.OlO in.), 0.50 mm (.020 in.), 0.75 mm (.030 in.), 1.00 mm I
i.039 in.).
Thrust
directlor Bore the cylinder to a dimension so that piston O.D. to 1
cylinder clearance meet% the specification. The standard
measuring point for piston O.D. is shown in _the jllustration. ._
(3) Based on the measured piston O.D.. calculate the boring :-
6EN054 dimension qr follows:
Boring dimensan = [Piston O~.D.] + [Piston-to-cylinder
4earance O_LU - u.1~5 mm (.0012 - .OOXUn.)l - [Honing .I
Alowance Cl.02 mm (.UUO8 in.jJ
(4) Bore each cyltnder to the calculated boring dimension.
Caution
To prevent distortion caused by temperature rise
during boring, work in the order of No. 2 to No. 4 to No.
1 to No. 3 cylinders.
(5) Hone to tinal tlnlsh dlmenslon. -
(6) Check piston to cylinder clearance.
Standard value: 0.03 - 0.05 mm t.0012 - .0020 in.)
 11-l
.

~INTAKE AND
~ EXHAUST
~ SYSTEM
II
/
I CONTENTS
EXHAUST MAN/FOLD .. . .. . .. . .. . .. . . .._..................... 9 SPECIFICATIONS . .. .. .. . .. .. . .. . . .. . .. .. .. . .. . . ... . _. . .. .. . .. .. . 3
General Specifications . .. .. . . ..._..............t.......... 3
EXHAUST PIPEq AND MUFFLERS . . .. .. .._......I 16
Sealants and Adhesives . .. .. . .. .. . .. . .. . .. .. .. . .. . .. . .. .. . . 4
GENERAL INFO(iMATION . . . .. . .. .. . .. . .. . .. . .. .. .._..._. 2 Service Specifications .. . .. . .. .. . .. .. . .. . .. .. .. . . .. .. . .. . . 3
Torque Specifications . ..._................................... 3
INTAKE MANlFtjLD . . .. . ..._.............._........_......__... 5
!
TURBOCHARGER . .. .. . . .. .. .. . .. .. . . .. .. . .. . .. . .. .. .. . .. . .. .. . .. 10
INTERCOOLER I .._..._..._.........._.._..,............__.__._._._. 7

SERVICE ADJU4TMENT PROCEDURES . . .. . . 4

Turbocharger Supercharging
Pressure InspeFtion . .. . . .. .. . .. . .. . .. . .. . .. . . .. . . .. . .. . .. . 4
 INTAKE AND EXHAUST SYSTEM - General Information

GENERAL INFORMATION Nllt3A4E

The intake manifold is made of an aiuminum casting. Engine coolant is arculated through the heat riser --;
located at the Injection mixer mounting area in order to improve-atomrzation_of air-fuel mixture3 addition, the ..=
jet air passage and EGR gas passage are provided and the thermostat housrng is installed near No. 1 port. ._
The exhaust manifold is made ofan iron casting, and is so designed as to allow installation of turbocharger. ._
The intercooIer is of an air-cooling, cross=flow type made of aluminum, and installed at the vehicle front. _
The turbocharger is a TD05 model. It consists of the turbine wheel cast fro-m Iron, compressor wheel made Ii
from aluminum alloy, full-floating bearing to support the wheel shaft. casing, turbine housing, compressor ;
housing, etc.
This turbocharger is a water-cooled type and the water jacket located at the-lubricating oil inlet area provrdea ;
the passage for engine coolant. (Refer to GROUP 7 COOIJNG.)
In addition, the waste gate valve and actuator are rnstalled to control =boost pressure. .;

Waste gate actuator

Compressor Water jacket

I I /
wheel

4l To 0; pan
Full-fIoating
bearing
 I
! INTAKE AND EXHAUST SYSTEM - SDecifications II-3
SPEClFlCAilONS NllC,A--
I
GENERAL SPECIFICATIONS
I
I Items ! Specifications
!
Turbocharger
j Exhaust gas turbine type
We
identification Nb. TD05- 12A-8
Supercharging ressure control Waste gate actuator and valve
P
Intercooler
Type Air cooled type
Exhaust system ,
Muffler Expansion resonance type
Coupling Spherical coupling
Suspension system Rubber O-rings

I
SERVICE SPECIFICATIONS NllCB--

items I Standard Limit

Intake and exhausjt manifolds

Distorsion $;$;;;er head contacting
surface Less than 0.15 (.0059) 0.3 LO1 2)
Supercharging pressure solenoid valve
terminal resistance [at 20°C (68”F)l
R , 36-44
Turbocharger j
Supercharging pressure (at 2,500 rpm)
kPa (psi) I 45 - 88 (6.6 - 12.8)
Waste gate valve opening pressure
kPa (psi) / Approx. 85 (12.3)

TORQUE SPEkIFICATIONS NllCC--

I

items / Nm ft.lbs.

Water outlet fittinb attaching bolt IO- 13 7-9

Turbocharger cou’P ling bolt 4-5 2.9 - 3.6
Waste gate actua or bolt IO-13 7.3 - 9.4
Front catalytic cojverter to manifold 30-40 22-29
Center exhaust pipe to main muffler 20-30 14-21
Intercooler air ho+e band 3-5 2-4
Turbocharger to-exhaust manifold 50-70 36-51
Catalytic convetej to turbocharger 50-70 36-51
Oil pipe flare nut 1 16-24 12- 17
Oil return pipe to turbocharger 8-10 5.8-7.2
Heat protector to turbocharger 8-10 5.8 - 7.2
Heat insulator to exhaust manifold 12-15 9-10
Front catalytic co!verter to rear catalytic converter 30-40 22-29
 -.-.

11-4 INTAKE AND EXHAUST SYSTEM - Specifications / Setice Adjustment Procedures

Items Nm ft.lbs.
__ .-.
Center exhaust pipe to rear catalytic converter 40-m ~- 29-43 ~~
Intake and exhaust manifold nuts or bolts 15-20 II-14
Oxygen sensor 25-39 18-22
Oil pipe joint 22.5-27.5 16.3-199
Oil pipe clamp 12-15 9-11
Injection mixer to manifold 15-20 11-14
Water outlet fitting 17-m 13-14
Compressor bracket bolt 40-50 29-36
20-30 14-21
ti

SEALANTS AND ADHESIVES NllCO--

Items Specified sealant Quantity

Threads of engine coolant temperature MOPAR Part No. 4318034 or equivalent As required
sensor, therm0 valve and engine coolant
temperature gauge unit

SERVICE ADJUSTMENT PROCEDURES

NllGAAA

TURBOCHARGER SUPERCHARGING PRESSURE

INSPECTION
Caution
Perform running inspection with two passengers in the
vehicle and where full throttle acceleration can be safely
made.
The pressure gauge reading is taken by a front seat
passenger.
I, Disconnect the superchargrng pressure take-off hose from I
the ait- intake pipe nipple and connect a pressure gauge ~1
between the hose and the nipple VEI a 3-way jornt. ~~
2, Drive the car with tull throttle and accelerate the e_r?glne to a -~;
speed of more than 2,50@pm. Measure the superchargrng ~
pressure when the pointer IS stabilrzed.
Standard value: 45 - 88 kPa (6.6 - 12.8 psi)
Caution
If the supercharging pressure deviates from the stan-
dard value, check the following items for possible
causes.
When pressure is high:
Waste gate actuator malfunction (Refer to P.ll-15
for inspection of waste gate actuator.)
When pressure is low:
Waste gate actuator malfunction (Refer to P.7 I-15
for inspection of waste gate actuator.)
Poor engine output
Supercharging pressure leaks
Faulty turbocharger (Refer to P.l I-10, 13.)
 1 INTAKE AND EXHAUST SYSTEM - Intake Manifold II-5
INTAKE MTNIFOLD NllMA--

REMOVAL AtiD INSTALLATION

I
Pre-removal Opeiation Post-installation Operation
l Draining Engine’Coolant l Refilling Engine Coolant
(Referto GROUP 0 LUBRICATION AND MAINTENANCE (Referto GROUP 0 LUBRICATION AND MAINTENANCE
- Replace of the Engine Coolant.) -Replace of the Engine Coolant.)

I n
I o--~u wrn
, ll-14 ft.lbs.

2030 Nm
14-21 ft.lbs.
q 29
20-30 Nm
14-21 ft.lbs.
do-50 Nm -

2030 Nm ’
14-21 ft.lbs.

Removal step4
1. Air/intake pipe
2. Int ke air temperature sensor B connector
co Rnection
4* 3. Injection mixer assembly
2: Taat;ertoutlet ftttrng 20. Engine coolant temperature switch (Vehicles
with an air conditioner)
4* 6. Th k”rmostat 21. Engine coolant temperature sensor
7. Secondary air cleaner assembly (Vehicles 22. Engine coolant temperature gauge unit har-
wi h an air conditioner) ness connector connection
8. SeE ondaryair pipe 23. Engine coolant temperature gauge unit
9. Oil’dipstick assembly 24. EGR valve
4* 10. Compressor and clutch assembly (Vehicles 25. Gasket
with an air conditioner) ++ 26. Thermovalve
11. Compressor bracket 27. Hose nipple
12. Heater hose 28. Intake manifold
13. Jor:nt 29. Intake manifold gasket
14. Brake booster vacuum hose
15. Water trap
16. Water hose NOTE
(1) Reverse the removal procedures to reinstall.
17. Cable assembly (2) *I):Refer to “Service Points of Removal”.
18. Cable clamp (3) l *: Refer to “Service Points of Installation”.
19. En ine coolant temperature switch harness (4) q : Non-reusable parts
co 1 nectar connection (Vehicles with an air (5) Of all intake manifold attaching parts, only this part marked
conditioner) with * is a bolt.
05Y650
17-6 INTAKE AND EXHAUST SYSTEM - Intake Manifold

SERVICE POINTS OF REMOVAL NllMBAE ~~

3. REMOVAL OF INJECTION MIXER ASSEMBLY

Refer to GROUP 14~FUEL SYSTEM. _.
6. REMOVAL OF THERMOSTAT
Refer to GR-OVP 7 COCKING.
10. REMOVAL OF COMPRESSOR AND CLUTCH ASSEM-
BLY
Remove thecompressorand clutch assembly with the ~;-
hose connected.
NOTE ~T-~-
If hose is disconnected, gas charge is required.

INSPECTION NIIMCAG

INTAKE MANIFOLD
Check the points described below; replace the part if a problem
is four-rd.
(1) Damage or cracking of any part.
(2) Clogging of thee negative pressure (vacuum) _outlet port, or
clogging of the water or-gas passages
(3) Check, by using a straight edge and feeler ga-uge, for
distortion of the cylinder head installation surface. _
5lNOl F Standard value: 0.15 mm l.0059 in.)
Limit: 0.3 mm t.012 ‘in.)

SERYICE POINT OF INSTALLATION NllMDAl

26. APPLICATION OF SEALANT TO THERM0 VALVE

Specified sealant: MOPAR Part No. 4318034 or equiva-
lent
 .
‘.

INTAKE AND EXHAUST SYSTEM - Intercooler 11-7

/
INTERCOOLER NIITA--

REMOVAL Ai$lD INSTALLATION

Removal kteps
05Y655
i Air guide panel assembly
2: Header panel
3. Air hose A
4. Air hose D
5. Vacuum hose connection
NOTE
8. Air cleaner (I) Reverse the removal procedures to reinstall.
7. Air hose B (2) **: Refer to “Service Points of Removal”.
8. Air hose C (3) l *: Refer to “Service Points of Installation”.
** I)* 9. Intercooler (4) Torque for tightening hose band marked with * is 3 - 5 Nm
16: Air pipe A (2 -4 ft.lbs.).
11. Air pipe B

SERVICE POINT OF REMOVAL NllTBAA

9. REMOVAL OF INTERCOOLER
Remove the intercooler bracket (right side) and the inter-
cooler mounting bolts and remove the intercooler from
below.
11-8 INTAKE
- AND EXHAUST SYSTEM - Intercooler
lNSPECTlON Nl?TCAA

e Check the rntercooler finsfor bending, damage, q: tore!gn

matter.
* Check the intercooler hoses tor cracking, damage, pr wear. ;

SERVICE POINT OF INSTALLATION NllTDAA

9. INSTALLATION OF INTERCOOLER
Connect the-air hoses and air pipes by aligning the paint ~;
marks on the-hoses with The projections and indentations I-
on the pipes.
Caution
Be careful not to allow any foreign matter to get into
the hoses, pipes, or the intercooler itself.

07Y555
 i INTAKE AND EXHAUST SYSTEM - Exhaust Manifold 11-9
EXHAUST MANIFOLD NllNJ--

REMOVAL Ai)lD INSTALLATION

I

/
Removal steps!
+I) l + 1. Turbocharaer

4. Exyust manifold gasket

/
NOTE
(I) Reverse the jernoval procedures to reinstall.
(2) *I): Refer to PService Points of Removal”.
(3) I)+: Refer to YService Points of Installation”.
I OlY689,

I
SERVICE POINT OF REMOVAL NllNEAJ

1. REMOVAL OF TURBOCHARGER
Refer to P.l l-IO.

INSPECTION NllNCAB

EXHAUST MANIFOLD
Check the points described below; replace the part if a problem
is found.
(1) Damage or cracking of any part.
(2) Check, by using a straight edge and .feeler gauge, for
distortion of the cylinder head lnstallatlon surtace.
Standard value: Less than 0.15 mm (.0059 in.)
Limit: 0.3 mm (.012 in.)
EXHAUST MANIFOLD GASKET
Gasket may be reused if it has no peeled-off or damaged
surface.

SERVICE POINT OF INSTALLATION NllNDAC

1. INSTALLATION OF TURBOCHARGER -i-

Refer to P.ll-IO. .-
/
II-10 INTAKE AND EXHAUST SYSTEM - Turbocharaer

TURBOCHARGER NllLA--

REMOVAL AND INSTALLATION

6-10 Nm
--

;- - .,

1 5.6-7.2 ft.lbs.
15-20 Nm

25-30 tim
16-22 ft.lbs.
22.5-27.5 Nm
16.3-19.9 ft.lbs. ‘\
3-5 Nm \ 1624
_- _-_ Nm. . \ /;7 2
/

5.6-7.2 ft.lbs.

05Y656
Removal steps
1. Heat protector 14. Gasket
2. Oxygen sensor 15. Water pipe A
3, Gasket 16. Water pipe B
4. Heat protector 17. Oil hoses
5. Secondary air pipe +* 18. Turbocharger
6. Air hose A 19. Oil return pipe
7. Boost hose 20. Gasket
8. Vacuum hose connection 21. Gasket ~_
9. Arr intake hose 22. Ring
*+ 10. Catalytic converter NOTE
11. Gasket (I 1 Reverse the removal procedures to rernstall
+I) I)+ 12. Oil pipe (2) **: Refer to “Service Points of ReriiovaC”.
13. Oil pipe joint (3) *+: Refer~to “Service Points of Installation”
(4) q : Non-reusable parts
 /
I INTAKE AND EXHAUST SYSTEM - Turbocharger II-11

Turbocharger side SERVICE POINTS OF REMOVAL NllLBAB

12. REMOVAL OF OIL PIPE

Remove the oil pipe.
Caution
Do not allow foreign matter to get into the oil path of
the turbocharger.

18. REMOVAL OF TURBOCHARGER

(1) Remove the oil return pipe clamp.
(2) Remove the turbocharger attaching nuts and remove
the turbocharger with oil return pipe installed.

INSPECTION NIILCAB

l Check the oil pipe for clogging, collapse or deformation.

l Check the oil return pipe for clogging, collapse or deforma-
tion.
l Check the turbine wheel and compressor wheel for
damage.
l Check the gasket for damage, corrosion and deformation.
INSPECTION OF SUPERCHARGING PRESSURE RELIEF
SOLENOID VALVE
(1) Disconnect the vacuum hoses (blue striped, yellow striped,
white striped) from the solenoid valve.
NOTE
Before disconnecting the hoses, mark them to ensure
correct reconnection at their original positions.
(2) Remove the connector.

(3) Connect a hand vacuum pump to the nipple to which the

blue striped vacuum hose has been connected.
(4) Apply the battery voltage to the solenoid valve terminals to
create negative pressure, and check air tightness when the
nipple to which the yellow striped hose has been con- ~
netted is both open and closed.

Negative pressure is maintained

.-A .__-

11-12 INTAKE AND EXHAUST SYSTEM - Turbocharger

(5) Connect a haGid vacuum fGrnp-t?o the nipple to which the =
white striped vacuum ho&e has been connect-&.
(6) Apply the battery voltage to the solenoid valve terminals to -_
create negative pressure, and check air tightness~when the I
nipple to which the yellow striped hose has been con-
netted is’ both open and closed.

INOOOE

(7) Measure the solenoid valve terminal resistance~r~

Standard value: 36 - 44 II [at 20°C (68”F)]

51N000:
J

SERVICE POINTS OF iNSTALLATlON NllLDAB

12. INSTALLATION OF OIL PIPE

Before installing the flare nut on the oil pipe turbocharger
side, pour a small amount of engine oil ins the oil path.
10. INSTALLATION OF CATALYTIC CONVERTER
When installing the catalytic converter or exhaust fitting,
tighten temporarily the turbocharger side first and-then the
exhaust pipe side. Then, tighten to specified torque.
 INTAKE AND EXHAUST SYSTEM - Turbocharger II-13
TURBOCHARGER NllLE--

DISASSEMB$Y AND REASSEMBLY

FORWARD

4-5 Nm
2.9-3.6 ft.lbs.

7.3-9.4 ft.lbs.

5lN0003

Disassembly(steps
1. Bbost hose
2. S/-~ap pin
3. Waste gate actuator
4. Cbupiing
l * l * 5. Tprbine housing
+I) I)* 6. Snap ring NOTE
4* 7. Cprtridge assembly (1) Reverse the disassembly procedures to reassemble.
l + 8. O,-ring (2) +*: Refer to “Service Points of Disassembly”.
9. Cpmpressor cover (3) l +: Refer to “Service Points of Reassembly”.
(4) q : Non-reusable parts

SERVICE POINTS OF DISASSEMBLY NllLFAB

5. REMOVAL OF TURBINE HOUSING

Before turbocharger is disassembled, make match marks
on turbine housing, cartridge and compressor cover.
Match marks
Caution
Never attempt to adjust the waste gate valve.

5lN021
 -

INTAKE AND EXHAUST SYSTEM - Turbocharger

6. REMOVAL OF SNAP RING
Place the compressor cover assembly on floor with its end _
surface down and remove the snap ring with pliers. 1
Caution
During removal, hold with a finger the snap ring which
can spring out.

S 5lN022
-
7. REMOVAL OF CARTRIDGE ASSEMBLY
Remove the cartridge ass@nbly by tapping the compressor 7
cover with a soft hammer.
Caution
Some resistance will be experienced in the removal due
to the O-ring on cartridge assembly.

3EN23 6

INSPECTION NllLGAA

TURBOCHARGER
(I) Inspect the cast-iron turbine housing for damage, cracks, or ~1
evidence of contact between the turbine blades and the 1
housrng.
(2) Manually open and close the waste gate valve to make sure 2
IT operates freely.
(31 Inspect the~turbine and -compressor wheels for wear, _
damage, bent or broken blades.
(4) Inspect the oil passage In the cartridge for signs of deposits !
or blockage.
(51 Clean the inlet sectron of the compressor cover with a rag. -
Inspect rt for signs of contact with the compressorturbrne.
If worn, replace It. :
WASTE GATE ACTUATOR
(I 1 Leak-test the waste gate valve actuator with a hand pump.
Replace then actuator of -leakage Indicates a ‘ruptured
diaphragm.
(2) Check the rodto see that It is not bent or binding so as-to ~1
require replacement, _
 INTAKE AND EXHAUST SYSTEM - Turbocharger II-15
SERVICE POINTS OF REASSEMBLY NllLHAA

8. INSTALLATION OF O-RING
(1) Apply thin coat of engine oil to the inside of new O-ring
and insert it in the groove in cartridge assembly.
Caution
- O-ring When O-ring is installed, be careful not to damage
O-ring. Otherwise, oil leaks may result.
(2) Apply thin coat of engine oil to the outside surface of
O-ring installed in cartridge assembly.
3EN23E Then install cartridge assembly to compressor cover.-
Caution
Chamfered
Snap ring edge When cartridge assembly is installed to compressor
cover, be careful not to damage vanes of cartridge
assembly.
6. INSTALLATION OF SNAP RING
Install snap ring with compressor cover side down.
Caution
Install snap ring with taper surface up.

INSTALLATION OF TURBINE HOUSING

(1) Place the compressor cover with cartridge assembly
inside on floor with its end surface down and install the
snap ring.
(2) Combine the compressor cover and cartridge assembly
with the turbine housing.
Caution
Do not damage the cartridge assembly vanes.

51NO24

TEST OF WASTE GATE ACTUATOR OPERATION

NllLIAC

OPERATION CHECK OF WASTE GATE ACTUATOR

(1) Connect the tester to nipple “C”. Open up nipple “A” to the
atmosphere.
(2) Plug nipple “B”.
(3) Apply pressure to the actuator and check that the rod
moves.
Applied pressure value: Approx. 85 kPa (12.3 psi)
UN07
Caution
Do not apply a pressure of more than 100 kPa (14.5 psi)
to the actuator. Otherwise, diaphragm may be dam-
aged.
Never attempt to adjust the waste gete valve.
‘Z $” -5 ~.___- -- -

1146 INTAKE AND EXHAUST SYSTEM - Exhaust Pipes and Mufflers

EXHAUST PIPES AND MUFFLERS NllRA.7 ~~

REMOVAL AND INSTALLATION

16

051654

22-29 ft.lbs.
29-43 f-t.lbs. 14-22 ft.lbs.
Removal steps
+* I. O-ring 11. Hanger
2. Main muffler 12. Bracket
+I) 3. O-ring 13. Hanger -
4. Hanger ++ 14. O-ring
5. Center exhaust pipe : 15. Bracket
6. Hook 16. Front catalytic converter _
+I) 7. Dring
9. Hanger NOTE
9. Rear catalytic converter (I) Reverse the r&oval procedures to reinstall.
(2) *+: Refer to “S&QvicePoints of Removal”. ~_. . z
+I) IO. O-ring

1-g

lNSPECTlON NllRCAF

* Check the mufflers and prpes for corrosron and. damage. .

l Check suspmenders and O-rings for wear and cracks.
@ Check the heat protector for corrosron and damage. 2

SERVICE POINTS OF INSTALLATION Nl IRDAF

14. INSTALLATION OF O-RING / 10. O-RING / 7. O-RING / 3.

O-RING / 1. O-RING
(1) Install the rubber O-rings so that they are identical (left ~z
and right) in length.
(2) Tighten the parts securely, and then confirm that there i,
is no interference with any body components.
(3) After installation, confirm that there isno g% leakage:
from mufflers and pipes. I .I
 FUEL
SYSTEM
CONTENTS
AUTOMATIC SPEED CONTROL (ASC) Injectors ...................... __._....... . ._.- ...____. -__ ._....... 67
SYSTEM .................................................... 83 Intake Air Temperature Sensor .................. _..... 63
ENGINE CONTROL ....................... ..-...- ... ___________~ 134 ISC Motor (DC Motor) ............. . ...................... ._.. 69 1
INSPECTION ........................................ ..- ..___._ ___._.-129 Motor Position Sensor (MPS) ........................ 66 .~I:
Checking Circuit and Individual Parts ............ 129 Oxygen Sensor .......................................... . ..... 66 ..
OUTLINE ................................................................ 83 Throttle Position Sensor (TPS) ........................ 65
Automatic Speed Control Configuration ........ 83 Vehicle Speed Sensor ...................... .._................ 67
Construction and Operation ............................ 85 Waste Gate Valve ............................................ 70
SERVICE ADJUSTMENT PROCEDURES ........ 126 FUEL LINE AND VAPOR LINE ............................ 81
Accelerator Cable Free Play Inspection FUEL PUMP ................................. ._........_.........~ ...... 78
and Adjustment ................................................ 126 FUEL TANK ........................................ _.... . _............. 79
Kickdown Switch Adjustment ............... ________- 127 GENERAL INFORMATION ................................ 2 ..
Speed Control Cable Adjustment .................... 126 INJECTION MIXER ................. .._.... ___ ................. 71
Speed Control System Check ........................ 127 SERVICE ADJUSTMENT PROCEDURES ........ 31
SPECIFICATIONS ................................................ 96 Control System Operation ................................ 51
General Specifications .................................... 96 ECI System Inspection ...... .._..*....-.*-.* .............. 49
Lubricant ............................................................ 97 Fuel Filter Replacement ..................................... 37
Service Specifications ............................. ..-- ... 97 Fuel Gauge Unit Replacement ........................ 37
TROUBLESHOOTING ........................................ 98 Fuel Pressure Measurement ............................. 38
Before Starting Troubleshooting .................... 98 Fuel Pump Operation Check ............................ 38 ~~
Control Section Parts Layout ...................... -. .. . 124 Idle Speed Check Procedure ............................ 32 _
Flowchart by Trouble Symptom .................... 104 Idle Speed Control (ISC) and Throttle
How to Troubleshoot .................................. ______ 103 Position Sensor (TPS) Adjustment ................ 32
Input Checking .................................................... 100 Injection Mixer Appearance ... .._........ __............ 31 r
Other Trouble Symptom Chart ........................ 106 Injection Mixerlnspection ................................ 35 --:
In-tank Fuel Filter Replacement .................... 37 =-
FUEL (ECI) SYSTEM ............................ 2 Overfill Limiter (Two-way Valve)
ECI SYSTEM COMPONENTS ....................... .._.. 59 Replacement ........ . ..................... ..--....-.~.~--.~..... 37
Air Conditioner Relay ........................................ 70 Releasing Residual Pressure of Fuel
Air Conditioner Switch .................................... 67 High Pressure Hose . .-...................e ................. 38
Air Flow Sensor ................................................ 63 Vacuum Hoses Diagram .................... ._............... 47
Barometric Pressure Sensor ............................. 63 SPECIAL TOOLS .................................................... 25
Component Location ........................................ 59 SPECIFICATIONS ........ . ....................................... 22
Control Relay .................................................... 70 General Specifications ....... ..-.........-~.- ............. 22. ;
Engine Coolant Temperature Sensor ............ 65 Service Specifications ............... L.... _.1....-._-..... 23
Engine Speed Sensor ........................................ 66 Torque Specifications ............. .._......................... 24
Idle Switch ........................................................ 65 TROUBLESHOOTING ............... . . .._......... .._........ 26
Inhibitor Switch ................................................ 67 Control Function Table ............. ._._.... _._______ -..-.. 30
Fuel Tank and Fuel Line ....................... ......f&, .. 29 ..
14-2 FUEL (ECI) SYSTEM - General Information

GENERAL INFORMATION N14BA..

The ECI (Electronic Controlled Injection)-Turbo System provides optimum air-fuel ratio contnol by judging the-
engine operating state with its electronic control unit (ECU) based on various- sensor input signals and
accordingly controlling the injecto,rs installed on the injection mixer. The ECU also performs the idle speed, =
ignition timing, and other controls.

.
b

s ECI SYSTEM DIAGRAM

l 1: Oxygen sensor l ignition switch-ST *I : lnector l Self-diagnoses output

l 2- Arr flow sensor l Power voltage *2: E A R control solenoid a Fuel pump control
l 3: Intake air temperature sensor a Vehicle speed sensor valve (control relay)
‘4. Engjne coolant temperature l Air conditioner switch t3: Secondary air control l t;vonditionerpower
sensor a Inhibitor switch solenoid valve
‘5: T$;;tle position sensor (vehicles with an automatrc
transmission)
c3 ECU G t4: Igniter
l 6: Idle switch t5: ISC servo
l 7: Motor position sensor . Boost meter
“8: Engine speed sensor
f9: Barometric pressure sensor Output signal

Canister
Input signal

Purge control valve

Waste gate Purge air C===

solenoid valve
1-r
l/ Mi"ll
I ,Fuel injector

Turbocharger

Arr cut valve II I Ih IIllllll

acg:
PCV valve
2!!id
*2
--------_--___ so,enol”
“alYe
Second&

Engine coolant
r------CL- II Vacr
G:
J”n-
1hose
Green
temp. sensor

*4--c Igniter 8: Black

Distributor signal -

/Vehicles with iln

Rear catalytrc converter automatic transmission)
TWX: Threeway catalytic converter

,
 FUEL (ECI) SYSTEM - General Information

Barometric pressure ECI SYSTEM COMPONENTS Nl4BBCAm-

sensor AIR FLOW SENSOR (AFS)

The OAFS meaSures the intake air volume. It makes use of.-
Karman vortex to detect the air flow rate and-sends it to the-_
ECU as the intake air volume signal.
The ECU uses this intake airvolume signal to decide the basic
fuel injection duration. -

EC153; 7

BAROMETRIC PRESSURE SENSOR N14BBDA

The barometncpressure sensor Installed on the AI-S senses_

the barometric pressure and - converts It rnto a voltage which IS-
smt to the ECU.
The ECU uses this sional to%ompute the altrtude at whtch the
vehicle IS runnrna Andy corrects accordrngly the air-fuel ratro to I
the optimum and also ccZerects the rgnrtron timing, thus
tmprovrng driveability at high altitude.

INTAKE AIR TEMPERATURE SENSOR N14BBEA

The intake air temperature sensor, located at the_-illustrated

position on AFS, is a resistor-based sensor for detecting the-
intake air temperature.
According to the intake air temperature information from the
sensor, the ECU provides necessary fuel injection amountt
control.

mperature sensor

EC155

ENGINE COOLANT TEMPERATURE SENSOR NlQBBAA

The engine co&ant temperature sensor installed in the engine.-

coolant passage of the intake manifold is a resistor-based-,
sensor. The ECU judges engine warm-up state by the sensor
output voltage-and provides optimum fuel enrichment when I
Terminal 1 the engine is cold. =

y Terminal 2
 FUEL (ECI) SYSTEM - General Information 14-5
THROTTLE POSITION SENSOR (TPS) N14BBBB

The TPS is a rotating type variable resistor that rotates together

with the injection mixer throttle shaft to sense the throttle valve
Joint Resistor angle. As the throttle shaft rotates, the output voltage of the
TPS changes and the ECU detects the throttle valve opening
based on the change of the voltage.
Based on this output voltage, the ECU computes throttle valve
opening change (output voltage change) and judges the engine
acceleration/deceleration state and accordingly corrects fuel
injection amount during acceleration/deceleration.

ad wire

I
Connector

ECl49(

IDLE SWITCH N14EBFA

The idle switch, which is a contact type switch, senses

accelerator operation. The switch is installed at the tip of the
ISC servo. When the throttle valve is at idle opening, the ISC
lever pushes the push pin to turn on the contact.

Throttle
lever
hxh ‘ISC lever

Throttle
shaft

ECXO;
14-6 FUEL (ECI) SYSTEM
-- .-- General Information

MOTOR POSITION SENSOR (MPS) NlQBBGA

The MPS, a varlable resistor type sensor, is instalied~in the ISCI

servo. Its sliding pin is in contact with the plunger end and as 2
the plunger moves, the internal resistance of the MPS changes 1
(namely, the output voltage changes).
The MPS senses the ISC servo plunger position and sends the L
signal to the ECU
The ECU controls the valve opening, and consequently the idle ’
speed by using; the MPS signal, idle signal, engine coolant
temperature signal, load signals (automatic transmission and air I
conditioner) and vehicle speed signal.

EC1472

ENGINE SPEED SENSOR (IGNITION COIL NEGATIVE TER-

MINAL VOLTAGE SENSOR) Nl‘lBBHB

The rgnitron cot negatrve terminal voltage makes sudden

Increase twrce per engine- revolutton synchronously wtth
rgnrrion timing. ~~ --I
By sensing this ignition coil kgative terminal voltage change ~‘-
and measuring -the time between peak voltages,Ahe ECU =
computes the engine speed, judges the engrne operating mode
and controls the air-fuel ratio and idle speed.

Ignition switch

7 lanition coil

Low speed High speed

I A I
Time for one engine
Igniter ’
ECU
ir 1 Spark
Plug

r i

L------J Time
Signal rotor

EC1731
 FUEL (ECI) SYSTEM - General Information 14-7
OXYGEN SENSOR N14BBIB
Stoiqhio metric ratio
2, The oxygen sensor installed in the exhaust pipe makes use of
the principles of solid electrolyte oxygen concentration cell. It is
characterized by sharp change of the output voltage in the
vicinity of the stoichiometric air-fuel ratio.

Air-fuel ratio ECIOO;

Using such characteristics, the oxygen sensor senses the

oxygen concentration in the exhaust gas and feeds it back to
the ECU. The ECU then judges if the air-fuel ratio is richer or
leaner as compared to the stoichiometric ratio and provides
feedback control to adjust the air-fuel ratio to the stoichiometric
ratio where the emission purification rate of the three-catalyst
converter is the optimum.

Stoichiometric ratio 01251:

I
EC1664

VEHICLE SPEED SENSOR N14BEJA

I 1 Rotor The vehicle speed sensor uses a reed switch.’ The speed
sensor built in the speedometer converts the transmission
speedometer gear revolution (vehicle speed) into pulse signals,
which are sent to the ECU.

0125081

INHIBITOR SWITCH - Vehicles with an Automatic Trans-

mission N14BBMB

This switch detects whether the select lever is currently

positioned at N or P. Based on this signal, the ECU senses the
automatic transmission load and drives the ISC servo to keep
optimum idle speed.
 FUEL (ECI) SYSTEM - General Information
g&
AIR CONDITIONER SWITCH N14BBNA

When the arr cond&oner IS turned on, the air conditioner -ON
signal is sent to the ECU. Based on this signal, the tCU drives 2
the ISC servo to keep optimum Idle speed.

DETONATION SENSOR NllBBOA

Installed on the cylinder block, the detonation sensor converts :

vibration into voltage by its piezoelectric element. When y
detonation occurs, it resonates with cylinder block vibration to -
generate high voltage which is sent to the igniter as Lthe z
detonation signal. Based on this signal, the igniter retards the2
ignition timing to prevent detonation. .i

Vibrator -
-
Fuel Inlet
INJECTION MIXER ASSEMBLY N14BCCA

Fuel return

Fuel pressure

--. Ml xition
Throttle valve sensor EC1666 ..;

The injection mfxer assembly consrsts of fuel injectors, fuel

pressure regulator and throttle valve. _
 FUEL IECI) SYSTEM - General Information 14-9
INJECTORS N14BCDA
Fuel
The injector, which is an injection nozzle with solenoid valve,
+ injects fuel based on the injection signal from the ECU.
The injectors are installed on the injection mixer and inject fuel
upstream of the throttle valve.
When the solenoid coil is energized, the plunger is attracted.
The needle valve integral with the plunger is then pulled to the
full open position with the plunger and fuel is injected through
the valve so opened.
,Coil As the injection nozzle opening is fixed and the fuel pressure is
also fixed, the injection amount is determined by the duration
during which the needle valve is open, namely, by the time
during which the solenoid coil is energized.

Injection 16246

FUEL PRESSURE REGULATOR N14BCEA

The fuel pressure regulator always keeps the injector fuel

pressure at a level 250 kPa (36 psi) higher than the injection
mixer inside pressure. By doing so, the fuel injection amount is
kept constant even when the mixer inside pressure changes.
The spring chamber is connected by vacuum hose to the mixer
nipple so that the mixer inside intake pressure always acts in
the spring chamber.
Therefore, when the fuel pressure becomes higher than the
spring tension plus intake air pressure in the mixer, the
diaphragm is forced up and excess fuel is returned through the
--d -
Fu
EC1667 return pipe to the fuel tank.

Fuel inlet +

RESISTOR N14BCFA

The resistor limits the electric current flowing to the injector

coil. The injector is required to respond quickly to the fuel
injection signal. This fast.response is achieved by reducing the
number of turns of the injector coil and thus improving current
rise when the coil .is energized.
This smaller number of turns, however, draws more current
and generates more heat. In order to prevent this, a resistor is
provided between the power supply (+) and the injector to limit
current flowing to the coil.
EC1232
-- ---

FUEL (ECI) SYSTEM - General Information

IDLE SPEED CONTROL (IX) SERVO NIQBCGA

The ISC servo consists of a motor, worm gear, worm wheel

and plunger.
Also are incorporated the motor position sensor [MPS) to
detect plunger position and the idle switch to detect idle _
position.
The worm gear;installed on-the motor shaft, transmits motor_:
rotation to the worm wheel.
The worm wheel is meshed with worm on the plunger so that
the plunger extends or retracts as the worm wheel rotates. 1
As the motor rotates according to-the signal from the ECU, the mm
plunger extends or retracts depending on the direction of
rotation of the motor to actuate the throttle valve via the ISC _
lever.
In this way, the idle speed is controlled by adequately changing
the throttle valve opening.

EC1451

IGNITER N14BCHA

The igniter, cons@ting of the knocking level evaluating sectjon-,

and the ignitions timing and boost pressure control section, ~
evaluates the knocking level and controls the ignition timing
and the boost pressure- When the knock sensor malfunction, it
retards the ignition timing by a fixed angle (except when idling)
to protect the engine. (Fail-safe design)

5FUOO19

WASTE GATE SOLENOID VALVE, CONTROL RELAY AND

AIR CONDITIONER POWER RELAY N14BCID

Reter to EC[ SYSTEM OPERATION, P.14-12. ~~

SECONDARY AIR CONTROL SOLENOID VALVE AND EGR

CONTROL SOLENOID VALVE N14BCJB

Refer to GROUP 25 EMISSION CONTROL SYSTEMS.

ELECTRONIC CONTROL UNIT (ECU) N14BDAC

Based on the information from various sensors, the ECU

determines (computes) an optimum control for varyrng operat-
rng conditions and accordingly drives the output actuators.
The ECU consists of an &biLmicroprocessor, random access 4 -
memory (RAM), read only memory (ROM) and input/output
(I/O) interface. :
 FUEL (ECI) SYSTEM - General Information 14-l 1
ECU
I I

I 1FU350

ECU Connector I/O Pin Composition

Connector 1: Engine speed sensor [Ignition coil (--)’ terminal]
2: Air flow sensor (AFS)
3: Motor position sensor (Ml%)
4: Sensor GND
5: Intake air temperature sensor
6: Engine coolant temperature sensor
7: Idle switch’
8:-
9:-
10: Sensor power
11: Oxygen sensor
12: ISC servo (for retraction)
13: Igniter - advance control signal
14: Sensor power - MPS backup
15: Throttle position sensor (TPS)
16: Barometric pressure sensor
17:- /<
- ‘Model No. 18:- .<
19: Vehicle speed sensor i
20: Secondary air control solenoid valve
21: Diagnosis output
5FUOO20 22: Control relay (fuel pump relay control)
23: ISC servo (for extension)
924: Air conditioner power relay
‘J(a& ;w,‘fchD CLJILP*IP P~LY
53: GND
54: EGR control solenoid valve
C n/ /,@ cJ-RN/r”c/gpu& 55. . Icr.1‘tio
.--q switch - ST terminal (start signal)
-56:-Airco.~ditioner switch (air conditioner- signal)
7/@ 57:Pov+r stir jcAc er/ez ~Flpp-oLq
%8++&bitor switch
59: Boost meter
60: Injector, small orifice
61 : Igniter - detonation control signal
62: Injector, large orifice
-v-’ CC 63iBack%i power e
14-12 FUEL (ECI) SYSTEM - General Information

ECI SYSTEM OPERATION N14BEBC

AIR-FUEL RATIO CONTROL SYSTEM

Air flow sensor

.
Engine speed sensor
.
Oxygen sensor
.
Engine coolant temperature sensor
Intake &temperature sensor
ECU Barometric pressure sensor
.
Throttle position sensor
- ,_. -i
Idle switch -
.
Ignition switch - ST terminal (start signal)
.

--

The air-fuel ratio-control is achieved by controlling t?e driving

time of two injectors installed to the injection mixer.
After passing through the in-tank filter, fuel is force-~fed by the ~=~
in-tank fuel pump so as to be sent to the two injectors on the ~I
injection mixer through the -main pipe and fuel filter.
The fuel pressure applied to the injector is maintained at a fixed 1
level by the fuel~pressure regulator so that it may 6e 250 kPa -T
(36.26~psi) higher than the internal pressure of the injection --
mixer where fuel injection takes place. After pressure regula-
tion, excess fuel is returned to the fuel tank through ‘the return -y
1 Is4 I ECt66f hose. When the injector is energized,
injector opens fully to inject the fuel.
the valve inside the z

Since the fuel pressure is kept at a fixed level, supply of fuel

Injected from the injectors into the injection mixer varies with
ihe energrzrng t-me.

FUEL INJECTION CONTROL

The amount ot fuel injection ?s basically determined-by the air ~~
flow sensor (AFS;) output frequency corresponding to the ._
amount of intake air.
With the increase of arr flow sensor output frequency, the
amount of fuel injectron Increases- and as the air tlow sensor I:
orrtput frequency decreases, the amount of fuel Injection -I
t&creases.
When the air flow sensor is in trouble. the backup-control IS y
made by driving the injectors by means of engine speed sensor
sIgnal.
 FUEL (ECI) SYSTEM - General Information 14-13
Injector Drive Range
In the range where the amount of intake air is small, only the
small flow type injector with a small orifice is driven and the
fuel injection intervals are reduced to inject fuel continuously
for improvement of idling stability.
In the range where the amount of intake air is large, both the
large flow type injector with large orifice and the small flow
type injector are driven to provide sufficient fuel supply.

ECl67C

I
Engine speed (rpm) ECl57C
Injector Drive (Fuel Injection) Timing
(1) Fixed injection
When starting (cranking) the engine, only small injector is .~
driven at a cycle of 13.3 Hz.
(2) Karman synchronous injection
After starting the engine, the injectors are driven synchro-
nously with air flow sensor signal.
NOTE
If the injector driving time is constant, air flow sensor
output frequency increases with the amount of intake air
and accordingly the number of injector driving time also
increases. Therefore, air-fuel ratio is maintained at a fixed
level.

Air flow
sensor output

Small air volume

Injector
driving
162406

Air flow
sensor output

Large air volume

Injector
driving
1620407
 -

FUEL (ECI) SYSTEM - General Information

injector Driving Time

The iniector driving time (amount of fuel injectron) at which the
air-fuel ratio for the amount of intake air reaches stoichiometric
arr-fuel ratio is called basic driving time and is stored in the I
memory ot ECU in advance
When starting (crankina) the engine. the map value* deter-
mrned by the engine coolant temperature sensorsignal is used
as the basic driving time. - ~~ _
Dunno the deceleration, the basic driving time is set as zero.
* Map value: The map value is a value set in advance and L
r;tored rn the ROM inside the ECU.
The injector driving time is obtained by making the following
correcrrons on the above-mentioned basic driving time.
a Oxygen sensor feedbackcorrection (Closed loop control _
correctton)
In normal operation (excluding idling*) after engine warm-
trig up, air-tuel ratio is corrected to stoichiometric air-fuel
ratro by using oxygen sensor signals. The three-way
c;italytrc comerter grves best degree of purification at 1
srorchiometric air-fuel ratio. -
- Excluding idling: A correction factor for oxvgen sensor -1
feedback operation has been stored in advance and
during idling, this factoris applied for correction on the I
rich side to increase the air-fuel ratio over the
storchiometric ratio, thus improving the idle stability.
During idling, secondary air is supplied from ~the reed AL
valve to reduce emissions (CO and HC).
r Atr-fuel ratio map correction (Open loop control correction)
Burino engine warming up and heavy load operation,
correctron to the optimumarr-fuel ratio is made by the map
values set by engine speed and amount of intake air. ~
* Engine coolant temperature correction
To maintain operability of cold engine, correction isso made
that the lower the enginecoolant. the more the amount of
fuel iniection.
* Intake air temperature correction
Change in air-fuel ratio dueto difference in intake air densitv
-
caused by intake air temperature is corrected.
d Barometric pressure correction -
Change in air-fuel ratio dueto difference in intake air density
caused by change in barometric pressure is corrected.
9 Acceleration/deceleration correction
In accordance with changein opening of throttle valve, fuel
amount IS corrected, improving operability at acceleration
and deceleration.
 FUEL (ECI) SYSTEM - General Information

l Dead time correction

The injectors opened by the driving signal from ECU have
operational lag which changes according to difference due
DrivZj IIOFF
signal to battery voltage. This means that actual injector valve
time I time
opening time becomes less than injector driving signal,
failing to provide expected air-fuel ratio.

Injector zq-&J

I‘ 4
16240:

Therefore, battery correction time corresponding to the

TCI
battery voltage is added.
hl

L b(“l
Battery
162402

IGNITION TIMING CONTROL SYSTEM Nl4BFBA

Intercooler

Pressure chamber
No. 1 \
Pressure chamber,
No. 2

, Signalgenerator 1

Waste,gate
solenoid valve 1 OFF ++ON systcm , , , 1 1 a

Engine speed sensor

Barometric pressure sensor ECU
Engine coolant temperature sensor
Ignition switch - ST terminal

SFUOO21
 ~~____~
___-~

14-16 FUEL (ECI) SYSTEM - General Information

the Iqnltlon tlmrnq control system provides the~followlng three

Types ot control.
Detonation Control
When detonatton control signal IS applied to the lgnlter Trom the
ECU, the igniter retards the lgnltton trmlng to suchan extent
that detonation IS ellmlnated (max. 12” In crank angle).
‘I;hould the harness trom the detonation sensor have an open or
,:hort clrcult, the lqnlter retards the Ignition tlmlng by a taxed
.?ngle (approx. 8” In crank angle) to prevent detonation (tail-sate
feature).
Cold and High Altitude Timing Control
When the enqlne coolant temperature IS low lapprox. 35°C
(95°F) or lower1 or the vehrcle IS drrvrng at altitude 1,200 m
(3,937~ ft.) or h&tier [barometric pressure 88 kPa (12-g psi) or
lowerl, the system causes the Ignition timing to advance a taxed
angle (approx. 5” in crank angle) to Improve mileage and
dnveabtllty.
l3oost Pressure Control
When qasollne with a high octane number IS used, the rgnrter
enerqlzes the waste sate salenoid valve so that the boost
pressure may be applied only to the pressure chamber No. 1. In
Ihis condltlon, the-waste gate valve does not open until the
boost pressure overcomes the torte of springs A and B,
resultlnq In a hlqher boost pressure being applied. When
regular gasoline IS used, the igniter turns oft the waste gate
Solenoid valve circuit to cause the boost pressure to be applied
TO the pressure chamber No3 as well. In this condltlon, the
waste gate valve_opens tt the boost pressure only overcomes
she force ot spring A. Accordingly, the boost pressure IS kept
lower, whrch protects the engine trom knockrng.
In case of vehtcles with a manual transmission, however, the
waste qate solenoid valve crrcult IS always turned otf II the
enylne speed IS lower than 4,000 rpm, as the Inhibitor switch
Terminal on the tqnlter IS qraunded at all times. Within this
range, theretore. the boost -pressure IS kept lower, which
prevents the transmission tram berng damaged.
 FUEL (EC31 SYSTEM - General Information 14-17
IDLE SPEED CONTROL (ISC) SYSTEM N14BGAA

FClJ
---
Engine speed sensor
-c Motor drive signal *
Engine coolant temper-
--o Motor drive signal ature sensor
Inhibitor switch (vehicles
with an automatic transmission)
.
-0 Sensor power Air conditioner switch
-0 Sensor power 4
--O Motor position Vehicle speed sensor
ISC 4
sensor
servo Ignition switch -
--O Idle switch ST terminal

--. Throttle position

sensor
I
---(t-;;jl Sensor ground

EC1606

The ISC system provides the following four modes of control.

Start Control
The throttle valve opening is controlled to optimum position for
start according to the engine coolant temperature.
Fast Idle Control
(1) When the idle switch is on, the engine speed is controlled
to a target rpm according to the engine coolant temperature
(rpm feedback control).
(2) When the idle switch is off, the ISC servo is actuated to
move the throttle valve to a -target opening position
according to the engine coolant temperature (target open-
ing control).
Idle Control
When the air conditioner switch is turned on or when the
transmission is shifted from N to D (vehicles with an automatic
transmission), the system causes the idle speed to increase to
the target rpm according to the load (rpm feedback control).
Dash Pot Control
The system provides dash pot control according to deceleration
conditions to alleviate shock at deceleration.

SECONDARY AIR CONTROL SYSTEM AND EGR CONTROL

SYSTEM N14BHBA

Refer to GROUP 25 EMISSION CONTROL SYSTEMS.

 FUEL (ECI) SYSTEM - General Information

AIR CONDITIONER RELAY CONTROL N14BKBA

,M;;;ditloner

r
l-=---- Air conditioner switch

r-IEcu a
Engine speed sensor

~
t -i
compressor Air condi-
tioner relay

When the aIrconditioner switch IS turned on while the engine IS --.I

at Idle, the ISC servo operates to Increase the engrn-e speed. .L
However, there IS some delay before the engine speed actually
Increas-e-s. To maintain the engine tree from the air csndltloner -~
load during that delay period, the ECU keeps the power
transistor off for a taxed time (about 0.5 second) to opxn the air m.
conditioner power relay clrcult. As a result, even of the air 1
conditioner switch IS on, the arr compressor IS not driven _
Instantly, preventing engine speed drop due to cunpressor em
load.

BOOST METER CONTROL N14BNAA

Boost meter

\Q I
L Air flow sensor (AK]

Engine speed sensor

0

4
Ignition switch

- Batten/
-

EC16U9
 FUEL (ECI) SYSTEM - General Information 14-19
The boost meter is basically an ammeter. Based on the intake
air volume signal from the air flow sensor (AFS) and the engine
speed signal from the engine speed sensor, the ECU computes
the load and determines the duty ratio accordingly and drives
the boost meter.
Load cx: intake air volume/rpm

T. Duty ratio NOTE

The duty ratio is the ON duration ratio of 13.3 Hz pulse or TZ/TI.
The higher the duty ratio, the more mean current flows to the
boost meter, and as a result, the boost meter reads the higher
value.
The smaller is the duty ratio, the boost meter reads the smaller

I
value.

l-l-l
75 msec. 75 msec.
162100: 2

POWER SUPPLY AND FUEL PUIVIP CONTROL N14BOAA

To injector
through resistor

Control relay

To AFS, igniter

EC1544

l While cranking (ignition switch at ST), current flows through

coil L, to close switch S,. As a result, the fuel pump is
driven.
Current also flows through coil L3 to close switch S2. As a
result, power is supplied to the ECU, AFS, igniter and
injectors.
l While the engine is running, the ECU turns on the power
transistor to supply current to coil L, and to close switch S.
As a result, the fuel pump is driven.
__- I.-.

14-20 FUEL (ECI) SYSTEM - General Information

e In the event of engine stall or other abnormal condrtrons, _

the ECU turn-s off the power transrsror and open the coil LI
crrcurt. As a result, switch S1 opens to stop dnvrng of the :
fuel pump, thus securing safety.

SELF-DIAGNOSIS N14BQAA

Self-diagnosis IS a system In whrch the input signal from each

sensor IS monrtored by the computer (ECU) and should any
abnormality happen In the Input signal, the abnormal Item is .__
memorized by the computer.~The diagnosis Items are 7 items :;
Including that fornormal condrtron and can be contrrmed usrng
a voltmeter.
The abnormalrty-diagnosrs memory is kept by direct power
supply from the battery. 1herefore, the memory of diagnosis
result IS not erased by turnrng oft the ignition switch. However,
It IS erased .rf the -back-up power supply IS turned off by =
drsconnectron of. battery cable or ECU connector. _.__
c
DIAGNOSIS ITEMS
The abnormality-dragnosrs Items are the following 6 items. If ~
there are two or more Items found abnormal, they are indicated :;
In the order of rncreasing me numbers. -z-

INDICATION METHOD
lndrcatron IS made by deflectron of the pornter of voltmeter. i
Connect a voltmeter to the~connector for diagnosrs and the 4
following lndrcatron will be made.

I/ 1. When normal
Constantly 12V is indicated.
 FUEL (EC11 SYSTEM - General Information 14-21
2. When abnormal
Indication alternates between OV and 12V every 0.4
second.
When there are two or more abnormal items, the low-code-
numbered item is first indicated. Then, after indication of OV
for 2 seconds, subsequent indication is made in the same
manner as mentioned above.
The following diagram shows an example of indication
where codes No. 2 and No. 5 are abnormal.

Indication starts. Indication ends.

1
0.4 sec. 0.4 sec. 1 Indication is repeated hereafter
+

,0.4 sec. 2sec. ,, 2sec. ,

v Y
Code No. 2 is indicated Code No. 5 is indicated

EC1239
14-22 FUEL (ECI) SYSTEM - Specifications

SPECIFICATIONS N14CA.A

GENERAL SPECIFICATIONS

Retumsysfem
Filter High pressure type

Identification model number 46ElD735 1

Injector type and number Electromagnetic, 2
Injector identification mark M Blue connector, large orifice)
L (Gray connector, small orifice)
Throttle bore mm (in.)
Fuel pressure regulator
Regulated pressure kPa (psi)
Throttle position sensor (TPS) Variable resistor type
Idle speed control (IX) servo Efectric motor
Idle position switch Contact type, within ISC servo

E2T13677 J

Air flow sensor (AFS) Karman vortex type

Barometric~pressure sensor Semiconductordiffusion type sensor
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia sensor
Vehicle speed sensor Reed switch type
Inhibitor switch Contact type switch

3utput actuator
Igniter
Identification model No. E2T16671
Control relay
Identification model No.
Resistor
ldentifrcatron model No. E8l-00271 -1.
EGR controTsofenoid valve ON-OFF solenoid valve
Secondary air control solenotd valve ON-OFF solenoid valve
Waste gate solenoid valve ON-OFF soleno?d valve
 FUEL (ECI) SYSTEM - Specifications 14-23
SERVICE SPECIFICATIONS N14CB-A

Items Specifications

Engine
BasidicjnitiZn timing IO” f 2”BTDC at curb idle
Actual ignition timing at high altitude 15”BTDC at curb idle
Curb idle speed rpm 850 & 100
Idle speed when air conditioner is on rpm 1,000 at neutral position
750 at D range
(Vehicles with automatic transmission)
Idle speed control (ISC) setting rpm 850
Throttle position sensor (TPS) regulating voltage V 0.48 - 0.52 at curb idle

Injection mixer
Injector coil resistance Q
Blue connector [at 20°C (68”F)] 2-3
Gray connector [at 20°C (68”F)] 2-3
Throttle position sensor (TPS) resistance kQ 3.5-6.5
Motor position sensor (MPS) output voltage V Approx. 0.5 - 5
ISC servo motor coil resistance [at 20°C (68”F)] R 5-35

Input sensor
Intake air temperature sensor resistance
[at 20°C (68”F)l kfl 2.7
Engine coolant temperature sensor resistance kR
20°C (68°F) 2.5
80°C (176°F) 0.3
Oxygen senior output voltage V Approx. 1
Air flow sensor output voltage V 2.2 - 3.2
. Barometric pressure sensor output voltage V
101 kPa (14.7 psi) 4
88 kPa (12.8 psi) 3.5

Output actuator
EGR control solenoid valve resistance [at 20°C (68”F)] IR 36-44 *
Secondary air control solenoid valve resistance
[at 20°C (68”F)l fi 36-44
Waste gate solenoid valve resistance [at 20°C (68”F)] R 36-44
14-24 FUEL (EC11 SYSTEM - SDecifications

TORQUE SPECIFICATIONS N14CG-

Items Nm ft.lbs,
-
Injection mixer-attaching bolt 15-m 10.8-14.5
Injector holder attaching screw 4-6 2.9-4.3
Engine coolanttemperature sensor 20-40 14.5-28.9
Oxygen sensor attaching nut 25-38 18-22 ~~
Detonation sensor 20-25 14.5-18.1
Throttle position sensor (TPS) 1.5-25 1.1 -1.8
Pipe assembly attaching bolt 1.0 0.7
Fuel gauge unit attaching bolt 1 .o 0.7
Fuel tank drain plug 15-25 11-18
Fuel tank attaching nut 25-30~ 18-22
Fuel main pipe flare nut 32-42 23-30
Fuel high pressure hose attaching bolt (eye bolt) 25-35 18-25
Accelerator cable lock nut 8-11 5.8-8.0
 FUEL (ECI) SYSTEM - Special Tools

SPECIAL TOOLS N14DA- -

Tool (Number and name) Use Tool (Number and name) Use

MD998451 Diagnosis and inspec- MD998452 Inspection for ECI sys-

ECI checker tion for ECI system Harness connector tern
Use with MD998451

MD998700 Measurement of fuel

Adapter pressure
14-26 FUEL (ECI) SYSTEM - Troubleshooting

TROUBLESHOOTING N14EBBA

When checking and correcting engine troubles, It IS important to=start with inspection of the basic systems.
In case you have such troubles as (1) engine start failure, (2) unstable idling or (3) poor acceleration, therefore,
you should first check the following basic systems:
(1) .poWBe=u&PIY

l Fusible link
@ Fuse
(2) Body ground
(3) Fuel supply
l Fuel line
e Fuel filter
@ Fuel pump
(4) Ignition system
* Spark plug
l High tension cable
* Distributor
@ Ignition coil
(5) Emissron control system
e PCV system
@ EGR system
* Vacuum leak
(6) Others
@ Ignition timing
@ Idle speed
Troubles with the ECI system are often caused by poor contact of harness connector. It is, therefore, ._
important to check harness connector contact. -
 FUEL (EC3 SYSTEM - Troubleshootina 14-27
N14EFBB

Symptom Probable cause Remedy

Engine will not start ECI system malfunction Check for output of self-diagnosis
or start too hard code
(cranks OK)
Fuel pump control system malfunction Check system
If faulty, check components

Distributor signal generator or igniter Check ignition pulse by using ECI

malfunction checker (MD9984511

Vacuum hose disconnected or damaged Repair or replace

Power is not supplied to ECU Check by using checker (MD9984511

Damaged control relay Replace

Idle switch malfunction Check by using checker (MD998451 1

(Check components and replace if
faulty)

Injector malfunction l Check drive signal by using

checker (MD998451)
l Check component

Damaged resistor Replace

Improper fuel pressure Check fuel pressure

Damaged ECU Replace

Harness broken/short-circuited or connector Repair or replace

not connected securely

Rough idle or engine ECI system malfunction Check for output of self-diagnosis
stalls code

Idle switch malfunction Check by using checker (MD998451 1

(Check components and replace if
faulty)

Injector malfunction l Check drive signal by using

checker (MD9984511
l Check component

Vacuum hose disconnected or damaged Repair or replace

Barometric pressure sensor malfunction Check by using checker (MD998451 1

Intake air temperature sensor malfunction Check by using checker (MD9984511

(Check components and replace if
faulty)

Vehicle speed sensor malfunction Check by using checker (MD9984511

Air conditioner switch malfunction Check by using checker (MD998451 1

Inhibitor switch malfunction Check by using checker (MD998451 1

ISC servo malfunction l Check drive signal by using

checker (MD9984511
l Check component

Improper fuel pressure Check fuel pressure

Harness broken/short-circuited or connector Repair or replace

not connected securely
\ :i.- .&ii. ._

14-28 FUEL (ECI) SYSTEM - Troubleshooting

Harness broken/short-circuited or connector Repair or replace

not connected secure1

Injector malfunction
 FUEL (ECI) SYSTEM - Troubleshooting 14-29
FUEL TANK AND FUEL LINE N14EAAA

Symptom Probable cause Remedy

Engine malfunctions Bent or kinked fuel pipe or hose Repair or replace

due to insufficient
fuel supply Clogged fuel pipe or hose Clean or replace

Clogged fuel filter or in-tank fuel filter Replace

Water in fuel filter Replace the fuel filter or clean the fuel
tank and fuel line

Dirty or rusted fuel tank interior Clean or replace

Malfunctioning fuel pump Replace

(Clogged filter in the pump)

Evaporative emission Mispiping of vapor line Correct

control system
malfunctions Disconnected vapor line piping joint Correct
(When tank cap is
removed, pressure Folded, bent, cracked or clogged vapor line Replace
releasing noise is
ieard) Faulty fuel tank cap Replace

Malfunctioning overfill limiter (two-way valve) Replace

CONTROL FUNCTION TABLE
 FUEL (EC11 SYSTEM - Service Adiustment Procedures 14-31
SERVICE ADJUSTMENT PROCEDURES Nl4FJ--

INJECTION MIXER APPEARANCE

Fuel pressure
regulator

connector

-.-J EC1672
Nipple “A”

- Motor position
sensor connector

Nipple “D” Nipple “M”

Nipple “E” EC1671

Engine

EC1673
14-32 FUEL (ECI) SYSTEM - Service Adiustment Procedures

IDLE SPEED CHECK PROCEDURE NllFHAA

Caution
The improper setting (throttle value opening) will increase
exhaust gas temperature at deceleration, reducing catalyst
life greatly and deteriorating exhaust gas cleaning per-
formance. It also has effect on fuel consumption and
engine braking.
Checking Conditions
l Engine coolant temperature: 85 - 95°C ~(185 - 205°F)
c Lights, electric cooling tan and accessory drive: OFF
l Transmission: Neutral (N or P for vehicles with an automa- ~
trc transmrssron)
e Steenno wheel: Straioht forward
- -
(I) Set the timing light and tachometer.
(21 Start the engine and let It idle.
(3) Check the basic ignition timing and adjust if necessary.
Basic ignition timing: 1O”BTDC S 2””

* When checking the basic ignition timing at high altitude, I

stop the engine and disconnect th,e waterproof female ;-
connector from the ignition timing adjusting connector. ~I
Connectalead wire with an alligator clip to the ignition I
timing adjusting terminal to ground it. n .~
NOTE
For the ignition timing check and adjustment procedures, --
refer to GROUP 8 ELECTRICAL - Ignition System.
(4) Run the encjiaeIfor more than 5 seconds at an en@ne speed 1
of 2,000 to ~3,000 rpm.
(5) Run the engine at idle for 2 ~minutes.
(6) Take Idle speed reading. If outside specified Irmits, check
the ISC system.
NOTE
The ~clle speed adjustment IS unnecessary since this ~~
system controls the idle speed.
Curb idle speed: 850 + 100 rpm

IDLE SPEED CONTROL (ISC) AND THROTTLE

POSITION SENSOR (TPS) ADJUSTMENT Nl4FIAA

Adjustment Conditions
* Engine coolant temperature: 85 - 95°C (185 Y 205°F)
e Lights, electric cooling fan and accessorres: OFF
+ Transmrssron: Neutral (N or P for vehicles with an automa-
TIC: transmrssion)
* Steering wheel: Straightforward (vehicles with -a power
steering)
 FUEL (ECI) SYSTEM - Service Adjustment Procedures 14-33
(1) Slacken the accelerator cable enough.
(2) Connect the tachometer.

(3) Turn ignition switch to “LOCK”.

(4) Disconnect the large harness connector and small harness
connector from the ECU.
(5) Set check switch of the ECI checker to OFF.
(6) Set select switch of the ECI checker to A.

(7) Connect white color connectors, with labeled “CHECKER”,

of the ECI harness connector Ah to the connectors of ECI
checker, and then connect ECI harness connector A to the
ECU and the harness connectors.
I ECI checker
MD998451
“CHECKER” labeled
white connector I

Harness connector
MD998452

EC1611

(8) Connect voltmeter to extension terminals of ECI checker,

and then change extension switch from check meter down
to extension position
Caution
Use an acculate digital voltmeter.
 14-34 FUEL (ECI) SYSTEM - Service Adjustment Procedures

(9) Set select swrtch of EC1 checker to “A” and check swatch
to “7”.
NOTE
The voltmeter Indicates motor posrtron sensor (MPSj I-
1:)crtput voltage. -~
(1O)lr-r order to prevent brndrng of the throttle valve, open the
throttle valve by hand to a half or more opening two or three
trmes and then release It to allow to return with a snap.
Then, loosenzthe Wed &AS e?ough.
(I 1 IStart the .englne and run-rdle.
(12)Check that the engine speed and motor position sensor
(MPS) output voltage (voltmeter readrng) are as specified.
Standard value:
Engine speed 850 rpm
MPS output voltage 0.9 v
NOTE -_ : ~~~
In case ot a vehicle whLch has not undergone enough :
break-in operations, there,may be a case where the output -Y
voltage of the motor positron sensor IS O.@to O.lSV higher _
than the standard value. In such a case, It IS not necessary
to adlust the engine.

(13)lf these are not as specrtred, adjust by the ISC adjustrng

mew. BEG_~
Caution
1. When turning the ISC adjusting screw, use hexagon
wrench whenever possible. To prevent the screw
from becoming loose due to backlash of the screw,
make the adjustment only when it is turned in the
tightening direction.
2. After adjusting with the ISC adjusting screw, allow
some time for the engine rotation to stabilize. Then,
read the ._ engine speed and the voltage.
-
(74)Turn the rgnrtron sw~rch_to “LOCK”.
(15)Disconnect the~ISC motor connector and fix the ISC motor. ?
(16)Start the engine and run idle.

ISC motor
connector
EC1677
L
- =-
(17)Tiqhten the ttxed SAS until the engrne speed starts to :
Increase. Then, loosen It until the engine speed-ceases to I
drop (touch pornt) and then loosen one turn fromthe touch I
point.
II 8)Stop the en-grne.
IlS)Set the ,select,_swrtch of_ EC.1,checker to “A”, and check
switch to “6“.

The ECI indicates the throttle posrtron sensor (TPS) output I

 FUEL (ECI) SYSTEM - Service Adjustment Procedures 14-35
(20)Turn the ignition switch to ON (engine does not start) and
check that the TPS output voltage is as specified.
Standard value: 0.48 - 0.52 V
(21)lf it is not as specified, loosen the TPS mounting screws
and adjust by turning TPS.
NOTE
Turning TPS clockwise increases the output voltage.
Caution
Securely tighten the mounting screws after adjust-
01 R0471 ment.

(22)Set check switch of the ECI checker to OFF.

(23)Set ignition switch to “LOCK”.
(24)Disconnect connectors of the ECI checker and the ECI
harness connector A from the ECU and the body side
harness connectors.
(25)Connect the body side harness connectors to the ECU.
(26)Adjust the accelerator cable free play. (Refer to P.14-126.)
(27)Connect ISC motor connector.
(28)Start the engine and check that the engine idle speed is as
specified.
Standard value: 850 + 100 rpm
(29)Turn the ignition switch to “OFF”.
Disconnect the battery terminal fQr 5 to 6 seconds and then
reconnect it. (This erases the data stored in diagnosis
memory during the ISC adjustment.)

INJECTION MIXER INSPECTION

DISTRIBUTOR ADVANCE CONTROL VACUUM (D
VACUUM) N14FUBA

Inspection Condition
Engine coolant temperature: 85 - 95°C (185 - 205°F)
(1) Disconnect the vacuum hose from the injection mixer D
vacuum nipple and connect a hand vacuum pump to the
nipple.
NOTE
For the location of the nipple, refer to the Injection Mixer
Appearance (P.14-31).
(2) Start and race the engine to make sure that D vacuum
increases with the engine speed.
NOTE
If abnormality is found in change of vacuum, clogged
injection mixer D port is suspected. Therefore, clean the
port as necessary.

Engine speed
3FU25:
14-36 FUEL (ECI) SYSTEM - Service Adjustment Procedures

EGR VALVE CONTROL VACUUM (E VACUUM) N14FVBA

Checking Condition
Engine coolant~temperatutez 85 - 95°C (185- - 205’F)
(I) Disconnect-the vacuum hose from the iniectisn mixer EL
vacuum nrpple and connect a hand vacuum pump to the
nipple.
NOTE ~~ ~~ 1
For the location of the nipple, refer to the lniection Mixer
Appearance (P. 14-31). ~

(2) Start and race the engine to make sure that i? vacuum I
increases w~ith the engine speed.
NOTE
If abnormality is found in change of vacuum, clogged
injection mixrarE port issuspected. Therefore, clean the ~~
port as necessary.

Engine sped 3FU254

SECONDARY AIR CONTROL VACUUM (M VACUUM) N14FXAA

Checking Condition
Engine coolant temperature-85 - 95°C (185 - 2CWF)
(1) Disconnect the vacuum bose from the injection mixer M
vacuum nrpple and connect a hand vacuum pump to the
nrpple.
NOTE
For the location of the r@ple, refer to the Injection Mixer ’
Appearance (P.14-31).

t) (2) Start and race the engine-to make sure that M vacuum is _
A
kept constant regardless of the increased engine speed. _
NOTE
If M vacuum is not formed, clogged injection mixer M port
is suspected_ Therefore, ~-clean the port as necessary. ’

>
3FU262

THROTTLE POSITION SENSOR N14FSAA

INJECTOR
ISC SERVO
FUEL PRESSURE REGULATOR
Refer to ECI SYSTEM COMPONENTS (P.14-59)
FUEL (ECI) SYSTEM - Service Adjustment Procedures 14-37
FUEL FILTER REPLACEMENT N14FCBA

(1) Reduce the internal pressure of the fuel pipes and hoses.
(2) Remove the eye bolts while holding the fuel filter nuts
securely.
(3) Remove the fuel filter assembly.

;BVk;FILL LIMITER (TWO-WAY VALVE) REPLACE-

Nl4FEAA

(1) Remove the overfill limiter mounting bolt.

(2) Disconnect the vapor hoses, and then remove the overfill
limiter.

FUEL GAUGE UNIT REPLACEMENT N14FFAD

(1) Pry up and remove the plug on the baggage compartment

floor.
(2) Disconnect the fuel gauge unit connectors.
(3) Remove the fuel gauge unit.
(4) After installing the fuel gauge unit, confirm that the unit is
securely grounded.
(5) When installing the floor plug, apply a semi-drying sealant
around the circumference of the floor plug mounting ’
surface.

IN-TANK FUEL FILTER REPLACEMENT N14FCBC

(1) Remove the high floor side panel located in the baggage
compartment floor.
(2) Pry up and remove the lid.
(3) Disconnect the fuel hoses from the pipe assembly.
(4) Remove the pipe assembly from the tank.
(5) Press the tabs on the filter, and remove the in-tank fuel
filter.

6.

NOTE
When installing the in-tank fuel filter, the filter should be
placed inside the reservoir cup located inside the fuel tank,
and then the pipe assembly should be tightened to the fuel
tank securely.
14-38 FUEL (ECI) SYSTEM - Service Adjustment Procedures
RELEASING RESIDUAL PRESSURE OF FUEL HIGH
PRESSURE HOSE N14FGAB

Reduce the internal pressure of the fuel main pipes and hoses
by using the fallotiing procejdure.~ 5
NOTE
Be sure to reduce&e internalfressure. If the hose is-removed _
from the fuel main pipe without reducing the internal pressure,
fuel will gush out. _
3
(I) Remove high- floor side_panel located in the baggage -
03Y673 compartment floor.
(2) Start the engine, and then disconnect the fuel gauge unit z
connector. -
(3) After the engrne has beenstopped, - set the rgnrtron key to c
“OFF” position
(4) Disconnect the battery cable from the negative terminal of
the battery. -

FUEL PUMP OPERATION CHECK NllFDAA

-
(1) Turn the ignitron switch to OFF.
(2) Apply batteryvoltage to the fuel pump connector%d check L
the pump operating sound.
NOTE :
The fuel pump G-r-tank type and its operating sound is hard 1
to hear without removing the fuel filler cap. ;
(3) Pinch the fuerhose with fingers to check that fuel pressure .-I
is felt. - -
ECl67:
-
FUEL PRESSURE MEASUREMENT N14FNAA

(1) Make the following operations to release- the pressure .I

remaining in fuel pipe line so that fuel will not flow out. ;
@ Disconnect :the fuel pump harness connector.
(Connector location: below rear seat cushion) =i
@ Start the.rrengine and after it stops by itself, turn the
ignition switch to OFF.
@ Disconnect the battery (-) terminal.
@ Connect the fuel pump harness connector.

(2) Disconnect the fuel high pressure hose from the rnjectron ~~
mixer.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
 FUEL (ECI) SYSTEM - Service Adjustment Procedures 14-39
(3) Set a fuel pressure gauge on the special tool, placing an
adequate O-ring or gasket between the gauge and tool to
prevent fuel leaks.

m EC168

(4) Install the special tool attached with fuel pressure gauge on
the injection mixer.
(5) Insert the fuel high pressure hose into the special tool and
tighten securely with the attached two special tool screws.
(6) Connect the battery 0 terminal.
(7) Apply battery voltage to the fuel pump terminal to operate
the fuel pump so that fuel pressure will act. In this state,
make sure that the fuel pressure gauge and special tool
connection present no fuel leaks.
(8) Measure the fuel pressure when the engine is running at
idle.
Standard value: 240 - 260 kPa (35 - 38 psi)
(9) If the pressure is out of specification, determine and
remove causes according to the following table.

Fuel pressure Probable cause Remedy

Lower than specified a. Clogged fuel strainer a. Replace fuel strainer

b. Faulty pressure regulator b. Replace pressure regulator
(regulator inside valve open)
c. Faulty fuel pump c. Replace fuel pump

Higher than specified a. Faulty pressure regulator a. Replace pressure regulator

(regulator inside valve binding)
b. Clogged fuel return hose or pipe b. Clean or replace hose or pipe

(lO)Stop the engine and check change of fuel pressure gauge

indication, which should not drop.
If the gauge indication drops, observe the rate of drop and
determine and remove the causes according to the follow-
ing table.

Fuel pressure Probable cause Remedy

Fuel pressure drops slowly a. Faulty injector (leaks due to trapped a. Replace injector
after engine is stopped foreign matter)

Fuel pressure drops a. Faulty fuel pump (pump inside check a. Replace fuel pump
sharply immediately valve binding)
after engine is stopped b. Faulty pressure regulator b. Replace pressure regulator
(regulator inside valve fails to close)

(11)Release residual pressure from the fuel pipe line.

(12)Remove the fuel high pressure hose and the special tool
from the injection mixer.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
 tment Procedures

(13)Using a new-o-ring, install the fuel high pressure hose.

Tighten the screws firmly.
(14)Check for f&-leaks. -
(jr) Apply battery voltage to the fuel pump terminal to
operate the fuel pump.
(21 With fuelpressure acting, check the fuel line for leaks.
 FUEL lECI) SYSTEM - Service Adjustment Procedures 14-41

CIRCUIT DlAdRAMS
(Vehicles with Manual Transmissi@-& yh p74/1

Combination meter

-22

2-BW
Y r) b-i\, ,@
-
I
1.25-i;
I 1I
I I r. m., *-:g
L-uy
YG -g

Battery

.c

) To compressor
[Refer to P.8-761

*
To A/C compressor relay
[Refer to P.8-761

2-BW

IJ- B-30
ECI control relay 1 2-B+ -&
Q-2
Fuel pump check connector
14-42 FUEL (ECI) SYSTEM

..T
aYWYG
Q
- Service Adjustment
--_
R
LR
W+te,g,at%,
~-@g

,
-~
Procedures

=@pJ

InJector
h .
-@f$

Secondary
air control
~== q

Resrstor solenoid valve

1414
Z-BW
'514
2-BY
1614
BW
'714 . - 1.:
:st4 Z-BY
VC
0 .I
nr D
\I
!RB).
if014
--- ---
--- ---
J

Air-flow sensor .*,1 .*.3 ,&.4

Detonation IZlstnbutor mntrol mtter
5loM aenerator
Wire color code
B: B&k Br: Brown _G: Green
Gr: Gray L: Blue. Lg. Li@t green
LI: Lloht blue 0: Oranae P: Pink
t3 Red W: Whtte Y: Yellow
 FUEL (ECI) SYSTEM - Service Adjustment Procedures

Idle speed
control servo

Oxygen
sensor

\I/, I
Q R B B RW BY BW

m A-88 R BY YG YB GP YL RB
A-68 IA-72
/ I
31;P .*5 .&j
I
L-l9111.25-R B-36
r
51
.*2 1.25-~
52
” s.3 ()*85-B
53
54
.*.4 2-E 55
BW 56
e 1. 25-R
57
2-w 58
59
0.85-i: , 60
61
0.85-i: 62
(RB)

1
2
3
4
5
6 -
7
IO
11
12
13

14
15
16
19
20
21
22
23

c
7 2
J’
A-7 1
l- -A A-90 A-76
Ignition timing
adjusting
~3.6 37Y584

Remarks
terminal (I) For detailsof grounding,points
^ _^u. (ex.: W-i,‘:
Motor position Engine coolant Throttle rerer LO page 8-.1
sensor .’ temperature position (2) The circuit lines ended with number(i).
sensor sensor (2) and so on are in continuation to those
LRB GE ,RY e
with the corresponding number on
opposed page. (i.e., the line cl) on the

G3 LY m
Gwa( @ left-hand page is connectedtothe line@
G3 - on the right-hand page.)
E
-E
14-44 FUEL (ECI) SYSTEM - Service Adjustment Procedures

CIRCUIT DIAGRAMS
(Vehicles with Automatic Transmission)

lgnltlon switch

Combimtion meter --

l-v
4%
‘g+
‘,
\ To turn slgnal L
flasher unit
S
Multi-purpose fuse
[ I 311 *-
(BRI ,,c,
- B *'5!
93)
7-RI.1

“I
(8 1
L-YG *,-.
*js.J

Pas e
e

---)
IRB),@
To compressor
[Refer to P.8-761

To AIC compressor
t --) relay
[Refer to P.8-761

BR ,fli
Battery J
(LgBj
+2
’ I .-

I Starter motor

InhIbItor swrtch
PN
2-BR
2-BY

p!q pA+--- T t-t/

ECI bontrol relayG30 1 244 *$ ~ f [m) rn) ~~Fu”‘p~~p
,;.2
Fuel pump check connector

...I 37Y586
 FUEL (EC11 SYSTEM - Service Adiustment Procedures 14-45

Self-diagnosis
connector

lizEgal ~ D-14

m
4

-
-

G: Green
Lg: Light green
0: Orange P: Pink
R: R&d W: White Y: Yellow
14-46 FUEL (ECI) SYSTEM - Service Adjustment Procedures

EGH control Qxyqen control motor switch

-.jIpnolc valve sensor

ECI control unit

51
52
53
54
=_
56
57
58
59
60
61
62
63
1
2
3
4
5
6
7
10
11
12
13
1181
14
15
1191 16
19
20
.z? 21
,2Y 22
23

(1) Ear details of grounding points (ex.: En.

Engine reter to page 8-I 0.
~l^..t )J”JI Ll”, I
131 ThP ,-,rr,
_ ..--,. II~ .I..--
Ibnes wd=vi
-..--- \h
.,1111 IlUl IU~l (,I),

sensor li/dnd so on are In contmuatm to thos e

with the corresponding number on
opposed page. (I.e.. the line ;ri on the
left-hand page IS connected to the line Q
@ 1 @ ‘-’ ;;he rig,,(.,,.,nd page,) 91-
VACUUM HOSES DIAGRAM

l 1: Oxygen sensor l Ignition switch-ST *l : injector l Self-diagnosis output

l 2: Air flow sensor l Power voltacre $12: EGR control solenoid . Fuel pump control
l 3: Intake air temperature sensor l Vehicle spegd sensor valve (control relay)
‘4: Engine coolant temperature l Air conditioner switch Q3: Secondary air control l tracgnditioner power
sensor l Inhibitor switch solenoid valve
l 5: :;gyle position sensor (ve,hicles with an automatic 44: Igniter
transmission) t5: ISC servo
l 6: Idle switch .
“7: Motor positi’on sensor Boost meter
“8: Engine speed sensor
“9: Barometric pressure sensor Output signal
I
Canister
Input signal
Distributor
Purge control valve
\

Purge air +==

Intercooler
solenoid valve
*’
I “Fuel injector

9 J

H I II I II *54+-l IIE

*2
EGR control
solenoid valve

Se
air

Vacuum hose color

G: Green
Y: Yellow
L; Light blue
g: Fete
B: Black
Distributor sickly , ‘gn’t~ b E Bane’;

( &I
Inhibitor switch
(Vehicles with an
5FUOO16
Rear catalytic converter automatic transmrssion)
TWC: Three-way catalvtrc converter
FUEL (ECI) SYSTEM - Service Adjustment Procedures
 FUEL (ECI) SYSTEM - Service Adjustment Procedures 7 4-49

ECI SYSTEM INSPECTION N14PAAA

(I) Before removing or installing a part, read diagnosis code

and then disconnect the battery 0 terminal cable.
(2) Before disconnecting the cable from battery terminal, turn
the ignition switch to OFF. Removal or connection of
battery cable during engine operation or while the ignition
switch is ON could cause erroneous operation of the ECU
or damage to semiconductors.
(3) The control harnesses between the ECU and the ignition
coil (0 terminal) and oxygen sensor are shielded wires with
shield grounded to the body in order to prevent influence of
ignition noises and radio interference. When the shielded
wire is faulty, therefore, the control harness must be
replaced.
(4) When ECI checker is used, pay attention to the following:
l Avoid rough operation of switches.
l Do not subject ECI checker to shock and other external
forces, heat, etc.
- l Keep the checker away from water and oil.
l Store ECI checker in a moisture- and dust-free place and
take steps to protect the checker from heat and
vibration.

