1991

300ZX
1991

300ZX
MANUAL
SERVICE

SERVICE MANUAL
INCH TO METRIC CONVERSION TABLE METRIC TO INCH CONVERSION TABLE
<Rounded-off for automotive use) <Rounded-off for automotive use>
inches mm inches mm mm inches mm inches
.100 2.54 .610 15.49 1 .0394 51 2.008
.110 2.79 .620 15.75 2 .079 52 2.047
.120 3.05 .630 16.00 3 .118 53 2.087
.130 3.30 .640 16.26 4 .157 54 2.126
.140 3.56 .650 16.51 5 .197 55 2.165
.150 3.81 .660 16.76 6 .236 56 2.205
.160 4.06 .670 17.02 7 .276 57 2.244
.170 4.32 .680 17.27 8 .315 58 2.283
.180 4.57 .690 17.53 9 .354 59 2.323
.190 4.83 .700 17.78 10 .394 60 2.362
.200 5.08 .710 18.03 11 .433 61 2.402
.210 5.33 .720 18.29 12 .472 62 2.441
.220 5.59 .730 18.54 13 .512 63 2.480
.230 5.84 .740 18.80 14 .551 64 2.520
.240 6.10 .750 19.05 15 .591 65 2.559
.250 6.35 .760 19.30 16 .630 66 2.598
.26'0 6.60 .770 19.56 17 .669 67 2.638
.270 6.86 .780 19.81 -18 .709 68 2.677
.280 7.11 .790 20.07 19 .748 69 2.717
.290 7.37 .800 20.32 20 .787 70 2.756
.300 7.62 .810 20.57 21 .827 71 2.795
.310 7.87 .820 20.83 22 .866 72 2.835
.320 8.13 .830 21.08 23 .906 73 2.874
.330 8.38 .840 21.34 24 .945 74 2.913
.340 8.64 .850 21.59 25 .984 75 2.953
.350 8.89 .860 21.84 26 1.024 76 2.992
.360 9.14 .870 22.10 27 1.063 77 3.031
.370 9.40 .880 22.35 28 1.102 78 3.071
.380 9.65 .890 22.61 29 1.142 79 3.110
.390 9.91 .900 22.86 30 1.181 80 3.150
.400 10.16 .910 23.11 31 1.220 81 3.189
.410 10.41 .920 23.37 32 1.260 82 3.228
.420 10.67 .930 23.62 33 1.299 83 3.268
.430 10.92 .940 23.88 34 1.339 84 3.307
.440 11.18 .950 24.11 35 1.378 85 3.346
.450 11.43 .960 24.38 36 1.417 86 3.386
.460 11.68 .970 24.64 37 1.457 87 3.425
.470 11.94 .980 24.89 38 1.496 88 3.465
.480 12.19 .990 25.15 39 1.535 89 3.504
.490 12.45 1.000 25.40 40 1.575 90 3.543
.500 12.70 2.000 50.80 41 1.614 91 3.583
.510 12.95 3.000 76.20 42 1.654 92 3.622
.520 13.21 4.000 101.60 43 1.693 93 3.661
.530 13.46 5.000 127.00 44 1.732 94 3.701
.540 13.72 6.000 152.40 45 1.772 95 3.740
.550 13.97 7.000 177.80 46 1.811 96 3.780
.560 14.22 8.000 203.20 47 1.850 97 3.819
.570 14.48 9.000 228.60 48 1.890 98 3.858
.580 14.73 10.000 254.00 49 1.929 99 3.898
.590 14.99 20.000 508.00 50 1.969 100 3.937
.600 15.24
 QUICK REFERENCE INDEX
GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL

ENGINE LUBRICATION & COOLING SYSTEMS -

ENGINE FUEL & EMISSION CONTROL SYSTEM -

ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
CLUTCH

NISSAN MANUAL TRANSMISSION

aoozx
MODEL Z32 SERIES
AUTOMATIC TRANSMISSION - - - - -

PROPELLER SHAFT & DIFFERENTIAL CARRIER -

FRONT AXLE & FRONT SUSPENSION - - -

REAR AXLE & REAR SUSPENSION - - - -

BRAKE SYSTEM

STEERING SYSTEM

BODY

HEATER & AIR CONDITIONER

ELECTRICAL SYSTEM

()
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________________________
© 1990 NISSAN MOTOR CO., LTD.
._
...._.
Printed in Japan
__.
llt Not to be reproduced in whole or in part without the prior written permission of Nissan Motor Company Ltd., Tokyo, Japan .
 FOREWORD
This manual contains maintenance and repair procedures for the 1991
Nissan 300ZX.

In order to assure your safety and the efficient functioning of tl'}e

vehicle, this manual should be read thoroughly. It is especially impor-
tant that the PRECAUTIONS in the Gl section be completely under-
stood before starting any repair task.

All information in this manual is based on the latest product informa-

tion at the time of publication. The right is reserved to make changes in
specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the
technjcian and the efficient functioning of the vehicle.
The service methods in this Seriice Manual are described in such a
manner that the service may be performed safely and accurately.
Service varies.with the procedures used, the skills of the technician and
the tools and parts available. Accordingly, anyone using service proce-
dures, tools or parts· which are not specifically recommended by
NISSAN must first completely satisfy himself that neither his safety
nor the vehicle's safety will be jeopardized by the service method
selected.

• NISSAN MOTOR CO., LTD.

Overseas Service Department
Tokyo, Japan
 GENERAL INFORMATION

SECTIONGI

CONTENTS
PRECAUTIONS ................................................................................................................................... Gl- 2
HOW TO USE THIS MANUAL ........................................................................................................ Gl- 6
HOW TO READ WIRING DIAGRAMS ........................................................................................... Gl- 8
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES ............................. ,................. Gl-11
CONSULT CHECKING SYSTEM ..................................................................................................... Gl-14
IDENTIFICATION INFORMATION ..................................................................................................... Gl-16
LIFTING POINTS AND TOW TRUCK TOWING ............................................................................ Gl-21
TIGHTENING TORQUE OF STANDARD BOLTS .......................................................................... Gl-24
 PRECAUTIONS

Observe the following precautions to ensure safe and proper

servicing. These precautions are not described in each individual
section.

Precautions for Supplemental Restraint System

"AIR BAG"
This model has a Supplemental Restraint System "Air Bag" to help
reduce the risk or severity of injury to the driver in a frontal
collision. The Supplemental Restraint System consists of an air bag
(located in the center of the steering wheel), five sensors, a control
unit, warning lamp, wiring harness and spiral cable. Information
necessary to service the system safely is included in the BF
section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could lead to
personal injury or death in the event of a . severe frontal
collision, all maintenance must be performed by an author-
ized INFINITI dealer.
• Improper maintenance, including incorrect removal and in-
stallation of the SRS, can lead to personal injury caused by
unintentional activation of the system.
• All SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation. Do not use electrical
test equipment on these circuits.

General Precautions
1. Do not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.
SGI285

2. Before jacking up the vehicle, apply wheel chocks or other tire

blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting and towing
before working on the vehicle.
These operations should be done on a level surface.
3. When removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance and
drop them. Also, do not allow them to strike adjacent parts,
especially the brake tubes and master cylinder.
SGI231

Gl-2
 PRECAUTIONS
General Precautions (Cont'd)
4. Before starting repairs which do not require battery power,
always turn off the ignition switch, then disconnect the ground
cable from the battery to prevent accidental short circuit.

SGI232

5. To prevent serious burns, avoid contact with hot metal parts

such as the radiator, exhaust manifold, tail pipe and muffler. Do
not remove the radiator cap when the engine is hot.

SGI233

6. Before servicing the vehicle, protect fenders, upholstery and

carpeting with appropriate covers.
Take caution that keys, buckles or buttons on your person do
not scratch the paint.

Fender cover
SGI234

7. Clean all disassembled parts in the designated liquid or solvent

prior to inspection or assembly.
8. Replace oil seals, gaskets, packings, 0-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
9. Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
10. Arrange the disassembled parts in accordance with their
assembled locations and sequence.
11. Do not touch the terminals of electrical components which use
microcomputers (such as electronic control units).
Static electricity may damage internal electronic components.
12. After disconnecting vacuum or air hoses, attach a tag to
indicate the proper connection.
13. Use only the lubricants specified in MA section.
14. Use approved bonding agent, sealants or their equivalents
when required.
15. Use tools and recommended special tools where specified for
safe and efficient service repairs.
16. When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
17. Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.

Gl-3
 PRECAUTIONS

Precautions for E.F.I. or E.C.C.S. Engine

1. Before connecting or disconnecting E.F.I. or E.C.C.S. harness
Control unit connector to or from any E.F.I. or E.C.C.S. control unit, be sure
to turn the ignition switch to the "OFF" position and discon-
nect the negative battery terminal.
Otherwise, there may be damage to control unit.
2. Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure to eliminate danger.
3. Be careful not to jar components such as control unit and air
flow meter.
SGI291

Precautions for Catalyst

If a large amount of unburned fuel flows into the converter, the
converter temperature will be excessively high. To prevent this,
follow the procedure below:
1. Use unleaded gasoline only. Leaded gasoline will seriously
damage the catalytic converter.
2. When checking for ignition spark or measuring engine com-
pression, make tests quickly and only when necessary.
3. Do not run engine when the fuel tank level is low, otherwise the
Clean floor engine may misfire causing damage to the converter.
SGI290 4. Do not place the vehicle on inflammable material. Keep inflam-
mable material off the exhaust pipe.

Precautions for Turbocharger

The turbocharger turbine revolves at extremely high speeds and
Cold engine becomes very hot. Therefore, it is essential to maintain a clean
supply of oil flowing through the turbocharger and to follow all
required maintenance instructions and operating procedures.
For proper operation of the system, follow the procedure below.
1. Always use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
2. Avoid accelerating engine to a high rpm immediately after
starting.
SGI292 3. If engine had been operating at high rpm for an extended
period of time, let it idle for a few minutes prior to shutting it
off.

Gl-4
 PRECAUTIONS

Precautions for Fuel

To maintain engine and exhaust system durability and performance,
UNLEADED PREMIUM gasoline with an octane rating of at least 91
AKI (Research octane number 96) must be used.
If premium unleaded gasoline is not available, REGULAR UN-
LEADED gasoline with an octane rating of 87 AKI (Research octane
number 91) may be used temporarily, but only under the following
conditions:
• The fuel tank should be filled only partially with unleaded
regular gasoline, and filled up with premium unleaded gasoline
as soon as possible.
• Full throttle driving and abrupt acceleration should be avoided.
Use UNLEADED fuel only. Under no circumstances should leaded
gasoline be used. Lead gasoline will damage the catalytic
converter and increase dangerous emissions from the vehicle
exhaust.

Gl-5
 HOW TO USE THIS MANUAL

1. A QUICK REFERENCE INDEX, a black tab (e.g. •) is provided on the first page. You can quickly find
the first page of each section by mating it to the section's black tab.
2. THE CONTENTS are listed on the first page of each section.
3. THE TITLE is indicated on the upper portion of each page and shows the part or system.
4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and
a number (e.g. "BR-5").
5. THE LARGE ILLUSTRATIONS are exploded views (See below.) and contain tightening torques, lubrication
points and other information necessary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriate PARTS CATALOG.

Example

Torque
member

Outer shim

A : N·m (kg-m, ft-lb)

SBR364A

6. THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of
work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for complicated units such as the automatic transaxle or
transmission, etc. are presented in a step-by-step format where necessary.
7. The following SYMBOLS AND ABBREVIATIONS are used:
Tightening torque S.O.S. Service Data and Specifications
L.H., R.H. Left-Hand, Right-Hand
Should be lubricated with grease.
M/T Manual Transaxle/Transmission
Unless otherwise indicated, use
A/T Automatic Transaxle/Transmission
recommended multi-purpose grease.
Tool Special Service Tools
Should be lubricated with oil.
A.T.F. Automatic Transmission Fluid
Sealing point o, Drive range 1st gear
Checking point 02 Drive range 2nd gear
03 Drive range 3rd gear
Always replace after every disas- 04 Drive range 4th gear
sembly. 0.0. Overdrive
Apply petroleum jelly. 22 2nd range 2nd gear
Apply A.T.F. 2, 2nd range 1st gear
Select with proper thickness. h 1st range 2nd gear
Adjustment is required. 1, 1st range 1st gear

Gl-6
 HOW TO USE THIS MANUAL

8. The UNITS given in this manual are primarily expressed as Sl UNITS (International System of Unit), and
alternately expressed in the metric system and in the yard/pound system.
"Example"
Tightening torque:
59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
9. TROUBLE DIAGNOSES are included in sections dealing with complicated components.
10. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data.
11. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury
and/or damage to some part of the vehicle.
• WARNING indicates the possibility of personal injury if instructions are not followed.
• CAUTION indicates the possibility of component damage if instructions are not followed.
e BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.

Gl-7
 HOW TO READ WIRING DIAGRAMS

WIRING DIAGRAM
Symbols used in WIRING DIAGRAM are shown below:

Example

POWER SUPPLY
CONNECTOR •This shows the igni-
This shows that these connectors are tion switch position
white 6 terminal connectors. in which the system
can be operated.
• See POWER SUPPLY
ROUTING in EL
section for the detailed
wiring diagram.
BRANCH
M/T model

SWITCH
This shows that conti-
nuity exists between
terminals CD and @.
~~~FUSE
Eli!
:el BLOCK
when the switch is
turned to ON position.
A/T model

r1 < IWhi") ~ l,iJJJ lilil

e
~B~
rt_G~
---+:m m:-L~
@~ ®
SWITCH

WIRE COLOR CODING

-±- B =Black BR =Brown
@: M/Tmodel BODY w =White OR =Orange
GROUND R =Red p =Pink
@: A/Tmodel This number shows where the
G =Green PU =Purple
connector is located. See
HARNESS LAYOUT in EL L =Blue GY =Gray

t
ABBREVIATIONS
section. The number is
identical with the one in
HARNESS LAYOUT.
I
y =Yellow
LG = Light Green
SB =Sky Blue

When the wire color is striped, the base

color is given first, followed by the stripe

~®!~
color as shown below:
Example: L/W =Blue with White Stripe

1: Instrument M:
harness Main harness
SGI543

SWITCH POSITIONS
Wiring diagram switches are shown with the vehicle in the
Normally open
following condition.
=
---o o-- • Ignition switch "OFF".
• Doors, hood and trunk lid/back door closed.

...
• Pedals are not depressed and parking brake is released.
Normally closed

SEL764E

Gl-8
 HOW TO READ WIRING DIAGRAMS

Example CONNECTOR SYMBOLS

• All connector symbols in wiring diagrams are shown from
the terminal side.

SGI362

Example • Male and female terminals

Connector guides for male terminals are shown in black and
Male terminal female terminals in white in wiring diagrams.

GuiM-[~
Connector
Connector symbol

Female terminal

Guide

Connector
Connector symbol MULTIPLE SWITCH
The continuity of the multiple switch is identified in the switch
SGI363
chart in wiring diagrams.
Example

WIPER SWITCH

1'\ OFF INT LO HI WASH Continuity circuit of wiper switch

1 0 SWITCH POSITION CONTINUITY CIRCUIT
-8/Y---, 2 IO OFF 3·4

~
-R-~D @ 0 0 ~ INT 3. 4, s. 6
-W/8- B E 4 0 0 LO 3·6
-L/Y- C (t) 5 0 HI 2·6
-B--•• ® 0 ~10 0 WASH 1 ·6
--Y---~

Example: Wiper switch in LO position

Continuity circuit: Red wire- @ terminal-@ terminal -Wiper switch ( 8- 8:
LOI- ®terminal- ®terminal- Black wire

SGI365

Gl-9
 HOW TO READ WIRING DIAGRAMS

SUPER MULTIPLE JUNCTION (S.M.J.)

• The "S.M.J." indicated in wiring diagrams is shown in a
simplified form. The terminal arrangement should therefore
be referred to in the foldout at the end of the Service
Manual.
• The foldout should be spread to read the entire wiring
diagram.

Example

STARTING SYSTEM STARTING SYSTEM

SUPER MULTIPLE JUNCTION (S.M.J.I
Wiring Diagram

Super Multiple Junction

IS.M.J.I
r-R---.,

~
')
S.M.J.
Refer to last page
(foldout page).
J
81 -+---L~

·-·-
r--R

~8 DO 8R~
(Main harness) ...__..J (Instrument
harness)

(---8----------~
(Main harness) (Instrument harness)

SEL653F

Gl-10
 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
Example

INSPECTION START

CHECK POWER SUPPLY. Check the following items.

1) Turn ignition switch "ON". N.G · 1) Harness continuity between
2) Check voltage between crank angle sensor and battery.
terminal @ and grpund. 2) E.C.C.S. relay-1 (See page EF &
Battery voltage should exist. EC-106.)
3) "BR" fusible link
O.K.
4) Power source for E.C.U.
SGI561 (See page EF & EC-104.)
5) Ignition switch

a Check the following items.

c CHECK GROUND CIRCUIT.
1) Turn ignition switch "OFF". 1) Harness continuity between
2) Disconnect crank angle ~ crank angle sensor and
sensor harness connector. ground
3) Check resistance between 2) Ground circuit for E.C.U.
terminal @and ground. (See page EF & EC-104.)
Resistance:
Approximately on
SGI562
O.K.

NOTICE
The flow chart indicates work procedures required to diagnose
problems effectively. Observe the following instructions before
diagnosing.
1) Use the flow chart after locating probable causes of a
problem following the "Preliminary Check" or the "Symp-
tom Chart".
2) After repairs, re-check that the problem has been com-
pletely eliminated.
3) Refer to Component Parts Location and Harness Layout
for the Systems described in each section for
identification/location of components and harness con-
nectors.
4) Refer to the Circuit Diagram for Quick Pinpoint Check.
If you must perform circuit continuity between harness
connectors more detail, such as in case of sub-harness Is
used, refer to Wiring Diagram and Harness Layout In EL
section for identification of harness connectors.
5) When checking circuit continuity, ignition switch should be
"OFF".
6) Before checking voltage at connectors, check battery
voltage.
7) After accomplishing the Diagnostic Procedures and Electrical
Components Inspection, make sure that all harness connec-
tors are reconnected as they were.

Gl-11
 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

HOW TO FOLLOW THIS FLOW CHART

ITJ Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in
enclosed blocks, as shown in the following example.
m +
CHECK POWER SUPPLY. ..--- Check item being performed.
1) Turn ignition switch "ON". }
2) Check voltage between Procedure, steps or
terminal@ and ground. measurement results
Battery voltage should exist.

IO.K.

[2] Measurement results

Required results are indicated in bold type in the corre-
sponding block, as shown below:
These have the following meanings:
Battery voltage -+ 11 - 14V or approximately 12V
Voltage: Approximately OV -+ Less than 1V

[.3] Cross reference of work symbols in the text and

illustrations
Illustrations are provided as visual aids for work procedures.
For example, symbol rJ indicated in the left upper portion
of each illustration corresponds with the symbol in the
flowchart for easy identification. More precisely, the proce-
dure under the "CHECK POWER SUPPLY" outlined previ-
m.
ously is indicated by an illustration

~ Symbols used in illustrations

r Symbols included in illustrations refer to measurements or
procedures. Sefore diagnosing a problem, familiarize your-
self with each symbol.

Direction mark
Example A direction mark is shown to clarify the side of connector (ter-
side .
View from(irterminal Connecto: symbol minal side or harness side).
Direction marks are mainly used in the illustrations indicating

~
.. J.L~.: I terminal inspection.

~--
~ View from terminal side ... T.S.
4..'' Connector Direction mark

View from harness side

.rlt
Connector symbol
• All connector symbols shown from the terminal side are
efil
lm
~-Y a single line.
View from harness side ... H.S.

rmmm • All connector symbols shown from the harness side are
enclosed by a double line.
~
Direction mark

~
Connector

SGI364

Gl-12
 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

Key to symbols signifying measurements or procedures

Symbol Symbol explanation Symbol Symbol explanation

~
-.:1'
Check after disconnecting the Current should be measured with
18 connector to be measured. an ammeter.

00
.-ET
Check after connecting the
E) connector to be measured.
Procedure with CONSULT

(&.~ Insert key into ignition switch. ® Procedure without CONSULT

00 Turn ignition switch to "OFF"

position. [§ A/C switch is "OFF".

00 ~
Turn ignition switch to "ON"
A/C switch is "ON".
position.

00
Fan switch is "ON". (At any posi-
·~
Turn ignition switch to "START"
position. tion except for "OFF" position)

OOcc Turn ignition switch from "OFF" to

"ACC" position.
~~ 2 3 ~
Fan switch is "OFF".

~F ~
Turn ignition switch from "ACC" to Apply battery voltage directly to
"OFF" position. components.

~ l~~
Turn ignition switch from "OFF" to
"ON" position. Drive vehicle.

~F ~
Turn ignition switch from "ON" to
"OFF" position. Disconnect battery negative cable.

~ ~
Do not start engine, or check
with engine stopped. Depress brake pedal.

ID Start engine, or check with engine

running.
~ Release brake pedal.

~ Apply parking brake.

~ Depress accelerator pedal.

~ Release parking brake.

~ ,___
Release accelerator pedal.

Pin terminal check for S.M.J.

cf~H
Check after engine is warmed up
sufficiently. u DIIMIT'H-11 type E.C.U. and A/T control

~I)
unit connectors.
For details regarding the

~
Voltage should be measured with a terminal arrangement, refer
voltmeter. to the foldout page.
..---
L5J Circuit resistance should be
measured with an ohmmeter.
'Ci)lj
~~

LBJ
Gl-13
 CONSULT CHECKING SYSTEM

Outside View

Power ON switch Diagnostic connector

Voltage probe

Battery pack

SG1619

System Application

~
Auto
E.C.C.S. AIT HICAS Air bag
e A/C

Work support X X - - -
Self-diagnostic
X X X X X
results

Data monitor X X X X -
Active test X X - X -
E.C.U. part
number
X - X X -
Function test X - - - -
X: Applicable

Gl-14
 CONSULT CHECKING SYSTEM

Function

Diagnostic mode Function

This mode enables a technician to

adjust some devices fa~•er and more
Work support accurately by following the indications
on CONSULT.

Self-diagnostic results can be read and

Self-diagnostic results
erased quickly.

Input/Output data in the control unit

Data monitor
can be read.

Mode in which CDr'SUL T drives some

actuators apart from the co"trol units
Active test
and also shifts some parameters in a
specified range.

E.C.U. part number E.C.U. part number can be read.

Checking Equipment

Tool name Description

NISSAN CONSULT kit

CD CONSULT unit
and accessories

Program card (UE900)

®
®
® Operation manuals

@ Binder
EJj
@ Carrying case
~
® Thermal paper (Rolls)
~

When ordering the above equipment, contact your NISSAN distributor.

Gl-15
 IDENTIFICATION INFORMATION

Model Variation
Road wheel
Transmis- Differential
Body Destination Model Engine size ... offset Tire size
sion carrier
mm (in)

Standard RL-JU RS5R30A

roof RL-JAU RE4R01A 7-1/2JJx16 P225/50R16
VG30DE R200V
KRL-XU RS5R30A ... 45 (1.77) 91V

KRL-XAU RE4R01A
2 seater FR:
Non-
KRL-XSU RS5R30A 7.5JJ-16 FR:
T-bar California
... 45 (1.77) P225/50ZR16
roof VG30DETI R230V
RR: RR:
KRL-XASU RE4R03A 8.5JJ-16 P245/45ZR16
... 35 (1.38)
7-1/2JJx16 P225/50R16
2+2 KRLG-XU VG30DE RS5R30A R200V
... 45 (1.77) 91V
U.S.A.
Standard RL-JV RS5R30A
roof RL-JAV RE4R01A 7-1/2JJx16 P225/50R16
VG30DE R200V
KRL-XV RS5R30A ... 45 (1.77) 91V

KRL-XAV RE4R01A
2 seater FR:
California KRL-XSV RS5R30A 7.5JJ-16 FR:
T-bar ... 45 (1.77) P225/50ZR16
roof VG30DETI R230V
RR: RR:
KRL-XASV RE4R03A 8.5JJ-16 P245/45ZR16
... 35 (1.38)
7-1/2JJx16 R225/50R16
2+2 KRLG-XV VG30DE RS5R30A R200V
... 45 (1.77) 91V

Standard RL-JN RS5R30A

roof RL-JAN RE4R01A 7-1/2JJx16 P225/50R16
VG30DE R200V
KRL-XN RS5R30A ... 45 (1.77) 91V

KRL-XAN RE4R01A
2 seater FR:
Canada KRL-XSN RS5R30A 7.5JJ-16 FR:
T-bar : .. 45 (1.77) P225/50ZR16
VG30DETI R230V
roof RR: RR:
KRL-XASN RE4R03A 8.5JJ-16 P245/45ZR16
... 35 (1.38)

KRLG-XN RS5R30A 7-1/2JJx16 R225/50R16

2+2 VG30DE R200V
KRLG-XAN RE4R01A ... 45(1.77) 91V

Gl-16
 IDENTIFICATION INFORMATION
Model Variation (Cont'd)

Prefix and suffix designations:

K R L G Z32 J A S

K T-bar roof T Non-California, U.S.A.

0: Standard roof California, U.S.A.
Canada
R VG30DE
s Twin turbo
L L.H.D.
0: Non-turbo
0: R.H.D.
A: Automatic transmission
G 2+2 0: Manual transmission
0: 2 seater
J GL
0: means no indication. X GLL

Gl-17
 IDENTIFICATION INFORMATION

Identification Number

Vehicle identification number

(Chassis number)
Emission control information
label (hood)

Vehicle identification number plate

Vehicle identif.ication
plate (radiator core)

certification label
SGI617

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

JN1 R Z 2 4 S * M X 000001

Manufacturer
JN1 : Nissan, Passenger vehicle
Engine type _ _ _ _ _ _ _ _ _ ___J
T 1L Vehicle serial number

Manufacture plant
X : Hiratsuka
R VG30DE
Model year
C : VG30DETT
M : 1991 year model
Vehicle line _ _ _ _ _ _ _ _ _ _ ___J
Check digit (0 to 9 or X)
Z : NISSAN 300ZX
The code for the check digit is
Model change (0 to 9) ----------..J determined by mathematical
computation.
Body type
4 2 seater Restraint system
6 : 2+2 seater S Standard
A : Automatic

Gl-18
 IDENTIFICATION INFORMATION
Identification Number (Cont'd)
IDENTIFICATION PLATE

NISSAN MOTOR CO., LTD. JAPAN

~ it ~i:J &
CHASSIS NO
1 Type
NO Ot: CHASIS 2 Vehicle identification number (Chassis number)
110011
IIOilt:LO 3 Model
4 Body color code
0 ~::::: ~ICION 0
5 Trim color code
.x:,... ENGINE
::; ;.... MOTOR
cc 6 Engine model
! ·.1-:,..:.;.... TRANS. AXLE
7 Engine displacement
7? J1. ,_ TRANS. EJ£ 8 Transmission model
PWIT
PWITA 9 Axle model
B ~ 13 lb • ~ it ~ *i MAD! IN JAPAN SGI315

ENGINE SERIAL NUMBER

SGI612

MANUAL TRANSMISSION NUMBER AUTOMATIC TRANSMISSION NUMBER

SGI611 SGI513

Gl-19
IDENTIFICATION INFORMATION

Dimensions
Unit: mm (in)

~
It

Overall length
2 seater

4,305 (169.5)
2+2

4,520 (178.0)

Overall width 1,790 (70.5) 1,800 (70.9)

Overall T-bar roof 1,250 (49.2) 1,255 (49.4)

height Standard 1,245 (49.0) -
Wheelbase 2,450 (96.5) 2,570 (101.2)

Front 1,495 (58.9) 1,495 (58.9)

Tread
Rear 1,535 (60.4) 1,535 (60.4)

Wheels and Tires

Road wheel
Aluminum Steel Offset mm (in)

Conventional 16 X 7.5JJ 45 (1.77)

16 X 8.5JJ*1 35 (1.38)*1
T-type 16x 4T 30 (1.18)
Space-saver tire 15 X 5J 30 (1.18)

Tire size
Conventional P225/50R 16 91V
P225/50ZR 16*2
P245/45ZR 16*3
Spare
T-type T125/90D16
Space-saver tire 165/800 15FS

* 1: Rear wheel for turbo model

*2: Front tire for turbo model
*3: Rear tire for turbo model

Gl-20
 LIFTING POINTS AND TOW TRUCK TOWING

Garage Jack and Safety Stand

WARNING:
• Never get under the vehicle while it is supported only by
the jack. Always use safety stands to support the frame
when you have to get under the vehicle.
• Place wheel chocks at the front wheels when the rear
wheels are raised and place wheel chocks at the rear
wheels when the front wheels are raised.
CAUTION:
Place a wooden or rubber block between safety stand and
vehicle body when the supporting body is. flat.

Rear towing hooks

Front towing hooks

SGI609

Gl-21
LIFTING POINTS AND TOW TRUCK TOWING

2-pole Lift
WARNING:
When lifting the vehicle, open the lift arms as wide as
possible and ensure that the front and rear of the vehicle are
well balanced.
When setting the lift arm, do not allow the arm to contact the
brake tubes and fuel lines.

Note:
Lift-up points
are the same as
pantograph jack
points.

Put the sill in the slit of the lift pad to prevent

SIII~'Jhp"' the sill from deforming. If the pad does not have
the slit, prepare a suitable attachment with slit.

SGI610
.
Tow Truck Towing
CAUTION:
• All applicable state or Provincial (in Canada) laws and local
laws regarding the towing operation must be obeyed.
• It is necessary to use proper towing equipment to avoid
possible damage to the vehicle during towing operation.
Towing is in accordance with Towing Procedure Manual at
dealer.
• When towing with the rear wheels on the ground, release the
parking brake and move the gearshift lever to neutral ("N"
position).
NISSAN recommends that vehicle be towed with the driving (rear)
wheels off the ground as illustrated.

Gl-22
 LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing (Cont'd)
TOWING AN AUTOMATIC TRANSMISSION MODEL WITH
FOUR WHEELS ON GROUND OR TOWING WITH FRONT
WHEELS RAISED (With rear wheels on ground)
Observe the following restricted towing speeds and distances.
Speed:
Below 50 km/h (30 MPH}
Distance:
Less than 65 km (40 miles}
If the speed or distance must necessarily be greater, remove the
propeller shaft beforehand to prevent damage to the transmission.

Front TOWING POINT

• Always pull the cable straight out from the vehicle. Never pull
on the hook at a sideways angle.
• Remove the first bolt under the front fender protector when
using the front towing hooks.

SGI614

Gl-23
 TIGHTENING TORQUE OF STANDARD BOLTS

Bolt dia- Tightening torque (Without lubricant)

Grade Bolt size Pitch mm
meter• mm Hexagon head bolt Hexagon flange bolt
N·m kg-m ft-lb N·m kg-m ft-lb
M6 6.0 1.0 5.1 0.52 3.8 6.1 0.62 4.5
1.25 13 1.3 9 1'5 1.5 11
M8 8.0
1.0 13 1.3 9 16 1.6 12
1.5 25 2.5 18 29 3.0 22
4T M10 10.0
1.25 25 2.6 19 30 3.1 22
1.75 42 4.3 31 51 5.2 38
M12 12.0
1.25 46 4.7 34 56 5.7 41
M14 14.0 1.5 74 7.5 54 88 9.0 65
M6 6.0 1.0 8.4 0.86 6.2 10 1.0 7
1.25 21 2.1 15 25 2.5 18
M8 8.0
1.0 22 2.2 16 26 2.7 20
1.5 41 4.2 30 48 4.9 35
7T M10 10.0
1.25 43 4.4 32 51 5.2 38
1.75 71 7.2 52 84 8.6 62
M12 12.0
1.25 77 7.9 57 92 9.4 68
M14 14.0 1.5 127 13.0 94 147 15.0 108
M6 6.0 1.0 12 1.2 9 15 1.5 11
1.25 29 3.0 22 35 3.6 26
M8 8.0
1.0 31 3.2 23 37 3.8 27
1.5 59 6.0 43 70 7.1 51
9T M10 10.0
1.25 62 6.3 46 74 7.5 54
1.75 98 10.0 72 118 12.0 87
M12 12.0
1.25 108 11.0" 80 137 14.0 101
M14 14.0 1.5 177 18.0 130 206 21.0 152

1. Special parts are excluded.

2. This standard is applicable to bolts having the following
marks embossed on the bolt head. •. Nominal diameter

Grade Mark
M 6
4T .......................................... 4
7T .......................................... 7
T.....
L _ Nominal diameter of bolt threads (Unit: mm)
_ - - - Metric screw threads
9T .......................................... 9

Gl-24
 MAINTENANCE

SECTION

CONTENTS
PRECAUTIONS ..... ........ .. ... ....... .... ... ..... ..... .... ....... .. .... ... .. ... .. ..... ... ... ............ .. .... .. ..... ...... ...... ..... ..... .. MA- 2
GENERAL MAINTENANCE ............................................................................................................. MA- 3
PERIODIC MAINTENANCE ............................................................................................................. MA- 5
RECOMMENDED FLUIDS AND LUBRICANTS ........................................................................... MA- 8
ENGINE MAINTENANCE ................................................................................................................ MA-10
CHASSIS AND BODY MAINTENANCE ........................................................................................ MA-17
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ...................................................................... MA-24
 PRECAUTIONS

Supplemental Restraint System "AIR BAG"

The Supplemental Restraint System "Air Bag" helps to reduce the
risk or severity of injury to the driver in a frontal collision. The
Supplemental Restraint System consists of an air bag (located in
the center of the steering wheel), sensors, a control unit, warning
lamp, wiring harness and spiral cable. Information necessary to
service the system safely is included in the BF section of this
Service Manual.
WARNING:
a. To avoid rendering the SRS inoperative, which could lead to
personal injury or death in the event of a severe frontal
collision, all maintenance must be performed by an author-
ized NISSAN dealer.
b. Improper maintenance, including incorrect removal and in-
stallation of the SRS, can lead to personal injury caus~d by
unintentional activation of the system.
c. All SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation. Do not use electrical
test equipment on any circuit related to the SRS "Air Bag".

MA-2
 GENERAL MAINTENANCE

General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the
checks and inspections themselves or they can have their NISSAN dealers do them for a nominal charge.

Item Reference page

OUTSIDE THE VEHICLE
The maintenance items listed here should be·performed from time to time, unless otherwise
specified.

Tires Check the pressure with a gauge periodically when at a service station, including the
spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or
excessive wear.
Wheel nuts When checking the tires, make sure no nuts are missing, and check for any loose
nuts. Tighten if necessary.
Tire rotation Tires should be rotated every 12,000 km (7,500 miles) for non-turbo models. MA-21
Wheel alignment and balance If the vehicle should pull to either side while driving on a MA-20
straight and level road, or if you detect uneven or abnormal tire wear, there may be a need FA-6
for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel
balancing may be needed.
Windshield wiper blades Check for cracks or wear if they do not wipe properly.
Doors and engine hood Check that all doors and the engine hood operate smoothly as well as
the trunk lid and back hatch. Also, ensure that all latches lock securely. Lubricate hinges and
latches if necessary. Make sure that the secondary latch keeps the hood from opening when
MA-23
the primary latch is released.
When driving in areas using road salt or other corrosive materials, check lubrication fre-
quently.
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when
performing periodic maintenance, cleaning the vehicle, etc.

Lights Make sure that the headlights, stop lights, taillights, turn signal lights, and other lights
are all operating properly and installed securely. Also check headlight aim.
Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are
operating properly.
Windshield wiper and washer Check that the wipers and washer operate properly and that
the wipers do not streak.
Windshield defroster Check that the air comes out of the defroster outlets properly and in
sufficient quantity when operating the heater or air conditioner.
Steering wheel Check that it has the specified free play. Be sure to check for changes in the
steering condition, such as excessive free play, hard steering or strange noises.
Free play: Less than 35 mm (1.38 in)
Seats Check seat position controls such as seat adjusters, seatback recliner, etc. to ensure
they operate smoothly and that all latches lock securely in every position. Check that the
head restrains move up and down smoothly and that the locks (if so equipped) hold securely
in all latched positions. Check that the latches lock securely for folding'iiown rear seat-
backs.
Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the belt MA-23
webbing for cuts, fraying, wear or damage.

MA-3
 GENERAL MAINTENANCE

Item Reference page

Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free
travel. CL-6
Brakes Check that the brake does not pull the vehicle to one side when applied.
Brake pedal Check the pedal for smooth operation and make sure it has the proper distance
under it when depressed fully. Check the brake booster function. Be certain to keep the BR-7
floor mats away from the pedal.
Parking bt:ake Check that the lever has the proper travel and confirm that your vehicle is
BR-21
held securely on a fairly steep hill with only the parking brake applied.
Automatic transmission "Park" mechanism Check that the lock release button on the
selector lever operates properly and smoothly. On a fairly steep hill check that your vehicle
is held securely with the selector lever in the "P" position without applying any brakes.
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically (e.g. each time you check
the engine oil or refuel).

Windshield washer fluid Check that there is adequate fluid in the tank.
Engine coolant level Check the coolant level when the engine is cold. MA-12
Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves,
etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or
loose connections.
Brake and clutch fluid levels Make sure that the brake and clutch fluid levels are between the
"MAX" and "MIN" lines on the reservoir. MA-17, 18

Battery Check the fluid level in each cell.lt should be between the "MAX" and "MIN" lines.
Engine drive belts Make sure that no belt is frayed, worn, cracked or oily. MA-10
Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and MA·14
turning off the engine.
Power steering fluid level and lines Check the level when the fluid is cold and the engine is MA-21
turned off. Check the lines for proper attachment, leaks, cracks, etc.
Automatic transmission fluid level Check the level on the dipstick after putting the selector
MA-18
lever in "P" with the engine idling.
Exhauat system Make sure there are no loose supports, cracks or holes. If the sound of the
exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble MA-22
and correct it.
Underbody The underbody is frequently exposed to corrosive substances such as those used
on icy roads or to control dust. It is very. important to remove these substances, otherwise
rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end
of winter, the underbody should be thoroughly flushed with plain water, being careful to
clean those areas where mud and dirt can easily accumulate.
Fluid leaks Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle
has been parked for a while. Water dripping from the air conditioner after use is normal. If
you should notice any leaks or gasoline fumes are evident, check for the cause and correct it
immediately.

MA-4
 PERIODIC MAINTENANCE

Two different maintenance schedules are provided, and should be used, depending upon the conditions in which
the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance
at the same mileage/time intervals.

SCHEDULE 1
Follow Periodic Maintenance Schedule 1 if your driving habits frequently includes one or more of the following
driving conditions:
• Repeated short trips of less than 5 miles (8 km).
• Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing.
• Operating in hot weather in stop-and-go "rush hour" traffic.
• Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery
use.
• Driving in dusty conditions.
• Driving on rough, muddy, or salt spread roads.
• Towing a trailer, using a camper or a car-top carrier.

SCHEDULE 2
Follow Periodic Maintenance Schedule 2 if none of the driving conditions shown in Schedule 1 apply to your
driving habits.

MA-5
 Abbreviations: R'"' Repalce I= Inspect. Correct or replace if necessary. [ l : At the mileage intervals only
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Perform at number of miles, Miles x 1,000 3.00 3.75 7.5 11.25 15 18.75 22.5 26.25 30 33.75 37.5 41.25 45 48.75 52.5 56.25 60
Reference page
kilometers or months, (km x 1,0001 (5) (6) (121 (1 8) (241 (30) (361 (42) (481 (54) (601 (66) (721 (78) (841 (90) (961
whichever comes first. Months 3 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

EMISSION· CONTROL SYSTEM MAINTENANCE

Drive belts See NOTE (1). I* MA-10
Air cleaner filter See NOTE (2). [R) [R) MA-13
Vapor lines I* I* MA-16
Fuel lines I* I* MA-12

Fuel filter See NOT..; (3).* MA-13

See NOTE (41. R* MA-11
Engine coolant
Engine oil R R R R R R R R R R R R R R R R MA-13

Engine oil filter (Use part No.

Turbo model R Then replace every 3,000 miles (5,000 kml or 3 months.
R R R R R R R R R R R R R R R R
MA-13
MA-14
.,
15208-60000 or equivalent.!
Spark plugs (PLATINUM-TIPPED type)
Turl).o model R Then replace every oil change.
[R)
MA-14
MA-15 en
n
"'
0-
:D

Timing belt

CHASSIS AND BODY MAINTENANCE

(R] EM-13 :::r
CD
~
-
n
0

~
l>
I
Brake lines & cables
Brake pads & discs
MA-19
MA-20
c
CD' ,.-
1:
en Manual & automatic transmission MA-11, 18, 19
~
z
-t

"',.zz
oil, & differential gear oil See NOTE (5).
Steering gear & linkage, axle & suspension parts MA-21, FA-5
Steering linkage ball joints & front suspension MA-21, FA-5
ball joints
SUPER HICAS linkage (Turbo model) MA-22
MA-22
I~
Exhaust system
--
Air bag system See NOTE (6). BF-59

NOTE: (1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km) or 12 months.
(2) If operating mainly in dusty conditions, more frequent maintenance may be required.
(3) If vehicle is operated under extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high,
the filters might become clogged. In such an event, replace them immediately.
(4) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months.
(5) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil at every 30,000 miles
(48,000 km) or 24 months.
(6) Inspect the air bag systP.m 10 years after the date of manufacture as noted on the F.M.V.S.S. certification label.
(7) Maintenance items and intervals with"*" are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance
in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
 Abbreviations: R"' Repalce I =Inspect. Correct or replace if necessary. [ 1: At the mileage intervals only

MAINTENANCE OPERATION MAINTENANCE INTERVAL

Perform at number of miles, kilometers Miles x 1,000 5.0 7.5 15 22.5 30 37.5 45 52.5 60
Reference page
or months, whichever comes first. (km x 1,000) (8) (12) (24) (36) (48) (60) (72) (84) (96)
Months 6 6 12 18 24 30 36 42 48

EMISSION CONTROL SYSTEM MAINTENANCE

Drive belts See NOTE (1). I* MA·10
Air cleaner fi Iter [R] [R] MA-13
Vapor lines I* I* MA-16
Fuel lines I* I* MA-12
Fuel filter See NOTE (2) *. MA-13
Engine coolant See NOTE (3). R* MA-11
Engine oil R R R R R R R R MA-13
Turbo model R Then replace every 5,000 miles (8,000 km) or 6 months. MA-13
Engine oil filter (Use Part No. R R R R MA-14 'V
m
15208-60UOO or equivalent.}
Spark plugs (PLATINUM-TIPPED type)
Turbo model R Then replace every second oil change.
[R)
MA-14
MA-15 en
n
-0c
XI

s:
Timing belt

CHASSIS AND BODY MAINTENANCE

[R] EM-13
:r
CD
~
-n
:1>
I
Brake lines 8t cables
Brake pads 8t discs
I
I
I
I
I
I
I
I
MA-19
MA-20 -
c:
CD
3:
!:
..... Manual 8t automatic transmission oil, 8t I I I I MA-17, 18, 19
~ z
.....
differential gear oil
m
Steering gear linkage, axle 8t suspension parts
SUPER HI CAS linkage (Turbo model) I
I

I
I
I
I MA-21, FA-5
MA-22
MA-22
,..zz
I I
Exhaust system
BF-59 n
Air bag system See NOTE (4). m
NOTE: (1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km) or 12 months.
(2) If vehicle is operated under extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high,
the filters might become clogged. In such an event, replace them immediately.
(3) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months.
(4) Inspect the air bag system 10 years after the date of manufacture as noted on the F.M.V.S.S. certification label.
(5) Maintenance items and intervals with"*" are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance
in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
 RECOMMENDED FLUIDS AND. LUBRICANTS

Fluids and Lubricants

Capacity (Approximate)
Recommended fluids and lubricants
us Imp
Liter
measure measure
Engine oil (Refill)
With oil filter 3-5/8 qt 3 qt 3.4
Energy Conserving Oils of API SG*2, *3
Without oil filter 3-1/8 qt 2-5/8 qt 3.0

Cooling system (With reservoir) 10-5/8 qt 8-3/4 qt 10.0 Anti-freeze coolant (Ethylene glycol base)

Manual transmission gear oil 5-7/8 pt 4-7/8 pt 2.8 API GL-4*2

Differential gear oil 3-1/8 pt 2-5/8 pt 1.5

API GL-5*2
Turbo model 3-7/8 pt 3-1/8 pt 1.8

Automatic transmission fluid 8-3/4 qt 7-1/4qt 8.3 Genuine Nissan ATF*1 or equivalent
Type DE)<RON™
Turbo model 8-5/8 qt 7-1/4qt 8.2

Power steering fluid Type DEXRON™

Genuine Nissan Brake Fluid*1 or equivalent

Brake and clutch fluid
DOT3 (US FMVSS No.116)

Multi-purpose grease NLGI No.2 (Lithium soap base)

*1: Available in mainland U.S.A. through your Nissan dealer.

*2: For further details, see "Recommended SAE viscosity number".
*3: Energy conserving oils
These oils can be identified by such labels as EC-1, EC-11, energy conserving, energy saving, improved fuel economy, etc.

MA-8
 RECOMMENDED FLUIDS AND LUBRICANTS

SAE Viscosity Number

Outside Temperature Range Outside Temperature Range
Anticipated Before Next Oil Change Anticipated Before Next Oil Change
ENGINE OIL GEAR OIL

0 +32~~~

SW-30

TI0002 TIOOOJ

1OW-30 is preferable for ambient temperatures 75W-90 for transmission and SOW-90 for differential
above -18°C (0°F). 20W-40 and 20W-50 are usable gear are preferable for ambient temperatures
for ambient temperatures above 10°C (50°F) for all below 40°C (104°F).
seasons.
For turbo engines, SW-30 should be used only
under extremely cold conditions.

MA-9
 ENGINE MAINTENANCE

Checking Drive Belts

Air conditioner
compressor

Alternator

/ Crankshaft
pulley
Idler
pulley

Adjusting bolt

'Y : Check point ~ : N·m (kg-m, ft-lb)

SMA141C

1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,

replace with a new one.
2. Inspect drive belt deflection by pushing on the belt midway
between pulleys.
Adjust if belt deflection exceed the limit.
Belt deflection: Unit: mm (in)

~
Used belt deflection
Deflection Deflection
Limit after of new belt
adjustment

7-8 6.5-7.5
Alternator 11.5 (0.453)
(0.28- 0.31) (0.256- 0.295)
8-9 7-8
Air conditioner compressor 12.5 (0.492)
(0.31 - 0.35) (0.28 . 0.31)
12-13.5 10.5- 11.5
Non-Turbo 19 (0.75)
Power steering (0.472- 0.531) (0.413- 0.453)
oil pump 10- 11 9- 10
Turbo 16 (0.63)
(0.39- 0.43) (0.35- 0.39)
Applied pushing force 98 N (10 kg, 22 lb)

Inspect drive belt deflection when engine is cold.

MA-10
 ENGINE MAINTENANCE

Changing Engine Coolant

WARNING:
To avoid the danger of being scalded, never change the coolant
when the engine Is hot.
======= tKitH Tl~iF.: ·-=-- -= MANUAL CONTROL
At·1E: I EtH :::Et-l 7 4. :::• F
E:•EF DUCT :::Et-l i'7. 5" F 1. Turn ignition switch "ON" and set temperature control lever of
UENT DUCT SEN 77.9"F
FLCil::iF.: DUCT :::E 77. 5" F manual air conditioner to maximum hot position.

AUTOMATIC CONTROL
M~= 1. Perform "AIR MIX DOORS" test in "ACTIVE TEST"
~ mode of "AUTO A/C" (Automatic Air Conditioner)
system.
Set "AIR MIX DOORS" at (full) HOT and wait 10
seconds before turning ignition switch off.
Perform self-diagnosis step 2 of Automatic Air Condi-
tioner system, referring to the following notes:
Turn ignition switch from "OFF" to "ON".
Press both "AUTO" and "OFF" switches for at least 5
seconds.
3) Press "AUTO" switch 2 times.
4) Confirm indication of the A/C display shown at left.
5) Wait 10 seconds before turning ignition switch off.

2. Open drain cock at the bottom of radiator, and remove radiator

cap.

3. Open drain plugs on both sides of cylinder block.

• Left side drain plug is located beside the left side engine
mounting.

MA-11
 ENGINE MAINTENANCE
Changing Engine Coolant (Cont'd)
4. Open air release plug to drain coolant.
5. Flush cooling system by running fresh water through radiator.
6. Close drain cock and tighten drain plugs securely.
• Apply sealant to the drain plug thread.
tcJ: 34 - 44 N•m
(3.5 - 4.5 kg-m, 25 - 33 ft-lb)

7. Fill radiator slowly with proper mixture of coolant and water. Fill
reservoir tank up to the "H" level. Then install radiator cap and
close air release plug.
Coolant capacity (With reservoir tank):
10.0 Q (10-5/8 US qt, 8-3/4 Imp qt)
Resenioir tank:
0.6 Q (5/8 US qt, 1/2 Imp qt)
Pour coolant through coolant filler neck slowly to allow air in
system to escape.

8. Start engine and warm it up until it reaches normal operating

temperature. Then race engine 2 or 3 times under no-load.
Watch coolant temperature gauge for signs of overheating.
9. Stop engine. After it completely cools down, refill radiator up to
filler opening. Fill reservoir tank up to the "H" level.
MAX. 10. Check drain cock and drain plug for any sign of leakage.

MIN.

SMA412B

Checking Fuel Lines

Inspect fuel lines and tank for improper attachment and for leaks,
cracks, damage, loose connections, chafing and deterioration.
If necessary, repair or replace faulty parts.

CAUTION:
3 mm 10.12 in)·
Tighten high-pressure rubber hose clamp so that clamp end is 3
mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber hose
clamps.
rRJ Fuel hOII clamps Ensure that screw does not contact adjacent parts.
· 1.0- 1.5 N·m
10.10- 0.15 kg-m,
0.7 - 1.1 ft-lb)

SMAB04A

MA-12
 ENGINE MAINTENANCE

Changing Fuel Filter

I FUEL PRES RELEASE I WARNING:
FUEL PUI·lP l•.IILL STOP E:'/ Before removing fuel filter, release fuel pressure from fuel line to
TOUCHHKi :3TAF.:T C:•URHll3 eliminate danger.
!OLE. .
CRANK A FEW TIMES AF-
TER ENGINE STALL. 00 1. Perform "FUEL PRESSURE RELEASE" in "WORK
SUPPORT" mode and release fuel pressure to zero.
2. Turn ignition switch off.

:=;:TJ:...F:T
SMA235C

fa>\1.
Disconnect fuel pump relay and start engine.
~2. After engine stalls, crank engine two or three times to
make sure that fuel pressure is released. Then turn
ignition switch off and reconnect fuel pump relay.

3. Loosen fuel hose clamps.

4. Replace fuel filter.
• Be careful not to spill fuel over engine compartment. Place a
shop towel to absorb fuel.
• Use a high-pressure type fuel filter. Do not use a synthetic
resinous fuel filter.
• When tightening fuel hose clamps, refer to "Checking Fuel
Lines".

Changing Air Cleaner Filter

The viscous paper type filter does not need cleaning between
renewals.

Changing Engine Oil

WARNING:
Be careful not to burn yourself, as the engine oil is hot.
1. Warm up engine, and check for oil leakage from engine
components.
2. Remove drain plug and oil filler cap.

MA-13
 ENGINE MAINTENANCE
Changing Engine Oil (Cont'd)
3. Drain oil and refill with new engine oil.
Oil capacity (Refill): Q (US qt, Imp qt)
With oil filter
3.4 (3-5/8, 3)
Without oil filter
3.0 (3-1/8, 2-5/8)

CAUTION:
• Be sure to clean drain plug and install with new washer.
Oil pan drain plug:
A: 29- 39 N•m
(3.0 - 4.0 kg-m, 22 - 29 ft-lb)
• Use recommended engine oil.
• Since the refill capacity changes depending on the oil
temperature and drain time, use these values as a reference
and be certain to check with the dipstick when changing the
oil.

4. Check oil level.

5. Start engine and check area around drain plug and oil filter for
oil leakage.
6. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.

"H"Ievel
Do not overfill.
SMA151C

Changing Oil Filter

1. Remove oil filter with a suitable tool.

WARNING:
Be careful not to burn yourself, as the engine and engine oil are
hot.

2. Before installing a new oil filter, clean the oil filter mounting
surface on cylinder block, and coat the oil filter rubber seal with
a little engine oil.

SMA010

MA-14
 ENGINE MAINTENANCE
Changing Oil Filter (Cont'd)
3. Screw in the oil filter until a slight resistance is felt, then tighten
additionally more than 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
2/3 of a turn

Changing Spark Plugs

1. Disconnect ignition coil harness connector.
2. Loosen ignition coil fixing bolts and pull out coil from intake
manifold collector.

• When changing No. 5 and No. 6 cylinder spark plugs, remove

balance tube first. (0-rings of balance tube may be reused, if
they are not worn.)

g
3. Remove spark plugs with suitable spark plug wrench.
Wrench with a magnet
to hold spark plug
Spark plug (Platinum-tipped type):
Non-turbo Turbo
Standard type PFR6B-11 PFRSB-11B
Hot type PFRSB-11 Ditto
1&mm Cold type PFR7B-11 PFR6B-11B
(0.63 in)
PFR6B-11
to.J: 20 - 29 N•m (2 - 3 kg-m, 14 - 22 ft-lb)

SEM294A

• Checking and adjusting plug gap are not required between

renewals.
• Do not use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used.
Cleaner air pressure:
Less than 588 kPa (6 kg/cm2 , 85 psi)
Cleaning time:
Less than 20 seconds

5 lines SMA673B

MA-15
ENGINE MAINTENANCE

Checking Vapor Lines

1. Visually inspect vapor lines for improper attachment and for
cracks, damage, loose connections, chafing and deterioration.
2. Inspect vacuum relief valve of fuel tank filler cap for clogging,
sticking, etc.
Refer to "EVAPORATIVE EMISSION CONTROL SYSTEM" in EF &
EC section.

MA-16
 CHASSIS AND BODY MAINTENANCE

Checking Clutch Fluid Level and Leaks

• If fluid level is extremely low, check clutch system for leaks.
Max.

Min.

SMA941B

Checking M/T Oil

1. Check for oil leakage.

SMA429A

2. If leakage is found, check oil level.

Never start engine while checking oil level.
Filler plug:
A: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

SMA103

Changing M/T Oil

1. Drain oil and refill with new gear oil.
2. Check oil level.
Oil capacity:
2.8 Q (5-7 /8 US pt, 4-7/8 Imp pt)
Drain plug:
A: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

SMA255A

MA-17
 CHASSIS AND BODY MAINTENANCE

Checking A/T Fluid

1. Check for fluid leakage.

SMA430A

• Front side
2. If leakage is found, check fluid level.
Hot: 50· 80°C O.K. Fluid level should be checked using "HOT" range on
(122·176°F) dipstick at fluid temperatures of 50 to 80°C (122 to 176°F)
after vehicle has been driven approximately 5 minutes in
urban areas after engine is warmed up. But it can be
checked at fluid temperatures of 30 to 50°C (86 to 122°F)
using "COLD" range on dipstick for reference after engine
is warmed up and before driving. However, fluid level must
be rechecked using "HOT" range.
1) Park vehicle on level surface and set parking brake.
2) Start engine and then move selector lever through each
gear range, ending in "P".
3) Check fluid level with engine idling.
4) Remove dipstick and wipe it clean with lint-free paper.
5) Reinsert dipstick into charging pipe as far as it will go.
6) Remove dipstick and note reading. If level is at low side of
either range, add fluid to the charging pipe.
Do not overfill.

3. Check fluid condition.

Check fluid for contamination. If fluid is very dark or smells
burned, or contains frictional material (clutches, band, etc.),
check operation of A/T.
Refer to section AT for checking operation of A/T.

Check fluid for contamination.

SMA853B

Changing A/T Fluid

1. Drain fluid by removing oil pan.
2. Replace gasket with new one.
3. Refill with fluid and then check fluid level.
Oil capacity (With torque converter):
Non-turbo
8.3 Q (8-3/4 US qt, 7-1/4 Imp qt)
Turbo
8.2 Q (8-5/8 US qt, 7-1/4 Imp qt)
SMA921B

MA-18
 CHASSIS AND BODY MAINTENANCE

Checking Differential Gear Oil

1. Check differential carrier for oil leakage.

SMA012C

2. If leakage is found, check oil level.

Filler plug:
~: 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb)

SMA257A

Changing Differential Gear Oil

1. Drain oil and refill with new gear oil.
2. Check oil level.
Oil capacity:
For non-turbo
1.5 Q (3-1/8 US pt, 2-5/8 Imp pt)
For turbo
1.8 Q (3-7/8 US pt, 3-1/8 Imp pt)
Drain plug:
~: 39 - 59 N•m (4 - 6 kg-m, 29 - 43 ft-lb)
SMA363A

Checking Brake Fluid Level and Leaks

• If fluid level is extremely low, check brake system for leaks.
=
MAX

=MIN

Checking Brake Lines and Cables

• Check brake fluid lines and parking brake cables for im-
proper attachment and for leaks, chafing, abrasions, deteri-
oration, etc.

SMA732A

MA-19
CHASSIS AND BODY MAINTENANCE

Checking Disc Brake

• Check condition of disc brake components.
ROTOR
• Check condition and thickness.
Unit: mm (in)

SMA260A
-------
Disc brake type

Standard thickness
Front

OPZ25VA

30.0 (1.181)
Rear

OPZ11VB

18 (0.71)

Minimum thickness 28.0 (1.102) 16.0 (0.630)

CALIPER
• Check operation and for leakage.

SBR739A

PAD
• Check for wear or damage.

------
Unit: mm (in)

Front Rear

Disc brake type OPZ25VA OPZ11VB

Standard thickness 10.0 (0.394) 11.5 (0.453)

Minimum thickness 2.0 (0.079)

SMAB47B

Balancing Wheels
• Adjust wheel balance using road wheel center.
Wheel balance (Maximum allowable unbalance
at rim flange):
Refer to S.O.S.

MA-20
 CHASSIS AND BODY MAINTENANCE

FRONT Tire Rotation (Non-turbo model only)

0 0lf
!i
• Do not Include the T-type or space saver spare tire when
rotating the tires.
Wheel nuts:
~: 98 - 118 N·m
(10.0 - 12.0 kg-m, 72 - 87 ft-lb)

004WHEELS
SMA736A

Checking Steering Gear and Linkage

STEERING GEAR
• Check gear housing and boots for looseness, damage or
grease leakage.
• Check connection with steering column for looseness.
STEERING LINKAGE
• Check ball joint, dust cover and other component parts for
• : Check grease leakage. looseness, wear, damage or grease leakage .

Q: Check tightening torque.

SST335B

Checking Power Steering Fluid and Lines

CHECKING FLUID LEVEL (WITHOUT SUPER HICAS
SYSTEM)
Fluid level should be checked using "HOT" range on dipstick at
fluid temperatures of 50 to 80°C (122 to 176°F) or using "COLD"
range on dipstick at fluid temperatures of 0 to 30°C (32 to 86°F).
CAUTION:
Do not overfill.

CHECKING FLUID LEVEL (WITH SUPER HICAS SYSTEM)

Maintain the fluid level so that the lower surface of the float is
maintained between the "L" and "H" marks on the gauge rod. The
fluid level should be checked when the engine is stopped and the
.----~;;::;;:::===:: O.K. fluid temperature is about 30°C (86°F).
CAUTION:
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid
"Dexron™" type.
• Note that fluid level will vary with fluid temperature by approx.
SST373B 1 mm/5°C (0.04 in/9°F) due to changes in fluid volume.
CHECKING LINES
Check lines for improper attachment, leaks, cracks, damage, loose
connections, chafing and deterioration.

MA-21
 CHASSIS AND BODY MAINTENANCE

Checking SUPER HICAS Linkage (With SUPER

HICAS system)
• Check power cylinder and linkage for damage, looseness and
leakage of oil or grease.

Q : Check tightening torque .

• : Check oil or grease leakage.

SMA188C

Checking Exhaust System

• Check exhaust pipes, muffler and mounting for proper attach-
ment, leaks, cracks, damage, loose connections, chafing and
deterioration.

SMA211A

MA-22
 CHASSIS AND BODY MAINTENANCE

Lubricating Locks, Hinges and Hood Latches

~---
~

SMA170C

Checking Seat Belts, Buckles, Retractors,

Anchors and Adjusters

CAUTION:
1. All seat belt assemblies, including
retractors and attaching I:Jardwares
such as guide rail set, etc., should be
inspected after any collision. Nissen
recommends that all seat belt assem- Check anchors for loose mounting.
blies in use during a collision be
replaced unless the collision was Check belts
minor and the belts show no damage
for damage.
and continue to operate properly.
Seat belt assemblies not in use during
a collision should also be inspected Check retractor
for smooth
and replaced if either damage or operation.
improper operation is noted.
2. If the condition of any component of
seat belt assembly is questionable, do
not have it repaired, but replaced as
seat belt assembly.
3. If webbing is cut, frayed, or damaged,
replace belt assembly.
4. Oo not spill drinks, oil, etc. on inner
lap belt buckle. Never oil tongue
and buckle.
5. Use a NISSAN genuine seat belt
assembly.
Check function of buckles
r.c!J Anchor bolt and tongues when buckled
and released.
43-55 N·m
(4.4- 5.6 kg-m, 32-41 ft-lb)
For automatic seat belt details,
refer to BF section.
SMA431C

MA-23
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Engine Maintenance

INSPECTION AND ADJUSTMENT

Drive belt deflection Spark plug
Unit: mm (in) Non-Turbo

~
Used belt deflection Standard type PFRSB-11
Deflection
Deflection of
Hot type PFR5B-11
Limit after new belt
adjustment
Cold type PFR7B-11
7-8 6.5-7.5
Alternator 11.5 (0.453)
(0.28 - 0.31) (0.256 - 0.295)
Turbo
Air conditioner 8-9 7·8
12.5 (0.492) Standard & hot type PFR5B-11B
compressor (0.31 - 0.35) (0.28 - 0.31)

Power steering oil Cold type PFR686B-11 B, PFR6B-11

pump
12-13.5 10.5- 11.5
Non-Turbo 19 (0.75)
(0.472-0.531) (0.413-0.453)

10- 11 9- 10
Turbo 16 (0.63)
(0.39- 0.43) (0.35- 0.39)

Applied pushing
98 N (10 kg, 22 lb)
force

Oil capacity (Refill)

Unit: 2 (US qt, Imp qt)

With oil filter 3.4 (3-5/8, 3)

Without oil filter 3.0 (3-1/8, 2-5/8)

Coolant capacity
Unit: 2 (US qt, Imp qt)

With reservoir tank 10.0 ( 1Q-5/8, 8-3/4)

Reservoir tank 0.6 (5/8, 1/2)

MA-24
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Chassis and Body Maintenance

INSPECTION AND ADJUSTMENT Brake

Unit: mm (in)
Clutch
Disc brake
Unit: mm On)
Pad
VG30DE VG30DETT Standard thickness
Engine
OPZ25VA 10.0 (0.394)
197- 207 183- 193
Pedal free height
(7.76- 8.15) (7.20-7.60) OPZJ1VB 11.5 (0.453)

Pedal free play 1 - 3 (0.04- 0.12) Minimum thickness

OPZ25VA 2.0 (0.079)

OPZ11VB 2.0 (0.079)

Front axle and front suspension (Unladen)* Rotor

Standard thickness
Camber degree OPZ25VA 30.0 (1.181)

Caster degree OPZ11VB 18 (0.71)

Toe-in mm (in) 0- 2 (0 - 0.08) Minimum thickness

OPZ25VA 28.0 ( 1.1 02)
(Total toe-in angle) degree 0'- 11'
OPZ11VB 16.0 (0.630)
Kingpin inclination degree
Pedal
Front wheel turning angle Free height
Full turn M/T 186-196 (7.32 -7.72)
degree
Inside/outside
A/T 195-205 (7.68- 8.07)
*· Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions. Free play at clevis 1-3 (0.04-0.12)

Depressed height
[under force of 490 N (50 kg,
Rear axle and rear suspension (Unladen)* 110 lb) with engine running]
M/T
Camber degree Without A.B.S. 95 (3. 74) or more

Toe-in mm(in) 0- 4 (0- 0.16) With A B.S. 105 (4.13) or more

(Total toe-in angle) degree o· -23' A/T

Without A.B.S. 105 (4.13) or more
*· Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions. With A.B.S. 110 (4.33) or more

Parking brake
Number of notches
[at pulling force 196 N 6-7
Wheel bearing
120 kg, 44 lbl I
Front Rear

Wheel bearing axle end 0.05 (0.0020)

play mm (in) or less
Wheel balance
Wheel bearing lock nut
Dynamic
206-284 206-275 10 (0.35)
Tightening torque (at rim flange)
(21- 29, (21- 28, Maximum (One side)
N-m (kg-m, ft-lb) g (oz)
152- 210) 152- 203) allowable
unbalance Static
20 (0.71)
g (oz)

MA-25
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Chassis and Body Maintenance (Cont'd)
TIGHTENING TORQUE
Unit N·m kg-m ft-lb

Clutch
A.S.C.D. cancel switch, 12. 15 1.2. 1.5 9. 11
HI CAS clutch switch and
power steering clutch.
switch lock nut
Manual transmission
Drain and filler plugs 25-34 2.5. 3.5 18.25
Final drive
Drain plug 39-59 4-6 29-43
Filler plug 39-59 4-6 29-43
Front axle and front
suspension
Tie-rod lock nut 78-98 8.0. 10.0 58.72
Rear axle and rear
suspension
Toe adjusting pin 69-88 7.0-9.0 51.65
Camber adjusting pin 69-88 7.0· 9.0 51.65
(Models without
super HICASI
Lower link lock nut 37-46 3.8-4.7 27.34
(Models with super
HICAS)
Brake system
Air bleed valve 7-9 0.7-0.9 5.1 -6.5
Brake lamp switch lock 12. 15 1.2. 1.5 9. 11
nut
. Breke booster input 16-22 1.6-2.2 12. 16
rod lock nut
Wheel and tire
Wheel nut 98. 118 10.0. 12.0 72 ·87

MA-26
 ENGINE MECHANICAL

SECTIONE

CONTENTS
PRECAUTIONS ................................................................................................................................. EM- 2
PREPARATION ................................................................................................................................. EM- 3
OUTER COMPONENT PARTS ....................................................................................................... EM- 6
COMPRESSION PRESSURE ...... .... ............................... .. .......... ................ ..... ....... .......... ....... ...... .. EM- 9
OIL PAN ............................................................................................................................................ EM-10
TIMING BELT .................................................................................................................................... EM-13
OIL SEAL REPLACEMENT ............................................................................................................ EM-21
THROTTLE CHAMBERS ............ ........... .......... ....... .................... ... ......... .... ..... ......... ... ..... ......... ...... EM-23
CYLINDER HEAD ...... ....... ....... .................... .. ......... ........ ... .............. .. ................ .......... ........ ... .. ...... .. EM-26
TURBOCHARGERS .......................................................................................................................... EM-38
INTERCOOLERS ........ ............ ... .............. ........... .. ........... ... ............................ ......... .. ........... ..... ...... .. EM-43
ENGINE REMOVAL ......................................................................................................................... EM-44
CYLINDER BLOCK ..................... ........................................ ................... ...... ....... ... .............. ......... ... EM-48
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ...................................................................... EM-60
 PRECAUTIONS

Supplemental Restraint System "AIR BAG"

The Supplemental Restraint System "Air Bag" helps to reduce the
risk or severity of injury to the driver in a frontal collision. The
Supplemental Restraint System consists of an air bag (located in
the center of the steering wheel), sensors, a control unit, warning
lamp, wiring harness and spiral cable. Information necessary to
.· service the system safely is included in the BF section of this
Service Manual.
WARNING:
a. To avoid rendering the SRS inoperative, which could lead to
personal injury or death in the event of a severe frontal
collision, all maintenance must be performed by an author-
ized NISSAN dealer.
b. Improper maintenance, including incorrect removal and in-
stallation of the SRS, can lead to personal injury caused by
unintentional activation of the system.
c. All SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation. Do not _use electrical-
test equipment on any circuit related to the SRS "Air Bag".

Parts Requiring Angular Tightening

• Some important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
• If these parts are tightened using a torque setting- method,
dispersal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method. . .
e Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they shoutd b~ used for
reference only.
• To assure the satisfactory maintenance of the engine, bolts and
nuts must be tightened using an angular-tightening method.
• Before tightening the bolts and nuts, ensure that the thread
and seating surfaces are clean and then coated with engine oil.
• The bolts and nuts which require the angular-tightening method
are as follows:
(1) Cylinder head bolts
(2) Connecting rod cap nuts

Liquid Gasket Application Procedure

a. Before applying liquid gasket, use a scraper to remove all

~
t;,,. traces of old liquid gasket from mating surface.
b. Apply a continuous bead of liquid gasket to mating surfaces.
· Inner
side {Use Genuine Liquid Gasket or equivalent.)
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide {for oil pan).
Groove Bolt hole • Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in)
wide {in areas except oil pan).
c. Apply liquid gasket to inner sealing surface around entire
SEM371C perimeter area.
(Assembly should be done within 5 minutes after coating.)
d. Walt at least 30 minutes before refilling engine oil and engine
coolant.

EM-2
 PREPARATION

SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

ST0501SOOO Disassembling and assembling

( )
Engine stand
assembly
CD ST05011000
( )
Engine stand
® ST05012000
( )
Base

KV10106500
( )
Engine stand shaft

KV10110001
( )
Engine sub-
attachment

ST10120000 Loosening and tightening

(J24239-01) cylinder head bolt
Cylinder head bolt
wrench

KV10111300 Disassembling and assembling

( ) valve components
Valve spring
compressor

CD KV10107501 Installing valve oil seal

( )
Valve oil seal drift
® KV10111400
( )
Attachment

ST27180001 Removing crankshaft pulley

(J25726-A)
Steering wheel puller

KV10114400 Loosening or tightening

(J-38365) exhaust gas sensor
Exhaust gas sensor
wrench

EM-3
 PREPARATION

Tool number
(Kent-Moore No.) Description
Tool name

CD EG14860000 Adjusting timing belt tension

(J-38387)
Push-pull gauge
® KV10112000

! 7"""]~
( ) ((
Hook

CD

(J36467) Removing valve oil seals

Valve oil
seal remover

EM03470000 Installing piston assembly into

(J8037) cylinder bore
Piston ring compressor

ST16610001 Removing crankshaft pilot bushing

(J23907)
Pilot bushing puller

KV10111100 Removing oil pan

( )
Seal cutter

WS39930000 Pressing the tube of liquid gasket

( )
Tube presser

ST33200000 Installing camshaft oil seal

(J26082)
Drift

KV38100300 Installing front oil seal

(J22888)
Drift

ST15310000 Installing rear oil seal

(J25640-BI
Drift

EM-4
 PREPARATION

COMMERICAL SERVICE TOOLS

Tool name Description

0
Spark plug wrench Removing and installing spark plug

16mm
(0.63inl

Pulley holder Holding camshaft pulley while

tightening or loosening camshaft €.----~~
bolt

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring

Valve guide drift Removing and installing valve guide

Intake & Exhaust:

A =9.5 mm (0.374 in) dia.
B =5.5 mm (0.217 in) dia.

Valve guide reamer Reaming valve guide CD

or hole for
oversize valve guide @

01 =6.0 mm (0.236 in) dia.

0 2 = 10.2 mm (0.402 in) dia.
o.

Engine slinger
Engine VG30DE VG30DETT

Front 10005-30P 10 10005-40P 10

Rear 10006-30P 10

EM-5
 OUTER COMPONENT PARTS

To intake manifold
collector Exhaust gas temperature
sensor (California model only)
E.G.R. control valve

~ 8.4-10.8
(0.86- 1.1,
6.2- 8.0)

Oil

Exhaust gas sensor

Exhaust gas sensor
~40- 50
(4.1- 5.1, 30- 37)

Gasket~
-~~ Exhaust manifold
Gasket~ \_ (Left side)
~24- 27
(2.4 - 2.8, 17 . 20)
'-------------------Non-turbo model--.....,..--------------.....1

~ : N·m (kg-m, ft-lb)

SEM807C

EM-6
 OUTER COMPONENT PARTS

Turbo model
Right side ~6.3-8.3~
Air inlet
(0.64 . 0.85, .Jil
4.6 -6.1) <.:.
Gasket~

Pre-catalyst cover

Gasket~

~ 16-21 (1.6-2.1,12-15)_)
Oil return tube j
~'
~ 6.3 . 8.3 (0.64. 0.85, 4.6 . 6.1)

Left side
Water tube

Exhaust manifold Exhaust gas sensor

Manifold cover

Turbocharger
unit

Oil inlet tube

Gak~
Pre-catalyst cover

Oil return tube

Ta~
Wastegate valve actuator
~ : N·m (kg-m, ft-lb)

SEM773C

EM-7
 OUTER COMPONENT PARTS

~ 16-21 (1.6-2.1,12-15)

I.A.A. unit
(A.A.C. valve and
F.I.C.D. solenoid)
Gasket~

~1st:
2nd: Intake manifold collector
3rd:

Throttle sensor &

~1st:
throttle valve switch
2nd:
To intake
manifold collector
balance tube
Fuel damper
~ 2.5-3.2 Fuel
(0.25 . 0.33, 1.8 . 2.4)

intake
manifold

Fuel temperature
Insulator sensor

Intake manifold

Gasket~
3·5
(0.3-0.5,
2.2- 3.6)
2nd: 16.20
(1.6. 2.0,
Front 12 -14)
side

~: N·m (kg-m, ft-lb)

SEM618C

EM-8
COMPRESSION PRESSURE

Measurement of Compression Pressure

1. Warm up engine.
2. Turn ignition switch off.
3. Release fuel pressure.
Refer to "Releasing Fuel Pressure" in section EF & EC.
4. Remove all spark plugs.
5. Disconnect crank angle sensor harness connector.

6. Attach a compression tester to No. 1 cylinder.

7. Depress accelerator pedal fully to keep throttle valve wide open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown.
Always use a fully-charged battery to obtain specified engine
revolution.
Compression pressure:
Unit: kPa (kg/cm 2 , psi)/300 rpm

VG30DE VG30DETT

-------------
Standard 1,285 (13.1,186) 1,177 (12.0, 171)

Minimum 981 (10.0, 142) 883 (9.0, 128)

Difference limit
98 (1.0, 14)
between cylinders

10. If cylinder compression in one or more cylinders is low, pour a

small amount of engine oil into cylinders through the spark plug
holes and retest compression.
• If adding oil helps compression, piston rings may be worn or
damaged. If so, replace piston rings after checking piston.
• 'If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valves and valve seats. (Refer
to S.O.S.) If valves or valve seats are damaged excessively,
replace them.
• If compression In any two adjacent cylinders is low and if
adding oil does not help compression, there may be leakage
past gasket surface. If so, replace cylinder head gasket.

EM-9
 OIL PAN

Removal
1. Drain engine oil.
2. Remove engine under cover.

SEM774C

3. Remove oil filter and bracket.

4. Remove engine rear gussets from both sides.

5. Disconnect A/C tube clamps as shown.

6. Disconnect steering column lower joint.

7. Remove tension rod fixing bolts from both sides.
8. Loosen transverse link bolts on both sides.

EM-10
 OIL PAN
Removal (Cont'd)
9. Set a suitable transmission jack under the suspension member.
• At this time, hoist engine with engine slingers.
10. Remove suspension member fixing bolts.
11. Remove engine mounting bolts from both sides and then slowly
lower transmission jack.
12. Remove oil pan bolts.

Oil pan Transmission

jack
Suspension member
SEM627C

13. Remove oil pan.

(1) Insert Tool between cylinder block and oil pan.
• Do not drive seal cutter into oil pump or rear oil seal retainer,
as aluminum mating surfaces may be damaged.
• Do not insert screwdriver, or oil pan flange may be deformed.

(2) Slide Tool by tapping its side with a hammer, and remove oil
pan.

(3) Remove oil pan.

Installation
1. Before installing oil pan, remove all traces of liquid gasket from
mating surface using a scraper.
• Also remove traces of liquid gasket from cylinder block mating
surface.

EM-11
 OIL PAN
Installation (Cont'd)
2. Apply sealant to oil pump gasket and rear oil seal retainer
gasket.

(8) : Sealing point

SEM894B

3. Apply a continuous bead of liquid gasket to oil pan mating

surface.
Use Genuine Liquid Gasket or equivalent.

• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide.

Cut here.

~ --------J
liQuid gasket

SLC906

4. Apply liquid gasket to inner sealing surface as shown in figure.

• Attaching should be done within 5 minutes after coating.

Inner
side

Groove Bolt hole SEM909B

5. Install oil pan.

@®@®®®® • Install bolts/nuts in their reverse order of removal.
=· ~
• Walt at least 30 minutes before refilling engine oil.

EM-12
 TIMING BELT

CAUTION:
a. Do not bend or twist timing belt.
b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike
piston heads.
c. Make sure that timing belt, camshaft sprocket, crankshaft sprocket, idler pulley and auto-tensioner are
clean and free of oil and water.
d. Timing belt installation should be carried out when engine is cold.

Timing belt cover (Rear)

~ 3. 5 (0.3. 0.5, 2.2. 3.61

Timing belt cover (Upper)

Right side camshaft

sprocket (lntakel

~43 . 58 (4.4 . 5.9, 32 . 431

Idler pulley

~
~rPJ14·19
(1.4. 1.9, 10. 141

~~

Crankshaft sprocket

Timing belt plate

Crank angle sensor
fR116. 21 (1.6. 2.1, 12. 151
Timing belt

Crankshaft pulley

rPJ : N·m (kg·m, ft-lbl

SEM619C

EM-13
 TIMING BELT

Removal
1. Remove engine under cover.
2: Drain coolant from both cylinder block drain plugs, and radiator
drain cock.

Cooling fan 3. Remove radiator.

and coupling 4. Remove drive belts, cooling fan and coupling.

5. Remove crankshaft pulley bolt.

(At this time, remove starter motor and set a suitable tool to
ring gear so that crankshaft cannot rotate.)

6. Remove crankshaft pulley using Tool.

EM-14
 TIMING BELT
Removal (Cont'd)
7. Remove water inlet and outlet.
8. Remove front timing belt covers.

9. Install a suitable stopper bolt (M6) into tensioner arm of

auto-tensioner so that auto-tensioner pusher does not spread
out.

Stopper bolt
(M6 size)

Unit: mm (in) SEM634C

10. Set No. 1 cylinder at T.D.C. on its compression stroke.

11. Remove auto-tensioner and timing belt.

EM-15
 TIMING BELT

Inspection
Visually check the condition of timing belt.
Replace if any abnormality is found.

Item to check Problem Cause

Tooth is broken/ • Camshaft jamming

tooth root is • Distributor jamming
cracked.
• Damaged camshaft/crankshaft oil seal

SEM394A

Back surface is • Tensioner jamming

cracked/worn.
• Overheated engine
• Interference with belt cover

SEM395A

Side surface is worn. • Improper installation of belt

• Malfunctioning crankshaft pulley plate/
timing belt plate

• Belt corners are worn and round.

• Wicks are frayed and coming out. SEM396A

Teeth are worn. • Poor belt cover sealing

• Coolant leakage at water pump

;71/;h f!dn •
•
Camshaft not functioning properly
Distributor not functioning properly

~ f!!!!!!:J' • Excessive belt tension

Rotating direction

• Canvas on tooth face is worn down.

• Canvas on tooth is fluffy, rubber layer is
wom down and faded white, or weft is
worn down and invisible. SEM397A

Oil/Coolant or water is • Poor oil sealing

stuck to belt.
• Coolant leakage at water pump
• Poor belt cover sealing

EM-16
 TIMING BELT
Inspection {Cont'd)
AUTO-TENSIONER
Check for oil leaks from pusher rod and diaphragm.
Pusher
Arm

Tensioner
pulley

Diaphragm

<Pusher> SEM636C

Installation
1. Confirm that No. 1 cylinder is set at T.D.C. on its compression stroke.
2. Align matching marks on camshaft and crankshaft sprockets with aligning marks on rear belt cover and oil
pump housing.
3. Remove all spark plugs.

Aligning mark
Aligning mark
Aligning mark
I /
~ ~
Aligning mark

r- Intake

Exhaust
camshaft
sprocket

When No. 1 cylinder

is set at T.D.C. on its
camshaft compression stroke,
sprocket the mark on the
crankshaft sprocket
will be in alignment
with the mark on the
camshaft oil pump housing.
sprocket Confirm these marks
and all other marks
are aligned correctly
before installing
timing belt.

sprocket
SEF0131

EM-17
 TIMING BELT
Installation (Cont'd)
4. Set timing belt.
a. Ensure timing belt and sprockets are clean and free from oil or water. Do not bend or twist timing belt.
b. Align white lines on timing belt with matching mark on camshaft sprocket and crankshaft sprocket.
c. Point arrow on timing belt towards the front.

(1) 145 '(44) (2) (1 )(24)(23)

Intake ! "'~:
12
camshaft~"""'
Ll..:.L/
~ Intake
sprocket camshaft
Idler sprocket
pulley

( 1)

Exhaust
camshaft
sprocket

pulley

sprocket

Crankshaft
sprocket
SEF0431

5. Adjust tensioner arm to give 4 mm (0.16 in) clearance with

pusher of auto-tensioner using a suitable vise, and then insert
stopper bolt into tensioner arm in order that clearance does
not change.
When adjusting clearance, do not push tensioner arm with
stopper bolt fitted because it will damage thread portion of
stopper bolt.

6. Install auto-tensioner and tighten nut ((D) and bolts (®, @)

slightly by hand.

EM-18
 TIMING BELT
Installation (Cont'd)
7. Push auto-tensioner slightly towards timing belt to prevent belt
from slipping.
Set tensioner slightly by pushing timing belt. Then, turn crank-
shaft 10 degrees clockwise and tighten nut (G)) and bolts (®.
@) to 16 to 21 N·m (1.6 to 2.1 kg-m, 12 to 15 ft-lb).
At this time, do not push auto-tensioner hard or belt will be
adjusted too tightly.

8. Turn crankshaft 120 degrees counterclockwise.

9. Loosen nut (G)) and bolts (®, @) 1/2 turn to set tensioner
body as for back as it will go.
10. Turn crankshaft clockwise and set No. 1 cylinder at T.D.C. on
its compression stroke.

SEM775C

11. Push the end of pusher with approx. 58.8 N (6.0 kg, 13.2 lb)
force using Tool (push-pull gauge) and tighten nut (G)) and
bolts (®. @) to 16 to 21 N•m (1.6 to 2.1 kg-m, 12 to 15 ft-lb).
If deflection of timing belt exceeds specification in procedure 15.,
change applied pushing force.

12. Turn crankshaft 120 degrees clockwise.

13. Turn crankshaft 120 degrees counterclockwise and set No. 1
cylinder at T.D.C. on its compression stroke.

SEM776C

14. Prepare a suitable steel plate to measure belt deflection as

shown.

Timing belt

Longer than
~width

8-10 2-3
(0.31 . 0.391 (0.08- 0.121 Unit: mm (inl
SEF0461

EM-19
 TIMING BELT
Installation (Cont'd)
15.
(1) Set plate and push it with 49 N (5 kg, 11 lb) force using Tool
Right (push-pull gauge) at each position of timing belt mid-way
side between pulleys as shown.
Left
side (2) Measure each deflection.
Deflection:
6 - 7 mm (0.24 - 0.28 in) or the average of
each portion
@+@+©+@
4
SEF0471 is 6 - 7 mm (0.24 - 0.28 in)

If not within specification, repeat procedure from step 7 through

step 15.

16. Confirm auto tensioner fixing nuts and bolts are tightened to 16
to 21 N•m (1.6 to 2.1 kg-m, 12 to 15 ft-lb).

17.
• Remove the auto-tensioner stopper bolt.
• After 5 minutes check the projection of the rod (clearance
between tensioner arm and pusher) stays at 3.5 - 5.2 mm
(0.138 - 0.205 in).

18. Check the proper installation (no slip or misplacement) of

timing belt at each position as shown.

@ ®
SEF0491

19. Install timing belt covers.

EM-20
 OIL SEAL REPLACEMENT

VALVE OIL SEAL

1. Remove intake manifold collector and valve cover.
2. Remove timing belt, camshaft sprocket and rear belt cover.
3. Remove camshaft brackets, camshaft and valve lifter.

4. Remove valve spring using Tool or a suitable tool.

• Piston concerned should be set at T.D.C. to prevent valve from
falling.
5. Pry out valve oil seal.

6. Apply engine oil to new valve oil seal and install it.
• Before installing valve oil seal, install inner valve spring seat.

Valve oil
seal
.. .. ..
8 8c:i
c:i +I
"N
Cl
c:i
+I
+I CXI C')

~-~-10
~-c:i c:i
g
...c:i ..
- -C')

.. ....
c:i c:i
seat +< +I
+I N
...
~ IIi ,..:

SEM681C Unit: mm (in)

OIL SEAL INSTALLATION DIRECTION

Engine • Engine
inside ---l~+--~ outside

Oil seal lip Dust seal lip

SEM715A

EM-21
 OIL SEAL REPLACEMENT

CAMSHAFT OIL SEAL

1. Remove timing belt and camshaft sprocket.
2. Remove rear belt cover and camshaft oil seal.
Be careful not to scratch camshaft.
3. Apply engine oil to new camshaft oil seal and install it using
Tool or a suitable tool.

FRONT OIL SEAL

1. Remove timing belt and crankshaft sprocket.
2. Remove oil pan and oil pump assembly.
3. Remove front oil seal from oil pump body.

SEM826A

4. Apply engine oil to new oil seal and install it using Tool or a
suitable tool.

REAR OIL SEAL

1. Remove flywheel or drive plate.
2. Remove rear oil seal from retainer.
Be careful not to scratch crankshaft.

3. Apply engine oil to new oil seal and install it using Tool or a
suitable tool.

EM-22
 THROTTLE CHAMBERS

Precaution
A letter, "U" or "L", is stamped on the throttle chambers. When
changing a throttle chamber, replace it with a new one that has the
same mark.

Installation
The intention of this installation and adjustment procedure is to
assure accurate synchronization of the throttle chamber opening
points.

Throttle chamber
(Right side)

SEM639C

1. Install accel-drum unit and throttle chambers (right side and left
side).

• When tightening bolts, free accel-drum unit so that drum unit

is left under its own weight. Do not apply external force to
accel-drum unit.
• When replacing throttle chambers only, you need not perform
procedures (3), (4) and (5).

unit
SEF0521

Tightening order:
(1) CD ~ ® ~ ® ~ @:
9 - 11 N·m (0.9 - 1.1 kg-m, 6.5 - 8.0 ft-lb)
(2) CD ~ ® ~ ® ~ @:
18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)
(3) @ ~ @ ~ © : Tighten by hand
(4)@ ~@ ~ @:
5 N·m (0.5 kg-m, 3.6 ft-lb)
(5)@ ~@ ~ @:
20 N·m (2.0 kg-m, 14 ft-lb)

EM-23
 THROTTLE CHAMBERS
Installation (Cont'd)
• Before Installing each throttle chamber, confirm that stopper
wire is installed In hole of rod pin.
If not, install suitable wire.

Rod pin

Right side

Lock nut

Rod pin

Joint lever
Left side SEF0511

2. Pull out stopper wire of right side throttle chamber in order to

secure right side joint lever.

Right side
SEF0531

3. Loosen left side throttle chamber lock nut and back-out

adjusting screw until there is clearance between the screw and
joint lever.

SEF0541

4. Set dial gauge on joint lever and set indicator to zero. Confirm
Adjusting screw
that bottom end of adjusting screw is not in contact with joint
lever of accelerator drum unit.

Accel-drum
unit

wire SEM640C

EM-24
 THROTTLE CHAMBERS
Installation (Cont'd)
5. Pull out left side throttle chamber stopper wire from rod pin.

SEM641 C

6. Turn adjusting screw until dial gauge indicator is within the

following range.
Range: 0.07 • 0.13 mm (0.0028 • 0.0051 in)
Then tighten lock nut.
7. Confirm that the dial gauge indicator is still within the above
range.

EM-25
 CYLINDER HEAD

Valve cover (Intake)

Ornamem cover

~1-3 ~
(0.1. 0.3, 0.7. 2.2)__,./ ~
J.-.-·

Cylinder head bolt

Refer to "Installation".

Cylinder head (Left side)

Hydraulic
valve I ifter

Gasket~ ~ : fJ Apply liquid gasket.

~ : N·m (kg-m, ft-lb)

* After installing gasket, cut off

any loose ends.

SEM620C

EM-26
 CYLINDER HEAD

CAUTION:
• When installing sliding parts such as camshaft, camshaft
bracket and oil seal, be sure to apply new engine oil on their
sliding surfaces.
• When tightening cylinder head bolts, intake camshaft
sprocket bolts and camshaft bracket bolts, apply new engine
oil to thread portions arid seat surfaces of bolts.

• Do not put hydraulic valve lifters upside down, otherwise air

will enter valve lifter, causing it to make a noise.
• Do not disassemble hydraulic valve lifter.
• Attach tags to valve lifters so as not to mix them up.
• Valve lifters should be immersed in engine oil.

O.K.

SEM529B

Removal
1. Remove intake manifold collector.

2. Remove injector pipe assembly.

3. Remove valve covers.

EM-27
 CYLINDER HEAD
Removal (Cont'd)
4. Remove timing belt.
Refer to "Removal" of TIMING BELT.
5. Remove idler pulley and its stud bolt.

6. Remove intake manifold.

7. Disconnect front exhaust tube from exhaust manifold.

8. Remove cylinder head with exhaust manifold.
Cylinder head bolts should be loosened in two or three steps.

Disassembly
1. Remove exhaust manifold from cylinder head.
2. Remove camshaft sprockets.
3. Remove timing belt rear cover.

4. Remove camshaft brackets.

Bolts should be loosened in two or three steps.
Before removing camshaft, measure camshaft end play.
5. Remove oil seals, camshafts and hydraulic valve lifters.

SEM777C

EM-28
 CYLINDER HEAD
Disassembly (Cont'd)
6. Remove valve springs with Tool or a suitable tool.
Suitable tool

7. Pull out valve oil seals.

Measuring points Inspection

CYLINDER HEAD DISTORTION
Head surface flatness:
Less than 0.1 mm (0.004 in)
If beyond the specified limit, replace it or resurface it.
Resurfacing limit:
The resurfacing limit of cylinder head is determined by the
cylinder block resurfacing in an engine.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is "9".
The maximum limit is as follows:
A + B =0.2 mm (0.008 in)
After resurfacing cylinder head, check to make sure that camshaft
rotates freely by hand. If resistance is felt, cylinder head must be
replaced.
Nominal cylinder head height from camshaft center:
Refer to S.O.S.

EM-29
CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT VISUAL CHECK
Check camshaft for scratches, seizure and wear.

CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indicator reading):
Limit 0.1 mm (0.004 in)
2. If it exceeds the limit, replace camshaft.

CAMSHAFT CAM HEIGHT

1. Measure camshaft cam height.
Standard cam height:
40.405 - 40.595 mm (1.5907 - 1.5982 in)
Cam wear limit:
0.15 mm (0.0059 in)
2. If wear is beyond the limit, replace camshaft.

CAMSHAFT JOURNAL CLEARANCE

1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
28.000 - 28.021 mm (1.1024 - 1.1032 in)

3. Measure outer diameter of camshaft journal.

Standard outer diameter:
27.935 - 27.955 mm (1.0998 - 1.1006 in)
4. If clearance exceeds the limit, replace camshaft and/or cylinder
head.
Camshaft journal clearance limit:
0.15 mm (0.0059 in)

EM-30
 CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT END PLAY
1. Install camshaft in cylinder head.
2. Measure camshaft end play.
Camshaft end play:
Standard
0.03 - 0.08 mm (0.0012 - 0.0031 in)

VALVE GUIDE CLEARANCE

1. Push valve stem out so that its end is even with valve guide
height. Measure valve runout by moving valve.
Valve deflection limit (Dial gauge reading):
0.2 mm (0.008 in)

2. If it exceeds the limit, check valve to valve guide clearance.

Micromet~er a. Measure valve stem diameter and valve guide inner diameter.
b. Check that clearance is within specification.
Inside micro
Valve to valve guide clearance limit:
dial gauge 0.10 mm (0.0039 in)
y

@) +x c. If it exceeds the limit, replace valve or valve guide.

rAl =11= ~~~ter

[gj
Valve guide
-x
Valve
Bottom

SEM537B

VALVE GUIDE REPLACEMENT

1. To remove valve guide, heat cylinder head to 150 to 160°C (302
to 320°F).

2. Drive out valve guide with a press [under a 20 kN (2 t, 2.2 US

ton, 2.0 Imp ton) pressure] or hammer and suitable tool.

EM-31
 CYLINDER HEAD
Inspection (Cont'd)
3. Ream cylinder head valve guide hole.
Valve guide hole diameter
(for service parts):
Intake and Exhaust
10.175 - 10.196 mm (0.4006 - 0.4014 in)

4. Heat cylinder head to 150 to 160°C (302 to 320°F) and press

service valve guide onto cylinder head.
Projection " Q":
15.1 - 15.3 mm (0.594 - 0.602 in)

Unit: mm (in) SEM038C

5. Ream valve guide.

Finished size:
Intake and Exhaust
6.000 - 6.018 mm (0.2362 - 0.2369 in)

VALVE SEATS
Check valve seats for evidence of pitting at valve contact surface,
and reseat or replace if it is worn excessively.
• Before repairing valve seats, check valve and valve guide for
wear. If they have worn, replace them. Then correct valve
seat.
• Cut with both hands to assure a uniform surface.

EM-32
 CYLINDER HEAD
Inspection (Cont'd)
REPLACING VALVE SEAT FOR SERVICE PARTS
1. Bore out old seat until it collapses. The machine depth stop
should be set so that boring cannot continue beyond the
bottom face of the seat recess in cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Intake
36.500 - 36.516 mm (1.4370 - 1.4376 in)
Exhaust
32.000 - 32.016 mm (1.2598 - 1.2605 in)
Reaming should be done to the concentric circles to valve guide
center so that valve seat will have the correct fit.

3. Heat cylinder head to 150 to 160°C (302 to 320°F).

4. Press fit valve seat until it seats on the bottom.

5. Cut or grind valve seat using suitable tool at the specified

dimensions as shown in S.O.S.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seat contact condition.

T (Margin thicknessl
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions, refer to S.O.S.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.

L
SEM188A

EM-33
 CYLINDER HEAD
Inspection (Cont'd)
VALVE SPRING
Squareness
1. Measure "S" dimension.
Out-of-square:
Less than 1.8 mm (0.071 in)
2. If it exceeds the limit, replace spring.

SEM288A

Pressure
Check valve spring pressure.
Pressure: N (kg, lb) at height mm (in)
Standard
536.4 (54.7, 120.6) at 26.5 (1.043)
Limit
More than 452.79 (46.17, 101.80) at 26.5 (1.043)
If it exceeds the limit, replace spring.

EM113

HYDRAULIC VALVE LIFTER

1. Check contact and sliding surfaces for wear or scratches.

SEM546B

2. Check diameter of valve lifter.

Outer diameter:
30.955 - 30.965 mm (1.2187 - 1.2191 in)

3. Check valve lifter guide inner diameter~

Inner diameter:
31.000 - 31.020 mm (1.2205 - 1.2213 in)
Standard clearance between valve lifter and lifter guide:
0.035 - 0.065 mm (0.0014 - 0.0026 In)

EM-34
 CYLINDER HEAD

Assembly
1. Install valve component parts.
• Always use new valve oil seal. (Refer to OIL SEAL RE-
PLACEMENT.)
• Install valve spring (uneven pitch type) with its narrow pitch
side (painted side) toward cylinder head side.

• To facilitate installation of collet, apply a small amount of grease

to a piece of wire or a pencil and attach collet to wire or pencil,
as shown.

SEM659C

2. Install camshafts as shown.

Knock pins

side

SEM660C

• Exhaust camshaft (left side) has spline for crank angle sensor.

SEM661 C

• When installing valve timing control solenoid valves, apply liquid

gasket to solenoid valve surfaces.

""
Valve timing
/ '
control
solenoid valve

EM-35
 CYLINDER HEAD
Assembly (Cont'd)
3. Install camshaft brackets.
Tighten camshaft bracket bolts gradually in two or three stages.

SEM663C

When installing front side camshaft brackets, apply liquid gasket

Q Front as shown.

SEM664C

4. Apply engine oil to camshaft oil seal lip and install it in place.
Always use new camshaft oil seal.
5. Install rear timing belt cover.
6. Install camshaft sprockets.
When tightening bolts, fix camshaft to prevent it from rotating.

Installation
1. Set No. 1 piston at T.D.C. on its compression stroke as follows:
(1) Align crankshaft sprocket aligning mark with mark on oil pump
body.

(2) Align camshaft sprocket aligning mark with mark on timing belt
rear cover.

EM-36
 CYLINDER HEAD
Installation (Cont'd)
2. Install cylinder head with new gasket.
• Be sure to install washers between bolts and cylinder head.
Cylinder head bolt • Do not rotate crankshaft and camshaft separately, or valves
washer direction will hit piston heads.
3. Install cylinder head bolts.
• Install short bolts (L2) into the correct holes of cylinders # 1

•
Cylinder head side
and #6 as shown in figure of step (6) .

SEM555B

Right cylinder head 4. Tighten cylinder head bolts in numerical order.

• Tightening procedure
(1) Tighten all bolts to 39 N·m (4.0 kg-m, 29 ft-lb).
(2) Tighten all bolts to 123 N•m (12.5 kg-m, 90 ft-lb).
(3) Loosen all bolts completely.
(4) Tighten all bolts to 34 to 44 N·m (3.5 to 4.5 kg-m, 25 to 33
ft-lb).
(5) Tighten all bolts to 123 N·m (12.5 kg-m, 90 ft-lb) or if an angle
wrench is available, tighten bolts 70 to 75 degrees (Lt), 65 to
70 degrees (L2) clockwise.
SEM667C

Left cylinder head

SEM668C

Front
·e oe OeO® (6) Tighten bolts ( ®) as shown to 10 to 12 N·m (1.0 to 1.2 kg-m,
7 to 9 ft-lb).

:e:e:e:
0 0 0 0

e
e: L,
0: L 1
®: M6 bolt
SEM669C

5. Install valve covers.

When installing exhaust side valve covers, apply liquid gasket
as shown.
6. Install remaining parts.

Exhaust side
valve cover SEM670C

EM-37
TURBOCHARGERS

Removal
RIGHT SIDE UNIT
1. Remove right part of cowl top.
2. Remove battery.

3. Remove air inlet hose and pipe.

4. Disconnect lower pipe from turbocharger unit.

5. Remove A.S.C.D. bracket with wiper motor and solenoid valves.

6. Disconnect exhaust gas sensor harness connector.

7. Remove turbocharger water hoses, and disconnect turbo-

charger oil inlet tube.
8. Remove two bolts fastening pre-catalyst to turbocharger unit.

9. Remove the following parts;

• oil pressure switch,
• oil filter,
• turbocharger oil return tube,
• front exhaust tube,
• pre-catalyst
10. Disconnect oil hose from oil filter bracket, and turbocharger
water tubes from turbocharger unit.

EM-38
 TURBOCHARGERS
Removal (Cont'd)
11. Remove rod pin of wastegate valve actuator.
12. Remove oil filter bracket.

13. Unbend locking plates for fastening nuts of turbocharger unit.

14. Remove turbocharger unit.
Locking plate

LEFT SIDE UNIT

1. Remove brake master cylinder and brake booster.
2. Disconnect exhaust gas sensor harness connector.

3. Remove air inlet hose and pipe.

4. Disconnect lower pipe from turbocharger unit.

5. Disconnect water tubes.

6. Remove two bolts fastening pre-catalyst to turbocharger unit.

EM-39
 TURBOCHARGERS
Removal (Cont'd)
7. Remove front exhaust tube and pre-catalyst.
8. Disconnect steering lower joint.

9. Remove turbocharger oil return tube and water tubes.

10. Disconnect E.G.R. tube and actuator bracket of turbocharger
wastegate valve.

11. Remove manifold cover and fastening nuts.

12. Remove turbocharger unit with exhaust manifold.

Inspection
Proceed the following checks. If N.G., replace turbocharger unit.
Check for cracks.

Check for leaks.

Actuator

Compressor wheel Turbine wheel

Turbine housing
SEM796C

EM-40
 TURBOCHARGERS
Inspection (Cont'd)
OIL AND WATER TUBES
Check tubes for clogging.

SEM797C

ROTOR SHAFT
1. Check rotor shaft for smooth rotating.

2. Check rotor shaft for carbon deposits.

3. Measure runout of rotor shaft.

Runout (Total Indicator reading):
0.056 - 0.127 mm (0.0022 - 0.0050 in)

SEMBOOC

4. Measure end play of rotor shaft.

End play:
0.013 - 0.096 mm (0.0005 - 0.0038 In)

EM-41
 TURBOCHARGERS
Inspection (Cont'd)
TURBINE WHEEL
Check turbine wheel for the following:
e Oil
• Carbon deposits
• Deformed fins
• Contact with turbine housing

SEM802C

COMPRESSOR WHEEL
Check compressor wheel for the following:
e Oil
• Deformed fins
• Contact with compressor housing

. SEM803C

WASTEGATE VALVE
Remove rod pin and check wastegate valve for cracks, deformation
and smooth movement.
Check valve seat surface for smoothness.

WASTEGATE VALVE ACTUATOR

Apply air pressure to wastegate valve actuator and check it for
smooth movement.
• Do not keep applying air pressure to the actuator.
• The air pressure should be in the range of 78 to 88 kPa (0.8
to 0.9 kg/cm 2 , 11 to 13 psi).

EM-42
 INTERCOOLERS

Removal
1. Remove front part of front fender protector.
2. Remove reservoir tank (left intercooler service only).

3. Remove front combination lamp.

-
-

[(,Jtj f
1~-----. . ~~
-----------
--S'-
SEM809C

4. Remove bolts fastening intercooler and front inlet cover.

5. Remove inlet and outlet hoses.

6. Remove intercooler unit.

EM-43
 ENGINE REMOVAL

Slinger
Slinger
(ql27 (2.8, 201 ~-

Insulator

A41-52
(4.2. 5.3, 30. 38)~
~ ~
_...,.--A 55.67
(5.6. 6.8, 41 • 49)

tc!J43. 55
(4.4. 5.6, 32. 41)
/tc!J35-45
)if (3.6 • 4.6, 26 . 33)
:;..-·
Dynamic damper
(M/T model only)

~')..----A M/T 62-78

(6.3 . 8.0, 46 . 58)

,~/
A/T 59· 75
(6.0 . 7 .6, 43 • 55)
t'll ., .................
A 35 • 45 (3.6 . 4.6, 26 • 33)
~tclJ51-65 (5.2 . 6.6, 38. 48)

tc!J: N·m (kg-m, ft-lb)

SEM621C

EM-44
ENGINE REMOVAL

WARNING:
a. Situate vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completely
cooled off. Otherwise, you may burn yourself and/or fire may
break out in fuel line.
d. For safety during subsequent steps, the tension of wires
should be slackened against the engine.
e. Before disconnecting fuel hose, release fuel pressure from
fuel line.
Refer to "Releasing Fuel Pressure" in section EF & EC.
f. Be sure to hoist engine and transmission in a safe manner.
g. For engines not equipped with engine slingers, attach proper
slingers and bolts described in PARTS CATALOG.

CAUTION:
• When lifting engine, be careful not to strike adjacent parts,
especially accelerator wire casing, brake lines, and brake
master cylinder.
• In hoisting the engine, always use engine slingers in a safe
manner.

M/T model
1. Remove engine under cover and hood.
2. Drain coolant from both cylinder block drain plugs, and radiator
drain cock.
3. Drain engine oil from drain plug of oil pan.
4. Remove vacuum hoses, fuel tubes, wires, harnesses and
connectors and so on.
5. Remove front exhaust tubes and propeller shaft.

6. Remove radiator.
7. Remove drive belts, cooling fan and coupling.
8. Remove P/S oil pump, alternator, A/C pump from engine, and
starter motor, and clutch operating cylinder.

9. Disconnect A/C tube clamps as shown.

EM-45
ENGINE REMOVAL
M/T model (Cont'd)
10. Disconnect steering column lower joint.
11. Remove tension rod fixing bolts from both sides.
12. Loosen transverse link bolts on both sides.

13. Set a suitable transmission jack under suspension member.

• At this time, hoist engine with engine slinger.
14. Remove suspension member fixing bolts.
15. Remove engine mounting bolts from both sides and then slowly
lower transmission jack.

EM-46
ENGINE REMOVAL
M/T model (Cont'd)
16. Remove engine with transmission as shown.

SEM671 C

A/T model
1. Perform the same procedures (1 to 8) as for M/T model.
2. Remove transmission from vehicle.
Refer to AT section.
3. Hoist engine with engine slingers and remove engine mounting
bolts from both sides.

4. Remove engine from vehicle as shown.

EM-47
 CYLINDER BLOCK

toJ 21· 26 (2.1. 2.7,15. 20)

Detonation sensor
~
~
'Cylinder block

Oil pump assembly

Front oil seal t)

toJ 83 . 93 (8.5 . 9.5, 61 . 69)
M6: lfll 6.3. 8.3
rrft (0.64. 0.85 4 6
~
sf
1
Main bearing

M8: ..- .. 22-29 •··· '

(2.2. 3.0, 16. 22)

Crankshaft
Flywheel or
drive plate
Connecting
rod ~ Rear plate

Refer to .. Assembly"._/
Main bearing beam

toJ 90. 100 (9.2. 10.2, 67. 74) ~·

0-ring t)-
~
~

fl Liquid gasket
Oil pan

Gasket t)

toJ 6.3. 8.3

(0.64 . 0.85, 4.6 . 6.1)

" ~ r:~~~~~~~t~b~asket.

SEM622C

EM-48
 CYLINDER BLOCK

CAUTION:
• When installing sliding parts such as bearings and pistons,
be sure to apply engine oil on the sliding surfaces.
• Place removed parts such as bearings and bearing caps in
their proper order and direction.
• When tightening connecting rod bolts and main bearing cap
bolts, apply engine oil to thread portion of bolts and seating
surface of nuts.

Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Remove timing belt.
3. Drain coolant and remove water pump.
4. Drain oil.
5. Remove oil pan, oil pump and rear oil seal retainer.
6. Remove intake manifold collector, intake manifold and cylinder
head.

7. Remove pistons.
• When disassembling piston and connecting rod, remove snap
ring first, then heat piston to 60 to 70°C (140 to 158°F) or use
piston pin press stand at room temperature.

8. Remove bearing cap and crankshaft.

• Before removing bearing cap, measure crankshaft end play.
• Bolts should be loosened in two or three steps.

Loosen in numerical order. SEM741D

Inspection
PISTON AND PISTON PIN CLEARANCE
• Confirm the fitting of piston pin into piston pin hole by
checking if it can be pressed in smoothly by finger pressure at
room temperature.
1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp":
21.987 - 21.999 mm (0.8656 - 0.8661 in)

SEM149B

EM-49
 CYLINDER BLOCK
Inspection (Cont'd)
2. Measure outer diameter of piston pin "Dp".
Standard diameter "D.p":
21.989 - 22.001 mm (0.8657 - 0.8662 In)
3. Calculate piston pin clearance.
dp - Dp = -0.004 to 0 mm (-0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with pin.

SEM821B

PISTON RING SIDE CLEARANCE

Side clearance:
Top ring
0.040 - 0.073 mm (0.0016 - 0.0029 In)
2nd ring
0.030 - 0.063 mm (0.0012- 0.0025 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
0-ring:
0.015 - 0.185 mm (0.0006 - 0.0073 In)
If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
End gap:
Feeler Top ring
gauge 0.21 - 0.40 mm (0.0083 - 0.0157 in)
2nd ring
0.50 - 0.76 mm (0.0197 - 0.0299 in)
Oil ring
0.20- 0.76 mm (0.0079- 0.0299 in)
Max. limit of end gap:
Measuring 1.0 mm (0.039 in)
Jjoint SEM822B If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, rebore cylinder and use oversized piston
and piston rings.
Refer to S.O.S.

CONNECTING ROD BEND AND TORSION

Bend:
Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in) per 100 mm (3.94 In) length
If it exceeds the limit, replace connecting rod assembly.

SEM150B

EM-50
 CYLINDER BLOCK
Inspection (Cont'd)
CYLINDER BLOCK DISTORTION AND WEAR
1. Clean upper face of cylinder block and measure the distortion.
Limit:
Measuring points 0.10 mm (0.0039 in)
2. If out of specification, resurface it.
The resurfacing limit is determined by cylinder head resurfacing
in engine.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is "B".
The maximum limit is as follows:
Warpage of surface:
A + B = 0.2 mm (0.008 in)
Less than 0.10 mm (0.003g in)
_____.---;c{ ~ 3. If necessary, replace cylinder block.
r----<"' •,

SEM319A

PISTON-TO-BORE CLEARANCE
Method A (Using bore gauge and micrometer)
1. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
Standard inner diameter:
87.000 - 87.030 mm (3.4252 - 3.4264 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X - Y) limit:
0.015 mm (0.0006 in)
Taper (A - B - C) limit:
0.015 mm (0.0006 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder block if
necessary.
2. Check for scratches and seizure. If seizure is found, hone it.

Unit: mm (in)
SEM321A

Piston grade number and ring set • If both cylinder block and piston are replaced with new ones,
select piston of the same grade number punched on cylinder
block upper surface.

EM-51
 CYLINDER BLOCK
Inspection (Cont'd)
3. Measure piston skirt diameter.
Piston diameter "A":·
Refer to S.O.S.
Measuring point "a" (Distance from the top):
48.0 mm (1.890 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
Non-turbo
0.015 - 0.035 mm (0.0006 - 0.0014 in)
Turbo
SEM739D 0.025 - 0.045 mm (0.0010 - 0.0018 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to S.O.S.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter "A".
Rebored size calculation:
D=A+B-C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque to
prevent distortion of cylinder bores in final assembly.
8. Cut cylinder bores.
• When any cylinder needs boring, all other cylinders must also
be bored.
• Do not cut too much out of cylinder bore at a time. Do not
cut more than 0.05 mm (0:0020 in) in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
• Measurement should be done after cylinder bore cools down.

Counterweight CRANKSHAFT
never disassemb/ CAUTION:
Never attempt to disassemble crankshaft counter weight.

SEM738D

1. Check crankshaft main and pin journals for score, wear or

A B
cracks.
2. With a micrometer, measure journals for taper and out-of-round.
X Out-of-round (X - Y):
Less than 0.005 mm (0.0002 in)
Taper (A - B):
y Less than 0.005 mm (0.0002 In)
Limit:
Taper: A- B
0.02 mm (0.0008 in)
Out-of-round : X - Y
SEM316A

EM-52
 CYLINDER BLOCK
Inspection (Cont'd)
3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.10 mm (0.0039 in)

Upper main bearing No. 1 • •: With oil groove BEARING CLEARANCE

N~~ ~RONT
• Either of the following two methods may be used; however,

No.4"~
No.3"

\) \Y method "A" gives more reliable results and is preferable.

Method A (Using bore gauge & micrometer)

~ ~~,····
Main bearing
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.

(\ \No.3

~ No.4
Lower main bearing
SEM327A

2. Install main bearing cap to cylinder block.

Tighten all bolts in correct order in two or three stages.
3. Measure inner diameter "A" of each main bearing.

4. Measure outer diameter "Dm" of each crankshaft main journal.

5. Calculate main bearing clearance.
Main bearing clearance (A - Om):
Standard
0.028 - 0.055 mm (0.0011 - 0.0022 in)
Limit
0.090 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.

a. When grinding crankshaft journal, confirm that "L" dimension in

fillet roll is more than the specified limit.
"L": 0.1 mm (0.004 in)
b. Refer to S.O.S. for grinding crankshaft and available service
parts.

EM-53
 CYLINDER BLOCK
Inspection (Cont'd)
8. If crankshaft, cylinder block or main bearing is reused again,
measure main bearing clearance.
If crankshaft, cylinder block and main bearings are replaced
with new ones, it is necessary to select thickness of main
bearings as follows:
a. Grade number of each cylinder block main journal is punched
on the respective cylinder block.

b. Grade number of each crankshaft main journal is punched on

the No. 1 counter weight of crankshaft.

No. 4 journal
No.3 grade number
No.2 SEM167B

c. Select main bearing with suitable thickness according to the

following table.

Main bearing grade number:

0 2

0 0 2

2 3

2 2 3 4

For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number = 1 + 2
=3

Connecting rod bearing (Big end)

1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter "C" of each bearing.

EM-54
 CYLINDER BLOCK
Inspection {Cont'd)
4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance (C - Dp):
Standard
0.028 - 0.048 mm (0.0011 - 0.0019 in)
Limit
0.090 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Refer to step 7 of "BEARING CLEARANCE - Main bearing".

8. If crankshaft, connecting rods or bearings are replaced with

new ones, it is necessary to select thickness of connecting rod
bearings as follows:
(c""""''"'""' a. Grade number of each connecting rod big end is punched on
the respective connecting rod.

Q ~RI~~
Oil hole/
Big end
grade No.

SEM675C

Crankshaft No.6 pin b. Grade number of each crankshaft pin journal is punched on the
pin grade No. No. 5 counter weight of crankshaft.
(For connecting
rod bearing)

pin
pin
SEF0021

c. Select connecting rod bearing with suitable thickness accord-

ing to the following table.

Connecting rod bearing grade number:

0 1 (I)

0 0

1 (I) 2

2 (II) 2 3

For example:
Connecting rod big end grade number: 1
Crankshaft pin grade number: 2
Connecting rod bearing grade number = 1 + 2
=3

EM-55
 CYLINDER BLOCK
Inspection (Cont'd)
Method B (Using "plastigage")
CAUTION:
• Do not turn crankshaft or connecting rod while plastigage is
being inserted.
• When bearing clearance exceeds the specified limit, ensure
that the proper bearing has been installed. Then if excessive
bearing clearance exists, use a thicker main bearing or
undersized bearing so that the specified bearing clearance is
obtained.

CONNECTING ROD BUSHING CLEARANCE (Small end)

1. Measure inner diameter "C" of bushing.

2. Measure outer diameter "Dp" of piston pin.

3. Calculate connecting rod bushing clearance.
C - Dp = 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit: 0.023 mm (0.0009 in)
If it exceeds the specified value, replace connecting rod
bushing and/or piston set with pin.

Micrometer

SEM903A

REPLACEMENT OF CONNECTING ROD BUSHING

(Small end)
1. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. After driving in small end bushing, ream the bushing.
Small end bushing inside diameter:
Finished size
22.000 - 22.012 mm (0.8661 - 0.8666 in)

SEM062A

FLYWHEEL/DRIVE PLATE RUNOUT

Runout (Total indicator reading):
Flywheel (M/T model)
Less than 0.15 mm (0.0059 in)
Drive plate (A/T model)
Less than 0.15 mm (0.0059 in)

EM-56
 CYLINDER BLOCK

Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.

SEM679C

2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,

piston pin, connecting rod and new snap ring.

.,
Engine front
•
•

•
Align the direction of piston and connecting rod.
Numbers stamped on connecting rod and cap correspond to
each cylinder.
After assembly, make sure connecting rod swings smoothly.
Oil hole

Oil ring
expander
* ..,..-::.
~~-....~
• SEM676C

Top ring
..... Oil ring
K upper rail
3. Set piston rings as shown.

Front 1/

I)
.-:;::::> .- . . Oil ring
lower rail
SEM160B

Punchmark side up
(if mark is present.)

~~~~~

SEM677C

EM-57
 CYLINDER BLOCK
Assembly (Cont'd)
Upper main bearing No. 1 • •: With oil groove CRANKSHAFT
No.2*~ 1. Set main bearings in their proper positions on cylinder block
No.3* ~ \) '1RONT
and main bearing cap.

No.4*~ ~
• Confirm that correct main bearings are used.
\) Refer to "Inspection".

~ ~~ 2 No.1
(\ \No.3

~ No.4
Lower main bearing
SEM327A'

2. Install crankshaft and main bearing caps and tighten bolts to

the specified torque.
• Prior to tightening bearing cap bolts, place bearing cap in its
proper position by shifting crankshaft in the axial direction.
• Tighten bearing cap bolts gradually in two or three stages.
Start with center bearing and move outward sequentially.
• After securing bearing cap bolts, make sure crankshaft turns
smoothly by hand.

3. Measure crankshaft end play.

Crankshaft end play:
Standard
0.05 - 0.18 mm (0.0020 - 0.0071 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace bearing with a new one.

4. Install connecting rod bearings in connecting rods and con-

necting rod caps.
• Confirm that correct bearings are used.
Refer to "Inspection".
• Install bearings so that oil hole in connecting rod aligns with oil
hole of bearing.

5. Install pistons with connecting rods.

a. Install them into corresponding cylinders with Tool.
• Be careful not to scratch cylinder wall by connecting rod.
• Arrange so that front mark on piston head faces toward front
of engine.

EM-58
 CYLINDER BLOCK
Assembly (Cont'd)
b. Install connecting rod bearing caps.
Tighten connecting rod bearing cap nuts to the specified
torque.
~: Connecting rod bearing nut
(1) Tighten to 14 to 16 N•m
(1.4 to 1.6 kg-m, 10 to 12 ft-lb).
(2) Tighten to 59 to 65 N·m
(6.0 to 6.6 kg-m, 43 to 48 ft-lb)
or if you have an angle wrench, tighten bolts
60 to 65 degrees clockwise.

6. Measure connecting rod side clearance.

Connecting rod side clearance:
Standard
0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit
0.40 mm (0.0157 in)
If beyond the limit, replace connecting rod and/or crankshaft.

REPLACING PILOT BUSHING

1. Remove pilot bushing (M/T)/pilot converter (A/T).

2. Install pilot bushing (M/T)/pilot converter (A/T).

Crankshaft side

M/T "----' A/T

SEM1638

EM-59
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications

Cylinder arrangement V-6

COMPRESSION PRESSURE
Unit: kPa (kg/cm 2 , psil/300 rpm
Displacement em• (cu in) 2,960 (180.62)
Non-Turbo Turbo
Bore and stroke mm (in) 87 X 83 (3,43 X 3.27)
Compression pressure
Valve arrangement D.O.H.C. 1,285 1,177
Standard
(13.1, 186) (12.0, 171)
Firing order 1-2-3-4-5-6
981 883
-Number of piston rings Minimum
(10.0, 142) (9.0, 128)
Compression 2
Differential limit
98 (1.0,14)
Oil between cylinders

Number of main bearings 4

Compression ratio
10.5/8.5
(Non-turbo/Turbo)

Cylinder number

FRONT SEM713A

EM-60
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Inspection and Adjustment

CYLINDER HEAD Valve spring
Unit: mm (in)
Free height mm (in) 43,1 ( 1.697)
Standard Limit
536.4 (54.7. 120.6)
Standard
Less than at 26.5 (1.043)
Head surface distortion 0.1 (0.004) Pressure
0.05 (0.0020) N (kg, lb) at height mm (in)
452.79 (46.17, 101.80)
Limit
at 26.5 (1.043)

Out-of-square mm(in) Less than 1.8 (0.071 I

H
Height (nominal) Hydraulic valve lifter
138±0.1 Unit: mm (in)
(5.433±0.004)
30.955 - 30.965
Lifter outer diameter
SEM570B (1.2187 -1.2191)

31.000- 31.020
Lifter guide inner diameter
VALVE (1.2205-1.2213)
Unit: mm (in)
Clearance between lifter and 0.035 - 0.065
lifter guide (0.0014- 0.0026)

d
Valve guide
Unit: mm (in)

Standard Service

Valve guide
L 10.023- 10.034 10.223- 10.234
Outer diameter
SEM188 (0.3946- 0.3950) (0.4025- 0.4029)

Valve head diamater "D" Valve guide

Intake 34.0 - 34.2 ( 1.339 - 1.346) Inner diameter 6.000- 6.018
(Finished size) (0.2362 - 0.2369)
Exhaust 29.5-29.7 (1.161 -1.169)
Cylinder head valve 9.975 - 9.996 10.175- 10.196
Valve length "L"
guide hole diameter (0.3927 - 0.3935) (0.4006- 0.4014)
Intake 103.1-103.3 (4.059 -4.067)
Exhaust 103.6- 103.8 (4.079- 4.087) Interference fit of 0.027 - 0.059
valve guide (0.0011 - 0.0023)
Valve stem diameter "d"
Intake 5.965 - 5.980 (0.2348 - 0.2354) Standard Max. tolerance

Exhaust 5.945-5.960 (0.2341 - 0.2346) 0.020 - 0.053

Intake
(0.0008- 0.0021 I 0.10
Valve seat angle "a" Stem to guide
Intake clearance (0.0039)
45° 15'- 45"45' 0.040 - 0.073
Exhaust
Exhaust (0.0016- 0.0029)

Valve margin "T" 0.20

Intake 1.15- 1.45 10.0453 - 0.0571 I
Valve deflection limit - (0.0079)
Exhaust 1.35 - 1.65 (0.0531 - 0.0650)

Valve margin "T" limit More than 0.5 (0.020)

Valve stem end surface

Less than 0.2 (0.008)
grinding limit

Valve clearance
Intake 0 (0)

Exhaust 0 (0)

EM-61
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection and Adjustment (Cont'd)
VALVE SEAT

Standard Service

SEM529C

Unit: mm (in)

Standard Service*

ln. 36.000.36.016 (1.4173 -1.4179) 36.500.36.516 (1.4370. 1.4376)

Cylinder head seat recess diameter (0 1 I
Ex. 31.500. 31.516 (1.2402. 1.2408) 32.000.32.016 (1.2598. 1.2605)

ln. 0.081 . 0.113 (0.0032 . 0.0044)

Valve seat interference fit
Ex. 0.064 . 0.096 (0.0025. 0.0038)

ln. 36.097.36.113 (1.4211 -1.4218) 36.597 • 36.613 (1.4408 . 1.4415)

Valve seat outer diameter (0 1 I
Ex. 31.580. 31.596 (1.2433. 1.2439) 32.080 • 32.096 ( 1.2630. 1.2636)

ln. 29.85 . 30.15 ( 1.1752 . 1.1870)

Valve seat inner diameter (0 1 I
Ex. 24.35 . 24.65 (0.9587 . 0.9705)

ln. 5.9 . 6.0 (0.232 . 0.236) 5.35. 5.45 (0.2106. 0.2146)

Height (HI
Ex. 5.9 . 6.0 (0.232 . 0.236) 5.9 . 6.0 (0.232 • 0.236)

ln. 45°
Face angle (8 I
Ex. 45°

Face inner diameter (D, I ln. 31.5 (1.240)

*: Valve seat surface must be
ln. 33.6 · 33.8 I 1.323 • 1.331 I
Face outer diameter ( o, I corrected to specified value. •
Ex. 28.9. 29.1 (1.138. 1.146)

EM-62
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection and Adjustment (Cont'd)
PISTON, PISTON R lNG AND PISTON PIN Piston ring
Unit: mm (in)
Available piston
Unit: mm (in)
Standard Limit

Side clearance
0.040 • 0.073
Top
(0.0016. 0.0029)
0.1 (0.004)
0.030 . 0.063
2nd
(0.0012. 0.0025)

a
O.Q15 · 0.185
Oil 0.2 (0.0079)
(0.0006 . 0.0073)

End gap
0.21 • 0.40
Top
(0.0083. 0.0157)

0.50. 0.76
2nd 1.0 (0.039)
(0.0197 • 0.0299)

SEM740D 0.20· 0.76

Oil (rail ring)
(0.0079 • 0.0299)
Piston skirt diameter" A"
Standard
Grade No.1 86.975 • 86.985 (3.4242 • 3.4246)
Grade No.2 86.985 • 86.995 (3.4246 • 3.4250)
Grade No.3 86.995. 87.005 (3.4250. 3.4254) Piston pin
0.25 (0.0098) Unit: mm (in)
87.225.87.275 (3.4340. 3.43601
oversize (Service)
Piston pin outer diameter 21.989. 22.001 (0.8657 . 0.8662)
0.50 (0.0197)
87.475.87.525 (3.4439. 3.4459)
oversize (Service) Interference fit of piston
0. 0.004 (0. 0.0002)
pin to piston
"a" dimension 48.0 (1.890)
Piston pin to connecting
Piston pin hole diameter 21.987 · 21.999 (0.8656 · 0.8661 I 0.005. 0.017 (0.0002. 0.0007)
rod bushing clearance

Piston clearance to *Values measured at ambient temperature of 20°C (68°F)

cylinder block
Non-turbo 0.015. 0.035 (0.0006. 0.0014)
Turbo 0.025. 0.045 (0.0010. 0.0018)
CONNECTING ROD
Unit: mm (in)

Center distance 154.1 · 154.2 (6.067 · 6.071 I

Bend [per 100 (3.94)]

Limit 0.15 (0.00591

Torsion [per 100 (3.94)]

limit 0.3 (0.012)

Piston pin bushing

22.000. 22.012 (0.8661 . 0.8666)
inner diameter*

Connecting rod big end

53.000 • 53.013 (2.0866 · 2.0871 I
inner diameter

Side clearance
Standard 0.20 · 0.35 (0.0079 • O.Q138l
Limit 0.40 (0.0157)

*After installing in connecting rod

EM-63
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection and Adjustment (Cont'd)
CAMSHAFT AND CAMSHAFT BEARING CYLINDER BLOCK
Unit: mm (in) Unit: mm (in)

A 0

SEM568A

Standard Max. tolerance

Surface flatness
Camshaft journal to 0.045 • 0.086 Standard Less than 0.03 (0.0012)
0.15 (0.0059)
bearing clearance (0.0018- 0.0034)
Limit 0.10 (0.0039)
Inner diameter of 28.000-28.021
camshaft bearing (1.1024- 1.1032) Cylinder bore
Inner diameter
Outer diameter of 27.935 - 27.955 Standard
camshaft journal (1.0998- 1.1006) Grade No.1 87.000-87.010 (3.4252- 3.4256)
Grade No.2 87.010-87.020 (3.4256- 3.4260)
Camshaft runout Less than Grade No.3 87.020- 87.030 (3.4260- 3.4264)
0.1 (0.004)
[T.I.A.*] 0.04 (0.0016)
Wear limit 0.20 (0.0079)
0.03-0.08
Camshaft end play Out-of-round IX- Y) Less than 0.015 (0.0006)
(0.0012- 0.0031)
Taper(A- B -C) Less than 0.015 (0.0006)

Main journal inner

diameter
Grade No. 0 66.645 - 66.654 (2.6238 - 2.6242)
Grade No.1 66.654- 66.663 (2.6242 - 2.6245)
Grade No.2 66.663-66.672 (2.6245- 2.6249)
EM671
Difference in inner
Cam height "A" diameter between
Intake cylinders
40.405-40.595 (1.5907- 1.5982)
Exhaust Standard Less than 0.05 (0.0020)

Wear limit of cam height 0.15 (0.0059)

*Total indicator reading

Valve timing

EM120

B.O.C. Unit: degree

a b c d e

248 248 -1 69 9 59

EM-64
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection and Adjustment (Cont'd)
CRANKSHAFT AVAILABLE MAIN BEARING
Unit: mm (in)

Main journal dia. "Om"

Grade No. 0 62.967 . 62.975 (2.4790 . 2.4793) Upper main bearing •: With oil groove
(With oil groove) No.1"
Grade No.1 62.959. 62.967 (2.4787 . 2.4790)
Grade No.2 62.951 . 62.959 (2.4784. 2.4787) No.: ~ G;J FRONT

···: ~~ ~~.
Pin journal dia. "Dp"
Grade No. 0 49.968 • 49.974 I 1.9672 · 1.96751
Grade No.1 49.962 · 49.968 I 1.9670. 1.96721
Grade No.2 49.955. 49.962 (1.9667 . 1.9670)

Center distance "r" 41.47. 41.53 (1.6327 ·1.6350)

Out-of-round IX- Y)
Standard less than 0.005 10.0002)

limit 0.02 (0.0008)

No.4 lower main bearing
Taper (A- B) (Without oil groove)
Standard less than 0.005 (0.0002) SEM327A
limit 0.02 (0.0008)

Runout [T.I.R.l
No. 1 main bearing
Standard less than 0.10 (0.0039)
Grade Thickness "T" Width "W" Identification
Free end play number mm(in) mm(in) color
Standard 0.05 . 0.18 10.0020 . 0.0011 I
1.817 -1.821
limit 0.30 (0.0118) 0 Black
(0.0715. 0.0717)
1.821 • 1.825
Brown
(0.0717. 0.0719)
1.825 • 1.829 22.4 • 22.6
2 Green
(0.0719. 0.0720) (0.882. 0.890)
1.829 • 1.833
3 Yellow
(0.0720 . 0.07221
1.833. 1.837
4 Blue
(0.0722 . 0.0723)

Dp

Out-of-round X - Y
No. 2 and 3 main bearing
Taper A- B
Grade Thickness "T" Width "'W" Identification
number mm(in) mm (in) color

1.817. 1.821
0 Black
(0.0715. 0.0717)
1.821. 1.825
Brown
(0.0717. 0.0719)
1.825 • 1.829 18.9. 19.1
2 Green
(0.0719. 0.0720) (0.744. 0.752)
EM715
1.829 • 1.833
3 Yellow
(0.0720. 0.07221
1.833 • 1.837
4 Blue
(0.0722 • 0.0723)

EM-65
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection and Adjustment (Cont'd)
No. 4 main bearing TURBOCHARGER Unit: mm (in)
Grade Thickness "T" Identification
Rotor shaft
number mm (in) color Runout [T.I.R.) * 0.056' 0.127 (0.0022 - 0.0050)
1.817- 1.821 End play 0.013- 0.096 (0.0005- 0.0038)
0 Black
(0.0715- 0.0717)
*Total indicator reading
1.821 -1.825
Brown
(0.0717- 0.0719)
1.825 - 1.829
2
(0.0719- 0.0720)
Green MISCELLANEOUS COMPONENTS
Unit: mm (in)
1.829 - 1.833
3 Yellow
(0.0720 - 0.0722) Flywheel
Runout [T.I.R.] * Less than 0.15 (0.0059)
1.833 - 1 .837
4 Blue
(0.0722 - 0.0723) *Total indicator reading

Bearing clearance
Unit: mm (in)
Undersize
Unit: mm (in) Main bearing clearance
Standard 0.028 - 0.055 (0.0011 - 0.0022)
Main journal
Thickness Limit 0.090 (0.0035)
diameter "Om"

Grind so that bearing Connecting rod bearing

0.25 1.948 - 1.956 clearance
clearance is the
(0.00981 (0.0767 - 0.0770) Standard 0.028-0.048 (0.0011 - 0.0019)
specified value.
Limit 0.090 (0.0035)

AVAILABLE CONNECTING ROD BEARING

Connecting rod bearing
Grade Thickness "T" Identification
number mm(in) color

1.496 - 1.499
0 No paint
(0.0589 - 0.0590)
1.499 - 1.502
Brown
10.0590- 0.0591 I
1.502 - 1.505
2 Green
(0.0591 - 0.0593)
1.505 - 1.508
3 Yellow
(0.0593 - 0.0594)

Undersize
Unit: mm (in)

Crank pin journal

Thickness
diameter "Dp"

0.08 1.540 - 1.548

(0.0031) (0.0606 - 0.0609)
Grind so that bearing
0.12 1.560 - 1.568
clearance is the
(0.0047) (0.0614- 0.06171
specified value.
0.25 1.625 - 1.633
(0.0098) (0.0640 - 0.0643)

EM-66
 ENGINE LUBRICATION I
COOLING SYSTEMS

SECTIONLC

CONTENTS
PREPARATION .................................................................................................................................. LC- 2
PRECAUTIONS .................................................................................................................................. LC- 3
ENGINE LUBRICATION SYSTEM ...................................... ,............. ,............................................. LC- 4
ENGINE COOLING SYSTEM .......................................................................................................... LC- 9
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ....................................................................... LC-16
 PREPARATION

SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

ST25051001
(J25695-1)
Oil pressure gauge

0
ST25052000 Adapting oil pressure gauge
(J25695-2) to cylinder block
Hose

WS39930000 Pressing the tube of liquid

( ) gasket
Tube presser

EG17650301 Adapting radiator cap tester

( ) to radiator filler neck
Radiator cap tester
adapter
fj

LC-2
 PRECAUTIONS

Supplemental Restraint System "AIR BAG"

The Supplemental Restraint System "Air Bag" helps to reduce the
risk or severity of injury to the driver in a frontal collision. The
Supplemental Restraint System consists of an air bag (located in
the center of the steering wheel), sensors, a control unit, warning
lamp, wiring harness and spiral cable. Information necessary to
service the system safely is included in the BF section of this
Service Manual.
WARNING:
a. To avoid rendering the SRS inoperative, which could lead to
personal injury or death in the event of a severe frontal
collision, all maintenance must be performed by an author-
ized NISSAN dealer.
b. Improper maintenance, including incorrect removal and in-
stallation of the SRS, can lead to personal injury caused by
unintentional activation of the system.
c. All SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation. Do not use electrical
test equipment on any circuit related to the SRS "Air Bag".

Liquid Gasket Application Procedure

a. Before applying liquid gasket, use a scraper to remove all

• traces of old liquid gasket from mating surface .

~~
b. Apply a continuous bead of liquid gasket to mating
Inner
surfaces. (Use Genuine Liquid Gasket or equivalent.)
side
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide (for oil pan).
Groove Bolt hole • Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in)
wide (in areas except oil pan).
c. Apply liquid gasket to inner sealing surface around hole
SEM371C perimeter area.
(Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and engine
coolant.

LC-3
 ENGINE LUBRICATION SYSTEM

Lubrication Circuit

Valve timing control

system

Valve timin!l control solenoid valve

Valve

Front ft-.
'-----Orifice (check ball)
side Y-'

Main gallery

Hydraulic
valve I ifter

S> Feed
. . Return

Non-turbo model Turbo model

r---------------
,-
'
II

•l
Oil cfoler
'---:.....rr-----l
Oil pan
{).

Oil pump
.J
---------------------------------------- - - l
Oil strainer
{y
I

I I
(::J Oil passage

Regulator valva I
.·---
..---
' • ..J.
~
Oil gallery
By-pass passage
To oil pan
Turbo model only

c_ Check valve

- J
Oil filter

Main gallery
I I Relief valve I

r-- . ~--.
r-- .____ M_a_in,b'Te_ar_in..:.g_--JI I Piston ail jets~ I Turbochargers ~

r,:~ -· 7g===-~===-~~~~
I _{7
:+- Connecting rod bearing I
: ~}
r;::::!

: I.___C:..;o;..;n;..;nect;,;;;.;.in.;:g:..;.ro.:.;d;__--JI IL Hydraulic valve lifter I

:: I '
Piston I

~ -------- :t ___ -------- ~-j I

I
I
----------------- ------------- ______ j

SLC5.80A

LC-4
 ENGINE LUBRICATION SYSTEM

Oil Pressure Check

WARNING:
• Be careful not to burn yourself, as the engine and oil may
be hot.
• Oil pressure check should be done in "Neutral" gear
position.

1. Check oil level.

2. Remove oil pressure switch.

3. Install pressure gauge.

4. Start engine and warm it up to normal operating tempera-
ture.
5. Check oil pressure with engine running under no-load.
ST25051001
(J25695-1) Engine Approximate discharge
rpm pressure kPa (kg/cm 2 , psi)

Idle speed More than 78 (0.8, 11)

3,000 353-451 (3.6- 4.6, 51- 65)
ST25052000
(J25695·2) SLC926
If difference is extreme, check oil passage and oil pump for
oil leaks.
6. Install oil pressure switch with sealant.

Oil Filter Bracket (Turbo model)

• Check oil cooler check valve for valve opening pressure.
Opening pressure:
324 - 363 kPa (3.3 - 3.7 kg/cm 2, 47 - 53 psi)

~ : N·m (kg-m, ft-lb)

SLC581A

LC-5
 ENGINE LUBRICATION SYSTEM

Oil Pump
REMOVAL
1. Drain oil.
2. Remove oil pan. (Refer to "OIL PAN - Removal" in EM
section.)
3. Remove oil pump assembly.

~ 22. 29
12.2 - 3.0, 16- 22)
~ lkg~.
' N·m ft<bl
SLC936

DISASSEMBLY AND ASSEMBLY

Cover

0 /~to.J3.7- 5.0
10.38- 0.51,
2.7-3.7)

·"-....~A' 6.3-8.3 (0.64-0.85,4.6-6.1)

Regulator valve

Spring
Oil strainer
Regulator
valve seat I

Cap
Washer
to.l 39 - 69 .0
~
~~ 10 ·21 IU-2.1, 12· 151
1 14-7,29-511 toJ : N·m lkg-m, ft-lb) SLC318A

• Always replace with new oil seal and gasket.

• When installing oil pump, apply engine oil to inner and
outer gears.
• Be sure that 0-ring is properly installed.

LC-6
 ENGINE LUBRICATION SYSTEM
Oil Pump (Cont'd)
INSPECTION
Using a feeler gauge, check the following clearances:

Standard clearance: Unit: mm (in)

Body to outer gear clearance CD 0.110 - 0.200 (0.0043 - 0.0079)

Inner gear to crescent clearance ® 0.223. 0.333 (0.0088- 0.0131)
Outer gear to crescent clearance @ 0.210-0.320 (0.0083- 0.0126)
Housing to inner gear clearance @ 0.050 - 0.090 (0.0020 - 0.0035)
Housing to outer gear clearance @ 0.050- 0.110 (0.0020- 0.0043)

If any clearance exceeds the limit, replace gear set or entire

oil pump assembly.

@.@ SLC550

REGULATOR VALVE INSPECTION

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil and check to make sure
that it falls smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.

SLC295

OIL PRESSURE RELIEF VALVE INSPECTION

Oil pressure relief valve Inspect oil pressure relief valve for movement, cracks and
breaks by pushing the ball. If replacement is necessary, remove
valve by prying it out with a suitable tool.
Install a new valve by tapping it in place.

SLC231A

LC-7
 ENGINE LUBRICATION SYSTEM

Oil Cooler (Turbo model)

DISASSEMBLY AND ASSEMBLY

rRJ3.8. 4.5
(0.39 • 0.46, ~ -
2.8. 3.3) ~,

'

rRJ : N·m (kg-m, ft-lb) SLC582A

LC-8
 ENGINE COOLING SYSTEM

Cooling Circuit

Cylinder - - - t l
block

From
cylinder
head
From
+ cylinder
head

+
t
From radiator

Throttle Throttle
chamber chamber
(Right (Left side)
Water side)
pump

From radiator

..
¢:J
L __ J
~--,
Thermostat open

Thermostat closed
Turbo model only

. ...
Radiator ~: =-=--=-=------_-_-_-_-_=-_, Reservoir tank
I

I
I
...
Thermostat
I

I Water outlet
I
-";>, Thermostat housing

I
I
+ ~---+----· --------t-----
Ill Turbocharger (Left side) I I Turbocharger (Right sld~) Jj
I Water pump

I ----l---------r---~1 I
•
Heater

I + II I I
l Cylinder block (Left side) Cylinder block (Right side) Throttle chamber (Loft side) Throttle chamber (Right sidell

l •
Cylinder head (Left side)
I I
+
Cylinder head (Right side) II
+
A.A.C. valve
I
• I
• SLC343A

LC-9
 ENGINE COOLING SYSTEM

System Check
WARNING:
Never remove the radiator cap when the engine is hot;
serious burns could be caused by high pressure fluid escap-
ing from the radiator.
Wrap a thick ·cloth around the cap and carefully remove by
turning It a quarter turn to allow built-up pressure to escape.
Then continue to turn the cap until it can be removed safely.

CHECKING COOLING SYSTEM HOSES

Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.

CHECKING COOLING SYSTEM FOR LEAKS

To check for leakage, apply pressure to the cooling system with
a tester.
Testing pressure:
98 kPa (1.0 kg/cm 2 , 14 psi)
CAUTION:
Higher than the specified pressure may cause radiator dam-
age.

SMA990A

CHECKING RADIATOR CAP

To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
78 - 98 kPa (0.8 - 1.0 kg/cm 2, 11 - 14 psi)

Water Pump
REMOVAL AND INSTALLATION
1. Drain coolant from drain cocks on both sides of cylinder block
and radiator.
2. Remove the following parts:
• Under cover
• Radiator
• Drive belts
• Cooling fan and coupling
• Water inlet and outlet

LC-10
 ENGINE COOLING SYSTEM
Water Pump (Cont'd)
• Crank pulley
• Timing belt cover
3. Remove water pump
4. After repairing or replacing water pump, install any parts
removed in reverse order of removal.

~ : Apply recommended sealant

(NISSAN genuine part: KP610-00250
or equivalent). SLC319A

CAUTION:
• When removing water pump assembly, be careful not to get
coolant on timing belt.
• Water pump cannot be disassembled and should be replaced
as a unit.
• After installing water pump, connect hose and clamp securely,
then check for leaks using radiator cap tester.

INSPECTION
1. Check for badly rusted or corroded vanes and body as-
sembly.
2. Check for rough operation due to excessive end play.

LC-11
 ENGINE COOLING SYSTEM

Thermostat
REMOVAL AND INSTALLATION
1. Drain coolant from drain cocks on both sides of cylinder block
and radiator.
2. Remove the following parts:
• Under cover
• Radiator upper hose
• Radiator shroud
• Fan belt
• Cooling fan and coupling
• Water inlet
3. Remove thermostat.

Heater pipe (feed)

Heater pipe
(return)
tql6.3 . 8.3
(0.64 . 0.85,
' 4.6- 6.1)
I

toJ 16.21
(1.6-2.1,
12-15)~....-
oOo"'·.[...· ~
tPJ 6.3. 8.3
(0.64 - 0.85, 4.6 - 6.1 I

l'J

tPJ : N·m (kg-m, ft-lb)

SLC320A

Upper
4. After repairing or replacing thermostat, install thermostat with
jiggle valve facing upward.

LC-12
 ENGINE COOLING SYSTEM
Thermostat (Cont'd)
INSPECTION
1. Check valve seating condition at ordinary room temperatures. It
should seat tightly.

2. Check valve opening temperature and maximum valve lift.

Standard

Valve opening temperature °C (°F) 76.5 (170)

Maximum valve lift mmfC (infFI 10/90 (0.39/194)

3. Then check if valve is 5°C (9°F) below valve opening

temperature.
• After Installation, run engine for a few minutes, and check
SLC343
for leaks.
• Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.

LC-13
 ENGINE COOLING SYSTEM

Radiator
REMOVAL AND INSTALLATION
1. Drain coolant from radiator drain cock.
2. Remove under cover.
3. Disconnect radiator upper and lower hoses.
4. Remove A/T oil cooler hoses. (A/T model only)
5. Remove radiator lower shroud.
6. Remove radiator.
7. After repairing or replacing radiator, install any part removed in
reverse order of removal.
Turbo model

Non-turbo
model

Front
~

cooler he»e
(A/Tmodel
qnly)

Reservoir tank

lA3.2-4.2
(0.33 . 0.43, 2.4 • 3.11
Radiator
lower
shroud
~ : N·m (kg-m, ft-tbl
SLC344A

Electric Cooling Fan Control System

Radiator (Condenser) fan is controlled by E.C.C.S. control unit.
For details, refer to EF & EC section.

LC-14
 ENGINE COOLING SYSTEM

Cooling Fan
DISASSEMBLY AND ASSEMBLY

Water
pump
pulley
A& -1o co.& -1.o.
4.3. 7.2)

SLC322A

INSPECTION
Check fan coupling for rough operation, oil leakage or bent
bimetal.

SLC072

LC-15
 SERVICE DATA· AND SPECIFICATIONS (S.O.S.)

Engine Lubrication System

Oil pressure check Oil·pump
Unit: mm (in)
Approximate discharge
Engine rpm
pressure kPa (kg/cm 2 , psi) Body to outer gear
0.110 • 0.200 (0.0043 • 0.0079)
Idle speed More than 78 (0.8, 11 I
clearance CD
Inner gear to crescent
3,000 353. 451 (3.6. 4.6, 51 • 65) 0.223. 0.333 (0.0088. 0.0131)
clearance®
Outer gear to crescent
0.210. 0.320 (0.0083. 0.01261
clearance@
Housing to inner gear side
0.050 • 0.090 (0.0020 • 0.0035)
clearance®
Housing to outer gear side
0.050. 0.110 (0.0020 • 0.0043)
clearance@

Engine Cooling System

Thermostat
Standard

Valve opening temperature

oC (oF) 76.5 (170)

Maximum valve lift

10/90 (0.39/194)
mmfC(infFI

LC-16
 ENGINE FUEL I
EMISSION CONTROL SYSTEM

SECTIONEF &EC
CONTENTS
PREPARATION .................................................................................................................... EF & EC-
PRECAUTIONS .................................................................................................................... EF & EC-
2
3
-
ENGINE AND EMISSION CONTROL OVERALL SYSTEM .......................................... EF & EC- 4
ENGINE AND EMISSION CONTROL PARTS DESCRIPTION ...................................... EF & EC- 14
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION ................................... EF & EC- 21
IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION ...................... EF & EC- 37
TROUBLE DIAGNOSES ..................................................................................................... EF & EC- 42
FUEL INJECTION CONTROL SYSTEM INSPECTION ................................................... EF & EC-191
EVAPORATIVE EMISSION CONTROL SYSTEM ............................................................ EF & EC-193
CRANKCASE EMISSION CONTROL SYSTEM .............................................................. EF & EC-195
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ......................................................... EF & EC-196

For assistance with wiring diagrams:

e Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES".
 PREPARATION

SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

CDKV109D0010 Measuring ignition timing

(J-36777-1)
Ignition timing
adapter coil
® KV10114200
(J-38386)
Adapter harness

KV10114400 Loosening or tightening

(J-38365) exhaust gas sensor
Exhaust gas sensor
wrench

EF & EC-2
 PRECAUTIONS

WIRELESS EQUIPMENT
• When installing C.B. ham radio or a
E.C.U. mobile phone, be sure to observe the
• Do not disassemble E.C.C.S. control following as it may adversely affect
unit (E.C.U.). electronic control systems depending
• Do not turn diagnosis mode selector on its installation location.
forcibly. 1) Keep the antenna as far as possible
• If a battery terminal is disconnected. from the electronic control units.
the memory will return to the ROM 2) Keep the antenna feeder. line more
value. The E.C.C.S. will now start to than 20 em (7.9 in) away from the
self-control at its initial value. Engine harness of electronic controls.
operation can vary slightly when the Do not let them run parallel for a long
terminal is disconnected. However, this distance.
is not an indication of a problem. Do 3) Adjust the antenna and feeder line so
not replace parts because of a slight that the standing-wave ratio can be
BATIERY variation. kept smaller.
• Always use a 12 volt battery as power 4) Be sure to ground the radio to vehicle
source. body.
• Do not attempt to disconnect battery
cables while engine is running.

INJECTOR
• Do not disconnect injector harness
connectors with engine running.
• Do not apply battery power directly to
injectors.

E.C.C.S. PARTS HANDLING

• Handle air flow meter carefully to avoid
damage.
• Do not disassemble air flow meter.
• Do not clean air flow meter with any
type of detergent.
WHEN STARTING FUEL PUMP
• Do not disassemble auxiliary air control
• Do not depress accelerator pedal when • Do not operate fuel pump when there
valve.
starting. is no fuel in lines.
• Even a slight leak in the air intake
• Immediately after starting, do not rev • Tighten fuel hose clamps to the
system can cause serious problems.
up engine unnecessarily. specified torque.
• Do not shock or jar the crank angle
• Do not rev up engine just prior to
sensor.
shutdown. E.C.C.S. HARNESS HANDLING
• Securely connect E.C.C.S. harness
connectors.
SUPPLEMENTAL RESTRAINT SYSTEM "AIR BAG" A poor connection can cause an
The Supplemental Restraint System "Air Bag" helps to reduce the risk or severity of injury extremely high (surge) voltage to
to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag develop in coil and condenser, thus
(located in the center of the steering wheel), sensors, a control unit, warning lamp, wiring resulting in damage to ICs.
harness and spiral cable. Information necessary to service the system safely is included in • Keep E.C.C.S. harness at least 10 em
the BF section of this Service Manual. (3.9 in) away from adjacent harnesses,
WARNING: to prevent an E.C.C.S. system
a. To avoid rendering the SRS inoperative, which could lead to personal Injury or death malfunction due to receiving external
in the event of a severe frontal collision, all maintenance must be performed by an noise, degraded operation of ICs, etc.
authorized NISSAN dealer. • Keep E.C.C.S. parts and harnesses dry.
b. Improper maintenance, including incorrect removal and installation of the SRS, can • Before removing parts, turn off ignition
switch and then disconnect battery
lead to personal injury caused by unintentional activation of the system.
ground cable.
c. All SRS electrical wiring harnesses and connectors are covered with yellow outer
insulation. Do not use electrical test equipment on any circuit related to the SRS "Air
Bag". SEF3231

EF & EC-3
 E.G.R. control
Valve timing control
z
valve 0
solenoid valves z
\ I.A.A. unit
Exhaust
gas sensor
(Left side)
!t
c:
:D
01
Exhaust gas 0
sensor 3:
(Right side) 0
c
m
m z
A.I.V.
control
r
-mz
C)

solenoid
valve ,..
z
E.G.R. Fuel filter
c
control m
solenoid valve s:
u;

.,m
Ignition coil relay rn
0 -0z
U)

Ignition 0
flO coiland
sparkplug#1
I ~0\~(_J
~~
~ 0
0
m 1/ 7 0
....z:D
C') 0
I 3
~ Power
"C 0
I IA /1 (\ \\~~ E.C.C.S. relay 0 r-

-
transistor ::::::1
unit r. CD 0
Check connector
for engine speed
, ,..m<
::::::1

ID
:D
r-
:::1.
fn r-
r- U)
0
~
Aad iator fan relay
-
n
ID
s·
::::::1
....
m
s:
Fuel temperature
sensor Carbon
Crank

1-'F"''
canister
angle
Throttle valve switch and
Engine sensor
temperature throttle sensor
(/)

...,
m
U)
sensor Air flow meter pressure Power steering
regu /ator oi I pressure
1:! switch
 .....
E.G.R. control Valve timing control c:
valve solenoid valves :a
m
0
Exhaust 3:
I.A.A. unit gas sensor 0
Exhaust gas Fuel damper
(Left side) c
sensor
(Right
.-m ·m
Wastegate valve control z
solenoid valve
(Left side) -
Ci)
z
,..
m
z
solenoid valve c
P.R.V.R. control
m
solenoid valve
3:
Wastegate valve control
solenoid valve u;
m
n -0z
(Right side) Ignition coil. relay (/)

m
"T1 n
flO Ignition coil and spark
.(n 0n
m n ....
0
z
0
I 3 ::D
0'1 E.C.C.S. relay "'C 0
Power
tra~sistor 1 1&\ // L\ \I a 0 r-

-., ,..
::::s
un1t CD 0
Check connector
::::s
<
m
for engine speed ::D
m
;:::L r-
en r-
r- (/)
0
-<
Radiator fan relay --· ....
n
m (/)

;-
0

sensor
Engine
canister
Throttle valve switch and
-::::s

n
0
::::s
3:

-
Crank throttle sensor '"t
temperature angle a.
en 111nsor Fuel ~nsor
m Air flow meter
"'11
~
pressure Power steering
regulator oil pressure switch
t
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM
E.C.C.S. Component Parts Location (Cont'd)
NON-TURBO MODEL

Throttle sensor &

throttle valve switch

Exhaust gas sensor

A.A.C. valve & F.I.C.D. solenoid valve

JGiovebox

mode
selector

Exhaust gas temperature sensor

(California model only)

SEF195J

EF & EC-6
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM
E.C.C.S. Component Parts Location (Cont'd)
TURBO MODEL

Throttle sensor &

throttle valve switch

-
~~'"'
Wastegate valve control
solenoid valve '\
I ~..----~=n:J

A.A.C. valve & F.I.C.D. solenoid valve

Air regulator

J Glove box

------~-~

selector

Exhaust gas temperature sensor

(California model only)

SEF196J

EF & EC-7
 z
0
z
~
c:
:IJ
m

jf"'r·. . ~_----r,;;;Y;'·:::::=~=-----. ~~~~~~

0
3:

I
Power transistor
unit
g: 0
c
m
r-
m
z
-mz
G)

,.z
@o
.... ' ~~
Crank angle
c
sensor m
~-----Air conditioner 3:
switch
u;
en
m
""
flO
:!7 ition-~
1 E.C.C.S.
control unit
Radiator fan relay

Power steering oil. pressure

switch
-
'<
en
CD
3
c
~
0
z
(')
0
m
0
Check engine light
m-· z
...
ca
0""''
I Neutral switch CMITI ::D
co ""---
Detonation....J sensor A/T control unit (A(TI m
3 r

~
sensor

0
<

=~
m
,.
::D
r
r
tn
U[i s==l_. ~
-t
m
3:
DTI---._ Muffler

(/1
trD
.,
m
~
0
~
 Ignition power
transistor unit
r----r---------------+------------------------------------
Jl ~ tion
tch

~I I
P.C.V.
_)1
Ill'
fj
~Crank angle
sensor
-;::::
m
"T1
flO
m
0I
CD

r:::::> Fuel
pump R
Vehicle speed
C/l sensor
.,....m
ID 'uu'
.....
<-
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM

System Chart

I I
Crank angle sensor
I Fuel injection &
mixture ratio control ) Injectors

I Air flow meter I

I
Ignition timing control ) Power transistors
I Engine temperature sensor r
I

I Exhaust gas sensors I

I Idle speed control
) Auxiliary air control (A.A.C.)
valve, F .I.C.D. solenoid
valve and Air regulator

'Ignition switch I

I. Throttle valve switch

(Idle position)
I

I
E.G.R. control
) E.G. R. control solenoid valve

I
~
I Throttle sensor
I II'
A.I.V. control

/
A.I.V. control solenoid valve

I Neutral switch/A/T control unit

(Gear position)
I
I
E.C.C.S.
control
unit
Valve timing control
) V.T.C. solenoid valves

I Vehicle speed sensor I

I

I Air conditioner switch I

J
Fuel pump control
) Fuel pump and
Fuel pump control unit

Check engine light

I Detonation sensor I
I Exhaust ga·s sensor ~ (On the instrument panel) or
monitor & self-diagnosiv Inspection lamp
(On the control unit)
I
I Fuel temperature sensor
I
"'"''"tlon cut oontro) Air conditioner relay
I Battery voltage
I II'

Exhaust gas temperature sensor I ~ Radiator fan control

I (California model only)
I
Radiator fan control
/
relay(s)

I Power steering oil pressure switch :

Pressure regulator
control ) P.R.V.R. control solenoid
valve

*Turbo model only

*Wastegate valve
control ) *Wastegate valve control
solenoid valves

EF & EC-10
 z
0
B z
I

Rear vacuum -t
0 gallery Right side vacuum gallery
c:
::D
m
0
3:
0

I~z
c
m
r

m
l>
z
Right side vacuum gallery c
solenoid valve m
control solenoid valve 3:
Right side c;;
Front
¢:l A.I.V. control VIEWS <
m ~
m side
Rear vacuum
gallery
valve
n 0
'T1 c
c z
f20 E.G.R. control valve 3 0
m 0
n (4 J:
0
z
.....
.....
I
solenoid valve
(I)
CD :a
..... _;·· 0
...mc 0
r-
-·((
~- <
\\:r.< '-·~­ f ' - E . G . R . ooo<col wlw
:::J
ca
m
:a
\-:y.>----.. l>
@ r-
0 r-
11
~
2
Leftside
~ A.I.V. control
en
A P.R.V.R. control
solenoid valve
-<
en
A.I.V. control valve solenoid valve
.....
VIEW A m
3:
{j) P.R.V .R. control solenoid valve to Air duct ® E.G.R. control solenoid valve to Right side vacuum gallery

® P.R.V.R. control solenoid valve to Intake manifold collector ® Throttle chamber to E.G.R. control solenoid valve

® P.R.V .R. control solenoid valve to Fuel pressure regulator ® Air gallery to E.G.R. control solenoid valve
@ Fuel pressure regulator to Vacuum gallery '@ Air duct to Air gallery

® Fuel damper to Balance tube @ A.I.V. control solenoid valve to A.I.V. control valve
Ul
.,
m ® E.G.R. control valve to Rear side vacuum gallery @ A.I.V. control solenoid valve to Air gallery
w @
1\) (f) Rear side vacuum gallery to Right side vacuum gallery A.I.V. control solenoid valve to Balance tube
!!!
 B -t
c:
D :D
ID
0
A.l. V. control 3:
Right side 0
A.I.V. control c
m
r
m
z
-zm
C)

:1>
z
Wastegate valve actuator c
m
Q s:
solenoid valve
VIEWB c;;
< !a
.,m P.R.V.R. control
S»
()
c
0
z
flO c
3 0
m ® 0 0
0I
:I:
0
z-1
...a en :D
CD
N 0
c
~
r-
S» 0
~- m
A.I.V. control valve
<
::::J

@
A
valve

VIEW A Wastegate valve

-CQ

0
0
::::J
:D
:1>
r-
r-
en
-
P.R.V .R. control solenoid valve to Vacuum tank ""t
@ P.R.V .R. control solenoid valve to Intake manifold @ Air duct to Right side air gallery
actuator
<
a. en
collector ® Air pipe to 3-way connector (For right side wastegate
@ A.I.V. control solenoid valve to A.I.V. control valve valve control) -1
® P.R.V.R. control solenoid valve to Fuel vacuum gallery
® A.I.V. control solenoid valve to Right side air gallery ~ Left side wastegate valve control solenoid valve to Air
m
@ Fuel pressure regulal!Or to Fuel vacuum gallery
through 3-way connector pipe through 3-way connector 3:
@ Fuel damper to Balance tube
® A.I.V. control solenoid valve to Balance tube ® Left side wastegate valve control solenoid valve to Suction
® E.G.R. control solenoid valve to Rear side vacuum gallery
® Right side recirculation valve to Intake manifold collector pipe
(f) Rear side vacuum gallery to Right side vacuum gallery (@l Right side wastegate valve control solenoid valve to Air @ Left side wastegate valve actuator to Air pipe through
® E.G.R. control solenoid valve to Right side vacuum pipe through 3-way connector 3-way connector
gallery @ Right side wastegate valve control solenoid valve to
~ ®l Throttle chamber to E.G.R. control solenoid valve @ Air pipe to 3-way connector (For left side wastegate valve
Suction pipe control)
~ 0 E.G.R. control solenoid valve to Right side air gallery @
<D
co through 3-way connector
Right side wastegate valve actuator to Air pipe through ~) Left side recirculation valve to Intake manifold collector
r... 3-way connector @ Canister purge I ine
 ...J"VL DIAGNOSTIC
CONNECTOR

Fu~LE~IGNITION~~
FOR CONSULT

LINK n ~ COIL "IE· c. c. s.8FUEL

URELAY U PUMP I I II,IIII:IJN
rEr FUSIBLE U RELAY RELAY
LINK
"::"
BATTERY IOFF,ACCI ON IST m
f-
8· 8 ~ FUSE
z
8
~~====~-------f~~j A. A. C. VALVE

~o[E~olgo~rE~~
-m
C')
z
'3
25 1---l--------f""\---.j....,fT'-l-6 WASTEGATE VALVE CONTROL
53
l>
58 SOLENOID VALVE- R.H.
L___ _ _ _ _.f]-.j....,fT'-l--6 WASTEGATE VALVE CONTROL z
):"'
z~
I 0I
33
SOLENOID VALVE- L.H.
I-J........-------+-'1fT'-I---e F. I. C. D.
c
~~
"'o
II 0 SOLENOID VALVE m
~"' 103
E. G. R. CONTROL
I 02 1-J........---------------4JT1~-6
SOLENOID VALVE s:::
u;
.. -z
Ill ~+--------~~~ P. R. V. R. CONTROL
SOLENOID VALVE
112
Q en
.,m 105

I I<
113 ~+---------------4-JTl~-6 V. T. C. SOLENOID

50 l
VALVE-R. H.
_j_~::::;------j~~1 V. T. C. SOLENOID
VALVE-L. H.
n
c
0
THROTTLE :::;
rzo ~ VALVE SWITCH 29 EXHAUST GAS
SENSOR-R. H. 0
~ (IDLE POSIT!~ 5'
m liS
2 0
(')
....
w
I
POWER STEERING
OIL PRESSURE
SWITCH
-=-
~I
57

I34
E. C. c. s.
CONTROL
UNIT
55

26 I
EXHAUST GAS
SENSOR-L. H.
..
m
cc
3
m
z-t
:D
0
I 0'
35
9
27
II I 1
r-
19
6 0
I
H..-------,.. <
I~ i ~~
1---+--
2
60
I \ ' I
m
I : I
:D
RESISTOR[!]
I I '
3
II
51
'I
h I
I
I
I
l>
I
I ''
I
I : r-
5 12
13
'2
52 ~ ~
---- "-' r-
CHECK IGNITION 23
ll .... _ _ _ _ _ _ _ _ _ JI
en
CONNECTOR COIL
RI07
108
~ h
<
en
116 •a -t
~To
,(, _ _ _ _ _ _ _ _ _ ft

SPARK~ m
~ ~ ~ ~
@: A/T model PLUG tachometer~ 7 38
---------M
@: M/T model
@: For California
CHECK
"" CONNECTOR

A/T I 0
..
5
28
30
s:::

@: Model with CONTROL l~ "IS

auto A/C UNIT 32 •o
® ]41
d
56
@:
ll
39
Model with
manual A/C
"
en NEUTRAL
I0 20 36
m
n
U1
CD
@: Turbo model THERMISTOR SWITCH
® -
I=
cp }'
w
Ill
 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

E.C.C.S. Control Unit (E.C.U.)

The E.C.U. consists of a microcomputer, an inspection lamp, a
diagnostic mode selector, and connectors for signal input and
output and for power supply. The unit controls the engine.

SEC220B

Crank Angle Sensor

The crank angle sensor is a basic component of the E.C.C.S. It
Light emitti
diode monitors engine speed and piston position, and sends signals to
the E.C.U. to control fuel injection, ignition timing and other
functions.
The crank angle sensor has a rotor plate and a wave-forming
circuit. The rotor plate has 360 slits for 1° signal and 6 slits for
Photo diode 120° signal. Light Emitting Diodes (L.E.D.) and photo diodes are
Wave built in the wave-forming circuit.
forming circuit Rotor plate
SEF971 E

When the rotor plate passes between the L.E.D. and the photo
diode, the slits in the rotor plate continually cut the light being
transmitted to the photo diode from the L.E.D. This generates
rough-shaped pulses which are converted into on-off pulses by
the wave-forming circuit, which are sent to the E.C.U.

Rotor plate SEF3261

Air Flow Meter

The air flow meter measures the intake air flow rate by measuring a
part of the entire flow. Measurements are made in such a way that
the E.C.U. receives electrical output signals varied by the amount
of heat emitting from the hot film placed in the stream of the intake
air.
When intake air flows into the intake manifold through a route
around the hot film, the heat generated from the hot film is taken
away by the air. The amount of heat reduction depends on the air
flow. The temperature of the hot film is automatically controlled to
a certain number of degrees.
Therefore, it is necessary to supply the hot film with more electric
current in order to maintain the temperature of the hot film. The
E.C.U. detects the air flow by means of this current change.

EF &. EC-14
ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Engine Temperature Sensor

The engine temperature sensor, located on the top of water
inlet housing, detects engine coolant temperature and transmits
a signal to the E.C.U.
The temperature sensing unit employs a thermistor which is
sensitive to the change in temperature. Electrical resistance of
the thermistor decreases in response to the temperature rise.

Throttle Sensor & Soft/Hard Idle Switch

The throttle sensor responds to accelerator pedal movement. This
Connector for sensor is a kind of potentiometer which transforms the throttle
throttle sensor
valve position into output voltage, and emits the voltage signal to
the E.C.U. In addition, the sensor detects the opening and closing
speed of the throttle valve and feeds the voltage signal to the
E.C.U.
Idle position of the throttle valve is determined by the E.C.U.
Connector for
hard idle switch
receiving the signal from the throttle sensor. This system is called
"soft idle switch". It controls engine operation such as fuel cut. On
SEF286D the other hand, "hard idle switch", which is built in the throttle
sensor unit, is used for engine control when soft idle switch is
malfunctioning.

~
Ill
Not used "0 Supply voltage:
c SV (Applied between terminal No. 4 and 6)
~, ... (Full throttle
"'"' 6.0..---------.,.-------.---------,
?~ switch)
ci
~2 1 Hard idle z Output voltage between

E:}
;;; terminal No. 4 and 5
~J switch c
E
~ 4.01----------+------,'<---t--------i
Throttle
sensor
6

Throttle valve opening angle (deg)

SEF2870

Fuel Injector
0-ring The fuel injector is a small, elaborate solenoid valve. As the
E.C.U. sends injection signals to the injector, the coil in the
injector pulls the needle valve back and fuel is released into the
intake manifold through the nozzle. The injected fuel is con-
trolled by the E.C.U. in terms of injection pulse duration.

SEC222B

EF &. EC-15
 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Pressure Regulator
The pressure regulator maintains the fuel pressure at 299.1 kPa
(3.05 kg/cm 2 , 43.4 psi). Since the injected fuel amount depends
To fuel tank
on injection pulse duration, it is necessary to maintain the
pressure at the above value.

To
intake
From fuel tube manifold

SEF3281

Exhaust Gas Sensor

The exhaust gas sensor, which is placed into the exhaust outlet,
monitors the amount of oxygen in the exhaust gas.
The sensor has a closed"end tube made of ceramic zirconia.
The outer surface of the tube is exposed to exhaust gas, and
the inner surface to atmosphere. The zirconia of the tube
compares the oxygen density of exhaust gas with that of
atmosphere, and generates electricity. In order to improve
Heater pad generating power of the zirconia, its tube is coated with
Isolation Zi
bearing tube platinum. The voltage is approximately 1V in a richer condition
SEF406H of the mixture ratio than the ideal air-fuel ratio, while approxi-
mately OV in leaner conditions. The radical change from 1V to
OV occurs at around the ideal mixture ratio. In this way, the
exhaust gas sensor detects the amount of oxygen in the
exhaust gas and sends the signal of approximately 1V or OV to
the E.C.U. A heater is used to activate the sensor.

Mixture ratio SEF2880

Fuel Pump
The fuel pump is an in-tank type with a fuel damper. Both the
pump and damper are located in the fuel tank.

From fuel filter Fuel Damper

The fuel damper, which consists of a diagram, reduces fuel
pressure pulsation in the fuel feed line between the fuel filter and
injectors.

To balance tube

SEF3291

EF 8r. EC-16
 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

'- ' .
Power transistor unit
Power Transistor Unit & Ignition Coil
The ignition signal from the E.C.U. is amplified by the power
/ transistor, which turns the ignition coil primary circuit on and off,
inducing the proper high voltage in the secondary circuit. The
ignition coil is a small, molded type.

To ignition
coil

~~

Ignition coil

SEF0271

Air Regulator
The air regulator provides an air by-pass when the engine is
cold for a fast idle during warm-up.
A bimetal, heater and rotary shutter are built into the air
regulator. When the bimetal temperature is low, the air by-pass
port opens. As the engine starts and electric current flows
through a heater, the bimetal begins to turn the shutter to close
~~:::S:!J~I.;t=~!r the by-pass port. The air passage remains closed until the
engine stops and the bimetal temperature drops.
flow

Idle Air Adjusting (I.A.A.) Unit

The I.A.A. unit is made up of the A.A.C. valve, F.I.C.D. solenoid
valve and idle adjust screw. It receives the signal from the E.C.U.
and controls the idle speed at the preset value.
Idle
adjusting ..
The F.I.C.D. solenoid valve compensates for changes in idle
screw speed caused by the operation of the air compressor.

SEF3301

Auxiliary Air Control (A.A.C.) Valve

The E.C.U. actuates the A.A.C. valve by an ON/OFF pulse. The
longer that ON duty is left on, the larger the amount of air that
will flow through the A.A.C. valve.

Air

SEF040E

EF & EC-17
 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Power Steering Oil Pressure Switch

The power steering oil pressure switch is attached to the power
steering high-pressure tube and detects the power steering
load, sending the load signal to the E.C.U. The E.C.U. then
sends the idle-up signal to the A.A.C valve.

Vehicle Speed Sensor

The vehicle speed sensor provides a vehicle speed signal to the
Magnetic line J
E.C.U.

0 ,' ---------
\ ," Reed Reed The speed sensor consists of a reed switch, which is installed
~ch •) switch
~·-- S N in the speedometer unit and transforms vehicle speed into a
',Magnetic pulse signal.
'-,_c--r.:::--;. _/ line
~
Field plate Field plate

SEF624B

Detonation Sensor
The detonation sensor is attached to the cylinder block and senses
engine knocking conditions.
A knocking vibration from the cylinder block is applied as pressure
to the piezoelectric element. This vibrational pressure is then
converted into a voltage signal which is sent to the E.C.U.

E.G.R. Control Valve

The E.G.R. control valve controls the quantity of exhaust gas to be
diverted to the intake manifold through vertical movement of a
taper valve connected to the diaphragm. Vacuum is applied to the
diaphragm in response to the opening of the throttle valve.

E.G.R. Control Solenoid Valve

The solenoid valve responds to the ON/OFF signal from the E.C.U.
When it is off, a vacuum signal from the throttle chamber is fed
into the E.G.R. control valve. When the control unit sends an ON
signal, the coil pulls the plunger downward and cuts the vacuum
signal.

EF & EC-18
 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Pressure Regulator Vacuum Relief (P.R.V.R.)

Control Solenoid Valve
The solenoid valve responds to the ON/OFF signal from the E.C.U.
When it is off, a vacuum signal from the intake manifold is fed into
the pressure regulator. When the control unit sends an ON signal,
the coil pulls the plunger downward and cuts the vacuum signal.

A.I.V. Control Solenoid Valve

The solenoid valve responds to the ON/OFF signal from the E.C.U.
When it is ON, a vacuum signal from the intake manifold is fed into
the A.I.V. control valve. When the control unit sends an OFF signal,
the coil pulls the plunger downward and cuts the vacuum signal.

Plunger
Wastegate Valve Control Solenoid Valve
The solenoid valve responds to the ON/OFF signal from the E.C.U.
When it is ON, a vacuum signal from the suction pipe or
compressor outlet is fed into the wastegate valve actuator. The
actuator is hard to open at this time. When the control unit sends
an OFF signal, the coil pulls the plunger upward and cuts the route
to the suction pipe.

Fuel Filter
The specially designed fuel filter has a metal case in order to
withstand high fuel pressure.

Diagnostic Connector for CONSULT

The diagnostic connector for CONSULT is located above the hood
release handle.

EF & EC-19
 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION

Exhaust Gas Temperature Sensor

The exhaust gas temperature sensor monitors the exhaust gas
temperature and transmits a signal to the E.C.U. The temperature
sensing unit employs a thermistor which is sensitive to the change
in temperature. Electric resistance of the thermistor decreases in
response to the temperature rise.

SEF072G

Front wheel house Air Induction Valve (A.I.V.)

The air induction valve sends secondary air to the exhaust manifold,
using a vacuum created by exhaust pulsation in the exhaust
manifold. When the exhaust pressure is below atmospheric pres-
sure (negative pressure), secondary air is sent to the exhaust
manifold. When the exhaust pressure is above atmospheric pres-
sure, the reed valves prevent secondary air from being sent back
to the sub-air cleaner.

exhaust tube
SEF3361

Valve Timing Control Solenoid Valve

The valve timing control solenoids are installed at the rear end of
the intake camshafts, and control oil pressure which regulates the
position of the intake camshafts.

Valve timing control

solenoid valve
SEF0281

~~___l-....__/1 Carbon Canister

Front suspension member
'::: .J.-( The carbon canister is filled with active charcoal to absorb
'--- evaporative gases produced in the fuel tank. These absorbed
gases are then delivered to the intake manifold by manifold vacuum
for combustion purposes.

Fuel Temperature Sensor

~tfir
:::>-----.:Fuel temperature sensor
:]1
The fuel temperature sensor, built into the fuel tube, senses fuel
temperature. When the fuel temperature is higher than specified,
the E.C.C.S. control unit turns the P.R.V.R. control solenoid valve
ON and raises fuel pressure.

SEF3381

EF & EC-20
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Fuel Injection Control

INPUT/OUTPUT SIGNAL LINE

I Crank angle sensor

I Engine speed and piston position
I
Amount of intake air
I Air flow meter
I ...

