VNX - Su Montero 1989 Service Manual PDF

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NrJDAA-A
GROUP INDEX
Service Manual
Introduction and
Master Troubleshooting
MONTCRO
......*....*...*..
Lubrication and Maintenance
. .. .. .. .. m.
Front Suspension .. .. ... . ... . ... . ... .. .. .. .. . . y
1989 : Volume
FOREWORD
This Service Manual has been prepared with the
latest service information
available at the time of
publication.
It is subdivided
into various group
categories
and each section contains diagnosis,
disassembly,
repair, and installation
procedures
along with complete specifications
and tightening
references.
Use of this manual will aid in properly
performing
any servicing necessary to maintain or
restore the high levels of performance
and reliability
designed into these outstanding
vehicles.
Rear Axle *.......*.......*................a.....*..

Srakes-
Service
Parking
. .. .. .. .. .. .. .. .. .. .. .. .. .. .. &
Clutch ................................................
Hi
Cooling
.............................................
Engine ...............................................
Intake and Exhaust ,.......*..........*......
ml
Fuel System . . .. .. .. .. .. .. ... . ... . .. . ... .. .. .. ... . mE

Propeller Shaft and Universal
Joint
Rear Suspension
Power Steering
.. .. . ... m;
.. .. .. .. . ... . ... . ... .. .. . ... .. mt

... . ..a*........................ m
Transmission - fity$tic
4liP
WESUPPORT
VOLUNTARY
TECHNICIAN
CE,TT,flCA~ONMROUGH
Wheels and Tires .............................
FP
Body ..................................................
Heater and Air Conditioning
Inr
Mitsubishi
Motors
corporation
reserves
the right to make changes
in
design or to make additions
to or improvements
in its products
without
imposing
any obligations
upon itself to install them on its products
previously
manufactured.
Q 1988
Mitsubishi
Motors
Corporation
Printed
........... p!
Emission Control Systems .............. &!!!!
MITSUBISHI
MOlUR SALES OF AMERICR
. .. .. .. ... ... &!a
in Japan
http://vnx.su/
NOTE
For Electrical refer to .._
Volume-2 Electrical
~~~~
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-.._i._--
--em._.
INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual
HOW TO USE THIS MANUAL

CONTENTS
The preceding
page contains the GROUP
which lists the group title and group number.
INDEX
PAGE NUMBERS
All page numbers
consist of two sets of digits
separated by a dash. The digits preceding the dash
identify the number of the group. The digits following the dash represent
the consecutive
page
number within the group. The page numbers can
be found on the top left or right of each page.
gg$I!
NWS&Wl g-
LIMIT
Shows the standard for judging the quality of a part
or assembly
on inspection
and means the maximum or minimum value within which the part or
assembly must be-kept functionally
or in strength.
It is a value established
outside the range of
standard value.
incidental operation
rformed
before re-
TEXT
Unless otherwise specified, each service procedure
covers all models.
Procedures
covering specific
models are identified by the model codes, or similar
designation
(engine type, transmission
type, etc.).
A description
of these designations
is covered in
this unit under VEHICLE IDENTIFICATION.
Removal steps : The numbers before part names b

correspond
to numbers in the illustration and indicate the order of
removal.
Disassemblv steos : The numbers
before
oat-t
names co&pond
to num6&
in the illustration, and indicate
the order ofdisassembly.
I
TROUBLESHOOTING
---I--
Installation
steps : This is provided if installation

cannot be made in the reverse
order of Removal steps; omitted if installation in the reverse
order of Removal
steps
is
possible.
Reassembly steps : This is provided if reassembly
order of Disassembly
steps:
omitted if reassembly
in the
reverse order
Troubleshootings
are classified into master troubleshooting and group troubleshooting
and located as
follows:
The master troubleshooting
is prepared when the
trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting
guide is prepared for
causes of problems related to that individual group
only; a troubleshooting
guide is prepared for each
appropriate group.
SERVICE PROCEDURES
The sewice steps are arranged in numerical order
and attentions to be paid in performing vehicle service are described in detail in SERVICE POINTS.
DEFINITION OF TERMS
STANDARD VALUE
indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
The following
abbreviations
are used
in this manual
for classification
of model
types.
M/T : Indicates the manual transmission,

or models equipped
with the manual transmission.
A/T : Indicates the automatic
transmission,
or models equipped with the automatic transmission.
F.B.C. : Indicates the feed back carburetor,
or engines equipped
with the feed back carburetor.
M.P.I. : Indicates the multi-point
injection,
or engines equipped
witkthe
multi-point
injection.
2.6 L Engine : Indicates the 2.6 liters (155.9 cuin.) engine, or a model equipped with such an engine.
3.0 L Engine : Indicates the 3.0 liters (181.4 cu.in.) engine, or a model equipped with such an engine.
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INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual
Page number
Group title
Section title
7-io
COOLING
- Thedostat
THERML vrra-r
. -.
REMOVAL
AND
INSTALLATlON
Indicates tightening
torque
Repair
shown.
kit or set parts are

fOnlv verv freouentlv
This number corresponds to

the number
in Removal
steps, Disassembly
steps, Installation
steps
or Reassembly steps.
1. Connection of enginecoolant
temperature
syitch connector
(Vehicles with an air condition-
+ee
3. Water outlet
4. Water outlet
5 Thermostat
fitting
fitting
gasket
SERVICE
S.
POINTS
INSTALIATION
Install
the thermostat
caution
The thermostat
ensure
OF INSTALLATIONOF THERMOSTAT
that
to the
intake
manifold as illustrated.
Range tits over the
the thermostat
is not installed
manifold
seat;
at an angle.
An explanation
of procedures,
regarding removal, installation.
and reassembly.
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notes, etc.
disassembly
,,
i
-
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.*,
,., L
INTRODUCTION AND MASTER TROUBLESHOOTING -Vehicle Identification
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER LOCATIONm..
The vehicle identification
number (V.I.N.) is located
attached to the left top side of the instrument
panel.
on a plate
--
VEHICLE IDENTIFICATION CODE CHART PLATE

All vehicle identification
number is a code which
T
-
3rd
digit
Vehicle
type
4
Multipurpose
vehicle
(MW
7Truck
Ibs. and
with
hydraulic
brakes
G50016000
Ibs. and
with
hydraulic
brakes
numbers contain 17 digits. The ve!h%

tells country, make, vehicle type, etc.
I---
6th
digit
7th
digit
Price
class
Body
4High
5Premium
33-door
metaltopor
van
8th
digit
9th
digit
/ 10th
digit
1 Engine 1 zi$c
/ Efe
cu.in.1
S3.0liters
(181.4
cuin.)
http://vnx.su/
12th thru
17th digit
I-Plant
Serial
number
JNagoya
-3
000001
to
999999
9
X
NOTE
Check digit means a single number or letter)( used to verify the accuracy of transcription
number.
( TSB Revision
11th
digit
!
of vehicle identification
-.
INTRODUCTION AND MASTER TROUBLESHOOTING

VEHICLE
FEDERAL
\DENTlFlCATlON
NUMBER
- Vehicle
Identification
LIST
NWCG
VIN (except sequence number)
Brand
q KJ
JA7FJ43E
JA7FJ43S 0 KJ
JA7FJ43S 0 KJ
JA7FJ53S Cl KJ
JA4GJ41 S 17 KJ
JA4GJ41 S 0 KJ
JA4GJSlSCiKJ
MITSUBISHI
MONTERO
\
Engine displacement
Model code
2.555 liters (155.9 cu.in.)
L042GTNJLF
2.972 liters (181.4 cub.)
L141GTNJLF
L141 GTRJLF
L141 GTRULF
Ll46GVMNJLF
L146GVMRJLF
L146GWMRULF
Engine displacement
Model code
CALIFORNIA
(Can also be sold in Federal states.]

JA7FJ43E 0 KJ
Brand
I
JA7FJ43S q KJ
JA7FJ43S q KJ
JA7FJ53S 0 KJ
JA4GJ41 S 0 KJ
JA4GJ41 S q KJ
JA4GJ51 S Cl KJ
I
MITSUBISHI
MONTERO
2.555 liters (155.9 cu.in.)
2.972 liters (181.4 win.)
L042GTNJLH
.~
L141 GTNJLH
L141GTRJLH
L141 GTRULH
L146GVMNJLH
Ll46GVMRJLl-l
L146GWMRULH
VEHICLE INFORMATION CODE PLATE
NN!CO.-
Vehicle information
code plate is riveted on the cowl top outer
panel (2.6L Engine) or front end upper bar (3.OL Engine) in the
engine compartment.
The plate shows model code, engine model, transmission
model, and body color code.
mc
A MllSUBlSHl
w-B-_1
.---I
-----xv2
1. MODEL
L146G
2.
6672
VMNJLF
ENGINE
L
3.
V5MTl
TRANS
AXLE
4.
Engine model
-L
COLOR, TRIM
OPT
Transmission
model
H84
L
HlXH84X85
Monotone
exterior
color code
Two-tone color code

/-T___
Exterior code
--:
Two-tone exterior isshown by the exterior
code followed by the two color codes.
mevision
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- Vehicle
Identification
CHASSIS NUMBER
STAMPING LOCATION
The chassis number is stamped
the right rear wheel.
CHASSIS
NUMBER
CODE CHART
L141
NOOCEon the side of the frame near

._
KJOOOOOI
VEHICLE SAFETY CERTIFICATION LABEL
NWCF
The vehicle safety certification

label is attached to face of left
door pillar.
This label indicates the month and year of manufacture,
Gross
Vehicle Weight Rating (G.V.W.R.), front and rear Gross Axle
Weight Rating (G.A.W.R.), and Vehicle Identification
Number
(V.I.N.).
ENGINE MODEL STAMPING

The engine model is stamped
top edge of the cylinder block
liter engines, it is stamped at
cylinder block.
These engine model numbers
~3.0 L Engine>
Nwce-
on the right front side on the

(for M-liter
engines). For 3.0the right rear of the top of the
are as shown
in the following.
Engine model
Engine displacement
G54B
2.555
6G72
2.972 liters (181.4 cu.in.)
liters (155.9 cu.iiTI
The engine serial number is stamped near the engine

number, and the serial number cycles, as shown below.
model
_ ~-
Engine serial number
Number cycling
AA0201
AA0201 to YY9999
/ Lo ABOOOl
I
1 LmBAOOOl
-..:-:--
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----3
A.49989
---+
AY9999
---+
YY9999
__.
1-
INTRODUCTION
AND MASTER TROUBLESHOOTING
- Vehicle Identification
BODY COLOR CODE

Exterior code
Wonotone
C46
H84
R82
s55
T86
wo9
R48
x15
rwo-tone
Cl XC46X85
H 1XH84X85
R2XR82X85
Sl XS55X85
T6HT86H84
W6XWO9X85
X2HX15H84
A) : Metallic paint
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Body color
Brown(M)
Silver(M)
Red
Beige(M)
Blue(M)
White
Red (M)
Black
Brown(M)/
Black
Silver(M)/
Black
Redl
Black
Beige (MM
Black
Blue(M)/
Silver(M)
White/
Black
Black/
Silver(M)
IV
~_-_
.L.
sYa-r*au.rd..
._,a--
_-
8 INTRODUCTION AND MASTER TROUBLESHOOTING

PRECAUTIONS
- Precautions
Before Service
BEFORE SERVICE
PROTECTING THE VEHICLE
WmoAAK
If there is a likelihood of damaging

painted or interior parts
during service operations,
protect them with suitable covers
(such as seat covers. fender covers, etc.).
REMOVAL AND DISASSEMBLY

When checking a malfunction.
find the cause of the problem.
If it is determined
that removal and/or disassembly
is necess&y, perform the work by following the procedures contained
in this Workshop Manual.
If punch marks or mating marks are made to avoid error in

assembly and facilitate the assembly work, be sure to make
them in locations which will have no detrimental
effect on
performance
and/or appearances.
If an area having many parts, similar parts, and/or parts which
are symmetrical
right and left is disassembled,
be sure to
arrange the parts so that they do not become mixed during the
assembly process.
I. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which are to
be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.
SPECIAL TOOLS
If other tools are substituted
for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged,
or the mechanic might be injured; therefore,
be
sure to use the special tool whenever
doing any work for
which the use of one is specified.
PARTS TO BE REPLACED
If any of the following
parts are removed,
replaced with new parts.
I. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts
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they
must
be
INTRODUCTION
Precautions
Before
Service 9
genuine
parts
PARTS
When
replacing
parts,
use MITSUBISHI
VEHICLE WASHING
If high-pressure
car-washing equipment
or steam car-washing
equipment
is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (11.8 in.) from
any plastic parts and all opening
parts (doors, luggage
compartment,
etc.).
nm
(in.)
smo59
SERVICING ELECTRICAL SYSTEM

1.
Note the following

before proceeding
with work on the
electrical system.
Note that the following
must never be done:
Unauthorized
modifications
of any electrical device or
wiring, because such modifications
might lead to a vehicle
malfunction,
over-capacity or short-circuit that could result
in a fire in the vehicle.
2. When servicing
the electrical
system, disconnect
the
negative cable terminal from the battery.
Caution
1. Before connecting
or disconnecting
the negative
cable, be sure to turn off the ignition switch and the
fighting
switch.
(If this is not done, there
is the possibility
of
semiconductor
parts being damaged.)
2. After
completion
of the work
steps [when
the
batterys
negative (-) terminal
is connected],
warm
up the engine and allow it to idle for approximately
five minutes under the conditions
described below,
in order to stabilize engine control conditions,
and
then check to be sure that the idling is satisfactory.
For 3.OL Engine models: If the engine rpm is high,
switch
OFF the ignition
switch,
and then, after
switching
it ON again, let the engine idle for 2 or 3
minutes.
This will cause the engine rpm to decrease about
100 rpm, so repeat this procedure
until the prescribed idling speed is reached.
Engine coolant temperature
: 85-95C (l85403F)
Lights, accessories
: OFF
Transmission
: neutral position
(Automatic
transmission
models:
IV or PJ
Steering wheel : neutral (center) position
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10 INTRODUCTION AND MASTER TROUBLESHOOTiNG - Precautions Before Service

WIRING HARNESSES
1. Secure the wiring harnesses by using clamps. However,
for any harness which passes to the engine or other
vibrating parts of the vehicle, allow some slack within a
range that does not allow the engine vibrations to cause
the harness to come into contact
with any of the
surrounding
parts.
Then secure the harness by using a clamp.
In addition, if a mounting
indication mark (yellow tape) is
on a harness, secure the indication mark in the specified
location.
2.
If any section of a wiring harness contacts the edge of a

part, or a corner, wrap the section of the harness with tape
or something
similar in order to protect it from damage.
F1617
3. When disconnecting
a connector,
connector, not the harness.
4.
be sure to pull only the
Disconnect connectors which have catches by pressing

the direction indicatedby the arrows in the illustration.
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in
INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Servicre 11

5. Connect connectors
which have catches
connectors
until they snap.
by inserting
the
ELECTRICAL COMPONENTS
1. When installing any of the vehicle parts, be careful
pinch or damage any of the wiring harnesses.
not to
2. Sensors, relays, etc., are sensitive to strong impacts.

Handle them with care so that they are not dropped
mishandled.
or
I
3. The electronic parts used for relays, etc., are sensitive to
heat. If any service which causes a temperature
of 80C
(176F) or more is performed,
remove the part or parts in
question before carrying out the service.
FUSES AND FUSIBLE LINKS

cwE331
1. If a blown-out fuse is to be replaced, be sure to use only a

fuse of the specified capacity. If a fuse of a capacity larger
than that specified is used, parts may be damaged and the
circuit may not be protected
adequately.
Caution
10A
1. If a fuse is blown-out,
be sure to eliminate the cause
of the problem
before installing
a new fuse.
2. Check the condition
of fuse holders. If rust or dirt is
found, clean metal parts with a fine-grained
sandpaper until proper metal-to-metal
contact is made.
Poor contact of any fuse holder will often lead to
voltage
drop or heating
in the circuit and could
result in improper
circuit operation.
15A
cnlY589 1
(SB
Revision
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12 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Service

Permissible
Nominal
size
0.3 mm2
0.5 mm2
0.85 mm*
1.25 mm2
2.0 mm*
3.0 mm2
5.0 mm2
SAE
current
I
Other
areas
2.
If additional optional equipment

is to be installed in the
vehicle, follow the procedure
listed in the appropriate
instruction
manual;
however,
be sure to pay careful
attention to the following points:
(1) In order to avoid overloading
the wiring, take the
electrical current load of the optional equipment
into
consideration,
and determine the appropriate wire size.
(2) Where possible, route the wiring through the existing
harnesses.
(3) If an ammeter or similar instrument is to be connected

to a live-wire circuit, use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
no contactwith
any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any gasoline,
parts, they might be adversely affected.
oil, etc., or rubber
LUBRICANTS
In accordance
with the instructions
in this Service Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
BRAKE FLUID
Be careful to avoid spilling
surfaces,
because the paint
damaged.
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any
coat
brake
might
fluid on painted
be discolored
or
INTRODUCTION
- t+mwtions
Before
Service
I3
DOING SERVICE WORK IN GROUPS OF TWO OR

MORE TECHNICIANS
If the service work is to be done by two or more technicians
working together,
extra caution must be taken.
NOTE ON INSTALLATION OF RADIO EQUlPM$ihlThe computers

of the electronic
control system has been
designed so that external radio waves will not interfere with
their operation.
However,
if antenna or cable of amateur transceiver
etc. is
routed near the computers,
it may affect the operation of the
computers.
even if the output of the transceiver is no more
than 25W.
To protect
each of the computers
from interference
by
transmitter
(hum, transceiver,
etc.). the following should be
observed.
1. Install the antenna on the roof or rear bumper.
2. Because radio waves are emitted from the coaxial cable of
the antenna,
keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross
the wiring harness, route it so that it runs at right angles to
the wiring harness.
3. The antenna and the cable should be well matched, and
the standing-wave
ratio should be kept low.
4. A transmitter
having a large output should not be installed
in the vehicle.
5. After installation of transmitter,
run the engine at idle, emit
radio waves from the transmitter
and make sure that the
engine is not affected.
*STANDING-WAVE
RATIO
If an antenna and a cable having different impedances
are
connected,
the input impedance
Zi will vary in accordance
with the length of the cable and the frequency
of the
transmitter,
and the voltage distribution
will also vary in
accordance
with the location.
The ratio between
this maximum
voltage and minimum
voltage is called the standing-wave
ratio. It can also be
represented
by the ratio between
the impedances
of the
antenna and the cable.
The amount of radio waves emitted from the cable increases
as the standing-wave
ratio increases, and this increases the
possibility
of the electronic
components
being adversely
affected.
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h-J
14
^.
INTRODUCTION AND MASTER TROUBLESHOOTING -
Treatment Before I
AftertheFotiingofastmsm
TREATMENT BEFORE/AFTER THE FORDING OF A STREAM

INSPECTION AND SERVICE BEFORE FORDING
NOW%A STREAM
Vehicles which are driven through
water, or which
may
possibly be driven through water, should be subjected to the
following
inspections
and maintenance
procedures
in advance.
e Seal the speedometer
cable with a water-resistant
grease
or tape.
a Inspect the dust boots and breather hose for cracks or
damage, and replace them if cracks or damage are found.
,-
Steering
joint assembly
1^.
1 Drive shaft boot -\l(.
dometer
/ Torsion bar dust cover
OOW528
( TSB Revision
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1Breath&
cable
hose==
~_

l
Treatment
Before /
AftertheFordingofaStream
I5
Apply grease to the lubricating points of the front suspension, steering linkage and propeller shaft.
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16
INTRODUCTION AND MASTERTROUBLESHOOTING
Treatment
Before I
AftertheFordingofaStream
INSPECTION AND SERVICE AFTER FORDING A

STREAM
After fording a stream, check the following points. If abnormal
condition is evident, clean, replace or lubricate.
Check for water. mud. sand. etc. in the rear brake drum.
clutch housing, &tarte; mot&, brake pipe and fuel pipe:
Check for water in the fluid or oil inside the front
differential.
rear differential,
transmission
and transfer
case.
Apply grease to the lubricating points of the front suspension, steering linkage and propeller shaft.
Check all boots and breather
hoses for cracks and
damage.
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INTRODUCTION
AND MASTER TROUBLESHOOTING - Towing and Hoisting
TOWING
17
AND HOISTING
This vehicle can only be towed from the front with conventional sling-type equipment and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4 x 4 x 55 wood beam) should be placed
forward of under guard and under towing hook/shipping
tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system must be used. This system must be
completely
independent.
of the primary lifting and towing
attachment.
Care must be taken in the installation of safety
chains to insure they do not cause damage to bumper, painted
surfaces or lights.
LIFTING-GROUND CLEARANCE
Towed vehicle should be raised until wheels are a minimum of
10 cm (4 in.) from the ground. Be sure there is adequate
ground clearance at the opposite end of the vehicle, especially
when towing over rough terrain or when crossing sharp rises
such as curbs. If necessary,
ground clearance can be increased by removing the wheels from the lifted end of the
disabled vehicle and carrying the lifted end closer to the
ground. A 20 cm (8 in.) ground clearance must be maintained
between brake drums and ground.
FRONT TOWING PICKUP

The vehicle may be towed on its rear wheels for extended
distances, provided the parking brake is released.
Make cartain the transmission
remains in NEUTRAL.
SAFETY PRECAUTIONS
The following precautions
should be taken when towing the
vehicle.
1. Remove exhaust tips and any other optional equipment,
that interface with the towing sling. Padding (heavy shop
towel or carpeting) should be placed between the towing
sling cross bar and any painted surfaces, and bumper
surfaces.
2. A safety chain system completely
independent
of the
primary lifting and towing attachment
must be used.
3. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior
to moving the vehicle.
4. Operator should refrain from going under a vehicle unless
the vehicle is adequately supported by safety stands.
5. Never allow passengers to ride in a towed vehicle.
6. State and local rules and regulations
must be followed
when towing a vehicle.
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18
INTRODUCTION
and Hoisting
- Towing
HOISTING
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with
the proper adapters in order to support the vehicle at the
proper locations.
(Shown in the illustration)
Conventional
hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the side
frame.
._
FLOOR JACK
A regular floor jack may be used under the front crossmember
or rear axle housing.
Caution
1. A floor
jack must never be used on any part of the

underbody.
2. Do not attempt
to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent
damage to the
body.
EMERGENCY JACKING
Jack receptacles
are located at the No. 2 crossmember
and
rear axle housing to accept the jack supplied with the vehicle
for emergency road service. Always block the opposite wheels
and jack only on a level surface.
FRAME CONTACT
SUPPORT LOCATIONS
1,175
mm (46.3 in.)
Wheel base
2.350 mm (92.5 in.)
Sectlon
NOTE
The locations of the support point shown as Section A-A are
the same as those of the twin post hoist shown in the next
paw.
1 TSB Revision
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A-A
INTRODUCTION
LIFTIYG
AND JACKING
<2.6L
Engine>
<3.OL
Engine>
C
m

SUPPORT
LOCATIONS
Twin post hoist

Floor jack
Emergency
jacking (jack supplied
with the vehicle)
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- Towing and Hoisting
19
20
General
Data
and Specifications
GENERAL DATA AND SPECIFICATIONS
<2-door
NW-
vehicles>
Models
L047.G
ascription
chicle dimensions
mm (in.)
Overall length
Without spare tire
With spare tire
Overall width
Overall height
Wheelbase
Tread
Front
Rear
Overhang
Front
Rear
Height at curb weight
(wt.)
Front bumper to ground
Rear bumperto ground
Minimum running ground
clearance
Angle of approach
Angle of departure
Ramp breakover angle
L141G
TNSL F/H
TNJL F/H
TRJL F/W
TRUL F/H
0
8
@
@
c3
@
6
@
(9,
3,900 (153.5)
3,935 (154.9)
1,680 (66.1)
1,840 (72.4)
2,350 (92.5)
1,400 (55.1)
1,375 (54.1)
685 (27.0)
900 (35.4)
3,905 (153.7)
3,940(155.1)
1,680 (661)
1,850 (72.8)
2,350 (92.5)
1,400 (551)
1,415 (55.7)
685 (27.0)
905 (35.6)
3,905 (153.7)
3,940(155.1)
1,880 (66.1)
1,850 (72.8)
2,350 (92.5)
1,400(55.1)
1,415 (55.7)
685 (27.0)
905 (35.6)
3,905 (153.7)
3,940(155.1)
1,680 (66.1)
1,850 (72.8)
2,350 (92.5)
1,400 (55.1)
1,415 (55.7)
685 (27.0)
905 (35.6)
@
0
0
480(18.9)
440(17.3)
210(8.3)
490 (19.3)
450 (17.7)
215 (8.5)
490(19.3)
450(17.7)
215(8.5)
490 (19.3)
450 (17.7)
215 (8.5)
38
28
21
38
28
21
38
28
21
8
38
8
28
-33 21
hicle weights
kg (Ibs.)
Curb weight
Gross vehicle weight rating
Gross axle
Front
weight rating
Rear
1,455 (3.207)
1,910(4.210)
1 ,I 00 (2.425)
1,450 (3.197)
2
Seating capacity
;---
-.
1,585
2,200
1,100
1,600
2
(3,494)
(4,850)
(2,425)
(3,527)
I TSB Revision
1,600
2,200
1,100
1,600
2
http://vnx.su/
(3.527)
(4,850)
(2,425)
(3,527)
1,605
2,200
1,100
1,600
2
(3,538)
(4,850)
(2,425)
(3,527)
INTRODUCTION AND MASTERTROUBLESHOOTING
L042G
TNJL F/H
TRJL F/H
TRUL F/H
G54B
In-line OHC
4
91.1 mm(3.59in.j
98.0 mm (3.86 in.)
2,555 cm3
(155.9 cuin.)
8.7
1-3-4-2
7BTDC 22
6672
V-type, OHC
6
91.1 mm(3.59in.j
76.0 mm (2.99 in.)
2,972 cm3
(181.4cu.in.)
8.9
1-2-3-4-5-6
5BTDC 22
6672
V-type, OHC
6
91.1 mm(3.59in.)
76.0 mm (2.99 in.)
2,972 cm3
(181.4cu.in.)
8.9
I -2-345-5
5BTDC i 2
6672
V-type, OHC
6
91.1 mm(3.59in.
76.0 mm (2.99 in.
2,972 cm3
(181.4 cuin.)
8.9
1-2-3-4.5-8
5BTDC +-2
KM145
S-speed manual
V5MTl
5-speed manual
KM148
&peed automatic
KM148
&peed automatic
1st
2nd
3rd
4th
5th
3.967
2.136
1.360
1.ooo
0.856
3.918
2.261
1.395
1.000
0.829
2.826
1.493
1 .ooo
0.688
2.826
1.493
1.000
0.688
-
Reverse
High
Low
3.587
1 .ooo
1.944
4.625
3.925
1.ooo
1.925
4.625
2.703
1 .ooo
1.925
4.625
2.703
1 .ooo
1.925
4.625
Dry single disc &

diaphragm spring
Dry single disc &

diaphragm spring
P225ff 5Rl5
P235ff5Rl5
independent
double-wishbone
Independent
Rigid axle
Rigid axle
Compression ratio
Firing order
Basic ignition timing
Type
Gear ratio
Transmission
Transfer case
L141G
TNSL FM
Engine
Model No.
Type
Number of cylinders
Bore
Stroke
Piston displacement
Transmission &transfer
Model No.
case
Final ring gear ratio

Clutch
Type
Chassis
Tire size
Front suspension
Type
double-wishbone
Rear suspension
Type
Brakes
Type
Front
Rear
Power steering
Gear type
Gear ratio
Fuel tank capacity
21
GeneralDataandSpecmcations
liters (gals.)
Disc
Disc
Drum
Drum (Leading and trailing)
(Leading and trailing)
Integral type
Integral type (Recirculating ball nut)
(Recirculatingball nut)
16.4
16.4
60 (15.9)
75 (19.8)
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-_-
22
<&door
General
Data
and Specifications
vehicles>
L146G
VMNJL F/H
L-
chicle dimensions
mm (in.)
Overall length
Withoutspare tire
With spare tire
Overall width
Overall height
Wheelbase
Tread
Front
Rear
Overhang
Front
Rear
Wt.)
Front bumperto ground
Rear bumper to ground
clearance
Angle of approach
Angle of departure
,hicle weights
kg (Ibs.)
Curb weight
Gross axle
weight rating
Seating capacity
Front
Rear
gine
Model No.
_-.
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Firing order
.-
VMRJL F/H
WMRUL F/H
a
@
0
@
Q
@
8
@
@
4,570 (179.9)
4,605 (181.3)
1,680 (66.1)
1,890 (74.4)
2,695 (106.1)
1,400 (55.1)
I,41 5 (55.7)
745 (29.3)
1 ,I 65 (45.9)
4,570 ( 179.9)
4,605(181.3)
1,680 (66.1)
1,890 (74.4)
2,695(106.1)
1.400(55.1)
1,415 (55.7)
745 (29.3)
1,165(45.9)
4.570 (179.9)
4,605 (181.3)
1,680 (66.1)
1,890 (74.4)
2,695(106.1)
1,400(55.1)
1,415 (55.7)
745 (29.3)
1,165 (45.9)
@
0
@
490 (19.3)
450(17.7)
215 (8.5)
490 (19.3)
450(17.7)
215 (8.5)
490 (19.3)
450 (17.7)
215 (8.5)
8
8
63
38
28
18
38
28
18
38
28
18
1,780 (3,924)
2,400 (5,291)
1,100(2,425)
1,600 (3,527)
5
1,795 (3,957)
2,400 (5,291)
1,100(2.425)
1,600 (3,527)
5
1,805
2,400
1,100
1,600
5
6672
V-type, OHC
6
91 .I mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3 (181.4 cu.in.)
8.9
l-2-3-4-5-6
5BTDC i2
6672
V-type, OHC
6
91 .l mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3 (181.4 cuin.)
8.9
1-2-3-4-5-6
5BTDC 22
:
3072
V-type, OHC
3
31 .l mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3 (181.4 cu.in.)
3.9
l-2-3-4-5-6
5BTDC 22
-i
1 TSB Revision
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(3,979)
(5,291)
(2,425)
(3,527)
General
Dataand
Swxifications
L146G
VMNJL F/H
Model No.
1St
2nd
3rd
4th
5th
Reverse
Transfer case
High
Low
Elutch
Type
KM148
4-speed automatic
KM148
4-speed automatic
3.918
2261
1.395
1.000
0.829
3.925
1.000
1.925
4.625
2.826
1.493
1.ooo
0.688
2.826
1.493
1 .ooo
0.688
-
2.703
1.ooo
1.925
4.625
2.703
1 .ooo
-1.925
4.625
P235ff 5 R 15
Type
Rear suspension
Independent
Type
Brakes
Rigid axle
Power steering
Gear type
Gear ratio
Fuel tank capacity
WMRUL F/H
EMT1
5-speed manual
Dry single disc &

diaphragm spring
Chassis
Tire size
Front suspension
Type
VMRJL F/H
case
Type
Gear ratio
Transmission
Front
Rear
liter (gal.)
doublewishbone
Disc
Integral type (Recirculating
16.4
92 (24.3)
1 TSB Revision
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ball nut)
23
24
Tightening
Torque
WasterTroubleshooting
TIGHTENING TORQUE
Description
Head mark
Thread for general purposes

(size x pitch) mm
6x1.0
8x 1.25
10x1.25
12x 1.25
14x 1.5
16x 1.5
18x 1.5
20x1.5
22x 1.5
24x 1.5
Description
Taper thread for pipes (size)
PT1/8
PT l/4
PT 3B
Taper thread for dry sealed pipes (size)
NFTF l/16
NPTF l/8
NPTF l/4
Head mark
Nm
ft.lbs.
3.0-3-s
7.9-12
16-23
29-43
46-70
67-l 00
100-150
150-190
ZOO-260
269-320
2.2-2.9
5.8-8.7
12-17
2132
35-52
51-77
74-110
110-140
150-190
1go-240
Nm
ftlbs.
Nm
ft.lbs.
4.9-7.8
13-19
27-39
47-72
77-110
130-160
180-230
160-320
340-430
420-550
3.6-5.8
9.4-14
20-29
35-53
57-35
SO-120
130-170
1 go-240
250-320
310-410
Remarks
7.9-I 2
76-19
19-30
34-45
39-54
58-73
5.9-9.7
12-14
14-22
25-33
29-40
43-54
Internal
Internal
Internal
Internal
Internal
Internal
thread:
thread:
thread:
thread:
thread:
thread:
Aluminum
Cast iron
Aluminum
Cast iron
Aluminum
Cast iron
4.9-7.8
7.9-12
7.9-12
16-1s
19-13
34-45
3.6-5.8
5.8-8.7
5.8-8.7
12-14
14-22
25-33
Internal
Internal
Internal
Internal
Internal
Internal
thread:
thread:
thread:
thread:
thread:
thread:
Aluminum
Cast iron
Aluminum
Cast iron
Aluminum
Cast iron
NceKAAO
MASTER TROUBLESHOOTING
ENGINE OVERHEATS
Reference
page or remedy
Symptom
Probable cause
Engine overheats
Cooling system faulty

Incorrect ignition timing
1 TSB Revision
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ENGINE WILL NOT CRANK OR CRANKS
- Master Troubleshooting
25
SLOWLY
Symptom
Probable cause
Reference
page or remedy
Engine will not crank or cranks

slowly
Starting system faulty
8-134.135
ENGINE WILL NOT START OR BE HARD TO START (CRANKS
OK)
Symptom
Probable cause
Reference
page or remedy
Engine will not start or be hard to

start(Cranks OK)
No fuel supply to carburetor or injection system
14-34,90
Carburetor or injection system problems
14-34,90
Ignition system problems
3-147 to 149
Vacuum leaks
- Purge control valve hose
- Vacuum hoses
intake manifold
- Air intake plenum
Carburetor or throttle body
EGRvalve
l
Repair as
necessary
l
l
Compression
too low
3-11.65
ROUGH IDLE OR ENGINE STALL

Probable cause
Symptom
Rough idle or
engine stalls
Vacuum leaks
Purge control valve hose
Vacuum hoses
Intake manifold
Air intake plenum
Carburetor or throttle body
EGRvalve
l
l
Reference
page or remedy
Repair as
necessary
l
l
l
l
1 Ignition system problems

Idle speed set too low
Idle~mrxture
1~
.
too lean or too rich
8-147 to 149
1 O-10.14-62
14-11
Carburetor or fuel injection system problems
m-34.90
Exhaust gas recirculation (EGR) system problems
25-17.32
Engine overheats
7-4
Compression
9-11, 65
too low
1 TSB Revision
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? f! .., .-, _-_
,_-
____
____ _L(
26 INTRODUCTION AND MASTER TROUBLESHOOTlNG
- Master Troubleshooting
ENGINE HESITATES OR POOR ACCELERATION

Symptom
Engine hesitates or
poor acceleration
Reference
page or remedy
Probable cause
-I
8-147 to 149
Ignition system problem
Vacuum leaks
Purge control valve hose
Vacuum hoses
- intake manifold
Air intake plenum
* Carburetor or throttle body
EGRvalve
Repair as
necessary
Air cleaner clogged
113.10
Fuel line clogged
1442.99
Carburetor or fuel injection system problem
14-34.90
Auxiliary acceleration
14-23
pump faulty (cold engine)
Emission control system problem

EGR system always on
- High-altitude compensation (HAC) system problem
25-77.22.32
Engine overheats
7-4
Compression
g-II.65
too low
ENGINE DIESELING
Symptom
Engine dieseling (runs after

ignition switch is turned off)
Probable cause
Reference
page or remedy
Carburetor problems
14-34
Incorrect ignition timing
8-14710 149
EXCESSIVE OIL CONSUMPTION

Symptom
Probable cause
Reference
page or remedy
Excessive oil consumption
Oil leak
Repair as
necessary
Positive crankcaseventilation
line clogged
o-13
Valve stem seal worn or damaged
Replace
Valve stem worn
Replace
Piston ring worn or damaged
9-43
1 TSB Revision
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I -..

POOR
FUEL
Master
Troubleshooting
27
MILEAGE
Symptom
Probable cause
Reference
page or remedy
Poor fuel mileage
Fuel leak
Repair as
necessary
1 Air cleaner clogged
1 11-3.10
1 Ignition problems
1 8-147to 149
Carburetor or fuel injection system problems
1434.90
1g-II.65
1 22-2
Clutch slips
16-4
Brakes drag
1 5-13
I
I
Compression
too low
Tires improperly
inflated
NOISE
Noise
Probable cause
Reference
page or remedy
Loose bolts and nuts
Retighten as
necessary
I 9-11
1 Enaine noise
HARD STEERING
Symptom
Probable cause
Reference
page or remedy
Hard steering
Loose power steering oil pump belt
19-10
Low fluid level
19-11
Air in power steering system
19-11
Low tire pressure
22-2
Excessive turning resistance of upper or lower ball joint
2-27
Excessivelytight
1937
linkage ball joint
Improperfrontwheel
alignment
2-13
Excessive turning resistance of tie-rod ball joint
19-38
No lubricantion
Lubricate
of tie-rod
Sticky flow control valve
19-33
No lubrication of idler arm
19-39
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INTRODUCTION
MASTER TROUBLESHOOTING
Master
Troubleshootha
POOR RETURN OF STEERING WHEEL TO CENTER

Symptom
Probable cause
Reference
page or remedy
Poor return of steering

wheel to center
improper front wheel alignment
2-13
Improper tire pressure
22-2
Damaged front wheel bearing
2-21
Probable cause
Reference
page or remedy
Impropertire
22-2
POOR RIDING
Poor riding
pressure
22-4
lmbalanced wheels
1 Improper front or rear wheel alignment
1 2-13.17-3.6
1 Malfunctioning
1 2-27,174.a
shock absorber
1 Broken or worn stabilizer

j 2-36
1 Broken or worn torsion bar spring

Loose suspension securing bolt(s)
Retighten
1 Worn lower arm bushing
/ 231
I
I
I
ABNORMAL TIRE WEAR

Symptom
Probable cause
Reference
page or remedy
Abnormal tire wear
Improper front or rear wheel alignment
2-l 3,17-3.6
22-2
lmbalanced wheels
22-4
Loose wheel bearings
2-19
Malfunctioning
2-27. 174.8
shock absorber
ROAD WANDER
Reference
page or remedy
Symptom
Probable cause
Road wander
19-6
Excessive play of steering wheel

Poor turning resistance of upper ball joint

/ Loose or worn lower arm or upper arm bushing
I
Loose or worn wheel bearinas
[ TSB Revision
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2-13. 17-3,6
2-27
22-2
2-28.31
I 2-19
__
1 ~-
rr.

VEHICLE
Master
Troubleshootina
29
PULLS TO ONE SIDE
Symptom
Probable cause
Reference
page or remedy
Vehicle pulls to one side
2-l 3.17-3.6
lmbalanced or worn tires
/ 224
Uneven tire pressure
22-2
Excessive turning resistance of upper ball joint
2-27
Wheel bearing seizure
2-21
Broken or worn torsion bar spring
2-36
Bend front axle drive shaft
2-40
Deformed
230
lowerarm
STEERING WHEEL SHIMMY

Reference
page or remedy
Symptom
Probable cause
Steering wheel shimmy
1 2-13,17-3,6
1 22-2
Imbalanced wheels
Repair
1 2-27
19%
Broken or weak stabilizer
1 2-39
Worn lower arm or upper arm bushing
I 2-28.31
I 2-27
1 Poorturning
resistance of upper ball joint
Excessive play of steering wheel
\ Malfunctioning
shock absorber
/ Broken or weak torsion bar spring or, leaf spring or coil spring
/ 2-36,17-4,9
Wear, play, or seizure of wheel bearing
2-19
Symptom
Probable cause
Reference
page or remedy
Bottoming
Overloaded vehicle
Correct
Broken or weak torsion bar spring, leaf spring or coil spring
236.1749
BOTTOMING
1 Malfunctionina
shock absorber
( TSB Revision
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1 2-27,174
I!
1: 1 --30
-~~
INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting
WHEEL BEARING TROUBLESHOOTING

Trouble
Symptom
Probable cause
Pitting
Pitting occurs because of uneven rotation of race

and bearing surfaces
Excessive bearing preload

Excessive load
Flaking
The surface peels because of uneven rotation of

the race and bearing surfaces
End of bearing life

Improper bearing assembly
Cracking
Chipping or cracking of cage or roller edges
Impact when bearing was

installed (such as being hit
with a hammer)
Flat spotting
When large load is applied, race and roller contact

surfaces compress, forming indentations

Excessive load
Vibration when bearings are
not used, such as during
shipment on freight cars,
transport trucks, etc.
Nicks
Instead of rolling along race surface,

rollers slide, thus damaging surface
Improper grease
Excessive load
Faulty oil seal
Damage or wear caused by minute particles

adhering to surfaces results in rough movement
and such high temperatures that parts of surface
melt
Excessive variation of loads on

bearings
Use of grease other than that
specified
Improper grease
?ust, corrosion
Appears on various areas of the bearing
Use of grease otherthan

that specified
Faulty oil seal
Presence of water or moisture
Near
Wear of surface areas caused by friction
Improper grease
Foreign matter
Rust or corrosion due to
moisture
Use of grease otherthan that
specified
Faulty oil eal
Xscoioration
Grease discoloration results from grease

deterioration which causes particles of pigment
contained in grease to adhere to surfaces
Heat discoloration will appear as a deep brown or
purple
Use of grease other than

that specified
Faulty oil seal
Excessive load
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METERS AND GAUGES - Specifications
METERS AND GAUGES

SPECIFICATIONS
GENERAL SPECIFICATIONS
METERS
AND GAUGES
Specifications
Items
Speedometer
Tw
Tachometer
Electromagnetic
Twe
Detection source
Fuel gauge
Pulse type
Ignition coil
Type
Fuel gauge unit
Bimetal type (voltage limiter incorporated for 7V)
Tw
Variable resistance type
Vw
gauge
Bimetal type (7V operation)
gauge unit
Type
Oil pressure gauge
Thermistor type
Twe
Oil pressure gauge unit
Bimetal type
Type
Inclinometer
Bimetal type
Tw
Damping system
Voltage meter
Gravity type
Oil-filled system
Bimetal type
Twe
INDICATOR
AND
WARNING
LIGHTS
Items
Specifications
W
Turn signal indicator lights
High beam indicator light
W
Door-ajar warning light
W
1.4 (74)
1.4 (74)
1.4 (741
Fasten seat belt indicator

W
Brake warning light
W
Charging warning light
W
1.4 (74)
1.4 (74)
1.4 (74)
4WD indicator light

W
Maintenance required warning light
W
Check engine warning light
1.4 (74)
1.4 (74)
PJF oil temperature warning light

Overdrive indicator light
W
W
Freewheeling
hub light
NOTE
The values parentheses
type
3.4 (158)
1.4 (74)
1.4 (74)
1.4 (74)
denote SAE grade numbers.

1 TSB Revision
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8-164
METERS AND GAUGES - Specifications
BUZZER
Items
Specifications
V
Range of voltage used
While buzzing (Terminal voltage at 13V)
IO-16
5357
Sound pressure
dB
Fundamental frequency
900+150
Hz
SERVICE SPECIFICATIONS
terns
Specifications
Standard values
Speedometer indication error
20
mph
2:
40
60
80
2;
23
:
100
Tachometer indication error
1,000 rpm
3,000 rpm
5,000 rpm
rp
rpm
+100
+150
k25Om
a
Fuel gauge resistance value
Between terminals 1 (power supply) and 2 (fuel gauge unit)
Between terminals 2 (fuel gauge unit) and 3 (ground)
Between terminals 1 (power supply) and 3 (ground)
n
Fuel gauge unit resistance value
Float point F
Float point I E
Fuel gauge unit float position
mm (in.)
2.6L Engine
Float point F
110
Float point E
3.OL Engine (2door vehicles)
Float point F
Float point E
3.OL Engine &door
Float point F
55
165
l-5
103-l
17
11-13
(.43-.51)
180-182
9-11
(7.09-7.17)
(.35-.43)
229-231
(9.02-9.09)
vehicles)
15-17
Float point E
Engine coolant temperature gauge resistance value
Between terminals 1 (power supply)
and 2 (water temperature gauge unit)
CI
Oil pressure gauge resistance value
Voltage meter resistance value
fi
Voltage meter indication
V
IOV
224-226
(8.82-8.90)
R
55
Approx. 50
380=460
+0.5-
16V
-t-O.5
\ TSB Revision
(.59-.67)
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METERS AND GAUGES - Troubleshooting
8-165
TROUBLESHOOTING
METER CIRCUIT
OPERATION
Fuel Gauge
When the ignition switch is turned to ON,
current flows through fuse No. 3 fuel gauge,
fuel gauge unit and ground, in turn operating
the fuel gauge.
When fuel level is high, the fuel gauge unit
internal resistance is small so that the current
passing through the circuit is relatively large.
This causes the gauge pointer to swing towards F.
When fuel level becomes low, the unit internal
resistance is increased, so only a small current
flows the circuit and the gauge pointer swings
towards E.
Inside the fuel gauge, there is a voltage limiter
which functions to maintain a constant output
voltage (at 7V) to the gauge units (fuel gauge
unit and engine coolant temperature
gauge
unit).
Engine Coolant Temperature
Gauge
When the ignition switch is turned to ON,
current
flows
through
fuse No. 3, engine
coolant
temperature
gauge,
engine
coolant
temperature
gauge unit, and ground, in turn,
operating
the engine
coolant
temperature
gauge.
When coolant temperature
is high, the gauge
unit internal resistance
is small so that the
current passing through the circuit is relatively
large. This causes the gauge pointer to swing
towards H.
When coolant temperature
is low, the unit
internal resistance
is increased
so a small
current flows in the circuit, and the gauge
pointer swings towards C.
Oil-pressure
gauge
With the ignition key at the ON position,
current
flows
to fuse No. 3, oil-pressure
the
Oil-pressure
gauge
unit,
and
gauge,
ground, and the oil-pressure
gauge is activated.
When the oil pressure is high, the contacts
(within the unit) close for a long time, with the
result that the amount
of current
flowing
through the circuit is great, and the gauges
indicator indicates at the high-pressure
area.
With the oil pressure
is low, the contacts
(within the unit) open for a short time, with
the result that the amount of current flowing
through
the circuit is low, and the gauges
indicator indicates at the low-pressure
area.
Brake Warning
Light
l
When the ignition switch is turned to ON
and before the engine starts, current flows
through fuse No. 3, brake warning light, alternator and ground. The brake warning
light
goes on and stays on until the engine starts.
The light goes off once the engine starts.
Burnt-out bulb check.
l
If the brake fluid level falls below the preset
level or the parking brake is applied, the brake
fluid level sensor switch or the parking brake
switch contacts close. This causes current to
flow through the brake warning light and brake
fluid level sensor or parking brake switch to
ground, causing the warning light to go on.
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8-166
METER ClRCUlT
CIRCUIT DIAGRAM <2.6L Engine>
@jay
@f
Multi-purpose
To seat belt wammg

I
timer
[Refer to P.8-84.1
To seat belt warning
buzzer [Refer to P.8-84.1
Toaltemator [Refer to P&51.1
To dimmer, passing
switch and light control
Irelay [Refer to P.8-64.1
To dome light
[Refer to P.8-78.
To door switch
[Refer to P.8-78.1
Combination
1 TSB
Revision
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meter
fuse
8-l67
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
Lg: Light green

W: White
L: Blue
Y: Yellow
lE3l
Oil pressure
gauge unit
El
4WD
indicator
switch
El
I
I
II-II
1
I 1 1 1 IC!
@-
yB
g:
WL/B
YL
a*
y D-29 y
84 y
Parking brake
switch
BI
IB
El
Y{
"
YL?
Engine coola
I^-^^. Î, ._
Combination
gauge
1 TSB Revision
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Remarks
(1) For information
concerning the ground points
(example: q ), refer to PB-12.
(2) The symbols @), Q, etc. indicate that the wiring
is connected (using the same numerical symbol1
to the facing page.
(In other words, @ on the right page is
connected to @I on the left page.)
8-168
METERS AND GAUGES -m~Troubleshooting
METER CIRCUIT
CIRCUIT
DWGRAM
<3.OL
Engine>
I-.
Sub fusible link
. m
EB
I--:&(--
-. .A_i
mou
I
$kin
y
B
- -_
OFF
ACC
3-R m3-R
u
fusible
I
cl?
To light control relay

[Refer to P.8-65.1
( IIp1
3-R
C-66
@j

To alternator
[Refer to P.8-51 .I
To dimmer, passing
witch and light control
clay [Refer to P.8-65.1
To dome light
[Refer to P.8-78.1
To door switch
Dioc
Combination
----
. _
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meter
Multi-purpose
fuse
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
IEd
Oil pressure
L: Blue
Y: Yellow
gR2;y
8-169
G: Green
P: Pink
Lg: Light green
W: White
gauge unit
indicator
0.85-B
WI,
04
BY
In\
\ I
$:
1".25-GB
-9.
! -+!
To cigarette lighter
[Refer to P.8-94.1
Parking brake
switch
Combination
ga we
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switch
al
Remarks
(1) For information concerning the ground points
(example: ,)Ffer
to P.814.
(2) The symbo s 1 , Q, etc. Indicate that the witin
9
.-is connected
AL- *__:_- usrng the same numerical symbo 1
Dage.
iIs,-@ on the right page is
connected to @ on the left page.)
-__..-
8-170
METERS
AND
GAUGES
Service
.._
Adjustment
Procedures
SERVICE ADJUSTMENT
PROCEDURES
SPEEDOMETER INSPECTION
NwilAFa
NOTE
if there is a special regulation
for speedometer
-indicator
difference in the area where the vehicle is operated, be sure
to meet the requirement
of the regulation.
(1) Adjust tire inflation pressure to the standard value. (Refer
to GROUP 22 - General Specifications.)
(2) Use speedometer
tester to check indicator difference.
Caution
When
checking
with
speedometer
tester,
block
nonoperating
wheels to prevent vehicle moving.
Tachodweil
meter
TACHOMETER
INSPECTION
<2.6L
Engine>
~08nm~
Connect a tachdwell
meter, and then compare the meter
readings at various engine speeds with the values indicated
on the tachometer.
Standard
value:
1,000 rpm
flO0
rpm
3,000 rpm
+I50 rpm
5,000 rpm
+250 rpm
Caution
The tachometer
is the negative-ground
type, and therefore should not be connected
in reverse polarity
to the
battery.
If the tachometer
is connected
in reverse polarity, the transistors
and diodes will be damaged.
TACHOMETER INSPECTION <3.OL Engine>
N(YM~
(I) Insert paper clip on 1 pin connector

(from harness side)
located between
the ignition coil (primary side) and LC
filter.
Caution
Insert paper clip along terminal
wall as illustrated.
Female pin
(Insert opposite
side of lock
retainer)
$%%ck
retainer
side)
OlLozm
(2) Connect a tachodwell

meter to paper clip. Compare the
tachodwell
meter reading with the tachometer
reading at
each engine speed and check that the error is within the
standard value.
Standard
value:
1,000 rpm
+I00 rpm
*I50
rpm
3,000 rpm
5,000 rpm
5250 rpm
Caution
The tachometer
is the negative-ground
type,
and
therefore
should not be connected
in reverse to the
battery.
If the tachometer
is connected
in reverse,
transistors
and diodes will be damaged.
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1
METERS AND GAUGES - Service
Adjustment
Procedures
8-171
FUEL GAUGE
SIMPLE
TEST
NO*HlCK
(I) Remove connector from fuel gauge unit in fuel tank.
(2) Connect test light between
yellow and black wires on
connector.
(3) Turn ON ignition key.
(4) Assure test light flashes and gauge needle moves.
(5) If test light flashes but gauge needle does not move,
replace fuel gauge.
If test light does not flash (and gatige needle does not
move), check fuse for broken wire, o: resistance between
gauge terminals (see pages 8-174.). or break in harness.
(2.6L
Engine>
Stopper
FUEL GAUGE UNIT INSPECTION
(upper)
To check the fuel gauge unit, remove the unit from

tank. (Refer to GROUP 14 - Fuel Tank.)
<3.OL
Engine>
<2.6L
Engine>
,Horizontal
NomIIG
the fuel
FUEL GAUGE UNIT FLOAT POSITION CHECK

Move the float and measure the float position at points
and E when the float arm contacts the stopper.
Standard
value:
<2.6L Engine>
A 11-13 mm (43-51
in.)
B 180-182
mm (7.09-7.17
in.)
<3.OL Engine (Gdoor vehicles)>
A 9-11 mm (.35-.43
in.)
B 229-231
mm (9.02-9.09
in.)
<3.OL Engine @l-door vehicles)>
A 15-17 mm (.59-.67
in.)
B 224-226
mm (8.82-8.90
in.)
line
FUEL GAUGE UNIT RESISTANCE

CHECK
(I) Check that the resistance between terminals is within the
standard value when the fuel gauge unit float is between
positions F and E.
Standard
value:
Point F
l-5 !&-l
103-117
fI
Point E
(21Also check that the resistancechangessmoothly when

the float is moved
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to F and E.
I
METERS AND GAUGES - Service Adjustment Procedures
ENGINE
COOLANT
SIMPLE TEST
TEMPERATURE
GAUGE
NI8moO.
(1) Remove
connector
from engine
coolant
temperature
gauge unit in engine compartment.
(2) Ground harness side connector via test light.
(3) Turn ON ignition key.
(4) Check that test light flashes and gauge needle moves.
(5) If test light flashes hut the gauge needle does not move,
replace engine coolant temperature
gauge.
If test light does not flash (and gauge needle does not
move), check fuse for broken wire, or resistance between
gauge terminals (see pages 8-174.). or break in harness.
ENGINE COOLANT TEMPERATURE GAUGE UNIT

WIKO
INSPECTION
Refer
Unit.
to GROUP
7 -
Engine
Coolant
Temperature
Gauge
FOIL PRESSURE GAUGE SIMPLE TEST

(I) Disconnect
the wiring connector
from the oil preszi
gauge unit inside the engine compartment.
(2) Ground the connector at the harness through a test light.
(3) Turn the ignition key to the ON position.
(4) Check to be sure that the test light illuminates
steadily
and the indicator of the oil pressure gauge moves.
(5) If both the test light and

gauge unit is normal and
the test light flashes but
gauge is faulty.
If neither the test light
pressure gauge circuit is
http://vnx.su/
gauge operate, the circuit to the

the gauge unit itself is faulty. If
the gauge does not operate, the
nor the gauge
faulty.
operates,
the oil
METERS AND GAUGES - sewice

Oil pressure
gauge unit
Adjustment
Procedures/Combination
Meter
OIL PRESSURE GAUGE UNIT CURRENT CHECKHIm
\ lc Test light
-@
(12Vr3.4W)
(1) Disconnect
the wiring connector
from the oil pressure
gauge unit inside the engine compartment.
(2) Apply battery voltage (through the test light) to the gauge
unit side terminal.
(3) Check to be sure that the test light switches OFF when
the engine
is stopped,
and that it flashes while the
engine is running.
VOLTAGE METER SIMPLE TEST

(I) Connect a voltmeter for testing.
(2) Turn the ignition key to the ON position.
(3) Compare the readings of the voltmeter for testing
the vehicles voltage meter.
Standard
value:
1ov
f0.5V
16V
f0.5V
COMBINATION
l 4
NoN5Gc
and of
METER
REMOVAL AND INSTALLATlON
Removal
8-173
steps
1. Meter cover
2. Connection of speedometer
3. Meter assembly
NOSNJAFl
cable
NOTE
(1) Reverse the removal procedures to reinstall.
(2) I)*
: Refer to Service Points of Installation.
INSPECTION
REED SWITCH
Using an ohmmeter,
check that continuity and discontinuity
alternate
between
terminals
1 and 2 four times at every
rotation of the shaft of the speedometer
cable connection.
II
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__
8-174
METERS AND GAUGES - Combination
Meter
BUZZER
Check to be sure that buzzer sounds when the batterys
positive (t-1 terminal
is connected
to terminal 2 and the
batterys negative (-1 terminal is connected to terminal 1.
FUEL GAUGE
Measure
the resistance
value
using an ohmmeter.
Standard
value:
1-2 terminals:
55 a
2-3 terminals:
165 ti
1-3 terminals:
110 0
between
the
terminals
by
Caution
If there is a malfunction
of the ground contact of the
voltage
regulator
even once during vehicle operation,
the excessive current flowing
through
the heat coil of
the engine coolant
temperature
gauge and the fuel
gauge will cause permanent
distortion
of the bimetal,
resulting
in the indications
being consistently
lower
than the actual value.
For this reason, therefore,
be sure to make the earth
contact securely.
ENGINE COOLANT TEMPERATURE

GAUGE
Measure
the resistance
value between
the
using an ohmmeter.
Standard
value:
Bimetal type
1-2 terminals:
55 Q
terminals
by
SERVICE POINTS OF INSTALLATION

2.
SF554
TSR
INSTALLATION
OF SPEEDOMETER
CABLE
Insert the cable until its stopper properly fits to the
speedometer
groove.
Caution
Poor installation
of the cable may cause a fluctuating
meter pointer, or noise and a damaged
harness inside
the instrument
panel.
1
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METERS AND GAUGES
Combination
Meter/3-meter
Unit
8-175
DISASSEMBLY AND REASSEMBLY
,6
Disassembly
steps
1. Meter cover
2. Buzzer
3. Fuel and engine coolant temperature
4. Tachometer
5. Speedometer
6. Indicator panel
7. Meter glass
8. Window plate
9. Meter case
10. Printed circuit board
NOTE
Reverse the disassembly procedures to reassemble,
3-METER UNIT
REMOVAL AND fNSTALLATlON
Removal
steps
1. Meter pad
2. Gauge assembly
NOTE
Reverse the removal procedures to reinstall.
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gauge
6-176
METERS AND GAUGES - 3-meter
Unit
INSPECTION
OIL PRESSURE GAUGE
Measure the resistance value between
ohmmeter.
Standard
value:
Approx. 50 n
VOLTAGE METER
Measure the resistance value between
ohmmeter.
Standard
value:
380450
fl
the terminals
with an
the terminals
with an
INCLINOMETER
(1) Check to be sure that operation
is smooth when the
inclinometer
is titled up/down and to the left and right.
(2) The inclinometer
can be considered to be in good condition if the pointer indicates the spherical dial horizontal
center line when the meter case is placed on a level
surface.
Dissssembly
1.
2.
3.
4.
5.
6.
7.
steps
Meter
glass
Window
plate
Oil pressure
gauge
Inclinometer
Voltage
meter
Meter case
Meter
harness
NOTE
Reverse the disassembly
procedures
to reassemble.
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METERS AND GAUGES - Indicators and Warning Lights
INDICATORS AND WARNING
8-177
LIGHTS
Symbol
Operation
Turn signal indicator
This indicator flashes, as do the same side of turn-signal

light flashes. If the turn-signal light is burnt out, the blinking
of indicator slows down.
This indicator is common with hazard light.
High beam indicator
This indicator illuminates when the headlights are on high

beam.
Door-ajar warning light
This warning light comes on when the door is either open or

not completely closed.
Fasten seat belt indicator
This indicator goes on for four to eight seconds when the

ignition key is in ON position, even if the driver has
fastened his seat belt.
Brake warning light
This warning light comes on when the ignition key is in

ON position, and goes off after the engine has started.
This warning light comes on when the parking brake is
applied or brake fluid level falls less than the specific level.
Charging warning light
This warning light comes

ON position, and goes
This warning light comes
the trouble occurs in the
Overdrive indicator
This indicator will illuminates when the overdrive control

switch is switched to the OFF position.
++
=0
BRAKE
on when
off after
on when
charging
the ignition key is in

the engine has started.
the drive belt breaks or
system.
%?
am0133
AR fluid temperature
light
T%
warning
This A/T fluid temperature warning light comes on when

automatic transmission fluid temperature becomes abnormally high.
ma68
Free-wheeling
hub indicator
This indicator comes on when the automatic

hubs are locked.
free-wheeling
WE4WD indicator
This indicator will light up when the transfer case shift lever
is shifted to the four wheel driving position (either the 4H
or the 4L position) and the ignition key is in the ON
position.
z4
MAINT
REQD
Maintenance
light
required warning
This light comes on when the ignition key is in ON

position, and goes off after the engine has started.
(Lights up after every 50,000 miles, 80,000 miles, 100,000
miles and 120,000 miles travelled.)
Engine warning light
This light illuminates when

ON position, but should
If the light illuminates while
malfunction of a component
CHECK
ENGINE
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1
I
the ignition key is turned to the

go out in a few seconds.
the vehicle is moving, there is a
related to exhaust gases.
METERS AND GAUGES - Indicators and Warning Lights

MAINTENANCE REQUIRED SYSTEM
RESET SWITCH
After checking is completed.
use the reset switch (located at
the rear of the combination
meter) to switch
OFF the
warning light.
Note that the warning lights bulb should be removed after
the 120,000 mileage.
NOTE
If the speedometer
is to be replaced, set the new odometer
to the same reading as the odometer
being removed.
1 TSB Revision
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o-1
LUBRICATION
AND
MAINTENANCE
INDEX
GENERAL INFORMATION
.................................
MAINTENANCE
SERVICE .................................
Air Cleaner Element
........................................
Automatic Transmission
.................................
Ball Joint and Steering Linkage Seals .............
Ball Joints with Grease Fitting ........................
Brake Hoses ....................................................
Canister ...........................................................
Carburetor Choke Mechanism
and Linkage .....................................................
Crankcase Emission Control System (Positive
Crankcase Ventilation Valve) ...........................
Distributor Cap, Rotor and
Advanced angle System .................................
Drive Belt ...............................................
..- .......
Drive Shaft Boots ............................................
EGR Valve ..............................................
.._... -Engine Coolant ................................................
Engine Idling Speed .............................
.._...._ .._
Engine Oil ........................................................
Engine Oil Filter ...................................
..- *__..*...
Engine Oil Inspection
......................................
Evaporative Emission Control
System (except Canister) ................................
Exhaust System (Connection
Portion of Muffler and Pipings,
and Keeping Warmth Covers) ................ .._......
Front Axle and Rear Axle .................................
2
9
12
22
24
25
24
16
11
13
17
19
25
16
23
IO
20
21
20
15
26
25
NWOA-
Front Disc Brake Pads .....................................

Front Wheel Bearing .......................................
Fuel Filter .........................................................
Fuel Hoses, and Vapor Hoses .........................
Fuel System
....................................................
Ignition Cables ................................................
Intake Temperature
Control
System
............................................................
Manual Transmission
......................................
Oxygen Sensor ...............................
..- .............
Propeller Shaft Joints ......................................
Rear Axle Oil (Limited Slip
Differential)
......................................................
Rear Drum Brake Linings and
Rear Wheel Cylinders ._._..................................
Solenoid Valve Air Filter of
Vacuum Control System
.................................
Spark Plugs .....................................................
Timing Belt ......................................................
Transfer Case ..................................................
Vacuum Hoses, Secondary Air Hoses,
Crankcase Ventilation Hoses
and Water Hoses ............................................
Valve Clearance . . . . . . . . .. . . .. . . . .._......~.. . .. .. . .. . . . . . . .. . .
RECOMMENDED
LUBRICANTS
AND
LUBRICANT CAPACITIES TABLE .....................
SCHEDULED MAINTENANCE
TABLE ..............
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24
25
12
12
12
16
18
22
17
26
26
24
18
16
19
23
12
9
6
3
LUBRlCATlON AND MAINTENANCE-General Information
GENERAL INFORMATION
?uloP&BCaution
Maintenance
and lubrication service recommendations have been compiled to provide maximum protection for the vehicle owners investment against all reasonable types of driving conditions.
Since these
conditions vary with the individual vehicle owners
driving habits, the area in which the vehicle is operated
and the type of driving to which the vehicle is sub
jetted, it is necessary to prescribe lubrication and
maintenance service on a time frequency as well as
mileage interval basis.
Oils, lubricants and greases are classified and graded
according to standards recommended
by the Society
of Automotive
Engineers (SAE), the American Petroleum institute (API) and the National Lubricating
Grease Institute (NLGI).
MAINTENANCE SCHEDULES
Information for service maintenance is provided under
SCHEDULED MAINTENANCE TABLE.
Three schedules are provided; one for Required
Maintenance,
one for General Maintenance
and
one for Severe Usage Service.
SEVERE SERVICE
Vehicles operating under severe service conditions will
require more frequent service.
Component service information is included in appropriate units for vehicles operaing under one or more of
the following conditions:
1. Trailer towing or police. taxi, or commercial type
operation.
2. Operation of Vehicle
(1) Short-trip operation at freezing temperature
(engine not thoroughly warmed up)
More than 50%operation
in heavy city traffic
during hot weather above 32C (90F)
13) Extensive idling
(4) Driving in sandy areas
(5) Driving in salty areas
(6) Driving in dusty conditions
(7) Driving on-off-road
ENGINE OIL
The SAE grade number indicates the viscosity of engine oils, for example, SAE 30. which is a single grade
oil. Engine oils are also identified by a dual number, for
example, SAE lOW-30, which indicates a multigrade
oil.
The API classification system difines oil performance
in terms of engine usage. Only engine oil designed
For Service SF or For Service SF/CC, when available, should be used. These oils contain sufficient
chemical additives to provide maximum engine protection. Both the SAE grade and the API designation can
be found on the container.
/ TSB Revision
Test results submitted
to EPA have shown that

laboratory
animals
develop
skin cancer after
prolonged
contact with used engine oil. Accordingly, the potential
exists for humans to develop
a number
of skin disorders,
including
cancer,
from such exposure
to used engine oil.
Care should be taken, therefore,
when changing
engine oil, to minimize the amount and length of
exposure time to used engine oil on your skin.
Protective
clothing
and gloves, that cannot be
penetrated
by oil, should
be worn. The skin
should be thoroughly
washed
with soap and
water, or use waterless
hand cleaner, to remove
any used engine oil. Do not use gasoline, thinners, or solvents.
GEAR LUBRICANTS
The SAE grade number also indicates the viscosity
of Multi-Purpose
Gear Lubricants.
The API classification
system defines gear lubricants in terms of usage. Typical gear lubricants
conforming
to API GL-4 or GL-5 with a viscosity of
SAE 8OW. SAE 96 are recommended
for manual
transmission,
front axle and rear axle (conventional
differential),
and MITSUBISHI genuine gear oil Part
No. 8149630EX or equivalent, for rear axle (limitedslip differential).
LUBRICANTS-GREASES
Semi-solid
lubricants
bear the NLGI designation
and are further classified as grades 0, 1, 2, 3 etc..
Whenever Chassis Lubricant
is specified,
MultiPurpose Grease; NLGI grade No. 2, should be
used.
FUEL USAGE STATEMENT

Use gasolines having a minimum anti-knock index
(Octane Value) of 87, (R + M)/Z. This designation
is
comparable
to a Research Octane Number of 91.
Unleaded gasolines only must be used in vehicles
equipped with catalyst emission control systems.
All vehicles, so equipped,
have labels located on
the instrument
panel and on the back of fuel filler
lid that state, UNLEADED
GASOLINE
ONLY.
These vehicles also have fuel filler tubes especially
designed to accept the smaller diameter unleaded
gasoline dispensing
nozzles only.
MATERIALS ADDED TO FUEL

Indiscriminate
use of fuel system cleaning
should be avoided. Many of these materials
ed for gum and varnish removal may contain
active solvents or similar ingredients
that
harmful to gasket and diaphragm matertals
fuel system component
parts.
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agents =
intendhighly
can be
used in
o-3
LUBRICATION AND MAINTENANCE - Scheduled Maintenance Table
SCHEDULED MAINTENANCE
TABLE
ram&-
SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE
Inspection and service should be performed any time a malfunction
for all vehicle emission services to protect your emission warranty.
is observed
or suspected.
Retain receipts
Emission Control System

Maintenance
Check Intake Temperature
Control System*3 Every 5 Years
Replace Solenoid Valve Air Cleaner Element of Vacuum

Control System* Every 5 Years
or
or
NOTE
(1) * : Shows recommended maintenance items for California vehicles only, but are required for vehicles except for
California. <2.6L Engine>
(2) * : <2.6L Engine>
(3) *3 : Except for California
1 TSB Revision
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_1
1.
-ES-
o-4
LUBRICATION AND MAINTENANCE
- Scheduled Maintenance Table

E-I
-g:
GENERAL MAINTENANCE SERVICE FOR PROPERVEHICLE PERFORMANCE

General Maintenance
Service interval
Timing Belt
~___
Drive,Belt (for Water Pump and
Alternator)
Kilometers inihousands
12 24
Mileage in Thousands
7.5
Replace
36 48
60
72
9ei
84
15 22.5 30 37.5 45 52.5 6C1
at
Replace
at
X
I
Engine Oil
Change Oil Every 12 Months
or
Engine Oil Filter
Replace Every 12 Months
or
Manual Transmission and Transfer

Oil
Check Oil Level
Automatic Transmission Fluid
Check Fluid Level Every 12 Months
Automatic Transmission and

Transfer Fluid
Change Fluid
Engine Coolant
X
1
at
X
X
or
Change Coolant Every 2 Years
orI I I /xl
I I lx
Front Disc Brake Pads
Inspect for Wear Every 12 Months
or
Rear Drum Brake Linings and Wheel

Cylinders
Inspect for Wear and Leaks Every 2

Years
orI
Brake Hoses
Check for Deterioration or Leaksvery

12 Months
ori
/X/
Ball Joint and Steering Linkage Seals
Inspect for Grease Leaks and Damage

Every 2 Years
or
Drive Shaft Boots
Inspect for Grease Leaks and Damage

Every 12 Months
or
Ball Joints with Grease Fitting
Lubricate Grease Every 12 Months
or
Front Wheel Bearing
Lubricate Grease Every 2 Years
or
xi
With LSD*
Change Oil
at
Without LSD*
Inspect Oil Level
at
Propeller Shaft Joint
Lubricate Grease Even! 2 Years
or
Exhaust System
Connection Portion of Muffler,
I Pipings and Converter Heat Shields
Check and Service as Required Every 2

Years
or
Front Axle and Rear

Axle
NOTE
* : LSD -Limited-slip
at
differential
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X
I
Ix/
/XI
~I,(
X
I
lx
/X
I
xi
xi
x
I
;x
x
X
LUBRICATION AND MAINTENANCE-Scheduled MaintenanceTable

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDlTlONS
The maintenance
items should be performed
according
to the following
table:
mission and
Transfer Case
Severe usage conditions
A-Driving in dusty conditions
B-Trailer towing, or police, taxi, or commercial type operation
C-Extensive idling
D-Shot--trip operation at freezing temperatures (engine not thoroughly warmed up)
E-Driving in sandy areas
F-Driving in salty areas
G-More than 50% operation in heavy city traffic during hot weather above 32C (90F)
H-Driving on off-road
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O-6
RECOMMENDED
Recommended
Lubricants
and Lubricant
Capacities
Table
LUBRICANTS AND LUBRICANT CAPACITIES TABLgm.,
RECOMMENDED LUBRICANTS
Parts
Specifications
Engine oil
API classification SF or SF/CC
Manual transmission
API classification GL-4 or higher
~
_
Automatic transmission
Remarks
DEXRON type
/ For further details, refer to SAE

1 vrscosity number
SAE grade number: SAE 8OW or
75Wl85W
fluid
Transfer case
SAE grade number: SAE 8OW or

75wmiw
Front axle
For further details, refer to SAE

viscosity number
For further details, refer to SAE

viscositv number
Conventional differential
Rear axle
Limited-slip differential
Mitsubishi Genuine Gear Oil Part No.

8148630EXor equivalent
Power steering
DEXRON type
Brakes and clutch
Conforming to DOT3
Fluid
D&QUEEN LONG-LIFE COOLANT

(Part No. 0103044) or HIGH QUALITY
ETHYLENE GLYCOL ANTIFREEZE
COOLANT
Engine coolant
Door hinges, back door hinges
E;f
=I~-
aax
.:
sFz
EX
BT
-
Engine oil
I---
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LUBRICANT
CAPACITIES
Recommended
Lubricantsand
Lubricant
Capacities
o-7
Table
TABLE
Description
Engine oil
Crankcase (except for oil filter)
Oil filter
Oil cooler
Cooling system (including front heater and coolant reserve tank)
Manual transmission
Transfer case
Front axle
Rear axle
Limited-slip differential
Power steering
Fuel tank
<2.6L Engine>
Metric
measure
U.S.
4.9 liters
0.4 liter
5.0 qts.
l/2 qt.
-
8.0 liters
2.2 liters
8-l/2 qts.
4.7 pints.
-
2.2 liters
1.1 liters
4.7 pints.
2.3 pints.
1.8 liters
1.8 liters
1.06 liters
60 liters
3.8 pints.
3.8 pints
2.2 pints.
15.9 gals.
measure
<3.OL Engine>
Metric
measure
U.S.
measure
4.71 liters
0.4 liter
0.3 liter
9.1 liters
2.5 liters
7.2 liters
2.2 liters
1.1 liters
5.0 qts.
lr2qt.
1/2qt.
9-l/2 qts.
5.3 pints.
15.2 pints.
4.7 pints.
2.3 pints.
2.6 liters
2.6 liters
1.06 liters
75 liters
92 liters**
5.5 pints.
5.5 pints.
2.2 pints.
19.8 gals.*
24.3 gals.:
*I: 2-doer models

*? 4-ooor models
SELECTION OF LUBRICANTS
qnticipated barometric
:emperature range
ENGINE OIL
SAE viscosity No.
zoco
Only those engine oils should be used which conform to the

requirements
of the API. classification
For Service SF or For
Service SF/CC, and have the proper SAE grade number for the
expected temperature
range.
38
100
27
80
16
60
Energy Conserving
32
In order to improve fuel economy and conserve energy new,

lower friction engine oils have been developed.
These oils are
readily available and can be identified by such labels as Energy
-12
IO
-23
-29
-10
Caution
Nondetergent
conserving,
-20
SAE 5W-20 Not recommended for sustained

high speed vehicle operation.
( TSB Revision
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or straight
mineral
oil must never be used.
Oil
Energy saving,
Improved
fuel economy,
etc.
O-8
Recommended
LuMcantrandLubricantCapacltiesTable
Oil Identification
Symbol
A standard symbol appears on the top of oil containers and has
three distinct areas for identifying
various aspects of the oil.
The top portion will indicate the quality of the oil. The center
portion
will show the SAE viscosity
grade,
such as SAE
IOW-30.
Energy Conservingshown
in the lower portion, indicates that the oil has fuel-saving capabilities.
72POO30
FRONT AXLE/REAR
AXLE (CONVENTIONAL
DIFFERENTIAL)
Lubricant
API classification
GL-5 or higher
Anticipated temperature
range
Viscbsity range
Above-23"C(-10F)
SAE90
SAE 85W-90
SAE 8OW-90
SAE 80W
SAE 8OW-90
SAE 75W
-20"Ct034"C
(-10F to -30F)
Below -34C (-30F)
REAR AXLE (LIMITED-SLIP
DIFFERENTIAL)
Refer to P.3-4.
COOLANT
Relation between
Coolant
Concentration
Coolanttemperature
ZO(68)
lO(50)
1
1
1.054
1.063
1
1
1.050
1.058
C (F) and specific gravity

30(86)
1
1
and Specific Gravity
1.046
1.054
Safe operating
temperature
C(F)
Coolant
concentration
(Specific
volume)
-16(3.2)
-11(12.2)
30%
-20(A)
-15(5)
35%
50(122)
M(lW
/
/
Freezing
temperature
C (F)
1.042
1.049
1 1.044
1.036
1.071
1.067
1.062
1.057
1.052
-25(-13)
-20(-4)
40%
1.079
1.074
1.069
1.064
1.058
-3O(-22)
-25(-13)
45%
1.087
1.082
1.076
1.070
1.064
-36k32.8)
-31 -(23.8)
50%
1.084
1.077
1.070
-42 (*I
-37(-35)
55%
1.084
1 1.076
-5O(-58)
-45(-w
60%
1.095
1.090
1.103
1.098
1.092
The safe operating temperature

20C (68F).
is - 15C (5F) when the measured specific gravity is 1.058 at the coolanttemperature
of
Cautions
1. If the concentration
of the coolant is below 30%, the anti-corrosion
property will be adversely affected. In addition, if the concentration
is above 60%, both the anti-freeze
and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.
2. Do not use a mixture of different brands of anti-freeze.
/ TSB Revision
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LUBRICATION
AND MAINTENANCE
o-9
- Maintenance Service
MAINTENANCE
NaosAca
SERVICE
VALVE CLEARANCE (Jet valve) (Check and adjust

as required)
<2.6L Engine>
(1) Warm up
85-95C
(2) Remove
(3) Remove
(4) Remove
the engine until the coolant temperature

(185-205F).
the air cleaner assembly.
the all spark plugs.
the rocker cover.
reaches
(5) Align the notch in the crankshaft pulley with the T mark
on the timing chain cover.
Check to be sure that the camshaft
sprocket and the
timing chains mating mark are in the position shown in
the figure.
Caution
Be sure not to rotate
direction.
the crankshaft
Note
If the camshaft
sorockets
mating
opposite position, the No. 4 cylinder
(6) Measure the jet valve clearance

the arrows in the figure.
With the No. 1 cylinder at compression
top dead center.
Standard
Note
The valve
No. 1
value (when
clearance
hot engine)
when
mark is at the 180

is at top dead center.
at the places
5EN27.1
With the No. 4 cylinder at compression
top dead center.
Timin
chain
side
No. 3 No. 4
5ENZ22
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shown
by
: 0.25 mm (.0098 in.)
cold is 0.17 mm
Caution
Be careful not to press the jet valve
valve springs
force is not strong.
No. 2
counterclockwise
LOO67 in.)
in, because
the jet
LUBRICATIGN
AND
MAINTENANCE
(7) Apply specified

Specified
(8) Install
(9) Install
(10)lnstall
sealant
Maintenance
Service
sealant to portions
: 3M ART Part
indicated
in ilIustration.
NO. 8660
the rocker cover.

the spark plugs.
the air cleaner assembly.
ENGINE
IDLlNG
SPEED
<2.6L
Engine>
WSADG.
Caution
The improper
setting (throttle valve opening) will increase
exhaust gas temperature
at deceleration,
reducing catalyst
life greatly and deteriorating
exhaust gas cleaning performance. If also has effect on fuel consumption
and engine
braking.
Inspection
Conditions
l
Engine Coolant temperature:
85-90C (185205F)
l
Lights and accessories (air-conditioner,
etc.): OFF
0 Transmission:
Neutral
l
Steering wheel: Centered (for power steering equipped
vehicles)
(1) Prepare a timing light and tachometer.
(2) Start the engine and allow it to idle.
(3) Depress accelerator
pedal once to release the fast idle.
(4) Inspect the ignition timing. Adjust the ignition timing if
necessan/.
Standard
*:
ignition
timing
: 7 BTDC
&2*
When inspecting
the standard ignition timing at high
altitudes, disconnect
the white striped vacuum hose
from the distributor
auxiliary compression
chamber
and temporarily close the end of the hose with a blind
plug. (Federal indicated high-altitude
specification
vehicles, California).
NOTE
Inspect and adjust ignition timing as described in GROUP
&Ignition
System.
(5) Run the engine for more than 5 seconds at an engine
speed of 2,000 to 3,OOOipm.
(6) Run the engine at idIe for 2 minutes.
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Maintenance
O-II
Service
(7) Read the idling speed.

If outside specified
limits, readjust the speed to the
specified
value by adjusting
the idle speed adjusting
screw No. 1 (SAS-1).
Curb idle speed (rpm)
For the First 500 km
(300 miles)
After 500 km
(300 miles)
800elOO
Caution
DO NOT TOUCH SAS-2. The idle speed adjusting
screw
(SASS) is the preset screw that determines
the relationship between
the throttle
valve and free lever, and has
been accurately
set at the factory.
If this setting
is
disturbed,
throttle
opener adjustment
and dash pot adjustment cannot be done accurately.
CARBURETOR CHOKE MECHANISM

AGE (Clean) <2.6L Engine>
The choke mechanism
is used to
during cold weather. Inject a solvent
choke and the throttle valves (where
horn) to prevent the choke from
deposits on the shaft. At the same
clean dirt from the fast idle cam
AND LINKNW-
facilitate engine starting

into the end of the autothey pass through the air
becoming
stuck by gum
time, inject a solvent to
and link.
Caution
1. All carburetors
have a tamper-proof
choke. The chokerelated parts are factory adjusted.
The choke adjustment is required
during service, except when major
carburetor
service or overhaul choke calibration
related
parts adjustments
are needed by state or local inspections.
2. All carburetors
also have a tamper-resistant
idle mixture adjusting
screw. The CO setting has been done as
a factory adjustment.
Neither removal of the plug nor
adjustment
of the mixture
screw is required
during
service unless a major carburetor
overhaul,
throttle
body replacement,
or high idle-CO adjustments
are
needed by state or local inspections.
/ TSB Revision
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LUBRICATION
AND MAINTENANCE
Maintenance
Service
FUEL FILTER (Replace)

<2.6L Engine>
The fuel filter should be replaced
regularly
because
its
performance
is reduced by dirt and water collected over an
extended
period of use. Replace as required.
FUEL SYSTEM (Check for leaks)

TANK,
LINES
AND
FUEL
FILLER CAP CONNECTIONS
1. Check for damage

or leakage in the fuel lines and
connections.
2. Inspect the surface of fuel hoses for heat and mechanical
damage. Hard and brittle rubber, cracking, checking, tears,
cuts, abrasions and excessive swelling indicate deterioration of the rubber.
3. If the fabric casing of the rubber hose is exposed by
cracks and abrasions in the fuel system, the hoses should
be changed.
VACUUM
HOSES, SECONDARY AIR HOSES,
CRANKCASE VENTILATION HOSES AND WATER
HOSES (Replace)
Replace them and make sure that the hoses do not come in
contact with any heat source or moving component
which
might cause heat damage or mechanical
wear.
FUEL HOSES, AND VAPOR HOSES (Replace) -F

Service procedures
to check the hoses for damage are the
same as those described
in the section Vacuum
hoses,
secondary air hoses, crankcase ventilation
hoses and water
hoses.
For removal and installation procedures,
refer to GROUP 14 Fuel Line and Vapor Line.
AIR CLEANER ELEMENT (Replace)
r4wsAKG
The air cleaner element will become dirty and loaded with
dust during use, and the filtering effect will be substantially
reduced. Replace it with a new one.
REPLACEMENT
OF AIR CLEANER ELEMENT
<2.6L Engine>
1. Remove the wing nut. Use pliers only if the wing nut is
difficult to remove.
2. Unsnap the finger clips.
3. Remove the element by hand, and replace it with a new
element.
4.
Install the air cleaner element, and then install the cover
and housing, taking care that the arrows are aligned.
5. Tighten the wing nut by hand.
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LUBRICATION
AND MAINTENANCE
o-13
<3.OL Engine>
(1) Loosen the clamp coupling the air intake hose and the air
cleaner cover, and separate the hose.
the air flow sensor connectors.
(2) Disconnect
the air cleaner cover clip.
(3) Disconnect
(4) Lifting the air intake hose, remove the air cleaner cover.
Caution
The air
because
cleaner cover should

be removed
it includes the air-flow
sensor.
carefully,
Remove the air cleaner element.

Set a new air cleaner element and clamp the air cleaner
cover.
CRANKCASE EMISSION CONTROL SYSTEM (Positive crankcase ventilation valve) (Clean)

NW
The crankcase
maintain good
ventilation
system
engine performance.
must
be kept
clean
Air cleaner
Breather
hose
Rocker
/cover
Intake
manifold
From rocker cover
PCV valve
VImtilation
hclse
I
k-.-J
I
SEMcsl
7EMOOSO
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to
LUBRICATION AND MAINTENANCE - Maintenance
Service
<2.6L Engine>
(I)
Disconnect
the ventilation
hose from the positive crankcase ventilation
valve. Then, remove Positive Crankcase
Ventilation valve from the rocker cover and reconnect it to
the ventilation
hose.
(2) idle the engine and put a finger to the open end of Positive
Crankcase Ventilation
valve to make sure that intake
manifold vacuum is felt on the finger.
NOTE
At this time, the plunger inside the Positive Crankcase
Ventilation
valve moves back and forth.
(3) If vacuum is not felt on finger, clean the Positive Crankcase Ventilation
valve and ventilation
hose in cleaning
solvent or replace if necessary.
(4) After completion
of the work, set the reset switch (at the
rear of the meter) to switch OFF the maintenancerequired warning light.
(Refer to GROUP 8 - Meters and Gauges.)
<3.OL Engine>
(1) Disconnect
the ventilation
hose from the air-intake plenum. and connect a hand vacuum pump to the ventilation
hose.
(2) At this time, make sure that there is leakage when vacuum
is applied, If there is no leakage when vacuum is applied,
either clean the positive crankcase
ventilation
valve or
replace it.
rear of the meter) to switch OFF the maintenancerequired warning light.
(Refer to GROUP 8 - Meters and Gauges.1
) TSB Revision
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,.,
LUBRICATION
AND
EMISSION
CONTROL
EVAPORATIVE
MAINTENANCE
SYSTEM
- Maintenance
o-15
Service
(Check for leaks and clogging)
- except
NWSAMB.
canister
<2.6L Engine>
Air cleaner
Purge control
valve
Fuel check valve

(Required FMVSS 301)
i
Overfill limiter
(2-way valve)
Vapor-liquid
seoarator
Gel filler cap

vacuum relief) -
mannolu
Fuel filler
<3.OL
Fuel vapor
---
Purge air
Engine>
Thermal
expansion
y
..-
++ -
Filter
Cani&er
---
pipe/w
To carburetor
I
II
Overfill Ii miter
(Level tul be)
/Air
cleaner
Overfill
limiter
,J
Fuel gauge
unit
Fuel tank
03W527
Fi,ti
Purge air
Fuel vapor
1. If the fuel-vapor vent line is clogged or damaged,

a fuelvapor mixture escapes
into the atmosphere
causing
excessive emissions.
Disconnect
the line at both ends,
and blow it clean with compressed
air. Remove the filler
cap from the filler pipe and check to see if there is
evidence that the packing makes improper contact to the
filler pipe.
2. The overfill limiter (Two-way valve) installed on the vapor
line should be checked for correct operation.
1 TSB Revision
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O-16
LUBRlCATlON
AND MAINTENANCE
CANISTER (Replace)
-a
If or when the canister filter becomes clogged, the purge air

volume will decrease and consequently,
the canister capacity
will be reduced.
After completion
of the work, set the reset switch (at the rear
of the meter) to switch OFF the maintenance-required
warning light.
NGK
SPARK PLUGS (Replace)
NoLs.4~
1. Spark plugs must fire properly to assure proper engine

performance
and emission-control.
Therefore, they should be replaced periodically with new
ones.
2. The new plugs should be checked for the proper gap.
Spark plug gap
: U-1.1
mm
(.039-.043
in.)
IGNITION CABLES (Replace)

The ignition cables should be replaced periodically with new
ones.
After replacing,
make sure that the ignition
cables and
terminals
are properly connected
and full seated.
NOTE
When disconnecting
an ignition
cap. If the cable is disconnected
an open circuit might result.
cable, be sure to hold cable

by pulling on the cable alone,
EGR VALVE (Replace)

Replace
EGR valve
MO.SMG
to a new one.
REMOVAL
OF EGR VALVE
<2.6L Engine>
1. Disconnect
the vacuum hoses from the EGR valve.
2. Remove the EGR valve from the intake manifold.
3. Replace the EGR valve gasket with a new one.
4. Install the EGR valve on the intake manifold and tighten to
the specified torque.
After completion
rear of the meter) to switch OFF the maintenancerequired
warning light.
<3.OL Engine>
1. Disconnect
the vacuum hoses from the EGR valve.
2. Remove the EGR valve from the air intake plenum.
3. Replace the EGR valve gasket with a new one.
4. Install the EGR valve on the air intake plenum and tighten
to the specified
torque.
After completion
rear of the meter) to switch
OFF the maintenancerequired warning light.
1 TSB Revision
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LUBRICATION
Hexagon nut
Housing
AND MAINTENANCE
Spring
Ele
03Esso
Maintenance
Service
O-17
OXYGEN SENSOR (Replace)

NOOSAOF
The oxygen sensor is a device which controls the fuel mixture.
If the oxygen sensor is damaged,
the exhaust-gas cleaning
effect as well as driveability deteriorates.
Therefore, it should
be replaced periodically
with a new one.
After completion
of the work, set the reset switch (at the rear
of the meter) to switch OFF the maintenance-required
warning light.
REMOVAL
OF OXYGEN SENSOR
<2.6L Engine>
1. Disconnect
the connector
of the oxygen sensor.
2. Remove the oxygen sensor from the exhaust manifold.
3. Replace the oxygen sensor on the exhaust manifold and
tighten to the specified torque.
<3.OL Engine>
1. Disconnect
the connector
of the oxygen sensor.
2. Remove the oxygen sensor from the front exhaust pipe.
3. Replace the oxygen sensor on the front exhaust pipe and
tighten to the specified torque.
DISTRIBUTOR CAP, ROTOR AND ADVANCED ANNoosA3B

GLE SYSTEM (Check) <2.6L Engine>
Check the distributor
cap, rotor and spark advance system to
maintain driveability
and good exhaust gas.
INSPECTION
OF DISTRIBUTOR
CAP AND ROTOR
Inspect in accordance with the following procedure. Repair or
replace as necessary.
l
Check the cap for cracks.
l
Check the cap and rotor electrodes
for damage.
l
Wipe clean the cap and rotor.
INSPECTION
OF CENTRIFUGAL
SPARK ADVANCE DNICE
1. Start the engine and allow it to idle.
2. FD;nnect
the vacuum hoses from the vacuum cham*: Disconnect the vacuum hoses from both the main and
sub vacuum
chambers,
(High-altitude
areas nationwide, California)
3. Inspect the advance angle while slowly increasing engine
speed.
The advance angle should change smoothly as engine

speed
increases.
1 TSB Revision
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O-18
LUBRICATION
AND
MAINTENANCE
- Maintenance
Service
NOTE
Centrifugal properties (Reference)
500 1000 1500 2000 2500 3000 3500

Distributor rpm
SEW
Probable Cause
Symptom
4.
When any of the above symptoms

inspect the distributor.
INSPECTION
OF VACUUM
appear, disassemble
ADVANCE
and
DEVICE
1. Start the engine and allow it to idle.

2. Disconnect
the vacuum-hoses
from the vacuum chamher*.
Connect a vacuum pump to the nipple.
*: Disconnect the vacuum hoses from the main vacuum
chambers.
(High-altitude
areas nationwide,
California)
3. Slowly apply vacuum with the vacuum pump and inspect
the advance angle.
The advance
angle should
change
smoothly
as the
vacuum increases.
NOTE
Pressure kPa (psi)
5~031
Symptom
Probable Cause
Advance angle is too large
Vacuum controller spring is weak

or missing
Advance angle changes

suddenly
Spring is broken
Angie too small or hysteresis

is too large
Does not advance
Poor breaker base operation
4.
Diaphragm is damaged
When any of the above symptoms

appear, disassemble
and inspect the distributor.
After removing
the distributor,
inspect
each part as
described
in GROUP 8 - Ignition System.
INTAKE
(Check)
TEMPERATURE
Check the vacuum

system to protect
2.6 L Engine, refer
System.
3.0 L Engine, refer
Procedure.
CONTROL
SYSTEM
t4oosATa
motor of the intake temperature

driveability
and fuel consumption.
to GROUP 25 - Exhaust Emission
to GROUP
14 - MPI-Service
1 TSB Revision
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Control
Adjustment
SOLENOID VALVE AIR FILTER OF VACUUM

TROL SYSTEM (Replace) <2.6L Engine>
[Secondary
air control
solenoid
valve,
ttle opener control solenoid valve]
Pull out the filter assembly in the direction
replace with a new filter assembly.
control
CONthro-
of the arrow
NOOSAVA
and

TIMING
waterpump
Pulleyn
pulley
o-19
BELT (Replace)
Iywsmc
Replace the belt with a new one periodically to assure proper

engine performance.
refer to GROUP 9 Timing belt.
DRIVE BELT (For water

(Replace)
<2.6L Engine>
Alternator
pUlk?y
o4soo2l
pump
and alternator)
NOOSBSK
Replace them with new ones, and make sure there is no

interference
between the belt and other engine components.
Then check the tension of the belt for the water pump and
alternator.
The deflection of the belt must be specified, when depressed
at a point midway between
the water pump pulley and the
alternator
pulley with a force of 100 N (22 Ibs.).
REPLACEMENT
OF DRIVE BELT
Vehicles without
an air conditioner
1. Loosen the alternator brace bolt and alternator support
nut, and then remove the alternator
drive belt.
2. install a new alternator
drive belt.
3.
Contact a bar or similar object to the stator part of the

alternator in order to provide the appropriate tension, and
then adjust the amount of belt deflection.
Standardvalue
4.
: 9-12
mm
Tighten the alternator

brace
nut at the specified
torque.
(.3!5-.47
in.)
bolt and alternator
support
Vehicles
with an air conditioner
1. Loosen the tension pulley nut.
2. Loosen the tension adjustment
nut and then remove
air conditioner
compressors
drive belt.
3.
4.
5.
6.
Loosen the alternator

brace bolt and alternator support
nut.
Loosen the tension adjustment
bolt, and remove the
alternator
drive belt.
Install a new alternator drive belt.
Adjust the amount of deflection
of the belt by using the
tension adjustment
bolt.
Standard
7.
8.
the
value
: 9-12
mm
(.35-.47
in.)
Tighten the alternator

support
nut, and the alternator
brace bolt at the specified
torque.
Install the air conditioner
compressors
drive belt, and
adjust the amount of deflection of the drive belt.

Refer to GROUP 24 - Service Adjustment
Procedures.
[ TSB Revision
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i-y
L....
~-.
O-20
LUBRICATION
_ _.
AND MAINTENANCE - Maintenance Service

c3.OL Engine>
Replace them with new ones, and make sure there is no
interference
between the belt and other engine components.
(1) Remove the air conditioner
compressor
belt and power
steering belt.
(2) Back the nut off l/8 turn.
(3) Loosen the adjusting bolt and remove the drive belt.
(4) Attach a new drive belt.
AAlternater
(5) Apply 100 N (22 tbs.) to the belt back at the middle point
between
the alternator
pulley and the drive belt lower
tensioner.
Turn the adjusting bolt to adjust the drive belt sag to the
standard value.
pulley
Standard
value: 6.6-6.0
Standard
N (110-155
value
e
72JOO5
Engine>
: 500-700
gauge
Ibs.)
is used, select any part between
the nut.
ENGINE OIL INSPECTION
Good
t-l
4.OL
in.)
gauge to adjust the sag to the
(6) Tighten
Engine>
(.2X-.315
Otherwise, use the tension

standard value.
NOTE
When the tension
any pulleys.
<2.6L
mm
Good
(1) Check to ensure that the engine

range indicated on the oil dip
(2) Check to ensure that the oil
mixed with coolant or gasoline,
viscosity.
NwaBS*
oil level is within the level
stick.
is not noticeably
dirty or
and that it has the proper
l-l
WSAPiBb
ENGINE OIL (Change)

Always use lubricants which conform
the API classification
For Service SF
when available, and have the proper
the expected
temperature
range.
Never use nondetergent
or straight
1 TSB Revision
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to the requirements
of
or For Service SF/CC
SAE grade number for
mineral
oil.
LUBRICATION
AND MAINTENANCE
o-21
(I) Afterwarming
up the engine, remove the oil filler cap.
(2) Remove the drain plug to allow the engine oil to drain.
(3) Replace the drain plug gasket with a new one and tighten
the drain plug.
(4) Supply new engine oil through the oil filler.
Engine oil total capacity :
<2.6L Engine>
4.9 liters (5.0 qts.)
<3.OL Engine>
4.7 liters (5.0 qts.)
[including oil filter 0.4 liter (l/2 qt.)]
(5) Start and run the engine a few minutes.
(6) Stop the engine and check the engine oil level.
ENGINE OIL FILTER (Change)

The quality of replacement
filters
high quality filters should be used
service.
Genuine oil filters require that the
standing a pressure of 256 psi are
recommended
as follows:
Oil Filter Part Number
Mitsubishi
Genuine
Parts
NWSABG
varies considerably.
Only
to assure most efficient
filter is capable of withhigh quality filters and are
: MD031805
or equivalent
NOTE
Factory
installed
Mitsubishi
Engine Oil Filter Part No.
MD084693
or MD031805.
ENGINE OIL FILTER SELECTION
This vehicle is equipped with a full-flow, throw-away
oil filter.
The same type of replacement
filter is recommended
as a
replacement
filter for this vehicle. It is possible, particularily in
cold weather, that this vehicle may develop high oil pressure
for a short duration. You should be sure that any replacement
filter used on this vehicle is a high-quality filter and is capable
of withstanding
a pressure of 256 psi (manufacturers
specifications) to avoid filter and engine damage. The following is a
high-quality filter and is strongly recommended
for use on this
vehicle
: Mitsubishi
Engine Oil Filter P/N MD031805
or
MD084693.
Any replacement
oil filter should be installed in accordance
with the oil filter manufacturers
installation
instructions.
(1) Remove the engine oil filler cap.
(2) Remove the engine oil drain plug, and drain out the engine
oil.
(3) Remove the engine oil filter by using the oil filter wrench.
(4) Clean the oil filter mounting
surface of the oil filter
bracket.
(5) Coat engine oil to the O-ring of new oil filter.
(6) Turn the oil filter by hand to install to the block.
NOTE
The oil filter tightening
torque is 11-13 Nm (8-10 ftlbs.)
(7) Supply engine oil.
(8) Start and run engine and check for engine oil leaks.
(9) After stopping
engine, check oil level and replenish as
necessary.
[ TSB Revision
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LUBRICATION AND MAINTENANCE - Maintenance Service

MANUAL TRANSMISSION
(Check oil level)
NWSSCC
inspect each component

for evidence of leakage, and check
the oil level by remaining
the filler plug. If the oil is
contaminated,
it is necessary to replace it with new oil.
INSPECTlON
l
With the vehicle on a level surface, remove the filler plug
and check whether or not the oil is at the same level as the
bottom
of the threads.
l
Check whether or not the transmission
oil is excessively
dirty, and if the viscosity is normal.
REPLACING
TRANSMISSION
OIL
1. Remove the drain plug and drain the transmission
oil.
2. Replace the gasket with a new one and tighten the drain
plug.
3. Apply a coating of sealant to the threaded
part when
installing the drain plug and the filler plug of the transmission of models with the 3.OL engine.
Specified sealant: Three Bond 1105D or equivalent
4. Fill with new oil through the filler plug until the-oil level
reaches the plug hole.
Manual transmission
oil capacity
:
<2.6L Engine>
2;2 liters (4.7 pints)
<3.OL Engine>
2.5 liters (5.3 pints)
HOT upper limit

HOT lower limit
COLD upper limit
COLD lower limit
COLD
AUTOMATIC TRANSMISSION
372029
(Check fluid level)

Nwssoe
Check the fluid level by removing the fluid level gauge. If the
fluid is contaminated,
it is necessary to replace it wjth new
fluid.
1. Place the vehicle on a level surface.
2. Wipe the area around the oil dipstick to remove accumulated dirt and then pull out the oil dipstick.
3. Set the selector lever to the P (Park) position and apply
the parking brake. Next, start the engine..
4. Check if the engine
idle speed
and fluid operating
temeprature
(50-80C;
12%176F)
are normal.
5. Move the selector lever toeach
position in turn to fill the
torque convertor and hydraulic system with fluid and then
return the selector lever to the N (Neutral) position.
6. Make sure the fluid level is in the HOT range of the oil
dipstick. If the fluid level is low, add fluid until it reaches
the HOT range.
REPLACEMENT
OF AUTOMATIC
TRANSMISSION
FLUID
Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new fluid after the cause of any contamination
has been corrected.
1. Place a large flat contain-er beneath the drain plug.
2. Remove the drain plug and drain the fluid.
3. Replace the gasket with a new one and tighten the drain
plug.
4. Pour 5 liters (10.6 pints) of specified ATF into casethrough
dipstick hole. [Total quantity of ATF required is approx. 7
liters (14.8 pints). Actually however, approx. 5.5 liters (11.6
pints) of fluid can be replaced
because
rest of fluid
remains in torque converter.]
HOT
_.
j TSB Revision
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-7
LUBRICATION
AND MAINTENANCE
.;
Specified
5.
Maintenance
fluid
: Automatic
DEXRON
Check the fluid level.
o-23
Service
transmission
type
TRANSFER CASE (Change oil)
fluid
NWSBNea
Drain the fluid and check whether there is any evidence of

contamination.
Replenish with new fluid after the cause of
any contamination
has been corrected.
1. With the vehicle on a flat, level surface, drain out the
transfer case oil.
2. Replace the packing with a new one, and close the drain
plug.
3. Supply new transfer case oil through the filler plug until it
reaches the same level as the plug hole.
Transfer case oil total capacity
: 2.2 liters (4.7 pints)
NOOSBEE
ENGINE COOLANT
Check the cooling system
oil cooler hoses thermostat
damage.
CHANGING
COOLANT
parts such as radiator, heater

and connections
for leakage
and
and
1. Set the temperature

control lever to the hot position.
2. Remove the radiator cap, radiator drain plug and engine
drain plug to drain the coolant.
Caution
When removing
the radiator
cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise
a little
to let pressure escape through
the vinyl tube. After
relieving the steam pressure, remove the cap by slowly
turning
it counterclockwise.
3. Remove the reserve tank and drain the coolant.
4. After draining coolant completely,
reinstall the drain plugs
and flush the engine and radiator using a radiator cleaning
fluid.
5. After the flushing is completed,
completely
drain the
cleaning fluid and install the radiator and engine drain
plugs.
6. By referring to the section on coolant (P.O-xx). select an
appropriate
concentration
for safe operating temperature
within the range of 30 to 60%. Refill the system with a
high quality ethylene
glycol antifreeze
at the selected
concentration.
A convenient
mixture is a 50% water and
50% antifreeze solution [Freezing point: -36C (-32.8F)].
Reinstall the radiator cap.
Engine coolant total capacity
[including
heater and coolant reserve tank)
8.0 liters (8-l/2 qts.)
<2.6L Engine>
<3.OL Engine>
9.1 liters (9-l/2 qts.)
7. Start the engine and warm it up until the thermostat
opens.
8. After repeating the engine racing up to 3,000 rpm several
times, stop the engine.
] TSB Revision
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LUBRICATION
AND MAINTENANCE
Maintenance
Service
9.
Remove the radiator cap after the engine has gotten cold,
and pour in coolant up to the entrance for water supplying.
IO. Add coolant to the reserve tank between the FULL and
LOW mark if necessary.
Caution
Do not overfill the reserve tank.
FRONT DISC BRAKE PADS (Inspect for weadBFI.
14K512
Check for fluid contamination

and wear. Replace complete set
of pads if defective.
Thickness
of lining (A)
Limit: 2.0 mm (.079 in.)
Caution
The pads for the right and left wheels should be replaced at
the same time. Never *split or intermix brake pad sets. All
four pads must be replaced as a complete
set.
REAR DRUM BRAKE LININGS AND REAR WHEEL

CYLINDERS (Inspect for wear and leaks) NMISBGCb
1. Remove the brake drum and check the thickness of brake
shoe lining for wear. Check the automatic brake adjusting
system by hand to see if it operates smoothly. Also see if
the gears are in proper mesh with each other. To assure
smooth functioning,
apply a very thin coat of multipurpose
grease to the friction surface of adjuster and link shaft.
2. Inspect the wheel cylinder boots for evidence of a brake
fluid leak. Visually check the boots for cuts, tears or heat
cracks. (A slight amount of fluid on the boot may not be a
leak, but may be preservative
fluid used at assembly.)
(I) Checking the Brake Shoes for Wear.
Thickness
of lining (B)
Limit: 1.0 mm (.039 in.)
14KO24
BRAKE HOSES (Check for deterioration
or le$&*
Inspection of brake hoses and-tubing should be included in all

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

(Inspect for grease leaks and damage)
NOOSWA
1. These components,
which are permanently
lubricated at
the factory, do not require periodic lubrication.
Damaged
seals and boots should be replaced to prevent leakage or
contamination
of the grease.
2. Inspect the dust cover and boots for proper sealing,
leakage and damage.
Replace them if defective.
/ TSB Revision
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L-
LUBRICATION
AND
MAINTENANCE
DRIVE SHAFT
and damage)
- Maintenance
BOOTS
o-25
Service
(Inspect
for grease
leaks
Nw.sB.bul
1. These components,
which are permanently
lubricated at
the factory, do not require periodic lubrication. Damaged
seals and boots should be replaced to prevent leakage or
contamination
of the grease.
2. Inspect the dust cover and boots for proper sealing,
leakage and damage. Replace them if defective.
BALL JOINTS
grease)
1
WITH
GREASE
FITTING
(Lubricate
NOOSSOBb
Fill the multipurpose

grease at the grease fitting till the grease
come out of the dust seal of the pitman arm, tie rod, lowercontrol arm and upper control arm.
FRONT
Inspect
and the
the hub
off the
grease.
WHEEL
BEARINGS
(Lubricate
grease)
for evidence of grease leakage around the hub cap

back of the hub. If there is leakage of grease, remove
and inspect its oil seal for damage. Clean the grease
hub and bearing and repack with new multipurpose
NOTE
Refer to GROUP 2-Axle Hub and Freewheeling
removal procedures
of the front hub.
Hub, for the
FRONT AXLE AND REAR AXLE (CONVENTIONAL

NLwsBra
DIFFERENTIAL
(Inspect oil level)
Remove the filler plug and inspect the oil level at bottom of
filler hole. If the oil level is slightly below the filler hole, it is in
satisfactory
condition.
-.
( TSB Revision
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T x -L- ii __~__
-.__
~._
____
,_,
O-26
- Maintenance
Service
REAR AXLE OIL (LIMITED-SLIP

(Change)
DIFFERENTIAL)
NIXIS-
Before changing the rear axle oil, check to make sure that
there is no oil leakage from the rear axle housing.
Remove the drain plug and-drain
out of the oil.
Put the oil plug back in place, and then pour new oil in through
the filler hole.
Oil capacity
:
<2.6L Engine>
<3.OL Engine>
1.6 liters
2.6 liters
PROPELLER SHAFT JOINTS
(3.6 pints)
(5.5 pints)
(Lubricate
Lubricate grease to the propeller shaft joints.

The propeller shaft joints should be repacked with
pose grease.
mu
grease)
rdoaa
multipur-
EXHAUST SYSTEM (CONNECTION PORTION OF

MUFFLER, PIPINGS AND CONVERTER HEAT
SHIELDS) (Check and service as required) NWSBLPU
1. Check for holes and gas leaks due to damage, corrosion,
etc.
2. Check the joints and connections
for looseness and gas
leaks.
3. Check the hanger rubber and brackets for damage.
[ TSB Revision
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9-1
ENGINE
CONTENTS
<2.6L>
..................................................
CYLINDER HEAD GASKET ...........................

ENGINE ADJUSTMENT
...............................
Compression
Pressure Check ...................
Drive Belts Tension Adjustment
................
Ignition Timing Inspection and
................................................
Adjustment
Lash Adjuster Check ..................................
Manifold Vacuum inspection
.....................
Silent Shaft Drive Chain Tension
Adjustment
................................................
.....................................
ENGINE ASSEMBLY
Crankshaft and Flywheel
.................. ..~~~~..
Cylinder Block ............................................
Cylinder Head ............................................
Front Case, Oil Pump and Silent Shaft .......
...................................
Jet Valve Assembly
Piston and Connecting Rod .......................
Rocker Arm and Shaft Assembly
...............
Rocker Arms, Rocker Arm Shafts
and Camshaft
............................................
Timing Chain Train .....................................
Valves and Valve Springs ...........................
ENGINE MOUNTING
....................................
GENERAL INFORMATION
...........................
Lubrication Diagram
..................................
Sectional View ...........................................
OIL PAN AND OIL SCREEN ..........................
SPECIAL TOOLS ...........................................
SPECIFICATIONS
.........................................
General Specifications
...............................
Sealants and Adhesives
.........................
-__
Service Specifications
...............................
Torque Specifications
................................
TROUBLESHOOTING
...................................
Compression
Too Low
Connecting Rod Noise/Main Bearing Noise
Excessive Engine Rolling and Vibration
Noisy Valves
Oil Pressure Drop
Oil Pressure Too High
Timing Chain Noise
<3.OL>
17
11
11
13
13
13
12
11
20
49
52
30
39
37
43
28
25
22
32
14
2
2
2
16
9
3
3
9
3
7
10
http://vnx.su/
..................................................
56
CYLINDER HEAD GASKET ...........................

72
ENGINE ADJUSTMENT
...............................
65
Compression
Pressure Check ...................
65
Drive Belts Tension Adjustment
................
67
Ignition Timing Inspection and
Adjustment
............................
- __...............
67
Lash Adjuster Check ..................................
67
Manifold Vacuum Inspection
.....................
65
Timing Belt Tension Adjustment
...............
66
ENGINE ASSEMBLY
.....................................
83
Crankshaft, Flywheel and Drive Plate ........ 105
Cylinder Block ............................................
109
92
Cylinder Head and Valve ............................
Oil Pan and Oil Pump .................................
97
Piston and Connecting Rod .......................
100
Rocker Arm and Shaft Assembly
...............
90
Rocker Arms, Rocker Arm Shafts
and Camshaft
............................................
86
ENGINE MOUNTING
....................................
68
ENGINE OIL COOLER ..................................
.llO
GENERAL INFORMATiON
...........................
56
Lubrication Diagram
..................................
56
Sectional View ...........................................
56
OIL PAN AND OIL SCREEN ..........................
69
SPECIAL TOOLS ...........................................
63
SPECIFICATIONS
.........................................
57
...............................
57
............... _._-___..... 63
...............................
57
................................
61
TIMING BELT ................................................
77
9-2
ENGINE
ENGINE <2.6L>
- General Information
<2.6L>
NG3NA-A
GENERAL INFORMATION
;ECTIONAL VIEW
.-
LUBRICATION DIAGRAM
http://vnx.su/
ENGINE <2.6L>
9-3
- Specifications
SPECIFICATIONS
-4
Items
Type
Vumber of cylinders
mm (in.)
3ore
Stroke
mm (in.)
iston displacement
Zompression ratio
Yring order
Jalve timing
intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve
Opens (BBDC)
Closes (ATDC)
Jet valve
Opens (BTDC)
Closes (ABDC)
Specifications
in-line OHC
4
91.1 (3.587)
98.0 (3.858)
2,555 (155.9)
8.7
1-342
cc (cuin.)
25
59
64
20
25
59
Items
Standard value
General
kPa (psi)/rpm
Compression pressure
Pressure difference of all cylinder
kPa (psi)
kPa (in.Hg)
Manifold vacuum
840 (119)/250--400
Less than 100 (14)
67 (20)
Cylinder head
90.0 (3.543)
Overall height
mm (in.)
mm
(in.)
Flatness of gasket surface
Less than 0.05 l.0020)
Flatness of manifold mounting surface
mm (in.)
Less than 0.15 (0059)
Over size rework dimension of valve seat hole
mm (in.)
47.306-47.325 (1.8622-I .8632)
Intake
0.3 (012) O.S.
47.600-47.625 (1.8740-l .8750)
0.6 (024) O.S.
40.300-40.325 (1.5866-l .5876)
Exhaust
0.3 (012) O.S.
40.600-40.625 (1.5984-l .5994)
0.6 (024) O.S.
*Limit must be -0.2 t-.008) combined
Limit
-0.2 (-.008)
0.2 (.008)
0.3(.012)
with amount of grinding of cylinder block gasket surface.
/ TSB Revision
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ENGINE <2.6L>
Items
Standard value
Oversize rework of valve guide hole (both inlet and

mm (in.)
exhaust)
0.05 (002) 0,s.
0.25 LOlO) OS.
0.50 (.OZO)O.S.
mm (in.)
Oversize rework of valve seat height
Intake
0.3 (.012)
0.6 (024)
Exhaust
0.3 (012)
0.6 (024)
Oversize rework of valve guide hole
(both intake and exhaust)
mm (in.)
0.05 (002) O.S.
0.25 (.OlO) 03.
0.50 (.020) 0,s.
riming chain
No. of links
Pitch
mm (in.)
riming chain 9 for silent shaft drive
No. of links
Pitch
mm (in.)
Clearance between chain and chain guide
Camshaft
Cam height
mm (in.)
Intake
Exhaust
Height of fuel pump drive cam
Journal diameter
mm (in.)
Oil clearance
mm (in.)
End play
mm (in.)
?ocker arm
I.D.
mm (in.)
Clearance (Rocker arm-to-shaft)
- Saecifications
-
Limit
13.056-13.068(.5136-5145)
13.250-73.268 (.5217-.5224)
13.500-13.518(.5315-.5422)
7.9-8.1
8.2-6.4
7.9-8.1
8.2-6.4
(.311-.319)
(.323-,331)
(31 l-.319)
(.323-,331)
13.050-13.068(.5138-.5145)
13.250-13.268(.5217-5224)
13.500-13.518 (5315-5322)
102
9.5 (374)
mm (in.)
mm (in.)
mm (in.)
so
8.0 (315)
0.2-0.8(.00&.031)
42.43 (1.6705)
42.43 (1.6705)
37 (1.46)
34 (1.34)
0.05-0.09 (.OO20--0035)
0.1-0.2 (.004-.008)
0.4 (016)
19 (75)
0.01-0.04
0. IO (.0039)
(.0004-.0016)
?ocker arm shaft

O.D.
mm (in.)
78.9(.744)
qocker arm shaft spring

Free length
mm (in.)
Intake
Exhaust
64.5 (2.539)
64.5 (2.539)
1 TSB Revision
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41.93 (1.6508)
41.93 (1.6508)
-~
ENGINE <2.6L>
terns
Standard value
tialve
Valve length
mm (in.)
intake
Exhaust
Stem O.D.
mm (in.)
Intake
Exhaust
Face angle
Thickness of valve head
mm (in.)
(Margin)
Intake
Exhaust
Valve stem to valve guide clearance
Intake
Exhaust
Limit
107.96 (4.2504)
105.86 (4.1677)
7.960-7.975
7.930-7.950
45-4530
(.3134-.3140)
(.3122-.3130)
1.2 (047)
2.0 LO791
0.7 (028)
1.5 i.059)
mm (in.)
0.03-0.06
0.05-0.09
/alve guide
Length
mm (in.)
intake
Exhaust
Service size
mm (in.)
ialve seat
Width of seat contact
Seat angle
- SDecifications
(.OOlZ-.0024)
(.0020-.0035)
0.10 (.0039)
0.15 (.0059)
47 (1.85)
52 (2.05)
0.05 (002). 0.25 LOlO),
0.50 (.020) Oversize
mm (in.)
0.7-I .2 (.028-.047)
45
/alve spring
Free length
mm (in.)
Load
N (Ibs.)
Installed height
mm (in.)
Out of squareness
49.8(1.961)
329 (73) at installed height
40.4(1.591)
Less than 2
let valve
Length
mm (in.)
mm (in.)
Stem O.D.
Seat angle
Valve clearance-Hot engine
mm (in.)
Valve clearance-Cold engine (Reference)
92.53 (3.6429)
4.3 t.169)
45
0.25 (.0098)
0.17(.0067)
mm (in.)
let valve spring

Free length
mm (in.)
Load
N (Ibs.)
Installed height
mm (in.)
Out of squareness
29.60 (1.1654)
35 (7.7) at installed height
21.50 (9465)
Less than 1.5
Cylinder block
Cylinder bore
mm (in.)
Out-of-roundness and taper of cylinder bore
Overall height
mm (in.)
mm (in.)
91 .I (3.587)
Less than 0.02 (0008)
316(12.44)
Less than 0.05 (0020)
mm (in.)
48.8(1.921)
41.4(1.630)
4
*-0.2 (-.008)
0.1 (004)
NOTE
*Limit must be-O.2 (-,008) combined with amount of grinding of cylinder head gasket surface.
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--
*I-L,
-.A,Ld
as-1
9-6
- -
.-
____
ENGINE
-------
<2AL>
--.---
Items
Saecificatiann
-r- -___- --_-__-
Standard value
Right silent shaft

mm (in.)
Front journal diameter
Rear journal diameter
mm (in.)
Oil clearance
mm (in.)
Rear
Front journal diameter
mm (in.)
Rear journal diameter
mm (in.)
Oil clearance
mm (in.)
Front
Rear
Piston
O.D.
mm (in.)
Clearance (piston-to-cylinder)
Ring groove width
mm (in.)
No. 1 and No. 2
Oil
Service size
mm (in.)
mm (in.)
Limit
21 (.83)
43 (I .69)
0.094-0.135(.0037-.0053)
23i.91)
43(1.69)
0.020-0.062
0.094-0.135
(.0008-.0024)
(.0037-.0053)
91 .I (3.587)
0.02-0.04 (.0008-.0016)
1.5 (.059)
4.0(.157)
0.25 (.OlO),0.50 (.020),
0.75 (.030), 1.OO(039) Oversize
Piston ring
Side clearance
mm (in.)
No. 1
No. 2
mm (in.)
End gap
No. 1
No. 2
Oil ring side rail
Service size
mm (in.)
0.05-0.09
0.02-0.06
(.0020:0035)
(.OOOS--0024)
0.12 (0047)
0.10 (.0039)
0.30-0.45 (.Ol IS-.0777)

0.8 (031)
0.25-0.40 (.0098-.0157)
0.8(.031)
0.30-0.80 (01 l&.0315)
1 .o (039)
0.25 (.OlO),0.50 (.020).
0.75 (030). 1.OO(039) Oversize
--
Connecting rod
mm (in.)
Bend
Twist
mm (in.)
Connecting rod big end to crankshaft
side clearance
mm (in.)
Piston pin press-in load
N (Ibs.)
Connecting rod bearing
Oil clearance
mm (in.)
Service size
mm (in.)
-.
Crankshaft main bearing
Oil clearance
mm (in.)
Service size
mm (in.)
0.05(.0020) or less
0.10 (.0039) or less
0.10-0.25 (.0039-.009B)
7.500-17.500
0.4(.016)
(1.653-3.858)
0.019-0.056 (.0007-.0822)
0.25 (.OlO). 0.50 (020).
0.75 (.030) Undersize
0.1 1.004)
0.021-0.046(.0008-.oDlS)
0.25 (.OlO). 0.50 (.020).
0.1 (004)
( TSB Revision
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ENGINE <2.6L>
Items
Crankshaft
Pin O.D.
mm (in.)
Journal O.D.
mm (in.)
Out-of-roundness of journal and pin
mm (in.)
Taper of journal and pin
mm (in.)
End play
mm (in.)
Undersize rework dimension of pin
mm (in.)
0.25 (.OlO) U.S.
0.50 (020) U.S.
0.75 (030) U.S.
Undersize rework dimension of journal
mm (in.)
0.25 (.OlO) U.S.
0.50 (020) U.S.
0.75 (030) U.S.
$vvheel
Runout
Standard value
Limit
53 (2.09)
60 (2.36)
0.015 (0006) or less
0.005 (0002) or less
0.05-0.18(.0020-.0071)
0.4 (016)
52.735-52.750 (2.0762-2.0768)
52.465-52.500 (2.0663-2.0669)
52.235-52.250 (2.0565-2.0571)
59.735-59.750 (2.3516-2.3524)
59.465-59.500 (2.3419-2.3425)
59.235-59.250 (2.3321-2.3327)
mm (in.)
0.13 (0051) or less
Iii pressure at curb idle speed [conditions: oil

emperature is 75-9oC (167-I 94F)J
kPa (psi)
Iii pump
Driven gear
Tip clearance
Side clearance
Drive gear
Tip clearance
Side clearance
9-7
- SDecifications
80 (11.4) or more
mm (in.)
mm (in.)
0.1 l-0.15 (.0043-.0059)

0.04-0.10 (.0016-.0039)
0.20 (.0079)
0.15 (.0059)
mm (in.)
mm (in.)
0.1 l-0.15 (.0043--0059)

0.05411
(.0020-.0043)
0.20 (.0079)
0.15 (.0059)
jelief spring
Free height
mm (in.)
Load
N (Ibs.) [at 40.1 mm (1.579 in.)]
46.6(1.835)
61 (13)
NOTE
O.D. = Outer Diameter
I.D. = Inner Diameter
OS. = Oversize Diameter
U.S. = Undersize Diameter
TORQUE SPECIFICATIONS
Items
Nm
ftlbs.
90-100
100-l 10
15-22
19-21
20-27
50-60
5-7
18-22
65-72
73-79
11-15
14-15
15-19
37-43
4-5
13-15
Rocker arm adjusting nuts for jet valve

Main bearing cap bolts
8-10
75-85
6-7
55-61
Connecting
45-48
33-34
Cylinder head bolts-Cold engine

Cylinder head bolts-Hot engine
Cylinder head bolts (M8 bolt)
Camshaft bearing cap bolts (M8X70 bolt)
(M8X25 bolt)
Camshaft sprocket bolts
Rocker cover bolts
Jet valve assembly
rod cap nuts
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9-8
ENGINE <2.6L>
Specifications
Items
Crankshaft pulley bolts
Oil pump driven gear bolt
Silent shaft sprocket bolt
Silent shaft chamber cover bolts
Flywheef bolts
Engine support brackets bolts
Chain guide B bolt (Upper)
Chain guide B bolt (Lower)
Oil pump cover bolt
Oil pump body screw
Oil pump assembly mounting bolt
Thrust plate bolt
Oil pan bolt
Oil pan drain plug
Oil screen bolt
Oil relief valve plug
Oil pressure switch
Exhaust manifold to front exhaust pipe
Engine mounting front insulator to frame
Engine to engine mounting front insulator
No. 2 crossmember to frame
Plate to body
Plate to transfer mounting insulator
Transfer mounting insulator to transfer mounting bracket
Transfer mounting bracket to transfer
No. 2 crossmember to engine mounting rear insulator
Engine mounting rear insulatorto engine
Rear engine support member to No. 2 crossmember
Power steering oil pump to pump bracket
Power steering breather pipe
Front insulator stopper to heat protector
Chain guide access hole cover bolt
Timing chain case bolt
Chain guide A bolt
Chain guide C bolt
Oil filter
j TSB Revision
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Nm
ft.lbs.
110-130
60-70
60-70
5-7
130-140
50-60
&IO
15-22
IO-12
8-10
IO-12
IO-12
6-8
35-45
15-22
30-45
15-22
20-30
30-40
13-20
55-75
18-25
18-25
16-25
18-25
18-25
18-25
18-25
25-33
8-12
6-10
IO-12
12-15
IO-12
IO-12
11-12
80-94
44-50
44-50
4-5
94-101
374
6-7
11-15
7-9
6-7
7-9
7-9
4-6
26-32
11-15
22-32
11-15
14-22
22-29
9-15
40-54
13-18
13-18
13-18
13-18
13-18
13-18
13-18
18-24
6-9
4-7
7-9
9-l I
7-9
7-9
8-9
ENGINE <2.6L>
Specifications
/ Special
Tools
SEALANTS AND ADHESIVES

Items
Specified sealants and adhesives
Semi-circular packing
Oil pressure switch
Contact surface between cylinder block
and chain case
Oil pan gasket
3M ART Part No. 8660 or equivalent

As required
As required
MITSUBISHI GENUINE Part

No. MZ100168or equivalent
As required
SPECIAL TOOLS
removed or installed
Use with MIT304204
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ENGINE
<2.6L>
- Special Tools /Troubleshooting
TROUBLESHOOT1NG
Symptom
Compression
too low
Probable cause
Remedy
Cylinder head gasket blown
Replace gasket
Piston ring worn or damage
Replace rings
Piston or cylinder worn
Repair or replace piston and/or cylinder

block
Valve seatworn
Oil pressure drop
or damage
Repair orreplace valve and/&-seat
Engine oil level too low
Check engine oil level
Oil pressure switch faulty

Oil filter clogged
Replace oil pressure switch

.~.
Install new filter
Oil pump gears or body worn
Replacegears
Thin or diluted engine oil
Change engine oil correct viscosity
Oil relief valve stuck (opened)

-Excessive bearing clearance
Repair relief valve
/ TSB Revision
and/or body
Replace bearings
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ring
-.
ENGINE <2.6L>
- Troubleshooting/Engine
9-11
Adjustment
Symptom
Probable cause
Remedy
Oil pressure too high
Oil relief valve stuck (closed)
Repair relief valve
Noisy valves
Incorrect auto-lash adjuster
Replace auto-lash adjuster
Thin or diluted engine oil (low oil pressure)
Change engine oil
Valve stem or valve guide worn or damage
Replace valve and/or guide
lnsuff icient oil supply
Check engine oil level
Low oil pressure
Refer to Oil pressure drop
Thin or diluted engine oil
Change engine oil
Excessive bearina clearance
Reolace bearinas
Connecting rod noise/

main bearing noise
1 Timing chain noise

Excessive engine rolling
and vibration
1 Loose timing chain
1 Replace timing chain and/or sprockets
Loose No. 2 member
/ Retighten
Broken mount insulator
Replace
ENGINE ADJUSTMENT
SILENT SHAFT
JUSTMENT
Chain guide B
bolt B
DRIVE CHAIN
TENSION
ADNo9A4
When a loose silent shaft drive chain is suspected

as the probable cause of abnormal
noise, the tension must be readjusted.
Tension of silent shaft drive chain can be adjusted
without removing timing chain cover as follows:
(1) Remove cover from access hole provided at center of chain
case (underwater
pump).
(2) Loosen special bolt B.
(3) Using your finger push projection on chain guide OB in
direction
of arrow.
Do not push projection
with a
screwdriver
or other tool. Improperly
chain tension will
cause abnormal noise.
(4) Tighten special bolt B.
(5) Install cover. Do not reuse damaged gasket.
Cover bolt tightening
torque:
10-12 Nm (7-9 ft.lbs.1
Projection
5ENOO7
COMPRESSION PRESSURE CHECK
NWFFAE
(1) Before checking compression,

ensure that engine oil, the
starter motor, and battery are all in normal operating condition.
(2) Start the engine and wait until engine coolant temperature
has risen to 85-95C (185-205F).
(3) Stop the engine and pull the spark plug cables.
(4) Remove the spark plugs.
(5) Crank the enigne to remove any foreign objects in the
cylinders.
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9-12
ENGINE <2.6L>
Engine
Adjustment
Caution
Cover the spark plug boles with shop towel,
etc., in
order to keep expelled foreign objects from flying out,
and keep away from the holes. When
measuring
compression
with water, oil, or fuel having entered the
cylinder through a crack, etc., these will come flying out
of the spark plug hole hot and fast, so to sure to take
the proper precautions.
(6) Set the compression
gauge to the spark plug hole.
(7) Holding the throttle valve full open, crank the engine and
measure compression.
Limit
: 640 kPa (119 psi) 1256-400
rpml
(8) Perform (6) and (7) above for all the cylinders, ensuring
that compression
pressure differential
for each of the
cylinders is within the specified
limit.
Limit
: Less than
100 kPa (14 psi)
(9) If a cylinders compression

or pressure differential exceeds
the limit, add a small amount of oil through the spark plug
hole and repeat steps (6) to (8).
0 If the addition of oil brings compression
up, it is possible that there is harmful friction between the piston ring
and cylinder wall.
0 If not compression
up, valve seizure,
poor valve
seating, or a compression
leak from the gasket are all
possible.
MANIFOLD VACUUM INSPECTION

(1) Before inspection,
put the vehicle into the following cty
tion.
e Engine coolant temperature
: 85-95C (185205F)
l
Lights, motor cooling fan, and accessories : OFF
e Transmission
: Neutral
e Steering wheel : Straight forward position
(2) Connect a tachometer.
(3) Disconnect
the ventilation
hose from
the positive
crankcase ventilation valve, and then connect the hose to a
vacuum gauge.
(4) Start the engine and check that idle speed is within
standard value range. Read off the vacuum gauge.
Standard
1 TSB Revision
value : 67 kPa (20 in.Hg)
http://vnx.su/
the
ENGINE <2.6L>
Engine
(5) If not at standard

and repair.
Symptom
9-13
Adjustment
value, refer to following
Cause
chart for cause
Remedy
The vacuum gauge reading is less than

standard value, but the needle is
stable.
Ignition timing is retarded.
Adjust the ignition timing.
The vacuum gauge needle swings

slowly.
The gas mixture is excessively

rich.
Check carburetor.
The vacuum gauge needle drops

irregularly.

lean.
Check carburetor.
The vacuum gauge needle drops

intermittently to 4.0 to 21.3 kPa (1.2 to
6.3 in. Hg).
- Incomplete close contact of

intake and exhaust valve seats.
Check and repair the valve.
The vacuum gauge needle drops suddenly from the normal reading to 33.3
kPa (9.8 in.Hg). then returns to normal.
Replace cylinder head gasket.
Malfunction
gasket
of cylinder head
DRIVE BELTS TENSlON ADJUSTMENT
NOSFMBDD
TENSION
BELT
DRIVE
ADJUSTMENT
OF THE
ALTERNATOR
to GROUP 0 - Maintenance
Service.
DEFLECTION
ADJUSTMENT
OF POWER STEERING
OIL
PUMP DRIVE BELT
Procedures.
TENSION ADJUSTMENT
OF THE AIR CONDITIONER
COMPRESSOR DRIVE BELT
Procedures.
Refer
IGNITION TIMING INSPECTION AND ADJUSTNWFIABO

MENT
Refer to GROUP
8 - Ignition
system.
LASH ADJUSTER CHECK

If an abnormal
(tappets),
check
noise
is heard
No9FE4h
from
the
lash
adjusters
as follows.
(1) While installed to the cylinder head, press the part where
the rocker arm contacts the lash adjuster at the very top. If
the adjuster is normal, the part pressed will feel very hard.
(2) If it easily moves all the way downward
when pressed..
there is a malfunction
of the lash adjuster and it should be
replaced with a new one.
(3) If it feels spongy or elastic, probably oil with air mixed in it
has entered the lash adjuster, so follow the steps below:
( TSB Revision
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-.L-
-_
;~
9-14
._
ENGINE
<2&L>
- Engine Adjustment
/ Engine Mounting
a Check whether
0
the amount of oil is too much or is not

enough.
Check whether the cause of air becoming
mixed into
the oil is a damaged
oil screen or oil screen gasket.
After repairing the cause of the air leak. warm up the
engine and then drive the vehicle at low speed for a
while.
Stop the engine and leave it off for a few minutes;
then restart the engine and drive at low speed. Repeat
this procedure
several times during the course of
about one hour so as to remove the air from the oil.
ENGINE MOUNTING
REMOVAL
AND
INSTALLATION
W9GA-A
Pre-removal
Operation
e Removal of the Air Cleaner (Refer
to GROUP 11 - Air Cleaner.)
e Removal of the Hood (Refer to
GROUP 23 - Hood.)
o Removal of the Under Skid Plate,
Undercover
and Transfer Case Protector (Refer to GROUP 23 - Under
Cover.)
610
Post-installation
Operation
l
installation
of the Under Skid
Undercover
and Transfer Case
tector (Refer to GROUP 23 Cover.)
l
installation
of the Air Cleaner
l
Installation
of the Hood (Refer
GROUP 23 - Hood.)
Nm
Removal
steps
++ WI
1. Heat protector
2. Front insulator stopper
3. Engine mounting front insulator
4. Plate
5. Transfer mounting
6. Transfer mounting
insulator
bracket
2 crossmember
8. Engine mounting
rear insulator
7. No.
//---
55-75
40-54
NOTE
(I)
(2)
(3)
Reverse the removal procedures

++
: Refer to Service Points
H
to reinstall,
of Removal.
of Installation.
/ TSB Revision
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1:
Nm
ft.lbs.
mws?3
Plate,
ProUnder
(Refer
to
ENGINE <2.6L>
9-15
- Engine Mounting
NOSBBAm
SERVICE POINTS OF REMOVAL
3. REMOVAL OF ENGINE MOUNTING FRONT INSULATOR
(I) Attach a chain to the engine hangers.
(2) Using a chain block-and-tackle,
hang the engine slightly up so that the insulator is free of engine weight.
(3) Remove the engine mounting
front insulator.
Caution
Avoid
applying
hoses and cables
(27.91)
ew
I
a strain on the radiator

by raising the engine
and fuel
too high.
NWGCAE
INSPECTION
708.8
l
l
mm (in.)
Check the
Check the
Check the
corrosion.
Check the
Check the
sion.
insulators for cracks, separation or deformation.

front insulator stoppers for deformation.
transfer mounting
bracket for deformation
or
plate for deformation
or corrosion.
No. 2 crossmember
for deformation
or corro-
OlW504

3.
INSTALLATION
OF ENGINE
LATOR
Make sure that the locating
ment.
Caution
Do not distort
portions
with
/ TSB Revision
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MOUNTING
NWGOAR
FRONT INSU-
boss and hole are in align-
rubber portions,
fuel or oil.
and never
stain
rubber
4=%-
ad.I?
9-16
ENGINE <2.6L>
.-
- Oil Pan and Oil Screen
OIL PAN AND OIL SCREEN

REMOVAL AND INSTALLATION
Removal
steps
1. Drain plug
2. Drain
I)+
plug
gasket
3. Oil pan
4. Oil pan gasket
5. Oil screen
3545
26-32
6. Oil screen gasket
Nm
ft.lbs.
NOTE
(2) ++
(3) a:
: Refer to Service
Non-reusable
parts
Points
6-8 Nm
4-6 ft.lbs
of Installation.
MS-
INSPECTION
*
l
l
Timing chain case

I
$$der
Check the oil pan for cracks.

Check the oil pan fitting
surface for damage and deformation.
Check the oil screen for cracked, clogged or damaged wire
net and pipe.
4.
INSTALLATION
OF OIL PAN GASKET
Apply a coating of the specified sealant (where shown in
the figure) to the lower surface (the surface where the oil
pan is installed) of the cylinder block.
Specifiedsealant
DEN04
NOSIUIAH
Oil seal cast
: MITSUBISHI
GENUINE
M2100168 or equivalent
\ TSB Revision
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Part
No.
ENGINE <2.6L>
CYLINDER
- Cylinder
9-17
Head Gasket
HEAD GASKET
tm9.m-*

Pre-removal
Operation
Removal of the Air Cleaner (Refer

l
Removal of the Hood (Refer to
GROUP 23 - Hood.)
0 Removal of the Under Skid Plate,
l
Undercover
and Transfer
Case Pro-
tector (Refer to GROUP 23 - Under

Cover.!
Post-installation
Operation
0 Installation of the Under Skid Plate,

Undercover and Transfer Case Protector (Refer to GROUP 23 - Under
l
Installation of the Air Cleaner (Refer
100-110
Nm
72-80 ft.lbs.
Removal
steps
1. Connection for accelerator cable
2. Radiator upper hose
3. Breather hose
4. P.C.V hose
5. Connection for oxygen sensor connector
I)+
6. Air-conditioner
drive belt
7. Connection for power steering breather
pipe
8. Spark plug cable
9. Connection for high tension cable
IO. Self locking nut
11. Connection for front exhaust pipe
12. Gasket
l + 13. Rocker cover assembly
14. Rocker cover gasket
Fixing to No. 1 cylinder TDC
*I)
l + 15. Distributor
+e l + 16. Camshaft sprocket bolt
l e I)+ 17. Cylinder head assembly
I)+ 18. Cylinder head gasket
M-22
lS---?=m
NOTE

(2) l + : Refer to Service Points of Removal.
(3) l I : Refer to Service Points of Installation.
(4)
: Non-reusable
ft.lbs.
parts
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OlW635
9-18
ENGINE <2.6L>
- Cvlinder Head Gasket

.
NQ9JaAM
FIXING TO NO. 1 CYLINDER

TDC
Turn the crankshaft.
Check to be sure that the camshaft
sprockets timing mark and the timing chains timing mark
(shiny white leaf plate) are aligned.
16. REMOVAL
OF CAMSHAFT
SPROCKET BOLT
Pull the camshaft
sprocket
(with the timing chain attached) out from the camshaft, and place it on top of the
camshaft
sprocket
holder.
Caution
1. The crankshaft
must not be rotated after the camshaft sprocket
is pulled out from the camshaft.
2. Be careful not to allow the timing chain to come off
from the camshaft
sprocket.
Front of engine
17. REMOVAL
OF CYLINDER
HEAD ASSEMBLY
(1) Disconnect
the fuel hose, vacuum hose and wiring
harness connected to the intake manifold and carburetor.
Refer to GROUP 11 - Intake Manifold and GROUP 14 Carburetor.
(2) Loosen the bolts (in the order indicated in the figure) in
2 or 3 steps, and remove from the cylinder head.
NWJDCI
18. INSTALLATION
OF CYLINDER
HEAD GASKET
Before cylinder head gasket is installed, apply specified
sealant to top surface of each butt joint between cylinder
block and timing chain case.
Specified
sealant:
Caution
Be careful not to allow
the cylinder block.
c1
Front of engine
sealant
to enter
the oil hole in
17. INSTALLATION
OF CYLINDER
HEAD ASSEMBLY
(1) Tighten the bolts (in the order indicated in the figure) in
2 or 3 steps, and finally tighten them at the specified
torque.
(2) Connect
the fuel hose, vacuum
hose and wiring
harness connected to the intake manifold and-carbure-,
tor.
Refer to GROUP 11 - Intake Manifold and GROUP 14 Carburetor.
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_
_
_
;
ENGINE
<2.6L>
- Cylinder
9-19
Head Gasket
16. INSTALLATION
OF CAMSHAFT
SPROCKET BOLT
install the camshaft sprocket to the camshaft. Check to be
sure that the timing chains timing mark and the camshaft
sprockets
timing mark are aligned.
15. INSTALLATION
OF DISTRIBUTOR
Refer to GROUP 8 - Ignition System.
13. INSTALLATION
OF ROCKER COVER ASSEMBLY
Apply a coating of the specified sealant to the semicircular
packing and the cylinder head top surfaces,
and then
tighten the rocker cover assembly at the specified torque.
Specified
sealant:
Caution
If they are overtorqued,
leakage could result.
6.
INSTALLATION
a deformed
OF AIR-CONDITIONER
rocker
cover
DRIVE
Adjustment
of drive belt tension for air-conditioner.
to GROUP 24 - Service Adjustment
Procedures.)
1. ADJUSTMENT
OF ACCELERATOR
CABLE
Refer to GROUP 14 - Engine Control.
1 TSB Revision
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or oil
BELT
(Refer
; :
fi
- ..:.*.- Iwzilj
_&
r:;
9-20
i_y_
_,
,,- _ )
ENGINE <2.6L>
- Engine Assembly
ENGINE ASSEMBLY
hw6A-A

We-removal
l
l
l
Operation
Post-installation

GROUP 23 - Hood.)
Removal of the Air Cleaner (Refer
Under Cover, Under Skid Plate,
Transfer Case Protector (Refer to
GROUP 23 - Under Cover.)
Removal of the Transmission Assembly (Refer to GROUP 21 Transmission Assembly.)
Removal of the Radiator (Refer to
GROUP 7 - Radiator.)
Operation
installation of the Radiator (Refer to

GROUP 7 - Radiator.)
Installation of the Transmission Assembly (Refer to GROUP 21 Transmission Assembly.)
Installation of the Undercover, Under Skid Plate, Transfer Case Protector (Refer to GROUP 23 - Under
Cover.)
Installation of the Air Cleaner (Refer
Installation of the Hood (Refer to
GROUP 23 - Hood.)
l
l
l
l
2
3
6,
Removal
++
steps
1.
2.
3.
4.
5.
6.
7.
8.
Accelerator cable
Heater hose
Brake booster vacuum hose
Water by-pass hose
Water hose
Radiator upper hose
Control harness
nector (Vehicles with an air
9. Engine coolant temperature
nector
10. Vacuum hose
Il. Engine coolant temperature
connector
++
4*
.d
+*
switch conconditioner)
sensor congauge unit
13.
14.
15.
16.
17.
18.
19.
20.
Oxygen sensor connector

Oil pressure gauge unit connector
Drive- belt (power steering)
Power steering oil pump
Drive belt (air conditioner compressor)
Air conditioner compressor
Fuel hose
Alternator connector
21. Ground cable
22. Fronfexhaust
pipe
NOTE
(2) q~* : Refer to Service Points of Removal.
(3) ++ : Refer to Service Points of Installation.
(4) q : Non-reusable parts.
http://vnx.su/
9-21
ENGINE <2.6L> - Engine Assembly
S-10
Nm
4-7 ft.lbs.
24
/
26
I
steps
23. Fuel hose clamp
24. Heat protector
25. Engine mounting
ing bolt
+* l + 26. Engine assembly
23
Removal
front insulator attach-
NOTE
(1) Reverse the removal procedui ss to reinstall.
(2) +*
: Refer to Service Poin ts of Removal.
(3) l + : Refer to Service Poin ts of Installation.
OlW636
ta9seDH
16. REMOVAL
OF POWER STEERING
OIL PUMP/IS.
AIR
CONDITIONER
COMPRESSOR
Remove the oil pump and air conditioner
compressor
(with the hose attached).
NOTE
Suspend the removed oil pump (by using wire or similar
material) at a place where no damage will be caused
during removal/installation
of the engine assembly.
26. REMOVAL
OF ENGINE ASSEMBLY
(1) Check to be sure that all cables, hoses, harness
connectors,
etc. are disconnected
from the engine.
(2) Lift the chain block slowly to remove the engine
assembly
upward from the engine compartment.
NoaSD*o
26. INSTALLATION
OF ENGINE ASSEMBLY
Install the engine assembly.
When doing so, check
carefully to be sure that all pipes and hoses are connected, and that none are twisted,
damaged,
etc.
17. INSTALLATION
OF DRIVE BELT (AIR CONDITIONER
COMPRESSOR)
Adjust
belt tension.
(Refer to GROUP 24 - Service
Adjustment
Procedures.)
15. INSTALLATION
OF DRIVE BELT (POWER STEERING)
Adjust
belt tension.
Adjustment
Procedures.)
1. ADJUSTMENT
OF ACCELERATOR
CABLE
Refer to GROUP
1 TSB Revision
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14 - Engine
Control.
9-22
ENGINE <2.6L>
- Engine Assembly
DISASSEMBLY AND REASSEMBLY (TIMING CHAIN TRAIN)
W-12 Nm
7-9 ft.lbs.
n12-15
an sbNm
Lj.
-
-I
l&13,,
,,,,
SO-94 ft.lbs.
Disassembly steps
1. Special washer
2. Crankshaft pulley
3. Timing chain case
4. Chain case gasket
5. Chain guide access hole cover
6. Chain guide access hole gasket
7. Oil seal
8. Chain guide B
9. Chain guide A
10. Chain guide C
11. Chain B
12. Crankshaft sprocket B
13. Oil pump sprocket
14. Left silent shaft sprocket
15. Spacer
16. Distributor gear
17. Spring pin
18. Timing chain
4I)
19. Camshaft sprocket
4*
20. Crankshaft sprocket
4+
21. Tension sleeve
22. Rubber sheet
23. Tensioner spring
24. Loose side chain guide
25. Tension side chain guide
26. Sprocket holder
/ TSB Revision
Reassembly
26
25.
24.
()+ 23.
++ 22.
+a~ 21.
20.
19.
+a 18.
17.
16.
15
e+ 14.
13.
+4 12.
l)+ 11.
IO.
9.
8.
+*
7.
6.
5.
4.
1)*
3.
2.
1.
steps
Sprocket holder
Tension side chain guide
Loose side chain guide
Tensioner spring
Rubber sheet
Tension sleeve
Crankshaft sprocket
Camshaft sprocket
Timing chain
Spring pin
Distributor gear
Spacer
Left silent shaft sprocket
Oil pump sprocket
Crankshaft sprocket 8
Chain B
Chain guide C
Chain guide A
Chain guide B
Oil seal
Chain guide access hole gasket
Chain guide access hole cover
Chain case gasket
Thing
chain case
Crankshaft pulley
Special washer
NOTE
(1) ++ : Refer to Service Points of Disassembly.
(2) l + : Refer to Service Points of Reassembly.
(3) q : Non-reusable pans
http://vnx.su/
ENGINE <2.6L>
Engine
9-23
Assembly
SERVICE POINTS OF DISASSEMBLY

18. REMOVAL OF TIMING
Er/ZO. CRANKSHAFT
CHAIN/IS.
CAMSHAFT
SPROCKET
Remove the timing chain combined

et and crankshaft
sprocket.
with camshaft
Camshaft
[
spmcket +
@-Plated
link
SPROCKsprock-
NOSWCAA
INSPECTION
l
riimwm
Check the timing chain for roller play, wear, damage or

disconnected
links.
Replace if necessary.
Check the tensioner and chain guide rubber shoe for wear
or damage.
SERVICE POINTS OF REASSEMBLY
NOSWHAA
23. INSTALLATION
OF TENSIONER
SPRING/22.
RUBBER
SHEET/Zl.
TENSIONER
SLEEVE
Install tensioner
spring, sleeve and rubber sheet to oil
w-w.
18. INSTALLATION
OF TIMING
CHAIN
(1) Turn crankshaft until piston of No. 1 cylinder is at top
dead center.
(2) Line up plated links of timing chain and timing marks
on sprockets
as chain and sprockets are assembled.
(3) While sliding crankshaft
sprocket
onto crankshaft,
install chain and sprocket. Place camshaft sprocket on
sprocket
holder.
Sprocket holder
SENOO2 ]
-
Engine
front
When symcket
is installed to oil
pump drive gear
Right side
C=
Engine
front
14. INSTALLATION
OF
(1) Assemble
silent
sure that timing
links.
(2) Use care not to
they are installed
LEFT SILENT SHAFT SPROCKET

shaft sprockets
to chain B. Make
marks are in alignment
with plated
confuse right and left sprockets,
in opposite directions.
as
&en sprocket
is installed to
left silent shaft
Left side 5ENMU
12. INSTALLATION
Install crankshaft
crankshaft.
Engine
front
Crankshaft sprocket B
Crankshaft sphcket
[ 5E/,,,c3
) TSB Revision
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OF CRANKSHAFT
sprocket
SPROCKET
B (for driving silent shafts) on
8,
a:
1
5
-1
^ ._...
_,,_
9-24
ENGINE
<2.6L>
- Engine Assembly
pt,
EZI
x.
11. INSTALLATION
OF CHAIN B
(1) Holding assembled
sprockets
and chain B, align
timing mark on crankshaft sprocket B with that on
chain B, and install sprockets to oil pump drive gear
and left silent shaft. Partially tighten bolt.
Chain guide B
Special bolt A
!%ctionY-Y
~_
I._r ~~
f$g m-5
mm-:.
Special bolt B
zT:g
Oil pump body
E Tiz
-A--.~
5
a
Plated
Y,\
S
Ti
t-r
Plated
link
Chain guide
C
Crankshaft
sprocket 8
SENOO!5
(2) Rotate-both
silent sh$t sprockets slightly to position
chain slack at point P.
(3) Adjust position of chain guide B so that when chain
is pulled in direction of arrow with finger tips, clearance between chain guide B and links of chain B.
0.2-0.8 mm
(.OOE-,031 in.)
Chain guide B
Sec%ionP-P
Specialbolt
Chain and chain guide 5 gap

Standard
value : 0.2-0.8 mm
(.008-.031
in.)
5ENoat
--
7.
INSTALLATIONS
OF OIL SEAL
Using special tool, install the oil seal.
3.
INSTALLATION
OF TIMING CHAIN CASE
(1) Clean the gasket surfaces of chain case and cylinder
block.
(2) Install the chain case: gaskets and chain case to the
cylinder block.
MB99093801
Oil seal
\
M,D99837&01
Timing chain case
5~~14
/
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levision
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ENGINE
DISASSEMBLY
CAMSHAFT)
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
l * 10.
*I, I)* 11.
12.
w+ 13.
++ 14.
AND
<2.6L>
REASSEMBLY
9-25
- Engine Assemblv
(ROCKER
steps
Breather hose
Pipe
Oil seal
P.C.V. hose
P.C.V. valve
Oil filler cap
Packing
Rocker cover
Rocker cover gasket
Rocker arm and shaft assembly
Auto-lash adjuster
Camshaft
Circular packing
NOTE
(1) Reverse the disassemblv orocedures to reass
i2j +e : Refer to Service Points of Disassembly.
(3) ++ : Refer to Service Points of Reassembly.
(4) q
: Non-reusable parts
I
TSB Revision
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ARMS,
ROCKER
ARM
SHAFTS
AND
NOSE-A
9-26
ENGINE <2.6L>
Engine
Assembly

M?998443-01
NWLRX
11. REMOVAL
OF ROCKER ARM AND SHAFT ASSEMBLY
Before removing the rocker arm and shaft assembly, use
the special tool to ensure that the auto-lash
adjuster
doesnt fall out.
Caution
Put the rocker arms and auto-lash
adjuster in order in
cylinder
No. separated
places with clear distinction
between
the intake
and exhaust
ones to prevent
confusion.
SENm
INSPECTION
.
CAMSHAFT
(1) Check camshaft journals for wear or damage. Replace
if necessary.
If journals are damaged,
also inspect
camshaft
bearings for wear or damage. If camshaft
bearing is badly worn, replace cylinder head.
(2) Check the fuel pump drive cam for wear or damage.
Camshaft
Standard
value
Height of fuel pump drive cam: 37 mm (1.46
in.)
Journal diameter:
34 mm (1.34 in.)
Oil clearance:
0.05-0.09
mm (.0020-.0035
in.)
(3) Check the cam surfacafor
abnormal wear or damage,
replace the part if required. Measure cam height (i.e.,
its diameter),
replace the cam if outside of the limit.
Cam
height
Standard
value
Intake: 42.43 mm (1.6705 in.)
Exhaust: 42.43 mm (1.6705 in.)
Limit
Intake: 41.93 mm (1.6508 in.)
Exhaust:
41.93 mm (1.6508 in.)
End play
Standard
value: 0.1-6.2 mm (.004-.OOS
Limit: 0.4 mm (.016 in.)
Camshaft
Engine
c
Rear bearina ceo

ular backing
front
Make surfaces flush
NWLGCS
14. INSTALLATION
OF CIRCULAR
PACKING
(1) Set circular packing on cylinder head as illustrated.
(2) install the cam cap, rocker arm and shaft assembly.
13. INSTALLATION
OF CAMSHAFT
Apply engine oil to the journals of camshaft
cylinder head.
CGlinder head
5EN17:
/
in.)
<
svision
http://vnx.su/
and install it to
ENGINE <2.6L>
Engine
Assembly
9-27
i 1. INSThATlON
OF ROCKER ARM AND SHAFT ASSEMBLY
(I) Insert the auto-lash adjuster from below as illustrated,
being careful not to spill the diesel oil inside it. Then
use the special tool to prevent adjuster from falling
while installing it.
(2) Place the rocker arm and shaft assembly
on the
cylinder head and tighten the bearing cap bolt.
(3) Remove the special tool.
MD99944301
6EN248
IO. APPLY SEALANT

TO SEMI-CIRCULAR
PACKING
Apply specified sealant to portions indicated in illustration.
Specified sealant:
3M ART Pat-t No. 8660 or equivalent
TSB Revision
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ENGINE <2.6L>
- Engine Assembly
IVD~NE~
DISASSEMBLY AND REASSEMBLY (ROCKER ARM AND SHAFT ASSEMBLY)
Disassembly
1.
2.
3.
4.
,+ 5.
6.
7.
8.
++ 9.
10.
11.
12.
+*13.
5ENCCQO
6-7 ft.lbs.
16
steps
Rear bearing cap

Rocker arm C
Rocker arm A
Rocker shaft spring
Bearing cap No.4
Rocker arm C
Rocker arm A
Rocker shaft spring
Bearing cap No.3
Rocker arm C
Rocker arm A
Rocker shaft spring
Bearing cap No.2
14.
15.
+a 16.
# 17.
++18.
**lg.
20.
21.
Rocker arm C
Rocker arm A
Wave washer
Right rocker arm shaft
Left rocker arm shaft
Front bearing cap
Nut
Adjusting screw
NOTE
(1) Reverse the disassembly procedures to reassemble.
(2) +* : Refer to Service Points of Reassembly.
INSPkTION
.
(pqy@
-1
ROCKER ARM
(1) Check rocker arms for wear or damage. Replace if necessary.
(2) Check to ensure that oil holes are clear.
Oil hole
BEN364
DSB
Revision
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1-
ENGINE <2.6L>
.
Oil holes
9-29
- Engine Assembly
ROCKER ARM SHAFT

(1) Check rocker arm mounting portions of rocker arm shaft
for wear or damage. Replace as necessan/.
5ENO53
Front
19. INSTALLATION
OF FRONT BEARING
GAP/18.
LEFT
ROCKER ARM SHAFT/17.
RIGHT ROCKER ARM SHAFT
(1) Insert the left and right rocker shafts into the front bearing
cap. The rear end of left (intake) rocker arm shaft has a
notch.
(2) Align the mating mark of the rocker arm shaft front end to
the mating mark of the front bearing cap. Then insert the
bolts to hold shafts in bearing cap.
Rocker arm shaft. left

for intake
Notch
5ENOT 7
Mating marks
[3 mm (.I2 in.) dia. hole]
(3) Assemble the rocker arm shaft so that the alignment mark
at the front end matches the alignment mark of the front
bearing cap.
Mating marks
.
12 mm LO8 in.) dia. embossing]
5ENOl
16. INSTALLATION
OF WAVE WASHER
Install the waved washer in the direction
illustration.
Rocker arm
Tir$g
NOSNHCA
chain e
shown
in the
t
Fmnt bearing cap
5ENo71
Timing chain side
Rocker cover installation
bolt
I
1
Identification
mark
Rocker cover install&on
X3./9./5.
INSTALLATION
OF BEARING CAP
Caps 2. 3 and 4 are of similar shape and require attention
the cap number during assembly.
bolt hole
I
5EN215 I
pSB
Revision
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to
9-30
ENGINE <2.6L>
- Engine Assembly
DISASSEMBLY AND REASSEMBLY (CYLINDER HEAD)

Cold engine
W-100 Nm
65-72
klbs.
Disassembly steps
+I) l + 1. Cylinder
head
+e
2. Bolt
3. Cylinder
l + 4. Cylinder
bolt
++
head
head
gasket
NOTE
(1) Reverse the disassembly
procedures
to reassemble.
(2) 41) : Refer to Service Points of Disassembly.
(31 IM
: Refer to Service Points of Reassembly.
(4) q : Non-reusable
parts

1.
Q
Timing chain side
REMOVAL
Remove
OF CYLINDER
cylinder
HEAD
BOLT/Z.
head bolts in sequence
NOOOFAC
BOLT
shown
in illustra-
tion.
5EN015
.
p5ic
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ENGINE <2.6L>
9-31
- Engine Assembly
NO9OH.U
INSPECTION
CYLINDER HEAD
(I) Before washing, check the cylinder head for water or
gas leakage, damage or cracks.
(2) Completely
remove oil, deposits, sealing agent, carbon, etc. After washing the oil passages,
blow air
through them to check that they are not clogged.
(3) Using a straight edge and feeler gauge, measure the
warpage on the A thru G areas as shown in the figure.
Standard value : Less than

Limit : 0.2 mm (.OOS in.)
0.05 mm
(.0020
in.)
(4) If the measured flatness exceeds the limit, grind and

repair the surface to gain the flatness of standard
value or less.
Grinding
limit
Overall height
Timing chain side
&ply
: 0.2 mm (.OOS in.)

: 90 mm (3.54 in.)
Caution
The cylinder head gasket surface should be ground to
within
0.2 mm LOO8 in.) even with the grind of the
cylinder
block gasket surface.
sealant
NWOOAC

4.
Ensure that the sealan
to enter the oil
INSTALLATION
OF CYLINDER HEAD GASKET
(1) Clean gasket surfaces of cylinder head and cylinder
block.
(2) Apply a sufficient amount of sealant or similar material
to the two guides on the cylinder block and chain case
as illustrated.
Specifiedsealant:
Iqentification
3M ART Part
or equivalent
No. 8660
mark
(3) Be sure to position the gasket on the cylinder

with the identification
mark up.
Identification
mark
: 54
(4) Align with the mark on the top of the cylinder

when installing.
Caution
Do not
2.
e
Timing chain side
apply
sealant
block
to cylinder
head
head
gasket.
INSTALLATION
OF BOLT/l.
CYLINDER HEAD BOLT
Install cylinder head bolts. Starting at top center, tighten
all cylinder
head bolts to l/2 of specified
torque in
sequence
shown in illustration.
SEN016
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ENGINE <2.6L>
- Engine Assembly
DISASSEMBLY AND REASSEMBLY (VALVES AND VALVE SPRINGS)
6---a
7---Qp
Disassembly
41) e+
++ ++
1.
2.
3.
**
4.
++
5.
+* ++ 6.
7.
+*
8.
~4
9.
+* l + 10.
** 11.
+* *+ 12.
**
13.
14.
15.
16.
17.
steps
Jet valve assembly
Retainer lock
Valve spring retainer
Valve spring
Intake valve
Retainer lock
Valve spring retainer
Valve spring
Exhaust valve
Valve stem seal
Valve spring seat
Valve stem seal
Valve spring seat
Intake valve guide
Exhaust valve guide
Intake valve seat
Exhaust valve seat
5EN212
NOTE
(2) +* : Refer to Service Points of DisasSembly.
(3) 41) : Refer to Service Points of Reassembly.
(4) q : Non-reusable parts

1. REMOVAL OF JET VALVE ASSEMBLY
Using special tool, remove the jet valve assembly.
CWtiOfl
When special tool is used, make certain that the wrench is

not tilted with respect to the center of the jet valve. If the
tool is tilted, the valve stem might be bant by the force
exerted on the valve spring retainer, resulting in defective
jet valve operation.
2./6.
REMOVAL
(1) Using
OF RETAINER
valve
spring
spring and remove

(2) Keep these parts
reinstalled
in their
6EI uo19
evision
http://vnx.su/
LOCK
compressor,
compress
the retainer locks.

in order so that
original
positions.
they
the valve
can
be
ENGINE <2.6L>
Engine
9-33
Assembly
10./12. REMOVAL
OF VALVE STEM SEAL
Remove the valve stem seals with pliers
them.
and
discard
INSPECTION
Stepped
NcPGAF
VALVES
(1) Replace the valve stem if it is worn (stepped wearing
or damaged.
Also replace it if the stem end (the
surface contacting the auto-lash adjuster) is recessed.
(2) Check the valve face contact area, and repair the valve
face by the valve refacer if it is defective. The valve
seat contact area must be even at the center of the
valve face.
(3) Replace the valve if the margin (thickness of the valve
head) exceeds the limit.
Standard
value:
Intake side: 1.2 mm (.047 in.)
Exhaust side: 2.0 mm (.079 in.)
Limit:
Intake side: 0.7 mm (.028 in.)
Exhaust side: 1.5 mm (.059 in.)
NWPGBD
VALVE SPRINGS
(1) Check free length of each valve spring and replace if
necessary.
(2) Using a square, test squareness
of each valve spring.
If spring is excessively
out of square, replace it.
wearing
1EN0034
Contact
area
the center
of
6ENO20
Valve spring
Standard
value
Free length:
49.8
Load: 329 N (73
Installed
height:
Out of squareness:
Limit
Free length:
48.8
Installed
height:
Out of squareness:
1 TSB Revision
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mm (1.961 in.)
Ibs.) at installed
height
40.4 mm (1.591 in.)
Less than 2
mm (1.921 in.)
41.4 mm (1.630 in.)
4
:;~
i:
t
-
9-34
ENGINE <2.6L>
.
- Engine Assembly
VALVE GUIDES
msmca
Check the valve stem-to-guide
clearance.
If the clearance
exceeds the limit, replace the valve guide with new oversize part.
Valve stem-to-guide
clearance
Standard value
Intake : 0.03-0.06 mm (.0012-.0024
in.)
Exhaust
: O.O!XI.OS mm (.0020-.0035
in.)
Limit
diameter
Intake : 0.10 mm (.0039 in.)

Exhaust
: 0.15 mm (.0059 in.)
Press
f?emovz
Installation
Press
VALVE GUIDE REPLACEMENT PROCEDURES NWPJEa
(I)
Recondition
the valve guide hole so that it matches
newly press-fit oversize valve guide.
the
Valve Guide Insert Oversizes

Size mm (in.)
Size
mark
Cylinder head hole size

mm (in.)
6ENO2-2
0.05 (.002)
O.S.
0.25 (.OlO) O.S.

0.50 (.020) O.S.
25
50
NOTE
Do not reinsert
mm (in.1
6EN319
13.050-I
3.068 (.5138-.5145)
13.250-13.268(.5217-.5224)
13.500-13.518(.5315-.5322)
a valve guide of the same size.
(2) Using the special tool, press-fit the valve guide. The valve
guide must be press-fit from the upper side of the cylinder
head. Keep in mind that the valve guides are of different
length [Intake side: 47 mm (1.85 in.), Exhaust side: 52 mm
(2.05
in.)].
(3) After the valve guide is press-fit, insert a new valve and
check for smooth sliding.
(4) After the valve guide is replaced, check the fit between
the valve and the valve seat.
VALVE SEAT RECONDITIONING PROCEDUREzwc,
1EN037
Exhaust
(I) Check the valve guide for wear. Replace the worn guide.
(2) Recondition
the valve seat with a seat grinder or cutter.
The valve seat contact width should be of the specified size
at the center of the valve face.
(3) The valve and valve seat should be lapped lightly with a
lapping compound.
intake
EN036
TSB Revision
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ENGINE <2.6L>
- Engine
9-35
Assembly
(4) Check valve seat insert sinkage. If the sinkage exceeds the
service limit, replace the insert with an oversize part as
described below.
(5) Measure the installed height of spring between the spring
seat and the retainer with the valve spring seat, spring retainer and retainer lock installed.
The amount of sinkage
can be judged from the measured value.
Installed height of spring A (both intake and exhaust)
Standard value : 40.4 mm (1.591 in.)
Limit : 41.4 mm (1.630 in.)
0.5-l
mm (.0197-.0394
VALVE SEAT
CEDURES
in.)
INSERT
REPLACEMENT
PRONWPIAE
(1) To replace: scrape the inner face of the valve seat to

reduce the wall thickness, and remove.
0.5-l
mm
(.0197-.0394
in.)
(2) Adjust the press fit diameter of the valve seat on the
cylinder head side so that it matches the diameter of the
oversize valve seat.
lENO89
L
Valve Seat Insert Oversizes

Description
Size mm (in.)
Intake valve
seat insert
0.3(.012)
OS.
30
7.9-8.1
(.31 lo-.3189)
0.6(.024)
O.S.
60
8.2-8.4
(.3228-.3307)
0.3 (.012) O.S.
30
7.9-6.1
(.3110-.3189)
0.6 (.024) O.S.
60
8.2-8.4
(.3228-.3307)
Exhaust valve
seat insert
Size mark
Insert height
mm (in.)
Cylinder head I.D.

mm (in.)
47.30-47.33
(1.8622-1.8632)
47.60-47.63
(1.8740-I .8750)
40.3wo.33
(1.5866-l .5876)
40.60-40.63
(1.5984-l .59941
(3) Heat the cylinder head to about 250C (480F) and press in
an oversie seat insert fit to the insert bore in the cylinder
head at normal temperature.
(4) Treat the valve seat in the way shown in the diagram.
(5) Use the lapping compound,
and lap the valve.
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9-36
ENGINE
<2.6L>
(9) Ensure
face.
Engine
that
Assembly
the seat is properly
centered
on the valve
No9pwb
SERVICE
POINTS
OF REASSEMBLY
13. 11. INSTALLATION
OF VALVE SPRING SEAT/X!.
10.
VALVE STEM SEAL
install the spring seat, then using special tool, install the
stem seal by lightly tapping the tool. Seal is installed in
specified position, using the special tool.
Caution
1. Incorrect
installation
of the seal without
using
special tool will result in poor sealing and cause oil
leakage down valve guide.
2. Do not reuse stem seal.
9. INSTALLATION
OF EXHAUST VALVE/5
INTAKE VALVE
Apply engine oil to each valve, insert valves into the valve
guides. Avoid inserting the valve into the seal with force.
After insertion, check to see if the valve moves smoothly.
Enamel
coated
side
8./4.
6./2.
INSTALLATION
OF VALVE SPRING
Valve springs should be installed with the enamel
side toward the valve spring retainer.
iNSTALlATlON
OF RETAINER
coated
LOCK
(1) Using the valve spring compressor,

valve spring and install the retainer
compress
lock.
the
Caution
When compressing
the spring with the Valve Spring
Compressor,
check to see that the valve stem seal is
not pressed to the bottom of the retainer. Then start
instailing
the retainer
lock.
MN019
(2) Make certain that retainer locks are positively

1. INSTALLATlON
OF JET VALVE ASSEMBLY
(1) Apply engine oil to the O-ring, jet body threads
surface.
Caution
Make sure that the O-ring
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is a new one.
installed.
and seat
ENGINE <2.6L>
- Engine Assembly
9-37
(2) Screw the jet valve assembly into cylinder head by hand.
Tighten the jet valve to the specified torque with Special
Tool and a torque wrench while holding the special tool in
line with the jet valve center line.
DISASSEMBLY AND REASSEMBLY (JET VALVE ASSEMBLY)
Disassembly
8--
steps
@--55
*I)+4
**
1. Retainer lock
2. Valve spring retainer
l 4 3. Valve spring
** 4. Jet valve
l 4 5. Stem seal
6. O-ring
7. Jet body
NOTE
(2) l *
E; 0
NWOE-L4
-6a
: Refer to Service Points of Disassembly.

: Non-reusable
parts
Em177
NomFMl
SERVICE POlNTS OF DISASSEMBLY

1. REMOVAL OF RETAINER LOCK
Using special tool, remove the retainer lock.
lEMOO!
INSPECTION
Make sure that the jet valve slides smoothly
and has no play.
in the jez;
Caution
Combination
of the jat valve and jet body should
disturbed
and the jet valve and jet body should
placed as an assembly.
not be
be re-
Check the valve head and valve seat for damage or seizure.
Check the spring for sag, cracks or breakage.
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ENGINE <2.6L>
9-38
- Engine Assembly
Standard value
Jet valve
Length : 92.53 mm (3.6429 in.)
Stem O.D. : 4.3 mm (.I69 in.)
Seat angle : 45
Jet valve spring
Free length : 29.66 mm (1.1654 in.)
Load : 35 N (7.7 Ibs.) at installed height
installed height : 21.50 mm (.8465 in.)
Out of squareness:
Less than 1.5
MD998308-01
-/n
5.
INSTALlATlON
OF STEM SEAL
Using special tool, install the stem seal.
4.
INSTALlATlON
OF JET VALVE
(I) Apply engine oil to the stem of the jet valve.
(2) Use care to prevent damage to the new seal lips.
(3) Check to ensure that the valve sliders smoothly.
3.
INSTALLATION
OF VALVE SPRING/2. VALVE SPRING
RETAINER/l.
RETAINER LOCK
(I) Mount the valve spring and valve spring retainer on jet
body.
(2) Compress
the valve spring with special tool, using
care not to damage the valve stem by hte bottom of
valve spring retainer.
(3) While the spring being kept compressed,
install the
retainer lock.
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B-C
mE -:
ggy:
3:~
-Er.
mar=
-~
-~
~~~~
ENGINE <2.6L>
9-39
- Engine Assembly
DISASSEMBLY AND REASSEMBLY (FRONT CASE, OIL PUMP AND SILENT SHAFT)
NoaRF-
4-6 ft.lbs.
Disassembly
++
l *
l *
+4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1;:
5EN0024
steps
Oil pump sprocket