CHECK PROCEDURE (SELF-DIAGNOSIS) N14PCAA

Precautions for Operation

(1) When battery voltage is low, no detection of failure js
possible. Be sure to check the battery for voltage and other
conditions before starting the test. “;e
(2) Diagnosis item is erased if the battery orthe ECU connector
is disconnected. Do not disconnect the batte.ry before the
diagnosis result is completely read.
(3) To diagnose the oxygen sensor, warm up engine and drive
a good distance. Do not turn off the ignition switch after
driving. If ignition switch is turned off, the result in memory
is erased.
(4) After check and correction ares-cover, disconnect ground
cable for 15 seconds or more from negative terminal of
battery and connect it again to make sure that failure code
is erased.

Check Steps
NOTE
, The memory of oxygen sensor (diagnosis code No. 1) is erased
from ECU when the ignition switch is turned off: Therefore, to
diagnose the oxygen sensor, drive the vehicle a good distance
and keep the engine running.
(1) Connect an analog voltmeter to the self-diagnosis output
harness connector located in the glove box.

EC170
 FUEL (ECI) SYSTEM - Service Adjustment Procedures

(2) On turnrno the rqnrtron switch to ON, the indicatron of ECU

memory contents WIII start. If the system IS in normal -
condrtron. pointer of voltmeter constantly Indicates 12V. If
any failure data IS stored in memory, the pointer of
voltmeter will deflect rndrcatrna abnormal Items as de- =
,scrrbed In “lndrcatron Method”. Abnormal item can be _
known from the number of pointer deflection which reflects
the voltage waveform peculiar to the Item-See “Dragnosrs
Chart” for the-voltage wavetorms of different abnormal
items.
Atter recording the abnormal item, check and repair each
part according to the check items rn “Diagnosis Chart”.
(3) If the defective parts have been reparred, disconnect
ground cable for 15 seconds or more from negative 1
terminal of battery and connect It agarn to make sure that
failure code has been erased.

Diagnosis Chart

Oxygen sensor signal does not l Wire harness and

change for 2OScBnds or more in
its feedback range.

l Wire harness and

butput voltage is 0.2V or

sensor output is 4.5V or rriore.

l Engine coolant~temperature l Enginecoolant
sensor output is 0.1 V or less. temperature sensor
 FUEL (ECI) SYSTEM - Service Adjustment Procedures 14-51
CONTROL SYSTEM OPERATION
IGNITION TIMING CONTROL SYSTEM INSPECTION
High Altitude and Cold Timing Control Function N14PIAA

Based on the information supplied by the atmospheric pressure

sensor and engine coolant temperature sensor, the ECI control
unit judges whether the vehicle is at high altitude and/or the
engine is cold, and in case such condition(s) exists, the ECI
control unit controls the ESC igniter for timing advance of
approximately 5” in crank angle. Check this function by the
.following procedure.
Altitude of Lower than 1,200 m (3,900 ft.)
(1) Check the ignition timing for both when battery voltage is
applied directly to the ignition timing adjusting terminal and
when not.

Battery voltage Ignition timing

LIZITI
ignition timing zh
I
When not applied
When applied I
Base (1O”BTDC at idle)
5” advanced (15”BTDC at idle) I
adjusting terminal
EC1621 Altitude of 1,200 m (3,900 ft.) or Higher
(2) Check the ignition timing for both when the ignition timing
adjusting terminal is grounded ,and when not.

~1~

(3) If the check result is out of specification, replace the ESC Lk-.
igniter.

Detonation Control Function

(1) Turn the ignition switch to OFF, after all the self-diagnosis
contents of the ECI system have been read out.
(2) Disconnect the air flow sensor connector .and start the
engine, running it at idle.

(3) Check that the ignition timing is retarded (approx. 8”) when
the detonation sensor connector is disconnected.
NOTE
(1) If the ignition timing is retarded but the engine knocks
(in full throttle acceleration etc.), replace the detonation
sensor and recheck. Be careful about continuous
knocking which damages the engine-
(2) If the ignition timing is not retarded, probably the
harness between detonation sensor and igniter is
broken or the detonation sensor is faulty. Repair or
replace it and i-echeck. If the ignition timing is not
retarded, replace the igniter.
14-52 FUEL (ECI) SYSTEM - Service Adiustment Procedures

(4) With the ignition switch at OFF, disconnect the battery

minus ~3 terminal for mot-e than 10 seconds, after the air
flow sensor has been connected.
NOTE
This operation IS for erasing the diagnosis memory of air
flow sensor farlure caused by disconnecting the air flow
sensor corinecror.
(5) Restart the engine and run~it at idle for more than 5 minutes
with the air conditioner switch at both ON and OFF
poslrlons. ~7
NOTE
Carry out break-in operation by this way.
Boost Pressure Control System Inspection
_--
(I) Turn off the Ignltlon-switch after all the self-diagnosis items
have been read out.

(2) ‘Remove the%aGum has@ (yellow stripe) from the waste

gate actuator, then conngct a hand vacuum pump to the
vacuum hosz
(3) Disconnect tke vacuum h&e (black) from the air intake pipe
between the intercooler a~nd injection mixer, then plug the
air intake pipe nipple.

(4) Apply negatiG pressure oFapprox. 20 kPa 13 psi) and check

for airtightness, which repeatedly stopping up or releasing
the hose end with a finger.

Negative pressure lea

NOTE :m =
If airtightness 1s not normal, check the waste gate solenord valve or
vacuum hose as It IS probably faulty.
 FUEL (ECI) SYSTEM - Service Adjustment Procedures 14-53
FUEL PUMP DRIVE CONTROL SYSTEM INSPECTION
N14PKAA

(1) Disconnect the high tension cable from the ignition coil.
.
(2) Holding the fuel hose connected to the injection mixer with
a hard, crank the engine and check that pulsation of fuel
flow is felt to the hand.
NOTE
If no fuel flow pulsation is felt, check the ignition switch,
control relay and fuel pump.

BOOST METER CONTROL SYSTEM INSPECTION N14PNAA

(1) Disconnect the vacuum hose (white stripe) from the

injection mixer and connect a vacuum gauge,to the nipple
(vacuum nipple “M”).
(2) Make road test and check that the boost meter indication
nearly agrees with the vacuum gauge indication.
(3) If the indication deviates greatly, check the harness for
open or short circuit and also check the boost meter, air
flow sensor and engine speed sensor.

SECONDARY AIR CONTROL SYSTEM INSPECTION N14POAA

Refer to GROUP 25 EMISSION CONTROL SYSTEMS.

EGR CONTROL SYSTEM INSPECTION N14PPAA

Refer to GROUP 25 EMISSION CONTROL SYSTEMS.

ECI SYSTEM INSPECTION BY USING ECI CHECKER N14PDBC

The electric system of ECI system can be quickly inspected and

maintained if the electric input and output sign.als of ECU are
checked by ECI checker and the component whose abnormal-
ity is indicated by the signal and the harness connected
between ECU and the component is checked as well.
Using the special tools (EC1 harness connector A and ECI
checker), perform the ECI system checks by the following
procedure.
Caution
Perform these checks after completion of all steps in the
preceding “CHECK PROCEDURE (SELF-DIAGNOSIS)“.
 Ejj
E-y
FUEL (ECI) SYSTEM - Service Adjustment Procedures giLT
8-G .G
Qs--~-
-
Check Steps
STEP 1
(1) Turn ignition switch to LOCK.
White connector
EC1 checker labeled “CHECKER” (2) Remove the E%LI cover.
MD998451 A (3) Remove the large harness connector and small harness
connector from the ECU.-~
(4) Set check switch of the ECI checker to OFF.
(5) Set select switch of the ECI checker to A.
(6) Connect whitecolor conn&ors labeled “CHECKER” of the
i ECI harness connector A to the ECI checker connectors.
Then connect ECI harness connector A to the ECU and
harness connectors.
\ (7) Perform checks -according to the “EC1 System Check
Harness Procedure Chart - Step 1.
connector A
MD998452 STEP 2
Connect to ECU
Connect to (8) Turn ignition switch to LOCK.
harness (9) Set check switch of the ECI checker to OFF

EC1618

(1O)Disconnect white color connectors labeled XHECKER” of

the ECI harness connector A from the ECI checker. Then
EC1 checker connect green-color connectors labeled “CHECKER“ of the
MD998451 ECI harness connector A to the connectors of ECI checker.
(1 l)Perform checks~ according to the “EC1 System Check
\ Procedure Chart - Step 2”.
(12)lf checker shows any deviation from specifications, check
the corresponding sensor and related electrical wiring.
.<a,, Repair or .replace if necessary.
.-
Green (13)After repair o~r%placement, recheck with the ECI checker
.” -. .: connector to confirm that the repair has removed the problem.
(14)Set the ignition switch to LOCK.
(15)Set the check switch of the ECI checker to OFF.
(16)Disconnect the connectors-of the ECI checker and the ECI
Zen harness connect-or A from the ECU and body side harness
connector A
Connect to MD998452 connectors. Make certain that the power supply has been
harness removed from ECU for at least 15 seconds. This will erase
the memory.
(17)Connect the body side harness connector to the ECU.
(18)After completion of the above test, perfarma road test to
be sure that the trouble has been eliminated.
 FUEL (EC3 SYSTEM - Service Adiustment Procedures 14-55
ECI SYSTEM CHECK PROCEDURE CHART
(Use Harness Connector - MD998452)
STEP 1 (Connect white color connectors labeled “CHECKER” of harness connector to ECI checker)

ECI Checker
Operation ECU Test
Check Item Terminal # Condition Specification
Select Check Checked
Switch Switch
1 Power supply 51 Ignition switch IIV - 13v
“LOCK” + “ON”

2 ignition pulse 1 Ignition switch “LOCK” -+ “START” 4v - IOV

3 Intake air 5 Ignition switch 0°C (32°F) 3.4V - 3.6V

temperature sensor “LOCK” + “ON”
20°C (68°F) 2.5V - 2.7V
40°C (104°F) 1.7v - 1.9v

80°C (176°F) 0.6V - 0.8V

4 Engine coolant 6 Ignition switch 0°C (32°F) 3.4V - 3.6V

temperature sensor “LOCK” + “ON”
20°C (68°F) 2.5V - 2.7V

40°C (104°F) 1.5v - 1.7v

80°C (176°F) 0.5v - 0.7v

5 Power supply for 10 Ignition switch 4.5v - 5.5v
sensor “LOCK” + “ON”

6 Throttle position 15 Ignition switch Accelerator fully closed 0.4v - 0.7v

“A” sensor “LOCK” --> “ON”
(Warm engine) Accelerator fully opened 4.5v - 5.5V

7 Motor position 3 Ignition switch After 15 seconds 0.8V - 1.2V

sensor “LOCK” --f “ON”

8 Idle position switch 7 Ignition switch Accelerator fully closed OV - 0.6V

“LOCK” -+ “ON”
Accelerator fully opened 8V - 13V

9 Cranking signal 55 Ignition switch Over 8V

n LOCK” + “START”

10 Vehicle speed sensor 19 Start engine and operate vehicle slowly in 1st or OV - 0.6V
reed switch DRIVE range
(pul&es)
Ove! 2V

11 Air conditioner switch 56 Ignition switch $irir;;ditioner switch OV - 0.6V

“LOCK” -+ “ON”

+ir,n$tioner switch IIV - 13v

12 Inhibitor switch 58 Ignition switch At “P” or “N” range OV - 0.6V

“LOCK” + “ON”
At “D” range IIV - 13v

NOTE
*I : ON means compressor clutch engaged.
14-56 FUEL (ECI) SYSTEM - Service Adjustment Procedures

STEP 1

Conditiori

xygen sensor

NOTE
*2’ Failure of parts other than the oxygen sensor can also cause deviation fromthe~speclflcatms. Therefore, check other parts
related to air-fuel ratio control. (Refer to P.14.30.)
 FUEL (EC11 SYSTEM - Service Adiustment Procedures 14-57
STEP 2 (Connect green color connectors labeled “CHECKER” of harness connector to ECI checker)

ECI Checker
Operation ECU Test
Check Item Terminal # Condition Specificatior
Select Check Checked
Switch Switch
1

2 Secondary air control 20 Hold engine over 1,500 rpm, 15 seconds after start of OV - 0.6V
solenoid valve warm engine then
13v - 15v

5 Barometric pressure 16 Ignition switch at sea level 3.W - 4.2L

sensor i “LOCK” -+ “ON”

Idling
“A”
6

7 Self-diagnosis 21 !y;it;,switch Refer to

+ “ON” P. 14-49.

10
11

I 12 I
ECU terminal

View from front as installed in ECU

5FUOO25
 ~~-~ ~__~

FUEL (EC11 SYSTEM - Service Adiustment Procedures

STEP 2

Condition

Injector No. 1 pulse

Quick acceleration from idling to above 2,000 rpm in Slight drop

“N” or “P” position
- ~~

*I : ON means compressor clutch engaged.

‘2. Pointer indicates over 6V momentarily. If It IS hard to read lndlcatlon, rep&t OFF -+ ON orON + OFF operation of air conditioner
switch several times. If the DoInter of voltmeter deflects, ISC motor is normal
 FUEL (ECI) SYSTEM - ECI System Components 14-59
ECI SYSTEM COMPONENTS Nl4ED-B

COMPONENT LOCATION
K J B C
U I L
\ \ \ \, \,
I / / \ \

--
5FUOO50
14-60 FUEL (ECI) SYSTEM - ECI System Components
 FUEL (ECI) SYSTEM - ECI Svstem ComDonents 14-61

Inhibitor switch x

Vehicle speed
Air conditioner sensor
switch
I $

7OY506 EC1696

Boost meter

EC1697
14-62 FUEL (ECI) SYSTEM - ECI System Components
 FUEL (ECQ SYSTEM - ECI System Components 14-63
AIR FLOW SENSOR (AFS)
INSPECTION
Check using the ECI checker. (Refer to P.14-53.)
NOTE
If the air flow sensor fails, the intake air volume cannot be
measured and as a result, normal fuel injection control is no
longer available. The vehicle can be run, however, by the
backup function.

BAROMETRIC PRESSURE SENSOR

INSfj&&l
Check using the ECI checker. (Refer to P.14-53.)
NOTE
Close the air cleaner air inlet gradually to about a half of opening
and check voltage change.

Pressure Voltage

Lower (close opening) Drops

information

Pressure kPa abs (psi abs) 47.6 101

6.9) (14.7)

1 Center voltage V 1 0.79 ( 1.84 1 4.00

INTAKE AIR TEMPERATURE SENSOR N14QHAA

AFSside connector INSPECTION

M r
(I) Disconnect the air flow sensor connectors.
5 6 1 I 1 (2) Measure resistance between terminals @ and @.
@3@ K
Temperature “C (“F) Resistance kS1

0 (321 i.0
ZO(68) 2.7
01i%13;
80(176) 0.4

(3) Measure resistance while heating the sensor using a hair

drier.

Temperature Resistance

Higher Smaller

(4) If the value deviates from the standard value or the

resistance remains unchanged, replace the air flow sensor
assembly.
14-64 FUEL (ECI) SYSTEM - ECI System Components

ENGINE COOLANT TEMPERATURE SENSOR N14ClABA

INSPECTION
(1) Remove engine coolant temperature sensor from the _
intake manifold.
(2) With temperature sensing portion of engine coolant
temperature-sensor immersed in hot water, ch~eck resis- :
tance. The sensor should be held with its housing 3 mm
(.I2 in.) away from the surface of the hot water.

Engine coolant
temperature sensor

(3) If the resistance deviatesfrom the standard value greatly,

OlR0129
replace the sensor.

Engine coolant temper-

3ture sensor connector
Isensor side connector
front vie4

INSTALLATION
(I) Apply anaerobic sealant to threaded portron.
(21 Install enginecoolant temperature sensor and tighten It to
specrired torque.
Sensor tightening torque: 20 - 40 Nm (14 - 29 ftlbs.)
(3) Fasten harness _connectors securely.
 FUEL (ECI) SYSTEM - ECI System Components 14-65
THROTTLE POSITION SENSOR (TPS) N14QBBA

Throttle position INSPECTION

sensor (TPS)
(1) Disconnect the throttle position sensor connector.
(2) Measure resistance between terminal @) (sensor GNP) and
terminal @ (sensor power).
Standard value: 3.5 - 6.5 k0
(3) Connect .a pointer type ohmmeter between terminal @
Supply (5v; (sensor GND terminal) and terminal @ (sensor output
terminal).
(4) Operate the throttle valve slowly from the idle position to
the full open position and check that the resistance changes
smoothly in proportion with the throttle valve opening
angle.
NOTE
The resistance changes within the range from approx. 0.5
kR to the value measured at step 2.
(5) If the resistance is out of specification, or fails to change
smoothly, replace the TPS.
TPS connector
(sensor side TPS installation torque: 1.5 - 2.5 Nm (1.1 - 1.8 ft.lbs.)
connector front
view) NOTE
OlR013C
For the throttle position sensor adjusting procedure, refer to
P. 14-32.

IDLE SWITCH N14QKAA

INSPECTION
(1) Disconnect the ISC motor connector.
(2) Check continuity between, terminal @ and body GND.

Accelerator pedal Continuity

)nt view) Depressed Non-conductive (m fi)

XZ servo assembly Released

(3) If out of specification, replace the ISC servo assembly.

MPS

Forward 0

Reverse 0
Idle switch
output

ISC motor
lotor position connector
3nsor connector _

4P-F 4P-M
(Sensor side con- (Motor side con-
nector front view) nectar front view)
OlR0141
 I=
=~-

14-66 FUEL (ECI) SYSTEM - ECI System Components

Lo
MOTOR POSITION SENSOR (MPS) N14QLAA

INSPECTION
Use the ECI checker for inspection. (Refer to P.14-53.)
NOTE
Inspection of -change on output voltage of MPS can be
Inspected by moving the ISC motor as follows.

ISC motor connector (1) Turn the ignition switch~ to “LOCK”.

(Sensor side con- (2) Disconnect -Ihe ISC mator connector.
nectar front view)
(3) Turn the ignition switch to “ON”. (Do not run the engine.)--
(4) Connect GVD-%(four dry cells) between terminal@ and c@
of the ISC--motor connector to operate the ISC motor
(extendiretract), ,and make sure that the MPS output
voltage changes smooth& between approximately 0.5 and--
5 v.
Caution
Apply only a 6V DC or lower voltage. Application of
EC1742
higher voltage could cause locking of the servo gears.
To spark plug ENGINE SPEED SENSOR (IGNITION COIL 0 TER-
MINAL) N14QCBA

INSPECTION
Check that there is continuity between the ignition coil 0 ~;
terminal and the electronic control unit (ECU) terminal No. 1.
NOTE
Shake the harness connecttito check for lurking open circuit.

OXYGEN SENSOR N14ClDBA

INSPECTION
Caution
1. Before checking, warm up the engine until engine
coolant temperature reaches 85 to 95°C (185 to 205°F).
2. Use an accurate digital voltmeter.
(1) Disconnect the ~oxvgen sensor connector and connect a
voltmeter to- the oxygen sensor connector.

(2) While repeating engine raYzing, measure the oxygen sensor

output voltage.

Connector
 FUEL (ECI) SYSTEM - ECI System Components 14-67
NOTE
For removal and installation of the oxygen sensor, refer to .~
GROUP 11 INTAKE AND EXHAUST SYSTEM.
Oxygen sensor installation torque:
25 - 30 Nm (18 - 22 ft.lbs.)

VEHICLE SPEED SENSOR N14QEBA

Refer to GROUP 8 ELECTRICAL.

AIR CONDITIONER SWITCH N14QQAA

Refer to GROUP 24 HEATERS AND AIR CONDITIONING.

INHIBITOR SWITCH - VEHICLES WITH AN AUTO-

MATIC TRANSMISSION N14QRAA

INSPECTION
(1) Disconnect the inhibitor switch connector.
(2) Operate the control lever to check continuity between
terminals @ and @ of the inhibitor switch side connector.

(3) If the check result is not as specified, adjust the inhibitor

V switch.,
Refer to GROUP 21 TRANSMISSION for adjusting proce-
4 5 6 L / dure.

INJECTORS N14OTAC

INSPECTION
Operation Sound Check
Using a sound scope, check operation sound (tick, tick). Check
that the sound is produced at shorter intervals as the engine 1
speed increases.
 E?L.sz
gg;;-
a=
pi?
14-68 FUEL (ECI) SYSTEM - ECI System Components :-

Gray Caution
Check carefully. Other injectors may produce sound as
they operate even if the inj~ector under checking does not
Injector operate.
(Small) Resistance between Terminals Measurement
Blue (1) Disconnect the jnjector conne~ctor.
(2) Measure resistance between terminals.
Standard value: 2 - 3 U [at 20°C (68”F)I
Injector
(Large) 1lZ (3) Install the injector connector.

* ECU
Injector
(Gray)
- Resistor

OlR012!

Injection State inspection

(1) Remove the air intake pipe.
(2) Disconnect the high tension cable from the ignition coil.

Injector with Gray Connector Inspection

(3) Ob!sertiing through the air inlet of the injection mixer,
visually check injection state of the injector with gray
connector when the ignition switch is set-to ST position.
Judge the injector as normal unless the injection state is
very poor.
(4) Turn the ignition switch-to OFF and check the injector
nozzle for leaks.
 FUEL (ECI) SYSTEM - ECI System Components 14-69
Injector with Blue Connector inspection
(5) Disconnect the injector harness of the blue connector.
(6) Connect the harness connected to the injector having gray
connector to the injector having blue connector.
Caution
Connect the harness with adequate slackness so that
undue tension will not act on the harness when the
engine is cranked.

(7) Observing through the air inlet of the injection mixer,

visually check injection state of the injector with blue
connector when the ignition switch is set to ST position.
Judge the injector as normal unless the injection state is
very poor.
(8) Turn the ignition switch to OFF and check the injector
nozzle for leaks.

ISC MOTOR (DC i&OR) N14QUAA

INSPECTION
(1) Disconnect the ISC motor connector.
(2) Check continuity of the ISC motor coil.

Measuring terminals Continuity

ISC motor connector Conductive

(motor side con- 8 - 0 [5 to 11 Q resistance
nector front view) at 20°C (68”F)l

(3) Connect 6V DC between terminals @ and @ of the ISC

ISC motor connector
(motor side con- motor connector and check that ISC servo operates.
Caution
Apply only a 6V DC or lower voltage. Application of
higher voltage could cause locking of the servo gears.
(4) If not, replace ISC servo as an assembly.

ECl74:
 -~
c;
er=,
e:
Sm~
FUEL (ECI) SYSTEM - ECI System Components
S-i
r_ -7
CONTROL RELAY N14QYAA --

INSPECTION
Caution -
When applying battery voltage directly, make sure that it is z
applied to correct terminal. Otherwise, the relay could be
damaged.
NOTE
Failure of the control relay prevents power supply to the fuel =
EC1234
pump, injectors and ECU, resulting in star? failure.
Ignition (1) Check contintiity betweti terminals for both when the _
;round switch relay coil is energized and when not.
“IG” ~~
NOTE
ECU Battery In the following tables, the arrows indicate direction of
esistor current flow.
Confirm circtiTt tester polarity before checking continuity.
ECU
Ignition
switch
Fuel “ST”
w-w

ECl23F Q Coils LI and L, -1

Condition Measuring Continuity

terminals

0-0 Non-conductive t= 11)

NOTE R.2
“Energized” means voltage applied across terminals (6) and &. z
@CoilL; -*
z=::-

s-
EpIm
NOTE e =-.
“tneqzed” means voltage applied acmss terminals @,I and (4,~
r
(2) If the result is not satisfactory, replace the control relay. E:-~
=-
e
AIR CONDITIONER RELAY N14RAAA ;-

Refer to GROUP~24 HEATERS AND AIR COFIDlTKINlNG. ~I a-:~.

--F
c.
WASTE GATE VALVE
Refer to GR(L)UP~li INTAKElAND EXHAUST SYSTEM.
 FUEL (EC11 SYSTEM - lniection Mixer 14-71
INJECTION MIXER N14NA- -

REMOVAL AND INSTALLATION

10.8-14.5 ft.lbs.

03Y753
Removal steps
1. Hose clamp
2. Air hose
3. Air intake pipe
4. Accelerator cable connection
5. Water hose connection
6. Vacuum hose connection
7. Engine control wiring harness connection
I)* 8. Fuel high pressure hose connection
9. O-ring NOTE
10. Fuel return hose connection (I 1 Reverse the removal procedures to reinstall.
11. Injection mixer (2) I)*: Refer to “Senke Points of Installation”
12. Gasket (3) q : Non-reusable parts
14-72 FUEL (ECI) SYSTEM - Injection Mixer

Injection mixer SERVICE POINT OF INSTALLATION NIQNDA

High pressure
8. INSTALLATION OF FUEL HIGH PRESSURE HOSE
When connecting the fsel high pressure hose to the _
injection mixer, coat the hQ.se union with gasoline and insert -
using care rv%to cause -damage to the O-ring.
 FUEL (EC11 SYSTEM - lniection Mixer 14-73

INJECTION MIXER N14NE- -

DISASSEMBLY AND REASSEMBLY

2.5-4.5 Nm----+3 - >L

1.6-3.3

1.5-2.5 Nk
l.l-1.8ft.lbs.

Disassembly steps
4I) I)4 1. Throttle position sensor (TPS) 22. Throttle cable bracket
5FU002E
2. Joint 23. Screw
3. Hose 24. Mixing body Injection mixer O-ring set
l 4 4. Screw I)+ 25. Seal ring
I)4 5. Injector holder 26. Throttle valve set screw (fixed SAS)
I)* 6. Fuel pressure regulator 27. Kickdown lever
7. O-ring 28. Adjusting screw
8. Pulsation damper cover 29. Free lever
9. Spring 30. Ring
l * 10. Diaphragm 31. Throttle lever
11. O-ring 32. Spring
+* l * 12. Injector 33. Return spring
C* l * 13. Injector 34. Throttle body
14. O-ring
15. Collar
l * 16. Seal ring NOTE
(1) Reverse the disassembly procedures to reassemble.
17. Damper spring (2) *I): Refer to “Service Points of Disassembly”.
18. Return spring (3) I)+: Refer to “Service Points of Reassembly”.
19. Connector bracket (4) •I : Non-reusable parts.
20. Connector bracket
4* 21. ISC servo assembly EC1711
FUEL (ECI) SYSTEM - Injection Mixer

SERVICE POINTS OF DISASSEMBLY

Caution
1. When loosening a Phillips screw which has been firmly
tightened, use a Phillips screwdriver that is an exact fit
for the screw.
2. Do not remove the throttle valve.
3. Do not remove the injector holder screen.
4. Do not remove the fuel return nipple.

1. REMOVAL OF THROTTLE POSITION SENSOR (TPS)

Do not remove- the throttle position sen-sor unless. it
requires replacement.

3FI J19:

12.13. REMOVAL OF INJECTOR

(1) Do not hold the injector by pliers when removing it.
(2) After removal of-an in@ctor, close the fuel inlet by seal
tape, etcr to prevent -entry of foreign matter.

21. REMOVAL OF ISC SERVO ASSEMBLY

(1) Do not remove the ISC servo assembly unless it
requires replacement.
(2) Do not disassemble the ISC servo assembly.

INSPECTION NllNGAA

INJECTORS
(1) Measure resistance of injector coils using a circuit tester.
Standard value: 2 - 3 fl [at 20°C (68”F)l
(2) If the resistance is out of sj%cification, replace the injector.

3FU194
 FUEL (ECI) SYSTEM - Injection Mixer 14-75
THROTTLE POSITION SENSOR (TPS) CONTINUITY CHECK
N14NJAA
Ground
(1) Measure resistance between terminals 1 and 3 of the
throttle position sensor using a circuit tester.
Standard value: 3.5 - 6.5 kR
(2) Check sensor body for cracks and .damages.

TPS output
TPS power
EC1717

ISC SERVO CONTINUITY CHECK N14NJBA

Measure resistance between terminals 1 and 4 using a circuit

tester.
Standard value: 5 - 11 fl [at 20°C (68”F)I

(Front view)
3FU20(

ISC SERVO OPERATION INSPECTION N14NJCA

Extend
(1) Connect 6V DC (four dry cells) to terminals 1 and 4 and .
check that the ISC servo extends and retracts,<by itself. ~_
Caution
Apply only a 6V DC or lower voltage. Application of
higher voltage could cause locking of the servo gears.

ISC servo motion r

i

(Front view) (Front view) 3~u2c

I When terminal 1 is 0 I ~ Retracts I
When terminal 4 is 0~ Extends

(2) If the ISC servo does not move, replace the ISC servo
assembly.
THROTTLE VALVE SHAFT INSPECTION N14NGBA

Check operation of the throttle valve shaft.. If it does not

operate smoothly and lightly, wash well and then apply a light
coat of engine oil to the shaft.

PARTS CLEANING N14NHAA

(1) Clean all parts. Do not use detergent to clean the following
parts:
l Throttle position sensor
0 ISC servo
Immersion of these parts in detergent causes damage to
insulation. Only wipe them with cloth.
(2) When cleaning the injectors and fuel pressure regulator,
close tightly the fuel inlet and outlet by sealing tape and use
clean detergent.
(3) Check the vacuum port and passage for clogging. Blow
compressed air in the vacuum and fuel passages to clean
them.
14-76 FUEL (ECI) SYSTEM - Injection Mixer

SERVICE POINTS OF REASSEMBLY NllNlAA

25. INSTALLATION OF SEAL RING

Make sure that the seal ring does not protrude from then-
groove. 1 I~ F

3FU195

16. INSTALLAnON OF SEAL RING

Install a new seal ring inthe mixing body. When fitting the
seal ring, make sure that its flat side faces up.

13.12. INSTALLATION OF INJECTORS

(1) Fit a newt O-ring and collar to the injector.
(2) Set the injector on the mixing body at correct position
,and push down firmly with a finger until it is seated.
Identification of injectors

Connector color Position Orifice

Blue Right Large

Gray ~~7 left Small

10. INSTALLATION OF DIAPHRAGM

Install the diaphragm in the injector hoIder in correctt:
direction as shown. _

6FUO5

6. INSTALLATiON OF FUEL PRESSURE REGULATOR

Fit a new O-riing to the regulator.
 FUEL (ECI) SYSTEM - Injection Mixer 14-77
-
5. INSTALLATION OF INJECTOR HOLDER / 4. SCREW
(1) Check the injector holder filter for clogging and damage. r
Replace if necessary.

Filter

(2) Set the injector holder and push it down firmly.

(3) Tighten the screw little by little and alternately. Finally
tighten to specified torque.

1. INSTALLATION OF THROTTLE POSITION SENSOR

UPS)
(1) Fit the joint “A” of throttle position sensor on the joint
“B” of throttle body and combine the throttle position
sensor to the throttle body by temporarily tightenivg the
screw.

6FUO4:

(2) Check correct installation of the throttle position sensor.

While moving the throttle lever in both open and close
directions, check that resistance between terminals 1
and 2 or 2 and 3 changes smoothly. If resistance
changes smoothly, the throttle position sensor ha?

43’
View S
2
3
been installed correctly.

AFTER REASSEMBLY INSPECTION N14NJDA

IDLE SWITCH CONTINUITY CHECK

(1) Using a circuit .tester, check continuity between the body
and terminal 2 when the throttle valve is fully closed and
when fully opened.
Extend 0
Throttle valve Continuity

Fully closed Conductive

Not used Fullv opened Non-conductive

(Front view)
(2) If otherwise than shown above, replace the. IX servo
3FU2Oi , assembly.
I --
14-78 FUEL (ECI) SYSTEM - Fuel Pump

FUEL PUMP
REMOVAL AND INSTALLATION

l Release of Residual Pressure

Removal steps
1. Fuel pump protector
2. Fuel pump
3. Fuel pump support

NOTE
Reverse the removal procedures to reinstall.
 FUEL (ECI) SYSTEM - Fuel Tank 14-79

FUEL TANK N74GA- -

REMOVAL AND INSTALLATION

Fi
l Release of Residual Pressure

Post-installation Operation
l Replenishment of Fuel I

031760

3
8

25-30 Nm I
03Y886
18-22 ft.lbs. 13 5*15-20Nm
1 I-18 ft.lbs.
Removal steps
1. High floor side panel
2. Fuel pipe cover
3. Fuel pump connector connection
4. Fuel tank cap
5. Drain plug
6. Fuel gauge unit connector connection
I)+ 7. Fuel high pressure hose connection
+4 8. Return hose
I)4 9. Vapor hose
10. Fuel filler hose
11. Fuel filler neck
12. Fuel tank
13. Electrical fuel pump
14. Separator tank FyT&verse the removal procedures to reinstall.
15. Fuel gauge unit (2) l *: Refer to “Service Points of Installation”.
16. Pipe assembly
17. In-tank fuel filter
14-80 FUEL (ECI) SYSTEM - Fuel Tank

INSPECTION N14GCAD

a Check the hoses and prpesfor cracks, bends, deformation,

wear or cloggrng.
@ Check the fuel t.ank cap for operation.
e Check the fuel tank for deformation, corrosion or cracks. .~
a Check the fuel tank for entry of dust or foreign -mater%+ ml
NOTE
If the inside ofthe fuel tank IS to be cleaned, use any one of ~~
the followrng:
(I 1 Kerosene-,
121 Trichioro$hylene -
(3) A neutral emulsion type detergent
e Check the In-tank fuel filter for damage or clogging.

SERVICE POINTS OF INSTALLATION N14GDAF

9. INSTALLATION OF VAPOR HOSE / 8. RETURN HOSE

When attachi.ng the hoses to the pipes, be sure that the
hose is attached -until its erid comes in touch with the bulge ~
of the pipe as -shown inYthe illustration.

03U001E I

7. INSTALLATION OF FUEL HIGH PRESSURE HOSE

When connecting the fuel high pressure hose to pump,
tighten the flarenut by hand, and then tighten it to 32 - 42 G
Nm.(23 - 30 ft.lbs.) being careful that the fuel hose does not boy
become twi$ted. .~

Secure side
03YO43
- -~ -
 . -c

FUEL (ECI) SYSTEM - Fuel Line and Vapor Line 14-81

FUEL LINE AND VAPOR LINE N14KA--

REMOVAL AND INSTALLATION

2330 ft.lbs.
Removal steps
1. Air cleaner
2. Eye bolt
*+ 3. Fuel high pressure hose
4. O-ring
5. Gasket
6. Fuel filter
** 7. Return hose
*+ 8. Vapor hose
9. Overfill limiter (two-way valve)
10. Purge control valve
11. Fuel check valve
12. Canister NOTE
13. Main pipe (1) Reverse the removal procedures to reinstall.
14. Return pipe (2) l *: Refer to “Service Points of Installation”.
15. Vapor pipe (3) q : Non-reusable parts
03Y700

INSPECTION N14KCAC

l Check the hoses and pipes for cracks, bends, deformation,

wear or clogging.
l Check the fuel filter for clogging or damage.
l Check the canister for clogging.
l Check the fuel check valve for malfunction.
14-82 FUEL (ECI) SYSTEM - Fuel Line and Vapor Line

1 To fuel injection mixer INSPECTION OF PURGE CONTROL VALVE

(throttle ported pressure applied) (1) Make sure that the engine coolant is at- a temperature
between 80 and 90°C (180 and 190°F). -
(2) Disconnect the purge con%& hose from the air cleaner and T
To fuel injection
mixer (turbocharged blow into the purge hose. If the valve is not open, its mE
pressure applied) operation is normal, Thenstart the engine and increase the L
+ Purge air outlet engine speedto 1,500 to 2,000 rpm and blow into-the purge T
- (to air intake hose) hose. If the valve is not open, check for clogged or broken ~~
vacuum hose, -or malfunctioning thermo valve.
Purge air inlet
Q (from canister) EC1119
-
INSPECTION OF OVERFILL LIMITER (TWO-WAY VALVE)
A simple way of inspection, however, may be adopted in which
the overfill limit@ is removed and then air is lightly blown into ~
either the inlet or outlet by mouth. If the air passes afEr a slight __
resistance, overfill=_ltmiter is-in good condition.

SERVICE POINTS iiF IiSTALLATlON N14KDAA

8. INSTALLATION OF VAPOR HOSE / 7. RETURN HOSE

When attaching the hosEs to the pipes, be sure that the
hose is attached until its end comes in~6uYiwithithe bulge ~5
of the pipe :aS shown in the illustration. ~_.

03u0019

3. INSTALLATION OF FUEL HIGH PRESSURE HOSES ---I

High pressure hase Injection mixer
(1) When connecting th3 fuel high pressure h_ose to theme;
injection mixer, apply gasoline to the hose union. Then
insert the hose, being careful not to damage the O-ring,.:
and tighten securely.
Caution
Because there is high pressure applied between the
fuel pump and the injection mixer, be especially
sure that there is no fuel leakage in this area.

(2) When connecting the fuel high press&e hose to pope,--

tightenthe flare nutb hand, and then tighten it to 32 ---
42 Nm (23; 30 ft.lbs.), being careful that the -~ fuel hose_
does nut become twisted.

Secure side
I 03YO43
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline

OUTLINE N14TAAC

AUTOMATIC SPEED CONTROL CONFIGURATION

Vehicle speed sensor
^---‘--ator cable (Reed switch)
vacuum pump relay
\ I Speed control switch /
Check valve Diagnosis
I connector I /
\\ Vacl Jum
:ch

7troI

\ inhibitor switch *’

“I : Vehicles with a manual transmission

I Cl&h switch
Stop light switch
*I

*2: Vehicles with an automatic transmission

16Y2904

System Block Diagram

Control switch

16Y2922
-- --~ s
e
-&+y*
CT==
s--
14-84 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline
Components and functions

Control switch

Controls ASC functions by SET (Coarse) and RESUME (Accel)

Vacuum system Generates vacuum to make up vacuum (intake manifold pressure)

when it is insufficient to drive the actuator

vehicles with an
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline 14-85
CONSTRUCTION AND OPERATION N14TBAC

ACTUATOR

Section A-A

Section B-B

Section C-C

16Y2921

The actuator is a diaphragm type vacuum servo which consists

of a diaphragm, return spring and two solenoid valves (control
Intake
valve and release valve) to control the vacuum.
In absence of signals from the ECU, the vacuum port is closed
and the atmosphere ports 1 and 2 are open as illustrated. When
the control valve is turned on, the atmosphere port 1 is closed
and the vacuum port is open, vacuum is introduced to open the
throttle valve.

I ’ Release valve
Control unit 16Y289:

VACUUM PUMP
This pump which is a diaphragm type generates vacuum to
secure control function when the intake manifold vacuum is
insufficient due to high load or other conditions.

16Y2935
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline

VACUUM SWITCH
This switch detectsis the pres%ure in the intake manifold and
operates according to that pressure as shown below, transmit- ~
ting the signal tcr operate the vacuum pump to the vacuum
pump relay.

2~5 + 15

16Y1191 16Y122

600 -150 f. 15
(-5.9 + 0.4) 16Y28B4
Pressure __=- y- - Vacuum

VACUUM PUMP RELAY

e-1
This relay operates the vacuum pump when thevacuum switch
is turned on.
L- 2 - 4-

16K36E

VACUUM PIPINGS

Vacuum
pump

I I I

r-
Vat :uum tank Injection
for automatic
air cnnditinner
_-. .-._ -
mixer
b-l Check valve

Vacuum switch

1tiY.2910

The actuator is driven by the vacuum of the injection mixer. In

case the vacuum drops to such level as to actuate the vacuum s
_~~~
switch, however, the vacuum pump is started and the vacuum FgP7
generated by the pump is used-to drive the actuator. The cheek ~ ~~g-
valve serves to prevent flow from the injection mixer side when -“i’ :
:
the vacuum pumpis-in operation and to prevent application of m: g:
positive pressure due to turbocharging.
&;
E-,
E!!L-~
& -“-I
&z&
p”
-c.
E;
--
 AUTOMATIC SPEED CONTROL IASC) SYSTEM - Outline 14-87
ELECTRONIC CONTROL UNIT (ECU) BLOCK DIAGRAM

16Y2916

The ECU with a built-in microcomputer has the current vehicle

speed set, deceleration set, acceleration set, resume, cancel,
low speed limit and high speed limit functions and the fail-safe
function.
The microcomputer outputs the control signals to the two
solenoid valves (release and control) of the actuator according
to the signals from the vehicle speed sensor and the switches.
The ASC operates only when the MAIN switch is on.
(1) Current vehicle speed set function
When the SET switch is pressed while driving within the
vehicle speed setting range of 40 21 3 to 200 + 5 km/h (25
t 2 to 124 -f- 3 mph), the vehicle speed when the switch is
turned from on to off is stored as the set vehicle speed and
thereafter the actuator is so controlled as to keep that
speed. The timing chart is shown below.
 14-88 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline

ON
MAIN switch
OFF

ON
SET switch
OFF

Release ON
valve OFF
ctuator I

! Control ON
valve
OFF

16Y2897
-

@ set up
In order to quickly control the throttle to specified
opening and to minimize vehicle speed variatlons after
the ASC has been set, a signal is output-whose pulse
width is set- based on the relationship between the
vehicle speed on a level road and with the actuator ~
operation rdelay and cable play amount taken into
account.
* Duty
After set up, the vehicle speed is measured successive- -=
ly by the-vehicle speed sensor and the set speed and
the actual sp-eed are compared. Based on this compari- mm
son, the energization time (duty) of the control valve and
consequently the throttle opening are controlled. When
the actual~ speed is higher than the set speed, the
control valve energization time is decreased for smaller
throttle valve opening. On the other hand, when the
actual vehicle speed becomes smaller than the set _
speed, thecontrol valve energization time is increased _
for largerthrottle valve openrng.

0 % duty Runs at set speed Max. 90 % duty

Actual speed larger than set speed Actual speed smaller than set speed
I ..-
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline 14-89
(2) Deceleration set function
When the SET switch is held down while driving in the ACS
mode, the vehicle continues to decelerate and when the
switch is released, the vehicle speed at that moment is
stored as the set speed. Thereafter, the actuator is so
controlled as to keep that speed.

ON
SET switch I I
I I
I I
I
I I
Release ON I
I I
valve OFF I
I
I
Actuator I I

Control
valve
ON
OFF Lllllll

16Y2899

(3) Acceleration set function

When the RESUME switch is held down (ON) while driving
in the ACS mode, the vehicle continues to accelerate and
when the switch is released (OFF), the vehicle speed at that
moment is stored as the set speed. Thereafter, the actuator
is so controlled as to keep that speed.

ON
RESUME switch 1
OFF I
I
I I
I
I
I
Release ON I
I
I
valve I
OFF 1 I
I I
Actuator -+ Approx. 0.5 sec. I
I
, I
Control ON
valve OFF - 1111111111 1111111
1 wt

16Y2900 _

(4) Resume function

After cancelling the ASC mode by the method described in
0, @ or @ of item (5), if the RESUME switch is turned on
while driving within the speed setting range, the vehicle
speed that was stored before cancelling the ASC mode is
resumed and thereafter the vehicle is run at that speed.
In case the speed has once dropped below the lower limit
speed [item (6)] or cancelling has been made by the method
given in @ or @ of item (5), the stored vehicle speed is
cleared and hence this function does not work.
AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline
(5) Cancel function
When any of the followingsignals is input while the vehicie
IS runnrng rnthe AX mode, srgnais to the two solenoid
valves of the~actuator are cut off to cancel the ASC mode.
I~I Stop light switch ON_(the brake pedal depressed)
(21 Clutch switch ON (the clutch pedal depressed) . . . ..
Vehicles with a manual transmission
13 I Inhibitor switch ON (the selector lever set to N position)
..:: Vehicles with an automatic transmission
141 MAIN switch OFF
i 31 Ignition switch OFF I-
In case the AX mode hasbeen cancelled by the signal KI,
i 2 I or (3). the set vehicle speed is kept stored.
(6) Low speed limit function-
When the vehicle speed drops to the low limit speed of 40
? 3 km/h (25 -& 2 mph) or lower, the ASC mode is cancelled
automatrcally.
(7) High speed limit function
In case the acceleration operation described in item (3) is
made while running at aspeed lower than the high speed
limit of 206~-~ 5 km/h T124 +- 3 mph), the vehicle is
accelerated to the hioh speed lrmrt and thereatter runs In
the ASC mode at that speed.
In case the current vehicle speed setting [item (111is made
while running at a speed higher than the high speed limit,
the-high limit speed is stored as the set speed and control is
made to keep that speed.
(8) Auto cancel function (indudinq fail-safe function)
When any otihe~following_signals is input while the vehicle
IS runnrng rn the ASC moae. signals to the two solenoid
valves of the actuator are cut off to cancel the ASC mode.
When the-vehicle speed drops to the low speed limit or
lower.
When the vehicle speed drops to a speed about 20
km/h (12~_mph) lowerthan the set speed.
When the vehicle speed once recovers to the set speed
less about IO km/h (6 mph) and then drops again more
than 20 k-m/h (12 mph) during the RESUME mode.
When depression of the brake pedal causesthe stop
light switch to turn onrn case the stop light fuse has
been blown.
When the stop light switch has an open crrcmt.
When the vehicle speed signal has not been input for a
fixed time-
When them SET switch- and the RESUME switch are
turned on simultaneously.
When the SET switch or the RESUME switch is turned
on srmultaneously with the CANCEL’ switch,.
When the-r,ontrol/release valve drive output transistor
has a short circuit
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline 14-91
VEHICLE SPEED SENSOR
The vehicle speed sensor sends to the ECU a pulse signal
Reed.swZch type proportional to the rotating speed (vehicle speed) of the output
gear of the transmission. It is mounted in the speedometer.
The sensor is of the reed switch type, and generates four pulse
signals at every rotation of the output gear. The sensor is
shared in common by other electronic control systems and in
the event of failure of the sensor itself, some troubles will
occur in all systems using it so that the failure of the sensor can
be known easily. The vehicle speed sensor input terminal of the
12R005C ECU is pulled up to about 12 V power via a diode and resistor as
illustrated.
Control unit

ASC CONTROL SWITCH

The MAIN switch to turn on/off the ASC control unit power and
the ASC command input switches (SET switch and RESUME
switch) are mounted on the column switch lever to the right of
the driver.

68Y531

Fusible link
~I--~CC(II Ground
1
Regulated power
supply circuit \d ignition switch

I MAIN

- SET
0
RESUME
Micro-
computer 0 Indicator

_I
Control unit
Ground

Actuator
solenoid valve
16Y2896
14-92 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline
(1) MAIN switch
This switch -turns on/off the power. When the swatch IS
turned on while the ignition switch IS in the ON position,
power IS supplied to the KU and the indicator in the switch __
lights up. Atthe~same time, power IS also supplied to the .
solenoid valves-of the actuator, to enable ASC *operation.
(2) ASC command input switches (SET and RESUME switch- __
4
The SET switch and the RESUME switch are both used to .L
Input the ASC control signals. Both are auto rese!, normal ~~~
open type switches. TV
The ECU input interface kpulled up by the battery voltage
and the terminal voltage goes low (0 V) when the switch is
on and goes high (approx. 12 V) when it IS off.
CANCEL SWITCHES
The cancel switches includezhe stop light switch, the clutch
switch (vehicles~ with a manual transmlssron) and inhibitor _
switch (vehicles with an automatic transmissron) and the ASC .._
is cancelled when any ot these rs operated, ~~

-
IG

ST

: Clutch switch
(manual transmission)

1 I

Inhibitor switch
(automatic transmission) Starter

r”
II
Micro-
computer

v I
II Clutch switch Vacuum pump 2
Stop light relay - - _~~~
I-..-
II 16Y2911
; x_
 .. -
AUTOMATIC SPEED CONTROL IASC) SYSTEM - Outline 14-93
(1) Stop light switch
Stop light circuit The switch is highly reliable with the stop light contact and
the ASC contact provided separately. When the brake pedal
OFF I ON is depressed, the ASC cancel contact of the stop light
switch opens to cut the signal to the actuator release valve,
thus cancelling the ASC. For auto cancel (fail-safe) function,
the power side and load side signals of the stop light switch
are also .ir$ut to the control unit.

ASC ckuit
7 6R099i

(2) Clutch switch

The contact of this switch closes when the clutch pedal is
depressed. When the clutch pedal is depressed during
driving in the ASC mode, the mode is cancelled.

(3) Inhibitor switch

The starter circuit and the inhibitor switch (provided for
automatic transmission control) signals are input to the ECU
as in the case of the stop light switch circuit. When the
selector lever is set to the neutral (N) position while driving
in the ASC mode, this signal causes the ASC to. be
cancelled:

16R103

SELF-DIAGNOSIS AND INPUT CHECK FUNCTIONS

(1) Self diagnosis
When there is a cancelation of the ASC system operation
not intentionally made by the driver, it is possible to
determine which circuit or what operation caused the
cancelation of the ASC system by (without stopping the
engine) stooping the vehicle (with the MAIN switch still ON)
and then connecting the diagnosis tester or a voltmeter to
the diagnosis harness connector.
NOTE
The display of the malfunction data starts if the vehicle
speed decreases to less than approximately 20 km/h (12
mph) after the cancelation of the ASC system function, and
stops if the vehicle speed increases to approximately 20
km/h (12. mph) or higher.
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline
Self-diagnosis descriptions and displays

Code Diagnosis item Display patterns Self-diagnosis description

No.
[Display pattern (when~ECUnormafI
I I I when vehicle speed is approximately
Continuous signal 20 km/h (12 mph) or higher, and
before fixed-speed driving has been
OFF set.]

Actuator drive (Example) Code No. 13 The control valve or its driving
circuit transistor, the release valve or its
driving transistor, or the brake switch
is damaged (open).

Vehicle speed Vehicle speed signal is not input for

signal circuit one second or longer.
malfunction

Low-speed limiter When the vehicle speed decreases

circuit OFF to-40 km/h (25 mph) or lower.
(OV)
Redundant brake When actual vehicle speed decreases
to approximately 20 km/h (12 mph)
ormore below the memorized vehicle
speed.

Control switch ahen the SET switch and the

RESUME switch are switched ON at
malfunction
3
I
2
Pause time: 3 seconds OFF
“Tens” rank signal:
1.5 second ON (called “IO”)
the same time.

iNhen cancel Rank division: 2 seconds OFF ~~ A/hen the stop light switch, clutch
signal is input “Units” rank signal: switch or inhibitor switch is
0.5 second ON, 0.5 second OFF signal switched ON, or there is damaged
(The number of ON periods is the number 3r disconnected wiring of the stop
of “unit” ranks.) ight switch input wire.

(2) Input check function

When the ignition switch is ON, and with the SET switch
and the RESUME switch ON (simultaneously pressed), the
input check mode can be selected by switching ON the
MAIN switch, thus permitting checking of the input circuits
In the same way as for self-diagnosis.
NOTE
1. The input check mode can be canceled by switching the
MAIN switch OFF. 1
2. The ASC system does not function during the input
check mode.
,& All of the code numbers in the table below are ~
sequentrally displayed in order from the lowest number.
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Outline
Input check mode

Code Input signal condition Display patterns,

No.

21 SET switch ON signal received. (Example) Code No. 23

22 RESUME switch ON signal received. F 3 flql+2q5&jc 3?
23 Cancel switch ON signal received.
(Stop light switch ON, clutch switch or inhibitor
switch ON)

24 Vehicle speed 40 km/h (25 mph) or higher signal

received. Ix x, A r ’

25 Vehicle speed less than 40 km/h (25 mph) signal 0

received.

8
I Pause time: 3 seconds OFF
2 “Tens” rank signal:
1.5 second ON, 0.5 second OFF;
then 1.5 second ON (called “20”)

8
3 Rank division: 2 seconds OFF
4 “Units” rank signal:
0.5 second ON, 0.5 second OFF signal
t;lh;sn;lmber of ON periods is the number of “unit”

03R0197
14-96 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Specifications

SPECIFICATIONS NWCA-6

GENERAL SPECIFICATIONS

Items

Rated load A
ON
SET, RESUME 0.1 -0.3 c
Voltage drop between terminals V
ON

Rated load A
Voltage drop between terminals V 0.15 cr less -i

Rated load A
0.15 or less

Set error [At 80 km/h (50 mph)] km/h (mph)

Vehicle speed memory variation [80 km/h (50 mph),
30 minutes at normal temperature] km/h (mph)

Servo type
Diaphragm stroke mm (in.)
Effective diameter mm (in.)
Effective area cm2 (in.‘)

Type
Rated current A 1.6 or less -

Jacuum switch
Cut-in vacuum mmHg (in.Hg) 130 - 160 (5.5 - 6.3)
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Specifications 14-97
S’ERVICE SPECIFICATIONS N14CB.B

Items Specifications

Speed’control system
.Terminal resistance of solenoid valve in actuator
Release valve 0 Approx. 60
Control valve Sz Approx. 30
Actuator stroke mm (in.) 36 (1.4)
Vacuum pump vacuum mmHg (in.Hg) 150 (5.9) or more
Control cable play mm (in.) O-3(0-.12)

LUBRICANT

Items . Specified lubricant Quantity

Grease for the moving points of the MOPAR Multi-mileage Lubricant As required
accelerator arm Part No. 2525035 or equivalent
14-98 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

TROUBLESHOOTING N14EBDC

BEFORE STARTING TROUBLESHOOTING

The ASC system controls setting and canceling of constant
driving speed based on various Input slgnal information.
For this purpose, the electronic control unit (ECU) has the y
self-diagnosis futiction to store the causes forcanceling of the 1
AX system operation regardless of whether the system is ;
normal or faulty and to display the causes In predetermined
patterns and the input check function to check whether or not .;
the ECU input &vitch or seYisor..Ls normal.
Through effective use of these functions, you can shorten the
Diagnosis harness connector-- time taken to troubleshoot, -check and repair the system.
-------
SELF-DIAGNOSIS CHECK
The self-diagnosis check is tcr_be made when the ASC system
is automatically canceled even if no attempt is made to cancel
the system. L-
Caution
The diagnosis code memory is cleared if the ECU power
(ignition switch or MAIN switch) is turned off. Keep the
power on, therefore, until the check is completed.

1. Connect a vol&-rieter between the ASC terminal and ground __.

terminal of the diagnosis-harness connector located at the TV
top in the glove compartment.
2. By checking -the voltmezter reading against the display
patterns shown below, the causes for canceli@ can be _
known.,
3. In case diagnosis code No. 1 1, 12, 15 or 16 is displayed,
check according to the check chart of number correspond-
ing to that code.
NOTE
DW762 There are six diagnosis items including those oT normal _
state The normal states tiean such states 3s code No. 16 I=
being stored as the cancel swrtch ON signal input &hen the
ASC system is canceled by depressing the brake pedal or
code No. 13 xx- 14 being stored when the ASC system is
canceled automatically due to decreased vehicle speed
resulting from driving along a sharp hill in the constant I
speed drivirqg mode.
In case the system is anceled contraryto the driver’s
Intention, however, the same code No. 16 can mean an i
open clrcult~rn the stop light switch input wire, stop light
switch ON failure or other troubles.
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting ‘14-99

Diagnosis display patterns

Display patterns (output codes) Probable cause

,
11 Abnormal condition of actuator drive system

12 1 2 Abnormal condition of vehicle speed signal system

12v

ov
13* 1 3 Low-speed limiter activations
12v (The system is normal if it can be reset)
ov
14"
12v
1 4 Automatic cancelation activated by vehicle speed reduction
(The system is normal if it can be reset)
ov
15"
12v
1 5 Control switch malfunction
(When SET and RESUME switches switched ON simultaneously)
ov
16" 12v
1 6 Cancel switch ON signal input (including stop light switch input

I I ov
wiring damage or disconnection)

03R0193

NOTE
1. Codes indicated by the *symbol are displayed, if the
conditions are satisfied, even if the system is normal. In
either case, the system is normal if it can be reset.
If there is an automatic cancelation not intentionally made
by the driver, however, excluding cancelations explicitly
made by the cancel procedure, there may be a temporary
malfunction such as poor contact of a harness connector
even though the system can be reset, and for that reason it
is necessary to check according To each individual check
chart that is applicable.

I
2. Diagnosis codes are displayed when, after cancelation, of
Display when vehicle speed is approx-
imately 20 km/h (12 mph) or higher, or the ASC system, the vehicle speed decreases to less than
before the ASC system is set. approximately 40 + 3 km/h (24.9 + 1.9 mph), and are
erased by switching OFF the ignition’switch or the MAIN
switch. When, after the diagnosis memory has been
0.5 set 0.5sec erased, the ECU power supply is once again switched ON,
the diagnosis output code will change to ON and OFF
signals at 0.8second intervals (as shown in the illustration
at the left) if the ECU is normal, regardless of whether or
not the system is normal.
03R0196
14-100 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshootinn

INPUT CHECKING
Input checks should be made when the ASC system cannot be- ’
set, and when it is necessary to check (when a malfunction ’
related to the ASC system occurs) whether or not the input mm
signals are normal.
NOTE
1. Input checks-can be made by certain fixed operations, and em
the terminal-that outputs~the display patterns is also used I
as the self-diaanosis terminal.
2. Display codes are ~displayed only if the circuit is normal
according to the- conditions shown in the table on the next :
page-
1. Connect a voltmeter be&veen ground Andy the diagnosis
harness connector’s ASC~ terminal (located at the inside 1
upper part o-the glove Icompartment).
2. Turn the ignition key to ON. (Check No. 1 to No. 3 of the .~
input check table.)
3. Start the engin~e. (Check No. 4 and No. 5 of the input check I
table.)

03Y762

4. Code call-out
(1) Turn ON the SET switch with the RESUME switch kept
ON.
(2) This procedure makes it possible to display the results
of the input check.
Caution
The ASC cannot be set during input check display. If
it is necessary to check the self-diagnosis, check the
input (after checking the diagnosis code) before
switching OFF the MAIN switch.
68Y531
5, Code read-out
(1) Perform peach input operation according to the input
check table and read out the codes.
NOTE ~~ 1
Each code will be displayed in an order of priority
beginningfrom No. I.
If there is no display, it is possible that there is a ~
malfunction of the ECU power-supply circuit or the SET
and RESUME switch, so check according to check
charts 0, 1 and 2. (Refer to P.14-108.)
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-101

Input check table

No. Input operation Code Display patterns Check results

No. (output codes)

1 SET switch ON SET switch circuit normal

I

2 RESUME switch ON 22 RESUME switch circuit

12v normal
ov
3 Each cancel switch ON 23 Each cancel switch circuit
1. Stop light switch normal
(brake pedal depressed)
2. Clutch switch *l 12v
(clutch pedal depressed)
3. Inhibitor switch ** ov
(shift lever to “N” range)

4 Driving at approximately 24 When both No. 4 and No. 5

12v
40 km/h (25 mph) or can be confirmed, vehicle
higher ov speed sensor circuit norma

5 Driving at less than 25

approximately 40 km/h 12v
(25 mph) or stopped
ov 03Fio192

NOTE
“1: Vehicles with a manual transmission
“2: Vehicles with an automatic transmission

(2) Switch the MAIN switch OFF.

NOTE
1. When each input operation is performed and the
signals for the conditions are received by the
computer, each output code will be repeatedly
displayed in the sequence of priority for as long as
that signal continues.
2. If, during the display of output codes, the input
operation is canceled (if, for example, the SET
switch is set from ON to OFF), the code will be
displayed for one cycle of the display, but will not be
displayed during the next cycle.
This makes it possible, therefore, to check the OFF
condition (existence or not of a short-circuit of the
input line or the switch).
3. The standard input check procedures and the
display patterns at that time are shown on the
following page.
14-102 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting
lput Check Procedures and Display Pattern Examples (when system is normal)

(3 SET switch: ON
RESUME switch: ON
MAIN switch: ON
All cancel switches: OFF
Vehicle speed:
_: Less than 40 km/h (25 mph), or stationary

(RESUME switch code disappears)

(Cancel switch code disappears) (Cancel switch code appears)

Vehicle speed 40 km/h

(20 mph) or higher

[Cancel switch code and vehicle speed less

than 40 km/h (25 mph) code disappear;
vehicle speed 40 km/h (25 mph) or higher appears]
AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-103

HOW TO TROUBLESHOOT
Caution
In case the system is canceled contrary to the driver’s
intention during constant speed driving, do not turn off the
ignition switch or the system MAIN switch or disconnect
the battery as such switch operation or battery disconnec-
tion causes the data stored in the computer (self-
diagnosis) to be lost for ever.
1. Select the corresponding trouble symptom from the Flow-
chart by Trouble Symptom (Symptom 1, 2) and from Other
Trouble Symptom Chart (Symptom 3 to 10).
2. Perform preliminary check (in the case of Symptom 2 to
IO).
3. Check in the order shown in the Flowchart by Trouble
Symptom or List.
4. If the check indicates all are okay, replace the ECU.
PRELIMINARY INSPECTIONS
1. Check that the accelerator and accelerator wires are
installed normally and wires are connected normally.
2. Check that the accelerator moves smoothly.
3. Adjust so that the control cable may not have excessive
play or tension.
4. Check that control unit, actuator, control switch and cancel
switch connectors have been connected securely.
 ~-__
e-v_

14-104 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

FLOWCHART BY TROUBLE SYMPTOM

SYMPTOM 1
.ASC: Automatic speed control _
ASC system is canceled without canceling ECU: Electronic control unit
operation or ASC system cannot be set
after it has been automatically canceled

No
Do ignition switch and MAIN switch * Can ASC system be set currently?
remain ON after trouble?
I I I
1
Yes Yes No
I

(7)
I Is trouble reproduced?
f
No (Normal)
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-105

SYMPTOM 2

ASC system cannot be set NOTE

If the ignition switch and MAIN switch are
kept ON after occurrence of the trouble, the
system that is responsible for canceling can
-be known by checking the diagnosis output
Prepare for input check code.
(Refer to P. 14-100.) This chart indicates troubleshooting’method
I in case self-diagnosis function is not
available.

l Open circuit in ECU power supply circuit

[go to check chart 0 (P.14-10811

[go to check chart 1, 2 (P. 14-10911

Yes

Are input check results okay?

Yes No

Check result Probable cause Remedy Check chart No.

Code No. 21 does not go out SET switch ON failure Replace control switch
when SET switch is turned (P.l& 09)
off Short circuit in SET Correct harness
switch input wire

Code No. 22 does not go out RESUME switch ON Replace control switch
when RESUME switch is failure (P.&IO)
turned off
Short circuit in RESUME Correct harness --
switch input wire

Code No. 23 does not go out Cancel circuits faulty Check and correct cancel 5-1, 5-2, 5-3
when cancel switch is turned (ON failure) circuits (P.14-114)
off

Code No. 2 does not go out and Vehicle speed sensor Check and correct vehicle-
code No. 24 is not displayed circuit faulty speed sensor circuit (P.1‘&11)
when vehicle speed is (open or short circuit)
increased to 40 km/h (20 mph)
or more

r l

l
Check actuator circuit
[go to check chart No. 4 (P.14-112)]
Check vacuum circuit
[go to check chart No. 7 (P. 14-120)]
Check vacuum pump circuit
[go to check chart No. 6 (P.14-118)]
NOTE
If results of each circuit check and independent
part check are okay, replace the electronic control
unit (ECU).
14-I 06 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

OTHER TROUBLE SYMPTOM CHART

edometercable or
dometer driven

ASC system is not can-

celed when clutch pedal is
depressed (vehicles with
a manual transmission)
[ASC system is canceled,
however, when brake
pedal is depressed]

with an automatic trans- according to check

mission) [ASC system is chart No. 5-3 (P. 14-l 161
canceled however when
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshootina 14-107

No. Symptom Probable cause Check method Remedy

8 ACCEL or RESUME by Open or short circuit Check according to Correct harness or

SET switch is impossible in RESUME switch input check chart No. 2 replace RESUME
circuit (P.14-112) switch

Poor actuator circuit Check according to Correct harness or

contact check chart No. 4 replace actuator
(P.14-113)
Actuator faulty

ECU faulty - Replace ECU

9 ASC system can be set or Vehicle speed sensor Check according to Correct vehicle speed
is not automatically circuit faulty check chart No. 3 sensor system or
canceled when vehicle (P.14-111) replace part
speed is below 40 km/h Speedometer cable or
. (20 mph) speedometer driven
gear faulty

ECU faulty - Replace ECU

IO When ASC system is set Open circuit in ECU Check ECU terminal Correct harness
while driving over about terminal No. 6 No. 6 grounding wire
110 km/h (68 mph), vehicle (High-speed change-
is decelerated to about over input terminal)
110 km/h (68 mph) and grounding wire
keeps that speed
ECU faulty - Replace ECU
 -_____-..

14-I 08 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

,O. Checking ~ECU power supply circuit

lgnrtion
switch
Fuse No. 14 To resistor

Sub fusible link

l-
Battery
1,

6,
-
ECU f -^

(ECU connector terminals) (Front harness side]

Probable cause Remedy

Replace fuse
Correct harness

Replace speed
control switch or
correct harness
(Refer to P.14-134.)

Correct harness

Correct harness

I. If the diagnoses codes or input check codes can be confrrmed. the ECU power supply circuit can be judged as normal. In this case,
checking with thus chart IS unnecessary.
2 For measurement of the terminal voltage or contrnuity test, use extra-tinecheck probes and apply them to correct terminals.
3. If all above check results are normal, the ECU power supply circuit is okay.
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooling Id-109
”
.’ .’ ..
I. Checking SET swit,&, circuit
”

0A Speed control switch

I
LB) (R)

--- ECU
--7 (B)

(ECU connector terminals) (Front harness side) (Speed control switch side)
03Y743

-r
Check method T JudFi Probable cause Remedy
Check item Normal Faulty
Continuity Eirtt; continuity With continuity, Open or short Replace speed
between @ con- remaining at 0 Sz circuit in SET control switch or
nector terminals t switch or harness correct harness
HR) - (WI Without’ Without conti- (Referto P.14-134.)
continuity nuity, remaining
(m a at ~0 fi
Ignition switch: Continuity With continuity With continuity, Short circuit in Correct harness
OFF position between ECU remaining at wire (LB) be-
@connector: terminal and (o? OR tween ECU and
Connect ground Without @ connector
ECU connector: (2 -Ground) continuity
Disconnect (a a Without conti- Short circuit in Correct harness
SET switch: nuity, remaining @ connector wire
ON -OFF at 00 R 2-B or wire (LB)
between ECU and
@connector

NOTE
1. If the indicator light comes on when the MAIN switch is turned on with the ignition switch, in the ON position, the @ connector
2-B wire is okay.
2. For measurement of the terminal voltage or continuity test..use extra-fine check probes and apply them to correct terminals.
3. If all above check results are normal, the SET switch circurt IS okay.
‘14-l IO AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

2 Checking RESUME switch circuit

I
--p-q -- [-j--p--{

(ECU connector terminals) (Front harnessside) (Speed control switch side)

03Y742

1 Check method Jud< F

Step Probable cause
Normal
1 Ignition switch: Continuity Fi;t continuity
OFF position between @con-
@ connector: nectar terminals 5
Disconnect L(Y)-WI Without (Refer to P. 14-l 34.1
RESUME switch: continuity
ON-OFF (a n)
2 Ignition switch: Continuity Fit$ continuity
OFF position between ECU
@connector: terminal and 5
Connect ground Without
ECU connector: (1 -Ground) continuity
Disconnect (a a
RESUMEswitch:
ON c-, OFF

NOTE
I. If the indicator light comes on when the MAIN switch is turned on with the rgnrtron swrtchrn the ON positron, the @I connector
2-B wire is okay.
2 Formeasurement of the termrnal voltage or contrnurty test, use extra-tinecheck probes and apply them to correct terminals. _
3, If all above check results are normal,the RESUME switch circuit is okay.
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-111

3. Checking vehicle speed sensor circuit

Combination meter ECU

r -- -1 -1

circuit I
8 Reed switch I I

L m-e i

(Front harness side) (ECU connector terminals) 03\174,

Check method Judgement

Step Probable cause Remedy
Condition Check item Normal Faulty
When driving at Error exceeds Poor speedometer Correct orreplace
indication error 40 km/h (25 mph), specified limit cabling or oil speedometer cable
‘i km/h or large pointer entering (Referto GROUP
Service Manual deflection 21 TRANSMISSION
Vol. 2 GROUP 8 21.5 mph -Service Adjust;
ELECTRICAL - ment Procedures.)

Speedometer Replace speed-

driven gear ometer driven
faulty gear (Refer to
GROUP 21
TRANSMISSION -
Speedometer
Sleeve Assembly.)

ECU terminal IOVormore Remains at 10 V Open circuit in Replace meter

voltage (3 - 5 or more vehicle speed assembly or correct
Ground) when 0 V (changes 4 sensor (reed harness (Refer to
speedometer times per every switch) or in Service Manual
inner cable is cable rotation) harness Vol. 2 GROUP 8
turned slowly ELECTRICAL -
MAIN switch: Remains at 0 V Short circuit in Meters and
vehicle speed Gauges.)
sensor (reed
switch) or in
harness

Unstable voltage Poor connector Check connector

change terminal contact terminal contact
pressure and
correct

NOTE
1. For measurement of the ECU terminal voltage, use extra-fine check probes and apply them to correct terminals.
2. If all above check results are normal, the vehicle speed sensor system is okay.
Caution
When speedometer indication error is checked with a speedometer tester, apply chocks to the driven
wheels to prevent the car from running away.
 pi f j__

14-I 12 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

To fuse No. 14 (IGJ *-L- f- _ _ _ L TorEto’

Speed control switch

ECU

1 I Actuator

r- -----I

Power
1 SUPPlY :
I I
L- em--- -J

t
To stop light switch

-
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-113

NOTE
The following check chart assumes that the circuit (ECU power supply circuit) indicated by broken lines in the
illustration is normal.

Check method Judgement

Step Probable cause Remedy
Condition Check item Normal Faulty
1 Disconnect ECU @ connector Battery voltage 0V Open circuit in Correct harness
harness connector (harness side) harness L wire
Ignition switch: terminal voltage between column
ON position (L - Ground) switch and @
MAIN switch: connector
ON position
2 Ignition switch: Resistance fpRqx. 30 fi ai-2 Open circuit in Replace actuator
OFF position between @ con- solenoid (Refer to P.14-135.)
Disconnect @ nectar (actuator pf,,. 60 fl
connector side) terminals Resistance too Short circuit in
(of solenoid) small solenoid
(L-R) (L-Y)
3 Connect @ ECU terminal Battery voltage 0V Open circuit in Correct harness
connector and voltage harness [(R), Y,
disconnect ECU (IZ-Ground) R] wires between
harness connector (4-Ground) actuator and ECU
Ignition switch:
ON position
MAIN switch:
ON position

NOTE
For measuremeniof the ECU terminal voltage or resistance, use extra-fine check probes and apply them to correct terminals.
 14-I 14 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

Checking stop light switch circuit

Sub fusible link

-
II

Stop light switch

*1
Xi To cluster switch

NO: Normal open

NC: Normal close (Front harness side) (ECU connector terminals) 03Y745 I
Check method Judgement

az
Step Probable cause
Normal

Battery voltage
harness connector side connector
terminal voltage
(8 -Ground)

Disconnect ECU ECU harness

harness connector side connector
ON c-, OFF terminal voltage
(9 -Ground)

Disconnect ECU Continuity

harness connector between ECU
g;p lig$;;witch: terminals
c, (5 - 12)
switch or correct

NOTE
I, For measurement of the terminal voltage. use extra-fine check probes and apply them to correct terminals,
2, If all above check resultsare normal. the stop light switch circuit is normal (the stop light must come on).
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshootincl 14-115

5-2. Checking clutch switch circuit

Vehicles with a manual transmission

ECU

Clutch switch

-
m
YZ
B *I
f7B
(Front harness side)
(ECU connector terminals)

03Y744

Judgement T Probable cause Remedy

Check item Normal Faulty
1 Disconnect ECU Continuity TVi! continuity Remains with Clutch switch ON Replace clutch
harness connector between ECU continuity (0 fl) failure switch
harness side ter- t
minal and ground Without Remains without
(7 - Ground) continuity continuity
when clutch (a a (m a
switch is turned
ON-OFF

NOTE
1. For measurement of the terminal voltage, use extra-fine check probes and apply them to correct terminals.
2. If all above check results are normal, the clutch switch circuit is normal.
14-116 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

I
1 5-3. Checking inhibitor switch circuit (
I

Vehicles with an automatic transmission

ECU
-

B
Ignition switch
START 12v
r Y
Sub fusible link

!nhjbitor switch

(Front harness side)

Starter motor
magnet coil

Starter relay

03Y746
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-117

Check method Judgement

Step Probable cause Remedy
Condition Check item Normal Faulty
1 Selector lever Starter motor Motor rotates Motor does not Starting circuit Refer to Service
atPorN rotates when rotate faulty Manual Vol. 2
ignition switch GROUP 8 ELEC-
is set at START TRICAL- Starting
System.
2 Selector lever Starter motor Motor does not Motor rotates Inhibitor Refer to GROUP
at D, 2 or L rotates when rotates incorrectly 21 TRANSMISSION
ignition switch adjusted -Service Adjust-
is set at START ment Procedures.

3 Disconnect ECU Continuity EV! continuity Without Open circuit in Correct harness
harness connector between ECU continuity harness between
Selector lever harness side con- (co a ECU and inhibitor
at PorN nectar terminal switch
and ground
(7 -Ground)

NOTE
If all above check results are normal, the inhibitor switch circuit is normal.
 SF~
gpg

ET-
14-I 18 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting
.-
1 1'
_.
1 6. Checking vacuum switch, pump and relay circuit 1

Ignition switch Fuse No. 14

-- 3-WB -L+--Z---i -he To resistdr

I ,,-.I\
‘“L’J
_-------

s
L ----em

(L)
-e -G\-l
Sub fusible link
_v------ -
I
I ii1 o’o-
-L
l- I ?-H-t
-I-
T
I Battery
I T II t iI O*-
I
I II I-@+-
LL Speed control switch
T
Vacuum switch I
PA 0 I

I
I I
--- ECU --

I 1
I
l- --me- L
11
Vacuum pump relay
-----lB 0 0

--
----- y+ To actuator

Vacuum pump I y +. To stop light switch

C
2-R
?----

(Front harness side)

 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-119

NOTE
The following check chart assumes that the circuit (ECU power supply circuit) indicated by broken lines and
the circuit (actuator circuit) indicated by double-dot-and dash line in the illustration are normal.

Check method Judgement

Step Probable cause Remedy
Condition Check item Normal Faulty
1 Disconnect ECU @connector Battery voltage 0V Open circuit in Correct harness
harness connector terminal voltage harness L wire
Ignition switch: (L - Ground) between column
ON position switch and @
MAIN switch: connector
ON position

2 Disconnect ECU @connector Battery voltage 0V Open circuit in Replace vacuum

harness connector terminal voltage vacuum switch switch
and disconnect (G-Ground) (Referto P.14-135 .)
vacuum switch
piping
Ignition switch:
ON position
MAIN switch:
ON position

3 Disconnect ECU @connector Battery voltage 0V Open circuit in Correct harness

harness connector terminal voltage harness G wire
and disconnect (G-Ground) between @
vacuum switch connector and @I
piping connector
Ignition switch:
ON position
MAIN switch:
ON position

4 Disconnect ECU @connector Battery voltage 0V Open circuit in Replace vacuum

harness connector terminal voltage vacuum pump pump relay
and disconnect [(Y) - Ground] relay coil
vacuum switch
piping
Ignition switch:
ON position
MAIN switch:
ON position
5 Disconnect ECU ECU terminal Battery voltage 0V Open circuit in Correct harness
harness connector voltage harness (Y) wire
and disconnect (12 - Ground)
vacuum switch
piping
Ignition switch:
ON position
MAIN switch:
ON position

6 Disconnect ECU @connector Battery voltage 0V Open circuit in Correct harness

harness terminal voltage harness 2-WB or or replace vacuum
connector and (R - Ground) 2-R wire or poor pump relay
disconnect vacuum pump
vacuum switch relay contact
piping
Ignition switch:
ON position
MAIN switch:
ON position

7t Disconnect @ Continuity Pitt continuity Without Open circuit in Correct harness

connector between @ con- continuity harness 0.85-B
nectar and ground (a a wire
(B-Ground)

NOTE
1. For measurement of the terminal voltage or continuity test, use extra-fine check probes and apply them to correct terminals.
2. If all above check results are normal, the vacuum pump is suspected faulty. Then, check the vacuum pump. (Refer to P.14-131 .I
I- I 1. ~~~~~

14-120 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

7. Checking vacuum circuit

Vacuum pump

Sectton C
/----I
sectlon A
-(Actuatorm Terminal C

I
Vacuum tank for
automatic air Choke
conditioner

itch
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-121

Check method Judgement

Step Probable cause Remedy
Condition Check item Normal Faulty

1 Disconnect Generation of Generated Not generated Faulty vacuum Replace vacuum

terminal Bat vacuum switch switch
section B
Apply vacuum
to switch side
using a hand
vacuum pump
2 Choke automatic Generation of Generated Not generated Check valve Replace check
air conditioner positive pressure faulty, terminal valve
side of terminal A A, B faulty, Replace terminal
Connect section vacuum pipe A. B
B of terminal B (check mixer) Replace vacuum
Disconnect faulty pipe valve to
section A injection
Apply positive
pressure to section
A on pipe side
using a hand
vacuum pump

3 Disconnect Generation of Generated Not generated Vacuum pump Replace vacuum

section C of vacuum faulty, terminal pump
actuator C faulty, vacuum Replace terminal
Apply vacuum to pipe (vacuum C
pipe side of pump to check Replace vacuum
section C using valve and terminal pipe
a hand vacuum C to actuator) faulty
pump

NOTE
1. Check that connectors and vacuum hose are free of detrimental cracks or collapse.
2. If all above check results are normal, check the actuator. (Refer to P.14-130.)
14-122 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

CIRCUIT DIAGRAMS

n Ignition switch &

ET
Vacuum switch

Multi-purpose fuse

I
E%85-B ' RL
'-
7
I,
-'
z
65
WL
-

0.85GW *'ii"
0.85WG -;;,
I I j_
Actuator A-l 1

I
Turn signal switch
” /
A-12 A-52 \

FJYI
Vacuum Column switch
1
pump relay

1 I Vacuum pump
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-123
Starter inhibitor
Starter motor relav Inhibitor ( / /r/ / )

A-20
B

I I I I I i I u

B-l 0

IIIII Remarks
(I) Dashed line shows wirinq for vehicles with a manual
transmission.
(2) Dot-and-dash line shows wiring for vehicles with an
Jtomatic transmission.
(3) ?Ior details of grounding points (ex.: I), refer to page 8-l 0.
(4) The circuit lines ended with number (1‘1,r2.1and so on are in
continuation to those with the corresponding number on
i-23 opposed page. (i.e., the line (I 1 on the left-hand page is
connected to the line (1) on the right-hand page.)