I Engine temperature sensor I

I
Engine coolant temperature

I Exhaust gas sensor

I Density of oxygen in exhaust gas
I

I Throttle sensor I
I
Throttle valve idle position E.C.C.S.
control
I
.I Injectors
I
unit

INeutral switch/ A/T control unit I

I
Gear position

Vehicle speed
.
I Vehicle speed sensor
I
Start signal
I Ignition switch
I ..
Battery voltage
I Battery
I ..
BASIC FUEL INJECTION CONTROL VARIOUS FUEL INJECTION
The amount of fuel injected from the fuel injector, INCREASE/DECREASE COMPENSATION
or the length of time the valve remains open, is In addition, the amount of fuel injection is com-
determined by the E.C.U. The basic amount of fuel pensated for to improve engine performance
injected is a program value mapped in the E.C.U. under various operating conditions as listed below.
ROM memory. In other words, the program value <Fuel increase>
is preset by engine operating conditions deter- 1) During warm-up
mined by input signals (for engine rpm and air 2) When starting ·the engine
intake) from both the crank angle sensor and the 3) During acceleration
air flow meter. 4) Hot-engine operation
<Fuel decrease>
1) During deceleration

EF & EC-21
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fuel Injection Control (Cont'd)
Closed loop ~ MIXTURE RATIO FEEDBACK CONTROL
control E.C.C.S.
) control The mixture ratio feedback system is used for precise control of
unit 1 . • the mixture ratio to the stoichiometric point, so that the three-way
Feed.Agnal njeeCtiOn
pulse
catalyst can reduce CO, HC and NOx emissions. This system uses
Exhaust an exhaust gas sensor in the exhaust manifold to check the air-fuel
(gas Injector ratio. The control unit adjusts the injection pulse width according
sensor to the sensor voltage so the mixture ratio will be within the range
CombustiB
Fuel
n injection of the stoichiometric air-fuel ratio.
This stage refers to the closed-loop control condition. The open-
Engine loop control condition refers to that under which the E.C.U. detects
SEF639B any of the following conditions and feedback control stops in order
to maintain stabilized fuel combustion.
1) Deceleration
2) High-load, high-speed operation
3) Engine idling
4) Malfunction of exhaust gas sensor or its circuit
5) Insufficient activation of exhaust gas sensor at low engine
temperature
6) Engine starting
7) Exhaust gas sensor high output voltage
MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture
ratio signal transmitted from the exhaust gas sensor. This feedback
signal is then sent to the E.C.U. to control the amount of fuel
injection to provide a basic mixture ratio as close to the theoretical
mixture ratio as possible. However, the basic mixture ratio is not
necessarily controlled as originally designed. This is due to manu-
facturing errors (e.g., air flow meter hot wire) and changes during
operation (injector clogging, etc.) of E.C.C.S. parts which directly
affect the mixture ratio.
Accordingly, a difference between the basic and theoretical mixture
ratios is monitored in this system. It is then computed in terms of
"fuel injection duration" to automatically compensate for the
difference between the two ratios.

• Simultaneous injection FUEL INJECTION TIMING

Two types of fuel injection systems are used - simultaneous
No.1 cylinder ...._ • - - - . . J _ L - - - - I _ L . . . -
injection and sequential injection. In the former, fuel is injected into
No. 2 cylinder ...._ • - - - . . J _ L - - - - I L . . . - all six cylinders simultaneously twice each engine cycle.
No. 3 cylinder-'~---..J_'----LL- In other words, pulse signals of the same width are simultaneously
No. 4 cylinder_,_._ _ _.J_L----I_L...- transmitted from the E.C.U. to the six injectors two times for each
No. 5 cylinder ...._•----'-.J_L----!__L...- engine cycle.
No. 6 cylinder In the sequential injection system, fuel is injected into each cylinder
~ 1 engine cycle ---J during each engine cycle according to the firing order.
When engine is starting, fuel is injected into all six cylinders
simultaneously twice per cycle.
• Sequential injection

No. 1 cylinderJl....___ _ _ _ _ _ __
No. 2 cylinder
No.3 cylinder _ _ _---J .__=-----
No.4 cylinder _ _ _ _ __, ....._ _ __
No.5 cylinder _ _ _ _ _ _ _..J '--~

No. 6 cylinder:-----------..lf"L
f - - - - 1 engine cycle---·-ll

SEC254B

EF & EC-22
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fuel Injection Control (Cont'd)
FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or high-
speed operation.

Ignition Timing Control

INPUT/OUTPUT SIGNAL LINE

I Engine speed and piston position

r Crank angle sensor I

L Amount of intake air

r Air flow meter I

l Engine coolant temperature

Engine temperature sensor
r I

I Throttle valve idle position

I Throttle sensor
I E.C.C.S.
I I
control .I Power transistors
Vehicle speed unit
I Vehicle speed sensor
I ...

I Start signal
I Ignition switch
I
Engine knocking
I Detonation sensor
I ...

I Battery voltage
r Battery J

EF & EC-23
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Ignition Timing Control (Cont'd)
SYSTEM DESCRIPTION
The ignition timing is controlled by the E.C.U. in e.g. N: 1,800 rpm, Tp: 1.50 msec
order to maintain the best air-fuel ratio in response A 0 8.T.D.C.
to every running condition of the engine. In addition to this,
The ignition timing data is stored in the ROM located 1) At starting
in the E.C.U. This data forms the map shown below. 2) During warm-up
The E.C.U. detects information such as the injection 3) At idle
pulse width and crank angle sensor signal which 4) At low battery voltage
varies every moment. Then responding to this infor- the ignition timing is revised by the E.C.U. ac-
mation, ignition signals are transmitted to the power cording to the other data stored in the ROM.
transistor.

Tp
(msec)

1.751----__...f----_ ___._ _ ___...._ _ __.__ _ _...__

A
1.50
Injection
pulse
width 1.25

1.00

0.75

•
~--~=---~=---~~-~~~--J_-~N
600 1,000 1,400 1,800 2,200
Engine speed (rpm)

SEC750A

The retard system, actuated by the detonation sen- However, if engine knocking occurs, the detonation
sor, is designed only for emergencies. The basic sensor monitors the condition and the signal is
ignition timing is pre-programmed within the anti- transmitted to the E.C.C.S. control unit. After re-
knocking zone, even if recommended fuel is used ceiving it, the control unit retards the ignition timing
under dry conditions. Consequently, the retard sys- to eliminate the knocking condition.
tem does not operate under normal driving condi-
tions.

EF &. EC-24
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Idle Speed Control

INPUT/OUTPUT SIGNAL LINE

I Crank angle sensor

I
Engine speed
.
I Engine coolant temperature
I Engine temperature sensor
I

I Ignition switch
I
Start signal
.
I Throttle valve idle position
I Throttle sensor
I .I .

I Neutral switch (M/T) I Neutral position

E.C.C.S.
control
. 1 A.A.C. valve
I
A/T control unit (A/T) I unit
~~ F.I.C.D. solenoid valve
I
I Air conditioner switch I
I
Air conditioner operation

I Power steering oil pressure switch I ..

I Battery voltage
I Battery
I

I Vehicle speed sensor l

I
Vehicle speed

SYSTEM DESCRIPTION •
the A.A.C. valve so that engine speed coincides with
This system automatically controls engine idle speed the target value memorized in ROM. The target
to a specified level. Idle speed is controlled through engine speed is the lowest speed at which the
fine adjustment of the amount of air which by-passes engine can operate steadily. The optimum value
the throttle valve via A.A.C. valve. The A.A.C. valve stored in the ROM is determined by taking into
repeats ON/OFF operation according to the signal consideration various engine conditions, such as
sent from the E.C.U. The crank angle sensor detects noise and vibration transmitted to the vehicle interior,
the actual engine speed and sends a signal to the fuel consumption, and engine load.
E.C.U. The E.C.U. then controls the ON/OFF time of

EF & EC-25
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Fuel Pump Control

INPUT/OUTPUT SIGNAL LINE
l
I Crank angle sensor
r
Engine speed ' ~

Amount of intake air

I Air flow meter
I .
l Engine coolant temperature
r Engine temperature sensor
I
~

E.C.C.S.
control
:: Fuel pump relay
l
r Ignition switch
l
r
Start signal ~ unit
.: Fuel pump control unit l
I Throttle valve idle position
I Throttle sensor
I
Battery voltage
I Battery
I ..

SYSTEM DESCRIPTION Condition Fuel pump operation

Fuel pump and air regulator ON-OFF control
The E.C.U. activates the fuel pump for several Ignition switch is tunred to ON.
Operates for
seconds after the ignition switch is turned on to 1 second
improve engine start-up. If the E.C.U. receives a 1°
Engine running and cranking Operates
signal from the crank angle sensor, it knows that the
engine is rotating, and causes the pump to activate. When engine is stopped Stops in 1.5 seconds
If the 1° signal is not received when the ignition
switch is on, the engine stalls. The E.C.U. stops Except as shown above Stops
pump operation and prevents battery discharging,
thereby improving safety. The E.C.U. does not di-
rectly drive the fuel pump. It controls the ON/OFF
fuel pump relay, which in turn controls the fuel pump.

Fuel pump voltage control

The fuel pump is controlled by the fuel pump control
unit adjusting the voltage supplied to the fuel pump.

Supplied voltage
Conditions
Turbo model Non-turbo model

• 1 second after ignition switch is turned ON

• Engine cranking
• 30 (*NA)/5 (**TC) seconds after engine start
Battery voltage Battery voltage
[above 50°C (122°F)]

• Engine temperature below 0°C (32°F)

• Engine is running under heavy load conditions

• Engine is running under middle load

conditions
Approx. 7V Battery voltage

• Except the above Approx. 6V Approx. BV

*NA: Non-turbo model **TC: Turbo model

EF & EC-26
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

E.G.R. (Exhaust Gas Recirculation) Control

INPUT/OUTPUT SIGNAL LINE

I Crank angle sensor

1 Engine speed
I

I Engine coolant temperature

I Engine temperature sensor
I E.C.C.S.
control
E.G.R. control solenoid
J Throttle valve idle position valve
unit
I Throttle sensor
I

I Ignition switch I
I
Start signal

SYSTEM DESCRIPTION This causes the port vacuum to be discharged

In addition, a system is provided which precisely into the atmosphere so that the E.G.R. control
cuts and controls port vacuum applied to the valve remains closed.
E.G.R. valve to suit engine operating conditions. 1) Low engine temperature
This cut-and-control operation is accomplished 2) Engine starting
through the E.C.U. When the E.C.U. detects any of 3) High-speed engine operation
the following conditions, current flows through the 4) Engine idling
solenoid valve in the E.G.R. control vacuum line. 5) Excessively high engine temperature

Air Induction Valve (A.I.V.) Control

INPUT/OUTPUT SIGNAL LINE
Engine coolant temperature
I
I Engine temperature sensor
I
Throttle valve idle position
l Throttle sensor I
I E.C.C.S.
control
A.I.V. control
Engine speed solenoid valve
unit
I Crank angle sensor
I ~

Vehicle speed
I Vehicle speed sensor
I ~

SYSTEM DESCRIPTION atmosphere under vacuum conditions, secondary air

The air induction system is designed to send sec- can be drawn into the exhaust manifold in proportion
ondary air to the exhaust manifold, utilizing the to the vacuum.
vacuum caused by exhaust pulsation in the exhaust The air induction valve is controlled by the E.C.C.S.
manifold. control unit, corresponding to the engine tempera-
The exhaust pressure in the exhaust manifold usually ture. When the engine is cold, the A.I.V. control
pulsates in response to the opening and closing of system operates to reduce HC and CO.
the exhaust valve and decreases below atmospheric This system also operates during deceleration for
pressure periodically. the purpose of blowing off water around the air
If a secondary air intake pipe is opened to the induction valve.

Engine coolant Vehicle speed A.I.V. control solenoid A.I.V. control

Engine condition
temperature °C (° F) km/h (MPH) valve system

Throttle valve is at Below 64 (147) Any condition

ON Operates
idle position Above 65 (149) Below 24 (15)

EF 8r. EC-27
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Fuel Pressure Regulator Control

INPUT/OUTPUT SIGNAL LINE
Fuel temperature
I
I Fuel temperature sensor
I
E.C.C.S.
Start signal P.R.V.R. control
I
I Ignition switch
I
control
unit
solenoid valve

l Crank angle sensor

I
J
Engine speed

SYSTEM DESCRIPTION Fuel temperature is

n
above 75° C (1 67° F)
The fuel "pressure-up" control system briefly in- START
creases fuel pressure for improved starting per-
ON
formance of a hot engine. Under normal operating
conditions, manifold vacuum is applied to the fuel Ignition OFF
switch ---t '
pressure regulator. When starting the engine, how-
. I
ever, the E.C.U. allows current to flow through the
ON/OFF solenoid valve in the control vacuum line, I
I.
ON
opening this line to the atmosphere. As a result,
atmospheric pressure is applied, restricting the fuel
return line so as to increase fuel pressure.
P.R.V.R.
control
solenoid
____,OFF .I OFF

valve Approx. 30 sec.

SEF741B

Acceleration Cut Control

INPUT/OUTPUT SIGNAL LINE
I ON s1gna
.
I Air conditioner system I
J
AC
E.C.C.S.
control
Air conditioner
relay j
I Throttle sensor I
I
Throttle valve opening angle unit

SYSTEM DESCRIPTION
When the accelerator pedal is fully depressed, the
air conditioner is turned off for a few seconds.
This system improves acceleration when the air
conditioner is used.

EF & EC-28
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Valve Timing Control

INPUT/OUTPUT SIGNAL LINE

I
Amount of intake air
..
Air flow meter
I
Engine speed
.
I Crank angle sensor
I
I Engine coolant temperature
E.C.C.S.
.I Valve timing control
I Engine temperature sensor
I
control
unit
"I solenoid valves I
I Throttle valve position
I Throttle sensor
I

I Neutral switch/AfT control unit I Neutral position

SYSTEM DESCRIPTION
The valve timing control system is utilized to in- amount of intake air, throttle valve position and gear
crease engine performance. Intake valve opening position are used to determine intake valve timing.
and closing time is controlled, according to the The intake camshaft pulley position is regulated by
engine operating conditions, by the E.C.U. oil pressure, which is controlled by the valve timing
Engine coolant temperature signals, engine speed, control solenoid valve.

Return spring

Camshaft (intake side) Valve timing control

solenoid valve

pressure Engine speed signal

gear (from crank angle sensor) - - - - . 1
Intake air signal
(from air flow m.. terl----.1 E.C.C.S.
Engine coolant temperature control
(from engine temperature sensor) -----1~ unit
Camshaft pulley (intake side) Throttle valve position
(from throttle sensor) ---~
Neutral position
(from neutral switch/A/T control unit)-----1~
L------~

SEFOOBI

EF & EC-29
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Valve Timing Control (Cont'd)
OPERATION

Engine operating Valve timing control Intake valve opening

Valve overlap Engine torque curve
condition solenoid valve and closing time

Idling, high speed OFF Retard Decreased CD

Low to medium speed ON Advance Increased ®

(I) Valve timing control solenoid valve is OFF. (II) Valve timing control solenoid valve is ON.

Drain

SEF0091

Exhaust closes
Overlap (8°)

Intake valve
Exhaust open time
valve
open
time

closes

CD ®

Effect
@ CD
t
Torque

Engine speed -
SEF0101

EF & EC-30
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Radiator Fan Control

INPUT/OUTPUT SIGNAL LINE
Vehicle speed
I Vehicle speed sensor
I Engine coolant
~

temperature E.C.C.S.
I Radiator fan
I Engine temperature sensor
I
Air conditioner
control
unit
control relay(s)

l Air conditioner switch I

J
"ON" signal

The E.C.U. controls the radiator fan corresponding to

the vehicle speed, engine temperature, and air con-
ditioner ON signal. The non-turbo model has 2-step
control [ON (HIGH)/OFF], and the turbo model 3-
step control [HIGH/LOW/OFF].

OPERATION
[Non-turbo model]
Air conditioner switch is "OFF" Air conditioner switch Is "ON"

Engine coolant temperature Engine coolant

oC (oF) Radiator fan Vehicle speed Radiator
temperature
km/h (MPH) oC (oF) fan
Below 104 (219) OFF
Below 94 (201) OFF
Above 105 (221) ON
Below 39 (24)
ON
Above 95 (203)
(HIGH)

Below 104 (219) OFF

Above 40 (25)
ON
Above 105 (221)
(HIGH)

[Turbo model]
Air conditioner switch is "OFF" Air conditioner switch is "ON"

Engine coolant temperature Engine coolant

Radiator fan Vehicle speed Radiator
oC tFl temperature
km/h (MPH) oC (oF) fan
Below 104 (219) OFF

Above 105 (221) Below 89 ( 192) OFF

ON
Between
Below 39 (24) LOW
90 (194) and 99 (210)

Above 100 (212) HIGH

Below 104 (219) OFF

Above 40 (25)
Above 105 (221) HIGH

EF 8t EC-31
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Wastegate Valve Control

INPUT/OUPTUT SIGNAL LINE

l Crank angle sensor I

I
Engine speed and piston position

Throttle valve idle position E.C.C.S. Wastegate valve

I Throttle sensor I
I
control control
unit solenoid valves
I Engine knocking
I Detonation sensor J

SYSTEM DESCRIPTION
The wastegate valve control solenoid valve changes When detonation signs are detected, which means a
the source vacuum which activates the actuator. This low octane fuel is being used, the solenoid valve
results in a suitable turbo-pressure. turns OFF, and turbocharger pressure becomes low.
OPERATION
Wastegate va!ve control Turbocharger
Engine conditions Wastegate valve actuators
solenoid valves pressure

• Engine running or cranking

• Throttle sensor output voltage: Lead to suction pipe
more than 0. 1V ON or turbocharger HIGH
compressor outlet
• Judged fuel quality: hi octane
(Detecting no sign of detonation)

Lead to turbocharger
• Except the above OFF
compressor outlet
LOW

EF & EC-32
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Fail-safe System
C.P.U. MALFUNCTION OF E.C.U.
Input/output signal line

I Crank angle sensor I

I
120° signal
1° signal
J
"I
Fuel injectors
l
I Ignition switch I
I
Start signal J
I
Power transistors
l
I Neutral switch/A/T control unit l Transmission gear position J
"I
Fuel pump
l
Battery voltage .I
I Battery
I • .I A.A.C. valve
I
E.C.C.S.
control
.,J E.G. A. control
solenoid valve I
unit .I Valve timing control I
I solenoid valve

.,J Radiator fan

control relay(s) I
.,J A. I. V. contro I
solenoid valve l
J P.R.V.R. control
I solenoid valve I
Outline In general, engine starting was difficult under the
The fail-safe system makes engine starting possible previously mentioned conditions. But with the provi-
if there is something malfunctioning in the E.C.U.'s sions in this fail-safe system, it is possible to start
C.P.U. circuit. the engine.

EF &. EC-33
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Fail-safe System (Cont'd)
Fail-safe system activating condition when E.C.U. Cancellation of fail-safe system when E.C.U. is
is malfunctioning malfunctioning
The fail-safe mode operation starts when the com- Activation of the fail-safe system is canceled each
puting function of the E.C.U. is judged to be mal- time the ignition switch is turned OFF. The system is
functioning. reactivated if all of the activating conditions are
When the fail-safe system activates, i.e. if a mal- satisfied after turning the ignition switch from OFF to
function condition is detected in the C.P.U. of the ON.
E.C.U., the CHECK ENGINE LIGHT on the instrument
panel lights to warn the driver. AIR FLOW METER MALFUNCTION
If the air flow meter output voltage is above or below
Engine control, with fail-safe system, operates the specified value, the E.C.U. senses an air flow
when E.C.U. is malfunctioning meter malfunction. In case of a malfunction, the
When the fail-safe system is operating, fuel injection, throttle sensor substitutes for the air flow meter.
ignition timing, fuel pump operation, engine idle Although the air flow meter is malfunctioning, it is
speed, E.G.R. operation, and so on are controlled possible to start the engine and drive the vehicle.
under certain limitations. But engine speed will not rise more than 2,400 rpm
in order to inform the driver of fail-safe system
operation while driving.

Operation

Engine condition Starter switch Fail-safe system Fail-safe functioning

Stopped ANY Does not operate -

Cranking Engine will be started by a pre-determined

ON
injection pulse on E.C.U.
Operates
Engine speed will not rise above
Running OFF
2,400 rpm

ENGINE TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR

MALFUNCTION MALFUNCTION
When engine temperature sensor output voltage is When fuel temperature sensor output voltage is
below or above the specified value, engine coolant below or above the specified value, fuel temperature
temperature signal is fixed at the preset value as signal is fixed at the preset value as follows:
follows:
Fuel temperature
Engine coolant temperature Engine condition
Engine condition preset valve °C (°F)
preset value °C (°F)
Start 20 (68)
Start 20 (68)
Running 80 (176)
Running 80 (176)

EF & EC-34
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION

Direct Ignition System

CHECKING IDLE SPEED AND IGNITION TIMING
Idle speed
• Method A (With pulse type tachometer)
Clamp loop wire as shown.
Loop wire
~

SEF0321

• Method B (With voltage type tachometer)

1. Disconnect check connector (Harness color: Y/R) for tachom-
eter.

2. Connect tachometer using suitable tool.

Ignition timing
e Method A (Without S.S.T.)
1. Remove No. 1 ignition coil.

· 2. Connect No. 1 ignition coil and No. 1 spark plug with suitable
high-tension wire as shown, and attach timing light clamp to
this wire.
3. Check ignition timing.

EF & EC-35
 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION
Direct Ignition System (Cont'd)
4. For above procedures, enlarge suitable high-tension wire end
with insulating tape as shown.

high-tension wire

Approx.
~
~.18\
APP'0 ""
14 (0.55) Unit: mm (in)

SEF457F

e Method B (With S.S.T.)

1. Disconnect connector of No. 1 ignition coil.

2. Connect S.S.T. and clamp wire with timing light as shown.

3. Check ignition timing.

Align direction marks on S.S.T. and timing light clamp if aligning

KV109D0010 mark is punched.
(J-36777-1)
KV10114200
(J-38386)

Align

SEF0391

EF & EC-36
 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

PREPARATION 2. On air conditioner equipped models, checks

1. Make sure that the following parts are in good should be carried out while the air conditioner
order. Is "OFF".
• Battery 3. On automatic transmission equipped models,
• Ignition system when checking Idle rpm, ignition timing and
• Engine oil and coolant levels mixture ratio, checks should be carried out
• Fuses while shift lever is in "N" position.
• E.C.U. harness connector 4. When measuring "CO" percentage, insert
• Vacuum hoses probe more than 40 em (15.7 In) into tall pipe.
• Air Intake system 5. Turn off headlamps, heater blower, rear defog-
(011 filler cap, oil level gauge, etc.) ger.
• Fuel pressure 6. Keep front wheels pointed straight ahead.
• Engine compression 7. Make the check after the radiator fan has
• E.G.R. control valve operation stopped.
• Throttle valve

Overall inspection sequence

INSPECTION START

I Perform self-diagnosis.
lN.G. I
I Repair or replace. I
I
O.K.

I Check & adjust ignition timing. l

I

I Check & adjust idle speed.

I
I •
~
Check exhaust gas sensor Check exhaust gas sensor
function. harness.
O.K. O.K. IN.G.
: Repair or replace harness.
r-
Check CO%.
N.G. IO.K.
II Replace exhaust gas sensor.
J
Check emission control parts
l
~ Check exhaust gas sensor
and repair or replace if
necessary.
function.
O.K.
I
c INSPECTION END ) ' t\
EF & EC-37
 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

( ___ s_TA~R_T_ ___.)

1
Visually check the following:
• Air cleaner clogging
• Hoses and ducts for leaks
• E.G.R. control valve operation

~~
TEMP d:
,, • Electrical connectors
• Gasket

1
t
120 270

Start engine and warm it up until water temperature

indicator points to the middle of gauge.
SEF246F
l
Open engine hood and run engine at about 2,000 rpm
for about 2 minutes under no-load.

1
Perform E.C.C.S. self-diagnosis. ~ ~~ ---~
SEF362
SEF247F O.K. lN.G.

Repair or replace components as necessary.

1
Does engine run smoothly?
O.K. lN.G.
I Clean injectors.
I"""
l

Race engine two or three times under no-load, I~

H
then run engine at idle speed. '
SEF248F l
Check ignition timing with a timing light.

15°±2° B.T.D.C.
O.K. lN.G.

Adjust ignition timing by turning crank angle ~

sensor after loosening securing bolts.

A B

EF & EC-38
 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

Check idle speed.

A/T: 770±50 rpm (in "N" position) [Non-turbo]

750±50 rpm (in "N" position) [Turbo]
M/T: 700±50 rpm
O.K. N.G.

Disconnect A.A.C. valve harness connector.

Adjust idle speed by turning idle speed

adjusting screw.
A/T: 720 rpm (in "N" position) [Non-turbo]
700 rpm (in "N" position) [Turbo]
SEF3641 M/T: 650 rpm

Connect A.A.C. valve harness connector.

Run engine at about 2,000 rpm for about 2 minutes

SEF247F
under no-load.

Set the diagnosis mode of E.C.U. to Mode II.

Inspection lamp
SEF957D Check left side exhaust gas sensor signal. does not blink.
Make sure that inspection lamp goes on and off more ~.:..:..:---=:..:.....------------,
than 5 times during 10 seconds (at 2,000 rpm).
O.K. Less than 5 times

Replace left side exhaust gas sensor.

Check left side exhaust gas sensor signal.

0. K. N.G.
SEF3621 14---l Make sure that inspection lamp goes on and off more 1----r-.CK
than 5 times during 10 seconds at 2,000 rpm.

Check right side exhaust gas sensor signal.

Make sure that inspection lamp goes on and off more
Inspection lamp
than 5 times during 10 seconds (at 2,000 rpm).
does not blink.
Less than 5 times

Replace right side exhaust gas sensor.

© @ ® ®
EF & EC-39
 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

(c ® f'

T
Check right side exhaust gas sensor signal. NG
Make sure that inspection lamp goes on and off more r-:-=-::-:--
than 5 times during 10 seconds at 2,000 rpm.
LO.K.
Exhaust gas
sensor
lljl i)
harness connector
~c:fu L8!IH-n
(
----- END

-r~
10 LELJoo <> Check right side exhaust gas sensor harness:
1) Turn off engine and disconnect battery
ground cable.
SEF5711 2) Disconnect 76-pin connector from E.C. U.
3) Disconnect right side exhaust gas sensor
harness connector.
4) Check for continuity between terminal
No. 29 of 76-pin connector and harness
connector for exhaust gas sensor.

Continuity exists ........... O.K. CD

Continuity does not exist . . . . N.G.
O.K. LN.G.

I Repair or replace harness. l

I

Connect 76-pin connector to E.C.U.

Check left side exhaust gas sensor harness:

1) Turn off engine and disconnect battery
ground cable.
Exhaust gas sensor liiOiil _,
harness connector l..llllliiiO 2) Disconnect 76-pin connector from E.C.U.

~r~;x ¢=-
3) Disconnect left side exhaust gas sensor
harness connector.
4) Check for continuity between terminal
No. 55 of 76-pin connector and harness
connector for exhaust gas sensor.
SEF3631

Continuity exists ........... O.K. CD

Continuity does not exist . . . . N.G.
O.K. l N.G.

I Repair or replace harness.

l
J

Connect 76-pin connector to control unit.

EF &. EC-40
 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION

Engine temperature
en sensor harness

Goo-~
1) Disconnect engine temperature sensor
harness connector.
¢::==- 2) Connect a resistor (2.5 kQ) between terminals
of engine temperature sensor harness connector.
2.5 kSl resistor 3) Disconnect A.I.V. control solenoid valve
SEC242B harness connector.

l ~~
TEMP 4
,,
t~
Start engine and warm it up until water temperature 120
indicator points to the middle of gauge.

l
Race engine two or three times under no-load,
SEF246F

then run engine at idle speed.

SEF248F
~
Check "CO" %.
.J
Idle CO: 0.2"' 8%

After checking CO%,

1) Disconnect the resistor from terminals O.K.
of engine temperature sensor.
2) Connect engine temperature sensor
harness connector to engine temperature
sensor.
3) Connect A.I.V. control solenoid valve
harness connector.

l N.G.

Connect exhaust gas sensor harness

connector to exhaust gas sensor.

l
Check fuel pressure regulator. .. ®

J
Check air flow meter.

Check injector.
l
Clean or replace if necessary.

~
Check engine temperature sensor.

l
Check E.C.U. function* by substituting ®
another known good E.C.U.

*· E.C.U . may be the cause of a problem,

but th is is rarely the case. I

EF & EC-41
 TROUBLE DIAGNOSES

Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair .... ..... .... ..... ...... .......... ... ... ......... EF & EC- 44
Self-diagnosis ................................................................................................................................................ EF & EC- 48
Self-diagnosis - Mode I ............................................................................................................................. EF & EC- 50
Self-diagnosis - Mode II (Self-diagnostic results) ............................................................................... EF & EC- 51
Self-diagnosis - Mode II (Exhaust gas sensor monitor) .................................................................... EF & EC- 54
Consult ............................................................................................................................................................ EF & EC- 55
Basic Inspection ............................................................................................................................................ EF & EC- 63
Diagnostic Procedure 1 - High Idling after Warm-up ......................................................................... EF & EC- 66
Diagnostic Procedure 2 - Hunting .......................................................................................................... EF & EC- 67
Diagnostic Procedure 3 - Unstable Idle ................................................................................................ EF & EC- 69
Diagnostic Procedure .4 - Hard to Start or Impossible to Start when the Engine is Cold ........ EF & EC- 73
Diagnostic Procedure 5 - Hard to Start or Impossible to Start when the Engine is Hot .. ... ..... EF & EC- 75
Diagnostic Procedure 6 - Hard to Start or Impossible to Start under Normal Conditions ... ..... EF & EC- 77
Diagnostic Procedure 7 - Hesitation when the Engine is Hot .......................................................... EF & EC- 79
Diagnostic Procedure 8 - Hesitation when the Engine Is Cold ........................................................ EF & EC- 80
Diagnostic Procedure 9 - Hesitation under Normal Conditions ....................................................... EF & EC- 81
Diagnostic Procedure 10 - Engine Stalls when Turning ..................................................................... EF & EC- 83
Diagnostic Procedure 11 - Engine Stalls when the Engine is Hot .................................................. EF & EC- 85
Diagnostic Procedure 12 - Engine Stalls when the Engine is Cold ................................................ EF & EC- 87
Diagnostic Procedure 13 - Engine Stalls when Stepping on the Accelerator Momentarily ....... EF & EC- 89
Diagnostic Procedure 14 - Engine Stalls after Decelerating ............................................................. EF & EC- 91
Diagnostic Procedure 15 - Engine Stalls when Accelerating or Cruising ...................................... EF & EC- 95
Diagnostic Procedure 16 - Engine Stalls when the Electrical Load is Heavy ............................... EF & EC- 98
Diagnostic Procedure 17 - Lack of Power and Stumble ................................................................... EF & EC-100
Diagnostic Procedure 18 - Detonation .................................................................................................. EF & EC-101
Diagnostic Procedure 19 - Surge ........................................................................................................... EF & EC-103
Diagnostic Procedure 20 - Backfire through the Intake .................................................................... EF & EC-104
Diagnostic Procedure 21 - Backfire through the Exhaust ................................................................. EF & EC-105
Diagnostic Procedure 22
MAIN POWER SUPPLY AND GROUND CIRCUIT ....................................................................... EF & EC-106
Diagnostic Procedure 23
CRANK ANGLE SENSOR ............................................................................................................... EF & EC-108
Diagnostic Procedure 24
AIR FLOW METER ........................................................................................................................... EF & EC-112
Diagnostic Procedure 25
ENGINE TEMPERATURE SENSOR ................................................................................................ EF & EC-116
Diagnostic Procedure 26
VEHICLE SPEED SENSOR ............................................................................................................. EF & EC-118
Diagnostic Procedure 27
IGNITION SIGNAL ............................................................................................................................. EF & EC-120
Diagnostic Procedure 28
ENGINE CONTROL UNIT ................................................................................................................ EF & EC-124
Diagnostic Procedure 29
E.G.R. FUNCTION ............................................................................................................................. EF & EC-126
Diagnostic Procedure 30
EXHAUST GAS SENSOR ................................................................................................................ EF & EC-130
Diagnostic Procedure 31
DETONATION SENSOR ................................................................................................................... EF & EC-134
Diagnostic Procedure 32
EXHAUST GAS TEMPERATURE SENSOR ................................................................................... EF & EC-136
Diagnostic Procedure 33
FUEL TEMPERATURE SENSOR .................................................................................................... EF & EC-138
Diagnostic Procedure 34
THROTTLE SENSOR ........................................................................................................................ EF & EC-140

EF 8r. EC-42
 TROUBLE DIAGNOSES
Contents (Cont'd)
Diagnostic Procedure 35
INJECTOR LEAK ............................................................................................................................... EF & EC-144
Diagnostic Procedure 36
INJECTOR CIRCUIT .......................................................................................................................... EF & EC-146
Diagnostic Procedure 37
THROTILE VALVE SWITCH ............................................................................................................ EF & EC-148
Diagnostic Procedure 38
START SIGNAL ................................................................................................................................. EF & EC-150
Diagnostic Procedure 39
POWER STEERING OIL PRESSURE SWITCH ............................................................................. EF & EC-152
Diagnostic Procedure 40
NEUTRAL SWITCH & A/T CONTROL UNIT (NEUTRAL SIGNAL) CIRCUIT ............................ EF & EC-154
Diagnostic Procedure 41
FUEL PUMP ...................................................................................................................................... EF & EC-156
Diagnostic Procedure 42
AIR REGULATOR ............................................................................................................................. EF & EC-160
Diagnostic Procedure 43
A.A.C. VALVE .............................. :..................................................................................................... EF & EC-162
Diagnostic Procedure 44
F.I.C.D. SOLENOID VALVE ............................................................................................................. EF & EC-164
Diagnostic Procedure 45
A.I.V. CONTROL SOLENOID VALVE ............................................................................................. EF & EC-166
Diagnostic Procedure 46
P.R.V.R. CONTROL SOLENOID VALVE ···················································'···································· EF & EC-168
Diagnostic Procedure 47
'v.T.C. SOLENOID VALVE ................................................................................................................ EF & EC-170
Diagnostic Procedure 48
RADIATOR FAN CONTROL ............................................................................................................ EF & EC-172
Diagnostic Procedure 49
WASTEGATE VALVE CONTROL SOLENOID VALVE .................................................................. EF & EC-176
Electrical Components Inspection ............................................................................................................ EF & EC-178

EF & EC-43
 TROUBLE DIAGNOSE.S

How to Perform Trouble Diagnoses for Quick

Sensors
and Accurate Repair
~ Control unit Actuators INTRODUCTION

~~·~
The engine has an electronic control unit to control major
systems such as fuel control, ignition control, idle speed control,
etc. The control unit accepts input signals from sensors and
instantly drives actuators. It is essential that both kinds of
signals are proper and stable. At the same time, it is important
that there are no conventional problems such as vacuum leaks,
SEF232G
fouled spark plugs, or other problems with the engine.
It is much more difficult to diagnose a problem that occurs
intermittently rather than continuously, Most intermittent prob-
lems are caused by poor electric connections or improper
wiring. In this case, careful checking of suspected circuits may
help prevent the replacement of good parts.
A visual check only may not find the cause of the problems, so
a road test with a circuit tester connected to a suspected
circuit should be performed.
Before undertaking actual checks, take just a few minutes to
talk with a customer who approaches with a driveability com-
plaint. The customer is a very good supplier of information on
such problems, especially intermittent ones. Through interaction
with the customer, find out what symptoms are present and
under what conditions they occur.
Start your diagnosis by looking for "conventional" problems first.
This is one of the best ways to troubleshoot driveability
problems on an electronically controlled engine vehicle.

EF & EC-44
 TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
WORK FLOW
SERVICE MANUAL
CHECK IN
REFERENCE ITEM & PAGES

DIAGNOSTIC WORKSHEET
LISTEN TO CUSTOMER COMPLAINTS
EF & EC-46

Basic Inspection
BASIC INSPECTION
EF & EC-63

r------ Do self-diagnostic results exist?* 1

No

INSPECTION ON THE
Diagnostic Procedures 22- 36
BASIS OF EACH MAL-
EF & EC-106- 146
FUNCTION

INSPECTION ON THE
Diagnostic Procedures 1 -21
BASIS OF EACH
EF & EC-66- 105
SYMPTOM*2

R EPA I R/R EPLACE

I
I
1 FINAL CHECK
N.G. Basic Inspection
L------ Confirm that the trouble is completely fixed by
EF & EC-63
performing Basic Inspection and Test Drive.

CHECK OUT

*1: If the self-diagnosis cannot be performed, check main power supply and ground circuit. (See Diagnostic Procedure 22.)
*2: If the trouble is not duplicated, see INTERMITTENT PROBLEM SIMULATION (EF & EC-47).

EF & EC-45
 TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
KEY POINTS
DIAGNOSTIC WORKSHEET
WHAT ..... Vehicle & engine model There are many kinds of operating conditions that lead to
WHEN ..... Date, Frequencies malfunctions on engine components.
WHERE ..... Road conditions A good grasp of such conditions can make trouble-shooting
HOW ..... Operating conditions, faster and more accurate.
Weather conditions, In general, feelings for a problem depend on each customer. It
Symptoms is important to fully understand the symptoms or under what
conditions a customer complains.
Make good use of a diagnostic worksheet such as the one
shown below in order to utilize all the complaints for trouble-
shooting.

Worksheet sample
Customer name MR/MS Model & Year VIN

Engine# Trans. Mileage

Incident Date Manuf. Date In Service Date

0 Impossible to start 0 No combustion 0 Partial combustion

0 Partial combustion affected by throttle position
0 Startability
0 Partial combustion NOT affected by throttle position
0 Possible but hard to start 0 Others [ I
0 No fast idle 0 Unstable 0 High idle 0 Low idle
0 Idling
0 Others [ I
Symptoms
0 Stumble 0 Surge 0 Detonation 0 Lack of power
0 Driveability 0 Intake backfire 0 Exhaust backfire
0 Others [ I
0 At the time of start 0 While idling
0 Engine stall 0 While accelerating 0 While decelerating
0 Just after stopping 0 While loading
0 Just after delivery 0 Recently
Incident occurrence
0 In the morning 0 At night 0 In the daytime
Frequency 0 All the time 0 Under certain conditions 0 Sometimes
Weather conditions 0 Not affected
Weather 0 Fine 0 Raining 0 Snowing 0 Others [ I
Temperature 0 Hot 0 Warm 0 Cool 0 Cold 0 Humid OF

Engine conditions 0 Cold 0 During warm·up 0 After warm-up

I I I I I
Engine speed
0 2,000 4,000 6,000 8,000 rpm
Road conditions 0 In town 0 In suburbs 0 Highway 0 Off road (up/down)
Driving conditions 0 Not affected
0 At starting 0 While idling 0 At racing
0 While accelerating 0 While cruising
0 While decelerating 0 While turning (RH/LH)
Vehicle speed I
bI I I I I I
10
I I
20
I
30 40 50
I I
60 MPH
Check engine light 0 Turned on 0 Not turned on

EF & EC-46
 TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd}
INTERMITTENT PROBLEM SIMULATION
In order to duplicate an intermittent problem, it is effective to
create similar conditions for component parts, under which the
problem might occur.
Perform the activity listed under Service procedure and note the
result.

~ Variable factor Influential part Target condition Service procedure

Made lean Remove vacuum hose and apply vacuum.

1 Mixture ratio Pressure regulator
Made rich Remove vacuum hose and apply pressure.

Advanced Rotate distributor counterclockwise.

2 Ignition timing Crank angle sensor
Retarded Rotate distributor clockwise.

Mixture ratio Exhaust gas sensor Suspended Disconnect exhaust gas sensor harness connector.
3
feedback control Control unit Operation check Perform self-diagnosis (Mode II) at 2,000 rpm.

Raised Turn idle adjusting screw counterclockwise.

4 Idle speed A.A.C. valve
Lowered Turn idle adjusting screw clockwise.

Electrical Tap or wiggle.

Poor electrical
connection Harness connectors
5 connection or
Race engine rapidly. See if the torque reaction of
(Electric and wires
improper wiring
continuity) the engine unit causes electric breaks.

Cooled Cool with an icing spray or similar device.

6 Temperature Control unit
Heat with a hair drier.
Warmed
[WARNING: Do not overheat the unit_)

Wet.
7 Moisture Electric parts Damp [WARNING: Do not directly pour water on
components. Use a mist sprayer_)

Turn on head lamps, air conditioner, rear defogger,

8 Electric loads Load switches Loaded
etc.

Idle switch
9 Control unit ON-OFF switching Rotate throttle sensor body.
condition

Try to flash timing light for each cylinder using

10 Ignition spark Timing light Spark power check
ignition coil adapter (S.S.T.).

EF & EC-47
 TROUBLE DIAGNOSES

Self-diagnosis
CHECK ENGINE LIGHT
A check engine light has been adopted on the California, Federal
and Canada models. This light blinks simultaneously with the RED
L.E.D. on the E.C.U.

E.C.U. L.E.D.
In the E.C.U., the Green and Red L.E.D.'s have now been
permanently changed to one RED L.E.D.

- -!~
RED L.E.D.
Diagnostic
mode
selector

SELF-DIAGNOSTIC FUNCTION

~
c
Engine
Mode I Mode II

Ignition stopped SELF-DIAGNOSTIC

BULB CHECK
RESULTS
~
switch in
"ON"
position Engine
EXHAUST GAS
running MALFUNCTION
00 ID
WARNING
SENSOR
MONITOR

EF 8r. EC-48
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
HOW TO SWITCH MODES

00
0
Turn ignition switch "ON".
(Do not start engine.)

Mode I - MALFUNCTION
Mode I - BULB CHECK
WARNING
Start engine.

(Turn diagnostic mode selector

on E.C.U. fully clockwise)

Wait at least 2 seconds.

(Turn diagnostic mode selector

fully counterclockwise.)

Mode II- SELF-DIAGNOSTIC Mode II - EXHAUST GAS

RESULTS SENSOR MONITOR
Start engine.

Wait at least 2 seconds.

• Switching the modes is not possible when the engine is

running.
• When the ignition switch is turned off during diagnosis in
each mode, and then turned back on again after power to the
E.C.U. has dropped off completely, the diagnosis will auto-
matically return to Mode I.

EF & EC-49
 TROUBLE DIAGNOSES

Self-diagnosis - Mode I
MODE I - BULB CHECK
In this mode, the RED L.E.D. in the E.C.U. and the CHECK ENGINE
LIGHT in the instrument panel stay "ON".
If either remain "OFF", check the bulb in the CHECK ENGINE
LIGHT or the RED L.E.D.

MODE I - MALFUNCTION WARNING

FOR CALIFORNIA MODEL

CHECK ENGINE LIGHT

and Condition
RED L.E.D.

When the following malfunction (check engine light item) is detected or

ON
the E.C.U.'s C.P.U. is malfunctioning.

OFF O.K.

Code No. Malfunction

12 Air flow meter circuit

13 Engine temperature sensor circuit
14 Vehicle speed sensor circuit
31 E.C.U. (E.C.C.S. control unit)
32 E.G. R. function
33 Exhaust gas sensor circuit (Left side)
35 Exhaust gas temperature sensor circuit
43 Throttle sensor circuit
45 Injector leak
51 Injector circuit
53 Exhaust gas sensor circuit (Right side I

e Th~se Code Numbers are clarified in Mode ll - SELF-

DIAGNOSTIC RESULTS.
e The RED L.E.D. and the CHECK ENGINE LIGHT will turn off
when normal condition is detected. At this time, the Mod~ 1I
- SELF-DIAGNOSTIC RESULTS memory must be cleared as
the contents remain stored.

FOR NON-CALIFORNIA MODEL

CHECK ENGINE LIGHT

and Condition
RED L.E.D.

ON When the E.C.U.'s C.P.U. is malfunctioning.

OFF O.K.

EF &. EC-50
 TROUBLE DIAGNOSES

Self-diagnosis - Mode II (Self-diagnostic

results)
DESCRIPTION
In this mode, a malfunction code is indicated by the number of
flashes from the RED L.E.D. or the CHECK ENGINE LIGHT as
shown below:

Example: Code No. 12 and Code No. 33

0.6 0.3 0.6 0.3'

ON

0.9 0.3 2.1 0.6 0.9 2.1 Unit: second

Code No. 12 Code No. 33

Long (0.6 second) blinking indicates the number of ten digits and
short (0.3 second) blinking indicates the number of single digits.
For example, the red L.E.D. flashes once for 0.6 seconds and then
it flashes twice for 0.3 seconds. This indicates the number "12"
and refers to a malfunction in the air flow meter. In this way, all the
problems are classified by their code numbers.

Display code table

California Non-California
Code No. Detected items
model model

11 Crank angle sensor circuit X X

12 ~ Air flow meter circuit X X
13 ~ Engine temperature sensor circuit X X
14
~ Vehicle speed sensor circuit X X
21 Ignition signal circuit X X
31 ~ E.C.U. X X
32 ~ E.G.R. function X -
33 ~ Exhaust gas sensor circuit (Left side) X X
34 Detonation sensor circuit X X
35 ~ Exhaust gas temperature sensor circuit X -
42 Fuel temperature sensor circuit X X
43 ~ Throttle sensor circuit X X
45 ~ Injector leak X -
51 ~ Injector circuit X -
53 ~ Exhaust gas sensor circuit (Right side) X X
54 Signal circuit from A/T control unit to E.C.U. (A/T only) X X
55 No malfunction in the above circuits X X

Available
X:
Not available
~ : Check engine light item

EF & EC-51
 TROUBLE DIAGNOSES
Self-diagnosis - Mode II (Self-diagnostic
results) (Cont'd)

Code No. Detected items Malfunction is detected when ... Check item (remedy)

*11 Crank angle sensor

circuit
• Either 1° or 120° signal is not entered for the
first few seconds during engine cranking.
• Harness and connector
(If harness and connector
are normal, replace crank
• Either 1° or 120° signal is not input often
enough while the engine speed is higher than angle sensor.)
the specified rpm.

12 Air flow meter circuit • The air flow meter circuit is open or shorted.
(An abnormally high or low voltage is
• Harness and connector
(If harness and connector
entered.) are normal, replace air
flow meter.)

13 Engine temperature • The engine temperature sensor circuit is open • Harness and connector
sensor circuit or shorted.
(An abnormally high or low output voltage is
• Engine temperature sensor

entered.)

14 Vehicle speed sensor

circuit
• The vehicle speed sensor circuit is open or • Harness and connector
shorted.
• Vehicle speed sensor
(reed switch)

*21 Ignition signal circuit • The ignition signal in the primary circuit is
not entered during engine cranking or running.
• Harness and connector

• Power transistor unit

31 E.C.U. • E.C.U. calculation function is malfunctioning . (Replace E.C.C.S. control

unit.)

32 E.G.R. function • E.G.R. control valve does not operate. • E.G.R. control valve
(E.G.R. control valve spring does not lift.)
• E.G.R. control solenoid
valve

33 Exhaust gas sensor • The exhaust gas sensor circuit is open or • Harness and connector
circuit (Left side) shorted.
(An abnormally high or low output voltage
• Exhaust gas sensor
53 Exhaust gas sensor is entered.) • Fuel pressure
circuit (Right side)
• Injectors

• Intake air leaks

34 Detonation sensor • The detonation circuit is open or shorted.

(An abnormally high or low voltage is
• Harness and connector
circuit
entered.)
• Detonation sensor

35 Exhaust gas
temperature sensor
• The exhaust gas temperature sensor circuit
is open or shorted.
• Harness and connector

circuit (An abnormally high or low voltage is • Exhaust gas temperature

sensor
entered.)

42 Fuel temperature • The fuel temperature sensor circuit is open • Harness and connector
sensor circuit or shorted.
(An abnormally high or low voltage is
• Fuel temperature sensor

entered.)

43 Throttle sensor circuit • The throttle sensor circuit is open or shorted. • Hatness and connector
(An abnormally high or low voltage is
entered.)
• Throttle sensor
* Check items causing a malfunction of crank angle sensor circuit first, if both code No. 11 and 21 are displayed at the same
time.

EF &. EC-52
 TROUBLE DIAGNOSES
Self-diagnosis - Mode U (Self-diagnostic
results) (Cont'd)
Code No. Detected items Malfunction is detected when ... Check item (remedy)

45 Injector leak • Fuel leaks from injector. • Injector

51 Injector circuit • The injector circuit is open. •• Harness and connector

Injector
54 Signal circuit from
A/T control unit to
• The A/T communication line is open or
shorted.
• Harness and connector

E.C.U. (A/T only)

RETENTION OF DIAGNOSTIC RESULTS

The diagnostic results will remain in E.C.U. memory until the starter
is operated fifty times after a diagnostic item has been judged to
be malfunctioning. The diagnostic result will then be cancelled
automatically. If a diagnostic item which has been judged to be
malfunctioning and stored in memory is again judged to be
malfunctioning before the starter is operated fifty times, the second
result will replace the previous one. It will be stored in E.C.U.
memory until the starter is operated fifty times more.

RETENTION TERM CHART (Example)

Code STARTER OPERATING TIMES

No. 50 100 150 200

50 times
CRANK ANGLE
SENSOR 11 V////////////h1

---r- --;,-;\;;;;---t--- --
~
t/"///////////////h-1
f----- - - - - - - f---- ----------- ----------- -

ENGINE
TEMPERATURE
SENSOR
13

i .
V////////////////.1:
~ 50 times

If the same d1agnost1c

;,.m) s
judged to be malfunctioning before
W;00/ff~ : Retention term
: Malfunction detecting point
the starter is operated fifty times,
it will be stored in E.C.U. memory
until the starter is operated fifty
times from this point in time.

SEF793D

HOW TO ERASE SELF-DIAGNOSTIC RESULTS

The malfunction code is erased from the backup memory on the
E.C.U. when the diagnostic mode is changed from Moden to Mode
J. (Refer to "HOW TO SWITCH MODES".)
• When the battery terminal is disconnected, the malfunction
code will be lost from the backup memory within 24 hours.
• Before starting self-diagnosis, do not erase the stored
memory before beginning self-diagnosis.

EF & EC-53
 TROUBLE DIAGNOSES

Self-diagnosis - Mode II (Exhaust gas sensor

monitor)
DESCRIPTION
In this mode, the CHECK ENGINE LIGHT and RED L.E.D. display
the condition of the fuel mixture (lean or rich) which is monitored
by the exhaust gas sensor.

CHECK ENGINE LIGHT Fuel mixture conditio(l Air fuel ratio feedback
and RED L.E.D. in the exhaust gas control condition

ON Lean
Closed loop control
OFF Rich

*Remains ON or OFF Any condition Open loop control

* · Maintains conditions just before switching to open loop.

If two exhaust gas sensors (right side and left side) are fitted on
the engine, the left side exhaust gas sensor monitor operates first,
when selecting this mode.

HOW TO CHANGE MONITOR FROM LEFT SIDE (Right

side) TO RIGHT SIDE (Left side)
1. Turn diagnostic mode selector on E.C.U. fully clockwise.
2. Wait at least 2 seconds.
3. Turn diagnostic mode selector on E.C.U. fully counterclockwise.
• These procedures should be carried out when the engine is
running.

[Left side - Right side)

0.2 0.2

Left side
..._,.._.,
0.6 3.0
Right side
monitor Indication monitor
of change
[Right side- Left side)
0.2

0.2 2.6
Right side Left side
monitor Indication
monitor
of change Unit: second

HOW TO CHECK EXHAUST GAS SENSOR

1. Set Mode IT. (Refer to "HOW TO SWITCH MODES".)
2. Start engine and warm it up until engine coolant temperature
indicator points to the middle of the gauge.
3. Run engine at about 2,000 rpm for about 2 minutes under
no-load conditions.
4. Make sure RED L.E.D. or CHECK ENGINE LIGHT goes ON and
OFF more than 5 times every 10 seconds; measured at 2,000
rpm under no-load.

EF & EC-54
 TROUBLE DIAGNOSES

Consult
CONSULT CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect "CONSULT" to diagnostic connector.
(Diagnostic connector is located in left dash side panel.)

SMA185C

3. Turn on ignition switch.

4. Touch "START".
NISSAN

CONSULT

:=====hitl= ===
STA~
SUB MODE I
SEF3921

5. Touch "ENGINE".
l1nJ SELECT SYSTEM

ENGINE
A/T
HI CAS
AUTO A/C

SEF202J

6. Perform each diagnostic mode according to the inspection

~ SELECT DIAG MODE 0 sheet as follows:
WORK SUPPORT For further information, see the CONSULT Operation Manual.
SELF-DIAG RESULTS

DATA MONITOR

ACTIVE TEST

ECU PART NUMBER

SEF203J

EF & EC-55
 TROUBLE DIAGNOSES
Consult (Cont'd)
E.C.C.S. COMPONENT PARTS APPLICATION

~
SELF-DIAGNOSTIC
WORK SUPPORT DATA MONITOR ACTIVE TEST
RESULTS
E

Crank angle sensor X X

Air flow meter X X

Engine temperature sensor X X X

Exhaust gas sensors X X

Vehicle speed sensor X X

Throttle sensor X X X
~

Fuel temperature sensor X X

Exhaust gas temperature sensor* X X

Detonation sensor X
1-
::;)
a. Ignition switch (start signal) X
~
Air conditioner switch X

Neutral switch X

Power steering oil pressure switch X

Battery X

A/T signal X X

Injectors X X X

Power transistors (ignition signal) X X (Ignition timing) X

A.A.C. valve X X X

F.I.C.D. solenoid valve X X

Valve timing control solenoid valve X X

1- A.I.V. control solenoid valve X X

::;)
a. P.R.V.R. control solenoid valve
1- X X
::;)
0
E.G.R. control solenoid valve X X

Wastegate valve control solenoid

X
valves

Air conditioner relay X

Fuel pump relay X X X

Radiator fan X X

* · The E.C.C.S. component part marked * is applicable to vehicles for California only.
X: Applicable

EF & EC-56
 TROUBLE DIAGNOSES
Consult (Cont'd)
FUNCTION
Diagnostic mode Function

This mode enables a technician to

adjust some devices faster and more
Work support
accurately by following the indications
on the CONSULT unit.

Self-diagnostic results can be read and

Self-diagnostic results
erased quickly.

Input/Output data in the control unit

Data monitor
can be read.

Mode in which CONSULT drives some

actuators apart from the control units
Active test
and also shifts some parameters in a
specified range.

E.C.U. part number E.C.U. part number can be read.

WORK SUPPORT MODE

WORK ITEM CONDITION USAGE

THROTTLE SENSOR CHECK THE THROTTLE SENSOR SIGNAL. When adjusting throttle
ADJUSTMENT ADJUST IT TO THE SPECIFIED VALUE BY sensor initial position,
ROTATING THE SENSOR BODY UNDER THE
FOLLOWING CONDITIONS.
• IGN SW "ON"
• ENG NOT RUNNING
• ACC PEDAL NOT PRESSED

IGNITION TIMING • IGNITION TIMING FEEDBACK CONTROL When adjusting initial

ADJUSTMENT* WILL BE HELD BY TOUCHING "START". ignition timing,
AFTER DOING SO, ADJUST IGNITION
TIMING WITH A TIMING LIGHT BY TURNING
THE CRANK ANGLE SENSOR.

AAC VALVE ADJUSTMENT SET ENGINE RPM AT THE SPECIFIED VALUE When adjusting idle
UNDER THE FOLLOWING CONDITIONS. speed,
• ENGINE WARMED UP
• NO-LOAD

FUEL PRESSURE RELEASE • FUEL PUMP WILL STOP BY TOUCHING When releasing fuel
"START" DURING IDLING. pressure from fuel line,
CRANK A FEW TIMES AFTER ENGINE
STALLS.

*· The ignition timing feedback control is not adopted on model 300ZX, so it is not necessary to perform IGNITION TIM-
ING ADJUSTMENT.

EF & EC-57
 TROUBLE DIAGNOSES
Consult (Cont'd)
SELF-DIAGNOSTIC RESULTS MODE

DIAGNOSTIC ITEM DIAGNOSTIC ITEM IS DETECTED WHEN .... CHECK ITEM (REMEDY)
CRANK ANGLE SENSOR* • first
Either 1° or 120° si~nal is not entered for the
few seconds during engine cranking.
• Harness and connector
(If harness and connector
are normal, replace crank
• enough
Either 1° or 120° signal is not input often
while the engine speed is higher than angle sensor.)
the specified rpm.
AIR FLOW METER • The air flow meter circuit is open or shorted.
(An abnormally high or low voltage is
• Harness and connector
(If harness and connector
entered.) are normal, replace air
flow meter.)
ENGINE TEMP SENSOR • The engine temperature sensor circuit is open
or shorted.
• Harness and connector
• Engine temperature sensor
(An abnormally high or low output voltage is
entered.)
CAR SPEED SENSOR • The vehicle speed sensor circuit is open or
shorted.
• Harness and connector
• Vehicle speed sensor
(reed switch)
IGN SIGNAL-PRIMARY* • The ignition signal in primary circuit is
not entered during engine cranking or running.
• Harness and connector
• Power transistor unit
CONTROL UNIT • E.C.U. calculation function is malfunctioning. (Replace E.C.C.S. control
unit.)
EGR SYSTEM** • E.G.R. control valve does not operate .
(E.G.R. control valve spring does not lift.)
• E.G.R. control valve

• E.G.R. control solenoid

valve
EXH GAS SENSOR
EXH GAS SENSOR-A
• shorted.
The exhaust gas sensor circuit is open or • Harness and connector

(An abnormally high or low output voltage • Exhaust gas sensor

is entered.) • Fuel pressure
• Injectors
• Intake air leaks
DETONATION SENSOR • The detonation circuit is open or shorted. • Harness and connector
(An abnormally high or low voltage is • Detonation sensor
entered.)

EXH GAS TEMP

SENSOR**
• The exhaust gas temperature sensor circuit is
open or shorted.
• Harness and connector
(An abnormally high or low voltage is • sensor
Exhaust gas temperature
entered.)
FUEL TEMP SENSOR • The fuel temperature sensor circuit is open
or shorted.
• Harness and connector
• Fuel temperature sensor
(An abnormally high or low voltage is
entered.)

THROTTLE SENSOR • The throttle sensor circuit is open or shorted. • Harness and connector
(An abnormally high or low voltage is • Throttle sensor
entered.)
*: Check items causing a malfunction of crank angle sensor circuit first, if both "CRANK ANGLE SENSOR" and "IGN
SIGNAL-PRIMARY" are displayed at the same time.

EF & EC-58
 TROUBLE DIAGNOSES
Consult {Cont'd)
DIAGNOSTIC ITEM DIAGNOSTIC ITEM IS DETECTED WHEN .... CHECK ITEM (REMEDY)

INJECTOR FUEL LEAK** • Fuel leaks from injector. • Injector

INJECTOR OPEN** • The injector circuit is open. • Injector

A/T COMM LINE • The AIT communication line is open or

shorted.
• Harness and connector

** · The diagnostic item marked ** is applicable to vehicles for California only.

EF & EC-59
 TROUBLE DIAGNOSES
Consult (Cont'd)
DATA MONITOR MODE
Remarks; • The monitor item marked"*" is applicable to vehicles for California only.
• Specification data are reference values.
• Specification data are out-put/in-put values which are detected or supplied by E.C.l). at the connector.
* Specification data may not be directly related to their components signals/values/operations.
ie. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification
data in spite of the ignition timing being not adjusted to the specification data. This IGN TIMING monitors the calculated data
by E.C.U. according to the input signals from crank angle sensor and other ignition timing related sensors.

MONITOR SPECIFICATION
CONDITION CHECK ITEM
ITEM WHEN OUTSIDE SPEC.
Non-turbo Turbo

CAS·RPM (POS) • Tachometer: Connect

Almost the same speed • Harness and connector
CAS·RPM (REF)
• Run engine and compare tachometer indication with the
as the CONSULT value. • Crank angle sensor
CONSULT value.

• Engine: After warming up, idle the engine

Idle 0.8- 1.5V 0.9-1.4V
AIR FLOWMTR • A/C switch "OFF" • Harness and connector
• Shift lever "N"
2,000 rpm 1.4- 1.8V 1.4- 1.8V • Air flow meter
• No-load

ENG TEMP SEN • Engine: After warming up More than 70° C (158° F) • Harness and connector
• Engine temperature sensor

EXH GASSEN
0- 0.3V- 0.6- 1.0V
EXH GAS
SEN-R
• Harness and connector

• Engine: After warming up

Maintaining engine speed • Exhaust gas sensor
M/R F/C MNT
at 2,000 rpm • Intake air leaks
LEAN- RICH
Changes more than 5
• Injectors
M/R F/C
times during 10 seconds.
MNT-R

CAR SPEED SEN • Turn drive wheels and compare speedometer indication Almost the same speed • Harness and connector
with the CONSULT value as the CONSULT value • Vehicle speed sensor

BATTERY VOLT • Ignition switch: ON (Engine stopped) 11 - 14V • Battery

• E.C.U. power supply circuit

• Ignition switch: ON
Throttle valve fully closed 0.4 -0.5V • Harness and connector
THROTTLE SEN
(Engine stopped) • Throttle sensor
Throttle valve fully opened Approx. 4.0V • Throttle sensor adjustment

FUEL TEMP SEN • Engine: After warming up 20- 60°C (68 -140°F) • Harness and connector
• Fuel temp. sensor

• Harness and connector

EGA TEMP SEN* • Engine: After warming up Less than 4.5V • Exhaust gas temperature
sensor

START SIGNAL • Ignition switch: ON-+START OFF-+ ON • Harness and connector

• Starter switch

Throttle valve:

• Ignition switch: ON
Idle position
ON
• Harness and connector
IDLE POSITION
(Engine stopped) • Throttle sensor
Throttle valve:
OFF • Throttle sensor adjustment
Slightly open

A/C switch "OFF" OFF

AIR COND SIG • Engine: After warming up, • Harness and connector
idle the engine
A/C switch "ON" ON • Air conditioner switch

Shift lever "P" or "N" ON

NEUTRALSW • Ignition switch: ON • Harness and connector
Except above OFF • Neutral switch

EF & EC-60
 TROUBLE DIAGNOSES
Consult (Cont'd)
SPECIFICATION
MONITOR CHECK ITEM
CONDITION
ITEM WHEN OUTSIDE SPEC.
Non-turbo Turbo

Steering wheel in neutral

• Engine: After warming up, (forward direction)
OFF • Harness and connector
PW/ST SIGNAL
idle the engine • Power steering oil pressure
switch
The steering wheel is turned ON

2.0-3.0 1.8- 2.5

INJ PULSE • Engine: After warming up Idle
msec. msec. • Harness and connector
• A/C switch "OFF" • Injector
• Shift lever "N"
2.0-3.0 1.8-2.2 • Air flow meter
INJ PULSE-A • No-load 2,000 rpm
msec . msec. • Intake air system

Idle 15° B.T.D.C. 15° B.T.D.C.

IGN TIMING ditto • Harness and connector
2,000rpm
More than More than
25° B.T.D.C. 25° B.T.D.C.
• Crank angle sensor

Idle 15-40% 15- 35%

AAC VALVE ditto • Harness and connector
2,000 rpm - - • A.A.C. valve

EF & EC-61
 TROUBLE DIAGNOSES
Consult (Cont'd)
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECKITEM(REMEDY)

• Engine: Return to the original trouble

• Harness and connector
FUEL INJECTION condition If trouble symptom disappears,
TEST • Change the amount of fuel injection with see CHECK ITEM. • Fuel injectors

the CONSULT. • Exhaust gas sensors

AACIV OPENING • Engine: After warming up, idle the engine •

Engine speed changes according to • Harness and co·nnector
TEST • Change the AAC valve opening percent
the opening percent. • AACvalve
with the CONSULT.

• Engine: Return to the original trouble • Harness and connector

ENGINE TEMP condition If trouble symptom disappears, • Engine temperature
TEST • Change the engine coolant temperature see CHECK ITEM. sensor
with the CONSULT. • Fuel injectors

• Engine: Return to the original trouble

condition
IGN TIMING TEST • Timing light: Set
If trouble symptom disappears, • Adjust initial ignition
see CHECK ITEM. timing
• Retard the ignition timing with the
CONSULT.

• Engine: After warming up, idle the engine . • Harness and connector

• A/C switch "OFF" • Compression

POWER BALANCE
• Shift lever "N" Engine runs rough or dies . • Injectors
TEST
• Cut off each injector signal one at a time • Power transistor

with the CONSULT. • Spark plugs

• Ignition coils

RADIATOR FAN • Ignition switch: ON

• Harness and connector
TEST • Turn the radiator fan "ON" and "OFF"
with the CONSULT.
Radiator fan moves and stops .
• Radiator fan motor

• Engine: After warming up, idle the engine .

• A/C switch "OFF"
Engine speed will increase • Harness and connector
FICO SOL/V TEST • Shift lever "N"
momentarily by approx. 200 rpm. • F lCD solenoid valve
• Turn the FICO solenoid valve "ON"
with the CONSULT.

• Ignition switch: ON (Engine stopped)

FUELPUMPRLY • Turn the fuel pump relay "ON" and Fuel pump relay makes the operating • Harness and connector
TEST "OFF" with the CONSULT and listen to sound. • Fuel pump relay
operating sound.

EGA CONT SOLIV

TEST

PRVR CONT SOL/V

TEST
• Ignition switch: ON
• Turn solenoid valve "ON" and "OFF" Each solenoid valve makes an • Harness and connector

AIV CONT SOLIV

with the CONSULT and listen to operating sound. • Solenoid valve
operating sound.
TEST

VALVE TIM SOL

TEST

SELF-LEARN
CONTTEST
• In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching
"CLEAR" on the screen.

EF & EC-62
 TROUBLE DIAGNOSES

D Basic Inspection
D
BEFORE STARTING
1. Check service records for any
recent repairs that may indicate
a related problem, or the current
need for scheduled maintenance.
2. Open engine hood and check
the following:

SEF1421
• Harness connectors for proper
connections
• Vacuum hoses for splits, kinks,
and proper connections
• Wiring for proper connections,
pinches, and cuts

m
CONNECT CONSULT TO THE
VEHICLE
Connect "CONSULT" to the diag-
nostic connector and select "EN-
GINE" from the menu. (Refer to
page EF & EC-55.)

ID
No
DOES ENGINE START? GO TO DJ
Yes

SEF1441

EJ
IN.G . .,
CHECK IGNITION TIMING. Adjust ignition timing
Warm up engine sufficiently and by turning crank
check ignition timing at idle using angle sensor.
timing light. (Refer to page EF &
EC-35.)
Ignition timing: 15° ±2°
B.T.D.C.

~O.K.
(Go to ® on next page.)

EF & EC-63
 TROUBLE DIAGNOSES
Basic Inspection (Cont'd)
A

I AAC VALVE ADJ.

SET ENGINE RPM AT THE CHECK IDLE ADJ. SCREW INI- Adjust engine rpm
SPECIFIED VALUE UNDER
THE FOLLOWING CONDITION
TIAL SET RPM. by turning idle ad-
fF.I\
1. Select "A.A.C. VALVE ADJ" justing screw.
e ENG WARMED UP ~ in "WORK SUPPORT"
e NO LOAD mode.
2. When touching "START",
does engine rpm fall to;
START M/T: 650 ±50 rpm
SEF3721 A/T: 720 ±50 rpm
(Non-turbo)
700 ±50 rpm (Turbo)
[in ''N" position]?
~----------OR------------~

ta\ When disconnecting A.A.C.

~valve harness connector, does
engine rpm fall to;
M/T: 650 ±50 rpm
A/T: 720±50 rpm (Non-turbo)
700 ±50 rpm (Turbo)
[in "N" position]?
SEF1461

I THROTILE SEN ADJ • D

CHECK THROTTLE SENSOR 1. Adjust output
IDLE POSITION. voltage by rotat-
* * ** ADJ MONITOR **** Perform "THROTTLE SEN.
ing throttle sen-
THROTILE SEN 0.46V sor body.
ADJ." in "WORK SUPPORT"
2. Disconnect throt-
mode.
===MONITOR=== tle sensor har-
CAS·RPM (POS) 800rpm 2. Check that output voltage
ness connector
IDLE POSITION ON of throttle sensor is 0.4 to
for a few sec-
0.5V. (Throttle valve fully
onds and then
closes.) and "IDLE POSI-
reconnect it.
SEF1471 TION" stays "ON".
3. Confirm that
~------OR ----------1 "IDLE POSITION"
stays "ON".
~· Measure output voltage of
~ throttle sensor using voltmeter,
and check that it is 0.4 to 0.5V.
(Throttle valve fully closed.)

O.K.

SEF1481

(Go to @ on next page.)

EF & EC-64
 TROUBLE DIAGNOSES
Basic Inspection (Cont'd)

-t:L MONITOR

START SIGNAL
-t:L NO FAIL

OFF
0 fJ ! ~
IDLE POSITION
AIR COND SIG
NEUTRAL SW
ON
OFF
ON
00
CHECK SWITCH INPUT SIGNAL.
Select the following switches in
"DATA MONITOR" mode,
Repair or replace
the malfunctioning
switch or its circuit.
a) Start signal,
b) Idle position,
c) Air conditioner signal,
d) Neutral (Parking) switch,
RECORD and check the switches' ON-
SEF1491 OFF operation.

6 OR

§ ®
~
Remove E.C.U. from front floor
panel and check the above
switches' ON-OFF operation
using voltmeter at each E.C.U.
terminal.

;d ~® Switch
Start
Condition
IGN
->
IGN
START
Voltage (V)
0-> Battery
voltage
signal ON

SEF1501 Idle
- -
position
A/C A/C Battery voltage
A/C OFF_.. ON
signal -> 0.5-0.7
(Engine running)
Shift lever is
Neutral uN" or "P"
(Parking) position-> 0-8.0-9.0
switch Except "N" and
"P"

m
• SELF-DIAG RESULTS. 0 READ SELF-DIAGNOSTIC
Yes
Go to the relevant
TIME RESULTS. inspection procedure.
(j) 1.
FAILURE DETECTED
ENGINE TEMP SENSOR 0
Perform "SELF-DIAG RE-
SULTS" mode.
2. Read out self-diagnostic re-
suits.
3. Is a failure detected?

ERASE"]! PRINT OR

SEF1511 ®1. Set "Self-diagnostic results

mode" in Mode II. (Refer to
page EF & EC-49.)
2. Count the number of RED
L.E.D. flashes and read out
the codes.
3. Are the codes being output?

No

SEF1521
INSPECTION END

EF & EC-65
 TROUBLE DIAGNOSES

D Diagnostic Procedure 1 - High Idling after

Warm-up
D
CHECK AIR REGULATOR. ~~ Check air regula-
When pinching the air regulator hose, tor and circuit.
does the engine speed drop?

No

SEF021K

6
• ACTIVE TEST. 0 CHECK INTAKE AIR LEAK.
Yes Discover air leak lo-
SELF-LEARN 100% ~
CONTROL R100%
= = --: MONITOR = = =
CAS·RPM (POS) 750rpm
001. Select "SELF-LEARNING
CONT" in "ACTIVE TEST"
cation and repair.

mode.
ENG TEMP SEN 179°F
EXH GAS SEN O.OOV 2. Clear the self-learning con-
EXH GAS SEN-R 0.04V trol coefficient by touching
~ "CLEAR".
3. Does the engine speed
CLEAR drop?
SEF3741
OR
®1. Disconnect. exhaust gas

2. 1
sensor harness connectors.
After racing engine at ,500
i5
Exhaust gas~,,~
rpm under no load for
about 30 seconds, does the
sensor "' engine speed drop?

/")~ ,, No
~v

SEF3751

I)
N.G.
1.
CHECK THROTTLE LINKAGE.
Check that throttle linkage
moves smoothly.
~
Repair throttle link-
age or sticking of
throttle valve.
2. Confirm that throttle valve both
fully opens and fully closes.

O.K.

(~_____I_N_s_P_Ec_T_Io__N_E_N_D______~)

EF 8r. EC-66
 TROUBLE DIAGNOSES

D DISCONNECT Diagnostic Procedure 2 Hunting

E8
\I/
D
CHECK EXHAUST GAS SENSORS. Check exhaust gas
IP=
/I\
When disconnecting exhaust gas
sensor harness connectors, is the
sensor(s). (See page
EF & EC-130.)
hunting fixed?

No

CiO~--- SEF307G

D
r-No~
• ACTIVE TEST.
***POWER BALANCE***
PERFORM POWER BALANCE TEST. Go to IJ.
= = = MONITOR = = =
CAS·RPM (POS) 850rpm
Perform "POWER BAL-
AIR FLOW MTR 1.13V
ANCE" in "ACTIVE TEST"
AAC VALVE 27% mode.
2. Is there any cylinder which
does not produce a mo-
mentary engine speed drop?
1 - - - - - - - OR - - - - - - - - l
SEF1571
® When disconnecting each igni-
tion coil harness connector one
at a time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

CHECK SPARK PLUGS. Repair or replace

Remove the spark plugs and check spark plug(s).
for fouling, etc.

O.K.

SEF1561

(Go to @ on next page.)

EF & EC-67
TROUBLE DIAGNOSES
Diagnostic Procedure 2 - Hunting (Cont'd)

!
~I
CHECK FOR INTAKE AIR LEAK. Discover air leak lo-
When pinching blow-by hose (lower- cation and repair.
ing the blow-by air supply), does the.
engine speed rise?

No

Ia
CHECK E.G.R. CONTROL VALVE.
Check E.G.R. control valve for
AI Repair or replace.
I
sticking.
O.K.

(~______I_N_sP_E_c_r_lo_N__E_N_o______)

EF & EC-68
 TROUBLE DIAGNOSES

o Diagnostic Procedure 3 - Unstable Idle

D
N.G. r
CHECK E.G.R. CONTROL VALVE.
Check E.G.R. control valve for
1---+1 Repair or replace.
I
sticking.
O.K.

6
I ACTIVE TEST I 0 ~,
***POWER BALANCE***
===MONITOR===
PERFORM POWER BALANCE
TEST.
Go to li)
I
CAS·RPM (POS)
AIR FLOW MTR
AAC VALVE
B50rpm
1.13V
27%
@1. Perform "POWER BAL-
ANCE" in "ACTIVE TEST"
mode.
2. Is there any cylinder which
does not produce a mo-
mentary engine speed drop?
SEF1571 OR
®When disconnecting each injec-
tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

SEF1581

11

OOf!;# Click
CHECK INJECTOR.
1.Remove crank angle sensor from
engine. (Harness connector
should remain connected.)
2. Turn ignition switch ON. (Do not
No
f---+1 Check injector(s)
and circuit(s).

/j
c,,•• start engine.)
3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591

m Yes
I CHECK IGNITION SPARK. I N.G. Check ignition coil,
1. Disconnect ignition coil assembly -----+ power transistor unit
from collector. and their circuits.
2. Connect a known good spark (See page EF &
plug to the ignition coil assembly. EC-120.)
3. Place end of spark plug against
Ignition coil a suitable ground and crank en-
gine.
,,, 1 4. Check for spark.
ro.K.
SEF1551
(Go to @ on next page.)

EF &. EC-69
 TROUBLE DIAGNOSES
Diagnostic Procedure 3 - Unstable Idle (Cont'd)

m l
CHECK SPARK PLUGS. N.G_j Repair or replace
Remove the spark plugs and check
for fouling, etc.
I spark plug(s).
I
O.K.

SEF1561

I FUEL PRES RELEASE I

m
~I I
CHECK FUEL PRESSURE. Check fuel pump
FUEL PUMP WILL STOP BY and circuit.
Perform "FUEL PRESSURE
TOUCHING START DURING 001.
IDLE. RELEASE" in "WORK SUP-
CRANK A FEW TIMES PORT" mode in order to
AFTER ENGINE STALL release fuel pressure to
zero.
2. Install fuel pressure gauge
and check fuel pressure.
START At idle approx. 255 kPa

• ®1.
(2.6 kg/cm2 , 37 psi)

OR
Release fuel pressure to
zero. (Refer to page EF &
EC-191.)
2. Install fuel pressure gauge
and check fuel pressure.

O.K.

SEF204J

(Go to @ on next page.)

EF & EC-70
 TROUBLE DIAGNOSES
Diagnostic Procedure 3 - Unstable Idle (Cont'd)

~MONITOR ~NO FAIL

CAS·RPM(POS)
0
2087rpm
1
CHECK EXHAUST GAS SENSOR. ~~ Replace exhaust gas
M/R F/C MNT
M/R F/C MNT-R
LEAN
RICH
@1. See "M/R F/C MNT (right
sensor(s). I
and left sides)" in "Data
monitor" mode.
2. Maintaining engine at 2,000
rpm under no-load (engine
RECORD is warmed up sufficiently.),
check that the monitor flue-
tuates between "LEAN" and
"RICH" more than 5 times
during 10 seconds.
RICH~ LEAN~ RICH~
1 time 2 times
LEAN~ RICH .......

OR
Set "Exhaust gas sensor
®1.
monitor" in the self-
diagnostic Mode II. (See
page EF & EC-54.)
SEF1521 2. Maintaining engine at 2,000
rpm under no-load, check
to make sure that RED LED
on the E.C.U. goes ON and
OFF more than 5 times dur-
ing 10 seconds.

O.K.

m
P.l ~
CHECK FOR INTAKE AIR LEAK. Discover air leak lo-
When pinching blow-by hose (lower- cation and repair.
ing the blow-by air supply), does the
engine speed rise?

No

,
(Go to @ on next page.)

EF&EC-71
 TROUBLE DIAGNOSES
Diagnostic Procedure 3 - Unstable Idle (Cont'd)

****
• AAC VALVE ADJ.

ADJ MONITOR
CAS·RPM (POS)
****
712rpm
0 1
CHECK IDLE ADJ. SCREW No Check for lAS clog-
CLOGGING. ging or throttle valve
1- -CONDITION SETTING- -
AAC VALVE FIXED @1. Perform "AAC VALVE ADJ"
in "WORK SUPPORT"
clogging.

===MONITOR=== mode.
ENG TEMP SEN 177°C 2. Can you set engine rpm as
IDLE POSITION ON
AIR COND SIG OFF follows by turning idle ad-
justing screw?
SEF1451 M/T: 650 ±50 rpm
A/T: 720 ±50 rpm
(Non-turbo)
700 ±50 rpm (Turbo)
[in "N" position]

OR

®1. Disconnect A.A.C. valve

harness connector.
2. Can you set engine rpm as
follows by turning idle ad-
justing screw?
SEF1611 M/T: 650 ±50 rpm
A/T: 720 ±50 rpm
IE (Non-turbo)
700 ±50 rpm (Turbo)
[in "N" position]

COMPRESSION Yes
IE
PRESSURE CHECK COMPRESSION PRESSURE.
N.G.
Check pistons, pis-
• Check compression pressure.
Standard: kPa {kg/cm2 , psi)/300
ton rings, valves,
valve seats and cylin-
rpm der head gaskets.
SEF309G 1,285 {13.1, 186)
Minimum: kPa {kg/cm2 , psi)/300
rpm
981 {10.0, 142)
Difference between each cylin-
der: kPa {kg/cm2 ,psi)/300 rpm
98 (1.0, 14)

O.K.

m
N.G.
CHECK E.C.U. HARNESS ...,.. Repair or replace .
CONNECTOR.
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.
O.K.

16
TRY A KNOWN GOOD E.C.U.

O.K.

(~______IN_S_P_E_CT_I_O_N_E_N_D______)
EF & EC-72
 TROUBLE DIAGNOSES

D Diagnostic Procedure 4 - Hard to Start or

~-----~~
Impossible to Start when the Engine is Cold
D

~~~ M
CHECK BATTERY AND STARTER. Repair or replace.
Check battery and starter condition.
(Refer to EL section.)
O.K.

SEF3801

PA
No
CHECK FUEL PRESSURE. Check fuel pump
f----+
1. Pinch fuel feed hose with fingers. and circuit. (See
2. When cranking the engine, is page EF & EC-156.)
there any pressure on the fuel
feed hose?
Yes

11
Yes
CHECK AIR REGULATOR AND
A.A.C. VALVE.
r-----. Check A.A.C. valve,
air regulator and cir-
When pressing accelerator pedal cuits. (See pages EF
fully, can you start the engine. & EC-160, 162.)

No

S6F3821

m
M
oo~; CHECK INJECTOR. Check injector(s)
1. Remove crank angle sensor from and circuit(s).
engine. (Harness connector
should remain connected.)
Click
/j
c,,e. 2. Turn ignition switch ON. (Do not
start engine.)
3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
Yes
m
CHECK IGNITION SPARK. N.G. Check ignition coil,
1. Disconnect ignition coil assembly r----+ power transistor unit
from collector. and their circuits.
2. Connect a known good spark (See page EF &
plug to the ignition coil assembly. EC-120.)
3. Place end of spark plug against
a suitable ground and crank en-
Ignition coil
gine.

,,, 4. Check for spark.

~O.K.
SEF1551
(Go to @ on next page.)

EF & EC-73
 TROUBLE DIAGNOSES
Diagnostic Procedure 4 - Hard to Start or
Impossible to Start when the Engine is Cold
(Cont'd)
m
CHECK SPARK PLUGS. N.G~I Repair or replace
Remove the spark plugs and check "I spark plug(s).
for fouling, etc.

O.K.

SEF1561

6
N.G.,
CHECK E.C.U. HARNESS CONNEC- f---+1 Repair or replace.
TOR. I
Check the E.C.U. pin termials for
damage or poor connection of E.C.U.
harness connector.
O.K.

m
CHECK E.C.U. POWER SUPPLY
AND GROUND CIRCUIT.
Refer to page EF & EC-1 06.
H Repair or replace.

O.K.
m
TRY A KNOWN GOOD E.C.U.

( ______I_N_S_PE_C_T_IO_N__E_N_D____~)

EF & EC-74
 TROUBLE DIAGNOSES

D Diagnostic Procedure 5 - Hard to Start or

Impossible to Start when the Engine is Hot
D
CHECK FUEL PRESSURE. No Check fuel pump
1. Pinch fuel feed hose with fingers.
f--+ and circuit. (See
2. When cranking the engine, is page EF & EC-156.)
there any pressure on the fuel
feed hose?
Yes

fJ
I ACTIVE TEST I 0
PRVR CONT SOL/V OFF
= ::;;___;::;_MONITOR==;:::;
CHECK FUEL VAPOR.

001.
Select "PRVR CONT SOL
H Check fuel properties.

CAS·RPM (POS) 750rpm VALVE" in "ACTIVE TEST"

ENG TEMP SEN 179°F mode.
EXH GAS SEN 0.92V
EXH GAS SEN-R 0.93V 2. After touching "ON", can
INJ PULSE 2.6msec you start the engine?
AAC VALVE 16%
OR
I ON II ON/OFF I••••• Disconnect fuel pressure
~ ®1.
SEF3831 regulator vacuum hose and
plug hose.
2. Can you start engine?

No

Bl
CHECK INJECTOR. No
,...__..... Check injector(s)
1. Remove crank angle sensor from and circuit(s).
engine. (Harness connector
should remain connected.)
2. Turn ignition switch ON. (Do not
start engine.)
3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
Yes
El
CHECK IGNITION SPARK. N.G.
Check ignition coil,
1. Disconnect ignition coil assembly ~
power transistor unit
from collector.
and circuits. (See
2. Connect a known good spark
page EF & EC-120.)
plug to the ignition coil assembly.
3. Place end of spark plug against
Ignition coil
a suitable ground and crank en-
gine.

,,
......
SEF1551
4. Check for spark.
~O.K.
(Go to @ on next page.)

EF 8r. EC-75
TROUBLE DIAGNOSES
Diagnostic Procedure 5 - Hard to Start or
Impossible to Start when the Engine is Hot
(Cont'd)

N.G.
CHECK E.C.U. HARNESS r---+ Repair or replace.
CONNECTOR.
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.

O.K.
m N.G.
CHECK E.C.U. POWER SUPPLY ;-----+ Repair or replace.
AND GROUND CIRCUIT.
Refer to page EF & EC-106.

O.K.
6
TRY A KNOWN GOOD E.C.U.

(~______IN_S_P_E_C_TI_O_N_E_N_D______)

EF 8r. EC-76
 TROUBLE DIAGNOSES

Diagnostic Procedure 6 - Hard to Start or

Impossible to Start under Normal Conditions
D
CHECK BATTERY AND STARTER.
Check battery and starter operation. ~ Repair or replace.

(Refer to EL section.)

O.K.

6
CHECK FUEL PRESSURE. No Check fuel pump
~
1. Pinch fuel feed hose with fingers. and circuit. (See
2. When cranking the engine, is page EF & EC-156.)
there any pressure on the fuel
feed hose?
Yes

IJ IJ
CHECK INJECTOR FOR LEAKAGE. H Check injector(s) for

~ <ID
When pressing accelerator pedal leakage.
fully, can you start the engine.
'
No

~ w SEF3821

m
00~,
CHECK INJECTOR. ______.
No Check injectors and
1. Remove crank angle sensor from circuits.
engine. (Harness connector
should remain connected.)
/1 Click 2. Turn ignition switch ON. (Do not
c,,•• start engine.)
3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
Yes
m
CHECK IGNITION SPARK. N.G.
1. Disconnect ignition coil assembly f----+ Check ignition coil,
power transistor unit
from collector. and circuits. (See
2. Connect a known good spark page EF & EC-120.)
plug to the ignition coil assembly.
3. Place end of spark plug against
a suitable ground and crank en-
gine.

,,, 4. Check for spark.

~O.K.
SEF1551
(Go to @ on next page.)

EF & EC-77
TROUBLE DIAGNOSES
Diagnostic Procedure 6 - Hard to Start or
Impossible to Start under Normal Conditions
(Cont'd)

CHECK SPARK PLUGS.

Remove the spark plugs and check
P.:.l Repair or replace
spark plug(s).
for fouling, etc.

O.K.

6
CHECK E.G.R. CONTROL VALVE.
Check E.G.R. control valve for
H Repair or replace.

sticking.

O.K.

m
CHECK E.C.U. HARNESS
CONNECTOR.
~I Repair or replace.
I
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.
O.K.
m
~,
CHECK E.C.U. POWER SUPPLY
AND GROUND CIRCUIT.
Refer to page EF & EC-106.
Repair or replace.
I
O.K.
1m Trouble is
fixed.
TRY A KNOWN GOOD E.C.U. Replace E.C.U.

Trouble is not fixed.

m
CHECK TIMING BELT FOR PROPER
INSTALLATION. H Replace timing belt.

O.K.

(~______IN_S_P_E_CT_I_O_N_E_N_D______~)

EF & EC-78
 TROUBLE DIAGNOSES

0 Diagnostic Procedure 7 - Hesitation when the ·

I ACTIVE TEST I D Engine is Hot
PRVR CONT SOL/V 0 FF
===MONITOR===
CAS·RPM (POS) 750rpm
D
ENG TEMP SEN 179°F CHECK FUEL VAPOR.
~ Check fuel properties.
EXH GAS SEN
EXH GAS SEN-A
INJ PULSE
AAC VALVE
0.92V
0.93V
2.6msec
16%
001. Select "PRVR CONT SOL
VALVE" in "ACTIVE TEST"
mode.
I ON II ON/OFF 11•11. 2. After touching "ON", per-
form cruise test.
~ SEF3831 Does the hesitation disap-
3.
pear?

OR

®1. Disconnect fuel pressure

regulator vacuum hose and
plug hose.
2. Perform cruise test.
3. Does the hesitation disap-
pear?

No

m
I
1.
CHECK CANISTER PURGE.
Disconnect canister purge line
hose and plug hose.
Yes Check purge and
·1 vacuum lines.
2. Perform cruise test.
3. Does the hesitation disappear?
No

/
SEF3851

C~ ______ IN_S_P_EC_T_IO_N
__E_N_D____ ~)

EF & EC-79
 TROUBLE DIAGNOSES

D Diagnostic Procedure 8 - Hesitation when the

Engine is Cold
D
N.G. Repair or replace
CHECK SPARK PLUGS.
Remove spark plugs and check for
r-----+ spark plug(s).
fouling, etc.

O.K.

SEF1561

II
Yes Discover air leak lo-
CHECK FOR INTAKE AIR LEAK. f---+
When pinching blow-by hose (lower- cation and repair.
ing the blow-by air supply), does the
engine speed rise?
No

II Trouble is
fixed.
TRY A KNOWN GOOD AIR FLOW Replace air flow
METER. meter.

Trouble is not fixed.

m
CHECK FOR INTAKE VALVE DE-
POSITS.
If there are deposits on intake valves,
remove them.

c INSPECTION END

EF & EC-80
 TROUBLE DIAGNOSES

D Diagnostic Procedure 9 - Hesitation under

Normal Conditions
D
CHECK SPARK PLUGS. ~ Repair or replace
Remove spark plugs and check for spark plug(s).
fouling, etc.
O.K.

SEF1561

0
H
trMONITOR trNO FAIL
CHECK EXHAUST GAS SENSOR. Replace exhaust gas
CAS·RPM(POS) 2087rpm (ij\ 1.
See "M/R F/C MNT (right sensor(s).
M/R F/C MNT LEAN ~-------~
~ and left sides)" in "DATA
M/R F/C MNT-R RICH
MONITOR" mode.
2. Maintaining engine at 2,000
rpm under no-load (with en-
gine warmed up sufficiently.),
check to make sure that
RECORD the monitor fluctuates be-
tween "LEAN" and "RICH"
more than 5 times during
10 seconds.
RICH~ LEAN~ RICH~
1 time 2 times
LEAN~ RICH ...... .

1 - - - - - - - OR --------1
Set "Exhaust gas sensor
monitor" in the self-
diagnostic Mode II. (See
page EF & EC-54.)
2. Maintaining engine at 2,000
SEF1521
rpm under no load, check
that RED LED on the E.C.U.
goes ON and OFF more
than 5 times during 10 sec-
onds.

No

CHECK CANISTER PURGE. ~ Check purge and

1. Disconnect canister purge line ~ vacuum lines.
hose and plug hose.
2. Perform cruise test.
3. Does the hesitation disappear?
No

(Go to @ on next page.)

EF & EC-81
 TROUBLE DIAGNOSES
Diagnostic Procedure 9 - Hesitation under
Normal Conditions (Cont'd)

m 1
CHECK FOR INTAKE AIR LEAK. ~ Discover air leak lo-
When pinching blow-by hose (lower- cation and repair.
ing the blow-by air supply), does the
engine speed rise?

No

SEF027K

(~____I_N_SP_E_C_T_IO_N__E_No______~)

EF & EC-82
 TROUBLE DIAGNOSES

D Diagnostic Procedure 10 - Engine Stalls when

Turning
D N.G. 1
CHECK FUEL LEVEL. "l Fill fuel tank with fuel.
Check to see that there is enough
fuel in tank.

O.K.

SEF3861

0
m
I ACTIVE TEST I
~, iJ
tc ***POWER BALANCE***
=CAS·=RPM
= MONITOR = ==
PERFORM POWER BALANCE TEST.
Perform "POWER BAL-
Go to
I
(POS) 850rpm 001.
ANCE" in "ACTIVE TEST"
AIR FLOW MTR 1.13V
AAC VALVE 27% mode.
2. Is there any cylinder which
does not produce a mo-
mentary engine speed drop?
OR
SEF1571
®When disconnecting each injec-
tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

SEF1581

I)

oo~;
No Check injector(s)
CHECK INJECTOR.
1. Remove crank angle sensor from and circuit(s).
engine. (Harness connector
should remain connected.)
/j Click 2. Turn ignition switch ON. (Do not
start engine.)
c,,e~ 3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
Yes
m
CHECK IGNITION SPARK. N.G.
Check ignition coil,
1. Disconnect ignition coil assembly power transistor unit
from collect9r. and circuits. (See
2. Connect a known good spark page EF & EC-120.)
plug to the ignition coil assembly.
3. Place end of spark plug against
a suitable ground and crank en-
gine.

,,, 4. Check for spark.

..I
O.K .
SEF1551
(Go to @ on next page.)
EF & EC-83
 TROUBLE DIAGNOSES
Diagnostic Procedure 10 - Engine Stalls when·
Turning (Cont'd)
I FUEL PRES RELEASE I
FUEL PUMP WILL STOP BY
TOUCHING START DURING
IDLE. N.G.
CHECK FUEL PRESSURE. Check fuel pressure
CRANK A FEW TIMES ~
AFTER ENGINE STALL. regulator diaphragm.
001. Perform "FUEL PRESSURE
RELEASE" in "WORK SUP-
PORT" mode in order to
release fuel pressure to
START

•
zero.
2. Install fuel pressure gauge
and check fuel pressure.
At idle approx. 255 kPa
(2.6 kg/cm2 , 37 psi)
The moment throttle valve
is fully open:
approx. 304 kPa (3.1
kg/cm2 , 44 psi)
OR
Release fuel pressure to
®1.
zero. (Refer to page EF &
SEF204J
EC-191.)
2. Install fuel pressure gauge
and check fuel pressure.

O.K.
m
~,
CHECK E.C.U. HARNESS
CONNECTOR.
Check the E.C.U. pin terminals for
Repair or replace.
I
damage or poor connection of E.C.U.
harness connector.
O.K.
6
CHECK E.C.U. POWER SUPPLY
AND GROUND CIRCUIT.
H Repair or replace.

Refer to page EF & EC-1 06.

O.K.
m
TRY A KNOWN GOOD E.C.U.

( INSPECTION END

EF & EC-84
 TROUBLE DIAGNOSES

D Diagnostic Procedure 11 - Engine Stalls when

I ACTIVE TEST I 0 the Engine is Hot
PRVR CONT SOL/V OFF
=CAS·RPM
::::::;:_- MONITOR
(POS)
=750rpm
== D
ENG TEMP SEN 179°F
EXH GAS SEN
CHECK FUEL VAPOR. Check fuel properties.
0.92V
EXH GAS SEN-R 0.93V Select "PRVR CONT SOL
INJ PULSE 2.6msec VALVE" in "ACTIVE TEST"
AAC VALVE 16%
mode.
I ON 1 oN;oFF I'•'** 2. After touching "ON", per-
form cruise test.
~ SEF3831 3. Does the engine stall disap-
pear?
1 - - - - - - - OR - - - - - - - - 1

Disconnect fuel pressure

regulator vacuum hose and
plug hose.
2. Perform cruise test.
3. Does the engine stall disap-
pear?

No

I ACTIVE TEST I 0
***POWER BALANCE***
PERFORM POWER BALANCE Go to GJ
== = MONITOR
CAS·RPM (POS) 850rpm
=== TEST.

AIR FLOW MTR 1.13V

Perform "POWER BAL-
AAC VALVE 27% ANCE" in "ACTIVE TEST"
mode.
2. Is there any cylinder which
does not produce a mo-
mentary engine speed drop?

SEF1571 1 - - - - - - - OR - - - - - - - 1

~When disconnecting each injec-

~ tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

SEF1581

oo~;
CHECK INJECTOR. Check injector(s)
1. Remove crank angle sensor from and circuit(s).
engine. (Harness connector
should remain connected.)
/1 Click 2. Turn ignition switch ON. (Do not
c,,e, start engine.)
3. When rotating crank angle sen-
Yes
sor shaft, does each injector
make an operating sound?
SEF1591
(Go to @ on next page.)

EF & EC-85
 TROUBLE DIAGNOSES
Diagnostic Procedure 11 Engine Stalls when
the Engine is Hot (Cont'd)
19 ~ N.G.
CHECK IGNITION SPARK. ---? Check ignition coil,
1. Disconnect ignition coil assembly power transistor unit
from collector.
and their circuits.
2. Connect a known good spark
(See page EF &
plug to the ignition coil assembly. EC-120.)
3. Place end of spark plug against

,,, a suitable ground and crank en-

gine.
4. Check for spark.
SEF1551
l O.K.
I FUEL PRES RELEASE I
CHECK FUEL PRESSURE. N.G.I Check fuel pressure
FUEL PUMP WILL STOP BY
TOUCHING START DURING 001.
Perform "FUEL PRESSURE
RELEASE" in "WORK SUP-
,.., regulator diaphragm.
I
IDLE.
CRANK A FEW TIMES PORT" mode in order to
AFTER ENGINE STALL release fuel pressure to
zero.
2. Install fuel pressure gauge
and check fuel pressure.
START At idle approx. 255 kPa

• (2.6 kg/cm2 , 37 psi)

The moment throttle valve
is fully open:
approx. 304 kPa (3.1
kg/cm 2, 44 psi)
OR

®1. Release fuel pressure to

zero. (Refer to page EF &
EC-191.)
2. Install fuel pressure gauge
and check fuel pressure.
SEF204J
O.K.
m
CHECK E.C.U. HARNESS CONNEC-
TOR.
~I Repair or replace.
I
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.
O.K.
6
CHECK E.C.U. POWER SUPPLY
AND GROUND CIRCUIT.
~I Repair or replace.
I
Refer to page EF & EC-106.

m O.K. Trouble is fixed.

TRY A KNOWN GOOD E.C.U.

I Replace E.C.U.
I
m Trouble is not fixed.

CHECK TIMING BELT FOR PROPER

INSTALLATION.
N.G.J Replace timing belt.
I
O.K.

(~______IN_s_P_E_c_T_Io_N__E_N_o____~)
EF & EC-86
 TROUBLE DIAGNOSES

D Diagnostic Procedure 12 - Engine Stalls when

the Engine is Cold
D
N.G.
CHECK AIR REGULATOR AND Check A.A.C. valve,
A.A.C. VALVE. air regulator and cir-
When the engine is cold, can you cuits. (See pages EF
start the engine when pressing ac- & EC-160, 162.)
celerator pedal fully?
O.K.
SEF3821

Bl 11
~
I ACTIVE TEST. 0 PERFORM POWER BALANCE TEST. Go to[!)
~***POWER BALANCE***~
=CAS·RPM
= = MONITOR ===
(POS)
AIR FLOW MTR
AAC VALVE
850rpm
1.13V
27%
CiY· Perform "POWER BAL-
ANCE" in "ACTIVE TEST"
mode.
2. Is there any cylinder which
does not produce a mo-
~
.000~~~
mentary engine speed drop?
0000 START OR
SEF1571 ® When disconnecting each injec-
tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

O.K.

SEF1581

11

~~~
CHECK INJECTOR. N.G. Check injector(s)
1. Remove crank angle sensor from and circuit(s}.
engine. (Harness connector
should remain connected.)
Click 2. Turn ignition switch ON. (Do not
/j
c,,•• start engine.)
3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
O.K.
El
CHECK IGNITION SPARK. N.G. Check ignition coil,
1. Disconnect ignition coil assembly 1----+ power transistor unit
from collector. and circuits. (See
2. Connect a known good spark page EF & EC-120.)
plug to the ignition coil assembly.
3. Place end of spark plug against
a suitable ground and crank en-
gine.

,,
SEF1551
.....
4. Check for spark.
~O.K.
(Go to @ on next page.)
EF &. EC-87
 TROUBLE DIAGNOSES
Diagnostic Procedure 12 Engine Stalls when
the Engine is Cold (Cont'd)

CHECK SPARK PLUGS. N.G. Repair or replace

---+ spark plug(s).
Remove the spark plugs and check
for fouling, etc.
O.K.

SEF1561

I I
m
FUEL PRES RELEASE N.G. Check fuel pressure
CHECK FUEL PRESSURE. f---+
FUEL PUMP WILL STOP BY regulator diaphragm.
Ci~Y·
TOUCHING START DURING
Perform "FUEL PRESSURE
IDLE. RELEASE" in "WORK SUP-
CRANK A FEW TIMES PORT" mode in order to
AFTER ENGINE STALL. release fuel pressure to
zero.
2. Install fuel pressure gauge
and check fuel pressure.
START At idle approx. 255 kPa

• (2.6 kg/cm 2, 37 psi)

The moment throttle valve
Is fully open:
approx. 304 kPa (3.1
kg/cm2, 44 psi)
OR
Release fuel pressure to
®1.
zero. (Refer to page EF &
EC-191.)
2. Install fuel pressure gauge
and check fuel pressure.
SEF204J
O.K.
6
CHECK E.C.U. HARNESS CONNEC-
TOR.
~I Repair or replace.
I
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.
O.K.

m
~,
CHECK E.C.U. POWER SUPPLY
AND GROUND CIRCUIT.
Refer to page EF & EC-1 06.
Repair or replace.
I
O.K.

m
TRY A KNOWN GOOD E.C.U.

INSPECTION END

EF & EC-88
 TROUBLE DIAGNOSES

D Diagnostic Procedure 13 - Engine Stalls when

I ACTIVE TEST I D Stepping on the Accelerator Momentarily
AAC/V OPENING 50%
D
===MONITOR===
CAS·RPM (POS) 850rpm CHECK A.A.C. VALVE. ~ Check A.A.C. valve
AIR FLOW MTR 1.24V and circuit. (See
ENG TEMP SEN 179°F Select "A.A.C. VALVE
page EF & EC-162.)
OPENING" in "ACTIVE
ij ij TEST" mode.
~I UP II OWN I~ 2. When touching "Qu" and
"Qd", does the engine
SEF1621
speed change according to
the percent of A.A.C. valve
D opening?
OR-------1

® When disconnecting A.A.C.

valve harness connector, does
the engine speed drop?

Yes

SEF1461

D
I ACTIVE TEST I
~***POWER BALANCE***~
PERFORM POWER BALANCE H_ Go to Iii
= = =MONITOR = = = TEST. ~-------~
CAS·RPM (POS) 850rpm
AIR FLOW MTR 1.13V Perform "POWER BAL-
AAC VALVE 27% ANCE" in "ACTIVE TEST"
mode .
. 0 ,_j= 2. Is there any cylinder which
• 00 2 TEST does not produce a mo-
0000 START mentary engine speed drop?
SEF1571 f-------OR -------1
~ When disconnecting each injec-
~ tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

SEF1581

~~,
. No
Check injector(s)
CHECK INJECTOR. r-+
1. Remove crank angle sensor from and their circuit(s).
engine. (Harness connector
should remain connected.)
/1 Click 2. Turn ignition switch ON. (Do not
c,,•• start engine.) Yes
3. When rotating crank angle sen- f - - - - - - - - - .
sor shaft, does each injector
make an operating sound?
SEF1591 (Go to @ on next page.)

EF & EC-89
 TROUBLE DIAGNOSES
Diagnostic Procedure 13 - Engine Stalls when
Stepping on the Accelerator Momentarily
(Cont'd)
El
CHECK IGNITION SPARK.
N.G. Check ignition coil,
1. Disconnect ignition coil assembly r---+ power transistor unit
from collector. and their circuits.
2. Connect a known good spark (See page EF &

,,,
SEF1551
plug to the ignition coil assembly.
3. Place end of spark plug against
a suitable ground and crank en-
EC-120.)

gine.
4. Check for spark.
I FUEL PRES RELEASE I
FUEL PUMP WILL STOP BY m !O.K.
TOUCHING START DURING
IDLE.
CHECK FUEL PRESSURE. ~~ Check fuel pressure
regulator diaphragm.
CRANK A FEW TIMES
AFTER ENGINE STALL.
001. Perform "FUEL PRESSURE
RELEASE" in "WORK SUP-
PORT" mode in order to
release fuel pressure to
zero.
START

•
2. Install fuel pressure gauge
and check fuel pressure .
At idle approx. 255 kPa
(2.6 kg/cm 2, 37 psi)
The moment throttle valve
is fully open:
approx. 304 kPa (3.1
kg/cm 2 , 44 psi)
OR
Release fuel pressure to
®1.
zero. (Refer to page EF &
EC-191.)
2. Install fuel pressure gauge
SEF204J and check fuel pressure.

m l O.K.

CHECK E.C.U. HARNESS CONNEC-

TOR.
Check the E.C.U. pin terminals for
H Repair or replace.

damage or poor connection of E.C.U.

harness connector.

6
l O.K.

CHECK E.C.U. POWER SUPPLY

AND GROUND CIRCUIT.
~I Repair or replace.
I
Refer to page EF & EC-1 06.

m
1 O.K.

TRY A KNOWN GOOD E.C.U.

l
( INSPECTION END

EF & EC-90
 TROUBLE DIAGNOSES

D Diagnostic Procedure 14 - Engine Stalls after

I ACTIVE TEST I D Decelerating
AAC/V OPENING 50%
D
= = MONITOR
=CAS·RPM = == CHECK A.A.C. VALVE.
No Check A.A.C. valve
(POS)
AIR FLOW MTR
850rpm
1.24V
r-----+ and circuit. (See
@1. Select "A.A.C. VALVE
ENG TEMP SEN 179°F page EF & EC-162.)
OPENING" in "ACTIVE
~ ~ TEST" mode.
~I UP II OWN I~ 2. When touching "Qu" and
"Qd", does the engine
SEF1621
speed change according to
the percent of A.A.C. valve
D opening?
OR
® When disconnecting A.A.C.
valve harness connector, does
the engine speed drop?

Yes

SEF1461

6
• AAC VALVE ADJ I D CHECK IDLE ADJ. SCREW CLOG-
No Check for lAS clog-
------+
** * *ADJ MONITOR * *** GING. ging or throttle
CAS·RPM (POS) 712rpm

- - CONDITION SETIING- -
AAC VALVE FIXED
001. Perform "A.A.C. VALVE
ADJ" in "WORK SUPPORT"
chamber clogging.

mode.
= MONITOR
=ENG=TEMP SEN
===
177°C
2. Can you set engine rpm as
follows by turning idle ad-
IDLE POSITION ON justing screw?
AIR COND SIG OFF
M/T: 650 ±50 rpm
SEF1451 A/T: 720 ±50 rpm
(Non-turbo)
700 ±50 rpm (Turbo)
[in "N" position]

OR
Disconnect A.A.C. valve
®1.
harness connector
2. Can you set engine rpm as
follows by turning idle ad-
justing screw?
M/T: 650 ±50 rpm
S.EF1611
A/T: 720 ± 50 rpm
(Non-turbo)
700 ±50 rpm (Turbo)
[in "N" position]

Yes

(Go to @ on next page.)

EF & EC-91
 TROUBLE DIAGNOSES
Diagnostic Procedure 14 - Engine Stalls after
Decelerating (Cont'd)
I ACTIVE TEST I D
~***POWER BALANCE***
@
= = MONITOR
=CAS·RPM (POS)
= ==
850rpm 11 ~
~,
AIR FLOW MTR
AAC VALVE
1.13V
27%
PERFORM POWER BALANCE
TEST.
Go to [8
I
Perform "POWER BAL-
@1.
ANCE" in "ACTIVE TEST"
mode.
2. Is there any cylinder which
SEF1571 does not produce a mo-
mentary engine speed drop?
OR
® When disconnecting each injec-
tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

SEF15BI

m
CHECK INJECTOR.
1. Remove crank angle sensor from
engine. (Harness connector
P.l Check injector(s)
and circuit(s).

should remain connected.)

2. Turn ignition switch ON. (Do not
start engine.)
3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
Yes
m
N.G. Check ignition coil,
CHECK IGNITION SPARK.
1. Disconnect ignition coil assembly power transistor unit
from collector. and circuits. (See
2. Connect a known good spark page EF & EC-120.)
plug to the ignition coil assembly.
3. Place end of spark plug against
a suitable ground and crank en-

,, .....
SEF1551
gine.
4. Check for spark.
O.K.

(Go to @ on next page.)

EF & EC-92
 TROUBLE DIAGNOSES
Diagnostic Procedure 14 - Engine Stalls after
Decelerating (Cont'd)
I FUEL PRES RELEASE I
FUEL PUMP WILL STOP BY
TOUCHING START DURING
IDLE. N.G. Check fuel pressure
CRANK A FEW TIMES CHECK FUEL PRESSURE.
AFTER ENGINE STALL regulator diaphragm.
Perform "FUEL PRESSURE
001.
RELEASE" in "WORK SUP-
PORT" mode in order to
release fuel pressure to
START

•
zero.
2. Install fuel pressure gauge
and check fuel pressure.
At idle approx. 255 kPa
(2.6 kg/cm 2 , 37 psi)
The moment throttle valve
is fully open:
approx. 304 kPa (3.1
kg/cm 2 , 44 psi)
OR

®1. Release fuel pressure to

zero. (Refer to page EF &
EC-191.)
SEF204J
2. Install fuel pressure gauge
and check fuel pressure.
"tl MONITOR "tl NO FAIL D
CAS· RPM(POS) 2087rpm
O.K.
M/R F/C MNT LEAN
M/R F/C MNT-R RICH
6
N.G. Replace exhaust gas
CHECK EXHAUST GAS SENSOR. 1----+ sensor(s).
See "M/R F/C MNT (right
001.
and left sides)" in "DATA
MONITOR" mode.
RECORD 2. Maintaining engine at 2,000
SEF1601 rpm under no-load (with en-
gine warmed up sufficiently.),
check to make sure that
the monitor fluctuates be-
tween "LEAN" and "RICH"
more than 5 times during
10 seconds.
RICH~LEAN~RICH~
'----
1 time 2 times
LEAN~ RICH .......

OR

SEF1521 ®1. Set "Exhaust gas sensor

monitor" in the self-
diagnostic Mode II. (See
page EF & EC-54.)
2. Maintaining engine at 2,000
rpm under no load, check
that RED LED on the E.C.U.
goes ON and OFF more
than 5 times during 10 sec-
onds.

l O.K.

(Go to © on next page.)

EF & EC-93
TROUBLE DIAGNOSES
Diagnostic Procedure 14 - Engine Stalls after
Decelerating (Cont'd)

N.G.
CHECK E.C.U~ HARNESS I----+ Repair or replace.
CONNECTOR.
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.
O.K.
m N.G.
CHECK E.C.U. POWER SUPPLY ~ Repair or replace.
AND GROUND CIRCUIT.
Refer to page EF & EC-106.

O.K.
1m
TRY A KNOWN GOOD E.C.U.

IN_S_P_EC_T_IO_N__E_N_o____~)
( _______

EF &. EC-94
 TROUBLE DIAGNOSES

D Diagnostic Procedure 15 - Engine Stalls when

• ACTIVE TEST • D Accelerating or Cruising
II** *POWER BALANCE***~
===MONITOR===
CAS· RPM (POS) 850rpm D
AIR FLOW MTR
AAC VALVE
1.13V
27%
PERFORM POWER BALANCE
TEST.
~I Go to 19
I
L-~~~~~~~~ Perform "POWER BAL-
001. ANCE"
•CDITJ0 TEST in "ACTIVE TEST"
CIJITJDD..___sTA_RT~ mode.
SEF1571
2. Is there any cylinder which
does not produce a mo-
mentary engine speed drop?
OR
® When disconnecting each injec-
tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

SEF1581

00~# ~I
CHECK INJECTOR. Check injector(s)
1. Remove crank angle sensor from and circuit(s).
engine. (Harness connector
should remain connected.)
/1 Click 2. Turn ignition switch ON. (Do not
start engine.)
c''•4- 3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
Yes
I]
CHECK IGNITION SPARK.
N.G.
Check ignition coil,
1.. Disconnect ignition coil assembly r------+ power transistor unit
from collector. and circuits. (See
2. Connect a known good spark page EF & EC-120.)
plug to the ignition coil assembly.
3. Place end of spark plug against
Ignition coil a suitable ground and crank en-
gine.
,,, 4. Check for spark.
SEF1551 O.K.

(Go to ® on next page.)

EF &. EC-95
 TROUBLE DIAGNOSES
Diagnostic Procedure 15 - Engine Stalls when
Accelerating or Cruising (Cont'd)
I FUEL PRES RELEASE I
FUEL PUMP WILL STOP BY
TOUCHING START DURING
@
IDLE.
CRANK A FEW TIMES
AFTER ENGINE STALL.
! N.G.
CHECK FUEL PRESSURE. --+ Check fuel pump,
Perform "FUEL PRESSURE circuit and fuel pres-
001. sure regulator.
RELEASE" in "WORK SUP-
START PORT" mode in order to

•
release fuel pressure to
zero.
2. Install fuel pressure gauge
and check fuel pressure.
At Idle approx. 255 kPa
(2.6 kg/cm2 , 37 psi)
The moment throttle valve
is fully open:
approx. 304 kPa (3.1
kg/em\ 44 psi)
OR
Release fuel pressure to
®1.
SEF204J zero. (Refer to page EF &
EC-191.)
2. Install fuel pressure gauge
and check fuel pressure.

O.K.

m
CHECK FOR INTAKE AIR LEAK. Yes Discover air leak lo-
~ cation and repair.
When pinching blow-by hose (lower-
ing the blow-by air' supply), does the
engine speed rise?

No

SEF027K (Go to @ on next page.)

EF & EC-96
TROUBLE DIAGNOSES
Diagnostic Procedure 15 - Engine Stalls when
Accelerating or Cruising (Cont'd)

~,
CHECK E.C.U. HARNESS
CONNECTOR.
Repair or replace.
I
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.

O.K.

If
CHECK E.C.U. POWER SUPPLY
AND GROUND CIRCUIT.
~ Repair or replace.
I
Refer to page EF & EC-1 06.
No

m
TRY A KNOWN GOOD E.C.U.

( INSPECTION END )

EF & EC-97
 TROUBLE DIAGNOSES

Diagnostic Procedure 16 - Engine Stalls when

the Electrical Load is Heavy
D
~,
CHECK BATTERY AND ALTERNA·
TOR.
Repair or replace.
I
Check battery and alternator condi-
tion. (Refer to EL section.)

.O.K.
SEF3891

6
I ACTIVE TEST I 0 ~,
~***POWER BALANCE***~
=== MONITOR
CAS·RPM (POS)
===
850rpm
PERFORM POWER BALANCE TEST.

001.
Perform "POWER BAL-
Go to (g
I
ANCE" in "ACTIVE TEST"
AIR FLOW MTR 1.13V
AAC VALVE 27%
mode.
2. Is there any cylinder which
L---~~~~~--~~ does not produce a mo-
•CDITJQJ TEST
mentary engine speed drop?
CIJITJDD START OR
SEF1571 ® When disconnecting each injec-
tor harness connector one at a
time, is there any cylinder
which does not produce a mo-
mentary engine speed drop?