Left silentshaft sprocket
Spacer
Oil drain plug
Oil drain plug gasket
Oil filter
Oil pan
Oil pan gasket
Oil screen
Oil screen gasket
Plug
Relief spring
Relief plunger
Flange bolt
C$pump body
19.
20.
21.
ww ++ 22.
** 23.
24.
w+ 25.
26.
27.
Woodruff key
Oil pump cover
Oil pump gasket
Thrust plate (with front bearing)
O-ring
Woodruff key
Left silent shaft
Right silent shaft
Rear bearing
NOTE
(1) Reverse the disassembly rocedures to reassemble.
(21 +w : Refer to Service P.ornts of Disassembly..
(3) l I : Refer to Service Points of Reassembly.
I)+ 17. Driven gear

l * 18. Drive gear
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-p
;
--..
~,--,-~
_.-ez
-_-~
~~.
ENGINE <2.6L>
9-40
Jxm,C
Engine
Assembly
NWRGAD
SERVICE
POINTS OF DISASSEMBLY
22. REMOVAL
OF THRUST PLATE
Install 8mm (.31 in.) dia. bolts into threaded holes of flange
and turn bolts in to remove the thrust plate.
Thrust plate
I
t shaft left
NWRCGB
INSPECTION
.
5ENlm
!I
OIL PUMP
(1) Check gear contacting surfaces of cover for step wear.
(2) Check the clearances of drive and driven gears. If
clearance is excessive, replace case and cover assembly and/or gears.
Standard
value
Driven gear
Tip clearance:
eeler gau
Side clearance:
Drive gear
Tip clearance:
Side clearance:
-_
0.1 l-0.15
mm
(.0043-JO59
in.)
0.04-0.10
mm
(.00X-.0039
in.)
0.11-0.15
mm
(.0043-3059
in.)
0.05-0,11
mm
(.0020-.0043
in.)
Limit
Driven gear
Tip clearance
: 0.20 mm (.0079 in.)
Side clearance
: 0.15 mm (.0059 in.)
Drive gear
Tip clearance
: 0.20 mm (.0079 in.)
Side clearance
: 0.15 mm (.0059 in.)
.
RELIEF PLUNGER AND SPRING

NosRaiC
(1) Insert the relief plunger in the oil pump body and
check to see if it operates smoothly.
(2) Check the relief spring for breakage or sagging.
Standard
value
Relief spring
Free length : 46.6 mm (1.635 in.)
Load : 61 N/40.1 mm (13 lbsJl.579
SILENT SHAFT
(1) Check journals
for wear,
excessive damage or seizure
as well. If necessary, replace
both.
(2) Check oil hole (passage) for
as necessary.
Standard
value
Oil clearance
Left silent shaft
Front : 0.020-0.062
Rear : 0.094-0.135
Right silent shaft
Rear : 0.094-0.135
I
1 TSB Revision
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in.)
NwRclA
damage
and seizure.
If
is evident, check bearing
silent shaft or bearing or
clogging.
Clean or repair
mm (.0006-.0024
mm (.0037-.0053
in.)
in.)
mm
in.)
(.0037-.0053
-.
ENGINE <2.6L>
Cylinder
black
- Engine Assembly
9-41
;u;~
SHAFT BEARING REPLACEMENT PROCEN-
(I) Using
special
tool,
remove
silent
shaft
rear bearing.
MD998251-01
5ENOZ
(2) Apply engine oil to O.D. of bearing, using special tool, install
silent shaft bearing to cylinder block.
MD99825041

Apply
engine
NOI(M
25. INSTALLATION
OF LEFT SILENT SHAFT
(1) Apply engine oil to journal of left silent shaft.
(2) Insert left silent shaft into cylinder block. Insert silent
shaft carefully to prevent damage to the bearing.
oil
5ENOZ!
23. INSTALLATION
OF O-RING
(1) Install o-ring in groove of thrust plate.
(2) Apply engine oil around O-ring.
New
O-ring
22. INSTALLATION
(I)
OF THRUST
PLATE
Install two guides in threaded holes for mounting thrust

plate. Guides should be fabricated
by cutting off hexagon heads bolts 6 mm I.24 in.) in diameter and 50 mm
(1.97 in.) long.
(2) Install thrust plate into cylinder block along guides.
Without use of guide, threaded holes will be hard to align.
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F
A-~-
~~
E-
:i __.. i.
.-
.__.
--~-
9-42
ENGINE <2.6L>
Engine
18. INSTALLATION
install oil pump
marks.
Assembly
OF DRIVE GEARI17.
DRIVEN GEAR
gears to oil pump body and align timing
Driven gear
Caution
If timing
marks are out of alignment,
shaft will change and vibration
will
Timing marks
Drive gear
phase
result.
of silent
5ENOZf
15. INSTALLATION
OF OIL PUMP BODY
Place pump assembly in same position as it was installed
on engine and supply approx. 10 cc (.6 cu.in.1 of clean
engine oil in delivery port.
8. INSTALLATION
OF OIL PAN GASKET
Refer to P.916.
7.
Chain case and cylinder block guide
fNSTALLATlON
Apply
sealant
the hatched
Specified
OF OIL PAN
to four places on the cylinder
area.
sealant:
MITSUBISHI
GENUINE
MZ100168
or equivalent
block side of
Part
No.
Eyiinder blodc and rear oil seal case guide qwwj4
6.
-
Cylinder
block side
\
Apply engine
INSTALLATION
OF OIL FILTER
Clean the mounting
surface on the cylinder block side,
apply a thin coat of engine oil to the oil filter O-ring and
tighten the oil filter.
oil
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ENGINE <2.6L>
9-43
- Engine Assembly
D\SASSEMBLY AND REASSEMBLY (PISTON AND CONNECTING ROD)
NWTE-A
Disassembly steps
1. Nut
a+ ++
+*
a*
++
4+
++
++
++
*+
2. Connecting rod cap

3. Bearing
4. Bearing
5. Piston and connecting
6. Bolt
7. No. 1 piston ring
8. No. 2 biston rini
9. Oil ring
IO. Piston pin
11. Piston
12. Connecting rod
rod assembly
3-Q9
248
NOTF
..-.(I) Reverse the disassembly procedures to reassemble.
(2) I)* : Refer to Service Points of Disassembly.
(3) 41) : Refer to Service Points of Reassembly.
&-Al%
ii-34
.- Nm
.__..
rtlbs.

2.
REMOVAL
OF CONNECTING
ROD CAP
Mark the large end of the connecting
rod with the cylinder
number for use during reassembly.
7.
REMOVAL
OF No. 1 PISTON
RING
Remove the piston rings with
DENOSO
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RING/L
No. 2 PISTON
a piston
ring expander.
9-44
ENGINE <2.6L>
Iden:. mark
Engine
Assembly
IO. REMOVAL
OF PISTON PIN
(1) Set piston and connecting
rod assembly in tool body in
such a way that front mark (arrow mark of piston or
identification
mark of connecting
rod) will be faced
upward.
(2) Press plates must be used to provide adequate support to
the base during pressing operations.
Ident. mark
(3) Place piston and connecting

rod with arrow mark or
identification
mark upward over anvil so lip of insert in
between
connecting
rod boss and inside surface
of
piston. The connecting
rod boss should bear on as much
of the insert surface as possible.
(4) Adjust connecting
rod rear support until rod is horizontal
to press bed surface. Misalignment
of pin and receiving
tube may result if support adjustment
is not correct.
(5) Position piston

press ram.
pin pusher
onto pin and remove
pin with
Caution
As piston pin is removed,
it must pass through
ing tube.
Check alignment
and adjust if necessary.
receiv-
lNSPECTlON
o
PISTON
(1) When there are streaks or signs of seizure on the outer
surface of the piston (especially on the thrust side), or
if there are cracks in the outer surface, replace.
(2) Check the pin boss area oil port. If clogged, clean the
oil pot-t.
NOTE
Replace the piston and the piston pin as a set.
PISTON PIN
The piston pin should be able to be inserted into the
piston pin hole merely by pushing it in with your finger. If
any resistance is noted or if the pin is loose, replace it.
NOTE
Replace
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the piston
and the
piston
pin as a set.
.-
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I ~_
ENGINE <2.6L>
Engine
9-45
Assembly
PETtiN RING
(1) Check for piston ring damage,
the rings if anything unusual
change the piston rings when
(2) Check the clearance between
groove. When it exceeds the
piston, or both.
NcaTcaE
wear, and bends, replaceing
is noted. Also be sure to
a new piston is installed.
the piston ring and the ring
limit, replace the rings, the
Piston ring side clearance

Stsndard value
No.1 : 0.05-0.08
mm (.0020-.0035
No.2 : 0.02-0.08
mm (BOOS--0024
Limit
No.1 : 0.12 mm (.0047 in.)
No.2 : 0.10 mm (.0039 in.)
in.)
in.)
(3) Insert the piston ring into the cylinder bore

against the top of the piston head and pressing
it makes a right angle, measure the piston ring
feeler gauge. When the gap is too large, replace
ring.
putting it
it in. When
gap with a
the piston
Piston ring end gap

Standard value
No.1 : 0.39-0.45 mm (.OlW--0177
in.)
No.2 : 0.2W.40
mm (.0098-.0157
in.)
Oil ring side rail : 0.30-0.80
mm (.0118-.0315
Limit
No.1 : 0.8 mm (.031 in.)
No.2 : 0.8 mm (.031 in.)
Oil ring side rail : 1.0 mm (.039 in.)
l
in.)
BEARING
(1) Visually check the surface of the bearing, replacing

those which are lopsided, streaked, damaged, or show
signs of seizure. When streaks or seizure are excessive, check the crankshaft. If damage is discovered on
the crankshaft,
either replace it or reuse it after
undersize machining.
(2) Measure the inner diameter
of the connecting
rod
bearing and the outer diameter of the crankshaft pin. If
the gap (oil clearance)
exceeds
limit, replace the
bearing, and, if necessan/, the crankshaft. Or, undersize machine the crankshaft and replace the bearings
with an appropriate
undersized
type.
Standard
value: 0.019-0.056
Limit: 0.1 mm (.004 in.)
mm
(.0007-.0022
in.)
NOTE
For the method by which the oil clearance is measured
using a plastigauge,
refer to the item on the crankshaft.
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9-46
ENGINE <2.6L>
Engine
Assembly

10. INSTALLATION
OF PISTON
PIN
(1) Thread stop plug approximately

half way into the
bottom of the receiving tube.
(2) Select the largest diameter piston pin guide that will
pass through piston and rod. install spring, spacer, and
guide into receiving tube.
lEN904
18441
II
II
lEN!M
Clearance
1ENSM
1 TSR Revision
(3) With connecting

rod removed
from piston, insert
piston pin into piston bore. Carefully measure amount
of pin that protrudes equally from both sides of piston.
Record this measurement
for future use.
(4) Position connecting
rod and piston over the anvil. The
spring loaded piston- guide will pass through piston
and rod and align it. Lubricate pin and insert it into
piston.
(5) Place piston pin pusher on piston pin and push pin
through connecting
rod unit1 the pin protrudes some
distance measured and recorded above in step 3.
Caution
The piston must be he to float during installation;
check frequently.
(6) Apply hydraulic pressure to pin and adjust stop plug
until stop plug comes in contact with spacer.
(7) Remove piston and pin assembly from anvil and check
piston pin to make sure it is centered.
Ifs it is not
centered, adjust stop plug up or down to obtain proper =
centering. The pin stop is now set for any remaining
pistons.
Caution
If the required installation
load is out of specification, replace piston pin and/or
connection
rod.
Piston pin press in load: 7500-I 7500 N
(1653-3858
Ibs.)
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ENGINE <2.6L>
Engine
9. INSTALLATION
(1) Assemble
Then, after
lower side
and lower
9-47
Assembly
OF OIL RING
the oil ring spacer into the piston ring groove.
assembling the upper side rail, assemble the
rail. There is no difference between the upper
side rails or spacers.
(2) The side rail may be easily installed by pushing it in with

your finger after fitting the end over the piston groove.
End of side rail

1
Caution
Do not use piston
rail.
ring expander
when
installing
side
lENOE.3
Distinguishing
t
I
stamped mark
8/7.
I
INSTALLATIQN
OF NO.2 PISTON RING/NO.1
PISTON
RING
Using a piston ring expander, install No.2 and No.1 piston ring.
Caution
1. Pay close attention
to the differences
in shape
between
Nos. 1 and 2 to avoid confusing
them.
2. Install piston rings 1 and 2 with the maker and size
marks facing up (toward
the top of the piston).
Side rail
No. 1
liming
side
Piston
spacer alignment
holes
5. INSTALLATION
OF PISTON AND CONNECTfNG ROD ASSEMBLY
(1) Apply plenty of engine oil to the outer piston surfaces, the
piston ring and the oil ring.
(2) Align the mating holes in the piston and oil rings (side rail,
spacer) as illustrated.
6ENO41t
(3) Orient the piston and connecting rod assembly so that the
front mark on the top of the piston and the front mark on
the connecting rod (distinguishing mark) face toward the
front of the engine (the timing belt side) and insert it into
the cylinder.
5EN211
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9-48
ENGINE
<2.6L>
2.
White paint
\
Identidtion
mark
(Front mark)
- Engine Assembly
INSTALLATION
OF CONNECTING ROD CAP
(I) When the connecting rod is installed, make sure that identification mark and notch are on same side.
Notch (Front mark
(2) Check the connecting
rod big end side clearance.
Connecting
rod big end side clearance
Standard value : 0.10-0.25 mm (.OOSS-.OOSS in.)
Limit : 0.4 mm (-015 in.)
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m.
gg--GzpJ
m.
ENGINE <2.6L>
9-49
- Engine Assembly
DISASSEMBLY AND REASSEMBLY (CRANKSHAFT AND FLYWHEEL)
NO9E-A
Disassembly steps
1. Ball bearing
2. Flywheel
3. Ring gear
4. Rear plate
5. Bell housing cover
6. Oil seal case
7. Oil seal case gasket
**
8. Oil separator
*a
9. Oil seal
IM 10. Bearing cap
IHI 11. Lower bearing
12. Crankshaft
I)+ 13. Upper bearing
5EN0045
NOTE

(2) I)+ : Refer to Service Points of Reassembly.
NWHAA
INSPECTION
.
CRANKSHAFT
(I)
Check the crankshaft

journals and pins for damage,
uneven
wear and cranks. Also check oil holes for
clogging.
Correct or replace any defective
part.
(2) Inspect
out-of-roundness
journal and pin.
Standard
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taper
of
crankshaft
value
Crankshaft
Crank
and
journal
pin O.D.
0.b.
: 53 mm
: 60 mm
(2.09
in.)
(2.36 in.1
ENGINE <2.6L>
Engine
Assembly
m.
Limit
Out-of-roundness
Taper of journal
of journal and pin :

0.015 mm (0006
and pin 0.005 mm (.0002
in.)
in.)
(3) To check the oil clearance,

measure
the outside
diameter of the crankshaft journal and the crank pin
and the inside diameter of the bearing. The clearance
can be obtained by calculating the difference between
the measured
outside and inside diameters.
Standard
value
Crankshaft
main bearing
Connecting
rod bearing
Crankshaft
Connecting
main bearing
rod bearing
: 0.021- 0.046 mm
(.0006-.0018
in.)
: 0.019-0.056
mm
(.ooO7-.OOZ
in.)
Limit
: 0.1 mm (.004 in.)

: 0.1 mm (.004 in.)
MAIN BEARINGS AND CONNECTING

ROD BEARINGS
Visually inspect each bearing for peeling, melt, seizure and
improper
contact. Replace the defective bearings.
PLASTIGAUGE
METROD
Plastigauge may be used to measure the clearance.
(1) Remove oil and grease and any other dirt from bearings and
journals.
(2) Cut plastigauge to the same length as the width of the bearing
and place it in parallel with the journal, off oil holes.
(3) Install the crankshaft, bearings and caps and tighten them
to the specified torques. During this operation,
do NOT
turn the crankshaft.
(4) Remove the caps. Measure the width of the plastigauge at
the widest part by using a scale printed on the plastigauge
sleeve.
(5) If the clearance exceeds the repair limit, the bearing should
be replaced or an undersize bearing used.
When installing a new crankshaft, be sure to use standard
size bearings.
(6) Should the standard clearance not be obtained even after
bearing replacement,
the journal should be ground to
undersize and a bearing of the same size should be
installed.
lENO67
l
OIL SEAL
Check front and rear oil seals for damage or worn lips. Replace
any seat that is defective.
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ENGINE <2.6L>
.
Engine
9-51
Assembly
RING GEAR
When there is wear, cracks, or other damage to the ring
gear teeth, replace the ring gear by the following procedure. Check the starter motor pinion.
Ring gear replacement
procedure
:
(1) Tap around the ring gear to loosen and remove it from
the flywheel.
Caution
The ring gear cannot be removed
while it is hot.
(2) Heat the ring gear to 300C (572F) and put it into the
flywheel.
FLYWHEEL
(1) Make a visual inspection of the clutch disc. If stepped
wear, streaking, or seizure are apparent,
replace it.
(2) If flywheel
run out exceeds the limit, replace it.
Limit
: 0.13 mm
(.005
in.)

Upper bearing
(for No.1, 2.4, 5)
NW-
13. INSTALLATION
OF UPPER BEARING
When reusing the main bearings,
remember
to install
them by referring to location marks made at the time of
removal.
Be sure oil holes in bearings align with oil hole in block.
11. INSTALLATION
OF LOWER BEARING
Check to ensure that the lower bearing has no oil groove.
Upper and lower bearings

(for center)
Arrow mark
indicating
front of enaine
Lap NO.
fz&
1ENOW
10. INSTALLATION
OF BEARING CAP
(1) The caps should be installed with the arrow mark
directed toward the crank pulley side of engine. Cap
numbers must be in correct order.
(2) Tighten cap bolts in sequence
: Center, No. 2, No.4,
front and rear cap bolts.
(3) Cap bolts should be tightened evenly in 2 to 3 stages
before they are finally tightened.
(4) Make certain that crankshaft turns freely and has the
proper clearance
between
the center main bearing
thrust flange and the connecting
rod big end bearing.
Standard
value : 0.05-0.18
Limit : 0.4 mm (.016 in.)
/ TSB Revision
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mm
(.0020-.0071
in.)
9-52
ENGINE <2.6L>
MD998376-01
P-I
- Engine Assembly
9. INSTALLATION
Using special
without tilting
OF OIL SEAL
tool, press fit the oil seal all the way
it.
Emm=
in
MB49093B-01
DEN063
8. INSTALLATION
OF OIL SEPARATOR
Press the oil separator into the oil seal case. Install it so
that the separator
oil hole is on the verv botttom,
as
illustrated.
iiJ
DISASSEMBLY AND REASSEMBLY (CYLINDER BLOCK)
!iO-SO Nm
37-43 ft.lbs.
I
++ ,*
1.
2.
3.
4.
5.
6.
6\
15-22 Nm
11-15
I ft.lbs.
Right engine support bracket

Left engine support bracket
Silent shaft chamber cover
Chamber cover gasket
Cylinder block
Oil pressure switch
5-7 Nm
4-5 ft.lbs.
5EN210
NOTE
(I) C+
(2) ++
: Refer to Service
: Refer to Service
Points
Points
of Disassembly
of Reassembly.
\ TSB Revision
50-50
37-43
http://vnx.su/
Nm
ft.lbs.
ENGINE <2.6L>
Engine
9-53
Assembly
SERVICE
POINTS
OF DISASSEMBLY
6. REMOVAL
OF OIL PRESSURE SWITCH
(1) Remove the terminal of oil pressure switch.
(2) Using the special tool, remove the oil pressure
MD99805441
Caution
Sealant is coated on the threaded
not to damage
when removing.
NmveAB
switch.
part, so be careful
7LUcoO5
INSPECTION
.
CD
A
B
2mm
4724
in.)
Center
Lower part73
BENO%
NWYHAll
CYLINDER
BLOCK
(1) Visually check the cylinder block for scores, rust and
corrosion. Also check for cracks or any other defects
by using a flaw detecting
agent (magnafluxing).
Correct or replace the block if defective.
(2) Measure the cylinder bore with a cylinder gauge at
three levels in the directions
of A and B.
(3) If the cylinder bores show more than specified out-ofround or taper, or if the cylinder walls are badly
scuffed
or scored, the cylinder
block should be
rebored and honed, and new oversize pistons and
rings fitted.
Measuring
points are as shown.
Standard
value
Cylinder
bore: 91.1 mm (3.567 in.)
Out-of-roundness
and taper of cylinder bore:
Less than 0.02 mm (.OOOS in.)
(4) If cylinder top ridge is worn in stages, cut away with
ridge reamer.
(5) Oversize pistons are available in four sizes.
Piston service size and mark
0.25 mm (.OlO in.) O.S.: 0.25
0.50 mm (.020 in.) O.S.: 0.50
0.75 mm (.030 in.) O.S.: 0.75
1.00 mm (.039 in.) O.S.: 1.00
(6) To rebore the cylinder bore to oversize, keep the
specified clearance between the oversize piston and
the bore, and make sure that all pistons used are of
the same oversize. The standard measurement
of the
piston outside diameter is taken at a level 2 mm (.08
in.) above the bottom of the piston skirt and across the
thrust faces.
Standard
value
Piston-to-cylinder
wall clearance:
0.02-0.04
mm
(.0006-.OOlS
in.)
(7) Check for damage and cracks.
1 TSB Revision
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EL-d--A
-i
..-A.
ENGINE <2.6L>
Engine
Assembly
(8) Check top surface for flatness. If excessive flatness is

evident, grind to minimum
limit or replace.
Standard
dimension:
0.05 mm (.OOZO in.) or fess
Limit: 0.1 mm (.004 in.)
Overall height
Standard
value: 318 mm (12.44 in.)
Limit (amount
of cylinder
block
-0.2 mm (-.008
in.)
gasket surface grind:
Caution
The cylinder block gasket surface should be ground
to within
0.2 mm (.008 in.) even with the grind of
cylinder head gasket surface.
.
OIL PRESSURE SWITCH

(1) Connect a tester (ohm-range)
between
the terminal
and the body and check for conductivity.
If there is no
conductivity,
replace the switch.
(2) Next insert a very fine wedge through
the oil hole,
pushing it slightly. There should be no conductivity
(resistance should be infinite). If there is conductivity
even when wedge is pushed, replace the switch.
(3) Or, if there is no conductivity
when a 50 kPa (71 psi)
pressure is placed through the oil hole, the switch is
operating properly. Check at this time to see that there
is no air pressure leakage. If there is air pressure
leakage, the diaphragm
is broken, and the switch
should be replaced.
BORING THE CYLINDER

(1) Based on the largest cylinder bore, determine
the over
sized piston to be used.
(2) Measure with the outside-diameter
of the piston as the
datum measurement
points.
Direction
of thrust
NOTE
There are four sizes of oversize piston : 0.25 mm (.OlO in.),
0.50 mm (020 in.), 0.75 mm (.030 in.), 1.00 mm (039 in.).
/ TSB Revision
=
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1 ~~
ENGINE <2.6L>
Engine
9-55
Assembly
(3) Calculate
the reground bore size based on the measured

value of the outside piston diameter.
NOTE
Bore size = outside piston diameter
+ 0.02-0.04
mm
(.0008-.OOlS in.) (gap between cylinder and piston) -0.02
mm t.0008 in.) (honing)
to the calculated
measure(4) Hone each of the cylinders
ment.
Caution
In order to avoid uneven boring due to*.. the . rise in
temperature,
bore the cylinders
in the toltowmg
sequence:
#2, #4, #I, and #3.
(5) Hone the cylinders, finishing them to the proper dimension (outside piston diameter
t gap with cylinder).
(6) Check the gap between
the piston and cylinder.
Standard
value
: 0.02-0.04
mm
(.0008-.OOlS
in.)

MD998054-01
6.
INSTALLATION
Coat the threads of switch with sealant and install
switch using the special tool.
Specified
Apply sealant
sealant:
http://vnx.su/
the
Caution
1. Keep the end of threaded
2. Avoid an overtightening.
[ TSB Revision
NLWWAB
portion
clear of sealant.
ENGINE <3.OL> - General Information
9-56
ENGINE
<3.OL>
GENERAL INFORMATION
;ECTIONAL VIEW
LUBRICATION DIAGRAM
http://vnx.su/
9-57
ENGINE <3.OL> - Specifications
SPECIFICATIONS
NWCA-B
Items
Specifications
Type
Number of cylinders
Bore
mm (in.)
Stroke
mm (in.)
Piston displacement
cc (cu.in.)
Compression ratio
Firing order
Valve timing
Intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve Opens (BBDC)
Closes (ATDC)
Valve overlap
Intake valve duration
Exhaust valve duration
V-type, OHC
6
91 .I (3.587)
76.0 (2.992)
2,972 (181.4)
8.9
l-2-3-+5-6
19
59
59
19
38
25%
258
terns
Standard value
Seneral
Compression pressure
kPa (psi)/rpm
Pressure difference of all cylinder
kPa (psi)
Manifold vacuum
kPa (in.Hg)
Cylinder head
Overall height
mm (in.)
mm (in.)
mm (in.)
Flatness of manifold mounting surface
Intake side
Exhaust side
Oversize rework dimension of valve seat hole
mm (in.)
Intake
0.3 (.012) O.S.
0.6 (024) O.S.
Exhaust
0.3 (012) O.S.

0.6 (024) O.S.
Limit
840(119)
100 (14)
69 (20)
84 (3.31)
Less than 0.05 (0019)
* - 0.2 (- .008)
0.2 (.008)
Less than 0.10 (0039)

Less than 0.15 (0059)
0.2 (008)
0.3 (012)
44.300-44.325
(1.7440-I .7451)
44.600-44.625
(1.7559-I .7569)
38.300-38.325
(1.5079-I .5089)
38.600-38.625
(1.5197-1.5207)
NOTE
*Limit must be-O.2 (-,008) combined with amount of grinding of cylinder block gasket surface.
) TSB Revision
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9-58
ENGINE
<3.OL>
Items
- Specifications
Standard value
Oversize rework dimension of valve seat height

mm (in.)
Intake
0.3 (.012)
0.6 (.024)
Exhaust
0.3 (.012)
0.6 l.024)
Oversize rework of valve guide hole
(both intake and exhaust)
mm (in.)
0.05 (.OOZ)OS.
0.25(.OlO)O.S.
0.50 (.020) OS.
Camshaft
Cam height
mm (in.)
Intake
Exhaust
Journal O.D.
mm (in.)
Bearing oil clearance
mm (in.)
?ocker arm
I.D.
mm (in.)
Clearance (Rocker arm to shaft)
7.9-8.1
8.2-8.4
7.9-8.1
8.2-8.4
I.31 l-.319)
(.323-.331)
(.311-,319)
(.323-.33 I)
13.050-13.068
(.5138-.5145)
13.250-13.268
(.52 17-5224)
13.500-13.518
(.5315--5322)
41.25 (1.6240)
41.25 (1.6240)
34 (1.34)
0.05-0.09
(.0020-6035)
mm (in.)
19(.75)
0.01-0.04
(.0004--0016)
Rocker arm shaft

O.D.
mm (in.)
18.9 (.744)
3ocker arm shaft spring

Free length
mm (in.)
intake
Exhaust
55.2 (2.173)
55.2 (2.173)
llalve
Valve length
Intake
Exhaust
Stem O.D.
Intake
Limit
40.75 (1.6043)
40.75 (1.6043)
0.10(.0039)
mm (in.)
103.0 (4X55)
102.7 (4;043)
mm(in.)
7.960-7.975
(.3134-.3140)
7.93c-7950
(.3122-.3130)
45O-45.5
Exhaust
Face angle
Thickness of valve head (Margin)
Intake
Exhaust
Ialve stem to valve guide clearance
Intake
Exhaust
mm (in.)
1.2 1.047)
2.0 (.079)
0.7 (.028)
1.5 (.059)
0.03-0.06(.0012-.0024)
0.05-0.09 (.0020-.0035)
0.10 (.0039)
0.15 i.0059)
mm (in.)
1 TSR Revision
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ENGINE
items
9-59
- SDecifications
Standard value
Valve guide
Length
mm (in.)
Intake
Exhaust
Service size
mm (in.)
Valve seat
Width of seat contact
Seat angle
<3.OL>
Limit
44(1.73)
48 (1.89)
0.05 (002). 0.25 (.OlO),
0.50 (020) Oversize
mm (in.)
0.9-I .3 (.035--051)
44O-44.5
Valve spring
Free length
mm (in.)
Load
N (Ibs.)
Installed height
mm (in.)
Out of squarness
50.5 (1.988)
329 (74) at installed height
40.4(1.591)
Less than 2
Cylinder block
Cylinder bore
mm (in.)
Out-of-roundness
and taper of cylinder bore
mm (in.)
mm (in.)
Piston
O.D.
mm (in.)
Clearance (Piston to cylinder)
Ring groove width
mm (in.)
No. 1
No. 2
Oil
Service size
mm (in.)
mm (in.)
49.5 (1.949)
41.4(1.630)
4
91.1 (3.587)
Less than 0.02 (0008)
Less than 0.05 (.0020)
0.10(.0039)
91 .I (3.587)
0.02-0.04(.0008-,001s)
1.51-1.53 (0596.0602)
1.51-1.53 (.0594-.0602)
4.010-4.035(.1579-.1589)
0.25 (.OlO), 0.50 (.020),
0.75 (030). 1 .OO(.039) Oversize
Piston ring
Side clearance
mm (in.)
No. 1
No. 2
End gap
mm (in.)
No. 1
No. 2
Oil ring side rail
mm (in.)
Service size
mm (in.)
Connecting rod
Bend
mm (in.)
Twist
mm (in.)
Connecting rod big end to crankshaft
side clearance
mm (in.)
Piston pin press-in load
N (Ibs.)
0.03-0.09 (.0012-.0035)
0.02-0.06 (.0008-.0024)
0.1 (004)
0.1 (004)
0.30-0.45 (.0118-.0177)
0.25-0.40 (.0098-.0157)
0.20-0.70 (.0079--0276)
0.25 LOlO), 0.50 (020).
0.75 (.030), 1 .OO(.039) Oversize
0.8 (031)
0.8 (031)
1.o (.039)
0.05 (0020) or less

0.1 (004) or less
0.10-0.25 (.0039-.0098)
7,500-17.500
( TSB Revision
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(1.686-3.934)
0.4(.016)
.r
-=
is. --
._
,d.
..--.
9-60
ENGINE <3.OL>
Items
Connecting rod bearing
mm (in.)
Oil clearance
Service size
mm (in.)
Crankshaft mai; bearing
Oil clearance
mm (in.)
Service size
mm (in.)
Crankshaft
Pin O.D.
mm (in.)
Journal O.D.
mm (in.)
Out-of-roundness of journal and pin
Taper of journal and pin
mm (in.)
mm (in.)
End play
Undersize rework dimension of pin
0.25(.010) U.S.
mm (in.)
0.50(.020)u.s.
0.75(.03O)U.S.
lywheel
Runout
Limit
0.016-0.046(.0006-.0018)
0.25(.010),0.50(.020),
0.1 (.004)
0.02-0.043 (.0008-.0019)
0.25(.010).0.50
l.020).
0.1(.004)
SO(1.97)
SO(2.36)
Less than 0.03 (.0012)
Less than 0.005 (.0002)0.05-0.25(.002C-.0098)
49.735A9.750
(1.9581-1.9587)
49.485-49.500
(1.9482-1.9488)
49.235-49250
(1.9384-1.9390)
U.S.
Undersize rework dimension of journal

0.25(.010) U.S.
Standard value
--
mm (in.)
59.735-59.750
(2.3518-2.3524)
59.485-59.500
(2.3419-2.3425)
59.235-59250
(2.3321-2.3327)
-mm (in.)
Conditions: oil temperature

167 to 194F)]
0.3(.012)
mm (in.)
0.50(.020) U.S.
0.75(.030)
- Specifications
&ssthan0.13(.0051)
is 75 to 90C
Side clearance
mm (in.)
Body clearance
Side clearance
qelief spring
Free length
mm (in.)
Load [37N (8.3 Ibs.)]
mm (in.)
0.100-0.181 (.0039-.0071)
0.040-0.095(.0016-.OcB7)
43.8(1.724)
) 40.1 (1.579)
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ENGINE <3.OL>
TORQUE
9-61
- Specifications
SPECIFICATIONS
W9U-B
Items
Timing belt cover bolt
Timing belt tensioner bolt
Camshaft sprocket bolt
Timing belt rear upper cover, left bolt
Alternator stay bolt
Alternator bracket bolt
Rocker cover bolt
Camshaft bearing cap bolt
Distributor adaptor bolt
Cylinder head bolt -Cold engine
-Hot engine
Oil pressure switch
Oil filter bracket bolt
Drain plug
Oil pan bolt
Oil screen bolt
Oil relief valve plug
Oil pump case bolt
Oil pump cover screw
Connecting rod cap nut
Flywheel bolt
Drive plate bolt
Transmission mounting plate bolt
Rear plate bolt
Oil seal case bolt
Bearing cap bolt
Engine support bracket, right
[IO x22 mm 1.39x.87 in.)]
[l2x22mm.
12x32mm(.47x.87in.,.47x1.26in.)]
Engine support bracket, left
Front insulator stopper to frame
Engine to engine mounting front insulator
Plate to frame
Plate to transfer mounting insulator
Support plate to No. 2 crossmember <M/T>
Engine mounting rear insulator to engine <M/T>
Engine support rear bracket to engine <A/T>
1 TSB Revision
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Nm
ft.lbs.
IO-12
2230
80-l 00
lo-12
2630
20-30
a10
19-21
12-15
90-100
100-I 10
a12
12-15
35-45
5-7
15-22
40-50
12-15
a12
50-53
73-77
73-77
IO-12
8-10
IO-12
75-85
7-9
16-21
58-72
7-9
15-21
15-21
6-7
14-15
9-10
65-72
73-79
6-9
9-l 0
2632
4-5
11-15
29-36
9-10
6-8
37-38
53-55
53-55
7-9
6-7
7-9
55-61
33-50
65-85
20-30
30-40
13-20
55-75
18-25
18-25
3040
18-25
I a25
18-25
24-36
47-61
15-21
22-29
9-15
40-54
13-18
13-18
22-29
13-18
13-18
13-18
9-62
items
Engine mounting rear insulator to engine support rear bracket ==A/T>
Rear engine support member to No. 2 crossmember <4/T>
Heat protector
Rear engine support member to frame
Oil cooler hose
Fuel high pressure hose
Front suspension crossmember to front differential
Front suspension crossmemberto
frame
41ternator brace bolt
Alternator support nut
EGR pipe
Heat protector to exhaust manifold
nilternator stay to alternator bracket
4ir intake plenum stay(front)
Bracket to exhaust manifold
Engine hangerto exhaust manifold
41ternator stay to exhaust manifold
Exhaust manifold to engine
3il level gauge guide to engine
3olt
4ir intake plenum stay (rear)
Radiator upper shroud to radiator lower shroud
Radiator upper shroud to radiator
Cooling fan to cooling fan bracket assembly
3il pump bracket
3il pump mounting bracket
Crankshaft pulley
3ocker arm and shaft assembly
Engine oil feed hose assembly to engine oil cooler
Engine oil return hose assembly to engine oil cooler
1 TSB Revision
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Nm
ftlbs.
18-25
18-25
6-70
IO-13
4w5
3545
IO-13
80-l 00
100-120
12-15
20-25
15-20
12-15
20-30
15-20
15-20
15-22
15-22
15-22
19-29
72-15
15-20
13-18
IS-18
4-7
7-9
29-32
25-33
7-9
58-72
72-87
a11
14-18
11-14
9-l 1
14-21
11-14
11-14
11-16
11-16
II-16
14-21
9-l 1
11-14
6-8
2-5
7-Q
25-33
25-33
8-11
3-7
lo-12
35a5
35-45
150-160
9-12
30-35
30-35
108-I 16
14-15
22-25
22-25

SEALANTS
AND
/ Special
9-63
Tools
ADHESIVES
NWCE4
items
Specified sealant
Quantity
Rocker arm shaft assembly

Oil pan
Oil pressure switch
Oil seal case
Rocker cover
Timing belt gasket
Cylinder head cam journal
3M NUT Locking No. 4171 or equivalent

Three Bond No. 1212D or equivalent
MITSUBISHI GENUINE PART MZ100168 or equivalent
3M Part No. 8660 or equivalent
3M Part No. 8660 or equivalent
Three-Bond No. 1212D or equivalent
3M adhesive EC 870 or equivalent
3M NUT Locking No. 4171
As required
As required
As required
As required
As required
As required
As required
As required
SPECIAL TOOLS
Tool
Nll9DA-a
Number
Name
MB99077541
Special spanner
Removal and installation of camshaft sprocket
MD99871 4
Circular packing
installer
Press fitting circular packing
MD998051-01
Cylinder head bolt

wrench
Loosening and tightening
M D998747
Crank pulley
holder
Removal and installation of crankshaft pulley
1 TSB Revision
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j Use
of cylinder head bolt
__
9-64
ENGINE
301
<3.OL>
- Special
Tools
Number
Name
Use
MD99E3377-01
Valve stem seal

installer
installation of Give stem seal
cs
Removal and installation of oil pre&re
MD99805401
switch
MD998717
Crankshaft front
oil seal installer
Press fitting c%nkshaft front oil seal
M D998727
Oil pan remover
Removal of oiipan
MD998184-01
Piston pin setting

tool (Use with
push rod and
guide set)
Removal and installation of piston and

connecting rod
MD998718
Crankshaft rear
oil seal installer
Press fitting crankshaft rear oil seai
MD998716-01
Crankshaft wrench
Used if thecrankshaft needsto be rotated to

attach the timing belt, etc. when the piston and
connecting rod assembly is assembled.
alm
wq
Q-9
RR
fxl
-il-;
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ENGINE <3.OL> - Engine Adjustment
9-65
ENGINE ADJUSTMENT
COMPRESSION PRESSURE CHECK
NWFFW
(1) Before checking compression,

ensure that engine oil, the
starter motor, and battery are all in normal operating
condition.
(2) Start the engine and wait until engine coolant temperature
has risen to 85-95C (185-205F).
(3) Stop the engine and pull the spark plug cables.
(4) Remove the spark plugs.
(5) Crank the engine to remove any foreign objects in the
cylinders.
Caution
Cover the spark plug holes with shop towel, etc., in
order to keep expelled foreign objects from flying out,
and keep away from
the holes. When
measuring
compression
with water, oil, or fuel having entered the
cylinder through a crack, etc., these will come flying out
of the spark plug hole hot and fast, so be sure to take
the proper precautions.
(6) Set the compression

gauge to the spark plug hole.
(7) Holding the throttle valve full open, crank the engine and
measure compression.
Limit:
840 kPa (119 psi)
(8) Perform (6) and (7) above for all the cylinders, ensuring
that compression
pressure differential
for each of the
cylinders is within the specified
limit.
Limit
: Less than
100 kPa (14 psi)
(9) If a cylinders
compression
or pressure differential
exceeds the limit, add a small amount of oil through the
spark plug hole and repeat steps (6H8).
0 If the addition
of oil brings compression
up, it is
possible that there is harmful friction between
the
piston ring and cylinder wall.
@I If not compression
up, valve seizure, poor valve
seating, or a compression
leak from the gasket are all
possible.
MANIFOLD VACUUM
INSPECTION
NWFNAL
(1) Before inspection put the vehicle into the following state.
l
: 85-95C (185-205F)
l
Lights, motor cooling fan, and accessories
: OFF
l
Transmission
: N or P range on vehicles with an
automatic
transmission)
l
Steering wheel : Straight forward position
\ TSB Revision
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; ;
9-66
Ey;
ENGINE <3.OL> - Engine Adjustment

(2) Connect a tachometer
(3) Connect a three-way joint to the vacuum hose between the
air intake plenum and the fuel-pressure
regulator, and then
connect a vacuum gauge.
(4) Start the engine and check that idle speed is within the
standard value range.
Read off the vacuum gauge.
Standard
value: 69 kPa (20 in.Hg)
(5) If not at standard value, refer to following
chart for cause
and repair.
Symptom
Cause
0 The vacuum gage reading is less than

standard value, but the needle is
stable.
Ignition timing is retarded.

rich.
0 Check ECI-MULTI system.

0 Check ECI-MULTI system.
gage needle swings
Remedy
Thevacuum
slowly.
The vacuum gage needle drops

irregularly.
0 The gas mixture is excessively

lean.
The vacuum gage needle drops

intermittently to 4.0 to 21.3 kPa (I .2
to 6.3 in.Hg)
Incomplete close contact of

intake and exhaust valve seats.
Thevacuum gage needle drops suddenly from the normal reading to 33.3
Malfunction
gasket
Adjust the ignition timing.
Check and repair the valve.

-
of cylinder head
Replace cylinder head gasket.
kPa (9.8 in.Hg), then returns to normal.
TIMING BELT TENSION ADJUSTMENT
NO%GDA
NOTE
Usually the timing belt tension is not adjusted.
However, if
irregular noise results from the belt hitting the timing belt
cover, tension should be adjusted
using the following
procedure.
(1) Remove the access cover.
NOTE
Work will be made easier, if the air conditioner
compressor
belt is removed.
(2) Loosen the timing belt tensioner
mounting
bolt 1 or 2
turns,
(3) Turn the crankshaft
two turns in the normal direction
(clockwise).
(4) Tighten the timing belt tensioner mounting bolt.
(5) Attach the access cover.
~~
/ TSB Revision
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Es--:
ENGINE
<3.OL>
- Engine Adjustment
DRIVE
BELTS
TENSION
9-67
ADJUSTMENT
w%=MBDl
TENSION
ADJUSTMENT
OF THE ALTERNATOR
DRIVE
BELT
Refer to GROUP 0 - Maintenance
Service.
DEFLECTION
ADJUSTMENT
OF POWER STEERING OIL
PUMP DRIVE BELT
Procedures.
TENSION ADJUSTMENT
OF THE AIR CONDITIONER
COMPRESSOR DRIVE BELT
Procedures.
IGNITION
MENT
TIMING
Refer to GROUP
INSPECTION AND ADJUSTNWRABI
8 - Ignition
system.
LASH ADJUSTER CHECK

Refer
to P.9-13.
1 TSB Revision
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NMFEAD
9-68
ENGINE <3.OL> - Engine
Mounting
ENGINE MOUNTING
GlWG.4..B
6-10 Nm
4-7 ft.lbs.
13-20 Aim
9-15 ff.lbs.
Removal of the Under Skid Plate,

unaercover,
bnow rr
- otection Undercover and Transfer C as8 Protector
(Refer to GROUP 23 - under Cover] 1
1Post-installation
Operation
Ie Installation of the Under Skid Plate. I
1 Undercover,
Snow Protection
Under- 1
cover and Transfer Case Protector
(Refer to GROUP 23 - Under Cover1
610
FIm
Ills
,A---.
3
.Ibs.
Removal
+e
++
steps
1. Heat protector
2. Front insulator
3. Engine
mounting
3040
Nm
22-29 ft.lbs.
stopper
front
insulator
4. Plate
5. Transfer
6. Transfer
7.
8.
9.
10.
mounting
mounting
insulator
bracket
Engine support rear bracket

No. 2 crossmember
Rear engine support member
Support plate
11. Engine
mounting
rear
NOTE
(I) Reverse the removal procedures
(2) +*
(3) I)*
insulator
<Vehicles
with a
manual transmission>
to reinstall.
of Removal.
of Installation.
<Vehicles
autometlc
with an
transmission>

3.
>
55-75
4654
Nm
ft.lbs.
olmn
NklSG8*H
REMOVAL OF ENGINE MOUNTING

FRONT INSULATOR
(1) Attach a chain to the engine hangers.
(2) Using a chain block-and-tackle,
hang the engine slightly up so that the insulator is free of engine weight.
(3) Remove the engine mounting
front insulator.
Caution
Avoid applying
a strain on the radiator
and fuel
hoses and cables by raising the engine too high.
NwGcAl
INSPECTION
Refer to P.9-15.

3.
1 TSB Revision
INSTALLATION
OF ENGINE
LATOR
Refer to P.9-15.
http://vnx.su/
MOUNTING
NWSOAS
FRONT INSU-
ENGINE <3.OL> - Oil Pan and Oil Screen
9-69
OIL PAN AND OIL SCREEN

r
N09m-s
Pre-removal
Operation
l
GROUP 23 - Hood.)
l
Removal of the Under Skid Plate.
Undercover,
Snow Protection
Undercover and Transfer Case Protection
Undercover
and Transfer Case Protector (Refer to GROUP 23 - Under
Cover.)
l
Removal of the Front Exhaust pipe
(Refer to GROUP 11 - Exhaust pipe
and Mufflers.)
l
Draining of the Engine Oil (Refer to
GROUP 0 - Maintenance
Service.)
6-10
Post-in~allatinn
Oaarntian
0 Installation -di &-f&t-Exhaust

1 pipe (Refer to GROUP 11 - Exhaust
pipe and Mufflers.)
l
Installation of the Under Skid Plate,
Undercover,
Snow Protection Undercover and Transfer Case Protector
(Refer to GROUP 23 - Under Covinstallation of the Hood (Refer to
::OUP
23 - Hood.,
Supplyin
of Engine oil (Refer to
GROUP \ - Maintenance
Service.)
1
l
Nm
8~100
Nm
58-72 ftlbs.
S-7 dm
Q-5 ft.lbs.
Removal
++
W*
*+
*41
steps
1. Starter
IEJ-44
a_
Nm
11-16 ft.lhc
._..__.
cover
2. Starter
3. Connection
for oil pressure
gauge
connector
4. Front suspension
crossmember
5. Transmission
stay (R.H.)
6. Transmission
stay (L.H.)
7. Connection
for ground
cable
8. Heat protector
9. Engine
mounting
bolt
10. Oil pan
11. Oil screen
12. Oil screen
gasket
13. Drain plug
14. Drain plug gasket
unit
100-120 Nm
72-87 ft.lbs.
NOTE
(1) Reverse the removal procedures
(2) 41* : Refer to Service Points
(3) +*
14) R
: Non-reusable pam
TSB Revision
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to reinstall.
of Removal.
of Installation.
8
-
:
2-s
;~~
9-70
__
.__
ENGINE <3.OL> - Oil Pan and Oil Screen

IO. REMOVAL
NostmAH
OF OIL PAN
(1) Knock the special tool in deeply between the oil pan
and cylinder block.
(2) Hitting the side of the special tool, slide and remove
the oil pan.
(3) Attach a chain to the -engine hangers.

(4) Raise the engine by using a chain block; then insert a
wooden spacer about 20 mm (.79 in.) thick between
the engine mounting
front insulator and the mount,
and lower the engine.
Caution
1. Be careful, when raising the engine, that it does
not strike and bend tubes or pipes.
2. After lowering
the engine, shake it gently to be
sure that it is correctly
mounted.
(5) Raise the vehicle by using a lift, and remove the oil pan
from the vehicles underside.
INSPECTION
No9Hc4E
Refer to P.9-16.
?mHo*o
10. INSTALLATION
OF OIL PAN
(I) Remove sealant from oil pan and cylinder block mating
surfaces.
(2) Degrease the sealant-coated
surface and the engine
mating surface.
(3) Apply the specified sealant around the gasket surface
of oil pan as specified
in illustration.
Specified sealant:
MlTSUBlSHl
GENUINE
PART
MZ100168
or equivalent
13
14
Groove
Hole of bolt
OlW59.3
/
J-ii
-
NOTE
The sealant should be applied in a continuous
bead
approximately
4 mm (.I6 in) in diameter.
(4) Assemble
oil pan to cylinder block within 15 minutes
after applying the sealant.
Caution
1. Tighten
the oil pan mounting
bolt in the order
illustrated
(left).
2. After installing
the oil pan, waft at least 30
minutes
before starting
the engine.
(5) Lower the vehicle; then attach a chain to the engine
hanger, and, using a chain block, raise the engine.
Caution
Be careful, when raising the engine, that it does not
strike and bend tubes or pipes.
(6) Remove the spacer between
the engine mounting
front insulator and the mount, and lower the engine.
evision
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ENGINE <3.OL> - Oil Pan and

6.
5.
Oil Screen
9-71
INSTALLATION
OF TRANSMISSION
STAY (L.H.)/
STAY (R.H.)
Transmission
stay installation
bolt size and torque are
different and caution must be paid to ensure that they are
properly installed.
TRANSMISSION
IndirAion for
hardness category
ront e
No.
Hardness category
(Head mark)
dx!
mm (in.)
Torque Nm
Wbs.)
12 x 35
(.47 x 1.37)
65-65
(47-61)
10 x 30
1.39 x 1.18)
3350
(24-36)
12 x 50
(.47 x 1.96)
65-85
(47-61)
Right side
TSB Revision
http://vnx.su/
i.
i
Irt&
,i
9-72
So
,_
ENGINE <3.OL> - Cylinder Head Gasket
CYLINDER
HEAD GASKET
Pre-removal
Operation
Removal of the Timing Belt
(Refer to P.9-77.)
l
Removal of the Intake Manifold.
(Refer to GROUP 11 - intake Manifold)
l
Undercover.
Snow Protection
Undercover and Transfer Case Protector
(Refer to GROUP 23 - Under Cover
l
Removal of the Front Exhaust Pipe
(Refer to GROUP 11 - Exhaust Pipe
and Mufflers)
l
12-15
Nn-II
15-22
11-16
Nm
ft.lbs.
s.
G-72-0-78-79
ft.lbs.
58-65-O-65-72
ft.lbs.
Xl-26
M-18
Nm
ft.lbs.
J-h.\
9
19-29
14-21
Removal
14 %
86
Nm
ft.lbs.
\
2~30
\
Nm lo
14-21
ft.lbs.
steps
1. Connection
for alternator
connector
2. Alternator
3. Connection
for spark plug cable
(No. 1, No. 3 and No. 5)
8. Heat protector
9. Engine hanger
10. Alternator
13.
l * 14.
15.
+e ++ 16.
l + 17.
20.
++ 21.
q~ 22.
++ w+ 24.
I)+ 25.
stay
Exhaust manifold (R.H.)

Oil level gauge guide
Gasket
Camshaft sprocket
Alternator bracket
Bolt
Rocker cover
Rocker cover gasket
Cylinder head assembly
Cylinder head gasket
1 TSB Revision
e
Rd.-
NOTE
(1) Reverse
(2) +e
:
(3) *+
(4) 0
:
http://vnx.su/
the removal procedures

Refer to Service Points
Non-reusable
parts
1:
to rein&II.
of Removal.
of Installation.
E&cc
~m&&e,
=
=
-
ENGINE
<3.OL>
- Cylinder
Head Gasket
9-73
S-10 Nm
67
Hot enaine
9O.h60-O-100-110
65-72-0-78-79
Cold enaine
80-90~0-90-100
58-65-O-65-72
Rbs*-Y
Nm
ft.lbs.
Nm
ft.lbs.
15-20
11-14
Nm
Ribs.
SO-100 Nm
58-72 Ribs.
\
10-12 Nm
71-z m YIL_
ILIDS.
I
\,b
15-2d
11-14
steps
4. Connection for spark plug cable
(No. 2, No. 3 and No. 6)
I)+
5. Distributor
6. EGR pipe
7. EGR Gasket
8. Heat protector
11. Air intake plenum stay (Front)
12. Bracket
13. Exhaust manifold (L.H.)
15. Gasket
+e l + 16. Camshaft sprocket
18. Timing belt rear cover
+I, I)+ 19. Distributor adaptor assembly
l + 21. Rocker cover
++ 22. Rocker cover gasket
23. Air intake plenum stay (Rear)
+* +a 24. Cylinder head assembly
I,?\
(
01W6l.
\
?m
12-15
9-11
Nm
ft.lbs.
Nm
ft.lbs.
Removal
*c
Post-installation
Operation
l
Installation of the Front Exhaust
pipe (Refer to GROUP 11 - Exhaust
pipe and Mufflers)
l
Installation
of the Under Skid Plate,
Undercover,
Snow Protection Under
(Refer to GROUP 23 - Under Cover1
l
Installation
of the intake Manifold
(Refer to GROUP 11 - Intake Manifold)
l
Installation of the Timing Belt (Refer
to P.977.)
l
Adjustment
of the Engine
(Refer to P.9-65.)
..V.L
(2) *I)
25. Cylinder head gasket

1 TSB Revision
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to reinstall.
of Removal.
(3) *c
(4)
: Non-reusable
parts
ii
*
at
9-74
a. i.
;..&a
._
ENGINE
<3.OL>
Cylinder
SERVICE
POINTS
Head
OF
Gasket
REMOVAL
NWJBBB
16. REMOVAL
OF CAMSHAFT
SPROCKET
Using special tool, loosen the camshaft sprocket
ing bolt.
19. REMOVAL
OF DISTRIBUTOR
ADAPTOR
mount-
ASSEMBLY
Caution
1. Remove the distributor
adaptor with care so as not
to damage
the O-ring.
2. Replace the O-ring if cracked or deteriorated.
24. REMOVAL
OF CYLINDER HEAD ASSEMBLY
Using the special tool, after loosening
the bolts in the
order shown in the figure (in 2 or 3 cycles), remove, and
then remove the cylinder head assembly.
SERVICE
POINTS
OF
lNSTALLATlON
25. INSTALLATION
OF CYLINDER HEAD
(I 1 Use a scraper to remove the cylinder
the cylinder block.
Caution
Take care that no foreign
coolant or oil passages.
evision
-1
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material
No9JDrn
GASKET
head gasket from
gets
into
the
ENGINE
<3.OL>
- Cylinder
9-75
Head Gasket
(2) Do not confuse cylinder head gaskets of each engine,

which have identification
marks on them to prevent
mistakes.
(3) Lay the cylinder head gasket on cylinder block with the
identification
mark at front top.
;;;;ification
24. INSTALLATION
OF CYLINDER
HEAD ASSEMBLY
(1) Use a scraper to remove the cylinder head gasket from
the cylinder head assembly.
Caution
Take care that

cylinder,
no foreign
material
gets
coolant
or oil passages.
(2) Using the special tool, tighten

shown in two or three steps.
Right
bank
@
or into
Caution
Attach the head bolt washer
in the figure.
Front
into
the
the bolts in the order
in the direction
shown
Left
bank
OlW594
Rocker
cover
notch
Rocker
I
cover
22. INSTALLATION
OF ROCKER COVER GASKET
Align the projection
of the gasket with the notch at the
inner side of the rocker cover, and secure so the gasket
wont get out of position.
ga<ket
21. INSTALLATION
OF ROCKER COVER
Coat sealing agent on the area specified
Specified
sealant:
1 TSB Revision
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Three-Bond
in the figure.
No. 1212D or equivalent
9-76
ENGINE <3.QL> - Cylinder
Head
Gasket
s
E-
19. INSTALLATION
OF DISTRIBUTOR
ADAPTOR ASSEMBLY
Coat engine oil on the oil seal lip area, the circumference
of the camshaft, the O-ring, and the cylinder head holes,
and install the distributor
adaptor.
17. INSTALLATION
OF ALTERNATOR
BRACKET
When installing the alternator bracket, tighten the bolts in
the sequence
shown in the illustration.
16. INSTALLATION
OF CAMSHAFT
Using the special tool, tighen
mounting
bolt.
SPROCKET
the camshaft
sprocket
14. INSTALLATION
OF OIL LEVEL GAUGE GUIDE
Coat engine oil on the O-ring before inserting the O-ring
on the oil level gauge guide, or before inserting the O-ring
equipped
oil level gauge guide into the cylinder block.
Oil level
Caution
Avoid damaging
the O-ring when inserting
gauge guide into the cylinder
block.
gauge guide
O-ring
(\
07RO618
5.
INSTALLATION
OF DISTRIBUTOR
Refer to GROUP 8 - Ignition System.
[ TSB Revision
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--
the oil level
9-77
ENGINE <3.OL> - Timing Belt
TIMING
NWIA-
BELT

Pre-removal
l
Draining
GROUP
Operation
of Engine Coolant (Refer tb
0 - Maintenance
Service.)
\
,
Removal
I)*
eq~
l I
4*
l e
4+
l a
l +
l +
l 4
l +
l +
l +
+a
I)+
I)*
+a
++ I)*
27 Nm
li
./
y-5:t
C6
ft.lbs.
steps
1. Connection for radiator upper hose
2. Radiator upper shroud
3. Cooling fan clutch assembly.
4. Drive belt (Air conditioner)
5. Drive belt (Power steering)
6. Drive belt (Alternator, Water pump)
7. Cooling fan pulley
8. Power steering oil pump
9. Oil pump bracket
10. Oil pump mounting bracket
11. Tension pulley bracket
12. Compressor (Air conditioner)
13. Compressor bracket (Air conditioner)
14. Cooling fan bracket assembly
15. Timing belt upper cover outer (8)
16. Timing
belt upper cover outer (A)
17. Timing belt lower cover outer
18. Gasket K
19. Gasket J
20. Gasket L
21. Gasket I
22. Gasket J
23. Gasket G
24. Gasket H
25. Crankshaft pulley
150-160
106-116
Nm
ft.lbs.
+4
28. Timing
01W602
15
26. Front flange

27. Timing belt tensioner
4*
++
bolt
belt
++ 29. Tensioner spring

++ 30. Timing belt tensioner
NOTE
(2) 41) : Refer to Service Points
(3) *4
1 TSB Revision
http://vnx.su/
to reinstall.
of Removal.
: Refer to Service Points of installation.
.,
&
;
_.
9-78
-=ese
i:.
ENGINE <3.OL> - Timing Belt

8ERVICE POINTS OF REMOVAL
8.
NWKBEB
REMOVAL
OF POWER STEERING OIL PUMP
Remove the power steering oil pump from the bracket and
hook it at the body side.
NOTE
Move the power steering oil pump with the pressure
and return hose still connected.
hose
12. REMOVAL
OF COMPRESSOR
(AIR CONDITIONER)
Remove the compressor
from the bracket and hook it at
the body side.
NOTE
Move the compressor
with the high-pressure
low-pressure
hose still connected.
25. REMOVAL
OF CRANKSHAFT
hose and
PULLEY
(1) Using the special tool and a disused

V-ribbed belt,
stop the rotation of the crankshaft
pulley.
Caution
1. This V-ribbed
belt will be damaged.
Do Not use
the engines V-ribbed
belt.
2. Never use a damaged
V-ribbed
belt.
(2) Remove the crankshaft
pulley bolt.
27. LOOSENING
TlMlNG
BELT TENSIONER
BOLT
Loosen the timing belt tensioner bolt and turn the timing
belt tensioner countercloc&wise
along the elongated hole.
Timing
28. REMOVAL
OF TIMING
BELT
When the timing belt is to be reused, in order to allow
reinstallation
of the belt so that it travels in the same
direction as before it was removed, mark the direction of
travel with an arrow before removing it.
Caution
1. As water or oil on the belt can seriously reduce its
usable life, ensure that the timing belt, sprocket,
and tensioner
stay clean and dry while removed,
and never wash them. Parts that have become too
dirty should be replaced.
2. When any of the parts are oily, check to see whether
there are any oil leaks in any of the oil seals or the
cam shaft oil seal on the front of the engine.
/ TSB Revision
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9-79
ENGINE <3.QL> - Timina Belt

INSPECTION
l
NWKCAE
TIMING
BELT
Check the belt in detail. If the following is evident, replace
belt with a new one.
(1) Hardened
back surface rubber
Back surface glossy, nonelastic
and so hard that even
if a finger nail is forced into it, no mark is produced.
7EN206
(2)
(3)
(4)
(5)
Crack
Cracked
Cracked
Cracked
Cracked
back surface
or separated
tooth bottom
side of belt
rubber
canvas
Separation
(6) Side of belt badly worn

NOTE
Normal belt should have clear-cut
sharp knife.
Separatio
Rounded
Abnormal wear
(fullv canvas fiber1
belt side
sides as if cut with a
7ENZ08
(7) Badly worn teeth

Initial stage:
Canvas is worn (fluffy canvas fibers are visible,
rubber is gone and color has changed to white.
Canvas texture is not clear.)
Last stage:
Canvas is worn out and rubber exposed and its
width is reduced.
(8) Missing tooth
Rubber
exposed
Tooth missing end
canvas fiber exposed
TIMING
BELT TENSIONER
If
When rotating the pulley, it does not rotate smoothly.
backlash or irregular noise is observed, replace the timing
belt tensioner.
EN0006
[ TSB Revision
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9-80
ENGINE <3.OL> - Timing
Belt
NlwrJEa
30. INSTALLATION
OF TIMING BELT TENSIONEW29.
TENSIONER SPRING
(1) Attach the tensioner and the timing belt tensioner.
(2) Engage the top of the tensioner spring on the water
pump pin. Attach the hook in the direction shown in
the drawing.
(3) Turn the timing belt tensioner

clockwise along the elongated
the timing belt tensioner.
to the extreme counterhole and temporarily fix
7EN21 I
28. INSTALLATION
OF TIMING BELT
(1) Align the timing marks of the camshaft sprockets (on
the right and left sides) and the crankshaft sprocket.
(At the top dead point of the No. 1 cylinder compression stroke.)
(2) First, route the timing belt on the crankshaft sprocket,
then on the camshaft sprocket on the side without
slackness in the tight side.
(3) Next, run the timing belt onto the water pump pulley,
the camshaft sprocket on the left side, and the timing
belt tensioner.
(4) Apply force counterclockwise
to the camshaft sprocket on the right side. When the tight side of the belt is
fault, check that the timing
marks are all aligned:
~
Timing
mark
Camshaft
Timing
sprocket
belt tensioner
Timirig
Crankshaft
?ii&rk
sprocket
7nc.937
[ TSB Revision
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ENGINE <3.OL> - Timing

(5) Attach
the
Belt
flange.
(6) Back off the fixing bolts of the temporarily

tightened
tensioner one or two turns and tighten the timing belt
with the tensioner
spring force.
(7) Using the special tool, turn the crankshaft two turns in
the normal rotating direction
(clockwise).
NOTE
Turn smoothly,
(counterclockwise).
._
but
not
in the
opposite
direction
7ENZ13
(8) Realign the sprockets

tensioner fixing bolts.
25. INSTALLATION
timing
OF CRANKSHAFT
marks
and tighten
the
PULLEY
(I) Using the special tool and a disused V-ribbed belt,

stop the rotation of the crankshaft
pulley.
Caution
1. This V-ribbed
belt will be damaged.
Do Not use
the engines V-ribbed
belt.
2. Never use a damaged
V-ribbed
belt.
(21 Tighten the crankshaft pulley bolt to the specification.
Right
Left bank
24. AITACHMENT
OF GASKET H/23. GASKET G/22. GASKET J/21. GASKET l/20. GASKET L/19. GASKET J/18.
GASKET K
Replace if there is cracking, peeling and/or deterioration.
Apply a coating of the specified
adhesive between
the
timing belt cover (front) and the gasket.
bank
Specified
SECT a-a
Gasket
G, H. J,l,
OlL0151
J, K, L
1 TSB Revision
http://vnx.su/
adhesive
: 3M adhesive
equivalent
EC870
or
9-82
ENGINE
<3,OL>
- Timing
Belt
17. INSTALLATION
OF TlMlNG BELT LOWER COVER OUTER/16. TIMING
BELT UPPER COVER OUTER (A)/15
TIMING
BELT UPPER COVER OUTER (B)
Since the mounting
bolts of timing cover are different in
size depending
on location, insert them with care.
Thread
A : 60
6 : 60
C : 60
diameter x
x 60 (2.36
x 2D (2.36
x 55 12.36
height mm (in.)
x 2.36)
x .79)
x 2.T7)
14. INSTALLATION
OF COOUNG
FAN BRACKET
BLY/II.
TENSION
PULLEY BRACKET
Cooling fan bracket and tension pulley bracket installation

bolt size and torque are different and caution must be paid
to ensure that they are properly installed.
@ylfYEF
Indication
hardness
ASSEM-
for
category
c4DOIl
No.
1
2
d x ( mm (in.)
Hardness- category
(Head mark1
10 x 95
(.39 x 3.74)
10 x 95
f.39 x 3.74)
10 x 110
(.39 x 4.33)
12 x 100
(.47 x 3.93)
10 x 85
(.39 x 3.34)
0
a-
o-
0
-
Torque
Nm (ftlbs.)
33-50
W-36)
65-85
(47-61)
33-50
(24-36)
~~
6:
INSTALLATION
OF DRIVE BELT (ALTERNATOR
PUMP)
Refer to GROUP 0 - Maintenance
Service.
5.
INSTALLATION
OF DRIVE BELT (POWER STEERING)
Refer to GROUP 7 - Seivice Adjustment
Procedures.
4.
INSTALLATION
OF DRlVE BELT (AIR CONDlTlONER)
Procedures.
/ TSB Revision
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WATER
ENGINE
9-83
Assembly
ASSEMBLY

Pre-removal
Operation
Removal of the Hood
(Refer to GROUP 23 - Hood.)
l
Removal of the Radiator
(Refer to GROUP 7 - Radiator.)
a Removal of the Under Skid Plate,
Undercover.
Snow Protection
Under
cover (Refer to GROUP 23 - Under
Cover.)
a Removal of the Front Exhaust Pipe
(Refer to GROUP 11 - Exhaust Pipe
and Mufflers.)
a Removal of the Transmission
and
Transfer Assembly
(Refer to GROUP 21 - Transmission
and Transfer Assemblv.)
a How to Reduce the Fuel Line Inter-
Post-installation
Operation
a Installation
of the Transmission
and
Transfer Assembly
(Refer to GROUP 21 - Transmission
Removal
,+
4*
*+
4*
4*
29-32
steps
1.
2.
3.
4.
5.
6.
Undercover, Snow Protection Under

(R;fer
to GROUP
23 - Under
for
O-ring
Connection for
Connection for
Connection for
Connection for
(Vehicles with
13. Connection for
fuel
high
Cov-
0 Installation of the Radiator

(Refer
to GROUP
7 - Radiator.)
10-13
7-Y-bs.
Nm
ftlbs.
Air cleaner duct

Drive belt (Air conditioner)
Compressor (Air conditioner)
Drive belt (Power steering)
Connection for oil cooler hose
7. Connection
8.
9.
10.
11.
12.
and Transfer Assembly.)

a Installation
of the Front Exhaust
Pipe (Refer to GROUP 11 - Exhausi
Pipe and Mufflers.)
a Installation
of the Under Skid Plate,
pressure
fuel return hose

vacuum hose
water hose A
water hose C
rear heater)
water hose 6
01 W625
hose
NOTE
(21 +,
(3) +a
parts
TSB Revision
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to reinstall.
of Removal.
of Installation.
ENGINE
9-84
<3.OL>
- Engine Assembly
28
OlW624
Removih
steps
14. Connection for alternator connector
15. Ignition coil and power transistor assembly
16. Connection for I.S.C. connector
17. Connection for throttle position sensor
connector
18. Connection for engine coolant temperature switch connector
(vehicles with air conditioner)
19. Connection for engine coolant temperature sensor connector
20. Connection for therm0 switch connector
(vehicles with automatic transmission)
21. Connection for engine coolant temperature gauge unit connector
22. Connection
hose ~
23. ;~yction
*e
+d
NOTE
for emission
control
for brake booster
vacuum
vacuum
24. Connection for control wiring harness

connectors
25. Connection for ground cable
26. Connection for oil pressure gauge unit
connector
27. Connection for ground cable
28. Heat protector
29. Engine mounting bolt
30. Engine assembly

(2) C+ : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation.
1 TSB Revision
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ENGINE <3.OL> - Engine Assembly
9-85

3.
REMOVAL
OF COMPRESSOR
Remove the compressor
from
the body side.
NcsBEc
(AIR CONDITIONER)
the bracket and hook it at
NOTE
Move the compressor
with the high-pressure
low-pressure
hose still connected.
6.
hose and
REMOVAL
OF POWER STEERING OIL PUMP
Remove the power steering oil pump from the bracket and
hook it at the body side.
NOTE
Move the power steering oil pump with the pressure
and return hose still connected.
7.
DISCONNECTION
OF FUEL
HIGH
PRESSURE
Caution
Cover fuel pipe line with rag after relieving
certain pressure may still remain.
30. REMOVAL
(I) Check
are all
(2) Slowly
engine
hose
HOSE
pressure
as
OF ENGINE ASSEMBLY
that the cables, hoses, harness connectors,
etc.
removed from the engine side.
remove the engine assembly upwards from the
compartment
with the chain block.
SERVlCE POINTS OF INSTALLATiON
Nll9s~
30. INSTALLATION
OF ENGINE ASSEMBLY
Check that dragging or biting is not occurring around the
harnesses, pipes, hoses, etc., install the engine assembly.
4.
INSTALLATION
OF DRIVE BELT (POWER
2.
INSTALLATlON
OF DRIVE BELT (AIR CONDITIONER)
Procedures.
) TSB Revision
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STEERING)
Procedures.
_)
9-86
DISASSEMBLY AND REASSEMBLY (ROCKER ARMS, ROCKER ARM SHAFTS AND

CAMSHAFT)
NWCE-B
Disassembly
1.
4*
2.
3.
4.
5.
4*
6.
4*
7.
8.
9.
10.
11.
12.
steps
Distributor adaptor
Camshaft oil seal
O-ring
Camshaft oil seal
Auto-lash adjuster (B)
Auto-lash adjuster (A)
Circular packing
Circular packing
Camshaft (B)
Camshaft {A)
(B)
(A)
Reassembly
l * 12.
+* Il.
I)+
8.
+*
7.
WI
6.
l + 5.
++ 10.
,+
9.
I)+
4.
l *
3.
I)*
2.
*C
I.
NOTE
(1) C+
(2) +41
13) q
steps
Camshaft (A)
Camshaft (B)
Auto-lash adjuster (A)
Auto-lash adjuster (B)
Circular packing
Circular packing
Camshaft oil seal
O-ring
Camshaft oil seal
Distributor adaptor

: Non-reusable
parts
5
( TSBRevision
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(A)
(B)
of Disassembly.
of Reassembly.
1
-

SERVICE
1.
POINTS
REMOVAL
9-87
Assembly
NWLFDPl
OF IllSASSEMBLY
OF DISTRIBUTOR
ADAPTOR
ASSEMBLY
Caution
(I) Remove the distributor
adaptor with care so as not
to damage the O-ring.
(2) Replace the O-ring if cracked or deteriorated.
5./6.
REMOVAL OF ROCKER ARM AND SHAFT ASSEMBLY

Before removing the rocker arm and shaft assembly, use
the special tool to ensure that the auto-lash adjuster
doesnt fall out.
Caution
Put the rocker arm and auto-lash
adjusters in order in
cylinder
No. separated
places with clear distinction
between
the intake
and exhaust
ones to prevent
confusion.
lNSPECTlON
.
CAMSHAFT
(I) Visually check the outer circumference
of the camshaft journal
diameter.
If damage,
wear, or heat
seizure is observed,
replace the camshaft.
If the
camshaft
journal is heat seized, check the cylinder
head for damage. Further, check the cylinder head oil
holes and the bearing cap for clogging.
(2) Check the tooth surfaces of the camshaft (A) distributor drive gear, and replace it if irregular wear is
observed.
(3) Check the cam surface for irregular wear or damage. If
observed, replace the camshaft. Further, measure cam
height (longer diameter of the cam). If it exceeds the
limit, replace the camshaft.
Standard
value:
Intake side . . . . . . . . . . . . . . . . . . . . 41.25 mm (1.6240
Exhaust side . . . . . . . . . . . . . . . . . 41.25 mm (1.6240
Limit : 46.75 mm (1.6043 in.)
SERVICE
POINTS OF REASSEMBLY
12./l 1. PNSTALLATION
OF CAMSHAFT
Install in the cylinder head after applying
oil to the camshaft
journal and cams.
1 TSB Revision
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in.)
in.)
NoaLGD%
a coat of engine
9-88

MD998+l3-01
Auto-lash
adjuster
8-n.
Assembly
INSTALLATION
OF AUTO-LASH
ADJUSTER/6./5.
ROCKER ARM AND SHAFT ASSEMBLY
(I) Insert the auto-lash adjuster from below as illustrated,
being careful not to spill the diesel oil inside it. Then
use the special tool to prevent adjuster from falling
while installing it.
7~~oo76
(2) Apply a minimum amount of sealing

places (shown in the figure).
agent on the four
NOTE
Be sure the sealing agent does not swell but onto the
cam journal surface of the cylinder head. If it swells
out, immediately
wipe it off before it can dry.
Specified
sealant:
3M
NUT
L&king
No. 4171
(3) Attach the rocker arm shaft assemblies

(A) and (B)
such that the arrow mark on the bearing cap faces in
the same direction as the arrow mark on the cylinder
head.
NOTE
The arrow marks face-each
assemblies
(A) and (B).
other on rocker arm shaft
(4) Tighten the bearing cap bolt to the specified torque.

(5) Remove the special tool that was attached in Step (1).
Arrow
mark (bearing
cap)
Rocker arm shaft

assembly (B)
0
Timing
Arrow
mark (cylinder
head)
Sealing
coating
belt side
Rocker arm shaft

assembly (A)
Arrow
1 TSB Revision
mark (bearing
http://vnx.su/
cap)
agent
location
ENGINE
<3.OL>
10./Q.
Engine
INSTALLATION
9-89
Assembly
OF CIRCULAR
PACKING
Attach to the special tool a spacer with 1.3 to 1.5 mm

(0.052 to 0.059 in.) thickness,
and press in the circular
packing.
Caution
Pressing in the packing without
attaching
the spacer
will result in over-insertion.
1 0.5 mm (0.020
150 m;(l.96in.)
in.)
4.
INSTALLATION
OF CAMSHAFT
OIL SEAL
(1) Apply a slight amount
of engine oil all over the
circumference
of the camshaft
oil seal lip section.
(2) Using the special tool, insert the oil seal.
3.
INSTALLATION
OF O-RING/S. CAMSHAFT
OIL SEAL /I.
DISTRIBUTOR
ADAPTOR
(1) Apply a coating of engine oil around the circumference
of the distributor
adapter and to the camshaft oil seal
lip, and press in to the distributor
adapter.
(2) Replace the O-ring if there is cracking or deterioration.
(3) After installing the O-ring to the groove in the distributor adapter, apply a coating of engine oil to the O-ring
and to the cylinder head hole.
(4) Apply a coating of engine oil ail around the circumference of the camshaft,
and install the distributor
adaptor to the cylinder head so that the O-ring is not

twisted.
1 TSB Revision
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up j_
9-90
DISASSEMBLY AND REASSEMBLY (ROCKER ARM AND SHAFT ASSEMBLY)
29-21
rawa-
-4
Nm
II
Disassembly steps
WI
1. Bearing
*)c 2. Rocker
3. Spring
l + 4. Rocker
5. Spring
+*
6. Bearing
+4
7. Rocker
8. Spring
++ 9. Rocker
10. Spring
++ 11. Bearing
++ 12. Rocker
++
+*
++
e+
13.
14.
15.
16.
17.
18.
Spring
Rocker
Spring
Rocker
Rocker
Bearing
cap No. 4
arm (B)
arm (A)
cap No. 3
arm (B)
arm (A)
cap No. 2
arm (B)
arm
7ENOO78
(A)
arm shaft (6)

arm shaft (A)
cap No. 1
NOTE
(2) I)+
: Refer to Service
procedures
to reassemble.
Points of Reassembly.
INSPECTION
w+NGAE
ROCKER ARM
(1) Check the roller surface and replace the rocker arm if
recesses, damage
or heat seizure is observed.
(2) Check roller rotation and replace the rocker arm if
uneven rotation or roller backlash is observed.
(3) Check the inside diameter and replace the rocker arm
if damage or seizure is observed.
ROCKER ARM SHAFT

(1) Check rocker arm mounting
portions of rocker arm
shaft for wear or damage.
Replace as necessary.
7EN0064
NwNHE4
18. INSTALLATION
OF BEARING CAP No. 1
Since bearing caps No. 1 and No. 4 look alike, check the
stamped
cap No.
1 TSB Revision
i
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_
+
-4s
ENGINE
Rocker
<3.OL>
9-91
- Engine Assembly
17. INSTitLLATlON
OF ROCKER ARM SHAFT (A)/16. ROCKER ARM SHAFT (B)
Insert bearing cap No. 1 so that the notch on the end of
the shaft faces in the direction shown in the figure and
insert the mounting
bolt.
arm shaft (B)
NOTE
Check that the oil groove faces downward as shown in the
figure and the oil port is located on the rocker shaft (A)
side.
Rocker
__&-_------0
arm
Rocker
arm shaft/ (B)

7EN0016
14./12./9./7./4./2.
INSTALLATION
OF ROCKER ARM/
11./6./l.
BEARING CAP
(I) Since bearing caps No. 2 and No. 3 look alike, check
the stamped
cap No. Then attach the caps.
(2) Coat engine oil on the inside diameter area of the
rocker arm and attach the rocker shaft.
Bearing
Front
mark
Bearing
cap No. 2
7EN0079
) TSB Revision
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cap No. 4

-
DISASSEMBLY AND REASSEMBLY (CYLINDER HEAD AND VALVE)
Cold engine
90-100 Nm
65-72 plbs.
Disassembly
steps
+I) ++
1. Cylinder head bolt

2. Washer
3. Cylinder head
I)+
4. Cylinder head gasket
+I* I)+
5. Retainer lock
+*
7. Valve spring
*4
8. inlet valve
*+ +a
9. Retainer lock
I** 11. Valve spring
I)+ 12. Exhaust valve
++ +4 13. Valve stem seal
+* 14. Valve spring sheet
+I) l 4 15. Valve stem seal
I)+ 16. Valve spring sheet
17. Inlet valve guide
18. Exhaust valve guide
19. Inlet valve sheet
20. Exhaust valve sheet
NOTE
(2)
(3) O+
++
(4)
: Refer to Sew&
: Refer to Service
: Non-reusable
Points
of Disassembly.
parts
rm9PFAF

1. REMOVAL
OF CYLINDER
(1) Using the special
HEAD
tool, loosen
BOLT
the cylinder
(2) Loosen the cylinder head bolts slowly

the sequence
shown_ in the figure.
head bolts.
and gradually
in
(=I
Timing
belt side
/ TSB Revision
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5./9.
9-93
Assembly
REMOVAL
OF RETAINER LOCK
(1) Using the valve spring compressor,
remove the retainer lock.
(2) Keep these parts in order so that they can be
reinstalled
in their original positions.
13./15. REMOVAL
OF VALVE STEM SEAL
Remove the valve stem seals with pliers
them.
and discard
INSPECTION
.
No9acAJ
CYLINDER
HEAD
(I) Before washing, check the cylinder head for water or
gas leakage, damage or cracks.
(2) Completely
remove oil. deposits, sealing agent, carbon, etc. After washing the oil passages,
blow air
through them to check that they are not clogged.
(3) Using a straight edge and feeler gauge, measure the
warpage on the A thru G areas as shown in the figure.
Standard
value : 0.05 mm
Limit : 0.2 mm (.008 in.)
(.0020
in.) or less
(4) If the measured flatness exceeds the limit, grind and

repair the surface to gain the flatness of standard
value or less.
Grinding
Overall
limit
height
: 0.2 mm (.008 in.)

: 84 mm (3.31 in.)
Caution
The cylinder head gasket surface should be ground
to within 0.2 mm (.008 in.) even with the grind of the
cylinder
block gasket surface.
.
VALVES
Refer to P.9-33.
1 TSB Revision
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NWPGAG

l
Out of squareness
Assembly
VALVE SPRINGS
of each valve spring and replace
necessary.
(2) Using a square, test squareness of each valve spring.
spring is excessively out of square, replace it.
(7) Check free length
ltFree
length
Standard
Free
Out
Limit
Free
Out
i
7ENO35
if
-:
E-
If
-~
value
length: 50.5 mm (I .988 in.)
of sawareness:
Less than 2
length: 49.5 mm (1.949 in.)

of squareness:
4
VALVE GUIDES
Refer to P.9-34.
VALVE SEAT RECONDITIONING
Refer to P.934.
0.5-l
.O mm
(.020-,039
VALVE SEAT
CEDURES
in.)
PROCEDURE
INSERT
REPLACEMENT
PRONomAo
(1) To replace: Scrape the inner face of the valve seat to

reduce the wall thickness. and remove.
0.5-l
.o mm
(.020-.039
in.)
lEN098
(2) Adjust the press fit diameter

of the valve seat on the
cylinder head side so that it matches the diameter of the
oversize valve seat.
1 EN099
Valve Seat Insert Oversizes

1 Description
1 Size mm (in.)
1 Sizemark
Seat insert height H mm(in.)
Cylinder head LD. mm (in
Intake valve
seat insert
0.3(.012)0.s.
0.6(.024)O.S.
30
60
7.9-8.1 (.311-.319j
8.2-8.4(.323-331)
44.300-44.325(1.7440-1.7451)
.~ 44.600-44.625(1.7559-1.7569)
Exhaust valve
seat insert
0.3(.012)0.s.
0.6(.024)O.S.
30
60
7.9-8.1 (.311--319)
8.2-8.4(.323-.331)
38.300-38.325(T:iO7W.5089)
38.600-38.625(1.5197-1.5207)
/ TSB Revision
-=
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1;
9-95
(6) Heat the cylinder head to about 250C (480F) and press in
an oversize seat insert fit to the insert bore in the cylinder
head at normal temperature.
(7) Treat the valve seat in the way shown in the illustration.
(8) Use the lapping compound, and lap the valve.
(9) Ensure that the seat is properly
centered
on the valve face.
6ENOZO
Press
Removal A
VALVE GUIDE REPLACEMENT PROCEDURES NWPHAE
Press
Installation
MD9981
1 S-01
(1) Recondition
the valve guide hole so that it matches
newly press-fit oversize valve guide.
Valve Guide Insert Oversizes
Size mm (in.)
6EN022
-I
Intake
mm (in.)
L----m
48
(1.89)
0.05 i.002) OS.

0.25 (.OlO) O.S.
0.50 (.020) O.S.
Size
mark
5
25
50
the
Cylinder head hole size

mm (in.)
13.050-13.068
(.513E-.5145)
13.250-13.268(.5217-.5224)
13.500-13.518(.5315-.5322)
J
NOTE
Do not reinsert a valve guide of the same size.
(2) The valve guide must be press-fit from the upper side of
the cylinder head. Keep in mind that the valve guides are of
different
length [Intake side:
44 mm (1.73 in.), Exhaust
side: 48 mm (1.89 in.)].
(3) After the valve guide is press-fit, insert a new valve and
check for smooth sliding.
(4) After the valve guide is replaced, check the fit between the
valve and the valve seat.
6EN31E
MD998377-01
/
NlwPKEe
16./14. INSTALLATION
OF VALVE SPRING SEAT/15./13.
VALVE STEM SEAL
install the spring seat, then using special tool, install the
stem seal by lightly tapping the tool. Seal is installed in
specified position, using the special tool.
Caution
1. Incorrect
installation
of the seal without
using
special tool will result in poor sealing and cause oil
leakage down valve guide.
2. Do not reuse stem seal.
1 TSB Revision
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9-96
ENGINE
<3.QL>
- Engine
Assembly
12. INSTALLATION
OF EXHAUST
VALVE/8.
iNLET
VALVE
Apply engine oil to each valve, insert valves iinto the valve
guides. Avoid inserting the valve into the seal with force.
After insertion, check to see if the valve moves smoothly.
11./7.
INSTALLATION
OF VALVE
SPRING
Refer to P.936.
9./5.
INSTALLATION
Refer to P.9-36.
OF RETAINER
LOCK
4.
INSTALLATION
OF CYLINDER
HEAD GASKET
(1) Clean the gasket mounting
surface of the cylinder
block and the cylinder head of remaining
gasket oil,
and other debris.
(2) When installing, face-the
identification
mark upward.
7EN232
identification mark
identification
mark...R
NOTE
Do not apply
sealant
to the cylinder
head
gasket.
1. INSTALLATION
OF CYLINDER
HEALI BOLT
(1) Using the sequence shown in the figure to tighten the
bolts with the special tool and a torque wrench.
0
Timing
side
belt
7EN238
(2) When tightening

the cylinder head bolts, repeat the
sequence
2 or 3 times to gradually
tighten them.
Finally tighten the bolt to the specified
torque.
http://vnx.su/
9-97

DISASSEMBLY AND REASSEMBLY (OIL PAN AND OIL PUMP)
NW*-
K-15 Nm
3-10 ft.lbs.
11-15 ftlbs.
h-50
26-36
Disassembly
1.
41) I)+
2.
+*
3.
4.
5.
6.
7.
41) ++
8.
9.
10.
11.
12.
13.
Nm
ft.lbs.
&-- I jnw
steps
Crankshaft sprocket
Oil pressure switch
Oil filter
Oil filter bracket
Oil filter bracket gasket
Drain plug
Drain plug gasket
Oil pan
Oil screen
Oil screen gasket
Plug
Relief spring
Relief plunger
I)*
++
&5E &.
Nm
ft.lbs.
36-45
26-32
14.
15.
16.
17.
18.
19.
Crankshaft
Oil pump
Oil pump
Oil pump
Oil pump
Oil pump
7EN0131
front oil seal

case
gasket
cover
outer rotor
inner rotor
NOTE
(I) Reverse the disassembly procedures to reassemble.
(2) +I) : Refer to Service Points of Disassembly.
(3) +a : Refer to Service Points of Reassembly.
(4) 1

2.
REMOVAL
Refer
OF OIL PRESSURE
to P.9-53.
/ TSB Revision
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SWITCH
--
9-98

8.
Assembly
REMOVAL
OF OIL PAN
(1) Knock the special tool deeply between the oil pan and
the cylinder block.
(2) Hitting the side of the special tool, slide the oil pan to
remove it.
INSPECTlON
e
Side
clearance
OIL PUMP
(1) Check the parts of the oil pump case for damage and
cracks.
(2) Assemble
the rotor on the oil pump and check the
clearance with a thickness
gauge.
Standard
value :
Body clearance : 0.100-0.181
mm
(.0039-.0071
in.)
Side clearance : 0.040-0.095
mm
(.0015-.0037
in.)
Body
clearance
7LUOOO2
NW-
OIL FILTER BRACKET

(1) Ensure that there is no damage
installation
surface.
(2) Check for cracks or oil leaks.
on the
oil filter
RELIEF PLUNGER AND SPRING

(1) Insert the relief plunger in the oil pump body and
check to see if it operates smoothly.
(2) Check the relief spring for breakage or sagging.
OIL PRESSURE SWITCH

(I) Connect a tester (ohm range) between
and the body and check for conductivity.
conductivity,
replace the switch.
the terminal
If there is no
7LUOOO6
(2) Next insert a very fine wedge through the oil hole,
pushing it slightly. There should be no conductivity
(resistance should be infinite). If there~is conductivity
even when wedge is pushed, replace the switch.
(3) Or, if there is no conductivity
when a 50 kPa (71 psi)
pressure is placed through the oil hole, the switch is
operating properly. Check at this time to see that there
is no air pressure leakage. If there is air pressure
leakage, the diaphragm
is broken, and the switch
should be replaced.
7LUOOO7
(
ii- evision
http://vnx.su/
c I_
.-

L=25
IL=Rolt
1.98)
lenoth
below
head
9-99
Assembly
SERVICE
POINTS
OF REASSEMBLY
15. INSTALLATION
OF OIL PUMP CASE
Attach the oil pump case with the gasket
NWRLAB
in between.
mm (in.) TV=MW?E
14. INSTALLATION
OF CRANKSHAFT
FRONT OIL SEAL
Using the special tool, knock the oil seal into the oil pump
case.
NOTE
Knock
Oil pump
case
Sealant coating
(Top view)
it as far as the surface.
7EN0139 I
8.
area
APPLICATION
OF SEALANT TO OIL PAN
(1) Clean the cylinder block and oil pan gasket surfaces.
(2) Apply specified sealant all around the oil pan flange to
a diameter
of 4 mm (.I6 in.).
Caution
Do not let the sealant
in the figure on the
Specified
Tightening
sequence
(bottom view)
of flange
sealant
ooze into the range (A) shown

oil pan flange.
: MITSUBISHI
GENUINE PART
MZ100166
or equivalent
(3) Install the oil pan within 15 mins. after applying the
liquid gasket.
(4) Tighten the flange bolts in the sequence shown in the
figure.
bolts
Timing
belt
side
e
7EN008l
1 TSB Revision
http://vnx.su/

3. INSTALLATION
Assembly
OF OIL FILTER
Refer to P.9-42.
2.
MD99805401
INSTALLATION
Coat sealant on the thread area, and using the special
install the pressure switch.
Specified
Apply
7LUOOO8
: 3M ART Part No. 8660 or equivalent
Caution
1. Do not let sealant ooze out of the top of the thread
area.
2. Do not overtighten
the pressure switch.
sealant.
sealant
DISASSEMBLY AND REASSEMBLY (PISTON AND CONNECTING
ROD)
Disassembly
1.
++ I)+
2.
3.
I)*
4.
5.
+* ,+
6.
4, ,d
7.
l a 8.
++ +*
9.
10.
11.
steps
Nut
Connecting rod cap
Connecting rod bearing (lower)
Piston, connecting rod assembly
Connectina rod bearina (uoper)
Piston rini No. 1
Piston rina No. 2
Oil ring
Piston pin
Piston
Connecting rod
12. Bolt
7EN0026
1--T@
50-5f Nm
37-38 ft.lbs.
zygeverse
the disassembly
(2) +I)
: Refer to Service
(3) ++
: Refer to Service
http://vnx.su/
procedures
to reasetible.
Points of Disassembly.
N-
g-101
ENGINE <3.OL> - Engine Assemblv

2.
6.
9.
REMOVAL
OF CONNECTING
ROD CAP
Refer to P.9-43.
REMOVAL
OF NO. 1 PISTON RiNGI7. NO. 2 PISTON
RING
Refer to P.943.
REMOVAL
OF PISTON PIN
Refer to P.9-44.
NOTE
For the piston and connecting
illustration
at the left.
rod front mark, refer to the
Front mark
Front
INSPECTION
PISTON
Refer to P.9-44.
PISTON PIN
Refer to P.9-44.
PISTON RING
NosTcec
(1) Check for piston ring damage,
wear, and bends.
Replace the rings if anything unusual is noted. Also be
sure to change the piston rings when a new piston is
installed.
(2) Check the clearance between the piston ring and the
ring groove. When it exceeds the limit, replace the
rings, the piston, or both.
Piston ring side clearance
Standard
value :
0.03409
mm (.0012-.0035
in.)
No. 1
No. 2
0.02-0.06
mm (.OOO&.0024 in.)
Limit :
No. 1
0.1 mm (.004 in.1
No. 2
0.1 mm I.004 in.)
(3) Insert the piston ring into the cylinder bore putting it
against the top of the piston head and pressing it in.
When it makes a right angle, measure the piston ring
gap with a feeler gage. When the gap is too large,
replace the piston ring.
Piston ring end gap
Standard
value :
No. 1
0.30-0.45
mm (.0116-.0177
in.)
0.25-0.40
mm (.0096-.0157
in.)
No. 2
Oil ring side rail
0.20-0.70
mm
(.0079-.0276
in.)
Limit :
No. 1
0.8 mm (.031 in.)
5ENC57
Kn
bythepisJ
No. 2
6ENO37
0.8 mm I.031 in.)
Oil ring side rail
1 TSB Revision
http://vnx.su/
1.0 mm
(.039 in.)
9-102
ENGINE <3.0L>
7EN246
Engine
Assembly
NomcDB
. BEARING
(1) Visually check the surface of the bearing. Replace
those which are lopsided, streaked, damaged, or show
signs of seizure. When streaks or seizure are excessive, check the crankshaft. If damage is discovered on
the crankshaft,
either replace it or reuse it after
undersize machining.
(2) Measure the inner diameter
of the connecting
rod
bearing and the outer diameter of the crankshaft pin. If
the gap (oil clearance) exceeds the limit, replace the
bearing, and if necessary, the crankshaft, or, undersize
machine the crankshaft and replace the bearings with
an appropriate
undersized type.
Standard
Limit
value : O.O184M?48
(.0008-.0018
: 0.1 mm (.004 in.)
mm
in.)
NOTE
For the method by which the oil clearance is measured
using a plastigage, refer to the item on the crankshaft.
Side
rail
Spat
9. INSTALLATION
OF PISTON PIN
Refer to P.9-46.
8. INSTALLATION
OF OIL RING
(1) Assemble
the oil ring spacer into the piston ring
groove. Then, after assembling
the upper side rail,
assemble the lower sjde rail. There is no difference
between the upper and lower side rails or spacers.
7EN0114
(2) The side rail may be easily installed by pushing it in

with your finger after fitting the end over the piston
groove.
Caution
Do not use piston
side rail.
ring
7EN249
/ TSB Revision
..http://vnx.su/
1%
-E-
expander
when
installing
9-103
Assembly
7. INSTALLATION
OF PISTON RING NO. Z/6. PISTON RING
NO. 1
(1) Using a piston ring expander, position the No. 2 and
No. 1 piston rings.
Identification
Identification
mark
NOTE
1. Keep in mind that Nos. 1 and 2 are different
in
shape.
2. Assemble the Nos. 1 and 2 piston rings with the
manufacturer
and size marks stamped on the side
facing upward (toward the piston top).
embossed
1
Barre
No. 1
Identification
mark
4.
Side rail
No. 1
+uzxJ,
I
No. 2 and
spacer slot
mark : No. 1 . . . Tl
No. 2 . .. 2R
INSTALLATION
SEMBLY
OF PISTON,
CONNECTING
ROD AS-
(1) Liberally coat engine oil on the circumference

of the
piston, piston ring, and oil ring.
(2) Arrange the piston ring and oil ring gaps (side rail and
spacer) as shown in the figure.
Side
rail
GENIIA,
(3) Insert
upper
the piston connecting

rod assembly
surface of the cylinder block.
from
the
Caution
1. The front
marks
on the pistons
should
be
oriented
as follows:
R on the No. I,3 and 5 cylinders and L on the
No. 2, 4 and 6 toward
the timing
belt.
2. Insert the connecting
rod with the front mark
directed toward
the timing belt side.
nt mark
Front
7EN255
(4) Securely pressing the piston ring with the ring band,
insert the piston connecting
rod assembly
into the
cylinder. Keep in mind that the piston ring or the crank
pin may be broken or damaged
if hit strongly.
//
7EN0032
,vision
http://vnx.su/
.p
-i--
z
--
g-104
:~
.~...
-I
ENGINE <3.QL>
2.
Stopper n
- Engine Assembly
INSTALLATION
OF CONNECTING
ROD CAP
(1) Install the connecting
rod, aligning it with the mark
made or the connecting
rod cap during disassembly.
When the connecting
rod being installed is new and
has no alignment mark, install it so that the notches in
the connetiing
rod and cap are on the same side, as
illustrated.
7ENZ56
(2) Check
the connecting.
rod big end side clearence.
Standard
value : 0.10-0.25
Limit : 0.4 mm (.016 in.)
1 TSB Revision
http://vnx.su/
mm
(.0039-.0098
in.)
:
_
9-105
(DISASSEMBLY AND REASSEMBLY (CRANKSHAFT, FLYWHEEL AND DRIVE PLAz$&

73-77
53-55
IO-12 Nm
7-9 ft.lbs.
Nm
ft.lbs.
2
\
s-10 Nm
&7 ft.lbs.
18
Disassembly
steps
1. Flywheel assembly
2. Ball bearing
3.
4.
5.
6.
7.
l + 8.
l + 9.
++ 10.
++ 11.
l + 12.
Vehicles with a
manual transmission
7EN0132
Adaptor plate
Vehicles with an
Drive plate
Crankshaft bush 1 automatic transmission
Transmission mounting plate
Rear plate
Oil seal case
Crankshaft rear oil seal
Bearing cap bolt
Bearing cap
++ 13. Thrust bearing B

q~ 14. Crankshaft bearing (lower)
15. Crankshaft
l + 16. Thrust bearing B
l + 17. Thrust bearing A
l + 18. Crankshaft bearing (upper)
NOTE
(1) Reverse the disassembly procedures to reassemble
(2) +a : Refer to Service Points of Reassembly.
Thrust bearing A
(31
[ TSB Revision
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9-106
ENGiNE <3.OL> - Engine
Assembly
INSPECTION
l
RING GEAR (vehicles with a manual transmission)

When there is wear, cracks, or other damage to the ring
gear teeth, replace the ring gear by the following procedure. Check the starter motor pinion.
Ring gear replacement
procedure
:
(1) Tap around the ring gear to loosen and remove it from
the flywheel.
Caution
The ring
3EN301
cannot
be removed
while
it is hot.
: 0.13 mm
(.0051
in.)
DRIVE PLATE (vehicles with an automatic

transmission)
Replace deformed,
damaged,
or cracked drive plates.
CRANKSHAFT
(1) Check the crankshaft
journals and pins for damage,
uneven wear and cranks. Also check oil holes for
clogging.
Correct or replace any defective
part.
(2) Inspect
out-of-roundness
and taper of crankshaft
journal and pin.
Standard
value
Crankshaft
journal
O.D. : 60 mm (2.36 in.)
Crank pin O.D. : 50 mm (1.97 in.)
Limit
Out-of-roundness
of journal and pin :
0.03 mm (6012 in.)
Taper of journal
and pin : 0.05 mm (6002 in.)
(3) To check the oil clearance,
measure
the outside
diameter
of the crankshaft
journal and the inside
diameter
of the bearing. The clearance can be obtained
by calculating
the difference
between
the
measured
outside and inside diameters.
Standard
value
Crankshaft
main bearing : 0.020-0.048
mm
(.OQO&.0019
in.)
Connecting
rod bearing : 0.016-0.046
mm
(.0006-.0018
in.)
Limit
Crankshaft
main bearing : 0.1 mm (004 in.)
Connecting
rod bearing
: 0.1 mm l.004 in.)
(4) If the oil clearance exceeds the limit, replace the main
bearing (and also the crankshaft if necessary). Or in
addition to undersizing
the crankshaft,
replace the
main bearing with an undersized
one.
(5) When grinding the crankshaft to under-size, take note
of the R dimensions of the fillets of the journal and pin
area.
7EN261
gear
(2) Heat the ring gear to 300C (572F) and install it into
the flywheel.
FLYWHEEL (vehicles with a manual transmission)
(1) Make a visual inspection of the clutch disc. If stepped
wear, streaking, or seizure are apparent,
replace it.
(2) If flywheel
run out exceeds the limit, replace it.
Limit
rmuHA6
Revision
http://vnx.su/
ENGINE (3.OL>
Engine
9-107
Assembly
MAIN BEARINGS AND CONNEC-WVG ROD BEARINGS

Visually inspect each bearing for peeling, melt, seizure an
improper
contact. Repolace the defective
bearings.
PLASTIGAGE
METHOD
Plastigage
may be used to measure the clearance.
(I) Remove
oil and grease and any other dirt from
bearings and journals.
(2) Cut plastigage to the same length as the width of the
bearing and place it in parallel with the journal, off oil
holes.
(3) Install the crankshaft, bearings and caps and tighten
them to the specified torques. During this operation,
do NOT turn the crankshaft.
Remove the caps. Measure the width of the plastigage at the widest part by
using a scale printed on the plastigage
sleeve.
If the clearance exceeds the repair limit, the bearing
should be replaced or an undersize bearing used.
When installing
a new crankshaft,
be sure to use
standard size bearings.
Should the standard clearance not be obtained even
after bearing
replacement,
the journal
should be
ground to undersize and a bearing of the same size
should be installed.
POINTS OF REASSEMBLY
SERVICE
N09GAF
18. INSTALLATION
OF CRANKSHAFT
BEARING
(UPPER)/17./12.
THRUST
BEARING
A/16./13.
THRUST
BEARING B/14. CRANKSHAFT
BEARING (LOWER)
(1) Classify the crankshaft bearings (upper and lower) by
whether there is an oil groove or not. Then, assemble
as shown in the figure.
(2) Assemble the thrust bearings (A and B) on the No. 3
journal area as shown in the figure.
Caution
Install them
with
the groove
No
Timing
belt
oil
side facing
groove
side
Timing
belt
TSB Revision
http://vnx.su/
side
7EN269
outward.
9-108
Assembly
11. INSTALLATlON
OF BEARING CAP/IO.
BEARING CAP
BOLT
(1) Attach the bearing cap on the cylinder block as shown
in the figure.
(2) Tighten the bearing cap bolts to the specified torque in
the sequence
shown in the figure.
(3) Check that the crankshaft
rotates smoothly.
7EN270
Timing belt side
MD99871
9.
INSTALLATION
OF CRANKSHAFT
REAR OIL SEAL
Using the special tool, press-fit a new crankshaft rear oil
seal into the oil seal case.
8.
INSTALLATION
OF OIL SEAL CASE
(1) Apply specified sealant to the area shown
MD998718
-7EN272
Specified
sealant
: 3M ART Part
or equivalent
in the figure.
No. 8660
(2) Apply a small amount

of engine
oil to the entire
circumference
of the oil seal lip section, and place the
oil seal on the cylinder block.
7EN273
TSB Revision
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DISASSEMBLY
AND
9-109
Assembly
(CYLINDER BLOCK)
REASSEMBLY
NO9W-B
20-30
15-21
Nm
ft.lbs.
Engine &pport
bracket, left
7810133
INSPECTION
.
CYLINDER
BLOCK
(I) Visually check for scoring, rust, and corrosion. Use a
flaw detecting
agent for inspection. Repair or replace
damaged
or flawed parts.
(2) Using a straight edge and thickness gage, measure
the flatness of the upper surface of the cylinder block.
Be sure that gasket chips do not remain on the upper
surface of the cylinder block during measurement.
Standard
value : 0.05 mm (.OOZO in.)
Limit : 0.1 mm (.004 in.)
Grindable
limit : 0.2 mm (-008 in.)
Caution
When the cylinder head is assembled,
in.) or less of grinding
is permissible.
0.2 mm (.008
(3) Check the cylinder wall for scoring and seizure. Repair
(over size) or replace it improper.
(4) Using a cylinder gauge, measure the inside diameter
and roundness
of the cylinder. If excessively worn,
repair (over size) the cylinder and replace the piston
and piston rings. The measurement
points are shown
in the figure.
BORING
Refer
THE CYLINDER
to P.9-54.
SB Revision
http://vnx.su/
Oil
Cooler
NWMA-
ENGINE OIL COOLER

,.-I
<Z-door
vehicles>
2lZl
.30-35
<4-door
vehicles>
Pre-remove1 Operation
Undercover, Snow Protection Under
$fer to GROUP 23 - Under Cov-
Removal
steps
l *
1.
2.
3.
4.
5.
6.
Nm
Removal of the Radiator Grille (Refer to GROUP 23 - Grille, Garnish.)

Draining En ine Oil
(Refer to GwOUP 0 - Maintenance
Service.)
Eye bolt
Gasket
Engine oil feed hose assembly
Engine oil return hose assembly
Engine oil cooler
Bracket
PosMwtallation
l
Operation
Installation of the Radiator Grille.

(Refer to GROUP 23 - Radiator
grille.)
Installation of the Under Skid Plate,
Undercover, Snow Protection Undercover, Snow Protection Undercover
and Transfer Case Protector (Refer
to GROUP 23 - Under Cover.)
Supplying of Engine OiI (Refer to
GROUP 0 - Maintenance Service.)
NOTE
(I) Reverse the rem&al procedures to reinstall.