Hazard Wire color code

- switch u B: Black Br: Brown G: Green
Speed control unit Gr: Gray L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink
Cluxch R: Red W: White Y: Yellow
.*.2 .%.4

YW LB YL
Lg R L B sll G B
I I I 37Y607
.$.5 8.3 .*. 1
Id-124 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting

CONTROL SECTION PARTS LAYOUT N14ED.A

Name Symbol

Actuator I B Efectrorfic control unit (ECU) I G

Brake switch E Vacuumpump - C

I
Clutch switch Vacuum pump relay A

Diagnosis terminal D Vacuumswitch i- ~-

ENGINE COMPARTMENT
Vacuum switch W

INSTRUMENT PANEL
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Troubleshooting 14-125
LUGGAGE COMPARTMENT
 .-

Service Adjustment
14-126 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Procedures

SERVICE ADJUSTMENT PROCEDURES

NWFBBS

ACCELERATOR CABLE FREE PLAY INSPECTION

AND ADJUSTMENT
(I) Run the enqine until it reaches the specified idle speed.
(2) Turn the ignition switckto “OFF” to stop the engine. -
(3) Check the accelerator cable for sharp bends.
(4) Check the inner cable that it has proper slackness. ~~
(5) If there is excessive or no slackness, adjust as follows.
1x1 Turn the ignition switch to “ON” for 15 seconds. (Do
not run Ihe engine.)
@ Loosen the adjustingcnut so that the throttle lever is
free.
@ Turn the accelerator adjusting nut to the point where I
the thro-ttle lever just-starts moving, then back off l/2 ~~
turn and secure the lock nut.

(6) Confirm that the idle position switch touches to the stopper
after the idle speed con-trol adjustment.

SPEED CONTROL CABLE ADJUSTMENT N14FAAA

(1) Adjust the play of accelerator cable. ~~

(2) Slide the speed control cable in the direction of the arrow
up to a point just beforethe accelerator pedal begins to
move, and secure the speed control cable by inserting a ~.
clip.
(3) Check to ensure-that the play of speed control cable is up to
standard value.
Standard value: 0 - 3 mm (0 - .I in.)
NOTE
If the play adjtistment~is incorrect, either an increase of idle
speed or lack of speed control in the high speed range will
result.
 Service Adjustment
AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Procedures 14-127
KICKDOWN SWITCH ADJUSTMENT
(1) Loosen the lock nut.
(2) Turn the kickdown switch to adjust it so that when pedal
stroke is between 36 and 38 mm (1.4 and 1.5 in.), switch I is
ON and when pedal stroke is between 45 and 49 mm (1.8
and 1.9 in.), switch II is ON.
NOTE
Make sure that overall pedal stroke is 57 mm (2.2 in.) or
more.
(3) After adjustment of kickdown switch, move the spring
holder to make adjustment so that as soon as the switch I
of kickdown switch is ON, the pin of accelerator arm may
contact the spring.

SPEED CONTROL SYSTEM CHECK

Indicator MAIN SWITCH CHECK
1. Turn the ignition key to ON.
2. Check that the indicator lights when the MAIN switch is set
to ON.

ON
-

SPEED CONTROL SET CHECK

1. Set the MAIN switch to ON.
2. Run the vehicle at a desired speed over approximately 40
km/h (25 mph).
+ SET 3. Press the SET switch of the control switch.
4. Check that the vehicle runs constantly at the desired speed
to when the switch is released.
ON

ACCELERATION SET CHECK

1. Set to the desired speed.
2. Turn the control switch to the RESUME position.
3. Check that acceleration continues while the switch is in the
RESUME position and after release, the vehicle keeps the
to speed at which it was running when the switch was
released.
RESUME

68Y531
14-128 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - ~~%%t!‘stme”t
DECELERATION SET CHECK
1. Set at the desired speed.
2. Press the SET switch of the control switch.
3. Check that deceleration continues while the switch is held
+ SET down and after release,-the vehicle keeps the speed at
which it was running when the switch was released. ~~
NOTE Y
If the vehicle-speed reaches the lower speed limit [approx. -
40 km/h (25 mph)] during deceleration, the speed control is
cancelled automatically.
68Y53' I -~
SPEED CONTROL CANCEL CHECK
I. Set the speed control.
2. Check that the vehicle returns to normal running mode
when any of- the following operations is made.
(1) Depress the brake pedal.
(2) Depresssthe clutch pedal. (Vehicles with a manual
transmrssion)
(3) Set the gear select lever to “N” (Neutral).
(4) Turn OFF-the speed control MAIN switch.

SET SPEED RE!%J-&‘lPTlON CHECK

1. Set the speed control.
2. Cancel the speed controlby making any of the following :
operation.
(1) Depress the brake pedal.
bc7 (2) Depress the clutch pedal. (Vehicles with a manual
RESUME transmissibn)
(3) Set the gear select lever to “N” (Neutral).
3. Turn the contpol switch tothe RESUME position while the ~~
68Y531 vehicle speed his approximately 40 km/h (25 mph) or higher.
4. Turn the control switch to check that the vehicle runs again
at the speed that was setbefore cancelling of the speed
control.
NOTE
When the vehicle speed once recovers to the set speed ~~~
less about 10 km/h (6 mph) and then drops again more than
20 km/h (12 mph) during -the RESUME mode, the ASC
mode is automatically cancelled.
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Inspection 14-129

INSPECTION N14TCAC

CHECKING CIRCUIT AND INDIVIDUAL PARTS

INSPECTION OF SPEED CONTROL SWITCH

Passing relay

ETACS unit

Ignition switch (IG)

Vacuum switch
Actuator
Speed control switch
Control unit

Ground 4 1 2-B 2

INSPECTION OF HARNESS
Disconnect the column switch connectors and check at the vehicle body sidb connector.

Terminal Destination MeiT;;ing Tester connection Check conditions Standard

3 Ignition switch (IG) Voltage 3 - Ground Ignition switch: 0 V-+ Battery voltage
OFF-+ ON

I 22 I Ground I Continuity
Continuitv I 2 - Ground I Normal 1 With continuity
continuitv

INSPECTION OF SWITCHES
Disconnect the column switch connectors and check at the switch side connector.

No.

NOTE
1. Replace the switch if out of specification.
2. An asterisk (“1 denotes tester polarity. To check for light (LED) open or short circuit, apply the circuit tester probes in such a
manner that the current will flow in the forward direction of the diode symbol.
14-130 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Inspection ze
-
_li _
INSPECTION OF ACTUATOR E”
-2
__
B’.
RESISTANCE CHECK- 1 sg
mz-
Measure resistaWe of each coil. -
Terminals 1 and 2 (control valve coil): hbprox. 30 R -- B
Terminals 1 and 3 (release valve coil): Approx. 60 R
e
E;
_-..I
F-
s-7
E:-
w
16Y290f j
_ . E
OPERATION CHECK
(1) Connect battery 0 to terminal 3 and battery 0 to terminals :
1 and 2. ;

16Y290
__
(2) Use vacuum pump to apply vacuum to the~vacuum port ot
the actuator and check that the accelerator cable is,...
smoothly drawn in and_ held. at drawn-in ppsit?on.

J
16Y291

-t
(3) Disconnect battery 0 forterminal 2 in the state ot (2) abovel
and check -that the aqcelerator cable oonneqing point_
smoothly moves back to the initial position. ;

El 16Y2908l

(4) Repeat steps (1) and (2) above to check that the accelerator-
cable connecting point smoothly moves back to the initi$
position when battery 0 is disconnected from terminal I._

16Y29091
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Inspection 14-131
INSPECTION OF VACUUM PUMP
(1) Connect a vacuum gauge to the vacuum pump.

03Y73C

(2) Connect battery 0 to terminal 1 and battery 0 to terminal 2

and operate the vacuum pump to check that a vacuum of
150 mmHg (5.9 in.Hg) or higher is generated.
(3) After releasing the vacuum, reconnect the battery and
generate a vacuum of 200 mmHg (7.9 in.Hg). Then
disconnect the ‘battery.
(4) In 2 minutes, check that vacuum is held at 150 mmHg (5.9
in.Hg) or higher.

16Y292C

INSPECTION OF VACUUM SWI;TCH

Connect a vacuum pump to the vacuum port of the vacuum
switch and apply a vacuum to check for continuity between
switch terminals.

16K1619

253115
(1.O -I 0.61
With
continuity
---
continuity
Without j-+L
600 -150 + 10 KTi$Y
(-5.9 + 0.4)
16Y119(
INSPECTION OF VACUUM PUMP RELAY
Check the continuity between terminals when relay coil is
energized and when not.
n

Not energized
Between terminals
@ and @

Between terminals
Approx. 70 R

No (cont$uity
1
@ and @ co

Power is applied Between terminals Continuity

between terminals @ and @ (Approx. 0 n)
16Y2925
@ and @
 --m-

E:
s-

14-132 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Inspection @z

INSPECTION OF VACUUM CHECK VALVE

(1) Blow into B tap and check that air blows out from A tap side
as illustrated.
a-
-

(2) With a vacuum pump connected at B tap side, apply a y 5:

vacuum and check that the vacuum does not drop sharply. ~~I z

1t3y292: 3

lNSPECTlON OF, VEHICLE SPEED SENSOR

Refer to Service Man~ual Vol. 2 GROUP 8 ELECTRICAL -
Meters and Gauges.

INSPECTION OF STOP LIGHT SWITCH

Refer to GROUP 5 BRAKES- Brake Pedal :~-

INSPECTION OF CLUTCH SWITCH

Refer to GROUP 6I CLUTCH - Clutch Pedal. _ _ -f

INSPECTION OF INHIBITOR SWITCH

Refer to GROUP 21 TRANSMISSION - Service Adjustment
Procedures. _ L ._

ELECTRONIC CONTROL UNIT (ECU) SIGNAL CIRCUIT

CHECK
With the ECU connector disconnected, check at the body side I-
connector. -

16Y296C I
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Inspection 14-133

Terminal Destination of part Measure- Tester connection Measuring

No. to be measured ment item condition Standard
0 side 0 side
1 RESUME switch Resistance 1 - Ground Steady state Without continuity

RESUME switch ON With continuity

(100 Sz or less)
2 SET switch Resistance 2 - Ground Steady state Without continuity

SET switch ON With continuity

(100 Cl or less)

3 Vehicle speed sensor Resistance 3 - Ground Vehicle running at To alternate between

speed of 1 km/h or less continuity (100 R or
less) and discontinuity

4 Control solenoid Resistance 11 -4 Steady state Approx. 30 fi

5 Release solenoid Resistance 11 -5 Steady state Approx. 60 fl

(vacuum switch con-
nector disconnected)

6 Selection port Resistance 6 - Ground Steady state With continuity

(100 R or less)

7*’ Clutch switch Resistance 7 - Ground Steady state Without continuity

Clutch switch ON With continuity

(100 Cl or less)

7*2 Inhibitor switch Resistance 7 - Ground Steady state Without continuity

Inhibitor switch With continuity

(100 0 or less)

8 Stop light circuit Voltage 8 - Ground Steady state Equivalent to battery

fuse voltage

9 Stop light switch Voltage 9 - Ground Steady state ov

Brake ON Equivalent to battery

voltage

IO Ground Resistance 10 - Ground Steady state With continuity

11 ECU power Voltage 11 - Ground Ignition switch ON ov

MAIN switch OFF

Ignition switch ON Equivalent to battery

MAIN switch ON voltage

12 Stop light switch Resistance 12 - 5 Steady state With continuity

Brake ON Without continuity

Voltage 12 - Ground Ignition switch ON Equivalent to battery

MAIN switch ON voltage

13*3 Self-diagnosis - - - -

NOTE
*I Vehicles with a manual transmission
“2 Vehicles with an automatic transmission
*3 Terminal No. 13 is okay if the self-diagnosis code can be confirmed when the ignition switch and MAIN switch are turned on, with
the ECU harness connector as connected. (Refer to P.14-98.)
14-134 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Engine Control

ENGINE CONTROL NMOA- -

REMOVAL AND INSTALLATION

1 17

24 22 23 21

16’12904

5.8-8.0fi.lbs.

Vehicles with a manual transmission

transmission

I, Accelerator cable
2. Speed control cable
connection
I)+ 3. Return spring
4. Cotter pin
5, Snap ring
I)+ 6. Spring
I)+ 7. Clevis pin
8. Spring holder
9. Accelerator arm
IO. Cotter pin
I)+ 11. Spring
l + 12. Clevis pin
13. Lever
14. Pedal pad
I)+ 15. Accelerator arm bracket
16. Kickdown switch

NOTE
(I) *a: Refer to “Service Points of Installation”.
(2) q : Non-reusable parts
 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Engine Control 14-135

22
26 2: I 21

18

16Y1855
.

17. Speed control switch

18. Brake switch
19. Clutch switch Post-installation Operation
20. Speed control cable l Adjustment of Accelerator Cable Free Play
(Refer to P.14-126.)
21. Vacuum switch l Adjustment of Speed Control Cable Play
22. Vacuum check valve (Refer to P.14-126.)
23. Vacuum pump relay l Inspection of Speed Control System
24. Actuator (Refer to P.14-127.)
25. Vacuum pump l Adjustment of Kickdown Switch
26. Vacuum hose (Referto GROUP 21 TRANSMISSION -
27. Electronic control unit (ECU) MANUAL AND AUTOMATIC -
On-vehicle Service.)

INSPECTION N140CAD

l Check the inner and outer cables for damage.

l Check the cable for smooth movement.
l Check the accelerator arm for bending.
l Check the return spring for weakness.
l Check the kickdown switch for operation. (Refer to GROUP
21 TRANSMISSION - On-vehicle Service.)
 ~~ ___~~ ~___~__.__--~---

14-136 AUTOMATIC SPEED CONTROL (ASC) SYSTEM - Engine Control

SERVICE POINTS OF INSTALLATION Nl4DDAJ

15. APPLICATION OF SEALANT TO ACCELERATOR ARM

BRACKET
Apply drying type sealant to accelerator arm bra.cket bolt
hole as shown in the illustration.

07Y552

12. APPLICATION OF GREASE TO CLEWS PIN / 11. SPRING

/ 7. CLEVIS PIN / 6. SPRING / 3. RETURN SPRING
Apply grease Apply specified grease to the positions shown in the
illustration. -
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent

07\155:
 16-1

PROPELLER SHAFT
AND
UNIVERSAL JOINTS
CONTENTS
GENERAL INFORMATION .._...___..............._._......... 2 Service Specifications . .. . ..._.__............................. 2
Torque Specifications .. . ..__.__......__.__._.._.__._............. 2
PROPELLER SHAFT . . .. . .. . .. . .. . .. . .. . . .. .. . .. . .. . .. . .. .. . . .. .. . . . 4
TROUBLESHOOTING .._............_..__........_...._.......... 3
SPECIFICATIONS .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . . .. . .. .. .. . . . .. .. . .. 2
Noise and Vibration at High Speed
General Specifications .,...................................... 2
Noise at Start
Lubricants ___.__..______._._._.___..___.___._..__....._._..~ _____.._._._.__ 2
--~~ --c- ” Mm
e
E&
my
16-2 PROPELLER SHAFT AND UNIVERSAL JOINTS - General Information / Specifications
-=
e-
Ed.-
GENERAL INFORMATION N16BAAC
Ed
e-~-
The propeller shaft is of two-joint type and tie utiiversal joint bearings-are lubrication-free. .-
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SPECIFICATIONS N16CA..

GENERAL SPECIFICATIONS

-f-ype
Length x Q,D,

Type CfosS type I

Bearing Lubrication-free needle roller bearing

- _
mz=
&E&x ..
E-

SERVICE SPECIFICATIONS N16CB. _

E+

Items Specifications I
3
Standard value
Journal end play mm (in.) 0.06 l.0024)
--~
Limit
gsg :
Propeller shaft runout (Dial indicator reading) mm (in.) 0.6 l.024) *~

pz;

TORQUE SPECIFICATIONS NIGCC..

Ee.~
Err
Items Nm ftlbs.
Flange yoke attaching bolts 50-6cl 36-43

LUBRICANTS

Items Specified lubricant Quantity

-.
Universal joint MOPAR Multi-Mileage Lubricant As required
Part No. 2525035 or equi;Nalent
Sleeve yoke surface MOPAR Hypoid Geai’Oil As required
Part No. 3744994 or equivalent
 PROPELLER SHAFT AND UNIVERSAL JOINTS - Troubleshooting 16-3
TROUBLESHOOTING Nl6EAAB

Symptom Probable cause Remedy

Noise at start Worn journal bearing Replace

Worn sleeve yoke spline

Loose propeller shaft installation Retighten

Noise and vibration at Unbalanced propeller shaft Replace

high speed
Improper snap ring selection Adjust the clearance

Worn journal bearing Replace

 __~- __~~~ - __ __-~~~
-_

16-4 PROPELLER SHAFT AND UNIVERSAL

~...~~ JOINTS - Propeller Shaft

PROPELLER SHAFT Nt6GA..

REMOVAL AND INSTALLATION

50-60 Nm
36-43 ft.lbs.

Removal steps
I, Flange yoke attaching bolt NOTE A
(1) Reverse the removal procedures to reinstall. -.
*I) ++ 2. Propeller shaft
(2) *I): ReTer to “Service Points of Removal”
(31 I)+: Refer to “Service Points of Installation”.
1mm7
__-~ .~~

SERVICE POINT OF REMOVAL NtGGBAC

2. REMOVAL OF PROPELLER SHAFT

Make the mating marks on the flange yoke land the
differential campanion flange.
Caution
Use care not to damage the lip of transmission oil seal.
Do not allow foreign matter to enter the transmission.

- -~

INSPECTION NlGGCAC

PROPELLER SHAFT RUNOUT

Measure the propeller shaftjunout.
If the runout exceeds the limit, replace the propeller shaft.
Limit: 0.6 mm (.024 in.)
l Wear and damage on splines of flange/sleeve -yoke
l Cracks of prQs6ller shaft-.yoke
 PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller Shaft 16-5
l Smooth operation of universal joints.

SERVICE POINT OF INSTALLATION NIGGDAD

2. INSTALLATION OF PROPELLER SHAFT

Clean the external periphery of the sleeve yoke and apply
specified transmission gear oil to the sleeve yoke.
Specified transmission oil: MOPAR Hypoid Gear Oil
Part No. 3744994 or
equivalent

DISASSEMBLY AND REASSEMBLY N16GE-.

Disassembly steps I
*I) ** 1. Snap ring
l * I)* 2. Journal bearing NOTE
*I) I)+ 3. Journal (I) Reverse the disassembly procedures to reassemble.
4. Sleeve yoke (2) +*: Refer to “Service Points of Disassembly”.
5. Flange yoke (3) l *: Refer to “Service Points of Reassembly”.

1 OY623

-SERVICE POINTS OF DISASSEMBLY NlBGFAG

1. REMOVAL OF SNAP RING

(1) Make mating marks on the yokes of the universal joint
that is to be disassembled.
NOTE
When the universal joint journal and journal bearing are
replaced, obtain the universal joint kit.
(2) Remove the snap rings from the yoke with snap ring
pliers.
 PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller Shaft

2. REMOVAL OF JOURNAL BEARING / 3. JOURNAL

(1) Force ouYthe journal bearings from the propeller shaft _ E
yoke with a large “C” clamp by the following proce- pY E
Large “C dures: ~-7
clamp
@ Install collar to the large “C” clamp proper. 5
@ Pressa journal bearing by using the large “C” clamp
to force out the journal bearing on opposite side. 7p E

I’

D1051i

& Pull out-the journal bearing from the yoke.

NOTE
If the-journal bearing is hard to remove, strike the E
yoke with a plastic hammer. _
-_

D1051:

($ Press-the~ journal shaft by using the large “C” clamp

to force out the remaining bearings.
@ Pull out the journal.
(2) Separate the journal together with the yoke from the
propeller shaft yoke. ~
(3) Force out’the journal bearings from the yoke~~and then
take out the journal from the yoke.

D10514

SERVICE POINTS OF REASSEMBLY NlGGHAJ

I Apply grease
3. INSTALLATION OF JOURNAL / 2. JOURNAL BEARING
(1) Apply specified grease to the following parts of univer-
sal joint kit:
@ Shaftsland grease=sumps of journal
@ Dust, seal lips
@ Needle roller of bearings
Specified grease: MOPAR Multi-Mileage Lubricant
Part No. 2525035 or equivalent
Caution
Do not excessively apply grease. Otherwise, faulty
fitting of bearing caps and errors in the selection of
snap rings may result.
PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller Shaft 16-7
(2) Press-fit the journal bearings to the yoke by using the
large “C” clamp according to the following procedures:
@ Install the base to the large “C” clamp proper.
@ Insert both bearings in the_ yoke, and hold and
press-fit them by using the large “C” clamp.
The guide of base stops the bearings at predeter-
mined position.

1. INSTALLATION OF SNAP RING

5 Large “C”
Gr- clamp (1) Fit snap rings of same thickness
yoke.
onto both sides of

(2) Press the bearing and journal to one side by using the
large “C” clamp.

Collar

D10519

(3) Measure the clearance between the snap ring and the
groove wall of yoke with a feeler gauge.
(4) If the clearance is more than the standard value, the
snap rings should be replaced.
(5) If the clearance is less than the standard value, the snap
rings need not be changed.
Standard value: 0.06 mm (.0024 in.)
 17-I

REAR
SUSPENSION
CONTENTS
FRONT SUPPORT .. ..__.._........._....._._..t.... _. .. . ..._.__.. 16 SPECIFICATIONS .. . .._.___.._.___...~~.__.I___._.t.............. 4
General Specifications j......*............................ 4
GENERAL INFORMATION .. . . .. .._._._.t..._.__._....__._ 2
Lubricants _...____._,......_....................~................ _. .. . 5 ..~
LOWER CONTROL ARM . .. . .. .. . .. . .. . ..._......._......... 9 Service Specifications . .. . .. .. . .. .. ..s...e................ 4
Torque Specifications .._....__._...__....__._................ 4
REAR CROSSMEMBER .. . . .. .. .. .._._._........~........ _ 18
STABILIZER BAR . . . .._..____._._
___
__.___._._.____.t..._........11
SERVICE ADJUSTMENT PROCEDURES .. . .. .. . 6
Wheel Alignment Inspection and STRUT ASSEMBLY . .. .. . .. ...__.__.._____....__.._..
_______... 12
Adjustment _.,..__._.,..._.._......_._........._....__..___
_. ..__._ 6
SUSPENSION ASSEiilBLY . .. .. ..__.t..._....._._. . .. .. .. . 7
SPECIAL TOOL .. . .. . . ..___.__._._.__._.._._....__._......._._.._..5
17-2 REAR SUSPENSION - General Information

GENERAL INFORMATION N17BAAG

The rear suspension is a simply constructed McPherson Strut type independent suspension system with light
unsprung weight.
The strut assembly is mounted, with its upper end supported by the wheel house through the Insulator and its =
lower end connected to the axle housing.
The lower control arms are connected to the front support, crossmember and axle housrng through bushings.
A cam mechanism is provided between each lower control arm and the crossmember for toe-in adjustment. ~_
The stabilizer-bars with their front ends bolted to the front support at two points, are connected to the
respective lower control arms.
The front support holds the torque tube and the lower control arms through upper and lower cushions and ~.
bushings, respectively. The both ends of the front support are bolted to the body with the mediate use of
bushings.

Stabilizer bar

Axle housing
Lower control an-n
 REAR SUSPENSION - General Information 17-3
ADJUSTABLE SHOCK ABSORBER (8 LEVELS)
The adjustable shock absorber can have its damping force
adjusted manually to any of eight levels according to the road
surface condition and driving condition. Rotary valve 1 gives the
lowest (softest) damping force and 2, 3, 4, 5. 6, 7 and 8 give
increasingly higher (harder) damping force, thus allowing
adjustment of the shock absorber damping force according to
the driving condition.

CONSTRUCTION AND FUNCTION

Piston rod The rotary valve has eight orifices “E” (El to E8) of different
\ rh sizes that give different levels of resistance to fluid flow. By
Rotary valve setting changing the orifices, therefore, the damping force of the
alignment mark
shock absorber can be changed.
I
OPERATION (FLUID FLOW WHEN EXTENDED)
The fluid in chamber B is pressurized and flows to chamber D.
In chamber D, a damping force develops as the fluid flows
through variable orifice E, and this force adds to the damping
force that is generated as the fluid flows to chamber A.
Therefore, by changing the size of orifice E, the damping force
can be changed.

Aotary valve- OPERATION (FLUID FLOW WHEN CONTRACTED)

Fluid in chamber A is pressurized and flows to chamber B; the
E 8 amount of fluid corresponding to the volume displaced by the
E3 E7 piston rod flows to chamber C. As the base valve is closed, this
6 same volume flows to chamber D, flowing through variable
E
Base valve ) orifice E and thus changing the damping force in the same way
as when the shock absorber extended.
12Y294 Handling Precautions
l Set both right and left damping forces at the same level.
Setting them at different levels adversely affects steering
stability.
l If set midway between numbers, the damper operates at
the hardest level (8).
 REAR SUSPENSION - SDecifications

SPECIFICATIONS Nl7CA..

GENERAL SPECIFICATIONS

Items Al 87AM Al 87 (Option)

Suspension system Strut type independent Strut type independent

suspension suspension
Coil spring
Wire dia. x O.D. x free length mm (in.) 12.2x132.2~327_7 -- 12.0 x 132.0 x 321114
f.48 x 5.20 x 12.9uS : (.47 x 5.20 x 12.61)
Coil spring identification color Pin k-2 _ Pink-l
Shock absorber_
Type Hydraulic, cylindrical, Gas damper type
double-acting type _ (Adjustable shock absorber)
Max. length mm (in.) 542 (21.3) - 542 (21.3)
Min. length mm (in.) 362 (14.3) 362 (14.3)
Stroke mm (In.) 180 (7.1) 180 (7.1)
Stabilizer bar 0,D. mm (in.) 19 (.75) 19 (.75)

SERVICE SPECIFICATIONS N17CE..

I Items Specifications

Standard value
Toe-in m-m (in.) 0 rk 2 (0 k .08)
Camber -0”15’ k 30’
Protruding length of stabilrzer bar installation bolt mm (in.) 15-17(.59-.67)
Limit
Piston rod O.D. mm (in.1 21.95 t.8642)

TORQUE SPECIFICATIONS N17CG.

Items 1 Nm ) ft.lbs.

Center exhaust pipe 20-3sI 13-22

Brake line flare nut 13-17 9-12
Propeller shaft 50-60 36-43
Lower controlarm to front support 130%250 94- 108
Lower control arm to crossmember 130-150 94- 108
Lower control arm to axle housing 110-130 80-94
Lower control arm locking pin 15-26 II-14
Strut assembly to axle housing 50--X] 36-51
Strut piston rod nut 70-m 51-65
Strut assembly to body 25-35 18-25
Stabilizer bar to front support 30-40 22 -29
Stabilizer bar to lower control arm IO-2x2 7-14
Front support lower stopper bolt to body 40-50 29-36
Front support nut to pin assembly 70-65 51 -61
Pin assembly to body 70-85 51 -61
 REAR SUSPENSION - SDecifications / SDecial Tool 17-5

Items Nm ft.lbs.

Support insulator to crossmember 25-30 18-22

Support insulator to rear support 30-35 22-25
Rear support to differential carrier 50-70 36-51
Bolt assembly to body 8-10 6-7
Bolt assembly to crossmember 70-85 51 261

LUBRICANTS N17CD- -

Items Specification lubricant Quantity

Lower arm shaft MOPAR Multi-Mileage Lubricant As required

Part No. 2525035 or equivalent

SPECIAL TOOL Nl7DA--

Tool (Number and name) Use

L-451 4 Removal and installation

Spring compressor of the coil spring
17-6 REAR SUSPENSION - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

;F;:L ALIGNMENT INSPECTION AND ADJUST-

Measure the wheel alignment--with the vehicle parked on level _

ground.
The rear suspen&rr and wh%ls should b& se-rviced to the 11
normal condltlon prior to measurement ot wheel alignment.

1. TOE-IN
(I) Measure the toe-in with a toe-in gauge:
Standard value: 0 t-2 mm (0 +- .08 in.)

(2) If the toe-in is not wrthrn the standard value, adjust It by

moving the mounting bolts located on the crossmem- :,
ber side of the lower:-control arm. ~~
NOTE -’
Make the adjustment by moving the left and right bolts 1
equally.
Movement of one division on the scale will cause toe-in -z
variation of about 1 mm C.04 in.).
2. CAMBER
Measure the camber with-a camber/caster/kingpin gauge. ~-
(Refer to GROUP 2 FRCINT SUSPENSION - Service r:
Adiustment Procedures.)
Standard value: -075 + 30’ (non-adjustable)
Difference between left and right wheels within 30’
 REAR SUSPENSION - Suspension Assembly 17-7
SUSPENSION ASSEMBLY N17GA- _

REMOVAL AND INSTALLATION

25-35 Nm
s 16-25 ft.lbs.

Pre-removal Operation
l Draining Brake Fluid

e
l Bleeding Brake Line (Refer to P.5-29.)

13-17 Nm
9-12 ft.lbs.

51-61 ft.lbs.

2030 Nm
14-22 ftlbs.
29-36 ft.lbs.

Removal steps
8. Pin assembly to front support mounting nut
+* +* 1. Propeller shaft
(Self-locking nut)
+* 2. Center exhaust pipe +I)
+a 3. Main muffler 9. Suspension assembly
+4 Parking brake cable adjustment
4. Parking brake cable connection NOTE
5. Rear brake hose connection (1) Reverse the removal procedures to reinstall.
(2) *+: Refer to “Service Points of Removal”.
+* 6. Strut assembly connection (3) l *: Refer to “Service Points of Installation”.
7. Crossmember mounting nut (Self-locking (4) q : Non-reusable parts
nut) 12Y714
REAR SUSPENSION - Suspension Assembly

SERVICE POINTS OF REMOVAL

1. REMOVAL OF PROPELLER SHAFT
Refer to GROUP 16 PROPELLER SHAFT AND UNIVERSAL
JOINTS - Propeller Shaft.
9. REM&AL OF SUSPENSION ASSEMBLY
(1) Support the vehicle with rigid racks at the specified
points, and remove the rear wheels.
NOTE
The height of the rigidracks should be 600 mm (24 in.)
or more. -
(2) Secure the strut assfibly to the crossmember with
rope.

(3) Lower the jack slowly, being sure to support both of the
left and right lower control arms and the strut assem-
blies.

SERVICE POINTS OF INSTALLATION

6. INSTALLATION OF STRUT ASSEMBLY
Refer to P.17z121
* PARKING BRAKE ADJUSTMENT
Refer to GROlJP 5 BRAKE - Service Adjustment Proce-
dures.
3. INSTALLATION OF MAIN MUFFLER / 2. CENTER EX-
HAUST PIPE
Refer to GROUP 11 INTAKE AND EXHAlJST SCTEM -
Exhaust Pipes and Mufflers.
1. INSTALLATION OF PROPELLER SHAFT
Refer to GROUPS 16 PROPELLER SHAFT AND LJNIVERSAL
JOINTS - Pmpeller~ Shaft:
 REAR SUSPENSION - Lower Control Arm 17-9
LOWER CONTROL ARM N17HAAA

REMOVAL AND INSTALLATION

IO-20 Nm

7-14ft-‘bs--2 Ia

*130-150 Nm
94-108 ft.lbs.

*I IO-130 Nm
SO-94 ft.lbs.

*130-150 Nm
94-108 ft.lbs.

15-20 Nm
11-14 ft.lbs.

Removal steps
1. Parking brake cable mounting stay connec-
tion
2. Stabilizer bar mounting nut
I)+ 3. Stabilizer bar connection NOTE
l * 4. Lower control arm (1) Reverse the removal procedures to reinstall.
5. Bushing A (2) **: Refer to “Service Points of Installation”.
6. Bushing B (3) q : Non-reusable parts
7. Bushing C (4) *: Must be tightened while vehicle is unladen

12Y713
REAR SUSPENSION - Lower Control Arm

INSPECTION N17HBAA

* Check the lower control arm toy detormation and damage.

r Check the bushrngs tor damage and wear.
a Check the bolts tor bend.

SERVICE POINTS OF INSTALLATION N17HDAD

4. INSTALLATION OF LOWER CONTROL ARM

(I) Apply specified grease to the concave part of the shaft
connecting the lower~control arm to the axle housing. ~-
Specified grease: MOPAR Multi-Mileage Lubricant
Part No. 2525035 or equivalent
Caution
Apply a thin coat of specified grease, taking care
that it does not adhere to the bushing.
(2) Insert the shaft with the mark on its head facing
downward.
(3) When installing the lower control arm to the crossmem- -1
ber, align the mark q the crossmember_with the _
reference 1in.e on theplate.
(4) Measure the wheel alignment.

3. INSTALLATION OF STABILIZER BAR CONNECTION

Refer to P.l7-7-l.
 REAR SUSPENSIONS - Stabilizer Bar 1741
STABILIZER BAR N17lA. -

REMOVAL AND INSTALLATION

IO-20 Nm
7-14 ft.lbs.

3040 Nm
22-Y - IL -
/

Removal steps
1. Bracket
2. Stabilizer bar mounting self lock nut
3. Center exhaust pipe rubber O-ring
4. Joint cup
5. Rubberbushing
++ 6. Stabilizer bar
7. Rubber bushing
8. Joint cup
9. Collar
10. Joint cup
11. Rubber bushing
12. Joint cup NOTE
13. Rubber bushing (1) Reverse the removal procedures to reinstall.
14. Joint cup (‘2) *a: Refer to “Service Points of Installation”
15. Bushing (3) m: Non-reusable parts
12Y712

INSPECTION Nl7lBAA

l Check the stabilizer bar for deformation and weakness.

l Check the bushings for cracks and damage.

SERVICE POINT OF INSTALLATION N171CAA

6. INSTALLATION OF STABILIZER BAR

When installing the stabilizer bar to the lower control arms,
tighten the nut so as to obtain the service standard.
Service standard: 15 - 17 mm (‘59 - .67 in.)
17-12 REAR SUSPENSION - Strut Assembly
_.___~
STRUT ASSEMBLY N17JA,.

REMOVAL AND INSTALLATION

25-35 Nm
18-25 ft.lbs.

50-70 Nm
3651 ft.lbs.

Removal steps
I. Trunk room side trim NOTE
2. Strut housing cap (I) Reverse the removal proceares to reinstall.
+I) +* 3. Strut assembly (21 9,: Refer to “Service Points of Removal”. -1
-. MY
4. Gasket (3) I)+: Refer to “Service Points of Installation”.
(4) q : Non-reusable parts
REAR SUSPENSION - Strut Assemblv 17-13
SERVICE POINT OF REMOVAL N17JBAA

3. REMOVAL OF STRUT ASSEMBLY

Detach the strut assembly from the axle housing.
NOTE
Push the axle housing downward while opening the
coupling on the housing.

SERVICE POINT OF INSTALLATION N17JCAA

3. INSTALLATION OF STRUT ASSEMBLY

Apply semi-drying sealant to the surface of the insulator
where it contacts the vehicle body.
NOTE
The gasket is installed at the factory.
 T L

17-14 REAR SUSPENSION - Strut Assemblv

DISASSEMBLY AND REASSEMBLY N17JD..

70-90 Nm
51-65 ft.lbs.

7-

12Y731

Disassembly steps
1 Self lock nut
+a 2. Strut insulator
I)* 3 Spring seat -
NOTE
4. Rubber helper (I) Reverse the disassembly procedures to reassemble
5. Dust cover (21 +*: Refer to “Service Points of Disassembly”.
a* 6. Coil spring (3) I)*: Refer to “Serwce Points of Reassembly”.
7. Strut assembly i4i IZJ 1. Non-reusable parts.

SERVICE POINT OF DISASSEMBLY N17JEAD

6. REMOVAL OF COIL SPRING

(I) Compress the coil spring by using the special tool.
 REAR SUSPENSION - Strut Assemblv 17-15

(2) Use power tool and remove the. top end nut.
(3) Remove strut insulator, spring seat, dust cover and
bump rubber.

SERVICE POINTS OF REASSEMBLY NlMGAC

3. INSTALLATION OF SPRING SEAT

Align the D-shaped hole in the spring seat with the
indentation on the piston rod, and be sure that the
projections on the dust cover are aligned with the holes in
the spring seat.

2. INSTALLATION OF STRUT INSULATOR

Temporarily tighten the strut insulator with a top end nut,
Left side Right side and align the studs in the insulator with the holes in the
bracket at the lower end of the strut, as shown in the
illustration.
17-16 REAR SUSPENSION - Front Support

FRONT SUPPORT
REMOVAL AND INSTALLATION

3545 Nm
25-33 ft.lbs.
30-40 Nm
I 22-29 ft.lbs.

iji-61 ft.lbs.
c130-15/o Nm I I/Y
94-108 ft.lbs.

70-85 Nm
51-H ft.lbs.

40-50 Nm
29-36 ft.lbs.

G1 2mONm
14-22 ft.lbs.

Removal steps
I)+ 1. Center exhaust pipe rubber O-ring
2. Stabilizer bar connection
3. Pin assembly to front support mounting nut
(Self-locking nut)
4. Lower stopper
+* 5. Front support NOTE emu_
6, Upper cushion (I) Reverse the removal procedures to reinstall. ~ .-
7. Lower cushion (2) **: Refer to “Service Pornts of Removal”.
(3) I)*: Refer to “Service Pomts of Installat)on”. ~~ :I
8, Bushing D
9. Upper stopper (4) q : Non-reusable parts
(5) *: Must be tightened while vehicle is unladen.
10. Pin assembly 12w15
REAR SUSPENSION - Front Sutmort 17-17
SERVICE POINT OF REMOVAL N17KBAA

4. REMOVAL OF FRONT SUPPORT

(1) Support the torque tube assembly with a jack or similar
equipment.
(2) Remove the front support.

INSPECTION N17KCAA

l Check the front support for deformation.

l Check the bushings for cracks and wear.

I BUSHING REPLACEMENT N17KDAD

(1) Press out bushing D.

I
(2) With the holes in bushing D located as shown in the
illustration, use a plastic hammer to insert the bushing into
the front support.

SERVICE POINT OF INSTALLATION

1. INSTALLATION OF CENTER EXHAUST RUBBER O-
RING
Refer to GROUP 11 INTAKE AND EXHAUST SYSTEM -
Exhaust Pipes and Mufflers.
 REAR SUSPENSION - Rear Crossmember

REAR CROSSMEMBER N17LA..

REMOVAL AND INSTALLATION

30-35 Nm
22-25 ft.lbs.

w-
25-30 Nm
18-22 ftlbs.

*130-150 Nm
36108 ft.lbs.

Removal steps
I)+ 1, tower control arm
2. F&at- support protector
3. Crossmember mounting nut (Self-locking
nut) NOTE
+I) 4. Crossmember (I) Reverse the ren%val procedures to reK?Ml.
(2) **-:Refer to “Service Points of Removal”.
*+ 5. Rear support insulator (3) *)+: Refer to “Service Points of Installation”.
6. Bolt assembly (4) q : Non-reusable parts
*+ 7. Rear support (5) *: Must be tlghtened while vehicle IS unladen.
13Y71R
-- ~-

SERVICE POINT OF REMOVAL -- N17LBAA

4. REMOVAL OF CROSSMEMBER
(1) Support Ahe drfterent%l Garner wrth a lack. -
(2) Remove. 3he crossmember.
REAR SUSPENSION - Rear Crossmember 17-19
INSPECTION N17LCAA

l Check the crossmember for cracks, deflection and damage.

l Check the rear support insulators for cracks and peeling.
l Check the rear support for deformation and damage.

SERVICE POINTS OF INSTALLATION N17LDAB

7. INSTALLATION OF REAR SUPPORT

(1) Align the positions of the projections of the rear
supports to the determining holes of the d.ifferential
carrier, and then mount the rear supports to the
differential carrier.
(2) Temporarily mount the rear support insulators~ to the
rear supports.

5. INSTALLATION OF REAR SUPPORT INSULATOR

(1) Align the rear support insulators to the crossmember
mounting holes, and then, while slanting the differential
carrier, mount it to the crossmember.

(2) Align the positions of the projections of th.e rear support

insulators to the determining holes of the rear supports,
and then tighten the mounting nuts of the rear support
insulators.

1. INSTALLATION OF LOWER CONTROL ARM

Refer to P.17-9
 19-1

STEERING
POWER
CONTENTS
GENERAL INFORMATION .. . . .. . .. .. .. . . .. . .. .. .._....... 2 STEERING COLUMN AND SHAFT . .. .. . .. .. . .. . .. . .. . 15

OIL PUMP . .. . ..._........................_...._...................... 31 STEERING HOSES . . .. . .. . .. .. .. . .. . . .. .. .. .. . .._....._........... 36

POWER STEERING GEAR BOX .. .. . .. . .. . . .. .. . ..._... 21 STEERING LINKAGE .. . . .. .. .. .. . .. . . .. .. .. . . .. . .. .. .. . .. .. . . .. . 37

SERVICE ADJUSTMENT PROCEDURES ........ 9 TROUBLESHOOTING . . .. ..._................................ 7

Air Bleeding ........................................................ 11 Droning Noise
Checking Drive Belt Tension ............................ 10 Excessive Play of Steering- Wheel
Checking Fluid Level ........................................ 11 Hissing Noise
Checking Stationary Steering Effort ................ 10 Oil Leakage from Gear Box
Checking Steering Angle ................................ 9 Oil Leakage from Hose Assembly
Checking Steering Gear Backlash .................... 9 Oil Leakage from Hose Connection
Checking Steering Wheel Free Play ................. 9 Oil Leakage from’ Oil Pump
Checking Steering Wheel Return Oil Leakage from Oil Reservoir
to Center ............................................................ 10 Rattling Noise
Oil Pump Pressure Test .................................... 12 Shrill Noise
Replacement of Fluid ........................................ 11 Squeaking Noise
Steering Wheel Centering ................................ 13 Squealing Noise
SPECIAL TOOLS . . . .. . .. . .. . . . . . . .._........................... 6 Steering Wheel Operation is Heavy
(Low Power Assist)
SPECIFICATIONS .. . ............................................. 3 Vibration
General Specifications .................................... 3 Whistling Noise
Lubricants ............................. .._............................ 5
Sealant and Adhesive ........................................ 5
Service Specifications .................................... 3
Torque Specifications ........................................ 4
19-2 STEERING - General Information

GENERAL INFORMATION NlSWEC

The steering column uses the tilt steering system to proviie optimum driving posItIon.
The power steerrng system uses an integral gear box (ball nut type) and a vane type oil pukp.
This power steerrng system IS characterized by steering ef@rt that changes with the engine speed. -~
Namely, only a slight steering effort is required when the engine speed is low and it increases with increasing .I
engine speed, thus offering outstanding steering stability. _

13Yi503
 STEERING - Specifications 19-3
SPECIFICATIONS NlSCA--

GENERAL SPlXlFlCATlONS

Items Specifications

Steering wheel diameter mm (in.) 380 (15.0)

Steering column and shaft type Collapsible steering column and
tilt-adjustable steering wheel
Gear box
Steering gear type Ball and nut, torsion bar type
Steering gear ratio 14.25
Oil pump
Oil pump type Vane type
Displacement 9.6 cmYrev. (59 in.%ev.)

SERVICE SPECIFICATIONS NlSCB--

Items Specifications

Standard value
Steering angle

Inner wheel 39”-,o.

Outer wheel 32”-0,

Steering wheel free play mm (in.) 25 (1 .O) or less
Stationary steering effort N (Ibs.) 30 (6.6) or less
V-belt tension mm (in.) 9 - 12 (35 - .47)
Mainshaft starting torque Ncm (in.lbs.) 25-65(2-6)
Mainshaft total starting torque Ncm (inAbs.) 50-90 (4-8)
Oil pump pressure kPa (psi)
Gauge hose valve closed 7,500 - 8,200 (I ,067 - 1,I 66)
Gauge hose valve opened 980 (I 42) or less
Ball joint starting torque Ncm (inAbs.)
Tie rod and relay rod (for pitman arm) 50 - 250 (4 - 22)
Relay rod (for idler arm) so-150(4-13)
Idler arm starting torque Ncm (in.lbs.), 300 - 900 (26 - 78).
Spring scale reading N (Ibs.) 26-78(6-18)
Limit
Steering wheel free play mm (in.) 50 (2.0)
Steering gear backlash mm (in.) 0.5 (.02)
Oil pump pressure kPa (psi)
Gauge hose valve closed 1,500 (2 18)
19-4 STEERING - Specifications

TORQUE SPECIFICATIONS NlSCC-.

Items Nm

Steering column and shaft

Steering wheel lock nut 25-33
Column tube clamp 5-8- 3.6 - 6.0
Steering column support plate 9-14 6.5: IO
Steering shaft to gear box bolt 20-25 13-18
Tiltlink cover 9-14 6.5 - IO
Power steeringgear box
Side cover 45-55 33-40
Adjusting bolt lock nut 30-45 22-33
Breather plug 3-4 2-3
Pifman arn%istallation 130- 150 94-108
Gear box installation 35-40 25-29
Circulators Fistallation 3.5 -4.5 2.5 - 3.3--
Valve housing 45-55 33-40
Lock nut* ~~~~ 180 - 230” ‘l30- 166”
Oil pump
Suction connector 6-10
Connector- 50-70 36-51
Reservoir 8-12 6-9
Oil pump bracket 14-21 10-15
27-41 20-30
Oil pump brace bolt 14-21 IO- 15
Oil pump cover 18-22 13-~16
Steering hoses
Pressure hose 30-40 22-29
Return hose 40-50 29-36
Clamp A 3.2-M 2.3 - 3.5
Steering linkage
Tie rod end 35-45 25-33
TieE?fsocket and relay rod 35-45 25-33
Relay rod to pitman arm 35-45 25-33 ~~
Relay rod to idler arm 35-45 25-33
Idler arm attaching nut 40-60 29-43
Tie rod end stud 50-55 36-40 ~
Idler arm support and frame 35-40 25-29
Stopper bolt lock nut for adjustment of steering angle 26 ~~ 14

NOTE
‘; If the specral tool IS used to measure the trghtenrng torque, the measurement IS135 - 175 Nm (98 - 127 ft.lbs.1
 STEERING - Specifications 19-5
LUBRICANTS NlSCD- -

Items Specified lubricants Quantity

Power steering fluid Automatic transmission fluid 900 cm3 (54.9 in.“)
DEXRON or,DEXRON II type
Steering shaft bearing MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Joint bearing MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Inside of joint socket and spring MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Joint pin A MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Inside of joint pin retainer MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Oil seal lip of cross-shaft MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Needle bearing of side cover MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
U-packing of side cover MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Oil seal lip of dust cover MOPAR Multi-mileage Lubricant As required
Part No. 2525035 or equivalent
Idler arm support, bearing and MOPAR Multi-mileage Lubricant As required
oil seal Part No. 2525035 or equivalent

SEALANT AND ADHESIVE NlSCE- -

Items Specified sealants Quantity 1

Inner bore of dash panel cover bolt holes MOPAR Lock N’Seal Adhesive As required
Part No. 4057989 or equivalent
 STEERING - Soeciai Tools

SPECIAL TOOLS NISDA..

Preload socket

Oil pressure gauge pump pressure Top cover remove~r

Pump pressure
 STEERING - Troubleshooting 19-7
TROUBLESHOOTING NlSEABA

Symptom Probable cause 1 Remedy

Excessive play of Excessive play in steering gear box Repair

steering wheel
Loose steering gear mounting bolts Retighten

Loose or worn stud of tie rod end Retighten or replace as necessary

Steering wheel Loose belt Adjust the belt tension

operation is heavy
(Low power assist) Damaged belt Replace the belt

Low fluidlevel Refill with fluid

Air in fluid line Bleed the system

Twisted or damaged hoses Correct the hose routing or replace

the hoses

Fluid leakage Check the fluid leakage

Malfunction of gear box Check and replace the gear box if

necessary

Malfunction of oil pump Check the oil pump pressure and

repair oil pump

Rattling noise Loose installation of oil pump or gear box Retighten the oil pump or gear box

Interference around column or between pressure Correct or replace the pressure hose
hose and other parts and the parts around the column
.~
Abnormal noise inside of gear box and oil pump Replace the gear box or oil pump

Shrill noise Air sucked into oil pump Check the oil level and hose clips,
bleed the system or replace the oil
pump
Oil pump seizure Replace the oil pump

Squealing noise Loose belt Adjust the belt tension

Oil pump seizure Replace the oil pump

Hissing noise Air sucked into oil pump Check the oil level and hose clips;
bleed the system

Damage to the olive of the gear box port section Replace the gear box

Malfunction of return hose Replace the hose

dhistling noise Malfunction of gear box port section Replace the gear box
19-8 STEERING - Troubleshooting

Oil leakage from oil

reservoir

NOTEF
* 4 slight “beat norse” IS produced by the 011pump; thts IS not a maltunctlon. (Thisnoise occurs particularly when a
,;tatronary steering etfort IS made.)
-- .A slroht vibration may be telt when the statronary steering etfort IS made due to the condition of the road surface.
I o check whether the vibratron actually exists or not, test-drrve the vehicle on a dry concrete or asphalt surface.
Moreover. a very slrght amount of vtbratron IS not a maltunctron.
STEERING - Service Adjustment Procedures 19-9
SERVICE ADJUSTMENT PROCEDURES
NlOFABD

CHECKING STEERING WHEEL FREE PLAY

1. With the engine stationary and the steering wheel in the
straight-ahead position,~apply a force of 5 N (1 .I Ibs.) to the
steering wheel in the peripheral direction. Measure the play
of the circumference of the steering wheel.
Standard value: 25 mm (1.0 in.) or less
Limit: 50 mm (2.0 in.)
2. If the measured value exceeds the limit, check the steering
gear backlash, and linkage ball joint end play.

CHECKING STEERING GEAR BACKLASH NISFOAC

1. Jack up the vehicle front and hold the steering wheel in the
straight-ahead position.
2. Disconnect the relay rod and pitman arm using the special
tool.
Caution
1. Tie the string to a nearby part so that the special
tool will not come loose.
2. Do not remove the ball joint nut but simply loosen.
3. Measure the steering gear backlash at the pitman arm top
end with dial indicator.
Limit: 0.5 mm (.02 in.)

4. If the measured value exceeds the limit, screw in the

steering gear box adjusting bolt until the steering wheel
free play is within the range of standard value.
Caution
1. Be sure to make the adjustment with the steering
wheel in the straight-ahead position.
2. If the adjusting bolt is overtightened, more steering
effort will be required, and return of the wheel will
be adversely affected.

CHECKING STEERING ANGLE NISFDBC

1. Place the front wheel on a turning radius gauge and

measure the steering angle.
Standard value:
Inner wheel 39”_~~

Outer wheel 32’-:1

 : --__~ __-
19-10 STEERING - Service Adjustment Procedures

2. Adjust the steering angle ot each wheel by turning the stop

bolt of the relay rod.
Caution
Be sure that the toe-in is properly adjusted before
adjusting the steering angle.

CHECKING STATIONARY STEERING EFFORT NlSFFAE -

1. Place the vehicle on a level surface and place the steering

wheel in the neutral position.
2. Set the engirre;speed to_ 1,000 rpm.
Caution
The engine speed should be lowered to the standard
(idling) speed after inspection.
3. Measure the tangential fprce with a spring balance by ~:i
turning the steering wheel clockwise and counterclocktiise ._
13Y1502 one and a half turns. c
Standard value: $0 N (6.6 ibs.)
4. If the stationary steering effort exceeds the standard value, 1
check tor belt slackness, damage, lnsutticlent oil, air mixed
Into 011, collapsed or twisted hoses, etc., and repalr it found. ~_

CHECKING STEERING WHEEL RETURN TO CEN-

TER NlSFGAD

1-o check for the return ot steering wheel to center,-carry out

drive test and check the following points.
I Make gentle and sharp turns and check to get a teel for that
There IS no appreciable drtterence in steering efiort and ~-
return to ce~nrer between right and lett Urns.
2~ Drive at a speed of about 35 km/h (22 mph), turn the a~_
:5teennu; -wheel 90” clockwrse or counterclockvvlse, and .~_
release the wheel one or two seconds-later. It the wheel
returns morerhan 70”, the return of steering wheel may be
consIdered good. ~.
NOTE
When the steering wheel IS turned abruptly, momentary
hard steering mlqht result, but this dbes not mean any ~~.
problem. It is-caused by low 011 pump delivery during idling.

CHECKING DRIVE BELT TENSION NISFHAE _

1. Check the belt for slackness by applying pressure of 100 N _

(22 Ibs.) to the-center of the belt.
Standard value: 9 - 12 mm (.35 - .47 in.)
2. If the measured value does not agree with the standard _
value, adjust the drive belt tension.
STEERING - Service Adiustment Procedures 19-11
--CHECKING FLUID LEVEL NlDFlAG

1. Start the engine on a level surface, and turn the steering-

wheel several times fully to the right and left while the
engine is idling.
2. Check the reservoir fo.r contamination.
3. Replace the fluid if it has bubbles or has become white.
4. Fill the reservoir with specified automatic transmission fluid
to the MAX IevelL
Specified fluid: MOPAR DEXRON or DEXRON II Auto-
matic Transmission Fluid Part No.
3549660 or 4131509, or equivalent
REPLACEMENT OF FLUID N19FKAG

Check for contamination in the fluid reservoir. Foamy or cloudy

fluid should be replaced.
1. Remove the reservoir cap.
2. Disconnect the return hose- from .the reservoir tank and
remove the fluid.
3. Disconnect the high tension cable. Run the engine intermit-
tently several times with the starter motor, and remove the
fluid from the gear box.
4. Attach the return hose and supply the specified fluid.
5. Bleed the system and check the fluid pressure.
Specified fluid: MOPAR DEXRON or DEXRON II Auto-
matic Transmission Fluid Part No.
3549660 or 4131509, or equivalent

AIR BLEEDING Nl3FKAE

Check the stationary steering effort. If it is not within the range

of the standard value, it is possible that air has been mixed into
the system. Bleed the air from the system.
1. Make certain the reservoir is filled up.
2. Jack up the front wheels.
3. Disconnect the high tension cable.
4. While turning the steering wheel completely to the right
and to the left, turn the-engine over by using the starter
motor. Repeat this several times.
5. Lower the front wheels.
6. Connect one end of a vinyl tube of suitable length to the
breather plug of the gear box, and place its other end in a
container.
7. Start the engine and idle it.
-- 2:

STEERING - Service Adjustment Procedures

1.. -F\/TeasIure the toe-in.

2. The steenng~wheel is offCenter to the left, subtract one i
millimeter from the measured value down to the;specifica-
tion limit.
The steeringYGvheel is off center to the-right-,-add one
millimeter tothe measured value up to the specification .~_
limit, as shown in the sample calculation.
Then adjust the tie rod to-change the toe by that number.
3. Hold the tie rod with a wrench while looserjng the tack 11
nuts.
4. Turn the tie rod l&turn for each two degrees the steering =~
wheel is off center. . * L-..
5. Re-check toe-in to be sure the specrfrcatron 7?not ex- i
13Y970 ceeded. Z-T -
Sample calculation: .~
Steering wheel 5” off center to right.
Measured toe-in = 2 mm (.08 in.) ~__ _~ ;_
Maximum toe-in = 5 m-m (.20 in.)
5 mm (.2O in.) - 2 mm (.08in.) = 3 mm (.12-in.) available for ~~
Off center to right correction
312 x 115 = 300 turn to brEg the steering wheel to within 2” IF
of being centered.

Off center to left

Tie rod viewed from above

115 turn of the tie rod

= 2 mm (.08 In.) toe change
= 2 degreesDr 114 in. at the steering wheel
~~
STEERING - Steering Column and Shaft 19-15
STEERING COLUMN AND SHAFT NlOGA- -

REMOVAL AND INSTALLATION

3545 Nm
25-33 fklbs.

20-25 Nm

13Y1504

Removal steps
4* 1. Horn pad
+* *+ 2. Steering wheel
3. Lower column cover
4. Uppercolumn cover
5. Column switch assembly
6. Spring
7. Steering column support plate
8. Brake pedal return spring
I)+ 9. Dash panel cover to dash panel bolt NOTE
IO. Steering shaft to gear box bolt (1) Reverse the removal procedures to reinstall.
l C 11. Steering shaft clamp (2) +I): Refer to “Service Points of Removal”.
12. Steering column assembly (3) l *: Refer to “Service Points of Installation”.
19-16 STEERING - Steering Column and Shaft

SERVICE POINTS OF REMOVAL NWGBAI

1. REMOVAL OF HORN PAD

Remove the: h-orn pad and disconnect the horn cable =
connector. 1-1 -

13K013

2. REMOVAL OF STEERING WHEEL

Remove the:steering wheel by using the special tool. _
Caution
Do not hammer on the steering wheel to remove it, or
else the collapsible mechanism may be damaged.

SERVICE POINTS OF INSTALLATION NWGDAF

11. INSTALLATION OF STEERING SHAFT CLAMP

Align the cut of the joint socket with the bolt hole of the _
clamp.

Socket Clamp I

9. INSTALLATION OF DASH PANEL COVER TO DASH -

PANEL BOLTS
When attaching the dash panel cover, apply specified
sealant around the bolt boles.
Specified sealant: MOPAR Lock N’Seal Adhesive Part
No. 4057989 or equivalent

2. INSTALLATION OF STEERING WHEEL

To install the steering wheel, hold the front wheels in the __
straight-ahead position, fit the three cancel pin2 into the
bottom holes jn the steering wheel, and tighten the .=
steering wheel lock nut to the specified torque.

3
 STEERING - Steering Column and Shaft

STEERING COLUMN AND SHAFT NlSGE--

DISASSEMBLY AND REASSEMBLY

Disassembly steps
1. Snap ring 18. Spacer
2. Stopper 19. Dash panel cover
3. Spacer ++ 20. Column tube clamp
l * 4. Steering shaft assembly 21. Lower column tube
5. Stopper 22. Column bushing
+* I)* 6. Joint pin retainer 23. Special bolt
7. Stopper 24. Steering lock bracket
+I) I)+ 8. Joint pin A +* ++ 25. Steering lock
I)+ 9. Joint socket 26. Tilt knob
IO. Spring seat 27. Tilt link cover
1;. ~~~~g 28. Upper column tube

Mb 13: Joint pin B NOTE

++ 14. Joint bearing (1) Reverse the disassembly procedures to reassemble.
15. Joint cover (2) +I): Refer to “Service Points of Disassembly”
I)* 16. Steering shaft bearing (3) l *: Refer to “Service Points of Reassembly”
17. Steering shaft (4) q : Non-reusable parts
 _-. ,1 !~T; ,.,. 8,

Ed.
P-=

EC=
Ed

E~C
19-18 STEERING - Steering Column and Shaft s=a ;
81=~
dLo
Eye
SERVICE POINTS OF DISASSEMBLY NWGFAG
B-Es
z
4. REMOVAL OF STEERING SHAFT ASSEMBLY I ~~
(I) Take out the steering shaft bearing from t.he lower .=
column tube.
(2) Remove the snap ring of the upper column shaft with
snap rings pliers,
(3) Take out the steering shaft from the colutii-~ tube. my=
Steering shaft bearing

F13517
-
6. REMOVAL 0-F JOINT PIN RETAINER
(1) Slide off the- joint co%% from the socket assembly.
(2) Remove the stoppers, and pull out the joint pin retainer.

8. REMOVAL OF JOINT PIN A

(I) With the-steering shaft set upright, pull out joint pin A
on both sides of the socket, by utilizing a magnet, while
holding the shaft downward. -
(2) Remove the joint sodket.
Caution
Be sure to use a magnet to remove joint pin A.
Striking the pin with a hammer will make it
unremovable.

43. REMOVAL OF JOINT PIN B

(1) If necessGv, press OC& joint pin B from the steering
shaft and-ta~ke out the joint bearing.
(2) Take out~fhe joint cover and steering shaft bearing.

--
25. REMOVAL OF STEERING LOCK
If it is necessary to remove the steering lock, cut a groove ~:
on the head of the spec~ial bolt with a metal saw, and
remove the steering lock with a screwdriver. ~-
Caution
The steering lock bracket (upper) and bolts should be
replaced with new ones without fail when installing the
steering lock.

- -
 STEERING - Steering Column and Shaft 19-19
INSPECTION NlSGGAG

l Check tilt bracket for cracks and damage.

l Check column bushing for damage.
l Check steering shaft bearing for wear.
l Check steering shaft for damage and deformation.
l Check joint cover for wear.
l Check joint bearing for wear and damage.
Steering shaft length: 727 mm (28.62 in.)

SERVICE POINTS OF REASSEMBLY NllGHAL

25. INSTALLATION OF STEERING LOCK

When the steering lock is to be installed to the column,
temporarily install the steering lock in alignment with the
column boss, and, after checking that the lock works
properly, tighten the special bolts until the heads twist off.

‘20. INSTALLATION OF COLUMN TUBE CLAMP

Attach the column bushing to the upper and lower column
tubes, and secure the upper tube with the clamp.
NOTE
Install the clamp so that the bolt tightening part of the
clamp is at the bottom.

Steering shaft bearing 16. INSTALLATION OF STEERING SHAFT BEARING

(1) Apply the specified grease to the inside of the steering
I shaft bearing, and then insert the steering shaft into the
bearing.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
I
(2) Apply specified adhesive to the surface where the
steering shaft bearing and the column tube contact.
+ : Multipurpose grease (3) Apply the specified grease to the inside of the upper
+ : Adhesive bearing.
13F5OC

Specified grease: MOPAR Multi-mileage Lubricant

Part No. 2525035 or equivalent
(4) Install the steering shaft with the steering shaft bearing
in the column tube.
 -

STEERING - Steering Column and Shaft

14. INSTALLATION OF JOINT BEARING

(1) Install the joint bearing (with the flanged surface facing
upward) on the steering shaft lower end.
(2) Align the-joint bearing hole with steering shaft hole, ~1
(3) Apply specified grease to joint pin B and insert in the .z
joint bearing.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
Caution
F1352, Be careful that the pin does not project over the
bearing surface.
9. INSTALLATIGN OF JOINT SOCKET
Fill the socketwith the specified grease, and then insert the _
seat, spring and spring seat into it.
L
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent

13F52F

8. INSTALLATlGiKGF JOINT PIN A

(1) Apply specified grease to joint pin A.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
(2) Insert the steering shaft lower end into the socket, and, --_
while holding the shaft downward, insert joint pin A by
hand.

F1352E

6. INSTALLATiOlVOF JOINT PIN RETAINER

(I) Apply the-specified grease to the inside of the joint pin
retainer.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
(2) Attach the joint pin retainer, and secure it with the ~_
stoppers.~
Cover with the joint tiver.
 STEERING - Power Steering Gear Box 19-21
POWER STEERING GEAR BOX NlSNA- -

REMOVAL AND INSTALLATION

Pre-removal Operation
l Draining Power Steering Fluid
(Refer to P-1 9-l 1)
20-25 Nm
14-18 ft.lbs.
Post-installation Operation
l Refilling Power Steering Fluid
l Bleeding Gear Box and Pipe Lanes
(Referto P.l9-II) 1

40-50 Nm
29-38 ft.lbs.

30-40 Nm
22-29 ft.lbs.

35-45 Nm
25-33 ft.lbs.

Removal steps
4+ I. Pressure hose connection
4+ 2. Return hose connection NOTE
3. Cotter pin (1) Reverse the removal procedures to reinstall.
4+ 4. Relay rod connection (2) 4W: Refer to “Service Points of Removal”
5. Gear box assembly (3) q : Non-reusable parks

SERVICE POINTS OF REMOVAL NlSNBAD

1. DISCONNECTION OF PRESSURE HOSE / 2. RETURN

HOSE
Disconnect the pressure hose and return hose from the
gear box.
Caution
Use pieces of cloth to close the end of each hose in
order to prevent escape of fluid and entrance of dirt and
other foreign material.
 .~~ ~~ -__ ~ _.
-ti-.
?
&FE?
EL&K-
19-22 STEERING - Power Steering Gear Box -
mz;;:
‘-
4. DISCONNECTiON OF RELAY ROD
Disconnect the pitman arm from the relay rod by using the F
special tool. ~~
 STEERING - Power Steering Gear Box 19-23
POWER STEERING GEAR BOX NlSNE- -

DISASSEMBLY

Disassembly steps
1. Breather plug cap 17. Seal ring
2. Breather plug 18. O-ring
3. Jam nut 4* 19. Top cover
4* 4. Pitman arm 20. Thrust needle bearing
4* 5. Side cover 4* 21. Ball bearing
6. Locknut 4* 22. Oil seal
4* 7. Cross-shaft 23. Mainshaft
4* 8. Adjusting bolt 24. Seal ring
9. Adjusting plate 25. O-ring
4* 10. U-packing (side cover side) 26. Thrust needle bearing
1 1. O-ring 27. Seal ring
12. Oil seal 28. O-ring
13. U-packing (pitman arm side) 29. Gear box housing
4* 14. Valve housing lock nut
4I) 15. Valve housing NOTE
4* 16. Rack piston (I) 4*: Refer to “Service Points of Disassembly”
(2) q : Non-reusable parts

13Y980
STEERING - Power Steering Gear Box

SERVICE POINTS OF DISASSEMBLY N19NFAO

4. REMOVAL OF PITMAN ARM

Remove the pitman arm-from the gear box assembly by
using the special tool.
5. REMOVAL OF SIDE COVER
Loosen the lock nut of the adjusting bolt and screw in the .
adjusting bolt-so that the side cover may be raised slightly.

-
7. REMOVAL OF CROSS-SHAFT
With the mainshaft and cross-shaft placed-in the neutral.
position, tap the bottom of the cross-shaft~with a plastic
hammer to take out the cross-shaft together with the side _
cover.
8. REMOVAL OF ADJUSTING BOLT
Remove theside cover IFy turning the adjustin-g bolt.

IO. REMOVAL OF U-PACKING (SIDE COVER SIDE)

(1) Remove the needle bearing rollers manually from the ~~
side cover.
(2) Remove the O-ring and U-packing.
NOTES -I- -
Unless there are fluid leaks from the Iadjusting bolt
threads, do not remove the U-packing. If removed, be ~
sure to use new U-packing.

14. REMOVAL OF VALVE HOUSING LOCK NUT

Remove the valve housing lock nut by using the special
tool.
15. REMOVAL OF VALVE HOUSING
Remove the valve housing together with the rack piston.
Caution
Use care not to drop the rack piston.

-
16. REMOVAL OF RACK PISTON
Remove the rack piston from the mainshaft by turning it
counterclockwise.
Caution
Be careful not to lose the 26 balls inside the rack piston.
 STEERING - Power Steering Gear Box 19-25
19. REMOVAL OF TOP COVER
Remove the top cover by using the special tool, and take
out the mainshaft, together with the top cover, from the
valve housing.

21. REMOVAL OF BALL BEARING / 22. OIL SEAL

Remove the ball bearing and the oil seal with a punch.

Spacer

13Y93C

INSPECTION NISNGAB

l Check the mainshaft for wear and damage.

l Check the cross-shaft and rack piston for wear and damage
of tooth surface.
l Check the adjusting bolt for uneven wear of contact part.
l Check the dust seal and oil seal for wear and damage.
l Check the O-rings for damage.

-
REASSEMBLY
180-230 Nm*
30-45Nm qn 130-166 ftlbs.
22-33 ft.1

45---.fE+Nm
.---. -
33-40 ftlbs.

is 19

@iFi=
16
17 13Y994

Gear box seal kit -~-

130-150 Nm
94-108 ft.lbs.
Reassembly steps
I. Gear box housing I)+ 18. Valve housrng
+* 2. O-ring I)+ 19. U-packrng (side cover side)
I)+ 3. Seal ring *+ 20 0ring
++ 4, Thrust needle bearing 21. Adjusttng plate
5. O-ring 22. Adjustrng bolt
6. Seal ring 23 Lross-shah
7. Marnshaft 24. Lock nut
I)+ 8. Oil seal I)+ 25. Srde cover
I)+ 9. Ball bearing I)4 Adjustment ot marnshaft total stdrtrng torque
++ 10. Thrust needle bearing ++ 26. Rtman arm
++ Adjustment of mainshaft starting torque ~~2-7’. Jam nut .-
11. Top cover 28. Breather plug
12. Valve housing lock nut 29. Breather plug cap
13. O-ring
14. Seal ring NOTE
I)+ 15. Rack piston (I) l +: Refer to “Servrce Points of Reassembly”
I)+ 16. U-packing (pitman arm) (2) q : Non-reusable parts
W 17. Oilseal (31 * : If the special tool IS used to measure the ttghtcrllng
torque, the measurement IS 135 - 175 Nm (98 - 127
ft.lbs.1.
 STEERING - Power Steering Gear Box 19-27
- SERVICE POINTS OF REASSEMBLY NlSNHAG

2. APPLICATION OF AUTOMATIC TRANSMISSION FLUID

Thrust needle bearing TO O-RING / 3. SEAL RING
Apply specified fluid to the O-ring and seal ring of the
mainshaft.
Specified fluid: MOPAR DEXRON or DEXRON II Auto-
matic Transmission Fluid Part No.
3549660 or 4131509, or equivalent
4. INSTALLATION OF THRUST NEEDLE BEARING
'03651
Install the thinner thrust plate, thrust needle bearing and
thicker thrust plate to the mainshaft in that order as shown
in the illustration.
8. PRESS-FIT OF OIL SEAL / 9. BALL BEARING
(1) Press-fit the ball bearing and oil seal into the top cover.
(2) Apply specified grease to the oil seal of the top cover.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent

Y1360F

10. INSTALLATION OF THRUST NEEDLE BEARING

(1) Install the thinner thrust plate, thrust needle bearing and
thicker thrust plate to the top cover in that order as C
shown in the illustration.
(2) Attach the top cover to the valve housing.
Caution
Be careful that the thrust plates and the thrust
needle bearing do not come off the top cover.

Cl3181

. ADJUSTMENT OF MAINSHAFT STARTING TORQUE

(1) In order to fit in the assembly parts, use the special tool
and a spring balance, and tighten the top cover until the
tangent force becomes 62 - 83 N (14 - 19 lbs.). Then
return the top cover until the tightening torque is 0 N (0
Ibs.).
Caution
After tightening the top cover, rotate the mainshaft
to confirm that there is no torque fluctuation or
abnormal noise.

(2) Measure the mainshaft starting torque by using the

special tools.
(3) Tighten the top cover until the mainshaft starting torque
is 20 - 30 Ncm (1.8 - 2.7 in.lbs.) greater than the
previously mentioned measurement value.
NOTE
Tighten the top cover gradually while measuring the
starting torque.
19-28 STEERING - Power Steering Gear Box
-
(4) Tighten the-valve housing lock nut by using the special
tool.
Caution
Be sure that the top cover does not turn together
with the lock nut at this time.

(5) Measure~Ihe mainshaft starting torque’ by using the =-

special tools. -
Standard value: 25 - 65 Ncm (2 - 6 in.lbs.)
(6) If the measured mainshaft starting torque does not
comply with the standard value, remove the valve
housing lock nut and adjust the tightening of the top
cover.

13S65C 1 “ - ~ ~
, -

15. INSTALLATION OF RACK PISTON

(1) Install the rack piston until it comes in contact With the
adge of themmainshaftr
(2) Rotate the mainshaft to align the ball raceway with the -
ball insertion- hole.

16. INSTALLATION OF U-PACKING (PITMAN ARM) / 17.

OIL SEAL
Install the U-packing on the-gear box and press-fit the oil
seal.

18. INSTALLATION OF VALVE HOUSING

(I) Apply specified automatic transmission fluid to the seal
rq of the rack piston. -
Specified fluid: MOPAR DEXRON or DEXRON II
Automatic Transmission Fluid Part
No. 3649660 or 4131509, or equiva-
lent
(2) Install the valve housino
0) Rotate the niainshaft unf? the rack piston moves to the
neurral position (center).
STEERING - Power Steering Gear Box 19-29
19. APPLICATION OF GREASE TO U-PACKING
(SIDE COVER SIDE)
(1) Apply specified grease to the seal surface of U-packing.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent
(2I) Apply specified grease to the needle bearings.
Specified grease: MOPAR Multi-mileage Lubricant
Part No. 2525035 or equivalent

20. APPLICATION OF AUTOMATIC TRANSMISSION FLUID

TO O-RING
Apply specified fluid to the O-ring, and attach it to the side
cover.
Specified fluid: MOPAR DEXRON or DEXRON II Auto-
matic Transmission Fluid Part No.
3549660 or 4131509, or equivalent

25. INSTALLATION OF SIDE COVER

With the mainshaft in the neutr\al position, install the side
cover assembly (with the cross-shaft) to the gear box.
NOTE
Apply specified automatic transmission fluid to the teeth
and shaft areas of the rack piston, and apply specified
grease to the oil seal lip.
Specified fluid: MOPAR DEXRON or DEXRON II Auto-
matic Transmission Fluid Part No.
3549660 or 4131509, or equivalent
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent
Caution
Do not rotate the side cover during installation.
Take care not to damage the cross-shaft oil seal.

. ADJUSTMENT OF MAINSHAFT TOTAL STARTING

TORQUE
(1) While turning the adjusting bolt, measure the mainshaft
total starting torque by using the special tools.
Standard value: 50 - 90 Ncm (4 - 8 in.lbs.1
NOTE
Position the mainshaft in the neutral position during
measurement.
(2) Tighten the adjusting bolt lock nut.
 26. INSTALLATION OF PITMAN ARM
Install the pitman arm to the gear box with the mating ~- g-
marks aligned.

I
 STEERING - Oil Pump 19-31
OIL PUMP NISRA- -
REMOVAL AND INSTALLATION

Pre-removal Operation
l Draining Power Steering Fluid
(Refer to P. 19-l 1)

l Refilling Power Steering Fluid

l Bleeding Power Steering Line
l Adjustment of Power Steering Belt Tension

8-12 Nm

3
14-21 Nm
IO-15 ft.lbs.

2741 Nm

14-21 Nm
IO-15 ft.lbs. 14-21 Nm
IO-15 ft.lbs.

Removal steps
1. Return hose connection
2. Suction hose
3. Pressure hose connection
z. ~ilyervoir

6: V-belt
7. Oil pump NOTE
8. Oil pump bracket Reverse the removal procedures to reinstall.
19-32 STEERING - Oil Pump

OIL PUMP
DISASSEMBLY AND REASSEMBLY

I8
50-70 INm
3651 ft.lbs.
I2 ~-
Y
6-10 Nm
4-7 ftlbs. 61113-==C$g
1 20
I I I4 -
---El
@
'5-g
J

3
?
3 -3'1 33
2
(im
cm'1 8 5m 3 16&Nm
13-16 ft.lbs.

Disassembly steps
13dllJ5 5 IO 8

I, Suction connector II Q
l + 2. O-ring
3. Oil pump cover 3 3
c5$$
4. Cam case 6 8
I)+ 5. O-rings I,.i

+I)
++
++
++
6.
7.
8.
Cam ring
Vanes
Snap ring
Oil pump seal
kit I Oil pumppulley
and shaft kit
Oil pump
cartridge kit ~~

++ 9. Rotor
+I) 10. Pulley assembly -
l + 11. Oil seal
12. Connector
13. O-rings
++ 14, Flow control valve NOTE
++ 15. Flow control spring (1) Reverse the disassembly procGfures to reassemble.
16. Cap (2) +I): Refer to “Servl:ce Points olfDisassembly”.
17. Oil filter (3) I)*: Refer to “Service, Points ofReassembly”.
18. Oil reservoir (4) q : Non-reusable parts.
STEERING - Oil Pume 19-33
SERVICE POINTS OF DISASSEMBLY NISRFAF

8. REMOVAL OF SNAP RING

Remove the snap ring of the shaft with snap ring pliers, and
separate the rotor from the shaft.

IO. REMOVAL OF PULLEY ASSEMBLY

Tap the rotor side of the shaft lightly with a plastic hammer,
and take out the pulley assembly.

14. REMOVAL OF FLOW CONTROL VALVE / 15. FLOW

CONTROL SPRING
(1) Remove the connector from the oil pump body, and
take out the flow control valve and flow control spring.
(2) Remove the O-ring from the connector.
Caution
Do not disassemble the flow control valve.

INSPECTION NISRGAE

l Check the flow control’valve for clogging.

l Check the shaft for wear and damage.
l Check the V-belt for cracks and wear.
l Check the rotor and vane for “stepped” wear of groove. --
l Check the cam ring and vanes for “stepped” wear of
contact surface.
l Check the vanes for damage.
l Check the pump body and pump cover with rotor for
streak-like abrasion of contact surface.

SERVICE POINTS OF REASSEMBLY

11. INSTALLATION OF OIL SEAL
Drive the oil seal into the pump body.

_...
19-34 STEERING - Oil Pump

9. INSTALLATION OF ROTOR
(1) Mount the rotor ontothe shaft.
(2) When installing the rotor, the countersunk part (shown
in the illustration) should face the pump cover side.

8. INSTALLATION OF SNAP RING

(1) Install the snap ring.

(2) Lift the rotor-and check to be sure that the snap ring has
entered--the coun.tersunk part.

7. INSTALLATION OF VANE s?Es

Direct round edge to the cam ring (1) Apply the specified automatic transmis.sion fluid to the z :
vanes. -L-
Specified fluid: MOPAR DEXRON or DEXRON II
Automatic Transmission Fluid Part
No. 3549660 or 4131509, or equiva-
lent
(2) Install the vanes on the rotor paying close attention to
Vane the installation direction.
13K562 13c217

6. INSTALLATION OF CAM RING

Install the cam ring with its punched mark facing the pump :
Punched mark body and its dowel holes aligned with the dowel pins on the
pump body.

Dowel pins
13wo3c I
 STEERING - Oil Pump 19-35
5. APPLICATION OF AUTOMATIC TRANSMISSION FLUID
TO O-RINGS

3oooo3 (1) Apply the specified

O-rings.
automatic transmission fluid to the

3
i ooo3
Specified fluid: MOPAR
Automatic
DEXRON or DEXRON
Transmission Fluid Part
II

QBO (2) Install the O-rings

No. 3549660 or 4131509,
lent
to the cam case.
or equiva-

13Y98:

2. APPLICATION OF AUTOMATIC TRANSMISSION FLUID

TO O-RING
(1) Apply the specified automatic transmission fluid to the
O-ring.
Specified fluid: MOPAR DEXRON or DEXRON II
Automatic Transmission Fluid Part
No. 3549660 or 4131509, or equiva-
lent
(2) Mount the O-ring onto the suction connector.
13Y98
19-36 STEERING - Steering Hoses

STEERING HOSES NlSTA..

REMOVAL AND INSTALLATION

/YL??;Y::4”“”
l
1 ~~
Drainiricj Power Steering Fluid

2.3-3.5 ft.lbs.
30-40 Nm
40-50 Nm 22-29 ft.lbs.
29-36 ft.lbs:

I
4 \ 3.2-4.8
2.3-3.5
30-40 Nm
Nm
ft.lbs.

22-29 ft.lbs.

Removal steps
1. Suction hose
2. Pressure hose
3. Return hose
4. Return hose
5. Cooler tube

NOTE
Reverse the removal procedures to reinstall.
 STEERING - Steering Linkage 19-37
STEERING LINKAGE NlSVA- -

REMOVAL AND INSTALLATION

Post-installation Operation
l Adjustment of Toe-in
(Refer to GROUP 2 FRONT SUSPENSION -
Service Adjustment Procedures.)

35-40 Nm

& 25-33 ft.lbs.

IZII
35-45 Nm
25-33 ft.lbs?---y@
35-45 Nm \3 3540Nm I% 2 d/”
25-33 ft.lbs. 25-29 ft.lbs
\

IElI 35-45 Nm
25-33 ft.lbs.