Yes

SEF1581

11

~~~
CHECK INJECTOR.
No Check injector(s)
1. Remove crank angle sensor from and circuit(s).
engine. (Harness connector
should remain connected.)
2. Turn ignition switch ON. (Do not
/1 Click start engine.)
c,,•• 3. When rotating crank angle sen-
sor shaft, does each injector
make an operating sound?
SEF1591
Yes
19
CHECK IGNITION SPARK. N.G. Check ignition coil,
1. Disconnect ignition coil assembly
----... power transistor unit
from collector. and circuits. (See
2. Connect a known good spark page EF & EC-120.)
plug to the ignition coil assembly.
3. Place end of spark plug against
Ignition coil
a suitable ground and crank en-
gine.

,,, 4. Check for spark.

~O.K.
SEF1551
(Go to @ on next page.)

EF & EC-98
 TROUBLE DIAGNOSES
Diagnostic Procedure 16 - Engine Stalls when
the Electrical Load is Heavy (Cont'd)
I FUEL PRES RELEASE I
FUEL PUMP WILL STOP BY
TOUCHING START DURING
IDLE. N.G. Check fuel pressure
CRANK A FEW TIMES
AFTER ENGINE STALL
CHECK FUEL PRESSURE.

001.
Perform "FUEL PRESSURE
RELEASE" in "WORK SUP-
regulator diaphragm.
I
PORT" mode in order to
START release fuel pressure to

•
zero.
2 . Install fuel pressure gauge
and check fuel pressure.
At idle approx. 255 kPa
(2.6 kg/cm 2 , 37 psi)
The moment throttle valve
is fully open:
approx. 304 kPa (3.1
kg/cm2 , 44 psi)
OR

®1. Release fuel pressure to

zero. (Refer to page EF &
SEF204J EC-191.)
2. Install fuel pressure gauge
and check fuel pressure.

O.K.

m
CHECK E.C.U. HARNESS
CONNECTOR.
~I Repair or replace.
I
Check the E.C.U. pin terminals for
damage or poor connection of E.C.U.
harness connector.
O.K.

6
CHECK E.C.U. POWER SUPPLY
AND GROUND CIRCUIT.
~I Repair or replace.
I
Refer to page EF & EC-106.
O.K.

m.
TRY A KNOWN GOOD E.C.U.

INSPECTION END

EF & EC-99
 TROUBLE DIAGNOSES

D Diagnostic Procedure 17 - Lack of Power and .

I FUEL PRES RELEASE I Stumble
FUEL PUMP WILL STOP BY
TOUCHING START DURING 0
IDLE. N.G.
CRANK A FEW TIMES CHECK FUEL PRESSURE. Check fuel pressure
AFTER ENGINE STALL. regulator diaphragm.
Perform "FUEL PRESSURE
@.1.
RELEASE" in "WORK SUP-
PORT" mode in order to
START release fuel pressure to

•
zero.
2. Install fuel pressure gauge
and check fuel pressure.
At Idle approx. 255 kPa
(2.6 kg/cm2 , 37 psi)
The moment throttle valve
Is fully open:
approx. 304 kPa (3.1
kg/cm 2, 44 psi)
OR
Release fuel pressure to
®1.
·. zero. (Refer to page EF &
SEF204J
EC-191.)
2. Install fuel pressure gauge
and check fuel pressure.

O.K.

PJ
Yes Discover air leak lo-
CHECK FOR INTAKE AIR LEAK.
When pinching blow-by hose (lower- cation and repair.
ing the blow-by air supply), does the
engine speed rise?

No

SEF027K

N.G.
CHECK TIMING BELT FOR PROPER Replace timing belt.
INSTALLATION.
O.K.

c INSPECTION END

EF & EC-100
 TROUBLE DIAGNOSES

Diagnostic Procedure 18 - Detonation

D
CHECK FOR INTAKE AIR LEAK. Discover air leak lo-
When pinching blow-by hose (lower- cation and repair.
ing the blow-by air supply), does the
engine rpm rise?

No

SEF027K

fA E.G.R.
No
CHECK E.G.R. OPERATION. Check E.G.R. valve
1. Apply vacuum directly to the for sticking.
E.G.R. valve using a handy vacu-
um pump.
2. Check to see that the engine
runs rough or dies.
Yes

• ACTIVE TEST I D N.G.

CHECK E.G.R. CONTROL SOLE- Check solenoid valve
EGA CONT SOL!V OFF NOID VALVE. and circuit.
===MONITOR===
CAS·RPM (POS) 787rpm Select "E.G.R. CONT SOL
VALVE" in "ACTIVE TEST"
mode.
2. Turn E.G.R. control solenoid

@, ON/OFF~-···
valve ON and OFF.
3. Check operating sound.
SEF3901 ~-----OR ---------1
Disconnect E.G.R. control
solenoid valve harness con-
nector.
2. Supply E.G.R. control sole-
noid valve terminals with
battery current and check
operating sound.

O.K.
BATTERY

SEF459J
(Go to @ on next page.)

EF 8t EC-1 01
 TROUBLE DIAGNOSES
Diagnostic Procedure 18 - Detonation {Cont'd)

1
CHECK VACUUM HOSES.
Check the following vacuum hoses
H Repair or replace.

for clogging, cracks and poor con-

nection.
a) Vacuum hose between E.G.R.
control valve and E.G.R. control
solenoid valve.
b) Vacuum hose between E.G.R.
control solenoid valve and throt-
tie chamber port.
c) Vacuum hose between E.G.R.
control solenoid valve and air
duct.

O.K.

m
CHECK FOR OIL LEAK TO COM-
BUSTION CHAMBER.
~ Check pistons, pis-
ton rings, valves,
Remove spark plugs and check for valve seats, valve oil
fouling with oil. seal, engine oil level,
etc.
No

SEF1561

( _______IN_S_P_E_C_T_IO_N__
EN_o_______)

EF & EC-102
 TROUBLE DIAGNOSES

D Diagnostic Procedure 19 - Surge

ttMONITOR ttNO FAIL D
D
CAS·RPM(POS) 2087rpm N.G. Replace exhaust gas
CHECK EXHAUST GAS SENSOR.
M/R F/C MNT
M/R F/C MNT-R
LEAN
RICH
--+ sensor(s).
001. See "M/R F/C MNT (right
and left sides)" in "DATA
MONITOR" mode.
2. Maintaining engine at 2,000
rpm under no-load (with en-
RECORD gine warmed up sufficiently.),
check to make sure that
SEF1601 the monitor fluctuates be-
tween "LEAN" and "RICH"
D more than 5 times during
10 seconds.
RICH~ LEAN~ RICH~
1 time 2 times
LEAN~ RICH .......

OR

® 1 . Set "Exhaust gas sensor

monitor" in the self-
diagnostic Mode II. (See
SEF1521 page EF & EC-54.)
2. Maintaining engine at 2,000
rpm under no load, check
that RED LED on the E.C.U.
goes ON and OFF more
than 5 times during 10 sec-
onds.

O.K.

II
~,
CHECK E.G.R. CONTROL VALVE.
Check E.G.R. control valve for
Repair or replace.
I
sticking.
O.K.

11
TRY A KNOWN GOOD E.C.U.

O.K.

C~ ______IN_S_P_E_C_T_IO_N__
E_No
______ ~)

EF 8r. EC-1 03
 TROUBLE DIAGNOSES

0 , Diagnostic Procedure 20 - Backfire through

the Intake
0
N.G. Repair or replace
CHECK SPARK PLUGS.
Remove the spark plugs and check spark plug(s).
for fouling, etc.

O.K.

SEF1561

Yes Discover air leak lo-

CHECK INTAKE AIR LEAK.
When pinching' blow-by hose (lower- cation and repair.
ing the; blow-by air supply), does the
engine speed rise?

No

SEF027K

CHECK FOR INTAKE VALVE DE·

POSITS.
If there are deposits on intake valves,
remove them.

(..___ _ _
IN_s_P_Ec_r_lo_N_E_N_o_ ____.;)

EF & EC-104
TROUBLE DIAGNOSES

Diagnostic Procedure 21 - Backfire through

the Exhaust
D
CHECK ENGINE TEMPERATURE A
NG Replace or repair. I
SENSOR. ~------------~
Check engine temperature sensor
and its circuit. (See page EF &
EC-116.)

O.K.

INSPECTION END

EF & EC-105
 TROUBLE DIAGNOSES

Diagnostic Procedure 22
MAIN POWER SUPPLY AND GROUND CIRCUIT

IGNITION
SWITCH
OFF ACC ON ST
I
2
3

_, '5
-
ID8- B ---< (Main
(E. F. J. harness)
ID9- W - I- harnes sl
116- B @@)
ID- B
16- OR
2D- B
OJ tOR
(Brownl

~
1111 lil
U-B/R
u- w -
SD- B - (Engine room
59- w
harness>
6D- B ---<

. ~

E. c. c. s.
CONTROL
@i@i E. C. C. S.
RELAY
FUSIBLE
LINK
HOLDER
ENGINE BODY ENGINE BATTERY
UNIT GROUND GROUND GROUND
SEC594B

Harness layout

SEF3661

EF &. EC-106
 TROUBLE DIAGNOSES
Diagnostic Procedure 22 (Cont'd)

u c.-'UNIT
16
]Of CCNECTCIR II ~ c INSPECTION START

[!)
CHECK POWER SUPPLY. N.G. Check the following items.
~ 1) E.C.C.S. relay
1) Turn ignition switch "ON".
m 2) Check voltage between Refer to "Electrical Com-
E.C.U. pin terminal @ ponents Inspection".
and ground. (See page EF & EC-190.)
Voltage: 2) "G" fusible link
SEC054B Approximately 0.8 • 1.0V 3) Harness continuity between
(;) 3) Check voltage b'etween E.C.C.S. relay and battery

II c.;uNIT }Of CONNECTOR II E.C.U. pin terminals@), ffi terminal

®.@and ground. Continuity should exist.
109 49 59
Voltage: Battery voltage 4) Harness continuity between
E.C.C.S. relay and E.C.U.
O.K. pin terminal @
Continuity should exist.

lil
N.G.
CHECK GROUND CIRCUIT. 1) Check if engine ground
1) Turn ignition switch "OFF". terminal connectors@,@
SEF4331
2) Disconnect E.C.U. harness and@ make contact with
connector. engine body properly.
3) Check harness continuity 2) Repair harness or connectors.
II between E.C.U. pin terminals
@. ®. ®. @. <@). <@),
@ and ground.
Continuity should exist.
O.K.

INSPECTION END

u CIUNIT ]Of CCNECTCIR II

10 20 50 60 107 108 116
Ill

SEC057B

EF & EC-107
 TROUBLE DIAGNOSES

Diagnostic Procedure 23
CRANK ANGLE SENSOR (Code No. 11)

@@)

16-
(E.F.I.
harness)
OR-...:.:=...:.=.==-._ OR
Jt
!Brownl
OR

!Engine room
harness)

iJ 11
illl:
0 '
••'

. lMJ®

CRANK
ENGINE
GROUND
[I
E. C. C. S.
E. C. C. S.
CONTROL
® ANGLE RELAY
SENSOR
UNlT

SEF3661

EF 8r. EC-1 08
 TROUBLE DIAGNOSES
Diagnostic Procedure 23 (Cont'd)
m ( INSPECTION START
~
[it m liJ
CHECK POWER SUPPLY. IN.G .• Check the following items.
COIINECT lv I 1) Turn ignition switch "ON". 1) E.C.C.S. relay
E) [<;:!:)_§,..._______
~ 2) Check voltage between ter- Refer to "Electrical Com-
minal @ and ground. ponents Inspection".

~0 =
Voltage: Battery voltage

O.K.
(See page EF & EC-190.)
2) "G" fusible link
SEF4351 3) Harness continuity between
E.C.C.S. relay and battery
liJ EB terminal
~15 Continuity should exist.
~~5 ~
41 Harness continuity between

@bTi@ 00 E.C.C.S. relay and crank

angle sensor terminal @
Continuity should exist.

.-----
~ [I lj]
[RJ ~15 CHECK INPUT SIGNAL
1) Start engine.
N.G.
CHECK HARNESS CON-
TINUITY BETWEEN E.C.U.
@
'-=------..::
SEF4361
2) Read cr~nk an.gle AND CRANK ANGLE
sensor s1gnals m SENSOR.
trMONITOR trNO FAIL D "DATA MONITOR" 1) Stop engine.
CAS·RPM (POS) 662rpm mode with CQNSUL T. 2) Disconnect crank angle
CAS· RPM (REF) 692rpm rpm: MIT 700±50 sensor harness connector.
A/T 770±50 3) Disconnect E.C.U. harness
[Non-turbo] connector.
750±50 4) Check harness continuity
[Turbo] between E.C.U. terminals

RECORD
SEF5841
® OR
2) Check that pulse signals
exist in E.C.U. ter-
@,®and terminal@,
E.C.U. terminals@, @ and
terminal©.
minals @,®and@, Continuity should exist.
[I II CAINIT JOf CONNECTOR I @ with logic probe. If N.G., repair harness or
41•42•51•52 Pulse signal should exist. connectors.
@, ®: 120° signal
@, @: 1 o signal 10.K.
O.K. CHECK COMPONENT
(Crank angle sensor).
Refer to "Electrical Components
Inspection".
(See page EF & EC-184.)

SEF4371
E~
EF & EC-109
 TROUBLE DIAGNOSES
Diagnostic Procedure 23 {Cont'd)
1!1
~,lblc I~) ~i5 II !
CHECK GROUND CIRCUIT.
N.G. I R . ·
• 1 epa1r harness or connectors.
1) Stop engine.
l.o I 2) Disconnect crank angle sensor
harness connector.
~
3) Check harness continuity

00 between terminal@ and

ground.
Continuity should exist.
SEF4381 =
O.K.

Reinstall any part removed.

Erase the self-diagnosis memory.

N.G.
Perform driving test and then 1) Perform E.C.U. input/output
perform self-diagnosis (Mode signal inspection test.
Ill again. 21 If N.G., recheck the E.C.U.
O.K. pin terminals for damage.
Check the connection at the
E.C.U. harness connector.

INSPECTION END

EF & EC-110
 TROUBLE DIAGNOSES

NOTE

EF 8r. EC-111
 TROUBLE DIAGNOSES

Diagnostic Procedure 24
AIR FLOW METER (Code No. 12) ~ (CHECK ENGINE LIGHT ITEM)

@(ill)
(E. F. 1.
harness>
16- OR-__;__ _ _ OR
_t ~ OR
<Brown)

(Engine room
harness>

..
®i
ENGlNE
GROUND
E. C. c. S.
E. C. C. S.
CONTROL
® AlR FLOW
METER
RELAY
UNlT BATTERY
SEC596B

Harness layout

SEF3661

EF & EC-112
 TROUBLE DIAGNOSES
Diagnostic Procedure 24 (Cont'd)

cm INSPECTION START

I!J
CHECK POWER SOURCE. ~ Check the following items.
1) Turn ignition switch "ON". 1) E.C.C.S. relay
2) Check voltage between ter- Refer to "Electrical Com-
minal ® and ground. ponents Inspection".
Voltage: Battery voltage (See page EF & EC-190.)
2) "G" fusible link
O.K. 3) Harness continuity between
SEC0688
E.C.C.S. relay and battery
EB terminal
Continuity should exist.
4) Harness continuity between
E.C.C.S. relay and air flow
meter terminal@.
Continuity should exist.

[I It]
CHECK INPUT SIGNAL. IN.G ...
CHECK HARNESS CON-
SEF4401
1) Start engine and warm it up TINUITY BETWEEN AIR
sufficiently. FLOW METER AND E.C.U.

t:rMONITOR t:rNO FAIL D

@ 2) Read air flow meter
signal in "DATA
1) Stop engine.
2) Disconnect air flow meter
AIR FLOW MTR 1.10V MONITOR" mode with harness connector.
CONSULT. 3) Disconnect E.C.U. harness
Voltage: 0.8 · 1.5V connector.
OR 4) Check harness continuity
® 2 ) Check voltage between between E.C.U. terminal ®
terminal @ and ground and terminal @.
at idle under no-load. Continuity should exist.
RECORD Voltage: 0.8 • 1.5V If N.G., repair harness or
SEF5851 connectors.

tO.K.

CHECK COMPONENT
(Air flow meter).
Refer to "Electrical Components
Inspection".
(See page EF & EC-184.)

II
SEC070B
CHECK GROUND CIRCUIT.
1) Stop engine. M Repair harness or connectors.

2) Disconnect air flow meter

[21
II CI'UNIT ]Of CONNECTOR II -
eJ
harness connector.
3) Check harness continuity
between terminal © and
ground.

---l-eS. . ._~_"_e'd_'T)
Continuity should exist.

l'--' O.K.

00 SEC071B
EB
EF &. EC-113
 TROUBLE DIAGNOSES
Diagnostic Procedure 24 (Cont'd)
II E~
~$[:iii)
Reinstall any part removed.
In I
'-'---

Erase the self-diagnosis memory.

00 .,
SEC072B
Perform driving test and then
N.G.
1) Perform E.C.U. input/output
perform self-diagnosis (Mode signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
O.K. pin terminals for damage.
Check the connection at the
E.C.U. harness connector.

(~___I_N_sP_E_c_T_Io_N__E_N_o__~)

EF & EC-114
 TROUBLE DIAGNOSES

NOTE

EF & EC-115
 TROUBLE DIAGNOSES

Diagnostic Procedure 25
ENGINE TEMPERATURE SENSOR (Code No. 13) ~ (CHECK ENGINE LIGHT ITEM)

ENGINE
TEMPERATURE
SENSOR

~ .PI!IIil
®W
....,
..

(E. F. I. harness>
28-Y/Gi-------------t-'
30- B --------------'

E. C. C. S.
CONTROL
®
UNIT
SEC597B

Harness layout

SEF3661

EF &. EC-116
 TROUBLE DIAGNOSES
Diagnostic Procedure 25 (Cont'd)
B ~MONITOR ~NO FAIL D INSPECTION START

ENG TEMP SEN 174°F

m 1!1
IN.G ... CHECK HARNESS CON-
CHECK INPUT SIGNAL
1) Start engine. TINUITY BETWEEN ENGINE
@ 2) Read engine tempera-
ture sensor signal in
TEMPERATURE SENSOR
AND E.C.U.
"DATA MONITOR" 1) Stop engine.
I RECORD I mode with CONSULT. 2) Disconnect engine temperature
Engine temperature should sensor harness connector.
SEF5861
gradually rise and reach 3) Disconnect E.C.U. harness
m more than 70°C (158°F) connector.
I CIUNIT ~CONNECTOR II (II after engine warm-up. 4) Check harness continuity
28 CIIIIET between E.C.U. terminal @
.....-
[YJ
if) ® OR
2) Make sure that voltage
between E.C.U. ter-
and terminal @.
Continuity should exist.
If N.G., repair harness or
~_§
'-=-------=-
minal @ and ground
connectors.
changes during engine
warm-up.

OOtiD =
SEC075B
Cold~ Hot:
Approximately
5-0V
CHECK COMPONENT
!O.K.

(Engine temperature sensor).

1!1 O.K. Refer to "Electrical Components

[2lli5 ~iS
Inspection".
(See page EF & EC-184.)

II CIUNI T ~ CCNECTOR II

1
28 [!]

l
N.G . .1
CHECK GROUND CIRCUIT. Repair harness or connectors.

~ 1) Stop engine.
2) Disconnect engine temperature

00 SEC076B
sensor harness connector.
3) Disconnect E.C.U. harness
connector.
[!] 4) Check harness continuity

~iS ~iS
between E.C.U. terminal@
and terminal@.

II CIUNIT ~CONNECTOR II O.K.

r
30

~
Reinstall any part removed.

t
00 SEC077B
Erase the self-diagnosis memory.

N.G.
Perform driving test and then 1) Perform E.C.U. input/output
perform self-diagnosis (Mode signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
O.K. pin terminals for damage.
Check the connection at the
E.C.U. harness connector.

( INSPECTION END

EF & EC-117
 TROUBLE DIAGNOSES

Diagnostic Procedure 26
VEHICLE SPEED SENSOR (Code No. 14) ~ (CHECK ENGINE LIGHT ITEM)

FUSE BLOCK
!Refer to •POWER SUPPLY
14 ROUTING• in EL section. l

r----8/R~G-~
16

22 I ,..----- G 20

@®@)
CONNECTOR
-~
IGNITION
SWITCH
0~~ ACC ON ST
I
2
3
4
!1: 5

rll!l EfE@) !Engine

Effi,....,... room

,_,_,_, t'"
LfU ~
jlf)
harness>
!E. F.!. U1ain
harness> harness> Jl:

®® t.
0
BOOY
GROUND !i:iii
CIIJ
t.GI
® @ uc
_,.
+''-

..'... ~J:

ls;l
@)11411111 n
!Brown>
@ [ITII111111
..'...
I <P®
@; : With air bag
!Engine
room
~
VEHICLE
harness> SPEED
E. C. C. S.
CONTROL
® @: Without air bag SENSOR

UNIT ® A/T model

@ : M/T model BATTERY
SEC598B

Harness layout

SEF3661

EF & EC-118
 TROUBLE DIAGNOSES
Diagnostic Procedure 26 (Cont'd)
r.:.1 INSPECTION START
"tl MONITOR "tl NO FAIL D
CAR SPEED SEN Om ph
N.G._..
Make sure that speedometer in ~-~ Check power supply and ground
combination meter operates circuit for instrument panel.
properly. (See EL section.)
O.K. If N.G., repair harness or con-
nectors.
I RECORD I
l
_,
SEF5871

CHECK COMPONENT
r.:.1
II c.-uNIT
53
~CONNECTOR II [it (Vehicle speed sensor).
Refer to "Electrical Components
Inspection".

IQI
18 (See page EF & EC-185.)

-
N.G.
CHECK INPUT SIGNAL CHECK HARNESS CON-

~ (j) 1) Read vehicle speed

sensor signal in "DATA
TINUITY BETWEEN COM-
BINATION METER AND
SEC091B
...
MONITOR" mode E.C.U.
m with CONSULT. 1 ) Remove combination meter

~i5
CONSULT value should be from instrument panel.
~~5~ the same as the speedometer 2) Disconnect combination

II c.-uNIT
53
lot CONNECTOR II mom indication
1 - - - - - OR -------t
~ 1) Jack up rear wheels.
~2) Disconnect E.C.U.
meter harness connector
@.
3) Check harness continuity
between E.C.U. terminal ®
harness connector. and terminal@.
IQI 3) Check resistance be- Continuity should exist.
tween E.C.U. terminal
'---
SEF4431 ® and ground.
With transmission in
neutral, turn both rear
wheels.
Continuity should be
intermittent.

O.K.

Reinstall any part removed.

Erase the self-diagnosis memory.

Perform self-diagnosis (Modell).

~----------.-----------~
O.K.
~ 1) Perform E.C.U. input/output
signal inspection test.
2) If N.G., recheck the E.C.U.
pin terminals for damage.
Check the connection at the
E.C.U. harness connector.

( ___I_N_SP_E_C_T_IO_N_E_N_D___)

EF 8r. EC-119
 TROUBLE DIAGNOSES

Diagnostic Procedure 27
IGNITION SIGNAL (Code No. 21)

POWER TRANSISTOR UNIT IGNITION

COIL

;
RELAY

I~V'Ir~l ®~
d' •S ~m
1!1

mm
[IIi]
!1:!1: !1: !1: !1:

..,..... ,.. .. .,.. .. ,.. @);;;pII

I
., !1:
"' "' "'
@)~ @)~ @@ ®@ @)@

BATTERY
~ w~
>:l 3E::::I
CO CIO
oa:: za::
E. C. C. S.
® IDCI WCI
CONTROL
UNIT No. 6
- -
No.5
-
No.4
-
No.3
-
No.2

SEC599B

Harness layout

SEF3661

EF & EC-120
 TROUBLE DIAGNOSES
Diagnostic Procedure 27 (Cont'd)
INSPECTION START

m N.G.
(!]
CHECK POWER SUPPLY. Check the following items.
1) Turn ignition switch "ON". 1) Ignition coil relay
2) Check voltage between Refer to "Electrical Com-
terminal @ and ground. ponents Inspection".
Voltage: Approx. battery (See page EF & EC-190.)
voltage 2) "G" fusible link
SEF4461 3) Harness continuity between
O.K.
ignition coil relay and
ignition coils.
Continuity should exist.
4) Harness continuity between
ignition coil relay and battery
EB terminal.
Continuity should exist.

[+l lil
~· Check the following items.
CHECK OUTPUT SIGNAL.
1) Start engine. 1) Power transistor unit
2) With logi_c probe make sure Refer to "Electrical Com-
that pulse signal exists ponents Inspection".
between terminal © and (See page EF & EC-185.)
ground. 2) Harness continuity between
Pulse signal should exist. terminal © and power
O.K. transistor terminals CD (No. 1
Logic
cylinder), ®
(No.2 cylinder),
probe ..... @ (No.6 cylinder).
Continuity should exist.
3) Harness continuity between
power transistor terminals
SEF4481
and E.C.U. terminals.
I!] (No.1 cylinder) CD-@ @·@
®-@ @-®
~ (2il i5 [II~CIUII~r~r:JOf810J~CCNE~-~-~c~~~ll
1 2 3 11 12 13
@-© @·CD
Continuity should exist.
~,
_
ID II
CHECK GROUND CIRCUIT. ~1 Repair or replace harness.
I
1) Stop engine.
2) Disconnect ignition coil and
power transistor harness
SEF4491 connectors.
3) Check harness continuity
between terminal @ ( CVl
and ground.
Continuity should exist.

O.K.

Reinstall any part removed.

SEF4501
ffi
EF & EC-121
TROUBLE DIAGNOSES
Diagnostic Procedure 27 (Cont'd)
E~

Erase the self-diagnosis memory.

Perform driving test and then N.G. 1) Perform E.C.U. input/output

perform self-diagnosis (Mode signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
O.K. pin terminals for damage or
the connection of E.C.U.
( INSPECTION END harness connector.

EF & EC-122
 TROUBLE DIAGNOSES

NOTE

EF & EC-123
 TROUBLE DIAGNOSES

Diagnostic Procedure 28
ENGINE CONTROL UNIT (Code No. 31) ~ (CHECK ENGINE LIGHT ITEM)

INSPECTION START

1) Turn ignition switch "ON".

2) Erase the self-diagnosis
memory.

Perform self-diagnosis again.

Does E.C.U. display Code No. Replace E.C.U.

31 again?
No

(~____IN_s_PE_c_T_Io__N_E_N_o____)

EF & EC-124
 TROUBLE DIAGNOSES

NOTE

EF & EC-125
 TROUBLE DIAGNOSES

Diagnostic Procedure 29
E.G.R. FUNCTION (Code No. 32) ~ (CHECK ENGINE LIGHT ITEM): For California model
(Not self-diagnostic item): For Non-California model
E. G. R. CONTROL IGNITION
SOLENOID VALVE SWITCH
OFF ACC ON ST
@~
~,?i'llillil .
I
II 2
"''
CD
3
4 ;l
5
®w "' There are no checking FUSE BLOCK
~~ points 111. (;]. [iJ .[!1 l in CRefer to •POWER SUPPLY

I 02- BR
_j this wiring diagram. CMaln
harness>
B/R
ROUTING• in EL section. l
-~
~- CE.F. !.
~ harness>
(!] CONNECTOR

@@)

8/R
j l CEng I ne room
harness>
8 / R - - + - - - - - - - - - + 8/R
,-------,

•
CBrownl
FR

® § FUSE BLOCK
(Jn RELAY
BOXl
[IJJ

E. C.
CONTROL
c. s. ® FUSIBLE
LINK
HOLDER
UNIT -
BATTERY
SEC600B

Harness layout

SEF3661

EF & EC-126
 TROUBLE DIAGNOSES
Diagnostic Procedure 29 (Cont'd)
INSPECTION START

m
N.G.
CHECK E.G. R. CONTROL Replace or repair
VALVE OPERATION. E. G. R. control valve.
Make sure that E.G.R. control
valve lifts up when applying
vacuum.

O.K.
SEC327 Gl
N.G. CHECK THROTTLE

.
CHECK VACUUM SOURCE
~ CHAMBER VACUUM PORT
t
..
To E.G.R.
. control valve From th rattle TO E.G.R. CONTROL
From a1r
chamber VALVE. FOR CLOGGING.
duct vacuum port
~ 1) Disconnect vacuum hose
~
___.I ___,..,ra ~~ connected to E.G. R. control
solenoid valve.
2) Make sure vacuum exists
when racing engine.
O.K.
[!1
SEF023K CHECK VACUUM HOSE. N.G. If necessary, replace vacuum
Check vacuum hose for clogging, hose or reconnect vacuum hose
cracks or improper connections. firmly.
~- Crack O.K.
(!]
CHECK E.C.U. OUTPUT N.G. (§I CHECK POWER SOURCE
SIGNAL. TO E.G.R. CONTROL
Clogging
1) Check voltage between SOLENOID VALVE.
E.C.U. terminal @Dand 1) Stop engine.
2) Turn ignition switch "ON".
D_ ~'-.. Improper connection
ground under the following
conditions: 3) Check voltage between
SEF816F terminal @ and ground.
Engine
Voltage Voltage: Battery voltage
condition
(!]
Idle 0.7- O.BV
li CHECK GROUND CIRCUIT.
~ I) I
102
c.-uNIT }Of CONNECTOR II Racing
(Less than Battery
1) Turn ignition switch
"OFF".
approx.
voltage 2) Disconnect E.C.U. harness
3,000 rpm) connector.

00 O.K.
3) Disconnect E.G.R. control
solenoid valve harness
connector.

~ID -
SEC1068
4) Check resistance between
E.C.U. terminal@ and
terminal@.
Resistance:
Approximately on
If N.G., repair or replace
harness.

SEC1078

EF & EC-127
 TROUBLE DIAGNOSES
Diagnostic Procedure 29 (Cont'd)

lili5 1 ~~ Replace E.G.R. control solenoid

lr.=l=CIUN==::::::n=i]O[ CONNECTOR II
102 00
CHECK COMPONENT.
Turn E.G.R. control
solenoid valve "ON" and
valve.

"OFF" in "ACTIVE
TEST" mode with CON-
SUL T and check operating
sound.
SEC10BB
OR

I ACTIVE TEST8 0 ®Check E.G.R. control

solenoid valve.
EGR CONT SOLN QN Refer to "Electrical Com-
ponents Inspection".
(See page EF & EC-186.)
====MONITOR====
CAS·RPM (POS) 750rpm
lO.K.

Check resistance of exhaust gas

• • • ,ON/OFF II OFF I temperature sensor.
SEF5881 (See page EF & EC-187.)

IIJ ROAD TEST l

Test condition Reinstall any part removed.
Drive vehicle under the following conditions
with a suitable shift position.
111 Engine speed:
l
2,200±200 rpm Erase the self-diagnosis memory.
12) Intake manifold vacuum: Make sure Code No. 55 is dis-
-30.0±10.0 kPa played in Mode II.
1-225±75 mmHg, -8.86±2.95 inHg)

Driving mode
Ill l
----------i
@ @ Perform driving test under the
~ ~@:Test
following conditions:
~,~;: ® condition
.....-...., @: 21 seconds 1) Warm up engine sufficiently .
or more 2) Use test driving modes
indicated in figure II).

Idling ---~
\ D l Comes
"ON"
Make sure check engine light
Ignition ij®
@ 6 ---+ Perform self-diagnosis and find
does not come "ON" during malfunction code. According to
switch: ~--r-.:::--------­ driving test.
OFF Time
displayed Code No., perform

Until green and red L.E.D.s go off. l Does not come "ON"
electronic control system
inspection.

CD
®
Start engine and warm it up sufficiently.
Turn off ignition switch and keep it off
( INSPECTION END

until red L.E.D. goes off.

@ Start engine and make sure that air
conditioner switch and rear defogger are
turned "OFF'' during driving test.
@ Keep engine running for at least 3 minutes.
@ Shift to suitable gear position and drive in
"Test condition" for at least 21 seconds.
® Decrease engine revolutions to less than
2,000 rpm.
(J) Repeat steps @ through ®
at lest 1 more
time.
SEF302H

EF & EC-128
 TROUBLE DIAGNOSES
Diagnostic Procedure 29 (Cont'd)
D

CHECK ENGINE LIGHT

SEF924F

EF & EC-129
 TROUBLE DIAGNOSES

Diagnostic Procedure 30
EXHAUST GAS SENSOR (Code No. 33 and 53) ~ (CHECK ENGINE LIGHT ITEM)

I GNI TJ ON
EXHAUST EXHAUST SWITCH
GAS GAS
SENSOR-R. H. SENSOR-L H. OFF ACC ON ST
I
2
3

'
5

®~~ FUSE BLOCK

• 1.. mmIilii (Refer to •POWER SUPPLY

ROUTING• in EL section. l
•'
I:I
(Main
harness)
8/R
-:=~
I
I
I
I
I
• CONNECTOR
.ln-.,
~@ @
I
I
I CONNECTOR
I
I

~@D
I
I
11s- a --~,H,-----':
29- w ~:::::::.:~ J+-----l-IT':
55- w
J----- -------------·
,_----- ----------- I
@ @) liJ
ffi Jfl j:;J
B/R~ ~
(E. F. I. <Engine room
harness) B/R+---h_a_r_ne_s_s_l---+-B/R-===f'--,
(Brownl
FR

n
w

§ *
FUSE BLOCK
(Jn RELAY
BOXl

®.___[ill
_ _,

ENGINE
GROUND
E. c. C. s. FUSIBLE
CONTROL LINK
UNIT HOLDER
BATTERY

SEC601B

Harness layout
~L----

-~
Exhaust gas sensor ·
::::::===r-==r-rrt===r::=====harness con~tor ~
SEF3661 - \ '.----=(left side}- SEF4531

~~
Exhaust gas sensor-
harness c~~~
(right sid~ ~
~-----~ (

EF & EC-130
 TROUBLE DIAGNOSES
Diagnostic Procedure 30 (Cont'd)
INSPECTION START

CHECK POWER SUPPLY. N.G. CHECK HARNESS CON-

~
1) Turn ignition switch "ON". TINUITY BETWEEN
2) Check voltage between EXHAUST GAS SENSOR
terminal @and ground. AND FUSE.
Voltage: Battery voltage 1) Turn ignition switch "OFF".
2) Disconnect exhaust gas sensor
O.K.
SEC111 B harness connector.
3) Disconnect "ENG CONT"
[;] fuse.

~ i5
4) Check harness continuity

cill0 r::i.t i5 between terminal @ and the

-r-G-<B"ENG CONT" fuse

fuse.
Continuity should exist
If N.G., repair harness or
connectors.
[ill
~
00 CHECK INPUT SIGNAL. ~ CHECK HARNESS CON-
SEC112B
1) Start engine and warm it up TINUITY BETWEEN
[!] sufficiently. EXHAUST GAS SENSOR
..:rMONITOR ~NO FAIL D fF.i\ 2) Make sure that "M/R AND E.C.U.
CAS·RPM(POS) 2087rpm ~ F/C MNT(R)" in 1) Stop engine.
M/R F/C MNT LEAN "DATA MONITOR" 2) Disconnect exhaust gas
M/R F/C MNT-R RICH
mode indicates "RICH" sensor harness connector.
and "LEAN" period- 3) Disconnect E.C.U.
ically more than 5 times harness con nectar.
during 10 seconds at 4) Check harness continuity
2,000 rpm. between E.C.U.terminals and
I RECORD I exhaust gas sensor terminals.
SEF1601
t<U\ 2) Make sure that red
Right side: ®- @
Left side: ®-@
\& L.E.D. on E.C.U. goes
Continuity should exist.
on and off periodically
If N.G., repair harness or
more than 5 times
connectors.
during 10 seconds at
2,000 rpm in self-
diagnosis Mode II.
l O.K.

O.K. I Replace exhaust gas sensor. I

SEF1521
CHECK GROUND CIRCUIT. ~r
~~ Repair harness or connectors. I
L __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _
1) Stop engine.
2) Disconnect exhaust gas

(;) l:tt i{) ~ [11 i8 sensor harness connector.

3) Check harness continuity
~ I c.-'UNI T JOf CONNECTOR II between terminal © and
(£Th l.9J 29 55
(Right \ rfQilfQl -! ground.
Continuity should exist
s1de) -~
O.K.
~ =
(Left [ill
side)
SEF4551

EF & EC-131
 TROUBLE DIAGNOSES
Diagnostic Procedure 30 (Cont'd}
II
~llli5 l
Reinstall any part removed.
In I
,_____ l
Erase the self-diagnosis memory.

00 -=-
SEC115B
l
Perform driving test and then N.G.
1) Perform E.C.U. input/output
perform self-diagnosis (Mode signal inspection test.
II) again. 2) If N.G., recheck E.C.U. pin
l O.K. terminals for damage or the
connection of E.C.U. harness
INSPECTION END ) connector.

EF & EC-132
 TROUBLE DIAGNOSES

NOTE

EF 8r. EC-133
 TROUBLE DIAGNOSES

Diagnostic Procedure 31
DETONATION SENSOR (Code No. 34)

<Sub-

Cr----------~

•
31:
I
harness>

-<>mm
w ~-e-o DETONATION
SENSOR

® 31:

I I
,
I I
I 1
I I
I 1
I 1
I 1
I I
I 1
I 1
I I
I 1
I I
I 1
I 1
I 1
23- w ~:::::::::::::::::::::::::::_J
<E. F. I. harness)

ENGINE
GROUND
E. c. c. s.
CONTROL
UNIT
SEC602B

SEF3661

EF 8r. EC-134
 TROUBLE DIAGNOSES
Diagnostic Procedure 31 (Cont'd)
m INSPECTION START

~i5 ~15 m l
~ II CAIN IT g CONNECTOR
23
II CHECK INPUT· SIGNAL
CIRCUIT.
H Repair harness or connectors.

1) Make sure that ignition switch

is in "OFF" position.
[ill 2) Disconnect detonation sensor

'----- ~
SEF4571
sub-harness connector.
3) Disconnect E.C.U. harness
connector.
El 4) Check harness continuity

~ [lti5
r----
between E.C.U. terminal @
and terminal @.
Continuity should exist.
[ill
El l O.K.

00
'-----
CHECK GROUND CIRCUIT.
1) Check harness continuity
AI Repair harness or connectors.
I
between terminal@ and
SEF4581 = ground.
Continuity should exist.

LO.K.

CHECK COMPONENT
(Detonation sensor).
Refer to "Electrical Com-
ponents Inspection".
(See page E F & EC-189.)

l O.K.

Reinstall any part removed.

!
Erase the self-diagnosis memory.
J
!
Perform driving test and then N.G.
1) Perform E.C.U. input/output
perform self-diagnosis (Mode ~
signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
! O.K.
pin terminals for damage or
the connection of E.C.U.
( INSPECTION END ) harness connector.

EF & EC-135
 TROUBLE DIAGNOSES

Diagnostic Procedure 32
EXHAUST GAS TEMPERATURE SENSOR {Code No. 35) ~ {CHECK ENGINE LIGHT ITEM);
CALIFORNIA MODEL ONLY

~[!]
30 _ B _ __c(::::.E.c...:F..:...~I;_.c...:h.:.:B::...r:..:.ne::..:S:..:S::....l- - - o - - ;

39- OR/B C!O----------,

~mli1
CL
ID
~ ID
0

®~

md~~r~
@: For Cali fornla

E. C. C. S.
CONTROL EXHAUST GAS
UNIT TEMPERATURE SEC603B
SENSOR
Harness layout
Exhaust gas temperature

r
ensor harness connector

SEF3661

EF & EC-136
 TROUBLE DIAGNOSES
Diagnostic Procedure 32 (Cont'd)
INSPECTION START
'(;MONITOR '(;NQ FAIL D
EGR TEMP SEN 3.1V m N.G.
[;)
CHECK INPUT SIGNAL. CHECK HARNESS CON-
1) Start engine and warm it up
r----+ TINUITY BETWEEN E.C.U.
sufficiently. AND EXHAUST GAS
@ 2) Read exhaust gas
temperature sensor
TEMPERATURE SENSOR.
1) Stop engine.
RECORD signal in "DATA 2) Disconnect E.C.U. harness
SEF5891 MONITOR" mode connector.
with CONSULT. 3) Disconnect exhaust gas
m [1t £) Voltage: temperature sensor harness
~ CCNIECTOR I COW£T
II CIUNIT Less than 4.5V connector.
4) Check continuity between
39
OR
® 2) Check voltage between
E.C.U. terminal® and
terminal@.

00 I VI
~ _§)~
'-'-----'--
E.C.U. terminal ® and
ground.
Continuity should exist.

l O.K.

~~ID
Voltage:

~ cff~H less than 4.5V

CHECK COMPONENT
-=- O.K. (Exhaust gas temperature
SEC123B
sensor).
Refer to "Electrical Com-
ponents Inspection".

~i5 II CIUNIT JOf CONNECTOR II

(See page EF & EC-187.)

r'- - - -'+4~e-l- - - '1

[i
~,
CHECK GROUND CIRCUIT.
1) Stop engine.
Repair harness or connectors.
I
2) Disconnect E.C.U. harness
connector.
SEC124B
3) Disconnect exhaust gas tern-
perature sensor harness
connector.
4) Check harness continuity
between E.C.U. terminal ®
- and terminal @.
[ill O.K.

[lt&')
II CIUNIT
l
JOfi=CONNE===c=rOR==illl 1
Reinstall any part removed.

SEC1256
Erase the self-diagnosis memory.

Perform driving test and then N.G.

perform self-diagnosis (Mode
r-------. 1) Perform E.C.U. input/output
signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
O.K. pin terminals for damage or
the connection of E.C.U.
( INSPECTION END ) harness connector.

EF & EC-137
 TROUBLE DIAGNOSES

Diagnostic Procedure 33
FUEL TEMPERATURE SENSOR (Code No. 42)
FUEL
TEMPERATURE

r
SENSOR

if~®
I;] ~

(E. F. 1. harness)
36-BR------~~~~~=---------~

E. C. C. S.
CONTROL
®
UNIT

SEC604B

Harness layout

SEF3661

EF & EC-138
 TROUBLE DIAGNOSES
Diagnostic Procedure 33 {Cont'd)
B <:rMONITOR <:rNO FAIL D INSPECTION START

FUEL TEMP SEN 78°F B

N.G.
m
00
CHECK INPUT SIGNAL.
Read fuel temperature
sensor signal in "DATA
f----+ CHECK HARNESS CON-
TINUITY BETWEEN E.C.U.
AND FUEL TEMPERATURE
MONITOR" mode with SENSOR.
CONSULT after engine 1) Stop engine.
I RECORD I warm-up. 2) Disconnect E.C.U. harness
SEF5901
Fuel temperature: connector.
20- 60°C (68 -140°F) 3) Disconnect exhaust gas
B OR temperature sensor harness
~
~CONNECTOR II I) connector.
COllET
II CAINIT ®Check voltage between 4) Check continuity between
36 E.C.U. terminal ® and E.C.U. terminal ®and fuel
- ground after engine warm· temperature terminal.
@a [Y] up.
Voltage: 0- s.ov
Continuity should exist.
<±) ~~----
O.K. l O.K.

~J~LD
~ cff~H -?
CHECK COMPONENT
SEF6001
(Fuel temperature sensor).
Refer to "Electrical Com-
m ponents Inspection".

r:itio
EJ
oo
I CAINIT )Of CONNECTOR II Reinstall any part removed.
(See page EF & EC-190.)

36

Erase the self-diagnosis memory.

SEF4691 l N.G.
Perform driving test and then
perform self-diagnosis (Mode
r-------. 1) Perform E.C.U. input/output
signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
O.K. pin terminals for damage or
the connection of E.C.U.
( INSPECTION END ) harness connector.

EF & EC-139
 TROUBLE DIAGNOSES

Diagnostic Procedure 34
THROTTLE SENSOR (Code No. 43) ~ (CHECK ENGINE LIGHT ITEM)

30- B - - - - - - - - -CE.-F.-I.- =harness>

---------,
38- w ~-----------------------------------------------,
----------------------------------------------,
48-0R/L - - - + - - - - - - - - - - -------,'

30 30

48 48

·E. C. C. S.
CONTROL
® THROTTLE
UNIT ENGINE SENSOR
GROUND
SEC605B

Harness layout

SEF4701 SEF3661

EF 8r. EC-140
 TROUBLE DIAGNOSES
Diagnostic Procedure 34 (Cont'd)
m INSPECTION START
coED [ill)
N.G.
ru CHECK POWER SOURCE. CHECK HARNESS CON-

00 ~§
~
1) Turn ignition switch "ON".
2) Check voltage between
terminal CD and ground.
TINUITY BETWEEN
THROTTLE SENSOR AND
E.C.U.

8 -=-
SEC1288
Voltage:
Approximately 5.0V
1) Turn ignition switch "OFF".
2) Disconnect throttle sensor
harness connector.
O.K. 3) Disconnect E.C.U. harness
connector.
4) Check harness continuity
between E.C.U. terminal @
CAJNJT JOf CCHIECTCIR II and terminal (f).
Continuity should exist.

~-;------JI
If N.G., repair harness or
connectors.

[!J
,---------''------------, N .G.
CHECK INPUT SIGNAL. ADJUST THROTTLE
SEC1298
fF.i\ Read throttle sensor SENSOR INITIAL POSITION.
~ output voltage in (See page EF & EC-187.)
• THROTILE SEN ADJ • D "WORK SUPPORT' mode
with CONSULT.
Throttle valve fully closed:
1
* * * * ADJ MONITOR**** CHECK HARNESS CON-
0.4- 0.5V TINUITY BETWEEN
THROTILE SEN 0.46V
Throttle valve fully open: THROTTLE SENSOR AND
=CAS·RPM
= = MONITOR
(POS)
= = =
800rpm
Approx. 4.0V E.C.U.
IDLE POSITION ON ~--------OR----~
1) Turn ignition switch "OFF".
2) Disconnect throttle sensor
~ Make sure that voltage be- harness connector.
SEF1471 ~ tween E.C.U. terminal @ 3) Disconnect E.C.U.harness
and ground changes when connector.
[!J ~~ accelerator pedal is de- 4) Check harness continuity
II CIUNJT ]Of CCHECTCIR II L1lllllDI 'SJ pressed. between E.C.U. terminal @
38 Voltage: and terminal @.
Throttle valve fully Continuity should exist.
closed: If N.G., repair harness or
0.4-0.SV connectors.
Throttle valve fully
open: ~O.K.
Approx. 4.0V
CHECK COMPONENT
SEC1308 O.K. (Throttle sensor).
Refer to "Electrical• Com-
ponents Inspection".
(See page EF & EC-187.)

,
SEC1318 EB
EF & EC-141
 TROUBLE DIAGNOSES
Diagnostic Procedure 34 (Cont'd)
1!1

~15 II 00 ~[ili5II Ill 1

CHECK GROUND CIRCUIT. N.G. 1) Check harness continuity
CAJNIT CCINNECTCit 1) Turn ignition switch "OFF". between throttle sensor and
caf® 30
2) Disconnect E.C.U. harness ground.
connector. 2) E.C.U. ground circuit.
3) Disconnect throttle sensor
In I harness connector.
4) Check resistance between
'--- E.C.U. terminal ® and
SEC1328
terminal@.
Continuity should exist.
t O.K. -

Reinstall any part removed.

l
Erase the self-diagnosis memory.

l N.G.
Perform driving test and then 1) Perform E.C.U. input/output
perform self-diagnosis (Mode signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
l O.K. pin terminals damage or
the connection of E.C.U.
INSPECTION END harness connector.

EF & EC-142
 TROUBLE DIAGNOSES

NOTE

EF & EC-143
 TROUBLE DIAGNOSES

Diagnostic Procedure 35
INJECTOR LEAK (Code No. 45) ~ (CHECK ENGINE
LIGHT ITEM); CALIFORNIA MODEL ONLY

Wet with fuel?

c INSPECTION START

Start engine and warm it up

sufficiently.
SEF832F

li) ROAD TEST Make sure engine runs smoothly Runs smoothly
Test condition
Drive vehicle under the following conditions with
a suitable shift position.
at idle after warm-up.
Does not run
1
Race engine two or three times
(1) Engine speed: 2,200±200rpm smoothly
(2) Intake manifold vacuum: under no-load, then run engine
-38.7±9.3 kPa Set the diagnosis mode selector at idle speed.
1-290±70 mmHg, -11.42±2.76 inHg) of E.C.U. to Mode II.
Driving mode
@ : 40 seconds or more
@ : 5 seconds or more
© 10 seconds or more
1
These inspections should be per-
Vehicle These inspections should be per-
formed on both exhaust gas
driving formed on both exhaust gas
sensors by changing monitor
sensors by changing monitor
from left side to right side.
Idling _ from left side to right side.
(Refer to EF & EC-54.)
Ignition (Refer to EF & EC-54.)
Set diagnosis to Mode II and
switch '---'---!-'"-----'-! Check if the red L.E.D. on
OFF ® Time
E.C.U. stays off during 10
check that red L.E.D. on E.C.U.
CDStart engine and warm it up sufficiently.
seconds at 1,000 rpm under
blinks at 2,000 rpm under
® Turn ignition switch OFF and wait for at no-load.
least 10 seconds.
@ Start engine and keep it at idle speed for at
least 40 seconds.
@ Shift to a suitable gear position and drive in
no-load.
Stays off 1 Does not
stay off
Does not blinkT
Check idle CO%.
Blinks

"Test condition" for at least 5 seconds.

@ Repeat steps ® through @ at least 5 times. Check mixture ratio (See page EF & EC-37.)
SEF5831 feedback system.

c
(See page EF & EC-37.)
INSPECTION END )

m
Yes Replace the injector in which
Remove all spark plugs from
intake manifold. Are plugs wet cylinder spark plug is wet with
with fuel? fuel.

1
CHECK ENGINE LIGHT
No
SEF924F

Remove injector assembly. (Go to @ on next page.)

(See page EF & EC-192.)
Keep fuel hose and all injectors
connected to injector gallery.

EF & EC-144
 TROUBLE DIAGNOSES
Diagnostic Procedure 35 (Cont'd)
E~

Drips Replace the injectors which

Turn ignition switch "ON".
Make sure fuel does not drip from
r----+ allow fuel to drip.
injector.
Does not drip

Reinstall any part removed.

Erase the self-diagnosis memory .

A
. Make sure Code No. 55 is dis-
played in Mode II.

1) Start engine and warm it up

sufficiently.
2) Disconnect both exhaust gas
sensor harness connectors for
at least 30 seconds at 1,500
rpm.

Connect both exhaust gas sensor

harness connectors.

(;]
Perform driving test as indicated
in figure (;].

[!) Comes
Make sure check engine light "ON"
1) Perform self-diagnosis and
does not come "ON" while
1--------+
find malfunction code.
engine is running. 2) According to displayed Code
Does not come "ON" No., perform "Diagnostic
Procedure".

c INSPECTION END )
3) If Code No. 45 is displayed
again, replace all injectors,
then perform "Diagnostic
Procedure".

EF &. EC-145
 TROUBLE DIAGNOSES

Diagnostic Procedure 36
INJECTOR CIRCUIT (Code No. 51) ~ (CHECK ENGINE LIGHT ITEM): For California model
(Not self-diagnostic item): For Non-California model
INJECTOR

I 1 l l 1
IDI- W
I 03-W/R
IDS- L
II D-W/G
112-W/B
~ ~ <Engine room
_~ ..t+L_ harness>
114-W/L ~ W/8--w w-W/8
!E. F. !. harness>
lWh i tel
[!]
58-WIB

FUSIBLE
E. c. c. s.
CONTROL
® LINK
HOLDER -
UNJT BATTERY SEC606B

Harness layout

SEF3661

EF & EC-146
 TROUBLE DIAGNOSES
Diagnostic Procedure 36 (Cont'd)
( INSPECTION START

CHECK POWER SUPPLY. I N.G . ., CHECK HARNESS

Check voltage between terminal CONTINUITY BETWEEN
@and ground. INJECTORS AND BATTERY.
Voltage: Battery voltage 1) Turn ignition switch "OFF".
2) Disconnect injector harness
O.K.
connector.
SEF4721
3) Disconnect battery EB ter-
minal.
4) Check harness continuity
between terminal @and
battery EB terminal.
Continuity should exist.
5) Check "G" fusible link.
If N.G., replace harness,
connector or fusible link.
IIISCDIIIKI

18 CHECK HARNESS CON- ~ Repair harness or connectors.

SEF4731
TINUITY BETWEEN
INJECTORS AND E.C.U.
1) Disconnect battery EB
terminal.
2) Disconnect injector harness
II CIUNIT ]Of CONNECTOR II connectors and E.C.U.

,No6)
101 103 105 110 112 114 _ . .,

U~l
harness connector.
3) Check harness continuity,
following figure [+l .
[ill (No.5) Continuity should exist.

8 O.K.
-+---18No. 4)
CHECK COMPONENT ~~R
~ · or rep 1ace ··
epa1r InJector.
(No.3) (Injector).

8 (No.2)
Refer to "Electrical Com·
ponents Inspection".
(See page EF & EC-189.)
8 (No.1) O.K.

8 Reinstall any part removed.

SEF4741

Erase the self-diagnosis memory.

Perform driving test and then ~ 1) Perform E.C.U. input/output

perform self-diagnosis (Mode signal inspection test.
II) again. 2) If N.G., recheck the E.C.U.
O.K. pin terminals for damage or
the connection of E.C.U.
harness connector.
( ____I_N_SP_E_C_T_IO_N__E_N_D____)

EF & EC-147
 TROUBLE DIAGNOSES

Diagnostic Procedure 37
THROTTLE VALVE SWITCH (Idle position) (Not self-diagnostic item)

mm
.? <E. F. J. harness)
54-LG/R----------------------------,
57-G/R----------------------------,

E. C. C. S. THROTTLE VALVE
CONTROL SWITCH
UNJT (Idle position)
SEC607B

Harness layout

SEF3661

EF & EC-148
 TROUBLE DIAGNOSES
Diagnostic Procedure 37 (Cont'd)
INSPECTION START
II CIUNIT JOf CONNECTOR II
~54
CHECK INPUT SIGNAL. N.G._ CHECK HARNESS CON-
CIIIIIIECT
1) Turn ignition switch "ON". r----+ TINUITY BETWEEN E.C.U.
£) 2) Check voltage between
E.C.U. terminal @ and
AND THROTTLE VALVE
SWITCH.
ground. 1) Turn ignition switch "OFF".
Voltage: 2) Disconnect throttle valve
SEF4761
Throttle valve fully closed: switch harness connector.
9.0 -10.0V 3) Disconnect E.C.U. harness
Throttle valve fully open:
~15
connector.
ov 4) Check harness continuity
II Cl\loll T ]Of CCMIECTCIR II ~O.K.
between E.C.U. terminals
57 54 @,(@and terminals@,

c INSPECTION END )
@.
Continuity should exist.
If N.G., repair harness or
connectors.

SEC136B
t O.K.

Check if throttle valve switch

(throttle sensor body) is
installed in proper position.
(See page EF & EC-187.)

~O.K.
CHECK COMPONENT
(throttle valve switch).
Refer to "Electrical Com·
ponents Inspection".
(See page EF & EC-189.)

EF & EC-149
 TROUBLE DIAGNOSES

START SIGNAL ( Diagnostic Procedure 38

Not self-diagnostic item)

IGNITION
SWITCH
I' OFF ACC ON s
I D
2
3 D
4 (
5

FUSE BLOCK

c"""'* :"F;-;~i
<Refer to ~POWER SUPPL

43-8/Y--- 8 /Y~ ~ 8 /Y-h_a_r_n_es_s_>_+-_-~----_-_-_-_-_-_-_-_-B/Y

<E. F. 1.
harness> <MaIn
8/Y
68
8A ~
lll1h
'n EL """'
I
o~ l

@) ____j

® @ ®EfE
@J)I=m
(Engine room l
harness> •

• •

E. c. C. S. FUSIBLE
CONTROL LINK
UNIT HOLDER
BATTERY
SEC608B

Harness layout

E.C.U. harness protector

SEF3661

EF & EC-150
 TROUBLE DIAGNOSES
Diagnostic Procedure 38 (Cont'd)
INSPECTION START
trMONITOR . trNO FAIL D
START SIGNAL
IDLE POSITION
AIR COND SIG
OFF
ON
OFF
m l N.G.
I;]
CHECK INPUT SIGNAL. Check the following items.
NEUTRAL SW ON

00
1) Turn ignition switch "ON".
2) Check start signal in
"DATA MONITOR"
1) "G" fusible link
2) "7.5A" fuse
3) Ignition switch
mode with CONSULT. 4) Harness continuity between
RECORD E.C.U. and ignition switch
IGN "ON" OFF Continuity should exist.
SEF1491
IGN "START" ON 5) Harness continuity between
battery EB terminal and
II CAJNI T JOf CONNECTOR II OR
43
® 2) Check voltage between
E.C.U. terminal @ and
ignition switch
Continuity should exist.

ground.
CONNECT
When cranking:
£) Battery voltage
Except above:

00-00
SEF4771
ov
tO.K.

c.-'UNI T ]Of CONNECTOR II ( INSPECTION END

----""'
L~
~l:ili57
SEF4781

EF &. EC-151
 TROUBLE DIAGNOSES

Diagnostic Procedure 39
POWER STEERING OIL PRESSURE SWITCH (Not self-diagnostic item)

<E. F. I. ~ frn'l <Engine room

~ ~
34-

~
G
harness>

GtiG harness>

ml!l <Brown>

CD

®_fi®
BODY GROUND
POWER
E. C. C. S.
CONTROL
® STEERING
OIL
UNIT PRESSURE
SWITCH
SEC609B

Harness layout

SEF3661

EF & EC-152
 TROUBLE DIAGNOSES
Diagnostic Procedure 39 (Cont'd)
m -t!MONITOR .-t!NO FAIL D INSPECTION START

PW/ST SIGNAL OFF l

CHECK INPUT SIGNAL.
1) Start engine.
~C~ __ IN_s_P_E_cT_I_o_N__
E_N_D__ ~)
rF.i\ 2) Check power steering
~ oil pressure switch
signal in "DATA
I RECORD I MONITOR" mode with
SEF5911 CONSULT.
Steering is neutral: OFF
m Steering is turned: ON

II CIUNIT g CONNECTOR II ~i) 1 - - - - - - - - OR - - - - - - 1

34
~ 2) Check voltage between

~
00 ~ E.C.U. terminal ® and
ground.
Steering is neutral:
~

...
@iD Approx. 8 - 9V
Steering is turned:
Approx. OV
SEF4791
lN.G.

CHECK HARNESS N.G. =i Repair or replace harness or

CONTINUITY BETWEEN connectors. I
POWER STEERING OIL
II CAJNI T JOf CONNECTOR II PRESSURE SWITCH AND
34
E.C.U.
1) Turn ignition switch "OFF".
2) Disconnect E.C.U. harness
connector and power steering
oil pressure switch harness
seF4SOI connector.
L--------------=:.=.:.....:.=c:...~ 3) Check harness continuity
[!) between E.C.U. terminal

~ ~
IIISCOIIIIECT
00 ®and@.
Continuity should exist.

I?J ,---

[ill lO.K.
N.G.
CHECK GROUND CIRCUIT
'----
Check harness continuity
between terminal @ and
ground.
SEF4811 -= Continuity should exist.

1 O.K.

CHECK COMPONENT.
(Power steering oil pressure
switch)
Refer to "Electrical Components
Inspection". (See page EF & EC-
190.)

. EF & EC-153
 TROUBLE DIAGNOSES

Diagnostic Procedure 40
NEUTRAL SWITCH & A/T CONTROL UNIT (NEUTRAL SIGNAL) CIRCUIT
(Not self-diagnostic item)

@ A/T model
@ M/T model

~mm @®
(E. F. I. @ @ (Engine room j '- (A I ternator

~
harness> harness> harness>
Y/L Y / L - - Q - - - - - - - - - - - - { Y/L YIG 1 ) - - - - ,
1: @)@ 1:

(Brown> r----Q>-U B CI:iJ nOJ B LJ---,

CBiuel

83±311111,~ PTh1f9 I l5<l I p<l Pf'm I 0

EHE I I I I I'~ Q'@J I p<l I l5<l b(f)(l)(b(l I @)d@)

NEUTRAL
BODY GROUND
E. C.
CONTROL
c. s. ® A/T CONTROL UNIT
SWITCH

UNIT SEC610B

Harness layout

SEF3661

EF & EC-154
 TROUBLE DIAGNOSES
Diagnostic Procedure 40 (Cont'd)
B INSPECTION START
~MONITOR ~NO FAIL D
START SIGNAL OFF
IDLE POSITION
AIR COND SIG
NEUTRAL SW
ON
OFF
ON
CHECK INPUT SIGNAL.
1) Turn ignition switch "ON".
~C~ ____ IN_S_P_EC_T_I_O_N__
EN__
D __ ~)
fF.I\2) Check neutral switch
~ signal in "DATA
MONITOR" mode with
I RECORD I CONSULT.
SEF1491 "N" or "P": ON
Except above: OFF
B 1-------0R
II CAJNIT B CONNECTOR II tOO t<U\2) Check voltage between
44 ~ E.C.U. terminal @ and

~
CONNECT I vi 8 ground.
"N" or "P": Approx. OV
Except above: 8 - 9V
£) j<±>G
'-=-----=-

-=- CHECK HARNESS CON- ~ Repair or replace harness or

SEF4821 TINUITY BETWEEN E.C.U. I I connectors.
AND NEUTRAL SWITCH
(A/T CONTROL UNIT)
1) Turn the ignition switch
E.C.U. control unit connector
"OFF".
CIUNIT ]Of CONNECTOR II ® 2) Disconnect E.C.U. harness
connector and neutral switch
~i5 harness connector (A/T con-
trol unit harness connector.)
13 A/T control unit
3) Check harness continuity
connector between E.C.U. terminal @
and@ (@J).
SEF4831
Continuity should exist.

[!] l O.K.
~--------~--------~N~.G~·----------~
CHECK GROUND CIRCUIT r-

(M/T only)
Check harness continuity
between terminal @ and
ground.
Continuity should exist.

SEF4841
= 1 O.K.

CHECK COMPONENT.
• (Neutral switch)
Refer to "Electrical Compo-
nents Inspection".
(See page EF & EC-189.)
• (A/T control unit)
See A/T section.
• (Inhibitor switch)
Refer to "Electrical
Components Inspection"
(See page EF & EC-190.)

EF & EC-155
 TROUBLE DIAGNOSES

Diagnostic Procedure 41
FUEL PUMP (Not self-diagnostic item)
FUEL PUMP RELAY

~ /:1 m ®®

/:JI!]
104-B/P
(E. F. J.
harness>
I
8/P
® ®

I,J~
rm,
l'f'r'l®
!Main harness>
OR
Jl OR
!Body
harness>
---.__,

Ill

Em®
35- PU
-------- -------------,
r------., r------------ 1 1
I I I 1 I
I 1 I
I I I
I
I
1 I
1 I

Ill

@)
w ~ ~
~

~ TITITITI TI Q~
. ..
~
~
It: "' " t:l
I;]
@: 2 seater model ~!!:!! ~
E. c. c. s.
CONTROL
® @: 2+2 seater model FUSIBLE
LINK
UNIT @: Turbo model HOLDER FUEL FUEL
-=- PUMP PUMP
BATTERY
SEC611B

Harness layout

SEF3661

~
SEF4851

EF & EC-156
 TROUBLE DIAGNOSES
Diagnostic Procedure 41 {Cont'd)
m2 seater INSPECTION START

m lil
IN.G ... Check the following items.
CHECK POWER SUPPLY.
1) Turn ignition switch "ON". 1) "G" fusible link
2) Check voltage between fuel 2) Harness continuity between
pump connector terminal •
battery EB
terminal and
fuel pump relay
@ and ground.
Battery voltage indication •
fuel pump relay and fuel
pump
SEF7671
should appear for 1 second
after turning ignition switch •
fuel pump relay and
E.C.U. terminal@
"ON".
Continuity should exist.
O.K.

[lti5 [!] 1
CHECK COMPONENT.

/!iii
~
2 seater
00
(Fuel pump relay).
Perform "Fl,!EL PUMP
RELAY TEST""in

io~
"ACTIVE TEST" mode
with CONSULT.
OR
~ 2+2
® Refer to "Eiect~ical Com-

i5® ponents Inspection".

(See page EF & EC-190.)

l!l ~
IN.G .• Check the following items.
CHECK GROUND CIRCUIT.
II 1:.1\JNIT ]Of CONNECTOR II Check voltage betweeen fuel Harness continuity between
pump terminal (~J and ground • fuel pump and fuel pump
under the following conditions. control unit
SEF7681
Idling Approx. 3 - 6V
• fuel pump control unit and
E.C.U. terminal (@
For 30 seconds Continuity should exist.
trMONITOR trNO FAIL D after starting Battery voltage
engine lO.K.
PW/ST SIGNAL OFF

CHECK COMPONENT.
jo.K.
:!:
(Fuel pump).

( INSPECTION END ) Refer to "Electrical Components

Inspection".
(See page EF & EC-185.)
RECORD
TN.G.
SEF5911

Replace fuel pump control unit.

I!] 2 seater

~[I]
COllET

£)
2+2

~@
CIIMIECT
£) SEF7691

EF & EC-157
 TROUBLE DIAGNOSES
Diagnostic Procedure 41 (Cont'd)

SEF7701

EF & EC-158
 TROUBLE DIAGNOSES

NOTE

EF 8t EC-159
 T8QUBLE·"DIAGNOSES

Diagnostic Procedure 42
AIR REGULATOR (Not self-diagnostic item)

AIR REGULATOR FUEL

PUMP
RELAY

l!J-s>EIIillil
W®
[1]-¢1!1
r?91®
lEG.. CDCD
"'"'
0 0~ ~~

18 18 __::.I
18-P/B-t-L
(E. F. I.
harness)
i::._j
____ , "'~
(Main
harness)

~®
~@D
"' CEng i ne room
~ harness)

~j ;IT ~~m
TI
g~goo
TijTI!
~
ENGINE
GROUND FUSIBLE
E. C. C.
CONTROL
s. ® LINK
HOLDER
UNIT -
BATTERY

SEC612B-

Harness layout

SEF3661
 TROUBLE DIAGNOSES
Diagnostic Procedure 42 (Cont'd)
INSPECTION START

CHECK POWER SUPPLY. N.G ....., Check the following items.

1) Start engine. 1) Harness continuity between
2) Check voltage between air • air regulator and fuel
regulator terminal @and pump relay
ground. • fuel pump relay and
Voltage: Battery voltage battery EB terminal
-=
SEF4921 O.K. • fuel pump relay and
E.C.U. terminal @
m Continuity should exist.
2) "G" fusible link
ffi9} r:tl i5 ~ l
-
~
CHECK COMPONENT.
[Jl] (Fuel pump relay).
llliCOIIIIECT

18
L..:...--
~
llsaiiiiECT
fF.i\ Perform "FUEL PUMP
~RELAY TEST" in

II CAJNI T
18
B CONNECTOR II
rMeo
"ACTIVE TEST" mode
with CONSULT.
OR-------1

t 8 ]
t<a\ Refer to "Electrical Com·
~ ponents Inspection".
(See page EF & EC-190.)

CHECK GROUND CIRCUIT. N.G . .I Repair or replace harness or

Check harness continuity connectors.
between air regulator terminal
(tv and ground.
SEF4931
Continuity should exist.
O.K.
IACTIVE TESTI 0
N.G.
FUEL PUMP RELAY ON CHECK COMPONENT. Repair or replace air regulator.
(Air regulator).
===MONITOR=== Refer to "Electrical Components
CAS·RPM (POS) 737rpm Inspection".
(See page EF & EC-188.)
O.K .
• • • • • ,ON/OFFII OFF I
SEF5921 INSPECTION END

l!l
r:tl b a
DISCIHIIIECT

18

SEF4941

EF & EC-161
 TROUBLE DIAGNOSES

Diagnostic Procedure 43
A.A. C. VALVE (Not self-diagnostic item)

IGNITION
A.A. C. SWITCH
VALVE ~ OFF ACC ON ST
1

rm @~
2
3

~~FJ(i)[i] if·~
4
5

[i] W®
!
4-G/L_j
..JO:

''
""'
m
1:1
FUSE BLOCK
!Refer- to •POWER SUPPLY
ROUTING• in EL section. l
!Main
har-nessl -~
B/R

CONNECTOR
!E. F. J.
har-nessl

FR

n
w

§ *
FUSE BLOCK
(In RELAY
BOXl

@....__[]]
_ _,

E. C.
CONTROL
c. s. ®
UNIT
BATTERY

SEC613B

Harness layout

SEF3661

EF & EC-162
 TROUBLE DIAGNOSES
Diagnostic Procedure 43 (Cont'd)
INSPECTION START

.----- N.G .
CHECK POWER SUPPLY. Check the following items.
00 1) Turn ignition switch "ON". 1) "G" fusible link
'----!~(++)
'-1+-----
2) Check voltage between 2) Ignition switch
A.A.C. valve terminal @ 3) "1 OA" fuses
and ground. 4) Harness continuity between
Voltage: Battery voltage. terminals:
SEF4961
• A.A.C. valve and ignition
O.K.
switch
• Ignition switch and
battery EB terminal.

N.G . .I Repair or replace harness or

CHECK HARNESS CON-
TINUITY BETWEEN A.A.C. connectors.
VALVE AND E.C.U.
Check harness continuity
between A.A.C. valve terminal
@and E.C.U. terminal@.
Continuity should exist.

O.K.

N.G.
CHECK COMPONENT. Repair or replace A.A.C. valve.
(A.A.C. valve).
fF.i\Perform "AAC VALVE
W OPENING TEST" in
"ACTIVE TEST" mode
with CONSULT.

~--------OR--------~

SEF4971
~ Refer to "Electrical Com-
~ ponents Inspection".

litiO r:il i5 (See page EF & EC-188.)

urr==~=n=i]Of CONNECTOR II ~
O.K.

~ ~
4
( _____IN_S_P_E_C_T_IO_N
__E_N_D
____

SEF4981

• ACTIVE TEST. 0
AAC/V OPENING 50%

=CAS·RPM
= = MONITOR
(POS)
= ==
850rpm
AIR FLOW MTR 1.24V
ENG TEMP SEN 179°F

~ ~
~I UP II DWNI~
SEF1621

EF & EC-163
 TROUBLE DIAGNOSES

Diagnostic Procedure 44
F.I.C.D. SOLENOID VALVE

F. I. C. D.
SOLENOID IGNITION
VALVE SWITCH
Ot-F ACC ON ST
I
2
3
4
5

FUSE BLOCK
(Refer to •POWER SUPPLY
ROUT I NG• in EL section. l
(Main
harness> -~
B/R

CONNECTOR
tE. F. J.
harness>
33- R:-----+-'

@@)

'------8/R
j l
tBrownl
tEngine room
harness>
8/R--t---------+B/R-==c---,
FR

n § FUSE BLOCK
Un RELAY
BOXl
[J]

E. C. C. S.
CONTROL
® FUSIBLE
LINK
UNIT HOLDER
BATTERY

SEC614B

Harness layout

SEF3661

F.I.C.D. solenoid valve harness connector is located near A.A.C. valve harness connector.

EF & EC-164
 TROUBLE DIAGNOSES
Diagnostic Procedure 44 (Cont'd}
B
~[iii)
c INSPECTION START

m m
~------------------~
N.G.
CHECK POWER SUPPLY. Check the following items.
Iv I 1) Turn ignition switch "ON". 1) "G" fusible link.
~e 2) Check voltage between 2) "1 OA" fuses.
=-------=-
F.I.C.D. solenoid valve 3) Ignition switch.
terminal @ and ground. 4) Harness continuity between

00 -=
SEF4991
Voltage: Battery voltage.

O.K.
terminals:
• F.I.C.D. solenoid valve
and ignition switch
• Ignition switch and
battery EB terminal.
Continuity should exist.
-CT

18 CHECK HARNESS CON- ~ Repair or replace harness or

· I connectors.
~i5
TINUITY BETWEEN F.I.C.D.
SOLENOID VALVE AND
E.C.U.
~ SEF5001
Check harness continuity
between F.I. C. D. solenoid valve
[!] terminal @ and E.C.U. terminal
II ~ CCNIECTOR II
[11
CIUNI T
33
00 @.
Continuity should exist.

O.K.
DISCONNECT In I
~~
18 L..:.--..:... CHECK COMPONENT Repair or replace F.I.C.D.
I solenoid valve.
~
(F.I.C.D. solenoid valve).
_, rF.J\ Perform "F.I.C.D. SOLE-
~ NOID VALVE TEST" in

SEF5011
@ 18 "ACTIVE TEST" mode
with CONSULT.
00 I ACTIVE TEST I 0 OR - - - - - - - - . 1

FICO SOLENOID/V OFF ~Refer to"Eiectrical Com-

===MONITOR=== ~ ponents Inspection".
CAS·RPM (POS) 762rpm (See page EF & EC-188.)
ENG TEMP SEN 177°F
IDLE POSITION ON O.K.
AIR COND SIG
AAC VALVE
OFF
18%

II ON/OFF 1'•11M
c INSPECTION END

I ON
SEF5931

EF & EC-165
 TROUBLE DIAGNOSES

Diagnostic Procedure 45
A.I.V. CONTROL SOLENOID VALVE (Not self-diagnostic item)

A. I. V. CONTROL
SOLENOID IGNITION
VALVE SWITCH

~-AC

~W®
ONS

®~,
:::"¢ Ellilllil ;::?'~ s 5

"'.. lEI
0:
FUSE BLOCK
!Refer to •POWER SUPPLY

e~
ROUTING• in EL section. l
-::::~
(Main
harness>
8/R

CONNECTOR

CE. F. I.
harness>

•
FR

El FUSE BLOCK
Un RELAY
~~ ~ ~ BOX)

@) r-+-r---+--+----. [IJJ

E. C. C. S.
CONTROL
®
UNIT
BATTERY

SEC615B

Harness layout

EF & EC-166
 TROUBLE DIAGNOSES
Diagnostic Procedure 45 (Cont'd)
m ( INSPECTION START

[11~
COIIIIECT
008 m
CHECK POWER SUPPLY.
N.G.
(;]
Check the following items.
£) Iv I 1) Turn ignition switch "ON". 1) "G" fusible link
@_~ 2) Check voltage between 2) "1 OA" fuses
'-------'--
A.I.V. control solenoid valve 3) Ignition switch·
terminal @and ground. 4) Harness continuity between
.,. Voltage: Battery voltage. terminals:
SEF5031
O.K. •A.I.V. control solenoid
valve and ignition switch
•Ignition switch and
battery EB terminal.
Continuity should exist.

[i
N.G .. I Repa1r
. or rep Iace harness or
CHECK HARNESS CON·
TINUITY BETWEEN A.I.V. connectors.
CONTROL SOLENOID
VALVE AND E.C.U.
Check harness continuity
SEF5041
between A. I. V. control solenoid

~i"~
valve terminal @and E.C.U.
[!) terminal@.
II CAJNI T ]Of CCNECTCIR II l..a'll ~ Continuity should exist.
8
O.K.
I!J
CHECK COMPONENT N.G. · 1 Repair or replace A.I.V. control

00
(A.I.V. control solenoid valve).
Perform "A.I.V. CON-
TROL SOLENOID
solenoid valve.

SEF5051
VALVE TEST" in
"ACTIVE TEST" mode
with CONSULT .
• ACTIVE TEST. 0
OR
AIV CONT SOL/V

==== MONITOR====
QN
® Refer to "Eiect~ical Com-
ponents Inspection".
CAS· RPM (POS) 750rpm (See page EF & EC-186.)
ENG TEMP SEN 177°C
EXH GAS SEM 0.93V O.K.
EXH GAS SEN-R 0.92V

MMIMI ON/OFF II OFF C..___I_N_SP_E_C_T_IO_N_E_N_D_ _.,)

SEF5941

EF & EC-167
 TROUBLE DIAGNOSES

Diagnostic Procedure 46
P.R.V.R. CONTROL SOLENOID VALVE (Not self-diagnostic item)

P.R. V. R.
CONTROL IGNITION
SOLENOID SWITCH

rm
VALVE
OFF ACCON ST

m~ I
2

~ @~
3
4
5
~ 1.11;][1 ~ ~
1f'® mu ..
J:

..
~' ~ FUSE BLOCK
CRefer to •POWER SUPPLY
y_j ROUT I NG• in EL section. l

-:~
111- CMain
harness>

\ J: 8/R

[I CONNECTOR

@)@)
CE. F. 1. ffi J:B (Engine room
harness> 8 /R~ ~ BI'R-+----h_a_r_n_es_s_l- - - + 8 1'•-==,----,
CBrownl
FR

n § FUSE BLOCK
Cln RELAY
BOXl
[IIJ

E. c. c. s.
CONTROL
®
UNIT
BATTERY

SEC616B

Harness layout
Non-turbo model'
=:f:\ .

EF & EC-168
 TROUBLE DIAGNOSES
Diagnostic Procedure 46 (Cont'd)
m
~~
( INSPECTION START

CONNECT

£) CHECK POWER SUPPLY. ~ Check the following items.

1) Turn ignition switch "ON". 1) "G" fusible link
2) Check voltage between 2) "1 OA" fuses
P.R.V.R. control solenoid 3) Ignition switch
valve terminal @ and ground. 4) Harness continuity between
Voltage: Battery voltage. terminals:
SEF5071
• P.R.V.R. control solenoid
O.K. valve and ignition switch
• Ignition switch and
battery EB terminal.

~
Continuity should exist.

DISCIIIIII£CT

18 CHECK HARNESS CON- ~ Repair or replace harness or

I IL-----------------------~
~i5
TINUITY BETWEEN P.R.V.R. connectors.
CONTROL SOLENOID
VALVE AND E.C.U.
~ SEF5081
Check harness continuity
between P.R. V. R. control
[!) solenoid valve terminal (liJ and
E.C.U. terminal@.
r;:ll==:=Coi\JN=:==I:::::::T=iJO[ CONNECTOR II
Continuity should exist.
111

~ r-
O.K.
DISCDIIIIECT [ill ~
18 '------+...'---.,j---
CHECK COMPONENT
(P.R.V.R. control solenoid valve).
Repair or replace P.R.V.R. con-
trol solenoid valve.
rF.I\ Perform "P.R.V.R. CON-
~ TROL SOLENOID
SEF5091
VALVE TEST" in
"ACTIVE TEST" mode
I!) with CONSULT.
I ACTIVE TEST I D OR _______,_,
PRVR CONT SOL/V OFF
=== MONITOR
CAS·RPM (POS)
===
750rpm
~ Refer to "Electrical Com-
ENG TEMP SEN 179°F ~ ponents Inspection".
EXH GAS SEN 092V (See page EF & EC-186.)
EXH GAS SEN-R 0.93V
INJ PULSE 2.6msec O.K.
AAC VALVE 16%

I ON
l'rf:
I ON/OFF I••••• SEF3831
INSPECTION END

EF & EC-169
 TROUBLE DIAGNOSES

Diagnostic Procedure 47
V.T.C. SOLENOID VALVE (Not self-diagnostic item)

V. T. C. V. T. C. IGNITION
SOLENOID SOLENOID SWITCH
VALVE-L ~ VALVE-~ ~ OFF ACC ON S
I
2
3
4
5

®cff
,..,
,,.
'' FUSE BLOCK
(Refer to •POWER SUPPLY
ROUTING• in EL section. J
(Main
harness> -~
8/R

113-G/B--~===:J

\[I CONNECTOR

@@)
(E. F. J.
harness>
8/R
j l
(Brown)
(Engine room
harness)
8 / R - + - - - - - - - - - - + 8/R....r==:=---,
FR

n
w
§
[IIJ
*
FUSE BLOCK
(Jn RELAY
BOXl

E.c.c.s.
CONTROL
®
UNJT
BATTERY

SEC617B

Harness layout

~~\~ V.T.C. solenoid

EF & EC-170
 TROUBLE DIAGNOSES
Diagnostic Procedure 47 (Cont'd)
EJ (Left side) (Right side) c INSPECTION START

[11~~ 00 EJ (;)
~--------------------~

0
CONNECT
CHECK POWER SUPPLY. Check the following items.
£) I vi 1) Turn ignition switch "ON". 1) "G" fusible link
:<!l_ _e
-=----..:::...
2) Check voltage between 2) "1 OA" fuses
V.T.C. solenoid valve 3) Ignition switch
terminal@ and ground. 4) Harness continuity between
Voltage: Battery voltage . terminals:
...
SEF5121 • V.T.C. solenoid valve and
O.K.
ignition switch
• Ignition switch and
battery EB terminal
Continuity should exist.

CHECK HARNESS CON- N.G . .I Repair or replace harness or

TINUITY BETWEEN V.T.C. connectors.
SOLENOID VALVE AND
E.C.U.
SEF5131
Check harness continuity
between V.T.C. solenoid valve
[i ~CONNECTOR terminal @ and E.C.U. terminal

[11
II CIUNIT
113
II
00 @
Continuity should exist.
UISCIIfllllCT
I In I O.K.
18 ~
)
CHECK COMPONENT N.G. 1 Repair or replace V.T.C.
solenoid valve.
I. { (V.T.C. solenoid valve).
fF.i\ Perform V.T.C.
~~
(Left (Right
side) side)
r:ill5 SEF5141
~SOLENOID VALVE
TEST" in "ACTIVE
TEST" mode with
00 CONSULT.
• ACTIVE TEST. 0 1-------0R - - - - - - - 1
VALVE TIMING SOL OFF t<i?\ Refer to "Electrical Com-
~ ponents Inspection".
===MONITOR=== (See page EF & EC-189.)
CAS·RPM (POS) 762rp-m
AAC VALVE 16% O.K.

I ON II ON/OFF , • • • • •
SEF5951
c INSPECTION END

EF & EC-171
 TROUBLE DIAGNOSES

Diagnostic Procedure 48
RADIATOR FAN CONTROL (Not self-diagnostic item)

IGNITION
@ : Turbo model SWITCH
@: Non-turbo model OFF ACC ON ST
1
2
3
4
5

<E. F. I.
harness>

·- w l @)@)
!9- L ---t:@~~ ~;iG'ircR===::::;--1
<Wh i tel

<Engine room
harness)
@)
RADIATOR~ ,A::
~~N,.OR ~ 't:f ~ ._
L u
§ FUSE BLOCK
RELAY
ITil (In
BOXl
c.___ _,®
RADIATOR
FAN
MOTOR
i5 ~"
®lMJ
®{i@) ~
BODY RADIATOR RADIATOR
E. C. C. S.
CONTROL
® GROUND FAN
RELAY
FAN SUB-
RELAY
UNIT
BATTERY

SEC618B

Harness layout

SEF3661

\ ~,., For radiator fan motor harness connector, see "HARNESS LAY-
OUT" in EL section.

EF & EC-172
 TROUBLE DIAGNOSES
Diagnostic Procedure 48 (Cont'd}
INSPECTION START

N.G.
CHECK POWER SUPPLY (1 ). Check the following items.
1) Turn ignition switch "ON". 1) "G", "R" and "L" fusible
IIISCIIIIIIECT
2) Check voltage between links.
10 radiator fan relay terminals
@, @and ground.
2) "1 OA" fuses
3) Ignition switch
Voltage: Battery voltage. 4) Harness continuity between
SEF5161
• radiator fan relay terminal
O.K.
@ and battery<±) terminal
• radiator fan relay terminal
@ and ignition switch
• ignition switch and
battery <±) terminal
Continuity should exist.

N.G.
CHECK POWER SUPPLY (2). Check the following items.
M 1) Turn radiator fan relay Harness continuity between
W "ON" in "ACTIVE • radiator fan motor and
TEST" mode with radiator fan relay
CONSULT. • radiator fan relay and E.C.U.
2) Check voltage between terminal@
radiator fan motor terminal
@ and ground.
Jo.K.
Voltage: Battery voltage. CHECK COMPONENT
(Radiator fan relay).
O.K.
fF.i\Perform "RADIATOR
W FAN TEST" in
"ACTIVE TEST" mode
with CONSULT.
SEF5171

l!1 ta\ Refer to "Electrical Com-

• ACTIVE TEST. D ~ ponents Inspection".
RADIATOR FAN OFF (See page EF & EC-190.)

=ENG= TEMP
= MONITOR = = =
SEN 177°F N.G.
CHECK GROUND CIRCUIT. Repair or replace harness or
Check harness continuity connectors.
between radiator fan motor
I HI II LOW, ••, • • terminal @ and ground.
SEF5961
Continuity should exist.
O.K.
[!)[It
~
CONNECT

~ IV)
f<±ie
~

=
SEF5181

EF & EC-173
 TROUBLE DIAGNOSES
Diagnostic Procedure 48 (Cont'd)

CHECK RADIATOR FAN Repair or replace radiator fan

CIUNIT ]Of CCNIECTOR " MOTOR. motor.
19
Supply radiator fan motor
terminals with battery voltage
and check operation.
Radiator fan motor should
operate.
O.K.

INSPECTION END

SEF5191

":
SEF5201

II
[21
IIICIIIIBT

eJ
00
SEF5211

EF & EC-174
 TROUBLE DIAGNOSES

NOTE

EF & EC-175
 TROUBLE DI~GNOSES

Diagnostic Procedure 49
WASTEGATE VALVE CONTROL SOLENOID VALVE (Not self-diagnostic item) :Turbo model only

WASTEGATE WASTEGATE
VALVE CONTROL VALVE CONTROL IGNITION
SOLE NOlO SOLENOID
SWITCH
VALVE-L.H. VALVE-R.H. OFF ACC ON ST
1

~ ~
2
3
4
5

FUSE BLOCK
<Refer to •POWER SUPPLY
ROUT I NG• in EL section. J

-=:~
<Main
harness>
8/R

CONNECTOR

2 5 - SB @@)
<E. F. I.
harness>
8/R
j l
<Brown>
<Engine room
harness>
8_,R-+-----'---'---'-----+8/R-==,--,
FR

§ FUSE BLOCK
<In RELAY
BDXJ
[IIJ

E. C. C. S.
CONTROL
® FUSIBLE
LINK
UNIT HOLDER
BATTERY

SEC619B

Harness layout

EF &·EC-176
 TROUBLE DIAGNOSES
Diagnostic Procedure 49 (Cont'd}
m
r:d (@i;;i' cm INSPECTION START

®ide)
~ CHECK POWER SUPPLY.
N.G.
G1
Check the following items.

~
COIIIIECT

£) I vi
1) Turn ignition switch "ON". 1) "G" fusible link
2) Check voltage between 2) "1 OA" fuses
(±)(:;) wastegate valve control 3) Ignition switch
solenoid valve terminal @ 4) Harness continuity between
and ground. terminals:
SEF213J ~ Voltage: Battery voltage. • Wastegate valve control
solenoid valve and ignition
GJ (Left side) (Right side) O.K. switch
(hlVJ Chl_VJ ~ • Ignition switch and

[:tl ~ battery (f) terminal

Continuity should exist.
IISCIIIIECT [ill
18 [!]
N.G.
CHECK HARNESS CON- Repair or replace harness or

~i5 TINUITY BETWEEN WASTE- connectors.

g SEF214J
GATE VALVE CONTROL
SOLENOID VALVE AND
E.C.U.
Check harness continuity
between wastegate valve control
solenoid valve terminal (Wand
E.C.U. terminal®.
Continuity should exist.

O.K.

N.G. Repair or replace wastegate

~ DISCUNIIECT CHECK COMPONENT
(!llg)JQWJ
(Left
side)
(Right
side)
L.AJI8 SEF215J
(Wastegate valve control
solenoid valve).
valve control solenoid valve:

Refer to "Electrical Components

Inspection".
(See page EF & EC-186.)

O.K.

(~____IN__SP_E_C_T_IO__N_E_N_o_____~

EF & EC-177
 TROUBLE DIAGNOSES

Electrical Components Inspection

E.C.U. INPUT/OUTPUT SIGNAL INSPECTION
1. E.C.U. is located behind front passenger side floor board. For
this inspection, remove the front passenger side floor board.

2. Remove E.C.U. harness protector.

SEF3661

3. Perform all voltage measurements with the connectors con-

nected.
Extend tester probe as shown to perform tests easily.

Tester probe

SEF3671

EF & EC-178
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
E.C.U. inspection table
*Data are reference values.

TERM I-
NAL ITEM CONDITION *DATA
NO.

1 IEngine is running. I Approx. 0. 1V

2
3
L Idle speed
Ignition signal
11
12
IEngine is running. J Approx. 0.14 V
13 L Engine speed is 2,000 rpm.

4 A.A.C. valve
I Engine is running. J Voltage briefly decreases from
L Racing condition battery voltage (11 - 14V).

IEngine is running., BATTERY BOL TAGE

LRadi·ator fan is not operating. (11 - 14V)
Radiator fan
6 sub-relay
(Turbo model) IEngine is running. I 0.1- 0.3V
LRadiator fan is operating.

lEngine is running. I Approx. 0.7V

L Idle speed
7 Tachometer
l Engine is running. J
Approx. 1.2V
LEngine speed is 2,000 rpm.

I Engine is running.,
Approx. OV
Lldle speed
8 A. I. V. control solenoid valve
I Engine is running.J BATTERY VOLTAGE
(11-14V)
LEngine speed is 2,000 rpm.

I Engine is running. I BATTERY VOLTAGE

(11-14V)
LAir conditioner switch "OFF"
9 Air conditioner relay
IEngine is running. I Approx. OV
L Air conditioner switch "ON"
IEngine is running. I 0.8 -1.0V
Lldle speed
E.C.U. power source
16
(Self-shutoff) lEngine is not running. J BATTERY VOLTAGE
L For a few seconds after turning (11 -14V)
ignition switch "OFF"

EF &. EC-179
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.

TERM I-
NAL ITEM CONDITION *DATA
NO.

!Ignition switch "ON"l

LFor 5 seconds after turning

0.7 · 0.9V
ignition switch "ON"

18 Fuel pump relay IEngine is running.,

IIgnition switch "ON"l BATTERY VOLTAGE

Lin 5 seconds after turning (11-14V)
ignition switch "ON"

IEngine is running. I BATTERY VOLTAGE

L Radiator fan is not operating. (11 -14VI
19 Radiator fan relay
IEngine is running. I 0.1- 0.3V
L Radiator fan is operating.

23 Detonation sensor
IEngine is running. I Approx. 2.5V
Lldle speed

IIgnition switch "ON" I BATTERY VOLTAGE

25
Wastegate valve
control solenoid valves
IEngine is running., (11 -14VI

(Turbo model) IEngine is racing. I Approx. 0.2V

LEngine speed is up to 2,000 rpm

IEngine is running.l (Warm-up condition) 0.8- 1.5V

L Idle speed
27 Air flow meter
IEngine is running. I(Warm-up condition) 1.0- 1.6V
L Engine speed is 2,000 rpm.
0-S.OV
28 Engine temperature sensor IEngine is running. I Output voltage varies with engine
temperature.

29 Right side exhaust gas sensor IEngine is running. I

0 +-~ Approx. 1.0V
L After warming up sufficiently and
55 Left side exhaust gas sensor engine speed is 2,000 rpm.

IEngine is running. BATTERY VOLTAGE

(11 -14V)
LAIC compressor is not operating.
33 F.I.C.D. solenoid valve
IEngine is running. I 0.7- 0.8V
LAIC compressor is operating.

EF & EC-180
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.

TERM I-
NAL ITEM CONDITION *DATA
NO.

IEngine is running. I 8.0- 9.0V

L Steering wheel is in the "straight
Power steering oil pressure ahead" position.
34
switch
IEngine is running. I Approx. OV
L Steering wheel is turned.
0-5.0V
36 Fuel temperature sensor IEngine is running. I Output voltage varies with
fuel temperature.

0.4- 4.0V
38 Throttle sensor IIgnition switch "ON" I Output voltage varies with
throttle valve opening angle.

IEngine is running. I(Warm-up condition) Less than 4.5V

Exhaust gas temperature
L Idle speed
39
sensor
IEngine is running. I(Warm-up condition) 0-1.0V
L E.G. R. system is operating.

41 Crank angle sensor

IEngine is running., 1.2- 1.4V
Do not run engine at high speed under Output voltage varies slightly
51 (Reference signal)
no-load. with engine speed.

42 Crank angle sensor

IEngine is running., 2.5- 2.7V
Output voltage varies slightly
52 (Position signal) Do not run engine at high speed under
no-load. with engine speed.

!Ignition switch "ON"l Approx. OV

43 Start signal
BATTERY VOLTAGE
!Ignition switch "ST ART"l (11 -14V)

IIgnition switch "ON"l

f- Gear position is "Neutral"
Approx. OV
(M/T model).
Neutral switch (M/T model) '--Gear position is "N" or "P"
44
A/T control unit (A/T model) (A/T model).

IIgnition switch "ON"l 8.0- 9.0V

L Except the above conditions

45 Ignition switch
IIgnition switch "ON" l BATTERY VOLTAGE
L Engine stopped (11 ·14V)

EF & EC-181
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.

TERM I·
NAL ITEM CONDITION *DATA
NO.

[Engine is running.l BATTERY VOLTAGE

LAir conditioner switch "OFF" (11-14V)
46 Air conditioner switch
I
Engine is running. I 0.5 · 0.7V
L Air conditioner switch "ON"
48 Power source for sensors
rlgnition switch "ON" I Approximately 5.0V
L Engine stopped
49 Battery source
rlgnition switch "ON" I BATTERY VOLTAGE
L Engine stopped (11-14V)

!Ignition switch "ON" I

LAccelerator pedal is fully released 9.0 -10;0V
(engine running).
Throttle valve switch
54
(Idle position)
[Ignition switch "ON" l
L Accelerator pedal is depressed ov
(engine running).

57
Power source for IIgnition switch "ON" I BATTERY VOLTAGE
throttle valve switch (11 ·14V)
L Engine running

59 Power supply
!Ignition switch "ON" I BATTERY VOLTAGE
L Engine running (11 · 14V)

101
103
105
110
Injectors rlgnition switch "OFF" I BATTERY VOLTAGE
(11 · 14V)
112
114

rEngine is running. I(Warm-up condition) 0.1. o.av

Lldlespeed
102 E.G.R. control solenoid valve
rEngine is running.l (Warm-up condition) BATTERY VOLTAGE
(11 · 14V)
L Engine speed is 2,000 rpm.

EF 8r. EC-182
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.

TERM I-
NAL ITEM CONDITION *DATA
NO.

Ignition switch "ON" I BATTERY VOLTAGE

L Engine stopped (11 - 14V)
35 Fuel pump voltage control
104 (35: Turbo model)
Engine is running.J (Warm-up condition)
Approx. OV
L Idle speed

0-1.0V
Stop and restart engine after (for 30 seconds after ignition switch
warming it up. is turned off.)
L Fuel temperature is above
75°C (167°F) BATTERY VOLTAGE
111 P.R.V.R. control (After 30 seconds)
solenoid valve
Stop and restart engine after
warming it up.
BATTERY VOLTAGE
LFuel temperature is below (11-14V)
75°C (167°F)

Engine is running. I BATTERY VOLTAGE

Lldle speed (11 -14V)
Valve timing control
113
solenoid valves
Engine is running. I 0.2- 0.5V
LEngine speed is 3,000 rpm.

E.C.U. HARNESS CONNECTOR TERMINAL LAYOUT

SEC250B

EF & EC-183
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
CRANK ANGLE SENSOR
1. Remove crank angle sensor from engine. (Crank angle sensor
Rotate
slowly harness connector should remain connected.)
by hand. 2. Turn ignition switch "ON".
3. Rotate crank angle sensor shaft slowly by hand and check
voltage between terminals CD. ® and ground.

Terminal Voltage

® (120° signal)
Voltage fluctuates between 5V and OV.
SEF3461 CD (1° signal)
If N.G., replace crank angle sensor.
After this inspection, malfunction code No. 11 might be displayed
though the crank angle sensor is functioning properly. In this
case erase the stored memory.

AIR FLOW METER

1. Fold back air flow meter harness connector rubber as shown in
the figure if the harness connector is connected.
2. Turn ignition switch "ON".
3. Start engine and warm it up sufficiently.
4. Check voltage between terminal @ and ground.
Conditions Voltage V

Ignition switch "ON" (Engine stopped.) Approximately 0.8

Idle (Engine is warm-up sufficiently.) Approximately 0.8- 1.5

5. If N.G., remove air flow meter from air duct. Check hot wire
for damage or dust.

ENGINE TEMPERATURE SENSOR

1. Disconnect engine temperature sensor harness connector.
2. Check resistance as shown in the figure.

Resistance Hl

20 (68) 2.1-2.9

50 (122) 0.68-1.00

80 (176) 0.30-0.33

SEF536H If N.G., replace engine temperature sensor.

EF 8t EC-184
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
IGNITION COIL
1. Disconnect ignition coil harness connector.
2. Check resistance as shown in the figure.

Terminal Resistance

CD-® Approximately 0.7n

If N.G., replace ignition coil.

POWER TRANSISTOR
1. Disconnect power transistor harness connector.
2. Check power transistor continuity between terminals as
shown in the figure.

Tester Con- Tester Con-

Terminal combination
polarity tinuity polarity tinuity

g g g g g g EB e Yes
No
a b c d e f e EB
SEF3491
g g g g g g EB Yes
e Yes
1 2 3 4 5 6 e EB
a b c d e f EB Yes
e No
1 2 3 4 5 6 e EB
If N.G., replace power transistor.

FUEL PUMP
1. Disconnect fuel pump harness connector.
2. Check resistance between terminals @ and @ .
Resistance: Approximately O.Sn
If N.G., replace fuel pump.

VEHICLE SPEED SENSOR

1. Jack up rear wheels. Use stands to support vehicle.
2. Disconnect vehicle speed sensor harness connector.
IIISCGIIIIECT
3. Check continuity between terminals @ and @ while rotating
rear wheel by hand.
18 Continuity should come and go.
If N.G. replace vehicle speed sensor.

00 SEF754H

EF & EC-185
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
WASTEGATE VALVE CONTROL SOLENOID VALVE
Check air passage continuity.

~~
Air passage continuity
Condition
between @ and @

----ffi 12V direct current supply

between terminals @and @
Yes

~i() No supply No

BATTERY SEF216J If N.G., replace solenoid valve.

E.G.R. CONTROL SOLENOID VALVE
A.I.V. CONTROL SOLENOID VALVE
P.R.V.R. CONTROL SOLENOID VALVE
Check air passage continuity.

Air passage Air passage

Condition continuity continuity
BATTERY between @ and @ between ® and ©
12V direct current
SEF459J supply between Yes No
terminals CD and@

No supply No Yes

If N.G., replace solenoid valve.

E.G.R. CONTROL VALVE

E.G.R.
Apply vacuum to E.G.R. vacuum port with a hand vacuum pump.
E.G.R. control valve spring should lift.
If N.G., replace E.G.R. control valve.

EXHAUST GAS SENSOR

Refer to "Diagnostic Procedure 30".
(See page EF & EC-130.)
EXHAUST GAS SENSOR HEATER
Check resistance between terminals @ and ©.
Resistance: 3 - 1,ooon
If N.G., replace exhaust gas sensor.

SEF6251

EF & EC-186
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
EXHAUST GAS TEMPERATURE SENSOR
Check resistance change and resistance value at 100°C (212°F).
• Resistance should decrease in response to temperature
increase.
Resistance: 100°C (212°F)
85.3 ± 8.53 k n
If N.G., replace exhaust gas temperature sensor.

THROTTLE SENSOR
1. Disconnect throttle sensor harness connector.
2. Make sure that resistance between terminals @ and ©
changes when opening throttle valve manually.

Accelerator pedal conditions Resistance kil

Completely released Approximately 1

Partially released 1 -9

SEF3511 Completely depressed Approximately 9

If N.G., replace throttle sensor.

Adjustment
If throttle sensor is replaced or removed, it is necessary to install it
in the proper position, by following the procedure as shown below:

1. Install throttle sensor body in throttle chamber. Do not tighten

• THROTTLE SEN ADJ • 0 bolts .
2. Connect throttle sensor and idle switch harness connector.
3. Start engine and warm it up sufficiently.
**** ADJ MONITOR**** 4. rij'\ Perform "THROTILE SEN ADJ" in "WORK SUPPORT"
THROTTLE SEN 0.46V W mode.
= = = MONITOR = = =
CAS·RPM (POS)
IDLE POSITION
800rpm
ON
® ~:::r~re output voltage of throttle sensor using volt-

SEF1471

5. Adjust by rotating throttle sensor body so that output voltage

is 0.4 to 0.5V.
6. Tighten mounting bolts.
7. Disconnect throttle sensor harness connector for a few sec-
onds and then reconnect it.

SEF1481

EF & EC-187
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
A.A.C. VALVE
• Check A.A.C. valve resistance.
Resistance:
Approximately 10 n

SEF3521

• Check plunger for seizing or sticking.

• Check for broken spring.

SEF381H

F.I.C.D. SOLENOID VALVE

e Check for clicking sound when applying 12V direct current to
terminals.

SEF3531

• Check plunger for seizing or sticking.

• Check for broken spring.

?l'"{
L. .
~
--~·
Plunger
Spnng

SEF342H

AIR REGULATOR
• Check air regulator resistance.
Resistance:
Approximately 70 - 80 n
• Check air regulator for clogging.

EF & EC-188
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
......._. Detonation sensor DETONATION SENSOR
\?,j_) terminal 1. Disconnect detonation sensor sub-harness connector.
2. Check continuity between terminal @ and ground.
Continuity should exist.
DISCONNECT

I?J

SEF3541

INJECTOR
1. Disconnect injector harness connector.
2. Check resistance between terminals as shown in the figure.
Resistance: 10 - 14Q

'"i::.~~
If N.G., replace injector.

SEF3551

VALVE TIMING CONTROL SOLENOID VALVE

Check valve timing control solenoid valve for normal operation by
supplying it with battery voltage between terminals @ and @ .
If N.G., replace solenoid valve.

SEF3561

THROTTLE VALVE SWITCH (Idle position)

1. Disconnect idle switch harness connector.
2. Check continuity between terminals @ and @ .

Accelerator pedal condition Continuity

Released Yes

Depressed No

If N.G., replace throttle valve switch.

NEUTRAL SWITCH
Check continuity between terminals @ and @ .

Conditions Continuity

Shift to Neutral Yes

Shift to other position No

If N.G., replace neutral switch.

SEF3571

EF & EC-189
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
INHIBITOR SWITCH
- - -..~ Inhibitor switch Check continuity between terminals @ and @ , CD.
~ terminal side
Continuity between Continuity between
Conditions
terminals @ and (tV terminals@ and (f)

Shift to "P" position Yes No

Shift to "N" position No Yes

Shift to positions
No No
SEF3581 other than "P" and "N"

E.C.C.S. RELAY, FUEL PUMP RELAY, RADIATOR FAN

RELAY AND IGNITION COIL RELAY
= Check continuity between terminals @ and @.

Conditions Continuity

12V direct current supply between

Yes
terminals CD and ®

No current supply No
SEF054F
If N.G., replace relay.
POWER STEERING OIL PRESSURE SWITCH
1. Disconnect power steering oil pressure switch harness con-
nector.
2. Check resistance between teminals.
Resistance: Approximately 2 - 3!1

Fuel temperature sensor terminal FUEL TEMPERATURE SENSOR

1. Disconnect fuel temperature sensor harness connector.
2. Check resistance between teminal and ground as shown in the
figure.

Resistance kf2

IIISCIIIIIIECT 20 (68) 2.1- 2.9

18 50 (122) 0.68. 1.00

SEF6241
80 (176) 0.30-0.33

If N.G., replace fuel inhibitor switch.

EF & EC-190
 FUEL INJECTION CONTROL SYSTEM INSPECTION

Releasing Fuel Pressure

Before disconnecting fuel line, release fuel pressure from fuel
line to eliminate danger.

fF.i\
Perform "FUEL. PRESSURE RELEASE" in "WORK SUP-
~ PORT" mode w1th CONSULT.

1. Remove fuel pump relay or disconnect fuel pump

' \~
'"_)$._
'\~~li ® connector.
2. Start engine.
~
· !fl
Hood lever 3. After engine stalls, crank it two or three times to

o-~ I~
release all fuel pressure.
4. Turn ignition switch off and reconnect fuel pump relay
or fuel pump connector.
I_~ . ·~ ~~
Fuel pump re~y 1
_. S" -·· y/1.'/ .
SEF449K

Fuel Pressure Check

a. When reconnecting fuel line, always use new clamps.
b. Make sure that clamp screw does not contact adjacent parts.
c. Use a torque driver to tighten clamps.
d. Use Pressure Gauge to check fuel pressure.
e. Do not perform fuel pressure check while fuel pressure
regulator control system is operating; otherwise, fuel pres-
sure gauge might indicate incorrect readings.
1. Release fuel pressure to zero.
2. Disconnect fuel hose between fuel filter and fuel tube (engine
side).
3. Install pressure gauge between fuel filter and fuel tube.
4. Start engine and check for fuel leakage.

5. Read the indication of fuel pressure gauge.

At idling:
When fuel pressure regulator valve
vacuum hose is connected.
Approximately 250.1 kPa
(2.55 kg/cm 2, 36.3 psi)
When fuel pressure regulator valve
vacuum hose is disconnected.
Fuel Approximately 299.1 kPa
~D,dhose (3.05 kg/cm 2, 43.4 psi)
~ SEF3691

EF & EC-191
 FUEL INJECTION CONTROL SYSTEM INSPECTION
Fuel Pressure Check (Cont'd)
6. Stop engine and disconnect fuel pressure regulator vacuum
hose from intake manifold.
7. Plug intake manifold with a rubber cap.
8. Connect variable vacuum source to fuel pressure regulator.

9. Start engine and read indication of fuel pressure gauge as

Vacuum Fuel pressure
vacuum is changed.
Fuel pressure should decrease as vacuum increases. If
results are unsatisfactory, replace fuel pressure regulator.

"to pressure regulator

SEF718B

Injector Removal and Installation

1. Release fuel pressure to zero.
2. Drain coolant from radiator drain cock.
3. Remove or disconnect the following:
• Related harnesses, wires and tubes
• Intake manifold collector
For details, refer to EM section.
4. Remove injectors with fuel tube assembly.
5. Remove injectors from fuel tube assembly.
6. Install injectors as follows:
1) Clean exterior of injector tail piece.
2) Use new 0-rings.
CAUTION:
After properly connecting injectors to fuel tube assembly, check
connections for fuel leakage.
7. Assemble injectors with fuel tube assembly to intake manifold.

EF & EC-192
 EVAPORATIVE EMISSION CONTROL SYSTEM

Description

Vapor vent line

Fuel tank

Q : Air
+: Fuel vapor

SEC544A

The evaporative emission control system is used to reduce hydro-

carbons emitted into the atmosphere from the fuel system. This
reduction of hydrocarbons is accomplished by activated charcoals
in the carbon canister.
The fuel vapor from the sealed fuel tank is led into the canister
which contains activated carbon and the vapor is stored there
when the engine is not running.
The canister retains the fuel vapor until the canister is purged by
the air drawn through the bottom of the canister to the intake
manifold when the engine is running. When the engine runs at idle,
the purge control valve is closed.
Only a small amount of stored vapor flows into the intake manifold
through the constant purge orifice. As the engine speed increases,
and the throttle vacuum rises higher, the purge control valve opens
and the vapor is sucked into the intake manifold through both the
main purge orifice and the constant purge orifice.

Turbo.models Inspection
CARBON CANISTER
Check carbon canister as follows:
@ . Blow air and ensure that there is no leakage.
@ : Blow air and ensure that there is leakage.

SEF450K

EF & EC-193
 EVAPORATIVE EMISSION CONTROL SYSTEM
Inspection (Cont'd)
FUEL TANK VACUUM RELIEF VALVE
1. Wipe clean valve housing.
2. Suck air through the cap. A slight resistance accompanied by
valve clicks indicates that valve is in good mechanical condition.
Note also that, by further sucking air, the resistance should
disappear with valve clicks.
3. If valve is clogged or if no resistance is felt, replace cap as an
assembly.

SEC308A

FUEL CHECK VALVE

~:::::;::=::::z:;==~­
1. Blow air through connector on fuel tank side.
'r;:::~~==::;:l ~
A considerable resistance should be felt and a portion of air
flow should be directed toward the canister.
2. Blow air through connector on canister side.
QAir
Air flow should be smoothly directed toward fuel tank .
• Fuel vapor
3. If fuel check valve is suspected of not properly functioning
in steps 1 and 2 above, replace it.

SEC309A

EF & EC-194
 CRANKCASE EMISSION CONTROL SYSTEM

Description
This system returns blow-by gas to both the intake The ventilating air is then drawn from the air inlet
manifold and air inlet tubes. tubes, through the hose connecting air inlet tubes to
The positive crankcase ventilation (P.C.V.) valve is rocker cover, into the crankcase.
provided to conduct crankcase blow-by gas to the Under full-throttle condition, the manifold vacuum is
intake manifold. insufficient to draw the blow-by flow through the
During partial throttle operation of the engine, the valve, and its flow goes through the hose connection
intake manifold sucks the blow-by gas through the in the reverse direction.
P.C.V. valve. On vehicles with an excessively high blow-by some
Normally, the capacity of the valve is sufficient to of the flow will go through the hose connection to
handle any blow-by and a small amount of ventilating the air inlet tubes under all conditions.
air.

P.C.V. valve~'
P.C.V.valve

Engine not running

Cruising
or backfiring

_J~
Idling or
·~
Acceleration
decelerating or high load

¢ : Fresh air
+- : Blow-by gas
-D> ·~
SEF3701

Inspection
P.C.V. (Positive Crankcase Ventilation)
With engine running at idle, remove ventilation hose from P.C.V.
valve; if the valve is working properly, a hissing noise will be heard
as air passes through it and a strong vacuum should be felt
immediately when a finger is placed over valve inlet.

VENTILATION HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.

ET277

EF & EC-195
 SERVICE DATA AND SPECIFICATIONS (S.D.S~)

General Specifications
PRESSURE REGULATOR
Regulated pressure
299.1 (3.05, 43.4)
kPa (kg/cm 2 , psi)

Inspection and Adjustment

Idle speed*1 rpm FUEL PUMP
No-load*2
MIT 700±50
Resistance n Approximately 0.5

A/T (in "N" position)

Non-turbo 770±50
Turbo 750±50 EXHAUST GAS TEMPERATURE SENSOR
Air conditioner: ON Resistance
Non-turbo 800±50 k.!1 85.3±8.53
[at 100°C (212° F))
Turbo 850±50

Ignition timing degree 15±2 B.T.D.C.

EXHAUST GAS SENSOR HEATER
Throttle sensor idle position
0.4-0.5 n
v Resistance 3- 1,000

*1: Feedback controlled and needs no adjustments

*2: Under the following conditions:
• Air conditioner switch: OFF A.A. C. VALVE
• Steering wheel: Kept straight
• Electric load: OFF (Lights, heater, fan & rear defogger) Resistance n Approximately 10
• Radiator fan: OFF

IGNITION COIL INJECTOR

Primary voltage v 12
Resistance n 10- 14
Primary resistance
[at 2cfC (68°F))
n Approximately 0. 7

THROTTLE SENSOR
Secondary resistance
Approximately 8
[at 20°C (68°F)] Accelerator pedal conditions Resistance k.!1

Completely released Approximately 1

ENGINE TEMPERATURE SENSOR AND Partially released 1-9

FUEL TEMPERATURESENSOR Completely depressed Approximately 9

Temperature °C (°F) Resistance k.!1

20 (681 2.1-2.9
AIR REGULATOR
50 (122) 0.68- 1.00
Resistance n 70.80
80 (176) 0.30-0.33

POWER STEERING OIL PRESSURE SWITCH

Resistance n Approximately 2- 3

EF 8r. EC-196
 ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS

SECTION FE
CONTENTS
ACCELERATOR CONTROL SYSTEM .............................................................................................. FE-2
FUEL SYSTEM .................................................................................................................................... FE-3
EXHAUST SYSTEM ... .. .. .... .. ....... ....... .... .... .... .. ......... ... .. .... .......... ...... ...... ..... ...... .. .. ..... ... ......... ...... ... ... FE-5
 ACCELERATOR CONTROL SYSTEM

• When removing accelerator cable, make a mark to indicate lock nut's initial position.
• Check that throttle valve opens fully when accelerator pedal is fully depressed and that it returns to idle
position when pedal is released.
• Adjust accelerator cable according to the following procedure.
Tighten "adjusting nut" until "throttle drum" starts to move.
From that position tum back "adjusting nut" 1.5 to 2 turns, and fasten it with a lock nut.
• Check accelerator control parts for improper contact with any adjacent parts.
• When connecting accelerator cable, be careful not to twist or scratch its inner wire.

Accelerator cable
~ 3. 4 (0.3 . 0.4, 2.2 . 2.91

. ----- ~ ::::--~-----
@ • ·-

0
.-------= ----

Kickdown switch
~12-15
(1.2 ·1.5, 9 ·111

Pedal bracket

Adjusting nut
~ 8 ·10 (0.8 ·1.0, 5.8. 7.21

~ 3 . 4 (0.3 . 0.4, 2.2 . 2.91

~: N.m (kg-m, ft-lbl

SFE059A.

FE-2
 FUEL SYSTEM

WARNING:
When replacing fuel line parts, be sure to observe the following:
e Put a "CAUTION: INFLAMMABLE" sign in workshop.
• Be sure to furnish workshop with a C02 fire extinguisher.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
• Be sure to disconnect battery ground cable before conducting operations.
• Put drained fuel in an explosion-proof container and put lid on securely.
CAUTION:
• Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to "Changing Fuel Filter" in
MA section.
• Do not disconnect any fuel line unless absolutely necessary.
• Plug hose and pipe openings to prevent entry of dust or dirt.
• Always replace 0-ring and clamps with new ones.
• Do not kink or twist hose and tube when they are installed.
• Do not tighten hose clamps excessively.
• When installing fuel check valve, be careful of its designated direction. (Refer to section EF & EC.)
• After assembly, run engine and check for fuel leaks at connections.

~~2.0·2.5
I (0.2 · 0.26, 1.4 · 1.9)
Fuel gauge
unit

fY:1 ..
~
. ·l1 ·
0"'" •• ,,
0-ring~
_\ . ~31-42
~ 3.9. 4.4 (3.2 . 4.3, 23 . 31)
(0.40 . 0.45, 2.9 . 3.3)
~ : N.m (kg-m, ft-lb)
SFE060A

FE-3
 FUEL SYSTEM

2 + 2 seater model

~2.5 ·2.6
(0.25 - 0.27. 1.8- 2.07

Fuel pump &

gauge assembly

0-ring ~

Fuel filler tube

~: N·m (kg-m, ft-lb)

Ventilation hose
SFE070A

FE-4
 EXHAUST SYSTEM

CAUTION:
• Always replace exhaust gaskets with new ones when reas-
sembling.
If gasket is left on flange surface, scrape off completely as
shown at left.
• With engine running, check all tube connections for exhaust
gas leaks, and entire system for unusual noises.
• After installation, check to ensure that mounting brackets and
mounting insulators are free from undue stress. If any of the
above parts are not installed properly, excessive noise or
SFE180A vibration may be transmitted to the vehicle body.

2 seater model

Rear muffler
~ 13-16
(1.3 -1.6, 9 -12)

Front exhaust tube assembly

(Catalytic converter
assembly)----,.

~ 13-16
I
(1.3 -1.6,
9 -12) ) I
~.

Turbo model ~ J

~/
~

~: N·m (kg-m, ft-lb)

SFE069A

FE-5
 EXHAUST SYSTEM

2+2 seater model

-\_
~43-55
(4.4 -56
• • 32 - 41)

~44-50 (45
. -5.1,33-37)

~: N·m(kg-m, ft-lb)

SFE063A

FE-6
 CLUTCH

SECTIONCL

CONTENTS
PRECAUTIONS AND PREPARATION ........................................................................................... CL- 2
CLUTCH SYSTEM ............................................................................................................................. CL- 4
INSPECTION AND ADJUSTMENT .................................................................................................. CL- 7
HYDRAULIC CLUTCH CONTROL .................................................................................................. CL- 9
CLUTCH RELEASE MECHANISM .................................................................................................. CL-13
CLUTCH DISC AND CLUTCH COVER ......................................................................................... CL-15
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ....................................................................... CL-18
 PRECAUTIONS AND PREPARATION

Precautions
• Recommended fluid is brake fluid "DOT 3".
• Never reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas.
• When removing and installing clutch piping, use Tool.
• Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
• Never use mineral oils such as gasoline or kerosene. It
GG94310000 will ruin the rubber parts of the hydraulic system.
I l
SBRSOO
WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air.

Preparation
SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

ST20050010 Inspecting diaphragm spring of clutch

( ) cover
Base plate

ST20050100 Inspecting diaphragm spring of clutch

( ) cover
Distance piece

GG94310000 Removing and installing each clutch piping

( )
Flare nut torque
wrench

ST20600000 Installing clutch cover and clutch disc

(J26366)
Clutch aligning bar

ST20050240 Adjusting unevenness of diaphragm spring

( ) of clutch cover
Diaphragm spring
adjusting wrench

CL-2
 PRECAUTIONS AND PREPARATION
Preparation (Cont'd)
COMMERCIAL SERVICE TOOLS

Tool name Description

Bearing puller Removing release bearing

Bearing drift Installing release bearing

a a: 50 mm (1.97 in) dia.

b: 45 mm (1.77 in) dia.

CL-3
 CLUTCH SYSTEM

VG30D E engine model

Clutch master Pedal bracket
cylinder

/rPJ 16 - 22 (1.6 - 2.2, 12 -16)

@
rPJ
'1fl 8 - 11
(0.8 - 1.1, 5.8 - 8.0)

j"
rPJ 8 - 11 (0.8 - 1.1, 5.8 - 8.0)

Fulcrum pin m© ~~ ~v \. ..,..._.,~

A.S.C.D. cancel switch

Clutch interl=-;ok_/
/:::; \ rPJ 12- 15 (1.2- 1.5, 9- 11)

~CI~"plo
switch
rPJ 12- 15
(1.2 - 1.5, 9 - 11)
EI(J;)
rPJ 12- 15 - - - - '
(1.2 - 1.5, 9 - 11)
Clutch
Power steering pedal
clutch switch

Clutch disc

Air bleeder
screw
A& -1o
(0.6 - 1.0,
4.3 - 7.2)

rPJ 17- 20
(1.7 - 2.0,
12 - 14)

Withdrawal lever Air bleeder screw

A& -1o
(0.6 - 1.0, 4.3 - 7.2)

Dust boot
Operating cylinder

: N•m (kg-m, tt-lb)

: Apply lithium-based grease including molybdenum disulphide.
SCL436

CL-4
 CLUTCH SYSTEM

VG30DETT engine model

Intake manifold

'~
Chookw~->?
Clutch master
cylinder

~\

~().
8
~AJ~~8-121..J
~
rlz.
(0.8. 1.2,
5.!_· 8.7) ___....
.--.
>
.

Clutch booster
~~ 16. 22 (1.6. 2.2, 12. 16)

~ <' Pedal bracket

. . . v ~·
·;-·~ ~ 8 . 11 (0.8 . 1.1, 5.8
. 8.0)

Lock nut
12 . 15 (1.2 . 1.5, 9 . 11)
, [ ] A.S.C.D.
Vacuum
~~ . ~
- . ..............-
cancel switch

[q] 8-11(0J-1.1,5A-8.,~~ '\ ~....,.HI CAS clutch switch

Clutch interlock switch _/ ~Lock nut

~" ~12. 15 (1.2. 1.5, 9. 11)
~ 12 . 15 (1.2 . 1.5, 9 . 11) · \_ Return spring
Clevis pin E! (Q
Clutch pedal

Clutch disc

Clutch cover

Air bleeder
screw
~6 -10
{0.6 . 1.0,
4.3 . 7.2)

lever

Dust boot

~ : N•m (kg-m, ft-lb)

lEI (Q : Apply lithium-based grease including molybdenum disulphide.
SCL437

CL-5
CLUTCH SYSTEM

Vacuum Hose Layout - VG30DETT Engine

Model

Clutch master cylinder

Clutch booster

SCL412

CL-6
 INSPECTION AND ADJUSTMENT

Adjusting Clutch Pedal

1. Adjust pedal height with A.S.C.D. cancel switch and HICAS
clutch switch or power steering clutch switch.
Pedal height "H":
VG30DE engine
197 - 207 mm (7.76 - 8.15 in)
VG30DETT engine
183 - 193 mm (7.20 - 7.60 in)

VG30DETT engine model VG30DE engine model

Lock nut

A.S.C.D. A.S.C.D.
HI CAS
cancel cancel
clutch
switch switch switch
switch Dash lower panel
Lock nut
~ 12 _ 15 N•m Clutch pedal
(1.2 - 1.5 kg-m, 9 - 11 ft-lb)
SCL408

2. Adjust pedal free play with master cylinder push rod. Then
tighten lock nut.
Pedal free play "A":
1.0 - 3.0 mm (0.039 - 0.118 in)
Push rod
Pedal free play means the following measured at position of
pedal pad:
• Play due to clevis pin and clevis pin hole in clutch pedal.
3. Make sure that clevis pin can be rotated smoothly.

Look"~~
If not, readjust pedal free play with master cylinder push rod.

~ VG30DE engine:
8- 11 N·m
(0.8 - 1.1 kg-m,
5.8 - 8.0 ft-lb)
VG30DETT engine:
16- 22 N-m
(1.6 - 2.2 kg-m,
12 - 16 ft-lb)

SCL409

CL-7
 INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal (Cont'd)
- U.S.A. model only -
4. Adjust clearance "C" between pedal stopper rubber and
threaded end of clutch interlock switch while depressing clutch
pedal fully.
Clearance C:
1.0 - 2.0 mm (0.039 - 0.079 in}

C SCL380

Bleeding Procedure
1. Bleed air from clutch operating cylinder according to the
following procedure.
Carefully monitor fluid level at master cylinder during bleeding
operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Fully depress clutch pedal several times.
d. With clutch pedal depressed, open bleeder valve to release air.
/
SCL203
e. Close bleeder valve.
f. Repeat steps c through e above until brake fluid flows from air
bleeder valve without air bubbles.
2. Bleed air from clutch piping connector according to the above
same procedure.
3. Repeat the above bleeding procedures 1 and 2 several times.

SCL384

CL-8
 HYDRAULIC CLUTCH CONTROL

Clutch Master Cylinder

Return spring
Piston assembly

Reservoir

Reservoir band

Cylinder body
El® Rubbing
surface
to piston
assembly

Dust cover
E!l@ Rubbing surface to
push rod

Stopper ring 0
Packing------------
• Apply brake fluid when assembling.
Valve stopper ~
~ 1.5. 2.9 (0.15. 0.3,1.1. 2.2) Push rod
• Remove this stopper, when E!l @ Contact surface to piston assembly
removing piston and return spring.

IIIEI!I ® : Apply rubber grease.

~: N·m (kg-m, ft·lb)
SCL348

DISASSEMBLY AND ASSEMBLY

• Push piston into cylinder body with screwdriver when
removing and installing valve stopper.

• Align groove of piston assembly and valve stopper when

installing valve stopper.
• Check direction of piston cups.

WJ.)JJJJJJ.JJJ (~ {)) -- ;:,[I]

Groove

SCL214

CL-9
 HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder (Cont'd)
INSPECTION
• Check cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
• Check piston with piston cup for wear or damage. Replace if
necessary.
• Check return spring for wear or damage. Replace if neces-
sary.
• Check reservoir for deformation or damage. Replace if
necessary.
• Check dust cover for cracks, deformation or damage.
Replace if necessary.

Operating Cylinder
~Eyebolt
U' . ~ 17-20 (1.7 -2.0,12-14)

'\_. . - "\_6
-\ \~
@

Bleeder screw
rRJ 7 . 9 (0.7. 0.9, 5.1 . 6.5)
~~'~ Operagting cylinder
IE!® Rubbing surface to piston assembly
Piston spring
A : N·m (kg-m, ft-lb)
Eal@: Apply rubber grease. Piston cup E!l@ SCL385

INSPECTION
• Check rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
• Check piston with piston cup for wear or damage. Replace if
necessary.
• Check piston spring for wear or damage. Replace if neces-
sary.
• Check dust cover for cracks, deformation or damage.
Replace if necessary.

CL-10
 HYDRAULIC CLUTCH CONTROL
Clutch Booster

A16. 22 (1.6. 2.2, 12. 16)

~ lop,l•od

As- 12 to.s- 1.2. 5.8-8.71

~ 8-12 (0.8 -1.2, 5.8- 8.7)

A: N·m (kg-m, ft-lb)

SCL390

INSPECTION
Hoses and connectors
• Check condition of vacuum hoses and connections.
• Check vacuum hoses and check valve for air tightness.

Check valve
To manifold • Install check valve properly paying attention to its direction.

...
l----rnTo clutch booster

SLC391

•
Engine side • When pressure is applied to the clutch booster side of check
valve and valve does not open, replace check valve with a new
one.

Clutch booster side

SCL392

CL-11
 HYDRAULIC CLUTCH CONTROL
Clutch Booster {Cont'd)
w ADJUSTMENT
Output rod length "A":
13.35 - 13.60 mm (0.5256 - 0.5354 in)

SCL393

If amount of adjustment required exceeds 0.5 mm (0.020 in),

reaction disc may have either been dislocated or fallen off.
Replace clutch booster assembly.

Input rod length "B":

113 mm (4.45 in)

8
SCL136

CL-12
 CLUTCH RELEASE MECHANISM

Release sleeve

Withdrawal lever

lEI©: Apply lithium-based grease including molybdenum disulphide.

SCL386
Ell© .
REMOVAL AND INSTALLATION
• Install retainer spring and holder spring.

SCL217

• Remove release bearing

CL145

• Install release bearing with suitable drift.

Drift

SCL222

CL-13
 CLUTCH RELEASE MECHANISM

INSPECTION
• Check release bearing to see that it rolls freely and is free
from noise, cracks, pitting or wear. Replace if necessary.
• Check release sleeve and withdrawal lever rubbing surface
for wear, rust or damage. Replace if necessary.

LUBRICATION
• Apply recommended grease to contact surface and rubbing
surface.
Too much lubricant might damage clutch disc facing.

Pack this recess

• I!EI(~)': Apply lithium-based grease including

molybdenum disulphide. SCL223

CL-14
 CLUTCH DISC AND CLUTCH COVER

Flywheel

/ Clutch disc
/ • Do not clean in solvent.
• When installing, be careful that grease applied to
main drive shaft does not adhere to clutch disc.

Clutch cover
B (LI : Apply lithium-based grease including
molybdenum disulphide.
SCL354

Clutch Disc

jJ i~
INSPECTION
• Check clutch disc for wear of facing.
t E Wear limit of facing surface to rivet head:
IE
M
0.3 mm (0.012 in)
ci

SCL229

• Check clutch disc for backlash of spline and runout of facing.

Maximum backlash of spline (at outer edge of disc):
1.0 mm (0.039 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
VG30DE engine
115 mm (4.53 in)
VG30DETT engine
120 mm (4.72 in)
SCL221 • Check clutch disc for burns, discoloration or oil or grease
leakage. Replace if necessary.

INSTALLATION
• Apply recommended grease to contact surface of spring
portion.
Too much lubricant might damage clutch disc facing.

CL-15
 CLUTCH DISC AND CLUTCH COVER

Clutch Cover and Flywheel

INSPECTION AND ADJUSTMENT
• Set Tool and check height and unevenness of diaphragm spring.
Diaphragm spring height "A":
VG30DE engine
37.5 - 39.5 mm (1.476 - 1.555 in)
VG30DETT engine
36.5 - 38.5 mm (1.437 - 1.516 in)
• Set 0.5 mm (0.020 in) feeler gauges on distance pieces
(ST20050100) when checking diaphragm spring height.
• Check thrust rings for wear or damage by shaking cover
assembly and listening for chattering noise, or lightly hammer-
ing on rivets for a slightly cracked noise. Replace clutch cover
assembly if necessary.
• Check pressure plate and clutch disc contact surface for slight
burns or discoloration. Repair pressure plate with emery paper.
• Check pressure plate and clutch disc contact surface for
~~~~~~~~~A deformation or damage. Replace if n.ecessary.

• Adjust unevenness of diaphragm spring with Tool.

Uneven limit:
0.5 mm (0.020 in)

FLYWHEEL INSPECTION
• Check contact surface of flywheel for slight burns or
discoloration. Repair flywheel with emery paper.
• Check flywheel runout.
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)

INSTALLATION
• Insert Tool into clutch disc hub when installing clutch cover
and disc.

CL-16
 CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel (Cont'd)
• Tighten clutch cover fixing bolts.
Bolt • Tighten bolts in crisscross order as shown in illustration, in
two steps.
Tightening torque:
First step
20 N·m (2.0 kg-m, 14 ft-lb)
Final step
22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-lb)

SCL447

CL-17
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications
CLUTCH CONTROL SYSTEM CLUTCH COVER
Type of clutch control Hydraulic Model C240S C250S

Engine VG30DE VG30DETT

CLUTCH MASTER CYLINDER 5,688 7,846

Full load N (kg, lb)
(580, 1 ,279) (800, 1 ,764)
Inner diameter mm (in) 15.87 (5/8)

CLUTCH BOOSTER (VG30DETT engine model)

CLUTCH OPERATING CYLINDER
Model M45
Inner diameter mm(in) 19.05 (3/4)
Diaphragm diameter mm (in) 114.3 (4.50)

CLUTCH DISC
Model 240TBL 250TBL

Engine VG30DE VG30DETT

Facing size 240 X 160 X 3.5 250 X 160 X 3.5

(Outer dia. x inner dia. (9.45 X 6.30 X (9.84 X 6.30 X
x thick ness) mm (in) 0.138) 0.138)

Thickness of disc assembly 8.1 -8.5 (0.319 -0.335)

With load mm (in) with 4,904 N (500 kg, 1,1031b)

Inspection and Adjustment

CLUTCH PEDAL CLUTCH COVER
Unit: mm (in) Unit: mm (in)

Engine VG30DE VG30DETT Model C240S C250S

197 - 207 183- 193 37.5- 39.5 36.5- 38.5

Pedal height "H*" Diaphragm spring height
(7 .76- 8.15) (7 .20-7 .60) (1.476- 1.555) (1.437- 1.516)

Pedal free play Uneven limit of diaphragm

1.0-3.0 (0.039 - 0.118) 0.5 (0.020)
(Backlash at clevis) spring toe height

Clearance between pedal

stopper rubber and threaded 1.0-2.0 (0.039- 0.079)
end of clutch interlock CLUTCH BOOSTER
*· Measured from surface of dash lower panel to pedal pad Unit: mm (in)

13.35 - 13.60
Output rod length "A"
(0.5256- 0.5354)
CLUTCH DISC Input rod length "B" 113 (4.45)
Unit: mm (in)

Model 240TBL I 250TBL

Wear limit of facing surface to

0.3 (0.012)
rivet head

Runout limit of facing 1.0 (0.039)

Distance of runout check

115 (4.53) 1120 (4.72)
point (from the hub center)

Maximum backlash of spline

1.0 (0.039)
(at outer edge of disc)

Cl-18
 MANUAL TRANSMISSION

SECTION

CONTENTS
PREPARATION ................................................................................................................................. MT- 2
ON-VEHICLE SERVICE ................................................................................................................... MT- 5
REMOVAL AND INSTALLATION ................................................................................................... MT- 6
MAJOR OVERHAUL ........................................................................................................................ MT- 7
DISASSEMBLY .................................................................................................................................. MT-12
INSPECTION ...................................................................................................................................... MT-20
ASSEMBLY ........................................................................................................................................ MT-22
Ill
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ....................................................................... MT-34
 PREPARATION

SPECIAL SERVICE TOOLS - for FS5R30A

Tool number
(Kent-Moore No.) Description
Tool name.

ST23540000 Removing and installing retaining pin

(J25689-A)
Pin punch

ST30031000 Removing 1st & 2nd synchronizer assembly

(J22912-01) Removing counter gear rear thrust bearing
Puller Removing main drive bearing
Measuring 2nd & 3rd inner baulk ring

ST33290001 Removing rear oil seal

(J25810-A)
Puller

ST33230000 Removing mainshaft and counter gear

( )
Drift
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.

ST22350000 Removing counter gear front bearing

(J25678-01) (Use with KV38100300)
Drift

KV38100300 Removing counter gear front bearing

(J25523) (Use with ST22350000)
Drift Installing counter gear rear bearing

ST30720000 CD Removing mainshaft front bearing

CD !J342BSI ® Installing mainshaft front bearing
cv (J34331)
Drift

ST33210000 CD Installing counter gear front bearing

CD!J25523) ® Installing front cover oil seal
cv (J25803-01)
Drift a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.

ST30613000 Installing main drive gear bearing

(J25742-3)
Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.

MT-2
 PRE~ARATION

Tool number
(Kent-Moore No.) Description
Tool name

ST37750000 CD Removing counter gear rear bearing

CD (J34286l ® Installing O.D. gear bushing
® (J34332) ® Installing reverse cone
® (J34334) ® Installing reverse counter gear
@ (J25679-01) @ Installing counter gear rear end bearing
Drift

a: 40 mm (1.57 inl dia.

b: 31 mm (1.22 inl dia.

ST22452000 Installing reverse hub

(J34337) Installing mainshaft rear bearing
Drift

ST33400001 Installing rear oil seal

(J26082)
Drift
a: 60 mm (2.36 inl dia.
b: 47 mm ( 1.85 inl dia.

(J26349-3) Installing mainshaft and counter gear

Puller leg (Use with J34328)

(J34328) Installing mainshaft and counter gear

Puller (Use with J26349-3)

(J26092) Installing sub-gear snap ring

Drift

a: 44.5 mm (1.752 inl dia.

b: 38.5 mm (1.516 inl dia.

(J34342) Installing O.D. main gear

Drift Installing reverse gear bushing

a: 44.5 mm (1.752 inl dia.

b: 40.5 mm (1.594 inl dia.

ST36730000 Installing sub-gear on reverse

( ) idler gear
Drift

a= 50 mm (1.97 inl dia.

b = 39 mm (1.54 in) dia.

MT-3
 PREPARATION

COMMERCIAL SERVICE TOOL - for FS5R30A

Tool name Description

Puller Removing counter gear rear end bearing

Removing mainshaft rear bearing
Removing reverse synchronizer hub
Removing reverse counter gear

MT-4
 ON-VEHICLE SERVICE

Replacing Rear Oil Seal

REMOVAL

INSTALLATION

Position Switch Check

BACK-UP LAMP SWITCH
• Check continuity .

Gear position Continuity

Reverse Yes
Except reverse No

SMT599B NEUTRAL SWITCH

• Check continuity .

Gear position Continuity

Neutral Yes

Except neutral No

MT-5
 REMOVAL AND INSTALLATION

Removal
• Remove exhaust tube.

• Remove support bracket from M/T assembly.

• Remove control rod from shift lever.

• Remove propeller shaft - Refer to section PD.

• Insert plug into rear oil seal after removing propeller shaft.
• Be careful not to damage spline, sleeve yoke and rear oil
seal when removing propeller shaft.
• Disconnect back-up lamp switch and neutral switch harness
connectors.
• Support manual transmission with a jack.
• Remove rear mounting.

• Lower manual transmission.

Installation
• Tighten all transmission bolts.

Bolt No. Tightening torque N-m (kg-m, ft-lb) Q mm (in)

CD 39- 49 (4.0 - 5.0, 29 - 36) 100 (3.94)

® 39- 49 (4.0- 5.0, 29 - 36) 65 (2.56)

@ 39 - 49 (4.0- 5.0, 29- 36) 60 (2.36)
@ 29 - 39 (3.0 - 4.0, 22 - 29) 55 (2.17)
SMT603B
® 29 - 39 (3.0 - 4.0, 22 - 29) 25 (0.98)

MT-6
MAJOR OVERHAUL

Case Components

'

Transmission case o
0
~I
Drain plug
A 25 - 34 12.5. 3.5, 1s . 251
rJ Thread of bolt '

I
A 1s- 21 11.s- 2.1. 12 -15)
Neutral switch
A 20- 2s 12.o. 3.o. 14- 221 ~
Control rod oil
seal~
mseallip

Dust cover

A : N·m (kg-m, ft-lbl

rJ : Apply recommended sealant (Nissan genuine
Part: KP610-00250) or equivalent.

SMT606B

MT-7
 ----1

4th baulk ring ~

Main drive gear bearing

Pilot bearing
Main drive gear .
Synchronizer cone
J;P- Insert spring
~
./'"
1st gear needle bearing
--
1st gear washer lEI

1st gear bushing

Q
!:
t
Spacer
Main drive gear snap ring* G Spacer
3rd & 4th synchronizer hub
nshaft front snap ring * 0 ~
~ Shifti
~
..n
CD
I» 0
::D
....s:
Main drive bearing ' ~- insert
snap ring ~-- 1st main gear
~
2nd inner baulk ring (with 0
I sub-gear) 3 m
co "a

l-"
Spread spring ::D
0
,..c
-
Counter gear rear thrust bearing Shifting insert ::::t %
Counter gear 7 1st & 2nd
CD
::::t
...
L,._
Spread spring synchronizer hub fn
(SteelbaiiiE!I I~ 2nd outer baulk ring
Synchronizer cone ~·
~i~ 2nd gear needle bearing @~

Counter gear
front bearing
 / Mainshaft rear snap ring ~

C-ring holder l
Mainshaft spacer/
C-ring *
7
J

------
Reverse gear
Reverse coupling sleeve\
Reverse hub-, \
I r? \.~
I~\,))

Mai nshaft rear bearing

l
R~~boulk<;~~O.boulk<;og~ ~~~-~r,
C) 3:
0.0. main gear CD
m
t0
110 ~

~ ~
:D

O.ooopll"''"~ ~-.....-.._
a . \\)
~~-rf\~~ ~
3: '......------1
0
3 ~
0

~
-t

~~ !. \-Sp~<
I
CD I. .
O.D.clounter gear---

~ L c Counter gear rear e

i
I
Coo•'"' "''"'" '""' ,;og *
"0
0
:I
m
:D
,..
:::z::
-

l ~ ~'-''"'""OM
,.
~ .
'- R
RM<R '""
nter gear
"" .... ;.,

• --
CD
:I
UJ
c
r-

-~
0 ,...rt ..,,;., 0

--
/
0
:I

~
w .D.gearneedlebeanng
. <hrun - " " * a..
o.o_.,.,,.,.;.,
bearing . ,rear A .a!----------=::::
\_ Reverse idler rear
Counter gear [) J 9

l--~ _/ ~ ~ \ ~
5 Sub-gearsp~ng
Reverse idler gear
Rob;o;og p;o ,... """"'
Reverse idler f ront thrust washer Apply gear oil to gears, shafts, synchronizers
Reverse idler shaft and bearings when assembling.
Vl
s:
-1
* : Select with proper thickness.
....
~

00
til
 MAJOR OVERHAUL

Shift Control Components

Interlock stopper
Retaining pin t)
r~~ _,.
0.0. & reverse fork rod

(2 ••• 3 ••• , •• 22]

Ae~; _b;~ plug : \

~~1
(1.9 - 2.6, 14. 19'1
~ Thread of bolt

~ 31-42
_r~---
(3.2- 4.3, 23-311
·-.
--<- Reverse
shift fork

1st & 2nd shift fork

.
S<dk;.,. ""' ~----
Striking interlock

·~·.:~:..~!.] ~ f Retaining pin t)

0.0. rod bracket

3rd & 4th shift fork 19 · 25 ij'·

Check ball plug_____/R, 19ro

~ (1.9- 2.6, 14. 191

~ Thread of bolt

Check spring
. 0.0. fork rod

Check ball
0.0. shift fork

~ : N-m (kg-m, ft-lbl

~ : Apply recommended sealant (Nissan genuine
~II\ part: KP610-00250I or equivalent.
~ ~ : Apply locking sealant.

SMT607B

MT-10
 MAJOR OVERHAUL
Shift Control c omponents (Cont'd)·

Console finisher

i
I
Boot

Control lever
~ 13 - 16 (1.3 - 1.6, 9 - 12)
~

'--Upper
dust
boot

~ : N·m (kg-m, ft-lb)

SMT651B

MT-11
 DISASSEMBLY

Case Components
1. Remove check ball plug, check spring and check ball. Then
remove interlock stopper.
If interlock assembly is removed as a unit, the check ball can
fall into transmission case.

2. Remove upper cover, return spring and check ball.

3. Drive out retaining pin from shift & selector lever.

4. Remove control rod from M/T assembly.
Be careful not to damage control rod oil seal and dust cover.

5. Drive out retaining pin from striking arm.

MT-12
 DISASSEMBLY
Case Components (Cont'd)
6. Remove rear extension together with striking arm by tapping
lightly.

SMT612B

7. Remove front cover and gasket.

8. Remove stopper ring and main drive bearing snap ring.

9. Remove transmission case by tapping lightly.

MT-13
 DISASSEMBLY
Case Components (Cont'd)
10. Remove front cover oil seal.

Shift Control Components

1. Mount adapter plate on vise.
2. Remove O.D. & reverse fork rod.

3. Remove check ball plug, check ball and return spring.

4. Drive out retaining pin from striking lever.

5. While pulling out striking rod, remove striking lever and striking
interlock. Then remove 1st & 2nd, 3rd & 4th and reverse shift
forks.

6. Drive out retaining pin from O.D. shift fork.

7. Pull out O.D. fork rod and then remove O.D. shift fork.

MT-14
 DISASSEMBLY

Gear Components
1. Before removing gears and shafts, measure each gear end play.

Gear End play mm (in)

1st main gear 0.23. 0.33 (0.0091 . 0.0130)

2nd main gear 0.23. 0.33 (0.0091 . 0.0130)
3rd main gear 0.23. 0.33 (0.0091 . 0.0130)
O.D. counter gear 0.23. 0.33 (0.0091 . 0.0130)
Reverse main gear 0.33. 0.43 (0.0130. 0.0169)

• If not within specification, disassemble and check contact

surface of gear to hub, washer, bushing, needle bearing and
shaft.

2. Remove rear side components on mainshaft and counter gear.

a. Remove snap ring, speedometer drive gear and steel ball.
b. Remove reverse coupling sleeve.

c. Remove mainshaft rear snap ring and counter gear rear snap
ring.
d. Remove C-ring holder and mainshaft C-rings from mainshaft.
Use punch and hammer to remove C-rings.

e. Pull out counter gear rear end bearing.

f. Remove reverse idler gear and reverse idler thrust washers.

MT-15
 DISASSEMBLY
Gear Components (Cont'd)
g. Remove sub-gear from reverse idler gear.

SMT831A

h. Pull out mainshaft rear bearing.

i. Pull out reverse main gear together with mainshaft spacer and
reverse synchronizer hub. Then remove reverse gear needle
bearings.

j. Pull out reverse counter gear.

k. Remove 0.0. coupling sleeve together with 0.0. baulk ring,
reverse baulk ring and spring inserts.

SMT773A

Pull out reverse gear bushing.

SMT770A

MT-16
 DISASSEMBLY
Gear Components (Cont'd)
m. Pull out 0.0. counter gear together with reverse cone.

3. Press out mainshaft and counter gear alternately.

I
Alternately
lr- ._._.

Be sure to press mainshaft and counter gear alternately so as not to allow

the front surface of one to contact the rear surface of the other. SMT772A

4. Remove front side components on mainshaft.

a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.

SMT383A

c. Press out 2nd main gear together with 1st gear bushing and
1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.

ST~031000
(J22912.01)

SMT384A

MT-17
 DISASSEMBLY
Gear Components (Cont'd)
e. Press out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.

5. Remove front side components on counter gear.

a. Remove counter gear rear thrust bearing.

b. Remove sub-gear components.

6. Remove main drive gear bearing.

a. Remove main drive gear snap ring and spacer.
b. Press out main drive gear bearing.

MT-18
 DISASSEMBLY
Gear Components (Cont'd)
7. Remove bearings from case components.

Counter gear front bearing in transmission case Mainshaft front bearing in adapter plate

SMT38BA SMT396A
Counter gear rear bearing in adapter plate

J:i."'-..-I _
.....
H

ST37750000
(J342861

SMT394A

MT-19
 INSPECTION

Shift fork Shift Control Components

• Check contact surface and sliding surface for wear, scratches,
projections or other damage .

•~,;··~ '1:$\
SMT398A

Mainshaft and gear Gear Components

GEARS AND SHAFTS
• Check shafts for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.

Counter gear

SMT423A

Shifting insert SYNCHRONIZERS

~~~
• Check spline portion of coupling sleeves, hubs, and gears for
wear or cracks.
• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation.
• Check insert springs for deformation.

t
Clearance between baulk ring and gear
• Measure wear of main drive, 1st and 0.0. baulk rings.

Unit: mm (in)
Standard Wear limit

1st 1.05. 1.3 (0.0413. 0.0512) 0.7 (0.028)

Main drive 1.05 . 1.3 (0.0413 . 0.0512) 0.7 (0.028)
0.0. 1.05. 1.3 (0.0413. 0.0512) 0.7 (0.028)

If the clearance is smaller than the wear limit, replace baulk ring.

MT-20
 INSPECTION
Gear Components (Cont'd)
Inner baulk ring • Measure wear of 2nd and 3rd baulk rings.
'\2nd inner baulk ring a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far as it
~h:oo"" ooo• will go, measure dimensions "A" and "8".

Unit: mm (in)

ST30031000~~~~
(J22912-01)
Dimension Standard Wear limit

Dial indicator 0.6-1.1

ST30031000 A
SMT041B (J22912-01)
(0.024- 0.043)
0.2 (0.008)
0.7-0.9
Outer baulk ring B
(0.028 - 0.035)
Synchronizer cone
2nd outer baulk ring
==~':"­
Feeler gauge c. If dimension "A" or "8" is smaller than the wear limit,
replace baulk ring.

J,V=9=s
~.s:.nchronizer cone
2nd outer baulk ring SMT042B

• Measure wear of reverse baulk ring.

a. Place baulk ring in position on reverse cone.
b. While holding baulk ring against reverse cone as far as it will go,
measure dimension "A" with dial indicator.
Unit: mm (in)
Standard Wear limit

-0.1 to 0.35
Dimension "A" 0.7 (0.028)
(-0.0039 to 0.0138)

c. If dimension "A" is larger than the wear limit, replace baulk ring.

BEARINGS
• Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

MT-21
 ASSEMBLY
Gear Components ( Cont' d)
1. Install bearings into case components.
Counter gear front bearing in transmission Mainshaft front bearing in adapter plate
case

SMT389A SMT397A

Counter gear rear bearing in adapter plate

SMT395A

2. Install main drive gear bearing.

a. Press main drive gear bearing.
b. Install main drive gear spacer.

c. Select proper main drive gear snap ring to minimize clearance

of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)

Main drive gear snap ring

Thickness mm (in) Part number

1.89 (0.0744) 32204-01GOO

1.98 (0.0780) 32204-01G01
SMT426A
2.05 (0.0807) 32204-01 G02
2.12 (0.0835) 32204-01 G03
2.19 (0.0862) 32204-01G04

d.· Install selected snap ring on main drive gear.

MT-22
 ASSEMBLY
Gear Components (Cont'd)
3. Install components on counter gear.
a. Install sub-gear components.
When installing sub-gear snap ring, tap sub-gear snap ring
into position on counter gear.

b. Install counter gear rear thrust bearing.

4. Install front side components on mainshaft.

a. Assemble 1st & 2nd synchronizer.

b. Assemble 3rd & 4th synchronizer.

Synchronizer hub
~=""""'*"-' Coupling sleeve tl
Insert spring

Rear ¢J

SMT615B

c. Press on 3rd & 4th synchronizer assembly together with 3rd

main gear and 3rd gear needle bearing.
Pay attention to direction of synchronizer assembly.

SMT399A

MT-23
 ASSEMBLY
Gear Components (Cont'd)
d. Select proper snap ring to minimize clearance of groove.
Allowable clearance of groove:
0 - 0.1 mm {0 - 0.004 in)

Mainshaft front snap ring

Thickness mm (in) Part number

1.89 (0.0744) 32204-01 GOO

1.98 (0.0780) 32204-01 G01
2.05 (0.0807) 32204-01 G02
SMT400A
2.12 (0.0835) 32204-01 G03
2.19 (0.0862) 32204-01 G04

e. Install selected snap ring on mainshaft.

f. Press on 1st & 2nd synchronizer assembly together with 2nd

main gear and 2nd gear needle bearing.

g. Press on 1st gear bushing using 1st gear washer.

h. Install 1st main gear and needle bearing.

i. Install steel ball and 1st gear washer.

Apply multi-purpose grease to steel ball and 1st gear washer
before installing.

SMT403A

MT-24
 ASSEMBLY
Gear Components (Cont'd)
5. Select proper counter gear front bearing shim when replacing
transmission case, counter gear, counter gear thrust bearing or
sub-gear components.
a. Install counter gear with sub-gear components, counter gear
front and rear thrust bearing on adapter plate.
b. Remove counter gear front bearing shim from transmission
"'~~111--Cou nter case.
gear
c. Place adapter plate and counter gear assembly in transmission
Counter gear rear
thrust bearing
case (case inverted).

SMT427A

d. Tighten adapter plate to transmission case using 2 bolts.

e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator
deflection.
g. Select proper shim using table below as a guide.
Counter gear end play:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Table for selecting proper counter gear front bearing shim

Thickness of
Dial indicator deflection
proper washer Part number
mm (in)
mm (in)

0.93 - 1.02 (0.0366- 0.0402) 0.8 (0.031) 32218-01 GOO

1.03 - 1.12 (0.0406 - 0.0441 ) 0.9 (0.035) 32218-01G01
1.13 - 1.22 (0.0445 - 0.0480) 1.0 (0.039) 32218-01 G02
1.23 - 1.32 (0.0484 - 0.0520) 1.1 (0.043) 32218-01 G03
1.33- 1.42 (0.0524- 0.0559) 1.2 (0.047) 32218-01 G04
1.43 - 1.52 (0.0563 - 0.0598) 1.3 (0.051) 32218-01 G05
1.53 - 1.62 (0.0602 - 0.0638) 1.4 (0.055) 32218-01 G06

MT-25
 ASSEMBLY
Gear Components (Cont'd)
6. Select proper reverse idler rear thrust washer when replacing
rear extension, reverse idler gear, reverse idler shaft or reverse
idler thrust washer.
a. Install reverse idler gear, reverse idler needle bearings, reverse
idler thrust washers and reverse idler shaft into rear extension.
When replacing reverse idler rear washer, install either A or B.
Reverse idler rear thrust washer

Thickness mm (in) Part number

A 1.97 (0.0776) 32284-01 G 10

8 2.07 (0.0815) 32284-01G11

b. Place dial indicator on front end of reverse idler shaft.

c. Put straightedge on front surface of rear extension as a
stopper of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 mm (0.0118 - 0.0209 in)
e. If not within specification, replace reverse idler rear thrust
washer with the other (A or B) and check again.

MT-26
 ASSEMBLY
Gear Components (Cont'd)
7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.

b. Install mainshaft a little on mainshaft front bearing.

To allow for installation of counter gear, do not install
mainshaft completely.

c. Install counter gear on counter gear rear bearing and install

main drive gear, pilot bearing and spacer on mainshaft.

When installing counter gear into counter gear rear bearing, push
Push up with screwdriver
up on upper roller of counter gear rear bearing with screwdriver.

d. Install Tools (J26349-3) onto adapter plate and C-ring and

C-ring holder on mainshaft.
e. Install Tool (J34328) on mainshaft.

MT-27
 ASSEMBLY
Gear Components (Cont'd)
f. Install mainshaft and counter gear completely by extending
length of J26349-3.

8. Install rear side components on mainshaft and counter gear.

a. Install 0.0. gear bushing while pushing on the front of counter
gear.

ST37750000~
/ (J34332
//
)- '--
SMT444A

b. Install 0.0. main gear.

Pay attention to direction of O.D. main gear. (B is wider than
A as shown at left.)
c. Install adapter plate with gear assembly onto transmission case.
d. Install 0.0. gear needle bearing and then install 0.0. counter
gear and reverse idler shaft.

e. Install reverse gear bushing.

f. Install reverse cone.

MT-28
 ASSEMBLY
Gear Components (Cont'd)
Insert spring g. Install insert springs and reverse baulk ring on 0.0. coupling
sleeve. Then install them and 0.0. baulk ring on 0.0. counter
gear.
Pay attention to direction of 0.0. coupling sleeve.
Reverse baulk ring

h. Install reverse counter gear.

i. Install sub-gear on reverse idler gear.

j. Install reverse gear needle bearing and then install reverse main
gear, reverse idler gear and reverse idler thrust washers.

ST36730010
( )

SMT832A

k. Install reverse hub.

Pay attention to its direction.

Front

MT-29
 ASSEMBLY
Gear Components (Cont'd)
I. Install mainshaft spacer and mainshaft rear bearing.
m. Install speedometer drive gear.

n. Install counter gear rear end bearing.

o. Separate adapter plate from transmission case and Mount
adapter plate on vise again.

p. Select proper mainshaft G-ring to minimize clearance of groove.

Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in}

Mainshaft C-ring

Thickness mm (in) Part number Thickness mm (in) Part number

2.63 (0.1035) 32348-01 G 15 3.19 (0.1256) 32348-01G07

2.70 (0.1063) 32348-01 GOO 3.26 (0.1283) 32348-01 GOB
2.77 (0.1091) 32348-01 G01 3.33 (0.1311) 32348-01 G09
2.84 (0.1118) 32348-01 G02 3.40 (0.1339) 32348-01 G 10
2.91 (0.1146) 32348-01 G03 3.47 (0.1366) 32348-01 G 11
2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01 G 12
3.05 (0.1201) 32348-01 G05 3.61 (0.1421) 32348-01 G 13
3.12 (0.1228) 32348-01 GOB 3.68 (0.1449) 32348-01 G 14

q. Install selected G-ring, G-ring holder and mainshaft rear snap

ring.

MT-30
 ASSEMBLY
Gear Components (Cont'd)
r. Install spacer and then select proper counter gear rear snap
ring to minimize clearance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Counter gear rear snap ring
Thickness mm ·(in) Part number

1.26 (0.0496) 32236-01 GOB

1.32 (0.0520) 32236-01GOO
1.38 (0.0543) 32236-01 GO 1
1.44 (0.0567) 32236-01G02
1.50 (0.0591) 32236-01G03
1.56 (0.0614) 32236-01G04
1.62 (0.0638) 32236-01 G05
1.68 (0.0661) 32236-01G06
1.74 (0.0685) 32236-01G07

s. Install selected counter gear rear snap ring.

t. Install reverse coupling sleeve.

Pay attention to its direction.
u. Measure each gear end play as a final check - Refer to
"OISASSEMBLY".

Shift Control Components

1. Install 0.0. fork rod and 0.0. shift fork. Then install retaining
pin into 0.0. shift fork.
2. Install 1st & 2nd, 3rd & 4th and reverse shift forks onto
coupling sleeve.

3. Install striking rod into hole of shift forks, striking lever and
interlock and then install retaining pin into striking lever.
Make sure that striking rod moves smoothly.

MT-31
 ASSEMBLY
Shift Control Components (Cont'd)
4. Install check ball, return spring and check ball plug.
Apply sealant to thread of check ball plug.

Case Components
1. Install front cover oil seal.
Apply multi-purpose grease to seal lip.
2. Install selected counter gear front bearing shim onto transmis-
sion case.
Apply multi-purpose grease.
3. Apply sealant to mating surface of transmission case.

4. Install gear assembly onto transmission case.

5. Install check spring and check ball into interlock stopper.
Apply multi-purpose grease to check ball.

6. Install interlock stopper assembly and then tighten check ball

plug.
Apply sealant to thread of check ball plug.

7. Install stopper ring and main drive bearing snap ring.

MT-32
 ASSEMBLY
Case Components (Cont'd)
8. Install front cover and gasket.
Apply sealant to thread of 3 bolts shown .left.
9. Apply sealant to mating surface of adapter plate.

10. Install rear extension together with striking arm.

11. Install retaining pin into striking arm.

12. Install control rod.

Be careful not to damage control rod oil seal and dust cover.
13. Install retaining pin into shift & selector lever.

14. Install return spring and check ball and then install control
housing.
Apply sealant to mating surface of rear extension.
15. Tighten control housing bolts.

MT-33
 SERVICE DATA A~D SPECIFICATIONS (S.O.S.)

General Specifications

Engine VG300E, VG300ETT

Transmission model RS5R30A

Shift pattern

1 3 5

~l_j
2
il
4 R

Synchromesh type Werner

Gear ratio
1st 3.214
2nd 1.925
3rd 1,302
4th 1.000
0.0. 0.752
Reverse 3.369

Number of teeth
Main drive gear 23
Main gear 1st 31
2nd 30
3rd 29
0.0. 24
Reverse 30

Counter drive gear 31

Counter gear 1st 13
2nd 21
3rd 30
0.0. 43
Reverse 12
Reverse idler gear 22

Oil capacity liter IUS pt, Imp pt) 2.8 (5-7/8, 4-7/81

MT-34
 SERVICE DATA AND SPECIFICATIONS. (S.O.S.)

Inspection and Adjustment

GEAR END PLAY DISTANCE BETWEEN REAR SURFACE
OF REVERSE CONE AND
Gear End play mm (in)
REVERSE BAULK RING
1st main gear
2nd main gear
3rd main gear
0.23-0.33 (0.0091 -0.0130)
0.23-0.33 (0.0091 -0.0130) r R~verse cone

~
0.23-0.33 (0.0091 - 0.0130)
O.D. counter gear 0.23-0.33 (0.0091 - 0.0130)
Reverse main gear 0.33-0.43 (0.0130- 0.0169)
Reverse baulkrin~ Unit: mm (in)
Counter gear 0.10-0.25 (0.0039 -0.0098)
Standard Wear limit
Reverse idler gear 0.30-0.53 (0.0118 -0.0209)
-0.1 to 0.35
Dimension "A" 0.7 (0.028)
(-0.0039 to 0.0138)

AVAILABLE SNAP RING

CLEARANCE BETWEEN BAULK RING
Main drive gear snap ring
AND GEAR
Allowable clearance 0-0.1 mm (0 -0.004 in)
1st, main drive and O.D. baulk ring
Thickness mm (in) Part number
Unit: mm (in)
Standard Wear limit 1.89 (0D744) 32204.01GOO

1 .05 -1.3 1 .98 (0.0780) 32204.01G01

1st 0.7 (0.028)
(0.0413- 0.0512) 2 .05 (0 .0807 ) 32204.01G02

Main drive 1.05 -1.3 2.12 (0.0835) 32204.01G03

0.7 (0.028)
(0.0413. 0.0512)
2.19 (0.0862) 32204.01G04
1.05 -1.3
O.D. 0.7 (0.028)
(0.0413. 0.0512)
Mainshaft front snap ring
Allowable clearance 0 -0.1 mm (0 -0.004 in)
2nd and 3rd baulk ring
Thickness mm (in) Part number
Outer baulk ring
1.89 (0.0744) 32204.01GOO
B
1.98 (0.0780) 32204.01G01
2.05 (0.0807) 32204.01G02
2.12 (OD835) 32204.01G03
2.19 (0.0862) 32204.01G04

Inner baulk ring

SMT044B Synchronizer cone Unit: mm (in) Counter gear rear snap ring

Standard Wear limit Allowable clearance 0-0.1 mm (0 -0.004 in)

Dimension
Thickness mm (in) Part number
0.6- 1.1
A (0.024- 0.043) 0.2 (0.008)
1.26 (0.0496) 32236.01G08
1 .32 (0 .0520) 32236.01GOO
0.7-0.9
B 0.2 (0.008)
(0.028 - 0.035) 1 .38 (0 .0543) 32236.Q1G01
1 .44 (0 .0567) 32236.01G02
1.50 (0.0591) 32236.Q1G03
1.56 IOD614l 32236.01G04
1.62 (0.0638) 32236.01G05
1 .68 (0 .0661 ) 32236.01G06
1.74 (0.0685) 32236.01G07

MT-35
 SERVICE DATA .AND SPEClFICATIO.NS (S~D.S~)

Inspection and Adjustment (Cont'd)

AVAILABLE C-RING
Mainsh~ftC.ring::

Allowable clearance 0-0.1 mm.(O :o.004 in)

Thickness Thicknes.s
Part number Part number
mm Onl mm (in)

2.63 (0.1035) 32348.01G15 3.19 (0.1256) 32348.01G07

2.70 (0.1063) 32348.01GOO 326 (0.12831 32348.01G08
2.77 (0.1091) 32348.01G01 3.33 (0.1311) 32348.01G09
2.84 (0.1118) 32348.01G02 3.40 (0.13391 32348.01 G 10
2.91 (0.1146) 32348.01G03 3;47 (0.13661 32348.01G11
2.98 (0.11731 32348.01G04 3.54 (0.1394) 32348.01G12
3.05 10.1201 I 32348.01G05 3.6.1 (0.14:?1 I 32348.01G13
3.12 (0.12281 32348.01G06 3.68 10.1449) 32348.01G14

AVAILABLE SHIM AND WASHER

Table for selecting proper counter gein
front bearing shim
Thickness of
Dial indicator deflection
proper washer Part number
mm (in)
mm (in)

0.93-1.02 (0.0366 -0.0402) 0.8 IOD31 I 32218.01GOO

1.03 -1.12 (OD406- 0.0441 I 0.9 (0.035) 32218.01G01
1.13 -122 (0.0445 - 0.0480) 1.0 (0.039) 32218.01G02
123-1.32 (0.0484 -0.0520) 1.1 (0;043) 32218.01 G03
1 .33 - 1 .42 (0 D524 - 0.0559 I 1.2 (0.047) 32218.01G04
1.43 - 1 .52 10 .0563 - o .0598 I 1.3 (0.051 I 32218.01G05
1.53-1.62 (0.0602 -0.0638) 1.4 (0.055) 32218.01G06

Reverse idler rear thrust washer

Thickness mm (in) Part number

1.97 (0.07761 32284.01 G1 0

2.07(0.0815) . 32284.01 G11

MT-36
 AUTOMATIC TRANSMISSION

SECTION AT
CONTENTS
PREPARATION ................................................................................................................................ AT- 2
PRECAUTIONS ................................................................................................................................ AT- 4
A/T CONTROL DIAGRAM ............................................................................................................. AT- 5
ON-VEHICLE SERVICE ... ......... .. ......... .. ... ... .... ..... .... .. ..... ..... .... ... .... ....... .... .. .... .. ... ... ..... ... ....... .. ..... AT- 8
TROUBLE DIAGNOSES ................................................................................................................. AT- 11
REMOVAL AND INSTALLATON ................................................................................................... AT-108
MAJOR OVERHAUL ....................................................................................................................... AT-110
DISASSEMBLY ................................................................................................................................ AT-118
REPAIR FOR COMPONENT PARTS ........................................................................................... AT-130
ASSEMBLY ...................................................................................................................................... AT-179
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ..................................................................... AT-198

When you read wiring diagrams:

e Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES".
 PREPARATION
SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

ST2505S001 Measuring line pressure

(J25695-A)
Oil pressure gauge set
CD ST25051 001
( )
Oil pressure gauge
® ST25052000
( )
Hose
@ ST25053000
( )
Joint pipe
@ ST25054000
( )
Adapter
@ ST25055000
( )
Adapter

KV31101201 Measuring line pressure

( )
Oil pressure gauge
adapter

ST07870000 Disassembling and assembling

(J37068) AfT
Transmission case
stand

KV31102100 Checking one-way clutch in

(J37065) torque converter
Torque converter one-
way clutch check tool

ST25850000 Removing oil pump assembly

(J25721-A)
Sliding hammer

KV31102400 Removing and installing clutch

(J34285 and return springs
J34285-87)
Clutch spring
compressor

ST33200000 Installing oil pump housing

(J26082) oil seal
Drift a: 60 mm (2.36 in) dia. Installing rear oil seal
b: 44.5 mm 11.752 in) dia.

AT-2
 PREPARATION

Tool number
(Kent-Moore No.) Description
Tool name

ST30720000 Installing rear oil seal

(J34331)
Drift
•: 77 mm 13.03 inl di•.
b: 55.5 mm (2.185 inl di•.

(J34291) Selecting oil pump cover

Shim setting gauge bearing race and oil pump
set thrust washer

AT-3
 PRECAUTIONS

Service Notice
• Before proceeding with disassembly, thoroughly • It is very important to perform functional tests
clean the outside of the transmission. It is whenever they are indicated.
important to prevent the internal parts from e The valve body contains precision parts and
becoming cont'aminated by dirt or other foreign requires extreme care when parts are removed
matter. and serviced. Place removed parts in order on a
• Disassembly should be done in a clean work parts rack so they can be put back in the valve
area. body in the same positions and sequences. Care
• Use lint-free cloth or towels for wiping parts will also prevent springs and small parts from
clean. Common shop rags can leave fibers that becoming scattered or lost.
could interfere with the operation of the trans- • Properly installed valves, sleeves, plugs, etc. will
mission. slide along their bores in the valve body under
• When disassembling parts, place them in order their own weight.
in a parts rack so that they can be put back into • Before ass~:~mbly, apply a coat of recommended
the unit in their proper positions. A.T.F. to all parts. Petroleum jelly may be applied
• All parts should be carefully cleaned with a to 0-rings and seals and used to hold small
general purpose, non-flammable solvent before bearings and washers in place during reassembly.
inspection or reassembly. Do not use grease.
• Gaskets, seals and 0-rings should be replaced • Extreme care should be taken to avoid damage
any time the transmission is disassembled. to 0-rings, seals and gaskets when assembling.
• After overhaul, refill the transmission with new
A.T.F.

AT-4
 "R" line pressure 0. l and 1 hne
check port pressure check
pori

I
:1>
..........
:::E: 0
'< 0
...
ca.
Dl
z
....
c
!4 -c;· XI
0
r
I
U'l 0
0
.......
~ -:1>c
C)
2. XI
:1>
...n9. 3:
-·enc....

I
I
I
I
en
)>

-
-l
1\1
w
ID
I
I

:
L __ _
~
-----------
~
I
 A/T CONTROL DIAGRAM

Electrical Control Chart

- El ect·ncaIs1ngna
.
Vehicle signal
Speed •nsor r Engine ~
-,
-+ Hydraulic pressure
Vehicle signal

Overdrive
switch
*
v
A/T
Overdrive off
indicator lamp

Kickdown switch
v AIT check
Power supply

r-----
•
----------l--------- -1---
Control signal

---. I
lamp

Idle switch
I
I Inhibitor switch I
Shift solenoid A Line pressure solenoidj :
I I
Full-throttle Fluid temperature Shift solenoid B r---
I
switch •nsor Overrun clutch
Throttle sensor
Engine rpm·
I
I
I
Revolution
sensor
solenoid
Lock-up solenoid
;I
I
Dropping
resistor I
signal I
I
L----t---------~--------

~~·?·C.S. contro
umt
AfT control unit
I
SAT161E

Mechanical Operation
Band servo
Forward Low Low&
Shift Reverse High Forward Overrun
one-way one-way reverse Lock-up Remarks
position clutch clutch clutch clutch 2nd 3rd 4th
clutch clutch brake
apply release apply

p PARK

R 0 0 REVERSE

N NEUTRAL

D
1st

2nd
0
0
(8
~1 0 0
•• • Automatic shift
*4 3rd

4th
0
0
0
®
0 *2®

*3®
®

® 0
• 0
1++2++3++4

1st 0 e • • Automatic shift

•
2
1++2
2nd 0 0 0

1
1st

2nd
0
0
0
0 0
•• 0 Locks (held sta-
tionaryl in 1st
speed 1 -2

*1. Operates when overdrive switch is set in "OfF" position.

*2. Oil pressure is applied to both 2nd "apply" side and 3rd "release" side of band servo piston. However, because oil pressure area on the
"release" side is greater than that on the "apply" side, brake band does not contract.
*3. Oil preslure is applied to 4th "apply" side in condition *2 above, and brake band contracts.
*4. AIT will not shift to 4th when overdrive switch is set in "Off" position.
0 : Operates.
0 : Operates when throttle opening is less than 1/16. Engine brake activates.
e: Operates during "progressive" acceleration.
® : Operates but does not affect power transmission.
8 : Operates when throttle opening is less than 1/16 but does not affect engine brake.

AT-6
 Lock-up piston

Torque converter

Converter housing Front planetary gear

Rear planetary gear
Transmission case
Forward clutch
Brake band

sn
Forward one-way clutch
Reverse clutch
Overrun clutch
High clutch
n
a 0
••
I
z
;I
!i
I
tn
CD
!1.
0
....
s· c
""""' :::s
!!.
<
;·
•,..
C)
:a

==

Ul

..
~
-4
hi
Ill
Input shaft
Control valve Output shaft
Ill
 ON-VEHICLE SERVICE

Control Valve Assembly and Accumulators

Inspection
1. Remove oil pan and gasket and drain A.T.F.

-----
SAT293C

2. Remove oil strainer.

3. Remove control valve assembly by removing fixing bolts and

disconnecting harness connector.

Bolt length and location

Bolt symbol Qmm (in) ~ Q
33 (1.30)

@ 45 (1.77)

4. Remove solenoids and valves from valve body if necessary.

5. Remove t~rminal cord assembly if necessary.

6. Remove accumulators A, B, C and D by applying compressed

air if necessary. ·
• Hold each piston with rag.
7. Reinstall any part removed.
• Always use new sealing parts.
ON-VEHICLE SERVICE

Revolution Sensor Replacement

1. Remove exhaust tube.
2. Remove revolution sensor from A/T assembly.
3. Reinstall any part removed.
• Always use new sealing parts.

Rear Oil Seal Replacement

1. Remove propeller shaft from vehicle. - Refer to section PD.
2. Remove rear oil seal.

3. Install rear oil seal.

• Apply A.T.F. before installing.
4. Reinstall any part removed.

Parking Components Inspection

1. Remove exhaust tube.
2. Remove propeller shaft from vehicle. - Refer to section PD.
3. Remove rear engine mounting member from A/T assembly
while supporting A/T with jack.

4. Remove rear extension from transmission case.

5. Replace parking components if necessary.
6. Reinstall any part removed.
• Always use new sealing parts.

AT-9
 ON-VEHICLE SERVICE

Inhibitor Switch Adjustment

1. Remove manual control linkage from manual shaft of A/T
assembly.
2. Set manual shaft of A/T assembly in "N" position.
3. Loosen inhibitor switch fixing bolts.

4. Insert pin into adjustment holes in both inhibitor switch and

manual shaft of A/T assembly as near vertical as possible.
5. Reinstall any part removed.
6. Check continuity of inhibitor switch. - Refer to "Electrical
Components Inspection".

Manual Control Linkage Adjustment

Move selector lever from "P" range to "1" range. You should be
able to feel the detents in each range.
If the detents cannot be felt or the pointer indicating the range is
improperly aligned, the linkage needs adjustment.
1. Place selector lever in "P" range.
2. Loosen lock nuts.

3. Tighten lock nut ® until it touches trunnion pulling selector

lever toward "R" range side without pushing button.
4. Back off lock nut ® 1 turn and tighten lock nut (!) to the
specified torque.
Lock nut:
tql: 11 - 15 N·m (1.1 - 1.5 kg-m, 8 - 11 ft-lb)
5. Move selector lever from "P" range to "1" range. Make sure
that selector lever can move smoothly.

SAT7888

Kic;kdown switc;h
Klckdown Switch Adjustment
thread 1. Adjust accelerator cable - Refer to section FE.
Loc;k nut
t,ql8 -12 N·m
2. Adjust clearance "C" between stopper rubber and end of
(0.8 - 1.2 kg-m, kickdown Switch thread while depressing accelerator pedal fully.
5.8 - 8.7 ft-lb) Clearance "C": 0.3 - 1.0 mm (0.012 - 0.039 In)
Kickdown switch

SAT449C

AT-10
 TROUBLE DIAGNOSES

Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair ...............................................................AT- 13
Preliminary Check ........................................ ,........................................................................................................... AT- 14
Diagnosis by CONSULT .......................................................................................................................................... AT- 32
AfT Electrical Parts Location ................................................................................................................................ AT- 35
Circuit Diagram for Quick Pinpoint Check ......................................................................................................... AT- 37
Wiring Diagram ................................................................................. ·······································································' AT- 38
Self-diagnosis ..................................................................................................................................,........................ AT- 40
SELF-DIAGNOSTIC PROCEDURE (With CONSULT) .................................................................................... AT- 40
SELF-DIAGNOSTIC PROCEDURE (Without CONSULT) ............................................................................... AT- 41
JUDGEMENT OF SELF-DIAGNOSIS CODE ................................................................................................... AT- 43
REVOLUTION SENSOR CIRCUIT CHECK ...................................................................................................... AT- 47
SPEED SENSOR CIRCUIT CHECK .................................................................................................................. AT- 48
THROTTLE SENSOR CIRCUIT CHECK ........................................................................................................... AT- 49
SHIFT SOLENOID A CIRCUIT CHECK ............................................................................................................ AT- 50
SHIFT SOLENOID B CIRCUIT CHECK ............................................................................................................ AT- 51
OVERRUN CLUTCH SOLENOID CIRCUIT CHECK ........................................................................................ AT- 52
LOCK-UP SOLENOID CIRCUIT CHECK .......................................................................................................... AT- 53
FLUID TEMPERATURE SENSOR CIRCUIT AND
A/T CONTROL UNIT POWER SOURCE CIRCUIT CHECKS ........................................................................ AT- .54
ENGINE REVOLUTION SIGNAL CIRCUIT CHECK ......................................................................................... AT- 56
LINE PRESSURE SOLENOID CIRCUIT CHECK ............................................................................................. AT- 57
INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH
CIRCUIT CHECKS .............................................................................................................................................. AT- 58
Diagnostic Procedure 1
(SYMPTOM: A/T CHECK lamp does not come on for about 2 seconds
when turning ignition switch to "ON".) .......................................................................................................... AT- 62
Diagnostic Procedure 2
(SYMPTOM: Engine cannot be started with selector lever in "P" or "N" range or engine
can be started with selector lever in "D", "2", "1" or "R" range.) ......................................................... AT- 63
Diagnostic Procedure 3
(SYMPTOM: Vehicle moves when it is pushed forward or backward
with selector lever in "P" range.) .................................................................................................................... AT- 63
Diagnostic Procedure 4
(SYMPTOM: Vehicle moves forward or backward when selecting "N" range.) ...................................... AT- 64
Diagnostic Procedure 5
(SYMPTOM: There is large shock when changing from "N" to "R" range.) .......................................... AT- 65
Diagnostic Procedure 6
(SYMPTOM: Vehicle does not creep backward when selecting "R" range.) .......................................... AT- 66
Diagnostic Procedure 7
(SYMPTOM: Vehicle does not creep forward when selecting "D" , "2" or "1" range.) ....................... AT- 67
Diagnostic Procedure 8
(SYMPTOM: Vehicle cannot be started from D1 on Cruise test- Part 1.) ............................................ AT- 68
Diagnostic Procedure 9
(SYMPTOM: A/T does not shift from D1 to D2 at the specified speed. A/T does not shift
from D4 to D2 when depressing accelerator pedal fully at the specified speed.) ................................... AT- 69
Diagnostic Procedure 10
(SYMPTOM: A/T does not shift from D2 to Da at the specified speed.) .................................................. AT- 70
Diagnostic Procedure 11
(SYMPTOM: A/T does not shift from Da to D4 at the specified speed.) .................................................. AT- 71
Diagnostic Procedure 12
(SYMPTOM: A/T does not perform lock-up at the specified speed.) ....................................................... AT- 72
Diagnostic Procedure 13
(SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds.) ..................................... AT- 73
Diagnostic Procedure 14
(SYMPTOM: Lock-up is not released when accelerator pedal is released.) ............................................ AT- 73

AT-11
 TROUBLE DIAGNOSES
Contents (Cont'd)
Diagnostic Procedure 15
(SYMPTOM: Engine speed does not return to idle smoothly when A/T is shifted
from 04 to 03 with accelerator pedal released.
Vehicle does not decelerate by engine brake when changing overdrive switch
to "OFF" position with accelerator pedal released.
Vehicle does not decelerate by engine brake when changing selector lever
from "0" to "2" range with accelerator pedal released.) ........................................................................... AT- 74
Diagnostic Procedure 16
(SYMPTOM: Vehicle does not start from o, on Cruise test - Part 2.) ................................................... AT- 75
Diagnostic Procedure 17
(SYMPTOM: A/T does not shift from 04 on 03 when changing overdrive switch
to "OFF'' position.) ............................................................................................................................................ AT- 75
Diagnostic Procedure 18
(SYMPTOM: A/T does not shift from 03 on 22 when changing selector lever from
"0" to "2" range.) ............................................................................................................................................. AT- 76
Diagnostic Procedure 19
(SYMPTOM: A/T does not shift from 22 to 1, when changing selector lever
from ''2'' to ''1'' range.) .................................................................................................................................... AT- 76
Diagnostic Procedure 20
(SYMPTOM: Vehicle does not decelerate by enigne brake when shifting from ~ (h) to 1,.) .............. AT~ 76
Electrical Components Inspection ........................................................................................................................ AT- 77
Final Check ............................................................................................................................................................... AT- 84
Symptom Chart .....................................................................................................;................................................... AT- 89
AIT Shift Lock System ........... .......... .. .. ... ....... .. .... ....... ... ... ... .... ..... ...... .. ..... .. .. ....... ... ............ ... .......... .... .. .... ... .. .. ..... AT- 92

AT-12
 TROUBLE DIAGNOSES

How to Perfor111 Trouble Diagnoses for Quick

and Accurate Repair
WORK FLOW

<
Reference item

LISTEN TO CUSTOMER
COMPLAINTS.

CHECK AIT FLUID LEVEL A/T FLUID CHECK

AND CONDITION. (See page AT-14.)
Preliminary
Check
ROAD TESTING
(See page AT-15.)
• PERFORM ROAD TESTING.
r--------- • PERFORM SELF-DIAGNOSIS. Self-diagnosis
(See page AT-40.)

Self-diagnosis
(See page AT-40.)
INSPECT MALFUNCTION ON
Diagnostic Proc.edure
THE BASIS OF EACH COM-
PONENT'S CONDITION. (See page AT-62.)

Symptom Chart
(See page AT-89.)

REPAI A/REPLACE.

N.G.
L _________ _ Final Check
FINAL CHECK
(See page AT-84.)

AT-13
 TROUBLE DIAGNOSES

Preliminary Check
AIT FLUID CHECK
Fluid leakage check
1. Clean area suspected of leaking, - for example, mating
surface of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in "0"
range and wait a few minutes.
3. Stop engine.

SAT767B

4. Check for fresh leakage.

' SATB01A

Fluid condition ·check

Fluid color Suspected problem

Dark or black with burned odor Wear of frictional material

Water contamination
Milky pink - Road water entering through
filler tube or breather

Oxidation
Varnished fluid, light to dark
- Over or under filling
SAT638A brown and tacky :
- Overheating

Fluid level check

Refer to ·section MA.

AT-14
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
ROAD· TEST PROCEDURE ROAD TESTING
I 1. Check before engine is started.
Description
• The purpose of this road test is to determine overall
performance of automatic transmission and analyze causes
of problems.
I 2. Check at idle. • The road test consists of the following three parts:
1. Check before engine is started
2. Check at idle

I 3. Cruise test.
3. Cruise test

SAT786A

• Before road test, familiarize yourself with all test procedures

and items to check.
• Conduct tests on all items. Troubleshoot items which check
out No Good after road test. Refer to "Self-diagnosis" and
''Diagnostic Procedure''.

AT-15
 TROUBLE' DIAGNOSES
Preliminary Check (Cont'd)
1. Check: before engine is started
D ·,
Park vehicle. on flat surface.

SAT787A

Move selector lever. to "P"

Does A/T check lamp come on Go to Diagnostic Procedure 1.

SAT768B for about 2 seconds?
Yes
IJEJ

i~~aa\c
Does A/T check lamp flicker for Perform self-diagnosis. ·
about 8 seconds? - Refer to SELF-DIAGNOSIS
PROCEDURE.

ODDDDD
rAIT check lampV

I [!c~,CR ~ 7/ Perform self-diagnosis.

-Refer to SELF-DIAGNOSIS
PROCEDURE and note N.G.
items.

Go to "ROAD TESTING
- 2. Check at idle",

AT-1-6
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
2. Check at idle
D
Park vehicle on flat surface.

Move selector lever to "P" or

SAT787A
"N" range .

•
Is engine started? Go to Diagnostic Procedure 2.
Yes

SAT769B

Move selector lever to "D", "1",

"2" or "R" range.

Is engine started? Go to Diagnostic Procedure 2.

SAT770B
No

Move selector lever to "P" range.

SAT768B

Push vehicle forward or back·

ward.

Yes . . - - - - - - - - - - - - - - ,
Does vehicle move when it is 1----+1 Go to Diagnostic Procedure 3.
pushed forward or backward?

No

SAT796A A

AT-17
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

Move selector lever to "N" range.

ID
·I
SAT771B
I J I,
.\
'\
Brake pedal

Yes r - - - : - ' " - - - - - - - - - .

Does vehicle move forward or ~~ Go to Diagnostic Procedure 4.1
backward?
SAT797A 6 ! No
I Apply foot brake.
m l
Move selector lever ·to "R" range.

r-------~---------~ Yes r----------------~

Is there large shock when I Go to Diagnostic Procedure 5.1
changing from "N" to "R"
range?
No
Release foot brake for several
SAT7728 seconds.

Brake pedal Does vehicle creep backward Go to Diagnostic Procedure 6.

when foot brake is released?
1m Yes
Move selector lever,to "D", "1"
and "2" ranges and check if
vehicle creeps forward.

For several seconds Does vehicle creep forward in all

SAT799A three ranges?
No
1m Go to Diagnostic Procedure 7.

AT-18
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
3. Cruise test

00 With CONSULT

• Using CONSULT, conduct a cruise test and record the result.

• Print the result and ensure that shifts and lock-ups take place
as per "Shift Schedule."
• Check all items listed in Parts 1 through 3.

CONSULT setting procedure

1. Turn off ignition switch.
CONSULT 2. Connect "CONSULT" to diagnostic connector. (Diagnostic
connector is located in left dash side paneL)

SMA185C

3. Turn on ignition switch.

'"I::;SAi·~--------·-·1 4. Touch "START".

II CCII"·.j:::.:t_! L T :
:
I
L ijiil I
_J

II .·. :-.~I
.-.---i ,:.::..,J--<
:::::
I
L _l
!~:...:·1
··-·' •._.'i :::::·
~--·'
.P·{,i (_J LH=
...__ II
SEF3921

5. Touch "A/T"_
0I1

.A.LJ ! fJ ,A, . l !._. __j

SAT672C

AT-19
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
6. Touch "DATA MONITOR".
Ib ::;ELECT [:• I AG t·1CiDE :=g
[ SELF -D I~ F:ESUL TS I
I DATA t·10tHTt:iR I
I ECU PART . t·lUt·1E:EP . I
I I
I =wJ
SAT671C

7. Touch "SETIING" to set recording condition.

Ib SELECT Ml:ltH TGR ITEM
ECU mPUT SIGNALS
t·1Alt~ SIGt·lALS
SELECT! Gt·l FRG~1 NEt-!U
ADDRESS SETT I t·l(l

c:·TAC:'T
•,_.1.r--:.,
I

SAT296C

8. Touch "LONG TIME" and "ENTER" key.

SAT297C

9. Go back to SELECT MONITOR ITEM and touch "MAIN SIG-

NALS".
10. Touch "START".

SAT298C

11. When performing cruise test, touch "RECORD".

i~~Kit·HTGR 'j:~{t·!G FAIL (;!
Et-!G REI...I 800rF'm
(lEAR 1
RANGE t·l·P
UEHICLE SPEED Okm.····h
THRTL OF'Et-l I t·lG o.o . · ·:::
LWE PRES [)TV 29~:
U:JCf<-UP WT'r' 4 ...
....
SHIFT SOL A lj t·l
SHIFT SOL B I) t·l
R:ECOPD
SAT299C

AT-20
 TR.OUBLE DIAGNOSES
Preliminary Check (Cont'd)
12. After finishing cruise test par~ 1, touch "STOP".

13. Touch "DISPLAY".

I REAL-TIME DIAG I

**** N0 FAILURE ****

14. Touch "PRINT".

~ EtlG GEAF.: F.:At·IGE
REI.)
18:01

•
(rt=·rl',)
704 D
704 D
704 D
00"00 704 [:o
00"13 704 [l
00"2€ 704 [l
00" 3' 704 1 [:•

SAT302C

15. Touch "PRINT" again.

Et·IG GEAF.: RA~IGE
F.:EI.)

[)
[:o
[:o
[l
D
D
D

SAT303C

16. Check the monitor data printed out.

Et·ll3 13EAF: F.:At·lGE CAF.: THF.:TL 17. Continue cruise test part 2 and 3.
F.:EI..J ::;F'EE[:• OPEt·l
18:01 ::;Et-J -HIG
( t· F'r11) km/h) ( ....-:::)
704 1 [:o 0 o.o
704 1 [:o 0 o.o
704 1 [:o 0 0.0
704 1 D 0 o.o
00"13 704 1 D 0 0.0
00 11 26 704 1 D 0 0.0
00 11 :3'31 704 1 D 0 0.0
00 11 52 '?04 1 D 0 0.0
OO"E.5 704 1 [:o 0 o.o
SAT304C

AT-21
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

u CIUNIT
35
JOf CONNECTOR II
34
® Without CONSULT

• Throttle position can be controlled by voltage across terminals

® and ® of A/T control unit.

SAT960B

AT-22
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
0 Cruise test- Part 1
0
Warm up engine until engine oil
and A.T.F. reach operating tem·
perature after vehicle has been
driven approx. 10 minutes.
A. T.F. operating temperature:
50· 80°C (122 • 176°F)

Park vehicle on flat surface.

Set overdrive switch in "ON"

position.

Move selector lever to "P" range.

SAT774B

El

Move selector lever to "D" range.

Accelerate vehicle to half throttle.

SAT775B

Does vehicle start from D1 7 Go to Diagnostic Procedure 8.

@ ~~ !~ ~o-;i~o~-J
Yes

SAT803A Half-way

AT-23
 . TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

~1)-------l
m
Does A/T shift from Dt to Di Go to Diagnostic Procedure 9.
at the specified !£leedi_-
!Read gear position, ""l
(j) :throttle opening and :
l_!!thicle speed..:.._.:_ _J
·· Specifiechpeed when shifting
· from Di to 02:
Refer to Shift schedule.
SAT804A

~m~======~m~-======~~---~--~~--~
Yes

8/8~,__ _ _ _---4 Does A/T shift from D2 to D3 Go to Diagnostic Procedure 10.

at the specifie~speed?_
fF.i\ 'iiead gear positi9n,l
~ !throttle opening and 1
t!!'!!_cle speed:_ _ _j
Specified speed when shifting
from 0 2 to Q3!
Refer to Shift schedule,
0/8l',___ _ _--l
SAT805A m Yes
r=--------L-----------,
Does A/T shift from D3 to D4 Go to Diagnostic Procedure 11.
at the specified speed?
ra\
~1
lftead gearposition.l
throttle opening and l
l!!_hicle speed. _ _ _j.
Specified speed when shifting
from 0 3 to 04:
Refer to Shift schedule~
Yes
No
Does A/T p~rform lock-up at Go to Diagnostic Procedure 12.
the specified speed?
(F.i\~eadvehicle speed., throt-1
~ ltle opening when lock-up
~ty becOI!!_BS 94%.:_ _ ~
l
Specified speed when lock-up
occun:
Refer to Shift schedule.

Yes
Does A/T hold lock-up condition Go to Diagnostic Procedure 13.
for more than 30 seconds?

Yes

AT-24
 TROUBLE DIAGNOSES
Preliminary Check {Cont'd)
mm
Release accelerator pedal.

m
0~ 'f_____ -;;:u________
~I}
~
Is lock-up released when
lfJaccele<ator pedal ~=1..,..1
Go to Diagnostic procedure 14.

SAT806A
Decelerate vehicle by applying
II Ill foot brake lightly.

Ill
No
Does engine speed return to idle Go to Diagnostic Procedure 15.
smoothly when A/T is shifted
from D4 to D3?
M [R·~ uear position
~·,engme speed.
andl
_j
L-------
Yes

Stop vehicle.

Go to "Cruise test- Part 2".

Cruise test -'-- Part 2

Confirm overdrive switch is in
"ON" position.

!
Confirm selector lever is in "D"
range.

D !
SAT803A Hlllf-way Accelerate vehicle to half
throttle again.
II
8/8 ~
Does vehicle start from D 1 ? ~ Go to Diagnostic Procedure 16. j
@ ~ead gear position:]
II ! Yes
Accelerate vehicle to A km/h as
shown in illustration.
SAT808A
+
®
AT-25
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
IJ Accel•ator .... II

~
BIB
o1 _:t-O~ 0 /
I/ fully
Depress Release accelerator pedal and
then quickly depress it fully.
/
/
Release ..().
/ . I/ Release
02?/ 13 Does A/T shift from D4 to D2 Go to Diagnostic Procedure 9.

MTJ.Ji 0/B j
e
as soon as accelerator pedal is
depressed fully!_ _ _ _
(E\ fRead gea~: position and
\J!!) ~rattle opening:_ _ _j
j
Yes

Does A/T shift from D2 to 0 3 Go to Diagnostic Procedure 10.

at the specified speed?
fF.I\ fiiead gear position,-l
~ 1throttle opening and 1
l!,!hicle speed. _ _ ~
Specified speed when shifting
from 0 2 to 03:
=============s=A=T8=10::A~ Refer to Shift schedule.
liB Yes

Release accelerator pedal after

shifting from D2 to D3.

No
Does A/T shift from D3 to D4 Go to Diagnostic Procedure 11.
and does vehicle decelerate by
0/8 \i-----.......L-=0=---~ engine brakeL_ ___ _
j
SAT811A @
[Read gear position,
Ithrottle opening and
~~cle speed.:.._ __ j
Yes

Stop vehicle.

Go to "Cruise test - Part 3".

AT-26
 TROUBLE DIAGNOSES
Preliminary Check {Cont'd}
D Cruise test - Part 3

Confirm overdrive switch is in

"ON" position.

Confirm selector lever is in "D"

range.

SAT812A D
Accelerate vehicle, using half-
throttle, to D4 .

6
Release accelerator pedal.

ll
Set overdrive switch in "OFF"
position while driving in D4
range.
SAT813A
m No
J J
@ 00 Does A/T shift from D4 to D3?
~------::11
IR~d gear position and I l
Go to Diagnostic Procedure 17.

•
~h1cle speed. _J
------
Yes
II
Does vehicle decelerate by
engine brake?
No J
.I Go to Diagnostic Procedure 15. I
SAT776B
m Yes
Move selector lever from "D" to
BIB "2" range while driving in D3 .

(o 6
3 (O.D. OFF0 No J I
•®
Does A/T shift from D3 to 22? Go to Diagnostic Procedure 18.
I
(i) ~ead gear positio;.- J
Yes
m
SAT777B
Does vehicle decelerate by
engine brake? H Go to Diagnostic Procedure 15. I
Yes

AT-27
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

m !
Move selector lever from. "2" to
"1" range while driving in 2 2 •

llil !
Does A/T shift from 2 2 to 1 1
range?
No J
I
Go to Diagnostic Procedure 19.
I
SAT778B
@ §_ead gear position. J
m !·Yes
J
Does vehicle decelerate by
engine brake?
No
I
Go to Diagnostic Procedure 20.
I
~Yes
Stop vehicle.

l
Perform self-diagnosis. - Refer
to SELF-DIAGNOSIS PRO·
CEDURE.

AT-28
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)

Vehicle speed when shifting gears

RE4R01A
Vehicle speed km/h (MPH)
Throttle position
o, ..... 02 02 ..... o, o, . . . o. o....... o, 03 --+ 02 02 --+ 0 1

60-64 107-115 166-176 161 - 169 96- 104 44-48

Full throttle
(37- 40) (66 -71) (103 -109) (100- 105) (60-65) (27 -30)

45-49 83-89 119-127 80-88 33-39 10- 14

Half throttle
(28 -30) (52- 55) (74 -791 (50- 55) (21 -24) (6 -9)

RE4R03A
Vehicle speed km/h (MPH)
Throttle position
o, --.o. o....... o, o, -+ o. o...... o, o, ..... o. o.-+ o,
68-72 120- 128 183- 193 177- 187 109-117 33-37
Full throttle
(42- 45) (75- 80) (114-120) (110-116) (68 -73) (21- 23)

47-51 89-95 136- 144 78-86 28-34 10- 14

Half throttle
(29- 32) (55- 59) (85-89) (48- 53) 117-21 I (6-9)

Vehicle speed when performing and releasing

lock-up
RE4R01A RE4R03A
Vehicle speed km/h (MPH) Vehicle speed km/h (MPH)
Throttle D.O. switch Throttle · 0.0. switch
position [Shift range) Lock-up Lock-up position (Shift range) Lock-up Lock-up
,.ON" "OFF" "ON" "OFF"

ON 167- 175 161 - 169 ON 184- 192 178- 186

[0 4 1 (104 -109) (100- 105) [0 4 ] (114-119) (111 -116)
Full throttle Full throttle
OFF 107-115 96- 104 OFF 120- 128 109-117
[D,J (66 -71) (60-65) [0 3 ] (75- 80) (68 -73)

ON 120- 128 84-92 ON 184- 192 117- 125

[0 4 ) (75 -80) (52- 57) [0 4 ] (114-119) (73 -78)
Half throttle Half throttle
OFF 91 -99 86-94 OFF 88-96 74-82
[D,) (57 -62) (53-58) [D,l (55- 60) (46- 51)

AT-29
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
Shift schedule (Overdrive ON) - RE4R01A

Upshift

- - - - - - Downshift

8/8
Kickdown range
7/8
I
1:11 I
6/8
·c:c I
&
0 5/8
1...l-2
I ,"'
1 I ,/
E
..
Ill
> 4/8
I / 1
e I /
.r: I /
f-
2/8
I- - J/
I
I
I

0 20 40 60 80 100 120 140 160 180

(0) (10) (20) (40) \50\ (60) (70) (80) (90) (100) (110) (120)

Vehicle speed km/h (MPH)

SAT177C

Shift schedule (Overdrive OFF) - RE4R01A

Upshift

- - - - - Downshift

8/8
Kickdown range
7/8
I
I
6/8 I
I
I
1:11
c
5/8 I
1--r-2 ......... ....
;'
c I I
& 418
I I
0

..e
.!!
3/8
I /1
I I
I I
.r: I I
f- 2/8 r-.J
I
1/8 I 3 --y- 3 lock-up
I
I L-~------~-----,
0/8
0 20 40 60 80 100 120 140 160 180 200

.(10) (20) (30). (40) (50) (60) (70) (80) (90) (100) (110) (1201

Vehicle speed km/h (MPH)

SAT305C

AT-30
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
Shift schedule (Overdrive ON) - RE4R03A

- - - - - Upshift

- - - - - Downshift

8/8
Kickdown range
7/8

6/8

Cll
5/8

--
c
..a.
·c:
.....
0
;::;
0
..c
1-
4/8

3/8
-- -- -- --
2/8

1/8

0/8
0 20 40 60 80 100 120 140 160 180 200

(0) (10) (201 (30) (40) (50) (60) (70) (801 (90) (100) (110) (120)

Vehicle speed km/h (MPH)

SAT162E

Shift schedule (Overdrive OFF) - RE4R03A

- - - - - Upshift

- - - - - Downshift

6/8

Cll
c
.
·c:
..~
"E
e
.s=
1-

0/BL---~L-~----------------------------------~L-----~--------------------__j

0 20 40 60 80 100 120 140 160 180' 200

(0) (101 (201 (30) (401 (50) (60) (701 (80) (901 (100) (110) 11201

Vehicle speed km/h (MPH)

SAT163E

AT-31
 TROUBLE DIAGNOSES

Diagnosis by CONSULT
NOTICE
1. The CONSULT electrically displays shift timing and lock-up timing (that is, operation timing of each solenoid).
When a noticeable time difference occurs between shift timing which is manifested by shift shock and the
CONSULT display, mechanical parts (except solenoids, sensors, etc.) are considered to be malfunctioning.
Check mechanical parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT and that indicated in Service Manual
may differ slightly. This occurs because of t~e following reasons:
• Actual shift schedule has more or less tolerance or allowance,
• Shift schedule indicated iri Service Manual refers to the point where shifts starts, and
• Gear position displayed on CONSULT indicates the point where shifts are completed.
3. Shift solenoid "A" or "B" is displayed on CONSULT at the start of shifting while gear position is displayed
upon completion of shifting (which is computed by AfT control unit).

AT-32
TROUBLE DIAGNOSES
Diagnosis by CONSULT (Cont'd)
DATA MONITOR APPLICATION

Item Application

Vehicle speed sensor 1 (A/T) X

Vehicle speed sensor 2 (meter) X
Throttle sensor X
Fluid temperature sensor X
Battery voltage X
Engine rpm X
Selector lever switch (0.0. switch) X
A.S.C.D. -cruise signal X
A.S.C.D. - O.D. cut signal X
Kickdown switch X
Power shift switch
Idle switch X
Full throttle switch X
Shift solenoid A X
Shift solenoid B X
Overrun clutch solenoid X
*Shift solenoid A (feedback) X
*Shift solenoid B (feedback) X
*Overrun clutch solenoid (feedback) X
Hold mode switch
1 range switch X
2 range switch X
D range switch X
N range switch X
R range switch X
Gear position X
Range position X
Vehicle speed X
Throttle opening X
Line-pressure solenoid X
Lock-up solenoid X

X: Applicable Not applicable

AT-33
TROUBLE DIAGNOSES
Diagnosis by CONSULT (Cont'd)
DATA ANALYSIS

Item Display Condition

Approximately 4% Lock-up "OFF"

Lock-up duty .j. .j.
Approximately 94% Lock-up "ON"

Low line-pressure
Approximately 29% (Small throttle opening)
Line pressure duty .j. .j.
Approximately 94% High line-pressure
(Large throttle opening)

Approximately 0.5V Fully-closed throttle

Throttle sensor
Approximately 4V Fully-open throttle

Approximately 1.5V Cold [20°C (68°F)]

Fluid temperature .j.
.j.
sensor
Approximately 0.5V Hot [80°C (176°F)]

Gear position 1 2 3 4

Shift solenoid A ON OFF OFF ON

Shift solenoid B ON ON OFF OFF

AT-34
 TROUBLE DIAGNOSES

A/T Electrical Parts Location

Models without air~

I~ 0.0. OFF indicator lamp...--

Line
pressure solenoid

SAT026E

AT-35
 TROUBLE DIAGNOSES
A/T Electrical Parts Location (Cont'd)

Revolution sensor

( )
Inhibitor switch
·harness connector

SAT306C

AT-36
 TROUBLE DIAGNOSES

Circuit Diagram for Quick Pinpoint Check

~orr+-~.....-~ CI)_J
1--------+-+-+------- To tachometer
U>-
•oCl
U...J
·LoJ
f- •0
ua:
...........
UZH
·OZ
Lo.IU::J
.-------;~~oo To A/C system
(Turbo mode ll
~o.~a:

1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I~
I:

IIi i
T

THROTTLE
N
DROPPING~®
r.:::l
~
RESISTOR -

@t..=.:.Je 1
I®
LINE PRESSU RE
SOLENOID
VALVE r=l
SWITCH I
a:
3:Lo.l
II e
CI:OI-
H...JioJ f-i1• i II OVERRUN CLUTCH
SOLENOID
Ii
oClU..:E I

CD
r=l I
§
LoJ
IJ ~ SOLENOID B
g !5
ocn
~.----+-----<1>-t-+-------IPl
-..f----'
... e ... I
a:z
~Lo.l
1 - ( 1'-~--~~---~~
)- •.• ~ SOLENOID A
REVOLUTION
@) •n I
(;"\ .Q SENSOR $ --- J

>
e lfi I .•• I ! I ___ !I
~~-------~~F::l~~-~11
LOCK-UP SOLENOID
a: 0
LoJ
.....
.....
""
Ill
® A/T FLUID $
~TEMPER= SENSOR
;1-----------11-<>=o+----111
KICKDOWN SWITCH

T ~L---~~'J------------Iro
e'!!Ye R
,1----,l
._T------------1'1
~ ~1---...J

~ lal 111~1----...--~-----.J ..-------11

~
~
~

.-----~r-i!il
i

~
H_J
.-+..----+--12!
.-----+--l ~ ""_J !S~o
CI:I-1- i5
.---+--I~ a: Lo.IZH ~

u
.....
u..1-
0
oucn
>03: 1!1

....
cna:
3:1- ~~(~
00
.---
u
"" ·Z ....
ocn
Zl-
....
OH
!i;,l----+--.....----1 t;8~ 1- r-!1•
a: Ia:
1-t.
HO
zt!IZ .....--+----! lj ~ ~
LoJCI)Q
HO
'---

...
.....
u
.....
_J Lo.lt.
cnc
·:I
u......
.... a:::J
t;;~~ I ro .......
cno
::J 111 uo
LoJ
I.__,_
r----a: 0 ·t. do!S
ouortEE~================~====~
Zlo.IUI
t!IZ
u ...
'OE
Q. Lo.l ...
c
1-tloJCI)
~Lo.IZ
OC111 00 LoJCLLoJ
oClZa:
............. 1-0 >(I) (I)
ouu..
1-tOO
Q.
:I
I
.3£
0
111
.QQ.
E
0111
..........
SAT078E

AT-37
 TROUBLE DIAGNOSES

Wiring Diagram
COMBINATION METER SUPPLy ROUT! NGN
E
DIAGNOSTIC
24 14 ...."
CONNECTOR 17 16 Ill
)..
FOR CONSULT Ill

,_0
BATTERY I
I

.. ... 0 0 MI03
__ _j
IDE ..., .... ~
....,,. " -J~~ m
cau
"'NUl -
CONNECTOR
-
0
WO w ....,...... @)@
I III I l
~j
WARNING LAMP
J(44)
T/81
!Brown>

~~® !Ia E§:a~ ~ u

L
@ @
"'•
.a G/L
GT
~ w t-- ORT

~ ~ I ;.;~
£ I-- w
"i sa
Y/G
G/W
I'
Y/R
2 3 y
(46) (47)
8 L--
Y/R
L !Black)
r-
CMa In harness>
f-

To tachometer

.'.. '"'.. "'..'

OVERDRIVE
SWITCH
m~§}&•~
®
.-----
-@
~®
KICKDOWN ....' "'..' ..'"' CE. F. I. harnessl
.----
@)
SWITCH 109- w - I LG=8~
~~s:
5 - PU

- 7 - Y/R PU
14- P/a P/8
w
@
IS- p
16- OR
26- II
27- w
30- a
---- ------ -----
------ --· " I
I
OR/L
G/R
CGray)
A. S.C. D. 37- OR ,. ------ ---------- -
I _, @
CONTROL UNIT 311- w
40- w ------ -- ----------
-- I -

I I
I
I
-t:l1

[l]f~
44- Y/L Y/L
I
48 -OR/L I I I
49- w -
50- II -<
I
I I
I
I I
OR }:jf
IEJ
I
IE 53- Y/B I I
I
I I car-own>
54 -LG/R I I
56- Y/R
57- G/R
59- w
I I I
w_@
60- 8 - I-:: I
I I
I I
I I lWhlte>
@ I I
@)
(Not • .;;;:;
I '
I I

,,,
i)
Ill
........
0
....
~--
0
"'"'"'
~CJ~

.r.yr @ctP @)Jt;P

. •Ji.
To CRUISE +-- ®
., .,.
Indicator lamp
@ ® rd~
BODY
GROU NO
L--

E. c. c. s.®
ID
1~
CONTROL UNIT
CRefer- to EFBoEC
section.>
ENGINE
GROUND AIR FLOW THROTTLE THROTTLE VALVE
METER SENSOR SWITCH

AT-38
 TROUBLE DIAGNOSES
Wiring Diagram (Cont'd)

REVOLUTION
SENSOR A/T CONTROL UNlT
DROPPlNG

ml RESlSTOR
Q.

~
E
-
II

I •~-o••~~~~N-o••~~~~-o••~•~~~N-a••~•~~~N­
..,.,..,...,,...,,..,..,.,..,..,,..NNNNNN NN---------- ®<t;>
Q.
:J
I

"'IIu
1111111111111111111 111111111111111111111 .c
ID
L' 0
"' 0 1-

Jl j

••
To stop lamp +i+----------------'
switch
(Not used)

!Eng i ne room
harness)

0::
0
Ill
l:
-= z
Ul
u Ul Ill
1- 0::
::1 ::1 Ul
BOOY ..J < Ill Ill 0::
GROUNO
~~.. .. z-
c
::10 ::10
u
0
.. .. a:: ..
c
0 11..0
c
Ill
c UIC
cffi
::1
1-
<
IZ a::z
1-Z 1-Z IZ
~UI O::UI !.LUI !.LUI UIUI
U..J UI..J .. ..J -..J Z..J
00 >O l:O l:O .. o ..JUI
Si:
@ ..Jill 0111 111111 ..Jill ILl-
"'"'
.tB- Y/L

~ DR -++---------------------------------------------,

®
ll I
•
'--- Y~B ;n_ ..as= Y~B === Y~B =9 €:=:e
® J: ~
~ ~ ~lternator VEHlCLE
harnessl SPEED
@@ SENSOR

@ : With air bag

@ : Without air bag
E. C. C. S.
RELAY BATTERY
FUSl BLE Ll NK
SAT02BE

AT-39
 TROUBLE DIAGNOSES

Self-diagnosis
~~' - Er·r
·-·
·=·u·:·rFt·1
·-• I ·-• - . =:g.
SELF-DIAGNOSTIC PROCEDURE ( @ With CONSULn
r-el~:;
~
T t··. ! !='
··-<J.I'il- I 1. Turn on CONSULT.
I .A,/T I 2. Touch "A/T".
CH T (' ,.·., •:_··
....._ .. ,1>-J.,\_:.
I
IT··-·1 /j,. ,./ c:
I·
,., I
,J..j,,l._. l._.
I
I l
I I
SAT672C

I• SELF-DIAG RESULTS •Dj

3. Touch "SELF-DIAGNOSIS".
CONSULT performs REAL-TIME SELF-DIAGNOSIS.

I ~~~LUR~ D~:~CTED I

ITHRUTL I
.:;.EN._.I_,f'_
I
I

I
I I
I'RA-=:E
c. ... ,.._, II F)Rd.T H''I1
SAT349C

AT-40
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
SELF-DIAGNOSTIC PROCEDURE(® Without CONSULT)
DIAGNOSIS START

Start engine and warm it up to normal engine operating temperature.

SAT774B D
Set overdrive switch in "ON" position.

Move selector lever to "P" range.

Does A/T check lamp come on for about 2 seconds?

SAT456C No
I Go to Diagnostic Procedure 1.j

Push shift lock release knob (if equipped).

Move selector lever to "D" range.

lit
Set overdrive switch in "OFF" position.

SAT401C

Wait for more than 2 seconds

after ignition switch "ON".

Move selector lever to "2" range.

Set overdrive switch in "ON" position.

SAT780B
Move selector lever to "1" range.

Set overdrive switch in "OFF" position.

SAT781B

AT-41
 TROUBLE DIAGNOSES
Self·dlagnosis (Cont'd)
II
Accelerator pedal
Depress accelerator pedal fully and release it.

Check A/T check lamp.

Refer to JUDGEMENT OF SELF-DIAGNOSIS CODE on next page.

Depress Release DIAGNOSIS END

SAT754A

AT-42
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)

JUDGEMENT OF SELF-DIAGNOSIS CODE

A/T check lamp Damaged circuit

All judgement flickers are same. All circuits that can be confirmed by self-diagnosis are
O.K.
~~:
_.L__j,
/ I I\"

I Self-diagnosis
start
St!'! s~l 10:_iudge':!'ent flicker~- Light

r - - -HI-1'-H-1'-l'-1'--f-l'-f-11 - Shade

SAT307C

1st judgement flicker is longer than Revolution sensor circuit is short-circuited or discon-
others. nected.

~o:
I\,,
/ I
r-
~
Revolution
sensor

--,---- - -- Light

I
--- UWLA~LA~LA-+
1 -Shade
l 25 35
A/T control unit

SAT308C • Go to revolution sensor circuit check. SAT965B

2nd judgement flicker is longer than Speed sensor circuit is short-circuited or disconnected.
others.

~o:
I \ ,,
/ I
I Electric
speedometer 1
\
Speed
sensor

--,---- -- Light

--- ......_......,,......._.._.,.......,~,-- Shade I 27

A/T control unit I
SAT309C • Go to speed sensor circuit check. SAT029E

3rd judgement flicker is longer than Throttle sensor circuit is short-circuited or disconnected.
others. Throttle sensor

~o:
I \ ,,
I ••• I
~
/ I

-- -- --- Light ~r- l

35 34 31
1 - - __ L.U..JLJI-W~IL.IIULJUI'-+, - Shade
A/T control unit

SAT310C
• Go to throttle sensor circuit check. SAT967B

t 1 = 2.5 seconds t 2 = 2.0 seconds t3 =1.0 second

AT-43
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)

A/T check lamp Damaged circuit

4th judgement flicker is longer than Shift solenoid A circuit is short-circuited or disconnected.
others.
Shift solenoid A
:~~ ~
~.....
I Self-diagnosis I ~Terminal

l start J cord
assembly
-- r-- --- Light
6
A/T control unit
- -- .._._....._....._u,......._.&...ll......._,'-+i- Shade

SAT311C . . Go to shift solenoid A circuit check. SAT968B

5th judgement flicker is longer than Shift solenoid B circuit is short-circuited or disconnected.
others. Shift solenoid B

:o~
I',. . .
/I

I'-- Terminal
-- ~ -- Light cord assembly
7

A/T control unit

!-
1-- - -'-'"-''".......,'-' ....uii...JL.A...JJL...IL.+ Shade

SAT312C . . Go to shift solenoid B circuit check. SAT969B

6th judgement flicker is longer than Overrun clutch solenoid circuit is short-circuited or
others. disconnected.
Overrun clutch solenoid

:a~
I',. . .
/I

~
.........__Terminal cord
----- - --- Light
assembly
8

--- LJL..JL..ILJL...L u................._,,_,_ Shade A?T control unit

SAT313C . . Go to overrun clutch solenoid circuit check. SAT970B

7th judgement flicker is longer than Lock-up solenoid circuit is short-circuited or disconnected.
others. Lock-up
solenoid

-t "'
~Terminal
+
cord assembly ~

--- - -- Light

5
A/T control unit
r-- - _._..._.,....._IL...IL......... ......_."-"-+~- Shade

SAT314C . . Go to lock-up solenoid circuit check. SAT971B

AT-44
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)

A/T check lamp Damaged circuit

8th judgement flicker is longer than Fluid temperature sensor is disconnected or A/T control
others. unit power source circuit is damaged.

:o~
/II\'-'
I Ignition 1
switch
~ Fuse
-(~ Fluid temperature
t:J sensor
~ ....?" Terminal cord
I Self-diagnosis I l;J V :::::"' · assembly
start

-- ,.....- - --- Light

Il 4
n 9 33
A/T control unit
35 I
4-Shade . . Go to fluid temperature sensor and AIT control
SAT315C · unit power source circuit check. SAT972B

9th judgement flicker is longer than Engine revolution signal circuit is short-circuited or dis-
others. connected.

:o~ I E.C.U. J
/II\'-'

--.----- -- Light

24
.....__ _ -L...IL..IL-'LJ'L..JL...IL...IL..JL..LUL..+-1, • Shade
I A/T control unit
I
SAT316C. . . Go to engine revolution signal circuit check. SAT 97 3 8

10th judgement flicker is longer than Line pressure solenoid circuit is short-circuited or discon-
others. nected. Line p~essure
1~ 1 soleno1d
I ooo J
:o~
/ 11''-'
I- Terminal
cord
assembly

--.----- -- Light [ rlWres1stor

Dr~pping
I I

- - ..L...JL..IL..JL..JL.JILJL...IL...IWL.L 4-- Shade 1 2

A/T control unit

SAT317C
. . Go to line pressure solenoid circuit check. SAT974B

Flickers as shown below. Battery power is low.

Battery has been disconnected for a long time.
Battery is connected conversely.
(When reconnecting A/T control unit connectors.- This
is not a problem.)

- - - - --- - r- - -t-- Light

- - - - ' - - '-- - - - - Shade

SAT318C

t4 = 1.0 second

AT-45
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)

AfT check lamp Damaged circuit

Does not come on. Inhibitor switch, overdrive switch, kickdown switch or
idle switch circuit is disconnected or A/T control unit is
damaged.

Self-diagnosis
start Throttle
·valve
switch

------------------- Light

~---------------4---Sh~e

SAT146B

• Go to inhibitor, overdrive, kickdown and idle switch

circuit checks.
SAT319C

AT-46
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
REVOLUTION SENSOR CIRCUIT CHECK
r--- Revolut ion N.G. Repair or replace revolution
~ sensor CHECK REVOLUTION
SENSOR. - Refer to "Electrical sensor.
Components Inspection".

m lO.K.
N.G.
CHECK INPUT SIGNAL Check harness continuity be-
r----.
'·I ~ GtD
25 35

I A/T control unit

I tween A/T control unit and

SAT965B

2.
~· ~.
I revolution sensor.

ocr• Select "E.C.U. INPUT

SIGNALS".
Read out the value
of "CAR SPEED
SENSOR 1" while
driving.
• Check the value chang-
es according to driving
speed.

f~:::rt1otH TOF: ~:::rt~C:i FAIL (;]

l.-.,. . . . . . .:·
·=·E
·-'
••.. Hi'.· ·-'
··· . ··r
1 • H·
i CAP.···::; SE2 • t'HF.:
Okm/,·,
5km ..... h ®
OR

Check voltage between

I THF.:OTTLE SEI·l o. 41.) A/T control unit terminal
FLUID TEt·1P SE 1. 21) ® and ground while
BATTEP'/ I.)I)L T 13. 41..J
Et·ll3 F.:EI...I 1024rPm driving.
SLCT LP..IEF.: ::;;I_,J l:i t·l (Measure with A.C. range.)
1P-F.:~~~·~f:£ SI.,J CiFF Voltage:
j l·l-F.:AI·l~E Sl.o.l 0 H
At 0 km/h (0 MPH):
[ F: ECCIPD J ov
At 30 km/h (19 MPH):
SAT320C 1V or more
(Voltage rises gradually in
m response to vehicle speed.)

~ 0
l O.K.

Perform self-diagnosis again after

driving for a while.
N.G. 1. Perform A/T control unit
input/output signal inspection.
2. If N.G., recheck AIT control
Jo.K.
unit pin terminals for damage
INSPECTION END or connection of AIT control
[it II CI\JifiT iof CGNNECTCIR II unit harness connector.
25
CDIET

~ BR

I vi
~If'

--= SAT976B

AT-47
 TR'OUBLE DIAGNOSES
Self-diagnosis
.
(Cont'd) .

SPEED SENSOR CIRCUIT CHECK

m
CHECK INPUT SIGNAL. N.G. Check the following items.
f----t
•
'·I ~ ttQ I
. Speed sensor and ground
T circuit for speed sensor
. ~ ~ .
- Refer to section EL.
2. • Harness continuity between
AIT control unit and speed
(j)• Select "E.C.U.
INPUT SIGNALS". sensor
FAIL [;]I • Read out the value
Okm/,-, of "CAR SPEED
5km ..... h SENSOR 2" while
0.41.) driving.
1 ·:;•II
1::::. 41.)
1024t·Pm
·• Check the value chang-
es according to driving
!) t·l speed.
CiFF
0 H OR

L. F::EC:l]F:[l J
SAT320C
®· Check voltage between
A/T control unit termi-
nal ® and ground
while driving at 2 to 3
km/h (1 to 2 MPH) for
Electric
1 m (3ft) or more.
speedometer t-----'"" Voltage: Varies from
Speed .0Vto5V

r
sensor
!O.K.

Perform self-diagnosis again after 1. Perform A/T control unit

driving for a whiJe. input/output signal inspection.
!O.K.
2. If N.G., recheck AIT control
unit pin terminals for damage
. INSPECTION END or .connection of A/T control
unit harness connector.
II CAINIT ]Of CONNECTOR I
27

Y/G

SAT030E

AT-48
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
THROTTLE SENSOR CIRCUIT CHECK
Perform self-diagnosis (Mode N.G. Check throttle sensor circuit for
III) for engine control. engine control. - Refer to sec-
O.K. tion EF & EC.

m
CHECK INPUT SIGNAL. N.G. Check harness continuity
between E.C.U. and AIT control

'·I ~ €J I
A/T control unit
unit regarding throttle sensor
SAT967B circuit.

oo·•
2.
Select "E.C.U. INPUT
SIGNALS".
Read out the value
of "THROTTLE
SENSOR".
Voltage:
Depress slowly.
Fully-closed throttle:
Approximately
0.5V
Fully-open throttle:
Approximately
f?ti:~JtH TCiP ~:':rtKi FAIL (;] 4V
lcAP/S SEl•A/T Okm/n OR
!CAR/S SE2·MTR 5km/h
!THROTTLE SEN 0.4U
1FLUID TEMP SE
lsATTEPY UOLT
ISLCT
Et·ll3 F:El..J
LEUER SW
1.2U
13.4U
1024r Pm
0 N
®· Check voltage between
A/T control unit
terminals ® and ®

I~=~~~~~ ~~ gF~
while accelerator pedal
is depressed slowly.
Il F)'• Er._..·:r_·ir::·c·r
~"'_·._·- - '
Voltage:
Fully-closed throttle:
SAT321C
Approximately
m 0.5V

~
Fully-open throttle:
Approximately
4V
. (Voltage rises gradually
Depress slowly. in response to throttle
valve opening.)

O.K.
[it II CIUNIT
34
~CONNECTOR II
35 Perform self-diagnosis again after N.G. 1. Perform AIT control unit
CIIIIECT
driving for a while. input/output signal inspection.
E) O.K. 2. If N.G., recheck AIT control
V/R B
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

[X]
~_\::f)t---"'
'-'=--------"-

SAT97BB

AT-49
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
SHIFT SOLENOID A CIRCUIT CHECK
a
N.G. 1. Remove control valve assem-
CHECK GROUND CIRCUIT.
Terminal bly.- Refer to "ON-VEHI·

'·I ~
cord

I
CLE SERVICE".
assembly F 2. Check the following items.
6 2. Disconnect terminal cord • Shift solenoid A - Refer to
"Electrical Components
A/T control unit assembly connector in engine
compartment, Inspection",
SAT968B 3. Check resistance between • Harness continuity of terminal
cord assembly
terminal ®and ground.
Solenoids Resistance: 20- 40n
harness
connector
1§1 l O.K.

CHECK POWER SOURCE N.G. Repair or replace harness

~
CIRCUIT. between A/T control unit and
terminal cord assembly.

'·I 18
2. Disconnect A/T control unit
I
-= SAT322C connector.

1§1
[:11 E1l1B Solenoids
harness
connector
3. Check resistance between
terminal ® and AIT control
unit terminal ®.
Resistance:
-IIECT @) Approximately on
IV LIW
4. Reinstall any part removed.
10.K.

Perform self-diagnosis after N.G. 1. Perform.A/T control unit

driving for a while. input/output signal inspection.
l O.K.
2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

CIUNI T [OJ CONNECTOR I

SAT323C

AT-50
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
SHIFT SOLENOID B CIRCUIT CHECK
Shift solenoid B
m
CHECK GROUND CIRCUIT. N.G. 1. Remove control valve assem"
bly.- Refer to "ON-VEHI-
1 I 18 CLE SERVICE".
cord assembly
2. Disconnect terminal cord
I 2. Check the following items.
• Shift solenoid B - Refer to
assembly connector in engine "Electrical Components
A/T control unit
compartment. Inspection".
SAT969B 3. Check resistance between • Harness continuity of terminal
cord assembly
terminal (j) and ground.
~Solenoids Resistance: 20 • 40n
ti_'\tj:j
v
harness
connector
I§) l O.K.
N.G.
CHECK POWER SOURCE .... Repair or replace harness
between AIT control unit and
CIRCUIT.
terminal cord assembly.
1 I Ia F
2. Disconnect A/T control unit
I
7" SAT324C connector.
3. Check resistance between
I§)
8 terminal (j) and AIT control

-TeJ~
Solenoids
harness unit terminal (j).
connector Resistance:
L/V ® Approximately on
4. Reinstall any part removed.
l O.K.
Perform self-diagnosis after N.G. 1. Perform A/T control unit
driving for a while. input/output signal inspection.
l O.K. 2. If N.G., recheck AIT control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

CIUNIT 101 CINECTCIR I

SAT325C

AT-51
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
OVERRUN CLUTCH SOLENOID CIRCUIT CHECK
a
CHECK GROUND CIRCUIT. N.G. 1. Remove control valve assem-
bly.- Refer to "ON-VEHI·

8
Terminal cord
assembly '·I ~ .

2. Disconnect terminal cord

I CLE SERVICE".
2. Check the following items .
• Overrun clutch solenoid. -
A'T control unit assembly connector in engine Refer to "Electrical Compo-
compartment. nents Inspection".
SAT970B
3. Check resistance between • Harness continuity of terminal
cord assembly
terminal @ and ground.
Solenoids
harness R!lsistance: 20 - 400
connector

GY ~ I!J l O.K.

CHECK POWER SOURCE N.G. Repair or replace harness

CIRCUIT. between A/T control unit and
terminal cord assembly.

-:-
'·I 18 F
2. Disconnect AIT control unit
I
SAT326C
connector.
m
_,
~
art:B Solenoids
harness
connector
@)
3. Check resistance between
terminal @ and A/T control
unit terminal @.
Resistance:
~ on
P/L
~pproximately
4. Reinstall any part removed.
!O.K.

Perform self-diagnosis after N.G. 1. Perform A/T control unit

driving for a while. input/output signal inspection.
LO.K. 2. If N.G., recheck AIT control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

CIUNI T 101 CCNIECTOR I

SAT327C

AT-52
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
Lock-up LOCK-UP SOLENOID CIRCUIT CHECK
solenoid

r+m+- m
CHECK GROUND CIRCUIT. N.G. 1. Remove oil pan.
I- Terminal
-Refer to "ON-VEHICLE

00
cord assembly ~

5
'·I
2. Disconnect terminal cord
I •
SERVICE".
2. Check the following items.
Lock-up solenoid - Refer to
A/T control unit assembly connector in engine "Electrical Components
compartment. Inspection".
SAT9718
3. Check resistance between • Harness continuity of terminal
cord assembly.
terminal@ and ground.
~Solenoids Resistance: 10 - 200
~harness
connector lO.K.
liJ
L 0 CHECK POWER SOURCE 1
N.G.• Repair or replace harness
CIRCUIT. between A/T control unit and
terminal cord assembly.

'·I 18 .

2. Disconnect A/T control unit

I
SAT328C
connector.
3. Check resistance between
~Solenoids terminal @ and A/T control
~harness unit terminal @.
connector
Resistance:

GY/R
® Approximately Oil
4. Reinstall any part removed.
l O.K.

Perform self-diagnosis after

driving for a while.
~ 1. Perform A/T control unit
input/output signal inspection.
l O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

CIUNIT ACCNECTOR I
5

SAT329C

AT-53
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
FLUID TEMPERATURE SENSOR CIRCUIT AND AIT
Fluid temperature
CONTROL UNIT POWER SOURCE CIRCUIT CHECKS
sensor
Terminal cord
11
·assembly N.G. Check the following items.
CHECK AIT CONTROL
UNIT POWER SOURCE. • Harness continuity between
ignition switch and AIT con-

1. ~~,
~-'
..__1 I
trol unit
• Ignition switch and fuse
- Refer to section E L.
2. Check voltage between AIT
SAT972B control unit terminals @ , ®
and ground.
Battery voltage should exist.

4 9 O.K.

CHECK FLUID TEMPERA- N.G. 1. Remove control valve cover.

G/L G/L 2. Check the following items.
TURE SENSOR WITH
TERMINAL CORD ASSEMBL V • Fluid temperature sensor
-Refer to "Electrical Com-
ponents Inspection".
• Harness continuity of terminal
2. Dis~onnect terminal cord cord assembly
SAT988B
assembly connector in engine
compartment.
3. Check resistance between
terminals@ and@ when
AIT is cold.
Resistance:
Cold [20°C (68°F))
Approximately 2.5 kn
4. Reinstall any part removed.
O.K.
SAT869C

AT-54
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)

N.G. Check harness continuity be-

CHECK INPUT SIGNAL OF
FLUID TEMPERATURE tween A/T control unit and
SENSOR. terminal cord assembly.
1.

2.

oo· Select "E.C.U. INPUT

SIGNALS".
• Read out the value
of "FLUID TEMPER·
ATURE SENSOR".
Voltage:
Cold [20°C (68°F)] -+
Hot [80°C (176°F)]:
Approximately
1.5V-+0,5V
.I
l
F?EL:I]F:D
------~
r--------OR--------~
SAT330C

Check voltage between

A/T control unit
terminal ® and ground
while warming up AlT.
Voltage:
Cold [20°C (68°F)] -+
Hot [80°C (176°F)):
Approximately
1.5V-+0.5V
u CIUNIT ]Of CONNECTIIR II
33 O.K.

Perform self-diagnosis after N.G. 1. Perform A/T control unit

PU driving for a while. input/output signal inspection.
O.K. 2. If N.G., recheck AfT control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

SAT990B

AT-55
 TROUBLE DIAGNOSES
Self-diagnosis·· {Cont'd)
ENGINE REVOLUTION SIGNAL CIRCUIT CHECK
I E.C.U. I

CHECK INPUT SIGNAL. N.G. Check harness continuity be-

I 24
A/T control unit I 1. tween AfT control unit and
E.C.C.S. control unit.

SAT973B
2.
fF.i\ • Select "E.C.U. INPUT
~ SIGNALS".
• Read out the value
of "ENGINE REVO-
LUTION".
• Check engine revolu-
tion changes according
to throttle opening.

~------OR--------_,

Check voltage between

A/T control unit termi-
{:AF.: ..···s SE 1 • A/T Okm/,·,
CAF.:-···s SE2 • MTF.: 5km/h nal.@ and ground.
THF.:t3TTLE SEt·l o. 41.) Voltage: 0.9 - 4.5V
FLUID TE~1P SE 1. 2U
BATTERV I..JGL T 1:3. 41.)
Et~G F.:EI..J 1024t"F'!fl
SLCT LEUER Sl~l G t·l
F.:-RAHGE Sl.~ GFF Perform self-diagnosis again after N.G. 1. Perform A/T control unit
t---•1
N-F.:At-l13E Sl.~ G ~l driving for a while. input/output signal inspection.
2. If N.G., recheck A/T control
PECORD O.K.
.unit pin terminals for damage
SAT331C INSPECTION END
or connection of A/T eontrol
unit harness connector.

u c.-\IIIT JOf CCINNECTGR n

24.

Y/R

SAT991B

AT-56
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
LINE PRESSURE SOLENOID CIRCUIT CHECK

Terminal
m
CHECK GROUND CIRCUIT. N.G. 1. Remove control valve assem-
cord
assembly bly.- Refer to "ON-VEHI-
1.1
Dropping
resistor 00
2. Disconnect terminal cord
I
CLE SERVICE".
2. Check the following items.
• Line pressure solenoid -
2 assembly connector in engine Refer to "Electrical Com-
A/T control unit
compartment. ponents Inspection".
SAT974B 3. Check resistance between • Harness continuity of terminal
cord assembly
terminal CD and ground.
Solenoids Resistance: 2.5 · sn
harness
connector 10.K.
liJ
R~ CHECK POWER SOURCE N.G. Check the following items.
CIRCUIT. • Dropping resistor- Refer to

1., "Electrical Components

~
Inspection".

2. Disconnect A!T control unit

I • Harness continuity between
A/T control unit ® and
SAT332C
connector. terminal cord assembly
3. Check resistance between
Solenoids terminal CD and A/T control
harness
connector unit terminal®.
Resistance: 11.2- 12.an
®
OR/B

II 1O.K.

CHECK POWER SOURCE N.G. Repair or replace harness

CIRCUIT between A/T control unit CD
1., and terminal cord assembly.

~ .

2. Check resistance between

I
terminal CD and A/T control
unit terminal CD .
Resistance:
Approximately on
CIUNIT ACONNECTOR I 3. Reinstall any part removed.
1 2
!O.K.
Perform self-diagnosis after N.G. 1. Perform A/T control unit
driving for a while. input/output signal inspection.
2. If N.G., recheck A!T control
!O.K.
unit pin terminals for damage
INSPECTION END or connection of A!T control
unit harness connector.

AT-57
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH
CIRCUIT CHECKS

CHECK INHIBITOR SWITCH t-N_._G~.~ Check the following items.

CIRCUIT. • Inhibitor switch- Refer to
1. "Electrical Components
Inspection".
• Harness continuity between
ignition switch and inhibitor
SAT319C 2.
fj\ .• Select "E.C.U. INPUT switch
• Harness continuity between
~ signals".
inhibitor switch and AfT
• Read out "R, N, D, 1
control unit
and 2 range switches"
moving selector lever
to each range.
• Check the selector
lever position is indi-
cated properly.

~------- OR----------~

~ Check voltage between

'l;.:::r·~~~:~~n:m<: .-. ~::Fm FA:,~--~ ~ A/T control unit terminals
-H~·~ ~El·H•T Lkm•n @,@,@,@),@and
SE2 • t·1TP
•CAP.····!:; 5k m/h ground while moving
THF.:OTTLE SEN 0.4U
FLUID TEMP SE 1.2U selector lever through
BATTEPY UOLT 13.4U each range.
jEAG REU 1024rPm Voltage:
1SLCT LEUER SW GN
! P-F.'(if·~I:;E !:;i.l fiFF B: Battery voltage
It·i-j;;:At·1!3E !~;j:,j ,j N 0: ov
F: ECOF:D
SAT334C
~@~@@@
••., P, N B 0 0 0 0

••
R 0 B 0 0 0
D 0 0 B 0 0
2 0 0 0 B 0
1 0 0 0 0 B

O.K.

II CAJNIT ]Of CONNECTOR II

16 17 18 19 20

A
SAT994B

AT-58
 TROUBLE DIAGNOSES
Self-diagnosis {Cont'd)

CHECK OVERDRIVE SWITCH N.G. Check the following items.

CIRCUIT. • Overdrive switch - Refer to
"Electrical Components
Inspection".
• Harness continuity between
A/T control unit and over·

oo·
2.
drive switch
Select "E.C.U. INPUT
• Harness continuity of ground
SIGNALS".
FAIL [Jj • Read out "SELECTOR
circuit for overdrive switch
Okm.····.-, LEVER SWITCH
5km ....-h (Overdrive switch)".
0. 41.)
1 ........
·::•11 • Check the selector
13. 41.) lever switch position
1024rt=·rf, is indicated properly.
!) t1
CiFF (Selector lever switch
Ci t·1 "ON" displayed on
________.
F: EC:fJF:D CONSULT means
overdrive "OFF".)
SAT335C
L-----------------------~----~ ~---------OR----------~

Check voltage between

A/T control unit
terminal @ and ground
when overdrive switch
is in "ON" position and
in "OFF" position.

Switch position Voltage

ON Battery voltage
OFF 1 V or less

II ~IT ]Of CONNECTOR II O.K.

39

GY

SAT995B

AT-59
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
@
[+1 l N.G.
CHECK KICKDOWN SWITCH Check the following items.
f--•
CIRCUIT. • Kickdown switch
•
e
Harness continuity between

'·I lg I •
A/T control unit and ·~ick-
down switch
Harness continuity of ground
2.

oo·• Select "E.C.U. INPUT

SIGNALS".
Read out "KICKDOWN
•
circuit for kickdown switch
Adjust kickdown switch-
Refer to "ON-VEHICLE
SERVICE".
O-RANGE SW OFF SWITCH" depressing
1-RANGE SW OFF accelerator pedal fully.
2-RANGE SW OFF
ASCD·CRUISE OFF • Check kickdown
switch position is
~~8~~~90 C~T OFF
~~L~D~WN ~w OFF indicated properly.
POWERSHIFT SW OFF
IDLE SW 0 N
FULL THRTL SW OFF OR
F:: EC:I]F::D
SAT336C ®· Check voltage between
A/T control unit
terminal @ and ground
while depressing accel-
era tor pedal slowly.
(after warming up
engine)
Voltage:
When releasing accel-
erator pedal: 3- SV
When depressing ac-
celerator pedal fully:
41 1V or less
COIIIIECT
E) O.K.
SB

SAT337C

AT-60
 TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
©
lil
CHECK IDLE SWITCH
1 N.G. Perform self-diagnosis (Mode
~
CIRCUIT. IV) for engine control.

'·I ~ w I
Check idle switch circuit.

!O.K.

Check harness
l
Check idle
N.G.

oo·
2.
continuity switch circuit
Select "E.C.U. INPUT
between A/T for engine
SIGNALS".

O-RANGE SW OFF
[!]I • Read out "I OLE
SWITCH" depressing
control unit
and idle switch.
control. -
Refer to sec-
tion EF & EC.
1-RANGE SW OFF ! and releasing acceler-
2-RANGE SW OFF ator pedal.
ASCD·CRUISE OFF
ASCD·OD CUT OFF • Check idle switch
KICKDOWN SW OFF changes ON or OFF.
POWERSHIFT SW OFF
IDLE SW 0 N OR
FULL THRTL SW OFF
L __ E_c_::L_J c_J-~
F:_: F_-.::
®· Check voltage between
A/T control unit
SAT338C
terminal @ and ground
while depressing accel-
erator pedal slowly.
Voltage:
When releasing
accelerator pedal:
8-15V
When depressing ac-
celerator pedal fully:
~lit II CYUNI T ]Of CONNECTOR I 1V.or less

CONNECT
£)
14
l O.K.
Perform self-diagnosis again after N.G. 1. Perform A/T control unit
LG/R
driving for a while. input/output signal inspection.
l O.K.
2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

SAT339C

AT-61
 TROUBLE DIAGNOSES

D Diagnostic Procedure 1
I ~n ]Of CCNECTGR II \2j SYMPTOM: A/T CHECK lamp does not come on for
about 2 seconds when turning ignition
i) switch to "ON".

D
CHECK A/T CONTROL N.G. Check the following items.
UNIT POWER SOURCE. • Harness continuity between

'I~W I
ignition switch and A/T con-
trol unit
SAT997B
• Ignition switch and fuse
- Refer to section EL.
2. Check voltage between A/T
control unit terminals @, ®
and ground.
Battery voltage should exist.

O.K.
N.G.
CHECK A/T CONTROL UNIT Check harness continuity
GROUND CIRCUIT. between A/T control unit and
ground.
SAT99BB
1. L . _ I_ OO_o_F~_._ ___.
_

2. Disconnect AIT control unit

Fuse connector.
Ignition
switch
3. Check resistance between AIT
control unit terminals@, @
0.0. OFF
indicator and ground.
lamp Resistance:
Approximately on
4 3 O.K.
A/T control unit 11
CHECK LAMP CIRCUIT. N.G.
Check the following items.

'I 00
• A/T check lamp
• Harness continuity between
ignition switch and A/T
2. Disconnect AIT control unit check lamp
connector. • Harness continuity between
3. Check resistance between AIT check lamp and AIT
A/T control unit terminals control unit
@and@.
Resistance: 50 - 1 oon
4. Reinstall any part removed.
SAT7380
O.K.

Check again. 1. Perform A/T control unit

input/output signal inspection.
O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

AT-62
 TROUBLE DIAGNOSES

0 Diagnostic Procedure 2
SYMPTOM: Engine cannot be started with selector

I Self-diagnosis
start
I lever in "P" or "N" range or engine can be
~-----~
started with selector lever in "D", "2", "1"
or "R" range.
-------------------Light

~--------------~---Sh~a
00 Does "E.C.U. INPUT
SIGNALS" show damage
Yes
--+
Check inhibitor switch circuit.
- Refer to "Self-diagnosis".
SAT146B to inhibitor switch
circuit?

OR

®
D
Does self-diagnosis show
damage to inhibitor switch
circuit?

~ ! No

SAT838B
Check continuity of inhibitor
switch 2-pin connector. - Refer H Repair or replace inhibitor switch.

to "Electrical Components
Inspection".

l O.K.

Check starting system.- Refer

to section EL.
N.G.I Repair or replace damaged parts.
I
l O.K.

INSPECTION END

Diagnostic Procedure 3
SYMPTOM: Vehicle moves when it is pushed forward
or backward with selector lever in "P"
range.

0
Check parking components. - ~, Repair or replace damaged parts.
--------..-_
Refer to "ON-VEHICLE
SERVICE".

l O.K.

INSPECTION END

AT-63
 TROUBLE DIAGNOSES

D Diagnostic Procedure 4
SYMPTOM: Vehicle moves forward or backward when
selecting "N" range.
I Self-diegnolil
start J
- - - - - - - - - - - - - - - - - - - Light
00 Does "E.C.U. INPUT
SIGNALS" show damage
Yes Check inhibitor switch circuit.
- Refer to "Self-diagnosis".
to inhibitor switch circuit?
1---------~--- Shade
SAT146B OR
D
® Does self-diagnosis show
damage to inhibitor switch
circuit?

No
6
Check manual control linkage. N.G. Adjust manual control linkage.
~

- Refer to "ON-VEHICLE - Refer to "ON-VEHICLE

SERVICE". SERVICE".
Lock nut(!)
O.K.
Le~ck nut@ IJ
SAT788B N.G.
Check A/T fluid level again. Refill A.T.F.
O.K.
19

~
1. Remove oil pan. 1. Disassemble A/T.
2. Check AlT. fluid condition. 2. Check the following items.
O.K. • Forward clutch assembly
• Overrun clutch assembly
• Reverse clutch assembly
• Accumulator piston D

N.G.
Check again. 1. Perform A/T control unit
input/output signal inspec·
O.K. tion.
2. If N.G .• recheck A/T control
INSPECTION END
unit pin terminals for damage
or connection of A/T control
unit harness connector.

AT-64
 TROUBLE DIAGNOSES

Diagnostic Procedure 5
Throttle sensor circuit SYMPTOM: There is large shock when changing from
Fluid temperature
sensor circuit "N" to "R" range.
Line pressure
solenoid 0 1!1
Does self-diagnosis show damage ~~ Check damaged circuit.- Refer
to throttle sensor, line pressure to "Self-diagnosis".
solenoid or fluid temperature
sensor circuit?
SAT340C No
II
N.G.
Check throttle sensor. - Refer Repair or replace throttle sensor.
to section EF & EC.
E.C.U.
O.K.
El
Check line pressure at idle with
~ 1. Remove control valve assem-
selector lever in "D" range. bly.- Refeqo "ON-VEHI-
- Refer to "PRESSURE CLE SERVICE".
Dropping resistor TESTING". 2. Check the following items.
O.K. • Valves to control line pressure
(Pressure regulator valve,
modifier valve, pilot valve and
pilot filter)
• Line pressure solenoid

Check again.
~ 1. Perform A/T control unit
input/output signal inspection.
O.K.
2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

SAT643A

AT-65
 TROUBLE DIAGNOSES

D Diagnostic Procedure 6
SYMPTOM: Vehicle does not creep backward when
selecting "R" range.

D
l N.G.
Check A/T fluid level again. Refill A.T.F.
I
O.K.
N.G. in both "1"
and "R" range
SAT638A
II r 1. Remove. control valve assem-
Check stall revolution with bly.- Refer to "ON-VEHI-
selector lever in "1" and "R" CLE SERVICE".
range. 2. Check the following items.
O.K.
O.K. in "1" range
• Valves to control line pressure
(Pressure regulator valve, pilot
N.G. in "R" range. valve and pilot filter)
11
Check line pressure at idle with N.G.
• Line pressure solenoid
3. Disassemble AlT.
selector lever in "R" range. 4. Check the following items.
-Refer to "PRESSURE
TESTING".
• Oil pump assembly

• Torque converter
O.K.
m • Reverse clutch assembly
1. Remove oil pan. N.G. • High clutch assembly
2. Check fluid condition. • Low & reverse brake assembly
O.K. • Low one-way clutch

lN.G.
Check again. 1. Perform A/T control unit
r input/output signal inspection.
O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END
I or connection of A/T control
unit harness connector.

AT-66
 TROUBLE DIAGNOSES

D Diagnostic Procedure 7
SYMPTOM: Vehicle does not creep forward when
selecting "D", "2" or "1" range.

D
N.G.
Check A/T fluid level again.

O.K.
I Refill A.T.F.
I
f)
Check stall revolution with N.G.
selector lever in "D" range.
f-----t 1. Remove control valve assem-
bly. - Refer to "ON-VEHI·
- Refer to "STALL TESTING".
CLE SERVICE".
O.K. 2. Check the following items.
11
Check line pressure at idle with N.G. • Valves to control line pressure
(Pressure regulator valve,
selector lever in "D" range. modifier valve, pilot valve and
- Refer to "PR.ESSU RE pilot filter)
TESTING".
• Line pressure solenoid

m O.K.
N.G.
3. Disassemble A/T
4. Check the following items.
1. Remove oil pan.
2. Check A/T fluid condition.
r--+ • Oil pump assembly
SAT642A

O.K. • Forward clutch assembly

• Forward one-way clutch
• Low one-way clutch
•• Low & reverse brake assembly
Torque converter

N.G. 1. Perform A/T control unit

Check again.
input/output signal inspection.
O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
I INSPECTION END
I or connection of A/T control
unit harness connector.

AT-67
 TROUBLE DIAGNOSES

D _:::0:.
- - / 1 1 \ ,......
Revolution sensor
Speed sensor
Diagnostic Procedure 8
SYMPTOM: Vehicle cannot be started from o, on
Shift solenoid A
Self-diagnosis Shift solenoid B Cruise test - Part 1.
start
Is Diagnostic Procedure 7 O.K.?
No
I
Go to Diagnostic Procedure 7.
I
Yes
D
Yes Check damaged circuit. - Refer
Does self-diagnosis show damage
to revolution sensor, speed to "Self-diagnosis".
sensor, shift solenoid A or B
after cruise test?
No
6
N.G.
Check throttle sensor. -:- Refer to Repair or replace throttle sensor.
section E F & EC.
O.K.
BJ
Check line pressure at stall point N.G.
~ 1. Remove control valve assem-
with selector lever in "D" range.
bly.- Refer to "ON-VEH 1-
- Refer to "PRESSURE
CLE SERVICE".
TESTING".
2. Check the following items.

m O.K. • Shift valve A

• Shift valve B
1. Remove oil pan. O.K.
• Shift solenoid A
2. Check A/T fluid condition.
• Shift solenoid B
N.G.I • Pilot valve
O.K.
O.K.
• Pilot filter

3. Disassemble A/T.
4. Check the following items.
• Forward clutch assembly
• Forward one-way clutch
SAT643A
• Low one-way clutch
• High clutch assembly
• Torque converter
• Oil pump assembly

1N.G. 1. Perform A/T control unit

Check again.
input/output signal inspection.
O.K. 2. If N.G., recheck A/T control
unit pin termrnals for damage
INSPECTION END or connection of A/T control
unit harness connector.

AT-68
 TROUBLE DIAGNOSES

D Diagnostic Procedure 9
SYMPTOM: AIT does not shift from o, to 02 at the
Self-diagnosis specified speed.
start A/T does not shift from 04 to 02 when
depressing accelerator pedal fully at the
-------------------Light specified speed.

Are Diagnostic Procedures 7 and No Go to Diagnostic Procedure 7 or

r---------------~---Sh~e BO.K.? 8.
SAT146B Yes

Electric
00 Does "E.C.U. INPUT
SIGNALS" show damage
Yes Check inhibitor switch circuit.
- Refer to "Self-diagnosis".
speedometer
to inhibitor switch circuit?
Speed
Revolution sensor
sensor OR

®
D
Does self-diagnosis show
damage to inhibitor switch
25 35 27 circuit?
A/T control unit
SAT031E No
6
Check revolution sensor and N.G. Repair or replace revolution
speed sensor circuit. - Refer to sensor and speed sensor circuits.
"Self-diagnosis".
O.K.
11
IN.G. I
Check throttle sensor. - Refer Repair or replace throttle sensor.
to section EF & EC.

m O.K.

1. Remove oil pan. N.G.

2. Check A/T fluid condition: 1. Remove control valve. -
Refer to "ON-VEHICLE
O.K.
SERVICE".
2. Check the following items.

I•
Shift valve A
O.K. • Shift solenoid A

O.K. • Pilot valve

• Pilot filter

3. Disassemble A/T.
4. Check the following items.
• Servo piston assembly
• Brake band
• Oil pump assembly

m N.G.
Check again. 1. Perform A/T control unit
input/output signal inspection.
O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

SAT118B

AT-69
 TROUBLE DIAGNOSES

D Diagnostic Procedure 10
SYMPTOM: A/T does not shift from Dz to 03 at the
Self-diagnosis specified speed.
start
Are Diagnostic Procedures 7 and No Go to Diagnostic Procedure 7 or
BO.K.? 8.
-------------------Light
Yes

~--------------~---Sh~a
SAT146B
00 Does "E.C.U. INPUT
SIGNALS" show damage
Yes
__. Check inhibitor switch circuit.
- Refer to "Self-diagnosis".
to inhibitor switch circuit?

OR

®
D
Does self-diagnosis show
damage to inhibitor switch
circuit?

No
B1
N.G.
Check throttle sensor. - Refer Repair or replace throttle sensor.
to section EF & EC.
O.K.
11
1. Remove oil pan. N.G.
~ 1. Remove control valve assem-
2. Check A/T fluid condition.
bly.- Refer to "ON-VEHI-
O.K.
CLE SERVICE".
2. Check the following items.

O.K. I •• Shift valve B

Shift solenoid B

O.K. • Pilot valve

• Pilot filter

3. Disassemble AlT.
4. Check the following items.
8181/1---------ll,l • Servo piston assembly
• High clutch assembly
• Oil pump assembly

m 1N.G.
Check again. 1. Perform A/T control unit
input/output signal inspection.
O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
SAT119B
unit harness connector.

AT-70
 TROUBLE DIAGNOSES

Revolution sensor Diagnostic Procedure 11

Speed sensor SYMPTOM: A/T does not shift from 03 to 04 at the
Shift solenoid A
Self-diagnosis Shift solenoid B
specified speed.
start Fluid
temperature Are Diagnostic Procedures 7 and No Go to Diagnostic Procedure 7 or
sensor
- --Light 8 O.K.? 8.
Yes
D
Shade Yes
Does self-diagnosis show damage Check damaged circuit. - Refer
to inhibitor switch, overdrive to "Self-diagnosis".
SAT342C 1-------------4 Light
switch, shift solenoid A, B,
revolution sensor, speed sensor
or fluid temperature sensor
circuit after cruise test?

No
6
N.G.
Check throttle sensor. - Refer Repair or replace throttle sensor.
to section EF & EC.
O.K.
11
1. Remove oil pan. N.G.
2. Check A/T fluid condition. 1. Remove control valve assem-
bly.- Refer to "ON-VEHI-
O.K.
CLE SERVICE".
2. Check the following items.

I ••
Shift valve B
O.K. Overrun clutch control valve
• Shift solenoid B
O.K.
• Pilot valve
• Pilot filter

3. Disassemble A/T.
4. Check the following items.
• Servo piston assembly

Ut-------ll,l • Brake band

818
• Torque converter
• Oil pump assembly

19
1N.G.
Check again. 1. Perform A/T control unit
input/output signal inspection.
O.K.
2. If N.G., recheck A/T control
unit pin terminals for damage

0/ 8 lll-------lll SAT120B
I INSPECTION END
I or connection of A/T control
unit harness connector.

AT-71
 TROUBLE DIAGNOSES

D Diagnostic Procedure 12
::::~~ SYMPTOM: AIT does not perform lock-up at the
/ ,,,,
_.L_j, specified speed.

D
-- r-- - - -- Light Yes Check lock-up solenoid circuit.
Does self-diagnosis show damage
to lock-up solenoid circuit after - Refer to "Self-diagnosis".
~-
: - - - __ L...JILJL.L.A..JLJI...J..uUL...u..+ Shade cruise test?

SAT314C
PJ l No
N.G.
Check throttle sensor. - Refer Repair or replace throttle sensor.
to section EF & EC.

lOK
N.G.
1. Remove control valve. - Refer Repair or replace damaged parts.
to "ON-VEHICLE SERVICE".
2. Check following items.
• Lock-up control valve
• Shuttle shift valve D
• Torque converter relief valve
• Lock-up solenoid
• Pilot valve

8/8 llJ-----~~~
• Pilot filter

11 l O.K.
1 N.G.
Check again. 1. Perform A/T control unit
input/output signal inspection .
.!_O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

0/Blt-l-------tll SAT121B

AT-72
 TROUBLE DIAGNOSES

Diagnostic Procedure 13
SYMPTOM: A/T does not hold lock-up condition for
more than 30 seconds.

D
--r--- -- Light Yes
Does self-diagnosis show damage Check engine revolution signal
to engine revolution signal circuit circuit.
I - - -- - J.JL.JL.JL..JWIWL~L...IL..-l-- Shade after cruise test? - Refer to "Self-diagnosis".
1

No
6
1. Remove oil pan. N.G. 1. Remove control valve assem- -
2. Check A/T fluid condition. bly.- Refer to "ON-VEHI-
O.K. CLE SERVICE".
2. Check the following items.
• Lock-up control valve

• Pilot
Pilot valve
O.K. •3. Disassemble
filter
A/T.
O.K. 4. Check torque converter and
oil pump assembly.

N.G.
Check again. 1. Perform A/T control unit
input/output signal inspection.
O.K. 2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

D Diagnostic Procedure 14
SYMPTOM: Lock-up is not released when accelerator
pedal is released.
Self-diagnosis
start
I
- - - - - - - - - - - - - - - - - - - Light (i) Does "E.C.U. INPUT
SIGNALS" show damage
Yes Check idle switch circuit. - Refer
to "Self-diagnosis".
to idle switch circuit?
~----------------~---Sh~e
SAT146B OR
D
®Does self-diagnosis show
damage to idle switch
circuit?

6 !_No

Check again.
~ 1. Perform A/T control unit

lO.K.
input/output signal inspection.
2. If N.G., recheck A/T control
unit pin terminals for damage
0/8
I INSPECTION END

•
I or connection of A/T control
unit harness connector .

AT-73
 TROUBLE DIAGNOSES

Diagnostic Procedure 15
SYMPTOM: Engine speed does not return to idle
smoothly when A/T is shifted from 04 to 03
with accelerator pedal released.
---.---- - --- Light
Vehicle does not decelerate by engine
brake when changing overdrive switch to
"OFF" position with accelerator pedal
t-- - -'--''U'-LA-.IL.LUUJULJIL-.j:-- Shade
released.
Vehicle does not decelerate by engine
SAT313C
brake when changing selector lever from
"0" to "2" range with accelerator pedal
released.

0
Yes
Does self-diagnosis show damage Check overrun clutch solenoid
to overrun clutch solenoid circuit circuit. - Refer to "Self-
after cruise test? diagnosis"_
No
6
I N.G . .1
Check throttle sensor_ - Refer Repair or replace throttle sensor.
to section EF & EC.
O.K.
11

~
1. Remove oil pan_
2_ Check A/T fluid condition. 1. Remove control valve assem-
bly_- Refer to "ON-VEHI-
OK CLE SERVICE"-
2. Check the following items-
• Overrun clutch control valve
OKI • Overrun clutch reducing valve

OK
• Overrun clutch solenoid

m8/8 ..------------r---il 3. Disassemble AlT.

4. Check the following items_
• Overrun clutch assembly
• Oil pump assembly

m N.G.
Check again. 1. Perform A/T control unit
input/output signal inspection.
OK 2. If N.G_, recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
unit harness connector.

Engme brake

SAT765B

AT-74
 TROUBLE DIAGNOSES

D Revolution sensor Diagnostic Procedure 16

Speed sensor SYMPTOM: Vehicle does not start from 01 on Cruise
Shift solenoid A
Self-diagnosis Shift solenoid B test - Part 2.
start
D
Light Does self-diagnosis show damage Yes Check damaged circuit. - Refer
to revolution sensor, speed sensor, to "Self-diagnosis".
shift solenoid A orB after cruise
Shade test?
SAT341C l No
N.G.
Check again. 1. Perform A/T control unit

l O.K.
input/output signal inspection.
2. If N.G., recheck A/T control
unit pin terminals for damage
I Go to Diagnostic Procedure 8.
I or connection of A/T control
unit harness connector.

D Diagnostic Procedure 17
SYMPTOM: A/T does not shift from 04 to 03 when
changing overdrive switch to "OFF"
I Self-diagnosis
start I position.

- - - - - - - - - - - - - - - - - - - Light
fF.i\
Does "E.C.U. INPUT
~ SIGNALS" show damage
l_~-~-.J Check overdrive switch circuit.
I I - Refer to "Self-diagnosis".
I
~--------------~---Sh~e to overdrive switch
SAT146B circuit?

~--------OR--------~
D
~ Does self-diagnosis show
~ damage to overdrive
switch circuit?

Go to Diagnostic Procedure 10.

AT-75
 TROUBLE DIAGNOSES

D Diagnostic Procedure 18
. ~·

SYMPTOM: AfT does not shift from 03 to 22 when

Self-diagnosis changing selector lever from "D" to "2"
I start I range.

- - - - - - - - - - - - - - - - - - - Light
00 Does "E.C.U. INPUT
SIGNALS" show damage
M Check inhibitor switch circuit.
- Refer to "Self-diagnosis".
~--------------~---Sh~e to inhibitor switch circuit?
SAT1468
OR
D
® Does self-diagnosis show
damage to inhibitor switch
circuit?

TNo

I Go to Diagnostic Procedure 9.

D Diagnostic Procedure 19
SYMPTOM: AfT does not shift from 22 to 11 when
Self-diagnosis changing selector lever from "2" to "1"
start range.

- - - - - - - - - - - - - - - - - - - Light 00 Does "E.C.U. INPUT

SIGNALS" show damage
Yes Check inhibitor switch circuit.
- Refer to "Self-diagnosis".
to inhibitor switch circuit?
~--------------~---Sh~e
SAT1468
OR

®
D
Does self-diagnosis show
damage to inhibitor switch
circuit?
1No
fJ
ICheck again.
L...-----------,--------~
~
r---- er orm A IT centrorumt
1. Pf ·
l O.K.
input/output signal inspection.
2. If N.G., recheck A/T control
unit pin terminals for damage
INSPECTION END or connection of A/T control
SAT7788
unit harness connector.
Diagnostic Procedure 20
SYMPTOM: Vehicle does not decelerate by engine
brake when shifting from 22 (12) to 11.

Is diagnostic procedure 6 0. K.? Go to Diagnostic Procedure 6.

Yes

Go to Diagnostic Procedure 15.

AT-76
TROUBLE DIAGNOSES

Electrical Components Inspection

INSPECTION OF A/T CONTROL UNIT
• Measure voltage between each terminal and terminal @ or
@ by following "A/T CONTROL UNIT INSPECTION TABLE".

• Pin connector terminal layout.

SAT032E

AT-77
 TROUBLE DIAG.NOSES
Electrical Components Inspection (Cont'd)
A/T CONTROL UNIT INSPECTION TABLE
(Data are reference values.)

Terminal Judgement
Item Condition
No. standard

When accelerator pedal is released

1.5 · 2.5V
after warming up engine.
1 Line pressure solenoid
When accelerator pedal is depressed
0.5V or less
fully after warming up engine.

~
When accelerator pedal is released
5- 14V
Line pressure solenoid after warming up engine.
2
(with dropping resistor)
When accelerator pedal is depressed
0.5V or less
fully after warming up engine.

When A/T check lamp

1V or less
is on.
3 A/T check lamp
When A/T check lamp
Battery voltage
is not on.

When ignition switch is turned to

Battery voltage
"ON".
4 Power source
When ignition switch is turned to
1Vorless
"OFF".

When A/Tis performing lock-up. 8- 15V

5 Lock-up solenoid
When A/T is not performing lock-up. 1V or less

When shift solenoid A is operating.

Battery voltage
(When driving in "0 1 " or "04 ".)
6 Shift solenoid A
When shift solenoid A is not
operating. 1V or less
(When driving in "0 2 " or "03 ".)

7 Shift solenoid B
(L~
..... .....
When shift solenoid B is operating.
(When driving in "0 1 " or "0 2 ".)

When shift solenoid B is not

Battery voltage

operating. 1V or less
(When driving in "0 3 " or "04 ".)

When timing solenoid is operating.

Battery voltage
(When driving in "0 1 " or "04 ".)
8 Overrun clutch solenoid
When timing solenoid is not
operating. 1Vorless
(When driving in "0 2 " or "0 3 ".)

AT-78
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)

Terminal Judgement
Item Condition
No. standard

9 Power source Same as No.4

10* - - -
11 - - -
12 - - -
13 - - -
When accelerator pedal is released
Idle switch 8 -15V
after warming up engine.
14 (in throttle valve
switch) When accelerator pedal is depressed
1V or less
after warming up engine.

15 Ground - -
When selector lever is set to 11 1~~
Battery voltage
Inhibitor "1 II range range.
16
switch When selector lever is set to other

~
1V or less
ranges.

When selector lever is set to "2"

Battery voltage
Inhibitor "2" range range.
17
switch When selector lever is set to other
1V or less
ranges.

When selector lever is set to 11 D"

Battery voltage
Inhibitor "D" range range.
18
switch When selector lever is set to other
1V or less
ranges.

When selector lever is set to "N"

Battery voltage
range.
Inhibitor "N" or "P"
19
range switch When selector lever is set to other
1V or less
ranges.

When selector lever is set to "R"

Battery voltage
Inhibitor "R" range range.
20
switch When selector lever is set to other
1V or less
ranges.

When accelerator pedal is depressed

Full throttle switch more than half-way after warming 8 -15V
21 (in throttle valve up engine.
switch) When accelerator pedal is released
1V or less
after warming up engine.

22 - - -
* · This terminal is connected to terminal No. 36 of E.C.C.S. control unit.
When code No. 54 appears during engine self-diagnosis, check line between above terminals for proper continuity.

AT-79
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)

Terminal Judgement
Item Condition
No. standard

When ignition switch is turned to

Battery voltage

tB ~
Power source "OFF".
23 or
(Back-up) When ignition switch is turned to
Battery voltage
"ON".

When engine is running at idle speed. 0.9V

24
Engine revolution
signal
~ ID When engine is running at 3,000 rpm.
Approximately
3.7V

1V or more
When vehicle is cruising at 30 km/h Voltage rises gradu-
Revolution sensor (19 MPH). ally in response to
25
(Measure in AC range) vehicle speed.

26 - !f..b
..... ......
When vehicle is parked.

-
When vehicle is moving at 2 to 3
ov
-
Vary from 0 to
27 Speed sensor km/h (1 to 2 MPH) for 1 m (3ft) or
5V
more.

28 - - -
29 - - -
30 - - -
Throttle sensor
31
(Power source)
- 4.5- 5.5V

32 - - -

33
Fluid temperature
sensor
~ When A.T.F. temperature is 20°C
(68°F).
Approximately 1.5 v
When A.T.F. temperature is 80°C
Approximately 0.5V
(176°F).

When accelerator pedal is depressed Fully-closed throttle

slowly after warming up engine. Approximately
0.5V
34 Throttle sensor Voltage rises gradually in Fully-open throttle:
response to throttle opening Approximately
angle.
4V

Throttle sensor
35
(Ground)
- -

36 - - -
When A.S.C.O. cruise is being per-

~
Battery voltage
formed. ("CRUISE" light comes on.)
37 A.S.C.D. cruise
·signal When A.S.C.D. cruise is not being
~ ~ performed. ("CRUISE" light does 1V or less
.not come on.)

AT-80
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)

Terminal Judgement
Item Condition
No. standard

38

When overdrive switch is set in "ON"

Battery voltage
position.
39 Overdrive switch
When overdrive switch is set in
1Vorless
"OFF" position.

When "ACCEL" set switch on

5-8V
A.S.C.O. 0.0. A.S.C.O. cruise is released.
40
cut signal When "ACCEL" set switch on
1V or less
A.S.C.O. cruise is applied.

When accelerator pedal is released

3-8V
after warming up engine.
41 Kickdown switch
When accelerator pedal is depressed
1V or less
fully after warming up engine.

42

When A/C switch is set in "ON"

8- 16V
position.
A/C switch
43
(Turbo model) When A/C switch is set in "OFF"
2V or less
position.

44

45

46

47

48 Ground

OVERDRIVE SWITCH
• Check continuity between two terminals.

0.0. switch position Continuity

ON No

OFF Yes

AT-81
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
INHIBITOR SWITCH
1. Check continuity between terminals CD and ® and between
terminals® and@,@,®. (j), @,®while moving selector
lever through each range.

~ p
n
CD ® ®

o- ~ o- t-o
@ @ ® (j) ® ®

R 0 -o
N o- r-0 ~

'-' -o
D 0 -o
,..,
2 '-'

1 "'-" -()

2. If N.G., check again with manual control linkage discon-

nected from manual shaft of A/T assembly. - Refer to step
1.
3. If O.K. on step 2, adjust manual control linkage. - Refer to
"ON-VEHICLE SERVICE".

4. If N.G. on step 2, remove inhibitor switch from A/T and

check continuity of inhibitor switch terminal. - Refer to
step 1.
5. If O.K. on step 4, adjust inhibitor switch. - Refer to "ON-
VEHICLE SERVICE".
6. If N.G. on step 4, replace inhibitor switch.

REVOLUTION SENSOR
• For removal and installation, refer to "ON-VEHICLE SERV-
ICE".
• Check resistance between terminals CD. ® and @.

Terminal No. Resistance

CD ® 500-6500

® ® No continuity

G) ® No continuity

AT-82
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
FLUID TEMPERATURE SENSOR
• For removal and installation, refer to "ON-VEHICLE SERV-
ICE".
• Check resistance between two terminals while changing
temperature as shown at left.

Resistance

20 (68) Approximately 2.5 kil

80 (176) Approximately 0.3 kil

LOCK-UP SOLENOID
• For removal and installation, refer to "ON-VEHICLE SERVICE".
• Check resistance between two terminals.
Resistance:
Lock-up solenoid 1o - 20 n

SAT846B

Ground 3-UNIT SOLENOID ASSEMBLY (Shift solenoids A, B and

overrun clutch solenoid) AND LINE PRESSURE
SOLENOID
• For removal and installation, refer to "ON-VEHICLE SERVICE".
• Check resistance between terminals of each solenoid.

Solenoid Terminal No. Resistance

Shift solenoid A @

Shift solenoid 8 ® Ground 20 -40il

@ terminal
Overrun clutch solenoid

Line pressure solenoid CD 2.5- 5il

Eu-----
DISCOIIII(CT

I
I
I
,. -~
I
I
I

,_-
I
I

SAT034

DROPPING RESISTOR
• Check resistance between two terminals.
Resistance: 11.2 - 12.sn

SAT848B

AT-83
 TROUBLE DIAGNOSES

Final Check
STALL TESTING
Stall test procedure
1. Check A/T and engine fluid levels. If necessary, add.
2. Warm up engine until engine oil and A.T.F. reach operating
temperature after vehicle has been driven approx. 10 min-
utes.
A.T.F. operating temperature:
50 - 80°C (122 - 176°F)

SAT779A

3. Set parking brake and block wheels.

4. Install a tachometer where it can be seen by driver during
test. ·
• It is good practice to put a mark on point of specified
engine rpm on Indicator.

5. Start engine, apply foot brake, and place selector lever in "0"
range.

SAT767B

6. Accelerate to wide-open throttle gradually while applying

foot brake.
7. Quickly note the engine stall revolution and immediately
release throttle.
• During test, never hold throttle wide-open for more than 5
seconds.
Stall revolution:
2,450 - 2,650 rpm (RE4R01A)
2,950 - 3,200 rpm (RE4R03A)

8. Shift selector lever to "N".

9. Cool off A.T.F.
• Run engine at idle for at least one minute.
10. Perform stall tests in the same manner as in steps 5
through 9 with selector lever in "2", "1" and "R", respec-
tively.

AT-84
 TROUBLE DIAGNOSES
--------------------------------
Final Check (Cont'd)
Judgement of stall test

Selector lever position udgement

D L 0 H
0 : Stall revolution is normal.
2 L 0 H
H : Stall revolution is higher
1 L 0 0 than specified.
L : Stall revolution is lower
R L H H than specified.

L ~
Damaged components

I Engine I

Hydraulic circuit for

line pressure control
(Line pressure is low.)

t
I

Clutches and brakes except

high clutch and brake band
are O.K. (Condition of high
clutch and brake band can·
not be confirmed by stall
D H H H 0 test.)

2 H H H 0
1 0 H H 0
R 0 0 H 0
Selector lever position Judgement
SAT107B

AT-85
 TROUBLE DIAGNOSES
Final Check (Cont'd)
RE4R01A PRESSURE TESTING
Front
• Location of line pressure test port
• Line pressure plugs are hexagon headed bolts.
• Always replace line pressure plugs as they are self-
sealing bolts.

SAT6;!3C

Line pressure test procedure

1. Check A/T and engine fluid levels. If necessary, add.
2. Warm up engine until engine oil and A.T.F. reach operating
temperature after vehicle has been driven approx. 10 min-
utes.
A.T.F. operating temperature:
50 - 80°C (122 - 176°F)

SAT779A

3. Install pressure gauge to line pressure port.

- D, 2 and 1 ranges -

AT-86
 TROUBLE DIAGNOSES
Final Check (Cont'd)
- R range-

\
\ :f)/
ST2505S001 ~ I
(J25695-A)

~~ SAT625C

4. Set parking brake and block wheels.

• Continue to depress brake pedal fully while line pressure
test at stall speed is performed.

5. Start engine and measure line pressure at idle and stall

speed.
• When measuring line pressure at stall speed, follow the
stall test procedure.
Line pressure:

Engine speed Line pressure kPa (kg/cm 1 , psi)

rpm D, 2 and 1 ranges R range

422-461 667 -706

Idle
SAT643A (4.3- 4.7. 61 - 67) (6.8- 7.2, 97- 102)

1,020 - 1,098 1.422. 1,500

Stall
(10.4- 11.2, 148- 159) (14.5- 15.3, 206- 218)

AT-87
 TROUBLE DIAGNOSES
Final Check (Cont'd)
JUDGEMENT OF LINE PRESSURE TEST

Judgement Suspected parts

Line pressure is low in all ranges. • Oil pump wear

• Pressure piston
Control damage
• Spring for pressurevalve
regulator or plug sticking
• Fluid pressure leakage betweenvalveoil damaged
regulator
• valve strainer and pressure regulator

Line pressure is low in particular range. • Fluid pressure leakage between manual valve and particular clutch .
.!!
::g
• For example;
If line pressure is low in "A" and "1" ranges but is normal in
....
<t "D" and "2" range, fluid leakage exists at or around low & reverse
brake circuit.

Line pressure is high. • Mal-adjustment of throttle sensor

• Fluid temperature sensor damaged
• Line pressure solenoid sticking
• Short circuit of line pressure solenoid circuit
• Pressure modifier valve sticking
• Pressure regulator valve or plug sticking

Line pressure is low. • Control

Mal-adjustment of throttle sensor
"i • Line pressure
piston damaged
Q)

a- • Short circuit ofsolenoid sticking

"ii • Pressure regulator valve or plugsolenoid
line pressure circuit
t:
~
• sticking
• Pressure modifier valve sticking
• Pilot valve sticking

AT-88
 TROUBLE DIAGNOSES

Symptom Chart

ON vehicle OFF vehicle

Reference page (AT- I 10• 82 82 86 83, 8• 8 8 118 • 149, 155,

155 159 177
14 135 83 83 83 130 153 170
~--------~~4-~4-~4-~~~~
Numbers are arranged in order of probability.
Perform inspections starting with number one

~.
and work up. Circled numbers indicate that

...li'
the transmission must be removed from the
vehicle.
I
l!!o ~CO?
B
c: "
f~
'
!
..
:!
J .. 0
-N
0 0
~.! ~ 1ii
.s:;
"
.a-5
IE: ~~ ..
• "E "E "5E
"-
.. a
. ·-"
~
- 0
"D :: O>.s:;
·- c: ] H !I" "!:l > "'
£8 ... < << IE: :I:

63 Engine does not start in "N", "P" ranges. 2 3 1

63 E·ngine sta"s in range other than "N" and "P". 1 2

- Transmission noise in "P" and "N" ranges. 1 3 4 5 2 ®®

Vehicle moves when changing intQ "P" range
63 or parking gear does not disengage when 1 .. ~
shifted out of "P" range.

64 Vehicle runs in "N" range. 1 4 @. ® @

Vehicle will not run in "R" range (but runs
66 in "0", "2" and "1" ranged. Clutch slips. 1 2 4 3 @@ (l). ® ®
Very poor acceleration.

- Vehicle braked when shifting into "R" range. 1 2 3 5 4 ® @. ® (j)

Sharp shock in shifting from "N" to "0"

- range.
2 5 1 3 7 6 4 8 ®·
Vehicle will not run in "0" and "2" ranges
- (but runs in "1" and "R" rangel.
1 ®
Vehicle will not run in ''0", "1", "2" ranges
67 (but runs in "R" rangel. Clutch slips. 1 2 4 3 5 ®® ®® ®
Very poor acceleration.

- Clutches or brakes slip somewhat in starting. 1 2 3 4 6 5 7 8 @@ ® ® (j])

- Excessive creep. 1 .
66,67 No creep at all. 1 2 3 . . ®@ @ .
- Failure to change gear from "0 1 " to "0 2 ". 2 1 . 5 4 3 ®
- Failure to change gear from "0 2 " to "0, ". 2 1 5 4 3 @ <D
- Failure to change gear from "0," to "0, ". 2 1 4 3 5 . ®
69, Too high e gear change point from "0 1 " to
70, "0 1 ",from "0 1 •• to "0 1 ", from "0 1 "
to "0 4 " .
1 2 3 4 . .
71

- Gear change directly from "0 1 " to "0,"

occurs.
1 2 . @
Engine stops when shifting lever into "R", "0",
- 1 3 2 @
"2" and "1".

- Too sharp a shock in change from "0 1 " to

"0,". 1 2 4 5 3 . . ®
Too sharp a shock in change from "0 2 to
- "0,".
"
1 2 4 3 @ ®

AT-89
 TROUBLE DIAGNOSES
Symptom Chart (Cont'd)

ON vehicle OFF vehicle

( T I 10, 82 82 86 83, 83 83 8, 8 8 118, 149, 155, 155 159 177

Reference page A • 14 135 83 130 153 170
'-.---------t----+---+----+-+--+--+--+--+-+--+-+--+--lr--+--t--1
Numbers are arranged in order of probability.
Perform inspections starting with number one
and work up. Circled numbers indicate that
the transmission must be removed from the
vehicle.
:;;
~
..... ~C?
~N t: .r;

~
u
c:
=a
~
2• 2• 8 .. ~'fi
.
l! : 3'S
u ~

.. ..,
• :IE u.i!
~
c: .. E E :I ~ u
·a, ! :I :I ~ ..
c: ·- !I I! 0 = a:> ·-
..
W..J << t-0 X

Too sharp a shock in change from "0 1 " to (.&)

2 4 3 (5)
"0•"·

Almost no shock or clutches slipping in change

2 3 5 4
from "0 1 " to "0 1 '",

Almost no shock or slipping in change from

2 3 5 4 (i)
"D," to ''0 1 ".

Almost no shock or slipping in change from

2 3 5 4
"0 1 "to"O•"·

Vehicle braked by gear change from "0 1 " to

"0,".

Vehicle braked by gear change from "0," to

(._2
"0,

Vehicle braked by gear change from "0," to

1 • (4)
"0• ...

Maximum speed not attained. Acceleration poor. 2 5 3 4 @® (6)(7) ®(8)

Failure to change gear from "0•" to "0 1 ". 2 6 4 5 3 (8) (J)

Failure to change gear from "0 1 " to "0 1 "

2 5 3 4 (ii (7)
or from "04 " to "0 1 ••.

Failure to change gear from "0," to "0 1 " (§) (8)

2 5 3 4 (J)
or from ··o," to "0 1 ".
Gear change shock felt during deceleration
2 4 3
by releasing accelerator pedal.

Too high a change point from "0•" to "0 1 ",

1 2
from "0•" to .. D, ",from "0 1 " to "0 1 ".

Kickdown does not operate when deprauing

1 2 • 3 4 •
pedal in "0•" within kickdow11 vehicle speed.

Kickdown operates or engine overruns when

depressing pedal in "0•" beyond kickdown 2 1 3 4
vehicle speed limit.

Races extremely fast or slips in changing

from "0•" to "0," when depressing pedal.
2 3 5 4 ®®
Races extremely fast or slips in changing (i)
2 3 6 5 4
from "0•" to "0," when depreuing pedal.

Races extremely fast or slips in changing

from "0 1 " to "0 1 " when depreuing pedal.
2 3 5 4 8 10 ®® ®
Races extremely fast or slips in changing from
"0•" or "0," to "0 1 " when depreuing pedal.
2 3 5 4 ®® ®
Vehicle will no.t run in any range. 1 2 3 4 ®@ ® ®® ®
Transmission noise in "0", "2", ,., "and "R"
ranges.

AT-90
 TROUBLE DIAGNOSES
Symptom Chart {Cont'd)

1 + - - - - - - - - - 0 N vehicle----------+1+-----0FF vehicle-----+!

Reference page (AT· 1 10, 83, 8, 118, 149, 155,

14 82 82 86 135 83 83 8 8 155 159 177
83 130 153 170
't--------+....:........f--+--+--+-----+--+--+--+-+-+--t--+--+----+---1
Numbers are arranged in order of probability.
Perform inspections starting with number one
and work up. Circled numbers indicate that
the transmission must be removed from the
a
c:
vehicle.
~
....
c:
= a
:g ;
!
·~ -~
~

~
=
!!
"
!~
.. 0
o.~

.. E"
E.!!
~
0
'
0 0

~ H ""
~t?
-N

;
'3'S
EE
II II
. ..
r
~
8
., E
""
e-o.
o=:
0.

W..J ... < << 1-0

Failure to change from "0 1 " to "2 1 " when

76
changing lever into "2" range.
7 1 2 6 5 4 3 @. ®

Gear change from "2 1 •• to "2 1 " in "2 .. range.

76 Engine brake does not operate in "1" range. 2 1 3 4 6 5 7 ®

Gear change from "1 1 " to "1. 1 .. in "1" range. 2 1

Does not change from "1 1 " to "1 1 " in "1" range. 2 4 3 5 ®
Large shock changing from "1 1 " to "1 1 " in "1"
range.

Transmission overheats. 3 2 4 6 5 @®®® ®

A.T.F. shoots out during operation.
White smoke emitted from exhaust pipe ®@@ ® (l)@
during operation.

Offensive small at fluid charging pipe. ® ®®

Torque converter is not locked up. 3 1 2 4 6 8 7 5

Lock-up piston slip 2 3 6 5 4

72 Lock-up point is extremely high or low. 1 2 4 3

A/T does not shift to "0 4 " when driving

with overdrive switch "ON".
2 1 3 8 6 4 5 7 ®
r-----+-----------------------------~--+-~r--+--1---+-~r--+--1---+-_,r--+--1---+-_, ___,____
Engine is stopped at "R", "0", "2" and "1"
ranges. 5 4 3 2

AT-91
 TROUBLE DIAGNOSES

A/T Shift Lock System

SHIFT LOCK SYSTEM ELECTRICAL PARTS LOCA~

A/T shift lock

control unit

SAT033E

AT-92
 TROUBLE DIAGNOSES
A/T Shift Lock System (Cont'd)
CIRCUIT DIAGRAM FOR QUICK PINPOINT CHECK

To time control unit

'
11

® till~ KEY SWITCH

5
....z1-
®~
(Sh i f t)
5 l 9 12 :J
12 ....1
0
0::
(Key) 1-
DETENTION z
0
FUSE SWITCH u
2 ~
u
0
....1
3 1-

~-STOP LAMP
....I:u.
~~SWITCH To stop lamp II)

8
KEY LOCK
SOLENOID

~ rm::i:E r~~kT
~~SOLENOID 9

SAT593C

AT-93
 :e
!z
To stop I a.mP G)
FUSE BLOCK <Refer to ~'POWERSUPPLY c
ROUTING" in EL section. l
- ;:
~:-
To time control
-- I unit
G)

~ONNECTOR
I
,..
:a
i:
I BATTERY
I I
I 1

~-or
IGNITION SWITCH
START
G/L

,@)
- I ®~STOP LAMP
=Bl~sWITCH

-1
r.;;;;'\
~
SHIFT LOCK :a
CONTROL UNIT 0
-== ~ c

~
cO
.P.
~ *
FR

I llll I '"
PU

L
'~~~~~:.r··:" JlJ l§l
@!)@
r.;;;;.,
~@
R/ Y
(Main
harness)
-
- I[] SHIFT LOCK
tn I'""'

---· ,-.
::r rn

6"n
m

c
Gl

~®
SOLENOID z

·II·
;:II;"
.-- 0
!f tn
-
en
CD
rn
tn

-
'---
&USE BLOCK <B I ac kl ~ 3
'----
<R~f:ELAY BOXl 0

--
SUPPLYto "POWER I 0
In EL ROUTJ NG"
section. l :I
a:
(Key)

~'
01 OETENTI ON

®fi@
SWITCH

KEY LOCK KEY BODY GROUND

SOLENOID SWITCH
~
"'~
n
 TROUBLE DIAGNOSES
A/T Shift Lock System (Cont'd)
D DIAGNOSTIC PROCEDURE 1
®i) [il SYMPTOM:
Selector lever cannot be moved from "P" range when applying
brake pedal or can be moved when releasing brake pedal.
e;j II liB Selector lever can be moved from "P" range when key is

J J R/Y Y
removed from key cylinder.

,....D=.C_H_E_C_K_P_O_W_E_R_SO_U_R_C_E-.--, N .G . .--C-h-e-ck-th_e_f_o_llo-w-in-g-it_e_m_s_:-----,
Control unit

I
~
11. OOF
terminal
1. Harness continuity between
SAT602C
.,.. battery and control unit
harness terminals ®, @
2. Check voltage between con- 2. Fuse
trol unit harness terminals

®i) [il ®, @ and ground.

Battery voltage should exist.

GIL[s bd .Ill I I PJ
r=----------~----------,
O.K.
Control unit CHECK IGNITION SIGNAL N.G. Check the following items:
terminal

'I oo I
1. Harness continuity between
battery and control unit
harness terminal ®
SAT603C
2. Check voltage between con- 2. Fuse
trol unit harness terminal ® 3. Ignition switch

®i8 [il and ground.

ov
IIWI~?IIIl
B
.--- Control unit
[QJ terminal
4. Check voltage between con-
r-~ ~-----J trol unit harness terminal ®
and ground.
Battery voltage should exist.
SAT604C
O.K.

CHECK GROUND CIRCUIT ~

I L Repair harness or connector.
FOR CONTROL UNIT. ~----------------------~

2. Disconnect control unit

harness connector.
3. Check continuity between
control unit harness terminal
® and ground.
Continuity should exist.

O.K.

AT-95
 TROUBLE DIAGNOSES
A/T Shift Lock System (Cont'd)
m @

®IS~ m
N.G.
CHECK INPUT SIGNAL Check key switch.
I w·lyl,il (KEY SWITCH). (Refer to "COMPONENT
Control unit G/L 1. Reconnect control unit har- CHECK".)
terminal ness connector.

2.1
((B.~ I
SAT822B 3. Check voltage between con-
trol unit terminal @ and
ground.
®I) [it ov
O.K.
I bd lfl,il m N.G.
Control unit G/L Check the following items:

@~
terminal
'·I I
1. Harness continuity between
control unit harness terminal
(jJ) and key switch harness
2. Check voltage between con-
terminal Ql).
trol unit harness terminal @
-= SAT822B
and ground.
2. Harness continuity between
key switch harness terminal
Battery voltage should exist.
~)and fuse
O.K. 3. Key switch (Refer to "COM-
PONENT CHECK".)
CHECK INPUT SIGNAL
(DETENTION SWITCH-SHIFT).

£J
N.G.
'·I @. I
Check detention switch-shift.
(Refer to "COMPONENT
CHECK".)
D) 2. Set selector lever in "P"
position and release
selector lever button.
6 3. Check voltage between
control unit harness ter·
minal @ and ground.
ov
O.K.

SAT819B

r
B

AT-96
 TROUBLE DIAGNOSES
A/T Shift Lock System {Cont'd)
@

N.G.
Brake pedal CHECK INPUT SIGNAL Check the following items:
(DETENTION SWITCH-SHIFT). 1. Harness continuity between

oo o
control unit harness terminal

®i) [il
'·I
(;) 2. Check voltage between
I
@ and detention switch har-
ness terminal @
2. Harness continuity between
detention switch harness
control unit harness ter-
II W1111 5~ minal @ and ground with
terminal (jJ) and key switch
harness terminal (jJ)
Control unit
brake pedal depressed and
3. Detention switch-shift
terminal Y/G selector lever button
(Refer to "COMPONENT
pushed.
CHECK".)
Battery voltage should
exist.
ID 3. Check voltage between
control unit harness ter-
Brake pedal
minal @ and ground with
selector lever set in any
position except "P".
When selector lever cannot
SAT628C
be moved from "P" posi-
tion with brake pedal
IDIET depressed, push shift lock
release knob.
Battery voltage should
exist.
Control unit
IIi] O.K.
terminal

CHECK INPUT SIGNAL N.G.

Check the following items:
(STOP LAMP SWITCH). 1. Harness continuity between
control unit harness terminal
SAT629C
@ and stop lamp switch
harness terminal @
m • Check voltage between con- 2. Harness continuity between
trol unit harness terminal @ stop lamp switch harness
and ground. terminal CV and fuse
3. Stop lamp switch
Brake pedal Voltage
(Refer to "COMPONENT
Depressed Battery voltage CHECK".)
Released OV

O.K.
SAT630C
Set selector lever in "P" position.

AT-97
 TROUBLE DIAGNOSES
A/T Shift Lock System (Cont'd)

! ~ Check harness continuity

IIIll I o lXII
111 I II
CHECK OUTPUT SIGNAL
(SHIFT LOCK SOLENOID). between control unit harness

lVI
, - ~ _5!:::)1----~
L Shift lock
harness
connector
'·I
II 2.
oo ttZJ I
Check voltage between
terminal (f'i and shift lock
solenoid harness terminal u!.

-~ ~ ~SAT608C shift lock harness con-

nector terminal Q) and
body ground.
Brake pedal Voltage
Depressed Battery voltage
Released ov

Shift lock
3.

~F
L
I vi"'
I
harness
b
r--~~~+~-------J
connector
I
11)4. Check voltage between
shift lock harness con-
-~ SAT609C nector terminal CD and
ground with brake pedal
depressed.
ov

Shift lock CHECK GROUND CIRCUIT ~ Repair harness or connector.

liD B
harness
connector
FOR SHIFT LOCK SOLENOID.
1. Disconnect shift lock harness
L.___ _ _ _ _ _ _ _ _ __J

r--~~-------J
connector.
2. Check continuity between
SAT610C
shift lock harness terminal ®
and ground.
Continuity should exist.

Check shift lock solenoid. IN .G · J Replace A/T shift lock control

(Refer to "COMPONENT I I device assembly.
CHECK".) L-----------------~

Reconnect shift lock harness

connector.

1
Recheck shift lock operation.
L-----------~----------~
~ 1. Perform control unit input/
output signal inspection test.
lO.K. 2. If N.G., recheck harness con-
nector connection.
INSPECTION END

AT-98
 TROUBLE DIAGNOSES
.A/T Shift Lock System {Cont'd)
D DIAGNOSTIC PROCEDURE 2

®i)~ SYMPTOM:
Ignition key cannot be removed when selector lever is set to "P"
position or can be removed when selector lever is set to any
BJj II liB position except "P".

J J A/Y Y
D
.--C-H_E_C_K_P_O_W_E_R_S_O_U_R_C_E_.-----., N .G:
Check the following items:
Control unit

'I oo
terminal 1. Harness continuity between
battery and control unit
-=--- SAT602C harness terminals@,@
2. Check voltage between con- 2. Fuse
trol unit harness terminals
@, @ and ground.
®i) [it Battery voltage should exist.

GILlis WIll I I O.K.

Control unit N.G. Check the following items:

CHECK IGNITION SIGNAL.
terminal f----+ 1. Harness continuity between

SAT603C
.. 1 oo
2. Check voltage between con-
I
battery and control unit
harness terminal ®
2. Fuse
3. Ignition switch
trol unit harness terminal @
®f8[il and ground.
ov

In!
lllfhiilll
8
Control unit
terminal
3
1 ~ o
4. Check voltage between con-
I
~~ ~----------
trol unit harness terminal ®
and ground.
Battery voltage should exist.
SAT604C
O.K.

CHECK GROUND CIRCUIT

FOR CONTROL UNIT.
4 Repair harness or connector.
~----------------------~

.. 1 ~ I
2. Disconnect control unit
harness connector.
3. Check continuity between
control unit harness terminal
@ and ground.
Continuity should exist.

O.K.

AT-99
 TROUBLE DIAGNOSES
A/T Shift Lock System ( Cont' d)
A

®IS~ N.G. Check key switch.

CHECK INPUT SIGNAL
I bd 111 8 11 (KEY SWITCH).
1. Reconnect control unit har·
(Refer to "COMPONENT
CHECK".)
Control unit G/L
terminal ness connector.

SAT822B When ignition key cannot be

removed, even if selector lever
is in "P" position, use
®IS [il emergency button.
3. Check voltage between con·
I Wlfi,DJ trol unit terminal @ and
ground.
Control unit
terminal
G/L
ov

N.G.
Check the following items:
SAT8228 1. Harness continuity between
control unit harness terminal
2. Check voltage between con· @ and key switch harness
trol unit harness terminal @ terminal@.
and ground. 2. Harness continuity between
Battery voltage should exist. key switch harness terminal
@and fuse
3. Key switch (Refer to "COM·
PONENT CHECK".)
CHECK INPUT SIGNAL
(DETENTION SWITCH-KEY).

1.1 ~. u
[i) 2. Set selector lever in "P"
I
N.G. Check detention switch-key.
(Refer to "COMPONENT
CHECK".)

position and release

selector lever button.
IJ 3. Check voltage between
control unit harness ter-
minal @ and ground.
ov
O.K.

AT-100
 TROUBLE DIAGNOSES
.AfT Shift Lock System (Cont'd)
@

N.G.
Brake pedal CHECK INPUT SIGNAL Check the following items:
(DETENTION SWITCH-KEY). 1. Harness continuity between

IOOJCJI
control unit harness terminal
@ and detention switch har-
ness terminal @
®i) [it C] 1. Check voltage b!!tween 2. Harness continuity between
control unit harness ter- detention switch harness
II WI!II,J minal @ and ground with terminal (j}) and key switch
brake pedal depressed and harness terminal (j})
Control
unit LfW selector lever button 3. Detention switch-key
terminal
pushed. (Refer to "COMPONENT
Battery voltage should CHECK".)
exist.,
(;] 2. Check voltage between
control unit harness ter-
Brake pedal minal @ and ground with
selector lever set in any
position except "P".
Battery voltage should
SAT634C
exist.

Set selector lever in "P" posi-

tion and release selector lever.
button.

SAT631C m
~----------~----------~ N.G.
m CHECK OUTPUT SIGNAL
(KEY LOCK SIGNAL).
Check harness continuity
between shift lock solenoid
harness terminal @ and control

I~OI
Key lock solenoid
harness connector unit harness terminal @.
OR O.K. N.G.
Check voltage between key lock
solenoid harness terminal @
and ground at the moment connector.
ignition key is turned from OFF
to ON.
SAT663C Battery voltage should exist for Replace control unit.
approximately 0.1 seconds.
O.K.

AT-101
 TROUBLE DIAGNOSES
AIT Shift Lock System (Cont'd)
©
®i)[ii~F
N.G.

----w-~m1 ~l•ooid
CHECK OUTPUT SIGNAL Check harness continuity
(KEY UNLOCK SIGNAL between shift lock solenoid
Koy lo<k CAUSED BY IGNITION harness terminal ® and control
harness connector
SIGNAL). unit harness terminal ®.
O.K.

SAT664C Check voltage between key lock connector.

=
solenoid harness terminal ®
Ill and ground at the moment
ignition key is turned from ON Replace control unit.
to OFF.
Battery voltage should exist for
approximately 0.1 seconds.

SAT632C

.----------------11
m r----~--~-.
1. Push selector lever button
with brake pedal depressed.

21 ~
When turning ignition key,
keep selector lever button
pushed and brake pedal

rn®iSril depressed.

~ Key lock solenoid

harness connector
w CHECK OUTPUT SIGNAL Replace control unit.
(KEY UNLOCK SIGNAL
CAUSED BY DETENTION
SWITCH-KEY).

Check voltage between key lock

solenoid harness terminal ®
SAT665C
and ground at the moment
selector lever button is released.
Battery voltage should exist for
approximately 0.1 seconds.

O.K.
@

AT-102
TROUBLE DIAGNOSES
.A/T ShiH Lock System (Cont'd)

T
Check key lock $Oienoid. H Replace key lock soleno1.d .
(Refer to "COMPONENT
CHECK".)

lO.K.

Recheck key lock operation.

~ 1. Perform control unit input/
output signal inspection test.
lO.K. 2. If N.G., recheck harness
connector connection.
INSPECTION END

AT-103
 TROUBLE DIAGNOSES
A/T Shift Lock System (Cont'd)
SHIFT LOCK CONTROL UNIT INSPECTION
CONNECT • Measure voltage between each terminal and terminal ® by
£) •
following "SHIFT LOCK CONTROL UNIT INSPECTION TABLE".
Pin connector terminal layout.

12-pin connector

SAT455C

AT-104
 TROUBLE DIAGNOSES
A/T Shift Lock System (Cont'd)
SHIFT LOCK CONTROL UNIT INSPECTION TABLE (Data are reference values.)
Terminal No.
Item Condition Judgement standard
(±) e
When selector lever is set

1 Shift lock signal 00

Except above
in "P" position and
brake pedal is depressed
Battery voltage

ov

2 Power source
00 Battery voltage

When brake pedal is depressed Battery voltage

3 Stop lamp switch
When brake pedal is released ov
9

4 Power source
00
When key is inserted into key cylinder,
Battery voltage

selector lever is set in "P" position and ov

5 Detention switch (Shift) selector lever button is released

Except above Battery voltage

6 Ignition signal
00 Battery voltage

Battery voltage
When ignition switch is turned from
8 10 Key lock signal LOCK, OFF or ACC to ON (Approximately 0.1 seconds)

Except above ov
9 - Ground - -
When ignition switch is turned from ON
to LOCK, OFF, or ACC, selector lever is Battery voltage
10 8 Key unlock signal set in "P" position and selector lever (Approximately 0.1 seconds)
button is released
Except above ov
When key is inserted into key cylinder Battery voltage
11 Key switch
When key is removed from key cylinder ov
9 When key is inserted into key cylinder,
selector lever is set in "P" position and ov
12 Detention switch (Key) selector lever button is released

Except above Battery voltage

AT-105
 TROUBLE DIAGNOSES
AfT Shift Lock System (Cont'd)
COMPONENT CHECK
Shift lock solenoid
• Check operation by applying battery voltage to shift lock
harness connector.
~~ Shift lock
~ l!.L!J.!Ij]] harness connector

Detention switch - shift

• Check continuity between terminals @ and @ of shift lock
harness connector.

Condition Continuity
Shift lock When selector lever is set in "P" position
harness No
connector
and selector lever button is released

Except the above Yes

SAT649C

Detention switch - key

• Check continuity between terminals @ and @ of shift lock
harness connector.

Condition Continuity
Shift lock
harness
When selector lever is set in "P" position
connector No
and selector lever button is released

Except the above Yes

SAT650C

Key lock solenoid

Key lock • Check operation by applying battery voltage to key lock
solenoid solenoid harness connector.
harness
Operating sound must be emitted.
connector

SAT347C

AT-106
 TROUBLE DIAGNOSES
A/T Shift Lock System (Cont'd)
Key switch
• Check continuity between terminals @ and ® of key switch
harness connector.

Condition Continuity

When key is inserted into key cylinder Yes

When key is removed from key cylinder No

Stop lamp switch

• Check continuity between terminals ® and @ of stop lamp
switch harness connector.

Condition Continuity

When brake pedal is depressed Yes

When brake pedal is released No

Check stop lamp switch after adjusting brake pedal - refer to

SAT635C
section BR.

AT-107
 REMOVAL AND INSTALLATION

Removal
• Remove exhaust tube .

•••
Remove fluid charging pipe from A/T assembly .
Remove oil cooler pipe from A/T assembly .
Remove control linkage from selector lever.
•• Disconnect inhibitor switch and solenoid harness connectors .
Remove speedometer cable from A/T assembly .
•• Plug up openings such as the oil charging pipe hole, etc .
Remove propeller shaft. - Refer to section PD .

SAT362C
•• Insert plug into rear oil seal after removing propeller shaft.
Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
•• Remove starter motor.
Remove gusset securing engine to A/T assembly .

••
Remove bolts securing torque converter to drive plate .
Remove the bolts by turning crankshaft.

•••
Support engine by placing a jack under oil pan .
Do not place jack under oil pan drain plug .
Remove transmission from engine .
• Support automatic transmission, while removing it.

SAT363C

Installation
• Drive plate runout
Maximum allowable runout:
0.5 mm (0.020 in)
If this runout is out of allowance, replace drive plate with
ring gear.

• When connecting torque converter to transmission, measure

distance "A" to be certain that they are correctly assembled.
Distance "A":
RE4R01A
26 mm (1.02 in) or more
RE4R03A
25 mm (0.98 in) or more
• Install converter to drive plate.
• Reinstall any part removed.
• After converter is installed to drive plate, rotate crankshaft
several turns and check to be sure that transmission rotates
freely without binding.

AT-108
 REMOVAL AND INSTALLATION
Installation (Cont'd)
• Tighten bolts securing transmission.
RE4R01A
Bolt length "ll"
Bolt No. Tightening torque N·m (kg-m, ft-lb)
mm (in)

1 39 - 49 (4.0 - 5.0, 29 - 36) 60 (2.36)

2 39 - 49 (4.0- 5.0, 29 - 36) 50 (1.97)
® A/T to engine
3 39- 49 (4.0- 5.0, 29- 36) 45 (1.77)
(gusset)
81 Engine (gusset) 4 29 - 39 (3.0 - 4.0, 22 - 29) 25 (0.98)
to A/T 5 29 - 39 (3.0 - 4.0, 22 - 29) 60 (2.36)
6 39- 49 (4.0- 5.0, 29- 36) 65 (2.56)
7 39 - 49 (4.0 - 5.0, 29 - 36) 25 (0.98)

Gusset to
29 - 39 (3.0 - 4.0, 22 - 29) 20 (0.98)
engine

RE4R03A
Bolt length "ll"
Bolt No. Tightening torque N-m (kg-m, ft-lb)
mm(in)

1 39 - 49 (4.0 - 5.0, 29 - 36) 60 (2.36)

2 39- 49 (4.0- 5.0, 29- 36) 60 (2.36)
3 39 - 49 (4.0 - 5.0, 29 - 36) 65 (2.56)
4 29 - 39 (3.0 - 4.0, 22 - 29) 25 (0.98)
5 29 - 39 (3.0 - 4.0, 22 - 29) 60 (2.36)
6 39- 49 (4.0- 5.0, 29- 36) 65 (2.56)
7 39- 49 (4.0- 5.0, 29- 36) 25 (0.98)

Gusset to
29 - 39 (3.0 - 4.0, 22 - 29) 20 (0.98)
engine

• Reinstall any part removed.

• Check fluid level in transmission.

• Move selector lever through all positions to be sure that
transmission operates correctly.
With parking brake applied, rotate engine at idling. Move
selector lever through "N" to "0", to "2", to "1" and to "A".
A slight shock should be felt by hand gripping selector each
time transmission is shifted.
• Perform road test. - Refer to "ROAD TESTING".

SAT638A

AT-109
 MAJOR OVERHAUL

RE4R01A
N·m (kg-m, ft-lb)
Apply recommended sealant Side seal
(Nissan genuine part: Sideseal ~
KP610~0250) or equivalent.
~: Apply A.T.F.
Pivot pin~'» j
El®: Apply petroleum jelly Control piston
* : Select with proper thickness.
* : Adjustment is required.

AT-110
MAJOR OVERHAUL
RE4R01A (Cont'd)

AT-111
 - - - - - - - · IMAJOR OVERHAUL

RE4R03A
toJ .: N·m (kg-m, ft-lb)
PI!
Y ·Apply recommend d
(Nissan gen . e sealant
KP6 ume part·
~
~ 10-00250) .
: Apply A.T F or equivalent.

* : A~ply P~troleum
El®: '·
jelly
* .. 5Adjustment.
e ect With pro per thickness
.
required.
IS •

toJ61-64
(6.2 -6 .5 , 45 -47)

AT-112
MAJOR OVERHAU
RE4 R03A (Cont'd)
L

AT-113
 MAJOR OVERHAUL

Oil Channel - RE4R01A

1 -+ 2 accumulator drain
3 -+ 4 & N -+ R accumulator shoulder pressure 2 -+ 3 accumulator back pressure
3 -+ 4 & N -+ R accumulator back pressure 1 -+ 2 accumulator back pressure

Servo 2nd apply chamber pressure -+::--~;;::c;;;,n,.'-ii 1-'.-::..,.~1--- N -+ D accumulator back pressure
Servo 3rd release chamber pressure ~-+J,I'--rirtjr\!' ~~.,.~~~1-t"-- 2 -+ 3 accumulator shoulder pressure
·Oil pump feedback pressure
N -+ D accumulator shoulder pressure
Servo 4th apply chamber pressure
Low & reverse brake pressure
Oil pump discharge pressure
Overrun clutch pressure
Front lubricating hole
High-clutch pressure
Forward clutch pressure
Torque converter pressure (lock-up released)
Reverse clutch pressure r--------------------------
1* Accumulator back and
Torque converter pressure (lock-up applied)
: shoulder pressure are shown below.
Oil pump suction hole : Back pressure Shoulder pressure
I I I
Accumulator ...0-
"><:.b,4.1,¥.--<'V
P\ston
I
High-clutch pressure Torque converter pressure (lock-up released)
I
I
Front lubricating hole I
I
I
Oil pump discharge hole I