(2) a+ : Refer to Service Points of Removal
(3) p
NWkl8AB
SERVICE POINT OF REMOVAL

1. EYE BOLT
Caution
Be sure to hold the weld
loosening
the eye bolt.
nut
of the oil cooler
NwMcA8
iNSPECTION
l
l
l
[ TSB Revision
Check
plugs.
Check
clogging
Check
Check
the
while
engine
oil cooler
fins
for
bends,
breaks
the engine oil cooler hoses for cracks, damage,

or deterioration.
the gaskets for damage
or deformation.
the eye bolts for clogging
or deformation.
http://vnx.su/
or
=
-
.=
14-I
FUEL SYSTEM
CONTENTS
AUTO-CRUISE
CONTROL SYSTEM
................................. 106
AUTO-CRUISE
CONTROL
............................................ 134
SERVICE ADJUSTMENT
PROCEDURES
..................... 125
Accelerator Cables Inspection and Adjustment
....... 127
.................... 125
Auto-cruise Control System Inspection
....................................... 128
Individual Parts Inspection
106
SPEClALTOOLS
...........................................................
106
SPECIFICATIONS
.........................................................
..............................................
I 06
........................................... . . 106
Torque Specification
........... ___________
_.__.-__.- _._-_____ 106
TROUBLESHOOTING
.............. ... ................................ 107
Auto-cruise Control Components
Location
........... _- 123
Auto-cruise Control Related Harnesses
................... 122
Check Chart ............................................ _____._
-___- 111
Input Check ......... ..- ............................................ ____ 121
Self-diagnosis
Check .............. ___._._I___
119
Troubleshooting
Quick-reference
Chart ................... 107
ENGINE CONTROL
............................................................
102
ACCELERATOR
CABLE AND PEDAL ........................... 104
SERVlCE ADJUSTMENT
PROCEDURES
..................... 102
.................. 102
Accelerator Cable Free Play Adjustment
SPECIFICATION
...........................................................
102
Service Specification
..................... -_-_-----102
............................................ -_ 102
102
TROUBLESHOOTlNG
...................................................
2
FBC SYSTEM
.....................................................................
CARBURETOR
..............................................................
34
.........................................
25
FBC SYSTEM INSPECTION
................ ___-__......................
Components
Location
Electric Choke Relay ..............ll. ..... --_. ......... .._. _-_ ii:
Sensor
....................... 30
Engine Speed Sensor ...............................................
31
32
Feedback Solenoid Valve ..........................................
Oxygen Sensor .........................................................
31
Slow Cut Solenoid Valve ..................... .- .................... 32
Throttle Opener Control Solenoid Valve for
Air Conditioner
............................... ..~ ........... ___. _._-- 32
30
Throttle Position Sensor ...........................................
Vacuum Switch .........................................................
31
52
FUEL LINE AND VAPOR LINE ......................................
FUEL PUMP ...................................................................
46
FUEL TANK ...................................................................
50
SERVICE ADJUSTMENT
PROCEDURES
..................... 11
Carburetor Appearance
............................................
11
Carburetor Inspection
...............................................
15
Dash Pot Adjustment
.................................. . . .--- 15
............................................
24
Fuel Filter Replacement
. 24
Fuel Gauge Unit and Pipe Assembly Replacement
.............................................
11
Idle Speed Adjustment
Idle Speed and Mixture Adjustment
.........................
11
11
Idle Speed Check Procedure
....................................
Overfill Limiter (Two-way Valve) Replacement
......... 24
...... 13
Throttle Opener Adjustment for Air Conditioner
.......................
13
Throttle Position Sensor Adjustment
SPECIALTOOLS
...........................................................
4
SPECIFICATIONS
................. 3.. ...................................
..............................................
..............................................
........ .._....................................
TROUBLESHOOTING
...................................................
Circuit Diagrams .......................................................
Control Functions Table ............................................
Fuel Tank and Fuel tine ............................................
MPISYSTEM
.....................................................................
FUEL LINE AND VAPOR LINE ......................................
FUEL TANK ...................................................................
INJECTOR .............................................................. .. ...
MPI SYSTEM INSPECTION
..........................................
Air Conditioner Switch ...................... ..- ....................
Air Conditioner Power Relay .....................................
Components
Location
..............................................
Control Relay ................. _.___________-___.-......._ ............
EGR Control Solenoid Valve (M/T models only) ........
EGR Temperature
Sensor California only) ...............
Sensor .......................
Idle Position Switch ..................................................
Idle Speed Control Servo (Stepper Motor) ................
Inhibitor Switch .........................................................
- .................................
Injectors ..................... -__~
Intake Air Temperature Sensor .................................
Malfunction
Indicator Light ......................................
..................
Oxygen Sensor ........................... _____-____
Power Steering Oil Pressure Switch .........................
Power Transistor
......................................................
Purge Control Solenoid Valve ...................................
Self-diagnosis
...........................................................
Throttle Position Sensor ...........................................
Vehicle Speed Sensor ...............................................
SERVICE ADJUSTMENT
PROCEDURES
.....................
...................................
Basic Idle Speed Adjustment
Curb Idle Speed inspection
......... .._- .......................
EGR Valve Control Vacuum Check ............................
Fixed SAS Adjustment
..............................................
Fuel Filter Replacement
............................................
..................................
Fuel Gauge Unit Replacement
Fuel Pressure Measurement
....................................
Fuel Pump Connector Disconnection
(Howto Reducethe Fuel Line Internal Pressure)
.....
Fuel Pump Operation Check ........................... ..- ......
Idle Position Switch andThrottle
Position Sensor
Adjustment
...............................................................
.........
Overfill Limiter(Two-way
Valve) Replacement
Purge Port Vacuum Check ........................................
Throttle Body (Throttle Valve Area) Cleaning
....... ....
SPECIAL TOOLS ...........................................................
SPECIFICATlONS
.........................................................
..............................................
..............................................
...............................................
THROTI-LE BODY .........................................................
TROUBLESHOOTlNG
...................................................
Circuit Diagrams
.......................................................
Control Functions
................................ -_ ._...............
Fuel Tank and Fuel Line ............................................
http://vnx.su/
2
2
3
4
5
9
8
7
54
99
96
90
71
86
89
71
88
89
86
84
85
87
86
86
84
74
86
86
89
89
75
85
86
62
63
62
70
66
67
67
68
67
68
65
67
70
65
56
54
54
55
55
93
56
60
59
62
14-2
FBC SYSTEM
- SDecifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
Items
Fuel tank capacity

Fuel return system
Fuel filter
Fuel pump
Type
Drive by
Discharge pressure
Carburetor
Specifications
lit. (gal.)
SO(15.9)
Provided
Cartridge type
Mechanical diaphragm type
Camshaft
19.6-29.4 (2.8-4.2~2500 rpm
kPa (psi)
Downdraft, Z-barrel feedback type

Automatic (electric type)
PTC heater
Type
Choke type
Heater
IdentificatTon model No.
for Federal/California
for California
3235 DlDEF-431
32-35 DIDEF-1
Throttle bore-primary
mm (in.)
secondary
mm (in.)
Feedback solenoid valve
Slow cut solenoid valve
Throttle opener
Dash pot
Throttle position sensor
Bowl ventvalve
Mixture control valve
Engine control unit
Identification model No.
Input sensors
Engine coolant temperature sensor
Oxygen sensor
Vacuum switch
Output actuators
Secondary air control solenoid valve
Throttle opener control solenoid valve
TSB
32(1.26)
35 (1.38)
Duty cycle solenoid
Duty cycle solenoid
Diaphragm type
Conventional type
Variable resister type
Vacuum type
Vacuum type
EZT55971
Thermistor type
Zirconia sensor
Control-type switch
ON-OFF Solenoid valve
ON-OFF Solenoid valve
Revision
http://vnx.su/
14-3
FBC SYSTEM - Specifications

SERWCE
SPECIFICATIONS
Specifications
Items
Standard value
Engine adjustments
Actual ignition timing at high altitude-Federal/California
and
high altitude vehicles for Federal
Curb idle speed
wm
For the first 500 km (300 miles)
After 500 km (300 miles)
Throttle opener adjustment
rpm
Rpm for air conditioner load
(when air conditioner ON)
Dash pot touch rpm
wm
Throttle-position sensor
V
Adjustment voltage (throttle valve completely closed)
Carburetor
Main jet - primary
secondary
Pilot jet- primary
secondary
Enrichment jet
Automatic choke heater
Choke breaker opening
mm (in.)
1st stage
2nd stage
First idle rpm
n
Feedback solenoid valve coil resistance
D
Slow cut-off solenoid valve coil resistance
kn
Throttle-position
sensor resistance
Input sensor
kD
Engine coolant temperature sensor resistance
20C (68F)
80C ( 176F)
V
Oxygen sensor output voltage
Vacuum switch
Output actuator
n
Secondary air solenoid valve resistance
Throttle opener control solenoid valve resistance
/ TSB Revision
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7+ 2BTDC at curb idle

Approx. 12BTDC
725:;;;
800-c 100
900-950
2000
0.250
# 107.5
#I90
#55
#70
#65
Continuity-approx.
6 D [at 20C (68F)]
2.3-2.5 (.091-0.98)
3.0-3.2(.118-,126)
Approx. 2,350
54-66 [at 20C (68F)]
48-60 [at 20C (68F)]
3.5-6.5
2.5
0.3
Approx. 1
ON more than 40 kPa (5.8 psi)
OFF less than 26 kPa (3.9 psi)
36-44 [at 20C (68F)]
40-48 [at 20C (68F)]
14-4
FBC SYSTEM - Specifications / Special Tools
TORQUE SPEClFlCATlONS
NWCC-A
Items
Carburetor installation bolt
Oxygen sensor
Throttle-position sensor installation screw
Therm0 valve (2 nipples)
Drain plug
Fuel tank to body
Fuel gauge unit
Air cleaner to rocker cover
Nm
15-20
20-40
4060
2.wa.5
20-35
15-20
2530
I
16-19
-.
ftlbs.
11-14
14-29
29-36
1.8-3.2
14-25
11-14
18-22
7
12-14
SEALANTS
NucE.A
items
Therm0 valve threads
Specified sealant and adhesive
sensor threads
3M Adhesive Nut Locking

No.4171 or equivalent
3M Adhesive Nut Locking
No.4171 or equivalent
SPECIAL TOOLS
roo1
Number
( TSB Revision
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Quantity
As required
As required
14-5
FBC SYSTEM - Troubleshooting
NI4.5BA.a
TROUBLESHOOTING
When checking and correcting engine troubles, it is
important
to start with inspection
of the basic
systems.
In case you have such troubles as (1)
engine start failure, (2) unstable idling or (3) poor acceleration,
therefore,
you should first check the
following
basic systems.
l
l
(4) Ignition system

0 Spark plug
l
High-tension
l
Distributor
l
Ignition coil
(5) Emission control system

l
PCVsystem
l
EGR system
l
Vacuum leak
Fusible link
Fuse
(6) Others
l
Ignition timing
l
Idle speed
(2) Body ground

(3) Fuel supply
l
Fuel line
l
Fuel filter
l
Fuel
Troubles with the FBC system are often caused by

poor contact of harness connector.
It is, therefore,
important to check harness connector contact.
pump
Symptom
Remedy
Probable cause
Engine will not start 01 Carburetor

start too hard (cranks
Choke valve remains open-cold
W
Clean choke bore and link

Check and adjust choke breaker
Check electricchoke
operation
Needle valve sticking or clogged
Repair and repalce
Vacuum hose disconnected
3ough idle or engine
engine
Electric choke malfunction
FBC system
malfunction
jtallS
cable
sensor
or damaged
1 Repair or replace
Check component
Feedback solenoid valve malfunction
Check component
Vacuum switch malfunction-cold
Check component
Faulty Engine Control Unit
Replace
Harness broken/short circuited or

connector not connected securely
Repair or replace
Carburetor
Choke valve malfunction
Improperfast
idle-cold engine
Improper idle adjustment
chokevalve
Check by using checker (MD9984061

(Check component and replace if faulty)
Slow-cut solenoid valve malfunction
engine
bodyand
Clean choke bore and link

Adjust fast idle speed
~Adjust idle speed
Check choke body and choke valve operation
Primary pilot jet clogged
Clean up or replace
Dash pot malfunction
Adjust
FBC system
1 TSB Revision
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Check drive signal by using checker

(MD998406)
Check component
I.
14-6
Symptom
Rough idle or engine
stalls

1 Probable cause
Remedy

malfunction
sensor
-~
or damaged.
Throttle position sensor malfunction
tngine hesitates or
3001 acceleration
Repair or replace
--
and adjust
Check by using checker (MD998406)

Check harnesses for continuity
Throttle opener control system

malfunction
Check system. If faulty, check components
Harness broken/short-circuited
or
connector not connected securely
Repair or replace
Carburetor
Acceleration
-~
pump malfunction
Choke valve remains open-cold
engine
Choke valve remains closed-hot
engine
Check pump discharge rate
1~ Clean choke bore and link-
Enrichment valve faulty
Repair or replace
Main jet clogged
Clean up
Enrichment jet clogged
Clean up
Secondary valve operation abnormal
Check valve operation
Auxiliary acceleration
-cold engine
Check pump discharge rate
pump malfunction

malfunction
Check chgke valve operation
Check drive signal by using checker

(MD998406)
Check component
Vacuum switch malfunction

sensor
oar fuel mileage
Check component
Engine speed sensor malfunction
FBC system
ingine dieseIrng (runs

ifter ignition switch is
urned off)


-
Check component
and adjust
Check by using checker (MD9984061

Check harnesses for continuity
Harness broken/short-circuited
or
connector not connected properly
Repair or replace
Carburetor
Engine idle speed too high
.~
_
Adjust idle speed
FBC system
Slow cut solenoid valve malfunction
Check component
Carburetor
Choke valve operation abnormal
Check valve operation
Engine idle speed too high
~~~
Adjust idle speed

Check choke body and valve operation
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FBC SYSTEM - Troubleshootina

Symptom
Poor fuel mileage
Probable cause
Remedy
Enrichment valve kept open
Repair or replace
Auxiliary acceleration pump is in

operation-hot engine
Repair or replace
FBC system
malfunction
sensor

Oxygen sensor malfunction

Check drivesignal by using

checker (MD998406)
Check component
Check drive signal by using

checker (MD998406)
Check components
Check component

check harnesses for continuity
Harness broken/short circuited or

connector not connected properly
Repair or replace
and adjust
FUEL TANK AND FUEL LINE

Symptom
Probable cause
Engine malfunctions
due to insufficient
fuel supply
Bent or kinked fuel pipe or hose
Repair or replace
Clogged fuel pipe or hose
Clean or replace
Clogged fuel filter or in-tank fuel filter
Replace
Water in fuel filter
Replace the fuel filter or clean the fuel tank

and fuel line
Dirty or rusted fuel tank interior
Clean or replace
Malfunctioning fuel pump

(Clogged filter in the pump)
Replace
Mispiping of vapor line
Correct
Evaporative emission
control system
malfunctions (When
tank cap is removed,
pressure releasing
noise is heard)
1 Remedy
Correct
Folded, bent, cracked or clogged vapor line
Replace
Faulty fuel tank cap
Replace
Malfunctioning overfill limiter

(two-way valve)
Replace
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Electric choke relay

(for air conditioner load)
Slow-cut solenoid valve
Vacuum switch
Oxygen sensor
Air conditioner switch
Engine-speed sensor
Throttle-position sensor
OTE
The * symbol indicates no direct relation to the control units control functions.
output
input
Power supply (battery back-up)

sensor
Air/fuel mixture
Throttle opener
ratio control (*FBC) control
Power supply (ignition switch interlock)
Function
CONTROL FUNCTIONS TABLE
Electric choke
relay control
Secondary air
control
7
14-9
NI4ElL4
CIRCUIT DIAGRAMS
Main
Sub fusible
To alternator
[Refer to GROUP
81 4
link
ignition
13:
I
c\
o*85-w
To multi-purpose
switch
fuse w
A-24
--1.25-R
2-BW
A-22
I I I
I
Feed back
solenoid valve
Slow cut
solenoid valve
YG
J.25-BW
1,Y
I
2-BW
Auto choke
heater
1.25-R
nrottle position
msor
G
YR
GY
,*
\G
:g
YL-0
s-2
7-BW
1
c.
b
yR 3
CD
A-20
Carburetor
assembly
l Z
Remarks
the ground points (exam(1) For information
concernin
ple: q ). refer to GROUP 8 .
(2) The symbols 0, @ etc. indicate that the wiring is connected
(using the same numerical symbol) to the following.
l 1
Color code for wiring

B : Black
Br : Brown
LI : Light blue 0
: Orange
G
P
: Green
: Pink
/ TSB Revision
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Gr
R
: Gray
:Red
L
Y
: Blue
: Yellow
Lg
W
: Light green
: White
;2-BW
To vacuum solenoid valve

[Refer to GROUP 81
A-35.
c
2-BW
-
1
i
---I
Feed back
carburetor
control unit
Vacuum
switch
control solenoid
A-45
GY
I
1 L- -7
L -----I
Remarks
(1) For information
concerning
the ground points (examle: q ), refer to GROUP 8.
(2) %-re symbols @, D etc. indicate that the wiring is connected
(using the same numerical symbol) to the previous page.
Color code for wiring
B : Black
Br : Brown
G : Green
Gr : Gray
L
LI : Light blue 0
: Orange
P : Pink
R : Red
Y
[ TSR Revision
sensor
a7wlm4
:aue
: Yellow
http://vnx.su/
Lg
W
: Light green
: White
14-11
FBC SYSTEM - Service Adjustment Procedures
SERVICE ADJUSTMENT
PROCEDURES
r4I.F.L
CARBURETOR APPEARANCE
B
Mixture
control
Air nipple
vent
2-stage choke breaker
Depression
chamber
Electrical auto-choke
Throttle openerDashpot
Sec&daty
well
bleed nipple
View B
5Fu121
%Ul20
I valve

-Ad
-
Throttle openerDashpot
Accelerator
pump-=
Vacuum nip
Vacuum nipp
WSWC
cuum nipple E (EGI
ViewA
rdmi/aa
IDLE SPEED CHECK PROCEDURE

Refer to GROUP 0 - Checking
wm
and adjustment
NI4FHsba
IDLE SPEED ADJUSTMENT

Refer to GROUP 0 - Idle Speed
Drill hole here at a 45 angle

towards concealment plug
of the iding
inspection
and Adjustment.
IDLE SPEED AND MIXTURE ADJUSTMENT (For

NIc=mF
Unscheduled Maintenance Only)
(I) Remove carburetor from engine (Refer to P.1434.)
(2) Clamp carburetor
in a vice with idle mixture adjusting
screw facing up (protect gasket surface from vice jaws.1
(3) Drill a 2 mm (5/64 inch) pilot hole in the casting surrounding the idle mixture adjusting screw then redrill the hole to
3 mm (116 inch).
(4) Insert a blunt punch into the hole and drive out plug.
(5) Reinstall carburetor on engine.
(6) Run the cold engine at fast idle until the cooling water
temperature
is raised to 85 to 95C (185 to 205F)
/ TSB Revision
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14-12
FBC SYSTEM - Service
Adjustment
Procedures
inspection
Conditions
l
Engine coolant temperature:
85 - 95C (185 - 295F)
8 Light and accessory operation
: off
e Transmission
: neutral
l
Steering wheel : center position (power steering equipped
vehicles)
(7) Prepare a timing light and tachometer.
(8) Depress accelerator
pedal once to release the fast idle.
(9) Check the cycle of the timing light. Adjust if necessary.
Timing
fight cycle
: PBTDC
+ 2
NOTE
Refer to GROUP 8 - Ignition System, for the timing
inspection
and adjustment
procedures.
cycle
(10)Turn off the ignition key.

(11)Disconnect
the cable from the negative terminal of the
battery for about 5 seconds. And then reconnect the cable
to the original terminal.
(12)Disconnect
the connector of the exhaust oxygen sensor.
(13)Run the engine for more than 5 seconds at the engine
speed of 2,000 to 3,000 rpm.
(14)Run ghe engine at idle for 2 minutes.
(15)Set the CO-HC tester.
5FU124
(16)Set the idle CO and the engine speed to the specified

value by adjusting the idle speed adjusting screw No. 1
and the idle mixture adjusting
screw.
ldleC0
: 0.1 to 0.3%
Curb idle speed :
Cl725 + 158
- 100 rpm
at nominal
curb
idle speed
/ *z800 f 180 rpm
NOTE
1. *I: For the first 500 -km (300 miles)
2. *2: After 500 km (300 miles)
3. If the idle CO adjustment
fails, suction of secondary air
is likely. Plug the secondary
air hose and try again.
Caution
DO NOT TOUCH the idle speed adjusting
screw No. 2.
The idle speed adjusting
screw No. 2 is the preset
screw that determines
the relationship
between
the
throttle
valve and free lever, and has been accurately
set at the factory. If this setting is disturbed,
throttle
opener adjustment
and dash pot adjustment
cannot be
done accurately.
/ TSB Revision
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Adjustment
14-13
Procedures
(17)Turn off the ignition switch.

(18)Connect
the oxygen sensor connector.
(19)lnstall the concealment
plug into the hole to seal the idle
mixture adjusting screw.
THROlTLE OPENER ADJUSTMENT FOR AIR CONN14FKBC

DITIONER
The throttle opener (idle-up actuator) described here controls
the idle speed when the air conditioning
is applied.
NOTE
Check the ignition
this adjsutment.
timing
and idle speed
before
performing
Inspection
Conditions
: 85 - 95C (185 - 205F)
Lights and accessories
: Set to OFF
Transmission
: Neutral
Steering wheel : Straightforward
(vehicles with a powersteering)
(1) Start the engine.
(2) Set the tachometer.
(3) Turn on the air conditioner
switch.
NOTE
The solenoid
valve will open and the intake manifold
vacuum will act on the throttle opener to fully actuate it.
(4) Check
the engine
Standard
value
speed
: 900-950
during
this operation.
rpm
If the engine speed is out of specification,

adjust using the
throttle opener (for air conditioner)
adjusting screw.
THROTTLE POSITION SENSOR ADJUSTMENzwm(;

(I) Loosen
the accelerator
1 TSB Revision
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cable enough.
.-
14-14
FBC
SYSTEM
Service
Adjustment
Procedures
(2) Loosen the speed adjusting

screw No. 1 and
sufficiently
to close the throttle valve completely.
Record the number of turns loosened.
NOTE
1. Turning
the screw
counterclockwise
No.
closes the valve.
2. At this time, the fast idle control should have been

released (the lever not resting on the fast idle cam).
Fast idle
cam
Lever
(3) Disconnct
the carburetor
connectors.
(4) Connect
the special tool (test harness) between
the
disconnected
connectors.
(5) Connect a voltmeter
between
terminal Q (red: sensor
output) and @ (blue: sensor ground) of the carburetors
connectors.
Caution
Use a good,
h 1D998474
Sensor outcut
(Red tenni$alj
(Front
view)
5FUl25
~;~OTE
Connection
as follows:
FBC
Terminal 0
Terminal @
Sensor
power
suPPlY
(Black
terminal)
Standard
5FUOO71
I
Throttle
position
sensor
calibrated
of FBC connector
digital
type
voltmeter.
and special tools terminal
is
connector
Special tool
(sensor output) and Terminal Red
(sensor ground) and Terminal Blue
(6) Turn the ignition switch to ON (Dont start the engine).

(7) Measure the voltage of the throttle position sensor output.
Sensor
ground
(Blue
terminal)
finely
value
: 0.250
(8) If it is out of specification,

loosen the throttle position
sensor attaching screw and adjust by turning the throttle
position sensor to the standard value.
NOTE
Turning the throttle position sensor clockwise increase the
output voltage.
(9) Turn the ignition switch-to
OFF.
(lO)Tighten
the SASI and SAM for the amount recorded in
step (2). (Return to the original position.)
(11)Remove
the voltmeter
and the special tool and connect
the carburetors
connectors.
5Fu127
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Adjustment
14-15
Procedures
(12)Adjust play of the accelerator

cable. (See P.14102).
(13)Start the engine and check that the idle speed is as
specified.
Standard
Curb
value :
idle speed
For the first 500 km (300 miles)
After
DASH POT
500 km (300 miles)

ADJUSTMENT
NOTE
Curb idle speed adjustment
inspecting
dashpot.
inspection
Free lever
: 725 :$rprn
: 800 nlO0
must be properly
rpm
NW=MAB.
adjusted
before
Conditions

: 85 - 95C (185 - 205F)
Lights and accessories
: Set to OFF
Transmission
: Neutral
Steering wheel : Straightforward
(vehicles with a power
steering)
-!3!
(1) Start the

(2) Open the
free lever
(3) Close the
and check
Standard
engine and run at idle.

throttle valve for full stroke of the rod until the
contact SAS3.
throttle valve unit1 SAS2 contacts the free lever
the engine speed at that moment.
value
: 2,000
rpm
(4) If engine speed is not as specified, adjust dashpot RPM by

turning SAS3.
(5) Release the free lever and verify that the engine returns to
idle speed slowly.
CARBURETOR INSPECTION
DISTRIBUTOR
ADVANCE
UUM)
Inspection
Condition
Engine
coolant
CONTROL
temperature:
VACUUM
[D VACNwFwAa
85 - 95C (185 - 205OF)
(1) Disconnect
the vacuum
hose from the carburetor
D
vacuum nipple and connect a hand vacuum pump to the
nipple.
NOTE
For the location of the
Appearance
(P.1411.)
(2) Start and race the engine
increases with the engine
nipple,
refer to the
to make
speed.
Carburetor
sure that D vacuum
NOTE
If abnormality
is found in change of vacuum, blocked
carburetor D port is suspected.
Therefore, clean the port
as necessary.
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14-16
FBC SYSTEM - Service Adjustment

EGR VALVE CONTROL
Inspection Condition
acuum pressure
Procedures
VACUUM
(E VACUUM)
N14FwPJI
-
o Engine coolant temperature

: 85 - 95C (185 - 205F)
(1) Disconnect
the vacuum
hose from the carburetor
E
nipple.
NOTE
For the location
ance (P.14-11).
1
Engine rpm
lFW46
of the nipple,
(2) Start and race the engine

increases with the engine
refer to Carburetor
to make sure that

speed.
AppearE vacuum
NOTE
If abnormality
is found in change of vacuum, blocked
carburetor E port is suspected.
Therefore, clean the port
as necessary.
VRV CONTROL VACUUM (A VACUUM)

vacuum pressure
Ml-

: 85-95C (185- 205F)
(I) Disconnect the vacuum hose from the carburetor A vacuum
nipple and connect a hand vacuum pump to the nipple.
Engine rpm
NOTE
For the location of the nipple, refer to Carburetor Appearance (P.14-11).
(2) Start and race the engine to make sure that A vacuum increases gradually with the engine speed.
lFuu7
NOTE
If abnormality is found in change of vacuum, blocked carburetor A port is suspected. Therefore, clean the port as necessary.
VACUUM SWITCH CONTROL VACUUM (F VACUUM)

NlWMl

: 85-95C (185- 205F)
(1) Disconnect the vacuum hose from the carburetor vacuum nip
ple and connect a hand vacuum pump to the nipple.
Vacuum pressure
NOTE
For the location of the nipple, refer to Carburetor Appearance (P.14-11).
(2) Start and race the engine to make sure that F vacuum drops
rapidly.
Engine t-pm
lFu44a
1 TSB Revkjx
NOTE
If abnormality is found in change of the vacuum, blocked carburetor F port and vacuum passage. Therefore, disassemble
and check the carburetor.
_
~A+
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~-
FBC SYSTEM - Service Adiustment
Additional
ryLI
14-17
Procedures
CARBURETOR
BLEED AIR PASSAGE (CARBURETOR
ALTITUDE
COMPENSATION
SYSTEM)
bleed air passage
PRIMARY WELL BLEED NIPPLE

Federal/California
and High-altitude
-c:
Air inlet of
additional
bleed air. I:
vehicles
HIGH
N14FRAB.
for Federal
NOTE
For the nipple position, refer to Carburetor Appearance
(P.1411).
(1) Disconnect the vacuum hoses from the air nipple and connect
a hand vacuum pump to the nipple.
(2) Apply vacuum to see that it leaks and does not build up inside
the carburetor.
(3) Disconnect the vacuum hose from the primary well bleed nip
ple and connect a hand vacuum pump.
(4) Apply vacuum to see that it leaks and does not build UP
inside the carburetor.
(5) If vacuum builds up, disassemble
and check the carburetor. (Refer to P.14-35.)
h-
Prima; wel
bleed nipplt
rimarj
nain jm
SECONDARY
High-altitude
WELL BLEED NIPPLE

vehicles for-Federal
N14msaa
NOTE
For the nipple position, refer to Carburetor Appearance
(P.1411.)
(1) Disconnect
the vacuum hose from the bleed nipple and
connect a hand vacuum pump to the nipple.
(2) Apply vacuum to see that it leaks and does not build up
inside carburetor.
and check the carburetor. (Refer to P.14-35.)
JET AIR NIPPLE
NWFRCA.
High-altitude
vehicles for Federal
Secondary throttle valve
NOTE
For the nipple position,
11.)
refer to Carburetor
Appearance
(P.14
(1) Disconnect the vacuum hoses from both air nipple and jet
air nipple and connect
a hand vacuum
pump to the
nipples.
(2) Apply vacuum to see that it leaks and does not build up
inside carburetor.
and check the carbure
tor. (Refer to P.1435.)
Primary throttle valve

1Fu3n
Revision
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Adjustment
CARBURETOR
Procedures
SECONDARY
VALVE
OPERATION
N14FOAAa
(1) Remove the air cleaner assembly.
(2) Disconnect the secondary valve vacuum hose from the carburetor throttle body and connect a hand vacuum pump to
the disconnected
end of hose.
OlR6676
(3) With a vacuum of 13.3 kPa (1.9 psi) applied by the vacuum
pump, fully open the primary throttle valve and check that
the secondarythrottlevalve
also opens fully.
Non return valve
Pump nozzle
,
Vacuum is not held in depression

chamber (vacuum leaks)
Replace depression chamber
Vacuum is held but secondary

valve does not operate
Clean secondary
and related parts
CARBURETOR
ACCELERATION
PUMP
throttle
valve
NMFPUv
(1) Remove the air cleaner assembly cover.

(2) While opening the choke valve, open the throttle valve and
check that fuel is injected from the pump nozzle.
If fuel is not injected, clean the carburetor fuel passage.
Choke valve
CHOKE VALVE
Refer to GROUP
N74FoAAb
0 - Maintenance
Service.
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ELECTRIC
Adjustment
Procedures
CHOKE
Electricauto-chol:e
14-19
NMFOBC
Two staae choke breaker
f-----T,
Caution
All carburetors
have a tamper-proof
choke. The chokerelated parts are factory adjusted. The choke adjustment
is
not required during service, except when major carburetor
overhaul or choke carburetor
related parts adjustments
are
needed by state or local inspections.
(1) Check that the alignment marks on the electric choke and
bimetal assembly are lined up. If not, align the marks.
NOTE
1. For removal of the bimetal assembly,
refer to DISASSEMBLY AND REASSEMBLY (P.14-35). -for the Federal/California.
2. Misalignment
and resultant symptom.
-~I
Poorer startability and more likely
(2) Check that engine coolant temperature

is below 10C (50F).
(3) Start the engine and check operation of the choke valve and
fast idle cam, with hand on the electric choke body.
Electric choke body
Gets gradually hotter after engine

Start
Choke valve
Opens as bimetal temperature

IiSeS
Fast idle cam
Fast idle control is released as engine coolant temperature rises

and fast idle breaker operates
(4) If the electric choke body remains cool even after the engine
is started, check the electric choke.
[ TSB Revision
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Front view
u -:1
Carburetor
CHOKE
float chamber
BREAKER
At less than
cover
5Fuoo72
SYSTEM
Adiustment
ELECTRIC CHOKE HEATER

N14FOCAb
(1) Disconnect the carburetor connector and check continuity
of the heater.
Normal state : Should be conductive
[approx.
6 R at
20C (68aF)]
(2) If the heater is not conductive,
replace the electric choke
body (bimetal assembly).
NOTE
For replacement
procedures,
refer to DISASSEMBLY AND
REASSEMBLY
(P.14-35.)
Nl4FoEaJ
18C (65OF) (1st stage)
Choke valve
Procedures
At 180C (65F) or higher
(2nd
stage)
@
-Manifold
vacuum
___-:I-.l
intake manifold vacuum
ThZ
valve
Closes at [l t %C(65F)and over]
Manifold vacuum -J
lFlJae2
To intake manifold
1FlJ391
hlnl-r
,,L
(1) Remove the air cleaner.

(2) Check conditions of the choke valve according
to the procedures
given in the table below.
For information
concerning
the checking
of the
thermo valve, refer to GROUP 25 - Exhaust Gas
Emission Control System.
Check conditions
Choke valve when normal
Before starting engine
10C (50F) or lower
25C (77F) or higher
Presumed cause
when abnormal
Malfunction of
bimetal assembly
Malfunction of link
Engine idling after start (Start

after first fully depressing
accelerator pedal one time.)
Slowly open slightly

immediately after starting
[Clearance: 2.3-2.5 mm
(.091-,098 in.)]
Delay valve clogged

Diaphragm damaged
(chamber A)
Disconnect the vacuum hose

(yellow stripe) from the choke
breaker during idling.
No movement
Malfunction of
therm0 valve
Connect the vacuum hose

(yellow stripe) and let the
engine idle.
When the chok;valve is

lightly closed by a finger,
stops at a position open
more than step 2.
[Clearance: approx. 3 mm
(.I2 in.)]
Malfunction of
therm0 valve
Diaphragm damaged
(chamber B)
/ TSB Revision
------I
http://vnx.su/
FBC SYSTEM
- Service Adjustment
CHOKE
BREAKER
14-21
Procedures
NISOlWl
OPENING
(1) After inspection of the choke breaker system, disconnect the

vacuum hose (yellow stripe) from the choke breaker and make
the following check.
(2) With the engine idling, close the choke valve lightly with a
finger until the choke valve stops. Then, measure the choke
valve to choke bore clearance.
Standard
value
: 2.3-2.5
mm
(.091-.098
in.)
(3) If the clearance is not as specified, stop the engine, remove

the bimetal assembly and adjust the rod end opening for standard clearance.
NOTE
For removal of the bimetal assembly,
BLY AND REASSEMBLY
(P.14-35).
Choke bkaker rod ?-
refer to DISASSEM-
3Fu133
When removing the bimetal assembly, put a mark on the electric choke body.
NOTE
\
\
.
(4) Reconnect the removed yellow stripe vacuum hose and measure the choke valve to choke bore clearance as in step (2).
Standard
value
: 3.0-3.2
mm
(.ll&.I26
(5) If the clearance is out of specification,

screw.
NOTE
in.)
adjust by the adjusting
Adjusting screw turning direction

Clockwise
Valve clearance
Expected result
Small
Counter clockwise
Large
Better startability but

plug more likely to
get sooty
Poor startability and
stall more likely
[ TSB Revision
http://vnx.su/
14-22
FBC SYSTEM - Service Adjustment
Procedures
FAST IDLE
NMFOGC
Choke breaker
v-
Cam follower
Intake manifold vacuum
1FlJ3sn
inspection
Conditions
o Engine coolant temperature:
85 - 95C (185 - 205F)
l
Lights and accessories:
Set to OFF.
l
Transmission:
Neutral
o Steering wheel: Straightforward
(vehicles with a power
steering)
(2) Install the tachometer.
(3) Disconnect the vacuum hose (white stripe) from the choke
opener.
(4) Set the lever on the second highest detent of fast idle
cam.
lW3S
(5) Start the engine

Standardvalue
and check
: 2350
the fast idle speed.
rpm
(6) If the fast idle speed is out of specification,

fast idle adjusting screw.
Fast idling adjusting screw
http://vnx.su/
adjust with the
Adjustment
OVATE
Rotation
direction
Adjusting
rection
screw
14-23
Procedures
of adjusting
di-
Clockwise
Counterclockwise
screw
and fast idle speed
Valve opening
Fast idle speed
Large
Increases
Decreases
Small
(7) Connect the vacuum hose removed in step (3) to the choke
opener and check that the choke opener cancels fast idle.
AUXILIARY
ACCELERATION
PUMP
Nw=YAAb
(1) Remove the air cleaner cover.
(2) Check to be sure that the engine coolant temperature
is
30C (86F) or lower, and then check according to the
steps in the table below.
uxiliafy
ccelerator
ump
Step
1
3Fu333
(for Auxiliary
Accelerator Pump)
Check conditions
With the engine idling, disconnect the
black vacuum
hose from the
carburetor Auxiliary Accelerator Pump.
Warm-up the
engine until the
temperature of
the engine
coolant reaches
Vacuum hose
Vacuum
Pump nozzle
Vacuum is felt
Fuel is sprayed
from the nozzle
when the hose
is disconnected.
when the hose
end is covered
by a finger.
Vacuum cannot
be felt by the
finger.
50C (122F) or
higher.
(3) If the change of the vacuum is incorrect, check the therm0

valve for the Auxilian/ Accelerator
Pump.
If vacuum
is normal but fuel is not sprayed from the
nozzle, clean the carburetors
fuel passage.
THERM0
VALVE
CONTROL)
(FOR AUXILIARY
ACCELERATOR
PUMP
NWFZAtL
(1) Disconnect
the vacuum hose (black) from the therm0
valve and connect a manual vacuum pump to the therm0
valve.
(2) Apply a vacuum
of 66 kPa (10.0 psi) to the therm0
valve.
When engine is cold [coolant

temperature 30C (86F) or lower]
Vacuum is not applied
After engine warm-up [coolant

temperature 50C (122F) or higher]
Vacuum is applied (no
(leakaae).
leakage).
(3) If incorrect,
replace the therm0 valve.
Caution
1. Do not use a wrench or similar tool at the resin part
when removing
or installing
the therm0
valve.
2. When installing,
apply a coating of an anaerobic sealant
to the threaded
part, and then tighten at a torque of
20-35 Nm (14-25 ftlbs.).
/ TSB Revision
J
http://vnx.su/
14-24
FBC SYSTEM - Service Adiustment
Procedures
THROTTLE OPENER CONTROL SYSTEM FOR AIR CONDINwPGBBb

TIONER LOAD
Inspection
Condition
: 85 - 95C (185 - 205F)
(I) Disconnect
the vacuum-hose
(yellow stripe) from the
throttle opener installed on the carburetor and connect a
hand vacuum pump to the nipple.
(2) Check that the throttle opener rod is pulled up when
vacuum is applied.
(3) Apply 67 kPa (10.0 psi) vacuum and check air tightness.
._
(4) Start the engine and close the vacuum hose (yellow stripe)
end with a finger to check vacuum when the air conditioner switch is turned on and off.
Air conditioners
switch
OFF
Engine speed
Hose end vacuum

Absent
=
Idle
Present
ON
1,200 mm or
more
Absent
FUEL FILTER REPLACiMENT

refer to GROUP
iIh;FFILL
0 - Fuel filter
(Replace)
LIMITER (TWO-WAY VALVE) REPLACENMFEAGI
(1) Remove the fuel filter hose protector.

(2) Disconnect the vapor hoses, and then remove
limiter.
the overfill
FUEL GAUGE UNIT AND PIPE ASSkMBiY

PLACEMENT
RENWFFAI
(1) Remove the fuel tank cap and lower the fuel tanks internal
pressure.
(2) ;isixrnect
the .harness connector
from the fuel gauge
(3) Remove the fuel gauge unit installation screws,
remove the fuel gauge unit and pipe assembly
fuel tank.
/ TSB Revision
http://vnx.su/
and then
from the
FBC SYSTEM - FBC System
FBC SYSTEM
COMPONENTS
14-25
Inspection
NMED-
INSPECTION
LOCATION
5FU131
Symbol
Throttle opener control solenoid valve (for

air conditioner)
Engine-speed sensor (ignition coil0)
Oxygen sensor
Electric choke relay
Throttle-position
Engine control
Vacuum switch
sensor
sensor
Name
Symbol
Name
[ TSB Revision
http://vnx.su/
unit
-
14-26
inspection
Vacuum
Throttle-Poskon
--
Secondary
switch
sensor
air controzienoid
-(
valve
/
/
f,
http://vnx.su/
Inspection
14-27
1. Before removing
or installing
a part, disconnect
the
battery - terminal.
2. Before disconnecting
battery terminals, turn off the ignition switch. Removal or connection
of battery terminals
during engine operation
or with the ignition switch ON
could cause erroneous
operation
of the Engine control
unit or damage to semiconductors.
3. The control harnesses between
Engine control unit and
ignition coil [ -terminal]
and between Engine control unit
and oxygen sensor are shielded wires with shield grounded to the vehicle body in order to prevent ignition noises
and radio interference.
When the shielded wire is faulty,
therefore,
the control harness must be replaced.
4. When ECI checker
is handled,
pay attention
to the
following
points.
l
Avoid rough operation
of switches.
l
Do not subject ECI checker to shock and other external
forces, heat, etc.
l
Keep away water and oil.
l
Store ECI checker in a moisture- and dust-free place
and take steps to protect the checker from heat and
vibration.
Connect to ECU
NI4PDAG
FBC SYSTEM INSPECTION
(USE ECI CHECKER)
Inspection
and maintenance
of electric system in the FBC
system can be made quickly by inspecting the Engine control
unit input and output electric signals with the ECI checker and
then by inspecting the component
whose signal is abnormal
and the harness between
the component
and the Engine
control unit.
Using the special tools (FBC Test Harness and ECI Checker),
check the FBC system by the following
procedure.
Inspection
Procedure:
(I) Turn ignition switch to LOCK.
(2) Remove the ECI cover.
(3) Disconnect
the Large harness connector
and Small harness connector
from the Engine control unit.
(4) Set check switch of the ECI checker to OFF.
(5) Set select switch of the ECI checker to A.
(6) Connect the FBC Test Harness to the connectors
of the
ECI checker, and then connect the FBC Test Harness to
the Engine control unit and harness connectors.
(7) Perform checks according
to the FBC System Check
Procedure chart.
(8) If checker shows any variance from specifications,
check
the corresponding
sensor and related electrical wiring
then repair or replacement.
(9) After repair or replacement,
recheck with the ECI checker
to confirm that the repair has corrected
the problem.
(lO)Set check switch of the ECI checker to OFF.
(1 l)Set ignition switch to Lock.
(12)Disconnect
connectors
of the ECI checker and the FBC
Test Harness from the Engine control unit and the body
side harness connectors.
(13)Connect the body side harness connectors to the Engine
control unit.
(14)After completion
of the above test make certain that the
trouble has been eliminated
on the road test.
1 TSB Revision
http://vnx.su/
14-28
FBC SYSTEM
FBC SYSTEM
CHECK
PROCEDURE
ECI Checker
Operation
CHART
(Use
FBC Test
Engine
control
unit
Terminal No.
Checked
Check Item
Select Check
switch Switch
- FBC System
12
/ I
Ignition switch
LOCK- START
I I
I I
Ignition switch
LOCK- ON
5
Setto
;4
Power supply
Ignition pulse
Throttle position
sensor
Engine coolant
temperature
sensor
Harness
Test
Specification
Ignition switch
LOCK-- ON
2V to 8V
I
lgniton switch
LOCK-ON
3
I
MD9994383
Condition
I I
1
inspection
Accelerator fully closed
0.4v to 0.N
Accelerator fully opened
4.5v to 5.5V
0C (32-F)
3.4v to 3.W
20C (68F)
2.4Vtc 2.7V
Power supply
for sensor
Ignition switch
LOCK-c ON
4.94 to 5.5v
Vacuum switch
for idle
position
10
Ignition switch
LOCK-, ON
9vto 13v
Idling (warm engine)
ov to 0.w
Feed back
solenoid valve
52
6
7
10
Slow cut-off
solenoid valve
56
sv
Ignition switch
LOCK-t ON
Idling (warm engine)
zvto
idling
OVto 0.6V
Cluick deceleration
with N position
from above 4000 rpm to idling
11
NOTE
SV = System Voltage
1 TSB Revision
http://vnx.su/
12v
Momentarily
sv

FBC SYSTEM
CHECK
PROCEDURE
ECI Checker
Operation
;elect Check
;witcr I Switch
1
Check Item
CHART
(Use
Engine
control
unit
Terminal No
Checked
Idle up control
solenoid valve
57
A/C cut-off relay
54
FBC Test
Inspection
Harness
MD998438)
Test
Specification
Condition
Test
Result
+i
A/Cswitch
Ignition switch
LOCK&ON
and
A/C switch ON
ON*
Accelerator fully closed
OVto0.6V
Accelerator fully opened
OV to 0.6V
3
4
jet to
B
Secondary air
control solenoid
valve
Idling 70 seconds after start of warm engine
58
Quick deceleration from above 2000 rpm to idling

with N
Electric choke
relay
Ignition switch
LOCK-cON
ovto0.6v
then SV
Momentarily
drop
OVto 0.6V
Idling
Oxygen sensor
Hold rpm constant above 1300 rpm, after 70

seconds from start of warm engine
ovto 1v
(pu&tesJ
22to
NOTE
*I ON means compressor clutch engaged.
2 Failure of parts other than the oxygen sensor can also cause deviation from the specifications.
parts related to air-fuel ratio control, which are listed on page 14-6.
SV= System
voltage
Engine control
unit Terminal
View
from
front
as installed
1 TSB Revision
http://vnx.su/
in Engine
control
unit
3v
Also check other
Inspection
ENGINE COOLANT TEMPERATURE SENSOR NI~AAU

INSPECTION
(1) Remove engine coolant temperature sensor from the intake
manifold.
(2) With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check electrical resistance. The sensor should be held with its housing 3 mm (.I2
in.) away from the surface of the hot water.
16R1251
Temperature c 0
Resistance 60)
0 02)
5.9
line coolant temperature

isor
20
Sensor
output
68)
2.5
40mw
1.1
80 (176)
0.3
Sensor
ground
(3) If the resistance deviates greatly from the standard

place the engine coolant temperature sensor.
value, re-
lNSTAUAllON
(I) Apply anaerobic sealant to threaded portion.
(2) Install engine coolant temperature
sensor and tighten
specified torque.
olR0129
Sensor tightening
torque
(3) Fasten harness connectors
: 20 - 40 Nm (14 - 29 ft. lb4

securely.
THROTTLE POSITION SENSOR

OlRo133
INSPECTION
(1) Disconnect
the carburetor
connector.
(2) Measure resistance
between
terminal
and terminal 8 (sensor ground).
Standard
OlR0490
(3) Connect
(sensor
(4) Operate
full open
smooth
opening.
value
it to
Nl4OEblC
4 (sensor
power)
: 3.5 - 6.5 K!A
an ohmmeter
(pointer type) between terminal 8
ground) and terminal 3 (sensor output).
the throttle valve slowly from,idle position to the
position and check that the resistance makes a
change
proportionally
with the throttle
valve
NOTE
The resistance changes within the range from approx.0.5
ka to the value measured at step (2).
(5) If the resistance is out of specification
or fails to change
smoothly,
replace the throttle position sensor.
5FUOO75
/ TSB Revision
TPS installation
torque
NOTE
I
Refer to P.1413
procedure.
for the throttle
http://vnx.su/
: 2.5 - 4.5 Nm (1.8 - 3.3 ft. Ibs.)

position
sensor
adjusting
14-31
Inspection
ENGlNE SPEED SENSOR (IGNITION

TERMINAL)
COIL
Nwlcmb
INSPECTION
Check that there is continuity
between
the ignition coil terminal and the electronic
control unit terminal 10.
NOTE
Shake the harness connector
to check for lurking open circuit.
OXYGEN SENSOR
INSPECTION
Caution
1. Before
checking,
warm
up the engine
until engine
coolant temperature
reaches 85 to 95 (185 to 205F).
2. Use an accurate digital voltmeter.
(1) Disconnect
the oxygen sensor connector
and connect a
voltmeter
to the oxygen sensor connector.
(2) While repeating
engine
racing,
measure
the oxygen
sensor output voltage.
Engine
Oxygen sensor
output voltage
Remarks
Racing
Approx. 1 V
Make air-fuel mixture richer
by accelerator
NOTE
For removal and installation
of the oxygen
GROUP 11 - Exhaust Manifold.
Oxygen
sensor
VACUUM
installation
torque
operation
sensor,
refer to
: 40 - 50 Nm
(30 - 36 ft. Ibs.)
N14OlAB
SWITCH
INSPECTION
(1) Disconnect
the vacuum
hose (green stripe) from the
device box, and connect a manual vacuum pump to the
device box nipple.
(2) Disconnect
the vacuum switch connector
(3) Apply negative pressure (vacuum) and check whether or
not there is continuity
between
the switch terminals.
Vacuum gauge
Measured
terminals
Continuity
26 kPa (3.9 psi) or

lower
c8-B
No (oat-L)
40 kPa (5.8 psi) or
Yes (On)
higher
5FUOO73
(4) If there
replace
is a problem, remove the device

the vacuum switch assembly.
/ TSB Revision
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box cover,
and
14-32
Inspection
NIUIOAaLI
FEEDBACK SOLENOID VALVE
INSPECTION
(1) Disconnect
the carburetor. connector.
(2) Apply battery voltage (approx. 12V) between the solenoid
valve terminals and check that the solenoid valve operates
with a click.
If no click is heard, replace the solenoid valve.
(Front view
at carburetor
side)
NOTE
For the feedback
solenoid valve removal and inspection
procedures,
refer to CARBURETOR
DISASSEMBLY
AND
REASSEMBLY,
P.14-35.
SFUOOM
SLOW CUT SOLENOID VALVE
(Front view
at carburetor
side)
NwoPAab
INSPECTION
(1) Disconnect
the carburetor_ connector.
(2) Apply battery voltage (approx. 12V) between the solenoid
valve terminals and check that the solenoid valve operates
with a click.
If no click is heard, replace the solenoid valve.
NOTE
For the slow.cut
solenoid valve removal and inspection
procedures,
refer to CARBURETOR DlSASSEMEfLY AND
REASSEMBLY,
P.14-35.
THR0l-tLE OPENER CONTROL SOLENOID VALVE

FOR AIR CONDITIONER
NIuLmAa
INSPECTION
NOTE
When disconnecting
the vacuum hoses from the solenoid
valve, put marks on the hoses for correct installation.
i
(1) Disconnect the vacuum hoses (white stripe, yellow stripe)

from the solenoid valve.
(2) Disconnect
the harness connector.
(3) Connect a hand vacuum pump to the nipple to which the
white stripe vacuum hose been connected.
(4) Apply vacuum and check air tightness
for both
battery voltage is directly applied to the solenoid
terminal and when no voltage is applied.
Battery voltage
~~ The other nipple
when
valve
Normal state
of solenoid valve
Applied
Not applied
Open
Vacuum leaks-
Closed with finger
Vacuum
is held
Open
Vacuum
is held
z
(5) Measure
Standard
1 TSB Revision
the solenoid
value
http://vnx.su/
coil resistance.
: 40 - 46!3 [at 20C (SSOF)]
jl
I
.-z
14-33
Inspection
Nw=ODB
ELECTRIC CHOKE RELAY

INSPECTION
(1) Remove the cover of the device

electric choke relay.
(2) Check for continuity

is not current flow
Item
2
Fz!zzkk
N.C.
Ignition switch
(W
Electric-choke
*PTC heater
l fTC heater: Positive Temperature

Coefficient Heater
No power flow
Power flow
box and remove
between terminals
to the relay coil.
Measured terminals
when
the
there is and
Continuity
Between terminals 0-Q
Yes (M)
Between terminals 0-Q
No (ma)
Between terminals 0 * @
Yes (approx. 1 OOi2)
Between terminals @ - @
Yes (On)
Between terminals 0 - @
No (a-l)
NOTE
1. + indicates the current flow direction.
2. inspect after checking the infinity of tester.
3. Tonenergize the relay coil, apply battery voltage directly to
terminals 0.
4. Use care as application
of battery voltage to incorrect
terminals can cause damage to the relay.
(3) If the continuity
test fails, replace the electric choke relay.
NOTE
If the electric choke body remains cool after engine start although the electric choke heater (PTC heater) and electric
choke relay are normal, check the vehicle body harness circuit.
1 TSB Revision
http://vnx.su/
14-34
FBC SYSTEM - Carburetor
CARBURETOR
1619 Nm
V-14 Ribs.
X-20
Nm
ft.lbs.
1 l-14
Pre-removal Operation
l
Removal
+* ++
I)*
++
+*
+*
steps
1. Air cleaner
Adjustment of
2. Connection
3. Connection
4. Connection
5. Connection
6. Connection
7. Connection
8. Connection
9. Carburetor
10. Gasket
accelerator cable
for accelerator cable
for water hose
for fuel vapor hose
for vacuum hoses
for control harness connector
for main hose
for return hose
NOTE
Draining
GROUP
of the Coolant (Refer to

0 - Coolant Replacement.)
(1) Tieverse the r&oval

procedures
(2) +I,
(3) ++
parts
to reinstail.
of Removal.
of installation
038552
1 TSB Revision
http://vnx.su/
14-35

NII(MSFlcb
1. REMOVAL
OF AIR CLEANER
Refer to GROUP 11 - Air cleaner.
7.
DISCONNECTION
OF MAIN HOSE/I.
RETURN
(1) Before disconnection
of the fuel hose, remove
tank cap to lower the pressure in the fuel
(2) With the receiver placed under the fuel inlet
receive fuel left in the hose, remove fuel hose
carburetor
inlet nipple.
9.
REMOVAL
OF CARBURETOR
NOTE
When the carburetor is removed, keep it horizontally
not to spill fuel from the carburetor.

.
ADJUSTMENT
Refer
OF ACCELERATOR
CABLE
HOSE
the fuel
thank.
fitting to
from the
SO as
NludDAc
FREE PLAY
to P.l4-102.
1. INSTALLATION
OF AIR FILTER
Carburetor assembly and gasket kit
-...
5. tlractcet
-12
Diassembly
steps
1.
2.
3.
4.
Throttle-return
spring
Damper spring
Throttle-return
spring bracket
Throttle opener/Dash pot
6.
7.
8.
9.
l + l + 10.
11.
12.
Hose
Vacuum-delay valve
Hose
Screw
Float chamber cover assembly
Float chamber cover gasket
Mixing body and throttle body assembly
NOTE
(1) Reverse the disassembly rocedures to reassemble.
(2) *I+ : Refer to ;Servjce 8-o!nts of Disassembly.
1Z31+
: Refer to Service Potnts of Reassembly
: Non-reusable Parts
d
1 TSB Revision
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FBC
Disassembly
steps
SYSTEM
dir
16. Needle valve seat

17. 0-rino
18.
19.
41) +4 20.
21.
22.
23.
24.
41) l + 25.
26.
27.
28.
*e I)+ 29.
30.
31.
32.
33.
34.
35.
36.
Carburetor
16
k-15
13. Pin
14. Float
15. Needle valve
Packing
Retainer
O-ring
O-ring
Tube
Retainer
O-ring
O-ring
Plate
Bimetal assembly
Packing
Connector
Cover
Diaphragm
Spring seat
Spring
Body
/ TSB Revision
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
41) I)+ 53.
l * l + 54.
ae l + 55.
56.
Spring
Diaphragm
Valve
Mixture control valve assembly
Gasket
Cover
Spring
Diaphragm
Body
Spring
Diaphragm
Bracket
Cover
Spring
Diaphragm
Body
Main air jet (primary)
Pilot jet (primary)
Pilot jet (secondary)
Float chamber cover
:

(2) +e : Refer to Y&vice Points of Disassembly.
(3) +* : Refer to Service Points of Reassembly.
(4)
: Non-reusable
http://vnx.su/
park
SF,,153
14-37
5FUOO70
72. Throttle (ever
73. Cam follower
74. Fast-idle adjustment screw
75. Free lever
76. Apartment plate
77. Idle-speed adjustment screw (SAS-2)
78. Spring
79. Secondary lever
80. Idle-speed adjustment screw (SAS-1)
81. Concealment plug
82. Mixture-adjustment
screw
83. Throttle body
Disassembly
steps
+a 57. Steel ball
++
++
+*
++
58.
59.
60.
61.
+I)
++ 62.
63.
+e
*+
++
+a
64.
65.
66.
67.
68.
69.
70.
71.
Weight
Ball
Plug
O-ring
Ball
Screw
Gasket
Main jet (primary)
Main jet (secondary)
Hose
Mixing body
Vacuum hose
Depression chamber
Throttle-position
sensor
NOTE
(1) Reverse the disassem,bly procedures, to reassemble.
\;I ;;
: Refer to ,,Serv!ce Points of Drsassembly
: Refer to Service Pornts of Reassembly
NIu.lFAE
Caution
1. Do not disassemble
the following
components
time of disassembly.
(1) Choke valve, choke shaft and automatic
device
(2) Inner venturi
(3) Throttle
valve and throttle
shaft
(4) Fuel inlet nipple
at the
choke
2. When looseninga Philipsscrew which has been firmly

tightened,
use a Philips
for the screw.
TSB Revision
http://vnx.su/
screwdriver
i
that
is an exact fit
14-38
Stopper
portion
10. REMOVAL
Connector
in
OF FLOAT
CHAMBER
COVER
ASSEMBLY
Caution
Ensure that the terminal
is not bent during removal of the
connector.
(1) With a pin or the like push the stopper portion to
remove each of the three
terminals
from the rear of the connectors.
Throttle position
sensor terminals
s)
5fUlX i
(2) Do not attempt to remove the cover at

held in position firmly by gasket. insert
blade between
the enrichment
cover
chamber cover as illustrated and lightly
lightly.
Caution
Do not
apply
excessive
14. REMOVAL
OF FLOAT/15.
Remove the pin and then
valve.
a time as it is
a screwdriver
and the float
pry and lift up
force.
NEEDLE VALVE
remove the float
and needle
Caution
1. Do not let the float drop or apply collapsing
load.
2. Use care not to damage the end of the needle valve.
16. REMOVAL
OF NEEDLE VALVE SEAT
Using flat blade screwdrivers,
pry up the needle valve seat
at both edges to remove.
Caution
Use care not to damage
pushing
up the needle
7--FC---4river
II..C
I
Needle
seat
(flat tip( Wd)\
the float chamber

valve seat.
cover
when
valve
,R,%
20. REMOVAL
OF FEEDBACK
SOLENOID
VALVE
Using a screwdriver
or other tool with a thin flat end, push
the stopper portion and remove the two terminals from
behind the connector.
Caution
is not bent during removal of
the connector.
NOTE
Unless the terminals are removed from the connector, the
feedback solenoid valve cannot be removed from the float
chamber cover.
1
Feed back solenoid valve

terminal (two pieces)
1 TSB Revision
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.I
z
FBC SYSTEM
14-39
- Carburetor
25. REMOVAL
OF SLOW CUT SOLENOID
VALVE
(1) Remove the retainer and pull out the slow cut solenoid
valve.
Cautioon
When removing
hold the body.
the valve, do not hold the leads but
(2) Using a screwdriver

or other tool with a thin flat end.
push the stopper section and remove the two terminals from behind the connector.
Slow cut solenoid

Valve termin;
(two
Caution
of the connector.
pieces)
is not bent during
removal
29. REMOVAL
OF BIMETAL ASSEMBLY
(1) Grind away the head of the two rivets of the bimetal
assembly using an hand grinder or other tool. remove
the screw.
(2) Remove the plate, the bimetal assembly
and the
packing.
(3) Remove the remaining rivet bodies using a pin punch
etc..

or other tool with a thin fiat end,
push the stopper section and remove the terminal
from behind the connector.
Caution
of the conector.
Bimetal
assembly
Terminal
is not bent during
removal
SW158
59. REMOVAL OF MAIN AIR JET (PRIMARY)/54.

PILOT JET
(PRIMARY)/55.
PILOT JET (SECONDARY)
(1) When removing the jets, use a screwdriver
that is an
exact fit for their slot and work carefully to prevent
damage.
R
FB
Revision
http://vnx.su/

63. REMOVAL
OF SCREW
(1) Use a Phillips screwdriver
that is an exact fit and work
carefully to prevent damage.
Caution
Do not cause burrs to the recess in screw head as
they could produce gap between
throttle
body and
the manifold
surface.
65. REMOVAL
OF MAIN JET (PRIMARY)/66.
MAIN JET
[SECONDARY)
When removing the jets, use a screwdriver that is an exact
fit and work carefully to prevent damage.
Drill hole here at a 45 angle

towards concealment
plug
I
Concealment
Plug
e
ing
hole
81. REMOVAL
OF CONCEALMENT
PLUG
(1) Clamp carburetor in a vice with idle mixture adjusting
screw facing up (protect gasket surface from vice
jaws).
(2) Drill a 2 mm (5/64 in.) pilot hole in the casting
surrounding
the idle mixture adjusting
screw then
redrill the hole to 3 mm (l/8 in.).
(3) Insert a blunt punch into the hole and drive out plug.
INSPECTION
GENERAL INSPECTION
Check the following and repair or replace parts if necessary.
(1) Check the fuel paths (jets) and air paths (jets or orifices)
for clogging. If clogged, wash thoroughly
with cleaning
solvent or detergent and blow by compressed
air. Do not
use metal wire or other metal pieces.
(2) Check the diaphragms
for damage and cracks.
(3) Check that the needle valve operates lightly. If the valve is
hard to slide or is binding. repair or replace. If there is
overflow, poor valve to seat contact is suspected.
Check
thoroughly.
(4) Check the fuel inlet filter (located above the needle valve)
for clogging and damage.
(5) Check the float operation.
Check the float and lever for
deformation
and damage and replace if necessary.
(6) Check operation of the throttle valve, choke valve and link.
If they do not operate lightly, wash well and apply engine
oil sparelingly to their shaft.
(7) Check the float chamber and main body for damage and
cracks.
1 TSB Revision
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14-41
-SLOW CUT SOLENOID VALVE OPERATION CHECK mm(1) Apply battery voltage directly to the slow cut solenoid
valve terminals.
(2) Check that the valve operates with a click.
SLOW CUT SOLENOID

VALVE RESISTANCE
MEASUREN14MGCAb
MENT
(1) Using a circuit tester, check that there is no continuity
between
the solenoid valve body and terminals.
(2) Measure
Standard
resistance
value
between
the terminals.
: 48 - 6On [at 20C (68F)]
FEEDBACK SOLENOID VALVE OPERATION CHECK N~.IGD~~

(1) Apply battery boltage directly to the feedback
solenoid
valve terminals.
(2) Check that the valve operates with a click.
(3) Check that the jet is free from
( TSB Revision
http://vnx.su/
clogging.
14-42
FBC SYSTEM
- Carburetor
FEEDBACK SOLENOID
VALVE RESISTANCE
MEASURENuMIIGEh
MENT
(1) Using a circuit tester, check that there is no continuity
between
the solenoid valve body and terminals.
(2) Measure
Standard
resistance
value
between
: 54 - m
the terminals.
(at ZOC (66F)]
BIMETAL ASSEMBLY RESISTANCE

Using a circuit tester, measure
terminal and body.
Standard
value
: Approx.
MEASUREMENT
NI,M=~~
resistance
between
the
60 [at ZOC(SVF]]
3Ful76
NWMGGA
DASH POT INSPECTION
Check that the dash pot operates normally. Resistance must
be felt when the dash pot rod is pulled. When the rod is
released, it must return quickly to the orignal position. If no
resistance is felt when it is pulled, the diaphragm or the check
valve is broken. If the rod returns slowly, the check valve is
binding. In either case, replace the dash pot.
B14MGHAa
DEPRESSION
CHAMBER
INSPECTiON
Check the depression chamber diaphragm
for damage. First,
push up the rod fully and closing tightly the nipple with a
finger, release the rod. The diaphragm is intact if the rod does
not return to the initial position while the nipple is held closed
with a finger. If the rod returns. the diaphragm
is broken. .~
Replace the depression
chamber.
1 TSB Revision
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--t
FBC
SYSTEM
14-43
Carburetor
MIXTURE
ADJUSTING
SCREW INSPECTION
Check the mixure adjusting screw for damage
taper end by ovettightening
etc..
THROTTLE
POSITION SENSOR
1. Measure
resistance
between
throttle position sensor.
Nl4MGlAb
caused
to its
NI4MGJh
INSPECTION
terminals
1 and 3 of the
Standard
value : 3.5 - 6.5 kn
2. Check the body for crack and damage.
Size symbol
SERVICE
POINTS
OF REASSEMBLY
NI4MHAn
66./65. IDENTIFICATION
OF MAIN JETS
Make sure that correct jets are installed
at correct
positions.
Note the size symbol stamped on each jet for identificaiton.
Primary
: #107.5
Secondary
: #I90
eFlJoo!2
62. INSTALLATION
OF BALL/61 . O-RING/60.PLUG/59.
BALL/58.
WEIGHT/57.
STEEL BALL
Install in correct sequence
and at correct positions.
k&
55. INSTALLATION
OF PILOT JET (SECONDARY)/54.
PILOT
JET (PRIMARY)/53.
MAIN AIR JET (PRIMARY)
Make sure that correct
jets are installed
at correct
positions.
Note the size symbol stamped on each jet for
identification.
Size symbol
Main air jet (primary)

: #70
Pilot jet (primary)
: #55
Pilot jet (secondary)
: #70
lFu291
[ TSfievision
http://vnx.su/

29. lNSTALLATION
(1)
Fit
the
bimetai
OF BIMETAL ASSEMBLY
end over the choke valve
(2) Install the plate and temporarily

(3) Align the mating marks.
tighten
lever.
the screw.
(4) Set the rivet as illus_trated.
(5) install the bimetal assembly

similar tool with the mating
(6) Tighten the screw.
Bimetal assembly
using a hand rivetter or

marks aligned correctly.
Hand rivetter
II
7Wl I
wu3n
(7) Install
Front view
SFU18
terminal
!!I
1 TSB Revision
http://vnx.su/
to the connector
at correct
position.
FBC
SCm blue1
I
FBSV (yellow)
FBSV (red)
SCd
(red)
Front view
Tps
output
(yellow
14-45
Carburetor
25. INSTALLATION
OF
SLOW
VALVE/;ZO.FEEDBACK
SOLENOlD
Install terminals to the connector
For Ips
For bimetal
assembly
SYSTEM
CUT
VALVE
at correct
SOLENOID
positions.
5Ful6
10. INSTALLATION
OF FLOAT CHAMBER COVER ASSEMBLY
(1) After installing the float chamber
cover, install the
throttle position sensor terminals (3) to the connector,
paying close attention to their positions.
greenhd
(omwl
TPS 0 (b&k/red)
SFUl62
INSPECTION
AND ADJUSTMENT
AFTER ASSEMNI4r.ll*ab
BLY
FAST IDLE OPENING
(1) Set lever on the second highest cam of the fast idle cam.
(2) Measure the primary valve to throttle bore clearance.
Standard
value : 0.80 mm (.031 in.)
(3) If the clearance is out of specification,
adjust using the
fast idle adjusting screw for the standard value.
NOTE
Adjusting
screw
1 Adjusting
screw
direction
of rotation
1 Valve opening
vs. idle rpm

1 Fast idle rpm
Clockwise
Larger
Increases
Counter clockwise
Smaller
Decreases
I
I
N14MIB.4
UNLOADER
OPENING
(1) Lightly press the choke valve with a finger to fully close it.
(2) In this state, fully open the throttle valve and measure the
choke valve to choke bore clearance.
Choke vahre
rance
Standard
,Fu3g,
IRevision
http://vnx.su/
value
: 1.9-2.1
mm
(.075-.083
in.)
14-46
Lever
(3) If the clearance is out of-specification,

bend the throttle
lever at illustrated portion to adjust the clearance to the
standard value.
NOTE
Lever bending
direction
Clearance
Remarks
UP
Larger
Poor response
Down
Smaller
Lower output
Plug likely to get sooty
CHOKE
Choke valve
ram
,,I
BREAKER
Nlawx
Caution
Check and adjust with the bimatal
assembly
removed.
(1) Lightly press the choke valve with a finger to fully close it.
(2) Push the choke breaker rod toward the diaphragm
and
measure the choke valve to choke bore clearance.
Standard
value :
1st stage : 2.3-2.5
2st stage : 3.0-3.2
\,I
lFU30
mm
mm
(.OSl-.098 in.)
(.I18 -.I26 in.)
(3) If the clearance is out of-specification.

the choke lever at illustrated
portion.
NOTE
adjust
by bending
.Lever bending
direction
Clearance
Remarks
Open
Larger
Poorer startability,
ly to stall
Close
Smaller
Plug likely to get sooty
more like-
NI4MHIIUr
CHOKE VALVE OPERATION
(1) Operate the choke valve with a finger and check for play,
incorrect operation
and binding.
(2) If the choke fails to operate smoothly and lightly, wash
around the choke valve.
(3) If the play is excessively large, replace the float chamber
cover.
NIUIIEh
SECONDARY
THROTTLE
VALVE OPERATION
(1) Fully open the throttle valve and operate the secondary
throttle valve lever with a finger to check for play, incorrect
operation
and binding.
(2) If it fails to operate smoothly and lightly, wash and apply
thin coat of engine oil to the shaft.
(3) If the play is excessively large, replace the throttle body.
Nwm=*
PORTS
(I) Connect a hand vacuum pump to each port and check for
clogging of the passage.
(2) If there is clogging,
clean the port and then blow
compressed
air into the port.
1 TSB Revision
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Additional
passage
Primary
emulsion
1447
INSPECTiON
OF HAC BLEED AIR PASSAGE
Iy14MlGh
Inspection
for Clogging
of Primary Well Bleed Nipple Federal/California
and High-altitude
(I) Connect a hand vacuum pump to the nipple.
(2) Apply vacuum to see that vacuum leaks and does not
build up.
and check the carburetor as incorrect installation
of gasket etc. is suspected.
bleed air

well
lFU371
Inspection
for Clogging of Secondary
Well Bleed Nipple N14MIHaa
High-altitude
(1) Connect a hand vacuum pump to the nipple.
build up.
and check the carburetor as incorrect installtion of gasket etc. is suspected.
5Fu37
Inspection
for Clogging
of Jet Air Nipple
- High-altitude
NI4M,Isa
(1) Connect a hand vacuum pump to the nipple.

build up.
and check the carburetor as incorrect installation
of gasket etc. is suspected.
5Fu371
1 TSB Revision
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14-48
FBC SYSTEM - Fuel Pump
FUEL PUMP
I
Removal
++ ++
4*
4*
41) I)+
M-19
12-14
Nm
ftlbs.
steps
1.
2.
3.
4.
Air cleaner
Connection
Connection
Fuel pump
for the main hose

for the return hose
5. Gasket
6. Insulator
j7.j Fgerse
:
(3) +a :
(4) q :
the removal procedures to reinstall;,

Refer to Servlce Points of Removal
Refer to Service Points of Installation.
Non-reusable parts.
Nl4HsACb
1. REMOVAL
OF AIR CLEANER
Refer to GROUP1 1 - Airrcleaner.
2. DiSCONNECTiON
OF MAIN HOSE/B. RETURN HOSE
Before disconnection
of the fuel hose, remove the fuel
tank cap to lower the pressure in the fuel tank.
4. REMOVAL
OF FUEL PUMP
(I) Turn the crankshaft to place No. 1 cylinder at top dead
center on compression
stroke.
NOTE
The above operation places the lift of fuel pump stroke
at the minimum positon, resulting in ease of fuel pump
removal.
/ TSB Revision
http://vnx.su/
FBC SYSTEM - Fuel Pump

,
+Front
14-49
(2) If interference
head, the
interfering
follows:
0 Remove
0 Loosen
in the
of engine
5ENOl6
of pump lever occurs in the cylinder

washer on the cylinder head bolt may be
with the pump lever. Therefore, proceed as
the rocker cover.
sylinder head bolts in the sequence
illustration.
Move the washer interfering with the pump lever in

the direciton shown in the illustration and remove
the furl pump.
INSPECTION
FUEL PUMP
Make the following
checks and replace as necessary.
Note that the fuel pump is non-maintainable
assembly
must be replaced as an assembly.
l
Oil or fuel leaks from breather hole
l
Damage, cracks on parts
l
Rocker arm for wear

4.
5EN016
shown
NUHCAC
and
N14HDIW
INSTALLATION
OF FUEL PUMP
(I) Make sure that piston in No. 1 cylinder is in the top
dead center on compression
stroke.
(2) If the washer is moved after loosening of cylinder head
bolt, proceed to the following
items.
0 Reinstall the washer in position.
@I Tighten the cylinder head bolts to specified torque
in the sequence
8 install the rocker cover.
1. INSTALLATION
OF AIR CLEANER
1 TSB Revision
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FBC SYSTEM - Fuel Tank
FUEL TANK
YI4GA.A

Pm-removal
l
Operation
Draining of the Fuel.
Post-installation
l
Operation
Supplying of the Fuel.
18
18
1 Nm
0.7 ft.lbs.
12
10
\
18
9 4
t-.
P I
13
16
.-
l&ONm
11-14 ftkls.
&C-
Ramoval steps
++
I)+
MI
I)+
*+
++
1. Drain plug
2. Fuel filler cap
3. Fuel filler hose protector
4. Vapor hose
5. Check valve
6. Overfill limiter (Two-way valve)
1. Clamp assembly
8. Fuel filler hose
9. Breather hose
10. Packing
11. Fuel filler neck
12. Main hose
13. Return hose
( TSB Revision
14,
15.
16.
17.
18.
19.
Fuel gauge unit connector connection

Fuel tank assembly mounting nuts
Fuel tank
Pipe assembly
Separator tanks
Fuel tank protector
NOTE
(1) Reverse the removal. procedures to reinstall.

(2) +* : Refer to Service Points of Installation.
http://vnx.su/
14-51
FBC SYSTEM - Fuel Tank
NWGCAGf
lNSPECTlON
l
l
l
l
e
l
Check the hoses and the pipes for crack or damage.

Check the fuel tank cap for malfunction.
Check the fuel tank for deformation,
corrosion or crack.
Check the fuel tank for dust or foreign material.
NOTE
If the inside of the fuel
of the following:
(I) Kerosene
(2) Trichloroethylene
(3) A neutral emulsion
Check the in-tank fuel
Check the check valve
tank is to be cleaned,
type detergent
filter for damage
for malfunction.
use any one
or clogging.
CHECKING
OVERFILL LIMITER
(TWO-WAY
VALVE)
A simple way of inspection,
however,
may be adopted in
which the overfill limiter is removed and then air is lightly
blown into either the inlet or outlet. If the air passes after a
slight resistance,
overfill limiter is in good condition.
NIGOAE
13. INSTALLATION
OF RETURN HOSE/lZ.
MAIN HOSE/4.
VAPOR HOSE
When attaching the hoses to the pipes, be sure that the
hose is attached
until its end comes in touch with the
bulge of the pipe as shown in the illustration.
9.
5.
INSTALLATION
OF BREATHER HOSE/8.
HOSE
Insert the hoses until their ends contact
FUEL FILLER
the fuel tank.
INSTALLATION
OF CHECK VALVE
Install the check valve to the fuel filler hose protector so
that the check valves arrow faces as shown in the figure.
TSB Revision
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FBC SYSTEM - Fuel Line and Vapor Line
FUEL LINE AND VAPOR LINE

Hl4KA-A
+a
l +
l *
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Fuel filter clamp

Fuel filter
Main hose
Return hose
Canister
Canister holder
Vapor hose
Fuel vapor pipe
Stay
Fuel purge hose

Purge control valve
Fuel vapor pipe
Fuel main pipe
Fuel return pipe
NOTE
++ : Refer To Service Points of Installation.
1 TSB Revision
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FBC SYSTEM - Fuel Line and Vapor
Line
-INSPECTION
14-53
WI4KW
Check the fuel hoses and pipes for cracks, bends,

deformation,
deterioration
or clogging.
l
Check the fuel filter for clogging or damage.
l
Check the canister for clogging or damage.
CHECKING
PURGE CONTROL VALVE
(1) Make sure that the cooling water is at a temperature
between
80 and 90C (180 and 190F).
(2) Disconnect
the purge control hose from the air cleaner
and blow into the purge hose. If the valve is not open, its
operation is normal. Then start the engine and increase
the engine speed to 1,500 to 2,000 rpm and blow into the
purge hose. If the valve is not open, check for clogged or
broken vacuum hose, or malfunctioning
therm0 valve.
l
t To carburetor
nd therm0 valve
To air filter
From canister

7.
NI4KDAD
INSTALLATION
OF VAPOR HOSE/4. RETURN HOSE/B.
MAIN HOSE
When attaching the hose to the pipes, be sure that the
hose is attached unit1 its end comes in touch with the
99u9919
1 TSB Revision
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14-54
MPI
SYSTEM
Specifications
SPECIFICATIONS
GENERAL
SPECIFICATIONS
Items
Fuel
Tank capacity
Return system
Filter
Specifications
lit (gal.)
75(19.8)
Equipped
High pressure type
Fuel pump
Electrical, in-tank type
Electric motor
Type
Driven by
Throttle body
Identification model No.
Throttle bore
mm (in.)
Idle speed control servo
AC54-102
54(2.126)
Variable resistor type
Stepper motor type
The stepper motortype
First Idle Air Valve
Rotary contact type
Idle position switch
by-pass air control system with the
Engine control unit

identification model No.
For Federal
For California
EZT34672
EZT3467 1
Input sensor
Air flow sensor
Barometric pressure sensor
Intake air temperature sensor
Oxygen sensor
Vehicle-speed sensor
Inhibitor switch
Top dead center sensor
Crank angle sensor
EGR temperature sensor(California only)
Power steering oil pressure switch
Karman vortex type

Semiconductor diffusion-typesensor
Thermistor type
Thermistor type
Zirconia sensor
Reed switch type
Contact switch type
Photo diode sensor
Photo diode sensor
Thermistor type
Contact switch type
3utput actuator
Control relay indentification mode No.
Injectortype and number
Injector identification mark
Purge control solenoid valve
EGR control solenoid valve (M/T)
%el pressure regulator
Regulated pressure
kPa (psi)
E8T0657 I
Electromagnetic, 6
BZIOH
ON/OFF type solenoid valve
Duty cycle type solenoid valve
335 (47.6)
1 TSB Revision
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--
MPI
SYSTEM
14-55
Specification
NI4cB.B
Items
Specifications
Standard value
Curb idle speed
rpm
rpm
Idle speed when air conditioner ON
<M/T>
aIT>
Basic idle speed
wm
Throttle position sensor output voltage
V
Throttle position sensor resistance
M
Idle speed control servo (stepper motor) coil resistance
intake air temperature sensor resistance
M
Engine coolant temperature sensor resistance
kfi
20C (68F)
80C (176F)
Fuel pressure regulator pressure
kPa (psi)
Vacuum hose disconnection
Vacuum hose connection
Injector coil resistance
n
5* 2 BTDC at curb idle

700~100
900 at neutral position
650 at D range
700*50
0.4-I .o
3.5-6.5
28-33 [at 20C (68F)]
2.7 [at 20C (68F)]
2.5
0.3
330-370 (47-53)
270 (38)
13-l 6 [at 20C (68F)]
Items
1 Nm
Engine Coolant temperature sensor

Throttle body mounting bolts
Fuel-pressure regulator attaching bolts
Delivery pipe mounting bolts
Throttle position sensor attaching screws
Idlespeed control servo attaching screws
High pressure hose to deliven/ pipe attaching bolt
Accelerator cable attaching bolt
High pressure hose to fuel pump
Fuel tank installation nut
Fuel tank protector installation nut
Drain plug
High pressure hose to main pipe
Eye bolt
ftlbs.
20-40
lo-13
7-l 1
IO-13
1.5-2.5
2.5-4.5
4-6
4-6
30-40
20-30
9-14
15-20
30-40
25-35
SEALANT
NI4cE-B
I Specified sealant
I Items
threaded portion
15-29
7-9
5-8
7-9.
1.1-1.8
1.8-3.3
3-4
34
22-29
18-22
6.5-10
11-14
22-29
18-25
sensor
3M NUTlocking
equivalent
I Quantity
No.4171 or
1 TSB Revision
http://vnx.su/
As required
.r
:
14-56
MPI SYSTEM - Special Tools /Troubleshooting
SPECIAL TOOLS
switch inspection
on sensor inspection
TROUBLESHOOTING
When checking and correcting engine troubles, it is
important
to start with inspection
of the basic
systems.
In case you have such troubles as (1) engine start
failure, (2) rough idling or (3) poor acceleration,
therefore, you should first check the following basic
systems:
(I) Power supply
l
Battery
l
Fusible link
l
Fuse
(2) Body ground
(3) Fuel supply
l
Fuel line
l
Fuel filter
e Fuel pump
(4) Ignition system

l
Spark plug
l
High tension cable
l
Distributor
l
Ignition coil
(5) Emission control system
e Crankcaseventilation
system
e Exhaust gas recirculation system
e Vacuum leak
(6) Others
l
Ignition timing
e Idle speed
Troubles with the MPI system are often caused by
poor contact of harness connector.
It is, therefore,
important to check harness connector contact.
( TSR Revision
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MPI SYSTEM
1
- Troubleshootina
symptom
Probable cause
Remedy
Engine will not start or

starttoo hard (Cranks
W
Trouble in the MPI system
Checkfor output of self-diagnosiscode. Readthe code

withavoltmetaror multLusetester(MB991307).
Malfunction
system
of the fuel pump drive control
perform cranking check with a multi-use

tester (MB991 307).Check the fuel pump
drive control sytsem and the fuel pump.
Malfunction
of the ignition timing
Perform cranking check with a multi-use

tester (MB991307).
Malfunction
of the power transistor
Check the power transistor as a single unit.
Power is not supplied to the engine control

unit.
Perform cranking check with a multi-use tester

(MB991307). Check the power supply circuit.
Malfunction
of the control relay
Replace
Malfunction
of the injector
Perform cranking check with a multi-use

tester (MB991 307). Check the injector drive
circuit. Check the injector as a single unit.
The fuel pressure is not proper.
Check thefuel
Repair or replace
Malfunction
?ough idle or engine

itables
or damaged
of the engine control unit.
pressure.
Replace
Wire breakage or short circuit occurs in the

harness, orthe connector is improperly
connected.
Repair or replace
Check for output of selfdiagnosis code

Read the code with a voltmeter or multi-use
tester (MB991307).
Malfunction of the sensor

lnake air temperature sensor
l
l
l
Ignition switch
l
l Throttle position sensor
l
Top dead center sensor, crank angle
sensor
l
l
l
Inhibitor switch
l
Air-flow sensor
0 Oxygen sensor
Check the sensor with a

multi-use tester (MB991307).
(Check the sensor-related circuit.
Check the sensor as a single unit.)
Malfunction of the engie control system

0 Stepper motor
0 Injector
0 Power transistor
Check the power supply circuit.

Check the actuator with a multi-use tester
(MB991307).
Malfunction of thevehicle-speed
Check thevehicle
reed switch
speed reed switch.
Check the fuel pressure.
Repair or replace.
Malfunction
or damaged.
Replace.
Wire breakage or short circuit occurs in the harness, Repair or replace.

or the connector is improperly connected.
1 TSB Revision
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MPI
- Troubleshootina
Probable cause
Remedy
Check foroutput of self-diagnosis &de

Read thecode with a voltmeter or multi-use
tester (MB991307).

l
0 Engine coolant temperature sensor
l
e Ignition switch
l
l
l
sensor
l
l
l
inhibitor switch
l Air-flow sensor
l
Oxygen sensor
Check
multiCheck
Check
Malfunction of the engine control system

Steppet motor
l
Injector
l
Power transistor
Check the power supply circuit.

Check the actuator with a multi-use tester
(MB9913D7).
Malfunction of the air conditioner

relay control system
Check the system, and the components

the system is found defective.
Symptom
Engine hesitat&
acceleration
SYSTEM
or poor
power

Malfunction
001. fuel mileage
or damaged:
the
use
the
the
sensor with a
tester (MB991 307)
sensor-related circuit.
sensor as a single unit.
if
Repair or replace.
Replace:
Wire breakage or short circuit occurs in the

harness, or the connector is improperly
connected.
Repair orreplace.
Check for output of self-diagnosis &de

Read the code with a voltmeter or multi-use
tester (MB991307).

l
l
l
Ignition switch
l
l
l
sensor
l
l
l
Inhibitor switch
l
Air-flow sensor
l
Oxygen sensor
Checkmthe sensorwith a
multi-use tester (MB991307)
(Check the sensor-related circuit.
Check the sensor as a single unit.)
Malfunction of the engine control system

Stepper motor
l
Injector
l
Power transistor
Check thk power supply circuit. ~Check the actuator with amulti-use tester
(MB991307).
1 TSB Revision
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~-
MPI SYSTEM
CONTROL
14-59
- Troubleshooting
FUNCTIONS
NMEE%
1
belated components
Ignition * Idle speed

Air
Fuel pump Purge air
timing
control conditioner
drive
control
power
control
control
relay
control
Power supply (ignition switch coupled)
Power supply (battery backup)
Air-flow sensor
Intake air temperature
sensor
sensor
x I x I xx I
Crank angle sensor

Oxygen sensor
Vehicle-speed
sensor
Air conditioner
switch
t Inhibitor switch (A/T models only)
1x1
I x

Ignition switch
Ignition switch terminal (start signal)
Injector
Idle speed control servo (Stepper motor)
Air conditioner
Power transistor
5
n
5
3
power relay
Control relay

EGRcontrol solenoid valve (M/T models only)
0-i rE
*VE rhicles with an automatic transmission
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EGR
control
MPI SYSTEM - Troubleshooting

CIRCUIT DIAGRAMS
NI4EC-B
I
.-e-L
I IGW
! !Y
t&y
Eo5
Z-BWI
2-BW
I
- YW
To automatic
hub indicator
free-wheeling
control
unit
M.P.I.
se*s)r
cCalifomia>
1 TSB Revision
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control
32
unit
rl r2
*I
MPI
SYSTEM
14-61
Troubleshooting
Wire color code

B: Black
~r:B;uytn
Gr: Gray
I$ L&h blue
0: Orange
Y: Yellow
G: Green
Lg: Li ht green
P: Pin f
W: White
(2)
-.:-7
The chain
llne
(-----)is
applicable
to A/
T models.
The symbols
%i%%at
the wiring
connected
(using the
is
Sal%
numerical
symbol)
to the
facing page.
(In other
words. @ on
the right page
is connected
to @ on the
left page.)
1.25-B
: 0.85BG
6e-Gw
* YR
G
: G?
.
M.P.I.
control
unit
Injector
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14-62
FUEL
TANK
MPI
SYSTEM
AND
FUEL
Troubleshooting
/ Service
Adjustment
Procedures
LINE
Symptom
Probable cause
Remedy
Engine malfunctions
due to insufficient fuel
suPPlY
Bent or kinked fuel pipe or hose
Repair orreplace
Clogged fuel pipe or hose
Clean or replace
Clogged fuel filter or in-tank fuel filter
Replace
Water in fuel filter
Replace the fuel filter or clean the fuel tank

and fuel line
Dirty or rusted fuel tank interior
Clean or&place
Malfunctioning fuel pump

(Clogged filter in the pump)
Replace
Mispiping of vapor line
Correct
Disconnectvapor
Correct
Evaporative emission
oontrol system malfunciions (When tank cap is
*emoved, pressure teeasing noise is heard)
.~.
line piping joint
Folded, bent, cracked or clogged vapor line
Replace
Faulty fuel tank cap
Replace
Malfunctioning overfill limiter

(two-way valve)
Replace
SERVlCE ADJUSTMENT
PROCEDURES
CURB
IDLE SPEED
INSPECTION
N14FK4C4
Caution
1. The improper
setting (throttle
valve opening)
will increase exhaust gas temperature
at deceleration,
reducing catalyst
iiie greatly and deteriorating
exhaust gas
cleaning
performance.
It also has effect on fuel consumption
and engine braking.
2. When the batterys terminal
is re-connected,
the engine
rpm can become
high.
When this happens,
refer to
GROUP
INTRODUCTION
AND
MASTER
TROUBLESHOOTING-Precautions
Before Service (Servicing Electrical System).
Pre-conditions
for checking
@ Engine coolanttemperatuie:
85-95X
(185205F)
l
OFF
l
Transmission:
neutral (N or P for vehicles with automatic
transmission)
o Steering wheel: neutral position
(1) Place the timing light in position.
(2) Connect the tachometer.
_
NOTE
Insert a paper clip from the harness side to the connector
(1 pin) between the primary side and noise filter of the ignition coil, and connect the tachometer.
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MPI SYSTEM - Service
Adjustment
14-63
Procedures
Caution
Insert
On the female pin

(Insert into the side
opposite the
lock hook.)
a paper
clip along
the terminal
cables.
On the male pin

(Insert into the
lock hook side.)
OILD2(1
(3) Start the engine and let it idle.

(4) Check the standard ignition timing.
Adjust the ignition timing if necessary.
Standard
ignition
timing:
BBTDC 2 2*
* When checking the standard ignition timing, disconnect
(with the engine stopped)
the female
connector
for
waterproofing
the connector for adjustment
of the ignition
timing, and then connect a lead wire with alligator clip to
the ignition timing adjusting terminal to ground it.
NOTE
For details regarding ignition timing checking and adjustment procedures,
refer to GROUP 8 - Ignition System.
(5) Run the engine for more than 5 seconds at an engine
speed of 2,000 to 3,000 rpm.
(6) Run the engine at idle for 2 minutes.
(7) Read the idling rpm.
If it is not within the specified
limits, check the ISC
system.
NOTE
Adjustment
of the idling speed is usually unnecessary,
because this system controls the idling speed.
Curb idle speed: 7OOklOO rpm
BASIC IDLE SPEED ADJUSTMENT
~14Fi-w
Caution
There should usually be no need to adjust the basic idle
speed because
it has been precisely
adjusted
by the
manufacturer.
Preconditions
for inspection
l
85-95C (185-205F)
l
OFF
l
Transmission:
neutral (N or P for vehicles with automatic
transmission)
l
Steering wheel: neutral position
if the multi-use tester is not used.
(2) Disconnect the female connector for waterproof
from the
connector
for ignition timing adjustment.
(3) Using a lead wire with alligator clips, ground the terminal
for adjustment
of the ignition timing.
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14-64
MPI SYSTEM
- Service Adiustment
Procedures
(4) Using a lead wire with alligator clips, ground the No. 10
terminal of the self-diagnosis
connector
or connect the
multi-use tester to the self-diagnosis
connector.
NOTE
By connecting
the multi-use
terminal of the self-diagnosis
(5) Start the engine
tester, ground
connector.
the
No.10
and run at idle.
(6) Check to be sure that the engine idlig speed is the basic
idle speed.
Basic idle speed: 700~?50 rpm
If there is a deviation of the engine speed from the basic
idle speed, first determine
whether or not the conditions
described below exist,and then use the speed adjustment
screw to adjust to the basic idle speed.
(a) The engine speed may be 20-100 rpm low for a new
vehicle jdriven about 500 km (300 miles) or less], but
adjustment
is not necessary.
(b) If engine stalling occurs or the engine speed is low
even though the vehicle has been driven about 500
km (300 miles) or more, it is probable that these are
deposits
adhered to the throttle
valve, SO it should
be cleaned.
(Refer to P.14-65.)
(c) If the engine speed is higher than the standard value
even though
the speed adjusting
screw is fully
close, check for any indication
that the (fixed SAS
position
has changed;
if there is such an indication,
adjust the fixed SAS).
If there is no evidence of a change of position, it is
probable that there is leakage resulting from deterioration
of the fast-idle
air valve so replace the
throttle
body.
NOTE
If the multi-use tester is used, select item No.22 and read
out the engine rpm.
(7) Turn OFF the ignition switch and stop the engine.
(8) Disconnect the lead wire for grounding
from the connector for self diagnosis.
~
Or disconnect
the multi-use
tester.
(9) Disconnect the lead wire for grounding
from the connectfor the ignition timing, and then connector the waterproofing connector.
(1O)Disconnect
the tachometer.
(11)Start the engine and let it idle for about five minutes;
check to be sure that the idling condition
is normal.
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/
z
MPI SYSTEM - Service Adiustment

~R.ONl-L~
BODY
14-65
Procedures
(THROITLE
VALVE
AREA)
NI.G=lcl
(1) Warm up the engine, then stop it.

(2) Remove the air intake hose from the throttle
(3) Plug the bypass passage inlet of the throttle
Caution
Do not
passage.
allow
cleaning
solvent
to
body.
body.
enter the
bypass
(4) Spray washing-solution

into the valve through the throttle
body intake port and leave it for about 5 minutes.
(5) Start the engine, race it several times and idle it for about
1 minute. If the idling speed becomes unstable (or if the
engine stalls) slightly open the throttle valve to keep the
engine running.
(6) If the throttle valve deposits are not removed, repeat steps
(4) and (5).
(7) Unplug the bypass passage inlet.
(8) Attach the air intake hose.
(9) Disconnect
the battery terminal for 10 seconds or more,
and then reconnect
it.
(10)Adjust the basic idle speed. (Refer to P.14-63.)
IDLE POSlTlON SWITCH AND THROTTLE POSINl4uAe

TION SENSOR ADJUSTMENT
(1) Loosen the tension of the accelerator cable sufficiently.
(2) Disconnect
the connector
of the throttle-position
sensor.
(3) Using lead wires with alligator clips between

and (2). connect an ohmmeter.
Lead wires
terminals
(1)
with
(4) Insert a feeler gauge with a thickness of 0.65 mm (.0256

in.) between
the fixed SAS and the throttle lever.
http://vnx.su/
14-66
Adjustment
Procedures
(5) Loosen the throttle-position

sensor
then turn fully clockwise.
(6) In this condition, check for continuity
(1) and (2).
installation
between
screw;
terminals
(7) Slowly turn the throttle-position

sensor in the counterclockwise direction until the point where there is no longer
continuity
is found; then securely tighten the throttleposition installation
screw at this point.
(8) Connect the connector
of the throttle-position
sensor.
side
(9) Connect a voltmeter between terminal 19 (throttle-position

sensor output voltage) of the engine control
unit and
terminal 24 (ground) or connect the multi-use tester to the
diagnosis
connector.
(1O)Switch
ON the ignition switch
(but do not start the
engine), and the check the output voltage of the throttleposition sensor.
connector
Standard
value : 0.4-l.OV
NOTE
If the multi-use tester is used, select item No.14 and read
out the throttle-position
7Fw327
(1l)lf
there is a deviation from the standard value, check the

throttle-position
sensor and the related harness.
(12)Remove
the feeler gauge.
(13)Switch
OFF the ignition switch.
(14)Adjust the tension of the accelerator cable. (Refer to P.14103.)
NMFIBB
FIXED SAS ADJUSTMENT
Caution
1. The fixed SAS should not be moved unnecessarily;
it
has been precisely
adjusted
by the manufacturer.
2. If the adjustment
for any reason is disturbed,
readjust
as follows.
(1) Loosen the tension of the accelerator
cable sufficiently.
(2) Loosen the fixed SAS lock nut; then turn the fixed SAS in
the counterclockwise
direction until the throttle valve is
completely
closed.
1 TSB Revision
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Es
MPI SYSTEM - Service Adjustment
Procedures
14-67
(3) Begin tightening

the fixed SAS; tighten it to a point 1 VI
turns beyond the point where there is contact to the
throttle
lever (in other words, to the point where the
throttle valve begins to open).
(4) While holding the fixed SAS so that it doesnt move,
tighten the lock nut securely.
(5) Adjust the tension of the accelerator
cable.
(6) Adjust the idling-position
switch
and throttle-position
sensor. (Refer to P.14-65.)
(7) Adjust the basic idling speed (SAS).
FUEL PUMP CONNECTOR DISCONNECTION

(HOW TO REDUCE THE FUEL LINE INTERNAL
NI4KAC
PRESSURE)
Make the following
operations
to release the pressure
remaining in fuel pipe line so that fuel will not flow out.
(I) Disconnect
the fuel pump harness connector
at the fuel
tank rear side.
(2) Start the engine and after it stops by itself, turn the
ignition switch to OFF.
(3) Disconnect
the battery (-) terminal.
(4) Connect the fuel pump harness connector.
/Fuel
filter
FUEL FILTER REPLACEMENT
YIGce.1
(1) Reduce the internal pressure of the fuel pipes and hose
(2) Remove the protector
of the fuel filter.
(3) Disconnect
the connection
between
the main pipe and
the high pressure hose. (Inlet and outlet)
(4) Disconnect the fuel filter mounting bolt, and then the fuel
filter and high-pressure
hose assembly
z;LF+FILL LIMITER (TWO-WAY VALVE) REPLACENMFEAGZ

(1) Remove the fuel filter hose protector.
(2) Disconnect the vapor hoses, and then remove
limiter.
FUEL GAUGE UNIT REPLACEMENT
the overfill
NI4mu
(1) Remove the fuel tank cap and lower the fuel tanks internal
pressure.
(2) Disconnect
the harness connector
from the fuel gauge
unit.
(3) Remove the fuel tank unit installation
nuts, and then
remove the fuel gauge unit from the fuel tank.
http://vnx.su/
14-68
MPI SYSTEM
FUEL
PUMP
Procedures
OPERATION CHECK
(1)Connect
terminal
the (+) battery terminal to the fuel pump drive

and the (-) terminal to the chassis. Confirm that
the fuel pump operates at this time.
Disconnect
the fuel pump connector.
the terminals,
wiring, etc., for damage.
Using
an
ohmmeter,
check the motor continuity.
(4)
1;;Check
FUEL PRESSURE MEASUREMENT
NWFNAD
(1) Reduce the internal
pressure of the fuel pipes and hoses.

(Refer to P.14-67.)
the fuel high pressure hose at the delivery
(2) Disconnect
pipe side.
Caution
Cover the hose connection
with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
(3) Set a fuel pressure gage on the special tool, placing an

adequate O-ring or gasket between the gage end special
tool prevent fuel leaks.
(4) Attach the special tool set in step (3) to the delivery
(5) Connect the (-) battery terminal.
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pipe.
Adjustment
Procedures
14-69
(6) Apply the battery voltage to the fuel pump drive terminal
to run the fuel pump. Confirm that no fuel leaks under
pressure around the fuel pressure gage connection areas
and special tool.
terminal
03W646
(7) Disconnect
the pressure regulator vacuum hose.
Measure the fuel pressure during idling.
Standard value : 330-370
kPa (47-53 psi)
(8) Measure the fuel pressure when the vacuum hose is
connected
to the pressure regulator.
Standardvalue:
270 kPa (38 psi)
(9) If the results of the measurements
made in steps (7) and
(8) above are not within the standard value, use the table
below to determine
the probable cause, and then make
the necessary
repair.
Symptom
Probable cause
Remedy
Fuel pressure is lower

than standard value
Clogged
Replace fuel strainer
fuel strainer
Faulty pressure regulator
Replace pressure regulator
Faulty fuel pump
Replace fuel pump
Fuel pressure is higher

than standard value
Faulty pressure regulator
Replace pressure regulator
Clogged fuel return hose or pipe
Clean or replace hose or pipe
Fuel pressure does not

vary even if the vacuum
hose is connected
Leakage around vacuum
Replace the vacuum hose.
hose
(lO)Stop the engine and

pressure gage. It is
within 2 minutes.
If the reading drops,
referring to the below
check the varying reading on the fuel

correct if the reading does not drop
observe the dropping speed. Then,
table, isolate the cause and repair it.
Symptom
Probable cause
Remedy
Fuel pressure drops

slowly after engine is
stopped
Faulty injector (leaks)
Replace injector
Fuel pressure drops

sharply immediately after
engine is stopped
Faulty fuel pump (pump inside check

valve binding)
Replace fuel pump
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14-70
MPI SYSTEM - Service Adjustment Procedures

(11)Release
residual pressure from the fuel pipe line.
(12)Disconnect
the fuel-pressure
gage and the special tools
from the delivery pipe.
Caution
(13)Connect
the fuel high-pressure
hose, and tighten
it
securely.
(14)Check for fuel leaks.
0 Apply battery voltage to the fuel pump drive terminal
to operate the fuel pump.
@ With fuel pressure acting, check the fuel line for leaks.
EGR VALVE CONTROL VACUUM
CHECK RWWWI
Check Condition
: 8595C
(185-205F)
(1) Disconnect the vacuum hose from the throttle body EGR
nipple.
(2) Start the engine and check to see that, after raising the
engine speed by racing the engine, vacuum raises proportionately with the rise in engine speed.
NOTE
If there is a problem with the change in vacuum, it is
possible that the throttle body port may be clogged and
require cleaning.
PURGE PORT VACUUM CHECK

Check Condition
Nw=vBc

: 8595C
(185-205F)
(1) Disconnect the vacuum hose from the throttle body purge
hose nipple and connect a hand vacuum pump to the
nipple.
(2) Start the engine and check to see that, after raising the
engine speed by racing the engine, vacuum remains fairly
constant.
NOTE
If there is no vacuum created,
it is possible that the
throttle body port may be clogged and require cleaning.
Engine
speed
(rpm)
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:j
_-~
-~.
MPI SYSTEM - MPI System
MPI SYSTEM
Inspection
14-71
INSPECTION
NWB-
COMPONENTS LOCATION
MPI control
ntake air temperature

arometric pressure sensor)
relay
Fuel pump drive terminal
Crank angle sensor

I
Electronic
Injector
EGR temperature
Oxygen sensor
EGR control
Purge control
solenoid
valve
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control
unit
sensor
solenoid
valve <M/T>
I
--
14-72
~~_
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Inspection
MPI SYSTEM
- MPI System
Inspection
Fuel pump
terminal
,
driving
l-i
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MPI SYSTEM - MPI System Inspection
14-74
MALFUNCTION
N14WAD
INDICATOR LIGHT
Among the self-diagnosis

items, a malfunction
indicator light
comes on to notify the driver of the emission control items
when an irregurality is detected.
However, when an irregular signal returns to normal and the
engine control unit judges that it has returned to normal, the
malfunction
indicator light goes out.
Moreover,
when the ignition switch is turned off, the light
goes out. Even if the ignition switch is turned on again, the
light does not come on until the irregularity
is detected.
Here, immediately
after the ignition switch is turn on, the
malfunction
indicator light is lit for 2.5 seconds to indicate that
the malfunction
indicator l[ght operates normally.
Items
indicated
by the
lightening
-
Computer
malfunction
light
Oxygen sensor
-
Malfunkion
indicator light
Air-flow sensor
?Flmm

Throttle
sensor
position sensor
-_
sensor
-
Crank angle sensor

Barometric
pressure sensor
injector
Fuel pump
EGR
+ marked is applicable
Malfunction
indicator
(1) When turning

comes on:
to vehicles for California only.
light
inspection
on the ignition
switch,
check
that the light
NOTE
If the light does not come on, check the harness
for breakage.
and light
1 TSB Revision
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Inspection
SELF-DIAGNOSIS
NwPAA!d
is backed up directly by the battery, the diagnosis

results are memorized
even if the ignition key is
turned off. The trouble codes will, however, be
erased when the battery terminal or the engine control unit connector is disconnected.
Caution
If the sensor connector
is disconnected
with the
ignition switch turned on, the diagnosis
code is
memorized.
In this case, disconnect
the battery
terminal
(-) for 10 seconds or more, and the
diagnosis memory will be erased.
The 12 diagnosis items are provided as follows, and
if plural items are activated, they are all indicated
sequentially from the smallest code number.
The engine control unit monitors the input/output

signals (some signals at all times and the others
under specified
conditions)
of the engine control
unit.
When it is noticed that an irregularity has continued
for a specified
time or longer from when the irregular signal is initially monitored,
passing a certain
number, the engine control unit judges that an irregularity
has occurred,
memorizes
the trouble
code, and outputs the signal to the self-diagnosis
output terminal.
There are 12 diagnosis
items, and the diagnosis
results can be read out with a voltmeter or multi-use
tester.
Moreover, since memorization
of the trouble codes
Malfunc-
Diagnosis item
11
I Oxygen
tion code
sensor
12
Air-flow sensor
13
14
21
Engine coolant tempemture
I 22 I Crank angle
sensor
sensor
1
sensor
23
Diagnosis item
I Top dead center sensor
24
Vehicle-speed reed switch
25
41
Injector
42
Fuel pump
43
1 EGFi*
* The diagnosis item marked * is applicable to vehicles for California only.
NUFlXE
CHECK PROCEDURE
(SELF-DIAGNOSIS)
Precautions
for operation
(1) When battery voltage is low, no detection
of failure is
possible.
Be sure to check the battery for voltage and
other conditions
before starting
the test.
(2) Diagnosis
item is erased if the battery or the engine
control unit connector
is disconnected.
Do not disconnect the battery
before the diagnosis
result is completely read.
(3) After check and correction
are over, disconnect
ground
cable for 10 seconds or more from negative terminal of
battery and connect lt again to make sure that failure
code is erased.
INSPECTION
TESTER)
PROCEDURE-(USING
MULTI-USE
NMPCM
(1) Switch OFP the ignition switch.

(2) Connect the tester side connector of the multi-use tester
to the connector
for diagnosis (located in the glove box
compartment).
(3) Connectthe power-sourceterminalof the multi-usetester

to the cigarette
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lighter
socket.
14-76

(4) Switch ON the ignition switch.
(5) Use the multi-use testerto check the self-diagnosis
codes.
of the repair or correction of the problem,
switch OFF the ignition switch; then disconnect the battery
terminals for ten seconds or longer and then, after reconnecting them, check to be sure that no malfunction
code is
displayed by the multi-use tester.
(7) Disconnect the multi-use tester.
INSPECTION PROCEDURE-(USING VOLTMETER)

N,WXG
ECl65C
DIAGNOSIS
(1) Connect an analogue voltmeter to the self-diagnosis

connectar.
(2) Turn ignition switch to ON, and indication of engine control
unit memory contents will immediately
start. If the system
is in normal condition,
pointer of voltmeter
indicates normal pattern. If any abnormality is in memory, the pointer of
voltmeter will deflect, indicating abnormal item as described in Diagnosis Chart.
After recording the abnormal item, check and repair each
part according to the check items in Diagnosis Chart.
(3) If the defective parts have been repaired, disconnect
the
negative terminal of battery cable for 10 seconds or more
and connect it again to make sure that the abnormal code
has been erased.
NI-
CHART (FAULT TREE)
Output
preference
order
1
Malfunction
Diagnosis
Enline
item
code
Output signal pattern
Oxygen sensor
Air flow sensor
Intake air
temperature
sensor
Throttle
sensor
Retained
Harness and connector

(If harness and connector
are normal, replace air
flow sensor assembly.)
Retained
l
l

sensor
Retained
l
0 Throttle position sensor
l
Retained
l
l
l3
:-l-lAmL
6
l
0 Oxygen sensor
l
Fuel pressure
0 injectors
(Replace if defective)
l
Intake air leaks
position
l4
Engine coolant
temperature
sensor
[ TSB Revision
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engine control
Retained
I2
J.-LNL
5
Check item (Remedy)
:n
4
I,#ace
y--LL
3
Memory
control
:-
No.


-r-
Malfunction
kqxlt
rreferencc
rrder
Diagnosis
item
Output
14-77
Inspection
code
signal pattern
Crank angle sensor
Check item (Remedy)
Memory
No.
22

are normal, replace
Distributor assembly.)
:nn
Top dead center
sensor
Vehicle speed sensor

(reed switch)
24
Retained
l
l

Vehiclespeed
sensor
(reed switch)
25
Retained

are normal, replace
barometric pressure
sensor assembly.)
41
Retained
l
0 Injector coil resistance
H
L
10
Barometric
sensor
pressure
11
nnluul
L
Injector
:nnnn
12
Fuel pump
42
Retained
13
EGR
43
Retained
l
l
l
l
H
L
l
l
14
Normal state
H
L
OTE- ,
neprace the engine control
check
^
^...items. . .
2.
=: c(;arnornra>

0 Control relay
nnnnnnnL
unit if a malfunction
code is output
although
the inspection
reveals that there is no problem
CHECKING BY USING THE MULTI-USE

(I) Switch OFFthe ignition switch.
(2)
Connect
the
the connector
(3)
Connect
the
tester

EGR therm0 sensor
EGRvalve
EGR valve control solenoid
valve <M/T models>
Therm0 valve <AA models:
EGRvalve control vacuum
side
connector
for diagnosis
power-source
with the
TESTER
of the
multi-use
tester
to
(located
beside the fuse block).
terminal
of the
multi-use
tester
to the cigarette lighter socket.

(4) Switch ON the ignition switch.
(5) Use the multi-use tester to make the various checks, and
repair if a problem is found.
NOTE
If the malfunction
indicator lamp (CHECK ENGINE lamp) il-
luminateswhile the checksare beingmade,checkthe selfdiagnosis

[ TSB Revision
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output.
14-n
inspection
(6) After repair, check once again to be sure the problem has
been corrected.
(7) Switch OFF the ignition switch.
(8) Disconnect the multi-use tester.
(9) Disconnect the battery terminals for ten seconds or longer.
This erases the self-diagnosis
code.
(10)Restat-t the engine.
Check (by a driving test and other
means) to be sure that the problem
Checking
the cranking
(Check when the engine
cant be started
or when
Check description
Check items
Check conditions
Power-supply voltage
Data reading
l Item No. 16
Ignition switch: ON
ll-13v
l
l
Throttle position
sensor
D Data reading
B Item No. 14
Self-diagnosis output
%el pump
D Actuater test
m item No. 7
gnition switch - ST
@ Data reading
B Item No. 18
Ignition switch: ON
Throttlevalve: idling position
(When the Throttle position
sensor output voltage is 1200
mV or lower, the engine control
unit diagnoses the injector
signal.)
Crank the engine for four
seconds or longer.
Ignition switch: ON
(Check for injector or
top dead
center sensor circuitry
disconnection or damage.)
Make the test

with relation to
both engine
cranking and fuel
pump forced
actuation.
Ignition switch:
ON
300-1000
mV
l
l
Normal
Pinch closed
the return
hose.
The pulsations
of fuel flow
can be felt by
the finger.
Listen close to
the fuel tank.
The pump
operation
sound can be
heard.
Engine
stopped
OFF
Cranking
ON
1 TSB Revision
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it is started.)
Probable cause of malfunction

action)
Norma) value
has been corrected.
(or
Low battery voltage

Power not supplied to the engine
control unit
(1)Check the power-supply circuit.
(2)Check the ignition switch,
ignition signal and input circuit.
(3)Check the control relay.
(4)Check the control relay control
circuit.
Malfunction of the engine control
unit earth circuit.
Maladjustment of the throttle
position sensor
Malfunction of the throttle position sensor or related circuitry
Check in accordance with the

diagnosis code.
[Note that the diagnosis code will be
erased if there is disconnection or
damage of the engine control unit
back-up power-supply circuit.)
If various diagnosis codes are
output, the most frequent cause is
damage or disconnection of the
power-supply or earth circuit.
Power is not supplied to the fuel
pump.
(1)Check the ignition switch (IG and
ST).
(2)Check the control relay.
(3)Check related circuitry.
Fuel pump malfunction
Ignition switch -ST signal circuit

check
Ignition switch check

Check items
Top dead center
sensor
l
Data reading
l
Item No. 22
injector
Data reading
l
Item No. 41
T
l
l
Check description
Check conditions
Engine cranking
Tachometer
connection (Use
the tachometer
to check the
cut-off of the
ignition coils
primary
currents.)

action)
Normal value
Engine cranking
Listen for
operation
sound.
Operation
sound of
injector is
audible.
Coolant
:emperature
C (F)
Actuation
time *z
(msec)
3 (32) *
Checking
Inspection
(or
If the tachometers indicated

read-out is 0, there is no cut-off of
the ignition coil primary currents.
(1)Checkthe power transistor unit
and control circuit.
(2)Check the ignition coil and the
coil power-supply circuit.
If the multi-use tester rpm. read-out
is abnormal
(1)Malfunction of thetop dead
center sensor circuit
(2)Malfunction of the top dead
center sensor
(3)Malfunction of the timing belt
0 Injector malfunction
Improper contact of connector and
relay contacts
l
l

malfunction
Ignition switch ST malfunction
/ Approx. 14
the sensors
Check description
Check items
Self-diagnosis output
Check conditions
Normal value
I Engine: idling
(2 minutes or more after engine
start)
Normal

action)
l
(or
Check in accordance with the

diagnosis code.
(Note that the diagnosis code will
be erased if there is disconnection
or damage of the engine control
unit back-up power-supply circuit.)
If various diagnosis codes are
output, the most frequent cause is
damage or disconnection of the
power-supply or earth circuit.
Oxygen sensor
B Data reading
l Item No. 11
1 Engine warm-up
(Make the
mixture lean by
engine speed
reduction, and
rich by racing.)
Engine
condition
Voltage (mV)
When sudden
deceleration
from 4,000
wm
200 or lower
When engine
is suddenly
raced
600-l ,000
If the oxygen sensor output voltage

is high during sudden deceleration
(1)Check for injector leakage.
(2)Check the oxygen sensor signal
circuit.
is low during engine racing
(1)Check the oxygen sensor and
signal circuit.
NOTE
*I : When the engine coolant temperature is 0C (32F), injectors inject simultaneously at 6 cylinders.
*2: Injector activation times are indicated at a battery voltage of 1 1V and a cranking speed of 250 rpm or lower.
/ TSB Revision
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14-80

Check description
Check items
Oxygen sensor
Data reading
D Item No. 17
Check conditions
l
Air flow sensor

Data reading
l Item No. 12
l
Normal value

action)
l
Engine warm-up
(Using the
oxygen sensor
signal, check the
air/fuel mixture
ratio, and also
check the
condition of
control by the
engine
control unit.)
Engine speed
(rpm.)
Voltage (mV)
700 (idle)
400 or lower
Engine warm-up
Engine
condition
If the oxygen sensor signal is

normal, the engine control unit is
regulating the air/fuel mixture ratio
normally.
is low at all times, check whether OI
not there is intake of air.
is high at all times, check for
leakage of the injector.
2.000
(or
(changes)
l
:
600-I ,000
Frequency (Hz)
700 rpm
(Idling)
25-45
2,000 rpm
85-105
Racing
Increase
If the air flow sensor output

frequency suddenly changes
greatly, improper contact ofthe air
flow sensor or connector is
probable.
If the output frequency of the air
flow sensor is unusually high or low
c&eck the air cleaner element.
If the output frequency of the air
Malfunction
of intake air
D Data reading
Item No. 13
ensor or related
the fixed SAS.
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l
l
14-81
Inspection
Data reading
item No. 21
If the rpm is low when cold,

clogging of thefast-idling airvalve
Barometric pressure
sensor
l
Data reading
l
Item No. 25

Data reading
l
Item No. 26
600-800
Altitude m (ft.)
Pressure mm
Hg
0 (0)
760
600 (1,969)
710
1,200 (3,937)
660
1,800 (5,906)
610
Barometric pressure sensor or related circuitry malfunction.

(If the barometric pressure sensor
pressure is low at high speed,
clogging of the air cleaner element
is probable.)
Engine: racing at
2,000 rpm
Gradually
close the airintake duct by
using a hand.
Ignition switch:
ON
(Checking by using the accelera:CI;ZI~~I several
Throttle valve
idling position
ON
Open the
throttle valve
slrghtly.
OFF
Idle position switch or related

circuitry malfunction
e Improper adjustment of the
accelerator cable orthe auto-cruise
cable
l
Idling-position switch: improper
adjustment.
Steering
wheel neutral
position
(wheels
straight-ahead
direction)
OFF
Steering
wheel half turn
ON
Power steering oil

pressure switch
l
Data reading
l
Item No. 27
Ignition switch:
ON
801176)
Engine: idling
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Decreases.

or signal circuit malfunction
14-82
Inspection
Check description
Check items
Check conditions
?
Data reading
l Item No. 28
EGR temperature
sensor (California only)
l Data reading
l Item No. 43
Checking
Engine: idling
(The air conditioner compressor could be acti
vated when the
air conditioner
switch is ON.)
Normal value
Air conditioner
switch OFF
$gine
is maintained in a constant state for 2
minutes or
more.)
OFF
Check air conditioner
-I--Air conditioner
switch ON
Engine
condition
Engine: warmed

action)
(or
system.
ON
Temperature
C (F)
l
l
l
l
l
temperature or higher
10-40c
(50-104F)
0 Water
temperature:
7OC(158F)
or higher
l While driving
continuously
for more than
30 seconds at
a vehicle
speed of
80-80 km/h
(50-56 mph)
Check the
Check the
Check the
Check the
only)
Check the
valve (M/T
Check the
EGR temperature sensor.

EGR control system.
EGR valve.
therm0 valve (A/T models
EGR control solenoid
models only)
EGR control vacuum.
the actuator
Check description
Check items
Injectors
Actuater test
l
Item No. l-4
Check conditions
l
Engine: warmed
Injector No.
;iut off the injectors in sequence

during idling after
engine warm-up:
check the idling
condition of a
cylinder that
doesnt change.)
Probable cause of malf~@on

action)
Normal value
2
3
4
5
Engine
(or
If the idling condition of one cylinde

doesnt change, check that cylinder
(1)Check the injector operation
sound.
(2)Check the spark plug and hightension cable.
(3)Check the power transistor unit
and control circuit.
If the injector activation times is unusually long or short, there is a

malfunction of the air-flow sensor,
Engine coolant temperature sensor,
inmke air temperature sensor, or
barometric pressure sensor.
If the injector activation time is long,
increased engine resistance or leakage of compression pressure is
orobable.
Idling condition changes

more.
(Becomes
more unstable, or
engine
stalls.)
6
Injector
Data reading
l
Item No. 41
l
Engine: warmed
UP
Engine
condition
Actuation time
(msec.)
700 rpm
(Idling)
2,7-3.2
2,000 rpm
2,4-2.9
Rapid racing
Increases.
i-
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Revision
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Check description
Check items
Check conditions
Ignition advance
(power transistor)
l
Data reading
l
Item No.44
Stepper motor
Data reading
l
Item No.45
l
l
Engine: warmed
up
Timing light: set
(The timing light
is set so as to
check the actual
ignition timing.)
Engine: idling
after warm-up
(Idle position
switch hust be
ON.)

action)
Normal value
Engine rpm
Ignition
advance
(BTDC)
700 (Idling)
13-20
2,000
38-42
Engine
condition
Step
If the ignition advance and actual

ignition timing are different, adjust
the ignition timing.
[The ignition timing may fluctuate
during idling, but this is not a problem. The advance is greater (approx
5) at high altitude.]
If the number of steps increases to

100 or 120 or decreases to 0, a
malfunction of the stepper motor
orthe activation circuit is probable.
If the number of steps is small,
check whether or not air is being
sucked in.
If the number of steps is large,
either of the following is probable:
(l)Deposits adhered to the throttle
valve part
(2)lncreased engine resistance
If the number of steps is abnormal
even though the engine is normal,
adjust the basic idle speed.
2-12
(The compressor
clutch should be
activated when
the air conditioner switch is
ON.)
Air conditioner relay

Data reading
l
Item No. 49
Purge control solenoid

valve
l Actuator test
l
ltemNo.8
EGR control solenoid

valve (M/T models
only)
Engine: idling
after warm-up
Ignition switch:
(OECigineStop)
Ignition switch:
g:gine
stop)
(or
700 rpm
(Idling)
14-83
Air conditioner
switch ON
(900 rpm)
30-70
Air-conditioner
switch ON shift
lever D range
(650 rpm)
20-60
Check the inhibitor switch and the

signal circuit.
Air conditioner
switch
Air conditioner
relay
OFF
OFF
(compressor
clutch nonactivation)
If the air conditioner relay output is

abnormal, check the air conditioner
signal input circuit and the air conditioner system.
If the activation of the air
conditioner
compressor clutch is not normal,
check the compressor clutch and
the relay circuit.
l
l
ON
ON
(compressor
clutch activation)
Actuator
forced
actuation
Operation
sound
audible
during
activation
Actuator
forced
actuation
Operation
sound
audible
during
activation
1 TSB Revision
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Check the air conditioner system.

If the engine speed does not increase when the air conditioner
switch is switched from OFF to ON,
check the stepper motor or the
activation circuit.
Check the purge control solenoid

valve
Check the purge control solenoid
valve drive circuit.
Check the EGR control solenoid
valve
Check the EGR control solenoid
valve drive circuit
1
*
14-84
Inspection
AIR-FLOW SENSOR
AFS side connector
NI4oGAD
BAROMETRIC
PRESSURE SENSOR
Use multi-use
tester
for inspection.
(Refer to P.1475.)
INTAKE AIR TEMPERATURE SENSOR
NMOHAB
INSPECTION
(I) Disconnect the air-flow serrsor connectors.
(2) Measure resistance between terminals @ and 0.
6FUO622
Temperature
(3) Measure
drier.
Resistance
Q (32)
6.0
20 (Sij
2.7
80(176)
0.4
resistance
Temperature
ECIMX,
C (F)
while
C(F)
heating
:
the sensor
Resistance
Higher
(kfi)
using a hair
km
Smaller
(4) If the value deviates from the standard

value
resistance remains unchanged,
replace the air-flow
assembly.
or the
sensor
ENGINE COOLANT TEMPERATURE SENSORNIwB
Engine
sensor
coolant
INSPECTION
(1) Remove
engine coolant temperature
sensor from the
intake manifold.
(2) With temperature
sensing
portion
of engine
coolant
temperature
sensor immersed
in hot water check resistance. The sensor should be held with its housing 3 mm
(.I2 in.) away from the surface of the hot water.
temperature
Temperature
i:Jl-E
01R0120
C (FJ
0 (32)
5.9
20 (68)
2.5
-
80 (176)
(3) If the resistance deviates
replace the sensor.

sensor connector
[sensor side front view)
Resistance
W-N
2.7
0.3
from the standard
.;
value greatly
INSTALLATION
(1) Apply sealant 3M NUT locking No. 4171 or equivalent to
threaded
portion.
(2) Install coolant
temperature
sensor and tighten
it to _
specified torque.
Sensor tightening
torque : 2040
Nrn (15-29 ft.lbs.)
(3) Fasten harness connectors
securely.
I
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14-85
MPI SYSTEM - MPI Svstem Inspection

THROlTLE
POSITION
SENSOR
N14aBBH
INSPECTION
(I) Disconnect
(2) Measure
terminal
the throttle
resistance
4 (sensor
Standard
position
between
power).
value : 3.5-5.5
sensor
terminal
connector.
1 (sensor earth) and
(3) Correct a pointer type ohmmeter

between
terminal
1
(sensor earth) and terminal 3 (sensor output).
(4) Operate the throttle valve slowly from the idle position to
the full open position and check that the resistance
changes smoothly
from in proportion
with the throttle
valve opening angle.
7FUO276
I
E
j$jlJ
0
-0
(5) If the resistance is out of specification,

or fails to change
smoothly,
replace the throttle position sensor.
Throttle
position
sensor installation
torque
:
1.5-2.5 Nm (1.1-1.8 ft.lbs.)
For the Idle position
adjusting procedure,
switch and throttle

refer to P.14-65.
position
sensor
IDLE POSITION SWITCH

/
7FUO330
NI-
INSPECTION
(1) With the accelerator pedal released, check to be sure that
the throttle valve lever or the fixed SAS is pushed.
NOTE
If it is not pushed, adjust the fixed SAS (Refer to P.14-66.)
(2) Disconnect
the throttle position sensor connector.
(3) Check the continuity
across the throttle position sensor
connector
terminal 1 (Sensor earth) and 2 (Idle position
switch).
Accelerator
El0
,Ej!J
-0
7Fuo3311
pedal
Continuity
Depressed
Nonconductive
Released
Conductive
(mfi)
(On)
NOTE
If there is no continuity
when the accelerator
pedal is
returned,
loosen the throttle-position
sensor
installation
screw;
then, after turning all the way in the clockwise
direction,
check again.
(4) Replace the throttle-position
sensor (idling-position
switch
incorporated)
if there is a malfunction.
NOTE
For replacement
procedure,
refer to the idle position
switch and throttle position sensor adjustment
section
(P.1465).
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I
I
14-86

OXYGEN SENSOR
NllODBG
Caution
1. Before checking,
warm
up the engine
until engine
coolant temperature
reaches 85 to 95C (185 to 205F).
2. Use an accurate digital voltmeter.
INSPECTION
(1) Disconnect
the oxygen sensor connector
and connect a
voltmeter
to the oxygen sensor connector.
(2) While repeating
engine
racing, measure
the oxygen
r
1
7FUO223
Engine
Oxygen sensor
output voltage
Remarks
Race
Approx. IV
Make air-fuel mixture

rich by accelerator
operation
INSTALLATION
1. For removal and installation
of oxygen sensor,
GROUP 15.
2. Oxygen sensor tighten to specified
torque
Specified
torque
: 46-50 Nm (29-36 ft.lbs.)
refer to
NlANcEH
TOP DEAD CENTER SENSOR

CRANK ANGLE SENSOR
Use multi-use tester for inspection.
(Refer
to
P.14-75.1
EGR TEMPERATURE SENSOR (California
only)
NWtCHC
Refer to GROUP
25 - Exhaust
Gas Recirculation
System.
VEHICLE SPEED SENSOR

Refer
to GROUP
8 - Meters
NWXNB,
and Gauges.
LI1-
AIR CONDITIONER SWITCH

Refer to GROUP
8 --Column
Switch.
NuGNAca
INHIBITOR SWITCH
Refer
to GROUP
21 - Service
Adjustment
Procedure.
POWER STEERING OIL PRESSURE SWITCHN,UIUb

Refer to GROUP
19 for power
INJECTORS
steering
system
inspection.
NIUJTAJ
OPERATIONAL
CEHCK
(1) Using the multi-use tester, conduct the check procedures
described
below.
0 Cut off the injector fuel injection one after another in
sequence.
0 Check the injector activation
time.
(Refer to the section concerning checking by using the
multi-use tester.)
http://vnx.su/
Inspection
14-87
MEASUREMENT
OF RESISTANCE
BETWEEN TERMlNALS
(1) Disconnect
the connector
for the injectors.
(2) Measure the resistance
between
terminals.
Standard
(3) Connect
value
: 13-16
the connector
0 at 20C (68F)
for the injectors.
IDLE SPEED CONTROL SERVO (STEPPER MOTOR)

N1404MG
Checking
the operation
sound
(1) Check to be sure that the sound of operation
of the
stepper motor can be heard from the Idle speed control
servo when the ignition switch is switched ON (without
starting the engine).
(2) If the operation sound cannot be heard, check the stepper
motor actuation
circuit.
(If the circuit is normal, the probable cause is a malfunction of the stepper motor or of the Engine control unit.)
(3) Using the multi-use tester, check the relationship between
the stepper motors step and the engine rpm.
(Refer to the sub section
Actuator
or the section
concerning
checking by the multi-use tester.)
Checking
the coil resistance
(1) Disconnect
the Idle speed control servo connector
and
connect the special tool (test harness).
(2) Measure the resistance between terminal @(white clip of
the special tool) of the connector at the Idle speed control
servo side and terminal @(red clip) or terminal @(blue clip).
Standard value : 28-33 fi [at 20C (68F)]
(3) Measure the resistance between terminal @(green clip of
the special tool) of the connector at the Idle speed control
servo side and terminal @ (yellow clip) or terminal @(black
clip).
Standard
value : 28-33 i2 [at 20C (68F)]
7FUOOlO
Checking
the operation
(1) Remove the throttle
(2) Remove the stepper
Idle speed
control
mo2931
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body.
motor.
14-88
eed
SeNO
7FucI294
(3) Connect the special tool (test harness) to the Idle speed
control servo connector.
(4) Connect the positive
0 terminal
of a power source
(approx. 6V) to the white clip or the green clip.
(5) Holding the Idle speed control servo as shown in the
illustration, connect the negative 0 terminal of the power
source to each clip in the sequence described below, and
check whether or not there is vibration (a feeling of very
slight shaking
of the stepper
motor) as a result of
activation
of the stepper motor.
0 Connect the negativea
terminal of the power source
to the red and yellow clips.
0 Connect the negativeB
0 Connect the negative-e terminal of the power source
to the red and black clips.
@ Connect the negativea
to the blue and black clips.
8 Connect the negative @terminal of the power source
to the blue and yellow clips.
@I Repeat the test in the reverse (8-o)
sequence.
(6) If. as a result of this test, vibration is felt, the stepper
motor can be considered
to be normal.
CONTROL RELAY
Nl4oYAc
INSPECTION
Caution
When applying battery voltage directly, make sure that it is
applied to correct terminal.
Otherwise,
the relay could be
damaged.
NOTE
Failure of the control relay prevents power supply to the fuel
pump, injectors, engine control unit, resulting in start failure.
(1) Remove the cover under the glove box and the glove box.
(2) Disconnect
the control relay and connector.
OlLO521
01 LO220
(3) Connect a 12V power supply @ terminal to the terminal @

of the control relay and measure the voltages at terminals
@ and @ when the a terminal
is connected
to and
disconnected
from the terminal @.
Terminal @and 12V power
supply 0 terminal
[ TSB Revision
Terminal @I
Terminal @
Connected
12v
12v
Disconnected
ov
ov
http://vnx.su/
14-89
MPI SYSTEM - NIP!. System Inspection

(4) Connect
a 12V power
supply@
terminal
to the terminal
to
the terminal @of the control relay and check the continuity
between
terminal 8 and @ when the @ terminal
is
connected
to and disconnected
from the terminal@.
Terminal B and 12V power
supply + terminal
Terminal 0 and
terminal @
Connected
Continuity
Disconnected
Discontinuity
(5) Connect a 12V power supply @ terminal to the terminal 8

of the control relay and measure the voltages at the
terminal @ when the o terminal is connected
to and
disconnected
from the-terminal
6.
Terminal 8 and - terminal
Terminal @
Connected
12v
Disconnected
ov
(6) If one of the above is improper,
replace the control
POWER TRANSISTOR
2 (ground)
-2,
relay.
NIulcGG
INSPECTION
(1) Disconnect
the power transistor
connector.
(2) Connect a power supply of 1.5V to terminals 0 (+) and
Q (-) of the power transistor
and then check for
continuity
between terminals
@ and Q under power-ON
and power-OFF
conditions.
NOTE
l
When checking
for continuity,
connect the circuittester to terminal @ on the positive side and terminal
@ on the negative side.
l
Check by using an analog-type
circuit tester.
I
I
Power ON
Terminal
Power OFF
@-CZ Terminal
Continuity
Non-continuity
6EL0016
AIR CONDITIONER POWER RELAY

Refer to GROUP
NIUIUB
24 - Air Conditioner.
PURGE CONTROL SOLENOID VALVE

Refer to GROUP 25 - Evaporative
Emission
Control
NlU(CM
System.
EGR CONTROL SOLENOID VALVE (M/T MODELS

ONLY)
Nl4RRClAa
Refer to GROUP 25 - Exhaust Gas Recirculation System.
[ TSB Revision
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14-90
MPI SYSTEM - Injector
INJECTOR
Removal
+I) ++
**
++ ,C
** +*
+*
,C
H
IH
steps
1.
2.
3.
4.
5.
6.
7.
6.
9.
10.
11.
12.
13.
Air intake alenum

Connection for high-pressure hose
Connection for return hose
Connection for vacuum hose
Pressure regulator
O-ring
Connection for harness connector
Delivery pipe
injector
O-ring
Grommet
Insulator
Insulator
NOTF
Il) Reverse the removal procedures

to reinstall.
12) 4,
: Refer to Service Point of Removal.
I3j I&+ : Refer to Service Point of In&l lation.
:41 0 j : Non-reusable parts
W626
N14ssA~

1. AIR INTAKE
PLENUM
For removal of the air intake plenum,

intake Manifold.
2.
HlGH
PRESSURE
Reduce the internal

P.14-67.)
HOSE
refer to GROUP
11 -
DISCONNECTION
pressure
in the fuel pipe line. (Refer to
Caution
Since slight residual pressure remains even after disconnection,
cover the hose end with a rag, etc. to
prevent the fuel from spilling.
8./9. REMOVAL
OF DELIVERY PIPE WITH INJECTOR
Disconnect
the delivery
the delivery pipe.
pipe with
the injector
attached
to
Caution
1. Be careful not to drop the injector when removing
the delivery
pipe.
2. Be aware that fuel will flow out when the injector is
removed.
http://vnx.su/
14-91

INSPECTION
N,-
INJECTORS
(1) Measure resistance
circuit tester.
between
terminals
of injector
Standard
value : 13-16 0, at 20C (68F)
(2) If the resistance
is out of specification,
injector.
using a
replace
the
6FU341
SERVKE POINTS OF INSTALLATION

13./12.
INSTALLATION
NWSDAG
OF INSULATOR
(1) Attach a new six injector

intake manifold.
(2) Attach a new four delivery
the intake manifold.
purpose
insulator
pipe,purpose
to the
insulator
to
11./10./9.
INSTALLATION
OF GROMMET,
O-RING AND
INJECTOR
(1) Install a new grommet and O-ring to the injector. Apply
a coating of spindle oil or gasoline to the O-ring of the
injector.
Grommet
EQ 1409
0-rin
(2) While turning the injector to the left and right, install it
to the delivery pipe.
(3) Check to be sure that the injector turns smoothly.
NOTE
If it does not turn smoothly,
the O-ring may be
jammed;
remove the injector, check O-ring and then
re-insert it into the delivery pipe and check once again.
elivery
w
8.
INSTALLATION
OF DELIVERY
PIPE
Attach the delivery pipe.

At this time, confirm that the insulator
into the pipe mounting
hole.
1 TSB Revision
http://vnx.su/
is properly
inserted

5.
INSTALLATION
OF FUEL PRESSURE REGULATOR
When connecting
the fuel-pressure
regulator to the delivery pipe, apply light oil or petrol to the O-ring, and then
insert, being careful not to damage the O-ring.
2.
CONNECTION
OF HIGH PRESSURE HOSE
(1) Apply engine oil to the hose union. Then insert the
hose, being careful not to damage the O-ring, and
tighten securely.
Caution
Because there is high pressure applied between the
fuel pump and the delivery pipe, be especially sure
that there is no fuel leakage in this area.
D&en/
pipe
03w124
Fuel high
1
Injection
mixer
03ro41
Fuel pump
driving terminal]
/ /
(2) Check fuel leakage in the following

manner.
0 Apply battery voltage on to fuel pump driving
terminal which is branched off from control harness on an upper part of firewall to put fuel pump
in motion.
Q Check for fuel leakage in the system, particularly
from connection
between fuel high pressure hose
and pipe with fuel line under regular pressure.
http://vnx.su/
MPI SYSTEM - Throttle Body
THROlTLE
BODY
IEMOVAL AND INSTALLATION
..
4-8 Nm
,%I
ft.lbs.
Removalsteps
I)+
1. Accelerator cable
2. Vacuum hose connection
3. Air intake hose connection
4. TPS connector
5. ISC motor connector
6. Water hose connection
7. Throttle body
8. Gasket
NOTE
(2) l + : Refer to Service Points
(3) q
: Non-reusable
parts
to reinstall.
of Installation.
si&$tkJ27
NI4sDAF
INSTALLATION
1. ACCELERATOR
CABLE
For information
concerning
cable, refer to P.14-103.
ADJUSTMENT
adjustment
of the accelerator
NUSE-
2.5-4.5
1.8-3.2
I.e.5
Nm
1.1-1.8 ft.lbs.
Nm
ft.lbs.
i
Disassembly steps
l + 1. Throttle position sensor (within Idle position switch)
2. Idle speed control servo assembly
3. Fixed .SAS
4. Adjusting nut
5. Throttle
7FUO275
5
NOTE
(I)
Reverse the disassembly procedures to reassemble.
(21 l +
body
j TSB Revision
http://vnx.su/
: Refer to Service
Points
of Reassembly.
14-94
MPI SYTEM - Throttle Body

NWSFAG
Caution
l
When loosening a Phillips screw which has been firmly
tightened,
use a Phillips screwdriver
that is an exact fit
for the screw.
l
Do not remove the throttle
valve.
l
Be careful when removing
the throttle
position
sensor
and idle speed control
servo mounting
screws,
as
adhesive has been applied these screws.
Connector viewed
from terminal end
7FUO278
INSPECTION
Nl4SIW:
THROTTLE
POSfTfON SENSOR CONTINUITY
TEST
(1) Disconnect
the throttle position sensor connector.
(2) Using a circuit tester, measure the resistance
between
terminals 4 (power) and 1 (ground).
Standard
value : 3.5-6.5 161
(3) Check the sensor body for cracks and damage.
IDLE SPEED CONTROL
SERVO ASSEMBLY
CONTINUITY
TEST
Measure the resistance
between
the respective
terminals.
Standard
value:
Terminal 0-O and 0
28-33 R [at 20C (66F)I
Terminal 049 and @
28-33 Cl [at 20C (68F)]
Connector
viewed
from terminal end
7FUOOlO
mJo294
mJoz35
IDLE SPEED CONTROL

SERVO ASSEMBLY
OPERATION
TEST
(1) Connect the special tool (test harness) to the Idle speed
control servo connector.
(2) Connect
the positive
@ terminal
of a power
source
(approx. 6V) to the white clip or the green clip.
(3) Holding the Idle speed control servo as shown in the
illustration, connect the negative 0 terminal of the power
source to each clip in the sequence described below, and
check whether or not there is vibration (a feeling of very
slight shaking of the stepper
motor)
as a result of
activation of the stepper motor.
0 Connect the negative 0 terminal of the power source
0 Connect the negative 0 terminal of the power source _
Q Connect the negative 0 terminal of the power source
to the red and black clips.
@ Connect the negative 0 terminal of the power source
to the blue and black clips.
6 Connect the negative Q terminal of the power source
to the blue and yellow clips.
@ Repeat the test in the reverse @I-@) sequence.
(4) If, as a result of this test, vibration
is felt, the stepper
motor can be considered
to be normal.
/ TSB Revision
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MPI SYSTEM - Throttle Body

CLEANING
THROlTLE
BODY PARTS
(1) Clean all throttle body parts.
Do not use solvent to clean the following
parts:
l
l
Idle speed control servo
0 Idle position switch
If these parts are immersed in solvent, their insulation
will deteriorate.
Wipe them with cloth only.
(2) Check if the vacuum port or passage is clogged.
Use
compressed
air to clean the vacuum passage.
NWSGAC3
1. INSTALLATION
OF THROTrLE
POSITION SENSOR
(1) Set the throttle position sensor to the throttle body as
shown in the diagram.
(2) After turning the throttle

counterclockwise
direction
the screw.
(3) Connect the circuit tester between 1 (ground) and 3

(output), or between
3 (output) and 4 (power). Then,
make sure that the resistance changes smoothly when
the throttle valve is slowly moved to the fully open
position.
(4) Check for continuity
across terminals 2 (Idle position
switch) and 1 (ground) with the throttle valve both fully
closed and fully open.
Throttle position
sensor power
I
Idle-position
switch
Throttle position
sensor output
position sensor 90 in the

to set it, tighten by turning
1 Throttle valve position

1 Fullv
closed
1 Fully
open
Continuity
Conductive
Non-conductive
If there is not continuity

with the throttle valve fully
closed, turn the throttle-position
sensor itself completely in the clockwise
direction,
and then check
again.
(5) If the above specifications
position switch.
1 TSB Revision
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are not met, replace the idle
I
I
14-96
MPI
SYSTEM
Fuel
Tank
FUEL TANK
IEMOVAL
AND
INSTALLATION
Pre-removal
Operation
l
Disconnection
of fuel pump
tion (Refer to P.14-67.)
l
Drainbg of the Fuel.
connec
Post-installation
Operation
Supplying
of the Fuel.
&door
vehicles
2-door
6.5-10
Removal
e+
~~
l *
l +
++
+I)
++
++
steps
1. Fuel pump
connector
connection
2. Fuel gauge unit connector
connection
3. Drain plug
4. Fuel filler cap
5. Fuel filler hose protector
6. Overfill
limiter
(Two-way
valve)
7. Check valve
8. Vapor hose
9. Clamp assembly
10. Fuel filler hose
11. Breather
hose
12. Packing
13. Fuel filler neck
14. High pressure
hose
15. Return
hose
16. Separator
tanks
/ TSB Revision
vehicles
ft.lbs.
17.
18.
19.
20.
21.
Fuek tank protector

Fuel tank
Fuel pump
Fuel gauge
unit
Separator
tanks
NOTE
(3) +*
http://vnx.su/
to reinstall.
of Removal.
of Installation.
MPI SYSTEM - Fuel Tank

14-97
NIIOBAF
14. REMOVAL OF HIGH PRESSURE HOSE TO FUEL PUMP

CONNECTION
Caution
INSPECTION
l
l
l
l
l
l
NI4GcP.m
Check the hoses and the pipes for crack or damage.

Check the fuel tank cap for malfunction.
Check the fuel tank for deformation,
corrosion or crack.
Check the fuel tank for dust or foreign material.
NOTE
If the inside of the fuel tank is to be cleaned, use any one
of the following:
(1) Kerosene
(2) Trichloroethylene
(3) A neutral emulsion type detergent
Check the in-tank fuel filter for damage or clogging.
Check the check valve for malfunction.
CHECKING
TWO-WAY
VALVE
A smiple way of inspection,
however,
may be adopted in
which the overfill limiter is removed and then air is lightly
blown into either the inlet or outlet. If the air passes after a
slight resistance,
overfill limiter is in good condition.
NUGDAK
15. INSTALLATION
OF RETURN HOSE/b
VAPOR HOSE
When attaching the hoses to the pipes, be sure that the
hose is attached
until its end comes in touch with the
03u0019
[ TSB Revision
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11
I--i-;
eG.cz,.
14-98
ilark
MPI SYSTEM - Fuel Tank
nut
Securk
side
03Yc.43
14. CONNECTION
OF HIGH PRESSURE HOSE TO FUEL
PUMP
Temporarily
tighten the flare nut by hand, and then tighten
it to the specified torque, being careful that the fuel hose
does not become twisted.
Caution
When tightening
flare nut, be careful not to bend or
twist line to prevent damage to fuel pump low connection.
11. INSTALLATION
OF BREATHER HOSE/IO.
FUEL FILLER
HOSE
insert the hoses until their ends contact the fuel tank.
7. iNSTALLATlON
OF CHECK VALVE
Install the check valve to the fuel filler hose protector so
that the check valves arrow faces as shown in the figure.
03W532
6.
INSTALLATION
OF TWO-WAY
VALVE
Install so that the two-way valve is facing
in the direction
Engine
REPLACEMENT OF FUEL PUMP
NMGFAE
(1) Disconnect
the fuel pump connector.
(Refer to P.14-67.)
(2) Remove the fuel tank cap.
(3) Drain the fuel.
(4) Disconnect
the fuel high pressure hose and main pipe.
Caution
(5) Remove the fuel pump installation
nuts and then remove
the fuel pump from thefuel tank.
1 TSB Revision
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MPI SYSTEM y Fuel kine
FUEL LINE AND VAPOR
and
Vapor
Line
14-99
LINE

I
N-
3OAO Nm
4-Q Nm
3-4 ft.lbs.
30-4ONm
22-29 fklbs.
Removal
steps
1. Clip
+w +*
2. Connection for high pressure
*I, **
3. Pressure hose
l + 4. Fuel return hose
5. Canister
6. Canister holder
e+
7. Vapor hose
+I) I)+
8. Pressure hose
++
9. Fuel return hose
10. Main pipe
11. Return pipe
12. Protector
13. Bolts
14. Eye bolts
4*
hose
I)+
15.
16.
17.
18.
19.
20.
21.
Fuel filter
Pressure hose
Clips
Clips
Main pipes
Return pipe
Vapor pipe
NOTE
(2) +I)
(3) **
(4) q
: Non-reusable
parts
1 TSB Revision
http://vnx.su/
to reinstall.
of Removal.
of Installation
14-100
MPI SYSTEM - Fuel Line and Vapor Line

2.
NMKBAI
DISCONNECTION
OF HIGH PRESSURE HOSE TO FUEL
DELIVERY PIPE 3./K hWN PlPE TO HIGH PRESSURE
HOSE
Caution
Cover the high pressure hose connection
with rags to
prevent splash of fuel that could be caused by some
residual pressure in the fuel pipe line.
14. REMOVAL
OF EYE BOLTS
Hold fuel filter with a wrench
and remove eye bolt
retaining fuel high pressure hose with an eye wrench.
INSPECTION
*
e
l
l
NIU(UG
Check the hose and pipes for cracks, bend, deformation

and clogging.
Check the canister for clogging.
Check the check valve for malfunction.
Check the fuel filter for clogging and damage.
NWOMM
16./8./3.
INSTALLATION
Temporarily tighten the flare nut by hand, and then tighten
it to the specified torque, being careful that the fuel hose
does not become twisted.
Secure
side
03YO43
9./7.
03u0019
ITSB
INSTALLATION
OF VAPOR HOSV4.
RETURN HOSE
When attaching the hose to the pipes, be sure that the
hose is attached
until its end comes in touch with the ._
Revision
http://vnx.su/
MPI SYSTEM
Deliverly
and
Line
14-101
Fuel
2.
CONNECTION
(1) Apply engine oil to the hose union. Then insert the
hose, being careful not to damage the O-ring, and
tighten securely.
Caution
Becasue there is high pressure applied between the
fuel pump and the delivery pipe, be especially sure
that there is no fuel leakage in this area.
pipe
Line
Vapor
(2) Check fuel leakage in the following

manner.
0 Apply pattery voltage on to fuel pump driving
terminal which is branched off from control harness on an upper part of firewall to put fuel pump
in motion.
@ Check for fuel leakage in the system, particularly
from connection
between fuel high pressure hose
and pipe with fuel line under regular pressure.
1 TSB Revision
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25-I
EMISSION CONTROL
SYSTEM
NZAA-
CONTENTS
EMISSION CONTROL SYSTEM
<2.6L ENGINE> .. . ...m..s.*.......................
CRANKCASE EMISSION CONTROL

SYSTEM .. . . . . . . . . . . . . . . . . . .. .. . . ...-...........................
CRANKCASE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . .. .. . . . . . . . .. .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . 27
EVAPORATIVE EMISSION CONTROL

SYSTEM .. .. .. . . . . . . . . . . ..*...-.................................
EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . .. .. . . . .. .. .. . . . . . . . . . . . . . . . . . .. . . .. .. . . 28
EXHAUST EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . .. . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . 13
EXHAUST EMISSION CONTROL

SYSTEM . . . . . . . . . . . . .. . . . .. . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . .. .. . . 31
SPECIFICATIONS
. .. .. . . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. . . . . .
..,................... ____
___..
. . . . . .._._............. ____._
. . . . . . . . . . . . ..___._............
. . . . . . . . . .._..._._._............
2
2
3
2
2
25
SPECIFICATIONS
. . .. ..a..................................
. . . . . .. .. . . . . .._...............
25
. ..._.._.....................
25
_............................
__ 25
. . .. .. .. . . . . . . . . . . . . .. .. . . . . . .. . 25
TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . .. .. .. .. . . . . . . . .
Engine Hesitates or Poor Acceleration
Engine Will not Start or is Hard to Start
Poor Fuel Mileage
Rough Idle or Engine Stalls
VACUUM
TROUBLESHOOTING
. ...s..............................
Engine Hesitates or Poor Acceleration
Engine Will not Start or Hard to Start
Excessive Oil Consumption
Poor Fuel Mileage
Rough Idle or Engine Stalls
HOSES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . .. . .

<3.0L ENGINE> .. . ...*.......................a....
VACUUM
http://vnx.su/
HOSES
25
26
. . . .. .. . . . . . .. .. . . . . . . . . . . . . . . . . .. . . . . . .. 26
25-2
EMISSION CONTROL SYSTEM <2.6L ENGINE> - Specifications
EMISSION CONTROL
SPECIFICATIONS
SYSTEM
<2.6L
ENGINE>
GENERAL SPEClFICATlONS
Crankcase emission
control
Evaporative emission control

Canister
Two-way valve
Purge control valve
Bowl vent valve
system
Closed type with positive
crankcase
system
Equipped
Equipped
Single diaphragm
Vacuum type
Exhaust emission control system

Jet control combustion type system
Air fuel ratio control system - FBC system
Secondary air supply system
Reed valve
Exhaust gas recirculation system
EGR valve
Vacuum regulator valve
Therm0 valve
High altitude compensation
system-Federal/California
and High altitude vehicles
for Federal
High altitude compensator
control system
Catalytic converter
Location
ventilation
-
valve
type
Jet swirl type

Oxygen sensor feedback
type
With air control valve

ON/OFF solenoid valve
Single type
With vacuum control
Wax type
Bellow type
Vacuum control type
Differential pressure type valve
Monolith type
Under floor
Items
Specifications
Secondary air control solenoid valve coil resistance 0

Therm0 valve temperature
(vacuum holds)
C (F)
36-44 [at 20C (SSF)]

18 (64) or more
65 (149) or more
Approx. 1,200 (3,900)
High altitude
compensator
operating
altitude
m (ft.)
Items
Secondary air pipe exhaust
EGR valve attaching bolt
Therm0 valve
manifold
side joint
) TSB Revision
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Nm
ftlbs.
50-60
70-I 00
19-28
20-40
37-44
52-74
14-20
1530
EMISSION CONTROL SYSTEM <2.6L ENGINE> -
Specifications
I Troubleshooting

I Items
Therm0
1 Specified
valve
sealants and adhesives
1 3M Adhesive
I Quantitv
Nut Locking 4171 or equivalent 1 As required
TROUBLESHOOTING
Symptom
Probable cause
Engine will not start

or is hard to start
(Cranking possible)

stalls
Poor fuel mileage
or damaged
Repair or replace
Mixture control valve kept open
Replace
EGR valve kept open
Repair or replace
or damaged
Repair or replace
High altitude compensation system faulty Federal/California and High-altitudevehicles

for Federal
Troubleshoot the system and check

components under suspicion
EGR valve kept open
Repair or replace
Faulty purge control system

Faulty bowl vent valve
Replace
Mixture control valve kept open
Replace
Faulty positive
Engine hesitates or
poor acceleration
Remedy
crankcase
ventilation
valve
Replace
Exhaust gas recirculation system faulty

each component under suspicion
High altitude compensation system faulty Federal/California and High-altitude vehicles

for Federal

Therm0 valve faulty - cold engine
Replace
control system faulty
Troubleshootthe
system and check
control system faulty

Exhaust gas recirculation system faulty

High altitude compensation system faulty Federal/California and High-altitude vehicles

for Federal

j TSB Revision
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25-3
25-4
EMISSION CONTROL SYSTEM <2.6L ENGINE> - Vacuum Hoses
VACUUM
HOSES
VACUUM
HOSES ROUTING
<FEDERAL
EXCEPT
-..-__
HIGH-ALTITUDE
VEHICLES>
I-..
1 TSB Revision
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EMISSION CONTROL &STEM

<HIGH-ALTITUDE
VEHICLES
<2.6L ENGINE> - Vacuum Hoses
FOR FEDERAL>
1 TSB Revision
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25-5
25-6
<FEDERAL/CALIFORNIA>
1 TSB Revision
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_
-
.-
=..L
--
To secondary
air control
25-7
valve
titude compensator
I/California
and High-altitud
Secondary
air control
solenoid
valve
SF1UlSO
INSPECTION
NZ.JCAEl
(1) Referring to the VACUUM HOSES ROUTING, confirm that
the vacuum hoses are properly connected.
(2) Check the hoses for irregularities
(disconnection,
looseness, etc.) and confirm that there is no breakage or
damage.
INSTALLATION
lWEJDAE1
(1) When connecting
a hose, firmly press it onto the nipple.
(2) Referring to the VACUUM HOSES ROUTING, connect the
hoses correctly.
1 TS5 Revision
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.,.
25-8 EMISSION CONTROL SYSTEM <2.6L ENGINE> CRANKCASE
EMISSION
CONTROL
missioncontrol
Crankcase
system
NztilA-A
SYSTEM
COMPONENTS LOCATION
Symbol
Name
Positive crankcase
POSITIVE
VALVE
ventilatioz
valve
CRANKCASE
VENTILATION
(PCV)
P4zmkE
For information
concerning
the checking
of the positive
crankcase ventilation valve, refer to GROUP 0 - Maintenance
Service.
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EMISSION CONTROL SYSTEM <2.6L ENGINE>
EVAPORATlVE
Evaporative Emission Control Svstem
25-9
N2n&A
COMPONENTS LOCATION
I- ~~
1Bowl vent
I Canister
Name
valve
) Symbol
I Purge control valve
t Therm0 valve
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Name
/ Symbol
I
25-l0EMlSSlON
CONTROLSYSTEM <2.6L ENGINE>
Evaporative Emission Crmtrol System
NislaAsm
BOWL VENT VALVE (SW)

INSPECTlON
Caution
Check after the engine is allowed
to cool
engine is not cold, fuel could gush out from
valve.
(2) Disconnect the bowl vapor hose from the
nipple and connect a hand vacuum pump
valve nipple.
enough.
If the
the bowl vent
bowl vent valve

to the bowl vent
(3) Apply a vacuum of 20 kPa (6.1 in.Hg) to the bowl vent valve
to checkthe condition as follows.
PURGE CONTROL SYSTEM

mister
Purge control valve

b
Therm0 valve
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Evaporative
Emission
Control
System
25-11
INSPECTION
(I) Disconnect
the black vacuum
hose from the intake
manifold nipple and plug the nipple. Then, connect a hand
vacuum pump to the disconnected
black vacuum hose.
(2) Check the following both when the engine is cold [engine
coolant temperature
50C (122F) or less] and when it is
hot [engine coolant temperature
85 to 95C (185 to 205F)j
When engine is cold
Vacuum
Engine state
53 kPa (15.7 in.Hg) 1 2,500 rpm
When
engine
1 Vacuum is held
is hot
Vacuum
I 4-L
Normal condition
Engine state
53 kPa (15.7 in.Hg)
Idling
53 kPa (15.7 in.Hg)
2,500 rpm
Normal condition
Vacuum is held
Vacuum leaks
PURGE CONTROL VALVE

INSPECTION
(1) Remove the purge control valve.
(2) Connect a hand vacuum pump to the vacuum nipple of the
purge control valve.
(3) Apply a vacuum of 53 kPa (15.7 in.Hg) to check air
tightness.
(4) Blow in air lightly from the canister side nipple to check
conditions
as follows.
Hand vacuum pump vacuum

0 kPa
(No vacuum is applied)
Normal condition
27 kPa (7.9 in.Hg) or more
Air blows through
Air does not blow through
THERM0 VALVE
N25iSD
INSPECTION
NOTE
This therm0 valve also controls the choke breaker, EGR and
choke opener.
(I) Disconnect
the vacuum hose (white stripe) from the
therm0 valve and connect a hand vacuum pump to the
therm0 valve.
(2) Apply vacuum to check therm0 valve condition as follows.
Engine coolant
10C (50F) or less
18C (65F) or more
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Normal condition
Vacuum leaks
Vacuum holds
25-l 2 EMlSSlON CONTROL SYSTEM <2.6L ENGINE> -
Evapomtiva
Emission
Control
Sy8tem
(3) Disconnect
all vacuum hoses from the therm0 valve.
(4) Connect a hand vacuum pump to nipples (B), (C) and (D)
and aooly vacuum to check therm0 valve condition
as
follows:
NOTE
Plug nipples other than
pump is connected.
40C (10&W or less
65C (1494) or-more
one to which
the hand vacuum
Normal condition
Vacuum leaks
Vacuum holds
REMOVAL
(1) When removing the therm0 valve, do not use wrenches or
other tools on the resin part.
(2) When disconnectingthe vacuum hose, put a mark on the
hose so that it may be reconnected
at original position.
INSTALLATION
(7) When installing, apply specified sealant to the threads
therm0 valve and tighten to specified
torque.
Specified
sealant
Specified
torque
: 3M Adhesive
Nut Locking
equivalent
: 2040
Nm (15-30 ft.lbs.)
of
4171
or
(21 When installing the therm0 valve, do not use wrenches

or
OVERFILL LIMITER (TWO-WAY VALVE)
NSPJEB.
For information
concerning the checking of the overfill
(two-way
valve), refer to GROUP I4 - Fuel Tank.
limiter
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EXHAUST EMISSION
25-I 3
ExhaustEmissionControlSystem
CONTROL SYSTEM
N25c-A
COMPONENTS LOCATION
Name
1 Svmbol
Air control valve
EGR valve
High-altitude compensator
<Federal/California
and High-altitudevehicles
for Federal>
Name
/ Svmbol
1 Reedvalve
I Secondary air control solenoid valve
1;

<High-altitude
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vehicles for Federal>
25-l 4 EMISSION CONTROL SYSTEM <2.6L ENGINE>
Exhaust
Emission
ContMSystem
AIR-FUEL RATIO CONTROL (FBC) SYSTEM ~25~

For information- concerning
the checking of the air-fuel-ratio
control (FBC) system, refer to GROUP 14 - Service Adjustment Procedures.
CATALYTIC CONVERTER
N!mceAE
REMOVAL
AND INSTALLATION
refer to GROUP 11 Exhaust Pipes-and
Main Muffler.
INSPECTION
Check for damage, cracks or fusion and replace if faulty.
Caution
1. Operation
of any type,
including
idling,
should
be
avoided if engine misfiring occurs. Under this condition
the exhaust
svstem
will operate
at abnormally
high
temperature,
which may cause damage to the catalyst
or under-body
parts of the vehicle.
-j
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Exhaust
Emission
Control
System
25-15
2. Alteration
or deterioration
of ignition or fuel system, or
any type of operating
condition
which results in engine
misfiring
must be corrected
to avoid overheating
the
catalytic
converters.
3. Proper maintenance
and tuneup according to manufacturers specifications
should be made to correct the
conditions
as soon as possible.
SECONDARY AIR SUPPLY SYSTEM

INSPECTION
(1) Disconnect
the air supply hose from the air cleaner and
hold a small steel plate at the disconnected
hose end to
check air suction.
Engine coolant ternperature
Engine state
Air suction
20-40C
(68-l 04F)
Yes
Idling
70C (158F) or more
Rapid deceleration
from 4,000 rpm
Caution
Note that if secondary
may blow back.
air control
No (70 seconds or
more after start)
Yes
valve is broken,
emission
SECONDARY AIR CONTROL VALVE
0
cleaner side
lEM150
INSPECTION
(1) Remove the secondary
air control valve
(2) Blow in air from the air cleaner side to check that air does
not blow through.
(3) Connect a hand vacuum pump to the secondary air control
valve nipple.
(4) Apply a vacuum of 67 kPa (19.7 in.Hg) and check air
tightness.
(5) Apply a vacuum of 20 kPa (6.1 in.Hg) and blow in air to
check condition
as follows.
Air blow direction
Normal condition
Air cleaner side to exhaust
Air blows through
manifold
side
Exhaust manifold
side to air
cleaner side
(6) If any fault is found

in above
secondary
air control valve.
checks,
replace
the
Exhaust
manifold side
Secondaryair control valve specifiedtightening torque!

lEM148
50-50
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Nm (37-U
ft.lbs.)
25-16 EMISSION CONTROL SYSTEM <2.6L ENGINE>

Red
I
tXlX
Exhaust Emission CWWOI System
SECONDARY AIR CONTROL SOLENOlD VAL..~

INSPECTION
NOTE
When disconnecting
the vacuum hose, put a mark on the
(1) Disconnect
the vacuum hoses. (red stripe. green stripe)
from the device box.
(2) Disconnect
6EMm2
(3) Connect a hand vacuum pump to the nipple to which red stripe
vacuum hose has been connected.
(4) Apply vacuum and check air tighteness both when the battery
voltage is applied directly to the solenoid valve terminal and
when not applied
Battery voltage
When applied
When not applied
(5) Measure
Standard
Other nipple of
device box
Open
Closed with finaer
) Open
solenoid
value
Normal condition
1 Vacuum leaks
1 Vacuhm holds
/ Vacuum holds
coil resistance.
: 36 - 44fl
[at 20C (66F)l
ENGINE COOLANT TEMPERATURE SENSOR,

ENGINE SPEED SENSOR AND VACUUM SWlTCl~
For information
concerning
the checking of these components, refer to GROUP 14 - Service Adjustment
Procedures.
THERM0 VALVE
NZSCNI
For information
concerning the checking of he therm0 valve.
refer to the section PURGE CONTROL SYS i-i M (page 25-10.)
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25-17
EXHAUST GAS RECIRCULATION (EGR) SYSTs$ll

INSPECTION
(1) Disconnect
the vacuum
hose (green stripe) from the
carburetor
throttle
body and connect
a hand vacuum
pump to the vacuum hose.
(2) Check the following both when the engine is cold [engine
coolant temperature
45C (113F) or less] and when it is
hot [engine coolant temperature
85 to 95C (185 to 205F)l
When engine is cold
Vacuum
Apply vacuum
3,500 rpm
When engine
Normal condition
Vacuum leaks - from
therm0 valve into atmosphere
is hot
N25lcKh
EGR VALVE
3EM13!
INSPECTION
(1) Remove the EGR valve and check it for sticking, deposit of
carbon, etc. If such condition exists, clean with adequate
solvent to ensure tight valve seat contact.
(2) Connect a hand vacuum pump to the EGR valve.
tightness.
(4) Blow in air from one passage of the EGR to check
condition
as follows.
Vacuum
8 kPa (2.4 in.Hg) or less
23 kPa (6.7 in.Ha) or more
Normal condition
Air blows through
Caution
When installing the EGR, use a new gasket
to 11 Nm (5 to 8 ftlbs.)
VACUUM
and tighten
REGULATOR VALVE (VRV)
to 7
Nz51a
INSPECTION
(1) Disconnect
the vacuum
hose (white stripe) from the
device box and connect a hand vacuum pump to the
device box.
(2) Apply a vacuum of 53 kPa (15.7 in.Hg) and check VRV
condition
as follow.
Engine state
Stopped
3.500 ipm
evision
Normal condition
Vacuum leaks
Vacuum holds
i
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25-18 EMlSSlON CONTROL SYSTEM <2.6L ENGINE> -
Exhaust Emission Control
System
EGR VALVE CONTROL VACUUM AND VRV CONNL4cFuu

TROL VACUUM
For information
concerning
the checking
of these components, refer to GROUP 14 - Service Adjustment
Procedures.
td?s-
THERM0 VALVE
For information
concerning the checking of the therm0 valve,
refer to the section PURGE CONTROL SYSTEM (page 25-10).
COMPENSATION
HIGH-ALTlTUDE
- High-altitude vehicles for Federal
SYSTEM
wcoEs
NOTE
When disconnecting
inspection
Condition
: 85-95C (185-205F)
(1) Set the timing light.
(3) Disconnect the vacuum hoses (black. red stripe, black) from
the carburetor primary emulsion well bleed nipple, secondary
emulsion well bleed nipple and jet air nipple and plug the
nipples.
(4) Connect a hand vacuum pump to the vacuum hoses, one hose
at a time, and check air tightness while running the engine at
idle.
vacuum hose
Primary emulsion weli
Secondary e&lsion(red stripe)
3
Jet air (black)
(5) Connect the disconnected
(6) Run the engine at idle and
step
1
2
Standard
value
Normal condition
(black)
well Vacuum holds
vacuum hoses to original position.

check ignition timing.
: 7BTDC -c 2
(7) While running the engine at idle, disconnect the vacuum hose
(yellow stripe) from the HAC and put a finger at the hose end
to check that vacuum is felt.
) TSB Revision
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_I

INSPECTION
AT ALTITUDE
Exhaust
Emission
ABOVE
Control
1200
Svstem
25-19
m (3,900 ft.)
NOTE
When disconnecting
inspection
Condition
: 85-95C (186205F)
(3) Disconnect the vacuum hoses (black, red stripe, black) from
the carburetor primary emulsion well bleed nipple, secondary
emulsion well bleed nipple and jet air nipple.
(4) Connect a hand vacuum pump to the vacuum hoses. one hose
at a time, and check air tightness while running the engine at
idle.
Step
1
2
3
Vacuum hose
emulsion
Primary
(black)
Secondary emulsion
(red stripe)
Jet air (black)
Normal condition
well
well
Vacuum leaks
(5) Connect the disconnected vacuum hoses to original position.

(6) Run the engine at ilde and check ignition timing.
Standard
value
HIGH-ALTITUDE
altitude
: Approx.
12BTDC
COMPENSATOR
(HACI - HighN251CPb
INSPECTION
AT ALTITUDE
BELOW 1,200 m (3,900 ft.)
(1) Disconnect the vacuum hose (yellow stripe) from the HAC
and connect a hand vacuum pump to the HAC nipple.
(2) Apply vacuum and check that it leaks and does not hold.
5EM103
(3) Disconnect the vacuum hose (red stripe) from the HAC and
connect a hand vacuum pump to the HAC nipple.
(4) Check that vacuum holds when applied.
5EMllO
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25-20 EMlSSlON CONTROL SYSTEM <2.6L ENGINE>
Exhaust
Emission
Control
System
INSPECTION
AT ALTITUDE
ABOVE 1,200 m (3,900 fi.)
(1) Disconnect the vacuum hose (yellow stripe) from the HAC
and connect a hand vacuum pump to the HAC nipple.
(3) Disconnect
the vacuum hose (red stripe) from the HAC
and connect
another
hand vacuum pump to the HAC
nipple.
(4) With vacuum held as in step (2). check that vacuum leaks
and dose not hold.
VACUUM SWITCHING VALVE (VSV) - High-altiN251cac

tude vehicles for Federal
INSPECTION
NOTE
When disconnecting
(1) Remove the vacuum switching
valve.
(2) Connect a hand vacuum pump to the black vacuum nipple
of the vacuum switching
valve.
tightness.
(4) Blow in air lightly from the carburetor air bleed side nipple
and check condition
as follows.
Hand vacuum pump vacuum
Normal condition
27 kPa (7.9 in.Hg)

or less 34 kPa (9.8 in.Hg) or more

Air blows through
CHECK VALVE - Federal/California

tude vehicles for Federal
and High-alti?425mca
INSPECTION
NOTE
When disconnecting the vacuum hose, put a mark on the hose so
that it may be reconnected at original position.
(1) Remove the check valve.
(2) Connect a hand vacuum pump to the check valve and check air
tightness.
Normal condition
Color of nipple to which hand vatuum pump is connected
i
Vacuum leaks
Dark blue
~,1
Vacuum holas
1 White
:
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1
1
EMISSION CONTROL SYSTEM ~2.61 ENGINE>
Exhaust
Emission
Control
System
25-21
CARBURETOR BLEED AIR PASSAGE CLOGGING

(CARBURETOR HIGH-ALTITUDE COMPENSATION
FUNCTION)
NmcvAa
Refer to GROUP
14 - Service
Adjustment
Procedures.
HIGH-ALTITUDE COMPENSATION SYSTEM - Federal/California

NZSICOF~
INSPECTION
AT ALTITUDE
BELOW
1,200
m, (3,900
ft.)
NOTE
: 85 - 95C (185 - 205F)

(3) Disconnect
the vacuum hose (black) from the carburetor
primary emulsion well bleed nippleand
plug the nipple.
(4) Connect a hand vacuum pump to the vacuum hose and check
that vacuum is held when applied while running the engine at
idle.
(5) Connect the disconnected
vacuum hose to original position.
(6) Run the engine at idle and check ignition timing.
Standard
value
: 7BTDC+2
(7) While running the engine at idle, disconnect the vacuum hose
(white stripe, two nipples side) from the HAC and hold a finger
at the hose end to check that vacuum is felt.
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25-22

INSPECTION
AT ALTITUDE
Exhaust Emission control sptem
ABOVE 1,209 m (3,990 ft.)
NOTE
: 85-95C(185
-205F)
(I) Set the timing light.
~
(3) Disconnect the vacuum hose (black) from the carburetor

man/ emulsion well bleed nipple.
prf-
(4) Connect a hand vacuum pump to the vacuum hose and while
running the engine at idle, apply vacuum to check the pressure
leaks and does not build up.
(5) Connect the disconnected vacuum hose to original position.

Run the engine at idle and check ignition timing.
6)
Standard
value
: Approx.
12BTDC
HIGH-ALTITUDE COMPENSATOR (HAC) - Feder?i25icm~

al/California
INSPECTION
AT ALTITUDE
BELOW
1,200
m (3,900
ft.)
(I) Disconnect the vacuum hose (white stripe, two nipples side)
from the HAC and connect a hand vacuum pump to the HAC
nipple.
(2) Apply vacuum and check that it leaks and does not hold.
[ TSB Revision
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s-7
25-B
(3) Disconnect the vacuum hose (black) from the HAC and connect a hand vacuum pump to the HAC nipple.
lNSPECTiON AT ALTITUDE ABOVE 1,200 m (3,900 ft.)

(1) Disconnect the vacuum hose (white stripe, two nipples side)
from the HAC and connect a hand vacuum pump to the HAC
nipple.
(3) Disconnect the vacuum hose (black) from the HAC and connect another hand vacuum pump to the HAC nipple.
(4) Holding the vacuum applied in procedure 2, apply vacuum and
check that it leaks and does not hold.
INTAKE AIR TEMPERATURE CONTROL SYSTEI-E

INSPECTION
(I) Remove the air cleaner cover and air duct.
(2) Run the engine at idle and check air control
condition.
Therm0 sensor temperature
30C (86F) or less
45C (113F) or more
valve
Normal condition
Cold air side inlet closes
Cold air side inlet opens
EM122
Compressed air 1,
NOTE
If necessary, apply compressed
hair dryer, etc. to heat.
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air to cool or apply hot air using a
25-24 EMISSION CONTROL SYSTEM
ENGINE> -
<2.6L
Exhaust
Emksion
Control
AIR CONTROL VALVE AND THERM0
System
SENSC&
INSPECTION
OF AIR CONTROL VALVE
(2) Disconnect the vacuum hose from the air control valve and
connect a hand vacuum pump to the valve nipple.
tightness.
5EhllZ
(4) Check air control valve operation.

Vacuum
9 kPa-(2.8 in.Hg) or less
25 kPa (7.5 in.Hg)
(5) Connect
tion.
the disconnected
Normal condition
-z Cold air side inlet opens
-Le Cold air side inlet closes
vacuum
hose to the original posi-
5EMlz4
INSPECTION OF THERM0 SENSOR

(7) Connect a hand vacuum pump to the therm0
and check air tightness.
Therrno sensor temperature
30C 186F) or less
1 45Z I1 13F) or more
(2) If any fault is found
cleaner body.
Vyive
sensor nipple
Normal condition
1 Vacuum holds
1 Vacuum leaks
in above
checks,
MIXTURE CONTROL VALVE (MCV)

with a manual transmission
I
replace
the
air
- Vehicles
Nzs1alEJ
INSPECTION
Caution
Check the valve after warming
up the engine.
(2) Start the engine and open and close the throttle valve
quickly to check MCV operation
and air suction noise.
Engine speed
Throttleleverinoperation
Idling
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Normal condition
MCV valve operation
Air suction noise
Pops &t once and Heard
quickly closes
j Remafiis clc&d
) Not heard
-
EMISSION CONTROL SYSTEMS <3.OL ENGINE> - smcmations
EMBSION
CONTROL
SYSTEM
<3.OL
25-25
ENGINE>
SPECIFICATIONS
Crankcase emission
control
system
Closed type with positive

valve
Evaporative emission control system

Canister
crankcase
ventilation
Canister storage type

Charcoal type
ON/OFF solenoid valve
Exhaust emission control system

Exhaust gas recirculation system
EGR valve
Therm0 valve <Vehicles with a manual transmission>
EGR control solenoid valve <Vehicles with an
automatic transmission>
EGR temperature
sensor <California>
Catalytic converter
Location
Vacuum-actuated
diaphragm
Bimetal type
Duty cycle solenoid valve
type
Thermistor type
Monolith type
Under floor
Items
Specifications
Purge control sole:oid valve coil resistance

Therm0 valve temperature
(vacuum holds)
EGR temperature
sensor resistance
kR
n
C (F)
EGR control
fi
solenoid
valve coil resistance
36
65
60
11
36
- 44
(149)
- 83
- 14
- 44
[at
or
[at
[at
[at
20C (68F)]
more
50C (122F)]
100C (212F]]
20C (68F)]
N25CC.B
Items
20-40
ftlbs.
EGR valve installation bolt

Therm0 valve
EGR temperature
sensor
17-26
20-40
10-12
12-18
1530
7.3-8.6

Specified
Items
Therm0
valve thread
portion
N2sCE.B
Quantity
sealant
3M NUT Locking
As required
No. 4171 or equivalent
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25-26 EMISSION CONTROL SYSTEM <3.OL ENGINE>
Troubleshooting
I Vacuum
Hoses
NEEA.6
TROUBLESHOOTING
Symptom
Probable
Engine will not start or

hard to start
Vacuum
aged
Remedy
cause
hose disconnected
or dam-
The EGR valve is not closed
Repair or replace
Malfunction of the purge control

lenoid valve
Repair or replace
_%.
so.-T
The EGR valve is not closed
Rep%
07 replace
Repair or replace
Stalk
Vacuum
aged
Engine hesitates
acceleration
or poor
hose disconnected
or dama_crankcase
Malfunction
ventilation
of the positive
Malfunction
tern
of the purge control
Malfunction
of the exhaust
culation system
Repair oi replace
;Replace
sys-
Check the system; if there is a problem, check its component parts.
gas rear--
Check the system; if there is a problem, check its component parts.

Check positive
VACUUM
crankcase ventilation
HOSES
ACUUM HOSES ROUTlNG

:Vehicles
with
a manual
<Vehicles
transmission>
with
an automatic
trensmission>
FRONT
FRONT
PU
SOI
EGR valve
regulator
regulator
G: Green
Y: Yellow
L: Light Blue
R: Red
B. Black
1 TSB Revision
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25-27
EMISSION CONTROL SYSTEM <3.OL ENGINE> - %%,?i%%$%:
INSPECTION
(1) Referring to the VACUUM HOSES ROUTING. confirmy
the vacuum hoses are properly connected.
(2) Check the hoses for irregularities
(disconnection,
looseness, etc.) and confirm that there is no breakage or
damage.
NZSJDAU
INSTALLATION
(1) When connecting
a hose, firmly press if onto the nipple.
(2) Referring to the VACUUM HOSES ROUTING, connect the
hoses correctly.
CRANKCASE
EMISSION
CONTROL
Nz5!A-I3
SYSTEM
COMPONENTS LOCATION
POSITIVE
VALVE
CRANKCASE
VENTILATION
(PCW
For information
concerning
the checking
of the positive
crankcase ventilation
valve, refer to GROUP 0 - Maintenance
Service.
REMOVAL
(1) Remove the air intake plenum. (Refer to GROUP 11 - Air
Intake Plenum.)
(2) Remove the positive crankcase ventilation
valve.
INSTALLATION
(I) Install the positive crankcase
to specified
torque.
Specified
(2) Install
Intake
tightening
the air intake

Plenum.)
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torque
plenum.
ventilation
: 8-12
Nm
valve and tighten

(6-g ft.lbs.)
(Refer to GROUP
11 - Air

EVAPORATIVE
COMPONENTS
EMISSION
CONTROL
EvapomtivtEmissionC~~ntrol
system
SYSTEM
LOCATION
181779
Canister
Purge control
solenoid
Name
Symbol
Name
valve
1 TSB Revision
Two-way
valve
http://vnx.su/
Symbol
C
EMISSION CONTROL SYSTEM <3.OL ENGINE> -
E vaporative
Emission
Control
System
25-29
URGE CONTROL SYSTEM
d
i
Control
relay
Air flow sensor

-4
Engine coolant
temperature
sensor
Throttle bodv
Engine
control
unit
ii
03W633
INSPECTION
(1) Disconnect the vacuum hose (red stripe) from the throttle
body, and connect a hand vacuum pump to the vacuum
hose.
(2) Cap the nipple from which the vacuum hose was disconnected.
(3) Under the engine conditions
described below, provide a
vacuum by using the hand vacuum pump, and then check.
When engine is cold-coolant
temperature
: 60C (14oOF) or
less
Engine operating
condition
Idling
50 kPa (14 in. Hg)
3,000 rpm
When engine
Result
Applying vacuum
is warm-coolant
temperature
Vacuum is
maintained
: 70C
(158F)
or higher
Applying vacuum
Result
Idling
50 kPa (14 in. Hg)
Vacuum is
maintained
Within 3 minutes
after engine start
~3,000 rpm
Try applying vacuum
Vacuum leaks
50 kPa (14 in. Hg)
Vacuum will be
maintained
momentarily after
which it will leaks.
Engine operating
condition
After 3 minutes have

passed after engine
start 3,000 rpm
/ TSB Revision
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25-30 EMISSION CONTROL SYSTEM <3.OL ENGINE> - ~spont~aEm~.si~Contro~systsm

PURGE CONTROL SOLENOID VALVE
INSPECTION
NOTE
When disconnecting
the vacuum hose, make an identification
mark on it so that it can be reconnected
to the original
position.
(l) Disconnect
the vacuum hose (black with red stripe) from
the solenoid valve.
(2) Disconnect
(3) Connect a hand vacuum pump to the nipple to which the
red-striped
vacuum hose was connected.
(4) Apply a vacuum and check for air-tightness
when voltage
applied directly to the purge-control
solenoid valve when
the voltage is discontinued.
Normal condition
Battery voltage
When applied
Negative pressure
tained.
is main-
Negative pressure leaks.
When discontinued
EC1510
(5) Measure
solenoid
the resistance
valve.
Standard
6EM13i
value
between-the
: 3644
terminals
of the
R [at 26C (68F)l
AIR FLOW SENSOR, ENGINE COOLANT TEMPNZSIBGB

ERATURE SENSOR
To inspect
Inspection.
these
parts,
refer to GROUP
14 - MPI System
OVERFILL LIMITER (TWO-WAY VALVE)

To inspect the overfill limiter (Two-way
14 - Fuel Tank.
valve), refer to GROUP
?tm818
CANlSTER
To inspect the canister,
Vapor Line.
( TSB &vision
refer to GROUP
1--.
http://vnx.su/
14 - Fuel Line and
EMISSION CONTROL SYSTEM <3.OL ENGINE>
EXHAUST
EMISSION
COMPONENTS
CONTROL
ExhaustEmissionContdSvstem
25-31
SYSTEM
?4251c-
LOCATION
Name
Catalytic
Symbol
converter
Name
EGR valve
EGR control solenoid valve

<Vehicles with a manual transmission>
Therm0 valve
<Vehicles with an automatic
EGR temperature
sensor <California>
Symbol
B
transmission>
Front exhaust pipe
1 TSB Revision
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Exhaust
Emission
Control
System
AIR-FUEL RATIO CONTROL (MPI) SYSTEM

a
l
NZSICAF
To inspect the air-fuel ratio control (MPI) system, refer to

GROUP 14 - service Adjustment Procedures.
For detailed information
concerning
the illumination
pattern of the malfunction-indicator
light and other aspects of
the self-diagnosis
function,
refer to GROUP 14 - Self
Diagnosis.
CATALYTIC CONVERTER
NZSICSF

Exhaust Pipes and Main Muffler.
refer to GROUP 11 -
INSPECTION
Check for damage, cracks or fusion and replace if faulty.
Caution
1. Operation
of any type, including idling, should be avoided if engine misfiring
occurs.
Under this condition
the
exhaust
system
will operate
at abnormally
high
temperature,
which may cause damage to the catalyst
or under-body
parts of the vehicle.
2. Alteration
or deterioration
of ignition or fuel system or
any type of operating
condition
which results in engine
misfiring
must be corrected
to avoid overheating
the
catalytic converters.
3. Proper maintenance
and tuneup according to manufacturers specifications
should be made to correct the conditions as soon as possible.
EXHAUST GAS REClRCULATiON (EGR) SYSTEM

INSPECTION
-
(II Disconnect the vacuum hose (green stripe) from the EGR
valve and connect, via a three-way terminal, a hand vacuum
pump.
(2) Check the following points while the engine is cold (engine
coolant temperature
60C (140F) or lower) and while it is
hot (engine coolant temperature
70C (158F) or higher).
When engine is cold
Engine condition
Depress the accelerator pedal

quickly and race the engine.
When engine
Normal condition
Negative pressure (vacuum) no
change (barometric pressure)
is hot
Engine condition
Depress the accelerator pedal
quickly and race the engine.
Normal condition
Negative pressure (is&urn)

temporarily
increases to 20 kPa
115.9 in.Hg) or higher.
[ TSB Revision
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EMISSION CONTROL SYSTEM <3.OL ENGINE> (3) Disconnect
Exhaust
the three-way
Emission
Control
terminal
System
25-33
and connect
the hand
vacuum pump directly to the EGR valve.

(4) Check whether or not the engine stalls or shows idling
instability when a negative pressure (vacuum) of 38 kPa
(11.0 in.Hg) or higher is applied during idling.
INSPECTION <Vehicles with an automatic

transmission>
.(I) Disconnect the vacuum hose (green stripe) from the throttle body, and connect a hand vacuum pump to the vacuum
hose.
(2) Plug the nipple from which the vacuum hose was disconnected.
(3) Check the following
points when the engine is cold
[coolant temperature
50C (122F) or below] and when it is
hot [coolant temperature
85-95C (185-205F) or higher.]
When engine is cold
Engine
condition
Normal condition
Applying vacuum
Vacuum leaks from

therm0 valve.
TV wpWg
Idling
vacuum
When enaine
is hot
Engine condition
Applying vacuum
Normal condition
Idling
9.3 kPa (2.8 in.Hgl
Vacuum holds
Changes from
idling to slightly
unstable.
38 kPa
(11 .O in.Hg)
Vacuum holds
EGR VALVE
INSPECTION
(1) Remove
the EGR valve and check
it for sticking,
deposit
of
carbon, etc.
If such condition exists, clean with adequate solvent to ensure tight valve seat contact.
(2) Connect a hand vacuum pump to the EGR valve.
(3) Apply a vacuum
of 67 kPa (19.6 in.Hg) and check air
tightness.
(4) Blow in air from one passage of the EGR to check condition
as follows.
Normal condition
Vacuum
9.3 kPa (2.8 in.Hg) or less
r~-
38 kPa (11.0 in.HgJ or more

/ Air blows through
(5) When installing the EGR valve,

lighten to specified torque.
Specified
/ TSB Revision
http://vnx.su/
tightening
torque
use a new
: 17-26
Nm
gasket
(12-18
and
ftlbs.)
Exhaust
THERM0 VALVE <Vehicles

transmission>
Emission
Control
with
System
an automatic
Nz5IceJ
INSPECTION
(1) Disconnect the vacuum hoses from the therm0 valve, and
connect a hand vacuum pump to the therm0 valve.
(2) Apply a vacuum and check the air passage through the
therm0 valve.
Normal condition
;
50C (122F) or leg

65C (149F) or more
Vacuum leaks.
: Vacuum holds
REMOVAL
(1) When removing the therm0 valve, do not use wrenches or
(2) When disconnecting
the vacuum hose, put a mark or the
INSTALLATION
(1) When installing, apply specified sealant to the threads of
therm0 valve and tighten to specified
torque.
Specified
sealant
Specified
torque
: 3M NUT Locking No. 4171 or equiv.

alent
: 20-40 Nm (X5-30 ft.lbs.)
(2) When installing the therm0 valve, do not use wrenches

EGR. TEMPERATURE SENSOR <California>
or
AIa~
INSPECTION
(I) Remove the EGR temperature
sensor.
(2) Place the EGR temperature
sensor in water, and then
measure the resistance value between terminals
1 and 2
while increasing the waters temperature.
Replace the EGR temperature
sensor if there is a significant deviation from the standard value.
TemperatureC
(F)
Resistance (k.Q
50(12ij
60-63
100 (212)
11-14
(3) Install the EGR temperature
sensor and tighten
to specified
torque.
Specified
; TSB Revision
tighten
torque
---
http://vnx.su/
: IO-12 Nm (7-9 fi.lbs.)
EMISSION CONTROL SYSTEM <3.OL ENGINE>
Exhaust
Em*sion
Control
System
25-35
EGR CONTROL SOLENOID VALVE <Vehicles with

a manual transmission>
INSPECTION
NmBR
NOTE
When disconnecting
the vacuum hose, make an identification
mark on it so that it can be reconnected
to the original position.
(I) Disconnect
the vacuum hose (yellow and green stripe)
from the solenoid valve.
(2) Disconnect
the harness
connector.
(3) Connect a hand vacuum pump to the nipple to which

green striped vacuum hose was connected.
the
a vacuum and check for air-tightness

when voltage
a&ikd
directly to the purge-control
solenoid valve when
the voltage is discontinued.
(4) Apply
(5) Measure
the resistance
between
the terminals
solenoid valve.
Standard value : 3644 R [at 20C (66F)l
RJST808013-921
TSB Revision
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of the
,.,
NOTE
http://vnx.su/
NOTE
http://vnx.su/
NOTE
http://vnx.su/
14-102
ENGlNE CONTROL
ENGINE
Spec~ficatiow~mubleshootinglSenrice
Adjustment
Procedures
CONTROL
SPECIFICATIONS
NI4cs-c
Items
Specifications
Standard value
Accelerator cable play <MPI
models>
mm (in.)
l-2
(.04-.08)
I Iterns
Accelerator
cable to air intake plenum
1 Nm
1 ftlbs.
14-s
13-4
TROUBLESHOOTING
ACCELERATOR CABLE AND ACCELERATOR PEDAL
Remedy
Symptom
Probable cause
Throttle valve will not

fully open or close
Misadjusted
accelerator
Misadjusted
cable
automatic
1 Accelerator pedal operation not smooth (over

acceleration)
cable
~1 Adjust
-~
speedcontrol
Broken return spring
Replace
Throttle
Replace
lever malfunction
/ Accelerator
Misinstalled
1 Accelerator
pedal wrongly
accelerator
tightened
cable
cable reouires
lubrication
1 Repair
Repair
1 Lubricate
or replace
SERVICE ADJUSTMENT
PROCEDlJW&
ACCELERATOR CABLE FREE PLAY ADJUSTMENT

<FBC models>
1. Run the engine until it reaches the specified
idle speed
level.
2. Loosen
the locking bolt or adjusting
nut at the cable
adjusting
portion so that the throttle
lever is free.
3. Move the holder to the position just before the throttle
leer begins to operate, and then return it far enough so
that there is an appropriate

amount of slack in the inner
cable and secure it at this position.
4. Operate the accelerator arm and confirm that the throttle
valve changes from fully closed to fully open.
[ TSB Revision
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I i =
._
ENGINE CONTROL - Service
Adjustment
<MPI models>
Procedures
14-103
N,UZICH
For models equipped

with the auto-cruise
control system,
refer to P.14-106.
(1) Turn air conditioner
and lights OFF.
Inspect and adjust at no load.
(2) Warm engine unit1 stabilized at idle.
(3) Confirm idle speed is at prescribed
rpm.
(4) Stop engine (ignition switch OFF).
(5) Confirm there are no sharp bends in accelerator
cable.
(6) Check inner cable for correct slack.
(7) If there is too much slack or no slack, adjust play by the
following
procedures.
0 Turn the ignition switch to the ON position (without
stamng the enigne) and leave in that condition
for
approximately
15 seconds.
Q Loosen the adjusting bolts on the air intake plenum,
and then secure the outer cable so that the free play of
the inner cable will be the standard value.
Standard value:
l-2 mm (.04-.08 in.)
NOTE
If there is excessive play of the accelerator
cable, the
vehicle speed drop (undershoot)
when climbing a slope
will be large.
If there is no play (excessive tension) of the accelerator
cable, the idling speed will increase.
(8) After adjusting, confirm that throttle valve fully opens and
closes by operating
pedal.
1 TSB Revision
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14-104
ENGINE CONTROL - Accelerator Cable and Pedal
ACCELERATOR
CABLE AND PEDAL

Nwm-

<FBC
models>
<MPI
19-19 Nm
/Ii!-14
ft.lbs.
models>
4-9 Nm
3-4 ft.lbs.7
Accelerator
cable removal steps

1. Air cleaner
I)+ Adjustment of accelerator cable free play
I)+
2. Accelerator cable
Acceleraot pedal removal steps
I)*
3. Accelerator arm bracket
4. Cotter pin
*+
5. Return spring
I)+
6. Accelerator arm
++
7. Spring
++ ++ 8. Pedal
NOTE
(1) Reverse
(2) *I+
the removal procedures to reinstall.

: Refer to Service Points of Removal.
(3) I)*
: Hefer to Service Points
(41 0 : Non-resusable
parts
of Installation.

8.
REMOVAL
OF ACCELERATOR
W14OSAC
PEDAL
Pull the left side of the accelerator

pedal toward you, and
then remove the accelerator
pedal from the accelerator
arm.
.-
07YO2:
http://vnx.su/
14-105
ENGINE CONTROL - Accelerator Cable and Pedal

INSPECTION
l
l
l
l
l
Check
Check
Check
Check
Check
the
the
the
the
the
inner and outer cable for damage.

cable for smooth movement.
accelerator
arm for bending.
return spring for deterioration.
connection
of cable to end metal
fitting.
SERVICE POINTS OF ISTALLATION
NWODA
8. APPLICATION
OF GREASE TO PEDAU7.
SPRING/G.
ACCELERATOR
ARM/B. RETURN SPRING/3. ACCELERATOR ARM BRACKET
Apply the multipurpose
grease around the each moving
point of the pedal.
2.
INSTALLATION
OF ACCELERATOR
CABLE
Make sure that the accelerator cable is laid without
bends.
ADJUSTMENT
OF ACCELERATOR
Refer to P.14-102.
TSB Revision
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CABLE
sharp
FREE PLAY
II-I
INTAKE AND
<2.6L ENGINE>
AIR CLEANER
<3.OL ENGINE>
...............................................
EXHAUST
MANIFOLD
EXHAUST
PIPES AND MUFFLERS
INTAKE MANIFOLD
..................................
..............
......................................
AIR CLEANER
AIR INTAKE PLENUM
...................................
11
EXHAUST
MANIFOLD
..................................
15
EXHAUST
PIPES AND MUFFLERS
SPEClFlCATlONS
. .. . . . .. . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . .
. . . . .._...__._....._...........
. . ..__._..... _. ..____..._._._
. .._. . . . .. . .. .. . .._.............
. . ..*..............................
TROUBLESHOOTING
Abnormal Noise
Exhaust Gas Leakage
...............................................
INTAKE MANIFOLD
http://vnx.su/
..............
......................................
10
16
12
SPECIFICATIONS
.........................................
...............................
.............................
................................
8
8
9
8
TROUBLESHOOTING
...................................
INTAKE AND EXHAUST <2.6L ENGINE> - SDecifications
INTAKE
AN5
EXHAUST
<2.6L
ENGINE>
SPECIFICATIONS
NHCA-0
Items
Specifications
Air cleaner
Element
Heated air intake
Unwoven cloth type

Vacuum motor type
Exhaust system
Front exhaust pipe
Muffler
Coupling
Suspension system
Dual type
Expansion resonance-type
Flat coupling
Rubber hangers and-suspenders
NIICC-0
Items
Air cleaner to rocker cover
Carburetor to intake manifold
Intake manifold to cylinder head
Water outlet fitting assembly to intake manifold
Therm0 valve assembly to intake manifold
E.G.R. valve assembly to intake manifold
Vacuum connector joint
gauge unit to intake manifold
Engine coolant temperature sensor to intake manifold
Oxygen sensor
Joint to intake manifold
Air pipe assembly to bracket
Air pipe assembly to reed valve B bracket
Exhaust manifold cover to exhaust manifold
Air pipe assembly to exhaust manifold
Exhaust manifold to cylinder head
Exhaust manifold to front exhaust pipe
Front exhaust pipe to exhaust pipe mounting bracket
Front exhaust pipe to under catalytic converter
Under catalytic converter to center exhaust pipe
Hanger bracket to suspender
Suspender to frame
Center exhaust pipe to main muffler
Main muffler to hanger
Hanger to frame
Nm
ft.lbs.
16-19
15-20
15-20
17-20
2@0
1g-28
8-12
IO-12
20-40
40-50
20-40
12-15
lo-13
12-75
70-I 00
15-20
20-30
2030
15-25
40-60
8-12
8-12
20-30
5-10
5-10
12-14
11-14
11-14
13-14
14-29
14-20
6-9
7-9
14-29
29-36
14-29
9-11
7-9
9-11
51-72
11-14
14-22
14-22
11-18
29-43
6-9
6-9
14-22
4-7
4-7
iEALANTS AND ADHESIVES
NIICD
Specified
Items
Engine
Engine
Engine
Therm0
coolant
coolant
coolant
valve
temperature
temperature
temperature
assembly and
gauge unit,
switch,
sensor,
Joint (threaded
sealants
and adhesives
3M ART Part No. 8660 or

equivalent
part)
TSB Revision
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Quantity
As required
INTAKE AND EXHAUST <2.6L ENGINE>
Troubleshooting
I Air
TROUBLESHOOTING
Probable cause
Remedy
Exhaust gas leakage
Loose joints
Retighten
Broken pipe or muffler
Repair or replace
Broken separator
Replace
noise
11-3
NII-
Symptom
Abnormal
Cleaner
Broken rubber
in muffler
hangers
or suspender
Replace
Interference of pipe or muffler with

vehicle body
Correct
Broken pipe or muffler
Repair or replace
NllFA-o
AIR CLEANER
Removal
steps
1. Wing nut
l a 2. Connection for breather hose
3. Air duct
4. Connection for air hose
5. Connection for vacuum hose
6. Air cleaner cover
7. Air cleaner element
8. Air cleaner body
9. Secondary air case
10. Secondary air cleaner
11. Air cleaner gasket
12. Heater duct
,+.
12-14
R.lbs.
2w
NOTE
(I) Reverse the removal procedures to reinstall.
(2) l * : Refer to Service Point of Installation.
INSPECTION
l
0
0
NllFcAD
Check the air cleaner body, cover or packing for deformation, corrosion
or damage.
Check the air duct for damage.
Check the air cleaner element for clogging, contamination
or damage.
If element is slightly clogged, remove dust by blowing air
from inside of element.
1 TSB Revision
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11-4
INTAKE AND EXHAUST <2.6L ENGINE>
Vacuum
Air Cleaner I Intake Manifold
HOT AIR CONTROL VALVE CHECK

Check to ensure that when negative pressure is applied to
nipple of vacuum motor, valve operates as indicated by arrow.
motor
\
NIWOAA
SERVICE POINT OF INSTALLATION

2.
INSTALLATION
OF BREATHER HOSE
NOTE
Be careful, when installing, not to apply
hose.
oil etc. to the
Hot aircontrol valve
INTAKE MANIFOLD
m,MI-o

Pra-removal
l
Operation
Draining of Coolant (Refer to

Post-installation
,I
19-19 Nm
12-14ftlbs.
19-20 Nm
libs
Operation
0 Supplying of Coolant (Refer to

l
Checking and adjustment of idling
rpm and ignition timing.(Refer to
GROUP 9 - Service Adjustment
Procedures.)
049569
11-14ftJbs.
Removal
steps
+e l +
+e l +
1.
2.
3.
4.
5.
6.
7.
8.
11. Connection for engine coolant

temperature
sensor
12. Connection for engine coolant
temperature
gauge unit
13. Intake manifold
14. Intake manifold gasket
Air cleaner
Carburetor assembly
Gasket
^
_
Connectton tor racitator upper hose
Connection for water by-pass hose
Water hose
Connection for heater hose
Exsuerection for brake booster vacuum
9. Connection
10. Connection
temperature
conditioner)
for vacuum hose

for engine coolant
switch (Vehicles with an air
/ -TSB Revision
NOTE
(I) Reverse the removal procedures to re%all.
(2) +e : Refer to Service Points of Removal.
(3) ++ : Refq to Service Points of Installation.
http://vnx.su/
INTAKE AND EXHAUST <2.6L ENGINE> - Intake
11-5
Manifold

REMOVAL
OF AIR CLEANER
Refer to P. 113.
2. REMOVAL
OF CARBURETOR
ASSEMBLY
Refer to GROUP 14 - Carburetor.
1.
INSPECTION
NllMcAp
Check the points described

below; replace
problem is found.
(1) Damage or cracking of any part.
(2) Clogging of the negative pressure (vacuum)
clogging of the water or gas passages.
the
OF CARBURETOR
if a
outlet port, or

2. INSTALLATION
part
NlllDAC.
ASSEMBLY
Refer to GROUP 14 - Carburetor.

1. INSTALLATION
OF AIR CLEANER
Refer to P. 11-3.
DISASSEMBLY AND REASSEMBLY (INTAKE MANIFOLD)

17-20
XI-14
Nm
ft.lbs
NIlhE-
Nm
IO-14
fklhc.
__..--.
x7-ill
Nm
~~~
14-28 ft.lbs.
20-40
Nm
8-8 ft.lbs.
al2
16
-6
19-28
14-20
Nm
Ribs.
Disassembly steps
++
1. Engine coolant temperature
switch
(Vehicles with an air conditipner)
2. F:g (Vehrcles wrthout an arr condition-.
+C
+*
l +
++
++
3.
4.
5.
6.
7.
8.
9.
Joint
Engine
Vacuum
Joint
Therm0
Engine
Engine
hanger
hose assembly
valve assembly
coolant temperature
coolant temperature
10. Purge control valve nipple
I)+
sensor
gauge unit
11.
12.
13.
14.
15.
16.
EGR valve assembly