35-45 Nm
Kill' 25-33 ft.lbs. 13Y1506

Removal steps
1. Cotter pin
*I) 2. Tie rod assembly, right NOTE
** 3. Tie rod assembly, left (I) Reverse the removal procedures to reinstall.
Nb 4. Relay rod (2) l *: Refer to “Service Points of Removal”.
*I) 5. Idler arm assembly (3) q : Non-reusable parts

SERVICE POINTS OF REMOVAL NlSVBAD

\ 2. DISCONNECTION OF TIE ROD ASSEMBLY, RIGHT / 3.

TIE ROD ASSEMBLY, LEFT / 4. RELAY ROD / 5. IDLER
ARM ASSEMBLY
Disconnect each linkage by using the special tool.
Caution
Do not remove the ball joint nut but simply loosen.

/ /I- 13Y98
I
 STEERING - Steering Linkage

STEERING LINKAGE NlSVG-.

DISASSEMBLY AND REASSEMBLY

40-60 Nm

06

87

4 50-55 Nm
36-40 ft.lbs.

20 Nm
14 ft.lbs. 1311505

Tie rod assembly disassembly steps Idler arm disassembly steps

l + Measurement of tie rod end ball joint starting *)+ Measurement of Idler arm starting torque
torque IO. Idler arm attaching nut
1. Dust cover ‘I I, Oil seal
2. O-ring 12. Idler arm bearing
I)+ 3. Tie rod outer end .I3. Idler arm
I)+ 4. Tie rod inner end 14. Pin -
I)* 5. Tie rod 15, Oil seal
16. Idler arm bearing
Relay rod disassembly steps ‘I 7. Idler arm support
6. Dust cover NOTE I
7. CRing (I 1 Reverse the disassembly procedures to reassemble.
8. Stopper bolts 12) *+: Refer to “Service Porn& of Reassembly”.
9. Relay rod 13) a: Non-reusable parts

INSPECTION NlSVHAA

* Check the idler arm support tor damage and deformation.

+ Check the Idler arm for damage and deformation.
* Check the idler arm beat-mgs tor wear and cracks.
l Check the dust covers and O-rings for damage and cracks.
@ Check the tie rods for damage and detormatlon.
@ Check the relay rod for bends and damage.
 STEERING - Steering Linkage 19-39
REPLACEMENT OF IDLER ARM BEARING NISVJAA

1. Apply a thin coat of specified grease to the inner surfaces of

the idler arm, outer surfaces of the bearings and lips of oil
seals.
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent
2. Install the bearings and oil seals to the idler arm.
3. Install the idler arm assembly to the idler arm support.

REPLACEMENT OF DUST COVER NlSVEAC

1. Remove the dust cover and O-ring from the ball joint.

i @k-i 13Y87(

‘2. When installing the dust cover, fill the cover lip and the
interior with the specified grease.
Specified grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent

13Y86:

MEASUREMENT OF IDLER ARM STARTING TORQUE

Measure the starting torque of the idler arm with a spring
balance.
Standard value: 300 - 900 Ncm (26 - 78 in.lbs.)
Spring scale reading
-
26 - 78 N (6 - 18 Ibs.)
 il-
._.__ me ’ -4.-

19-40 STEERING - Steering Linkage

Ez
L.H. side SERVICE POINTS OF REASSEMBLY NlSVIAA
--
@ 5. INSTALLATION OF TIE ROD / 4. TIE ROD INNER END / z
3. TIE ROD OUTER END m+
gg
I, Apply the specified grease to the threaded portion of
the tie rod
2. Temporarily tighten the tie rod so that the-distance [l
between the stud bolls of the tie rod is the.following __
dimensio-n.
Tie rod end ball joint center distance Ai-
372 mm (14.65 in.)
Caution -
Tie rod end tightness, left and right, should be
uniform.

* MEASUREMENT OF TIE ROD END BALL JOINT START-

ING TORQUE
Secure the relay rod and the tie rod in a vice.
Mount the nut to the balljoint, and then measure the ball
joint starting- torque. _
Standard value:
Tie rod and relay rod (for gear box)
50 - 250 Ncm (4 - 22 in.lbs.) ”
Relay rod (for idler arm) E
50 - 150 Ncm (4 - 13 in.lbs.) ;
_
 21-I

TRANSMISSION
MANUAL AND AUTOMATIC
CONTENTS
AUTOMATIC TRANSMISSION ............ 32 MANUAL TRANSMISSION ................ 2
ACCUMULATOR ................................................ 118 COUNTERSHAFT ................................................ 29
AUTOMATIC TRANSMISSION EXTENSION HOUSING .................................... 27
ASSEMBLY ............................................................ 82 EXTENSION HOUSING COVER ........................ 31
BRAKE BAND AND BAND SERVO .................... 116 GEARSHIFT LEVER ASSEMBLY .................... 9
CONNECTING DRUM ASSEMBLY ................ 119 GEARSHIFT LEVER ASSEMBLY .................... 30
CONTROL VALVE BODY .................................... 120 GENERAL INFORMATION ................................ 2
DIRECT CLUTCH AND HIGH-REVERSE MAINSHAFT ASSEMBLY .................................... 24
CLUTCH ................................................................ 110 SERVICE ADJUSTMENT PROCEDURES ........ 8
DRUM SUPPORT ................................................ 107 Speedometer Cable Replacement ................ 8
FORWARD CLUTCH ............................................ 114 Transmission Fluid Inspection ........................ 8
GENERAL INFORMATION ................................ 32 Transmission Fluid Replacement .................... 8
GOVERNOR ........................................................ il7 SPECIAL TOOLS .................................................... 6
LOW-REVERSE BRAKE .................................... 115 SPECIFICATIONS ................................................ 3
OIL PUMP ............................................................ 105 General Specifications .................................... 3
ON-VEHICLE SERVICE ........................................ 70 Lubricants ................................ ............................ 5 .:
PLANETARY CARRIER ........................................ 119 Sealants and Adhesives .................................... 5
SERVICE ADJUSTMENT PROCEDURES ........ 68 Service Specifications .................................... 3 :-
Speedometer Cable Replacement ................ 69 Torque Specifications ......................................... 5 _
Transmission Fluid Inspection ........................ 68 SPEEDOMETER SLEEVE ASSEMBLY ............ 28
Transmission Fluid Replacement .................... 68 TRANSMISSION ................................................ IO
SPECIAL TOOLS .................................................... 51 TROUBLESHOOTING ........................................ 7
SPECIFICATIONS ................................................ 48 Abnormal Noise and Vibration
General Specifications .................................... 48 Gear Jump Out
Lubricants ............................................................ 50 Oil Leaks
Service Specifications .................................... 49 Shifting Hard or Difficult
Torque Specifications ........................................ 49
TRANSMISSION ................................................ 80
TRANSMISSION CONTROL ............................ 77
TRANSMISSION OIL COOLER ........................ 75
TROUBLESHOOTING ........................................ 52
Diagnostic Road Test
Preliminary Checks (Prior to road testing)
Pressure Testing
Road Test Symptom Chart
Stall Test
Troubleshooting Chart
Troubleshooting Guide
21-2 MANUAL TRANSMISSION - General information

GENERAL INFORMATION
The KM132 5-speed manual transmlsslon has the gear reduction and ratio selectton tunctlons combrned Into
one unrt and housed rn the aluminum drecast houslng and case. _ ~~
The gear train LSall constant mesh type both forward and reverseand In order to provide dnvlng p&ormance ‘-
meetinq the enqlne pertormance, the gear train has a close gear ratio in the case ot engine with Intercooler.

1320002
 MANUAL TRANSMISSION - Specifications 21-3
SPECIFICATIONS
GENERAL SPECIFICATIONS

Items ; Specifications

Model KM132-M-CNL
We 5 speed, Floor-shift
Gear ratio 1st 3.369
2nd 2.035
3rd 1.360
4th 1.000
5th 0.856
Reverse 3.578
Speedometer gear ratio (drive/driven) 8123

SERVICE SPECIFICATIONS
Items Specifications

Standard value
Main drive gear end play 0 - 0.06 (0 - ,002)
Front bearing retainer end play 0 - 0.1 (0 - .0040)
3rd-4th synchronizer hub end play O-0.08(0-.003)
Countershaft preload 0 - 0.05 (0 - .0020)
Overdrive gear sleeve end play 0 - 0.2 (0 - .0080)

ADJUSTMENT SPACER AND SNAP RINGS

Part name Thickness Identification Part No.

symbol

Snap ring 2.30 i.091) White MD701729 -

(for adjustment of main drive gear end play) 2.35 t.093) None MD701 730
2.40 (.094) Red MD701731
2.45 f.096) Blue MD701 732
2.50 i.098) Yellow MD701 733

Snap ring 2.17 (085) White MD729I79

(for adjustment of overdrive gear sleeve end play) 2.36 (.093) Blue MD7291 80
2.55 (. 100) Black MD7291 81
2.74 (.I 08) None MD7291 82
2.93 (.I 15) Brown MD729183
3.12 (.123) Red MD729184
3.31 (.130) Yellow MD7291 85
3.50 (.138) White MD7291 86
3.69 (.145) Blue MD729187 ;

Snap ring 2.15 (.085) Blue MD701761

(for adjustment of 3rd-4th speed synchronizer 2.22 (.087) None MD701 762
hub end play) 2.29 (090) Brown MD701 763
2.36 (093) White MD701 764
 MANUAL TRANSMISSION - Specifications

Part name Part No

MD706580
(for adjustment of countershaft preload) MD706581
MD706582
MD706583
MD706584~
MD706585
MD706586-:
MD706587
MD706588
M D706589
MD706590 .~
MD706591
MD706592
MD706593
M D706594
MD706595
MD706596
MD706597
MD706598
MD706599
2.44 t.096) MD7C16600
MD706601
MD706602
M D7Q6603--
MD706604
MD7066B5
M DF.66606
MD706607
MD706608

MD725212-
for adfustment of front bearing retainer end play) MD72521 3
MD725214.
MD725215
MD72521 6
 !

MANUAL TldANSMlSSlON - Specifications 21-5

TORQUE SPECIFICATIONS NPlCG-

Items Nm ft.lbs.

Propeller shaft flange yoke attaching bolt 50-60 36-43

Transmission mounting bolt 43-55 31 - 40 ‘il.:’
#A.
Starting motor mounting bolt 22-32 16-23
Engine to transmission 43-55 31-40
Mainshaft locking nut 250-270 181-195
Countershaft locking nut 160- 190 116-137 ‘..a,
Idler shaft locking nut 20-60 14-43 ~$&I,
Idler shaft set bolt 15-22 11-15 t.
Drain plug 35-45 26-32 \-
Oil filler plug 30-35 ,22-25
Back-up light switch 30 22
Under cover 15-22 IO-15
Seal plug (Neutral return plunger plug) 30-42 22-30
Speedometer sleeve clamp bolt IO-13 7 - 9~
Control lever 15-22 11-15
Rear engine mounting to transmission bolt 20-24 14-17
Rear engine mounting to body bolt 10 7

LUBRICANTS NZlCD- -

Items Specified lubricant Quantity

Manual transmission oil lit. (qts.) MOPAR Hypoid Gear Oil 2.3(2.4)
Part No. 3744994 or equivalent
s
z

SEALANTS AND ADHESIVES NZICE-- z

I Items 1 Specified sealant 1 Quantity I

Threaded portion of extension housing 3M Super Silicone 8662 or As requrred
mounting bolt equivalent
ixtensron housing mounting bolts 3M Liquid Gasket 8959 or As required
(special bolt) equivalent
21-6 MANUAL TRANSMISSION - Srecial Tools

SPECIAL TOOLS NZIDA-.

MD998067
Mainshaft bearing installer Taper bearing puller

9
H
-
 MANUAL TRANSMISSION - Troubleshooting 21-7
TROUBLESHOOTING N2lEAACa

Symptom Probable cause Remedy

Abnormal noise and a. Loose or broken transmission and engine a. Tighten or replace mounts
vibration ~~~~ mounts

b. Improper end play of counter gear b. Correct

c. Worn or damaged gear c. Replace

d. Improper grade of oil d. Replace to the specified grade of ”

oil

e. Low oil level e. Add oil

Oil leaks a. Damaged oil seal or gasket a. Replace

Shifting hard or a. Abnormal contact or worn synchronizer ring a. Replace

difficult and gear corns

b. Synchronizer spring weakened b. Replace synchronizer ring

c. Improper grade of oil c. Replace to the specified grade of

oil

Gear jump out a. Worn gear shift fork or broken poppet a. Replace
spring

b. Excessive synchronizer hub to sleeve spline b. Replace

play
21-8 MANUAL TRANSMISSION - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

N21FCAAa

TRANSMISSION FLUID REPLACEMENT

(1) Position vehicle on a flat level and rem~ove drain-plug to -_
drain transmission oil.
(2) Replace packing with a new one and tighten the drG;ainplug. 11

- -- _
(3) Pour in freshtransmrssron~pil through filler plug hole until rt- --;+
reaches the bottom of finer port.
Specified transmission oil:
MOPAR Hypoid Gear Oil Part No. 3744994 or
equivalent
Quantity: 2.3 lit. (2.4 qts.)
Oil level ---
-- - -
---
----

TRANSMISSION FLUID INSPECTION NZlFBAAa

Reter to GROUP Q LUBRIC;ATION AND MAINTENANCE - ~~

Manual Transm%Sion.

SPEEDOMETER CABLE REPLACEMENT NZlFEAAa

(1) Replace the cable -assembly if there is a malfunction.

(2) When connecting the cable to the meter, insert the cable -y
until its stopper properly fits to the meterside groove. -_

- -
(3) After installing the speedometer, pull the sp-eedometer --
cable through the grommet in the toeboard~untifthe-cable -L
marking is v$ible from the engine compartment srde.
Caution
Poor installation of the cable may cause a fluctuating
meter pointer, or noise and a damaged harness inside
the instrument panel.
 MANUAL TRANSMISSION - Gearshift Lever Assembly 21-9
GEARSHIFT LEVER ASSEMBLY NZlGA-.

REMOVAL AND INSTALLATION *

4

Removal steps
** 1. Gearshift lever knob
2. Spool release lever 091643
3. Cover
4. Inner box
5. Rear console box
6. Side console cover
7. Front console box NOTE
8. Dust cover retaining plate (1) Reverse the removal procedures to reinstall.
*I) 9. Gearshift lever assembly (2) +I): Refer to “Service Points of Removal”.

SERVICE POINT OF REMOVAL NZIGBAA

9. REMOVAL OF GEARSHIFT LEVER ASSEMBLY

(1) Remove the bolts attaching the control lever cover.
(2) Uncouple stopper plate from extension cover. ;..:.
(3) Remove the gearshift lever assembly by lifting it up.
NOTE
Keep the gearshift lever in the neutral position.

SERVICE POINT OF INSTALLATION NZlGDAG

1. INSTALLATION OF GEARSHIFT LEVER KNOB

(1) Loosely tighten the nut down to the end of threaded
portion of the shift lever. Then back off the nut about a
half turn and install the spring washer.
(2) Give one turn to the knob after the spring washer
begins to bend. Tighten further the knob until the shift
pattern faces toward the front of vehicle and adjust.
NOTE
If the knob has been fully tightened by the above
procedure, back off it not more than one turn and make
ow34: adjustment.
21-10 MANUAL TRANSMISSION - Transmission

TRANSMISSION N21MA. -

REMOVAL AND INSTALLATION

Post-installation Operation
l Refilling Transmission Oil
(Refer to P.Zl-8.)
l Installation of Under Cover
50-60 Nm
35-43 Ribs.

..a
1

IONm
7 ft.lbs.

35-45 Nm
B-32 ft.lbs.

Removal steps
+I) I, Gearshift lever assembly
++ 2. Propeller shaft
+* 3. Back-up lamp harness connector
++ 4. Speedometer cable
4,
++
4,
5. Clutch release cylinder
6. Bell housing cover \I Nm / ft.bs. 1 idenz$2ation

7. Starting motor
8. Rear engine mounting
+O I)* 9. Transmission assembly

NOTE ~~
(I 1 Reverse the removal procedures to rernstall.
(2) +*: Refer to “Service Points of Removal”.
(3) ++: Refer to “Service Points of Installation”.
 MANUAL TRANSMISSION - Transmission 21-11
SERVICE POINTS OF REMOVAL NSlMBAD

1. REMOVAL OF GEARSHIFT LEVER ASSEMBLY

Refer to P.21-9.
2. REMOVAL OF PROPELLER SHAFT
(1) Make the mating marks on the flange yoke and the
differential companion flange.
(2) Pull out the propeller shaft from the transmission.
Caution
Use care not to damage the lip of transmission oil
seal.
Do not allow foreign matter to enter the transmis-
sion.
3. DISCONNECTION OF BACK-UP LAMP HARNESS CON-
NECTOR / 4. SPEEDOMETER CABLE
Disconnect the speedometer cable and the back-up lamp
switch harness. ,

5. REMOVAL OF CLUTCH RELEASE CYLINDER

Remove the release cylinder attaching bolts and slide the
release cylinder sideway.

6. REMOVAL OF BELL HOUSING COVER

lW \u-u/ -
Remove the bell housing cover.

I \ I FO9004

7. REMOVAL OF STARTING MOTOR

Remove the starting motor.
f
 MANUAL TRANSMISSION - Transmission

9. REMOVAL OF TRANSMISSION ASSEMBLY

(1) Remove the transmission mounting bolts (two bolts on
the upper- side) fromthe bell housing.
(2) Remove the remaining transmission mounting bolts.
(3) Support the transmission with a jack.
(4) Remove -the engine:support bracket and- insulator
assembly with the ground cable which is tightened
together with the insulator.

(5) Lower the transmission as shown in the Tffustration.

NOTE ~~~_ =
Place a piece of cloth on the rear of the cylinder head to ~1
prevent damage to the toeboard.
Remove~the-gearshiftjever assembly while the lever is I
in the neutral positio~n.

(6) Remove the transmission by pulling it toward the rear of

the vehicle.

SERVICE POINT OF INSTALLATION NZlMDAE

9. INSTALLATION OF TRANSMISSION ASSEMBLY

Note that transmission mounting bolts differ in size from
one place toanother.

O.D. x length mm (in,) b

 MANUAL TRANSMISSION - Transmission 21-13

TRANSMISSION NPlME- -

DISASSEMBLY AND REASSEMBLY

30-42Nm 11

-- 30-42 Nm
22-30 ft.lbs.
15-22 Nm
11-15 ft.lbs.
IO-13 Nm’
7-9 ft.lbs.

30 Nm
22 ft.lbs.

30-35 Nm
L4 22-25 ft.lbs.
3
F
35-45 Nm
2632 ft.lbs.

Disassembly steps
1. Oil filler plug
2. Gasket
3. Oil drain plug
4. Gasket
5. Sleeve clamp
I)+ 6. Speedometer assembly
7. Back-up lamp switch
8. Steel ball
** 9. Spring NOTE
I)* 10. Ball (I) Reverse the disassembly procedures to reassemble.
l * 11. Plug (2) *I): Refer to “Service Points of Disassembly”.
*41 12. Spring (3) *a: Refer to “Service Points of Reassembly”.
I)+ 13. Neutral plunger A (4) q : Non-reusable parts
I)+ 14. Neutral plunger B
+* l + 15. Extension housing
16. Extension housing gasket

132083
21-14 MANUAL TRANSMISSION - Transmission

II&J28 30

26

I9----25ill

&.--- 15-22 Nm
lo-15 ftlbs.

Disassembly steps
17, Under cover
18. 0rina
19. Snap ring
20. Mainshaft rear bearing
21. Snap ring
*+ 22. Plug
*+ 23. Poppet spring
*9 24. Steel ball
de *+ 25. Spring pin
NOTE 26. ‘l-2 shift rail
(I) Reverse the disassembly procedures to reassemble. ~ 27. 3-4 shift rail
(2) +*: Refer to “Service Points of Disassembly”. *I) *+ 28. Spring pin
(3) *+: Refer to “Service Points of Reassembly”. 29. OD-R shift rail
(4) q : Non-reusable parts 30. OD-R shift fork
31. Interlock plunger

I .ouuu/J
.-
 MANUAL TRANSMISSION - Transmission 21-15

181-195 ftlbs.

160-190 Nm
II&137ft.lbs.

Disassembly steps 1320004

(II) I)* 32. Mainshaft lock nut
+I) *(I 33. Countershaft lock nut 55 11-15 ft.lbs.
4* 34. Counter rear bearing
4* 35. Counter overdrive gear
36. Reverse idler gear
37. Spacer
I)+ 38. Snap ring
+W -39 Overdrive gear sleeve
4* 40--Needle bearing
4* 41. Overdrive gear / ,,I.
l * 42. Synchronizer ring
*(I 43. OD-R synchronizer sleeve -iL=%r &
I)+ 44. Synchronizer spring L
l * 45. Synchronizer key f
I)+ 46, Synchronizer hub
I)* 47. Synchronizer ring i
48. Reverse gear
49. Needle bearing
50. Bearing sleeve -ii Go
51. Split pin
52. Slotted nut
53. Thrust washer NOTE
54. Reverse idler gear (I) Reverse the disassembly proceduresto reassemble.
55. Needle bearing (2) +il):Refer to “Service Points of Disas’sembly”.
+I) I)+ 56. Reverse idler gear shaft (3) I)4: Refer to “Service Points of pe$?&erqb!y”. .r-.: ‘: -: :
57. Rear bearing retainer (4) q : Non-reusable parts
 MANUAL TRANSMISSION - Transmission

IO-13 Nm
7-S ft.lbs.
71

Disassembly steps
+I) I)+ 58. Mainshaft center bearing
l a 59. Spacer
60. Counter center bearing outer race
I)+ 61. Front beariny retainer
I)+ 62. Spacer
*+ 63. 011 seal
64. Spacer
65. Counter front bearing outer race
+d I)+ 66. Snap ring
+* *+ 67. Main drive yh’r bearing
68. Main drive $ar
69. 1 st-2nd shift,fork
70. Countershaft assembly NOTE
71, 3rd-4th shift fork (I 1 Reverse the disassembly procedures to reassemble.
72, MaInshaft assembly !2) +*, Refer to “Service-Points of Disassembly”.
73 Needle bearing !?I I)+. Refer tn “ServIcc? Points of Reassembly”.
74. Transmlsston case 141 q : Non-reusable parts
 -xgp -; d+&
MANUAL TRANSMISSION - Transmission 21-17
SERVICE POINTS OF DISASSEMBLY NZlMFBH

15. REMOVAL OF EXTENSION HOUSING

While pushing the change shifter down to left, remove
extension housing by pulling rearward.

,.

132036
!I _
r
.Li
25.28. REMOVAL OF SPRINGr’PlNS
Using a pin punch, drive out the spring pins.

-7#2. REMOVAL OF MAINSHAFT LOCK NUT / 33. COUNTER-

SHAFT LOCK NUT
(‘I) Using blunt punch or chisel that has a blade as shown in
the illustration, bend back lock tabs of the mainshaft
and countershaft lock nuts.
(2) Shift the OD-R synchronizer sleeve in reverse, and then
Ist-2nd synchronizer sleeve in -2nd. i?i
(3) Remove the mainshaft lock nut and count&shaft lock
nut.

34. REMOVAL OF COUNTER REAR BEARING 1.35. COUN- ‘a\+!

TER OVERDRIVE GEAR I
Pull off counter overdrive gear and ball bearing by using a
suitable puller.
-“l--.---~~ ~~ ~_ ~ ~~- ~-~~-_ _
&
E
21-18 MANUAL TRANSMISSION - Transmission
9
39. REMOVAL OF OVER DRIVE GEAR SLEEVE / 49, NEEDLE
BEARING / 41. OVER DRIVE GEAR
Using the special tools, remove over drive gear sleeve. _

56. REMOVAL OF REVERSE IDLER GEAR SHAFT

(1) Remove fou-r reverse idler gear shaft:mounting bolts. ~_
(2) Drive reverse idler gear shaft from inside of case. ;

-
58. REMOVAL OF MAINSHAFT CENTER BEARING
Using the special tools, remove mainshaft rear bearing.

66. REMOVAL OF SNAP RING

Remove the snap ring with snap ring pliers.

.~ =
67. REMOVAL OF MAIN DRIVE GEAR BEARING
Use the special t&l to remove the main drive gear bearing.
 MANUAL TRANSMISSION - Transmission 21-19
SERVICE POINTS OF REASSEMBLY
67. INSTALLATION OF MAIN DRIVE GEAR BEARING
Use the special tool to install the main drive gear bearing.

-_- ._..-.- _______ ____- _... ~~__

66. INSTALLATION OF SNAP RING
Install the snap ring with snap ring pliers.~

-63. INSTALLATION OF OIL SEAL

Apply transmission oil to oil seal lip, and install the oil seal to
the front bearing retainer using the special tool.

62. INSTALLATION OF SPACER / 61. FRONT BEARING

RETAINER
.~ ~~
Spacer Select spacer to adjust clearance (C) to the standard value
before installing the front bearing retainer. I_;r~

Standard value: 0 - 0.1 mm (0 - -004 in.)

1’;

59. INSTALLATION OF SPACER

(1) Hold down counter gear and bearing outer race (in the
direction of arrow shown in the illustration). _
x
 .__

MANUAL TRANSMISSION - Transmission

(2) Drive in Spring pin so as to place slit in drrectron ot

center line of shift rail.~-Drive_in spring pin for 3rd-4th and 1
1 st-2nd shift forks inthe same manner.
NOTE .~
Do not reuse spring spin.

Shift rail
14501

24. ~~L~~iON OF STEEL BALL / 23. POPPET SPRING /

5.5-6.0 mm
(22.-.24 In.)
(I) Insert steel ball and poppet spring into each -shift rail.
Tighten plug to specified position. _ .

Seal with sealer

5.5-6.0 mm
(.22-.24 in.)
5.5-6.0 mm
--i k-- L22-,24 in.) 134041

-- (2))lnsert~pC5j5pet spring with small end on ball stde. Three

springs are identical _fo one another.
Poppet spring
Ball (3) After installation. sea! plug head withy sealer.
I I Specified sealant: 3M Super Silicone 8662 or
equivalent

Small end

14501:

15. INSTALLATION OF EXTENSION HOUSING

When installing the extension housing, put the change
shifter down inthe arrow:direction, and fit control finger in
groove provided in selector.

Neutral rety ~~ &I1 Resistance spring 14. INSTALLATION OF NEUTRAL PLUNGER B / 13. NEU-
finrYE ‘, t TRAL PLUNGER A / 12. SPRING / 11. PLUG / 10. BALL /
9. SPRING
Install neutral return plungers% and B and springs. Then -=
install steel ball a.nd resistance spring, and tighten the seal
plugs.

Neutral return Net&al return ipring

plunger A plunger B 119CJ:iff
 -; ,

MANUAL TRANSMISSION - Transmission 21-23

6. INStALLATlON OF SPEEDOMETER ASSEMBLY .
Align mating marks accordin_&To.the number of teeth of
Extension
housing speedometer driven gear and Install assembly.

Mating marks
134045
21-24 MANUAL TRANSMISSION - Mainshaft Assembly

MAINSHAFT ASSEMBLY NPIPE-.

DISASSEMBLY AND REASSEMBLY

18 19
761517 I I

Disassembly steps
++ I. Ball bearing Inner race
2. 1 st speed gear
3. Bearing sleeve
4. Needle bearing
I)+ 5. 1 st-2nd synchronizer sleeve
6 Synchronizer ring
I)+ 7. Synchronizer spring
*+ 8. Synchronizer key
*+ 9. I st-2nd svnchronlzer hub
+I) IO. 2nd speed gear
11. Needle bearing
12. Snap ring
13. Synchronizer rtng
*+ 13. Synchronizer spring ,; IO
I)+ 15. Svnchronlzer key 6
** 16. 3rd-4th synchronizer hub
*+ 17. 3rd-4th synchronizer sleeve
18. Needle bearing
19. 3rd speed gear
20. Mainshaft

NOTE
(I 1 Reverse the disassembly procedures to reassemble.
(2) **. Refer to “Scrwce Points of Dlsassemblv”.
(3) +*: Refer to “Service Points of Reassembly’“.
(41 q : Non-reusde parts

+’

‘e
 MANUAL TRANSMISSION - Mainshaft Assembly ) 21-25 .:

SERVICE POINTS OF DISASSEMBLY NPIPFAA

1. REMOVAL OF BALL BEARING INNER RACE / io.

SECOND SPEED GEAR
Holding second speed gear on press base, push rear end of
mainshaft to remove bearing inner race-(double bearing
only), gear bearing sleeve, first speed gear, Ist-2nd speed
synchronizer and second speed gear.

INSPECTION N2lPGAA

l Check synchronizer ring for worn and damaged internal

threads. --
l With synchronizer assembled to cone of each gear, check
dimension “A”. .-
If “A” exceeds the limit, replace synchronizer ring and/or my;
gear. -~
Limit: 0.5 mm (.OZO in.)

jynchronizer ring Gear

SERVICE POINTS OF REASSEMBLY

-I-Tooth missing here
17. INSTALLATION OF 3RD-4TH SYNCHRONIZER SLEEVE /
NZlPHAA

16.3RD-4TH SYNCHRONIZER HUB / 15. SYNCHRONIZ-

ER KEY / 14. SYNCHRONIZER SPRING
(1) Mate synchronizer hub with sleeve using mark made at
disassembly. Make sure that hub and sleeve slide
smoothly. If they slide unsmoothly, replace hub and
sleeve assembly.
(2) 3rd-4th synchronizer sleeve has teeth missing at six _-
Synchrdnizer kev ./ -1, portions. Assemble hub to sleeve in such a way that
._ center tooth “T” between two missing teeth will touch
synchronizer key.

(3) Use care when installing 3rd-4th synchronizer hub since

only 3rd-4th synchronizer is directional. Smaller dia-
meter side “A” of center boss is front of 3rd4th _
synchronizer hub.
Front
‘I

145025
21-26,. MANUAL TRANSMISSION - Mainshaft Assembly

(4) insert th~t%elkeys in@ groove of synchronizer hub.

(5) Install two synchronizer springs to synchronizer.
When synchronizer springs are installed, make sure that
front and rear ones are not faced in same direction. ._

110013
- .-
16. INSTALLATlON OF 3RD-4TH SYNCHRONIZER HUB / 12.
SNAP RING
Mainsha (1) Assemble Sd-4th synchronizer positioning hub toward
3rd-4th I
synchroniz correct direction. ~
hub (2) As for mi;iir%haft fronfend snap ring, select and install
one of such thickness that will minimize -clearance _
Snap ring between snap ring and hub. In other words, install the
thickest snap ring that fits in snap ring groove.
(3) Make sure that 3rd speed gear turns smoothly.

13402i

9. INSTALLATION OF IST-END SYNCHRONIZER HUB / 8.

SYNCHRONIZER KEY / 7. SYNCHRONIZER SPRING / 5.
IST-2ND SYNCHRONIZER SLEEVE
Assemble Ist-2nd synchronizer in the same manner as tor
the 3rd-4th synchronizer described in the preceding step.
 MANUAL TRANSMISSION - Extension Housing 21-27
EXTENSION HOUSING NZlQE- -

DISASSEMBLY AND REASSEMBLY

Disassembly steps
** l + 1. Lock pin
l * l * 2. Spring pin
Control flange and control shaft
Neutral return finger
Change shifter
Dust seal guard
Oil seal
Extension housing

..

l8 NOTE
(I) Reverse the disassembly procedures to reassemble.
(2) *I): Refer to ‘:Service Points of Disassembly”.
(3) l *: Refer to “Service Points of Reassembly”.
(4) q : Non-reusable parts
132040

SERVICE POINTS OF DISASSEMBLY NZlQFA- -

Neutral return 1. REMOVAL OF LOCK PIN / 2. SPRING PIN

Change shifter To remove control shaft from extension housing, remove

lock pin from neutral return finger and remove spring pin
from change shifter with the special tool, Lock Pin
.
Extractor. Then remove control shaft toward front of
housing.

SERVICE POINTS OF REASSEMBLY NZlQHAA

7. INSTALLATION OF OIL SEAL

- Oil seal (1) Apply oil to lip of oil seal.
(2) Install oil seal with lip toward front of housing.

Apply oil

132041

2. INSTALLATION OF SPRING PIN / 1. LOCK PIN

Align pin holes of control shaft, neutral return finger and
change shifter and using the special tool, Lock Pin Installer,
install lock pin and spring pin.
NOTE
Do not reuse spring pin.
 MANUAL TRANSMISSION - Speedometer Sleeve Assembly

SPEEDOMETER SLEEVE ASSEMBLY N21RE..

DISASSEMBLY AND REASSEMBLY

Disassembly steps
I)+ 1. Spring pin
2. Driven gear
3. Sleeve
4. O-ring
5. O-ring

NOTE
(I ) Reverse the disassembly procedures to reassemble.
(2) *+: Refer to “Setice Points of Reassembly”.
(3) cilli Non-reusable parts

11000a _

SERVICE POINT OF REASSEMBLY

1. REMOVAL OF SPRING PIN
Drive spring pin in, while making sure that slit does not face ._
gear shaft. _
NOTE
Do not reuse spring pin.’

0-rina 1 lOOI<
 MANUAL TRANSMISSION - Countershaft 21-29
COUNTERSHAFT NPlXE- -

DISASSEMBLY AND REASSEMBLY

Disassembly steps
+I) l * 1. Counter front bearing
CI) I)+ 2. Counter center bearing
3. Countershaft gear

NOTE
(I) Reverse the disassembly procedures to reassemble.
(2) +*: Refer to “Service Points of Disassembly”.
(3) l +: Refer to “Service Points of Reassembly”.

132069

SERVICE POINTS OF DISASSEMBLY NPlXFAA

Taper bearing
1. REMOVAL OF COUNTER FRONT BEARING / 2. COUN-
TER CENTER BEARING
Remove taper roller bearings installed on both ends of
countershaft gear using the special tool.

Cylinder Counter gear ,320,18

j

SERVICE POINTS OF REASSEMBLY NPlXHAA

Press
1. INSTALLATION OF COUNTER FRONT BEARING / 2.
a
COUNTER CENTER BEARING
[I.D. 26 mm (1.024 in.: Using a steel pipe with dimensions shown in the illustra-
O.D. 30-31 mm tion, press fit the taper roller bearings.
(1.181-1.220 in.11 Be sure to set the pipe in such manner that it will press only
the bearing inner race, and not the cage.

13201
21-30 MANUAL TRANSMISSION - Gearshift Lever Assembly

GEARSHIFT LEVER ASSEMBLY NIlYE-.

DISASSEMBLY AND REASSEMBLY

Disassembly steps
1. Gearshift lever
2. Lever bushing
3. Gasket
4, Stopper plate

NOTE
(I 1 Reverse the disassembly procedures to reassemble.
(2) q : Non-reusable parts I 1-15 ftlbs.

INSPECTION NZIYGAA

l Check for play between control lever andcontrol lever “E”. i

If play is evident, replace- lever assembly.
@ Push control lever in and-check to ensure that it moves -1.
smoothly up and down.
l Check cover for damage and replace if necessary. To
remove cover;-~~ cut away with knife. To install new cover, _
first apply thincoat of oil tb periphery of control lever “B”.
Then install by sliding it down from top of lever “6”.
@ Check lever bushing for wear and replace ~if necessary.

Control lever

Control lever cover

L
cover

-Lever bushing
11004*
-
 MANUAL TRANSMISSION - Extension Housing Cover 21-31
EXTENSION HOUSING COVER NPIZE- .

DISASSEMBLY AND REASSEMBLY

Disassembly steps
1. Nut (2)
2. Spring washer (2)
** 3. Stopper bracket
l + 4. Special bolt (2)
5. Extension housing cover
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) I)*: Refer to “Service Points of Reassembly”.

11-15 ftlbs. 132013

SERVICE POINTS OF REASSEMBLY NSlZHAA

4. INSTALLATION OF SPECIAL BOLT

Apply recommended sealant to two special bolts (except
threaded portions) and install them to cover. Do not wipe
away excess sealant from cover.
Recommended sealant: 3M Liquid Gasket 8959 or
equivalent

3. INSTALLATION OF STOPPER BRACKET

(1) When installing the stopper bracket, apply recom-
mended sealant to threads of special bolts and torque
nuts.
Recommended sealant: 3M Liquid Gasket 8959 or
equivalent

(2) Check to ensure that reverse resistance plate moves

smoothly in directions A and B shown in the illustration
and is brought back by return spring.

resistance plate
3
21-32 AUTOMATIC TRANSMISSION - General Information

GENERAL INFORMATION NZ16AEU

Ez
The JM600 transmission is a fully automatrc unit consrstrng pnmarily of a 3 element hydrauliclock-up torque _ z
converter and three planetary gear sets. Three multrple-disc clutches, a mul$ple-disc brake, two brake bands, =
and a one-way clutch provide the friction elements necessayto obtain the desired function of -the three -- G
planetary gear-sets. E
A hydraulic control system IS used to operate the friction elements and automatic shift controls.
The lock-up torque converter IS attached to the crankshaft throu4h.a flex.ible$ive plate and serves to directly
couple the turbine and pump Impeller through the lock-up pistonwhich is controlled by the lock-uj, control 1
valve. Heat generated in the torque converter is dissipated by circulating the transmission fluid through an ._ s
oil-to-air type cooler. &s-
The welded constructron of the torque converter prohibits disassembly or service unlesshighly specialized s‘
equipment is available.

19 20 21 22 23 24 25
-

1.Converter housing 14. Low-@verse crutch_ .~

2.Torque converter 15. TransmiSsion case,. ~~
3.Oil pump 16. Governor valve mu
4. O.D. planetary gear 17. Output shaft
5.
6. Direct clutch
Drum support 18.
19. Rear-extension
Lock-up clutch _ .-
7.intermediate shaft 20. 1nptiBhaft
8. Second band brake 21. O.D. case
9. High-reverse clutch (Front) -22. O.D-brake band
IO.
11. Forward
Front clutch (Rear)
planetary 24.
23. Control
Oil p%
12. Rear planetary gear 25. Oil dE%ibutor
valve assembly
gear :
13. One-way clutch
 AUTOMATIC TRANSMISSION - General Information 21-33
IDENTIFICATION NUMBER
STAMPED POSITION
The plate is located on the top of the transmission.
IDENTIFICATION OF NUMBER ARRANGEMENTS