~~~i72.c:11
I
Torque converter pressure I
(lock-up applied) : ________________ __?~u~c_!l .?~:s~~~-

Oil pump feedback pressure

Oil pump suction hole

pressure

High-clutch pressure
Torque converter pressure
(lock-up released) Reverse clutch pressure
Forward clutch pre-ssure

Forward clutch pressure Servo 3rd chamber pressure 3 -+ 4 & N -+ R accumulator back pressure
Servo 4th apply chamber pressure
Servo 2nd apply
chamber pressure

SAT186B

AT-114
 MAJOR OVERHAUL

Oil Channel - RE4R03A

H ig h-cl utch pressure

Front lubricating hole

Oi I pump d isch~a~r~ge~h~o;le~~~?.~~~-j:;~(::rl Torque converter pressure

(lock-up applied)

Oil pump suction hole

pressure

Torque converter pressure

(lock-up applied)
Torque converter pressure Reverse clutch pressure
(lock-up released)

Overrun clutch pressure pressure

rear lubricating hole

SAT611 B

AT-115
 Outer diameter of snap rings

CD 00 @ @ (f) Item Outer diameter

number mm (in)

00 I 161.0 16.341
@ I 140.1 15.521
@ I 156.416.161
® I 142.0 15.591
(f) I 159.2 16.271

Thrust washers
Item
Color
number

CD Black
@ White

3C
mr-
:;, 0 t
a.n 0
en!. :a
!i
I
::J -·
ID 0
-c; 0
<
..a m
..a :DO
:;·- :a
en Outer diameter of needle bearings
caz l:
)>
Item Outer diameter
number mm (in)
en CD c
® 47 (1.85) I~ r-
:DCD
® 53 (2.09)
mm
® 53 (2.09) ..S:.CD
;:am
@ 7813.07) 0 ::::!.
~:;,
@ 5312.09) )>CC
@) 7813.07) !"
@ 59 (2.32)
..
-1
:;,"
®
-
78(3.07)
c
@ 6412.52) en
Installation of one-piece bearings
Item
number
Bearing race
(black) location
Inner diameter of bearing races
~
en
..
Item Outer diameter
Ul @ Front number mm (in) :;,"
)> CD
~
Ql ® Rear side @ 58 (2.28) en
~ @ Rear side @) 58.8 12.315)
)>
 Outer diameter of snap rings

Outer diameter
Item number
mm(in)

®.® 164.0 (6.46)

® ® @ ® (3) 176.0 (6.93)

® 172.0 (6.77)

Thrust washers
Item number Color

Q) Black

® White

Outer diameter of bearing races

Outer diameter i
mr s:
Item number
mm (in) ::::s 0
Q.n
t
(j) 43.5 (1.713) 0
en!. ::D
~
@' 82.0 (3.228) ::::s -·
mo 0
@ -a;
- <
I 63.2 (2.488)
..a m
..a :DO ::D
._...
1nstallation of one-piece bearings
Bearing race
:;·
caz
en CD
,..:::cc:
I~
Item number
(black) location r
@ @ Q$' Rear side ::DCD
Qj'. Rear side mm
~CD
;:um
0 :::::!.
Inner and outer diameter of needle bearings w::::s
® ® @ @ ® Outer diameter Inner diameter Number of
)>CC
Item number
mm (in) mm (in) needles
I !!'
-t
(Jj 47.0 ( 1.850) 30.0 (1.181) -
...
::r
@
®.@
@.@
@
53.0 (2.087)
85.0 (3.346)
64.0 (2.520)
64.0 (2.520)
35.1 ( 1.382)
62.7 (2.468)
45.0 (1.772)
45.0 (1.772)
-
-
52
50
-:e
c
en

m
en
::r
en
)>
-;
en
@
@
64.0 (2.520)

78.1 (3.075)
44.0 (1.732)
-
34
-
...
CD
en
w
en
n @ 64.0 (2.520) - -
 DISASSEMBLY

Disassembly
1. Remove torque converter by holding it firmly and turning
while pulling straight out.

2. Check torque converter one-way clutch.

a. Insert Tool into spline of one-way clutch inner race.
b. Hook bearing support unitized with one-way clutch outer
race with suitable wire.
c. Check that one-way clutch inner race rotates only clockwise
with Tool while holding bearing support with wire.

SAT019B

3. Remove inhibitor switch from transmission case.

-=--::-=-------=----= --------- SAT021"B

4. Remove oil pan.
a. Drain A.T.F. from rear extension.
b. Raise oil pan by placing wooden blocks under converter
housing and rear extension.
c. Separate the oil pan and transmission case.
• Always place oil pan straight down so that foreign parti-
cles inside will not move.

SAT186B

5. Place transmission into Tool with the control valve facing up.

SAT187B

AT-118
 DISASSEMBLY
Disassembly (Cont'd)
6. Check oil pan and oil strainer for accumulation of foreign
particles.
• If materials of clutch facing are found, clutch plates may be
worn.
• If metal filings are found, clutch plates, brake bands, etc.
may be worn.
• If aluminum filings are found, bushings or aluminum cast
parts may be worn.
In above cases, replace torque converter and check unit for
cause of particle accumulation.

7. Remove lock-up solenoid and fluid temperature sensor

connectors.
• Be careful not to damage connector.

8. Remove oil strainer.

a. Remove oil strainer from control valve assembly.
Then remove 0-ring from oil strainer.

SATOOBB

b. Check oil strainer screen for damage.

Screen Screen

SAT025B

9. Remove control valve assembly.

a. Straighten terminal clips to free terminal cords then remove
terminal clips.

AT-119
DISASSEMBLY
Disassembly (Cont'd)
b. Remove bolts @ and @ , and remove control valve as-
sembly from transmission.

Bolt symbol Qmm (in) ~ Q

33 (1.30)
@ 45(1.77)

c. Remove solenoid connector.

• Be careful not to damage connector.

d. Remove manual valve from control valve assembly.

10. Remove terminal cord assembly from transmission case

while pushing on stopper.
• Be careful not to damage cord.
• Do not remove terminal cord assembly unless it is dam-
aged.

AT-120
 DISASSEMBLY
Disassembly (Cont'd)
11. Remove converter housing from transmission case.

12. Remove 0-ring from input shaft.

13. Remove oil pump assembly.

a. Attach Tool to oil pump assembly and extract it evenly from
transmission case.

b. Remove 0-ring from oil pump assembly.

c. Remove traces of sealant from oil pump housing.
• Be careful not to scratch pump housing.

d. Remove needle bearing and thrust washer from oil pump

assembly.

AT-121
 DISASSEMBLY
Disassembly (Cont'd)
14. Remove input shaft and oil pump gasket.

15. Remove brake band and band strut.

a. Loosen lock nut and remove band servo anchor end pin from
transmission case.

b. Remove brake band and band strut from transmission case.

c. Hold brake band in a circular shape with clip.

16. Remove front side clutch and gear components.

a. Remove clutch pack (reverse clutch, high clutch and front sun
gear) from transmission case.

AT-122
 DISASSEMBLY
Disassembly (Cont'd)
RE4R01'A
b. Remove front bearing race from clutch pack.
c. Remove rear bearing race or front needle bearing from clutch
pack.

Front Rear

SAT113B

RE4R03A

Front Rear

SAT637C

RE4R01A d. Remove front planetary carrier from transmission case.

SAT031B

SAT326B

RE4R01A e. Remove front needle bearing or front bearing race from front
planetary carrier.
f. Remove rear needle bearing from front planetary carrier.

SAT96BA

AT-123
 DISASSEMBLY
Disassembly {Cont'd)
RE4R03A

Front Rear

SAT327B

g. Remove rear sun gear from transmission case.

17. Remove rear extension.

a. Remove rear extension from transmission case.
b. Remove rear extension gasket from transmission case.

c. Remove oil seal from rear extension.

• Do not remove oil seal unless it is to be replaced.

d. Remove revolution sensor from rear extension.

e. Remove 0-ring from revolution sensor.

AT-124
 DISASSEMBLY
Disas.sembly (Cont'd)
18. Remove output shaft and parking gear.
a. Remove rear snap ring from output shaft.

b. Slowly push output shaft all the way forward.

• Do not use excessive force.
c. Remove snap ring from output shaft.

d. Remove output shaft and parking gear as a unit from trans-

mission case.
e. Remove parking gear from output shaft.

f. Remove needle bearing from transmission case.

19. Remove rear side clutch and gear components.

a. Remove front internal gear.

AT-125
 DISASSEMBLY
Disassembly (Cont'd)
b. Remove bearing race from front internal gear.

c. Remove needle bearing from rear internal gear.

d. Remove rear internal gear, forward clutch hub and overrun

clutch hub as a set from transmission case.

0 e. Remove needle bearing from overrun clutch hub.

f. Remove overrun clutch hub from rear internal gear and forward
clutch hub.

AT-126
 DISASSEMBLY
Disassembly (Cont'd)
g. Remove thrust washer from overrun clutch hub.

0
h. Remove forward clutch assembly from transmission case.

20. Remove band servo and accumulator components.

a. Remove band servo retainer from transmission case.

b. Apply compressed air to oil hole until band servo piston comes
out of transmission case.
• Hold piston with a rag and gradually direct air to oil hole.
c. Remove return springs.

d. Remove springs from accumulator pistons B, C and D.

e. Apply compressed air to each oil hole until piston comes out.
• Hold piston with a rag and gradually direct air to oil hole.

Identification of accumulator pistons A B c D

Identification of oil holes a b c d

A B c D SAT040B

AT-127
 DISASSEMBLY
Disassembly (Cont'd)
f. Remove 0-ring from each piston.
Front . .

E pfj T,~. b
(2--+3) (3--+4,N-->A)
Accumulator Accumulator

Accumulator Accumulator
piston A piston C
SAT937A

21. Remove manual shaft components, if necessary.

a. Hold width across flats of manual shaft (outside the transmis-
sion case) and remove lock nut from shaft.

SAT04iB

b. Remove retaining pin from transmission case.

c. While pushing detent spring down, remove manual plate and

parking rod from transmission case.

d. Remove manual shaft from transmission case.

AT-128
 DISASSEMBLY
Disassembly (Cont'd)
e. Remove spacer and detent spring from transmission case.

f. Remove oil seal from transmission case.

r
-------..)
SAT044B

AT-129
 REPAIR FOR COMPONENT PARTS

Oil Pump

Friction ring El ® ~ : N·m lkg.m, ft-lb)

@ : Apply A.T.F.
0-ring~~
lEI® : Apply petroleum jelly.
Pivot pin
Oil pump housing Side seal E1 ®
Control piston
Oilseal~@ Side seal El ® Oil pump cover assembly

0-ring ~~

A 16-21
11.6. 2.1,
12. 15)

High clutch seal ring

-M-~-®
Cam ring spring

SAT648A

DISASSEMBLY
1. Loosen bolts in numerical order and remove oil pump cover.

Inscribe identification mark 2. Remove rotor, vane rings and vanes.

• Inscribe a mark on back of rotor for identification of
fore-aft direction when reassembling rotor. Then remove
rotor.

3. While pushing on cam ring remove pivot pin.

• Be careful not to scratch oil pump housing.

AT-130
REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
4. While holding cam ring and spring lift out cam ring spring.
• Be careful not to damage oil pump housing.
• Hold cam ring spring to prevent it from jumping.

5. Remove cam ring and cam ring spring from oil pump
housing.

6. Remove pivot pin from control piston and remove control

piston assembly.

7. Remove oil seal from oil pump housing.

• Be careful not to scratch oil pump housing.

INSPECTION
011 pump cover, rotor, vanes, control piston, side seals, cam
ring and friction ring
• Check for wear or damage.

SAT656A

AT-131
 REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
Dial indicator Side clearances
• Measure side clearances between end of oil pump housing
Straight edge and cam ring, rotor, vanes and control piston in at least four
places along their circumferences. Maximum measured val-
ues should be within specified ranges.
• Before measuring side clearance, check that friction rings,
0-ring, control piston side seals and cam ring spring are
removed.
Standard clearance:
Vane Cam ring
SAT657A 0.01 - 0.024 mm (0.0004 - 0.0009 in)
Rotor, vanes, control piston
0.03 - 0.044 mm (0.0012 - 0.0017 in)
• If not within standard clearance, replace oil pump assembly
except oil pump cover assembly.

Seal ring clearance

• Measure clearance between seal ring and ring groove.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Wear limit:
0.25 mm (0.0098 in)
• If not within wear limit, replace oil pump cover assembly.

SAT658A

ASSEMBLY
1. Drive oil seal into oil pump housing.
• Apply A.T.F. to outer periphery and lip surface.

2. Install cam ring in oil pump housing by the following steps.

a. Install side seal on control piston.
• Pay attention to its direction - Black surface goes toward
control piston.
• Apply petroleum jelly to side seal.
b. Install control piston on oil pump.

AT-132
REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
c. Install 0-ring and friction ring on cam ring.
• Apply petroleum jelly to 0-ring.

d. Assemble cam ring, cam ring spring and spring seat. Install
spring by pushing it against pump housing.

e. While pushing on cam ring install pivot pin.

3. Install rotor, vanes and vane rings.

• Pay attention to direction of rotor.

SAT662A

4. Install oil pump housing and oil pump cover.

a. Wrap masking tape around splines of oil pump cover
assembly to protect seal. Position oil pump cover assembly
in oil pump housing assembly, then remove masking tape.
b. Tighten bolts in a criss-cross pattern.

AT-1~~
 REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
5. Install seal rings carefully after packing ring grooves with
petroleum jelly. Press rings down into jelly to a close fit.
El® • Seal rings come In two different diameters. Check fit
Small dia. carefully in each groove.
seal rings
Small dia. seal ring:
p® No mark
Large dia.
seal rings Large dia. seal ring:
Yellow mark in area shown by arrow
• Do not spread gap of seal ring excessively while installing.
It may deform ring.
SAT663A

AT-134
 REPAIR FOR COMPONENT PARTS

Control Valve Assembly

Lock-up solenoid
~ 10·13 (1.0-1.3, 7 -9)~
Fluid temperature sensor .

Harness clip

Harness clip

'
Reamer b o l t - - - - - - ' " '
Pilot filter -----::::::=~d -r---------- Lower separate gasket~

Upper separate gasket~

0-ring
,-
~----q· .
\
\
.
\
- _ __;.
\
1 0-ring ~
Line pressure solenoid ~ ~-.,
u
I~ , · 3-onit solenoid assembly
~ f' ~ ~
\ (overrun clutch solenoid and
shift solenoids A and B)

~: N·m (kg-m, ft·lb)

~ 7. 9 (0.7. 0.9, 5.1. 6.5)
SAT638C

AT-135
REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
DISASSEMBLY
1. Remove solenoids.
a. Remove lock-up solenoid and side plate from lower body.
b. Remove 0-ring from solenoid.

SAT194B

c. Remove line pressure solenoid from upper body.

d. Remove 0-ring from solenoid.

e. Remove 3-unit solenoid assembly from upper body.

f. Remove 0-rings from solenoids.

2. Disassemble upper and lower bodies.

a. Place upper body facedown, and remove bolts, reamer bolts
and support plates.
b. Remove lower body, separator plate and separate gasket as
a unit from upper body.
• Be careful not to drop pilot filter, orifice check valve,
spring and steel balls.

c. Place lower body facedown, and remove separate gasket

and separator plate.
d. Remove pilot filter, orifice check valve and orifice check
spring.

SAT670A

AT-136
REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
e. Check to see that steel balls are properly positioned in
upper body and then remove them from upper body.

SAT671A

INSPECTION
Lower and upper bodies
• Check to see that there are pins and retainer plates in lower
body.

SAT672A

• Check to see that there are pins and retainer plates in upper
body.
• Be careful not to lose these parts.

SAT673A

• Check to make sure that oil circuits are clean and free from
damage.
• Check tube brackets and tube connectors for damage.

Separator plates
• Check to make sure that separator plate is free of damage
and not deformed and oil holes are clean.

AT-137
 REPAIR FOR COMPONENT PARTS
Control Valve Assembly {Cont'd)
Pilot filter
• Check to make sure that filter is not clogged or damaged.

SAT676A

Lock-up solenoid
• Check that filter is not clogged or damaged.
• Measure resistance. - Refer to "Electrical Components
Inspection''.

Line pressure solenoid

• Check that filter is not clogged or damaged.
• Measure resistance. - Refer to "Electrical Components
Inspection".

3-unit solenoid assembly (Overrun clutch solenoid and shift

solenoids A and B)
• Measure resistance of each solenoid. - Refer to "Electrical
Components Inspection".

SAT0958

Fluid temperature sensor

• Measure resistance. Refer to "Electrical Components
Inspection".
Fluid temperature

SAT1968

AT-138
 REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
ASSEMBLY
1. Install upper and lower bodies.
a. Place oil circuit of upper body face up. Install steel balls in
their proper positions.

b. Install reamer bolts from bottom of upper body and install

separate gaskets.

Reamer bolt (short)

SAT681A

c. Place oil circuit of lower body face up. Install orifice check
spring, orifice check valve and pilot filter.

SAT682A

d. Install lower separate gaskets and separator plates on lower

body.
e. Install and temporarily tighten support plates, fluid tempera-
ture sensor and tube brackets.

SAT197B

AT-139
 REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
f. Temporarily assemble lower and upper bodies, using reamer
bolt as a guide.
• Be careful not to dislocate or drop steel balls, orifice
check spring, orifice check valve and pilot filter.

SAT1988

g. Install and temporarily tighten bolts and tube brackets in

their proper locations.

Bolt length and location:

~ m
a b c d

70 50 33 27
Bolt length mm (in)
(2.76) (1.97) (1.30) (1.06)

2. Install solenoids.
® - S i d e plate a. Attach 0-ring and install lock-up solenoid and side plates
onto lower body.

SAT2008

b. Attach 0-rings and install 3-unit solenoids assembly onto

upper body.

c. Attach 0-ring and install line pressure solenoid onto upper

body.
3. Tighten all bolts.

AT-140
 Torque converter rei ief valve

~- --~--
CDI
,J..
Return spring

r """"' .,. .
R .

;· (V Return spring Plug

Sleeve
Plug
~~~ matb. ~ ~ \[][) r''"
Upper body I/'I Pressure regulator valve Spnng
. seat \ Sleeve plug
Lock-up control valve
/;
~
Return spring . I I~. -rO!fl9 '(((((((@ ([D \\

-~·Q~r I
Pin
I
\ ~~7f~~~
/l Pressure modifier valve @ Return
spring
\ IJ-- Pin
Plug .,m
::D

~
-~-oct-·-m ~p· ::D
.,
Sl~eve
i7z ""'
·· Accumulator control valve\ In (')
0
~ -
0
::D

~ //I (((((((~CO
.0..
::I
0

%/0 /
~ """'~ ~lw ~
Pin
Pilot valve 0
....
I

2
Return4- I '4' R \ llil\._ Plug <
ID .,0s::
....
~ @ . Plug \:!..! eturn spnng

f} ~'"J <
/ J

spring @
I L
R . Shuttle shift valve 0
~ eturn spnng CD z

j;L '"
1
Shuttle shift valveS--------£. cc«mmo I (\
~((([((((0~. c: m
"0 z
@Return spring
~
• #
~
Shift ~lw 8 """"" •'"'
"0
...
CD .,
ooot

3>
Plug -----~c§'
m
~(!}
""~ ~
::D
P .
1n-~

)-%;"":=.I <t- """'"" .,.,4-2 relay valve Sh1ft valve A 8

@ Return spring
0
a.
"<
ooot
tn

~ ron\...
! .

"""'ru" oMoh """""' ~lw

/(((U,((O

@R""'" """' T
Plug ""

~
.. ,((((((((((0 ~
@Return spring 0 verrun clutch (riO
t Pin
reducing vave Plug
Ul
)>
.; Numbers preceding valve springs correspond with
en
w Apply A.T.F. to all components before their installation. those shown in Spring Chart on page A T-144.
ID
n
 REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
DISASSEMBLY
1. Remove valves at parallel pins.
• Do not use a magnetic hand.

SAT834A

a. Use a wire paper clip to push out parallel pins.

b. Remove parallel pins while pressing their corresponding

plugs and sleeves.
Plug
• Remove plug slowly to prevent internal parts from jumping
out.

c. Place mating surface of valve facedown, and remove internal

parts.
• If a valve is hard to remove, place valve body facedown
and lightly tap it with a soft hammer.
• Be careful not to drop or damage valves and sleeves.

~ Soft hammer
SAT824A

2. Remove valves at retainer plates.

a. Pry out retainer plate with wire paper clip.

Retainer plate
SAT825A

AT-142
REPAIR FOR COMPONENT PARTS
Control Valve Upper Body {Cont'd)
b. Remove retainer plates while holding spring.

c. Place mating surface of valve facedown, and remove internal

parts.
• If a valve is hard to remove, lightly tap valve body with a
soft hammer.
• Be careful not to drop or damage valves, sleeves, etc.

• 4-2 sequence valve and relay valve are located far back in
upper body. If they are hard to remove, carefully push them
out using stiff wire.
• Be careful not to scratch sliding surface of valve with wire.

AT-143
 REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
INSPECTION
Valve springs
• Measure free length and outer diameter of each valve spring.
Also check for damage or deformation.
• Numbers of each valve spring listed in table below are the
same as those in the figure on AT-141.

II : Free length

SAT829A

Inspection standard
Unit: mm (in)

Item
Part No. 1! D
Parts

CD Torque converter relief valve spring 31742-41X23 38.0 ( 1.496) 9.0 (0.354)

® Pressure regulator valve spring 31742-41X24 44.02 (1.7331) 14.0 (0.551)

@ Pressure modifier valve spring 31742-41 X19 31.95 (1.2579) 6.8 (0.268)

@ Shuttle shift valve D spring 31762-41XOO 26.5 (1.043) 6.0 (0.236)

@ 4-2 sequence valve spring 31756-41XOO 29.1 (1.146) 6.95 (0.2736)

@ Shift valve B spring 31762-41 X01 25.0 (0.984) 7.0 (0.276)

(j) 4-2 relay valve spring 31756-41 xoo 29.1 (1.146) 6.95 (0.2736)

® Shift valve A spring 31762-41X01 25.0 (0.984) 7.0 (0.276)

® Overrun clutch control valve spring 31762-41X03 23.6 (0.929) 7.0 (0.276)

® Overrun clutch reducing valve spring 31742-41X20 32.5 (1.280) 7.0 (0.276)

@ Shuttle shift valve S spring 31762-41 X04 51.0 (2.008) 5.65 (0.2224)

@ Pilot valve spring 31742-41X13 25.7 (1.012) 9.1 (0.358)

@ Lock-up control valve spring 31742-41X22 18.5 (0.728) 13.0 (0.512)

• Replace valve springs if deformed or fatigued.

Control valves
e Check sliding surfaces of valves, sleeves and plugs.

AT-144
REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
ASSEMBLY
1. Lubricate the control valve body and all valves with A.T.F.
Install control valves by sliding them carefully into their
bores.
• Be careful not to scratch or damage valve body.

• Wrap a small screwdriver with vinyl tape and use it to insert

the valves into proper position.

Pressure regulator valve

• If pressure regulator plug is not centered properly, sleeve
cannot be inserted into bore in upper body.
If this happens, use vinyl tape wrapped screwdriver to
center sleeve until it can be inserted.
• Turn sleeve slightly while installing.

Accumulator control plug

• Align protrusion of accumulator control sleeve with notch in
plug.
• Align parallel pin groove in plug with parallel pin, and install
accumulator control valve.

2. Install parallel pins and retainer plates.

SAT834A

AT-145
REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
• While pushing plug, install parallel pin.

4-2 sequence valve and relay valve

• Push 4-2 sequence valve and relay valve with wire wrapped
in vinyl tape to prevent scratching valve body. Install parallel
pins.

• Insert retainer plate while pushing spring.

AT-146
 Lower body

Pin

Plug

\\o~ ,m
:D

:!:
:D
0 'TI

-
0 0

~
:D
(((((I .0..
:::::1

0
~ -< 0
I
~

~
Retainer plate DJ
<
,03:
..... ----=-r CD
z
@ Return spring 3-2 timing valve ( ) - - - - - Modifier accumulator piston r m
0
:eCD z
... ,,.
-1

1-
--
CD Return spring m
0
a.
:D
-1
Retainer plate ----\t} f!!!!j- Plug
'< f/)

~Pin

Manual valve

Ill
)>
-1
en Numbers preceding valve springs correspond with those shown in Spring Chart on
~
0
n Apply A.T.F. to all components before their installation. the next page.
 REPAIR FOR COMPONENT PARTS
Control Valve Lower Body (Cont'd)
DISASSEMBLY
1. Remove valves at parallel pins.
2. Remove valves at retainer plates.
For removal procedures, refer to "DISASSEMBLY" of Con-
trol Valve Upper Body.

SAT838A

INSPECTION
Valve springs
• Check each valve spring for damage or deformation. Also
measure free length and outer diameter.
• Numbers of each valve spring listed in table below are the
same as those in the figure on AT-147.

2 : Free length

SAT829A

Inspection standard: Unit: mm (in)

Item
Part No. £ D
Parts

CD Modifier accumulator piston spring 31742-41 X15 30.5 (1.201) 9.8 (0.386)

® 1st reducing valve spring 31756-41X05 25.4 ( 1.000) 6.75 (0.2657)

@ 3-2 timing valve spring 31742-41 XOB 20.55 (0.8091) 6.75 (0.2657)

@ Servo charger valve spring 31742-41 X06 23.0 (0.906) 6.7 (0.264)

• Replace valve springs if deformed or fatigued.

Control valves
• Check sliding surfaces of control valves, sleeves and plugs
for damage.

ASSEMBLY
• Install control valves.
For installation procedures, refer to "ASSEMBLY" of Control
Valve Upper Body.

SAT838A

AT-148
 REPAIR FOR COMPONENT PARTS

Reverse Clutch
1:r For the number of clutch sheets (drive plate and
driven plate), refer to the below cross-section. @£) : Apply A.T.F.
* : Select with proper thickness.

Direction of dish plate

Direction. of oil seal '

Rwon• ''""h d<"m ~ ' Retaining plate*

Piston @D
Oilseai~@D

Snap ring

RE4R01A RE4R03A

Dish plate
SAT641C

DISASSEMBLY
1. Check operation of reverse clutch.
a. Install seal ring onto oil pump cover and install reverse clutch.
Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not move to snap ring, D-ring or oil seal
may be damaged or fluid may be leaking at piston check ball.

2. Remove drive plates, driven plates, retaining plate, dish plate

and snap ring.

AT-149
 REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont'd)
3. Remove snap ring from clutch drum while compressing clutch
springs.
• Do not expand snap ring excessively.
4. Remove spring retainer and return spring.

5. Install seal ring onto oil pump cover and install reverse clutch
drum. While holding piston, gradually apply compressed air to
oil hole until piston is removed.
• Do not apply compressed air abruptly.
6. Remove D-ring and oil seal from piston.

INSPECTION
Reverse clutch snap ring and spring retainer
• Check for deformation, fatigue or damage.

Reverse clutch return springs

• Check for deformation or damage. Also measure free length
and outside diameter.
Inspection standard:
Unit: mm (in)

Model Part No. 2 D

2 : Free length RE4R01A 31505-41 X02 19.69 (0. 7752) 11.6 (0.457)

RE4R03A 31505-51XOO 37.8 (1.488) 14.8 (0.583)

SAT829A

Thickness Reverse clutch drive plates

• Check facing for burns, cracks or damage.
• Measure thickness of facing.
Facing Thickness of drive plate:
Standard value: 2.0 mm (0.079 In)
Wear limit: 1.8 mm (0.071 in)
• If not within wear limit, replace.
Core plate
Reverse clutch dish plate
• Check for deformation or damage.
SAT845A

No air leakage Air leakage is present. Reverse clutch piston

Check ball Check ball • Shake piston to assure that balls are not seized.
i~,.___---1 • Apply compressed air to check ball oil hole opposite the
return spring to assure that there is no air leakage.
• Also apply compressed air to oil hole on return spring side
to assure that air leaks past ball.

SAT846A

AT-150
REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont'd)
ASSEMBLY
1. Install D-ring and oil seal on piston.
• Apply A.T.F. to both parts.

2. Install piston assembly by turning it slowly and evenly.

• Apply A.T.F. to inner surface of drum.

3. Install return springs and spring retainer.

4. Install snap ring while compressing clutch springs.

• Do not align snap ring gap with spring retainer stopper.

AT-151
 REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont'd)
Snap ring RE4R01A 5. Install drive plates, driven plates, retaining plate and dish
plate.

Drive plate
Driven plate

Dish plate

SAT851A

RE4R03A
Snap ring

Retaining plate

Dish plate

SAT642C

6. Install snap ring.

SAT842A

7. Measure clearance between retaining plate and snap ring. If not

within allowable limit, select proper retaining plate.
Specified clearance:
Standard
0.5 - 0.8 mm (0.020 - 0.031 in)
Allowable limit
1.2 mm (0.047 in) (RE4R01A)
1.4 mm (0.055 in) (RE4R03A)
Retaining plate:
Refer to S.O.S.

8. Check operation of reverse clutch.

Refer to "DISASSEMBLY" of Reverse Clutch.

AT-152
 REPAIR FOR COMPONENT PARTS

High Clutch
RE4R01A

High clutch drum @ Retaining plate*

1 D-ring (Large)~@
I D-ring (Small)~@
Clutch piston

Driven plate

Snap ring~

Spring retainer

~ : Apply A.T.F. Drive plate

* Select with proper thickness.
SAT365C

RE4R03A

Retaining plate *
Snap ring~
Snap ring

Spring retainer--, Drive plate ~

D-ring (Small) ~@V

D-ring (Large) ~@D

Driven plate~
High clutch drum @) ........ ..- ...............
-----
r
..-..-

I "'
-~5-36-51XOO)
Driven plate (31536-51X06)

".,.,.,.,,...

Clutch piston @D

(J'\fF) :. Apply A.T.F.

~ Select with proper thickness.

SAT643C

AT-153
 REPAIR FOR COMPONENT PARTS
High Clutch (Cont'd)
Service procedures for high clutch are essentially the same as
those for reverse clutch, with the following exception:

• Ch.eck of high clutch operation

KV31f02400 • Removal and installation of return spring

(J34285 and
J34285-87)

• Inspection of high clutch return springs

Inspection standard: Unit: mm (in)

Part No. Q D

31505-21 X03 22.06 (0.8685) 11.6 (0.457)

2 : Free length

SAT829A

Thickness • Inspection of high clutch drive plate

Thickness of drive plate:
Standard
Facing 1.6 mm (0.063 in)
Wear limit
1.4 mm (0.055 in)

Core plate

SAT845A

• Measurement of clearance between retaining plate and snap

ring
Specified clearance:
Standard
1.8 - 2.2 mm (0.071 - 0.087 in)
Allowable limit
3.2 mm (0.126 in) (RE4R01A)
3.0 mm (0.118 in) (RE4R03A)
Retaining plate:
Refer to S.O.S.

AT-154
 ~~::C:O~M~P~O~N~E=N=~~~---------------
REPAIR FOR PARTS

Forward and Overrun Clutches

For the nu b
driven plat:, ' ;;f
of
er clutch sheets (d nve
to the below . plate and
cross-section.

Direction of d"ISh plate

Snap ring

~
D
Direction of d.ISh plate Retaining plate *
Snap ring Drive plate @
D.nven plate
Retaining plate * Dish plate

'
Drive plate @)
Driven plate
Dish plate

Overrun clutch Pate

I

Forward clutch plate

Driven plate .,

I Drive plate
I
j_
RE4R01A

* . Apply
(@)· A.T.F.
Select w·It h proper thickne ss.

SAT644C

AT-155
REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont'd)
Service procedures for forward and overrun clutches are es-
sentially the same as those for reverse clutch, with the following
exception:
• Check of forward clutch operation.

• Check of overrun clutch operation.

• Removal of forward clutch drum

Remove forward clutch drum from transmission case by
holding snap ring.

• Removal of forward clutch and overrun clutch pistons

1. While holding overrun clutch piston, gradually apply com-
pressed air to oil hole.

2. Remove overrun clutch from forward clutch.

AT-156
 REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont'd)
• Removal and installation of return springs

KV31102400
(J34285 and
J34285~7)

SAT864A

• Inspection of forward clutch and overrun clutch return

springs

Inspection standard: Unit: mm (in)

Model Part No. Q D

RE4R01A 31505-41 X01 35.77 (1.4083) 9.7 (0.382)

Q : Free length
RE4R03A 31505-51 X04 36.8 ( 1.449) 9.8 (0.386)

SAT829A

Thickness • Inspection of forward clutch drive plates

Thickness of drive plate:
Standard
Facing
1.6 mm {0.063 in) {RE4R01A)
2.0 mm (0.079 in) {RE4R03A)
Wear limit
1.4 mm (0.055 in) {RE4R01A)
Core plate 1.8 mm (0.071 in) {RE4R03A)

SAT845A

Thickness • Inspection of overrun clutch drive plates

Thickness of drive plate:
Standard
Facing 2.0 mm (0.079 in) {RE4R01A)
1.6 mm (0.063 in) {RE4R03A)
Wear limit
1.8 mm (0.071 in) {RE4R01A)
Core plate 1.4 mm {0.055 in) {RE4R03A)

SAT845A

• Installation of forward clutch piston and overrun clutch

piston
1. Install forward clutch piston by turning it slowly and evenly.
• Apply A.T.F. to inner surface of clutch drum.

AT-157
REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont'd)
• Align notch in forward clutch piston with groove in forward
clutch drum.

2. Install overrun clutch by turning it slowly and evenly.

• Apply A.T.F. to inner surface of forward clutch piston.

• Measurement of clearance between retaining plate and snap

ring of overrun clutch
Specified clearance:
Standard
1.0 - 1.4 mm (0.039 - 0.055 in)
Allowable limit
2.0 mm (0.079 in) (RE4R01A)
2.2 mm (0.087 in) (RE4R03A)
Retaining plate:
Refer to S.O.S.

• Measurement of clearance between retaining plate and snap

ring of forward clutch
Specified clearance:
Standard
0.45- 0.85 mm (O.o1n - 0.0335 In)
Allowable limit
2.25 mm (0.0886 in) (RE4R01A)
2.45 mm (0.0965 in) (RE4R03A)
Retaining plate:
Refer to S.O.S.

AT-158
 REPAIR FOR COMPONENT PARTS

Low & Reverse Brake

Snap ring

~L1
Return spring

Retaining plate
Direction of oil seal
Driven plate

~ : ApplyA.T.F.
B ® : Apply petroleum jelly. RE4R03A
* : Select with proper thickness. Drive plate Drive plate
SAT166E

DISASSEMBLY
1. Check operation of low and reverse brake.
a. Install seal ring onto oil pump cover and install reverse
clutch. Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not move to snap ring, D-ring or oil
seal may be damaged or fluid may be leaking at piston
check ball.

SAT872A

2. Remove snap ring, low and reverse brake drive plates,

driven plates and dish plate.

SAT873A

AT-159
 REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd)
3. Remove low one-way clutch inner race, spring retainer and
return spring from transmission case.

4. Remove seal rings from low one-way clutch inner race.

5. Remove needle bearing from low one-way clutch inner race.

6. Remove low and reverse brake piston using compressed air.

7. Remove oil seal and D-ring from piston.

INSPECTION
Low and reverse brake snap ring and spring retainer
• Check for deformation, or damage.

Low and reverse brake return springs

....
CD • Check for deformation or damage. Also measure free length
~
;:;
and outside diameter.
....CD
Inspection standard: Unit: mm (in)
8
Model Part No. 2 D

2 : Free length RE4R01A 31521-21 xoo 23.7 (0.933) 11.6 (0.457)

31505-51X06
20.43 (0.8043) 10.3 ( 0.406)
SAT829A (Inner)
RE4R03A
31505-51 X05
20.35 (0.8012) 13.0 (0.512)
(Outer)

AT-160
 REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd}
Thickness Low and reverse brake drive plates
• Check facing for burns, cracks or damage.
• Measure thickness of facing.
Facing Thickness of drive plate:
Standard value
2.0 mm (0.079 in) (RE4R01A)
1.6 mm (0.063 in) (RE4R03A)
Core plate Wear limit
1.8 mm (0.071 In) (RE4R01A)
1.4 mm (0.055 in) (RE4R03A)
SAT845A
• If not within wear limit, replace.
Low one-way clutch inner race
• Check frictional· surface of inner race for wear or damage.

SAT877A

• Install a new seal rings onto low one-way clutch inner race.
-j 1-- Clearance
• Be careful not to expand seal ring gap excessively.
~ng • Measure seal ring-to-groove clearance.
Inspection standard:
Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Allowable limit: 0.25 mm (0.0098 in)
• If not within allowable limit, replace low one-way clutch inner
race.

- - - - - - - - ' - - SAT878A

ASSEMBLY
C)-m® 1. Install bearing onto one-way clutch inner race.
• Pay attention to its direction - Black surface goes to rear
side.

' • Apply petroleum jelly to needle bearing.

SAT1128

2. Install oil seal and D-ring onto piston.

• Apply A.T.F. to oil seal and D-ring.
Oil seal~

D-ring~
SAT879A

AT-161
REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd)
8. Measure clearance between retaining plate and snap ring.
If not within allowable limit, select proper retaining plate.
Specified clearance:
Standard
1.1 - 1.5 mm (0.043 - 0.059 in)
Allowable limit
2.9 mm (0.114 in) (RE4R01A)
3.1 mm (0.122 in) (RE4R03A)
Retaining plate:
Refer to S.O.S.

9. Install low one-way clutch inner race seal ring.

• Apply petroleum jelly to seal ring.
• Make sure seal rings are pressed firmly into place and
held by petroleum jelly.

AT-162
 REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd)
3. Install piston by rotating it slowly and evenly.
• Apply A.T.F. to inner surface of transmission case.

4. Install return springs, spring retainer and low one-way clutch

inner race onto transmission case.

RE4R01A 5. Install dish plate, low and reverse brake drive plates, driven
Driven plate
plates and retaining plate.
• Two types of drive plates are used on the RE4R03A trans-
mission. One type uses a "waving" design and the other type
uses a "flat" design. Either one can be installed first since
they are interchangeable.
6. Install snap ring on transmission case.

Drive plate
SAT367C

RE4R03A Driven plate

Drive plate
SAT646C

7. Check operation of low and reverse brake clutch piston.

Refer to "DISASSEMBLY".

AT-163
 REPAIR FOR COMPONENT PARTS

Forward Clutch Drum Assembly- RE4R01A

Needle bearing

Snap ring
Forward clutch drum assembly
Low one-way clutch

Side plate

Snap ring

SAT886A

DISASSEMBLY
1. Remove snap ring from forward clutch drum.

2. Remove side plate from forward clutch drum.

3. Remove low one-way clutch from forward clutch drum.

0 .

SAT889A

AT-164
 REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly- RE4R01A
(Cont'd)
4. Remove snap ring from forward clutch drum.

SAT890A

5. Remove needle bearing from forward clutch drum.

INSPECTION
Forward clutch drum
• Check spline portion for wear or damage.
• Check frictional surfaces of low one-way clutch and needle
···~ bearing for wear or damage.

,. , t

SAT892A

Needle bearing and low one-way clutch

• Check frictional surface for wear or damage.

SAT893A

ASSEMBLY

0
1. Install needle bearing in forward clutch drum.

SAT113B

AT-1R~
REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly- RE4R01A
(Cont'd)
2. Install snap ring onto forward clutch drum.

SAT890A

3. Install low one-way clutch onto forward clutch drum by

pushing the roller in evenly.

• Install low one-way clutch with flange facing rearward.

4. Install side plate onto forward clutch drum.

5. Install snap ring onto forward clutch drum.

AT-166
 REPAIR FOR COMPONENT PARTS

Forward Clutch Drum Assembly - RE4R03A

Low one-way clutch

Front

Side plate~

Forward clutch
drum assembly

Needle bearing

SAT452B

DISASSEMBLY
1. Remove side plate from forward clutch drum.

..
2. Remove low one-way clutch from forward clutch drum.

SAT454B

3. Remove snap ring from forward clutch drum.

SAT455B

AT-167
REPAIR FOR COMPONENT PARTS
Forward Clutch D-rum Assembly - RE4R03A
(Cont'd)
4. Remove needle bearing from forward clutch drum.

SAT456B

INSPECTION
Forward clutch drum
• Check spline portion for wear or damage.
• Check frictional surfaces of low one-way clutch and needle
bearing for wear or damage.

SAT457B

Needle bearing and low one-way clutch

• Check frictional surface for wear or damage.

SAT893A

ASSEMBLY_
1. Install needle bearing in forward clutch drum.

SAT458B

2. Install snap ring onto forward clutch drum.

SAT455B

AT-168
 REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly - RE4R03A
(Cont'd)
3. Install low one-way clutch onto forward clutch drum by
pushing the roller in evenly.

SAT450B

• Install low one-way clutch with flange facing rearward.

SATB95A

4. Install side plate onto forward clutch drum.

\ ~~~~II

\\'~~

~~::SAT459B

AT-169
 REPAIR FOR COMPONENT PARTS

Rear Internal Gear and Forward Clutch Hub

Rear internal gear (with forward one-way clutch inner race)

Thrust washer B ®
Forward clutch hub (with forward one-way clutch outer race)
Snap ring
Forward one-way clutch

End bearing E! ®: Apply petroleum jelly.

SAT896A

DISASSEMBLY
1. Remove rear internal gear by pushing forward clutch hub
forward.

2. Remove thrust washer from rear internal gear.

3. Remove snap ring from forward clutch hub.

SAT899A

AT-170
 REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont'd)

0... 4. Remove end bearing .

~
?-~~~'~)_I-
III
il-") 1"-fnl
r - SAT900A

5. Remove forward one-way clutch and end bearing as a unit

from forward clutch hub.

SAT955A

6. Remove snap ring from forward clutch hub.

SAT901A

INSPECTION
Rear internal gear and forward clutch hub
• Check gear for excessive wear, chips or cracks.
• Check frictional surfaces of forward one-way clutch and
thrust washer for wear or damage.
• Check spline for wear or damage.

SAT902A

Snap ring and end bearing

00 • Check for deformation or damage.

0 SAT903A

AT-171
REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont'd)
ASSEMBLY
1. Install snap ring onto forward clutch hub.
2. Install end bearing.

3. Install forward one-way clutch onto clutch hub.

• Install forward one-way clutch with flange facing rearward.
4. Install end bearing.
5. Install snap ring onto forward clutch hub.

6. Install thrust washer onto rear internal gear.

• Apply petroleum jelly to thrust washer.
• Securely Insert pawls of thrust washer into holes in rear
internal gear.

7. Position forward clutch hub in rear internal gear.

8. After installing, check to assure that forward clutch hub

rotates clockwise.

AT-172
 REPAIR FOR COMPONENT PARTS

Band Servo Piston Assembly

E-ring (large)
Return spring A
D-ring t ) @!)
Return spring B
Servo piston spring retainer

Gasket t )
Piston stem 0-ringt)~
D-ring t)~ O.D. servo
0-ring t ) @ ! ) piston retainer
D-ring t)~

,. 'i!m.!:•c<="li
Servo cushion spring retainer
Band servo piston
g
O.D. band servo piston
Servo piston retainer
@ : Apply A.T.F.
SAT908A

DISASSEMBLY
1. Block one oil hole in 0.0. servo piston retainer and the
center hole in 0.0. band servo piston.
2. Apply compressed air to the other oil hole in piston retainer
to remove 0.0. band servo piston from retainer.
3. Remove D-ring from 0.0. band servo piston.

4. Remove band servo piston assembly from servo piston

retainer by pushing it forward.

SAT910A

5. Place piston stem end on a wooden block. While pushing

servo piston spring retainer down, remove E-ring.

E-ring

SAT911A

AT-173
 REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
6. Remove seiVo piston spring retainer, return spring C and
piston stem from band servo piston.

SAT912A

7. Remove E-ring from band servo piston.

SAT913A

8. Remove servo cushion spring retainer from band servo

piston.
9. Remove 0-rings from band servo piston.
10. Remove 0-rings from servo piston retainer.

SAT914A

INSPECTION
Pistons, retainers and piston stem
e Check frictional surfaces for abnormal wear or damage.

t
. Servo cushion spring retainer
SAT915A

Return springs
e Check for deformation or damage. Measure free length and
s outer diameter.
Inspection standard: Unit: mm (in)
A
Parts Free length Outer diameter

Spring A 45.6 (1.795) 34.3 ( 1.350)

Spring 8 53.8 (2.118) 40.3 (1.587)

Spring C 29.7 (1.169) 27.6 (1.087)

SAT916A

AT-174
REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
ASSEMBLY
1. Install 0-rings onto servo piston retainer.
• Apply A.T.F. to 0-rings.
• Pay attention to position of each 0-ring.

2. Install servo cushion spring retainer onto band servo piston.

3. Install E-ring onto servo cushion spring retainer.

4. Install 0-rings onto band servo piston.

e Apply A.T.F. to D-rings.

5. Install servo piston spring retainer, return spring C and

piston stem onto band servo piston.

SAT912A

AT-175
REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
6. Place piston stem end on a wooden block. While pushing
servo piston spring retainer down, install E-ring.

7. Install band servo piston assembly onto servo piston re-

tainer by pushing it inward.

8. Install D-ring on 0.0. band servo piston.

e Apply A.T.F. to D-ring.

9. Install 0.0. band servo piston onto servo piston retainer by

pushing it inward.

AT-176
 REPAIR FOR COMPONENT PARTS

Parking Pawl Components

Parking rod toJ 24 - 29 N-m

(2.4 - 3.0 kg-m, 17 - 22 ft-lb)
Parking actuator support
Parking pawl shaft

Rear extension Bolt

Output shaft Parking gear

SAT205B

DISASSEMBLY
1. Slide return spring to the front of rear extension flange.

2. Remove return spring, pawl spacer and parking pawl from

rear extension.
3. Remove parking pawl shaft from rear extension.

4. Remove parking actuator support and rod guide from rear

extension.

AT-177
REPAIR FOR COMPONENT PARTS
Parking Pawl Components (Cont'd)
INSPECTION
Parking pawl and parking actuator support
• Check contact surface of parking rod for wear.

ASSEMBLY
1. Install rod guide and parking actuator support onto rear
extension.
2. Insert parking pawl shaft into rear extension.

3. Install return spring, pawl spacer and parking pawl onto

parking pawl shaft.

4. Bend return spring upward and install it onto rear extension.

AT-178
 ASSEMBLY

Assembly
1. Install manual shaft components.
a. Install oil seal onto manual shaft.
• Apply A.T.F. to oil seal.
• Wrap threads of manual shaft with masking tape.
b. Insert manual shaft and oil seal as a unit into transmission
case.
c. Remove masking tape.

d. Push oil seal evenly and install it onto transmission case.

e. Align groove in shaft with drive pin hole, then drive pin into
position as shown in figure at left.

f. Install detent spring and spacer.

g. While pushing detent spring down, install manual plate onto

manual shaft.

AT-179
 ASSEMBLY
Assembly (Cont'd)
h. Install lock nuts onto manual shaft.

SAT936A

2. Install accumulator piston.

Front . . a. Install 0-rings onto accumulator piston.
• Apply A.T.F. to 0-rings.

Pb t?p~ob
Accumulator Accumulator

~ Accumulator piston 0-rings:

Accumulator A B c
· Unit: mm (in)

Accumulator Accumulator Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29(1.14)

piston A piston C
Large diameter end 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77)
SAT93iA

b. Install return spring for accumulator A onto transmission

case.

Free length of return spring: Unit: mm (in)

Accumullitor A

Free length 43 (1.69)

c. Install accumulator pistons A, B, C and D.

• Apply A.T.F. to transmission case.

3. Install band servo piston.

a. Install return springs onto servo piston.

SAT941A

AT-180
 ASSEMBLY
Assembly (Cont'd)
b. Install band servo piston onto transmission case.
• Apply A.T.F. to 0-ring of band servo piston and transmis-
sion case.
c. Install gasket for band servo onto transmission case.

SAT942A

d. Install band servo retainer onto transmission case.

4. Install rear side clutch and gear components.

a. Place transmission case in vertical position.

ST07870000
(J37068)

SAT943A

Forward clutch drum b. Slightly lift forward clutch drum assembly and slowly rotate it
clockwise until its hub passes fully over the clutch inner
race inside transmission case.

SAT944A

c. Check to be sure that rotation direction of forward clutch

----- ------· assembly is correct.

SAT945A

AT-181
 ASSEMBLY
Assembly (Cont'd)
d. Install thrust washer onto front of overrun clutch hub.
~-® • Apply petroleum jelly to the thrust washer.

~Pawl • Insert pawls of thrust washer securely into holes in

overrun clutch hub.

e. Install overrun clutch hub onto rear internal gear assembly.

f. Install needle bearing onto rear of overrun clutch hub.

• Apply petroleum jelly to needle bearing.

g. Check that overrun clutch hub rotates as shown while

holding forward clutch hub.

h. Place transmission case into horizontal position.

AT-182
 ASSEMBLY
Assembly (Cont'd)
i. Install rear internal gear, forward clutch hub and overrun
clutch hub as a unit onto transmission case.

j. Install needle bearing onto rear internal gear.

• Apply petroleum jelly to needle bearing.

k. Install bearing race onto rear of front internal gear.

• Apply petroleum jelly to bearing race.
• Securely engage pawls of bearing race with holes in front
internal gear.

I. Install front internal gear on transmission case.

AT-183
 ASSEMBLY

Adjustment
When any parts listed in the following table are replaced, total
end play or reverse clutch end play must be adjusted.

~
Reverse clutch
Total end play
Pa end play

Transmission case • •
Low one-way clutch inner race • •
Overrun clutch hub • •
Rear internal gear • •
Rear planetary carrier • •
Rear sun gear • •
Front planetary carrier • •
Front sun gear • •
High clutch hub • •
High clutch drum • •
Oil pump cover • •
Reverse clutch drum - •

1. Install front side clutch and gear components.

a. Install rear sun gear on transmission case.
• Pay aHention to its direction.

AT-184
 ASSEMBLY
Adjustment {Cont'd)
Rear . . . . . Front b. Install needle bearing on front of front planetary carrier.
• Apply petroleum jelly to needle bearing.
c. Install needle bearing on .rear of front planetary carrier.
• Apply petroleum jelly to bearing.
• Pay attention to its direction - Black side goes to front.

Black side goes to front.

SAT967A

d. While rotating forward clutch drum clockwise, install front

planetary carrier on forward clutch drum.

• Check that portion A of front planetary carrier protrudes

Front planetary carrier approximately 2 mm (0.08 in) beyond portion B of forward
clutch assembly. (RE4R01A only)

Portion A

Portion B
SAT970A

e. Install bearing race (RE4R01A) or needle bearing (RE4R03A)

on rear of clutch pack.
• Apply petroleum jelly to bearing races.
• Securely engage pawls of bearing race with hole in clutch
pack.

f. Place transmission case in vertical position.

AT-185
 ASSEMBLY
Adjustment (Cont'd)
g. Install clutch pack into transmission case.

SAT973A

2. Adjust total end play.

Total end play "T1":
0.25 - 0.55 mm (0.0098 - 0.0217 in)

race bearing SAT975A

V (J34291-5)
Lock
a. With needle bearing installed, place J34291-1 (bridge),
J34291-2 (legs) and the J34291-5 (gauging cylinder) onto oil
(J34291-2) pump. The long ends of legs should be placed firmly on
machined surface of oil pump assembly and gauging cylin-
der should rest on top of the needle bearing. Lock gauging
cylinder in place with set screw.

SAT976A

b. Install J34291-23 (gauging plunger) into gauging cylinder.

c. With original bearing race installed inside reverse clutch

drum, place shim selecting gauge with its legs on machined
surface of transmission case (no gasket) and allow gauging
plunger to rest on bearing race. Lock gauging plunger in
place with set screw.

AT-186
 ASSEMBLY
Adjustment (Cont'd)
d. Remove Tool and use feeler gauge to measure gap between
gauging cylinder and gauging plunger. This measurement
should give exact total end play.
Total end play "T,":
0.25 - 0.55 mm (0.0098 - 0.0217 in)
• If end play is out of specification, decrease or increase
thickness of oil pump cover bearing race as necessary.
Available oil pump cover bearing race:
Refer to S.O.S.

3. Adjust reverse clutch drum end play.

Reverse clutch drum end play "T2":
0.55 - 0.90 mm (0.0217 - 0.0354 in)

a. Place J34291-1 (bridge). J34291-2 (legs) and J34291-5

(gauging cylinder) on machined surface of transmission case
(no gasket) and allow gauging cylinder to rest on front
thrust surface of reverse clutch drum. Lock cylinder in place
with set screw.

b. Install J34291-23 (gauging plunger) into gauging cylinder.

c. With original thrust washer installed on oil pump, place shim

setting gauge legs onto machined surface of oil pump
assembly and allow gauging plunger to rest on thrust
washer. Lock plunger in place with set screw.
Lock

AT-187
 ASSEMBLY
Adjustment (Cont'd)
d. Use feeler gauge to measure gap between gauging plunger
and gauging cylinder. This measurement should give you
exact reverse clutch drum and play.
Reverse clutch drum end play "T2":
0.55 - 0.90 mm (0.0217 - 0.0354 in)
• If end play is out of specification, decrease or increase
thickness of oil pump thrust washer as necessary.
Available oil pump thrust washer:
Refer to S.O.S.
-....:::::;:.....-<:::~~~~~::"Feeler gauge
SAT984A

Assembly
1. Install output shaft and parking gear.
a. Insert output shaft from rear of transmission case while
slightly lifting front internal gear.
• Do not force output shaft against front of transmission
case.

b. Carefully push output shaft against front of transmission

case. Install snap ring on front of output shaft.
• Check to be sure output shaft cannot be removed in rear
direction.

c. Install needle bearing on transmission case.

• Pay attention to its direction - Black side goes to rear.
• Apply petroleum jelly to needle bearing.

d. Install parking gear on transmission case.

AT-188
 ASSEMBLY
Assembly (Cont'd)
e. Install snap ring on rear of output shaft.
• Check to be sure output shaft cannot be removed in
forward direciton.

2. Install rear extension.

a. Install oil seal on rear extension.
• Apply A.T.F. to oil seal.

b. Install 0-ring on revolution sensor.

e Apply A.T.F. to 0-ring.
c. Install revolution sensor on rear extension.

d. Install rear extension gasket on transmission case.

e. Install parking rod on transmission case.

AT-189
 ASSEMBLY
Assembly (Cont'd)
f. Install rear extension on transmission case.

RE4R01A 3. Install front side clutch and gear components.

a. Install rear sun gear on transmission case.
• Pay attention to its direction.

SAT974A

RE4R03A

,,.~

SAT544B

Rear . . . . Front b. Make sure needle bearing is on front of front planetary carrier.
• Apply petroleum jelly to needle bearing.
c. Make sure needle bearing is on rear of front planetary carrier.
• Apply petroleum jelly to bearing.
• Pay attention to its direction - Black side goes to front.

Black side goes to front.

SAT967A

d. While rotating forward clutch drum clockwise, install front

planetary carrier on forward clutch drum.

AT-190
 ASSEMBLY
Assembly (Cont'd)
• Check that portion A of front planetary carrier protrudes
Front planetary carrier approximately 2 mm (0.08 in) beyond portion B of forward
clutch assembly. (RE4R01A only)

Portion A

Portion B
SAT970A

e. Make sure bearing race (RE4R01A) or needle bearing

El® (RE4R03A) are on front and rear of clutch pack.
• Apply petroleum jelly to bearing races.
• Securely engage pawls of bearing races with holes in clutch
pack.

Front Rear

SAT971A

f. Install clutch pack into transmission case.

Wooden block

SAT220B

4. Install brake band and band strut.

a. Install band strut on brake band.
• Apply petroleum jelly to band strut.

b. Place brake band on periphery of reverse clutch drum, and

insert band strut into end of band servo piston stem.

AT-191
 ASSEMBLY
Assembly (Cont'd)
c. Install anchor end bolt on transmission case. Then, tighten
anchor end bolt just enough so that reverse clutch drum
(clutch pack) will not tilt forward.

5. Install input shaft on transmission case.

• Pay attention to its direction - 0-ring groove side is front.
6. Install gasket on transmission case.

7. Install oil pump assembly.

a. Install needle bearing on oil pump assembly.
• Apply petroleum jelly to the needle bearing.
b. Install selected thrust washer on oil pump assembly.
• Apply petroleum jelly to thrust washer.

c. Carefully install seal rings into grooves and press them into
the petroleum jelly so that they are a tight fit.

d. Install 0-ring on oil pump assembly.

• Apply petroleum jelly to 0-ring.

0-ring lEI®
SAT991A

AT-192
 ASSEMBLY
Assembly (Cont'd)
e. Apply petroleum jelly to mating surface of transmission case
and oil pump assembly.

SAT992A

f. Install oil pump assembly.

• Install two converter housing securing bolts in bolt holes
in oil pump assembly as guides.

Transmission case Oil pump assembly • Insert oil pump assembly to the specified position in trans-
mission, as shown at left.

8. Install 0-ring on input shaft.

• Apply A.T.F. to 0-rings.

SAT1 148

9. Install converter housing.

a. Apply recommended sealant (Nissan genuine part:
KP610-00250 or equivalent) to outer periphery of bolt holes in
converter housing.
• Do not apply too much sealant.

SAT36BC

AT-193
 ASSEMBLY
Assembly {Cont'd)
b. Apply recommended sealant (Nissan genuine part:
KP610-00250 or equivalent) to seating surfaces of bolts that
secure front of converter housing.

c. Install converter housing on transmission case.

10. Adjust brake band.

a. Tighten anchor end bolt to specified torque.
Anchor end bolt:
~: 4- 6 N·m
(0.4 - 0.6 kg-m, 2.9 - 4.3 ft-lb)
b. Back off anchor end bolt two and a half turns.

c. While holding anchor end pin, tighten lock nut.

11. Install terminal cord assembly.

a. Install 0-ring on terminal cord assembly.
• Apply petroleum jelly to 0-ring.
b. Compress terminal cord assembly stopper and install terminal
cord assembly on transmission case.

AT-194
 ASSEMBLY
·Assembly (Cont'd)
12. Install control valve assembly.
a. Install accumulator piston return springs B, C and D.

Fr~e length of return springs: Unit: mm (in)

~ m
B c D

Free length 66 (2.60) 45 (1.77) 58.4 (2.299)

b. Install manual valve on control valve.

• Apply A.T.F. to manual valve.

c. Place control valve assembly on transmission case. Connect

solenoid connector for upper body.
d. Install connector clip.

e. Install control valve assembly on transmission case.

f. Install connector. tube brackets and tighten bolts ® and @ .
• Check that terminal assembly harness does not catch.

Bolt symbol Q mm (in)

33 (1.30)

@ 45 (1.77)

AT-195
 ASSEMBLY
Assembly (Cont'd)
g. Install 0-ring on oil ·strainer.
• Apply petroleum jelly to 0-ring.
h. Install oil strainer on control valve.

SAT221 B

i. Securely fasten terminal harness with clips.

j. Install lock-up solenoid and fluid temperature sensor connec-

tors.
Connector

13. Install oil pan.

a. Attach a magnet to oil pan.

b. Install oil pan gasket on transmission case.

c. Install oil pan and bracket on transmission case.
• Tighten four bolts in a criss-cross pattern to prevent dislo-
cation of gasket.

AT-196
 ASSEMBLY
Assembly (Cont'd)
14. Install inhibitor switch.
a. Check that manual shaft is in "1" range.
b. Temporarily install inhibitor switch on manual shaft.
c. Move manual shaft to "N".

d. Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin vertically
into locating holes in inhibitor switch and manual shaft.

15. Install torque converter.

a. Pour A.T.F. into torque converter.
• Approximately 2 liters (2-1/8 US qt, 1-3/4 Imp qt) of fluid are
required for a new torque converter.
• When reusing old torque converter, add the same amount of
fluid as was drained.

b. Install torque converter while aligning notches and oil pump.

c. Measure distance A to check that torque converter is in proper

position.
Distance "A":
RE4R01A
26 mm (1.02 in) or more
RE4R03A
25 mm (0.98 in) or more

AT-197
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications

Engine VG300E VG300ETT

Automatic transmission model RE4A01A RE4A03A

Transmission model code number 45 X 65 51 X 08

Stall torque ratio 2.0: 1

Transmission gear ratio

1st 2.785 2.784
2nd 1.545 1.544
Top 1.000 1.000
0.0. 0.694 0.694
Reverse 2.272 2.275

Automatic transmission fluid

Recommended oil
Type OEXRON ™

Oil capacity 2 (US qt, Imp qtl 8.3 (8-3/4, 7-1/41 8.2 (8-5/8, 7-1/41

Specifications and Adjustment - RE4R01A

VEHICLE SPEED WHEN SHIFTING GEARS

Vehicle speed km/h (MPHI
Throttle position
01 -+ 03 03 -+ 03 o ..... 04 04 .... 03 0 3 -+ 0 3 0 2 -+0 1

60-64 107- 115 166-176 161 - 169 96- 104 44-48

Full throttle (60. 651 (27 -30)
(37. 40) (66 -711 (103- 109) (100- 1051

45-49 83-89 119-127 80-88 33-39 10-14

Half throttle (21 -24) (6 -9)
(28 -301 (52- 551 (74 -79) (50- 551

VEHICLE SPEED WHEN PERFORMING AND STALL REVOLUTION

RELEASING LOCK-UP Stall revolution rpm
Vehicle speed km/h (MPH)
2.450- 2,650
Throttle 0.0. switch
position [Shift range) Lock-up Lock-up
''ON•' "OFF"

ON 167- 175 161 - 169 LINE PRESSURE

[0•) (104. 1091 (100- 1051
Full throttle Line pressure kPa (kg/em'. psi I
Engine speed
OFF 107. 115 96- 104
rpm
[0 1 ) (66. 711 (60- 65) 0, 2 and 1 ranges A range

ON 120-128 84-92 422-461 667.706

Idle
[0•) (75 -80) (52 -571 (4.3- 4.7, 61- 67) (6.8- 7.2, 97 -102)
Half throttle
OFF 91 -99 86-94 1,020 - 1,098 1,422 • 1,500
Stall
[0,] (57 -621 (53-581 (10.4- 11.2, 148- 1591 (14.5- 15.3, 206-2181

AT-198
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Specifications and Adjustment RE4R01A
(Cont'd)
RETURN SPRINGS
Unit: mm (in)

Item
Part No. Free length Outer diameter
Parts

Torque converter relief valve spring 31742-41X23 38.0 ( 1.496) 9.0 (0.354)

Pressure regulator valve spring 31742-41X24 44.02 (1.7331) 14.0 (0.551 I

Pressure modifier valve spring 31742-41X19 31.95 (1.2579) 6.8 (0.268)

Shuttle shift valve D spring 31762-41XOO 26.5 (1.043) 6.0 (0.236)

4-2 sequence valve spring 31756-41XOO 29.1 (1.146) 6.95 (0.2736)

Shift valve B spring 31762-41X01 25.0 (0.984) 7.0 (0.276)

Upper
body 4-2 relay valve spring 31756-41XOO 29.1 (1.1461 6.95 (0.2736)

Shift valve A spring 31762-41 X01 25.0 (0.984) 7.0 (0.276)

Control
Overrun clutch control valve spring 31762-41X03 23.6 (0.929) 7.0 (0.2761
valve
Overrun clutch reducing valve spring 31742-41X20 32.5 ( 1.280) 7.0 (0276)

Shuttle shift valve S spring 31762-41X04 51.0 (2.008) 5.65 (0.2224)

Pilot valve spring 31742-41X13 25.7 (1.012) 9.1 (0.358)

Lock-up control valve spring 31742-41X22 18.5 (0. 728) 13.0 (0.512)

Modifier accumulator piston spring 31742-41X15 30.5 (1.201) 9.8 (0.386)

1st reducing valve spring 31756-41X05 25.4 (1.000) 6.75 (0.2657)

Lower
body 3-2 timing valve spring 6.75 (0.2657)
31742-41X08 20.55 (0.8091 I

Servo charger valve spring 31742-41X06 23.0 (0.906) 6.7 (0.264)

Reverse clutch 16 pes 31505·41 X02 19.69 (0.7752) 11.6 (0.457)

High clutch 16 pes 31505-21X03 22.06 (0.8685) 11.6 (0.457)

Forward clutch 20 pes 31505-41X01 35.77 (1.4083) 9.7 (0.382)

(Oiterrun clutch)
Low & reverse
18 pes 31521-21XOO 23.7 (0.933) 11.6 (0.457)
brake

Spring A 31605-41X05 45.6 (1.795) 34.3 (1.350)

Band servo Spring B 31605-41XOO 53.8 (2.118) 40.3 (1.587)

------
Spring C 31605-41X01 29.7 (1.169) 27.6 (1.087)

Accumulator A 31605-41X02 43.0 (1.693)

Accumulator
Accumulator B 31605-41X10 66.0 (2.598)

-------
-------
-----
Accumulator C 31605-41 X09 45.0 (1.772)

Accumulator D 31605-41X06 58.4 (2.299)

AT-199
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Specifications and Adjustment RE4R01A
(Cont'd)
ACCUMULATOR 0-RING
Diameter mm (in) IForward clutch I
Number of drive plates 7
Accumulator A B c D
Number of driven plates 7
Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14)
Thickness of drive plate
Large diameter end 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77)
mm(in)
Standard 1.6 (0.063)
Wear limit 1.4 (0.055)

Clearance mm (in)
CLUTCHES AND BRAKES
Standard 0.45 ° 0.85 (0.0177 ° 0.0335)
IReverse clutch I Allowable limit 2.25 (0.0886)
Number of drive plates 2 Thickness
Part number
mm (in)
Number of driven plates 2
4.0 (0.157) 31537o41X07
Thickness of drive plate
4.2 (0.165) 31537°41 X08
mm (in) Thickness of retaining plate
4.4 (0.173) 31537-41 X09
Standard 2.0 (0.079)
4.6 (0.181) 31·537°41 X 10
Wear limit 1.8 (0.071)
4.8 (0.189) 31537-41X11
5.0 (0.197) 31537-41X12
Clearance mm (in)
5.2 (0.205). 31537-41X13
Standard 0.5 ° 0.8 (0.020 ° 0.031)
Allowable limit 1.2 (0.047)
IOverrun clutch I
Thickness Number of drive plates 3
Part number
mm(in)
Number of driven plates 5
4.6 (0.181) 31537°21 xoo
Thickness of drive plate
4.8 (0.189) 31537°21X01
Thickness of retaining plate mm(in)
5.0 (0.197) 31537o21X02
Standard 2.0 (0.079)
5.2 (0.205) 31537 °21 X03
Wear limit 1.8 (0.071)
5.4 (0.213) 31537 °21 X04
5.6 (0.220) 31567°21X13 Clearance mm(in)
5.8 (0.228) 31567·21X14 Standard 1.0 ° 1.4 (0.039 ° 0.055)
2.0 (0.079)
IHigh clutch I Allowable limit
Number of drive plates 5 Thickness
Part number
mm (in)
Number of driven plates 5
4.0 (0.157) 31537-41 X79
Thickness of drive plate
4.2 (0.165) 31537-41 X80
mm (in) Thickness of retaining plate
4.4 (0.173) 31537-41X81
Standard 1.6 (0.063)
4.6 (0.181) 31537-41X82
Wear limit 1.4 (0.055)
4.8 (0.189) 31537-41X83
Clearance mm(in) 5.0 (0.197) 31537-41 X84
Standard 1.8 ° 2.2 (0.071 ° 0.087) 5.2 (0.205) 31537-41X20
Allowable limit 3.2 (0.126)

Thickness
Part number
mm (in)

3.4 (0.134) 31537-41X71

3.6 (0.142) 31537-41X61
Thickness of retaining plate 3.8 (0.150) 31537°41 X62
4.0 (0.157) 31537-41X63
4.2 (0.165) 31537°41 X64
4.4 (0.173) 31537-41X65
4.6 (0.181) 31537°41 X66
4.8 (0.189) 31537-41X67

AT-200
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Specifications and Adjustment RE4R01A
(Cont'd)
REVERSE CLUTCH DRUM END PLAY
ILow & reverse brake I Reverse clutch drum end play 0.55 • 0.90 mm
Number of drive plates 7 "T2 ,, (0.0217 • 0.0354 in)

Number of driven plates 9 Thickness

Part number
mm (in)
Thickness of drive plate
mm(in) 0.7 (0.028) 31528-21 xoo
Standard 2.0 (0.079) Thickness of oil pump thrust 0.9 (0.035) 31528-21X01
Wear limit 1.8 (0.071) washer 1.1 (0.043) 31528-21X02
1.3 (0.051) 31528-21X03
Clearance mm (in) 1.5 (0.059) 31528-21 X04
Standard 1.1 . 1.5 (0.043 . 0.059) 1.7 (0.067) 31528-21 X05
Allowable limit 2.9 (0.114) 1.9 (0.075) 3152B-21X06

Thickness
Part number
mm(in)

7.2 (0.283) 31667-41X13

REMOVAL AND INSTALLATION
Thickness of retaining plate 7.4 (0.291) 31667-41X14
Manual control linkage
7.6 (0.299) 31667-41 X07
Number of returning
7.8 (0.307) 31667-41X08
revolutions for lock nut
8.0 (0.315) 31667-41XOO
8.2 (0.323) 31667-41X01 11 -15 N·m
Lock nut tightening torque
IBrake band I ( 1 .1 • 1.5 kg-m, 8 • 11 ft·lb)
Anchor end bolt tightening 4-6 Distance between end of conver-
torque N·m (kg-m, ft-lb) (0.4. 0.6, 2.9. 4.3) 26.0 mm (1.024 in) or more
ter housing and torque converter
Number of returning Drive plate runout limit 0.5 mm (0.020 in)
revolutions for anchor 2.5
end bolt

OIL PUMP AND LOW ONE-WAY CLUTCH

Oil pump clearance mm (in)
Cam ring - oil pump housing
Standard 0.01 • 0.024 (0.0004 • 0.0009)

Rotor, vanes and control

piston - oil pump housing
Standard 0.03 • 0.044 (0.0012 • 0.0017)

Seal ring clearance mm (in)

Standard 0.10. 0.25 (0.0039. 0.0098)
Allowable limit 0.25 (0.0098)

TOTAL END PLAY

0.25 • 0.55 mm
Total end play "T 1 "
(0.0098 • 0.0217 in)

Thickness
Part number
mm lin)

0.8 (0.031) 31429-21XOO

Thickness of oil pump 1.0 (0.039) 31429-21 X01
cover bearing race 1.2 (0.047) 31429·21 X02
1.4 (0.055) 31429-21 X03
1.6 (0.063) 31429-21X04
1.8 (0.071) 31429-21 X05
2.0 (0.079) 31429-21 X06

AT-201
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Specifications and Adjustment - RE4R03A

VEHICLE SPEED WHEN SHIFTING GEARS

Vehicle speed km/h (MPH)
Throttle position
D,-+ 0 2 02 -+ 0 3 o.-+ o. o. -+ o. o. -+ o, o,-+ o,

68-72 120- 128 183- 193 177- 187 109-117 33-37

Full throttle
(42 -45) (75 -80) (114-120) (110-116) (68 -73) (21- 23)

47-51 89-95 136- 144 78-86 28-34 10-14

Half throttle
(29- 32) (55- 59) (85- 89) (48-53) (17- 21) (6 -9)

VEHICLE SPEED WHEN PERFORMING AND STALL REVOLUTION

RELEASING LOCK-UP Stall revolution rpm
Vehicle speed km/h (MPH)
Throttle 0.0. switch 2,950- 3,200
position [Shift range) Lock-up Lock-up
''ON" "OFF"

ON 184- 192 178- 186 LINE PRESSURE

[0 4 ) (114-119) (111 -116)
Full throttle line pressure kPa (kg/em•. psi)
109-117 Engine speed
OFF 120- 128
[0 1 ) (68 -73) rpm
(75- 80) D, 2 and 1 ranges R range

ON 184- 192 117- 125 422-461 667-706

Idle
[0 4 ) (114-119) (73- 78) (4.3- 4.7. 61 - 67) (6.8- 7.2, 97 -102)
Half throttle
OFF 88-96 74-82 1,020 - 1,098 1,422 - 1,500
Stall
[0 1 ) (55- 60) (46- 51) (10.4- 11.2, 148- 159) (14.5- 15.3, 206- 218)

AT-202
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Specifications and Adjustment RE4R03A
(Cont'd)
RETURN SPRINGS
Unit: mm (in)

Item
Part No. Free length Outer diameter
Parts

Torque converter relief valve spring 3174241X23 38.0 11.496) 9.0 10.354)

Pressure regulator valve spring 3174241X24 44.02 11.7331) 14.0 10.551)

Pressure modifier valve spring 3174241X19 31.95 11.2579) 6.8 10.268)

Shuttle shift valve D spring 3176241XOO 26.5 11.043) 6.0 10.236)

4-2 sequence valve spring 3175641XOO 29.1 11.146) 6.95 10.2736)

Shift valve B spring 3176241X01 25.0 10.984) 7.0 10.276)

Upper
body 4-2 relay valve spring 31756-41XOO 29.1 11.146) 6.95 10.2736)

Shift valve A spring 3176241X01 25.0 10.984) 7.0 10.276)

Co.ntrol
Overrun clutch control valve spring 3176241X03 23.6 10.929) 7.0102761
valve
Overrun clutch reducing valve spring 3174241X20 32.5 11280) 7.010.2761

Shuttle shift valve S spring 3176241X04 51.0 12.008) 5.65 10.22241

Pilot valve spring 3174241X13 25.7 11.012) 9.1 10.358)

Lock-up control valve spring 3174241X22 18.5 10.728) 13.0 10.5121

Modifier accumulator piston spring 3174241X15 30.5112011 9.8 10.3861

1st reducing valve spring 3175641X05 25.4 11.000) 6.75 1026571

Lower
body 3-2 timing valve spring 3174241X08 20.55 10.8091) 6.75 10.26571

Servo charger valve spring 3174241X06 23.0 10.9061 6.7 102641

Reverse clutch 16 pes 31505-51 xoo 37.8 11.488) 14.8 10.5831

High clutch 16 pes 31505-21 X03 22.06 10.86851 11.6 (0.4571

Forward clutch
20 pes 31505-51 X04 36.8 (1.449) 9.8 (0.3861
(Overrun clutch)

Inner 16 pes 31505-51 X06 20.43 (0.8043) 10.3 (0.4061

Low & reverse
brake
Outer 16 pes 31505-51X05 20.35 (0.80121 13.0 10.512)

'Spring A 3160541X05 45.6 (1.7951 34.3 (1.350)

Band servo Spring 8 3160541XOO 53.8 12.118) 40.311.5871

------
Spring C 3160541X01 29.7 (1.1691 27.6 (1.0871

Accumulator A 3160541X02 43.0 (1.693)

Accumulator
Accumulator 8 3160541X10 66.0 12.5981

-------
-------
-----
Accumulator C 3160541X09 45.0 11.772)

Accumulator D 3160541X06 58.4 12.2991

AT-203
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Specifications and Adjustment RE4R03A
(Cont'd)
ACCUMULATOR 0-RING
Diameter mm (in) IForward clutch I
Number of drive plates 8
Accumulator A 8 c 0
Number of driven plates 8
Small diameter end 2911.14) 32 11.26) 45 (1.77) 2911.14)
Thickness of drive plate
Ulrge diameter end 45 (1.77) 50 11.97) 50 (1.97) 4511.77)
mm (in)
Standard 2.0 (0.079)
Wear limit 1.8 (0.071)

Clearance mm (in)
CLUTCHES AND BRAKES
Standard 0.45-0.85 (0.0177- 0.03351
!Reverse clutch! Allowable limit 2.45 (0.09651
Number of drive plates 3
Thickness
Part number
Number of driven plates mm(inl
3

Thickness of drive plate 4.2 (0.165) 31537-51X67

mm(in) Thickness of retaining plate 4.4 (0.173) 31537-51X05
Standard 2.0 10.079) 4.6 (0.1811 31537-51X06
Wear limit 1.8 (0.071) 4.8 (0.189) 31537-51X07
5.0 (0.1971 31537·51X08
Clearance mm (in) 5.2 (0.2051 31537-51X09
Standard 0.5 - 0.8 10.020- 0.031)
Allowable limit 1.4 (0.055) IOverrun clutch I
Number of drive plates 4
Thickness
Part number Number of driven plates 7
mm (in)

4.4 (0.173) Thickness of drive plate

Thickness of retaining plate 31537-57X61
4.6 (0.181) mm(inl
31537-51XOO
4.8 (0.189) Standard 1.6 (0.0631
31537-51X01
Wear limit 1.4 (0.055)
5.0 (0.197) 31537-51 X02

jHigh clutchj Clearance mm (in)

Number of drive plates Standard 1.0 - 1.4 (0.039 - 0.055)
7
Allowable limit 2.2 (0.087)
Number of driven plates 7+1
Thickness
Part number
Thickness of drive plate mm (in)
mm(in)
3.8 (0.150) 31537-51X11
Standard 1.6 (0.063)
Thickness of retaining plate 4.0 (0.1~71 31537-51X12
Wear limit 1.4 (0.055)
4.2 (0.1651 31537-51X13
Clearance mm(in) 4.4 (0.1731 31537-51X14
Standard 1.8-2.2 (0.071 -0.087) 4.6 (0.1811 31537-51X15
Allowable limit 3.0 (0.118) 4.8 (0.189) 31537-51 X64

Thickness
Part number
mm (in)

4.0 (0.157) 31537-51X19

Thickness of retaining plate 4.2 (0.1651 31537-51 X60
4.4 (0.1731 31537,51 X61
4.6 (0.181) 31537-51XOO
4.8 (0.1891 31537-51 X01
5.0 (0.197) 31537-51 X02

AT-204
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Specifications and Adjustment RE4R03A
(Cont'd)
REVERSE CLUTCH DRUM END PLAY
ILow & reverse brake I Reverse clutch drum end play 0.55 • 0.90 mm
Number of drive plates 2+6 "T2" (0.0217 • 0.0354 in)

Number of driven plates 8 Thickness

Part number
mm (in)
Thickness of drive plate
mm (in) 0.7(0.0281 31528-21XOO
Standard 1.6 (0.063) Thickness of oil pump thrust 0.9 (0.035) 31528-21 X01
Wear limit 1.4 (0.055) washer 1.1(0.043) 31528-21X02
1.3(0.051) 31528-21 X03
Clearance mm (in) 1.5(0.059) 31528-21X04
Standard 1.1 . 1.5 (0.043 • 0.0591 1.7 (0.067) 31528·21X05
Allowable limit 3.1 (0.1221 1.9 (0.075) 31528-21X06

Thickness
Part number
mm(in)

4.2 (0.165) 31667-51X10

REMOVAL AND INSTALLATION
Thickness of retaining plate
4.4 .(0.173) 31667-51 xoo
Manual control linkage
4.6 (0.1811 31667-51X01
Number of returning
4.8 (0.1891 31667-51X02
revolutions for lock nut
5.0 (0.1971 31667-51 X03

lsrake band I Lock nut tightening torque

11-15N·m
( 1.1 • 1.5 kg-m, 8 • 11 ft-lb)
Anchor end bolt tightening 4-6
torque N·m (kg-m, ft-lb) (0.4. 0.6, 2.9. 4.31 Distance between end of clutch
25.0 mm (0.984 in) or more
housing and torque converter
Number of returning
revolutions for anchor 2.5 Drive plate runout limit 0.5 mm (0.020 in)
end bolt

OIL PUMP AND LOW ONE-WAY CLUTCH

Oil pump clearance mm(inl
Cam ring- oil pump housing
Standard 0.01 • 0.024 (0.0004 • 0.00091

Rotor, vanes and control

piston - oil pump housing
Standard 0.03. 0.044 (0.0012. 0.00171

Seal ring clearance mm (in)

Standard 0.10. 0.25 (0.0039. 0.00981
Allowable limit 0.25 (0.00981

TOTAL END PLAY

0.25 • 0.55 mm
Total end play "T 1 "
(0.0098 • 0.0217 in)

Thickness
Part number
mmlinl

0.8(0.0311 31429-21 xoo

Thickness of oil pump 1.0 (0.039) 31429-21 X01
cover bearing race 1.2 (0.047) 31429-21X02
1.4 (0.0551 31429-21X03
1.6 (0.063) 31429-21X04
1.8 (0.071) 31429-21xos
2.0 (0.079) 31429-21 X06

AT-205
 . .

PROPELLER SHAFT I
DIFFERENTIAL CARRIER

SECTIONPD

CONTENTS
PREPARATION .................................................................................................................................. PO- 2
PROPELLER SHAFT ................... .. ....... ........... ........... ......... ........ ................ ........ .......... .. .. ............... PO- 7
ON-VEHICLE SERVICE (Final drive) ............................................................................................. PD-12
REMOVAL AND INSTALLATION .................................................................................................... PD-14
FINAL DRIVE .................................................................................................................................... PD-15
DISASSEMBLY .................................................................................................................................. PD-17
INSPECTION .... ........ .. ...... .... .... .......... ....... .. .. .. ... ................ ... ..... .. ....... .. ... ..... ...... ..... .... ...... ......... ....... PD-22
ADJUSTMENT (R200V) .................................................................................................................... PD-23
ADJUSTMENT (R230V) .................................................................................................................... PD-30
ASSEMBLY ..... ... ...... ............ ... ... ..... ................ .............. ......... .... .. ................. .. ........... .... .. .... ... ........... PD-35
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ....................................................................... PD-41
 PREPARATION

SPECIAL SERVICE TOOLS

Tool number Unit app.lication

(Kent-Moore No.) .. Description
Tool name · ::.'.~; · R200V R230V

ST38060002 · Removing and installing propeller

(J34311) shaft lock nut, and drive pinion X
Drive pinion flange lock nut.
wrench Use two holes and propeller shaft connecting bolt to hold companion flange

xxxxxxxxxx Removing and installing propeller

~
shaft lock nut, and drive pinion - X
Drive pinion flange lock nut
wrench

KV38100800 Mounting final drive

~
( - ) (To use, make a new hole.)
Equivalent tool X X
(J25604-01)
Differential a: 156 mm (6.14 in) - R200V
attachment 178 mm 11:01 in)- R230V

ST3090SOOO Removing and installing drive

( - ) pinion rear cone
Drive pinion rear

~
inner race puller set
· '·>@'st30031000
(J22912-01)
Puller
-
~
® ST30901000 X
( - )
Equivalent tool
(J26010-01)
Base

ST3002SOOO Removing and installing drive

( - ) pinion rear cone
Drive pinion rear inner
race puller set
CD ST30021 000
( - )
Puller
® ST30022000 X
( - )
Base

PD-2
 PREPARATION

Tool number Unit application

(Kent-Moore No.) Description
Tool name R200V R230V

ST3306S001 Removing and installing differential

( - ) side bearing inner cone
Differential side
bearing puller set
CD ST33051 001
( - )
Equivalent tool
X
(J22888)
Body
® ST33061000
(J8107-2)
Equivalent tool
(J26010-01)
Adapter

ST3306S001 Removing and installing differential

( - ) side bearing inner cone
Differential side
bearing puller set
CD ST33051 001
( - ) X
Equivalent tool
(J22888)
Body
® xxxxxxxxxx
( - )
Adapter

ST30611000 Installing pinion rear bearing outer

(J25742-1) race X X
Drift

ST30613000 Installing pinion front bearing outer

(J25742-3) race X
Drift

0
~~ Installing pinion front bearing outer
xxxxxxxxxx
) ~ race
X
Drift 8
a: 79 mm (3.11 in) dia.

KV38100200 Installing side oil seal

(J26233) X
Oil seal drift

PD-3
 PREPARATION

Tool number Unit application

(Kent-Moore No.) Description
Tool name R200V R230V

KV38102510 Installing side oil seal

( ) X
Oil seal drift

KV38100500 Installing front oil seal

( ) X
Oil seal drift

xxxxxxxxxx Installing front oil seal

Oil seal drift a: 85 mm (3.35 in) dia.

X
b: 69 mm (2.72 in) dia.

KV38100300 Installing side bearing inner cone

(J25523) X
Drift

xxxxxxxxxx Installing side bearing inner cone

X
Drift a: 64 mm (2.52 in) dia.
b: 55.5 mm (2.185 in) dia.

KV38100600 Installing side bearing spacer

(J25267)
X
Side bearing spacer
drift

xxxxxxxxxx Installing side bearing spacer

X
Side bearing spacer
drift

ST3127SOOO Measuring pinion bearing preload

(See J5765-A) and total preload
Preload gauge
CD GG91030000
(J25765)
Torque wrench
X X
® HT62940000
( )
Socket adapter
@ HT62900000
( )
Socket adapter

PD-4
 PREPARATION

Tool number Unit application

(Kent-Moore No.) Description
Tool name R200V R230V

HT72400000 Removing differential case assembly

( ) X X
Slide hammer

(J34309) Adjusting bearing preload and

Differential shim gear height
selector
X

(xxxxxx) Adjusting bearing preload and

Differential shim gear height
selector
X

Selecting pinion height adjusting

@
(J25269-4)
Side bearing discs washer
X
(2 Req'd)

Selecting pinion height adjusting

@
(xxxxxxx)
Side bearing discs washer
X
(2 Req'd)

(J8129) Measuring carrier turning torque

Spring gauge
X X

PD-5
 PREPARATION

COMMERCIAL SERVICE TOOL

Unit application
Tool name Description
R200V R230V

Drift Installing pinion rear bearing outer

race
X X
a: 89 mm (3.50 in) dili. - R200V
99 mm (3.90 in) dia.- R230V
b: 200 mm (7.87 in)

PD-6
 PROPELLER SHAFT

Washer
Apply a-c-o-at_o_f_m_u_·. ----- .
~rease containing mlt:-purpose lithium Propeller shaft 2 nd tube

b~:~:i~:~ ~~ct~ of t~eyc~~~:~:a:i~ulfide

:;------=~~ae ewasher. nng and
Lock nut~
rPJ245- 294
(25- 30• 181 -2171

~ .......1
Spacer

t-.-0 A...\.. (4.0-45 2

9·331

rPJ 39-44 (4 .0-45

• • 29 - 33)

Companion flange

M/Tmodel

Propeller shaft 1st tube

rPJ 59-78
(6.0 -8 .0 • 43 -58)

Propeller shaft 2
Lock nut~ nd tube

A245 -294
(25- 30 • 181 -2171

Companion flange
MIT model

Propeller shaft 1st tube

A 59-78
(6.0 -80
. • 43 -58)
rPJ: N·m (k g-m, ft-lb)

PD-7
 PROPELLER SHAFT

On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft
runout first.
1. Raise rear wheels.
2. Measure propeller shaft runout at indicated points by rotat-
ing final drive companion flange with hands.
Runout limit: 0.6 mm (0.024 In)

Propeller shaft run out measuring points:

Distance "A":
162 mm (6.38 in)
Distance "B":
3S71A: 172 mm (6.77 in}
3S80A-VL107: 200 mm (7.87 in)
Distance "C":
3S71A: 192 mm (7.56 in)
3S80A-VL107: 200 mm (7.87 in)

SPD915

3. If runout exceeds specifications, disconnect propeller shaft at

final drive companion flange. Rotate companion flange 90°
(3S71A) or 60° (3S80A-VL107), and reconnect propeller shaft
and check runout.
Repeat above operation when companion flange is rotated 180°
(3S71A) or 120° (3S80A-VL107) and 270° (3S71A) or 180°
(3S80A-VL107), respectively. Also, for 3S80A-VL107, the oper-
ation should be repeated at 240° and 300°. Securely connect
propeller shaft at the , point. where the smallest runout of the
three measurements occurs.
Runout limit: 0.6 mm (0.024 in)
4. Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.
5. Perform road test.
APPEARANCE CHECKING
• Inspect propeller shaft tube surface for dents or cracks.
If da!Jlaged, replace propeller shaft assembly.
• If center bearing is noisy or damaged, replace center bearing.

Removal
• Put matchmarks on flanges and separate propeller shaft from
final drive.

Po~s
 PROPELLER SHAFT
Removal (Cont'd)

• Draw out propeller shaft from transmission and plug up rear

Transmission end of transmission rear extension housing.

SPD359

Installation
• Temporarily install differential companion flange and flange yoke
so that their alignment marks (original marks) are located as
close to each other as possible.
• Turn propeller shaft until alignment marks face straight upward.
Securely fasten propeller shaft so that lower side wall of
concave flange yoke will touch lower side wall of convex
companion flange.

· Inspection
• Inspect propeller shaft runout. If runout exceeds specifica-
tions, replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)

W(
tv

SPD106

• Inspect journal axial play.

If the play exceeds specifications. replace propeller shaft
assembly.
Journal axial play:
0 mm (0 in)

SPD874

PD-9
PROPELLER SHAFT

Disassembly
CENTER BEARING
1. Put matchmarks on flanges. and separate 2nd tube from 1st
tube.

2. Put matchmarks on the flange and shaft.

3. Remove locking nut with Tool.

Tool number:
ST38060002 (J34311)

4. Remove companion flange with puller.

5. Remove center bearing with Tool and press.

Tool number: ST30031000 (J22912~01)

PD-10
 PROPELLER SHAFT

Assembly
CENTER BEARING
• Install center bearing with insulator's protrusion side facing
front of vehicle.
• Apply a coat of multi-purpose lithium grease containing
molybdenum disulfide to the end face of the center
bearing and both sides of the washer.

SPD970

• Stake the nut. Always use new one.

• Align matchmarks when assembling tubes.

SPD971

PD-11
ON-VEHICLE SERVICE (Final drive)

Front OU Seal Replacement (R200V)

CAUTION:
For final drive mqdels using collapsible spacer (R230V), bearing
preload must b' adjusted whenever companion flange Is re-
moved~ In order. to do this adjustment correctly, final drive
overhaul Is required.
1. Remove propeller shaft.
2. Loosen drive pinion nut with Tool.
Tool number: ST38060002 (J34311)

3. Remove companion flange.

4. Remove front oil seal.

5. Apply multi-purpose grease to sealing lips of oil seal. Press

front oil seal into carrier.
6. Install companion flange and drive pinion nut.
7. Install propeller shaft.

Side Oil Seal Replacement

1. Remove drive shafts.
Refer to RA section.
2. Remove final drive side flange.
3. Remove oil seal.

PD-12
ON-VEHICLE SERVICE (Final drive)
Side Oil Seal Replacement (Cont'd)
4. Apply multi-purpose grease to sealing lips of oil seal. Press-fit
oil seal into carrier with Tool.
Tool number:
KV38100200 (J26233) - R200V -
xxxxxxxxxx ( - ) - R230V -
5. Install final drive side flange and drive shaft.

PD-13
REMOVAL AND INSTALLATION

Removal
• Remove exhaust tube.
• Remove propeller shaft.
Plug up rear end of transmission rear extension housing.
• Remove drive shafts.
Refer to RA section.
• Remove nuts securing final drive rear cover to suspension
member.
• Support weight of final drive using jack.
• Remove final drive mounting member from front of final drive.
• Move final drive forward together with jack. Remove rear cover
stud bolts from suspension member.
• Lower final drive using jack. Remove jack from rear of vehicle.
CAUTION:
• Be careful not to damage spline, sleeve yoke and front oil
seal, when removing propeller shaft.
• After final drive is removed, support suspension member on a
stand to prevent its insulators from being twisted or dam-
aged.

Installation
• Fill final drive with recommended gear oil.

SPD973

PD-14
 Side oil seal ~

.~ a~~~s~~na~ing
Pinion
mate
shaft
washer*
Side gear (L.H.)

~,
with viscous

Side __s- race

bearing 1
Out~:r race
1

Pinion height s:
0 :!!
., Pinion
rear
adjusting washer - - -

___r--- Inner race --

a.
!!.
z
)>
r-
c bearingL__Outer race ::IJ
c
....
I 1\)
0 ::IJ
U'l ~ <
m

Inner Outer
race race

L I Pinion front
bearing
Front oil
seal~
Companion flange

~ : N·m (kg-m, ft-lb)

,en
0
g
'"
)>
 A 88-118
Differential Pinion A 39-49 (4.o- s.o. 2s- 36) ~ "\. 1s.o- 12.o. 65- 87)
mate
case Thrust

washer Circular
shaft
Breather~ -~
clip~~ Side gear {L.H.)
with viscous
/
coupling ~
~
!Special
Thrust
washer
washer

~oo s::
c -~~~v~t@~ :.
0

.,c
Pinion
a.

~
j
rear Inner race
bearing Bq,;og "P l "'-"' !!.
Outer race
:D
...en
I
88 _
98
(9.0 ·100
/ Dlff'::ential
case

~..... /
-

--- ~-.. 132-152

I
-. J -\'
:::

.
~
~
spacer
/
~ /
65-72)..
~~.
~ ~~
P'!""n
{13.5-155 98.
•• -112]

Inner Outer
race race

LJ Pinion front
bearing
Front oil
seal~
Companion flange
Drain plug IE!
~ 39 -59 {4- 6, 29 - 43) u

~: N·m {kg-m, ft-lb)

en
"0
0 Side flange
0
I>
(J1
)>
 DISASSEMBLY

Pre-inspection
Before disassembling final drive, perform the following inspection.
• Total preload
1) Turn drive pinion in both directions several times to set bearing
rollers.
2) Check total preload with Tool.
Tool number: ST3127SOOO (See J25765-A)
Total preload:
1.4- 1.7 N·m
(14 - 17 kg-em, 12 - 15 in-lb)

• Ring gear to drive pinion backlash

Check ring gear-to-drive pinion backlash with a dial indicator
at several points.
Ring gear-to-drive pinion backlash:
0.10 - 0.15 mm (0.0039 - 0.0059 in)

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
• Tooth contact
Check tooth contact. (Refer to Adjustment.)

Runou~ !!_m_i!: ~.~5 mm~0.0020 in) SPD886

Differential Carrier
1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool.
Tool number: KV38100800 ( - )

Tool
SPD975
'-------------·
2.
Paint or punch matchmarks on one side of the side bearing
cap so it can be properly reinstalled.
Bearing caps are line-bored during manufacture. Replace them in
their proper positions.

PD-17
 DISASSEMBLY
Differential Carrier (Cont'd)
3. Remove side bearing caps.

4. Lift differential case assembly out with Tool.

Tool number: HT72400000 ( - )

Keep the side bearing outer races together with inner cone - do
not mix them up.
Also, keep side bearing spacer and adjusting shims together
with bearings.

5. Loosen drive pinion nut and pull off companion flange.

Tool number:
ST38060002 (J34311) - R200V -
xxxxxxxxxx { - ) - R230V -

PD-18
 DISASSEMBLY
Differential Carrier (Cont'd)
6. Take out drive pinion (together with rear bearing inner race,
bearing spacer and adjusting washer).
7. Remove oil seal.
8. Remove front bearing inner race.
9. Remove side oil seal.

10. Remove pinion bearing outer races with a brass drift.

PD349

11. Remove p1mon rear bearing inner race and drive pinion
height adjusting washer with suitable tool.

Suitable tool

PD179

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
® ST33051 001 ( - )
@ ST33061000 (J8107-2) - R200V -
xxxxxxxxxx ( - )- R230V -

SPD920

PD-19
 DISASSEMBL V
Differential Case (Cont'd)
Be careful not to confuse left- and right-hand parts.

SPD022

2. Loosen ring gear bolts in a criss-cross fashion.

3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

Thrust washer
Pinion mate thrust washer

~ Pinion mate shaft

Thrust washer

Differential case A

Differential case B

Side gear (R.H.I

Pinion mate gear

Side gear ( L.H.I with viscous coupling

SPD861

PD-20
 DISASSEMBLY
Differential Case (Cont'd)
4. Loosen screws on differential cases A and B.
5. Separate differential cases A and B.
CAUTION:
Assemble differential case firmly.

Matching
mark

SPD862

PD-21
 INSPECTION

Contact Surfaces
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found to be burred or scratched,
smooth with oil stone.
• Differential case A
• Differential case B
• Side gear
• Pinion mate gear
• Pinion mate shaft
3. Check viscous coupling for oil leakage. If necessary, replace it
with new one.

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

PD-22
ADJUSTMENT (R200V)

For quiet and reliable final drive operation, the following five
adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear-to-pinion backlash (Refer to ASSEMBLY.)
5. Ring and pinion gear tooth contact pattern

Side Bearing Preload

A selection of carrier side bearing preload shims Is required
for successful completion of this procedure.

1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or Dexron™ type automatic trans-
mission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.

3. Put the side bearing spacer in place on the ring gear end of
the carrier.

4. Using the J-25267 side bearing spacer drift, place both of

the original carrier side bearing preload shims on the carrier
end, opposite the ring gear.

PD-23
 ADJUSTMENT (R200V}
Side Bearing Preload (Cont'd}
5. Install the side bearing caps in their correct locations and
torque the bearing cap retaining bolts.
Specification:
88 - 98 N·m
(9 - 10 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.

7. Measure the turning torque of the carrier at the ring gear

retaining bolts with a spring gauge, J-8129.
Specification:
34.3 - 39.2 N
(3.5 - 4 kg, 7.7 - 8.8 lb)
of pulling force at the ring gear bolt.

8. If the carrier turning torque is not within the specification

range, increase or decrease the total thickness of the side
bearing adjusting washers until the turning torque is correct.
If the turning torque is less than the specified range, install
washers of greater thickness; if the turning torque is greater
than the specification, install thinner washers. See the S.O.S.
section for washer dimensions and part numbers.
9. Record the total amount of washer thickness required for
the correct carrier side bearing preload.

10. Remove the carrier from the final drive housing, saving the
selected preload washers for later use during the assembly
of the final drive unit.

Pinion Gear Height and Pinion Bearing Preload

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion preload
shim selector Tool, J-34309.

li!!!l!l!ll!lllll!llijl!li!Oi

SPD769

PD-24
 ADJUSTMENT (R200V)
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
• Front pinion bearing - make sure the J-34309-3 front pinion
bearing seat is secured tightly against the J-34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J-34309-5, to
secure the bearing in its proper position.
• Rear pinion bearing - the rear pinion bearing pilot, J-34309-8,
is used to center the rear pinion bearing only. The rear pinion
bearing locking seat, J-34309-4, is used to lock the bearing to
the assembly.
· • Installation of J-34309-9 and J-34309-16 - place a suitable 2.5
mm (0.098 in) thick plain washer between J-34309-9 and
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must be
parallel with a clearance of 2.5 mm (0.098 in).

3. Place the p1n1on preload shim selector Tool, J-34309-1,

gauge screw assembly with the pinion rear bearing inner
cone installed into the final drive housing.

c/~\
/
Ill SPD893

4. Assemble the front pinion bearing inner cone and the J-34309-2
gauge anvil together with the J-34309-1 gauge screw in the final
drive housing. Make sure that the pinion height gauge plate,
J-34309-16, will turn a full 360 degrees, and tighten the two
sections together by hand.

5. Turn the assembly several times to seat the bearings.

SPD770
'---------·-------

PD-25
ADJUSTMENT (R200V)
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
6. Measure the turning torque at the end of the J-34309-2
gauge anvil using torque wrench J-25765A.
Turning torque specification:
1.0- 1.3 N·m
(10 - 13 kg-em, 8.7 - 11.3 in-lb)

7.Place the J-34309-11 "R200A" p1n1on height adapter onto

the gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

- PINION BEARING PRELOAD WASHER SELECTION -

B. Place the solid pinion bearing spacer, small end first, over the
J-34309-2 gauge anvil and seat the small end squarely against
the tip of the J-34309-1 gauge screw in the tool recessed
portion.

9. Select the correct thickness of pinion bearing preload adjusting

washer using a standard gauge of 3.5 mm (0.138 in) and your
J-34309-101 feeler gauge. The exact measurement you get
with your gauges is the thickness of the adjusting washer
required. Select the correct washer.
Drive pinion bearing preload adjusting washer:
Refer to S.O.S.

PD-26
 ADJUSTMENT (R200V)
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
10. Set your selected, correct pinion bearing preload adjusting
washer aside for use when assembling the pinion gear and
bearings into the final drive.

- PINION HEIGHT ADJUSTING WASHER SELECTION -

11. Now, position the side bearing discs, J-25269-4, and arbor
firmly into the side bearing bores.
Install the side bearing caps and tighten the cap bolts to
proper torque.

12. Select the correct standard pinion height adjusting washer

thickness using a standard gauge of 3 mm (0.12 in) and your
J-34309-101 feeler gauge. Measure the distance between the
J-34309-11 pinion height adapter including the standard gauge
and the arbor.

13. Write down your exact measurement (the value of feeler gauge).

14. Correct the p1n1on height washer size by referring to the

"pinion head number."
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set and
should be the same as the number on the ring gear. The
second number is the "pinion head height number," and it
refers to the ideal pinion height from standard for quietest
operation. Use the following chart to determine the correct
pinion height washer.

SPD542

PD-27
ADJUSTMENT (R200V)
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
Add or remove from the standard
Pinion head height number pinion height washer thickness
measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)

15. Select the correct pinion height washer from the following chart.
Drive pinion height adjusting washer:
Refer to S.O.S.
16. Remove the J-34309 pinion preload shim selector Tool from
the final drive housing and disassemble to retrieve the
pinion bearings.

Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gears which are not positioned properly in relation to one
another may be noisy, or have short life or both. With the checking
of gear tooth contact pattern, the most desirable contact for low
noise level and long life can be assured. ·

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered titanium oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

PD-28
 ADJUSTMENT (R200V}
Tooth Contact (Cont'd)
3. Hold companion flange steady by hand and rotate the ring
gear in both directions.

SPD308

Usually the pattern will be correct if you have calculated the shims correctly and the backlash is correct.
However, in rare casas you may have to usa trial-and..rror proca-s until you gat a good tooth contact pattern.
The tooth pattern is the bast indication of how wall the final drive has bean sat up.

Heel contact Face contact Toe contact Flank contact

To correct, increase thickness of pinion

height adjusting washer in order to bring
drive pinion close to ring gear.
~~ To correct, reduce thickness of pinion
height adjusting washer in order to make
drive pinion go away from ring gear.

c.--·~--/ V--t="
~
~ SPD007

PD-29
ADJUSTMENT (R230V)

For quiet and reliable final drive operation, the following five
adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Ring gear-to-pinion backlash (Refer to ASSEMBLY.)
4. Ring and pinion gear tooth contact pattern

Side Bearing Preload

A selection of carrier side bearing preload shims is required for
successful completion of this procedure.

1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or Dexron™ type automatic transmission
fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.

3. Put the side bearing spacer in place on the ring gear end of
the carrier.

4. Using the xxxxxx side bearing spacer drift, place both of the
original carrier side bearing preload shims on the carrier end,
opposite the ring gear.

PD-30
 ADJUSTMENT (R230V)
Side Bearing Preload {Cont'd)
5. Install the side bearing caps in their correct locations and
torque the bearing cap retaining bolts.
Specification:
88- 98 N·m
(9 - 10 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.

7. Measure the turning torque of the carrier at the ring gear

retaining bolts with a spring gauge, J-8129.
Specification:
34.3- 39.2 N
(3.5 - 4 kg, 7.7 - 8.8 lb)
of pulling force at the ring gear bolt.

8. If the carrier turning torque is not within the specification range,

increase or decrease the total thickness of the side bearing
adjusting washers until the turning torque is correct. If the
turning torque is less than the specified range, install washers
of greater thickness; if the turning torque is greater than the
specification, install thinner washers. See the S.O.S. section for
washer dimensions and part numbers.
9. Record the total amount of washer thickness required for the
correct carrier side bearing preload.

'i'f' 10. Remove the carrier from the final drive housing, saving the
H selected preload washers for later use during the assembly of

/;5
'· Tool
the final drive unit.

PD344

Pinion Gear Height

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion preload shim
selector Tool, xxxxxx.

SPD987

PD-31
 ADJUSTMENT {R230V)
Pinion Gear Height {Cont'd)
3. Place the pinion preload shim selector Tool, xxxxxxx, gauge
screw assembly with the pinion rear bearing inner cone
installed into the final drive housing.

4. Turn the assembly several times to seat the bearings.

SP0770

5. Now, position the side bearing discs, xxxxxxx, and arbor firmly
into the side bearing bores.
Install the side bearing caps and tighten the cap bolts to
proper torque.

6. Select the correct standard pinion height adjusting washer

thickness using a standard gauge of 3 mm (0.12 in) and your
xxxxxxxxx feeler gauge. Measure the distance between the
xxxxxxxx pinion height adapter including the standard gauge
and the arbor.

7. Write down your exact measurement (the value of feeler gauge).

PD-32
 ADJUSTMENT (R230V)
Pinion Gear Height (Cont'd)
8. Correct the pinion height washer size by referring to the "pin-
ion head number."
There are two numbers painted on the pinion gear. The first one
refers to the pinion and ring gear as a matched set and· should
be the same as the number on the ring gear. The second number
is the "pinion head height number," and it refers to the ideal
pinion height from standard for quietest operation. Use the
following chart to determine the correct pinion height washer.

SPD542

Add or remove from the standard

Pinion head height number pinion height washer thickness
measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)

9. Select the correct pinion height washer from the following chart.
Drive pinion height adjusting washer:
Refer to S.O.S.

Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gears which are not positioned properly in relation to one
another may be noisy, or have short life or both. With the checking
of gear tooth contact pattern, the most desirable contact for low
noise level and long life can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered titanium oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

PD-33
 ADJUSTMENT (R230V)
Tooth Contact (Cont'd)
3. Hold companion flange steady by hand and rotate the ring gear
in both directions.

SPD308

Usually the pattern will be correct if you have calculated the shims correctly and the backlash is correct.
However, in rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern.
The tooth pattern is the best indication of how well the final drive has been set up.

Heel contact Face contact Toe contact Flank contact

To correct, increase thickness of pinion

height adjusting washer in order to bring
drive pinion close to ring gear.
~~ To correct, reduce thickness of pinion
height adjusting washer in order to make
drive pinion go away from ring gear.

c........... ~·-/ ~!:::::,

~
~ SPD007

PD-34
 ASSEMBLY

Differential Case
THRUST WASHER SELECTION
Feeler gauge ~ Fee 1er gauge
CD o.o3 co.oo121 ~ CD o.o3 10•00121 Whenever side gears or pinion mate gears are replaced, select
<V 0.10 (0.0039) <V 0.10 (0.0039) suitable thrust washers as follows:
1. Clean side gears and pinion mate gears using white gasoline.
2. Before assembling gears, apply hypoid gear oil to frictional
surfaces.
3. Install the previously removed thrust washer on right side gear.
On left side gear, install a suitable thrust washer.
Temporarily tighten differential cases using two screws.
Unit: mm (in) SPD863
4. Position differential assembly so that right side gear is on the
upper side. Place a 0.03 mm (0.0012 in) feeler gauge (for
example) between right side gear and thrust washer.
Do not insert feeler gauge in oil groove portion of differential
case.
5. Also place a 0.03 mm (0.0012 in) additional feeler gauge
between right side gear and thrust washer so that it is
positioned diagonal to (180° apart from) the feeler gauge
described previously.
6. Rotate right side gear with a suitable tool attached to splines.
If right side gear cannot be rotated, replace thrust washer used
on left side gear with a thinner one.
7. Replace both 0.03 mm (0.0012 in) feeler gauges with 0.10 mm
(0.0039 in) gauges. At this point, make sure right side gear
does not rotate. If it does, replace thrust washer on left side
gear with a thicker one so that right side gear does not rotate.
8. As explained in above example, select suitable thrust washers
to ensure that:
a) Both side gears rotate. [0.03 mm (0.0012 in) feeler gauges are
used in this case.]
b) Side gear is held stationary. [0.10 mm (0.0039 in) feeler gauges
are used in this case.]
(Refer to S.O.S.)

ASSEMBLY
1. Install differential case A and B.

Matching
mark

2. Place differential case on ring gear.

3. Apply locking sealant to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

PD-35
 ASSEMBLY
Differential Case (Cont'd)
4. Press-fit side bearing inner cones on differential case with Tool.
Tool number:
@ KV38100300 (J25523) - R200V-
Tool@ xxxxxxxxxx ( - ) - R230V -
@ ST33061000 (J8107-2) - R200V -
xxxxxxxxxx ( - ) - R230V -

Tool @ PD353

Differential Carrier
Pinion rear 1. Press-fit front and rear bearing outer races with Tools.

outer~r~ac=e.JJ.I=:;:is-""'f'i'"""'"""""~~ ~
Tool number:
bearing ® suitable tool
@ ST30611000 (J25742-1)
@ ST30613000 (J25742-3) - R200V-
xxxxxxxxxx ( - ) - R230V -
2. Select pinion bearing adjusting washer and drive pinion bearing
spacer, referring to ADJUSTMENT.
Pinion front

SPD976

3. Install selected drive p1nron height adjusting washer in drive

pinion, and press-fit pinion rear bearing inner cone in it, using
press and Tool.
Tool number:
ST30901 000 ( ) - R200V-
ST30022000 ( ) - R230V-

4. Place pinion front bearing inner cone in final drive housing.

PD-36
 ASSEMBLY
Differential Carrier (Cont'd)
R200V Drive pinion 5. Set drive pinion assembly (as shown in figure at left) in

Ispace~
differential carrier and install drive pinion, with press and
Pinion bearing adjusting suitable tool.

"''""'"' ~"'1b~
Pinion bearing Stop when drive pinion touches bearing.
Apply multi-purpose grease to pinion rear bearing inner race,
El pinion front bearing inner race and front pilot bearing.

~
~
Pinion front bearing inner race B SPDB 97

R2lOV

Coll•p•lblo •P"l)1
Drive pinion

~-
~ Pinion front bearing inner race B
SPD989

Press.

6. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install front oil seal with Tool.
Tool number:
KV381 00500 ( ) - R200V-
xxxxxxxxxx ( ) - R230V-

SP0557

7. Install companion flange.

- R200V-
Tighten pinion nut to specified torque with Tool.
- R230V-
Tighten pinion nut to 127 N•m (13 kg-m, 94 ft-lb).
Make sure that threaded portion of drive pinion and pinion nut
are free from oil or grease.
Tool number:
ST38060002 (J34311) - R200V -
xxxxxxxxxx ( - ) - R230V -
P0416

PD-37
 ASSEMBLY
Differential Carrier (Cont'd)
8.
- R200V-
Turn drive pinion in both directions several times, and measure
pinion bearing preload.
Pinion bearing preload:
1.1 - 1.4 N·m
(11 - 14 kg-em, 9.5 - 12.2 in-lb}
When pinion bearing preload is outside the specifications, re-
place pinion bearing adjusting washer and spacer with a different
thickness.

- R230V-
Tighten the pinion nut by very small degrees until the specified
preload is achieved. When checking the preload, turn the drive
pinion in both directions several times to set the bearing rollers.
Pinion bearing preload:
1.8 - 2.6 N·m
(18 - 27 kg-em, 16 - 23 in-lb}
This procedure will have to be repeated if:
• Maximum preload is achieved before the minimum pinion nut
torque is reached.
• Minimum preload is not achieved before maximum pinion nut
torque is reached.
9. Install differential case assembly with side bearing outer races
into gear carrier.

SPD919

10. Insert left and right side bearing adjusting washers in place
between side bearings and carrier.

11. Drive in side bearing spacer with Tool.

~-;"' Tool number:
~~' KV38100600 (J25267} - R200V -
xxxxxxxxxx ( - ) - R230V -

SPD559

PD-38
 ASSEMBLY
Differential Carrier (Cont'd)
12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.

13. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install side oil seal.
Tool number:
KV381 00200 (J26233) - R200V -
KV381 02510 ( - ) - R230V -

14. Measure ring gear-to-drive pinion backlash with a dial indicator.

Ring gear-to-drive pinion backlash:
0.10- 0.15 mm
(0.0039 - 0.0059 in)
• If backlash is too small, decrease thickness of left shim and
increase thickness of right shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the
bearing preload.

SPD513

15. Check total preload with Tool.

When checking preload, turn drive pm1on in both directions
several times to seat bearing rollers correctly.
Total preload:
Value more than 0.29 N•m (3.0 kg-em, 2.6 in-lb) added
on measured value of drive pinion preload
• If preload is too great, remove the same amount of shim from
each side.
• If preload is too small, add the same amount of shim to each
side.
Never add or remove a different number of shims for each side
as it will change ring gear-to-drive pinion backlash.
16. Recheck ring gear-to-drive pinion backlash because increase or
decrease in thickness of shims will cause change of ring
gear-to-pinion backlash.

PD-39
 ASSEMBLY
Differential Carrier (Cont'd)
17. Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
• If backlash varies excessively in different places, foreign matter
may be caught between the ring gear and the differential case.
• If the backlash varies greatly when the ring gear runout is
within a specified range, replace the hypoid gear set or
differential case.
18. Check tooth contact.
Refer to ADJUSTMENT.
19. Install rear cover and gasket.

PD-40
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Propeller Shaft
GENERAL SPECIFICATIONS
Vehicle model 2 seater 2+2 seater

Engine VG30DETT VG30DE

Transmission M/T A/T M/T A/T M/T A/T

Propeller shaft model 3S80A-VL 107 3S71A

Number of joints 3

Coupling method with transmission Sleeve type

Shell type
Types of journal bearings (non-disassembly type) x 2, Shell type (non-disassembly type)
CVJ* X 1

Distance between yokes mm (in) 80.0 (3.150) 71.0 (2.795)

Shaft length mm (in)

(Spider to spider)
1st 606 (23.86) 489 (19.25) 606 (23.86) 510 (20.08) 606 (23.86) 510 (20.08)

2nd 388 (15.28) 419 (16.50) 539 (21.22)

Shaft outer diameter mm (in)

1st 82.6 (3.252) 75 (2.95)

2nd 75.2 (2.961) 75 (2.95)

* · Constant velocity joint

INSPECTION AND ADJUSTMENT

Unit: mm (in)

Propeller shaft model 3S71A I 3S80A-VL107

Journal axial play 0 (0)

Propeller shaft ru nout

0.6 (0.024)
limit

PD-41
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Final Drive
GENERAL SPECIFICATIONS Available side bearing adjusting washers
Final drive model R200V R230V Thickness mm (in) Part number

Ring gear pitch diameter 2.00 (0.0787) 38453-N3100

205 (8.07) 230 (9.06)
mm (in) 2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N31 02
Gear ratio 4.083 .3.692 2.15 (0.0846) 38453-N3103
2.20 (0.0866) 38453-N31 04
Number of teeth
49/12 48/13 2.25 (0.0886) 38453-N3105
(Ring gear/Drive pinion)
2.30 (0.0906) 38453-N3106
Oil capacity (approx.) 1.5 1.8 2.35 (0.0925) 38453-N31 07
!1 (US pt, Imp pt) (3-1/8, 2-5/8) (3-7/8, 3-1/8) 2.40 (0.0945) 38453-N3108
2.45 (0.0965) 38453-N31 09
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
INSPECTION AND ADJUSTMENT (R200V)
2.60 (0.1024) 38453-N3112
Ring gear runout 2.65 (0.1 043) 38453-N3133

Ring gear runout limit

0.05 (0.0020)
mm (in)
Drive pinion height adjustment
Available pinion height adjusting washers
Side gear adjustment
Thickness mm (in) Part number
Side gear back lash
(Clearance between side gear 0-0.15 (0- 0.0059) 3.09 (0.1217) 38154-P60 17
and differential case) mm (in) 3.12 (0.1228) 38154-P6018
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020
Available side gear thrust washers 3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022
Thickness mm (in) Part number 3.27 (0.1287) 38154-P6023
0.80 (0.0315) 38424-40F60 3.30 (0.1299) 38154-P6024
0.83 (0.0327) 38424-40F61 3.33 (0.1311) 38154-P6025
0.86 (0.0339) 38424-40F62 3.36 (0.1323) 38154-P6026
0.89 (0.0350) 38424-40F63 3.39 (0.1335) 38154-P6027
0.92 (0.0362) 38424-40F64 3.42 (0.1346) 38154-P6028
0.95 (0.0374) 38424-40F65 3.45 (0.1358) 38154-P6029
0.98 (0.0386) 38424-40F66 3.48 (0.1370) 38154-P6030
1.01 (0.0398) 38424-40F67 3.51 (0.1382) 38154-P6031
1.04 (0.0409) 38424-40F68 3.54 (0.1394) 38154-P6032
1.07 (0.0421) 38424-40F69 3.57 (0.1406) 38154-P6033
1.10 (0.0433) 38424-40F70 3.60 (0.1417) 38154-P6034
1.13 (0.0445) 38424-40F71 3.63 (0.1429) 38154-P6035
1.16 (0.0457) 38424-40F72 3.66 (0.1441) 38154-P6036
1.19 (0.0469) 38424-40F73
1.22 (0.0480) 38424-40F74
1.25 (0.0492) 38424-40F75 Drive pinion preload adjustment
1.28 (0.0504) 38424-40F76
Drive pinion preload with
1.31 (0.0516) 38424-40F77
front oil seal 1.1 -1.4 (11- 14, 9.5 -12.2)
1.34 (0.0528) 38424-40F78
N·m (kg-em, in-lb)
1.37 (0.0539) 38424-40F79
1.40 (0.0551) 38424-40F80
1.43 (0.0563) 38424-40F81
1.46 (0.0575) 38424-40F82
1.49 (0.0587) 38424-40F83

Side bearing adjustment

Side bearing preload measured
34.3-39.2
at ring gear retaining bolt
(3.5 - 4.0, 7.7 - 8.8)
N (kg,lb)

PD-42
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Final Drive (Cont'd)

Available drive pinion bearing preload adjusting washers Available side gear thrust washers
Thickness mm (in) Part number Thickness mm (in) Part number

3.80-3.82 (0.1496- 0.1504) 38125-61001 0.80 (0.0315) 38424-40FOO

3.82- 3.84 (0.1504- 0.1512) 38126-61001 0.85 (0.0335) 38424-40F08
3.84-3.86 (0.1512- 0.1520) 38127 61001 0.90 (0.0354) 38424-40F01
3.86-3.88 (0.1520- 0.1528) 38128-61001 0.95 (0.0374) 38424-40F09.
3.88 - 3.90 (0.1528- 0.1535) 38129-61001 1.00 (0.0394) 38424-40F02
3.90- 3.92 (0.1535- 0.1543) 38130-61001 1.05 (0.0413) 38424-40F10
3.92- 3.94 (0.1543- 0.1551) 38131-61001 1.10 (0.0433) 38424-F4G03
3.94-3.96(0.1551-0.1559) 38132-61001 1.15 (0.0453) 38424-40 F 11
3.96- 3.98 (0.1559- 0.1567) 38133-61001 1.20 (0.0472) 38424-40F04
3.98-4.00 (0.1567- 0.1575) 38134-61001 1.25 (0.0492) 38424-40 F 12
4.00-4.02 (0.1575-0.1583) 38135-61001 1.30 (0.0512) 38424-40F05
4.02 - 4.04 (0.1583 - 0.1591) 38136-61001 1.35 (0.0531) 38424-40F 13
4.04- 4.06 (0.1591 - 0.1598) 38137-61001 1.40 (0.0551) 38424-40F06
4.06 - 4.08 (0.1598 - 0.1606) 38138-61001 1.45 (0.0571) 38424-40F14
4.08-4.10 (0.1606- 0.1614) 38139-61001 1.50 (0.0591) 38424-40F07

Side bearing adjustment

Available drive pinion bearing preload adjusting spacers
Side bearing preload measured
34.3-39.2
Length mm (in) Part number at ring gear retaining bolt
(3.5- 4.0. 7.7- 8.8)
N (kg,lb)
45.60 (1.7953) 38165-10V05
45.90 (1.8071) 38165-10V06
46.20 (1.8189) 38165-10V07 Available side bearing adjusting washers
46.50 (1.8307) 38165-1 ovoo
46.80 (1.8425) 38165-10V01 Thickness mm (in) Part number

2.00 (0.0~87) 38453-40POO

2.05 (0.0807) 38453-40P01
Total preload 2.10 (0.0827) 38453-40P02
2.15 (0.0846) 38453-40P03
Value of more than 38453-40P04
2.20 (0.0866)
0.29 N-m (3.0 kg-em, 2.6 in-lb) 38453 -40P05
Total preload 2.25 (0.0886)
added on to measured value 38453-40P06
2.30 (0.0906)
of drive pinion preload 38453-40P07
2.35 (0.0925)
2.40 (0.0945) 38453-40P08
Ring gear backlash mm(in) 0.10-0.15(0.0039-0.0059)
2.45 (0.0965) 38453-40P09
2.50 (0.0984) .38453-40P10
2.55 (0.1004) 38453-40P11
2.60 (0.1024) 38453 -40P 12

INSPECTION AND ADJUSTMENT (R230V)

Ring gear runout
Ring gear runout limit
0.05 (0.0020)
mm (in)

Side gear adjustment

Side gear backlash
(Clearance between side gear 0-0.15
and differential case) (0- 0.0059)
mm (in)

PD-43
 SERVICE DATA AND SPECIFICATIONS (S.D. S.)
Final Drive (Cont'd)
Drive pinion height adjustment
Available pinion height adjusting washers
Thickness mm {in) Part number

2.59 (0.1020) 38154-40POO

2.61 (0.1028) 38154-40P01
2:63 (0.1035) 38154-40P02
2.65 (0.1043) 38154-40P03
2.67 (0,1051) 38154-40P04
2.69 (0.1059) 38154-40P05
2.71 (0.1067) 38154-40P06
2.73 (0.1075) 38154-40P07
2.75 (0.1083) 38154-40P08
2.77 (0.1091) 38154-40P09
2.79 (0.1098) 38154-40P 10
2.81 (0.1106) 38154-40P 11
2.83 (0.1114) 38154-40P 12
2.85 (0.1122) 38154-40P 13
2.87 (0.1130) 38154-40P14
2.89 (0.1138) 38154-40P 15
2.91 (0.1146) 38154-40P16
2.93 (0.1154) 38154-40P 17
2.95 (0.1161) 38154-40P 18
2.97 (0.1169) 38154-40P 19

Drive pinion preload adjustment

Drive pinion preload with
1.8-2.6
front oil seal
(18 -27,16 -23)
N·m (kg-em, in-lb)

Total preload adjustments

Value of more than
0.29 N·m (3.0 kg-em, 2.6 in-lb)
Total preload
added on to measured value
of drive pinion preload

Ring gear backlash

0.13-0.18 (0.0051- 0.0071)
mm {in)

PD-44
 FRONT AXLE &
FRONT SUSPENSION

SECTION FA
CONTENTS
PRECAUTIONS AND PREPARATION ........................................................................................... FA- 2
FRONT AXLE AND FRONT SUSPENSION .................................................................................. FA- 4
CHECK AND ADJUSTMENT - On-vehicle ................................................................................. FA- 5
FRONT AXLE .................................................................................................................................... FA- 9
FRONT AXLE - Wheel Hub and Steering Knuckle ................................................................ FA-10
FRONT SUSPENSION ...................................................................................................................... FA-14
FRONT SUSPENSION - Coil Spring and Shock Absorber ................................................... FA-15
FRONT SUSPENSION - Third Link and Upper Link .............................................................. FA-17
FRONT SUSPENSION - Transverse Link and Lower Ball Joint ........................................... FA-20
FRONT SUSPENSION - Tension Rod and Stabilizer Bar ..................................................... FA-21
ADJUSTABLE SHOCK ABSORBER .............................................................................................. FA-22
ADJUSTABLE SHOCK ABSORBER - Trouble Diagnoses ..................................................... FA-23
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ....................................................................... FA-29
 PRECAUTIONS AND PREPARATION

Precautions
• When installing each rubber part, final tightening must be
carried out under unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.
• When removing each suspension part, check wheel align-
ment and adjust if necessary.
• Use Tool when removing or installing brake lines.

Preparation
SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

HT72750000 Removing tie-rod outer end and lower

( ) ball joint
Ball joint remover

HT717BOOOO Removing and installing coil spring

( )
Spring comp.ressor

ST35652000 Fixing shock absorber

( )
Shock absorber
attachment

GG94310000 Removing and installing brake piping

( )
Flare nut torque
wrench

ST30031000 Removing bearing inner race

(J22912-0l)
Bearing inner race
puller

FA-2
 PRECAUTIONS AND PREPARATION
Preparation (Cont'd)
COMMERCIAL SERVICE TOOLS

Tool name Description

Wheel bearing drift Removing wheel bearing

J~~f-A=-'!Jm 12.'"'"''""
}_ 8: 37 mm (1.46 in) dia.

Wheel bearing drift Installing wheel bearing

Baffle plate drift Installing baffle plate

A: 125 mm (4.92 in) dia.

B: 106 mm (4.17 in) dia.

Tension rod bushing Removing and installing

drift tension rod bushing

A: 78 mm (3.07 in I dia.
8: 66 mm (2.60 in) dia.
C: 62 mm (2.44 in) dia.
0: 25 ·55 mm (0.98 • 2.17 in) dia.

Grease seal drift Installing wheel hub grease seal

Cap drift Installing king pin cap

Bearing drift Installing king pin lower bearing

Bearing drift Installing king pin upper bearing

A: 57 mm (2.24 in) dia.
B: 46 mm (1.81 in) dia.
C: 40 mm (1.57 in) dia.
0: 2.5 mm (0.098 in)

Grease seal drift Installing king pin grease seal

A: 68 mm (2.68 in) dia.

B: 58 mm (2.28 in) dia.

FA-3
 FRONT AXLE AND FRONT SUSPENSION

/
~toj31·42
(3.2. 4.3, 23. 31)

~A1o8-121
(11 . 13,80. 94)
Shock absorber
mounting insulator
Upper link bracket
Coil spring
~toJ 56-64
(5.7. 6.5, 41 • 47) ~tql88·108
(9.0 -11,65. 80)
Front suspension
member

Shock absorber

~ toJ 108. 127 -----'

(11-13,80-94)

Tension rod bracket

toJ 39. 49 (4.0 . 5.0, 29 . 36) Tension rod

When installing stabilizer bar, tension rod and transverse

link, final tightening must be done with vehicle under
unladen condition*, with tires on the ground.
tql : N·m (kg-m, ft-lb)
*; Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated position.

SFA736A

FA-4
CHECK AND ADJUSTMENT - On-vehicle

Front Axle and Front Suspension Parts

• Check front axle and front suspension parts for looseness,
cracks, wear or other damage.
(1) Shake each front wheel to check for excessive play.

(2) Retighten all nuts and bolts to the specified torque.

Tightening torque: Refer to pages FA-4 and FA-14.
(3) Make sure that cotter pin is inserted.
(4) Check front axle and front suspension parts for wear, cracks
or other damage.

• Check shock absorber for oil leakage or other damage.

• Check suspension lower ball joint and tie-rod ball joint for
grease leakage, and dust cover for cracks or other damage.

FA-5
CHECK AND ADJUSTMENT- On-vehicle
Front Axle and Front Suspension Parts (Cont'd)
• Check spring height from the top of the wheelarch to the
ground.
(1) Vehicle must be unladen*, parked on a level surface, and tires
checked for proper inflation and wear (tread wear indicator
must not be showing).
* Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
(2) Bounce the vehicle up and down several times before meas-
uring. Unit: mm (in)

~
SFA750A Standard

2 seater 2+2 seater

Front (Hf) 675 (26.57) 676 (26.61)

Rear (Hr) 676 (26.61) 675 (26.57)

(3) Spring height is not adjustable. If out of specification, check for

worn springs or suspension parts.

Front Wheel Bearing

• Check tightening torque of wheel bearing lock nut.
(OJ: 206 - 284 N·m
(21 - 29 kg-m, 152 - 210 ft-lb)
• Check wheel bearings for smooth operation.
• Check axial end play.
Axial end play: 0.05 mm (0.0020 in) or less
• If axial end play is not within specification or wheel bearing
does not turn smoothly, replace wheel bearing assembly.
Refer to FRONT AXLE - Wheel Hub and Knuckle.

Front Wheel Alignment

Before checking front wheel alignment, be sure to make a
preliminary inspection.
PRELIMINARY INSPECTION
Make the following checks. Adjust, repair or replace if necessary.
• Check tires for wear and improper inflation.
• Check front wheel bearings for looseness.
• Check wheel runout.
Refer to S.O.S.
• Check front suspension for looseness.
SFA575B • Check steering linkage for looseness.
• Check that front shock absorbers work properly.
• Check vehicle posture (Unladen).
("Unladen": Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.)

FA-6
 CHECK AND ADJUSTMENT - On-vehicle
Front Wheel Alignment (Cont'd.)
CAMBER, CASTER AND KINGPIN INCLINATION
• Camber, caster and kingpin inclination are preset at factory
and cannot be adjusted.
• Measure camber, caster and kingpin inclination of both right
and left wheels with a suitable alignment gauge.
Camber:
-1°35 1 to -0°05'
Caster:
9°00' - 10°30'
Kingpin inclination:
SFA894 12°10 1 - 13°40 1
• If camber, caster and kingpin inclination are not within
specification, inspect and replace any damaged or worn front
suspension parts.

TOE-IN
1. Draw a base line on tread surface of tires.
After lowering front of vehicle, move it up and down to eliminate
friction, and set wheels in straight-ahead position.

SMA123

2. Measure toe-in.
Measure distance "A" and "B" at same height as hub center.
Toe-in:
A- B 0 - 2 mm (0 - 0.08 In)
2 8 (Total toe-in angle) 0' - 11 1

Front
II# 9 Total toe-in angle "' 28
SFA234A

3. Adjust toe-in by varying length of steering tie-rods.

(1) Loosen lock nuts.
(2) Adjust toe-in by turning tie-rod forward or backward.

FA-7
 CHECK AND ADJUSTMENT - On-vehicle
Front Wheel Alignment (Cont'd)
Make sure both tie-rods are the same length.
Standard length "L":
155 mm (6.10 In)
(3) Tighten lock nuts to the specified torque.
rPJ: 78 - 98 N·m
(8.0 - 10.0 kg-m, 58 - 72 ft-lb)

SFA545A

FRONT WHEEL TURNING ANGLE

1. Set wheels in straight-ahead position and then move vehicle
forward until front wheels rest on turning radius gauge properly.

2. Rotate steering wheel fully to the right or left; measure turning

angle.
Wheel turning angle:
t
Front Full turn
Inside wheel: A

Outside wheel: B
A: Inside
8: Outside

SFA898

FA-8
 FRONT AXLE

Buffle plate

Wheel bearing ~ lEI

Snap ring

(Models without A.B.S.)

Wheel hub
toJ : N·m (kg-m, ft-lb)

SFA743A

FA-9
FRONT AXLE - Wheei Hub and Steering Knuckle

Removal
CAUTION:
Wheel bearing usually does not require maintenance. If any of
the following symptoms are noted, replace wheel bearing as-
sembly.
• Growling noise is emitted from wheel bearing during opera-
tion.
• Wheel bearing drags or turns roughly when hub is turned by
hand.
• Remove brake caliper assembly and rotor.
Brake line need not be disconnected from brake caliper. Be
careful not to depress brake pedal, or piston will pop out.
Make sure brake line is not twisted.

• Remove tie-rod ball joint and lower ball joint with Tool.
CAUTION:
Steering knuckle is made from aluminum alloy.
Be careful not to hit steering knuckle.

• Remove kingpin lower nut then remove steering knuckle as-

sembly.

Installation
e Install steering knuckle assembly.
• Apply anti-rust wax as follows:
• Portions around lower ball joint connections
• Portions around tie-rod ball joint connections
• Portions around kingpin lower nut location
• Portions around A.B.S. sensor connection

FA-10
 FRONT AXLE - Wheel Hub and Steering Knuckle

Disassembly
CAUTION:
When removing wheel bearing from steering knuckle, replace
wheel bearing assembly (outer race, inner races and grease seal)
with a new one.

• Remove hub cap and wheel bearing lock nut.

SFA744A

• Remove wheel hub with a suitable tool.

• Remove circular clip with a suitable tool.

•
Press • Press out wheel bearing assembly from steering knuckle.

FA-11
FRONT AXLE - Wheel Hub and Steering Knuckle
Disassembly (Cont'd)
• Drive out wheel bearing inner race (to outside) from wheel hub,
then remove grease seal.

Inspection
WHEEL HUB AND STEERING KNUCKLE
• Check wheel hub and steering knuckle for any cracks.
CIRCULAR CLIP
• Check circular clip for wear or cracks.
Replace if necessary.

Assembly
1.Press new wheel bearing assembly into steering knuckle from
outside of steering knuckle.
Maximum load P:
34.3 kN (3.5 t, 3.9 US ton, 3.44 Imp ton)
CAUTION:
• Do not press inner race of wheel bearing assembly.
• Do not apply oil or grease to mating surfaces of wheel
bearing outer race and wheel hub.

2. Install circular clip into groove of steering knuckle.

3. Apply multi-purpose grease to sealing lip.

4. Install grease seal.
Maximum load P:
10 kN (1 t, 1.1 US ton, 1.0 Imp ton)
5. Install splash guard.

FA-12
FRONT AXLE - Wheel Hub and Steering Knuckle
Assembly (Cont'd)
6. Press wheel hub into steering knuckle.
Maximum load P:
29 kN (3 t, 3.3 US ton, 3.0 Imp ton)
7. Tighten wheel bearing lock nut to the specified torque.
toJ : 206 - 284 N·m (21 - 29 kg-m, 152 - 210 ft-lb)

SFA757A

8. Stake wheel bearing lock nut.

9. Install hub cap.

Drive hub cap onto steering knuckle by lightly tapping with a
plastic hammer. After hub cap is in close contact with steering
knuckle, tighten bolts.

SFA759A

10. Check wheel bearing preload and axial end play.

Before checking, spin wheel hub at least 10 revolutions in both
directions.
Turning torque:
0.34 - 2.16 N·m (3.5 - 22.0 kg-em, 3.0 - 19.1 in-lb)
(NSK bearing)
0.44 - 3.33 N·m (4.5 - 34.0 kg-em, 3.9 - 29.5 in-lb)
(NTN bearing)
As measured at wheel hub bolt:
5.9 - 37.3 N (0.6 - 3.8 kg, 1.3 - 8.4 lb)
(NSK bearing)
7.8 - 57.9 N (0.8 - 5.9 kg, 1.8 - 13.0 lb)
(NTN bearing)
Axial end play:
0.05 mm (0.0020 in) or less

FA-13
 FRONT SUSPENSION

Oust cover
~toJ 31· 42
(3.2. 4.3, 23. 31)~
~~·34-44
(3.5. 4.5. 25. 33)~ ~

Gasket""""""-..~~
~~
Upper link bracket
Upper plate !

Bushing~

Upper mounting~
insulator ~
Upper link
~~~er·rubber~T j Third link
~~88-108
(9.0 ·11,
65 ·80)
Shock absorber assembly
,.~~;:98-118
~ (10-12,
~ 72-87)
_y Upper bearing ~
~~ 98-118
(10-12,;\
72 -87)
Nut cap iTIJ @
~~ 56-64
(5.7. 6.5,
41. 47)