EGR valve aasket
Water o&e? fitting assembly
Gasket
Thermostat
Intake manifold
NOTE
(2) H
(3) 0
I
1 TSB Revision
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15. INSTALLATION
OF THERMOSTAT
Refer to GROUP 7 - Thermostat.
9. APPLKATION
OF SEALANT
TO ENGINE
TEMPERATURE
GAUGE UNIT/8.
ENGlNE
TEMPERATURE
SENSOR/7.
THERM0
ASBEMBLY/8./3./1.
JOINT
AND ENGINE
TEMPERATURE
SWITCH
04W563
EXHAUST
COOLANT
COOLANT
VALVE
COOLANT

sealant to the threaded
part, and then tighten at the specified
torque.
Specified sealant : 3M ART Part No. 8860 or
equivalent
MANIFOLD
NlfW

K-19
12-14
Nm
ftlbs.
12-15 Nm
9-11 ftlbs..
4S50
29-36
Removal
steps
++ ++
1.
2.
3.
4.
5.
6.
Nm
ft.lbs.
Air cleaner
Air duct
Heat duct
Air pipe assembly
Reed valve B bracket
Exhaust manifold cover
7. Oxygen sensor
8. Self-locking nut
9. Connection for exhaust manifold
front exhaust pipe
10. Gasket
11. Engine hanger
12. Exhaust manifold
and
gasket
NOTE
(II Reverse the removal procedures to reinstall.
(2) l * : RefeT to Service Points of Removal.
(3) +*
(41 q
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.~
.Ez.
E
_
=
INTAKE AND EXHAUST <2.6L ENGINE> - s;z
I;$;:;
Mufflers

1.
11-7
NIINSAb
REMOVAL
OF AIR CLEANER
Refer to P. 11-3.
INSPECTION
EXHAUST
NIINCAP
MANIFOLD
Check the exhaust manifold

for damage and
replace it if any defects are found.
EXHAUST MANIFOLD
GASKET
Check for flaking or damage of the gasket.
cracks,
NIlNOAh
1. INSTALLATION
OF AIR CLEANER
Refer to P. 11-3.
EXHAUST
PIPES AND MUFFLERS

El0 Nm
4-7 ft.lbs.
40-60
20-30
Nm
_...
Llbs.
/I
Nn
Nm
*. .*
11-18
ft.lbs.
8-8 ft.lbs.
1. Gasket
w+
2. Front exhaust pipe
I)*
3.
4.
5.
6.
**
++
Spring
Suspender
Hanger bracket
Center exhaust pipe
7. Hanger
I
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8. Main muffler
9. Catalytic converter
10. Self-locking nut
NOTE
(1) l *
: Refer to. Service
(2) 0
Points
and
assembly
of Installation.
INTAKE AND EXHAUST <2.6L ENGINE> - Exhaust Pipes and MuHlers

INTAKE AND EXHAUST <3.OL ENGINE> - specifications
II-8
NWICAE
INSPECTION
l
Check the mufflers or pipes for corrosion
or damage.
@ Check the rubber hangers or suspenders
for deterioration
or damage.
b Check for gas leakage from mufflers or pipes.
N(lRDAE
2.
INSTALLATION
OF FRONT EXHAUST PIPE/G. CENTER
EXHAUST PIPE/S. MAIN MUFFLER/S.
CATALYTIC CONVERTER ASSEMBLY
(1) Temporarily
install the front exhaust pipe, the cataalytic
converter assembly the center exhaust pipe, and the
main muffler in that order.
Caution
With temporarily
tightened,
check to be sure there
is no distortion
of the hangers.
(2) After fully tightening
each exhaust pipe and main
muffler, check to be sure there is no contact with the
chassis
INTAKE
AND
EXHAUST
<3.OL
at any place.
ENGINE>
NIICA-I
SPECIFICATIONS
Items
Specifications
Air cleaner
Element
Filter paper type
Exhaust system
Front exhaust pipe
Muffler
Coupling
Suspension system
Dual type
Expansion resonance type
Flat coupling
Rubber hangers, O-rings and suspenders
I
NIICCI
Items
Air cleaner to body
Air duct to fender shield
Accelerator cable bracket to air intake plenum
EGR pipe attaching bolts to air intake plenum
Engine oil filler neck bracket to air intake plenum
Throttle body to air intake plenum
Air intake plenum to front stay, rear stay
Air intake plenum to intake manifold
EGR valve to air intake plenum
[ TSB Revision
http://vnx.su/
Nm
ftibs.
8-10
8-10
4-6
15-20
8-l 0
IO-13
1.5-20
15-20
17-26
6-7
6-7
34
11-14
6-7
7-9
II-14
II-14
12-19
INTAKE AND EXHAUST <3.OL ENGINE>

[terns
Fuel high pressure hose to delivery pipe
Delivery pipe to intake manifold
Heater pipe attaching bolts to intake manifold
Intake manifold to engine
Oxygen sensor
Front exhaust pipe to exhaust manifold
Front exhaust pipe (L.H.) to front exhaust pipe (R.H.)
Front exhaust pipe (L.H.) to oil pan bracket
Front exhaust pipe (R.H.) to catalytic converter
Heat protector to exhaust manifold
Engine hanger to engine
Alternator stay to engine
Exhaust manifold to engine
EGR pipe to exhaust manifold
Bracket to engine
Air iritake plenum stay to bracket
Front exhaust pipe to under catalytic converter
Under catalytic converter to center exhaust pipe
Hanger bracket to suspender
Suspender to frame
Center exhaust pipe to main muffler
rail pipe to hanger
Hanger to frame
Tail pipe to main muffler
switch
sensor
rhermo switch
sngine coolant temperature
gauge unit
rhermo valve assembly
Spectications
11-9
I Troubleshooting
Nm
ft.lbs.
IO-13
7-l 1
IO-13
15-20
40-50
30-40
2C-30
20-30
I!%25
12-15
l&22
15-22
15-22
1 E-20
15-22
15-20
15-25
40-60
8-12
a12
20-30
5-10
5-10
30-40
IO-14
2Wzo
6-8
IO-12
20-40
7-8
5-8
7-8
11-14
28-36
22-29
14-22
14-22
11-18
9-11
11-16
11-16
11-16
11-14
11-16
11-14
11-18
29-43
6-8
6-9
14-22
4-7
4-7
22-29
7-l 0
Id-29
4-7
7-8
14-27
N,,CC-B
Items
/ Specified

Therm0 valve assembly and
gauge unit,
switch,
sensor, Therm0 switch,
Joint (threaded part)
TROUBLESHOOTING
Refer
to P. 1 l-3.
TSB Revision
http://vnx.su/
3M ART Part No. 8660 or