JAT0002 i NUMBER DESIGNATION

31020

Serial production number for

~~~n~~hprodm~ion
1 : Jan., 2: Feb., .. . . . .
X: Oct., Y: Nov., Z: Dec.
Last figure denoting the year (A.D.)

TORQUE CONVERTER
Turbine The torque converter is with a lock-up clutch, which is designed
to operate when specified vehicle speed is exceeded in the
“D” range, 4th speed.
Lock-up
clutch

One-way
clutch

‘Stator

JATOOOC AUTOMATIC TRANSMISSION MECHANISM

The transmission mechanism consists of three sets of multiple
disc clutches, two sets of band type brakes, one set of one-way
clutch and single row type planetary gear and double row type
(called Simpson type) planetary gear.
The three sets of clutches are the element to control input to
the planetary gears and the three sets of brakes and one-way
clutch are the element to fix or prevent rotation of the planetary
gears. By these elements, the point at which the input is made
and the gears which are to be fixed are controlled, thus giving
the gear change ratio meeting the driving conditions.
When and which element operates is shown in the Element in
Use at Each Position of Selector Lever.
21-34 AUTOMATIC TRANSMISSION - General Information
Element in Use at Each Position of Selector Lever

HYDRAULIC CONTROL SYSTEM

The hydraulic control system consists of~an oil pump that generates hydraulrc pressure, the valve body
assembly incorporating a hydraulic pressure control valve, oil passage change-over valve, etc., hydraulic
piston to operate the clutches and brakes, etc. These elements are operated erther manually or hydraulically
tom controlLthepIanetary gears.
OIL PUMP
The oif pump generates hydraulic pressure to supply oil to the torque converter or control the hydraulic control
system and to lubricate the planetary gear sets, overrunnrng-clutch and Qther parts requiring lubrication.
The oil pump is an internal/external gear pump of which drive gear is driven by the pump drive hub welded at
the center of the torque converter shell, constantly developing hydraulic pressure while the engine is running.
 AUTOMATIC TRANSMISSION - General information 21-35
PRESSURE REGULATOR VALVE
The pressure regulator valve automatically regulates the hydraulic pressure supplied to each element to a
pressure (line pressure) according to current vehicle speed and engine output (throttle valve opening).
MANUAL VALVE
This valve provides switching of oil ways that is linked to the selector lever. The valve causes either P, R, N, D,
2 or L range to be selected according to the lever operation.
IST-2ND SHIFT VALVE
This valve automatically switches oil ways between the 1st and 2nd speeds according to the governor
pressure and throttle pressure.
2ND-3RD SHIFT VALVE
This valve automatically switches oil ways between the 2nd and 3rd speeds according to the governor
pressure and throttle pressure.
PRESSURE MODIFIER VALVE
This valve controls the throttle pressure acting on the pressure regulator valve to reduce line pressure when
the vehicle is running at high speed.

1. Pressure regulating valve

2. Manual valve
3. 2nd-3rd shift valve
4. 1 st-2nd shift valve
5. Pressure modifier valve
6. 3rd-4th shift valve
7. Vacuum throttle valve
8. Throttle back-up valve
9. Solenoid downshift valve
10. Second lock valve

JATO05
 -__

21-38 AUTOMATIC TRANSMISSION - General Information

HYDRAULIC CONTROL CIRCUIT

“N” (NEUTRAL)

Throttle
 AUTOMATIC TRANSMISSION - General Information 21-39
“P” (PARKING)

High-
OD O.D. reverse Forward 2nd Low Et

=
Torque cancel clutch clutch rwerse
Drect band band

-
Con”erter snlenad IFront) Read brake
brake brake

OD
lnd!ca IOr
swltct 1’
1I
I
[

ft

modlfter valve

I 11 --II

-LG-I I LKle preSS”re

Throttle pressure
D Governor pressure
0 Torque converter pressure
Secondary Primary Note, Marked x are drain.
go”er”orvalve go”er”or valve

JATISS
21-40 AUTOMATIC TRANSMISSION - General Information

“D” (DRIVE) - FIRST

011
IP
so band clutch
IFront)
clutch
Reari
band
I._.._
hds

B e

3t0, ,,I---
h TIC
back-up
-1
valve

-= hltl
d
 AUTOMATIC TRANSMISSION - General Information 21-41
“D” (DRIVE) - SECOND

High-
reverse Forward 2nd
Torque clutch clutch
CCl”WS,W 011
Pump

P-

T/C
back-up
valve

diaphragm -t IH
I I I

JLIBIIII -R I-flIR I11

Lock-up
control
valve

Accumulatl
q
EC q
=
I,
Front I,
lubricatton

1st.2nd f’
shlfl valve

2nd.3rd
shift valve

Secondary Primary Note. Marked x are drain.

governor valve governor valve

JAT202
21-42 -
AUTOMATIC TRANSMISSION - General Information

- THIRD, O.D. SOLENOID IN OPERATION

 AUTOMATIC TRANSMISSION - General Information

“D” (DRIVE) - FOURTH, TORQUE CONVERTER LOCKED UP

High-
O.D. 0.D reverse Forward 2nd

T/C
back-w

dI
Valve

% Front
lubrlcatlon

Second
lock valve

II h II III
a Throttle pressure
0 Governorpressure
0 Torque converter pressure
Secondary Primary Note Marked x are drain.
governor valve go”er”orvalve

JAT204
AUTOMATIC TRANSMISSION - General Information

brake

Ii!

-I -~
w
Throttle
rei1ef valve

1
 AUTOMATIC TRANSMISSION - General Information 21-45
“2” (SECOND) - SECOND

High-
0.D reverse Forward 2nd Low 8
.
.n CI”K2”
.- band reverse

0.D
mdv xtor
swt ch T/C
back-u$
valve

olapnragm solenoid
I
I ( _

Lock-up
Control
valve

Front
lubncatlon I!
=l IIL e== modlfler valve

--ii

P-m-
d
PreSSll, Second
regulatl lock valve

======+
n
ph--,_l Throttlepressure
0 Governor pressure
0 Torque converterpressure
Secondary Primary Note. Marked x are drain.
governor valve governorvalve

JAT206
21-46 AUTOMATIC TRANSMISSION - General Information
II,
L
II
(LOCK-UP)

hlh
d

2nd3rd
shift valve

IA I7OH
 AUTOMATIC TRANSMISSION - General Information
“R” (REVERSE)

HIah-
OD r&erse Forward
Torque
converter

OD
rndlca
swltct I’

t
II T/C
back-ul.
valve
-
J
E F

4
Lock-up
Control
valve

kcumulat

Front
lubrxatlon

Lk!I= modlfvxvalve m

w Throttlepressure
0 Governor pressure
0 Torque conveJter pressure
Secondary Primary Note Marked x are dram
go”er”or valve go”er”orMlve

JAT200
 : .____~

21-48 AUTOMATIC TRANSMISSION - Specifications

SPEClFlCATlQNS NZlCA-.

GENERAL SPECIFICATIONS
Items Specifications :-

Torque converter
Type With lock-up clutch
Stall torque ratio 2.0 : 1
Stall speed wm 2,750 - 3,050 _
Transmissiorr
Type 4-speed, Full-automatic
Gear ratio 1st 2.458
2nd 1.458
3rd 1.000
4th (7.686
Reverse 2.182
Direct clutch
We Multiple-disc _~
No. of drive plates 2
No. of driven plates 2
High-reverse clutch
Type Multiple-disc
No. of drive plates 4
No. of driven plates 5
Forward crutch
Type Multiple-disc ~
No. of drive plates 6
No. of driven plates 6
Overdrive brake
We Band
Second brake
Type Band
Low/reverse brake
Type Multiple-disc
No. of drive plates 8
No. of driven plates 8
Oil pump
Type Internal-external gear type
Driven by Engine
Oil cooler Oil-to-water type
 AUTOMATIC TRANSMISSION - Specifications 21-49
SERVICE SPECIFICATIONS NZlCB- -

Items Standard Limit

Engine idle speed rpm 850+100 -

Stall speed wm 2,750-3,050 -
Direct clutch side plate clearance mm (in.) O-O.2 (O-.008) -
High-reverse clutch clearance mm (in.) 1.6-2.0(.063-.079) -
Forward clutch clearance mm (in.) 0.8- 1.6(.031 -.063) -
Low-reverse brake clearance mm (in.) 0.80-1.25 (.031 -.049: -
Front end play mm (in.) 0.5-0.8(.020-.031) -
Front total end play mm (in.) 0.25-0.50(.010-.020) -
O.D. pack end play mm (in.) 0.5-0.8(.020-.031) -
O.D. total end play mm (in.) 0.25-0.50 (.OlO-,020) -
Clearance between oil pump outer gear and 0.14-0.21 (.0055-.0083) 0.25(.0098)
crescent ~mrn (in.1
Clearance between oil pump outer gear and 0.05-0.20(.0020- -0079) 0.25(.0098)
housing mm (in.)
Oil pump gear end play mm (in.) 0.02 -0.04 (.0008-.0016) 0.08 (.0031)

TORQUE SPECIFICATIONS NZlCC-.

ems Nm ft.lbs.

ransmission installation
Drive plate to crankshaft 128-138 94-100
Drive plate to torque converter 56-62 42-46
Converter housing to engine 43-54 31-39
omponent part
Converter housing mounting bolt 44-54 33-40
Rear extension mounting 20-25 14-18
Oil pan bolt 5-7 3.6-5.1
2nd servo piston retainer to transmission case 7-9 5-6
2nd piston stem (when adjusting band brake) 12-15 9-11
[Turn back three [Turn back
turns after three turns after
tightening] tightening]
2nd piston stem lock nut 15-39 II-29
One-way clutch inner race tightening bolt 13-18 9-13
Control valve body mounting bolt 5.4-7.4 4.0-5.4
Lower valve body to upper valve body 2.5-3.4 1.8 - 2.5
O.D. servo cover to retainer 5-7 3.6-5.1
O.D. servo piston retainer to O.D. case IO-15 7-11
O.D. stem (when adjusting band brake) 7-10 5-7
O.D. stem lock nut 15-39 II-29
Governor tube 15-18 II-13
 AUTOMATIC TRANSMISSION - Specifications

Oil strainer to lower valve body

Governorvalve body mounting bolt
Oil pump housing to oil pump cover
Cross-shaft to cross-shaft lever
Shaft to detent plate
Inhibitor switch mounting bolt
Manual shaft lock nut
Oil cooler pipe to transmission case
Test plug (oil pressuminspection hole)
Support actuator (parking rod inserting position) to
rear extension
Drum support to O.D. case
Downshift solenoid
Vacuum diaphragm
O.D. solenoid

LUBRICANTS NZlCD.

Sliding parts of selector lever

 AUTOMATIC TRANSMISSION - Special Tools 21-51
SPECIAL TOOLS
Tool (Number and name) Use Tool (Number and name) Use

M D998393 Assembly of oil pump MD998390 Removal of oil pump

Guides and O.D. case Sliding hammer

MD998394 Use with oil pressure MD998391 Assembly and dis-

Oil pressure gauge adaptor gauge Clutch spring compressor assembly of clutch

‘-
*

c-3292 Measurement of oil MD998392 Loosening and tighten-

c-3293 pressure Hex-head extension ing of one-way clutch
Oil pressure gauge inner race bolt
21-52 -~
AUTOMATIC TRANSMISSION - Troubleshooting

TROUBLESHOOTING N21ERADa

PRELIMINARY CHECKS (Prior to road testing)

VERIFY CUSTOMER COMPLAINT
The customer should supply as much informatron as possible,
rncluding any unusual characterrstlcs that accompany the
complarnt. -
FLUID LEVEL
I. Drive the car -several miles (kilometers) to bring the
rransmrssron up to notmal operating temperature [50 to -~I
8OT (122 to: 176”F)1. 4
2. Park the car on a level surface.
3. Put wheel chocks in place, apply parking brake se$rely and y:
leave the engine running.
4. Slowly move the selector lever through the entire shift i
pattern, and-return it to-“N” neutral. __
5. Remove the dipstick, clean it, and replace it fully m the filler AL
tube.
6. Quickly remove it againr%nd read the level. -~
Keep the fluid at the proper level. Overfilling may blow off L
the fluid during high-speed driving. Underfilling may cause
JA-KlO3 the clutches-to slip, and burn. .-7
The “L” mark on the dipstick indicates the transmission IS --
dgproximately 0.4 liter (718 pt.) low.
Add onlv clean DEXHON II type transmrssron fluid.
FLUID LEAKAGE
To detect a fluid leak: _
I. Halse car. ~~ mu
1’. Clean area suspected oGeak;ing.
9d 1 Start enqrnerapply foot brake, place gear selector rn drive,
and wait a few mrnutes.
-
4. Stop engine.
5. Check for fresh leakage:
If the transmrssron breather IS suspected:
I. Raise car. - _
2. Clean the area-around the breather.
3. Run the car at. highway speeds.
4. Check the breather for fresh leakage.
FLUID CONDITION
rransmission tluid color and exture can ard greatly in._~transmit-
sron troubleshootrnq. When checking fluid level, examine the-=
transmrssron fluid and noterts color, texture, and odor.
Some common ?orms of ctrntamrnatlon are listed below: ~_
Dark or Black Fluid:
With a burned odor - Wom tnctron material.
Milky Pink Fluid: Water contaminatron
= Road water entering through filler tube or breather. _
Varnished Fluid. Liht to Dark Brown and lfacky: Uxidation
_ C!ver or undertillrng.
_ Overheating.
AUTOMATIC TRANSMISSION - Troubleshooting 21-53
ENGINE IDLE SPEED
Check and adjust idle speed to specifications.
Standard value: 850 f 100 rpm
ENGINE OIL AND COOLANT LEVELS
Prior to road testing, check engine oil and coolant levels, and fill
as necessary.
SHIFT LINKAGE
Start in Park position, depress detent button and slowly move
the gear selector through all ranges. The detent “clicks” should
correspond with the range indicator.

DIAGNOSTIC ROAD TEST

Prior to road testing, perform the preliminary inspections
outlined earlier. If the car is not equipped with a tachometer,
install a portable tachometer in the car. And also install a
suitable vacuum gauge and pressure gauge. If the customer
has a specific complaint, select road conditions similar to those
described. (e.g. steep hills, freeways, etc.)
Follow the test sequence as outlined in this section and mark
the results on the Symptom Chart on page 21-64. It may be
necessary to repeat sections of the test under different throttle
conditions (e.g. light, medium or full throttle). After completing
the road test, compare the test results to the Troubleshooting
Chart on page 21-60.
ROAD TESTING
PARK RANGE
Place the selector lever in “P” range and start the engine.
Stop the engine and repeat the procedure in all other ranges
and neutral. In park, the car should be locked in position, unable
to roll or move. Mark all results on the Symptom Chart.
REVERSE
Manually shift the selector lever from “P” to “R”, and note
shift quality. Drive the car in reverse long enough to detect
slippage or other abnormalities. Note results.
NEUTRAL
Manually shift the selector lever from “P” to “N” and note
quality. In neutral, there should be no movement. Note results.
21-54 AUTOMATIC TRANSMISSION - Troubleshooting

DRIVE RANGE I .~
Manually shift the selector lever to range “D”, and note shift -1
quality. Drive the ca.r through all automatic shifts and in aIf gear
ranges. Note shift quality and timing [km/h (MPH)], and check ‘-
whether torque converter is- locked up or not at ‘specified
speed. Check forslippage, noke, or other abnormal conditions. --
If necessary, drive the test sequence under different throttle -i
&l opening (e.g. light,~ medium or full throttle).
Check overdrive range for slippage, noise, or other abnormal
Drive in different
throttle conditions conditions. Maintain.a constant speed of 56 to 64 km/h (35 to
JAT182 40 MPH) on a level surface and turn the O.D. switch on the I
console “ON” and- “OFF”. The transmission should upshift :
rmmediately when the switch IS turned “ON”, and downshift :
immediately when the swatch is turned “OFF”.
Because the shock is very low and is not notrceable when the _
torque converter:is locked up, it is difficult to confrrm whether
the torque converter IS locked up or not. So please check the ~z
engine rpm with tachometer while the car is driving to confirm ~~
it. If the torque converter IS locked up the engine rpm is .~-
decreased 290--to -400 rpm at the same time. ..
Lock-up zone: Refer to Shift Schedule on page 21-56.

RANGE “2” -r
Manually shift the -selector -lever to range I’,“. Check for ~_
slippage, hesita.tion or abnormal condition. The transmission ~1
should remain in 2nd gear regardless of car speed or engine
revolutions. Note results. _
RANGE “L”
Manually shift the selector -lever to range I’L”. Note shift ~
quality. It should, however, downshift immediately to 2nd gear 1
and downshift again to lstgear as road speed decreases.
JAT18E Accelerate and. decelerate in 1st gear to determjne engine -:
revolutions. Note results. ~;~
The transmission should not shift rnto 1 st gear-trom mWD’rrange I~:
If the car road speed is above approxrmately 50 km/Ii30 MPH).
Record line pressure at each range and at each throttle vacuum .
in accordance withy the pressure testing desdrjbed below. _
 AUTOMATIC TRANSMISSION - Troubleshootina
CAR SPEED AND LINE PRESSURE WHEN SHIFTING GEARS

Dz+ DI II-20(7-12) 350-600

-26.7 (-200,-7.9) D I+ Dz 16-26(10-16) 500-800

Dz+Ds 20-33(12-21) 600-1,000

D3-+Da 41-57(25-35) 1,260-1,760

D 4-3 Ds 18-34(11-21) 560-1,060

II-28(7-17) 350-850
E:z k Or

D 2-? D, II-20(7-12) 350-600

+46.7 (+350, +13.8) 123 11 44-54(27-34) 1,350-1,650

-60(-450,-17.8) 12-? I, 42-52(26-32) 1,300-1,600

21-56 AUTOMATIC
__~. TRANSMISSION - Troubleshooting

SHIFT SCHEDULE 4OO

(300,
11.81) I
I
26.7 I

-26.7
(-200, L-

P I
20 ,4?, 60
I,
80I . 100
1
1
120

kioo, 60, i60) (70)

km/h (MPH) JATl90 - so

PRESSURE TESTING
The transmission is provided with two pressure test ports.

pressure for “RY range JATISI

LINE PRESSURE
1. Disconnect both line pressure and servo release pressure
plugs and, irr theirplaces, attach pressure gauges. ;

\ / JAT19; ,

2. Install vacuum gauge. 7 -~~

3. Check levels of engine:cooling water, engine oil and ’
automatic transmission fluid. Add as necessary, to reach -1
the specified level.
4. Warm up engine until engine oil and automatic transmission ..?
fluid reach rtormal -operating temperatures.
5. Place wheel chocks at all wheels, and firmly engage parking =
brake.
6. Measure line pressure ~lt idle and at SIT& point while
depressing brake pedal fully.
AUTOMATIC TRANSMISSION - Troubleshooting 21-57
Line Pressure at Idle

Range Line pressure kPa (psi)

R 304 - 441 (44 - 64)

D 275 - 373 (40 - 54)
2 785 - 1,128 (114 - 164)
1 275 - 373 (40 - 54)

Line Pressure at Stall Point

Range Line pressure kPa (psi)

R 1,961 - 2,354 (284 - 341)

D 1,667 - 1,883 (242 - 273)
2 1,667 - 1,785 (242 - 259)
1 1,667 - 1,883 (249 - 273)

Key points of pressure testing are:

1. Pressure at idle: Lock for a steady rise in pressure as car
speed increases under light load.
2. Pressure drop between shift points should not exceed 98
kPa (14 psi). Excessive pressure drop may indicate an
internal leak at servo or clutch seal.

STALL TEST
The stall test is an effective method of testing clutch and band
holding ability, torque converter one-way clutch operation, and
engine performance. A stall test should only be performed as a
last resort because of the high fluid temperature it generates
and the excessive load it places on the engine and transmis-
sion.
Caution
1. During test, never hold throttle wide-open for more
than 5 seconds.
2. Do not test more than two gear ranges without driving
car to cool off engine and transmission.
STALL TEST PROCEDURE
1. Transmission and engine fluid levels should always be
checked and fluid added as needed.
2. Run engine at 1,200 rpm to attain proper warm-up.
3. Set parking brake and block wheels.
4. Install a tachometer where it can be seen by driver during
test.
JATl9i
5. Start engine and place selector lever in “D” range.
6. Apply foot brake and accelerate to wide-open throttle. Do
not hold throttle open longer than five seconds.
7. Quickly note the engine stall speed and immediately
release throttle.
Standard value: 2,750 - 3,050 rpm
8. Shift selector lever to ‘IN”.
9. Run engine at 1,200 rpm for at least one minute, allowing it
to cool off.
10. Perform stall tests in the same manner as in steps 5
through 9 with select lever in “Z”, “L” and “R”, respective-
JATI 9E IY.
21-58 AUTOMATIC TRANSMISSION - Troubleshooting

STALL TEST ANALYSIS

1. Satisfactory titilts in “D” range indicates forward clutch ~_
(Rear), direct-crutch, highzreverse clutch (Front), one-way
clutch of transmission, and one-way clutch of torque
converter, are functioning properly.
The analysis diagram is shown below.

“D” range test

N.G.

Stall sieed is

I
‘7’
Direct clutch, forward clutch (Rear) or
one-way clutch slips

“L” range test

Direct clutch or forward ilutch ~~

(Rear) slips

“R” range test

Direct’clutch
(Rear) slips slips

.r-
Toolow
I
Lock-up clutch IS dragging, converter one-way
clutch is faulty (slipping), or engine
is not perfortnrng properly.

IO.K.
!
I 1
See next page
- -.
AUTOMATIC TRANSMISSION - Troubleshooting 21-59

Continuous from previous page

1 “R” ‘;lit 1 _

Stall speed is

$
Too high

I
High-reverse clutch (Front) or
low and reverse brake slips

I
Perform road tests to’ determine whether
high-reverse clutch (Front) or low
and reverse brake slips

I
When shift select lever is in “L” range

No engin: braking

l
Low and reverse brake
slips

Effective enLine braking

I
High-revetse clutch
(Front) slips

1
Too low

Lock-up clutch is dragiing, converter one-way

clutch is faulty (slipping), or engine
is not performing properly.

If converter one-way clutch is frozen, car will have poor high

speed performance. If converter one-way clutch is slipping, car
will be sluggish up to 50 or 60 km/h (30 or 40 MPH).
 pg 1

:-

AUTOMATIC TRANSMISSION - Troubleshooting

TROUBLESHOOTING CHART
ON CAR : OFF CAR

Numbers are arranged In order of probabill-

ty. Perform inspections starting with number
one and working up. Circled numbers Indi-
cate that thetransm_csron must be removed
from the car
a,
g
E
Y
it
1
-
Engine does not start In “N”, “P” ranges
-
E;gine starts in range other than “N” and
,I
-
Transmission noise in “P” and “N” ranges
-
Car moves when changing Into “P” range 1
or parking gear does not disengage when
shiftedaut nf “P” range
-
Car runs in “N” range 1
- -
c+r, w,ill ,Fot ru; i; “R” range (but runs In 6 4
2 and L ranges). Clutch slops
Ve& poor acceleration
-
Car braked when shiftina into “R” range 61
- -
Sharp shock in shifting from “N” to “D”
range
-
Car will not run in “D” range
(but runs In “2”. “L” and “R” ranges)
-
Car will not run in “D”. “L”. “2” ranges 6 3 7
(but runs in “R” range) Clutch slips
Very poor acceleration
-
Clutches or brakes slip somewhat In startIn<
-
Excessive creep
-
-
No creep at all I 2 . 5
- -
Failure to chanae aear from “1st” to “2nd” 1 5 6
~ -
Failure to change gear from “2nd” to “3rd’ 1 5 6 -
Failure lo change--gear from “3rd” to “4th” 5 6
-
Too high a gear change point from “1st” 3 5 6
to “2nd”, from “2nd” to “3rd”. from
“3rd” to “4th”

Gear change directly from “1st” to “3rd”

3ccurs
__ _~ -
Gear change directly from “2nd” to “4th”
3ccurs
 AUTOMATIC TRANSMISSION - Troubleshooting 21-61

Numbers are arranged in order of probability.

Perform inspections starting with number one

to “4th”

Yom “3rd” to “1 st”

, from “2nd” to “1st”

 AUTOMATIC TRANSMISSION - Troubleshooting

ON CAR OFF CAR

.a
a
Numbers are arranged In order
of probabllltv. Perform insaec-
tlons starting wirh numbe;
and workrng up. Circled number
indicate that the transmrssion
must be removed from the

Transmissron nurs-e rn “0”.

nd” to “3rd” In

nslve sme

-Ight inslde O.D. cancel switch

lees not glow even rf trans-
nission is shifted to 0-D.

*’ Reter to the next page

 AUTOMATIC TRANSMISSION - Troubleshooting 21-63

ON CAR OFF CAR

b
5
z
Numbers are arranged in order of probability. 2
Perform inspections starting with number one and working up. c 9 z
0
Circled numbers indicate that the transmission must be removed z tii T c
from the car. r E ‘a,
$ 22 5 al b p
36 z 2v) Q
.G z8 g ‘5
P .E E
f f n 9 4 sf
F ? .-P P 2
8 8 1P 6 p 34 32 5

Torque converter is hot locked up

Lock-up piston slips

-ock-up point is extremely high or low

Engine is stopped at “R”, “D”, “2” and “L” ranges

rransmission overheats
-i-.

21-64 AUTOMATIC TRANSMISSION - Troubleshooting

ROAD TEST SYMPTOM CHART

Engine
Braking
 AUTOMATIC TRANSMISSION - Troubleshooting 21-65
TROUBLESHOOTING GUIDE

Order Test item Procedure

Checking 1. Oil level gauge Check gauge for oil level and leakage before and after each
test.
2. Downshift solenoid Check for sound of operating solenoid when depressing
accelerator pedal fully with ignition key “ON”.
3. Manual linkage Check by shifting into “P”, “R”, ‘IN”, I’D”, “2” and “L”
ranges with selector lever.
4. Inhibitor switch Check whether starter operates in “N” and “P” ranges
only and whether reverse light operates in “R” range only.
5. Engine idling rpm Check whether idle speed meets specifications.
6. Vacuum pressure of vacuum Check whether vacuum pressure is more than 60.0 kPa
pipe (450 mmHg, .177.72 in.Hg) at idle and whether it decreases
with increasing rpm.
7. Operation in each range ~~ec~w~~h~~Ir~S~1Ss,loN?,engages positively
~ I, L” and I,N I, ~ by
I, R:hifting
range while’idling with b;ake applied.
8. Creep of car Check whether there is any creep in “D”, “2”, “L” and
“R” ranges.

Stall test 1. Oil pressure before testing Measure line pressures in I’D”, “2”, “L” and “R” range
while idling.
2. Stall test Measure engine speed and line pressure in “D”, “2”. “L”
and “R” ranges during full throttle operation.
Temperature of torque converter oil used in test should be
from 60 to 100°C (140 to 212°F) i.e., sufficiently warmed
up but not overheated.
Caution
To cool oil between each stall test for “D”, “2”, “L”
and “R” ranges, idle engine, i.e., rpm at about 1,200
rpm for more than 1 minute in “P” range. Measure-
ment time must not be more than 5 seconds.
3. Oil pressure after testing Same as item 1.

Road test 1. Slow acceleration, Check car speeds and engine rpm in shifting up 1st + 2nd,
Ist+ 2nd 2nd -+ 3rd range and 3rd + 4th range and when torque
2nd + 3rd converter is locked up while running with lever in “D”
3rd + 4th range and engine vacuum pressure of about 0 kPa (0
mmHg, 0 in.Hg).
2. Quick acceleration, Same as item 1 above except with engine vacuum
Ist+ 2nd pressure of +46.66 kPa (+350 mmHg, +13.78 in.Hg) (i.e.,
2nd -+ 3rd in position just kickdown).
3. Kickdown operation, Check whether the kickdown operates and measure the
4th + 3rd. 3rd -+ 2nd or time delays while running at 30,40, 50, 60.70, 100 km/h
2nd+ 1st (19,25,31,37,43, 62 MPH) in “D3” or “D4” range.
4. Shift down, Check car speeds and engine rpm in shifting down from
Da+ Dz+ Dz-+ D, 4th + 3rd + 2nd + 1st (sequentially) while coasting with
accelerator pedal released in “D4” range and engine
vacuum pressure of about -60.0 kPa (-450 mmHg, -17.72
in.Hg).
5. Shift down, Check for shifting down D3+ I2 and engine braking, and
Dz+ lz+ I, further for shifting down I?+ 1 1and engine braking after
shifting the lever into “L” range with the accelerator pedal
released and the engine vacuum pressure of about 60 kPa
(450 mmHg, 17.72 in.Hg) while driving at about 50 km/h
(30 MPH) in “D3” range.
6. Shift down, Check for quick shifting down D3 + 2 and engine braking,
D3+2 after shifting the lever into “2” range while driving at about
50 km/h (30 MPH) in “D3” range.
Also, check for locking of the transmission in 2nd gear ratio
regardless of car speed.
21-66 AUTOMATIC TRANSMISSION - Troubleshooting

Order Test item Procedure

-.
Road test -e.1 17. Shiftup, Check for failure of the transmission to stjfrgp du;g
1 I-+ 12 acceleration. when starting in “L” range.
8. Shift up or down when start- Check the transmissionjor note shifting up or down during
ing in “2” range acceleration or deceleration, when starting in “2” range.
9. Parking Confirm that car will not move on grade when shiftjng to
“P” range:
10. 0-D. cancel switch operation Confirm that transmission will not shift to overdrive while
running with O.D. can@-switch ON.
Il. O.D. indicator light Confirm that O.D. iridicatsr light glows when ignition
switch is ON (engine notstarted), and that it goes off as
soon as engine is started. Confirm that light glows when
transmissionis shifted to O.D. and driven in “D” range
with O.D,cancel switch -OFF.

Others Abnormal shock, oil leakage Enter into record conditions observed duringthese tests
such as gear noise, abnormal clutch noise and acceleration
performance.
 AUTOMATIC TRANSMISSION - Troubleshooting 21-67
4-SPEED AUTOMATIC TRANSMISSION

CIRCUIT DIAGRAM
Battery Sub fusible link 2

Multi-purpose
@(I fuse

Engine coolant
temperature B-23
gauge unit

I
1 R
Overdrive
switch

- Br
B-46
I

Kick down switch I I

1 Br r
klll I I I
LgB u.

1 Br zrdrivzoiq

A-19 1w 1
Down shift solenoid
~fzf~fmercontrol

[Refer to P.*-66.1 =
Over drive relay
Wire color code
B: Black 11;: &3rn G: Green
Remark Gr: Gray Lg: Light green
For details of grounding points (ex.: I), LI: Light blue 0: Orange P: Pink
refer to page 8-i 0. R: Red W: White Y: Yellow 37Y597
rmxll, * .-----~~- ___~~-

21-68 AUTOMATIC TRANSMISSION - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

TRANSMISSION FLUID INSPECTION

(1) Place vehicle-on level fla_pr.
(2) Befdre remting dipstick, wipe all dirt from area around T
dipstick.
(3) With selector lever in “P”1Park) and parking brake applied,
start engine. =
JATOO
(4) Engine should be running at idle speed. Trai%missi& -7
should be warmed-up suf%ently [fluid temperatcre 50 to I’
80°C (I 20 ta: 18O”FjI.
(5) Move selector lever sequentially to every posItion to till
torque converter and hydraulic circuit wrth fiuld, then place ~~
lever in “N” (Neutral) posItIon.
(6) Check to see rf fluid level IS In the range indrcated on ii
dipstlck.
If it is low, add ATF until level reaches that range. -1
Transmission fluid: DEXRON II type
Low fluid level can cause a variety of troubles because It
allows pump to take in art- along with fluid. Air trapped in
hydraulic circuit forms bubbles which make fluid spongy.
Therefore, pressure-s will be erratic, and causes delay of 1
shifting, and slippage ot clutch and brake.
Improper filling can ralSe fluid level too high. When .mT
transmission has too much fluid, gears churn up foam and
cause same conditions which occur with low fluid level, ~_
resulting in accelerated deterioration ot ATF.
In either case, air bubbles can cause overheating, fluid z
(j%ldatlon, and varnishing,. which can lntertere with normal
valve, clutch, and servo operation.
Foaming can also result in fluid escaping from transmission ._
vent where it may be mistaken. tar a leak. Along with fluid ~~
level, It is impdnant to check the condition of the fluid. ~.
When fluid smells burned, It IS contaminated vth metal c
bushing or friction material particles, and a complete ~-
transmlsslon overhaul is needed. Be sure TV examrne fluid
on dipstick closely. If there is any doubt about Its condition, me
drain out sample for double check. After ~fluid has been 11
checked, seat dipstick tully to seal out water and dirt. _

TRANSMISSION FLUID REPLACEMENT NZlFCBAa

Refer to GROUP U LUBRIC?,TION AND l&lAINTENANCl$ - __

Automatic Transmission. :
 AUTOMATIC TRANSMISSION - Service Adiustment Procedures 21-69
SPEEDOMETER CABLE REPLACEMENT N21FEAAa

(1) Replace the cable assembly if there is a malfunction.

7 (2) When connecting the cable to the meter, insert the cable
until its stopper properly fits to the meterside groove.

16F554

(3) After installing the speedometer,’ pull the speedometer

cable through the grommet in the toeboard until the cable
marking is visible from the engine compartment side.
Caution
Poor installation of the cable may cause a fluctuating
meter pointer, or noise and a damaged harness inside
the instrument panel.
21-70 AUTOMATIC TRANSMISSION - On-vehicle Service

ON-VEHICLE SERVICE NZlFA- -

The following parts can be servrced wrth the transmrssron on

the vehicle.
I. Control valve body assembly
i-.
‘> Extension oil seal ==
3. Parkinq components !.
4. Governor valve assembly
5. Inhibitor switch _~
6. Vacuum diaphragm and downshitt solenord
Check and/or replace faulty parts as toliows;

CONTROL VALVE BODY ASSEMBLY

1. Drain fluid by removing oil pan.
2. Remove dowshift solenoid and vacuum diaphragm and
rod. Be careful not to lose vacuum rod.

- -
3. Remove seX@ei~ bolts and remove control valve body I~
assembly.
4. Disassemble, inspect and reassemble control valve body
assembly. Refer to page 21-120 for Control Valve Body. -T

JATOlt:

5. Set manual shaft In Neutral, then align manual plate with-

groove in manual valve.- .~
6. Install control valve body assembly and tighten seven bolts ‘1
to the specified torque.-
Control valve body mounting bolts:
5.4 - 7.4 Nm (4.0 - 5.4 ft.lbs.)
7. After instatalliiig control valve body to transmission case,
make sure that-control Icver can be moved to all position.
8. Install downshift solenoid and vacuum diaphragm and rod. -T
Make sure that vacuumdiaphragm rod does not interferes.:
with side plate of control valve.
9. Install new gasket and oil pan.
Oil pan bolts: 5 - 7 Nm (3.6 - 5.1 ft.lbs.)
IO. Secure clamps of governor tube and oil cooler tubes. _=
11. Refill with automatrc transmrssron fluid.
 AUTOMATIC TRANSMISSION - On-vehicle Service 21-71
\ r Puller EXTENSION OIL SEAL REPLACEMENT
1. Remove propeller shaft.
2. Remove extension oil seal use with suitable puller.

ATOIE

3. Apply coat of ATF to oil seal surface, then drive new seal
into place.
4. Coat sealing lips with Vaseline, then install propeller shaft.
Refer to Propeller Shaft for installation.

JATOlS

PARKING COMPONENTS
1. Drain oil by removing oil pan.
2. Remove propeller shaft.
3. Remove speedometer cable from transmission, then re-
move speedometer sleeve assembly.
4. Support transmission with a jack and wooden block, then
remove rear mounting bolts.
5. Remove rear extension bolts, then remove rear extension
with rear mounting.
6. Remove control valve assembly. Refer to Control Valve
Assembly.
7. Inspect and repair parking components. Refer to Parking
Mechanism for inspection.
8. Install control valve assembly. Refer to Control Valve
Assembly for on-vehicle service.
9. Install rear extension, then install rear mounting parts.
IO. Install speedometer sleeve assembly and cable.
11. Install propeller shaft. Refer to Propeller Shaft for installa-
tion.
12. Install oil pan with new gasket.
Oil pan bolts: 5 - 7 Nm (3.6 - 5.1 ftlbs.)
13. Refill with automatic transmission fluid.
__.- -. i _______

21-72 AUTOMATIC TRANSMISSION - On-vehicle Service

-GOVERNOR VALVE ASSEMBLY

1. Drain oil by removing oil pan.
2. Remove rear~mqynting pa@, then remove rear extension. =
Refer to Parking Components.
3. Remove govmQr= valve assembly.
4. Inspect and repair governor valve assembly. Refer to
Governor forinspection.
5. Install governor valve ass_embly.
Governor valve mounting bolts:
JATOZ:
5 - 7 Nm (3.6 - 5.1 ft.lbs.)
6. Install extensiorrthen inst-all rear mounting parts. Refer to
Parking Components. 7.
7. Install oil panwrth new gasket.
Oil pan bolts: 5 - 7 Nm (3.6 - 5.1 fklbs.)

INHIBITOR SWITCH ADJUSTMENT

The inhibitor switch- has twomajor functions. It causes the
back-up lights to illuminate when the shift lever is placed in the Xv
reverses range. Itsaleo acts as-3 neutral safety switch allowing
current to pass frQm the starter only when the lever isplaced in -1
Inhibitor the “P” or “N” ran-ge.
switch
/ INSPECTION
A continuity tester may be used to check the inhibitor switch _:
for proper operation. ._
1. Check continuity at “N”, “P” and “R” ranges.
2. With control lever held in Neutral, turn manual clever an ‘-
equal amount in both directions to see $-current flow 11~
ranges are nearly the same. (Current normally begins to .Y
flow before manual lever reaches an angle Qf J.52n either ‘T
L
direction.)
If current flows outside normal range, or if nOrmal flow
range is out_ of specifications, properly adjust inhibitor -
switch.

._~ %
ADJUSTMENT
1. Place the manual valve i_rr Neutral (vertical position).
2. Remove the screw as illustrated.
3. Loosen the -attaching bolts.
 AUTOMATIC TRANSMISSION - On-vehicle Service 21-73
4. Using an aligning pin, [2.0 mm (.079 in.) dia.] move the
switch until the pin falls into the hole in the rotor.
5. Tighten the attaching bolts equally.
Inhibitor switch mounting bolts:
5- 7 Nm (3.6 - 5.1 ft.lbs.)
6. Recheck for continuity. If faulty, replace the switch.

JATOZC j

r Note seated valve body

“L” depth -,
Transmission case wall
VACUUM
The vacuum diaphragm
help determine
DIAPHRAGM ROD ADJUSTMENT
and the length of its diaphragm
the shift patterns of the transmission.
rod
It is
essential that the correct length rod be installed.
1. Disconnect vacuum hose at vacuum diaphragm and re-
move diaphragm from transmission case.
2. Using a depth gauge, measure depth ‘IL”. Be sure vacuum
throttle valve is pushed into valve body as far as possible.
3. Check “L” depth with chart below and select proper length
Diaphragm rod rod.
Valve bodv side elate JATO27
Vacuum Diaphragm Rod Selection

I
Measured depth “L” mm (in.) Rod length
mm (in.)
Under 25.55 (1.0059) 29.0 (1 .I 42)
25.65 - 26.05 (1.0098 - 1.0256) 29.5 (1.161)
26.15 - 26.55 (1.0295 - 1.0453) 30.0 (1.181)
26.65 - 27.05 (1.0492 - 1.0650) 30.5 (1.201)
Over 27.15 (1.0689) 31 .o (1.220)

DOWNSHIFT SOLENOID
1. Disconnect downshift solenoid harness.
2. Remove downshift solenoid and O-ring.
NOTE
Catch oil draining from the hole.

JATO2t

3. Check to verify that downshift solenoid is operating

properly. If faulty, replace it with a new one.
4. Apply coat of ATF to O-ring, and install O-ring and downshift
solenoid.
5. Connect downshift solenoid harness.
6. Refill with automatic transmission fluid.

JATOLS
 ~--~__

AUTOMATIC TRANSMISSION - On-vehicle Service

KICKDOWN SWITCH ADJUSTMENT

The kickdown switch is located at the upper post of the
accelerator pedal, inside the car.
When the pedal is fully depressed, a click can be he&d just
before the pedal bott-oms out.3 the click is not heard, loosen ~-
the lock nut and extend the switch until the pedal lever makes TI
contact with the~switch and-the switch clicks. _
Do not allow the switch~to make contact too soon. Thjs would .z
cause the transmission to dqwnshift on part throttle. .;
DIAGNOSIS
Switch can be heard clicking,and the transmissionstill does =
not ktckdown: - ~~
Check the contrnurty of the switch usrng a continuity tester, -
Also check for available current.
The car upshrfts at approximately 60 and 100 km/h (36 and 60 =z
MPH) only:
The kickdown switch may be rnternally shorted. (When the ~_
swatch IS shorted, there is contrnurty through the swrtch In any
position).

O.D. CANCEL SOLENOID

LOCATION
The O.D. cancel solenoid is located on left side of transmission. ~

JATOJL

INSPECTION
Confirm that clicking sound is heard when power is applied.

JAT03E
 AUTOMATIC TRANSMISSION - Transmission Oil Cooler 21-75

TRANSMISSION OIL COOLER NZlSA- -

REMOVAL AND INSTALLATION

Post-installation Operation
l Installation of Air Guide Panel
l RefWng with Automatic Transmlsslon Fluid
(Refer to GROUP $ LUBRICATION AND MAINTENANCE - (Refer to GROUP 0 LUBRICATION AND MAINTENANCE -
#

1. Eye bolts
2. Gasket
3. Oil return tube
4. Oil feed tube
5. Oil return hose
6. Oil feed hose
7. Oil return tube
8. Oil feed tube
9. Oil return hose
10. Oil feed hose
11. Oilcooler assembly
NOTE
4*: Refer to “Service Points of Removal”

04Y669

Nm
22-36 ft.lbs.
21-76 AUTOMATIC TRANSMISSION - Transmission Oil Cooler

SERVICE POINT OF REMOVAL NZlSSAA

71. REMOVAL OF OIL COOLER ASSEMBLY

Caution
Plug the ends of the oil cooler hoses and the oil cooler
and transmission ports to prevent the transmission
fluid from spilling out and foreign material from getting
in.

INSPECTION NZlSCAC

m Check the Gil cooler hoses for cracks. damage and ._

deterioration.
* Check the pad for damage and deterioration.
@ Check the oil cooler for foreign mater-M.
 AUTOMATIC TRANSMISSION - Transmission Control 21-77
TRANSMISSION CONTROL NZllA- -

REMOVAL AND INSTALLATION

I ’ '4
/

26 18-24 Nm
11 17F, II%‘?

13-17 ft.lbs.

-- 18
Removal steps
1. Spool release lever
2. Cover 09Y644
3. Inner box
4. Rear console box
5. Side console cover
6. Front console box
7. Push button 21. Cross-shaft
l * 8. Selector knob 22. support
4* 9. Selector lever cover 23. Cross-shaft bushing
10. Adjusting cam 24. Lever
4W l * 11. Selector lever 25. Protector
12. Selector lever rod 26. Rod
13. O.D. (overdrive) switch harness 27. Bracket
14. Lever 28. Slider
15. Detent plate 29. Indicator panel
16. Shaft
17. Pin NOTE
18. Support (1) Reverse the removal procedures to reinstall.
19. Boot (2) C*: Refer to “Service Points of Removal”.
20. Dust boot (3) l *:.Refer to “Service Points of Installation”.
21-78 AUTQMATIC TRANSMISSION - Transmission Control

SERVICE POINTS OF REMOVAL N211BAD

NOTE _
Before servicing-be sure to-set the selector lever to “N” =,
position, and then ~disconnect the lever and rpd from the i_
cross-shaft. -~

8. REMOVAL OF SELECTOR KNOB / 9. SELECTOR LEVER

COVER
(1) Remove--then front co&ole box.
(2) Push down the selector lever cover.-:
(3) Remove the. selector.iknob. from the selectar lever. .:I

\\1’
J \\ 09Ylli

11. REMOVAL OF SELECTOR LEVER / 27. BRACKET

(1) Disconnect the connector of indicator illumingion light. __

(2) Remove tK e selector lever and bracket.

(3) Remove the split pinsin order to disconnectihe lever :I
from bracket.

INSPECTION N2llCAD

l Check the detent plate for wear.

e Check the pin eat the end of selector lever for wear.
l Check the contact surfams of push button and adjusting _
cam for wear.
l With the 00 switch turned on, check for continuity across ;
the terminals.
l Check the 0.D. switch harness for continuity.
Terminal

08YllE ,
-
 AUTOMATIC TRANSMISSION - Transmission Control 21-79
SERVICE POINT OF INSTALLATION NZlIDAK

11. INSTALLATION OF SELECTOR LEVER

(1) Apply a thin coat of specified multipurpose grease to
the sliding parts.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No. 2525035 or equivalent

09Y637

(2) Place the shift lever in the “N” position, and then turn
the sleeve so that the clearance between the sleeve
and the lever assembly end is within the specified
range.
NOTE
-17 Be sure to face A of the adjusting cam to the
-.62)
pushbutton (driver’s side).

mm (in.)
09Y116

Selector lever 1Transmission (3) Connect the control rod to the transmission side lever
and the cross-shaft assembly lever. With the selector
lever set to “N” position and the transmission side lever
to its neutral position, connect and lock the lever to
cross-shaft.

Y09612 1
-- .- :. a- _____

21-80 AUTOMATIC TRANSMISSION - Transmission

TRANSMISSION
REMOVAL AND INSTALLATION

l Refilling with Transmission Fluid

(Refer to GROUP 0 LUBRICATION AND MAINTENANCE-

OQY642

Removal steps
1. Transmission control harness
2. Filler tube
3. O-ring
4. Oil feed tube and oil return tube connection
5. Bell housing cover
4* 6. Special bolts
7. Speedometer cable
8. Transmission control rod
9. Ground cable
4+ 10. Propeller shaft ft.lbs. 0.D;; ;;;g’” Bolt
4* identificatron
11. Engine support rear bracket ..-
** ++ 12. Transmission assembly 31 -40 @ IO x 40 (1.6J @ A x B
31 -40 @ 10 x 65 (2.6)
NOTE ~-1A
(1) Reverse the removal procedures to reinstall.
(2) *I): Refer to “Service Points of Removal”.
(31 l +: Refer to “Service Points of Installation”.
(4) q : Non-reusable parts
16 - 23 7
14-20 7 8 IO x 60 (2.4)
8x55(2.21
AUTOMATIC TRANSMISSION - Transmission 21-81
SERVICE POINTS OF REMOVAL N21 LBAD

6. REMOVAL OF SPECIAL BOLTS

Remove six special bolts connecting the torque converter
and drive plate.
10. REMOVAL OF PROPELLER SHAFT
Refer to GROUP 16 PROPELLER SHAFT AND UNIVERSAL
JOINT - Propeller Shaft.

11. REMOVAL OF ENGINE SUPPORT REAR BRACKET

Support the rear of the engine with jack or similar device.
With the transmission assembly supported by using trans-
mission jack, remove the engine support rear bracket.
Caution
When the transmission assembly is supported on a
service jack, the supporting area should be as wide as
possible.

12. REMOVAL OF TRANSMISSION ASSEMBLY

Move the transmission rearward to separate it from engine.
Caution
The torque converter should not remain on engine
when separated.

YO9620

SERVICE POINT OF INSTALLATION NPlLDAD

12. INSTALLATION OF TRANSMISSION ASSEMBLY

Install automatic transmission reversing the removal proce-
dure and noting the following exception.
Before installing automatic transmission to vehicle, mea-
sure distance “A” to be certain that they are correctly
assembled.
Distance “A”: More than 26 mm (1.03 in.)
Refill automatic transmission with fluid and check fluid
level.
Check inhibitor switch for operation. Starter motor should
be brought into operation only when selector lever is in “P”
and “N” positions (it should not be started when selector
lever is in ‘ID”, “2”, “L” and “R” positions). Back-up light
should also light when selector lever is placed in “R”
position.
 i
..~~ z_ ~.~~-~ ____~ ____--__~~~ ---.

21-82 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly

AUTOMATIC TRANSMISSION ASSEMBLY NZ1l.E. ._

011 pump assembly, n

56-62 Nm
42-46 ft.lbs.

A’-‘-. One w,~y clutch assembly

---I Collllcctlng drun1

Hc,lr pl;lnct.rry qxr dssenlbly

Y

AUTOMATIC TRANSMISSION - Automatic Transmission Assembly 21-83

O.D. brake band

Bearing /

-ms
Direct clutch assembly

c-..... Connecting shell

Connecting shell
Front planetary
gear assembly

V Forward clutch assembly

Bearing
011 seal
\
ParkIng pawl part Hear extension

Speedometer drrve gear

Speedometer
plnlon assembly 5-7 N*
3.6-5.1 ft.lbs.
Beanno
Oil charging pipe

Governor valve \ Parkino actuator part

8-11 Nm
dlst .ributor
5.8-8.0 ftlbs.
O-ring Manual plate /
- ’ /
Manual shaft Parking rod -Downshift solenoid
.. ..i
29-39 Nm
22-29 ft.lbs --. -Vacuum diaphragm

0
rod

-!
-3 itrol valve assembly
Zndbandb rake
c
servo asser nbly _~
7-9 Nm
5.1-6.5 ft.lbs.

Adjust brake band -1 - & \’

5.4-7.4 Nm
4.0-5.4 ft.lbs.
Y
5-7 Nm
Tube clamp
3.6-5.1 ft.lbs.
21-84 AUTOMATIC TRANSMISSION - Automatic Transmission Assemblv

SERVICE NOTES
Before proceeding ~with disassembly, thoroughly clean the
outsrde of the transmission.. It is important to prevent con-
tamrnatron by dirt or other foreign matter.
Disassembly should be done In a clean work area. ;_
Use a nylon cloth or paper towel tor wrprng parts clean.
Common shop rags can leave lint that mrght interfere with the ~.
transmisston’s operation.
The transmissio_rrconsists ofrmany small parts that are quite
alike in construction yet machined to very close tolerances.
When disassembling parts, be sure to place them in order in _~
part rack so they can be put back In the unit In their proper
posrtrons. All parts should becarefully cleaned wrth a general
purpose, non-flammable solvent before inspection or reassem-
bly. Gaskets, se&, and similar parts should be replaced. It is
also very rmportant to perform functional tests whenever
designated.

DISASSEMBLY
The steps below show disassembly of the following compo-
nent parts down to sub-assembly configurations. -
9 Oil pump assembly
l Front clutch assembly
@ Rear clutch assembly
d Direct clutch assembly
@ Control valve assembly
@ Governor valve assembly
l FYanetary gear assembly
For repair procedures of each sub-assembly, refer-to page
y- 1 05 to 21-1z!3.

1. Remove tor@E converter and drain transmission fluid i

through end pf rear extension.

I, .,

JATO31
ids - ._ ~-
2. Remove governor tube.
 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly 21-85

3. Remove converter housing.

JAT04(

4. Remove O.D. component assembly, then remove high-

reverse clutch (Front) thrust washer and needle bearing and
race.

5. Remove input shaft and intermediate shaft.

JAT0007

MD998390 6. Attach the special tool to oil pump and remove oil pump
from O.D. case.

JAT04

7. Remove O.D. servo cover, then loosen O.D. band servo

piston stem.
_~ ..~ --a
~____~~.__.___~
--

21-86 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly fF

g /

8. Remove O.D.: pack (O.D. planetary gear and direct clutch

assembly).

-.e--- JATO4!

9. Remove needle bearing, race and direct clutch thrust ~_

washer, then remove O.D. brake band and striit.

IO. Remove 0.D.. servo assqnbly by lightly tapping retainer.

JAT04i

11. Remove acam:ulator snap rrng, then apply pressure to

remove accumulator plug, piston and spring.

- ..
12. Remove 0.0. cancel solenord and 0-ring,-
 AUTOMATIC TRANSMISSION - Automatic Transtiission Assembly 21-87

13. Remove drum support from O.D. case.

J ATOSC

14. Remove downshift solenoid, vacuum diaphragm, rod and

nshift solenoid
O-rings.
15. Remove speedometer pinion from rear extension.

Vacuum diaphragm JAT051

16. Remove oil pan and inspect its contents. An analysis of any
foreign matter can indicate the types of problems to look
for. If the fluid is very dark, smells burned, or contains
foreign particles, the frictional material (clutches, band) may
need replacement. A tacky film that will not wipe clean
indicates varnish’ build up which can cause valves, servo
and clutches to ‘,stick and may inhibit pump pressure.

JATO5:

17. Remove control valve body.

Remove manual valve from valve body as a precaution, to
prevent valve from dropping out accidentally.

JATO51

18. Loosen 2nd band servo piston stem lock nut and tighten
piston stem. If it turns more than two turns, the band is
worn out. Back off band servo piston stem to release band.

JAT05E
L
 ~.~

21-88 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly e-

_

19. Remove brake -band strut, Brake band and clutch and _
planetary gear pack [including high-reverse ~clutch (Front),
forward clutch (Rear) and front planetary gear]. may be =
removed together.

Flexible type 20. To prevent brake linings-from cracking or peeling, do not

band brake stretch the .fle>tible band unnecessarily. Before removing -1
the brake band, always secure it with a clip as shown in the mP
illustration.
Leave the clip in position- after removing the brake band. -I

Approxlrnately
mm (in.) 2 t.08) dia. Wire Chp JATOS;

21. Remove 2nd band servo retarnrng bolts. Apply pressure

remove 2nd band servo.

22. Check onezway clutch to see it It operates properly.

23. Remove re$r planetary carrier snap ring and rear planetary
carrier.

I JATOGO
AUTOMATIC TRANSMISSION - Automatic Transmission Assemblv 21-89
24. Remove output shaft snap ring.

25. Remove connecting drum with internal gear.

26. Pry off one end of snap ring with a screwdriver. Remove
snap ring from low and reverse brake assembly while
applying plier force in direction of arrow.

27. Remove low and reverse brake clutch assembly.

28. Remove rear extension.

Be careful not to lose parking pawl, spring and retainer
washer.

JATO65
 E ~5
21-90 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly Esz:
se;=
29. Remove outj?Kt shaft with governor.
30. Remove governor thrust ~washer and needle bearing.

~_
31. Remove one-way clutch inner race attaching hex-head
slotted bolts using the special tool.

32. Remove oneway clutch inner race, return thrust washer, =

low and reverse return spring and spring thrust ring.

33, Using an air @E.Gth a tapered rubber tip, carefully apply air r
pressure to remove low .and reverse brake piston. a

JAT069 1

34. Pry off snap-Gig (1) from both ends of parking brake lever
(2) and remove the lever. Back off manual shaft lock nut (3) .-
and remove manual plate (4) and parking rod (5).
35. Remove inhibitor switch and manual shaft by loosening two
retaining bolts,

JATO
AUTOMATIC TRANSMISSION - Automatic Transmission Assemblv 21-91

REASSEMBLY NPILF- -

When installing/assembling needle bearing, bearing race, snap

ring and O-ring (seal ring), use the following illustration as a
guide to installation procedures and locations.

#2 #7 #8

JATOOI 6

1. Before proceeding with the reassembly of all components,

it is important to verify that the case, housing and parts are
clean and free from dust, dirt and foreign matter (use air
gun). Have a tray available with’ clean transmission fluid for
lubricating parts.
Petroleum jelly can be used to secure washers during
installation. All new seals and rings should have been
installed before beginning final assembly.

JATI 31
21-92 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly

2. Lubricate andinstall. low and reverse piston rnto the case. :

3. Install thrust ring, piston return spring, thrust washer and i

one-way clutch inner r-acme. _

4. Tighten inner race attaching bolts to specrtred torque using

the special taoI.
Caution
Check that return spring is centered on race before
tightening.
One-way clutch inner race tightening bolt:
13 - 18 Nm (9 - 13 ftlbs.)

-
5. Install steel dished plate first, then steel and friction plates,
and, finally, t-etarning plate and snap ring.

6~. After low and reverse brake has been completely assem-
bled, measure clearance .between snap ring and retainer -
plate. If mesurement e%ceeds specifications it can be
adjusted by replacing retainer plate with one of adifferent ._
thickness. -~ -~
Standard value: 0.80 - 1.25 mm (.031 - .049 in.)
AUTOMATIC TRANSMISSION - Automatic Transmission Assembly 21-93

7. Using an air gun with a tapered rubber tip, check low and
reverse brake operation.

8. Install governor thrust washer and needle bearing.

JATI 3;

9. Slide governor distributor assembly on output shaft from

front of shaft. Install shaft and governor distributor into
case, using care not to damage distributor rings.

JATl3E

IO. Install connecting drum with sprag by rotating drum

clockwise using a slight pressure and wobbling to align
plates with hub and sprag assembly. Connecting drum
should now be free to rotate clockwise only. This check will
verify that sprag is correctly installed and operative.

11. Install rear internal gear.

JATI
 m-
_3_

---

21-94 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly

12. Install snap ring on shaft.

13. Secure thrust bearing and thrust washer with petroleum

jelly and install rear planetary carrier.

.- 5--
14. Install rear planetary carrier snap ring.
This snaps ringis thinner than a clutch drum snap ring so be g
sure you are using correct size. If you have insufficient .I E
space to install snap ring-into drum groove, pull connecting z
drum forward as far as possible. This will give you sufficient ii=
groove clearance to install drum snap ring. e

JAT143

-0.D. case 15. Adjust front’end play as follows:

iru??~on ),,,,,- Gasket

Clutch pack ’
1: Front end play
2: Total end play JAT144

(1) Assemble high-reverse clutch (Front) and forward ~;

clutch (Rear), front internal gear, front planetary carrier.
and connecting shell. Secure thrust bearings with
petroleum jelly.

AT145
 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly 21-95

(2) Install assembly into transmission case. Check that

parts are properly seated before proceeding with
measurements.

JATI 4E

(3) Using a dial gauge or caliper with a seven inch base,

measure from rear hub thrust bearing race to case
(dimension A).

Bearing race /--‘-

- Thrust bearing [~e~r~~r~{LL

JAT14E

(4) Assemble high-reverse clutch (Front) and forward

clutch (Rear) drum assemblies together and lay them
flat on bench. Be sure rear hub thrust bearing is properly
seated.
1, High-reverse clutch
(Front) drum

Forward clutch
(Rear) drum
Thrust gearing JATI 4!

Measure from face of clutch drum to top of thrust

bearing race (dimension B).

IATI 5f
21-96 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly gg-
- -~
e*,
(5) Measure from top of drum support shaft (front clutch _ F
and rearclutch side) to instalLed gasket (dimension C).

JAT151

m”
(6) Install thrust washer. Measure trom top ot drum
support shaft (front clatch and rear clutch-side] to thrust - E
washer (dimension a.
(7) Difference between dimension [A - 0.1~ mm (.004 in.) - ~- s-m
B] and (C - D).is front end play and must be within ??
standard value.
Standard value: 0.5 - 0.8 mm (.020 - .031 in.) EEm.-
Front end play can be adjusted with high-reverse clutch &
(Front) thrust washers of different thicknest .~_
JAT152 Available High-Reverse Clutch (Front)
Thrust Washer

Thickness mm (In.1 Part number

1.3 (.051) MD610212

1.5 i.059) MD610213
1.7 t.067) MD610213
1.9 i.075) MD610215
2.1 t.083) MD610216.~
2.3 (.0911 MD61021 7
2.5 m38) MD6lC)218
2.7 i.106) MDU02 19

16. Adjust total end play asfollows:

This adjusttirit is seldom required because this type of _ =
thrust bearing and race will normally show very little wear.
- Transmission We also have a standard tolerance of 0.25 to 0.50 mm
(.0098 to .0197 in.). However, we are presenting correct ~_
checking procedure.
(1) Measure dimension &using instructions-in steps (I), (21
Needle bearing and (3) under para. 15 above.
Clutch pack A (2) Measure-dimension C using instructions in step (5) 1
1: Front end play under para. 15 above.
2: Total end play JAT153
(3) Differerzz between dimension [A - 0.1 mm LOO4 in.)] ~_
;Ind C IS total end play and It must be wlthrn standard ~_
value.
Standard value: 0.25 - 0.50 mm (.OlO - .020 in.)
It difference betweeKIA - 0.2 mm (.008 in.)] and C IS
not wrthln tolerance, select proper srze 011 pump cover
bearlnq race.
--
AUTOMATIC TRANSMISSION - Automatic Transmission Assembly 21-97
Available Oil Pump Cover Bearing Race

Thickness mm (in.) Part number

1.2 f.047) MD61 0221

1.4 l.055) MD61 0222
1.6 (.063) MD61 0223
1.8 (.071) MD61 0224
2.0 (.079) MD61 0225
2.2 t.087) MD61 0226

17. Install brake band, band strut and band servo. Lubricate
servo O-rings before installing. Care should be taken to
avoid damaging O-rings when reassembling.

JAT154

18. Install and torque the retainer bolts. Loosen piston stem.
Servo piston retainer bolt: 7 - 9 Nm (5 - 6 ft.lbs.)

19. Finger tighten brake band servo piston stem enough to

prevent brake band and strut from falling out. Do not adjust
brake band at this time.

20. Apply petroleum jelly to bearing race and thrust washer,

Q--- Bearing race
then mount them on drum support.
Thrust washer
(Fiber)

JAT157
 21-98 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly

21. Mount drum support gasket on drum support after coating ~:

with petroleum jelly. Apply automatic transmission fluid to :_
O-ring of drum support. AKgn drum support with O.D. case I
to transmission case and install.

Between oil pump Between drum support

and O.D. case to transmission case
JATlM I

Spacer [I5 mm (.59 in.) thick] Before iristalliing drum support and O.D. case on transmis- ;
7 sion case, ensure that they have been centered properly.
Refer to Compornent Service Drum Support on page
21-107. -~
Install O.D. case, and temporarily tighten it using two ~;
converter housi~ng securing bolts. =+

Transmission case JAT’159

i

22. Insert intermediate shaft-being especially careful of its

direction.

I)
Front IAT

Bearing race 23. Adjust O.D. back end play and O.D. total end play as ~I
r Oil pump follows:
/- ‘,A,-L Gasket
,-. .’
t
F
L
O.D. case

case
4: O.D. iotaTend 6lai I

.__-- (1) AssembleTdirect clutch assembly, O.D. planetary gear

set and connecting drum, and install them on O.D. pack.
i\ ‘i
‘“17-d i Connecting drum
cf&&-- O.D. sun gear
O.D. carrier
fp
Sea1 sleeve
Upward
O.D. internal gear-
Direct clutch
assembly
\ A.-. ,
JAT162
I-
 AUTOMATIC TRANSMISSION - Automatic Transmission Assemblv 21-99

(2) Install oil pump bearing, gasket and O.D. pack on oil
pump, and measure dimensions F and H.

F
H

JAT16:

(3) Attach thrust washer and needle bearing to drum

support and O.D. case, and measure dimensions E and
G.

(4) Difference between dimension [E - 0.1 mm (.004 in.)]

and F is O.D. pack end play and must be within the
standard value.
Standard value: 0.5 - 0.8 mm (.020 - .031 in.)
O.D. pack end play can be adjusted with O.D. thrust
washers of different thicknesses (these parts are the
sam’e as the front clutch thrust washers).
21-I 00 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly

Available O.D. Race Bearing

MD61 0285

MD61 0287
MD61 0288
MD670288-~
MD610290

(5) Difference between drmensron 1G - 0.1 mm t.004 rn.IJ

rind H is O.D. total end play and rt must be wrthrn the
9andard value.
Standard value: 0.25 - 0.50 mm (.OlO - .020 in.) -
It difference between1G - 0.1 mm (.004 in.11 and H IS
not wrthrn the tolerance, select proper srze C2.D. bearing
race. -
Available O.D. Bearing Races

Thickness mm (In.1 Part number

MD61041 5
1.4 (.055) MD67041 6
1.6 t.063) MD610417
1.8 (.071) MD610418
2.0 t.0791 MD61 0419
2.2 C.087) MD610420

24. Adjust band. Make sure that brake band strut IS correctly_-
installed. Torque piston stem to specified value.-Back off 1
two full turns and secure with lock nut.
Piston stem: 12 - 15 Nm (9 - 11 ft.lbs.)
Piston stem lock nut: 15 - 39 Nm (11 - 29 ftlbs.)

!jr. ‘,.J I ‘7. ,’

. /\
I i /’

I i 1'
JATl6’ 5
_ -
O.D. band servo -, 25. Lubricate C).D 3ervo O-r-Ergs with automatic transmrssion .I
fluid, then install brake band, band strut and O.D. band _I
servo.

Band strut

JATI 66
 AUTOMATIC TRANSMISSION - Automatic Transmission Assemblv 21-101
Dack 26. Apply automatic transmission fluid to seal ring of direct
clutch, then install O.D. bearing and race, O.D. thrust
washer and O.D. pack on drum support. Make sure that
brake band strut is correctly installed.
27. Apply automatic transmission fluid to O-ring of oil pump,
then install needle bearing, race and oil pump.
Before installing oil pump housing and oil pump on O.D.
case, ensure that they have been centered properly.
Refer to Oil Pump in Component parts.

and race bearing JAT00.10

28. Adjust O.D. band. Adjust torque piston stem to the

specified value. Back off two full turns and secure with lock
nut.
Piston stem: 12 - 15 Nm (9 - 11 ft.lbs.)
Piston stem lock nut: 15 - 39 Nm (11 - 29 ft.lbs.)

29. Using an air gun with a tapered rubber tip, test O.D. band
servo operation.

JATI 6E

30. Install accumulator parts, then secure with snap ring.

Spring

Accumulator plug
I Snap ring ’ .lAT17(

31. Remove the two bolts used to temporarily tighten O.D.

case. Apply sealant to seating surfaces of converter
housing at bolt locations. Install converter housing on O.D.
case and tighten converter housing securing bolts.
Converter housing bolt: 44 - 54 Nm (33 - 40 ft.lbs.)

q : Apply sealant
JATI 71
- d -

2 I- 102 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly

32: lnstafl input shaft.

33. Before proceeding with installation of valve body assemtily, --
perform a final air check of-all assembled components. This
will ensure that you havenot overlocked tightening of any --
bolts or damaged any seals during assembly.

r-4 ,.: ’
., JAT172

Air check pointy

Servo release

JAT17:

34. Using an air gun w-ith a-tapered rubber tip, perform air
checks. I

35. Check that ~parkrng paw!, pm, sprrng and washer are _
assembled correctly.
36. Install rear extension. :-
Rear extension bolt: 20 - 25 Nm (14 - 18 ft.1bs.j

\
c---’ ,,. ‘. \ JATl?E

37. Install control valve body. Be sure manual valve IS In

alignment with selector -Tin. Tighten control valve body
attaching bolts
NOTE
Attaching bolts come inthree different lengths.
Control valve body attaching bolt:
5.4 - 7.4 Nm (4.0 - 5.4 ft.lbs.)
After installing- control valve body to transmission case,
make sure that manual lever can be moved to allWpositions.
 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly 21-q 03
38. Before installing vacuum diaphragm valve, measure depth
Transmission case wall vacuum diaphragm
of hole in which it is inserted. This measurement deter-
Note seated valve body \ \ mines correct rod length to ensure proper performance.
Vacuum Diaphragm Rod Selection

Measured depth “L” mm (in.) Rod length Part number

mm (in.)

Under 25.55 (1.0059) 29.0 (1.142) MD61 0614

25.65 - 26.05 (1.0098 - 1.0256) 29.5 (1 .I 61) MD61 0615
26.15 - 26.55 (1.0295 - 1.0453) 30.0 (1.181) MD610616
26.65 - 27.05 (1.0492 -~ 1.0650) 30.5 (1.201) MD610617
Over 27.15 (1.0689) 31 .o (1.220) MD610618

39. Install vacuum diaphragm.

Make sure that vacuum diaphragm rod does not interfere
with side plate of control valve.

40. Install downshift solenoid, O.D. cancel solenoid.

O.D. cancel solenoid JAT

41. Install inhibitor switch. Check for proper operation in each

range using a circuit tester. Refer to On-vehicle Service.
d .-__---v- ~_____ __~~__ __--

-fK
,;-z
e
P

21-q 04 AUTOMATIC TRANSMISSION - Automatic Transmission Assembly =-

/ ,--- I__
42. Before installing oil pan, check alignment and operation of
,.l control leverymd~parking paw1 engagement. Blow mecha- -
!.I!, nism with air to clean. Make fina! check to be sure-all bolts -1
are installed fin valve body.

~_ -
43. Install oil pan with new gasket.
Oil pan bolt: 5 - 7 Nm (3.6 - 5.1 ft.lbs.1

44. Install governor -tube.

Carefully inspect torque converter for damage. Check =

converter hub for grooves caused by hardened seals. Also
check bushing contact ajea.

-.
Lubricate ails pump lip seal and converter neck before ,_
installing converter.
Install converter, being sure that converter is- properly
meshed with oil pump drive gear.
 AUTOMATIC TRANSMISSION - Oil Pumt, 21-105
OIL PUMP NZILG-.

DISASSEMBLY
1. Remove front pump gasket and O-ring. Inspect pump body,
bushing and pump shaft for wear.
2. Remove pump cover from pump housing.

Valve Spring Chart

Valve spring Wire dia. Outer No. of Free length

mm (in.) coil dia. active coil mm (in.)
mm (in.)

Lock-up control valve 0.70 5.50 13.5 26.3 16.0 16.7

i.0276) (.2165) (1.035) (.630) (3.74)

3. Remove retaining pin using a punch [outer dia. 1.5 to 1.8

mm (.059 to .071 in.)], then remove lock-up control valve
and spring.
4. Inspect gears, lock-up control valve, spring and all internal
surfaces for faults and visible wear.

5. Measure clearance between outer gear and crescent.

Standard value: 0.14 - 0.21 mm (.0055 - .0083 in.)
Limit: 0.25 mm (.OOSS in.)

JATO7:

6. Measure clearance between outer gear and pump housing.

Standard value: 0.05 - 0.20 mm (.0020 - .0079 in.)
Limit: 0.25 mm (.0098 in.)

JAT074
-I _I___ ..;_ -

21-106 AUTOMATIC TRANSMISSION - Oil Pump

@&p,
7. Using a fekle.r-gauge and strarght edge, measure clearance .- E
between gears and pump cover.
Standard value: 0.02 - 0.04 mm (.0008 - .0016 in.)
Limit: 0.08 mm (.0031 in.)

z
--
6%
Retaining pin REASSEMBLY ----;-
Plug - 27 1. Install lock-up control valve and spring into oil pump cover, E
Spring 4 then install retaining pin;
LOCK-up4
control valve
= c.

L ..~_ .-
MD998393 2. Install inner and outer pump gears to pump housing.
3. Insert guides-into bolt holes and install pump cover onto ~-
pump housing.
4. Tighten pump securing bolts to specified torque.
Oil pump housing to oil pump cover:
6 - 8 Nm (4.3 - 5.8 ftlbs.)
5. Install new Q-ring. -

JAT07E ,
 AUTOMATIC TRANSMISSION - Drum Support 21-107
DRUM SUPPORT NZlLT- .

DISASSEMBLY
1. Inspect drum support bushing and ring groove areas for
wear.

JAT07E

2. Remove drum support and gasket from O.D. case.

JATO79

3. Remove retaining pin using a punch [outer dia. 1.5 to 1.8

mm (.059 to .071 in.)], then remove O.D. cancel valve and
spring.
4. Don’t remove it from contacting face side.
5. Inspect O.D. cancel valve, spring and all internal surfaces
for faults and visible wear.

JATO8: JAT08(

Valve Spring Chart

Valve spring Wire dia. Outer No. of Fr;m 17;g,fh Installed

mm (in.) coil dia. active coil
mm (in.) Length Load
mm (in.) N (Ibs.)

O.D. cancel valve 0.65 4.95 12.8 23.0 16.0 12.26

(.0256) (. 1949) (.906) (.630) (2.76)

Clearance 6. Measure clearance between seal ring and ring groove.

Standard value: 0.05 - 0.20 mm (.0020 - .0079 in.)
7. Replace if the clearance exceeds 0.20 mm (.0079 in.).
Of course, it is good practice to replace all seal rings during
an overhaul.

JATOBI
 _____~

T"
:
_
I

21-108 AUTOMATIC
~i~.~ TRANSMISSION
~~__~ - Drum Support z!!!ez
ggt.
REASSEMBLY
Retaining pin -,
1. Install O.D. cSWel valve and spring into drum support, then g
tap retaining pins.
O.D. cancel valve

JATOK ,
-
2. Install lubrication plug in drum support.

JATOiIll

&e-way plug 3. Install one-way plug In O.D. case.

JATOOI;
 AUTOMATIC TRANSMISSION - Drum Support 21-109
4. Install new O-ring and gasket on O.D. case.
5. Install drum support on O.D. case.
6. Insert the special tool into the bolt holes and perform the
centering.
7. Tighten drum support securing bolts to specified torque.
Drum support to O.D. case: 7 - 9 Nm (5.1 - 6.5 ft.lbs.)

JATO8; 7

INSPECTION
1. Inspect contacting surface of oil distributor and ring groove
areas for wear.

JAT08E

ce
2. Measure clearance between seal ring and ring groove.
ring Standard clearance:
0.04 - 0.16 mm (.0016 - .0063 in.)
Replace if the clearance exc~eeds 0.16 mm i.0063 in.).
Of course, it is good practice to replace all seal rings during
an overhaul.

JATO8
21-110 AUTOMATIC TRANSMISSION - Direct Clutch and High-Reverse Clutch

DIRECT CLUTCH AND HIGH-REVERSE CLUTCH NZlLHCAa

Drum assembly
O-ring
Piston I

Number of return springs

-1

keturn spring (5)

ish plate
Driven plate (Steel plate) (5)
rive plate (Friction plate) (3)
\ Retainer plate
Snap ring
High-reverse clutch
Layout of direct Layout of high-reverse /
clutch plates clutch plates

Dish plate
\, 2riveplates / D&eplates mmL
Retaining plate
Chew,iy ClUtCII 0.0
JAT0013

DISASSEMBLY
1. Using a screwdriver, remove large clutch retaining plate
snap ring.
2. Remove clutch~ plate assembly.

3. Corripress clutch springs using the special tool and remove ~~

1
MD998391
snap ring frDm spring retainer.
 AUTOMATIC TRANSMISSION - Direct Clutch and High-Reverse Clutch 21-111
When tool is to be used, cut toe-tips of three legs with a
grinding wheel.
J
i
//////a
?
15mm
t.059 in.)

1‘t.79 in.)
Cut off hatched portion.
JATOS:

4. Remove spring retainer and springs.

5. For easy removal of piston from drum, mount clutch on
drum support. Use an air gun with a tapered rubber tip to
carefully apply air pressure to loosen piston from drum.
6. Check clutch drive plate facing for wear or damage. Drive
plate thickness must not be less than limit.
Drive plate thickness
Standard value: 1.50 - 1.65 mm (.0591 - .0650 in.)
Limit: 1.4 mm (.055 in.)
7. Check for wear on snap ring, weak or broken coil springs, -
JAT094
and warped spring retainer.
Air is blocked here. 8. Check the operation of check ball in piston by applying air
pressure.

I \ \ .lATl-W

REASSEMBLY
1. Lubricate clutch drum hub and seals, and install inner seal
and piston seal as illustrated. Be careful not to stretch seals
during installation.
Never assemble clutch dry; always lubricate its compo-
nents thoroughly.

JAT096

2. Assemble piston, being careful not to allow seal to kink or

become damaged during installation. After installing, turn
piston by hand to ensure that there is no binding.

JAT097
21412 AUTOMATIC TRANSMISSION - Dir&t Clutch and High-Reverse Clutch

,./--J 3. Reassemble sprrng and retainer. Reinstall snap ring. Be _

,.-_ ’ sure snap ring is properly seated.

..-
JATOSE
- --
High-reverse clutch 4. Install dish plate with dish facing outward.
te 5. Now install driven plate (steel plate), then a drive plate
(friction plate) and repeat in this order until correct number _ _
of plates has been installed (check ServiceSpecifications
for proper quantity of plates). Now install retainerplate and
snap ring.

JATUO~I
-.
6. Measure clearance between retarner plate and snap rrng. _x
Standard value:
Direct 1.6 - 1.8 mm (.063 - .071 in.)
High-reverse 1.6 - 2.0 mm I.063 - .079 in.)
If necessary, try other retaining plates having different
thicknesses until correct- clearance is obtained.
Available Retaining Plate for High-Reverse Clutch

‘i.--- A” Thickness mm (In.1 Part number

JATIOC
!I 5.0 (.19i MD6TD366
5.2 (205) MD610367
5.4 i.213) MD610368
5.6 (2201 MD61~036S~F
5.8 (228) MD61 0375
6.0 (23-6) MD610371
6.2 (.244) MD610372

Available Retaining Plate for Direct Clutch

Thickness mm (In.1 Part number

5.6 t.220) MD61 0252.

5.8 t.228) MD61 02&
6.0 f.236) MD610254
6.2 (.244) MD61 0255
6.4 i.252) MD61 0256
6.6 t.260) MD610257
6.8 l.268) MD61 0258
-
7.0 t.276) MD61 0259
I
AUTOMATIC TRANSMISSION - Direct Clutch and High-Reverse Clutch 21-l 13
7. Testing high-reverse clutch (Front)
With high-reverse clutch (Front) assembled on oil pump
cover, direct a jet of air into hole in clutch drum for definite
clutch operation.

JATlO
21-114 AUTOMATIC TRANSMISSION - Forward Clutch

FORWARD CLUTCH

In regard to the number of clutch plates (drive plate

and driven plate), refer Qspecifications.

Return spring (10)

Rear clutch drum

REASSEMBLY
1. Service procedures for forward clutch (Rear) are essentially _
the same as-those for high-reverse clutch (Front), with the
following exception:
Standard value: 0.8 - 1.5 mm (.031 - .059 in.)

JATI 0:

2. Test rear clutch operation

JAT104
 AUTOMATIC TRANSMISSION - Low-Reverse Brake 21-115
LOW-REVERSE BRAKE NZlLJ- -

In regard to the number of clutch plates (drive plate

and driven plate), refer to specifications.

Piston

Toward
front Low and reverse return spring
c Return thrust washer -,

Driven plate (Steel plate) (8)

Drive plate (Friction plate) (81

Retainer plate

Snap ring

JATI 05

INSPECTION
1. Examine low and reverse brake for damaged clutch drive
plate facing and worn snap ring.
2. Check drive plate facing for wear or damage; if necessary,
replace.
Drive plate thickness
Standard value: 1.90 - 2.05 mm (.0748 - .0807 in.)
Limit: 1.8 mm (.071 in.)
 ?’ ___~~ ~.__-__ __ _~____~
-----

21-116 AUTOMATIC TRANSMISSION - Brake Band and Band Servo

BRAKE BAND AND BAND SERVO NZlLV- -

Return I,,ing -\ mj$j

Band sewo piston

Servo retainer

Band servo piston stem

JAT106

INSPECTION
1. Inspect band friction material for wear. If cracked, chipped
or burnt spotsare apparent, replace the band.

L--.
JAT107

2. Check band servo components for wear and scoring.

Replace piston- O-rings-and all other components as-
necessary.

--.__ JAT108
 AUTOMATIC TRANSMISSION - Governor 21-117
Tightening torque: GOVEiRNOR N21 LM- -

DISASSEMBLY
1. Remove governor body from oil distributor.
2. Disassemble governor and check valves for indication of
burns or scratches. Inspect springs for weakness or
distortion. Replace parts as necessary and reassemble.
Do not interchange components of primary and secondary
governor valves.
JATl OSI

REASSEMBLY
Reassemble governor, noting the following.
1. For identification of primary and secondary governor valve
springs, refer to the following chat-t.

---I cI- Wire dia.

JATl 1I

Governor Spring Chart

Wire dia. Outer No. of Frrrn lyr,y,‘h Installed

mm (in.) coil dia. active coil
mm (in.) Length Load
mm (in.) N (Ibs.)

Primary governor 0.45 8.75 5.0 21.8~ 7.5 2.109

LO1 77) (.3445) (.858) (.295) (0.474)

Secondary governor 0.70 9.20 5.5 19.9 10.5 6.86

(.0276) (.3622) (.783) (.413) (1.54)
21-118 AUTOMATIC TRANSMISSION - Accumulator

ACCUMULATOR NZILW- -

’ piston

Accumulator plug
Snap rim-l

m-
DISASSEMBLY EE!s
-TAccumulator
Remove accumulator snap ring, then apply pressure ta remove ~~
accumulator plug, piston, spring and spacer.

INSPECTION
Check accumulator-components for wear and scoring; Replace ~
O-ring, seal rings and all other components as necessary. ~~_

AT112 ,

Governor Spring Chart

AUTOMATIC TRANSMISSION - Planetary Carrier / Connecting Drum Assembly 21-119

-IF--- Clearance I PLANETARY CARRIER NPlLX- -

The planetary carrier cannot be divided into its individual
components.
If any part of the component is faulty, replace the carrier as an
unit.
1. Check clearance between pinion washer and planetary
carrier with a feeler.
Standard value: 0.20 - 0.70 mm (.0079 - .0276 in.)
- _- Replace if the clearance exceeds 0.80 mm (.0315 in.).
JATl13
2. Check planetary gear sets for damaged or worn gears.
Gear sets that have been damaged by overheating will have
a blue discoloration.

CONNECTING DRUMASSEMBLY NPILY- _

If one-way clutch is out of order as determined during

disassembly, repair it as follows:
1. Remove the snap rings inner and outer races.

Connecting drum IATnnl5

2. Inspect one-way sprag and contacting surface for wear or

burns.
Replace parts as necessary.
reward front 3. Assemble those parts.
Install one-way clutch so that the arrow mark I’+” is
toward front of vehicle. It should be free to rotate only in
clockwise direction.

JAT115
AUTOMATIC TRANSMISSION - Control Valve Body

CONTROL VALVE BODY NzlLO- .

The valve body contarns many precrsron parts and requrres

extreme care when parts are removed and serviced. Place I
removed parts on a parts rack so they can be put back in the -r
valve body in the.same posrtrons and sequences. Care will also -1
prevent springs and small parts from becoming scattered or ;
lost.

DISASSEMBLY
1. Remove oil strainer and-.its attaching screws, nuts and ~~-
bolts.

JATllC 5

2. Disassemble valve body and tts remarnrng attachrng bolts 5

and nuts to carefully separate lower body, separator plate
and upper body.

3. During valve body separation,-do not scatter or lose orifice

check valve,- servo orificecheck valve, throttle relief check .~
valve (ball) and related springs.
 AUTOMATIC TRANSMISSION - Control Valve Body 21-121

r Spring seat

\Ir Spring
Sleeve r Pressure regulator valve
7

: Second lock valve

Lower valve body

JAT119

4. Remove side plateA, pressure regulator valve, spring,

spring seat, sleeve, plug, second lock valve and spring.
Place each loose part on a rack to retain correct sequence
of assembly.

Lower valve

Vacuum throttle valve Side plate “B” 1

Throttle back-up valve Kickdown valve

 AUTOMATIC TRANSMISSION - Control Valve Body

5, Remove side plate 8, 3r&4th shift valve, vacuum throttle ~~

valve, throttle back-up valve and spring, and the kickdown
valve and spring. Place each loosen part on a rack to retain _
sequence of assembly.

6. Remove side plate C, pressure modifier valve and spring

2nd-3rd shift valve, spring-and plug, and 1 st-2nd shift valve ~~-
and spring.
Remove 3-2riming valve and spring from lower valve body.
7. Place each .loose part on a rack to retain sequence of 1
assembly.
Manual valve,was removed when valve body was removed I:
from- transn%.S?on. Include valve in subsequent inspection
and service sequence. AL

~1st-2nd shift valve

U
‘nd3rd shift valve

-El I I
Side plate “C”m
INSPECTION
JATIPI PRECAUTION FOR INSPECTION
A newly manufactured valve body represents precision manu-
factured valves assembled wtih close tolerances lntopreclsron
bores of the valve body. It InspectIon reveals excessive ~~~
clearances, 0.03 mm (.OOi2 5-G or more, between the valves
;Ind the valve body bores, replace the entire valve body rather
than attempt rework.
If one or moreoalves are sticking from varnish deposits or
burns resulting from deteriorated oil or overheating, you may
be able to clean the valves and valve bodies. Always uze crocus I
cloth, which IS a very fine type of cutting materiaf.
Never use emery cloth, as It IS too coarse and can scratch the _i
valves or valve bores. Scratches can lead to tuture deposits of
varnish or foreign matter.
During cleaning, do not remove the sharp edges of the valve. ;
When edges arerounded or scratched, entry IS provided for dirt
or foreign matterto work intorthe sides of the valves and hinder ,-
valve movement.
The valves may be cleaned using alcohol or lacquer thinner.
The valve bodies can be dip cleaned with a good carburetor ~_
cleaner or lacquer thinner. Do not leave valve bodies sub- _-
merged in carburetor cleaner longer than five minutes. Rinse _
parts thoroughly and dry.
Lubricate all parts in clean automatic transmissron fluid before .I
reassembly.
 AUTOMATIC TRANSMISSION - Control Valve Bodv 21423
1. Check valves for signs of burning. Replace if beyond
chean-up.
2. Check oil strainer for general condition. Replace if neces-
sary.

JATl2i

3. Check separator plate for scratches or damage. Replace if

necessary. Scratches or score marks can cause oil to
bypass correct oil passages and result in system malfunc-
tion.
4. Check oil passages in upper and lower valve bodies for
varnish deposits, scratches or other damage that would
impair valve movement. Check threaded holes and related
bolts and screws for stripped threads; replace as needed.
5. Test valve springs for weakened load condition. Refer to
Valve Body Spring Chart for spring specifications.
JAT123

REASSEMBLY

4 I-- Wire dia.

JAT12
 ~:.rL .I .-~

21-124 AUTOMATIC TRANSMISSION - Control Valve Body

Valve Body Spring Chart

%xvo orifice check

 AUTOMATIC TRANSMISSION - Control Valve Bodv 21-125

Pressure regulator sleeve

Pressure regulator plug

Pressure regulator valve

?k 3rd-4th shift plug

Vacuum throttle valve

2nd-3rd shift valve 3rd-4th shift valve

3rd-4th shift sleeve

Side plate “A” Thrott

JATI 25

1. Assemble side plate A group of parts into lower valve body.

Reinstall side plate and finger tighten screws.
Assemble side plate B group and side plate C group in same
manner as A group.

2. Tighten screws.
Side plate to valve body: 2.5 - 3.4 Nm (1.8 - 2.5 ft.lbs.)

JAT126

3. Install orifice check valves, valve springs, throttle relief

valve spring and steel ball in valve body.
4. Install 3-2 timing valve and spring.

Valve spring 3-2 timing valve .lAT137

 p--.
p.-
LST
21-126 AUTOMATIC TRANSMISSION - Control Valve Body -z
__
m
sg&
__
5. Install upper and lower valves.
Upper and lower valves: 2.5 - 3.4 Nm (1.8 - 2.5 ft.lbs.) ~- Em
Reamer bolt: 5 - 7 Nm (3.6 - 5.1 ft.lbs.) _
6. Install oil stt%ner.
Oil strainer to valve body: 3 - 4 Nm (2.1 - 2.8 ftlbs.) EG
The manual valve is inserted into the valve body when the s
latter is institlled in the -transmission. _ ~- EP
y--
=z
w-
---
I
 22-1

WHEELS
AND
TIRES
CONTENTS
GENERAL INFORMATION . . .. .. . . .. . .. .. . . .. . .. .. . .. . .. . .. . .. 2 TROUBLESHOOTING .._......._....._...._...................... 3
Bald Spots
SERVICE ADJUSTMENT PROCEDURES ............ 4
Cracked Treads
Tire Inflation Pressure Check ................................ 4
Feathered Edge
Tire Wear ................................................................ 4
Rapid Wear at Center
Wheel Runout ........................................................ 4
Rapid Wear at Shoulders
SPECIFICATIONS .................................................... 2 Scalloped Wear
General Specifications ........................................ 2 Wear on One Side
Service Specifications ........................................ 2
WHEEL AND TIRE .................................................... 5
Torque Specification ............................................ 2
 WHEELS AND TIRES - General Information / Specifications

GENERAL INFORMATION NZZBAAJ

All vehicles are equipped wrth aluminum type wheels, and spare wheels are hrgh pressure type.
Front and rear trre sizes are different. - i. .~

SPECIFICATIONS NZZCA- -
GENERAL SPECIFICATIONS

Tire size == 225/5OVR16

Wheel type Aluminum type
Wheel size _~ 9J-16
Amount of wheel offset
mm (in.) -10 k-.4) 0 (0)
Compact spare wheel
Tire size T13519ODT5
Wheel type Steel
Wheel size 4-T x 15
Amount of wheel offset
mm (in.) 40 (1.571
Tire inflation pressure
Four original tires 190 (27) 270 (39)
Compact spare tire 420 (601

SERVICE SPECIFICATIONS N22CB..

. Items
Limit
Wheel runout
Radial 3.0 (. 12)
Lateral 3.0 (.12)
Tread depth of tire 1.6 (.06)

TORQUE SPECIFICATION

Items Nm ft.lbs.

Wheel nuts go-110 65-80

 WHEELS AND TIRES - Troubleshooting 22-3
TROUBLESHOOTING NZZEA- _

AT SHOULDERS

:DGE

XALLOPED LACK OF ROTATION OF TIRES Replace the tires

‘VEAR OR WORN OR OUT-OF- Inspect the front
ALIGNMENT SUSPENSION suspension alignment
 -____

WHEELS AND TIRES - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

N22FDAB

TIRE INFLATION PRESSURE CHECK

‘I. Check the inflation pressure ot the trres.
2. If it is not within the specrtred tire rnflatron pressure, make I
the necessary adlustment;

TIRE WEAR N22FElAA

1. Measure thetread depth of tires.

Limit: 1.6 mm (.06 in.)
2. If the remaining tread depth is less than the service limit, ._
replace the tire. .~
NOTE I?
When the tread depth of tires is reduced to 1.6 mm (.06 in.)
or less, wear indicators mill appear.

WHEEL RUNOUT NZZFCAA

1. Jack up the vehicle so thatthe wheels are clear of the floor.

2. While slowly turning the wheel, measure wheel runout with z
a dial indicator--~
3. If wheel runout exceeds-the service limit, re$ace the T
wheel. -
Limit:
Radial 3.0 mm (.I2 in.)
Lateral 3.0 mm (.I2 in.)
 WHEELS AND TIRES - Wheel and Tire 22-5
WHEEL AND TIRE NZZGA- -

REMOVAL AND INSTALLATION

Removal steps
1. Center cap
2. Wheel nut
3. Wheel
4. Tire
5. Balance weight

NOTE
Reverse the removal procedures to reinstall. 90-I 10 Nm
cc onu I L.,&J5.
"a-0" IL-
I 1lY&%

TIRE AND WHEEL ROTATION NZZGE- -

Caution
1. Do not use the compact spare wheel in tire rotation. ’
2. Do not rotate the tires because their front and rear
wheels/tires are different in size from each other.
Finger-tighten wheel nuts then use a torque wrench to tighten
the wheel nuts to specification.
NOTE
Do not use an impact wrench or apply oil to the wheel studs.

INSTRUCTIONS FOR ALUMINUM TYPE WHEELS

NZZGFAA

1. Aluminum is vulnerable to alkalies. If a vehicle washing

detergent has been used, or salt from sea water or road
chemicals has adhered, wash the vehicle as soon as
possible. After washing the vehicle, apply body or wheel
wax to the aluminum type wheels to prevent corrosion.
2. When cleaning the vehicle with steam, do not direct steam
onto the aluminum type wheels.
When tightening nuts for aluminum type wheels, particular-
ly observe the following:
(1) Clean the hub surface of aluminum type wheels.
(2) After finger-tightening wheel nuts, tighten them to
specifications.
(3) Do not use an impact wrench or push the wrench by
foot to tighten the wheel nuts.
(4) Do not apply oil to the threaded portions.
 __.__ __-.

22-6 WHEELS AND TIRES - Wheel and Tire

TIRE CHAINS AND SNOW TIRES NZZGGAE

Caution
Do not install the tire chains.
If installed, the chains will interfere with the fenders and
give damages to them.
When using snow tires, use them on all four wheels for
maneuverabIlIty and satety.

INSTRUCTIONS FOR COMPACT SPARE TIRE NZZGHAA

i. The compact spare tire rs deslgned to save space rn the -

luggage compartment, and Its lighter weight makes It
dasler to use rf a flat tire occurs.
3c/ The following instructions for the compact spare irre should 1
be observed.
(1) Check the inflation pressure atter rnstalllng the spare
trre. and adjust to the specltled pressure. ~~
(2) Avoid driving through automatic car washes and over ~_
obstacles that couKposs]bly damage the vehicle’s
undercarriage. Because the tire IS smaller than the 1
orqnal tire, car ground clearance IS slightly reduced. .~
(3) The compact spare tire should not be mounted on any
txher type disc wheels, nor should standard tires, snow .~.
tires, wheel covers OL trim rings be mounted on disc :
wheel for compact spare tire. It such use is attempted,
damaqe to-these Items or other vehicle components
may occur.-
 23-I

BODY
CONTENTS
AERO PARTS . . ..._._.____t___..
____.._._...__....__._
___.__._.___...82 SERVICE ADJUSTMENT PROCEDURES ........ 29
Door Fit Adjustment ................................... _... . 30
AUTOMATIC SEAT BELTS . . .. . . .. ..._...t....._ __....___.106
Door Glass Adjustment ............ .._.._.._..._..._..... .._ 30
BUMPER _ 42
. .. . .. . .. .. . .. . . .. .. . . ._._....___...__..._._....__...___.__.... Floor Pan Inspection ............ ... _._._..................... 31
Hood Fit Adjustment ......................... ..-.-..- ....... 29
DOOR ASSEMBLY . .. . .. . ..._..._._...___..
___. . ..__...__...__
_.__ 62
Inside Handle Play Adjustment .................. ...... 30
DOOR MIRROR . . .. .. . .. . . .. .. . .. . .. . .. .._....__._. . .. .. . . .. . .._... 77 Outside Handle Adj&tment ............................ 31
Rear Hatch Fit Adjustment ................................ 29
DOOR TRIM . . .. . .. ..t_..... _.. . .._....._....._....__._.___..___...__.,. 64
SPECIAL TOOL . ... .._....._.._..__....~...................~... _... 4
FENDERS .___..____..._...47
. . . ...I__.._.____..._....__...._......._.____._
SPECIFICATIONS . .. . .. . .. .. . ..___ _. ..__......................... 2
FLOOR CONSOLE .. . . .. . .. .. .. . . .. . .. . .. . .. . .. .. . .._..... _.. . .._. 93
General Specifications .. .. . .. .. .. . . .. .. .. . .. ..a........... 2
FRONT DOOR GLASS AND REGULATOR .. .. 66 Lubricants . . .. .. .. . .. . .. . .. .. .. =..___....._._....__,_.._ _. . .. .._........ 4
Sealants and Adhesives . . .._____.___ ..: _._.___... ___....__. 4
FRONT DOOR HANDLE AND LATCH _....._._... 71
Service Specification . .. ..____.. ____._ .~__...........,....... 3
FRONT DOOR WEATHERSTRIP . .. .. . .. _._. .. .._....._. 75 Torque specifications . .. . .. .._.*............................-..
- 3

FUEL FILLER DOOR . . . .. .. . .._._.._.__...___._____._.__.___._..

34 SUNROOF . . .. .. .. ..__.........~.....~.....~.................~......... 79

GRILLE AND MOULDING .. . .. . .. .._..._.__...__...___.._.__.50 TRIMS . .. ..._.__.._._.___.___.___.______...~..............~~

___._I__..._._, 95

HEADLINING . .. .._._.__._...__....._...._....___....__..__........._
101 TROUBLESHOOTING . . .. .._._...__...._....._.._.........___ 5
Automatic Seat Belt -
HOOD ..,....._._ ___..___
_...____.._._..._.....__....._._..__....._....__.32
Central Door Locking System
INSTRUMENT PANEL . . .. . ..._....__...._..................... 87 Power Windows
Remote-controlled Mirror
QUARTER WINDOW ..,.._._..___..._________..___ _ 60
_...___I...__
Sunroof Water leaks
36 Wind noise
REAR HATCH .. . ._.. . ..._........................._..................
Troubleshooting of Wind Noise
REAR SEAT BELTS _...,.._....._....._ _. .. . .. . .. . .. . .. . .. .. . . . 124
WINDSHIELD . . .. . .._....__.........__....___...___...._......_..._._55
SEATS _.._._.___.._
____.__._...____..._..........................~.._. . .. . 103
WINDSHIELD AND QUARTER WINDOW . .. . .. . . 53
23-2 BODY - Specifications

SPECIFICATIONS N23CA-.

GENERAL SPECIFICATIONS

Construction Front-hinged, sash construction

Regulator system

Windshield glass
Quarter window glass

Windshield glass
Quarter window glass
Rear hatch window glass
Door window glass

Type Permanent magnet type (built-in circuit breaker)

Revolutions under load rpm -
At 1 Nm (0.72 ftlbs.)
At 2 Nm (1.45 ftlbs,)

Range of voltage used V

Locking current A 4or less

Type Ferrite magrxet motor

Rated current mA
Remote control mirror switch
We

Rated load mA
Regular up-down or right-left direction
 BODY - Specifications 23-3

Items Specifications

Automatic seat belt motor

Type Ferrite magnet motor
No-load speed rpm 180
No-load current A 4 or less
Load current at 125 Ncm (11 in.lbs.) A 6.4 - 6.8
Load speed at 125 Ncm (11 in.lbs.) wm 125-225
Lock test current A 38 or less

SERVICE SPECIFICATIONS N23CB- -

mm (in.)

I Items Specifications I
Standard value
Play of inside handle 4-10(.16-.39)
Play of outer handle 3-8(.12-.31)

TORQUE SPECIFICATIONS N23CG -

Items Nm ft.lbs.
Hood hinge ’ 9-14 6.5- 10
Hood latch 7-11 5-8
Hood hook 4-6 ’ 2.9 -4.3
Rear wiper arm locking nut 6-9 4-7
Windshield wiper arm locking nuts IO- 16 7-12
Door hinge
Body side 13-26 9‘- 19
Door side 17-26 12-19
Hatch hinge
Hatch side 5-8 4-6
Body side IO-15 7-11
Hatch latch 4-6 2.9 -4.3
Air spoiler (center) attaching nuts 3.5 - 5.0 2.5 - 3.6
Front seat mounting nuts 24-36 17-26
Front seat mounting bolts 35-55 25-40
Rear seat cushion mounting bolts 4-6 3-4
Rear seat hinge bracket mounting bolts 9-14 6-10
Rear seat striker 4-6 3-4
Front/rear seat belt anchor plate 35-55 25-40
Rail guide 4-6 2.9 - 4.3
Outer casing (B) 4-6 2.9 - 4.3
Rail guide bracket attaching bolts 8-12 5.8 - 8.7
Retractor
For shoulder belt 17-26 12-19
For lap belt 35-55 25-40
Buckle 35-55 25-40
Shoulder belt sub anchor 35-55 25-40
 ______-

BODY - Specifications / Special Tool

LUBRICANTS N23CD-. E;
B$z
--
1

Part Number 2932524

Sliding portion of rear hatch link MOPAR Multi-Purpose Grease Lo
Part Number 2932524 or equivalent
Sliding portion of rear hatch hinge MOPAR Multi-PurposeGrease -
Part Number 2932524 qr equivale;t
Sliding portion of rear hatch latch MOPAR Multi-Purpose Grease ~
Part Number 2932524 or equivalent
Sliding portion of front door hinge

Sliding portion of door glass guide

SEALANTS AND ADHESIVES N23CE..

Rear hatch glass to rear hatch Urethane adhesive_CEssex Urethane “E”

garnish contact surface . . Auto Glass Sealant]
Flange parts of the fender Dry sealant _
Between windshield and body Urethane adhesive.LEssex Urethane “E”
,. Auto Glass Sealant)
Stud hole Urethane adhesive (Essex Urethane “E”
,,. Auto Glass Sealant) ~~
Between windshield and moulding
Between quarter window and body Urethane adhesive_fEssex Urethane “E” As required
Auto Glass Sealant)
Waterproof film MOPAR Rope Caulk Sealer 3116 x80” As required
roll Part No. 4026044
Door openingweatherstrip

Roof lid female hinge MOPAR Vinyl-Acrylic Sealant

Part Number 4026043-or equivalent
Air spoiler (center)

SPECIAL TCK9L NOZDA- .

 BODY - Troubleshooting 23-5
TROUBLESHOOTING N23EAAO

Symptom . Probable cause Remedy

Sunroof
Water leaks Deteriorated roof lid weatherstrip Replace

Excessive roof lid-to-body clearance and Adjust

improperly fitted weatherstrip

Wind noise Loose or deformed deflector Retighten or replace

Door glass fails to Dismount window glass regulator Adjust

operate up and down
Detached sash Attach

Broken sash Replace

Collapsed sash Repair or replace

Collapsed window glass regulator arm Repairor replace

Broken window glass regulator Replace

Door glass operates Improper window glass position Adjust

up and down hardly
Collapsed sash Repair or replace-

Collapsed window regulator arm Repair or replace

Wind noise from Insufficient weatherstrip holding force Adjust door installation
around door
Improper-weatherstrip installation or Repair or replace
deteriorated weatherstrip

Incomplete door closing Adjust

Improper door installation Adjust

Improper gap between door glass and weatherstrip Adjust

Deformed door Repair or replace

Rear hatch is “heavy” Insufficient grease on hinges Apply chassis grease

ahen opened/closed;
abnormal noise is
leard from hinges

tiind noise from~ Insufficient weatherstrip holding force Adjust rear hatch installation
around rear hatch
Improperweatherstrip installation or Repair or replace
deteriorated weatherstrip

Uneven clearance between body and rear hatch Adjust

Deformed rear hatch Repair or replace

 TROUBLESHOOTING OF WIND NOISE
(1) Apply cloth tape to all potential sources of wind noise such =_
as panel joints, protrusions, moulding joints, glass to body
joints in the-dirrection from which noises- are heard.
(2) Drive under this condition to make sure that wind noises ~:
are eliminated. .

18Y1715

(3) Remove tape one after another until wind noises are
produced again.

Remove
18Y1715

(4) If removal ofI% tape causes norse generation, apply tape

again to that location and remove other tapes one after
another to check that no noise is produced.
(5) The location with tape left applied to the last is responsible
for wind noise. - -

ex. Noise produced here

18Y1716

(6) Cut the left tape into smaller preces and remove piece after
piece in the:same manner as before to localize suspected _
source. ~=

Cut tape into pieces

(7) Remove the last piece Jett and check that its removal _
causes wind noise and its application stops wind noise. -:
(8) Apply butyl tape or body sealer to the thus located area to -:
minimize gq?
 BODY - Troubleshooting 23-7
POWER WINDOW

CIRCUIT DIAGRAMS

A-82
8-W n 5-w ,@

To motor
antenna relay 4
0.85-i-O

To turn signal
flasher unit 4 0*85-RL

c-33
4
YL

-r
TAC unit

Remarks
(1) For details of grounding points (ex.: I), refer to page 8-10. Wire color code
(2) The circuit lines ended with number 0. @and so on are in B: Black Br: Brown G: Green
continuation to those with the corresponding number on Gr: Gray L: Blue Lg: Light green
opposed page. (i.e., the line @ on the left-hand page is LI: Light blue 0: Orange P: Pink
connected to the line @ on the right-hand page.) R: Red W: White Y: Yellow
 ..-

23-8 BODY - Troubleshooting

Power wlndow maln switch

I

Power window relay

------I

I-32

Power wIndoN
motor (L.H.1

/RW\ (RWI- IRCi Power wlndow

C-ii
I B-32 [ . _ . 1 1,7-C-27

(L.H.1 (R.H.i
Door switch

Power wlndow sub switch

 BODY - Troubleshooting
OPERATION TROUBLESHOOTING HINTS
l When the ignition switch is turned to 7iON”, 1. The door windows cannot be operated by using
current flows through fuse No. 13, the power the main switches.
window relay (coil), and ground, closing the l Malfunctioning main switch
power window relay contacts.
l When the power window switch is set at the 2. The door windows can be operated by using the
“UP” or “DOWN” position with the ignition main switches, but cannot be operated byusing
switch turned to “ON”, current flows through the sub switches.
the power window relay (contact), the power l Malfunctioning sub switch
window switch, and ground, and the power 3. The door windows can be operated (by using the
window motor revolves to raise or lower the sub switches) even though the lock switch is at
door window glass. “ON“.
l If the lock switch of the power window main
switch block is set at “ON”, however, the door l Malfunctioning main switch lock
window glass can neither be raised nor lowered
by operating the sub switches.
l For operation of the power window timer, refer
to GROUP 8 ELECTRICAL - ETACS.
 --

23-10 BODY - Troubleshooting

CENTRAL DOOR LOCKING SYSTEM
CIRCUIT DIAGRAM

Doorfock
Door lock relay Door unlock relay actuator (L.H.1

Battery Sub fusible llnk 2

20-BY
I

Door switch (L.H.1

Door swatch (R.H.) IpEiy-yJ

Key reminder
switch WI II
0 ,rGW Inn\ 1

-’

le?m-+-ii3 L I I I I I I I

D-l
Sell-dtagnosls
connector
L r‘nmh,n.T+.n..
\,‘,lIL,,1,l”,l”l, TAC unit
mrtpr actua~tor (R.H J

rkdhl
ml 37Y mm

Remark
For details of grounding points
(ex : mi. refer to page 8-10.
B iiiack Br Brown ti. Green Gr I;rav L Blue Lg. Light green
LI Ltghf blue 0 Orange P. Pink R tied W While Y Yellow

OPERATION AND TROUBLESHOOTING HINTS

Refer to GRCKJP 8 ELECTRICAL- FTACS for operation and trqubleskootlng hints for the centraldoor locking.
system.
 BODY - Troubleshooting 23-I I
REMOTE-CONTROLLED MIRROR

CIRCUIT DIAGRAMS

Batters
Ignition switch

Main A-80
fusible link

El

tLRlcO
0.85-B o

m
A
I-
r

q:
3-BR n
2-B
2-BR :a
@
Sub fusible
Iink 1 A-35

0.85-LR n0.85-LB
u *o

control unit

m
r:
dT
iI a
c-34 r
n v n
w
LR B

TAC unit Defogger relay

23-12 - BODY - Troubleshooting

Remarks
111 For details ot aroundlnq points (ex.: EJ). refer to page 8-10.
(2) The clrcult lines ended with number, I 8, z 1and so on are In
Irrvvlnuatlon to those with the corresponding number on
clpposea page. (I.e., the Ilne 11 /on the left-hand page IS
c~.annected to the line c 1 I on the nqht-hand page.)
Detoqgerswitch, Remote-controlled mirror (L.H.)

mLI
YEa
LYB
D-14
m

ILRJ
;:::0.85-B

B-09

I
L

,51~ 0.85-LB

B-31

-16

Remote-controlled mirror switch Remote-controlled mirror (R.H.)

Wire color code

B: Black Br: Brown Gr: Gray L: Blue Lg: Light green
LI. Light blue 0: Oranqe R: Red W: White Y: Yellow
 BODY - Troubleshootinn 23-13
OPERATION TROUBLESHOOTING HINTS
When the remote-controlled mirror switch is Neither right nor left mirror operates.
operated while the ignition key is in “ON” 1. Also turn signal lights do not operate either.
position, current flows through fuse No. 13,
remote-controlled mirror switch, remote- * Check the fuse.
controlled mirror, remote-controlled mirror 2. Check the remote-controlled mirror switch.
switch, and ground, causing the mirror to move. l Check the remote-controlled mirror switch.
For operation of the heated remote-controlled
mirrors, refer to the “DEFOGGER TIMER”
section in GROUP 8 ELECTRICAL - ETACS.
AUTOMATIC SEAT BELT - :7
CIRCUIT DIAGRAMS

Spool release lever switch

Battery lgnrtion swatch

Clrcutt
QQQ I
breaker
B-01

3-LW -(&
3-RY
3-RW :@@

Combrnation
meter

C-24

Key reminder Buckle swatch (L.H.stdel (R.H. side)

switch \ Y I
Motor
Remarks
(I) The crrcutt lines ended with number (9, (2) and so on are in conttnuatton to those wtth thecorrespondtng number on opposed
page. (I.e.. the line Ltj on the left-hand page IS connected to the IlneQ) on.the right-hand page.)
(2) For-detaifs of groundtrig points (ex.: E!If. refer to page 8-10.
 BODY - Troubleshooting 23-15

Door lock switch

Release switch Fasten switch (L.H. side)
(L.M.) (L.H.)
-

C-06 -38

Automatic seat belt

control unit

Release switch Fasten switch (R.H.)

(R.H.) Door
.-.. lock switch
(K.H. side) 371599
Wire color code
B: Black Br: Brown G: Green Gr: Gray L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink R: Red W: White Y: Yellow
 ,A .a-

23-16 BODY - Troubleshooting

“release” position (spool replace the fuse No. 1

release switch is turned

d or disconnected

ECU: Electronic Control Unit

 BODY - Troubleshooting 23-17

Trouble symptom Cause Check method Remedy

The system performs Damaged or disconnected Check by using check chart Repair the harness or
fastening operations but wiring of door lock switch No. 3 (P.23-22) replace the door lock
not unfastening operations, input circuit switch, fasten switch or
or vice-versa. release switch

Damaged or disconnected Check by using check chart Repair the harness or

wiring of motor drive input No. 4 (P.23-24) replace the motor
circuit

Malfunction of ECU - Replace the ECU

Even. .~after
~~~~ turning the Damaged or disconnected Check by using check chart Repair the harness or
ignrtron switch from “LOCK” wiring of “fasten seat belt” No. 6 (P.23-26) replace the indicator light
or “ACC” to “ON” without indicator light and buckle and buckle switch
fastening the L.H. seat lap switch input circuit
belt, neither the “fasten
seat belt” indicator light Damaged or disconnected Check by using check chart Repair the harness or
goes on nor does the wiring of buzzer circuit No. 8 (P.23-28) replace the buzzer
buzzer sound.
Damaged or disconnected Check by using check chart Repair the harness or
wiring of ECU power supply No. 1 (P.23-20) replace the fuse No. 1
and ground circuit

Malfunction of ECU - Replace the ECU

The “fasten seat belt” Damaged or disconnected Check by using check chart Repair the harness or
indicator and the spool wiring of “fasten seat belt” No. 6 (P.23-26) replace the indicator light
release indicator light indicator light and buckle and buckle switch
neither go on nor blink, and switch input circuit
the buzzer does.~,~not
~~ sound
.
when the ignrtron swatch Damaged or disconnected Check by using check chart Repair the harness or
is turned from “LOCK” or wiring of buzzer circuit No. 8 (P.23-28) replace the buzzer
“ACC” to “ON” while
the spool release lever
remains in its “release”
position (spool release
switch is turned off).

ECU: Electronic Control Unit

2348 BQDY - Troubleshooting
CIRCUIT BREAKER RESETTING
(1) Insert wire in the reset hole and push lightly.
(2) Check the circuit breaker for continuity across the circuit
breaker terminals. If the=-is no continuity, replace the I
circuit breaker.
(3) If the circuit breaker blows again, the circuit is-shorted. ,I

I 18Y1811l

TO
batterv I

switch

Door lock r
switch
IL H.l
I
Door lock
swmzh +--++ switch
(R H.I Iclose)
h
Y
To ignltlon
switch * 1

To battery d

-. - -
ECU _

ECU: Electronic Control Unit (ECU connector termmats)

 BODY - Troubleshooting 23-19
CHECKING CIRCUIT
Index of Check Chart

Chart No. Circuit name Page No.

1 ECU power supply and ground circuit 23-20

2 Ignition switch (ON) input circuit 23-21

3 Door lock switch, fasten switch and release switch input circuit 23-22

4 Motor power supply and drive circuit 23-24

5 Spool release lever switch and indicator light circuit 23-25

6 Buckle switch and “fasten seat belt” indicator light circuit 23-26

7 Key-reminder switch input circuit 23-27

8 Buzzer circuit 23-28

23-20 BODY - Troubleshooting

Sub fwble
IInk box 2

rE(:lJ connector terminals)

Check method Judgement

Step p- p-
Condition Check object Normal _ Malfunction
1 ECU terminal Battery voltage ov
voltaae
(21 --Ground)
Harness damaged Repalr the harness
or dlsconnected
2 Disconnect ECU’s Continuity of Continuity m LZ Harness damaged Repair the harness
harness connector ECU ground or disconnected
circuit
(16 - Ground)

ECU: Electronic Control Unrt

 BODY - Troubleshootina 23-21

2. Ignition Switch (ON) Input Circuit

ECU
-----
Ignition switch

Sub
fusible
link 2

Battery T
f

/
(ECU connector terminals)

1613666

1
Check method Judgement
Step Cause Remedy
Condition Check object Normal Malfunction

2 IG SW: ON ECU terminal Battery voltage 0V Fuse @ blown Repair the harness
voltage or disconnected
(18 - Ground)
Harness damaged Repair the harness
or disconnected

IG SW: Ignition Switch

ECU: Electronic Control Unit
 -mms

E
BODY - Troubleshooting
a

3. Door Lock Switch, Fasten and Release Switch Input Circuit

L)oor loch switch

iL H.)

CLOSE OPEN

J
ECU
c-02 a

C-06

48

\rlJ -

(VW) ,(YW)
.

To lgnltlon
switch
-Id A-1 l&-i- -18i)-c-l

C-13

Release Fasten
switch swttch
Ii3.H.l (R.H.) c-19

C-06 C-13
C-02

FtLGW
a3
(Roof har .ness side)
Door lock switch
(R.H.)

(Rear harness side) (Door harness side) itCU connector terminals)

 BODY - Troubleshooting 23-23

Check method Judgement

Step Cause Remedy
Condition Check object Normal Malfunction
1 C-02 and C-l 9 Continuity be- OR++CQR Remains Door lock switch Replace the door
connectors: tween C-02 and Ofiormfl damaged lock switch
Disconnected C-l 9 connector (Refer to P.23-71.)
Door lock switch: terminals
CLOSE H OPEN (B-G). (B - RI
2 C-21 and C-38 Continuity be- OR++mCl Remains Fasten switch Replace the fasten
connectors: tween C-38 con- Ofiormfl damaged switch
Disconnected nectar terminals (Refer to P.23-119.)
Fasten switch: (GL- GB)
ON -OFF Continuity be-
tween C-21 con-
nector terminals
(YB - G)

3 C-06 and C-l 3 Continuity be- OR-mR Remains Release switch Replace the release
connectors: tween C-06 con- 0~1or~n damaged switch
Disconnected nectar terminals (Refer to P.23-119.)
Release switch: (RL- GW)
ON f--2 OFF Continuity be-
tween C-l 3 con-
nector terminals
(R -VW)

4 C-02 and C-l 9 Continuity 0 0 - cmII Remains 00 0 Harness damaged Repair the harness
connectors: between ECU or disconnected
Connected terminals and
C-38 and C-21 left and right Remains 0 f1 Harness short-
connectors: door lock switch circuited
Connected Left door lock
ECU connector: switch
Disconnected (9 - Ground)
Right door lock
switch
(2 - Ground)

5 C-06 and C-l 3 Continuity OR*+~n Remains ~0 bZ Harness damaged Repair the harness
connectors: between ECU or disconnected
Connected terminals and
C-02 and C-l 9 left and right Remains 0 fI Harness short-
connectors: door lock switch circuited
Connected Left door lock
ECU connector: switch
Disconnected (8 - Ground)
Door lock switch: Right door lock
OPEN switch
Release switch: (3 -Ground)
ON e OFF

ECU: Electronic Control Unit

23-24 BODY - Troubleshooting

1 4. Motor Power-supply and Drive Circuit 1

Motor tL.H.1
n -Motor (R.H.)

To batterv
Circuit
breaker
E!l
M

C-24

ECU
C-37 C-24

(ECU connector terminals)

iRear harness side)

Check method Judgement

Step Cause Remedy
Condition Check object Malfunction
.~., I
1 C-37 and C-24 Conttnuity be- Remains Motor damaged Replace the motor
connectors: tween C-37 and 0 f2 or m 0 (Refer to P.23-1 19.)
Disconnected C-24 connector
terminals
A (LW - RW)
B (LY - RY)
-
2 C-37 and C-24 Continuity 0 f-2 Remains-cc f1 Repair the harness
connectors: between ECU
Connected terminals
ECU connector: L.H. motor side Remains 0n
Disconnected (7 - IO)
R.H. m’otor side
(4- 1)
3 C-37 and C-24 ECU connector Battery voltage OV
connectors: terminal voltage
Connected (I 1 - Ground) (Refer to P.23-18.
ECU connector:
Disconnected

4 C-37 and C-24

connectors:
Continuity be-
tween ECU ter-
“”
Connected minal and ground
ECU connector: (6 - Ground)
Disconnected

ECU: Electronic Control Unit

 BODY - Troubleshooting 23-25

5. Spool Release Lever Switch and Indicator Light Circuit

ECU

lever indicator

To door lock
swrtch (R.H.)
-(i:ii

(ECU connector terminals)

c-40 c-41
q
LO B
LR LB
B El

(Rear harness side) lSY1846

Step
T Check
T
method T Judgement
Cause Remedy
Condition Check object’ Normal Malfunction

1 C-41 connector: Continuity be- Remains Spool release Replace the spool
Disconnected tween C-41 con- Oflorm3 switch damaged release lever
nector terminals switch
(LB-B) (Refer to P.23.119.)

2 C-40 connector: Continuity be- OCI Remains 00 fl Spool release Replace the spool
Disconnected tween C-40 con- lever indicator release lever
nector terminals light damaged indicator light
(LR - LO)
3 C-41 connector: Continuity Remains a 0 Harness damaged Repair the harness
Connected between ECU or disconnected
Spool release connector
switch: terminal Remains 0 0 Harness short-
ON ++ OFF (15 - Ground) circuited
ECU connector:
Disconnected
4 C-40 connector: ECU connector Replace the fuse
Connected terminal voltage
IG SW: ON (19 - Ground)
ECU connector: Repair the harness
Disconnected

IG SW: Ignition Switch

ECU:Electronic Control Unit
 /,.-A. *I .. _ ..,. dU
--. .-.____

23-26 BODY - Troubleshooting

6. Buckle Switch and Fasten Seat Belt indicator Light Circuit

r - -
ECU .. _~

Buckle switch
;wltch l-----

T
B-22 B-23

(ECUconnector terminals)

(Front harness sIdeI tl?car harness srde)

Check method Judgement

Ster Cause Remedv
Condltlon Check object / Normal Malfunction I

C-30 connector: Contlnulty be- ocz- x 12 Remains Buckle switch Replace the buckle
Disconnected tween C-30 con- 0 iI or r 12 damaged switch
Buckle switch. nector terminals (Refer to P.23-? 19.)
ON -OFF (RG - B)
B-23 and B-22 Continuity be- 0 c1 Remains x 0 Replace the “faster
connectors: tween B-23 and belt” indicator seat belt” indicator
DIsconnected B-22 connector light
terminals
(RB - GB) I
C-30 connector: Continuity
Connected between ECU
ECU connector: connector
Disconnected terminals
Buckle switch: (17 - Ground)
ON -OFF

B-23 and 8-22 ECU connector Battery voltage

connectors. terminal voltage
Connected (20 - Ground)
ECU connector:
DIsconnected or short-circuited
IG SW: ON

IG SW: lanltloli Switch

ECU. ELctronic Control Unit
 BODY - Troubleshootiw 23-27

7. Key-reminder Switch Input. Circuit

Knv-reminder

To fasten
switch (L.H.)
B-49

(ECU connector terminals)

(Front harness side) (Door harness side)

18Y1848

Step
I Check method T Judgement
I Lause Remedy
Condition Check object Normal 5I-
B-49 connector: Continuity be- Replace the key-
Disconnected tween B-49 con- reminder switch
Key-reminder nector terminals (Refer to P.8-156.)
switch: ON (Key) (YG - RB)
-OFF (No key)
C-02 connector: Continuity be- Remains Door lock switch Replace the door
Disconnected tween C-02 con- OQormfl damaged lock switch
Door lock switch: nector terminals (Refer to P.23-71.)
CLOSE * OPEN (G - 8). (B-R)
B-49 connector: ECU connector Battery voltage ov Fuse @ blown Replace the fuse
Connected terminal voltage
ECU connector: (12 - Ground) Harness damaged Repair the harness
Disconnected disconnected or
IG SW: ON short-circuited

C-02 connector: Continuity be- Remains ~0 0 Harness damaged Repair the harness
Connected tween ECU con- or disconnected
ECU connector: nector terminals
Disconnected (13 - Ground) Remains 00 / F$n;;;short-
Door lock switch:
CLOSE * OPEN

IG SW: Ignition Switch

ECU: Electronic Control Unit
 . I

____ ____ -

23-28 BODY - Troubleshooting

1 8. Buzyr &cyit 1

Buzzer

Key-
rernrnder
SLZ/IICh

Door lock
switch
(L.H.1

Spool release
lever switch

Buckle
switch

B-41
LO

I3 (ECU connector terminals)

B
[Front harness side) IXY IMY
--. .-

Check method Judgement

Ster
Condition Check object Normal Malfunction
1 Separate the B-41 connector Battery voltage 0V
B-41 connector (front harness
side) terminal
voltage
(LO - Ground) I
Connect the ECU harness side Battery voltage 0V ‘~
B-41 connector connector ter-
Separate the minal voltage
ECU’s harness (14 - Ground)
connector

ECU: Electronic Control Unit

 BODY - Service Adjustment Procedures 23-29
SERVICE ADJUSTMENT PROCEDURES
N23FAAI

HOOD FIT ADJUSTMENT

1. Adjust the longitudinal and lateral positions of the hood by
utilizing the oblong holes in the hinge.
2. Adjust the vertical position of the hood by adjusting the
hood bumper either up or down.