~~ 88-108
(9.0 -11,
65-80)

Wheel hub and

steering knuckle
assembly

Transverse link
with ball joint

Tension rod Tension rod ~~108·127

bracket (11. 13,
80-94)
Tension rod bushing ~

Final tightening for rubber parts must be done under ~: N·m (kg·m, ft·lb)
unladen condition*, with tires on ground.
* Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats in designated positions.
SFA761A

FA-14
FRONT SUSPENSION - Coil Spring and Shock Absorber

Removal
• Remove shock absorber fixing bolt and nut (to hoodledge).
• Do not remove piston rod lock nut.

Disassembly
1. Set shock absorber on vise with Tool, then loosen piston rod
lock nut.
• Do not remove piston rod lock nut.

2. Compress spring with Tool so that shock absorber mounting

insulator can be turned by hand.

3. Remove piston rod lock nut.

SFA765A

Inspection
SHOCK ABSORBER ASSEMBLY
• Check for smooth operation through a full stroke, both com-
pression and extension.
• Check for oil leakage occuring on welded or gland packing
portions.
• Check piston rod for cracks, deformation or other damage.
Replace if necessary.

FA-15
 FRONT SUSPENSION -·Coil Spring and Shock Absorber
Inspection (Cont'd)
MOUNTING INSULATOR AND RUBBER PARTS
• Check cemented rubber-to-metal portion for separation or
cracks. Check rubber parts for deterioration.
Replace if necessary.
COIL SPRING
• Check for cracks, deformation or other damage. Replace if
necessary.

Assembly

m
.
I
I
.
• When installing coil spring, be careful not to reverse top and
bottom direction. (Top end is flat.)

~ Bottom SRA247A

• When installing coil spring on shock absorber, it must be

Upper end
positioned as shown in figure at left.

~
=r-- Lowe""'
SRA248A

FA-16
FRONT SUSPENSION - Third Link and Upper Link

Removal
CAUTION:
Kingpin bearing usually does not require maintenance. If any of
the following symptoms are noted, replace kingpin bearing
assembly.
• Growling noise is emitted from kingpin bearing during oper-
ation.
• Kingpin bearing drags or turns roughly when steering knuckle
is turned by hand.

1. Remove cap and kingpin upper nut.

• Do not remove kingpin lower nut.
2. Remove shock absorber fixing nut and upper link fixing bolts.
3. Remove third link and upper link.

SFA720A

Installation
THIRD LINK
• Pack kingpin housing and cap with multi-purpose grease.
Grease capacity:
Kingpin housing 10 g (0.35 oz)
Cap 5 g (0.18 oz)

SFA727A

• Install third link and cap.

SFA728A

FA-17
 FRONT SUSPENSION -Third Link and Upper Link
Installation (Cont'd)
UPPER LINK
• Upper link has characters "A" and "L" (or "R") on it as shown.
Always install upper link with "A" side facing axle and side
without a character facing vehicle body.
Upper link bushings cannot be disassembled.

SFA859A

Disassembly
• Remove upper bearing (inner race and ball).

Upper bearing

SFA721 A

• Remove kingpin grease seal.

• Remove lower bearing (inner race and ball).

Lower bearing

• Remove upper and lower outer race.

• Be careful not to damage kingpin housing.

Outer race
Kingpin housing

Outer race

SFA723A

Press Assembly
• Install lower bearing.

SFA724A

FA-18
 FRONT SUSPENSION -Third Link and Upper Link
Assembly (Cont'd)
• Install upper bearing.

Press • Install lower oil seal.

• Apply multi-purpose grease to oil seal lip.

Kingpin
grease seal

SFA726A

FA-19
 FRONT SUSPENSION - Transverse Link and Lower Ball Joint

Removal and Installation

• Remove tension rod, ball joint and transverse link assembly.
• During installation, final tightening must be done at curb weight
with tires on ground.
• After installation, check wheel alignment.
Refer to "Front Wheel Alignment" of CHECK AND ADJUST-
MENT - On-vehicle.

Inspection
TRANSVERSE LINK
• Check transverse link for damage, cracks or deformation.
Replace it if necessary.
• Check rubber bushing for damage, cracks and deformation.
Replace transverse link if necessary.

LOWER BALL JOINT

Measuring swing force
• Check ball joint for play. If ball stud is worn, play in axial
direction is excessive or joint is hard to swing, replace
transverse link assembly.
Swing force and turning torque
Before checking, turn ball joint at least 10 revolutions so that ball
joint is properly broken in.
Swing force:
Cotter pin hole
(measuring point: cotter pin hole of ball stud)
7.8 - 53.0 N (0.8 - 5.4 kg, 1.8 - 11.9 lb)
SFA756 Turning torque:
0.49 - 3.43 N•m (5.0 - 35 kg-em, 4.3 - 30.4 in-lb)
Measuring turning torque

SFA757

Vertical end play (On-vehicle)

(1) Jack up front of vehicle and set the stands.
(2) Clamp dial indicator onto transverse link and place indicator tip
on lower edge of brake caliper.
(3) Make sure front wheels are straight and brake pedal is
depressed.
(4) Place a pry bar between transverse link and inner rim of road
wheel.
(5) While pushing and releasing pry bar, observe maximum dial
indicator value.
Vertical end play: 0 mm (0 in)
(6) If not to above specification, replace transverse link.

FA-20
 FRONT SUSPENSION - Tension Rod and Stabilizer Bar

Removal and Installation

• Remove tension rod and stabilizer bar.

• When removing tension rod bushing, place one drift on lower

side of bushing and the other on upper side, and press
bushing out.
• Place arrow mark on bushing facing tension rod before install-
ing bushing.

SFA767A

Front • When installing stabilizer, make sure that paint mark and clamp
face in the correct direction.

Front

SFA769A

FA-21
 ADJUSTABLE SHOCK ABSORBER

toJ 3. 4 (0.3. 0.4, 2.2. 2.9)-------

Shock absorber actuator~~

~A19-25t1.9-2.s,14-19)~~
Actuator bracket
Dust cover

A 34. 44 t3.5. 4.5, 25. 331 _ _,

~toJ 31-42 (3.2-4.3,23-31)~ -~

9
Gasket~~
. ~
I
Upper plate~

Bushing e
Upper mounting insulator~
Upper rubber seat~ j

Adjustable shock absorber

assembly

~toJ 98-118
(10 -12,72. 87) ~@
toJ: N·m (kg-m, ft-lb)
SFA792A

Removal and Installation

• Disconnect sub-harness connector.
• Remove shock absorber actuator fixing bolts.

• Before installing actuator, ensure shock absorber control rod

is aligned with actuator output shaft.
Otherwise, actuator may be damaged.
• Refer to FRONT SUSPENSION for other procedures.

Inspection
• Replace shock absorber assembly if it is damaged.
Refer to FRONT SUSPENSION - Coil Spring and Shock
Absorber.

FA-22
 ADJUSTABLE SHOCK ABSORBER -Trouble Diagnoses

Component Parts and Harness Connector

Location

~Front

Parking brake switch

Front shock absorber actuator Select switch SFA794A

Circuit Diagram for Quick Pinpoint Check

I IGNITION SWITCH
ON or START
FUSE@

FRONT SHOCK
6 (2) ABSORilERACTIJATOR

·~a-
2
SHOCK ABSORBER
SELECT SWITCH ®
6 .II ••• J
3
<@ .......... SPORT
-=- 0 0 R.H.
6
6
I <D 1
@ID®
-- EMEe ADJUSTABLE
SHOCK
ABSORBER
®
6
(.3) g
'DIODE CONTilOl L.H.
UNIT
@ID®

: . .,aJ
PARKING BRAKE REAR SHOCK
SWITCH
(i) ASSORBER ACTIJATOR
=G) 8
-1 me 7 .lT
~ I
R.H.
F101n BRAKE wwning lamp
® ,fihl, ®
®
5 (6) .1~
(1) II :11

LH .
-'-- •
SFA795A

FA-23
 SHOCK ABSORBER
~UNIT

I!IW!·m ,..
FUSE BLOCK cc..
(Refer to "POWER SUPPLY
ROUTING" in El section.) ~@) c
~" »<!!! .. en
lr~~=S~=-~ ~7
g:
;m
L=:r= ISA BR

,___ r
m
(/)

:J 1:~~~ ~~
%
0
0
II '
@) (§) @)
REAR SHOCK
ABSORBER
ACTUATOR R.H.
·~
:::!.
::s
,.."
~:§3~1
CD
(Body co (/)
~
harness)
(Body
c 0
I
harness
No.2) i" ::D
N CD
~ ...
co
m
m
::D

~~
3
From brake warning lamp ~
I
@ .
@§)
sa @
-o:1 @2) t @j) REAR SHOCK ...
-t
0
1-1 1 IT l~@a v~Puffi eEP!v v:au:8 Ill DIODi ABSORBER
ACTUATOR l.H. c
C"
wmsa-1---.....J iD
c
SHOCK ABSORBER
SELECT SWITCH
@.....,~-
Y.f'U-[]]~ i"
PARKiNG -::c
cc::s
BRAKE
SWITCH 0
en
@@_@ @,(S,@
~~
CD
en

BODY GROUND BODY GROUND

.,
(II

-
)>
0
-..J
Ill
 ADJUSTABLE SHOCK ABSORBER - Trouble Diagnoses

m Diagnostic Procedure

( START

m
Engage parking brake and chock
all four wheels.

No Repair or replace parking brake

SAT597
CHECK PARKING BRAKE
WARNING LAMP. switch, warning lamp or
1) Set shift lever to "P" (A/T harness.

®go
model) or "N" (M/T model).
2) Set select switch to
"TOURING".
3) Start engine.
TOURING
4) Check that parking brake
warning lamp comes on when
engine starts.

Yes

SFA819A

CHECK SWITCHING OF Damping force

SHOCK ABSORBER ofall shock
ACTUATOR. absorber does
• Release and engage parking not change.
brake.
• Push down on body above
each wheel with your hand
1
CHECK CONNECTOR
to check damping force of
CONTINUITY.
shock absorber.
Disconnect control unit and
• Release parking brake. Push
SFA797A select switch connectors and
down on body above each
reconnect them firmly.
wheel to check if damping
force of shock absorber
changes.

Damping force of one

or more shock absorbers
changes.

CHECK SWITCHING OF
~-----------+'@
SHOCK ABSORBER Damping force of all shock
SFA835A
ACTUATOR. absorbers does not change.
• Release parking brake.
• Move select switch from
"TOURING" to "SPORT". ~-----•'©
• Push down on body above Damping force of some
each wheel with your hand shock absorbers does not
to see if damping force of change.
each shock absorber changes.

Damping force of all shock

absorbers changes.

SFA797A (~_ _ _ _ _E_N_D_ _ _ ___,)

FA-25
ADJUSTABLE SHOCK ABSORBER -Trouble Diagnoses
Diagnostic Procedure (Cont'd)

li
CHECK CONTROL UNIT
i 12V are indicated regardless of
parking brake lever position.
INPUT SIGNAL.
Check control unit input signal
+
Repair or replace harness
at terminal CD. between control unit and
• Set select switch to parking brake switch.

-=- SFASOOA
..,.....
"TOURING".
• Parking brake lever:

Approx. 12V
...
Engaged ... OV
} O.K.
OV are indicated regardless
of parking lever position.

-
_l_o.K.
[!I Ill
CHECK CONTROL UNIT CHECK SELECT SWITCH
POWER SUPPLY. CONTINUITY.
1) Turn ignition switch "ON". 1) Disconnect select switch
2) Measure voltage across connector.
control unit terminals IGN 2) Check continuity between
and ground. select switch terminal G)
-= SFA799A
Voltage: and GND.
Approximately 12V Continuity should exist.
... O.K.
O.K. lN.G.
~O.K. N.G.
Replace
Replace select switch.
control unit. I
Repair or replace harness
Check and repair fuse and
between control unit and
power supply harness.
parking brake switch.
SFA820A

Ill T N.G.J
CHECK SELECT SWITCH
CONTINUITY.
L Replace select switch. I
1) Disconnect select switch
connector.
2) Check continuiW between
select switch terminal ·CD
and GND.
Continuity should exist.

! O.K.

Repair or replace harness

between control unit and
select switch.

FA-26
 ADJUSTABLE SHOCK ABSORBER -Trouble Diagnoses
Diagnostic Procedure (Cont'd)

~::,;oo
@ output shaft
D
CHECK ACTUATOR.
l Rubbing noise
is emitted from
actuator.
~~ Replace actuator.
Remove actuator from shock
absorber (for those shock

·~-·
absorbers in which damping
Output shaft
force does not change). Switch
rotates.
select switch to check if @
actuator output shaft rotates.
SFA798A "SPORT"

Control unit
"TOURING"

Actuator IJ
1 Output shaft
does not rotate.
harness
harness connector Interchange left and right Yes Old actuator malfunctions.
connector
actuators and check that
output shafts rotate.
Replace. I
II l No
N.G. Repair or replace harness
CHECK HARNESS
CONTINUITY BETWEEN between control unit and
CONTROL UNIT AND actuator.
SFA821A ACTUATOR.
1) Disconnect control unit
II connector and actuator
connector.
2) Check continuity between
control unit harness
connector terminals and
corresponding terminals of
actuator harness connector.
Continuity should exist.

SFA797A
i O.K.

Replace control unit.

Visually check bracket Replace bracket.

for deformities.
O.K.
II
N.G . ..J Replace shock absorber.
CHECK SWITCHING OF 1
SHOCK ABSORBER L-----------------------~
ACTUATOR.
After checking that output
shafts rotate with left and right
actuators interchanged, install
actuator on shock absorber for
which damping force does not
change, and check that damp-
ing force changes properly.
O.K.
Old actuator malfunctions.
Replace.

FA-27
ADJUSTABLE SHOCK ABSORBER -Trouble Diagnoses
Diagnostic Procedure (Cont'd)
CONTROL AND OPERATION OF SHOCK ABSORBER
DAMPING FORCE

~ TOURING SPORT

Parking brake lever released Soft Firm

Parking brake lever engaged Firm Firm

CONTROL UNIT INSPECTION TABLE

Terminal No. Connected to Standard value

CD Select switch OV ("SPORT"); 12V ("TOUR- *1

and parking lNG")
brake switch OV (parking brake lever released); *2
12V (parking brake lever engaged)

® Front actuator When select signal is emitted, 12V * 1

"Firm" (approx.) instantaneously drops
to2-3V.

® Front actuator When select signal is emitted, 12V * 1

"Soft" (approx.) instantaneously drops
to 2 · 3V.

® GND ov

® IGN Approx. 12V

(j) Rear actuator When select signal is emitted, 12v*1

"Firm" (approx.) instantaneously drops
to 2 · 3V.

® Rear actuator When select signal is emitted, 12V * 1

"Soft" (approx.) instantaneously drops
to 2 · 3V.

* 1: Measure with parking brake released.

*2: Measure with select switch set to "TOURING".

FA-28
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications
COIL SPRING

~
VG30DE
VG30DETT
It 2 seater 2+2 seater

Wire diameter mm (in) 12.1 (0.476) 11.9 (0.469) 12.1 (0.476)

Coil diameter mm (in) 100.1 (3.94) 99.9 (3.933) 100.1 (3.94)

Free length mm (in) 360 (14.17) 370 (14.57)

Spring constant N/mm (kg/mm, lb/in) 29.4 (3.0, 168) 27.5 (2.8, 157) 29.4 (3.0, 168)

Identification color Light blue x 1, Pink x 1 Light blue x 2 Light blue x 1, Orange x 2

SHOCK ABSORBER

lte ~· VG30DE VG30DETT

Shock absorber type Double acting gas type

Piston rod diameter mm (in) 12.5 (0.492) 14.0 (0.551)

Inner cylinder bore diameter mm (in) 25.0 (0.984) 30.0 (1.181)

Damping force
[at 0.3 m (1.0 ft)/sec.) Firm Soft
N (kg, lb)

1'177 - 1,569 1,608 - 2,118 1,138-1,510

Expansion
(120- 160,265- 353) (164- 216,362- 476) (116- 154, 256- 340)

559-814 1,138-1,608 686-981

Compression
(57- 83, 126- 183) (116- 164, 256- 362) (70- 100, 154- 221)

FRONT STABILIZER BAR TENSION ROD

I~
Stabilizer diameter mm (in) 27.2 ( 1.071)
VG30DE VG30DETT
Identification color White

Rod diameter mm (in) 20.0 (0.787)

FA-29
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Inspection and Adjustment

WHEEL ALIGNMENT (Unladen*1) LOWER BALL JOINT

Camber degree -1°35' to -o·o5' Swing force
(Measuring point: cotter pin
Caster degree 9•oo·- 1o•3o· hole of ball stud)
7.8-53.0
Toe-in (Total) N (kg,lb)
(0.8- 5.4, 1.8- 11.9)
mm (in) 0- 2 (0- 0.08)
Turning torque
degree 0'- 11'
0.49-3.43
N-m (kg-em, in-lb)
Kingpin inclination degree 12°10'- 13°40' (5.0- 35, 4.3- 30.4)

Vertical end play

Front wheel turning angle
mm(in) 0 (0)
Full turn*2
degree
inside/outside

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.
*2: On power steering models, wheel turning force (at circum- WHEEL RUNOUT (Radial and lateral)
ference of steering wheel) of 98 to 147 N (1 0 to 15 kg,
22 to 33"1b) with engine idle. Wheel type Radial runout Lateral runout

Aluminum wheel
0.3 (0.012) or less
mm (in)
WHEEL BEARING
Wheel bearing axial end play
0.05 (0.0020) or less
mm (in)
WHEELARCH HEIGHT
Wheel bearing lock nut Unit: mm (in)
Tightening torque 206-284 (21- 29, 152- 210)

~
N·m (kg-m, ft-lb) Standard

2 seater 2+2 seater

Wheel bearing turning resistance
N·m (kg-em, in-lb)
0.34-2.16 Front (Hf) 675 (26.57) 676 (26.61)
NSK bearing
(3.5- 22.0, 3.0- 19.1)
Rear (Hr) 676 (26.61) 675 (26.57)
0.44-3.33
NTN bearing
(4.5- 34.0, 3.9- 29.5)

At wheel hub bolt

N (kg,lb)
NSK bearing 5.9- 37.3 (0.6- 3.8, 1.3- 8.4)

NTN bearing 7.8-57.9 (0.8- 5.9,1.8 -13.0)

SFA750A

FA-30
 REAR AXLE I
REAR SUSPENSION

SECTIONRA

CONTENTS
PRECAUTIONS AND PREPARATION ........................................................................................... RA- 2
REAR AXLE AND REAR SUSPENSION ...................................................................................... RA- 4
CHECK AND ADJUSTMENT - On-vehicle ................................................................................ RA- 5
REAR AXLE AND REAR SUSPENSION ASSEMBLY ............................................................... RA- 8
REAR AXLE - Wheel Hub and Axle Housing ...... .. ... .. ........... ................ ... ... ............. ............. RA- 9
REAR AXLE - Drive Shaft .......................................................................................................... RA-13
REAR SUSPENSION ....... .. .... .. ... ......... ... ..... ....... ... ... ... ... .. .......... ... ...... ... ... .. .. .. ....... .. ... ... ... ..... .. ........ RA-18
REAR SUSPENSION - Coil Spring and Shock Absorber ..................................................... RA-19
REAR SUSPENSION - Multi-link and Lower Ball Joint ......................................................... RA-21
REAR SUSPENSION - Stabilizer Bar ........................................................................................ RA-22
ADJUSTABLE SHOCK ABSORBER ... ... ... .. ... .. .... .. .. ......... .. ...... ... .. ...... ............. ... .. ... .. .... ... .. .. ........ RA-23
SUPER HI CAS ........ .. ... ... ......... .... ........ ... .. ... ... .. .. .. .... ... ... .. ... .. ......... .. ... ... ..... ..... ...... ... .. .. .... ..... ...... ... . RA-25
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ...................................................................... RA-27
 PRECAUTIONS AND PREPARATION

Precautions
• When installing each rubber part, final tightening must be
carried out under unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools, and mats in designated positions.
• Use Tool when removing or installing brake lines.
• When removing each suspension part, check wheel alignment
and adjust if necessary.
GG94310000
I I • Do not jack up at the lower arm.

SBRSOO

Preparation
SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

HT71780000 Removing and installing coil spring

( )
Spring compressor

ST35652000 Fixing strut assembly

( )
Shock absorber
attachment

GG94310000 Removing and installing brake piping

( )
Flare nut torque
wrench

ST30031000 Removing inner race of wheel bearing

(J22912-01)
Bearing puller

ST38280000 Removing and installing bushing

( ) of rear axle housing
Arm bushing remover

IM23600800 Measure rear wheel alignment

( ) A: scr- M24 X 1.5
Attachment 8: 35 (1.38) dia.
C: 65 (2.56) dia.
Wheel alignment D: 56 (2.20)
E: 12 (0.47) Unit: mm lin)

RA-2
 PRECAUTIONS AND PREPARATION
Preparation (Cont'd)
COMMERCIAL SERVICE TOOLS

Tool name Description

Rear wheel hub drift Installing wheel bearing

A: 41 mm (1.61 in) dia.
8: 49 mm (1.93 in) dia.

Wheel bearing drift Removing rear wheel hub

A: 26 mm (1.02 in) dia.

8: 40 mm (1.67 in) dia.

Rear drive shaft plug Installing rear drive shaft plug seal
seal drift
A: 67 mm (2.64 in) dia.
8: 85 mm (3.35 in) dia.

Rear axle Removing ball joint

housing ball
joint drift A: 20 (0.791 dia.
8: 28 (1.10) dia.
C: 40 ( 1.571 dia.
0: 43 (1.69) dia.

Unit: mm (in)

Rear axle Installing ball joint

housing ball
joint drift A: 33 (1.301 dia.
8: 43 (1.69) dia.
C: 30 (1.181 dia.
0: 40 (1.57) dia.

Unit: mm (in)

RA-3
 REAR AXLE AND REAR SUSPENSION

Final tightening for rubber parts must be done

under unladen condition•, with tires on ground.
• Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats in designated positons.

Spring upper seat

~~16 -19
(1.6 - 1.9, 12- 14)

~~69-88
(7 .0 - 9.0, 51 - 65)
Lower link ~~n-98
(7.9- 10.0,
57. 72)
~77-98
(7.9 - 10.0,
57. 72)

I
~

L~
I "I:"!]~,;.'_'~... ,. -
25 _ 32
87J
Suspension member
(2.6 - 3.3, 19 - 24)
Dynamic damper assembly
(All non-turbo models except ~~77-98
A/T 2+2 seater models) (7.9 - 10.0, 57 - 72)

~ : N•m (kg-m, ft-lb)

SRA220A

RA-4
CHECK AND ADJUSTMENT - On-vehicle

Rear Axle and Rear Suspension Parts

Check axle and suspension parts for looseness, wear or damage.
• Shake each rear wheel to check for excessive play.

• Retighten all nuts and bolts to the specified torque.

Tightening torque:
Refer to pages RA-4 and RA-18.
• Make sure that cotter pin is inserted.
• Check rear axle and rear suspension parts for wear, cracks or
other damage.

• Check shock absorber for oil leakage or other damage.

• Check wheelarch height. Refer to section FA.

• Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage.

RA-5
 CHECK AND ADJUSTMENT - On-vehicle

Rear Wheel Bearing

• Check tightening torque of wheel bearing lock nut.
to.J: 206 - 275 N·m
(21 - 28 kg-m, 152 - 203 ft-lb)
• Check wheel bearings for smooth operation.
• Check axial end play.
Axial end play:
0.05 mm (0.0020 in) or less
If axial end play is not within specification or wheel bearing does
not turn smoothly, replace wheel bearing assembly.
SRA227A
Refer to REAR AXLE - Wheel Hub and Axle Housing.
Rear Wheel Alignment
Before checking rear wheel alignment, be sure to make a prelimi-
nary inspection.
PRELIMINARY INSPECTION
Make the following checks. Adjust, repair or replace if necessary.
• Check tires for wear and for improper inflation.
Inside • Check rear wheel bearings for looseness.
• Check wheel runout.
Refer to S.O.S.
• Check that rear shock absorber works properly.
SFA575B
• Check rear axle and rear suspension parts for looseness.
• Check vehicle posture (Unladen).
("Unladen": Fuel tank, radiator and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.)

CAMBER
.
Attachment ------ • Measure camber of both right and left wheels with a
suitable alignment gauge and adjust In accordance with

-------- the following procedures.

SRA096A

Camber:
-1°36' to -0°36'

RA-6
 CHECK AND ADJUSTMENT - On-vehicle
Rear Wheel Alignment (Cont'd)
If camber is not within specification, adjust by turning the
adjusting pin.
(1) Turn the adjusting pin to adjust.
Camber changes about 5 1 with each graduation of the
adjusting pin.
(2) Tighten to the specified torque.
toJ: 69 - 88 N·m
(7.0 - 9.0 kg-m, 51 - 65 ft-lb)

SRA098A

TOE-IN
1. Draw a base line across the tread.
After lowering rear of vehicle, move it up and down to
eliminate friction.

SMA123

2. Measure toe-in.
Measure distance "A" and "8" at the same height as hub center.
Toe-in:
A-8
0 - 4 mm (0 - 0.16 in)
2 (} (Total toe-in angle)
01 - 23 1

Front
Toe-in= A- B
It# 6 Total toe-in angle= 26
SFA234A

3. Adjust toe-in by turning adjusting pins.

Toe changes about 1.5 mm (0.059 in) [One side] with each
graduation of the adjusting pin.
4. Tighten to the specified torque.
toJ: 69 - 88 N·m
(7.0 - 9.0 kg-m, 51 - 65 ft-lb)

Drive Shaft
Check boot and drive shaft for cracks, wear, damage or grease
leakage.

SRA796

RA-7
REAR AXLE AND REAR SUSPENSION ASSEMBLY

Removal and Installation

• Remove exhaust tube.

• Disconnect propeller shaft rear end.
• Disconnect hand brake wire front end.

• Remove brake caliper assembly.

Brake line need not be disconnected from brake caliper.
Be careful not to depress brake pedal, or piston will pop out.
Make sure brake line is not twisted.

• Remove upper end nuts of shock absorber.

Do not remove piston rod lock nut.
• Remove suspension member fixing nuts. Then draw out rear
axle and rear suspension assembly.

RA-8
 REAR AXLE -Wheel Hub and Axle Housing

Wheel bearing lock nut Insulator~ Adjusting cap

A 2os- 275 121 - 2s. 152 - 2o31\

.,. ;"' ~ I@_~ ~

I

~fl.-}
Drive shaft ~

Wheel bearing with flange~ ---------- -..j

'

A : N·m (kg-m, ft-lb)

SRA296A

Removal
• Remove wheel bearing lock nut.

• Remove brake caliper assembly and rotor.

Brake line need not be disconnected from brake caliper. Be
careful not to depress brake pedal, or piston will pop out.
Make sure brake line is not twisted.

SFA110A

RA-9
REAR AXLE -Wheel Hub and Axle Housing
Removal (Cont'd)
• Separate drive shaft from axle housing by slightly tapping it.
When removing drive shaft, cover boots with waste cloth to
prevent them from being damaged.

• Remove axle housing.

• Remove wheel bearing with flange, and wheel hub from axle
housing.

Installation
• Install axle housing with wheel hub.
• Tighten wheel bearing lock nut.
to.J: 206 - 275 N·m
(21 - 28 kg-m, 152 - 203 ft-lb)

SRA226A

• Check wheel bearing axial end play.

Axial end play: 0.05 mm (0.0020 In) or less

SRA227A

RA-10
 REAR AXLE -Wheel Hub and Axle Housing

Disassembly
CAUTION:
Wheel bearing with flange usually does not require mainte-
nance. If any of the following symptoms are noted, replace
wheel bearing assembly (including flange, and inner and outer
seals).
• Growling noise is emitted from wheel bearing during
operation.
• Wheel bearing drags or turns roughly when hub is turned
with your hand after bearing lock nut is tightened to
specified torque.
• After wheel bearing is removed from hub.
WHEEL HUB
• Remove wheel bearing (with flange) and wheel hub as one
unit from axle housing before disassembling.

WHEEL BEARING

•
Press
• Using a press and drift as shown in figure at left, press
wheel bearing out.
• Discard old wheel bearing assembly. Replace with a new
wheel assembly.

SRA229A

• Remove inner race from hub using a bearing replacer/puller.

CAUTION:
a. Do not reuse old inner race although it is of the same
ST30031000
brand as the bearing assembly.
(J22912.{)1) b. Do not replace grease seals as single parts.

SRA110A

AXLE HOUSING
• Attach a drift on outer shell of bushing as shown in figure at
left, remove bushing using arm bushing remover.
ST38280000 When placing axle housing in a vise, use wooden blocks or
( )
copper plates as pads.
( Axle housing

Drift

SRA111A

RA-11
 REAR AXLE - Wheel Hub and Axle Housing
Disassembly (Cont'd)
• Ensure axle housing bore is free from scratches or de-
formities before pressing bushing into it.
• Attach bushing to chamfered bore end of axle housing and
press it until it is flush with end face of axle housing.

• When installing shock absorber bushing, make sure that it is

positioned as shown.

SRA241A

Inspection
WHEEL HUB AND AXLE HOUSING
• Check wheel hub and axle housing for cracks by using a
magnetic exploration or dyeing test.
• Check wheel bearing for damage, seizure, rust or rough
operation.
• Check rubber bushing for wear or other damage.
Replace if necessary.

Press
Assembly
Drift
• Place hub on a block. Attach a drift to inner race of wheel
bearing and press it into hub as shown in figure at left.
Be careful not to damage grease seal.

Drift

SRA239A

RA-12
 REAR AXLE - Drive Shaft

~ : N·m (kg-m, ft-lb)

SRA230A

Removal
When removing drive shaft, cover boots with waste cloth to
prevent damage to them.

FINAL DRIVE SIDE

• Remove side flange mounting bolt and separate shaft.

WHEEL SIDE
• Remove drive shaft by lightly tapping it with a copper
hammer.
To avoid damaging threads of drive shaft, install a nut while
removing drive shaft.

SRA232A

Installation
• Insert drive shaft from wheel hub and temporarily tighten
wheel bearing lock nut.
• Tighten side flange mounting bolts to specified torque.
• Tighten wheel bearing lock nut to specified torque.

RA-13
 REAR AXLE - Drive Shaft

Components

Drive shaft

Joint assembly

Boot

SRA233A

Disassembly
FINAL DRIVE SIDE
1. Remove boot bands.
2. Put matching marks on slide joint housing and inner race,
before separating joint assembly.
3. Pry off snap ring "A" with a screwdriver, and pull out slide joint
housing.

SRA249A

4. Put matching marks on inner race and drive shaft.

5. Pry off snap ring "8", then remove ball cage, inner race and
balls as a unit.
6. Draw out boot.
Cover drive shaft serration with tape so as not to damage the
boot.

RA-14
 REAR AXLE - Drive Shaft
Disassembly (Cont'd)
WHEEL SIDE
Suitable tool CAUTION:
(Sliding hammer)
The joint on the wheel side cannot be disassembled.
• Before separating joint assembly, put matching marks on drive
shaft and joint assembly.
• Separate joint assembly with a suitable tool.
Be careful not to damage threads on drive shaft.
• Remove boot bands.
Wheel bearing
lock nut

SFA092A

Inspection
Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for evidence of deformation or other
damage.

DRIVE SHAFT
Replace drive shaft if it is twisted or cracked.

BOOT
Check boot for fatigue, cracks, or wear. Replace boot with new
boot bands.

JOINT ASSEMBLY (Final drive side)

• Replace any parts of double offset joint which show signs of
scorching, rust, wear or excessive play.
• Check serration for deformation. Replace if necessary.
• Check slide joint housing for any damage. Replace if necessary.

JOINT ASSEMBLY (Wheel side)

Replace joint assembly if it is deformed or damaged.

Assembly
• After drive shaft has been assembled, ensure that it moves
smoothly over its entire range without binding.
e Use NISSAN GENUINE GREASE or equivalent after every
overhaul.

WHEEL SIDE
1. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage
boot during installation.

RA-15
 REAR AXLE - Drive Shaft
Assembly (Cont'd)
2. Set joint assembly onto drive shaft by lightly tapping it.
Install joint assembly securely, ensuring marl<s which were
Wheel bearing ·lock nut made during disassembly are properly aligned.

SFA130A

3. Pack drive shaft with specified amount of grease.

Specified amount of grease:
Without turbo
165 - 175 g (5.82 - 6.17 oz)
With turbo
170 - 190 g (6.00 - 6.70 oz)

4. Set boot so that it does not swell and deform when its length
is "L, ".
Make sure that boot is properly installed on the drive shaft
groove.
Length "L,":
Without turbo
96 - 98 mm (3.78 - 3.86 in)
With turbo
101 - 103 mm (3.98 - 4.06 in)

5. Lock new larger and smaller boot bands securely with a

suitable tool.

SFA395

SFA472

RA-16
 REAR AXLE - Drive Shaft
Assembly (Cont'd)
FINAL DRIVE SIDE
1. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.

2. Securely install ball cage, inner race and balls as a unit, making
sure the marks which were made during disassembly are
properly aligned.
3. Install new snap ring "8".

4. Pack drive shaft with specified amount of grease.

Specified amount of grease:
Without turbo
165 - 175 g (5.82 - 6.17 oz)
With turbo
180 - 200 g (6.35 - 7.05 oz)
5. Install slide joint housing, then install new snap ring "A".
6. Set boot so that it does not swell and deform when its length
is "L/'.
Make sure that boot is properly installed on the drive shaft
groove.
Length "~":
Without turbo
93 - 95 mm (3.66 - 3.74 in)
With turbo
102.5 - 104.5 mm (4.04 - 4.11 in)

7. Lock new larger and smaller boot bands securely with a

suitable tool.

SFA395

RA-17
 REAR SUSPENSION

~toJ 69- 88
Dynamic damper assembly (7.0- 9.0, 51 - 65)---._
(All non-turbo models
except A/T 2+2 seater models)
~ toJ 98 -118

~~toJn-98
Suspension member (10 _ 12, 72 _
8711

EY . (7.9 - 10, 57 - 72)

~ toJ 77 - 98 (7.9 - 10, 57 - 72)

/ ~toJ n-98
(7.9 - 10, 57 - 72)

Shock absorber

Axle assembly

rod

@(I
J'lj(j
~ Stabilizer
·-~98-118
(10 - 12, 72 - 87)
Bushing
~
)0 e ~
'I

toJ 2os - 21/

~ (21 - 28, 152 - 203)
®....._ -. Insulator
toJ 43- 55 . ~toJ9 -12
(4.4 - 5.6, 32 - 41) (0.9 _ 1.2, 6.5 _ 8.7) Adjusting
cap

CAUTION:
Do not jack up lower arm.
Final tightening for rubber parts must be done
under unladen condition•, with tires on ground.
• Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats In designated positons.
toJ : N·m (kg-m, ft-lb)

SRA234A

RA-18
REAR SUSPENSION - Coil Spring and Shock Absorber

Removal
• Remove shock absorber upper and lower fixing nuts.
• Do not remove piston rod lock nut on vehicle.

Disassembly
1. Set shock absorber on vise with attachment, then loosen
piston rod lock nut.
• Do not remove piston rod lock nut.

2. Compress spring with Tool so that the strut upper spring

seat can be turned by hand.

3. Remove piston rod lock nut.

SRA246A

Inspection
SHOCK ABSORBER ASSEMBLY
• Check for smooth operation through a full stroke, both com-
pression and extension.
• Check for oil leakage occurring on welded or gland packing
portions.
• Check piston rod for cracks, deformation or other damage.
Replace if necessary.
UPPER RUBBER SEAT AND BUSHING
• Check rubber parts for deterioration or cracks.
Replace if necessary.

RA-19
 REAR SUSPENSION - Coil Spring and Shock Absorber
Inspection (Cont'd)
COIL SPRING
• Check for cracks, deformation or other damage. Replace if
necessary.

Assembly

FM
,
I
I
,
• When installing coil spring, be careful not to reverse top and
bottom direction. (Top end is flat.)

~ Bottom SRA247 A

Upper end • When installing coil spring on strut, it must be positioned as

shown in figure at left.

~
~ Low"'"'
SRA248A

RA-20
REAR SUSPENSION - Multi-link and Lower Ball Joint

Removal and Installation

• Refer to "Removal and Installation" of REAR AXLE AND
REAR SUSPENSION ASSEMBLY.

Before removing, put matchmarks on adjusting pin.

• When installing, final tightening must be done at curb weight
with tires on ground.
• After installation, check wheel alignment.
Refer to "Rear Wheel Alignment" of CHECK AND ADJUST-
MENT- On vehicle.

SRA129A

Inspection
REAR SUSPENSION MEMBER
• Replace suspension member assembly if cracked or de-
formed or if any part (insutator, for example) is damaged.
UPPER AND LOWER LINKS
• Replace upper or lower link as required if cracked or
deformed or if bushing is damaged.

SUSPENSION LOWER BALL JOINT

e Measure swing force, turning torque and vertical end play in
axial direction. (Use same measurement procedures as that
of FA section.)
• If ball stud is worn, play in axial direction is excessive, or
joint is hard to swing, replace lower arm.

7.8 · 54.9 N
Swing force
(0.8- 5.6 kg, 1.8- 12.3 lb)
Ball joint
0.5 · 3.4N-m
specifications Turning torque
(5 - 35 kg-em, 4.3 · 30.4 in-lb)

Vertical end play 0 mm {Oin)

RA-21
 ·RE-AR SUSPENSION - Stabilizer Bar

Removal
• Remove connecting rod and clamp.

Inspection
• Check stabilizer bar for deformation or cracks. Replace if
necessary.
• Check rubber bushings for deterioration or cracks. Replace
if necessary.

Installation
• When installing connecting rod, make sure direction is
correct (as shown at left).
Connecting rod

SRA128A

RA-22
 ADJUSTABLE SHOCK ABSORBER

~ ~ 19.25 (1.9. 2.6, 14. 19) ----~

Shock absorber actuator

Actuator bracket -----~

fBl
~19-25(1.9-2.6,14-19) ~
p ~~~18-19(1.8·1.9,12-141
Gasket__......./" @>

u... ,.,.,,~
B"'h;og~ Coil spring

Upp" ,.,,,,.~, - /~
Upper rubber seat~/
~
Bushing___,., /
®
Plate_/=

Dust cover~
v Shock absorber

~: N·m (kg-m, ft-lb)

~~~77-98 (7.9 -10.0, 57. 72)
SRA257A

Removal and Installation

• Remove room trim. Refer to section BF.
• Disconnect sub-harness connector.
• Remove shock absorber actuator fixing bolts.

• Before installing actuator, ensure angle of shock absorber

control rod is aligned with that of actuator output shaft.
Otherwise, actuator may be damaged.
• Refer to REAR SUSPENSION for other procedures.

RA-23
ADJUSTABLE SHOCK ABSORBER

Inspection
• Replace shock absorber assembly if it is damaged.
Refer to REAR SUSPENSION - Coil Spring and Shock
Absorber.

Trouble Diagnosis
Refer to ADJUSTABLE SHOCK ABSORBER - Trouble Diagnoses
in section FA.

RA-24
 SUPER HICAS

Rear Wheel Alignment

TOE-IN
1. Draw a base line across the tread.
After lowering rear of vehicle, move it up and down to eliminate
friction.

SMA123

2. Measure toe-in.
Measure distance "A" and "B" at the same height as hub center.
Toe-In:
A-B
0 - 4 mm (0 - 0.16 in)
2 (J (Total toe-in angle)
01 - 23 1

Front
Toe·in •A -B
I# 9 Total toe-in angle= 211
SFA234A

3. Adjust toe-in by varying length of power cylinder lower links.

(1) Loosen lock nuts.
(2) Adjust toe-in by turning lower links forward or backward.

Make sure both lower links are the same length.

Standard length "L":
L 185.5 mm (7.30. in)
(3) Tighten lock nuts to the specified torque.
rRl: 37 - 46 N•m
(3.8 - 4.7 kg-m, 27 - 34 ft-lb)
e Refer to CHECK AND ADJUSTMENT for other procedures.

SRA260A

RA-25
 SUPER HICAS

Rear Axle Housing Ball Joint

Swing force ~Turning torque INSPECTION
~ e Measure swing force, turning torque and vertical end play in
axial direction.
• If ball joint is worn, play in axial direction is excessive, or joint
is hard to swing, replace ball joint.

6.9- 68.6 N
Swing force
(0.7- 7.0 kg, 1.5- 15.4 lb)
Ball joint specifi-
SRA349A 0.3- 2.9 N·m
cations Turning torque
(3 - 30 kg-em, 2.6 - 26.0 in-lb)

Vertical end play 0 mm (0 in)

Front REMOVAL

1J •
•
Remove ball joint snap ring.
Press out ball joint from axle housing.

Ball joint

SRA261A

ASSEMBLY
• Press new ball joint assembly into axle housing.
• Install snap ring into groove of ball joint.
• Refer to REAR AXLE - Wheel Hub and Axle Housing for other
Ball join procedures.
Axle housing
• Refer to ST section for power cylinder and SUPER HICAS -
Trouble Diagnoses.

Front

0.RA262A

RA-26
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications
COIL SPRING

~I VG30DE VG30DETT

I 2 seater
I 2+2 seater 2 seater

Wire diameter mm (in) 11.4 (0.449) 11.2 (0.441)

Coil diameter mm (in) 100 (3.94)

Free length mm (in) 371.5 (14.63)

I 380 (14.96) 370 (14.57)

Spring constant N/mm (kg/mm, lb/in) 21.6 (2.2, 123) 23.5 (2.4, 1341

Identification color White x 1, Yellow x 1

I Purple x 1, Pink x 1 Purple x 1, Light green x 1

SHOCK ABSORBER

~·
I
VG30DE VG30DETT

Piston rod diameter mm (in) 12.5 (0.4921 14.0 (0.551)

Damping force N (kg,lb)

Firm Soft
[at 0.3 m (1.0 ftl/sec.]
873-1,187 1.432 - 1,903 834-1,128
Expansion
(89- 121, 196- 267) (146- 194, 322- 428) (85. 115, 187- 254)

520-755 971 - 1,383 481-696

Compression
(53- 77, 117- 170) (99 ·141, 218- 311) (49- 71, 108- 157)

DRIVE SHAFT

~
Final drive side
VG30DE VG30DETT
I /lv
Joint type
Final drive side DS90 DS100 I[]D
~
Wheel side ZF100 BF100

Diameter mm (in)
Wheel sideD, 30 (1.18) 33 (1.30)
Wheel drive side
Grease

Specified amount of grease

Nissan genuine grease or equivalent
v "/IVn
1I
'~~
Final drive side
g (oz)
165- 175 (5.82- 6.171 180 - 200 (6.35 - 7 .05)
!o I
Wheel side

Boot length
Final drive side ( L 1 I
mm (in)
165. 175 (5.82. 6.17)

93. 95 (3.66- 3.74)

170- 190 (6.00. 6.70)

102.5- 104.5 (4.04- 4.11)

L. ~
Wheel side ( L 2 I 96- 98 (3.78- 3.86) 101 - 103 (3.98- 4.06) SRA236A

RA-27
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
General Specifications (Cont'd)

REAR STABILIZER BAR

~
VG30DE
VG30DETT
I 2 seater 2+2 seater

Stabilizer diameter
mm (in)
15.9 21.0 25.4
Outer
(0.626) (0.827) (1.000)

12.3 15.8 19.4

Inner
(0.484) (0.622) (0.764)

Inspection and Adjustment

WHEEL ALIGNMENT (Unladen*) WHEEL RUNOUT (Radial and lateral)
Camber degree Wheel type Radial runout Lateral runout

Toe-in Aluminum wheel ·mm(inl 0.3 (0.012) or less

mm(inl 0-4(0-0.16)

(Total) degree o· -23'

* Tankful of fuel, radiator coolant and engine oil full.
LOWER BALL JOINT
Spare tire, jack, hand tools, mats in designated position.
Swing force
7.8-54.9
(Measuring point: cotter pin
(0.8 - 5.6, 1.8 - 12.3)
hole of ball stud) N (kg, lb)
WHEEL BEARING
Turning torque
0.5 - 3.4 (5- 35, 4.3 - 30.4)
Wheel bearing axial end play N·m (kg-em, in-lb)
mm lin) 0.05 (0.0020) or less
Vertical end play mm lin) 0101
Wheel bearing lock nut
Tightening torque
206-275 (21 -28, 152- 203)
N·m (kg-m, ft-lb)
LOWER LINK BALL JOINT (SUPER HICAS)
Swing force (at cotter pin hole) 6.9-68.6
N (kg,lb) (0.7- 7.0, 1.5- 15.4)

Turning torque 0.3-2.9

N·m (kg-em, in-lb) (3- 30, 2.6- 26.0)

Vertical end play mm (in) 0 (0)

RA-28
 BRAKE SYSTEM

SECTIONBR

CONTENTS
PRECAUTIONS AND PREPARATION ........................................................................................... BR- 2
CHECK AND ADJUSTMENT ..... ................ ............... .... ............. ............... ...... .................. .............. BR- 3
BRAKE HYDRAULIC LINE ........ ........... .......... .. ......... ........ ............ ................. ................ ................ BR- 4
BRAKE PEDAL AND BRACKET ... ...... .. ... .. ..... ... ........ .. .. ...... .... .... .... ... ................. ... ...... .. ....... .... .. . BR- 6
BRAKE BOOSTER ......... ........ ................................ .................................... ............ .......................... BR- 8
VACUUM PIPING ............................................................................................................................. BR- 9
MASTER CYLINDER ........................................................................................................................ BR-11
FRONT DISC BRAKE (OPZ25VA) - Caliper ............................................................................ BR-12
FRONT DISC BRAKE (OPZ25VA) - Rotor ............................................................................... BR-15
REAR DISC BRAKE (0PZ11VB) - Caliper ............................................................................... BR-16
REAR DISC BRAKE (OPZ11VB) - Rotor ................................................................................. BR-20
PARKING BRAKE CONTROL ................................................... ..................................... ................ BR-21
PARKING DRUM BRAKE (DS17HD) ............................................................................................ BR-23
ANTI-LOCK BRAKING SYSTEM ............ ........................................................ ...................... .......... BR-25
TROUBLE DIAGNOSES ............................................................................ ...................................... BR-29
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ...................................................................... BR-54
 PRECAUTIONS AND PREPARATION

Precautions
• Recommended fluid is brake fluid "DOT 3".
• Never reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas.
• To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
• Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of hydraulic system.

• Use Tool when removing and Installing brake tube.

WARNING:
• Clean brake pads and shoes with a waste . cloth, then
collect dust with a dust collector.

SBR500

Preparation
SPECIAL SERVICE TOOL

Tool number
(Kent-Moore No.) Description
Tool name

GG94310000 Removing and installing

( ) each brake piping
Flare nut torque
wrench

KV991V0010 Measuring brake fluid pressure

( )
Brake fluid
pressure gauge

KV999P1000 Checking brake fluid pressure of

( )
A.B.S. checker ·-
~~ER ...f!!. _t;?,. .•.~. •

.~
A.B.S. actuator

.~l-"'-· ~- .~ i" .
.:::::· .•
·~..:;. -:::.~- _,.. ·;;:

KV999P1020 Checking brake fluid pressure of

( ) A.B.S. actuator
A. B.S. checker adapter
harness

BR-2
 CHECK AND ADJUSTMENT

Checking Brake Fluid Level

• Check fluid level in reservoir tank. It should be between Max.
=MAX and Min. lines on reservoir tank.
• If fluid level is extremely low, check brake system for leaks.
=MIN

Checking Brake System

• Check brake lines (lines and flexible hoses) for cracks, deteri-
oration or other damage. Replace any damaged parts.
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
• Check for oil leakage by fully depressing brake pedal.

Changing Brake Fluid

1. Drain brake fluid in each air bleeder valve.
2. Refill until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid.
Refer to Bleeding Procedure.
• Refill with recommended brake fluid "DOT 3".
• Never reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas.

BR-3
 BRAKE HYDRAULIC LINE

Models with A.B.S.

Proportioning valve
(Do not disassemble.)
actuator

Brake booster

Master
cylinder

Primary line
- Secondary line rPJ
o Flare nut
SBR729A 15 • 18 N·m (1.5- 1.8 kg-m, 11- 13 ft-lb)

Front brake

Proportioning valve
(Do not disassemble.)

Brake booster

cylinder

-
Primary line
Secondary line rPJ
o : Flare nut
15-18 N•m (1.5 ·1.8 kg-m,11 -13ft-lb) SBR481B

BR-4
 BRAKE HYDLAULIC LINE

Bleeding Procedure
CAUTION:
• Carefully monitor brake fluid level at master cylinder
during bleeding operation.
• Fill reservoir with recommended brake fluid. Make sure it
is full at all times while bleeding air out of system.
• Place a container beneath master cylinder to avoid spill-
age of brake fluid.

SBR995

• Bleed air according to the following procedure.

Left rear caliper
t
Right rear caliper
t
Left front caliper
t
Right front caliper
t
Front side air bleeder on A.B.S. actuator (Models with A.B.S.)
t
Rear side air bleeder on A.B.S. actuator (Models with A.B.S.)
• To bleed air out of lines, wheel cylinders and calipers, use
the following procedure.
1) Connect a transparent vinyl tube to air bleeder valve.
2) Fully depress brake pedal several times.
3) With brake pedal depressed, open air bleeder valve to
release air.
4) Close air bleeder valve.
5) Release brake pedal slowly.
6) Repeat steps 2) through 5) until clear brake fluid comes out
of air bleeder valve.

Removal and Installation

1. To remove brake flexible hose, first remove flare nut securing
brake line to hose, then withdraw lock spring.
2. Cover openings to prevent entrance of dirt whenever discon-
necting hydraulic line.
3. All hoses must be free from excessive bending, twisting and
pulling.
4. After installing brake lines, check for oil leakage by fully
depressing brake pedal.

SBR500

Inspection
Check brake lines (lines and flexible hoses) for cracks, deteriora-
tion or other damage. Replace any damaged parts.
If leakage occurs around joints, retighten or, if necessary, replace
damaged parts.

BR-5
 BRAKE PEDAL AND BRACKET

Removal and Installation

rn
spring

Stop lamp switch

rPJ 12-15 (1.2 -1.5, 9-111

• Replace clevis pin if plastic stopper, Brake pedal

which is located at the end of clevis
rPJ : N·m (kg-m, ft-lbl
pin, is deformed or damaged.
SBR730A

Inspection
Check brake pedal for following items.
• Brake pedal bend
• Clevis pin deformation
• Crack of any welded portion

BR-6
 BRAKE PEDAL AND BRACKET

Adjustment
Check brake pedal free height from dash reinforcement panel.
Adjust if necessary.
H: Free height
Refer to S.O.S.
D: Depressed height
Refer to S.O.S.
Under force of 490 N (50 kg, 110 lb)
with engine running
C1: Clearance between pedal stopper and threaded
end of stop lamp switch
0.3 - 1.0 mm (0.012 - 0.039 in)
C2: Clearance between pedal stopper and threaded
end of A.S.C.D. switch
0.3 - 1.0 mm (0.012 - 0.039 in)
A: Pedal free play
1 - 3 mm (0.04 - 0.12 in)

Dash lower
panel

SBR890A rRJ : N-m (kg-m, ft·lb)

1. Adjust pedal free height with brake booster input rod. Then
tighten lock nut.
Make sure that tip of input rod stays inside.

SBR930

2. Adjust clearance "C1" and "C2" with stop lamp switch and
A.S.C.D. switch respectively. Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamp is off when pedal is released.
4. Check brake pedal's depressed height while engine is
running.
If depressed height is below specified value, check brake
system for leaks, accumulation of air or any damage to
components (master cylinder, wheel cylinder, etc.); then
make necessary repairs.

BR-7
 BRAKE BOOSTER

Removal and Installation

* Replace clevis pin if plastic stopper,

which is located at the end of clevis ~ : N·m (kg-m, ft-lb)
pin is deformed or damaged. SBR892A

Inspection
OPERATING CHECK
• Depress brake pedal several times with engine off, and
check that there is no change in pedal stroke.
• Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.

AIRTIGHT CHECK
O.K. N.G. • Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. If pedal goes further down
the first time and gradually rises after second or third time,
booster is airtight.
• Depress brake pedal while engine is running, and stop
engine with pedal depressed. If there is no change in pedal
stroke after holding pedal down 30 seconds, brake booster
is airtight.

OUTPUT ROD LENGTH CHECK

1. Supply brake booster with vacuum of -66.7 kPa (-500 mmHg,
-19.69 inHg) using a handy vacuum pump.
2. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
3. Adjust rod length if necessary.
4. If rod length is without specification, replace brake booster.

BR-8
 VACUUM PIPING

Removal and Installation

~ (] ~ iJ (

~
Brake booster
Vacuum hose

CAUTION:
Do not apply any oil or lubricants to
vacuum hoses and check valva.

Intake manifold SBR734A

CAUTION:

------1.~.
When installing vacuum hoses, pay attention to the following
points.
_,..., 24mm • Do not apply any oil or lubricants to vacuum hose and check
valve.
(0.94 in)
e Insert vacuum tube into vacuum hoses as shown.
- - - . .,~
_________ ll~----
Connect hose until it contacts
protrusion on vacuum tube.
SBR225B
• Install check valve, paying attention to its direction.

Intake manifold

.,~• =
E. . :·:·:·:·:·:···--.-A:·:_..
Brake booster

·~ :J •
;=··:·:·:·:·:·:··········'
J··-·······t-.:-:·:~·-· ::f .:..............·.·.
··.····
SBR49BA

Inspection
HOSES AND CONNECTORS
• Check vacuum lines, connections and check valve for
airtightness, improper attachment chafing and deterioration.

BR-9
 VACUUM PIPING
Inspection (Cont'd)
CHECK VALVE
• When pressure is applied to brake booster side of check
valve and valve does not open, replace check valve with a
new one .

• Brake
Manifold booster
side side SBR475A

BR-10
 MASTER CYLINDER

Removal and Installation

R•e~i'""U

Oil Iii<"~

Float~

Reservoir tank

Primary piston assembly

Secondary
piston
assembly

Piston cup*

* Lubricate piston cup with brake

fluid or rubber grease when
assembling master cylinder.
Dual proportioning valve
(Do not disassemble.) SBR735A

• Replace stopper cap if claw is damaged or deformed.

• Bend claws inward when installing stopper cap.

SBR011A

Secondary piston
• Pay attention to direction of piston cups in figure at left.
• Check parts for wear or damage. Replace if necessary.

Primary piston

SBR012A

BR-11
 FRONT DISC BRAKE (OPZ25VA) - Caliper

E:l ®:P.B.C. (Poly Butyl Cuprysil) grease or

silicone-based grease point
A 1-9 10.1- o.9. 5.1 - s.5) E:l@: Rubber grease point
~ @: Brake fluid point
A=N·m (kg-m, ft-lb)
Caliper

E:l®

~-~--- ----
Do not remove or
L loosen these bolts.

A 98-118 11o.o -12.o. 12- 87)

Inner shim A

Outer~
shim B

Cross spring

Front

SBR856A

Pad Replacement
CAUTION:
• When pads are removed, do not depress brake pedal be-
cause piston will pop out.
• Be careful not to damage dust seal or get oil on rotor.
Always replace shims when ·replacing pads.
1. Remove clip from pad pin and then remove pad pin.
2. Remove cross spring.

SBR737A

3. Pull out outer pad and insert it temporarily between lower

piston and rotor as shown.
4. Push back upper piston with a suitable tool and insert new pad
so it contacts upper piston as shown.
5. Pull out old pad.
6. Push back lower piston with a suitable tool.
7. Pull out new pad and reinstall it in the proper position.
8. Repeat step 3 to 7 for inner pad.
9. Install cross spring, pad pin and clip.

BR-12
FRONT DISC BRAKE (OPZ25VA) - Caliper

Removal and Installation

1. Disconnect brake tube.
2. Remove brake pad.
3. Remove brake caliper mounting bolts.

Disassembly
1. Remove retaining ring.

SBR914A

2. Push out piston with dust seal using compressed air.

SBR913A

3. Remove piston seal.

CAUTION:
Be careful not to loosen or remove bolts joining both sides of
caliper.
If there is any fluid leakage, replace caliper assembly.

SBR933A

BR-13
 FRONT DISC BRAKE (OPZ25VA) - Caliper

Inspection
CALIPER
• Check dust seals for damage.
• Check calipers for damage, rust or foreign materials.
• Check inside surface of cylinder for scoring, rust, wear,
damage or foreign materials. Replace if any such condition
exists.
• Eliminate minor damage from rust or foreign materials by
polishing surface with fine emery paper.
CAUTION:
Use brake fluid to clean.
PISTON
Check piston for scoring, rust, wear, damage or foreign materials.
Replace if any condition exists.
CAUTION:
Piston sliding surface is plated. Do not polish with emery paper
even if rust or foreign materials are stuck to sliding surface.

PAD PIN AND CLIPS

Check for wear, cracks deformation, deterioration, rust or other
damage. Replace if any such condition exists.

Assembly
Retaining
1. Insert piston seal into groove on cylinder body,

..
2. With dust seal fitted to piston, install piston into cylinder body.
3. Secure dust seal properly.
4. Install retaining ring .

SBR743A

Inspection (On-vehicle)
DISC PAD
• Check pad shims for deformation or damage.
• Check disc pad for wear or damage.
Pad standard thickness (A):
10.0 mm (0.394 in)
Pad wear limit (A):
2.0 mm (0.079 in)

BR-14
FRONT DISC BRAKE (OPZ25VA) - Rotor

Inspection
RUBBING SURFACE
Check rotor for roughness, cracks or chips.

RUNOUT
Check runout using a dial indicator. Make sure that axial end play
is within the specifications before measuring. Refer to section FA.
Rotor repair limit:
Maximum runout
(Total indicator reading at center of rotor pad
contact surface)
0.07 mm (0.0028 In)

THICKNESS
Standard thickness:
30.0 mm (1.181 in)
Minimum thickness:
28.0 mm (1.102 in)

SBR746A

BR-15
 REAR DISC BRAKE (OPZ11VB) - Caliper

rP.J38- 52
(3.9 - 5.3, 28 - 38)
Piston boot lEI ®
Retaining ring

Outer pad lEI ®

v
Outer shim B lEI ® Pad pin

Inner shim A lEI®

Inner shim B lEI ® a"w •h;m A El Ci'J

Pad retainer lEI ®

lEI®: P.B.C. (Poly Butyl Cuprysil) grease or
Front silicone-based grease point
lEI@: Rubber grease point
~ @: Brake fluid point
SBR857A rP.J: N·m (kg-m, ft-lb)

Pad Replacement
CAUTION:
When pads are removed, do not depress brake pedal because
piston will pop out.
1. Remove clip from pad pin and then remove pad pin.
2. Remove cross spring.

3. Pull out inner and outer pads.

CAUTION:
Be careful not to damage dust seal or get oil on rotor.
Always replace shims when replacing pads.

BR-16
REAR DISC BRAKE (OPZ11VB} - Caliper

Removal and Installation

1. Disconnect brake tube.
2. Remove brake pad.

3. Remove brake cable and bracket.

SBR752A

4. Remove axle housing fixing bolts.

Disassembly
1. Remove retaining ring.

2. Push out piston with dust seal using compressed air.

BR-17
REAR DISC BRAKE (OPZ11VB) - Caliper
Disassembly (Cont'd)
3. Remove piston seal.

CAUTION:
Be careful not to loosen or remove bolts joining both sides of
caliper.
If there is any fluid leakage, replace caliper assembly.

SBR861A

Inspection
CALIPER
• Check dust seals for damage.
• Check calipers for damage, rust or foreign materials.
• Check inside surface of cylinder for score, rust, wear or other
damage.
• Minor damage from rust of foreign materials may be eliminated
by polishing surface with a fine emery paper. Replace if
necessary.
CAUTION:
Use brake fluid to clean.

PISTON
Check piston for score, rust, wear or other damage. Replace if
necessary.
CAUTION:
Piston sliding surface is plated. Do not polish with emery paper
even If rust or foreign matter Is stuck to sliding surface.

PAD PIN AND CLIP

Check for wear, cracks deformation, deterioration, rust or other
damage. Replace if necessary.

BR-18
REAR DISC BRAKE (OPZ11VB) - Caliper

Assembly

""~
nng 1.
2.
Insert piston seal into groove on cylinder body.
With dust seal fitted to piston, install piston into cylinder body.
3. Secure dust seal properly.
4. Install retaining ring.

SBR756A

Inspection (On-vehicle)
DISC PAD
• Check pad shims for deformation or damage.
• Check disc pad for wear or damage.
Standard thickness (A):
11.5 mm (0.453 In)
Pad wear limit (A):
2.0 mm (0.079 in)

BR-19
REAR DISC BRAKE (OPZ11VB) - Rotor

Inspection
RUBBING SURFACE
Check rotor for roughness, cracks or chips.

RUN OUT
• Check runout using a dial indicator.
• Make sure that axial end play is within the specifications before
measuring. Refer to section RA.
Rotor repair limit:
Maximum runout
(Total indicator reading at center of rotor pad
contact surface)
0.07 mm (0.0028 in)

THICKNESS
Standard thickness:
18 mm (0.71 in)
Minimum thickness:
16 mm (0.63 in)

SBR746A

BR-20
 PARKING BRAKE CONTROL

Removal and Installation

Control lever_/

Front cable

'"'~

L. H. rear cable

SBR891A

• Before removing parking brake control, remove console box.

• Loosen cable using control lever adjuster, and separate front
and rear cables.
Apply multi-purpose grease to areas between control lever drum
and cables.
Be careful not to damage boot and inner cable.

Inspection
1. Check control lever for wear or other damage. Replace if
necessary.
2. Check parking brake cables, lamp and switch. Replace if
necessary.
3. Check parts at each connecting portion for deformation or
damage. If found, replace.

Adjustment
Perform shoe clearance adjustment before adjusting control lever
stroke.
1. Turn adjusting nut.

SBR760A

BR-21
 PARKING BRAKE CONTROL
Adjustment ( Cont' d)
2. Pull control lever with specified amount of force. Check lever
stroke and ensure smooth operation.
Number of notches: 6 - 7

3. Bend parking brake warning lamp switch plate so that brake

warning light comes on when ratchet at parking brake lever is
pulled "A" notches and goes out when fully released.
Number of notches "A": 1

SBR762A

BR-22
 PARKING DRUM BRAKE {DS17HD)

Guide plate~
Return spring~

Strut I!;)
W7
~
~

Ll r Ao,;.,..,,,,.,;og
Retainer
/

~
\"""'" spring

spring

Antt rattle pin ~\ A•"•""' ""'"'

Retamer
Iii @ : Brake grease point
Anti-rattle pin

SBA763A

Shoe Replacement
1. Remove disc rotor (With parking drum brake).
Tighten two bolts gradually if disc rotor is hard to remove.

2. After removing anti-rattle pin, remove spring by rotating shoes.

Be careful not to damage parking brake cable when separating it.

BR-23
PARKING DRUM BRAKE (DS17HD)
Shoe Replacement (Cont'd)
3. Apply brake grease to the contact areas shown at left.

Shoe Clearance Adjustment

1. Remove adjuster hole plug, and turn adjuster wheel with a
screwdriver until shoe touches brake drum.
Make sure that parking control lever is released completely.

2. Return adjuster wheel 5 to 6 latches.

3. Install adjuster hole plug, and make sure that there is no drag
between shoes and brake drum when rotating disc rotor.

Breaking in Drum and Lining

1. Using either low or 2nd transmission speed, drive the unloaded
vehicle on a safe, level and dry road.
2. Depress the release button of parking brake lever, then pull the
lever with a force of 98 N (10 kg, 22 lb).
3. While holding the lever, continue to drive the vehicle forward
100 m (328 ft) at approximately 35 km/h (22 MPH).
4. While holding the lever, drive the vehicle in reverse 10 m (33ft)
at approximately 10 km/h (6 MPH).
5. Repeat steps 1 through three times and then repeat only step
4 one more time.
Drum Inspection
Standard inner diameter:
172.0 mm (6.77 In)
Maximum inner diameter:
173.0 mm (6.81 In)

SBR768A

BR-24
 ANTI-LOCK BRAKING SYSTEM

System Components
Piping
Harness

Front wheel sensor

Hydraulic Circuit

Proportioning valve
(Do not disassemble.)

Master cylinder

8 rake booster

Front R.H. wheel

,--------·
I Feeling
· Check valve valve
(Front L.H.I (Front)

Caliper

I
I

I WT"+-4--<>+o-+o:-:.:.:...:.:::..J

~ _ _____.I I
I
'
L___ _______________
Reservoir Reservoir J
IF_r_o_n~-----'R:_ar_l________ _
I

L Front L.H. wheel Rear L.H.

wheel
SBR769A

BR-25
 ACTUATOR
FUSE BLOCK 4 II 6 5
(Refer to *POWER SUPPLY ROUTING"
In EL section. l

~~ITION
:I
0
(Body harness> .....
SW - BR------~--------------~ 0
I
:u @ :AfT model
L.=_or START :u @ :MiT model
IT1 ~:u
r IT1 @ : 2 seater model
)>
r
CONNECTOR ~ -< )> @ : 2 + 2 seater model
-<
@ : With air bag
@ : Without air bag
WARNlfN: L'MP ® • =JitSI@)
oz
rl>
Iii ~ " ' '
~~, ' §il o •
(Mo 'n haenos"' "' • o <Bod>
,,,hoenoosl
II 3 2 I 21 9 7

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~' ~ ~L -,\C.~= " en

n RELAY
(J BOX) "' g In e room harness> t.;;";;;\ h(Body
FUSE. BLOCK

I~
,...,- ' - 2l

~
<

•FR '" -,
-;...uJ
-
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l <
=:i' =!i!l
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lF B/W -------------- --------- --- ''{'
BR -- I -t
m
ill- ""
~ ..::::::::::::-
':.-.-_-_-_-_-_-_-_-_-_--,:::::::::: ,------------~ B/W - - 21 3:
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=- ------=~jr-----

l ::
LG ------- __,1 B/Y--
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- - 20
@® ~..::---
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=®
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= =~R
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=9
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(A I ternator I
:: If-
I: I: i r--~ OR -
8
2-'

"':ev-
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: :: :
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B/P-- 26

@)~ Q!> Q!>

W/R
-1 " ~ : I 1 I REAR SENSOR

~~ ~ ~
I ; ;; ;
~®
r.tt'\ "" ® •
.-.1 I
IDOl IDOl I : : :
24--c'\
26~R.H.
8 :~ :IL~

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'iii83'
© ·~-::- ©: 18J07'1_ ~~
['-- I OR --24
B/P --26 ~B ~
;::::el. H.
~-
BR -- 8
9 9
BODY --- B/R - -
rn FRONT FRONT
"':JJ FUSIBLE LINK HOLDER
SENSOR SENSOR
L. H.
ALTERNATOR GROUND GROUND
BODY
..."'"'ID -
BATTERY
R. H.
ANTI-LOCK BRAKING SYSTEM

Removal and Installation

CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
FRONT WHEEL SENSOR

REAR SENSOR

SBR772A

• Remove rear sensor rotor with differential side flange after

drive shaft removal.
Refer to RA section.

BR-27
 nnectors an d brake tubes.
k t
• Disconnect 3 cofxing actuator to brae e .
• Remove 3 nuts I

BR-28
 TROUBLE DIAGNOSES

Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair ............................................................. BR-30
Symptom Chart .......................................................................................................................................................... BR-33
Preliminary Check 1 ................................................................................................................................................. BR-34
Preliminary Check 2 ................................................................................................................................................. BR-35
Preliminary Check 3, 4 ............................................................................................................................................. BR-36
Self-diagnosis ............................................................................................................................................................ BR-37
Component Parts Location ..................................................................................................................................... BR-38
Harness Connector Location .................................................................................................................................. BR-39
Ground Circuit Check .............................................................................................................................................. BR-40
Circuit Diagram for Quick Pinpoint Check .......................................................................................................... BR-41
Diagnostic Procedure 1 ........................................................................................................................................... BR-42
Diagnostic Procedure 2 ........................................................................................................................................... BR-43
Diagnostic Procedure 3 ........................................................................................................................................... BR-44
Diagnostic Procedure 4 ........................................................................................................................................... BR-44
Diagnostic Procedure 5 ........................................................................................................................................... BR-45
Diagnostic Procedure 6 ........................................................................................................................................... BR-45
Diagnostic Procedure 7 ........................................................................................................................................... BR-46
Diagnostic Procedure 8 ........................................................................................................................................... BR-47
Diagnostic Procedure 9 ........................................................................................................................................... BR-48
Diagnostic Procedure 10 ......................................................................................................................................... BR-49
Diagnostic Procedure 11 ......................................................................................................................................... BR-50
Diagnostic Procedure 12 ......................................................................................................................................... BR-51
Electrical Components Inspection ......................................................................................................................... BR-52

BR-29
TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
INTRODUCTION
The A.B.S. system has an electronic control unit to control
major functions. The control unit accepts input signals from
sensors and instantly drives actuators. It is essential that both
kinds of signals are proper and stable. At the same time, it is
important that there are no conventional problems such as air
leaks in the booster or lines, lack of brake fluid, or other
problems with brake system.
It is much more difficult to diagnose a problem that occurs
intermittently rather than continuously. Most intermittent prob-
lems are caused by poor electric connections or faulty wiring. In
this case, careful checking of suspicious circuits may help
prevent the replacement of good parts.
A visual check only may not find the cause of the problems, so
a road test should be performed.
Before undertaking actual checks, take just a few minutes to
talk with a customer who approaches with a A.B.S. complaint.
The customer is a very good source of information on such
problems; especially intermittent ones. Through the talks with
the customer, find out what symptoms are present and under
what conditions they occur.
Start your diagnosis by looking for "conventional" problems first.
This is one of the best ways to troubleshoot brake problems on
an A.B.S. controlled vehicle.

BR-30
 TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
WORK FLOW

<Reference item

LISTEN TO CUSTOMER DIAGNOSTIC WORKSHEET

COMPLAINTS (See page BR-32.)

INVESTIGATE ITEMS YOU

SHOULD CARRY OUT Symptom Chart
RELATED TO EACH (See page BR-33.)
SYMPTOM AND NOTE

ELIMINATE GOOD SYSTEMS Preliminary Check

r-------------------- ON GOOD PARTS (See page BR-34- 36.)

Self-d

DETERMINE MALFUNCTION-
Self-diagnosis
ING CIRCUIT(S) OR PART(S)
(See page BR-37.)

• DIAGNOSTIC
WORKSHEET
• Component Parts Location
(See page BR-32.)
ELIMINATE GOOD PART(S), (See page BR-38.)
• Diagnostic Procedure(s)
HARNESS(ES) OR CONNEC- • Harness Connector Location
1 to 6
TOR(S) THROUGH ELEC- (See page BR-39.)
(See pages BR-42- 45.)
TRICALLY TESTING • Ground Circuit Check
• Circuit Diagram for Quick
Pinpoint Check (See page BR-40.)
(See page BR-41.)

INSPECTION Diagnostic
ON THE BASE Procedure( s)
7 to 12
OF EACH COMPONENT (See pages BR-46- 51.)

REPAIR OR REPLACE

N.G.
~---------------------- FINAL CHECK

BR-31
 TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
KEY POINTS
DIAGNOSTIC WORKSHEET
WHAT ..... Vehicle model There are many kinds of operating conditions that lead to
WHEN ..... Date, Frequencies customer complaints, even if the system is normal.
WHERE ..... Road conditions A good grasp of such conditions can make trouble-shooting
HOW ..... Operating conditions, faster and more accurate.
Weather conditions, In general, feelings for a problem depend on each customer's
Symptoms information. It is therefore important to fully understand the
symptoms or under what conditions a customer complains.
Make good use of a diagnostic worksheet such as the one
shown below in order to utilize all the complaints for trouble-
shooting.

Worksheet sample

Customer name MR/MS Model & Year VIN

Engine# Trans. Mileage

Incident Date Manuf; Date In Service Date

Symptoms 0 Pedal vibration and 0 0 0 0 0 0

noise Warning Long Abnormal A. B.S. A. B.S. A. B.S.
activates stopping pedal doesn't works works
distance action work but warning frequently
activates

Engine conditions 0 When starting 0 After starting

0 Engine speed: 5,000 rpm or more

Road conditions 0 Low friction road (0 Snow 0 Gravel 0 Other)

0 Protrusion

Driving conditions 0 High speed cornering

0 Vehicle speed: Greater than 10 km/h (6 MPH)
0 Vehicle speed: 10 km/h (6 MPH) or less
0 Vehicle is stopped

Applying brake conditions 0 Suddenly

0 Gradually

Other conditions 0 Operation of electrical equipment

0 Large pedal stroke
0 Operation of clutch

BR-32
 TROUBLE DIAGNOSES

Symptom Chart

iii ...."'c:
u cJ
...G>(.)
·;:
u
E:
0
Q)
Q)
c. 0
c: "'·-
c:
c:
.....
BR-52 Actuator inspection 0
0
w c.-

-g .<.: ,:,/. BR-40 Motor ground 0

:::::1 :::::1 u
0 ~ ~
5uu

--
BR-40 Sensor shield 0 0

c BR-51 L.E.D. comes off 0 0 0 0 0 0

Q)U!
:;...J BR-50 L.E.D. flashing 16 0 0 0 0 0 0
"C .J::.
f! .<.: ci
e ~ z
a.. c: en BR-49 L.E.D. flashing 10 0 0 0 0 0 0
u .5! c:
·~ t) ~
0 Q) Ill BR-48 L.E.D. flashing 9 0 0 0 0 0 0
c: ~;;:::
enc:
Ill · -
oo BR-47 L.E.D. flashing 5 • 8 0 0 0 0 0 0

--
Q)
a;
(/)
BR-46 L.E.D. flashing 1 · 4 0 0 0 0 0 0

BR-45 Diagnostic Procedure 6 0

....
Q)
BR-45 Diagnostic Procedure 5 0
:::::1
"C
Q)
u
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a..
BR-44 Diagnostic Procedure 4 0
u
·;;
VI BR-44 Diagnostic Procedure 3 0
0
c:
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Ill
6 BR-43 Diagnostic Procedure 2 0

BR-42 Diagnostic Procedure 1 0

,:,/.
u BR-36 Preliminary Check 4 0 0 0 0 0 0
Q)
.J::.
(..)
BR-36 Preliminary Check 3 0 0
>
....
Ill
c:
:§ BR-35 Preliminary Check 2 0 0 0
a;
....
a.. BR-34 Preliminary Check 1 0 0 0

en
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a.. a: en
Q)
a.. 3: .9 <( <i. <i.ii

BR-33
 TROUBLE DIAGNOSES

Preliminary Check 1

N.G.
---+Fill up brake fluid.
=
MAX

=MIN
,-----------CHECK------------

O.K.

Check brake fluid level in reservoir tank.

. b ra k e system. +--
Repa1r N.G.

SMA732A

Check brake system.

Refer to CHECK AND ADJUSTMENT.

1 O.K

,-----------CHECK -----------.

N.G.
. or rep Iace booster system. +--
Repair

O.K.

Check brake booster operation and airtight·

ness.
Refer to "Inspection" of BRAKE BOOSTER.
N.G.
____. Replace malfunctioning parts.

Check brake pads and rotor.

Refer to "Inspection" of FRONT and REAR
DISC BRAKE.

BR-34
 TROUBLE DIAGNOSES

Preliminary Check 2

------
Check sensor clearance.

Front wheel sensor

Clearance mm (in)
0.22-0.71
(0.0087- 0.0280)
0.06-0.93
_N_.G_.- - - - - - - - • Check sensor for the following items:
• Dust, foreign materials, etc., at
fastening portion

•
Rear sensor
(0.0024- 0.0366) • Improper installation

1 Breakage

+----------~~O.K.
N.G.

o._K.
,-------CHECK~

~v~~ 4

Repair or replace malfunctioning sensor.

N.G.
--+ Replace sensor rotor.
SBR778A

Check sensor rotor for teeth damage.

Number of teeth:
Front: 46
Rear: 46

BR-35
 TROUBLE DIAGNOSES

Preliminary Check 3, 4 Preliminary Check 4

--------------CHECK----~------

N.G.
____.Replace.

O.K.

SBA556B

Measure each sensor resistance. Check warning lamp activation.

0.8-1.2 kil When ignition switch is turned on, warning
lamp turns on.

IO.K. l N.G.
. Check fuse .
•,. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___J Check bulb condition and remedy.

N.G.

Check warning lamp for deactivation.

When engine starts, warning lamp deactivates.
~O.K.
DRIVE
• Keep engine on and running.
• Count the number of L.E.D. flashes during
5 to 10 second "OFF" period.

l
Go to Self-diagnosis.
(See page 8 R-37 .)
~ v
Drive vehicle at 30 km/h (19 MPH) for at
least one minute. - SBR530A

~
,-----------~HECK------------

N.G.

O.K.
____.If Preliminary Check 2 is not performed
and there is abnormal A. B.S. operation,
perform Preliminary Check 2.
Ensure warning lamp remains off while driving.

BR-36
 TROUBLE DIAGNOSES

Self-diagnosis
CHECKING THE NUMBER OF L.E.D. FLASHES
When a problem occurs in the A.B.S., the warning light on the instrument panel comes on. As shown in
the Table, the control unit performs self-diagnosis.
To obtain satisfactory self-diagnosing results, the vehicle must be driven above 30 km/h (19 MPH) for at
least one minute before the self-diagnosis is performed. After the vehicle is stopped, the number of L.E.D.
flashes is counted while the engine is running.
The L.E.D. is located on the control unit, identifying a malfunctioning part or unit by the number of flashes.
Both the warning light and the L.E.D. persistently activate, even after a malfunctioning part or unit has
been repaired, unless the ignition switch is turned "OFF". After repairs, turn the ignition switch "OFF".
Then start the engine and drive the vehicle over 30 km/h (19 MPH) for at least one minute to ensure that
the malfunctioning part or unit has been repaired properly.
If more than two circuits malfunction at the same time, the L.E.D. will flash to indicate one of the
malfunctioning circuits. After the circuit has been repaired, the L.E.D. will then flash to indicate that the
other circuit is malfunctioning.

No. of L.E.D.
Malfunctioning part or unit
flashes

1 Left front actuator solenoid circuit

2 Right front actuator solenoid circuit

3 or4 Rear actuator solenoid circuit

5 Left front rotor sensor circuit

6 Right front rotor sensor circuit

7 Right rear rotor sensor circuit

8 Left rear wheel sensor circuit

9 Actuator motor, motor relay circuit

10 Actuator solenoid valve relay

16 Control unit

Warning acti-
vates and
Power supply or ground circuit for control unit
L.E.D.
"OFF"
Example
Improper operation of left front rotor sensor circuit

1 cycle

L.E.D. "ON"
L.E-.D. "OFF" -
Ln_n_n_r- ILfU1__IUl --- Repeat

1--
1-2 sec. 5-10sec.

SBR531A

Go to Diagnostic Procedure from 7 to 10, where malfunction portion is concerned.

BR-37
- - - - - - - -TTIROUBLE DIAGNOSES

Component Parts Location

2 seater

2+2 seater

SBR555B

BR-38
 TROUBLE DIAGNOSES

Harness Connector Location

Front wheel sensor R.H. Front wheel sensor L.H.

SBR785A

BR-39
TROUBLE DIAGNOSES

Ground Circuit Check

FRONT WHEEL SENSOR L.H. SHIELDED WIRE GROUND
• Check resistance between both terminals.
Resistance: approx. on

FRONT WHEEL SENSOR R.H. SHIELDED WIRE

GROUND
• Check resistance between both terminals.
Resistance: approx. on

ACTUATOR MOTOR GROUND

• Check resistance between both terminals.
Resistance: approx. 0 n

BR-40
 TROUBLE DIAGNOSES

Circuit Diagram for Quick Pinpoint Check

STOP LAMP
SWITCH
1 GNI TI ON SWITCH
ON or START

®~~~
tmjffimur
• The Unit side connectors with a
double circle "0" are connected
to the harness side connectors -=
shown in the "Harness Connector
Location". (See page BR-39.)
• The terminal numbers in the con-
nector coincide with the circuit
numbers surrounded by a single
circle "o ". SBR881A

BR-41
 TROUBLE DIAGNOSES

Diagnostic Procedure 1
Brake pedal
SYMPTOM: Pedal vibration and noise
Refer to worksheet result.

Check whether the symptom ap- Yes

1--'-'~11"1 When brake is normally applied,
pears only when brake is ap- A.B.S. works and produces
plied suddenly. pedal vibration or noise.
0
SAT797A
Check whether the symptom ap- Yes
!---!-!=-~ Refer to Preliminary Check 4
pears only when engine is result.
started.

I ·~ tiD
0

Check whether the symptom ap- Yes

t-=-==-~ Check whether the symptom dis-
pears onlywhen the vehicle appears within 5 seconds.
speed is within 10 km/h (6 MPH) es
after starting engine.
0

A.B.S. may sometimes operate

when load is high and voltage is
low due to insufficient alternator
output.

Check whether the symptom ap- No

pears while the vehicle is being @
driven.
es

No
Brake pedal (Appears when brake
.-----------~~--------_,isnot~a~~~------------------,
Check whether the symptom ap- t---~ Check if there are any condi-
pears when brake is applied tions, among those listed below,
gradually. when symptom appears.
es • Shifting
• Operating clutch
• Passing protrusion
es

SAT797A

@ Under these conditions individ-

ual wheel speed can change
suddenly. This may sometimes
cause the A.B.C. to operate.

BR-42
TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Cont'd)
~
...
Check if there are any condi- Yes For such conditions, if wheel
tions, among those listed below, speed is considerably different
when symptom appears. between front and rear or left
• Low friction road and right, A.B.S. will work nor-
• High speed cornering mally.
• Passing protrusion
No
A

Check whether engine speed is Yes Vibration related to sensor may

over 5,000 rpm with vehicle cause A.B.S. operation.
stopped.
No

Check whether electrical equip- Yes Check front wheel sensor shield
ment switches are operated. ground.
No Refer to Ground Circuit Check.
l N.u. IU.K.
!:
Refer to Preliminary Check 4 IRemedy. I
result.
Go to Self-diagnosis. (See page ...
BR-37.) IReplace control unit. I

Diagnostic Procedure 2
SYMPTOM: Long stopping distance
Refer to worksheet results.

Yes
Check if road condition is ...,. Stopping distance may be
slippery with snow or gravel. longer than vehicles which are
not equipped with A.B.S.
No

Disconnect actuator connector No Refer to Preliminary Check 4

and check whether stopping result.
distance is still long. Go to Self-diagnosis. (See page
Yes BR-37.)

Perform Preliminary Check 1

and air bleeding.

BR-43
 TROUBLE DIAGNOSES

Diagnostic Procedure 3
SYMPTOM: Abnormal pedal action
Refer to worksheet results.

Check whether brake pedal Yes Vehicle equipped with A.B.S.

stroke is abnormally large. may have a tendency for large
No pedal strokes.

Check that brake pedal force is Yes

~I I
Normal condition.
I
firm but brake is effective.
No
m
Disconnect actuator connector Yes Refer to Preliminary Check 4
and check whether brake is result.
effective. Go to Self-diagnosis. (See page
BR-37.)
No

Perform Preliminary Check 1.

Diagnostic Procedure 4
SYMPTOM: A.B.S. doesn't work.
Refer to worksheet results.
NISSAN ~
G ASS-CHECKER .....
KV999P1000
1!1
... Check whether warning activates. 1
Yes Refer to Preliminary Check 4
Main switch__...-<j result.

0
~~®--a·
.2.
9 No Go to Self-diagnosis. (See page
BR-37.)

SBR902A Check whether vehicle speed is Yes A. B.S. doesn't work in this
under 10 km/h (6 MPH). condition.
No

Refer to Preliminary Check 2

result.
O.K. but
[!] A. B.S. still doesn't work.
Check actuator by referring to
Electrical Components lnspec-
tion- ACTUATOR.
(See page BR-52.)

BR-44
 TROUBLE DIAGNOSES

Diagnostic Procedure 5
SYMPTOM: A. B.S. works but warning activates.

Check whether alternator

produces proper output.
~ Remedy.
I
Refer to EL section.

l Yes

Check whether battery has

enough voltage.
~ Remedy. I
Refer to EL section.

lYes

Refer to Preliminary Check 4

result.
Go to Self-diagnosis. (See page
BR-37.)

Diagnostic Procedure 6
SYMPTOM: A.B.S. works frequently.

m N.G.J
CHECK BRAKE FLUID
PRESSURE.
"I Perform Preliminary Check 1.
I
Check whether brake fluid
pressure distribution is normal.
02/01:
Rear 4,609 - 5,002 kPa
SBR792A
(47 • 51 kg/cm 2 ,
668 - 725 psi)/6,865 kPa
I!! P, = P2 ,,'
(70 kg/cm 2 , 995 psi)
~~-
~ ~
'iii

o. ,,''
\ ,.,',
I!] l O.K.

E "eu
.....
~ i
--------------;~'----

5 /
,,
Check whether front axles have
excessive looseness. H Remedy .
I
~-
.J:J <a
.._a..
<a~
~a: o,
! No

P1 kPa (kg/cm 2 , psi) Perform Preliminary Check 2 and

Front brake fluid pressure Ground Circuit Check.
SBR543A

SMA525A

BR-45
 TROUBLE DIAGNOSES

Control unit connector Diagnostic Procedure 7

@4) ACTUATOR SOLENOID (L.E.D. flashing number 1 - 4)

INSPECTION START
Remove battery negative
terminal connector.

l O.K.I
CHECK SOLENOID VALVE --+I Replace control unit.
SBR847A RESISTANCE.
Disconnect control unit con-
Actuator connector 8105
nector.
Check resistance between con-
trol unit connector (vehicle side)
terminals.
Flashing number 1:
Terminals @ and ®
Flashing number 2:
Terminals @ and ®
Flashing number 3 or 4:
Terminals@ and@
SBR841A Resistance: 0.7- 1.&n
JN.G.
Disconnect actuator connector. ~ Repair harness between actuator
Check resistance between connector and control unit con-
actuator connector (actuator nector.
side) terminals.
Flashing number 1:
Terminals @ and CD
Flashing number .2:
Terminals @ and ®
Flashing number 3 or 4:
Terminals @ and @
Resistance: 0.7- 1.&n

l N.G.

Replace actuator.

BR-46
 TROUBLE DIAGNOSES

EJ Control unit connector Diagnostic Procedure 8

WHEEL SPEED SENSOR (L.E.D. flashing number 5 - 8)

INSPECTION START
Remove battery negative
terminal connector.

DISCIIIIIIfCT
m 1 O.K.J
CHECK SPEED SENSOR l Replace control unit.
J
10 RESISTANCE
Disconnect control unit con-
nector.
Check resistance between con-
trot unit connector (vehicle side)
terminals.
Flashing number 5 (Fr, L.H.):
Terminals @ and ®
Flashing number 6 (Fr, R.H.):
Terminals @ and ®
Flashing number 7 (Rr, R.H.):
Terminals ® and @
Flashing number 8 (Rr, L.H.):
Terminals @ and ®
Resistance: 0.8 · 1.2 k.G

l O.K.
N.G.J
Refer to Preliminary Check 3
result.
'I Replace sensor.
J
Check whether sensor has 0.8 -
1.2 k.n resistance.

! O.K.

Repair harness between sensor

connector and control unit con-
nector.

BR-47
 TROUBLE DIAGNOSES

Control unit connector ~

Diagnostic Procedure 9
~
ACTUATOR MOTOR RELAY (L.E.D. flashing number 9)

INSPECTION START
Remove battery negative
terminal connector.

-lET m l lil
IV
SBR849A
CHECK MOTOR RELAY
SOLENOID RESISTANCE.
N.G.
Disconnect actuator connector.
Check resistance between
Disconnect control unit con· actuator connector (actuator
Actuator connector
nector. side) terminals @ and @.
8 Check resistance between con- Resistance: 45- 55il

I IV~
9
10
trol unit connector (vehicle side)
terminals@ and@.
Resistance: 45- 55il
lO.K.
II ~ N.G.
Repair harness Replace
!O.K. between motor
IE)
actuator and relay.
CHECK MOTOR RELAY control unit.
DEACTIVATION.
SBR791A
Disconnect actuator connector.
Check continuity between

~0 actuator connector (actuator

side) terminals @ and ®.
cI II ! Yes No

Replace motor relay.

I
(!)
No Perform Electrical Components
Check visually if motor's fusible
link is blown. Inspection- ACTUATOR.
Resistance: (See page BR-52.)
Approximately Oil ~O.K. ~N.G.
! Yes Replace
control unit.
Replace
actuator.
J Replace fus1ble hnk.

SBR843A

BR-48
 TROUBLE DIAGNOSES

Diagnostic Procedure 10
ACTUATOR SOLENOID VALVE RELAY (L.E.D. flashing
number 10)
INSPECTION START
Remove battery negative
terminal connector.

m 1!1
CHECK SOLENOID VALVE N.G. Check resistance between
~
SBR850A RELAY RESISTANCE. actuator connector (actuator
Disconnect control unit con- side) terminals (j) and @,
I!J Actuator connector
nector. Resistance: 80 - 90il
8 Check resistance between con-
l
trol unit connector (vehicle side)
~O.K. [iJ N.G.
terminals @ and @, Repair harness Replace sole-
Resistance. 80-90il between noid valve
O.K. actuator and relay.
control unit

I!J [iJ
SBR757A Yes .1
CHECK SOLENOID VALVE Replace solenoid valve relay.
RELAY MOVEMENT.
Disconnect actuator connector.
Check continuity between
actuator connector (actuator
side) terminals ® and @.

No
lil
No
Check visually if solenoid valve ~ Perform Electrical Components
relay fuse is blown. Inspection- ACTUATOR.
Yes (See page BR-52.)

.l N.G. !O.K .
I Replace fuse.
I Replace
actuator.
IReplace
control unit.

SBRB44A

BR-49
TROUBLE DIAGNOSES

Diagnostic Procedure 11
CONTROL UNIT (L.E.D. flashing number 16)

INSPECTION START

Control unit malfunction.

Replace control unit.

BR-50
 TROUBLE DIAGNOSES

Diagnostic Procedure 12
CONTROL UNIT OR POWER SUPPLY AND GROUND
CIRCUIT (Warning activates but L.E.D. comes off.)

( INSPECTION START

DISCONIECT
m ! N.G. Check if control unit "lOA" fuse
CHECK CONTROL UNIT
I?J POWE A SUPPLY. is blown.
SBR851A
Disconnect control unit con- !Yes ! No
nector.
Check voltage between control
unit connector (vehicle side)
I
Replace fuse.
I Repair power
supply harness.
terminal CD and body ground
with ignition switch turned on.

liJ l O.K.
N.G.
CHECK ALTERNATOR L Check if other warnings activate.

-= SBR852A
TERMINAL VOLTAGE.
Disconnect control unit con- l Yes l No
nector. Malfunc-
Repair harness
Check voltage between control tioning
between alter-
unit connector (vehicle side) alternator.
nator and
terminal @ and body ground
control unit.
after engine starting.
Voltage: 6V or more

[i) !O.K.
N.G.
Check continuity between Repair ground harness.
control unit connector (vehicle
DISCGIIIECT
side) terminal ® and body
E?J ground with ignition switch
"OFF".
~O.K.

Replace control unit.

BR-51
 TROUBLE DIAGNOSES

Electrical Components Inspection

ACTUATOR (Not self-diagnostic Item)

INSPECTION START

Connect A.B.S. checker to actua-

tor connector and vehicle har-
ness with battery terminal con-
nected and all checker switch
turning off.
Motor relay
Solenoid indicator ~o~er supply Use harness for 3 channel.
valve indiCatOr"\ Indicator Set channel select switch to 3
MSSAN I
channel.
G ABS-CHECKER ~
KV999P1000
...
Main switch___.-(j Turn checker main switch on. No Replace battery with fully

~-®--a· 9 Check power supply indicator charged new one, if checker

---
G

-- SBR902A
for coming on.

I!)
~--~------L---------~
es
connection is correct.

p=---·111>1 Replace solenoid valve relay, if

checker connection is correct.

!-'-'-'=---·~ Replace motor relay, if checker

connection is correct.

Check motor for operational No Replace actuator as assembly, if

sound beside the actuator in a Diagnostic Procedures 7- 12 are
quiet place. already performed and checker
es connection is correct.

...
@

BR-52
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)

II ~•
Bring checker in the vehicle
and depress the brake pedal.

~
Check brake pedal for vibra- N.G. ~ Replace actuator as assembly.
tion when motor switch is
turned on or while operating
solenoid valve selecting switch
'SBR797A with motor switch turned on.
N.G.: No vibration
O.K.: Vibration
f.K.
Check brake pedal for depres- N.G. ~ Replace actuator as assembly.
sion when select pressure in-
creases.
LU.K.
Have all wheel positions been No ~ Repeat from step @ .
checked?
1Yes

I Actuator works•normally

CAUTION:
Do not set checker at pressure decrease position for more than
5 seconds at a time. Actuator solenoid valve may be damaged.

BR-53
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications
Applied model VG30DE VG30DETT

Without With
A. B.S. A.B.S.
-

Front brake
Brake model OPZ25VA

Cylinder bore diameter

40.45 ( 1.5925) X 4
mm (in)

Pad length x width 116 X 50 X 10

x thickness mm (in) (4.57 X 1.97 X 0.39)

Rotor outer diameter 280 X 30

x thickness mm (in) (11.02 X 1.18)

Rear brake
Brake model OPZ11VB

Cylinder bore diameter

38.1 (1.5001 x2
mm (in)

Pad length x width 71.8 X 36.5 X 11.5

x thickness mm(inl (2.827 X 1.437 X 0.453)

Rotor outer diameter 297 X 18

x thickness mm (in) (11.69 X 0.71)

Master cylinder
Cylinder bore diameter 23.81 26.99
mm(inl (15/161 (17/161

Control valve
Proportioning valve
Valve model
(within master cylinder)

Split point x reducing 3,432 2.452

ratio (35, 4981 (25, 3561
kPa (kg/em•, psi) X 0.4 X 0.4

Brake booster
Booster model M215T

Diaphragm diameter Primary: 230 (9.061

mm (in) Secondary: 205 (8.071

Brake fluid
Recommended brake
DOT3
fluid

Parking drum brake

Brake model DS17HD

Lining
Width x thickness 154.1 X 25.0 X 3.0
x length mm(inl (6.07 X 0.984 X 0.118)

Drum inner diameter

172.0 (6.771
mm(inl

BR-54
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

Inspection and Adjustment

FRONT DISC BRAKE BRAKE PEDAL
Unit: mm (in) Unit: mm (in)

Brake model OPZ25VA Applied model M/T A/T

Pad wear limit 186-196 195-205

2.0 (0.07~) Free height
Minimum thickness (7 .32 - 7 .72) (7 .68- 8.07)

Rotor repair limit Depressed height

Minimum thickness 28.0 (1.102) [under force of 490 N (50 kg,
110 Ib) with engine running]
Maximum runout 0.07 (0.0028)
With A.B.S. 105 (4.13) 110(4.33)

Without A.B.S. 95 (3.74) 105 (4.13)

REAR DISC BRAKE Clearance between pedal stopper

0.3 - 1.0 (0.012 - 0.039)
Unit: mm (in) and threaded end of switches

Brake model OPZ11VB Pedal free play at clevis 1 - 3 (0.04 - 0.12)

Pad wear limit

Minimum thickness 2.0 (0.079)

Rotor repair limit PARKING BRAKE

Minimum thickness 16.0 (0.630)
Number of notches
Maximum runout 0.07 (0.0028) [under force of 196 N 6-7
(20 kg, 44 Ib) l

Number of notches
PARKING DRUM BRAKE (when warning switch
Unit: mm (in) comes on)

Brake model DS17HD

Lining replacement limit

Minimum,thickness 1.5 (0.059)

Drum repair limit

Maximum inner diameter 173.0 (6.81)

BR-55
 STEERING SYSTEM

SECTIONST

CONTENTS
PRECAUTIONS ....................................................................................................................... ST- 2
PREPARATION ........................................................................................................................ ST- 3
ON-VEHICLE INSPECTION ..................................................................................................... ST- 5
ON-VEHICLE INSPECTION (Power steering) ........................................................................ ST- 7
STEERING WHEEL AND STEERING COLUMN ...................................................................... ST-10
POWER STEERING GEAR AND LINKAGE (Model PR26SE) ................................................. ST-14
POWER STEERING OIL PUMP ............................................................................................... ST-26
TWIN ORIFICE POWER STEERING SYSTEM ........................................................................ ST-30
TWIN ORIFICE POWER STEERING SYSTEM- Trouble Diagnoses ................................... ST-32
SUPER HICAS SYSTEM ......................................................................................................... ST-43
SUPER HICAS SYSTEM- On-vehicle Inspection ............................................................... ST-44
SUPER HICAS SYSTEM- Repair of Component Parts ...................................................... ST-48
SUPER HICAS SYSTEM- Trouble Diagnoses .................................................................... ST-60
SERVICE DATA AND SPECIFICATIONS (S.O.S.) .................................................................. ST-96
 PRECAUTIONS

Supplemental Restraint System "AIR BAG"

The Supplemental Restraint System "Air Bag" helps to reduce
the risk or severity of injury to the driver in a frontal collision.
The Supplemental Restraint System consists of an air bag
(located in the center of the steering wheel), five sensors, a
control unit, warning lamp, wiring harness and spiral cable.
Information necessary to service the system safely is included
in the BF section of this Service Manual.
WARNING:
a. To avoid rendering the SRS inoperative, which could lead
to personal injury or death in the event of a severe frontal
collision, all maintenance must be performed by an autho-
rized NISSAN dealer.
b. Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
c. All SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation. Do not use electrical
test equipment on any circuit related to the SRS "Air Bag".
Steering System
• Before disassembly, thoroughly clean the outside of the
unit.
• Disassembly should be done in a clean work area. It is
important to prevent the internal parts from becoming
contaminated by dirt or other foreign matter.
• When disassembling parts, be sure to place them in order
in a parts rack so they can be reinstalled in their proper
positions.
• Use nylon cloths or paper towels to clean the parts;
common shop rags can leave lint that might interfere with
their operation.
• Before inspection or reassembly, carefully clean all parts
with a general purpose, non-flammable solvent.
• Before assembly, apply a coat of recommended A.T.F.* to
hydraulic parts. Vaseline may be applied to 0-rings and
seals. Do not use any grease.
• Replace all gaskets, seals and 0-rings. Avoid damaging
0-rings, seals and gaskets during installation. Perform
functional tests whenever designated.
*· Automatic transmission fluid

ST-2
 PREPARATION

SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name
KV48100700 Measuring pinion rotating torque
(J26364)
Torque adapter

ST27180001 Removing steering wheel

(J25726-A)
Steering wheel puller

HT72750000 Removing ball joint

( )
Ball joint remover

ST27091000 Measuring oil pressure

(J26357)
Pressure gauge

KV48102500 Measuring oil pressure

( )
Pressure gauge adapter

ST3127SOOO Measuring turning torque

(See J25765-A)
G) GG91030000
(J25765-A)
Torque wrench
@HT6294000
( )
Socket adapter
@ HT62900000
( )
Socket adapter
KV48104400 Reforming teflon ring
( )
Rack seal ~ngr~ormer

ST-3
 PREPARATION

SPECIAL SERVICE TOOLS (Cont'd)

Tool number
(Kent-Moore No.) Description
Tool name
KV32101100 Removing and installing tube seat
( )
Pin punch

COMMERCIAL SERVICE TOOLS

Tool name Description

Rear oil seal drift Installing rear oil seal

Pinion oil seal drift Installing pinion oil seal

Oil pump attachment Disassembling and assembling oil

pump
40
(1.57)

Unit: mm (in) SST481A

ST-4
 ON-VEHICLE INSPECTION

Checking Steering Wheel Play

• With wheels in a straight-ahead position, check steering
wheel play.
Steering wheel play:
35 mm (1.38 In) or less
• If it is not within specification, check steering gear assem-
bly when front suspension and axle, steering gear assem-
bly and steering column are mounted correctly.

O.K. N.G. Checking Neutral Position on Steering Wheel

Pre-checking
• Make sure that wheel alignment is correct.
Wheel alignment:
Refer to section FA for S.O.S.
• Verify that the steering gear is centered before removing
the steering wheel.

Checking
SST104B
1. Check that the steering wheel is in the neutral position
when driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel
and reinstall it correctly.
3. If the neutral position is between two serrated teeth, loosen
tie-rod lock nut and move tie-rod in the opposite direction
by the same amount on both left and right sides to compen-
sate for error in the neutral position.

Front Wheel Turning Angle

1. Rotate steering wheel all the way right and left; measure
turning angle.
Turning angle of full turns:
Refer to section FA for S.O.S.

2. If it is not within specification, check rack stroke.

Rack stroke "L":
Refer to S.O.S.

SST307B

ST-5
ON-VEHICLE INSPECTION

Checking Gear Housing Movement

1. Check the movement of steering gear housing during
stationary steering on a dry paved surface.
• Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check
the gear housing movement.
Turn off ignition key while checking.
Movement of gear housing:
± 2 mm ( ± 0.08 in) or less
2. If movement exceeds the limit, replace mount insulator
after confirming proper installation of gear housing clamps.

Adjusting Rack Retainer

• Perform this driving test on a flat road.
1. Check whether vehicle moves in a straight line when
steering wheel is released.
2. Check whether steering wheel returns to neutral position
when steering wheel is released from a slightly turned
(approx. 20•) position.
• If any abnormality is found, correct it by resetting adjusting
screw.

ST-6
ON-VEHICLE INSPECTION (Power steering)

Checking and Adjusting Drive Belts

Refer to section MA for Drive Belt Inspection.

Checking Fluid Level

Check fluid level.
Fluid level should be checked using "HOT" range on dipstick at
fluid temperatures of 50 to 80°C (122 to 176°F) or using "COLD"
range on dipstick at fluid temperatures of 0 to 30°C (32 to 86°F).
CAUTION:
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid
"DEXRON™ Type".

Checking Fluid Leakage

Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing or deterioration.
1. Run engine at idle speed or 1,000 rpm.
Make sure temperature of fluid In oil tank rises to 60 to 80°C
(140 to 176°F).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each "lock" position for five seconds
and carefully check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut
and then retighten.
Do not overtighten connector as this can damage 0-ring,
washer and connector.

Bleeding Hydraulic System

1. Raise front end of vehicle until wheels clear ground.
2. Add fluid into oil tank to specified level. Meanwhile, quickly
turn steering wheel fully to right and left and lightly touch
steering stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2 above.
• Incomplete air bleeding will cause the following to occur.
When this happens, bleed air again.
ST-7
 ON-VEHICLE INSPECTION (Power steering)
Bleeding Hydraulic System (Cont'd)
a. Generation of air bubbles in reservoir tank
b. Generation of clicking noise in oil pump
c. Excessive buzzing in oil pump
While the vehicle is stationary or while turning the steering
wheel slowly, fluid noise may occur in the valve or oil pump.
This noise is inherent in this steering system, and it will not
affect performance or durability of the system.

Checking Steering Wheel Turning Force

After turning
360° 1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tem-
perature. [Make sure temperature of fluid is approximately
60 to 80°C (140 to 176°F).]
Tires need to be Inflated to normal pressure.
4. Check steering wheel turning force when steering wheel
has been turned 360° from the neutral position.
Steering wheel turning force:
39 N (4 kg, 9 lb) or less

5. If steering wheel turning force is out of specifications, check

rack sliding force to detect condition of steering gear
assembly.
a. Disconnect steering column lower joint and knuckle arms
from the gear.
b. Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.
c. While pulling tie-rod slowly in the ±11.5 mm (±0.453 in)
range from the neutral position, make sure rack sliding
force is within specification.
SST090B
Average rack sliding force:
Without HICAS
Average value • (Max. value + Min. value) 206 • 265 N (21 • 27 kg, 46 • 60 lb)
1/ 2
{d! With HICAS
.
8
L Maxi mum value
d.
201.0 • 250.1 N (20.5 • 25.5 kg, 45.2 • 56.2 lb)
Check sliding force outside above range.
r Maximum rack sliding force:
Mini mum value Not more than 39 N (4 kg, 9 lb) beyond abov~ value
. 6. If rack sliding force is not within specification, overhaul
steering gear assembly.
-(-DA53)
11.& N ut 1 11.& Rack stroke
1 ra (0.4&3)-
SST717A position Unit: mm (in)

ST-8
 ON-VEHICLE INSPECTION (Power steering)

Checking Hydraulic System

Before starting, check belt tension, driving pulley and tire
pressure.
1. Set Tool. Open shut-off valve. Then bleed air. (See
"Bleeding Hydraulic System".)
2. Run engine.
Make sure temperature of fluid In tank rises to 60 to 80°C (140 to
176°F),
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, oil pressure In oil pump will
Increase to relief pressure, resulting In an abnormal rise In oil
' - - - - - - - ' - - Low-preuure
temperature.
. . : Direction of oil flow hose 3. Check pressure with steering wheel fully turned to left and
right positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Oil pump maximum standard pressure:
SST834 7,649- 8,238 kPa (78 - 84 kg/cm 2, 1,109- 1,194 psi)
4. If oil pressure is below the standard pressure, slowly close
shut-off valve and check pressure.
• When pressure reaches standard pressure, gear is dam-
aged.
• When pressure remains below standard pressure, pump is
damaged.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
5. If oil pressure is higher than standard pressure, check oil
pump flow control valve.
6. After checking hydraulic system, remove Tool and add fluid
as necessary, then completely bleed air out of system.

ST-9
 STEERING WHEEL AND STEERING COLUMN

Without air bag

~ ~ 29 - 39 ------'\
Column cover~ (3.0 - 4.0, 22 - 29)
Steering wheel

Steering tube assembly

~24- 29
) • a~ 11 ·"22""')~ With air bag

Steering wheel
@

~ : N·m (kg-m, ft-lb)

Lower joint
SST701B

Removal
STEERING WHEEL (With air bag)
• Remove screws from both sides of steering wheel and pull
out horn pad. Refer to section BF for Air Bag Module and
Spiral Cable Removal.

SBF812E

• Align spiral cable correctly when installing steering wheel.

Alignment mark

SST4958

STEERING WHEEL (Without air bag)

• Remove screw from rear of steering wheel and pull out
horn pad.

SST312B

ST-10
 STEERING WHEEL AND STEERING COLUMN
Removal (Cont'd)
• Remove steering wheel with Tool.

Installation
STEERING WHEEL
When installing steering wheel, apply multi-purpose grease to
entire surface of turn signal cancel pin (both portions) and also
to horn contact slip ring.

SST112B

STEERING COLUMN
i • When installing steering column, fingertighten all lower
bracket and clamp retaining bolts; then tighten them se-
L. curely. Do not apply undue stress to steering column.
• When attaching coupling joint, be sure tightening bolt faces
cutout portion.
CAUTION:
After installing steering column, turn steering wheel to make
sure it moves smoothly and that the number of turns from the
Lower joint straight forward position to left and right locks are equal.
SSTBOOA
Be sure that the steering wheel is in a neutral position when
driving straight ahead.

ST-11
 STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly

Steering lock
assembly

Jacket tube
bracket insulator

Column shaft assembly

A
~-a
I2A • 3.0, 17 . 22)
I~
,
~

[ql : N·m (kg-m, ft-lb) Lower joint

SST314B

• When disassembling and assembling, unlock steering lock

with key.
• Install 0-ring G) before inserting shaft into jacket tube.
Ensure that rounded surface of snap ring faces toward
bearing when snap ring is installed.

SST428A

• Install snap ring on upper shaft with box wrench.

1 - - - - Upper shaft

SST770A

ST-12
STEERING WHEEL AND STEERING COLUMN
Disassembly and Assembly (Cont'd)
•a) Steering lock
Break self-shear type screws with a drill or other appropri-
ate tool.
b) Install self-shear type screws and then cut off self-shear
type screw heads.

Self·shear screw

SST742A

Inspection
• When steering wheel can not be rotated smoothly, check
the steering column for the following matters and replace
damaged parts.
a. Check column bearings for damage or unevenness. Lubri-
cate with recommended multi-purpose grease or replace
steering column as an assembly, if necessary.
b. Check steering column lower shaft for deformation or
breakage. Replace if necessary.
• When the vehicle is involved in a light collision, check
SST315B
steering column length "L 1 " and steering column lower
shaft length "L 2 ". If it is not within specifications, replace
steering column as an assembly.
Steering column length "L 1":
Without air bag
745.9- 747.5 mm (29.37- 29.43 in)
With air bag
749.4 - 751.0 mm (29.50 · 29.57 In)
Steering column lower shaft length "L 2":
280.6- 282.2 mm (11.05- 11.11 In)

ST-13
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)

Removal and Installation

~24-29
(2.4- 3.0, 17- 22)

Gear housing mounting bracket Rack mounting insulator

/Cotter
~ 29 -39 (3.0 - 4.0, 22- 29) ...( pin~

~ ~
©

Gear and linkage

assembly
Front

~ : N·m (kg-m, ft-lb)

SST317B

• Detach tie-rod outer sockets from knuckle arms with Tool.

SST783A

• Install pipe connector.

CD Low-pressure side
tsJ: ·36- 40 N·m (3.7- 4.1 kg-m, 27- 30 ft-lb)
® High-pressure side
tcj: 30- 35 N·m (3.1 - 3.6 kg-m, 22- 26 ft-lb)

ST-14
POWER STEERING GEAR AND LINKAGE {Model PR26SE)
Removal and Installation {Cont'd)
• Observe specified tightening torque when tightening high-
pressure and low-pressure pipe connectors. Excessive
tightening can damage threads or damaged connector
0-ring.
• The 0-ring in low-pressure pipe connector is larger than
that in high-pressure connector. Take care to install the
proper 0-ring.

• Initially, tighten nut on tie-rod outer socket and knuckle arm

to 29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten
further to align nut groove with first pin hole so that cotter
pin can be installed.
CAUTION:
Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).

arm SSTB24A

• Before removing lower joint from gear, set gear in neutral

(wheels in straight-ahead position). After removing lower
joint, put matching mark on pinion shaft and pinion housing
to record neutral position of gear.
• To install, set left and right dust boots to equal deflection,
and attach lower joint by aligning matching marks of pinion
shaft and pinion housing.

ST-15
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)

........
~

~®~
-
()~~ ~16-21(1.6-2.1,12-15)

(~
~

~ "'" hoo''""uom~y fJ:\ \

Rear housing cover

'L
\ ~-.ol 7-12 (0.7 -1.2, 5.1· 8.7)

Solenoid valve
'!..K~- \

~)

r
- 0 ':...~l

- __..----- Lock nut ~Pinion

~ 39-59~Adjustingscrew~IE!I
(4.0 -6.0,
s~al ~
nng~
29. 43) ;L~ Spring Pinion
rJ ~ Sp.ring disc assembly IE!I
~ 0-nng~\

Washer
Spring seat
~
12

Retainer
y--..
12
Shim~~
~~Pinionoilseai~IE!I

'
,
~
;:::::::;::· ~
__. . .
'...!..\--1

Cylinder tube
~ 20-26 (2.0. 2.7, 14- 20)

Tie-rod ~ : N·m (kg-m, ft-lbl

Do not disassemble.
SST319B

ST-16
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)

Disassembly
1. Prior to disassembling, measure pm1on rotating torque.
Record the pinion rotating torque as a reference.
• Before measuring, disconnect cylinder tube and drain fluid.
• Use soft jaws when holding steering gear housing. Handle
gear housing carefully, as it Is made of aluminum. Do not
grip cylinder In a vise.
2. Remove pinion gear.
• Be careful not to damage pinion gear when removing
pinion seal ring.

3. Remove tie-rod outer sockets and boots.

4. Loosen tie-rod inner socket by prying up staked portion,
and remove socket.
5. Remove retainer.
6. Remove pinion assembly.

SST881

7. Drill staked portion of cylinder end cover with drill of 2 to 2.5

mm (0.079 to 0.098 in) diameter, until the staking is elimi-
nated.

SST450A

8. Remove gear housing end cover assembly with Tool.

9. Draw out rack assembly .

SST081B

10. Remove rack seal ring.

• Using a heat gun, heat rack seal to approximately 4o·c
(104.F).
Rack seal
ring • Remove rack seal ring.
• Replace rack seal ring and 0-ring with new ones.
Be careful not to damage rack.

SST082B

ST-17
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Disassembly (Cont'd)
11. Remove center bushing and rack oil seal using tape
wrapped socket and extension bar.
Do not scratch inner surfaces of pinion housing.

29 mm socket

SST472A

Inspection
Thoroughly clean all parts In cleaning solvent or automatic
transmission fluid "DEXRON™" type, and blow dry with com-
pressed air, if available.
BOOT
Check condition of boot. If cracked excessively, replace it.

RACK
Thoroughly examine rack gear. If damaged, cracked or worn,
replace it.

PINION ASSEMBLY
• Thoroughly examine pinion gear. If pinion gear is damaged,
cracked or worn, replace it.
• Inspect bearings to see that they roll freely and are free
from cracked, pitted, or worn balls, rollers and races.
Replace if necessary.

TIE-ROD OUTER AND INNER SOCKET

• Check ball joint for swinging force.
Tie-rod outer ball joint:
4.61 - 46.1 N
--
(0.47- 4.7 kg, 1.04 - 10.4 lb)
Tie-rod inner ball joint:

~"":W 8.8- 78.5 N

(0.9- 8.0 kg, 2.0- 17.6 lb)

SST333B

• Check ball joint for rotating torque.

ST3127SOOO Tie-rod outer ball joint:
(See J25765-AI
0.29 - 2.94 N·m
(3.0 - 30.0 kg-em, 2.6 - 26.0 ln-lb)
Tie-rod Inner ball joint:
1.0- 8.8 N·m (10- 90 kg-em, 8.7- 78.1 in-lb)

SST751A

ST-18
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Inspection (Cont'd)
• Check ball joint for axial end play.
Tie-rod outer ball joint:
0 mm (0 in)
Tie-rod inner ball joint:
0 mm (0 in)
• Check condition of dust cover. If cracked excessively,
replace it.

CYLINDER TUBES
Check cylinder tubes for scratches or other damage. Replace if
necessary.

Assembly
1. Using a heat gun, heat rack seal ring (made of Teflon) to
approximately 40"C (104"F) and install it onto rack with your
hand.

SST0838

• Using Tool, compress periphery of rack seal ring (made of

Teflon) to position and secure it on rack.
Always Insert the tool from the rack gear side.

SST084B

2. Insert rack oil seal.

• Place plastic film into rack oil seal to prevent damage by
rack teeth.
• Always remove plastic film after rack oil seal is positioned
c--------:::; •
properly.
Make sure lips of rack oil seal face each other.
Film

Rack 011 seal

SST201A

ST-19
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Assembly (Cont'd)
3. Install center bushing and rack oil seal with rack assembly.

4. Insert rack oil seal and end cover assembly to rack then
tighten end cover assembly.

End cover assembly

SST321B

5. Fasten cylinder end cover assembly to gear housing by

staking.

End cover
Gear
assembly
housing

SST073B

6. Set rack gear in neutral position.

Rack stroke "L":
Refer to S.O.S.

SST307B

7. Coat seal lip of oil seal with multi-purpose grease and

install new pinion oil seal to pinion housing with a suitable
tool.
• Make sure lip of oil seal faces up when installed.

-;!__ Oil seal

Rack assembly.........._

ST-20
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Assembly (Cont'd)
8. Install pinion bearing adjusting shim(s).
• Whenever pinion assembly, gear housing and rear housing
are disassembled, replace shim(s) with new ones. Always
use the same number of shim(s) when replacing.

SST074B

9. Install pinion seal ring on pinion gear assembly.

• Using a heat gun, heat pinion seal ring to approximately
40°C (104°F) before installing it onto pinion gear assembly.
• Make sure pinion seal ring is properly settled in valve
groove.

SST323B

10. Apply a coat of multi-purpose grease to needle bearing

roller and oil seal lip before installing pinion assembly in
gear housing.

Needle bearing

SST075B

11. Install pinion assembly to pinion housing.

Be careful not to damage pinion oil seal.

12. Apply a coat of multi-purpose grease to rear oil seal lip

before installing rear housing.

ST-21
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Assembly (Cont'd)
13. Install rear cover cap so that protrusion of rear housing
cover is positioned as shown in figure at left.
Be careful not to damage worm ring and oil seal.

SST326B

14. Install solenoid valve.

SST3168

15. Install diaphragm spring at retainer.

• Always install retainer, spring washer and diaphragm
spring in that order.
• Make sure convex end (painted white) of diaphragm spring
faces outward when installing.
16. Install retainer spring and adjusting screw temporarily.

CAUTION:
Ensure steering gear spacer is installed with rubber side facing
rack.
• Attach lock plate ®to side rod inner socket CD.
• Insert steering gear spacer @ to rack @.
• Apply locking sealant to inner socket threads @. Screw
inner socket into rack @ and tighten to specified torque.
• Stake lock plate at two places.

17. Install steering gear spacer ® to lock plate ®.

ST-22
POWER STEERING GEAR AND LINKAGE {Model PR26SE)
Assembly {Cont'd)
18. Tighten outer socket lock nut.
Tie-rod length "L":
Refer to S.O.S.

L !ji ~~

SST093B

19. Measure rack stroke.

Rack stroke "L":
Refer to S.O.S.

SST307B

20. Before installing boot, coat the contact surfaces between

boot and tie-rod with grease.

SST329B

21. Install boot clamps.

• To install, wrap boot clamp around boot groove twice.
Tighten clamp by twisting rings at both ends 4 to 4-1/2 turns
with screwdriver while pulling with a force of approx. 98 N
(10 kg, 22 lb).

• Install boot clamp so that it is to the rear of the vehicle when

gear housing is attached to the body. (This will prevent
interference with other parts.)

ST-23
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Assembly (Cont'd)
• N 110 kg, 22 lb) • Twist boot clamp in the direction shown in figure at left.

'"
SST440A

• After twisting boot clamp, bend twisted and diagonally so it

does not contact boot.

SST126B

Lock nut Adjustment

Adjust pinion rotating torque as follows:
1. Set gears to Neutral without fluid in the gear.
2. Coat the adjusting screw with locking sealant and screw it
in.
3. Lightly tighten lock nut.
4. Tighten adjusting screw to a torque of 4.9 to 5.9 N·m (50 to
60 kg-em, 43 to 52 in-lb).
5. Loosen adjusting screw, then retighten it to 0.05 to 0.20 N·m
(0.5 to 2 kg-em, 0.43 to 1.74 in-lb).
SSTOB9B
6. Move rack over its entire stroke several times.
7. Measure pinion rotating torque within the range of 180°
from neutral position.
Stop the gear at the point of maximum torque.
8. Loosen adjusting screw, then retighten it to 4.9 N·m (50
kg-em, 43 in-lb).
9. Loosen adjusting screw by 60° to 100°.

SST320B

10. Prevent adjusting screw from turning, and tighten lock nut
to specified torque.

SST557A

ST-24
 POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Adjustment (Cont'd)
11. Check steering gear for rack sliding frictional force.
Around neutral point of rack stroke
±5.5 mm (±0.217 In):
122.6 - 166.7 N (12.5- 17 kg, 27.6- 37.5 lb)
Except for neutral point:
122.6- 186.3 N (12.5- 19 kg, 27.6- 41.9 lb)
• If sliding frictional force is out of specification, repeat the
adjustment procedure, starting from No. 4.
• After the readjustment, if sliding force is still out of speci-
fication, steering gear is damaged.
SST090B

12. Measure pinion rotating torque within the range of ± 100"

from the neutral point.
Average rotating torque
[(Max. measured value + Min. measured value) x 0.5]:
0.8- 1.3 N·m (8- 13 kg-em, 6.9- 11.3 ln-lb)
Maximum torque increment:
Less than 0.4 N·m (4 kg-em, 3.5 in-lb)
Except for above ·mentioned measuring range:
Maximum rotating torque
1.9 N·m (19 kg-em, 16 in-lb)
SST320B
Maximum torque Increment
Less than 0.6 N·m (6 kg-em, 5.2 ln-lb)
• If pinion rotating torque is not within specification, readjust
it.
• After the readjustment, if pinion rotating torque is still out of
specification, steering gear is damaged.

13. Check rack sliding force on vehicle as follows:

a. Install steering gear onto vehicle, but do not connect tie-rod
to knuckle arm.
b. Connect all piping and fill with steering fluid.
c. Start engine and bleed air completely.
d. Disconnect steering column lower joint from the gear.
e. Keep engine at idle and make sure steering fluid has
reached normal operating temperature.
f. While pulling tie-rod slowly in the ± 11.5 mm ( ± 0.453 in)
range from the neutral position, make sure rack sliding
SST090B
force is within specification.
Average rack sliding force:
Average value • (Max. value +Min. value) Without HICAS
1/ 2
~ 206 - 265 N (21 - 27 kg, 46 - 60 lb)
.21 - I_L
I
Maximum value
With HICAS
201.0 - 250.1 N (20.5 - 25.5 kg, 45.2 - 56.2 lb)
a>
s g. Check sliding force outside above range.
..- Mini mum value Maximum rack sliding force:
..
u
a: •
Not more than 39 N (4 kg, 9 lb) beyond above value
If rack sliding force is not within specification, readjust by
repeating adjustment procedure from the beginning.
- 1 1 •6 11.5 Rack stroke
(-0.453) Neutral (0.4531- • If rack sliding force is still out of specification after read-
SST717A position Unit: mm (in)
justment, gear assembly needs to be replaced.
 POWER STEERING OIL PUMP

Disassembly and Assembly

Connector bolt rPJ 49- 69 (5.0 - 7 .0, 36 ·51)

rPJ 14 -18 .
(1.4 -1.8, 10 -13)

27-35
; : (2.8 -3.6,
20.261

Sub-brae ket

rPJ: N·m (kg-m, ft-lb)

SST331B

Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following
items are found.
• Oil leak from any point shown in the figure.
• Deformed or damaged pulley.
• Poor performance

SST128B

ST-26
 POWER STEERING OIL PUMP

Disassembly
CAUTION:
• Parts which can be disassembled are strictly limited.
Never disassemble parts other than those.speclfied.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• Follow the procedures and cautions in the Service Manual.
• When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

• Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shaft.

SST010B

• Remove oi I seal.
Be careful not to damage front housing.

• Remove connector.
Front housing Be careful not to drop control valve.

SST036A

Inspection
Inspect each component part for wear, deformation, scratches,
and cracks. If damage is found, replace the part.

ST-27
 POWER STEERING OIL PUMP

Assembly
Assemble oil pump, noting the following instructions.
• Make sure 0-rings and oil seal are properly installed.
• Always install new 0-rings and oil seal.
• Be careful of oil seal direction.
• Cam ring, rotor and vanes must be replaced as a set if
necessary.
• Coat each part with A.T.F. when assembling.

SST038A

Rear housing side Front housing side • Pay attention to rotor direction.

SST289A

• When assembling vanes to rotor, rounded surfaces of

vanes must face cam ring side.

Flat portion

SST843A

• Apply A.T.F. to 0-ring.

SST332B

ST-28
 POWER STEERING OIL PUMP
Assembly (Cont'd)
• Insert pin ® into pin groove CD of front housing and front
side plate. Then install cam ring @ as shown at left.

f Front housing side

SST497A

ST-29
 TWIN ORIFICE POWER STEERING SYSTEM

Hydraulic Circuit
Steering gear assembly
r-----------------,
1 Rotary valve
I
I
I
I
I
I
I
I Power cylinder
I

Speed sensor

Reservoir Solenoid valve

tank Pump
r.-7\

I
I
I
I
I
I
I
I
I Control unit
I
I
~------------------~

SST337B

Schematic

DIAGNOSTIC
CONNECTOR
FOR CONSULT

®POWER
STEERING
~SOLENOID
UlillJ VALVE

INHIBITOR
SWITCH

0 (ill) VEHICLE
SPEED
@ : M/T model -::- -::- -::- -::- SENSOR
INHIBITOR
@ : With air bag RELAY NEUTRAL PARKING CLUTCH

®00 e(!E)I
SWITCH BRAKE SWITCH
@ : Without air bag SWITCH
E)r;! ~e
SST760B

ST-30
 COMBINATION METER

FUSE BLOCK
(Refer to "POWER SUPPLY ROUTING"

r-=-
29 16 I 24 16
in EL section. l I
18 1 18
112 I 112
I

GiY
t~iY==- [ffH+F+iJ H++~ E+E+±~
FfM ~ I
G
' I GN I T I ON SWI T CH I l
~
;::;:::;::: I I [ftH+H-i] FfE
L_orSTART GiL
_j- Gil- I .

~@) 8lif8offfiJ@ Effio~ @) HBoE+$) ~@)

Gl r ~~ CD 0 r ~~ CD

w jTT1 wo
To stop lamp
....
~
INHIBITOR @
-z
SWITCH
t==t===
.--1 B
B /Y-
- -
- -~
DIAGNOSTIC 0
1l~IRI~I
0 J21 1

-0-m
'----f---++f-t--1'--- G
rmllfol
___j CONNECTOR ::D
FOR CONSULT
2
3 "11
4 @)
BRBR I> 8@
.,
GIL

;~
POWER STEERING

-·~-·
@ CONTROL UN! T

II
6 (Black)
7
""t

-~~
8

I :::s 0
9

en 1--- PU
o
6 (Q
~
.... ® L
B
5
4
c
-·
m
&J~~:~I>
iY
w
I
----------{A GiL Gil&-- >--- m ::D
...A.
0®
(Q
""t
en
....
INHIBITOR
CEng i ne room R=J fm (Main m m
RELAY
harness) __.Q;J u:;g_ harness)
3 m
~;;:~~;;:-~'----
®BtiDSTOP LAMP
/Y --n1

-::Dz
/B -{1j SWITCH

------lcul--+rr _ .:ffi ~L. _______ __J

G)
en
~ '~ ~ r'~ ~
r'
~ /:u =8J®~CLUTCH
~SWITCH
-<
en
....m
~~@l~i ~i(
PU
..
~
uel ~ ~ 3:
§ I ~ ~®rffil?l ~( ~~PARKING
[ill£ FR
®~
iI
~

~ ??
~ ~ Y/PU--(]] BRAKE
SWITCH

@)~@)
~
@
I II II 8v~G::{j~~~~i~~L @ : A/T model
FUSE BLOCK
(J n RELAY BOXl
(Refer to "POWER
SUPPLY ROUTING"
in El section. )
BODY
GROUND
POWER
STEERING
®
I l____L.L_ Y/a--Cbo(}-----Q SPEED
VEHICLE
®fi@ BODY @
@ :MiT model
@ :With air bag
: Without air bag
SOLENOID ~ l ~~SENSOR GROUND
en VALVE (A 1 ternator harness)
en
--i
"
~
tD
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses

Precautions
BEFORE DIAGNOSING THE POWER STEERING SYSTEM,
ENSURE THAT:
Vehicle stopped
a. Power steering components (gears, oil pump, pipes, etc.)
are free from leakage, and that oil level Is correct.
b. Tires are Inflated to specified pressure and are of specified
size, and that steering wheel Is a genuine Nissan part.
c. Wheel alignment Is adjusted properly.
d. Suspension utilizes the original design, and Is free of
modifications which increase vehicle weight.
Vehicle in operation
a. Understand the trouble symptoms.
b. Engine Is operating properly.

PRELIMINARY KNOWLEDGE HELPFUL IN CONDUCTING

i Steering force during
fail-safe control~
DIAGNOSES

!
., Steering force
Lduring full turns
~
The power steering system is a twin orifice type, which uses a
vehicle-speed sensing, electronic control design. Valve sensi-
tivity is controlled in response to vehicle speed to achieve
optimum steering effort. When a vehicle-speed signal is not
al 175 entered into the power steering control unit for approximately
us (1091 10 seconds during normal operation (see NOTE below), a
0 50 100 150 200 fail-safe system activates to maintain the steering effort at a
(0) (31) (62) (93) (124) level similar to that experienced during high-speed operation.
Vehicle speed km/h (MPH)- SST338B More precisely, if a foot-brake signal, parking-brake signal
and/or transmission position signal (N or P-range signal on
automatic transmission models and a neutral or clutch signal on
manual transmission models) are not entered, the power steer-
ing system is held in a "fail-safe" control state. When this
happens, a symptom referred to as "heavy steering during
stationary turns" sometimes occurs.
NOTE:
Normal operation refers to a driving condition In which the foot
brake pedal and parking brake lever are released, the shift
lever Is in any position other than "P" or "N" (automatic
transmission models), the shift lever set In any position except
"N" (manual transmission models) and the clutch pedal Is not
depressed.

ST-32
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses

Diagnostic Procedure 1
SYMPTOM:
Heavy steering operation during stationary turns

START

!
1) CHECK STOP LAMP SIGNAL.
Turn ignition switch "ON" (with
engine OFF), release foot brake
pedal and parking brake lever.
m Set shift lever to any position

[:it !ol
-CT
I I IdlE except "P" and "N" on auto-
matic transmission models or
B/V set shift lever to any position
10 I vi
except "N" on manual transmis-
sion models, and ensure clutch

00 ~ pedal is released.

m ~
~ -= Depress brake pedal and mea-
~""IGo to 2).
SST779B sure voltage between solenoid
valve terminals of diagnostic
connector for CONSULT.
- Normal stop lamp sw•tch

r·· . . . . . . .
- - - - Malfunctioning uop lamp sw1tr;h
Ignition switch ON

t 1
~
•.•• &.&V

I
I
I
~------
1.0·1.1V
Approx.1DSK. I SST340B
T•me

Voltage:
4.4 • 6.6 volts (constant)
... O.K.
Outside the above range or
voltage fluctuations
... N.G.

r.G.
Check if terminal voltage drops ~ IGo to 5).
to 1 - 1.5V range approx. 10 sec-
onds after ignition switch is
turned ON.
No change (outside 4.4 • 6.6V
range) ... O.K.
Voltage drop ... N.G.

r-G.

ST-33
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Diagnostic Procedure 1 (Cont'd)
I!)
@
[il [ 4 111 I II I!) ~
CIIIIET Check if stop lamp switch signal N.G. Malfunctioning stop lamp switch
£) A/B
00 is present at power steering system
control unit.
@__§-
00 YES (12 volts- Brake pedal
depressed.) ... O.K.
NO (0 volts) ... N.G.
"='

JO.K.
SST7808

_,
Ensure that power steering con-
[!) trol unit connector is connected

~ jojj I !,±±B. properly.

B/Y [!) ~
eJ
~
After ignition switch is turned N.G. Malfunctioning power steering

® ~
"ON", depress brake pedal and
measure voltage between sole-
noid valve terminals of diagnos-
control unit.

~ ':'

SST7798
tic connector for CONSULT.
4.4 - 6.6 volts (constant)
... O.K.
Voltage fluctuations
... N.G.

~O.K.
Check if heavy steering opera- ~Goto4).
tion occurs during stationary
turns.
YES ... N.G.
NO (Lighter steering opera-
lion) ... O.K.

!O.K.

END

ST-34
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Diagnostic Procedure 1 (Cont'd}
m m
~lol I I 17E±J 2) CHECK PARKING BRAKE ~~Goto3). I
SIGNAL.
-•cr Release foot brake pedal and
18 B/Y

~
apply parking brake lever.

00 Measure voltage between sole-

noid valve terminals of diagnos-

!:..
tic connector for CONSULT .

-=
• - - N o r m a l parktng brake swttch
------Malfunctioning parktng
lgnt110n swttch ON bake SWitCh
SST781B Parktng brake applied

1_'_
:;"• I
4.4 · 6.6V

(;] I
I
I ______
!_

[11
CONIET
mm
Y/PU
6

Voltage:
Approx. 10 sec.

Ttme
1.0 · 1.5V

SST34QB

£) [YJ 4.4 - 6.6V (constant)

kB ... O.K.
@a Outside the above range or
voltage fluctuations
-= ... N.G.
SST782B
~N.G.
Check if terminal voltage drops ~~Goto5). I
to 1.0 - 1.5V range approx. 10
seconds after ignition switch is
turned ON.
No change (outside 4.4- 6.6V
range) ... O.K.
Voltage drop ... N.G.

(;] ~N.G.
Check if parking brake switch N.G. Malfunctioning parking brake
signal is present at power steer- system
ing control unit.
YES (0 volts - Parking brake
applied.)
NO (12 volts) ... N.G.

~O.K.
Ensure that power steering con-
trol unit connector is connected
properly.

@
i.

ST-35
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Diagnostic Procedure 1 (Cont'd)
[iJ
_,
~1·11111111

'
0 1 I I 17J J J
_l_
[iJ
Turn ignition switch ON and ap- N.G. Malfunctioning power steering
eJ
B/Y

~
ply parking brake lever. control unit

00 ~
Measure voltage between sole-
noid valve terminals of diagnos-

~
tic connector for CONSULT.
Voltage:
~

4.4 • 6.6 volts (constant)

SST781B
... O.K.
Voltage fluctuations
... N.G.

!O.K.

Check if heavy steering opera- ~~ Goto4).

I
tion occurs during stationary
turns.
YES ... N.G.
NO (lighter steering opera-
tlon) ••• O.K.

!O.K.

END

ST-36
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Diagnostic Procedure 1 (Cont'd)
m m
~ lol I I IliE
3) CHECK NEUTRAL POSITION O.K. Depress clutch pedal (M/T
SIGNAL. model) and move shift lever to
-•ct B/Y Release parking brake lever. "P" (AIT model).
IV
~
Move shift lever to Neutral (A/T Measure voltage between sole-

00
and MIT models). Measure volt- noid valve terminals at diagnos-
age between solenoid valve ter- tic connector for CONSULT.
minals of diagnostic connector Voltage:
for CONSULT. N.G. 4.4 • &.&V (constant) .•• O.K.
-= r--
--Normal position switct.
Outside the above range or
SST7838 -----Malfunctioning position switch
Ignition switch ON voltage fluctuations .•• N.G.
Position switch ON
g. I
(;) -a ~ O.K.
>
' 4.4 ·6.&V

lO&lJJI
I

[it I

r------
I

1.0 -1.5V
CONNECT Approx. 10 Me.
J
£)
SST340B
Y/L
C5ZJ Time

j<±le Voltage:

00 4.4 • &.&V (constant)

••• O.K.
Outside the 4.4 - &.&V range
Go to 4).

-=
or Voltage fluctuations
SST7848 ••. N.G.

N.G. +
Check if terminal voltage drops O.K. Go to 5).
to 1.0 - 1.5V range approx. 10
seconds after ignition switch is
turned ON.
No change (outside 4.4 • &.&V
range) •.• O.K.
Voltage drop ••• N.G.

I;) ~N.G.
Check if position switch signal is N.G. Malfunctioning position switch
present at power steering con- system
trol unit.
YES (0 volts, when position
switch is ON) ••• O.K.
NO (4 • 5 volts) ••• N.G.

JO.K.

Ensure that power steering con-

trol unit connector is connected
properly.

~
©

ST-37
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Diagnostic Procedure 1 (Cont'd)
[+J
~ lo\l I 17llE
~
[+J ©
...
B/Y Turn ignition switch ON, depress N.G. Malfunctioning power steering
EO
~
clutch pedal (MIT model) and control unit

00 move shift lever to "P" (A/T

model).
Measure voltage between sole-
noid valve terminals of diagnos-
-= tic connector for CONSULT.
SST783B
Voltage:
4.4 - 6. &V (constant) ... O.K.
Voltage fluctuations ... N.G.

!O.K.

Check if heavy steering opera- ~~ Goto1).

I
tion occurs during stationary
turns.
YES ... N.G.
NO (Lighter steering opera-
lion) ... O.K.

~O.K.
END

m Fm~------------~
4) CHECK POWER STEERING N.G. Malfunctioning power steering
SOLENOID VALVE FOR
... solenoid valve
PROPER OPERATION.
Disconnect solenoid valve con-
nector. Check if plunger clicks
when voltage is applied between
connector terminals (on solenoid
valve side).
Clicks ... O.K.
NO clicks ... N.G.

O.K.

• Malfunctioning steering gear

assembly
• Malfunctioning oil pump

ST-38
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Diagnostic Procedure 1 (Cont'd)
m m
5) CHECK POWER STEERING N.G. Malfunctioning ignition power
[11 [, I II I II CONTROL UNIT FOR PROPER
OPERATION.
circuit
L __ _ _ _ _ _ _ _ ____J
CIIIINECT G/Y

£) Check if power voltage is

present at power steering con-

00 trol unit.
YES (12V) ... O.K.
NO (OV) ... N.G.

O.K.
SST786B li)
~~--------L---------~
Measure solenoid valve resis- N.G. Malfunctioning solenoid valve
tance. system
Disconnect solenoid valve con-
nector, and measure resistance
between connector terminals (on
solenoid valve side.)
Resistance:
4 - 6 ohms ... O.K.
0 ohms or infinite ... N.G.
O.K.

Ensure that power steering con-

trol unit connector is connected
properly.

Check if heavy steering opera- N.G. Malfunctioning power steering

tion occurs during stationary control unit
turns.
YES ... N.G.
NO (Lighter steering opera-
tion) ... O.K.
O.K.

END

ST-39
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses

Diagnostic Procedure 2
[llloiiii7J±E SYMPTOM:

-eJ 8/Y
Light steering operation during high-speed driving
Raise rear wheels off ground
and start engine.

00 Measure voltage between sole- O.K.

noid valve terminals of diagnos- ©
tic connector for CONSULT while
SST783B
driving vehicle from 0 to 100
km/h (0 to 62 MPH).
Voltage:

IIIII 0 km/h (0 MPH):

4.4 · 6.6V ... O.K.
100 km/h (62 MPH):
1.8 • 2.8V ... O.K.
Constant voltage ... N.G.

~ N.G.
Check speedometer for proper N.G. Malfunctioning vehicle speed
SST788B operation. sensor or speedometer
YES ... O.K.
NO ... N.G.
"!ith air bag [SiH•EfEI [f+t+EEETI ~O.K.
l) [11 '-------- Check A.S.C.D. and vehicle N.G. Check if vehicle speed signal is

:'",:' [ffi+&HI ~ speed-sensing door lock for

proper operation.
present at speedometer.
Disconnect speedometer from
YES ... O.K. vehicle to facilitate work. Recon-
[Y]
- ~
I
Y/G
NO ... N.G. nect wiring. Measure voltage
between speedometer terminals
O.K.
while driving vehicle at very
SST789B slow speeds.
1 volt (Min.) and 5 volts (Max.)
are alternately repeated ...
O.K.
No voltage is present ... N.G.

O.K. N.G.
Check if vehicle speed signal is N.G.
present at power steering con-
trol unit.
Malfunctioning
While driving at very slow
speedometer
speeds, connect power steering
unit connector. Measure termi-
nal voltage.
1 volt (Min.) and 5 volts (Max.)
are alternately repeated
... O.K.
No voltage is present ... N.G.

~O.K.
Ensure that power steering con- Improper connection between
trol unit connector is connected speedometer and power steer-
properly. ing control unit

~
ST-40
TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Diagnostic Procedure 2 {Cont'd)

lil.
Measure voltage between sole- O.K. Check if steering operation is
noid valve connector terminals heavy during high-speed driv-
of diagnostic connector for CON- ing.
SULT while driving vehicle from YES ••• O.K.
0 to 100 km/h (0 to 62 MPH). NO .•• N.G.
Voltage:
N.G. O.K.
0 km/h (0 MPH):
SST7888 4.4 • &.&V ••• O.K.
100 km/h (62 MPH): END
1.8 • 2.8V ..• O.K.
No voltage variations •..
N.G.
1+------tc
N.G.

Measure solenoid valve resis- Disconnect solenoid valve con-

tance. nector.
Disconnect solenoid valve con- Apply voltage between connec-
nector, and measure resistance tor terminals (on solenoid valve
between connector terminals (on side) and listen for clicks (which
solenoid valve side). N.G. indicate operation).
Resistance: Clicks •.• O.K.
4 • 6 ohms ••• O.K. No clicks ••• N.G.
0 ohms or Infinite .•• N.G.
N.G. O.K.
O.K.

Malfunctioning power steering Malfunctioning

control unit solenoid valve

• Malfunctioning steering gear

assembly
• Malfunctioning oil pump

ST-41
 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses

Control Unit Inspection Table

The standard values (voltage), measured with an analog tester
in contact with the control unit terminal, are shown below:

Terminal No. Application Standard value

1 Power Approx. 12V
2 Ground ov
1 volt (min.) and 5 volts
(max.) are alternately re-
3 Vehicle speed sensor input
peated when vehicle is
driven at very slow speeds.
Pressed: Approx. 12V
4 Stop lamp switch input
Released: OV
OV (clutch engaged and
shift lever in "N")
... MIT models
5 Neutral switch input OV (selector lever in "N" or
"P") ... A/T models
4- 5V (except for the
above)
Applied: OV
6 Parking brake switch input
Released: Approx. 12V
0 km/h 4.4 - 6.6V
Power steering solenoid
7 100 km/h 1.8- 2.8V
valve output
Fail-safe 1.0 - 1.5V

Performance of Controller

1.1
~
.,
0>
1.0
.,~
Q.
E
..."'
::I
0.8

9-
::I
0
0.6

0.5

0.1
12 (7) 30 (19) 50 (31) 175 (109)

0 50 (31) 100 150 200

(62) (93) (124)

Vehicle speed km/h (MPH)

SST349B

ST-42
 SUPER HICAS SYSTEM

HICAS Component Parts Location

Steering
angle sensor

Fail-safe valve

Power steering
solenoid

SST372B

System Diagram

HICAS solenoid

Vehicle speed sensor

Steering angle Power

cylinder

~
t Ce~tering
sprmg

·~·--
~ -- -- ..._______,
-- ' Fail-safe
valve
Power steering
solenoid

SST451B

ST-43
SUPER HICAS SYSTEM - On-vehicle Inspection

Checking Fluid Level

Maintain the fluid level so that the lower surface of the float is
maintained between the "L" and "H" marks on the gauge rod.
The fluid level should be checked when the engine is stopped
and the fluid temperature is about 30"C (86"F).
CAUTION:
• Do not overfill.
• Recommended fluid Is Automatic Transmission Fluid
"Dexron 1 Mu type.
• Note that fluid level will vary with fluid temperature by
approx. 1 mm/5"C (0.04 ln/9"F) due to changes in fluid
volume.

Checking Fluid Leakage

Check lines for proper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
Fluid leakage should be checked for when the oil temperature is
normal with the engine idling.

..

SST374B

ST-44
 SUPER HICAS SYSTEM- On-vehicle Inspection

Measuring Rear Toe-in

Measure distance "A" and "B" at the same height as hub
center.
Toe-in:
A-B
0 - 4 mm (0 - 0.16 In)
29 (Total toe-in angle)
0'. 23'
Front Refer to "SUPER HICAS" in RA section.
~
SFA234A 9 Total toe-in angle • 29

Inspection of HICAS System Operation

CAUTION:
Ensure that shift lever Is set to "P" (A/T model) or "Neutral"
(M/T model) before checkin~ICAS system operation.
When CONSULT Is used: li
1. Have a helper sit in the river's compartment and raise
vehicle.
(Use a two-pole lift or a center pole lift so that the four
wheels are free to rotate.)
2. Connect CONSULT unit to diagnostic connector and start
engine.
3. Touch "START" on CONSULT display.
4. Touch "HICAS", "ACTIVE TEST" and "SIMULATED DRIVE"
in that order.

5. Touch "START" when MAIN SIGNALS display is reversed .

• SIMULATED DRIVE TEST •
~ SELECT MONITOR ITEM

SELECTION FROM MENU

START
SST375B

6. Touch "START."
• ACTIVE TEST • 0 After simulated drive condition has continued for 5 minutes, It
DRIVE HIGH SPEED
will automatically cancel and CONSULT unit will then show
CONDITION "TEST IS INTERRUPTED TO AVOID OIL TEMP. RISE" display.
===MONITOR=== To cancel this mode during self-diagnosis, simply touch
STEERING ANG R11°
HICAS SOL R0.58A "CANCEL".
POWER STR SOL 1.05A

CANCEL
SST3778

ST-45
 SUPER HICAS SYSTEM - On-vehicle Inspection
Inspection of HICAS System Operation {Cont'd)
7. Operate engine at speeds greater than 2,000 rpm, and turn
steering wheel 180° in one direction from the neutral
position. Measure extension value of one power cylinder
rod and retraction value of the other. Then, turn steering
wheel 180° in the other direction from the neutral position,
and measure extension value of one cylinder rod and
retraction value of the other. Determine strokes of respec-
tive power cylinders by adding (measured) extension and
retraction values.
Measure rod strokes in as short a period of time as possible.
SST378B
Specifications:
When turned to the right
3 mm (0.12 in)
When turned to the left
3 mm (0.12 in)
Total stroke
6 mm (0.24 in)

When CONSULT is not used:®

4 sec.
1. Have a helper sit in the driver's compartment and raise
vehicle.
... (Use a 2-pole lift or a center pole lift so that the four wheels
~
a: R.H. are free to rotate.)
.,... -., L.H. 2. Set HICAS system in self-diagnosis mode .
::1-

=
I!! ~
.. (1) Turn ignition switch "OFF".
Q.o..
=~
(2) Set shift lever to "P" or "N" position (A/T model), or
Oti "Neutral" position (MIT model).
Time (3) Turn ignition switch "ON".
ssT44ss (4) Immediately start engine .
._____ _ _ _ _ _ _ _ _ ____;:;__--' (5) Turn steering wheel from left to right (at least 20° from the
neutral position ) 5 times or more, then depress foot brake
pedal at least 5 times all within 10 seconds after ignition
switch has been turned "ON".
3. Set steering wheel to a point approximately 10° from the
neutral position and check to ensure that rear wheels turn
to the left and ri.ght alternately.

ST-46
 SUPER HICAS SYSTEM - On-vehicle Inspection
Inspection of HICAS System Operation (Cont'd)
4. Operate engine at speeds greater than 2,000 rpm, and turn
steering wheel 1ao· in one direction from the neutral
position. Measure extension value of one power cylinder
rod and retraction value of the other. Then, turn steering
wheel 1ao· in the other direction from the neutral position,
and measure extension value of one cylinder rod and
retraction value of the other. Determine strokes of respec-
tive power cylinder rods by adding (measured) extension
and retraction values.
Measure rod strokes in as short a period of time as possible.
ssT37BB Specifications:
L...,__ _ _ _ _ _ _ _ _ _ _ ____J When turned to the right
3 mm (0.12 in)
When turned to the left
3 mm (0.12 in)
Total stroke
6 mm (0.24 in)
Do not depress foot brake pedal during operation check,
otherwise the operation will be stopped.

Bleeding Hydraulic System

Before bleeding air from the HICAS system, be sure to bleed air
from the power steering system.
Refer to "SUPER HICAS SYSTEM - Repair of Component
Parts".

ST-47
 SUPER HICAS SYSTEM - Repair of Component Parts

Power Cylinder

. '"'-..,
-~ ~oo

tcJ 84.108
(8.6. , , 62. 80)

~~A 45- 6o 1u- 6.1. 33- 44)

rPJ: N·m (kg-m, ft-lb)
SST379B

REMOVAL
• Detach power cylinder lower links from axle housing sock-
ets with Tool.

• Disconnect oil pipes from power cylinders and remove

power cylinders.
CAUTION:
Plug openings of oil pipes and power cylinders to prevent entry
of foreign particles after removal.

INSTALLATION
1. Before installing power cylinder on suspension member,
wipe power cylinder bracket and mating surface of suspen-
sion member. Using the left side of the bracket as a
reference point, locate the right side (oblong hole side) and
install power cylinder.
¢::1 L.H. R.H.¢ CAUTION:
a. To prevent entry of foreign particles, clean oil pipes and
connectors using dry compressed air.
SST3B2B b. Ensure that your hands are clean and free from foreign
particles when connecting oil pipes.
ST-48
 SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd)
2. Install power cylinders and oil pipes.
3. After installing lower link assemblies, check toe-in to en-
sure that it is within specifications. If it is not within
specifications, perform proper adjustments.
Refer to "SUPER HICAS" in section RA.

BLEEDING HYDRAULIC SYSTEM

Before bleeding air from the HICAS system, be sure to bleed air
from the power steering system.
CAUTION:
Ensure that shift lever is set to "P" (A/T model) or "Neutral"
(MIT model).
When CONSULT Is used: 00
1. Connect CONSULT unit to diagnosis connector on body
side.
2. Have a helper sit in the driver's compartment and raiss
vehicle.
Use a two-pole lift or a center pole lift so that the four wheels
are free to rotate.

3. Start engine .
• SIMULATED DRIVE TEST •
4. Touch "START" on CONSULT display. (Display will then
~ SELECT MONITOR ITEM
change.)
5. Touch "HICAS", "ACTIVE TEST", "SIMULATED DRIVE"
and "START" in that order.
Before touching "START", ensure that MAIN SIGNALS display
Is reversed.
6. Touch "START".
START
SST37tsB

ST-49
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd)
7. Operate engine at speeds greater than 2,000 rpm, and turn
steering wheel 180° to the right from the neutral position.
Loosen right power cylinder bleeder valve to bleed air, then
retighten. Return steering wheel to the neutral position.
8. Operate engine at speeds greater than 2,000 rpm, and turn
steering wheel 180° to the left from the neutral position.
Loosen left power cylinder bleeder valve to bleed air, then
retighten. Return steering wheel to the neutral position.
9. Repeat steps 7. and 8. until there are no air bubbles in fluid.
While bleeding air from power cylinders, never allow fluid
level to drop below inlet port of reservoir tank (by adding
fluid as required).
10. Touch "CANCEL" on CONSULT display and turn ignition
switch OFF.

When CONSULT is not used: ®

1. Have a helper sit in the driver's compartment, and raise
vehicle.
Use a two-pole lift or center pole lift so that the four wheels are
free to rotate.
2. Set HICAS system in self-diagnosis mode.
(1) Turn ignition switch "OFF".
(2) Set shift levar to "P" or "N" position (A/T model), or
"Neutral" position (M/T model).
(3) Turn ignition switch "ON".
(4) Immediately start engine.
(5) Turn steering wheel from left to right (at least 20° from the
neutral position ) 5 times or more, then depress foot brake
pedal at least 5 times all within 10 seconds after ignition
switch has been turned "ON".
3. Set steering wheel within 10° from the neutral position.
Ensure that rear wheels turn to the left and right alternately.
4. Operate engine at idling speed, and turn steering wheel
180° to the right from the neutral position. Loosen right
power cylinder bleeder valve to bleed air, then retighten.
Return steering wheel to the neutral position.
5. Operate engine at idling speed, and turn steering wheel
180° to the left from the neutral position. Loosen left power
cylinder bleeder valve to bleed air, then retighten. Return
steering wheel to the neutral position.
6. Repeat steps 4. and 5. above until there are no air bubbles
in fluid. While bleeding air from power cylinders, never
allow fluid level to drop below inlet port of reservoir tank (by
adding fluid as required).
7. Turn ignition switch OFF to complete self-diagnosis opera-
tion.

ST-50
 SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd}
DISASSEMBLY AND ASSEMBLY

Dust boot lEI

r
Jr--[_
~ 37-46
(3.8. 4.7. 27. 34)

Outer link

L.oo•b~

~ : N·m (kg·m, ft-lb)

SST384B

Power cylinder assembly cannot be disassembled. When it is

malfunctioning, replace power cylinder as an assembly.

DISASSEMBLY
1. Remove clamps from left and right dust boots, and move
dust boots toward outer links.
2. Attach wrenches to left and right ball joint sockets, and turn
in directions that loosen lower links. Remove one of loos-
ened lower link assemblies.

SST386B

3. Loosen stroke stopper lock nut from which lower link

assembly was removed, and remove stroke stopper.

~,·1Lfl ~· ~·
w.,.......,""' ~
Stroke stopper SST 3868

ST-51
 SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd)
• While attaching a wrench to "width across flats" section of
rod end from which stroke stopper was removed, remove
the other lower link assembly.

ASSEMBLY
1. Install stroke stopper and lock nut on the lower link assem-
bly to be assembled.

SST388B

2. Apply Locktite to inner ball joint thread. Attach a wrench to

"width across flats" section of piston rod (located on the
other side) to prevent rod from turning. Install lower link
assembly.

3. After installing stroke stopper and lock nut on the other

lower link assembly, install lower link assembly. Attach a
wrench to inner ball joint (to prevent it from turning), tighten
inner socket to specified torque.
Inner socket:
lCj: 78- 98 N·m (8- 10 kg-m, 58- 72 ft-lb)

SST390B

Lock nut 4. If stroke stopper was moved during removal of lower link,
toJ 49 • 69 N•m adjust it after installation, as described below:
(5.0 • 7.0 kg·m, 36 ·51 ft·lbl (1) Loosen lock nut which secures stroke stopper.
(2) Turn stroke stopper until clearance between inner ball joint
and stroke stopper is 3 mm (0.12 in) on each side.
(3) Tighten lock nut securely.
Lock nut:
lCJ: 49 - 69 N·m (5.0 - 7.0 kg-m, 36 - 51 ft-lb)
(4) Recheck clearance between inner ball joint and stroke
stopper on each side.
SST391B

ST-52
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder {Cont'd)
5. Install dust boot using new boot band and clamp.
• Apply a coat of grease to grooves at boot location.

SST392B

ST-53
 SUPER HICAS SYSTEM -. Repair of Component Parts

Oil Pump

rRJ31- 42
(3.2 -4.3,
23- 31)

toJ : N·m (kg-m, ft-lb)

SST393B

PRE-DISASSEMBLY INSPECTION
Disassemble the power steering oil pump only if the following
items are found.
• Oil leak from any point shown in the figure.
• Deformed or damaged pulley.
Procedures for disassembly and assembly are the same as
those for the power steering oil pump.

SST3948

ST-54
SUPER HICAS SYSTEM- Repair of Component Parts
Oil Pump (Cont'd)
Disassembly
CAUTION:
• Parts which can be disassembled are strictly limited. Never
disassemble parts other than those specified.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• Follow the procedures and cautions in the Service Manual.
• When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

1. Remove connector.
Be careful not to drop control valve.
Be careful not to confuse main side with sub side.

SST395B

2. Remove rear housing.

3. Remove center housing.
4. Remove cam ring, rotor and other parts from center hous-
ing (sub side).

5. Remove cam ring, rotor and other parts from front housing
(main side).
Be careful not to confuse main side with sub side.

SST401B

6. Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shaft.

Drive shaft

SST399B

ST-55
 SUPER HICAS SYSTEM - Repair of Component Parts .
Disassembly (Cont'd)
7. Remove oil seal.
Be careful not to damage front housing.

Inspection
If any of the following parts are scratched or damaged, replace
oil pump assembly.
• Mating surfaces of front housing and cam center housing
• Mating surfaces of rear housing and cam center housing
• Front housing bushing (at drive shaft support location)
• Flow control valve
• Drive shaft
• Rotor

Assembly
Assemble oil pump in the reverse order of disassembly, noting
the following instructions.
• Before installation, coat the 0-rings and oil seal with A.T.F.
• Make sure 0-rings and oil seal are properly installed.
• When assembling vanes to rotor, rounded surfaces of
vanes must face cam case side.
• Always install new 0-rings and oil seal.
• Be careful of oil seal direction.

Press
2. Press shaft assembly into front housing and install snap
ring.

SST403B

ST-56
 SUPER HICAS SYSTEM - Repair of Component Parts
Assembly {Cont'd)
3. Install component parts on front housing in the order
indicated below:
Valvewasher 1) 0-ringx2
2) Wave washer
3) Side plate
4) Rotor [thickness: 16.25 mm (0.6398 in) (main side); 13 mm
(0.51 in) (sub side)]
5) Vane
6) Pin
7) Cam ring [thickness: 16.25 mm (0.6398 in) (main side); 13
mm (0.51 in) (sub side)]
4. Place packing on front housing and position center housing
on the packing. In the manner similar to step 3. above,
Gasket install component parts on front housing (sub side).
CAUTION:
• Ensure that 0-rlngs are positioned properly.
• Ensure that vane Is installed with curved side facing cam
Front housing ring.
• Use cam, rotor vane as original single unit.
• Ensure that control valve moves smoothly.

SST404B

Rear housing side Front housing side • Pay attention to rotor direction.

SST281A

• Pay attention to cam ring direction.

f Front housing side

SST205B

ST-57
 SUPER HICAS SYSTEM - Repair of Component Parts .

HICAS Solenoid and Fail-safe Valve

• Do not loosen lock nut which secures solenoid since HICAS
solenoid fail-safe valves are of types that should not be
disassembled.
• If any part is found to be malfunctioning, always replace as
a valve assembly.

SST405B

SST406B

• Whenever tubes are disconnected, check tube seat for

KV32101100 scratches or damage. A scratched or cracked tube seat may
( I cause oil leakage. Replace it using pin punch.

SST397B

Control valve Cut-off valve

Part No. 49528-31 P1 0 49528-52L 10
A (dia.) mm (in) 1.5 (0.059) 6.5 (0.256)

-1-t4-- A (dla.)

Steering Angle Sensor

• Ensure that steering angle sensor bolts are secure and
tight.
• If any part of steering angle sensor is malfunctioning,
replace steering angle sensor assembly.

ST-58
 SUPER HICAS SYSTEM - Repair of Component Parts

O.K. N.G. Steering Wheel

CHECKING NEUTRAL POSITION
• Check that the steering· wheel is in the neutral position
when driving straight ahead at a speed of at least 70 km/h
(43 MPH).
• If it is not in the neutral position, remove the steering wheel
and reinstall it correctly.
• If the neutral position is between two serrated teeth, loosen
tie-rod lock nut and move tie-rod in the opposite direction
ssno4a by the same amount on both left and right sides to compen-
.___ _ _ _ _ _ _ _ _ _ _ __. sate for error in the neutral position.

ST-59
 SUPER HICAS SYSTEM - Trouble Diagnoses

Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair .................................................ST-61
Symptom Chart ......................................................................................................................................ST-62
Preliminary Check .................................................................................................................................ST-63
Component Parts and Harness Connector Locations ..........................................................................ST-66
Circuit Diagram for Quick Pinpoint Check ...........................................................................................ST-67
Wiring Diagram ......................................................................................................................................ST-68
Self-diagnosis .........................................................................................................................................ST-69
Diagnostic Procedure 1 .........................................................................................................................ST-75
Diagnostic Procedure 2 .........................................................................................................................ST-76
Diagnostic Procedure 3 .........................................................................................................................ST-78
Diagnostic Procedure 4 .........................................................................................................................ST-79
Diagnostic Procedure 5 .........................................................................................................................ST-85
Diagnostic Procedure 6 .........................................................................................................................ST-87
Diagnostic Procedure 7 .........................................................................................................................ST-88
Diagnostic Procedure 8 .........................................................................................................................ST-89
Diagnostic Procedure 9 ................................................................................................:........................ST-90
Diagnostic Procedure 10 .......................................................................................................................ST-91
Diagnostic Procedure 11 .......................................................................................................................ST-93
Diagnostic Procedure 12 .......................................................................................................................ST-94
Control Unit Inspection Table ...............................................................................................................ST-95

ST-60
 SUPER HICAS SYSTEM - Trouble Diagnoses

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
WORK FLOW

<Reference item

LISTEN TO CUSTOMER
COMPLAINTS AND CONFIRM.

INVESTIGATE ITEMS RELATED Symptom Check

TO EACH SYMPTOM. (See page ST -62 .)

Fluid level and leakage check

BASIC INSPECTION (See page ST -63.)

Self-diagnosis Preliminary
PERFORM SELF-DIAGNOSIS (See page ST-69.) check
PERFORM REAR WHEEL ACTION
CHECK Rear wheel action check
------ (See page ST-64.)

INSPECTION ON THE Diagnostic Procedures 1 to 4

BASIS OF EACH (See pages ST-75 to 84.)
SYMPTOM

Self-di

INSPECTION ON THE Diagnostic Procedures 5 to 12

BASIS OF EACH MAL- (See pages ST-85 to 94.)
FUNCTION

I
I
I
I
I
L - - - - --- - ~·~· FINAL CHECK

ST-61
 SUPER HICAS SYSTEM- Trouble Diagnoses

Symptom Chart
DIAGNOSTIC TABLE

Preliminary
PROCEDURE Diagnostic Procedure
Check

REFERENCE PAGE (ST-) 63 63 64 75 76 78 79 85 87 88 89 90 91 93 94

~
.....
..... C\1
..... C\1 M ..... ll) <D t- 00 en .....
..... C\1 M ~ ...::I ...::I ...::I ...::I
Q) Q) Q) Q)
~ ...::::1
Q)
~ ~ ~ ~ ~
.... .... .... ::I ::I ::I ::I ::I ::::1 ::::1

"0 "0 "e "...0 "...0 "e "0 "0... "e "e 0... "0
()
'0
() () Q) Q) Q) Q) Q) Q) CD Q) Q) Cl) Q) Q)
Q) Cl) Cl) () () () () () () () () () () () ()

:s. ...
J:: J:: J::
SYMPTOM
() () ()

~
Q. Q. :s.
Q. Q. Q. :s. Q. Q. Q. Q.
~ ~ () () () ()
.!:! () .!:! .!:! .!:! ()
()
.!:!
Ill
c
Ill
c
Ill
c ~ iii :; :;0 :;0 ~
0
iii
0
:;
0
iii
0
iii
0
iii
0
:;
0
:§ :§ :§ 0
c
0
c
0
c c
Ol
c
Ol
c
Ol
c
Ol
c c
0>
c
0>
c
Ol
c
0>
a; 0> Ol 0> Ol
~ ~ D..... Ill
Ill Ill Ill Ill Ill .!!! Ill Ill Ill Ill Ill
D.. D.. c c c c c c 0 c c c c c
No warning lamp comes on when ignition switch is turned "ON" 0 0

Warning lamp comes on when engine is running 0 0 0 0 0 0 0 0 0 0 0 0 0

Abnormal noise is emitted. 0 0 0 0

Vehicle behavior is unusual (due to malfunctioning HICAS system.) 0 0 0 0 0 0 0 0 0 0 0 0

System Is not set in self-diagnosis mode. 0

Self-
diagnosis Diagnosed part CONSULT indication
code No.

HICAS solenoid (RH) output Is HICAS SOLENOID-R

1 0
not present. [ABNORMAL SIGNAL]

HICAS solenoid (LH) output is HICAS SOLENOID-L

2 0
not present. [ABNORMAL SIGNAL]

Fail-safe valve output is not FAIL-5AFE VALVE

3 0
present. [ABNORMAL SIGNAL]
!!! Power steering solenoid output POWER STEERING SOL
:; 4 0
Ul Is not present. [ABNORMAL SIGNAL]
~
()
VEHICLE SPEED SENSOR
~ Vehicle speed signal is not [NO SIGNAL] (·a)
0
c 5 0
0> present. CAR SPEED SENSOR
Ill
[SIG-SUDDEN TURN] (-b)
~
Qj STEERING ANGLE SEN
rn [NO ANG SIGNAL] (·a)
6
STEERING ANGLE SEN
Steering angle sensor Input is [NO NEUT SIGNAL] (·b)
0
not present. STEERING ANGLE SEN
(NEUT SIG-360' OFF] (·c)
7 STEERING ANGLE SEN
(NEUT SIG-30' ON] (·d)

Parking brake (AT) or clutch

8
switch (MT) input is not present.
- 0

Inhibitor switch (AT) or neutral

9
switch (MT) input is not present.
- 0

ST-62
 SUPER HICAS SYSTEM - Trouble Diagnoses

Preliminary Check
CHECK 1
Checking fluid level and fluid leakage
Refer to "SUPER HICAS SYSTEM- On-vehicle Inspection" on
page ST-44.

SST373B

0 '"'

SST374B

CHECK 2
Perform self-diagnosis.
Refer to "Self-diagnosis" on page ST-69.
16 SELECT DIAG MODE
I SELF-OIAG RESULTS
I DATA MONITOR
I ACTIVE TEST
I ECU PART NUMBER

SST476B

ST-63
 SUPER HICAS SYSTEM - Trouble Diagnoses
Preliminary Check {Cont'd)
CHECK 3
I SIMULATED DRIVE TEST I Perform rear wheel action check.
~ SELECT MONITOR ITEM

When CONSULT Is used: 00

SELECTION FROM MENU
1. Have a helper sit in the driver's compartment, and raise
vehicle.
(Use a two-pole lift or a center pole lift so that the four
START wheels are free to rotate.)
SST375B 2. Connect CONSULT unit to diagnosis connector and start
engine.
3. Touch "START" on CONSULT display.
4. Touch "HICAS", "ACTIVE TEST" and "SIMULATED DRIVE"
in that order.
5. Touch "START" when "MAIN SIGNALS" display is re-
versed.

6. Touch '·'START."
I ACTIVE TEST I 0 After simulated drive condition has continued for 5 minutes, It
DRIVE HIGH SPEED will automatically cancel and CONSULT unit will then show
CONDITION "TEST IS INTERRUPTED TO AVOID OIL TEMP RISE" display. To
===MONITOR=== cancel this mode during self-diagnosis, simply touch
STEERING ANG Rll 0
HICAS SOL R0.58A "CANCEL".
POWER STR SOL 1.05A

CANCEL
SST377B

7. While running engine at speeds greater than 2,000 rpm, turn

steering wheel 180° to the left and right from the neutral
position. Ensure that rear wheels steer in response to
rotation of steering wheel.

ST-64
 SUPER HICAS SYSTEM - Trouble Diagnoses
Preliminary Check (Cont'd)
When CONSULT Is not used: ~
1. Turn key switch "OFF". ~
2. Set HICAS system in self-diagnosis mode.
(1) Turn ignition switch "OFF".
(2) Set shift lever to "P" or "N" position (A/T model), or
"Neutral" position (MIT model).
(3) Turn ignition switch "ON".
(4) Immediately start engine.
(5) Turn steering wheel from left to right (at least 20° from the
neutral position) 5 times or more, then depress foot brake
L--------------=s~s~T4~1~7B:!.J pedal at least 5 times all within 10 seconds after ignition
switch has been turned "ON".
3. Set steering wheel to a point approximately 10° from the
neutral position and check to ensure that rear wheels turn
to the left and right alternately.

SST477B

ST-65
 SUPER HICAS SYSTEM - Trouble Diagnoses

Component Parts and Harness Connector

Location

HI CAS warning lamp

HI CAS control valve

Vehicle speed sensor

Diagnostic connector
for CONSULT

Power cylinder
Power steering solenoid

Fail-safe valve
Steering angle sensor Oil pump

SST409B

ST-66
 I
IGNITION SWITCH
@
@
QV
A/T model
MIT model
With air bag
ON or START
I "T"vJ
FUSE~
~ Without air bag

FUSE~-~- FUSE
~FUSE STOP LAMP
FUSE
@ SWITCH @

~~ @m f 0
DIAGNOSTIC.
CONNECTOR ~
@:~~~
~ ~1W51 0 II STEERING
ANGLE f--
I
@ ® .,c:m
FOR CONSULT ®: ~ 3! 7 161 SENSOR To stop lamp
:D
@
,..en-
01®1® To E.C.C.S. control unit :::r:
~o [ _ (Engine r . p . m.) 0
I 9 2 7 15 16 3 19 4 11 5

-·0...n
~------------------~---r-+-+__,1
JOINT fu4?\ en
CONNECTOR ~ 101--- -<
en
en
.....
I ~~
ELECTRIC I
j_
1111
6 HICAS CONTROL UNIT ~~
Ltij.ffi ~ 241-----<
-
-·cc
-·m
.....
m
s::
~ SPEED-
I
en
..... @ OMETER
r:::e:I
l>l>>-t
3:DO~
20 14 13 18 8 22 23 ca
... I
-,-----,.-, "UZl> m ........
QV: SB
H(/)

-...
3