equivalent
1 Quantity
As required
11-10
INTAKE AND EXHAUST <3.OL ENGINE> - Air Cleaner
N,WA-I
AIR CLEANER
S-IO Nm
,6-7 ft.lbs.
-8-10
Nm
6-7 ft.lbs.
Removal
steps
1. Connection
of air flow
sensor
connector
2. Breather hose
3. Air intake hose
.~
4. Air cleaner
5.
6.
7.
8.
9.
10.
17.
12.
13.
14,
15.
16.
Air duct 8
Air duct A
Air cleaner cover
Air cleaner element
Air flow sensor assembly
Air flow sensor asket
Noise reduction 9.ilter
Cover
Grommet
Air cleaner body
Insulator
Collar
NOTE
16 15
INSPECTION
to reinstall.
NIIFCAE
Check the air cleaner body, cover or packing for deformation, corrosion
or damage.
l
Check the air cleaner element for clogging, contamination
or damage.
If element is slightly clogged, remove dust by blowing air
from inside of element.
AIR-FLOW
SENSOR CHECK
For inspection
of air-flow sensor, refer to GROUP 14 - AirFlow Sensor Check.
_
._
/ TSB Revision
--~~
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INTAKE AND EXHAUST <3.OL ENGINE> - Air intake
AIR INTAKE
II-11
Plenum
PLENUM
Removal
+*
steps
1. Connection for air intake hose
2. Accelerator cable adjusting bolts
3. Connection for throttle control cable
~~~~;cles with an automatrc transmts-
05w532
4. Connection for accelerator cable

6. Connection for brake booster vacuum
hose
7. EGR temperature
sensor connector
9. EGR pipe attaching bolts
10. Gasket
12. Ignition coil
13. Engine oil filler neck bracket
14. Connection for PCV hose
15. Throttle body assembly
16. Throttle
17. Bolts
18.
19.
20.
21.
22.
23.
24.
body gasket
Bolts and nuts

Air intake plenum
Air intake plenum
EGR valve
EGR gasket
Air intake plenum
Air intake plenum
gasket
front stay
rear stay
NOTE
(2) **
NIIOBAS
15. REMOVAL
OF THE THROTTLE BODY ASSEMBLY
Take out the throttle body installation
bolts, taking care
not to disturb the throttle body during the operation.
NOTE
Leave the water hoses attached
to the throttle
body
assembly.
INSPECTION
NIIUCAC
Check the air intake plenum for damage and cracks and
replace
it if any defects
TSB Revision
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are found.
i
-~--cc.
i
--.
waif=_
11-12
,_- ;---*ihi
-~,
.--
INTAKE AND EXHAUST <3.OL ENGINE> - intake Manifold
INTAKE MANIFOLD
~g!GJEgJ;;;,,4_
l
Reduction
Post-installation
Operation
Filling of Engine Coolant
$;$r
to GROUP 0 - Maintenance
of the Fuel Line internal
o Adjustment otAccelerator
Ser-
Cable
(Refer to GROUP 14 - Engine Control.)

0 Inspection
of fuel pressure
(Refer to GROUP 14 - MPI System.)
E-20
11-14
19
Removal
Nm
ft.lbs
n/
aa
IS
4-6Nm
34 ft.lbs.
steps
1. Connection for air intake hose
2. Throttle position sensor connector
3. Stepper motor connector
4. Accelerator cable adjusting bolts
5. Connection for throttle control cable
W&es
with an automatic transmis-
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
6.
7.
8.
9.
10.
Connection for accelerator cable

Connection for water hoses
EGR temperature sensor connector
Connection for brake booster vacuum
hose
/ TSB Revision
NOTE
Ignition coil
En@ne oil filler neck bracket
Cofinection for PCV hose
EGR pipe attaching bolts
Gasket
Boits
Bolts and nuts
Air intake plenum and throttle
Air intake plenum gasket
(lj Reverse the- removal

(2) a
: Non-reusable
http://vnx.su/
procedures
parts
to reinstall.
body
INTAKE AND EXHAUST <3.OL ENGINE> - Intake Manifold
II-13
IO-13 Nm
7-9 ftlbs.
rnw531
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Connection for fuel high pressure hose

Connection for fuel return hose
Vacuum hose
Connection for control harness
Deliven/ pipe, fuel injector and pressure
regulator
Vacuum hose and pipe assembly
Connection for engine coolant
temperature
gauge unit connector
temperature
switch connector (Vehicles
with an air conditioner)
temperature
sensor connector
Connection for therm0 switch
connector (Vehicles with an automatic transmission)
Radiator upper hose
Connection for water by-pass hose
Heater pipe attaching bolts
35.
36.
37.
38.
39.
l + 40.
++ 41.
++
++
42.
43.
Gasket
Intake manifold
Intake manifold gasket
Water outlet fitting assembly
Gasket
Thermostat
switch
(Vehicles with an air conditioner)
sensor
Therm0 switch (Vehicles with an
automatic transmission)
Engine coolant temperature gauge unit
Therm0 valve assembly
++ 44.
++ 45.
NOTE
(2) ++ : Refer to Service Points of Removal.
(3) **
/ TSB Revision
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INTAKE AND EXHAUST <3.OL ENGINE>
- Intake Manifold
NI,MBAL
22. DISCONNECTION
OF FUEL HIGH PRESSURE HOSE
Caution
Cover fuel pipe line with rag after relieving pressure as
certain pressure
may still remain.
26. REMOVAL
OF DELIVERY PIPE, FUEL INJECTOR
AND
PRESSURE REGULATOR
Remove delivery
pipe with fuel injector and pressure
regulator.
Caution
Do not drop injector
when removing
delivery pipe.
INSPECTION
INTAKE MANIFOLD
Check the points described
below; replace the
problem is found.
(I) Check for damage or cracking of any part.
(2) Check for clogging
of the water passages.
SERVICE IfOlNTS OF INSTALLATION
part
if a
NIlUDIT
45APPLlCATlON
OF SEALANT
TO THERM0
VALVE
ASSEMBLYbl4.
ENGINE
COOLANT
TEMPERATURE
GAUGE
UNIT/43.
THERM0
SWITCH/42.
ENGINE
ENGINE
COOLANT
TEMPERATURE
SENSOW41.
COOLANT
TEMPERATURE
SWITCH
Refer to P. 11-6.
46. INSTALLATION
OF THERMOSTAT
Refer to GROUP 7 - Thermostat.
1 TSB Revision
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INTAKE AND EXHAUST <3.OL ENGINE> - Exhaust
EXHAUST
11-15
Manifold
NIINA-I
MANIFOLD

30-40 Nm
22-29 klbs.
I
I
Removal of Under Guard and Snow
C. ,3rA
uucu
($&fe,to GROUP 23 - Under
\
\
40-50
._ -- Nm
._...
,26-36 ft.lbs.
Post-installation Operation
. Installation of Under Guard and
I Snow Guard
GROUP 23 - Under
655-25
12-15 Nm
6-11 ft.lbs.
\
/,
Nm
11-18 klbs.
15-22 Nm
11-16 ft.lbs.
15b2 Nm
11-16 ft.lbs.
15-k Nm
11-16 ftlbs.
I
12-15 Nm
9-11 ft.lbs.
OSW528
Removal
Removal
steps of exhaust manifold (Right)

1. Oxygen sensor
2. Front exhaust pipe (L.H.)
3. Front exhaust pipe (R.H.)
4. Gasket
5. Air duct
6. Heat protector
7. Engine hanger
8. Alternator stay
9. Exhaust manifold
10. Gasket
NOTE
(1) Reverse the removal procedure to reinstall.
(2) m : Non-reusable parts
I
TSB Revision
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steps of exhaust manifold (Left)

4. Gasket
11. EGR pipe
12. EGR gasket
13. Heat protector
14. Air intake plenum
15. Bracket
17. Gasket
II-16
INTAKE AND EXHAUST <3.OL ENGINE> - Exhaust
EXHAUST
PIPES AND MUFFLERS
[EMOVAL AND INSTALLATION
Pipes and Mufflers
E-12 Nm
6-9 ft.Ibs.
14
Prs-removal
l
Operation
Removal of Under Guard and Snow

Guard
(R&;,$
GROUP 23 - Under
Installation of Under Guard and

E-10 Nm
4-7 ft.lbs.
1. Gasket
2. Self-locking nut
I)+
l I
l + 4. Front exhaust pipe (R.H.)
+*
5.
^^. Oxygen sensor
6. aprmg
I)+
7.
^ Catalytic converter assembly
8. Hanger bracket
9. Suspender
e)+ 10. Center exhaust pipe
e+ 11. Main muffler
12.
13.
14.
15.
O-ring
Hanger
Tail pipe (2 d6or vehicles)
Tail pipe (4 door vehicles)
NOTE
(1) *4
(2) l
05W524
: Refer to Service Point? of Installation.

r4I,RcAJ
INSPECTION
o
l
Check the mufflers

or pipes for corrosion
or damage.
Check the rubber hangers,
suspenders
and O-rings for
deterioration
or damage.
Check for gas leakage from mufflers
or pipes

3./4.
NImrJAJd
INSTALLATION
OF FRONT EXHAUST PIPE/
7. CATALYTIC
CONVERTER
ASSEMBLY/IO.
CENTER
EXHAUST PIPE/ll.
MAIN MUFFLER/l4./15.
TAIL PIPE
(1) Temporarily
install the front exhaust pipe, the catalytic
converter assembly, the center exhaust pipe, the main
muffler
and tail pipe in that order.
Caution
With temporarily
is no distortion
tightened,
check
of the hangers.
to be sure there
(2) After fully tightening

each exhaust
pipe and main
muffler, check to be sure there is no contact with the
chassis at any place.
1 TSB Revision
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7-I
COOLING
Nom4-
CONTENTS
COOLING
RADIATOR
FAN
..................................................
........................................................
. . . . . . . . . . . .. .. .. . . . . . .. .. .. . . . . . . . . . .. . . . . . .. . . . .
THERMOSTAT
THERM0 SWITCH, ENGINE COOLANT

TEMPERATURE GAUGE UNIT, ENGINE
COOLANT TEMPERATURE
SENSOR AND
SWITCH
. . . . . . . .. . . .. . . . . . . . . . . . . . . . .. .. . . . . . . . . .. . . . . . . . . . . .. . . . . . . 16
.........
SERVICE ADJUSTMENT
PROCEDURES
..................
Drive Belt Deflection Adjustment
Drive Belt Deflection Check ...........................
Engine Coolant Leak Check ...........................
Engine Coolant Replacement/
Concentration
Test ........................................
Radiator Cap Pressure Test ........... _......... __ ...
5
5
SPECIAL TOOL
5
6
5
5
. . . . . . . .. .. . . . . . . . .. . . . . . . . . . .. . . . . . . . .
TROUBLESHOOTING
No Rise in Temperature
Overheat
WATER HOSE AND PIPE <2.6L ENGINE>
.................................................
WATER PUMP <2.6L ENGINE>

SPECIFICATIONS
.............................................
.............. ......I._. ..........
......................................................
Lubricants
.................................
...................................
....................................
2
2
4
4
2
3
.. . . . . 13
. . .. .. .. . . . . . . . . .. .. .. 11
WATER PUMP, WATER PIPE AND WATER

HOSE <3.OL ENGINE>
. . . . . . . . . .. .. . . . . . .. .. . . . . . . . .. . . . . . 14
http://vnx.su/
7-2
COOLING - Specifications
SPECIFICATIONS
GENERAL SPEClFlCATlONS
N07cA-
Items
Specifications
Cooling method
Radiator
Water-cooled,
Type
Performance
kJ/h (kcal/h, B.T.U./h)
<2.6 L Engine>
<3.0 L Engine>
Vehicles with a manual transmission
Vehicles with an automatic transmission
Fan clutch
Pressurized corrugated
Type
Water pump
Thermostatic
Type
Thermostat
Impeller of centrifugal type
Type
Identification
Drive belt
Wax pellet type with jiggle valve

88 (Stamped on flange)
mark
pressurized, forced circulation
182,512 (43,600,173,016)
193,396 (46,209.183,333)
199,591 (47,680, 189,206)
control type with spiral type bimetal
Type
Therm0 switch (for air conditioner)
V-belt
Type
Engine coolanttemperature
transmission)
Heat-sensitive
thermistor
Thermo-ferrite
type
Type
Twe
fin type
type
switch (for automatic
sensor
Thermistor type
gauge unit
Thermistor type
TVpe
Items
Standard value
Range of coolant antifreeze concentration
%
Thermostat
Valve opening temperature of thermostat
C (F)
Full-opening temperature of thermostat
C (F)
Opening pressure of radiator cap high pressure valve
kPa (psi)
Drive belt deflection
mm (in.)
<2.6 L Engine>
<3.0 L Engine>
When a new belt is put in
When a used belt is put in, or the one now in use is restretched
Therm0 switch (for automatic transmission control system)
Continuity temperature
C (F)
Engine coolant temperature gage unit
Resistance
At 70C (158F)
R
At 115C (239F)
fi
1 TSB Revision
http://vnx.su/
30-6088(190)
100 (212) or more
75-105(11-15)
9-l 2 (.35-.47)
6.5-8.Q(.256-.315)
9.0 (354)
50 (122) or more
104* 13.5
23.8225
7-3
COOLING - Specifications
Items
Specifications

Resistance
At 20C (68F)
M
At 80C (176F)
a
Engine coolant temperature switch
Activation temperature at when the switch is turned to ON
Limit
Opening pressure of radiator cap high pressure valve
2.45~0.24
296a32
C (F)
kPa (psi)
112-l 18 (234-244)
65 (9.2)
Items
<2.6 L Engine>
Alternator brace bolt
Alternator support nut
Radiator
Radiator shroud to radiator
Radiator to headlight support
Cooling fan to fan clutch
Fan clutch to water pump pully
Water outlet fitting attaching bolt
Air cleaner attaching nut
Air pipe assembly to reed valve bracket
Air pipe assembly flare nut
Exhaust manifold attaching nut
Exhaust manifold to exhaust pipe
Water pipe attaching bolt
Therm0 switch
~3.0 L Engine>
Radiator shroud to radiator
Radiator to headlight support
Radiator upper shroud to radiator lower shroud
Cooling fan to fan clutch
Fan clutch to water pump pully
Power steering oil pump to oil pump mounting bracket
Oil pump mounting bracket to oil pump bracket
Oil pump bracket to engine
Timing belt cover
Water pump
Heater pipe assembly to intake manifold
Timing belt tensioner bolt
Fuel high pressure hose to delivery pipe
Delivery pipe to air intake plenum
Air intake plenum to air intake manifold
Crankshaft pulley
Water pipe assembly to engine
Water outlet fitting attaching bolt
Therm0 switch
1 TSB Revision
http://vnx.su/
Nm
ftlbs.
12-15
20-22
9-l 1
14-16
3-7
8-l 1
IO-12
8-10
17-20
16-19
IO-13
70-l 00
12-15
15-20
20-30
IO-12
6-9
IO-14
20-40
10-12
2-5
6-8
7-9
6-7
13-14
12-14
7-9
51-72
9-l 1
11-14
14-22
7-9
4-7
7-l 0
14-29
7-9
3-7
8-l 1
8-l 1
IO-12
IO-12
3545
35-45
35-45
IO-12
20-27
IO-13
2230
7-l 1
IO-13
15-20
150-l 60
12-15
17-20
6-9
20-27
IO-12
2-5
6-8
6-8
7-9
7-9
25-33
25-33
25-33
7-9
14-20
7-9
16-21
5-8
7-9
11-14
108-116
9-11
13-14
4-7
14-20
7-9
7-4
COOLING
- Specifications
/ Special Tool /Troubleshooting
LUBRICANTS
FJwcDItems
Recommended
antifreeze
DIA QUEEN LONG-LIFE CoOLANT

(Part No. 0103044) or HIGH QUALITY
ETHYLENE GLYCOLANTIFREEZE
COOLANT
Engine coolant
Quantity
<2.6 L Engine>
+8.0 lit. (8% qts.)
C3.0 L Engine>
Vehicles without rear heater
*9.1 lit. (9% qts.)
Vehicles with rear heater
9.95 lit. (10% qts.)
NOTE : * Includes 0.65 lit. (.69 qts.) in reserve tank.
SEALANTS
AND ADHESIVES
NOXE-
Items
Specified sealants
Therm0 switch (threaded part)

(threaded pat-t)
(threaded part)
(threaded part)

Quantity
L
As required
As required
As required
As required
SPECIAL TOOL
Tool
NmmNumber
Name
Use
MIT210863
Radiator cap test

adapter
Radiator cap test
TROUBLESHOOTING
3verheat
Probable cause
Remedy
Insufficient coolant
Replenish
Antifreeze concentration
too great
Loose or broken drive belt

Inoperativefan
clutch
Replace
Damaged or blocked (insufficiently

ventilated) radiator fins
Water leaks
Damaged radiator core joint
Corroded or cracked hoses
(radiator hose, heater hose, etc.)
Loose bolt or faulty gaiket in
water outlet fitting (thermostat)
Loose water pump mounting bolt or
faulty gasket
Faulty radiator cap valve or setting
of spring
1 TSB Revision
Correct
Replace
Replace
Correct or replace
Correct or replace
Replace
http://vnx.su/
COOLING
- Troubleshooting
Symptom
1 Probable cause
Overheat
Faulty thermostat
No rise in
temperature
/ Service
Adjustment
7-5
Procedures
/ Remedy
operation
Replace
Faulty water pump operation
Replace
Water passage clogged with slime or

rust deposit or foreign substance
Clean
Faulty thermostat
Replace
SERVICE ADJUSTMENT
PROCEDURES
ENGINE COOLANT LEAK CHECK
NmFAAc
1. Loosen radiator cap.

2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and
apply 160 kPa (23 psi) pressure. Hold for two minutes in
that condition,
while checking
for leakage from the
radiator, hose or connections.
Caution
Be sure to completely
clean away any moisture
from
the places checked.
When the tester is removed,
be careful not to spill any
coolant from it.
Be careful, when installing and removing the tester and
when testing,
not to deform
the filler neck of the
radiator.
4. If there is leakage, repair or replace the appropriate
part.
NrnFBAB
RADIATOR CAP PRESSURE TEST

1.
2.
3.
Use an adapter to attach the cap to the tester.

Increase the pressure until the indicator of the gauge
stops moving.
Standard
value : 75-105 kPa (11-15 psi)
Limit : 65 kPa (9.2 psi)
Replace the radiator cap if the reading does not remain at
or above the limit.
ENGINE COOLANT
RATION TEST
Refer to GROUP
Pulley
REPLACElVlENT/CONCENTNO,FcMa
0 - Maintenance
Service.
NWf-EA
DRIVE BELT DEFLECTION CHECK

I.
/
yw
V-&bed belt
IncorreCt
Correct
I
Incorrect
Check to be sure that the belt is correctly

groove of the pulley.
installed
in the
Caution
If there is belt squeal or slippage, check the amount
deflection,
check for wear, damage or deterioration
the surface of contact with the pulley, and check
scars on the pulley.
CC003 2
1 TSB Revision
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of
at
for
7-6
COOLING - Service Adiustment Procedures
<2.6L Engine>
2. Apply IOON (22 Ibs.) force to the belt back midway between the pulleys as shown in the figure, measure the
deflection or measure tension with a tension gauge according to its instruction.
Standard value :
Adjustment
Items
Crankshaft
2.6L
Engine
3.OL
Engine
:%z
New belt
value
Used belt
Deflection
mm (in.)
Q-12
(.35-.47 in.)
Deflection
mm (in.)
5.0-6.0
(.197-.236)
6.5-8.0
(.256-.315)
9.0
(.354)
350-600
(77-132)
500-700
(Ilo-155)
400
(88)
Gauge
N (Ibs.)
Caution
e Measure the amount of belt deflection
between
the
designated
pulleys.
l
An over-tensioned
belt could
cause
not only
premature
belt wear but also noise and damage to
water pump bearing and alternator
bearing.
A loose belt also could cause failure of the alternator
to generate enough power and consequently
a rundown battery.
DRIVE BELT DEFLECTION ADJUSTMENT

<2.6L ENGINE>
lumFF.40.
Vehicles without an air conditioner

1. Loosen the alternator brace bolt and the alternator support nut.
2. Place a bar or similar object in contact with the stator part
of the alternator, and manually provide the suitable tension
to adjust the amount of belt deflection.
3. Tighten the alternator brace bolt and the alternator support
nut to the specified torqueVehicles with an air conditioner
1. Loosen the alternator support nut and the bolt holding the
alternator.
2. Adjust the amount of deflection
of the belt by using the
tension-adjustment
bolt.
3. Tighten the alternator support nut and the bolt holding the
alternator.
<3.OL ENGINE>
39-60 Nm
S3-43ft.lbs.
1. To increase belt tension, loosen the nut l/8 turn, turn the
left-hand threaded bolt clockwise viewed from the arrow
direction, and displace thetension
pulley slightly.
Caution
Put the adjusting
bolt into the recess at the far depth of
the elongated
hole on the tension bracket.
2. Tighten the nut.
3. Turn the engine one time or more and check the belt tension. Readjust, if necessary.
NOTE
Even for a new belt, the adjustment
value for a used belt
should be used to make the adjustment
if the belt has been
used for as long as five minutes or more.
[ TSB Revision
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~~
=
7
7-7
COOLlNG - Radiator
RADIATOR
l
Draining of the Coolant (Refer to

<2.6L
<3.OL
NomA-
Supplying of the Coolant (Refer to

Engine>
Engine>
2-5 ft.lbs.
3-7 Nm
2-5 ft.lbs.
S-11 Nm
6-8 ft.lbs.
Radiator
removal steps
1. Air duct <2.6L Engine>
2. Radiator cap
3. Drain plug
4. Connection for overflow hose
5. Radiator upper hose
6. Radiator lower hose
8. Hose clamp <3.OL Engine>
9. Radiator lower shroud
10. Connection for automatic oil cooler

hoses (Vehicles with an automatic transmission)
11. Radiator
Reserve tank removal
4. Connection for overflow hose
12. Overflow tube
13. Reserve tank
NOTE
Reverse
TSB Revision
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the removal
procedures
to reinstall
the radiator.
7-8
COOLING - Radiator
/ Cooling
Fan
INSPECTION
e
e
e
e
Check
Check
Check
Check
tion.
l
Check
l
Check
@ Check
COOLING
for
the
the
the
NWXAS
foreign material between

radiator-fins.
radiator fins for bend or damage.
radiator for corrosion,
damage, rust or scale.
radiator hoses for cracks, damage or deteriora-
the reserve tank for damage.

the spring of radiator cap for deterioration.
the packing of radiator cap for damage or cracks.
FAN

S-10 Nm
6-7 ftlbs.
I
Post-installation
Oneration
3-7 Nm
2-5 ft.lbs.
<3.OL
Engine>
3-7 Nm
2-5 ft.lbs.
\
lo-12 Nm
7-9 ftlbs.
Removal
8-11 Nm
steps
1.
2.
3.
4
6-8 ftlbs.
NOTE
Reverse
TSB Revision
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Radiator
upper
Radiator
upper
Cooling
fan
Fan clutch
the removal
hose <3.OL
shroud
procedures
to reinstall.
Engine>
COOLING - Coolinn
7-9
Fan / Thermostat
INSPECTION
NO-
COOLING
FAN
l
Check for cracks and damage around bolt holes in fan
hub.
l
If any portion of fan is damaged
or cracked,
replace
cooling fan.
FAN
CLUTCH
Check to ensure that fluid in fan clutch is not leaking at
case joint and seals. If fluid quantity decreases due to
leakage, fan speed will decrease and engine overheating
might result.
When a fan attached to an engine is turned by hand, it
should give a sense of some resistance. If fan turns lightly,
it is faulty.
Check bimetal strip for damage.
THERMOSTAT
<2.6L
Engine>
17-20
__ _-
Nm
.-...
13-14
ft.lbs.
Removal
steps
1. Connection
for engine
ture switch
connector
air conditioner)
<2.6L
2. Connection
for radiator
3. Water
outlet fitting
C3.OL Engine>
coolant
tempera(Vehicles
with an
Engine>
upper hose
4. Water outlet fitting gasket

l
5. Thermostat
TSB Revision
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.
NOTE
(2) tb+ : Refer to Service Points
13) a
: Non-reusable
parts.
I
04W578
to reinstall.
of Installation.
COOLING - Thermostat
MS%OAE
INSPECTION
THERMOSTAT
o Check that valve closes tightly at room temperature.
l
Check for defects or damage.
a Check for rust or encrustation
on valve. Remove if any.
l
Immerse thermostat
in container of water.
Stir to raise
water temperature
and check that thermostat
opening
valve temperature
and the temperature
with valve fully
open [valve lift-over8 mm (.31 in.)] are at the standard value.
Standard value:
Opening valve temperature
Full-open temperature
88C (190F)
100C (212F)
NOTE
Measure valve height when fully closed.
measuring the height when fully open.
Calculate
lift by
Valve
lift

5.
INSTALLATION
OF THERMOSTAT
Install the thermostat
to the intake manifold
NCOGW
as illustrated.
Caution
The thermostat
flange fits over the manifold
seat;
ensure that the thermostat
is not installed at an angle.
Must i;e
<3.OL
bnost
Engine>
1 TSB Revision
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7-11
COOLING - Water Pump <2.6L Engine>
WATER
PUMP <2.6L
ENGINE>

Pre-removal
Drainin
GROU8
Operation
of the Coolant (Refer to
0 - Maintenance
Service.)
Water
3-7 Nm
2-5 ft.lbs.
P
Removal
+4
*I)
++
pump
kit
steps

2. Radiator lower shroud
3. Cooling fan clutch assembly
Adjustment of air conditioner compressor
drive belt deflection
4. Air conditioner compressor drive belt
(Vehicles with an air conditioner)
Adjustment of alternator drive belt deflection
l *
Fseverse
(2) +I)
drive belt
of power steering oil pump
drive belt deflection
6. Power steering
oil pump drive belt
7. Water pump pully
8. Connection of radiator lower hose
9. Connection of heater hose
10. Water pump
11. Water pump gasket
the removal procedures
to reinstall.
(3) l + : Refer to ,,Seryice points of (natajjation.

parts
No7MCAC
4.
DRIVE
REMOVAL
OF AIR CONDITIONER
COMPRESSOR
(I) Loosen the nut holding the tension pulley.

(2) Loosen
the nut for tension
adjustment,
remove the drive belt.
http://vnx.su/
and
then
7-12
COOLING - Water
5.
-Bolt
<2.6L
Engine>
REMOVAL
OF ALTERNATOR
DRIVE BELT
Vehicles without
an air conditioner
Loosen the alternator brace bolt and the alternator
nut, and then remove the alternator drive belt.
support
Vehicles with an air conditioner

(1) Loosen the bolt holding the alternator and then loosen
the alternator support nut.
(2) Loosen the bolt for deflection
adjustment,
and then
remove the alternator
drive belt.
for
I
Pump
&IiGment
INSPECTION
WATER
0
l
PUMP
Check each part for cracks, damage or wear, and replace

the water pump assembly if necessary.
Check the bearing for damage,
abnormal
noise and
sluggish rotation, and replace the water pump assembly if
necessary.
Check the seal unit for leaks, and replace the water pump
assembly if necessary.
Check for water leakage. If water leaks from hole A seal
unit is faulty. Replace as an assembly.
t---l
NOIMLlAH

1coo05
NV
IO. INSTALLATION
OF WATER PUMP
Water pump7nstallation
bolt size are different and caution
must be paid to ensure that they are properly installed.
I1 I
No.
Indication for hardness

category
Hardness category
(Head mark)
CT--
dx/mm
(in.)
TX 23 (.31 x .90)
c9
8x28(.31
x1.10)
8 x 88 (.31 x 3.46)
CT
8 x 78 (.31 x 3.07)
Torque
Nm (Wbs.)
12-15
D-10)
ADJUSTMENT
OF POWER STEERING OIL PUMP DRIVE
BELT DEFLECTION
Procedures.
ADJUSTMENT
OF ALTERNATOR
DRIVE BELT DEFLECTION
Refer to P.7-5.
ADJUSTMENT
OF AIR CONDITIONER
COMPRESSOR
DRIVE BELT DEFLECTlON
Refer to GEOUP 24 - Service Adjustment
Procedures.
3evision
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COOLING
WATER
Water
Hose
HOSE AND PIPE <2.6L
and
IO-13
15-20
11-14
<2.6L
Engine>
7-13
ENGINE>
12-15 Nm
Q-11 Ribs.
Pipe
Nm
19-19 Nm
12-14, Ribs.
Nm
ft.lbs.
70-100 Nm y
51-72 ft.lbs.
I IPm-removal
ODeration
pipe removal
Water
+e +*
1.
2.
3.
4.
5.
6.
7.
8.
Air cleaner
Reed valve and air pipe assembly
Reed valve bracket
Engine hanger
Connection for oxygen sensor connector
Self-locking nut
Connection for exhaust manifold and
exhaust
,I
steps
pipe
9. Gasket
12. Connection for heater hose

13. Heater hose
14. Water pipe
Water
hose removal
15. Water hose
16. Water by-pass hose
NOTE
(1) Reverse the removal procedures to reinstall the water
(2) $F : Refer to Service Points of Removal.
(3) I)* : Refer to Service Points of Installation.
(4) IBI : Non-reusable parts
aasket
NO,IMSI
1. REMOVAL
OF AIR CLEANER
Refer to GROUP 11 - Air Cleaner.
N07loAG.
11. INSTALLATION
OF EXHAUST MANIFOLD
GASKET
Replace the gasket if there is peeling, flaking or damage.
1.
INSTALLATION
OF AIR CLEANER
Refer to GROUP 11 - Air Cleaner.

1 TSB Revision
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I.tmyi- ismL&.u,.
,gsaaG
-ili4li%jl
-.
COOLING - water
Pum,
__
Water Pim and Water Hose c3.OL Engine>
WATER PUMP, WATER PIPE AND WATER HOSE <3.OL ENGINE>

Pre-removal
Operation
l
Draining of Engine Coolant
(Refer to GROUP 0 - Maintenance
Service.)
l
Lowering of Fuel Pressure in the
Fuel Line
Adjustment
Procedure)
l
Removal of the Timing Belt
(Refer to GROUP 9 - Timing Belt)
Post-installation
Operation
l
Installation
of the Timing Belt
(Refer to GROUP 9 - Timing Belt)
l
Filling of Engine Coolant
(Refer to GROUP 0 - Coolant Replacement)
l Adjustment
of Accelerator
Cable
iffier
to GROUP 14 - Engine Cone inspection
of Fuel Pressure
(Refer to GROUP 14 - MPI System)
I
Removal
l +
++
4*
4*
++
I)4
steps
1. Air intake plenum
2. Connection
for fuel high
pressure hose
3. Connection
for fuel return hose
4. Connection
for vacuum hose
5. Connection
for control harness
6. Delivery pipe, fuel injector and
pressure regulator
7. Vacuum hose and pipe assembly
8. Connection
for engine coolant
temperature
gauge unit connector
9. Connection
for engine coolant
temperature
switch connector
(Vehicles with air conditioner)
c,
10. Connection
for engine coolant
(7
temperature
sensor connector
11. Connection
for thermo switch
connector
(Vehicles with
automatic transmission)
12. Radiator hose, upper
13. Water by-pass hose
14. Radiator hose, lower
15. Connection
for water hose A
16. Water hose B
17. Connection
for water hose
(Vehicles with rear heater)
18. Heater pipe assembly
19. Gasket
20. Water hose A
21. Connection
for water hose B
22. Intake manifold
OlW6.26
*+
I)+
23.
24.
25.
26.
27.
Gasket
Water pump
Water pump gasket
Water pipe assembly
D-ring
NOTE
(2) +*
parts
1:; H
; N on-reusable
( TSB Revision
http://vnx.su/
to reinstall.
of Removal.
of Installation.
COOLING - water
P ump,
Water
Pipe
and
Water
Hose
<3.OL
7-15
Engine>
NO7BAC

1. REMOVAL
OF AIR INTAKE
Refer to GROUP
2.
DISCONNECTION
PLENUM
11 - Air intake
plenum.
OF FUEL HIGH PRESSURE
Caution
Cover fuel pipe line with rag after relieving
certain pressure
may still remain.
6.
HOSE
pressure
as
REMOVAL
OF DELIVERY PIPE, FUEL INJECTOR AND
PRESSURE REGULATOR
Remove delivery pipe with fuel injector and pressure
regulator.
Caution
Do not
drop
injector
when
removing
delivery
pipe.
22. REMOVAL
OF INTAKE MANIFOLD
Refer to GROUP 11 - Intake manifold.
hWCAB
INSPECTION
-Ib=
04W57i
O-ring
NrmmAC
27. INSTALLATION
OF O-RING/26.
WATER PIPE ASSEMBLY
insert the O-ring to the water inlet pipe, and coat the outer
circumference
of the O-ring with water.
By coating with water, the insertion to the water pump will
become easier.
WATER PUMP
l
Check each part for cracks, damage or wear, and replace
the water pump assembly
if necessary.
l
Check the bearing for damage,
abnormal
noise and
sluggish rotation, and replace the water pump assembly if
necessary.
l
Check the seal unit for leaks, and replace the water pump
assembly
if necessary.
l
Check for water leakage if water leaks from hole A seal
unit is faulty. Replace as an assembly.
Caution
Care must be taken not to permit
greases to adhere to the O-ring.
7cooo23
engine
22. INSTALLATION
OF INTAKE MANIFOLD
Refer to GROUP 11 - Intake manifold.
1.
INSTALLATION
OF AIR INTAKE
Refer to GROUP 11 - Air intake
TSB Revision
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PLENUM
plenum.
oil or other
7-16
COOLING
Thermo Switch, Engine Coolant Tempsratum Gauge Unit, Engine

CoolsntTempsretum
Sensor and Engine CoolantTemperature
Switch
THERM0 SWITCH, ENGINE COOLANT TEMPERATURE GAUGE UNIT,

ENGINE COOLANT TEMPERATURE SENSOR AND ENGINE COOLANT
TEMPERATURE SWITCH
I
Pre-removal
Operation
l
Draining of the Engine Coolant
(Refer to GROUP 0 - Maintanance
Service.)
II
Post-installation
Operation
l
Supplying
of the Engine
<2.6L
Engine>
I
,
1674
Coolant

Service.)
<3.OL
Engine>
4.
20-M
14-29
e*
H
*+
NOTE
l *
Switch
Nm
ft.lbs.
1. Therm0 switch
(Vehicles with
2. Engine coolant
(Vehicles with
3. Engine coolant
4. Engine coolant
I)+
Therrno
Nm
: Refer to Service
INSPECTION
an automatic transmission)
temperature switch
an air conditioner)
temperature sensor
temperature gauge unit
Points
of Installation.
No7oap3
THERM0
SWITCH (For automatic
transmission
control)
Raise engine coolant temperature
and check continuity when
it reaches the specified temperature.
Standard
value :
50C (122F) or more
Continuity
Less than 50C (122F)
No continuity
:h
IWO328
Thermometer
ENGINE COOLANT
TEMPERATURE
SWITCH
(For air conditioner)
(I) Immerse the engine coolant temperature
switch in oil and
then heat (by using a gacS stove flame or similar method)
so as to increase the oil temperature.
(2) Check to be sure that the engine coolant temeprature
switch is switched OFF when the oil temperature
reaches
the standard value.
Standard value : 112-118C
(23~244T)
Caution
The oil used above should be engine oil and should be
stirred well while being heated; do not heat more than
necessary.
http://vnx.su/
COOLING
Thermo
Coolant
Switch,
Engine Coolant
Temperature
Gauge Unit, Engine
Temperature
Sensor and Engine Coolant
Temperature
Switch
7-17
ENGINE COOLANT
TEMPERATURE
GAUGE UNIT
(1) Immerse the engine coolant temperature
switch in oil and
then heat (by using a gas stove flame or similar method)
so as to increase the oil temperature.
(2) Measure the resistance if within the standard value.
Standard
value :
At 70C (158F)
At 115C (239F)
104-cl3.5
23.8k2.5
n
i-l
Caution
The oil used above should be engine oil and should be
stirred well while being heated; do not heat more than
necessary.
ENGINE COOLANT
TEMPERATURE
SENSOR
(For engine control)
Raise the water temperature
and measure the resistance
within the standard value.
Sensor
0400033
I/
Sealant
1
Standard
value :
At 20C (6BF)
At 80% (176OF)
2.45-cO.24
Id-l
296-+32 Cl
NmJE4G
1. INSTALLATION
OF THERM0
SWITCH/Z.
ENGINE
COOLANT
TEMPERATURE
SWITCH/3.
SENSOR/4.
ENGINE COOLANT
TEMPERATURE
GAUGE UNIT
Apply sealant to threaded
portion and tighten.
Specified
1 TSB Revision
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sealant
if
NOTE
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6-I
CLUTCH
CONTENTS
CLUTCH
DISC
...................................................
CLUTCH
MASTER
CLUTCH
PEDAL
CLUTCH
RELEASE CYLINDER
CLUTCH
RELEASE FORK
CYLINDER
73
AND TUBE
.......
................................................
9
7
.........................
11
. . . . . . . . . . . . . .. .. .. .. .. . . .. . . .. . . 15
SERVICE ADJUSTMENT
PROCEDURES
Bleeding
........................................................
Clutch Pedal Inspection and Adjustment
.........
SPECIFICATIONS
.............................................
...................................
Lubricants
......................................................
......
5
6
5
2
2
3
NCSAA-
................. . .................
............................
._......
TROUBLESHOOTING
.......................................
Clutch Chattering
Clutch Dragged (Clutch did not Release)
Clutch Noisy
Clutch Operation Erratic or Rough
Clutch Slipping
Difficult Gear Shifting
(Gear Noise During Shifting)
Hard Pedal Effort
CAUTION
When servicing clutch assemblies
or components,
do NOT
create dust by sanding,
grinding
or by cleaning
clutch
parts with a dry brush or with compressed
air. (A water
dampened
cloth should be used.) The clutch disc contains
Asbestos
Fibers which can become airborne
if dust is
created during service operations.
Breathing dust containing Asbestos
Fibers may cause serious bodily harm.
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2
3
4
6-2
CLUTCH - Specifications
SPECIFICATIONS
T
Items
2.6LEngine
Clutch operating method

Inside diameter of clutch master cylinder
Clutch disc
Type
Facing Size (outside x inside)
Number of torsion springs
Clutch cover assembly
Type
Setting load
N (Ibs.)
Mounting bolt circle diameter
Clutch release bearing
Type
Free travel
mm (in.)
Clutch release cylinder
Cylinder bore diameter
mm (in.
mm (in.)
mm (in.)
mm (in.)
3.OL Engine
Hydraulic type
15.87 (6248)
Hydraulic type
15.87 r.6248)
Single dry disc type

225 x 150 (8.9 x 5.9)
4 (single type)
Single dry disc type

240 x 160 (9.4 x 6.3)
4 (Dual type)
Diaphragm spring strap drive type

4600(1014)
264(10.4)
Diaphram spring strap drive type

5500(1213)
276(10.9)
Self-centering type
0 (0) constant contact type
Self-centering type
0 (0) constant contacttype
19.05 (75)
19.05 (.75)
Items
Specifications
Standard values
Clutch pedal height
mm (in.)
Clutch pedal clevis pin play
mm (in.)
Clutch pedal free play
mm (in.)
Clearance between clutch pedal and
floorboard when pedal is depressed
mm (in.)
Limit
Clutch disc rivet sink
mm (in.)
186-l 91 (7.3-7.5)
l-3 (.04-.I21
8-16 (.31-.63)
35 (1.38) or more
0.3(.012)
TSB Revision
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.-
CLUTCH
TORQUE
6-3
- Specifications
SPECIFICATIONS
NOSVS
Items
Clutch to flywheel
Release cylinder to transmission case
Fulcrum
Clutch pedal to pedal bracket
Eye bolt
Clutch tube flare nut
Clutch master cylinderto firewall
Clutch pedal bracket
Bleeder plug
Reservoir band
Nm
ft.lbs.
15-22
31-42
31-42
25-35
20-25
13-17
7-8
18-25
8-13
5-7
11-15
22-30
2230
18-25
15-18
lo-12
5-7
13-18
7-8
4-5
LUBRICANTS
NO&CDSpecified lubricants
Items
Clutch fluid
<2.6 L Engine>
Clutch disc spline
Clutch release fork shaft bearing
Clutch release bearing inner surface
Clutch release cylinder push rod and
clutch release fork
Release cylinder inner surface
C3.0 L Engine>
Clutch release bearing and rocker arm
contact surfaces
Release fork and fulcrum head contact
surfaces
rTSB
Quantity
Brake Fluid SAE J1703 (DOT3)
As required
MITSUBISHI Genuine Grease

Part No. 0101011 or equivalent
Part No.0101011 orequivalent
Brake Fluid SAE J1703 (DOT3)
As required
MOLYKOTE BR-2 PLUS

MOLYKOTE BR-2 PLUS
As required
As required
MOLYKOTE BR-2 PLUS
As required
Revision
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As required
As required
As required
As required
6-4
CLUTCH -Troubleshooting
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Clutch slipping
l
Vehicle will not
respond to
engine speed
during
acceleration.
l
improper
vehicle speed
l
Lack of power
during uphill
driving
Improper pedal free play
Adjust
Excessive wear of clutch disc facing
Replace
Hardened clutch disc facing, or oil on

surface
Replace
Damaged pressure plate or flywheel
Replace (Refer to GROUP 9. for flywheel:
Weak or broken pressure spring
Replace
Excessive clutch pedal free play
Adjust
Interference
Correct
Clutch drags or does

lot release
between pedal and floor panel
Pilot bearing worn or broken
bearing
Replace
~~
Repair or replace
Hydraulic system fluid leakage or air

mixed in
Xfficult gear shifting
gear noise during
shifting)
:lutch
noisy
Replace (Refer to GROUP 9.)

Replace
Clutch disc warped

Pressure plate, disc or throwout
damaged
~~
_
Excessive pedal free play

Hydraulic system fluid leakage or air
mixed in
Repair or Replace
Unusual wear or corrosion of clutch disc

spline
Replace
Excessive vibration (distortion) of clutch

disc
Replace
When
clutch is
not used
Improper play of clutch pedal
Adjust
A noise is
heard after
clutch is
disengaged
Unusual wear and/or damage of release

bearing
Replace
A noise is
heard when
clutch is
disengaged
Improper grease on the sliding surface

of bearing sleeve
Repair
Improperly installed clutch assembly or

bearing
Repair
A noise
is heard
when
vehicle
is suddenly rolled of with
clutch
partially
engaged
Excessive wear of clt%h disc facing
Damaged pilot bearing
Replace
Replace (Refer to GROUP 9.)
I 7-c. n-..:-:--
http://vnx.su/
CLUTCH - Troubleshooting
/ Service
Adjustment
6-5
Procedures
Symptom
Probable cause
Remedy
Clutch chatters
Facing hardened
Replace
Facing stained with oil or grease
Repair or replace
Weak or broken disc damper springs
Replace
Improper facing contact or disc runout
Replace
Pressure plate or flywheel warped
Replace (Refer to GROUP 9. for flywheel)
Loose engine mounting
Repair or replace (Refer to GROUP 9.)
Improper lubrication of clutch pedal

shaft
Repair
Improper lubrication of clutch disc
Repair
Hard pedal effort
spline
Clutch operation
erratic or rough
improper lubrication of clutch release

lever shaft
Repair
Improper lubrication of front bearing

retainer
Repair (Refer to GROUP 21.)
Facing stained with grease or oil
Repair or replace
Facing worn or rivet loose
Replace
Torsion spring deteriorated
or broken
Replace
Improper lubricant on clutch pedal pivot
Clutch pedal height
Clutch pedal
clevis pin play
Lubricate
SERVICE ADJUSTMENT
PROCEDURES
CLUTCH PEDAL INSPECTION AND ADJUSTME!&

1.
Measure the clutch pedal height (from the face of the

pedal pad to the floorboard) and the clutch pedal clevis pin
play (measured
at the face of the pedal pad).
Standard
Standard
2.
1dehicles
i n&o-cruise
I system
without
control
VI ahlicles with autocr ui se control system
value (A) : 185-191

value (B) : l-3 mm
mm (7.3-7.5
(.O&.lZ
in.)
in.)
If either the clutch pedal height or the clutch pedal clevis

pin play are not within the standard value range, adjust as
follows:
(I) For vehicles without auto-cruise
control system, turn
the stopper bolt to adjust the clutch pedal height to
agree with the standard value and then secure the bolt
with the lock nut.
For vehicles with auto-cruise control system, disconnect the clutch switch connector and turn the switch
for standard clutch pedal height. Then lock with the
lock nut.
t
levision
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CLUTCH
Procedures
NOTE
When the pedal height is lower than the standard
value. loosen the bolt or clutch switch, and then turn
the push rod to make the adjustment.
After making the
adjustment,
tighten the bolt or clutch switch to reach
the pedal stopper, and then lock with the lock nut.
(2) Turn the push rod to adjust the clutch pedal clevis pin
play to agree with the standard value and then secure
the push rod with the lock nut.
Caution
When adjusting
the clutch pedal clevis pin play, be
careful not to push the push rod toward the master
cylinder.
oawa29
Clutch pedal free play
Distance between the

clutch pedal and the
floorboard when the
3. After completing
the adjustments,
confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of the
pedal pad) and the floorboard
when the clutch is disengaged are within the standard value ranges.
Standardvalue
(C) : 8-16 mm (.31-.63 in.)
Standard value (D) : 35 mm (1.38 in.) or more
4.
If the clutch pedal free play and the distance between the
clutch
pedal and the floorboard
when the clutch
is
disengaged
do not agree with the standard values, it is
probably the result of either air in the hydraulic system, or
a faulty master cylinder or clutch. Bleed the air, or
disassemble
and inspect the master cylinder or clutch.
BLEEDING
Whenever the clutch tube, the clutch hose, and/or the clutch
master cylinder have been removed, or if the clutch pedal is
spongy, bleed the system.
Specified
clutch fluid
: Brake
Fluid
Caution
Use the specified brake fluid. Avoid
specified
fluid and other fluid.
/ TSB Revision
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SAE 51703
(DOT3)
using a mixture
of the
CLUTCH - Clutch
CLUTCH
PEDAL <2.6L
Pedal
<2.6L
6-7
Engine>
ENGINE>

Post-installation
l
NWA-0
Operation
Adjustment of Clutch Pedal

(Refer to P.&5.)
25-35
Removal
++
+*I
++
,
++
++
Nm
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Return spring
Cotter pin
Washer
Clevis pin
Clutch pedal bracket
Pedal shaft
Clutch pedal
Bushing
Spacer
NOTE
(21 +a : Refer to * Service Points of Installation.
08W510
INSPECTION
Check the pedal shaft bushing for wear.
Check the pedal arm for bend or torsion.
Check the return spring for deterioration.
l
l
l
NWPCAC
l
?wPDAR
9.
APPLICATION
OF GREASE TO SPACER/8. BUSHING/G.
PEDAL SHAFT
Apply multipurpose
grease to the pedal shaft, spacer and
bushings.
4.
APPLICATION
OF GREASE TO CLEVIS PIN/3. WASHER
grease to the clevis pin and
washer.
1 TSB Revision
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6-8
CLUTCH - Clutch Pedal <3.OL Engine>
CLUTCH PEDAL <3,OL ENGINE>

Post-installation
l
Operation
Adjustment of Clutch Pedal

(Refer to P.65.)
25-35
Nm
Removal
steps
1. Cotter pin
+*
2. Return spring
3. Bracket
4. Cotter pin
+a
5. Bushing
6. Stopper bolt
7. Clutch switch
8. Cotter pin
+a
9. Washer
+* 10. Clevis pin
++ 11. Clutch pedal mounting bolt
12. Clutch pedal
I)+ 13. Bushings
l a 14. Spacer
15. Pedal pad
NOTE
(2)
+ : Refer to Service Points of Installation.
(3) b
INSPECTION
Refer
to P.B-7.
No6PDPI(I
14. APPLICATION
OF GREASE TO SPACER/lB.
ING/II.
CLUTCH PEDAL MOUNTING
BOLT
Apply multipurpose
bushings.
r h%k!li
IO. APPLICATION
Refer
5.
to the pedal shaft,
OF GREASE TO CLEVIS
PIN/g.
spacer
and
WASHER
to P. 67.
APPLICATION
SPRING
OF GREASE
Apply multipurpose
bushing.
1 TSB Revision
grease
BUSH-
http://vnx.su/
grease
TO BUSHING/2.
to
the
return
RETURN
spring
and
CLUTCH - Clutch Master Cylinder and Tube
CLUTCH
MASTER
CYLINDER
6-9
AND TUBE

,
?aeMez-
0 Drainina of Clutch Fluid
SupDlvina Clutch Fluid
Clutch master cylinder

removal steps
1. Cotter pin
2. Washer
I)*
3. Clevis pin
4. Clutch master cylinder
5. Sealer
Clutch line removal steps
l e
6.
7.
+I) l * 8.
9.
I)+ 10.
c2.6L-
Eye bolt
Gasket
Clutch hose
Hose clip
Clutch tube
20-i5 Nm
15-18 ftlbs.
gine>
Y
-5-2
.Y.bnl iknin->
.d.~..m-
NOTE
moval procedures to reinstall.

(I* : Heter to Service Points of RemovaI.
)* : Refer to Service Points of Installation
q : Non-reusable parts.

8.
REMOVAL
OF CLUTCH
NlMBAE
HOSE
Holding the nut at the clutch

nut of the clutch tube.
hose side,
loosen the flare
iNSPECTION
l
l
Check the master

Check the clutch
NOMcylinder
or clutch
hose or tube
hose for fluid leakage.
for cracks
or clogging.
14W593

10. INSTALLATION
OF CLUTCH
TUBE/8.
CLUTCH
NWMOAI
HOSE
(1) Temporarily
tighten the clutch tube flare nut by hand,
and then tighten
it to the specified
torque,
being
careful
Se&e side
that the clutch
TSB Revision
http://vnx.su/
hose does not become
twisted.
6-10
CLUTCH - Clutch
Master
Cvlinder
and
Tube
(2) Connect the clutch hose to the release cylinder at the

stepped portion shown in the illustration.
(3) After tightening the clutch tube flare nut and eye bolt,
check to be sure there is no leakage of the clutch fluid.
3. APPLICATION
OF GREASE TO CLEVIS
Refer to P. 6-7.
PIN/2.
WASHER
FmsNA-
Disassembly
steps
1. Piston stop ring
++
2. Damper and push
+I) I)+ 3. Piston assembly
4. Reservoir
rod
cap
5. Reservoir
I)+ 6. Reservoir band
7. Master cylinder body
NOTE
(I) Reverse the disassembly
(2) +e : Refer to Service
(3) l)a : Refer to Service
procedures
to reassemble

1. REMOVAL
OF PISTON STOP RING
Remove the piston stop ring.
3. REMOVAL
OF PISTON ASSEMBLY
Pull out the piston assembly.
Caution
1. Do not damage the master cylinder body and piston
assembly.
2. Do not disassemble
piston assembly.
INSPECTION
l
l
l
Check
Check
Check
NOWCAB
the inside cylinder body for rust or scars.

the piston cup for wear or deformation.
the piston for rust or scars.

6.
/ TSBRevision
INSTALLATION
OF RESERVOIR BAND
After installing the reservoir, tighten the reservoir
the range shown in the-:figure.
http://vnx.su/
7
-
Ncaow38
band in
CLUTCH
Clutch Master
and Tube
Cylinder
I Clutch
~ekase
6-11
Cylinder
3. APPLICATION
OF CLUTCH FLUID TO PISTON ASSEMBLY
Apply specified
clutch fluid to the inner surface of the
cylinder and to the entire periphery of the piston assembly.
Specified
clutch
fluid
: Brake
Fluid
SAE J1703
(DOT3)
05Y51
CLUTCH RELEASE CYLINDER

Pre-removal
l
Draining
Operation
of Clutch Fluid
Post-installation
Operation
Supplying
Clutcti Fluid
0 Bleeding (Refer to P.B-6.)
Ribs.
Removal
steps
1. Bleeder screw
2. Eye bolt
&KIz
3. Gasket
l * 4. Connection of clutch hose
l a 5. Clutch release cylinder
7-9
ftlbs.
20-25
14-18
NOTE
to reinstall.
(2) I)* : Refer to Service Points of Installation.
(3) q
: Non-reusable
parts
ES.
08W520
ND6HCPrP
INSPECTION
Check the clutch release cylinder for fluid leakage.
Check the clutch release cylinder boots for damage.
l
l
NOWOAD
5. APPLICATION
OF GREASE TO CLUTCH RELEASE CYLINDER
Apply a coating of the specified grease to the contact parts
of the release fork and release cylinder push rod.
Specified
4.
grease
: MITSUBISHI
Genuine
Grease
CONNECTION
OF CLUTCH HOSE
(1) Connect the clutch hose to the release cylinder at the
stepped portion shown in the illustration.
(2) After tightening the eye bolt, check to be sure there is
no leakage of the clutch fluid.
tvision
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6-12
CLUTCH - Clutch Release Cviinder
GASSEMBLY
Disassembly
1.
2.
3.
4.
+I) *q
5.
6.
7.
8.
9.
AND REASSEMBLY
steps
Valve plate
Spring
Push rod
Boots
Piston and cup
Conical spring
Cap
Bleeder plug
Release cylinder
08W523
NOTE
(2) a+ : Refer to Service Points of Disassembly.
(3) +4 : Refer to Service Points of Reassembly.
WsLaAA

5.
REMOVAL
OF PlSTON AND CUP
Remove the piston from the release
pressed air.
cylinder
using com-
Caution
1. Cover
with
rags to prevent
the piston
from
popping
Out.
2. Apply compressed
from splashing.
air slowly
to prevent
brake fluid
INSPECTION
(I) Check the inner surface
of the release cylinder
for
scratches
or irregular wear.
(2) Replace if the piston cup outer circumference
is scratched
or shows signs of fatigue, or if there is excessive wear of
the lip where indicated in the figure.
NOSLOAO
5. APPLICATION
OF FLUID TO PISTON AND CUP
After applying a coating of the specified brake fluid to the
inner surface of the release cylinder body and to the entire
circumference
of the piston and cup, insert the piston and
cup into the release cylinder.
Specified
clutch
http://vnx.su/
fluid
: Brake
Fluid
SAE J1703
(DOT 3)
CLUTCH - Clutch
CLUTCH
6-13
Disc
DISC

71
Removal steps
41) ++ 1. Transmission and transfer
assembly
41) l + 2. Clutch cover assembly
H 3. Clutch disc
NOTE
(1I Reverse the removal procedures to reinstall.

(21 l * : Refer to Service Points of Removal.
15-21 Nm
I 1-15 klbs.

1. ;EX;L
2.
OF TRANSMISSION
AND
TRANSFER
AS-
Refer to GROUP 21 - Transmission

and Transfer Assembly.
REMOVAL OF CLUTCH COVER ASSEMBLY
(1) insert clutch disc guide, or main drive gear of transmission in center spline to prevent dropping of clutch disc.
(2) Diagonally loosen bolts retaining clutch cover to flywheel.
Back off bolts, one or two turns at a time, in succession, to avoid bending cover flange.
Caution
DO NOT clean clutch disc or release bearing with
cleaning
solvent.
CLEANING AND INSPECTION
NWGCAE
Clean clutch dust from clutch housing with vacuum brush

or shop towel. Do not use compressed
air. Inspect for oil
leakage through engine rear main bearing oil seal and
transmission
front oil seal. If leakage is noted, it should be
corrected at this time.
Friction face of pressure plate should be have a uniform
appearance
throughout
entire disc contact area. If there is
evidence of heavy contact on one portion of wear circle
and a very light contact 180 degrees from that portion,
pressure plate may be improperly mounted or sprung.
Friction face of flywheel should also be free from excessive discoloration,
burned
areas, small cracks, deep
grooves, or ridges.
Wipe friction surface of pressure plate with a cleaning
solvent.
Using a straight edge, check pressure plate for flatness.
The pressure plate friction area should be flat within 0.5
mm (.020 in.) and free from discoloration,
burned area,
cracks, grooves or ridges.
l
l
/ TSB Revision
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6-14
CLUTCH - Clutch
l
*
e
Disc
Visually inspect the cover outef mounting

flange for
flatness. It should be free-of nicks, burrs, dents or other
damage.
The three dowels on the. flywheel should be tight and
undamaged.
The cover stamping should be a snug fit on the dowels.
if the clutch assembly does not meet these requirements,
it should be replaced.
CLUTCH DISC
(1) The disc assembly should be handled without touching
facings. Replace disc if facings show evidence of grease
or oil soakatie.
(2) Use the caliper gauge to measure the dimension from the
facing surface to the rivet head.
Limit
(3) ii;:
: 0.3 mm
measured
(.012 in.)
value is below the limit, replace the clutch
(4) Thehub splines and splines on transmission

input shaft
should be a snug fit without signs of excessive wear:
(5) Metallic portions of disc assembly should be dry and clean
and show no evidence of having been hot. Each of the
arched springs between facings should be unbroken and
all rivets should be tight.
SERWCE POINTS OF INSTALLATION

3.
Clutch disc
This surface has
NOGGDAJ
INSTALLATION
OF CLUTCH DISC/2. CLUTCH COVER
ASSEMBLY
(I) If there are oils or greases on clutch facing and
pressure plate, throughly wipe away with a dry cloth.
(2) Lightly specified grease clutch disc spline.
Specified
grease
: MITSUBISHI
Gemtine Grease
(3) Using clutch disc guide, or main drive gear of transmission, install clutch disc and clutch cover assembly
on flywheel.
(4) When installing
clutch disc, be sure that surface
having manufacturers
stamped
mark is on pressure
plate side.
(5) When installing the clutch cover assembly, align the

clutch cover assemblys
dowel pin hole and the
flywheels
dowel pin, and then gradually tighten the
bolts alternately.
1. INSTALLATION
ASSEMBLY
OF TRANSMISSION
Refer to GROUP 21-Transmission

1
1
1 TSB Revision
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AND
and Transfer
TRANSFER
Assembly.
P
---
CLUTCH - Clutch
Release
CLUTCH RELEASE FORK <2.6L
Fork
6-15
<2.6LEngine>
ENGINE>
NnsR4--I
Removal
++ WI
++
++ I)*
steps
1. Transmission
2. Return clip
and transfer
assembly
3. Clutch release bearing

4. Clutch release fork
5. Clutch release fork boot

6. Fulcrum
NOTE
(2) **
(3) l *
: Refer to Service Points of Removal..

NOSRBAA
1. REMOVAL
OF TRANSMISSION
AND TRANSFER ASSEMBLY
4.
DCLOOZ
I-
REMOVAL
OF CLUTCH RELEASE
Slide release fork in direction
of
fulcrum from clip.
Caution
Attempting
to remove release fork
direction
will result in damage to
FORK
arrow
to disengage
by sliding
clip.
it in other
SERVlCE POINTS OF INSTALLATION
NcmDAA
4. APPLICATION
OF GREASE TO RELEASE FORK
Pack the release fork fulcrum hole with specified grease.
Specified
grease
3. APPLICATION
BEARING
Pack specified
I.D.
Specified
fork
: MITSUBISHI
Genuine
Part No. 0101011
OF
GREASE
grease in groove
grease
TO
Grease
CLUTCH
on clutch
RELEASE
release bearing
: MITSUBISHI
Genuine
Grease
1. INSTALLATiON
OF TRANSMISSION
AND TRANSFER
ASSEMBLY
http://vnx.su/
6-16
CLUTCH - Clutch
Release
Fork
<3.OLEngine>
CLUTCH RELEASE FORK <3.OL ENGINE>

2
Removal steps
+e l + 1. Transmission
+*
+*
2.
3.
4.
5.
6.
and transfer assembl

Return spring
Clutch release fork
Clutch release fork boot
Fulcrum
NOTE

(2) *I)
(3) l + : Refer to Service points
Clutch
release
to reinstall.
of Removal.
of Installation.
bearing
1.
No6aaAe
REMOVAL
OF TRANSMISSION
SERWCE POINTS OF INSTALLATION
4. APPLICATION
OF GREASE TO RELEASE FORK
Pack the release fork fulcrum hole with specified grease.
Fulcrum
Specified
grease
3. APPLICATION
BEARING
Pack specified
I.D.
Release
NM)mAa
Specified
fork
Y
: MOLYKOTE
OF
GREASE
grease in groove
grease
: MOLYKOTE
BR-2 PLUS
TO
CLUTCH
RELEASE
on clutch release
bearing
BR-2 PLUS
1. INSTALLATION
OF TRANSMISSION
AND TRANSFER
ASSEMBLY
( TSB Revision
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21-I
TRANSMISSION
MANUAL
AND AUTOMATIC
r&?,AA-
CONTENTS
............ 57
...........................
GENERAL INFORMATION
SERVICE ADJUSTMENT
PROCEDURES
.....
......
Propeller Shaft Oil Seals Replacement
............
Speedometer
Cable Replacement
.......
Throttle Cabel Check and Adjustment
Transmission
Fluid and Transfer Oil
...........................
Changing and Inspection
SPECIAL TOOLS ...........................................
.........................................
SPECIFICATIONS
...............................
Lubricants
..................................................
............ _______._
____
-_.
...............................
...... ..- ............. .._......
MANUAL TRANSMISSION
57
88
89
89
89
88
76
69
69
75
75
70
74
TRANSMISSION
AND TRANSFER
95
...................................................
ASSEMBLY
........................
90
TRANSMISSION
CONTROL
....................
163
TRANSMISSION
OIL COOLER
...................................
77
TROUBLESHOOTING
Converter Stall Test .................................
_. 84
...................
77
Fluid Level and ATF Condition
77
General ......................................................
Governor Pressure Test ..........................
___ 84
84
Hydraulic Pressure Test .............................
78
Inhibitor Switch ..........................................
.........................................
78
Manual Linkage
Overdrive Control System Circuit ..............
86
79
Road Test ..................................................
Selector Lever .....................................
..-. ___ 78
Throttle Control Cable ..............................
__ 78
http://vnx.su/
..................
..................
GEARSHIFT LEVER ASSEMBLY
...........................
GENERAL INFORMATION
.....
SERVICE ADJUSTMENT
PROCEDURES
......
............
Speedometer
Cable Replacement
Transmission and Transfer Oil Changing
...........................................
and Inspection
SPECIAL TOOLS ...........................................
.........................................
SPECIFICATIONS
...............................
Lubricants
..................................................
.............................
...............................
................................
TRANSMISSION
AND TRANSFER
.......................
ASSEMBLY <2.6L ENGINE>
TRANSMISSION
AND TRANSFER
.......................
ASSEMBLY <3.OL ENGINE>
...................................
TROUBLESHOOTING
Gears slip out
Noise, Vibration
Oil is leaking
Shifting gears is hard or troublesome
2
52
2
IO
II
11
IO
8
3
3
7
7
3
5
12
29
10
21-2
MANUAL
GENERAL
MANUAL TRANSMISSION
- General Information
TRANSMISSION
INFORMATION
<2.6L Engine>
<3.OL Engine>
MTlOWG
TSB Revision
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_i
MANUAL TRANSMlSSlON
21-3
- Specifications
SPECIFICATIONS
Nz1cA-o
Items
2.6 L Engine
3.0 L Engine
Model
Transmission
KM 145-B-FSL
V5MTl-O-AFSL
Type
Gear ratio
5-speed 4-wheel drive

3.967
2.136
1.360
1 .ooo
0.856
3.578
4.625
26l8
5-speed 4-wheel drive

3.918
2.261
1.395
1.000
0.829
3.925
4.625
26f8
Tape
Gear ratio
Constant mesh type

1.000
1.944
Chain drive
Direct drive
Constant mesh type

1.000
1.925
Chain drive
Direct drive
1st
2nd
3rd
4th
5th
Reverse
Final gear ratio
Speedometer gear ratio
Transfer case
High
Low
Drive system
Front wheel
Rear wheel
NZ1CB-O
Transmission
<2.6L Engine>
mm (in.)
Items
Standard value
Main drive gear preload
Front bearing retainer and bearing clearance
3-4speed synchronizer hub end play
Counter shaft preload
Limit
Synchronizer ring and clutch gear clearance
O-0.06 (O-.002) . .. Adjusted by spacer

O-O.1 (O-.004) . . Adjusted by spacer
O-0.08 (O-.003) . .. Adjusted by snap ring
O-0.05 (O-.0020) . .. Adjusted by spacer
0.5 (.02) . .. Replacement
of gear or synchronizer ring
<3.OL Engine>
mm (in.)
Items
-1
Limit
Synchronizer ring and clutch gear clearance
Specifications
0.2 (.009)
1 TSB Revision
http://vnx.su/
. Replace of gear or synchronizer ring
21-4
MANUAL TRANSMISSION
Specifications
Transfer
Specifications
=
items
Standard value
Input gear end play
H-L clutch hub end play
Out put shaft bearing end play
Snap rings and spacers

<2.6L Engine>
O-0.06 (O-.002) .. . Adjusted by snap ring

O-0.08 (O-.003) .. . Adjusted by snap ring
O-O.1 (O-.004) . . . Adjusted by spacer
for transmission
adjustment
mm (in.)
Part name
Snap rings
~for adjustment
mm (in.)
1
Thickness
of main drive gear preload)
Spacers
:for adjustment
clearance)
of front bearing retainer and bearing
Snap rings
for adjustment
clearance)
of 34 gear synchronizer hub
Spacers
for adjustment of counter shaft preload)
2.36i.091)
2.35 i.092)
2.40 i.094)
2.45 i.096)
2.50 (098)
Identification symbol
-~
Part No.
Whitez
Brown
None
Blue
Yellow
MD701729
MD701 730
MD701731
MD701 732
MD701 733
0.84 C.033)
0.93 t.037)
1.02 (.040)
1.11 1.044)
1.20 f.047)
1.29(.051)
1.38 (.054)
Black -None
Red
White
Yellow
Blue
Green
MD701845-MD701 839
MD701 840
MD701841
MD701 842
MD701843
MD701844
2.15(.085)
2.22 t.087)
2.29 i.090)
2.36 t.093)
Yellow
Greerr
White
MD701762
MD701763
MD701764
1.84 t.072)
1.87 f.074)
1.90 f.075)
1.93 (.076)
1.96 t.077)
1.99 i.078)
2.02 (.080)
2.05 (.081)
2.08 f.082)
2.11 t.083)
2.14 t.084)
2.17 (.085)
2.20 l.087)
2.23 i.088)
2.26 (.089)
2.29 (.090)
2.32 t.091)
2.35 f.093)
2.38 C.094)
2.41 (.095)
2.44 (.096)
2.47 (.097)
2.50 (.098)
2.53 (.lOO)
2.561.101)
2.59(.102)
2.62 (.103)
2.65(.104)
2.68l.106)
[ TSB Revision
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84
87
:z
96
99
02
05
08
11
14
17
20
23
26
29
32
2
41
44
47
50
53
56
59
62
65
68
MD706580
MD706581
MD706582
MD706583
MD706584
MD706585
MD706586
MD706587
MD706588
MD706589
MD706590
MD706591
MD706592
MD706593
MD706594
MD706595
MD706596
MD706597
MD706598
MD706599
MD706600
MD706601
MD706602
MD706603
MD706604
M D706605
MD706606
MD706607
MD706668
MANUAL TRANSMISSION
Snap rings and spacers
for transfer
21-5
Specifications
adjustment
mm (in.)
Part name
Snap rings
(for adjustment
of input gear end play)
Snap rings
for adjustment
of H-L clutch hub end play.)
Spacers
(for adjustment
of output shaft bearing end play)
Thickness
Identification symbol
Part No.
2.30(.091)
2.35 (.093)
2.40 (.094)
2.45 (.096)
2.50 (.098)
None
Red
White
Blue
Green
MD7041 99
MD704200
MD704201
MD704202
MD704203
2.14(.084)
2.21 (.087)
2.28 (.090)
2.35 (.093)
2.42 (.095)
None
Yellow
White
Blue
Red
MD704212
MD704213
MD704214
MD704215
MD704216
0.84
0.93
1.02
1.11
1.20
1.29
1.38
Black
None
Red
White
Yellow
Blue
Green
MD701 845
MD701 839
MD701 840
MD701841
MD701842
MD701843
MD701844
(033)
(037)
(040)
(.044)
(047)
(.051)
(054)
N21cc-o
Items
Nm
Transmission <2.6L Engine>

Transmission to engine
Starting motor mounting bolts
Transmission to exhaust pipe mounting bracket
Control housing to cover
Front exhaust pipe mounting bolt
Clutch release cylinder mounting bolt
Engine mounting rear insulator to No. 2 crossmember
Engine mounting rear insulator to transmission
Mainshaft lock nut
Idler shaft lock nut
Under cover attaching bolt
Countershaft gear lock nut
Reverse idler gear shaft nut
Backup light switch
Oil drain plug
Oil filler plug
Rear bearing retainer attaching bolts
Reverse idler gear shaft attaching bolts
Front bearing retainer installation bolt
Bell housing attaching bolts
Stopper bracket assembly attaching bolt
Transfer adaptor and transmission case coupling bolt
1 TSB Revision
http://vnx.su/
43-55
27-34
20-27
IO-12
2030
55-75
31-42
18-25
18-25
250-270
20-60
8-10
160-190
20-60
30
60
3035
15-22
15-22
IO-12
10-12
15-22
15-22
ftlbs.
32-39
20-25
15-20
7-9
15-22
40-54
22-29
13-18
13-18
181-195
15-43
5-7
116-137
15-43
22
43
22-25
11-15
1 I-15
7-9
7-9
IT-15
II-15
21-6
MANUAL TRANSMlSSlQN
Items
Transmission <3.OL Engine>
Transmission to engine (A)
Transmission to engine(B)
Starting motor mounting bolt
Transmission to transmission stay
No. 2 Crossmember to frame
Clutch release cylinder mounting bolt
Engine mounting rear insulator to No. 2 crossmember
Engine mounting rear insulator to transmission
Transmission case and clutch housing
Transmission case and transfer case adapter
Transmission case and lower case
Transmission case PTO cover
Filler plug
Drain plug
Main shaft rear lock nut
Reverse shaft lock piece installation bolt
Lower arm pivot
Back light switch
Poppet spring instalfation screw plug
Adapter part poppet spring installation screw plug
Adapter part side poppet spring installation screw plug
Adapter cover installation bolt
Transfer case
Pulse rotor installation bolt
Pulse generator bolt
Adapter to transfer case mounting bolts and nuts
Chain cover bolt
Side cover bolt
Rear cover bolt
Cover bolt
Control housing bolt
Oil filler plug
Drain plug
Select plunger plug
Lock plate bolt
Rear output shaft lock nut
Speedometer sleeve clamp bolt
Seal plug
4WD indicator light switch
Transfer mounting bracket to transmission
Transfer mounting bracket to body
Gear shift lever assembly
Control housing to transfer case
Control housing cover to control housing
http://vnx.su/
SDecifications
Nm
ftlbs.
65-85
SO-100
27-34
30-42
55-75
31-42
18-25
18-25
119
41
24
19
55-85
5535
250-270
41
58
30-40
40
48
30-42
24
47-61
58-72
20-25
22-30
40-54
22-29
13-18
13-18
86
30
17
14
40-61
40-61
181-195
30
42
22-29
29
35
2230
17
15-22
10-12
3042
30-Q
&IO
15-22
15-22
15-22
3035
3035
3035
15-22
100-130
15-22
30-42
30
18-25
18-25
11-15
7-9
2230
22-30
5-7
11-15
11-15
11-15
22-25
22-25
22-25
11-15
72-94
11-15
22-30
22
13-18
13-18
15-22
IO-12
11-45
7-9
MANUAL TRANSMISSION
21-7
- Specifications
LUBRICANTS
N2ICD-U
Items
Transmission
<2.6L Engine>
<3.OL Engine>
Transfer case
Specified lubricant
Quantity
Hypoid gear oil API classification GL-4

or higher SAE viscosity 80W. 75W85W
or higher SAE viscosity 80W. 75W85W
Hypoid gear oil API classification GLd,
or higher SAE viscosity 8OW. 75W-85W
2.2 lit. (4.7 pints)


Items
Transmission
<2.6L Engine>
Front bearing retainer
Extension gasket
Rear bearing retainer bolt
Reverse idler gear shaft bolt
Poppet plug
<3.OL Engine>
Transmission case and clutch housing
installation surfaces
Transmission case and adaptor
Transmission case and lower case
Poppet spring part screw plug threads
Adapter cover and adapter plug
threads
Drain plug and filler plug threads
Reverse shaft lock piece bolt threads
Adapter part poppet spring part screw
plug threads
fransfer
Control housing
Control lever gasket
Housing cover gasket
Stopper bracket installation bolt
Stopper bracket installation bolt (threads)
Adapter gasket
Chain cover gasket
Cover gasket
Cover installation bolt (threads)
Rear cover gasket
Speedometer cable grommet
NPICE-0
Quantity
3M
3M
3M
3M
3M
As
As
As
As
As
ART Part No. 8660

ART Part No. 8660
STUD Locking No.
STUD Locking No.
ART Part No. 8660
Mitsubishi genuine
or equivalent
Mitsubishi genuine
or equivalent
Mitsubishi genuine
or equivalent
Mitsubishi genuine
or equivalent
Mitsubishi genuine
or equivalent
Three Bond 1105D
Three Bond 1105D
Three Bond 1104J
3M
3M
3M
3M
3M
3M
3M
3M
3M
3M
3M
or equivalent
or equivalent
4170 or equivalent
4170 or equivalent
or equivalent
required
required
required
required
required
sealant Part No. MD997740
As required
As required
As required
As required
As required
or equivalent
orequivalent
or equivalent
ART Part No. 8660 or equivalent

Scotch Grip No. 2353 or equivalent
Adhesive Nut Locking 4171 or equivalent
ART Part No. 8001 or 8011, or equivalent
TSB Revision
http://vnx.su/
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
MANUAL TRANSMISSION
- Special Tools
SPECIAL TOOLS
<2.6L Enaine>
Number
Name
Use
M D998245-0 1
Lock pin installer
Driving in of Iock pin and spring pin
MD998020
Bearing puller
Removal of main drive gear and main shaft

bearing
MD998067-01
Mainshaft
installer
Driving in oknain shaft bearing
MD998029-01
Main drive gear

bearing installer
MD99820601
Front bearing
retainer oil seal
installer
MD99834&01
Taper bearing pulle;
Removal of counter shaft bearing
ME990938-01
Handle
Use with MD998200

Driving in of front oil seal
M IT4336
Bearing driver
handle
M D998809
Lock nut wrench
Number
Name
MH061002
Snap ring expander
MH061405
Dummy bearing
bearing
Driving in of main drive gear be&g
Driving in of front oil seal
- Use with MD998067-01, MD998029-&

Driving in of main drive gear and main shaft
bearing
Y
For remova?installation
of main shaft lock nut
<3.OL Engine>
Tool
[ TSB Revision
/ Use
For snap ring removal/installation
------I
For counter shaft bearing tap-in
http://vnx.su/
MANUAL
\ Tool
TRANSMISSION
Special
21-9
Tools
Number
Name
Use
MH061400
Puller and installer

kit
For removal/installation
bearings
MH061407
Oil seal installer
For clutch housing oil seal press-in
of transmission
ball
For removal of 3rd gear, 3rd an 4th

synchronizer hub
Composition
Code No.
of puller
MH061322
Oil seal guide
For clutch housing installation
MD99824501
Lock pin installer
For spring pin tap-in
MD998809
Lock nut wrench
For removal/installation
nut
and installer
Part No.
kit (MH061400)
Note
I Part name
MH061409
MH061410
MH061411
MH061306
MH061412
MH061308
MH061309
71.8 mm (2.827 in.) For drive pinion

68.8 mm (2.709 in.) For main shaft (rear)
64.8 mm (2.551 in.) For counter shaft(front/rear)
Main shaft bearing claw

Main shaft bearing claw
Counter shaft bearing claw
Protector
Body
Bearing puller rod
Bearing puller rod
Bolt
Plug
03726-81016
03726-81017
For drive pinion

For counter shaft
For counter shaft (front/rear) bearing removal
For drive pinion bearing removal
14
of mainshaft lock
34
For main shaft(rear) bearing removal
67
For press-in of all bearings
1 TSB Revision
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,..
21-10
MANUAL TRANSMISSION
Troubleshoatine
I Service
Adiustment
Procedures
TROUBLESHOOTING
Trouble
m1EAAb
Service Operation
Cause
The transmission
or damaged.
and engine mount is loose
Tighten orreplace the mount.
c - Correct the end play.
The end play of each shaft is not proper.

Gears are worn or damaged.
Replace the gears.
The oil grade is improper.
Replace with the specified
The oil level is low.
Add oil.
The engines idling speed is not proper.
Adjust the idling speed.
oil.
.~
Oil is leaking
.-
The oil seal or O-ring is damaged.
Shifting gears is hard or

troublesome
The synchronizer ring and gear conesmesh

poorly or are worn.
1
The synchronizer spring is fatigued.
Gears slip out
Replace the oil seal or O-ring.

Repair or replace.
Replace the synchronizer
ring.
The oil grade is improper.
Replace with the specified oil.
The gear shift forks are worn or the poppet

spring is broken.
Replace the shift forks or poppet spring.
The clearance between the synchronizer

hub and sleeve is too large.
Replace the synchronizer
SERVICE ADJUSTMENT
hub and spring.
PROCEDUREi&
TRANSMISSION AND TRANSFER OIL CHANGING

AND INSPECTION
1.
2.
3.
4.
5.
Raise vehicle on hoist.

Remove the filler plug from the transmission
or transfer
and check that the transmission
oil is up to the oil level. If it
is lower, replenish specified transmission
oil to the oil level
and if it is higher; drain transmission
oil as described
below.
Remove drain plug to let oil drain.
Tighten the drain plug completely.
Replenish the specified transmission
oil to the level.
Specified
transmission
oil:
Quantity
:
Transmission
<2.6L Engine>
<3.OL Engine>
Transfer case
Hypoid gear oil API classification GL-4 or higher SAE

viscosity
8OW, 75w-85W
___
1 TSB Revision
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-.
.I
MANUAL TRANSMISSION
21-11
- Service Adiustment Procedures
6. Tighten
the filler plug.
NOTE
Apply a coating of sealant to the threaded
part when
installing the drain plug and the filler plug of the transmission of models with the 3.0-liter engine.
Specified
:ront
sealant
: Three
Bond
1105D
or equivalent.
PROPELLER SHAFT OIL SEALS REPLACEMLIL
Rear

or a similar tool, remove the oil seals.
(2) Install the oil seals.
Caution
Use a new
oil seal.
(3) Apply a coating

the oil seals.
of the multipurpose
grease
to the lip of
N21Fml
SPEEDOMETER CABLE REPLACEMENT
(1) Replace the cable assembly

if there is a malfunction.
(2) When connecting
the cable to the meter, insert the cable
until its stopper properly fits to the meterside
groove.
(3) After installina the speedometer,

pull the speedometer
cable throughthe
grommet in the toe-board until the cable
marking is visible from the engine compartment
side.
(4) Apply the specified sealant to the outside surface of the
grommet.
Specified
sealant:
3M ART Part NO. 8001

or equivalent
or 8011,
(5) Securely clamp the transmission

side marking
speedometer
cable to the frame side clip.
(green)
of
Caution
Poor installation
of the cable may cause a fluctuating
meter pointer, or noise and a damaged
harness inside
the instrument
panel.
[B
Revision
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21-12
MANUAL
TRANSMISSION
TRANSMISSION
- Tmnsmission
AND TRANSFER
and Tmnsfer Assembly <2&L Engine>
ASSEMBLY
<2.6L
ENGINE>

Pm-removal
Operation
Post-installation
l
l
installation of Transmission and
Removal of Transmission and Transg-5;hift Lever Knob (Refer to P.
l
l
Removal of Transfer Case Protector

Draining of Transmission Oil and
Transfer Oil (Refer to P. 21-10.)
Removal of Front and Rear Propeller Shaft (Refer to GROUP 16 Propeller Shaft.)
20-30
15-22
Nm
ft.lbs.
7.
Operation
Installation of Front and Rear Pro

peller Shaft (Refer to GROUP 16 Propeller Shaft.)
Supplying of Transmission Oil and
Installation of Transfer Case Protec-
30-35
22-25
Nm
Ribs.
8-
18-25
13-18
55-75
40-54
Removal
++
4+
++
Nm/
ft.lbs.
80
_^ Nm
.&
.a
Q.3
rr.lDs.
1845Nm
13-18 ft.lbs.
Nm
ft.lbs.
13
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Dust seal guard

Ground cable
Back-up light switch connector
4WD indicator liaht switch connector
Speedometer
cable
Front exhaust pipe mounting bolt
Bell housing cover
Exhaust pipe mounting bracket
Starter motor
Transfer mounting bracket
12. Bolt
13. No. 2 crossmember
) TSB Revision
14. Engine niounting rear insulator

*e ++ 15. Transmission and transfer assembly
NOTE
(2) 4*
(3) e+ : Refer to Service Points of Installation.
Nm
ftlbs.
O.D. x Length
A 43-55
B 43-55
C 27-34
31-40
31-40
20-25
3 10x401.4x1.6)
@ 10x65(.4x2.6)
@ 10x60(.4x2.4)
D 20-27
E 20-27
16-20
1520
@ 8x55(.3x2.2)
@ 8x25(.3x1.0)
http://vnx.su/
/
--.
mm (in.) Bolt identification

@ DxL
D
Y09512
MANUAL TRANSMISSION
T ransmission
and
Transfer
Assembly
<ML
Engine>
21-13

6.
NZIYBAM
REMOVAL
OF CLUTCH RELEASE CYLINDER
Remove the clutch-release
cylinder (with the clutch hose
connected
to it) from the transmission,
and suspend it
from the body by using a piece of wire or a similar
method.
10. REMOVAL
OF STARTOR MOTOR
Remove the starter motor (with the harness connected to
it) from the transmission,
and suspend it from the body by
using a piece of wire or a similar method, so that it doesnt
fall.
11. REMOVAL
OF TRANSFAR
MOUNTING
Before removing
the transfer mounting
transmission
jack to hold the transfer.
15. REMOVAL
SEMBLY
OF TRANSMISSION
AND
BRACKET
bracket, use a
TRANSFER
AS-
Caution
When removing the transmission
from the engine, care
must be taken not to shake or rock with force, because
to do so might cause damage to the end of the main
drive gear, the pilot bearing, or the clutch disc, etc.
mw51
(1) Disconnect
the transmission
and transfer assembly
from the engine by pulling it slowly toward the rear of
the vehicle.
(2) When the transmission
are
lowered, tilt the front of the transmission
downward
and slowly lower forward, while using care to make
sure that the rear of the transmission
does not
interfere with the No. 4 crossmember.
NZlMDAK
15. INSTALLATION
OF TRANSMISSION
AND TRANSFER
ASSEMBLY
(1) Insert a wedge-shaped
piece of wood between
the
engine oil pan and the front differential housing so that
the engine is tilted toward the rear.
(2) On the engine side, there are two centering locations.
Make sure that the transmission
mounting bolt holes
are alignedwith them before mounting the transmission and transfer
http://vnx.su/
assembly
to the engine.
21-14
MANUAL TRANSMISSION
- Transmission
and
DISASSEMBLY AND REASSEMBLY (TRANSMISSION
Transfer
Assembly
<26L
Engine>
AND TRANSFER ASSEMBLY)

Nz1ME.c
\
P
30-35 Nm
22-25 fms.
19
30-42 Nm
22-30 ft.lbs.
Disassembly
steps
1.
2.
3.
4.
5.
6.
*,+ 7.
8.
9.
**lo.
-11.
I)+ 12.
Oil filler plug

Oil drain plug
Select plunger plug
Gasket
Select spring
Select plunger
Spring pin
Cord fastener
Cord fastener
Change shifter
Transfer case assembly
Adapter gtisket
13. Plug
14. Spring
15.
16.
17.
18.
19.
Steel ball
Seal plug
Neutral return spring
Neutral return plunger (B)
Neutral return plunger (A)
NOTE
(2) I)4 : Refer to Service Points of Reassembly.
(3) R
-_
/ TSB Revision
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MANUAL TRANSMISSION
T ransmission
and Transfer Assembly
<2.6L Engine>
21-15
24
15-22
Nm
11-15
Disassembly
steps
30 Nm
22 ft.lbs.
6
22. Backup light switch
23. Steel ball
+424.
Breather
25. Plug
***426.
-27.
28.
29.
30.
31.
ft.lbs.
20
30-35
Nm
-_
-- ._...
22-25
ft.lbs.
60 Nm
43 ft.lbs.
Transfer adapter
Extension gasket
Lock pin
Control finger
Control shaft
Transmission assembly
NOTE
(2) ++
(4) q
: Non-reusable
par&s
NzlMFno
26. REMOVAL OF TRANSFER ADAPTER

Turn the control shaft to the left and remove the control finger
from the groove in the shift lug, then remove the transfer
adapter from the transmission.
N21MGBG
27. INSTALLATION
OF EXTENSION GASKET/26. TRANSFER
ADAPTER
(1) Apply sealant to both sides of the extension gasket and
affix the gasket to the rear surface of the transmission
case.
Specified
sealant:
3M ART Part
or equivalent
TSB Revision
http://vnx.su/
No. 8660
21-16
MANUAL TRANSMISSION
Transmission
< Z&L Engine>
(2) Turn the control shaft to the left and install the transfer
adapter.
(3) Turn the control shaft to the right and insert the control
finger in the groove of the shift lug.
Identification
mark
24. INSTALIATION
OF BREATHER
Install the breather with the identification
rear.
mark toward
the
12. ASSEMBLY OF ADAPTER GASKETIll.

TRANSFER CASE
ASSEMBLY/lo.
CHANGE SHIFTER
(1) Apply sealant to both sides of the gasket and affix it to the
rear surface of the adapter.
Specified
3M ART Part No. 6660

or equivalent
(2) Install the transfer case installing the change shifter to the
control shaft.
7.
sealant:
INSTALLATION
OF SPRING PIN
(I) Drive the spring pin in using the special
tool.
(2) Drive the spring pin in with the slit in the spring pin parallel
to the shaft center of the shift rail, so that the
dimensions
are as shown in the illustration.
NOTE
Do not reuse spring pin.
[ TSB Revision
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te
MANUAL TRANSMISSION
- Transmission
21-17
c2.6L Engine>
ASSEMBLY)
8
9
14
160490
.l.P 4J-w Nm
Ilw.
I ,PlJ,
250470
181-195
,,.IY3.
Nm
Ribs.
15-22
11-16
Disassembly
1.
2.
I)*
3.
*+
4.
l + 5.
+e w+ 6.
++ l + 7.
8.
9.
IO.
+e I)+ 11.
12.
+I)
+* I)+ 13.
+r, w+ 14.
15.
+I) ++ 16.
17.
18.
19.
20.
21.
22.
23.
24.
+*
25.
+a 26.
+a 27.
e+ 28.
steps
Under cover
Under cover gasket
Plug
Poppet spring
Steel ball
Spring pin
Spring pin
OD-R shift rail
34 speed shift rail
OD-R shift fork
Countershaft
lock nut
Countershaft
rear bearing
Counter overdrive gear
l-2 speed shift rail
Interlock plunger
Main shaft lock nut
Spacer
Reverse idler gear
Spacer
Sleeve
Steel ball
Overdrive gear
Needle bearing
Bearing sleeve
Bearing spacer
Synchronizer ring
OD-R synchronizer sleeve
Synchronizer spring
Nm
ft.lbs.
20-60 Nm
15-43
4b
b-22
11-15
ft.lbs.
Nm
ft.lbs.
1450005
a,
we 29. Synchronizer key

I)* 30. Synchronizer hub
31. Reverse gear
32. Needle bearing
33. Bearing sleeve
34. Spacer
35. Cotter pin
36. Slotted nut
37. Thrust washer
38. Reverse idler gear
39. Needle bearing
I)+ 40. Reverse idler gear shaft
w+ 41. Rear bearing retainer
NOTE
procedures
to reassemble.
(2) 41) : Refer to Sewice Points of Disassembly.
(3) ++
(41 q
: Non-reusable
parts
1 TSB Revision
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21-18
MANUAL TRANSMISSION
- Trawmission
and
Transfer
Assembly
<2.6L
Engine>
58
Disassembly
+*
04
+*
42.
43.
44.
I)+ 45.
I)+ 46.
*+ 47.
I)+ 48.
49.
50.
** ++ 51.
52.
53.
l * ,*
54.
55.
56.
57.
58.
steps
Main shaft bearing
Spacer
Counter rear bearing outer race
Front bearing retainer
Front bearing retainer gasket
Spacer
Oil Seal
Spacer
Counter front bearing outer race
Snap ring
Main drive gear assembly
1-2 speed shift fork
Counter shaft assembly
34 speed shift fork
Main shaft assembly
Needle bearing
Transmission case
1450029
NOTE

(2) +I) : Refer to Service Points of Disassembly.
13) I)+ : Refer to Service Points of Reassembly.

6./7.
REMOVAL
Drive
the
OF SPRING
spring
_.
evision
http://vnx.su/
pin out
PIN
using
the
pin punch.
Nnhm3L
MANUAL TRANSMISSION
Transmission
and Transfer Assemblv
<2&L Engine>
21-19
11. REMOVAL
OF COUNTERSHAFT
LOCK NUT
(1) As shown in the illustration, use the front edge of the
blade of a chisel or a blunt punch to loosen the baffle
on the main shaft and counter shaft lock nuts.
(2) Shift the OD-R synchronizer sleeve to the reverse side,
then shift the l-2 synchronizer
sleeve to the 2nd speed
side.
(3) Remove the main shaft lock nut and the counter shaft
lock nut.
12. REMOVAL
COUNTER
RAIL
(I) Pull off
using a
OF COUNTERSHAFT
OVERDRIVE
GEAR/14.
counter
suitable
(2) Pull off overdrive
overdrive
puller.
REAR BEARING/lB.
1-2 SPEED SHIFT
gear and ball bearing
gear and 1st - 2nd speed
by
shift rail.
16. REMOVAL
OF MAIN SHAFT LOCK NUT
(1) As shown in the illustration,
use the front edge of the
blade of a chisel or a blunt punch to loosen the baffle
on the main shaft lock nuts.
(2) Shift the OD-R synchronizer
sleeve to the reverse side,
then shift the 1st - 2nd speed synchronizer sleeve to
the 2nd speed side.
[ TSB Revision
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21-20
MANUAL TRANSMISSION
- Transmission
and
Transfer
Assembly
<2.6L
Enginsz
(3) Remove the main shaft lock nut loosening

special tool.
it with the
24. REMOVAL
OF OVERDRIVE
GEAR BEARING SLEEVE
(1) Using the special tool, remove the overdrive gear and
bearing sleeve.
40. REMOVAL
OF REVERSE IDLER GEAR SHAFI(1) Remove four reverse idler gear shaft mounting
bolts.
(2) Drive the reverse idler gear shaft from inside of case.
42. REMOVAL
OF MAIN SHAFT CENTER BEARING
(1) Remove main shaft bearing snap ring.
(2) Using Special Tools remove main shaft rear bearing.
51. REMOVAL
OF SNAP RING/54.
COUNTER SHAFT ASSEMBLY
(1) Remove the snap ring by using snap-ring pliers.
(2) Remove the counter shaft assembly
while pressing
the main drive gear.
1 TSB Revision
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1:
MANUAL TRANSMISSION
Transmission
and
Transfer
Assembly
<Z&L
21-21
Engine>
NaMOBP
54. INSTALLATION
OF COUNTER SHAFT ASSEMBLY/51.
SNAP RING
(1) Install the counter shaft assembly while pressing the
main drive gear.
(2) Install the snap ring.
48. INSTALLATION
OF OIL SEAL
Apply transmission
oil to the lip of the oil seal, then drive
the oil seal into the front bearing retainer using the special
tools.
47. INSTALLATION
OF SPACEW46.
FRONT BEARING RETAINER GASKET/45.
FRONT BEARING RETAlNER
(1) Before installing the front bearing retainer, select a
spacer which will bring the clearance
(c) to the
standard value.
Standard
value:
O-O.1 mm
(O-.004
in.)
(2) Apply sealant to both sides of the front bearing

retainer gasket and affix it to the case. Then immediately set the spacer selected in (1) in place and install
the bearing retainer.
Specified
1
I
No. 8660
race (in the
132015
(2) Put a spacer of proper thickness (slightly thinner than dimension H shown in illustration) on outer race.
-Counter gear
3M ART Part
or equivalent
43. INSTALLATION
OF SPACER
(1) Hold down counter gear and bearing outer
direction of arrow shown in illustration).
Counter gear
sealant:
132016
IRevision
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MANUAL TRANSMlSSlON
I
- Trsnsmission
and
Transfer
Assembly
<2.6L
Engine>
(3) Put straight edge on spacer and try to turn spacer by index
finger. If spacer turns lightly, replace it with spacer one
rank [0.03 mm LOO12 in.)1 thicker, and similarly turn this
spacer. In this manner, choose and install a spacer which
makes clearance between straight edge and spacer closest to 0. Make sure that the bearings are NOT preloaded.
Standard
value : O-0.05
mm (O-.0020
in.)
42. INSTALLATlON
OF MAIN SHAFT BEARlNG
After installing the snap ring on the main shaft bearing, drive
the main shaft bearing into the transmission case using the
special tool.
MD998067-07
41. INSTALLATION
OF REAR BEARING RETAINER
Apply a coating of sealat-&to the threaded part of The bolt.
and tighten at the specified torque.
Specifiedsealant
: 3M STUD
equivalent.
Locking
No.
4170
or
40. INSTALLATION
OF REVERSE IDLER GEAR SHAFT
(1) Position the reverse idler gear shaft with bolts and
drive it in.
(2) Apply a coating of sealant to the threaded part of the
bolt, and tighten at the specified
torque.
Specified
sealant
: 3M STUD
equivalent.
locking
No. 4170
or
30. INSTALLATlON
OF SYNCHRONIZER
HUBB.
SYNCHRONIZER KEY/28. SYNCHRONIZER
SPRING/27. OD-R SYNCHRONIZER SLEEVE
(1) Assemble synchronizer hub and sleeve. Make sure that
hub and sleeve slide smoothly.
(2) Insert three keys into groove of hub. Assemble hub and
keys as shown in illustration since they have a definite
direction to be assembled.
-
(3) Install two synchronizer springs. When installing springs,

make sure that steps of front and rear springs are positioned on synchronizer key, but not on the same key.
110013
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MANUAL TRANSMISSION
Transmission
26. INSTALLATION
and
Transfer
Assembly
c2.6L
OF SYNCHRONIZER
Engine>
21-23
RING
Engage synchronizer ring to OD gear as shown in illustration

before installing OD gear and ensure that there is certain clearance A.
If dimension A exceeds the limit, replace the ring and/or
gear.
Limit
Synchkizer
: 0.5 mm (.020 in.)
ring
16. INSTALLATION
OF MAIN SHAFT LOCK NUT
(1) Tighten main shaft lock nut to specified
torque
using the special tool.
(2) Stake the area as shown in illustration without

prevent lock nut from loosening.
(3) Ensure that OD gear rotates smoothly.
by
fail to
14. INSTALLATION
OF 1 - 2 SPEED SHIFT RAIL/13. COUNTER OVERDRIVE
GEAR
(1) Install the over drive gear and 1st - 2nd speed shift
rail.
11. INSTALLATION
OF COUNTER SHAFT LOCK NUT
(1) Tighten the counter shaft lock nut to specified torque.
(2) Stake the area as shown in illustration without fail to
prevent lock nut from loosening.
(3) Ensure that the OD gear rotates smoothly.
110032
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21-24
MANUAL TRANSMISSION
7./6.
and
Assembly
<26L
Engine>
INSTALLATION
OF SPRING PIN
(1) Drive in the OD-R shift fork spring pin using the special
tool.
NOTE
Do not reuse
5.
5.5-6.0
(.22-24
Transfer
(2) Drive in spring pin so as to place slit in direction

of
center line of shift rail. Drive in spring pins for 3rd-4th
and Ist-2nd
speed shift forks in the same manner.
Shift fork
Springein
Transmission
mm
in.)
the spring
pin.
INSTALLATION
OF STEEL BALL/4. POPPET SPRING/3.
PLUG
(1) Insert the steel ball and poppet spring into each shift
rail. Tighten the plug to the specified
position.
Seal with sealer

- 5.5-6.0 mm
(.22-.24 in.)
5.5-6.0
L22-.24
Poppet
Ball
mm
in.)
spring
134041
(2) Insert the poppet spring with small end on ball side.
Three springs are identical to one another.
(3) After installation,
seal the plug head with sealer.
Specifiedsealant:
Small
end
http://vnx.su/
3M ART Part
or equivalent
No. 8660
MANUAL
DISASSEW3LY
TRANSMISSION
AND
REASSEMBLY
(MAIN
Transmission
and
DRIVE
Transfer
GEAR
Assembly
~2.6L
Engine>
21-25
ASSEMBLY)
110038
Disassembly
**l
+**+P.
steps
NOTE
(2) l * : Refer to Service Points of Disassembly.
(3) l 4 : Refer to Service Points of Reassembly.
(4) 0
: Non-reusable
parts.
Snap ring
Bearing
3. Main drive gear

2.
tviD998020
REMOVAL OF BEARING
(I) Remove main drive gear snap ring.
(2) Using Special Tool, pull ball bearing from main drive gear.
w
134011

2.
INSTALLATION
OF BEARING
With Special Tools, applied to main drive gear
bearing in by means of a hammer or a press.
press
1. INSTALLATION
OF SNAP RING
Select and install main drive gear snap ring of such thickness
that will minimize clearance between snap ring and bearing. In
other words, install the thickest snap ring that can fit in snap
ring groove.
Standard
1 TSB Revision
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value : O-0.06
mm (O-.002
in.)
21-26
MANUAL TRANSMISSION
T fansmission
and
Transfer
Assembty
<26L
Engine>
DISASSEMBLY AND REASSEMBLY (MAIN SHAFT ASSEMBLY)
Disassembly
Nz1PE-c
steps
1. Ball bearing inner race

2. First speed gear
3. Bearing sleeve
4. Needle bearing
WC 5. 1-2 speed synchronizer
6. Synchronizer ring
+C 7. Synchronizer spring
l a 8. Synchronizer key
l C 9. 1-2 speed synchronizer
l *
IO. Second speed gear
11. Needle bearing
l *12. Snap ring
**14. Synchronizer spring
l C15. Synchronizer key
l C16. 3-4 speed synchronizer
1)*17.3-4
speed synchronizer
18. Needle bearing
19. Third speed gear
20. Main shaft
a+
sleeve
hub
hub
sleeve
NOTE
(2)*+ : Refer to Service Points of Disassembly.
(3)+* : Refer to Service Points of Reassembly.
146163
(1)
(4)
: Non-reusable
parts.
NZl?FMZ
1. INSTALLATION
OF BALL BEARING INNER RACE/lO. SECOND SPEED GEAR
Holding second speed gear on press base, push rear end of
main shaft to remove bearing inner race (double bearing only),
gear bearing sleeve, first speed gear, l-2 speed synchronizer
and second speed gear.
14!no2
INSPECTlON
e
e
Check synchronizer
ring for worn and damaged iTe=
threads.
With synchronizer assembled to cone of each gear check dimension A. If dimension A exceeds the limit, replace the
synchronizer ring and/or gear.
Limit
Synchrkizer
ring
: 0.5 mm (.020 in.)
Gear
levision
__
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MANUAL TRANSMISSION
Transmission
and
Transfer
Assamblv
42.61

1
1
Synchr&izer
pth
missing hers
key
Engine>
21-27
W?,-
17. ASSEMBLY OF 3-4 SPEED SYNCHRONIZER SLEEVEIl6.

3-4 SPEED SYNCHRONIZER
HUBMS. SYNCHRONIZER
KEYI14. SYNCHRONIZER SPRING
(1) Mate synchronizer hub with sleeve using mark made at
disassembly.
Make sure that hub and sleeve slide
smoothly. if they slide unsmoothly, replace hub and sleeve
assembly.
(2) 34 synchronizer sleeve has teeth missing at six portions.
Assemble hub to sleeve in such a way that center tooth T
between two missing teeth will touch synchronizer key.
(3) Use care when installing 3-4 synchronizer hub since only
3-4 synchronizer is directional. Smaller diameter side A
of center boss is front of 3-4 synchronizer hub.
146025
(4) insert three keys into groove of synchronizer hub.

(5) Install two synchronizer springs to synchronizer. When
synchronizer springs are installed, make sure that front
and rear ones are not faced in same direction.
110013
Main shaft
3-4 speed
synchronizer
hub
Snap ring,
-w
I II
>
16. INSTALLATION
OF 3-4 SYNCHRONlZER
HUB/lZ. SNAP
RING
(1) Assemble 34 synchronizer positioning hub toward correct
direction.
(2) As for main shaft front end snap ring. select and install one
of such thickness that will minimize clearance between
snap ring hub. In other words, install the thickest snap ring
that fits in snap ring groove.
(3) Make sure that 3rd speed gear turns smoothly.
9.
ASSEMBLY OF l-2 SPEED SYNCHRONIZER HUB/S. SYNCHRONIZER

KEY/7. SYNCHRONIZER
SPRINGI5.
l-2
SPEED SYNCHRONIZER
SLEEVE
Assembly the 1-2 synchronizer by the same procedure as for
the 3-4 synchronizer in the previous item.
/ TSB Revision
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21-28
MANUAL TRANSMISSION
- Tmnsmission
c26L
Ennine>
DISASSEMBLY AND REASSEMBLY (COUNTER SHAFT ASSEMBLY)
WIXE-11
i
Diissembly
4**+
*+*KL
steps
NOTE
(2) **
(3) ib+ : Refer to Service Points of Reassembly.
1. Counter front bearing

Counter center bearing
3. Counter shaft gear
132069
Taper bearing
SERWCE POINTS OF DISASSEMBLY

1.
REMOVAL OF COUNTER
CENTER BEARING
FRONT BEARINGM.
NzlxFAe
COUNTER
Removal the taper roller bearing from the end of the counter
shaft gear using the special tool.
&linder
Counter gear
,=,*
-

Steal q ioe
Inner diameter:
7-m
Outer Diameter:
(1.18 - 1.22 in.)
NZlXXMl
1. PRESSURE INSERTION OF COUNTER FRONT BEARINGM.

COUNTER CENTER BEARING
Pressure insert the taper roller bearing using a steel pipe with
the dimensions shown in the illustration.
Set the steel pipe so that it presses on the inner race only and
doesnt contact the bearing cage.
1 TSB Revision
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MANUAL TRANSMISSION
TFWNSMlSSlON
- Transmission
AND TRANSFER
and
Transfer
Assembly
ASSEMBLY
<3.OL
21-29
ENGINE>
<3.OL ENGINE>

Pre-removal
0 Removal
g-5;h)ift
l
0 eration
of P ransmission
and TransLever Knob (Refer to P.
Installation of Front and Rear Propeller Shaft (Refer to GROUP 16 -
Removal of Transfer Case Protector
Propeller Shaft.)
Supplying
of Transmission
Oil and
Installation of Front Exhaust Pipe

(Refer to GROUP 11 - Exhaust
0 Removal of Front Exhaust Pipe

0 Draining of Transmission
Oil and
l
N21MA-Z
Removal of Front and Rear Propeller Shaft (Refer to GROUP 16 Prooeller
Post-installation
Shaft.)
l
Pipe.)
Installation
tor
Installation
Operation
of Transfer
Case Protec-
of Transmission
and
Transfer Shift Lever Knob (Refer to

P. 21-52.)
30-42
Nm
18
Removal
4*
4+
++
I)+
4*
OSW561
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Dust seal guard

Ground cable
4WD indicator light switch connector
Speedometer
cable
Back-up light switch connector
Starter cover
Starter motor
Transmission stay (R.H.)
A
Transmission stay (L.H.)
Bell housing cover
B
C
14. Bolt
D
+I) ++
15. No. 2 crossmember

16. Engine mounting rear insulator
17. Transmission and transfer assembly
NOTE

(2) +I)
(3) l * : Refer to Service Points
Nm
ftlbs.
65-65
80-100
47-61
58-72
20-25
2230
27-34
3042
1 TSB Revision
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O.D. x Length
(7~
@
@
@
12x40(.5x1.6)
12x55(.5x2.2)
10x55(.4x2.2)
10x40(.4x1.6)
mm (in.)
to reinstall.
of Removal.
of Installation.
Bolt identification
@
DxL
21-30
MANUAL TRANSMISSION
- Transmission
and Transfer
Assembiv
<3.OL
Enaine>
NZIMBAN
7.
REMOVAL OF CLUTCH RELEASE CYLINDER

Referto P. 21-13.
9. REMOVAL OF STARTER MOTOR
Referto P. 21-13.
13. REMOVAL OF TRANSFAR MOUNTING
BRACKET
Refer to P. 21-13.
17. REMOVAL
OF TRANSMISSION
AND
TRANSFER
ASSEMBLY
Refer to P. 21-13.

17. INSTALLATION
OF TRANSMlSSlON
ASSEMBLY
Referto P. 21-13.
NZ,HDU
AND
TRANSFER
11. INSTALLATION
OF TRANSMISSION
STAY (L.H.)/lO.
TRANSMISSION
STAY (R.H.)
Transmission
stay installation
bolt size and torque are different and caution must be paid to ensure that they are properly installed.
Indicaiion for
hardness category
I I
No.
ront Q
Hardness category
dxl
(Head mark)
mm (in.)
72X35(.47X1.37]
65-65
(47-61)
10x30(.39x1.18)
33-50
W-36)
12x50(.47x1.96)
65-65
(47-61)
Right side
1 TSB Revision
Torque Nm
(ft.lbs.)
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MANUAL TRANSMISSION
T ransmission
and
DISASSEIVIBLY AND REASSEMBLY (TRANSMISSION

30-42
22-30
Disassembly
1.
2.
3.
4.
5.
6.
w
7.
++
8.
l + 9.
++ IO.
11.
12.
Transfer
Assembly
-SOL
21-31
Engine>
AND TRANSFER ASSEMBWA
Nm
ftlbs.
steps
13. Steel ball
Oil filler prug

Oil drain plug
Select plunger plug
Gasket
Select spring
Select plunger
Spring pin
Change shifter
Transfer case assembly
Adapter gasket
Plug
Spring
14.
15.
16.
17.
MT1 0002
Seal plug
Neutral return spring
Neutral return plunger
Neutral return plunger
(B)
(A)
NOTE
(2) l
(3) d
: Non-reusable
parts
NZIMGBN
10. ASSEMBLY OF ADAPTER GASKET/S.

ASSEMBLY/8.
CHANGE SHIFTER
CASE
Refer
7.
to P.Zl-16.
DRIVING
Refer
IN OF SPRING
to P.Zl-16.
1 TSB Revision
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PIN
TRANSFER
21-32
MANUAL TRANSMISSION
- Transmisrion and
Transfer Assembly
<3.OL Engine
ASSEMBLY)
24 Nm
17 Rltjs.
24 Nm
17 ftlbs.
/I
6
\
.__.
.
14 ft.lbs.
MT10003
Disassembly
I)+
1.
*+
2.
+a
3.
++
4.
I)+
5.
6.
7.
8.
9.
l 4 10.
++ 11.
+* 12.
13.
14.
steps
Adaptor cover
Adaptor cover gasket
Air breather
Spring pin
Transfer case adaptor
Seal ring
1st & 2nd gear shift jaw
3rd & 4th gear shift jaw
5th & Rev gear shift jaw
Gear shift lower case assembly
Clutch housing assembly
Oil Seal
Transmission power take off cover
Power take off cover gasket
( TSB Revision
NOTE
(1) Reverse the disassembly procedures to reassemble
(2) + : Refer to Servrce Points of Reassembly.
(3) b
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MANUAL TRANSMISSION
Transmission
and
Transfer
Assembly
<3.OL
Engine>
MT10008
Disassembly
15.
16.
17.
18.
19.
20.
21.
22*
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
steps
Locking nut
Lock piece
Reverse shaft
O-ring
Side washer
Needle bearing
Reverse gear
Snap ring
Ball bearing
Snap ring
Snap ring
Ball bearing
Snap ring
Ball bearing
Snap ring
Snap ring
Bali bearing
Main shaft assembly
Drive pinion
Pilot bearing
Transmission case
Reassembly
36.
35.
I)* 31.
+a 29.
+* 33.
+* 30.
+a 34.
.+ 32.
++ 27.
*+ 28.
++ 25.
.+ 26.
I)* 24.
I)+ 23.
** 22.
21.
20.
,+ 19.
18.
17.
16.
I)+ 15.
steps
Transmission case
Ball bearing
Snap ring
Drive pinion
Snap ring
Pilot bearing
Main shaft assembly
Snap ring
Ball bearing
Snap ring
Bali bearing
Snap ring
Ball bearing
Snap ring
Reverse gear
Needle bearing
Side washer
O-ring
Reverse shaft
Lock piece
Locking nut
NOTE
(I) l +
(2) I)*
(3) m

LTSB Revision
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21-33
21-34
MANUAL
TRANSMISSION
Transmission
and
Transfer
Assembk
<3.OL
Elaine>
SERWCE POINTS OF DISASSEMBLY
NzlYFLW
15. REMOVAL
OF LOCKING
NUT
Uncrimp the locking nut by using a screwdriver
sharp tip or a similar tool, and then use a special
remove.
with a
tool to
F1604A
17. REMOVAL
OF REVERSE SHAFT
Screw in (Ml2 x 1.25) the slide hammer
the reverse shaft.
tip and remove
MT10002
22J24.129.
REMOVAL
OF SNAP RING
Using the special tool, remove the snap rings.
Flb02A
23./26./28./31.
REMOVAL
OF BALL BEARING /25./27./3Q
SNAP RING
Remove the snap rings for all ball bearings, and then,
using the special tool, remove the ball bearings. In order
to avoid dropping
the countershaft
and damaging
the
teeth, etc., remove the bearings after first receiving at the
reverse gear part.
t&061400
F1603A
( TSB Revision
NOTE
Each bearing
must be removed
by changing
the kit
combination.
(Refer to 3. Special Tools.) The illustration
at the left shows the countershaft
part.
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MANUAL
TRANSMISSION
- Transmiaion
and
Transfer
Assemblv
<3.OL
21-35
Enaine>
33. REMOVAL
OF DRIVE PINION
Take out the drive pinion after first removing
shaft assembly from the transmission.
the main
NOTE
The diameter of the drive pinion gear is larger than the
transmission
cases ball bearing outer diameter,
so the
drive pinion must be removed from the inner side of the
transmission
case.
31. INSTALLATION
NOTE
The 29. snap
pinion
Main
BEARINGR9.
SNAP
RING
(I) Using the special tool. tap the ball bearing into the
drive pinion.
(2) Using the special tool, secure the ball bearing by the
snap ring.
,MH061400
Drive
OF BALL
NaPdam
ring is not to be installed.
33. INSTALLATION
OF DRIVE PINION/30.
SNAP RING/34.
PILOT BEARING/BZ.
MAIN SHAFT ASSEMBLY
(I) Insert the drive pinion from the inner side of the
transmission
case.
(2) Tap in the drive pinion by using a soft hammer so that
there is no damage at the transmission
case.
As shown in the illustration at the left, the tapping in
must be done until the ball bearing completely comes
out of the case.
(3) Install the snap ring to the ball bearing, and insert the
pilot bearing to the driver pinion.
(4) Insert the main shaft assembly from the inner side of
the case, and then insert into the pilot bearing part of
the drive pinion.
(5) Using the special tool, press-in the drive pinion until
the bearing part snap ring contacts the transmission
case.
shaft
F1606A
NOTE
In order to prevent pilot bearing damage at the time of
insertion, the main shaft assembly should be raised to
the center of the shaft.
28. INSTALLATION
OF BALL
BEARINGI27.
SNAP
RING
(I) Install the snap ring at the outer circumference

of the
bail bearing.
(2) Using the special tool, press-in the ball bearing until
the snap ring and case contact.
MH061400
F1.60 7A
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21-36
MANUAL TRANSMISSION
- Tmnsmiasion
and
Transfer
AssembIy
<3.OL
Engine>
26. INSTALLATION
OF COUNTER SHAFT BALL BEARING
(FRONT)/24./25.
SNAP RING
(1) Install the snap ring to the ball bearing.
(2) While using the special tool to hold the rear part of the
counter shaft, use the special tool to press in.
(3) Using the special tool, install the snap ring to the
counter shaft and secure the bearing.
(4) Remove the counter shafts dummy bearing.
F1609A
23. INSTALLATION
OF COUNTER
SHAFT BALL BEARING
(REAR)&?.
SNAP RING
(1) Using the special tool, press-in the ball bearing.
(2) Using the special tool, install the snap ring to the
counter shaft and secure the bearing.
F1610A
19. INSTALLATION
OF SIDE WASHER
Install the side washer so that the
groove of the transmission
case.
bent
15. INSTALLATION
OF LOCKlNG
NUT
(1) Using a special tool, tighten
the
specified
torque.
-
part
lock
is in the
nut
at the
(2) After tightening,

the groove of the main shaft must be
crimped securely at two places.
F1608A
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MANUAL TRANSMISSION
- Tmnsmisrion
and
Tmnsfer
Assembly
<J.OL
21-37
Engine>
12. INSTALLATION
OF OIL SEAL
Using the special tool, press the oil seal into the clutch
housing.
71. INSTALLATION
HOUSING
(I) Apply a coating

of sealant
installation
surface.
eal installer
Specified
II
OF CLUTCH
sealant
F1624A
(2) Apply
of the
(3) Install
install
ASSEMBLY
to the
clutch
: Mitsubishi
genuine
Part No. MD997740
equivalent
housing
sealant
or
a coating of multipurpose
grease to the lip part
oil seal.
the special tool to the drive pinion, and then
to the clutch housing.
F1625A
IO. INSTALLATlON
OF GEAR SHIFT LOWER CASE ASSEMBLY
Apply a coating of sealant to the installation surface of the
gear shift lower case, and then install.
Specified
5.
Sealant
sealant
or equivalent
INSTALLATION
OF TRANSFER
CASE ADAPTER
(I) Apply a coating of sealant to the installation surface of
the transmision
case.
Specified
Transmission case
\
: Mitsubishi
genuine
Part No. MD997740
sealant
: Mitsubishi
Part No.
equivalent
genuine
MD997740
sealant
or
(2) Align the shift rails with the shift rail holes in the
transfer case adapter, and provisionally
install.
(3) After installing each shift jaw from the adapter cover
holes in the transfer case adapter to each shift rail,
install the transfer case adapter.
Shift rail
lnkallation bolts
1 TSB Revision
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21-38
MANUAL TRANSMISSION
Slit (facing forward

or backward)
Tap in until flush.

/
4.
Transmission
and
Transfer
Assembly
<3.OL Engins>
INSTALLATION
OF SPRING PIN
Using a pin punch, tap in the spring
pin.
NOTE
Tap in to the end of the shift jaw so that the slit faces
forward or backward.
F1595A
3.
INSTALLATION
OF AIR BREATHER
(1) Install the breather with the identification
the rear.
mark toward
Rear of transmission
F1596A
2.
INSTALLATION
OF ADAPTOR
COVER
GASKET/l.
ADAPTOR COVER
Apply a coating of sealant to the installation surface of the
adapter cover, and then install.
Specified
sealant
1 TSB Revision
: Mitsubishi
genuine
Part No. MD997740
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sealant
or equivalent
MANUAL
TRANSMISSION
Transmission
and
Transfer
Assemblv
-S.OL
Engine>
DISASSEMBLY AND REASSEMBLY (MAIN SHAFT ASSEMBLY)
E1612A
ii
Disassembly
e+
1.
2.
3.
4.
l + **
5.
+4
6.
7.
I)+
8.
9.
10.
11.
12.
++ ++ 13.
I)+ 14.
15.
I)+ 16.
17.
4*
18.
+*
19.
I)+ 20.
steps
Thrust washer
0.D gear
Needle bearing
Synchronizer ring
Snap ring
Synchronizer sleeve
Shifting key
Shifting key spring
Synchronizer hub
Reverse gear
Needle bearing
Synchronizer ring
Snap ring
Synchronizer sleeve
Shifting key
Shifting key spring
Synchronizer hub
3rd gear
Needle bearing
Thrust washer
21. Steel ball

l * l * 22. Snap ring
e* 23. Thrust washer
24. 2nd gear
25. Needle bearing
*+ l * 26. Snap ring
I)* 28. Synchronizer sleeve
29. Shifting key
l * 30. Shifting key spring
31. Synchronizer hub
32. 1st gear
33. Needle bearing
34. Main shaft
NOTE
(4) q : No-reusable parts
TSB Revision
http://vnx.su/
21-39
21-40
MANUAL TRANSMlSSlON
T mnsmission
and Tmnsfer
Assembly
<3.OL Engine>
SERVICE POINTS OF DiSASSEMBLY

5./13./22./26.
REMOVAL
OF SNAP RING
Using
the special
tool,
remove
each
NZWFAB
snap ring.
MH061002
F1614A
17./l&
REMOVAL
OF 3RD GEAR, 3RD AND 4TH SYNCHRONIZER
HUB
Using the special tool, remove 3rd gear and the 3rd & 4th
synchronizer
hub.
3rd %=r
F1615A
N2woAs
INSPECTION
o
l
Check synchronizer
ring for worn and damaged
internal
threads.
With synchronizer
assembled to cone of each gear check
dimension A. If dimension A exceeds the limit replace
the synchronizer
ring and/or gear
Limit
1 Synchronizer
: 6.2 mm
(.009
in.1
ring
N.nFwA*
30./16./8.
INSTALLATION
OF SHIFTING
KN SPRING
Install so that the open part of the shifting key spring is as
Shifting
key spring
Shifting
key (3 places)
F0581A
28./14./6.
INSTALLATION
OF SYNCHRONIZER
SLEEVE
Assemble
each synchronizer
sleeve so that the shifting
keys are at -each of the- three places indicated by the *
symbols in the illustration.
F0582A
http://vnx.su/
MANUAL TRANSMlSSlON
T qnsmission
and
Transfer
Assembly
c3.OL
Engine>
21-41
26./22./13./5.
INSTALLATION
OF SNAP RING
Install each snap ring by using the special tool. (Refer to
the section concerning
removal.)
23./20./l.
INSTALLATION
OF THRUST WASHER
Install each thrust washer so that the surface in which
there are oil channels faces toward the gear side.
Oil channel
F0583A
DISASSEMBLY AND REASSEMBLY (COUNTER SHAFT ASSEMBLY)
Disassembly
steps
1. OD
**
l +
gear
2. Snap ring
3. Counter shaft
NOTE
(1)
(2)
(3)
(4)

procedures
to reassemble.
+e
: Refer to Service Point of Disassembly.
w
: Refer to Service Point of Installation.
q : Non-reusable parts
SERVICE
POINT
REASSEMBLY
2.
)B
F1616A
OF
DISASSEMBLY
AND
N21XF.G
REMOVAL
AND INSTALLATION
OF SNAP RING
Using the special tool, remove the snap ring from
counter shaft.
Installation
is in the same way.
Revision
http://vnx.su/
the
21-42
MANUAL TRANSMISSION
T ransmission and
Transfer
Assembly
c3.OL
Engine>
DISASSEMBLY AND REASSEMBLY (LOWER CASE ASSEMBLY)
Disassembly
++ *+
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
N21.7K..
steps
Backup lamp switch
Screw plug
Puppet spring
Steel boo1
Screw plug
Puppet spring
Steel boo1
Dust plug
Spring pin
Gear shift fork
5th b Rev. shift rail
Gear shift fork
3rd b 4th shift rail
3A Gear shift fork
1st b 2nd shift rail
Gear Shift lower case
SERVICE POINT OF DlSASSEMBLY

9.
REMOVAL
OF SPRING PIN
Using a pin punch, tap out the spring
F1620A
pin.
SERVICE POINT OF REASSEMBLY
Shift fork
9.
INSTALLATION
OF SPRING PIN
Using a pin punch, tap in the spring
pin.
NOTE
Tap in until the shift fork end, and so that the slit faces
forward or backward.
$lit
F1621A
1 TSB Revision
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MANUAL
TRANSMISSION
- Transmission and Transfer Assembly
DISASSEMBLY AND REASSEMBLY (TRANSFER ASSEMBLY)
21-43
WIMRIF
30-42 Nm
22-30 Ribs.
II-15
Disassembly
++
l *
l +
+a
l *
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
ftlbs.
steps
16.
17.
I)+ 18.
+* 19.
** 20.
l * 21.
22.
Sleeve clamp
Speedometer gear assembly
4WD indicator light switch
Gasket
Steel ball
Rear cover
Rear cover gasket
Spacer
Dust seal guard
Oil seal
Spring pin
Seal plug
Poppet spring
Steel ball
H-L shift rail
Interlock plunger
Pulse generator
Cover
Cover gasket
Spacer
Wave spring
Pulse rotor
NOTE
(I) Reversethe disassembly procedures to reassemble
(2) *+I : Refer to Service Points of Reassembly.
1450027
,
TSB Revision
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MANUAL
TRANSMISSION
- Transmission
3042 Nm
22-30 ft.lbs.
46
Disassembly
++
+a
++
+* I)+
4+ ++
4+
+e
++
41)
I)+
+4
++
+4
++ ++
+4
++
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
steps
Snap ring
Chain cover
Chain cover gasket
Oil guide
Side cover
Side cover gasket
Lock plate
Counter gear shaft
O-ring
Counter gear
Thrust washer
Needle bearing
Bearing spacer
Snap ring
Spring retainer
Spring
Spring retainer
Spring pin
24WD shift rail
Distance piece
2WD4WD
shift lug
Output shaft assembly
2-4WD shift fork
H-L shift fork
H-L clutch sleeve
Needle bearing
1 TSB Revision
53
w 49. Snap ring
M 50. Input gear assembly
l 4 51. Oil seal
52. Baffle plate
53. Dust seal guide
** 54. Oil seal
55. Transfer case
NOTE
(1) Reversethe disassembly procedures to reassemble.
(2) +* : Refer to Service Points of Disassembly.
(4) m : Non-reusable parts.
http://vnx.su/
MANUAL
TRANSMISSION
- Transmission
and
Transfer
Assemblv
21-45
SERVICE
POINTS
OF DISASSEMBLY
29. REMOVAL OF LOCK pLATE/30. COUNTER GEAR SHAFT
Remove the lock plate and pull out the counter gear shaft.
32. REMOVAL OF COUNTER GEAtU33. THRUST WASHER/

34. NEEDLE BEARING/BB. BEARING SPACER
Remove the counter gear, two thrust washers, two needle
bearings and the spacer through the side cover opening.
Thrust washer
Count&
gear
144011~
44. REMOVAL
OF OUTPUT SHAFT ASSEMBLY
Remove the front output shaft, rear output shaft and chain
together.
SERVICE
POINTS
OF REASSEMBLY
54. INSTALLATION
OF OIL SEAL (FRONT OUTPUT SHAFT)
Apply transmission
oil to the lip of the oil seal and pressure
insert it.
Specified
Specified oil
oil:
Hypoid
higher
gear oil API classification

GL-4 or
SAE viscosity
SOW, 75W-85W
144018
51. INSTALLATION
OF OIL SEAL (INPUT GEAR)
Apply transmission
oil to the lip of the oil seal and pressure
insert it.
Specified
144019
oil:
Hypoid
higher
gear oil API classification

GL-4 or
SAE viscosity
SOW, 75W-85W
TSB Revision
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21-46
MANUAL TRANSMISSION
Transmission
50. INSTALLATION
(I) Insert the
and fasten
(2) Select the
and install
Standard
and
Transfer
Assemblv
OF INPUT GEAW46. SNAP RING

input gear assembly into the transfer case
it with the snap ring.
thickest snap ring that will fit into the groove
it.
value
: O-0.06 mm (O-.002 in.)
47. INSTALLATION
OF H-L CLUTCH SLEEVE/46. H-L SHIFT
FORK
(I ) Install the H-L clutch sleeve and H-L shift fork.
(2) Make sure the direction of the sleeve is correct.

The
direction of the sleeve is the same for both 2WD and
4WD.
Front
44. INSTALLATION
OF OUTPUT SHAFT ASSEMBLY
(1) Engage the chain precisely with the sprockets of the
rear output shaft and the front output shaft.
(2) Install the 2-4WD shift fork on the 2-4WD clutch sleeve.
While passing them along the 2-4WD shift rail, install
the rear and front output shaft and chain.
35. INSTALLATION
OF BEARING
SPACER/
34. NEEDLE
BEARING/ 33. THRUST WASHER/ 32. COUNTER GEAR
(1) Assemble the needle bearings (2 PCS) in the counter
gear, then after inserting the spacer, install the counter
gear inside the transfer case.
(2) Place thrust washers on the front and rear of the
counter gear.
Thrust washer
Revision
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MANUAL
TRANSMISSION
Transmission
and
Transfer
21-47
Assembly
30. INSTALLATION
OF COUNTER GEAR SHAFT/ 29. LOCK
PLATE
(1) insert the counter shaft, being careful of the direction of
the groove in the locking plate.
(2) Install the lock plate.
26. INSTALLATION
OF OIL GUIDE/
25. CHAIN COVER
GASKET/ 24. CHAIN COVER
(I) Install the oil guide.
(2) Apply sealant to the gasket, then affix it to tha transfer
case.
Specified
sealant:
3M ART Part
or equivalent
NO.
8666
(3) Install the chain cover so that the end of the oil guide
enters the window in the chain cover.
21. INSTALLATION
OF THE WAVE SPRING/ 20. SPACER/ 19.
COVER GASKET/ 18. COVER
(1) Measure the amount of front output shaft rear bearing
thrust (A) and the covers indentation (B).
If the clearance exceeds 2 mm (.08 in.), insert spacer at
the place shown in the figure.
(2) Apply a coating of sealant to both surfaces of the cover
gasket, and attach it to the chain cover.
4-B
3
Wave
Specified
(3) Apply a coating

cover installation
Specified
spring
Spacer
145105
sealant:
1 TSB Revision
http://vnx.su/

or equivalent
of sealant to the threaded
bolt, and then tighten it.
adhesive
: 3M Adhesive
or equivalent
part of the
Nut Locking
4171
21-48
MANUAL
TRANSMISSION
- Transmission
and Transfer
Assembly
11. INSTALLA-I-ION
OF SPRING PIN
(1) Align the H-L shift rail spring pin hole, and then use the
special tool to drive it in.
(2) Drive in so that the slit is parallel with the axial
direction of the shift rail.
&Y!
8. INSTALLATION
OF SPACEFW. REAR COVER GASKET/G.
REAR COVER
(1) Measure the amount of protrusion of the rear output shaft
rear bearing A and the amount of inset in the cover B.
Select a spacer which adjusts the end play to the standard
value:
Standard value : 0 - 0.1 mm (0 - .6&I in.)
(2) Apply sealant to both sides of the rear cover gasket and
affix the rear cover gasket to the chain cover.
Specified
Sleeve
Extension
housi
M&g
2.
sealant:

or equivalent
INSTALLATION
OF SPEEDOMETER GEAR ASSEMBLY
Match the mating marks to the number of teeth on the speedometer
driven gear and install the speedometer
gear
assembly.
marks
http://vnx.su/
MANUAL TRANSMISSION
DISASSEMBLY
AND
REASSEMBLY
- Transmission
(OUTPUT
SHAFT
ASSEMBLY]
7. Chain
l a 2. Snap ring
l + 3. Clutch hub (H-L)
++
4.
5.
6.
7.
Bearing spacer
Low speed gear
Needle bearing
Lock nut
*+16.
17
c*
8.
9.
10.
11.
12.
13.
14.
l *l 5.
Radial ball bearing

Sprocket spacer
Steel ball
Drive sprocket
Needle bearing
Sprocket spacer
Steel ball
Clutch sleeve
+I)
Clutch hub (2-4WD)

4tnnnar
date
19. Rear o&M shaft

20. Bearing
21. Front output shah
NOTE
(2) l e : Refer to Service Points of Disassembly.
(3) ,*
(4) q
: Non-reusable
parts

8. REMOVAL OF RADIAL BALL BEARINGI18.
Pull the bearing out using a press.
evision
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BEARING
21-50
MANUAL
TRANSMISSION
- Transmission
and Transfer
Assembly
20. REMOVAL OF BEARING

Pull out the bearing using a press.
Front
45 30
Sleeve
Hub
16. INSTALLATION
OF CLUTCH HUB (2-4WD)/15.
CLUTCH
SLEEVE
Assemble the hub and sleeve as shown in the illustration.
14%?33
7. INSTALLATION
OF LOCK NUT
After tightening the lock nut at the proper torque, crimp the
lock nut in the groove in the output shaft at the location shown
in the illustration.
148008
mvse=-
Front
3. INSTALLATION
OF CLUTCH HUB (H-L)/Z. SNAP RING
(1) Install the clutch hub in the direction shown in the illustration
144023
(2) Select the thickest snap ring that will fit into the groove in
the front end of the rear output shaft and install it.
1 TSB Revision
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,.:
s.
E_
% 1..
e--m-~
&I
p; -:~
MANUAL TRANSMISSION
IISASSEMBLY
AND
REASSEMBLY
Transmission
(INPUT
and
SHAFT
Transfer
21-51
Assembly
ASSEMBLY)
NZIMlBl
Disassembly
*al.
l ***2.
steps
Snap ring
Bearing
3. Spacer
4. Snap ring
5. Cone spring
6. Sub gear
7.
Input gear
NOTE
(2) l , : Refer to Service Points of Disassembly.
(3) l * : Refer to Service Points of Reassembly.
(4) j : Non-reusable parts
145109

2.
REMOVAL
OF BEARING
Support the bearing on a press, then press on the front of the

input gear and pull out the bearing.

2.
PRESSURE INSERTION OF BEARING

(I) Pressure insert the bearing into the input gear. Be sure to
press the inner race.
(2) After pressure insertion, make sure that the bearing turns
smoothly.
1. INSTALlATlON
OF SNAP RING
Select the thickest snap ring that will fit into the groove in the
front end of the input gear and install it.
DISASSEMBLY AND REASSEMBLY (SPEEDOMETER SLEEVE ASSEMBLY)

Disassembly
steps
l * 1. Spring pin
2. Driven gear
4. O-ring
5. O-ring
3. Sleeve
NOTE
(2) +4 : Refer to Service Points of Reassembly.
1 TSB Revision
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WIRE-C
21-52 MANUAL
TRANSMISSION
Transmission
and
Transfer
Assembly
/ Gear&ii
Lever
Assembly
1. INSTALLATlON
OF SPRING PIN
Drive spring pin in while making sure that slit does not face
gear shaft.
Spring
NOTE
Do not reuse spring pin.
C-ring
llael?

Removal
+a
41) I)+
41) I)+
Ip(lWM2
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Transmission shift lever knob

Transfer shift lever knob
Front floor console
Control lever cover
Transmission control lever assembly
Gasket
Stopper plate
Gasket
Control lever bush
Transfer control lever assembly
( TSB Revision
11.
12.
13.
14.
15.
16.
Control
housing cover
Gasket
Control housing
Gasket
Front floor console
Shift lever boot
reinforcement
NOTE
(2) 4* : Refer to Service Points of Removal.
(3) l *
Refer toService Points of installation.
(4) q : Non-reusable pans
http://vnx.su/
MANUAL TRANSMISSION
- Gearshift
Lever
21-53
Assembly
N.?lGBIv)
SERVlCE POINTS OF REMOVAL

5.
REMOVAL
OF TRANSMISSION
CONTROL LEVER ASSEMBLY/IO.
TRANSFER CONTROL LEVER ASSEMBLY
Remove the control lever attaching bolts and detach the
control lever assembly.
Caution
When the control lever assembly
is removed, keep the
transmission
control lever and the transfer control lever
in the following
positions.
Transmission
control lever - Neutral position
Transfer control lever - 2H (a-wheel
drive - high
range) position
After the control
lever assembly
has been removed,
cover with a cloth to prevent entry of foreign substances
into the extension
housing.
INSPECTION
ontrol
lever 8
H1IGCAAl
Check for play between control lever and control lever 8. If

play is evident, replace lever assembly.
Push control lever in and check to ensure that it moves
smoothly up and down.
Check the cover for damage and replace if necessary. To remove cover, cut away with knife. To install new cover, first
apply thin coat of oil to periphery of control lever B. Then
install by sliding it down from top of lever B.
Check the lever bushing for wear and replace if necessary.
l
l
N2lGOAFa

10. INSTALLATION
OF TRANSFER
SEMBLY
(1) Check to be sure that the
installation
part (transmission
CONTROL
LEVER AS-
transfer lever assembly

side) is at the position
OQB0027
(2) When assembling,

Apply the specified
Specified
sealant:
replace the gaskets.

sealant to both sides of gasket.
or equivalent
(3) Apply the multipurpose

grease
control lever sliding surface;
1 TSB Revision
http://vnx.su/
generously
to transfer
21-54
MANUAL TRANSMISSION
-
5.
Gasket
- Gearshift
Specified
Lever
-.
bushing
Transfer
sealant:
Spring
Transfer
Vehicle
Shift pattern
\
3M ART Part
or equivalent
No. 8660

grease generously
to both
inside and outside
surfaces
of lever bushing
and
control lever sliding surface.
D~~,JOI
shift lever
Assembly
INSTALLATION
OF TRANSMISSION
CONTROL LEVER
ASSEMBLY
(1) When assembling,
replace the gaskets.
Apply specified sealant to both sides of each gasket.
I
Jontrol /lousing
Lever
2.
washer
INSTALtiTlON
OF TRAf&FER
SHIFT
LEVER
KNOB
(1) After manually screwing the nut all the way to the end
of the threaded part ofthe shift lever, return it about a
half turn and install the spring washer.
shift lever
09wo32
(2) After turning the shift lever knob about one turn
beyond where the spring washer begins to yield, screw
in further and adjust until the shift pattern on the knob
faces the front of the vehicle.
front
NOTE
If the adjustment
cannot be made as described in (2)
above, first screw the- shift lever all the way in, and
then return about one turn to make the adjustment.
) TSB Revision
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~~
MANUAL
DISASSEMBLY
AND
TRANSMISSION
REASSEMBLY
1. Bolt
2. Control housing cover
W+ 3. Control housing cover gasket
4. Transfer control lever
5. Transmission control lever
l r 6. Gasket
7. Stopper plate
8. Nut
9. Spring washer
+*lO. Stopper bracket assembly
11. Return spring
l *12. Special bolt
13. Control housing
- Gearshift
(CONTROL
LEVER
Lever Assembly
ASSEMBLY)
21-55
NzlGE-
9-
8
7
15-22 Nm
II-15
145042
ft.lbs.
NOTE
(2) e+ : Refer to Service Points of Reassembly.
INSPECTION
l
Check for play between control lever and control lever yyf
play is evident replace lever assembly.
Push control lever in and check to ensure that it moves
smoothly up and down.
Check cover for damage and replace if necessary. To remove
cover, cut away with knife. To install new cover, first apply thin
coat of oil to periphen/ of control lever B. Then install by
sliding it down from top of lever B.
Check lever bushing for wear and replace if necessary.
ntrol lever cover
&Lever
bushing
I
1 TSB Revision
http://vnx.su/
21-56
MANUAL TRANSMISSION
Gearshift
Lever
Assembly
-.SERVICE POINTS OF REASSEMBLY

r
bracket
assembly
NZIGHAG
12. INSTALLATlON
OF
SPECIAL
BOLT/IO.
STOPPER
BRACKET ASSEMBLY
(1) Apply sealant to peripheries (except threaded portions) of
two special bolts and install them to cover. Do not wipe
away excess sealant from cover.
Specified
sealant:
3M ART Part
or equivalent
No. 8660
(2) Mount stopper bracket assembly and apply adhesive

threaded portions of special bolts.
Specified
to
: 3M Scotch Grip No. 2353

or equivalent
(3) Check to ensure that reverse resistance plate moves
smoothly in directions A and B shown in illustration and is
brought back by return spring.
6.
sealant
INSTALLATION
OF GASKET/B.
CONTROL
COVER GASKET
(1) Apply specified sealant to both surfaces
kets.
Speciiied
sealant:
1 TSB Revision
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HOUSING
of

or equivalent
I =~
the gas-
21-I
TRANSMISSION
MANUAL
AND AUTOMATIC
r&?,AA-
CONTENTS
............ 57
...........................
GENERAL INFORMATION
SERVICE ADJUSTMENT
PROCEDURES
.....
......
............
Speedometer
Cable Replacement
.......
Throttle Cabel Check and Adjustment
Transmission
Fluid and Transfer Oil
...........................
Changing and Inspection
SPECIAL TOOLS ...........................................
.........................................
SPECIFICATIONS
...............................
Lubricants
..................................................
............ _______._
____
-_.
...............................
...... ..- ............. .._......
MANUAL TRANSMISSION
57
88
89
89
89
88
76
69
69
75
75
70
74
TRANSMISSION
AND TRANSFER
95
...................................................
ASSEMBLY
........................
90
TRANSMISSION
CONTROL
....................
163
TRANSMISSION
OIL COOLER
...................................
77
TROUBLESHOOTING
Converter Stall Test .................................
_. 84
...................
77
Fluid Level and ATF Condition
77
General ......................................................
Governor Pressure Test ..........................
___ 84
84
Hydraulic Pressure Test .............................
78
Inhibitor Switch ..........................................
.........................................
78
Manual Linkage
Overdrive Control System Circuit ..............
86
79
Road Test ..................................................
Selector Lever .....................................
..-. ___ 78
Throttle Control Cable ..............................
__ 78
http://vnx.su/
..................
..................
...........................
GENERAL INFORMATION
.....
SERVICE ADJUSTMENT
PROCEDURES
......
............
Speedometer
Cable Replacement
Transmission and Transfer Oil Changing
...........................................
and Inspection
SPECIAL TOOLS ...........................................
.........................................
SPECIFICATIONS
...............................
Lubricants
..................................................
.............................
...............................
................................
TRANSMISSION
AND TRANSFER
.......................
ASSEMBLY <2.6L ENGINE>
TRANSMISSION
AND TRANSFER
.......................
ASSEMBLY <3.OL ENGINE>
...................................
TROUBLESHOOTING
Gears slip out
Noise, Vibration
Oil is leaking
Shifting gears is hard or troublesome
2
52
2
IO
II
11
IO
8
3
3
7
7
3
5
12
29
10
AUTOMATIC
AUTOMATIC
GENERAL
TRANSMISSION
TRANSMISSION
INFORMATION
1 TSB Revision
http://vnx.su/
General
information
21-57
http://vnx.su/
&To
372087
cooler
Throttle
II--------
1 &/e%al~
clutch,
Direct
Brake
No.1
Brake
No.2
i2.F
0
c=J
OD
solen
vatve
N (Neutral)
Governor pressure
Converter pressure, Lubrication
D-2 down
oil pressure
Thmttle pressure
@ii1 Cut beck pressure
Line pressure
Detent regulator
pressure, Intermediate
mcduiator pressure, Low coast modulator
pressure
5
ii
http://vnx.su/
-=7 372088
To cooler
11 Secondawlla
1111 1
IIcut II PresI II
Overdrive
clutch
_ __
brake
Forward
clutch
!dIITbl
clutch
Brake
No.1
I
Brake
Ny.2
Brake
No.3
Low coast
modulator
Ill
0
m
m
a
m
0
II
P (Parking)
Ilshift valve II II
shift v&n
D2 down
timing valve
Line pressure
Detent regulator
pressure. Intermediate
modulatolr pressure, Low coast modulator
pressure
Throttle pressure
cut back pressure
Governor pressure
Converter pressure, Lubrication oil pressure
http://vnx.su/
372089
3gulaiol
alve
modulator valve
0
m
m
0
D-l (DRIVE 1ST)
Line pressure
Detent regulator
pressure,
Intermediate
modulator pressure, Low coast modutator
pressure
Throttle pressure
Cut beck pressure
Governor pressure
Converter pressure, Lubrication oil DWWIIP
AUTOMATIC
TRANSMISSION
- General
information
27-61
) TSl3 Revision
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..
21-62
AUTOMATIC
TRANSMISSION
1 TSB Revision
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General
Information
AUTOMATIC
TRANSMISSION
( TSR Revision
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General
21-63
Information
http://vnx.su/
To cooler
1+
rimary
aulato
he
Overdrive
Direct
cl*ftch
Brake
Nq.3
Ii
Ii
;e clutch
we valve
0
E&i
m
0
m
0
#!J
D-4 (DRIVE 4TH)
D-2 down
timing vatve
Line pressure
Detent regulator
pressure, Intermediate
modulator pressure, Low coast mo4iulator
pressure
Throttle pressure
Cut back pressure
Governor pressure
Converter pressure, Lubrication oil pressure
AUTOMATIC
TRANSMISSION
1 TSB Revision
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General
information
21-65
21-66
AUTOMATIC
TRANSMISSION
TSB Revision
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General
Information
AUTOMATK
TRANSMISSION
- General
information
E
-I-----
1 TSB Revision
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ii
21-67
--
21-68
TSB Revision
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General
information
AUTOMATIC
TRANSMISSION
Specifications
21-69
SPEClFlCATlONS
Specifications
terns
btomatic transmission
-0rque converter
and transfer case model
KM1 48-6-FSI
Type
Stall torque ratio
3 elements, 1-step 2-phase system

2.02
One-way clutch
$mg We
iransmission
-orward 4 gears, reverse 1 gear, single-line planetary
gear and Simpson planetary gear
Type
Control elements
Clutch
Brake
One-way clutch
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
Reverse
Shift control method
Select pattern
blultiple disc type

3 pairs
4 pairs
Llultiple disc tyep
3 pairs
Swag tVpe
2.826
1.493
7.000
0.688
2.703
Floor shift type
P-R-N-D-2-L and overdrive switch
Oil pump
Type
Drive system
Hydraulic control system
Oil-cooling system
Gear type
Directly coupled to engine via torque converter
Throttle opening and vehicle speed detection
Air-cooled system + water-cooled system oil cooler
(secondary cooling method)
Transfer
Type
Shift control method
Shift ratios
Always-engaged
LOW
HIGH
Speedometer
1.944
Single-lever floor-shift type
1.000
gear ratio
type
2618
http://vnx.su/
Transmission
number
marking
position
Specifications
and designation
D N 6
q -IXI~
T-TT
[ Serial number
per month1
Fixed number
(Mitsubishi exclusive
Transmission number
head number)
1 Classification
N.: AW372
of type
1 Manufacturing
month
year
A: January
P: April
M : December
1 Manufacturing
88:
1988
Items
2100-2400
Stall speed (rpm)

Sovernor pressure
1000 rpm
Standard
kPa (psi)
133-l 63
(19.4-23.6)
251-281
(36.4-40,6)
400-430
(58-62.2)
2000 rpm
3000 rpm
-ine Pressure kPa (psi)
D range
When idling
510-590
(74-35)
1080-I 280
( 156-I 85)
During stall
R range
When idling
770-890
(112-130)
1570-I 960
(227-285)
During stall
/ TSB Revision
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Limit
Items
1
Input shaft end play
Oil pump
Side clearance
Body clearance
Standard
mm (in.)
0.02-O-65
(.0008-.0020)
0.07-0.15
(.0028-.0059)
0.1 l-0.14
(.0043-.0055)
mm (in.)
mm (in.)
Clutch and brake piston stroke

Overdrive clutch(CO)
mm (in.)
I .56-2.53
(.0614-.0996)
1.43-2.93
(.0563-.1154)
0.91-I .99
(.0358-.0783)
0.80-I .73
(.0315-.0681)
1 .Ol-2.25
(.0398-.0886)
Forward clutch (C)

Direct clutch (C2)
No. 1 brake (B)
No. 2 brake (EP)
Brake clearance
mm (in.)
Overdrive brake (B)
0.65-2.21
(.0256-.0870)
0.61-2.64
(.0240-.I 039)
No. 3 brake (B3)

Transfer
mm (in.)
input gear bearing end play

Input gear end play
Limit
0.3-0.9
(.012-.035)
mm (in.)
Tip clearance (driven gear)
21-71
- Specifications
O-O.08
(o-.003)
O-0.06
(O-.002)
O-0.06
(O-.002)
mm (in.)
mm (in.)
Transmission control
Sleeve and selector lever clearance
mm (in.)
1 TSB Revision
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15.2-l 5.9
(.60-.62)
(.004)
0.3
(012)
0.3
(012)
I ..
21-72
Spring
AUTOMATIC
TRANSMlSSlON
- Specifications
identification
mm (in.)
Identification
color
Free
height
Outside
diameter
Number
of loops
Wire
diameter
1-2 shift valve spring
34.52
7.56
13.0
0.56
Pressure-relief valve
spring
32.14
13.14
9.0-
2.03
Primary regulator valve

spring
65.56
17.2
'13.0
1 .a
LIGHT BLUE
35.18
10.6
145
1.1
GREEN
Oil cooler bypass valve

spring
28.9
13.8
6.5
1.6
ORANGE
Damping check valve

spring
20.0
4.97
.-
16.0
0.40
2-3 shift timing valve

spring
35.10
8.96
12.5
0.76
WHITE
Reverse clutch sequence

valve spring
37.55
9.2
14.0
1.2
RED
low-coast modulator
valve spring
42.35
9.24
15.0
0.84
Detent regulator valve
31.39
8.85
13.5
0.90
ORANGE
14.4
0.90
RED
Spring
Valve body springs

-ower valve
oody
3ear upper
/alve body
Intermediate
valve spring
modulator
35.43
8.8
._-
?ont upper
/alve body
Xtch
Throttle valve spring
21.94
8.58
8.0
7
0.71
Down shift plug spring
39.76
10.83
11.5
1.2
Secondary regulator
valve spring
71.27
17.43
15.0
1.93
GREEN
.~~
-.
and brake return springs
Overdrive and forward clutches
PURPLE
15.10
-8.0
5.5
1.1
RED
-
Iirect clutch
15.10
8.0
5.5
1.1
3rake
16.12
8.0
6.0
1.0
1 TSB Revision
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RED
AUTOMATIC
TRANSMISSION
21-73
- Specifications
mm (in.)
Free
height
Spring
Accumulator
Cl
C2
Clutch
Brake
Wire
diameter
No. 1
64.68
17.5
18.5
4.0
2.0
No. 1
32.2
14.7
6.5
1.6
ORANGE
No. 2
43.56
14.3
9.45
1.8
BLUE
20.4
12.0
3.2
LIGHT
GREEN
/
66.68
of clutches,
brakes
and accumulators
of discs
__...... Co .. .. . ..__..__.___
.____
__..__..______._
________
________
___._____
.___
_____._._____
2
Cl
. . .. .. . .. . .. .. .. . . .. .. . .. .. . . .. .. . .._...__..._..._.._.__..~
-.... _.--.__._..-. __. 5
Cz . .._.....__...................... ________
___.__.
_..__-__.._
.__._______.__
__.__ 3 (single piston)
.._...... Bo __..__...__.__..
__.___._...__.__..__.......
_______
_.__..__.__._..___._..........3
Bl . . .. ..._._. . .._.._._._.___.__________..._........
_.___..__.__.__._
____._...__.._2
Bz . . ..._.......__.__________._
____.___
_.___.__..._._.____..__
_.._...__.._._.._.__.3
8s ._..I.__._.._______.__
.__.___..__..__...._~...~.~
___
__.____
_____._
_..__...I_.__ 5
Accumulator
piston OD x Length
Bz .. . . .._.._. .. . .. .. . .. ..._____________
._.__.,........._._.............. _._.............._._........ __.__ 34.8 x 48.5 mm (1.370 x 1SOS in.)
. . . . . . . . . . _. . . . . . . . . . . . . . . . . . . . . ._ . . . . _.._..._..__ . . . . . . . . . . . . _. ..-.
__.____-.-.-_..-._ . .._..... _ 31.8 x 45.0 mm (1.252 x 1.772 in.)
Cl .. . .. .. . .. .. . . .. _.__.-___
_____
______
_......._... ____________._
.._____....._.........___________._____
31.8 x 49.5 mm (1.252 x 1.949 in.)
cz
Accumulator
Identification
color
-1
a2
Number
Number
of loops
springs
Identification
Outside
diameter
piston spring
82 . .. .. .._..__..__._
__.__..._...______
.. . . ___.__.._...._.._..._..
_.. . .. .. ..-.. _. .._._..._..._.._._...... Single
Cz __.___-_._
_.____._
_____..______.__._._........................
__.____________.___
_~_______
_...__..._._ Double
Ci .. .. .. .. .. . .. . . .. .. .. . ._.._._.____
___..__....................~.. ______..__
.__._......_. .. .. .. . .. .. .. . .._ Single
1 TSB Revision
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21-74
- Specifications
Items
Transmission control lever
Transmission control rod (6) to pin
Cross shaft bracket (A) to body
Selector handle mounting screw
Transmission control arm to bracket
Transmission
Oil filler tube to transmission
Rear engine support member to frame
No. 2 crossmemberto
transmission
Transmission to engine (A)
Transmission to engine(B)
Transmission to engine ID)
Transmission to starter motor
Torque converter to drive plate
Converter housing installation bolt
IO mm (.39 in.) dia. bolt
12 mm j.47 in.) dia. bolt
Oil pump assembly installation bolt
Oil pump body and cover-tightening bolt
Center support installation bolt
Adapter installation bolt
Cover plate installation screw
All bolts of valve body
Throttle cam installation bolt
Valve body assembly installation bolt
Oil screen installation bolt
Parking cam plate installation bolt
Oil pan installation bolt
Union
Elbow connector
Plug (for hydraulic test)
Oil pan drain plug
Overdrive solenoid valve installation bolt
Plug
Manual lever installation nut
Transmission oil cooler
Transmission oil cooler eye bolts
Transmission oil cooler tube flare nut
Transfer
Transfer case installation bolt
Transfer case installation nut
Chain cover bolt
Side cover bolt
Rear cover bolt
Cover bolt
Control housing bolt
[ TSB Revision
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Nm
ft.lbs.
13
IO-13
2
18-24
9
7-9
0.4
13-17
IO-12
55-75
IO-13
18-25
65;85
80-l 00
30-42
27-34
36-712
7-Q
40-54
7-Q
13-18
47-61
58-72
22-30
20-25
25-30
2742
48-68
18-25
6-9
24-28
27-42
6-9
5-6
6-9
8-12
5%
6-9
4-5
30=40
30-40
6-9
18-23
JO-16
IO-16
14-18
20-30
3549
13-18
4.3-6.5
17-20
20-30
4.3-6.5
3X-4.3
4.3-6.5
5.8-9
3.6-4.3
4.3-6.5
2.9-3.6
22-29
22-29
4.3-6.5
13-17
7-12
7-12
IO-13
30-35
40-50
22-25
29-36
30-42
30-42
31-42
6-10
15-22
15-22
15-22
~:
22-30
2230
2230
5-J
11-15
II-15
1 I-15
.._
+
-.
21-75
- Snecifications
terns
Oil filler plug
Drain plug
Select plug
Locking plate bolt
Rear output shaft lock nut
Speedometer sleeve clamp bolt
Seal plug
4WD switch
Control shaft set screw
Control lever assembly to control housing
Transfer mounting bracket to pipe
Nm
ftlbs.
3035
3035
30-35
15-22
100-l 30
1.5-2.2
30-42
30
8-10
8-10
18-25
30-42
22-25
22-25
22-25
11-15
72-84
1.1-1.6
22-30
22
5-7
5-7
13-18
22-29
LUBRICANTS
NZlMI
Items
Quantity
Specified lubricants
Transfer oil
Transfer control lever

assembly O-ring
fluid
AutomaticTransmission
DEXRON type
Fluid
Approx. 7.2 lit. (15.2 pints)
Hypoid gear oil API classification GL-4 or

higher SAE viscosity No. 80W or
75w-85w
Hypoid gear oil API classification GL-4 or
higher SAE viscosity No. 80W or
75w-85w
Approx. 2.2 lit. (4.7 pints)
Small quantity
?421cE-l
items
Oil pump installation bolt(threads)
Adaptor gasket (both sides)
Air breather (press-in circumference)
Chain cover gasket (both sides)
Rear cover gasket (both sides)
Cover gasket (both sides)
Control housing gasket (cover side
surface only)
Bolt (threads)

3M
3M
3M
3M
3M
3M
3M
ART
ART
ART
ART
ART
ART
ART
Part
Part
Part
Part
Part
Part
Part
No.
No.
No.
No.
No.
No.
No.
8660
8660
8660
8660
8660
8660
8660
or
or
or
or
or
or
or
equivalent
equivalent
equivalent
equivalent
equivalent
equivalent
equivalent
3M Adhesive Nut Locking 4171 or

equivalent
TSB Revision
http://vnx.su/
Quantih/
As
As
As
As
As
As
As
required
required
required
required
required
required
required
As required
21-76
- Soecial Tools
SPECIAL TOOLS
MD998412
~.
MD99821 7
Guide
Gauge
T x
Installation of oil pump
-.
Check of quality of assembly condiG&
/
MB998903
-~
Spring compres&
/ TSB Revision
Disassembly and assembly of clutch and brake
http://vnx.su/
-:
Tool
*/,
- Special
Tools
21-77
/ Troubleshooting
Number
Name
Use
MD99821 1
Retainer
Disassembly and assembly of No. 3 brake

spring
MD998353
Torque driver set
Tightening of valve body screw
e
a
/
8
TROUBLESHOOTING
AZEBAP
GENERAL
Automatic
transmission
malfunctions
may be caused by the following conditions:
(I) Improper maintenance
and adjustment
(2) Mechanical malfunctions
(3) Hydraulic malfunctions
(4) Poor engine performance
Troubleshooting
in the event of any such malfunctions should begin by checking fluid level, ATF condition, manual linkage adjustment,
throttle control
cable adjustment
and other conditions
whose
deviation from standards can be readily known.
Then, road test shall be performed
to determine
whether or not the problem has been corrected or
more diagnosis
is necessary.
If the problem still
persists after these tests and corrections,
hydraulic
tests should be performed
for further troubleshooting.
FLUID LEVEL AND ATF CONDITION

(1) Place the vehicle on a level surface.
(2) Before removing the dipstick, wipe all dirt from
area around the dipstick.
(3) With the selector lever in the P position and
the parking brake applied, start the engine.
(4) The engine should be running at idle and the
transmission
should be warmed up sufficiently.
(5) Move the selector lever through all positions to
fill the torque converter and hydraulic circuit
with fluid. Then, place the lever in theN or P
position.
(6) Check to see that the fluid level is within the
range between
COLD upper limit and the
HOT
lower
limit
on the
dipstick.:NL
If the fluid level is low, top up until the level rises
to within the range between the HOT lower
and upper limits.
J
COLD
!.
HOT
37202s
Low fluid level can allow the oil pump to take in air
together with fluid, leading to various troubles.
Air
trapped
in hydraulic circuit forms bubbles which
make the fluid spongy.
This loweres pressure and
slows down pressure buildup.
If the transmission
has too much fluid, gears churn
up foam and cause same conditions
as when the
fluid level is low, resulting in premature
deterioration of ATF. In either case, air bubbles can cause
overheating
and fluid oxidation
and varnishing,
which can interfere with normal valve, clutch and
servo operation.
Foaming can also result in fluid
escaping from the transmission
vent where it may
be mistaken for a fluid leak.
Along with the fluid level, it is equally important to
check condition of fluid. When fluid smells burned,
it is contaminated
with metal bushing or friction
material particles and hence a complete overhaul of
the transmission
is needed.
Be sure to examine
fluid on the dipstick closely.
After fluid has beenchecked,insert the dipstickuntil it is seated fully to seal out water and dirt.
TSB Revision
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21-78
MANUAL LINKAGE
- Troubleshooting
INHIBITOR SWITCH
The inhibitor
switch is installed on the
lever.
After checking
normal operation
switch, place the selector lever in the N
If the notch of the selector lever on the
sion side faces directly down, the linkage
adjusted correctly.
selector
of this
position.
transmishas been
THROTTLE CONTROL CABLE

Throttle control cable adjustment
is very important
to assure normal operation
of the transmission.
Shift speed control, shift feeling and transmission
slip depend greatly on this adjustment.
If the throttle outer cable is set too long (namely.
the inner cable is too tight], the throttle valve is
already
in operating
state and consequently,
presense
of hydraulic
pressure
higher
than
specified is suspected.
The throttle pressure acts
on each shift valve and when upshifting, the governor pressure that counteracts
against the throttle
pressure is higher than normal. Namely, if the outer
cable is set too long, upshift takes place at vehicle
speed higherthan
normal.
On the other hand, if the outer cable is set too short
(the inner cable is slack), upshift takes at vehicle
speed lower than normal.
[ TSB Revision
Check to see that the engine starts only when the

selector lever is in the N or P position and that it
does not start when the selector lever is in other
positions.
SELECTOR LEVER
(1) Check to see that the vehicle moves forward
when the selector lever is shifted from the N
position to the D range and that the vehicle
reverses when the lever is shifted to the 5
range.
(2) Stop the engine.
(3) Shift the selector lever from the N position to
the D range and then to the 2 position to
check that the Tever can be operated smoothly
and engage at each position with reasonable
firmness.
L
(4) Check to see that shifting to each of the P,
R, 2 and L positions can take place only
when the selector lever is pushed in.
http://vnx.su/
21-79
- Troubleshooting
ROAD TEST
Prior to performing
road test, be sure to make basic checks
including check and adjustment
of fluid level and condition and
adjustment
of the throttle cable. For road test, the transfer
must be placed in the 2H (2WD-high) position.
In road test, various changes such as slips in transmission
and
shifting conditions
are checked and hence the transmission
operation at each shift position must have been checked.
D RANGE TEST
Start with throttle valve opened (50% and full), and check
upshift from l-speed + Z-speed, Z-speed -. 3-speed and
3-speed + 4-speed. Check that speed change points match
shift pattern. (Refer to P.21-83.)
1
Will not upshift,
1-speed -P-speed
l
l
1
Will not upshift,
3-speed-4speed
(with throttle
valve opening under 85%)
Will not upshift,

2-speed +3-speed
1
Speed change
points incorrect
Governor
malfunction
l-2 shift valve
malfunction
l
at 2-speed, 3-speed and 4-speed.

Check that possible kickdown vehicle speed limit at 2speed - l-speed, 3-speed -) l-speed, 3-speed -+ 2speed,
- l-speed, Cspeed - 2-speed. 4-speed -) 3speed conforms with the shift pattern, (Refer to P.2183.)
1 TSB Revision
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Incorrect throttle
cable adiustment
AUTOMATIC TRANSMlSSlON
- Troubleshooting
When traveling in 3-speed or 4-speed, release accelerator

and shift to L. Check that 3-speed - Z-speed or 4-speed
- 3-speed takes place immediately and Z-speed - l-speed
dowsnshift conforms with shift pattern. (Refer to P.21;83.)
When traveling in 3-speed or 4-speed, shift to 2 and L and

check engine brake function in each range.
Check for abnormal

noise(s) during acceleration
and
deceleration.
Check for shocks when slipping and changing speed.
I
o Accumulator
1 TSB Revision
malfunction
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.-
--
EE
AUTOMATIC
TRANSMISSION
Check for abnormal

B-speed or 4-speed.
- Troubleshootina
21-81
noise(s) or vibration when traveling in
Strong abnormal noise and vibration
Incorrect torque converter installation

a Speed change gear wheel not meshing correctly
Incorrect drive plate installation
NOTE
Abnormal noises and vibrations are often caused by an unbalanced
engine etc. Extremely thorough inspection is therefore required.
propeller shaft, differential,
tire, torque converter,
Check that lock up ON, OFF and speed change point conforms with shift pattern.
NOTE
(1) Determine the moment when lock up turns ON by decreased engine rpm or by a slight shock back and forth.
(2) Determine the moment when lock up turns OFF by increased engine rpm.
(3) Check lock up condition by pumping the accelerator slightly. If en ine rpm rises in accordance with throttle valve
opening size, determine that the lock up is OFF, if not, determine It43 N.
When lock up is OFF, drive power is transferred throu h the fluid in the torque converter and therefore, when the
accelerator pedal is depressed, slipping occurs inside t7l e torque converter with a resulting large increase in engine
I rpm.
I
[ TSB Revision
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--
21-82
- Troubleshooting
2 RANGE TEST
Start with throttle valve openrng at 50% and full. Check that
I
I
Kickdown and check that possible kickdown vehicle speed

- l-speed conforms with shift pattern.
Will not downshift
or icorrect speed change point.

I
o Detent regulator pressure malfunction

l
Governor malfunction
l
Misadjusted throttle cable
l
1-Z shift valve malfunction
l
Line pressure malfunction
L RANGE TEST
Check that it dose not upshift to Z-speed
-7
Upshifts
I
Low coast modulator valve malfunction
[ TSB Revision
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.-:
AUTOMATIC
TRANSMISSION
21-83
- Troubleshooting
R RANGE TEST
Start with full throttle and check for slippage.
Brake No. 3 malfunction

OD clutch or direct clutch malfunction
OD one-way clutch malfunction
0 Low line pressure
l
l
l
P RANGE TEST
Park vehicle on an incline (more than 5). Release parking
and service brakes and check that the vehicle does not
Vehicle moves
I
l
l
Park mechanism malfunction

Misadjusted shift lever
100
80
-I,
1-2
P
g 60
.z
s
z
a, 40
E
e
c
20
Idle
0
1,000
2.000
3,000
4.000
5.000
Transfer shaft speed

0
I
0
10
20
30
40
50
60
70
60
90
100
110
120
130
140
150
Vehicle Speed (km/h)

/
IO
20
30
40
50
60
70
Vehicle Speed (mph)
/ TSB Revision
http://vnx.su/
80
90
1480028
21-84
AUTOMATK
TRANSMISSION
4. Apply fully the parking and service brakes.
CONVERTER
STALL
TEST
In this test, the engine maximum speed when the
torque con verter stalls with the shift lever in the
ID or R range is measured to check operation of
the torque converter, stator and oneway clutch and
check holding performance
of the transmission
clutch (including brake).
Caution
do not stand in front or at rear of the vehicle during this test.
1. Check the transmission
fluid level. The fluid
temperature
should be at the level after normal
operation [5O - 80C (122 - 176F)l. The engine
coolant temperature
should also be at the level
after normal operation [80- 90 (176 - 194F)].
2. Apply chocks to the rear wheels (right and left).
3. Mount an engine tachometer.
JUDEGEMENT
- Troubleshooting
Start the engine.
:: With the selector
7.
lever in the D range, fully

depress the accelerator pedal and read off the
engine maximum speed.
Standard
value: 21062400
rpm
NOTE
When doing so, do not keep the engine running
with throttle full open for more than necessary
duration (5 seconds or more).
If two or more
stall tests are needed, place the selector lever in
the N position and run the engine at about
1,000 rpm to allow the transmission
fluid to cool
before another stall test.
Place the selector lever in the R range and perform the test as above.
OF STALL TEST RESULTS
Stall speed in D and f? range is equal to each other but

lower than the nominal value.
(I) Engine output is 10-w

(2) Stator one-way clutch is faulty.
(Faulty torque converter is suspected if it is lower
than nominal by more than 600 rpm.)
Stall speed in D range is higher than nominal.
(I)
(2)
(3)
(4)
(5)
O.D. clutch slipping.

O.D. one-way clutch faulty
Forward clutch slipping
One-way clutch No. 2 faulty
Low line pressure
Stall speed in R range is higher than nominal.
(I)
(2)
(3)
(4)
(5)
.O.D. clutch slipping.

O.D. one-way clutch faulty
Direct clutch slipping
Brake No. 3 slipping
Low line oressure
HYDRAULIC
PRESSURE
TEST
The hydraulic pressure tesrs (governor
pressure
and line
pressure tests) are important
in determining
the causes of
transmission
failures.
Before conducting
these tee.
fluid level and condition
and
throttle cable adjustment
etc, must be checked for defects or
abnormalities.
When conducting
the tests, the engine and
transmission
should be at correct operating
temperatures,
[engine cooling water 80 - 90C (176 - 194F). transmission
fluid 50- 8OC(122- 176OF)].
GOVERNOR
PRESSURETEST
1. Place vehicle on a chassis dynamometer.
2. Remove plug from governor pressure takeoff port.
3. Install special tool as shown in figure and place the meter
inside vehicles.
NOTE
When the adapter interferes with teh extension housing,
repair the tool as shown
4. Apply parking brake.

5. Start engine.
6. Release parking brakes.
1 TSB Revision
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in figure.
AUTOMATIC
TRANSMISSION
7.
Shift to D and measure

shaft rpm.
Standard value:
JUDGEMENT
BY GOVERNOR
special
tool
Apply the parking

Start the engine.
Place the selector
1,000
28(17)
133-163(19.4-23.6)
2,000
56 (35)
251-281 (36.4-40.6)
3,200
90 (56)
400-430 (58-62.2)
l
l
l
Governor pressure
kPa (psi)
Line pressure malfunction

Oil leak in governor circuit
Governor malfunction
as shown
in the figure
7. Depress the brake pedal firmly by the left foot

and operates the accelerator pedal by the right
foot to measure the line pressure at each engine
and
rpm.
If the measured
check adjustment
brake.
just
lever in the D range.
Standard
if necessary
again.
8. Place the selector
as above.
value:
pressure
of the throttle
before
is not nominal,
cable and read-
conducting
kPa (psi)
D range
R range
51 O-590 (74-85)
770-890 (112-130)
1080-1280(156-185)
1570-l 960 (227-285)
BY LINE PRESSURE
Hydraulic pressure higher than nominal in all ranges
(1)Regulatorvalve faulty
(2)Throttle valve faulty
(3)Throttle control cable incorrectly adjusted
Hydraulic pressure lower than nominal in all ranges
(1)Oil pump faulty

(2)Regulator valve faulty
(3)Throttle valve faulty
(4)Throttle control cable incorrectly adjusted
(5)0.D. clutch faulty
Hydraulic pressure lower than nominal in D range
(1)Largefluid leaks in D range hydraulic circuit

(2)Forvvard clutch faulty
Hydraulic pressure lower than nominal in R range
(1)Largefluid leaks in R range hydraulic circuit

(2)Brake No. 3 faulty
(3)Direct clutch faulty
[ TSB Revision
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the test
lever in the R range and test
Line pressure
JODGEMENT
at each output
Vehicle speed
km/h (mph)
place the meter inside vehicle.

4.
5.
6.
pressure
Output shaft
speed (rpm)
LINE PRESSURE TEST

1. Place the vehicle on a chassis dynamometer.
2. Remove the plug from the line pressure takeoff
port.
Install
governor
PRESSURE
Governor pressure,is not within

the standard value
3.
21-85
- Troubleshooting
21-86
AUTOMATIC
TRANSMISSJON - Troubleshooting
WERDRIVE CONTROL SYSTEM CIRCUIT
To alternator
[Refer to GROUP
8.1
q
To combination
(Refr.
._ rnn,
meter
In n 1
To turn signal
flasher
not
IRefer to GROW
R&i;mer
[Refer
o*85-w
BY
8.1
control
to GROUP
8.1
GO 6
r
Remarks
(1)
For
information
concerning the ground points (example:
0). refer to Group 8.
I21 The symbols 0, 0. etc. indicate that the wiring
is
connected
(using the same numerical svmboi) to the
facing page.
(In other words, 0 on the right page is connected to 0 on
the
left
page.)
Wiring color code

8: Black
6r: Brown
G: Green
LI: Lrght blue 0: Orange
P: Pink
Gr: Gray
L: BIue
Lg: Light green
R: Red
Y: Yellow
W: White
0 PERATION
Automatic
transmission
oil temperature
warning
light
.
When the ignition switch is placed in the ON position
without starting the engine, current will flow to fuse No.
3. the automatic transmission
oil temperature
warning
light, diode alternator, and the ground, and the warning
lights will light. This is a circuit for the purpose
of
checking for bulb circuit breakage, and the lights will go
out when the engine is started.
l
l
When the engine is started, current flows to the ignition

switch. fuse No. 3, and the automatic transmrssion
oil
temperature
warning light, the batten/ voltage will go to
the oil temperature
switch.
When ATF temperature
rises above 50C (122F), the oil
temperature
switch will go on.
When the oil temperature
switch goes on, current will
flow
to
the
ignitioi,
switch,
fuse
No.
3, the
automatic
oil
temperature
warnfig light, oil temperature
switch and the
ground and the warning lights will go on.
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AUTOMATIC
TRANSMISSION
[Refer
(VW)
2-BY
@o1
- Troubleshooting
21-87
to GROUP
8.1
2-BY
To starter
[Refer
to GROUP
8.1
oil temperature switch
E3
Overdrive-off
l
0
8
solenoid
valve
When the overdrive-OFFswitch

is switched ON (with the
ignition switch at the ON position). battery voltage is
applied, through fuse No. 3 and the overdrive-OFF
relay,
to the engine coolant temperature
switch.
When the coolant temperature
becomes 80C (176F) or
higher,
the engine
coolant
temperature
switch
is
switched ON.
When the engine coolant temperature
switch is switched
ON, current flows to the ignition switch, fuse No. 3. the
overdrive-OFF
switch, the overdrive-OFF relay, the engine
coolant temoerature
switch, and around. and the relav is
switched
Oi\l.
1 TSB Revision
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When the overdrive-OFF

relay is switched ON, current
flows to the ignition switch, fuse No. 3, the overdrive-OFF
switch, the overdrive-OFF
relay, the overdtive-OFF
solenoid, and ground, and the solenoid valve is activated.
When the overdrive-OFF
switch is switched ON, current
flows to the ignition switch, fuse No. 3, the overdrive-OFF
switch, ihe overdrive-OFF
indicator, and ground, and the
indicator illuminates.
~~lmlma
21-88
gj-
2. :
I,.&,
__ _
AUTOMATIC
--
TRANSMISSION
__-.
- Service Adjustment Procedures
SERVICE ADJUSTMENT
;~$iSMISSION
PROCEDURE&
FLUID CHANGING AND INSPEC-
(1) Check the fluid level (automatic transmission

case).
(2) For the checking procedures
of automatic
fluid (ATF), see P.21-77.
Filler plug
(3) Check the

removed.
transfer
case
oil
level
with
and transfer
transmission
the
filler
plug
(4) The fluid level is okay if it is at the same level as the lowest
point of the filler plug hole.
(5) Install the filler plug and gasket, and tighten to 30-35 Nm
(22-25 ft.lbs.).
ATF CHANGING
PROCEDURES
Caution
If ATF change is required due to damage to the transmission, be sure to clean the cooler system.
(I)
(2)
13)
(4)
(5)
COLD lower
limit
COLD
HOT upper
limit
HOT lower
limit
(6)
HOT
(7)
37zozs(
Raise the vehicle on hoist. Place a drain container with

large openig under the drain plug (located in bottom of the
oil pan).
Remove the drain plug to let ATF drain
install the drain plug and-new gasket and tighten to 16-23
Nm (13-17 ft.lds.).Refill ATF through the oil level gauge hole until its level
reaches the COLD lower limit of the level gauge.
Start the engine and allow to idle for at least two minutes.
Then. with the parkino brake and service brake applied,
move the selector lever through all positions and finally
place in the N or P position.
After the transmission
is warmed
up to the normal
operating temperature,
recheck the fluid level, which must
be between
the HOT upper limit and HOT lower limit
marks.
Insert the . dipstick fully to prevent dirt from entering the
transmrssron.
\ TSB Revision
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AUTOMATIC
TRANSMISSION
21-89
TRANSFER CASE OIL CHANGING

PROCEDURES
(I) Remove the filler plug.
(2) Place a drain container with large opening under the drain
plug.
(3) Remove the drain plug to let oil drain.
(4) Install the drain plug and new gasket and tighten to 30-35
Nm (22-25 ftlbs.).
(5) Refill specified transfer case oil up to specified
level.
(6) Install the filler plug and gasket and tighten to 30-35 Nm
(22-25 ftlbs.).
THROlTLE
CABLE CHECK AND ADJUSTME!?-
(1) Check for defective or bent throttle lever or throttle cable

bracket.
(2) Check that the distance between the inner cable stopper
and dust cover surface is within the standard value.
Standard value : O-l mm (O-.04 in.)

(3) If outside
the standard
value, adjust
with
adjusting
nut.
PROPELLER SHAFT OIL SEALS REPLACEME!L=

Refer to P.21-11.
SPEEDOMETER CABLE REPLACEMENT

Refer to P.21-11.
[ TSB Revision
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NzlFLUd
21-90
AUTOMATIC
TRANSMISSION
TRANSMISSION
- Transmission Control
CONTROL
4
1
26
19
012
25
Removal
steps
I, Plate B
Floor console
3. Overdrive switch connection
4. Selector handle
5. Overdrive switch harness and front wir.*
Ing narness connecuon
6. Cover
7. Inhibitor switch and front wiring harness
connection
8. Position indicator light and front wiring
harness connection
9. indicator panel
IO. Bracket assembly
11. Heat protector
12. Cotter pin
13. Transmission control rod /BI
14. Dust cover
2.
**
+w ++
15. Snap ring

I)+ 16. Spring
e)+ 17. Cross- shaft
*+
18. Cross_ shaft
+I) ++ 19. Select cross
++ I)+ 20. Transmission
21. Cap
1)4 22. Bushing
e)+ 23. Cross shaft
H
24. Cross shaft
e+ 25. Bushing
*+ 26. Pin
bushing
boot (B)
shaft
control rod (A)
bracket (A)
boot
NOTE

(3) r)* : Refer to Service Points of Installation.
(4) q
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- I
.J
AUTOMATIC
TRANSMISSION
21-91
- Transmission Control
FJamAF

4. REMOVAL
OF SELECTOR HANDLE
(I) Press the cover downward.
(2) Disconnect
the overdrive switch
selector handle.
(3) Remove
the selector
handle
from
connector
the shift
from
the
lever.
13. DISCONNECTION
OF TRANSMISSION
CONTROL ROD
(B)
(I) Disconnect
the transmission
control rod (B) from the
transmission
control arm by lossening the nut from
under the floor.
(2) Disconnect
the select cross shaft from the heat
protector.
(3) Disconnect
the select cross shaft from transmission
control rod B.
control rod (6)
Transmission
19. REMOVAL OF SELECT CROSS SHAFT/ZO. TRANSMISSION CONTROL

ROD (A)
(1) Disconnect
the select cross shaft from transmission
control rod A.
r TSB Revision
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AUTOMATIC
TRANSMISSION
- Transmission
Control
(2) Remove the dust cover, and then remove the snap ring
that holds the spring.
(3) Remove the cross shaft bracket mounting
bolts from
the transfer assembly.
(4) Detach the cross shaft bracket from the bracket on the
No. 1 crossmember
side.
(5) Remove
sion.
-I
transmission
control
rod A from the transmis-
SERVICE POlNTS OF INSTALLATION
N2IIoAn
26.APPLlCATlON
OF GREASE TO PIN/25
BUSHING/24.
CROSS SHAFT BOOT/23.
CROSS SHAFT BRACKET
(A)/22. BUSHING/20.
TRANSMISSION
CONTROL ROD
(A)/19.
SELECT CROSS SHAFT/lS.
CROSS SHAFT
BOOT (B)/17. CROSS SHAFT BUSHING/lG.
SPRING
Apply a coating of the multipurpose
grease to the bushing
inner surface and the sliding parts shown in the figure.
13. INSTALLATION
OF TRANSMISSION
CONTROL ROD (B)
(1) Move the transmission
and shift lever to the N
position, and then install the transmission
control arm
and transmission
control rod (B) as shown in the figure.
(2) Check, while driving, to be sure that the transmission
is
set to each range when the selector lever is shifted to
each position.
(3) Check, while driving, to be sure that the overdrive is
activated and cancelled correctly when the overdrive
switch is used.
1 TSB Revision
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AUTOMATIC
TRANSMISSION
- Transmission
Control
dSASSEMBLY AND REASSEMBLY
Removal
NZWE-
steps
1.
2.
3.
l 4 4.
5.
6.
I)*
7.
I)*
8.
9.
** 10.
l * 11.
I)* 12.
13.
r)+
Position indicator light

18
Inhibitor switch
Overdrive switch
Pushbutton
Spring
8
Selector handle
Bushings
Transmission control arm
Shift lever
Sleeve
Spring
Rod assembly
Bracket
NOTE
(2) I)+ : Refer to Service
Overdrive
procedures
to reassemble.
N2lmAC
INSPECTION
switch
\
Selector
Check for unusual wear of the brackets detent plate part,

rod end pin, each bushing, pushbutton
and sleeve contact
surface.
l
Check for weakness
of the spring.
l
Check the operation of the overdrive switch. (Check the
continuity.)
When the overdrive switch is OFF: continuity
When the overdrive switch is ON: non-continuity
l
handle
000
k!zl
m
I
Inhibitor switch
Check the continuity
with the select lever at each position.
NOTE
m
rTSB
indicates
Revision
http://vnx.su/
that
there is continuity
1
between
the terminals.
21-94
AUTOMATIC
TRANSMISSION
- Transmission
Control
SERVICE POlriliS OF REASSEMBLY
N2mu&
12. APPLICATION
OF GREASE TO ROD ASSEMBLY/II.
SPRING/lO.
SLENE/8.
TRANSMlSSlON
CONTROL
ARM/7.
BUSHINGS/A
PUSHBUTTON
grease to each sliding part of the
lever.
Pushbutton
10. INSTALLATION
OF SLEEVE
Move the selector lever to the N position, and turn the
sleeve so that the angled surface of the sleeve is at the
pushbutton
side, At this time, adjust the clearance between the sleeve and the selector lever so that it is the standard value.
side
Sleeve
Selector
Standard value : 15.2-15.9
lever
mm (.60-.62
NOTE
Move the 6 part of the sleeve
(drivers seat side).
25
N position
in.]
to the pushbutton
side
2. INSTALLATION
OF INHIBITOR SWITCH
(1) Temporarily install the inhibitor switch.
(2) Set the shift lever so that the pin at the end of the rod is
at the position shown in the figure.
Pin at the end of the rod

mm (in.)
cm565
(3) Using a circuit tester between

2-BY and 2-BY of the
inhibitor switch connector,
check the continuity when
the inhibitor switch is moved back and forth, and mark
the bracket.
(4) Tighten the inhibitor switch mounting

screws at the
position where the clearance between
the inhibitor
switch and the selector lever is the specified distance.
nm fin.1
. ;
Gevision
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-.
AUTOMATIC
TRANSMISSION
TRANSMISSION
- Transmission
AND TRANSFER
21-95
ASSEMBLY
EMOVAL AND INSTALLATION

Post-installation
Operation
Supplying
of Automatic Transmit
sion Fluid and Transfer Oil (Refer tc
GROUP O-Maintenance
Service)
l
Installation of Front Exhaust Pipe
(Refer to GROUP II-Exhaust
Pipe)
l
Installation of Front and Rear Propeller shaft (Refer to GROUP 16Propeller shaft)
l
Installation
of Cross Shaft Protector
l
Installation
of Transfer Case Protector
l
Checking of Selector Lever Aotiva-
Pre-removal
Operation
l
Removal of Cross Shaft Protector
0 Removal of Front Exhaust Pipe
0 Removal of Transfer Case Protector
l
Draining of Automatic
Transmission
Fluid and Transfer Oil (Refer to
GROUP O-Maintenance
Service)
l
Removal of Front and Rear Propeller shaft
(Refer to GROUP 16-Propeller
shaft)
tinn
IO-12 Nm
7-9 ft.lbs.
I
Removal
+q
l *
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Dust seal guard

Ground
cable
Oxygen
sensor
connector
4WD indicator
light switch
connector
Speedometer
cable
Overdrive
solenoid
valve connector
Throttle
control
cable
Oil filler tube
O-ring
Automatic
tmnsmlssion
cooler
tube
NOTE
(3) a
: Non reusable parts
1 TSB Revision
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to reinstall.
of Installation.
21-96
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
OSW562
+*
+*
e*
4*
+a
4+
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Stator cover
Stator motor
Transmission stay (R.H.)
Transmission stay (L.H.)
Bell housing cover
Cotter pin
Bolts.
No. 2 crossmember
and rear engine
support member with transfer control
rod
No. 2 crossmember
Transmission control rod assembly
Transfer control lever mounting bolts
Special bolts (six)
/ TSB Revision
+I* ++
I)*
24.
25.
26.
27.
28.
29.
Transmission and transfer

Front floor console
Control lever assembly
ControT housing gasket
Contorl housing cover
assembly
NOTE
12) +I) : Refer to Service Points of AemovaI.
(3) *
: Refer to Service Points of Installation*.
(41 j : Non reusable parts
=
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AUTOMATIC
TRANSMISSION
- Transmission
SERVICE POINTS
21-97
OF REMOVAL
N21LBAN
12. REMOVAL
OF STARTER MOTOR
Refer to P.Zl-13.
16. REMOVAL
OF TRANSFER MOUNTING
Refer to P.21-13.
BRACKET
22. REMOVAL OF TRANSFER CONTROL LEVER ASSEMBLY

MOUNTING
BOLTS
Move the transfer control lever to the 2H position and
remove the control lever assembly
mounting
bolts.
24. REMOVAL
OF TRANSMISSION
(I) Disconnect
the transmission
from the engine by pulling it slowly toward the rear of
the vehicle.
(2) When lowering the transmission
and transfer assembly, tilt the front of the transmission
downward
and
slowly lower forward, while using care to make sure
that the rear of the transmission
does not hit the No. 4
crossmember.
NOTE
Detach so that the torque
the engine side.
converter
does not remain at
%?,LDAs
28. APPLICATION
OF SEALANT TO CONTROL HOUSING
GASKET
Apply semi-drying
sealant to both surfaces of the control
housing gasket.
24. INSTALLATION
OF TRANSMISSION
AND TRANSFER
ASSEMBLY
On the engine side, there are two centering
locations.
Make sure that the transmission
mounting
bolt holes are
aligned with them before mounting the transmission
and
transfer assembly to the engine.
21. INSTALLATION
OF TRANSMlSSlON
CONTROL
ROD
ASSEMBLY
(1) Apply a coating of multipurpose
grease to the sliding
parts.
(2) Confinn the position of the selector lever.
(Refer to P.21-78.)
14. INSTALlATlON
OF TRANSMlSSlON
TRANSMISSION
STAY (R.N.)
Refer to P.21-30.
1 TSB Revision
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STAY
(L.H.)/13.
21-98
9.
Automatic
transmission
- Transmission
Transfer
Assembly
APPLICATION
OF LUBRICANT
TO O-RING
Apply a small amount of the specified automatic
sion fluid to the O-ring and then install.
Specified
7.
and
transmission
CONNECTION
fluid:
OF THROTTLE
transmis-
Transmission
Automatic
Fluid DEXRON
type
CONTROL
CABLE
Refer to P.21-99.
DlSASSEMBLY
I\-.\
1
jRevision
3720004
Caution
1. When removing
the transmission
assembly
from the
vehicle, use care so that the oil pan is not hit by the
transmission
jack.
2. The automatic
transmission
is built of accurately
machined parts which should be handled during disassembly with utmost
care to prevent
damage.
3. When separating
light alloy metal parts such as the
case, do not pry with a screwdriver
but tap lightly with
a soft headed hammer
(p&tic
hammer).
4. Place rubber mat on the work bench and keep it clean.
5. During disassembly,
do not wear cloth gloves or use
rags.
If necessary,
use nylon cloth or paper towel.
6. Clean all parts that have been disassembled.
Ordinary
detergent
may be used for cleaning metallic parts but
after washing,
be sure to dry with air.
7. Wash the clutch disc, brake disc, resin and rubber parts
in ATF (automatic
transmission
fluid) and keep them
free from dust.
5. If the transmission
itself is damaged,
disassemble
and
clean the cooler system.
(I) Remove sand and dirt from the outside of the transmission.
(2) Remove the transfer (P.21-154).
(3) Place the transmission
assembly on a bench with the oil
pan down.
Caution
Do not place the assembly
with the oil pan up before
the oil pan is removed.
This is necessary
to prevent
foreign
matter
in the oil pan from entering the valve
body.
(4) Remove the torque converter.
(5) Remove the O.D. solenoid valve.
(6) Remove tt,e oil pump:
(a) Remove the seven bolts.
(b) Position the special tool on the shaft in back of the
spline.
(c) Turn bolt of the special tool to free the pump.
Caution
l
Do not damage
the shaft bushing
surface.
(d) Grasp the front pump stator shaft and pull the pump
from the case.
;
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~.r
AUTOMATIC
TRANSMISSION
- Transmission
(7) Watch
and
for the bearing
Transfer
Assembly
and race behind
21-99
the oil pump.
(8) Remove the torque converter housing:

(a) Remove the two 12-mm bolts and four IO-mm bolts.
(b) While holding the input shaft, remove the converter
housing.
(9) Remove the adapter and gasket.

(lO)Remove
the governor mounting
bolt.
(1 l)Lift up the governor retaining ring lightly by a screwdriver
and remove the governor assembly from the output shaft.
(12) Remove the governor strainer:

(a) Remove the four screws and plate.
(b) Remove the strainer from the case.
(13) Remove the oil

(a) Remove the
(b) Remove the
Caution
l
Do not turn
contaminate
collected
in
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pan and gasket:

fourteen
bolts.
oil pan with the transmission
case lifted.
the transmission
over as this will
the valve body by foreign
materials
the bottom
of oil pan.
21-100 AUTOMATIC TRANSMISSION
- Transmission
and
Transfer
Assembly
(14) Examine metellic particles in the oil pan as follows:

Remove the magnet and use it to collect any steel chips.
Look carefully at the chips and particles in the oil pan and on
the magnet to guess *here
the wear occurs in the
transmission:
Steel (magnetic)
= bearing, gear and clutch plate wear.
Brass (nonmagnetic)
= bushing wear.
(15) Turn the transmission

over and remove the tubes by prying
up both ends of each tube with a large screwdriver.
(16) Remove the strainer.
_
(17) Remove
the seventeen
valve
body fixing
(18) Lift slightly the valve body and disconnect

from the cam, then remove the valve
(19) Remove
the CZ accumulator
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..-
piston
bolts.
the throttle
body.
spring.
cable
AUTOMATIC
TRANSMISSION
Transmission
and
Transfer
21-101
Assembly
(20) Using a 10 mm (.39 in.) socket, push the plastic throttle

cable retainer out of the transmission
case to remove the
cable with retainer.
(21) Position a rag to catch each piston. Blow low-pressure

compressed
air (100 kPa, 14.5 psi) into each of the holes
shown to let the piston into the rag.
Remove the pistons and springs.
Caution
l
Keep face away to avoid injury.
l
Do not use high-pressure
air.
(22) Remove the

(a) Remove
(b) Remove
(c) Remove
parking lock linkage:

the cam plate.
the parking lock rod.
the spring, pivot pin and parking
lock pawl.
(23) Remove the manual lever and shaft:

(a) Using a hammer and punch, drive out the pin.
(b) C$dz. the shaft out the case and remove the detent

efficient work.
Caution
l
Place
avoid
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on a cylindrical
shop rags between

the
damaging
the case.
case
stand
and
for mure
stand
to
21-q 02 AUTOMATIC
TFIANSMISSION
- Transmission
and Transter
Assembly
(25) Set the special tool on the overdrive case and measure the
distance between
the top of overdrive case and clutch
cylinder.
Make a note of the distance for reassembly.
(26) Grasp the shaft and pull out the overdnve clutch assembly.
Watch for bearings
and races on both sides of the
assembly.
(27) Remove the overdnve case and brake as follows:

Hold both sides of the overdrive case and pull it out from
the transmission
case. -Watch for bearings and races on
both sides of the assembly.
(28) Set the sfjecial tool in the case. Measure the distance
between
the top of case flange and the clutch drum.
Make a note of the finding for reassembly.
(29) Grasp the-*aft

and pull out the forward clutch assembly.
Watch for bearings and races on both sides of the
assembly.
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.-
AUTOMATIC
TRANSMISSION
- Transmission
(30) Remove
pulling
the direct clutch by grasping

it out from the case.
(31) Remove the center support

(a) Remove the two center
21-103
the clutch
hub and
and sun gear:

support bolts.
372002:
Ib) Grasp the center support assembly

center support with sun gear.
(32) Remove the reaction

screwdriver.
plate retaining
and pull out the
ring using a long-shank
(33) Remove the No. 3 brake and planetary carrier assembly by

pulling out the intermediate
shaft.
If the brake apply tube and rear thrust bearing and races do
not come out with the assembly, remove them from the
case.
ievision
http://vnx.su/
- Transmission
REASSEMBLY
NZWAF
Caution
l
Before
assembly,
make
sure that
all component
assemblies
are assembled
correctly.
l
If something
wrong is found in a certain
component
assembly
while
assembly,
inspect
and repair
this
assembly
immediately.
GENERAL ASSEMBLY
NOTES
@) The automatic
transmission
is composed
of highly
precision-finished
parts, necessitating
careful inspection before assembly because even a small nick could
cause fluid leakage or affect performance.
@ Before assembling
new clutch discs, soak them in
ATF for at least two hours.
@I Apply ATF on sliding or rotating surfaces of the parts
before assembly.
@ Use petroleum
jelly to keep the small parts in their
@ g?%i
use sealant or adhesive cements on gaskets
and similar parts.
@ When assembling
the transmission,
be sure to use
new gaskets and O-rings.
@ Dry all parts by blowing with compressed
air.
Never use shop rags.
@ Be sure to install the thrust bearings and races in the
correct direction and position.
on a cylindrical stand
efficient work.
Caution
l
Place shop rags between
the case and
avoid damaging
the case.
for more
stand
to
35515
(2) Install the thrust bearing #20 and then the race #21 facing
the cup side downward.
--
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Lo
._
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HRUST
AUTOMATIC
TRANSMISSION
BEARING
RACE
AND
- Transmission
and Transfer
Assembly
21-105
POSITIONS
II
3720337
16
3720359
(3) Install the brake apply tube onto the case, aligning the
tubes locking tab (part A) with part B of the case.
NOTE
Make sure that the tab of the tube is completely fitted in the
case.
(4) Insert
the output
01
shaft
assembly
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into the case.
Transmission
and
Transfer
Assembly
(5) With the case in upright position, make sure that the No. 3
brake is lower than the ledge below the retaining snap ring
groove.
If the No. 3 brake is not lower than the ledge, components
may be misassembled
or there may be excess ATF
between
the disc and plate.
Standard
value:
Dimension
A: 0.61 - 2.64 mm (.024-.I04
in.)
(6) Install
the reaction plate-as follows:

Position the notched tooth of the reaction plate toward the
valve body side of the case. Push it into place.
NOTE
The reaction plate is correctly installed if the retaining snap
ring groove is fully visible.
(7) Install the retaining snap ring as follows:

Use a large screwdriver
to compress the snap ring. Push
the snap ring into place by hand. Work around the case.
Visually check to make sure that the ring is fully seated.
Make sure that the ends of the snap ring are between the
lugs.
KY Push
the center support assembly

into the case whrle
aligning the oil hole and bolt hole of the center support with
those of the body side.
(9) Install the two center support

Finger tighten the bolts.
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bolts with
wave
washers.
AUTOMATIC
TRANSMISSION
Transmission
and
Transfer
Assemblv
21-I 07
(10)lnstall the direct clutch in the case while turning the clutch
to mesh its hub with the center support.
(11)Check for correct installation of the direct clutch.
If the direct clutch is fully meshed with the center support,
the splined center of the clutch will be flush with the end of
the planetary sun gear shaft.
(12)After being coated with petroleum jelly, install the thrust

bearing race #I 6 over the splined end of the direct clutch in
case with its lip toward the direct clutch.
(13)After being coated with petroleum

jelly, install the thrust
bearing #I5 and race #I4 on the forward clutch, with the
races lip outward.
(14)lnstall the forward clutch assembly in the case:

(a) Align flukes of the direct clutch discs and mesh them
with the forward clutch hub.
(b) Push the forward clutch assembly into the case.
Caution
0 Be careful not to let the thrust
bearing
drop.
ulD998217
\/F
(15)Check for correct installation

of the forward
clutch as
follows:
Set the special tool on the transmission
case as shown in
the figure.
Measure the distance between the top surface of the tool
and forward clutch assembly. If the distance corresponds to
that during disassembly,
the forward clutch is installed
correctly.
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21-108
AUTOMATIC
MD998412
TRANSMISSION
- Transmission
and Transfer
Assembly
(16)lnstall the special tool on the case.

jelly, install
bearing #lO on the forward clutch.
the thrust

jelly, install the thrust
race #9 on the overdrive case end with its lip toward the
overdrive case.
(19)lnsert the overdrive case gently into the transmission

case
through the two guide pins with the part indicated by arrow
facing in the direction shown.
(20)Coat the thrust washers&with

petroleum
jelly. Install
washers on the overdrive planetary gear.
NOTE
The washer lugs should be inserted in the holes.
the
(2l)lnstali
the overdrive clutch in the case as follows:
Align the disc flukes in the overdrive case. Align the flukes
with the slots of the overdrive
clutch and press the
overdrive clutch into the overdrive case.
Caution
l
Be careful
not to let the thrust
washer
drop.
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AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-109
(22)Check for correct installation

of the overdrive clutch as
follows:
Set the special tool on the overdrive case as shown in the
figure.
Measure the distance between the top surface of the tool
and the overdrive clutch. If the distance corresponds to that
during disassembly, the overdrive clutch is installed correctIv.
MD998217
372002
(23)lnstall the O-ring on the overdrive case.

(24)lnstall the torque converter
housing by using
12-mm bolts (B) and four IO-mm bolts (A).
Tighten the bolts to specification.
the two
(25)Coat the thrust bearing race #3 with petroleum jelly and

install it on the overdrive clutch.
(26)Coat the thrust bearing #2 and race #I combination
with
petroleum
jelly and install it on the oil pump.
(27)lnstall the oil pump:

(a) Install the oil pump gently through the two guide bolts,
being careful that the thrust washer does not fall out.
(b) Coat the five set bolts with sealant, and finger tighten
them.
remove the special tool. In the
(cl Using a screwdriver,
place of it, install the two set bolts coated with sealant.
Specifiedsealant:
or equivalent
the set bolts gradually
and evenly to the
(d) Tighten
specified
torque.
(28)Tighten
the two center support
(5.16 ftlbs.)
increments
until
reached.
NOTE
Firest tighten the accumulator
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bolts alternately in 7 Nm
the specified
torque
is
side bolt.
21-1 IO AUTOMATIC
TRANSMlSSlON
Transmission
and
Transfer
Assembly
(29)Check the operation of pistons as follows:

Blow low-pressure
compressed
air into the passages
indicated in the figure and listen for noise from piston
movement.
@ Overdrive clutch
@ Overdrive brake
@ Forward clutch
@ Direct clutch
@ Brake No. 7
@ Brake No. 2
@ Brake No. 3
If the pistons do not move. disassemble and inspect them.
(30)Check the input shaft and output shaft:
(a) Make sure that the input shaft has play in axial direction
and that it turns.
(b) Make sure that the output shaft has an appropriate end
pay.
End play: 0.3 - 0.9 mm (.0X2-.035
in.1
(31Jinstall the manual valve lever and shaft into the case:
(a) Install the manual valve lever shaft to the transmission
case through the manual valve lever.
(b) Drive in a new slotted spring pin with the slot at a right
angle to the shaft.
372030'
(32)lnstall
the parking
paw), pivot
prn and spring
in the case.
(33)lnstall the cam plate on the case with the two bolts. Tighten
the bolts to the specified torque. Make sure the paw1
moves freely.
NOTE
Be careful, as it is possible for the cam plate to be installed
too far forward, where it will bind the pawl.
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AUTOMATIC
TRANSMISSION
- Transmission
z!-lll
the operation
of the parking lock paw/.
The planetary gear output shaft must be locked when
manual valve lever is in the P range.
(34)Check
the
(35)lnstall a new O-ring on the throttle cable fitting.

(36)lnstall the throttle cable in the case by pushing the cable
through the case, being careful not to damage the O-ring.
Check for full seating.
Caution
l
In subsequent
work, do not roll the case over the
cable and break the cable fi%ting.
(37)lnstall the accumulator

piston and springs.
Refer to the tables Spring identification
(page 21-72) and
Identification
of Clutches,
Brakes and Accumulators
(page 21-72, 73) for installation
of correct springs and
accumulator.
372000.3
(38)Place the valve body on the transmission

as follows:
Make sure the accumulator
pistons are pressed fully into
the bore. Align the manual valve with the pin on the manual
valve lever, and lower valve body into place.
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21-l
12 AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
(39)Lift a side of the valve body and attach the throttle
(40)Make sure that the lower spring IS installed

piston.
cable.
on the BI or C?
(4l)lnstall the bolts in the valve body and tighten the bolts to
specified torque.
The length of each bolt is as shown in the figure < unit: mm
(in.) >
(42)lnstall the detent spring.

(43)lnstall the oil strainer and tighten
torque.
the bolts
to specified
(44)Using a soft hammer, install the oil pipes into the position
indicated
in the figure.
Caution
l
Be careful not to bend or damage
the pipes.
3720314
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AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-I
13
(45)lnstalI the magnet in the oil pan and install the oil pan with a
new gasket.
Caution
l
Make sure that the magnet does not interfere with
the oil pipes.
(46)lnstall
the drain plug with
a new gasket.
(47)lnstall the governor line strainer

and then install the plate.
on the transmission
case
(48)lnsert a slot screwdriver

between the governor retaining
ring and governor body and install the governor to the
output shaft.
(49)Install the adapter and gasket.
(50)lnstail
the O.D. solenoid.
Caution
Be sure to use two
(5l)lnstall
(52)lnstall
O-rings.
torque converter to transmission.

the transfer assembly (P.21-162).
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21-q 14 AUTOMATIC TRANSMISSION
GENERAL NOTES ON DISASSEMBLY

NENT ASSEMBLIES
AND ASSEMBLY
Of COMPOW1NEAA
GENERAL CLEANING NOTES:
GENERAL ASSEMBLY NOTES:
(1) All disassembled

parts should be washed clean
and the fluid passages and hole blown through
with compressed
air to make sure that they are
not clogged.
(2) The cleaning solvent used should be the recommended
ATF or kerosene.
(3) When using compressed
air to dry parts, avoid
spraying ATF or kerosene in your face.
(1) All -oil seal rings, clutch discs, clutch plates,

rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
(2) All gaskets and O-rings should be replaced.
(3) Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in the groove correctly.
(4) If a worn bushing
is to be replaced,
the
replacement
must be made with the component assembly
containing
that bushing.
(5) Check thrust bearings and races for wear or
damage.
(6) Use petroleum
jelly to keep parts in their
places.
PARTS HANDLING
NOTES:
(1) After cleaning. the parts should be arranged in

proper order to allow performing
the inspection, repairs, and reassembly
with efficiency.
(2) When disassembling
the valve body, be sure to
keep each valve together with its own spring.
(3) New brake and clutch discs that are to be used
for replacement
must be soaked in ATF for at
least two hours before assembly.
OIL PUMP
Oil pump body
Drwe gear
Oil pump cover

I
Drwen gear
Sealrmg
011 Seat
3720342
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AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
21-115
DISASSEMBLY
(I) Use the torque converter as a work stand.
(2) Remove the two seal rings from the oil pump
(3)
(4)
(5)
(6)
cover.
Remove the six bolts.

Remove the oil pump cover.
Remove the O-ring from the oil pump body.
Remove the oil pump drive gear and driven gear.
Identify their top and bottom by appropriate
marking
proper reassembly.
for
INSPECTION
BODY CLEARANCE
CHECK
(I) Push the driven gear to one side of the body. Using a feeler
gauge, measure the clearance.
Standard
value: 0.07-O-15 mm (.0029-.0059
in.)
Limit: 0.3 mm (.012 in.)
TIP CLEARANCE
CHECK
(1) Measure the gap between the drive and driven gear teeth
and the cresent-shaped
part of pump body.
Standard
value: 0.11-0.14
mm (.0043-.0055
in.)
Limit: 0.3 mm (-012 in.)
SIDE CLEARANCE
CHECK
(1) Using a steel straightedge
and a feeler gauge,
side clearance of drive and driven gears.
Standard
value: 0.02-0.05
mm (.000&.0020
Limit: 0.1 mm (.004 in.)
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measure
in.)
the
21-l
16 AUTOMATIC
TRANSMISSION
- Transmission
FRONT OIL SEAL CHECK

(1) Check for wear, damage or cracks.
If necessary, replace the oil seal by the following
steps.
(2) Pry off the oil seal with a screwdriver.
(3) install a new oil seal.
NOTE
The seal end should be flush with outer edge of pump
body.
REASSEMBLY
(1) Set the oil pump
body on the torque converter.

and drive gears on the oil pump body in
correct directions
according
to the marks put during
disassembly.
(31 Install the oil pump cover on the body.
(2) Install the driven
(41 Align the bolt holes in cover with those in body.

Install the six bolts with wave washers finger tight.
(5) install the special tool around the oil pump body and cover.
Tighten the special tool to align the body and cover.
Tighten the six pump cover bolts to the specified torque.
I;; Remove the special tool.
(8) install the two seal rings on the pump
cover by spreading
apart and sliding them into the groove.
Hook both ends by hand.
(9) Install a new O-ring on the pump.
Make sure the O-ring is not twisted and is fully seated in the
groove.
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25
AUTOMATIC
TRANSMISSION
- Transmission and Transfer Assembly 21-l 17
OVERDRIVE INPUT SHACT AND CLUTCH
?WLHEB
Overdrive
brake hub
Sni 3P ring
I
I Snap ring
mne-way clutch retainer
I
Overdrive
clutch piston
Retym spring
Spring retainer
Snap ring
Thrust
bearing #2
Thrust washer
I
Planetary gear
C(u$g(thinner)
disc
Clutch
disc -
3720345
DISASSEMBLY
(I) Pull the overdrive clutch assembly from the input
(2) Remove the thrust bearing #4 and the race #5.
shaft.
(3) Remove the snap ring and overdrive brake hub from the
overdrive clutch assembly.
(4) Remove the snap ring, flange. clutch disc and plate.
NOTE
Do not allow the removed disc to dry out.
3720042
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21-I I8 AUTOMATIC
TRANSMIWON
- Transmission
and
Transfer
Assembly
(5) Place the special tool on the spring retainer and compress
the return springs with a shop press. Using a screwdriver,
remove the snap ring.
(6) Remove the spring retainer and eighteen return springs.
(7) Assemble the overdrive clutch cylinder and piston set on

the oil pump and blow otit the piston:
(a) Slide the overdrive clutch cylinder and piston set onto
the oil pump.
(b) Apply compressed
air to the oil pump to remove the
piston.
k) Remove the overdrive
clutch cylinder from the oil
w-w
(8) Remove the O-rings from the overdrrve clutch piston.

(9) Remove the snap ring from the overdrive plan&n/
gear
assembly.
(10)Remove
the one-way clutch retainer, one-way clutch and
outer race from the overdrive planetary gear assembly.
(11 IRemove the four pinion shaft plugs by a magnet.

Caution
l
Keep the four plugs together
to prevent
losing
them.
(12)Remove
the one-way
clutch
3720047
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from
the outer
race.
AUTOMATIC
TRANSMISSION
- Transmission
21-I
19
INSPECTION
CLUTCH PISTON CHECK
(I) Check that the check ball is free by shaking the piston.
(2) Check that the valve does not leak by applying low-pressure
compressed
air.
ASSEMBLY
(I) Install
the four pinion
shaft
plugs.
12) Install the thrust bearing race #3 and thrust

coated with petroleum
jelly.
bearing
#2
3720050
Front
(3) Install the one-way clutch:

(a) install the one-way clutch into the outer race.
(b) Install the one-way clutch retainers on both sides of the
one-way clutch.
(4) Install the

(a) Install
(b) Install
(cl Install
(d) Install
thrust washer and one-way clutch assembly:

the thrust washer, facing the grooves upward.
the one-way clutch assembly in correct direction.
the thrust washer.
the snap ring.
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21-120
AUTOMATIC
TRANSMISSION
- Transmission
(5) Install the overdrive clutch piston in

cylinder.
(a) Install a new O-ring on the piston.
ATF.
(b) Press piston into the drum with
(6) Install the eighteen
return springs
retainer and snap ring in place.
the overdrive
clutch
Coat the O-ring with

the cup side up.
and set the spring
(7) Compress the return springs and install the snap ring in the
groove:
(a) Place the special tool on the spring retainer, and
compress the springs on shop press.
(b) Install the snap ring with a screwdriver.
Be sure the end gap 5i the snap ring is not aligned with
the spring retainer claw.
(8) Install the clutch plate and disc.

(a) Using low-pressure
compressed
air, blow all excess
ATF from the disc.
Caution
l
High-pressure
air will damage
the disc.
(b) Install the parts in the order shown below.
Do not install the thinner snap ring yet.
NOTE
A new clutch disc should- be seaked in ATF for at least two
hours before installation.
(9) Check the piston stroke of the overdrive clutch.
(a) Install the overdrive
clutch hub and snap ring.
(b) ~n;t-~ the overdrive clutch cylinder onto the oil pump
Using a dial indicator, measure the stroke applying and
releasing the compressed
air (400-800
kPa, 58-l 16
psi) as shown.
Standard
value:
1.56-2.53
mm (.0614-.0996
in.)
If the stroke exceeds the limit, the disc and/or plate are
probably worn. If the stroke is less than limit, parts may
be misassembled
or there may be excess ATF on the
discs.
(c) After the check, remove the snap ring and overdrive
brake hub.
(I 0)Compress and lower the snap ring by hand into the groove
in clutch cylinder. Check that the ends of the snap ring are
not aligned with one of the cutouts.
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AUTOMATIC
TRANSMISSION
- Transmission
21-121
(1l)lnstall
the overdrive brake hub and snap ring.
Check that the ends of the snap ring are not aligned
any of the cutouts.
with
(12)Assemble
the overdrive
clutch assembly
and overdrive
planetary gear assembly while meshing the overdrive brake
hub with the disc by twisting or jiggling the hub as required.
3720041
(13)Hold the overdrive clutch cylinder and turn the overdrive

planetary gear shaft to check the operation of one-way
clutch.
The shaft should turn freely clockwise and should lock
counterclockwise.
WERDRIVE CASE AND BRAKE
MlUAB
Spring retainer
Tt~~;earing
\
Snap ring
I
1
Seal ring
I Brake piston
Return spring
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Overdrive
case
3720346
21-122
AUTOMATIC
TRANSMISSION
- Transmission
DISASSEMBLY
(I) Remove the snap ring from the overdrive case.
(2) Remove the flange, brake discs, brake plates and cushion
plate.
NOTE
Do not allow the removed brake discs to dry out.
(3) Remove the planetary ring gear and thrust race #6.
(4) Remove the thrust bearing #7 and race #8 from the
overdrive case.
Note position of the race(5) Remove the snap ring, spring retainer and return springs.
(6) Remove the brake piston.
Brow compressed
air through the overdrive
case hole
indicated in the figure to force out the brake piston.
if the piston does not come out, lift it out with needle nose
plrers.
(7) Remove
(8) Remove
the two oil seal rings from the overdrive

the O-rings from the piston.
case.
ASSEMBLY
(I) Install the two seal rings on the overdrive case by spreading
apart and sliding them into the groove. Hook both ends by
hand.
(2) Install new O-rings on piston. Coat the O-rings with ATF.
(3) Install the brake piston in the overdrive case with the cup
side up, being careful not to damage the O-rings.
(4) Install the return springs and set the spring retainer and
snap ring in place.
Check that the ends of the snap ring are not aligned with
any of the cutouts.
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AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assemblv
21-123
(5) Install the thrust bearing #7 and races #6 and #8 to the

planetary ring gear and set the ring gear in the overdrive
case.
NOTE
Make sure that the thrust bearing races are installed in the
correct direction.
-IJM
Cushion plate
372006
(6) Install the cushion plate. brake discs, brake plates and
flange:
compressed
ATF from the discs
(b) Install the parts in the order shown below.
NOTE
New clutch discs should be soaked in ATF for at least two
Cushion plate (rounded end down) + Brake plate +
Brake disc + Brake plate -+ Brake disc + Brake plate
-+ Brake disc + Flange (flat end down)
Check that the ends of the snap ring are not aligned
one of the cutouts.
(8) Measure the distance between snap ring and flange
feeler gauge to check the brake clearance.
Standard
(9) Install
value:
the thrust
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0.65-2.21
washer
mm
(.0256-.0870
onto the planetary
with
with
in.1
ring gear.
I.
21-124
AUTOMATIC
.&L
TRANSMISSION
- Transmission
and Transfer
Assembly
:ORWARD CLUTCH
Nzlumc
Snap ring
Thrust be%rmg #12
Clutch
Forward
cylinder
clutch
disc
Clutch
return
Snap
ring
spring
Forward ] Spring ]
I ret?ner
I
I
~~
\
ihrust
bearing race #13
Thrust bearing race #l 1

Snap ring (thinner)
Clutch disc
Clutch plate
3720347
DISASSEMBLY
(1) Use the extension
housing as a work stand.
(2) Remove the snap ring from the forward clutch cylinder.
(3) Remove the direct clutch hub and forward clutch hub.
(4) Remove the thrust bearing

#13.
(5) Remove the clutch disc.
NOTE
Do not allow the removed
#I2
and the races #I 1 and
disc to dry out.
(6) Remove the snap ring.

(7) Remove the remaining
clutch plates and discs.
NOTE
Do not allow the removed discs to dry out.
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AUTOMATIC
TRANSMISSION
- Transmission
21-125
(8) Set the special tool on the spring retainer and compress the
clutch return springs with a shop press.
Using a screwdriver,
(9) Remove the special tool, then remove the spring retainer
and eighteen clutch return springs.
720073
(10)Assemble
the forward clutch cylinder and piston on the
overdrive case and force out the piston by compressed
air:
(a) Slide the foward
clutch cylinder and piston onto the
overdrive case.
(b) Apply compressed air to the overdrive case to remove
the piston.
(c) Remove the forward clutch cylinder from the overdrive
case.
(11 )Remove the O-rings from the forward clutch piston.
372,,,1
INSPECTION
FORWARD CLUTCH PISTON
(I 1 Check that check ball is free by shaking the forward clutch
piston.
compressed
air.
NOTE
Prepare new discs by soaking them at least two hours in
ATF.
ASSEMBLY
(I) Install new O-rings on the forward clutch piston.
Coat the O-rings with ATF.
(2) Press the forward clutch piston into the forward
cylinder with the cup side up (check ball down).
Be careful not to damage the O-rings.
clutch
(3) Install the eighteen clutch return springs, spring retainer

and snap ring in place.
(4) Compress the clutch return springs and install snap ring in
the groove:
(a) Set the special tool on the spring retainer, and compress the springs on a shop press.
(b) Install the snap ring using a screwdriver.
Be sure the end gap of snap ring is not aligned with the
spring retainer claw.
[ TSB Revision
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21-l 26
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
(5) Install the clutch discs and plates without assembling the
snap ring.
NOTE
A new clutch disc should be soaked in ATF for at least two
compressed
ATF from discs.
mm
Caution
l
High-pressure
air will damage
discs.
lb) Install the clutch plates and discs alternately.
Do not
install the snap ring (thinner) yet.
(6) Check the piston stroke of forward clutch:
(a) install the direct clutch hub and snap ring.
(b) Install the forward clutch cylinder assembly onto the
overdrive case.
air (400-800
kPa. 58-116
psi).
Standard stroke:
1.43-2.93
mm (.0563-.I164
in.)
If the stroke exceeds the limit, the clutch discs and/or
plates are-probably
worn. If the stroke is less than the
limit, parts may be misassembled
or there may be
excess ATF on the discs.
(c) After the check, remove the snap ring and direct clutch
hub.
(7) Compress and lower the snap ring into the groove by hand.
Check that the ends of the snap ring are not aligned with
any of the cutouts.
03) Install the clutch disc. -
(9) Install the thrust bearing #I2 and the races #I 1 and #13,
all coated with petroleum
jelly.
(10)lnstall the forward clutch hub while aligning the disc lugs
with the hub teeth. Make sure the hub meshes with all the
discs and IS fully inserted.
1 TSB Revision
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AUTOMATIC
TRANSMlSSlON
- Transmission
and Transfer
Assembly
21-127
(11 )Install the direct clutch hub and snap ring.

Check that the snap ring ends are not aligned with any of
the cutouts.
DIRECT CLUTCH
Direct
Direct
clutch
cylinder
S
ri
Springretainer
3720400
DISASSEMBLY
(I) Remove the snap ring from the direct clutch
(2) Remove the flange, clutch discs and plates.
NOTE
Do not allow the clutch discs to dry out.
cylinder.
(3) Set the special tool on the spring retainer and compress the
piston return springs with shop press.
Using snap ring pliers, remove the snap ring.
(4) Remove the spring retainer and eighteen piston return
springs.
3720085
/
TSB Ret&ion
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21-128 AUTOMATIC TRANSMlSSlON
- Transmission
and Transfer
Assembly
(5) Assemble the direct clutch-cylinder

and piston set on the
center support and force out the piston by compressed
air:
(a) Slide the direct clutch cylinder andpiston set onto the
center support.
(b) Apply compressed
air to the center support to remove
the piston.
(c) Remove the direct clutch from the center support.
(6) Remove the O-rings from-the
direct clutch piston.
372008f
INSPECTION
DIRECT CLUTCH PISTON
(1) Check that the check ball is free by shaking each piston.
compressed
air.
372001
ASSEMBLY
(1) Install new O-rings on the direct clutch piston.
Coat the O-rings with ATF.
(2) Install the direct clutch piston in the direct clutch cylinder.
To install, press the direct clutch piston into the cylinder
with the cup side up, being careful not to damage the Orings.
~\1?+-+-P
MD998903
(3) install the eighteen

piston return springs and set the
retainer with snap ring in place.
(4) Compress the piston return springs and install thesnap
ring:
(a) Set the special tool on the spring retainer, and compress the springs on a shop press.
(b) With snap ring pliers, install the snap ring.
Be sure theend gap of the snap ring is not aligned with
the spring retainer claw.
(5) Install the clutch discs, plates and flange:

NOTE
compressed
ATF from the clutch discs.
Caution
* High-pressure
air will damage
the discs.
(b) Install the parts in the following order:
Clutch plate + Clutch disc -+ Clutch plate -+ Clutch disc
?
3 Clutch plate + Clutch disc + Flange (flat end down)
1 TSB Revision
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AUTOMATIC
TRANSMISSION
- Transmission
21-129

Check that the snap ring ends are not aligned with any of
the cutouts,
(7) Check the piston stroke of direct clutch as follows:
Install the direct clutch onto the center support. Using a dial
indicator, measure the stroke applying and. releasing the
compressed
air (400 - 800 kPa, 4 - 8 kg/cm2, 58 - 116 psi)
as shown.
Standard piston stroke:
0.91-1.99
mm (.0358-.0783
in.)
plates are probably worn. If the stroke is less than the limit,
parts may be misassembled
on the discs.
CENTER SUPPORT
SnaF1 ring
Clutch
Center suppori
Clutch
plate
I
Piston
return
No. 1 brake
Piston
SIl ) ring
Flange
lutch
SC
Clutch
plate
I
Planetary sun gear

I
Snap ring
Spring retainer
Brake return spring
No. 2 brake piston
One-way
clutch assembly
1 TSB Revision
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21-130
AUTOMATIC
TRANSMISSION
- Transmission
DISASSEMBLY
(I) Remove the snap ring from the end of planetary
shaft.
(21Pull the center
gear.
support
assembly
from
sun gear
the planetary
sun
(3) Remove the snap ring from the front of center support
assembly (No. 1 brake).
(41 Remove the flange, clutch disc and plate (No. 1 brake).
NOTE
Do not allow the removed clutch disc to dry out.
(51 Set the special tool on

springs with a shop
the spring
(61 Remove
springs.
the spring retainer and compress the

press.
retainer and twelve
brake return
air through the center support

(7) Blow compressed
remove the No. 1 brake piston.
(8) Remove the No. 1 brake piston O-rings.
oil hole to
over and remove the rear

(9) Turn the center supportassembly
snap ring (No. 2 brake).
(lOIRemove
the flange, clutch discs and plates, (No. 2 brake).
NOTE
Do not allow the removed clutch discs to dry out.
.-
/ TSB Revision
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;I
AUTOMATIC
TRANSMISSION
Transmission
and
Transfer
(11)Set the special tool on the spring
springs with a shop

(12)Remove
the spring
springs.
press.
remove
retainer
Assembly
21-13
retainer and compress

the snap ring.
and twenty
brake
the
return
(13)Blow compressed
air through the center support oil hole to
remove the No. 2 brake piston.
(14)Remove
the No. 2 brake piston O-rings.
(15)Remove
the three
oil seal rings from the center
(16)Remove
the one-way clutch assembly
from the planetary sun gear.
3720103
support.
and oil seal rings
372010'
INSPECTION
ONE-WAY
CLUTCH ASSEMBLY
(1) Hold the No. 2 brake hub and turn the planetary sun gear.
The sun gear should turn freely counterclockwise
and
should lock clockwise.
If the one-way clutch does not operate properly, replace it.
) TSB Revision
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21-l 32
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
(2) If necessary, replace the one-way clutch:

(a) Bend the tabs back with a tapered punch.
(b) Pry off the retainer with a screwdriver.
Leave the other
retainer on the hub.
(c) Remove the one-way clutch.
(d) Install the one-way clutch into the brake hub facing the
spring cage toward the front.
3720108
3720107
(e) Hold the brake hub in vise with soft jaws, and bend the
tabs with a chisel.
(f) Check to make sure that the retainer is centered.
ASSEMBLY
(I) Install the two seal rings and one-way
the planetary sun gear.
3720110
clutch
assembly
on
372011
(2) Install the three seal rings in the groove of center

Hook both ends of ring by hand as shown.
http://vnx.su/
support
AUTOMATIC
TRANSMISSION
- Transmission
21- 133
(3) Install new O-rings on piston. Coat the O-rings with ATF.
(4) Press the No. 1 brake piston into the center support with
the cup side up, being careful not to damage the O-rings.
(5) Install the twelve piston return springs and set the retainer
with snap ring in place.
(6) Set the special tool on the spring retainer, and compress
the springs on a shop press.
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned with the
(7) Install new O-rings on the piston and center support. Coat
the O-rings with ATF.
63) Turn the center support over, then press the No. 2 brake
piston into the center support with the cup side up, being
careful not to damage the O-rings.
(9) Install the twenty piston return springs and set retainer with
snap ring in place.
(10)Set the special tool on the spring retainer, and compress
the springs on a shop press.
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned with the
(11)Turn the center support over and install the No. 1 brake
piston, clutch plate, disc and flange:
NOTE
compressed
ATF from the disc.
Caution
l
High-pressure
air will damage
the disc.
(b) Install the parts in the following
order:
Clutch plate + Clutch disc ---) Clutch plates (2 pieces) 3

Clutch
) TSB Revision
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disc +
Flange
(rounded
edge
down)
21-134
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
(12)lnstall the snap ring in the center support.

Check that the snap ring ends are not Sgned with any of
the cutouts.
(13)Check the piston stroke of No. 1 brake as follows:
air (400-800 kPa, 56-I 16 psi) as
shown.
0.80-1.73
mm (.0315-.0681
in.)
plates are probably worn. If the stroke is less than the limit,
on the discs.
(14)Turn the center support over and install the No. 2 brake,
clutch plates, discs and flange:
NOTE
compressed
ATF from-the
discs. _
Caution
l
High-pressure
air will damage
the disc.
(b) Install the parts in the following
order.
Clutch plate --+ Clutch disc + Clutch plate -+ Clutch disc
-+ Clutch plate + Clutch disc -f Flange
(15)lnstall the snap ring in the center support.
Check that snap ring ends are not aligned with any of
cutouts.
(16)Check the piston stroke %f No. 2 brake as follows:
air (400-800 kPa, 58-l 16 psi) as
shown.
1.01-2.25
mm (.0398-.0886
in.)
plates are probably worn. If the stroke is less than limit,
on the discs.
(17)Assemble
the center support and planetary sun gear:
(a) Align the brake No. 2 clutch disc flukes.
(b) Mesh the brake hub with the discs, twisting and jiggling
the hub as required.
I/
3720719
(18)lnstall
the snap ring on end of the planetary
http://vnx.su/
sun gear.
AUTOMATIC
LANETARY
GEAR
TRANSMISSION
AND
OUTPUT
- Transmission
and
Transfer
Assemblv
21-I
35
&WXA.=
SHAFT
Reaction plate
Pressure
Clutch
I disc
plate
Snap ring
Thrust washer lsteel washer)

Frbnt planetary
gear
Thrust
bearing
I
117
Nylon washer
Intermediate
shaft
Seal ring
Rear planetary
Planetary
sun gear
ring gear
Thrusiwasher
(nylon washer)
3720362
DISASSEMBLY
(1) Remove the No. 3 brake discs and plates
planetary gears.
and the [rant
372012 1
(2) Remove the steel thrust washer from the front planetary
gears.
NOTE
The thrust washer may have stuck to the inside of the front
planetary gear case.
(3) Remove the clutch discs and plates from the front planetary
gears.
(4) Remove the reaction plate from the front planetary gears.
3720122
3720123
/ TSB Revision
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- Transmission
(5) Remove the snap ring and one-way clutch from the front
planetary gears.
(6) Remove the nylon washer from the front planetary gears.
.
5
(7) Remove the brake apply tube and pressure plate.

(8) Compress the snap ring and remove the front planetary ring
gear:
(a) While pulling up the ring gear, compress the snap ring
with needle-nose
pliers and remove it from the groove.
(b) Pull out the front planetary ring gear by hand.
(9) Remove the intermediate

shaft assembly from the output
shaft.
(lO)Remove
the thrust bearing #20 and race #19 from the
output shaft.
(ll)Remove
the three seal rings from the ouput shaft.
372011
(12)Remove
the nylon thrust washer from the rear planetary
gear.
(13)Remove
the planetary sun gear.
(14)Remove the rear planetary gear from the intermediate
shaft
assembly.
(15)Remove
the thrust bearing #I7 from the intermediate
shaft.
Note the position of the races.
(16)lnvert the intermediate

shaft and remove the set ring.
(17)Remove
the rear plan&ary
ring gear and thrust bearing
race #I8 from the intermediate
shaft.
Note the position of the race.
http://vnx.su/
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-137
ASSEMBLY
(I) Install the thrust bearing race #I8 and rear planetary ring
gear on the intermediate
shaft as follows:
Slip the thrust bearing race and ring gear onto the
intermediate
shaft with the exterior splines up, as shown,
(2) Install the set ring on the intermediate
shaft.
Make sure the rear planetary ring gear is secure on the
intermediate
shaft.
(3) ply
over the intermediate
shaft and install thrust bearing
(4) Install the pinion gear assembly and nylon thrust washer on
the rear planetary carrier.
Install the washer with the lugs down, fitting them into the
rear planetary gear carrier.
Caution
l
Make sure the different
lug shapes
match the
openings
on the plate.
(5) Install the three oil seal rings on the output shaft by
spreading apart and sliding them into the groove.
Hook both ends by hand.
(6) Use the extension
housing as an assembly stand.
(7) Install the thrust bearing #20 and race #I9 on the output
shaft.
(8) Install the intermediate

shaft assembly in the output shaft.
(9) Install the rear planetary gear in the output shaft.
(10)lnstall the planetary sun gear in the rear planetary gear.
( TSB Revision
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:i
21-138
ffz i ..
AUTOMATIC
/ il.
TFlANSMlSSlON
- Transmission
(1l)lnstall the snap ring on the front planetary ring gear.

(12)Set the front planetary ringgear on the output shaft drum.
Align the ends-of the snap ring with the wide gap between
the teeth.
(13)While pushing down the front planetary ring gear, squeeze
the snap ring ends to install it into the groove.
(14)lnstall the nylon washer in the front planetary gear. facing

the lugs downward and aligning them with the slots in back
of the planetary gear.
37201x
(15)lnstall the one-way clutch and snap ring into the front
planetary gear, facing the spring cage toward the front.
(16)lnstali the reaction plate on the planetary gear for testing

purpose.
(17)Test the one-way clutch.
The planetary gear must rotate freely counterclockwise
and
lock clockwise.
If the clutch does not work correctly, it must be replaced.
(18)Remove
the reaction plate.
(19llnstall
the thrust washer
(steel washer)
coated
petroleum
jelly on the front planetary gear.
1 TSB Revision
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1
-
with
AUTOMATIC
TRANSMISSION
Transmission
and
Transfer
Assembly
21-139
the front planetary

gear assembly
to the intermediate shaft.
(2l)lnstall the brake apply tube and the pressure plate facing
the flat surface toward the intermediate
shaft.
(20)lnstall
(22)lnstaii the No. 3 brake discs and plates.

compressed
ATF from the discs.
Caution
l
High-pressure
air will damage
the discs.
(b) install the parts in the following
order:
Clutch disc -+ Clutch plate + Clutch disc -+ Clutch plate
+ Clutch disc + Clutch plate -+ Clutch disc + Clutch
plate -+ Clutch disc
NO.3 BRAKE PISTON AND TRANSMISSION
CASE
NmJac
Transmission
Pis ton return
w ing
Snap ring
spring
stainer
f,Fe;F
No. 3 Brake
priman/ piston
O-ring
case
No. 3 Brake
secondary
piston
O-ring
O-ring
3720353
DISASSEMBLY
(1) Install the special tool. Gradually and evenly tighten the bolt
to compress the springs, being careful not to damage the
transmission
case with the special tool.
and a hook, remove the snap ring.
;evision
http://vnx.su/
21-140
AUTOMATIC
TRANSMISSION
- Transmission
(3) Remove
springs.
the
spring
and Transfer
retainer
and
Assembly
sixteen
piston
return
(4) With the frontend

down, place the transmission
case on a
workbench.
Place several clean shop rags under the case to
catch the piston and sleeve. Apply compressed
air to the
primaty and secondary piston oil holes to force the piston
and sleeve out.
(5) If the piston and sleeve do not come out with the
compressed
air:
(a) Using needle-nose
pliers, lift the primary piston from
the case.
\ \
372014
(b) insert two long hooks behind the reaction sleeve and
gradually lift it out of the case.
(c) Using hooks, lift the secondaty
piston out of case in
the same manner.
(6) Remove the O-rings from the primary and secondary
pistons and the reaction sleeve.
REPLACEMENT
OF MANUAL
SHAFT OIL SEALS
(1) Remove the manual shaft oi! seals with a screwdriver.
(2) Drive in new left and right oil seals with a socket wrench.
PSI3
Revision
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AUTOMATIC
TRANSMISSION
- Transmission
21-141
ASSEMBLY
(1) Install new
Caution
O-rings
on the reaction
sleeve
and pistons.
The thinner O-ring
goes on the outside

of the
reaction sleeve.
(2) Install the primary and secondary pistons in the reaction
sleeve:
(a) Push the secondary piston into the cupped side of the
reaction sleeve.
(b) Push the primary piston onto the other side of the
reaction sleeve.
(3) Hold by hand the assembly with the primary piston up
(spring seats visible). and push the assembly into its bore in
the case.
Caution
l
Be careful not to damage
the O-rings.
(4) Install the special tool (MD99821 1) under the transmission
case.
l
(5) install the sixteen piston return springs and set the spring
retainer with snap ring in place.
NOTE
The piston return springs are visible through the cutout in
the case, which helps position them more easily.
(6) Carefully position the special tool (MD998903)

on the
spring retainer.
(7) Gradually and evenly tighten the special tool (MD99804) to
compress the springs, being careful not to damage the
transmission
case with the special tool.
Caution
l
Avoid bending the spring retainer by ovettightening
the special tool.
(8) Push the snap ring by hand into place. Visually check to
make sure it is fully seated and centered by the three lugs
on the spring retainer.
(9) Remove the special tool.
Revision
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21-142
AUTOMATIC
VALVE
BODY
TRANSMISSION
- Transmission
and Transfer
Assembly
NmLo-
77 76
73
6
72
Q
1 TSB Revision
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AUTOMATIC
TRANSMISSION
- Transmission
1. Throttle cam
2. Cam spacer
3. Return spring
4. Throttle valve
5. Throttle valve primary spring
6. Kickdown valve
7. Upper front vahre body
8. Check valve
9. Check ball
10. Throttle valve keep plate
11. Secondan/ regulator valve spring
12. Secondary regulator valve
13. Front valve end cover
14. l-2 shii valve
15. l-2 shift valve plug
16. Valve retainer
17. 34 shift valve
18. 3-4 shift valve plug
19. Locating pin
20. D-2 down timing valve
21. D-2 down timing valve plug
22. Valve retainer
23. Primary regulator valve
24. Primary regulator valve spring
25. Primary regulator valve plungef
26. Primary regulator valve sleeve
27. Valve retainer
28. Check valve
29. Check valve
30. Manual valve
31. Plate
32. Oil screen gasket
33. Oil screen
34. Pressure relief valve
35. Pressure relief valve spring
36. Retainer
37. Detent spring
38. Detent spring plate
39. Lower valve body cover gasket (upper)
40. Lower valve body cover plate
41. Lower valve body cover gasket flower)
42. Lower valve body cover
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
1 TSB Revision
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21-143
Check valve
Locating pin
Manual plug
Third coast shift valve plug
Third coast shift valve
34 shift control valve
3-4 shift control valve spring
Low coast shift valve cover
Low coast shift valve
I-2 shift valve spring
Lower valve body
Plug
Lower valve body gasket
Check valve
Separate plate
Valve body gasket
Check valve
Valve retainer
Cut back plug
Cut back valve
Throttle valve secondary spring
E-ring
Reverse brake sequence valve
Low coast modulator valve spring
Plug
Low coast modulator valve
Check valve
Valve retainer
Intermediate coast shift valve plug
Intermediate coast shift valve
Upper rear valve body
23 shift valve
2-3 shift valve plug
Valve retainer
Intermediate coast modulator valve
Detent regulator valve spring
Valve retainer
intermediate coast modulator valve spring
Reverse clutch sequence valve spring
Rear valve cover
21-144
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
DISASSEMBLY
For disassembly, observe the precautions given below.
(1) Keep the disassembled parts orderly for efficient reassembly
operation. Attach tags to springs for identification.
(2) When disassembling the valve, do not attempt to remove the
valve with undue force. The valve and valve hole could be
damaged or burred, leading to faulty valve operation.
(3) When removing the front upper and rear valve bodies from the
lower valve body, use care not to lose check balls and springs.
INSPECTlON
Wash the removed
ing checks.
parts and dry with air. Then, make the follow
Caution
When making checks, usa care not to damage
side and valve body holes.
valve land out-
(1) Check the valves for damage and wear.

(2) Insert the valves in the valve body and check smooth rotation
and sliding.
(3) Check the valve body for damage and wear of valve hole bores
and for clogging of oil holes and oil ways.
(4) Check for damage of the valve body plate wear and damage of
check balls.
(5) Check for clogging of the oil strainer.
Kick-d&n
valve
Secondary
regulator valve
388181
) TSB f&vision
.-
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_-
AUTOMATIC
REAR VALVE
TRANSMISSION
- Transmission
21-145
BODY
intermediate
2-3 shift valve
coast shift valve
I
&QgQ&J
(g&g*
Intermediate
modulator
valve
Low coast modulator
valve
Reverse clutch sequence valve
373oa3
(6) Check the springs and replace if broken or excessively

deteriorated
(See the table on page 21-72.)
3WER VALVE BODY
Plug
Low coast shift valve
l-2 yhift valve
I+
WI
Third coast shift valve
D-2 down timing valve
34 shift control valve
II
-c
-I
,I
(..I
t
Primary regulator valve
EltlBllD0
/
Pressure relief valve

I +--Manual
valve
e
373063
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21-146 AUTOMATIC TRANSMISSION -
Transmission
and Transfer
Assembly
REASSEMBLY
Caution
Before reassembly,
wash the parts in a clean detergent
and
dry with air. Do not wipe with rags for drying. Entry of dust
could cause faulty vahfe operation.
3551Sl
(1) Install primary regulator valve 1, spring 2, plunger 3 and sleeve

4 in the lower valve body in the order shown and insert retainer 5 to prevent the valve and other parts from coming
loose.
(2) Install 1-2 shift valve 1 and valve plug and insert retainer 3 to
prevent the valve from coming loose.
(3) install l-2 shift valve spring 1, low coast shift valve 2 and plug
3 and fit low coast shift valve cover 4.
372&a
(4) Install pressure
relief valve 1, spring 2 and retainer 3.
(5) install spring, check valve and check valve spring at illustrated
locations.
3!%1681
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AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-147
(6) install the spring, 3-4 shift valve and plug and then insert the
locating pin.
(7) install the D-2 down timing valve and plug and insert the seat.
(8) install 2-3 shift valve spring 1, 2-3 shift valve 2, 2-3 shift valve
plug 3 and retainer 4 in the upper rear valve body.
(9) Install intermediate coast shift valve 5. plug 6 and retainer 7.
(10)lnstall detent regulator valve 1, spring 2 and retainer 3 in the

order shown.
35517c
(11 )Install low coast modulator valve 1, plug 2, reverse brake sequence valve 3 and intermediate coast modulator valve 4.
(12)lnstall valve springs.
(13)lnstall rear valve cover 5.
avision
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21-148
AUTOMATIC
- Transmission
TRANSMISSION
and Transfer
Assembly
(14)Place check balls (rubber) at illustrated

the bottom of the lower valve body.
locations
in oil ways in
(15)When installing the lower valve body cover, use the correct
gasket. One with oval holes for check balls is for the lower
valve body.
(16)lnser-t secondary regulator valve spring 1 and secondan/ regulator valve 2 in the front upper valve body and install front
valve end cover 3.
(17)lnser-t throttle valve 1. throttle valve secondary spring 2 and E

rings 4 in the order shown and fit key plate 3 in the oil way at
illustrated location. Then, install throttle valve primary spring 5
and kickdown valve 6.
Caution
1. Install sama number of E rings as before disassembly
for not disturbing throttle valve adjustment.
2. Insertion of the throttle
valve key plate at incorrect
location could cause faulty valve operation.
(18)lnstall the throttle cam and spring on the upper front valve
body and tighten bolts temporarily. When installing, note the
location of the spring end on the body side. Then, hook the
other end of the spring to the cam and bolt the cam to the
valve body. After installation, check that the throttle cam turns
through full stroke smoothly.
ook spring to this hole
Caution
Hook the spring
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to the correct
hole.
AUTOMATIC
TRANSMISSION
- Transmission
21-149
cut back valve 1, valve plug 2 and retainer 3. fnstalf the

cut back plug with the larger land end facing out.
(19)lnstall
(20)install
the check ball (rubber) at the illustrated
location.
355171
(21 IPlace a new lower valve body gasket on the lower valve body.
NOTE
Do not use gasket for the upper valve body.
For lower valve body
(22)lnstall the separator plate and tighten bolts at illustrated

tions temporarily.
loca-
(23)Place a gasket for upper valve body, aligning with the separator plate.
(24)lnstall the check valve (steel) in the position shown in the
figure.
The three check valves (rubber) are identical and may be
installed in any other positions.
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21-q
50
AUTOMATIC
TRANSMISSION
- Transmission
(25)lnstall the lower valve body onto the rear upper valve body
and tighten the bolts (indicated by (A)) temporarily from the
lower valve body side.
(26)Remove the two bolts tightened in step (22).
(27)lnstall the lower valve body onto the rear upper valve body
and tighten the bolts (indicated by(B)) temporarily from the
(28)lnstall the detent plate.
(29)lnstall the lower valve body onto the upper front valve body
and temporarily tighten the bolts shown at left from the
(3O)Turn the valve body upside down and temporarily

the illustrated bolts from the upper valve body side.
tighten
(31)Then. temporarily tighten the remaining valve body bolts as

illustrated.
(32)Tighten all bolts of the valve body to specified torque.
(33)lnstall the manual valve.
Fi
le
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AUTOMATIC
TRANSMISSION
- Transmission
21-151
GOVERNOR
JJ-
Outer governor
spring
Inner governor
spring
Secondary
Governor
we&t
valve shaft
Governor
retaining
ring
Lock plate
DISASSEMBLY
(I) Compress the spring by pushing up on the governor valve
shaft and down on the governor weight. Remove the E-ring
with a screwdriver.
Lift off the governor weight.
(2) Remove the governor valve by letting it down through the
bore.
3720265
(3) Remove the governor retaining ring. To remove, disengage

the end indicated by an arrow, being careful not to scratch
the governor body.
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21-152 AUTOMATIC TRANSMISSION - Transmission
and Transfer
Assembly
ASSEMBLY
(1) Install the governor retaining ring by fitting the ring end
indicated by an arrow in the hole. Be careful not to scratch
the governor body.
(2) install the

governor
(a) install
(b) Install
governor valve, secondary weight. springs and

valve shaft:
the secondaryweight
to the governor valve shaft.
the two springs.
(c) Slide down

(d) Slide down
3720270
the governor valve through the bore.

the spring and shaft through the bore.
3720271
(3) Install the governor weight and E-ring on the governor valve
shaft as follows:
Compress the spring, and install the E-ring on the shaft with
needle-nose
pliers. Make sure that it is fully seated in the
groove.
NOTE
Make sure that the valve moves smoothly.
OVERDRIVE SOLENOID VALVE
NZINWA
INSPECTiON
(I) Inspect the overdrive
between the terminal
solenoid by checking
and body.
Standard resistance: About 13 SI
Sevision
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the resistance
AUTOMATIC
TRANSMISSION
- Transmission
and Transfer
Assembly
21-153
IXANSFER
ht
w-76
61
58
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Snap ring
Spring retainer
Shift rail
Cotter pin
H-L shift fork
Spring
Steel ball
Stopper plate
Clutch sleeve
Clutch hub
Bearing
Rear output shaft
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Low speed gear

Needle bearing
Bearing spacer
H-L clutch hub
Snap ring
Needle bearing
Clutch sleeve
Snap ring (optional)
Input gear
Bearing
Snap ring
Oil guide
Side cover
Oil seal
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Buff le plate
Side cover gasket
Dust seal guard
Oil seal Transfer case
Chain cover gasket
O-ring
Thrust washer
Needle bearing
Bearing spacer
Counter gear shaft
Counter gear
Lock plate
Dust seal guard
Dust seal
Rear cover
Rear cover gasket
Steel ball
4WD lamp switch
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46.
47.
4%
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
&I.
Seal plug
Poppet spring
Seal ball
Cord fastener
Interlock plunger
Ball bearing
Steel ball
Chain
Needle bearing
Sprocket sleeve
Drive sprocket
Bearing
Front output shaft
Sprocket spacer
Lock nut
Chain cover
Pulse generator
Cover
Cover gasket
Spacer
Wave spring
Pulse rotor
Snap ring
H-L shift rail
Wave spring
Speedometer sleeve
assembly
Sleeve clamp
ControT lever assembly
Control housing cover
Gasket
Breather
Plug
Gasket
Select spring
Select plunger
2-4WD shift fork
Distance piece
2-4WD shift lug
Spring pin
1480001
21-154
AUTONIATIC TRANSNIISSION
- Transmission
REMOVAL
(I) Remove the plug from the right side of the transfer case and
take out the select spring and select plunger.
(2) Fitmove the control lever housing assembly, cover and gas(3) Remove the transfer case to adapter attaching bolts and nuts.
(4) Pull the transfer case back to separate from the adapter.
DISASSEMBLY
4WD switch
(1) Remove two 4WD light switches.Take out two steel balls.
(2) Remove the speedometer
sleeve clamp and remove the
speedometer
sleeve assembly.
(3) Remove the rear cover attaching bolts and remove the spacer
and gasket.
(4) Remove the cover (front output shaft portion) and take out the
wave spring, spacer (if inserted) and gasket.
(5) Remove the side cover and gasket.
(6) Drive out the spring pin from the H-L shift fork by using the
special tool or a pin punch (commercially available).
(7) Remove the two seal plugs and take out the two poppet
springs and balls.
3) Pull out the H-L shift rail rearward.
3) Take out the interlock plunger.
IO)Remove the snap ring from the rear output shaft rear bearing.
I l)Remove the chain cover.
I2)Remove the oil guide.
(13)Remove
the countershaft
countershaft.
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locking
plate and pull out the
AUTOMATIC
Thrust
TRANSMISSION
and
Transfer
21-I 55
Assemblv
(14)Take out the counter gear, two thrust washers

bearings and spacer from the side cover hole.
washer
- Transmission
and needle
Counter aear
(15)Remove the snap ring from the 2-4WD shift rail and remove
the two spring retainers and spring from the shift rail.
(16)Take out the front output shaft, rear output shaft, 24WD
shift fork and chain together
from the transfer case.
(17)Tap the spring pin out so that the 2-4WD shift rail,
distance piece and 24WD shift lug can be removed.
(18)Remove
the H-L shift fork and clutch sleeve.
(19)Remove
the needle bearing from the input gear.
(20)Remove
the snap ring and then
assembly.
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remove
the input
gear
21-156 AUTOMATIC TRANSMISSION - Transmission and Transfer Assembly

DISASSEMBLY OF REAR OUTPUT SHAFT
(1) Remove the snap ring from the rear output shaft front end and
remove the H-L clutch hub, low speed gear, thrust washer and
needle bearing.
(2) Pry up the staked portion o? the rear output shaft lock nut and
loosen and remove the lock nut.
(3) Remove the ball bearing from the rear end using a bearing
puller (commercially available) or a press.
(4) Remove the sprocket spacer and steel ball.
(5) Remove the drive sprocket, two needle bearings, sprocket
sleeve and steel ball.
(6) Remove the 2-4WD clutch sleeve, hub and stop plate and pull
out the ball bearing using a puller or press.
123
1.
2.
3.
4.
5.
6.
456
Snap ring
H-L clutch hub
Low speed gear
Ball bearing
Stop-plate
2-4WD clutch sleeve
76
7.
8.
9.
10.
11.
12.
9 10
11
2-4WD clutch hub

Drive sprocket
Sprocket spacer
Ball bearing
Lock nut
Rear output shaft
13. Thrust washer

14. Needle bearing
15. Steel ball
16. Sprocket sleeve
17. Needle bearing
18. Steel ball
144616
REASSEMBLY OF REAR OUTPUT SHAFT

For reassembly, follow the disassembly steps in reverse order,
paying attention to the following.
(1) Prior to reassembly, wash parts and check sliding and rotating
parts for damage. Replace parts if excessively worn or damaged.
(2) Apply transmission oil to rotating and sliding parts before reassembly.
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AUTOMATIC
\
I
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-157
(3) When installing the clutch hub, note the direction.
Also check
that the sleeve slides smoothly when installed.

sleeve may be installed in either direction.
The clutch
Front
A
(4) Install a snap ring for H-L clutch hub on the front end of the
rear output shaft. Use the thickest snap ring that fits in the
groove.
Standard value: O-0.08
mm (O-.003
in.)
(5) Tighten the lock nut to specified torque and then stake at the
illustrated location, aligning with the groove.
(6) Check that the low speed gear and drive sprocket ball bearing
rotate smoothly.
REASSEMBLY
(1) Press fii new oil seals in the input gear portion and front output
shaft portion of the transfer case. Fit the baffle plate on the
input shaft side. Apply specified oil to the oil seal lips.
Specified
oil:
http://vnx.su/
Hypoid gear oil API classification

GL-4 or
higher SAE viscosity No. 8OW, 75W-85W
21-158 AUTOMATIC TRANSMISSION -
Transmission
and
Transfer
Assembly
(2) Press fit the ball bearing to the input gear, pushing the inner
race. Check that the bearing rotates smoothly.
(3) Fit a snap ring on the front end of the input gear. Use the
thickest one that fits in the groove.
Standard
value : 0 - 0.06 mm (O-.002
in.)
(4) Insert the input gear assembly in the transfer case and fit a
snap ring. Use the thickest one that fits in the groove.
Standard value : 0 - 0.00 mm (O-.002 in.1
(5) lnsert the needle bearing in the input gear.
(6) Install the H-L clutch sleeve and shift fork.
(7) Install the 24WD shift lug, distance piece and 24WD shift
rail in this order, and then tap the spring pin in place.
E
s
I_
(8) Engage chain securely with the rear output shaft and front
output shaft sprockets. Then, install the rear and front output
shahs and chain together, while sliding the 2-4WD shift fork
with the clutch sleeve attached over the 24WD shift rail.
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-~
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-I
59
(9) Install two spring retainers and spring over the 2-4WO shift rail
and fit a snap ring.
Thrust washer
(IO) Insert two needle bearings and spacer in the counter gear and
install the assembly in the transfer case. Install a thrust
washer on each of the counter gear.
Counter gear
(1l)lnser-t
the countershaft
and fit the locking plate.
(12) Install the oil guide.

(13)lnstall the chain cover and gasket, making sure that the oil
guide edge is in the chain cover window. Apply sealer to the
gasket.
Specified
sealant:
(14ITighten the chain cover bolts to specified torque. Apply sealer

to threads of bolts fitted in holes that go through the case.
Specified
3M Adhesive
Nut Rocking 4171
or equivalent
(15)Fit a snap ring in the groove of the bearing at the rear end of
the rear output shaft.
1 TSB Revision
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sealant:
21-I 60 AUTOMATIC TRANSMISSION - Transmission and Transfer Assemblv

(16)lnsert the interlock plunger in the hole of the chain cover.
(17)lnsert the H-L shift rail through the H-L shift fork. The H-L shift
rail cannot be inserted unless the 2-4WD shift rail is shifted to
the 4WD side.
(18) Install poppet balls and springs two each and fit the seal plugs.
Face the smaller end of poppet springs toward the ball.
(19)Aligning the spring pin holes of the H-L shift fork and shift rail,
drive in the spring pin by using the special tool or a pin punch
(commercially available). When installing the spring pin, face
its slit toward the shift rail center.
(20)Measure the output shaft rear bearing protrusion A and rear

cover recess B to calculate the end play. Select the spacer that
gives specified end play.
(21)Apply sealer to a new rear cover gasket and attach it to the
chain cover side.
Specified
(22):At/;he
sealant:
selected spacer on the rear of the output shaft rear
(23)lnstall the rear cover and tighten the bolts to specified torque.
Apply sealant to threads of bolts fitted in holes that go through
the case.
Specified
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3M Adhesive
equivalent
Nut
Rocking
4171
or
AUTOMATIC
TRANSMISSION
- Transmission
and
Transfer
Assemblv
21-161
(24)Measure protrusion A of the front output shaft rear bearing

and recess B of the cover and calculate the clearance. If it is
more than nominal, place a spacer at illustrated location.
-II-B
3
, A
Standard value : 2 mm (.078 in.)

(25)Apply sealer to a new cover gasket and attach it to the chain
cover.
or equivalent
(26)lnstall the wave spring spacer (if necessary) on the rear of the
bearing.
(27)lnstall the cover and tighten the bolts to specified torque.
Apply sealer to threads of bolts.
Wave spring
Specified
sealant:
Specified
sealant:
3M Adhesive
equivalent
Nut
Rocking
4171
or
Spacer
i/
Extension
housing
(2B)inser-t the speedometer

sleeve assembly in the rear cover.
Line up the mating mark on the extension housing with the
mark corresponding
to the speedometer
driven gear tooth
number range put on the sleeve.
(29)lnstall the sleeve clamp and tighten the bolt.
Mating mark
134MC ,
F
4WD switch
79
(30)lnstall the two 4WD light switches,

balls are fitted.
making sure that steel
I====
\
REASSEMBLY
For reassembly,
follow the removal steps in reverse order,
paying attention
to the following.
1. Apply sealer to one side of the two control housing
gaskets and attach them to both sides of the control
housing cover.
Specified
sealant:
2. Apply sealer to the adapter gasket.

Specified
sealant:
1 TSB Revision
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1
,DlSASSEMBLY AND REASSEMBLY (Transfer Control)
Disassembly
**
1.
2.
3.
4.
5.
6.
steps
Spring pin
Set screw
Control lever assembly

Control finger
o-ritig
Control housing
4
3
Reassembly steps
3. Control lever assembly
++ 5. O-ring
6. Control housing
4. Control finger
*+ 1. Spring pin
2. Set screw
NOTE
(l)++
(2)**
(3)m
: Refer to Service Points of Disassembly

N21KFu
1. REMOVAL OF SPRING PIN

(1) Drill 12 mm (.47 in.) diameter hole in the center of the boss
16 mm (63 in.) diameter on the control housing not to
damage the control finger and control lever assembly.
(2) Draw out the spring pin using a punch.

5.
APPLICATION
OF LUBRICANT
TO O-RING
Install the O-ring to the control lever assembly and apply a
small amount of the specified
oil on the O-ring.
Specified
Cut out portion
.N21WAB
oil:

GL-4 or
higher SAE viscosity No. 8OW, 75W-85W
1. IbiSTALLATlON
OF SPRING PIN
(1) Drive the spring pin using a punch so that the cut out
portion of the spring pin is in the axial direction of the
control lever assembly.
(2) Apply the sealant in the inner surface of the worked hole
and drive the sealing cap up to the dimension shown in the
figure.
TSBRevision
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=I
AUTOMATlC
TRANSMCSSION
TRANSMISSION
- Transmission
and
Transfer
Assembly
21-I
63
OIL COOLER

I
SO-35 Nm
?c--7-----.
Pre-removal
0 Removal
/3
Operation
of Under
Post-installation
Removal
steps
a+
1.
2.
3.
4.
5.
6.
7.
8.
+a
++
Eye bolts
Gaskets
Oil cooler assembly
Hose
Return tube
Feed tube
Feed tube
Return tube
Operation
04w.5**
NOTE
1;; **
(4) tit
j Non-reusable parts

1. REMOVAL
N21ssAE
OF EYE BOLTS
Caution
Loosen the eye bolts
the oil cooler.
while
tightening
the weld
INSPECTION
nut of
N2IScAo
Check the oil cooler fins for bend, damage

and foreign
matters caught between
fins.
Check the oil cooler tubes for crack, damage, clogging and
deterioration.
Check the gaskets for damage
and deformation.
Check the eye bolts for clogging
and deformation.
l
l
l
l

8.
INSTALLATION
For installation
transmission,
OF RETURN
of the feed
first loosely
N2,SDbA
TUBE//.
FEED TUBE
tube and return tube to the
tighten
each coupling
and
clamp, and then make the final tightening in sequence

from
the feed
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tube
and return
tube
coupling.
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22-1
WHEELS
AND
TIRES
CONTENTS
SERVICE ADJUSTMENT
PROCEDURES
..........
Checking Tire Inflation Pressure .....................
Checking Tire Wear .........................................
Checking Wheel Runout
................... ..~ ..... .._..
4
4
4
4
SPARE TIRE CARRIER
........................................
SPECIFICATIONS
...............................................
....................................
Sealant and Adhesive
......................................
.....................................
.................................
2
2
2
2
2
..-.
NzzpJr
TROUBLESHOOTING
.. . . . .. . . . . . .. . . .. . . . . . . . .. . . .. . . . . . . .. .
Bald Spots
Cracked Treads
Feathered Edge
Rapid Wear at Center
Rapid Wear at Shoulders
Scalloped Wear
Wear on One Side
WHEELS AND TlRES
http://vnx.su/
. .. . .. . . . . . . . .. . .. . . . . . . .. . . . .. . . . . . .. .. .
WHEELS AND TIRES - Specifications
SPECIFICATIONS
items
2.61 Engine
Wheel
Tire size
Wheel type
Wheel size
Amount of wheel
(in.)
P225175R-15
Steel type
6JJ x 15
22 (67)
offset
Tire inflation pressure

Front wheels
Rear wheels
mm
3.OL Engine
P235/75R-15
Steel or Aluminum
,6JJx15
22 f.87)
type
BgL
E&c
kPa (psi)
-2:
180 (26)
240 (35)
180 (26)
240 (35)
E
cs
mc
Items
Limit
-Wheel runout
Radial mm (in.)
Lateral mm (in,)
Tread depth of tire
Specifications
2 (.08)
2 (.08)
1.6 (.06)
mm (in.)
NzzccItems
Hub nuts for steel wheel

Spare tire bracket to body
z
Nm
ftlbs.
100-l 20
8-10
72-87
6-7
SEALANT AND ADHESIVE
Spare tire bracket mounting
Specified
bolts
gg.:
e!eE*r
w
si
Nz?cD--
Items
sealant and adhesive

-
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lk
--I
_
C- ~:-z
Quantity
As required
I-
WHEELS AND TIRES-Troubleshooting
TROUBLESHOOTING
Symptom
Probable cause
Rapid wear
at shoulders
Underinflation
or lack of
rotation
Rapid wear
at center
T Remedy
Adjust the tire pressure
OverIinflation
,or lack of
Irotation
Cracked
treads
IJnder-inflation
Wear on
one side
I:xcessive
Feathered
edge
I ncorrect
t:oe
3ald spots
Inspect the camber
I:amber
qdjust the toe-in
II
qdjust the imbalanced wheels
IJnbalanced
\Nheel
3calloped
Near
1.ack of rotation of tires

or out-ofi alignment suspension
C)r worn
-I-
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; Rotate the tires

: Inspect the front
suspension alignment
22-3
22-4
WHEELS AND TIRES
Service Adjustment
Procedures
/ Wheels and mires
SERVICE ADJUSTMENT
CHECKING
TIRE
Check the inflation

If it is not within
adjustment.
PROCEDURES
INFLATION
PRESSURE -
pressure of the tires.

the standard value,
make the
necessary
h!.maAa
CHECKING TIRE WEAR

Measure
Limit
the tread depth of tires
: 1.6 mm I.06 in.)
If the remaining
tire.
531510
tread depth
is less than the limit, replace the
NOTE
When the tread depth of tires is reduced
less, wear indicators will appear.
to 1.6 mm (.06 in.) or
NzzFcAc
CHECKING WHEEL RUNOUT
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with a
dial indicator.
Limit
: Radial
Lateral
If wheel
runout
2 mm (.08 in.)
2 mm (.08 in.)
exceeds
WHEELS AND TIRES

steps
1. Center cap
2. Hub nut
1)* 3. Center cap holder
4. Balance weight
5. Steel wheel
6. Tire
Removal
NOTE
NOTE
(2) ++ : Refer to Service Points of instailation.
I
1 TSB Revision
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the limit,
replace
the wheel.
WHEELS AND TIRES - Wheels and Tires

For front
wheel
SERVICE
For rear wheel
3.
POINTS
INSTALLATION
OF INSTALLATfON
22-5
NZZODA&
OF CENTER CAP HOLDER
NOTE
Note that the center cap attaching metal fittings
front and rear wheels are different in shape.
for the
CA ends
73wozc
Front
(1) Align any of the guides (three projections)

inside the
fitting with a bolt position, and install the fitting on the
hub, while using care to make sure that the cut ends
are not opened. (Front wheel)
wheel
(2) Align any of the guides (three projections)

inside the
fitting with the position of a wheel attaching hole (B)
and install the fitting properly to the disc wheel from
inside the disc wheel. (Rear wheel)
WHEEL ROTATION
Rotate the wheels
illustrated.
BOE501
W2OE-
in order to equalize tire wear in the patterns
TIRE CHAINS AND SNOW TIRES

1.
NZZOGAE
Use tire chains only on rear wheels. Do not use tire chain
on front wheels.
2. When using snow tires, use them on all four wheels for
maneuverability
and safety.
1 TSB Revision
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22-6
WHEELS AND TIRES - Spare
Tire
Carrier
SPARE TIRE CARRIER

llW623
Removal steps
1. Spare tire lock cylinder
2. Hub nut
+a
NOTE
3. Spare tire
4. Spare tire bracket

4. APPLICATION
OF SEALANT
Apply a coat of the specified

bracket mounting
bolts.
Specified
1 TSB Revision
sealant
NZZHDK
TO SPARE TIRE BRACKET

sealant
around
the spare tire
: 3M AFIT Part No. 8834 or equivalent
http://vnx.su/
_-
BRAKES
SEVICE AND PARKING
CONTENTS
BRAKE BOOSTER
..............................................
22
NOSAA-
Parking Brake Lever Stroke Check and

Adjustment
.. . .. ._. ..-.._ ___________
_.._.-_._-_-______
-______. 9
BRAKE LINE ........................................................
24
Parking Brake Switch Check _......... _.,_.....__._..____.....IO
BRAKE PEDAL
17
Valve Operation Check .. ... . .._..........................- __..___ 12
....................................................
FRONT DISC BRAKE
..........................................
FRONT DISC BRAKE CALIPER

MASTER
CYLINDER
26
..........................
27
..........................................
. . . . .. . . . . . . . .. .. . . . . . .. . . . .. . . . .. . . . . . . . . .. . . . .
SPECIFICATIONS
. . .. . . . . . . .. .. .. . . . . . .. . . . .. . . .. . . . . . . . .. . .. . . .
Lubricants
19
PARKING
BRAKE CABLE
...................................
36
PARKING
BRAKE LEVER
...................................
35
REAR BRAKE SHOE
SPECIAL TOOLS
...........................................
30
. ... . .. ...__..___-_
~~~...~...~_~~~~~..~
_ 2
... . .._.......................-...-.... _____._______