3. Adjust the position of the hood lock so that it is in proper

alignment with the hook.
NOTE
Apply specified grease to the sliding part, the rotating part
and the spring of the hood lock.
Specified grease: MOPAR Multi-purpose grease
Part No. 2932524 or equivalent

4. Adjust the length of the hook bolt.

REAR HATCH FIT ADJUSTMENT N23FLAA

1. Loosen the hatch hinge mounting nuts on the body side.

2. Adjust the hatch by moving it so that the clearance is equal
on all sides.
Caution
Do not loosen the hatch hinge mounting nuts more
than two full turns.

3. Adjust the position of the hatch striker so that it matches

that of the hatch latch.

I I I 18Y15341
23-30 BODY - Service Adjustment Procedures

4. Adjust the posrtron of the hatch latch so that It matches that _

of the hatch striker.

DOOR FIT ADJUSTMENT N23FEAi.I

1. Loosen the hinge mounting bolts on the body side, and

then move -the =door upward, downward, forward and
backward to adjust it so ~that the clearance around it is
equal. ~_
2. Loosen the hinge mountin&bolts of the door stde,-and then _
move the door to the left and right to adjust the surfaces. _
Caution
Attach protection tape to the fender edges near the
place where the hinge is installed.

3. Adjust fit between the front fender and hot-&door panel by

loosening the door side attaching bolts and_increasing or ;=;;
decreasing s&-r%.
4. Adjust engagement between the striker and~dooFlatch by, ;_
increasing or decreasing striker shims and/or sliding the 1
striker vertically or horizontally.

S18641 S1864

DOOR GLASS ADJUSTMENT N23FFAE

1. Remove the-door trim and waterproof film. (Refer to ~_

P.23-64.)
2. Raise the door glass fulls and then adjust the following I
items so that the door glass fits evenly into the door glass -
channel all the way around: -
(1) Loosen the door glassmounting nuts, and then adjust -
the door glass by moving it forward, backward, upward,
downward, and- to the left and right.
(2) Adjust the tilt of the door glass by tightening-the door -_
glass mounting nuts. =
INSIDE HAND/E PLAY ADJUSTMENT- N23fGAD

1. Remove the door trim and waterproof film.

2. Move the mounting position of the inside handle longitudi- _
nally in order to adjust the play of the inside handle.
Standard value (A): 4 - 10 mm (.I6 - .39 in.)
 BODY - Service Adiustment Procedures 23-31
-I
OUTSIDE HANDLE ADJUSTMENT N23FHAD

1. Remove the door trim and waterproof film.

2. Remove the outside handle rod from the outside handle,
and then adjust the play of the outside handle by turning the
top of the rod.
Standard value (B): 3 - 8 mm (.I2 - .31 in.)
NOTE
Be sure to install new rod snap.

Cl8517

Front floor pan FLOOR PAN INSPECTION N23FIAA

A common result of bodyleaks is a soaked floor mat pad or

carpet, and it’s not unusual to find that the water is getting in
through the floor pan to some other low point in the body. It is
possible however, for water to enter higher up and run
downward to soak the mat.
Since a soaked mat should be removed for drying, it’s a good
way to start your check. Of course, mat removal means you’ll
have to take off door sill plates and pull out seats or seat
cushion. But, this gives you a clear field for action so you can
c : Drain plug position ,8y1778
check body seam sealing and the plugs in the floor pan.
It’s usually not practical to water test for floor pan or
Rear floor pan wheelhousing leaks unless a special underbody water spray
arrangement is available. As an alternate, the best way to
locate these leak points is to look for rusty seam edges or other
traces of leaks after the mats and cushions are removed.
Traces of mud are an indication that the water is coming in from
below.

.-
IS\/1779
23-32 BODY - Hood -

HOOD N23tiAAH

REMOVAL AND INSTALLATION

4-6Nm
2.9-4.3 ft

7-11 Nm *
5-8 ft.lbs.
I-/

._=
1811803

Hood panel removal steps Release cable removal steps

I. Hood weatherstrip, front 10. Hood lock plate
2. Hood hook 11. Hood Lock
3. Heat protector 12. Hood release handle
4. Hood weatherstrip, rear 13. Release cable
5. Hood damper
6. Hood bumper NOTE
7. Hood support rod (1) Reverse the removal procedures to reinstall.
+I) 8. Hood switch (2) +I): Refer to “Service Points of Remoygl”.
9. Hood panel

SERVICE POINT OF REMOVAL

8. REMOVAL OF HOOD SWITCH
Remove thE hood switch as shown.
 BODY - Hood 23-33
INSPECTION
HOOD SWITCH
(1) Disconnect the hood switch connector.
(2) Check the continuity between the terminals.

Terminal 1 2

Hood switch unpressed 0 0

Hood switch depressed
18R0665

NOTE
O-O indicates that there is continuity between the terminals.

HOOD HINGE REPLACEMENT

When replacing the hood hinges, use a hood hinge kit by the
following procedure:
(1) Remove the hood from the hood hinges.
Caution
Protect the front deck with a cloth so that the hood
protrusions do not damage it.

(2) Remove the hood hinges by breaking the spot welds

fastening the hinges to the front deck by using a drill 8 mm
(.32 in.) in diameter.
Caution
Be careful not to drill holes in the deck panel.
NOTE
After removing the hinges, make sure that the hinge
mounting surfaces on the front deck are flat and level.

(3) Mark the hinge mounting positions on the front deck by

using a punch.
(4) Drill the holes by using a drill 8 mm (.32 in.) in diameter.

(5) Remove the access hole cover together with the boost
sensor and the wiper motor. (Refer to GROUP 8 ELECTRIC-
AL - Windshield Wipers and Washer.)
(6) Insert the brackets from the inside of the front deck, fit the
hinges, and tighten the nuts temporarily.
NOTE
The work of installing hinges will be facilitated if adhesive is
applied to the surfaces of the brackets in contact with the
front deck.
(7) Install the hood.
i
(8) Adiust the hood alianment.
23-34 BODY - Fuel Filler Door

FUEL FILLER DOOR N23JAAJ

REMOVAL AND INSTALLATION

WY1044

Removal steps
+* *+ I. Scuff plate
+I) 2, Quarter trim
++ *+ 3. Trunk room side trim -
4. Lock release panel
5. Lock release cable -
6. Filler door panel
7. Stop assembly NOTE
8. Filler neck cover (1) Reverse t& removal procedures to reinstall.
9. Grommet (2) +*: Refer 10 “Service Points of Removal”.
(3)- I)+: Referto “Service Points of Installatron”.
IO. Soft vinyl tube
BODY - Fuel Filler Door 23-35
SERVICE POINTS OF REMOVAL
1. REMOVAL OF SCUFF PLATE / 2. QUARTER TRIM / 3.
TRUNK ROOM SIDE TRIM
Refer to P.23-95.

SERVICE POINTS OF INSTALLATION

3. INSTALLATION OF TRUNK ROOM SIDE TRIM / 1.
SCUFF PLATE
Refer to P.23-95.
23-36 BODY - Rear Hatch

REAR HATCH N230AAG

REMOVAL AND INSTALLATION

Post-installation Operation IO-15 Nm-

l Adiustina Rear Hatch Fits 7-l 1 ftlbs.
1 (Refer to”P.23.29.)

5--8Nm -“,-.--E
4-S ftlbs.

15 6-9 Nm
-44ftlbs.

Rear hatch glass removal steps

** 1. Rear wiper arm 18Y1858
Rear hatch trim
32: Rear wiper motor
4. Rear hatch striker
5. High mounted stop light
connector connection
Roll bar trim
Defogger terminal connection
Rear hatch stopper (with stay switch)
Ball joint
Rear hatch hinge
Protector
Rear hatch garnish
(with rear spoiler)
4* I)+ 13. Rear hatch upper moulding
4, I)+ 14. Rear hatch side moulding
15. Rear hatch opening weatherstrip
16. Rear hatch glass
Lock release cable removal steps 4-6Nm
*I) *+ 17. Scuff plate 2.94.3ft.lbs. ,8y,8,5
4* 18. Quarter trim
4~ I)+ 19. Trunk room side trim /
*+ I)+ 20. Rear end trim
+* I)+ 21. Rod snap
+I) r)+ 221 Rear hatch link assembly
** a+ 23. Rear hatch latch 23
24. Rear hatch handle
25. Lock release cable
26. Rear hatch lock key retainer
27. Rear hatch lock kev cvlinder

NOTE _
(1) Reverse the removal procedures to reln<t&.
(2) +*I Refer to “Service Points of Removal”.
(3) ++: Refer to “Service Points of Installation”.
(4) CiT: Non-reusuable parts.
 BODY - Rear Hatch 23-37
SERVICE POINTS OF REMOVAL
6. REMOVAL OF ROLL BAR TRIM
Refer to P.23-95.

8. REMOVAL OF REAR HATCH STOPPER (WITH STAY

SWITCH)
(1) Remove the rear hatch stopper from the body.

Tool A Tool B 12. REMOVAL OF REAR HATCH GARNISH (WITH REAR

SPOILER)
Align the tools shown in the illustration along the glass,
press them in with a plastic hammer or similar tool, and cut
the adhesive.
Remove the rear hatch garnish.
Caution
Remove foreign material from the gap between the
glass and the garnish with compressed air.
mm (in.) 18Y1561 Be careful not to scratch the glass.

18Y170r

13. REMOVAL OF REAR HATCH UPPER MOULING /

14. REAR HATCH SIDE MOULDING
Remove the rear hatch mouldings while using tool A to cut
the adhesive.

18Y156:
23-38 BODY - Rear Hatch

17. REMOVAL OF SCUFF PLATE / 18. QUARTER TRIM / 19.

TRUNK ROOM SIDE TRIM / 20. REAR END TRIM
Refer to P.2395.

21. REMOVAL OF ROD SNAP

(I) Disconnect the rod snap and the left and right rods from
the rear hatch link assembly.
(2) Disconnect the lock release cable from the rear hatch it
link assembly.

Rear hatch link assembly/ Rear hatch latch 22. REMOVAL ~OF REAR HATCH LINK ASSEMBLY / 23.
REAR HATCH LATCH
(1) Remove the rear hatch link assembly.
(2) Removethe left and right rear hatch latches together
with the rod.

18Y152; INSPECTION
STAY SWITCH
(I) Disconnect the stay switch connector. Then, with the rear
hatch closed (with stay switch turned ON), check the stay
switch for continuity across terminals.

R.H. side

Stay switch
 BODY - Rear Hatch 23-39
REAR HATCH SWITCH
(1) Unlock the rear hatch link.
(2) Check the continuity between the terminals.

Terminal I A I B I
I Rear hatch link locked I I I
Rear hatch link unlocked I -+- I
. NOTE
18Y181C
C-O indicates that there is continuity,between the terminals
REAR HATCH KEY CYLINDER UNLOCK SWITCH
(I) Turn the key to unlock the lock cylinder.
(2) Check the continuity between the terminals.

16Y3608 NOTE
O-O indicates that there is continuity between the terminals.
l Check the rear hatch hinge for cracks and damage.
l Check the rear hatch stopper for deterioration.
l Check the rear hatch link assembly for wear, damage or
malfunction.
l Check the rear hatch latch for wear, damage or malfunction.
l Check the rear hatch striker for wear. .
l Check the rear hatch opening weatherstrip for cracks,
damage or deformation.

SERVICE POINTS OF INSTALLATION

23. INSTALLATION OF REAR HATCH LATCH / 22. REAR
HATCH LINK ASSEMBLY / 21. ROD SNAP
(1) Install the rear hatch latch.
NOTE
Be sure the rear hatch latch is unlocked.
Install the rear hatch link assembly1
(2) Install the left and right rods and secure them with the,
clip.
(3) Apply the specified grease to the moving parts of the
rear hatch link assembly and rear hatch latch assembly.
Specified grease: MOPAR Multi-purpose grease
Part No. 2932524 or equivalent
20.lNSTALLATlON OF REAR END TRIM / 19. TRUNK
ROOM SIDE TRIM / 17. SCUFF PLATE
Refer to P.23-95.
23-40 BODY - Rear Hatch

14. APPLICATION OF SEALANT TO REAR HATCH SIDE

MOULDING / 13. REAR HATCH UPPER MOULDING
Install the rear hatch mouldings after applying the specified ._
sealant (from the kit) to the entire circumference at the _
positions indicated in the illustration. ~
Specified sealant: Urethane adhesive (Essex Urethane
“E” . . . Auto Glass Sealant)

18Y156r

12. APPLICATION OF SEALANT TO REAR HATCH GARNISH

(WITH REAR SPOILER)
(1) Apply the specified sealant (from the kit) to the entire _
circumference of the rear hatch garnish in the positions I
h shown in the illustration.
sh
Specified sealant: Urethane adhesive (Essex
Urethane “E” . .. Auto Glass
Sealant)
(2) Align themounting po-ion of the rear hatch garnish so ~_
Hatch glass Nut
18Y170E that the left and right clearances between the garnish -1
and the rear hatch glass, and between the garnish and
the rear hatch side moulding. are equal, and tighten the
nuts. 1,

10. APPLICATION OF GREASE TO REAR HATCH HINGE

Apply the specified grease to the rear hatch hinge.
Specified grease: MOPAR Multi-purpose grease
Part No. 2932524 or equivalent

-
Caution --
When installing the hatch glass, be sure that the rib of
the packing projects from the glass surface so that the
back plate does not contact the glass directly.

Back plate
18Y154(
 BODY - Rear Hatch 23-41
8. INSTALLATION OF REAR HATCH STOPPER (WITH
STAY SWITCH)
(1) Install the ball joint on the body.
(2) Install the stopper on the rear hatch, and then push the
bottom tip of the stopper into the ball joint.
Caution
1. Never attempt to disassemble the rear hatch stop-
per or dispose of it in a fire.
2. When disposing of the rear hatch stopper, first drill
a hole at the label position to allow the gas inside it
18Y51E
to escape.
1. INSTALLATION OF REAR WIPER ARM
Refer to GROUP 8 ELECTRICAL - Rear Window Wiper and
Washer.
23-42 BODY - Bumper

BUMPER N232AAM

REMOVAL AND INSTALLATION

Front

=.

18Y1841

Rear

Front bumper removal steps

I. Front combrnation light bezel
2. Front combinatron ltght
3. Licence plate bracket
4. Air guide panel Wehrcles
with a manual transmrssron)
5. Arr guide panel (Vehicles
with an automatic transmrssron)
++ 6. Front bumper assembly wrth front
skrrt panel (Parts 7 through IO)
7. Front skirt panel
8. Bumper reinforcement
9. Bumper core
10. Bumper face

Rear bumper removal steps

+I) 11. Rear bumper assembly
(Parts 12 through 15)
12. Bumper plate
13. Bumper reinforcement
14. Bumper core
15. Bumper face NOTE
16. Bumper guide plate (I 1 Reverse the removal procedures to rernstall.
(2) **: Refer to “Service points of Removal”.
 BODY - Bumper 23-43
SERVICE POINTS OF REMOVAL
6. REMOVAL OF FRONT BUMPER ASSEMBLY WITH
FRONT SKIRT PANEL
(1) Remove the bolts (indicated by arrows) which attach
the front skirt panel to the fender.

18Y1840

(2) Remove the stay bolts.

11. REMOVAL OF REAR BUMPER ASSEMBLY

Remove stay bolts from inside the trunk and from the rear
end crossmember.

/
II I 18Y1504 18Y1503

URETHANE BUMPER REPAIR

REPAIRABLE RANGE
HOLES
The damaged area must be shaped to a round or oval hole so
that it can be easily filled with the putty; however, the diameter
or length of the hole must be within 50 mm (2.0 in.).
CRACKING - SPLITTING
If the two sides of the crack have not separated, the length
must be within 200 mm (8.0 in.).
If one end of the crack extends to the edge of the bumper, not
only must the length of the crack be within 200 mm (8.0 in.),
but also the length of the crack must be less than one-half of
the bumper in the damaged area.
-.& .-.

23-44
p-*- z-
URETHANE BUMPER REPAIR PROCEDURE --_ =
1. If the damage is a hole, use a knife or similar toolto shape -~ 6:
the hole into a round or-oval opening. YB
_
2. If the damage-is a crack orsplit, use a knife or similar tool to I z
widen the opening to approximately 2 mm (.08 in.).
3. G~rind the damaged area totapering shape of approximately - IE
10 to 15 mm (.4 to .6 in,) in width with a sanding disc
(approx. #36[to #50). .~

18Y93; ,
m
4. After initial grinding, the 3~basic types of reparrs should be mi -.

9
Hole
as shown in the illustrations. =z
- rz:
=-
--~
-

IO-15mm
i.4 - .6 In.)

5. Using a disc, remove the surface coatmg around the

damage, feather-edging the boundary line between the -r
finish and the urethane at the same time.
Try to feather-edge for 30 mm (I. 18 in.) around the damage. 1,

6. After feather-edging, the 3 basic types of repair should be =

as shown in the illustraiions.

.j;
m+$,,,
30-35 mm/
(I .2 - 1.4 in.)

7. Remove.anydirt adhering to the damaged-area wrth a rag ~1

soaked in benzine.
Caution
Do not use a lacquer-type thinner.
 BODY - Bumper 23-45
8. Cover the back surface of the damage with a piece of
aluminum tape.

9. Prepare the adhesive, and apply it to the damaged area

using a spatula.
NOTE
If the damage is large, apply two coats of adhesive. Apply
the adhesive by moving the spatula from the edge of the
damaged area toward the center, so that the damaged area
will be filled with adhesive.

IO. After applying the adhesive, let it dry.

11. Polish the repaired area, using a double-action sander with a
disc.
NOTE
Sand repaired hole or cracks for about five minutes with the
disc.

12. Finish the surface of the repaired area with a hand sanding
block.
NOTE
The area should be carefully sanded so that there is no step
at the boundary line between the adhesive and the
undamaged surfacce coating.

13. To improve the grip of the paint, wet-sand the entire

surface of the bumper face while using #400-grit waterre-
sistant sandpaper and a rubber pad.

18Y945
23-46 BODY - Bumper

1
14. Cover the uncoated portion of the bumper face with
masking tape.
15. Clean away any dirt from the bumper face with a rag soaked
-
in benzine.

16. Spray a co%of primer on the damaged area.

17. Mix an appropriate combination of color coat and clear coat, I:;
and then spray the whole surface of the bumper face.

-------“------^-
-- 18Y94i
 BODY - Fenders 23-47

FENDERS N23KAAQ

REMOVAL AND INSTALLATION

18Y1722

\ IO-16 Nm
10 7-12 ftlbs.

Removal steps
c* 1. Radiator grille
2. Front corner garnish
3. Header panel
4. Front combination light bezel 18Y1842
5. Front combination light unit
6. Air guide panel (Vehicles with
a manual transmission)
7. Air guide panel (Vehicles with
an automatic transmission)
4* 8. Front fender side stay
4* 9. Front bumper assembly with front
skirt panel
I)* 10. Wiper arm
4* II. Front deck garnish NOTE
12. Front bumper plate (1) Reverse the iemoval procedures to reinstall.
13. Fender liner (2) +*: Refer to “Service Points of Removal”.
+* I)* 14. Fender (3) I)+: Refer to “Service Points of Installation”.
 SERVICE POINTS OF REMOVAL
1 . REMOVAL OF RADIATOR GRILLE
Remove screws, force out the clips from inside the engine IT
room and remove the radiator grille.

C : Screws

8. REMOVAL OF FRONT FENDER SIDE STAY

Remove the IsFde stay bolts (indicated by arrows) and
remove the ~front fender-side stay.

L7
----.--___

18Yl841

9. REMOVAL OF FRONT BUMPER ASSEMBLY WITH

FRONT SKIRT PANEL
(1) Remove the bolts which attach the front skirt panel to
fender.

(2) Remove the bumper stay bolts and then remove the L
bumper assembly with front skirt panel.

-
17,REMOVAL OF FRONT DECK GARNISH
Using the trim stick, remove the front deck garnish by ;
prying at the cljp positions.

--
 BODY - Fenders 23-49
14. REMOVAL OF FENDER
Remove the fender mounting bolts.

SERVICE POINTS OF INSTALLATION

14. INSTALLATION OF FENDER
Fender
seal (1) Mount the fender seal packing in the position shown in
packing the illustration.
(2) Temporarily mount the fender in position, check
whether clearance is uniform at all points, and then
tighten securely.
(3) Apply specified sealant to the flange part of the fender
when installing the fender liner.
Specified sealant: Dry Sealant or equivalent
IO. INSTALLATION OF WIPER. ARti
Refer to GROUP 8 ELECTRICAL - Windshield Wiper and
Washer.
23-50 BODY - Grille and Moulding

GRILLE AND MOULDING N23R.40

REMOVAL AND INSTALLATION

IO-16 Nm
7-12 ftlbs.

18Y1830

Radiator grille removal Chipping protector removal

++ 1. Radiator grille I)* 6. Front quarter film chipping protector
t+ 7. Rear quarter film chipplng protector
Front deck garnish removal steps
Rear panelparnish removal steps
2. Wiper arm
+?) 3. Front deck garnish 8. Rear end trim
S_Rear combination lamp
10. Rear panel garnish
Air outlet garnish removal steps
NOTE -:
4. Quarter trim (1) Reverse the removal procedures to reinstall
+* 5. Air outlet garnish 13) +I): Refer to “Service Points of Removal”.
(3) l *: Refer to “Service Points of Installation”.
(4) q , Non-reusable parts.
-.~ .
 BODY - Grille and Mouldinn 23-51
SERVICE POINTS OF REMOVAL
1. REMOVAL OF RADIATOR GRILLE
Remove radiator grille mounting nuts and clips and remove
the radiator grille.

I & : Screws 18Y1743

3. REMOVAL OF FRONT DECK GARNISH

Using the trim stick, remove the front deck garnish by
prying at the clip positions.

5. REMOVAL OF AIR OUTLET GARNISH

Remove the air outlet garnish mounting nuts, and then
remove the garnish outward.

Front quarter film 3ear quarter film SERVICE POINTS OF INSTALLATION

chipping protector :hipping protector
7. INSTALLATION OF REAR QUARTER FILM CHIPPING
PROTECTOR / 6. FRONT QUARTER FILM CHIPPING
PROTECTOR
(1) Use lead-free gasoline to clean the mounting positions.
(2) After removing the paper protecting the back, .affix the
chipping protector at the correct location, paying heed
to the measurements shown.
Caution
mm (in.) 18Y2062 mm (in.) 18Y206 1. The application should be done in a place with
little or no dust, and at an ambient temperature
of 20 - 40°C (70 - 100°F).
2. If the ambient temperature is below 20°C (7O”F),
warm both the chipping ljrotector and the body
FoppF;ation surfaces) to within 20 - 40°C (70 -
23-52 BODY - Grille and Moulding

(3) Use the stripe tape spatula to press on the chipping

protector beginning at the center and moving evenly to ,;
both the hop and bottom, in order to remove any
‘_ trapped air bubbles. _
\ t Caution
‘& Be sure to press on the chipping protector with
‘a enough force to prevent it from coming off.
Stripe tape \,
spatula
1
Chipplnq ’
protector 18C15t

___--
(4) Pull the paper protecting the front straight and slowly.
(5) If there are any air bybbles in the chipping protector
after the Application is finished, use a sewing needle to ~
make small holes in the bubbles, and use the corners of l
the spatula to press the air out.

Good
 BODY - Windshield and Quarter Window 23-53
WINDSHIELD AND QUARTER WINDOW
N23LAAF

GENERAL
The windshield glass is attached by an urethane-base-adhesive
to the window frame. This adhesive not only provides rrnpt%%d
glass holding and sealing, but also permits use &of -body
openings having a greater structural strength.

ADHESIVE KIT AND RESERVE ITEMS

Adhesive kit and reserve items Applications Quantity

Adhesive kit
(Essex Chemical Corporation)
Urethane adhesive (Essex Urethane “E” One cartridge
. . . Auto Glass Sealant)
Dispensing nozzle One
Glass blackout primer As required
Dauber for applying blackout primer One

Reserve items
Wire (dia. x length) for cutting adhesive Five pieces of wire
0.6 x 1 mm
(024 x .040 in.)
Adhesive gun for adhesive application One
Isopropyl alcohol for cleaning jointing surfaces As required
Wiping rags As required
Window weatherstrip sealant for prevention of water leaks and As required
(MOPAR KIOI CEMENT Part No. 383769) gathering after adhesive application
MEK (Methyl Ethyl Ketone) or Toluene As required
Grow Chemical Solvent GS-35 for cleaning As required
Glass holder Two
Window moulding remover (Special Tool One
MB9904491
Spacers (Service Part) Two
Dam (Service Part) As required
Tectyl 506T (Valvoline Oil Company) As required

NOTE
MEK (Methyl Ethyl Ketone), Toluol (Toluene), Grow Chemical Solvent GS-35 can be obtained directly from a chemical
house handling these chemicals.
 BODY - Windshield and Quarter Window

WINDSHIELD INS’ TALLATION PROCEDURE

(wire)

--
BOdV Glass

r,&,
_-_-, I-----------
1
I
r--------- inspection of glass
If reusing glass/
r--------- ------------1
$?_emo-va!
_ of1-----
adhesive ____
and -__I
dam,

I I I
I
I I
l-
J ----
I I [:+$ni $&ass_ -2
I I
(Toluene or paint thinner!
I I I
I (Isopropyl alcohol)
I
I I t------
spacers and studs

c +-g+q;
I I
Application
(glass blackout
of primer
primer) a
Application of solvent
I I
I I
(MEK or Toluene)
pGGzdGq/
L.-~-~-~~--~~~~ (urethane adhesive)

Installation of glass

If water leaks

----.----+,
- - --_-- ---------- -___ 4

(Grow chemrcal solvent GS-35)

 BODY - Windshield 23-55
WINDSHIELD N23LBAH

REMOVAL AND INSTALLATION

Removal steps
1. Sunvisor
2. Dome light assembly
3. Inside rearview mirror
4. Assist grip
5. Front pillar trim
6. Headlining
7. Front side moulding
8. Front upper moulding
9. Window moulding clip
10. Moulding retainer
11. Windshield moulding retainer
NOTE
+I) l + 12. Windshield (I) Reverse the removal procedures to reinstall.
I)+ I 3. Window glass spacer B (2) l *: Refer to “Service Points of Removal”.
l + 14. Window glass spacer A (3) l +: Refer to “Service Points of Installation”
l * 15. Window dam (4) q : Non-reusable parts
18YA17
 m
E
23-56 BODY - Windshield

SERVICE POINTS OF REMOVAL

5. REMOVAL OF FRONT PILLAR TRIM
Refer to P.23-95. -_

6. REMOVAL OF HEADLINING
Remove the headlining from the roof panel to provide space
for extending wire between the top and bottom edges ot -1
windshield. -

7. REMOVAL OF FRONT SIDE MOULDING / 8. FRONT

UPPER MOULDING / 9. WINDOW MOULPING CLIP
(1) Remove?he mouldi_ngs by using the special tool _
(MB99Q449).

Moulding. (2) Remove the mouldtng clips by using the special tool
Clir,
(MB990449).

12. REMOVAL OF WINDSHIELD

(1) ‘Using a sharp-pointeddrill, make a hole in the adhesive _
Cloth tape area aft the windshi&j.
Insert a wire through the hole from the inside. 1
Caution
Use cloth tape to protect the painted body surfaces.

/ Y1805C
 BODY - Windshield 23-57
(2) From inside the vehicle, insert one end of wire through
adhesive at the upper edge of the windshield.
(3) Insert the other end of wire from inside the vehicle
through adhesive at the lower edge of the windshield.
(4) Secure each end of wire to a wooden handle or the like.
(5) Carefully cut through adhesive by pulling wire along the
windshield from outside the vehicle in a sawing motion.
Caution
In order to protect the body from damage, apply
cloth tape to all body areas around the installed
glass before cutting the adhesive.
(6) Make mating marks on the glass and body if the glass is
Glass holders to be reinstalled.
(7) Take out the glass with glass holders.
NOTE
If the glass being removed is to be reinstalled, place it
on a protected bench or holding fixture.
(8) Use a screwdriver or similar tool to pry up and remove
the moulding clips.

‘/ ’ \ 18Y55E

INSPECTION
Check the moulding clips and studs. Replace them if they are
damaged.
NOTE
If a moulding clip stud has been broken, drill a hole of 3 mm
(.I 25 in.) in diameter in the stud, apply specified sealant to this
hole, and then install the moulding clip with a self-tapping
screw.
Specified sealant: Urethane adhesive (Essex Urethane “E”
. . . Auto Glass Sealant)
Caution
After installing the clip, apply antirust solvent to the screw
head and the clip to protect them from rust.

SERVICE POINTS OF INSTALLATION

15.-INSTALLATION OF WINDOW DAM
(1) Wipe surface of glass, to which bead of adhesive will be
applied [within 25 mm (1 in.) from the edge of glass]
with a cloth dampened in isopropyl alcohol.
Caution
Do not touch surfaces that have been degreased
with isopropyl alcohol.

Y18831
23-58 BODY - Windshield

(2) Remove Vie back paper from the dam, and attach the ~:
dam to the glass.
(3) Apply glass primer to the entire bonding surfaGe of the ~~
glass, both to the inside surface and the edge of the z
glass Allo_w to dry for ten minutes.
Caution
Use care to avoid spilling primer solution on trim or
a painted surface. Wipe away any spilled solution
immediately, because the primer will damage trim
or painted surfaces.
nm (in.) 18Y1551 Do not touch the primer coated surface.
14. INSTALLATION OF WINDOW GLASS SPACER A / 13.
Spacer A Spacer B WINDOW GLASS SPACER B
(1) Using a clean lint-free_ cloth liberally dampened with
solvent (MEK or Toluene), briskly rub over old adhesive
material remaining onpinch-weld flange.
bw3 off (2) Cut off an-amount from spacers A and B equal to the
thickness of the adhesive remaining [within 2~mr-n (.08
in.)] on the pinch-weld flange.

Y1855H

(3) Attach the spacers In- the proper directions on the

flange. 1

1 1
mm (In.1

1. Spacer A 2. Spacer B

Y186S

12. INSTALLATION OF WINDSHIELD

(1) Using a sharp knife, remove old adhesive on the body
opening pinch-weld flange evenly to a thickness of
within 2 mm (.08 in.7 all around. Finish the flange
surfaces So that they are smooth.
Caution
Be careful not to remove more adhesive than
necessary, and also not to damage the paintwork
on the body surface with the knife. If the paintwork
is damaged, repair the damaged area with touch-up
paint or antl-rust solvent.
 BODY - Windshield 23-59
(2) With an adhesive gun, apply the specified adhesive to
the entire windshield mounting surface along the dam.
Specified. adhesive: Urethane adhesive (Essex
Urethane “E” . . . Auto Glass
Sealant)
NOTE
Cut the nozzle tip into a V shape to facilitate adhesive
application. Adhesive material begins to cure after
fifteen minutes when exposed to air.
mm (in.) 18Y98E (3) Using a glass holder, place the glass on the body
opening.
Press the glass gently so that no adhesive appears.
Caution
Do not move the glass after installing it to the body.
Apply specified sealan Place the glass in the previously marked position.
Use care not to close the water groove (in the lower
corner of the pinch-weld flange) with adhesive.
(4) Wipe away excess adhesive from the glass.
(5) Test for water leakage.
(6) If there is leakage, fill the leaking area with specified
sealant.
PI 852s 3
Specified sealant: MOPAR KIOI CEMENT
Part No. 383769 or equivalent
Caution
Do not apply water directly to the bonded area.
(7) Install the clips to the body.
(8) Apply tectyl to the clips.
(9) Attach the mouldings to the clips by tapping.
 Removal steps
1. Rear pillar trim
2. Upper quarter trim
3. Rear side shelf
+* 4. Quarter window moulding
I)+ 5. Quarter window glass
6. Quarter window spacer
7. Sealant

NOTE ~-
(1) Reverse the removal procedures to reInstall.
(2) **: Refer to “Service Points of Removal”.
(3) l *: Refer to “Service Points of Installation”.
(4) q : Non-reusable parts
lAYA
L -_ mi--

SERVICE POINT OF REMOVAL

4. REMOVAL OF QUARTER WINDOW MOULDING
(1) Open the hatch. -
(2) Remove -the quarter window moulding mounting -1
screws and bolt.

18Y1527

(3JmWithm the special tool mB990449), remove the quarter ~~

window moulding by-prying at the clip position of the
quarter window moulding.
Caution
Be careful not to scratch the painted surface of the
body.
 BODY - Quarter Window 23-61
(4) Remove the quarter window mounting bolts.
(5) Cut the butyl tape and remove the quarter window
glass.

SERVICE POINT OF INSTALLATION

5. APPLICATION OF ADHESIVE TO QUARTER WINDOW
Auto window sealer
GLASS
When the window glass is installed, apply the specified
adhesive all around the circumference of the inside of the
glass.
+ Specified adhesive: Urethan adhesive (Essex Urethane
5 mm (.2 in.) “E” . . . Auto Glass Sealant)
 -1 re: .,!
‘11- . rt
1, ,-~-IL
.--.

23-62 BODY - Door Assembly

DOOR ASSEMBLY N23MAAJ

REMOVAL AND INSTALLATION

Door removal steps 18Y1801

1. Door wiring harness connection -
2. Upper hinge cover
I)+ 3. Door upper hinge -~
4. Door upper hinge shim -
5. Lower hinge cover Door switch removal steps
*+ 6. Door lower hinge
‘8. E;o,; lower hinge shim ‘1I.- Door opening switch cap
1’2. Door switch
Striker removal steps f NOTE r:m: -
9. Striker (I) Reversethe removal p%cedures to reinstall.
10. Striker shim (2) *+: Refer to “Service Points of Installation”.

INSPECTION
DOOR SWITCH
Operate the switch, and check the continuity between the
terminals.

NOTE
rI&0 Indicates tf-& there IS conmurty between the terminals.

@ Cracks, damage, or abnormal norse of door hinges

9 Looseness of door hinge attaching bolts
l Damage or-deformation-of door panel
 BODY - Door Assembly 23-63
SERVICE POINT OF INSTALLATION
6. REMOVAL OF DOOR LOWER HINGE / 3. DOOR UPPER
HINGE
Apply specified grease to the door hinge sliding portions.
Specified grease: MOPAR Multi-purpose grease
Part No. 2932524 or equivalent

18Y1727
 BODY - Door Trim

DOOR TRIM N23MBAI

REMOVAL AND INSTALLATION

18Y1802

Removal steps
I. Door corner trim
2. Inside handle cover
3. Door grip
4. Power window switch
+I) 5. Door sash trim
4, 6. Door upper trim
+I) 7. Door lower trim
8. Door light NOTE
9. Speaker garnish (I) Reve@ iBe removal procedures to reinstall.
IO. Door grip bracket (2) **: Rgfer to “ServicePoints
-. of Removal”.
11. Trim clips (3) C denotes clip posItIon

SERVICE POINTS OF REMOVAL

5. REMOVAL OF DOOR SASH TRIM
Remove the front door sash trim mounting. scrqws, and -
then remove the trim by pulling it upward.
 BODY - Door Trim 23-65
6. REMOVAL OF DOOR UPPER TRIM
Remove the clips with the trim stick.
From the outside of the vehicle, remove the trim by pulling
it upward while holding the sheet-metal part of the door
upper trim.

7. REMOVAL OF DOOR LOWER TRIM

Remove the clips from the edge of the door lower trim by
using the trim stick.

INSPECTION
POWER WINDOW SWITCH
Operate the switch, and check for continuity between the
terminals.
MAIN SWITCH

Drivefsw;, ci;dow Passenger’s

window switch

2 1 4 6 2 3 7 6

NOR-
Main switch MAL

LOCK
Sub switch
DOWN o----O
o----o 0 0

16Y173i SUB SWITCH

 a j
-- -__.

23-66 BODY - Front Door Glass and Regulator

FRONT DOOR GLASS AND REGULATOR

REMOVAL AND INSTALLATION g&5

Removal steps
4+ I. Door trim
+I) *+ 2. Waterproof film
4II) 3. Door drip moulding
4+ 4. Door belt moulding
+I) 5. Door window rear sash moulding
6. Door belt inside weatherstrip
I)+ 7. Door glass stabilizer (inner)
I)+ 8. Door glass stabilizer (outer)
4+ I)+ 9. Front door glass
+I) Ib4 IO. Power window regulator
4d 11. Power window motor
NOTE
(I ) Reverse the removal procedures to relnstall.
(2) +I): Refer to “Serwce Potnts ot Removal”.
(31 1)4: Refer to “Servrce Points of Installation”
 BODY - Front Door Glass and Regulator 23-67
SERVICE POINTS OF REMOVAL
1. REMOVAL OF DOOR TRIM
Refer to P.23-64.

I IIIIII 2.0 (.8) I 2. REMOVAL OF WATERPROOF FILM

Cut away the non-drying adhesive around the waterproof
film with a cutter or similar tool.

I Thickness:
1 LO4)
mm (in.) I Caution
If the clip for the door trim is still in the mounting
in the body, remove it with the tool shown
hole
in the
illustration.

3. REMOVAL OF DOOR DRIP MOULDING / 4. DOOR BELT

MOULDING / 5. DOOR WINDOW REAR SASH MOULD-
ING
Insert the trim stick at the position of the moulding clips,
and then pry the mouldings to remove them in the following
order:
(1) Door drip moulding
(2) Door belt moulding
(3) Door window rear sash moulding

9. REMOVAL OF FRONT DOOR GLASS

(1) Turn on the ignition switch and operate the windows.
Be sure to turn the ignition switch off after finishing.
(2) Remove the door glass stabilizer.
(3) Remove the glass mounting nuts.
(4) Pull the glass upward and remove it.

.lO. REMOVAL OF POWER WINDOW REGULATOR

(1) Remove the door glass guide..
 ~______~.
E-
&g-i
BODY - Front Door Glass and Regulator
(2) Remove’the door glass gurde through the acqass hole ~_
while moving the lower edge of the guide forward. ~-
(3) Remove the- motor connector.

(4) Remove the regulator- mounting bolts. ~~

(5) Remove the. regulator through the access hole.

EE=
e-
11. REMOVAL OF POWER WINDOW MOTOR
Remove then power window motor from the regulator I: z
assembly.
Caution
When loosening the connecting screws of the regulator
and the motor assembly, the compressed force of the
regulator spring may cause the regulator arm to spring
up.

INSPECTION
POWER WINDOW MOTOR
(1) Remove the Ipower window motor and regulator.
(2) Connect then-motor ~terminals directly to the battery and
check that the motor operates smoothly. Next, reverse the
polarity and check that the motor operates-smoothly in the
reverse direction.
To check the circuit breaker built in the motor, -install the
motor and regulator to the body and then proceed as r
follows: r
(‘iI Press the UP switch to wide open thee door window : ~
glass and hold down the swatch for about 1 Q-seconds. I
Upon releasrng the UP-switch, press the DOWN switch. ’
;$I The crrcuit breaker is,Tudged good if the door window I
glass starts to openTn 60 seconds or less.
y SL
p-;=~
EEzY
e=r_.
ST-
 BODY - Front Door Glass and Reaulator 23-69
POWER WINDOW RELAY
(1) Remove the power window relay.

16Y15401

(2) Check continuity between terminals 1 and 3 when the

battery voltage is applied to terminal 2, and terminal 4 is
grounded.

Voltage applied Terminals 1 - 3 Conductive

Voltage not Terminals 1 - 3 Non-conductive
applied
Terminals 2 -4 Conductive

16LO312 16WSOE

SERVICE POINTS OF INSTALLATION

10. APPLICATION OF GREASE TO POWER WINDOW REG-
ULATOR
Apply the specified grease to the door glass guide and
Guide pie guide piece.
Specified grease: MOPAR Multi-mileage lubricant
Door glass guide Part No. 2525035 or equivalent

18Y149E

9. INSTALLATION OF FRONT DOOR GLASS

(1) Lower the power window regulator until the door glass
and regulator installation point is visible through the
service hole.
(2) Install the door glass to the power window regulator
and temporarily tighten the nuts.
(3) Loosely tighten nuts A.
(4) After making the adjustment of the door glass tilt,
tighten nuts A.
 a
;z:
- _____~~~ .-. ~~-~e

Ek.

B!-=
w-
23-70 BODY - Front Door Glass and Regulator
sy
gIc+:
8. INSTALLATION OF DOOR GLASS STABILIZER (OUTER) s
Door glass Door outer E:
stabilizer (outer) t3anel I / 7. DOOR GLASS STABILIZER (INNER)
Install the door glass stabilizers to the door panel at the s:
positions shown in the illustration.

\
Door glass stabil;er
stabilizer (inner)
(inner) 1RY491 I

2. APPLICATION OF SEALANT TO WATERPROOF FILM

Apply the sp~ecfied sealant at the position shown in the
illustration, and then attach the waterproof film.
Specified Sealant: MOPAR Rope Caulk Sealer 3/16 x
80” roll Part No. 4026044 or equiva-
lent.
 BODY - Front Door Handle and Latch 23-71
FRONT DOOR HANDLE AND LATCH N23MDAM

REMOVAL AND INSTALLATION

Removal steps
(II) 1. Door trim
I)+ 2. Waterproof film
3. Rod snap
4. Rod snap
4* 5. Door inside handle
6. Inside lock rod
7. Inside handle rod
8. Rod snap
9. Door outside handle
l * l + IO. Reed switch
11. Lock cylinder retainer
l * 12. Key cylinder NOTE
(1) Reverse the removal procedures to reinstall.
l * 13. Door latch (with door lock switch) (2) +I): Refer to “Service Points of Removal”.
I)* 14. Rod snap (3) I)*: Refer to “Service Points of Installation”.
l + 15. Door lock actuator (4) q : Non-reusable parts
23-72 BODY - Front Door Handle and Latch
SERVICE POINTS OF REMOVAL
I. REMOVAL OF DOOR TRIM
Refer to P.2364.

5. REMOVAL OF DOOR INSIDE HANDLE

Remove the inside handle mounting screws, and then
disconnect the .inside lock rod and the inside handle rod ii
from the inside handle.

-
10. REMOVAL OF REED SWITCH
(1) Disconnect the reed switch connector from lhe door ;_
harness.:~ :
(2) Remove Ihe reed switch from the key cylinder.

INSPECTION
DOOR LOCK ACTUATOR
(1) Remove the’door lock actuator from the. door panel.
(2) The actuatoflswitch circuit is functioning properly if con- -
tinuity exists between actuator connector terminals (2) and _;
(4) while the actuator plunger is out (while the -door lock
actuator switch is OFF), -and c-eases to exist &hen the ~1
plunger goes in (when the door lock actuator switch -_
becomes ON).
(3) Connect the battery source to the actuator terminals (1) and -2
16Y265:
(3). and check the shaft for operation. If the shaft moves in .
opposite direction when the connectlon polarity IS changed,
the actuator should be consrdered to be in normal condition. .z
 BODY - Front Door Handle and Latch 23-73
DOOR LOCK RELAY AND DOOR UNLOCK RELAY
(I) Remove the door lock relay and door unlock relay.

II \ 16Y361

(2) Check continuity between terminals 3 and 5 when the

battery voltage is applied to terminal 2, and terminal 4 is
grounded.

Voltage applied Terminals 3 - 5 Conductive

Voltage not Terminals 3 - 5 Non-conductive

applied
Terminals 1 - 3
I Conductive
16Y3658 Terminals 2,4 -- Conductive

Caution
The battery voltage should not be applied for longer
than one minute.

16Y3659 18Y182E

DOOR LOCK SWITCH

(I) With the latch placed at the lock and unlock positions,
check for continuity.

Door unlock 0 0

Door lock 0 0
18Y185'
 __~ ~~

23-74 BODY - Front Door Handle and Latch

DOOR KEY CYLINDER UNL-OCK SWITCH

(1) Unlock the lock cylinder-by turning the key.
(2) Check the continuity between the terminals.

Condition

Door lock cylinder locked

Door lock cylinder u cl
N& -1 I- 1 -
iIi~-i 1inrilcates that there IS contlnuitv between the terminals.

SERVICE POINTS OF INSTALLATION

15. INSTALLATION OF DOOR LOCK ACTUATOR / 14. ROD
SNAP / 13. DOOR LATCH (WITH DOOR LOCK SWITCH)
(1) Mount the rod snap in the latch lock lever and mount
the actuator rod to the rod snap.
(2) Fix the actuator rod and latch lock lever in the lock
positlon md tighten tetnporarily the latch mounting
bolts.
(3) Lightly force up (toward the lever) the door lock actuator
and tighten the latch mounting bolts. Tighten-the door
lock actuator mounling bolts.
12. INStALLATlON OF KEY CYLINDER / IO. REED SWITCH
Pant mark I
Install the key cylinder and the reed switch as shown with
, Key cylinder their paint mark directed upward.

Reed switch

2. INSTALLATION OF WATERPROOF FILM

Refer to P.23-66.
 BODY - Front Door Weatherstrip

FRONT DOOR WEATHERSTRIP N23MEAH

REMOVAL AND INSTALLATION

Removal steps
+* I)* 1. Door opening weatherstrip NOTE
4I) 2. Door belt inside weatherstrip (I ) Reverse the removal procedures to reinstall.
4* 3. Door sash inside weatherstrip (2) **: Refer to “Seruice Points of Removal”.
4. Door drip weatherstrip (3) l *: Refer to “Service Points of Installation”.
18Y1737

SERVICE POINTS OF REMOVAL

1. REMOVAL OF DOOR OPENING WEATHERSTRIP
Remove the door opening weatherstrip by using the tool
shown in the illustration.
 _____ _~~__~~--

23-76 BODY - Front Door Weatherstrip

2. REMOVAL OF DOOR BELT INSIDE WEATHERSTRlP-I 3.
DOOR SASH INSIDE WEATHERSTRIP
Remove the door sash inside weatherstrip and the door belt _~_
inside weatherstrip by hand.

SERVICE POiNT OF INSTALLATION

1. INSTALLATION OF DOOR OPENING WEATHERSTRIP
Apply the specified adhesive at the position shown in the my
illustration, arid then attach the door opening weatherstrip. ~1
Specified adhesive: MOPAR Rope Caulk Sealer 3/16 x
80” roll Part No. 4026044 or
equivalent.

INSPECTION
@ Check door Inside handle-and latch for wear, damage or
maltunctton.
 BODY - Door Mirror 23-77

DOOR MIRROR N23QAAD

REMOVAL AND INSTALLATION

19Y706

Mirror switch removal steps

1. Spool release lever
2. Rear console panel
(with mirror switch)
Mirror removal steps
3. Door corner trim NOTE
4. Door mirror assembly Reverse the removal procedures to reinstall.

18Y1745
 BODY - Door Mirror

INSPECTION
MIRROR SWITCH
4’r I-L Operate the stitch and check for continuity between the
12 3 4 terminals.
5 6 7 8 9

18Y1809
L -

NOTE
~IJ---LIJ
Mcates that there IScontlnulty between the terminals.

; DOOR MIRROR ASSEMBLY

(1) Confirm that the mirrors moves correctly when battery
voltage is a~pplied to the mirror side terminals as indicated~ _
below.

I I A I
I WI i 0 I

SBattery (ElectrIcal source)

- -E (Ground)
(2) Check to see that there IS contlnulty between heater
terminals 1 and 4.
 BODY - Sunroof 23-79
SUNROOF N23TAAG

REMOVAL AND INSTALLATION

I 16

18Y1369

Roof lid glass removal steps

1. Sliding lock latch assembly
2. Roof lid male hinge assembly
3. Roof lid outer weatherstrip
l 4 4. Roof lid glass
c* 5. Deflector
Roof lid regulator assembly removal steps
6. Roof lid latch catch
7. Retainer
*I) I)+ 8. Roof lid regulator assembly
Headlining removal steps
9. Roof lid inner weatherstrip
c* 10. Roof side trim
4* 11. Front pillar trim
4* 12. Rear pillar trim
4* 13. Roll bar trim
4* 14. Upper quarter trim
15. Assist grip
16. Sunvisor
17. Room lamp cover
18. Room lamp
19. Rear view inside mirror
4* 20. Headlining
Drain pipe removal steps
4* 21. Cowl side trim (L-H. side)
22. Relay box
c* 23. Glove box
c* 24. Rear drain pipe
4* 25. Front drain pipe
I)* 26. Roof lid female hinge assembly

NOTE
(1) Reverse the removal procedures to reinstall.
(2) *I): Refer to “Service Points of Removal”.
(3) I)+: Refer to “Service Points of Installation”.
19lY710
 SERVICE POINTS OF REMOVAL
5. REMOVAL OF DEFLECTOR
Remove the --deflector assembly.

1.~ -L z.3
-.
8. REMOVAL OF ROOF LID REGULATOR ASSEMBLY
Remove the roof lid regulator assembly.

/’ /
18Y1346
-
10. REMOVAL OF ROOF SIDE TRIM / 11. FRONT PILLAR
TRIM / 12. REAR PILLAR TRIM / 13. ROLL BAR TRIM /
14. UPPER QUARTER TRIM
Refer to P.2-3-95.
20. REMOVAL OF HEADLINING
Refer to P.-Z-101. Pm
21. REMOVAL OF COWL SIDE TRIM (L.H. SIDE
Refer to P.23-95.
23. REMOVAL OF GLOVE BOX
Refer to P.23-88.

24. REMOVAL OF REAR DRAIN PIPE / 25. FRONT DRAIN

PIPE
Remove the frQnt land rear drain pipe, 1-1

Front dram pope Rear dram pope

 BODY - Sunroof 23-81
SERVICE POINTS OF INSTALLATION
26. INSTALLATION OF ROOF LID FEMALE HINGE ASSEM-
BLY
(1) For installation, insert front drain pipe from above, and
rear drain pipe from below.
(2) After installing the roof lid female hinge assembly, apply
the specified sealant to illustrated screw heads.
Specified sealant: MOPAR Vinyl-Acrylic Sealant
Part Number 4026043 or
equivalent

8. INSTALLATION OF ROOF LID REGULATOR ASSEMBLY

With the roof lid fully closed, check to ensure that the
regulator knob marks are in alignment.

18E24L

mm (in.) mm(in.) 4. INSTALLATION OF ROOF LID GLASS

(1) Before installing the headlining, perform a water test by
following procedure.
@ Fully close the roof lid.
@ Spray water against the seam between the roof lid
and roof all around. Hold the hose and roof about _
300 mm (11.8 in.) from the roof and spray water for
more than five minutes.
NOTE
18E245 18Y391 Adjust the water pressure so that the height of water
sprayed will be about 500 mm (19.7 in.) as shown in
illustration.
@ Check for water leaks in the passenger compart-
ment.
@ If water leaks are evident, refer to troubleshooting
and correct.
(2) If there are no leaks after the water test, remove the
regulator, retainer and latch catch and install the
headlining.
(3) Reinstall the regulator, retainer and latch catch.
23-82 BODY - Aero Parts

AERO PARTS N23XAAD

REMOVAL AND INSTALLATION (FRONT)

Vehicles with a manual transmission

Vehicles with an automatic transmission

Front skirt panel removal steps

I. Air guide panel
2. Radiator grille
+* 3, Front bumper assembly with front skirt panel -.
4. Front skirt panel -
5. Air dam bracket

NOTE ~.
(1) Reverse the removal procedures to relnstall.
(2) +I): Refer to “Service Potnts of Removal”

1:iYlrn.’3 1
~“_ _-
 BODY - Aero Parts
SERVICE POINTS OF REMOVAL
2. REMOVAL OF RADIATOR GRILLE
Refer to P.23-51.
3. REMOVAL OF FRONT BUMPER ASSEMBLY WITH
FRONT SKIRT PANEL
Refer to P.23-43.

4. REMOVAL OF FRONT SKIRT PANEL

Upper plate Ny Remove the nuts which attach the front skirt panel and the
upper plate from the front bumper face, and then remove
the front skirt panel.

Bumper face
*
Front skirt panel
18Y185
23-84 BODY - Aero Parts
REMOVAL AND INSTALLATION (SIDE AND REAR)

s ~-~ \ 3.5-5.0
2.5-38
Nm
ft.lbs.
.-

Side step panel removal

*I) I. Side step
lW1714 --
&t-
Air spoiler removal steps
2. Rear hatch trim
+r) *+ 3. Air spoiler (center)
** I)+ 4. Trunk room side trim NOTE-
+* 5. Air spoiler (side) (1) Reverse the remwal procedures to reinstall. _
(2) a*: Refer to “Service Points of RemovaI”.
(3) *+: Refer to “Service Pornts of Installation”.

SERVICE POINTS OF REMOVAL

1. REMOVAL OF SIDE STEP PANEL
Remove the plugs and remove the side step panel
mounting bolts.

L
 BODY - Aero Parts
3. REMOVAL OF AIR SPOILER (CENTER)
(1) Remove the air spoiler attaching nut through the service
Rear hatch garnish
hole provided in the rear hatch window glass.

18Y1706

(2) Using an allen wrench, remove the special bolt from

each end of the air spoiler to remove the air spoiler.
NOTE
Cut the allen wrench [with a width across the flats of 5
mm (.20 in.)] to the dimension shown in the illustration.
(3) Remove the air spoiler mounting nuts from the rear
Allen wrench hatch garnish.
(4) Remove the air spoiler from the rear hatch garnish with
a sharp knife to cut the adhesive.
18Y1703

4. REMOVAL OF TRUNK ROOM SIDE TRIM

Refer to P.23-95.

5. REMOVAL OF AIR SPOILER (SIDE)

(1) Remove the plug from the rear end of the side spoiler.
(2) Remove the side spoiler mounting nuts and clips to
remove the side spoiler.

SERVICE POINTS OF INSTALLATION

4. INSTALLATION OF TRUNK ROOM SIDE TRIM
Refer to P.23-95.
23-86 BODY - Aero Parts
E:
3. INSTALLATION OF AIR SPOILER (CENTER) =
(I) Before itMaIling the air-spoiler, apply speclfled adhesive
to entire periphery of-installation surface. E
Specified adhesive: MOPAR Rope Caulk Sealer 306
x 80” roll Part No. 4026044 or
equivalent
(2) Because the air spoilq- is made of urethane resin, be ~;
sure to follow the Instructions below concerning -1
maintenance.
The air spoiler will be discolored or starned if such :
things as brake fluid, engine oil, grease, parnt
thinner, battery fluid, ordinary wax,- etc. become
adhered to it. If any of these things accidentally spill
onto the air spoiler, they should be immediately
cleaned by usrng alcohol.
Da not use a compound-type wax or a hard brush,
etc. ta clean the air spoiler; doing so could scratch
the air spoiler.
If the possibility exists that the arr spoiler might be
subjected to high temperature during repair proce-
dures, it should either be removed, or treated in
some way so as TO protect It from heat.
The air spoiler surface will become whitish if 1
ordinary wax or mud adheres to it. After cleaning the
surfaze -well, apply a coating of black upholstery
cleaner.
 BODY - Instrument Panel 23-87
INSTRUMENT PANEL N23VAAH

The following bolts and screws are used for instrument panel
installation. In the illustration for “Service Points of Removal”,
they are identified by symbols.

Symbol Name and shape Dimension mm (in.) Symbol Name and shape Dimension mm (in.)

F Washer assembled O.D. = 5 (20) A Washer assembled O.D. = 5 (20)

screw L= 16 (63) screw L = 16 (.63)

18UO419 19W654

G Washer assembled O.D. = 6 (24) E Tapping screw O.D. = 5 (20)

bolt L= 16(.63) L = 12 (47)

19W651 18UO418

Ii Washer assembled O.D. = 6 (24) D Tapping screw O.D. = 5 (20)

bolt L = 16 (.63) L = 16 (.47)

18UO418

B Tapping screw O.D. = 5 (20) I Washer assembled O.D. = 5 (20)

L = 20 (78) screw L = 12 (47)

18110418 19W564

C Washer assembled O.D. = 5 (20)

screw L = 25 (1 .O)

19Y709
 ..* -: ~~

23-88 BODY - Instrument Panel

INSTRUMENT PANEL
REMOVAL AND INSTALLATION
8

Removal steps
+I) I. Steering wheel
2. Hood lock release handle
3. Fuse block
*I) 4. Knee protector
+I) 5. Lower steering column cover
4* 6. Upper steering column cover
a* 7. Column switch 191717
*;I) 8. Meter hood
e* 9. Combination meter
l * 10. Side console cover
l * 11. Rear console box
Mb 12. Front console box
13. Under cover
C* I)+ 14. Glove box
15. Ashtray
+* 16. Heater control panel
17. Digital clock
a* 18, Side defroster upper grille NOTE
*I) 19. Instrument pad side cover (I) Reverse !he removalprocedures to relnstall.
20. Side defroster duct 12) a*: Refer to “Service Points of Removal”.
4* l + 21. Instrument panel (3) *+:Refer to-“Serwce Points of Installation”.
*I) 22. Center reinforcement
 BODY - Instrument Panel 23-89
SERVICE POINTS OF REMoVAL
1. REMOVAL OF STEERING WHEEL
Refer to GROUP 19 STEERING - Power Steering Column
Shaft.

4. REMOVAL OF KNEE PROTECTOR

Remove the hole cover and remove the knee protector
attaching screws and then remove the knee protector.

5. REMOVAL OF LOWER STEERING COLUMN COVER / 6.

UPPER STEERING COLUMN COVER
(1) Remove the column cover attaching screws and then
remove’the column cover.

7. REMOVAL OF COLUMN SWITCH

(1) Remove the column switch attaching screws.
(2) Disconnect the column switch harness connectors and
then remove the column switch.

-C 18Y1796

8. REMOVAL OF METER FOOD

(1) Remove the meter hood mounting screws.
(2) Pull both edges of the bottom side of the hood forward,
and then, while still holding it inthis position, pull it
obliquely upward and out.
(3) Disconnect the cluster switch connectors on both sides
of the meter hood.
 - ~~, ii-M_*b..---m._ ~- ~=
p&i

F:
BODY - Instrument Panel --.

9. REMOVAL OF COMBINATION METER

(1) Remove the screws on the bottom part of the case. ~~
(2) Remove the nuts .onthe upper part of the case. Pull ._
both sides of the lower part of the case up while pulling :
it forward at the same time.

10. REMOVAL OF SIDE CONSOLE COVER

(1) Remove the side console cover screws.
(2) Remove~the cover da_wnward while pushing it slightly
forward.

19Y60!

11. REMOVAL OF REAR CONSOLE BOX / 12. FRONT

CONSOLE BOX
-
Refer to P.2344.

14. REMOVAL OF GLOVE BOX

(1) Grasp and release the glove box lid lock to open the lid.
Pull the glove bsx forward while pressing both sides
inward. -

(2) Removerthe glove box,

BODY - Instrument Panel 23-91
16. REMOVAL OF HEATER CONTROL PANEL
(1) Pull off the heater control knobs..
(2) Insert the tool shown in the illustration into the lever
hole of the heater control panel, and pull to remove.
Remove the connector for the control panel light.

18. REMOVAL OF SIDE DEFROSTER UPPER GRILLE

Insert a screwdriver from the ‘door glass side, and twist and
pry the side defroster upper grille forward to pull it out.

19. REMOVAL OF INSTRUMENT PAD SIDE COVER

Insert the tip of the trim stick into the space between the
instrument panel side cover and the instrument pad, and
then twist to remove the left and right instrument panel
side covers.

21. REMOVAL OF INSTRUMENT PANEL

(1) Remove the installation screws and bolts from the
places shown below.
(2) Remove the front harness and glove compartment
harness combination.
(3) Pull the instrument panel outward.
 BODY - Instrument Panel

22. REMOVAL OF CENTER REINFORCEMENT

(1) Remove the center reinforcement bolts.
(2) Loosen the clamp for the main harness, and remove the
panel.
(3) Take outthe center reinforcement.

Instrument Body side SERVICE POINTS OF INSTALLATION

panel side
21. INSTALLATION OF INSTRUMENT PANEL
(1) Place theguide pin so that it catches in the body of the
heater unit (upper part).
(2) Check to- be sure that the ventilator duct, wiring _
harness, etc., are correctly installed.

19Y673 19Y674 1

13. INSTALLATION OF GLOVE BOX

When the glove box IS berng rnstalled, frrst te~mporarily
tighten each screw, and then, after checking the left and
right clearances b-etween the glove box lids and the _
instrument pad while the lid is locked, tighten the screws
completely.
 BODY - Floor Console 23-93
FLOOR CONSOLE N23UBAH

REMOVAL AND INSTALLATION

19Y708

Removal steps
1. Anchor plate connection
2. Spool release lever
3. Rear console panel
4. Remote control mirror switch
5. Rear console box harness
6. Inner box
l 4 7. Bezel
+* 8. Rear console box
9. Ashtray
IO. Accessory panel
11. Accessory box lid
12. Shift lever knob
4* 13. Side console cover
4* 14. Front console box
15. Radio
16. Parcel box NOTE
17. Radio panel (1) Reverse the removal procedures to reinstall.
18. M/T garnish (2) C*: Refer to “Service Points of Removal”.
19. Shift lever cover (3) I)*: Referto “Service Points of Installation”.
 SERVICE POINTS OF REMOVAL
8. REMOVAL OF REAR CONSOLE BOX
(1) Remove~the installation screws for the rear console I
box. -I =;
(2) Remove-the bezel. Putthe seat belt in the console box. --t

lQY7Oi

13. REMOVAL OF SIDE CONSOLE COVER

(I) Remove the side console cover screws.
(2) Remove the cover downward while pushing it slightly =-
forward. ~~

19Y605

14. REMOVAL OF FRONT CONSOLE BOX

(1) Remove the- radio installation screws from the center __
reinforcement.
(2) Move the shift lever to 4th gear.
(3) Pull the front console box slightly backward. .-

-
(4) Remove the~part where the radio antenna teeder line IS ~-1
inserted and the connector for them radio. _
(5) Pull the-front console box out toward the passenger I~m
seat.

SERVICE POINT OF INSTALLATION

7. INSTALLATION OF BEZELS
Draw out the shoulder belts from the consolebo~, ant _
install bezels to the console box while paying attention to ~=
the installation direction. If the bezel is installed in the Zi
wrong way, the belt wiff twist in the console-box.

Bottoml 19Y701
 BODY - Trims 23-95
TRIMS N23VCAI

REMOVAL AND INSTALLATION

4-6 Nm
3-4 ft.lbs.

Removal steps
1. Rear seat
*I) I)* 2. Scuff plate
+* +a 3. Roof side trim
4* 4. Front pillar trim
4* 5. Cowl side trim
4* 6. ECI cover NOTE
41) I)+ 7. Rear pillartrim (1) Reverse the removal procedures to reinstall.
+* I)+ 8. Roll bar trim (2) 4*: Refer to “Service Points of Removal”.
(3) *4: Refer to “Service Points of Installation”.
4M I)+ 9. Upper quarter trim
4* 10. Quarter trim
+W I)+ 11. Lap-round trim
++ I)+ 12. Rear end trim
41) l 13. Trunk room side trim
4* 14. Rear side shelf

19Y676
23-96
SERVICE POINTS OF REMOVAL
2. REMOVAL OF SCUFF PLATE
Insert the trim stick between the clip and then body, and
remove the.scuff plate.

A$:\ 19Y600
.-
3. REMOVAL OF ROOF SIDE TRIM
Insert the trim stick into the upper part of the roof side trim :
from inside the vehicle, and then pull it forcefully while
prying downward.

/
19Y628

4. REMOVAL OF FRONT PILLAR TRIM

Remove the front pillar trim by pulling it in the direction of ~_
the arrow. ~L~- ~

19Y60:

5. REMOVAL OF COWL SIDE TRIM / 6. ECI COVER

(1) Remove the relay box installation screvvs (driver’s side),
and then remove the cowl side trim.~(driver’s side).
(2) Remove rthe ECI cover (passenger side), and then ~.
remove the cowl side trim (passenger side).

7. REMOVAL OF REAR PILLAR TRIM

(1) Open the rear hatch. __=
(2) Insert the trim stick-between the budy and. the clip, _
twist downward, and remove the rear pillar trim.
BODY - Trims 23-97
8. REMOVAL OF ROLL BAR TRIM
Pull the rear edge of the roll bar trim downward, insert the
trim stick between the body and the clip, remove the clips,
and then pull out the roll bar trim to the rear.

9. REMOVAL OF UPPER QUARTER TRIM

(1) Insert the trim stick from the center of the body into the
upper right end of the upper quarter trim, and then
remove the clip.
(2) Insert the trim stick from the lower side of the lower left
end of the quarter trim, and then remove the clip.
(3) The trim stick cannot be used for the remaining clips, so
insert a hand to the clip position, pull out the quarter
trim, and then remove the clips.
(4) The quarter trim should be removed by pulling it
forward.
10. REMOVAL OF QUARTER TRIM
(1) Remove the quarter trim installation bolt and screw.
(2) Pull out the quarter trim forward at an angle.

11. REMOVAL 0F LAP-ROUND TRIM

(1) Remove the lap-round trim installation screws.
(2) Remove the lap-round trim by pulling it to the lower
front side.

12. REMOVAL OF REAR END TRIM

(1) Remove the trunk room mat. At this time, detach the
parcel strap and gather it at the end of the trunk room
near the rear combination lights.
(2) Pull both sides of the front of the rear center shelf
upward, and remove the rear center shelf.
_- ~ “/ - ___.

23-98 BODY - Trims

(3) Remove the lack storage cover from the trunk room -_
side trim. -
(4) Remove’the rear end trim lid.

(5) Insert the trim stick into the gap between the weather- ~;
strip at the top of the tail lights and the rear _end trim, __
and remove the clips
(6) While pulling the rear end trim slightly upward, push the ~
end toward the rear seat, and remove the_ trim.

. :.
13. REMOVAL OF TRUNK ROOM SIDE TRIM
(1) Remove the trunk room side trim mounting screw, and ~.
then remove the clips by using the trim s&k.
(2) Pull the lower end of-the trunk room side tr@n toward =_
the center of the vehicle, and remove the trim. ~

14. REMOVAL OF REAR SIDE SHELF

(1) After removing the cap of the rear washer tank, detach
the tube- from the rear side shelf. ;
NOTE
Be sure to drain the washer fluid before removal in ’
order to avoid the possibility of the fluid spilling in the I
vehicle interior during the removal procedure.
(2) Disconnect the trunk room illumination connector.
(3) Disconnect the reaLspeaker connector.
9Y63 (4) Disconnect the rear_defogger connector.
(5) Remove. the mounting screws of the rearaside shelf.--
(6) Close the rear hatch.
(7) Pull then rear side shelf forward.
(8) Remove the rear seat belt cover by passing’it through
the hole of the rear side shelf.

I( \ 19Y623I
 BODY - Trims 23-99
SERVICE POINTS OF INSTALLATION
13. INSTALLATION OF TRUNK ROOM SIDE TRIM
When installing the trunk room side trim, fit it securely into
the groove in the rear side shelf.
12. INSTALLATION OF REAR E_ND TRIM
When installing the rear end trim, be sure to use new clips,
and insert them, beginning from the clips at the lower part
of the trim.

19Y632

11. INSTALLATION OF LAP-ROUND TRIM

When installing the lap-round trim, insert and set the hooks
on the back of the lap-round trim into the holes on the body
at an angle from the lower front side.

I l-9 , ,, ) Section.A-A 1 9. INSTALLATION OF UPPER QUARTER TRIM

When installing the upper quarter trim, align the positions of
the right bottom end of the trim and the rear side shelf
while fitting the upper quarter trim in from the front (the
body flange should be overlapped by the trim), and then tap
in the clips at both ends of the trim lightly by hand.
NOTE
Be sure to use new clips.

8. INSTALLATION OF ROLL BAR TRIM

When installing the roll bar trim, fit the hooks at the end of
the roll bar trim into the hooks at the back end of the
headlining, and then tap in the clips from the bottom side of
the trim lightly by hand.
Begin by first tapping in the clip in the center, and then tap
in the clips on the left and right sides.
NOTE
Be sure to use new clips.

7. INSTALLATION OF REAR PILLAR TRIM

When installing the rear pillar trim, tap in the clips by fitting
them in while tapping lightly by hand from the end of the
trim.
NOTE
Be sure to use new clips.
23-100 BODY - Trims
3. INSTALLATION OF ROOF SIDE TRIM
(1) When installing the roof side trim, attach the trim to the ~_
clips (the clips are fastened to the body by sCrewsI by
tapping the end of the trim lightly with your hand.
(2) Be sure that the gaps at places where the various trims =
meet are uniform. 1

1W680
.-
Section E-E 2. INSTALLATION OF SCUFF PLATE
Scuff olatc
(I) When installing the scuff plate, be sure that the gaps at
places where it meets any of the trims are uniform. T
(2) Attach the clip by tapping lightly by hand from the end =
of the trim.
 BODY - Headlining 23401
HEADLINING N23UDAJ

REMOVAL AND INSTALLATION

Vehicles with sunroof

Headlining removal steps

(Vehicles with a sunroof)
c* 1. Roof side trim
4* 2. Front pillar trim 19Y684
4* 3. Rear pillar trim
4* 4. Roll bar trim
4* 5. Upper quarter trim
6. Assist grip
7. Sunvisor assembly Vehicles without sunroof
+* 8. Dome light cover _,
+* 9. Dome light
I)4 10. Roof lid glass
4* I)4 11. Roof lid regulator assembly
12. Roof lid inner weatherstrip
+* 13. Headlining
Headlining removal steps
(Vehicles without a sunroof)
+* 1. Roof side trim
+I) 2. Front pillar trim
+I) 3. Rear pillar trim
+* 4. Roll bar trim
+* 5. Upper quarter trim
6. Assist grip
7. Sunvisor assembly
4* 8. Dome light cover
+* 9. Dome light
+I) 13. Headlining

NOTE
(1)Reverse the removal procedures to reinstall.
(2) 4*: Refer to “Service Points of Removal”.
(3) l 4: Refer to “Service Points of Installation”
19Y683
 s
!!tEzzY

BODY - Headlining B’
e.
SERVICE POINTS OF REMOVAL
1. REMOVAL OF ROOF SIDE TRIM / 2. FRONT PILLAR
TRIM / 3. REAR PILLAR TRIM / 4. ROLL BAR TRIM / 5.
UPPER QUARTER TRIM
Refer to P.23Y95

&g-i
8. REMOVAL OF DOME LIGHT COVER / 9. DOME LIGHT gg
(1) Use a screwdriver to remove the cover of the dome .~_ s
light.
(2) Remove the dome light installation screws, and then
pull out tbe~dome light slightly.
(3) Remove the connector, and then remove thti dome -1
light. .~

I /I II 19Y611
-
11. REMOVAL OF ROOF LID REGULATOR ASSEMBLY
Refer to P.2579.

13. ‘REMOVAL OF HEADLINING

(1) Remove the mquntingscrews at the rear edge of the
headlining.
(2) Insert the trim stick into the gap between the body and
the headlining from the front of the headlining, then pry ~_
downward to removes the retainers.

-
SERVICE POINT OF INSTALLATION
11. INSTALLATION OF ROOF LID REGULATOR ASSEMBLY
/ 10. ROOF LID GLASS
Refer to P.23-79.
 BODY - Seats 23-103
SEATS N23UEAH

REMOVAL AND INSTALLATION

Front seat Rear seat

4-6Nm
3--4ft.lbs.,

6-10 ft.lbs.

\4-6Nm
3-4 ft.lbs.

24-36 Nm
17-26 ft.lbs.

Front seat removal steps Rear seat removal steps

+* 1. Cover 4* 10. Cover
2. Head restraint 4* 11, Rear seat cushion
3. Upper reclining cover ** l * 12. Rear seatback
4. Lower reclining cover 13. Striker
5. Cushion shield
6. Reclining adjuster NOTE
7. Seat back (I) Reverse the removal procedures to reinstall.
8. Seat cushion (2) a*: Refer to “Serwce Points of Removal”.
l * 9. Seat side adjuster (3) **: Refer to “Service Points of Installation”.

19Y670

Front SERVICE POINTS OF REMOVAL

1. 10. REMOVAL OF COVER
(1) Disconnect the seat-belt indication light connector
located beneath the front seat on the driver’s side.
(2) While pushing open the end of the front and rear seat
anchor covers to the outside, pull out the covers.

19Y63(
 BODY - Seats

Rear

19Y63C

11. REMOVAL OF REAR SEAT CUSHION

(1) Remove the mounting bolts at the front of the seat 1
cushion.
(2) Lift up thee seat cushion, and then pull atit the rear seat .I
belts (backbone side) through the hole in theYcushion. -2
(3) Remove -the seat cushion.

12. REMOVAL OF REAR SEATBACK

(1) Fold down the seatbacks, and then remove the carpet
cover screws which f-asten both the trunk room floor ~~.
mat and the lower part of the seatbacks.
(2) Raise theseatbacks and then lock them so that they do
not fold down.

a .-

(3) Removem’the seatbaG_k mounting bolts in the order ~~

indicated in the illusEation.
(4) Release fhe left and-right seatback locks, -and then --
remove both seatbacks simultaneously.

SERVICE POINTS OF INSTALLATION

12. INSTALLATION OF REAR SEATBACK
(1) When assembling and installing the left and right
seatbacks, the right-hand bracket should be on the .;
bottom (the left-hand bracket should be on-the top). ~:
(2) Tighten -the left andjght brackets together.
(3) If there are two different size holes -in th@Is&atback -~
mounting brackets, use the smaller hole.
Right-hand bracket
\
BODY - Seats 23-105
(4) Temporarily tighten each mounting bolt, confirm that
both seatbacks fold up and down properly and that the
locks function correctly, and then tighten the bolts
securely.
9. INSTALLATION OF SEAT ADJUSTER
Install the seat adjuster in the position farthest back
(because of the positioning bolts on the body) from the
front. At this time, first temporarily tighten the mounting
nuts and bolts, confirm that the lock of the adjuster
functions correctly and the adjuster opertes back and forth
correctly, and then tighten the nuts and bolts securely.
23-106 BODY - Automatic Seat Belts

AUTOMATK SEAT BELTS N23UGAQ

GENERAL INFORMATION
The Automatic Sat-Belts aregesigned to automatically wrap
themselves around the driver_and front passenger as-they get
into the car and close the docz. thereby protecting them from
second collisions-during affront-end crash or similar-Accident. -;
The shoulder belt, which interlocks the opening and closing of
the door, is designed to automatically wrap itself around, or ~~
unwrap itself from, the occupant within 2.5 sec.
The lap belt for the driver’s seat is provided with the ELR (ELR: -:
Emergency Lockrng Retractor], and that for the fronLpassen- -=
uer’s seat wrth the ELR-ALR” to support the Child Restraint ~1
System incorporated Into theseat. (“ALR: Automatic~Locking :
Retractor)
The seat belts consist of ashoulder belt vv!CJQemergency _
release mechanrsm, manual lap belt, knee protector, and other
components. I .~

COMPONENTS

Rail qulde Shoulder belt

\ / Skie anchor
SMe anchor (set posttlon) 7 t&x-Ott posltlon~
Ecking device
Release switch
Fastcn switch

Buzzer
Door lock switch

Knee protector

Control unit
(front console box) -
Outer casing
(harness & scuff plate
are rmodlfledl L Retractor
(ELR for acme lap belt)

Spool release lever

Driver’s side -. ELR

(For active shoulder belt) 1Passenger’s side -- ELI7 + ALR

Spool release
lever switch
 BODY - Automatic Seat Belts 23-107
OPERATION OF AUTOMATIC SEAT BELTS
The operation of the Automatic Seat Belts is as follows.
(1) The belts unwrap itself from the occupant when the door is
opened with the ignition switch in the ON or LOCK or ACC
position.
(2) The belts wrap itself around the occupant when the door is
closed with the ignition switch in the ON position.
(3) The belts cease to wrap itself around the occupant if the
ignition switch is turned to LOCK or ACC during the belt
motion.
(4) The spool release lever (indicated as “LIFT FOR EMERGEN-
CY EXIT”) fitted to the rear floor console, if pulled when the
ELR is locked by a collision shock, causes the ELR to be
unlocked allowing the occupant to leave the car or to be
rescued from it.
(5) When the body rolls by an accident, the slide anchor moves
upward to be locked in position via the locking device.
(The longer holes in the tape drive, in mesh with the plastic
gear, permits the slide anchor to move upward.)
(6) When a binding load is applied to the belts or slide anchor
due to a driver or passenger rushing into or out of the car, it
causes the slide anchor to be locked up immediately.
(7) The seat belts and door for the driver’s and front passen-
ger’s seats operate independently of each other.
OPERATION OF ELR + ALR EQUIPPED BELT FOR FRONT PASSENGER’S SEAT

Gear A
(made integral with webbing
rotor and V gear)
V gear /- Gear C (internal teeth type) ) made Integrated
\ I
J

ELR section -..

prong to keep paw1 6 either

engaged for ALR or not.
Sensor ball Paw1

19UO326

(I) ELR
The webbing is locked when the G-sensor senses an abrupt
deceleration of vehicle. The sensor ball is moved by the
inertia and pushes the pawl up to lock the V-gear (ratchet
wheel), thus preventing the webbing from extracting.
23408 BODY - Automatic Seat Belts
-
(2) ALR
Gear B Gear C 1. Pull out the webbing.
The number of webbing rotor revolutions is reduced~~by
gears A, B and C to-rotate the cam.

2. When the webbing has been extended almosttully. the ~_

Gear C cam strikes paw1 B to engage It with V-gear and locks
the webbing.

Pawl e

Cam

3. Then, retract the webbing. When it has been retracted

almost fully, the cams returns paw1 B to its original
position, bringing the system into ELF? state.

Gear C
 BODY - Automatic Seat Belts 23409
CIRCUIT DIAGRAM

-
-- -1
Clrcult breaker
-0
lattery i 1 7 Fasten
1 1 Buzzer I t
Motor
M (L.H.)
I
C. Release
/ 10
r
3
Door lock (open) i'r:.:-
switch
(L.H.)

Fasten
T
Motel
(R.H.1
Release I
switch (R.H.1 Release
Door lock
switch i
(R.H.) :
To ignition
switch

To battery d

lever switch
/iA.

-
7 ECU

(ECU connector terminals1 18Yi850

ECU: Electronic Control Unit

 ___~
~-~

BODY - Automatic - Seat Belts

COMPONENT PARTS AND FUNCTION

Automatic Seat Belt Control Unit Located at the front console box.
Controls the system based on the various input signals.

emergency. -
The control unit normally receives an ON signal from the
switches, but when the spool release lever is pulled (the ELR is
unlocked), the switches transmit an OFF signal to~the control unit.

6 seconds after the ignition

 BODY - Automatic Seat Belts 23-I 11

Buckle Switch (L.H.) Located at the driver’s seat belt buckle.

This switch transmits an OFF signal to the control unit when the lap
belt is fastened and an ON signal when it is not fastened.

18Y 1859

Motor (L.H., R.H.) Located at the inner quarter panel.

The motor operates to move the shoulder belt.
It receives direction of rotation, start, and stop signals from the
control unit, and operates according to these signals.

19Y716

Door Lock Switch (L.H., R.H.) Located at the door latch.

These switches detect the open/close condition of the doors.

The following components also constitute the automatic seat belts system.

Ignition Switch (ON position) This switch sends a HIGH signal to the control unit when the ignition
key is at the*ON position.