~~~~
~ @) ~1 8 1!:tl0 0
-®- 0
c
S!:
EEm
II<VII 1I I
MY 0
c
-· cam-·
CD
c
®®~ @:@) , ® ~ ® n
.,-· =
~

II
@: ®jj@
INHIBITOR @ @ @ @ (!)
®]
~ ~@
VEHICLE
SPEED
@)_ SWITCH
~~6 rI l@ l ~~ ~: =
0
(I)

~ @) CD
•
SENSOR
L4@ @
"C
2. (I)

-==-
0--1
@ :TO
(1)
@)
6 ocr
....
"'c
"10"
0
(1)
INHIBITOR NEUTRAL PARKING HICAS HICAS POWER HICAS
RELAY SWITCH BRAKE CLUTCH FA! L-SAFE STEERING SOLENOID CD
QV:@@ HICAS ~
OIL LEVEL ~ SWITCH SWITCH VALVE SOLENOID VALVE n
SWITCH VALVE ~

@~ ®~ @~ @rnl @rn!rnl@])~ ®~ (22tfm23)@

~
III
 COMBINATION METER
~~~~ING STEERING

~~
16
NEUTRAL
SWITCH ® A/T model 18
VEHICLE
® : M/T medal 14

~
SPEED
SENSOR ® : With air bag

~
@ :

w
Without air bag

®w rt;HW ~~~
~ ~r ~~ mtD;l@

,.-;;WI
FUSE BLOCK
®<t;> INHIBITOR
SWITCH
(Refer to 'POWER SUPPLY
ROUTING' in EL sect ian.)
.,@B) 11
'"'" "
iii~
« .. ~
., ~~~.. Ll.lfflJJ
cc:~.~
GJZ-< GJ
< <
iilr _R
~
II'" r-·--;;;~-~~1] ~ ;---,>
,. ...

I I I I I I II 1
.,
~

ON or START l Jj
.... J 1-----1
.,c:m
fn
:Ill

-'"",...
0
i rl BATTERY I i CONI ~ECTOR To E.C.C.S.
control unit
u
J~.,_
~r ~r ~ CD
v
VIR

i~ ::D
V/8

l® lEa;Bl® ~® ~ LIN

-n:z::
@ LIB
L ______ _ RIB
VIL

~@ ~@)
r - - 'Y/PU
@) f{jfB ~@) @@) I--
< )>
iilr ~r ~ !II !II~
fn

..-·-·
HI CAS

IF r1 L_ '41 CONTROL
~ fn

;Ji(;
"' UNIT
"'
"" "" -<
fn
-t ¥1 ~
ca
fn
-t
m
m
LIIL c
-· s:
INHIBITOR (Main harness)
® @®
.. ..
RELAY
Q) DJ
DJ~tr YIL
Y/8
8/Y
if
0
YIL
Y/8
8/Y
>----®
•V/PU-{]1
r.<.;\
~
~PARKING
BRAKE
SWITCH
ca
DJ
I
-t
@!@ 3 0
BATTERY~ (Engine
room AIY -DI r:J.J"ffiil
STOP LAMP c

[[
1-AIY
harness)
ffil+lmoo
__!;!;] ~
RIY R/Y
~~ .. ~~ 1 ~elay-
I
1 - - - A/11-DI ~SWITCH
@)
B©J -
17
CD

~~~~ -·cac
PU- I ~1Y/PU-DI
B -DI
HICAS
U CLUTCH
~ SWITCH
DJ
§
t
[IJJ UP @.103t_l@
.. . ..
(
IAIY ~ lfVV
~
'---- To stop lamp
0
~

(I)
® ~ wllllillll @ CD
FUSE BLOCK
!In 'IELAY BOX)
I, I
.. w ~.,
~~'ill .. I . rIIIITIIII ® (I)

.....I
~
Ref 'r !;o;J. ~F'tl!!!;R
SUPPL . .
@)~
!II .. ..'il

cl> ®
., i!'il 'iii! rEG> ill'" II I E
II
(Body
harness) (:~~) harness
in EL sect ion.) q)@ @Ylffi33 ®Efffml
ri 1 @~1~ 0@
! LN/Bi ~w/6-fw~::B ~
m~~
§ /IH.".l\ 11 HICAS
~ lkihYII•I @ A ~ FAIL-SAFE
VALVE

HlCAS HICAS POWER @)@) 35~20!·~20! 0

@) ~~~CTCA @ ~~~@ill)
SOLENOID
VALVE
OIL LEVEL STEERING
SWITCH SOLENOID BODY
HICAS 41--<>· : HICAS 41--<> 7
I DIAGNOSTIC
CONNECTOR BODY
VALVE GROUND Fr:A CONSULT BODY GROUND

I
GROUND
 SUPER HICAS SYSTEM - Trouble Diagnoses

Self-diagnosis (When CONSULT is used)

I~ SELECT DIAG MODE Dl • Start engine.
I SELF-DIAG RESULTS e Touch START (on CONSULT display).
I DATA MONITOR • Touch HICAS.
e Touch SELF-DIAG RESULTS.
I ACTIVE TEST
I ECL! PART NUMBER

SST412B

• Self-diagnostic results are shown on display.

Refer to Table on page ST-70 .
• SELF-DIAG RESULTS I D
FAILURE DETECTED
NO SELF DIAGNOSTIC
FAILURE INDICATED.
FURTHER TESTmG
MAY BE REQUIRED. ••

PRINT
• SELF-DIAG RESULTS I D
FAILURE DETECTED
HICAS SOLENOID-L
(ABNORMAL SIGNAL]

PRINT

SST758B

For reference:
~ SELECT DIAG MODE Dl Recording input/output signals using data monitor function
SELF-DIAG RESULTS I • Start engine.
• Touch START (on CONSULT display).
DATA MONITOR I e Touch HICAS.
ACTIVE TEST I e Touch OAT A MONITOR.
ECU PART NUMBER I

SST414B

• Check to ensure that the ALL SIGNALS display is reversed.

Touch START. Refer to Table on page ST-71.

SETTING START
SST415B

ST-69
 SUPER HICAS SYSTEM - Trouble Diagnoses
Self-diagnosis (When CONSULT is used) (Coni' d)
• Touch RECORD to record data.
Ensure that ON-OFF signal is produced when signal is entered
ti'MONITOR ti'NO FAIL
CAR SPEED (REF)
lil
Okm/h.
from each sensor while monitoring.
STEERING ANG LBO To cancel data recording during operation, touch CANCEL.
NEUTRAL SIG ON
STOP LAMP SW OFF
PKB/CLUTCH SW ON
NEUTRAL SW ON
ENG REV UNDER 1500
HICAS SOL ROOO\
POWER STR SOL 1.05A

RECORD I
ti' MONITOR ti' NO FAIL ~
FAILSAFE/V OFF
FAILSAFE NON
WARNING LAMP OFF

RECORD

SST416B

Self-diagnosis items

Diagnostic item Description

* NO SELF DIAGNOSTIC • Even if no self diagnostic failure is indicated, further testing may be required
FAILURE INDICATED. as far as the customer complains.
FURTHER TESTING
MAY BE REQUIRED. **
VEHICLE SPEED SENSOR • No vehicle speed signal is entered after vehicle has been operated.
[NO SIGNAL] (·a)
VEHICLE SPEED SENSOR • Vehicle speed signal abruptly changes during operation.
[SIG-SUDDEN TURN] (·b)
STEERING ANGLE SEN • Steering angle has not been changed while driving at a speed of at least 60
[NO ANG SIGNAL] (·a) km/h (37 MPH).
STEERING ANGLE SEN • Neutral (ON) signal is not entered after vehicle has been driven.
[NO NEUT SIGNAL] (·b)
STEERING ANGLE SEN • Neutral (ON) signal is not entered even after steering wheel has been turned
[NEUT SIG-360• OFF] (·c) at least 360·.
STEERING ANGLE SEN • Neutral (ON) signal is continually shown at steering angle of at least 30•.
[NEUT SIG-30• ON] (·d)
FAILSAFE VALVE • Output terminal voltage is abnormal due to broken or shorted HICAS fail-safe
[ABNORMAL SIGNAL] valve circuit.
HICAS SOLENOID-A • Output terminal voltage is abnormal due to broken or shorted HICAS solenoid
[ABNORMAL SIGNAL] (RH) circuit
HICAS SOLENOID-L • Output terminal voltage is abnormal due to broken or shorted HICAS solenoid
[ABNORMAL SIGNAL] (LH) circuit
POWER STEERING SOL • Output terminal voltage is abnormal due to broken or shorted power steering
[ABNORMAL SIGNAL] solenoid circuit.

ST-70
 SUPER HICAS SYSTEM - Trouble Diagnoses
Self-diagnosis (When CONSULT is used} (Cont'd}
Data monitoring items
0: Standard
1::::.: Optional selection

Monitor item selection

Item Remarks
All items Item menu
Vehicle speed sensor (km/h) 0 1::::. -
Abnormal value is shown before straight-
Steering angle sensor (deg) 0 1::::. ahead position ("0") is set and after battery
is disconnected and reconnected.
Neutral signal
0 1::::. -
(ON-OFF display)
Stop lamp switch signal
0 1::::. -
(ON-OFF display)
Parking brake/Clutch switch Clutch switch signal for MIT model and
0 1::::.
(ON-OFF display) parking brake switch signal for A/T model.
Neutral switch Neutral switch signal for MIT model and in-
0 1::::.
(ON-OFF display) hibitor relay (N or P) signal for A/T model.
Engine rpm Engine speed greater than/less than 1,500
0 1::::.
("OVER 1,500" or "UNDER 1,500" is shown.) rpm is shown.
Controlled current flow from control unit to
HICAS solenoid
0 1::::. HICAS solenoid and direction of current con-
(R/L) (A)
trol are shown.
Controlled current flow from control unit to
Power steering solenoid (A) 0 1::::.
power steering solenoid is shown.
Fail-safe valve ON (when connected) or OFF (when discon-
0 1::::.
(ON-OFF display) nected) is shown.
NON (fail-safe valve ON) referring to
Fail-safe system "normal" conditioner CUT (fail-safe valve
0 1::::.
(CUT-NON display) OFF) when in "fail-safe" condition are
shown.
Warning lamp Illumination control of control unit's HICAS
0 1::::.
(ON-OFF display) warning lamp is shown.
Voltage measured with voltage probes is
• Voltage (V) - 1::::.
shown.
Value measured with pulse probes is
shown.
• Pulse (ms, Hz or ) - 1::::. If pulse cannot be measured, "#" is down.
"#" is also shown at left of final data until
measurement results are determined.

ST-71
SUPER HICAS SYSTEM - Trouble Diagnoses

Self-diagnosis (When CONSULT is not used)

SELF-DIAGNOSIS PROCEDURES
1. Input starting conditions for self-diagnosis.
(1) Turn ignition switch "OFF".
(2) Set shift lever to "P" or "N" position (A/T model), or
"Neutral" position (M/T model).
(3) Turn ignition switch "ON".
(4) Immediately start engine.
(5) Turn steering wheel from left to right (at least 20° from the
neutral position ) 5 times or more, then depress foot brake
pedal at least 5 times all within 10 seconds after ignition
switch has been turned "ON".
2. Input self-diagnosis item.
(1) Depress and release foot brake pedal.
(2) Turn steering wheel from left to right (at least 20°) from the
neutral position.
(3) (MIT model)
Depress clutch pedal and move gear shift lever to any
position other than Neutral land return to Neutral. Release
clutch pedal.
(A/T model)
Disengage and engage parking brake lever. Move shift
lever to any position other than Neutral or Parking and
return to Parking.
(4) Move car at least 3 meters (10ft) forward and proceed at an
indicated speed of at least 2 km/h (1 MPH) in self-diagnosis
mode.

3. The self-diagnosis mode will then appear in the "HICAS"

warning lamp.
When all systems are normal:
HICAS warning lamp flashes at 0.25-second intervals.

ST-72
 SUPER HICAS SYSTEM - Trouble Diagnoses
Self-diagnosis {When CONSULT is not used) {Cont'd)
When there is a system malfunction:
Example: When ® HICAS solenoid LH, @ power steering
solenoid and @ vehicle speed sensor have experi-
enced a malfunction.
The warning lamp displays abnormal mode (1 sec. ON).
EJ If fail-safe system was operated (fail-safe valve is operat-
ing) when ignition switch was turned OFF for the last time,
fail-safe items will be displayed in numerical order in
modes indicated. After all items are displayed, display is
repeated again.
• To change the display mode to EJ, turn OFF Ignition switch
after mode I!J Is displayed.
• When battery charge Is Insufficient, mode(;) Is displayed.

Indicator 0.1 sec. Display repeats until

(Normal key switch is turned
- Diagnosis starts
mode OFF or after approxi-
1 sec. (Abnormal mode displays.)
10 times ( displays.) I- mately 5 minutes have

ON "i 1 passed.

OFF
2 sec. each for
CD through®
5 sec. 5 sec.

Inhibitor
Steering
HICAS HICAS Fail-safe Power Vehicle Steering sensor sensor
neutral
Diagnosis part solenoid solenoid valve steering speed angle. MIT: M/T:
position
A. H. L.H. solenoid sensor sensor Clutch Neutral
sensor
sensor sensor

SST418B

ST-73
 SUPER HICAS SYSTEM - Trouble Diagnoses
Self-diagnosis (When CONSULT is not used) (Coni' d)
li1 If fail-safe system was not operated when ignition switch
was turned OFF for the last time, display will show self-
diagnosis results in numerical sequence in modes indi-
cated below. After all self-diagnosis results are shown,
display is repeated again.

Display repeats until

Indicator key switch is turned
1 sec. (Abnormal mode displays.) 0.1 sec. OFF or after approxi·
(Normal
ON ~- Diagnosis starts
mode
mately 5 minutes have

I( I
-
passed.
displays.)

OFF

5 sec. 5 sec.

Steering Inhibitor
HI CAS HI CAS Power Vehicle Steering sensor sensor
Fail-safe neutral
Diagnosis part solenoid solenoid steering speed angle M/T:
valve position M/T:
R.H. L.H. solenoid sensor sensor Clutch
sensor Neutral
sensor sensor

SST419B

CANCELING THE SELF-DIAGNOSIS FUNCTION

There are three methods for canceling the self-diagnosis func-
tion, as described below:
• The self-diagnosis system is canceled by the turning igni-
tion switch "OFF".
• After self-diagnosing has been operated for approximately
5 minutes, the self-diagnosis system will be automatically
canceled.
• The self-diagnosis system is canceled by a vehicle speed of
30 km/h (19 MPH) or over.

ST-74
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 1
SYMPTOM:
No warning lamp comes on when ignition switch is turned
"ON".
START

CHECK WARNING LAMP N.G. Check and repair wiring.

POWER SUPPLY.
SST417B 1) Turn ignition switch "ON".
2) Measure voltage across
Without
fJ With air bag air bag warning lamp connector ter-
minal® and ground.
II:=I~B Voltage:
Approximately 12V
OR OR

Replace warning lamp.

SST774B

ST-75
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 2
SYMPTOM (A):
Warning lamp comes on during operation.
START

Check in self-diagnosis mode.

Refer to page ST-69.

SST417B

Repair malfunctioning part de- O.K.

m tected by self-diagnosis.
END

00
_!~~
Refer to Diagnostic Procedures
5 to 12.
SEI.fCT DIAG MODE
SELF.OIAG RESULTS
DATA MONITOR
ACTIVE TEST
Check connectors for improper O.K. END
ECU PART NUMBER
contact.
N.G.

SST476B Check steering neutral position.

Refer to page ST-59.

ST-76
 SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 2 {Cont'd}
SYMPTOM (B):
Warning lamp comes on when Ignition switch Is turned ON;
however, it does not go out after engine start.
SELECT DIAG MODE
SELF·DIAG RESULTS
DATA MONITOR
START
ACTIVE TEST
ECU PART NUMBER

Check in self-diagnosis mode. O.K. No engine rpm signal is en-

Refer to page ST-69. tered.
SST476B

Warning lamp
remains ON Repair malfunctioning part de-
L-----~1 tected by self-diagnosis.
Refer to Diagnostic Procedures
5 to 12.

Check rear wheel action. No No power is supplied to control

Left and right rear wheels are unit.
turned in response to rotation of
steering wheel.
Refer to page ST-64.

Insufficient oil quantity.

Replace fluid level sensor (on

reservoir tank) if warning lamp
remains on during engine oper-
ation.

ST-77
SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 3
SYMPTOM:
Abnormal noise occurs.

START

Disconnect HICAS solenoid con- Yes Noise stops.

nector and check noise for L.__ _ _ _- ._ _ _ ___J

changes.

No

Noise occurs in any system Bleed air from hydraulic system.

other than HICAS. Refer to page ST-49.
N.G.

I Locate and repair.

Replace control unit.

SST3768
N.G.

END

IReplace HICAS solenoid valve.

SST4408

ST-78
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 4
SYMPTOM:
Vehicle behavior is abnormal. (Vehicle sways or jerks.)

~ tr-- ~= =
rd\\AI" ~
I START
I

00•
.rg.
M
~t)
\\

SST4758
m r
Check steering wheel neutral
position for misalignment and
steering angle sensors for
looseness.
O.K. END

(;] Refer to page ST-59.

.~~J
(j) (;]
N.G.
I~ SELECT DIAG MODE CJI N.G.
Check in self-diagnosis mode. Repair malfunctioning system
I SELF-DIAG RESULTS I
I DATA MONITOR I Refer to page ST-69. detected by self-diagnosis.
I ACTIVE TEST I
·~ ~~~~~
Refer to Diagnostic Procedures
I O.K.
I ECU PART NUMBER 1!§:1!!!!1 5 to 12.
I 1\1'
I I
""-.._ Check static HICAS characteris-
SST476B tic performance.
Refer to flow chart A on page
ST-80.

Check dynamic HICAS charac-

teristic performance.
Refer to flow chart B on page
ST-83.

ST-79
 SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)
A. Static HICAS characteristic performance check

START
I~ SELECT OIAG MODE
I SELF-OIAG RESULTS
I DATA MONITOR
I ACTIVE TEST Set CONSULT in ACTIVE
I ECU PART NUMBER TEST mode.
~--------OR----------~

t<a\ Set self-diagnosis mode.

~ Refer to page ST-69.
SST476B
~----------------------~~
~--------~~----------.
• Run engine at a speed or less
than 2,000 rpm.
• Turn steering wheel approxi-
mately 180" to the left or right.

CHECK POWER CYLINDER O.K. END @

STROKES.
Each stroke from neutral
position:
SST378B 2.9- 3.1 mm
L.,_-------------------------------1 (0.114- 0.122 in)
Refer to page ST-45.

N.G.
CHECK RESISTANCE OF HICAS N.G. Replace HICAS solenoid valve.
SOLENOID VALVE.
Stop engine and disconnect HI-
CAS solenoid valve.
Measure resistance between
HICAS solenoid connector termi-
nals ®and@, and@.
SST441B Resistance:
4-60
O.K.

ST-80
 SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)

DRIVE
I ACTIVE TEST
HIGH SPEED
I 0 00 ;:::I;]::::.__ _ ___,AL--------,
CHECK CONTROL UNIT N.G. Replace control unit.
CONDITION OUTPUT VOLT AGE.
===MONITOR===
STEERING ANG R11° fF.i\Set CONSULT in ACTIVE
HICAS SOL R0.58A W TEST mode.
POWER STR SOL 1.05A HICAS solenoid valve
output amperes:
1.1 • 1.2A
CANCEL 1 - - - - - OR------;
SST3778 Set self-diagnosis mode.
• Run engine at a speed

~1500 ®
of more than 2,000 rpm.
• Turn steering wheel
approximately 180".

Ill I I ODd I I Ill fiiiliJJ~ • Measure voltage

across control unit con-
BR ~BR/Y B
nector terminals@ and
@,and@.
I
I Output voltage:
I
I
I More than 4.4V

SST442B @
L---------------------~~
ST27091 000 IJ263571 r---------~L---------~
r-----------, CHECK HICAS OIL PUMP RE· N.G. Replace oil pump.
I I
I LIEF PRESSURE.
I
I • Cancel self-diagnosis mode.
I
• Check HICAS oil pump relief
pressure with engine running
at a speed of more than 2,000
rpm.
Relief pressure:
More than 5,884 kPa
'-----------'-- Low-pressure (60 kg/cm 2 , 853 psi)
. . . : Direction of oil flow hose SST478B r.l
.. O.K.
r=---------1-----------
CHECK OIL PRESSURE
AT FAIL-SAFE VALVE.
fF.i\
Set CONSULT in ACTIVE
SELECT OIAG MODE
~TEST mode.
SELF-OIAG RESULTS
OR
DATA MONITOR
ACTIVE TEST
ECU PART NUMBER

SST476B

ST-81
 SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd}
ST27091000(J26357)
r---- --------,
I
I valve is
c
I closed
I
I • Run engine at a speed of N.G. Replace HICAS solenoid valve.
I
I'--- _ _ _ _ _ _ _ _ _ _J more than 2,000 rpm and turn
steering wheel approximately
180" to the left and right. CHECK POWER CYLINDER
• Check oil pressure at bleeder STROKE.
valve of power cylinder. Each stroke from neutral posi-
Oil pressure: tion:
SST479B More than 5,394 kPa 2.9-3.1 mm
(55 kg/cm 2 , 782 psi) (0.114 - 0.122 in)
Refer to page ST-45.
N.G. O.K.

Replace power cylinder. Replace fail- @

safe valve.

SST378B

ST-82
 SUPER HICAS SYSTEM- Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)
B. Dynamic HICAS characteristic performance check

START

CHECK PIPING AND CONNEC-

TIONS. ALSO BLEED AIR FROM
HYDRAULIC SYSTEM.
• Replace piping or connectors
which are found to be dam-
aged.
• Bleed air from hydraulic sys-
tem.
Refer to page ST-49.

a
1 sELEcT oiAG Mooe
I SELF-OIAG RESULTS

I DATA MONITOR
Set CONSULT in ACTIVE
I ACTIVE TEST
TEST mode.
I ECU PART NUMBER
r---------OR----------~

® Set in self-diagnosis
mode.
SST476B Refer to page ST-69.
~----------------------------~

Run engine at a speed of more

than 2,000 rpm.

CHECK REAR WHEELS

FOR PROPER
MOVEMENT.
fF.I\ Ensure that rear wheel
SST460B ~ turns to the left or right
when steering wheel is
turned to the left or right.
1 - - - - - - - - - OR------------!
~ Ensure that rear wheels
~ intermittently turn to the
left and right when steer-
ing wheel is set to the
neutral position.

SST477B
CHECK POWER CYLINDER O.K. ~L_ _ _ _ _E_N_D_ _ _ _---'
STROKES.
Each stroke from neutral posi-
tion:
,Neutral position More than 2.0 mm
(0.079 in)

N.G .

@
...

SST378B

ST-83
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 {Cont'd)

Replace HICAS solenoid valve.

CHECK POWER CYLINDER END

STROKE.
• After replacing HICAS sole-
SST378B noid valve, check power cylin-
der stroke.
Each stroke from neutral posi-
tion:
More than 2.0 mm
(0.079 in)
N.G .
•
IReplace power cylinder.

ST-84
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 5
SYMPTOM:
System is not set in self-diagnosis mode.

I START

~~~
m l
CHECK CONNECTOR CONTINU- ~~ Poor connector connection
,,..~ ITY.
ssT4468 Disconnect steering angle sen-
'----------------=:.::..:....:..;.::~ sor connector and control unit
connector, and reconnect them
*MONITOR 'tfNO FAIL [i] M
CAR SPEED (REF) Okm/h. ~ firmly. Conduct self-diagnosis.
STEERING ANG L8°
NEUTRAL SIG ON
STOP LAMP SW OFF
PKB/CLUTCH SW ON CHECK STOP LAMP IN- N.G. Malfunctioning stop lamp switch
NEUTRAL SW ON PUT SIGNAL. system
ENG REV UNDER 1500
HICAS SOL RO.@ fF.i\ Set CONSULT in DATA
POWER STR SOL 1.05A W MONITOR mode.

I RECORD I ON-OFF display

1 - - - - - - OR - - - - - - 1

'tf MONITOR 'tf NO FAIL

FAI LSAFE/V OFF
~ ® Check that stop lamp in-
put is present at control
FAILSAFE NON unit.
WARNING LAMP OFF Brake ON:
Approximately 12V
Brake OFF:
ov

RECORD
CHECK STEERING NEU- O.K. Replace control unit.
SST416B TRAL POSITION SENSOR
INPUT SIGNAL.
fF.i\ Set CONSULT in DATA
W MONITOR mode.

~1500® ON-OFF display

1 - - - - - - OR-----......j
fU\
: 1: :,,~ : t : IMxl I 12~
Check that steering neu-
~ tral input is present at
8 control unit when steer-
A/8
ing wheel is turned to the
left and right at least 20"
from the neutral position.
Neutral position:
SST447B Approximately SV
When turned at least 20":
ov

LIW 8

I vi
-I@__§ f----.'
~

SST44BB

ST-85
 SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 5 (Cont'd)

®
Without
B
With air bag
~
air bag O.K.

rm
CHECK STEERING NEUTRAL Repair or replace harness be-
B ltfliBJ POSITION SENSOR OUTPUT
SIGNAL.
tween control unit and steering
angle sensor.
LIW L/W Check that steering neutral out-
put is present when steering
wheel is turned to the left and
right at least 20" from the neu-
SST7758
tral position.
Neutral position:
Approximately SV
When turned at least 20":
OV
N.G.

r------------------------------.1 O.K. Replace steering angle sensor.

1!11 1!11 CHECK STEERING ANGLE
Without ~ SENSOR POWER SUPPLY.
air bag With air bag ~ 1) Turn ignition switch

ffi 1 Ii I I
2 I I i 13~ ~ i)
G/Y
"ON".
2) Measure voltage across
steering angle sensor
G/Y
00 connector terminal IGN
'-------------~~~~~ - and ground.
Voltage:
... Approximately 12V
SST7768 II CHECK STEERING ANGLE
~----------------------------~
SENSOR GROUND CIR-
II
B~lil
CUIT.
Check continuity between
B Without ~ Withair steering angle sensor ter-
air bag bag '-.} minal GND and body metal

00 (ground).
Continuity should exist.

N.G.

Check and repair power supply

harness or ground harness.
SST7778

ST-86
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 6
SYMPTOM:
HICAS solenoid (left and right) output is not present.

START

CHECK CONNECTOR CONTINU- O.K. Poor connector connection

ITY.
SST421 B Disconnect HI CAS solenoid con-
.•
~----------------------------~
nector and control unit connec-
tor, and reconnect them firmly.

I
~------ . Conduct self-diagnosis.
I
I
I

CHECK RESISTANCE OF LEFT N.G. Replace HICAS solenoid

AND RIGHT HICAS SOLENOIDS
(on solenoid side).
1) Disconnect HICAS solenoid
connector.
2) Measure resistance between
SST422B
HICAS solenoid connector
terminals@ and@, and

Q!Ufl ~.
@.
8 Resistance:
4- &Q
BR/Y I BR I?J O.K.
I

~-+-----
I
I
I
I
00 CHECK RESISTANCE OF LEFT
AND RIGHT HICAS SOLENOIDS
(on control unit side).
O.K. j Replace control unit.

1) Disconnect control unit con-

SST423B nector.
2) Measure resistance between
body connector terminals @
and@, and@.
Resistance:
4- &n
N.G.

Repair or replace harness

between control unit and
HICAS solenoid.

ST-87
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 7
SYMPTOM:
Fail-safe valve output is not present.

START

CHECK CONNECTOR CONTINU- IPoor connector connection

ITY.
SST424B Disconnect fail-safe valve con-
' - - - - - - - - - - - - - - - - - ' nector and control unit connec-
tor, and reconnect them firmly.
Conduct self-diagnosis.

CHECK RESISTANCE OF FAIL- N.G. Replace fail-safe valve.

SAFE VALVE (on fail-safe valve
side).
1) Disconnect fail-safe valve
connector.
2) Measure resistance between
SST426B
connector terminals ®and
@.
Resistance:
[:it i5 ~ 13. 17Cl
O.K.
lllb81111 CHECK RESISTANCE OF FAIL- O.K. IReplace control unit.
SAFE VALVE (on control unit
side).
1) Disconnect control unit con-
nector.
SST471B
2) Measure resistance between
body connector terminals
®and®.
Resistance:
13. 17Cl
N.G.

Repair or replace harness

between control unit and fail-
safe valve.

ST-88
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 8
SYMPTOM:
Power steering solenoid output Is not present.

IPoor connector connection

SST427B Disconnect power steering sole-
~----------------------_;~~~
noid connector and control unit
connector, and reconnect them

[ltij00 firmly. Conduct self-diagnosis.

,---~~~~~--~
CHECK RESISTANCE OF N.G. Replace power steering sole-
POWER STEERING SOLENOID noid.
(on solenoid side).
1) Disconnect power steering
solenoid connector.
2) Measure resistance between
SST4
solenoid connector terminals
®and@.
Resistance:
4-60
O.K.

CHECK RESISTANCE OF O.K. Replace control unit.

8/Y B
POWER STEERING SOLENOID
(on control unit side).
1) Disconnect control unit con-
nector.
SST429B 2) Measure resistance between
body connector terminals @
and@.
Resistance:
4. 60
N.G.

Repair or replace harness

between control unit and
power steering solenoid.

ST-89
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 9
SYMPTOM:
Vehicle speed signal Is not present.

START

CHECK CONNECTOR CONTINU- O.K. J Poor connector connection I

ITY.
SST430B Disconnect control unit connec-
tor and reconnect it firmly. Con-
duct self-diagnosis.
~MONITOR ~NO FAIL
CAR SPEED (REF)
STEERING ANG
NEUTRAL SIG
L8°
ON
[i)
Okm/h.
00 t;l ~N.G.
STOP LAMP SW OFF CHECK CONTROL UNIT ~~ Replace control unit.
PKB/CLUTCH SW ON INPUT SIGNAL.
NEUTRAL SW ON 1) Raise rear end of vehi-
ENG REV UNDER 1500
HICAS SOL RO.~ cle so that rear wheels
POWER STR SOL 1.05A rotate freely.
I RECORD I rF.i\ 2) Set CONSULT in DATA
\l!!) MONITOR mode.
~MONITOR ~ NO FAIL ~ Vehicle speed display
FAILSAFE!V OFF (km/h)
FAILSAFE NON OR-------i
WARNING LAMP OFF

® Measure voltage varia-

tions between control
unit connector termi-
nals@ and@ while
slowly rotating rear
L--1_ __:_:_:RE=-::C::..::O:..:. .R:.:::D_ __jl wheels by hand.
· Voltage must change
between 0 and 5V.
SST416B

~l) 00®
Repair or replace harness be-
tween speed sensor or control
unit and speedometer.

~ I I Ill I I'B IPtd I I,~

y /B
B

lVI
~~_§t---­
~ SST431B

ST-90
 SUPER HICAS SYSTEM - Trouble Diagnoses

Diagnostic Procedure 10
SYMPTOM:
Steering angle sensor input is not present.

I START
I
CHECK CONNECTOR CONTINU- ~~ Poor connector connection
ITY.
SST430B Disconnect control unit connec-
tor and reconnect it firmly. Con-
duct self-diagnosis.
-trMONITOR -trNO FAIL
CAR SPEED (REF)
STEERING ANG
Okm/h
L8°
[i)
00 (!1 lN.G.
NEUTRAL SIG
STOP LAMP SW
ON
OFF CHECK CONTROL UNIT O.K. ·•I Replace control unit.
PKB/CLUTCH SW ON INPUT SIGNAL.
NEUTRAL SW ON 1) Turn ignition switch
ENG REV UNDER 1500
HICAS SOL RO.~ "ON".
POWER STR SOL 1.05A rF.J\ 2) Set CONSULT in DATA

I RECORD I ~ MONITOR mode.

Steering angle deg.
-tr MONITOR -tr NO FAIL ~ Neutral signal ON-OFF
~----oR-----__,
FAILSAFE/V OFF
FAILSAFE
WARNING LAMP
NON
OFF
® Measure voltage varia-
tions between control
unit terminalsCfl, @
and @ , and @ when
steering wheel is
slowly turned to the left
RECORD and right at least 20"
from the neutral posi-
tion.
SST416B
Do not turn steering
wheel quickly.

® ,. . .= L/W
~ l) 00 Voltage must change
from 0 to at least SV.
L[!l-----,--liN-.G-.------'

I I I 11XJ 11,4r7~ IN I 12 !I CHECK STEERING ANGLE SEN- O.K. Repair or replace harness be-

R/G~
B SOR OUTPUT SIGNAL. ~ tween control unit and steering
L/G 1) Turn signal switch "ON". angle sensor.
I 1 2) Measure voltage variations
!! lVI between steering angle sen-
'·.!--:'~o...--.j{.~i:\ §(.-)~ sor connector terminals Cfl,
~.ft~·~· @and@, and@.
Voltage must change from 0
to at least SV.

r,f
Without
air bag
R~G- - - ' B With air
bag 1...N.G.

a [Bm3J ~;1s~J] ®
L/W --'~ L/G L/W ~ R/G

f\ll I I I
LYJ I :\:
'--- ~ ~G:+>I--L.-:....'- - L.i--L~
- ....\
LIG~
SST778B

ST-91
 SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 10 {Cont'd)

Without 11Ft\
air bag With air bag ~

ffi~ Ii I I I Ii 13~ [1t i) li] CHECK STEERING ANGLE O.K. IReplace steering angle sensor.
G/Y SENSOR POWER SUPPLY.
G/Y
1) Turn ignition switch
"ON".
2) Measure voltage across
steering angle sensor
connector terminal@
SST776B
and ground.
Voltage:
w~~~~ i
a
111
Without
mE] [it
With air ';\
(I
Approximately 12V
CHECK STEERING ANGLE
air bag bag 'S....J SENSOR GROUND CIR-
CUIT.

00 Check continuity between

steering angle sensor ter-
minal @ and body
metal (ground).
Continuity should exist.
SST777B

Repair or replace power supply

harness or ground harness.

ST-92
 SUPER HICAS SYSTEM - Trouble Diagnoses

m Diagnostic Procedure 11
SYMPTOM:
Parking brake (A/T) or clutch switch {MIT) Input Is not present

~
~.It
I
m
START

r
I
I Poor connector connection
CHECK CONNECTOR CONTINU-
ITY.
O.K.
I
SST430B Disconnect control unit connec-
tor and reconnect it firmly. Con-
I!] duct self-diagnosis.
*MONITOR *NO FAIL
CAR SPEED (REF)
STEERING ANG
NEUTRAL SIG
Okm/h
L8°
ON
[i]
00 I!]
~N.G.

STOP LAMP SW OFF CHECK CONTROL UNIT O.K. J Replace control unit. I
PK8/CLUTCH SW ON INPUT SIGNAL.

00
NEUTRAL SW ON Set CONSULT in DATA
ENG REV UNDER 1500
HICAS SOL RQ()(A MONITOR mode.
POWER STR SOL 1.05A ON-OFF display

I RECORD I ® OR
Measure voltage varia-
tions between control unit
*MONITOR *NO FAIL ~
FAILSAFE/V OFF terminals@ and ®when
FAILSAFE NON parking brake is pulled
WARNING LAMP OFF (A/T) or clutch is de-
'
pressed (MIT).
Voltage:
OV --+ Approximately SV

~N.G.
I RECORD I Check parking brake switch or
clutch switch and harness.
SST416B

= [2ill)
Ill I I u~3I±JJI
Y/PU B

SST436B

ST-93
 SUPER HICAS SYSTEM - Trouble Diagnoses

m Diagnostic Procedure 12
SYMPTOM:
Inhibitor switch (A/n or neutral switch (M/T) Input Is not

~
present.

I START
I
~,#4 m 1 ~~
CHECK CONNECTOR CONTINU- .
ITY.
Poor connector connection
I
Disconnect control unit connec-
SST430B
tor and reconnect it firmly. Con-
I!) duct self-diagnosis.
'CrMONITOR 'CrNO FAIL
CAR SPEED (REF)
STEERING ANG
Okm/h
LBO
lil @ I!) ~N.G.
J Replace control
NEUTRAL SIG
STOP LAMP SW
ON
OFF
CHECK CONTROL UNIT
INPUT SIGNAL.
O.K. unit.
I
PKB/CLUTCH SW ON
@Set CONSULT in DATA
NEUTRAL SW ON
ENG REV UNDER 1500 MONITOR mode.
HICAS SOL RO.~ ON-OFF display
POWER STR SOL 1.05A

I RECORD I ® OR
Measure voltage varia-
tions between control unit
'Cr MONITOR 'Cr NO FAIL ~ terminals 14 and 24 when
FAILSAFE/V OFF shift lever is moved from
FAILSAFE NON P to any other position
WARNING LAMP OFF
(AfT) or shift lever is
moved from neutral to
any other position (MIT).
Voltage:
OV -+ Approximately SV
I RECORD I ~N.G.

SST4168 Check inhibitor switch or neutral

switch and harness.

:
lill5®
Ill I 11XI l,m IMxJ 112~

SST4378

ST-94
 SUPER HICAS SYSTEM - Trouble Diagnoses

Control Unit Inspection Table

The standard values (voltage) measured with an analog tester, in contact with the control unit terminal,
are shown below:

Terminal No. Application Standard value

1 Service support CLK input -
2 Service support RX output -
Key switch ON: Approximately 12V
3 IGN power supply
Key switch in other position: OV
4 Battery Approximately 12V
5 E.C.C.S. revolution signal -
Rear wheel rotating
6 Vehicle speed signal
OV ..... -+ greater than 5V (approx.), intermittent
7 Steering neutral position sensor Approximately 5V (Neutral position)
8 Resistance of power steering solenoid 4-60
9 Service support TX output -
10 Ground OV
Brake ON: Approximately 12V
11 Stop lamp switch signal
Brake OFF: OV
Parking brake engaged (A/T)I
13 Parking brake signal (A/T), Clutch signal (MIT)
clutch disengaged (MIT): Approximately 5V
Shift lever in any position other than
14 Inhibitor signal (A/T), Neutral signal (M/T)
Parking (A/T) or neutral (MIT): Approximately 5V
Steering wheel turned
15 Steering angle sensor-1 signal
0 <--+ Approximately 5V, intermittent
Steering wheel turned
16 Steering angle sensor-2 signal
0 <--+ Approximately 5V, intermittent
18 Resistance of fail-safe valve 13-1m
Ignition switch ON: Approximately 12V
19 IGN power supply
Ignition switch in other position: OV
Lamp ON: OV
20 HICAS warning lamp
Lamp OFF: Approximately 12V
22 Resistance of HICAS solenoid (R.H.) 4-60
23 Resistance of HICAS solenoid (L.H.) 4-60
24 Ground ov

1 2 3 0 4 5 6 7 ~ 0 18 19
8 9 10 11jX 13 14 15 16 20 ~22 23 24
SST438B

ST-95
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications
Without With
SUPER HICAS SUPER HICAS

Steering model Power steering

Steering gear type PR26SE

Steering overall gear ratio 16.9 14.8

Turn of steering wheel

2.7 2.4
(Lock to lock)

Steering column type Collapsible

Inspection and Adjustment

STEERING WHEEL STEERING GEAR AND LINKAGE

Steering wheel axial play

mm(in)
0 (0)
I ~e PR26SE

Steering wheel play Tie-rod outer ball joint

0 - 35 (0 - 1.38)
mm(in)
Swinging force 4.61 - 46.09
(at cotter pin hole) N (kg, lb) (0.47- 4.7, 1.04- 10.36)

Rotating torque 0.29- 2.94

N·m (kg-em, in-lb) (3.0 - 30.0, 2.6 - 26.0)
STEERING COLUMN
Axial end play mm (in) 0 (0)
Without air bag With air bag Tie-rod inner ball joint
Steering column length "L 1" 745.9- 747.5 749.4- 751.0 8.8- 78.5
mm (in) (29.37 - 29.43) (29.50 - 29.57) Swinging force* N (kg, lb)
(0.9- 8.0, 2.0 - 17.6)
Steering column lower shaft Rotating torque 1.0- 8.8
length "L 2" 280.6-282.2 (11.05- 11.11) N·m (kg-em, in-lb) (10- 90, 8.7- 78.1)
mm(in)
Axial end play mm (in) 0 (0)

Tie-rod standard length "L"

155 (6.10)
mm (in)

*: Measuring point

SST315B

SST304B

Rack stroke "L" mm (in)l 59.5 (2.343)

SST307B

ST-96
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection and Adjustment (Cont'd)
POWER STEERING POWER CYLINDER LOWER LINK
(SUPER HICAS)
Without With
SUPER SUPER Power cylinder lower link
HI CAS HI CAS ball joint
Rack sliding force N (kg, lb)
Swinging force• N (kg, lb) 2.9- 41.2
Under normal operating (0.3 - 4.2, 0.7 - 9.3)
oil pressure Axial end play mm (in) 0 (0)
Range within ± 11.5 mm Power cylinder lower link
206- 265 201.0 - 250.1 309.5 (12.19)
( ± 0.453 in) from the neu- standard length "L" mm (in)
(21 - 27, (20.5 - 25.5,
tral
46- 60) 45.2- 56.2) Stroke mm (in) 3.0 (0.118)
position

Not more than 39 (4, 9) ·: Measuring point

Except above range
beyond above value

Retainer adjustment L

Adjusting screw
*
Initial tightening torque
N·m (kg-em, in-lb)

Retightening torque
4.9 - 5.9 (50 - 60, 43 - 52)
J rl]a =
0.2 (2, 1.7)
after loosening

Tightening torque after

4.9 (50, 43) SST486B
gear has settled

Returning angle degree so· - 1oo·

Steering wheel turning force

(Measured at one full turn from
39 (4, 9) or less
the neutral position)
N (kg, lb)

Fluid capacity (Approximate) 1.3 2.0

e (US qt, Imp qt) (1-3/8, 1-1/8) (2-1/8, 1-3/4)

Main:
7,649 - 8,238
7,649 - 8,238 (78- 84,
Oil pump maximum pressure 1,109 -1,194)
(78- 84,
kPa (kg/cm 2 , psi) 1,109- 1,194) Sub:
6,375 - 6,865
(65- 70,
924- 995)

ST-97
 BODY

SECTIONBF

CONTENTS
GENERAL SERVICING
(Including all clips & fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BF- 2
BODY END .............................................................. BF- 5
DOOR
(Including "Power Window" & "Power Door Lock") ............................. BF-10
INSTRUMENT PANEL ..................................................... BF-16
INTERIOR AND EXTERIOR
(In EXTERIOR, including "Weatherstrips") ................................... BF-18
T-BAR ROOF ............................................................ BF-30
SEAT ................................................................... BF-32
WINDSHIELD AND WINDOWS ............................................. BF-35
AUTOMATIC SEAT BELT SYSTEM ......................................... BF-40
REAR AIR SPOILER ..................................................... BF-45
Ml RROR ................................................................ BF-46
BODY ALIGNMENT ...................................................... BF-48
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ................................ BF-55
TROUBLE DIAGNOSES -Supplemental Restraint System (SRS) ................... BF-63

When you read wiring diagrams:

• Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.

* For conventional seat belt, refer to MA section.

 GENERAL SERVICING

Precautions
• When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
• Handle trim, molding, instruments, grille, etc. carefully during removing or installation. Be careful not
to soil or damage them.
• Apply sealing compound where necessary when installing parts.
• When applying sealing compound, be careful that the sealing compound does not protrude from parts.
• When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust
prevention measures.

Supplemental Restraint System "AIR BAG"

The Supplemental Restraint System "Air Bag" helps to reduce the risk or severity of injury to the driver
in a frontal collision. The Supplemental Restraint System consists of an air bag (located in the center of
the steering wheel), sensors, a control unit, warning lamp, wiring harness and spiral cable. Information
necessary to service the system safely is included in the BF section of this Service Manual.
WARNING:
a. To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of
a severe frontal collision, all maintenance must be performed by an authorized NISSAN dealer.
b. Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system.
c. All SRS electrical wiring harnesses and connectors are covered with yellow outer insulation. Do not
use electrical test equipment on any circuit related to the SRS "Air Bag".

Time (sec.l Circuit Breaker Inspection

100 I---~Jo+-t---;;*::-::-;~t:7--t- For example, when current is 30A, the circuit is broken within 8
501---I---M-t-+-+-+--t- to 20 seconds.
Circuit breakers are used in the following systems.
20 r---lf---1"""'foo4. • Power window & power door lock
,x~~~~-1-1-t- • Power seat
s~~~~~t-+-+-

BF-2
 GENERAL SERVICING

Clip and Fastener

• Clips and fasteners in BF section correspond to the following numbers and symbols.
• Replace any clips and/or fasteners which are damaged during removal or installation.

No. Symbol Shape Removal & Installation

Removal:
Remove by bending up with
a flat-bladed screwdriver.

<§!)
c& SBF092B
~
SBF109B
t~ ~==o=

SBF094B

~ - ~b
~
T SBF113B
SBF114B

.. ~
,,,,.
~ ~
Removal:
Pull up while rotating.
SBF115B

Removal:
Tilt clip as indicated by

w
_ ~rrow, then draw out.
c§§)
y
~~
SBF141B SBF142B SBF143B

Removal:

~
Remove with flat-bladed
screwdriver or pliers

t~~1
~
w SBF089B
0 q
SBF090B
__.__.,
-~ SBF091B

BF-3
 GENERAL SERVICING
Clip and Fastener (Cont'd)
No. Symbol Shape Removal & Installation
Pu1h center pin to
catching p01ition.

H !
Push (Do not ramova

• center pin by hitting it.)

T
Push
c§) •
~ SBF318C
'iP "............ ~
SBF319C
,
SBF708E

- ,~
!--
·--''7!J
~
~
~

SBF1038 SBF104B SBF147B

Removal:

SBF653B SBF654B

Removal:
Holder portion of clip must be
spread out to remove rod.

·~

fiDq~\1
~

SBF768B
SBF770B

Removal:
Screw out with a Phillips
screwdriver.

i T ~
~
~
$
SBF138B SBF139B
i SBF140B

BF-4
 BODY END

Body Front End

• Hood adjustment: Adjust at hinge portion.
• Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to
hood lock engaging mechanism.
• Hood opener: Do not attempt to bend cabre forcibly.

Bumper shock absorber inspection

1. Check shock absorber for oil leakage, cracks or deformation.
2. Function of shock absorber;
( 1) Place vehicle in front of a wall.
Apply parking brake and place tire stoppers securely.
(2) Place a jack between bumper and wall; jack is positioned squarely with bumper, directly in line with
shock absorber to be checked.
(3) Apply pressure to compress shock absorber at least 10.0 mm (0.394 in).
Use a jack with capacity of more than 600 kg (1,323 lb).
(4) Make sure bumper returns to its original position when jack is retracted. Replace if necessary.
CAUTION:
It is not recommended to confirm proper installation by driving into walls or other barriers as this could
cause personal injury or damage to the vehicle.
When replacing shock absorbers, make sure they are of the same type and rating, and manufactured by the
same maker.

BF-5
 BODY END
Body Front End (Cont'd)

Hood lock a d j u s t m e n t - - - - - - - - - - - - - - - - - - ,
• Adjust lock so that hood primary lock meshes at a position
where hood is 1 to 1.5 mm (0.039 to 0.059 in) lower than
fender.
• After hood lock adjustment, adjust bumper rubber.
• When securing hood lock, ensure it does not tilt. Striker must
be positioned at the center of hood primary lock.
a After adjustment, ensure that hood primary and secondary
lock operate properly.

Hood lock secondary latch hooking length - - - - - - - - - - - - - - - - \

Hood adjustment m
More than~
5mm Hood
(0.20 in I

~Secondary latch
~ 21-26 (2.1- 2.7, 15- 20)

Bumper rubber a d j u s t m e n t - - - - - - - - - - - - - - - - - - ,
• Adjust so that hood is aligned with
fender. [Bumper rubber free height
is approx. 15 mm (0.59 in).)

Engine under cover

Retainer

* : Bumper assembly mounting

bolts, nuts and screws
~ : N·m (kg-m, ft-lb)
~ : Double-faced adhesive tape

BF-6
 BODY END
Body Front End (Cont'd)

~13-;e~
(1.3 -1.6,
9-12~>

Pawl

SBF856E
Service Notice
• Be sure to enlarge hood hinge holes (hinge to hood side) less than 10 mm (0.39 in) dia. for easy hood
adjustment at hood-hinge portion.
• Be sure to take rust prevention measures after enlargement of holes.

BF-7
 BODY END

Body Rear End and Opener

• Back door adjustment: Adjust at hinge-body portion for proper back door fit.
• Back door lock system adjustment: Adjust lock & striker so that they are in the center. After
adjustment, check back door lock operation.
WARNING:
a. Be careful not to scratch back door stay when installing back door. A scratched stay may cause
gas leakage.
b. The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or
allow fire near it.
• Opener cable: do not attempt to bend cable using excessive force.
• After installation, make sure that trunk lid/back door and fuel filler lid open smoothly.
• Remove washer tank (located at left of luggage compartment) before removing or installing bumper.

Back door hinge

adjustment 11

~ 13-16
(1.3- 1.6, 9- 12)

~13 -16
(1.3- 1.6, 9- 12)

Sealing washer

Back door lock

adjustment I!]

Bumper reinforcement

Energy absorber forming

Bumper side bracket 1§1

* : Bumper assembly mounting

bolts, nuts and clips
~ : N·m (kg-m, ft-lb)

BF-8
 BODY END r (Cont'd)
End and Opene
Body Rear Iii "'""" "•'•

SBF857E

BF-9
 DOOR

• After adjusting door or door lock, check door lock operation.

As.1-6.s
(0.52 • 0.66,
3.8-4.8)

~ Locking sealant
Window guida rail
crank adjustment· ® I!]
adjustment

A: N·m (kg·m, ft-lb)

BF-10
 DOOR

Hinge-Body adjustment
Outside
handle

Outside handle adjustment

(Turn holder until clearance between
holder & rod is specified value.)

Escutcheon

Inside
base
han~

Striker adjustment

tp,l13 -16
(1.3 -1.6,
9 -12)

SBF858E

BF-11
 -
r' 'if~!:
FUSE BLOCK
(Refer t 0 •POWE R SUPPLY ROUTIN
IGNITION - _ G• In EL
~
lJ
zC')
c
)>
C')
lJ
)>
REGULATOR ffiriver sid~
s:

(Engine
room
harness> F• B

8
l(~~~~ess>
~®r- d~ _____j®
"''" @)~~@)
"' .. .,
BODY GROUND '
-<
I:D '
"
'
"
®b@ BODY GROUND
0
~
,m (Main
...CD c
0
~
harness)
I
..l (Door harness L.H.) ® @) } To illumination system
0

I ~;~'"
:::s ::0
N g;~. c.
R/Y
G/Y ness R. H. > 0
~
~~ 8 /Y~~·/Y:Jd~~~:~ ~~
<Dooc hoc R W"DDW '"'
0 "" ®
,~ ..m
II 1li @iD @j!) lil:ioongoc 0 <" ' SWITCH
on
B 8/W
W/8
• 0 "'Ii!
~~: I 8/Y
G
o

-® r- "' ..
I"'"Cl'O'l:CD'

~
l:::V-< ~

ILL.~
D
~o5cH
(D~~~~~~~g

~®
'

MANUAL
5 3

LOCK 6a~=-
SWITCH SIDE
POWER rrl"
WINDOW
AMPLJ FI ER

ro
@d_®
BODY GROUND
(/) POWER WINDOW MAIN
.,
m

"'m
.,
U1
 DOOR
Power Window ( Cont' d)
POWER WINDOW AMP. INSPECTION

FRONT DRIVER SIDE POWER

WINDOW SWITCH
FR Driwstde
One·
1\ toudl
(Auto I
Manual Connections

UN D UN D
1 From-· window AMP\2~
-2 Q F<Om _,window AMPl21l
r-- 3 10 II From-· window AMP\21)
4 Q Ground

-:-

I IGNITION SWITCH ON orST

(Via ignition relay)
I

VOLTMETER
FRONT DRIVER
Window
operating
direction / SIDE POWER WINDOW
REGULATOR 1§2
L::....=..: -:;-
UP
t Current
flow
~ I
I 1 ~
I
I
/
Down
\ direction
\: L CIRCUIT
BREAKER
VOLTMETER

l\ I
i..,.{v}.,
=-.:::....:::;
-:!:-
~ -=-
~

AMP. OPERATION

1\
24
27
Power source UGNJ
Ground
Connections

12V
Ground
•
Manual operation
12V
Ground
12V
Operations

Ground
One-touch (Auto) Ope,.tion
12V
Ground
12V
Ground
12V
Ground

~
From ignition SW tON or ST) ONo•ST ION., ST ONo• ST iON o•ST ON or ST ON o•ST

t- ·f :~"~~=,·~~ro;m
28 ~ OFF OFF OFF OFF ON OFF

21 ; !?..:::=·~~; ~r OFF ON OFF OFF OFF OFF

t- :.a. To FA driver side power
22 window SW (DOWN I (2) OFF OFF ON OFF ON OFF
FA driver side regulator Approx. Approx. Approx. ApproJC. Approx. ApptDil.
25 ov
I- i•
wC
("Up" power source I OV owr9V OV ov ov
26 p·! FA driver side regulator
( .. Down" power source)
Approx. Approx. Approx. Approx.
ov ov owr9V OV
Aprrox.
owr9V
Appro•.
owr9V

Keeps operat·
Down· ing Until fully
Upwonl Starti,g open, then
Regulator Operating Condition Slop opera- won! Stop stops
opera-
tion automatically.
tion
Downward operation

Carry out this operation check in this chart from left to right
POWER WINDOW AMP.- Front driver side door (Behind door trim)
SBF219F

BF-13
 ~.

FUS£.BLOCKCRe(er to
•POWER
...
SUPPLY
- -
ROUTING• in
..
-z
:::D
C)
~TiERYCvla
. slbl'e I ink-blue> -0~
-
CONNECTOR PASSENGER SIDE DOOR
:::D
)>
@ .. s:

L
L/G
.i
@<§Y·
1 .<Door harness R. H.>
o
.
L
L/G------J
~.ll
r===: L(ll=ib
EfJ
(Sub
harness)

.,
0

,CD ..c
~
CD

.....
.. I~
I
0
.... 0
r-
~ @)~02
[:; ;;:~=uh···'
0
ness L. H. l n
~
h" ®
"'1J IIL.:·:m
L/G:j!S
@®a· ...... a
')(
..
"'
ID
®fi@
BODY GROUND
"T1
~
Cll
"T1
 DOOR

NOTE

BF-15
 INSTRUMENT PANEL

• When removing instrument panel assembly, remove defroster grille, combination meter, cluster lid and
radio first.

Clip li)

Pawll!ll

Metal clip II

R : Double-faced adhesive tape

BF-16
 INSTRUMENT PANEL

Flat-bladed
screwdriver

~
-~~
Fastener (Body side)

Clip (Instrument panel side)

II

SBF859E

BF-17
 INTERIOR AND EXTERIOR

Interior
SIDE, LUGGAGE AND FLOOR TRIM
2 seater model
Pawl
Metal clip [!]
I for standard roof modell

Metal clip IJ

2+2 seater model

Screw cap [!I
Metal clip f:.l

BF-18
 INTERIOR AND EXTERIOR
Interior (Cont'd)

Hole plug & door outer

finisher (Refer to
"Exterior".)

MOhlol"ll~

cap

Metal clip

Pawl

BF-19
 INTERIOR AND EXTERIOR
Interior (Cont'd)

IB L.H. side II R.H. side

Pawt-----...
(Bend when
installing.)

~~
L~·~· . ~
Flat-bladed ~
screwdriver Y

SBF007F

BF-20
 INTERIOR AND EXTERIOR

NOTE

BF-21
 INTERIOR AND EXTERIOR
Interior ( Cont' d)
BACK DOOR TRIM

Pawl [ill

Metal clip m Removal

Metal clip & pawl I§)

I!]

m I§) [ill

~
I!]
~-··"· Pawl

SBF861E.

BF-22
 INTERIOR AND EXTERIOR
Interior (Cont'd)
ROOF TRIM

Welt m

Welt liJ

Metal clip li]

Metal clip

!_Roof trim
Front

li] Type I Type II

SBF862E

BF-23
INTERIOR AND EXTERIOR

Exterior

SBFB63E

BF-24
 INTERIOR AND EXTERIOR
Exterior (Cont'd)
CD Hood front and rear seal @ Windshield side molding
Standard roof model
• : ClipA ~

X: ClipB

For this portion of

\'"'
T-bar roo.f model,
refer to "T-BAR
ROOF".

~-,·-----
~
SBF864E ClipB~

® ® ~
M~dlog fu''""~
Cowl top seal and cowl top grille

(Set when windshield glass

is installed.)

Double-faced
adhesive tape
[When in-
stalling fas-
tener, heat
body panel
and fastener
Cowl top seal to approx.
30 to 40°C
(86 to
104°F)].
SBF865E SBF866E

@ Windshield upper molding

Method 1 Cut off top portion of molding Method 2
and clean glass and panel 1. Cut off sealant at glass end.
surfaces. 2. Clean the side on which panel was mounted.

~I!RF·~·
I 3. Set molding fastener and apply sealant & primer to body
panel, and apply primer to molding.

I
•
I

Apply sealant to top portion of

molding. I
a,{)
~ 5@~::~
4. Install molding by aligning the molding mark located on center
Cut off lower portion •
1 with vehicle center.
of new molding
Be sure to install tightly so that there is no gap around the
corner.

Finish well to give it a

good 'appearance.
SBF301C

BF-25
 INTERIOR AND EXTERIOR
Exterior (Cont'd)
® Body side weatherstrip
T-bar roof model
Basically the same as the standard roof model

Sponge tape

Sponge tape
Sponge tape

end cover
S8F868E

(j) Door weatherstrip

--GO

~JR
i;l. SBF869E

BF-26
 INTERIOR AND EXTERIOR
Exterior (Cont'd)
® Door out side molding @ T-bar roof side weatherstrip

""'Front T -bar roof glass

T-bar roof
side panel

T-bar roof side

SBF870E weatherstrip

® Door outer finisher

'?;

T-bar roof side

weatherstrip
Always adjust if not
sufficiently watertight.
SBF871E SBF873E

® T -bar roof sash and T-bar roof weatherstrip @ Back door glass upper molding
These are part of the T-bar roof glass and cannot
be removed. (Refer toT-BAR ROOF.)
If they are damaged, replace entire T -bar roof glass
assembly.

Clip
SBF874E (Inserted into upper molding)

BF-27
 INTERIOR AND EXTERIOR
Exterior (Cont'd)
@ Back door glass side molding @ Back door finisher

door glass side molding

Back door panel

SBF875E

@ Back door weatherstrip

Vehicle center

~-'
0~""'
Upper

SBF877E

® Back door molding @ Rear panel finisher

Back door
molding

SBF878E

BF-28
 INTERIOR AND EXTERIOR
Exterior (Cont'd)
@ Rear combination lamp

• Warm up lamp assembly area to a temperature a little • Apply butyl seal evenly as it tends to become thin in the
below 60°C (140°F). corners.
• Warm up lamp essembly area to a temperature a little
below 60°C (140° Fl.
SBF886E

BF-29
 T-BAR ROOF

• Handle T-bar roof glass with care so not to damage it.·

• Apply sealant to portions susceptible to water leakage if necessary.
• Side molding, sash, lock basement and glass of T-bar roof constitute one Linit and cannot be disas-
sembled.

T-bar roof garnish

Cover

Key cylinder'
assembly

~ 13 ·16 N·m ~'- , Rotator

(1.3-1.6kg-m,9-12ft-lb) ·.Jz. ~-
-~~

Butyl tape~-~
!~Lever
T-bar roof glass
~
assembly

Lock assembly lubricant m

(Bonded on glass surface) ·

and weatherstrip
(Bonded on glass side)

Spacer

retainer

Roof side
molding

BF-30
 T-BAR ROOF

T-bar roof hook

Ea!l Silicon-based grease points

T-bar roof female lock ad'JUstment

Front Rear
Female lock Female lock

Adjusting shim
Adjusting shim
[t = 1.0 mm (0.039 in)]
=
[t 1•0 mm (0.039 in)]

SBF885E

BF-31
 SEAT

• When removing or installing the seat trim, handle it carefully to keep it from becoming dirty and to avoid
damage.

FRONT SEAT
For power seat Headrest removal [!]

~~43·55
~ 14.4. 5.6, 32. 41)

~
i

c.. 14.4. 5.6, 32. 41)

For manual seat

~21·26~
12.1·2.7,15·2~1\

~ : N·m lkg·m, ft·lb)

BF-32
 SEAT

rPJ 25- 31 (2.5- 3.2, 18- 231

Push (trim-covere d) lock kno b to remove headrest.

Lock
knob

SBF879E

,·\n~- 5.1-6.5
.. (0.52. 0.66,
3.8·4.8)

\_Grommet ........
~. N·m (kg-m, ft-lb)
SSIB~F~9~54~E:__ _ _ _ _ _ _ _ _ _ _ _ _ _ BF-33
 .,
0
:!!
m
::c
(I)

IE @)
.,
l r

"' (Engine room (MaIn

~~~~L~L~g~TIN~n
<R fer to nPOWER
In EL section.)

CIRCUIT
m
)>
....
~
~@) harness) harness> CONNECTOR, BREAKER

~ ~~nm~ L/RWJcml/R----®'~
::c

~ ~~M~ @j)@ ~-
m. I z
G)

c
BATTERY )>
FUSIBLE LINK HOLDER G)
::c
)>
s:

I
I'I
SEAT LIFTING MOTOR-Front

Sea. t operatIng~
direction
--- -- --

llj ~!~~ent
CIRCUIT- MOTORl
BREAKER ~~

I.... j&aIR- --
~® - -

I®~
Down M
.,m '-·_ _ _.:.UP . ~l d 1recti on
BODY GROUND
(/)

I
w
~
SEAT SLIDING MOTOR

~..
DRIVER SEAT

E
I S~at j ---
ol?erat i ng
d1rect1on ___..-
,
1\ LIFT-FR I SLIDE LIFT-RR I RECLINING

l~
Up Down N Forward Backward Up Down N Up Down

I' I Backward~ ~:~:ction

Forward ~~~~.;urrent ( ) ()
I 0 0 ( (

2 0 I < Q
J ( 0 0
SEAT LIFTING MOTOR-Rear '5 ( ( ~
( (

II' I ~~~~c~~~~ating ------ I I

~ . ....
-~JUCa 6
7 ()
II ~.;urrem;
I
I
Down
I.L=====~~======~=======
Up
flow
~~direction CIRCUIT MOTOR
.M '
I v
I
e 0 () 0
- BREAKER _____ • 0
,o
0 ( I
~
II ( ( ) ( ) 0 0
SEAT RECLINING MOTOR
bQ
I """'
I
'I
Seat operatIng I
dIrect I on
___.-f-
I.--- ·
~~~current
....
CIRCUIT-
BREAKER MOTOR
~
j&~:
W
~;
I Up
~~di~:ction C - I
en
.,
OJ
<D
01
.,....
 WINDSHIELD AND WINDOWS

Windshield
REMOVAL INSTALLATION
After removing moldings,
• Use genuine Nissan Sealant kit or equivalent. Follow instructions provided with
remove glass. each kit.
• After installation, the vehicle should remain stationary for about 24 houn.
Cutting -lent
• Do not use sealant which is more than 12 months past its production date.
• Do not leave cartridge unattended with its cap open.
• Keep primers and sealant in a cool, dry place. Nissan recommend$ that they are
stored in a refrigerator.
• Be sure to install moldings.

Clean bonding surfaces thoroughly. WARNING:

Keep heat or open flames rtWay es
Glass side primers are flammable.

Body side
CAUTION:
Be careful not to scratch glass when
removing.

SBF413B

Body side Glass side

Install spacers to panel with Install dam rubber & spacers with double·faced adhesive tepa.
double-faced adhesive tape.

Unit: mm (in)
Vehicle center adhesive
joint portion
SBF196E tape

Install molding fastener.

When installing, heat body panel and
fastener to approx. 30 to 4o•c (86 to Apply primer A.
104°F).
Upper & side molding
fastener

Fastener

Panel
ouble-faced
hesive tape
Fastener
of glass
Panel SBF719C
ouble-faced CAUTION:
hesive tape
Allow primers to dry for 10 to 15
SBF881E
minutes before proceeding to the next
step.

BF-35
 WINDSHIELD AND WINDOWS
Windshield (Cont'd)
@

Apply primer E.
T Apply sealant evenly.

More than
12 (0.471

Unit: mm (in) SBF199E

SBF038B

CAUTION: CAUTION:
Allow primers to dry for 10 to 15 Windshield glass should be instilled
minute' before proceeding to the next within 15 minutes of applying sealant
step. sealant starts to harden 15 minutes
after it is applied.

Set glass in position and

press glass lightly and evenly.

Apply . .lent additionally to lo-r portion of glas

end make it uniform u shown below:
Glass

Additional sealant SBF720C

CAUTION:
For sealant drying period, refer to
Check for water leakage.
"Drying Time for Sealant".

Apply sealant to upper & side molding

fixing portion.

Set upper and side moldings.

CAUTION:
Molding must be installed securely so
that it is in position and leaves no gap.

Install lower molding. For details of moldings, refer to

"Exterior".

BF-36
 WINDSHIELD AND WINDOWS

Side Window

2 seater model 2+2 seater model

Spacer and clip portion Unit: mm (in)

2+2 seater model

6
1510.59) 10"591

~......,
230
19.06) 230
19.06)

Clip portion Clip portion

marking marking

Clip 8

Front molding
!Bonded on
glass side)

SBF010F

BF-37
 WINDSHIELD AND WINDOWS

Back Door Window

• Construction and removal/reinstallation method of back door window are basically the same as those of
windshield.
• For sealant drying time, refer to "Drying Time for Sealant".
• For details of moldings, refer to "Exterior".

505 (19.88) Vehicle center

Clip
(Inserted into upper mold

[!] . Sealant quantity

Back door
glass

More than
12 (0.471

Unit: mm (in)
SBF884E

BF-38
 WINDSHIELD AND WINDOWS

Drying Time for Sealant

Reference: Time required for sealant to dry to desired hardness.
Unit: days

T
~ 40 (104) 1.0
90 50

1.5
25

3.0

25 (77) 1.5 2.5 5.0

5 (41) 3.0 8.0 13.0

CAUTION:
Advise the user of the fact that vehicle should not be driven on
rough roads or surfaces until sealant has properly vulcanized.

Repairing Water Leaks for Windshield, Side

Window and Back Door Window
Leaks can be repaired without removing and reinstalling glass.
If water is leaking between caulking material and body or between glass and caulking material, determine the
extent of the leak by applying water while pushing glass outward.
To stop the leak, apply primer and then sealant to the leak point.

Tdm;M.
Work into joints.

Polysulphide or polyurethane sealant

SBF543B

Afterwards, install molding securely.

BF-39
 AUTOMATIC SEAT BELT SYSTEM

Unit Location

Shoulder belt anchor

m
installation

Door latch switch

Shoulder belt retractor

and lap belt retractor
installation (;]

Belt buckle-----\----(
switch

tql43 -55
(4.4. 5.6, 32. 41)

Control unit

• Control unit is located under

right side of dashboard.

tql : N.m (kg-m, ft-lb)

BF-40
 AUTOMATIC SEAT BELT SYSTEM
Unit Location (Cont'd)
Door hook striker
11.3·15.2
11.15 ·1.55,
8.3 ·11.2)

Door
hook

rPJ 43.55
(4.4. 5.6, 32. 41)

SBFSSOE

BF-41
 -l
FUSE BLOCK
~efer to wPQWER SUPPLY ROUTING n in EL section.)

COMBINATION
METER
~
'-!!:V
I:DAPTER - - -
~

~~~t·11
' IGNITION SWITCH BATTERY Cvla
~ ON or START fusible link-blue>
(MaIn CONNECTOR-
harness>

II®
"11Z-i G
·~
~~
y

DR/L
G/Y
__ j ,.c:
-1

11
29 <Door harness@
~ R H. l --Q Ql
lfUNUJI. UN I R. H. SIDE 0
r:EUI 8
r= :··== :· DPrlcto5Eb DOOR
LATCH SWITCH s::
=[ -tJ dl
>>rn

~H~ULDERR~5b6ER ~ ~
:J:;Ql> ~ G O R@11110
/LI Sl DE
"'03--t 'fJ
zm
EEJ=fT"S :::::!. 0
"''"
II· g =83
:1:
r LG
a o a @@ o 1 TENSION :I
.,.:D
-i
(Q en
~ ffii?T"5 I m
/G
2
g =83
tn.iiill H. SIDE
c
~
I
8
G G o EAP
TENS BELT
I ON REDUCER
i' !4
N R. H. SIDE
~
<Main <Door harness ...
(Q
m UJ
m
I® 0~~~·-' OR:~i~
SEAT BELT SWITCH harness l ldHHW I L. H. Sl DE
I .tt'lf Al'lf IJ
a DOOR 3 !:i
I!Effi: L OR/LI®
LG LG__r--
LATCH SWITCH

~
Q@0
rmm=
,.,
L
B

LG
e o

LG
-1 LG
a =83 EEJ=fT"S I LSHOULDER
K SlOE
BELT
TENS I ON REDUCER
~ @) @)
LG-{T.J ~I L. H. SlOE
m
s::
liJil a ~ ~ a a --m 0
LAP -BELT REDUCER
TENSION.
0
I !~i:L!:E%NDI~Ii
F 1 n nf••'\• ~ .. "'"', "'.'
±
td
X ®®
L. H. SIDE
SEAT BELT SWITCH ~ 1111111111
]g
I
UMJ @{¥@) ® : With air bag

~ [ffi~-mllll I 1""~'1111"N I BODY

GROUND
@ : Without air bag

WARNING TIME CONTROL UNIT SEAT BELT

CHIME CONTROL UNIT
rn
,
!IJ
U)
Cll
...,
!IJ
 AUTOMATIC SEAT BELT SYSTEM

Preparation for Trouble Diagnoses

1. Remove floor board located in front of passenger leg space.
2. Disconnect harness connector.

Power Supply Circuit Check

~ Qu_31 oI 1111 @seat~elt
!..all uul- - - . control Unit Terminals Ignition switch

DISCOIIIItCT ' EB e OFF or ACC ON

I§J ! '
oo
@_ ~(.::11---""
® Ground ov 12V

® Ground 12V 12V

SBF003G

Ground Circuit Check

[1111 I I lstl±JI ®r:t:~~elt
IIISCOIIIIECT
Terminals Continuity

I§J LRi ®-Ground Yes

SBF004G

@seat belt
Trouble Diagnoses
control unit
SYMPTOM:
@: For L.H. Warning lamp flashes continuously.
(~): For R.H.
m ~
In I Does continuity exist between terminal @ and ground or terminal
@ and ground?
Yes

Repair harness.
SBFOOSG

Does door latch switch signal (battery voltage) exist between terminal
I!J @seat belt
control unit
® and ground or terminal ([j) and ground? I
filii Ill j,J'DJ
DISCOIINECT @ : For L.H.
Yes

I§J l I~: IFor R.H. Replace door lock assembly.

Replace control unit.

'-'"''---+~ffi+ __§:'-)!----..
'--=------"-
Door Close
ov
Door Open
12V
SBF006G

BF-43
 AUTOMATIC SEAT BELT SYSTEM
Trouble Diagnoses (Cont'd)
IJ @Seat belt
SYMPTOM:

rill!., I Ill ,,~ control unit

Warning lamp does not flash when ignition switch is "ON".
[I

00
DISCOIIIIECT
Does warning lamp flash if terminal @ is grounded?

Yes No

IV • Check harness.
• Check bulb.
Replace control unit.
SBF007G

SYMPTOM:
I!J @Seat belt control unit
Warning chime does not operate for 6 seconds after ignition
ri1 [sl I Ill I I switch is ON, when releasing belt from buckle.
IISCIIIIIIECT
I!J
IV riD Check continuity between terminal
O.K.
® and ground.
N.G.
-
• Check harness.
• Check shoulder belt buckle.
Do other warning chimes such
as light warning chime operate?
1. Continuity should not exist when Yes No
all seat belts are fastened.
2. Continuity should exist when either • Go to "TIME CONTROL SYSTEM" in EL section.
the driver's or passenger's seat belt
Check harness between terminal
is unfastened.
CD and chime.

SBFOOSG

BF-44
 REAR AIR SPOILER

• When installing, make sure that there are not gaps or waves at ends of air spoiler.
• Before installing spoiler, clean and remove oil from s·urtace where spoiler will be mounted.

REAR AIR SPOILER

~ : Double-faced adhesive tape

~Sealing
V rubber

~Clip

MBF032A

BF-45
 MIRROR

Door Mirror

Mirror removal fi1

SBF188E

BF-46
 MIRROR
Door Mirror (Cont'd)
WIRING DIAGRAM

@)~

L;~~~~~~J1 @§) Mirror

operating

4
P~;~~Dl: frJ+n::::;
direction
L G , - - -..
Left
PU/W PU/W Right
Y/8 Y/B Y/B
l/8 L/B ~~!
Mirror
operating
(Main tDoor harness R. H. l direction
harness)
D""'"
Up

@)@

".J .. i:.J

PU/W~ l::::r
harness

®l4J Y/l Y/L

mI L/R l/R

®®
[j1J
L..__,::ll~:
MIRROR SW. CHANGE-
OVER SW.

DOOR Ml RRORii'"
DEFOGGER
SWITCH® _ _ @!)
DOOR MIRROR SWITCH BOOYGROUND
SBF224F

BF-47
 BODY ALIGNMENT

• All dimensions indicated in figures are actual ones.

• When a tram tracking gauge is used, adjust both pointers to equal length and check the pointers and
gauge itself to make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
• An asterisk(*) following the value at the measuring point indicates that the measuring point on the other
side is the same value.
• The coordinates of the measurement points are the distances measured from the standard line of "X",
"Y" and "Z".
"Y"

@
Q
-----+-------------- '"Z"
'?('' H . . . . C+I
"'X" : Vehicle center
''Y'' "Y" : Center line of front axl1
"Z" : lmagin~ry bal81ine
@: L.H. side [200 mm below datum line
<§): R.H. side ("OZ" at design planl)

Engine Compartment
MEASUREMENT

Unit: mm

SBF002G

BF-48
 BODY ALIGNMENT
Engine Compartment ( Cont' d)
MEASUREMENT POINTS Unit: mm

Cowl top center

SBF983E

11 dia.

:/
SBF917E
·-
9dia.~
;o/;
u

front side member

~

1 10 dia. 10 dia.
SBF957E

BF-49
 NS::
"'C'D )>
m
All dimensions indicated in this figure ~en
are actual ones. ~ c
(There are no projected dimensions.) 3 ::0
o m
c.s::
CD m
L.H. side
-z
-1
1)
1,924*
1,142
675
314 381 625*

c
m
:I
0
a. c
-<
.,
a::J Front
Ill en...F ~tK~ ...
...
CD
cr ,..r-
I
Cl1 ~
en
~0 N ...en ww ww
011
N N en
011 en
011
en
011
w
.....
011
w
en
Rear

¢
0
a.
'<
-
G)
0 Ill L ~"
z
s:
m
z-1

937* 1,143
1,192* 560* 1,384*
1,215* 1,580*

R.H. side

v
(I)
Ill
'T1
co
Ul
Cll
Unit: mm
m
 BODY ALIGNMENT
Underbody (Cont'd)
MEASUREMENT POINTS
2 seater model

SBF959E

BF-51
 NS:
+ m
All dimensions indicated in this figure N)>
"'
are actual ones. m c(I)
(There are no projected dimensions.) ; :D
.., m
3 s:
o m
L.H. side c..z
~-4
{t
675 314 381 585*

c: m
:::J 0
a. c
...C"
CD <
., r
~lIll b
Front

~~
~
Dl Rear

I y ~
N
CD
~
G)
!:l
N
CD
~
G)
c) 0
a. C)
l>
-
r-
C1l
N CD ~ 't;>.
-
'<
0
0
:::J
z
3:
m
z
''ld----®Df I
,@~

II 'W/~I®fl~
@
@ -
-
~
a.
.....

792* 306 374 916*

1,192*
937* 500*
.. 1,38()*
1,502*
1,215* 1,777*

0
R.H. side

en
..,
(lJ

~.., Unit: mm
 BODY ALIGNMENT
Underbody (Cont'd)
MEASUREMENT POINTS
2+2 seater model

Q)

~¢
..J

SBF564F

BF-53
 BODY ALIGNMENT
Underbody (Cont'd)

Front and rear strut tower centers

Coordinates:
®.®
Front side member and
front extension 1
I Unit: mm

Coordinates: (8),@ ~·
X: 473.4
®.® 13 dla.
V: 52.3
I
·~·~~
Z: 727.2 X: 315
Y: -460
Z: 205.1
©.CD
X: 477.9
V: 2,489.3 Rear: ©. CD 46 dia. @.@
X: 255.8
(2 seater modell Y: -431
2,609.3 Z: 205.1
(2+2 seater modell
Z: 727.8
©.© CD
X: 394 X: 171
MBF052A
Y: -170 Y: 917
Z: 330 Z: 249

@.@ @
X: 388 X: 161
Y: -22 v: 9n
Z: 330 Z: 249

®.® ®
X: 408.2 X: 171
Y: 750 Y: 977
Z: 152.6 Z: 249

® (8),@
Y: 161 X: 408.2
Y: 917 Y: 1,250
Z: 249 Z: 152.6
SBF566F

Rear side member and

rear extension (2+2 seater model)

Coordinates:
CD. CD @,(])
X: 420
V: 1,860 X: 575
Y: 2,150
Z: 286.1
Z: 180.7

@.CD
X: 575 ®.®
V: 2,030 X: 365
z: 179.1 Y: 2,625
Z: 259.6

® ©.CD
X: 430
X: 348
V: 2,350
Y: 2,740
Z: 459.6
Z: 334.3

® ~.@
X: 450
X: 418.5
V: 2,350 V: 2,800
Y: 3,000
z : 459.6 z: 460 Z: 459.8

©.CD ®.® ®.®

X: 343 X: 418
X: 378
Y: 2,620 Y: 3,153.1
Y: 3,290
z: 334.3 z: 434.1 Z: 530

SBF963E SBF567F

BF-54
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS Component Parts Location

Right crash zone sensor

"AIR BAG" warning lamp

Air bag module

Tunnel sensor
and sating sensor
Left crash zone sensor

Driver's side door switch

MBF234F

BF-55
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Caution Labels
The CAUTION LABELS are Important when servicing air bags in
the field. If they are dirty or damaged, replace then with new
ones.

MBF235A

BF-56
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Caution Labels {Cont'd)

I DRIVER-AIRBAG WARNING SRS AIRBAG

e THIS CAR IS EQUIPPED WITH A DRIVER AIR BAG

AS A SUPPLEMENTAL RESTRAINT SYSTEM
INFORMATION SRS AIRBAG (S.R.S.)
• ALL S.R.S. ELECTRICAL WIRING AND CONNEC-
• THIS CAR IS EQUIPPED WITH A DRIVER AIR BAG TORS ARE COLORED YELLOW.
AS A SUPPLEMENTAL RESTRAINT SYSTEM e DO NOT USE ELECTRICAL TEST EQUIPMENT ON
(S.R.S.) TO REDUCE INJURY TO THE DRIVER IN THESE CIRCUITS.
A FRONTAL COLLISION. • TAMPERING WITH OR DISCONNECTING THE
e THE SYSTEM IS DESIGNED TO SUPPLEMENT S.R.S. WIRING AND CONNECTORS COULD RE-
THE ACCIDENT PROTECTION PROVIDED BY THE SULT IN ACCIDENTAL DEPLOYMENT OF THE
DRIVER'S SEAT BELT. BUT IT IS NOT A SUBSTI- AIR BAG OR MAKE THE SYSTEM INOPERATIVE,
TUTE FOR THE BELT SYSTEM. WHICH MAY RESULT IN SERIOUS INJURY.
• ALWAYS WEAR YOUR SEAT BELT WHEN THE
CAR IS IN USE.
• THE SYSTEM MUST BE INSPECTED 10 YEARS
AFTER DATE OF MANUFACTURE, AS NOTED ON CAUTION SRS AIRBAG
THE CERTIFICATION LABEL LOCATED ON THE
LEFT FRONT DOOR. e BEFORE ASSEMBLY;
e THE "AIRBAG" LAMP WILL LIGHT MOMEN- -
LINE UP THE FRONT WHEELS STRAIGHT
TARILY WHEN THE IGNITION KEY IS TURNED TO AHEAD.
THE "ON" OR "START" POSITION. THIS MEANS - ALIGN THE ARROW WITH THE YELLOW
THE SYSTEM IS OPERATIONAL. MARK ON THE SIDE GEAR.
• HOWEVER, IF ANY OF THE FOLLOWING CONDI- - READ SERVICE MANUAL.
TIONS OCCUR, THE SYSTEM MUST BE SER- e NO SERVICEABLE PARTS INSIDE.
VICED: • DO NOT DISASSEMBLE OR TAMPER.
1. THE "AIR BAG" LAMP DOES NOT GO ON AS
DESCRIBED ABOVE.
2. THE "AIRBAG" LAMP FLASHES INTERMIT-
Iii
TENTLY OR REMAINS ON. WARNING SRS AIRBAG
3. ANY PORTION OF THE FRONT END OF THE
CAR IS DAMAGED. BEFORE MOUNTING STEERING WHEEL;
4. THE AIR BAG HAS DEPLOYED. • MAKE SURE THAT THE FRONT WHEELS ARE IN
e SEE YOUR OWNER'S MANUAL FOR DETAILS STRAIGHT-AHEAD POSITION.
ABOUT THE FUNCTIONING, SERVICE, AND DIS- e ALIGN THE ARROW WITH THE YELLOW MARK
POSAL PROCEDURES FOR THE S'vSTEM. ON THE SIDE GEAR. (SPIRAL CABLE)
• READ SERVICE MANUAL.

NOTICE SRS AIRBAG

e THIS CAR IS EQUIPPED WITH A DRIVER AIR BAG

AS A SUPPLEMENTAL RESTRAINT SYSTEM
(S.R.S.)
• IT IS DESIGNED TO SUPPLEMENT THE SEAT
BELT.
e ALWAYS WEAR YOUR SEAT BELT.

BF-57
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Caution Labels (Cont'd)

D
WARNING SRS AIRBAG CAUTION SRS AIRBAG

• THIS AIRBAG MODULE CANNOT BE REPAIRED. e NO SERVICEABLE PARTS INSIDE.

• USE DIAGNOSTIC INSTRUCTIONS TO DETER- e DO NOT DISASSEMBLE OR TAMPER.
MINE IF THE UNIT IS OPERATIONAL. e DO NOT DROP; KEEP DRY.
e IF NOT OPERATIONAL, REPLACE AND DISPOSE e WHILE REMOVED, STORE IN A CLEAN AND DRY
OF THE ENTIRE UNIT AS DIRECTED IN THE AREA.
INSTRUCTIONS. • IF WET CONDITION OCCURS, THIS UNIT MUST
• UNDER NO CIRCUMSTANCES SHOULD A DIAG- BE SERVICED.
NOSIS BE PERFORMED USING ELECTRICALLY
POWERED TEST EQUIPMENT OR PROBING DE-
VICES.
CAUTION SRS AIRBAG
• TAMPERING OR MISHANDLING CAN RESULT IN
PERSONAL INJURY.
e STORE THE REMOVED AIRBAG MODULE WITH e TO AVOID DAMAGING THE S.R.S. SPIRAL CA-
BLE, WHICH COULD MAKE THE SYSTEM INOP-
THE PAD SURFACE UP.
ERATIVE, REMOVE THE STEERING WHEEL BE-
• FOR SPECIAL HANDLING OR STORAGE REFER
FORE REMOVING THE STEERING LOWER JOINT.
TO SERVICE MANUAL.

WARNING SRS AIRBAG

DANGER POISON

• KEEP OUT OF THE REACH OF CHILDREN.

e DO NOT DISASSEMBLE OR TAMPER.
• CONTAINS SODIUM AZIDE AND POTASSIUM NI-
e DISMANTLING AND INSTALLATION SHOULD
ONLY BE PERFORMED BY TRAINED PERSON-
TRATE.
NEL.
• CONTENTS ARE POISONOUS AND EXTREMELY
FLAMMABLE.
• CONTACT WITH ACID, WATER OR HEAVY MET-
ALS MAY PRODUCE HARMFUL AND IRRITATING
GASES OR EXPLOSIVE COMPOUNDS.
e DO NOT DISMANTLE, INCINERATE, OR BRING
INTO CONTACT WITH ELECTRICITY OR STORE
AT TEMPERATURES EXCEEDING 200"F.
• FIRST AID: IF CONTENTS ARE SWALLOWED,
INDUCE VOMITING;
- FOR EYE CONTACT, FLUSH EYES WITH WA-
TER FOR 15 MINUTES
- IF GASES FROM ACID OR WATER CONTACT
ARE INHALED, SEEK FRESH AIR
-IN EVERY CASE, GET PROMPT MEDICAL
ATTENTION
• FOR ADDITIONAL INFORMATION, SEE MATE-
RIAL SAFETY OAT A SHEET (MSDS) FOR THIS
PRODUCT.

BF-58
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Maintenance Items
1. Check "AIR BAG" warning lamp
When the ignition key is in the "ON" or "START" position,
the "AIR BAG" warning lamp will illuminate for about 7
AIR seconds and then turn off. This means that the system is
BAG operational.

SBF806E

Center crash zone sensor

Front

Right crash zone sensor

Left crash zone sensor

2. Visually check SRS components

(1) Sensors
• Check sensors to ensure the arrow marks face the front of
the vehicle.
• Check body and sensor brackets for deformities or rust.
• Check sensor case for dents, cracks, deformities or rust.
• Check sensor harness for binds, connector for damage, and
terminals for deformities.

(2) Control unit- Airbag

• Check case and bracket for dents, cracks or deformities.
• Check connectors for damage, and terminals for deformi-
ties.

(3) Main harness and instrument harness

• Check connectors for poor connections.
• Check harnesses for binds, connectors for damage, and
terminals deformities.

(4) Spiral cable

• Visually check lock (engagement) pins and combination
switch for damage.
• Check connectors, flat cable and protective tape for dam-
age.
• Check steering wheel for noise, binds or difficult operation.
BF-59
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Maintenance Items (Cont'd)
(5) Steering wheel
• Check harness (built into steering wheel) and connectors
for damage, and terminals for deformities.
• Install air bag module to check fit or alignment with steering
wheel.
• Check steering wheel for excessive free play.

(6) Air bag module

• Remove air bag module from steering wheel.
Check harness cover and connectors for damage, terminals
for deformities, and harness for binds.
• Install air bag module to steering wheel to check fit or
alignment with the wheel.
CAUTION:
Replace previously used screws with new ones.

BF-60
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Removal and Installation - Control Unit and

Sensors
CAUTION:
• Before servicing SRS, turn the ignition switch off, discon-
nect battery ground cable and wait for at least 10 minutes.
• The special bolts are coated with bonding agent. Discard
old ones after removal; replace with new ones.
• Check all sensors for proper installation.
• Check all sensors to ensure they are free of deformities,
dents, cracks or rust. If they show any visible signs of
damage, replace them with new ones.
• Check sensor brackets to ensure they are free of deformi-
ties or rust.

Left crash zone sensor

Control unit

rRJ : N•m (kg-m, ft-lb)

MBF237A

BF-61
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Removal .......... Air Bag Module and Spiral Cable

Spiral cable

~ N.m (kg-m, ft-lb)

SBF810E

CAUTION:
Before servicing SRS, turn the ignition switch off, disconnect
battery ground cable and wait for at least 10 minutes.
1. Remove lower lid from steering wheel, and disconnect air
bag module connector.

2. Remove side lid. Using the TSOH torx bit, remove left and
right special bolts. Air bag module can then be removed.

SBF812E

CAUTION:
• Always place air bag module with pad side facing upward.
• Do not attempt to disassemble air bag module.
• The special bolts are coated with bonding agent. Discard
old ones after removal; replace with new ones.

BF-62
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Contents
Schematic ............................................................................................................................................ BF-64
Wiring Diagram ................................................................................................................................... BF-65
Self-diagnosis ..................................................................................................................................... BF-66
USING CONSULT .......................................................................................................................... BF-66
USING THE WARNING LAMP ....................................................................................................... BF-69
Diagnostic Procedure 1 ...................................................................................................................... BF-72
SYMPTOM: Warning lamp flashes.
Diagnostic Procedure 2 ...................................................................................................................... BF-72
SYMPTOM: Warning lamp does not come on.
Diagnostic Procedure 3 ...................................................................................................................... BF-73
SYMPTOM: Warning lamp does not go off.
Collision Diagnosis ............................................................................................................................. BF-74

BF-63
TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Schematic

!ONIGNITION SWITCH
or START BATTERY I
COMBINATION METER
AIR BAG
WARNING
LAMP
(Li6\D .)
THERMISTOR FUSE ~FUSE FUSE

17

RIGHT , J..---~--1 7
CRASH
ZONE
n
1?
U
1
u • SPIRAL
CABLE
SENSOR '---~--1 12 AIR BAG
MODULE

4 r---+---,. c:::..l~>---t--+-,
CENTER
CRASH
ZONE
SENSOR
5
: ®
v::3'

.--~---1 8
19r------------.
LEFT
~~ .
1-
CRASH H
z 20 1-----------~
ZONE :::J
SENSOR 11 DIAGNOSTIC
_.J
0 CONNECTOR
a: FOR CONSULT
1-
z ~

0
u .----1rJf--
1-1-----'
18~--~---l 1-1-----~
I-
I-
1-
.---.-+---l 6 1
,__ - r - - - - - - - - '

~~
TUNNEL
SENSOR <
13 1 1----+------------'
2

~~
SAFING
SENSOR < 15 ~--+------------~
3
16 1----+-----,

DOOR SWITCH
L.H.
14

SBF969F

BF-64
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Wiring Diagram
CAUTION:
• Do not use a circuit tester to check SRS "Air Bag" harness connectors. The wiring harness and
connectors have yellow outer insulation for easy identification.
• Do not attempt to repair, splice or modify the SRS "Air Bag" wiring harness. If the harness is
damaged, replace it with a new one.
• Keep ground portion clean.

a: a: a: a:
f-I 0 WI 0 I 0
I(I')W(I') f-(I')W(I') f-(I')W(I')
(!)~ZZ z~zz LJ..~ZZ
HIIOW wa:ow wa:ow
IIUN(I') UUN(I') ...JUN(I') CONTROL UNIT

g a: >-

®
~ (!)
(!)
ID Q. ...J (!) II
0
(I)

Il I I II I Z(!)
wz
~j~j
Y/R
(I')H
lJ..
...J~a:
I- Y/B W(I')O
z (I)
ZDZ
::>ZW
f-~(1')
I
u @ ~

F:o-,~~
f-
H
3:
(I) ...J
a:
OI
0·
-en
OJ
men
~w
II...J
HID
a.~
O...J .CQ) (I')U
c
t..C..
-rllll
_5.C

(jJ ~w
en IIJ...J
Q) :::>
>-C liD
"Ct.. HQ
<[~
om
fg.C
I I
D
z
>-:::>
G DO
OII
R/L IIJ(!)
y
B
B I
(jJ
en
Q)
~

00

I
c
t..
Ill a:
.c w
c f-
..... a: w
0 ~
Ill r-
rn
~ ......._ B H z
::E 0
a: H
~R/W U.J f-
:I:
r- <[
~G z
a:
0 H
f- IIl
u CI:C!l ~ ~
H<( 0
<liD u

en mm
Q) en
c
.,.... E
Q)
c 0
O)Ot..
com z
>-::>
~c...c 00
OII
IIJ(!)
SBF970F

BF-65
 TROUBLE DIAGNOSES - Suppleme_ntal Restraint System (SRS)

Self-diagnosis
USING CONSULT
The self-diagnosis results can be read by CONSULT, as follows:
1. Connect "CONSULT" to vehicle harness connector.

2. Turn ignition switch to "ON". (When CONSULT is con-

nected, the "AIR BAG" warning lamp will be turned to
present diagnosis mode.)
~
3. Touch "START" to operate "CONSULT".

~
4. Touch "AIR BAG" to choose air bag system.

~
5. Touch "SELF DIAG RESULTS" to read self-diagnosis re-
sults.

6. Problem codes are displayed on "SELF DIAG RESULT 1"

(first page - present mode). The problem code last indi-
cated is displayed on "SELF DIAG RESULT 2" (second page
- initial mode).

~
7. When "PRINT" is pressed, information displayed on "SELF
DIAG RESULTS 1 and 2" is printed out.

~
8. After repairing malfunctioning parts, press "ERASE" to
clear self-diagnosis results.
• After repairing malfunctioning parts, attempt to clear self-
diagnosis results from memory.
• If malfunctioning parts are not completely repaired, self-
~ SELECT SYSTEM D
~ diagnosis results remain stored in memory.
ENGINE
A/T 9.
+
Push Back Key of CONSULT until SELECT SYSTEM mode
appears to make "SELF-DIAGNOSIS" user mode.
HI CAS
AUTO A/C
AIR BAG
+
10. Push the power off switch.

SBF939F

11. Turn off ignition switch.

BF-66
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
Self-diagnosis results

Failure parts group Repair order

Explanation
[Present] and [Initial] • Recheck SRS at each replacement.
•••• NO SELF DIAGNOSTIC Normal. The SRS "Air Bag" is in good order. -
FAILURE ••••

SAFING SENSOR The circuit for the sating sensor is open or 1. Visually check the wiring harness connec-
[OPEN/LWR-GND-SHORT] the wire from the safing sensor to the control tions.
unit (terminal No. 3) is shorted. 2. Replace the safing sensor.
SAFING SENSOR Both the wires for the sating sensor are (sating sensor and tunnel sensor unit)
[SHORT /LWR-VB-SHORT] shorted or the wire from the sating sensor to 3. Replace the control unit.
the control unit (terminal No. 3) is shorted to 4. Replace the main harness.
some power supply circuit.
AIRBAG MODULE The circuit for the air bag module is open. 1. Visually check the wiring harness connec-
[OPEN] (including the spiral cable) tions.
2. Replace the spiral cable.
AIRBAG MODULE The circuit for the air bag module is shorted
3. Replace the air bag module.
[VB-SHORT] to some power supply circuit. (including the
(Before disposing of it, it must be de-
spiral cable)
ployed.)
AIRBAG MODULE The circuit for the air bag module is shorted. 4. Replace the control unit.
[GND-SHORT] (including the spiral cable) 5. Replace the main harness.
TUNNEL SENSOR The circuit for the tunnel sensor is open or 1. Visually check the wiring harness connec-
[OPEN/UPR-VB-SHORT] the wire from the control unit (terminal No. 6) tions.
to the tunnel sensor is shorted to some 2. Replace the tunnel sensor.
power supply circuit. (sating sensor and tunnel sensor unit)
TUNNEL SENSOR The circuits for the tunnel sensor are shorted 3. Replace the control unit.
[SHORT] to each other. 4. Replace the main harness.

CRASH ZONE SEN-RH The circuit for the right crash zone sensor is 1. Visually check the wiring harness connec-
[OPEN/UPR-VB-SHORT] open or the wire from the control unit (termi- tions.
nal No. 7) to the right crash zone sensor is 2. Replace the right crash zone sensor.
shorted to some power supply circuit. 3. Replace the control unit.
4. Replace the main harness.
CRASH ZONE SEN-RH The circuits for the right crash zone sensor
[SHORT] are shorted to each other.
CRASH ZONE SEN-LH The circuit for the left crash zone sensor is 1. Visually check the wiring harness connec-
[OPEN/UPR-VB-SHORT] open or the wire from the control unit (termi- tions.
nal No. 8) to the left crash zone sensor is 2. Replace the left crash zone sensor.
shorted to some power supply circuit. 3. Replace the control unit.
CRASH ZONE SEN-LH The circuits for the left crash zone sensor 4. Replace the main harness.
[SHORT] are shorted to each other.
CRASH ZONE SEN-CTR The circuit for the center crash zone sensor 1. Visually check the wiring harness connec-
[OPEN/UPR-VB-SHORT] is open or the wire from the control unit (ter- tions.
minal No. 9) to the center crash zone sensor 2. Replace the center crash zone sensor.
is shorted to some power supply circuit. 3. Replace the control unit.
4. Replace the main harness.
CRASH ZONE SEN-CTR The circuits for the center crash zone sensor
[SHORT] are shorted to each other.
CONTROL UNIT The control unit (diagnostic unit) is out of 1. Visually check the wiring harness connec-
order. tions.
2. Replace the control unit.
3. Replace the main harness.

BF-67
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
Failure parts group Repair order
Explanation
[Present] and [Initial] * Recheck SRS at each replacement.

INDEFINITE FAILURES A problem which cannot be specified occurs 1. See the SELF-DIAGNOSIS RESULT 2 fail-
because more than two parts are out of or- ure parts group [initial], then repair as
der. necessary.
2. Visually check the wiring harness connec-
tions.
3. Replace the control unit.
4. Replace all sensors, the spiral cable and
air bag module.
5. Replace the main harness.

BF-68
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
USING THE WARNING LAMP
Self-diagnosis results can be also read by using the "AIR BAG"
warning lamp.
The "Air bag" warning lamp operates as shown below:

How to alternate self-diagnosis

Driver's door switch is turned Driver's door switch is turned
ON and OFF more than 5 ON and OFF 1 time after
times within 7 seconds after ·gnition
I switch has been
ignition switch is turned "ON". turned "ON" for 7 seconds.
Present Initial
User
diagnosis diagnosis
mode
mode mode
Driver's door switch is turned Driver's door switch is turned
ON and OFF more than 5 ON and OFF 1 time after
times within 7 seconds after ignition switch has been
ignition switch turned "ON". turned "ON" for 7 seconds.

IGN OFF-+ ON IGN OFF-+ ON

Problem codes are displayed in present diagnosis mode (self-diagnosis result 1). The problem code last
indicated is displayed in initial diagnosis mode (self-diagnosis result 2).

After the malfunctioning parts have been repaired and the system is returned to the user mode, the
present diagnosis mode information, displayed as self-diagnosis results, is automatically cleared from
memory.
• After repairing malfunctioning part, attempt to clear self-diagnosis results from memory.
• If a malfunctioning part is not completely repaired, information stored In memory will not be cleared.
User mode

G) Normal (OFF)
IGNON
~ Light check
ON

OFF
j,. 7 sec . .,,

® Failure (flashing)
ON

OFF

0.5 sec . .,I ! I,. 0.5 sec.

@Air bag is deployed or part of control unit is malfunctioning. (ON)

ON

OFF SBF235F

BF-69
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)

Present diagnosis mode (self-diagnosis result 1I

@ Start signal; Start signal identifies display modes.

® @ © ® @ © @ ®through @are repeated.

ON

OFF
..I ..3
---1-H--·-fo1.... sec ..,,
._---t-~·--fooii·
1-
...I---Varies with failed part~
I
2 sec. 2 sec.

• No failure (or intermittent failure/repair completion)

® @ ® @ ® @ ® @ ® @ ® @ ® through @ are repeated.
ON

OFF

~
2 sec.

SBF236F

Initial diagnosis mode (self-diagnosis result 21

(11, Start signal; Start signal identifies display modes.

I
!® Cii/ @ @ ® Cii; © @ @ through @ are repeated.
ON I
I
I
I
OFF
3 2

Unit: sec.
• No failure

@ ® @ ® ® through @ are repeated.

ON

OFF

2 sec.
SBF237F

Self-diagnosis results in present- and initial-diagnosis modes

can be identified by number of flashes (d). Refer to Table on
next page for failed parts.

BF-70
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
Warning lamp flashing times and repair

Flash code@ Repair order

Explanation
(# of flashes) • Recheck SRS at each replacement.
0 Normal. The SRS "Air Bag" is in good
order.
-
1 The circuit for the sating sensor is out of 1. Visually check the wiring harness con-
order. nections.
2. Replace the sating sensor.
(sating sensor and tunnel sensor unit)
3. Raplace the control unit.
4. Replace the main harness.
2 The circuit for the air bag module is out 1. Visually check the wiring harness con-
of order. nections.
2. Replace the spiral cable.
3. Replace the air bag module.
(Before disposing of it, it must be de-
ployed.)
4. Replace the control unit.
5. Replace the main harness.
3 The circuit for the tunnel sensor is out of 1. Visually check the wiring harness con-
order. nections.
2. Replace the tunnel sensor.
(sating sensor and tunnel sensor unit)
3. Replace the control unit.
4. Replace the main harness.
4 The circuit for the right crash zone sen- 1. Visually check the wiring harness con-
sor is out of order. nections.
2. Replace the right crash sensor.
3. Replace the control unit.
4. Replace the main harness.
5 The circuit for the left crash zone sensor 1. Visually check the wiring harness con-
is out of order. nections.
2. Replace the left crash zone sensor.
3. Replace the control unit.
4. Replace the main harness.
6 The circuit for the center crash zone sen- 1. Visually check the wiring harness con-
sor is out of order. nections.
2. Replace the center crash zone sensor.
3. Replace the control unit.
4. Replace the main harness.
7 The control unit (diagnostic unit) is out of 1. Visually check the wiring harness con-
order. nections.
2. Replace the control unit.
3. Replace the main harness.
8 More than two parts groups are out of 1. See the SELF-DIAGNOSIS RESULT 2
order. failure parts group [Initial], then repair
it.
2. Visually check the wiring harness con-
nections.
3. Replace the control unit.
4. Replace all sensors, spiral cable and
air bag module.
5. Replace the main harness.

BF-71
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Diagnostic Procedure 1
SYMPTOM: Warning lamp flashes.
m Connect the CONSULT "' Refer to SELF-DIAGNOSIS RE-
~ and operate it. Read the SULTS and repair.
SELF-DIAGNOSIS RE-
SULTS 1 and 2.
1 - - - - - - OR - - - - - - i Refer to the number of warning
~ Refer to warning lamp .,. lamp flashes. Repair as neces-
~ self-diagnosis. sary.

1. Fuse Diagnostic Procedure 2

SYMPTOM: Warning lamp does not come on.

1. Check the warning lamp fuse. N.G . .,., Replace the fuse.
METER O.K.
2.M Connect the CONSULT N.G . .,., Replace the control unit.
~unit and begin diagnosis.
Upside<? e Is "AIR BAG'.' dis-
played on the
CONSULT screen?
O.K.
•
3-(F.J\Read the SELF- N.G. Refer to SELF-DIAGNOSIS RE-
~DIAGNOSIS RESULTS 1 SULTS and repair.
and 2.
O.K.
•
4. Check the warning lamp bulb. IReplace the warning lamp bulb.
O.K.
5.~Check
•
the warning lamp j Replace the harness.
~harness connection.
O.K.
•
6. ®Replace the control unit.

BF-72
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

2. Fuse Diagnostic Procedure 3

AIR BAG SYMPTOM: Warning lamp does not go off.

1. Is the air bag module de- ~~ Replace the air bag module.
ployed?

~No
ROOM L.
2. Check the fuses used for the ~~ Replace the fuse.
Upside¢ SRS "Air Bag" and "Room
Lamp".
SBF941F
~----------~----------~
~O.K.
f.-.__ -
Diagnostic connector
for CONSULT _ \\ ~· -~
3.rF.J\ Connect the CONSULT ~~ Replace the control unit.
- . 1\ '~ ~unit and operate it.

j·g;[_ '~;' l,w~ ~~//

• Is "AIR BAG" dis-
played on the
CONSULT?

,. _ _ ~1
-· \\' c,

"'~~,D~
:) \_~~~ ..,,..
4.~ Read the SELF- N.G. Refer to SELF-DIAGNOSIS RE-
~ DIAGNOSIS RESULTS 1 SULTS and repair.
and 2.*
1------- OR - - - - - - - - 1
~ Refer to the warning N.G. Refer to the warning lamp flash-
\..&
lamp self-diagnosis. • ing times and repair as neces-
sary.
O.K.

5.~Check the harness con- .J!4j Replace the harness.

\&nection between the
warning lamp and the
control unit.

6.®Replace the control unit.

* Recheck SRS after each replacement.

BF-73
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Collision Diagnosis
To repair the SRS "AIR BAG", perform the following steps.
G) Check the control unit (diagnostic unit).
• Connect CONSULT and then erase the memory. (How-
ever, the memory may not be cleared.)

OR

• Check "AIR BAG" warning lamp and perform the follow-

ing twice: turn driver's door switch ON and OFF 5 times
within 7 seconds after ignition switch turned "ON".

l lf "AIR BAG" warning lamp

comes on continuously .

.IReplace the control unit. I

® Remove the deployed air bag module.
@ Check the SRS components using the table shown below:
• If the SRS components are showing any visible damage
such as dents, cracks, or deformation, replace them with
new ones.
@ Conduct self-diagnosis using CONSULT or "AIR BAG"
warning lamp to ensure entire SRS operates properly
except open circuit of air bag module.
@ Install new air bag module.

------------
Inspection Inspection
(when air bag deploys in collision) (when air bag does not deploy in low-speed collision)
Steering wheel (1) Check harness (built into steering wheel) and connectors for damage, and terminals for
deformities.
(2) Install air bag module to check fit or alignment with steering wheel.
(3) Check steering wheel for excessive free play.
In-compartment sensor (1) Check body and sensor brackets for deformities or rust.
All sensors (except those (2) Check sensor case for dents, cracks, deformities or rust.
(3) Check sensor harness for binds, connector for damage, and terminals for deformities.
affected by collision)
Air bag module Replace air bag module. (1) Remove air bag module from steering wheel.
Check harness cover and connectors for damage,
terminals for deformities, and harness for binds.
(2) Install air bag module to steering wheel to check
fit or alignment with the wheel.
(3) Replace screws with new ones.
Harness connector (1) Check connectors for poor connections.
(Main and Instrument har- (2) Check harness for binding, connectors for damage, and terminals for deformities.
ness)
Spiral cable (1) Visually check lock (engagement) pins and combination switch for damage.
(2) Check connectors, flat cable and protective tape for damage.
(3) Check steering wheel for noise, binds or heavy operation.
Control unit Replace control unit (diagnostic (1) Check case and bracket tor dents, cracks or defor-
unit). mities.
(2) Check connectors for damage, and terminals tor
deformities.

BF-74
 HEATER I
AIR CONDITIONER

SECTIONHA

CONTENTS
PRECAUTIONS- Supplemental Restraint System "AIR BAG" ....................................... HA- 2
DESCRIPTION- Overall System ....................................................................................... HA- 3
DESCRIPTION- Refrigeration System ............................................................................. HA- 10
PRECAUTIONS ..................................................................................................................... HA- 12
PREPARATION ..................................................................................................................... HA- 15
DISCHARGING, EVACUATING, CHARGING AND CHECKING ........................................... HA- 22
SERVICE PROCEDURES ...................................................................................................... HA- 34
COMPRESSOR OIL- Checking and Adjusting ................................................................. HA- 38
COMPRESSOR- Model DKS-16H (DIESEL-KIKI make) ................................................... HA- 40
DIAGNOSES - Overall System .......................................................................................... HA- 43
TROUBLE DIAGNOSES- Manual Air Conditioner ........................................................... HA- 55
TROUBLE DIAGNOSES- Auto Air Conditioner ............................................................... HA- 90
SYSTEM DESCRIPTION- Manual Air Conditioner .......................................................... HA-150
SYSTEM DESCRIPTION- Auto Air Conditioner ............................................................... HA-154
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ................................................................ HA-164

When you read wiring diagrams:

• Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES".
PRECAUTIONS- Supplemental Restraint System "AIR BAG"

Supplemental Restraint System "AIR BAG"

The Supplemental Restraint System "Air Bag" helps to reduce
the risk or severity injury to the driver in a frontal collision. The
Supplemental Restraint System consists of an air bag (located
in the center of the steering wheel), sensors, a control unit,
warning lamp, wiring harness and spiral cable. Information
necessary to service the system safely is included in the BF
section of this Service Manual.
WARNING:
a. To avoid rendering the SRS inoperative, which could lead
to personal injury or death in the event of a severe frontal
collision, all maintenance must be performed by an autho-
rized NISSAN dealer.
b. Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
c. All SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation. Do not use electrical
test equipment on any circuit related to the SRS "Air Bag".

HA-2
 DESCRIPTION - Overall System

Features - Auto Air Conditioner

OUTLET AIR TEMPERATURE CONTROL (Air mix dQor control)
When the desired temperature is set on the control panel, the automatic temperature control system
determines both the head and foot target temperatures, as well as target upper (VENT and DEF) and
lower (FOOT) outlet air temperatures. This computation is accomplished in relation to the desired
temperature, and outside conditions (ambient temperature and sunload). The automatic temperature
control system then controls the air mix door position so that the outlet air temperatures meet target*
outlet air temperatures.
A summary of the automatic temperature control system is as follows:
1. The upper and lower air temperatures are independently controlled to provide a comfortable ride.
2. Optimum outlet air temperatures can be set to the passenger's preference.
3. Outlet air temperature feedback control through duct sensors permits a "potentiometerless" air mix
door design. It requires no adjustment, increases service life and improves performance reliability.

FAN SPEED CONTROL

The A.T.C. system continuously regulates fan speed according to the difference between the target
temperature and the temperatures detected at the upper and lower in-vehicle sensors. The greater the
difference between the temperatures the higher the blower speed. If the cabin sunload or ambient
temperature is high, fan speed will be increased.

INTAKE DOOR CONTROL

The A.T.C. system adjusts the intake door position once every thirty seconds. The system is programmed
to take in outside air as much as possible.

OUTLET DOOR CONTROL

The A.T.C. system controls distribution of air through the VENT, DEF and FOOT outlets based on the cabin
sunload, ambient temperature and the set temperature.

COMPRESSOR MAGNET CLUTCH CONTROL

The A.T.C. system automatically shuts off the compressor at temperatures lower than o·c (32.F).
SELF-DIAGNOSTIC SYSTEM
The A.T.C. system contains an on-board diagnostic system which can be used to check the A.T.C. system
sensors and motors and any trouble data stored in the memory.
Pushing the "AUTO" and "OFF" switches at the same time for more than 5 seconds will give the
self-diagnostic mode. There are 4 kinds of self-diagnostic systems (STEP 1 to STEP 4). Each step can be
accessed by pushing the "AUTO" switch. The functions of each step are as follows:
• STEP 1 -Monitor diagnosis
• STEP 2 - Actuator test
• STEP 3 - Change of difference between upper and lower target temperature
• STEP 4 - Readout of trouble data memory

*· Target temperature
When a temperature for the cabin is set using the TEMP. SET switch, the A.T.C. system calculates an
initial target temperature based on information from the various A.T.C. system sensors. This target
temperature is continuously updated to bring the cabin temperature to the set temperature in the most
comfortable way possible for the occupants. (The program for this was made after careful study of
comfort levels related to car interiors).

HA-3
DESCRIPTION - Overall System

Acceleration Cut System

This system is controlled by the E.C.C.S. control unit.
When the engine is heavily overloaded, the compressor is
turned off for several seconds to reduce overloading.

Water Cock Control System

The water cock is connected to the air mix doors with a cable.
When the air mix doors are at the full-cold position, the water
cock is fully closed, and when the air mix doors are at the
full-hot position, the water cock is fully opened.

HA-4
 DESCRIPTION - Overall System

Control Operation - Manual Air Conditioner

Air conditioner switch Recirc switch

Mode switch Temperature control lever

Fan control lever SHA782C

FAN CONTROL LEVER

This lever turns the fan ON and OFF, and controls fan speed.

MODE SWITCH
This switch allows you to select the outlet air flow.
In the "DEF" mode, the intake door is set to "FRE". The compressor turns on in "DEF" or "F/D" mode.

TEMPERATURE CONTROL LEVER

This lever allows you to adjust the temperature of the outlet air.

RECIRC SWITCH
OFF position:
Outside air is drawn into the passenger compartment when this switch is OFF.
ON position:
Interior air is recirculated inside the vehicle. This switch does not work in the "DEF" mode.

AIR CONDITIONER SWITCH

Start the engine, move the fan control lever to the desired (1 to 4) position and push the air conditioner
switch to turn ON the air conditioner. The indicator light will come on when the air conditioner is ON. To
stop the air conditioner, push the switch again to return it to the original position.
The air conditioner cooling function operates only when the engine is running.

HA-5
 AUTO SWITCH DEF SWITCH
INTAKE DOOR POSITION INTAKE DOOR POSITION OUTSIDE AIR
OUTLET DOOR POSITION OUTLET DOOR POSITION DEFROSTER
AUTOMATIC CONTROL
AIR MIX DOOR POSITION AIR MIX DOOR POSITION AUTOMATIC CONTROL
FAN SPEED FAN SPEED AUTOMATIC CONTROL
ON [outside air temperature COMPRESSOR ON [outside air temperature above 0°C (32° F)]
COMPRESSOR
above 0°C (32°F)]
REMARKS Fan speed can be set at 4 speeds.
Fan speed can be set at
REMARKS
4 speeds.

~
Outlet mode can be set at
4 modes.
TEMP. SET SWITCH
OFF SWITCH Each time corresponding switch is pressed, set temperature
is increased or decreased by 1°F. When it is pressed for
INTAKE DOOR POSITION OUTSIDE AIR
OUTLET DOOR POSITION ~~ ~\®\ ::~,:::~" 0 5~""''·.., "m""'"" ~" b• ooo<l""""'''

\ _,. i\
AUTOMATIC CONTROL
AIR MIX DOOR POSITION
FAN SPEED OFF MODE SWITCH
COMPRESSOR OFF ~ '"~".-..- 1\
•=• ~ ~ ~ ....J ~ fJ
,.. ~ • •fJ D~F
SET V . .; :;
:a: REMARKS
REC switch and MODE switch
can be set. = VEt-NT -+ 8/L -+ FOOT -+
I · Outlet mode can be set at
m 4 modes.

"" OFF ECON AE~

\ lP ~ e)) \a FAN SWITCH

I . ~ ~ ~
.......
~
...
....~
...
....~
•
.......
~
LO -+ Ml -+ M2 -+ HI
_j
"'
Fan speed can be set at 4 speeds in any mode.

RECIRC SWITCH
ECON SWITCH
INDICATOR ON OFF
INTAKE DOOR POSITION OUTSIDE AIR
INTAKE DOOR RECIRCULATED AUTOMATIC
OUTLET DOOR POSITION
POSITION AIR CONTROL
AIR MIX DOOR POSITION AUTOMATIC CONTROL Recirculation mode changes to automatic control
FAN SPEED mode ten minutes after "RECIRC" switch is
turned "ON".
COMPRESSOR OFF
"RECIRC" switch does not function when it is in
(J)
Fan speed can be set at REMARKS
:J: REMARKS "DEF" mode.
~ 4 speeds. Recirculation function is canceled when
~ Outlet mode can be set at "RECIRC" switch is pressed again.
0
4 modes.
 DESCRIPTION- Overall System

Component Layout

Side defroster duct Defroster duct

r Side defroster duct

Intake unit

'

_J

SHA306C

HA-7
 DESCRIPTION - Overall System

Air Flow
Foot

Ventilation

Outside air

Defroster

Outside air

. . : Air passed through heater core

<1$zrn : Mixed air . . . +<:;:::::J

¢::::J : Air not passed through heater core

SHA305C

HA-8
 DESCRIPTION - Overall System
Air Flow (Cont'd)
AIR DISTRIBUTION RATIOS

... ...
VENT B/L FOOT F/0 DEF

I
• ®•
.,._;t ~
"I "I 100%
I
I
I
I DEF
VENT I
I
I
I
I 50
I
I
I
FOOT I
I
I
I
I
I
0%

SHA266C

HA-9·
 DESCRIPTION - Refrigerant System

Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the receiver
drier, through the evaporator, and back to the compressor.
Refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case.

FREEZE PROTECTION (For manual air conditioner)

The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the
compressor operation. When the evaporator coil temperature rises above the specified point, the thermo
control amplifier allows compressor operation.

FREEZE PROTECTION (For auto air conditioner)

When the A/C is switched on, the compressor runs continuously, and the evaporator pressure is
controlled by a suction throttle valve (S.T.V.) to prevent freeze up.

REFRIGERANT SYSTEM PROTECTION

Low-pressure switch
The refrigerant system is protected against excessively low pressures by the low-pressure switch,
located on the receiver drier. If the system pressure falls below the specifications, the low-pressure
switch opens to interrupt compressor operation.

Fusible plug
Opens at temperature above 1os·c (221.F), thereby discharging refrigerant to the atmosphere. If this plug
is melted and opened, check the refrigerant line and replace the receiver drier.

Pressure relief valve

The refrigerant system is also protected by a pressure relief valve, located on the end of the high
pressure flexible hose near the compressor. When the pressure of refrigerant in the system increases to
an abnormal level [more than 3,727 kPa (38 kg/cm 2 , 540 psi)], the release port on the pressure relief valve
automatically opens and releases refrigerant into the atmosphere.
High-pressure Low-pressure
~ gas ~ liquid
Eill High-pressure EllEii! Low-pressure
Compressor liquid gas

Outside air '--------'-!LV

Receiver drier

..
u
Expansion valve
Suction throttle valve
(for Auto A/C)

Low-pressure switch SHA463C

HA-10
 DESCRIPTION - Refrigerant System

Refrigerant System

Expansion valve

Low-pressure
(Suction) service valve
High-pressure
(Discharge) service valve

Low-pressure switch
Cooling unit

Pressure relief valve

Receiver drier

Condenser

SHA798C

HA-11
 PRECAUTIONS

PRECAUTIONS FOR THE HANDLING OF REFRIGERANT

Goggles • Always wear eye protection when working around the
system.
• Always be careful that refrigerant does not come in contact
with your skin.
• Keep refrigerant containers stored below 4o·c (1 04 ·F) and
never drop from high places.
• Work in well-ventilated area because refrigerant gas evap-
orates quickly and breathing may become difficult due to
the lack of oxygen.
c____ _ _ _ _ _ _ _ _ _ _ _RH_A_2s_o_Js • Keep refrigerant away from open flames because poison-
ous gas will be produced if it burns.
• Do not increase can temperature beyond 4o·c (104.F) in
Gloves
charging.
• Do not heat refrigerant container with an open flame. There
is a danger that container will explode.
CAUTION:
• Do not use steam to clean surface of condenser or evapo-
rator. Be sure to use cold water or compressed air.
• Compressed air must never be used to clean a dirty line.

RHA261B

Avoid Open Flame

RHA262B

No Direct Heat
on Container

• Do not release refrigerant into the atmosphere.

HA-12
 PRECAUTIONS

r- Valve press point • Do not use manifold gauge whose press point shape is
different from that shown. Otherwise, insufficient evacuat-
ing may occur.

• Do not over-tighten service valve cap.

• Do not allow refrigerant to rush out. Otherwise, compressor
oil will be discharged along with refrigerant.

PRECAUTIONS FOR REFRIGERANT CONNECTIONS

WARNING:
Gradually loosen discharge side hose fitting, and remove it
after remaining pressure has been released.
CAUTION:
When replacing or cleaning refrigerant cycle components,
observe the following.
• Do not leave compressor on its side or upside down for
more than 10 minutes, as compressor oil will enter low
pressure chamber .
.___ _ _ _ _ _ _ _ _ _ _ _s_HA_s_9s__,A • When connecting tubes, always use a torque wrench and a
back-up wrench.

• After disconnecting tubes, plug all openings immediately to

prevent entrance of dirt and moisture.

Plug

SHAOSB

HA-13
 PRECAUTIONS

Apply 0-ring • Always replace used 0-rings.

c:ompr1110r oil. • When connecting tube, apply compressor oil to portions
shown in illustration. Be careful not to apply oil to threaded
portion.
• 0-ring must be closely attached to inflated portion of tube.

SHA897A

• After inserting tube into union until 0-ring is no longer

visible,tighten nut to specified torque.
UnGn®~N"' • After connecting line, conduct leak test and make sure that
there is no leakage from connections. When the gas leaking

~~
point is found, disconnect that line and replace the 0-ring.
Then tighten connections of seal seat to the specified
torque.

em
ij

l
8uru-
~
-Q- -@-
SHA898A

PRECAUTIONS FOR SERVICING COMPRESSOR

• Plug all openings to prevent moisture and foreign matter
from entering.
• Do not leave compressor on its side or upside down for
more than 10 minutes.
• When replacing or repairing compressor, check compres-
sor oil level in system.
• When replacing with a new compressor, drain specified oil
from new compressor. Refer to COMPRESSOR OIL.
• Be sure there is no oil or dirt on frictional surface of clutch
disc and pulley.
• When replacing compressor clutch, be careful not to
scratch shaft or bend pulley.
• When replacing compressor clutch assembly, do not forget
BREAK-IN OPERATION.
• Replace shaft seal, seal seat, oil seal and 0-ring as a set.
• When installing shaft seal, Seal seat, oil seal, 0-ring and
gaskets, apply compressor oil sparingly to the contact
surface. Do not reuse them.
• After replacement or repairs, conduct a Leak Test.

HA-14
 PREPARATION

SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name
KV99232022 Removing ctutch disc
(J26571-A)
Clutch disc puller

KV99235140 Removing and installing shaft seal

(J37876)
Shaft seal remover
and installer

KV994C1552 Charging refrigerant

(J37880)
Charge nozzle

KV99231010 Removing shaft nut and clutch disc

(J37877)
Clutch disc wrench

KV99233040 Removing pulley

oD
(J26720-A)
Puller pilot

KV99234160 Installing pulley

(J37879)
Pulley installer
ijp
KV99267420 Installing shaft seal

~
(J37878)
Shaft seal guide

KV99235160 Removing lock nut

(J37882)
Nut wrench

HA-15
 PREPARATION

Service Tools
Tool name Description
Manifold gauge Discharging, evacuating and charging
(3-valve type) refrigerant

RHA570B

Charging hose Discharging, evacuating and charging

(Four) refrigerant

RHA571B

Adapter valve Discharging, evacuating and charging

refrigerant

Two pieces on each high

pressure and tow pressure line
RHA573B

Thermometer Checking temperature

RHA5748

Vacuum pump Evacuating

RHA575B

Gas leak detector Checking refrigerant leaks

RHA577B

Charging cylinder Checking amount of refrigerant and

charging refrigerant

RHA578B

HA-16
 PREPARATION
Service Tools {Cont'd)
Tool name Description
Weight scale
r Checking amount of refrigerant

l ~~oool
0000
0000
0000

RHA579B

Refrigerant recycling Capturing and recycling refrigerant

equipment

SHA732C

For details of such handling methods, refer to the Instruction

Manual aHached to each of the service tools.

Low pressure High pressure HANDLING METHOD AND STRUCTURE

compound gauge compound gauge
Manifold gauge
The manifold gauge is used to measure the operating pressure
accurately in the high pressure and low pressure lines of the
refrigerating system. The high pressure gauge measures from
-101.3 kPa (-760 mmHg, -29.92 inHg) to 2,942 kPa (30 kg/cm 2 ,
427 psi), and the low pressure gauge measures generally from
-101.3 kPa (-760 mmHg, -29.92 inHg) to 1,471 kPa (15 kg/cm 2 ,
213 psi).
CAUTION:
• When installing the gauge to the refrigerating system, use
utmost care not to mistake high pressure and low pressure
Inner valve
Vacuum line connections. (Wrong connections will lead to a dam-
incorporated
valve cock
aged gauge.)
Center joint (A): • Before evacuating, confirm that the gauge has a negative
Use for evacuating.
pressure scale. (If not, the gauge will be damaged.)
High pressure side joint (8):
Connect to high pressure side service valve
of refrigerating system.
Low pressure side joint (C):
Connect to low pressure side service valve
of refrigerating system.
Refrigerant joint (D):
Use for charging refrigerant.
RHA580B

HA-17
 PREPARATION
Service Tools (Cont'd)
Charging hose
1. Completely tighten the high pressure valve, low pressure
valve and vacuum pump valve cocks of the gauge manifold.
2. Connect the charging hoses to the high and low pressure
lines.
3. Connect the charging hose fitted with a valve core to the
charging cylinder.
4. Connect the vacuum pump hose to the vacuum pump.
The high and low pressure hoses are color coded to prevent
wrong connection.

High pressure line hose Red

Low pressure line hose Yellow
Charging hose Blue or green (with valve core)
Vacuum pump hose Blue or green

CAUTION:
• Check each hose for cracks. If found, discard the hose.
• Do not use any hose if bulges are found.
• Check the rubber packing. If any deterioration or cracks are
found, replace it with a new one.

Packing
RHA5818

Installing the adapter valve

Install the adapter valve to each of the high pressure and low
pressure service valves so that air purging from the charging
hose can be omitted. This also ensures that refrigerant leakage
upon disconnection of the hose can be prevented.
1. Before connecting the adapter valve to the on-vehicle
service valve, turn the adapter valve handle fully counter-
clockwise to retract the pin.
CAUTION:
Check the packing for any sign of deterioration or cracks. If any
abnormality is found, replace the packing with new.
2. Connect the high and low pressure hoses to the adapter
valves.
Turning the handle clockwise will cause the on-vehicle service
valve pin to be pushed open by the adapter valve pin, thus
opening the refrigerant passage. Turning the handle counter-
clockwise will close the passage. Before removing the adapter
valve from the on-vehicle service valve, be sure to fully turn the
handle counterclockwise to shut off the refrigerant passage.

HA-18
 PREPARATION
Service Tools (Cont'd)
Vacuum pump
The vacuum pump is used to purge air and moisture from the
inside of the refrigeration system by evacuation, thereby ensur-
ing proper functioning of the air conditioner system.
Check the vacuum pump to see that the vacuum pump capacity
is greater than -100.0 kPa (-750 mmHg, -29.53 inHg).

RHA5878

Vacuum pump performance check procedure

1. Connect the vacuum gauge to the system.
2. Run the vacuum pump, and check to see that the needle
r;::.l:::_==:nJ-:;~~ Vacuum gauge
0 to -101.3 kPa pointers of the gauge manifold and vacuum gauge move
(0 to -760 mmHg, smoothly, indicating a similar value.
0 to -29.92 inHg)
3. After running the vacuum pump for two or three minutes,
read the vacuum gauge. The measured value indicates the
capacity of the vacuum pump.
Connecting nipple
RHA5888

Gas sampling adapter Gas leak detector

The gas leak detector is used to check whether the refrigeration
system is leaking. The detector is available in two types; halide
torch or electrical. The features of these gas leak detectors are
listed below. We recommend the electrical type because of its
greater detection ability and ease of handling.

Power/sensitivity selector switch

- L.E.D. lever meter
RHA5898

HA-19
 PREPARATION
Service Tools (Cont'd)
Type Detection ability Features

• Low price
• Low sensitivity
Halide torch 200 g (7.05 oz)/year (thin green)
• Less safe because of the use of
flame for detection
• Easy handling
Discharge type • Medium sensitivity
3- 50 g (0.11 - 1.76 oz)/year
(Suction type) • Each point needs tow or more sec-
onds for detection.
Electrical
• High sensitivity
Positive ion
• High price
emission type 2 g (0.07 oz)/year
• Warm-up time is needed because a
(Suction type)
heater is incorporated.
• Can be used easily in refrigerant
1 kg (2 lb)/month; if 13.3 kPa
Other simple checking method: charging operation.
(100 mmHg, 3.94 inHg) change in vac-
Changing in vacuum when evacuating • Detection ability is very low with vac-
uum is detected in 10 minutes.
uum gauge in gauge manifold.

• Leakage inspection of a refrigeration system needs a

sensitivity greater than 20 g (0.71 oz)/year.
• The actual amount of leak is estimated at 5 to 10 times the
detected amount.
• Insufficient cooling may be felt if leakage exceeds 150 to
200 g {5.29 to 7.05 oz).

Temperature gauge
Use to check the air conditioner performance. An etched stem
type thermometer may be used. A hydrometer must also be
used because the air conditioner performance depends on the
humidity.

Etched-stem
tank type
Wet and dry bulb thermometer
hydrometer RHA590B

Scale
Measure the weight of the refrigerant to determine how much
the refrigerant is charged.

HA-20
 PREPARATION
Service Tools (Cont'd)
Charging cylinder
The charging cylinder is used to correctly measure the amount
of refrigerant to be charged.
Features
• With the charging cylinder, the operator can measure
correctly the amount of refrigerant to be charged into the
system.
• Change in the refrigerant volume due to a change in
temperature and pressure can be supplemented, and this
ensures correct charging of refrigerant.
CAUTION:
• Never attempt to carry the charging cylinder containing
refrigerant.
• Do not put the charging cylinder in a hot place. If the
temperature and pressure of the refrigerant in the cylinder
increase, the safety valve will be pushed open and the
refrigerant will be released into the atmosphere.
• Do not expose the cylinder to the direct sunlight.
• Do not over-charge the refrigerant so that it exceeds the
maximum limit of the cylinder.
• Do not charge the cylinder with more refrigerant than is
RHA674B needed.

HA-21
 DISCHARGING, EVACUATING, CHARGING AND CHECKING

Work Procedure
In service A/C system
J
•
I

When it is necessary to replace parts.

.
I I When it is not necessary to replace parts. 1

+
Check the spot where malfunction I +
Check the spot where refrigerant
occurs. leaks.
I
+ ~
Discharging*1
I Repair.
I
j_ :t
Replace parts. Add refrigerant.
I I
I
I New A/C system • LInstall the service tools.
IInstall the A/C system. I
Evacuating
l
Run pump for over 5 minutes.

1 N.G. J
Checking airtightness
Shut off the high and low pressure
Repair
J
valves of the manifold gauge, and
leave system as it is for 5 to 10 min-
utes.
.O.K.
Evacuating*2
Run pump for over 20 minutes.

Charging
+
Charge approx. 200 g (7.05 oz) re-
frigerant from high pressure side
(with engine shut off).

+
Preliminary refrigerant leak check N.G.

jO.K.
Charging
Charge a specified amount of refrig-
erant from high pressure side (with
engine shut off).

+
Checking refrigerant leaks I N.G.

+ox
Checking amount of refrigerant
Start engine, and check after in-
creasing engine speed to 1,500 to
2,000 rpm.

+
Check operation of A/C system. *1: Do not discharge refrigerant
into the air. Capture all refrig-
Remove service tools.
+ erant in your recycling equip-
Use care not to allow refrigerant to ment.
leak out when removing. Make sure *2: Working operation depends
that refrigerant remaining in service upon the performance of the
canister is not leaking. pump and the weather.

HA-22
 DISCHARGING, EVACUATING, CHARGING AND CHECKING

Setting of Service Tools

Make sure that the service tools are set as indicated below and
that no refrigerant is leaking.

Adapter valve
l._ Connect service
~ve low and,high.

----- ~
:: f-!igh pressure.___..,..__
service valve

Connect
refrigerant
~
Low pressure ((
Charging hose (red) servtce valve \
container
(charging cylinder). I II\\

Refrigerant
recycling equipment

'1: If a 13.6 kg (30 lb)

For evacuation container of refrigerant is
used a weight scale will
be needed.
This scale is to determine
the amount of refrigerant
that is used.
Vacuum pump • 2: Transfer refrigerant from
a 13.6 kg (30 lb) con-
tainer to a charging
cylinder, and measure the
amount of refrigerant.
SHA733C

HA-23
 DISCHARGING, EVACUATING, CHARGING AND CHECKING
Setting of Service Tools (Cont'd)
When a 3-valve type manifold gauge is unavailable, use a
2-valve type manifold gauge with one additional valve at the end
of the charging hose.

Adapter valve
l..___ Connect service
~ve low and 1 high.
-High pressure~
-service valve
~_.....,...__

//.
/

~
Low pressure [
serv1ce valve \
Charging hose I /1\\
(yellow)

Connect charging cylinder

or refrigerant recycling
equipment.

Refrigerant
recycling equipment

·1: If a 13.6 kg (30 lb)

container of refrigerant is
used a weight scale will
be needed.
For evacuation This scale is to determine
the amount of refrigerant
that is used.
•2:Transfer refrigerant from
a 13.6 kg (30 lb) con-
taimir to a charging
Vacuum pump cylinder, and measure the
amount of refrigerant.

SHA761C

HA-24
 DISCHARGING, EVACUATING, CHARGING AND CHECKING

Discharging
WARNING:
Discharge only into your recycling equipment.
Do not release refrigerant into the air.
Slowly open the valves to discharge the refrigerant. If they are
opened quickly, compressor oil will also be discharged.

- High pressure valve

Refrigerant
Vacuum pump valve
recycling
equipment
SHA734C

Compressor
Evacuation
Low pressure
gauge EVACUATION PROCEDURE
From
evaporator To condenser 1. Completely tighten the low pressure and high pressure
Refrigerant adapter valves.
container Turn on the high and low pressure service valves.
2. Open the high and low pressure valves and vacuum pump
High pressure valve
valve of the manifold gauge set.
(open) 3. Run the vacuum pump.
Vacuum Vacuum pump valve
Charging
pump
cylinder SHA735C

4. Perform evacuation for more than five minutes to stabilize

the vacuum inside the system. Check to ensure that the low
pressure gauge indicates -98.6 to -101.3 kPa (-740 to -760
mmHg, -29.13 to -29.92 inHg).
5. Shut off the high and low pressure valves and vacuum
-101.3 kPa
(-760 mmHg,
pump valve of the manifold gauge set.
r.=l!Eiib..:Y~;::::s:;:~ -29.92 inHg)

CHECKING AIRTIGHTNESS
1. Shut off the high and low pressure valves and vacuum
pump valve of the manifold gauge set, and leave the system
as it is for 5 to 10 minutes.
2. Make sure that the needle of the low pressure gauge will
not move back toward the atmospheric pressure side
(gauge pressure 0).
If any reverse movement is noted, it indicates poor system
airtightness. Service the system until airtightness is complete.
If pressure changes approx. 13.3 kPa (100 mmHg, 3.94 inHg) in
10 minutes, the refrigerant in the system will be exhausted in
about one month.

vacuum pressure
service pump service
valve valve
High pressure
Vacuum pump valve
valve cock
cock (close)
(HI) (close)

RHA5988

HA-25
DISCHARGING, EVACUATING, CHARGING AND CHECKING
Evacuation (Cont'd)
MAINTENANCE
If inadequate airtightness is detected, check and service the
following portions:

Leak from pipe joints Leak from manifold gauge set

• Contaminated, damaged, or de- • Malfunctioning hose
formed 0-ring • Improper installation of manifold
• No oil applied when connecting • Malfunctioning valve
pipe • Malfunctioning packing
• Excessive or insufficient tighten-
ing of pipe joint

EVACUATION
If no abnormality is found during the airtightness check, perform
evacuation again for more than 20 minutes.
1. Run the vacuum pump.
2. Open the high and low pressure valve and vacuum pump
valve of the manifold gauge set.
3. Evacuate for more than 20 minutes.
4. Close the high and low pressure valves and vacuum pump
valve of the manifold gauge set.

Charging Refrigerant
Install the charging cylinder correctly to the vehicle. Refer to
"Setting of Service Tools".

PRELIMINARY CHARGING OF REFRIGERANT-1

1. Make sure that the inlet and outlet valves of the charging
cylinder are closed.
2. Slowly open the outlet valve of a refrigerant container (13.6
kg (30 lb)].
3. Slowly open the inlet valve of the charging cylinder.
valve The refrigerant will flow into the sight glass of the charging
(slowly
open) cylinder as the valve is opened.
Inlet valve (slowly open)

.RHA677B

4. Slowly open the upper vent valve to release pressure from

the charging cylinder. While doing so, continue charging
until the required amount of refrigerant is reached.
The refrigerant volume changes with the temperature and
pressure. It is necessary to charge refrigerant with a little more
than the required amount (indicated on the sight glass). Refer to
the CAUTION label attached on the vehicle, or to the Service
Manual.
5. Close the inlet valve and upper vent valve of the charging
cylinder.

HA-26
DISCHARGING, EVACUATING, CHARGING AND CHECKING
Charging Refrigerant (Cont' d)
6. Turn on the heater switch (the charging cylinder is provided
with a heater.)
The refrigerant charging time can be reduced by heating the
refrigerant to increase its pressure. In this case, do not allow
the pressure in the cylinder to rise higher than 1,030 kPa (10.5
kg/cm 2, 150 psi). (If pressure rises above this level, turn off the
heater.)
The pressure in the charging cylinder can be measured by the
upper pressure gauge.

AHA6798

EVACUATION AND AIRTIGHTNESS CHECK

Refer to "EVACUATION PROCEDURE" and "CHECKING
AIRTIGHTNESS" in "Evacuation".

SETTING OF FLOW METER

1. Rotate the charging cylinder main body until the scale for
R12 is at the correct position on the sight glass.
2. Read the charging cylinder pressure gauge.
3. Rotate the charging cylinder so that the scale of the
charging cylinder agrees with the pressure value indicated
on the pressure gauge.
4. Open the outlet valve of the charging cylinder.

RHA680B

HA-27
DISCHARGING, EVACUATING, CHARGING AND CHECKING
Charging Refrigerant (Cont' d)
CALCULATING CHARGING AMOUNT OF REFRIGERANT
1. Record the amount of refrigerant in the sight glass before
charging.
2. Subtract the required amount of refrigerant (charge quan-
tity specified for the vehicle) from the amount of refrigerant
recorded in step 1. Charge refrigerant into the system until
Sight
glass the remaining value equals to the value indicated on the
Referigerant level sight glass.
before charging Example:
Level in sight glass: 3 lb 8 oz
-ISpecified amount
of charge Charge specification (from S.O.S.) 2.0 - 2.4 lb.
Calculate charge quantity into lb and oz as follows: 1 lb = 16 oz,
Refrigerant level and 0.1 lb = 1.6 oz, so that 2.0 lb = 32 oz, 2.4 lb = 32 + (4 x
after charging 1.6) = 32 + 6.4 = 38.4, round off to 38. Therefore our charge
quantity will be between 32 and 38 oz, or 2 lb 0 oz to 2 lb 6 oz.
Subtract 2 lb 6 oz from the level in the sight glass (3 lb 8 oz) =
1 lb 2 oz.
This will be our ending point.

RHA681B

If a flow meter is not available, the amount of charged refriger-

ant also can be determined by subtracting the weight of the
canister measured after charging from its weight measured
before charging.

Weight
scale

RHA602B

HA-28
 DISCHARGING, EVACUATING, CHARGING AND CHECKING
Charging Refrigerant (Cant' d)
r-
-
- ,...
f-
V
ll Sight
glass
PRELIMINARY CHARGING OF REFRIGERANT-2
1. Slowly open the high pressure side valve of the manifold
- I"' r-
,... gauge to charge refrigerant from the high pressure side.
f-
f- 2. Close the high pressure valve after charging approx. 200 g
-
-
~~ r--
(7.05 oz) refrigerant.
CAUTION:
The refrigerant in the charging cylinder is kept in the liquid
1- state, so the refrigerant should be charged from high pressure
,... 1-
1- f- side. Do not start the engine with the high pressure valve kept
,... 1-
1- open.
1- RHA682B
PRELIMINARY CHECK FOR REFRIGERANT LEAKS
Refer to "PRELIMINARY CHECK FOR REFRIGERANT LEAKS"
in "Charging Refrigerant".

CHARGING REFRIGERANT
1. Slowly open the high pressure valve of the manifold gauge,
and charge the calculated amount of refrigerant in "CAL-
CULATING CHARGING AMOUNT OF REFRIGERANT".
CAUTION:
The refrigerant in the charging cylinder is kept in the liquid
state, so the refrigerant should be charged from high pressure
side. Do not start the engine with the high pressure valve kept
open.
2. Close the high pressure valve of the manifold gauge.
3. Make sure that the calculated amount of refrigerant is in the
sight glass.
4. Close the charging cylinder outlet valve.
5. Turn off the heater if it is on (when using heater equipped
type).

HA-29
 DISCHARGING, EVACUATING, CHARGING AND CHECKING

Inspection for Refrigerant Leaks

WORK PROCEDURE
To facilitate inspection for refrigerant leaks, establish the
following conditions:
• Start the engine.
• Run the air conditioner.
• Set the blower fan control to MAX.
• Set the temperature control to FULL COLD.
• Run the refrigerant system for more than 5 minutes after
setting the above-mentioned conditions (to circulate the
refrigerant through the system).

Refrigerant leaks should be checked immediately after stopping

the engine, beginning with the high pressure line, using a gas
' leak detector. This Is because the pressure in the high pressure
line drops gradually after the refrigerant circulation stops while
I
I the pressure in the low pressure line rises gradually as shown

----~-~;;:.:;;.-;~""'
in the graph. Leaks can be detected easily when pressure is
high.
• pressure line

•
Compressor stops.
Time

RHA604B

To prevent detecting errors, make sure that there is no refrig-

erant vapor or tobacco smoke in the vicinity of the vehicle. It is
also necessary to shield the vehicle from the wind so that the
leaking refrigerant is not blown away.

HA-30
 DISCHARGING, EVACUATING, CHARGING AND CHECKING
Inspection for Refrigerant Leaks (Cont'd)
Example: INSPECTION POINTS
Check carefully each of the tube joints. To check, wipe the
portion to be checked with waste cloth, and move the tester
probe all around the joint.

Compressor
Check the shaft seals and bolt holes, and also around the
magnet clutch.

Receiver drier
Check the pressure valve, safety valve and the fusible plug
mounts.

Service valve
Check all around the service valves.
Ensure that the valve core is not loose.
The service valve cap must be attached to the valve (to prevent
leak).
Also check that there are no foreign objects inside the cap.

Inside of cooling unit

RHA606B
To check, insert the leak tester probe into the drain hose
immediately after stopping the engine. (Keep the probe inserted
for more than 10 seconds.)

Recovery Procedure
REMOVAL OF REFRIGERANT CHARGING DEVICE
1. Completely loosen the adapter valves of the low pressure
and high pressure lines. The inner valve of the adapter
valve will prevent the refrigerant from leaking out.
2. Remove both the high-pressure and low-pressure side
adapter valves from the on-vehicle service valve.
If adapter valve is not used for charging, proceed as follows to
minimize the refrigerant discharge into the atmosphere.
3. Loosen the nut of the low pressure charging hose while
pressing it against the service valve to prevent refrigerant
leakage.
4. After loosening the nut, quickly remove the charge valve
from the service valve.
5. Wait until the high pressure gauge indication drops to
below 981 kPa (10 kg/cm 2 , 142 psi), then similarly discon-
nect the high pressure charging hose.

HA-31
 DISCHARGING, EVACUATING, CHARGING AND CHECKING

Confirmation of Amount of Charged Refrigerant

The amount of refrigerant charged into the system can be
observed through the sight glass by watching the flow of the
refrigerant and by reading the high pressure and low pressure
manifold gauges under the following conditions:

CONDITIONS
• Doors:
Close completely.
• Window glasses:
Close completely.
• Intake door position:
RECIRC
• Mode door position:
VENT
• Blower fan:
HI
• TEMP control:
Optional (Set so that intake air temperature is 30 to
35"C (86 to 95"F).
• AIR CON switch:
ON
• Engine speed:
Approx. 1,500 rpm
WORK PROCEDURE
Engine speed: Approx. 1,500 rpm
I
~
After warming up engine, adjust intake air temperature to 30 to 35"C (86 to 95"F).
Wait until high pressure is stabilized at approx. 1,471 kPa (15 kg/cm 2 , 213 psi).*1

*1: Cover the entire condenser until the required pressure is indicated.

Check the sight glass of the refrigerant

system.*2
Touch the high and low pressure tubes of the
system to get an idea of the temperature.

*2: Refer to sight glass inspection.

N.G.
Check to see whether the refrigerant If white clouding or air bubbles are found:
is free of white clouding and bubbles. I
O.K.

Charge refrigerant until while clouding or

bubbles disappear.

Wait for some time to all ow the refrigerant to sta-

bilize after charging, then check the condition
through the sight glass.

Charged amount of refrigerant is O.K. ,

HA-32
 DISCHARGING, EVACUATING, CHARGING AND CHECKING
Confirmation of Amount of Charged Refrigerant (Cont' d)

Overcharged, or
Appropriate Refrigerant is insufficient Almost no refrigerant
air in system

Temperature of high and High pressure side is hot High pressure side is No difference is felt be- High pressure side is very
low pressure pipes while low pressure side is warm and low pressure tween high and low hot.
cold. side is somewhat cold. presser sides.

Flow of refrigerant viewed Mostly transparent. Bubbles are always flow- Nothing is visible. If overcharged, no bub-
through sight glass Occasionally some bub- ing. Refrigerant is cloudy. bles are seen. If there is
bles are seen when en- air in the system, large
gine rpm is increased or bubbles are seen.
decreased.

Pressure Normal high pressure: Both high and low pres- High pressure value is Both high and low pres-
1,373- 1,765 kPa sure values are insuffi- very small. sure values are exces-
(14 - 18 kg/cm 2 , cient. sive.
199 - 256 psi)
Normal low pressure:
147- 294 kPa
(1.5- 3 kg/cm 2 ,
21 - 43 psi)

Action to take Air bubbles may be gen- Add refrigerant after Check the refrigerant sys- Stop the compressor and
erated when the receiver checking for leaks. tem. extract excessive refriger-
drier strainer is clogged, ant. If air is found, per-
or when the expansion form evacuation, then
valve is opened exces- charge the specified
sively. amount of refrigerant.

CAUTION:
The condition of bubbles seen through the sight glass as well as
the intake and discharge pressures are Influenced by the
ambient temperature, wind velocity, weather, and by the air
temperature in front of the condenser, etc.

HA-33
 SERVICE PROCEDURES

Refrigerant Lines
VG30DE ENGINE MODEL

~ 10-20
(1.0. 2.0,
7 -14)
~10-20
(1.0. 2.0,
J -14)

~15-25
(1.5. 2.5,
11. 18)

High-pressure
Low-pressure (Discharge) service valve
(Suction) service valve rP.J 10. 20
(1.0. 2.0,
7 -14)
~ 20-29
(2.0-3.0,
14. 22)

~ 20-29
(2.0. 3.0, 14. 22) Cooling unit

~ 15-25
(1.5. 2.5,
11 -18) ~15 -19
r;oJ10-20 (1.5 ·1.9,
(1.0. 2.0, 11. 14)
7 -14)

~ 20. 29 (2.0. 3.0,

14. 22)

~ 20.29 (2.0. 3.0, 14. 22)

~ : N·m (kg-m,ft-lb)

SHA310C

HA-34
 SERVICE PROCEDURES
Refrigerant Lines (Cont'd}
VG30DETT ENGINE MODEL

rPJ 10.20
(1.0. 2.0,
7 -14)
rPJ 10-20
(1.0 ·2.0,
7-141

~15-25
(1.5. 2.5,
11 -181

rPJ 10.20
(1.0. 2.0,
7 -14)

low-pressure
(Suction I service valve
High-pressure
(Discharge I service valve

rPJ 15. 19
(1.5. 1.9,
11. 141

Receiver drier
~ 14 -18 (1.4 ·1.8, 10. 13)

A 20 - 29 12.o . 3.o. 14. 221

rPJ: N·m (kg-m, ft-lb)

SHA527C

HA-35
SERVICE PROCEDURES

Compressor Mounting

Compressor

' VA 50 - 68 (5.1 - 6.9, 37 - 50)

SHA837C

Belt Tension
• Refer to section MA.

Fast Idle Control Device (F.I.C.D.)

• Refer to section EF & EC.

HA-36
SERVICE PROCEDURES

Removal and Installation - Compressor

REMOVAL
1. Remove battery cable.
2. Discharge refrigerant into your refrigerant recycling equip-
ment.
3. Remove under cover.