__..._.... 4
___.
_.. . .. . ... .. .. .. ... . .. . ... .. . ... .. .. .
..____................................ ___.._ 3
.. ... . .._...___..__.........................
. .. . . . . . .. . . . . . . . .. . . .. . . . . . . .. . . . . .. . . .
Brake drag
REAR BRAKE WHEEL CYLINDER

SERVICE ADJUSTMENT
Bleeding
......................
PROCEDURES
32
..........
.................................................................
8
13
Groaning, clicking or rattling noise

Improper braking power
Improper parking brake function
Increased pedal stroke
Blend Proportioning Valve Function Test ..............
12
Brake Booster Operating Test ......................... ..-.
10
Poor parking brake function
Brake Drum Inside Diameter Check
......................
16
Scraping or grinding noise
............................
10
Squealing, groaning or chattering noise
Brake Fluid Level Sensor Check
Brake Lining and Brake Drum

Connection Check .....................................
Squealing noise
___._______16
Brake Lining Thickness Check ...............................
16
Brake Pad Inspection and Replacement
...............
13
Brake Pedal Inspection and Adjustment
...... ..- .....
http://vnx.su/
TROUBLESHOOTlNG
Vehicle pulls to one side
.-
11 I;, v
5-2
BRAKES - Specifications
CAUTION
When servicing
brake assemblies
or components,
do not create dust by sanding,
grinding,
or by
cleaning brake parts with a dry brush or with compressed
air. A WATER DAMPENED CLOTH SHOULD
BE USED. Many brake components
contain
asbestos
fibers which can become airborne
if dust is
created during service operations.
Breathing
dust which contains asbestos fibers can cause serious
bodily harm.
SPECIFICATIONS
Specifications
items
Master
cylinder
Tw
I.D.
mm (in.)
Brake booster
Tandem type
23.81 (15/16)
Type
mm (in.)
Effective dia. of power cylinder
2.6L Engine
3.OL Engine
Boosting ratio [Brake pedal depressing force1
2.6L Engine
3.OL Engine
Front brakes
Vacuum
Type
mm (in.)
Disc O.D.
2.6L Enigne
3.OL Enigne
Disc thickness
mm (in.)
Pad thickness
mm (in.)
Cylinder I.D.
mm (in.)
Clearance adjustment
Rear brakes
AD-type
type
230 (9.0)
205 (8.0)+230
(9.0)
4.0
5.0
disc
258 (10.2)
277 (10.9)
22 (.866)
10.5 (413)
57.15 (2.2499)
Automatic
Leading
We
Drum I.D.
mm (in.)
mm (in.)
Lining thickness
mm (in.)
Cylinder I.D.
Clearance adjustment
Parking brakes
and trailing
shoe type drum
254 (10.0)
4.6 f.18)
22.22 (7/8)
Automatic
Mechanical
Lever type
Type
Brake engagement
Cable routing
brake acting on rear wheels
V-type
1 TSB Revision
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-1 :-
5-3
BRAKESSpecifications
NOSCBItems
Specifications
Standard Value
Brake pedal height
mm (in.)
Brake pedal free play
mm (in.)
Brake pedal to firewall clearance
mm (in.)
Parking brake lever stroke
Brake booster operating test
Air-tightness test with no load
kPa (in.Hg)
Air-tightness test under load
kPa (in.Hg)
Boosting function test
MPa (psi)
At 100 N (22 Ibs.) foot force
Non-boosting function test
MPa (psi)
Blend proportioning valve function test
MPa (psi)
2.6L Engine
At 6.0 MPa (853 psi) input pressure
At 9.0 MPa (1,280 psi) input pressure
3.OL Engine
<Zdoorvehicles>
At 6.0 MPa (853 psi) input pressure
At 11 .O MPa (1,565 psi) input pressure
<4-doorvehicles>
At4.2 MPa (597psi) input pressure
At 9.7 MPa (1,377psi) input pressure
Brake dragging force
N (Ibs.)
[Brake dragging torque]
Nm (ftlbs.)
Booster push rod to master cylinder piston clearance
19%196(7.5-7.7)
3-8(.12-.31)
95 (3.74) or more
4-6 clicks
3.3 (0.97) or less
3.3 (0.97) or less
2.45-3.92 (356-569)
9.81-l 2.26 (1,422-l ,778)
0.20 (28)
1.67 (242)
mm (in.)
-imit
Pad thickness
mm (in.)
Disc thickness
mm (in.)
Brake disc runout
mm (in.)
Lining thickness
mm (in.)
Drum I.D.
mm (in.)
3.325-3.725
4.725-5.325
(472.9-529.8)
(672.0-757.4)
3.325-3.725
5.480-6.080
(472.9-529.8)
(779.4-864.8)
4.000-4.400 (568.3625.8)
9.380-9.980(843.1-928.4)
86(19.0)orless
[6 (4) or less]
0.1-0.5 (.004-.020)
2.0 (079)
20.4 (803)
0.15 i.0059)
1.o (039)
256.0 (10.079)
[ TSB Revision
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5-4
BRAKES - Specifications
Items
Nm
Brake booster to pedal support member

Brake pedal shaft
Pedal support member installation bolt
Steering column assembly installation bolt
Reservoir stopper bolt
Piston stopper
Master cylinder to brake booster
Fitting
Master cylinder to brake line connector
Brake line flare nut
Bleeder screw
Mounting support to knuckle
Guide pin bolt
Lock pin bolt
Wheel cylinder to backing plate
ft.lbs.
a12
25-35
18-25
18-25
1.540
1.5-3.0
8-12
15-18
25-35
13-17
7-8
80-I 00
40-50
32-42
18-21
a9
18-25
13-18
13-18
l-2
l-2
6-9
11-13
18-25
g-12
5-7
5a72
28-36
23-30
13-15
LUBRICANTS
Items
Brake fluid
Dust boot mounting groove in the caliper
body
Contacting surfaces at the shoe
assemblies and backing plate
Rear brake piston and wheel cylinder
Rotating portion of the shoe adjuster
assembly
Quantity
DOT3
Repair kit grease (pink)
As required
As required
Brake grease SAE J310, NLGI No. 1
Small quantity
Repair kit grease (pink)

Brake greaseSAE J310, NLGI No. 1
As required
Small quantity

Items
Thread part of fitting
Shoe holddown pin
Rear wheel cylinder
Both sides of the sealer
Specified sealantS and adhesives

3M
3M
3M
3M
ART Part No. 8663,866l or equivalent

Sealant Part No. 8634 or equivalent
Sealant Part No. 8634 or equivalent
ART Part No. 8661 or eauivalent
1 TSB Revision
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Quantity
As
As
As
As
required
required
required
required
BRAKES -Special
Tools
/ Troubleshooting
SPECIAL TOOLS
Tool
Number
Name
MB990620-01
Piston cap installer
Use
Installation of rear wheel
cylinder piston cap
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Vehicle pulls to one

side when brakes are
applied
Grease or oil on pad or lining surface
Replace
Inadequate
Correct
Improper braking
power
Increased pedal
stroke
(Reduced pedal to
firewall clearance)
contact of pad or lining
Auto adjuster malfunction
Adjust
Drum eccentricity
Repair or replace as necessary
Low or deteriorated
or uneven wear
brake fluid
Replenish or change
Air in brake system
Bleed air
Overheated brake rotor due to dragging of

pad or lining
Correct
Grease or oil on pad surface
Replace
Inadequate
Correct
contact of pad or lining
Brake booster malfunction
Replace
Adjust
Clogged brake line
Correct
Proportioning
Replace
valve malfunction
Air in brake system
Bleed air
Worn lining or pad
Replace
Broken vacuum hose
Replace
Brake fluid leaks
Correct
Adjust
Excessive push rod to master cylinder

clearance
Adjust
Faulty master cylinder
Replace
1 TSB Revision
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$ zJ
5-6
BRAKES
- Troubleshooting
fmptom
Probable cause
Remedy
ake drag
Incomplete
Correct
rproper parking
ake function
release of parking brake
Incorrect parking brake adjustment
Adjust
Worn brake pedal return spring
Replace
Broken rear drum brake shoe return spring
Replace
Lack of lubrication in sliding parts
Lubricate
improper push rod to master cylinder

clearance
Adjust
Faulty master cylinder piston return spring
Replace
Clogged master cylinder return port
Correct
Worn brake lining
Replace
--
Excessive parking brake lever stroke
Adjust the parking brake lever

stroke or check the parking brake
cable routing
Grease or oil on lining surface
Replace
Adjust
c
r
Replace
Sticked wheel cylinder or caliper piston
Replace
Worn brake linings
Replace
Caliper to wheel interference
--
Correct or replace
Dust cover to drum interference
Correct or replace
Bent brake backing plate
Correct or replace
;
Cracked drums or brake disc

luealing, groaning
chattering noise
len brakes are
plied
Disc brakes-missing
outer shim
or damaged brake pad-
Brake drums and lining, discs and pads

worn or scored
Correct or replace .~ Replace

Correct orreplace
-7.
Improper lining parts
Correct or replace
Disc brakes-burred or rusted calipers
Clean or deburr
Dirty, greased, contaminated

linings
1-
.-
Parking brake cable sticking
:raping or grinding
bise when brakes
s applied
or glazed
Drum brakes-weak damaged or incorrect

shoe hold-down springs, loose or
damaged shoe hold-down pins and springs
booster push rod
http://vnx.su/
Clean or replace
Correct orreplace
BRAKES
- Troubleshantina
Symptom
Probable cause
Remedy
Squealing noise
when brakes are not
applied
Bent or warped backing plate causing

interference with drum
Replace
Improper machining of drum causing

interference with backing plate or shoe
Replace drum
Disc brakes-rusted,
Lubricate or replace
Groaning, clicking or
rattling noise when
brakes are not
applied
Poor parking brake

function
stuck
Worn. damaged or insufficiently lubricated

wheel bearings
Drum brakes-weak, damaged or incorrect
shoe return spring
Loose or extra parts in brakes
Fietighten
Improper positioning of pads in caliper
Correct
Improper installation of support mounting

and caliper body
Correct
Poor return of brake booster or master

cylinder or wheel cylinder
Replace
Incorrect adjustment
booster push rod
Adjust
of brake pedal or
Stones or foreign material trapped inside

wheel covers
Remove stones, etc.
Loose wheel nuts
Retighten
Disc brakes-failure of shim
Replace
Disc brakes-loose installation bolt
Retighten
Worn, damaged or dry wheel bearings
booster push rod
Adjust
of brake pedal or
Worn brake lining

Poor condition of brake lining surface
Parking brake cable sticking
Auto-adjuster
Replace
malfunction
Excessive parking brake lever stroke
1 TSB Revision
http://vnx.su/
Adjust the parking brake lever

stroke or check the parking brake
cable arrangement
5-8
BRAKES - Service Adjustment Procedures
SERVICE ADJUSTMENT
PROCEDURE&
BRAKE PEDAL INSPECTION AND ADJUSTMENT

I.
Measure the brake pedal height as illustrated.

If the brake
pedal height is not within the standard value, adjust as
follows.
Standard
value (A) : 191-196 mm (7.6-7.7 in.)
(1) Disconnect
the stop light switch connector,
and then
loosen the stop light switch locking nut.
Move the stop light switch to a position where it does
not contact the brake pedal arm.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating
rod locking nut
loosened),
until the correct
brake pedal height is
obtained.
(3) After turning the stop light switch until it contacts the
pedal stop (until immediately
before the brake pedal
begins to move), turn the stop light switch back l/2 to
1 revolution
and secure with a lock nut.
(4) Contact the stop light switch connector.
(5) Ensure that the stop light does not come on without
the brake pedal being pushed.
2. While the engine is stopped, depress the brake pedal two

or three times. After thuseliminating
the vacuum in the
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met (the
free play) is within the standard value range.
Standard
value(B)
: 3-6
mm
(.12--31
in.)
If the free play is less than the standard value, confirm that
the clearance between
the outer case of the stop light
switch and brake pedal is within the standard value.
If the free play exceeds the standard value, the clearance
between the clevis pin and the brake pedal arm might be
excessive. Check and replace the faulty parts if necessary.
/ TSB Revision
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BRAKES - Service Adiustment

3.
5-9
Procedures
Start the engine, depress the brake pedal with approximately 500N (110 Ibs.) of force, and measure the clearance
between
the brake pedal and the firewall.
Standardvalue
(C) : 95 mm
(3.74
in.) or more
If the clearance is less than the standard value, check for

air in the brake line or brake fluid leakage, and check the
brakes themselves
(for excessive shoe clearance caused
by a malfunction
of the automatic
adjuster mechanism),
and repair where necessary.
PARKING BRAKE LEVER STROKE CHECK AND

NOSMB
ADJUSTMENT
1.
Pull the parking brake lever with a force of approx.

(45 Ibs.), and count the number of clicks.
Standard
value
200N
: 4-6 clicks
2. If the parking brake lever stroke is not within the standard

value range, make adjustment
by the following
procedures:
(1) Loosen the adjuster to slacken the parking brake cable.
(2) Tighten the adjuster slightly, repeating
pulling and
releasing the parking brake lever, to adjust the brake
shoe clearance.
(3) Tighten the adjuster until the parking brake lever stroke
is the standard value.
NOTE
After adjustment,
be sure that the adjuster
with the nut holder.
is secured
Caution
If the number of brake lever clicks engaged is less
than the standard
value, the cable has been pulled
excessively,
and failure of the automatic
adjuster
mechanism
will result. Be sure to adjust it to within
the standard value.
3.
Return the parking brake lever, remove the brake drum,

and check to ensure that the brake lever adjuster is
touching the shoe.
Caution
If the parking brake cable is pulled too far, the adjuster
lever does not fii the adjuster,
resulting
in faulty
operation
of the brake shoe adjuster.
4.
With the parking brake lever in the released
position,
turn
the rear wheel to confirm that the rear brakes are not
I
t.wsom
dragging.
1 TSB Revision
http://vnx.su/
BRAKES
Service
Adjustment
Procedures
BRAKE FLUID LEVEL SENSOR CHECK
mwma,
1. Connect an ohmmeter
to the connector of the brake fluid
level sensor.
2. Move the float from top to bottom and check for continuity. The brake fluid level sensor is in good condition if there
is no continuity when the float surface is above A, and if
there is continuity
when the float surface is below A.
PARKING BRAKE SWITCH CHECK
NOYDAPI
1. Remove the floor console.

2. Disconnect the parking brake switch connector,
and then
connect
an ohmmeter
between
parking brake switch
terminal and the mounting bolt.
3. If there is continuity when the parking brake is pulled, and
there is no continuity when it is released, the parking brake
switch is good condition.
Good
BRAKE BOOSTER OPERATING TEST
No good
0
b
14UOO6:
When
-pwJ
engine
is
gredengine
is
No5FcAo
TEST WITHOUT A TESTER

For simple checking of the brake booster operation, carry out
the following tests:
1. Run the engine for one or two minutes, and then stop it.
Step on the brake pedal several times with normal
pressure.
If the pedal depress fully the first time but gradually
becomes higher when depressed
succeeding
times, the
booster is operating properly.
If the pedal height remains unchanged,
the booster is
faulty.
2. With the engine stopped, step on the brake pedal several
times with the same foot pressure to make sure that the
pedal height will not change.
Then step on the brake pedal and start the engine.
If the pedal moves downward
slightly, the booster is in
good condition.
If there is no change, the booster is faulty.
b\
14110059
Good
14UOO6t
3. With the engine

stop the engine.
Hold the pedal
height does not
the pedal rises,
No good
running,
step on the brake pedal and then
depressed
for 30 seconds. If the pedal
change, the booster is in good condition, if
the booster is faulty.
If the above three tests are okay, the booster performance

can
be determined
as good.
If one of the above three tests is not okay at last, the check
valve, vacuum hose, or booster will be faulty.
14w6of
l4weot
1 TSB Revision
http://vnx.su/
~-
BRAKES - Service
Adjustment
5-I
Procedures
TEST WITH A SIMPLE TESTER

Prior to the test, remove the check valve from the brake
booster and check the check valve for operation. (Refer to P.512.)
With the check valve removed, make connections
as shown,
using another check valve (MB238892,
etc.), vacuum gauge,
pressure gauges and foot pressure gauge, bleed the pressure
gauges, and proceed as follows:
Test with No Load
Test 1 - Air-tightness
(2) Stop the engine when the vacuum gauge reaches approximately 68 kPa (20.1 in.Hg).
After stopping the engine, wait approximately
15 seconds,
and then measure the decrease in vacuum.
Standard
value
: 3.3 kPa (0.97
in.Hg)
or less
(3) If the vacuum decrease exceeds the standard value, check

the vacuum hoses, and the brake booster, and make any
necessary corrections.
Test 2 - Air-tightness
Test Under Load
(2) Depress the brake pedal at a force of .approximately
200 N
(44 Ibs.).
Stop the engine when the vacuum gauge reaches approximately 68 kPa (20.1 in.Hg).
(3) After stopping the engine, wait approximately
15 seconds,
and then measure the decrease in vacuum.
Standard
value
: 3.3 kPa (0.97
in.Hg)
or less
(4) If the vacuum decrease exceeds the standard value, check

the check valve, the vacuum
hoses, and the brake
booster, and make any necessary corrections.
Test
3 - Boosting
Function
Test
Start the engine.
Depress the brake pedal when the vacuum gauge reaches
approximately
68 kPa (20.1 in.Hg).
(3) Check to be sure that the brake fluid pressure is the
standard value when the brake pedal is depressed
at a
foot force of 100 N (22 Ibs.) and 300 N (66 Ibs.)
[:I
Standard
value :
At 100 N (22 Ibs.)
2.45-3.92
MPa
At 300 N (66 Ibs.)
9.81-12.26
MPa
foot force
(356-569
psi)
foot force
(1,422-1,778
psi)
(4) If the output fluid pressure agrees with the standard

the brake booster is functioning
properly.
1 TSB Revision
http://vnx.su/
value,

Test 4 - Non-boosting
Function
Test
(1) Stop the engine.
(2) Confirm that the vacuum gauge indicates 0 kPa (0 in.Hg).
(3) Check to be sure that the brake fluid pressure is th-e
standard value when the brake pedal is depressed
at a
foot force of IOON (22 Ibs.) and 300N (66 Ibs.)
Standard
value :
At 100 N (22 Ibs.) foot
0.20 MPa (28 psi)
At 300 N (66 Ibs.) foot
1.67 MPa (242 psi)
force
force
(4) If the output fluid pressure-agrees

the brake booster is functioning
with the standard

properly.
VALVE OPERATION CHECK

1. Remove
2. Remove
Valve
Spring
3.
value
NOSFNAC
the vacuum hose at the brake booster side.

the check valve from the brake booster.
Check the operation

pump.
of the check valve by using a vacuum

-
Vacuum pump connection
Accept/reject
Connection at the brake

booster side 0
urn) is created
Connection at the intake

mainfold side Cp
A negative pressure (vacuurn) is not created.
BLEND PROPORTIONING
TEST
criteria
A negative pressure (vacuand held.
VALVE FUNCTION
NIWKAB
1. Connect two pressure gauges, one each, to the input side

and output side of blend proportioning
valve. Bleed the
system.
2. Gradually depress the brake pedal and check to be sure
that the fluid pressure atthe output side is the standard
value when the fluid pressure at the input side is 6.0 MPa
(853 psi) or 4.2 MPa (597 psi) and 9.0 MPa (1,280 psi), 11 .O
MPa (1,565 psi) or 9.7 MPa (1,377 psi).
Standard value:
2.6L Engine
At 6.0 MPa (853 psi)
3.325-3.725
MPa (472.9-529.8
At 9.0 MPa (1,280 psi)
4.725-5.325
MPa (672.0-757.4
3.OL Engine
<2-doer
vehicles>
3.325-3.725
MPa (472.9-529.8
At 11.0 MPa (1,565 psi)
5.480-6.080
MPa (779.4-864.8
[ TSB Revision
-_/
http://vnx.su/
psi)
psi)
psi)
psi)
BRAKES
Service
Adjustment
5-13
Procedures
<4-door
vehicles>
4.0004.400
MPa (568.9-625.8
At 9.7 MPa (1,377 psi)
9.386-9.980
MPa (843.1-928.4
3.
If the measured
ranges, replace
pressures are not within

the blend proportioning
Caution
Do not disassemble
depends
on preset
psi)
psi)
the permissible
valve.
the B.P.V. since its performance

load of the spring.
NOSwAaa
BLEEDING
The brake hydraulic system should be bled whenever

the
brake tube, brake hose, master cylinder or wheel cylinder has
been removed or whenever
the brake pedal feels spongy
when depressed.
Bleed the brake system in the sequence
Specified
brake fluid:
DOT 3
Caution
1. Use the specified brake fluid. Avoid using a mixture of
the specified
brake fluid and other fluid.
2. If brake fluid is exposed
to the air, it will absorb
moisture;
as water is absorbed from the atmosphere,
the boiling point of the brake fluid will decrease and the
braking performance
will be seriously impaired. For this
reason, use a hermetically
sealed 1 Iii. (1.06 U.S.qt.) or
0.5 lit. (0.52 U.S.qt.) brake fluid container.
3. Firmly close the cap of the brake fluid container
after
use.
New
BRAKE PAD INSPECTION AND REPLACEMk$T
Worn
NOTE
The brake pads have been equipped with wear indicators, so
that when the brake pad thickness reaches 2 mm (.08 in.), the
wear indicator
touches
the brake discs and produces
a
warning squeaking
sound.
1. Jack up the vehicle to remove the front wheel.

2. Through the inspection hole in the caliper body, check the
disc pad for wear.
Limit
3.
: 2.0 mm (.079 in.)
If the pad assemblies

are worn
them as following procedure.
1480023I
PB
Revision
http://vnx.su/
beyond
the limit, replace
BRAKES
Procedures
Caution
The pad assemblies should be replaced
outer) for both the left and right wheels
as sets (inner and

at the same time.
(I) Remove the lock pin bolt.

boll
Caution
There is a coating of special grease on the lock pin.
Be careful that this grease is not removed.
and that
dirt does not contam%ate
the grease on thipin.
1480024
(2) Lift up the caliper body by using the guide

fulcrum.
NOTE
Use wire or the like to suspend
pin bolt as a
the caliper body.
(3) Remove the inner shim, the outer shim, the pad assemblies and pad clips from the support mounting.
Out& shim
u&J
ii
(4) Clean the disc surface to remove dirt and rust.

(5) Measure the thickness of brake disc at four or more
locations.
Limit : 20.4 mm (803 in.)

Replace the brake disc if thickness below the limit is
found at one or more locations.
Where the disc
develops uneven wear, grind it to the limit.
14F611
(6) Measure the runout of the brake disc at the edge of the
brake disc circumference.
Limit
: 0.15 mm (.0059 in.)
( TSB Revision
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BRAKES - Service Adjustment
5-15
Procedures
If the brake disc

position at which
tightening torque
Check the runout
replace the brake
runout exceeds the limit, change the

it is tightened to the hub or adjust the
to be even.
again, and if it cannot be corrected,
disc.
NOTE
Before measuring the runout of the brake disc, check the
play of the wheel bearing and, if necessary, correct it.
Also, the disc surface should be cleaned to remove any
dirt, grime or corrosion.
(7) To measure the pad dragging force,
rotational force with the pad removed,
measure the hub

(Refer to step 11)
(8) Install the pad clip.

(9) Align the pins and holes of the inner and outer shim
with those of the disc pad and install to the caliper support.
(1O)Press the piston into the cylinder.

NOTE
Before performing
this procedure,
bleed off a little of
the brake fluid from the reservoir;
otherwise,
fluid
overflows the reservoir when the piston is pushed.
Before setting the tool, clean the piston.
Make sure that the piston boot is not dislocated from
the piston.
(11)Use the following procedure to measure the brake dragaina force:
6 -:a;;:;
engine and depress the brake pedal for 5
Q) Turn engine off.
@ Retate the brake disc a few revolutions.
@ Use a spring scale as illustrated to measure the
brake drag.
@ The difference
between brake drag and rotational
force (measured at the time of inspection)
should
not exceed the standard value.
Standard value : 86 N (19.0 Ibs.) or less