Key-reminder Switch Located at the door latch.

(for lighting monitor) These switches detect the open/close condition of the doors.

Buzzer Located at the center reinforcement.

The power for this buzzer is supplied from the battery through fuse
No. 8.
 11 q: :,, .: -;.I~-
r 7F / j
~_~
&f=
23-l 12 BODY - Automatic Seat Belts $g:
B-i
-
OPERATION
=*
1. BELT WRAPPING MOTION E
E=
(1) If the belt IS not In the wrap posrtron (the L.H, or R.H. gEL
droor lock switch at Dtir Closed posltton; the L.H. or E
R.H. fasten switch at-ON posItIon) when the door IS _ E
_-.
t:losed with the Ignition switch In the ON position, the
belt automatically moves to the wrap position. For the ~_ z-
period between the rnltlatlon and completion ot the
belt’s motion In the wrap drrectlon, the “fasten seat E-
CI
belt” lndlcator light either stays IIt or .bllnks.
From thelnitlatlon ot the belt’s wrapprng motion (I.e., E
from the time when the door IS closed), the “fasten z-
:se;ii beltKrndlcator light stays lit for approxrmately 6 g
seconds, ~then blinks for another approximately 3 z
cpt><lnds,
.~.i -. _ E z-
(2) With a lapse ot approximately 60 seconds atter the belt _ g
has stopped Its wrappmg motion due to torergn object g:-
wedged In the mechanrsm, the protective timer ot the _ z=
CPU IS activated causlnq the motor output to be cut ott. s
The circuit description of this. operation IS as .tollows: F
When the L.H. or R.H. door lock switch IS turned ON to i z:
the Door Closed posItIon. a Door Closed signal IS Input
ho the CP~UI which causes a driver drive signal to be - ~1
nljtput via the driver crrcult trom the CPU, closing the __ z-
relax b ta the Bert Wrap side. e-
pl-
As a result, a HIGH slgnal (wrap motion srgnal, 12 V) IS 3z =_
applied to the co11 ot relay b by the driver circuit, closing ~- E
relay b contacts to energize motor MIS. This completes ~- Em
rhe belt’s wrapprng motion. EL 3~
When thebelt completes Its wrapplng motion, the L.H. c
or R.H. fasten switch IS turned OFF, which cuts ott the ~~ s-
-__E
current flowlnq to the relay coil. As a result, relay b IS
&actuated shutting ott the motor current. G,=
The output of the driver circuit then drops tromp HIGH to 1’ :E
LOW. II-
The same dperatlon E also true with the belt on the I r
front passenger‘s seat. w
e
2. BELT UNWRAPPING MOTION
. =
(I) When the door IS opened, the L.H. or R.H. door lock =c
Swllch (door lock swltch) IS turned ON. to the Unwrap _ z-
side regardless of whether the lgnltlon ,swltch IS In the Em
0N or LCTCKor ACC position. This actuates the L.H. or 1 E-
R.H. release switch (seat belt unwrap switch) causing r
the belt to move In the unwrapping dIrection. I-he L.H. m? %-
or R.H. release switch IS deactuated when the belt pi F
Em==
completes its unwrapping motion.
The buzzer an the rns_trument panel sounds tor approx- g-
Ir-nately O-7 seconds since the start of the belt’s motion. _
(2) If the bell is still In the process of unwrapping with a = g
lapse of approxrmately 60 seconds atter the start of ; -
motion, the protecttve timer rn c;PU IS activated causing ~I=
the motor output to be shut off. -
Li
m
sz
=y
_~
es+ -
E!%,

s7.

$$-
5 -2
-ir:zx
BODY - Automatic Seat Belts 23-113
3. BELT UNWRAP POSITION
When the belt is not in the unwrap position, the L.H. or R.H.
release switch (seat belt unwrap switch) is in the ON
position. When the L.H. or R.H. door lock switch is turned
ON to the Door Open position, a Door Open signal is input
to the CPU, which causes a driver drive signal to be output
via the driver circuit from the CPU, closing the relay a to the
Belt Unwrap side. As a result, a HIGH signal (unwrap
motion signal, 12 V) is applied to the coil of relay a by the
driver circuit, closing relay a contacts to energize motor MO.
This completes the belt’s unwrapping motion.
When the belt completes its unwrapping motion, the L.H.
or R.H. release switch is turned OFF, which cuts off the
current flowing to the relay coil. As a result, relay a is
deactuated shutting off the motor current. The output of
the driver circuit then drops from HIGH to LOW.
The same operation is also true with the belt on the front
passenger’s seat.
4. EMERGENCY STOP
(1) If a shock is applied to the belt anchor or a sudden
tension force is applied to the shoulder belt during the
belt unwrapping motion, a motor current will increase.
This increase in the motor current (approximately 5 A or
more within approximately 0.4-sec. interval) is detected
by the current increase detecting circuit installed be-
tween the CPU and relay circuit and the detecting
circuit causes relay a to be turned OFF, thus temporarily
halting the belt’s unwrapping motion for approximately
1.7 seconds. This is called the emergency stop.
During this period of emergency stop (for approximately
1.7 seconds), the buzzer on the instrument panel kept
sounding. Then, the circuit resets to allow the belt to
restart its unwrapping motion.
(2) The number of emergency stops made until the belt
reaches its unwrap position is three. The fourth or more
emergency stop will not be made even when a shock is
applied. The emergency stop count is reset to 0 once
the belt reaches its unwrap position.
(3) If the door is closed during an emergency stop being
under way, that particular emergency stop is canceled
to bypass the belt unwrapping mode. The belt unwrap-
ping mode refers to a series of operation mode in which
the belt unwrapping motion is temporarily halted by the
emergency stop, the circuit resets, and the belt re-
sumes its unwrapping motion.
(4) The emergency stop is not activated for an approx-
imately 0.6-sec. interval from the start of the belt’s
unwrapping motion after the door has been opened.
The emergency stop is activated and deactivated for the
belt on the driver’s seat independently of that on the
front passenger’s seat.
(CPU: Computer)
23-114 BODY - Automatic Seat Belts

WARNING SYSTEM
Ignltlon 1. IGNITION SWITCH INITIAL WARNING
swwlLOCK
or/El-J-
When the ignition switch-is turned from LOCK or ACC to i=
ON, the “fasten seat belt’:indicator light lights up and stays
Fasten seat belt ‘ON) 1-L
ndlcator tight (OFF) lit for approtimately 6 semnds and spool release indicator T-
t&2 light lights up and stays lit for approximately 1.5 seconds.
6 WC The lights go off if the ignition switch is turned LOCK or
ACC during the predetem-rined period of time.~

2. DRIVER’S SEAT LAP BELT WARNING

lgmtlon
swrtch ,o,FI If the lap belt on the driver’s seat is not buckled when the ~_
Buckle ON (unfastened) ignition switch is turned ON from the LOCK or ACC -1
switch OFF (fastened) position, buzzers is activeed for approximately 6 seconds. -I
The “fasten seat belt” indicator light, at the same time,
Buzzer ,“,Pnnrm lights up and stays lit for the same period of time. _
Fasten seat
belt indicator
light OOFNF-
Approx. 6 sec.
16Y3ti5i

3. AUTOMATIC SEAT BELT LATCH RELEASE WARNING -

When the ignition swatch IS turned ON with the spool
release lever pulled (spool release lever swatch rn OFF _
posrtron), Intermittent buzzer sounds. .~
When the ignrtron switch IS turned ON from the LOCK or 1
ACC posrtion, the “fasten-seat belt” Indicator light lights up
and stays lit for approximately 6 seconds, then starts 1
blinkrng. Thespool release lndrcator light lights up and stays .-
lit for approximately 1,5seconds, then starts blinking.
If the spool release lever IS pulled w&h a lapse of
approxrmately 6 seconds after the ignition switch has been ~:
turned ON, buzzer sounds rntermrttently.
At the same time, the “fasten seat belt” Indicator light and ~c
the spool reJease rndrcator light blink rntermrttently.
 BODY - Automatic Seat Belts 23-115

Ignition switch ON
I
LOCK or ACC )
I

Spool release
lever switch

Buzzer

“Fasten seat belt”

indicator light

To: For approximately 0.7 sec.

Spool release T,: For approximately 6 sec.
indicator light T2: For approximately 1.5 sec.

19110323

4. KEY REMINDER
~;~y~hminder When the door lock switch on the driver’s side door is
turned LOCK or ACC from ON position (close + open), the
Ignition (ON) I---- buzzer will sound without interruption in case the steering
switch (LOCK or ACC) lock switch is ON (key inserted in key cylinder) and the
Iriver’s side ignition switch is in LOCK or ACC position.
door lock switch
close side) ,kznlll-

3uzzer (Fin
16Y365:

Automatic seat belt control

AUTOMATIC SEAT BELT CONTROL UNIT INPUT/
unit connector terminals OUTPUT SIGNALS
1. POWER SUPPLY AND GROUND CIRCUIT

Name Terminal No. Voltage level

Battery (+B) I 21 I H I
Automatic seat belt 11 H
motor (+B)
16Y3667
GROUND (GND) 16 L

NOTE
H and L in the voltage level column indicate the terminal voltage of
each signal.
H : Battery voltage
L: Ground voltage (0.8V or less)
23416 BODY - Automatic Seat Belts
2. INPUT SIGNALS
Input signals (to the computer) corresponding to the ON/OFF conditio_n of each of the switches and
sensors are as shown In the table below.
Note that the checking should be done with the lgnltlon key at the ONTbosition, otherwise the correct
voltage measurement might not be obtalned.

(driver’s side, front) belt is not rele

belt is fastened completely 16R0919

Door lock switch Driver’s door is closed

(driver’s side)

Fasten switch

Lever is pulled up

Buckle switch -17 Lap belt is fastened OFF H

(driver’s seat)
Lap belt is not fastened ON L g A---
16R0919
 BODY - Automatic Seat Belts 23-l 17
3. OUTPUT SIGNALS
Signals output from the computer in accordance with changes of input signals are as shown in the table
below.
(1) Buzzer drive (terminal No. 14)

Output signal waveform and its operation

Condition at inout side
Output signal Buzzer
Buckle switch at ON Ignition switch
(not fastened)

Ignition svGtch at Door lock switch OFF

LOCK and ACC and [close side) (l%k, Door closed
H
key-reminder switch > Door open ON
at ON

Spool release lever ignition switch

I---- OFF
(unlock)
L I----

switch at OFF

L
16R0017 1

Door lock switch at

3N (open side) and
3elt anchor and
shoulder belt
FREE I OFF

-elease switch at
3N
An impact
or sudden
pull force
: lJu-Lr I ON

0.7 sec.-+ WI.7 sec.

is applied 16Y3654 1

(2) Fasten seat belt indicator light drive (terminal No. 20)

Output signal waveform and its operation

Condition at input side

:

Ignition switch

I 16Fi0022 1

Spool release lever Ignition switch

switch at OFF or
door lock switch at
ON (close side)

I 16Y3656 1

I----
Buckle switch at ON gnition switch OFF
:not fastened) .e 6sec.

ON
c l-r
23-118 BODY - Automatic Seat Belts

(3) Spool release indicator light drive (terminal No. 19)

Output signal waveform and its operation

Condition at input side
Output signal

Ignition switch

Spool release lever ignition switch

switch at OFF

(4) Motor (shoulder belt release side: terminal No. 7 - driverBide and terminal No. 4 -passenger’s slcie)

Output signal waveform and its operation

Condition at input side
Output signal Mot.&
Door lock switch at Ignition switch Operate
ON (open srde)
stop
16R0919 t----i

(5) Motor (shoulder belt fasten side: termtnal No. 10 -driver% side-and terminal No. 1 - passenger’s stde)

Output signal waveform and its operation

Condition at input side
Output ~signal Motor
Door lock switch at Ignition switch ON H Operate
ON (close side)
LOCK Lm --J--I- stop
or ACC 16R0919
 BODY - Automatic Seat Belts

EMOVAL AND INSTALLATION

Pre-removal Operation ~,.

_
l Front PillarTrim
l Roof Side Trim 18
l Upper Quarter Trim
l Wrap Round Trim
l Quarter Trim

35-55 Nm
2540 ft.lbs.

Post-installation Operation
l Headlining
l Front PillarTrim
l Roof Side Trim
l Upper Quarter Trim
l Wrap Round Trim

2.943 ft.lbs.
4-6 Nm
2.943 ft.1bs.d

4-;Nm
2.943 ft.lbs.

Driving device assembly removal steps

1. Buckle
2. Front seat
3. Buckle switch
connector connection
(driver’s side only)
4. Anchor plate connection
5. Retractor (for lap belt)
6. Driving device assembly
(Parts 7 through IO)
l * l 4 7. Outer casing (B)
r)+ 8. Tape guide
9. Outer casing (A)
10. Rail guide
11. Release switch connector connection FyTEeverse the removal procedures to reinstall.
12. Fasten switch connector connection (2) +*: Refer to “Service Points of Removal”.
13. Motor (3) I)+: Refer to “Service Points of Installation”.
 ,

18Y1833

-
Shoulder belt removal steps Automatic seat belt control unit removal steps
4. Anchor plate connectlon *I) I)+ 20. Floor console
14, Spool release lever 2 I. Autamatlc seat belt control unit
15. Rear console cover
** I)+ 16. Rear console box Circuit breaker removal
*+ 17. Retractor (for shoulder belt)
22. Circuit breaker
Shoulder sub anchor removal steps
NOTE
+* 18. Door sash trim (I) Reverse the removal procedures to relnstall
19. Shoulder sub anchor (21 +I), Refer to “Service Points of Removal”
(31 l +: Refer to “Serwce Points of Installation”
BODY - Automatic Seat Belts 23-121
SERVICE POINTS OF REMOVAL
7. REMOVAL OF OUTER CASING (B)
Raise the claw of the outer casing (B) and disconnect the
outer casing (A) from the tape guide. Then, with the tape
pulled all the way out, remove the outer casing (B).

16. REMOVAL OF REAR CONSOLE BOX

Remove the inner box cover and remove the rear console
box attaching screws shown. Then, remove the rear
console box.

18. REMOVAL OF DOOR SASH TRIM

Refer to P.23-64.
20. REMOVAL OF FLOOR CONSOLE
Refer to P.23-93.

INSPECTION
RAIL GUIDE
(1) Check the tape moves smoothly and does not catch when
pulled and pushed.
If not, check the guide rail for foreign particles.

(2) Check the tape for wear or damage.

Caution
Do not wipe off the grease and take care not to soil the
tape.
23-722 BODY - Automatic Seat Belts

(1) Remove the motor.

(2) Connect the motor termmals directly to the battery and
check that the motor operates smoothly. Next, reverse the
polarity and check that the motor operatessmoothly in the
reverse direction.

(3) Check the glear<or’wearFor damage.

19Y697

Knob RELEASE SWITCH AND FASTEN SWITCH

(1) Remove the release switch and fasten switch. _
(2) Check the continuity between the terminals.

Release the switch knob

Push the switch knob

NOTE
O-0 indicates that there is continuity between the terminals.
SPOOL RELEASE LEVER SWITCH
(1) Disconnect the spool release lever switch connector.
(2) Check the contrnuity between the terminals.

Spool release lever does not opei%te 0 0

19Y69!
Spool release lever lift up

NOTE
C.+LJ lndlcates that there IS continuity between the terminals.
 BODY - Automatic Seat Belts 23-123
BUZZER
(1) Remove the buzzer from the center reinforcement.

(2) Check that buzzer sounds when battery voltage is applied

to the buzzer terminal.

16R145E

BUCKLE SWITCH
(1) Disconnect the buckle switch connector (L.H. only).
(2) Check the continuity between the terminals.

El 1
2

16110368
Terminal

Buckle unlock
Buckle

NOTE
lock
1

0
2

O-O indicates that there is continuity between the terminals.

SERVICE POINTS OF INSTALLATION
20. INSTALLATION OF FLOOR CONSOLE
Refer to P.23-93.
17. INSTALLATION OF RETRACTOR (FOR SHOULDER
BELT)
When installing. the retractor, make sure that the retractor
locking tab fits into bracket hook as illustrated.

16. INSTALLATION OF REAR CONSOLE BOX

When passing the shoulder belt out through the bezel of
console box after the rear consle box has been installed,
ensure that the bezel is positioned with correct top-to-
bottom orientation and the belt is not twisted inside the
TOP console box.

Bottom
 &
23-124 BODY - Automatic Seat Belts / Rear Seat Belts I~
1--
Es :‘z-
8. INSTALLATCON OF TAPE GUIDE --“_
(1) Pass the-tape into the tape guide.
(2) Mesh the hole in tapewith the motor gear w&h proper z
tension. Then, mount the tape guide to the motor. ~_ EE

18Y1812

7. INSTALLATION OF OUTER CASING (B)

After the tape tias been passed into the outer casing (B),
insert until the outer casing (B) claw catches the tape guide
claw.

r 18Y1791

REAR SEAT BELTS N23VGAR

REMOVAL AND INSTALLATION -

35-55 Nm
2540 ft.lbs. -
35-55 Nm
2 25-40 ft.lbs.

3-4 ft.lbs.
Removal steps
NOTE ~_=~
I. Rear seat cushion (I 1 ReversFthe removal procedures to reinstall.
++ ++ 2. Rear seat belt (2) **: Refer to “Service Piiints of Removal”.
(3) *+: Refer to “SGvice Wints of installation”.
BODY - Rear Seat Belts 23-125
SERVICE POINT OF REMOVAL
2. REMOVAL OF REAR SEAT BELT
Remove the rear seat belt.
NOTE
Special bolts (inch-size) are used for the seat belt mounting
bolts.

SERVICE POINT OF INSTALLATION

2. INSTALLATION OF REAR SEAT BELT
Position the anchor plates by using the following procedure,
and then secure the plates with the bolts.
(1) Install the plates at the center of the vehicle so that the
belts are parallel to the vehicle center line.
(2) Install the anchor plates at the sides of the vehicle with
retractor vertical.
 24-1

HEATERS
AND
AIR CONDITIONING
CONTENTS
AIR CONDITIONING ............................ 20 TROUBLESHOOTING ........................................ 38
AIR CONDITIONER CONTROL SWITCH ........ 88 Automatic Air Conditioning System
........................................ 93 Control Parts Layout ........................................ 70
BLOWER ASSEMBLY
Control Unit Terminal Voltage Table ................ 64
COMPRESSOR .................................................... 101 Operational Check and Causes
EVAPORATOR .................................................... 95 of Troubles ;....................................................... 38
................................ 20 Self-diagnosis .................................................... 60
GENERAL INFORMATION
System Diagnostic Procedure ........................ 42
HEATER UNIT ........................................................ 89 Troubleshooting Table .................................... 56
RECEIVER, CONDENSER, COMPRESSOR VENTILATORS .................................................... 104
CLUTCH ASSEMBLY ............................................ 98
SAFETY PRECAUTIONS .................................... 73 HEATERS .. .... .. ..... .. ..I..._.......................... 2
SERVICE ADJUSTMENT PROCEDURES ........ 74 BLOWER ASSEMBLY . .. . .. .. . .. .. . . .. .. . .. . .. . .. .. . .. . .. .. . . 15
Charging the System ........................................ 84 GENERAL INFORMATION . .. .. .. . . .. .. . .. . .. . .. . .. .. . .. . . 2
Compressor Drive Belt Adjustment ................ 87 HEATER CONTROL . .. . .. .. . .. . .. . .. . .. .. . .. . .. .. .. . . .. . .. .. . .. 8
Compressor Noise ............................................ 87
Correcting Low Refrigerant Level .................... 81 HEATER UNIT . . .. . .. .. . .. . .. . .._...._................................ 12
Discharging the System .................................... 82 SERVICE ADJUSTMENT PROCEDURES .. . .. . .. 6
Evacuating the System .................................... 83 Temperature Control System Adjustment . .. . 6
Handling Tubing and Fittings ............................ 85
Manifold Gauge Set Installation .................... TROUBLESHOOTING . .. . .._..t..............._.._.._........ 3
74
Performance Test ............................................ 80 Blower Motor Inoperative
Refrigerant Leak Repair Procedure ................ 80 Insufficient Heat
Testing the System for Leaks ........................ 79 No Ventilation even when Mode Selection
Test Procedures ................................................ 75 Lever is Operated
SPECIFICATIONS ................................................ 37 VENTILATORS . . .. . .. .. . .. . .. .. . .. . ..._........................... 17
General Specifications ....... . ............................ 37
Service Specifications .................................... 37
Torque Specifications ........................................ 37
24-2 HEATERS - General Information

HEATERS
GENERAL INFORMATION
The heater system IS a composrte type where the heater unit rs centrallylocated in the vehicle with the ~_
blower and connected by ductrng, and an excellent blendParr system IS rncorporated -to respond to
temperature control.
In the blend air heat control system, the blower brings In outsideor inside air-which will be guided by dampers =
(blend air damper and by-pass damper) located along the heater core and controls the amount of air which
passes through the heater core and whrch will be by-passed. All of the air isbrought togetherin the- mixture 1:
chamber behind the heater core from which the mixed air-is conducted to the various outlets.
A dual high br-level heater IS provided which directs hot air to the windshield or occupants’ legs and cool air to .r
their faces Also a lap heater duct IS provided to direct warm air to front seat occupants’ laps.
Heater core
Seaarator /
Blend air damper
Bv-pass damper

FQOT’DEF

IO TOOT
area

2OY601

Air selection Mode selection

control lever lever

Defroster air

a Defroster

A A
air
Heater f&switch Temperature
control lever

Floorair fresh air

Recirculation air
 HEATERS - Troubleshooting 24-3
TROUBLESHOOTING N24EAAD

‘-I

Symptom Probable cause Remedy

Insufficient heat Obstructed floor outlets Correct

Changeover dampers improperly adjusted or Correct

binding

Clogged heater hoses Replace

Improperly adjusted control cables Adjust

Plugged or partially plugged heater core Clean or replace

No ventilation even Incorrect adjustment of changeover dampers Adjust

when mode selection
lever is operated Incorrect installation of mode selection control Adjust
wire

Improper duct connection, collapse or clogging Repair or replace

Blower motor Burnt-out fuse Replace

inoperative
Poor grounding Correct

Blower switch malfunction Replace

Blower motor malfunction Replace.

24-4 HEATERS - Troubleshooting
-.
CIRCUIT DIAGRAM

Blower relay
Ignition switch

A-34
Blower motor
Sub fusible

-E M
link 2
0
i
0 -Ev

3 3 2-B c 2-8
A In
LA LA 3-k _ L-Lti

1.25-LY 1.25-LY

. - - -. . , , l-l.%-I
---- -..w t ,
+ 85-’ w u
I
Battery Resistor

Fo_‘details of grounding potnts (ex.: m. I 8-10

37Y589

Wire color code

B: Black Br: Brown G: Green ;;: Grad/ ~- L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink Y: Yellow W: White
 HEATERS - Troubleshootinn 24-5
OPERATION N24EAAH TROUBLESHOOTING HINTS
l When the ignition switch is at “ON”, current Blower motor turns only at high speed.
flows through fuse No. 12, blower relay (coil), l Check resistor.
and ground, causing the blower relay contacts to
close.
l Then, when the blower switch is set at any of
“ LO ” , “ME” or “HI”, current flows through fuse
No. 5, blower relay (contacts), blower switch,
resistor, blower motor and ground, causing the
blower motor to rotate.
24-6 HEATERS - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES

TEMPERATURE CONTROL SYSTEM ADJUST-

MENT
MODE SELECTION LEVER
1. Set the mode selection lever to every position to operate
the blower. Check to see that the air blows out correctly
according to the lever posrtrons.
2. If air does not~blow out from the outlets matched with the :
mode selection lever position, adjust the mode selection
control wire. If then result of the adjustment is unsatisfac- mZ
tory, then adjust the damper.
Adjustment of the Mode Selection Control Wire
1. Disconnect the defroster duct at the driver’s seat~side from
the heater unit and the-defroster nozzle,
2. Disconnect the mode selection control wire from the heater. _
unit’s clip.

3. Set the mode selection lever of heater control to the “XL? ”

Mode selection position. ~~
4. Turn the mode selection damper lever completely to the
left.
5. Connect the~mode selection control wire to the-air outlet
changeoverdamper lever, and to the clip part of the heater
unit.
Caution
Be careful that the lever does not move when clipping.
6. Check that the heater control mode selection lever moves
smoothly with some resistance at each position and air
blows outfrom the outlets matched with the lever position.
7. If air blows out from the outlets not matched with the mode ._
selection lever position eden after control wire adjustment,
adjust the “VENT” damper and “FOOT/DEF” -damper. Y
8, Connect thedriver’s side defroster duct to the heater unit
and defroster nozzle.

Adjustment of the Damper

1. Disconnect the mode selection control wire from the mode ~_
selection damper lever and the heater unit’s clip. -.
2. Adjust the “VENT” damper as follows:
(1) Unlock the mode selection damper lever clip and -
disconnect the link for the “VENT” damper from the _
mode selection damper lever.

2OY
1587
 HEATERS - Service Adiustment Procedures 24-7
(2) Turn the mode selection damper lever completely to
the right.
(3) Pull the “VENT” damper lever completely downward,
and move the damper to the position (not visible)
shown in the illustration.
(4) Attach the end of the link for the “VENT” damper to the
mode selection damper lever.

3. Adjust the “FOOT/DEF” damper as follows:

(1) Unlock the mode selection damper lever clip and
disconnect the link for the “FOOT/DEF” damper from
the mode selection damper lever.
(2) Turn the mode selection damper lever completely to
the right.

(3) Pull the “FOOT/DEF” damper lever completely down-

ward and move the damper to the position shown in the
illustration (Make sure that the packing is in contact
“FOOT/DEF” with the case).
NOTE
Confirmation can be made that the “FOOT/DEF”
damper is raised upward through the defroster blower
outlet of the heater unit (with defroster duct discon-
netted).
lever 2OY 158E

(4) Attach the end of the link for the “FOOT/DEF” damper
to the mode selection damper lever.
NOTE
When attaching it, pull the lever end (A in the illustra-
tion) in the direction of the arrow.
4. Referring to the paragraph on adjustment of the mode
selection control wire, connect the mode selection control
wire to the mode selection damper lever.
24-8 HEATERS - Heater Control

HEATER CONTROL N24GA- .

REMOVAL AND INSTALLATION

2011647

Removal steps 1: 2OY 1603

1. Heater control knobs
4* 2. Heater control panel
3. Heater control panel illumination lamp
4. l-amp case
5. Lamp cover
6. Springs -
l I) I)+ 7. Floor console
4* Ib+ 8, Instrument panel
9. Defroster nozzle, passenger’s side
+I) 10. Air selection control wire connection ~~ _
++ Adjustment of air selection control wire _.
4* 11. Temperature control wire connection -~
64 Adjustment of temperature control wire z
.~
+I) 12. Mode selection control wire connection
64 Adjustment of mode selection control wire
I)+ 13. Heater control assembly
14. Optical fiber lamp assembly
15. Heater fan switch NOTE
16. Micro switch (1) Reverse the removal procedures to reinstall.
17. Slide switch (2) 4*: Refer to “Service Points of Removal”.
(3) I)+: Refer to “Service Points of Installation”.
 HEATERS - Heater Control 24-9
20 t.78) SERVICE POINTS OF REMOVAL N24GBAF

2. REMOVAL OF HEATER CONTROL PANEL

__ _-----
Insert the tool shown in the illustration into the lever hole of
the heater control panel, and pull to remove.
7. REMOVAL OF INSTRUMENT PANEL / 8. FLOOR CON-
SOLE
Refer to GROUP 23 BODY - Instrument Panel / Floor
Console.

10. DISCONNECTION OF AIR SELECTION CONTROL WIRE /

11. TEMPERATURE CONTROL WIRE / 12. MODE SELEC-
TION CONTROL WIRE
Disconnect the control wires from the heater unit and
blower assembly.
NOTE
Detach the control wires with a screwdriver as shown in
the illustration.

2OY51

INSPECTION N24GCAD

Operate the switch, and check the continuity between the

terminals.
2
\ NOTE
CSO indicates that there is continuity between the terminals.
BLOWER SWITCH

Y2054:

I OFF

l (Low) I c4-0 I
I 0 (Medium) I --t-+-Q I
SLIDE SWITCH

a 20K56E
 Ez
m:
24-10 -~
HEATERS - Heater Control -_c
=i-
MICRO SWITCH

2OK6701
-

SERVICE POINTS OF INSTALLATION N24GClAF

13. INSTALLATION OF HEATER CONTROL ASSEMBLY

(1) Apply chassis greasefo all moving-parts of the heater -
control assembly.

_ _
(2) Insert the- heater contml assembly bracket in the center .._
reinforcement. .-

.--1
Mode selection . ADJUSTMENT OF MODE SELECTION CONTROL WIRE
-- -- ..._
I / control wire (1) Set the mode selection lever to-C3 position.
(2) With then-ode selection damper lever pushed in the -~
directionof arrow, connect the inner cable of the mode ~~_
Mode selectioncontrol wire~to the end of the mode selection __
selection damper lever and clip down the cable casing.
damper le

!
i
.
i 2OY51F
. -- ~_
l ADJUSTMENT OF TEMPERATURE CONTROL WIRE .-
. Water (1) Set the temperature control lever to the extreme left. ,.~
valve (2) With the blend air damper lever pushed in the direction =
of arrow, connect the inner cable of the temperature ~~
control wire to the end-of the blend air damper lever and -
clip down the cable casing.

, 2OY811
 electior
rol wire
1
HEATERS

.
- Heater Control

ADJUSTMENT OF AIR SELECTION

(1) Set the air selection
(2) With the air selection
direction
selection
CONTROL
24-11

control. lever to&position.

damper
of arrow, connect
WIRE

lever pushed in the

the inner cable of air
control wire to the end of the air selection

1
damper lever and clip down the cable casing.

I
2OY8' 13

8. INSTALLATION OF INSTRUMENT PANEL / 7. FLOOR

CONSOLE
Refer to GROUP 23 BODY - Instrument Panel / Floor
Console.
24-12 -~ HEATERS - Heater Unit ~~~~~
HEATER UNIT N24vGA

REMOVAL AND INSTALLATION

Pre-removal Operation
l Draining Coolant
(Refer to GROUP 0 LUBRICATIONA-ND MAINTENANCE-
Coolant Change.)

Post-installation Operation
l Adjustment of Heater Control Wire
(Refer to P.24-IO)
l Refilling Coolant
(Refer to GROUP 0 LUBRICATION AND MAINTENANCE-
Coolant Change)

‘6

Removal steps
+I) 1. Water hoses
4* *+ 2. Floor console
+* ++ 3. instrument panel
4. Center ventilator duct
5. Lap heater duct
6. Center reinforcement ~~ NOTE -~:
(1) Revecse~the removal procedures to reinstall.
7. Heater unit (2) C*: F(ef6r to “Service Points of Removal”.
8, Blower relay (3) l *: Refer to “Service Points of Installation”.
 HEATERS - Heater Unit 24-13
SERVICE POINTS OF REMOVAL N241BAF

1. REMOVAL OF WATER HOSE

(I) Move the temperature control lever to the “warm”
position.
(2) Disconnect the water hoses from the heater unit.
2. REMOVAL OF INSTRUMENT PANEL / 3. FLOOR CON-
SOLE
Refer to GROUP 23 BODY - Instrument Panel / Floor
Console.

INSPECTION N241CAB

l Check the dampers and link mechanism for proper opera-

tion.
l Check the heater core for clogging or water leakage.
l Check the water valve for operation and clogging.
BLOWER RELAY
(1) Remove the blower relay.

(2) Check continuity between terminals when the battery

voltage is applied to the terminal 2 and the terminal 4 is
grounded.

Voltage applied Terminals 1 -3 Conductive

Voltage not Terminals 1 -3 Non-conductive

applied
Terminals 2 - 4 Conductive

16E628

16D598
16LO312

HEATER CORE AND WATER VALVE REPLACE-

MENT N24lGABl

1. Unlock the water valve lever clip and disconnect the link for
the blend air damper from the water valve lever.

I Blend air damDer link 7~~071

24-14 HEATERS - Heater Unit

2. Remove the Ifollowing parts and then remove the water

valve.
(1) Clamp
(2) Joint hose clamp
(3) Joint hose mm
(4) Screw em
3. Remove the plate and remove the heater core. Ifit is hard If
to remove due to its contact with the damper lever, remove
the damper .kver first. .

-
4~. Install the heater core arid water valve.
5. Push the water valve lever all the way k-ward so* that the T
water valve is at the closed position.
6. Pull the blend air damper lever fully in the directionof arrow -i
so that the blend air damper is completely closed.

damper lever I
2OYlSOC

SERVICE POINTS OF INSTALLATION N24lEAE

3. INSTALLATION OF INSTRUMENT PANEL / 2. FLOOR

CONSOLE
Refer to GROUP 23 BODY - Instrument Panel / Floor ~_
Console.
 HEATERS - Blower Assemblv

BLOWER ASSEMBLY N24KA-A

REMOVAL AND INSTALLATION

Removal steps
1. Under cover
.4 Adjustment of air selection control wire /
c* 2. Glove box 1
3. Air selection control wire connection
4. Duct (vehicles without air conditioner) or
duct joint (vehicles with air conditioner)
5. Blower assembly
6. Resistor
7. Hose NOTE
(1) Reverse the removal procedures to reinstall.
8. Blower motor (2) *I): Refer to “Service Points of Removal”.
9. Blower (3) I)*: Refer to “Service Points of Installation”.
2OY1611

SERVICE POINT OF REMOVAL N24KBAFl

2. REMOVAL OF GLOVE BOX

(1) Grasp and release the glove box lid lock to open the lid.
Pull the glove box forward while pressing both sides
inward.

(2) Remove the glove box.

24-16 HEATERS - Blower Assembly

INSPECTION N24KCAE

RESISTOR
Connect an ohmmeter to each terminal of the resistor and
measure the resistance. z

Terminal cotinections Resistance

1 - 2 (Low) Approx. 1.4 R

1 - 3 (Medium) Approx. 0.4 R

2OY1641
1 - 4~(High) Approx. 0 R

Motor turns BLOWER MOTOR

(1) Connect the__blower motor to the battery (battery positive
terminal to terminal “2” and battery negative terminal to
terminal “1”) and check that the motor runs smoothly.
(2) Check that abnormal noise is not produced during rotation.

SERVICE POINT OF INSTALLATION N24KDAD

@ ADJUSTMENT OF AIR SELECTION CONTROL WIRE

(1) Set the air selection control lever to &?I position.
(2) With the air selection damper lever pushed in the
directioMof’arrow, connect the inner cable of air
selection control wire to the end of the air selection
damper lever and clip down the cable casing.

p-
I 2OY81:
 HEATERS - Ventilators 24-17
VENTILATORS N24MA-A

REMOVAL AND INSTALLATION

Removal steps
1. Demister upper outlet
4+ 2. Instrument panel
3. Lap heater duct

/ wr
4. Air duct
5. Knob ;7
4+ 6. Airduct 16
4+ 7. Demister duct /
4* 8. Demister nozzle 18
9. Side air outlet
4+ 10. Demister lower outlet
4* 11. Center air duct
4+ 12. Center air outlet
4+ 13. Defroster garnish
14. Center ventilator duct
15. Duct
16. Demister hose
17. Air duct
18. Lap heater center duct NOTE
4* 19. Defroster duct (1) Reverse the removal procedures to reinstall.
4+ 20. Side ventilator duct (2) 4*: Refer to “Service Points of Removal”.
Y1612
SERVICE POINTS OF REMOVAL N24MBAJI

2. REMOVAL OF INSTRUMENT PANEL

Refer to GRUUP 23 BODY - Instrument Panel.

6. REMOVAL OF AIR DUCT

Remove the air duct at&knob, and then remove the air ~.
duct.

7. REMOVAL OF DEMISTER DUCT / 8. DEMISTER NOZZLE

Remove the demister duct and the demister nozzle.

10. REMOVAL OF DEMISTER LOWER OUTLET

Remove the clip, and then remove the demister lower _i
outlet. = -

11. REMOVAL OF CENTER AIR DUCT / 12. CENTER AIR

OUTLET ’
Remove the center air duct, and then remove the center air ~.
outlet. -.
HEATERS - Ventilators 24-19
6. REMOVAL OF AIR DUCT / 19. DEFROSTER DUCT
Remove the air duct, and then remove the defroster duct.
Remove the instrument pad. (Refer to GROUP 23 BODY -
Instrument Panel.)

20. REMOVAL OF SIDE VENTILATOR DUCT

Remove the side ventilator duct from the body.

INSPECTION
Check all ducts for cracks.
24-20 AIR CONDITIONING - General Information

GENERAL INFORMATION NZ4BBAD

For car interior temperature control, a “feedback- control .._

system” is employed, in which the difference between set _
temperature and inside temperature is compared by a micro- ~:
computer and the system mechanisms are so- operated as to
eliminate the difference. In the microcomputer, the input data =
6 from various sensors (interior temperature sensor, foot area ~!
temperature sensor, photo-sensor, thermistor. hot water ther-
moserrsor), potentiometers and control switches are _
processed and its outputs control the selection ofjnside air I
Cooling unit recirculation or introduction okoutside air, direction of_air flow,
Intenor temperature sensor
Blower motor outlet air temperature and air volume. c_~
Receiver assembly Further, as a backup circuit is provided to store set temperature 1:
Condenser and temperature conditions outside air/recirculation, in-memory _~-
Compressor
Photo-sensor even when the ignition switch IS turned OFF (witi battery
Heater unit terminals in connect condition). if the ignitionswitch IS turned
Foot area temperature sensor ON again, the system resumes automatic control operation in
the same condition as before turning off of. ignition switch
provided the sw.itch is in ALJTO position.
2O'f152
By changeover of the switch,manual operation-is also possible.
In thus case, the functions oth-er than those selected for manual ~_
control are accomplrshed In _automatrc control mode.
 AIR CONDITIONING - General Information 24-2 1

Ignition switch Battery

Interior temperature + Heater capacity ........ Servo motor

sensor ~~~~~

+ Cooling capacity ........ Compressor

I
Foot area temperature
sensor t -+ Air volume ........
Power transistor
H relay

Thermistor
---c Outside air/recirculation

Outlet air flow direction

Vacuum solenoid
... . valve and actuator

)I S$tt;rperature digital 1

r
Photo-sensor I-

Blend air damper

potentiometer I-
r----+ Self diagnosis

T
TEMP switch Blower switch AUTO switch OUTSIDE/ Air flow
INSIDE mode switch
UP, DOWN OFF. @ , $? switch
- ~,Uqjp
24-22 AIR CONDITIONING - General Information

SUMMARY

Receiver Condenser

r-l

Control panel
 AIR CONDITIONING - General Information 24-23
TEMPERATURE CONTROL DIAGRAM
[Blend air damper opening in AUTO (DRY) mode is different from that in ECONOMY mode.1

PJ;; (DRY) ECONOMY

mode I

Heating
zone balance zone

Arcond~tioning heat load

2OY1576

OUTLET AIR TEMPERATURE CONTROL

1. Blend Air Damper Operating Range
On activating the AUTO switch, inside temperature and set
temperature are compared and, on the basis of preset
control conditions before starting (hereinafter called
“temperature control value”, the temperature control value
is changed according to detected temperature difference to
the HOT side if inside temperature is lower and to the
COOL side if it is higher. The servo motor is driven and
blend air damper opening is controlled according to the
change in temperature control operation value so that in the
case of change to the HOT side, blend air damper will open
to raise outlet air temperature and in the case of change to
the COOL side, blend air damper will close to lower outlet
air temperature.
In the AUTO mode, the blend air damper operating range is
from the point “a” to the point “d” in the control diagram,
and the temperature control operation value changes from
value “A” to “D” according to damper position. In the
ECONOMY mode, the damper operating range and the
corresponding temperature control value range are from
the point “a” to “c” and from the value “A” to “C”,
respectively.
24-24 AIR CONDITIONING - General Information

7
_. Evaporator Temperature _ Variable Range (Evaporator
temperature vanable rangels set of the ECONOMY mode is
selected.)
If Inside temperature becomes higher when the. blend art-
damper is closed and the system IS in the cooling range, a
command IS given to lower evaporator temperature with
blend art- damper closed, whrch causes the compressor
operating rate to Increase, If Inside temperature becomes
lower, a command is given to raise evaporator temperature
wrrh blend air damper In closed posrtron. and a lower
compressor operating rate results. Through the course of
above operatronr the outlet art- temperature is controlled to
dn optimum level. The evaporator temperature control
range to change compressor operating rate is between the ~-
points, “c” and “d” in the control diagram. In the AUTO
mode, however, this control range (between points “c” and
“d”) is cleared. If compressor operatrng rate- reaches 100%
and further coolI_ng IS required, air volume IS increased in
the ranqe between “d” and “e” In the control-diagram.
On the contrary, rt blend air damper openrng reaches MAX
HOT and further heating IS required, air volume is increased
in the ranpe between pornts 6 and A In the cfkgram.
3. Selection of ECONOMY Mode -
i
If the ECONOMY switch IS pressed, the control range
mentroned Inthe above paragraph 2 IS established and if
the swatch 1s pressed again, the compressor stops and only
art- is supplied through outlets.

AIR VOLUME CONTROL

Outlet air volume is controlled automatically in either cooling .-
range or heating-range if the system is in AUTO mode. In the
MANUAL mode, the system operates according to the button
settings. -
Blower speed is -controlled~ according to the temperature
control value obtained by comparing inside temperature and
set temperature,
Outlet voltage from the computer controls power transistor to OF
change blower motor voltage. For the maximum speed -
NY 157' operation, the relay is energized to directly apply the maximum :
supply voltage to the blow@ motor. 5-

Cooling range Heating range Manual control

.~
10 steps ~~ 8 steps 2 steps

In the temperature control diagram, the outlet air volume --

control range isbetween points “d” and “e” for cooling and ~z
between points- “a” and “by” for heating.
Approx
Control unit output 5 04 2OY 157c
 AIR CONDITIONING - General Information 24-25
Air volume control INSIDE/OUTSIDE AIR CONTROL
In the AUTO mode, the inside/outside air damper operation for
selecting blower air suction port is controtled automatically
according to the temperature control value obtained through
comparison of inside temperature and set temperature. In the
cooling range, the inside air circulation is selected if inside
temperature is high and the outside air introduction is selected
if inside temperature is low.
Even in AUTO mode, the selection is possible as desired by
MAX
MAX
COOL Temperaturecontrol HOT pressing the MANUAL button. However, this method of control
command value 2OY154! -has the following limitations:
(1) After start, outside air is introduced for two minutes.
(2) Outside air is introduced in DEF mode.
(3) Inside air recirculates when set temperature is 18°C (65°F).
(4) Outside air is introduced when set temperature is 32°C
(90°F).

AIR FLOW CONTROL

Economy mode
Air blown by the blower is cooled or heated with the evaporator
or heater to an optimum temperature and then supplied to the
car interior through various outlets. For the air flow directions,
any of the three modes FACE, FACE/FOOT and FOOT is
determined depending on temperature setting conditions and
selected automatically through operation of blend air damper.
Between DRY and ECONOMY modes, the air flow mode
change points are different as illustrated.
However, the air flow selecting operation has the following
limitations:
(1) Set temperature 18°C (65°F) Fixed to FACE mode
Set temperature 32°C (90°F) Fixed to FOOT mode
(2) Coolant temperature compensation in heating
When inside temperature is lower than set temperature by
more than 3°C (37.4”F), the air outlet and blower speed are
fixed as follows depending on engine coolant temperature
to improve heating at system start time.
0 20 30 40 50 60 70 80 100
MAX MAX Coolant Air flow Blower speed Compressor
COOL HOT temperature mode
Blend air damper position
20Y 1568

z 0.5 /
g% 0.4 COMPENSATION OF SOLAR RADIATION
$ 0.3
5a 0.2 The photo-sensor (photodiode) senses the solar radiation
amount. The data from this sensor is used for correcting the
2 0.1 temperature control value. According to the corrected value,
0’ the blend air damper position or blower speed is controlled for
50.000 100.000 an optimum interior temperature.
Solar radiation amounf (LX) 20Y 156
24-26 AIR CONDITIONING - General Information

VACUUM SYSTEM
The vacuum system consrsring of vacuum tank, check valve, .:
vacuum hoses, vacuum solenord valves and vacuum actuators,
energizes or de-energizes the- solenoid valves In response to
!Zgnals from computer and operates the vacuum actuators to .i
open or close ~the dampers for switching aIt- flow. The
relatronshlp between modes-Andy solenoids are as shown __
below.

Outside air introduction

No. 1 solenoid valve

II
Intake manifold
INSIDE air damper
vacuum actuator
- -

No. 2 solenoid valve

Check valve /
FACE/FOOT damper
v vacuum actuator
Vacuum tank

DEF damper
vacuum actuator
No. 4 solenoid
valve

INsIDE air damp&

varxum actuator

vacuum actuator

vacuum actuator

Check valve
 AIR CONDITIONING - General Information 24-27
FAN CONTROL SYSTEM
This system detects the air conditioner operating state and
coolant temperature through the information from the air
conditioner switch, pressure switch and thermosensor, and
controls the operation of radiator fan and pusher fan
FAN CONTROL MODES

Fan operation
Status of
switches and sensors Radiator Radiator Pusher
fan motor fan motor fan motor
Engine No. 1 No. 2
Air con- Pressure coolant Thermo- Thermo-
ditidner temper- sensor sensor
switch
switch ature No. 1 No. 2
switch ON OFF ON OFF ON OFF

OFF OFF 0 0 0

OFF - - ON OFF 0 0 0

ON ON 0 0 0

ON OFF OFF 0 0 0

ON ON OFF 0 0 0
OFF
ON ON ON 0 0 0

OFF ON ON 0 0 0
ON
ON OFF OFF 0 0 0

ON ON OFF 0 0 0
OFF
ON ON ON 0 0 0

OFF ON ON 0 0 0

Remarks:
Contact operating pressure and temperature
Pressure switch: 1,912 kPa (277 psi) -+ ON
Engine coolant temperature switch: 113°C (235°F) -+ OFF
Thermosensor No. 1: 85°C (185°F) -+ ON
Thermosensor No. 2: 100°C (212°F) + ON
24-28 AIR CONDITIONING - General Information

AUTO (DRY) ECONOMY

mode mode

.
Winter season

Mid season

Summer season

HZting Point of Cooling

zone balance zone

Air-cond~tmmg heat load

The following eZplanatron IS- one sample of operatrons for _

automatic art- condrtroner. _
A: COOL START (summer season, high solar radiation) ~-
[CONDITIONS] ~~
@ Car Interior temperature: 32°C (90°F)
l Sets temperature: 75°F
* Ambrent temperature: 3u”C (86°F)
‘I. Push AUTO switch (air cpndrtioner ON).
It starts at positron (1) on above temperature condrtrons,
each modes should be as follows:
a Arr flow control: FACE mode
e Insrde/outsslde air: lnsrde crrculatron -.
NOTE
After start, outside arr IS Introduced for 2 minutes. .;
@ Blower speed: MAX HIGH speed (10th step)
* Blend air -damper opening ratio: MAX COOL (close)
@ Compressor: ON _
2. Blower is controlled low speed according to the lower :
Intenor temperature and then blower speed which balances
with cooling load marntarns to be same temperature ;
between rnterro-r and set. IAir mix damper-opening ratio is .
MAX COOL Iposition (1_) to (j]).]
AIR CONDITIONING - General Information 24-29
3. In case of low cooling load caused by lower solar radiation
and ambient temperature 30 to 25°C (86 to 77”F), blower
stays LO speed and blend air damper opening ratio is
controlled between MAX COOL (0 %) to 30 % and then
interior temperature is stabilized to be same with set
temperature.
(Blend air damper opening ratio is position @ to 0.)
B: ECONOMY SWITCH ON
If push the economy switch during @ and @ in the diagram,
blend air damper stays at MAX COOL position and it controls
running ratio of compressor.
As a result, interior temperature is stabilized to be same with
set temperature.
(If cooling load goes to @ from 0, off time of compressor
becomes longer.)
C: INSIDE/OUTSIDE MODE CHANGE OVER
In case of cooling, after start, outside air is introduced for 2
minutes and then changes to inside air.
When blower speed goes down to 3rd lower step, inside mode
changes to outside mode (position @).
However in case of high solar radiation, when blower speed
goes to 5th step, it changes to outside mode.
(Position @ to 0, @ to @J is always outside mode.)
D: HEATING (winter season to mid season)
[CONDITIONS]
l Car interior temperature: -10°C (14°F)
l Set temperature: 75°F
l Ambient temperature: -10°C. (14°F)
1. Push AUTO switch.
It starts at position @ on above temperature conditions.
Each modes should be as follows:
l Air flow control: FOOT mode
l Inside/outside air: Outside air
l Fan speed: H2 (8th step, MAX speed)
l Compressor: OFF
However, radiator temperature is cold at engine starting,
therefore air flow control keeps DEF mode and blower
stays 5th speed step.
2. Fan speed and blend air damper opening ratio is controlled
low according to the higher interior temperature, and then
fan speed blend air damper which balances with heating
load maintains to be same temperature between interior
and set.
[Fan speed is 3rd to 4th step, blend air damper opening ratio
is 70 % to 80 % (position @ to @).I
NOTE
Fan speed and blend air damper move symmetrically during
position @ to 0.
24-30 AIR CONDITIONING - General Information

3. In case of ambient temperature 0.6 to 5°C (32 to 41”f), fan

speed and blend atr damper openrng ratro goes to low by
lower heat load.
The air flow mode changes to Bl LEVEL mode at posltlon
(71.
NOTE
Compressor begins to run-at above ambrent temperature ~1
06°C (32°F).
4. In case of ambrent temperature IO to 15°C (50 to 59°F) fan
speed and blend air damper openrng ratio goes to- !ower by
much lowerheat load and the air flow mode changes to ;
FACE at position (6). :
E: MID SEASON
Low heat load like ambient temperature 5 to 15°C (41 to 59°F)
and set temperature 75°F. _
1. If interror temperature is over the set temperature during @,I
to ~3!, art- conditioner starts by COOL.
2. If interior temperature Is-below the set temperature, air ~~
conditroner starts by heat during ($I to (3.

OPERATION
AIR CONDITIONING - General Information 24-31
CONTROL PANEL
1. Air Selection Switch
Ignition switch at ON and control in AUTO mode:
Inside air recirculation or outside air introduction mode as
selected in AUTO mode is established, with the lamp lit
dim.
Manual setting:
By every depression of the switch, the selected mode is
reversed and the status is held, with corresponding lamp lit.
2. Outside Air Introduction Mode Display LED (Green) and
Inside Air Circulation Mode Display LED (Orange)
Ignition switch at ON and control in AUTO mode:
The LED lights to indicate inside air recirculation or outside
air introduction mode as selected in AUTO mode.
Manual setting:
The LED indicates inside air recirculation or outside air
introduction mode.
3. ECON Operation Display LED (Orange) and ECON Switch
The LED operation and ECON switch operation are synchro-
nized.
Ignition switch ON and control in AUTO mode:
Switch lamp is lit dim and LED is off.
Manual setting:
If ECONO key is pressed, ECONO mode is set and ECONO
switch and LED are lit.
If the key is pressed again, compressor OFF mode is set
and ECONO switch is lit dim, with LED being off (fan in
operation).
The ECONO and OFF modes are established alternatively at
every depression of ECONO key.
4. Air Flow Mode Selection Switch
Ignition switch at ON and control in AUTO mode:
(1) Air flow mode is determined in AUTO mode.
(2) Al1 lamps are lit dim.
Manual setting:
(1) Air flow mode is established as selected.
(2) Lamps for set keys only are lit.
5. Air Flow Mode Operation Display LED (Orange)
Ignition switch at ON and control in AUTO mode:
LED for mode selected in AUTO mode is lit. [LED for FACE,
FACE/FOOT, FOOT or DEF mode is lit (when coolant
temperature is compensated).]
Manual setting:
LED for set air flow mode (FACE, FACE/FOOT, FOOT, DEF
or FACE/DEF) is lit. Simultaneous selection of DEF and
FOOT is impossible. (DEF is selected if they are selected
simultaneously.)
* The LED’s for two modes selected within a second are lit.
In case of concurrent selection of DEF and FOOT,
however, the mode selected later becomes effective.
24-32 AIR CONDITIONING - General Information

6. For OperaTtiCn Display LED (Orange) and Blower Switch -_

The LED operation IS synchronized with switch operation.
Ignition at ON and control In AUTO mode:
(I) Blower speed level IS determined by deviation of =_’
interior temperature trom set temperature.
(2) Switch lamps are all IIt dim.
Manual setting:
(I) Blower speed level IS set as selected (OFF”, Lo or Hi). ~_
(2) Switch lamps and LED’s are lit for set keys only.
’ If OFF-key is pressed, ECONO operaCon display LED, ==
ECONO~ switch lamp and AUTO switch lamp are IIt
dim (wrth compressor OFF).
7. TemperaturCControl Switch
(I ) After ignition switch IS set to ON, lamp IS always IIt dim.
(2) Beep sound IS produced once at every set temperature
change. (Setting changes at 1°F increments from 65 to
90°F.)
(3) If pressed slmultaneausly, no change occurs rn Set I
Temperature. No beep sound. .-
(4) No etfect on other switches.
(5) If the switch IS kept pressed, set temperature conrlnues IT
to change down to 65°F or up to 90°F. [Below 65°F or
above XC?, neither set temperature change nor beep
sound IS caused even It the switch IS pressed). ~~
8. AUTO OperaTitin Display LED (Orange) and AUTO Switch .i
The LED opei%mn and AUTO switch operation are synchro-
ntzed.
(I) Ignition SWlTch ON:
AUTO switch lamp and LED only are lit. (Other switch
lamps are lit dim.) Operation drsplay LED’s are as
described in the respective displays.
Manual setting:
When the blower speed level and air flow Fade are ~I
selected and compressor IS In OFF mode, AUTO swrtch _
lamp IS lit dim and AUTO LED indicatoris ott. 1~ case of
#2/r selection mode and ECONOMY mode -;zelection, 1:
however--AUTO switch lamp and LED will be lit. 1
(2) If AUTO key is pressgd again, AUTO mode is set and ._
AUTO s@Ztch lamp and LED will be !rt except when
temperature is same as seT temperature.
 AIR CONDITIONING - General Information 24-33
SENSOR MOUNTING POSITION

Interior temperature sensor Photo-sensor

2OY18‘l

Foot area temperature sensor

/
2OY1620

\
Engine coolant temperature sensor

/I 36YO14

Thermistor
 AIR CONDITIONING - General Information

INTERIOR TEMPERATURE SENSOR AND FOOT AREA

Interior temperature TEMPERATURE SENSOR
sensor
I Changes in interjor_t_emperatures, cause thermi$tor resistance ~1
in those sensors_tgchange and apply such resistance change =.I_
data as input to the microcomputer. _

Foot area’temperature sensor

2OY156;

Thermistor characteristics The temperatures detected by Intenor temperature zznsor and .I

foot area temperature sensor-are averaged and obtdined value ~._
c is used as an it$ejor temperature data. _ _;
y 20 c

I:;! 10 -5 0 5 10 15 20 25 30 35 40
114) 1231 (321141) 150) :59) (68) (79~ WZ9(95)(1041
Temperature “C 1°F)
20Y156t
_ _ -~ 7-
THERMISTOR
This sensor serrsesrevaporatqr air flow temperature and inputs
the signal to the -microcovputer for compressor ON-OFF::
control.
Further, it detects the frost point to prevent frosting of .~
evaporator. .~

(501 (68) (86)

Temperature “C (“F)
 AIR CONDITIONING - General Information 24-35
AIR CONDITIONER SYSTEM COMPONENTS N24BBBC

Piping
Vacuum tank
Liquid line

To cooling unit
Dual pressure
switch

Thermosensor No. 1

Thermosensor No. 2

I Suction line
Sub condenser Engine compartment
(vehicles with an
automatic transmis
&i&P \c Discharge line
Tension pulley.bracket

Compressor bracket
Receiver ,@,

Pusher fan @’ Crankshaft nullev

Receiver

2OYPPP

Passenger compartment

Air-conditioning switch
Sub condenser
(vehicles with an 2011651
automatic transmission)
I Heater unit

Air-conditioning unit

Blower assembly

DW3
Drain hose
joint
Grommet
2OY1504
 I ;$$-:”-id .:. ; ‘; fj :j;, fi ’ fj
.-,I.. = :;a
.__-~ in-

AIR CONDITIONING - General Information

Compressor - The prime purpose of the compressor IS to

r:ompress the low pressure refrigerant vapor from the evapo-
rator rnto a high pressure, high temperature vapti The 6
cylinder DR6148_compressor_rs used on all vehicles .~ in this
Service Manual. .~ ~~
Magnetic Clutch - are mounted on the compressor provrdrng
d convenrent way to drrve and disengage it in accordance to the
coolrng needs.
Condenser - IS located In tront of the radiator. Its function IS to
cool the hot, high pressure retngerant gas causing it to
condense into high pressure_lrqurd refrigerant.
Receiver Drier - is used to remove any traces of moisture from
the refrigerant system. This component rncorporates the sight
glass.
Sight Glass - at the top ot the recerver drier 1; provrded as a
diagnostic tool to observe refrigerant flow and indjcate re-
frigerant level.
Dual Pressure Switch - prevents damage to the compressor
In case ot system loss and over of refngeran7 charge.
Fusible Plug - is 1ocate.d on the receiver drier. Its function IS to
prevent damage to the air-condrtroning system In the event that
ekcessrve pressures develops due to condenser air flow being
restricted by forexample, leaves, newspaper, and overcharge
of refrigerant, or air In the system.
Expansion Valve - The expansion valve IS used tor all
applicatrons. Its functron IS I to meter refrigerant into the
evaporator In accordance with cooling requirements.
Evaporator Coil - is located rn the evaporator and Its tunction
is to cool, and dehumidify the arr before it enters the vehicles.
Freeze Control - A thermistor is Installed at the heater srde
evaporator.
The main function of a freeze control is to keep condensate
water -on the fa_ce of the esporator coil fro-m freezing and
restricting air flow.
Service Valves - at the compressor and the discharge. The
valves are used tom test and setvrce the refrigerant system.
 AIR CONDITIONING - Specifications 24-37

SPECIFICATIONS
GENERAL SPECIFICATIONS N24CA-.

Items Specifications

Air conditioner type AC1 74LN

Compressor
Type DR6148
Compressor oil cc (fl.02.) DENS0 OIL 170 (5.7)
Protective devices
Pressure switch kPa (psi) ON at 1,912 (277). OFF at 1,618 (235)
Dual pressure switch kPa (psi) Low pressure switch
ON at 230 (33.4). OFF at 206 (29.9)
High pressure switch
OFF at 2,648 (384). ON at 2,059 (299)
Thermosensor No. 1 “C (“F) ON at 85 (185). OFF at 81 (177.8)
Thermosensor No. 2 “C (“F) ON at 100 (212). OFF at 96 (204.8)
Enginecoolant temperature switch “C (“F) ON above 106 (222.81, OFF at 113 (235)
Refrigerant and quantity to be charged g (oz.) RI2 910 (32)

SERVICE SPECIFICATIONS

, Items Specifications

Standard value
Drive belt deflection mm (in.) 17 - 20 (.7 - .8)
Therm~o switch “C (“F)
OFF+ ON 46-54(115-129)
ONA OFF 43 (109) or more
Potentiometer 0
MAX HOT position 180
MAX COOL position 4,640

TORQUE SPECIFICATIONS

I Items Nm ( ft.lbs

Liquid line 12-15 9-11

Suction line 30-34 22-26
Discharge line 20-25 15-18
Center piece securing nut 15- 17 11-13
Front housing through bolt 25-26 18-20
24-38 AIR CONDITIONING - Troubleshooting

TROUBLESHOOTING NZUEBAD

OPERATIONAL CHECK AND CAUSES OF TROUBLES

Operate the switches In the sequence In the followlng table and check the operation of each controller
.~ to _i
verify correct operation ot respective system components.

coolant is sufficiently switch is pressed.

- Problem in switch

setting remains unchanged.

- Problem in switch

l Outlet air reaches the warmest~..

attained or, conversely, temperature

- Problem in fan controller

 AIR CONDITIONING - Troubleshooting 24-39

No. Action Normal operation Abnormal operation/

Probable cause

3 Change temperature l Upon depression of DOWN switch, l No beep sound. Temperature setting
setting from 90 to beep sound is produced and the remains unchanged.
65°F. sound stops once 65°F temper- - Problem in switch
ature is reached. - Problem in wiring harness

l Beep sound is heard while temper- @ Temperature indication remains

ature setting is being changed. unchanged.
-Problem in indicator
- Problem in wiring harness

l When 65°F temperature is reached, l Air flow does not change to FACE
the indication changes from mode or air outlet does not corre-
“FOOT” to “FACE/FOOT” and then spond to the indicated mode.
to “FACE”, and also the air outlet - Problem in air flow changeover
accordingly. (Observe LED also.) vacuum solenoid or actuator

l Outlet air temperature becomes l Outlet air does not become cooler,
the lowest (blend air damper is much less the lowest temperature
closed). (blend air damper does not operate).
- Problem in blend air damper servo
motor

l Compressor comes into operation. l Compressor does not operate.

- Problem in air conditioner

l Air flow changes from introduction l Outside air is introduced.

of outside air to recirculation of - Problem in air selection damper
inside air. actuator

l Blower speed becomes “H” (H relay l Blower speed remains unchanged

closes). and H relay is inoperative.
- Problem in power transistor
- Problem in relay

4 Press air selection l Every depression of air selection l Beep sound is produced but lamp
switch twice and then causes beep sound and switch lamp does not light.
press AUTO switch. is kept lit in that while. - Blown lamp bulb
(Temperature setting Once AUTO switch is pressed, the
is 77°F.) air selection lamp goes off. l Neither beep sound is produced
nor lamp lights.
-Problem in switch

l On depression of air selection l Damper position does not change

switch, the damper position changes (but air flow indication changes).
from recirculation position to out- - Problem in recirculation/outside
side air position and vice-versa. air damper actuator

l If AUTO switch is pressed, damper

returns automatically to its original
position and indication also returns
to “AUTO”.
24-40 AIR CONDITIONING - Troubleshooting

Probable cause

l Second depression of switch causes

compressor to stop and switch lamp
and AUTO lamp to go off.

l When AUTO switch is pressed, l Compressor operates but condenser

ECONOMY switch lamp goes off and fan does not.
air conditioner comes into - Problem in condenser motor

l AUTO lamp goes off when any of the

switches is pushed.

l Air comes out from the outlets l Air flow direction does not change.
corresponding to pushed switch. - Problem in damper actuator

to switch position. setting the switch to different

positions (8 and&@).
- Problem in switch
- Pmroblem in wiring harness

l If AUTO mode switch is activated, l Fan motor does not operate in

air volume changes automatically both 8 and $3 positions.
- Problem in fan controller

- Broken harness

l When engine is cold, if AUTO mode l When AUTO mode switch is activated,
switch is activated, fan speed is fan turns at high speed even in cold
fixed to low speed for some while season or stays turning at low speed
after start of engine. even after the engine is warmed.
- Problem in water temperature switch
- Problem in water temperature switch
wiring harness
 AIR CONDITIONING - Troubleshootina 24-41

No. Action Normal operation Abnormal operation/

Probable cause

8 Check for AUTO mode l When the interior temperature l Neither touching the sensor with
function (interior sensor is touched with hand, the hand nor cooling it causes the
temperature sensor air flow mode becomes to FACE, results.
operation). the blend air damper moves to the - Problem in interior temperature
(Set AUTO mode switch coolest position and blower speed sensor
to ON; temperature changes to H level. The interior -Problem in wiring harness
setting is 77°F.) air recirculates under this condition. - Problem in controller
(If the system is in ECONOMY
* Touch interior tem- mode, the compressor comes into
perature sensor heat operation.)
sensing plate with hand
to warm it to 30°C l When the interior temperature
(86°F) or over. Then sensor is cooled down, the outside
cool the plate down to air is introduced, the blend air
10°C (50°F) or below. damper moves to the warmest posi-
tion and the air flow mode becomes
to FOOT. Also, the fan speed becomes
MH level. (If the system is in
ECONOMY mode, the compressor
stops.)

9 Check photo-sensor for l When the sensor is exposed to l No change results from action on
function. sunbeam, the outlet air temperature sensor.
(With the system in lowers. (Blower speed increases - Problem in photo-sensor
AUTO mode, set the in summer.) -Broken wiring harness
blower switch to AUTO - Problem in controller
position temperature l When the sensor is covered by hand, (Clean the photo-sensor.)
setting is 77°F.) the outlet air temperature rises.
Expose the photo-sensor (Blower speed decreases in
to sunbeam for checking. summer.)

10 Check engine coolant l When engine coolant temperature is l Blower motor speed is not fixed to
temperature switch for lower than 50°C (122°F). the blower L level even when engine coolant
operation. (With the speed is in L level and the air flow temperature is lower than 50°C
system in AUTO mode, mode becomes DEF. (122°F).
set the blower switch -Problem in controller
to AUTO position; -Problem in wiring harness
temperature setting.)
l When engine coolant temperature l Airflow remains in $9 mode.
* Cool the interior rises to 50°C (122°F) or higher, the -Problem in engine coolant temper-
temperature sensor heat blower speed increases and air flow ature switch
sensing plate down to mode becomes FOOT, FACE/FOOT or -Broken wiring harness
20°C (68°F) or lower. FACE. - Problem in controller
 AIR CONDITIONING - Troubleshooting

SYSTEM DIAGNOSTIC PROCEDURE

[Main diagnostic flow)

(When selt-dragnosis did not solve

START ..... ..- _. ... ..__._
.... .._.._. ...__-...-..._.f. .. ... ... ..~.L.I..... The prob,em,)

No
Does AUTQ lamp light when
ignrtron key is set to ON?

Yes ( (-$)
‘_
i
Go to Diagnosis 3
between 8 and $j 9 P.24-45
swatch posrtron!

Yes

Can set temperature be

changed between 18 and 32°C
(65 and 90”FV

/ Is outlet arr cool at \ No

.I.i
18°C (65°F) setting?
i
,

Do compressor, condenser
fan and radiator fan
operate normally and engine
operate at fast idle speed?

t
Does recirculatronioutside
air damper position
change normally?
I
Yes

See next page

 AIR CONDITIONING - Troubleshooting 24-43
Continued fro? previous page
\L3/
$
Does inside air sensor operate No
normally?

Does photo-sensor operate No

normally?
I

Does set temperature remain

in memory when ignition key is
set to OFF and ON repeatedly?

Yes
”
END
24-44 AIR CONDITIONING - Troubleshooting

Diagnosis 1

No Replace the fuse

Do ali other switch lamps Is IOA fuse in fuse +
block normal?

.~~
No Replace control box
Do self-diagnosis lamps > ~_ _~ ~~ --~
flicker?
\ /
Yes
:
Replace AUTO lamp
 AIR CONDITIONING - Troubleshooting

Yes

rL Check wiring

Replace control
harness

panel

\ No I I
( Blower H rel,a;Terates? )-I Replace relay

Replace wiring harness

24-46 AIR CONDITIONING - Troubleshooting

Diagnosis 5 I

Is beep sourrd produced

hen UP side of
set switch IS pressed? [Beep sound stops when
32°C (90°F) is exceeded.]
Yes
!

/ Is beep sound produced \ ,,,, I Reptace control panel I

/ wheri DOWN .side of \ I’” -
temperature set switch is
pressed? [Beep sound st
ting is changed
Yes ature below 18 “C (65”F).l
! \ No
Is digital display available? ’
(Lamp check is in
Yes

1 Reprac% wirrng harness 1

 AIR CONDITIONING - Troubleshootincl 24-47

Diagnosis 7

Outlet air is not warm

enough even with tem-
perature setting at 90°F

No
Replace power control
assembly
(Potentiometer pointer
’ Yes swings to MH side.)

--+ Replace wiring harness

Is rod lin~v~r~ damper Link rod to damper lever

Yes

Does damper move too Repair blend air damper to

slowly? I eliminate sticky movement
I [Damper can be moved
Yes with a 10 N (2 Ibs.)
or less force when rod
is unlinked.]

Does hot water valve open No Replace hot water valve

or close normally?
I
Yes
I
 ,l. .__~

24-48 AIR CONDITIONING - Troubleshooting

a
Replace power control Ezzs

(Potentiometer Dointer .-
Yes swings to MC side.)

Replace wiring harness

 AIR CONDITIONING - Troubleshootincl 24-49

Compressor, condenser fan

and radiator fan do not
operate, and engine does
not run at fast idle speed.

pLizgGqNo ,,i__yra_l~ I 1
Yes

( Does air;;:plyer relay p Replace control box

3

Yes

-+I Replace air conditioner

relay

Replace fuse

Yes

Replace relay

(7,. , Replace HP and LP switches -

YC / 1 \ No I I
I Replenish refrigerant

(’ belt in noF)“’ , Adjus:,,“kte;;pn or

See next page See next page

24-50 AIR CONDITIONING - Troubleshooting

Continued from Continued from

previous page previous pa<
t

Is condenser Yes
fan motor >“” ,(y) Is condenser relay normal? No , Replace relay __
normal?

Does therm0 control - Does frosting occur!-1 Turn control box therm0
function normallv? volume to H
I I I
Y@S Yes
I

Insufficient cooling? No Turn control box thermo

+
volume to C
 AIR CONDITIONING - Troubleshooting 24-5 1

Diagnosis 13

No Reprace control panel

Air selection
switch normal?
I

1, 7 Replace wiring harness

* Harness on switch side

Is vacuum buildup ) No ,(W)

sufficient?

Yes

Does solenoid valve No Replace solenoid valve

>
operate normally?

( dam:$;z;F)
! No
Ll

,
Check wiring harness

Replace actuator
 --

24-52 AIR CONDITIONING - Troubleshooting

I Diagnosis 15 I

Incorrect air flow damper

operation
I

No Replace mode switch

Do mode switches operate
correctly!

Yes

- Replace cdntrol box

Is vacuum buildup Check hose or check valve

Tufficient? l---l

Does solenoid valve No Replace all solenoids_ _

>
operate correctly? (three PCS.)

Yes
 AIR CONDITIONING - Troubleshootincr 24-53

Diagnosis 17

I
NO
Do self-diagnosis lamps
flicker correctly?

I Yes

I Diagnosis 19 I

Photo-sensor functioning
improperly

<

Does system respond to , ) Replace sensor

sunbeam radiation?
24-54 AIR CONDITIONING - Troubleshooting

Diagnosis 21
I

Does switch close at

engine coolant temper-
ature of 50°C (122”FJ
or higher?

Yes
!
Does wiring harness No
conduct?

Yes
I
Does preset engine Replace control box
coolant temperature resume -
after switch is opened? [Switch is opened when
interior temperature is
Yes lower by 3°C (5.4”F)
than set temperature.]
 AIR CONDITIONING - Troublesliooting

I Diagnosis 23 I

When ignition key is turned

to OFF then back to ON,
temperature setting is
different between before
and after key operation.

Y
No
Is backup power supply in
circuit?

Yes
I
No
Is battery voltage 9V or
higher?

I Yes

I Replace control box I

24-56 AIR CONDITIONING - Troubleshooting

TROUBLESHOOTING TABLE

Symptom

Check item _

(6)

4 I Blower does not run 1.i)

13
;
Air inlet swrtchrng damper
-
7 Air outlet switching damper
does not operate
-
3 Pusher fan does not operate ’ !3
when air conditioner is
operating

3 Temperature setting changes

when iqnition switch is turn-
ed to “OFF” position and
then back to “ON” position

1. 1.~)Indicates items reyurnng check (number In circle Indicates check order).

2. Use selt-draonosrs and measure terminal voltage for control unit check.
 Symptom Probable cause Remedy

1. “AUTO” lamp Open No. 12 fuse Replace fuse

does not illumi-
nate when ignition Faulty control unit Check diagnosis output
switch is turned
to “ON” position Faulty full auto air conditioner panel assembly Replace full auto air conditioner panel
assembly

Burnt-out “AUTO” indicator bulb Replace “AUTO” lamp bulb

Open harness between full auto air conditioner Correct harness

panel assembly and control unit

2. Inside tempera- Faulty control unit Check diagnosis output

ture does not rise
(no hot air) Faulty interior temperature sensor input circuit

Faulty foot area temperature sensor input circuit

Faulty thermistor input circuit

Faulty blend air damper potentiometer input

circuit

Faulty blend air damper control motor Replace blend air damper control
motor

Inadequate connection between blend air damper Correct connection

control motor lever and blend air damper

Seized blend air damper Correct blend air damper

Water valve failure Replace water valve

Open harness between blend air damper Correct harness

control motor and control unit

3. Inside tempera- Faulty control unit Check diagnosis output

ture does not drop
(no cool air) Faulty upper interior temperature sensor input
circuit

Faulty lower interior temperature sensor input

circuit

Faulty thermistor input circuit

Faulty blend air damper potentiometer input

circuit

Faulty blend air damper control motor Replace blend air damper control
motor

Inadequate connection between blend air damper Correct connection

control motor lever and blend air damper

Seized blend air damper Correct blend air damper

NOTE
When engine coolant temperature is below 50°C (122°F). blower speed is held at LOW.
24-58 AIR CONDITIONING - Troubleshooting

or compressor

ness between blower switch Correct harness

operate

ull auto air conditioner panel

 AIR CONDITIONING - Troubleshooting 24-59

Symptom Probable cause Remedy

6. Air inlet switching Open harness between full auto air conditioner Correct harness
damper does not panel assembly and control unit
operate
Open harness between air inlet switching Correct harness
vacuum solenoid valve and control unit

7. Air outlet switch- Faulty control unit Check diagnosis output

ing damper does
not operate Defective vacuum solenoid valve Replace vacuum solenoid valve

Defective or disconnected vacuum hose Check or replace vacuum hose

Defective vacuum system including vacuum Check or replace vacuum system

tank

Faulty full auto air conditioner switch Replace full auto air conditioner panel
(mode selection) assembly

Faulty air outlet switching control vacuum Replace air outlet switching control
actuator vacuum actuator

Inadequate engagement between cam and Correct engagement or adjust

damper link or incorrect adjustment

FACE/DEF or FACE/FOOT damper failure Correct FACE/DEF or FACE/FOOT

damper

Open harness between full auto air conditioner Correct harness

panel assembly and control unit

Open harness between air outlet switching

vacuum solenoid valve and control unit

3. Pusher fan does Faulty power relay (for pusher fan) Replace power relay
not operate when
air conditioner is Faulty therm0 sensor No. 2 Check or replace therm0 sensor
operating (vehicles with an intercooler)

Fault,y pusher fan motor Check or replace fan motor

Faulty pressure switch Check or replace pressure switch

(vehicles with an intercooler)

3. Temperature setting Faulty control unit Check diagnosis output

changes when
ignition switch is Insufficient battery charge or faulty battery Recharge, adjust specific gravity or
turned to “OFF” replace battery
position and back
to “ON” position Open harness between ignition switch and Correct harness
control unit
24-60 AIR CONDITIONING - Troubleshooting
Ed
3
SELF-DIAGNOSIS
The self-diagnostic function provides indication of abnormal ~1
conditions with microcomputer, sensors and potentiometer ~_
wiring (broken wire, short circuit, etc.) and also an automatic
control function by which a_ failure is compensated for by
substitution of value to minim-Fe the trouble resulting from the
failure.
 AIR CONDITIONING - Troubleshootina 24-61
SELF-DIAGNOSIS INDICATIONS

io,de Diagnosis display pattern Malfunction Probable cause Failsafe

(AK condition)

0 Normal - -

‘Zv” m Continuous

2 Open or shorted l Disconnected interior Set interior temper-

interior temper- temperature sensor connector ature sensor input
ature sensor l Open or shorted internal wir- signal at 25°C
1;; Jjl nn m ;;“,“,‘;i”,rw;;;gnsor . ;fe;yrt;;~;t;d~~s~;n (77°F)

interior temperature sensor

circuit or disconnected
connector

3 Open or shorted l Disconnected foot area Set foot area temper-

foot area temper- temperature sensor connector ature sensor input
ature sensor l Open or shorted internal wir- signal at 25°C

‘zt J/Jfj nM 1 Et!iLftJ)!$ier- . ~%&Sothaor~~~“~~ (77”F)

foot area temperature sensor

circuit or disconnected
connector

4 Open or shorted l Disconnected thermistor Set thermistor

wiring of thermistor connector input signal at 1“C
1;; mn nm c&r-LnlkokoJ;ulty l Open or shorted internal (33.8”F) and turn
wiring of thermistor off compressor
l Open or shorted harness in
thermistor circuit or
disconnected connector

6 Open or shorted l Disconnected blend air damper Set blend air damper
blend air damper potentiometer connector at MAX HOT position
potentiometer l Open or shorted internal
circuit or faulty wiring of blend air damper
I:; mfl nr t&y$??;;y potentiometer
l Open or shorted harness in
blend air damper poten-
tiometer circuit or discon-
nected connector

l Replace control unit -

l~~~~~~;;stantly ~~tr~“luf$ure Of

12v
Constantly
ov ov

NOTE
1. Code Nos. 1, 5, 7 and 8 are intentionally omitted.
2. If two or more troubles are caused at the same time, one with the largest code No. is displayed,
3. The contents of troubles are stored until the ignition switch is turned off.
 ..-_ -. _

24-62 AIR CONDITIONING - Troubleshooting

DIAGNOSIS DISPLAY PATTERN 2

Disconnect interior temper- Faulty interior temperature Replace interior temperature

ature sensor connector. No ,ri 1 sensor
Is interror sensor temper- 9
ature resrstance normal?
(Refer to P.24-34.)
I
Yes

Connect interior temperature Open harness between.

sensor connector. interior temperature sensor
Does approx.~ 125V appear No and control unit
between A-16 terminal and
ground of control unit

I
I
at-a room temperature
25°C (77”F)?
of
I

Yes

1 , Inadequate control unit

connector contact or faulty
control unit

DIAGNOSIS DISPLAY PATTERN 3

Replace foot area

temperature sensor

I Yes

Connect foot area temper- Open harness between foot

ature sensor connector. Does area temperaturee
approx. 1.25V appear betweer No > sensor and control unit-
A-6 terminal and ground
of control unit at a room
temperature of 25°C (77”F)?

Yes
 AIR CONDITIONING - Troubleshooting 24-63
DIAGNOSIS DISPLAY PATTERN 4

Yes
4

Connect thermistor
connector. Does approx.
No ,T! (-T-r
1.25V appear between A-19
terminal and ground of
control unit at a room
temperature of 25°C (77”F)?
I
Yes

I
I Inadequate control unit
connector contact or
I I Check and correct connector
> contact or replace control
I
faulty control unit unit
1

DIAGNOSIS DISPLAY PATTERN 5

Yes

Connect blend air damper Open or shorted harness Correct harness

potentiometer connector. between blend air damper
Does approx. 2.5V appear No potentiometer and control
between A-15 terminal and > unit >
ground of control unit when
potentiometer is set to
MAX COOL position?

Yes

1 , Inadequate control unit

connector contact or faulty
control unit
i
24-64 AIR CONDITIONING - Troubleshooting
c.
as
CONTROL UNIT TERMINAL VOLTAGE TABLE B-
PRECAUTIONS ON TERMINAL VOLTAGE CHECKING ._ E
Arrangement of control unit terminals I. Before disconnecting or=:reconnecting the control unit -; Em
connector, beg sure to disconnect the battery terminals. .
2. Measure the~terminal voltage between each terminal and
ground (body) or 6 terminal with the control unit connector rz
connected.
When measuring the terminal voltage, be sure to observe ._ g
the following. -
(1) Make surethat the tester is set in the voltage (V) range. .; -g-
2OY 159; 7
(2) Do not a-cFidentally short the terminal to be measured E-
wrth other terminals. _
Use of a tester in resrstance (ohm) range or shorting 7
between termrnals could cause damage to ejectronrc ~I
parts In the control unit.
3, Make sure that the corpctors are connected zecurely.
Pay partrcularattentron to the controller assembly (mcluding ~~
the panel) connector connectrons. -~
 AIR CONDITIONING - Troubleshooting 24-65

Pin
No.