4. Remove low pressure tube, front stabilizer bar and its

clamps.
5. Loosen idler pulley nut and adjusting bolt.
Remove idler pulley.

6. Remove air pipes and hoses to make room.

7. Remove two nuts to separate high and low pressure flexible
hoses from compressor.
8. Disconnect compressor harness connector.
9. Remove two compressor fixing bolts (upper).

10. Remove two compressor fixing bolts (lower).

11. Remove the compressor as shown in the left-hand figure.

INSTALLATION
Installation is the reverse order of removal. Tightening torque
related to front stabilizer: refer to FA section.

HA-37
 COMPRESSOR OIL - Checking and Adjusting

Maintenance of Oil Quantity in Compressor

The oil used to lubricate the compressor circulates through the
system with the refrigerant. Whenever any component of the
system is replaced or a large amount of gas leakage occurs,
add oil to the compressor to maintain the specified amount.
If oil quantity is not maintained properly, the following malfunc-
tions may result:
• Lack of oil: May lead to a seized compressor
• Excessive oil: Inadequate cooling (thermal exchange im-
peded)
START

Perform oil return operation for 10 minutes. After that, stop the en-
Can oil return operation be performed? gine.

• A/C system works properly. CONDITION

Yes
• There is no evidence of a large amount --+ Operation must be performed as follows:
of oil leakage. Vehicle location: Indoors or in the shade
{in a well ventilated place)
No
TEMP set: Full cold
A/C switch: ON
..------~ Fan speed: Max.
Intake air: REC
Engine speed: Idle speed - 1,200 rpm
CAUTION:
Should the compressor be replaced? If excessive oil leakage is noted, do not perform the oil return op-
eration.
Yes No

®
{Go to next page.)

Remove the compressor and measure the

amount of residual oil as follows:
With the compressor upside down, drain oil
through the suction port. After oil stops
flowing, rotate the clutch hub two or three
times to drain oil completely.

@+
{Go to next page.)

HA-38
 COMPRESSOR OIL - Checking and Adjusting
Maintenance of Oil Quantity in Compressor (Cont'd)

Decide on the amount of oil to be drained A new compressor is charged with the specified amount of oil (the
from the new compressor in accordance overall amount needed in the system). So some oil needs to be
with the table on the right. drained from a new compressor to ensure that the amount of oil in
the compressor is the same as was in the old compressor.

...I
Amount of oil to be extracted from new compressor
Unit: me (US fl oz, Imp fl oz)
Extract as much oil as necessary from the Pre-charged Recovered amount Amount of oil to be
new compressor. Type amount of oil in of oil from old drained from new
(refer to the table at right.) new compressor compressor compressor

Less than 70
110 (3.7, 3.9)

l
®
DKV14B
DKV14C
200 (6.8, 7.0)
(2.4, 2.5)
r--------- 200--------
(6.8, 7.0)- (Re-
Greater than 70
(2.4, 2.5)
covered amount
20 (0.7, 0.7))
+

Less than 90
90 (3.0, 3.2)
(3.0, 3.2)
NVR140
200 (6.8, 7.0)
1-------- --------
NVR140S 200 (6.8, 7.0) - (Re-
Greater than 90
covered amount +
(3.0, 3.2)
20 (0.7, 0.7))

Less than 190

60 (2.0, 2.1)
(6.4, 6.7)
DKS16H
250 (8.5, 8.8)
1-------- 1--------
DKS16N 250 (8.5, 8.8) -
Greater than 190
[Recovered amount
(6.4, 6.7)
+ 20 (0.7, 0.7)]
MJS130
MJS170
150 (5.1, 5.3) - 80 (2. 7' 2.8)

Less than 95
This amount of oil 150 (5.1' 5.3)
(3.2, 3.3)
Recovered must be extracted.
V-5 236 (8.0, 8.3)
-------- --------
236 (8.0, 8.3) -
oil AHA609B Greater than 95
(Recovered amount
(3.2, 3.3)
+ 20 (0.7, 0.7))

f
'Y

Is there any part to be replaced? (Evapora- ~.. After replacing any of the following major components of the sys-
tor, condenser, receiver drier or in case tern, be sure to add the correct amount of oil to the system.
there is evidence of a large amount of oil Amount of oil to be added
leakage.) ----------------~----------------~------------
Oil to be added to system

Part replaced Amount of oil Remarks

me (US II oz, Ratio(%)
Imp II oz)

I Carry out the ~-

45- 75
A/C performance test. Evaporator
(1.5- 2.5, 1.6- 2.6)
30 -
30- 50
Condenser
(1.0- 1.7, 1.1- 1.8)
20 -
15- 25
Receiver drier
(0.5 - 0.8, 0.5 - 0.9)
10 -
30- 50
In case of refrigerant leak (1.0- 1.7, 1.1 - 1.8)
- Large leak

- - Small leak'
': II refrigerant leak is small, no addition of oil is needed.
"Ratio" in this table indicates the ratio of added oil to the overall amount of oil
needed in the system.

HA-39
 (')
0
s:
"V
::rJ
Magnet coil \ , m
U)
Screw U)
rRl 5 • 6 (0.5 • 0.6, 3.6 • 4.3) 0
::rJ
I
Lock washer
··~\ s:
0
a.
:::1:
l>
A
Lock nut
34 • 39 (3.5 • 4.o. 25 • 29) -c
CD

J,.
0 "
U)
I
.A
en

--
:::1:
c
m
U)
Shaft nut m
rRJ14 • 16 r-
1

""--
(1.4 • 1.6;10 • 12)

3
C»

Adjusting shim
-
~
CD

::0
:I:
r:c!J· : N•m (kg-m, ft-lb)
l;
~
a!
 COMPRESSOR- Model DKS-16H (DIESEL-KIKI make)

Compressor Clutch
REMOVAL
• When removing shaft nut, hold clutch disc with clutch disc
wrench.

SHA899B

• Using clutch disc puller, clutch disc can be removed easily.

SHA474A

• Bend down pawl of lock washer.

KV99235160
(J37882l • When removing pulley, remove lock nut with nut wrench.

• Remove the pulley by hand. If difficult, use puller pilot.

KV99233040
(J26720-AI

SHA700B

HA-41
 COMPRESSOR- Model DKS-16H (DIESEL-KIKI make)
Compressor Clutch (Cont'd)
INSPECTION
Clutch disc
If the contact surface shows signs of damage due to excessive
Clutch disc Pulley Coil
heat, the drive plate and pulley should be replaced.

Pulley
Check the appearance of the pulley assembly. If the contact
surface of the pulley shows signs of excessive grooving due to
slippage, both the pulley and drive plate should be replaced.
SHA703B The contact surfaces of the pulley assembly should be cleaned
with a suitable solvent before reinstallation.

Coil
Check coil for loose connection or cracked insulation.

INSTALLATION
• Install the key in the keyway on the compressor drive shaft.
• Install the coil to compressor (lead wire up) and tighten the
mounting screws.
• Install the lead wire into the holder correctly.

• Install lock washer and nut with nut wrench.

• Bend one pawl of the lock washer up against the nut to
prevent the nut from loosening.

• Check to ensure that the clutch clearance is between 0.3 to

0.6 mm (0.012 to 0.024 in). Adjust the clearance using
shim(s) as necessary.

BREAK-IN OPERATION
When replacing compressor clutch assembly, do not forget
break-in operation, accomplished by engaging and disengaging
the clutch about thirty times.
Break-in operation raises the level of transmitted torque.

SHA707B

HA-42
 DIAGNOSES - Overall System

How to Perform Trouble Diagnoses for Quick

and Accurate Repair- Manual Air Conditioner
WORK FLOW
<Reference item

LISTEN TO CUSTOMER COMPLAINT AND CONFIRM Operational Check

BY PERFORMING OPERATIONAL CHECK:. (See pages HA-45 - 46.)
Can be
confirmed confirmed
EDUCATE CUSTOMER ON
CORRECT OPERATION OF
SYSTEM.

Symptom Chart
(See page HA-56.)
LISTEN TO CUSTOMER COMPLAINTS
AND CONFIRM.

INVESTIGATE ITEMS YOU SHOULD Symptom Chart

CARRY OUT RELATED TO EACH (See page HA-56.)
SYMPTOM.

ELIMINATE GOOD SYSTEM(SI/ Preliminary Check

r - - - - - - - - - - - --- PART(S). (See pages HA-57- 62.)

Main Power Supply

CHECK MAIN POWER SUPPLY and Ground Circuit
AND GROUND CIRCUITS. Check
(See page HA-68.)

• Diagnostic Proce-
dure(s) (See pages
HA-69 · 83.) ELIMINATE GOOD PART(S)/ Harness Layout for
• Circuit Diagram for HARNESS(ES)/CONNECTOR(S) A/C System
Quick Pinpoint ELECTRICALLY. (See pages HA-63- 64.)
Check (See page
HA-65.)
Malfunctioning Malfunctioning
harness(es)/ part(s)
connector(s)
Electrical Components
Inspection
(See pages HA-84- 86.)

L - - - - - - --- - - - - FINAL CHECK

N.G.~---------- --------------~

HA-43
 DIAGNOSES - Overall System

How to Perform Trouble Diagnoses for Quick

and Accurate Repair - Auto Air Conditioner
WORK FLOW
<Reference item

LISTEN TO CUSTOMER COMPLAINT AND CONFIRM Operational Check

BY PERFORMING OPERATIONAL CHECK. (See pages 46- 48.1
Can be
confirmed confirmed
EDUCATE CUSTOMER ON
CORRECT OPERATION OF
SYSTEM.

Symptom Chart
(See pages HA-92 - 93.1
LISTEN TO CUSTOMER COMPLAINTS
AND CONFIRM.

INVESTIGATE ITEMS YOU SHOULD

Symptom Chart
CARRY OUT RELATED TO EACH
(See pages HA-92- 93.1
SYMPTOM.

PERFORM SELF-DIAGNOSIS. Self-diagnosis

(See pages HA-94- 101.1

Cannot be performed

CHECK MAIN POWER Main Power Supply and

SUPPLY AND GROUND Ground Circuit Check
CIRCUIT. (See page HA-116.1

Preliminary Check
r-------------- (See pages HA-103 -110.1
1

I • Diagnostic Proce-
I dure lsi (See pages
ELIMINATE GOOD PART(Sl/ Harness Layout for
I HA-117-144.1
HARNESS(ESI!CONNECTOR(SI A/C System
• Circuit Diagram for
Quick Pinpoint ELECTRICALLY. (See pages HA-111 - 112.1
Check (See page
HA-113.1 Malfunctioning
part(sl
harness(esl/
connectorlsl Electrical Components
Inspection
(See pages HA-145- 147.1

L __ - - - - - - - - - - - - - FINAL CHECK
N.G. L..._ _ _ _ __

O.K.

CHECK OUT

HA-44
 DIAGNOSES - Overall System

Operational Check- Manual Air Conditioner

The purpose of the operational check is to confirm that the
system operates as it should. The systems which are checked
are the blower, mode (discharge air), intake air, temperature
decrease, temperature increase.

CONDITIONS:
Engine running at normal operating temperature.

PROCEDURE:
1. Check blower
1) Slide Fan lever to 1-speed.
Blower should operate on 1-speed.
2) Then slide Fan Lever to 2-speed.
3) Continue checking blower speed until all four speeds are
checked.
4) Leave blower on 4-speed.
I
RHA783B

2. Check discharge air

1) Set Mode switch at VENT position.
2) Confirm that all discharge air comes out of face vents.
3) Set Mode switch at 8/L position.
4) Confirm that discharge air comes out of face vents and foot
vents.
5) Set Mode switch at FOOT position.
6) Confirm that discharge air comes out of foot vents, with
some air from defroster vents.
7) Set Mode switch at F/D position .
.___ _ _ _ _ _ _ _ _ _ _ _s_HA_7_a4_,c 8) Confirm that discharge air comes out of foot vents and
defroster vents, and that compressor turns ON.
9) Set Mode switch at DEF position.
10) The discharge air should be coming only from defroster
vents. At the same time intake door position should be at
FRE.

3. Check recirc
1) Press RECIRC button.
RECIRC indicator should light.
2) Listen for intake door position change (you should hear
blower sound change slightly).

SHA785C

HA-45
 DIAGNOSES - Overall System
Operational Check - Manual Air Conditioner (Cont'd)
.-------------------------~
4. Check temperature decrease
1) Slide temperature control lever to full cold.
2) Check for cold air at discharge air outlets.

SHA786C

5. Check temperature increase

1) Slide temperature control lever to full hot.
2) Check for hot air at discharge air outlets.

SHA787C

6. Check air conditioner switch

Move fan control lever to the desired (1 to 4-speed) position
and push the air conditioner button to turn ON the air
conditioner.
The indicator light should come on when air conditioner is
ON.

SHA788C

Operational Check - Auto Air Conditioner

The purpose of the operational check is to confirm that the
system operates as it should. The systems which will be
checked are the blower, mode (discharge air), ambient display,
intake air, defrost, econ, auto, temperature decrease, temper-
ature increase, and the memory function.

CONDITIONS:
Engine running at normal operating temperature.

PROCEDURE:
1. Check blower
1) Press FAN switch one time.
ECON indicator should light.
Blower should operate on low speed, and the fan symbol
should have one blade lit ( ~ ).
2) Press FAN switch one more time.
3) Continue checking blower speed and fan symbol until all
four speeds have been checked.
4) Leave blower on high speed.

HA-46
 DIAGNOSES - Overall System
Operational Check - Auto Air Conditioner (Cont'd)
.-------------------------~
2. Check discharge air
1) Press MODE switch one time.
Display should show air to face ( •; ).
2) Confirm that all discharge air comes out of face vents.
3) Press MODE switch one more time.
Display should show air to face and foot (bi-level) ( ':.J )
4) Confirm that discharge air comes out of face and foot vents.

~
5) Press MODE switch one more time.
Display should show air to foot ( ~i ).
6) Confirm that discharge air comes mostly from foot outlets,
SHA790C with some air from defroster outlets.
7) Press MODE switch one more time.
Display should show air to foot and defroster ( ®J ).
8) Confirm that discharge air comes out of foot vents and
defroster vents.
9) Leave system in F/D mode.

3. Check recirc
1) Press RECIRC switch.
RECIRC indicator should light.
2) Listen for intake door position change (you should hear
blower sound change slightly).

SHA791C

4. Check defrost
1) Press DEF switch.
2) Check that RECIRC, ECON, MODE and Fan are canceled.
The discharge air should be coming only from defrost
-~
-, vents.
3) Confirm that compressor clutch is engaged (visual inspec-
tion).
Display should show air to defroster ( ®J ).

SHA792C

5. Check ECON mode

1) Press ECON switch.
Defrost should be canceled.
Discharge air outlet will depend on ambient, in-vehicle, and
set temperatures.
2) Confirm that the compressor clutch is not engaged (visual
inspection).

SHA793C

HA-47
 DIAGNOSES - Overall System
Operational Check- Auto Air Conditioner (Cont'd)
.--------------, 6. Check AUTO mode
1) Press AUTO switch.
2) Confirm that compressor clutch engages (audio or visual
inspection).
Discharge air will depend on ambient, in-vehicle, and set
temperatures.

SHA794C

7. Check temperature decrease

1) Press temperature set switch until 1o·c (60.F) is displayed.
2) Listen for changes in blower speed as set temperature
changes.
3) Check for cold air at discharge air outlets.

SHA795C

8. Check temperature increase

1) Press temperature set switch until 1o·c (90.F) is displayed.
2) Listen for changes in blower speed as set temperature
changes.
3) Check for hot air at discharge air outlets.

SHA796C

9. Check memory function

1) Press oft button.
2) Turn ignition off.
3) Wait 15 seconds.
4) Turn ignition on.
5) Press AUTO button.
6) Confirm that the set temperature remained at 4o·c (90.F).

SHA797C

HA-48
DIAGNOSES - Overall System

Performance Chart
TEST CONDITION - For Manual Air Conditioner
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well venti-
lated place)
Doors: Closed
Door windows: Open
Hood: Open
TEMP. lever position: Max. COLD
Mode switch: ..J (Ventilation) set
REC switch: ~ (Recirculation) set
FAN level position: Max. position
Engine speed: 1,500 rpm
Time required before starting testing after air conditioner
starts operating: More than 10 minutes

TEST CONDITION - For Auto Air Conditioner

Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well venti-
lated place)
Doors: Closed
Door windows: Open
Hood: Open

fiJ\ Set up ACTIVE-TEST with CONSULT and set each

~ component as follows:
Mode door: VENT
Intake door: REC
Air mix door: Full-cold
Compressor: ON
Blower motor: 12V
@ Set up self-diagnosis STEP 2 and set code -;

HA-49
 DIAGNOSES - Overall System
Performance Chart (Cont'd)
TEST READING
Recirculating-to-discharge air temperature table

Inside air(Recirculating air)

at blower assembly inlet Discharge air temperature at center ventilator
Relative humidity Air temperature ·c ("F)
% ·c ("F)
20 (68) 5.9 - 7.8 (43- 46)
25 (77) 8.0- 10.7 (46- 51)
50-60
30 (86) 11.0 - 14.4 (52 - 58)
35 (95) 14.8- 19.4 (59 - 67)
20 (68) 7.8- 9.9 (46 - 50)
25 (77) 10.7 - 13.6 (51 - 56)
60-70
30 (86) 14.4- 18.2 (58- 65)
35 (95) 19.4- 24.8 (67 - 77)

Ambient air temperature-to-compressor pressure table

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (kg/cm 2 , psi) kPa (kg/cm 2 , psi)
% ·c ("F)
608- 912 177- 245
20 (68)
(6.2- 9.3, 88- 132) (1.8 - 2.5, 26 - 36)
814- 1,147 186- 255
25 (77)
(8.3- 11.7, 118- 166) (1.9 - 2.6, 27 - 37)
50-70
1,020 - 1,402 196- 265
30 (86)
(10.4- 14.3, 148 - 203) (2.0 - 2.7, 28 - 38)
1,236 - 1,638 226- 314
.35 (95)
(12.6- 16.7, 179- 237) (2.3 - 3.2, 33 - 46)

HA-50
 DIAGNOSES - Overall System

Performance Test Diagnoses·

Characteristics revealed by the manifold gauge In the following table, the portion smeared with
readings for the air conditioning system are ink on each gauge scale indicates the range
shown in the following. showing that the air conditioning system is in
For how to do the performance test, refer to the good order. This range is described in Perfor-
item "Performance Chart". mance Chart.

Condition Probable cause Corrective action

INSUFFICIENT REFRIGERANT CHARGE
Insufficient cooling. Refrigerant is low, 1. Leak test.
Bubbles appear in sight or leaking slightly. 2. Repair leak.
glass. 3. Charge system.
Evacuate, as necessary, and
recharge system.

jALMOST NO REFRIGERANT!
No cooling action. Serious refrigerant leak. Stop compressor immedi-
A lot of bubbles or ately.
something like mist 1. Leak test.
appears in sight glass. 2. Discharge system.
3. Repair leak(s).
4. Replace receiver drier if
necessary.
5. Check oil level.
6. Evacuate and recharge
system.

Slight cooling. Expansion valve restricts If valve inlet reveals sweat

Sweat or frosting on refrigerant flow. or frost:
expansion valve inlet. • Expansion valve is 1. Discharge system.
clogged. 2. Remove valve and clean
• Expansion valve is it. Replace it if necessary.
inoperative. 3. Evacuate system.
Valve stuck closed. 4. Charge system.
Thermal bulb has If valve does not operate:
lost charge. 1. Discharge system.
2. Replace valve ..
3. Evacuate and charge sys-
tem.
AC354A

HA-51
 DIAGNOSES - Overall System
Performance Test· Diagnoses (Cont'd)
Condition Probable cause Corrective action
Insufficient cooling. Expansion valve allows too Check valve for operation.
Sweat on suction line. much refrigerant through If suction side does not
evaporator. show a pressure decrease,
replace valve.

No cooling. Malfunctioning 1.. Discharge system.

Sweat or frosting on expansion valve. 2. Replace valve.
suction line. 3. Evacuate and charge
system.

lAIR IN SYSTEM I
Insufficient cooling. Air mixed with refrigerant 1. Discharge system.
Sight glass shows occasion- in system. 2. Replace receiver drier.
al bubbles. 3. Evacuate and charge
system.

AC359A

IMOISTURE IN SYSTEM I
After short operation, Drier is saturated with mois- 1. Discharge system.
suction side may show ture. Moisture has frozen in 2. Replace receiver drier
vacuum pressure reading. expansion valve. Refriger- (twice if necessary).
During this condition, ant flow is restricted. 3. Evacuate system c.om-
discharge air will be warm. pletely. (Repeat 30-
As a warning of this, reading minutes evacuating three
vibrates around times.)
39 kPa (0.4 kg/cm 2 , 6 psi). 4. Recharge system.

AC360A

HA-52
 DIAGNOSES - Overall System
Performance Test Diagnoses (Cont'd)
Condition Probable cause Corrective action
IMALFUNCTIONING CONDENSER I
. No cooling action: engine Usually a malfunctioning • Check radiator fan motors .
may overheat. condenser. • Check condenser for dirt
Bubbles appear in sight accumulation.
glass of drier. • Check engine cooling sys-
Suction line is very hot. tem for overheating.
• Check for refrigerant over-
charging.
If pressure remains high in
spite of all above actions
taken, remove and inspect
the condenser for possible
oil clogging.

AC361A

!HIGH PRESSURE LINE BLOCKED!

Insufficient cooling. Drier clogged, or restriction 1. Discharge system.
Frosted high pressure in high pressure line. 2. Remove receiver drier or
liquid line. strainer and replace it.
3. Evacuate and charge
system.

AC362A

!MALFUNCTIONING COMPRESSOR I
Insufficient cooling. Internal problem in com- 1. Discharge system.
pressor, or damaged gasket 2. Remove and check
and valve. compressor.
3. Repair or replace
compressor.
4. Check oil level.
5. Replace receiver drier.
6. Evacuate and charge
system.

AC363A

HA-53
 DIAGNOSES - Overall System
Performance Test Diagnoses (Cont'd)
Condition Probable cause Corrective action
TOO MUCH OIL IN SYSTEM (Excessive)
Insufficient cooling. Too much oil circulates Refer to COMPRESSOR OIL
with refrigerant, causing for correcting oil level.
the cooling capacity of the
system to be reduced.

AC364A

HA-54
 TROUBLE DIAGNOSES - Manual Air Conditioner

Contents
Symptom Chart .......................................................................................................................................................... HA-56
Preliminary Check ......... .. .... ....... ... ... ... .... ...... ...... ..... .... ......... ..... ............. .. .......... ..... ................. ................................ HA-57
PRELIMINARY CHECK 1
(Intake door is not set at "FRESH" in DEF mode) ...................................................................................... HA-57
PRELIMINARY CHECK 2
(A/C does not blow cold air) ............................................................................................................................ HA-58
PRELIMINARY CHECK 3
(Magnet clutch does not engage in FOOT & DEF or DEF mode) ............................................................. HA-59
PRELIMINARY CHECK 4
(Air outlet does not change) ............................................................................................................................. HA-60
PRELIMINARY CHECK 5
(Noise) ................................................................................................................................................................... HA-61
PRELIMINARY CHECK 6
(Insufficient heating) ............................................................................................................................................ HA-62
Harness Layout for A/C system ............................................................................................................................ HA-63
Circuit Diagram for Quick Pinpoint Check .......................................................................................................... HA-65
Wiring Diagram .......................................................................................................................................................... HA-66
Main Power Supply and Ground Circuit check .. ...... .... ..... ............ .. ........ .. ....... ................... ................................ HA-68
Diagnostic Procedure 1
(Blower motor does not rotate) ........................................................................................................................ HA-69
Diagnostic Procedure 2
(Air outlet does not change) ............................................................................................................................. HA-71
Diagnostic Procedure 3
(Intake door does not charge in VENT, 8/L or FOOT modes) ................................................................... HA-73
Diagnostic Procedure 4
(Magnet clutch does not engage when A/C switch and fan switch are ON) ........................................... HA-74
Diagnostic Procedure 5
(Illumination or control panel indicators do not come on) ........................................................................... HA-78
Diagnostic Procedure 6 ·
(Temperature of air outlet does not change) ................................................................................................. HA-82
Electrical Component Inspection ........................................................................................................................... HA-84
Control Rod Adjustment .......................................................................................................................................... HA-87

HA-55
 z -ns: <:;- :;- .., c
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(f)
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• Preliminary check 1 HA-57
..,
::0
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Preliminary check 3
HA-58

HA-59
~
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:;·
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OJ
r-
•
'!i
< m
Preliminary check 4 HA-60
..
n
::r
c
• •
Preliminary check 5

Preliminary check 6
HA-61

HA-62
n
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e 0 0 Diagnostic procedure 1 HA.69 • 70
CJ) z
e Diagnostic procedure 2 HA-71 · 72
0
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-
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• 0
Diagnostic procedure 3

Diagnostic procedure 4
HA-73

HA-74 · 77
g
;;·
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0
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g
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I
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Diagnostic procedure 5

Diagnostic procedure 6
HA-78- 81

HA'82 · 83
a.
c:
;;;
0
:::r 3:

-
S»
0 0 0 0 0 0 Control amp. HA-68
n
0 Cl ~ ~
§. a :g 3·
...
S» :::s
c::
nc:<-c S»
0 0 0 0 0 0 0 Fuses HA-68 ~a~~
~ a. ~

0 Fan switch HA-84 ...!:

0 I 0 I 0 I Blower motor HA-84 0
0
0 I 0 I 0 I Blower resistor HA-84 :::s
a.
0 A/C .Witch HA-85 m

~ a:
0
0 0 0 l Low pressure switch HA-85
~ :::s
0 0
0 I I
0 I RELAYS
I MODE switch
HA-85

HA-86
n
0
3
"~
0
...
CD

0 THERMO CONTROL AMP. HA-86 ~

:;·
0 Air mix door motor
-5
~
c;·
0 Mode door motor
"
0 0 Intake door motor

0 0 0 I Compressor

0 0 0 0 0 0 I 0 I Harness
 TROUBLE DIAGNOSES - Manual Air Conditioner

Preliminary Check
PRELIMINARY CHECK 1
Intake door is not set at "FRESH" in DEF mode.

Is intake door in "Fresh"

position when REC switch is
~I Go to Diagnostic Procedure 3.
I
turned from ON to OFF in
VENT, 8/L, FOOT or FOOT &
DEF modes with ignition switch
at ON and fan speed at 4?
(Intake door must be at REC/
FRE position when VENT mode
is selected.)
(Can you hear air moving from
the intake unit? Or open glove
box and check intake door
operation which is located
behind the glove box.)

l Yes

Is intake door in "REC"

position when R EC switch is
~I Go to Diagnostic Procedure 3.
I
turned from OFF to ON in
VENT, 8/L, FOOT or FOOT &
DEF modes with ignition switch
at ON and fan speed at 4?
(Can you hear air moving from
the intake unit? Or open glove
box and check intake door
operation which is located
behind the glove box.)

l Yes

Is intake door in "Fresh" No Replace control amp. built-into

position when DEF mode is heater unit.
selected?
(Can you hear air moving from
the intake unit? Or open glove
box and check intake door
operation which is located
behind the glove box.)

t Yes

INSPECTION END

HA-57
 TROUBLE DIAGNOSES - Manual Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
A/C does not blow cold air.

N.G. IS BLOWER MOTOR

DOES AIR FLOW FROM
VENTS? OPERATING NORMALLY?
Condition
• Ignition switch, A/C switch,
Yes l No

and fan switch are ON. CHECK BLOWER

• Mode switch is in VENT MOTOR OPERATION.
mode and temperature lever Go to Diagnostic
is in full cold position Procedure 1.

l
CHECK COMPRESSOR BELT
TENSION.
M CHECK COMPRESSOR
OPERATION.
O.K.

CHECK VENTILATOR DUCT

FOR AIR LEAKS.
Refer to MA section.
lO.K. O.K. l N.G.
JN.G.

Adjust or replace
O.K.
CHECK REFRIGERATION I Repair air leaks.
CYCLE PRESSURE WITH
compressor belt. MANIFOLD GAUGE
CONNECTED.
CHECK THERMO CONTROL
Refer to Performance Chart.
AMP.
CHECK REFRIGERANT.
Connect manifold gauge then l N.G. O.K.
Refer to Electrical Components
inspection.
check syStem pressure. Go to Performance Test
l N.G. O.K. Diagnoses. I O.K.

I
!N.G.

Replace thermo
CHECK FOR control amp.
REFRIGERANT
LEAKS.
I Go to Diagnostic Procedure 6. I
, CHECK FOR EVAPORATOR
COIL FREEZE UP.
Go to Preliminary check 3. Remove intake unit and check
if evaporator freezes.

HA-58
 TROUBLE DIAGNOSES - Manual Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 3
Magnet clutch does not engage in FOOT & DEF or DEF modes.
• Perform PRELIMINARY CHECK 2 and 4 before referring to the
following flow chart.
No _j
With engine running, does
magnet clutch engage normally
~
1 Go to Diagnostic Procedure 4. I
when A/C switch and fan switch
are ON?

-l Yes

Push A/C switch and turn A/C

system OFF. Make sure that
magnet switch is disengaged.

]
~r I
With engine running, does Replace control amp. built-into
magnet clutch engage normally heater unit.
when FOOT & DEF or DEF
switch and fan switch are ON?

l Yes

INSPECTION END

HA-59
 TROUBLE DIAGNOSES - Manual Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 4
Air outlet does not change.

DOES AIR COME OUT FROM EACH DUCT NORMALLY WHEN Go to Diagnostic Procedure 2 •
EACH MODE SWITCH IS SELECTED WITH IGNITION SWITCH
ATON?

~
Air outlet

-;
...
v
VENT

FOOT& VENT

Mode
'll
• FOOT& DEF

fJ FOOT& DEF

~ DEF

AIR DISTRIBUTION RATIOS

VENT B/L FOOT F/0 DEF

INSPECTION END

HA-60
 TROUBLE DIAGNOSES - Mant.iai·Air Conditioner
Preliminary Check (Cont'd)
~ ~ ' ~ . . ..
PRELIMINARY CHECK 5
Noise

I Check where noise comes from. I

l l l
I Blower motor
I Expansion valve Compressor
I Refrigerant line·
I I Belt

l l I
~ Replace blower Replace Replace
motor. I expansion valve. compressor.

l l
The line is fixed directly to the
body.
The line is not fixed.
I
l l
Fix the line with rubber or
some vibration absorbing
Fix the line tightly.
I
material.

I
l l
The belt vibration is intense. Side of belt is worn out.

l 1
The pulley center does not
Readjust belt tension.
Refer to ENGINE MAIN- match.
TENANCE in MA section. Readjust the pulley center.

HA-61
 TROUBLE DIAGNOSES - Manual Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 6
Insufficient heating
DOES AIR FLOW FROM ~ CHECK BLOWER MOTOR
OPERATION.
FOOT AREA?
Condition: Go to Diagnostic Procedure 1.
• Ignition switch and fan switch
are ON.
• Mode switch is in FOOT mode
and temperature lever is in
full hot position.

l O.K.

CHECK AIR MIX DOOR

OPERATION.
Go to Diagnostic Procedure 6.

HA-62
 TROUBLE DIAGNOSES - Manual Air Conditioner

Harness Layout for A/C System

ENGINE COMPARTMENT

--------- . ~
-----------------
.... ..--..
Low-pressure switch ~

SHA315C

HA-63
 TROUBLE. DIAGNOSES - Manual Air· Conditi(mer
Harness Layout for A/C System (Cont'd)
'·'.

PASSENGER COMPARTMENT

-·\
-~,

'

v
Air conditioner
switch unit
connector

Rear of fuse block

HA-64
 Iii
II GNJ Tl ON SWJ TCH
ON or START BATTERY
I IGNITION SWITCH
ACC or ON
® I36126!27!281341291351Xl241251
aiD: Turbo model
I MODE DOOR MOTOR
® CNI): Non-turbomodel

~'"" 0'"" ~
~

1~1~1~
'""
®
0
~ 1®1®1®1®1®1®1®1® ~7
1-=- -t
® I® I®
:a
0
~@ 0 -
c
2' 25 26 27 28 29
3or---t-------__J m
RAELAY RADIATOR omO) I
r-
m
~
FAN

®®
RELAY
.----+--1-__J
® 0 Clb® 19
• r---t-t-----_j
31
c
;;
rm G)
~---+--------Uu 1--tT-+---;@~---------
ALTERNATOR
11 z
0~COMPRE~SOR
0
13

CONTROL AMP. •3
0CD
...-·
n
0
en
m
20
c en
,..
:I: ®
~
~
-:-
RADIATOR
INTAKE
DOOR
21
19
:;:::;:
c I
& 0 F. I. C 0.
FAN MOTOR MOTOR
~
~~
__[j]___ ®n76
22

~
~
12

r.'t++-----~
m-· ~
Ul VALVE
SOLENOID ,__--t-_ __:I.:.J:::::9
1
...
CD
m
II
® m ~~
T"}.;'T';) ;;;·
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c
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llii

I
1
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I
I
I
a:D9
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0
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I :®
(I
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-- 0 ~ :::::J
-~
~ L_-~====~=====:j" l6
J CD :!! :;:::;:
............__ _____.
@
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••
-

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:::::J
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-
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23

To I l l u m i n a t i o n { @ ~ ~
0
-·
:::::J
...
CD

l199l @lll flllllllll J-111461.1111

ILLUMINATION
IIIII P1llllllll bd 6 33
control system

0
::r
CD
• All connectors shown in this illustration are unit side connectors. n
~
• The unit side connectors with a double circle " 0 " are connected to the harness side connectors shown in
C/1 the "Harness Layout for A/C System". (See PIIIIBS HA-63 - HA-64.)
J:
)> • The terminal numbers in the connector coincide with the circuit numbers surrounded by a single circle " 0 "
.....
U)
U)
n
 TROUBLE DIAGNOSES - Manual Air Conditioner

Wiring Diagram

ROUTlNG• In EL section. l

l-GNlTlON S~l~II
ON or START TCH

!Body IMa in harnessl

harnessl

BODY GROUND
!Engine room
harnessl
lA I terns tor @ @
@ h{arnessl W/R-@ @-w/R
®] !f}_w,..R @ @) AIC IGNITION
RELAY
ALTERNATOR ffi. JB BODY GROUND
W/R-w w-W/R

l GNl Tl ON SWl TCH 1------,

ON or START

FR

FUSE BLOCK
*
(] n RELAY BOlO
!Refer to •POWER
SUPPLY ROUTING•
in EL sect I on. l
~
t:::::l
w

~ngine room harnessl

®
[IIJ ® B~=~
~--OR~

HA-66
 TROUBLE DIAGNOSES - Manual Air Conditioner
Wiring Diagram (Cont'd)

SWITCH UNIT

Jl o-------------------~
BLOWER BLOWER
RELAY-2 RELAY-3 CONTROL AMP. c 80,....._-----,.

lllm
~®~® I•P..-11! -+'

ID.>-
31:
,,..
u
CIH!'
31:
'~
"'
iMJii'dmUBiltiiM ® ~~
N-~~~~~~~~N-Q~~~~~~nN-O~G~~~n ~
~nn~NNNNNNNNN----------

11111111111111111111111111111
~>->-~~~~>->- ~« m ~~m~m~ m ~~
''''o''ocm~m'~'c>-~''''''~'~'m
'"'~"'~ ll:m ~ ll:lj ~~ull:~~~ ~ ~

J0
= A / C SWITCH
• 0 0
=REC SWITCH
® 12 0 0

·~·~° :~A/C
Y/R
W/a
OR~B •• INDICATOR

1~
ID L/8

~@
- R
G/W REC INDICATOR
-R/Y I
-= -G/R
f - - - BR
BODY -L/R
GROUND
'ILLUMINATION

;I®~
®
- G/W~
BR
Y/R 0
tfw
e
a /W
/R

G • AIR MIX
DOOR MOTOR
@) BR/Y
G/Y
L/W
G /IN
M

lv•
CSub- harness)
CMain
harness)

CBrownl
L_

L__

@) CE. F. I. harness)
~a/R
sa

OR
CBrownl
G-

~w L
I ....___
@ I 0:
I I I I
o:
I
m
"'' m
0 ..J 0:: ""' CD : A/T model

@g ®~ I I Q;D : MiT mode I

CfiD : Turbo model

~ ~
CiiT):
® IIIII b<l I IIIIIII,N 1~1[®]1 P\J IIIII II II II Glllll Non-turbo model

COMPRESSOR F. I. C. D.
111111 M1111111 ;•g ~ ~ 1.,11111111111 ~II II
SOLENOID
VALVE
E. C. C. S. CONTROL UN! T CRefer to EF&EC section. l

SHASOOC

HA-67
 TROUBLE DIAGNOSES - Manual Air Conditioner

Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK FOR A/C SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" in section EL and A/C
ELECTRICAL CIRCUIT.

CONTROL AMP. REMOVAL

1. Remove driver side instrument lower lid.
2. Remove vent duct.
3. Remove control amp. with harness connected.

Control amp. harness connector ® CONTROL AMP. CHECK

_,
ritWfl WI b<WI .------
1. Disconnect control amp. harness connector.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. @ or No. @ and body
ground.
eJ I
G/W: L/W
'
00
@__§ Voltmeter terminal

00 L.....-_

EB 8
Voltage

SHA313C = @
Body ground Approximately 12V
@

Control amp. harness connector ® Check body ground circuit for control amp. with ignition switch
OFF.

fit IIIII ffi J,iWJ 1. Disconnect control amp. harness connector.

2. Connect ohmmeter from harness side.
3. Check continuity between terminal No. @ and body ground.
iV B IQI

00
SHA314C =

HA-68
 TROUBLE DIAGNOSES - Manual Air Conditioner

Diagnostic Procedure 1
\1
INCIDENT

Fan fails to rotate

Flow
chart No.

w
SYMPTOM: Blower motor does not rotate.
• Perform PRELIMINARY CHECK 2 before referring to the
following flow chart.
2 Fan does not rotate at speed 1. [2]
3 Fan does not rotate at speed 2. ~ Check if blower motor rotates
properly at each fan speed.
4 Fan does not rotate at speed 3. @]
Conduct checks as per flow
5 Fan does not rotate at speed 4. ~ chart.

a Blower motor harness connector

m
CHECK POWER SUPPLY FOR
[]
~~ ~
c
@]
D
liD
E

@) BLOWER MOTOR. (Go to next page.)

Disconnect blower motor
harness connector.
N.G.
Do approximately 12 volts exist Check fuses at fuse block.
between blower motor harness (Refer to "POWER SUPPLY
terminal No.@ and body ROUTING" in EL section and
ground? A/C ELECTRICAL CIRCUIT.)

O.K.
SHA316C
lil
Check circuit continuity N.G. Reconnect blower motor harness
Blower motor harness connector between blower motor harness connector.
@) terminal No. @ and body
ground.

O.K.

CHECK BLOWER MOTOR.

(Refer to Electrical Com·
ponents Inspection.)

~ N.G.
Continuity should exist. SHA317C
Replace blower motor.
Resistor harness
connector@

[f[BJ~i5 @1
L CHECK BLOWER MOTOR N.G. Disconnect blower motor and
~

CIRCUIT BETWEEN BLOWER resistor harness connectors.

MOTOR AND RESISTOR.
Do approximately 12 volts exist 1!1 Note
between resistor harness
-~~
Check circuit continuity
terminal No. @and body between blower motor harness
SHA318C
ground? terminal No. @ and resistor
terminal No.@.
I!J Blower motor harness Resistor harness O.K.
connector® connector®

@
(Go to next page.)

Note:
- If the result is N.G. after checking circuit continuity, repair harness or
SHA319C
connector.

HA-69
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 1 (Cont'd)
Switch unit harness @ c D E
connector@

Y/R
Tm ._j ~ @] ~

CHECK RESISTOR AFTER

DISCONNECTING IT.
OR/B w
----K-~ _S2:'-)I---
(Refer to Electrical Components
Inspection.)

O.K. N.G.

SHA320C'
lrOFF~
c:::uuuu=> I Replace resistor.

Iii Switch unit harness

connector·@

[il
CIIIIIECT
e11!1 ni
3 Y/R
Reconnect resistor harness
connector.

1!1 [2] ~ @]
£)
~
BR

CHECK FAN SWITCH ~

~ CIRCUIT.
Do normal volts exist between

00 ~::>
SHA321C
switch unit harness connector
terminals?

Flow Normal
Terminal No.
chart No.
(Fan SW
voltage li
(Approx.)
position) EB 8 N.G. Do approx. 5 volts exist
-----+ between control panel terminal
[2] (1) 2V
No.@ and No.@?
~(2) 3V
@] (3)
® @
4V L
O.K.
~(4) 5V
Fan switch Replace fan switch.

~ [!1 O.K.
SHA322C
CHECK CONTROL AMP.
HARNESS TERMINAL
VOLTAGE.
Do approximately 12 volts or
0 volts exist between control
amp. harness terminal No. @ ,
@ , @. or @ and body ground?

Flow FanSW
Terminal operation
chart
No.
No. ON OFF
Approx.
~ @ ov 12V
Approx.
~ @ ov 12V
Approx.
@] @ OV
12V

~ @ ov Approx.
~,
12V Replace control amp.
I
O.K.

Replace blower motor.

HA-70
 TROUBLE DIAGNOSES - Manual Air Conditioner

Switch unit harness Diagnostic Procedure 2

connector® SYMPTOM: Air outlet does not change.
Y/R

liiiiii~H
e Perform PRELIMINARY CHECK 4 and Main Power Supply and
Ground Circuit Check before referring to the following flow
chart.
~ P/8

CIIIIIECT

E) CHECK MODE DOOR MOTOR N.G. Disconnect switch unit harness

f---t connector.
00 SHA323C
POSITION SWITCH.
Measure voltage between switch
unit harness connector terminal (;] l
No.® and@. Do approximately 5 volts exist
(;] Switch unit between switch unit harness
harness connector @ Terminal No.
Mode Voltage connector terminal No. ®
[±31 Ill 1~ [il-•cr
18 1
switch ffi 8 (Approx.)
and@.
1 VENT
B/L
5V
4V
N.G. ! O.K.
BR Y/R

00 FOOT
F/D
DEF
® @ 3V
2V
ov I Replace switch unit.
I
I vi [i
'-~ 81---'
'----
O.K. Do approximately 5 volts exist
SHA324C
between control amp. harness
connector No. ® and @.

l
l
N.G. O.K.

Repair harness or
connector.

Replace control amp.

Control amp.
harness connector®
lil
~,
I
SHA325C
Measure voltage between control Repair harness or connector.
amp. harness connector terminal
No.® and@.

Mode Terminal No. Voltage

switch (Approx.)
ffi 8
VENT 5V
B/L 4V
FOOT ® @ 3V
F/D 2V
DEF ov
Control amp.
harness connector@
SHA326C
O.K.
1!11
Mode door
motor harness
connector@
CHECK BODY GROUND
CIRCUIT FOR MODE DOOR
H Repair harness or connector.

Ellis;=;'';=;'=4m-¥o-i!==;<=lXl:;;:::::::;:=:;'11 ~ i5 MOTOR.
Does continuity exist between
mode door motor harness
B connector terminal No.® and
body ground?

~O.K.
SHA327C

HA-71
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 2 (Cont'd)
@

f~\
1
Control amp.
harness connector®
Check circuit continuity
between each terminal on
R
NG
Repair harness or connector.
J

i[;;:aJWpm
IB/A ~ control amp. and mode door
motor.

II
I
II
W/LI
I
I Y/G
I
GY I
I
I
GY

amp.
Terminal No.
Control Mode door Continuity
motor
I
I .... ___
I
:~
I
....~
I
:
----~~---~ . ®
®
®
®
® @and@
Yes
,,. ,-- .,,,~r-,~-,-----" ® ®
1 la:l,:la:la:IC11 a: I> > @ @and@
l"'liiii:S:IOiii;l)::l 0 IC1 C1
® ®

.JM~ 1m
Mode door motor
[!1
CHECK FOR OUTPUT OF
O.K.

~ Replace control amp. J

connector® CONTROL AMP. L-----------------------~

SHA328C Do approximately 12 volts exist

between control amp. harness
Control amp. terminal No.® and® when
harness connector ® mode is switched from "VENT"
to "DEF" or when mode is
switched from "DEF" to
"VENT"?

Terminal
Mode door motor
No.
Mode Direction
® ® door of linkage
SHA329C operation rotation

8 8 Stop Stop
VENT-+
8 EB DEF
Clockwise

DEF-+ Counter-
EB 8 VENT clockwise

O.K.

Replace mode door motor.

HA-72
 TROUBLE DIAGNOSES - Manual Air Conditioner

m harness
Intake door motor
Diagnostic Procedure 3
connector ® SYMPTOM: Intake door does not change in VENT, 8/L, or FOOT
mode.
e Perform PRELIMINARY CHECK 1, and Main Power Supply and
Ground Circuit Check before referring to the following flow
G/W
CYJ chart.
'-----+~ffi+ .:::::_8+-----..

CHECK POWER SUPPLY FOR ~ Check intake door motor J

INTAKE DOOR MOTOR. power supply circuit continuity.
SHA330C Disconnect intake door motor
harness connector.
Do approximately 12 volts exist
between intake door motor
harness terminal No. @ and
body ground?

O.K. [!]
[;]
Select VENT mode and check N.G. Check the voltage between
f----+ control panel harness connector
the voltage between intake door
motor harness terminal No.®, terminal No. @land@.
SHA331C @, @ and body ground. Terminal
Voltage
A/C.switch No.
Terminal voltage (Approx.)
Switch unit A/C REC (Approx.) ® @
Mode
switch switch ov
harness connector @
Y/R
® @ @ Switch pressed
EB e
[2111 I I llll~lli
Switch free 5V
ON ON REC 12V 12V ov

CONNECT
ON

OFF
OFF

OFF
REC/
FRE
FRE
12V

OV
ov
12V
12V

12V
N.G. l O.K.

E) W/B
I Replace control amp.
I
O.K.

00 I Replace intake door motor.

I Disconnect control panel con-
SHA332C nectar.

Switch unit
connector@
I
lil
r:t1 I I I ITII~S
IIISCIIIIIIECT
Check circuit continuity
between control panel terminal ~ Replace control panel.

18 No.@) and@.

Continuity
REC switch between terminal
No. @land@
Switch pressed Yes
SHA333C
Switch free No

O.K.
II
Check circuit continuity
between control panel harness
~I Repair harness or connector.
I
terminal No. @l (@)and
control amp. harness terminal
No. @l (Qj)).
O.K.
Control amp.
'------h-ar_n_e_ss_co_n_ne_ct_o_r____s_H_A_3_3_4_c...J I Replace control amp.

HA-73
 TROUBLE DIAGNOSES - Manual Air Conditioner

Compressor harness Diagnostic Procedure 4

connector@
SYMPTOM: Magnet clutch does not engage with A/C switch and

A/C switch
~ [11
G
i5 (lfe, fan switch ON.
e Perform PRELIMINARY CHECK 2 before referring to the

~ID
ON
following flow chart.

'-----~~~B
§~-~--~
O.K.
CHECK POWER SUPPLY FOR Check magnet clutch coil.

SHA335C
COMPRESSOR.
Disconnect compressor harness l N.G.
connector.
Replace magnet clutch.
A/C relay harness Do approximately 12 volts exist
A/C switch Refer to COMPRESSOR-
connector@ between compressor harness
ON Model DKS-16H (DIESEL-KIKI
[ii~G
connector terminal No. @ and
make).
body ground?

liJ l N.G. lil

CHECK A/C RELAY N.G.
OPERATION.
r--- CHECK POWER SUPPLY FOR
A/C RELAY.
Do approximately 12 volts exist Disconnect A/C relay.
between A/C relay harness Do approximately 12 volts exist
SHA336C connector terminal No. @ and between A/C relay harness
body ground? terminal No.@.® and body
A/C relay harness
Compressor harness ground?
connector® connector@

m lO.K.

Disconnect A/C relay harness

IO.K. N.G.

connector.
G
[;] l Note
CHECK POWER SUPPLY
CIRCUIT AND FUSE AT
Check circuit continuity FUSE BLOCK.
between A/C relay harness (Refer to "POWER SUPPLY
SHA337C
connector terminal No. @ and ROUTING" in EL section and
compressor harness connector A/C ELECTRICAL CIRCUIT.)
terminal No. @.

=r&;!Q
A/C relay harness
connector®

G~ [it
G/W i.-.ct
l
EO CHECK A/C RELAY AFTER
H Replace A/C relay.
DISCONNECTING IT.
00 (Refer to Electrical Components
Inspection.)

SHA338C l O.K.

Reconnect A/C relay.

1
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-74
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 4 (Cont'd)
Low-pressure switch
harness connector @

T
CHECK COIL SIDE CiRCUIT
N.G.
Check circuit continuity
LG/B OF A/C RELAY.
r-----. between A/C relay harness
Do approximately 12 volts exist connector terminal No. ® and
between low-pressure switch low-pressure switch harness
harness connector terminal No. connector terminal No. @>.
@ and body ground?
SHA339C O.K.
It Ill Note
A/C relay harness Low-pressure switch Do approximately 12 volts exist N.G. Check circuit continuity
connector@ harness connector @
between E.C.C.S. control unit
r---+ between low-pressure switch
harness terminal No. ® and harness connector terminal No.
body ground? ® and E.C.C.S. control unit
harness connector terminal
O.K.
LG/B
LG/B No.®.

lO.K. Note
CHECK LOW-PRESSURE
SHA340C
SWITCH.
(Refer to Electrical Components
It E.C.C.S. control unit
connector @
Inspection.)

II c-'UNIT fof CONNECTOR II ~i)

9
l N.G.

A/Cswitch ~ Replace low-pressure switch.

OFF
OR
Iv I tl4 0
@e Do approximately 8 to 9 volts N.G. CHECK E.C.C.S. CONTROL
For terminal arrangement, refer to exist between E.C.C.S. control UNIT.
Circuit Diagram for Quick Pinpoint Check. (Refer to EF & ECsection.)
unit harness connector terminal
SHA341C -= No. @ and body ground?

Ill
~ -·CT 00
10 ~
Low-pressure
switch connector
O.K.

Disconnect thermo. amp.

II B II @) d'® harness connector.

l
c-'UNI T CONNECTOR
E.C.C.S. control 9
O.K.
unit connector
OR
® OR @
-
For terminal [ill
arrangement
refer to Circuit -
Diagram for Quick Pinpoint Check. SHA342C

D
II CAJNIT B CONNECTOR II ~ i)
E.C.C.S. CO'""' ... A/C ~'"h@)
unit connector OFF

SB lVI ON
-f<£) C::::Jr----.
L.::.-....::..

For terminal arrangement, refer to

Circuit Diagram for Quick Pinpoint Check.
Note:
If the result is N.G. after checking circuit continuity, repair harness or
SHA343C -=
connector.

HA-75
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 4 (Cont'd)
IISCIIIIIIEtT

lV
00 Thermo control

rr=!l
c;\ OFF amp. harness
connector@

====~:::::::=::~==r=iJOft=CONN=E=c=:so=R,IIIW3lj]
IJ T
Check circuit continuity
Note

E.C.C.S. control
between thermo. control amp.
unit connector @ harness connector terminal No.
SB L/B ® and E.C.C.S. control unit
For terminal arrange- harness connector terminal No.
ment, refer to Circuit @.
Diagram for Quick
Pinpoint Check. SHA344C
l O.K.
Thermo control amp. N.G.
harness connector ® CHECK POWER SUPPLY FOR CHECK POWER SUPPLY
THERMO. AMP. CIRCUIT AND FUSE AT FUSE
GM IMJ=MI [it i) Do approximately 12 volts exist
between thermo. amp. harness
BLOCK.
(Refer to "POWER SUPPLY
connector terminal No. @ and ROUTING" in EL section and
body ground? A/C ELECTRICAL CIRCUIT.)

l O.K.

SHA345C
Is the voltage between thermo.
amp. harness connector ter-
~L~_~_h
1 ..... ~ep
___
ace t ermo. contro 1 amp.
_----.~l.
minal No.@ and body ground
Thermo control amp. less than 1V?
harness connector@

lb<bf=@J [it i) 00 l O.K.

Note
Check continuity between
W/B [YJ thermo. control amp. harness
'---~k+l:t+) Ale-)!----.. connector terminal No. @ and
control amp. harness connector
terminal No. @.

S.::346C Ill
.------L------~
l O.K .

CHECK A/C SWITCH OF N.G. Disconnect switch unit con-

II) Thermo control amp.
harness connector ®
Control amp.
harness connector
®
SWITCH UNIT.
Check the voltage between
nector. I
IW~I!Il III FFtl I I II switch unit harness connector
terminal No. ® and (j}).
12J W/B
W/B REC switch
Terminal
No. Voltage
(Approx.)
@ Qi)
In I
'---- 00
SHA347C
Switch pressed
Switch free EB 8
ov
5V

Ill Switch unit

harness connector®
l O.K.

Y/R I Replace control amp.

[:d lU±sl I I 0
11
1 11
CONNECT
E) R
-
©
[JZJ
00 <:Be-
-=---=-
SHA348C
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-76
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 4 (Cont'd)
Switch unit harness
connector®

[11 [Q]sl ? ll,,fl

Y/R 1
Check circuit continuity H Replace switch unit. j

DISaiiiiiECI between switch unit harness L-------------------~

10 R
connector terminal No. @ and
@.

00 A/C switch
Continuity
between
terminal No.
SHA349C
@and@
Switch pressed Yes
r!'l Switch unit
Switch free No
harness connector ®

Jffi,l?ll' O.K.
Note

R I Y/R Check circuit continuity

I between switch unit harness
I connector terminal No. @ (@)
I
I and control amp. harness con-
I nector terminal No. @ (@l.
I
I
'. O.K.

Replace control amp.

,. ------
1
I

! I Y/R

~
R

m;d>d\sW
Control amp.
harness connector ® SHA350C

Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-77
TROUBLE DIAGNOSES - Manual Air Conditioner

Diagnostic Procedure 5
SYMPTOM: Illumination or control panel indicators do not come
on.
• Perform Main Power Supply and Ground Circuit check before
referring to the following flow chart.

Turn ignition switch and lighting switch ON.

CHECK ILLUMINATION AND INDICATORS.

• Turn A/C, REC and fan ON.
• Rotary VENT, 8/L, FOOT, F/D and DEF switches in
order.
• Check for incidents and follow the repairing methods as
shown.

INCIDENT

ILL
How to repair
Control A/C REC
panel

Go to DIAGNOSTIC
X 0 0
PROCEDURE 5-1.
Go to DIAGNOSTIC
0 X 0
PROCEDURE 5-2.
Go to DIAGNOSTIC
0 0 X
PROCEDURE 5-3.
Go to DIAGNOSTIC
0 X X
PROCEDURE 5-4.

0: Illumination or indicator comes on.

X: Illumination or indicator does not come on.

HA-78
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 5 (Cont'd)
DIAGNOSTIC PROCEDURE 5-1

CHECK THE OTHER ILLUMI- I N.G.~ CHECK ILLUMINATION SYS-

NATION SYSTEMS EXCEPT TEM.
FOR A/C SYSTEM. Refer to Illumination/Wiring
Do the other illuminations come Diagram in E L section.
on with ignition switch and
lighting switch ON?

10.K.
SHA351C
Turn ignition switch and lighting
(;J Switch unit switch OFF.
harness connector@
m l
CHECK ILLUMINATION
·BULB.
~I Replace illumination bulb(s).

Remove switch unit and dis-

connect harness connectors.
Remove illumination bulb(s)
and check them.

SHA352C
IE) 10.K.
N.G.
CHECK POWER SUPPLY FOR CHECK POWER SUPPLY FOR
ILLUMINATION WITH ILLUMINATION SYSTEM.
LIGHTING SWITCH ON. Refer to Illumination/Wiring
Do approximately 12 volts exist Diagram in EL section.
between switch unit connector
harness terminal No. CD and
body ground?

l O.K.

CHECK TIME CONTROL

SYSTEM.
Refer to TIME CONTROL
SYSTEM in EL section.

HA-79
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 5 (Cont'd)
r.w Control amp. harness DIAGNOSTIC PROCEDURE 5-2
liil Switch unit harness ~
connector @) connector ~

~.CJij
5m
N.G.

m!1111115
L/R L/R
CHECK MAGNET CLUTCH
OPERATION.
Does magnet clutch operate
r---+ Go to Diagnostic Procedure 4.

~~.
normally when engine is ON and
A/C switch, fan switch are ON?

r2ili5 m l O.K.

Check continuity between

SHA853C
switch unit harness connector
terminal No. @ and control
amp. harness connector terminal
No.@.

l N.G.

Replace switch unit.

Control amp. harness DIAGNOSTIC PROCEDURE 5-3

EJ Switch unit harness
connector ®
connector®

Hll i£8 7 BihlTI:n CHECK INTAKE DOOR

OPERATION.
~I Do to Diagnostic Procedure 3.

L/8 L/8
Does intake door operate
normally when engine is ON and
IQI A/C switch, fan switch are ON?
-=--------=-
[ili5 m l O.K.

SHA854C Check continuity between

switch unit harness connector
terminal No. (j) and control
amp. harness connector terminal
No. (j).

lN.G.

Replace switch unit.

HA-80
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 5 (Cont'd)
liJ Switch unit harness connector@
DIAGNOSTIC PROCEDURE 5-4

lU4111111l ~ i5 Turn ignition switch and lighting

switch OFF.

G/W

----!<@±)
[YJ
~c:-~--....
l
L...:....-..;.. Disconnect switch unit harness
connector.

SHA356C
m l N.G.
CHECK POWER SUPPLY Check harness of switch unit
FOR SWITCH UNIT power supply circuit.
(;) Control amp. harness connector @ Do approximately 12 volts exist (Refer to "POWER SUPPLY
~ ~-~ between switch unit harness ROUTING" in EL section and
1111112m ~ 18 connector terminal No. @ and
body ground?
A/C ELECTRICAL CIRCUIT.)

In I
B
(;) l O.K.

CHECK BODY GROUND

Cl RCUIT FOR CONTROL
-
SHA357C
AMP.
Does continuity exist between
control amp. harness connector
terminal No. @ and body
ground?
l O.K.

Replace control amp.

HA-81
 TROUBLE DIAGNOSES - Manual Air Conditioner

m Switch unit harness Diagnostic Procedure 6

connector@ SYMPTOM: Temperature of air outlet does not change.
[11
I I I 1om
is Y/R
CIIIIIECT
£) CHECK TEMPERATURE
CONTROL LEVER.
M Disconnect control amp. harness
connector.

00
p
Measure voltage between
control panel harness connector
terminals No. @and ([j).
1§11 1
Check if approximately 5 volts
Temp. Terminal exist between control panel
SHA521C Voltage
control No. harness connector terminals
(approx.)
(!] Control amp. harness connector
lever
® e No. @ and ([j).
® [il Full hot
Full cold
@ (j])
5V
ov N.G. lO.K.
CIIIIIET
£) (!] O.K.
I Replace control amp. I
p 00 Measure voltage between
control amp. harness connector
terminals No. @ and ([j).
@ (Go to next page.)

Temp. Terminal
No. Voltage
control
(approx.)
SHA522C lever
® e
Full hot 5V
@ (j])
[I Control amp. harness~ ~ ,1iit\\ Full cold ov
connectors @) lolll'll s=t.J ~
O.K.
[I
Check continuity between each
terminal of control amp. and
air mix door motor.
H Repair harness or connector.

Terminal No.
Air mix Continuity
Control
door
amp.
motor

~w ~!»
~r ~
liJ Control amp. harness ~· cyr, Yes
connector @) ~t @
'll~ ®
IIIII f±l1 liJ O.K.

CHECK FOR CONTROL AMP.

OUTPUT.
Check if 12 volts exist between
H Replace control amp.

control amp. harness connector

SHA524C
terminals No. ® and ®when
temp. control lever is moved.
H Replace air mix door motor.

Terminal Air mix

Switch unit harness ~ -~~ No. door motor Direction of
connector@ \..m V Air mix linkage
~.91 @J door rotation
operation

e 8 Stop Stop
BR e ® Cold-Hot Clockwise
Counter·
® e Hot-Cold
clockwise

SHA525C

HA-82
 TROUBLE DIAGNOSES - Manual Air Conditioner
Diagnostic Procedure 6 (Cont'd)
@
[itij
~ ---..
lWHffijij--aR Check if approximately 5 volts
exist between control amp.
H Replace control amp.
L---------------------~
J
Y/R Control amp.harness harness connector terminals
connector @ No. @ and (j]).

O.K.

SHA526C
Repair harness or connector.
I

HA-83
 TROUBLE DIAGNOSES - Manuai.Air Conditioner

Electrical Components Inspection

FAN SWITCH
Check resistance between terminals at each switch position.

Resistance between terminals No. @ and @)

Switch position
(Approx. n)

OFF 710
1 1,140
2 460
3 270
Switch unit connector 4 0

BLOWER MOTOR
Confirm smooth rotation of the blower motor.
• Ensure that there are no foreign particles inside the intake unit.

BLOWER RESISTOR
Check continuity between terminals.

HA-84
 TROUBLE DIAGNOSES - Manual Air Conditioner
Electrical Components Inspection (Cont'd}
A/C SWITCH
Check continuity between terminals at each switch position.

Switch condition Terminal No. Continuity

While A/C switch is pushed ® @ Yes

While REC switch is pushed @ @ Yes

Switch unit connector @

00i5 ~ WsllB~
11
A/C switch
~
1
I
I
I ....
I
____ _

SHA362C

LOW-PRESSURE SWITCH

High-pressure side line pressure

•
Operation Continuity
kPa (kg/cm 2 , psi)

196 (2.0, 28) Turn OFF Does not exist

Low-pressure switch '

~~~c
206 (2.1, 30) Turn ON Exist

RELAYS
Check circuit continuity between terminals by supplying 12 volts to
coil side terminal of relay.

RHA675A

HA-85
TROUBLE DIAGNOSES - Manual Air Conditioner
Electrical Components Inspection (Cont'd)
MODE SWITCH
Check resistance between terminals at each switch position.

Switch position
Resistance between terminals No. ® and No. ®
(Q)

VENT 0

B/L 270

FOOT 460

FOOT/DEF 1,140

DEF 710

SHA364C

THERMO CONTROL AMP.

1. Run engine and operate A/C system.
2. Connect the voltmeter from harness side.
3. Check thermo control amp. operation shown in the table.

Evaporator outlet air

Thermo amp. Voltage
temperature
oC (oF) operation (Approx.)

Decreasing to 3.0 (37) Turn OFF 12V

Increasing to 4.5 (40) Turn ON ov

HA-86
 TROUBLE DIAGNOSES - Manual Air Conditioner

Control Rod Adjustment

MODE DOOR
1. Move side link by hand and hold mode door in VENT mode.
2. Install mode door motor on heater unit and connect it to
harness.
3. Turn ignition switch to ON.
4. Turn VENT switch ON.
5. Attach mode door rod to side link rod holder.
6. Check that when DEF position is selected, only DEF door is at
full-open position, and when VENT position is selected, only
VENT door is at full-open position.

INTAKE DOOR
1. Install intake door motor on intake unit.
2. Connect intake door motor harness connector.
3. Turn ignition switch to ON.
4. Turn REC switch ON.
5. Install intake door lever.
6. Set intake door rod in REC position and fasten intake door rod
to holder on intake door lever.
7. Check that intake door operates properly when REC switch is
turned ON and OFF.

Intake door rod

Intake

Intake
door

HA-87
TROUBLE DIAGNOSES - Manual Air Conditioner
Control Rod Adjustment (Cont'd)
AIR MIX DOOR
1. Connect harness to air mix door motor and set temperature
control lever at full-cold position.
2. Set air mix doors I and II at full-cold position and fasten door
rod.
3. Check that when temperature control lever is at full-cold, both
doors are at full-cold position, and when temperature control
lever is at full-hot, both doors are at full-hot position.

SHA309C

WATER COCK CONTROL CABLE

Clamp cable at full-close position when air mix doors I and II are at
full-cold position, and full-open position when air mix doors I and II
are at full-hot position.

HA-88
 TROUBLE DIAGNOSES -.Manual Air Conditioner

NOTE

HA-89
 TROUBLE DIAGNOSES -··Auto. Air Conditioner

Contents
Symptom Chart ....... ...... ........ ........ ..... .. ... ...... ..... ......... .......... ... .... .... ...... ... .............. .. ... ..... .... ... .... .... .. .... .. .... .. ...... .... HA- 92
Self-diagnosis ....... ............... .... ...... .... .. .... .... ....... .. .. .... ............ .... .... ..... ... .. .... .. .. ...... ...... .... .... ...... .. ...... .... .. ..... ..... .... .. HA- 94
CHECKING PROCEDURE ................................................................................................................................. HA- 96
STEP 1: MONITOR DIAGNOSIS .............. :....................................................................................................... HA- 98
STEP 2: ACTUATOR TEST ............................................................................................................................... HA- 99
STEP 3: AUXILIARY MECHANISM ................................................................................................................. HA-100
STEP 4: READOUT OF TROUBLE DATA STORED IN MEMORY .............................................................. HA-101
Consult ...................................................................................................................................................................... HA-102
Preliminary Check ................................................................................................................................................... HA-103
PRELIMINARY CHECK 1
(Air outlet does .not change) ........................................................................................................................... HA-103
PRELIMINARY CHECK 2
(Intake door does not change) ....................................................................................................................... HA-104
PRELIMINARY CHECK 3
(Insufficient cooling) .......................................................................................................................................... HA-105
PRELIMINARY CHECK 4
(Insufficient heating) .......................................................................................................................................... HA-107
PRELIMINARY CHECK 5
(Blower motor operation is malfunctioning) .................................................................................................. HA-108
PRELIMINARY CHECK 6
(Magnet clutch does not engage) .................................................................................................................. HA-109
PRELIMINARY CHECK 7
(Discharged air temperature does not change) ........................................................................................... HA-110
PRELIMINARY CHECK 8
(Noise) ................................................................................................................................................................. HA-110
Harness Layout for A/C System .......................................................................................................................... HA-111
Circuit Diagram for Quick Pinpoint Check .. .. .. .. .. .. ...... .. .... .... .. .. ..... .. .... .. .. ...... .. .. .. .... .. ... .... .. ...... .. ...... .... .. .. .. ..... . HA-113
Wiring Diagram ........................................................................................................................................................ HA-114
Main Power Supply and Ground Circuit Check .. .. .. .. .... .... .... .... .. ...... .. .. .. .. ............ .... .. .. ...... .. .. ..... .. ..... ... .. .. .. .. .. . HA-116
Diagnostic Procedure 1
(SYMPTOM: Self-diagnosis detects intermittent short or open circuit in each sensor circuit) ........... HA-117
Diagnostic Procedure 2
(SYMPTOM: Ambient sensor circuit is open) .............................................................................................. HA-118
Diagnostic Procedure 3
(SYMPTOM: Ambient sensor circuit is shorted) .......................................................................................... HA-119
Diagnostic Procedure 4
(SYMPTOM: Upper in-vehicle sensor circuit is open) ................................................................................. HA-120
Diagnostic Procedure 5
(SYMPTOM: Upper in-vehicle sensor circuit is shorted) ............................................................................ HA-121
Diagnostic Procedure 6
(SYMPTOM: Lower in-vehicle sensor circuit is open) ................................................................................. HA-122
Diagnostic Procedure 7
(SYMPTOM: Lower in-vehicle sensor circuit is shorted) ............................................................................ HA-123
Diagnostic Procedure 8
(SYMPTOM: Def. duct sensor circuit is open) ............................................................................................. HA-124
Diagnostic Procedure 9
(SYMPTOM: Def. duct sensor circuit is shorted) ........................................................................................ HA-125
Diagnostic Procedure 10
(SYMPTOM: Vent duct sensor circuit is open) ............................................................................................ HA-126
Diagnostic Procedure 11
(SYMPTOM: Vent duct sensor circuit is shorted) ....................................................................................... HA-127
Diagnostic Procedure 12
(SYMPTOM: Floor duct sensor circuit is open) ........................................................................................... HA-128
Diagnostic Procedure 13
(SYMPTOM: Floor duct sensor circuit is shorted) ...................................................................................... HA-129

HA-90
 TROUBLE DIAGNOSES - Auto Air Conditioner
Contents (Cont'd)
Diagnostic Procedure 14
(SYMPTOM: Sunload sensor circuit is shorted) .......................................................................................... HA-130
Diagnostic Procedure 15
(SYMPTOM: Air mix door does not operate normally) ............................................................................... HA-131
Diagnostic Procedure 16
(SYMPTOM: Intake door does not operate normally) ................................................................................. HA-132
Diagnostic Procedure 17
(SYMPTOM: Mode door does not operate normally) .................................................................................. HA-133
Diagnostic Procedure 18
(SYMPTOM: Mode door does not move at all) ........................................................................................... HA-134
Diagnostic Procedure 19
(SYMPTOM: Magnet clutch does not engage) ............................................................................................ HA-135
Diagnostic Procedure 20
(SYMPTOM: Air conditioner control swtich panel illumination does not come on) ............................... HA-137
Diagnostic Procedure 21
(SYMPTOM: Set temperature and mode display do not appear on display window) ............................ HA-138
Diagnostic Procedure 22
(SYMPTOM: When air conditioner switch is operated it does not beep) ............................................... HA-139
Diagnostic Procedure 23
(SYMPTOM: Figures of set temperature do not appear on the display window
and indicator lamp (L.E.D.) does not come on) .......................................................................................... HA-140
Diagnostic Procedure 24
(SYMPTOM: Switches do not work) .............................................................................................................. HA-141
Diagnostic Procedure 25
(SYMPTOM: Blower motor operation is malfunctioning) ........................................................................ HA-142
Electrical Components Inspection ....................................................................................................................... HA-145
Control Rod Adjustment ........................................................................................................................................ HA-148

HA-91
 TROUBLE DIAGNOSES - Auto Air Conditioner

Symptom Chart
DIAGNOSTIC TABLE

Symptom Possible cause Diagnostic procedure

Air outlet does not • Mode door motor not o~erating correctly Proceed to Preliminary check 1, then to
change • Inaccurate sensor input Diagnostic procedures 17 and 18 if air mix
• No output to mode door motor from
auto amplifier
door is malfunctioning.

Intake door does not

change
• Intake door motor or mechanism
malfunctioning
Proceed to Preliminary check 2. If intake
door is at fault, go to Diagnostic procedure
• Inaccurate sensor input 16.
• No output to intake door motor from
auto amplifier

Insufficient cooling • Compressor clutch not engaged Proceed to Preliminary check 3. If air mix
• Air mix door motors not working
properly
doors do not operate properly, go to
Diagnostic procedure 15.
• Condenser fan inoperative Check compressor clutch operation and freon
• Low freon level level of system .

Discharged air • Air mix doors do not operate correctly Proceed to Preliminary check 7.
temperature does not
change
• Incorrect sensor input

Noise • Compressor belt tension Proceed to Preliminary check 8 .

• Blower motorcomponent
Compressor malfunction
• Radiator cooling fan interference
interference
•
Air conditioner control • Blown fuse Proceed to Diagnostic procedure 20.
switch panel illumi- • Blown bulbopen in harness
Loose or
nation does not come
on
•
Insufficient heating • Coolant temperature is low Proceed to Preliminary check 4. If air mix
• Air mix doors not in correct position doors do not operate correctly, go to
• Incorrect sensor input Diagnostic procedure 15.

Blower motor operation • Vents

Blower motor is not receiving power Proceed to Preliminary check 5. If blower
is malfunctioning • Motor may be obstructed motor is malfunctioning, go to Diagnostic
• Air intake obstructed
does not spin freely procedure 25.
• Blown fuse
•
• Malfunctioning blower relay
Magnet clutch does • A/C
Blown fuse Proceed to Preliminary check 6, then
not engage • Openrelay inoperative Diagnostic procedure 19 if clutch is at fault .
• Open ambient
in wiring
• Low freon levelsensor circuit
•
• Malfunctioning clutch assembly

HA-92
 TROUBLE DIAGNOSES - Auto Air Conditioner
Symptom Chart (Cont'd)

Symptom Possible cause Diagnostic procedure

No display on A/C • Blown fuse Proceed to Diagnostic procedure 20.

switch panel • Malfunctioning bulb

Set temperature and • Malfunctioning switch unit Proceed to Diagnostic procedure 21.
mode indication do not • Open in circuit
appear on display
window
• Malfunctioning auto amplifier

When air conditioner • Malfunctioning A/C switch Proceed to Diagnostic procedure 22 .

switch is operated, • Open in harness or connector
if does not beep • Malfunctioning auto amplifier

Set temperature and • Open in harness Proceed to Diagnostic procedure 23.

mode indication do not • Malfunctioning switch panel
appear in display and
indicator lamp (L.E.D.)
• Malfunctioning auto amplifier

does not come on

Switches do not work • Malfunctioning switch panel Proceed to Diagnostic procedure 24.
• Open in harness
• Malfunctioning auto amplifier

HA-93
 TROUBLE DIAGNOSES - Auto Air Conditioner

Self-diagnosis
CONSULT AND ONBOARD SELF-DIAGNOSTIC SYSTEM
Function of CONSULT and ONBOARD SELF-DIAGNOSTIC SYSTEM are as follows:

READOUT OF TROUBLE DATA

MONITOR CHANGE PARAMETER
ITEM STORED IN MEMORY

CONSULT ON BOARD CONSULT ON BOARD CONSULT ON BOARD

Ambient temp. 0 0 0 0

In-vehicle temp. (Upper) 0 0 0 0

In-vehicle temp. (Lower) 0 0 0 0

Duct temp. (Defroster) 0 0 0 0

Duct temp. (Ventilator) 0 0 0 0

Duct temp. (Floor) 0 0 0 0

Sun load 0 0 ·o 0

Water temp. 0 0

Mode door P.B.R. 0 0

In-vehicle target temp. (Upper) 0

In-vehicle target temp. (Lower) 0

Outlet air target temp. (Upper) 0 0 *0

Outlet air target temp. (Lower) 0 0 *0

Mode door target position 0 0 *0

Intake door target position 0 0 *0

Blower motor target voltage 0 0 *0

Difference between upper and

0 0 *0
lower target temp.

Output signal to compressor 0 0 *0

Set temp. 0

Selected mode 0

Operated switches status 0

Manual select status 0

*· These can be set by self-diagnosis step II; their combinations are as follows:

Actuator test

doorio~ O~j·
.,
Code Intake Outlet AIM door Comp. Code Voltage
• Mode SET
~ 4V voltage [60. 60
Press
MODESW.l
f.l
Outside air DEF Full Hot OFF Press
FANSW.l
8t 6V
o8f9 • ~- STEP monitor
~~~~tor _J·~q *,Jl
Ouuide air FOOT Full Hot OFF

;)

-;
Partial outside air

Recirculation air
B/L

VENT
30'C (86'FI

Full Cool
ON

ON
,
~ 9V

12V
. 0

L ·):J~ ~
-·--·--·
~
J.

*: Mode door voltage: 0 =VENT, 5 = DEF

Ten times the value in V.
SHA755C

HA-94
 TROUBLE DIAGNOSES -Auto Air Conditioner
Self-diagnosis (Cont'd)
The self-diagnostic system diagnoses the sensors, door motors,
blower motor, etc. by system line. Refer to applicable sections
(items) for details. Shifting from normal control to the self-
diagnostic system is accomplished by starting the engine
(turning ignition switch from "OFF" to "()N"), and pressing
both the (AUTO) and (OFF) switch for at least 5 seconds.
This system will be cancelled by either pressing the (OFF)
switch or turning the ignition switch "OFF". Shifting from one
step to another is accomplished by means of pushing the
(AUTO) switch, as required.

Start engine.
(Ignition switch OFF-+ ON)

l
I
Press !AUTO switch, while continu-
ing to press it press IOFF I switch.
Hold these two switches for at least 5
seconds.

.I
~~

STEP 1 Ignition switch: OFF

B~
Monitor diagnosis 9Jt-:te..-
joFFj switch: PRESS

l
Press jAUTOj switch.

l
STEP 2
§.~
Ignition switch: OFF
r Self-diagnostic function is
Actuator test c••
jOFFj switch: PRESS
"Icancelled. I
!
Press jAUTOj switch.

STEP3
l ~~ Ignition switch: OFF
91---
Change of difference between upper
and lower target temperatures joFFj switch: PRESS

l
Press jAUTOj switch.

STEP4
l ,_,_ Ignition switch: OFF
Readout of trouble data memory
loFFj switch: PRESS
l
Press jAUTOj switch.

HA-95
 TROUBLE DIAGNOSES - Auto Air Conditioner
Self-di~gnosis (Cont'd)
CHECKING PROCEDURE Note

Start engine.

Check if
SET and Mode data
(VFD display)
illuminate.
No
I Faulty wiring or VFD
I
Yes
Set in self-diagnostic mode.
(Press AUTO switch, while continuing to press it
press OFF switch. Hold these two switches for
at least 5 seconds.)
Yes
Check if
air conditioner operates No
Faulty "AUTO" or "OFF" switch
and ~~~-appears.

Sensor monitor

§J,_ STEP 1 Code Item Unit Code Item Unit

I SENSOR MONITOR •; Ambient temperature 81 •; -

1-------
~ -; Upper companment
temperature 81 -; -

r1 Identification data of each sensor is Lower compartment

f--
81 J -
shown.
P~u
FANSW.
i 86' •;
J temperature

DEF outlet air temperature

°C (°F)

~ •;
-;
Internal data 1-------

f--
-
8e -; ~ -
+
VENT outlet air temperature
f--

y Press MODE switch or FAN switch.

·~..
MODESW. 1 l!e..J
~ •;
FOOT outlet air
tempereture

Sun load ., ,~ ..)

-; 0 ifference between upper and

tovvertarget temperatures
-
•ci°FI

~ -; °C I°F)
IC..J -
+
Water temperature •3 Internal data
i

~ J Mode do~¥ voltage • 4 '2

Press AUTO switch.
*1: One tenth of the value in kcat/h·m 2 unit
•2: Ten times of the value in V
•3: When coolant temperature is below 4o"C (104°F), indicates 2o"C (68°F)
When coolant temperature is avove 4o"C 1104° FJ, indicates a(fc (176DFJ
•4: Mode door voltage: 0 • VENT,5 = OEF

Data __rq:·--~
D'dJ D'dJj
)j-
monitor SET
lb0_60
STEP monitor

§J~- I STEP2
ACTUATOR TEST
~
~~n~tor_J
L
:.
-~-J
~l
SHA754C

,. Code No. of actuators test pattern is

indicated on display.
Actuator test
Code Intake Outlet A/M door Comp.

Press
CJ Outside air DEF Full Hot OFF

~ MODESW.l
s
y
Outside air FOOT Full Hot OFF

Press MODE switch or FAN switch. :; Partial outside air B/L 30'C (86'F) ON

-; Recirculation air VENT Full Cool ON

~
Code Voltage
• Mode door _JD;:=t §1J SET
c::>. ;:j
~ 4V voltage !§ _bG
Press
"?o~ • .i!!l-
~ STEP monitor

Note:
FAN SW.l ~ 6V
Code
monaor J
L ~-J
li
"!,
1. Without engine running, STEP 1 and.2 are not useful Qt 9V •: Mode door voltage: 0., VENT,

•
5 • OEF
for some case because compressor not operate. 12V Ten times the value in V.
SHA755C

HA-96
 TROUBLE DIAGNOSES - Auto Air Conditioner
Self-diagnosis (Cont'd)

Press AUTO switch.

STEP 3 ..... STEP 3 should not be used for diagnostic purposes.

r

Press AUTO switch.

STEP4
READOUT OF TROUBLE
DATA STORED IN MEMORY

~
[No. of engine starts/stops occurring
--. since last problem was detected for
each sensor]

~ Press MODE switch or FAN switch.

Press OFF switch.

END

Readout of trouble data stored in memory

Code Item Trouble diagnosis criteria Remarks

Ambient sensor trouble Less than -70°C (-94.FI

GPJ data Greater than 141-°C (286°FI

Upper in-vehicle sensor

•j trouble data

lower in-vehicle sensor

,J
Press ~ trouble data

Less than -38•c (-36°F}

FAN SW.
8e •; OEF Duct sensor trouble
data Greater than t41°C (286°FI

8e -; VENT Duct sensor trouble

l
data

Press FOOT Duct sensor trouble

MOOESW. 8B ,J data

Sunload sensor trouble Detects only

~ GPJ data
- short circuit

~0~
Trouble data---t vc:::::>v c::::?J SET
Open circuit l~_bG=
PoL!II w Ill!!!;..
Short circuit I e-lSTEP · monitor Trouble data
No. of IGN ON/OFF operations since
Code monitor· ~,I
I_ ___"Y_J last trouble was detected.
50: No problem
49- 01: Problem existed
0: Problem exists
SHA756C

HA-97
 TROUBLE DIAGNOSES - Auto Air Conditioner
Self-diagnosis (Cont'd)
STEP 1: MONITOR DIAGNOSIS
By setting in self-diagnostic mode, VFD display shows that Step 1
Data ~---~
monitor--IOd OdJ. SET mode has begun.
lbO_bQ In this mode, each time the FAN or MODE SW is pressed, the
ogrg =-~-- STEP monitor code monitor changes in turn, and data corresponding with each
~~~~tor-!. ©a@ ~
L -~
- - - -~,J
---·
•1 code appears in the data monitor.

If the temperature shown on the display greatly differs from the

actual temperature, check the sensor circuit first, then inspect the
sensor itself according to the procedures described in Electrical
SHA754C
Components Inspection.

* For cross-reference of code and corresponding data, refer to

"Sensor monitor" in "Checking procedure".

Code Item Unit Code Item Unit

•; Ambient temperature 81 •; -

-; Upper compartment
temperature 81 ..J -
Lower compartment
J temperature 81 .J -

Press
FANSW.
r Be•J DEF outlet air temperature
•c (°FI

~ •;
Internal data
-

8fJ I..J VENT outlet air temperature ~ ..J -

Press
MODESW.
1 ge ~ FOOT outlet air temperature
~ .J -

~ •J Sunload *1
• -; Difference between upper and
lower target temperatures
°C (°F)

~ ..J
~ J
wa·ter temperature *3 .

Mode door voltage*4

•c (°FI

*2
• ..J Internal data -

*1: One tenth of the value in kcal/h·m 2 unit

*2: Ten times of the value in V
*3: When coolant temperature is below 40"C (104°F), indicates 2o•c (68°F)
When coolant temperature is avove 40°C (104°F), indicates so•c (176°F)
*4: Mode door voltage: 0 =VENT, 5 = DEF

HA-98
 TROUBLE DIAGNOSES - Auto Air Conditioner
Self-diagnosis (Cont'd)
STEP 2: ACTUATOR TEST
By pushing the AUTO SW once, self-diagnosis is changed from
step 1 to step 2.

During inspection in STEP 2 mode, the auto amplifier will forcefully

transmit an output to the affected actuators in response to the
code shown on the display, as indicated in the table below. Each
operating condition can be set in turn by pressing FAN or MODE
*:Mode door voltage: 0 =VENT, sw.
5 = DEF Checks must be made for improper operation visually, by listening
Ten times the value in V. SHA 755 c to any noise, or by touching air outlets with your hand, etc.

Press Press
~
MODE SW. FAN SW.

~
A

Mode door
!®J

DEF
.....
®•

p/FOOT
....••

B/L
.~ ·;
VENT
~
Voltage
r
~

4V
81
6V
~

9V
•
12V

50%
Intake door FRE FRE REC
FRE

Full Full 30°C Full

Air mix door
Hot Hot (86°F) Cold

Compressor OFF OFF ON ON

Operating condition of each actuator cannot be checked by

indicators.

1) Mode and fan speed can be set independently.

2) When ':J appears, air mix door activates.
A stabilized outlet temperature 30°C (86°F) is reached after air mix door has been operating for
approximately one minute.

HA-99
 TROUBLE DIAGNOSES - Auto.·Air Conditioner
Self-diagnosis (Cont'd)
Difference between STEP 3: AUXILIARY MECHANISM
target
temperatures
Changes of difference between upper and lower target tempera-
tures.
""-r© 0~1· SET
[60.60
Figures in parentheses "( )" refer to values for "°F" specifi-
. og~ - ~-.- STEP monitor cations.
Each time the "MODE" switch is pressed, the number in the SET
~~~
-~ ~,.
.l section advances. This number will increase up to 20 for °C
L___~_.J specifications and 36 for °F specifications. Each time the "FAN"
switch is pressed, the number decreases. This number decreases
to -20 for °C specifications and -36 for °F specifications.
SHA760A
For °C specifications, pressing the "MODE" or "FAN" switch each
time increases or decreases the data number by "1" degree (and
by "1" through "3" degrees for °F specifications).

Press Press )
FAN SW. MODESW.

Data -20 ---- -1 0 1 ---- 20

°C specifications Difference between

upper and lower -2.0°C ---- -1°C 0°C 0.1°C ---- 2.0"C
target temperatures

Data -36 ---- -2 0 2°C ---- 36

° F specifications Difference between

upper and lower -3.6°F ---- -0.2°F .0°F 0.2°F ---- J:6°F
target temperatures

Difference between upper and lower target temperatures changed in the preceding procedure is kept until the next change is
done or the battery cable is removed.

HA-100
 TROUBLE DIAGNOSES - Auto Air Conditioner
Self-diagnosis (Cont'd)
STEP 4: READOUT OF TROUBLE DATA STORED IN
MEMORY
By pushing the AUTO SW once in step 3, self-diagnosis is changed
to step 4.
In this mode, each time the FAN or MODE SW is pressed, the
code monitor changes in turn, and data or status of each sensor
appears in the data monitor.
When the sensor becomes inoperative, the number of IGN ON/OFF
operations occurring since the last trouble was detected appears
in the SET section.
SHA756C
Open circuit or short circuit is indicated by " 0 " or "o".

Conditions for open or short circuit

Code Sensor Open circuit Short circuit

®·
... Ambient sensor Less than -70°C (-94°F) Greater than 141°C (286°F)

-; Room upper sensor Less than -38°C (-36°F) Greater than 141°C (286°F)

....1• Room lower sensor Less than -38° C (-36° F) Greater than 141°C (286°F)

00®J DEF duct sensor Less than -38°C (-36°F) Greater than 141 o C (286° F)

fJB -; VENT duct sensor Less than -38°C (-36°F) Greater than 141 o C (286° F)

00 . . ; Floor duct sensor Less than -38°C (-36°F) Greater than 141°C (286°F)

Greater than 1. 784 kW (1,534 kcal/h, 6,087

Open circuit can not be
~®J $unloaded sensor BTU/h)/m 2 [19.19 kW (16,506 kcal/h, 65,502
detected by self-diagnosis.
BTU/h)/sq ft)

HA-101
 TROUBLE DIAGNOSES - Auto Air Conditioner

Consult
CONSULT INSPECTION PROCEDURE
CONSULT
1. Turn off ignition switch.
2. Connect "CONSULT" to diagnostic connector.
(Diagnostic connector is located in left dash side panel.)

SMA185C

~----•w--w,,,,_,.... __,____,,...._,,_.__,1 3. Turn on ignition switch.

! i 4. Touch "START".
~ i '!' ,-.,-.,.· .• :.!
i'"il-:•-:•Hl'"i I
i

r=:: r=J t··-..~ :::~: L.J ~

I ;
~-=--====~======-~
! ·:::· -r· r\ !=:o ·-r
··--·' i ,,.:..."",t ·.. !
.rl

1' !
I
; =:-=::-F~=~- r; r-·, r
;1 ,.-., ~
J ··-·' 1._.: L_) f '=' ! !_.r L__.i t::. .
'---··--------·--·---'
SEF3921

5. Touch "AUTO A/C" .

.t:... !._.! T fJ A ,/ i._::

HI r._...•. l'o o:_·. ~.-._:•
i

i
SHA535C

6. Perform each diagnostic mode according to the inspection

q .....
L_Ji
~::::::::::..-:::::::.7.:::~:::::~~=-·~::::::::::.~::::::::::::::=::::=::::::::=:=::-~9
sheet as follows:
' --- ·:: ·_,-';--..,. For further information, read the CONSULT Operation Manual.
~-==::--=============--==~
:_~~-~..F-f_)-_iL.~G RESULTS ~
~~==--=========~=--~
, ;~ i H ;:-;~) T Tr·;~· j
~=::::-:::=.::==--====--===:==-.-====--==~
~(:TI!JE TEST i
!:=:.~::::-~:::::::=:::::::::::::::=:::======== :

[ ECU F'.ART NUMBER !

i====::::::::::-.::::.======-.::=====-~

L____________________j
' i

SEF3941

HA-102
 TROUBLE DIAGNOSES - Auto Air Conditioner

Preliminary Check
PRELIMINARY CHECK 1
Air outlet does not change.

Does this incident occur only Yes Go to Diagnostic Procedure 24.

in Manual Select Mode?
No

®
CHECK SENSOR CIRCUIT.
Read out trouble data
with CONSULT.
N.G. CHECK SENSOR CIRCUIT IN DETAIL
ACCORDING TO THE DIAGNOSTIC PROCEDURE
BELOW CORRESPONDING TO EACH CODE NO.
or
® S e t up self-diagnosis STEP
4. Is each sensor circuit
00 ®
Self-diagnosis
How to repair
Reference
page
CONSUlT indication
normal? code No. ld•t•
Ambient sensor circuit is Go to Diagnostic
O.K.. open '"",J 0
procedure 2.
HA-118

Ambient sensor circuit is Go to Diagnostic

shorted. '"",J ~

procedure 3.
HA-119
CHECK MODE DOOR OPERATION.
(j) Set up "ACTIVE TEST" mode with CONSU 1,. T.
Upper in-vehicle sensor
circuit Is open.
Upper in-vehicle sensor
-,I 0

.,,..
Go to Diagnostic
procedure 4.
Go to Diagnostic
HA-120
--
or circuit is shorted. -,J procedure 5.
HA-121

Lower in-vehlcle.sensor Go to Diagnostic

@set up self-diagnosis STEP 2. circuit is open. .... ; 0
procedure 6.
HA-122

Lower in-vehicle sensor

. . ,J , .. Go to Diagnostic
HA-123
Does air outlet change according to each mode? circuit is shorted. procedure 7.
f-- - - - - - - ----
oerroster (duct) sensor Go to Diagnostic
circuit is open. /:~r;;'"",J 0
procedure 8.
HA-124

@ s e t mode OEF HEAT B/L VENT

/:~}'"",I ..
Defroster (duct) sensor Go to Diagnostic
HA-125
circuit Is shorted. procedure 9.
·-· ·- ...... ..... ·------ ·-- -·----------·-·--· - -- ·----- ···----
Vent (ductJ sensor circuit Go to Diagnostic
/:~t;\-J 0 HA-126

·,~ ~~
is open. procedure .10.
-+--- -
-~
--------·

'~
----·-·----
@code No. Vent (duct) sensor circuit Go to Diagnostic
~}0-,J
._.n)
=
procedure 11.
HA-127
is shorted.
r---- - ------------
FOOT/ FOOT/ Floor (duct) sensor circuit Go to Diagnostic
Air outlet OEF VENT is open. ~JB!)' ,J
r
0
procedure 12.
HA-128
DEF VENT -- ----
Floor (duct) sensor circuit Go to Diagnostic
Refer to AIR DISTRIBUTION. is shorted. fJP,J
.v .. ~

procedure 13.
HA-129
- · - - - - - - - - - - - - r · - - - - - - · - - ------
Sunload sensor circuit ~~,I Go to Diagnostic
HA-130
""'n~)
-~

is shorted. procedure 14.

O.K. N.G.
When malfunctioning sensor circuit, ambient sensor,
in-vehicle sensor, and duct sensors are suspected, it is
useful to check temperature detected by each sensor
with self-diagnosis STEP 1 to confirm the
temperature is within normal range before
performing Diagnostic Procedures.

CHECK SIDE LINK ~, Repair or

adjust.
MECHANISM.
Refer to Control Rod
Adjustment.

l O.K.

Air outlet control system is normal. Go to Diagnostic Procedure 17

Refer to Outlet door control specification. or 18.

HA-103
 TROUBLE DIAGNOSES - Auto Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
Intake door does not change.

00
CHECK SENSOR CIRCUIT.
Read out trouble data
with CONSULT.
N.G.
CHECK SENSOR CIRCUIT IN DETAIL
ACCORDING TO DIAGNOSTIC PROCEDURE
BELOW CORRESPONDING TO EACH CODE NO.
or
® S e t up self-diagnosis STEP
4. Is each sensor circuit 00
CONSULT indication
®
Sell-diagnosis
How to repair
Reference
pnge
normal? code NO. data
Ambient sensor circuit is Go to Diagnostic
O.K. open "",J 0
procedure 2.
HA-118

Ambient sensor circuit is Go to Diagnostic

CHECK INTAKE DOOR MOTOR. shorted. "",J "' procedure 3.
HA-119

Upper in-vehicle sensor Go to Diagnostic

OOSet up "ACTIVE TEST" mode with CONSULT. circuit is open ..
-,J 0 procedure 4.
HA-120

Upper in-vehicle sensor Go to Diagnostic

or circuit is shorted. -,I = procedure 5.
HA-121

®Set up self-diagnosis STEP 2. Lower in-vehicle sensor Go to Diagnostic

circuit is open. ... ,J 0 procedure 6.
HA-122

Lower in-vehicle sensor Go to Diagnostic

circuit is shorted.
... ,J =
procedure 7.
HA-123

Does intake air change according to each ordered Defroster (duct) sensor Go to Diagnostic
position? circuit is open. rCJ:a"",J 0
procedure 8.
HA-124

Defroster (duct) sensor

circuit is shorted.
ff]<ifi,J - Go to Diagnostic
procedure 9.
HA-125
FRE/
® s e t position FRE
REC
REC Vent (duct) sensor circuit
is open.
:::r;-,1 n Go to Diagnostic
procedure ..10.
HA-126

Vent Cduct) sensor circuit

is shorted.
(\8 )
f~ .) -
·-=
Go to Diagnostic
procedure 11.
HA-127

@code No.
·,~ ~,I ,,I -,I Floor (duct) sensor circuit
is open. ~ ... ,1 n
Go to Diagnostic
procedure 12.
HA-128

Floor (duct) s"ensor circuit Go to Diagnosti~

FRE/ Is shorted. fJR ... ,J ·= procedure 13.
HA-129
Air intake FRE REC --·----·---- --- - ---------- - - -
REC Sunload··sei1Sor clrclijt q~,·,I ~
Go to Diagnostic
HA-130
Is shorted. f!l) procedure 14.
- -·

O.K. N.G. When malfunctioning sEmsqr circuit, ambient sensor,

in vehicle sensor, and duct sensors are suspected, it is
useful to check temperature detected by each sensor
with self-diagnosis STEP 1 to confirm the
temperature is within normal range before performing
Diagnostic Procedures.

CHECK INTAKE DOOR N.G._I Repair or

ROD or LEVER adjust.
I
MECHANISM.
Refer to Control Rod
Adjustment.

~
l O.K.

Intake door control system is normal.

Refer to Intake door control specification. I Go to Diagnostic Procedure 16. I

HA-104
 TROUBLE DIAGNOSES - Auto Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 3
Insufficient cooling
• Read out se·lf-diagnosis result with CONSULT or perform self-diagnosis STEP 4 before referring to the
following flow chart.

CHECK MODE DOOR N.G.I Go to Preliminary Check 1.

L __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ J
OPERATION.
O.K.
CHECK INTAKE DOOR Go to Preliminary Check 2.
OPERATION.
O.K.
CHECK BLOWER MOTOR Go to Prelimina.ry Check 5.
OPERATION.
O.K.
CHECK MAGNET CLUTCH Go to Preliminary Check 6.
OPERATION.
O.K.
CHECK COMPRESSOR BELT N.G. Adjust or replace compressor
TENSION. belt.
Refer to MA section.
O.K.
CHECK AIR MIX DOOR Go to Preliminary Check 7.
OPERATION.
O.K.
CHECK RADIATOR FAN Refer to EF & EC section.
MOTOR OPERATION.
O.K.
CHECK REFRIGERATION N.G. Go to Performance Test
CYCLE PRESSURE WITH Diagnoses.
MANIFOLD GAUGE CON-
NECTED.
Refer to Performance Chart.

O.K.
CHECK FOR EVAPORATOR Replace suction throttle valve.
COIL FREEZE UP.
(Freeze up)
1. (F.!\ Set up "OATA
~MONITOR" mode
with CONSULT.
or
~Set up self-diagnosis
~STEP 1.
2. Measure evaporator outlet
air temperature detected by
vent duct sensor.
O.K. (Does not freeze up)
CHECK DUCTS FOR AIR N.G .....
,-R_e_p-ai-r-ai-r-le-a-ks-.------------,
LEAKS. ·
O.K.

HA-105
TROUBLE DIAGNOSES - Auto Air Conditioner
Preliminary Check (Cont'd)

PERFORM TEMPERATURE
SETTING (Upper and lower).
1. fF.i\Set up "WORK
~SUPPORT" mode
with CONSULT.
or
r<a\ Set up self-diagnosis
~STEP3.
2. Adjust difference between
upper and lower target
temperatures.

HA-106
 TROUBLE DIAGNOSES - Auto Air Conditioner
Preliminary Check {Cont'd)
PRELIMINARY CHECK 4
lns"'fficient heating
• Check coolant level, engine temperature and heater hoses, and read out self-diagnosis result with CONSULT
or perform self-diagnosis STEP 4 before referring to the following flow chart.

CHECK MODE DOOR N.G. k1

Go to Preliminary Chec .
OPERATION.
O.K.

CHECK INTAKE DOOR

OPERATION.
O.K.

CHECK BLOWER MOTOR

OPERATION.
O.K.

CHECK AIR MIX DOOR Go to Preliminary Check 7.

OPERATION.
O.K.

CHECK AIR DUCTS FOR AIR Repair air leaks.

LEAKS.
O.K.

PERFORM TEMPERATURE
SETTING (Upper and lower).
1·(F.j\ Set up "WORK
Ji; SUPPORT" mode
with CONSULT.
or
~Set up self-diagnosis
~STEP3.
2. Adjust difference between
upper and lower target
temperatures.

HA-107
 TROUBLE DIAGNOSES -Auto Air Conditioner
Preliminary Check {Cont'd)
PRELIMINARY CHECK 5
Blower motor operation is malfunctioning.

Does this incident occur only

in Manual Select Mode?
Yes
I Go to Diagnostic Procedure 24.
I
No

N.G. CHECK SENSOR CIRCUIT IN DETAIL

@
CHECK SENSOR CIRCUIT.
Read out trouble data
with CONSULT.
ACCORDING TO THE DIAGNOSTIC PROCEDURE
BELOW CORRESPONDING TO EACH CODE NO.
or
®Set up self-diagnosis STEP
4. Is each sensor circuit
00
CONSULT indication
®
Self-diagnosis
How to repair
Reference
page

normal? code No. Jdata

O.K.
Ambient sensor circuit is
open
,I
<ill 0
Go to Diagnostic
procedure 2.
HA·118

Ambient sensor circuit is Go to Diagnostic

shorted.
<ill ,I ~

procedure 3.
HA-119
CHECK BLOWER MOTOR OPERATION.
Vpper ln·vehicle. sensor Go to Diagnostic
® e t up "ACTIVE TEST" mode with CONSULT. circuit is open.
-,I 0 procedure 4.
HA-120

Upper in-vehicle sensor Go to Diagnostic

or circuit is shorted. -,I = procedure 5.
HA·121

@Set up self-diagnosis STEP 2. Lower in-vehiCle sensor Go to Diagnostic

circuit is open. ... ,I 0 procedure 6.
HA-122

Lower in-vehicle sensor Go to Diagnostic

circuit Is shorted.
.... ,J .-.
procedure 7.
HA-123

Does blower motor speed change according to each Defroster ~duct) sensor QD<i/1,1 0
Go to Diagnostic
HA-124
ordered fan speed,? circuit is open. ''II!) procedure 8.
Defroster (duct) sensor Go to Diagnostic
circuit is shorted.
fl:B<i/1,J ~

procedure 9.
HA-125

OOset fan speed 4V 6V 9V 12V Vent (duct) sensor circuit Go to Diagnostic

is open. ~'-,1
A5 0
procedure .10.
HA-126
----·--
Vent (duct) sensor circuit Go to Diagnostic
is shorted. ~-,1 =
procedure 11.
HA-127

-~ ~J '~ -J
@code No. Floor (duct) sensor circuit Go to Diagnostic
is open. ~i"'fr5 ... ,1 0
procedure 12.
HA·128

-
Floor (duct) sensor circuit Go to Diagnostic
,0fi? ... ,l ~··~

procedure 13.
HA·129

SIS 31• it •
Is shorted.
Fan speed
Go to Diagnostic
D Sun load _sensor circuit
Is shorted.
[Jf]fJil,I procedure 14.
HA-130

O.K. N.G. When malfunctioning sensor circuit, ambient sensor,

in vehicle sensor, and duct sensors are suspected, it is
useful to check temperature detected by each sensor
with self-diagnosis STEP 1 to confirm the
temperature is within normal range before performing
Diagnostic Procedures.

I Go to Diagnostic Procedure 25.

I
Is engine coolant temperature below 40°C (104°F) N.G. Blower motor operation is normal.
and foot duct temperature below 30°C (86°F)? Refer to Fan speed control specification.
O.K.

~I
IS BLOWER MOTOR CONTROLLED UNDER FAN Check engine temperature sensor control circuit.
STARTING SPEED CONTROL?· Refer to EF & EC section.
Refer to Starting fan speed control specification.

Yes

Blower motor operation is normal.

HA-108
 TROUBLE DIAGNOSES - Auto Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 6
Magnet clutch does not engage.

CHECK SENSOR CIRCUIT. N.G.

@ Read out troubl_e data
with CONSULT.
CHECK SENSOR CIRCUIT IN DETAIL
ACCORDING TO THE DIAGNOSTIC PROCEDURE
BELOW CORRESPONDING TO EACH CODE NO.
or
®Set up self-diagnosis STEP
4. Is each sensor circuit 00
CONSULT indication
®
Self-diagnosis
How to repair
Reference
page

normal? code No. data

Go to Diagnostic
Ambient sensor circuit is
<;ii,J 0 HA-118
O.K. open procedure 2.
Ambient sensor circuit is
shorted.
<;;1,1 - Go to Diagnostic
procedure 3.
HA-119

CHECK MAGNET CLUTCH OPERATION. Upper in-vehicle sensor Go to Diagnostic

circuit is open. -,I 0 procedure 4.
HA-120

Ci)Set up "ACTiVE TEST" mode with CONSULT. Upper in-vehicle sensor Go to Diagnostic
circuit is shorted. -,J ~

procedure 5. HA-121

or ------ - - - - -
Lower in-vehicle· sensor Go to Diagnostic
circuit Is open. .. ) 0
procedure 6.
HA-122
®Set up self-diagnosis STEP 2. ----·
Lower In-vehicle sensor Go to Diagnostic
circuit is shorted.
.. ,I "
procedure 7.
HA-123

Check if magnet clutch engages according to order Defroster lduct) sensor (lQ<;il ,I 0
Go to Diagnostic
HA-124
circuit is open. ""'() procedure a.
from CONSULT or each code No.

00 Set magnet
clutch OFF ON
Defroster (duct) sensor
circuit is shorted.
-----------------
Vent (duct) sensor circuit
is open.
f:IQ<;i/,1
r-~-'fiJ

fig-,J
~

0
Go to Diagnostic
procedure 9.
Go to Diagnostic
procedure .10.
--
HA-125

HA-126
operation ------------- ------------------ ·--- -------···-----
f!{r?-,1 ..-
Vent (duct) sensor circuit Go to Diagnostic
HA-127
is shorted. procedure 11.
------· ----------- -------- ------- -- -------·--------- ------
fiiiJ ~,I Floor (duct) sensor circuit
/~f?.. ,J
Go to Diagnostic

'J -,I
®Code No. is open.
0
procedure 12.
HA-128
------------------- · - - -- - - - · - - - - · - - -
Floor (duct) sensor circuit (ln ,J ~
Go to Diagnostic
HA-129
is shorted. c·'{) .. procedure 13.
Magnet clutch ------------- ---- --
OFF ON
operation Sun load sensor circuit a-.,<¥il,J Go to Diagnostic
HA-130
is shorted. ''n~i ·~·
procedure 14.

O.K. N.G.
When malfunction sensor circuit, ambient sensor,
in vehicle sensor, and duct sensors are suspected, it is
useful to check temperature detected by each sensor
with self-diagnosis STEP 1 to confirm the
temperature is with normal range before performing
Diagnostic Procedures.

N.G.
... CHECK REFRIGERANT.
Connect manifold gauge
----. Check for
refrigerant
then check system pressure. leaks.

l O.K.

Magnet clutch control system is normal.

Refer to MAGNET CLUTCH CONTROL. I Go to Diagnostic Procedure 19. I

HA-109
 TROUBLE DIAGNOSES - Auto Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 7
Discharged air temperature does not change.

00
CHECK SENSOR CIRCUIT.
Read out trouble data
with CONSULT.
N.G. CHECK SENSOR CIRCUIT IN DETAIL
ACCORDING TO THE DIAGNOSTIC PROCEDURE
BELOW CORRESPONDING TO EACH CODE NO.
or
®Set up self-diagnosis STEP
4. Is each sensor circuit 00
CONSULT indication
®
Self-diagnosis
How to repair
Reference
page
normal? code No. data

l O.K.
Ambient sensor circuit is
open
Ambient sensor circuit Is
<;iii,J 0
Go to Diagnostic
procedure 2.
Go to Diagnostic
HA-118

<;iii,J
00
CHECK AIR MIX DOOR OPERATION.
Set up "ACTIVE TEST" mode with CONSULT.
shorted.
Upper in-vehicle-sensor
circuit Is open. -,J
""·"'

0
procedure 3.
Go to Diagnostic
procedure 4.
HA-119

HA-120

Upper in-vehicle sensor Go to Diagnostic

or -,I = HA-121
circuit is shorted. procedure 5.
®Set up self-diagnosis STEP 2. Lower in-vehicle sensor Go to Diagnostic
circuit is open. ... ,I 0
procedure 6.
HA-122

Lower In-vehicle sensor Go to Diagnostic

circuit is shorted.
,,J ~-
procedure 7.
HA-123

Check if discharge air temperature changes as in Oefroster (duct) sensor_ Go to Diagnostic

following chart. circuit is open. .Cif]v,J 0
procedur~ 8.
HA-124

00 S~t discharge
a1r Full Hot
30°C
(86°F)
Full
Cool
Defroster (duct) sensor
circuit is shorted.
Vent (duct) sensor circuit
&v,J
fJf;~-,1
=

n
Go to Diagnostic
procedure 9.
Go to Diagnostic
HA-125

HA-126
temperature Is open. procedure ..10.
------
Vent (duct) sensor circuit Go to Diagnostic

·,~ •,,I
is shorted. tJa-,1
._, = procedure 11 .
HA-127

@code No. ,,~

-,I Floor (duct) sensor circuit
is open. & ... ,1 0
Go to Diagnostic
procedure 12.
HA-128

Floor (duct) sensor circuit Go to Diagnostic

Discharge air 30°C Full Is shorted.
,GfiS,,I """' procedure 13.
HA-129
Full Hot f----
temperature (86°F) Cool Sunload sensor circuit
Is shorted.
,fJ!)V,/ ... Go to Oiagnonic
procedure 14.
HA-130

l O.K. N.G.
When malfunction sensor circuit, ambient sensor,
Air mix door control system in vehicle sensor, and duct sensors are suspected, it is
is normal. useful to check temperature detected by each sensor
Refer to Specification of air with self-diagnosis STEP 1 to confirm the
mix door control. temperature is with normal range before performing
Diagnostic Procedures.

CHECK AIR MIX DOOR MECHANISM.

Refer to DOOR CONTROL. H Repair or adjust.
J
O.K.

Go to Diagnostic Procedure 15.

PRELIMINARY CHECK 8
Noise
Refer to page HA-61.

HA-110
 DIAGNOS ES- Auto
~~~~··r~C~o~n~d~it=io~n_e_r_____
-
- - - - -TROUBLE Layout for A/C System
Engine comp artment Harness

Air conditioner

C/ l ' < , ~~''' ~

~
~ow-pressur e (C))
--------- switch

SHA542C

HA-111
 TROUBLE DIAGNOSES - Auto Air Conditioner
Harness Layout for A/C System (Cont'd)
Passenger compartment

Sun load sensor connector

®
~ Def duct sensor and .
~~sunload sensor
L ~-. _.. connector @ __;
Defroster duct

--
1ntermed iate ......_
connector@

Vent duct

Foot duct L.H. relay connector

SHA543C

HA-112
 [
IGNITION SWITCH
ON or START I
IGNITION SWITCH.J
ACC or ON
I
BAT;ERY

~'""
DIAGNOSTIC CONNECTOR
CfQ): Turbo model
.-----1-+--+--~ FOR CONSULT

'"" '=?:®
I t:tt:ttl;:I;J•I FUSE
([f): Non-turbo model

20 18 )9

<2 AIR MIX IGfj:TJ ~

~~w ATOR " ~g~~R I lilliiJ ~ -1
:a
JIIIL
RELAY << AIR MIX~~
0
A/C ® CD [D"'[[ <5 DOOR II lilliiJ ~ c:
RELAY
_IDIDl ® MOTOR
INTAKE lill:j'"]J ~ m
~ « ~g~~R lillTIJ ~ r-
39 m
® ® @
c
~
@) 38

® ~
37 AUTO AMP.
"
@
® ;;
36 C)
Ill ® I ~ I~g~gR DOOR 0 z
I I
5<

- ®""
CD
- ••
@
@
® . ...-· 0
:I:
:1>
~
~
I
®~COMPRESSOR
®
®
omD0 M0
® RADIATOR
-=-
FAN MOTOR
I
2
-
JS

I
2
21
54
12
13
21

2<
@
SUNLOAO
SENSOR
~®
-
n
c
-·
c
-·
m
en
m
en
I
...
-...-·
3
w CD
J
® tD
12~1® :J>
F. I. c. D. DEF DUCT
SOLENOID ' ' 25
SENSOR m c

-
VALVE 5 5
@ 3
-... 0
6

®~6'
SWITCH UNIT 6

LOW-
~ :~ .7

•
7
8

•
40424346
41444547
35 39 55
37 38 33
26

27
® ®
FOOT DUCT i2QQ91®
SENSOR

VENT DUCT l8)1ei2?l ®

0 :J>
PRESSURE
SWITCH
t;;\
0_; ® 10 10
SENSOR
c 0
II II
28 AMBIENT A® =·
n
0.
::s
"
IS
"
IS @
SENSOR
~ Q.
29 IN-VEHICLE ~
16 16 @ SENSOR-LWR 268029
3:
17 17
® IN-VEHICLE
0 :P. 0
12 IJ 32 SENSOR-UPR ::s ::s
@ "0
...CD
II
-=-
®I ~ASPIRATOR

-
MOT OR
• 61
3260 62:

® -
2.
::s
0
::::r
CD
n
• All connectors shown in this illustration are unit side connectors. ~
• The unit side connectors with a double circle " 0 " are connected to the harness side connectors shown in
the "Harness Layout for A/C System". (See pages HA-111- HA-112.)
en
:I: • The terminal numbers in the connector coincide with the circuit numbers surrounded by a single circle " 0 "
>
00
0
(l
 TROUBLE DIAGNOSES -Auto Air Conditioner

Clli: Turbomodel
Wiring Diagram
<liT): Non-turbo model

AUTO AMP.

DIAGNOSTIC

@I
CONNECTOR AIC
FOR CONSULT IGNITION
RELAY

-N~~~~~~•a-N~~~~~~•c-~~~~~~-Nn~~~~m~a-Nn~~~~~~~
----------NNNNNNNNnnnnnnnnn~~~~~~~~~~~

0:
0 ~ ...

1-L/R
SWITCH UNIT @) ~= Y;l
M42 · - Y/G
5-Y/B

~ t ~~r~.
To illumination {
16-
17-BR/W
BR

contro I system +---_.J

DEF DUCT
SENSOR @ (Main harness>
YH4---++++++~~---44-----l:B~
j
· ~~:~~============================~~44-ii----trr---H-H11+++-----rr----R/l
~ @
S~NL;D ~
SENSOR - @)

L___-+++---++1-++-ir++-t--++---- l/BJ

BLOWE@.@)
MOTOR fTb- M l -----------------------------t---HH----__J
l[__l/R-~--------------------------t---HH------_J

!Sub-harness> ®@
AI~ ~=~~::w~~~~~;~~~y~~
DOOR I r;;;;--, W/B W/B-

~ W~R W~R====1r~~----ff~~~~llj
AI~~~y
MOTOR

@)
DOOR II
J
,...
111
o: ~ ...
MOTOR C3 '"' ... o ~~ll!
~ Q-R/l J,l..,..,., ~~~
VENT
DUCT
SENSOR
L:::::::::::... B-
~
W/R @ t.t::fflll @ ltfi:jjJ

FOOT DUCT
SENSOR
®$®fi®
~~;~~~~
~@
IN-VEHICLE
SENSOR-LWR '"r m
DOOR MOTOR MODE DOOR
MOTOR
BODY
GROUND BODY
GROUND

HA-114
 TROUBLE DIAGNOSES - Auto Air Conditioner
Wiring Diagram (Cont'd)

UJ!r
...JO.. FUSE BLOCK (Refer to •POWER SUPPLY ROUTING• in EL section.)
U::l
~I

ra::
UJO
>II)
IZ
ZLU
lr I-GNI Tl ON
ACC or ON
S~I~ - I GNI Tl ON SWITCH
ON or START
~-~-~-~-K--,
RELAY
IGNITION SWITCH
ON or START
~II)

BATTERY

(Engine
@ BLOWER
room

I
harness>
RELAY

R/L

L__
BR
CBody 10 "'
harness>~.
®~~®
BODY CONNECTOR
GROUND
CMa in harness> @@)@)@)

EID

c
~@)
. ~
0: IDO:
lr
0
1-
-'3: "';:;
~~
0
0
...
0
.,
U]
I@
II..
Ul
U]
tl
1-
...J
<[
c
u
LU
.,
L
FR
oil £
lL
LU
...;
...
0

L
...
tl
6

@] 19
.
6

-
-
-
w
OR
L -
u:
~ RADIATOR
FAN SUB
RELAY
jn;€Jilcj~U
U
~
§ FUSE BLOCK
CI n RELAY BOX)
CRefer to •POWER
SUPPLY ROUTJ NGn
I
®.__[IIJ
tl in EL section. l
E!:; -
JJ

-
R
58 I ® _ _,
1-
~
''
z
::l
...J
0
lr
1-
z
0
u

vi
t.i
t.i
uJ l___ __j®

SHA802C

HA-115
 TROUBLE DIAGNOSES - Auto .Air Conditioner

Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK FOR A/C SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" in section EL and A/C
ELECTRICAL CIRCUIT - Auto Air Conditioner.

AUTO AMP. REMOVAL

1. Remove driver side instrument lower lid.
2. Remove vent duct.
3. Remove auto amp. with harness connected.

Auto amp. harness connector ® AUTO AMP. CHECK

-~millrn ~
1. Disconnect auto amp. harness connectors.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. @ or No. @ and body
1YJ I?J ground.
i(t)_§l
~
Voltmeter terminal Voltage

00 SHA369C
-=
EB
@
e (Approx.)

Body ground 12V

@

Check body ground circuit for control unit with ignition switch
Auto amp. harness connector ® OFF

[2il
IISCIIIET
rrr3+ErJt=_,, B
1. Disconnect auto amp. harness connector.
2. Connect ohmmeter from harness side.
3. Check continuity between terminal No. ® or ® and body
I?J TQl ground.

00
......___

..,. SHA370C

HA-116
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 1
SYMPTOM: Self-diagnosis detects intermittent short or open
circuit in each sensor circuit.
Check each connector connection as shown in the following table,
and check each line's condition.

Connector No. to be checked

Malfunctioning circuit Engine room Body
Main harness A/C sub-harness
harness harness

Ambient sensor @) @)(illY

Upper in-vehicle sensor ®® @@)
Lower in-vehicle sensor ®® ®®
OEF duct sensor @) ®
VENT duct sensor ®® ®®
Floor duct sensor ®® ®®
Sunload sensor @) ® ®

HA-117
 TROUBLE DIAGNOSES - Auto Air Conditioner

EJ Ambient sensor harness Diagnostic Procedure 2

. connector.@
SYMPTOM: Ambient sensor circuit is open. (CONSULT or
self-diagnosis STEP 4 indicates this.)
R/L w
N.G. Disconnect auto amp. harness
CHECK AMBIENT SENSOR
1----+ connector.
CIRCUIT BETWEEN AMBIENT

SHA373C
SENSOR AND AUTO AMP.
Disconnect ambient sensor
harness connector.
I§) l
Check circuit continuity
Note

Do approximately 5 volts exist between ambient sensor harness

I§) Ambient sensor harness between ambient sensor harness connector term ina I No. @ and
connector @ connector terminal No. ®:l and auto amp. harness connector
[iii{) ~ @? terminal No.®.

~.~~~ 00
O.K.
JR/L ril O.K. Note
Check circuit continuity
between ambient sensor harness
connector terminal No. ® and
auto amp. harness connector
Auto amp. harness
connector ® SHA374C terminal No.®.

[il I
Ambient sensor harness Auto amp. harness
connector @ connector ®
l O.K.

I Replace auto amp.

I
~ [2ll
II ~ I ~ I ~ II
Eu
-CT
w
w I CHECK AMBIENT SENSOR.
(Refer to Inspection of Sensor.)
II N.G.J.1 Replace ambient sensor. I
\Q\
~8
'-=------=. 00
SHA375C
r
Replace auto amp.
O.K.

Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-118
 TROUBLE DIAGNOSES - Auto Air Conditioner

Ambient sensor harness

Diagnostic Procedure 3
connector @ SYMPTOM: Ambient sensor circuit is shorted. {CONSULT or
self-diagnosis STEP 4 indicates this.)

R/l w

CHECK AMBIENT SENSOR. ~~ Disconnect auto amp. harness

CIRCUIT BETWEEN AMBIENT connector.
SENSOR AND AUTO AMP.
Disconnect ambient sensor
harness connector.
liJ l Note
Check the circuit between auto
SHA376C
Do approximately 5 volts exist amp. harness connector terminal
liJ Auto amp. harness between ambient sensor harness No. ®and @ is not shorted.
connector @) connector terminal No. @ and
Jo.K.
@?
O.K. I Replace auto amp.
I
N.G.
CHECK AMBIENT SENSOR. Replace ambient sensor.
(Refer to Inspection of Sensor.)
Continuity should
not exist SHA377C O.K.

Replace auto amp.

Note:
If the result is N.G. after checking insulation of each terminal, repair
harness or connector.

HA-119
 TROUBLE DIAGNOSES - Auto Air Con.diUoner

£1 In-vehicle upper sensor Diagnostic Procedure 4

harness connector @
SYMPTOM: Upper jn-vehicle sensor circuit is open. (CONSULT
or self-diagnosis STEP 4 indicates this.)

BR

M_
R/L

CHECK IN-VEHICLE UPPER Disconnect auto amp. harness

SENSOR CIRCUIT BETWEEN connector.

SHA378C
IN-VEHICLE UPPER SENSOR
AND AUTO AMP.
Disconnect in-vehicle upper
li1 l
Check circuit continuity
Note

sensor harness connector.

between in-vehicle upper sensor
In-vehicle upper sensor Do approximately 5 volts exist
harness connector @ harness connector terminal No.
between in-vehicle upper sensor
harness connector terminal No.
® and auto amp. harness con-
nectar terminal No.®.
@and@?

O.K. lO.K.
[!) Note
Check circuit continuity
between in-vehicle upper sensor
harness connector terminal No.
Auto amp. harness connector
SHA379C @ and auto amp. harness con-
nectar terminal No.@.
In-vehicle upper sensor
harness connector @
lO.K.

I Replace auto amp.

I

CHECK IN-VEHICLE UPPER

SENSOR. ~I Replace in-vehicle upper sensor.

(Refer to Inspection of Sensor.)

O.K.

Replace auto amp.

Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-120
 TROUBLE DIAGNOSES -Auto Air Conditioner

if&1 In-vehicle upper sensor

Diagnostic Procedure 5
harness connector @) SYMPTOM: Upper in-vehicle sensor circuit is shorted. (CON-

BE [ilK)~ SULT or self-diagnosis STEP 4 indicates this.)

BR R/L
N.G. Disconnect auto amp. harness
CHECK IN-VEHICLE UPPER
SENSOR BETWEEN IN- connector.
VEHICLE UPPER SENSOR
AND AUTO AMP.
[;] I Note

SHA381C Disconnect in-vehicle upper Check the circuit between auto

sensor harness connector. amp. harness connector terminal
li1 Do approximately 5 volts exist No. @ and @ is not shorted.
@
W Auto amp. harness connector
between in-vehicle upper sensor l
~II lili5
O.K.
harness connector terminal No.
~~g~r! @and@?
I Replace auto amp. I
R/ L RR
In I
j<f)__§
~
00 O.K.

N.G.
CHECK IN-VEHICLE UPPER Replace in-vehicle upper sensor.
SENSOR.
Continuity should not exist. SHA382C (Refer to Inspection of Sensor.)
O.K.

Replace auto amp.

Note:
If the result is N.G. after checking insulation of each terminal, repair
harness or connector.

HA-121
 TROUBLE DIAGNOSES - Auto Air Conditioner

m In-vehicle lower sensor

harness connector @) .
Diagnostic Procedure 6.
SYMPTOM: Lower in-vehicle sensor circuit is open. (CONSULT

~liJi5~ or self-diagnosis STEP 4 indicates this.)

R/L p

N.G. Disconnect auto amp. harness

CHECK IN-VEHICLE LOWER
SENSOR CIRCUIT BETWEEN connector.
IN-VEHICLE LOWER SENSOR
AND AUTO AMP.
I§) -l Note

SHA383C Disconnect in-vehicle lower Check circuit continuity

sensor harness connector. between in-vehicle lower sensor
liJ Auto amp. harness In-vehicle lower sensor Do approximately 5 volts exist harness connector terminal No.
connector @ harness connector @ .(@) and auto amp. harness con·
between in-vehicle lower sensor

~'Ba I bJ1 mI ~ r&J

harness connector terminal No. nector terminal No.@.
@and(@)?
lO.K.
[iJ Note
R/L
E8 R/L
O.K.
Check circuit continuity

lnl 00) between in-vehicle lower sensor

harness connector terminal No.
------IA\::1.::::: ~~----'
'---- @ and auto amp. harness con-
SHA384C nector terminal No.@.

[iJ Auto amp. harness

connector @
In-vehicle lower sensor
harness connector@
1 O.K.

I Replace auto amp.

I
[lelkNWII ~, ~
18
p
p

CHECK IN-VEHICLE LOWER

N.G.
Replace in-vehicle lower sensor.

em~
SENSOR.
(Refer to Inspection of Sensor.)
'-----~~~~~+~----------~ O.K.
SHA385C
Replace auto amp.

Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-122
 TROUBLE DIAGNOSES - Auto Air Conditioner

In-vehicle lower sensor

Diagnostic Procedure 7
harness connector @ SYMPTOM: Lower in-vehicle sensor circuit is shorted. (CON-
SULT or self-diagnosis STEP 4 indicates this.)

N.G. Disconnect auto amp. harness

CHECK IN-VEHICLE LOWER
SENSOR CIRCUIT BETWEEN
r----+ connector.
IN-VEHICLE LOWER SENSOR
AND AUTO AMP.
Disconnect in-vehicle lower
(;] l
Check the circuit between auto
Note

SHA386C
sensor harness connector. amp. harness connector terminal
Do approximately 5 volts exist No. ® and ® is not shorted.
between in-vehicle lower sensor
harness connector terminal No.
l O.K.

®and@? Replace auto amp.

O.K.

Continuity should not exist.

CHECK IN-VEHICLE UPPER
SENSOR. H Replace in-vehicle lower sensor.

SHA387C (Refer to Inspection of Sensor.)

O.K.

Replace auto amp.

Note:
If the result is N.G. after checking insulation of each terminal, repair
harness or connector.

HA-123
 TROUBLE DIAGNOSES -Auto Air Conditioner

Def. duct sensor harness Diagnostic Procedure 8

connector @) SYMPTOM: Def. duct sensor circuit is open. (CONSULT or
self-diagnosis STEP 4 indicates this.)

W/L

CHECK DEF. DUCT SENSOR

CIRCUIT BETWEEN DEF.
M Disconnect auto amp. harness
connector.

SHA388C
DUCT SENSOR AND AUTO
AMP.
Disconnect def. duct sensor
m l
Check circuit continuity
Note

harness connector. between def. duct sensor harness

Do approximately 5 volts exist connector terminal No. @l and
(;) Auto amp. harness Def. duct sensor
connector @ harness connector@) between def. duct sensor harness auto amp. harness connector
connector terminal No. ®and terminal No.®.
@l?
lO.K.
AiL O.K.
E!ll Note
RIL
Check circuit continuity

00
'---------~~~ ~~+*---------~
between def. duct sensor harness
connector terminal No. ® and
auto amp. harness terminal No.
SHA389C ®.
E!J Auto amp. harness
connector @
Def. duct sensor
harness connector1®
l O.K.

I Replace auto amp.

I
N.G., Replace def. duct sensor.
CHECK DEF. DUCT SENSOR.
(Refer to Inspection of Sensor.) I
O.K.

SHA390C Replace auto amp.

Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-124
 TROUBLE DIAGNOSES - Auto Air Conditioner

lfa1 Oef. duct sensor harness Diagnostic Procedure 9

connector @ SYMPTOM: Def. duct sensor circuit is shorted. (CONSULT or
self-diagnosis STEP 4 indicates this.)

W/L R/L

CHECK DEF. DUCT SENSOR I N.G ... Disconnect auto amp. harness
BETWEEN DEF. DUCT SEN- connector.
SOR AND AUTO AMP.
Disconnect def. duct sensor
harness connector.
lil 1 Note
Check the circuit between auto
SHA391 C
Do approximately 5 volts exist amp. harness connector terminal
Auto amp. harness between def. duct sensor harness No. ® and (2)) is not shorted,
connector @ connector terminal No. ®and
lO.K.
@)?
O.K.
I Replace auto amp.
I
N.G., Replace def. duct sensor.
CHECK DEF. DUCT SENSOR.
(Refer to Inspection of Sensor.) I
O.K.
SHA392C Continuity should not exist.
Replace auto amp.

Note:
If the result is N.G. after checking insulation of each terminal, repair
harness or connector.

HA-125
 TROUBLE DIAGNOSES - Auto Air Conditioner

EJ Vent duct sensor harness Diagnostic Procedure 10

connector® SYMPTOM: Vent duct sensor circuit is open. (CONSULT or
self-diagnosis STEP 4 Indicates this.)

R/L W/R

CHECK VENT DUCT SENSOR N.G. Disconnect auto amp. harness

CIRCUIT BETWEEN VENT connector.

SHA393C
DUCT SENSOR AND AUTO
AMP.
Disconnect vent duct sensor
I!J 1
Check circuit continuity
Note

harness connector. between vent duct sensor

Do approximately 5 volts exist
I!J Auto amp. harness Vent duct sensor harness
between vent duct sensor
harness connector terminal No.
connector @ connector® @ and auto amp. harness con-
harness connector terminal No.
[GMJ1
d lit nector terminal No.®.
MmII
I-()
@and@?

R/L
R/L O.K. II 1 O.K.
Note
Check circuit continuity

In I
1<2~
00 between vent duct sensor har-
ness connector terminal No. @
and auto amp. harness connector
SHA394C terminal No. ® .

lO.K.
II Auto amp. harness Vent duct sensor harness
connector @ connector ®
I Replace auto amp. I
oo EN m I()
l. lit [(18]
27

W/R
11
· -T W/A

CHECK VENT DUCT SENSOR. N.G.,

[ill (Refer to Inspection of Sensor.)

Replace def. duct sensor.
I
00 ~ @~------- O.K.

SHA395C Replace auto amp.

1

Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-126
 TROUBLE DIAGNOSES - Auto Air Conditioner

f11 Vent duct sensor harness Diagnostic Procedure 11

connector @)
SYMPTOM: Vent duct sensor circuit is shorted. {CONSULT or

~[21115~
self-diagnosis STEP 4 indicates this.)

R/L W/R

CHECK VENT DUCT SENSOR ~~- Disconnect auto amp. harness

BETWEEN VENT DUCT connector.
SENSOR AND AUTO AMP.
Disconnect vent duct sensor m T Note

SHA396C
harness connector. Check the circuit between auto
Do approximately 5 volts exist amp. harness connector terminal
between vent duct sensor No. @ and @ is not shorted.
harness connector terminal No.
@and@? lO.K.

O.K. Replace auto amp.

I I

N.G.I
CHECK VENT DUCT SENSOR.
(Refer to Inspection of Sensor.)
Replace vent duct sensor.
I
Continuity should not exist. O.K.
SHA397C

Replace auto amp.

Note:
If the result is N.G. after checking insulation of each terminal, repair
harness or connector.

HA-127
 TROUBLE DIAGNOSES - Auto Air Conditioner

m Foot duct sensor harness

connector@
Diagnostic Procedure 12
SYMPTOM: Floor duct sensor circuit is open. (CONSULT or
self-diagnosis STEP 4 indicates this.)

W/B R/L

N.G. Disconnect auto amp. harness

CHECKFOOTDUCTSENSOR
CIRCUIT BETWEEN FOOT connector.
DUCT SENSOR AND AUTO
AMP.
Disconnect foot duct sensor
m 1
Check circuit continuity
Note
SHA398C
harness connector. between foot duct sensor har·
Do approximately 5 volts exist ness connector terminal No.®
(;) Auto amp. harness Foot duct sensor harness
connector @ connector @) between foot duct sensor har, and auto amp. harness connector
ness connector terminal No. terminal No.@.

~1~ I ~m 1\
[:il
-IIECT
rfb ®and®?
[!I l O.K. Note
R/L
18 R/L O.K. Check circuit continuity
between foot duct sensor har-

~
[ill 00 ness connector terminal No. ®
and auto amp. harness connector
terminal No.@.
SHA399C
1 O.K.
[!I Auto amp. harness Foot duct sensor harness
connector @ connector@
I Replace auto amp. I
~ llifb
II~ I"~ m 18 1\ IISCIIIIIIECT
W/8
CHECK FOOT DUCT SENSOR.
(Refer to Inspection of Sensor.)
N.G.,
Replace foot duct sensor.
I
W/8
O.K.
\QI
~<=>-~
'-'----
00 Replace auto amp.
SHA400C

Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.

HA-128
 TROUBLE DIAGNOSES - Auto Air Conditioner

m connector®
Foot duct sensor harness Diagnostic Procedure 13
SYMPTOM: Floor duct sensor circuit is shorted. (CONSULT or
self-diagnosis STEP 4 indicates this.)

W/B R/L

CHECK FOOT DUCT SENSOR I N.G. Disconnect auto amp. harness

BETWEEN FOOT DUCT connector.
SENSOR AND AUTO AMP.
Disconnect foot duct sensor
(;') l Note

SHA401C
harness connector. Check the circuit between auto
Do approximately 5 volts exist amp. harness connector terminal
between foot duct sensor No. ®and ® is not shorted.
Auto amp. harness
connector @ harness connector terminal No.
®and @?
l O.K.

O.K.
I Replace auto amp. I
~,
CHECK FOOT DUCT SENSOR.
(Refer to Inspection of Sensor.)
Replace vent duct sensor.
I
O.K.
Continuity should not exist. SHA402C

Replace auto amp.

Note:
If the result is N.G. after checking insulation of each terminal, repair
harness or connector.

HA-129
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 14
m Sunload sensor harness
connector ®
~. ~
l....ldiJ ss.J SYMPTOM: Sunload sensor circuit is shorted. (CONSULT or
self-diagnosis STEP 4 indicates this.)

~~-oo
N.G. Disconnect auto amp. harness
CHECKSUNLOADSENSOR
BETWEEN SUNLOAD SENSOR connector.
AND AUTO AMP.
Disconnect sunload sensor
harness connector.
(;) 1
Check the circuit between auto
Note

SHA403C
Do approximately 5 volts exist . amp. harness connector terminal
(;) Auto amp. harness between sunload sensor harness No. ® and @ is not shorted.
• connector ® connector terminal No. @and
@? TO.K.

R/L
WIG
O.K. I Replace auto amp.
I

Continuity should not exist. SHA404C

CHECK SUN LOAD SENSOR.
(Refer to Inspection of Sensor.) H Replace sunload sensor.

O.K.

Replace auto amp.

Note:
If the result is N.G. after checking insulation of each terminal, repair
harness or connector.

HA-130
 TROUBLE DIAGNOSES - Auto Air Conditioner

m Intermediate connector between auto amp.

Diagnostic Procedure 15
harness and air mix door motor harness. SYMPTOM: Air mix door does not operate normally.
G/Y
® • Read out self-diagnosis result with CONSULT or perform
self-diagnosis STEP 4 before referring to the following flow
GY chart.
• Remove combination meter assembly to make working space
and reconnect air conditioner switch connector.

SHA405C
CHECK FOR SIGNALS TO N.G. Check circuit continuity

00
AIR MIX DOOR MOTOR.
Set up '~ACTIVE TEST"
mode w1th CONSULT.
between auto amp. harness
connector terminals and inter-
mediate connector terminals.
®Set up self-diagnosis Inter- Auto
STEP 2. mediate amp. Continuity
Set air mix door position as connector connector

shown in the following chart. @ @ Yes

Check if approximately 10V @ @ Yes
exists for 3 seconds every 10 @ @ Yes
seconds between each terminal.*
Air mix door I
@ @ Yes

BR/' G/Y
motor connector
~ @ ®
Terminal No.

l O.K. N.G.
....._{lffi Air mix
Air mix
door I
Air mix
door II
BR/Y door
position
Code No.
e e e e
@ @ @ ~
I Replace auto amp.
I
·.~
Full-Hot
Air mix door II
Full-Cool -,I (4~ @ @ @
motor connector

e-1--""'--L -! 14!111 II O.K. I Repair harness or connector.

I
GY *· After two minutes power
supply is automatically cut off.

SHA406C
Remove heater unit assembly.

m
~,
Check continuity between
intermediate connector terminal
Repair harness or connector.
I
and each air mix door motor
harness connector terminal.
Air mix
Inter-
door I
mediate Continuity
motor
connector
connector

@ @ Yes

@ @ Yes

Air mix
Inter·
door II
mediate Continuity
motor
connector
connector
@ @ Yes

@ @ Yes

O.K.

Replace air mix door motor.

HA-131
 TROUBLE DIAGNOSES - Auto Air Conditioner

m Intake door motor

harness connector @
Diagnostic Procedure 16
SYMPTOM: Intake door does not operate normally.

~i5 G/Y
~~I
• Read out self-diagnosis result with CONSULT or perform
self-diagnosis STEP 4 before referring to the following flow
chart.
I VI BR

-r 00
CHECK FOR SIGNALS TO
INTAKE DOOR MOTOR.
N.G. CHECK OUTPUT OF AUTO
AMP.
SHA408C
Disconnect intake door motor
harness connector.
@ Set up "_ACTIVE TEST"
mode w1th CONSULT.
Intake door motor @'Set up "ACTIVE TEST" ®Set up self-diagnosis

-·
mode with CONSULT.
[11£)00 connector@
®Set up self-diagnosis
STEP 2.
Set intake door position as
Auto amp. harness
connector @ IV STEP 2. shown in the following chart.
---------~ Set intake door position as Check if approximately 10V
shown in the following chart. exists for 2.5 seconds between
Check if approximately 1OV each terminal.
exists for 2.5 seconds between
each terminal.
00 ® Terminal
No.
SHA409C
@ ® Terminal
No.
Intake door
position
Code No.
EB 8
[!l Intake door FRE/REC-+
'"~-,1
Code No. @ @
position
EB 8 REC
Intake door
motor connectQr
FRE/REC-+
,,J~-,1 @ (@) REC-+ FRE .... ,J~·,I @ @
REC

REC-+ FRE . . J~•,I (@) @ O.K. N.G.

lO.K. I Replace auto amp.

I
[I
I Replace intake door motor.
I Check continuity between auto
amp. harness connector terminal
No. @ and intake door motor
harness connector terminal No.
@.
Check auto amp. harness con-
nector terminal No. @ and
intake door motor harness con-
Auto amp. harness nector terminal No. ~.
connector @
l N.G.

Repair harness or connector.

SHA410C

HA-132
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 17

®~15@a
Auto amp. harness connectors @
SYMPTOM: Mode door does not operate normally.
• Read out self-diagnosis result with CONSULT or perform

r, kN
self-diagnosis STEP 4 before referring to the following flow
chart.

I ;>+--II-lga____,or-i CHECK P.B.R. CIRCUIT

N.G.
----+ CHECK MODE DOOR MOTOR.
@Set up "ACTIVE TEST" Refer to Electrical Components
mode with CONSULT. Inspection.
SHA411C
®Set up self-diagnosis O.K. N.G.
STEP 2.
Replace mode

Auto amp. harness

~-CT

~ ~~
Set mode door motor as shown
in the following chart. I door motor.

connectors @
®Check P.B.R. voltage (;]
with data monitor

:;.1::EE I \XM mI function in "ACTIVE CHECK HARNESS BETWEEN

TEST" mode. AUTO AMP. AND MODE
DOOR MOTOR.

v& Mode door motor

harness connector ®
Mode door

DEF
position

FOOT/DEF
P.B.R. voltage
(approx.)
4.8V
2.5V
Auto
amp.
harness
Mode
door
motor
harness
Continuity

~
connector
SB
8/L 1.1V connector
terminal

Il
terminal
VENT ov
@ No
A/G R/L Check if voltage between
I
I
I
1
I
I
I
I
® auto amp. harness con-
necor terminals @ and
® @
@
@
Yes
No
Yes
I I @ varies from approxi·
..,..__ _ _ ,.!I___ ,I @ @ No
mately 5V to approxi-
mately OV according to @ No
mode door position varies. @ No
SHA412C
Voltage ® @ No

® @ ®
@ Yes

Code No.
,. e (±) O.K. N.G.
·v- 4.8V
,.:- 2.5V
..'t

=
1.1V
ov I Repair harness or connector.
I
O.K.

Go to diagnostic procedure 18.

HA-133
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 18
Mode door motor
harness connector @ SYMPTOM: Mode door does not move at all.
L • Read out self-diagnosis result with CONSULT or perform
self-diagnosis STEP 4 before referring to the following flow
IIISCIHIIIECT
chart.
18 OR

00 SHA413C
CHECK FOR SIGNALS TO

00
MODE DOOR MOTOR.
Set up "ACTIVE TEST"
N.G.
r----+ CHECK OUTPUT OF AUTO

00
AMP.
Set up "ACTIVE !EST"
mode with CONSULT. mode with CONSULT.
®Set up self-diagnosis ®Set up self-diagnosis

[iti)~
STEP 2. STEP 2. .
Set mode door position as Set mode door position as
Auto amp. harness
Mode door shown in the following chart.
connector @ shown in the following chart.
motor connector
Check if approximately 10V
[JJfiEJ exists between mode door
motor harness connector
Check if approximately 1OV
exists between mode door

lF
motor harness connector
terminals @ and ® for terminals @and@ for
approximately 1.3 second approximately 1.3 second
every 10 seconds. every 10 seconds.
SHA414C

00 ®
Mode door
Terminal
No.

<±:l 8
00 ®
Mode door
Terminal
No.

position
Code No.
position
Code No. <±:l 8
..,,)
DEF ® @ DEF
-.~
@ @
VENT -,) @ ® VENT -,) @ @

LO.K. O.K. N.G.

Auto amp. harness

connector@
Mode door motor
harness connector
@ I Replace mode door motor. I IReplace auto amp. I
~ li:~btll\
L
[!)
OR Check continuity between auto
L OR
amp. harness connector terminal
No.@, @ and mode door
motor harness connector
terminal No.@, ® respectively.

O.K. N.G.

Repair harness
or connector.
SHA415C

INSPECTION END

HA-134
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 19
SYMPTOM: Magnet clutch does not engage.
e Perform Preliminary check 6 before referring to the following
flow chart.

Compressor harness N.G.

CHECK POWER SUPPLY FOR CHECK A/C RELAY OPER-
connector @
COMPRESSOR. ATION.
~G Disconnect compressor harness
connector.
Do approximately 12 volts exist
between A/C relay harness
SHA416C
(j)Set up "ACTIVE TEST" connector terminal No. @) and
mode with CONSULT. body ground?
®Set up self-diagnosis
STEP 2. I N.G. O.K.
Set compressor as shown in the
A/C relay harness
connector@)
following chart.
Check if approximately 12V
~G
Disconnect A/C relay harness
exists between compressor
connector.
harness connector terminal
and body ground. [!] Note
Check circuit continuity
SHA417C
® ®
Compressor Code No.
Terminal No.
between A/C relay harness
f--· connector terminal No. @ and
ON -,J @ Iground
Body
compressor harness connector
terminal No.(@.
l O.K.
Compressor
harness Check magnet clutch.
A/C relay harness
connector@)
connector
@) l N.G.
G~ Replace magnet clutch.
Refer to COMPRESSOR-
SHA418C
Model DKS-16H (DIESEL-KIKI
make).
I!] ~~-;\ ~
A/C relay harness l..tllal V ~
connector@ I!] J N.G.
~ CHECK POWER SUPPLY FOR
~ CHECK POWER SUPPLY CIA-
G/W

GIW
mJ A/C RELAY.
Disconnect A/C relay.
CUlT.
(Refer to "POWER SUPPLY
Do approximately 12 volts exist ROUTING" in EL section and
between A/C relay ahrness con- A/C ELECTRICAL CIRCUIT.)
nector terminal No. <@, (@ and
body ground respectively?

(§I Low-pressure
SHA419C
l O.K.

switch harness N.G.,

CHECK A/C RELAY AFTER ~~ Replace A/C relay.
connector
DISCONNECTING IT. I
(Refer to Electrical Components
Inspection.) Note:
LG/B
If the result is N.G. after checking
lO.K. circuit continuity, repair harness or
connector.
Reconnect A/C relay.

SHA420C
4 (Go to next page.)

HA-135
 TROUBLE DIAGNOSES - Auto Air Conditioner
Diagnostic Procedure 19 (Cont'd)
li
Low-pressure
switch harness
lit i5 00 T
connector@ Turn ignition switch ON and

~
press <QED switch.
~
A/C relay
harness
connector® II li Note
LG/B LG/B
N.G.
JQJ CHECK COIL SIDE CIRCUIT Check circuit continuity
OF A/C RELAY. between A/C relay harness
'-- Do approximately 12 volts exist connector terminal No.@ and
SHA421C
between low-pressure switch low-pressure harness connector
harness connector terminal No. terminal No.@.
E.C.C.S. control unit
connector@ @ and body ground?
Coi\JNIT ]Ofl=c=oNN====EC=:=TOR::::::=illl
[ill) [it
O.K.
Ill Note

00
9
A/C switch
OFF Do approximately 12 volts exist N.G. Check circuit continuity
OR
I vI DN between E.C.C.S. control unit between low-pressure switch
harness connector terminal No.
harness connector terminal No.
----;(-~<±> t::;A+----...
'-=-------"- ®and body ground? ® and E.C.C.S. control unit
For terminal arrangement, refer to harness connector terminal
Circuit Diagram for Quick Pinpoint Check. O.K.
No.®.
SHA341C

~ ~ l1fil:\\ Low-pressure
l O.K.

l...lllll. WiV ~ switch connector CHECK LOW-PRESSURE

r;::ll=CoiUN==:I;::::T=tJO[ CONNECTOR II @) d® SWITCH.
(Refer to Electrical Components
E.C.C.S. control 9
unit connector
Inspection.)
® OR
-
OR
l N.G.
[ill
For terminal
arrangement
refer to Circuit -
D
I Replace low-pressure switch.
I
Diagram for Quick Pinpoint Check. SHA342C
Do approximately 8 to 9 volts ____.
N.G. CHECK E.C.C.S. CONTROL
D exist between E.C.C.S. control UNIT.
(Refer to EF & EC s~ction.)
II [ill)
unit harness connector terminal
II CIUNI T ]Of CONNECTOR No. @ and body gorund?
E.C.C.S. control 46 A/C switch
unit connector OFF lfF:1::1 O.K.

® SB lvl ~ Disconnect auto amp. harness

----"@_~AI---
'----
connector.
For terminal arrangement, refer to O.K.
Circuit Diagram for Quick Pinpoint Check. IJ
SHA343C Check circuit continuity
between auto amp. harness
E.C.C,S. control unit connector@ connector terminal No.® and
fW lor
~I() jl
DISCIIIIIECT
c.-uNIT JOlcONNECTDR 11
E.C.C.S. control unit harness
connector terminal No.@ .

Auto amp.
harness
connector
00 O.K.

Replace auto amp.

For terminal arrange-
ment, refer to Circuit
Diagram for Quick Note:
Pinpoint Check.
If the result is N.G. after checking circuit continuity, repair harness or
SHA425C connector.

HA-136
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 20
SYMPTOM: Air conditioner control switch panel illumination
does not come on.

Switch unit harness

connector ® cJjV I Turn on light switch.
Set illumination control switch
N.G. Check illumination control
system. Refer to section EL.
I
IW II Efl ~::11 "y
G/Y
- •
SHA426C
at brightest position.
Check if approximately 12V
exists between switch panel
harness connector terminal No.
@and@.

l O.K.

I Replace bulb.

HA-137
 TROUBLE DIAGNOSES - Auto Air Conditioner

m Diagnostic Procedure 21
Switch unit harness
connector @
rili5 SYMPTOM: Set temperature and mode display do not appear
on display window.

!W II IT.ilm 00
OR BR/W
~
Check if approximately 0.5 to
N.G. Check if approximately 0.5 to
[YJ --+
2V exist between switch unit 2V exist between auto amp.
harness connector terminals

9
harness connector terminals
No.@ and@. @and@.
SHA427C l O.K. O.K. l N.G.

I§]
Auto amp. harness
connector @
[iii) I Replace switch unit. I I Replace auto amp.
I
mffiig 00 Repair harness or connector
(terminal No.@.@).

"Wilo' ~ SHA428C

HA-138
 TROUBLE DIAGNOSES - Auto Air Conditioner

m Diagnostic Procedure 22
Switch unit harness
connector @
[iti) SYMPTOM: When air conditioner switch is operated it does
not beep.

IW II &Eam
G/B BR/W
00
r--

00
Do approximately 12 volts exist
between air conditioner switch
~I Replace air conditioner switch.
I
~
unit harness connector terminal
No. (j) and @ ?
SHA429C
(;] l O.K.

Do approximately 12 volts exist N.G. Repair harness or connector

----.
Auto amp. harness
connector @
between auto amp. harness con-
nectar terminal No. (j) and @ ?
(terminal No. @ ).
J
wlli1:g l O.K.

~,
J
t"~ l:
Check switch panel. Replace auto amp.
Refer to Electrical Components
Inspection.

lO.K.
SHA430C
Replace switch panel.

HA-139
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 23
Switch unit harness SYMPTOM: Figures of set temperature do not appear on the
connector ·@ display window and Indicator lamp (L.E.D.) does

BR
:MJ 11 ITlnu
BR/Y R/W
not come on.

Do approximately 12 volts exist

N.G.
Do approximately 12 volts exist
between switch unit harness between auto amp. harness
connector terminal No. @. @ connector terminal No. @,@
and@? and@?
SHA431C
O.K. ~O.K. ~ N.G.

Auto amp. harness

connector @
Repair harness or
connector
l Replace
auto amp.
(Terminal No. @.
@and@).

lVI
~e
l
Check switch unit. N.G. Measure voltage between auto
'-----------------~--' Refer to Electrical Components amp. harness connector terminal
Inspection. No.®.®.@. (iJ) and@.
SHA432C
iO.K. Terminal No. Voltage
(approx.)
ffi 8
I Replace switch panel.
I ® 1.0V

® 0.65V
@ @ o.av
OV (Light OFF)
(iJ) 12V (Light ON)

Switch unit harness O.K. lN.G.

connector ®
SHA433C Repair harness
or connector
I Replace
auto amp.
(Terminal No.
®.®,®.
(iJ) and @l.

Auto amp. harness

connector @

SHA434C

HA-140
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 24
SYMPTOM: Switches do not work.
Switch unit harness
connector @
N.G.
Check switch panel. r--+ Replace switch panel.
Refer to Electrical Components
Inspection.

m l O.K.
N.G.
Check continuity between auto ~ Repair harness or connector.
amp. harness connector terminal
No. CD-® and switch panel
harness terminal No. CD - ®
respectively.

TO.K.
Replace auto amp.

SHA435C

HA-141
 TROUBLE DIAGNOSES - Auto Air Conditioner

Diagnostic Procedure 25
m Blower control
SYMPTOM: Blower motor operation is malfunctioning.
• Perform Preliminary check 5 before referring to the of flowing
flow chart.

N.G.
CHECK POWER SUPPLY CHECK POWER SUPPLY
FOR FAN CONTROL AMP. FOR BLOWER MOTOR.
Do approximately 12 volts exist Do approximately 12 volts exist
SHA449C between fan control amp. between blower motor harness
harness connector terminal No. connector terminal No. ~ and
(;] @ and body ground? body gorund?
Blower control
amp. harness
connector @) O.K. Note

CHECK BODY GROUND Note

Cl RCUIT FOR FAN CON·
Check circuit continuity be-
TROL AMP.
tween blower motor harness
Does continuity exsit between
connector terminal No. @ and
fan control amp. harness con-
fan control amp. harness con-
nector terminal No. ® and
nector terminal No. @.
body ground?

Blower control O.K.

1 O.K.
amp. harness ~ CIINNECT ~ CHECK BLOWER MOTOR
connector@) ~ £) ~ CHECK OUTPUT OF AUTO (Refer to Electrical Components

--L~~!\3slss!~!--~8----~
AMP. inspection.)
(F.i\ Set up "ACTIVE TEST"
~mode with CONSULT. 1 N.G.
~Set up self-diagnosis
Replace blower motor
~STEP2.
Measure voltage across fan con-
- trol amp. harness connector
SHA451C
terminals No. ® and®.
I!] Blower motor
harness con nectar
@ Terminal

LIR
Blower
motor
®
Code
No. Voltage
(Approx.)
(V)
voltage No. e e
(V)
4 ~ 1.2
6 g: 1.3
9 ® ® 1.4

SHA452C
12

= O.K.
1.6

Replace fan control amp.

Blower motor Blower control

harness connector ®
; m
amp. harness

SHA453C

HA-142
 TROUBLE DIAGNOSES - Auto Air Conditioner
Diagnostic Procedure 25 (Cont'd)
Blower control @
amp. harness
connector@
II [!1
L --L--
!!3sJssl"-!
00 Set up "ACTIVE TEST" ~ CHECK FOR OUTPUT OF
mode with CONSULT. AUTO AMP.
Set blower motor voltage (j)Set up "ACTIVE TEST"
at 9 volts mode with CONSULT.
®Set up self-diagnosis STEP. Set blower motor voltage
SHA454C
2. Set code No. in~. at 9 volts
®Set up self-diagnosis STEP
Do approximately 12 volts exist
2. Set code No. in~.
between fan control amp.
£)
CONNECT
Auto amp. harness
harness connector terminal No. Do approximately 12 volts exist

L-mrn
connector@
®and@? between auto amp. harness con-
nectar terminal No. @ and
O.K. body ground?

Replace fan control amp. N.G. 1 O.K.

Ill l Repair harness o connector

SHA455C CHECK FOR FEEDBACK

SIGNAL TO AUTO AMP.

~I
Disconnect fan control amp.
Auto amp. harness
connector@ connector only. Repair harenss or connector
I
~1500~
Do approximately 12 volts exist
between auto amp. harness con-

H
r ~ J}·
nectar terminal No. @ , ® Replace auto amp.
and body ground?

SHA456C

HA-143
 TROUBLE DIAGNOSES - Auto Air Conditioner
Diagnostic Procedure 25 (Cont'd)
D @
Blower relay
harness
connector
D
N.G.
Check power supply circuit.
CHECK POWER SUPPLY
FOR BLOWER RELAY.
r------ (Refer to "POWER SUPPLY
Do approximately 12 volts exist ROUTING" in EL section.)
between blower relay harness
connector terminal No. @,
~ and body ground?
SHA536C

O.K.
II IB
Blower relay N.G.
harness
connector
Do approximately 12 volts exist
between blower relay harness
r---+ Check voltage between blower
relay harness connector ter·
connector terminal No. 0 and minal No. @ and body ground
body ground? is less than 1.5 volt.

O.K. ~O.K. N.G.

Check 12A fuse at fuse block.

Refer to "POWER SUPPLY
Replace blower relay I
SHA458C ROUTING" in EL section and II Note
A!C ELECTRICAL CIRCUIT.)
Does continuity exist between
blower relay harness connector
Blower relay teminal No. ~ and auto amp.
harness harness connector terminal
connector No.®.

l
Replace auto amp.

Note:
-= SHA537C If the result is N.G. after check-
ing circuit continuity, repair
II harness on connector.

Auto amp. harness Blower relay

connector @ connector

~~r SHA460C

HA-144
 TROUBLE DIAGNOSES - Auto Air Conditioner

Electrical Components Inspection

TEMPERATURE SENSORS
After disconnecting temperature sensors harness connector
measure resistance between terminals of each sensor, using the
table below.

Temperature oC (° F) Resistance kU
®Ambient
sensor -40 {-40) 210.55
connector -35 (-31) 146.86
SHA436C
-30 (-22) 103.97
-25 (-13) 74.63
-20 (-4) 54.28
-15 (5) 39.97
-10 (14) 29.77
-5 (23) 22.43
0 (32) 17.07
5 (41) 13.11
10 (50) 10.18
15 (59) 7.96
SHA437C
20 (68) 6.29
IN-VEHICLE SENSOR LOWER 25 (77) 5.00
AND FLOOR DUCT SENSOR
30 (86) 4.01
Aspirator and 35 (95) 3.24
in-vehicle sensor (LWR)
40 (104) 2.63
45 (113) 2.15
5o 11221 1.77
55 (131) 1.47
60 (140) 1.22
65 (149) 1.02
70 (158) 0.86
75 (167) 0.73
80 (176) 0.62

SHA439C

HA-145
 TROUBLE DIAGNOSES - Auto Air Conditioner
Electrical Components Inspection (Cont'd)
VENT DUCT SENSOR

Vent duct L.H.

Ventduct /)
sensor ___.--

---~
SHA440C ~i5
SUNLOAD SENSOR
Measure voltage between terminals @ and ® at vehicle harness
side using the table below.

Input current rnA Output voltage (V)

0 5
0.1 4

0.2 3
0.3 2

0.4 1
0.5 0

• When checking sunload sensor, select a place where sun

shines on it directly.

SHA441C

MODE DOOR MOTOR

Check to see if motor rotates when 12V is applied across mode
door motor connector terminals No. @ and No. ®.

Terminal No.
Mode door operation
@ ®
8 EB VENT-+ DEF
8 ·8 STOP
EB 8 DEF-+ VENT

Check to see if mode door P.B.R. resistance is varied according to

mode door position, as shown in the following table.
Resistance between terminal
Mode door position No.@ and@
DEF 3kQ

FOOT/DEF 1.6 kQ

B/L 0.7 kil

VENT on

HA-146
 TROUBLE DIAGNOSES - Auto Air Conditioner
Electrical Components Inspection (Cont'd)
AIR CONDITIONER SWITCH UNIT
Check the resistance between switch unit connector terminals as
follows:

Switch condition Resistance

Press Less than 500il

Free 00

Example:
When Auto switch is pressed, the .resistance between terminal No.
CD and @ is less than 500 n .
AUTO ECON DEF

OFF MODE UP

REC FAN DOWN

SHA442C

BLOWER MOTOR
• Refer to page HA-84.

RELAY
• Refer to page HA-85.

LOW-PRESSURE SWITCH
• Refer to page HA-85.

HA-147
 TROUBLE DIAGNOSES - Auto Air Conditioner

Control Rod Adjustment

MODE DOOR
1. Move side link by hand and hold mode door in VENT mode.
2. Install mode door motor on heater unit and connect it to
harness.
3. Turn ignition switch to ON.
4. Set up "ACTIVE TEST" mode with CONSULT or set up
self-diagnosis STEP 2.
5. Set MODE DOOR position as in the following table.

00
MODE DOOR POSITION
®
Code No.

VENT -,I
6. Attach mode door rod to side link rod holder.
7. Check mode door operates when position is changed with
CONSULT or when code No.-,I is changed to others.

Mode door motor

SHA307C
®
Code No.
~,I
:,I ~,I -,I

Mode door position DEF HEAT B/L V.ENT

INTAKE DOOR
1. Install intake door motor on intake unit.
2. Connect intake door motor to harness.
3. Turn ignition switch to ON.
4. Set up "ACTIVE TEST" mode with CONSULT or set up
self-diagnosis STEP 2.
5. Set INTAKE DOOR position as in the following table.

Intake door rod

@
INTAKE DOOR POSITION
®
Code No.
Intake
REC -~
6. Install intake door lever.
7. Set intake door rod in REC position and fasten intake door rod
Intake to holder intake door lever.
door 8. Check intake door operates properly when position is changed
with CONSULT or when code No.-~is changed to others.

®
Code No.
·,~ :.,J :,J -,J

Partial Recir-
Intake door position Outside air
outside air culation

HA-148
TROUBLE DIAGNOSES - Auto Air Conditioner
Control Rod Adjustment (Cont'd)
AIR MIX DOOR
1. Connect harness to air mix door motors I and II and set
temperature control lever at full-cold position.
2. Set air mix doors I and II at full-cold position and fasten door
rod.
3. Check that when temperature control lever is at full-cold, both
doors are at full-cold position, and when temperature control
lever is at full-hot, both doors are at full-hot position.

SHA366C

WATER COCK CONTROL CABLE

Clamp cable at full-close position when air mix door II is at full-cold
position, and full-open position when air mix door II is at full-hot
position.

HA-149
 SYSTEM DESCRIPTION - Manual Air Conditioner

Control Switches
SWITCHES AND THEIR CONTROL FUNCTIONS

~
Indicator illuminates
Air outlet Intake air Compressor
A/C ~

~~
A/C

... 0 ON*1

...I
.....
VENT

8/L
*3

*5
*1*4

*1*4

Mode .,.1• FOOT *5 *1*4

®•
....... F/D *5 ON*1

~ DEF FRE ON*1

~ 0
~ REC*2 ON*1

*1: Compressor is operated by thermo control amp. and E.C.C.S. control unit.
*2: Depending on mode switch position.
*3: When vent mode is selected, REC switch function is as in the following chart:
*4: Depending on A/C switch ·position.
*5: Depending on REC switch position.

I~
REC

ON OFF

ON REC REC/FRE
A/C
sw
OFF REC FRE

SHA267C

HA-150
 SYSTEM DESCRIPTION - Manual Air Conditioner

Specifications
AIR MIX DOOR MOTOR
The air mix door motor is attached to the heater unit. It rotates,
opening the air mix door to the position set by the temperature
control lever.
Motor rotation is conveyed through shafts and linkages. The air mix
door position is fed back to the control amplifier by the Potentia
Balance Resistor (P.B.R.) built into the air mix door motor.

Air mix door motor operation

Air mix door Direction of

1 2
operation lever movement

3 Clockwise (Toward
EB e COLD -+HOT passenger
compartment)

e e STOP STOP

(Co I d <Hot Counterclockwise

side)
P. B. R.
sIde) e EB HOT -+COLD (Toward engine
com part me nt)

SHA269C

Characteristics of P.B.R.

(k!l)

3
"1ii
c:
.E
...1;;c:
Ill
Ill
2
!®
.0"0
c:
gIll 111

~@ 1
·enIll 0.
a:z

COOL HOT
82.5°C
(181° F)

SHA270C

HA-151
SYSTEM DESCRIPTION - Manual Air Conditioner
Specifications (Cont'd)
MODE DOOR· MOTOR
When a mode switch is selected, the position switch built into it
reads the corresponding mode to determine the direction of
motor rotation. As soon as the desired mode is set, the position
switch stops the motor.

8 -+--- --- A

To control amp.

I® 10) 101 ®I ®I01 ® V1 cv I® I SHA272C

HA-152
 SYSTEM DESCRIPTION - Manual Air Conditioner
Specifications (Cont'd)
INTAKE DOOR MOTOR
The intake door motor is installed on the side portion of the intake
unit. Using a rod and link it opens and closes the intake door.
When the REC switch is ON (OFF), the ground line of the intake
door motor is switched from terminal ® to @ (@ to @). This
causes the motor to start because the position switch contacts
built into it are now set to the current flow position.
The contacts turn along with the motor. When they reach the
non-current flow position, the motor will stop. The motor always
turns in the same direction. (FRE-+REC-+REC/FREC)

I gn i t i on switch
ACC

To
control
unit
SHA284C

HA-153
 SYSTEM DESCRIPTION - Auto Air Conditioner

Specifications
AUTO AMPLIFIER
The auto amplifier has a built-in microcomputer which processes
information from the A.T.C. system sensors. Signals are sent from
the auto amplifier to activate the A.T.C. system depending upon the
information sent by these sensors and the set temperature se-
lected on the switch panel.
The A.T.C. system's self-diagnostic capabilities are built into the
auto amplifier.

I Ambient temp. sensor~

Mode door motor J Venti I a tor door I
P. B. R. (Potent I o

I
ba I ance Res i storl
H I
~
bu i I d-in mode Floor door
I n-veh i c I e sensor
(Upper) door motor

I
y Defroster door I
~
In-vehicle sensor
Clower)
Air mix door motor
(I) J Air mix door (!)I
I Duct sensor
(Defroster)
~ Automatic
amp I If i er
(Miera- Air mix door motor
(Ill Air mix door em I
I computer)
Duct sensor
(Vent I I atorl
~ I
Intake door motor
I \ Intake door
I
I Duct sensor
(F loorl
~ Fan control amp I i f i er Blower motor
I
l Sunload sensor
~
Compressor

l Thermal transmitter~
CWater temp. l
(Magnet c I utchl
I
i
Temperature
set switch

SHA255C

HA-154
 SYSTEM DESCRIPTION - Auto Air Conditioner
Specifications {Cont'd)
AIR MIX DOOR I and II MOTORS
Component and related parts
• Auto amplifier
• Air mix door motors
• In-vehicle sensors (upper and lower)
• Duct sensors (vent, floor, defroster)
• Ambient sensor
• sunload sensor

Operation of air mix door I and II motors

@ @ Air mix door I Direction of

@ @ and II operation lever movement

8 (±) COLD-? HOT *Clockwise

8 8 STOP STOP
(±) 8 HOT-? COLD *Counterclockwise

*· "Direction of lever
Heater
movement" is as
unit
viewed from arrow P
Air mix door Air mix door 11

SHA274C

System operation
The air mix door motors are attached to the bottom of the heater
unit. The motors rotate, moving a lever system which varies the air
mix door position to heat or cool the inlet air. Outlet air tempera-
ture is measured by the duct sensors, signals from which are sent
to the auto amplifier which uses them to modify the air mix door
position to achieve the current target temperature.
• It takes about 1 minute to stabilize duct air temperature.
• When ambient temperature is below 5°C (41°F) or above
60°C (140°F), air mix door position is fixed.

HA-155
 SYSTEM DESCRIPTION - Auto Air Conditioner
Specifications {Cont'd)
MODE DOOR MOTOR
Component and related parts
• Auto amplifier
• Mode door motor with potential ballast resister (P.B.R.)
• Lower in-vehicle sensor
• Ambient sensor
• Sunload sensor

~
\
SHA275C'

Mode door motor operation

Mode door motor operation

70 • 48
47 73 72
Mode door Direction of
@ ® operation side link rotation
72
e (±) VENT~ DEF Clockwise

e e STOP STOP
(±) e DEF ~VENT Counterclockwise

SHA276C

System operation
The mode door motor is attached to the heater unit The motor
operates a cam assembly which moves the air outlet doors. The
auto amplifier controls air distribution to the VENT, DEF and FOOT
outlets. Outlet door position is conveyed to the auto amplifier by
the P.B.R. built into the mode door motor.
The auto amplifier computes air outlet conditions according to
ambient temperature, set temperature and sunload. When thermal
loads are great, the air outlet computation is additionally influenced
by the foot area temperature. The air outlet positions are smoothly
adjusted in response to changes in ambient temperatures.
When the set temperature is decreased or when the sunload is
increased, the air flow volume from the vent outlets is increased.

HA-156
 SYSTEM DESCRIPTION - Auto Air Conditioner
Specifications (Cont'd)
INTAKE DOOR MOTOR
Component and related parts
• Auto amplifier
• Intake door motor
• Upper in-vehicle sensor
• Vent duct sensor
• Ambient sensor
• Sunload sensor

Intake door operation

Intake door operation

~ Intake door Direction of
~ @ (@
operation lever rotation

8 EB REC-+ FRE Counterclockwise

8 8 STOP STOP

EB 8 FRE-+ REC Clockwise

SHA278C

System operation
The intake door motor is attached to the air intake unit. Intake door
position is controlled approximately once every thirty seconds,
according to the difference between target and actual vent air
temperatures. When the actual outlet air temperature is higher than
the target vent air temperature, the intake door will gradually shift
toward the recirculation-air side. When the outlet air temperature
reaches the target outlet air temperature, the intake door will
gradually shift toward the fresh air side. However, when the
ambient temperature is lower than 20°C (68°F), 100% fresh air is
taken is regardless of outlet air temperatures.
When the compressor is "OFF" the auto amplifier sets the intake
door at the "FRESH" position except when the "RECIRC" switch
is "ON".

HA-157
 SYSTEM DESCRIPTION - Auto Air Conditioner
Specifications (Cont'd)
TEMPERATURE SENSORS

Ambient temperature sensor Upper in-vehicle sensor

Floor<ductlsensor Lower in-vehicle sensor

Defroster (ductlsensor Vent<ductlsensor

SHA256C

SUNLOAD SENSOR
The sunload sensor is located on the right defroster grille. It
detects sunload entering through the windshield by means of a
Sunload sensor photo diode and converts it into a current value which is then
/ input into the auto amplifier.

SHA292C

HA-158
 SYSTEM DESCRIPTION - Auto Air Conditioner
Specifications {Cont'd)
FAN CONTROL AMPLIFIER
The fan control amplifier is located on the cooling unit. It amplifies the base current flowing from the auto
amplifier to change the blower speed.

ACC
:f

Fan control
amp I if i er
~------ ---,
Auto amp I i f i er
1 I
I I
I ~
Micro-
computer 1---~~oo+
Output signal
process
circuit
I
I
m
I I
I I
L _____ _ __j

SHA257C

HA-159
 SYSTEM DESCRIPTION - Auto Air Conditioner

System Operation
SWITCH PANEL

Control Unit Switch panel

Power {
supply

Buzzer
control
signals

Indicator{·
control
signals

A/C switches

AUTO ECON DEF

Switch OFF MODE UP
output
signals
REC FAN DOWN
Signa I PAP
Switch SignaiPBP
input
signals SignaiPCn

Ground

To
i I I um i nation
control
circuit
SHA265C

System operation
Except for illumination lamp terminals @ and @, the switch panel is operated by signals emitted from the
control unit. There are three categories of signals.
1) Power and ground signals
2) Indicators (VFD and LED) and buzzer control signals
3) Switch input and output signals
The control unit always sends three different signals to the switch panel on three lines @, @, and @.
For example, when the "Auto" switch is pushed, signal "A" returns to the control unit on line No. CD. And when
the "Econ" switch is pushed, signal "B" returns to the control unit on line No. CD.
Similarly for the other switches; the control unit recognizes which signal returns on which line, and then
identifies which switch is pushed.

HA-160
 SYSTEM DESCRIPTION - Auto Air Conditioner
System Operation (Cont'd}
AMBIENT TEMPERATURE INPUT PROCESS
iL 3 (5.4) ------------------
For A.T.C. system operation an accurate ambient sensor signal is
0
u necessary. The auto amplifier contains a circuit to ensure accurate
2 (3.6)
~ measurement of increases in ambient temperature. Sudden in-
B
ca crease in temperature of 16°C (61°F} or more, which may be
~
a. detected after encountering heavy traffic after a period of high
E
~ speed cruising, are processed through a delay circuit. The delay
circuit processes any temperature increase in increments of 0.06°C
Time (min.) (0.11°F} every 12 seconds and, in this way, the A.T.C. system is
protected from any sudden changes in ambient sensor signal due
to low air flow around the sensor.
Temperature decreases are not processed through the time
delay circuit.
Example:
In the case of a signal stop after high-speed cruising, the ambient
temperature will rises suddenly.
SHA245C
The ambient temperature input process functions at this time to
prevent unpleasant air conditioning system changes.

SUNLOAD INPUT PROCESS

0.010(9,36)~ The sunload input circuit in the auto amplifier also features a time
delay to prevent abrupt A.T.C. system changes. This feature
[0.11(97,38:ACC)
operates under rapid increases and decreases in sunload.
~ec. Example:
When entering a tunnel the sunload will change suddenly. The
2
kW (kcal/h, BTU/hl/m \ sunload input process system functions at this time to prevent
[kW (kcal/h, BTU/hl/sq ft)
unpleasant air conditioning system changes.
1.151 (990, 3,928)
[12.38 (10,652, ----------- ----
E 42,27311
.e> 0.768 (660, 2,619)
§ [8.26 (7.102,28,182))
(/)

0.384 (330, 1,309)

[4.13 (3,551,14,09111

0 2 3
Time (min.l
SHA246C

HA-161
 SYSTEM DESCRIPTION - Auto Air Conditioner
System Operation {Cont'd)
SENSOR INPUT PROCESS
A fixed resistor is built into the auto amplifier. 12V DC is converted
to SV DC by the constant voltage circuit where it is then applied to
the ground line of the auto amplifier by the fixed resistor and
sensors. The auto amplifier monitors the voltage between each
sensor and the fixed resistor. The resistance of each sensor varies
according to temperature.
Accordingly, the voltage at each sensor varies according to the
temperature. The voltage signal is processed by the auto amplifier
for A.T.C. system operation.

Each sensor
I
I
I
I I
I I
I I
I I
I I
I I
I
I I
I I
I ____________ j I
L-------

SHA247C

STARTING FAN SPEED AND OUTLET DOOR CONTROL

Component parts
Starting fan speed control components are:
• Auto amplifier
• Fan control amplifier
• In-vehicle sensors (Upper and Lower)
• Duct sensor (Defroster, Ventilator and Floor)
•. Ambient sensor
• sunload sensor
• Thermal transmitter (Engine coolant temperature sensor)

System operation
• Fan speed control
At a set temperature of 25°C (77°F), when the upper compartment temperature is below 21°C (70°F) and
the outlet duct temperature is lower than 35°C (95°F), the fan starts at minimum flow rate. As the discharge
air temperature increases, the air flow rate increases to bring the compartment temperature to the target
level as quickly as possible.
When the ambient temperature is above 40°C (104°F), fan air flow rate is at full volume.
As interior temperature begins to reach the target temperature, fan speed decreases.
Under heavy sunload conditions, fan speed is increased to maintain uniform interior temperature. Fan speed
also increases if the set temperature is decreased.
• Outlet door control
At a set temperature of 25°C (77°F), when the upper in-vehicle temperature is lower than 21 °C (70°F) and
all of the outlet air temperatures are lower than 24°C (75°F), the system starts with the minimum airflow rate
in the defroster mode. When defroster duct temperature rises above 24°C (75°F), the air outlet mode
changes from the defroster mode to the DEF/FOOT mode. When floor duct temperature exceeds 39°C
(102°F), the starting fan speed control and outlet door control mode is replaced by the normal automatic
control mode. When the upper in-vehicle temperature is far greater than the lower in-vehicle temperature
because of a large sunload, the system starts with the ventilator mode, which is replaced by the automatic
control mode as the coolant temperature and outlet air temperature increases.

HA-162
 SYSTEM DESCRIPTION - Auto Air Conditioner
System Operation (Cont'd)
Starting fan speed and outlet door control specifications

5 sec.

.:}--=t J!
1G'.--;1---;f---+----..
6
~ '- A"'~o<doo....., oootrol
Outlet is fixed in VENT.
4 1'--------..J,
4V
Outlet is fixed in DEF.
'®
0~---------------------------.
Time

~
1
2 :
\£:/ :
When both upper and lower in-vehicle temperatures are inuch higher than set temperature.
When upper in-vehicle temperature is higher than set temperature.
@ : When upper in-vehicle temperature is lower than set temperature.
@ When DEF duct temperature rises above 24° C (75° F)
(Exact temperature depends on ambient temperature.)
~iii : When FLOOR duct temperature rises above 39°C (102°Fl
(Exact temperature depends on ambient temperature.)
t.¢' When water temperature rises above 40" C ( 104° Fl and difference between outlet air temperature and target temperature is
lower than 5" C (9° F I.

SHA290C

MAGNET CLUTCH CONTROL

ON The auto amplifier controls compressor operation by the ambient
temperature and signals from the E.C.C.S. unit.
The auto amplifier will turn the compressor "ON" or "OFF" as
OFF
determined by a signal detected by the ambient temperature
sensor.

-1 (30) 1 (34)

Ambient temperature • C (° F)
SHA291C

HA-163
 SERVICE DATA AND SPECIFICATIONS (S.O.S.)

General Specifications
COMPRESSOR LUBRICATION OIL
DIESEL-KIKI make DIESEL-KIKI make
Model Model
DK5-16H DKS-16H

Type Slvash plate Type SUNISO 5GS

Displacement cm 3 leu ini/Rev. 167 (10.19) Capacity

ml1 (US fl oz, Imp fl oz)
Cylinder bore x stroke . 37.0 X 25.8 200 (6.8, 7 .0)
Total in system
mm (in) (1.457 X 1.016)
Amount of oil which can
Clockwise 130 (4.4, 4.6)
Direction of rotation be drained
(viewed from drive end)
Compressor (Service parts)
Drive belt PolyV 200 (6.8, 7.0)
charging amount

REFRIGERANT
Type R12

Capacity kg (lb) 0.75-0.85 (1.65- 1.87)

Inspection and Adjustment

ENGINE IDLING SPEED (When A/C is ON.) COMPRESSOR
• Refer to EF & EC section. Model DKS-16H

BELT TENSION Clutch disc-pulley clearance

0.3 - 0.6 (0.012 - 0,024)
mm(in)
• Refer to Checking Drive Belts (MA section).

HA-164
 ELECTRICAL SYSTEM

SECTIONEL
When you read wiring diagrams:
• Read Gl section~ "HOW TO READ WIRING DIAGRAMS".

CONTENTS
PRECAUTIONS ............................................................................................ ............. ..................... .. EL- 2
HARNESS CONNECTOR ............................................................................................................... EL- 3
STANDARDIZED RELAY ................................................................................................................ EL- 4
POWER SUPPLY ROUTING .......................................................................................................... EL- 6
BATTERY .......................................................................................................................................... EL- 11
STARTING SYSTEM ....................................................................................................................... EL- 19
STARTING SYSTEM - Starter - .............................................................................................. EL- 21
CHARGING SYSTEM ............. ......................................................................................................... EL- 27
CHARGING SYSTEM - Alternator - ....................................................................................... EL- 29
COMBINATION SWITCH .................................. ..................................................... ......................... EL- 37
INSTRUMENT SWITCH .... ........................... .................................................................................... EL- 40
HEADLAMP ..... ........... ....... ............................................................................................................... EL- 42
EXTERIOR LAMP ............................................................................................................................ EL- 49
INTERIOR LAMP ............ ........ ......................................................................................................... EL- 54
METER AND GAUGES .................................................................................................................. EL- 57
WARNING LAMPS AND CHIME .................................................................................................. EL- 63
TIME CONTROL SYSTEM ............................................................................................................. EL- 68
WIPER AND WASHER ................................................................................................................... EL- 83
HORN, CIGARETTE LIGHTER, CLOCK ...................................................................................... EL- 88
REAR WINDOW DEFOGGER ....................................................................................................... EL- 89
AUDIO AND POWER ANTENNA ................................................................................................. EL- 92
AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) ................................................................ EL- 98
THEFT WARNING SYSTEM .......................................................................................................... EL-115
LOCATION OF ELECTRICAL UNITS ........................................................................................... EL-136
HARNESS LAYOUT ........................................................................................................................ EL-141
SPECIAL SERVICE TOOLS ........................................................................................................... EL-155
WIRING DIAGRAM REFERENCE CHART

E.C.C.S................................................................................................................................ EF & EC SECTION

AT CONTROL, SHIFT LOCK ...................................................................................................... AT SECTION
ADJUSTABLE SHOCK ABSORBER .......................................................................................... FA SECTION
ANTI-LOCK BRAKING SYSTEM ................................................................................................ BR SECTION
POWER STEERING, SUPER HICAS .......................................................................................... ST SECTION
HEATER AND AIR CONDITIONER ............................................................................................ HA SECTION
POWER WINDOW, POWER DOOR LOCK, DOOR MIRROR, POWER SEAT,
AUTOMATIC SEAT BELT AND SRS "AIR BAG" .................................................................... BF SECTION
 PRECAUTIONS

Supplemental Restraint System "AIR BAG"

The Supplemental Restraint System "Air Bag" helps to reduce the
risk or severity of injury to the driver in a frontal collision. The
Supplemental Restraint System consists of an air bag (located in
the center of the steering wheel), sensors, a control unit, warning
lamp, wiring harness and spiral cable. Information necessary to
service the system safely is included in the BF section of this
Service Manual.
WARNING:
a. To avoid rendering the SRS inoperative, which could lead to
personal injury or death in the event of a severe frontal
collision, all maintenance must be performed by an author-
ized NISSAN dealer.
b. Improper maintenance, including incorrect removal and in-
stallation of the SRS, can lead to personal injury caused by
unintentional activation of the system.
c. All SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation. Do not use electrical
test equipment on any circuit related to the SRS "Air Bag".

EL-2
 HARNESS CONNECTOR

Description

HARNESS CONNECTOR
• All harness connectors have been modified to prevent accidental looseness or disconnection.
• The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.

[Example]

PUSH
Terminal retainer

LIFT PUSH

PUSH

PUSH
PUSH

PUSH
(For combiMtion m._l (For relevl

SEL769D

EL-3
 STANDARDIZED RELAY

Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.

NORMAL OPEN RELAY NORMAL CLOSED RELAY MIXED TYPE RELAY

Does not
flow¢
Flows
.. Flows
..
LL.
LL.
= Does not Q
p flow

3:
(I)

=0 I = 0....__---11 = 0....__---11
sw 1 BATTERY SW 1 BATTERY SW 1 BATTERY

Flows
Does not
Does not
flow¢~--~
flow¢

z 0-+----
9 = Flows

3:
(I)
L L L
SW 1 BATTERY sw 1 BATTERY BATTERY

SEL881H

TYPE OF STANDARDIZED RELAYS

1M .......... 1 Make 2M 2 Make

1T .......... 1 Transfer 1M ·1 B .......... 1 Make 1 Break

1M 2M

1M

--- ......
2M

1T 1M·1B

1T

,,
,. -....... 1B

\
I \
I I

.. __ , "
\ I
\ I

'
1M

SEL882H

EL-4
 STANDARDIZED RELAY

Type Outer view Circuit Connector symbol Case color

and connection

1T BLACK

1M BLUE or
GREEN

2M BROWN

CD

lM·lB GRAY

SEL883H

EL-5
 -,
@ : Turbo model
FUSE B ::.L::.;OC:::K.:..___

~~~CUlT
IGNITION SWITCH
> IGNITION RELAY
OFF ACC ON ST

~ ~~~
I
2 WI I BREAKER

®: ~ g[;~~
3 ~ BLOWER
RELAY ACCESSORY
RELAY
4
5 rtml®
CDCDm
~'''r
~ .....
(Main I
harness>

"-t------
L/W-1•
B/Yj
@• .,
Horn.
un i t.
Time control
A. S. C. D.