[Dragging torque : 6 Nm (4ft.lbs.) or less]
/ TSB Revision
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.1)
.g
4
--~daaL~bmwzr~i-
.*n(tb
5-16
-/
~~~_-,
VW
.~-I_
J.

@ If the difference
exceeds
the standard
value,
remove the caliper body and disassemble
it. Check
the piston and seal for deterioration,
corrosion, dirt
or scoring.
t4c5w
BRAKE LINING THICKNESS CHECK
1. Remove the brake drum.

2. Measure the wear of the brake lining at the place worn the
most.
Limit : 1.0 mm (-04 in.)
Replace the shoe and lining assembly
if brake lining
thickness is less than the limit if it is not worn evenly. For
information
concerning
the procedures
for instaffation of
the shoe and lining assembly,
refer to P.530.
Caution
Whenever
the shoe and lining assemlby
is replaced,
replace both*RH and LH assemblies
as a set to prevent
car from pulling to one side when braking. If there is a
significant
difference
in the thicknesses
of the shoe and
lining assemblies
on the left and right sides, check the
sliding condition
of the piston.
BRAKE DRUM INSIDE DIAMETER CHECK

1. Remove the brake
2. Measure the inside
or more locations.
Limit : 256.0 mm
3.
Micrometer
for inner
side
14LO119
drum.
diameter
(10.079
NOSFJM
of the hub and drum at two

in.)
Replace brake drums and shoe and lining assembly when

wear exceeds the limit value or is badly imbalaced.
BRAKE LINING
TION CHECK
AND BRAKE DRUM
CONNECNOSFPM
._
1. Remove the brake drum:

2. Remove the shoe and lining assembly (Refer to P.5-30)
3. Chalk inner surface of brake drum and rub with shoe and
lining assembly.
4. Replace shoe and lining assembly or brake drums if very
irregular contact area.
For information
conerning the procedures
for installation
of the shoe and lining assembly,
refer to P. 5-30.
NOTE
Clean off chalk after check.
/T
I- Revision
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;;
BRAKES - Brake Pedal
BRAKE PEDAL
I
25-35Nm
8-12 Nm
6-9 ft.lbs.
14W604
Removal
4*
13.
14.
++ 15.
++ 16.
17.
Brake pedal installation

Brake pedal
Bushing
Spacer
Pedal support member
(under the combination
18. Pedal support member
(fastened together with
umn assembly)
19. Pedal support member
and nut
l * 20. Pedal support member
steps
1. Meter cover
2. Combination meter installation
screw
3. Combination meter assembly
4. Lower column cover
5. Upper column cover
6. Stop light switch connector connection
7. Stop light switch
l + 8. Return spring
+a
9. Return spring of clutch pedal
IO. Cotter pin
+a 11. Washer
+* 12. Clevis pin
bolt
installation bolt
meter)
installation bolt
the steering colinstallation
NOTE
(2) C* : Refer to Service Points of Removal.
(4) @ : Non-reusable parts
TSB Revision
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bolt
5-18
BRAKES - Brake Pedal

NOSGBAB
3. REMOVAL
OF COMBINATION
METER ASSEMBLY
Refer to GROUP 8 -Meter and Gauges.
INSPECTION
e
a
o
--No
NOSGUD
Check the bushing for wear.

Check the brake pedal for bend or twisting.
Check the brake pedal return spring for damage.
CHECKING STOP LIGHT SWITCH

Connect an ohmmeter
to the connector
of the stop light
switch, and then check for continuity when the plunger of the
stop light switch is pressed in and when it is released
outward.
The stop light switch is in good condition
if there is no
continuity
when the plunger is pressed in, and if there is
continuity when the plunger is released outward.
continuity
In:
Instrument
NO5GD.U
20. INSTALLATION
OF PEDAL SUPPORT MEMBER
After temporarily
fastening the installation bolts and nuts
of the pedal support member,
tighten them in the sequence shown by the numbers in the figure.
edal support member
Grease
16. APPLICATJON
OF GREASE TO SPACEWIB.
BUSHING
/12. CLEVlS PIN/ll.
WASHER
grease to the contact surface
shwon in the illustration.
Grease
9.
INSTALLATlON
OF RETURN SPRING OF CLUTCH PEDAL/8. RETURN SPRING
Install the return spring to the position as shown in the
figure.
( TSB Revision
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5-19
BRAKES - Master Cylinder
MASTER
CYLINDER
6-E3
Draining Brake Fluid
Brake master
cylinder seal kit
ml
@aye?
NcaU-
I5 2::
-=-%m2
l
Brake master cylinder kit
-7
----X3-17 Nm
,
S-12 f&.lbs.
14W627
Removal
steps
I. Connection of brake fluid level sensor

connector
2. Connection of brake tube
3. Connector
4. Master cylinder
I)*
5. Reservoir cap
l + 6. Diaphragm
7. Oil reservoir float
8. Reservoir installation screw
9. Reservoir
10. Reservoir seal
11. Piston stopper bolt

12. Gasket
Adjustment of clearance between brake
l +
booster push rod and primary piston
13. Piston stopper ring
++
l I) I)+ 14. Primary piston assembly
41) I)+ 75. Secondary piston assembly
+*
NOTE
(2) *+ : Refer to Service Points of Removal.
(3) ** : Refer to Service Points of Installation.
I-
NOSIBAH

11. REMOVAL OF PISTON STOPPER BOLT
Remove the piston stopper
bolt while
piston.
TSB Revision
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depressing
the
BRAKES - Master
Cylinder
13. REMOVAL OF PISTON STOPPER RING

Remove the piston stopper
ring while
piston.
14. REMOVAL
OF PRIMARY
Caution
Do not disassemble
15. REMOVAL
PISTON
the primary
OF SECONDARY
depressing
the
ASSEMBLY
piston
assembly.
PISTON ASSEMBLY
NOTE
If the secondary
piston is difficult
to remove,
apply
compressed
air gradually from the secondary side outlet
port of the master cylinder, and then remove the secondary piston from the cylinder.
Caution
Do not disassemble
the secondary
piston
INSPECTION
@ Check the
scars.
e Check the
ing, wear,
I) Check the
inner surface
assembly.
NcnIcAA
of master
cylinder
body for rust or
primary and secondary pistons for rust, scourdamage or deterioration.

diaphragm for cracks or deterioration.
No!mA~
15. APPLICATION
OF BRAKE FLUID TO SECONDARY
PISTON ASSEMBLY/lB.
PRIMARY PISTON ASSEMBLY
Apply the specified
brake fluid sufficiently
to the inner
surface of the master cylinder body and to the entire
periphery of the secondary
and primary pistons.
Specified
brake fluid:
ADJUSTMENT
OF
BOOSTER PUSH ROD
Check and adjust the
booster push rod and
steps below.
http://vnx.su/
DOT 3
CLEARANCE
BETWEEN
BRAKE
AND PRIMARY PISTON
clearance (A) between
the brake
the primary piston by following the
BRAKES - Master
(I)
5-21
Cylinder
Measure the dimension

(6) from
master cylinder to the piston.
the
edge
of the
NOTE
Obtain the dimension
(B) by first placing a straight
scale against the edge of the master cylinder, and then
measuring and subtracting the thickness of the straight
scale.
(2) Obtain the dimension (C) from the master cylinders

brake booster installation surface to the edge.
(3) Measure the dimension (D) from the brake boosters

master cylinder installation surface to the end of the
push rod.
NOTE
Obtain the dimension
(D) by first placing a straight
scale against the edge of the brake booster, and then
measuring and subtracting the thickness of the straight
scale.
(4) Obtain the clearance (A) between the brake booster

push rod and the primary piston. from the values
obtained
in (I), (2) and (3) previously.
Standardvalue
: 0.1-0.5
mm
(.0&l-.020
in.)
.(5) If the clearance is not within the standard value range,

adjust by changing the push rod length by turning the
screw of the push rod.
Caution
Improper
clearance
may cause excessive
6. APPLICATION
OF BRAKE
RESERVOIR CAP
Apply the specified
brake
Specified
1 TSB Revision
http://vnx.su/
brake fluid:
FLUID
fluid
DOT 3
brake drag.
TO DIAPHRAGM
to the
contact
/5.
surface
5-22
BRAKES - Brake Booster
BRAKE BOOSTER
29-35
19-25
$12 Nm
9-9 ft.lbs.
3
13-?7 Nm
9-12 ft.lbs.
Removal
IH
+$, I)+
++
H
+a
13117 Nm
9-12 ft.lbs.
steps
1. Connection of brake fluid level sensor
connector
2. Connection of brake tube
3. Connector
4. Master cylinder assembly
Adjustment of clearance between brake
booster push rod and primary piston
5. Vacuum hose
6. Check valve
7. Cotter pin
8. Washer
9. Clevis pin
10. Brake booster installation nuts
11. Brake booster
12. Sealer
13. Spacer
14. Sealer
15. Fitting
Pm-removal
Draining
0 Adjustment
Operation
of Brake Fluid
of Brake
Pedal Refer
to
NOTE
(2) +I) : Refer to Service Points of Removal.
(3) **
: Refer to Sefyice Points of Instafiation.
(4) cL7J : Non-reusable parts

5 . REMOVAL
OF VACUUM
IWJBAD
HOSE
Caution
1. When removing
the vacuum
hose from the brake
booster, pull it out straight.
2. The check valve installed
on the brake booster will
be damaged
if the vacuum
hose is forced up and
down or to the left and right.
( TSB Revision
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BRAKES - Brake
5-23
Booster
- SERVICE POINTS OF INSTALLATfON

Fitting
No5JOAG
15. INSTALLATION
OF FllTlNG
When installing the fitting, apply the specified
its threaded
portion.
Specified
9.
sealant:
3M ART
equivalent
Part
No.
8663,
sealant
to
8681
or
APPLICATION
OF GREASE TO CLEVIS PIN/8. WASHER
After applying the multipurpose
grease to the clevis pin
and washer, inset-t a clevis pin and bend the split pin
tightly.
Grease
5. INSTALLATION
OF VACUUM HOSE
Fasten the vacuum hose securely to prevent
the connections.
air leaks from
NOTE
When the hose clip on the brake booster side is installed,
fix it on the brake booster pipe and do not bring it into
contact with the check valve.
c
Brake
booster
side
ADJUSTMENT
OF CLEARANCE
BETWEEN
BOOSTER PUSH ROD AND PRlMARY PISTON
Refer
to P.5-20.
) TSB Revision
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BRAKE
BRAKE LINE
tEMOVAL AND INSTALLATION
<2.6L
Engine>
25-35 Nm
18-25 ft.lbs.
-Iare nut
13-17 Nm
S-12 ft;lbs.
14FO33
Pre-removal
l
+*
4*
Operation
Draining of Brake Fluid
I)+
1.
2.
3.
4.
5.
6.
7.
9.
11.
12.
Brake tube
Brake hoses
Brake tube (front,
Brake tube (front,
Connector
Brake tube (A)
Brake tube (main)
Blend proportioning
Brake tube (rear.
Brake tube (rear,
14W621
L.H.)
R.H.)
valve
L.H.)
R.H.)
NOTE
(I) 4*
(2) l +
: Refer to Se&ice
: Refer to Service
TSB Revision
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Points
Points
of Removal.
of installation.
BRAKES - Brake
<3.0L
5-25
Line
Engine>
25-35 Nm
Pre-removal
l
Operation
Drainina of Brake Fluid
Post-installation
l
l
*+
Operation
Supplying Brake Fluid

Bleedina (Refer to P.513.1
I)+
1.
2.
3.
4.
Brake
Brake
Brake
Brake
tube
hoses
tube (front,
tube (front,
L.H.)
R.H.)
5. Connector
6. Brake tube (A)
7.
8.
9.
10.
11.
12.
Brake tube (main)

Brake tube (main, rear)
Blend proportioning
valve
Connector
14W622
assembly
NOTE
(I) l *
(2) ++
Brake tube (rear, L.H.)

Brake tube (rear, R.H.)


2.
N-AI.
REMOVAL
OF BRAKE HOSE
Holding the nut at the brake hose side, loosen the flare nut
of the brake tube.
http://vnx.su/
5-26
BRAKES
Brake
9.
Line/Front
REMOVAL
Disc
Brake
OF BLEND
PROPORTIONING
VALVE
ChlJtiOll
Do not
depends
disassemble
on preset
the B.P.V. since its performance

load of the spring.
INSPECTION
PJOSKUB
e Check the brake tubes for cracks, crimps and corrosion.
e Check the brake hoses for cracks, damage and leakage.
e Check the brake tube flare nuts for damage and leakage.
SERVICE
POINTS
OF INSTALLATION
2. INSTALLATION
OF BRAKE HOSE
install the brake hoses without twisting
NOTE
When installing,
contact edges,
AND
them.
check to be sure the brake hose does not

weld beads or moving parts.
--
FRONT DISC BRAKE

REMOVAL
rucsuoIB
80-100 Nm
58-72 ft.lbs.
INSTALLATION
l
Draining
of Brake
Fluid
1. Flare nut of brake tube

2. Clip
*4
3. Front disc brake assembly
NOTF
..-._
(11 Reverse the removal procedures
to reinstall.
(2) **
: Refer to Service Points of Installa(3)
tion.
..-
For removal
cover, refer
WW617
Nm
58-72 ft.lbs.
&-lo0
of the brake disc and the dust

to GROUP P-Hub and Knuckle.
SERVICE POINTS OF INSTALLAnON
m5lMc
3. INSTALlATlON
OF FRONT DISC BRAKE ASSEMBLY
Push the pad open to the outside and install the front disc
brake assembly to the knuckle.
1 TSB%evision
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BRAKES-Front Disc Brake Caliper
MSLE--
FRONT DISC BRAKE CALIPER

WASSEMBLY AND REASSEMBLY
40-50
29-36
Nm
ftlbs.
16
Caliper disassembly
1.
2.
3.
**
4.
+* 5.
W+ 6.
l a 7.
*I)
8.
*I)**
9.
****lo.
l ***l
1.
1.
3.
12.
13.
14.
15.
16.
steps
Lock pin bolt

Guide pin bolt
Caliper support
Guide pin sleeve
Lock pin sleeve
Lock pin boot
Guide pin boot
Boot ring
Piston boot
Piston
Piston seal
Disc pad disassembly
steps
Lock pin bolt

Caliper support
Caliper body
Inner shim
Outer shim
Disc pad
Pad clip
5-27
NOTE
(2) +e : Refer to Service Points of Disassembly.
(3) +a: Refer to Service Points of Reassembly.
parts
TSB Revision
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BRAKES-Front Disc Brake Caliper

SERVICE POiNTS OF DISASSEMBLY
8. REMOVAL OF BOOT RING
Using a screwdriver, remove the boot ring.
9.
REMOVAL
OF PISTON BOOT /lg. PISTON
Remove the piston and piston boot by applying compressed
air through the brake hose fitting hole.
Caution
By no means should the caliper be held in hand when this
procedure is being done.
Place a piece of cloth in front of the piston, and slowly
increase the force of the compressed
air to prevent the
piston from springing out abruptly.
14KOSl
11. REMOVAL OF PISTON SEAL

(1) Remove the piston seal from the cylinder by hand.
Caution
Never use a screwdriver
or similar tools, because
ing so could damage the cylinder surface.
(2) iie~
the caliper bore with brake cleaner, alcohol or brake
NOSLUF
INSPECTION
e
o
e
e
e
Check
Check
Check
Check
Check
the
the
the
the
the
piston for rust.

cylinder portion
piston seal for
piston boot for
caliper support
of caliper body for cracks or rust.

wear and deterioration.
cracks and deterioration.
for cracks.
CHECKING BRAKE PAD THICKNESS

Measure the thickness of the pad assembly
wear is the greatest.
Limit
at the place where

..-
: 2.0 mm LO79 in.)
If the pad assemblies
/ TSB Revision
do-
are worn beyond the limit, replace them.
._
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r4
1
BRAKES-Front
5-29
Disc Brake Caliper
SERVICE
POINTS
11. INSTALLATION
OF REASSEMBLY
OF PISTON
,wiwm
SEAL
\
NOTE
The piston seal is already packed and coated with the specified grease; do not wipe it away.
10. APPLICATION OF BRAKE FLUID TO PISTON

Apply brake fluid to outside surface of the piston and slowly
insert the piston by hand, while using care not to twist it.
Specified
brake fluid: DOT 3
9. APPLICATION OF GREASE TO PISTON BOOT

Apply the specified grease to the piston boot mounting
in the caliper body.
Specified
grease
groove
: Repair kit grease (pink)
7. APPLlCATlON OF GREASE TO GUIDE PIN BOOTI6. LOCK

PIN BOOTI5. LOCK PIN SLEEVU4. GUIDE PIN SLEEVE
Apply specified grease to the outer surfaces of guide pin
sleeve and lock pin sleeve and the caliper body contacting
surfaces of lock pin boot and guide pin boot.
Specified
/ TSB Revision
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grease
: Repair kit grease (pink)
5-30
BRAKES - Rear
Brake
Shoe
REAR BRAKE SHOE

Backing
_I^.^
hstallation
Adjustment
Onerstion
of Parking
Brake
Lever
Stroke (Refer to P.5-9.)

Removal
4+
l +
++
l +
l +
steps
1. Brake drum
2. Shoe return spring with brake shoe
adjuster
3. Adjusting spring
4. Shoe retainer spring
5. Shoe hold-down spring
6. Shoe and lining assembly
7. Shoe and lever assembly
8. Shoe hold-down pin
NOTE
(2)
(3)
+*
++
: Refer to Service
: Refer to Service
Points of Removal.
Points of Installation.

1. REMOVAL OF BRAKE DRUM
If the brake drum is difficult to remove, follow
steps described below.
(1) When using the brake shoe adjuster.
0
Brake/ shoe
adjuster
Remove
the adjusting
MHUBAB
either of the
hole cover at the rear side of
the backing plate.

Insert a screwdriver
into the adjustment
hole and
use it to separate the adjustment
lever from the
brake shoe adjuster.
Insert another
screwdriver into the adjustment

hole
and use it to turn the brake shoe adjuster in the
direction
shoe.
http://vnx.su/
of the arrow so as to compress
the brake
BRAKES - Rear Brake
5-31
Shoe
(2) When using the bolts.
Screw the bolts (M8 x 1.25) in the threaded

provided in the drum flange surface.
INSPECTION
holes
No6cA.J
CHECKING BRAKE LINING THICKNESS

(I) Measure the wear of the brake lining at the place worn the
most.
Limit
14uoo75
: 1.0 mm (.039 in.)
(2) If the thickness of the brake lining is the limit value or

below, or if there is noticeable abnormal wear, replace the
shoe assembly.
NOTE
In order to prevent one-sided braking,
and right shoe assemblies as a set.
CHECKING
BRAKE
Refer to P.5-16.
DRUM
CHECKING
BRAKE LINING
Refer to P.516.
AND
DIAMETER
BRAKE DRUM
CONTACT
NOSUDAH

8. APPLlCATlON
OF GREASE TO SHOE HOLD-DOWN
Apply the specified
sealant to the shoe hold-down
inserting portion of the backing plate.
Specified
7.
sealant:
3M Sealant Part
or equivalent
PIN
pin
No. 8834
APPLICATION
OF SEALANT
TO SHOE AND LEVER
ASSEMBLY/G.
SHOE AND UNING ASSEMBLY
Apply the specified grease to the contacting
surfaces of
the shoes and backing plate, anchor plate and wheel
cylinder piston ends.
Specified
INSIDE
replace both the left
Revision
http://vnx.su/
grease:
Brake
grease
SAE J310,
NLGI
No. 1
5-32
BRAKES
- Rear Brake Shoe/Rear
Brake Wheel Cylinder
2. INSTALLATION
OF SHOE RETURN
SPRING
BRAKE SHOE ADJUSTER
(1) Apply the specified grease to the thread portion
adjuster.
Grease
Specified
identification
groove
14W581 I
-I
grease:
Brake grease
NLGI No. 1
WITH
of the
SAE J310,
(2) Install the R.H. thread brake adjuster

brake, and L.H. thread brake adjuster
brake.
to the L.H. side

to the R.H. side
(3) Install the brake shoe adjuster, so that the identification

grooves face outward.
(4) Attach the longer end of the shoe return spring to the
shoe and lever assembly.
groove
to be directed
outward
(5) Turn the brake shoe adjuster to adjust

diameter of brake shoe as illustrated.
NOTE
Adjusting
illustrated
the outside
will facilitate
diameter
adjustment
the outside
of brake shoe as
of the shoe clear-
ance.
253.1-253.4
mm (9.965 - 9.976 in.]

I.WOJ
REAR BRAKE WHEEL CYLINDER

REMOVAL
AND
INSTALLATION
NCSVA-
IS-21 Nm
13-15 ft.lbs
l
Draining
of Brake
Fluid
-.J
I Post-installation
Operation
0 Supplying
Brake-Fluid
l
Bleeding [Refer to P.5-13.)
Removal
steps
1. Brake drum
2. Bleeder screw
3. Brake tube
*q
4. Wheel
cylinder
assembly
NOTE
(2) **
http://vnx.su/
I.weOO
to reinstall.
of Installation.
!%
BRAKES - Rear Brake

\
Wheel
5-33
Cylinder
NON
4. APPLICATION
OF SEALANT
TO WHEEL CYLINDER
ASSEMBLY
Apply the specified sealant to the wheel cylinder assembly
fitting surface before installation
to the backing plate.
Specified
sealant:
3M Sealant Part
or equivalent
No. 8634
\a, ws5~
1
140545
3
Lb
Disassembly
_
++
1.
l + 2.
3.
*I, ++ 4.
5.
steps
. . I.
wheel
Piston
Piston
Piston
Wheel
Wheel cylinder kit
.
cylrnder boot
assembly
cup
cylinder
NOTE
procedures
to reassemble
(2) ++ : Refer to Service Points of Disassembly
body
NO5VFAE
When disassembling
the wheel cyinders, disassemble
both
sides (left and right) as a set.
4. REMOVAL
OF PISTON CUPS
Remove the piston cup, being careful not to damage the
piston.
INSPECTION
NONmrJ
Check the piston and wheel cylinder walls for rust or damage,
and if there is any abnormality,
replace the entire wheel
cylinder assembly.
TSB Revision
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BRAKES - Rear Brake Wheel Cylinder

-

4. INSTALLATION OF PISTON CUP
(1) Wash the inner surface of the wheel cylinder and outer
surface of the piston with trichloroethylene.
alcohol or
brake fluid.
(2) Apply the specified brake fluid to the entire surface of
the piston cups and to the external periphery of the
special tool.
Specified
brake fluid:
DOT 3
Caution
Use a repair kit to replace
cylinder
boot.
the piston
cup and wheel
(3) Attach the special toolLto the piston, fit the piston cup
onto the special tool with the lips of the piston cup
directed upward, and push down (with finger tips) to
let it slide along the outer surface of the special tool
until it fits into position.
Face lip upward
Caution
When pushing down the piston cup, push uniformly
and slowly with both hands, without
stopping,
so
that deformation
or turning
over will not result.
14uoo93
2. APPLlCATiON
OF BRAKE FLUID TO PISTON ASSEMBLY
Apply the specified brake-fluid to the inner surface of the
wheel cylinder and to the entire periphery of the piston
cups, and install the piston assemblies.
Specified
14Y553
Grease
(pink)
brake fluid:
DOT 3
1. APPLlCATfON
OF GREASE TO WHEEL CYLINDER BOOT
Apply the specified
grease to the piston and the wheel
cylinder, and install the boot.
Specified
grease:
L TSB Revision
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Repair
kit grease
(pink)
5-35
BRAKES - Parking Brake Lever
PARKING
BRAKE LEVER
-3
13
?
?
Removal
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Rear console panel

Inner box
Floor console assembly
Floor console bracket
Cable adjuster
Connection of parking brake cables
Lever pin
Nut holder
Cable equalizer
Parking brake shaft cover
Parking lever stay
++
I)+
=4-L
4
14W613
lever bushing
13. Connection of parking brake switch
nectar
14. Parking brake lever assembly
15. Parking brake switch
16. Cover
17. Sealer
18. Cotter pin
19. Clevis pin
20. Parking brake cable
NOTE
(2) MI : Refer to Service Points of Installation.
(3) q
: Non-reusable
parts
INSPECTION
Check the brake
1 TSB Revision
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NOSWCAA
lever ratchet
for wear.
5-36
BRAKES - Parking Brake Lever / Parking Brake Cable

NW

16. APPLICATION
OF SEALANT TO COVER
Apply a coat of the semi-drying
of the sealer.
sealant
to the both sides
14. APPLICATION
OF GREASE TO PARKING BRAKE LEVER
ASSEMBLYIlP.
PARKING LEVER BUSHING
grease to the clevis pin, bushing
and ratchet plate.
Bushing
Clevis pin
UVOW
PARKING BRAKE CABLE
<2&L
Engine>
A
Post-installation
Operation
l
Adjustment
of Parking Brake
Stroke [Refer to P.59.)
Removal
14W630
Lever
steps
1. Brake drum
2. Bolt
41) ,+
3. Parking cable heat protector

4. Parking brake cables
NOTE
(1) Reverse the removal procedures to relnStSll.
(2) **
(3) +*
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BRAKES
<3.OL
Parkina
Brake
5-37
Cable
Engine>
I Post-installation
Omration
Removal
steps
dl) l +
2. Bolt
3. Parking cable heat protector
<2-door vehicles>
4. Parking brake cables
1. Brake
drum
NOTE
to reinstall.
(2) l * : Refer to Service Points of RemovaI.
(3) l a : Refer to Service Points of Installation.
to Qdoor
(4) The * symbol indicates applicability
vehicles
NOSXBAC
4. REMOVAL
OF PARKING BRAKE CABLE
(1) Disconnect the cable end of the parking brake cable from
brake shoe assembly.
(2) Pass the parking brake cable through an offset box-end

wrench (12 mm) and push the wrench further on the
parking brake cable until it reaches the stopper part. In
that condition, pull the parking brake cable out from the
rear side of the backing plate.
NOTE
Push the offset box-end
stopper is pushed in.
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wrench
until
the
tab
of the
BRAKES - Parking Brake Cable

NmxcAa
INSPECTION
e
Check
the parking
brake cable for operation
SERVICE POINTS OF lNSTALLATlON

4. INSTALLATION
(1) Install the
(2) install the
(3) Turn the
diameter
253.1-253.4
mm (9.965-9.976
in.)
WUMLI,
\ TSB Revision
or damage.
NEXDU

cable end to the brake shoe assembly.
brake shoe assembly.
brake shoe adjuster to adjust the outside
of brake shoe as shown in the illustration.
NOTE
Adjusting the outside diameter
in the illustration will facilitate
clearance.
http://vnx.su/
of brake shoe as shown

adjustment
of the shoe
19-1
POWER STEERING
tmAA-
CONTENTS
OIL PUMP
. . . . . . . . . . . . . . . .. .. .. .. .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
POWER STEERING
GEAR BOX ........................
22
SERVICE ADJUSTMENT
PROCEDURES
.........
Air Bleeding
...................................................
Ball Joint End Play Check ...............................
Drive-Belt Tension Check ..............................
Fluid Level Check .........................
..~~~.-~~........
Fluid Replacement
.......................................
__
Oil Pressure Switch Check .......... .._...............
Oil Pump PressureTest
......... . ................... . ...
Power Steering Gear Box Oil Leakage
Check .............................................................
Stationary Steering Effort Check ...................
Steering Angle Check ............................
. _-._
Steering Gear Backlash Check ......................
Steering Wheel Centering
............ .._.._._4-41--..
Steering Wheel Free Play Check ....................
Steering Wheel Return (to Center) Check ......
8
11
8
10
11
11
13
12
IO
9
9
8
SPECIAL TOOLS
. . . . . . . .. . . . . . . . . . . . .. .. . . . . . . . . . . . . . . .. .. .. .. .
SPECIFICATIONS
.............................................
...................................
Lubricants
.........................
_______.._._...._. .._......
.................................
...................................
....................................
STEERING
COLUMN
STEERING
HOSES
STEERING
LINKAGE
TROUBLESHOOTING
13
8
9
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AND SHAFT
...................
5
2
2
4
4
2
3
15
............................................
36
........................................
37
.......................................
POWER STEERlNG - SDecifications
SPECIFICATIONS
NWCA-
Items
Specifications
Steering wheel diameter

mm (in.)
Power steering gear box
Steering gear type
Steering gear ratio
Oil pump
Oil pump type
Displacement
cc/rev. (cu.in./rev.)
380 (14.9)
Ball and nut, torsion

16.4
bar type (integral
Vane type
9.6 (.59)
Items
Specifications
Standard value
Steering wheel free play mm (in.)
Steering angle
Inner wheel
Outer wheel
Stationary steering effort
N (Ibs.)
Drive belt tension
mm (in.)
Oil pump pressure kPa (psi)
Gauge hose valve closed
Gauge hose valve opened
Pressure switch activation oil pressure
<Vehicles with an automatic transmission>
ON
OFF
Mainshaft starting torque
Nm (in.lbs.)
Mainshaft total starting torque Nm (inAbs.)
Ball joint starting torque
Nm (in.lbs.)
Idler arm turning torque
Nm (in.lbs.)
Spring balance reading
N (Ibs.)
Limit
Steering wheel free play mm (in.)
Steering gear backlash
mm (in.)
Ball joint end play mm [in.)
Oil pump pressure kPa (psi)
Gauge hose valve closed
Space betvveen vane and rotor mm(in.)
i TSB Revision
25 (.98) or less
3230 -;
29OO
37 (8.2)
9-12 (.35-.47)
7.500-8,200
(1,067-I,
980 (142) or less
1.5-2.0 (213-284)
0.7-1.2 (100-171)
0.25-0.60 (2-5)
0.45-I .25 (4-I 1)
l-3 (9-26)
3-9 (26-78)
25-75 (6-17)
50 (1.97)
0.5 1.020)
1.5 (.059)
1,500 (218)
0.06 (.0024)
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type)
166)
POWER
TORQUE
STEERING
19-3
- Specifications
SPECIFICATIONS
NWCC-
Items
Steering column and shaft
Steering wheel lock nut
Steering column A to steering column B
Column tube clamp
Dash panel cover
Steering shaft A to steering shaft B
Steering shaft B to joint assembly
Joint assembly to steering gear box
Plate to instrument panel reinforcement
Gear box installation
Gear box to joint assembly
Pitman arm to relay rod
Gear box to pressure hose
Gear box to return hose
Side cover
Adjusting bolt lock nut
Breather plug
Pitman arm installation
Valve housing
Valve housing lock nut*
Oil pump
<2.6L Engine>
Front
Right side
Front
Rear
Oil pump to pressure hose
Oil reservoir to reservoir bracket
Oil reservoir to oil pump body
Oil pump body to oil pump bracket
<3.OL Engine>
Oil pump to oil pump bracket
Oil pump to pressure hose
Oil pump to pressure switch
Connector to oil pump body
Suction plate to oil pump body
Pump cover to oil pump body
NOTE
* If the special tool is used to measure the tightening
torque,
1 TSB Revision
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the measurement
Nm
ft.lbs.
3M5
20-25
8-10
3-5
15-20
30-35
30-35
18-25
25-33
14-28
6-7
2-4
11-15
22-25
22-25
13-18
55-65
36-35
45
30-40
40-50
45-55
30-45
3-4
136-l 50
45-55
18Q-230*
40-47
22-25
33
22-29
29-36
33-40
22-33
2-3
94-108
33-40
136-166
14-21
IO-15
14-21
2741
16-24
6-10
1a22
25-33
IO-15
20-30
12-17
4-7
13-16
18-24
3545
35-45
16-24
2530
40-60
6-10
18-22
25-33
25-33
12-17
18-22
29-43
4-7
13-16
is 135-175
Nm (98-127
ft.lbs.).
19-4
POWR STEERING - Specifications
Items
Steering hoses
<2.6L Engine>
Pressure hose assembly to oil pump
Pressure hose assembly to gear box
Breather pipe to engine
<3.OL Engine>
Pressure hose to oil pump
Pressure hose to pressure tube assembly
Pressure tube assembly to gear box
Return tube assembly to gear box
Clip to radiator
Pressure hose clip to tube stay
Return hose clip to tube stay
Tube stay to frame
Tube clip to crossmember
Steering linkage
Tie rod end to knuckle
Tie rod end to relay rod
Tie rod end to pipe
Relay rod to pitman arm
Relay rod to idler arm
Idler arm to idler arm support
Idler arm support to frame
Nm
ft.lbs.
16-24
30-40
a12
12-17
22-29
6-9
16-24
36-40
30-40
40-50
8-10
8-12
8-12
16-24
a12
12-17
22-29
22-29
2%36
6-7
6-8
6-9
12-17
6-9
45
45
65-80
45
45
40-60
55-65
33
33
47-58
33
33
2Wl.3
40-47
LUBRICANTS
NWCO-
Items
Power steering
Specified
fluid
lubricant
Quantity
DEXRON type
DEXRON type
Needle bearing of side cover
fluid
-.
fluid
1.06 lit (2.2 pints)

As required

Specified
Items
Dash panel cover bolt -installation
Inside steering column 8 nut
Installation surface of dust cover
Nf9CE-
hole
/ TSB Revision
sealant
3M ART Part %o. 8513, or equivalent

3M Stud locking 4170, or equivalent
3M ART Part No. 8663, or equivalent
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POWER STEERING - Special
Tools
19-5
SPECIAL TOOLS
ction of the idler arm and relay
1 TSB Revision
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19-6
POWER
STEERING
Name
Number
Tool
- Special Tools/Troubleshooting
Use
MB99022B01
torque
TROUBLESHOOTING
Remedy
Symptom
Probable cause
Excessive play of
steering wheel
Excessive play G steering-gear

Loose steering
Steering wheel operation

is hard (insufficient
power assist)
gear mounting
box
bolts
Retighten
Retighten
Loose belt
Adjust
Damaged
Refill with fluid
Air in fluid line
Bleed the system
or damage
hoses
Correct the hose routing

hoses
noise
or replace the
Check the fluid leakage
of gear box
Check and replace the gear box if

necessary
Malfunction
of oil pump
Check the oil pump pressure

oil pump
of oil pump or
@tighten
the oil pump
and repair
or gear box
Interference around column or between pressure hose and other parts
Correct or replace the pressure hose

and the parts around the column
Abnormal noise inside of gear box

and oil pump
Replace the gear box or oil pump
Air sucked
Check the oil level and hose clips,

bleed the system or replace the oil
pump
Replace the oil pump
Oil pump
Squealing
.~
Malfunction
Loose installation
gear box
belt
Low fluid level
i:
Shrill noise
or replace as necessary
the belt tension
Replace-the
belt
Fluid leakage
noise
Loose or worn stud of tie rod end _
Twisted
Rattling
Repair
into oil pump
seizure
Loose belt
Adjust the belt tension
Oil pump seizure
Replace the oil pump
\ TSB Revision
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POWER STEERING - Troubleshooting
NOTE
* A slight beat noise is produced by the oil pump;
stationary steering effort is made.)
** A slight vibration may be felt when the stationary
To check whether the vibration actually exists or
Moreover, a very slight amount of vibration is
this is not a malfunction.
(This noise occurs particularly when a
steering effort is made due to the condition of the road surface.

not, test-drive the vehicle on a dry concrete or asphalt surface.
not a malfunction.
) TSB Revision
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19-8
POWER
STEERING
Service
Adiostment
Procedures
SERVICE ADJUSTMENT
PROCEDURES
STEERING
WHEEL
FREE PLAY
CHECK
NWFABh
1. With the engine stationary and the steering wheel in the
straight-ahead
position, apply a force of 5N (1 .I Ibs.) to the
steering wheel in the peripheral direction.
Measure the
play on the circumference
of the steering wheel.
Standard
value
Limit : 50 mm
: 25 mm
(1.97 in.)
(.98 in.) or less
If the measured
steering gear-
value exceeds
13W656
2.
the repair limit, check the

ball joint end play.
backlashand linkage
N19FOdE
STEERING
GEAR
BACKLASH
CHECK
1. Jack up the vehicle front and hold the steering wheel in
the straight ahead position.
2. Disconnect
the pitman arm and the relay rod by using
special tool.
3.
Measure the steering gear backlash

end with a dial indicator.
Limit
4.
: 0.5 mm
(.020
at the pitman
arm top
in.)
If the meas.%%% value exceeds the limit, screw in the

steering gear box adjusting bolt until steering wheel free
play is within the range of standard value.
Caution
1. Be sure to make the adjustment
with the steering
wheel in the straight-ahead
position.
2. If the adjusting
bolt is over-tightened,
more steering
effort will be required, and return of the wheel will
be adversely
affected.
N19feAa
BALL
JOINT
END PLAY
CHECK
1. Hold the ball joint with pliers.
2. Set a caliper gauge as shown in left figure and measure
the displacement
with the ball stud compressed.
Limit : 1.5 mm (-059 in.)
3. If the measured displacement
is over the limit, replace the
-~
ball joint.
1 TSB Revision
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.;
19-9
POWER STEERING - Service Adiwstment Procedures
Nm=oAca
STEERING ANGLE CHECK

1. Place the front wheel on a turning
measure the steering angle.
Standard
13F006
radius
gauge
and
value : Inner wheel 32030%

Outer wheel 29OO
2. Adjust the steering angle of each wheel by turning the

stop bolt of the knuckle arm.
NOTE
After adjusting the steering angle, mount the cap onto the
jam bolt so that the edge of the slit side of the cap and the
head of the stop bolt are flush and face in the same
direction, and then pack the head of the stop bolt with the
multipurpose
grease.
Caution
Be sure
adjusting
that the toe-in

is properly
the steering
angle.
adjusted
STATIONARY STEERING EFFORT CHECK
before
~,wmm
1.
Place the vehicle on a level surface and place the steering

wheel in the straight-ahead
position.
2. Set the engine speed to 1,000 r/min.
3. Measure the tangential
force with a spring balance by
turning the steering wheel clockwise and counterclockwise one and a half turns.
Standard
4.
value
: 37 N (8.2 Ibs.) or less
If the stationary
steering
effort exceeds the standard
value, check for belt slackness, damage, insufficient
oil,
air mixed into oil, collapsed or twisted hoses, etc., and
repair if found.
STEERING WHEEL RETURN (TO CENTER) Cl-l~l~a

To check for the return of steering wheel to center, carry out
drive test and check the following
points.
1. Make gentle and sharp turns and check to get a feel for
that there is no appreciable
difference in steering effort
and return to center between
right and left turns.
2. Drive at a speed of about 35 km/h (22 mph), turn the
steering wheel 90 clockwise
or counterclockwise,
and
release the wheel a second or two later. If the wheel
returns more than 70. the return may be considered
good.
NOTE
When the steering wheel is turned abruptly, momentary
hard steering might result, but this does not mean any
problem.
It is caused by low oil pump delivery during
idling.
1 TSB Revision
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POWER STEERING - Service
Adjustment
Procedures
POWER STEERING GEAR BOX OIL LEAKAGE

NlOF6Alh
CHECK
Copper
gasket
Lock nut
O-ring
63
If there is oil leakage at the gear box side cover adjustment

bolt (malfunction
of the cross shaft U-gasket), repair as
described
below- rather than by using the repair kit.
1. Remove the adjustmet
bolts lock nut.
Cap nut
Caution
Because the meshing of the main shaft and the cross
shaft will change if the adjustment
bolt is turned, a
screwdriver
should be used to prevent it from turning
when removing
the nut.
2.
Clean away all mud, paintremnants,

surface of the side cover.
3. Apply
repair
a coating of automatic
transmission
fluid to the
kits O-ring, and then fit into the lock nut.
Specified
4.
fluid
: Automatic
Ww
torque
: 3645
Caution
If the adjustment
must be adjusted.
Tighten
Specified
6.
transmission
fluid
DEXRON
Fit the copper gasket, an&hen

tighten the lock nut at the
specified
torque to lock the adjustment
bolt.
Specified
5.
etc. from the upper
bolt
Nm (22-33
is turned,
the gears
the cap nut at the specified

torque
: 15-22
ft.lbs.)
Nm (11-16
backlash
torque.
ft.lbs.)
Supply automatic transmission

fluid and bleed out the air;
then check to be sure that there is no oil leakage at the
lock nut.
Specified
fluid
: Automatic
Ww
transmission
fluid
._
DEXRON
7. Apply black paint to prevent

the lock nut,
-
corrosion
of the cap nut and
N,N%#.Da
DRIVE-BELT TENSION CHECK

1. Check the belt for slackness by applying
(22 Ibs.) to the center of the belt.
Standard
2.
13Y613
1 TSB Revision
value
: g-12
pressure
mm (.35-.47
in.)
If the measured
tension-is
different
value, adjust the drive belt tension.
1
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from
of IOON
the standard
1_
POWER STEERING - Service Adjustment

FLUID
Fluid fluctuation
LEVEL
19-11
Procedures
NW=!&=,
CHECK
1. Start the engine on a level surface, and turn the steering

wheel several times fully to the right and left while the
engine is idling.
2. Replace the fluid if it has bubbles or has become white.
3. Fill the resetvoir with specified automatic
transmission
fluid to the MAX level.
While engine
running
Specified
FLUID
Return
hose
xz!$
13AO142
While engine
running
While engine
stopped
Bleed
fluid
: Automatic
tVpe
the system
AIR BLEEDING
111
transmission
fluid
DEXRON
N,SF.JAFb
Check for contamination

in the fluid reservoir. Foamy or
cloudy fluid should be replaced.
I. Remove the reservoir cap.
2. Disconnect
the return hose from the reservoir tank and
remove the fluid.
3. Disconnect
the high tension cable.
4. Run the engine intermittently
several times with the
starting motor, and remove the fluid from the gear box.
5. Attach the return hose and supply the specified fluid.
6.
: within
: Automatic
We
REPLACEMENT
Specified
Fluid fluctuation
5 mm (.2 in.)
fluid
transmission
and check
the fluid
fluid
DEXRON
pressure.
N19FUAD
Check stationary
steering effort. If it is different from the
standard value, air in the system is suspected.
Bleed the
system.
1. Make certain the reservoir is filled up.
2. Jack up the front wheels.
3. Remove the high tension cable.
4. While turning the steering wheel completely to the right
and to the left, turn the engine over by using the starting
motor. Repeat this several times.
Caution
Do not carry out bleeding with the engine running, high
speed rotation
of the oil pump
mixes the power
steering fluid with air, making it impossible
to throughly bleed the system.
TSB Revision
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POWER STEERING - Service
Adjustment
Procedures
5.
6.
Lower the front wheels.

Connect one end of a vinyl tube of suitable length to the
breather plug of the gear box, and place its other end in a
container.
7. Start the engine and idle it.
8. Loosen the breather plug, and then turn the steering
wheel completely to the right and left continuously
until air
bubbles no longer appear in the fluid coming out of the
tube.
Caution
Do not hold the steering completely
to the left or right
for IO seconds or more.
9. After completion
of the bleeding,
tighten the breather
plug. Check the fluid level. and refill if necessary.
10. When turning the steering wheel right and left fully, check
that the fluid level variation is less than 4 mm (.I6 in.)
OIL PUMP PRESSURE TEST
IV,sFLm.
1. Disconnect
the pressure- hose from the
connect the special tool as illustrated.
NOTE
Use the adaptor
to connect
the special
oil pump
and
tool to the pump.
2. Bleed the power steering system.

3. Start the engine and operate it until the fluid temperature
reaches about 55C (131F).
4. Run the engine at 1,000 r/min.
5. Completely close the shut-off valve of the special tool and
read the gauge pressure.
Caution
Do not close the shut-off
more than 3 seconds.
Standard
Valve
Valve
Limit :
Valve
6.
valve
of the special
value :
closed 7,500-8,200
kPa (1,067-1,166
opened 980 kPa (142 psi)
opened
1,500
tool
for
psi.)
kPa (218 psi)
If the hydraulic pressureis

not within the range of the
standard value, replace the oil pump.
7. Completely open the shut-off valve of the special tool and
read the gauge pressure. If the hydraulic pressure is not
within the range of then standard
value, check for a
clogged or collapsed oil line, or for a clogged oil passage
inside the gear box.
8. With the shut-off valve of the special tool completely
open, and turn the steering wheel completely to the right
or left, then measure the maximum
oil pressure in this
condition.
If the maximum oil pressure is not within the
range of the standard value, (valve closed) the valve of the
gear box is faulty, and the gear box must be replaced.
I1 TSB Revision
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POWER
/
Q
T\v17
STEERING
\ on steering
1 wheel hub
v/
13W659
Lines at
straight-ahead
position
Distance
wheel
off-center
<Vehicles
with
NlIIFuMa
1. Disconnect the pressure hose from the oil pump, and then
connect the special tools.
2. Bleed the air, and then turn the steering wheel several
times while the vehicle is not moving
so that the
temperautre
of the fluid
rises
to approximately
50-6OC( 122-140F).
3. The engine should be idling.
4. Disconnect the connector for the oil pressure switch, and
place an ohmmeter
in position.
5. Gradually close the shut-off valve of the pressure gauge
and increase the hydraulic pressure then check whether
the hydraulic pressure that activates the switch is the
standard value.
Standard
value: 1.5-2.0 MPa (213-284
Ibs.)
6. Gradually open the shut-off valve and reduce the hydraulic
pressure: then check whether the hydraulic pressure that
deactivates
the switch is the standard value.
Standard
value: 0.7-1.2 MPa (100-171
Ibs.)
7. Remove the special tools, and then tighten the pressure
hose to the specified torque.
8. Bleed the system.
13W667
steering
19-13
Procedures
OIL PRESSURE SWITCH CHECK

an automatic
transmission>
Pressure gauge
(MB990662-01)
Adaptor
(MB990993-01)
,, ,
STEERING
rin
WHEEL
CENTERING
NIFNAB
SIMPLIFIED
STEERING WHEEL CENTERING
DETERMINING
STEERING WHEELS
OFF CENTER
1. For the road test, take along chalk or tape and a ruler.
2. Drive straight ahead on an uncambered
level surface.
3. When the vehicles wheels are pointing straight ahead,
mark the steering wheel hub and column cover with a
chalk or tape line.
4. Stop the vehicle and line up the marks on the hub and
column cover.
5. Place a tape strip or mark on the steering wheel rim.
6. Hold a ruler next to the rim as shown in the illustration,
and centered
position.
7. Record the distance the strip or mark on the rim has
moved. This is how far the steering wheel is off center. If it
is more than 16 mm (5/8 in.) of center, it can be centered
by indexing it ten degrees towards the center.
INDEXING STEERING WHEEL TO CENTER IT
The steering wheel shaft has 36 splines, allowing the steering
wheel to be indexed in ten-degree
increments.
1. Remove the steering wheel.
2. Without
disturbing
the position of the steering wheel
shaft, re-install the wheel as near on-center as possible.
1 TSB Revision
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POWER STEERING - Service Adjustment
Procedures
PRECISION
STEERING WHEEL CENTERING
In general, the tie rods are adjusted to steer the front wheels in
the same direction that the steering wheel is off center. If the
steering wheel is off center to the left, center it by adjusting
the tie rods to make the front wheels steer toward the left, and
vice versa.
Steering
wheel
off center
left
131655
Adjust
tie rods to steer
left
731586
J
7i
1. Hold the tie rods with -a wrench while loosening

the
locking nuts at least I/$ turn.
2. Hold the tie rod end with 3 wrench and turn the tie rod the
desired number of turns. Adjust both tie rods equally in the
same direction
to center the steering wheel.
NOTE
By turning the tie rods l/6 of a turn, an adjustment
of 2 (at
the steering wheel center) or 6 mm (.25 in.) (at the steering
wheel rim) can be made.
13W58
7
f
Off center
to right
TSB Revision
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POWER STEERING - Steering
STEERING
COLUMN
Column
and
19-15
Shaft
AND SHAFT
N19GAS-45
Nm
-3
ftlbs.
\
W-25
13-18
30-35
22-28
Removal
++ e+
Nm
ft.lbs.
Nm
ftlbs.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
Bolt
Horn pad
Jam nut
Steering wheel assembly
Lower column cover
Upper column cover
Lap heater duct
Cable band
Column switch
Ignition switch
+*
11.
12.
13.
14.
15.
Key remained switch

Brake pedal return spring
Washer bolts
Bolts
Steering column and shaft assembly
NOTE
(I)
(2)
(3)

**
l + : Refer to Service Points
to reinstall.
of Removal.
of Installation.

4.
REMOVAL
Remove
OF STEERING
the steering
WHEEL
NIJOWN
ASSEMBLY
wheel.
NOTE
In the event that the only steering wheel is to be removed,
make the mating
marks on both steering
shaft and
steering wheel.
TSB Revision
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19-16
Column
and Shaft
NWGMM
13. APPLICATION
OF SEALANT TO WASHER BOLTS
Attach the dash panel cover and apply a coating of the
specified sealant in the bolt installation
hole from inside
the vehicle.
Specified
sealant
Caution
Do not loosen
bolts should
while pulling
interior
side.
4.
/ TSB Revision
: 3M ART Part
or equivalent
No. 8513
the column tube clamp bolts. If the clamp

be loosened,
retighten
them
securely
the steering
shaft out fully toward
the
INSTALLATlON
OF STEERING WHEEL ASSEMBLY
Position the front wheels in the straight-ahead
position
and install the steering wheel.
If the center of the steering wheel is not in alignment,
make the steering wheel centering adjustment.
(Refer to
19-13.)
http://vnx.su/
POWER
DlSASSEMBLY
AND
STEERING
- Steering
Column
19-17
and Shaft
NWGE-
REASSEMBLY
2&25
14-18
Disassembly
Nm
ft.lbs.
16
steps
I)+
1. Bolt
2. Return springs
**
3. Clevis pin
I)+
4. Bolts
I)+
5. Bolt
I)+
6. Bushings
7. Snap rini
4*
8. Stopper
9. Spacer
I)+ 10. Steering shaft A
++ 11. Dust seal
*+ 12. Bushing
13. Steering column A
+e w+ 14. Special bolts
41) ++ 15. Steering lock assembly
I)+ 16. Dash panel cover
17. Column tube clamp
18. Steering column B
19. Column bushing
20. Column tube
21. Steering shaft B
22. Snap ring
23.
24.
*e I)+ 25.
+I) l * 26.
27.
28.
++ 29.
30.
e+ 31.
32.
33.
34.
35.
36.
37.
+q~ 38.
Clip
Bearing
Special bolts
Plate
Nut plate
Snap pin
Lever assembly
Snap ring
Plate assembly
Lower boot
Upper boot
Dust cover
Spring
Steering shaft C
Steering shaft D
Joint assembly
NOTE
(2) *I) : Refer to Service Points of Disassembly.
1 TSB Revision
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19-18
POWER STEERING - Steering Column and Shaft

7.
REMOVAL
OF SNAP RING
Using the snap ring pliers, remove the snap ring from
steering shaft A and exttct
steering shaft A from the
bottom of steering column A.
NOTE
Release
the steering
lock to extract
steering
shaft
A.
14. REMOVAL
OF SPECIAL BOLTS/%.
STEERING LOCK
ASSEMBLY
If it is necessan/ to remove the steering lock, cut a groove
on the head of each special bolt with a metal saw, and
remove the steering lock with a screwdriver.
25. REMOVAL
OF SPECIAL BOLTW26.
PLATE
If it is necessary to remove the plate of steering column B,
cut a groove on the head of each special bolt with a metal
saw, and remove the plate with a screwdriver.
INSPECTION
Check
Check
Check
Check
Check
Check
Check
Check
wear.
the
the
the
the
the
the
the
the
plate for cracks or damage.

column bushing for damage.
dash panel cover for damage.
steering shaft bearing for wear.
steering shaft for damage and deformation.
teeth of the plate assembly for wear.
steering shaft joint for play or faulty operation.
dust seal and bushing for damage or unusual

38. INSTALLATION
(1) Plate the upper
the lower boot
OF JOINT ASSEMBLY
boot over steering shaft C assembly
and dust cover over steering shaft
NOTE
Leave the upper and lower boots
assembling
them to the universal
::Ss::z
[ TSBRevision
:I
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NISGHA~
on the shafts
joint.
and
D.
without
Column
and
19-19
Shaft
grease to the steering
shaft C and
D.
Steering shaft D
Steering
shaft C
1ss734
Caution
After inserting steering shaft D make sure that the tilt of
the yoke of steering shaft D in relation to the yoke of
steering
shaft C is within
the angle measurement
(3) Assemble
the upper and lower boots
and the dust cover.
NOTE
Align the arrows on the upper and lower boots to the slits
on the yokes in order to assemble.
Siit
138691
31. APPLICATION
OF GREASE TO PLATE ASSEMBLYI29.
LEVER ASSEMBLY
When installing the lever assembly and the plate assembly, apply the multipurpose
grease to the following
locations:
(1) The surface of the cam part of the lever which contact
steering column B.
(2) The surface of the plates clevis pin which contact
steering column B.
(3) The space between the plates clevis pin and return
spring.
26. INSTALLATION
OF PLATE/25. SPECIAL BOLTS
(1) Apply a coating of the multipurpose
grease to the
periphery of the bolt hole at the steering column B and
plate alignment
surface.
13W661
1 TSB Revision
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POWER STEERING - Steering Column and shaft

(2) When mounting the plate onto the steering column B,
tighten the special bolts until the heads twist off.
16. APPLICATION
OF GREASE TO DASH PANEL COVER
grease to the dash panel cover
grommet.
f5. INSTALLATlON
OF STEERING
LOCK ASSEMBLY/14.
SPECIAL BOLTS
(1) When installing the steering lock onto steering column
A, install it loosely in alignment with the column boss
and check that it works properly.
(2) Then tighten the special bolts until the heads twist off.
12. APPLICATION
OF GREASE TO BUSHING/ll.
DUST
SEAL
Apply a coating of multipurpose
grease to the bushing of
the dust seal and steering shaft A contact surfaces.
10. INSTALLATION
STEERING SHAFT A
Align the projection
of the dust seal and the notch of
steering column A, and then install steering shaft A to
steering column A.
j TSB Revision
-z
http://vnx.su/
.~

6.
Column
and
19-21
Shaft
APPLICATION
OF GREASE TO BUSHINGS
Apply the multipupose
grease to the bushings
steering column A.
and install
5.
INSTALLATION
OF BOLT
Assemble steering column A and steering column 6 by
aligning the yellow line on the serrated part of steering
shaft B with the yoke groove in steering shaft A.
4.
APPLICATION
OF ADHESIVE TO BOLTS
Apply specified adhesive to the nut of steering
and tighten the bolt.
13W604 II
Specified
adhesive
: 3M Adhesive
equivalent
Caution
If there is any adhesive hardened
tap to remove it before applying
13w55
stud locking
column
4170 or
inside the nut, use a

the adhesive.
OF CLEVIS PIN
3. INSTALLATION
Insert a new clevis pin until the tip of the pin is flush with
steering column B.
1. INSTALLATION
OF BOLT
Align the white line on steering shaft B and the yoke
groove in steering
shaft C, and then tighten
at the
specified
torque.
White
line
13W604
1 TSB Revision
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POWER STEERING - Power Steering
19-22
Gear Box
POWER STEERING GEAR BOX

r/
l
Removal of the Power Steering
Supplying of Power Steering Fluid
Bleeding of the Power Steering

Fluid Line (Refer to P.1912.)
Removal
steps
+*
2.
3.
4.
5.
6.
7.
8.
9.
4030
29-36
1. Bolt
*
*+
+a
Connection
Connection
Nri
ft.lbs.
of pressure hose
of return hose
Cotter pin
45Nm/
33 ft.lbs.
Slotted nut
Connection of relay rod
Self-locking nuts
Connection of joint assembly
4m
ZFzeverse the removal procedures to reinstaft.

+* : Refer to Service Points of Removal.
(4) l : Non-reusable parts
(2)

2.
NWNBAF
DISCONNECTION
OF PRESSURE
HOSE/3.
RETURN
HOSE
Disconnect
the pressure hose and return hose from the
gear box.
Caution
Use waste cloth to close the end of each hose in order to
prevent escape of fluid and entrance of dirt and other
ioreign
material.
6. DISCONNECTION
OF RELAY ROD
Disconnect the pitman arm from the relay rod by using the
special tool.
;
http://vnx.su/
POWER STEERING - Power
Steering
Gear
19-23
Box

9.
INSTALLATION
OF POWER
STEERING
NISNDAS
GEAR BOX
Install the power steering

bear box to the frame after
inserting the power steering gear box mainshaft
into the
joint assembly.
NIW4E-A
DISASSEMBLY
8
IA
.T
Disassembly
4v
*I)
4v
++
IO.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Jamnut
Pitman arm
Dust cover
Breather plug cap
Breather plug
Washer bolts
Side cover
Adjusting bolt lock nut
Cross-shaft
NOTE
(I) +,
(2) q
1 TSB Revision
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Adjusting bolt
Adjusting plate
O-ring
U-packing
Valve housing lock nut
Bolts
Valve housing
Rack piston
Seal ring
O-rings
Top cover
Main shaft
Thrust needle bearings
Ball bearing
Oil seal
O-rings
Seal rings
Oil seal
U-packing
Gear box housing
: Refer to Service Points of Disassembly

POWER STEERING - Power Steering Gear Box

NISNFAC
2. REMOVAL
OF PITMAN ARM
Remove the pitman arm from the gear box assembly by
using the special tool.
5. REMOVAL
OF BREATHER PLUG
Remove the breather plug, and drain the steering gear oil.
8.
REMOVAL
OF ADJUSTING
BOLT LOCK NUT
Loosen the lock nut of the adjsuting bolt and screw in the
adjusting
bolt so that the side cover raises slightly.
9. REMOVAL
GF- CROSS-SHAFT
With the mainshaft and cross-shaft placed in the straight
ahead position, tap the bottom of the cross-shaft
with a
plastic hammer to take out the cross-shaft together with
the side cover.
10. REMOVAL
OF ADJUSTING
BOLT
Remove the side cover by turning
the adjusting
bolt.
13. REMOVAL
OF U-PACKING
Do not remove the U-packing at the rear of the needle
bearing unless there is fluid leakage from the threads of
the adjusting
bolt. If there is leakage, replace the Upacking with a new one.
14. REMOVAL
Remove the
tool.
18. REMOVAL
Remove the
MBQ90852-01
OF VALVE HOUSING
LOCK NUT
valve housing lock nut by using the special
OF VALVE HOUSING
valve housing together
Caution
Use care not to drop
the
with the rack piston.
rack piston.
17. REMOVAL
OF RACK PISTON
Remove the rack piston from the mainshaft
counterclockwise.
_
Caution
Be careful
not to lose the 26 balls inside the rack piston.
Cl3159
( TSB Revision
by turning
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it
Steering
Gear
Box
19-25
20. REMOVAL
OF TOP COVER
Remove the top cover by using the special tool, and take
out the mainshaft, together with the top cover, from the
valve housing.
23. REMOVAL
OF BALL BEARING/24.
OIL SEAL
(1) Temporarily attach the top cover to the valve housing.
(2) Drive out the ball bearing and the oil seal.
INSPECTION
l
l
l
l
l
NlDNGAc
Check the mainshaft

for wear and damage.
Check the tooth surface of cross shaft and the rack piston
for wear and damage.
Check the contact part of adjusting bolt for uneven wear.
Check the dust seal and the oil seal for wear and damage.
Check the O-rings for damage.
1 TSB Revision
http://vnx.su/
/-
.I
__
POWER STEERING
19-26
Power
Steering
Gear
Box
REASSEMBLY
3340 ft.lbs.
Gear box seal kit
Ball screw sub unit
29
130-150 Nm
94-108 ft.lbs.
13W652
Reassembly steps
1. Gear box housing
2. U-packing
3. Oil seal
4. Seal rings
5. O-rings
l + 6. Oilseal
I)+
7. Bali bearing
*+
8. Thrust needle bearings
9. Main shaft
++ Adjustment of main shaft starting torque
IO. Top cover
11. Valve housing lock nut
12. O-rings
13. Seal ring
++ 14. Rack piston
e* 15. Valve housing
16. Bolt
I)+
I)*
*+
*+
I)+
I)+
*+
94
**
17. U-packing
_^ ^
w. u-ring
n,c.+n
19. Adjusting plate
20. Adjusting bolt
21. Cross-shaft
22. Adjusting
ng bolt lock nut
wer
23. Sidecover
Adjustment t of main shafttotal
shaft total starting
torque
24. Washer bolts
25. Breather plug
26. Breather plug capP
27. Dust cover
28. Pitmanarm
29. Jam nut
NOTE
(1) ++
ii; y
>lS.C

: Non-reusable pans.
: if the specrattool ISused to measure the ti htenin
torg;.~ the measurement IS 135-175 Nm. a96-l 2
[ TSB Revision
http://vnx.su/
me
-Ez

SERWCE
2.
Steering
POINTS
Gear
Box
OF REASSEMBLY
INSTALLATION
OF U-PACKING/B.
OIL SEAL
install the U-packing on the gear box, and press-fit
seal by using special tools.
19-27
NIwJt!Ah
the oil
6.
INSTALLATION
OF OIL SEAL/7. BALL BEARING
(I) Press-fit the ball bearing and oil seal into the top cover
by using special tools.
(2) Apply multipurpose
grease to the oil seal of the top
cover.
8.
INSTALLATION
(1) Install the
and thicker
shown in
(2) Attach the
OF THRUST NEEDLE BEARING

thinner thrust plate, thrust needle bearing
thrust plate to the top cover in that order as
the illustration.
top cover to the valve housing.
Caution
Be careful that the thrust
plates and the thrust
needle bearing do not come off the top cover.
Thrust
needle
(3) Install the thinner thrust, plate, thrust needle bearing

and thicker thrust plate to the mainshaft in that order
as shown in the illustration.
bearing
l
240
mm (9.4 in.)
ADJUSTMENT
OF MAINSHAFT
STARTING TORQUE
(I) In order to fit in the assembly parts, use the special tool
and a spring balance, and tighten the top cover until
the tangent force becomes 62-83 N (14-19 Ibs.). Then
return the top cover until the tightening torque is 0 N (0
ft.)
Caution
After tightening
the top cover, rotate the mainshaft
to confirm . that
there is no torque fluctuation
or
.
abnormal
noise.
1 TSB Revision
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19-28
POWER
STEERING
- Power Steering
Gear Box
(2) Measure the mainshaft

starting torque by using the
special tools.
(3) Tighten the top cover until the mainshaft
starting
torque is 0.2-0.3
Nm (2-3 in.lbs.) greater than the
previously
mentioned
measurement
value.
NOTE
Tighten
starting
the top cover

torque.
gradually
while
measuring
(4) Tighten the valve housing lock nut to the

torque by using the special tools.
Caution
Be sure that the top cover does
with the lock nut at this time.
(5) Measure the mainshaft

special tool.
Standard
starting
value : 0.25-0.65
not turn
torque
Nm (25
the
specified
together
by using the
in.lbs.1
(6) If the measured

mainshaft
starting torque does not
comply with the standard value, remove the valve
housing lock nut and adjust the tightening
of the top
cover.
14. INSTALLATION
OF RACK PISTON
Install the rack piston until it comes in contact with the
edge of the mainshaft.
Rotate the mainshaft to align the ball raceway with the ball
insertion hole.
15. INSTALLATiON
OF VALVE HOUSING
(1) Apply specified
automatic transmission
seal ring of the rack piston.
Specified
fluid
: Automatic
RON type
transmission
fluid
fluid
to the
DEX-
(2) insert the valve housing.

(3) Rotate the mainshaft until the rack piston moves to the
neutral position (center).
/ TS6 Revision
-7
~: -.
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POWER STEERlNG - Power Steering
Gear
19-29
Box
17. APPLICATION
(1) Apply
packing.
OF GREASE TO U-PACKING
multipurpose
grease to the seal surface
(2) Apply specified

needle bearing.
Specified
fluid
automatic
transmission
: Automatic
RON type
transmission
fluid
of Uto the
fluid
DEX-
137696
18. APPLlCATlON
OF AUTOMATIC
TRANSMISSION
FLUID
TO O-RING
Apply specified automatic transmission
fluid to the O-ring,
and attach it to the side cover.
Specified
fluid
: Automatic
Wpe
transmission
fluid
DEXRON
21. INSTALLATION
OF CROSS-SHAFF/22.
ADJUSTING
BOLT LOCK NUT
install the cross-shaft to the side cover, and then temporarily tighten the adjusting bolt lock nut.
23. INSTALLATION
OF SIDE COVER
install the side cover assembly (with
the gear box.
the cross-shaft)
to
NOTE
Apply specified automatic transmission
fluid to the teeth
and shaft areas of the rack piston, and apply multipurpose
grease to the oil seal lip,
Specified
fluid
: Automatic
transmission
Caution
Do not rotate the side cover during
care not to damage
the cross-shaft
ADJUSTMENT
TORQUE
OF
MAINSHAFT
fluid
DEXRON
installation.
oil seal.
TOTAL
Take
STARTING
(I) While turning the adjusting bolt, measure the mainshaft total starting torque by using the special tool.
Standard
valve
: 0.45-1.25
NOTE
Position the mainshaft
measurement.
1 TSB Revision
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Nm
(4-11
in the center
in.lbs.)
position
during
19-30
POWER STEERING - Power Steering

Mating
(2) Tighten
torque.
marks
Gear Box / Oil pump
the adjusting
bolt lock nut to the specified
28. INSTALLATION
OF PITMAN ARM
Install the pitman arm to the gear box with the mating
marks aligned.
OIL PUMP
<2.6L
Engine>
Pre-removal
ODeration
l
Removal of the Power Steering
Fluid (Refer to P.1912.)
Post-installation
SUPP
(Refe
0 Bleec
Fluid
Oaeration
5-10 Nm
4-7 +lbs.
2!5-33Nm
W-24 ft.lbs.
Removal
steps
1. Connection of return hose
2. Suction tube
3. Connection
4. Connection
of breather
of pressure
Nm
ft.lbs.
qe I)*
8. Drive belt
9. Oil pump
10. Oil pump
hose
hose
bracket
NOTE
12) l * : Refer to Service Points
(3) l O : Refer to Service Points
5. Bolts
6. Oil reservoir
7. Bolts
2741
20-30
assembly
[ TSB Revision
http://vnx.su/
to reinstall.
of Removal.
of Installation.
19-31
POWER STEERING - Oil Pump

<3.0L
Engine>
3-14
7-10
Nm
klbs.
Dmin of the Power Steering Fluid
Post-installation
l
-4
Operation
Supplying of Power Steering fluid

(Refer to P.19-12.)
Bleeding of the Power Steering
Fluid Line (Refer to P. 19-12)
3!5-45
2533
Removal
Nm
ft.lbs.
steps
13w070
11. Connection for pressure switch connector <Vehicles with an automatic transmission>
1. Connection for return hose
12. Suction hose
4. Connection for pressure hose
5. Bolts
++ l a 8. Drive belt
9. Oil pump
10. Oil pump bracket
13. Oil pump mounting bracket
14. Oil reservoir
NOTE
(2) 41) : Refer to Service Points of Removal.
(3) M
: Refer to Service Points of Installation

8.
REMOVAL
OF DRIVE
When removing
er, compressor
conditioner)
NIJRSAU
BELT
the drive belts,
remove
the air condition-
drive belt (models

equipped
with air
and the alternator drive belt (2.6 Engine only).

8. ADJUSTMENT
Refer to P.19-II.
/ TSB Revision
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OF DRIVE
BELT TENSION
POWER STEERING - Oil .Pump

Oil pump
cartridge
kit
Oil pump
seal kii
610 Nm
4-7 ft.lbs,
+4
4+
Disassembly
1.
*4
2.
3.
4.
5.
6.
+4
7.
8.
l a 9.
l 4 10.
l 4 11.
+4 12.
13. Rotor
14.
15.
16.
l 4 17.
4I) l 4 18.
19.
4+
20.
21.
*4 22.
23.
24.
25.
26.
27.
28.
29.
+4 30.
31.
steps
Suction connector
O-ring
Plate
Suction plate
Suction tube
Reservoir bracket
Pump cover
Cam case
O-ring
Cam ring
Vane
Snap ring
<3.OL
> Engine>
<2.6L
Engine>
l)4
++
Pulley assembly
Oil seal
Connector
O-ring
Flow control valve
Flow control spring
Terminal assembly
Plug
O-ring
Spring
Piston rod
Plunger
Snap ring
Terminal
washer
Insulator
O-ring
Oil pump body
J
<Vehicles
with an
automatic
transmission>
NOTE
(I) Reverse the disassembly procedures to reassemble
(2) 4*
(3) w4 : Refer to Service Points of Reassembly.
(41 q : Non-reusable parts

14. REMOVAL
Tap the
hammer,
NlBaFM
OF PULLEY ASSEMBLY
rotor side of the shaft lightly with
and take out the pulley assembly.
evision
http://vnx.su/
~_.
.
-
a plastic
19-33
18. REMOVAL OF FLOW CONTROL VALVE/lS.

FLOW CONTROL SPRING
Remove the flow-control
valve and the flow-control
spring
from the oil pump body.
Caution
Do not
disassemble
the flow
control
valve.
INSPECTION
Check the
Check the
Check the
Check the
stepped
Check the
l
l
l
l
l
NISRGAL
flow control valve for clogging.

pulley assembly for wear or damage.
groove of rotor and vane for Stepped wear.
contact surface of cam ring and vanes for
wear.
vanes for damage.
CHECK OF GAP BEIWEEN

VANE AND ROTOR GROOVE
Install vane to rotor groove as illustrated. Measure the gap
between
vane and rotor groove with feeler gage.
Limit: 0.06 mm (.0024 in.]
Mark A. B or C
Mark A, B or C
44
-
NWRliM
18. INSTALLATION
OF FLOW CONTROL VALVE
(1) If the flow control valve is to be replaced, install the
flow control valve to the oil pump body corresponding
with the body identification
mark (A&C,).
(2) Apply the specified
fluid to the outside of the flow
control valve.
Specified fluid: Automatic
transmission
fluid DEXRON type
1 TSB Revision
http://vnx.su/
19-34
POWER STEERING - Oil Puma,

30./22./17./9./2.
INSTALLATlON
OF O-RINGS
Apply specified fluid on 0-rh-rgs to install.
Connector
Specified
fluid : Automatic
type
I.D. x Width
No.
1
2
3
4
5
6
13K752
Terminal assembly
13K753
Suction connector
transmission
fluid
DEXRON
Identification colour
mm (in.)
11 x 1.9(.43-x .0748)
13x1.9(.51.x.0748)
14.8 x 2.4 (58 x .0945)
11.5x1.5(.45x.0591)
3.8x 1.9(.15x .0748)
11.8x 2.4 (.46 x .0945)
Yellow
Blue
White
lSRo461
15. INSTALLATION
OF OIL SEAL
Drive the oil seal into the pump body with the special tools.
14. INSTALLATlON
OF PULLEY ASSEMBLY
Apply specified fluid to entire shaft circumference
assembly and install to pump body.
Specified
Punch mark
+
fluid
: Automatic
tVpe
transmission
13. INSTALLATION
OF ROTOR
install the rotor to the pulley assembly
punch mark is at the pump cover side.
fluid
of pulley
DEXRON
so that the rotors
12. INSTALLATION
OF SNAP RING
After installation of the snap ring, lift the rotor and check to
be sure that the snap ring is in the countersunk
part.
( TSB Revision
http://vnx.su/
19-35

11. INSTALLATION
OF VANE/IO.
(I) Apply specified

surface.
Specified
fluid:
fluid
CAM
to vane
Automatic
RON type
RING
and cam
ring friction
transmission
fluid
DEX-
(2) Align the dowel pins of the pump body with the dowel
holes of the cam ring, and then install so that the cam
rings punch mark is at the pump body side.
(3) Apply specified fluid to the vanes and install the vanes
on the rotor, paying close attention to the installation
direction.
Direct round edge

to the cam ring
Specified
9.
Vane
13R0577
7.
fluid:
Automatic
RON type
INSTALLATION
Apply specified
case.
OF O-RING
fluid to O-ring
Specified
Automatic
me
fluid:
transmission
and install
transmission
INSTALLATION
Apply specified
cover.
OF PUMP COVER
fluid to rotor friction
Specified
Automatic
type
1 TSB Revision
http://vnx.su/
fluid:
transmission
fluid
firmly
fluid
surface
fluid
DEX-
on cam
DEXRON
of pump
DEXRON
. .
19-36
gg
--
POWER STEERING - Steeri;-
STEERING HOSES
REMOVAL
AND
Nlsm-
INSTALLATION
Pm-removal
Operation
_,
1. Drain of the Power Steering Fluid
l
(Refer to P. 1412.)
Removal of under skid plate
Post-installation
,...-En+=)
<2.6L
8-12 Nm
9-9 ft.ll@.
1
9-10
Nm
-5
s-7 ft.lbs.
Operation
0 Supplying of Power Steering Fluid
11.
the Power Steering

defer to P. 19-12.)
0 lnstallatior sf under skid Dlate
<3.OL
Engine>
16-24 Nm
12-17
3040
ii-29
ft.ltk.
Nm
ft.lbs.xx
:.k.
10
I)*
I)*
1.
2.
3.
4.
5.
6.
7.
Pressure hose assembly <2.6L Engine>

Return hose
Return tube assembly
Breather hose <2.6L Engine>
Breather pipe <2.6L Engine>
Pressure hose <3.OL Engine>
Pressure tube assembly <3.OL Engine>
1 TSB Revision
13W669
8L12 Nm
6-9 ft.lbs.
8.
9.
10.
11.
12.
13.
Suction hose <3.OL Engine>

Return hose clip
Tube clip
Clip
Pressure hose clip
Tube stay
NOTE
++ : Refer to Service Points of lnstall~tion.
http://vnx.su/
--.
e-
~,
:
f.i
Hoses
/ Steering
Linkage
SERVICE POINTS OF INSTALLAnON

6.
Pressure
INSTALLATION
TUBE ASSEMBLY
Align the pressure
mark and tighten
mm (.079 in.) or
OF
PRESSURE
HOSEI7.
19-37
NIORDAJ
PRESSURE
hose and pressure tube assembly paint

is a deviation of 2
more, reinstall the tube.
the flare nut. If there
Presshre tube
assembly
STEERING
LINKAGE

55-65Nm
4cM7 .ys.
80
40-60 Nm
29d3 ftlbs.
65-80 Nm
47-58 klbs.
Removal
dte ++
**
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
Under skid plate

Cotter pins
Slotted nuts
Tie rod ends
Cotter pins
Slotted nuts
Relay rod
Self-locking nuts
idler arm suo~ort
Dust covers
Nuts
Pipes
13.
14.
15.
16.
17.
18.
Dust cover
O-ring
Self-locking nut
Washer
Idler arm
Bushings
NOTE
(2) l * : Refer to Sewice Points of Removal.
(3) **
1 TSB Revision
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__l_i_li_
19-38
POWER STEERING - Steering Linkage
Nl9VTlAG

4. DISCONNECTION
OF TIE ROD ENDS
Using the special tool, disconnect
the tie rod ends,
then remove the tie rod assembly.
and
Caution
1. Use cord to bind the special tool closely so it wont
become separated.
2. The nut should be loosened
only, not removed.
7.
DISCONNECTION
OF RELAY ROD
Using the special tool, disconnect the connecting
portions
of the idler arm and the steering gear box, and then
remove the relay rod.
INSPECTION
Check the
Check the
@ Check the
l
Check the
e Check the
l
Check the
l
l
CHECKING
Standard
Nl-
idler arm support for damage and deformation.

idler arm for damage and deformation.
dust covers for damage and cracks.
tie rods for damage and deformation.
relay rod for bends and damage.
grease nipples for clogging and looseness.
BALL
value
JOINT
: l-3
STARTING
Nm (9-X
TORQUE
in.lbs.)
CHECKING
Standard
IDLER ARM
STARTING
value : 3-9 Nm (28-78

(6-17 Ibs.)]
http://vnx.su/
TORQUE
in.lbs.)
[25-75
19-39
POWER STEERING - Steering Linkage
N19vEAh
REPLACEMENT OF DUST COVER

(I) Remove
arm.
the dust
NOTE
For the idler
arm, also remove

dust cover.
Pack grease
L-l
cover from the tie rod end or the idler
(3) Use the multipurpose

surface, and then
Specified
sealant
the O-ring.
grease
grease
to the lip portion

inside
the dust
of the
cover.
sealant to the dust cover installation

press in.
REPLACEMENT OF IDLER ARM BUSHING
NIOVFPIB~

grease to the inside surface of the
bushing and the idler arm support shaft.
(2) Inset-t the bushing into the idler arm.
(3) Insert the idler arm support into the idler arm.
(4) install so that the knurled surface of the washer is facing
the bushing side.
(5) Tighten the self-locking
nut at the specified torque.
NWJDAA

Knuckle
Relay rod side
297.5
mm (Il.71
in.)
side
4.
INSTALLATION
OF TIE ROD ENDS
(1) Apply the specified anti-corrosion
agent to the threaded portion of the tie rod end.
(2) Temporarily
tighten the tie rod so that the distance
between stud bolts of the tie rod is the value shown in
the figure.
Caution
Tie rod
uniform.
end
tightness,
left
and
right,
should
be
(3) Install the tie rod assembly after first confirming which
side is the relay rod side and which side is the knuckle
side.
) TSB Revision
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NOTE
http://vnx.su/
FRONT
SUSPENSION
N-
CONTENTS
AXLE HUB AND FREE-WHEELING
HUB
DIFFERENTIAL
CARRIER
DRIVE SHAFT
...................................................
FRONT DIFFERENTIAL
INNER SHAFT
KNUCKLE
..........
..................................
MOUNTING
17
53
40
...............
...................................................
51
48
33
..........................................................
LOWER ARM .....................................................

............
Replacement
of Lower Arm Bushing
Replacement
of Lower Ball
Joint Dust Cover ............................................
30
31
.........
SERVICE ADJUSTMENT
PROCEDURES
......
Differential Carrier Oil Seal Replacement
...........................
Drive Shaft End Play Check
Front Axle Gear Oil Level Check ....................
Front Axle Total Backlash Check ............ ..- ...
13
16
15
15
14
Wheel Alignment Inspection and

....................................................
Adjustment
13
SHOCK ABSORBER AND UPPER ARM ............

Replacement
of Upper Ball Joint ...................
SPECIAL TOOLS
...............................................
32
25
28
6
SPECIFICATIONS
. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . .. . . . . . .
. . . . .. .. . .._..........- ____
___.....
. . ..._. _____.__......._...............~....... __._..._
Lubricants
._..._..._..__..._...............
._.._.._.._.rr__._____..__.
_._. .._
.__..._._,._._.__
_____
_._.__._._
__._
STABILIZER
TORSION
BAR
BAR
. . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . .. . . . . . . . 39
_.................................................
TROUBLESHOOTING
. . . . . ..a...............................
AUTOMATIC FREE WHEELING HUB . . . . . . .. . . . . _
Does not lock
Locks but does not become free
Ratcheting readily occurs
DIFFERENTIAL
.._.._____._._..._._......._.___._......_.....
Bearing noise while driving or coasting
Constant noise
Gear noise while coasting
Gear noise while driving
Heat
Noise while turning
Oil leakage
DRIVE SHAFT, INNER SHAFT . . .. .. . . . . . . . ._. . . . . . _..
Noise due to excessive play of wheel in
turning direction
Noise during wheel rotation
http://vnx.su/
2
2
5
5
3
4
36
10
10
11
10
2-2
FRONT SUSPENSION - Specifications
SPECIFICATIONS
Items
Suspension
system
Kingpin inclination angle

Torsion bar
Length x O.D.
mm (in.)
2door vehicles
4-doer vehicles
Spring constant (wheel position
when body set)
N/mm (tbs./in.)
2door vehicles
4door vehicles
Torsion spnfg constant
Nm/deg (ft.lbs./deg)
2door vehicles
4door vehicles
Shock absorber
Type
Maximum length
mm (in.)
Compressed
length
mm (in.)
Stroke
mm (in.)
Damping force [at 0.3m/sec.
C.984 ft./set.)]
Expansion
N (Ibs.)
Contraction
N (Ibs.)
2.6L Engine
3.OL Engine
Independent double wishbone

with torsion bar and telescopic
shock absorber
8
Independent
double wishbone
with torsion bar and telescopic
shock absorber
8
1,277.5 x 24.5 (50.295 x .965)
1.277.5 x 23.5 (50.295 x -925)

1.277.5 x 24.5 (50.295 x .965)
22 (123)
22 (123)
34.61 (25.03)
Hydraulic cylindrical
ing type
335 (13.19)
215 (8.46)
120 (4.72)
doubleact-
Hydraulic cylindrical
ing type
335 (13.19)
215 (8.46)
120 (4.72)
double-act.
1,940-2,560 (428-564)
900-I ,300 (198-287)
1,940-2,560 (428-564)
900-l ,300 (198-287)
Tapered roller bearing
Tapered roller bearing
73.431 x 45.242 (2.8910 x

1.7811)
73.431 x 45.242 (2.8910 x
1.7811)
73.431 x 45.242 (2.8910 x

1.7811)
73.431 x 45.242 (2.8910 x
1.7811)
B.J. (Birfield Joint)

D.O.J. (Double Offset Joint)
B.J. (Birfield Joint)

D.O.J. (Double Offset Joint)
267 (10.5)
265.5 (10.45)
267 (10.5)
294 (11.6)
283.5 (11.16)
294 (11.6)
432 (17.0)
62 x 35 (2.44 x 1.38)
432 (17.0)
62 x 35 (2.44 x 1.38)
%ont axle hub bearing

Type
Dimensions
Outer
(O.D. x I.D.)
mm (in.)
Inner
Irive shaft
Joint type
Outer
Inner
(Joint to joint)
Length
mm (in.)
Left
Manual transmission
Right
Manual transmission
nner shaft
Shaft overall length
mm (in.)
Bearing dimensions
(O.D. x I.D.)
mm (in.)
i TSB Revision
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2-3

Items
Differential
Final drive gear type
Reduction ratio
Differential gear type
Number of teeth
Drive gear
Drive pinion
Side gear
Pinion gear
2.6L Engine
3.OL Engine
Hypoid gear
4.625
Straight bevel gear
Hypoid gear
4.625
Straight bevel gear
37
8
14
10
37
8
14
10
NOZCB-
Specifications
Items
Standard values
Toe-in
mm (in.)
Camber
Caster
mm (in.)
Drive shaft end play
Front hub turning resistance
Nm (inlbs.)
N (lbs.)
[Spring scale reading]
mm (in.)
Front hub play in the axial direction
Automatic free-wheeling
hub
mm (in.)
Brake assembly thickness
Nm (in.lbs)
Upper ball joint starting torque
Clearance between bump stopper and bump stopper
mm (in.)
bracket
mm (in.)
Shock absorber attaching dimension
Stabilizer attaching bolt end attaching
mm (in.)
dimension
mm (in.)
Anchor arm attaching dimension
L.H.
R.H.
Setting of D.O.J. boot length
Differential
Final drive gear backlash
Differential gear backlash
Drive pinion rotation torque
With oil seal
<2.6L Engine>
<3.OL Engine>
Without oil seal
<26L Engine>
<3.OL Engine>
5.523.5 (.217+.138)
la30 (Left/right deviation: within 30)
255+- 1 (Left/right deviation: within 30)
0.2-0.5 (.008-.020)
0.3-l .3 (2.6-l 1.3)
4.3-l 8.6 (0.94-4.10)
0.05 (0020) or less
10.5 (41)
0.8-3.5 (730)
71 (2.80)
7-8 (.27-.31)
6-8 (.24-.31)
135.2-143.2 (5.323-5.638)
124.3-132.3 (4.894-5.210)
77-83 (3.03-3.27)
mm (in.)
mm (in.)
mm (in.)
Nm (in.lbs.)
0.1 l-0.16 (.0043-.0063)

c-O.076 (O-.0030)
0.35-0.45 (3.04391)
0.6-0.7 (5.21-6.08)
0.15-0.25 (1.30-2.17)
0.4-0.5 (3.47-4.34)
1 TSB Revision
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2-4

hems
Specifications
Limits
Front axle total backlash
mm (in.)
hub
Freewheeling
hub turning resistance
Nm (in.lbs.)
N (lbs.)
Brake assembly thickness
mm (in.)
Return spring deterioration
mm (in.)
Shift spring deterioration
mm (in.)
Upper arm shaft starting torque
Nm (ftlbs.)
N (Ibs.)
Lower ball joint end play
mm (in.)
Differential
Drive gear runout
mm (in.)
mm (in.)
14 i.55)
1.0 (8.7)
14 (3.1)
9.6 f.378)
35 (1.38)
30 (1.18)
15 (11)
6.5 (1.4)
0.5 (.OZO)
0.05 (.0020)
0.2 (.008)
mmx- :
Items
Automatic free-wheeling hub cover
Free wheeling hub body or front hub assembly
Front hub to brake disc
Knuckle to front brake assembly
Upper arm shaft to crossmember
Rebound stopper to upper arm
Upper ball joint to knuckle
Front shock absorber to crossmember
Front shock absorber to lower arm
Lower ball joint to knuckle
Lower arm shaft
Lower arm ball joint to lower arm
Bump stopper to lower arm
Anchor arm B
Anchor arm lock nut
Stabilizer bar clamp A
Knuckle to tie rod assembly
Right drive shaft to inner shaft
Left differential mounting bracket to differential carrier
Right differential mounting bracket to housing tube
Differential mounting brackets to frame
Housing tube to differential carrier
Bracket to differential carrier
Front propeller shaft to differential carrier
Front suspension crossmember
mounting bolts
Drain plug
Filler plug
1 TSB Revision
Nm
1 79-35
50-60
50-60
80-I 00
100-l 20
8-12
60-90
12-18
15-22
120-180
140-I 60
54-75
20-30
95-l 20
4050
a12
45
50-60
80-I 00
80-I 00
80-I 10
80-I 00
80-I 10
50-60
100-l 20
60-70
40-60
ftlbs
13-25
36-43
36-43
58-72
72-87
6-9
43-65
9-13
11-16
87-l 30
101-116
39-54
14-22
69-87
29-36
6-9
33
36-43
58-72
58-72
58-80
58-72
58-80
36-43
72-87
43-51
29-43
http://vnx.su/

items
Nm
Companion flange to drive pinion

<2.6L Engine>
<3.OL Engine>
Differential cover to differential carrier
Bearing cap
Differential case to drive gear
Under skid plate to side frame
Under cover to frame
Brake tube flare nut
ftlbs
160-220
1go-250
15-22
55-65
80-90
18-25
IO-13
13-17
116-159
137-181
11-16
40-47
58-65
13-18
7-9
g-12
LUBRICANTS
NOXD-
Items
Specified
Front axle gear oil

Front differential
lubricants
Quantity
Hypoid gear oil API classification GL5 or higher SAE viscosity No. 8OW.
90
Repair kit grease
Repair kit grease
D.O.J. boot grease

B.J. boot grease
1.10 lit. (2.3 pints)
1 IO g (3.9 oz.)*,
110 g (3.9 oz.)*,
130 g (4.6 ozf

130 g (4.6 ozf
*I: 2.6L Engine, *: 3.OL Engine
@a!cESpecified
Items
Slot of the upper or lower ball joint
Contact surface of free-wheeling
hub and front axle
hub
Drive gear threaded hole
Differential cover

3M Adhesive STUD LOCKING 4170 or equivalent
1 TSB Revision
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2-6
FRONT SUSPENSION - Special
Tools
SPECIAL TOOLS
NOWANumber
Name
Use
MB990241-01
Drive shaft
attachment
Removal andinsertion of inner shaft assembly

(use with MB99021 I-01)
MB99021 l-01
Sliding hammer
Removal of housing tube oil se&

Removal and insertion of inner shaft
assembly (use with MB990241-01)
MB99092501
Bearing and oil sea

installer set
Pressing of front axle hub bearing outer race

MB990935;01
Pressing of drive pinion bearing outer race
MB990934-01, MB990935-01, MB990936-01
Pressing of differential carrier oil seal
MB990934-01
MB9909380
Handle
Pressing
Pressing
Pressing
Pressing
Pressing
Pressing
Pressing
MB990954-01
Lock nut wrench
Removal and adjustment
MB990955-01
Oil seal installer
Pressing of front axle hub oil seal

Pressing of housing tube oil seal
MB99081 l-01
Sidebearing cup
remover step plate
Disassembly and reassembly of automatic

free-wheeling hub
Removal ofside bearing inner race
[ TSB Revision
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offront axle hub bearing outer race

offront axle hub oil seal
of knuckle needle bearing
of knuckle oil seal
of housing tube oil seal
of differential carrier oil seal
of drive pinion bearing outer race
of lock nut
2-7
FRONT SUSPENSION - Special Tools
Disconnection
) TSB Revision
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of upper ball joint
2-8
Tool

--_
Number
MB990956-01
Name
Tools
Use
--Needle bearing
installer
Pressing of knuckle needle bearing
MB99098501
Oil seal installer
Pressing of knuckle oil seal
MB991 150
Dust cover installer
Pressing of drive shaft dust cover
MD99834901
Bearing separator
Removal and pressing of inner shaft bearing
MB990339-01
Pinion carrier bearin{

puller
Removal of side bearing inner race

Removal ofdrive pinion front bearing inner race
MIT303173
Insert
MIT44601
Collet set
MB990767-01
End yoke holder
1 TSB Revision
Holding of end yoke
http://vnx.su/
MB990925-01
2-9
Tools
Number
Name
Use
MB990901-01
Pinion height gauge

set
Adjustment
MB99080201
Bearing installer
Pressing of drive pinion front bearing inner race

Pressing of side bearing inner race
MB990031-01
Drive pinion oil seal

installer
Pressing of drive pinion oil seal
MIT304180
Handle
of pinion height
Tool number
Installer disc O.D.
MB990926-01
MB990927-01
MB9909280 1
MB99092901
MB990930-0 1
MB990931-01
MB990932-01
MB990933-01
MB990934-01
MB99093501
MB990936-01
MB990937-01
39.0 (1.54)
45.0 (1.77)
49.5 (1.95)
51 .o (2.01)
54.0 (2.13)
57.0 (2.24)
61 .O (2.40)
63.5 (2.50)
67.5 (2.66)
71.5 (2.81)
75.5 (2.97)
79.0 (3.11)
1 TSB Revision
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mm (in.)
FRONT SUSPENSION
- Troubleshootins
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Brake sliding portion worn
Replace and adjust hub

attaching surface shims
Brake(B) lug portion broken

Housing damaged
Drive gear damaged
Slide gear damaged
Retainer (A) damaged
Cam damaged
Shift spring deteriorated
Slide gear C ring out of position
Replace
Automatic free wheeling hub attaching bolt

loose
Fietighten Caching
Return spring deteriorated

Replace
Foreign substances on tooth s&aces of

drive gear and slide gear
Foreign substances on tooth surfaces of
slide gear and housing gear
Clean tooth&aces
4UTOMATIC FREE
NHEELING HUB
Does not lock
Locks but does not

become free
Excessive front power train resistance

Ratcheting readily
occurs
_ Adjust differential
or replace-
preload
Water in brake portion
Clean and then apply grease
Retainer(B) worn
Slide gear damaged
Housing gear damaged
Shift spring deteriorated
Replace
Automatic free wheeling hub attaching

bolts loose
Retighten the attaching bolts
Housing tube bent

Inner shaft bent
Replace
IRIVE SHAFT, INNER

;HAFT
Noise during wheel
rotation
bolts
.~
Inner shaft bearing worn. pounding
Replace
Drive shaft assembly worn damaged, bent
Check or replace
Noise due to exces- inner shaft and side gear serration play
sive play of wheel in
turning direction
Drive shaft and side gear serration play
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Replace
Replace
FRONT SUSPENSION -Troubleshooting

Symptom
Probable cause
Remedy
improper adjustment of drive gear and drive

pinion (poor meshing)
Correct or replace
Loose, worn or damaged side beating
Correct or replace
Loose, worn or damaged drive pinion

bearing
Correct or replace
Worn drive gear, drive pinion
Correct or replace
E;:
Replace
DIFFERENTIAL
Constant noise
Gear noise while

driving
side gear thrust washer or pinion
Deformed drive gear or differential case
Replace
Damaged gear
Replace
Foreign material
Eliminate the foreign material

and check; replace if
necessary
No oil
Fill or change
Poor gear engagement
Correct or replace
Improper gear adjustment
Correct or replace
Improper drive pinion preload adjustment
Correct or replace
Damaged gear
Replace
Foreign material

necessary
Insufficient
oil
) Fill or change
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Z-11
Br*
XL ~2
___ _I~,
2-12
_--_
FRONT SUSPENSION - Troubleshooting
Symptom
Probable cause
Remedy
Improper drive pinion rotation torque

adjustment
Correct or replace
Damaged differential gear
Replace
Bearing noise while

driving or coasting
Cracked or damaged drive pinion rear

bearing
Replace
Noise while turning
Loose side bearing
Replace
Damaged side gear, pinion gear or pinion

shaft
Replace
Improper differential gear backlash

Excessive preload
Adjust
Insufficient oil
Fill or change
Clogged vent plug
Clean or reTlace
Cover tightened not

Seal malfunction
Retighten, apply sealant, or replace the gasket
Worn or damaged oil seal
Replace
Excessive oil
Adjust the oil level
Gear noise while

coasting
Heat
Oil leakage-
--
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FRONT SUSPENSION - Service
Adjustment
SERVICE ADJUSTMENT
{W&L
2-13
Procedures
PROCEDURt$-
ALIGNMENT INSPECTION AND ADJUST-
1. Measure the wheel alignment with the vehicle parked on

level ground and with the front wheels placed in the
straight ahead positions.
2. Front suspension,
steering
system,
wheels and tires
should be serviced to normal condition prior to measurement of wheel alignment.
TOE-IN
1. Measure
the toe-in.
Standard
value : 5.5k3.5
mm
(.217&.138
in.)
2.
If the toe-in does not agree with the standard value, use
the left and right tie rod turnbuckles to adjust it.
3. Make the adjustment
by turning the left and right turnbuckles the same amount in opposite directions. The toe-in
value will decrease if the left turnbuckle is turned toward
the front of vehicle and the right one is turned toward the
rear, and vice a half-turn of the turnbuckles will result in an
approximately
15 mm (.59 in.) adjustment
in the toe-in.
CAMBER
1. Remove the free-wheeling
hub.
2. Measure the camber with a camber/caster/kingpin
Standard
3.
value : lzk30
within
(Left/right
30)
gauge.
deviation:
Make adjustment
of the camber by incerasing or decreasing the thickness
of the adjusting shims between
the
upper arm shaft and the crossmember.
A total of 4 mm (.I6 in.) shim thickness is normally required
for standard camber. A 1 .O mm (.039 in.) adjustment
in
thickness of shims will provide about 13 minutes adjustment of camber.
Camber
adjustment
Part number
shim (yellow
plating)
Thickness
MB176288
1 .o (.039)
MB176289
2.0 (079)
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mm (in.)
2-14
Adjustment
Procedures
CASTER
hub.
2. Measure caster with a camber/caster/kingpin
turning radius gauge.
Standard
3ight side
-eft side
3.
To increase
To increase
caster
To reduce caste]
value
: 2%5-~ 1 (Left/right
within
30)
gauge and a
deviation:
If caster does not meet specifications,

remove the upper
arm from the crossmember
and then adjust by turning the
upper arm shaft.
A half turn of upper arm shaft will cause 1.25 mm (649 in.)
fore or aft movement
of the upper arm shaft, resulting in
about 17 minutes adjustment of caster.
The adjustment
must be made so that the difference
between the casters left side and right side is within 30
minutes.
FRONT AXLE TOTAL BACKLASH CHECK
NOMM.
1. If the vehicle vibrates and produces a booming sound due

to the unbalance of the drivetrain, measure the front axle
total backlash as follows to see if the differential
carrier
assembly requires removal.
(1) Place the free-wheeling
hub in the lock condition.
NOTE
Place the transfer shift lever in 4H position and drive
the vehicle 1 to 2 meters (3.3 to 6.5 ft.) to engage the
hub with the drive shaft.
(2) Secure the wheels
2H.
and set the transfer
control
lever to
NOTE
If the vehicle is raised on a jack, the wheels will turn
and it will not be possible to measure the backlash.
(3) Turn the companion

flange clockwise until all play is
removed. Make mating marks on the dust cover of the
companion flange and on the differential carrier.
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Adjustment
2-15
Procedures
(4) Turn the companion

flange counterclockwise
until all
play is removed and measure the amount of distance
through which the mating marks moved.
Limit : 14 mm (55 in.)
(5) If the backlash exceeds the limit, remove the differential carrier assembly and adjust the backlash and drive
shaft or inner shaft spline play.
2. If the backlash exceeds the limit, remove the differential
carrier assembly
and final drive gear, and check for
differential gear meshing condition and drive shaft or inner
shaft spline looseness.
FRONT AXLE GEAR OIL LEVEL CHECK
mxmm
Remove the filler plug and check the oil level. The oil level
should be somewhere
within 8 mm (31 in.) from the bottom
of the filler plug hole.
Specified
OQFO12
gear oil : Hypoid gear oil API classification

GL-5
or higher SAE viscosity
No. 8OW, 90
[I.10 lit. (2.3 pints)]
DRIVE SHAFT END PLAY CHECK

1. Place the free-wheeling
hubs
ND2FFrn
in the free condition.
NOTE
The free condition can be obtained by shifting the transfer
shift lever to the 2H position and then moving in reverse
for 1 to 2 m (3.3 to 6.5 ft.).
2. Jack the vehicle up and remove the front wheels.
hub covers.
4. Rotate the drive shaft forward, and backward and then set
the drive shaft to the position (the position where end play
is maximum) mid-way between where the rotation feels
heavy for each (where there is a stopping feeling).
5. Set the dial gauge as shown in the figure; then move the
drive shaft in the axial direction and measure the play.
Standard
6.
value
: 0.2-0.5
mm (.OO&.020
If the play is out of standard

removing shims.
1 TSB Revision
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in.)
value, adjust
by adding
or
7~ cc 7,
2-16
.--.--
..- .-. ~_
FRONT SUSPENSION - Service Adjustment
-DIFFERENTIAL
MENT
1. Remove
2. Remove
3. Remove
Procedures
CARRIER
OIL SEAL
REPLACEIUOi?FGABb
the under cover. (Refer to P.230.)

the front hub and knuckle assembly.
the left drive shaft. (Refer to P.2-40.)
Caution
When pulling the left drive shaft from the differential
carrier assembly, be careful that the drive shaft spline
does not damage
the oil seal.
4.
5.
Remove
bly.
Remove
the right drive shaft from the inner shaft assemthe inner
shaft
assembly.
Caution
When pulling the inner shaft assembly from the differential carrier, be careful that the spline of the inner
shaft does not damage
the oil seal.
6.
Remove
housing
the differential
mounting
tube. (Refer to P.2-48.)
7.
Use the special
8.
Press-fit the oil seal positively with the special tool and
apply a thin coat of multipurpose
grease to the lip of the
oil seal.
9.
Install the drive shaft using care not to damage

lip.
tool to remove
bracket
(R.H.)
and
the oil seal.
the oil seal
NOTE
On R.H. side, after installation
of the oil seal, install the
housing tube and differential
mounting
bracket (R.H.).
Install the inner shaft with care not to damage the oil seal
lip, and install the drive shaft.
Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached to the B.J. side spline with
a new one.
10. Install
11. Install
the front hub and

the under cover.
[ TSB Revision
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knuckle
assembly.
FRONT SUSPENSION - Axle
AXLE HUB AND FREE-WHEELING
Hub
and
Free-Wheeling
Hub
2-17
HUB
WXGA-A
Front hub shim set
SO-100 -Nm
S-7-72 ftlbs.
130400
94-145
Nm4
ft.lbs.4
Nmd5
Nm
ft.lbs+l8
ftlbs.
50-50 Nm
3Q-43 ft.lbs.
Removal
steps
4*
1. Hub cover
Adjustment
2. Snap ring
3. Shim
4. Front brake
Adjustment
hub turning
5. Bolts
l 4
+*
4*
*4
4*
l +
of drive shaft end play
*4
assembly
of automatic
resistance
4+
4+
free-wheeling
6. Automatic free-wheeling
hub
assemory
7. Lock washer
Adjustment of wheel bearing preload
8. Lock nut
9. Front hub assembly
NOTE
(2) *+ : Refer to Service Points of Removal.

1. REMOVAL
NIKGBAG
OF HUB COVER
(1) Place the free-wheeling
hub
in the free
condition.
NOTE
condition
can be obtained
by shifting the
transfer shift lever to the 2H position and then moving
in reverse for 1 to 2 meters (3.3 to 6.5 ft.).
The free
(2) Remove
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the hub cover.
2-18
Hub
and
Free-Wheelina
Hub
NOTE
When the cover cannot be loosened by hand, use an
oil filter wrench with a protective cloth in between not
to damage the cover.
2.
REMOVAL
OF SNAP RING
Using a snap ring pliers, remove
drive shaft.
the snap ring from
the
Caution
The proper tool for removing
and installing
the snap
ring is a pair of snap ring pliers. Use of a screwdriver
or
other tool can deform or spread the snap ring beyond
fts yield point. Please be sure to use only snap ring
pliers for removing
and installing
this snap ring.
4.
REMOVAL
OF FRONT BRAKE ASSEMBLY
(1) Remove the front brake assembly with the brake hose
connected.
(2) Use wire to suspend the front brake assembly from
the upper arm so thatthe
front brake assembly wont
fall.
Caution
Do not twist
5.
REMOVAL
brake
hose.
OF BOL?S
Using the hexagonal

wheeling
hub.
8.
the
wrench,
remove
the automatic
REMOVAL
OF LOCK NUT/S. FRONT HUB ASSEMBLY
(I) After the lock washer has been removed, remove the
lock nut with the special tool.
(2) Remove the front hub assembly
from the knuckle
together
with the inner and outer bearings.
NozGcA4
INSPECTION
l
l
l
1 TSB Revision
free-
Check the wheel bearing for seizure, discoloration

rough raceway surface.
Check the front hub for cracks.
Check the oil seals for cracks and damage.
http://vnx.su/
and
FRONT SUSPENSION - Axle Hub and Free-Wheeling Hub

l
2-19
NLUGDAH
ADJUSTMENT
OF WHEEL BEARING PRELOAD
(1) Using the special tool, tighten the lock nut by the
following
procedures.
Tighten to 130-200 Nm (94-145 ft.lbs.)
t
I
Loosen to 0 Nm (0 ftlbs.)
t
Retighten to 25 Nm (18 ftlbs.) and then loosen 30-40
(2) Loosen the lock nut approximately

30 to 40 degrees to
adjust the front hubs turning resistance and play in
the axial direction so that they agree with the standard
values.
Standard
value
Standardvalue
: 0.3-1.3 Nm
(2.6-11.3
in.lbs.)
4.3-18.6
N (0.944.10
Ibs.)
: 0.05 mm (.OOZO in.) or less
NOTE
If adjustment
is not possible, the bearing may be
incorrectly
installed;
check and, if necessary,
repair.
The lubrication
condition
should also be checked.
(3) Mount the lock washer. If the lock washer holes do not
align with the lock nut holes, loosen the lock nut (no
more than 30 to 40 degrees) to align them.
6. INSTALLATION
ASSEMBLY
OF AUTOMATIC
FREE-WHEELING
HUB
(1) Apply a coating of specified sealant, equally all around

and without
any missed spots, to the free-wheeling
hub body assembly
and front hub contact surfaces.
Specified
sealant
Caution
Make sure that there is no excess semi-drying

sealant on the hub outside surface.
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--
...~~-.-_.--:
FRONT
~-_
SUSPENSION
_.
- Axle Hub end Free-Wheeling
Hub
(2) Align the key of the brake (B) and the keyway of
knuckle spindle and loosely install the automatic freewheeling
hub assembly.
(3) Check that the hub proper and automatic free-wheeling hub assembly are brought into intimate contact
when the assembly
is fored lightly against the hub
proper. If not; turn the hub until intimate contact is
achieved.
ADJUSTMENT
OF AUTOMATIC
FREE-WHEELING
HUB
TURNING
RESISTANCE
(1) Use a spring scale to measure the front hub turning
resistance
again. Ensure that the difference
of the
turning resistance
between
automatic
free wheeling
hub and hub without automatic free wheeling hub) is
within the limit.
Limit
: 1.0 Nm (8.7 in. Ibs.)

14 N (3.1 Ibs.)
(2) If the free-wheeling

the limit, disassemble
ing hub again.
hub turning resistance exceeds

and reassemble the free-wheel-
ADJUSTMENT
OF DRIVE SHAFI. END PLAY
(I) Rotate the drive shaft forward, and backward and then
set the drive shaft to the position (the position where
end play is maximum)
mid-way between
where the
rotation feels heavy for each (where there is a
stopping
feeling).
(2) Set the dial gauge asshown
in the figure; then move
the drive shaft in the axial direction and measure the
play.
Standardvalue
: 0.2-0.5
(3) If the play is out of standard

removing shims.
/ TSB Revision
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mm
(.008-.020
in.)
value, adjust by adding
or
FRONT SUSPENSION - Axle Hub and Free-Wheeling

DISASSEMBLY
Disassembly
AND
REASSEMBLY
(Front
Axle
Hub
2-21
Hub)
steps
HWesO
bearing
Oil seal
Inner bearing
Brake disc
Front hub
1. Outer
l * 2.
3.
4.
++
5.
NOTE
(I)
(2) ++
: Refer to Service
(3) H
(4) q

Points
of Disassembly.

4.
REMOVAL
NO.?lmM
OF BRAKE DISC
Make the mating marks on the brake disc and front hub,
and then separate
the front hub and brake disc, if
necessary.
Outer bearing
REPLACEMENT OF BEARING
Inner bearing
rm?noma
(1) Remove the oil seal.

(2) Wipe off grease from the front hub interior.
(3) Using the drift against, drive out the inner and outer
bearing outer races by tapping them uniformly.
grease to the outside surface of
the new inner and outer bearing outer races.
IOuter~~bearing
Inner bearingrol
(5) Press-fit the inner and outer

the suitable drift
bearing
NOTE
The bearing inner race and bearing
replaced as an assembly.
http://vnx.su/
outer races by using
outer race should
be
Hub
Now-
2. INSTALLATION
OF OIL SEAL
grease to the oil seal lip and
inside surface of the front hub.
(2) Apply
the multipurpose
grease
to the inner
bearing
inner race and install the inner race into the front
hub.
(3) Press-fit the new oil seal into the front hub by using
the special tools, until it is flush with the front hub end
face.
DISASSEMBLY AND REASSEMBLY (Free-Wheeling
Disassembly
**
MI
4*
e*
4*
**
++
+a
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Hub)
steps
Hub cover
O-ring
Housing
Housing C ring
Brake (B)
Brake (A)
Brake spring
Housing snap ring
Retainer (B) C ring
Drive gear assembly
Slide gear assembly
Return spring
Retainer (B)
Retainer bearing
Drive gear snap ring
+*
16.
17.
18.
19.
20.
21.
22.
Retainer (A)
Drive gear
Slide gear C ring
Cam
Spring holder
Shift spring
Slide gear
NOTE
procedures
to reassemble.
(2) (I+
(3) I)+
(4) m
: Non-reusable
parts
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--
Hub
and
Free-Wheeling
Hub
2-23
NO?JEA!J
4.
REMOVAL
OF HOUSING
C RING
NOTE
The ring is easily removable by pushing the brake (B) in
and using a small-end screwdriver,
etc.
9.
REMOVAL
OF RETAINER (B) C RING
Using a special tool, lightly push the drive gear in and
remove the retainer (B) C ring.
NOTE
Since the return spring relaxes approx. 40 mm (1.57 in.),
the stroke of the press should be set to more than 40 mm
(1.57 in.)
Caution
1. Place a protective
cover not to damage the cover
attaching
surface of the housing before setting on
the press table.
2. Make sure that the pressing force does not exceed
200 N (44.1 Ibs.).
10. REMOVAL
OF DRIVE GEAR ASSEMBLY/l
1. SLIDE
GEAR ASSEMBLY/lZ.
RETURN SPRING
Slowly reduce the pressure of the press until the return
spring fully relaxes.
Caution
When the pressure of the press is removed,
make sure
that the retainer (A) is not caught by the retainer (B).
18. REMOVAL
OF SLIDE GEAR C RING
Push the cam in and remove the slide gear C ring with the
spring compressed.
INSPECTION
l
l
l
l
l
Check the
Check the
damage.
Check the
Check the
damage.
Check the
wear and
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drive gear and slide gear splines for damage.

cam portion
of retainer (A) for wear and
cam for wear and damage.
slide gear and housing tooth
retainer
damage.
B and housing
contact
surfaces
for
surfaces
for
2-24
Hub
BRAKE ASSEMBLY
THICKNESS
CHECK
Check the brake assembly thickness by following the steps
below.
(I) Assemble
brake (A) and brake (B) and then use slide
calipers to measure the thickness of the assembly at the
two lugs on brake (A).
Standardvalue
: 10.5 mm (.413 in.)
Limit : 9.6 mm (.378 in.)
NOTE
Measure each side separately.
(2) If the measured value is below the limit, replace brake (A)
and brake (B) as a set.
eFp=x.
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s.
=
I
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E
DETERIORATION
OF RETURN SPRING CHECK
Check the return spring for deterioration
by following
the
steps below.
(1) Measure the dimension
A shown in illustration
at the
opposite
side of spring end.
Limit : 35 mm (1.38 in.]
Caution
To measure
the dimension
A shown
in illustration,
measure the dimension
from the outermost
extremity
of one wire diameter to that of the other wire diameter.
llW56
(2) If the
spring.
measured
value
is below
the
limit,
replace
the
DETERIORATION
OF SHIFT SPRING CHECK
Check the shift spring for deterioration
by following the steps
below.
(1) Measure the dimension
B shown in illustration
at the
opposite
side of spring end.
Limit
: 30 mm
(1.18 in.)
Caution
To measure
the dimension
B shown
in illustration,
measure the dimension
from the outermost
extremity
of one wire diameter to that of the other wire diameter.
(2) If the measured
value is below the limit, replace the
spring.
NOWDAAb

components.
grease to the attaching
surfaces
of all
13. APPLICATION
OF GREASE TO RETAINER (B)
Pack the grooves of retainer (B) with the multipurpose
grease.
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es
E :~-
FRONT SUSPENSION
Axle
Hub
and
Free-Wheeling
Hub
12. INSTALLATION
/ Shock
Absorber
OF RETURN
and
Upper
APPLICATION
Pack the
grease.
OF GREASE
grooves
of brake
2-25
SPRING
Install the return spring with the smaller

toward the cam.
5.
Arm
TO BRAKE
(B) with
coil diameter
side
(B)
the
multipurpose
SHOCK ABSORBER AND UPPER ARM

NWMA-.

12-18
100-120
Nm
72-67 ft.lbs.
9\
8-12 Nm
6-8 ft.lbs.
16-22
11-16
Nm
fTg----;;J
,,9-12
ft.lbs.
Nm
ft.lbs.
60-90 Nm
43-66 ft.lbs.
12W557
Shock absorber
l +
Upper
+4
4*
4*
removal
steps
1. Shock absorber
arm removal
steps
Adjustment
of clearance between bump
stopper and bump stopper bracket
2. Anchor arm assembly adjusting nut
3. Hose clip
4. Connection of brake hose
5. Cotter pin
6. i;m;;tion
of upper ball joint and
+* *a
7.
8.
9.
10.
Brake hose support

Rebound stopper
Shim
Upper arm
NOTE
(2) q+ : Refer to Service Points of Removal.
(3) l * : Refer to Service Points of Installation.
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P: r- 7
2-26
FRONT SUSPENSION - Shock Absorber and Upper Arm

hwhmw
2.
LOOSENING
OF ANCNOR ARM ASSEMBLY ADJUSTING
NUT
Loosen the anchor bolt of the torsion bar all the way.
NOTE
When the anchor arm assembly adjusting nut is loosened,
use a jack to support the lower arm of the side to be loosened, thus the work easier.
6.
DISCONNECTION
OF UPPER
BALL
JOINT
AND
KNUCKLE
(I) Loosen the nut tightening
the upper ball joint to the
knuckle.
NOTE
The nut should be partially loosened and should not be
removed.
(2) Using a special tool, disconnect
the upper ball joint
from the knuckle.
10. REMOVAL OF UPPER ARM

(1) Remove the upper arm installation
(2) Move the rear end of upper

take out the front end.
bolts.
arm toward
the rear and
(3) Take out the rear end of upper arm.

If the shaft comes in touch with the bracket,
shaft to take it out.
\ TSB Revision
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turn the
FRONT
SUSPENSION
Shock
Absorber
end
Upper
2-27
Arm
(4) If the upper arm cannot be removed by steps (1)

through (3). loosen the body mount attaching nuts or
screws except those four at the rear.
(5) Use a floor jack to raise the body approx.

and take out the upper arm.
5 mm (-2 in.)
lNSPECTl0.N
l
Check the upper arm for cracks or deformation.

Check the upper arm shaft for cracks or bends.
SHOCK
Expand
damage,
12W55P
NWMCAb
ABSORBER CHECK
and contract the shock absorber
oil leakage or abnormal noise.
UPPER ARM
SHAFT
STARTING
TORQUE
to check
it for
CHECK
Check the upper arm shaft starting torque by following

the
steps below.
1. With the upper arm shaft held in a vice, measure the upper
arm shaft starting torque with a spring balance.
Limit
2.
: 15 Nm (11 ft.lbs.)
6.5 N (1.41bs.)
If the upper arm shaft starting

replace the upper arm assembly
torque
exceeds
the limit,
UPPER BALL JOINT STARTING

TORQUE CHECK
Check the upper ball joint starting torque by following
the
steps below.
1. Measure the upper ball joint starting torque with a torque
wrench.
Standard
2.
value
: 0.6-3.5
If the upper ball joint starting
replace the upper ball joint.

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Nm (730
torque
in.lbs.1
is out of specification,
2-28
FRONT SUSPENSION - Shock

72.5 (2.854)
r-1
Absorber
and
Upper
Arm
UPPER ARM SHAFT TIGHTENING

AMOUNT
Give appropriate
amount of turn to the shaft so as to obtain
the specified dimension.
72.5 (2.854)
Caution
The dimensions
shown
in the illustration
dimensions
that determine
the caster.
are important
REPLACEMENT OF UPPER BALL JOINT
NOi?.mAaa
1. Remove the dust cover together with the ring.

2. Remove the snap ring from the upper ball joint by using a
snap ring pliers.
MB990940-01
Upper arm ball joint
3. Press the upper ball joint out of the upper arm by using the
special tools.
4.
111525
Press-fit the new upper ball joint with special tools aligning
the mating mark with the upper arm center.
MB99
5. Using a snap ring pliers, Tit the snap ring securely

groove of the joint case.
Caution
Limit the opening
Revision
http://vnx.su/
of the snap
ring
in the
to a minimum.
FRONT SUSPENSION - Shock

6.
and the upper
Apply the specified

ball joint.
Specified
8.
Secure
sealant
2-29
Upper Arm
and
cover
7.
Absorber
grease to both the interior
sealant
to the grooves
in the upper
the dust cover to the upper
ball joint with a ring.

rection
bolt
of dust
ball joint.
N02MEp9
10. INSTALLATION
OF UPPER ARM
When the upper arm assembly is installed to the crossmember, insert the upper arm shaft attaching bolts from
outside the crossmember
and put adjusting shims between the crossmember
and upper arm shaft.
.
ADJUSTMENT
OF CLEARANCE
BETWEEN
BUMP
STOPPER AND BUMP STOPPER BRACKET
Refer to P. 2-38.
1. INSTALLATION
OF SHOCK ABSORBER
(1) Install the shock absorber so that the white paint mark
at the lower side of the shock absorber faces the outer
side of the vehicle.
12154
(2) Tighten the shock absorber installation nut so that the

dimension shown in the figure is the standard value.
Standard
12W533
1 TSB Revision
http://vnx.su/
value
: 7-8
mm
(.27-.31
in.)
2-30
FRONT SUSPENSION - Lower Arm
LOWER ARM
18-Z Nm
13-18 ftlbs.
18w654
15-22 Nm
11-16 ft.iJbs.
7-6 ~klbs.
12W341
40-50 Nm
26-36 ftlbs.
ldb160
*7
Nm
lULlSO
Nm
rs=?
/ a/
11
20-30 Nm
14-2.2 ftlbs.
12w333
36-64 klbs.
Removal
I)*
4+ r)4
+*
*+
**
steps
1. Under skid plate
2. Under cover
Adjustment of clearance between bump
3. Torsion bar
4. Cotter pin
5. F,qj;;;tion
of lower ball joint and
6. Self-locking nut
7. Stabilizer bar
8. Shock absorber mounting
bolts
9.Lower
lO.Anchor
11. Lower
12. Bump
13.LowEr
fityksverse
(2) ++
(3) *+ :
(4) q :
(5) + :
http://vnx.su/
arm shaft
arm 8
arm
stopper
ball joint mounting
nuts

Refer to Service Points of Removal.
Non-reusable parts
Must he tightened while vehicle is unladen.
2-31

SERVICE
POINTS
rw?lwAK
OF REMOVAL
3.
REMOVAL
OF TORSION
Refer to P.2-36:
5.
DISCONNECTION
OF LOWER
BALL
JOINT
AND
KNUCKLE
(1) Loosen the nut tightening
the lower ball joint to the
knuckle.
(2) Using a special tool. disconnect
the lower ball joint
from the knuckle.
Caution
become separated.
only, not removed.
8.
REMOVAL
OF SHOCK ABSORBER MOUNTING
BOLTS
Remove the shock absorber lower part and compress the
shock absorber.
MB99080~1
/IY
BAR
NOZNcApr
INSPECTION
l
l
Check the lower arm for cracks or deformation.

Check the anchor arm assembly
for wear or damage.
Check the lower ball joint dust cover for cracks or
deterioration.
LOWER BALL JOINT END PLAY CHECK

Check the lower ball joint end play by following
the steps
below.
I. Measure the lower ball joint end play with a dial indicator.
Limit
2.
: 0.5 mm
(-020
in.)
If the lower ball joint end play exceeds

the lower ball joint.
the limit,
replace
REPLACEMENT OF LOWER ARM BUSHING N02ND~

1. Using a special
bracket.
tool,
remove
the
bushing
NOTE
When removing
the left hand bushing
differential
carrier. (Refer to P.2-53.)
1 TSB Revision
http://vnx.su/
A from
the
A. detach
the
2-32

2. Using a special
bracket.
tool,
bushing
press-fit
B from
the
the
bushing
lower
A into the
3.
Remove the
special tools.
arm
4.
Coat the bushing B and the lower arm with soap solution
and press-fit the bushing B into the lower arm by using
special tools and taking care not to twist or tilt the bushing
B.
NOTE
Press-fit the bushing again from the opposite
equalize bushing projections at both ends.
;EO\l.;EMENT
by using
side
to
OF LOWER BALL JOINT DUST

NOZNEP&
I,

grease to the interior of the dust
cover and the lower ball joint.
2. Apply the specified sealant to the grooves in the lower ball
joint.
Specified
3.
Secure
sealant
the dust cover to the

-
lower ball joint with a ring.

7.
NOZNFAA
INSTALLATION
OF STABILIZER
BAR
Install the stabilizer bar to the lower arm in such a way that
the amount of protrusion of the stabilizer bar installation
bolt is the standard value
Standard
value
: 6-8
NOTE
The dimension
show
bushing is used.
1 TSB Revision
_-
http://vnx.su/
mm
(.24-.31
in figure
in.)
is the value when
a new
zz7.
2-33
FRONT SUSPENSION - Lower Arm / Knuckle

3. INSTALLATION
Refer
l
OF TORSION
BAR
to P.2-36.
ADJUSTMENT
STOPPER AND
OF CLEARANCE
BUMP STOPPER
BETWEEN
BRACKET
BUMP
Refer to P.2-38.
KNUCKLE
60-60
43-65
Nm
ftlbs.
SO-100 Nm
58-72 ft.lbs.
94-145 ft.lbs.
SO-100 Nm
58-72 ft.lbs.
Removal
4~
4*
+*
c*
I)+
bs. + 18 klbs.
50-60
3643
Nm
ftlbs.
steps
1.
2.
3.
4.
Front axle hub and free-wheeling

hub
Dust cover
Cotter pin
Connection of tie rod assembly and
knuckle
5. Cotter pin
6. Connection of lower ball joint and knuckle
7. Cotter pin
8. Connection
le
9. Knuckle
of upper ball joint and knuck-
1 TSB Revision
http://vnx.su/
NOTE
(2) +I)
(3) +*
(4) m : Non-reusable
parts
to reinstall.
of Removal.
of Installation
234
FRONT SUSPENSION - Knuckle

No2mA.i

1.
REMOVAL OF FRONT AXLE HUB AND FREE-WHEELING

HUB
Refer to P.2-17.
4.
DISCONNECTION
OF TIE
KNUCKLE
Disconnect
the tie rod from
special tool.
ROD
the
ASSEMBLY
knuckle
AND
by using
the
Caution
become separated.
2. The nut should be loosened only, not removed.
6.
DISCONNECTION
OF LOWER
BALL
JOINT
AND
KNUCKLE/ 8. UPPER BALL .fOiNT AND KNUCKLE
Using the special tool, remove the lower ball joint and
upper ball joint.
Caution
1. Support
the lower arm with a jack when removing
the knuckle from the lower ball joint or the upper
ball joint.
2. After the knuckle has been removed,
lower the jack
slowly.
~~
become separated.
only, not removed.
INSPECTION
l
o
e
ww
Check the needle bearing for wear or damage.

Check the knuckle for cracks or bends.
Check the knuckle spindle for wear or pounding.
NOZPDAB

1.
1 TSB Revision
INSTALLAnON
OF
WHEELING
HUB
Refer to P.2-17.
http://vnx.su/
FRONT
AXLE
HUB
AND
FREE-
2-35

Disassembly
+I)
*
w
w
1.
2.
3.
4.
NotpE-
steps
Oil seal
Spacer
Needle
bearing
Knuckle
NOTE
(2) 41) : Refer to Service
(3) ++ : Refer to Service
(41 q : Non-reusable parts
procedures
to reassemble.

3.
b!OPWA
REMOVAL
OF NEEDLE BEARING
(1) Remove the oil seal and take out the spacer.
(2) Drive out the needle bearing by tapping
uniformly.
Caution
Once removed,
reused.
the
needle
bearing
must
needles
not
NozPGABa
Eog3m
3.
MB990956-01
/
be
INSTALLATION
OF NEEDLE BEARING
grease to the roller surface
the new needle bearing.
of
(2) Press-fit the needle bearing by using the special tools,

until it is flush with the knuckle end face.
Caution
Use care to prevent
far in.
1 TSB Revision
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driving
the needle
bearing
too
2-36

2.
INSTALLATION
(I)
/ Torsion
Bar
OF SPACER

grease
ing surface of the spacer.
to the knuckle
(2) Install the spacer to the knuckle with

side toward the center of vehicle.
1. INSTALLATION
attach-
the chamfered
OF OIL SEAL
(1) Press-fit the new @I seal by using the special tools,

until it is flush with the knuckle end face.
(2) Pack the multipurpose
grease in the oil seal inside and
lip.
MB990938-01
TORSION BAR
121558
Removal
steps
1. Heat protector (right side only)

Adjustment of clearance between bump
2. Anchor arm assembly
+I)
3. Dust covers
4. Heat cover (left side only)
++ 5. Torsion bar
*+
----
NOTE
(lb Reverse the removal procedures
(21 +I)
(31 **
to reinstall.
: Refer to Servicx Points of Removal.
: Refer to Sewice
] TSti Revision
http://vnx.su/
.-
.
-
.-
FRONT SUSPENSION - Torsion
2-37
Bar

2.
NozsB/\I\
REMOVAL OF ANCHOR ARM ASSEMBLY

Support the lower arm from which the torsion
removed, with a jack.
INSPECTION
0
l
bar is to be
NozacAA
Check the torsion bar for bends or damage.

Check the dust cover for cracks or damage.
Nclz.sDAa.

grease to the torsion bar serrations,
the anchor arm assembly
serrations.
the anchor arm B
serrations. the dust cover inside and the anchor bolt thread.
Mating
mark
identification
mark
5. INSTALLATION
OF TORSION BAR
(I) Identify the right and left torsion bars referring to the
identification
mark put on the torsion bars.
Face the end having identification
mark forward, and
align the mark on anchor arm B with the mating mark
on torsion bar when the torsion bar is inserted in the
anchor arm B.
Whi&z mark
NOTE
When installing a new torsion bar, align the serration
painted white with the mark on anchor arm B.
(2) Select the relative position of the torsion bar serrations
and the anchor arm serrations so that the length shown
in the illustration may have specified dimension when
the torsion bar and the anchor arm are assembled, with
the upper arm rebound stopper in contact with the
crossmember.
Standard
http://vnx.su/
value
: L.H. 135.2-143.2
in.)
R.H. 124.3-132.3
in.)
mm (5.323-6.638
mm
(4.894-5.210
2-38
FRONT SUSPENSION - Torsion

.
Bar
ADJUSTMENT
OF CLEARANCE BETWEEN BUMP STOPPER AND BUMP STOPPER BRACKET
(1) Use the curb weight to obtain the amount of anchor
bolt projection from the following table.
NOTE
The anchor bolt projection
amount
is a reference
dimension
used when the torsion bar spring is installed.
Finally, adjust so that the distance to the bump stopper
bracket is the standard value.
This method can also be used to make the adjustment
on previously sold vehicles.
Example
For a vehicle with a curb weight of
the table shows the following
left
projections.
60
Left . . . . . . . . . . . . . . _. . . . . ..__.__.._....
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
c
.g
mm (2.36 in.)
mm (2.80 in.)
NOTE
For curb weights of the various models, refer to INTRODUCTION AND MASTER TROUBLESHOOTING
- General
Date and Specifications.
2-2
zJ)-
1,440 kg (3,175 Ibs.).

and right anchor bolt
90 (3.54
60 (3.15)
I
F0
h
z
8
2L
50 (1.97)
aP
40 (1.57)
I
r Rightlside
I
,--/
70 (2.76)
60 (2.36)
161.4 16:8
13:2 13:s 14.0 14.4 1419 15.2 1516 Id0
(29.1)(30.0~~30.8~(31.7)l32.6x33.5)(34.4)(35.3)(362)(37.0)l~.91(~.8)(~.7)~~.6)
1712
1716
IdO
1814
14woa1
Curb weight
(x 100 lb-s.)
:xlOOkg
(2) With the vehicle unladen, measure the dimension from

the bump stopper to-the
bump stopper bracket to
check for conformance
with standard value.
Standard
value
: 71 mm (2.80 in.)
(3) If it is out of specification.

on the anchor bolt.
1 TSB Revision
http://vnx.su/
adjust with the adjusting
nut
2-39
FRONT SUSPENSION - Stabilizer Bar
STABlUZER
BAR
NwrA-
1843
13-18
Nm
ftlbs.
3yIi =-===f~
Removal
steps
1. Under skid plate
2. Self-locking nut
3. Clamp A
4. Stabilizer bushina
5. Self-locking nut 6. Hanger
++ 7. Stabilizer bar
8-12 Nm
8-9 ftlbs.
12w555
NOTE
(2) l * : Refer to Service Points of Installation
parts.
INSPECTION
rauTuA
Check the stabilizer bar for deformation

or damage.
Check the hanger for bends or damage.
Check the rubber parts for cracks, deterioration
or wear.
l
l
l
NWTDAA
7. INSTALLATION
OF STABILIZER BAR
When installing the hanger to the stabilizer bracket, tighten
the nut so as to obtain the specified dimension.
Standard
value
: 6-8 mm (.24-.31
in.)
When installing both ends of the stabilizer bar to the lower

arms, tighten
the nut. so as to obtain the specified
dimension.
Standard
value
: 6-3 mm (.24-.31
in.)
NOTE
The dimensionshown in the figure is the value when a

new bushing
1 TSB Revision
http://vnx.su/
is used.
2-40
FRONT SUSPENSION - Drive Shaft
DRIVE SHAFT
Right drive shaft
lcl3 Nm
7-g klbs.
5C-60 Mm
36-43 ft.lbs.
Removal
steps
1. Under cover
2.
Hub cover
4*
Adjustment
of drive shaft end play
l 4
0
3. Snap ring
4. Shim
5. Front brake assembly
++
6. Cotter pin
7. Connection of tie rod assembly and
+*
knuckle
8. Cotter pin
9. Connection of lower ball joint and
4*
knuckle
70. Cotter pin
11. Connection of upper ball joint and
4*
knuckle
12. Front hub and knuckle assembly
44 +4 13. Left drive shaft
14. Circlip
15. Right drive shaft
NOTE
(2) 4* : Refer to Service Points of Removal.
(3) +4 : Refer to Service Points of lnstallatton.
i TSB Revision
I-
http://vnx.su/
FRONT SUSPENSION - Drive
2-41
Shaft
NOZOBACI

2.
REMOVAL
OF HUB COVER
Refer to P.2-17.
3. REMOVAL
OF SNAP RING
Refer to P.2-17.
5. REMOVAL
OF FRONT BRAKE ASSEMBLY
c
Refer to P.2-17.
7. DISCONNECTION
OF TIE ROD ASSEMBLY
AND
KNUCKLE
Refer to P.2-34.
9. DISCONNECTION
OF LOWER
BALL
JOINT
AND
KNUCKLE / 11. UPPER BALL JOINT AND KNUCKLE
Refer to P.2-34.
13. REMOVAL
OF LEFT DRIVE SHAFT
Pull the drive shaft out from the differential
carrier.
Caution
When pulling the drive shaft out from the differential
carrier, be careful that the spline part of the drive shaft
does not damage
the oil seal.
Nomcm
INSPECTION
Check the boot for damage or deterioration.

Check the ball joint for operating condition and excessive
looseness.
Check the splines for wear or damage.
l
l
l
la3mDAM
13. INSTALLATION
OF LEFT DRIVE SHAFT
Drive the drive shaft into the front differential carrier with a
plastic hammer.
Caution
Be careful not to damage the lip of the oil seal. Replace
the circlip which is attached
to the D.O.J. side spline
part with a new one.
l
ADJUSTMENT
Refer
to P.2-20.
) TSB Revision
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OF DRIVE
SHAFT
END PLAY
2-42
Nozoa-
Left drive shaft
E.J. repair kit LH

79
D.O.J. repair kit

Disassembly
+*
4*
4*
l +
**
4*
4*
l *
1.
2.
3,
4.
5.
6.
7.
8.
9.
IO.
1 I.
12.
13.
14.
15.
16.
17.
18.
Boot repair kit (B.J.)
steps
Reassembly
Boot band A
Soot band B
Circlip
D.O.J. outer race
Dust cover
Balls
D.OJ. cage
Snap ring
D.O.J. inner race
D.O.J. boot
Dust cover
Boot protector band
Boot protector
Boot band A
Boot band B
B.J. boot
Drive shaft and B.J.
Circiip
I)+
I)+
I)+
ma
ed
++
++
+a
MI
+a
I)+
+a
04
I)+
NOTE
(1) +I)
(2) ~4
: Refer to Service
: Refer to Service
Boot repair kit (D.O.J.)
$1
(5)
R
D.OJ.
steps
17.
16.
14.
15.
2.
10.
I.
7.
9.
8.
6.
5.
4.
3.
18.
13.
12.
11.

B.J. boot
Boot band A
Boot band B
Boot band B
D.OJ. boot
Boot band A
D.O.J. cage
D.O.J. inner race
Snap ring
Balls
Dust cover
D.O.J. outer race
Circlip
Circlip
Boot protector
Boot protector band
Dust cover
: Bitfield Joint
: Double OffseLIoint
1 TSB Revision
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FRONT
SUSPENSION
Drive
2-43
Shaft
Right drive shaft
B.J. repair kit RH

I
17,
-.-9
IlQ 16*r
.llW608
D.OJ. repair kit
Disassembly
4*
+*
4+
+*
4*
4*
4*
NOTE
[I) 4~
I.
2.
3.
4.
6.
7.
8.
9.
10.
II.
12.
13.
14.
15.
16.
17.
l!J
lIW6OP
Boot repair kit (D.OJ.)
Boot repair kit (B.J.)
Reassembly steps
steps
Boot band A
Boot band B
Circlip
D.O.J. outer race
Balls
D.O.J. cage
Snap ring
D.O.J. inner race
D.O.J. boot
Dust cover
Boot protector band
Boot protector
Boot band A
Boot band B
B.J. boot
: Refer to Service
2 10 16318
l 4
l 4
I)+
1)4
l 4
l 4
l +
l 4
1)4
e4
1)4
++
1)4
(3) lsl
17.
16.
14.
15.
2.
10.
1.
7.
9.
8.
6.
4.
3.
13.
12.
II.

B.J. boot
Boot band A
Boot band B
Boot band B
D.O.J. boot
Boot band A
D.0 J. cage
D.OJ. inner race
Snap ring
Balls
D.O.J. outer race
Circlip
Boot protector
Boot protector band
Dust cover
: Non-reusable
parts
Birfield Joint
(5) D.OJ. I Double Offset Joint
(4)
(2) l 4 : Refer to Service Points of Reassembly.
B.J.
1 TSB Revision
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2-44

PJo2aFAF Em
5.
REMOVAL OF DUST COVER

Remove the dust cover from the D.O.J. outer race.
6.
REMOVAL OF BALLS
Remove the balls from the D.O.J. cage.
7.
REMOVAL OF D.O.J. CAGE

Remove the D.O.J. cage from the D.O.J. inner race in the
direction of the B.J.
8. REMOVAL OF SNAP RING

Remove the snap ring from the drive shaft with a snap ring
pliers, and then withdraw the D.O.J. inner race and D.O.J.
cage from the drive shaft.
10. REMOVAL OF D.O.J. BOOT

(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaftso that the D.O.J. boots are not
damaged when they are removed.
(2) Withdraw the D.O.J. boots from the drive shaft..
http://vnx.su/
Es-1
p-L
-a-
2-45
11. REMOVAL OF DUST COVER

Remove the dust cover from the drive shaft and B.J.
13. REMOVAL OF BOOT PROTECTOR

After extending the folded over part of the boot protector
and removing the boot protector band, push the boot protector to the B.J. side and then remove it.
16. REMOVAL OF B.J. BOOT

(1) Wrap vinyl tape around the spline part on the D.O.J.
side of the drive shaft so that the B.J. boot are not
damaged when they are removed.
(2) Withdraw the B.J. boot from the drive shaft.
Caution
Do not disassemble
the B.J.
llW604
INSPECTION
l
l
l
l
l
l
Nozo6A6
Check the drive shaftfor bending or wear.

Check the B.J. for entry of water, foreign matter and rust.
Check the B.J. ball for damage.
Check the D.O.J. cage, D.O.J. inner race and ball for rust,
wear and damage.
Check the circlip for damage or deformation.
Check the D.O.J. outer race for wear or damage.
NOMHAL
16. /14. / 15. / 2. / 10. / 1. INSTALLATION

OF BOOTS AND
BOOT BANDS
(1) Apply the specified grease to the drive shaft, and wrap
vinyl tape around the spline part on the D.O.J. side of
the drive shaft.
Specified
1 TSB Revision
http://vnx.su/
grease : Repair kit grease
2-46

(2) lnstell
D.O.J.
the B.J. boot,~ boot bands (new ones),

boot on the drive shaft, in that order.
and
Identification No.
Boot bands A identification
No.
2.6 L Engine, 3.0 L Engine (A,T)

1 3.0 L Engine (M/T)
D.O.J.
B.J.
20-75
20-110
j 20-69
/ 20-70
NOTE
Install the boot so that when it is tightened,
its lever
may be located toward the rear of vehicle.
Caution
The B.J. and D.O.J. boots are different
in size and
shape, so make sure they are correct.
(3) Apply all the specified grease, half of it to the inner
side of the B.J., and the other half to the inner side of
the B.J. boot.
Specified
grease :
Repair kit grease
[I10 gr (3.9 oz.)]
<2.6 L Engine>
<3.0 L Engine>
[I30 gr (4.6 oz.))
i i 80071
(4) Secure the B.J. boot to the drive shaft by boot bands A
and B.
. Inner
7. INSTALLATION
OF D.O.J. CAGE / 9. D.0.J INNER RACE
(1) Install the D.O.J. cage onto the drive shaft so that the
smaller diameter
side of the cage is installed first.
(2) Apply the specified grease to the D.O.J. inner race and
the D.O.J. cage, and then fit them together.
Specified grease : Repair kit grease
race
11 BOW
/
6. APPLICATION
OF GREASE TO BALLS
Apply the specified grease to the ball insertion parts of the
D.O.J. inner race and D.O.J. cage, and insert the balls.
Specified grease : Repair kit grease
4.
INSTALLATiON
OF D.O.J. OUTER RACE
(I) Apply the specified
grease to the D.O.J. outer
Specified-grease
: Repair kii grease
<2.6 L Engine>
155 gr (1.9 oz.)]
<3.0 L Engine >
160 gr (2.3 oz.)]
(2) Fit the drive shaft into the D.0.J outer race.
(3) Add the specified
grease to the D.O.J. outer
Specified
grease :
Repair kit grease
<2.6 L Engine>
[55 gr (1.9 oz.)]
(3.0 L Engine >
[SO gr (2.3 oz.)]
( TSB Revision
http://vnx.su/
race.
race.
FRONT SUSPENSION - Drive
2-47
Shaft
(4) install the circlip onto the D.O.J. outer race.

(5) Place the D.O.J. boot over the D.O.J. outer
then use boot band B to secure the boot.
race, and
Caution
Do not secure the boot band A
Boot band B
(6) Secure the driveshaft, and then move the D.OJ. outer
race until it is at the position where the D.O.J. boot
assembly dimension is the standard value.
Boot band A ,,yogo
Standard
value
: 77-33 mm (3.03-3.27
in.)
(7) Remove a part of the D.O.J. boot from the D.O.J. outer
race and release the air within the boot.
(8) Secure the boot band Aon D.O.J. boot.
Caution
Be sure that the
bands is correct.
installation
direction
of the boot
13. INSTALLATION
OF BOOT PROTECTOR / 12. BOOT PROTECTOR BAND
(1) After installating the boot protector to the B.J., secure
by the boot protector band.
Caution
Be sure that the
bands is correct.
installation
direction
of the boot
(2) Securely fold over the end of the boot protector.

11. INSTALLATION
OF DUST COVER
With the special tool applied to dust cover, strike with a

plastic hammer to press the cover to the drive shaft.
1180072
5.
Steel pipe
i
INSTALLATION
OF DUST COVER
Using the steel pipe as specified
cover to the D.O.J. outer race.
below,
mm (in.)
Steel Pipe
II
Outside diameter
1 TSBFevision
http://vnx.su/
force the dust
77 (3.0)
2-48
FRONT SUSPENSION - Inner Shaft
INNER SHAFT
hm?fu-

D-100 Nm
E-72 ft.lbs.
\
, .I
9
//--7f-?
\ 60-100 Nm
_ 58-72 ft.lbs.
q S
.I522
1116
50-50
36-43
Nm
klbs
Nm
ft.lbs.
10-13 Nm
7-9 ft.lbs.
Removal
steps
NOTE
(2) 4e : Refer to Service Points of Removal.
(3) **
Refer to Service Points of Installation
(4) q
1. Under cover
*II) ++ 2. Front hub and knuckle assembly
3. Shock absorder lower mounting bolts
a+ WI 4. Drive shaft assembly (R.H.)
+*
WI
5. Inner
6.
7.
8.
9.
shaft
Circlip
Self locking nut
Differential mounting
Housing tube
bracket (R.H.)

2.
REMOVAL OF FRONT HUB AND KNUCKLE

/ 4. DRIVE SHAFT ASSEMBLY
(R.H.)
Refer
) TSB Revision
to P.240.
http://vnx.su/
NASSEMBLY
2-49

5.
REMOVAL
OF INNER SHAFT
Attach the special tools to the flange of the shaft, and
drive the inner shaft out from the front differential
carrier.
Caution
1. Being careful
not to scratch
or scar the shock
absorber
with the special tool, remove the lower
mounting
bolts
of the
shock
absorber,
and
compress
the shock absorber
as much as possible.
2. When pulling
the inner shaft out from the front
differential
carrier, be careful that the spline part of
the inner shaft does not damage the oil seal.
INSPECTION
l
l
l
l
Check
Check
Check
Check
the
the
the
the
inner shaft for bend.

bearing for wear or discoloration.
housing tube for cracks.
dust seal for cracks or damage.
NomAe

5.
INSTALLATION
OF INNER SHAFIDrive the inner shaft into the front differential
using the special tools.
carrier by
Caution
1. Replace the circlip which is attached
to the inner
shaft spline part with a new one.
2. Be careful not to damage the lip of the dust seal and
oil seal.
4.
Disassembly
INSTALLATION
OF DRIVE SHAFT ASSEMBLY
FRONT HUB AND KNUCKLE ASSEMBLY
Refer to P.2-40.
(R.H.)/2.
steps
.
llWS97
1. Inner shaft
+a
I)*
3. Dust &er
4. Housing tube
5. Dust seal
NOTE
procedures
to reassemble.
(2) l + : Refer to Service Points of Disassembly.
(3) ++ : Refer to Service Points of Reassembly
(4) q
[ TSB Revision
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2-50

2.
REMOVAL
OF BEARING
(1) Bend the outside periphery
hammer.
lWZRFA6
of dust cover inward with a
.-
(2) After the special tool has been installed as shown,

tighten the nut of the special tool until the portion A
of the special tool touches the bearing outer race.
..-
(3) Press out the inner shaft from the bearing.

Caution
Do not allow the inner shaft to drop.

5.
MB990955-01
N-a
INSTALLATION
OF DUST SEAL
(I) Press-fit the new dust seal into the housing tube by
using the special tools, until it is flush with the housing
tube end face.
grease to the dust seal lip.
3. INSTALLATION
OF DUST COVER
Using a steel pipe, force a new dust cover onto the inner
shaft.
http://vnx.su/
FRONT SUSPENSION - Inner Shaft / Front Differential
2-51
Mounting
NOTE
After the dust cover has been installed, apply multipurpose grease to the inside of the dust cover.
2.
INSTALLATION
Using
shaft.
FRONT DIFFERENTIAL
OF BEARING
the special
tool, force
the bearing
onto the inner
MOUNTING
-.
58-30
h-42
22-30
s....
ft.lbs.
Nm
ft.lbs.
12W554
1%?i Nm
7-9 ft.lbs.
Removal
+e e+
+I) I)+
4*
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Under cover
Drive shaft
Circlip
Inner shaft
Circlip
Self-locking nut
Self-locking nut
**
rubber A
rubber B
bracket (L.H.)
11.
12.
13.
14.
15.
16.
Differential
Differential
Differential
Self-locking
Differential
Differential
mounting
mounting
mounting
nut
mounting
mounting
rubber A
rubber B
bracket (R.H.)
rubber C
rubber D
NOTE
(1) Reverse the removal procedures to reinstall
(3) ** : Refer to Service Points of Installation.
(4) q : Non-reusable parta
/ TSB Revision
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2-52
FRONT SUSPENSION - Front
Differential
Mounting
NOZOBAB
2.
REMOVAL
OF DRIVE
Refer to P. 240.
SHAFT
4.
REMOVAL
OF INNER SHAFT
Attach the special tools to the flange of the shaft. and
drive the inner shaft out fmm the front differential
carrier.
Caution
1. Being careful
not ato scratch
OP scar the shock
absorber
mounting
bolts of the shock absorber, and compress
the shock absorber
as much as possible.
2. When pulling
the inner shaft out from the front
differential
the inner shaft does not damage the oil seal.
1lW.524
9. REMOVAL
OF DIFFERENTIAL
MOUNTlNG
BRACKET
(L.H.) / 13. DIFFERENTIAL
MOUNTiNG
BRACKET (R.H.)
While supporting the differential carrier with a jack, remove
the differential
mounting
bracket.
NOTE
Support the differential
carrier with a jack until installing
the differential
mounting
bracket.
INSPECTION
No*cm
@ Check the differential

mounting
bracket for deformation
and damage.
@ Check the bracket for deformation
and damage.
@ Check the differential
mounting
rubber for cracks and
damage.

4.
INSTALLATION
OF INNER SHAFT
Drive the inner shaft into the front differential
Caution
Be careful
seal.
2.
/ TSB Revision
not to damage
INSTALLATION
OF DRIVE
Refer to P. 240.
http://vnx.su/
NOZUDP9,
carrier
by
the lip of the dust seal and oil

SHAFT
FRONT SUSPENSION - Differential
DIFFERENTIAL
2-53
Carrier
CARRIER
?m?A-
I
1
I-rn
80-110 Nm
/58-80
ft.lbs.
43-51
7i-87
ft.lbs.
ft.lbs.
80-100
10-13 Nm
7-9 Ribs.
Removal
steps
1.
++ l *
2.
3.
qe l + 4.
5.
6.
4+
7.
8.
4*
9.
10.
11.
12.
13.
14.
15.
Nm
80-100 Nm
58-72 ft.lbs.
Pm-removal
Operation
Under cover
l
Draining of Gear Oil
Drive shaft
Post-installation
Operation
Circlip
l
Supplying Gear Oil (Refer to P. 2Inner shaft
l!i\
Circlip
Front propeller shaft
Self-locking nut
Differential mounting bracket (L.H.)
Self-locking nut
Front suspension crossmember and front
differential carrier assembly
Self-locking nut
Front suspension crossmember
NOTE
Differential mounting bracket (R.H.)
(2) l * : Refer to Service Points of Removal.
Housing tube
(3) I)+ : Refer to Service Points of Installation
Front differential carrier assembly
1 TSB Revision
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=I--
.nYI.L*.
-2,:
FRONT SUSPENSION - Differential Carrier

m2vEAB
2.
REMOVAL
OF DRIVE SHAFT
Refer to P.2-40.
4. REMOVAL
OF INNER SHAFT
Drive the inner shaft out from the front differential carrier.
Caution
1. Being careful
not to scratch
or scar the shock
absorber
mounting
bolts
of the
shock
absorber,
and
compress the shock absorber as much as possible.
2. When pulling the inner shaft out from the front
differential
the inner shaft does not damage
the oil seal.
6.
REMOVAL
OF FRONT PROPELLER SHAFT
Make the mating marks on the flange yoke and the
differential
companion
flange.
Detach the propeller
shaft from the front differential
carrier assembly.
8. REMOVAL
OF DIFFERENTIAL
MOUNTING
BRACKET
(L.H.)
While supporting
the differential
carrier with a jack,
remove the differential
mounting
bracket.
INSPECTION BEFORE DISASSEMBLY
NOZVCAC
Remove the cover and gasket. Hold the working base tn a

vice, and install the differential
carrier assembly
to the
working base.
FfNAL DRIVE GEAR BACKLASH

CHECK
Check the final drive gear backlash by following
the steps
below.
(1) With the drive pinion locked in place, measure the final
drive gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference
of
the drive gear.
Standard value : 0.11-6.16
mm (.0043-.0063
in.)
(2) If the backlash is not within the standard value, adjust it by
using the side bearing adjustment
spacers.
DRIVE GEAR RUNOUT CHECK
Check the drive gear runout by following
the steps below.
(1) Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit:
0.05 mm 1.0020 in.)
(2) If the runout exceeds the limit, check for improper
tightening
of the drive gear and differential
case.
levision
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I
2-55
Carrier
DIFFERENTIAL GEAR BACKLASH CHECK

Check the differential
gear backlash by following
the steps
below.
(1) While locking the side gear with the wedge, measure the
differential
gear backlash with a dial indicator
on the
pinion gear.
NOTE
The measurement
individually.
should
be made for both pinion gears
Standard value : O-6.076 mm

Limit : 0.2 mm (.008 in.)
(O-.0030
in.)
(2) If the backlash exceeds the limit, adjust by using the side
gear thrust spacers.
FINAL DRIVE GEAR TOOTH CONTACT
CHECK
Refer to GROUP 3 - Differential
Carrier (Inspection
Before
Disassembly).

4.
INSTALLATION
OF INNER SHAFT
Drive the inner shaft into the front differential
Caution
Be careful
seal.
2.
not to damage
INSTALLATION
OF DRIVE
Refer to P.2-40.
1 TSB Revision
http://vnx.su/
NOZVDAB
carrier
by
the lip of the dust seal and oil

SHAFT
.i~

IISASSEMBLY
16
30
0 Differential Gear Backlash

Final Drive Gear Tooth Contact
Disassembly
+*
4*
4*
*+
l +
+*
+*
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
steps
Differential cover
Bearing caps
Differential case assembly
Side bearing adjusting spacers
Side bearing outer races
Side bearing inner races
Bolts (IO)
Drive gear
Lock pin
Pinion shaft
Pinion gears
Pinion washers
Side gears
Side gear thrust spacers
Differential case
Companion flange self-locking nut
Washer
Drive pinion assembly
Drive pinion front bearing inner race
TSB Revision
*+
**
20. Drive pinion front shim (for pinion

height adjustment)
21. Drive pinion
22. Companion flange
23. Drive pinion spacer
24. Drive pinion rear shim (for preload adjustment)
25. Oil seal
26. Drive pinion rear bearing inner race
27. Drive pinion rear bearing outer race
28. Drive pinion front bearing outer race
29. Oil seals
30. Gear carrier
31. Vent plug
--.
---
y
_-s
gg$.i
--.~
gg
NOTE
(I]
41) : Refer to Service Points of Disassembly.
http://vnx.su/
~~
.c
s--IilzL
7
FE Ii.
Carrier

3.
2-57
NO2vFAC
REMOVAL OF DIFFERENTIAL CASE ASSEMBLY

Take out the differential
case assembly with a hammer
handle.
Caution
When taking
out the differential
case assembly,
be
careful not to drop and damage the side bearing outer
races.
NOTE
Keep the right and left side bearings and side bearing
adjusting spacers separate, so that they do not become
mixed at the time of reassembly.
6.
REMOVAL OF SIDE BEARING INNER RACES

Pull out the side bearing inner races by using the special
tools.
8.
REMOVAL: OF DRIVE GEAR

(1) Make the mating marks to the differential case and the
drive gear.
the drive gear attaching
bolts in diagonal
(4 Loosen
sequence to remove the drive gear.
9. REMOVAL OF LOCK PIN

Drive out the lock pin with a punch.
NOTE
The removed side gears and side gear thrust spacers,
and right, should be retained for reassembly.
left
16. REMOVAL
OF COMPANION
FLANGE SELF-LOCKING
NUT
Use the special tool to hold the companion
flange and
remove the companion flange self-locking nut.
1 TSB Revision
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Carrier
18. REMOVAL OF DRIVE PINION ASSEMBLY

(I) Make mating marks on the drive pinion and companion
flange.
Caution
The mating mark made on the companion
flange
must not be on the coupling
surface of the flange
yoke and the front propeller shaft.
12) Drive out the drive pinion together
spacer and drive pinion shims.
MB99033901
with the drive pinion
19. REMOVAL OF DRIVE PINION FRONT BEARING INNER

RACE
Pull out the drive pinion front bearing inner race by using
the special tools.
27. REMOVAL
OF DRIVE PINION REAR BEARING OUTER
RACE /28. DRIVE PINION FRONT BEARING
OUTER
RACE
(1) Drive out the drive pinion rear bearing outer race from
the gear carrier by using the brass rod.
(2) Drive out the front bearing outer race in the same
manner.
INSPECTION
l
e
l
l
l
l
Check the companion flange for wear or damage.

Check the oil seal for wear or deterioration.
Check the bearings for wear or discoloration.
Check the gear carrier for cracks.
Check the drive pinion and ring gear for wear or cracks.
Check the side gears, pinion gears and pinion shaft for
wear or damage.
Check the side gear spline for wear or damage.
1 TSB Revision
http://vnx.su/
:-
-fJ
L .s
2-59

EASSEMBLY
-G.OL Engine>
196-250 Nm
137-M
ft.lbs.
<2.6L Engine>
166-220 Nm
NozvH-
SO-90 Nm
il
\
15-22
11-16
Nm
ft.lbs.
kill134
Differential
Reassembly
l +
I)+
l +
l 4
1.
2.
3.
4.
5.
6.
7.
8.
+4
9.
IO.
11.
12.
13.
14.
15.
16.
17.
14
s11135
gear set
Final drive gear set
steps
Vent plug
Gear carrier
Oil seals
Drive pinion front bearing outer race
Drive pinion rear bearing outer race
Adjustment
of pinion height
Drive pinion
Drive pinion front shim (for pinion
height adjustment)
Drive pinion front bearing inner race
Adjustment
of drive pinion preload
Drive pinion rear bearing inner race
Oil seal
Drive pinion rear shim (for preload adjustment)
Drive pinion spacer
Drive pinion assembly
Companion flange
Washer
Companion flange self-locking nut
Differential case
18.
19.
20.
21.
*a
22.
we 23.
l * 24.
25.
++ 26.
27.
I)4
28.
29.
30.
l + 31.
NOTE
(1) ++
(2)
) TSB Revision
http://vnx.su/

Side gears
Pinion washers
Pinion gears
Adjustment of differential gear backlash
Pinion shaft
Lock pin
Drive gear
Bolts (10)
Adjustment of final drive gear back lash
Side bearing adjusting spacers
Bearing caps
Differential cover
: Refer to Service
Points
of Reassembly.
2-60
Carrier
?tc%?wAF
3. INSTALLATION
OF OIL SEALS
Install the oil seal with the special tool and apply a thin
coat of multipurpose
grease to the lip of the oil seal.
11BOOZC
4.
MB99093S-01
Ml399093641
INSTALLATION
OF DRWE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion front bearing outer races into the
gear carrier by using the- special tools.
NOTE
Perform
race.
5.
press-fitting
carefully
so as not to tilt the outer
INSTALLATION
OF DRIVE PINION
REAR BEARING
OUTER RACE
Press-fit the drive pinion rear bearing outer races into the
gear carrier by using the special tools.
NOTE
Perform
race.
press-fitting
carefully
MB990901-01
ADJUSTMENT
OF PINION HEIGHT
Adjust the drive pinion height by the following procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races to the gear carrier in the sequence
MB9909053-01
MB990905l-01
(2) Tighten
the handle of the special tool until the
standard
value of drive pinion rotation
torque
is
obtained.
1 TSB Revision
http://vnx.su/
2-61
Carrier
(3) Measure the drive pinion rotation

oil seal) by using the special tools.
MB990905l-01
toroue
(without
the
Standard
value :
<2.6L Engine>
0.15-0.25
Nm (1.30-2.17
in.lbs.)
<3.OL Engine>
0.4-0.5 Nm (3.474.34
in.lbs.)
NOTE
1. Gradually tighten the handle of the special tool
while checking the drive pinion preload.
2. Because one rotation cant be made when the
special tool is in contact with the gear carrier, move
it a few times and, after seating the bearing,
measure the rotation torque.
(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion front shim of
a thickness which corresponds
to the gap between the
special tools.
NOTE
1. Be sure to clean the side bearing seat thoroughly.
When positioning the special tool, be sure that the
cut-out sections
of the special tool are in the
position shown in the illustration, and also confirm
that the special tool is in close contact with the side
bearing seat.
2. When selecting the drive pinion front shims, keep
the number of shims to a minimum.
(5) Fit the selected drive pinion front shim(s) to the drive
pinion, and press-fit the drive pinion front bearing inner
race by using the special tool.
ADJUSTMENT
OF DRIVE PINION PRELOAD
Adjust the drive pinion turning
torque
by using the
following
procedure:
Without
Oil Seal
(1) Insert the drive pinion into the gear carrier, and then
install, from the front side of the carrier, the drive
pinion spacer, the drive pinion rear shim, the drive
pinion rear bearing inner race, and the companion
flange in that order.
NOTE
Do not install the oil seal.
(2) Tighten the companion
flange
by using the special tool.
A/
\Y
1-
Revision
http://vnx.su/
to the specified
torque
2-62
FRONT SUSPENSION - Diierential

(3) Measure
oil seal).
Carrier
the drive pinion
rotation
torque
(without
the
Standard
value :
<2.6L Engine>
0.15-0.25
Nm (1.30-2.17
in.lbs.)
<3.OL Engine>
0.4-0.5 Nm (3.474.34
inhs.)
(4) If the drive pinion rotation torque is not within the
range of the standard value, adjust the preload by
replacing
the drive pinion rear shim(s) or the drive
pinion spacer.
NOTE
When selecting
the drive pinion rear shims, if the
number of shims is large, reduce the number of shims
to a minimum
by selecting the drive pinion spacers.
(5) Remove
again.
the companion
flange
and drive pinion
once
With Oil Seal

(1) After setting the drive pinion rear bearing inner race,
drive the oil seal into the gear carrier front lip by using
the special tool.
(2) App!y the multipurpose
grease to the oil seal lip.
(4) Install the drive pinion assembly and companion flange

with mating marks properly aligned, and tighten the
companion
flange self-locking
nut to the specified
(5) Measure the drive pinion rotation torque (with oil seal)
to verify that the drive pinion preload complies with the
standard value.
Standard
value :
<2.6L Engine>
0.35-0.45
Nm (3.04-3.91
in.lbs.)
<3.OL Engine>
0.6-0.7 Nm (5.21-6.08
inAbs.)
11Y223,
Revision
(6) If the measured value is not within the standard value

range, check for faulty installation
of the oil seal or
taulty tightening of theself-locking
nut.
I
I_
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-
FRONT
SUSPENSION
.
Differential
2-63
Carrier
ADJUSTMENT
OF DIFFERENTIAL GEAR BACKLASH
(1) Assemble
the side gears, side gear thrust spacers,
pinion gears, and pinion washers into the differential
case.
(2) Temporarily install the pinion shaft.
NOTE
Do not drive in the lock pin yet.
(3) Insert a wedge between the side gear and the pinion
shaft to lock the side gear.
(4) Measure
the differential
gear backlash with a dial
indicator on the pinion gear.
Standard value : O-0.076 mm
Limit : 0.2 mm (.008 in.)
(O-.0030
in.)
(5) If the differential

gear backlash exceeds the limit,
adjust the backlash by installing thicker side gear thrust
spacers.
(6) Measure the differential gear backlash once again, and
confirm that it is within the limit.
If adjustment
is not possible, replace the side gears
and pinion gears as a set.
23. INSTALLATION
OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the differential
case lock pin hole, and drive in the lock pin.
(2) Stake the lock pin with a punch at two points.
24. INSTALLATION
OF DRIVE GEAR
(1) Clean the drive gear attaching bolts.
(2) Remove the adhesive adhered to the threaded holes of
the drive gear by turning the tap tool (Ml0 x 1.25). and
then clean the threaded holes by applying compressed
air.

the drive gear.
Specified
adhesive
adhesive
to the threaded
: 3M Adhesive
or equivalent
holes of
stud locking
4170
(4) Install the drive gear onto the differential case with the
mating marks properly aligned. Be sure to tighten the
bolts to the specified torque in a diagonal sequence.
1 TSB Revision
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.II ? % YL
. -~~--~--.
i . ..-
=~
_
gg
2-64
FRONT
SUSPENSION
- Differential
Carrier
26. INSTALLATION
OF SIDE BEARING INNER RACES
Press-fit the side bearing inner races to the differential
case by using the special tool.
l
ADJUSTMENT
OF FINAL DRIVE GEAR BACKLASH
(I) Install the side bearing adjusting spacers, which are
tinner than those remwed,
to the side bearing outer
races, and then mount the differential
case assembly
into the gear carrier.
NOTE
Select side bearing adjusting spacers with the same
thickness for both thedrive
pinion side and the drive
gear side.
(2) Push the differential
case assembly to one side, and
measure the clearance between
the gear carrier and
the side bearing adjusting spacer with a feeler gauge.
+Clfwance
+
0.051771~7
2
(.002 in.)
= Thickness of the
spacer on one side
(3) Measure the thickness-of

the side bearing adjusting
spacers on one side, select two pairs of spacers which
correspond
to that thickness
plus one half of the
clearance plus 0.05 mm (.002 in.), and then install one
pair each to the drive pinion side and the drive gear
side.
(4) install the side bearing-adjusting

spacers and differential case assembly, as shown in the illustration, to the
gear carrier.
(5) Tap the side bearing adjusting spacers with the brass
bar to fit them to the side bearing outer race.
( TSB Revision
http://vnx.su/
2-65
Carrier
(6) Align the mating marks on the gear carrier and the
bearing cap, and then tighten the bearing cap.
(7) With the drive pinion locked in place, measure the final
drive gear backlash with a dial indicator on the drive
gear.
NOTE
Measure at four points
of the drive gear.
Standardvalue
r If backlash
is too small -,
or more on the circumference
: 0.11-0.16
mm
(.0043-.0063
in.)
(8) Change the side bearing adjusting spacers as illustrated, and then adjust the final drive gear backlash
between
the drive gear and the drive pinion.
NOTE
When increasing the number of side bearing adjusting
spacers, use the same number for each, and as few as
possible.
If backlash
is too large--l
(9) Check the drive gear and drive pinion for tooth contact.
If poor contact is evident, make adjustment.
[Refer to GROUP 3 - Differential
Carrier (Inspection
Before Disassembly)]
(lO)Measure
reverse
Limit
(ll)lf
Cross section
A-A
Flange
2.
the drive gear runout at the shoulder

side of the drive gear.
: 0.05 mm
(.0020
on the
in.)
the drive gear runout exceeds the limit, reinstall by

changing the phase of the drive gear and differential
case, and remeasure.
31. APPLICATION
OF SEALANT TO DIFFERENTIAL
COVER
Apply the specified
sealant to the cover flange face as
illustrated, then install the differential cover to the differential carrier.
Specified
1 TSB Revision
http://vnx.su/
sealant
: 3M ART Part No. 8663, or equivalent
NOTE
http://vnx.su/
REAR
SUSPENSION
CONTENTS
NlmA-
<2.6L ENGINE>
REAR SUSPENSION
ASSEMBLY
SERVICE ADJUSTMENT
Rear Wheel Alignment
. . . . . . . . .. .. . . . 3
PROCEDURES
.... 3
Inspection
......... 3
SPECIFICATIONS
. . . . . . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . .
Genefal Specifications
_..................... r._..
............................
. . . . . . . .._..................
2
2
2
2
<3.OL ENGINE>
COIL SPRING AND AXLE BUMPER
............
LOWER ARM . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. .. .. .. .. . . . . . . . . . .
Lower Arm Rear Bushing
Replacement
. . . . . . . .. .. .. . . . . . . . . . . . . . . . .. .. . . . . . . . . . .
7
7
http://vnx.su/
SERVICE ADJUSTMENT
PROCEDURES
....
Rear Wheel Alignment Inspection
. . .. . . . . .
6
6
SHOCK ABSORBER AND LATERAL

Lateral Rod Bushing Replacement
ROD . . .
,.......
8
8
. . . . . . . .. .. . . . . . . . . . . . .. .. .. . . . . . .. . . . . . . .
SPECIAL TOOLS
SPECIFICATIONS
.........................................
...........................
........ ._......._ ..........
..................... ..- ...
STABILIZER
BAR ..........................................
5
5
5
5
10
17-2
REAR SUSPENSION <2.6L ENGINE> - Specifications
REAR SUSPENSION
<2.6L
-gy
ENGINE>
SPECIFICATIONS
Items
Specifications
Suspension system
Asymmetrical
Leaf springs
Number of leaf springs
Straight span
mm (in.)
Camber (unladen)
mm (in.)
Spring constant
N/mm (Ibs./in.)
-as installed
at load of 1 ,OOD-2,500 N (220-551 Ibs.)
at load of 5.5OD-8.500 N (1.213-l ,874 1bs.J
semielliptic leaf springs
4
1,196.5-l 203.5 (47.106-47.382)
72.5-83.5 (2.854-3.287~
24(134)
56(314)
Shock absorbers
Type
Max. length
mm (in.)
Min. length
mm (in.)
Stroke
mm (in.)
Damping force [at 0.3 m/set. (0.984 ft./set.)]
Expansion
N (Ibs.)
Compression
N (Ibs.)
Hydraulic cylinder, double-acting

548 (21.6)
328(12.9)
220 (8.7)
type
1.580-2.100 (348-463)
580-860 (128-190)
Items
Specifications
.
Standard value
Toe-in
mm (in.)
Camber
0 (0) [Non adjustable]

0 [Non adjustable]
N1XC-9
Items
Shackle assembly mounting nut
Front pin assembly mounting nut
Shock absorber mounting nut
Front pin assembly mounting bolt
U-bolt mounting nut
1 TSB Revision
Nm
ftlbs.
4&o
45-60
18-25
14-20
85-110
33-43
33-43
73-18
10-14
61-80
I
http://vnx.su/
_--
._
REAR SUSPENSION
<2.6L
ENGINE>
Procedures
/ fear Suspension
SERVICE ADJUSTMENT
Assembly
17-3
PROCEDU13JSIU
REAR WHEEL ALIGNMENT INSPECTION

The rear suspension assembly must be free of worn, loose or
damaged parts prior to measurement
of rear wheel alignment.
Standardvalue
: Toe-in 0 mm
Camber 0
NOTE
Toe-in and camber
adjusted.
REAR SUSPENSION
(0 in.)
are set at the factory
and cannot
ASSEMBLY

Post-installat.ion
Operation
0 Inspection of Rear Wheel alignment.
Removal
l +
l +
+4
steps
1. Parking brake cable attaching
2. Shock absorber
3. U-bolt seat
4. U-bolts
5. Bump stopper
6. Front pin assembly
7. Rubber bushings
8. Shackle plate
86-110 Nm
61-80 ft.lbs.
bolt
++
++
9. Shackle assembly
10. Rubber bushings
11. Rear spring
NOTE
(1) Reverse the removal procedures fo reinstall.
(2) **
(3) *
: Tighten when the vehicle is unloaded.
[ TSB Revision
http://vnx.su/
be
REAR SUSPENSION <2.6L ENGINE> - Rear Suspension
Assembly
INSPECTION
NI7GCU
o Check the leaf springs for damage or deterioration.

0 Check the U-bolt for cracks or bends.
0 Check the rubber parts for cracks or deterioration.
SHOCK ABSORBER
CHECK
Expand and contract
the shock absorber
to check it for
damage, oil leakage or abnormal
noise.

Vehg
11. INSTALLATION
OF REAR SPRING
Instail the spring assembly to vehicle. Make sure the front
end (front pin side) to center bolt distance is shorter than
the rear end to center bolt distance.
front
Center
Front
pin side
Inside of
vehicle
NIIGDAE
c3
bolt
Shackle
side
9.
Inside of e
vehicle
4.
1 TSB Rev&ion
INSTALLATION
OF SHACKLE
PIN ASSEMBLY
(1) Install the front pin assembly
the inside of vehicle.
(2) Install the shackle assembly
the inside of vehicle.
ASSEMBLY/G.
FRONT
from the outside
toward
from
toward
the outside
INSTALLATION
OF U-BOLT/B.
U-BOLT SEAT
Before the U-bolts are tightened
to specified
torque,
confirm the relative position of the center bolt and axle
housing and that of the center bolt and the hole in the Ubolt seat.
http://vnx.su/
REAR SUSPENSION <3.OL ENGINb
REAR SUSPENSION
17-5
Specifications
<3.OL ENGINE>
SPECIFICATIONS
Nmx-1
Items
P-door vehicles
4door vehicles
Suspension system
3-link, rigid
3-link, rigid
Coil spring
Wire dia. x O.D. xfree length
mm (in.)
Spring constant
N/mm (Ibs./in.)
Coil spring identification color
14.0 x 174.0 x433.3

(55 x 6.73 x 17.06)
18(101)
Pink-l Line
14.7 x 174.7 x 440.9

(58 x6.88x 17.36)
22(123)
Green-l Line
Max. length
mm (in.)
Min. length
mm (in.)
Stroke
mm (in.)
Hydraulic cylinder,
double-acting type
501 (19.7)
313(12.3)
188 (7.4)
Hydraulic cylinder,
double-acting type
501 (19.7)
313 (12.3)
188 (7.4)
Damping force [at 0.3 mlsec. (0.984 ft./set.)]

Expansion
N (Ibs.)
Compression
N (Ibs.)
1.550-2.050 (342452)
480-720 (106-I 59)
1,550-2,050 (342-452)
460-720(106159)
Shockabsorbers
Type
NrxB-I
Items
Standard value
Toe-in
mm (in.)
Camber
Stabilizer bar mounting
dimension
mm (in)
Specifications
0 (0) [Non adjustable]
O[Non adjustable]
bolt attaching
15-l 7 (.59--67)
Nmx-l
Items
Lower arm to body
Lower arm to rear axle housing
Shock absorber to body
Shock absorber to rear axle housing
Lateral rod mounting nut
Axle bumper to body
Stabilizer bar to rear axle housing
[ TSB Revision
http://vnx.su/
Nm
ftlbs.
130-150
1go-220
40-50
110-130
110-130
a12
30-40
94-l 08
137-l 59
29-36
80-94
80-94
6-9
22-29
17-6
REAR SUSPENSION <3.OL ENGINE>
Special
Tools/Service
Adjustment
Procedures
N,mA-
SPECIAL TOOLS
Tool
_~
Number
Name
Use
MB&?93
Rear suspension
bushing arbor
Removal and installation of lower arm rear bushing--
MB990891
Bushing
remover/installer
base
MB990650
Lower arm
bushing arbor
-.
Removal and installation of lateral rod bushing
SERVICE ADJUSTMENT
PROCEDURE!iiw
REAR WHEEL ALIGNMENT INSPECTION

Refer to P. 17-3.
/ TSB Revision
http://vnx.su/
17-7
REAR SUSPENSION <3.OL ENGINE> - Lower Arm
LOWER ARM
REMOVAL
INSTALLATION
137-159
<bdoor
ftlbs.,
SO-94 ftlbs.
vehicles>
*
130-150 Nm
94-108 ft.lbs.
<4-door
Removal
vehicles>
steps
1. Parking brake cable attaching bolt
2. SGFeyk absorber mounting bolts (Lower
3. Low& arm
4. Lower arm front bushing
5. Lower arm rear bushing
HW642
NOTE
(2) l : Tighten when the vehicle is unloaded.
INSPECTION
MB991293
NVHBA6
(1) Check the lower arm for damage or crack.

(2) Check the bushing for cracking, deterioration
wear.
or unusual
LOWER ARM REAR BUSHING REPLACEMEyTHaAB
MB990891
(1) Replace
press.
(2) When
the bushing
pressing
by using
the bushing
the special
tools
and a
in, be sure that the difference
between the projecting

lengths (A - B) does not exceed
the following
value.
A - B = 0 f 1.0 mm (0 f .04 in.)
121664
I
1
-
1 TSB Revision
http://vnx.su/
..
17-8
REAR SUSPENSION <3.OL ENGINE>
SHOCK ABSORBER AND LATERAL

Removal
<2-doer
vehicles>
d-door
vehicles>
Shock Absorber
and Lateral Rod
ROD
NW3A-
steps
1.
2.
3.
4.
5.
Parking brake cable attaching bolt

Shock absorber mounting bolt
Lower arm mounting bolt (left side only)
Lateral rod
Lateral rod bushing
NOTE

to reinsrall.
(2) * : Tightenwhen
the vehicle is unloaded.
INSPECTJON
(1) Check the lateral rod for deformation
or damage.
(2) Check the rubber parts for cracks or deterioration.
SHOCK ABSORBER CHECK
Expand and contract
the shock absorber
to check
damage, oil leakage or abnormal
noise.
LATERAL ROD BUSHING REPLACEMENT
NV-
it for
-
rwmm
(I) Use the special tool to drive out and press in the lateral
rod bushing
(2) Be careful that the difference (A- B) in bushing projection
distances
does not exceed the following
value.
A - B = 0. rfr 1 .O mm-(0 F .04 in.)
Caution
When
presSing
in the bushing,
apply a sufficient
amount of soapsuds to the inside of the lateral rod eyes
and the rubber area of the bushing.
http://vnx.su/
REAR SUSPENSION
<3.OL ENGINE>
coil Spring and axle Bumper
17-9
COIL SPRING AND AXLE BUMPER

NrmA/22-29
3WO Nm
ft.1b.s.
110-130 Nm
80-94 ft.lbs.
\S-12
Nm
8-9 ftlbs.
.llO-130 Nm
80-94 ft.lbs.
Removal
steps
1. Lateral rod mounting

only)
2. Shock
absorber
NOTE
bolt (body side
mounting

to reinstall.
(2) *i+
(3) l a : Refer to Service Points of Installation.
: Tighten when the vehicle is unloaded.
(4) *
bolt
+* l + 3. Coil spring
4. Spring
seat
5. Axle bumper
SERVICE POINT OF REMOVAL
N17QBAA
3. REMOVAL
OF COIL SPRING
Slowly lower the jack and remove the coil spring and
spring seat.
Caution
When lowering
the jack, take care not to damage the
rear brake tube between
the main brake tube and the
rear axle housing.
INSPECTION
V-Spring
Identification color
seat
(I) Check the coil springs for crack, damage

(2) Check the rubber parts for damage.
N17ClCAA
or deterioration.

3.
(Load
classification)
NlllwPlA
INSTALLATION
OF COIL SPRING
When replacing
the coil spring, select the correct coil
spring for the vehicle according to its identification
color.
12W64h
TSB Revision
http://vnx.su/
REAR SUSPENSION <3.OL ENGINE> - Stabilizer
STABILIZER
Bar
BAR
NmA-

30-40
Nm
t2-door
vehicles>
<4-door
Removal
I)+
vehicles>
steps
7. Rubber bushing
8. Collar
9. Stabilizer
1. Parking brake cable attaching bolt

2. Shock absorber mounting bolts
(Lower side)
3. Bracket C
4. Bushing B
5. Stabilizer bar mounting bolt and nut
6. Joint cup
a*
NOTE
(1) Reverse the remove1 procedures to reinstall.
(2) ++ : Refer to Servjce Points of Removal.
(3) 14 : Refer to Service Pornts of Installation
: Tighten when the vehrcle is unloaded.
(4)

9.
REMOVAL
OF STABILIZER
BAR
Slowly lower the jack and remove the stabilizer bar to the
vehicle right side.
Caution
When lowering
the jack, take care not to damage the
rear brake tube between
the main brake tube and the
rear axle housing.
NVIBAB
INSPECTION
a
e
NI7mU
Check
Check
the stabilizer bar for bend and deformation.

the rubber parts for cracks or deterioration.
NI7lCP5
Joint cup
Rubber
bushing
5. STABIUZER
BAR MOUNTING
BOLT AND NUT
(1) To install the stabilizer bar, assemble
the joint cups
and rubber bushings
by the order and the certain
direction as shown in the figure.
(2) Install the nut on the stabilizer bar mounting bolt to the
specified
dimensions.
Standardvalue
: 15-17 mm (.59-.67 in.)
Joint cup
Rubber
bushing
Joint cup
12w547
TSB
evision
http://vnx.su/
2E
16-1
PROPELLER SHAFT
AND
UNIVERSAL JOINTS
CONTENTS
PROPELLER SHAFT
SPECIAL TOOL
...........................................
...................................................
SPEClFlCATiONS
...............................................
....................................
Lubricants
.......................................................
Torque Specification
3
2
2
2
TROUBLESHOOTING
Noise and Vibration
Noise at Start
http://vnx.su/
NISAA.....................................
.......................................
2
2
........................................
at High Speed
16-2
PROPELLER SHAFT AND UNIVERSAL JOlNTS - Specifications
SPECIFICATIONS
Items
3.0 L Engine
2 door vehicles
2.6 L Engine
4 door vehicles
AK--
M/T
Propeller shaft
Type
Length (joint tc
joint) x 0.0.
mm (in.)
Front
Rear
P-joint type
P-joint type
2-joint type
Z-joint type
P-joint type
665 x 50.8
(26.2 x 2.0)
598 x 75
(23.5 x 3.0)
642 x 50.8
(25.3 x 2.0)
568 x 75
(22.4 x 3.0)
700 x 50.8
(27.6 x 2.0)
510 x 75
(20.1 x 3.0)
642 x 50.8
(25.3 x 2.0)
913 x 75
(35.9 x 3.0)
700 x 50.8
(27.6 x 2.0)
855 x 75
(33.7 x 3.0)
Universal joint
Cross type
Oiled needle
roller bearing
14.7 (.58)(Type 1)
Type
Bearing
Journal O.D.
mm (in.)
AA
M/T
M/T : Manual transmission

AfT : Automatic transmission
Cross type
Oiled needle roller bearing

Front propeller shaft: 14.7 (58) (Type I),
Rear propeller shaft: 18.3 (72) (Type 2)
Items
Standard value
Journal end play
Specifications
:
mm (in.)
::
0.06 (.OU24) or less
-~
Limits
~r
Propeller shaft runout (Dial indicator reading)
Front
Rear
mm (in.)
0.5 (.Ozo)
0.6 (024)
TORQUE SPECIFICATION
Item
._-
Cm
Flange yoke attaching bolts

! Transfer case drain plug
~1 Transfer case filler plug
50-60
30-35
3035
LUBRICANTS
36-43
22-25
22-25
-5
NWcD.8
Specified lubri&nt~
Items
Sleeveyoke~sunace
Transfer case
t-k.
Hypoid
higher
Hypoid
higher
Gear &I API

SAE viscosity
Gear Oil API
SAE viscosity
classification GLGr
8OW, 75W-85W
classification GL-4 or
8OW. 75W-85W
http://vnx.su/
PROPELLER SHAFT AND UNIVERSAL JOINTS
Special Tool
PmpellerShsft
/Trwbleshooting
SPECIAL TOOL
Tool
NIODA-
Number
Name
Use
MB990840-01
Universal joint
remover and
installer set
Removal and installation of journal bearing

(Except type 2)
TROUBLESHOOTING
N16EAAP.l
Symptom
Probable cause
Remedy
Noise at start
Worn journal bearing

Worn sleeve yoke spiine
Replace
Loose
Retighten
Noise and vibration at

high speed
propeller
Unbalanced
Improper
shaft
installation
propeller shaft
Replace
Adjust the clearance
snap ring selection
Worn journal bearing
Replace
PROPELLER SHAFT
Pre-removal
Draining
Operation
of the Transfer
Gear Oil
Supplying theTransfer
Gear Oil
(Referto GROUP21 -Transmission
50-60 Nm
36-43 ft.lbs.
? \I
Removal
++ ,e
(111)w*
16-3
----7/
30-35
Nm
,$=/22-25ftJbs.
NOTE
steps

(2) +e
1. Rear propeller shaft

2. Front propeller shaft
(3) **
1 TSB Revision
http://vnx.su/
16-4
PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller Shaft

Nlsotlls
1. REMOVAL OF REAR PROPELLER SHAFT/Z. FRONT PROPELLER SHAFT

(I) Place the free wheel hubs in the FREE position and set
the transfer lever to ZH.
(2) Make mating marks on the flange yoke and the
differential companion flange.
Caution
1. Be careful not to damage the lip of the transmission oil seal or the lip of the transfer case oil seal.
2. Do not allow foreign matter to enter the transmission or transfer.
Front
091529
OOWS26
INSPECTION
0
l
l
l
Nl6GCAS
Check the sleeve yoke and flange yoke for wear, damage
or cracks.
Check the propeller shaft yokes for wear, damage
or
cracks.
Check the propeller shaft for bends, twisting or damage.
Check the universal joints for smooth
operation
in all
directions.
CHECKING
PROPELLER
Measure propeller shaft
SHAFT RUNOUT
runout with a dial indicator.
Limits
Front propeller shaft
Rear propeller shaft
0.5 mm
0.6 mm
I.020
(.024
in.)
in.)
NISODAC
2. INSTALLATION
OF FRONT PROPELLER SHAFT/l.
REAR
PROPELLER SHAFT
(I) Apply the specified hypoid gear oil to the sleeve yoke.
Specified
gear oil : Hypoid gear oil API classification

GL-4 or higher/SAE
viscosity
SOW, 75W-85W
1OGDOOl
[ TSB Revision
http://vnx.su/
PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller

(2) With the mating marks in alignment,
ler shaft to the companion flange.
16-5
Shaft
install the propel-
Caution
Degrease the thread of the mounting
bolts and nuts
before tightening
these parts. Otherwise,
they could
become loose.

Front propeller
shaft
Rear propeller
Disassembly steps
++ Adjustment of journal end play
1. Snap ring
4+
2. Grease fitting
4+ ++ 3. Journal bearing
+*
4. Journal
5. Flange yoke
6. Sleeve yoke
shaft
NOTE
(3) ++ : Refer to Service
lOW502
procedures
to reassemble.

1.
N16GFAC
REMOVAL OF SNAP RING

(1) Make mating marks on the yokes of the universal joint
that is to be disassembled.
(2) Remove the snap rings from the yoke with snap ring
pliers or two screwdrivers.
Caution
When disassembling,
note the positions
of snap
rings so that they may be reinstalled
in the same
positions.
3.
REMOVAL OF JOURNAL BEARING

(1) Type 1 propeller shaft, remove the journal bearing
from the propeller shaft yoke with special tool.
TSB Revision
http://vnx.su/
16-6
PROPELLER SHAFT AND UNIVERSAL JOINTS - Propeller Shaft

(2) Type 2 propeller shaft, applying the socket wrench to
the outside of the propeller shaft flange yoke force out
one journal bearing using a vise as illustrated.
(3) Pull out the journal bearing from the yoke.
(4) Remove the other journal

as described
above.
bearing
in the same manner
NOTE
15the journal bearing is hard to remove,
with a plastic hammer as illustrated.
YIOOO!

4.
lOY6Oi
1 Front
DIUDeller
Rear propeller
,
I
Shaft
strike the yoke
N*soHAl*
INSTALLATION
OF JOURNAL/O.
JOURNAL
BEARING
grease to the following parts;
0 Shafts and grease sumps of journal
0 Dust seal lips
0 Needle roller bearings
Caution
Use of excessive amounts
of grease may result in
difficulty
in assembling
unit and incorrect selection
of snap rings.
NOTE
When the journal and journal bearing are replaced,
obtain the universal joint kit.
(2) With the grease fitting directed
as shown in the
illustration,
install it properly.
shaft
(3) Type 1 propeller shaft, press the journal

yoke with special tool as illustrated.
Be sure to align the mating marks on
(4) Type 2 propeller shaft, press the journal
yoke with socket wrench.
Be sure to align theamating
marks on
los531]
rTSB Revision
http://vnx.su/
bearing to the
the yokes.
bearing to the
the yokes.
_
_.
PROPELLER SHAFT AND UNIVERSAL JOINTS - ProDeller

.
ADJUSTMENT
OF JOURNAL
Shaft
END
16-7
PLAY
(1) install snap rings of the same thickness

onto both
sides of each yoke with snap rings pliers or brass bar.
(2) Press the bearing

brass bar.
We
Tw
and journal
into one side with the
(3) Measure the clearance shown in the illustration with a

feeler gauge. If the clearance exceeds the standard
value, the snap rings should be repalced.
Snap
ring
Standard
Snap
ring
1 TSB Revision
http://vnx.su/
value:
0.06 mm
(.0024
in.) or less
NOTE
http://vnx.su/
3-1
REAR AXLE
CONTENTS
AXLE ASSEMBLY
<2.6L
ENGINE>
..................
14
AXLE ASSEMBLY
<3.OL ENGINE>
..................
16
AXLE SHAFT
......................................................
18
DIFFERENTIAL
CARRIER
23
...................................
NWAA-
TROUBLESHOOTING
. .. .. . . . .. . . . . . . .. . . . .. . . . . . .. .. . . . .. . . .
AXLE SHAFT, AXLE HOUSING
. .. .. ... . ... . ...r______.___.__.8
Grease Leakage
Noise While Wheels are Rotating
DIFFERENTIAL (CONVENTIONAL
DIFFERENTIAL) .. . .. .. .. . .. ..._..............-....... _. .. .. _..__I...
11
Bearing Noise While Driving or Coasting
12
Constant Noise
Axle Shaft Check for End Play ................................
11
Gear Noise While Coasting
Gear Oil Level Check ..............................................
11
Gear Noise While Driving
12
Heat
11
Noise While Turning
SERVICE ADJUSTMENT
PROCEDURES
Axle Housing Oil Seal Replacement
..........
......................
Limited Slip Differential Preload Measurement
....
Rear Axle Total Backlash Check .............................
Oil Leakage
SPECIAL
TOOLS
SPECIFICATIONS
................................................
...............................................
Lubricants
...........................................
..............................................................
DIFFERENTIAL (LIMITED SLIP

DIFFERENTIAL) .. ..__......._.. .. .. . ..___.-.-
Abnormal Noise during Driving or Gear

Changing
Abnormal Noise When Cornering

Breakdown
............................................
Gear Noise
............................................
Gear Oil Leakage
Sealant and Adhesive
......................................
..- ...
Limited Slip Differential Does

not Function
Seizure
http://vnx.su/
_..______.._..... 9
3-2
REAR AXLE - Specifications
SPECIFICATIONS
items
Axle housing type
Axle shaft
Supporting type
Shaft dimensions
Bearing portion dia.
mm (in.)
Center portion dia.
mm (in.)
Overall length
mm (in.)
<2.61 Engine>
<3.OL Engine>
Bearing
O.D. x I.D. x width
mm(in.)
Differential
Reduction gear type
Reduction ratio
Differential lock type
Differential geartype and
configuration
Side gear
Pinion gear
Number of teeth
Drive gear
Drive pinion
Side gear
<2.6L Engine>
<3.OL Engine>
Pinion gear
Vehicles with conventional

differential
Vehicles with limited slip

differential
Banjo type
Banjo type
Semi-floating type
Semi-floating type
40 (1.57)
34.5 (1.358)
40 (1.57)
34.5 (1.358)
703.5 (27.700)
723.5 (28.484)
703.5 (27.700)
723.5 (28.484)
80 x 40 x 19.75
(3.15 x 1.57 x .7776)
80x 40 x 19.75
(3.15 x 1.57 x .7776)
Hypoid gear
4.625
Hypoid gear
4.625
Disc type
Straight bevel gear x 2


37
8
37
8
14
19
IO
16
16
10
/ TSB Revision
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I
-
REAR
AXLE
Specifications
SERVICE SPECfFlCATlONS
Items
Standard value
Axle shaft end play
mm (in.)
Limited slip differential preload
(on Vehicle) Nm (ftlbs.)
Parking brake lever stroke
Stabilizer attaching bolt end
attaching dimension
mm (in.)
Final drive gear backlash mm (in.)
<2.6L Engine>
<3.OL Engine>
Differential gear backlash mm (in.)
<2.6L Enigne>
<3.OL Engine>
Drive pinion turning torque
Without oil seal
Nm (in. Ibs.)
With oil seal
Nm (in. Ibs.)
Difference in total thickness
between left and right clutch plates
mm (in.)
Clearance between the clutch plates
and the differential case
mm (in.)
Difference in distances from backs
of left and right pressure rings to
end of thrust washer mm (in.)
Clearance of the side gear
in the axial direction
mm (in.)
Limited slip differential preload
When equipped with new clutch
plates Nm (ft. Ibs.)
When equipped with old clutch
plates Nm (ft. Ibs.)
Limit
Rear axle total backlash
mm (in.)
Drive gear runout

mm (in.)
mm
(in.)
Friction plates and friction discs
warpping (flatness) mm (in.)
Friction plates and friction discs
wear (difference in thicknesses
of friction surfaces and
mm (in.)
projections)
Vehicles with conventional

differential
Vehicles with limited slip

differential
0.05-0.20
-
0.05-0.20 (.0020-.0079)
35 (25) or more
(.OOZo-.0079)
4-6 clicks
4-6 clicks
15-I7 (59~67)
15-17 (.59-.67)
0.1 l-O.16 (.0043-.0063)

0.13-0.18(.0051-.0071)
0.1 l-0.16 (.0043-.0063)

0.13-0.18(.0051-.0071)
0.01 O-0.076 (.0004-.0030)

O-0.076 (O-.0030)
0.4-0.5 (3.5-4.3)
0.65-0.75 (5.6-6.5)
0.4-0.5 (3.5-4.3)
0.65-0.75 (5.6-6.5)
0.05 (0020) or less
0.06-0.20 (.0024.0079l
0.05 (.0020) or less
0.05-0.20 (.0020-.0079)
65-l 00 (47-72)
35-l 00 (25-72)
5 (20)
5 (20)
0.05 (.0020)
0.2 (.008)
0.05 (0020)
0.08 (0031)
0.1 (004)
/ TSB Revision
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3-4
REAR AXLE - Specifications
items
ft. lbs.
Nm
<2.6L Engine>
Shackle assembly attaching nut
Shock absorberattaching
nut
U-bolt attaching nut
Differential carrier to rear axle housing
<3.OL Engine>
Lower arm to frame side bracket
Lower arm to axle housing side bracket
Shock absorber attaching nut
Lateral rod attaching nut
Stabilizer bar to axle housing side bracket
Differential carrier to rear axle housing
Brake tube flare nut
Propeller shaft attaching nut
Bearing case to rear axle housing
Rear axle bearing lock nut
Filler plug
Drain plug
Companion flange
Differential case to drive gear
Bearing cap
Lock plate
45-60
18-25
85-110
25-30
33-43
13-18
61-80
18-22
130-150
1go-220
1 IO-130
1 IO-130
30-40
40-55
13-17
50-60
50-60
189-220
40-60
60-70
190-250
80-90
55-65
15-22
94-l 08
137-159
86-94
80-94
22-29
29-40
9-12
36-43
36-43
135159
29-43
43-51
137-181
58-65
40-47
11-16
LUBRICANTS
Items
Rear axle gear oil
Limited slip differential
or higher/SAE viscosity No. 90,8OW
MITSUBISHI Genuine Gear Oil Part No.
8149630 EXor equivalent
Quantity
2.6L Engine:
3.OL Engine:
2.6L Engine:
3.OL Engine:
1.80
2.60
1.80
2.60
lit.
lit.
lit.
lit.
(3.80
(5.49
(3.80
(5.49
SEALANT AND ADHESIVE

Items
Axle shaft shim
Differential carrier to axle housing
Drive gear threaded hole
pints)
pints)
pints)
plants)
NOJCCSpecified lubricants
3M Adhesive stud locking 4170 or equivalent
1 TSB Revision
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Quantity
As required
As required
As required
REAR
AXLE
- Special
Tools
SPECIAL TOOLS
Removal of axle shaft
Removal of axle housing oil seal
Pressing of axle shaft bearing outer race

MB990937-01
Pressing of axle shaft oil seal
MB990937-01
Pressing of drive pinion rear bearing outer race
MB990936-01, MB990937-01
Pressing of drive pinion front bearing outer race
MB990934-01
Refer to GROUP 2
bearing outer race

t bearing outer race
MB990785-01
Lock nut spanner

wrench
Removal and installation of lock nut
MB990787-01
Rear axle bearing

case remover
Removal of axle shaft bearing and bearing case
MB990799-01
Axle bearing
remover and
installer
Pressing of axle shaft bearing inner race
1 TSB Revision
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3-6
REAR AXLE - Special Tools

Number
Name
M B990339-01
Pinion carrier

Removal of drive pinion rear bearing inner race

MB99081 I-01
Side bearing cup

remover step plate
Ml3990767-01
Holding of companion
flange
MB990901-01
Pressing of d&e pinion rear bearing inner race

Pressing of side bearing inner race
1 TSB Revision
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REAR AXLE
1 MB990988
1
2
A
Y--
Soecial
Tool number
3-7
Tools
O.D.
-
M8990551
Box
MB990989
Base
(MB990990)
Tool A
25 t.98)
(MB990991)
Tool B
28(1.10)
(M B990992)
Tool C
31 (1.22)
1 TSB Revision
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mm(h)
REAR
AXLE
- Troubleshooting
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Brake drag
Bent axle shaft
Worn or scarred axle shaft bearing
Replace

Malfunction of bearing seal
Replace
Improper final drive gear tooth contact

adjustment
Loose, worn or damaged side bearing
Loose, worn or damaged drive pinion
bearing
Correct or replace
Worn drive gear, drive pinion

Worn side gear thrust washer or pinion
shaft
Deformed drive gear or differential case
Damaged gear
Replace
Foreign material

necessary
No oil
Fill or change
Poor gear engagement

Improper gear adjustment
Correct or replace
Damaged gear
Replace
Foreign material

and check: replace the parts if
necessary
Insufficient oil
Fill or change
Gear noise while

coasting
Correct or replace
Damaged gear
Replace
Bearing noise while

driving or coasting
Cracked or damaged drive pinion rear

bearing
Replace
Noise while turning
Loose side bearing

Damaged side gear, pinion gear or pinion
shaft
Replace
Heat
Improper gear backlash

Excessive preload
Adjust
Insufficient oil
Fill or change
AXLE SHAFT,
AXLE HOUSING
Noise while wheels
are rotating
__.
Grease leakage
DIFFERENTIAL
(CONVENTIONAL
DIFFERENTIAL)
Constant noise
Gear noise while

driving
---. .
1 TSB Revision
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3-9
REAR AXLE -Troubleshooting

Symptom
Oil leakage
DIFFERENTIAL
[LIMITED SLIP
DIFFERENTIAL)
Abnormal noise
during driving or
gear changing
Probable cause
Remedy
Clogged breather hose
Clean or replace
Cover tightened not

Seal malfunction
Retighten, apply sealant, or

replace the gasket
Replace
Excessive oil
Adjust the oil level
Excessive final drive gear backlash

Insufficient drive pinion preload
Adjust
Excessive differential gear backlash
Adjust or replace
Worn spline of a side gear
Replace
Loose spline coupling self-locking nut
Retighten or replace
NOTE
In addition to a malfunction of the differential carrier components, abnormal noise can also be caused by the
universal joint of the propeller shaft, the axle shafts, the wheel bearings, etc. Before disassembling any parts, take
all possibilities into consideration and confirm the source of the noise.
Abnormal noise
when cornering
Gear noise
Damaged differential gears

Damaged pinion shaft
Nicked and/or abnormal wear of inner and
outer clutch plates
Poor gear oil
Abnormally worn or damaged thrust
washer
Replace
Improper gear oil quantity
Refill or replace
Improper final drive gear tooth contact

adjustment
Adjust or replace
Incorrect final drive gear backlash

Adjust
Damaged. broken, and/or seized tooth

surfaces of the drive gear and drive pinion
Damaged, broken, and/or seized drive
pinion bearings
Damaged broken, and/or seized side
bearings
Damaged differential case
Poor gear oil
Replace
Refill or replace
NOTE
Noise from the engine, muffler vibration, transmission, propeller shaft, wheel bearings, tires, body, etc., is easily
mistaken as being caused by malfunction in the differential carrier components.
Be extremely careful and attentive
when performing the driving test, etc.
Test methods to confirm the source of the abnormal noise include: coasting, acceleration, constant speed driving,
raising the rear wheels on a jack, etc. Use the method most appropriate to the circumstances.
1 TSB Revision
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REAR AXLE-Troubleshooting
Symptom
Gear oil leakage
Probable cause
Remedy
Worn or damaged front oil seal, or an

improperly installed oil seal
Damaged gasket
Replace
Loose spline coupling self-locking nut
Retighten or replace
Loose filler or drain plug
Seizure
T
-
~~
Retighten or apply adhesive
Clogged or damaged breather hose
Clean or replace
Improper final drive gear backlash

Excessive drive pinion preload
Excessive side bearing preload
Improper differential gear backlash
Excessive clutch plate preload
Adjust
Improper gear oil
Replace
Refill or replace
NOTE
In the event of seizure, diassemble and replace the parts involved, and also be sure to check all components
any irregularities and repair or replace as necessary.
Breakdown
Incorrect final drive gear backlash

Incorrect drive pinion preload
Incorrect side bearing preload
Excessive differential gear backlash
Incorrect clutch plate preload
Adjust
Loose drive gear clamping bolts
Retighten
Operational malfunction
clutch
Avoid excessively rough

operation
due to overloaded
NOTE
In addition to disassembling and replacing the failed parts, be sure to check all components
repair or replace as necessary.
Limited sap
The limited slip device is damaged
differential does not
function (on snow,
mud, ice, etc.).
1 TSB RevisionA
http://vnx.su/
for
_
for irregularities and
Disassemble, check the

functioning,
and replace the
damaged parts
3-11
REAR AXLE - Service Adiustment Procedures
SERVICE ADJUSTMENT
PROCEDUREk$G
REAR AXLE TOTAL BACKLASH CHECK
llYSO3
If the vehicle vibrates and produces a booming sound due to

the unbalance of the drivetrain, use the following procedure
to measure the rear axle total backlash to see if it is necessary
to remove the differential
carrier assembly.
(I) Park the vehicle on a flat, level surface.
(2) Set both the transmission
shift lever and the transfer shift
lever to neutral.
(3) Chock the wheels.
NOTE
If the vehicle is to be raised on a lift, engage the parking
brake to lock the wheels.
(4) Manually turn the propeller shaft clockwise as far as it will
go and make mating marks on the companion flange dust
cover and the gear carrier.
(5) Manually turn the propeller shaft couterclockwise
as far as
it will go and measure the movement of the mating marks.
Limit : 5 mm (.20 in.)
(6) If the backlash exceeds the limit, remove the differential
carrier assembly
and adjust it.
AXLE SHAFT CHECK FOR END PLAY

1.
2.
3.
4.
5.
\
US0671
Jack up the vehicle and remove

Remove the brake drums.
Measure the axle shaft end play
Pull the axle shaft all the way out
indication
on the dial indicator.
Standard
value : 0.05-0.20
mm
with a dial indicator.

and note the end play
(.0020-.0079
in.)
If the axle shaft end play exceeds the standard value,

withdraw
the axle shaft, and then adjust to the standard
value by changing the shim thickness. (Refer to P.3-18.)
GEAR OIL LEVEL CHECK

1. Remove the filler plug,
2. The oil level is sufficient
OQFO12
NOJF3AB
the rear wheels.
N03FCAC
and check the oil level.

if it reaches the level plug hole.
Specified
gear oil:
Conventional
differential
GL-5 or higher/SAE
viscosity
No. 90, 80W
<2.6L Engine>
[I.80 lit. (3.80 pints)]
<3.OL Engine>
[2.60 lit. (5.49 pints)]
Limited
slip differential
MITSUBISHI
Genuine Gear Oil Part No. 8149630 EX or
equivalent
<2.6L Engine>
[I.80 lit. (3.80 pints11
<3.OL Engine>
[2.60 lit. (5.49 pints)]
1 TSB Revision
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3-12
REAR AXLE
Procedures
LlMlTED SLIP DIFFERENTIAL

SUREMENT
PRELOAD
MEANC3FDM
1. To measure the preload of the limited slip differential,

set
the shift lever of the transmission
to the neutral position,
lock the front wheels, and fully release the parking brake.
One of the rear wheels should be maintained
in contact
with the ground surface,and
the other should be raised
2.
Measure the axle shaft turning torque at the side on which

the wheel is raised position
by using the following
procedure:
(I) Remove the wheel.
(2) Mount the special tool to the hub bolts with the hub
nuts.
(3) Find the limited slip differential
preload by measuring
the axle shaft turning torque in the forward direction
with a torque wrench.
NOTE
Before measuring
the turning torque,
shaft to remove any initial resistance.
turn
the
axle
Standard value : 35 Nm (25 ftlbs.) or more

(4) lf the turning torque is less than the standard value,
remove the limited slip differential
from the vehicle
and repair it. (Refer to P.337.)
AXLE HOUSING OIL SEAL REPLACEMENT
NO3FEAG
1. Disconnect
the parking brake cables from the equalizer
and then remove the clamps from the parking brake
cables. (Refer to GROUP 5 - Parking Brake Cable.)
NOTE
Do not disconnect the parking brake cable and rear brake
connection.
2. Before disconnecting
the brake tube, drain the brake fluid
from the bleeder screw at the left side of the rear brake.
3. Pull the rear axle shaft with rear brake assembly attached.
to remove,
the special
http://vnx.su/
-1
REAR AXLE - Service
_Adjustment
3-13
Procedures
4. Use special tool with hook attached
to remove
the oil seal.
5. Apply the multipurpose

grease to the oil seal fitting area of
the rear axle housing.
6. Drive the new oil seal into the rear axle housing end by
7. Apply the multipurpose
8. Adjust the clearance between the bearing case and rear
axle housing end. (Refer to P.3-23.)
9. Install the rear axle shaft assembly
to the rear axle
housing.
IO. Connect the brake tube and bleed out the air. (Refer to
GROUP 5 - Service Adjustment
Procedures.)
11. Connect the parking brake cable, and adjust the stroke of
the parking brake lever.
Standard
(Refer
value
to GROUP
1 TSB Revision
http://vnx.su/
: 4-6
clicks
5 - Service
Adjustment
Procedures.)
AXLE ASSEMBLY
<2.6L
ENGINE>
50-60 Nm
36-43 ft.lbs.
-
13-17Nm
s-12 ft.lbs.
45-60 Nm*
33-43 ft.lbs.*
-3
Air Bleeding
Adjustment
of Parking Brake Lever
Stroke [Refer to GROUP 5 - Service
Removal
l * ++
4+
+*
I)+
from
Brake
llW641
Lines (Re-
steps
1. Brake drums
2. Parking
brake cable attaching
bolts
3. Connection
of parking
brake cable end
and brake shoe assembly
4. Connection
of brake hose
5. Connection
of breather
hose
6. Rear propeller
shaft
7. Connection
of shock absorbers
(lower
part only)
1 TSB Revision
4+
+(
4+
8. U-bolts
and bump
9. Shackle
assembly
10. Axle assembly
stopper
NOTE
to reinstall.
(2) w
(3) ++
14) The part with *-must
be tightened
with the vehicles
lowered to the ground.
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REAR AXLE - Axle Assembly <2.6L Engine>

3-15
NWGSAF
3. DISCONNECTION
OF PARKING
BRAKE CABLE END
AND BRAKE SHOE ASSEMBLY
Refer to GROUP 5 - Parking Brake Cable.
4. DISCONNECTION
OF BRAKE HOSE
Before disconnecting
the brake tube, drain the brake fluid
from the bleeder screw at the right side of the rear brake.
6. REMOVAL
OF REAR PROPELLER SHAFT
Make the mating marks on the flange yoke of the rear
propeller shaft and the companion
flange of the differential case.
8. REMOVAL
OF U-BOLT AND BUMP STOPPER
Before removing the U-bolt and the bumper stopper, place
the jack underneath
the center of the axle assembly to
hold it slightly upward.
10. REMOVAL
OF AXLE ASSEMBLY
Draw out the axle assembly toward the rear of the vehicle.
Caution
The axle assembly
is unstable
on the jack; be careful
not to allow it to fall.
NrnCDAF
9.
Inside of
vehicle
INSTALLATION
OF SHACKLE ASSEMBLY
Install the shackle assembly from the outside toward the
inside of vehicle.
6. INSTALLATION
Align the mating marks on the flange yoke and the
companion
flange to install the rear propeller shaft,
3. CONNECTION
BRAKE SHOE ASSEMBLY
pSB
Revision
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END AND
?(
u
--,--
--=.-_-eI.
3-16
_-I
----
i_h_
-_.-~
REAR AXLE - Axle Assembly <3.OL Engine>
AXLE ASSEMBLY <3.OL ENGINE>

110-130
Nm
8044 ftlbs
30-40 Nm
22-29
ft.lbs.
lliLl3f1
?30-150
Nm
Nm
94-108 ftlbs.
Removal
+I, e*
4*
4~ I)+
++
+I) ++
+*
steps
1. Brake drum
2. Parking brake cable attaching bolts
3. Connection of parking brake cable end
4. Connection of brake hose
5. Connection of breather hose
7. Stabilizer bar installation bolt
8. lower
arm
9. Lateral rod
10. Connection of shock absorbers (lower
part only)
[ TSB Revision
l *
11. Axle assembly

12. Coil spring
13. Stabilizer bar
NOTE
to reinstall.
(2) *I)
(31 ++
(4) The part with --must be tightened
with the vehicles
lowered to the ground.
(5) q
: Non-reusable
parts.
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-_~.
_e=-* ~~
3-17
REAR AXLE - Axle Assembly <3.OL Engine>

N03G.sAo
3.
DISCONNECTION
OF PARKiNG
BRAKE CABLE
4.
DISCONNECTION
OF BRAKE HOSE
Refer to P.3-15
REMOVAL
Refer to P.3-15
6.
END
8.
REMOVAL
OF LOWER ARM
After supporting
the axle assembly by floor jacks, remove
the lower arm.
11. REMOVAL
OF AXLE ASSEMBLY
Draw out the axle assembly toward the rear of the vehicle.
Caution
The axle assembly
is unstable
on the jack; be careful
not to allow it to fall.

9.
INSTALLATION
Install
the
lateral
OF LATERAL
rod from
Ncl3GclAu
ROD
the axle housing
side.
12W562
8.
7.
,2W5B3
6.
3.
INSTALLATION
OF LOWER ARM
Install the washers (facing as shown
lower arm.
in the figure) to the
INSTALLATION
OF STABILIZER
BAR INSTALLATION
BOLT
When installing the stabilizer
bar to the stabilizer bar
bracket, check to be sure that the amount of projection of
the stabilizer bar installation
bolt is within the standard
value range.
Standard value : 15-17 mm (.5Q-.67 in.)
NOTE
The dimension
shown in figure is the value when a new
bushing is used.
INSTALLATION
Refer to P.3-15.
CONNECTION
OF PARKING BRAKE CABLE END AND
BRAKE SHOE ASSEMBLY
Refer
to GROUP
1 TSB Revision
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5 - Parking
Brake Cable.
REAR AXLE - Axle Shaft
AXLE SHAFIREMOVAL AND INSTALLATION
1180085
Rear axle shaft shim

set
ljD;60 Nm
36-43 ft.lbs.
llW640
Adjustment of Parking Brake Lever
Removal
++ I)+
**
l *
l *
++ I)+
steps
1. Brake drum
4. Connection of brake tubes
5. Nuts
6. Rear axle shaft assembly (with parking
brake cable)
7. Shims
8. O-ring
Adjustment of axle shaft end play
9. Lock nut
/ TSB Revision
+*
++
41) *+
*+
*a
+I) +a
+I* +*
10.
11.
12,
13.
14.
15.
16.
17.
Lock washer
Washer
Rear axle shaft
Bearing inner race
Bearing case
Oil seal
Bearing outer race
Oil seal

(2) +*
(3) **
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3-19

3.
4.
6.
9.
MB99078501
\
DISCONNECTION
OF PARKING
AND BRAKE SHOE ASSEMLBY
Refer to GROUP
DISCONNECTION
Refer to P.3-15.
BRAKE
NDWBAF
CABLE
END
5 - Parking Brake Cable.

OF BRAKE TUBES
REMOVAL
OF REAR AXLE SHAFT ASSEMBLY
Pull the rear axle shaft with rear brake assembly attached.
If the rear axle shaft is hard to remove, use the special
tools.
NOTE
Do not damage the oil seal during its removal.
REMOVAL
OF LOCK NUT
Remove the lock nut by following
the steps below.
(I) Straighten the bent tab of the lock washer with the
screwdriver.
(2) Remove
(3) Remove
the lock nut by using the special

the lock washer and the washer.
tool.
12. REMOVAL
OF REAR AXLE SHAFT
(1) Reinsert the lock nut on the axle shaft approximately
three turns.
(2) install the special tool as figure to remove the rear axle
shaft from the bearing case.
Be sure to install nuts and washers diagonally.
(3) Turn nuts with equal pressure to ensure smooth
removal of the wheel bearing.
16. REMOVAL
OF BEARING OUTER RACE
Using a hammer and drift, remove bearing outer race from
bearing case.
17. REMOVAL
OF OIL SEAL
Remove the oil seal from the end of rear axle housing with
the special tool, if necessary.
1 TSB Revision
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3-20

INSPECTION
l
l
l
NWHCAA
Check the dust cover for deformation

and damage.
Check the oil seal for damage.
Check the inner and outer bearings for seizure, discoloration and rough raceway surface.
Check the axle shaft for cracks, wear and damage.
NOQHDAH
17. INSTALLATION
OF OIL SEAL
grease to the oil seal fitting
area of the rear axle housing.
(2) Drive the new oil seal into the rear axle housing end by
16. INSTALLATION
OF BEARING OUTER RACE
grease to the external surface
of the bearing outer race.
(2) Press-fit the bearing outer race into the bearing case
by using special tools.
MB99093801
Bearing
case
\