Photo-sensor (input)

10

Voltage changes with

dimmer control settin

11

12

13

14 Control panel display power

Ifrom light controller)
When lighting switch is ON Voltage changes with
dimmer control setting

15 Sensor power - Approx. 2.5V

16 nterior temperature sensor When room temperature is 25°C Approx. 1.25V

(77°F)

When harness is open ov

24-66 AIR CONDITIONING - Troubleshooting

r outlet mode selection

cuum solenoid valve

vacuum solenoid valve

When OFF (other than above)

 AIR CONDITIONING - Troubleshooting 24-67 .-II=

CIRCUIT DIAGRAMS

Interior
temperature sensor Vacuum solenoid valve
;;\ Foot area
temperature
sensor

L-
c-22 B-71
0
0
I

Blowe
motor ,“I ,I -
starter I D n.4.l \*o

cutout
relay B-67

Blowe

relay

‘ower
transistor

lowe
iotor B-70
r

.-. .-. ..-

~,L
(I) The circuit lines ended with number 61,
ti) and so on are in continuation to those
with the corresponding number on p.g 5 b
opposed page. (i.e.. the line @ on the 0305 c2
l-m+
left-hand page is connected to the line@ Light controller
on the right-hand page.)
(2) For details of grounding points (ex.: R),
refer to page 8-10.

Wire color code

B: Black Br: Brown G: Green $: gjg/ L: Blue Lg: Light green
LI: Light blue 0: Orange P: Pink Y: Yellow W: White
 AIR CONDITIONING - Troubleshooting

lgnitron switch
wYG LiiE?l
Servo motor /f--Y y
En_alne coolant- Photo 1
temperature gauge sensor
?Itllt

3-LR ,-,3-:LR-
9,J.25-BI
- a__. . ! j ! I

\ DID j I I I I I I l I I I I I I I I I I
me , ” I I I I I I I I I I I I

B-76 1 II - B-75

Self-dragnosrs
connector

I
-Automatic air conditioi-& !$ntfol unit 1

37Y!S32

~- D-07 ..-
 AIR CONDITIONING - Troubleshooting 24-69

Radiator Thermo- Radiator DUElI Engine

Thermo- fan motor sensor fan motor F’cis;;re g;p;;re Condenser coolant
sensor No. 1 No. 2 No. 2 fan motor temperature
No. 1 switch
r;
L
m Magnet
A-58 A-61 A-6C A-89
-I-3
clutch
:
II a z
:Li
cl -, 0.85-BMAq,,

L
-
f

q0
“:
In
t 0

cu

T
. -
.
-/
s
El

conneCtor

Radiator Radiator fan Radiator fan , Condenser Magnet

fan motor air conditioner air conditioner fan motor clutch relay
.-. ,.,
relay No. 2 relay (2) relay (I) relay

@ pf g/q gij iii 37y58:

.%.I92 .%.I$52
24-70 AIR CONDITIONING - Troubleshooting

AUTOMATIC AIR CONDITIONING SYSTEM CONTROL PARTS LAYOUT

ENGINE COMPARTMENT
tia El

3adiatpr fan air, I_~

\

‘/Jwn 18Y1824
 AIR CONDITIONING - Troubleshooting

INSTRUMENT PANEL
q

Automatic air

x
\

’ I
’ 1646
20Y
’

ransistor 2OY1645

F M Thermistor

Blower motor \’ m
Foot area temperature H starter cutout4 Blower motor
sensor 36YOl4 relav ” - hiah sDeed relav 20)
24-72 AIR CONDITIONING - Troubleshooting

ROOF

1
@zizz3
E
Interior temperature sensor
>
 AIR CONDITIONING - Safetv Precautions 24-73
SAFETY PRECAUTIONS N24PAAA

The refrigerant used in all air-conditioning installations is R-l 2. It is transparent and colorless in both the liquid
and vapor state. Since it has a boiling point of -29.8”C (-21.7”F), at atmospheric pressure, it will be a vapor at
all normal temperatures and pressures. The vapor is heavier than air, non-flammable, and nonexplosive. It is
nonpoisonous except when it is in direct contact with open flame. It is noncorrosive except when combined
with water. The following precautions must be observed when handling R-12.
Caution
Wear safety goggles when servicing the refrigeration system.
R-l 2 evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything
it contacts. For this reason, extreme care must be taken to prevent any liquid refrigerant from contacting the
skin and especially the eyes.
Always wear safety goggles when servicing the refrigeration part of the air-conditioning system. Keep a bottle
of sterile mineral oil handy when working on the refrigeration system. Should any liquid refrigerant get into the
eyes, use a few drops of mineral oil to wash them out. R-l 2 is rapidly absorbed by the oil. Next, splash the
eyes with plenty of cold water. Call your doctor immediately even though irritation has ceased after
treatment.
Caution
Do not heat R-12 above 52°C (125°F).
.ln most instances, moderate heat is required to bring the pressure of the refrigerant in its container above the
pressure of the system when charging or adding refrigerant. A bucket or large pan of hot water not over 52°C
(125°F) is all the heat required for this purpose. Do not heat the refrigerant container with a blow torch or any
other means that would raise temperature and pressure above this temperature. Do not weld or steam clean
on or near the system components or refrigerant lines.
Caution
Keep R-12 containers upright when charging the system.
When metering R-12 into the refrigeration system, keep the supply tank or cans in an upright position. If the
refrigerant container is on its side or upside down, liquid refrigerant will enter the system and damage the
compressor.
Caution
Always work in a well-ventilated room.
Good ventilation is vital in the working area. Always discharge the refrigerant into the service bay exhaust
system or outside the building. Large quantities of refrigerant vapor in a small, poorly ventilated room can
displace the air and cause suffocation.
Although R-12 vapor is normally nonpoisonous, contact with an open flame can cause the vapor to become
very poisonous. Do not discharge large quantities of refrigerant in an area having an open flame. A poisonous
gas is produced when using the flame-type leak detector. Avoid inhaling the fumes from the leak detector.
Caution
Do not allow liquid refrigerant to touch bright metal.
Refrigerant will tarnish bright metal and chrome surfaces, and in combination with moisture can severely
corrode all metal surfaces.
 1, i

~~- _~
P ~- _ ----“I

24-74 AIR CONDITIONING - Service Adjustment Procedures

SERVICE ADJUSTMENT PROCEDURES N24FDAA

MANIFOLD GAUGE SET INSTALLATION

Suction gauge Discharge gauge

Discharge port
I

Suction port

2OY1630

Manifold Gauge Valves - should be closed when connectrng

the manifold gauge set to the servrce port of the compressor
and the drscharge line% The suction gauge valve at the left is ;
opened to provrde a passagebetween the suctron gauge and
the center manrfold outlet. The discharge gauge valve at the .-
right IS opened to provide a passage between the discharge __
pressure gauge :and the center manifold outlet.
Detailed rnstructCons for proper use of the gauge set manifold z
dre contained in the text covenng each test and service
operation employrng these gauges. _z
Suction Gauge - the lett side of the manitold~set is calibrated
to register 0 to -100 kPa (0 to 30 in. of vacuum) and 0 to 1,000 ‘I
kPa (0 to 150 psj). This gauge IS connected to the suction port -
of the compressor.
Discharged Gauge - the rrght of the manifold set IS calibrated
to regrster 0 to 2,100 kPa (0 to 300 psi). For all tests this gauge ;
IS connected to the discharge port of the system
Center Manifold Outlet - provides the necessary connection
for a long service hose used when discharging the system,
using a vacuum pump to “pull a vacuum” before charging the __
system, and for connecting the supply of refrigerant when
chargrng the system.
AIR CONDITIONING - Service Adjustment Procedures 24-75
TESt PROCEDURES N24FEAD

RECEIVER DRIER
The receiver drier assembly consists of; Drier reservoir,
Refrigerant level sight glass and Fusible plug.
To Test the Receiver Drier
(1) Operate the unit and check the piping temperature by
touching the receiver drier outlet and inlet.
(2) If there is a difference in the temperatures, the received
drier is restricted.
2OY 1638 Replace the receiver drier.
SIGHT GLASS REFRIGERANT LEVEL TEST
The sight glass is a refrigerant level indicator. To check the
refrigerant level, clean the sight glass and start the vehicle
engine. Push the air conditioner button to operate the com-
pressor, place the blower switch to high and move the
temperature lever to extreme left. After operating for a few
minutes in this manner, check the sight glass.
(1) If the sight glass is clear, the magnetic clutch is engaged,
the compressor discharge line is warm and the compressor
inlet line is cool; the system has a full charge.
(2) If the sight glass is clear, the magnetic clutch is engaged
and there is no significant temperature difference between
compressor inlet and discharge lines; the system has lost
some refrigerant.
(3) If the sight glass is clear and the magnetic clutch is
disengaged; the clutch is faulty or, the system is out of
refrigerant. Perform low pressure switch test to determine
condition. Check low pressure switch, and clutch coil for
electrical continuity.
(4) If the sight glass shows foam or bubbles, the system could
be low on charge. Occasional foam or bubbles are normal
when the ambient temperature is above 43°C (110°F) or
below 21°C (70°F).
Adjust the engine speed to 1,500 rpm. Block the air flow
thru the condenser to increase the compressor discharge
pressure to 1,422 to 1,520 kPa (206 to 220 psi). If sight
glass still shows bubbles or foam, system charge level is
low.
The refrigerant system will not be low on charge unless
there is a leak. Find and repair the leak. If the leak can be
repaired without discharging the system an oil level check
is not necessary. Use the procedure for correcting low
refrigerant level found in the Refrigerant System Service
Procedure Section.
FUSIBLE PLUG
In 105°C (221°F) ambient, the fusible link melts and the ’
refrigerant in the system is discharged.
Once the fusible link has melted, it cannot be reused.
Therefore, install a new fusible link and charge the system with
refrigerant.
 --
-
E

AIR CONDITIONING - Service Adjustment Procedures E

DUAL PRESSURE SWITCH e

.
Dual pressure swlfch IS rnstalled to the lrqurd lrne at the receiver
outlet.
This combrnes the high pressure switch with low pressure
swrtch.

LOW PRESSURE SWITCH

Dual pressure switch
The low pressureswitch, is w_ired in series with the magnetic .I
clutch. It cuts off the electricalpower supply to the clutch when ;
refrigerant pressures drops below the control point of the
switch.
Whenever the system is inactivated by the low pressure switch
due to refrigerant loss, the refrigerant oil may have been lost. g
Therefore, to prevent damage to the comp%ssor due to -.- Z
operation without sufficient. lubrication, the_ !eak must be
repaired and the compressor oil [ 15 cc (0.5 fl.oz.)] added before
L 2OY 16.38 final charge of the system.
The switch is a Sealed, factorycalibrated unit. No_~attempt shall
be made to adjust or otherwrse repair IL If It IS found to be 1
faulty It must be replaced.
TO Test the Low Pressure Switch (Engine Off)
(1) Jump wire leads.
(2) Press the A/C switch an> blower switch on.
(3) Momentarily turn the rgnrtron switch on (do not crank the ~;
engine), listen for the clutch engaging.
(4) It the clutch does not engage, the thermistor, coolant --
temperature swrtch, high.~pressure switch-or fuse may be r
faulty.
(5) If clutch engages, connect the manrtold gauge set and read
pressure. At pressure of 206 kPa (3U psi) or above, switch mA
must actuate the clutch.
If the pressure IS below 2@ kPa (30 PSI), retrrgerant system
IS low In charge. For correctjve action refer to refrigerant
leak repair procedure.
(6’1 Reconnect wire on swrtt-h and perform step number 3. -1
If the clutch does not -engage, discharge the system,
replace the switch. andrecharge the system.

HIGH PRESSURE SWITCH

I he high pressure switch cutsott the electrical power supply to
the magnetic clutch when refrrgerant pressure rises-above the~:I
setting.
This switch may -operate when the flow of air across the
condenser IS obstructed by the dead leaves, newspaper, etc.
blocking the condenser surface, or the refrigerant system is
overcharged.
 AIR CONDITIONING - Service Adiustment Procedures 24-77
To Test the High Pressure Switch (Engine Off)
(1) Jump the wire leads.
(2) Press the A/C switch and blower switch ON.
(3) Momentarily turn the ignition switch on (do not crank the
engine), and listen for the clutch engaging.
(4) If the clutch does not engage, the thermistor, low pressure
switch, coolant temperature switch, or fuse may be faulty.
Correct fault.
(5) If clutch engages, connect the manifold gauge set and read
pressure. At any pressure of 2,010 kPa (291.5 psi), the
switch must be off.
(6) If the clutch does not engage, replace -the switch.
THERMISTOR
The thermistor turns on/off the compressor clutch depending
on the temperature of the air flowing through the evaporator
outlet.
When the air temperature at the evaporator outlet rises due to
reduced air flow rate, clogged evaporator fin or insufficient
refrigerant, the thermistor detects it and sends the signal to the
automatic air conditioner to turn on the compressor clutch.
If the evaporator fin surface is covered with frost, the faulty
thermistor is suspected.
To Test the Thermistor
(1) Disconnect the thermistor connector at the evaporator case
10 and measure the resistance with an ohmmeter. If the
resistance value is within the range shown in the illustra-
9 tion, the thermistor is in order. If not, replace the thermis-
a,6
2 tor.
s4
w
(2) If the thermistor is in order, the automatic air conditioner
‘g 2 2OUO298 may be faulty. Replace it.
K

Temperature “C (“F) 20110292

ENGINE COOLANT TEMPERATURE SW1TCl-i

The engine coolant temperature switch is located on the
thermostat housing, and is connected to the clutch in series.
When the coolant temperature in the radiator reaches above
113°C (235”F), it turns the compressor OFF. This is to prevent
engine overheating.
To Test the Engine Coolant Temperature Switch
(1) Remove wire from engine coolant temperature switch and
jump leads together.
(2) Press the A/C switch and blower switch ON.
(3) Momentarily turn the ignition switch ON (do not crank the
engine), and listen for the clutch engaging.
(4) If the clutch does not engage the thermistor, low pressure
switch, high pressure switch wiring or fuse may be faulty.
(5) If clutch engage, replace the switch.
24-78 AIR CONDITIONING - Service Adjustment Procedures

PHOTO-SENSOR
The photo-sensorsenses the intensity of sunshine and when it
is high, has the fan speed increased, preventing the room =I
temperature from becoming high. .-
To Test the Photo-sensor
In the sunshine, cover the photo-sensor with a hand. If the fan
speed is reduced, the photo-sensor is in order.-,lf not,replace.

MAGNETIC CLUTCH
(1) Disconnect the w-iring to-the magnetic clutch. ~~
(2) Connect battery (+) voltage directly to the wiring for the .r
magnetic clutch.
(3) If the magnetic clutch is normal, there will be a “click”. If -:~
the pulley and armature do not make contact (“clicJ”1 there --
is a- malfunction.

2OYl616
-x
. F

:a

COMPRESSOR
Suction Discharge Discharge service port
gauge gauge \ I (1) Install the ma~nifold gauge set, and run the air conditioner.
(2) If a pressure of approx. 490 kPa (71 psi) is indicated on the ._
suction gauge side and a pressure of approx. 883 kPa (128 -r
psi) is indicated on the discharge gauge side, the:zompres- +s
sor has abnormal compression. -
Replace the compressor.

(3T~~If a pressuteot 294 to 392 kPa (33 to 59 psi) is rndrcated-on ~_

Discharge the suction gauge side and a pressure of approx. 1,961 kPa II
gauge (284 psi) is indicated on-the discharge gauge side, it is
suspected that air is present in the air conditioning system. -
Discharge the system, evacuate and recharge with speci- .-
fied amount ~of refrigerant.
Recharging condition
o Air temperature sucked in cooler (evaporator):
30 - 35°C (86 - 95°F)
e Engine speed: 2,000-rpm
e Blower speed: High -~
(4) During operatron ot the arr condrtroner, cold arr may stop
Suction Discharge flowing afterthe elapse of time and this state is maintained
w-w gauge before cold air flows out a~gain. If cold air stops flowing out
with negative pressure indicated on the suction gauge side
and a pressure of 588 to980 kPa (85 to 142 psi) indicated
on the discharge gauge side, it is suspected that water is
present in the air conditioning system.
Discharge the system. Replace receiver drier.
Evacuate and check for leaks, and recharge with specified
amount of refrigerant.
 AIR CONDITIONING - Service Adiustment Procedures 24-79
TESTING THE SYSTEM FOR LEAKS N24FFAA

A leak is likely to occur where two components are connected

together. See the illustration for possible locations.
The Leak Detector Torch is a butane gas-burning torch used to
locate a leak in any part of the refrigeration system. Refrigerant
gas drawn into the sampling or “sniffer” hose will cause the
flame to change color in proportion to the size of the leak. A
very small leak will produce a flame varying from yellowish-
green to bright green. A large leak wjll produce a brilliant blue
flame.
Caution
Do not use the lighted detector in any place where
explosive gases, dust or vapors are present. Do not
breathe the fumes that are produced by the burning of
refrigerant gas. Large concentrations of refrigerant in the
presence of a live flame become dangerously toxic.

2011652

Leak detector torch Refrigerant If the flame remains bright yellow when the tester is removed
Compressor leak tester from a possible leak point, insufficient air is being drawn in
through the sampling tube, or the copper reaction wire is dirty.
(1) Assemble leak detector as shown. Be sure detector is
seated tightly over torch gasket.
(2) Holding torch upright, screw-in butane charger (clockwise)
until punctured. (Do not use force.)
(3) Screw-out butane charger (counterclockwise) about l/4
turn.
(4) Point torch away from body - then light escaping gas with
match. Always keep torch in upright position.
(5) Adjust flame by turning cartridge in or out as required.
Electric leak tester (6) Allow 30 seconds to heat copper reaction wire.
(\
Caution
Never remove butane charger while torch is lighted or
in the presence of any open flame.
(7) Examine all tube connectors and other possible leak points
by moving the end of the sampling hose from point to point.
Always keep torch in upright position. Since R-12 is heavier
than air, it is good practice to place the open end of
sampling hose directly below point being tested. Be careful
not to pinch sampling tube since this will shut off air supply
2OUO338
-I to flame and cause a color change.
(8) Watch for a change in the color of the flame.
Small leaks will produce a green color and large leaks a
bright blue- color. If leaks are observed at tube fittings,
tighten the connection, using the proper flare wrenches,
and retest.
NOTE i
An electric leak tester which sounds to alarm also be used.
24-80 AIR CONDITIONING - Service Adjustment Procedures k .-~

PERFORMANCE TEST N24FWAA

Dry bulb thermometer Air temperature in test room must be 21°C (70°F) minimum for
this test.
(I) Connect a tachometer and manifold gauge set.
(2) Set A/C controls to A/C, panel temperature lever on
RECIRC, and blower on high.
(3) Start engine and adjust R.P.M. to 1,000 with AC clutch
,,-A- engaged.
(4) Engine should be warmed up with doors, windows, and
Dry bulb thermometkr
hood open.
TOY %Jt (5) Insert a thermometer in-the left center A/C outlet and ~.
aperate the -engine for 5minutes.
(6) Note the discharge art- temperature.
NO-E
If the clutch cycles, take the readrng before the clutch
drsengaqes.
Performance Temperature Chart

Leak detector torch Refrigerant REFRIGERANT LEAK REPAIR PROCEDURE N24FHAO

Cornwressor -f-L- leak tester LOST Cl-fARGE

If the system has lost all charge due to a leak: ==
(1) Evacuate ths~system. (See procedure,)
(2) Charge the -system with approximately one pound of em
refrigerant.
(3) Check for leaks.
(4) Discharge the system.
(5) Repair leaks.
2OU031E
(6) Replace rec%!ver drier.
,--
Caution
Electric leak tester C, Replacement filter-drier units must be sealed while in
storage. The drier used in these units will saturate
water quickly upon exposure to the atmosphere. When
installing a drier, have all tools and supplies ready for
quick reassembly to avoid keeping the system open
any longer than necessary.
(7) Evacuate and charge the system.

2OUO338
AIR CONDITIONING - Service Adjustment Procedures 24-81
LOW CHARGE
If the system has not lost all of its refrigerant charge; locate and
repair all leaks. If it is necessary to increase the system
pressure to find the leak (because of an especially low charge)
add refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the procedure for
correcting low refrigerant level.

CORRECTING LOW REFRIGERANT LEVEL

Since the refrigeration system is completely sealed, refrigerant
level will not be low unless there is a leak in the system.
Before adding refrigerant when the cause of low level is not
known, the system should be tested for leaks. Assuming that
leaks have been corrected without discharging the system,
proceed with partial charge.
Install and connect manifold gauge set.
(1) Close both gauge set manifold valves.
(2) Connect the suction gauge test hose to the suction port of
the compressor. Connect the discharge gauge test hose to
2OY1619 the discharge port.
(3) Connect one end of long test hose to center .manifold
outlet, other end to refrigerant dispensing manifold.
(4) Close two dispensing manifold valves and open rema~ining
dispensing manifold valve. Remove protective cap from
opened valve.
(5) Screw a can of R-12 to the opened manifold valve. Be sure
gasket is in place and in good condition. Tighten refrigerant
can and manifold locking nut to insure a good seal. Do not
overtighten. 8 to 11 Nm (6 to 8 ft.lbs.) is sufficient if gasket
is in good condition.
(6) Turn manifold valve (above the refrigerant can) completely
clockwise to puncture the can. This closes the valve and
seals the refrigerant in the can.
Caution
Never heat small cans of refrigerant over 52°C (125°F) as
they may explode.
(7) Place the refrigerant in a large pan of water heated to 52°C
(125°F). Place pan of water-containing the refrigerant can on
an accurate scale so the amount of refrigerant added can be
weighed. Open the refrigerant manifold valve.
(8) Purge all air from test hoses. Air in the system will be
trapped in the condenser causing abnormally high dis-
charge pressures and interfering with condensing of the
refrigerant.
(9) Slightly loosen both test hoses at the gauge set manifold.
Tighten the hoses as soon as the air is purged.
(10)Slightly loosen charging hose connection at gauge set
manifold. This will purge air from the charging hose. Tighten
connection as soon as air is purged.
(1 l)With vehicle windows open and hood up, operate engine at
1,500 rpm and jump the low pressure switch terminals
located on the receiver drier so the clutch will remain
engaged.
(12)Place air conditioner control on A/C and place the blower
switch on high.
24-82 AIR CONDITIONING - Service Adjustment Procedures

(13)lf necessary, block the condenser to malntatn a discharge

pressure ot 1,422 to .i ,520 kPa (206 to 220 PSI). System -.
must be charged through-the evaporator suction service
ports as tallows:
ia) Slowly open the sucmn service gauge valve.
Meter tlow ot retngerant by adlustIng the suction
service gauge valve so that pressure reg-rsrered at the
?llctlon service gauqe does not exceed 345 kPa (50 psi).
Keep retngerant contatner uprrght.
(b) Supply refrigerant gas until there IS no toam visible at
the sight glass. fhen.,Tdd 6 oz. ot refrigerant.
(c) Close the~~suctlon gauge valve.
Caution
Too much refrigerant in the system can cause
abnormally high discharge pressures. Care must be
used so that the exact recommended amount of
refrigerant is added after foam clears in the sight
glass.
(d) Close dlspenslng manifold valve. Remove test hoses I
And adapters trom the service ports ot compressor,
Install prolectlve caps at service porrs and reconnect ~~
wlrrng.
le) Check system pertormance. (P.24-80)

DISCHARGING THE SYSTEM

Since the air conditjoning refrderant system is pressurized, it ~.
will be necessary to completely discharge the system (in a well .y
ventilated area) before replacing any refrigerant component.
The procedure is as follows:
(1) tnstall manifold gauge set,Make sure the gauge set valves ;=
are closed before attaching the hoses tom the refrigerant
system.
(2) Install a long hose to the r6anifotd gauge set connector. Run =
this hose to the oil ..collector can near a shop exhaust ~
system.
A good oil collector can may be made from a large empty
cofTee can w?h-i plastic toip. Slit the plastic top in~the form
of a Y to make an entrance for the refrigerant hose and an
exit for the gas.
(3) Open the compressor discharge and suction liner pressure ~~
valves and blow the refrigerant into the oil collector can. _
Watch to make sure the-hose does not blow out of the
0.11collector can collector canA
(4) When the system has been completely discharged, mea- i-
sure the amaunt of oil collected in the can, The amount of __
2OY1618 oil measured--should be added to the refrigerant system
before it is recharged. Add new oil - discard the-used oil. =i
Caution
It is important to have the correct amount of oil in the
refrigerant system.
Too little oil WIII provide Inadequate compressor lubrication
And cause a compressor failure. Too much al WIII increase ._
discharge art- temperature. ..-
AIR CONDITIONING - Service Adiustment Procedures 24-83
When a DR6148 compressor is installed at the factory, it
contains 170 ml of refrigerant oil. While the air conditioning
system is in operation, the oil is carried through the entire
system by the refrigerant. Some of this oil will be trapped
and retained in various parts of the system.
When the following system components are changed, it is
necessary to add oil to the system to replace the oil being
removed with the component.
Compressor: 115 cc (3.9 fl.oz.)
Condenser: 25 cc (0.8 fl.oz.)
Evaporator: 35 cc (1.2 fl.oz.)
Line: 15 cc (0.5 fl.oz.)
Receiver drier: 0 cc (0 fl.oz.)

EVACUATING THE SYSTEM

Whenever the system has been ,opened to the atmosphere, it
is absolutely essential that the system be evacuated or
“vacuumed” to remove all the air and moisture. Air in the
refrigerant system causes high compressor discharge pres-
sures, a loss in system performance, and oxidation of .the
compressor oil into gum and varnish. Moisture in the re-
frigerant system can cause the expansion valve to malfunction.-
Under certain conditions, water can react with the refrigerant to
form destructive acids. It is necessary to adhere to the
following procedure to keep air and moisture out of the system.
(1) Install manifold gauge set. Make sure the gauge set valves
are closed before attaching the hoses to the refrigerant
system.
(2) Discharge the system slowly if the manifold gauge set
indicates pressure in the system.
(3) Connect a long test hose from gauge set manifold center _. - .
connection to vacuum pump.
(4) Open both manifold gauge set valves.
(5) Start the vacuum pump and operate until the evaporator
suction gauge registers at least -101 kPa (29.9 in. of I
vacuum).
If at least -101 kPa (29.9 in. of vacuum) cannot be obtained,
either the system has a leak or the vacuum pump is
defective. Check the vacuum pump. If the pump proves to
be functioning properly, the system has a leak. Charge the
system with one can (14 oz.) of refrigerant. Locate and
repair all leaks. Discharge the refrigerant and evacuate the
system.
(6) Continue to operate the pump for at least five minutes.
(7) Close manifold valves. Turn off the vacuum pump and
observe evaporator suction gauge for two minutes. The
vacuum level should remain constant.
If the vacuum level falls off, the system has a leak.
Charge the system with one pound of refrigerant. Locate
and repair all leaks. Discharge the system and repeat
evacuation procedure.
24-84 AIR CONDITIONING - Service Adjustment Procedures

CHARGING THE SYSTEM

The refrigerant system must have been evacuated using the
previous procedure before charging.
Charge using only R-l 2 refrigerant. R-12 is available in bulk ~I
tanks or small cans. Follow the safety precautions for handling
R-12 as listed in the beginning of this group.

2011627
-
CHARGING WITH SMALL CANS
When using drsposable cans_.ot this type, follow carefully the
can manufacturers Instructtons.
Caution
Never use these cans to charge into the high pressure side
of the system (compressor discharge port) or into a system
that is at high temperature, because the high system
pressures could be transferred into the charging can
causing it to explode.
Keep the refrigerant manrtold valves capped when not In use. i
Keep a supply of extra refrigerant-can-to-refngeran?Gmanifold
gaskets on hand so that gaskets can be replaced periodically.
This will insure a sood seal wrthout excessive tighter$ng of the L
can or the manifold nuts. _
(I 1 Attach center hose from manifold gauge set to-retngerant
dispensing manifold. Turn_ refrigerant manifold valves corn-
pletely counterclockwrseso they are fully open. Remove ’
protectrve caps from refrigerant manifold
(2) Screw refrrgerant cans rnro manifold. Be sure $nifold-to-c-
can gasket IS In place and In good condition. Tighten can
and manifold nuts to 8~0 1 i Nm (6 to 8 ft.&). =
(3) Turn refric@%nt manrtold valves completely clockwise to ?
puncture the cans and close the manifold valves.
(4) Purge the art- from the~~charging line by loosening the
charging hose at the gauge set manifold and turnrng one of 1~
the refrigerant valves counterclockwise~ to release re-+
fngerant. When the retngerant gas starts escaping from the
loose connection, re-tighten the hose. _
Caution
Never heat small refrigerant cans over 52°C (125°F) as
they may explode.
(5) Fully open all retrigerant manifold valves berng used and _
place the cans of retrqerant Into a pan containing 52°C
(I 25°F) water. The waterwill warm the charging can and aid
in the transfer of the charge Into the system. Place the-?
water pan and refrigerant cans on a scale and. note- the
weight.
(6) Jump the low pressure-switch terminals -.located on the .~
recerver dri;er so the clutch will remain engagjd.
(7) Start the engrne and move the controls to A/C-switch ON -
and low blower posrtron.
The low pressure switch will prevent the clutch from
engagrng until refrigerant IS added to the system. If the
clutch does engage, repface the switch before proceedings
any further -
 AIR CONDITIONING - Service Adjustment Procedures 24-85
(8) Charge through the suction side of the system .by slowly
opening the suction manifold valve, Adjust the valve as
necessary so charging pressure does not exceed 345 kPa
(50 psi). Maintain the tempe~rature of the water in the pan
by adding warm water as ‘necessary.
Note the weight of water added, to ensure accuracy when
determining amount of refrigerant added to system.
(9) Adjust the engine speed to a fast idle of approximately
1,500 rpm.
(10)When specified refrigerant charge 910 g (32 oz.) has
entered the system, close the gauge set manifold valves,
refrigerant manifold valves, and reconnect wiring.
Each can contains 14 oz. of R-12. Use 2% cans.

HANDLING TUBING AND FITTINGS N24FIAC

2-15 Nm
-11 ft.lbs.

12-15 Nm
9-I 1 ft.lbs.

\
30-34 Nm
22-26 ftlbs.

30-34 Nm
22-26 ft.lbs.

20-25 Nm
15-18ft.lbs.

2OY1654
24-86 AIR CONDITIONING - Service Adjustment Procedures

Kinks in the refrrgerant tubing or sharp bends In the retngerant _

hose lines w-ill greatly reduce the capacity of the entire system.
High pressuresare produced In the system when it is =
operatrng. Extreme-care must be exercised to make sure that -
dll connections are pressure tight. Dirt and moisture can enter ~:;
the system when rt IS opened for repair or replacement of lines
or componenrs. -The followingprecautions must be observed. :
The system must be completely discharged beforeopening ml
any fitting or co=nnectron In rhe refrigeration system. Open
fittings with cautron even after the system; has been dis-
charged. If any pressure is noticed as a fitting IsJoosened, alIow
trapped pressure to bleed off very slowly. Never attempt to
rebend formed lines to fit. Use the correct line for the :
installation you are- servicing.
A good rule for then flexible hose lines IS keep the radius of all ,;
bends at least I,0 times the diameter of the hose. Sharper ..-
bends will reduce the flow ofretngerant. The flexible hose lines -7
should be routed so that they_are at least 8U mm (3 in.) from the
exhaust manifold. It-is g;lod practice to Inspectall flexible hose
lines at least once a year to make sure they are in good =
condition and properly routed.
All plumbrng connectrons use O-rings which are not reusable. .i-

Nut O-RING INSTALLATION

Union
(1) Clean sealing surface.
(2) Make sure O-ring does% have any scratches.
(3) Connect fitting. install fastener, and torque to amdunt~~
shown in the illustration.
The internal parts of the refrigeration system will-remain in ~:~
a state of chemical stabiljty as long as pure-moisture-free 2
R-12 and refrigerant oil is used. Abnormal amounts of dirt,
moisture oraircan upset the chemical stability and cause .-
operational troubles or even serious damage if present in .I
2OUO26; more than minute quantities.
When it is necessarS/fo opn the refrigeration system, have
everything you will need to service the system -ready, so IT
the system WIII not be le& open any longer than necessary. _
Cap or plug all lines and frttrngs as soon as they are opened
to prevent the entrance of dirt and moisture. AT-lines and
components In parts stock should be capped or sealed until -1
they are ready to be used.
All tools, Including the refrigerant dispensing manifold, the
gauge set manrfold and test hoses should be kept clean and --
dry.
 AIR CONDITIONING - Service Adjustment Procedures 24-87
COMPRESSOR DRIVE BELT ADJUSTMENT N24FJAA

Satisfactory performance of the air-conditioning system is

dependent upon drive belt condition and tension. If the proper
tensions are not maintained, belt slippage will greatly reduce
air-conditioning performance and drive belt life. To avoid such
Tension pulley adverse effects, the following service procedure should be
followed:
(1) Any belt that has operated for a minimum of one half-hour is
considered to be a “used” belt. Adjust air-conditioning drive
belt at the time of new-car preparation.
(2) Check drive belt tension at regular service ‘intervals and
adjust as needed.
Standard value: 17 - 20 mm (.7 - .8 in.)

Crankshaft pulley

2OY160(
COMPRESSOR NOISE N24FLAA

When investigating an air-conditioning related noise, you must

first know the conditions when the noise occurs. These
conditions are: weather, vehicle speed, in gear or neutral,
engine temperature or any other special conditions.
Noises that develop during air-conditioning operation can often
be misleading. For example: what sounds like a failed front
bearing or connecting rod, may be caused by loose bolts, nuts,
mounting brackets, or a loose clutch assembly. Verify acces-
sory drive belt tension (power steering, alternator or air pump).
Improper accessory drive belt tension can cause a misleading
noise when the compressor is engaged and little or no noise
when the compressor is disengaged.
Drive belts are speed sensitive. That is, at different engine
speeds, and depending upon belt tension, belts can develop
unusual noises that are often mistaken for mechanical prob-
lems within the compressor.
ADJUSTMENT PROCEDURES
(1) Select a quiet area for testing. Duplicate conditions as much
as possible. Switch compressor on and off several times to
clearly identify compressor noise.
To duplicate high ambient conditions (high head pressure),
restrict air flow through condenser. Install manifold gauge
set to make sure discharge pressure doesn’t exceed 2,070
kPa (300 psi).
(2) Tighten all compressor mounting bolts, clutch mounting
bolt, and compressor drive belt. Check to assure clutch coil
is tight (no rotation or wobble).
(3) Check refrigerant hoses for rubbing or interference that can
cause unusual noises.
(4) Check refrigerant charge (see “Charging the System”).
(5) Recheck compressor noise as in Step 1.
(6) If noise still exists, loosen compressor mounting bolts and
retorque. Repeat Step 1.
(7) If noise continues, replace compressor and repeat Step I.
24-88 AIR CONDITIONING
-
- Air Conditioner Control Switch

AIR CONDITIONER CONTROL SWITCH N24OA. _

REMOVAL AND INSTALLATION

Removal steps
I. Heater control bezel
*I) 2. Glove box
3. Air conditioner control switch

F??everse the rermval procedures to reinstall

(2) *e): Refer to “SetvIce Points of Removal”.

2011648
- .-
-i
-2

SERVICE POINT OF REMOVAL N24QtlAC

2. REMOVAL OF GLOVE BOX

Grasp and release the glove box lid lock to open the lid.
Pull the glove box forward while pressing both sides mm
inward.
 AIR CONDITIONING - Heater Unit 24-89

HEATER UNIT N241A.B

REMOVAL AND INSTALLATION

2011644

r
Removal steps
Pre-removal Operation *I) +* 1. Water hoses
l Draining Coolant +I) ++ 2. Floor console
(Refer to GROUP 0 LUBRICATION AND MAINTENANCE - +* +* 3. Instrument panel
Coolant Change) 4. Center ventilator duct
5. Lap heater duct
6. Center reinforcement
Post-installation Operation 7. Heater unit
l Adjustment of Heater Control Wire c* 8. Servo motor

(Refer to GROUP 0 LUBRICATION AND MAINTENANCE- NOTE

(1) Reverse the removal procedures to reinstall.
(2) *I): Refer to “Service Points of Removal”.
(3) l *: Refer to “Service Points of Installation”.

_
_J_I -, ___- --

24-90 AIR CONDITIONING - Heater Unit

SERVICE POINTS OF REMOVAL N241BAG

1. REMOVAL OF WATER HOSES

(1) Start the -engine land operate the set temperature
change switch to adjust the temperature setting to L
change kwfi/’ MAX HOT, then stop the engine.
(2) Disconnedt the water-hoses from the heater unit. .I

2OY81

2. REMOVAL OF INSTRUMENT PANEL / 3. FLOOR CON- ~-

SOLE
Refer to GROUP 23 BODY -. Instrument Panel / Floor
Console.

8. REMOVAL OF SERVO MOTOR

Using a screwdriver, uncouple the blend air damper and the .
servo motor rod. ~~~ L _

Remove scr&vssecurrng=the servo motor and remove the ._

servo motor from the heater unit. _ ~~~

-
INSPECTION N241CAC

@ Check the dampers and link mechanism for proper opera-

tron.
l Check the heater core for clogging or w-ater leakage. _
l Check the water valve for operatron and cloggrng. --
 - I

AIR CONDITIONING - Heater Unit 24-9 1

Battery MOTOR
Check that the motor runs when battery voltage is applied to
the motor connector. Also check that the motor runs in the
opposite direction when the polarity is reversed.

POTENTIOMETER
Ohmmeter
I Connect an ohmmeter to the potentiometer connector termi-
nals (BR and RG) and check resistance reading when the lever
is moved to positions A and B.
Standard value:
MAX HOT A 180 cl
MAX COOL B 4,640 Cl

\ I I

Lever
2OY1581

SERVICE POINT OF INSTALLATION

1. INSTALLATION OF WATER HOSES
(1) Install the water hoses, and tighten the clamps in the
positions shown in the illustration.
(2) The hose with the painted mark should be connected to
nt
rks the engine side.
NOTE
Tighten each clamp screw until dimension A shown in
the illustration is 4 - 9 mm- (.I6 - .35 in.).
20X0047
200380

HEATER CORE AND WATER VALVE REPLACE-

MENT N241GAB2

1. Unlock the water valve lever clip and disconnect the link for
the blend air damper from the water valve lever.

Blend air damper link 2oy1aoj

2. Remove the following parts and then remove the water

valve.
(1) Clamp
(2) Joint hose clamp
(3) Joint hose
(4) Screw
3. Remove the plate and remove the heater core. If it is hard
to remove due to its contact with the damper lever, remove
the damper lever first.
24-92 AIR CONDITIONING - Heater Unit
-
4. Install the he;tter core and water valve. G
5. Push the~water valve leverall the way inward so-that the I E
water valve is at the closed position.
6. Pull the blend. air damper lever fully in the direction-of arrow i E
so that the blend air darnper is completely closed.

I .-.
Blend air
damper lever
 AIR CONDITIONING - Blower Assembly 24-93

BLOWER ASSEMBLY N24KA-6

REMOVAL AND INSTALLATION

Removal steps
I. Under cover
4* 2. Glove box
3. Duct joint
4. Blower assembly
5. Hose NOTE
6. Blower motor (1) Reverse the removal procedures to reinstall
7. Fan (2) *+: Refer to “Service Points of Removal”.
20'0642

SERVICE POINT OF REMOVAL N24KBAF2

2. REMOVAL OF GLOVE BOX

(1) Grasp and release the glove box lid lock to open the lid.
Pull the glove box forward while pressing both sides
inward.

(2) Remove the glove box.

24-94 AIR CONDITIONING - Blower Assembly

INSPECTION NZ4KCAF

BLOWER MOTOR
Motor turns
(1) Connect the blower motor to the battery (battery positive
terminal to terminal “2” and battery negative tetiinal to
terminal “1 “) and check that the motor runs smoothly.
-
(2) Check that abnormal noise15 not produced during rotation. ~
@

Battei-v

16Y296
 AIR CONDITIONING - Evaporator 24-95

EVAPORATOR N24RA--

REMOVAL AND INSTALLATION

, I, - 12-15 Nm
\
9-l 1 tt.lbs.

w ZZ-Zbtt.lbS.

12

2OY1626

Removal steps
*(I
l +
1.
2.
3.
Liquid line connection
Suction line connection
Nut
p%%&G;;~;::n;
1
4. Vacuum hose
Grommet
5.
6.
7.
8.
Glove box
Under cover
Lap heater duct
).z
Post-installation Operation

9. Side console duct

10. Glove box lower flame
11. Defroster duct
12. Duct joint NOTE
13. Drain hose connection (1) Reverse the removal procedures to reinstall.
14. Harness connector connection (2) +*: Refer to “Service Point of Installation”.
15. Vacuum hose
16. Bolt
24-96 AIR CONDITIONING - Evaporator

SERVICE POINTS OF INSTALLATION N2QRDAC

2. APPLICATION OF COMPRESSOR OIL TO SUCTION LINE
/ 1. LIQUID LINE
Apply compressor oil to portions indicated before installing _
the liquid line and suction line. :A

DISASSEMBLY AND REASSEMBLY N24RE-.

Vacuum pipe

Disassembly steps
2OY1624
1. Harness
2. Vacuum hose
+I) 3. Clip
4. EGiporator case upper
5. Air flow sensor
6. Evaporator case lower
7. Evaporator assembly
8. Sheet NOTE
9. Clip (1) Reverse the disasse_mbly procedures to re&seriible.
+* I)+ 10. Expansion valve (2) +*I Refer to “Service Points of Disassem_bly”.
(3) l +: Refer to “Service Points of Reassembly”.
 AIR CONDITIONING - Evaporator 24-97
SERVICE POINTS OF DISASSEMBLY N24RFAB

3. REMOVAL OF CLIP
Remove the clips with a flat-blade screwdriver covered with
a shop towel to prevent damage to case surfaces.

Clip
20’11625

IO. REMOVAL OF EXPANSION VALVE

Use two wrenches to loosen the flare nut on the pipe
connection (for both the inlet and outlet).

O-ring SERVICE POINT OF REASSEMBLY N24RHAD

10. APPLICATION OF COMPRESSOR OIL TO EXPANSION

d&l
VALVE
Apply compressor oil to the O-rings and install the expan-
sion valve to the evaporator assembly.

7ni
24-98 AIR CONDITIONING - Receiver, Condenser, Compressor Clutch Assembly

RECEIVER, CONDENSER, COMPRESSOR CLUTCH ASSEMBLY N24TA..

REMOVAL AND INSTALLATION

‘re-removal Operation
m Discharge of Refrigerant (Refer to P.24-82.)
D Removal of Radiator Grille
(Refer to GROUP 23 BODY- Grille, Garnish, Moulding)

18

3034 Nm
A@
POY1553

20-25 Nm
‘15-18ft.lbs.

Receiver removal steps

+* I, Liqurd line connectron /IO
2. Receiver mounting bolts
3. Receiver drier

Condenser
4.
removal
Pusher fan
steps
:7 :4 \16 2QY1622

5. Discharge line connection

6. Discharge line (Vehicles with an automatic
transmission)
7. Condenser mounting bolts
8. Condenser
9. Sub condenser (Vehicles with an automatic
transmission)

Compressor removal steps

10. Ignition coil
11. Tension adjustment bolt -
12. V-belt
13. Magnetic clutch harness connector connec-
tion
+I) 13. Dischange line connection -
*I* 15. Suction line connection .~
16. Mounting bolt
17. Compressor
18. Compressor bracket
19. Tension pullev NOTi
20. Tension bracket (‘I j Reverse the removal procedures to reinstall.
21. Crankshaft compressor pulley (2) +*I Refer to “Service Points of RemovaI”. mm 20YlG22
13
 AIR CONDITIONING - R eceiver, Condenser, Compressor Clutch Assembly 24-99
SERVICE POINT OF REMOVAL N24TBAB

Caution
If the hose or pipes are disconnected, cap the hoses or
pipes with a blank plug to prevent entry of dust, dirt, and
water.

iNSPECTION OF RADIATOR FAN AIR CONDITION-

ER RELAY, MAGNETIC CLUTCH RELAY, CON-
DENSER FAN MOTOR RELAY NZTCAD

(1) Remove the relay.

Radiatb; ian
n air conditioner
Ni’relav (2)

(2) Check continuity between Terminals when the battery

voltage is applied to the terminal 2 and the terminal 4 is
grounded.

Voltage applied Terminals 1 - 3 Conductive

Voltage not Terminals 1 - 3 Non-conductive

applied
Terminals 2 - 4 Conductive

EL0312
16W90

INSPECTION OF ENGINE COOLANT TEMPERA-

TURE SENSOR
(1) Remove the engine coolant temperature sensor.
--L. ----2xp___, ~~_I~ -- - -_____
B&g
_

24-100 AIR CONDITIONING - Receiver, Condenser, Compressor _Clutch Assembly

(2) ImmHse the~.sensor sectron of the sensor In water and =

make sure that continuity IS as follows~- at the water Y EZ
temperatures shown. ~ !!!!!-

Standard value:
At 44 - 56°C (Ill- 133’F) or higher Conductive
At 43°C (109’F) or lower Non-conductive

_- 2OY164S

-~ (31 After inspectlan, apply adhzslve to the thre@ed @rtion of *

the engine coolant temperature sensor and i%tall the ~_
sensor on the manifold.

?
30-40 Nm
(22-29 ft,lbs.)
04BOOhi
-
 AIR CONDITIONING - Compressor 24-101

COMPRESSOR N24TE- -

DISASSEMBLY AND REASSEMBLY

‘6 IO

15-17 Nm
I 1-13 ft.lbs.

25-26 Nm
16-20 ft.lbs:

\ 2OY1634
14 1‘3

Magnetic clutch disassembly steps

1. Nut
2. Clutch hub
3. Shims
4. Snap ring
+I) l 5. Rotor assembly
6. Snap ring
7. Ground terminal
I)+ 8. Clutch coil

Compressor front housing

9. Oil drain guide
10. Woodruff key
11. Through bolts
*a Refilling compressor oil
12. Front housing NOTE
l * 13. Shaft seals (1) Reverse the disassembly procedures to reassemble
l * 14. Seal plate (2) *I): Refer to “Service Points of Disassembly”.
15. Gasket (3) **: Refer to “Service Points of Reassembly”.
16. O-ring (4) •l : Non-reusable parts
24-102 AIR CONDITIONING - Compressor

/ - SERVICE POINT OF DISASSEMBLY N24TFAE

5. REMOVAL OF ROTOR ASSEMBLY

It may be necessary to lightly tap the rotor with a plastic ~1
hammer.

Clutch rotor Y2071

INSPECTION N24TGAE

* Check the surface of the clutch hub for scoring or bluing.

@ Check the surtace of the_ rotor tor scoring or b;ruing.
l Check the sealing surtaces for cracks, -scratches and 1:
deformation.
B Check the front houslng tor cracks or scoring on the sealing .i
surfaces. z
@ Check the compressor shaft tor scoring. .I

SERVICE POINTS OF REASSEMBLY N24THAE

‘i,, Front housing
I 14. INSTALLATION OF SEAL PLATE
/ : I’/ I -1 Lubricate the_s_e_aI plate and a pew O-ring with compressor
-*;-
,! l-b!3\k>.
‘.--i-c.-. oil. Push the seal plate arrd O-ring into the front housing.

Seal plate 2OY789

.- 5
Install the seal plate into the front housrng with a 19 mm -
deep well socket. -

19 mm deep socket ZO'i7C

- - 13. INSTALLATION OF SHAFT SEAL

(3
s Shaft
seal Lubricate the shaft seal with compressor oil. Install the
!?I shaft seal on the shaft.- .~
NOTE
Rotate the shafl seal iighfly by hand to check that it is fitted:,
into the notch on the compressor shaft.

2OY788
AIR CONDITIONING - Compressor 24-103
. REFILLING COMPRESSOR OIL
Pour the 115 cc (3.9 fl.oz.) or 170 cc (5.7 fl.oz.) of new
compressor oil into the service valves.
When only compressor has been removed:
115 cc (3.9 fl.oz.)
When entire refrigerant system has been replaced:
170 cc (5.7 fl.oz.) 1

2OY94f

8. INSTALLATION OF CLUTCH COIL

The clutch coil must be aligned with the pin in the
compressor housing.

5. INSTALLATION OF ROTOR ASSEMBLY

Clutch hub to rotor.assembly clearance must be checked
after installation.

Y2071t

MAGNETIC CLUTCH CLEARANCE

1. Tighten the clutch nut.
2. Check the clutch clearance as illustrated.
Pressure plate to rotor clearance:
0.4 - 0.7 mm (.02 - .03 in.)
NOTE
Remove clearance adjusting shims to decrease clutch
clearance. Add shims selected from the following table to
increase clutch clearance.
Clearance Adjustment Shims

3. Turn the rotor by hand to confirm that it rotates freely.

24-I 04 AIR CONDITIONING - Ventilators

VENTILATORS N24iMA-8

REMOVAL AND INSTALLATION

4 6

Removal steps
1. Demlster upper outlet
4, 2. Instrument panel
3. Lap heater duct
;: fl&ct
4* 6. Deflector duct
4, 7. Demister duct
4, 8. Demister nozzle / -.
9- Side air outlet 18
+* 10. Demister lower Outlet 2OY1640
4* I 1, Center air duct
4, 12. Center air outlet
+* 13. Defroster garnish
13. Center ventrlator duct
15. Duct joint
16. Demister hose NOTE
17. Air duct (1) Reverse the removal procedures to reinstall.
18. Lap heater duct (2) +I): Refer to “Service Points of Removal”,
*I) 19. Defroster duct
4, 20. Side ventilator duct
L
AIR CONDITIONING - Ventilators 24-105
SERVICE POINTS OF REMOVAL N24MBAJ2

2. REMOVAL OF INSTRUMENT PANEL

Refer to GROUP 23 BODY - Instrument Panel.

6. REMOVAL OF AIR DUCT

Remove the air duct and knob, and then remove the air
duct.

7. REMOVAL OF DEMISTER DUCT / 8. DEMISTER NOZZLE

Remove the demister duct and the demister nozzle.

10. REMOVAL OF DEMISTER LOWER OUTLET

Remove the clip, and then remove the demister lower
outlet.

11. REMOVAL OF CENTER AIR DUCT / 12. CENTER AIR

OUTLET
Remove the center air duct, and then remove the center air
outlet.
24-106 AIR CONDITIONING - Ventilators

6. REMOVAL OF AIR DUCT / 19. DEFROSTER DUCT

Remove the air duct, andzhen remove the defroster duct. -=
Remove the instrument pad. (Refer to GROUP 2333ODY- 1;
Instrument Panel.)

20. REMOVAL OF SIDE VENTILATOR DUCT

Remove the 3de ventilator duct from the body.

-
INSPECTION N24MCAAZ

Check all ducts tor cracks. _

 25-1

EMISSION
CONTROL SYSTEMS
CONTENTS
CRANKCASE EMISSION CONTROL GENERAL INFORMATION .. .. . .. . .. . .. . .. . .. . .. .. . .. .. 2
SYSTEM . . . .. .. . .. . . .. . .. .. . . .. . .. . .. .. . . .. . .. .. . . .. . .. .. .. . . .._...._... 17 Crankcase Emission Control System .. .._........... 4
Components Location . .. . . .. . .. .. . .. . . .. .. . ..._.._......_ 17 ECI System Diagram . ..._............................_.......... 3 ~~
Positive Crankcase Ventilation (PCV) Evaporative Emission Control System .. . .. .. . . .. .. .. . 5
Valve .._.....,................_.....__..._..._................_.._._.__.. 17
Exhaust Emission Control System . . . . .. .. .. . 6
EVAPORATIVE EMISSION CONTROL
SYSTEM .. . .. . .. . . .. .. . . .. .. . . .. .. . . .. . .. .. . .. . . .. .. . .. . .. . .. .. .._... 18 SPECIFICATIONS .. . . .. .. .. . .. . .. . . . .. . .. . . . . .. .. .. .. . 12
Components Location . . .. . . .. .. . .. _. .. .. .. . . .. . .. . .. .. . .. 18 General Specifications _....._.._._........_.._............ 12
Overfill Limiter (Two-way Valve) . .. .. . . .. . .. .. . .. . .. 21 Service Specifications _.._................................ 12
Purge Control System . . .. . .. . .. .. . . .. . .. .. . . .. . .. .. .. . . .. 19 Torque Specifications _.._.._....__._....._................... 12
Purge Control Valve . . .. . . .. .. . .. . .. . .. .. .. .. .. . .. ..‘....... 20 TROUBLESHOOTING . .. . .. .. . .. . .. . .. . .._................... 13
Therm0 Valve . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . . .. . .. .. . .. . 20 Emission Control Device
EXHAUST EMISSION CONTROL SYSTEM .. . 22 Engine Hesitates or Poor Acceleration
Air-Fuel Ratio Control (ECI) System .. . .. .. . . . . . 24 Engine will not Start or is Hard to Start
(Cranking possible)
Components Location .. . .. ..._.......................... 22
Poor Fuel Mileage
EGR Control Solenoid Valve .. . .. . . .. .. . .. . . .. .. .. . . .. . . 28
Rough Idle or Engine Stalls
EGR Valve . . .. .. . . .. . .. . .. . .. .. . . . .. .. . .. . .. . .. . . .. .. . .. . .. . .. . ..._.._ 27
Engine Coolant Temperature Sensor VACUUM HOSES . .. . . .. . .. .. .. . . .. . .. .. .. . . .. .. . .. .. . .. .. . . .. .. . 14
and Idle Switch . .. .. . . .. . .. . . .. .. . .. . . .. .. . .. . .. . .. .. . . .. .. . . .. 27 Vacuum Hoses Diagram .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . 14
Exhaust Gas Recirculation (EGR)
System . . .. .. . . .. .. . . .. . .. .. . . .. . .. . .. . .. . .. . .. . .. .. . . .. . .. .. . . .. .. . .. . 27
Reed Va Ive . . .. . .. . .. . . . . .. .. . . .. .. .. . . . . .. . . . . . . . . . 25
Secondary Air Cleaner .. . . .. .. . .. . . .. .. .. . . .. . .. .. . .. . .. . . 25
Secondary Air Control Solenoid Valve .._......_.. 26
Secondary Air Supply System . . .. . . . . . . . . .. . . . . 24
Three-way Catalytic Converter . . . .. . . . .. . .. .. . .. . . 24
 ; I j- p / 11
q;i .i ., ~ [’
: i j.
___A’-__--- ___~. - --,** -=
A-f

g +
25-2 EMISSION CONTROL SYSTEMS - General Information
m-
c:-
GENERAL INFORMATION N25BEBAa
!eF+

The emission control system has the following three major %ystems. - Es

(I) Crankcase emlsslon control system @s

(2) Evaporative emission control system Egg--
(3) Exhaust emission control system &&

The crankcase emrsslon control system IS a system adopting a c,losed-type crankcase ventilation to prevent ~~ Es-
S
blow-by gas from escaping into the atmosphere. The generated-gas IS Instead-led to the combustion chamber s r
for combustion,- gg+
mu_
gE==
The evaporative emlsslon control system tor preventtng loss ot tuel vapor trom the tuel system to the Et&
.-rttnosphere consists of various components (a cantster, purge control valve, two-way valve and so on) which II
I~l~)llect and lead venerated fuel vapor to the combustion chamber for combustton. EiG
Z
The exhaust emlsslon control system consists ot an air-tuel ratio control system (tCi system), three-way gp
I:.rltalytic converter, exhaust gas recrrculatlon system, secondary atr supply system and so on to reduce
t!nllsstutIs ut CO. HC and NOx.

Eel: Electronicallv Controlled lnlectlon !g

SPY
ECI SYSTEM DIAGRAM

‘1:
“2:
:;-

l 5.

‘6.
“7:
‘8.
l9
Oxygen sensor
Air flow sensor
Intake atr temperature sensor
Enginecoolant temperature
sensor
~Ti;tle positton sensor
Idle switch
Motor position sensor
Engine speed sensor
Barometric pressure sensor
l
0
l
l
l
Ignition switch-ST
Power voltage
Vehicle speed sensor
Air conditioner swttch
Inhibitor switch
(vehicles with an automatic
transm’ssion)
c3
qECU
c3 ~

Output s’gnal

Cantster
Input signal
Dtstrtbutor
Purge control valve
I \ w

Purge atr e
Intercooler
F+il
/Fuel infector
Secondary atr
control solenotd valve

Atr cut valve II I Ihn

I( --- I;---&-Jl ‘EGR valve

Vacuum hose color

G: Green
Y: Yellow

Reed valve

COII
InhIbItorswitch 5FUOO16
(Vehtcles wtth an
Rear catalyttc converter automattc transmtsson)
TWC Three-way catalyttc converter
 -

25-4 EMISSION CONTROL SYSTEMS - General Information

CRANKCASE EMISSION CONTROL SYSTEM N25HAAAa

Breather hose
Rocker cover

Air cleaner

Ventilzition intake manifold

011 separator hose 6EN121

.-.
From rocker
To Intake + - cover
manifold (crankcase)

\ Spring

A closed-type crankcase ventllatlon system is utilized to ._

prevent the blow-by gas trom_escaping Inro~ the atmosphere.
This system has-a positive crankcase ventilatron valve (PCV ~.
valve) at the rocker cover.
This system supplies fresh air to the crankcase throubh the air Ed
cleaner. lnsrde the crankcase, the tresh air is mixed with .I
blow-by gases, arcd this mixture passes through the PCV valve
Into the intake manifold.
The PCV valve has a metered &fice through which the mixture
l:~ffresh air and blow-by gases~Ts drawn into the intake manifold -1
In response to the intake manltold vacuum. Ihe valve.capacity
IS adequate for all -normal driving conditions.
 EMISSION CONTROL SYSTEMS - General Information 25-5
EVAPORATIVE EMISSION CONTROL SYSTEM NZBHBAB

urge control valve

Overfilllimiter
(Two-way valve)
Fuel vapor
17.-Purge air
03uoo45

In order to prevent the loss of fuel vapor from the fuel system
into the atmosphere, the evaporative emission control system
consists of charcoal canister, a purge control valve, etc.

To purge CANISTER NZlHBBB

control vale
While the engine is inoperative, fuel vapor generated inside the
fuel tank is absorbed and stored in canister.
When the engine is running, the fuel vapor absorbed in canister
is drawn into the air intake hose through the purge control
valve.
Charcoal -

To injection mixer PURGE CONTROL VALVE N25HBDB

t The purge control valve is kept being closed during idling to

prevent vaporized fuel from entering into the air intake hose for
positive control of high-idle CO emission, which is a particular
To injection problem under high ambient temperature condition and once
-) mixer the throttle ported vacuum or turbocharged’ pressure working
on the diaphragm of the valve exceeds the preset value, the
9
To air intake purge control valve is opened.
hose

0 from canister EC11 19

 .‘I?. c ;
.-II _ -A.-

25-6 EMISSION CONTROL SYSTEMS - General information

THERM0 VALVE NZlHBFA
To purge
control valve The therm0 valve, for sensing the engine coolant temperature
at the intake manifold, closes the purge control valve when the -
Injection
mixer engine coolant temperature is lower than the pre-set value in mm
order to reduce G!!and HC e_missions under eggine~warm-up I,
conditions, and opens the purge control valve when the engine ~
coolant temperature is above_ the pre-set temperature.

Thermo sensor
GEMOK
-
FUEL CHECK VALVE N25HBGA

) To overflll limiter The fuel check valve is used to prevent fuel leaks, should the
car suddenly roll over. This~vaEe is connected in the fuel vapor
line (between fua tank and oyerfill limiter) and is insTalled on
the fuel tank.
The fuel check valve contains two balls as show.0 in the .I
illustration. Under normal conditions, the gasoline vapor pas-
sage in the valve is opened, but if roll-over occurs one of the I
balls closes the fuel passage, thus preventing fuel leaks.
From fuel tank
WE5 1I

FUEL FILLER CAP N25HBHA

F?ellef valve
Fuel filler cap is~ equipped tiith relief valve to prevent the _
/c-r==? escape of fuel vapor into the atmosphere.

ket

EXHAUST EMISSION CONTROL SYSTEM = N25HCAC

Exhaust emlsslorrs (CO, HC, NJx) are controlled by a combrna- ~~

tlon ot engine mudificatlons and the addition at special control
02mponents. ~_
Modifications to.. the combu&on chamber. Intake manifold, ;
camshatt, carburetor and ignltron system torm the basic control
system.
AddItional control devices include a jet air system, an exhaust
qas recrrculatlon (tGR) system, dual catalytic converters, a
secondary ait- supply system,-a dash pot, a heated atr intake I
system and hig h altitude compensation system.
These systems -have been Integrated Into a highly effective L
system whrch controls exhaust emlssrons while majntaining -
good dnveability and fuel economy.
 EMISSION CONTROL SYSTEMS - General Information 25-7
JET AIR SYSTEM NZIHCBB

In addition to the intake valve and exhaust valve, a jet valve has
been provided for drawing jet air (super lean mixture or air) into
the combustion chamber.
A jet air passage is provided in the injection mixer, intake
Exhaust -
manifold and cylinder head. Jet air flows through two intake :
openings provided near the throttle valve of the injection mixer,
goes through the passage in the intake manifold and cylinder
head, and flows through the jet valve and the jet opening into ’
the combustion chamber.
-I l-
3EM097 The jet valve is actuated by the same cam as the intake valve
and by a common rocker arm so that the jet valve and intake
valve open and close simultaneously.
The jet air flowing out of the jet opening scavenges the residual
gases around the spark plug and creates a good ignition ~~
condition. It also produces a strong swirl in the combustion I
chamber which continues throughout the compression stroke
and improves flame propagation after ignition, assuring high _
combustion efficiency.

AIR-FUEL RATIO CONTROL SYSTEM

[ELECTRONICALLY CONTROLLED INJECTION (ECI) SYS-
TEM] N25HCCBa

The ECI system uses oxygen sensor electric signals to control ~~

and drive the injector installed upstream of the throttle valve so
as to accurately control the air-fuel ratio for minimizing
emissions.
This in turn allows the engine to produce exhaust gases of the
proper composition to permit the use of a three-way catalyst.
The three-way catalyst is designed to convert the three
pollutants (1) hydrocarbons (HC), (2) carbon monoxide (CO),
and (3) oxides of Nitrogen (NOx) into harmless substances.
There are two operating modes in the ECI system:
(1) Open ,Loop
Air-fuel ratio is controlled by information programmed into ~~
the ECU at manufacture.
(2) Closed Loop
Air-fuel ratio is varied by the ECU based on information my
supplied by the oxygen sensor.
NOTE
Refer to GROUP 14 FUEL SYSTEM - General Information.
25-8 EMISSION CONTROL SYSTEMS - General Information

CATALYTIC CONVERTER NlBHCDB

Front catalytic converter Rear catalytic converter

StaInless steel wire

/-mesh

Cover Exhaust 3

! StaInless steel lEM127

Stainless _ -
steel wire
meshes

5EM058

The three-way catalytic converters which are monollthlc type

with catalytic composltions applied to the Integrally con-
strutted honeycomb carrrer surface are rnstalled to the exhaust
port of the turbocharger /trot-&catalytlc converter) and in the -!
center of the exhaust pipe (rear catalytic converterj. The
converter, working In combrnatlon with the air-fuel ratio ..=
feedback control of the oxygensensor, oxrdlzes CO and HC and
reduces NOx. ~~~
 EMISSION CONTROL SYSTEMS - General Information 25-9
Function
The three-way catalytic converter removes CO, HC and NQx
most effectively in the vicinity of the stoichiometric ratio. ’
The air-fuel ratio feedback control by’ the oxygen sensor
controls the air-fuel mixture to the stoichiometric ratio and the
catalytic converter promotes both oxidation and reduction of
resultant exhaust gas to make it clean before it is released to
atmosphere.
Caution
Stoichiometric ratio The catalytic converters require the use of unleaded
01251:
gasoline only. Leaded gasoline will destroy the effective-
ness of the catalysts as an emission control device.
Under normal operating conditions, the catalytic convert-
ers will not require maintenance. However, it is important
to keep the engine properly tuned. If the engine is not kept
properly tuned, engine misfiring may cause overheating of
the catalysts. This may cause heat damage to the convert-
ers or vehicle components. This situation can also occur
during diagnostic testing if any spark plug cables are
removed and the engine is allowed to idle for a prolonged
period of time.

SECONDARY AIR SUPPLY SYSTEM

Fuel injector 1

-1
Control relay
Secondary air
control solenoid
/
6--

ISC motor

+@

Ii 1

Secondary
air cleaner

perature sensor
Oxygen s”e;;gor

F ECU
II’
Ignition coil
Air flow sensor
TWC: Three-way catalytic converter
5EM059
25-10 EMISSION CONTROL SYSTEMS - General Information

The reed valve supplies secondary air Into the exhaust pipe for _
the purpose oft promoting oxldatlon of exhaust emissions. __
The reed valve is actuated by exhaust vacuum being generated ~_
from pulsation i17 the exhaust manifold, and additional air IS ~;
supplied into the exhaust manitold through~ th_e secpndary air _
cleaner, -
Contents of Control
When the engirre coolant Is~:cold 115 to 63°C (59 to 145”F)l.
when the engrnels at Idle, orwhen the vehlcie is decelerating, :
the ECU turns own the power transistor to energize rhe ;
secondary air cuntrol solenord valve. As a result, the Intake
manifold vacuum is Introduced to the arr cut valve and the i:
secondary air IS. supplied to_the exhaust pipe.

EX#AUST GAS RECIRCULATION (EGR) SYSTEM NZ5HCFB

Fuel injector
/

solenoid valve

---_
--- I ~_~_ .
------
----_
,I EGR val%
-

/”
Engine coolant

Y
temperature sensor
ECU Control r&w I
I I /* 1
.‘. -
kJlitiOtl Coil Bat&v
EMISSION CONTROL SYSTEMS - General Information 25-11
Exhaust Gas Recirculation (EGR) system is designed to reduce
oxides of nitrogen in the vehicle exhaust.
In this system, the exhaust gas is partially recirculated from an
exhaust port at the cylinder head into a port located at the
intake manifold while the EGR flow is controlled by an EGR
control valve, an EGR control solenoid valve, and an ECU.
Contents of Control
As the engine is warmed up and the engine coolant tempera-
ture rises [to 55°C (131°F) or higher] but the engine speed is
low (approximately 3,500 rpm or less), the ECU turns off the
power transistor so as to shut off current flowing to the EGR ~-
control solenoid valve. As a result, the mixing body E port
vacuum acts on the EGR valve to open it.
At this time, the EGR flow rate is controlled by the E port
vacuum. Namely during idling or wide throttle valve opening
operation when the E port vacuum is low, the EGR valve is
closed by the spring force so that EGR gas does not flow.
NOTE
During idling, the EGR gas is shut off to ensure stable idling
operation.
25-12 EMISSION CONTROL SYSTEMS - SDecifications

SPECIFICATIONS N25CA..

GENERAL SPECIFICATIONS

Po%ifive crZnkcase ventilation (PCVI valve

Canister
Two-way valve
Purge control valve

Air-fuel ratio control system - ECI TURBO system Oxygen sensorfeedback type
(Purpose: Control of CO, HC, NOx emission)
Three-way catalytic converter Dual monolithictype (Front and Rear CCI
(Purpose: Control of CO, HC. NOx-emission)
Secondaryair supply system
Reed valve
Secondary air control solenoid valve On-off solenoid valve
Secondary air cleaner

Exhaust gasrecirculation system

EGR valve
EGR control solenoid valve

SERVICE SPECIFICATIONS NZ5CB..

Items Specifications

Secon~dary airontrol solenoid valve coil resistance

[at 20°C (68”FJI 0 36 1~44
EGRcontrol slolenoid valve coil resistance
[at 20°C (68”FTl 0 36-44
Therm0 valve opening temperature “C (“F) 60 (I 40)

TORQUE SPECIFICATIONS N25CG.

Items Nm ~~ ftlbs.

Secondary air pipe reed valve side joint 50-Xl 37-52 -

Secondary air pipe exhaust manifold side joint 70 - 100 52-73
EGR valve attaching bolt 7-11 5-8
Therm0 valve 20-40 15-30
 EMISSION CONTROL SYSTEMS - Troubleshooting 25-13
TROUBLESHOOTING NZEA- -a

Symptom Probable cause Remedy

Engine will not start EGR valve kept open Repair or replace
or is hard to start
(Cranking possible) Vacuum hose disconnected or damaged Repair orreplace

Rough ~cfleor engine EGR valve kept open Repair or replace

stalls
Vacuum hose disconnected or damaged Repair or replace
Purge control system faulty Troubleshoot the system and check
components under suspicion

Engine hesitates or poor Exhaust gas recirculation system faulty Troubleshoot the system and check
acceleration each component under suspicion

Poor fuel mileage Exhaust gas recirculation system faulty Troubleshoot the sytem and check
components under suspicion

Secondary air cleaner

Reed valve

Secondary air control

solenoid valve

EGR valve

EGR control solenoid

valve
25-14 EMISSION CONTROL SYSTEMS - Vacuum Hoses

VACUUM HOSES N25JA..

VACUUM HOSES DIAGRAM

-1-r
 EMISSION CONTROL SYSTEMS - Vacuum Hoses 25-15

.’
m
25-16 EMISSION CONTROL SYSTEMS - Vacuum Hoses

INSPECTION N25JCAC

!‘I) Check that the vacuum hoses have been connected _

~orrecrlv according to the vacuum hoses diagram.
(2) Check hose connectlon (dIsconnectIons, loose clamping,
r”~c 1 and check tor bends, datnaqe and other abnormalities.

INSTALLATION N25JDAC

(I 1 When connectlnq a hose, connect securely to the nlpple.

(2) Connect correctly reternnq to the vacuum hoses diagram
 EMISSION CONTROL SYSTEMS - Crankcase Emission Control System ’ 2547
CRANKCASE EMISSION CONTROL SYSTEM N25KA- -

COMPONENTS LOCATION

Name Symbol

PCV valve A

5EM062

POSITIVE CRANKCASE VENTILATION (PCV)

VALVE N25KBAA

Refer to GROUP 0 LUBRICATION AND MAINTENANCE -

Maintenance Service for the inspection of the positive crank-
case ventilation (PCV) valve.
 i ‘Ai T l-i- 1;.ip!- ~‘I~ _
---,, .__

25-18 EMISSION CONTROL SYSTEMS - EWporative Emisshn Control System

EVAPORATIVE EMISSION CONTROL SYSTEM N25i.A

COMPONENTS LOCATION

5FU0050
 EMISSION CONTROL SYSTEMS - Evaporative Emission Control System 25-19

I 5EM070

PURGE CONTROL SYSTEM NZBLBAB

Air flow sensor

(Air cleaner)
25-20 EMISSION CONTROL SYSTEMS 7 Evaporative Emissibn Control System -.
__~~
I_
!!!!ex-

INSPECTION
(1) Disconnect the purge air hose from the air intake hose and ~~ c
plug the air intake hose. Then, connect a hand vacuum : EE
pump to the disconnected purge air hose.
(2) Check the following both whenthe engine is cold [engine
coolant temperature 45°C (T13”F) or less] and whenjt is hot
[engine coolant temperature 85 to 95C (185 to 205’F)I.
When engine is -cold

Vacuum Engine state Normal condition

13 kPa (I .9 psi) 2,500 rpm Vacuum is held

When enqrne IS hot

PURGE CONTROL VALVE N251ECBa

INSPECTION
(1) Remove the purge control valve.
(2) Connect a hand vacuum pump to the vacuum nipple of the
purge control valve.
(3) Apply a vacuum of 53 kPa (7.7 PSI) and check air tightness.
(4) Blow in air lightly from the canister side nipple and check
conditions as _follows.

__.._
Valve
/ ll-n

(5) Connect a hand vacuum pump to the positive pressure ’

nipple of the purge control valve.
(6) Apply a vacuumm of 53 kPa (7.7 psi) and check air tightness. _

THERM0 VALVE N25lFJDG ~_

INSPECTION
(1) Disconnect the vacuum hoses (black and blue stripe) from
the therm0 valve and connect a hand vacuum pump to the
therm0 valve.
(2) Apply vacuum and check therm0 valve condition as follows.

Engine coolant temperature Normal condrtron

45T (I 13°F) or less _ Vacuum leaks

Therm0 sensdr for engine coolant
temperature detection 80X (176’F) or more Vacuum holds
--
EMISSION CONTROL SYSTEMS - Evaporative Emission Control System 25-21
REMOVAL
(I) When removing the therm0 valve, do not use wrenches or ~1
other tools on the resin part.
(2) When disconnecting the vacuum hose, put a mark on the I-
hose so that it may be reconnected at original position.- ‘--
INSTALLATION
(I) When installing, apply sealant (3M NUT Locking No. 4171 ~.
or equivalent) to the threads and tighten to 20 to 40 Nm (15--- ‘=
to 30 ft.lbs.).
(2) When installing the therm0 valve, do not use wrenches or
other tools on the resin part.

OVERFILL LIMITER (TWO-WAY VALVE) N25lBEB

Refer to GROUP 14 FUEL SYSTEM - Fuel Tank for the

inspection of the overfill limiter (two-way ~valve).
 _~
EXHAUST EMISSION CONTROL SYSTEM N25MA..

SE
gsI
COMPONENTS LOCATION

---
E

-+
5FUOO50
EMISSION CONTROL SYSTEMS - Exhaust Emission Control System 25-23

6EM070
25-24 EMISSION CONTROL SYSTEMS - Exhaust Emission Control System

AIR-FUEL RATIO CONTROL (ECl) SYSTEM N25lCAB.a

Heter to GROUP- 14 FUEL SYWEM - Service Adystment

Procedures tor the InspectIon -ot the air-fuel ratlo control (EC11
~:~‘jsTem.

THREE-WAY CATALYTIC CONVERTER N25lCBAa

REMOVAL AND INSTALLATION

For removal and rnstallatlon procedures, reter-to GROUP 11
INTAKE AND EXHAUST SYSTEM - Exhaust Pipes and Muf-
tiers.
INSPECTION
cI:heck tor damage, cracks or tusron and replace iI taulty.
Caution
1. Operation of any type, including idling, should be
avoided if engine misfiring occurs. Under this condition
the exhaust system will operate at abnormally high
temperature;which may cause damage to the catalyst
or under-body parts of the vehicle.
2. Alteration or deterioration of ignition or fuel system, or
any type of operating condition which results in engine
misfiring must be corrected to avoid overheating the
catalytic converters.
3. Proper maintenance and tuneup according to manufac-
turer’s specifications should be made to correct the
conditions as soon as possible.

iocker cover Secondary air InjectIon SECONDARY AIR SUPPLY SYSTEM N25lCCCa

1 cleaner !i mixer INSPECTION

Put a finger at the end of the extension hose to check air
suction.
Caution
When a suction is felt by this inspection procedure, use
care not to be sealded by exhaust gas flowing backward
Intake due to breakage of reed valve.
manifold
air Inlet 5EM075
 EMISSION CONTROL SYSTEMS - Exhaust Emission Control System 25b25
SECONDARY AIR CLEANER N251CDBa

INSPECTION
(1) Disconnect the air hose from the reed valve. ‘- =-~=

5EM076 .-

(2) Disconnect the vacuum h&e (yellow stripe) rrom the

secondary air control solenoid valve and connect a hand
vacuum pump to the hose end.

(3) Apply a vacuum of 67 kPa (10.0 psi) and check air tightness. --;
(4) Blow in air from the end of the extension hose connected-in
step (1) and check condition as follows.

REED VALVE N25lCEAa

Exhaust INSPECTION
manifold Air cleaner
side & (1) Remove the reed valve.
(2) Blow in air and check condition as follows.

Air blow direction Normal condition

Air cleaner side to Air blows through
exhaust manifold side

3EM17( Exhaust manifold side Air does not blow through

to air cleaner side

(3) If any fault is found in above checks, replace the reed valve.
Reed valve tightening torque:
50 - 70 Nm (37 - 52 ftlbs.)
 EMISSION CONTROL SYSTEMS - Exhaust Emission Control System

SECONDARY AIR CONTROL SOLENOID VALVE

N25lCFBa

lNSPECTlON
NOTE
When drsconnecbthe vacuum hose, put a mark on the hose __
so that It may be reconnected at orrgrnal position, .._
(I) Disconne.ct the vacuum hqses (blue strrpe, yellow stripe, ~~
, whrte stripe) from the solenord valve. ~~
(2) Disconnect the harness connector. -

(3) Connect a hand vacuum pump to the nrpple to whrch white _~

stripe vacuum hose has been connected.

I 5EM1651
_~- -”
(4) Apply vacuum and check arr tightness both when the 1
battery voltage is applied directly to the ‘solen-d;ld valve 1,
terminal and when not applied.

Battery voltage Normal condition

When applied Vacuum leaks

When not applied Vacuum holds

(51 Connect a hand vacuum pump to the nrpple to whrch blue _

stripe vacuum hose hasbeen connected, =I

-
(6) Apply vacuum and check air trghtness both ~when the
battery volta-ge is applied directly to the solenoid valve -
terminal Andy when not applied.

Battery voltage
 (fS--Measuresolenoid coil resistance. -
Standard value: 36 - 44 CR [at 20°C (68”F)];
-~
a

5EM16C

ENGINE COOLANT TEMPERATURE SENSOR AND

IDLE SWITCH N251CHAa

Refer to GROUP 14 FUEL SYSTEM - Inspection of ECI System

Components for the inspection of these parts.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM .~

N25iCJBa--~

INSPECTION
~_~~
(1) Disconnect the vacuum hose (green stripe) from the mixing ~~_
body and connect a hand vacuum pump to--the vacuum-, F
hose.
(2) Check the following both when the engineJszcbld [engine : _
coolant temperature 50°C (122°F) or less] and when it is hot
Iengine coolant temperature 85 to SSQ185. to 2Q5”F)I.
When engine is cold

Vacuum Engine state Normal condition

Apply vacuum Idling Vacuum- leaks from EGR

control solenoid. valve

When engine is hot

EGR VALVE N25lCKBa

INSPECTION
(1) Remove the EGR valve and check jt for sticking, deposit of
carbon, etc.
If such condition exists, clean with adequate. solvent to _p
ensure correct valve seat contact.
 EMISSION CONTROL SYSTEMS - Exhaust Emission Control System

(2) Connect a hand vacuum pump to the EGR valve.

Caution
Plug one nipple of the EGR valve.
(3) Apply a vacuum of 67 kPa(10.0 psi) andcheck air tightness. -I
(4) Blow in air from one pasage of the EGR to check condition
as follows.

Vacuum Normal condition I

lEM15f
I 8 kPa (1.2 psi) or less ( Air does not blow through 1
23 kPa (3.3 psi) or more I Air blows through

Caution
When installing the EGR valve, use a new gasket and
tighten to 7 to 11 Nm (5 to 8 ftlbs.).

EGR CONTROL SOLENOID VALVE N251CRAa

INSPECTION
NOTE
When disconnecting the vacuum hose, put a mark on the hose _
so that it may beg reconnected at original position.
(I 1 Disconnect the-vacuum hoses (blue stripe, red stripe) from
the solenoid--valve.
(2) Disconnect the harness connector.
(3) Connect a hand vacuum pump to the nipple to which red .-
stripe vacuum whose has been connected.

(4) Apply vacuum and check air tightness both when the
battery~ voltage is applied directly to the EGR control
solenoid valve and when not applied.

Battery voltage Normal condition

When applied Vacuum leaks
When not applied Vacuum holds

(5) Measure solenoid coil resistance.

Standard value: 36 - 44 il [at 20°C (68”F)I

I0 i
5EM17;
HY70BO70-916



67$5,21