Head I amp R. H. • Daytime

'1 ~
::!.
0
=e
m
:a
light control unit
®
.,.,r-c:
:I 0
m ca
II'~ f :~,
Head I amp L. H. • DaytIme
I ight control unit

:~l~;~gc~mEM t ~~ F~i::WJ ,
r- c
1

en m-·
[ 1111 ...m
ca <
:a
Shift lock control
~ ..'
r
@ 3 0
unit. Key switch

Front fog lamp

~@) .. c:
:::1

--~
~(@) z
Fuel pump
Bulb check relay
Boost sensor @ -----~ ~ ..'
r
®ft®
BODY GROUND L_---,---- C)

E. c. C. S. @Y lllriTI§l
1 .a
llfl @ill) ® &
o:p:l
~ngine room ~ m m ~~ m
Radiator fan reI ay. A/C ~
harness) m
o
system. Daytime I i ght ~
control unit
::r
Stop I amp switch.
A. S. C. D. contra I
unit. A/T contra I ~
g
~
r
~~r~~ ~
~
3
Dl

111
~~., ... r,~,.,~,
.,.,m r .,., E4J Ul
unit. Shift lock ''' @ f!!.

IW I
r Theft warning
contra I unit. ...~., ., r m ; reI ay

~I
Anti-lock braking '" '"
system control unit. ~ Radiator
'control
- " •<eec;
un1tng • • fan motoc @ ,<;"), fill'
~ ~~ ~ fil2'
~ ~~ ,<;"), @7
HI CAS control unit FR...... Head I amp .,. .,. "" ""
..... -:.- washer motor .• BODY GROUND BODY GROUND
FUSE BLOCK!In RELAY BO~ BATTERY FUSIBLE LINK HOLDER
 JE
Jk: Rear window defogger switch
A/T control unit. Theft warning control unit.
i I lumination

II
Door lock system. Auto A/C control amp.• Key hole
_ _ _FUSE BLOCK r.iii't i I I um i nation. Foot I amp. Audio. C I oc k, HI CAS control unit@
~ Air bag control unit @

~ - 3A
z A - L/G ____l 1
JA- Y
r---
=::::::J r - -
WarnIng chI me
Hazard warning I amp
4A 4A - y :::::::=.J ~
2A
~: I 7 A - G/L
B A - 8/Y
===::::::.s--- E. c. c. S. contra I unit
9A Power steering contra I unit@. HICAS control unit@
~= = LL/~
9 A - G/Y
2 38
~~ : Power window amp. Automatic seat belt system @
;: = :;:- '
58

-:1 I ~~~ ~ T; me eontro I un; t. C I oek. Ooor mIrror eyetem

118
98
Time control unit
Turn signa I I amp, A/C ignition relay
Exterior lamps<clearanc~ I icens~ tal I and side
marker>. I I lumination. Time control unit. Dimmer relay~

_]J~
Audio
@ .,
ICI
Automatic seat belt system
@)
IC=ORL/L~-
I
A/T control unit. Shift lock control unit.~ 0
G/L~ A. S.C. D.• Back-up lamp ~
2C Inhibitor switch.
r--
~g I 2C
=e
m
L_
7C
20
!!
20-
;
G
I' : Heater and A/C.
Time control unit
Meter and Gauges. Warning
Theft warning control

lamp,
unit
~
:::::!.
::D
tn
m @
Diagnostic connector for CONSULT
::I
c.a .,.,c:
r-
1
..... ~~
I
. I::Ju__u~mm~ IE~
~~
4F
l lE-OR/B_...r-
~e - . M.
3 E - UR
4F - L/R
Cigarette I ighter
Air bag control unit ry:;..
Js ~
I ower motor, Auto A/C control amp
c
-·
I»
c.a
r-
-<
~
I» ::D
0:
-
A/T model
IG Bill :I IJit3 lG- L Speaker@ 3 0
@: M/T model c:
® 0 :j

--
0 z
II
@ : Bose speaker model
Rear washer motor ::I
~t- @: C)
f. 1:·M I--
~ 4L =
6L
LG
G/L __j r-----
-f"M\~ Back-up I amp @
For U. S. A.
a.
~t I 7L LG/8 1!!!1-- @: 5-speaker model
L _ 7L -LG~ Front washer motor

~ ~
Front wiper motor
@: 2+2 seater model

® Turbo model

®
INI t IN-
Non· turbo model
Power antenna timer
@
~
: With air bag
~~
G/L Rear wiper motor
2N 2 N - L/G

~ abs:r~!r~~st:y@stem, Aspirator motor

ock br
' @ ~ l__

~
3N 3 N - BR

~~~ ~ P~r
4N 1P- L
4 N - R/8 Anti-1
Adjustable shock
1P
NDOW
:R = "_- " '
(81 .,
Interior 1
emp. Spot I am
antenna tl mer P.
m TC ·

'""'~,_I ••o· ©C .P~r

antenna timer

en
m
r
~
....
,
L ----
~ jRear window defogger
 POWER SUPPLY ROUTING

Fuse Block Internal Circuit

I l
r -
r.- -
ACCESS CRY
RELAY
JA
2A 1----1--
I~~ §~
I
r-
7A 4
lA
9A _r-
18
I 28
38 I J
A ~ 88 -
68 ~
I GNI Tl ON
A 7B RELAY
BB
9B
H I

-
-
r ~~
5
6
II\] :n;rnl
BL OWER
IC- RE LAY
2C

I
5C- h I
6C-
7C
""'T
~ L-
~§~
10 4
20
30 .., L~

·ruh
40
60 ICi
70 RE AR WINDOW
H 1 OE FOGGER RELAY

-
•11\]:n:J
l--1 '---- I ..... I
-2
3
-4
-5
-l---6

IE
2E- -
I'
I 3E
4E
IF ~

2F ~
BULB CHECK
3F
4F - ---, RELAY

~~~;~I
I
2
IG I 3
~
Ill
I I 2G
2 IH
2H .~
r- 4

~ I~ CIRCUIT
BREAKER

L: J
-I
-2 t@J~I
ADAPTER
..... I
2 IH [8::::§]
I

,lrr 2
"--3 ~~
2~ I f
4
I

J 3P
4P
.._ II

L.:::
~

J
J
L=_ IQ~
2Q

~J

I h J
r I
z:z:
-N

SEL919P

EL-8
 POWER SUPPLY ROUTING

Fuse
a. If fuse is blown, be sure to eliminate cause of problem
before installing new fuse.
b. Use fuse of specified rating. Never us.e fuse of more than
specified rating.
c. Do not install fuse In oblique direction; always insert it
into fuse holder properly.
d. Remove fuse for clock if vehicle is not used for a long
period of time.
O.K. Blown

SEL954J

Fusible Link
A melted fusible link can be detected either by visual inspection
or by feeling with finger tip. If its condition is questionable, use
circuit tester or test lamp.
CAUTION:
a. If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
b. Never wrap periphery of fusible link with vinyl tape.
Extreme care should be taken with this link to ensure that
it does not come into contact with any other wiring
harness or vinyl or rubber. parts.

EL-9
 POWER SUPPLY ROUTING

NOTE

EL-10
 BATTERY

CAUTION:
a. If it becomes necessary to start the engine with a booster
battery and jumper cables, u• a 12-volt booster battery.
b. After connecting battery cables, ensure that they are tightly
clamped to battery terminals for good contact.
c. Never add djstilled water through the hole u•d to check
specific gravity.

How to Handle Battery

Keep clean and dry
METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-dis-
charging a ba'ttery ..
• The battery surface (particularly its top) should always be
kept clean and dry.
If the top surface of a battery is wet with electrolyte or
water, leakage current will cause the battery to discharge.
Always keep the battery clean and dry.
SEL711E

• When the vehicle is not going to be used over a long period

of time, disconnect the negative battery terminal. (If the
vehicle has an extended storage switch, turn it off.)

• Check the charge condition of the battery.

Periodically check the specific gravity of the electrolyte.
Keep a close check on charge condition to prevent over-
discharge.

SEL4420

EL-11
 BATTERY
How to Handle Battery (Cont'd)
CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If the acid contacts the eyes, skin or clothing, immediate·
ly flush with water for 15 minutes and seek medical attention.
Normally the battery does not require additional water. How-
ever, when the battery is used under severe conditions, adding
distilled water may be necessary during the battery I ife.

• Remove the cell plug using a suitable tool.

• Add distilled water up to the MAX level.

SULPHATION
_ _ Normal battery
When a battery has been left unattended for a long period of
- Sulphated battery
Charging voltage time and has a specific gravity of less than 1.1 00, it will be com-
l Charging voltage
pletely discharged, resulting in sulphation on the cell plates.
Compared with a battery discharged under· normal conditions,
the current flow in a "sulphated" battery is not as smooth
Charging current
• Charging current although its voltage is high during the initial stage of charging,
as shown in the f~gure at the left.

Duration of charge SE L 709E

Hydrometer SPECIFIC GRAVITY CHECK

Read top level
with scale 1. Read hydrometer and thermometer indications at eye level.

EL-12
 BATTERY
How to Handle Battery (Cont'd)
• When electrolyte level is too low, tilt battery case to raise it
Hydrometer -....._ ~ for easy measurement.

SEL7t0E

2. Convert into specific gravity at 20° C (68° F).

Example:
• When electrolyte temperature is 35° C (95° F) and specific
gravity of electrolyte is 1.230, converted specific gravity at
20° C (68° F) is 1.240.
• When electrolyte temperature is Oo C (32° F) and specific
gravity of electrolyte is 1.210, converted specific gravity at
20° C (68° F) is 1 .196.

Converted specific gravity IS2ol

1.30

~
.. 1.28

a 1.26
..
I!
Q.
E
!
>
.. 1.22
eu
....
1.20

1.18
•
~
·:;; 1.1&
•
;;. 1.14
-.....
.!:!

Q.
1.12
en
1.10

-30 -20 -10 0 10 50

1-221 1-41 1141 1321 1501 11221
Electrolyte temperature •c I" Fl
SEL0420

EL-13
 BATTERY

Battery Test and Charging Chart

Chart I

VISUAL INSPECTION
• Check battery case for cracks or bends.
N.G.
• Check battery terminals for damage.
• If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in),
it is O.K.

O.K.
,
Replace battery.
CHECKING SPECIFIC GRAVITY
Refer to "Specific Gravity Check".

l
I Below 1.100 1 1 1 .1 oo _, .220 I Above 1 .220 1
+ ~
SLOW CHARGE •
Refer to "A: Slow CAPACITY TEST
STANDARD CHARGE QUICK CHARGE Refer to "Chart II".
Charge".
Refer to "B: Standard Refer to "C: Quick
Charge". Charge".
O.K. I N.G.

CAPACITY TEST
Refer to "Chart II".
+
Ready for use
CAPACITY TEST

1
• Mount battery again
Refer to "Chart II".
and check loose ter-
O.K.l N.G. minals. Also, check

Ready Replace
O.K.
1 N.G. other related circuits.

for use battery. ~

Ready for use
CHECKING SPECIFIC GRAVITY QUICK CHARGE
Refer to "Specific Gravity Check". Refer to "C: Quick
Charge".

I • Time required: 45 min.

RECHARGE CAPACITY TEST

Refer to "C: Quick Charge". Refer to "Chart II".
elf battery temperature rises above so•c
(140°F), stop charging. Always charge !N.G.
battery when its temperature is below
so•c I140°F). Replace
for use battery.

CAPACITY TEST
Refer to "Chart II".

O.K.~ 1N.G .
Ready •
Replace
for use battery.

* "STANDARD CHARGE" is recommended in case that the vehicle is in storage after charging.

EL-14
 BATTERY
Battery Test and Charging Chart (Cont'd)

Chart II I
• Check battery type and
determine the specified
current using the following
table.

Fig. 1 DISCHARGING CURRENT

(Load tester!
Test using battery
checker. Test using load tester. Type Current (AI
28B19R(LI 90
34819R(LI 99
46824R(L) 135
Follow manufacturer's Read load tester voltage
instructions to check and when specified discharging 55B24R(L) 135
determine if battery is current (Refer to Fig. 1 .I 50D23R(L) 150
serviceable. flows through battery for 55D23RILI 180
15 seconds. 65D26R(L) 195
O.K. N.G.
80D26RILI 195
75D31RILI 210
Ready for use Go to next step.
95031RILI 240
95E41R(L) 300
130E41RILI 330

Ready for use Go to next step.

~.r!1
0 . . .o_
00

SEL6978

EL-15
 BATTERY
Battery Test and Charging Chart (Cont'd)

A: SLOW CHARGE
Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)

:::;:::; :::;:::; :::; :::;:::; :::;

:::;:::;
a:: a:
....
(I) (I)
ir~
~~
a:: a:
C")C")
22
a:: a:
U)U)
a:
r;
--
.. -
a:: a: a:
;
NN NN Mot w
IDID
~~
IDID
U)LI)
otLD
00
~18
00
l8i
0
Ll)
.....
ow
LI)LI)
(I) (I) ..
fil
Determine initial charging current from
specific gravity referring to Fig. 2:
4.0 5.0 7.0 8.0 9.0 10.0 14.0
Below 1.100
IAI (A) IAI (AI (AI (AI lA)

• Charge battery. • Check battery tYpe and determine the specified current using the
• Check charging voltage 30 minutes after table shown above.
starting the battery charge. • After starting charging, adjustment of charging current is not
I1IIC8IIBI'y.

Fig. 3 ADDITIONAL CHARGE (Slow charge)

O.K. N.G.

Replace battery.
r Below 1.150
l I 1.150 . 1.200 1 I 1 .200 _ 1 .240 1 r Above 1.240 1
Continue to charge for
12 hours.
Charge for 5 hours Charge for 4 hours Charge for 2 hours
at initial charging at initial charging at initial charging
current setting. current setting. current setting.

CHECKING SPECIFIC GRAVITY

Refer to "Specific Gravity Check". l
~
Go to "CAPACITY TEST".

CAUTION:
Conduct additional charge as per a. Set charging current to value specified in Fig.
Fig 3, if necessary.
2. If charger is not capable of producing speci-
fied current value. set its charging current as
close to that value as possible.
Go to "CAPACITY TEST".
b. Keep battery away from open flame while it is
being charged.
c. When connecting charger. connect leads first.
then turn on charger. Do not turn on charger
first. as this may cause a spark.
d. If battery temperature rises above 60°C
(140° f). stop charging. Always charge battery
when its temperature is below 60°C (140° F).

EL-16
 BATTERY
Battery Test and Charging Chart (Cont'd)

I 8: STANDARDCHARGE
Fig. 4 INITIAL CHARGING CURRENT SETTING
(Standard charge)

:J:J :J:J :J:J :J:J :J :J:J :J

....
a:: a:
0101
a:: a:
••
NN
a:: a:
MM
NN
a:: a:
IDID
NN
a:
r; ....
"i"i
Mot
ow
a:
;
w
Determine initial charging current from
specific gravity, referring to Fig. 4.
11:111:1
~~
11:111:1
IDitl
otltl
00
Oltl
ltlltl
00
ltiO
IDID
0
Ill
..... ltlltl
0101 ..fil
1.100-1.130 4.0 lA) 5.0 (A) 6.0 (A) 7.0 lA) B.OIAI 9.0 IAI 13.0 (A)

1 1.130 · 1.160 3.0 lA) 4.0 (A) 5.0 lA) 6.0 lA) 7.0 (A) 8.0 (A) 11.0 (A)

,- Charge battery for B hours.

I 1.160 · 1.190 2.0 IAI 3.0 (A) 4.0 (AI 5.0 lA) 6.0 (A) 7.0 (AI 9.0 (A)

l
CHECKING SPECIFIC GRAVITY
•
1.190-1.220 2.0(A) 2.0IAI3.0(A)4.0(A) S.O(A) S.O(A) 7.0(A)

Check battery type and determine the specified current using the table
shown above.
• After starting charging, adjustment of charging current is not necessary.
Refer to "Specific Gravity Check".

l
Conduct additional charge as per
Fig. 5, if necessary.

l
Fig. 5 ADDITIONAL CHARGE (Standard charge)

T ~ Tl
Go to "CAPACITY TEST".
Above 1.240
l
Charge for 3.5 hours Charge for 2.5 hours Charge for 1 .5 hours
at initial charging at initial charging at initial charging
current setting. current setting. current setting.

~ ~ l
+
Go to "CAPACITY TEST".

CAUTION:
a. Do not use standard charge method on a battery whose specific gravity is less than 1.100.
b. Set charging current to value specified in Fig. 4. If charger is not capable of producing specified current
value, set its charging current as close to that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this
may cause a spark.
e. If battery temperature rises above 60°C (140° F), stop charging. Always charge battery when its tempera-
ture is below 60° C (140° F).

EL-17
 BATTERY
Battery Test and Charging Chart (Cont'd)

C: QUICK CHARGE
Fig. 6 INITIAL CHARGING CURRENT SETTING AND
CHARGING TIME IOuick charge)

BATTERY ::;

Determine initial charging current setting and

TYPE
:J:J
a: a:
......
0101
:J:J:J :J:J:J :J:i:J
iririr iririr a:u:u:
'Ot'OtM MUIUI
---
......... ...
u:
..,
CUR\ IDID
NNN NNN MM'Ot
1111110 0 0 0 cow
w
charging time from specific gravity, referring
to Fig. 6.
CON·
VERT ED
RENT
[A)
Cll'Ot
NM ~1110
111111
1111110 111111111
IIIUICXl .... 0)01 ...
~

SPECIFIC
GRAVITY 10 lA) 151Al 20 lA) 30 lA) 401Al

1.100 ·1.130 2.5 hours

1.130-1.160 2.0 hours

Charge battery
1.160-1.190 1.5 hours

1
Go to "CAPACITY TEST".
1.190-1.220

Above 1.220
1.0 hours

0.75 hours 145 min.)

• Check battery type and determine the specified current using the table
shown above.
• After starting charging, adjustment of charging current is not necessary.

CAUTION:
a. Do not use quick charge method on a battery whose specific gravity is less than 1.1 00.
b. Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads fint, then turn on charger. Do not turn on charger fint, as this
may cause a spark.
e. Be careful of a rise in battery temperature because a large current flow is required during quick-charge
operation.
If battery temperature rises above 60"C (140° F), stop charging. Always charge battery when its tem-
perature is below 60"C (140" F).
f. Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can
cause deterioration of the battery.

Service Data and Specifications (S.O.S.)

Applied model MIT A/T
Type 65D26L 80D26L
CapacitY V-AH 12-65

EL-18
 STARTING SYSTEM

Wiring Diagram
THEFT INHIBITOR
WARNING STARTER
SWITCH

[;~
OFF ACC ON ST PRN0 2 l
I ( l
2 2
3 3
4 4
5 rs
6
~® ?f~® 7
8
-~a:: ~' -~~
CONNECTOR 9
IDIDma:
.. 01

A/T mode I (MB in

harness>
M/T mode I

@)~
tiw =
Ill G/Lf ~G/L
®fi®~
• .; 0
g
e
1111TJ111 -
BATTERY
BODY CLUTCH THEFT WARNING
GROUND INTERLOCK CONTROL UNIT FUSIBLE LINK HOLDER
SWITCH SEL920P

M/T MODELS FOR CANADA

OFF ACC ON ST
I (
2
3
4
5

(Main
harness)

p:J1m ®®
L__ _ _ _ _ R/T-{)Q-8/T
<A I ternator
harness>

1...---.+-----111 -ttll.t:ti-w ----;::===~--

@)(@])

"'
Q

l£±:tEJ Ill @)
llllrTlllll BATTERY
THEFT WARNING
CONTROL UNIT FUSIBLE LINK HOLOER
SEL921 P

El-19
 ' I
O.K. .,
Check battery for charging condition \ N.G. • Charge or replace battery.
and battery terminals for connections and • Repair connections and corrosion of
corrosion. battery terminals.

O.K.

N.G. Repair wiring or replace electrical units.

Check pinion roller clutch for damage. • Ignition switch
Replace if necessary. • Inhibitor switch
O.K. • Starter relay
• Connections
Check reduction gear, armature and gear
shaft for damage.
Replace if necessary.

Can You hear magnetic switch of starter ~~ I

~
• Repair or replace magnetic switch.
motor operating? .....
Yes a
c :::u
m N.G. • Adjust dimension 11. c:r
a; ::t
r-
1
Is meshing condition of pinion and ring
• Check shift lever for deformation, z
gear O.K.?
return spring for fatigue and pinion
I
en Q
N :::r
0 O.K. for sliding condition. U)
0

~m
• Correct meshing condition of pinion 0
Remove starter motor from engine. and ring gear. Replace if necessary. =:!:
Does starter motor turn under no load :::s
by connecting battery (±) terminal to M ca
terminal of starter motor and battery
• Check armature assembly, field coil,
!:
8 terminal to starter motor body?
and brush.
Yes Replace if necessary.
N.G. (Turns slowly.)
r---------------------~
Check battery for charging condition
) N.G. I) •1
and battery terminals for connections Check magnetic switch contacts.
and corrosion. Replace if necessary.

,---------,
O.K.
Check ignition system
and fuel system. Repair or replace starter motor.

j c=> I I j
I
1 Check item. Problem or
corrective action I 1

Starter motor does not I If any abnormality is found, imm~iately 1

stop if ignition switch is
turned off.
Repair or replace ignition switch, starter
relay or magnetic switch. ~::::~~~ negeti:•-=~~- J
 STARTING SYSTEM Starter

Construction
M2T25281

Adjusting plate ~
Plate thickne•:
Holder 0.25 (0.00981
0.50 (0.01971

Adjusting washer
Washer thickn-:
0.25 (0.00981
0.50 (0.01971

E!l® Pinion assembly

r;o;l2.5- 4.4
(0.25 - 0.45,
1.8-3.31

Unit: mm (in)
rP;l :
N-m (kg-m, ft-lb)
B @ : High-temperature grease point
SEL038N

EL-21
 STARTING SYSTEM -Starter-

Removal and Installation

REMOVAL
1. Remove starter insulator.
2. Remove starter harness connector and cable.
3. Remove starter fixing bolt and nut and remove starter.

INSTALLATION
• Installation procedure is in reverse order of removal.

From battery Magnetic Switch Check

• Before starting to check, disconnect battery ground cable.
e Disconnect "M" terminal of starter motor.
1. Continuity test (between "S" terminal and switch body).
• No continuity ... Replace.

SELSSSE

2. Continuity test (between "S" terminal and "M" terminal).

• No continuity ... Replace.

SEL556E

Pinion/Clutch Check
1. Inspect pinion teeth.
• Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
• If it does not lock (or locks) in either direction or unusual
resistance is evident ... Replace.
3. Inspect reduction gear teeth.
SEL048D
• Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)

EL-22
 STARTING SYSTEM - Starter

Brush Check
BRUSH
Check brush for wear.
Wear limit length:
Refer to S.O.S.
Vernier caliper • Excessive wear ... Replace.

SEL626B

BRUSH SPRING PRESSURE

Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to S.O.S.
• Not within the specified values ... Replace.

SEL656M

BRUSH HOLDER
1. Perform insulation test between brush holder (positive side)
and its base (negative side).
• Continuity exists .... Replace.
2. Check brushes to see if they move smoothly.
• If brush holder is bent, replace it; if surfaces of brush holder
and base are dirty, clean them.

Field Coil Check

1. Continuity test (between field coil positive terminal and positive
brushes).
• No continuity ... Replace yoke.
2. Insulation test (between field coil positive terminal and yoke).
• Continuity exists .... Replace yoke.

SEL 102E

Armature Check
1. Continuity test (between two segments side by side).
• No continuity ... Replace.

Ohmmeter

SEL625B

EL-23
 STARTING SYSTEM - Starter -
Armature Check (Cont'd)
2. Insulation test (between each commutator bar and shaft).
·. • Continuity exists .... Replace.

3. Check commutator surface.

• Rough ... Sand lightly with No. 500 - 600 sandpaper.

4. Check diameter of commutator.

Commutator minimum diameter:
Refer to S.O.S.
• Less than specified value ... Replace.
Vernier caliper

u.-......,....- m SEL418A

5. Check depth of insulating mold from commutator surface.

e Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)

O.S·O.Bmm
Round 10.020 · 0.031 inl

~ Correct

-~L- ~-

Commutator
_.._..,_. Segment
Mold

Incorrect EE021

EL-24
 STARTING SYSTEM - Starter

Adjusting washer
Reassembly
Idler gear Carefully observe the following instructions.
a. Apply grease to:
• Rear cover metal
• Gear case metal
• Frictional surface of pinion
• Moving portion of shift lever
• Plunger of magnetic switch
b. After assembling gear case, pinion assembly, idler gear,
adjusting washers and center bracket, turn idler gear with
your hand in axial direction and adjust end play to the 0.1 to
0.5 mm (0.004 to 0.020 in) range using adjusting washer(s).
c. Check pinion to see if its engagement length is correct.

Measure difference in height " Q" of pinion assembly front edge

when pinion assembly is forced out by the magnetic switch and
then when it is pulled out by hand.
Difference "Q ": 0.3 - 2.0 mm (0.012 - 0.079 in)
T
: Battery
I
..J...

SEL839M

• Not in the specified value ... Adjust by adjusting plate.

EL-25
STARTING SYSTEM - Starter -

Service Data and Specifications (S.O.S.)

STARTER
M2T25281
Type
Reduction gear

System voltage v 12

Terminal voltage v 11.0

No-load Current A 70

Revolution rpm More than 2,000

Minimum length of brush mm (in) 11.5 (0.453)

Brush spring tension 13.7. 25.5

N (kg,lb)
(With new brush) (1-4. 2.6, 3.1. 5.7)

Minimum diameter of
mm (in) 31.4 (1.236)
commutator

Difference "Q" in height of 0.3. 2.0

mm (in)
pinion assembly (0.012. 0.079)

EL-26
 FUSE BL
SUPPLYOCK <Refer COMBINATION METER
BULB C- ROUTING". l to "POWER
CHARGE CHARGE

~~~ IG~~T~~"s~Afc~
RELAY HECK - -
29 o-----@----o 7 2~ o-----@----o ~
1 GNITI ON SWITCH
ON or START
[M-t-1•1-H-fl [H+H4ll HE-E+Ml IE¥H·H31
~ngine
room CONNECTOR
FR harnes~

t lOA G
P/B fltEoF+±iJ fJ±JoFffiJ 8±3+++;fl D-tfioffi
So g,@.,~@
~
B/R B/R
W/R (: w J m

§ (")
<Ma In harness)
J:
[ill ® ...:;·-·~ )>
:D
m
r- FUSE BLOCK ~ngine room harnes~
ca
c
-z
G')

N
1

....,
n RELAY BOXJ
(1
<Refer to "POWER -·
D)
G')
SUPPLY ROUTING". l ...
ca tn

® ' A/T model

D)
3 ~
-f
@ : M/T model m
~ ~
€UI 3:

e@)
:u :u

~@)
~ <BI
~@)
I uel
@
@
:: Wrth air bag

: Without air bag

$® ~® ~ ~®
~
€
:u
'
:u
€UI

€€ @) €

~@)
I ~ I
(f ~
tS=w~R
® 6 I II I
@)~@)
m
TITITITITITI

til
m
r
~=
@0-B ------------------------------~
~lternator harnes~ BODY
j ~UMU
CD GROUND FUSIBLE LINK HOLDER
1\J ALTERNATOR BATTERY
1\J
"t)
 CHARGING SYSTEM

Trouble-shooting
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and
suitable test probes are necessary for the test. The alternator can be checked easily by referring to the
Inspection Table.
Before starting trouble-shooting, inspect the fusibl~ link.

WITH IC REGULATOR
With alternator side L terminal
grounded, internal short occurs Burned-out
bulb. Replace
® when+ diode is short-circuited.
and Proceed
Ignition Disconnect to "A".
switch "ON" connector (S, *See 4) for grounding F terminal.
Ll and ground
Damaged IC-RG,
L lead wire l--~ Connect con-
-.___,---" nector (S, L) Replace.
I and ground F
I terminal
I
I
: (MITSUBISHI
~~~e.!_ _ _ _ _ _ - - - - - - - - - - - - - DaAmaCgeGd IC-RG
Of ...

Check or replace Engine idling

drive belt.

Engine speed: More than 15.5V - Damaged IC-RG,

1,500 rpm Replace.
(Measure B
terminal volt-
age.) - - - -L....Io_.K_._ ___,
1) Use fully charged battery.
2) Light Charge warning light Make sure connector
A.C.G. Alternator parts except IC regulator (S, L) is connected
IC-RG IC regulator correctly.
O.K. IC alternator is in good condition.
3) When reaching "Damaged A.C.G.", remove
alternator from vehicle and disassemble, inspect
and correct or replace faulty parts.
4) *Method of grounding F terminal (HITACHI make
only)
Gasoline engine model
Contact tip of wire with brush and attach
wire to alternator body.

5) Terminals "S", "L", "B" and "E" are marked on

rear cover of alternator.

EL-28
 CHARGING SYSTEM - Alternator

Construction
LR180-724 Pulley assembly * Rear bearing
Front cover Rotor

.....
.. '='-'~~-,-

'-"-=""'"
Bearing retainer

Front bearing

Diode assembly

lillliJI~~
liJI liJI
li1l
~lill Through-bolt
A3.1-3.s
(0.32 - 0.40, 2.3 - 2.91

Brush assembly ~ : N-m {kg-m, ft-lbl

SEL686N

A3T05192 Rotor

Rear cover
assembly

IC voltage regulator assembly

tql : N·m {kg-m, ft·lbl

Stator SEL687N

*Rear bearing
CAUTION:
Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. Be careful not to
lose this ring during removal.

EL-29
CHARGING SYSTEM -Alternator-

Removal and Installation

REMOVAL
1. Loosen alternator belt.
2. Remove alternator adjusting bar.
3. Remove harness connector and cable from alternator.

4. Remove stabilizer bracket fixing bolts.

5. Remove· radiator lower hose bracket and push lower hose
upward to make room.

6. Remove alternator fixing bolt and take out alternator as shown

in the figure.

INSTALLATION
• Installation procedure is in reverse order of removal.

Disassembly
REAR COVER REMOVAL
CAUTION:
Rear cover may be hard to remove because a ring is used to lock
outer race of rear bearing. To facilitate removal of rear cover,
heat just bearing box section with a 200W soldering iron.
Do not use a heat gun, as it can damage diode assembly.

SEL628D

EL-30
 CHARGING SYSTEM - Alternator

Ohmmeter Rotor Slip Ring Check

1. Continuity test
• No continuity ... Replace rotor.

Ohmmeter 2. Insulator test

• Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to S.O.S.

Brush Check
1. Check smooth movement of brush.
• Not smooth ... Check brush holder and clean.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.

3. Check brush lead wire for damage.

2 mm (0.08 in) • Damaged ... Replace.
4. Check brush spring pressure.
Measure brush spring pressure with brush projected approxi·
mately 2 mm (0.08 in) from brush holder.
Spring pressure:
Refer to S.D .S.
• Not with in the specified values ... Replace.
EE049

EL-31
 CHARGING SYSTEM - Alternator

[HITACHI make]
Stator Check
To test the stator or diode, you must separate them by un-
soldering the connecting wires.
CAUTION:
Use only as much heat as required to melt solder. Otherwise,
diodes will be damaged by excessive heat.

SEL587A
[MITSUBISHI make]
Long nose pliers
used as a heat sink

SEL0540

1. Continuity test
• No continuity ... Replace stator.

2. Ground test
• Continuity exists ... Replace stator.

EL-32
 CHARGING SYSTEM - Alternator

Diode Check
MAIN DIODES
• Use an ohmmeter to check condition of diodes as indicated in chart below.
• If any of the test results is not satisfactory, replace diode assembly.

Ohmmeter probes

-------------
Diodes check (Positive side)
Positive <±l
Positive diode plate

Diode terminals
Negative

Diode terminals
8

Positive diode plate

Continuity

Yes

No

Negative diode plate Diode terminals No

Diodes check (Negative side)
Diode terminals Negative diode plate Yes

[HITACHI make] [MITSUBISHI make]

Negative diode
plate SEL7680

R·.tti
plate SEL493H

SUB-DIODES
[HITACHI make]
/::-=/1 . . - .
l
I I
~. • Attach ohmmeter's probe to each end of diode to check for

J) -
V/
(11)~
continuity.
\ I I I{
• Continuity is N.G .... Replace diode assembly.
\I
'I
~·
;-/
I
(l
)
I /.
I
I
~
--

l .. /_ -

[MITSUBISHI make]

EL-33
 CHARGING SYSTEM - Alternator

Assembly
Carefully observe the following instructions.
• When soldering each stator coil lead wire to diode assembly
terminal, carry out the operation as fast as possible.

WHEN SOLDERING BRUSH LEAD WIRE

[MITSUBISHI make]
• Position brush so that its wear limit line protrudes 2 mm
(0.08 in) beyond end face of brush holder.

[HITACHI make]
( 1) Position brush so that it extends 10.5 - 11.5 mm (0.413 -
0.453 in) from brush holder.

SEL595A

(2) Coil lead wire 1.5 times around terminal groove. Solder out-
side of terminal.
When soldering, be careful not to let solder adhere to insulating
tube as it will weaken the tube and cause it to break.

After soldering,
place insulating tube
on terminal.

1 mm 10.04 in)
SEL596A

RING FITTING IN REAR BEARING

[HITACHI make]
• Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.

[MITSUBISHI make]
• Always press new bearing into place with ring groove toward
slip ring.

EL-34
CHARGING SYSTEM - Alternator-
Assembly (Cont'd)
REAR COVER INSTALLATION
(1) Before installing front cover with pulley and rotor with rear
cover, push brush up with fingers and retain brush by insert-
ing brush lift wire into brush lift hole from outside.
(2) After installing front and rear sides of alternator, pull out
brush lift wire.

SEL766D

SEL598A

EL-35
 CHARGING SYSTEM- Alternator-

Service Data and Specifications (S.O.S.)

ALTERNATOR
· LR180-724 A3T05192
Type
HITACHI make MITSUBISHI make

Applied engine VG30DE VG30DETT

Nominal rating V-A 12-80 12-90

Ground polarity Negative

Minimum revolution under-no-load

Less than 950 Less than 1,300
(when 13.5 volts is applied) rpm

More than 65/2,500 More than 65/2,500

Hot output current A/rpm
More than 80/5,000 More than 90/5,000

Regulated output voltage v 14.1-14.7

Minimum length of brush mm(in) More than 7.0 (0.276) More than 8.0 (0.315)

Brush spring pressure N (g, oz) 1.863-3.040 (190- 310,6.70- 10.93) 3.040-4.217 (310- 430,10.93 -15.17)

Slip ring minimum outer diameter

More than 30.6 ( 1.205) More than 22.1 (0.870)
mm(in)

EL-36
 COMBINATION SWITCH

Combination Switch/Check
A.S.C.D.
(With air bag)

CANCEL

{J
TURN N

{f ~
(L ACCEL/
V RESUME
COAST/SET

1111'~'1t' Horn and A.S.C.D.

A.S.C.D. switch
switch (On the steering wheel pad)
(With air bag) (Non-turbo model
without air bag)

TURN
HORN DIMMER SIGNAL
SWITCH A.S.C.D. SWITCH SWITCH SWITCH

~
m
A B c
5 IQ
6 6
11 51
or 8 0
9 0
43 lo
44 1<5

SEL0110

EL-37
 COMBINATION SWITCH

Combination Switch/Replacement
For removing/installing air bag module and spiral cable, refer to
BF section.
• Each switch can be replaced without removing combination
switch base.

SEL0240

• To remove combination switch base, remove base attaching

screw and turn after pushing on it.

SEL007N

EL-38
 COMBINATION SWITCH

Steering Switch/Check
TURBO MODELS WITHOUT AIR BAG

0
HORN
TERMINAL

A.S.C.O.
SLIP
STEERING
RING
SWITCH

STEERING ANGLE
SENSOR

A.S.C.D. STEERING SWITCH

HORN SWITCH

2
~
3

SEL528N

EL-39
 INSTRUMENT SWITCH

Check

-+--:---FRONT FOG LAMP

SWITCH

~--7---ILLUMINATION

LIGHT CONTROL
SWITCH
2ND

~ST
OFF
Headlamp washer switch
(Canada)

REAR AS.C.D. FRONT

LIGHTING DEFOGGER MAIN FOG LAMP
SWITCH SWITCH SWITCH SWITCH
'\ ['\,. OFF ON
"
OFF ON OFF N ON

11 IO 14 0 17 I<
12
<> 15 0 0 18 I<
X ~~ 16 0 6 rx 111

13 _Q 19 IC>

HEAD LAMP ILLUMINATION

WASHER CONTROL CLUSTER
SWITCH SWITCH ILLUMINATION

~
~·Iii m2
1
~

EL-40
 INSTRUMENT SWITCH
Check (Cont'd)

HAZARD
SWITCH

REAR
WIPER

,.
~

WASH

1 oN
"OFF

MIST
I 3
4

Variable
intermittent MANUAL
wiper volume

AUTO
Refer to
HA section.

FRONT WIPER
A/C SWITCH, MANUAL TYPE REAR WIPER SWITCH
SWITCH
1 WIPER MIST OFF ON WASH
2
(§)! ]ILLUMINATION
WASH

;
!OF. liNT L0 HI Yv !oFF ON 20 ( I 01~ (

..---- 1010 0 21 10
~ ro 0 ro
~
1--
~
f--..;
i
:-
A/C
11
12
13
0
I
0
0
22
23 0 1010

6~ f-f- ~
5 ·- f--.: =---- 14 6
~........':...-
15
..---..--- 17
~
~
1--
1---' ~
~ REC
18
IX
19
®
0
0

7
f--.: F--
L....::...._

fkJ
3
8
L v IJ.'( F~ 0
9 Q 0
0 I
~ 0
~
~

(4) (3) (2) (1)

HI MH ML LO OFF
10 0 0
0 I
i-- 0
11 !---
.....__
SEL529N

EL-41
 HEADLAMP

Operation (Daytime light system equipped model}

After starting the engine with the lighting switch in the "OFF" position, the headlamp high beam automatically
turns on. Lighting switch operations other than the above are the same as conventional light systems.

Engine With engine stopped With engine running

OFF 1ST 2ND OFF 1ST 2ND

Lighting switch
A B c A B c A B c A B c A B c A B c
0 0
High beam X X 0 X X 0 0 X 0 0
.. 0 X
/),. /),. /),. /),.

Headlamp
Low beam X X X X X X X 0 X X X X X X X X 0 X

Clearance and tail lamp X X X 0 0 0 0 0 0 X X X 0 0 0 0 0 0

License and instrument illumination lamp X X X 0 0 0 0 0 0 X X X 0 0 0 0 0 0

0 Lamp "ON"
X Lamp "OFF"
6 Lamp dims.
0 Added functions

EL-42
 .,
0
I8ArTERrl ::D
I
c:
in
~
~FUSE FUSE ~ FUSE

....... ...__

l1il
I l):__j
DIMMER
RELAy
n611
uw HEADLAMP
RELAY-L
n611
HEADLAMP
U~ RELAY-R

LIGHTING
SWITCH
..!:- OFF11STI2N

(/)
n
J ::::r %
( CD
m
.....
-o--
@)
3
I»
!:c
=.
~
I
r-i..___:Q__J n !;
w .,s::
To Illumination
r----1 control system
0 0
HIGH~ ~~ ~i~HEADLAMP ~~ ~i~HEADLAMP
BEAM "¥J z.~ ~~ L. H.
:u
z 1.::fJ 1.::fJ :u·
~ R. H. To c I earance. I i cense.
tal I and I I lumlnatlon
lamps

II
DIMMER
SWITCH

T·~·-·;~-· (: I j l
1/)
m
r
fl
0
z -=
 'TI
0
IIGNITION SWITCH
START
IGNITION SWITCH
ON or START BATTERY
I
I :II
0
•z
~FUSE ~FUSE •c
FUSE FUSE FUSE
•
ll-t--
$ CHARGE
WARNING
LAMP
1

®
rxT
r JJ
THEFT
WARNING
RELAY
l[jH ::oo
m....
r::I
>:I
-<m
::0
~s~
~I>
,
r::I
::O::t
ffi Q
::O::t
mm

~~,
::O::I

-=
LJI 1--
(/)

~~~~I~r I I r :: II II I I I II 1 :>---
n
~
CD
:::t
UNIT
!:c
m
r-
1
~
~
HIGH
BEAM
Q. ..
~
To head lamp {.....,
washer system ., 1 1 1 I + ~
~
-- .,
3
ID
c:;· §;
n s:::

--
~To I I luminatlon 0
control system :::J

~
r::t ;o~

1ft -
·m >
m
->z ::t>
·o m
z ;x~ a:
::u r ::u r
To c I earance. I i cense.
> >
,
:I ,
:I tai I and I I lumination
lamps

JH' --SH6r---~

1
7
I8
• (JI
I9
I2
L

en
ALTERNATOR ~YTIME LIGHT CONTROL UNIT @: A/T model
L
m @: M/T model -=
.-
UI
!:!
z
 .,
0

rBA'T"::~OUT!Nr
FUSE BLOC
•POWER SUP~CRefer to ::D
DIMMER c:
RELAY
HEADLAMP HEADLAMP
! en
~ ~
RELAY-L RELAY-R
FUSE BLs8~~~~efer to
I
I I
•POWER
ROUTING•.)

,.;~~~ ®~ ®~ ®~
L: LIGHTING
SWITCH
1'- OFF 1ST 2ND
2121 ..,. ..
I r
~~~ ~-
=f:C:Ui1 :;a::a "'11~
ID ~':IE ''
IDGI
"''
r
I
2
,-I
-11 Il @@) -B
3
4
0

it
P/a 5
..___a
p 6 c
R/L '>--
I BATTERY~ PUIIPU
G:R • G:R -R/Y
G/R
X ~
0
7 0

P/B P/a
!BI ackl !Main
harness) ~
IEngi ne ::l. :::t
m
HEADLAMP R. H. @) room
harness)
0® DIMMER ::::s
co ~
LOW (b ._ t--Oo 13: SWITCH

W/B~ ~R/G
r- BEAM -{]" G/
R/Gy
c c
l
i·l
1
IBrownl
):
~
01
HIGH a;--- -oi IB=W/a
BEAM "iJ'
IB lack)
R/G

@) @])@
,..--a
i-- a
PU
p
P/a
..
m
co
m
3:
"V
R/a~ ~R/a -
i-- a 3
HEADLAMP L. H. @)
HIGH a;---
} ft warning system

BEAM -Qa!S=W/a
-LI" R/a
IB lack)
l ~- llumlnation
LOW
BEAM
a;--- -Qa!S=G/Y
!Brown)
R/a

@) "'' "''
ID G>
Jb..
"'"'
''.,
I rol system

I earance. I i cense.
and I I luminatlon
s
(300R±n @[t+Hoi¥R
@: Wrth air bag
@: Wrthout air bag [J-H;IIIYEJ ~·QIH
.. HIGH BEAM I HIGH BEAM I
®i)® 25~26 2 1 o------@------- 2 0
01

Ill
m
r
BODY GROUND
COMBINATION METER
®ft®
ID
N BODY GROUND
.,w
 ""0
:a
~
[BATTERY] I IGNITION SWJTCH
ON·or START
I HEADLAMP
R~ELAY-L
HEADLAMP
R~ELAY-R ~~~~rNG
I GNJ Tl ON SWJ TCH
ON or START
FUSE BLOCKCRefer to
•POWER SUPPLY ROUTING•.!
z
l>
c
I I I~:GNJTJON S~~
11 11
DIMMER
r = =
RELAY RELAY
H IGNITION SWITCH
START r-1 ON or START ,
l>

FUSE BLOCKCRefer to
•POWER SUPPLY ROUTING•. l
= =
. - - - - - l BATTERY
~To theft warnlno

•lA ~¢it~· ®IN'-®~ ®rn'ffi ®~

contra I unIt &jg,
DIMMER
SWITCH
r--------------W/R '
_j
II I
' • '~ r m~m m •m• •m• ~ • CONNECTO

iI I . "
II ..,.,,.
.. :0

(@)@ ®
..au~
I I I p~·~~
...s·~
(Engine room PU PU CMaln
LOW @) harness! P • o P harness!

,...
m BEAM P/B CBiackl P/8-------im~== p~·~ P
a a
I I
2
3
0~~ IS 2ND
ca
::1:
£!
HIGH
BEAM
rO- R/B
'{)- R/B 1.-..-
}
To headlamp
i
tfJi2l @1
mm
rr= R/L
B~~ '5 c c
CB 1@
...SD 5:3::"V
I

~ washer system ~~ R ® i'

en ~ ca
@ m X CD

-
HEADLAMP L H. R/B_ffij G/R

IHIGH~~ r{)-B/R-
7
Ll GHTIN
3
BEAM ~ ' { J - R / B - @D® @
CB I ackl
1Hl SWITCH G
0

--a:
L WR/B
~~M <ert-9 r8= =~~
CBrownl
@)
11111111' I GY

P~B .1m
GY~
I DIODE
0
::::s

.. ..r
DAYTIME
Ll GHT
CONTROL

UNIT
L:J ruE =~=- R~G
r;t5: R/W==::t1~.J
'1f;!t!~i
8/W
R
® ®
ijl
W/R _fB. '.ffi-w/R~
~ .4t_
W/R~ ~W/R
eiiJ
'~!~~;~:ror
®~ Itt++~®
'

fl:ooiF!J [Wt+mw-1
''
To i llumlnatlon
control system

To c I earance.

~
I I cense. tal I and
@) ®® HIGH BEAM
,
II luminatlon lamps
., To theft warning
o----@-+1---o 2 0
. ~®
2 I 1 control unit

@:
@:
A/T model

M/T model
®{i®
BODY GROUND
reJ
ALTERNATOR
24~4
CHARGE

COMBINATION METER
®/i@
BODY GROUND
Ill
m
r
..
U)
....,
"D
 HEAD LAMP

Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall, screen or headlamp tester. When operating
any aimer, it should be in good repair, calibrated and used
according to the operation manual supplied with the unit.

HEADLAMP AlMER ADAPTER

Attach the headlamp aimer using Tool (aimer adapter). Place the
aimer adapter on the 3 points of the headlamp, then push the lever
down to secure it.
If no aimer is available, aiming adjustment can be done as follows:
For details, refer to the regulations in your own country.
CAUTION:
a. Make sure tires are inflated to correct pressures.
b. Place vehicle and tester on the same flat surface.
c. See that there is no load in the vehicle (coolant, engine oil
filled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in driver's position).

SEL895M

1. Turn headlamp low beam on.

2. Use adjusting screws to perform aiming adjustment.
• First tighten the adjusting screw all the way and then make
adjustment by loosening the screw.

• Adjust headlamps so that upper edge and left edge of high

WL = 1,067 (42.01 I
intensity zone are within the acceptable range as shown at
left.
• Dotted lines in illustration show center of headlamp.
"H": Horizontal center line of head lamps
H "WL": Distance between each head lamp center

"H" : Horizontal center line

of head lamps
Vertical centerline
ahead of headlamps

Left edge of high

intensitY zone
~ = ACCEPTABLE RANGE
Unit: mm (in) SEL914D

EL-47
 HEAD LAMP
Aiming Adjustment (Cont'd)
Push the tongue and pull the lever up to remove the adapter.

Bulb Replacement

" .
Push to remove connector
' r 1 ..,._::..

The Headlamp is a semi-sealed beam type which uses a replacea-

ble Headlamp (halogen) bulb. A bulb can be replaced from inside
the engine compartment without removing the Headlamp assembly.
CAUTION:
High pressure halogen gas is sealed inside the halogen bulb.
The bulb may break if the glass envelope is scratched or the
bulb is dropped.
Hold the plastic base when handling the bulb. Never touch the
glass envelope.

REMOVING HEADLAMP BULB

1. Disconnect battery negative cable.
2. Disconnect electrical connector from rear end of bulb.
3. Turn plastic base counterclockwise until it is free from head-
lamp reflector, then remove it.
4. Remove headlamp bulb. Do not shake or rotate bulb when
removing it.

REPLACING HEADLAMP BULB

1. Insert bulb into headlamp reflector with plastic base facing
downward and turn it clockwise until it stops.
2. Push electrical connector into bulb plastic base until it snaps
and stops.
CAUTION:
Do not touch the bulb.
• Use the same number and wattage as originally installed:

Inside Outside
(High beam) (Low beam)

Wattage (W) 65 55
Bulb no. 9005 9006

EL-48
 Ll GHT I NG SWITCH ~ack door

R~G::::8el1!
FUSE BLOCKIRefer to harnes~
•POWER SUPPLY ROUTING•. l STOP 1'\ OFF 1ST 2ND ~
I 0 STOP AND TAIL .-------
LAMP LAMP SENSOR ~

~~~ I ..I
SWITCH 2 HIGH-
,~ MOUNTED

~
3 STOP

~~
4 :I Ill ' ~ LAMP
5 c Gl

6
o-
:I
cc
@DeW La ® ~ NS

~
LJ.~,. .u
(1) ~ ~
@)~ ®~
lA
7 c u @ IIWII ®cffir~
..
,...' ,,
~a
<Ill
\\'
,...,.~
,,,.,~ "'
:111111:11~
:::UIDG'I .. .,'lll

I ll ®® I @
8 -ch ~ REAR SIDE
G/R--(J' !3) MARKER

To illumination
control system ' "11"' LAMP R. H.
LAMP R. H.

REAR COMBINATION

TAIL en m
(Main
®® ® ar i' ~
STOP
harness)
.....m
"'11"'
Y:R$~ ca m
m
r-
1
~ FRONT COMBINATI
<Body harness! TAIL
STOP
ID ID
3 n:I
!'
-0
::D

::D
CD LAMP R. H.
r
SIDE
MARKER ®~LICENSE
G~R=83 0 LAMP
c:;·
CD
§;
.,s:
.' .'
:I
CLEARANCE "' en
~ CD

®W REAR COMBINATION
LAMP L. H. -1
!:
FRONT COMBINATION
LAMP L. H.
®Yrr±El. @) TAIL ID
@) .'
"'
'
STOP :I
a.
-----t I
~

SIDE ~
- /R::::rn....

MARKER ~ €=-

CLEARANCE
8 (Engine
harness!room
G/R----~~--------------~

I
IBATTERY I
I
: -o:::J9l

@)
!E""H.....I...L
TAIL
STOP
-
C/)
0
"C
r
.'... ...c
FR.®
8 -(h ~
/R--(J' REAR SIDE
(~ MARKER
ID
3
LAMP L. H. "C
.... .. en
(/)
m
r
@ : Without rear air spoiler
®{i@) ItggJ rrn § I ®ft® ~
ID FUSE BLOCKIRefer- to :::!.
1\J BODY GROUND •POWER SUPPLY ROUTING•.) BODY GROUND :I
.,
Ul
ca
 EXTERIOR LAMP

Back-up· Lamp/Wiring
---=~___:_______ ~------------~~~D,•iaagram
~UPPLY

(Main
harness>

@
:G~::m ~BACK-UP
LAMP
:G/Y R. H.

G/W_t
t:=;';;l\
t_ G/W
~®
~
1'1
. G~w::m ~. BACK-UP
LAMP
"' @) L.H.
Q;>@)

~
0: A/T model
@' M/T model ®@®
BACK-UP @: 2 seater model
LAMP SWITCH BODY-=- G~OUND
@: 2+2 seat er model
SEL926P

EL-50
 HEADLAMP HEADLAMP LIGHTING
RELAY-R RELAY-L SWITCH
DIMMER OFF JST 2ND
DIMMER
RELAY

I I i
I SWITCH
HEADLAMP 2
RELAY-R

I
3

iJ
4
5
6
o-
r?9l® ~® ~® f®® n-j
0 0

~~
X $
7 c
;a,. "11:::11 "11 :U21:::U

.."' ....
~~~~m,. ..."'\
~
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, :II'::D
.i ~.

-@
'CN ·a

nil liD r-

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aa' 'liiD'''
,.. li.U
0® l.J
J .,...
m ~~~p n~ to=
®
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ciYr,,lYr
G/R 11/R
1@-
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-.,
0
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m
~
m
:a
r-
I RELAY U~ ~11/L
G/R C P • o p
c 0 0
~ L - + - - - - - - - - - P/8 co :a
U1
,..
P/8
<Eng I ne room (8 I ac kl (MaIn I""
harness> harness> I» I""
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"0
"0

~~~ ~ ~.).dl 1
1 I :di 1:: .--
-·iE
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co
c
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FOG ~ o0-- a----<
LAMP \&L----0' <Q- 11/R - - BATTERYl
C1
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L. H. Ill 3
1111~111@

(/)
m ®i)@)
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1

[§-00~1
I
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II
r-
1
@ :
@ :
For U.
For Canada
s. A.
-
DIODE
m
llll1miU I

®i)®
..
r FUSE BLOCK(Refer to FOG LAMP
Ul
w BODY GROUND •POWER SUPPLY ROUTING•. l SWITCH BODY GROUND
Ul
z
 COMBINATION METER
HAZARD
SWITCH TURN R. H. TURN R. H.

G) : W~h air bag I D

WF ON
COMB INA Tl ON
FLASHER
25~ 26 28~ 34
2 D 27

- m
19
<§) : W~haut air bag
3
4
5
6
TURN
SIGNAL
SWITCH Ell ""[!] TURN L H.

[}ffiEPI
TURN L H.

rml@)
7
IX ~
~@ fo/1® ~"±++Ef#l
~'
8 @ @V
e~e
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e
:e: e c; E?e
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w
m,,
rCUD

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g

-'
r
m m ......,,

To l l l u m i n a t i o n ( _ j
control system
Ill
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[f
:1 5ff
. c-t rn
-· c
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...
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rn
m
r-
1
en
CII:ICIII:I

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.:r-m-<
BODY GROUND
SD(IJ
3 cS"
::2
-0
::D

::D
!!!.
N @) @
ID ,..r-
'""' I
COMBINATION
LAMP R. H.
TURNW JL.~,
~ I ~G/B VT
G/Y
G/B-----.
I G~Y~ ~TURN I~EA:INATION
LAMP R. H.
::2
a.
:I:
.,3::
ID
N
~nglne room
harnes~
(Body
harness>
...
ID
a.
~
@ ® ...
ID
::2
G~B~ ~TURN ,~EA:INATION :r
COMBINATION
ORONT
LAMP L. H.
I TURN~
~~· G/B
It
~'------'·LAMP L. H. CD
r-
ID
3
.... -a
@)ii@)
BODY GROUND
®li.®
BODY GROUND
(I)

~
Ul ::::!.
m ::2
r-
eo CD
N
.....
-u
 EXTERIOR LAMP

Stop and Tail Lamp Sensor Check

• Before checking, ensure that bulbs meet specifications.

STOP LAMP
1. Start engine.
2. Stop lamp switch on.

Stop lamp in good ordar

.•. Approx. 12 volts
Stop lamp ramovad
... Approx. 2.5 volts
SEL011N

Tail Lamp
1. Start engine.
2. Lighting switch on.

Tail lamp in good order

•.• Approx. 12 volts
Tail lamp removed
••. Approx. 2.5 volts
SEL012N

Test lamp 127WI

Combination Flasher Unit Check
• Before checking, ensure that bulbs meet specifications.
• Connect a battery and test lamp to the combination flasher unit,
as shown. Combination flasher unit is properly functioning if it
blinks when power is supplied to the circuit.

Battery SEL 122E

Bulb Specifications

Wattage (W) Bulb No.

Front combination lamp

Turn Signal/Clearance 27/8 1157
Front side marker 3.8 194
Rear combination lamp
Turn signal 27 1156
Stop/Tail 27/8 1157
Back·up lamp 27 1156
Rear side marker lamp 3.8 194
License plate lamp 3.8 194
Front fog lamp 35
High-mounted stop lamp 13
Interior lamp 10
Spot lamp 3.6.
Luggage room lamp 3.4
Foot lamp 2

EL-53
 HAZARD
SWI TCH
I LLUMI NATION
FRONT WIPER
SWITCH
(Door harness L. H.)
@H IL
~ ~;
FUSE BLOCK!Refer to I I
•POWER SUPPLY ROUTING•.)

lsAT~ERYI ~~
POWER WINDOW
MAIN SWITCH
! ® ILLUMINATION

~
c ~~ ~ l!rm ®~ ~fii5JI "'~"' ~n56 ~§
TIME
CONTROL
UNIT
J
R/Y
"'
'
®
~
w
ljj26'l "'"'"'
'''
..
,"' ,"' r.;/,;"\M(O
~
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r ·I
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··
"' "'
''

- -.....z
[I]
(MaIn harness)
01 ::o"':J: c=
ctli::E>
n""'~-ootz
<+ct-tC
3 m
m
r-
1
C1l
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o :J:r ::II
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;a
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ct ct ::ec -·
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g<+:x~
5"
ca
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e: WRh air bag :._oco
z c
@ : Without air bag
:J: ....
>-t -·
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ca
UJ::iio>
;
ctctOC
o ... z-t 3
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 METER AND GAUGES

Combination Meter
TYPE A

( I!:!J BRAKE

29 8 25 27 28 17 33

ELECTRIC
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SEL010Q

EL-57
 METER AND GAUGES
Combination Meter (Cont'd)

TYPE B

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MEL028A

EL-58
 IGNITION SWITCH
ON or START
FUSE BLOCK (Refer to n: m
FUSE BLOCK
NNECT@R
~-------
• 6~NITION
__
!Refer to ,. POWER SUPPLY
SWITC_H______ ROU_TING")
lOA 10
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FUEL TANK
GAUGE
UNIT-MAIN
FUEL TANK
GAUGE
UNIT-SUB
FUEL TANK
GAUGE
UNIT

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 METER AND GAUGES

Inspection/Fuel Gauge and Water Temperature

Gauge

( INSPECTION START

O.K.

CHECK POWER SOURCE Check the following items.

1) Turn ignition switch "ON". N.G. 1) Harness continuity between
2) Check voltage between ~ battery terminal and
terminal @ and ground. combination meter
Battery voltage should exist. 2) Ignition relay
3) Fusible link and fuse
O.K. 4) Ignition switch

N.G.
CHECK GAUGE OPERATION
1) Turn ignition switch "ON".
H Repair or replace gauge.

2) Connect terminals @ , @ ,
@ and ground with wire
through 3.4W test bulb.
3) Check operation of gauge.
SEL0250 Gauge should move smoothly
to full scale.
O.K.

Check harness continuity be-

tween component and combina·
H Repair or replace.

tion meter @, © and @ .

O.k. ..
N.G.
@ : Water temperature gauge CHECK COMPONENT Repair or replace.
@ : Fuel gauge ~
Check gauge units and harness. Refer to FE section. (Fuel tank
@ : Oil pressure gauge SEL0260
Refer to ••fuel Tank Gauge Unit gauge unit)
Check", ''Thermal Transmitter
Check" and "Oil Pressure Sending
Unit Check".
O.K.

Reinstall any part removed.

(Type A) (Type B) (Type A) (Type B)

(
~m'~m
INSPECTION END

emmw~ur~
©

@ : Water temperature gauge

@ : Fuel gauge
@ : Oil pressure gauge
SE L0270

EL-60
 METER AND GAUGES

Main tank
Fuel Tank Gauge Unit Check
• For removal, refer to FE section.
Check the resistance between terminals @ and ®.
2 seater model:
Ohmmeter
Float position Resistance value
(+) (-)
mm (in) tnl

Main 41.0 (1.614)

1* Full 8.6- 11.6
Sub 40.0 (1.575)

Sub tank position Main 137.0 (5.39)

G E 2* 1/2 55.4-68.6
Sub 139.5 (5.49)

Main 232.0 (9.13)

2* 3* Empty 157.6- 170.6
Sub 261.0 (10.28)
3*
1 * and 3*: When float rod is in contact with stopper.
Float I
ce_:j

Empty stopper
position
SEL019N

2+2 seater model:

Ohmmeter Float position Resistance value
(+) (-)
mm (in) tnl

1* Full 21.0 (0.827) 4.3-5.8

G E 2* 1/2 115.0 (4.53) 27.7-34.3

3* Empty 207.0 (8.15) 78.3-84.8

1 * and 3 *: When float rod is in contact with stopper.

Empty stopper position SEL209N

Fuel Warning Lamp Sensor Check

~
2+2 seater 2 seater
• It will take a short time for the bulb to light.

Test lamp
12V, 3.4W
ON -..'
------<
~--·

BATTERY

®
2+2 seater 2 seater
Test lamp
12V, 3.4W
OFF

BATTERY
SEL656N

EL-61
 METER AND GAUGES

Thermal Transmitter Check

Ohmmeter Check the resistance between the terminals of thermal transmitter
and body ground.

Water temperature Resistance

Approx. 70 · 90!l

Approx. 21 - 24!l
SEL698F

Oil Pressure Sending Unit Check

Check the resistance between the terminals of oil pressure sending
unit and body ground.
Oil pressure Resistance value
kPa (kg/cm 2 , psi) (!l)

0 (0, 0) (Engine is stopped) More than 83

'--"-----'
I 392 (4, 57) Approx. 26 · 37
'*" SEL021N 588 (6, 85) Approx. 18-26

Boost Sensor Check

1. Connect vacuum pump gauge to boost sensor vacuum hose.
2. Disconnect harness connector from boost sensor and connect
battery and voltmeter as shown.
3. Apply vacuum pressure to boost sensor by vacuum pump
gauge and measure voltages.
Voltage:
Approx. 2.2V at 0 kPa (0 kg/cm2, 0 psi)
(Atmospheric pressure)
Approx. 1.3V at -55 kPa (-0.56 kg/cm2, -8 psi)

Speed Sensor Signal Check

1. Remove speed sensor from transmission.
Location: Refer to "LOCATION OF ELECTRICAL UNITS" in
Service Manual.
2. Turn speedometer pinion quickly and measure voltage across
@ and (~j.

SEL022N

EL-62
 WARNING LAMPS AND CHIME

Warning Lamps/Schematic

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DOOR SWI TCH L. H.

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WASHER FLUID LEVEL SWITCH

!In front tank)
WASHER
I•
WASHER FLUID LEVEL SWITCH
!In rear tank>
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BULB
CHECK
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CHARGE

SEL931P

EL-63
 STOP ANI
IWIHER FLUID A.B.S.
==
=i
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TAIL L.....
~~eaal SENSOR LEVEL SWITCH
(In rear tank)
CONTROL
UNIT
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CONTROL UNIT
(Refer to 8F section.)
THEFT WARNING
CONTROL UNIT

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harness)
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STOP AND
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SENSOR
WASHER FLUID
LEVEL SWITCH
A.B.S.
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harness) (In rear tank) l-"'IT
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AL TERNATDR NIR -ID @- I IR W~ @ ~ (Body harness
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2+2 seater made 1
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THEFT WARNING AUTOMATIC SEA~IT

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E.C.C.S. CCNTIU.. l.l'llT (Mfr to EF ll EC ooatton.) CIMIINATI~ ICTUO WARNINII LMP
 FUSE BLOCK
FUSE BLOCK (Refer to <Refer to •POWER SUPPLY ROUTING•.)
•POWER SUPPLY ROUTING•.)

Ir--
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I8 [!Tif91®
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LIGHTING SWITCH CONTROL UNIT
BODY GROUND <Refer to BF
~ TIME CONTROL UNIT KEY SWITCH CHI ME SWITCH section. l
t;
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~
 WARNING LAMPS AND CHIME

Diode Check
• Check continuity using an ohmmeter.
• Diode is functioning properly if test results are as shown in the
figure at left.

SEL901F

• Diodes for warning lamps are built into the combination meter
printed circuit.

Warning Chime Check

SEL024N

EL-67
 TIME CONTROL SYSTEM

Description
FUNCTION
• Time control unit has the following functions.

Item Details of control

Regulates intermittent time from approximately 3 to 23 seconds depending
1, 2 Intermittent wiper control
on the intermittent wiper volume setting.
3 Washer and wiper combination control Wiper is operated in conjunction with washer switch.
When driver's door is opened with light switch ON and ignition switch OFF,
4 Light warning chime timer
warning chime sounds.
When driver's door is opened with ignition switch OFF, warning chime
5 Ignition key warning chime timer
sounds.
Sounds warning chime for about 7 seconds if ignition switch is turned "ON"
6 Seat belt warning chime timer
when seat belt switch is "ON" (seat belt is unfastened).
Seat belt warning lamp blinks for about 7 seconds when ignition switch is
7 Seat belt warning lamp timer
turned to "ON".
8 Rear defogger timer Rear defogger operates for about 15 minutes when defogger switch is ON.
9 Interior lamp timer Fades out interior lamp when driver's side door is opened and closed.
10 Door key hole illumination Illuminates for about 7 seconds when door outside handle is pulled.
11 Illumination control The brightness of the instrument panel light can be adjusted.

EL-68
 . . .,. ,. , ,. . . .
.!I§[}TI~I
FUSE BLOCK IRe fer to HEADLAMP

~ ·~I
HEADLAMP ~:~~tR
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...
0
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FUSE BLOCK!Refer to •POWER

I~~-IGNITION
n S~ITCH
ROOM
LAMP
DIODE

I ~

~
II ACC or ON

Hfl§Sl~
l!ill
II
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?;>@ ®@ ®f9!91 lijr lijr

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LJ~~~~ ,. »S» ~ sss rl·(!:;:.=:::=J R/0

®®
r-_:_~~~~~gf==~~f~t~§~=:;=j--~ (EngIne
room
ca~NECTOR
@ @
' iiiiiii
. ,~C:;:;o en" '
r•
r
r-"J(.]kiih ~'f!@)~r
®@~< ~0t
harness> WARNING

f~i , . " ' {!ill)~, r ~({ill)~~ ~ ~

CHIME

.::LL
r

·~ :::t
~ MO~ ~"
BODY ,..
~@rml .. ~s
n CH R/W
111
g
j DIODE • 0

@) ¥i ~
31:
0

i!l:I:OOW 1$ ~ 111111111.~!
@) 0>00'

~ sw:~CH ~ ~
I IIIQ I t!!l' @J @) 0
m
~~80~o
@)
~® [If\lpmll] [E$ r1111 t 111 1@ IWI ® 19 :7.1 @D2
@nl4' :ooR ::::!. n
m ·~@ _t ' T . i
1 1
@ .,. e~ ® ~~ ~ ~~~~ :I 0
L-W @)~ILLUMINATION c-·
FRONT WIPER ,

~
r
m
r- ir ~ ~ <jj - ° KEY HOLE co z

m~ ll·:·=Jn~~lll
• CH

"~" 'I : ;:
,~ I I ~·· ~..... . ~ ..
-t
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,......
1
0') :J a :::j:j;]
®· - a
OR/I :::Q;l S» 0
(D © ,.,_... L H ) co r-

[jJ ~o-m
o
DIMMER SWITCH
@· GL model for Canada @ , model
For U. S. A. _!; DOOR HANDLE S» U)
•t
3 @ @ SWITCH
3 <
II
@, For Canada @ U)
STI2N
® =· ___">..,'"' "'"'" I ~' -t
il
.~.~
R/L @ • "' - '"' - ".., ,____,., '" SEAT BeLT m
a
p
P/0---
0
®{i@ 31:
L '---
I I O:;: ""
m
U1a In harness>
'5=
= BODY GROUND I
~
r
I ~ il ,I I ! I C[J-w-u
LIGHTING HEADLAMP

~"" 111111m~ 1111111 ill I

SWITCH WASHER SWITCH

ci
~a-o~
,
c
.,
•'Vlia
•
0 r":rra 0

•:m """"'
.,. na
a'ocn''•,c•''n''''•c'
a• .... ,....
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a
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33 ~10 20 ~ 2 : 27 ~' 24 ~ 1 SEAT SEAT
~ ~
m ~£>L.
_ ___,_--~,_ _,__,.,_,_• REAR KEY BELT BELT 17 .,_I o 12.,._1
,- 17 TIME CONTROL ILLUMINATION WINDOW SWITCH SWITCH SWITCH ILLUMINATION SEAT BELT ' ILLUMINATION SEAT BELT
ID
w FRONT WIPER AND UNIT CONTROL SWITCH ~~~g~ER COM~NATDN METER COMBINATION METER
I» WASHER SWITCH
"IJ
 TIME CONTROL SYSTEM

Trouble Diagnoses
SYMPTOM CHART

Main Power
Supply
Preliminary
PROCEDURE and Diagnostic Procedure
Check
Ground
Circuit Check

REFERENCE PAGE
...,.... ...,.... ,....... ,....
N
,....
'<t ,....
U)
,....
U) co
,.... ,....
";
co
,.... <»
,.... <»
,.... 0
co
...co N
coI
~ ~ ~
I
~
I I I I I
~
I I
....1 ....1 ....1 ....1 ....1 ....1 ....1 ....1 ....1 ....1
w w w w w w w w w w w w w w w
>--
'0."5
Q.O
:l
rn o ·= ;!
-
~

C\1 <') ~ C\1 <') ll) ID co 01

~

...
'-"'C
CD 0:: """ ""' ~

~ CD
::I
~
::I 0== ::I
0
~~ ~t!
rl)::::l
rn ::I
~~ ~t! ~t! ~~ -~ ~ ~~ ;;t..
rn ::I rl)::::l rll::::l rn::::l 7ii ::I rn ::I
(.)

rn ::I
Q)
·-- : ...I
(.) Q) .2
rll::::l
CD
...
O"'C O"'C O"'C O"'C ~a:
::I
"'C "'C "'C C.'- O"'C O"'C O"'C O"'C O"'C 0-c
Q) CD CD o::(!l 0:: Cl) I: CD 0:: Cl) I: CD I: CD 0:: CD 0:: CD 0:: CD 0:: Q) I: CD
(.) (.) (.) Cl(.) CIO CIO CIO Cl(.) Cl(.) CIO CIO CIO 0:: 0 CIO

SYMPTOM
...
0
a..
...
0
a..
e
a..
·-
111 "'C
:E
0::
111 ca..... ·-
ca..._ ·-
ca..... 50: ·- ·- ._ 5a. ·-ca..._
ca..... 50: 50: ca..
111 0 1110 111 0 1110 1110 111 0 111 0 111 0 111 0 111 ...
50: ·-
Clo 1110

.._ Intermittent wiper does not

Q) 0 0
s::. operate.
Ill
as
3: Intermittent time of wiper
o!S 0
.._ cannot be adjusted .
Q)
Q.
Wiper and washer activate
§: individually but not in combination.
0

Light warning chime does

0 0 0
not activate.

Ignition key warning chime

Cl 0 0 0
0:: does not activate.
·c:
:;; Seat belt warning chime
3: 0 0 0
does not activate.

Seat belt warning lamp does not come

0 0
on, or does not go off alter coming on.

GiCl
:;; Rear defogger does not activate, or
CD 0
Cl 0 0
a: a; go off alter activating.
"'C

Interior lamp does not

fade out alter driver's 0 0
0::
door is closed.
0
:;0:: Door key hole illumination
·e does not come on even if 0 0
~ door handle is pulled.

Illumination control does not

0
actuate.

EL-70
TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
PRELIMINARY CHECK
Preliminary check 1
• Light warning chime does not activate.

Does ignition key warning Yes Go to "DIAGNOSTIC PROCE-

chime activate? DURE 4 - Step 1"0

No

Does interior lamp come on? Yes Go to "DIAGNOSTIC PROCE-

DURE 4 - Step 2" 0
No

Go to "DIAGNOSTIC PROCE-
DURE 4 - Step 3" 0

Preliminary check 2
• Ignition key warning chime does not activate.

Does light warning chime acti- Yes Go to "DIAGNOSTIC PROCE-

vate? DURE 5 - Step 1"0

No

Does interior lamp come on? Yes Go to "DIAGNOSTIC PROCE-

I DURE 5 - Step 2"0
No

Go to "DIAGNOSTIC PROCE-
DURE 5 - Step 3" 0

Preliminary check 3
• Seat belt warning chime does not activate.

Does seat belt warning lamp go Yes Go to "DIAGNOSTIC PROCE-

off or come on? DURE 6 - Step 1"0

~No
Go to "DIAGNOSTIC PROCE-
DURE 6 - Step 2" 0

EL-71
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
Time control unit connector ® MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK
Main power supply
Battery voltage existence condition
Terminals Ignition switch position
OFF ACC ON
B @-@ Yes Yes Yes
@-@ No No Yes

SEL822P ®-@ No Yes Yes

® Ground circuit
Time control unit connector
Terminals Continuity

IIIII .i5J 1111112!1 ~

@-Ground Yes

SEL823P

EL-72
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
CIRCUIT DIAGRAM FOR QUICK PINPOINT CHECK
~ . BACK DOOR
~I·
SWITCH
INTERIOR LAMP
r
=
... ~ I•
DOOR >-
:ED..<
&;;:,. O:E...J
'\9 ~ O<LJJ DOOR SWITCH
I• O:...JO: (Passenger s i del
OFFO ON
= ~ I•
KEY HOLE DOOR SWITCH
I LLUMI NATION
LJJ
V)
:;)
/-;..._
~
.
N
~
CDr I ver s I del
= ~
I
u.

~ ~ DOOR HANDLE
SWITCH
1!1
z
~w
><=

""" 1-
...J ~
=
L._. --
I
I•
Z:E AUTOMATIC LJJ

~ ~@
a:~ !OJ:
SEAT BELT u REAR WINDOW
<r
3:U [ CONTROL 1-1-
<~
DEFOGGER SWIT CH
UNIT
..--- SEAT BELT
LJJ3:
V)V) .., =-
_....
I
I•
J: us
u LJJ
WARNING
1-1-
~a:
3:<
II) I-
V)
:;)
u.
LAMP c;;:,.
-...:!J :E'~
1 !
ILLUMINATION
CONTROL SWITCH
zOL
V)
Ul
1-
~

z
. DARK
..... o
1- ~ -=-
'II .. :;)

...
N I
I•

=
~z
zo 0 0
...J
0
BRIGHT
1!1 REAR WINDOW a:
~ LJJ DEFOGGER RELAY 1-
'----- V) 0 0 z
:;)
u. 0 ~
_j
u

~ . LJJ
:E
~
INTERMITTENT
1- WIPER VOLUME
~ ~

=
N
_j
~
~
KEY SWITCH
I--
H:sJ :::!
INTERMITTENT
: WIPER SWITCH
.. =
~

J:
u LJJ
1-0:
ZLJJ.
CD.. D..
r @" ~ _.... _.... I
I•
1- V) r:r~:E
~z :;) U.3:< ILLUMINATION
3:0
V) u. LAMPS
L I•
zo -
0
~u
1-U
~<
y ~
FRONT WASHER
SWITCH
z1!1
,___
~
L:
(In front tank)
"""
><=
=- I•
~~
~
FRONT WASHER MOTOR

>-
LJJ
V)
:;)
u.
L: (In rear tank)
'---

z=
u
r-- ro I )I

=z
0 0
0::
LJJ
1-
u- r- 1--- ' I l l
'-=
= _.... I
Jl
1-
< u
HEADLAMP HEADLAMP
0 0 WASHER RELAY WASHER SWITCH
10
'--
-..1.1..1...
....=.
LJJ HEADLAMP
V) RELAY-R
:;)
u.

~
L=z 0
~--
CH--

0 °
1
I•
Q;
1::1

E
0
<i.
vi
:::i
oa
"tl
oa
coa
u
HEADLAMP ~
I
~~
RELAY-L L L
ill
1!1
z
Cl
zN a:r
LJJU (.)
I N

..
0
u.
..
0
u.
..
~:r:
.....
LJJ
V)
1-(.)
r>-
1!1~
~3:
-
V)

u.
Ia I: I-
I:~
~3:
OVl
al
<
10101
e@@ -=
:;)
...JV) u.
u. 0

L-Q
SEL933P

EL-73
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
m Time control unit connector ® DIAGNOSTIC PROCEDURE 1
SYMPTOM: Intermittent wiper does not operate.
[11 m
!ill I I~ I I I II~
.-BY
L/Y. 1
WIPER RELAY OUTPUT SIGNAL O.K. Check wiper amp.
CHECK Refer to "WIPER AND

[5l]
B
00 1) Turn ignition switch to
"ACC".
WASHER".

O.K. lN.G.
2) Turn wiper switch to "INT"
~~ ~0 SEL824P
or "OFF".
3) Measure voltage between Replace
control unit harness termi- wiper amp.
liJ Time control unit connector ® nals G) and @ .

[il Condition of
wiper switch
Voltage [V]

~ III CIIIIIECT OFF Approx. 12 Check wiper amp. circuit.

1!
OR
!121 I 1\ £) Pointer swings
from 0 to 12 ev-
INT
ery 3 to 23 sec-

00
B

00 (;) ~N.G.
onds

-@___(2
'-=----=... N.G.
SEL825P
INTERMITIENT SWITCH INPUT Check wiper switch.
SIGNAL CHECK Check harness continuity be-
Measure voltage between con- tween T.C.U. and wiper switch.
trol unit harness terminals @
and@.
Condition of
Voltage [V]
wiper switch
OFF Approx. 12
INT 0

I O.K.
y
Replace control unit.

EL-74
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
r.i) Time control unit connector @ DIAGNOSTIC PROCEDURE 2
SYMPTOM: Intermittent time of wiper cannot be adjusted.
[II aiiET
m
ffiitll I I I II £) INTERMITTENT WIPER VOLUME ~ Replace control unit.
PU
~ 00 INPUT SIGNAL CHECK
Measure resistance between
control unit harness terminals

In I
c___.__
~c ® and @ while turning inter-
mittent wiper volume.
SEL826P Position of wiper
Resistance [Q]
knob
s 0
L Approx. 1 k

N.G.

Check intermittent wiper vol-

ume.
Check harness continuity be-
tween T.C.U. and wiper switch.

m Time control unit connector ® DIAGNOSTIC PROCEDURE 3

SYMPTOM: Wiper and washer activate individually but not in
[il
ffi, f.8 Ill II
1
QIIET

£)
m
combination.

p~ WASHER SWITCH INPUT SIG- N.G. .,. Check harness continuity be-

00
NAL CHECK tween T.C.U. and washer
1) Turn ignition switch to switch.
I vi "ACC".
(±)G 2) Measure voltage between
~

SELB27P control unit harness termi-

nals@ and@.
fiJ Time control unit connector @ Condition of
Voltage [V]
washer switch
L/Y

ii,I I I ~
[il OFF
ON
Approx. 12
0
IIII QIIET

B
E) m ~O.K.

~ .,.,
IV I
@_~
'-=--
00 WIPER AMP. OUTPUT SIGNAL
CHECK
Measure voltage between con-
Replace control unit.

trol unit harness terminals (j)

SEL828P
and @ after operating washer
switch.
OV for approx. 3 seconds after
washer has operated.

lo.K.

Replace wiper amp.

El-75
 TIME CONTROL SYSTEM
Trouble Diagnoses {Cont'd)
m Time control unit connector ® DIAGNOSTIC PROCEDURE 4

~i)
SYMPTOM: Light warning chime does not activate.
• Perform "PRELIMINARY CHECK - Procedure 1" before

II I I I ~ l,a~G referring to the following flow chart.

B m Step 3
DOOR SWITCH INPUT SIGNAL N.G. ~ Check door switch.

00 [JZJ
~ SEL829P
CHECK
Measure voltage between con-
trol unit harness terminals @
Check harness continuity be·
tween T.C.U. and door switch.

and @).
liJ Time control unit connector ® Condition of driv-
Voltage [V]
er's door
[iii) Door is closed
Door is open
Approx. 12
0

II I I I WJ I l,s! ~ G/Y O.K.

B liJ Step 2
.....-- O.K.

00 [YJ
~~
c=..-.=..
SEL830P
CHIME OUTPUT SIGNAL
CHECK
Measure voltage between con-
Check chime.
Check harness continuity be-
tween T.C.U. and chime.
trol unit harness terminals @
[f) Time control unit connector ® and @).
Condition of driv-
Voltage [V]

~i)
er's door

II I I I Etii±DJ Door is closed

Door is open
Approx. 12
Pointer deflects

y G/R
00 intermittently

N.G.

I vi
-~ <t>r---
~ [f)
LIGHT SWITCH INPUT SIGNAL
Step 1 N.G.
Check light switch.
SEL831P CHECK Check harness continuity be-
Measure voltage between con- tween T.C.U. and light switch.
trol unit harness terminals @
and@).
Condition Voltage [V]
Light switch is Approx. 12
ON
Light switch is
0
OFF

O.K.

Replace control unit.

EL-76
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
m Time control unit connector ® DIAGNOSTIC PROCEDURE 5

~i)
SYMPTOM: Ignition key warning chime does not activate.
• Perform "PRELIMINARY CHECK - Procedure 2" before

II I I I hO l,s! ! !' G
referring to the following flow chart.

B m Step 3
DOOR SWITCH INPUT SIGNAL N.G. Check door switch.

00 I vI
~.&>
--=c.
SEL829P
CHECK
Measure voltage between con-
trol unit harness terminals @
Check harness continuity be-
tween T.C.U. and door switch.

and@.
(;} Time control unit connector ®
Condition of driv-
Voltage [V)
er's door

~i) Door is closed

Door is open
Approx. 12
0

II I I I hO I 119! ,,G/Y
O.K.
B I!] Step 2
O.K.

00 I vI
~~
SEL830P
CHIME OUTPUT SIGNAL
CHECK
Measure voltage between con-
Check chime.
Check harness continuity be-
tween T.C.U. and chime.
trol unit harness between @
[!] Time control unit connector ® and@.

~i) Condition of driv-

er's door
Voltage [V)

En I I l'oii
G/L Door is closed Approx. 12
Pointer deflects
II I I I Door is open
intermittently
B
N.G.
[!]
00 !vi
~[+)
~
SEL832P SIGNAL CHECK
1

IGNITION KEY SWITCH INPUT

Step 1
N.G. Check ignition key switch.
Check harness continuity be-
Measure voltage between con- tween T.C.U. and ignition key
trol unit harness terminals @) switch.
and@.
Condition Voltage [V)
Key is inserted Approx. 12
Key is pulled 0

~O.K.
Replace control unit.

EL-77
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
m Time control unit connector ® DIAGNOSTIC PROCEDURE 6
SYMPTOM: Seat belt warning chime does not activate.
[IIi) • Perform "PRELIMINARY CHECK - Procedure 3" before

II III fQ I l,e! !IG/v

m
referring to the following flow chart.
Step 2
PU SEAT BELT SWITCH INPUT N.G. ~ Check seat belt switch.
SIGNAL CHECK Check harness continuity be-
[ill
00 ,___
SEL833P
Check continuity between con-
trol unit harness terminals @
and@.
tween T.C.U. and seat belt
switch.

Condition Continuity
li] Time control unit connector ® Unfastened Yes
Fastened No
[ill)
I I I ~I l,e! ~~Gtv
O.K.
li] Step 1
II CHIME OUTPUT SIGNAL O.K.~ Check chime.
B CHECK Check harness continuity be-
1) Connect T.C.U. harness con- tween T.C.U. and chime.

00 [Y]
fe<±>
=---=-
nector.
2) Turn ignition switch "ON".
SEL834P 3) Measure voltage between
control unit harness termi-
nals@ and @.
Condition of seat
Voltage [V]
belt
Pointer deflects
Unfastened
intermittently
Fastened Approx. 12

~N.G.

Replace control unit.

EL-78
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 7
E,1

w
Time control unit connector

IIIIIWIIIII~£)
@

~ c.ET
SYMPTOM: Seat belt warning lamp does not come on, or does
not go off after coming on.

~
WARNING LAMP OUTPUT SIG- Yes Check warning lamp.
y " For U.S.A.: G/R
NAL CHECK
1) Connect T.C.U. harness con-
Check harness continuity be-
tween T.C.U. and warning lamp.
For Canada: L
nector.
2) Turn ignition switch "ON",
SEL835P after connecting control unit
harness terminals @) and
@.
3) Does voltmeter needle keep
swinging for about 7 sec-
onds after ignition switch
has been turned "ON"?

~No
Replace control unit.

m Time control
unit connector®
DIAGNOSTIC PROCEDURE 8
SYMPTOM: Rear defogger does not activate, or does not go off
after activating.
LIB
[it m
[EEFiiR I I I I .£) c.ET REAR WINDOW DEFOGGER
OUTPUT SIGNAL CHECK
O.K. Check rear window defogger
relay.
II

IV]
-~~f----'
00 Measure voltage between con-
trol unit harness @ and @.
Condition of de-
Voltage [V]
Check rear window defogger
circuit.

SEL836P logger switch

Defogger switch
Approx. 12
liJ Time control
is "OFF"
unit connector ® Defogger switch
0
is '_'ON"

N.G.
liJ
1ffi'FfH1 I I II!,
18 B
REAR WINDOW DEFOGGER
SWITCH INPUT SIGNAL CHECK
N.G. Check rear window defogger
switch.
1) Disconnect T.C.U. harness Check harness continuity be-

IOI
L...:--..!f---"
00
SEL837P
connector.
2) Check continuity between
control unit harness termi-
tween T.C.U. and rear window
defogger switch.

nals@ and@.
Condition of de-
Continuity
logger switch
Defogger switch
No
is "OFF"
Defogger switch
Yes
is "ON"

O.K.

Replace control unit.

EL-79
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
m Time control unit connector ® DIAGNOSTIC PROCEDURE 9

[iti) SYMPTOM: Interior lamp does not fade out after driver's door
Is closed.

II III~ l,a~G m
DOOR SWITCH INPUT SIGNAL N.G. Check door switch.
8 CHECK Check harness continuity be-
Measure voltage between con- tween T.C.U. and door switch.

00 Iv I
\G~
SELB29P
trol unit harness terminals @
and@.
Condition of driv-
Voltage [V]
er's door
I§) Time control unit connector ® Door is closed Approx. 12
Door is open 0

[2il
I II I ~ I I 12~ RIW I§) ~O.K.
COINCT
INTERIOR LAMP SIGNAL O.K. Check interior lamp and har-
B £) CHECK ness between T.C.U. and inte-
Measure voltage between con- rior lamp.
I vi
8__@
'----
00 trol unit harness terminals @)
and@.

SEL838P Condition of Voltage [VI

driver's door
Door is closed 0-+ Approx. 12
Door is open 0

.lN. G.

Replace T.C.U.

EL-80
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
m Time control unit connector®
DIAGNOSTIC PROCEDURE 10
SYMPTOM: Door key hole illumination does not come on even
if door handle is pulled.

j ~rtl£8
II I I I
[it m
CIIIIIET
N.G.
R/8
£) DOOR SWITCH INPUT SIGNAL
CHECK
Check door handle switch.
Check harness continuity be-

L~_j ~
Measure voltage between con- tween T.C.U. and door handle
trol unit harness terminals @ switch.
and @).
SEL839P
Condition of Voltage [V]
driver's handle
[;] Time control unit connector ® Handle is pulled 0
Handle is released Approx. 12

[it
II I I I En I I
B
121!
RIW
COllECT
£)
[;] i_O.K.
O.K.
KEY HOLE ILLUMINATION SIG- 1---... Check key hole illumination and

00
NAL CHECK harness between T.C.U. and
Iv I Measure voltage between con- key hole illumination.
e~ trol unit harness terminals @>
SEL838P
and @).

Condition of Voltage [V]

driver's door
Door is closed 0-+ Approx. 12
Door is open 0

N.G.

Replace T.C.U.

EL-81
 TIME CONTROL SYSTEM
Trouble Diagnoses (Cont'd)
f4 Time control unit connector @ DIAGNOSTIC PROCEDURE 11
SYMPTOM: Illumination control does not actuate.
~ rw m
IIIII hl'11ill ~£J
COMET

LIGHT SWITCH INPUT SIGNAL N.G. Check light switch.

~ G/A ~ CHECK Check harness continuity be-
Measure voltage between con- tween T.C.U. and light switch.
trol unit harness terminals @

~ and@.

Condition Voltage [V]

SELB31P Light switch is on Approx. 12
~----------------------------~
Light switch is off 0
m.
1:1 r;;--,
Time control unit connector ~...!!!...;

O.K.

ILLUMINATION CIRCUIT CHECK ~.. Check meter illumination.

Measure voltage between con- Check harness continuity of illu-
trol unit harness terminals @ mination circuit.
and@.

Condition Voltage [V]

Light switch is on Approx. 12
Light switch is off 0
SELB40P

[!I Time control unit connector ® O.K.

,,......,..----
ILLUMINATION CIRCUIT CHECK ~..
pt.' SB Measure resistance between
Check illumination control
switch.

I III
B
EffrRJ control unit harness terminals
(f) or @ and @ .

Terminals
Illumination control Res is-
Check harness continuity be-
tween T.C.U. and illumination
switch.
switch condition tance [UJ
DARK 0
@ ® BRIGHT Except 0
DARK Except 0
([) ® BRIGHT 0
SEL841P

O.K.

Replace T.C.U.

EL-82
 FRONT WIPER
SWITCH
SUPPLY ROUTING". l

----;GNITION S~~
ACC or ON ,
11l010
__ _j 121 lOTOTO

• '
131 111110 DIODE

,...
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control system

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 SUPPLY ROUTING". l REAR WIPER
---- REAR WASHER MOTOR
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REAR WIPER AND
WASHER
-

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0
SWITCH
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 HEADLAMP HEADLAMP
RELAY-L RELAY-R
DIMMER

II
SWITCH

FUSE BLOCK (Refer to

•POWER SUPPLY ROUTING•. l DIODE cR-, 5 ABC
~
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8

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BODY GROUND
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 WIPER AND WASHER

Installation

1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it "OFF" (Auto
Stop).
2. Lift the blade up and then set it down onto glass surface to set the blade center to clearance "C" or "D"
immediately before tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it "OFF".
4. Ensure that wiper blades stop within clearance "C" or "0".
Clearance "C": 0 - 10 mm (0 - 0.39 in)
Clearance "D": 73 - 88 mm (2.87 - 3.46 in)
• Tighten windshield wiper arm nuts to specified torque.
Front wiper:
r:qJ: 26 - 32 N·m (2.7 - 3.3 kg-m, 20 - 24 ft-lb)
Rear wiper:
r:qJ: 13 - 18 N•m (1.3 - 1.8 kg-m, 9 - 13 ft-lb)

Front wiper and washer

*1: 364 (14.33)

*2: 200 (7 .87)
*3: 411 (16.18)
*4: 255 (10.04)
*5: 173 (6.81)
*6: 198 (7.80)
*7: 370 (14.57)
*7 *8
*8: 416 (16.38)
All the diameters of these circles are less
Unit: mm (in) than 80 (3.15).
SEL025N

Rear wiper and washer

-Clearance "D"

*1: 170 (6.69)

*2: 50 (1.97)
*3: 220 (8.66)

Nozzle Molding end

*1
All the diameters of these circles are
Unit: mm (in) Ia• than 80 (3.15). SEL026N

• Before reinstalling wiper arm, clean up the pivot area as

illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

EL-86
 WIPER AND WASHER

Washer Nozzle Adjustment

• Adjust washer nozzle with J36126 as shown in the figure at left.
Before attempting to turn the nozzle, gently tap the end of the
tool to free the nozzle. This will prevent "rounding out" the small
female square in the center of the nozzle.

SEL117K

Check Valve
• A check valve is provided in the washer fluid line. Be careful
not to connect check valve to washer tube in the wrong
From. C~heckvalve direction.
reservotr
tank

-+0 ..
SEL411H

Rear washer tank (2 seater)

Rear pump

Front washer tank

(For Canada 2+2 seater)
From rear tank Motor only (2 seater for U.S.A.)

SEL027N

Wiper Amplifier Check

1. Connect as shown in the figure at left.
2. If test lamp comes on when connected to terminal ® and
battery ground, wiper amplifier is normal.

Test
lamp

EL-87
 CIGARETTE DIGITAL
LIGHTER CLOCK
FUSE BLOCK (Refer to nPOWER SUPPLY ROUTING

~T-I ON -~
n. l
l11rnl
~®
SWITCH-
I ~or
I
ON I I ,., '
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l____:~r= E?l~® 0 .,
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9
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m ca
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co i"
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L__-----l'l _J ~ ...
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(Air bag harness) To i I lumlnatlon ::1:
BODY GROUND control system 3 ....
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<Brown)
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LOW ~ IT:r G

::-
SLIP
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FR.®~ @ : Non·turbo model
RING HORN
SWITCH

§ITIJ
@ : With air bag @-en~
en
m
@ : Without air bag
•CD FUSE BLOCK !Refer to
Col
Cll nPOWER SUPPLY ROUTINGn. l STEERING SWITCH
-o
 -,
TIME CONTROL UNIT

lllllli!illllll FUSE BLOCK (Refer to nPOWER SUPPLY ROUTING". J

~-~=
1 =
RE:R WINDOW--
DEFOGGER
® II II fEJTIJil RELAY I
I

.-,...,,
~~~~

~IGNITION SWITCH
ON or START

REAR WINDOW ~ :D
ITI
-------~~======================::
I
SWITCH
DEFOGGER lllil 1§0- L/G L/G
L/B
~
(MaIn harness>
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11"·" -
CONNECTOR :::!.
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REAR
WINDOW
DEFOGGER
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@ : Turbo model B -cD L.J----'

door~
@ : Non·turbo model CBack
harnoos> I
. "'
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en BODY GROUND BODY GROUND
m
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 REAR WINDOW DEFOGGER

[+] [-]
Filament Check
1. Attach probe circuit tester (in volt range) to middle portion
of each filament.

6 volts (normel filementl SEL263

2. If a filament is burned out, circuit tester registers 0 or 12

r Burned out point
volts.
(+] (-]

SEL264

Burned-out point

Ovolts SEL265

3. To locate burned out point, move probe to left and right

[-]
along filament to determine point where tester needle
(+]
swings abruptly.

SEL266

EL-90
 REAR WINDOW DEFOGGER

Filament Repair
REPAIR EQUIPMENT
1. Conductive silver composition (Dupont No. 4817 or equiva-
lent)
2. Ruler 30 em (11.8 in) long
3. Drawing pen
4. Heat gun
5. Alcohol
6. Cloth

REPAIRING PROCEDURE
1. Wipe broken heat wire and its surrounding area clean with a
Heat wire cloth dampened in alcohol.
2. Apply a small amount of conductive silver composition to tip of
drawing pen.
Shake silver composition container before use.
3. Place ruler on glass along broken line. Deposit conductive
silver composition on break with drawing pen. Slightly overlap
existing heat wire on both sides [preferably 5 mm (0.20 in)] of
Unit: mm (in) the break.
Drawing pen
BE540
4. After repair has been completed, check repaired wire for
continuity. This check should be conducted 10 minutes after
,-- Repaired point
silver composition is deposited.
Do not touch repaired area while test Is being conducted.
j

[U
-&t.- SEL012D

5. Apply a constant stream of hot air directly to the repaired

area for approximately 20 minutes with a heat gun. A
minimum distance of 3 em (1.2 in) should be kept between
repaired area and hot air outlet. If a heat gun is not available,
let the
repaired area dry for 24 hours.

SEL013D

EL-91
 ~
0
m
RADIO AND ~
CASSETTE PLAYER
!Sub-
m
FUSE SUPPLY ROUTING•.) harness> 0
rn
--~ EiiFB ~ Clln:::::J-

'I WINDOW ROD m

~J
ANTENNA ANTENNA
~
~
~~@ ~- m
s:
~~r ~~~~rm o~~ ~ BODY GROUND
r- -<:II:G:IE 21 ::a,.-< Iii

r-<
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c
--'

z
m I I
CL
s· .,c
~
~ To i I lumination control system(:
I
CD
N To power antenna system ------------...1 ...fB
8/P
@
r:tJ--isf1 REAR
:::!.
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ca :a
.....---oR~ L____f1J ~:~~KER
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DOOR
SPEAKER ~~
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_r;:;- 8R
(Door harness R. H. )
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LG
~8 ® r:tJ--isr1 ~~~~KER
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D-•l JOINT CONNECTOR

EEII1
WINDOW
ANTENNA
ROD
ANTENNA
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en
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if
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ACC or ON i tEI1li®
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 POWER
ANTENNA
TIMER

~
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FUSE BLOCK <~•'•" to ·~OWER SUPP'Y II

r 111::8 ID:II

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direction
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flow
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RADIO
a
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B/R
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B/R • 0
(Body harness>
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 AUDIO AND POWER ANTENNA

Location of Antenna

~""'"""'""''
Power antenna timer
®-~jyaatil
Supporter
Nut
, ~Water proof ring
Main
" O·ring

feeder

Antenna
assembly

Drain tube

SEL028N

Antenna Rod Replacement

REMOVAL
1. Remove antenna nut and antenna base.

SEL029N

2. Withdraw antenna rod while raising it by operating antenna

motor.

EL-95
 AUDIO AND POWER ANTENNA
Antenna Rod Replacement (Cont'd)
INSTALLATION
1. Lower antenna rod by operating antenna motor.
2. Insert gear section of antenna rope into place with it facing
toward antenna motor.
3. As soon as antenna rope is wound on antenna motor, stop
antenna motor. Insert antenna rod lower end into antenna
motor pipe.
4. Retract antenna rod completely by operating antenna motor.
5. Install antenna nut and base.

SEL031N

Radio Fuse Check

EL-96
 AUDIO AND POWER ANTENNA

Window Antenna Repair

ELEMENT CHECK
l I
1. Attach probe circuit tester (in ohm range) to antenna
D 'L..----n" terminal on each side.
~·1-----il'"~---ul
~ ""'

I Ohmm.ter

IT] \
)
( ® SEL2501

2. If an element is broken, no continuity will exist.

I f Breakpoint

.._______, 'I ,.
l I .l L...----.(11

-r co ®e+----'
No continuity SEL2511
~
l f Breakpoint
.___ _...,'I
~; L...--~r
l
I

l [ij-'•'
r-®e+----'
..__
Continuity exist SEL2521

3. To locate broken point, move probe to left and right along

element to determine point where tester needle swings
l c:; abruptly .
.---•0 1....____ _.(1,.
I I..,

I~--......iJ \
®-+---__,
'---- SEL2531

ELEMENT REPAIR
Refer to REAR WINDOW DEFOGGER "Filament Repair".

EL-97
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)

Component Parts and Harness Connector

Location
1§1 A.S.C.D. main switch
A.S.C.D. combination switch (Steering switch)
Indicator lamp

I!] A.S.C.D. cancel switch

Stop lamp switch
A.S.C.D. clutch switch (M/T models)

A.S.C.D. actuator

I;] A.S.C.D. hold relay

(Auto A/C models)
[!I A.S.C.D. actuator assembly

II A.S.C.D. control unit

A.S.C.D. actuator
assembly@!)

SEL751P

EL-98
 A.S.C.O.

~· Hi
ll!iill ®@
~@@ ®[WimE
~l~ITOR ®
wl~ ~~~ 1~•
,..c:
....
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illumination lamps

,..
:!:

II·:i:-1.
INHIBITOR SWITCH WARNING LAMP

:::!
n
en
II
7
IIR
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m
c
m Gill~,~ CQ n
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LIGHTING SWITCH
(Q
(Q CQ

~ 1
1111 1111111 I 1 L~tl I I»
3 ....0
c
m
s
t ~ n
y
RIY -{]I STOP LAMP

(Alternator
harness)
j ~
RIB -GI ~ SWITCH
@
m
(2)::9 €: v'ie v'ie v'ie Is ?>en
VEHICLE fA9\

~~ \!V
@
mm
@ To stop la...,
.p
•v~a~~v'ia 1• ~~SS~ ~~~~ ..~r .. s~
A/T CONTROL
®@)
c
~@) @~ ..:.,...
UNIT
(Refer to
AT section.)

lw:6nl ~~
@!)

@ A/T model A.S.C.O. A.S.C.O.

@ M/T model CLUTCH
SWITCH
CANCEL
SWITCH
® With B1r bill! A.S.C.O.
@ Without a1r bill! CONTROL UNIT

(JJ @ Auto A/C model

m @ Manual A/C model
r-
<D
@ Turbo model without air bag
~
"0 <@ Nan-turbo model wttho\.lt atr bag
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)

Trouble Diagnoses
SYMPTOM CHART
PROCEDURE Diagnostic Procedure Electrical Components Inspection
REFERENCE PAGE

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SYMPTOM
A.S.C.D. control unit cannot be
0 0 0 0 0 0 0 0
set properly.
Engine hunts 0 0 0
Large difference between set
0 0 0
speed and actual vehicle speed.
Deceleration is greatest immedi-
0 0 0
ately after A.S.C.D. has been set.
ACCEL switch will not operate. 0 0 0
RESUME switch will not operate. 0 0 0 0 0
Set speed cannot be cancelled. 0 0 0 0 0
"CRUISE" indicator lamp blinks. 0 0 0 0

EL-1 00
 [ IGNITION SWITCH
ON or START j-sA~Yj
-n
n
::rJ
c:
=i
c

~~0 FUSE~ ~
:;
FUSE FUSE~ ®
Ci)
::rJ
,.c::
FUSE
FUSE INHIBITOR )lro
SWITCH @ 3:
s,w, 1111\1~1 ~s Q)cncn I
!:IRI~.IDI 2 P .,
r-- A. S.C. D. STEERING SWITCH
®rtnl~~
0
::rJ
....
0
HORN~~~~
RELAY ~·
~=SWITCH
®
CANCEL
1 0
RESUME/ACCEL
~SWITCH
,~ rmJ W!J :rr
CD ~
"1l
A. S.C. D.
MAIN
SWITCH ~~rl61611111 11 nc:
0
,.
3:
-1
I~ @ll~l,sl~llll ;;IIi;
"0 0
To horn
L...O
SET/COAST
SWITCH ! I® 0 z
"0
en
.,
-: o -1m
-z 0... cm
m
r- 2 1 11
14
A. S.c. D.
CLUTCH
SWITCH
@
INHIBITOR
RELAY
-IC
n c::r
~ i'
o
o
.....
1

.--------------------4----~7 ~ £ ~ ~ CONTROL UNIT

s CD ® n c z
;;IIi;-· ....
0
..... 13 12 3 14 10 9 8
tiD® di'b ®
!jiiiJ_
i!ltJ
-=-®
I»
CQ
g
::D
0
r-
OFT jl s Tj2ND c
0
m~OOJ§I~~~~ s (1)
CD
!.<
m
0-

ELECTRIC
,.-1 SPEED-
G)
IOTO f----
o-

ltJjGJij
l
-i
0
37 40
A/T
CONTROL
UNIT @
'-----t-ro;:-UM
A. S.C. D.
PUMP

G) VACUUM
MOTOR
--,.
0
:::::J

Q..
-~
~
0
m

OMETER LIGHTING
SWITCH
-·
--
~
8
~ <~
. < I
c
3
-·
AIR
VALVE
~
-
1 ~
:J
Dl
0: A/T model

~
COMBINATION r+
METER -·
WARNING
0
:J
RELEASE @: M/T model
r:;..VALVE
@CD® LAMP -Dl I ~~~ @: With air bag
~'"'-' 3
u
Ill @ : Without air bag
CJ>
m
VEHICLE
SPEED
SENSOR
- -:
G1J®
~
"tl
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses {Cont'd)
m A.S.C.D. main switch connector@ DIAGNOSTIC PROCEDURE 1
SYMPTOM: A.S.C.D. control cannot be set.

fi ~i5 Turn A.S.C.D. main switch "OFF" N.G.

m
CHECK POWER SUPPLY FOR

rllill II and "ON" to make sure indicator A.S.C.D. MAIN SWITCH.

~ r----,
illuminates.
O.K.
1. Disconnect main switch har-
ness connector.

00 2. Do approx. 12 volts exist be-

tween main switch harness
terminal @ and body
SEL757P
ground?

@] A.S.C.D. control unit connector @ ~No. Yes

Check fuse and har-

~ [il ness.
I

Ill I tfl4EDI i) CHECK A.S.C.D. MAIN SWITCH.

Refer to "Electrical Components

~ 00 Inspection".
om CHECK A.S.C.D. HOLD RELAY.
@] r
CHECK POWER SUPPLY CIA- N.G. Check continuity between control
SEL758P
CUlT FOR A.S.C.D. CONTROL unit harness terminal @ and
@ UNIT. A.S.C.D. hold relay.
[!] A.S.C.D. control unit connector
AfT shift lever~ Except "N" and "P" 1. Turn A.S.C.D. main switch
(A/T models) "ON".
2. Check voltage between con-
trol unit harness terminals @
llllEHHf
i) lllll:lJI] and@.
BaHery voltage should exist.
G/R
[!] ~O.K.
Brake pedal · }
Clutch pedal Released
~ CHECK CUT-OFF CIRCUIT FOR
A.S.C.D. CONTROL UNIT.
N.G. CHECK A.S.C.D. CANCEL
SWITCH, A.S.C.D. CLUTCH
(M/T models) SEL759P
Check voltage between control SWITCH (M/T models) AND IN-
(;] A.S.C.D. control unit ·connector @ unit harness terminals @ and HIBITOR SWITCH (A/T models).
@. Refer to "Electrical Components
BaHery voltage should exist. Inspection".
[it O.K. CHECK INHIBITOR RELAY (A/T
G/Y
CIIIIIECT models).

rn=Frrin E) (;]
CHECK SET/COAST SWITCH N.G._.. Does horn work?

~
CIRCUIT FOR A.S.C.D. CONTROL Yes
tNo
~ UNIT.
1. Turn and keep on SET/COAST
~r-
-=----=. switch of A.S.C.D. combina-
Check fuse and horn I
SEL760P relay.
tion (steering) switch.
2. Check voltage between con-
trol unit harness terminals ®
CHECK A.S.C.D. COMBINATION
and@.
(STEERING) SWITCH.
BaHery voltage should exist.
Refer to "Electrical Components
lO.K. Inspection".
@
(Next page)

EL-1 02
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
Gil A.S.C.D. control unit connector@

CHECK SPEED SENSOR CIR- N.G. CHECK SPEED SENSOR.

CUlT. Refer to "Electrical Components
1. Apply wheel chocks and jack Inspection".
up rear of vehicle.
2. Connect voltmeter between
Y/G
control unit harness terminals
(j) and @.
3. Slowly turn rear wheel.
SEL761P 4. Check deflection of voltmeter
pointer.
II A.S.C.D. control unit connector@ ~O.K.
CHECK A.S.C.D. ACTUA- N.G. Replace A.S.C.D. actuator
TOR/A.S.C.D. PUMP. assembly.
Refer to "Electrical Components
Inspection".

l/W
~O.K.
CHECK A.S.C.D. ACTUA- N.G. Repair short or open circuit in
TOR/A.S.C.D. PUMP CIRCUIT. A.S.C.D. actuator assembly.
1. Check voltage between con-
A.S.C.D. control unit connector@ trol unit harness terminals
@and@.
,--;;--- ---- ...., Voltage is OV.
,/ , I
2 Disconnect A.S.C.D. control

~~ ! unit connector.

wre.l j
3 Measure resistance between
control unit harness terminals
@and@,@,@.
L/W ~
. tJlJ Terminals Resistance [0)
® Approx. B - 45
@ @ Approx. 65
SEL763P @ Approx. 65

Replace A.S.C.D. control unit.

EL-103
AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 2
SYMPTOM: Engine hunts.
~~
Check vacuum hose for break-
age, cracks or fracture.
Repair or replace hose.
I
~O.K.
~~
Does A.S.C.D. wire move
smoothly?
Repair or replace wire.
I
~O.K.
CHECK A.S.C.D. ACTUA- N.G. Replace A.S.C.D. actuator
TOR/A.S.C.D. PUMP. assembly.
Refer to "Electrical Components
Inspection".

~O.K.
Replace A.S.C.D. control unit.

DIAGNOSTIC PROCEDURE 3
SYMPTOM: Large difference between set vehicle speed and
actual speed.
Check A.S.C.D. wire and N.G. Replace wire or A.S.C.D. actua-
A.S.C.D. actuator move tor assembly.
smoothly.

~O.K.
Check vacuum hose for break- N.G ... Repair or replace hose.
age, cracks or fracture.

~O.K.
CHECK A.S.C.D. ACTUA- N.G. Replace A.S.C.D. actuator
TOR/A.S.C.D. PUMP. assembly.
Refer to "Electrical Components
Inspection".

~O.K.
I Replace A.S.C.D. control unit.

EL-1 04
AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 4
SYMPTOM: Deceleration is greatest immediately after A.S.C.D.
has been set.
Check tension of A.S.C.D. wire N.G . ..,. ADJUST OR REPLACE A.S.C.D.
r---'
and that A.S.C.D. wire moves WIRE.
smoothly. Refer to "A.S.C.D. Wire
Adjustment".
O.K.

'
Check vacuum hose for break- N.G. ..,., Repair or replace hose.
age, cracks or fracture.

~O.K.
CHECK A.S.C.D. ACTUA- N.G.
- 1..,. Replace A.S.C.D. actuator
TOR/A.S.C.D. PUMP. assembly.
Refer to "Electrical Components
Inspection".
O.K.

Replace A.S.C.D. control unit.

EL-1 05
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
EJ A.S.C.D. control unit connector @
DIAGNOSTIC PROCEDURE 5
SYMPTOM: ACCEL switch will not operate.

Check constant-speed function N.G. ~ Go to "DIAGNOSTIC PROCE-

for operating using SET/COAST DURE 1".
switch .
.,._ O.K.
RESUME/ACCEL ,w_____...L--------,
switch "ON" Check voltage between control N.G.
unit harness terminals G) and
SEL764P
@ after turning on and holding
(;J A.S.C.D. control unit connector@ RESUME/ACCEL switch.
BaHery voltage should exist.

O.K.

Check voltage between control N.G. CHECK A.S.C.D. COMBINATION

unit harness terminals G) and (STEERING) SWITCH.
@ after releasing RESUME/AC- Refer to "Electrical Components
RESUME/ACCEL CEL switch. Inspection".
switch "Released" Voltage Is OV.

[!) O.K.
SEL765P . - - - - - - - - - - " ' - - - - - - - - - - - ,
'------------------' Does vehicle accelerate when No Replace control unit.
RESUME/ACCEL switch is
RESUME/ACCEL
switch "ON"
turned on?
Yes

Does vehicle maintain the new 1-!N..:.:o~ll>l Replace control unit.

(faster) speed when RESUME-
/ACCEL switch is released?
Yes

ISystem is O.K. ""

SEL766P L...--------------1
L---------------~

EL-1 06
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
rJ A.s.c.o. control unit connector @) DIAGNOSTIC PROCEDURE 6
SYMPTOM: RESUME switch will not operate.

Check constant-speed function N.G. Go to "DIAGNOSTIC PROCE-

for operation using SET/COAST DURE 1".
switch .
._. O.K.
.-------L---------.
RESUME/ACCELr.J
switch "ON" Check voltage between control N.G.
unit harness terminals G) and
SEL764P
@ after turning on and holding
RESUME/ACCEL switch.
(;) A.S.C.D. control unit connector®
BaHery voltage should exist.

O.K.

Check voltage between control N.G. CHECK A.S.C.D. COMBINATION

unit harness terminals G) and (STEERING) SWITCH.
@ after releasing RESUME/AC- Refer to "Electrical Components
RESUME/ACCEL CEL switch. Inspection".
switch "Released" Voltage is OV.

[!) O.K.
SEL765P ;=.--------:l!---------.
~------------------------~ Set vehicle speed at 80 km/h (50
MPH) by turning on SET/COAST
SET/COAST switch.
switch "ON"
O.K.

While cruising at set speed, de-

press and release brake pedal.
O.K.

Does speed control disengage No "" CHECK STOP LAMP SWITCH,

and "CRUISE" lamp turn off? A.S.C.D. CANCEL SWITCH AND
A.S.C.D. CLUTCH SWITCH (M/T
~------------------------s_E_u_s7~P Yes
models).
Refer to "Electrical Components
Inspection".

Above 48 km/h (30 MPH), press

Brake pedal
and release "RESUME/ACCEL
switch.
O.K.

SEL76BP
Does vehicle return to previ-
ously set speed [80 km/h (50
IReplace control unit.

~------------------------~~~
MPH)]?
RESUME/ ACCEL Yes
switch "ON"
System is O.K.

SEL766P

EL-1 07
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
m A.S.C.D. control unit connector @ DIAGNOSTIC PROCEDURE 7
SYMPTOM: Set speed cannot be cancelled.

~ m N.G.
.
I II li:riE
CIIIIIBT CHECK A.S.C.D. CANCEL, CHECK A.S.C.D. CANCEL,
:-----
£) CLUTCH, INHIBITOR SWITCH CLUTCH, and INHIBITOR
CIRCUIT. SWITCH.
G/R

~
00 1. Turn A.S.C.D. main switch on.
2. Check voltage between con-
trol unit harness terminals @
Refer to "Electrical Components
Inspection".

<±)_§:!
and@.
SEL770P
Voltage
Conditions
(V]
De-
A.S.C.D. 0
pressed
cancel
Approx.
switch Released
12
M/T
De-
A.S.C.D. 0
pressed
clutch
Approx.
switch Released
12
A/T shift lever posi-
Approx.
tion is at any posi-
12
A/T lion except Nor P.
A/T shift lever posi-
0
tion is at N or P.

(;] A.S.C.D. control unit connector @ (;] ~O.K.

CHECK STOP LAMP SWITCH N.G .• CHECK STOP LAMP SWITCH.

~ CIRCUIT.
Check voltage between control
Refer to "Electrical Components
Inspection.
dB
Fill CDIET
£) unit harness terminals @ and
@.

00
R/B Voltage
Condition
[V]
!vi Stop lamp l Depressed Approx. 12
@§ SEL771P
switch I Released 0

lO.K.
~..~Replace A.S.C.D.
Check A.S.C.D. wire moves
smoothly.
wire.
I
~O.K.
CHECK A.S.C.D. ACTUA- N.G. Replace A.S.C.D. actuator
TOR/A.S.C.D. PUMP. assembly.
Refer to "Electrical Components
Inspection".

~O.K.
Replace A.S.C.D. control unit.

EL-1 08
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 8
SYMPTOM: "CRUISE" indicator lamp blinks.

Does indicator lamp blink when Yes Does indicator lamp blink when
A.S.C.D. main switch is turned brake pedal is depressed
to "ON" again? slowly?

No No Yes

Adjust installation of
stop lamp switch
and A.S.C.D. cancel
switch.
Refer to BR section.

CHECK A.S.C.D. COMBINATION

(STEERING) SWITCH.
Refer to "Electrical Components
Inspection".

~N.G. O.K.

Replace A.S.C.D.
combination (steer-
ing) switch.
A.S.C.D. control unit connector®

IReplace control unit.

CHECK A.S.C.D. ACTUA- N.G. -• Replace A.S.C.D. actuator

L/W TOR/A.S.C.D. PUMP. assembly.
[YJ Refer to "Electrical Components L--------------'
_ __..lr.--r.-.+r--L
~-__.1
Inspection".
O.K.
A.S.C.D. control unit connector®
CHECK A.S.C.D. ACTUA- N.G. Repair short or open circuit in
TOR/A.S.C.D. PUMP CIRCUIT. A.S.C.D. actuator/A.S.C.D. pump
1. Check voltage between con- harness.
trol unit harness terminals
®and@.
Voltage is OV.
2 Disconnect A.S.C.D. control
unit connector.
3 Measure resistance between
control unit harness terminals
SEL763P ®and@,@),@.
Terminals Resistance [OJ
® Approx. 8 - 45
@ @ Approx. 65
@ Approx. 65

~O.K.
I Replace A.S.C.D. control unit.

El-1 09
AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
A.S.C.D. WIRE ADJUSTMENT

A.S.C.D. actuator A.S.C.D. wire

CAUTION:
• Be careful not to twist A.S.C.D. wire when removing it.
• Do not tense A.S.C.D. wire excessively during adjustment.
After confirming that accelerator wire is properly adjusted,
adjust the tension of A.S.C.D. wire in the following manner.
(1) After adjusting the length of the accelerator wire, turn a
securing nut by 112 to 1 turn from throttle open starting
position to the wire loosening direction to fix. (Must be
securing carried out to prevent response delay of operation
of the A.S.C.D.)
(2) Securely tighten lock nut to hold adjusting nut in place.

EL-11 0
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
fi.1 A.S.C.D. pump connector~ ELECTRICAL COMPONENTS INSPECTION
A.S.C.D. actuator/A.S.C.D. pump
1. Disconnect A.S.C.D. actuator/A.S.C.D. pump connector.
2. Check A.S.C.D. actuator/ A.S.C.D. pump operations as
shown.

Check to see if motor starts N.G. ~ Replace A.S.C.D. actuator

when 12V D.C. is applied across assembly.
G) and@.
SEL030Q ' - - - - - - - - . . - - - - - - - - - '
' - - - - - - - - - - - - - - - - ' li) O.K.
r-----~-----.
Check to see if A.S.C.D. wire is N.G.
pulled when 12V D.C. is applied
across G) , ® , @ and @ .
O.K.(Wire is
pulled.)

Check to see if A.S.C.D. wire N.G. Replace A.S.C.D. actuator

returns to original position 50 to assembly.
60 seconds after disconnecting
lead from@.
O.K. (Wire does
not return.)

Disconnect lead from G) to see N.G. ~ Replace A.S.C.D. actuator

if A.S.C.D. wire returns immedi- assembly.
ately.
O.K. (Wire re-
turns.)

A.S.C.D. actuator/A.S.C.D. pump

are O.K.

SEL032Q

SEL033Q

EL-111
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
A.S.C.D. main switch® A.S.C.D. main switch
Check continuity between terminals by pushing switch to each

::::-----::·
position.

14 15 16
s
,-...
ON 0 ~
..()

N () .n

SEL769P
OFF

A.S.C.D. combination switch A.S.C.D. combination switch

8
(Models with air bag)
Check continuity between terminals by turning lever.

~~--~-------
IIISCIIIIIET
=---------=:
L
11 12 13

"
I
I
I
I
I
I
I

·-------+1±!
\
eJ SET/COAST
RESUME/ACCEL

CANCEL
0

0
0
()
-()

..... ..
..()

'!"'
..()

..()

A.S.C.D. steering switch

(Non-turbo models without air bag) ®
A.S.C.D. steering switch
Check continuity between terminals by pushing each button.

~·'
B
1 2 3

SET/COAST 0 .()

RESUME/ACCEL
0 ::-a
CANCEL .......
....., .()
(Turbo models without air b!!-g)@

IFRII=%ildkTI~=:::: :.-.

SEL772P

A.S.C.D. cancel switch Stop lamp switch A.S.C.D. cancel switch and stop lamp switch
C® (@ Continuity

r21i5 Condition A.S.C.D. cancel

switch
Stop lamp switch

When brake pedal is depressed No Yes

When brake pedal is released Yes No
Check each
. .
sw1tch after adJustmg brake pedal - refer to BR
section.
SEL773P

EL-112
 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.)
Trouble Diagnoses (Cont'd)
Clutch switch (For M/T models)
Clutch switch ~
Condition Continuity

1-0
When clutch pedal is depressed No
When clutch pedal is released Yes
Check switch after adjusting clutch pedal-refer to CL section.

SEL774P

Inhibitor switch (For A/T models)

Inhibitor switch harness connector @

Sh
~I 3 4 6

up" 0 .()

"N"
Except "N" or "P"

Speed sensor
1 Remove speed sensor from transaxle.
2. Turn speedometer pinion quickly and measure voltage
across @ and @ .

SEL378P

EL-113
 AUTOMATIC SPEED CONTROL DEVICE {A.S.C.D.)

NOTE

EL-114
 THEFT WARNING SYSTEM

Component Parts and Harness Connector

Location
[!I Back door unlock switch - - - - - - - - - - . I!] Door lockswitch
Back d9or key cylinder tamper switch-:::::=:::::.r Door unlock switch
Back door switch Door key cylinder tamper switch
II Door switch

I!] Door lockswitch m Theft warning relay

Door unlock swiich
Door key cylinder tamper switch

II Door switch
II Door unlock sensor J
IIJ Theft warning horn
riJ Theft warning control unit
Theft warning horn relay

!I/(--(
Door switch
+
\
®.®1 Door unlock sensor
(In power door lock
switch or actuator)
I@,(§)
~
~­
Door lock switch@, ([@)
-z:r-
Door unlock switch \~ \
Door key cylinder tamper switch

SEL752P

EL-115
 THEFT WARNING SYSTEM

Wiring Diagram
HEADLAMP HEADLAMP
RELAY-L RELAY-R FUSE BLOCKCRefer to

~,~~m~
•POWER SUPPLY ROUTING•. l

Gil--------,

~fHH1@ ~® ~® rm®
ii
~ ... ~ ~
I
~~ ~·
L_7
., ..... -=~-=
I eN I
~~~ ~
i ffi '-------- ___ ___j
,· @)j [J
@)@ (§)
I.

~
II CEng i ne room
harness) Gil (@)IDl @ Gil

L.:::==::-t-rr---tt=====-----;:::==t~=t::::==.,.® ~: II:~~-------
HEADLAMP R. H. @ CB I ac kl

~cB:=~: CMaln
harness)
@fi
r0-B/R
"0--R/8
~­ l
_!3D ~l
HEADLAMP L. H. B @

(@) @)

....us
. '""J I CBrownl
GR.I'L

'' ''
~-tl-
III:L G:IE

G/8

THEFT
WARNING
HORN ~ ®

SWITCH lt~~==========~~~~~~~~~~~~==bL-LlL-~ ~
riGNITION
ON or START I @ ~
(~, ~ R/f 18) 8/f -oo- 11/Y - - - - - - - - -
I IGNITION SWITCH I t;!l
1 sTART r 1
'BATTERY~----~~~ ~
s~.t:~
M
~- a: 1 •
&__
~- -=~
-'
~-
r

~~® ~®~®
"
<!!!>®
..
D.~..1.
6
FR.
® "'''
"'" m!f IcLosED I
HOOD SWITCH

FUSE BLOCK CRefer to STARTER RELAY RELAY BODY GROUND

•POWER SUPPLY ROUTING•. l RELAY

EL-116
 THEFT WARNING SYSTEM
Wiring Diagram (Cont'd)

THEFT WARNING COMBINATICN

CONTROL UN! T METER

1-.ul 5
SECURITY
o-----o@--o l D 8
SECURITY
<>----@-----o 9
[}33i[3i8J

® IJriijilll

BACK DOOR UNLOCK SWITCH AND

KEY CYLINDER TAMPER SWITCH
I
.
,--DR/L~
r - - R/W
.- 0 e Ei N CK AM

DOOR SWITCH
!Door

'- t I
harness ~ d3 f?!~~LO~CK~IEUN~~EC3KI
~R. ~ . - . PASSENGER
~
Sl DE DOOR
SENSORC!n power door UNLOCK
lock
@) @!3) H. l 9!) actuator)

~ ~ ~
@Ij) PASSENGER SIDE DOOR LOCK SWITCH. DOOR UNLOCK
SWITCH AND KEY CYLINDER TAMPER SWITCH
0
L/R ~ K UNL CK A

Ttttt===GI(JR :,:;.RR B'R Elil S~~~E ~~:;:~N A~gl~ N~~:;:~N A~L~ S~~~kE NORMAL £I~~
l/R L/R GY/R
IWhltel @E)
t;;;";\ IDoo r
~@ harness

~:~J l:.lL""' ·: !!IJ

~~~LO~C~KIEUN~LOEC3KI DRIVER Sl DE DOOR UNLOCK SENSOR
tfj : 8 : CI n power door I oc k switch)

GY/R GY/R ~ DRIVER 51 DE DOOR LOCK SWITCH. DOOR UNLOCK

L/R L/R SWITCH AND KEY CYLINDER TAMPER SWITCH
====::::;-,
---.I ( IWhl tel

8 ~~=
GY/R~
:::ciT.J
@)
8ml
CK UNL CK A

®
@' For U. 5. A.
lA I ternator I ~
@), For Canada
harness)
'" @), M/T model for Canada
®o
~ @ Except@)
@) M/T model for U. 5. A.
.. 0 A/T model

®ft® @>: With air bag

INHIBITOR SWITCH BODY GROUND GJ: Without air bag

SEL944P

EL-117
 THEFT WARNING SYSTEM

Trouble Diagnoses
SYSTEM OPERATION CHECK
If ignition switch is set in the "ACC" position in the step of START to ARMED or in the ARMED state shown
in this flow chart, the system operation is canceled.
START

Turn ignition switch "OFF" then pull

out ignition key from key cylinder.

Does indicator lamp ~ DOOR SWITCH INPUT SIGNAL CHECK

"SECURITY" blink when No Go to Diagnostic Procedure 1-(1).
~--------------------:
,..-- door is opened?
f---------- ------ 1-'N'-'-'o=+r--t~l HOOD SWITCH INPUT SIGNAL CHECK
INDICATOR LAMP CIRCUIT No f-- hood is opened? Go to Diagnostic Procedure 1-(2).
CHECK 4---- ~---------------- No
Go to Diagnostic Procedure 2. f-- back door is opened? ..:=
r----- - - - - - - - - - - - -
'--- key cylinder is withdrawn? BACK-DOOR SWITCH INPUT SIGNAL
CHECK
Yes Go to Diagnostic Procedure 1-(3).

KEY CYLINDER TAMPER SWITCH IN-

~· PUT SIGNAL CHECK
Go to Diagnostic Procedure 1-(4).

(When key is not being used) (When key is being used)

...
Does indicator lamp
Lock door without
key.
_________ _
..._go off when

door is closed? No
r-----------
hood is closed? ~
,----------
back door is closed? ~
~---------
Close doors, hood No
and back door. key cylinder is in-
stalled?

Lock door with key.

DOOR LOCK
DOOR UNLOCK SENSOR IN- No Does indica- SWITCH INPUT SIG-
1+-~-""'i Does indicator lamp
PUT SIGNAL CHECK tor lamp rN~o~----· NALCHECK
come on?
Go to Diagnostic Procedure 3. come on? Go to Diagnostic
Procedure 4.
I J
Yes

®
(Go to next page.)

EL-118
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
A

ARMEDj
•.J Replace control unit.
After 30 - 40 seconds, does indica- No
tor lamp go off?

Yes

Unlock door without key.

Open door, hood or back door.

No
... ALARM OUTPUT SIGNAL CHECK
Go to Diagnostic Procedure 5.

Does alarm (horn and headlamp)

operate? No
....---------------
Can starter motor be operated? (Starter motor can operate.)

Yes ~ STARTER OUTPUT SIGNAL CHECK

Go to Diagnostic Procedure 6.

l
Does alarm stop auto-
Replace No
~
control unit.
matically after approx.
3 minutes?
Unlock using key.
I

-?.E~~!!r:!!l..!t~.z.- ~
DOOR/BACK DOOR UNLOCK SWITCH
Can starter motor INPUT SIGNAL CHECK
No
be operated? Go to Diagnostic Procedures 7, 8.

~Yes

I System is O.K.
I

EL-119
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
CIRCUIT DIAGRAM FOR QUICK PINPOINT CHECK

•SECURITY• LAMP
FUSE r-----------~~--------------------~2
\:;./

IBATTERY r-----------1 r---~----------------------------------~ l

FUSE
IIGNITION SWITCH l
ACC or ON It--+-~ r---;-----------------------------------~ 3
THEFT 9 I---
WARNING r-l
IIGNIT!ON SWITCH I ~ ~
~~O~N~o~r~S~T~AR~T~J=it====~--------~~~-rn~~--------~~~----====~--~ 4
tf1~~oij_~~~JlA~~~~==
Q
Q
STARTER
RELAY
CLUTCH
INTERLOCK
-=
SWITCH B-

I IGNITION SWITCH I
START I
~~r-
J:; == .~-===r-------~~--~l~==iPiR~NjD~2~1
I~ [1--'"'"""~b-...---.,
.---)- [

?lf -~

L-l-lrrn-......n~
BA T;ERY 1'----------+-"
STARTER ~ INHIBITOR
MOTOR SWITCH

7 f-----
11 f-----
5 f----
THEFT ....1
0
WARNING a:
THEFT HORN 1-
WARNING z
0
HORN u
FUSE RELAY 1!1
z
~~~----+~~==~~------~ z
r~ I .. I a:
FUSE ~
1-
~r--------------~ u.
lJJ
J:
1-

~r-----------~
~r-----,
~ 12

CN

to~

HEADLAMP
R. H. 1
I~~~~~~PI+-----+---~--~----~~-+~~------~ OFF ST 2ND
14 >----

HEAD LAMP 6 f----

L. H.

I HIGH,._,
BE AM''li,...,_.,
'--~---()
16
15 I----

~~~~ AB~
CN

1
~ujL!r--fJ ~ LlGHTING
I DAYTIME
I oa: ~~ ~~
SWITCH

liiil
LlGHT 12134567 8 ~
CONTROL DIMMER 911UI11121314115116J ~
UNIT -= = SWITCH

EL-120
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)

DOOR

DRIVER SIDE DOOR LOCK SWITCH. DOOR UNLOCK

SWITCH AND KEY CYLINDER TAMPER SWITCH
LOCK UNLOCK TAMPER
i 3
1
2
FULL BETWEEN FULL N BETWEEN FULL FULL NORMAL KEY CYLINDER
STROKE STROKE AND N STROKE AND N STROKE WITHDRAWN

3
4

s PASSENGER SIDE DOOR LOCK SWITCH. DOOR UNLOCK

SWITCH AND KEY CYLINDER TAMPER SWITCH
LOCK UNLOCK TAMPER
i 1
2
FULL BETWEEN FULL N BE!~EN~ULL FULL NORMAL KEY CYLINDER
STROKE STROKE AND N STROKE AND N STROKE WITHDRAWN

3
4

-::

BACK DOOR UNLOCK SWITCH AND

KEY CYLINDER TAMPER SWITCH
® UNLOCK
FULL BE TWE~N FULL
AMPER
KEY CYLINDER
rfdih 1
STROKE STROKE AND N N NORMAL WITHDRAWN
2
3

A/T model
0'
G), M/T model

0
UJ
c -
UJ
c
U)
@), For U. S. A.
@) For Canada
em, @) M/T model for Canada
@, Except@)
-::

DOOR SWITCH

SEL943P

EL-121
 THEFT WARNING SYSTEM
Trouble Diagnoses {Cont'd)
POWER SUPPLY AND GROUND CIRCUIT CHECK
Theft warning control unit connector @D
Main power supply circuit check
Ignition switch position
Terminals
OFF ACC ON
G)-@ Battery voltage Battery voltage Battery voltage

SELn6P

Power supply circuit check for system cancel

Theft warning control unit connector @D
Ignition switch position
Terminals
OFF ACC ON
@-@ ov Battery voltage Battery voltage

SEL777P

Theft warning control unit connector @D Ground circuit check

Terminals Continuity
@-Ground Yes

SEL788P

EL-122
 THEFT WARNING SYSTEM
Trouble Diagnoses (Co/nt'd)
EJ Theft warning control unit connector @ DIAGNOSTIC PROCEDURE 1
SYMPTOM: • Indicator lamp does not blink.
• Indicator lamp remains blinking.

I II fWIJ l1t i5 Diagnostic procedure 1-(1)

/ ·~ DOOR SWITCH INPUT SIGNAL O.K. •I Go to Diagnostic Procedure 2.

In I CHECK ·
Check voltage between control
SEL779P
unit harness terminals ® and
I;J Theft warning control unit connector ® @).
Condition Voltage
All doors are
Battery voltage
closed
Driver's side door switch® At least one
Passenger side door switch§ OV
door is open

rrriTtE33 = AIW
f,J
l®G
~
~--}§"•
DOOR SWITCH CHECK . N.G. Replace door switch.
Refer to "Electrical Compo-
nents Inspection".
SEL780P

,O.K.

DOOR SWITCH CIRCUIT CHECK

Check harness continuity be-
N.G. •I Repair harness or connectors.

tween control unit harness ter-

minal ® and door switch har-
ness terminal.
Continuity should exist.

. lO.K.
•
CHECK THE CONNECTIONS AT
EACH CONNECTOR.

EL-123
 THEFT WARNING SYSTEM
Trouble Diagnoses {Cont'd)
m Theft warning control unit connector @) Diagnostic procedure 1-{2)
m
ri~i8~ HOOD SWITCH INPUT SIGNAL
~~ Go to Diagnostic Procedure 2.
I
IIi IIIII,~ B
CHECK
Check continuity between con-
trol unit harness terminals @
OR/L
and@.

lVI Condition Continuity

'--@. ~1----" Hood is open Yes
Hood is closed No
SEL781P

N.G.
[;)

[iti8 ~i8
®
Check hood switch and hood
fitting condition.
N.G. ~ Adjust installation of hood
switch or hood.

rnfF!J;a
Theft warning control unit connector
Hood ..moh &"M@ HOOD SWITCH CHECK
O.K.

N.G. ~ Replace hood switch.

OR/L
Refer to "Electrical Compo- I
OR/L - nents Inspection".
[ill
[;) O.K.
~

HOOD SWITCH CIRCUIT CHECK N.G. ~ Repair harness or connectors.

Hood switch connector ® • .Check harness continuity be- I
tween control unit harness
cD ~i8 terminal @ and hood switch
harness terminal.
B
• Check harness continuity be-
In I tween hood switch terminal
'--- and body ground.
Continuity should exist.

!O.K.
-=
SEL782P CHECK THE CONNECTIONS AT
EACH CONNECTOR.

EL-124
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
m Theft warning control unit connector ® Diagnostic procedure 1-(3)
m
rn:fll;rg~i5(@3 BACK DOOR SWITCH INPUT
SIGNAL CHECK
~I Go to Diagnostic Procedure 2.
I
Check voltage between control
OR unit harness terminals @ and
@.
lVI Condition Voltage

~§
Back door is
Approx. OV
open
SEL783P Back door is
Approx. 12V
closed
I!J Theft warning control unit Back door N.G.
connector® switch
[;)
I Does room lamp come on?
mi+tm connector@

EJ 'r:il
Yes BACK DOOR SWITCH CIRCUIT
CHECK

rili8 OR OR
-
10
No

BACK DOOR SWITCH CHECK

Refer to "Electrical Compo-
O.K.
Check harness continuity be-
tween control unit harness ter-
minal @ and back door switch

LE nents Inspection". harness terminal.

1----' -lN.G. ! O.K.

SEL764P I Replace back door switch. CHECK THE CONNECTIONS AT
EACH CONNECTOR.

EL-125
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
m@)Theft warning control unit connector
[II._CT Diagnostic procedure 1-(4)
m
O.K.
"ji I I ffil1 I,.! . IV KEY CYLINDER TAMPER
SWITCH INPUT SIGNAL CHECK
Check continuity between con-
Go to Diagnostic Procedure 2.

B/R
trol unit harness terminals @
and@.
Condition Continuity
Tamper switch is
Normal No
[Example] Removed Yes

N.G.

KEY CYLINDER TAMPER N.G. ~ Replace key cylinder tamper

SWITCH CHECK switch.
Refer to "Electrical Compo-
nents Inspection".

O.K.
No continuity ... O.K.
KEY CYLINDER TAMPER Repair harness and connectors.
[Example] SWITCH CIRCUIT CHECK
• Check harness continuity be-
tween control unit harness
terminal ® and tamper
switch harness terminal.
• Check harness continuity be-
tween tamper switch terminal
and body ground.
Continuity should exist.

Reed switch turns on when O.K.

key cylinder is removed.
CHECK THE CONNECTIONS AT
Continuity exists ... O.K.
EACH CONNECTOR.
SEL785P

Theft warning control Tamper switch connector

unit connector @) (Driver's side)@

~
!lll .I ··~~::"
r-to
B/R ~8
~
~
[ill ,!
(Back door)@
I
I
(___R~l~Ojlj
Tamper switch connector
(Driver's side)@
(Passenger side) @B)

~__:._--, I
(Back door)@ :
I
_[QJ_ B :
u._j_,~-'

SEL786P

EL-126
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
m Theft warning control unit connector ®
DIAGNOSTIC PROCEDURE 2
SYMPTOM: Indicator lamp does not blink.
m
Bftb~£> ~~I Replace control unit.
I
00
INDICATOR LAMP OUTPUT
SIGNAL CHECK
PU
B OFF Check voltage between control
lVI unit harness terminals @ and
@.
'--<B 81-"
..:::::....--=. Pointer of voltmeter should de·
SEL787P fleet lntermiHently.

Iii Theft warning control unit connector® l O.K.

Theft warning
N.G._J Replace indicator lamp.
ri~i5
INDICATOR LAMP CHECK
indicator
lamp connector@ Refer to "Electrical Compo-
I I
@ ---
nents Inspection".

sn1fh:n I?J
~' P~ fHoffi @
I!) ~O.K.

W1of~
PU
INDICATOR LAMP CIRCUIT N.G. J-, Repair harness or connectors.
CHECK
1
[ill PU
Check harness continuity be-
--------" tween control unit harness ter-
@ : With air bag @ : Without air bag SEL?BBP
minal @ and indicator lamp
harness terminal.
Continuity should exist.

~O.K.
CHECK THE CONNECTIONS AT
EACH CONNECTOR.

EL-127
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
m Theft warning control unit connector @) DIAGNOSTIC PROCEDURE 3
SYMPTOM: Indicator lamp does not come on.

[;ITiJtrm ~ ~~
m
DOOR UNLOCK SENSOR INPUT O.K.__.,I Go to Diagnostic Procedure 4.
I
? SIGNAL CHECK
I
O.K.
Check continuity between con-
L':
I
[ill !:
I
trol unit harness terminals ®
(Driver's side) or @ (Passen-
I I
ger side) and @.
~----------------) SEL789P Condition
Locked
Continuity
No
I Replace control unit. I
(;) Theft warning control unit connector @ Unlocked Yes

Door actuator connector

(Unlock sensor) ~N.G.

"i I

,~· !ID:I~~~ J;I:;:~;.:;::p~

N.G. Replace door lock actuator.

11• 0

Passenger side @D) AL DOOR UNLOCK SENSOR CIR- N.G. "i Repair harness or connectors. I
Door actuator connector ITl ' CUIT CHECK
(Unlock sensor) Ll l 1 • Check harness continuity be-
Driver's side ® tween control unit harness
EtiE-----~ terminal ® (Driver's side) or
I
@ (Passenger side) and
\
Passenger side @D) door actuator terminal.
I
• Check harness continuity be-

cif~
I
I
I tween door actuator terminal
I and body ground.
I
,10 \
I
I
I
Continuity should exist.

L---------~--_-_-__-_-_-_-_~__________s_E_U_9~0P .------------~~<O__.K_.________~
CHECK THE CONNECTIONS AT
EACH CONNECTOR.

EL-128
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
m Theft warning control unit connector @D DIAGNOSTIC PROCEDURE 4

I II ffi 1'1.4~
SYMPTOM: Indicator lamp does not come on.
m
DOOR LOCK SWITCH INPUT
SIGNAL CHECK (LOCK SIG-
O.K. i Go to Diagnostic Procedure 3.
I
O.K.
NAL)
Check continuity between con-
trol unit harness terminals (!)
and@.

Continuity exists ~N~~tral

Locky-J
Key position
Neutral/Lock
Between neutral
Continuity
No I Replace control unit.
I
Yes

~
and lock

N.G.
Driver's side
Ne~tray- Continuity exists DOOR LOCK SWITCH CHECK ~~ Replace key cylinder switch. I
Refer to "Electrical Compo-
:=-yunlock
nents Inspection".

~
Passenger side
SEL791P
O.K.

DOOR LOCK SWITCH CIRCUIT N.G. :f Repair harness or connectors. I

CHECK
• Check harness continuity be-
li)·rheft warning control unit connector @D
tween control unit harness
terminal (!) and door lock

roJfhiE
~ ~ ~LIR (Driver's
Door lock switch connector
side)@
switch terminal.
• Check harness continuity be-
tween door lock switch termi-
~ Sv [RJ (Passenger side)@ill)
L/R tij nal and body ground.
Continuity should exist.

[lli) CHECK THE CONNECTIONS AT

Door lock switch connector
EACH CONNECTOR.
(Driver's side)®
(Passenger sidell[@)

t±3r----B-----+ocru
r:iti5

SEL792P

EL-129
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
m Theft warning control unit
DIAGNOSTIC PROCEDURE 5
SYMPTOM: Alarm does not operate.
co~~i) m
ILIH?JHQ~,__I
. B --- ALARM SIGNAL OUTPUT ~~ Replace control unit.
CHECK
GY Check voltage between control
unit harness terminals @ and
@.
Condition Voltmeter
SEL793P Except alarm
12V
phase
Pointer deflects
(;] Alarm phase
Theft warning horn relay connector (§!) intermittently

em G/B ~O.K.
I Check theft warning horn relay. N.G. ~~ Replace relay.

(;] iO.K.
THEFT WARNING HORN CIR- ~~ Repair harness and connectors.
CUIT CHECK
Check if voltage across theft
Theft warning warning horn relay harness ter-
Theft warning control unit horn relay
connector@ connector~ minal and body is 12V.
·~ Check continuity between theft
warning horn relay terminal
-CI
and control unit harness termi-
G/W 18 nal@.
Continuity should exist.

ro.K.
THEFT WARNING HEADLAMP N.G. I Repair harness and connectors.
CIRCUIT CHECK
Check continuity between head-
SEL794P
lamp relay terminal and control
unit harness terminal @.
Theft warning control
unit connector ® Headlamp relay
connector®
~O.K.
~ _m_tor Check headlamp system. Refer
illl\illll ~i5~USA to "HEADLAMP".

[il GY ~~nada ~ I; (Left)

--
18
--~+
enI i
'p
- ___ ._I ____ ..,I
!
IPtB
(Right)
SEL795P

EL-130
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
@
DIAGNOSTIC PROCEDURE 6
Theft warning control unit connector
SYMPTOM: STARTER MOTOR can be operated. (Starter killed
phase)
~I)@)
''='='=~~~
Appro X. 12V
I l,s!! 8 or
OR

lv I
00 STARTER MOTOR KILL OUT-
PUT SIGNAL CHECK
Check voltage between control
~ Replace control unit.

unit harness terminals @ and

@~
SEL796P
@ when ignition switch is
turned to ON or "START".

~Approx. 0 volt

Check theft warning relay. N.G . .,.. Replace theft warning relay.

~O.K.
Repair harness between control
unit and theft warning relay.

EL-131
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
E) Theft warning control unit connector @ DIAGNOSTIC PROCEDURE 7
SYMPTOM: Alarm does not stop even if stop signal Is given.
B
m
DOOR UNLOCK SWITCH INPUT
SIGNAL CHECK (UNLOCK SIG-
~I Replace control unit.
I
GY/R ,.-
NAL)
[ill Check continuity between con-
trol unit harness terminals @
and@.
Key position Continuity
Neu~ral_/ Continuity exists
Neutral/Unlock No
L-YUnlock Between neutral
Yes
and unlock

0 ~N.G.

~I
Driver's side
Continuity exists~ N utral
7
DOOR UNLOCK SWITCH
CHECK
Replace key cylinder switch.
I
"~®
Refer to "Electrical Compo-
nents Inspection".

O.K.
Passenger side
SEL797P
DOOR UNLOCK SWITCH CIR- N.G. ci Repair harness or connectors. I
CUIT CHECK
• Check harness continuity be-
Door unlock switch
Theft warning control connector tween control unit harness
unit connector ® (Driver's side)@) terminal @ and door unlock

mHI:m (Passenger side)@@)

Efj GY/R
switch terminal.
• Check harness continuity be-
tween door unlock switch ter-

~ =~15
minal and body ground.
GY/R Continuity should exist.

i5 '-----~~·
[ill
~--------~
~O.K.
CHECK THE CONNECTIONS AT

Efj,___s EACH CONNECTOR.

~I()
Door unlock switch
connector
(Driver's side)@)
(Passenger side)@@)

SEL798P

EL-132
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
m Theft warning control unit connector @ DIAGNOSTIC PROCEDURE 8
SYMPTOM: Alarm does not stop even if stop signal Is given.
~ rw--T m
BJHffi6J ~ 18
OR/L [SJB Neu~ral/
c:::Y
Continuity
ex1sts
BACK DOOR UNLOCK SWITCH
INPUT SIGNAL CHECK (UN-
LOCK SIGNAL)
O.K. ·: Replace control unit.
I
cru ®""'"' Check continuity between con-
trol unit harness terminals @)
and@>.
SEL799P Key position Continuity
Neutral/Unlock No
1§1 Theft warning control unit connector ® Between neutral
Yes
and unlock

-
I?J Back door unlock N.G.
switch connector@
BACK DOOR UNLOCK SWITCH N.G. ·: Replace key cylinder switch. I

·~c>t---0----""r~
CHECK
Refer to "Electrical Compo-
nents Inspection".

O.K.

BACK DOOR UNLOCK SWITCH N.G . ...I Repair harness or connectors.

CIRCUIT CHECK I

Back door unlock switch connector@)

• Check harness continuity be-
tween control unit harness
terminal @) and back door
unlock switch terminal.
• Check harness continuity be-
tween back door unlock
switch terminal and body
ground.

~O.K.
~----------------------~____s_E_L_ao_oP~,-C_H_E_C_K_T_H_E__
C_O~N-N_E_C_T-IO_N_S__
A_T-,

EACH CONNECTOR.

EL-133
THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
ELECTRICAL COMPONENTS INSPECTION
Door switches
Check continuity between terminal and switch body.

Hood switch
Check continuity between terminals when hood switch is
pushed and released.

~ a
Pushed Released

9
b 6

UNLOCK

EL-134
 THEFT WARNING SYSTEM
Trouble Diagnoses (Cont'd)
Tamper switch for door Key cylinder tamper switch, door lock switch and door
unlock switch
• Door
TAM PER SWITCH DOOR LOCK SWITCH I DOOR UNLOCK SWITCH

Between Between
Key cyl- Key cyl- full full
Full Full
inder is inder is stroke Neutral stroke
stroke stroke
installed removed and neu- and neu-
tral tral
Reed switch turns on when
tamper switch is removed from door. 1 0
2 )
Tamper switch for back door

~Koy cy~;oo.,
3 ?
4 6 ) )

T~~
Reed switch turns on when
key cylinder is removed.
• Back door
TAMPER SWITCH

Key cylinder Key cylinder

Back door unlock switch

Between full
Full stroke stroke and Neutral
is installed is removed
neutral
Fu~ll
stroke Neutral
Full stroke 1 0
I
2 9
'~/ '
' ,,
'
3 6 6
t ' ->

SELBOSP

EL-135
 LOCATION OF ELECTRICAL UNITS

Engine Compartment

A.S.C.D. pump

Fusible link holder

Headlamp
washer relay

Starter
relay (Except
HICAS solenoid M/T model
valve (Turbo model) for Canada)

·Power transistor
unit

Relay & fuse box

Relay & fuse box

Headlamp relay-L Ignition coil relay

Horn relay E.C.C.S. relay

Headlamp relay-A
Radiator fan sub-relay (Turbo model)

Air conditioner relay

Radiator fan relay

Inhibitor relay
(A/T)
Front fog lamp relay

Dimmer relay

SEL012Q

EL-136
 LOCATION OF ELECTRICAL UNITS

Passenger Compartment

Fuse block Shift lock control unit (A/T)

Chime assembly
Rear window defogger Combination flasher unit
relay
Kickdown switch (A/T)
Circuit breaker E.C.C.S. control unit
Blower relay-1 (Manual A/C)
Bulb check
relay A.S.C.D. hold relay (Manual A/C)
A/C ignition relay
Theft warning control unit
Power steering control unit
(Non-turbo model) HICAS
control unit (Turbo model)

Audio relay
(Bose system)
Blower relay-2
(Manual A/C)
A.S.C.D. hold relay
(Auto A/C)
Blower relay-3
(Manual A/C)
A/T control unit
Theft warning horn relay
A.S.C.D. control unit

Automatic seat belt control unit

A.S.C.D. cancel switch

Accessory
relay Power window amp.
Ignition relay Stop lamp switch

A.S.C.D. clutch switch (M/T)

Blower relay
Air bag control unit

Time control unit Fuel pump relay

SEL013Q

EL-137
 LOCATION OF ELECTRICAL UNITS

Luggage Compartment
2 SEATER

SEL753P

Wiper motor

Fuel pump control unit

(------- SEL754P

EL-138
 LOCATION OF ELECTRICAL UNITS
Luggage Compartment (Cont'd)
2+2 SEATER

Actuator (for anti-lock braking system)

( ------- S'L'5''

EL-139
 LOCATION OF ELECTRICAL UNITS

NOTE

EL-140.
 HARNESS LAYOUT

Outline

Body harness no. 2

Door harness R.H.

Engine room harness

Alternator harness

Back door harness

Body harness

Door.harness L.H.

Air bag harness

SEL014Q

EL-141
 Diode@

Seat belt warning~ Seat belt switch

lamp Time control unit Body ground
Time control unit Front washer switch
Headlamp washer Front washer motor
relay

s:: ,..
:::1:
!!. ::D
m
:::::1 z
m
r-
....
~
I
..
:::1:
I»
:::::1
en
en
N
CD
fn
fn
5:-<
0
c
-t

//.®
4'\ ~/~~
 ® Time control unit
® Rear wiper and washer switch @ Blower relay-2 (Manual A/C model)
® Fuel pump relay
® Mode door motor (Manual A/C model) @ A.S.C.D. hold relay (Auto A!C model)
® Body ground
® Mode door motor (Auto A/C model) @ Audio relay (Manual A/C model with Bose system)
® To body harness ® ® A/C control unit (Manual A/C model) @ Body ground
® To body harness ® ® A/C control unit lAuto A/C model) ® Theft warning control unit
@ To engine room harness 0 ® Air mix actuator (Manual A/C model) @) Power steering control unit (Non-turbo model)
® To engine room harness 0 ® To A/C sub-harness (Auto A/C model) @) A.S.C.D. control unit
@ To engine room harness ([@:) (Black)
@ Fuse block
® Foot lamp L.H. ® Automatic seat belt control unit (For U.S.A.)
® Radio and cassette player @ To E.F.I. harness ®
® Fuse block
®
@) Fuse block
Joint connector (Bose system model) ® Clutch switch (Black) (M/T)

@) Fuse block
® Shift lock solenoid· Detention switch (A/T model) @) Steering angle sensor·Steering switch (Turbo

@) To door harness L.H. ® ® Digital clock model without air bag)

® ® O.D. control switch and A/T illumination (A/T model) @) A/C ignition relay
® To door harness L.H.
® Parking brake switch @) To body harness no.2 ~ (Turbo model)
@ Diagnostic connector for CONSULT
@)
® Seat belt switch R.H. 8 HICAS control unit (Turbo model)
Joint connector (Turbo model)
@) Diode (For Canada)
® Ashtray illumination @l Combination meter (With air bag)

@
® Cigarette I ighter @> Combination meter (With air bag) ::1:
A.S.C.D. clutch switch (Blue) (M/T model)
@) Door mirror control switch· Shock absorber select @) Combination meter (With air bag) 3: )>
@) Clutch interlock switch (Blue) (M/T model for U.S.A.)
~
!. :rJ
m @) Shift lock control unit (A/T model)
switch Steering angle sensor (With air bag) :::I z
r- ® Warning chime
@) Door mirror defogger switch ~ To air bag harness §
::1: m
0
1
..a @) Combination meter (Biack)(Without air bag)
@)
®
Seat belt switch l.H. (For Canada)
To seat sub-harness (With power seat)
~
~
Theft warning horn relay
Warning lamp (With air bag)
...
I»
:::I
0
~ @)
~
Combination meter (White)(Without air bag) CD
® @
w Thermo control amplifier (Manual A/C model) Warning lamp (With air bag) fl)
®
-
Cluster switch
@
® Body ground § Steering switch (With air bag) fl)
-<
Cluster switch
@) Intake door motor (Manual A/C model) 0
® lighting switch· Headlamp washer switch
@) Intake door motor (Auto A/C model)
0 c
0 -1
® Combination flasher unit
® Glove box lamp Diode@!) :::I

-
@) Warning lamp (A/T modei)(Without air bag) ""t
@) Warning lamp (Without air bag)
® A.S.C.D. hold relay (Manual A/C model)
Head lamp relay-A ~Head lamp washer relay a.
@) Blower relay-1 (Manual A/C model)
@ Dimmer switch Headlamp R.H.
@) Steering switch (Non-turbo model without air bag)
® Blower motor
Headlamp relay-L
@ Kickdown switch (White) (A/T model)
® A/C sensor (Auto A/C model)
Headlamp L.H. Dimmer relay
@ Heater resistor !Manual A/C model)
@) A.S.C.D. cancel switch (Blue)
@ Stop lamp switch (Black)
® Blower control amplifier (Auto A/C model) Diode@
@) Foot lamp R.H.
@ Key lock solenoid (A/T model)
@ Ignition switch
® To door harness R.H. @Ij) Theft warning I ..,, I '
@) Key switch
® To door harness R.H. ~ horn relay
@) Diode (For Canada) Headlamp relay-A t I ..,, I t Theft warning
® Key hole illumination
@ To engine room harness 0 (Black) lighting switch }
control unit
@) Combination meter (Without air bag) @) 0
I'
To engine room harness Dimmer switch
® Hazard warning switch
~®
.- A/C switch unit (Manual A/C model)
@) To engine room harness ([ill) (Brown)
Hhdl~p L.H ., :
@ Diode Fog lamp relay Fog lamp switch
~@) A/C switch unit (Auto A/C model)
@
~@) Front wiper and washer switch
Blower relay-3 (Manual A/C model) Not used Not used
Audio relay (Auto A/C model)
 1\)

E
m
::D

m
0
,..
J:

a. :::D

rrrYr
m '< z

II;\~:~~
r- m
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I
~

~
...
m
:I
en
~
CD
(I) ~
(I) -<
0
c:
-t
 Body harness Body harness no. 2

® : To engine room harness @ @ : Rear speaker L.H. (Bose system) 0 : To engine room harness @Bl
® : To main harness ® ® : Front washer motor (White) ([@) : To engine room harness 8
® : To main harness @ ® : Rear washer motor (Green) 0 : Body ground

® : Fuse block @ : Washer fluid level switch (Black) @ill) : Anti-lock braking system control unit
® : @ : Actuator (For anti-lock braking system)
® : Fuse block Rear side marker lamp l.H.
® : Door switch l.H. @ : Stop and tail lamp sensor @Y : To body harness ®
® Body ground ® : Rear combination lamp l.H. @ill) : Body ground

® : Fuel pump control unit @ : Back-up lamp l.H. ~ : Rear sensor (For anti-lock braking system)
® : Room lamp relay ® : License lamp (§!) : To main harness ~ (Turbo model)
@) Diode @) : Body ground ~ : HICAS fail-safe solenoid valve (Turbo model)
@) : Fuel pump @ : Back door key switch @I!) : Diode (Turbo model)

® Fuel tank gauge unit @ : Back door switch @ill) : To body harness @) (Turbo model)
® : To body harness no. 2 @Y ® Back-up lamp R.H.
@) Door switch A. H. @ : Rear combination lamp R.H.
@
,.
Diode
@ : Rear speaker R.H. (Except Bose system) ® : Rear side marker lamp R.H.
® : Rear speaker R.H. (Bose system) @ : Power antenna timer
Brake warning lamp
m ::a:
0
® Spot lamp ® Power antenna motor a. :a
m ® In-vehicle sensor upper· Aspirator motor ® Diode ShoO< '"''""'~p.,k;og ""'' •wrtoh '< z
::a: m
control unit
r- (Auto A/C model) @) Shock absorber control unit (Turbo model) 0
I Shock absorber · Brake fluid level switch
... 0
m
,.
~
@ : Interior lamp @) To body harness no.2 0 (Turbo model)
select sw1tch - ·· HICAS control unit
~ @ : To back door harness ~ ® : Rear shock absorber actuator R.H. ::::s r
(A/T model) CD
0'1 @) @§) en
- ....
To back door harness (Turbo model)
@ : en -<
Rear speaker L.H. (Except Bose system) ® Rear shock absorber actuator L. H. 0
(Turbo model) n c:

--
0
Diode @)@) :I
a.
@)
Foot lamp • I ~ I • Door switch R.H.
Door switch L.H.
Time control unit
Door warning lamp ' +I ~ I I Back door switch

Room lamp relay I ~ I 1

®
Ul
m
,....
~
a>
0
 1\)

+
1\)

(I)

~m
::u

m ,.
0
:r::
a. :D
m '< z
:r:: m
r-
I
.....a ~~/~ r@~~l$J!.
en
... en
m
~
en
@.@]) ~
CD
en
en
-n
s
c0
0 ....
~

-
""t
a.
 Body harness Body harness no. 2

® : To engine room harness ffi @ : To back door harness @!]) @!]) : To engine room harness ~
® : To main harness ® ® : To back door harness ~ 0 To engine room harness @!)
® : To main harness ® @ : Rear speaker l.H. (Except Bose system) @ Body ground

® : Fuse block @) : Rear speaker L.H. (Bose system) {§9 : Anti-lock braking system control unit
® : Fuse block ® : Rear side marker lamp L.H. €@) : Actuator (For anti-lock braking system)

® : Door switch L.H. @ : Stop and tail lamp sensor 8 : To body harness ®
® Body ground ® : Rear combination lamp L.H. @!) : Body ground
@ : Fuel pump control unit @ : Back-up lamp L.H. 0 : Rear sensor (For anti-lock braking system)
® : Room lamp relay ® : License lamp
@) : Diode @ : Body ground
® : Fuel tank gauge unit @) : Back door key switch
@ : To body harness no. 2 (§) ® : Back door switch
® : Door switch R.H. @ : Back-up lamp R.H.
@ : Rear speaker R.H. (Except Bose system) @ Rear combination lamp R.H.
@) : Rear speaker R.H.(Bose system) @ : Rear side marker lamp R.H.
:::1:
@) Spot lamp ® : Power antenna timer m )>
@ : In-vehicle sensor upper·Aspirator motor @ : Power antenna motor 0 :D
® :Diode a. z
m (Auto A/C model) "<
r- @) Interior lamp ® : Luggage room lamp :::1:
m
tn
I
..a ...m
::::J
tn
~ Diode @@) CD §;
......
-....
(I)
-<
(I)

@ 0
c:
n -t
Foot lamp • I .., I • Door switch R.H. 0
::::J

Door warning lamp ' +I .-+ I I '

Door switch L.H.
Time control unit
Back door switch -a:
Room lamp relay
Luggage room lamp
I: I ' 1

@)

en
m
,....
0
...,
p
 Body ground

:::t
m
:I
)>
ca ::D
m ~ ~~
-·
:I z
m
r-

I
CD
0
.....
I
@)@)@) ::D 0
0
~
co 0 §;
3 <
..
:::t
m
:I
CD
0
...
c
en
en
 ® : Front wiper motor @ : Front washer motor (White)
® : Brake fluid level switch @ : Rear washer motor (Gray)
® : Starter relay (Except M/T model for Canada) @ : Washer fluid level switch (Brown)
® : Front wiper amplifier @D : Headlamp washer motor (Black) (Fo·r Canada)
® : Power steering oil pressure switch {Black) @ : To alternator harness ® {Black)
® Power steering solenoid (Gray) @ : To alternator harness ® (Blue)
® : Hood switch @ : To alternator harness @ (A/Tmodel)
® Front sensor L.H. (For anti-lock braking system) @ : To alternator harness ®(MIT model)
®: Relay box (Refer to page EL· .) ® : To alternator harness ®
® : To E.F .I. harness @ (White) ® : Inhibitor switch (A/T model)
@D : To E.F.I. harness @ (Gray) @ Revolution sensor (A/T model)
® : To E.F.I. harness @ (Brown) @ : To AJT solenoid harness (A/T model)
@) Body ground @) Front sensor R.H. (For anti-lock braking system)
® : Headlamp L.H. (Low beam) (Brown) @) A.S.C.D. pump
@ : Headlamp L.H. (High beam) (Black) ® Dropping resistor (A/T model)
@) Front combination lamp L.H. @) Battery
@)
@)
Front fog lamp L.H.
Horn-low
@ : Fusible I ink holder
® : Daytime light control unit (For Canada) m J:
::II
,..
@) Radiator fan motor (Non-turbo model) ® : Head lamp washer relay (For Canada) (Q :D
:r z
m @ :
.... @)
Headlamp R.H. (High beam) (Black)
Headlamp R.H. (Low beam) (Brown)
@ : Front shock absorber actuator R.H.
(Turbo model)
CD m f/)
....
I
@; : Body ground @ : Boost sensor (Turbo model)
:D
0
f/)

~
U)
@
@
:
:
Ambient sensor (Auto A/C model)
Low-pressure switch
® Front shock absorber actuator l. H.
(Turbo model)
0
3 < 5:
@ : Horn-high @ : Radiator fan motor (Turbo model) :z:: c0
@
@)
: Front fog lamp R.H.
Front combination lamp R.H.
@ :
@)
HICAS solenoid valve (Turbo model)
HICAS oil level switch (Turbo model)
...
SD
::II
-1
CD
® : Theft warning horn en
-
en
n
0
::II

-
P'!
Q,

(/)
m
r-
0
00
0
 m
::J
,..
::1:
CD :D
m
-·
::J
CD m
z
r- en
1
-a :D en
0'1
0
0
0
3 <
,..
r-

::1: 0
...::J
D) c
.....
CD
0

@]) To main harness @ ~

~
-
0

n
0
::J
0
(@)
8
0
To main harness
To main harness
To body harness
Fuse block
®
@
®
(Black)
-
""t
a.

@Y Fuse block
0 A/T control unit
@Y : To body harness no. 2 (§})
(@!) : To body harness no. 2 0
en
@ll : To main harness @ (Black)
m
r-
0
(@}) : To main harness @
<0 @3) : To main harness ® (Brown)
0
 Engine ground @) : Compressor @) : Crank angle sensor
@) : To engine room harnes @) (White) @) : Thermal transmitter
@) To engine room harness @) (Gray) @) Engine temperature sensor
@) : To engine room harness @) (Brown) @) : Power transistor unit
@) : Check connector ® : Power transistor unit

@ : E.C.C.S. control unit @) : Check connector @) V.T.C. solenoid valve- R.H.

® To main harness @ @) : Body ground @) Exhaust gas sensor - A. H.
® Resistor @) : Air flow meter ® : A.I.V. control solenoid valve
® Exhaust gas temperature sensor @) : Engine ground
(For California) @) : Injector No. 5
® : V.T.C.solenoidvalve-L.H. @) : Ignition coil No. 5
® Exhaust gas sensor - L.H. @) Injector No. 3
@ Air regulator
@ To detonation sensor
sub-harness
Engine ground
® LJ
--~~ 1/\'lt\

!"1 ,..
:I:

m
.:n- ::D
z
rn
r- :I: en
....
1
...
I» en
en
.... Ignition coil No.3
Injector No. 1
Ignition coil No. 1
::::::1
CD
en
en s
0
c
-1
Wastegate valve control
solenoid valve L.H.
(Turbo model)

® Wastegate valve control

solenoid valve R.H.
(Turbo model)
@ : E.G.R. control solenoid valve

® Ignition coil No. 6

@) Engine ground
@) A.A.C valve
@) Injector No.4
@) F.I.C.D. solenoid valve @)
(J)
m @) Ignition coil No. 4 @) Ignition coil No. 2
,....
0 @) : P.R.V.R. control solenoid valve @) Throttle valve switch
"'0
p @) Fuel temperature sensor @) Throttle sensor
HARNESS LAYOUT

Air Bag Harness

~ Left crash zone sensor

~ Center crash zone sensor
~ Right crash zone sensor
(§]) To main harness
@!3) : Tunnel and sating sensor
~ : Air bag module
~ : Air bag control unit

SEL0210

EL-152
 HARNESS LAYOUT

Door Harness L.H.

® To main harness @ @) Power window amplifier

® To main harness @ @) Door latch switch (Black)

® Door mirror motor @) Door handle switch and key hole illumination

® Door speaker (Except Bose system) (Black) (GLL model)

® Door speaker (Bose system) ® Lap belt tension reducer (White)

® Power window regulator ® Shoulder belt tension reducer (White)
@ Power window switch @) Door lock switch
® Door key switch (Brown)

CJ

D
Qo
SEL0220

Door Harness R.H.

@]) To main harness @ @?) Power window regulator

@E) To main harness @!) 8 Power window switch
@® Door mirror motor (§) Lap belt tension reducer (White)
([@ Door speaker (Except Bose system) @ill) Shoulder belt tension reducer (White)
@® Door speaker (Bose system) 0 Door lock actuator (White)
(§) Door key switch (Brown)
<§) Door latch switch (Black)

0
0
oCJ
SEL023Q

EL-153
 HARNESS LAYOUT

Back Door Harness

<@D : To body harness ® ~ Rear wiper motor

@'§) : To body harness ® (@) Condenser
@§) Rear window defogger ~ High-mounted stop lamp
(@9 : Body ground @D) Rear window defogger
@ill) Body ground

Body ground

SEL995M

Alternator Harness
® To engine room harness @ (Black)
® To engine room harness @) (Blue)
® To engine room harness @) (A/T model)
® : To engine room harness @ (M/T model)
® : To engine room harness ®
® Alternator
® Oil pressure sending unit
® Starter motor

® : Vehicle speed sensor

@ Inhibitor switch (A/T model)
@ Back-up lamp switch (M/T model)
@ Neutral switch (M/T model) SEL996M

EL-154
 SPECIAL SERVICE TOOLS

Tool number
(Kent-Moore No.) Description
Tool name

26081 30POO (right) Attaching headlamp aimer

26086 30POO (left)
Headlamp aimer
adapter

(J36126) Adjusting washer nozzle

Washer nozzle
adjusting tool

EL-155
1991
300ZX
1991

300ZX
MANUAL
SERVICE

SERVICE MANUAL