MB990937-01
/
15. INSTALLATION
OF OIL SEAL
grease to the external surface
of the new oil seal.
(2) Press-fit the new oil seal into the bearing case until it is
flush with the face of the bearing case by using special
tools.
(3) $.py
the multipurpose
grease to the lips of the oil
1 TSB Revision
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REAR AXLE
3-21
- Axle Shaft
13.lfS~~U&I$N
OF BEARING
INNER
RACE/IS.
REAR

grease to the roller surfaces of
the bearing inner race.
(2) Install the rear brake assembly attached with bearing
case and the bearing inner race in that order to the
axle shaft.
(3) Press-fit the bearing inner race into the axle shaft by
using special tool.
(4) Pack the bearing case with the multipurpose
grease.
11. INSTALLATION
LOCK NUT
OF
WASHER/IO.
LOCK
WASHER/S.
Install these parts with cares described

below.
(I) Apply the multipurpose
grease to the thread portion of
the axle shaft, to which the locking nut is installed.
(2) Align the washer tab with the slot of the axle shaft to
install the washer.
(3) Align the lock washer tab with the slot of the axle shaft
to install the lock washer as figure.
(4) Install the lock nut with its chamfering
in the directions
(5) Tighten the lock nut to the specified
the special tool.
(6) Bend the tab of the lock washer

nut.
torque
by using
into the slot of the lock
NOTE
If the slot in the lock nut and the tab of the lock washer
are out of alignment, turn the lock nut in until they are
in alignment.
Sevision
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3-22

.
ADJUSTMENT
OF AXLE SHAFT END PLAY
Adjust the clearance between the bearing case and rear
axle housing end by the-following
procedure.
(1) Insert a 1 mm (.04 in.) thick shim and O-ring into the
left side rear axle housing.
(2) Apply the specified sealant to the mating surface of
bearing case, install the left axle shaft into rear axle
housing and tighten the nuts.
NOTE
Tighten
the nuts
Specified
in diagonal
sealant:
sealant:
NOTE
Tighten
the

or equivalent
3M ART Part
or equivalent
nuts in diagonal
No. 8663
sequence.
(8) Check to assure that the axle shaft axial play is within
the standard value.
Standard
3.
! TSB Revision
value
: 0.06420
mm (.0020-.0079
CONNECTION
BRAKE SHOE ASSEMBLY
http://vnx.su/
sequence.
(3) Install the right axle shaft without a shim (s) and O-ring
and temporarily
tighten to about 6 Nrn- (4.3 ft.Ibs.).
(4) Measure the clearance-between
the bearing case and
rear axle housing end with a feeler gage.
(5) Select shims of the thickness which is equal to the
sum of the measured clearance and 0.05-0.20
mm
(.0020-.0079
in.)
(6) Remove the right axle shaft, and install shim (s) and 0ring on the right side-rear
axle housing end.
(7) Apply the specified sealant to the mating surface of
bearing case, install the right axle shaft into rear axle
housing and tighten the nut.
Specified
~~
in.)
END AND
=
.
REAR AXLE - Dikrential
DIFFERENTIAL
Carrier
CARRIER

50-60
35-43
Nm
ft.lbs.
13-17 Nm
9;12 ft.lbs
40-50
2-3
Nm
ft.lbs.
Post-installation
Operation
0 Air Bleeding from Brake Lines (Fiefer to GROUP 5 - Service Adjustment Procedures)
0 Adjustment
of Parking Brake Lever
Stroke (Refer to GROUP 5 - Service
Pre-removal
Operation
Drain of Differential Gear Oil
Adjustment Procedures)
Filling of Differential Gear Oil (Refer
to P.3-Il.)
Removal
41, ,+
4*
steps
1. Brake drums
4. Connection of brake tubes
5. Nuts
4*
6. Rear axle shaft assembly
*+ I)+
+I) I)*

6. Differential carrier
NOTE
(1)
(2)
(3)

+e
I)*
to reinstall.
of Removal.
of Installation.
NOJIeAF
3.
END
DISCONNECTION
OF PARKING
BRAKE CABLE
1 TSB Revision
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3-24
REAR AXLE - Differential

4.
MB990241-01
6.
Carrier
DISCONNECTION
OF BRAKE TUBES
Refer to P.3-15.
REMOVAL
OF REAR AXLE SHAFT ASSEMBLY
Pull out the right and left axle shafts by about 70 mm (2.8
in.). If it is hard to pull out, use the special tools.
7.
REMOVAL
OF REAR PROPELLER
Refer to P.3-15.
SHAFT
8.
REMOVAL
OF DIFFERENTIAL
CARRIER
Remove the attaching
nuts and strike the lower part of
differential
carrier assembly with a square lumber several
times, to remove the assembly.
Caution
(1) Do not remove
the uppermost
nut but keep it
loosened
all the way to the stud bolt end.
(2) Use care not to strike the companion
flange.
N00,DAF
8. APPLlCATlON
OF SEALANT TO DIFFERENTIAL
CARRIER
When the differential
carrier is installed, apply specified
sealant to the differential
carrier mounting surface of the
axle housing as illustrated
in either of the illustrations.
Specified
sealant:
7.
INSTALLATION
Refer to P.3-15.
3. CONNECTION
OF PARKING BRAKE CABLE END AND
BRAKE SHOE ASSEMLBY
1 TSB Revision
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I:
REAR
AXLE
Differential
3-25
Carrier
INSPECTION
BEFORE
DISASSEMBLY
MWEAA
Secure the working base in a vice and then install the removed
differential carrier assembly.
FINAL DRIVE GEAR BACKLASH

With the drive pinion locked in place, measure the final drive
gear backlash with a dial indicator on the drive gear.
NOTE
Measure at four points or more on the circumference
of the
drive gear.
Standard
value :
<2.6L Engine>
0.1 l-0.16 mm (.0043-.0063
in.)
<3.OL Engine>
0.13-0.18
mm (.0051-.0071
in.)
DRIVE GEAR RUNOUT
Measure the drive gear runout at the shoulder on the reverse
side of the drive gear.
Limit : 0.05 mm (.0020 in.)
DIFFERENTIAL
GEAR BACKLASH
(CONVENTIONAL
DIFFERENTIAL)
While locking the side gear with the wedge, measure the
differental
gear backlash with a dial indicator on the pinion
gear.
Standard
value :
<2.6L Engine>
0.010-0.076
mm (.0004-.0030
in.)
<3.OL Engine>
O-0.076 mm (O-.0030 in.)
Limit : 0.2 mm (.008 in.)
FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by following the steps
below.
(I) Apply a thin, uniform
coat of machine
blue to both
surfaces of the drive gear teeth.
1 TSB Revision
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3-26
REAR
AXLE
Differential
Carrier
(2) Insert a brass rod between the differential carrier and the
differential case, and then rotate the companion flange by
hand (once in the normal direction, and then once in the
reverse direction) while applying a load to the drive gear,
so that the revolution torque [appro::imately
2.5-3.0 Nm
(1 B-2.2 ft.lbs.)I is aoolied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
(3) Check the tooth-contact
drive pinion.
condition
of the drive gear and
NOTE
Checking the tooth contact pattern is the way to confirm
that the adjustments
of the pinion height and backlash
have been done properly. Continue to adjust the pinion
height and backlash until the tooth contact pattern resembles the standard pattern.
If, after adjustments
have been made, the correct tooth
contact pattern cannot be obtained, it means that the drive
gear and the drive pinion have become worn beyond the
allowable limit. Replace the gear set.
Caution
If either
replaced,
the drive gear or the drive pinion is to be

be sure to replace both gears as a set.
( TSB Revision
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.._
_
miL
E.
g.S&
REAR
Standard
tooth
contact
AXLE
Differential
3-27
Carrier
pattern
1 Toe
2 Drive-side
3
Heel
4 Coast-side
Solution
Problem
Tooth contact
ion height
pattern
resulting
The drive pinion is positioned

drive gear.
from
excessive
Pin-
too far from the center of the
Increase the thickness of the pinion height adjusting shim,

and position the drive pinion closer to the center of the drive
%:I
for backlash adjustment,
farther from the drive pinion.
Tooth
height
contact
pattern
resulting
The drive pinion is positioned

drive gear.
from
insufficient
position
the drive
gear
pinion
too close to the center of the
Decrease the thickness of the pinion height adjusting shim,

and position the drive pinion farther from the center of the
drive gear.
Also, for backlash adjustment, position the drive gear closer
to the drive pinion.
llS642
, TSB Revision
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-y->
REAR AXLE
3-28
- Differential
Carrier
DISASSEMBLY
<Conventional
differential>
<Conventional type>
(Refer to P.3-25.1
. Final Drive Gear Tooth Contact (Refer to P.3-25.1
18
118546
Disassembly
+*
+*
+*
4*
4*
+*
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
\
7
steps
Lock plates
Side bearing nuts
Bearing caps
Bolts (10)
Drive gear
Lock pin
Pinion shaft
Thrust block
Pinion gears
Pinion washers
Side gears
Differential case
Limited slip differential case assembly
Self-locking nut
Washer
20. Drive pinion

21. Drive pinion
adjustment)
22. Drive pinion
23. Drive pinion
24. Drive pinion
adjustment)
25. Drive pinion
26. Companion
27. Oil seal
28. Drive pinion
29. Drive pinion
30. Drive pinion
31. DifferentEl
NOTE
(1) +II)
(2) 0
llBOlZ4
assembly
front shim (for preload
spacer
rear bearing inner race
rear shim (for pinion height
flange
front bearing inner r&e
front bearing outer race
rear bearing outer race
carrier

( TSB Revision
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REAR AXLE
- Differential
SERVICE
2.
POINTS
3-29
Carrier
PJo31-
OF DISASSEMBLY
REMOVAL
OF SIDE BEARING
Using the special tool, remove
NUT
the side bearing
nut.
4.
REMOVAL
OF DIFFERENTIAL
CASE ASSEMBLY
Take out the differential
case assembly
with hammer
handles.
NOTE
Keep the right and left side bearings and side bearing nuts
separate, so that they do not become mixed at the time of
reassembly.
6.
REMOVAL
OF SIDE BEARING INNER RACE
Pull out the side bearing inner races by using the special
tools.
8.
REMOVAL
OF DRIVE GEAR
(1) Make the mating marks to the differential case and the
drive gear.
(2) Loosen the drive gear attaching
bolts in diagonal
sequence
to remove the drive gear.
9.
DRIVE-OUT
OF LOCK PIN
Drive out the lock pin with a punch.
NOTE
The removed side gears and side gear thrust spacers,
and right, should be retained for reassembly.
[ TSB Revision
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left
I~
.-,..
^ --_..,_
---emsa
cI
REAR AXLE
_=_
- Differential
Carrier
18. REMOVAL
OF SELF-LOCKING
NUT
Use the special tool to hold the companion
flange
remove the companion
flange self-locking
nut.
and
20. REMOVAL
OF DRIVE PINION ASSEMBLY
(1) Make the mating
marks to the driie pinion and
companion
flange.
Caution
The mating
mark made on the companion
flange
must not be on the coupling
surface of the flange
yoke and the rear propeller
shaft.
(2) Drive out the drive pinion together
with the drive
pinion spacer and drive pinion front shims.
23. REMOVAL
OF DRIVE PINION REAR BEARING INNER
RACE
Pull out the drive pinion rear bearing inner race by using
the special tools.
MIT303173
29. REMOVAL OF DRIVE PINION FRONT BEARING OUTER

RACE/30. DRIVE PINION REAR BEARING OUTER RACE
Drive out the drive pinion front bearing outer race from the
gear carrier.
INSPECTION
NOJIHAC
Wash the disassembled

pa& in cleaning solvent, dry them
using compressed
air, and then check the following
areas: __
l
Check the companion
flange for wear or damage.
l
Check the oil seal for wear or deterioration.
l
Check the bearings for wear or discoloration.
l
Check the gear carrier for cracks.
o Check the drive pinion and ring gear for wear or cracks.
1
o Check the side gears, pinion gears and pinion shaft for
wear or damage.
<conventional
type>
l
Check the side gear spline for wear or damage. <conven- :
tjonal
[ TSB Revision
type>
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_I

REASSEMBLY
<Conventional
Xi-22
lh-260
137-181
Carrier
<Limited
Nm
ft.lbs.
differential>
Nm
slip differential>
3P
<Conventional
17 18
differential>
18 20
Differential gear set
Reassembly
14
16-22
71-16
3J
Nm
ft.lbs.
llW546
2?
Final drive gear set
steps
1. Differential carrier
I)+
2. Drive pinion rear bearing outer race
+a
3. Drive pinion front bearing outer race
Adjustment of pinion height
+4
4. Drive pinion
5. Drive pinion rear shim (for pinion height
adjustment)
6. Drive pinion rear bearing inner race
Adjustment of drive pinion preload
l 4
7. Drive pinion front bearing inner race
8. Oil seal
9. Drive pinion front shim (for preload
adjustment)
10. Drive pinion spacer
11. Drive pinion assembly
12. Companion flange
13. Washer
14. Self-locking nut
15. Differential case
16. Limited slip differential case assembly
17.
18.
19.
20.
I)+
21.
22.
e+ 23.
l 4 24.
25.
++ 26.
27.
28.
w+ 29.
l 4
30.
31.
NOTE
(1) 1)4
(2)
[ TSB Revision
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Side gears
Pinion washers
Pinion gears
Adjustment
of differential gear backlash
Thrust block
Pinion shaft
Lock pin
Drive gear
Bolts (IO)
Bearing caps
Adjustment
of final drive gear backlash
Side bearing nuts
Lock plates

-I
3-32
REAR AXLE
- Differential
SERVICE
2.
Carrier
POINTS
OF REASSEMBLY
INSTALLATION
OF DRIVE PINION
REAR BEARING
OUTER RACE
Press-fit the drive pinion rear bearing outer race into the
gear carrier by using special tools.
MB990937-01
NOTE
Perform
race.
llYO5s
carefully
3.
MB99093801
I IMB99093441
INSTALLATION
OF DRIVE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion front bearing outer race into gear
carrier by using special tools.
NOTE
Perform
race.
MB990905-310
MB9909052-01
press-fitting
~MB990901-01
MB990905101
press-fitting
carefully
ADJUSTMENT
OF PINION HEIGHT
Adjust the drive pinion height by the following
procedures:
(I) Install special tools and drive pinion front and rear
bearing inner races to the gear carrier in the sequence
For vehicles with 3.OL Engine, fit in an attachment
with
a thickness of 15 mm (.59 in.) above MB996820-01.
(2) Tighten tfie nut of the special tool until the standard
value of drive pinion turning torque is obtained.
(3) Measure the drive pinion

oil seal).
Standardvalue
: W-O.5
turning
torque
Nm (3.5-4.3
(without
the
in.lbs.)
NOTE
1. Gradually tighten the nut of the special tool while
checking the drive pinion turning torque.
2. Because one rotation cannot be made when the
special tool is in contact with the gear carrier,
move it a few times and, after seating the bearing,
measure the rotation torque.
1 TSB Revision
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_
_I
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=zr
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si
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rc:,
z
3-33
Carrier
(4) Position
the special tool in the side bearing seat of the

gear carrier, and then select a drive pinion rear shim of
a thickness which corresponds
to the gap between the
special tools.
NOTE
Be sure to clean the side bearing seat thoroughly.
When positioning the special tool, be sure that the cutout sections of the special tool are in the position
shown in the illustration,
and also confirm that the
special tool is in close contact with the side bearing
seat.
When selecting the drive pinion rear shims, keep the
number of shims to a minimum.
(5) Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
race by using the special tool.
ADJUSTMENT
OF DRIVE PINION PRELOAD
Adjust the drive pinion turning
torque
by using
following procedure:
the
Without Oil Seal

(1) Fit the drive pinion front shim(s) between
the drive
pinion spacer and the drive pinion front bearing inner
race.
(2) Tighten the companion
flange to the specified torque
by using the special tools.
NOTE
Do not install the oil seal.
(3) Measure
seal)
Standard
the drive pinion turning

value
: 0.4-0.5
torque
Nm (3.54.3
(without
the oil
in.lbs.)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTE
When selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims
to a minimum
by selecting the drive pinion spacers.
(5) Remove
again.
1 TSB
Revision
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the companion
flange
and drive pinion once
,Kf
#&
z-
3-34
-~----
.l___i
REAR AXLE
_~
- Differential
Carrier
Wiih Oil Seal

(1) After setting the drive pinion front bearing inner race,
drive the oil seal into the gear carrier front lip by using
the special tool.
(2) Apply multipurpose
(3) Install the drive pinion assembly and companion flange

with mating marks properly aligned, and tighten the
companion
flange self-locking
nut to the specified
(4) Measure the drive pinion turning torque (with oil seal)
to verify that the drive pinion turning torque complies
with the standard value.
Standard
value
: 0.65475
Nm
(5.6-6.5
in.lbs .I
llY223
l
ADJUSTMENT
OF DIFFERENTIAL
GEAR BACKLASH
(1) Assemble
the side gears, side gear thrust spacers,
pinion gears, and pinion washers into the differential
case.
(2) Temporarily
install the pinion shaft.
L
NOTE
Do not drive in the lock pin yet.
(3) [nsert a wedge between the side gear and the pinion
shaft to lock the side gear.
1
(4) While locking the side gear with the wedge, measure
the differential
gear backlash with a dial indicator on ~=_
the pinion gear.
Standard
value :
<2.6L Engine>
0.010-0.076
mm (.0004-.0030
in.)
<3.OL Engine>
O-O.076 mm (O-.0030 in.)
Limit : 0.2 mm (.008 in.)
--- . _
I
1 TSB Revislon
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3-35
Carrier
(5) If the differential

gear backlash exceeds
adjust the backlash by installing
thicker
thrust spacers.
(6) Measure the differential gear backlash once
confirm that it is within the limit.
If adjustment
is not possible, replace the
and pinion gears as a set.
23. INSTALLATION
OF LOCK PIN
(1) Align the pinion shaft lock pin hole with the
case lock pin hole, and drive in the lock
(2) Stake the lock pin with a punch at two
24. INSTALLATION
OF DRIVE GEAR
the limit,
side gear
again, and
side gears
differential
pin.
points.
(1) Clean the drive gear attaching

bolts.
(2) Remove the adhesive adhered to the threaded holes
of the drive gear by turning the tap tool (Ml0 x 1.25),
and then clean the threaded
holes by applying compressed air.

the drive gear.
Specified
adhesive
adhesive
to the threaded
: 3M adhesive
or equivalent
holes of
stud locking
4170
(4) Install the drive gear onto the differential case with the
mating marks properly aligned. Be sure to tighten the
bolts to the specified torque in a diagonal sequence.
26. PRESS-FIT OF SIDE BEARING INNER RACE

Press-fit the side bearing inner races to the differential
case by using the special tool.
29. INSTALLATION
OF BEARING CAP
Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.
1 TSB Revision
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REAR AXLE
.
MB990201-01
- Differential
Carrier
ADJUSTMENT
OF FINAL
DRIVE
GEAR BACKLASH
(1) Using the special tool, temporarily

tighten the side
bearing nut until it is in the state just before preloading
of the side bearing.
(2) Measure
Standard
I
k
When backlash
sufficient
IWhen
MB990201-01
MB092153
bad&h
the final drive
gear backlash.
value :
<2.6L Engine>
0.11-0.16
mm
<3.OL Engine>
0.13418
mm
(.0043-.0063
in.)
(.0051-.0071
in.)
(3) Using the special tool (MB990201 I, adjust the backlash

to standard value by moving the side bearing nut as
shown.
NOTE
First turn the side bearing nut for loosening, and then
turn (by the same amount) the side bearing nut for
tightening.
is in-
is ex- J
(4) Using the special tool: to apply the preload, turn down
both right and left side bearing nuts on half the
distance between centres of two neighbouring
holes.
(5) Choose
MB0921 54
and install
[ TSB Revision
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the lock plates
(two
kinds).
3-37
REAR AXLE - Differential Carrier
(6) Check the final tooth contact.

If poor contact
evident, make adjustment.
(Refer to P.3-25.)
(7) Measure the drive gear runout.
Limit
: 0.05 mm
(.0020
is
in.)
If the drive gear runout exceeds the limit, reinstall by

changing the phase of the drive gear and differential
case, and remeasure.
OVERHAUL <Limited
Disassembly
l * I)*
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Slip Differential >
steps
Screw
Differential case (A)
Thrust washer
Spring plate
Spring disc
Friction plate
Friction disc
Friction plate
Friction disc
Pressure ring
Side gear
Thrust block
Differential pinion gear
Differential pinion shaft
Thrust block
16.
17.
18.
19.
20.
21.
22.
23.
24.
I)+ 25.
NOTE
(1)
(2)
Side gear
Pressure ring
Friction disc
Friction plate
Friction disc
Friction plate
Spring disc
Spring plate
Thrust washer
Differential case (B)

+e
: Refer to Service
(3) .4
/ TSB Revision
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procedures
to reassemble.
.?, .T ..jp
~------
--~
3-38
~=_.
_~
REAR AXLE - Differential Carrier

hwwlb.
1. REMOVAL OF SCREW
(1) Loosen screws of the differential
cases (A) and (B)
uniformly a little at a time.
(2) Separate differential case (A) from differential case (B).
NOTE
Before disassembling
the differential
cases. confirm
that the mating marks (numbers) on case A and case B
are the same.
(3) Remove the components
from differential
case(B).
NOTE
Keep the right and left thrust washers, spring plates,
spring discs, friction plates, and friction discs separate
in order to be able to distinguish them for reassembly.
INSPECTION
e
e
No31a4A
Check the side gears, pinion gears and pinion shaft for
wear or damage.
Check the side gear spline for wear or damage.
INSPECTION
OF CONTACT AND SLIDING SURFACES OF
PARTS
(1) Inspect the friction plate, friction disc, spring plate, spring
disc and pressure ring.
A The friction surfaces ofthe friction plate, friction disc,
spring plate, and spring disc. If there are any signs of
seizure, severe friction, or color change from the heat, it
will adversely affect the locking performance;
replace
the part with a new one.
NOTE
The strong contact on the inner circumference
of the
friction surfaces is because of the spring plate and the
spring disc; this wear is not abnormal.
B The six projections
on the inner circumference
of the
friction disc.
If there are nicks and dents, it will cause abnormalities
in the clutch pressure.
Repair the parts by using an oil stone; if the parts
cannot be repaired, replace them.
C The four projections
on the outer circumference
of the
friction disc.
If there are nicks and dents, it will cause abnormalities
in the clutch pressure.
Repair the parts by using an oil stone; if the parts
cannot be repaired, replace them.
D The friction surface of the friction disc of the pressure
ring.
If there are nicks or scratches, repair the part by first
grinding with an oil stone and then polishing
with
rubbing compound
on a surface plate.
0
Q
115659
1 TSB Revision
NOTE
The strong contact on-the inner circumference
of the
friction surface is because of the spring plate and the
spring disc; this wear is not abnormal.
http://vnx.su/
-1
REAR AXLE
0
G
F
E
i ti
Ii
Dhferential
3-39
Carrier
(2) Inspect the contact and sliding surfaces listed below, and
repair any nicks and burrs by using an oil stone.
E The sliding surfaces of the thrust washer and the case.
F The spring contacting
surface of the differential case.
G The contact surfaces of the outer circumference
of the
pressure
ring and the inner circumference
of the
differential
case.
H The sliding surface of the thrust washer.
I The sliding surfaces of the hole in the pressure ring
and the outer circumference
of the side gear.
J The projection
on the outer circumference
of the
pressure ring.
K The spherical surface of the differential
pinion. gear
and the inner diameter of the pressure ring.
L The V-shaped groove in the pressure ring, and the Vshaped part in the pinion shaft.
M The outer diameter of the pinion shaft and the hole of
the differential
pinion gear.
N The outer circumference
groove of the side gear.
0 The inner circumference
groove of the differential
case.
P The sliding surface of the thrust block.
i
llS662
INSPECTION
FOR WARPING
OF FRICTION
PLATE AND
FRICTION DISC
Using a dial indicator, measure the amount of warping (the
flatness) of the friction plate and the friction disc on a surface
plate by turning the friction plate or disc.
Limit
: 0.08
mm
(.0031
in.)
INSPECTION
FOR WEAR OF FRICTION PLATE AND FRICTION DISC
(1) In order to measure the wear, measure the thickness of
the friction surfaces and projections of the friction disc and
plate, and then find the difference.
(The same procedure is used for the spring discs and the
spring plates.)
Limit
: 0.1 mm
(.004 in.)
NOTE
Make the measurement
at several
(2) If the parts are worn beyond

them
with
1 TSB Revision
http://vnx.su/
new parts.
I
different
the allowable
points.
limit, replace
Carrier
NoJ,RlC
25. INSTALLATION
OF DIFFERENTIAL
CASE (B)
Before assembly, use the following
method to adjust the
clearance between the spring plates and differential cases
(for adjustment
of the clutch plate friction force). and to
adjust the axial clearance of the side gear when installing
the internal components
into the differential case.
(1)Arrange the two (each) friction discs and friction plates

for each side, one on top of another, as shown in the
figure, combining
them so that the difference
in
thickness between the left and the right is the standard
value.
Standard
value
: 0.05 mm (.0020 in.) or less
NOTE
For new ones, there is one type of friction plate: 1.75
mm (0689 in.); there are two types of friction disc:
1.75 mm (.0689 in.) and-l.85 mm (0728in.).
(2)Arrange one spring disc and one spring plate for each
side, one on top of the other, so that the difference
between the left and the right thickness is minimized.
NOTE
For new ones, there is one type of spring
spring plate: 1.75 mm (0689 in.).
disc and
(3)Assemble
the pressure rings internal components
(differential
pinion shaft and pressure ring) and the
friction discs and friction plates, and then, as shown in
the figure, measure the overall width.
(4Kalculate
the total value (C) of the thickness
of the
spring discs and spring plates plus the value measured
in (3) above.
(5)Obtain the dimension

(D) between
the spring plate
contact surfaces when differential cases (A) and (B) are
combined.
(D=E+F-G)
(6)Change the thickness of the friction disc so that the
clearance (D - C) between the differential
case and
the spring plate becomes the standard value.
Standard
j TSB Revision
value
http://vnx.su/
: 0.05420
mm (.0024-.0079
in.)
REAR AXLE
- Differential
3-41
Carrier
(7)Remove the spring plates, spring discs, friction plates

and friction disc.
(8)lnstall the thrust washer as shown in the figure, and
then select a thrust washer so that the difference
between
the left and right dimensions
from the
pressure ring rear face to the thrust washer end face is
the standard value.
Standard
value
: 0.05 mm (.0020 in.) or less
NOTE
Measure the distance
groove manually.
(9)Measure the dimension
surafce to end surafce.
while
squeezing
the V-shaped
(H) from the thrust washer
end
Thrust
washer
.*..--a
(10)Obtain
the dimension
(I) between the thrust washer
contact surfaces when differential cases (A) and (B) are
combined.
(I=J+K+L)
NOTE
Dimension J is the distance between the spring plate
contact surfaces when differential
cases (A) and (B)
are combined.
(Refer to P.340.)
(1 l)Change the thickness of the thrust washer so that the
clearance ( I - H ) between the thrust washer and the
differential
case is the standard value.
Standard
value
: 0.05420
mm
(.0020-.0079
in.)
NOTE
1. Select the thrust washer so that the difference
between
the left and right dimensions
from the
pressure ring rear face and the thrust washer end
surface are the standard value even when the
thrust washer is changed.
2. There are three sizes of new thrust washers: 1.50
mm (0591 in.), 1.60 mm (.0630 in.), and 1.70 mm
(.0670 in.)
Spring
(12)Place the each part in the differential

directions shown in the figure.
plate
case
(B) as
NOTE
1. Before assembly, apply the specified gear oil to
each component
especially careful to coat contact
surfaces and sliding surfaces.
jTSB
Revision
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Carrier
Specified
gear oil:
MOPAR Hypoid Gear Lubricant
Part No. 4318058
plus MOPAR Hypoid Gear Oil Additive-Friction
Modifier, Part No. 4318060 or equivalent
2.
Be careful not to -insert the friction plates and

friction discs in the incorrect order and to install the
spring plates and spring disc in incorrect direction.
1. INSTALlATlON
OF SCREW
(1) Align the mating marks (the same numeral on each
case) of differential
case (A) and differential
case (B).
(2) Turning the screwdriver
slowly several times, tighten
the screw so that the-cases
are in close contact.
NOTE
If, even though
the screw is tightened,
the end
surfaces of case (A) and case (B) do not come into
close contact. probably the thrust washer and spring
plate are not fit correctly into the groove, so make the
assembly again,
(3) After assembly, in order to check the frictional force of
the clutch plate, use the special tools to measure the
turning torque.
Standard
value:
When a new clutch plate is used
66-100 Nm (47-72 ft.lbs.)
When an old clutch plate is used
36-100 Nm (25-72 ft.lbs.)
NOTE
Measure the turning torque
after rotating
slightly.
When measuring the torque, do so at the beginning of
movement.
rTSB Revision
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~_
8-133
STARTlNG SYSTEM - Specifications
STARTING
SYSTEM
SPECIFICATIONS
NC#E-
Items
2.6L Engine
3.OL Engine
Reduction drive
MlT70481
Reduction drive
MIT72581
MD136933
Starter motor
Type
Model No.
Part No.
Rated output
MD099667
1.2/12
8
kWN
No. of pinion teeth
1.2/12
8
SERVICE SPEClflCATlONS
NMFC-
Items
Specifications
Standard values
Starter motor
Free running characteristics
Terminal voltage
Current
A
Speed
rpm
11
Max. 90
Min. 3000
mm (in.)
Under-cut depth
Commutator diameter
mm (in.)
Pinion gap
Commutator
0.5 (.020)
29.4 (1.157)
0.5-2.0 (.020-.079)
0.05 (.0020)
mm (in.)
runout
mm (in.)
-imit
Commutator
Commutator
diameter
runout
mm (in.)
mm (in.)
28.8 (1.134)
0.1 f.004)
NMFD-
Items
Starter motor mounting
bolts
TSB Revision
Nm
ft.lbs.
27-34
20-24
http://vnx.su/
8-134
STARTING SYSTEM - Troublesbooting
TROUBLESHOOTING
STARTING CIRCUIT
Ignition
switch
C:IRCUIT DIAGRAM
<Vehicles with a Manual Transmission>
Batten!
Main fusible
link
t3.0L
B-01
Engine only>
.&a
Remark
I?) Lines and connectors indicated by the * symbol are
applicable to the 2.6liter models.
(2) The broken line (----I
is applicable to the 3.0-liter
models only.
(3) For information
0). refer to P.812, 14.
Wiring color code
6: Black
Br: Brown
LI: Light blue
0: Orange
OPERATION
l
G: Green
P: Pink
;;:$$v
L: Blue
Y: Yellow
Lg: Light green

W: White
TROUBLESHOOTING NINTS
1. Starter motor does not turn over

When the ignition switch is turned to START
with the inhibitor switch in P or N position
1) Starter motor operating sound is heard for
an instant
(automatic
transmission
vehicles),
current
l
Check starter motor for condition of its
flows through the inhibitor switch and starter
magnetic switch.
coil to ground. This closes the contacts of the
starter switch (magnetic switch).
2) Starter motor does not operates at all
l
Check starter motor coils.
Closing the magnetic
switch contacts
com2. Starter motor does not stop
pletes the circuit from the battery to magnetic
i l
Checkstarter
motor for condition of its
switch to starter motor and ground, so that the
starter motor starts rotating.
magnetic switch.
I l-CR Rawieirm http://vnx.su/
-E
--
p--i
_
.-
STARTING
<Vehicles
with
an Automatic
SYSTEM
8-135
- Circuit Diagram
Transmission>
Ignition switch
Battery
C-56
Inhibitor
switch
L
Remark
For infomation
concerning
refer to P.8-14.
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
L: Blue
Y: Yellow
the ground
points (example:
110,
G: Green
P: Pink
Starter
TSB
Revision
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----mu
_-__
: -t
~_
..,.
8-136
STARTING SYSTEM - Starter
Motor
STARTER MOTOR
<2.6L
NoIFJ*N
Engine>
Drainage
6 Removal
of Automatic
Transmission
of Oil Cooler Tube. (Refer
Post-installation
Operation
l
Installation of Oil Cooler Tube.
l
Supplying of Automatic Transmission
Fluid. (Refer to GROUP 21 Transmission
Oil Cooler)
<3.OL Engine>
Removal steps
1. Connection for starter
2. Starter cover
l *
3. Starter motor
motor
27-34
20-25
Nm
ftlbs.
r/
connector
NOTE
(1)
(2)

**

3. REMOVAL
OF STARTER MOTOR
Models with manual transmission
Jack up the vehicle; then remove (from below the body)
the starter motor mounting bolts, and separate the starter
motor from the transmission
assembly.
/ TSR
Revision
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8-137
Motor
INSPECTION
yp/(zJ
motor
L-J
BELo
PINION GAP ADJUSTMENT

(1) Disconnect field coil wire from
switch.
(2) Connect a 12V battery between
terminal.
(3) Set switch to ON, and pinion
Caution
This test must be performed
seconds) to prevent coil from
(4) Check pinion to stopper
feeler gauge.
Standard
value:
0.5-2.0
M-terminal
S-terminal
and M-
will move out.

quickly (in less than
burning.
clearance
mm
of magnetic
(pinion
(.020-.079
gap) with
10
a
in.)
Pinion
(5) If pinion
removing
bracket.
Field coil wire
gap is out of specification,

adjust by adding or
gaskets between
magnetic
switch and front
PULL-IN TEST OF MAGNETlC

SWITCH
(1) Disconnect
field coil wire from M-terminal
of magnetic
switch.
S-terminal and M-terminal.
Caution
quickly (in less than 10
seconds)
to prevent coil from burning.
(3) If pinion moves out, then pull-in coil is good. If it doesnt
replace magnetic switch.
HOLD-IN TEST OF MAGNETIC
SWITCH
(I) Disconnect
of magnetic
switch.
(2) Connect a 12V battery between S-terminal and body.
Caution
quickly (in less than 10
seconds)
to prevent coil from burning.
Field coil wire
(3) If pinion remains out, everything

is in order. If pinion
moves in, hold-in circuit is open. Replace magnetic
switch.
TSB Revision
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~.
-
-.
-.
~. ~
8-138

Carbon-pile
rheostat
Motor
FREE RUNNING
TEST
(1) Place starter motor in a vise equipped with soft jaws and
connect a fully-charged
12-volt battery to starter motor as
follows:
(2) Connect a test ammeter
(IOO-ampere scale) and carbon
pile rheostat
in series with battery positive post and
starter motor terminal.
(3) Connect a voltmeter (1 Ervolt scale) across starter motor.
(4) Rotate carbon pile to full-resistance
position.
(5) Connect
battery cable from battery
negative
post to
starter motor body.
(6) Adjust rheostat until battery voltage shown on the voltmeter reads 1 IV.
(7) Confirm that the maximum amperage
is within the standard value and that the starter motor turns smoothly and
freely.
Standard
value:
Current
Max. SOA
Min. 3,000 rpm
Speed
RETURN TEST-OF MAGNETIC

SWITCH
(II Disconnect
switch.
M-terminal
Caution
quickly (in
seconds) to prevent coil from burning.
(3) Pull pinion out and release. If pinion quickly
original position, everything
is in order.
replace magnetic switch.
/ TSB Revision
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of magnetic
and body.
less than
IO
returns to its
If it doesnt,
8-739
STARTING SYSTEM - Starter Motor

DISASSEMBLY
Disassembly
l *
*+
+I)**
+I)**
AND
REASSEMBLY
steps
1. Screw
2. f&gnetic switch
h[
3. Screw
4. screw
5. Rear bracket
6. Brush holder
7. Brush
8. Rear bearing
9. Armature
IO. Yoke assembly
11. Ball
12. Packing A
13. Packing B
14. Plate
15. Planetary gear
16. Lever
17. Snap ring
18. Stop ring
19. Over running clutch
20. Internal gear
21. Planetary gear holder
22. Front bracket
A\\
EL199
NOTE
(2) +*

9.
REMOVAL
OF ARMATURE
/ 11. BALL
When removing the armature,

do not lose the ball which
acts as a bearing for the armature and tip.
1 TSB Revision
http://vnx.su/
8-140

Socket
Stop ring
Pinion gear
17. REMOVAL
OF SNAP RING / 18. STOP RING
(I) Push the stop ring towards the snap ring using the
proper socket.
(2) After removal of the snap ring with the snap ring
pliers, remove the stop ring and the over-running
clutch.
CIwmning
6ELOO97
CLEANING
STARTER MOTOR PARTS
1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning clutch is pre-lubricated
at the factory and solvent will
wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
Snap ring
INSPECTION
CHECKING COMMUTATOR
(1) Plate the armature
on a pair of V blocks
run-out with a dial gauge.
Standard
value:
0.05 mm LOO20 in.)
Limit:
0.1 mm l.004 in.1
(2) Check the outer diameter.

Standard
value:
29.4 mm (1.157
Limit:
28.8 mm (1.134 in.)
(3) Check the depth

Standard
value:
Undercut
lEl.OS!3~
rTCRRPvicinn http://vnx.su/
and
in.)
of the undercut between

0.5 min. (.020 in.)
segments.
check
8-141
BRUSH HOLDER
Check conductivity
between the brush holder plate and brush
holder. It there is no conductivity
this is normal.
OVERRUNNING
CLUTCH
1. While holding clutch housing,
rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function properly, replace overrunning
clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or
burred, replace overrunning
clutch assembly.
If pinion is
damaged, also inspect ring gear for wear or burrs.
l&l
n
-Limit
line
FRONT AND REAR BRACKET BUSHING

Inspect bushing for wear or burrs. If bushing is worn or
burred,
replace front bracket
assembly
or rear bracket
assembly.
REPLACEMENT
OF BRUSHES AND SPRINGS
1. Brushes that are worn beyond limit line, or are oil-soaked,
should be replaced.
2. When replacing field coil brushes, crush worn brush with
pliers, taking care not to damage pigtail.
3.
Sand pigtail
end with
sandpaper
to ensure
good
soldering.
4. Insert pigtail into hole provided in new brush and solder
it. Make sure that pigtail and excess solder do not come
out onto brush surface.
5. When replacing ground brush, slide the brush from brush
holder by prying retaining spring back.
New brush
I
TESTING ARMATURE
Glower
TESTING ARMATURE
FOR SHORT-CIRCUIT
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while
rotating armature slowly in growler. A shorted armature
will cause blade to vibrate and be attracted to the core.
Replace shorted armature.
-
aos2J
)ievision
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TESTING ARMATURE
FOR GROUNDING
Check the insulation in the space between the segments
of
the commutator
and the armature and coil core. If there is no
conductivity
this is normal.
CHECKING
CIRCUIT BRAKE BETWEEN ARMATURE
AND
COIL
Check conductivity
between
each segment.
If there is conductivity this is normal.

18. INSTALLATION
OF STOP RING / 17. SNAP RING
Using a suitable pulling tool, pull overrunning
clutch stop
ring over snap ring.
/ TSB
Revision
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ml%=-3:
s-!
IGNITION SYSTEM - lanition &stem
c2.6L Engine>
8-153

5. INSTALLATION OF DISTRIBUTOR
dead center.
(2) Align the distributor
Gears matinal
so that the No. 1 cylinder
is at top
housing
marks.
and gear mating
(3) Install the distributor

to the engine while aligning the
fine cut (groove or projection)
of the distributors
installation
flange with the center of the distributor
installation stud.
Housin
mark
1 TSB
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8-154
IGNlTlON
SYSTEM
- ignition
System <Z&L Engine>
1. INSTALLATION
OF SPARK PLUG CABLE
Improper arrangement
of spark plug cables will induce
voltage between
the cables, causing miss firing and
developing
a surge at acceleration
in high-speed
operation. Therefore,
be careful to arrange the spark plug
cables properly by the following procedure.
1. Install the spark plug cable clamps as shown in the
illustration.
2. The numerals on the support and clamp indicate the
spark plug cable No.
3. Pay attention to the following
items when the spark
plug cables are installed.
(I) Install the cables securely to avoid possible contact with metal parts.
(2) Install the cables neatly, ensuring they are not too
tight, loose, twisted or kinked.
View P
5ELma
r TSR
Rnvininn
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IGNITION SYSTEM - Ignition System <&OL Engine>
IGNllTlON SYSTEM <3.OL ENGINE>

20-30
15-21
Nm
ft.lbs.
12-15 Nm
.9-l 1 ft.lbs.
+Q $4
a*
a*+
NOTE
(1) +I)
(2) P)*4
1.
2.
3.
4.
5.
Spark plug cable

Spark plug
High tension cable
Distributor
Ignition coil assembly
: Refer to Service
: Refer to Service
7EL0061
Points of Removal.
1
TSB
Revision
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8-l 56
IGNITION SYSTEM - Ignition System <3.OL Engine>

1. REMOVAL OF SPARK PLUG CABLE/3. HIGH TENSION
CABLE
Refer to P.8-151.
INSPECTION
SPARK PLUG
Refer to P.8-152.
SPARK PLUG CABLE

(1) Check cap and coating for cracks.
(2) Measure resistance.
Unit: kLI
High tension cable
Approx. 3
00
Highvoltage
terminal
?ELoos7
) 9
1 8.5
10
12
IO
IGNITION COIL
(1) Measurement of the primary coil resistance
Measure the resistance of the positive (+I terminal and
negative (-) terminal of the ignition coil.
Standard value: 0.72-0.99 rc2
(2) Measurement of the secondary coil resistance
Measurement the resistance of the positive (+) terminal
and the high-voltage terminal.
Standard value: 10.3-13.9 ka
POWER TRANSISTOR
(1) Connect
the negative
(-) terminal
of the 1.W power
supply to terminal @ of the power transistor, then check
whether
there is continuity
between
terminal
@ and
terminal @ when terminal @ and the positive (+) terminal are connected
and disconnected.
lTertninal @ and (+) terminal ( Terminal @ and terminal @ 1
6El0103
Connected
Continum/
Unconnected
No contirruity.
(2) Replace the power
1 TSB Revision
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transistor
if there
is a malfunction.
IGNITION SYSTEM - Ignition System <3.0L Engine>
8-157

4. lNSTALLATlON OF DlSTRlBUTOR
dead center.
(2) Align the distributor
Mating
mark
so that the No. 1 cylinder
is at top
housing
marks.
and gear mating
7EL0058
(3) Install the distributor

to the engine while aligning the
fine cut (groove or projection)
of the disbributors
installation
flange with the center of the distributor
installation stud.
1. INSTALLATION OF SPARK PLUG CABLE

Refer to P. 8-154.
7EL0060
TSB
Revision
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8-158
IGNITION SYSTEM - Distributor
DKI-RIBUTOR
<2.6L Engine>
<2.6L ENGINE>
9 11
4.3\I
21
20
I
15
Disassembly
1.
2.
3.
;.
I)+
+I)
4* ++
I)4
2:
+I) ++
steps
Engines
Federal
for
&
Breather
Distributor cap
Packing
i~&&tct carbon
6: Vacuum control
7. Ground wire
8. Lead wire
;dyE;nt
of air gap
10: 8 otor
shaft
11. Signal rotor
12. Breaker plate
13.
14. Spring
Governorretainer
spring
15. Governor weight
16. Lock pin
17. Driven gear
18. Washer
19. O-ring
20. Distributor shaft
21. Washer
22. Oil seal
23. Distributor housing
lEL0003
NOTE
;;I
F;rse
the disassembly pro!edures

to reassemble.
. Refer to Servrce Pornts of Disassembly.
:. Refer to Service Points of Reass-embly.
: Non-reusable
parts

10. REMOVAL
OF ROTOR SHAFT/ll.
SIGNAL ROTOR
Place igniter base on soft base (wooden block) and lightly
tap rotor shaft to remove it from signal rotor.
levision http://vnx.su/
8459
IGNITION SYSTEM - Distributor <ML Engine>

13. REMOVAL
SPRING
OF SPRING RETAINER/14. GOVERNOR
Remove two spring retainers

two governor springs.
*Pin
II
Contact
with pliers and then remove
17. REMOVAL OF DRIVEN GEAR
punch
(1) Mark location of driven gear on distributor shaft.

(2) Place driven gear on soft base (wood btock) so that
spring pin can be removed.
(3) Using a pin punch, remove spring pin.
Distributor
INSPECTION
carbon
Check according
to the
replace anything faulty.
following
provisions
and
repair
or
CAP ROTOR
(1) Ensure there are no cracks in the cap.
(2) Ensure that the electrodes of the cap and of the rotor are
undamaged.
(3) Wipe off any dirt from the cap or the rotor.
&Pin
II
punch
Before
Distributor
servicing
be sure to clean and inspect
all parts.
17. INSTALLATION OF DRIVEN GEAR

Install driven gear
marked location.
into
distributor
shaft
at previously
12. INSTALLATION OF BREAKER PLATE

Install igniter base to housing. Position the igniter base so
that the projection (A) fits into the groove (B).
TSB
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IGNITION SYSTEM
Distributor
~2.6~ EngineHDiibutor
-4.0~ Engine>
11. INSTALLATION OF SIGNAL ROTOR

install signal rotor to rotor shaft. Position the signal rotor
so that the dowel pin fits into the groove.
Socket
ADJUSTMENT OF AIR GAP

Adjust
air gap between
Standard value:
signal rotor and pickup
or igniter.
0.8 mm (.0315 in.)
DlSTRlBUTOR <3.OL ENGINE>

Disassembly
steps
1. Distributor cap
2. O-ring
3. Contact carbon
4. Rotor
++r)+
NOTE
1;; Fy
5.
6.
7.
8.
9.
Lead wire
Spring pin
Driven gear
O-ring
Distributor housing assembly
the disassembly procedures to reassemble.

: Refer to Service
: Refer to Service
7ELOO62
1 TSB Revision
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=zzr
-
8-761
IGNITION SYSTEM - Distributor <3.OL Enaine>

Punch
7.
REMOVAL OF DRIVEN GEAR

(1) Make a position identification
mark (for the drive gear)
on the distributor shaft.
(2) Place the drive gear on a soft base (wooden block) so
that the spring pin can come out.
(3) Punch out the spring pin by using a pin punch.
INSPECTION
Check the following
found.
points;
repair or replace
if a problem
CAP ROTOR
(1) There must be no cracking in the cap.
(2) There must be no damage to the caps electrode
rotors electrode.
(3) Clean away any dirt from the cap and rotor.
is
or the
7ELOo64

Take out and clean the disassembled
parts.
cleaning oil or similar product for cleaning.
7.
Do not
use
INSTALLATION
OF DRIVEN GEAR
(1) Align with the mark made at the time of disassembly,
and install the drive gear to the distributor shaft.
(2) When aligning the driven gears mating mark and the
housings mating mark, make the combination
so that
A (rotor mounting threaded hole) at the shaft end is
at the position shown in the figure, and then align the
spring pin hole and drive in a new spring pin.
Caution
Drive in the spring pin so that the slits are at a
right angle dative
to the shaft.
7EL0065
1 TSB Revision
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8462
IGNITION SYSTEM - lanition Switch
IGNITION SWITCH
Removal
steps
1. Lower column cover
2. Upper column cover
3. Cable band
4. I nition switch
5. It ey remind switch
75w<
16Wl695
1
NOTE
INSPECTION
Key reminder
switch
(1) Disconnect the wiring connector from the ignition switch,

and connect an ohmmeter
to the switch side connector.
(2) Operate the switch, and check the continuity
between
the terminals.
LOCK
ACC
Removed
o--o
Inserted
ON
START
o-0
-0
NOTE
O-O indicates that there is continuity
terminals.
16UO360
1 TSR
Revision
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-0
between
the
8-116
CHARGlNG SYSTEM
- Specifications
CHARGING SYSTEM
SPECFICATIONS
-
ALTERNATOR
Items
2.6L Engine
Tvw
Battery voltage sensing
Model No.
Part No.
Rated output
A2TO3477
MD1 10318
12/50
A3TO2 198
MD126796
12r75
Electronic built-in type
Electronic built-in type
Items
2.6L Engine
3.OL Engine
Tvw
Ampere hours (5 HR)
55B24RWMF
75D26R-MF
40
433
79
57
480
V/A
Voltage regulator
3.OL Engine
_
Battery voltage sensing
BATTERY
Ah
Cranking rating [at - 17.8C (0F)I

min.
Reserve capacity
123
NOTES
I. CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 or
greater at a specified temperature.
2. RESERVE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimum terminal
voltage of 10.5 at 26.7C (80F).
-.
Items
Specifications
Standard values
Regulated voltage
V
Ambient temp. at voltage regulator
-20C (-4F)
20C (68FI
60C (140F)
14.2-15.4
13.9-14.9
13.4-14.6
80C (176C)
Slip ring O.D.
mm (in.)
/UT03477
23 t.906)
A3TO2198
Field coil resistance
22.7 t.894)
3-5
Limit
Output current
A2TO3477
A3TO2 198
Slip ring O.D.
A2TO3477
13.1-14.5
1.
A
Min. 35
Min. 52.5
mm (in.)
22.2 0374)
22.1 f.870)
A3TO2198
---
_ .
/ TSB Revision
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a-117
CHARGING SYSTEM - Specifications

No8ED-
Items
Nm
ft.ibs.
Alternator lock bolt

Alternator pivot nut
High pressure hose nut
12-15
20-22
20-25
9-11
14-16
Low pressure hose nut
30-35
TSB Revision
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14-18
22-25
._
CHARGING SYSTEM - Troubleshooting
TROUBLESHOOTING
CHARGING CIRCUIT
Ignition
switch
IRCUT DIAGRAM
Main
I-1
-I-t
q El-
Alternator
!-Bk
--,
I
I
I
I
I
I
I
I
,. ._. _. ._
8-03
h,
5-w
r *.n
Choke relay
Combination
meter
Auto choke relay
Remark
(1) The broken line I----)
and connectors indicated by the
g symbol are applicable to the 25liter
models
(2) The chain line (- - -) is applicable to 30liter
models
(3) %information
concerning
01, refer to P.&12. 14.
Wiring color code
Br: Brown
B: Black
Ll: Light blue
0: Orange
the ground
points (example:
G: Green
P: Pink
I TSB Revision
L: Blue
Y: Yellow
http://vnx.su/
Lg: Light green

W: White

OPERATION
Before engine starts
l
First, when the ignition switch is turned to
ON,
and before the engine starts, current
.
flows through
fuse No.3, charging
indicator
light, then to alternator,
and ground, causing
the charging indicator light to go on.
When alternator
is generating
current
l
Once the engine
starts,
battery voltage
is
applied to alternator
S terminal. The battery
voltage imposed on this terminal is monitored
by the IC voltage regulator. and according to
the voltage detected,
the IC voltage regulator
regulates the alternator field coil current, thus
controlling the current the alternator generates.
l
Once the alternator starts generating current, a
voltage. slightly higher than battery voltage is
applied to L terminal.
This prevents
current
from flowing to the charging indicator light and
the light goes off.
l
At alternator
B terminal,
a load current proportional to the battery voltage is produced and
is sent to any load.
Remarks
The alternator
relay is to ensure charging the
battery even when the charging indicator light
bulb is burnt out.
8-7 79
TROUBLESHOOTING
HINTS
1. Charging indicator light does not go on when
the ignition switch is turned to ON, before
the engine starts
l
Check the bulb.
Charging
indicator light fails to go off once the
2.
engine starts
l
Check drive belt tension.
l
Check the IC voltage regulator.
3. Discharged or overcharged
battery
l
Check the IC voltage regulator.
[ TSB Revision
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8-120
CHARGING
SYSTEM
BATTERY
TESTING
- Troubleshooting
PROCEDURE
RESULT
TEST STEP
A0
A3
Remove negative cable, then positive cable.
-@
Check for dirty or corroded connections.
0
0
LOOSE BATTERY POST

l
A2
ACTION TO TAKE
CLEAN terminals and

clamps..GO to Al.
GOtoAl.
REPLACE battery.
GOtoA2.
REPLACE battery.
GOtoA3.
CHARGE battery at 5
amps then GO to A3
VISUAL INSPECTION
l
Al
Check for loosebattery
post.
@
0
0
CRACKED BATTERY COVER

l
Remove holddowns
Check for broken/cracked
TEST INDICATOR/OPEN
l
and shields.
-@
case or cover.
0
0
CIRCUIT VOLTAGE TEST
Turn headlamps on for 15 seconds
Turn headlamps off for 2 minutes to allow battery

voltage to stabilize
Disconnect cables
Read open circuit voltage
h%B
Revision
@
BLUE DOT INVISIBLE
AND OPEN CIRCUIT
VOLTAGE UNDER 12.4
VOLTS
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8-121

TEST STEP
A4
RESULT
ACTION TO TAKE
LOAD TEST
l
Connect a load tester to the battery.
Load the battery at the recommended discharge rate

(See LOAD TEST RATE CHART) for 15 seconds.
Read voltage after 15 seconds, then remove load.
VOLTAGE IS LESS
THAN MINIMUM
LISTED WHITE INDICATOR)
OK b
VOLTAGE IS MORE
THAN MINIMUM
LISTED
LOAD TEST RATE CHART

Load test
Cranking
rating
Reserve
capacity
Application
21OA
433A
79 minutes
55B24R(S)-MF
240 A
490 A
123 minutes
75D26R-MF
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REPLACE battery.
Batten/ OK
8-122
CHARGING SYSTEM - Service
sdu;~
ADJUSTMENT
Adjustment
Procedures
meter to the B terminal and the (-) lead to

the disconnected
output wire.
NOTE
Use of. a clamp type ammeter
that can measure current without disconnecting
the harness
is preferred. The reason is that when checking
a vehicles that has a low output current due to
poor connection of the alternator B terminal,
such poor connection
is corrected as the B
terminal is loosened
and a test ammeter
is
connected
in its place and as a result, causes
for the trouble may not be determined.
(5) Connect a digital voltmeter
between
the alternator B terminal and battery (+) terminal.
Connect the (+) lead wire of the voltmeter to
the B terminal and the (-) lead wire to the
battery (+) terminal.
(6) Connect the batterv around cable.
(7) Leave the hood opo<
PROCENaaELAb
CHARGING SYSTEM INSPECTION

VOLTAGE
DROP TEST OF ALTERNATOR
OUTPUT WIRE
This test judges whether or not the wiring (including the fusible link) between
the alternator
B
terminal and the battery (+) terminal is sound by
the voltage drop method.
Preparation
(1) Turn the ignition switch to OFF.
(2) Disconnect the battery ground cable.
(3) Disconnect the alternator output lead from the
alternator B terminal.
(4) Connect a DC ammeter
(0 to 100 A) in series
to the B terminal
and the disconnected
output lead. Connect the (+) lead of the aml-l
OUTPUT CURRENT TEST

Test
This test judges whether
or not the alternator
gives an output current that is equivalent
to the
(2) Turn on or off the headlights and small lights
nominal output.
and adjust the engine speed so that the ammeter reads 20A and read off the voltmeter
Preparation
indication under this condition.
(1) Prior to the test, check the following items and
Result
correct as necessary.
(1) It is okay if the voltmeter
indicates the stan(a) Check the battery installed in the vehicle to
dard value.
ensure that it is in sound state*.
The
battery checking
method
is described
in
Standard
value:
0.2V max.
BATTERY.
(2) If the voltmeter
indicates a value that is larger
NOTE
than the standard value, poor wiring is sus* The battery that is used to test the
pected, in which case check the wiring from
output current should be one that has been
the alternator
B terminal to fusible link to
rather discharged. With a fully charged batbattery (+) terminal. Check for loose connectery, the test may not be conducted
cortion, color change due to overheated
harness,
rectly
due-to
an
insufficient
load.
etc. and correct them before testing again.
(b) Check tension of the alternator drive belt.
(3) Upon completion
of the test, set the engine
The belt tension
check method
is despeed at idle. Turn off the lights and turn off
scribed in GROUP 7 - Service Adjustthe ignition switch.
ment Procedures.
(5) Disconnect
the ammeter
and voltmeter
that
(2) Turn off the ignition switch.
have been connected for the test purpose.
(6) Connect the alternator output wire to the alter(4) Disconnect the alternator output wire from the
nator B terminal.
(7) Connect the battery ground cable.
TPP m^..:s:....
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Adjustment
8-123
Procedures
40 A
!--z-II
j-Y&-
Charge
-wamino
w Load
T
lioht
Battery
Voltmeter

(0 to IOOA) in series
between
the B terminal
and the disconnected output wire. Connect the (+) lead of
the ammeter
to the B terminal and connect
the (-1 lead wire to the disconnected
output
wire.
NOTE
Tighten
each connection
by bolt and nut
securely as a heavy current will flow. Do not
relay on clips.
(6) Connect a voltmeter
(0 to ZOV) between
the
B terminal and ground. Connect the (+) lead
wire to the alternator
B terminal and (-)
lead wire to a sound ground.
(7) Set the engine tachometer
and connect the
battery ground cable.
(8) Leave the engine hood open.
Test
(1) Check to see that the voltmeter
reads the
same value as the battery voltage.
If the voltmeter
reads OV. an open circuit in
the wire between
the alternator B terminal
and battery (-) terminal, a blown fusible link or
poor grounding is suspected.
(2) Turn on the headlight
switch and start the
engine.
(3) Set the headlight at high beam and the heater
blower switch at HIGH, quickly increase the
engine
speed to 2,500 rpm and read the
maximum output current value indicated by the
ammeter.
NOTE
After the engine start up, the charging current
quickly drops, therefore, above operation must
be done quickly to read maximum
current
value correctly.
1 TSB Revision
d0
Ammet er
wa
1482
Result
(1) The ammeter
reading must be higher than the
limit value. If it is lower but the alternator
output wire is normal, remove the alternator
from the vehicle and check it.
Limit value:
35A min. 2.6L engine
52.5A min. 3.OL engine
Caution
1. The nominal
output
current
value
is
shown on the nameplate
affixed to the
alternator
body.
2. The output
current value changes with
the electrical
load and the temperature
of the alternator
itself. Therefore,
the
nominal
output
current
may not be
obtained
if the vehicle electrical
load at
the time of test is small. In such a case,
keep the headlights
on to cause discharge
of the battery
or use lights of
another
vehicle as a load to increase the
electrical
load. The nominal
output
current may not be obtained
if the temperature of the alternator
itself or ambient
temperature
is too high. In such a case,
reduce the temperature
before testing
again.
(2) Upon completion
of the output current test,
lower the engine speed to the idle speed and
turn off the ignition switch.
(4) Remove the test ammeter
and voltmeter
and
the engine tachometer.
(5) Connect the alternator output wire to the alternator B terminal.
(6) Connect the battery ground cable.
http://vnx.su/
8-124
REGULATED
VOLTAGE TEST
The purpose of this test is to check that the
electronic
voltage regulator
controls the voltage
correctly.
Preparation
(I) Prior to the test, check the following items and
correct if necessary.
(a) Check the battery installed on the vehicle
to see that it is fully charged. For battery
checking method, see BATTERY.
(b) Check the alternator drive belt tension. For
belt tension check, see GROUP 7 - Service Adjustment
Procedures.
Adjustment
Procedures
Turn the ignition switch to OFF.

Disconnect the battery ground cable.
Connect a digital voltmeter
between
terminal of the alternator and ground.
the (+) lead of the voltmeter
to
terminal of the alternator,
inserting
wire side of the two way connector
nect the (-) lead to sound ground
(-) terminal.
the S
Connect
the S
from the
and conor battery
1660346
(5) Disconnect the alternator output wire from the

(0 to IOOA) in series
between
the B terminal
and the disconnected output wire. Connect the (+) lead of
the ammeter to the B terminal and connect
the (-) lead wire to the disconnected
output
wire.
(7) Set the engine tachometer
and connect the
battery ground cable.
Test
(1) Turn on the ignition switch and check that the
voltmeter
indicates the following value.
Voltage:
Battery voltage
If it reads OV there is an open circuit in the
wire between
the alternator
S terminal and
the battery (+) or the fusible link is blown.
(2) Start the engine. Keep all lights and accessories off.
(3) Run the engine at a speed of about 2,500 rpm
and read the voltmeter
when the alternator
output current drops to IOA or less.
1 TSB Revision
Result
(1) If the voltmeter
reading agrees with the value
listed in the regulating voltage table below, the
voltage regulator is functioning
correctly. If the
reading is other than the standard value, the
voltage regulator or the alternator is faulty.
Regulating
Voltage regulator ambient
temperature
C PF)
-20
20
60
80
(2) Upon
(-4)
(66)
(140)
(176)
voltage
table
Regulating voltage
14.2-15.4
13.9-14.9
13.4-14.6
13.1-14.5
completion
of the test, set the engine
speed at idle and turn off the ignition switch.
and ammeter
and
(4) Remove the test voltmeter
the engine tachometer.
(5) Connect the alternator output wire to the alternator B terminal.
Connect
the battery ground cable.
P-3)
http://vnx.su/
CHARGING SYSTEM
Service
Adiustment
BAITERY INSPECTION
Procedures
NcamM
BATTERY VISUAL INSPECTION

(1)
The battery contains a visual test indicator which gives blue
signal when an adequate
charge level exists, and white
signal when charging is required.
Charging
necessary
Good
condition
LOAD TEST RATE CHART
210A
433 A
79 minutes 55B24R(StMf
240 A
490 A
123 minutes 75026R-MF
LOAD TEST CHART

Minimum
Voltage
9.6
Temperature
F
70 and above 21 and above
9.5
60
16
9.4
50
10
9.3
40
9.1
30
-1
BAlTERY
VlSUAL INSPECTION
(2)
Make sure ignition switch is in Off position and all battery
feed accessories are Off.
1. Disconnect ground cable from battery before disconnecting (+) cable.
2. Remove battery from vehicle.
Caution
Care should
be taken in the event battery
case is
cracked or leaking to protect hands from the electrolyte. A suitable
pair or rubber gloves (not the household type) should be worn when removing
battery by
hand.
3. Inspect battery carrier for damage caused by loss of acid
from battery. If acid damage is present, it will be necessary to clean area with a solution of clean warm water
and backing soda. Scrub area with a stiff bristle brush and
wipe off with a cloth moistened with ammonia or baking
soda in water.
4. Clean top of battery with same solutions, as described in
Step (3).
5. Inspect battery case and cover for cracks. If cracks are
present, battery must be replaced.
6. Clean the battery post with a suitable battery post cleaning tool.
7. Clean the inside surfaces of the terminal clamps with a
suitable battery terminal cleaning tool. Replace damaged
or frayed cables and broken terminals clamps.
8. Install the battery in vehicle.
9. Connect (+) and (-) cables to battery in the order of
mention.
10. Tighten the clamp nut securely.
OPEN CIRCUIT VOLTAGE TEST (3)
1. Turn headlamps on for 15 seconds.
2. Turn headlamps off for 2 minutes to allow battery voltage
to stabilize.
3. Disconnect cables.
4. Read open circuit voltage.
5. If the open circuit voltage is under 12.4 volts. charge the
battery. (See BATTERY CHARGING)
LOAD TEST (4)

1. Connect a load tester to the battery.
2. Load the battery at 15 amp for 15 seconds to remove
surface charges.
3. Load the battery at the recommended
discharge rate.
(See ROAD TEST RATE CHART)
4. Read voltage after 15 seconds then remove the load.
Note
5. If the voltage is not maintained at the minimum voltage in
The temperature is an ambient temperathe LOAD TEST CHART throughout
the test, the battery
ture of the battery that has been exposed
should be replaced.
to for the preceding few hours.
[ TSB Revisionhttp://vnx.su/
8-126
BAlTERY CHARGING
-0
Caution
When batteries
are being charged,
an explosive gas forms beneath
the cover of each cell.
Do not smoke
near batteries
on charge
or
which
have recently
been charged.
Do not
break live circuits at the terminals
of the batteries on charge. A spark will occur where the
live circuit
is broken.
Keep all open flames
away from the battery.
Battery
electrolyte
be allowed
electrolyte
temperature
Adjustment
NOTE
1. When the charging is performed
at 5 amperes,
charging is virtually 100% three hours after the
indicators
indication
changes
from white
or
blue.
Use fast charging only in an emergency.
If the indicator does not turn to blue even after
the battery is charged, the battery should be
2.
replaced; do not overcharge.

Charge Rate Chart
may
temporarily
Increase of
55C (131F) is
Battery
to rise to 55C (131F).

temperature
above
75D26R-MF
(490 A)
REMOVAL AND INSTALLATION <2.6L Engine>

Air Conditioner>
Adjustment of the Drive Belt
Tension (Refer lo GROUP 7 Service Adiustment Procedures1
Removal
steps
I. Connection
2. Alternator
3. Shim
of alternator connector
Sll
Ribs.
NOTE
http://vnx.su/
5AlOhrs.
/
ALTERNATOR
without
Slow charging
55B24R(S)-MF
(433 Al
harmful to the battery,

causing deformation
of
battery cell, decrease in life of battery, etc.
CHARGE RATE
If the test indicator is white, the battery should be
charged as outlined below.
When the dot appears or when maximum charge
shown
below
is reached,
charging
should be
stopped.
<Vehicles
Procedures/Alternator
20 A 2.5 hrs.
IO A5 hrs.
5A15hr.s.
lOA7.5
Fast charging
30 A I .5 hrs.
I
20 A 3.75 hrs.
hrs.
30 A 2.5 hrs.
CHARGING SYSTEM - Alternator

<Vehicles
with
Air Conditioner>
- Service Adjustment Procedures)
1.
2.
3.
4.
5.
6.
Connection
Connection
Connection
Compressor
Connection
Alternator
for high pressure hose

for low pressure hose
for compressor connector
for alternator connector
NOTE
Reverse
the remove1 procedures
to reinstall.
[EMOVAL AND INSTALLATION <3.OL Engine>
12-15 Nm
S-11 ftp.
_- -..--.
Service Adiustr
,
nent Procedures)
Removal
steps
1. Connection
2. Alternator
for alternator connector
NOTE
Reverse
the remove1 procedures
to reinstall.
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Revision
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8-127

)&ASSEMBLY AND REASSEMBLY
c2.6L
Engine>
7
c3.OL
Engine>
7ELoMo
Disassembly steps
*I)
1. Pulley
2. Seal
M
3.
4.
5.
6.
7.
8.
9.
10.
Rotor assembly
Rear bearing
Bearing retainer
Front bearing
Front bracket
Stator
Terminal
Plate
+*
il.
&&$ator
and brush holder
13:
14.
15.
16.
Brush spring
Slinger
Rectifier assembly
Rear bracket
NOTE
(2) **
(3) **
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8-129

REMOVAL
OF STATOR AND REAR BRACKET
Inset-t plain screwdriver
between
front bracket and stator
core and pry downward.
Caution
Do not insert screwdriver
too deep, as there is danger of
damage to stator coil.
1. REMOVAL
OF PULLEY
(1) Clamp the rotor in a vise with soft jaws.
(2) After removing the nut, remove the pulley and front
bracket from the rotor.
1El.109
11. REMOVAL
OF REGULATOR
AND BRUSH HOLDER
(1) Unsolder three stator leads soldered to main diodes
on rectifier.
(2) Unsolder two soldered points to rectifier.
Caution
1. When soldering
or unsoldering,
use care to
make sure that heat of soldering
iron is not
transmitted
to diodes for a long period. Finish
soldering
or unsoldering
in as short a time as
possible.
2. Use care that no undue force is exerted
to
leads of diodes.
INSPECTION
ROTOR
l
Check rotor coil for continuity. Check to ensure that there
is continuity between slip rings.
If resistance
is extremely small, it means that there is a
short. If there is no continuity or if there is short circuit,
replace rotor assembly.
Standard
value:
3-5 n
@EL116
TSB
Check rotor coil for grounding. Check to ensure that there

is no continuity
between
slip ring and core. If there is
continuity,
replace rotor assembly.
Revision
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STATOR
l
Make continuity test on stator coil. Check to ensure
there is continuity between coil leads.
If there is no continuity,
replace stator assembly.
that
Check coil for grounding.

Check to ensure that there is no
continuity
between
coil and core. If there is continuity,
replace stator assembly.
RECTIFIERS
l
Positive rectifier test
Check for continuity between positive rectifier and stator
coil lead connection terminal with a circuit tester. If there
is continuity in both directions, diode is shorted.
Replace rectifier assembly.
1ELllO
Negative
rectifier test
Check for continuity between negative rectifier and stator
coil lead connection terminal. If there is continuity in both
direction,
diode is shorted, and rectifier assembly
must
be replaced.
Diode trio test

Check three diodes for continuity
by connecting
a circuit
tester to both ends or each diode. If there is no continuity
or no continuity in both directions, diode is defective and
heatsink assembly must be replaced.
http://vnx.su/
8-737

REPLACEMENT
OF BRUSH
A brush worn away to the
procedure below.
limit
is replaced
using
the
Limit line
3ELOl5
(1) Remove
spring.
the pigtail solder and take out the old brush and
(2) Install brush spring and new brush in brush holder.

(3) Insert the brush to where there is a space 2-3 mm
(.079-.I18
in.) between the limit line and the end of the
brush holder.
(4) While maintaining

the position of the
pigtails to the end of the brush holder.
1%
Revision
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step,
solder
the
8-132
CHARGING SYSTEM
- Alternator

3.
Wire
INSTALLATION
OF ROTOR ASSEMBLY
(I) Push the brushes into the holder; then pass the wire
through the small hole in the rear bracket and the
small hole in the brushes.
(2) Install the front bracket and the rotor to the rear
bracket.
(3) Remove the wire.
Rear bracket
r TSB Revision
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LIGHTING
SYSTEM
8-l 95
Troubleshooting
Column switch
Light control
relay
(R.H.)
License
plate
kght
(L.H.)
Rear
combination
I#!&
Rear
combination
lit%.,
Remarks
(1) The broken lines are applicable to models equipped with
an automatic transmission.
(2) For information
1, refer to P-8-14.
(3) P he symbols 0, Q etc. indicate that the wiring is
connected (usrng the same numerical symbol) to the
facing page.
(In other words, @ on the right page is connected to @
on rhe left page.)
BACKUP
GW
6
D-23
37wBBl
LIGHTS
OPERATION
l
When the gearshift
lever is moved to R
position,
with the ignition switch
turned to
ON, the backup light switch (manual transmission vehicles) or inhibitor switch (automatic
transmission
vehicles) is closed, allowing current to flow through fuse No. 4 (manual transmission vehicles),
3 (automatic
transmission
vehicles), backup light switch
or inhibitor
switch, backup lights, and ground.

the backup lights to go on.
This causes
TSB
Revision
TROUBLESHOOTING
HINTS
1. Only one backup light does not go on
l
Check bulb
2. Backup light fail to go off
l
Check
backup
light switch.
- Manual
http://vnx.su/
transmission vehicles.
l
Check inhibitor switch.

mission vehicles.
- Automatic
trans-
LIGHTING SYSTEM - Troubleshootins

INSTRUMENT PANEL ILLUMlNATlON
:IRCUIT DIAGRAM
<2.6L Engine>
_ili
-- ~7
fusible
link
Optical
fiber
knob
I
I
Dimmer
Ashtray
illumination
light
&
4 - --Mter
illumination
Cigarette
Heater control
9
illumination
lighter
illun ;ination light
illumination
light
~.
m
gnl&
&J
gQ
light
Y&Y
Remarks
(1) The broken lines are applicable to models equipped with an automatic transmission.
(2) For information concerning the ground points (example: 01, refer to P.8-12, 14.
http://vnx.su/
I Rear def@ger
I switch
--
control
switch
LIGHTING SYSTEM - Troubleshootina
Engine>
Main
fusible
link
CL
t-4
B-88 []
&
S-A
Optical
fiber
To railo
I -
Column
switch
firinicplor
Li: Light blue
code
Br: Brown
0: Orange
;: ;rken
:
TSB Revision
http://vnx.su/
L: Blue
Y: Yellow
Lg: Light green

W: White
8-198
LIGHTING SYSTEM - Service
Adjustment
Procedures
SERVICE ADJUSTMENT PROCEDURES

HEADLIGHT AlMlNG
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Calibration fixture
Thumb adjusting screws
Level vial
Floor level offset dial
Horizontal dial knob
Vertical dial knob
Aimer level vial
Level vial bubble
Top pot-t hole
Viewing port
hrrm-l
Split image
not aligned
c:)j
Bubble
168024!
E!llE3
Split image
aligned
6-3
not centered
Bubble centered
1660246
PRE-AIMING
INSTRUCTlONS
1. Test dimmer switch operation.
2. Observe operation of high beam indicator light mounted
in instrument
cluster.
3. Inspect for badly rusted or faulty headlight~assemblies.
These conditions must be corrected before a satisfactory
adjustment
can be made.
4. Place vehicle on a level floor.
5. Jounce front suspension through three (3) oscillations by
applying body weight to hood or bumper.
6. Inspect tire inflation.
7. Rock vehicle sideways
to allow vehicle to assume its
normal position.
8. If fuel tank is not full, place a weight in trunk of vehicle to
simulate weight of a full tank [3 kg (6.5 Ibs.) per gallon].
9. There should be no other load in the vehicle other than
driver or substituted
weight of approximately
70 kg (150
Ibs.) placed in drivers position.
10. Throughly clean headlight lenses.
11. Adjust headlights
by following
the instrutitions
for the
headlight tester manufacturer.
LUMINOUS
INTENSITY
MEASUREMENT
fvleasure the luminous intensity of headlights
with a phtometer in accordance with the instruction manual prepared by
the manufacturer
of the photometer
luminous intensity is within the following limit.
Luminous
intensity at the center of high intensity zone for
high beam.
Limit: 20,000 cd or more
NOTE
1. When measuring
the luminous
intensity
of headlight.
keep the engine at 2,000 rpm and have the battery
charged.
2. If there are specific regulations for luminous intensity of
headlihgts
in the region where the vehicle is operated,
make sure that the intensity conforms
to the requirements of such regulations.
1 TSB Revision
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1 .:
=?s!x
-
!
1
L16HTlNGmSYgTEM - Headlight
I
HEADLIGHT
0 Adjustment
of Headlight
NMIUAE
Aiming
=
m
Renroval
steps
I. kadiator grille
2.
3.
4.
5.
NOTE
Reverse
Front combination
Headlihgt bezel
Rataining -ring
Headlight
the removal
procedure
light
to reinstall.
16W963
INSPECTION
HEADLIGHT
CONTROL RELAY
Remove the headlight control relay from the inner side of the
left fender shield.
For models equipped
with headlight washers,
remove the
headlight washer tank, and then remove the headlight control
relay.
Check for continuity

between
the terminals
being supplied and while it is not.
while
power
16W896
NOTE
-
(1) O-O indicates that there is continuity between

terminals.
(2) CD;ZDyindicates
aII
=
I
L(fjT! k@
lSW897
Revision
http://vnx.su/
the connection
with
the power
the
is
8-200
LlGHTlNG SYSTEM - Column Switch
COLUMN
SWITCH

6
HEWA&
2
35-45 Nm
8-202
LIGHTING SYSTEM -
Hazard Wring
Switch/Dimmer
Control Switch

1. HAZARD WARNING
SWITCH
Insert the trim stick into the switch and pry the switch
remove it from the instrument
panel.
to
INSPECTION
Operate the swtich
terminals.
and check
the continuiv
between
I lIndi-l
NOTE
C-0
indicates that there is continuity between the
terminals.
DIMMER CONTROL SWITCH

Removal
steps
1. Knob
2. Ring nut
3. Dimmer control switch
http://vnx.su/
the
8-201
LIGHTING SYSTEM - Column Switch/Hazard Wiring Switch

INSPECTION
Remove the steering lower column cover, and then detach

the connector of the column switch from the wiring harness.
Operate the switch an check the continuity between the
terminals.
LIGHTING SWITCH
7
lbW15DS
OFF
<WE
EO
0
A
NOTE
O-O Indicatesthat there is continuity between the

terminals.
DIMMER-PASSINCi SWITCH
Terminal
,4
,0
16W1530
--
DI
NOTE
O-O indicates that there is continuity
terminals.
between
the
TURN SIGNAL SWITCH

22
21
16
Neutral
Right
NOTE
O-O Indicates that there is continuity
terminals.
HAZARD WARNING SWITCH

Qor)
NOTE.
cc*
1. Hazard warning switch

i
TSB Revision http://vnx.su/
between
the
Ymu!!r!!
8-202
LIGHTING SYSTEM -
Hazard
Wiring
Switch/Dimmer
Control
Switch

1. HAZARD WARNING SWITCH
Insert the trim stick into the switch and pry the switch to
remove it from the instrument panel.
INSPECTION
Operate the swtich and check the continuity between the
terminals.
l\Terminal 1 I I I I I I I I I IIndi-!I
NOTE
O-O Indicates that there is continuity
terminals.
16Wl604
between the
DIMMER CONTROL SWITCH

Removal
steps
1. Knob
2. Ring nut
3. Dimmer control switch
NOTE
16W936
INSPECTION
(1) Measure
the continuity
between
the
switch terminals with an ohmmeter.
(2) If the resistnace
value varies smoothly
dimmer
between
control
0 and
100 throughout the entire operation range, the dimmer

control switch is functioning properly.
16F68
r-E
levision
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AUTOMATIC FREE-WHEELING HUB INDICATOR SYSTEM - specifications
AUTOMATIC
FREE-WHEELING
HUB INDICATOR
8-261
SYSTEM
SPECIFICATIONS
NcmsSpecifications
Pulse generator
Type
Vehicle-speed
hub indicator light
W (SAE trade number)
1.4(74)
Magnet coil type
sensor
Reed switch type
4 pulses/rotation
Twe
Pulse generation
SERVlCE SPEClFlCATlONS
NOWiG
II terns
Specifications
Standard values
Pulse generator resistance
fi
Vehicle-speed sensor output voltage
When OFF
When ON
215-275
V
4 or more
0
1 TSB Revision
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8-262
AUTOMATIC FREE-WHEELING HUB INDICATOR SYSTEM
Tmubleshooting
TROUBLESHOOTING
AUTOMATIC FREE-WHEELING HUB INDICATOR SYSTEM CIRCUIT
Nr!aR~
DIAGRAM
-
@nitvan switch
Remarks
(1) Lines and connectors indicated by the * symbol are applicable to the Xi-liter
models.
(2) For information
concerning the ground points (example: q l. refer to P.8-12. 14.
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
L: Blue
Y: YWlow
OPERATION
automatic
free-wheeling
hub indicator control
l
When the ignition
switch
is placed in the
unit
and
the
ground,
lighting
the automatic
ON position, battery voltage will go to the
free-wheeling-indicator
light.
automatic
free-wheeling
hub indicator control
unit through fuse No. 3.
o When the vehicle is stopped in this situation,
the pulse signal and vehicle speed signal are
* When driving with the free-wheeling
hub in
not
input, and the contrl unit memory circuit
the LOCK position, the pulse signal from the
leaves
the indicator light on.
pulse generator
and the vehicle speed signal
from the vehicle speed sensor will be input
l
When driving with the free-wheeling
hub in
into the control unit.
the FREE position, the pulse signal is not
input to the control unit causing the control
l
When vehicle
speed
increases
over about
unit to go OFF and the indicator light to go
Skm/h (3 mph), the control
unit goes on,
out.
electrical current flows to fuse No. 3, the
:
-w
1 TSB Revision
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AUTOMATJC FREEWHEELING HUB INDICATOR SYSTEM - pulseGenerator
8-263
PULSE GENERATOR
I
Removal
steps
1. Pulse generator
2. O-ring
NOTE
(2) m
I
INSPECTION
1ewo92
Check whether
Check whether
or not the installation
bolts of the pulse
rotor or the pulse generator are loose.
(For detailed information
concerning the pulse rotor, refer
to GROUP 21 - Transfer.)
or not metal particles

pole (iron core) of the pulse generator.
are adhered
to the
CHECKING PULSE GENERATOR

RESISTANCE
Check whether or not the resistance between the terminals
shown in the figure is within the standard value range.
Standard
value:
215-275
0
If the resistance
is not within the standard value range,
replace the pulse generator.
TSB Revision
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---
-.
8-264
_ .~
AUTOMATIC FREE-WHEELING HUB INDICATOR CONTROL UNIT - cmtmtunit
AUTOMATIC FREE-WHEELINGHUB INDICATOR CONTROL UNIT

Removal steps
1
1. Glove compartment stopper
2. Automatic free-wheeling hub indicator
control unit
lewlssa
NOTE
Reverse
the removal
procedures
to reinstall.
CHECKING OUTPUT VOLTAGE OF THE VEHICLESPEED SENSOR (REED TYPE SWITCH)

1. Turn the ignition key to ON.
2. Insert a test probe from the rear side of the conncetor of
the automatic free-wheeling
hub indicator control unit.
3. Measure the output voltage of the vehicle-speed
sensor
when the vehicle is moved a distance of about 0.5 m
(1 Bft.).
Standard
values:
Vehicle-speed
Vehicle-speed
sensor
sensor
OFF: 4V or higher
ON: OV
If there is a malfunction
of the vehicle-speed
sensor,
replace it by replacing the speedometer
assembly.
I TSB
Revision
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RJST808D13-284
NOTE
http://vnx.su/
NOTE
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24-1
HEATERS
AND
AIR CONDITIONING
CONTENTS
AIR CONDITIONING
.............................
17
AIR CONDlTlONER
SWITCH ........................
COMPRESSOR
.............................................
FRONT EVAPORATOR
.................................
REAR EVAPORATOR
....................................
......................................
REAR FAN SWITCH
REAR VENTILATORS
...................................
RECEIVER DRIER, CONDENSER,
COMPRESSOR
CLUTCH ASSEMBLY
.........
SAFETY PRECAUTIONS
...............................
SERVICE ADJUSTMENT
PROCEDURES
.....
Compressor Drive Belt Adjustment
...........
Compressor Noise .....................................
Handling Tubing and Fittings .....................
Manifold Gauge Set Installation
................
Performance Test ......................................
Refrigerant Leak Repair Procedure
...........
........................................
Test Procedures
Testing System for Leaks ..........................
SPECIAL TOOLS ...........................................
SPECIFICATIONS
.........................................
...............................
...............................
................................
TROUBLESHOOTlNG
...................................
Air is Emitted but is Not Cool
Cool Air Flow is Intermittent
Insufficient Air Flow
Insufficient Cooling
44
55
45
48
45
52
53
31
32
43
44
42
32
36
37
32
36
18
17
17
17
17
18
HEATERS *.....*.....,..........................,.*....
N.?4AA2
BLOWER ASSEMBLY
.. .. . . . . .. . . . . . . . .. .. .. . . . . ..a..... 13
HEATER CONTROL
. . . . . . . .. . . . . . . .. . . . . . ..a.............
8
HEATER UNIT . . . . . . . . . . . . .. . .. . . . .. .. . . . . . . . . . .. .. . . . . . . . . . . 11
SERVICE ADJUSTMENT
PROCEDURES
..... 5
Temperature
Control System
Adjustment
. . . . . . . . . . . . . .._._...............-....-.........
5
Water Valve Replacement
. .. .. . . . . . . . . .. . . . ..~.~.. 7
SPECIFICARONS
. . . .. .. .. .. .. . .. . .. . . . . . . . . . .. . . . . . . . . . .. 2
_._..._.._..________
_._........ 2
TROUBLESHOOTING
. . . . . . . ..*.......*..........*......
2
Improper Heat
No Ventilation Even When Mode
Selection Lever is Operated
VENTILATORS
. . . . . . . . . .. .. . . .. . . .. . . . . . . . . . . . . . .. . . . . . . . . . . 14
http://vnx.su/
24-2
HEATERS
- Specifications
/ Troubleshooting
HEATERS
SPECIFICATIONS
N24cA.A
Items
Specifications
Type
Performance
Selective recirculating, warm water type (air-miytype)

17,372(4,150, 16,468)
kJ/h (kcal/h. B.T.U./h)
Pd24SUl
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Improper heat
Obstructed
Correct
floor outlets
Changeover dampers improperly

adjusted or binding
Correct
Obstructed
Replace
Adjust
heaters hoses
Improperly &usted
control cables
Plugged or partially plugged heater core mz Clearn or replace

No ventilation even
when mode selection
lever is operated
dampers
Adjust
of changeover
:
Incorrect installation mode selection

control wire
Ducts are incorrectly incompletely
connected, crushed, bent or clogged.
Adjust
---~ Repair or replace
http://vnx.su/
HEATERS
HEATER
CIRCUIT
24-3
- Troubleshooting
CIRCWT
DIAGRAM
c2.6L
Engine>
Ignition switch
Remark
For information concernin
the ground points (example:
En,). refer to GROUP E&ectncal
System Parts Loch
wiring color code
B: Black
Br: Brown
U: Light blue
0: Orange
G: Green
P: Pink
OPERATION
l
When the ignition switch is at ON, current
flows through fuse No. 3, heater relay (coil),
and ground, causing the heater relay contacts
to close.
l
Then when the blower switch is set at any of
L, M,, I, MY, or H, current flows through
fuse No. 6, heater relay (contacts),
blower
switch,
resistor,
blower
motor, and ground,
causing the blower motor to rotate.
TROUBLESHOOTING
Blower motor turns
l
Check resistor.
1 TSB Revision
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HINTS
only at high speed.
24-4
HEATER
HEATERS
- Troubleshootinn
CIRCUIT
CIRCUIT DIAGRAM <3.OL Engine>
SK Brawn
il: L&M blue
0: OEdlQe
OPERATION
l
When the ignition switch is at ON, current
flows through fuse No. 3, heater relay (coil).
and ground, causing the heater relay contacts
to close.
l
Then when the blower switch is set at any of
#y-m, M, .,, I,
MY, or H, current flows through
fuse No. 6, heater relay (contacts),
blower
switch, resistor,
blower motor, and ground,
causing the blower motor to rotate.
1 TSB Revision
TROUBLESHOOTING
Blower motor turns
8 Check resistor.
http://vnx.su/
~c
HINTS
only at high
speed.
HEATERS
Service
Adjustment
SERVICE ADJUSTMENT
gEi-EMl;ERATURE
24-5
Procedures
CONTROL
PROCEDURES
SYSTEM
ADJUSTN24Fc99
MODE SELECTION LEVER

1. Move the mode selection lever to each position and check
the air flow with the blower operating.
2. If the air flow is not correct for any position of the mode
selection lever, adjust the mode selection control wire. If
this adjustment
does not help, adjust the damper.
Adjustment
of the Mode Selection
Control Wire
1. Disconnect the defroster duct and the lap heater duct (B)
at the drivers seat side from the heater unit.
2. Disconnect
the mode selection
control wire from the
mode selection damper lever and the heater units clip.
3. Set the mode selection lever of temperature

control
q
position.
4. Turn the mode selection damoer lever all the way
direction of the arrow.
5. Connect the mode selection
control wire to the
selection damper lever. and to the clip part of the
unit.
Caution
Be careful
that the lever does not move
when
to the
in the
mode
heater
clipping.
6.
Check to be sure that the mode selection

lever moves
smoothly to each position and that the air flow is correct
for each position.
7. If the air flow is not correct for any position of the mode
selection lever even after the mode selection control wire
has been adjusted, adjust the VENT damper and the
FOOT/DEF
damoer.
8. Connect the drivers side defroster duct and lap heater
duct (B) to the heater unit.
Adjustment
of the Damper
1. Disconnect
the. mode selection
control wire from the
mode selection damoer lever and the heater units clip.
2. Adjust the VENT damper as described
below:
(1) Unfasten the clip of the mode selection damper lever,
and disconnect
the link for the VENT damper from
the mode selection
damper lever.
levision
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m-.*.-
24-6
HEATERS - Service Adjustment
Procedures
(2) Turn the mode selection
damper lever all the way in the

direction of the arrow.
(3) Pull the VENT damper lever completely
downward
and move the VENT damper to the position (not
visible) shown in the figure.
(4) Attach the end of the link for the VENT damper to the
mode selection damper lever.
3. Adjust the FOOT/DEF

damper as described below.
(1) Unfasten the clip of the mode selection damper lever,
and disconnect
the link for the FOOT/DEF
damper
from the mode selection
damper lever.
(2) Turn the mode selection damper lever all the way in the
direction
of the arrow.
(3) Pull the FOOT/DEF damper lever completely

upward
and move the FOOT/DEF
damper to the position
shown in the figure. (The packing should contact the
case.)
NOTE
Confirmation
can be made that the FOOTKIEF damper is raised upward through the defroster blower outlet
of the heater unit (with defroster duct disconnected).
(4) Attach the end of the link for the FOOT/DEF

to the mode selection damper lever.
damper
NOTE
When attaching it, pull the lever end (A in the figure) in
the direction of the arrow.
4.
Referring to the section which explains the adjustment

of
the mode selection control wire, connect the control wire
to the mode selection damper lever.
TEMPERATURE CONTROL LEVER

1. Move the temperature
control lever from its extreme left
position to its extreme right position and check to be sure
that it moves correctly and smoothly to each position.
2. Then move the temperature
control lever to the extreme
left position, and check to be sure that warm air does not
come out when the blower is operated.
3. If the air flow is not correct in the above step, adjust the
temperature
control wire.
1 TSB Revision
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:f
HEATERS
Procedures
24-7
Adjustment
of the Blend Air Damper
1. Move the warm water flow control lever to the extreme left
position.
2. Disconnect the water valve control wire from the blend air
damper lever and the heater units clip.
3. Remove the water valve cover.
4.
Unfasten the clip of the blend air damper lever, and

disconnect the link for water valve lever from the blend air
damper lever.
5. Push the water valve lever all the way inward so that the
water valve is at the closed position.
6. Turn the blend air damper lever all the way in the direction
of the arrow so that the blend air damper is completely
closed at the lower most position.
7. Attach the end of the link for the water valve lever to the
blend air damper lever.
8. Install the water valve cover.
9. After connecting
the water valve control wire to the blend
air damper lever, connect to the clip part of the heater unit.
Caution
Be careful
that the lever does not move when
IO. Check to be sure that

operates smoothly at each
that the blend air damper
temperature
control lever
position and the extreme
WATER
VALVE
clipping.
the temperature
control
lever
position. Also check to be sure
is completely closed when the
is moved to the extreme left
right position.
REPLACEMENT
W4FBAF
1. Set the temperature

control lever to the extreme right
position.
2. Remove the radiator drain plug, and then drain the engine
coolant.
3. Remove the air cleaner <2.6L Engine>
4. Remove the air intake plenum <3.OL Engine>
(Refer to GROUP II-Air
Intake Plenum)
5. Remove the heater hose clamp to disconnect the heater
hose.
1 TSB Revision
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,.
_,.,.
HEATERS
=_
Procedures
/ Heater Control
6.
Disconnect the water valve control wire from the blend air
damper lever and the heater units clip.
7. Remove the water valve_cover.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Remove the piping clamp.

Unfasten the clip of blend air damper lever, and disconnect the link for the water valve lever from the blend air
damoer lever.
Remove the joint hose clamp.
Cut the joint hose.
Remove the water valve from the heater core.
Apply a coating of soapywater
to the inside surface of the
new joint hoses, and then connect them to the pipe part
of the water valve and the heater core.
Connect the link, and then install the heater cover.
Close the radiator drain plug and refill the engine cooling
system with coolant.
Check operation.
-
HEATER CONTROL
REMOVAL
AND
N24GA-
INSTALLATION
?
Removal
*+
l +
steps
1. Glove box stoppers
2. Air selection
control
8.
9.
10.
11.
12.
Defroster
duct
Mode selection
conlrol
wire
Water valve control
wire
Heater control
assembly
Blower
switch
wire
++ e)+
*c+~**
++
panel wiring
harharness
connector
NOTE
(2) *I,
13) +41 : Refer tu Service Points
3. Knobs
4. Pluas
5. Center panel
6. Connection
of center
ness to front wiring
7. Lap heater duct (B)
( TSB Revision
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to reinstall.
of Removal.
of Installation.
--1
B&z.
=i
HEATERS
24-9
- Heater Control
SERVICE
POINTS
N24GBu
OF REMOVAL
2.
REMOVAL
OF AIR SELECTION
CONTROL WIRE
(1) Use a screwdriver
to pry and remove the clip that
holds the outer cable of the air selection control wire.
(2) Disconnect the inner cable of the air selection control
wire from the end of the recirculation/fresh-air
changeover damper lever.
9.
REMOVAL
OF MODE SELECTION
(1) While using a screwdriver to pry
outer cable of the mode selection
outer cable to remove it from
(2) Disconnect
the inner cable of
control wire from the end of
damper lever.
CONTROL WIRE
the clip that holds the
control wire, pull the
the clip.
the mode selection
the mode selection
10. REMOVAL
OF WATER VALVE CONTROL WIRE
(1) Use a screwdriver to pry and remove the clip that holds
the outer cable of the water valve control wire.
(2) Disconnect the inner cable of the water valve control
wire from the end of the water valve control lever.
INSPECTION
BLOWER SWITCH
Operate the switch,
minals.
lW4GCACI
and check the continuity
between
NOTE
0-O indicates that there is continuity between the terminals.
2OW7Oi
svision
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the ter-
HEATERS - Heater Control

Top view
Bottom
11. APPLICATION
SEMBLY
OF GREASE
TO HEATER CONTROL

grease to all the moving
the heater control assembly.
2OW553
view
AS-
parts of
2OWS.34
10. INSTALLATION
OF WATER VALVE CONTROL WIRE
Connect the water valve control wire to the water valve
control lever by following
the steps below.
(1) Move the temperature
control lever to the extreme left
position.
(2) With the water-valve
control lever pressed inward in
the direction indicated by the arrow, connect the inner
cable of the water-valve control wire to the end of the
water-valve
control lever, and then secure the outer
cable by using a clip.
\
2OW75C
9.
INSTALLATION
OF MODE SELECTlON CONTROL WIRE
Connect the mode selection
control wire to the mode
selection
damper lever by following
the steps below.
(1) Move the mode selection
lever to the-Z
position.
(2) With the mode selection damper lever pressed inward
in the direction indicatecl
by the arrow, connect the
inner cable of the mode selection control wire to the
end of the mode selection lever, and then secure the
outer cable by using a clip.
2.
INSTALLATION
OF AIR SELECTION
CONTROL WIRE
Connect the air selection control wire to the air selection
damper lever by following
the steps below.
(1) Move the air selection control lever to the &3 position.
(2) With the air selection damper lever pressed inward in
the direction indicated by the arrow, connect the inner
cable of the air selection control wire to the end of the
air selection lever, and then secure the outer cable by
using a clip.
TSB Revision
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HEATERS - Heater
24-11
Unit
HEATER UNIT
NZ4lA..

Pre-removal
Draining
($&reo
l
l
Operation
of Coolant
GROUP 0 - Maintenance
Removal of the Air Cleaner

<2.6L Engine>
Removal of the Air Intake Plenum
<3.OL Engine> (Refer to
GROUP 11 - Air Intake Plenum)
Post-installation
Operation
l
Installation of the Air Cleaner
<2.6 iL Engine>
. I<+2 llation of the Air Intake Plenum
<3.OL Engine> (Refer
.-.---- to-Intake Plenum)
GROUP 11 -Air
0 Supplying
of Coolant
Service)
,,
..-
2OW823
Removal
steps
+*
1. Heater
hose connection
2. instrument
panel
**
N.OTE
(2) +*
(3) I)*
3. Duct
4. Center
5. Heater
ventilator
unit
duct
to reinstall.
of Removal
of installation.

2.
REMOVAL
Refer
OF INSTRUMENT
PANEL
to GROUP 23 - Instrument
Panel.
INSPECTION
l
a
l
NUIBAN
tu41cAA
Check the damper and link mechanism

for operation.
Check the heater core for clogging or water leakage.
Check the water valve for operation and clogging.
j TSB Revision
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24-12
HEATERS - Heater
Unit
HEATER CORE REPLACEMENT

1. Remove
2.
the water
valve cover.
Remove the fcllowing

(1) Piping clamp
(2) Water valve link
(3) Joint hose clamp
(4) Joint hose
(5) Screw
parts to remove
the water
valve.
3.
Remove the FOOT/DEF-damper

link from the mode
selection
damper lever.
4. Move the damper lever to the position at which the mode
selection damper lever does not protrude very much to the
heater core side.
5.. Remove the heater core. If at this time the damper lever
and heater core are in contact, making removal difficult,
remove the damper lever.
Caution
To prevent interference
between
the heater core and
case, use care not to peel the heater core felt away
when the heater core is removed.
6. After installing the heatercore
and water valve, install the
link for each damper
after referring
to the Service
adjustment
procedures
section.

2. INSTALLATION
OF INSTRUMENT
Refer to GROUP 23 - Instrument
1 TSB Revision
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PANEL
Panel.
24-13
HEATERS - Blower Assembly
BLOWER
ASSEMBLY

Removal
steps
1. Lap heater duct (C)
2. Glove
++ I)+
box
3. Air selection
control wire
4. Duct
*I)
5. Blower assembly
6. Resistor
7. Hose
8. Blower motor
9. Packing
IO. Fan
TE
**
: Refer to Service
Points
**
-6
to reinstall.
of Removal.
of Installation
2OW606
N24K6A

3.
REMOVAL
OF AIR SELECTION
CONTROL WIRE
(1) Use a screwdriver
to pry and remove the clip that
holds the outer cable of the air selection control wire.
(2) Disconnect
the inner cable of the air selection control
wire from the end of the air selection damper lever.
5. REMOVAL
OF BLOWER ASSEMBLY
(I) Disconnect
the connector of the front wiring harness
(connected
to the resistor).
(2) Remove the ground installation bolt. (Tightened together with the blower assembly.)
(3) Remove the blower assembly installation
bolt.
INSPECTION
NZMCAD
RESISTOR
Connect an ohmmeter
to each terminal
measure the resistance.
Terminal connections
I-2(M,)
Approx.
1.22n
1-3(Mz)
Approx.
0.41R
Approx.
2.250
Approx.
OQ
I-4(Low)
. a
Revision
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and
Resistance
1 -5(High)
rTSB
of the resistor
24-14
HEATERS - Blower Assembly / Ventilators

BLOWER MOTOR
(1) Connect the blower motor terminals directly to the battery
and check that the blower motor operates smoothly.
(2) Next, reverse the polarity and check that the blower motor
operates smoothly
in the reverse direction.

3.
INSTALLATION
Refer
OF AIR SELECTION
CONTROL
to P. 24-10.
VENTILATORS
REMOVAL AND INSTALLATON
Removal
steps
*+
1.
2.
3.
4.
5.
6.
7.
9.
++
++
c+
*+
*+
*+
(Ventilators
Demister grille
Lap heater garnish
Lap heater duct (B)
Lap heater duct (C)
Defroster duct (L.H.)
Lap heater duct (A)
Defroster duct (R.H.)
Air duct [R.H.) (Only vehicles with air
conditioner)
9. Lap heater duct (A)
10. Air duct (L.H.) (Only vehicles with air
conditioner)
of instrument
++
Il.
12.
13.
14.
15.
16.
17.
panel)
Instrument panel
Defroster duct
Center ventilator duct
Center air outlet
Knob
Air duct
Side air outlet
cyTEeverse the removal procedures to reinstall.

.-
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NSKOAG
WIRE
24-15
HEATERS - Ventilators
W?4MBAG#
I.
REMOVAL
OF DEMISTER GRILL
While using a screwdriver to pry the lock of the demister
grill, use another screwdriver
to pry the end of the
clemister grill to remove it.
2.
REMOVAL
OF LAP HEATER GARNISH
While using a screwdriver to pry the lock of the lap heater
garnish, use another screwdriver to pry the end of the lap
heater garnish to remove it.
6.
REMOVAL
OF LAP HEATER DUCT (A)
Remove the screw at the side of the instrument
then remove the lap heater duct (A).
panel, and
7.
REMOVAL
OF DEFROSTER DUCT (R.H.)/8.
(R.H.)
(1) Open the glove box lid.
(2) Remove the glove box stopper.
(3) Pull the glove box outward.
(4) Remove the defroster
duct (R.H.)
(5) Remove the air duct (R.H.)
9.
REMOVAL
OF LAP HEATER DUCT (A)
(1) Remove the center panel. (Refer to GROUP 23 - Floor
Console)
(2) Remove the heater control assembly. (Refer to P.24-3.)
(3) Insert a hand through
the heater control assembly
installation
hole in the instrument
panel, and remove
the installation
screw of the lap heater duct (A).
TSB Revision
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AIR DUCT
24-16
HEATERS
- Ventilators
10. REMOVAL
OF
(1) Remove the
Meters and
(2) Remove the
AIR DUCT (L.H.)

combination
meter.
Gauges)
air duct (L.H.).
(Refer to GROUP 8 -
I 1. REMOVAL
OF INSTRUMENT
PANEL
Refer to GROUP 23 - Instrument
Panel.
REMOVAL
Removal
AND
INSTALLATION
(Rear heater
ducts)
steps
1. Floor console
2. Front seat
3. Rail cover
4. Carpet
5. Rear heater duct (B)
6. Rear heater duct (A)
NOTE
Reverse the removal prczedures to reinstall.
\ TSB Revision
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W4MA.B
AIR CONDITIONING
24-17
- Specifications
AIR CONDlTlONING
SPECIFICATIONS
N2dCA.E
Items
2.6 L Engine
Compressor
Model
No. of cylinders and displacement
Compressor oil
cc (fl.oz.)
cc (fl. oz.)
High pressure relief valve

kPa (psi)
Open
Close
Protective equipment
Cycling clutch switch
C(F)
OFF
ON
Dual pressure switch
kPa (psi)
Low-pressure side
OFF
Differential
High-pressure side
OFF
ON
C(F)
OFF
ON
Freezer prevention [Air temperature thermistor]
OFF
ON
Fusible plug (Bum out temperature)
C(F)
Refrigerant and quantity
g (oz.)
3.0 L Engine
6P148 Inclined-plate type

6 cylinders 148 (5.0)
DENS0 oil 6
1 IO (3.7)
lOPAl Inclined-plate type

10 cylinders 155.3 (5.3)
DENS0 oil 6
8Oi20 (2.7-cO.6)
3.160-4.220 (449-600)
2.810 (400)
3.160-4.220 (449-600)
2,810 (400)
1.o (22)
4.5 (39)
1.o (22)
4.5 (39)
21o-c20 (3023)
25 (3.6) or less
ZlO-e20(30%3)
25 (3.6) or less
2,700 ? 200 (384 I 28)

2.100 zt 200 (299 + 28)
2.7OO-e200(384-~28)
2,100 -c 200 (299 2 28)
113+3(235r5)
106 (223)
115-c3(239*5)
108 (226)
1 (22)
4.5 (39)
Burn out temperature 106 (222)
R-12 SlO(32)
1 (22)
4.5 (39)
Burn out temperature 106 (222
R-12 910 (32)
C(F)
N24cB2.6 L Engine
Items
Standard value
Drive belt deflection
mm (in.)
When a new belt installed
When a used belt installed
Pressure plate to rotor clearance
mm (in.)
Air conditioner idle-up engine speed
vm
13-15 (.51-.59)
17-20 (.67-.78)
0.4-0.7(.016-,028)
900
3.0 L Engine
5.0-6.0 (.20-.24)
8.5-9.5 (.33-.37)
0.35-0.65 (.0138-.0256)
900
?UdCC-
Items
Nm
ft.lbs.
Suction line to cooling unit

Liquid line to cooling unit
Liquid line to receiver drier
Suction line to suction hose
3035
12-15
12-15
3035
22-25
S-1 1
S-11
22-25
Liquid line to liquid pipe

Liquid line to condenser
12-15
9-11
20-25
15-18
1 TSB Revision
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24-18
AIR CONDITIONING
- Specifications
/ Special Tools / Troubleshooting
Items
Nm
fi.ibs.
30-35
20-25
20-25
15-17
22-25
15-18
15-18
-.
Suction line to Gompressor

Discharge line to compressor
Discharge line to liquid pipe
Compressor shaft nut
Through hoit
11-13
16-20
26-26
SPECIAL TOOLS
Tool
Number
Name
use
MB990%33-01
Steering pinion i&a;

remover/installer
Installation of seal plate
TROUBLESHOOTING
?4aEsAM
Before replacing or repairing air conditioning

components, first determine if the malfunction
is; due
to refrigerant
charge, air flow, or compressor
related.
The following
diagnostic
charts
have
been
developed as a quick reference and in determinMALFUNCTlON
CAUSES AND REMEDIES
ing the cause of malfunction.

If these charts do not
satisfactorily
describe the problem,
refer to appropriate section for detailed explanation.
After correcting
the malfunction,
check out the
complete
system to assure satisfactory
performance.
(Numbers
-4
indicate
checking/inspection
l.Check
the fuse (2OA)
order.)
l-l
Replace
---)
Replace
Replace
3.Check the air conditioner

switch
4.Check the low pressure

switch
5.Check the thermistor

and air conditioner
-c
relay
6.Check the blower

switch
--I
ICheck the blower motor
relay
Replace
l-l
1
>
Replace
SEE NEXT PAGE
[ TSB Revision
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;
e
AIR CONDITIONING
24-19
Troubleshooting
CONTINUED FROM PREVIOUS PAGE
lnsufficient
cooling
-e
P.lnsufficient refrigerant
Check the refrigerant
3Receiver drier clogged
Check the receiver drier
4.Abnormal rotation
compressor
Check the drive belt tension
-+
6Expansion valve clogged
6.Poor compression of
compressor
of
amount
-r
Supply
refrigerant
a Replace
tPt
_
Check the expansion valve
Replace
Check the compressor
-)
Replace
Check the refrigerant amount
Supply
refrigerant
Remove
excess
refrigerant
Check the drive belt tension
A&st
Replace
l.lnsufficient
refrigerant
PReceiver drier
clogged
Check the receiver drier
3.Condenser surface clogged
Check the fin surfaces
--c
4.Excessive
refrigerant
. Check the refrigerant
compressor
the
amount
the
6.Poor compression of
compressor
7.Air in unit
Measure the pressure
ApPlV
vacuum;
supply
refrigerant
8.Expansion valve clogged
Check the expansion valve
Replace
1 TSB Revision
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24-20
AIR CONDITIONING
7
Insuf__
ficient
air flow
;z
:
interm&tent
- Troubleshooting
1 .Leakage at a duct
joint
2,Evaporator frost
-,
3.Blower motor malfunction

1.Air in refrigerant
-.
Check the duct joint _
-)
Replace
Measure the pressure
APP~V
vacuum;
supply
refrigerant
Z.Expansion valve
malfunction
+ Check the expansion valve
1 TSB Revision
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Replace
AIR CONDITIONING
SINGLE
AIR CONDITIONER
CIRCUIT
DIAGRAM
<2.6L
24-21
- Troubleshooting
CIRCUIT
Engine>
Ignition switch
Main
Kbte
&mition
vuiring color coda

Br: Brown
B: Black
LI: Light blue
0: Orange
witch)
G: Green
P: Pink
OPERATION
Blower Control
Refer to the Heater section.
Compressor
Control
l
Battery voltage is always applied to the heater
relay (contacts),
air conditioner
relay A (contacts), and the condenser
blower motor relay
(contacts).
l
When the ignition key is turned to the ACC
position,
current flows to fuse No. 10, air
conditioner
relay B (coil), and ground, and the
contacts of air conditioner
relay B close.
( TSB Revision
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When the ignition key is turned to the ON

position, current flows to fuse No. 3, the heater
relay (coil), and ground: the contacts of the
heater relay then close, and, at the same time,
battery voltage
is applied,
through
the sub
fusible link, fuse No. 6 and the heater relay
(contacts),
to the blower switch.
When the blower switch and the air conditioner
switch are switched ON, current flows to the
sub fusible link, fuse No. 6, the heater relay
(contacts), the blower switch, the air conditioner switch termistor.
air conditioner
relay B
(contacts).
air conditioner
relay A (coil), the
switch, and groI
___.-
AIR CONDlTlONlNG
Air conditioner
r&y
- Troubleshooting
Airmndnioner
relay A
-23
Vacuum
solenoid
(1)
For &ormation
conCerni
IllI.
refer to GROUP &ecmcal
System Pans Low
tion.
(21 The symbols Q, Q. etc. indicate ffiat the witinp IS
mnnected lusmg the same numerical symbol) to Ihe
lacing page. (In other words. 0 on the righr page is
connected to 8 on the left page.)
und, and the contacts

of air conditioner
relay
A close.
When this happens, current flows through the
sub-fusible
link, the dedicated fuse, air conditioner relay A (contacts),
and the pressure
switch to the magnet clutch or the condenser
blower motor relay (coil), and then to ground;
the contacts of the condenser
blower motor
relay then close, and, at the same time, current
flows to the sub-fusible
link, the dedicated
fuse, the condenser
blower motor relay (contacts),
the condenser
blower
motor,
and
ground, and the condenser
blower motor and
the compressor
are activated.
Note that the compressor is stopped under the

following
conditions:
1. When the temperature
at the evaporator
becomes 3C (37.4F) or lower . . . detected
by thermistor.
2. When the pressure within the piping be
comes 210 kPa (30 psi) or lower . . . detected
by the dual pressure switch.
3. When the pressure within the piping becomes 2,700 kPa (334 psi) or higher . . .
detected
by the dual-pressure
switch.
4. ~When the temperature
of the coolant becomes 113C (235F) or higher . detected
by the engine coolant temperature
switch.
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AIR CONDITIONING
24-23
- Troubleshooting
SiNGLE AIR CONDITIONER

CIRCUIT
CIRCUIT DIAGRAM
<3.OL Engine>
OFF
I
10.85-B
To turn signalftasherunitr0e85-RL
5
1T1
Heater
V&$or
Ll: L!ght blue
0.85-B
c@
relay
code
Br: Bmwn
0: orange
G: Green
P: Pink
OPERATION
Blower
Control
Refer to the heater
section.
Compressor
Control
l
Batten/ voltage is always applied to the heater
relay (contacts),
air conditioner
relay A, (contacts), and the condenser
blower motor relay
(contacts).
l
When the ignition key is turned to the AX
position,
current flows to fuse No. 10, air
conditioner
relay B (coil), and ground, and the
contacts
of air conditioner
relay B close.
i: Blue
y: Yellow
1 TSB Revision
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Lg: tight green

w: Whll%

position, current flows to fuse No. 3, the heater
relay (coil), and ground;
the contacts of the
heater relay then close. and, at the same time,
battery voltage is applied, through
the sub
fusible link, fuse No. 6 and the heater relay
(contacts),
to the blower switch.
When the blower switch and the air conditioner
switch are switched ON, current flows to the
sub fusible link, fuse No. 6, the heater relay
(contacts), the blower switch, the air conditioner switch thermistor,
air conditioner
relay B
(contacts). pressure switch, condenserblower
24-24
AIR CONDITIONING
- Troubleshooting
;: o.85-Lw
r
o1o.85-m
motor relay (coil), and then to ground;

the
contacts of the condenser blower motor relay
then close, and, at the same time, current
flows to the sub-fusible
link, the dedicated
fuse, the condenser
blower motor relay (contacts),
the condenser
blower
motor,
and
ground, and the condenser
blower motor is
activated. When, at this time, current from the
air conditioner
relay B (contacts) flows to air
conditioner
relay A (coil) and the M.P.I. control
unit (ground), current flow through the subfusible link. the dedicated fuse, air conditioner
relay A (contacts).
the magnet
clutch and
ground, and the compressor
is activated.
1 TSB Revision
Note that the compressor

is stopped under the
following
conditions:
I. When the temperature
at the evaporator
becomes3C
(37.4F) or lower . . . detected
by thermistor.
2. When the pressure within the piping becomes 21D kPa (30 psi) or lower . . . detected
3. When the pressure within the piping becomes 2,700 kPa (384 psi) or higher .. .
detected
4. When the temperature
of the coolant becomes 115C (239F) or higher . . . detected
by the engine coolant temperature
switch.
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--;
-_
_
AIR CONDITIONING
DUAL
:IRCUIT
AIR CONDITIONER
24-25
- Troubleshooting
CIRCUIT
DIAGRAM
Main
fusible
llk
-21
OPERATlON
Front Blower Control
Refer to the Heater section.
Rear Blower Control
l
When the ignition key is at ON or ACC
position, current flows through fuse No. 10, air
conditioner
relay D (coil), and ground, causing
the air conditioner
relay D contacts to close.
Then, when the rear blower switch is set at anv

of I,
Ml,
MZ, or H, current flows
through
air conditioner
dedicated
fuse, air
conditioner
relay D (contacts),
blower switch,
resistor, blower. motor, and ground, causing
the blower motor to rotate.
1 TSB Revision
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24-26
AIR CONDlTlONlNG
- Troubleshooting
010.85-B
@*
0-85-LW
+0.85-WE
Remarks
Engine coolant
temperature
switch
Condenser
l
Fan Control
When, with the ignition

key at the ON
position, the front blower switch and the A/C
switch are switched ON, current flows to fuse
No. 6, the heater relay, the front blower switch,
the A/C switch, the thermistor,
air conditioner
relay B (contacts),
the pressure switch, dual
pressure switch, condenser
blower motor relay
(coil), and ground, and the contacts
of condenser blower motor relay close.
1 TSR Revision
12) The Symbols Q, @. etc. indicate

that the wiring 1s connected
(using the fame numerical
symbol) to the facing page.
iln other words. Q on the right
Page is cOnnected to @ on the
left Page.)
When this happens,

current flows to the air
conditioner
dedicated
fuse, the condenser
blower motor relay (contacts), the condenser
fan motor, and ground, and the condenser fan
motor is activated.
Compressor
Control
Refer to P. 24-23.
Magnetic
Valve Control
l
When the ignition key is at ON or KC
position, current flows through fuse No. IO. air
http://vnx.su/
.-
AIR
CONDITIONING
24-27
- Troubleshooting
MaQnetic
valve
Rear blower
motor
Rear blower
resis tar
motor
B
Air mn@tioner
relay E
r--E-l
Rear blower
I I
COZSkY
fan maoI
I I
mmnditioner
Sub c%en.se
fan motor
-56
Remark
In the illustration. the numbered wiring
on this ,BQe mrresponds
to me
numberina on the wevious @acre. 6 on
this caQe-&resooixls
to Ej 06 the
previot.2 ,?+?Qe.etc.1
-
relay D
hl; Lish
conditioner
relay D (coil), and ground, causing
the air conditioner
relay D contacts to clo$e.
Then, when the rear blower switch is set at any
of I,
Ml,
MZ,
or H. current flows
through
air conditioner
dedicated
fuse, air
conditioner
relay D (contacts),
and the blower
switch to the magnetic
valve.
Then, when the front blower switch and AK
switch are switched ON, current flows to fuse
No. 6, the heater relay, the front blower switch,
the A/C switch, the thermistor,
the air conditioner relay B (contacts), air conditioner
relay A
switch
/ TSB Revision
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blue
0: DC2nQe
y: Yellow
P: Pink,
W: White
(coil) and M.P.I. control unit (ground), and the

contacts of air conditioner
relay A close.
While the contacts are closed, current flows
through the air conditioner
dedicated fuse, air
conditioner
relay A (contacts),
air conditioner
relay E (coil) and ground.
When the thermistor
is switched ON, current
flows through
the rear blower switch,
the
magnetic valve, the thermistor,
air conditioner
relay E (contacts) and ground, and the magnetic valve is activated.
24-28
AIR CONDITIONING
- Troubleshooting
PARTS LOCATION
<2&L Engine>
Name
1 Symbol
Air conditioner
Condenser
Dedicated
16W1801
!
relay A, B
blower
.fuse
Dual press;;
motor relay
switch
/
bl
1 TSB Revision
( Symbol
1 Name
Heater relay
Thermistor
Vacuum solenoid
http://vnx.su/
valve
switch
(
-
IAt
AIR CONDITIONING
-Evaoorator
<3.OL
- Troubleshootina
Engine>
di
Engine coolant
Air conditioner
Condenser
relay D. E (for rear air
blower
motor
relay
I Magnetic
temperature
switch
valve (for rear air conditioner)
Dedicated
fuse (for front air conditioner)
Thermistor
(for front
Dedicated
fuse (for rear air conditioner)
Thermistor
(for rear air conditioner)
Dual pressure
switch
TSB Revision
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air conditioner)
J
G
J
24-30
AIR CONDITIONING
- Troubleshooting
r-
TSB Revision
http://vnx.su/
Air conditioner
relav
AIR
SAFETY
CONDITIONING
PRECAUTIONS
Safety
Precautions
24-3 1
N24Pruw.
Caution
SAFETY
PRECAUTIONS
The refrigerant
used in all air conditioning
installations is R-12. It is transparent
and colorless in both
the liquid and vapor state. Since it has a boiling
point of -29.8X
(-21.7F).
at atmospheric
pressure, it will be a vapor at all normal temperatures
and pressures. The vapor is heavier than air, nonflammable,
and nonexplosive.
It is nonpoisonous
except when it is in direct contact with open flame.
It is noncorrosive
except when combined
with
water. The following
precautions
must be observed when handling R-12.
Caution
Wear safety goggles when servicing the refrigeration system.
R-12 evaporates
so rapidly at normal atmospheric
pressures and temperatures
that it tends to freeze
anything it contacts. For this reason, extreme care
must be taken to prevent any liquid refrigerant
from contacting
the skin and especially the eyes.
Always wear safety goggles when servicing the
refrigeration
part of the air- conditioning
system.
Keep a bottle of sterile mineral oil handy when
working on the refrigeration
system. Should any
liquid refrigerant get into the eyes, use a few drops
of mineral oil to wash them out. R-12 is rapidly
absorbed
by the oil. Next, splash the eyes with
plenty of cold water. Call your doctor immediately
even though irritation has ceased after treatment.
Caution
Do not heat R-12 above 52C (125F)
In most instances,
moderate
heat is required to
bring the pressure of the refrigerant in its container
above the pressure of the system when charging
or adding refrigerant.
A bucket or large pan of hot
water not over 52C (125F) is ail the heat required
for this purpose.
Do not heat the refrigerant
container with a blow torch or any other means
that would raise temperature
and pressure above
this temperature.
Do not weld or steam clean on or
near the system components
or refrigerant
lines.
Keep R-12 containers

upright when charging the
system.
When metering R-12 into the refrigeration
system,
keep the supply tank or cans in an upright position.
If the refrigerant container is on its side or upside
down, liquid refrigerant will enter the system and
damage the compressor.
Caution
Always work in a well-ventilated
room.
Good ventilation is vital in the working area. Always
discharge
the refrigerant
into the service bay
exhaust system or outside the building.
Large
quantities
of refrigerant
vapor in a small, poorly
ventilated
room can displace the air and cause
suffocation.
Although
R-12 vapor is normally nonpoisonous,
contact with an open flame can cause the vapor to
become very poisonous.
Do not discharge large
quantities of refrigerant in an area having an open
flame. A poisonous gas is produced when using
the flame-type
leak detector.
Avoid inhaling the
fumes from the leak detector.
Caution
Do not allow liquid refrigerant
to touch bright
metal.
Refrigerant
will tarnish bright metal and chrome
surfaces, and in combination
with moisture can
severely corrode all metal surfaces,
Revision
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,__-
24-32
.~
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AIR CONDlTlONlNG
SERVICE ADJUSTMENT
.I
Nz4FDADa
PROCEDURES
MANIFOLD GAUGE SET INSTALLATION

<lOPA15>
Suction
gauge
Yehow
or blue
ked
Manifold
Gauge Valves should be closed when
connecting
the manifold gauge set to the service
port of the compressor
and the discharge hose.
The suction gauge valve at the left is opened to
provide a passage between the suction gauge and
the center manifold outlet. The discharge gauge
valve at the right is opened to provide a passage
between
the discharge
pressure gauge and the
center manifold outlet.
Detailed instructions
for proper use of the gauge
set manifold
are contained
in the text covering
each test and service operation employing these
gauges.
Suction Gauge; the left side of the manifold set is
calibrated to register 0 to 1,000 kPa (0 to 150 psi).
This gauge is connected
to the suction port of the
compressor.
2oW646
NZ4F6AO
TEST PROCEDURES
RECEIVER
DRIER
The receiver driver assembly

consists
of; Drier
Refrigerant
level sight glass and Fusible plug.
To Test
the
(1) Operate
touching
(2) If there
drier is
Replace
[ TSB Revision
&._
m:
E
iii&
e
ej
m
=+
Discharge Gauge;the
right of the manifold set is
calibrated to register 0 to 2,100 kPa (0 to 300 psi).
For all tests th& gauge
is connected
to the
discharge port of the system.
Center Manifold _outlet; provides
the necessary
connection
for a long service hose used when
discharging
the system, using a vacuum pump to
pull a vacuum before charging the system, and for
connecting the supply of refrigerant when charging
the system.
Receiver
reservoir,
Drier
the unit and check the plumbing temperature

by
the receiver drier outlet and inlet.
is a difference in the temperatures,
the received
restricted.
the receiver drier.
~-~ -.
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AIR CONDITIONING
SIGHT GLASS REFRIGERANT

LEVEL TEST
The sight glass is a refrigerant
level indicator. To
check the refrigerant
level, clean the sight glass
and start the vehicle engine. Push the air conditioner button to operate the compressor,
place the
blower switch to high and move the temperature
lever to extreme
left.
After operating for a few minutes in this manner,
check the sight glass.
(1) If the sight glass is clear, the magnetic clutch is
engaged,
the compressor
discharge
line is
warm and the compressor
inlet line is cool: the
system has a full charge.
(2) If the sight glass is clear, the magnetic clutch is
engaged
and there is no significant
temperature difference
between compressor
inlet and
discharge
lines; the system
has lost some
refrigerant.
(3) If the sight glass is clear and the magnetic
clutch is disengaged;
the clutch is faulty or, the
system is out of refrigerant.
Perform dual-pressure switch test to determine condition. Check
dual-pressure
switch and clutch coil for electrical continuity.
(4) If the sight glass shows foam or bubbles, the
system could be low on charge. Occasional
foam or bubbles are normal when the ambient
temperature
is above 43C (110F) or below
21C (70F).
Procedures
24-33
Adjust the engine speed to 1,500 rpm. Block the

airflow through
the condenser
to increase the
compressor
discharge pressure to 1,422 to 1,520
kPa (206 to 220 psi). If sight glass still shows
bubbles or foam, system charge level is low.
The refrigerant system will not be low on charge
unless there is a leak. Find and repair the leak. If
the leak can be repaired without discharging
the
system an oil level check is not necessary. Use the
procedure for correcting low refrigerant level found
in the Refrigerant System Service Procedure Section.
FUSIBLE PLUG
When ambient
temperature
of the fusible plug
reaches 105C (221F). the fusible plug melts and
the refrigerant
in the system is released.
Once the fusible plug is operated,
it cannot be
used again.
So. it is necessan/ to install new one and charge
the refrigerant
in the system.
DUAL PRESSURE SWITCH

The dual pressure switch, located on the liquid line, is wired in
series with the magnetic
clutch. It cuts off the electrical
power supply to the clutch when refrigerant pressure drops
below the control point of the switch. Whenever the system is
inactivated by the dual pressure switch due to refrigerant loss,
the refrigerant oil may have been lost. Therefore, to prevent
damage to the compressor due to operation without sufficient
lubrication, the leak must be repaired and add compressor
oil
[I5 cc (0.5 fl.oz.)] before final charge of the system. The
switch is a sealed, factory calibrated unit. No attempt should
be made to adjust or otherwise
repair it.
If it is found to be faulty it must be replaced.
To
(1)
(2)
(3)
Test the Dual Pressure Switch (Engine Off)

Jump the wire leads.
Press the air conditioner
switch and blower switch on.
Momentarily
turn the ignition switch on (do not crank the
engine), listen for the compressor
clutch engaging.
(4) If the clutch does not engage, the fin thermistor,
engine
coolant temperature
switch or fuse may be faulty.
(5) If clutch engages, connect the manifold gauge set and
read pressure. At pressure of 210 kPa (30 psi) or above,
switch must actuate the clutch.
If the pressure is below 210 kPa (30 psi), the refrigerant
system is low in charge. For corrective
action refer to
refrigerant
leak repair procedt Are.
fvision
1
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24-34
AIR CONDITIONING
- Service
Adjustment
Procedures
(6) Reconnect
boot on switch and perform step number 3.
If the clutch does not engage,
discharge
the system,
replace the switch, and-recharge
the system.
(7) If the magnet clutch switches
OFF during driving even
though the temperature
inside the vehicle has not decreased, it is possible that the high-pressure
side of the
dual-pressure
switch has activated.
(8) install a manifold gauge-and
then drive the vehicle and
read the value at which the magnet clutch is switched
OFF.
(9) If the value at which the magnet clutch is switched OFF is
2,700 kPa (384 psi) or less. there is an incorrect setting of
the dual-pressure
switch, and replacement
must be made.
FREEZE UP CONTROL
Evaporator freeze up is controlled by a thermistor attached to
the evaporator
fins. The control is an electronic
type and
consists of two parts (therm0
relay and thermistor).
It is
connected to the magnetic clutch of the compressor
in series.
When the temperature
of the evaporator
drops below 3C
(37.4F), the compressor
is turned OFF.
To Test the Thermistor

(1) Jump the wire lead (LB to GB) of the connector
portion.
(2) Press the air conditioner
(3) Momentarily
engine), listen for the clutch engaging.
(4) If the clutch does not engage, the dual pressure switch,
switch wiring or fuse may be
faulty.
(5) If the clutch operates,
replace the thermostat.
ENGINE COOLANT
TEMPERATURE
SWITCH
The engine coolant temperature
switch is located on the
thermostat
housing. The engine coolant temperature
switch
is connected
to the clutch in series. When the coolant
temperature
in the radiator reaches above 113C (235F), it
turns the compressor
OFF.
This is to prevent engine overheating.
When the engine coolant temperature
switch is activated and
the clutch is OFF, check the surface of the condenser
and
radiator, the belt tension,
and the coolant volume in the
radiator, and return.to
the normal condition.
To Test the Engine Coolant
Temperature
Switch
(1) Remove wire from engine coolant temperature
switch and
jump lead wires.
(2) Press the air conditioner
(3) Momentarily
engine), listen for the clutch engaging.
(4) If the clutch does not engage, the fin thermistor,
dual- :
pressure switch, wiringor
fuse may be faulty.
(5) If clutch engages, replace the switch.
evision
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I-
AIR
CONDITIONING
Service
Adjustment
Procedures
AIR CONDITIONER SWITCH

To Test the Air Conditioner
Switch
(I) Ft;E;nect
the harness connector
2OUO31!
for the air conditioner
(2) Jump ;he lead wires as shown.

(3) Turn the blower switch ON.
(4) Momentarily turn the ignition switch on (do not crank the engine), listen for the clutch engaging.
(5) If the clutch does not engage, fin thermostat,
water
temperature
switch, wiring or fuse may be faulty.
(6) If clutch engages,
replace the air conditioner
switch.
MAGNETIC CLUTCH
(1) Disconnect the wiring to the magnetic clutch.
(2) Connect battery (+) voltage directly to the wiring for the magnetic clutch.
(3) If the magnetic clutch is normal, there will be a click. If the
pulley and armature do not make contact (click), there is a
malfunction.
Suction gauge
phaw
Suction
gauge
w-w
Discharge
gauge
COMPRESSOR
(1) Install the manifold gauge set, and run the air conditioner.
(2) If a pressure of approx.490 kPa (71 psi) is indicated on the
suction gauge side and a pressure of approx.883 kPa (128 psi)
is indicated on the discharge gauge side, the compressor has
abnormal compression.
Replace the compressor.
(3) If a pressure of 294 to 392 kPa (43 to 59 psi) is indicated on the
suction gauge side and a pressure of approx.1961 kPa (284
psi) is indicated on the discharge gauge side, it is suspected
that air is present in the air conditioning system.
Discharge the system, evacuate and recharge with specified
amount of refrigerant.
Recharging
condition
l
Cooler discharge
temperature
Discharge
ww
: 30-35C
(86-95F)
Engine revolutions
: 2,000 rpm
Blower : HI
(4) During operation of the air conditioner, cold air may stop flowing after the elapse of time and this state is maintained before
cold air flows out again. If cold air stops flowing out with
negative pressure indicated on the suction gauge side and a
pressure of 588 to 980 kPa (85 to 142 psi) indicated on the
discharge gauge side, it is suspected that water is present in
the air conditioning system.
Discharge the system. Replace receiver drier. Evacuate and
check for leaks, and recharge with specified amount of refrigerant.
l
Suction
gauge
(evaporator)
Revision
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24-36
AIR CONDITIONING

TESTING SYSTEM FOR LEAKS
<lOPAlS>
kwR%%
A leak is likely to occur where two components are connected

together. See illustration for possible locations.
The Leak Detector Torch is a butane gas-burning torch used to
locate a leak in any part of the refrigeration system. Refrigerant
gas drawn into the sampling or sniffer hose will cause the flame
to change color in proportion to the size of the leak. A very small
leak will produce a flame varying from yellowish-green
to bright
green. A large leak will produce a brilliant blue flame.
Caution
Do not use the lighted detector in any place where explosive
gases, dust or vapors are present. Do not breathe the fumes
that are produced
by the burning of refrigerant
gas. Large
concentrations
of refrigerant
in the presence of a live flame
become dangerously
toxic.
If the flame remains brigtit yellow when the tester is removed
from a possible leak point, insufficient air is being drawn in through
the sampling tube, or the copper reaction wire is dirty.
(1) Assemble leak detector as shown be sure detector is seated
tightly over torch gasket.
(2) Holding torch upright screw-in butane charger (clockwise) until
punctured. (Do not use force).
(3) Screw-out butane charge (counterclockwise)
about l/4 turn.
(4) Point torch away from body-then
light escaping gas with
match. Always keep torch in upright position.
(5) Adjust flame by turning cartridge in or out as required.
(6) Allow 30 seconds to heat copper reaction wire.
-eak detector
,orch
Caution
Never remove butane charger
presence of any open flame.
ilectric-type
leak tester
while
PERFORMANCE TEST
I
or in the
(7) Examine all tube connectors and other possible lead points by
moving the end of the sampling hose from point to point.
Always keep torch in upright position. Since R-12 is heavier
than air, it is good practice to place the open end of sampling
hose directly below point being tested. Be careful not to pinch
sampling tube since this will shut off air supply to flame and
cause a color change.
(8) Watch for a change in the color of the flame. Small leaks will
produce a green color and large leaks a bright blue color. If
leaks are observed at tube fittings, tighten the connection,
using the proper flare wrenches, and retest.
NOTE
Gas leaks can also be detected
of leak tester (which employs
torch is lighted
2OW848
/
by using the electric

an audible alarm).
type
NZUWAC
(1) Park the vehicle to be tested at the place where it will not
be in direct sunlight.
and manifold gauge set.
I
ivision
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AIR CONDITIONING
24-37
(3) Set the controls
of air conditioner
(loaded on the vehicle]
to the following
positions.
l
Air conditioning
switch : A/CON
position
l
Mode selection lever : Face position
l
Temperature
control lever : Max. cooling position
l
Air selection
lever : Recirculation
position
l
Blower switch : HI (Fast) position
(4) Start engine and adjust rpm to 1,000 with air conditioner
clutch engaged.
(5) Engine should be warmed up with doors windows close
and hood open.
(6) Insert a thermometer
in the left center air conditioner
2OW851
outlet
and
operate
the engine
for 20 minutes.
(7) Note the discharge air temperature.

NOTE
If the clutch cycles, take the reading
disengages.
Performance
Temperature
SINGLE AIR CONDITIONER
before
the clutch
Chart
Garage ambient
temperature C (F)
21(70)
26.7(80)
32.2(90)
37.8(100)
43.3(110)
2-5
(35-41)
2-5
(35-41)
2-5
(35-41)
2-5
(35-41)
2-5
(35-41)
Compressor discharge
pressure kP8 (psi)
621-834
(90-121)
703-97s
(102-142)
841-1138
(122-165)
Compressor suction
pressure kPa (psi)
124-207
(18-30)
130-221
(IS-321
138-241
(20-35)
Discharge air temperature

C (F)
993-1345
(WI- 195)
145-255
(2-I -37)
(1.13'1-1.517)
(164-220)
152-276
(22-40)
DUAL AIR CONDITIONER

Garage ambient temperature
C (F)
Discharge air
temperatore
C (F)
21(70)
26.7(80)
32.2(90)
37.8(100)
43.3(110)
Front
2-8
(35-46)
3-s
(37-48)
4-10
(39-50)
7-14
(45-57)
12-18
(54-64)
Rear
2-8
(35-46)
3-s
(37-48)
4-10
(39-50)
7-14
(45-57)
12-18
(54-64)
981-1.373
(142-199)
981-1,373
(142-199)
1.079-1,472
(156-213)
1.373-1.766
(199-256)
1.668-2.060
(242-299)
108-206
(16-30)
108-206
(16-30)
128-226
(18-33)
Compressor
kPa (psi)
discharge pressure
Compressor
kPa (psi)
suction pressure
Leak detector
torch
Refrigerant
leak tester
226-324
(33-47)
REFRIGERANT LEAK REPAIR PROCEDURE WHMI\N

LOST CHARGE
If the system has lost all charge due to a leak:
(1) Evacuate the system. (See the procedure).
(2) Charge the system with approximately
one
refrigerant.
(3)
(4)
(5)
(6)
( TSB Revision
Check for leaks.

Discharge
the system.
Repair leaks.
Replace receiver drier.
http://vnx.su/
pound
of
~-ml
hi
.~
24-38
*.
-_-.
AIR CONDlTiONlNG
2OW848
LOW
REFRIGERANT
Adjustment
Procedures
Caution
Replacement
filter-drier
units must be sealed while
in
storage. The drier used in these units will saturate water
quickly upon exposure to the atmosphere.
When installing
a drier, have ali tools
and supplies
ready for quick
reassembly
to avoid keeping the system open any longer
than necessary.
(7) Evacuate and charge the system.
LOW CHARGE
If the system has not lost all of its refrigerant charge: locate
and repair all leaks. If it is necessary to increase the system
pressure to find the leak (because of an especially low charge)
add refrigerant.
If it is possible to repair the leak without
discharging
the refrigerant
system, use the procedure
for
correcting
low refrigerant
level.
Electrbtype
leak tester
CORRECTING
- Service
LEVEL
n(Discharge
gauge
Discharge
valve
gauge
<6P146>
don
Hot water
52C I1 25F)
uction
Since the refrigeration

system is completely
sealed, refrigerant level will not be low unless there is
a leak in the system.
Before adding refrigerant when the cause of low
level is not known, the system should be tested for
leaks.
Assuming that leaks have been corrected without
discharging
the system.
proceed
with partial
charge.
install and connect manifold gauge set.
(1) Close both gauge set manifold valves.
(2) Connect the suction gauge test hose to the
suction port of the compressor.
Connect the
discharge
gauge test hose to the discharge
port.
(3) Connect one end of long test hose to center
manifold
outlet, other end to refrigerant
dispensing manifold.
(4) Close two dispensing
manifold
valves and
open remaining
dispensing
manifold
valve.
Remove protective
cap from opened valve.
(5) Screw a can of R-12 to the opened manifold
valve. Be sure gasket is in place and in good
condition. Tighten refrigerant can and manifold
locking nut to insure a good seal. Do not
over-tighten.
8 to 11 Nm (6 to 8 ftlbs.)
is
/ TSBRevision
port
oort
sufficient
if gasket is in good condition.
(6) Turn manifold valve (above the refrigerant can)
completely clockwise to puncture the can. This
closes the valve and seals the refrigerant in the
can.
Caution
Never heat small cans of refrigerant
over 52C
(125F) as they may explode.
(7) Place the refrigerant
in a large pan of water
heated to 52C (125F). Place pan of water
containing
the refrigerant
can on an accurate
scale so the Zimount of refrigerant
added can
be -weighed.
Open the refrigerant
manifold
valve.
(8) Purge all air from test hoses. Air in the system
will be trapped
in the condenser
causing
abnormally high discharge pressures and interfering with condensing
of the refrigerant.
(8) Slightly loosen both test hoses at the gauge set
manifold. Tighten the hoses as soon as the air
is purged.
(10)Siightly
looseo charging
hose connection
at
gauge set manifold. This will purge air from the
charging hose.
Tighten connection
as soon as air is purged.
-http://vnx.su/
-d
,s
AIR
CONDITIONING
- Service
(11)With
vehicle windows
open and hood up,
operate
engine at 1,500 rpm and jump the
switch terminals
located on so the clutch will
remain engaged.
(12)Place air conditioner
control on air conditioner
and place the blower switch on high.
(13)lf necessary, block the condenser to maintain a
discharge pressure of 1,422 to 1,520 kPa (206
to 220 psi.)
System must be charged through the evaporator suction service ports as follows:
(a) Slowly open the suction
service gauge
valve. Meter flow of refrigerant by adjusting the suction service gauge valve so that
pressure registered at the suction service
gauge does not exceed 345 kPa (50 psi).
Keep rifrigerant
container
upright.
DISCHARGING
collector
can
2ouo3ls
Replacement
component
Compressor
Condenser
Evaporator
Pipe
1 m (3.3 ft.) or
more
1 m (3.3 ft.) or
less
Receiver
drive
Replenishment oil cc (fl.oz.

6P148
lOPA
90 (3.2)
40 (1.4)
30(1.0)
60(2.0)
3Ofl.O)
6Ot2.0)
5CO.2)
5(0.2)
0 (0)
0 (0)
lO(O.3)
lO(O.3)
Adiustment
Procedures
24-39
(b) Add refrigerant

gas until there is no foam
visible at the sight glass. Then add a further
170 g (6 oz.).
(c) Close the suction gauge valve.
Caution
Too much refrigerant
in the system can
cause abnormally
high discharge
pressures. Care must be used so that the
exact recommended
amount
of refrigerant is added after foam clears in the sight
glass.
(d) Close dispensing
manifold valve. Remove
test hoses and adapters from the service
ports of compressor,
install protective caps
at service ports and reconnect wiring.
(e) Check system performance
P. 24-37.
THE SYSTEM
Since the air conditioning

refrigerant system is pressurized, it
will be necessary to completely
discharge the system (in a
well ventilated area) before replacing any refrigerant component. The procedure
is as follows:
(1) Install manifold gauge set. Make sure tha gauge set valves
are closed before attaching the hoses to the refrigerant
system.
(2) Install a long hose to the manifold gauge set connector.
Run this hose to the oil collector can near a shop exhaust
system.
A good oil collector can may be made from a large empty
coffee can with a plastic top. Slit the plastic top in the
form of a Y to make an entrance for the refrigerant hose
and an exit for the gas.
(3) Open the compressor
discharge and suction line pressure
valves and blow the refrigerant
into the oil collect can.
Watch to make sure the hose does not blow out of the
collector can.
(4) When the system
has been completely
discharged,
measure
the amount
of oil collected
in the can. The
amount of oil measured should be added to the refrigerant
system before it is m-charged.
Add new oil-discard the
used oil.
Caution
It is important
to have the correct amount
of oil in the
refrigerant
system.
Too little oil will provide inadequate
compressor
lubrication
and cause a compressor
failure. Too much oil Will increase
discharge air temperature.
When a compressor
is installed at the factory, it contains
refrigerant
oil:
While the air conditioning
system is in operation,
the oil is
carried through the entire system by the refrigerant. Some of
this oil will be trapped and retained in various parts of the
system.
When the following
system components
are changed, it is
necessary to add oil to the system to replace the oil being
removed with the component.
1 TSB Revision
http://vnx.su/
24-40
EVACUATING
AIR CONDITIONING
Procedures
THE SYSTEM
2ouo317
Whenever
the system has been opened to the
atmosphere,
it is absolutely
essential
that the
system be evacuated or vacuumed
to remove all
the air and moisture. Air in the refrigerant system
causes high compressor
discharge
pressures,
a
loss in system performance,
and oxidation of the
compressor
oil into gum and varnish. Moisture in
the refrigerant
system can cause the expansion
valve to malfunction.
Under certain conditions,
water can react with the refrigerant
to form
destructive
acids. It is necessary to adhere to the
following procedure to keep air and moisture out
of the system.
gauge set. Make sure the
(1) Install manifold
gauge set valves are closed before attaching
the hoses to the refrigerant
system.
(2) Discharge the system slowly if the manifold
gauge set indicates pressure in the system.
(3) Connect a long test hoses from gauge set
manifold center connection
to vacuum pump.
(4) Open both manifold gauge set valves.
(5) Start the vacuum pump and operate until the
evaporator suction gauge registers at least-l 01

kPa (29.9 in.of vacuum).
If at least-101 kPa (29.9 in. of vacuum) cannot
be obtained, either the system has a leak or the
vacuum pump is defective.
Check the vacuum pump. If the pump proves
to be functioning
properly, the system has a
leak. Charge the system with one can (14 oz) of
refrigerant.
Locate and repair all leaks. Discharge the refrigerant
and evacuate the system.
(6) Continue to operate the pump for at least five
minutes.
valves. Turn off the vacuum
(7) Close manifold
pump and observe evaporator
suction gauge
for two minutes.
The vacuum
level should
ramain constant.
If the vacuum level falls off, the system has a
leak. Charge the system with one pound of
refrigerant.
Locate and repair all leaks. Discharge the system and repeat evacuation procedure.
CHARGING THE SYSTEM

Air
discha
Hot
water
The refrigerant system must have been evacuated

using the previous
procedure
before charging.
Charge using only R-12 refrigerant.
R-12 is available in bulk tanks or small cans. Follow the safety
precautions
for handling
R-12 as listed in the
beginning
of this group.
Charging
with Small Cans
When using disposable
cans of this type, follow
carefully the can manufactures
instructions.
[ TSB Revision
Caution
Never use these cans to charge into the high
pressure
side of the system
(compressor
discharge port) or into a system that is at high
temperature,
because the high system pressures
could be transferred
into the charging can causing it to explode.
http://vnx.su/
AIR
Keep
the
refrigerant
CONDITIONING
manifold
valves
capped
Service
when
not in use.
Keep a supply of extra refrigerant-can-to-refrigerant-manifoid
gaskets on hand so that gaskets can
be replaced periodically.
This will insure a good
seal without excessive tightening
of the can or the
manifold nuts.
(1) Attach center hose from manifold gauge set to
refrigerant
dispensing
manifold. Turn refrigerant manifold valves completely
counterclockwise so they are fully open. Remove protective
caps from refrigerant
manifold.
(2) Screw refrigerant cans into manifold. Be sure
manifold-to-can
gasket is in place and in good
condition. Tighten can and manifold nuts to 8
to 11 Nm (6 to 8 ftlbs.)
manifold
valves completely
(3) Turn refrigerant
clockwise to puncture the cans and close the
manifold
valves.
Purge
the
air from the charging line by loosen(4)
ing the charging hose at the gauge set manifold and turning one of the refrigerant
valves
counterclockwise
to release refrigerant.
When
the refrigerant
gas starts escaping
from the
loose connection,
re-tighten
the hoses.
Caution
Never heat small refrigerant
(125F) as they may explode.
cans
over
52C
Adjustment
Procedures
24-41
(5) Fullv oaen all refriaerant manifold valves beina

used and place tee cans of refrigerant into s
pan containing
52C (125F) water will warm
the charging can and aid in the transfer of the
charge into the system. Place the water pan
and refrigerant cans on a scale and note the
weight.
(6) Jump the low pressure switch terminals located on the receiver drier so the clutch will
remain engaged.
(7) Start the engine and move the controls to air
conditioner switch on and low blower position.
The low pressure switch will prevent the clutch
from engaging until refrigerant is added to the
system. If the clutch does engage, replace the
switch before proceeding
any further.
Charge
through
the
suction
side of the system
63)
by slowly opening the suction manifold valve.
Adjust the valve as necessary
so charging
pressure does not exceed 345 kPa (50 psi).
Maintain the temperature
of the water in the
pan by adding warm water as necessary. Note
the weight of water added, to ensure accuracy
when determining
amount of refrigerant added
to system.
(9) Adjust the engine speed to a fast idle of
approximately
1,500 rpm.
(10)When specified refried refrigerant charge 900
(31.7 Ibs.) has entered the system, close the
gauge set manifold valves. refrigerant manifold
valves, and reconnect
wiring. tach can contains 397 g (14 oz.) of R-12. Use 2 l/2 cans.
http://vnx.su/
24-42
AIR CONDITIONING
IANDLING
jingle
TUBING
Procedures
FITTINGS
AND
Air Conditioner
<lOPA15>
12-l
9-11
Suction
line
Liquid
line \
15-18
30-35
22-25
Nm
R.lbs.
ftlbs.
20-25
15-18
30-35
22-25
12-15 Nm
9-11 ft.lbs.
Nm
ft.lbs.
Nm
ft.lbs.
15-18
12-15 Nm
9-11 Ribs.
Dual Air Conditioner
22-25
12-15
20-25
15-18
ft.lbs.
ft.lbs.
Nm
Nm
ft.lbs.
12-15 Nm
9-11 ft.lbs.
Is.-p
30-35
22-25
Nm
ft.lbs.
Discharge
+
2%30
E-22
20-25
Nm
Kinks in the refrigerant tubing or sharp bends in the

refrigerant hose lines will greatly reduce the capacity of the entire system.
High pressures
are
produced
in the system
when it is operating.
Extreme care must be exercised to make sure that
all connections
are pressure tight. Dirt and mois-
1 TSB Revision
20-25
E-18
Suction
line
line
Nm
Ribs.
Nm
ftlbs.
ture can enter the system when it is opened for

repair or replacement
of lines or components.
The
following
precautions
must be observed.
The system must be completely
discharged before
opening any fitting or connection
in the refrigeration system.
http://vnx.su/
AIR CONDITIONING
Open fittings with caution even after the system

has been discharged.
If any pressure is noticed as
a fitting is loosened,
allow trapped pressure to
bleed off very slowly. Never attempt
to rebend
formed
lines to fit. Use the correct line for the
installation
you are servicing.
A good rule for the flexible hose lines is keep the
radius of all bends at least 10 times the diameter of
the hose.
Procedures
Sharper bends will reduce the flow of refrigerant.

The flexible hose lines should be routed so that
they are at least 80 mm (3 in.) from the exhaust
manifold. It is good practice to inspect all flexible
hose lines at least once a year to make sure they
are in good condition
and properly routed.
All plumbing
connections
use O-rings which are
not reusable.
O-RING INSTALLATION
Flange
Flange
Ttll
Tube
(1) Clean sealing surface.

(2) Make sure O-ring does not have any scratches.
(3) Connect fitting, install fastener,
and torque to amount
shown in illustration.
The internal part of the refrigeration
system will remain in a
state of chemical stability as long as pure-moisture-free
R-12
and refrigerant oil is used. Abnormal amounts of dirt, moisture
or air can upset the chemical stability and cause operational
troubles
or even serious damage if present in more than
minute quantities.
When it is necessary to open the refrigeration
system, have
everything you will need to service the system ready so the
system will not be left open any longer than necessary. Cap or
plug all lines and fittings as soon as they are opened to
prevent the entrance
of dirt and moisture.
All lines and
components
in parts stock should be capped or sealed until
they are ready to be used.
All tools, including the refrigerant
dispensing
manifold, the
gauge set manifold and test hoses should be kept clean and
dry.
2060141
<2.6L
COMPRESSOR DRIVE BELT ADJUSTMENT
Engine>
Satisfactory
performance
of the air conditioning
system is
dependent
upon drive belt condition and tension. If the proper
tensions are not maintained,
belt slippage will greatly reduce
air conditioning
performance
and drive belt life. To avoid such
adverse effects, the following
service procedure
should be
followed:
(1) Any belt that has operated for a minimum of one half-hour
is considered
to be a used belt. Adjust air conditioning
drive belt at the time of new-car preparation.
(2) Check drive belt tension at regular service intervals and
adjust as needed.
Crankshaft
pulley
<3.OL
Engine>
Tension
Standard
When
2.6
3.0
When
2.6
3.0
pulley
100 N (22 Ibs.)
;;,n;ressor
a
Crankshaft
pulley
L
rue.rma
201838
1 TSB Revision
http://vnx.su/
value
a new belt
L Engine :
L Engine :
a used belt
L Engine :
L Engine :
installed
13-15 mm (.51-.59 in.]
5.0-6.0 mm (.20-.24 in.)
installed
17-20 mm (.67-.78 in.)
8.5-9.5 mm (.33-.37 in.)
24-44
AIR
CONQlTlONlNG
Service
COMPRESSOR NOISE
WFUA
When investigating
an air conditioning
related
noise, you must first know the conditions when the
noise occurs.
These conditions
are weather,
vehicle speed, in
gear or neutral, engine temperature
or any other
special conditions.
Noises that develop during air- conditioning
operation can often be misleading.
For example: what
sounds like a failed front bearing or connecting
rod, may be caused by loose bolts, nuts, mounting
brackets, or a loose clutch assembly. Verify accessory
drive belt tension (power steering, alternator
or air pump). improper accessory drive belt tension
can cause a misleading noise when the compressor is engaged
and little or no noise when the
compressor
is disengaged.
Drive belts are speed sensitive. That is, at different
engine speeds, and depending
upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the compressor.
AIR CONDlTlONER
Adjmtment
Procedures
/ sir
Conditioner
Switch
Adjustment
Procedures
(1) Setect a quiet area for testing. Duplicate conditioEs.as much as possible. Switch compressor
on and off several times to clearly identify
compressor
noise.
To duplicate
high ambient
conditions
(high
head pressure),
restrict air-flow through condenser. Install manifold
gauge set to make
sure discharge
pressure
does not exceed
2,070 kPa (300 psi).
(2) Tighten all compressor
mounting bolts, clutch
mounting
bolt, and compressor
drive belt.
Check to assure clutch coil is tight (no rotation
or wobble).
(3) Check refrigerant hoses for rubbing or interference that can Eause unusual noises.
(4) Check refrigerant
charge (See Charging
the
System).
(5) Recheck compressor
noise as in Step 1.
(6) If noise still exists, loosen compressor
mounting bolts and retorque.
Repeat Step 1.
(7) If noise continues,
replace compressor
and
repeat Step 1.
SWITCH

I
I
L
3-P connec
2-P
Removal
steps
1. Lap heater duct (C)
2. Glove box stoppers
3. Knobs
4. Plugs
5. Center panel
6. Connection of center panel wiring harness to iront wirrng harness connector

7. Air conditioner switch
NOTE
I TSB Revision
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to remsaIl.
-r
AIR CONDITIONING
24-45
- Rear Fan Switch
REAR FAN SWITCH

INSPECTION
BLOWER SWITCH
Operate the switch,
terminals.
W?GCAU
and check
the continuity
between
NOTE
C-O indicates that there is continuity between the terminals.
1 TSB Revision
http://vnx.su/
I
,
the
24-46
AIR-CONDITIONING
- Front Evaporator
FRONT EVAPORATOR
Removal
++
++
steps
7. Drain line connection

8. Bolt
9. Evaporator
1. Liquid 1in.e connectiqn

$: $tion
line connectlon
4. Glove box
5. Main harness connector
6. Duct joint
NOTE
(1) Reverse 3he removal procedures to reinstall.
connection

Caution
If the hoses or pipes are disconnected,
cap the hoses or pipes
with a blank plug tu prevent entry of dust, dirt, and water.
NY
Uyion
NURDAE
2. APPLICATION
OF COMPRESSOR
OIL TO SUCTION
LINE/l.
LIQUID LINE
Apply specified
compressor
oil to portions
indicated
before installing the liquid pipe and suction flexible hose.
Specified
zvision
compressor
http://vnx.su/
oil
1
;~
DENS0
6GS
OIL
6 or SUNlSO
AIR-CONDITIONING
DISASSENIBLY
AND REASSEMBLY
N24FlE.A
2
Disassembly
+I)
qw l +
1.
2.
3.
4.
5.
6.
7.
8.
24-47
- Front Evaporator
1
steps
Air conditioner relay
Thermistor
Screw
Clip
Evaporator case (upper)
Evaporator case (lower)
Evaporator assembly
Expansion valve
NOTE

(3) w+ : Refer to Service Points of Reassembly.
&f
A-------6
201828
N248FAB

4.
REMOVAL
OF CLIP
Remove the clips with a flat-blade screwdriver covered with a

shop towel to prevent damage to case surfaces.
8.
REMOVAL
OF EXPANSION
VALVE
Use two wrenches to loosen the flare nut on the pipe connktion (for both the inlet and outlet).
O-ring
dlAlh
Hear
w!!!f,
N24anAE

8. APPLICATION
VALVE
OF COMPRESSOR
OIL TO EXPANSION
Apply specified
compressor
oil to the O-rings and install
the expansion
valve to the evaporator
assembly.
Specified
TSB Revision
http://vnx.su/
oil : DENS0
OIL 6 or SUNISO
5GS
24-48
Ail? CONDITIONING
Rear
Evaporator
REAR EVAPORATOR
Removal steps
++ 1. Liquid line connection
+* 2. Suction line connection
3. O-ring
4. Duct
5. Connector
6. Rear evaporator assy
NOTE
(2) ++
to reinstall.
of Installation
SERVICE POlNTS OF REMOVAL

Caution
cap the hoses or
pipes with a blank plug to prevent entry of dust, dirt, and
water.
INSPECTION
BLOWER
MOTOR
ASSEMBLY
(I) Connect the blower motor terminals directly to the battery

and check that the blower motor operates smoothly.
(2) Next, reverse the polarity and check that blower motor
operates smoothly
in the reverse direction.
l&U
87
1 TSB Revision
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AIR CONDITIONING
BLOWER RESISTOR
(1) Check for resistance
as described
Terminals measured
Magnetic valve
24-49
- Rear Evaporator
below.
Standard value
Between terminals @-@
Approx. 0.5
Between terminals @!-@I
Approx. 1.8
Between terminals @-@
Approx. 3.3
MAGNETIC VALVE
(1) Connect terminal 0 to the positive (+) terminal of the battery, and connect terminal @ to the negative (-) terminal of
the battery.
(2) The condition of the magnetic valve can be considered
satisfactory
if the operation sound (a click sound) of the
magnetic valve can be heard when this check is made.

2. APPLICATION
LINE/l. LIQUID
OF COMPRESSOR
LINE
Refer to P. 24-46.
( TSB Revision
http://vnx.su/
OIL TO
Nz1RDAl.
SUCTION
All? CONDITIONING
Rear EveDorator
Disassembly
1.
2.
3.
2:
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
steps
Case assembly
Grille assembly
Grille filter
gAit!iet plate
Protector trim
Tray assembly
Bracket
Tray
Blower resistor
Duct
Blower assembly
Pipe
Blower fan
Blower case
Packing
Motor assembly
Blower case
A/C harness
Thermistor bracker
Thermistor
Plate
Blacket
Evaporator
Cooling unit case
Expansion valve
I&i;;lzic
valve
Liquid pipe
Suction pipe
Liquid pipe
Drain hose
33. tirommet
NOTE
(1 f Reverse
the disyem.bly
[;I
: Refer to ,,Seyce
(4)
: Refer to Service
: Non-reusable
parts
rocedures to reassemble.
B-o!nts of Drsassembly
Points of Reassembly
F4mlFAH
26. REMOVAL
OF EXPANSION
VALVE
Use two wrenches
to loosen the flare nut on the pipe
connection
(for both the inlet and outlet).
2-
Exaansion
valve
/
l-6
-
http://vnx.su/
AIR CONDITIONING
Rear
24-5 1
Evaporator
27. REMOVAL
OF MAGNETIC
VALVE
Use two wrenches
to loosen the flare nut on the pipe
connection

Magnetic
\
valve
27. INSTALLATION
OF MAGNETIC
N24miAN
VALVE
(1) Apply specified

compressor
oil to the O-rings and
install the magnetic valve to the evaporator assembly.
Specified
compressor
oil : DENS0
5GS
OIL 6 or SUNISO
(2) Use two wrenches to tighten the flare nut on the pipe
connection
26. INSTALLATION
OF EXPANSION
VALVE
(1) Apply specified

compressor
oil to the O-rings and
install the expansion valve to the evaporator assembly.
Exoansion
valve
Fir
E3
Specified
compressor
oil : DENS0
5GS
OIL 6 or SUNISO
q@?ki!LJ
O-ring
(2) Use two wrenches to tighten the flare nut on the pipe
connection
) TSB Revision
http://vnx.su/
24-52
AIR CONDITIONING
- Rear Ventilators
REAR VENTILATORS
Removal
*I)
+I) ++
steps
I.
2.
3.
4,
5.
6.
7.
8.
Air outlet grille

Retainer B
Rear headlining
Roof duct assembly (R.H.)
Roof duct assembly (L.H.)
Rear roof duct assembly
Pillar duct
Duct
NOTE
12) *+ : Refer to Service Points of Removal.
(3) **
MMBBB

1. REMOVAL
Using
OF AIR OUTLET
a plastic
3. REMOVAL
trim
tool.
GRILLES
remove
the
air outlet
OF REAR HEADLINING
Refer to GROUP
23 -Headlining
and Assist

3. INSTALLATION
Refer
/ TSB%evision
grille.
to GROUP
http://vnx.su/
Strap.
NZ4WDBB
OF REAR HEADLINING
23 -~Headlining
and Assist
Strap.
AIR-CONDITIONING
- Receiver
~tisr,Condenser,
RECEIVER, DRIER CONDENSER,
compressor
Clutch
COMPRESSOR
Assembly
24-53
CLUTCH ASSEMBLY

Single Air Conditioner
20-25
l
Remove the Radiator Grille. (Refer
Disconnect the Liquid Pipes and
<2.6L
Nm
Engine>
Install the Radiator Grille. (Refer to
GROUP 23 -Grille, Garnish, Mould-
Charge the Refrigerant. (Refer to
<3.OL
drier removal steps

1. Receiver drier mounting
2. Receiver drier
Condenser removal steps
3. Blower motor connector
4. Blower motor mounting
5. Blower motor
Engine>
Receiver
6. Condenser
mounting
bolt
Compressor
8.
9.
10.
11.
bolt
clutch assembly removal steps

Clutch coil connector
Drive belt
Line mounting bolt
;CIFpressor clutch assembly mounting
12. Compressor
clutch assembly
NOTE
bolt
7. Condenser
1 TSB Revision
http://vnx.su/
24-54
AIR CONDITIONING
Receiver
Drier,
Condensr.
CompressDI
Clutch
Assembly
Dual Air Conditioner

l
Discharge the Refrigerant. (Refer to
Remove the Radiator Grille. (Refer
o DitIinact
the Liquid Pipes and

20-25 Nm
22-25 ft.lbs.
15-22 fttbs.
xAv.365
Receiver drier removal steps

1. Receiver drier mounting bolt 4
2. Receiver drier
Main condenser removal steps
3. Blower motor connector
4. Blower motor mounting bolt
5. Blower motor
6. Condenser mounting bolt
7. Condenser
Compressor clutch assembly removal steps
8. Clutch coil connector
9. Drive belt
10. Line mounting bolt
11. C&npressor clutch assembly mounting
12. Compressor
lOUP ?J-Grille, Garnish, Mould- !iMO.)

l
Charge the Refrigerant. (Refer to
-Jj
Adjustment of the. Tension of the

fr2Csftq:ioner
Dnve Belt. (Refer to
I
-1
Sub condenser removal steps

13. Condenser
14. Blower motor
15. Blacket
NOTE
Reverse the removal procedures to reinstall
clutch assembly
NruTcAc
Caution
cap the hoses or
pipes with a blank plug to prevent entry of dust, dirt, and
water.
http://vnx.su/
AIR CONDITIONING
- Compressor
24-55
COMPRESSOR
?42aE-
<6P148>
16-17
11-13
Nm
ftlbs.
26-26
16-20
Nm
ft.lbs.
<lOPA15>
25Nm
19 fths.
208856
Magnetic clutch disassembly

steps
++ Adjustment of clutch clearance
1. Clutch hub
4+
2. Shims
3. Snap ring
4. Rotor assembly
4*
5. Snap ring
6. Ground terminal
l + 7. Clutch coil
Compressor front housing and shaft seal disassembly steps

8. Oil drain guide
9. Woodruff key
10. Through bolt
4*
l * Refilling of compressor oil
w* 11. Front housing
12. Felt
4*
13. Felt holder
14. Snap ring
++ I)* 15. Shaft seal
l + 16. Shaft plate
17. Gasket
18. O-ring
NOTE
(I)
(2)

++
: Refer to Service
rocedures to reassemble.
B.olnts of Disassembly.
(3) w
(4)
: : Non-reusable
1 TSB Revision
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parts
24-56
AIR CONDlTlONlNG
- Compressor
N24rFhH
1. REMOVAL
OF CLUTCH HUB (lOPA%)
(1) Secure the compressor
in a vise.
(2) If the clutch hub cannot be pulled off by hand, screw in
an 8 mm (.315 in.) completely
threaded bolt so as to
raise the clutch hub so it can be removed.
2OW851
4.
REMOVAL
OF ROTOR
Using a plastic hammer,
ASSEMBLY
lightly tap the rotor off the shaft.
10. REMOVAL
OF THROUGH
BOLT
Remove the through
bolt after first securing the rear
housing of the compressor
by placing it in a vise.
Caution
If the through
bolt is removed
without
the rear housing wiil become uncoupled
sor oil will escape.
12. REMOVAL OF FELT (lOPA15)
Using a flat-tip 8 screwdriver,
front housing.
remove
first doing so,

and compres-
the felt from
the
2OW859
15. REMOVAL OF SHAFT SEAL (IOPAl 5)

Using a flat-tip Q screwdriver,
remove the shaft seal from
the front housing.
20R070
NuTGplc
INSPECTION
o
J
8
l
1 TSB Revision
Check the surface of the clutch hub for scoring or bluing.

Check the surface of the rotor for scoring or bluing.
Check the sealing surfaces
for cracks, scratches
and
deformation.
Check the front housing for cracks or scoring on the
sealing surfaces.
shaft for scoring.
http://vnx.su/
--
AIR CONDITIONING
SERVICE
Front
housing
Shaft piate
24-57
Compressor
POINTS
WM
OF REASSEMBLY
16. INSTALLATION
OF SHAFT PLATE (6P148)
(I) Lubricate
the shaft plate and a new O-ring with
compressor
oil. Push the shaft plate and O-ring into
the front housing.
(2) Install the seal plate
special tool.
MB990783-01
into the front
housing
with
2OWBs~
15. INSTALLATION
OF SHAFT
SEAL
6P148
Lubricate the shaft seal with compressor
shaft seal on the shaft.
oil. Install the
NOTE
Rotate the shaft seal lightly by hand to check that it is
fitted into the notch on the compressor
shaft.
1 OPAI 5
(1) Lubricate
oil.
the shaft seal with specified
compressor
Specified
compressor
oil :
DENS0 OIL 6 or SUNISO 5GS
e
(2) Set the shaft seal to the front housing so that the
projection side of the center ring is at the shaft seal
side.
(3) Using a 21 mm (.83 in.) socket, install the shaft
seal.
2ow**o
11. INSTALLATION
OF FRONT HOUSING
(lOPAl5)
(I) Apply the specified
compressor
oil on the shaft.
Specified
compressor
oil :
DENS0 OIL 6 or SUNISO 5GS
(2) Install the front housing, taking care not to damage
lip part of the shaft seal.
the
(3) Mount the bolt on the shaft,

shaft starting torque.
the
2OW862
Standardvalue
(4) Remove
1 TSB Revision
http://vnx.su/
and then
: 5.0 Nm (43 in.lbs.)
the bolt from
the shaft.
measure
or less
24-58
AIR CONDITIONING
e
Comwessor
REFILL OF COMPRESSOR
OIL
When the compressor
is disassembled,
supply compressor oil of which quantity is the same as that which went
out when the compressor
is disassembled
adding 20 cc
(0.7 fl.oz.) with it from the suction hole side.
Specified
mm.6
oil
: DENS0
OIL 6 or SUNISO
NOTE
1. The quantity of compressor
ing the compressor
with
loPai5
6P148
lOPA
56s
oil to supply at when exchangnew one.
: 90 cc (3.2 fl.oz.)
: 40 cc (1.4 fl.oz.)
2. When exchanging
the whole refrigerant
system,
supply the compressor
oil with it for it is supplied
hand.
7.
INSTALLATION
OF CLUTCH COIL
The clutch coil must be aligned with
compression
housing.
the
pin
do not
before
in the
ADJUSTMENT
OF CLUTCH CLEARANCE
(1) Connect the magnetic
clutch to the battery.
(2) The clutch hub wiil be attracted to and fit closely to the
rotor.
(3) Use a shim(s) to adjust so that the amount
of
movement
of the clutch hub is as described below.
Standard
value
6P148
:
lOPA
:
0.4-0.7 mm (.016-.028 in.)

0.35465 mm (.0138-.0256
in.)
NOTE
1. For the 6P148, use a feeler gauge for clutch
clearance measurement.
2. Remove clearance
adjusting
shims to decrease
clutch clearance.
Add shims selected
from the
following
table to increase clutch clearance.
Clearance
Adjustment
Shims
(4) Turn the rotor by hand to confirm

1 TSB Revision
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that it rotates
freely.
8-257
BACK DOOR WINDOW DEFOGGER - Specifications
b4dX DOOR WINDOW DEFOGGER

SPEC:lFICATIONS
b SPECIFICATIONS
Specifications
Items
Back door window
TYPS
Rated current
defogger
switch
Seesaw type
20
Back door window glass with defogger

No. of printed heater lines
W
Power consumption [20%(68F)]
11
112-148
( TSB Revision
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8-258
BACK DOOR WINDOW DEFOGGER - Troubleshooting
TROUBLESHOOTING
DEFOGGER CIRCUIT
DIAGRAM
Ignition swtch
OFF
[Refer to P&51 .I
[Refer to P.e-66, es.1
WII
Defogger
2-B
Z-BR
,-2-RW
m
u
C-12
2F-Bm3-B
hi3
Y
N
aF
Remarks
(1) The broken line (----)
and lines indicated by the S symbol are applicable to 26liter
(2) The chain line (- - - - -) is applicable to 3.0-liter models.
(3) For infomiation
concerning the ground points (example: q ), refer to P.8-12, 14.
~rin~cclor
Lf: Light blue
OPERATION
l
code
Br: Brown
0: Orange
;,: gken
.
gr:RtTY
L: Blue
Y: Yellow
models.
Lg: Li ht green
W: Wfite
I
37W721
TROUBLESHOOTING HINTS
1. Both defogger
and indicator
light
With the ignition switch at the ON position,
voltage is applied, through fuse No. 5 and the
operate
defogger timer unit, to the defogger switch.
(1) Blower motor also does notqperate
When the defogger
switch
is switched
ON
l
Check fuse.
(automatic return), current flows to fuse No. 5,
I(2) Blower motor operates
the defogger
timer unit, the defogger
switch,
* Check defogger switch.
and ground, and the timer switch (within the
2. Defogger does not operate
=
defogger timer unit) operates for ten minutes.
(1) Indicator light goes on
When the timer switch is activated,
current
e Check defogger.
flows to the fusible link, the defogger
timer
unit, the defogger, and ground, and the defogger is activated.
-http://vnx.su/
: TCR
Rovicinn
b-
do
not
_.
li
II
II
m
ml
BACK DOOR WINDOW DEFOGGER

-DEFOGGER SWITCH
8-259
- Defogger Switch
NOSPJAD
REUVl10VAL
AND INSTALLATION
1. Defogger switch
m
--,
m
I

1. REMOVAL OF DEFOGGER SWITCH
and pry the switch
panel.
Insert the trim stick into the switch
remove
it from the instrument
to
INSPECTION
DEFOGGER SWITCH
(1) Remove the defogger switch from the instrument
panel
and connect an ohmmeter
to the switch side connector.
(2) Operate the switch and check the continuity between the
terminals.
**:
*: indicator light
Illumination light
46G0193
I
I
I
I
I
I
I
NOTE
U
indicates that there is continuity between
terminals.
i
--
1 TSB
Revision
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I
the
8-260
BACK DOOR WINDOW DEFOGGER - Printed Heater Lines

Normal
characteristic
PRINTED HEATER LINES
curve
Voltage
INSPECTION
2jk
Positive
terminal
Printed
Abnormal
heater
line
charactenstic
!$zi;t?
curve
Voltage
I
2vi point
I
:
I
6Vov Positive
terminal
Printed
Alignment
Masking
tape
heater
line
Negative
terminal
holes
RcmPu44
1. The printed
heater lines should be tested while the
engine is running at 2,000 rpm and the battery is being
charged.
2. Turn the defogger switch to the ON position, and use
voltmeter
to measure the voltage of each printed heater
line at the back doorwindow
glass center point A.
3. If all of the heater lines indicate approximately
6V, the
back door window
printed heater lines are functioning
properly.
4. if a voltage of 12V is indicated at point A, the heater
line is broken between
point A and the negative (-)
terminal. Move the test probe gradually toward the negative (-) terminal, and search for the place where there is
a sudden change in the voltage (to 0 V).
5. This place where the voltage suddenly changes indicates
the location of the broken heater line.
6. If OV is indicated at point A, the heater-line
is broken
between point A and the positive (+) terminal. Find the
point where there is a sudden change in the voltage (to
12V), as described in step 4. above.
REPAIR
16F65(
1. Prepare the following items:

l
Conductive
paint
l
Paint thinner
* Masking tape, decal, etc.
* Unleaded gasoline
l
Thin brush
Wipe the glass adjacent to the broken heater line, clean
with unleaded gasoline, and bond a decal or masking tape
as shown.
2. Shake the electroconductive
paint container
well, and
remove the amount of paint needed. Dilute it with a small
quantity of paint thinner, and apply three coats with the
brush at intervals of about 15 minutes.
3. Remove the tape or decal and leave the repaired defogger unused for a while before supplying power.
4. For a better finish, scrape away excess deposits with a
knife after drying is complete (one day later).
Caution
After repair, clean the glass with a soft dry shop
towel or wipe along the printed
heater line with a
slightly moistened
shop towel.
1 TSB Revision
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14-q 06
AUTO-CRUISE CONTROL SYSTEM - Specifications/Special Tools
AUTO-CRUISE
CONTROL
SYSTEM
SPEClFlCATlONS
Items
Specifications_
Auto-cruise control switch

Rated load A
MAIN
SET
RESUME
Voltage drop V
1.0
0.2-10.1
0.210.1
0.1 or less
Stop light switch

Rated load A
Voltage drop (at rated load)
0.1-1.5
0.15 or less
Clutch switch
Rated load A
Voltage drop (at rated load)
Auto-cruise control unit
Set error km/h (mph)
Range of speed control
0.1-I .5
0.15 or less
/
I
25 (23)
40-145 (25-9Q3
km/h (mph)
4ctuator
Drive system
Stroke mm (in.)
Electrical (DC motor)

36-Q (1.5-.I .7)
-~
Items
Specifications=
Accelerator cable B (throttle valve side) play

Actuator clutch coil resistance fi
mm (in.)
l-2 (.04-,081
Approx. 20
Items
Auto-cruise control actuator
Actuator bracket
Accelerator cable plate
protector
SPECIAL TOOLS
Tool
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Nm
ftlbs.
4-6
9-14
4-6
3-4
7-10
3-4
AUTO-CRUISE CONTROL SYSTEM
- Troubleshootinn
14-107
TROUBLESHOOTING
Nll(EBDL
The auto-cruise control system performs control functions for

the setting or cancellation
of the fixed-speed
driving speed
based upon the data provided by input signals. As a result,
when the auto-cruise control system is canceled, the cause of
the cancellation
is memorized in a separate circuit by the autocruise control unit, regardless of whether or not the auto-cruise
control system condition is normal or abnormal, thus providing
the auto-cruise control unit with the self-diagnosis
function by
certain fixed patterns, as well as the function of being able to
check whether or not the auto-cruise control units input switches or sensor are normal.
Thus, by effectively using these
function, the time required checking and repair can be shortened.
NOTE
When the computer (auto-cruise control unit) power supply (ignition switch and main switch) is switched OFF, the memorized diagnosis
codes are erased, and so for this reason the
power supply must be left ON until the checking is completed.
TROUBLESHOOTING QUICK-REFERENCE CHART

Auto-cruise control system is canceled
1 when cancellation not wanted.
1
Or, the auto-cruise control system cannot
be set after an automatic cancellation.
After the occurrence

the ignition
ON?
switch
of the problem, was

and MAIN switch
yes
With the MAIN switch ON and the engine

b running, check the diagnosis code. (P. 14119)
left
Go to check chart 2
onpage14-Ill.
Set the auto-cruise

control
system
and
conduct a road test.
Yes
No (now normal)
Check whether or not, then, the vehicle was driven on a

steep slope, or the SET and RESUME control switches
were operated simultaneously.
(The cause is not clear
under the present circumstances.)
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14-108
AUTO-CRUISE CONTROL SYSTEM - Troubleshooting

NOTE
if, after the occurrence of the problem, the ignition
the MAIN switch have not been switched OFF, it is
determine
(by checking the djagnosis output code)
cuit canceled the systems operation.
This chart is to be used, then, for troubleshooting
possible to use the self-diagnosis for checking.
Auto-cruise control system cannot be set.
Prepare to conduct input check.
No
Were codes No. 21, 22 and 25 displayed

when, with the vehicle stationary, the input check codes were recalled?
Yes
Y
switch and
possible to
which cirif it is not
0 Damaged or disconnected wiring of the auto-cruise

control unit power-supply circuit (Go to check chart 1 on
page 14-111.)
l
Damaged
or disconnected
wiring of the SET or
RESUME switch (Go to check chart 2 and 3 on page
14-111.112.)
Are the results of all input checks normal?
es
No
Check results
Probable cause
Remedy
Check chart
No.
Code 21 remains even though

SET switch is set to OFF.
SET switch ON malfunction
Replace the control

switch
No. 2
SET switch input fine

short-circuit
Repair the harness.
RESUME switch ON
malfunction
Replace the control

switch.
RESUME switch input

line short-circuit
Repair the harness.

CANCEL switch is set to OFF.
Malfunction of theCANCEL circuit

(ON malfunction)
Check or repair each

CANCEL circuit.
Code 25 does not disappear, and

code 24 does not appear, even
though vehicle speed reaches approximately40 km/h (25 mph) or
higher.
Malfunction of thevehi&-speed sensor circuit (damaged or

dis-connected wiring,
or short-circuit)
Checkorrepairthe
-~ No.4
vehicle speed sensor
circuit.

RESUME switch is set to OFF.
r--
Check the actuator circuit.

(Go to check chart No.5 on page 14-114.)
No.3
No. 6i,6-2.
6-3
MATE
IlL
If the results of the check ofthe
actuator circuit (check chart
No.5) and of the-actuator
itself (P.14114,
129) reveal no abnormal condition, replace the auto-cruise control unit (ECU).
[ TSB Revision
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14-109

Trouble symptom
l
l
Probable cause
Check chart No.
Remedy
No.4
Repair the vehicle

speed sensor system,
or replace the part.
No. 5
Repair the actuator

system, or replace the
part.
Malfunction of the
auto-cruise control unit
Replace the
auto-cruise control unil
Damaged ordisconnetted wiring of the

stop light switch input
circuit: brake switch
(for the auto-cruise
control) malfunction
(short-circuit)
If the input check code

No. 23 indicates a
malfunction. No. 61
Repairthe harness or
replace the stop light
switch.
Actuator drive circuit

short-circuit
No. 5
Repair the harness or

replace the actuator..
Malfunction of the
Replace the
Damaged or
disconnected wiring of
clutch switch input
circuit

No. 23 indicates a
malfunction. No.63
Repair the harness, or

repair or replace the
clutch switch.
Malfunction of the
Replace the
Damaged or
inhibitor switch input
circuit

No. 23 indicates a
malfunction. No62
Repair the harness, or

repair or replace the
inhibitor switch.
Replace the
The set vehicle speed varies greatly

Malfunction of the
upward or downward.
Hunching (repeated alternating
circuit
acceleration and deceleration) occurs _
Malfunction of the
after setting is made.
speedometer cable or
speedometer drive gear
Actuator circuit poor
contact
Malfunction
actuator
The auto-cruise control system is not

canceled when the brake pedal is
depressed.

canceled when the clutch pedal is
depressed. (vehicles with a manual
transmission) (It is canceled, however,
Nhen the brake pedal is depressed.)

:anceled when the selector handle is
noved to the N position.
Vehicles with an automatic
:ransmission) (It is canceled, however,
Nhen the brake pedal is depressed.)
of the
Clutch switch improper

installation (wont
switch ON)
Improper adjustment
inhibitor switch
of
Malfunction of the
TSB Revision
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Trouble symptom
Probable cause
Check chart No.
Remedy
Cannot decelerate by using the SET

switch
Temporary damaged or
SET switch input circuit
No. 2

replace the SET switch.

contact
No. 5

replace theactuator.
Malfunction of the
Replace the
Damaged or
disconnected wiring, or
short-circuit, of
RESUME switch input
circuit
No. 3

replace the RESUME
switch.

contact
No. 5

replace the actuator.
Malfunction of the
Replace the
Malfunction of the
circuit
No. 4
Repair the vehicle

speed sensor system,
or replace the part.
Replace the
Malfunction
actuator
Cannot accelerate or resume speed by

zsing the RESUME switch.
Malfunction
actuator
Auto-cruise control system can be set

Nhile traveling at a vehicle speed of less
!han 40 km/h (25 mph), or there is no
sutomatic cancellation at that speed.
of the
of the
Malfunction of the
speedometer cable or
the speedometer drive
gear
Malfunction of the
The MAIN switch indicator light does

lot illuminate.
But auto-cruise control system is
iormal.)
3verdrive is not canceled during fixed

speed driving. <A/T>
Damaged or
disconnected bulb of
MAIN switch indicator

replace the control
switch.
Harness damaged or
disconnected
Malfunction of circuit
related to overdrive
cancelation,or
malfunction of the
autocruise contorl unit
No.7
10 shift to overdrive during manual

Iriving <A/T>
TSB Revision
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~~

replace the part.
AUTO-CRUISE
14-111
CONTROL SYSTEM - Troubleshooting
CHECK CHART
. CHECKING
THE CONTROL
Ignition
UNIT
POWER
SUPPLY
Main switch
ICruise control
switch
n
, 3-W
(<-
CIRCUIT
3BW
- -
RL
switches)
) (
&w+&-py
(Auto-cruise
Sub
fusible
link
control
switches
side)
0.85-R
Auto-cruise
control unit
Main
hi
Battery
03w554
+,
f
(Auto-cruise
Description
Troubleshooting
hint
Auto-cruise
control
unit
terminal
cruise
earth.
10
2.
side)
Contorl
I PIY
unit
power
sup-
ground
to the control
When
the cruise-control
switched
ON, with the
switch
ignition
(MAIN)
is
switch
ON.
12v
I
CIRCUIT
Set switch
(Auto-cruise
control
I--
voltage
ov
switch
BFij
(Auto-cruise
switches)
2-B
-18
ON
I-1
unit, and to
Terminal
At all times
THE SET SWITCH
To Ignition
switch,
Conditions
Control unit
CHECKING
control
voltage
ITeEF
I
unit connector
of operation
When the Main switch (of the cruise controls

switches) is switched ON while the ignition switch
is ON, current flows to the ignition switch, to the
control
control
switches
side)
Auto-cruise
control unit
(Auto-cruise
control
unit connector
side)
03W565
1 TSB Revision
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14-I 12
Description
of operation
When the SET switch is switched
ON (at the
vehicle speed desired to be maintained,
and with
the MAIN switch of the cruise control switches
ON) that vehicle speed is maintained as a constant
speed. Furthermore,
the constant speed is gradually reduced (the coasting
feature) when the SET
switch
is pressed
speed, and, when the SET
switch is released, the vehicle then maintains that
Troubleshooting
hint
Diagnosis-No.
15 (automatically
Auto-cruise
control
unit terminal
Terminal
No.
5
newly set constant speed (the speed at which the

SET switch was released).
Current flows to the confrol unit, the cruise control
switch (SET), and to earth.
cancelled)
voltage
Signal
Conditions
Terminal voltage
SET switch
ov
When the SET switch is switched
3. CHECKING
THE RESUME
SWITCH
OZF
12v
CIRCUIT
1
Auto-cruise
control unit
(Auto-cruise control switches side)
(Auto-cruise control unit connector side)

03W566
Description
of operation
The RESUME switch is switched
ON and held
while the vehicle is traveling at a constant speed,
the vehicle speed will increase (The vehicle speed
cannot increase to 145 km/h (90 mph) or more.);
the speed at which the switch is subsequently
released will become
the newly set constant
speed. In addition, the set speed (before cancellation) resumes
when
the RESUME
switch
is
switched
ON, even if the constant-speed
control
Troubleshooting
hint
Diagnosis-No.
15 (automatically
Auto-cruise
control
unit terminal
Terminal
No.
4
cancelled)
voltage
Conditions
Signal
RESUME switch
has been cancelled.

That speed will not resume,
however, even if the RESUME switch is switched
ON, if the MAIN switch is switched OFF and if the
vehicle speed decreases to 40 km/h (25 mph) or
lower.
Current flows to the control unit, the cruise control
switch (RESUME),. and to earth.
When the RESUME switch
Terminal voltage
is switched
When the RESUME swi_tch is switched
1 TSB Revision
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I-
ON
ov
OFF
12v
.-
zix
__
14-113

4. CHECKING
THE VEHICLE-SPEED
SENSOR
CIRCUIT
Y&+q
15
Combination
meter
2-B
---
/
A&-cruise
control unit
I33Y
(Auto-cruise
(Reed-switch
side) (Harness
control
unit connector
side)
side)
03W567
Description
of operation
The vehicle-speed
sensor is installed within the
speedmeter;
it sends to the control unit pulse
signals that are proportional
to the rotation speed
(i.e., the vehicle speed) of transmissions
output
Troubleshooting
hint
Diagnosis-No.
12 (automatically
Auto-cruise
control
unit terminal
cancelled)
voltage
Conditions
Signal
I I
Vehicle-speed
15
sensor
gear. This vehicle-speed

sensor is the reed switch
type of sensor; it generates four pulse signals for
each rotation of the speedometers
driven gear.
Set the select lever to the 3

range or 1 range, and move
the vehicle forward slowly.
1 TSB Revision
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Terminal voltage
OV - 0.6V + Flashing -. 2V or
higher
AUTO-CRUISE CONTROL SYSTEM - Troubleshootina

CHECKING THE ACTUATOR CIRCUIT
To lgnitoin
switch
ch
Set switch
Resume switch
Auto-cruise
control switches
4
(Auto-cruise
control
unit connector
side)
top light
(Auto-cruise
control
switch side)
switch
Eiectromannetic
clutch coil
Clutch
plate
Planetary
pinion
Actuator
,T
Sel&tor
Sun gear
Description
Worm
gear
drive shaft
*II0077
of operation
Limit
switch
Selector (cruise
control cable
installation
part1
07R0103
1. When (with the MAIN switch ON) the driver

switches
ON the SET switch when the prescribed vehicle speed is reached, the control
unit sends current
to the electromagnetic
clutch coil of the actuator, thus attracting the
clutch plate, and also illuminating
the autocruise indicator light. Then, when the ring gear
of the planetary pinion is secured, the control
motor at the same time causes the DC motor
to be switched ON, and the DC motor operates
at high speed.
2. The rotation ofthe DC motor is, as described in

the illustration above, transmitted
to the worm
gear, and thereafter
to the worm wheel, the
sun gear, and the planetary
pinion in that
sequence. Because the ring gear is secured at
this time, the planetary
pinion rotates while
revolving around the sun gear. Because the
planetary pinion is installed to the carrier, both
the carrier and the selector drive shaft unified
with it, as well as the selector, are caused to
rotate.
http://vnx.su/

3.
The switching
of the direction
(PULL or REL.) of
5.
rotation
of the selector
is accomplished
by
revekng
the direction
of current flow to the
motor, and this is automatically
regulated
by
the control unit.
4. The current flow to the electromagnetic
clutch
is interrupted
if the driver switches
OFF the
MAIN switch, or if the operation
of the auto
cruise control system is cancelled as a result of
the input of a cancel signal to the control unit
because the stop light switch, clutch switch
(for a manual transmission)
or the inhibitor
switch (for an automatic
transmission)
is activated.
Troubleshooting
hint
Diagnosis-No.
11 (automatically
Auto-cruise
control
unit terminal
As a result
Conditions
Transistor for electromagnetic clutch coil
When the cruise-control

ON
DC motor
side)
drive (PULL
During acceleration
DC motor
side)
drive (REL.
During speed reduction
DC motor
1 side)
drive (PULL
DC motor
side)
drive (REL.
6-1. CHECKING
to the
During acceleration
switch
Terminal voltage
(MAIN) is switched
LIGHT
During speed
SWITCH
ov
by RESUME switch
(coasting)
ov
by SET switch
reduction
(coasting)
12v
by RESUME switch
THE STOP
current
cancelled)
voltage
2o
of the interruption
electromagnetic
clutch,
the clutch plate is
caused to return from the electromagnetic
clutch side to the ring gear side by the force of
the spring, and therefore
the ring gear becomes free.
6. When the ring gear becomes free, the planetary pinion becomes free relative to the sun
gear, and thus the selector is caused, by the
return spring installed to the selector part, to
return to its original postion.
Terminal
No.
14-115
- Troubleshooting
by SET switch
12v
ov
CIRCUIT
Actuator
Sub
fusible
link
0.85-R
aMain
fusible
link
Battery
LO
QC-CR
control unit
i
NOTE
(1) NC: Indicates ON at all times.
(2) NO: Indicated OFF at all times.
T
L
T

osw5as
1 TSB Revision
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a.
14-116
.- ,J~-L,*><.
I
*-
Description
of operation
When the brake pedal is depressed
during constantspeed
travel, the stop light switchs
(NC)
contacts for the cruise-control
system open, with
the result that the current to the electromagnetic
clutch of the actuator is interrupted,
thus cancelling the constant-speed
travel.
At the same time, moreover, the closing of the
Troubleshooting
hint
Diagnosis-No.
16 (automatically
Auto-cruise
control
unit terminal
Terminal
No.
3
(NO) contacts for the stop light switch results in

the sending of the cancel signal to the control unit,
so that the actuators electromagnetic
clutch current is discontinued
within the control unit, thereby
canceling the constant-speed
travel.
The flow of current is from the battery to the stop
light switch, and the control unit.
cancelled)
voltage
Signal
Tertnianl voltage
Conditions
Stop light switch (load

side)
When the brake pedal is-depressed
z~
12v
z
When the brake pedal is not depress:d
11
Stop light switch (power supply side)
6-2 CHECKING
THE INHIBITOR
OV
At all times
SWITCH
CIRCUIT
12v
<ATT>
Inhibitor
switch
Auto-cruise
control unit
(Auto-cruise
To batten/
*
control
unit connector
side)
Starter
Description
of operation
When , during driving at a constant speed,
selector handle is moved to the N position,
[ TSB Revision
the
the
inhibitor switch is switched

ON (continuity),
and
the cancel signal is input to the control unit.
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14-117

Troubleshooting
hint
Diagnosis-No.
16 (automatically
Auto-cruise
control
unit terminal
Terminal
No.
cancelled)
voltage
Signal
inhibitor
6-3. CHECKING
Conditions
switch
THE CLUTCH
Termianal voltage
Selector
handle set to N or P
ov
Selector
handle set to other than N or P
12v
SWITCH
CIRCUIT
<M/T>
Ignition switch
RL
3-w
,
Main
fusible
link
_ RB
- GB
Auto-cruise
control unit
Battery 1
Description
of operation
If the clutch pedal is depressed
during constantspeed travel, the contacts
of the clutch switch
close, with the result that the cancel signal is sent
to the control unit, so that the current to the
electromagnetic
clutch of the actuator is discontinTroubleshooting
unit, thereby
canceling
the
hint
Diagnosis-No.
16 (automatically
Auto-cruise
control
unit temrinal
cancelled)
voltage
Terminal
No.
1
ued within the control

constant-speed
travel.
Conditions
Clutch switch
When the clutch
pedal is depressed
When the clutch pedal is not depressed
[ TSB Revision
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Terminal voltage
12v
ov
14-118
CHECKING
TNE CIRCUITS
RELATED
TO THE OVERDRNE-CANCELLATION
FUNCTION
<A/T>
lgnitin switch
, 3-W
(/--
3-BW -
I.
I;II
meter
I
OD-OFF
Main
fusible
link
4-J (Auto-uuise control unit connector side)
OD-OFF
solenoid
Description
of operation
This is a function
that cancels
tha overdrive
function for a certain fixed period of time, if during
constant-speed
travel in overdrive, the actual vehicle speed decreases to less than the vehicle speed
retained in the memory, and then after a shot-t time
causes the vehicle speed to return to the vehicle
speed retained in the memory.
Overdrive is canceled under the following
conditions.
1. If the RESUME
switch is used.
2. If, during constant-speed
travel, the actual
vehicle speed decreases
to 1.25 kmk (.78
mph) or more below the set vehicle speed.
Troubleshooting
hint
Auto-cruise
control
unit terminal
/ Terrryl
Under either of the conditions

described
above,
the overdrive-ON
signals output from the microcomputer
(within the control unit) are no longer
output, and transistor Trl is switched
OFF.
As a result, transistor
Tr2 is also switched
OFF,
causing the current passing through the overdrive
switch of the selector handle to be interrupted
at
transistor
TR, with the result that the drive is
controlled
at 3rd gear.
voltage
signal
Terminal voltage
13
I Overdrive
switch
I When
~~ the overdrive
switch
is swit&ed
ON
14
Overdrive
switch
When the overdrive
switch
is swit&d
ON
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12v
12v
14-119
SELF-DIAGNOSIS CHECK
Self-diagnosis
checking is performed when there has been an
automatic
cancellation,
without
cancel switch operation.
(1) The following
method
can be used for checking
the
diagnosis. When the glove compartment
is removed (as
shown in the illustration), the diagnosis check connector
can be found at the upper part.
0 If a multi-use tester is used.
Connect the multi-use testers socket and connector
to the cigarette lighter socket and the self-diagnosis
check connector,
and set the tester.
Use the tester according to its operation instructions;
display the diagnosis
code number and then check.
@ If a voltmeter
is used.
Connect a voltmeter between the ground terminal and
the terminal for auto-cruise
control of the diagnosis
check connector.
It is possible to discover which circuit is the cause of
the cancellation
by verifying the indication shown by
the voltmeter with the display patterns shown on the
next page.
(2) When diagnosis code No. 11, 12, 15 or 16 is displayed,
check by referring to the check chart applicable
to that
number.
NOTE
There are six diagnosis items, inclucing the one for the
normal condition. As examples of the normal condition,
code No. 16 is entered in the memory as cancel switch
ON signal input if the system is canceled by depressing
the brake pedal, and code No. 13 or No. 14 is entered
when there is an automatic
cancellation
because the
vehicle speed drops when the vehicle is driven up a steep
slope with the preset speed setting left set, etc.. When,
however, there is a cancellation
not intentionally
made by
the driver, the cause might be damaged or disconnected
stop light switch input wiring, a malfunction
of the stop
light switch ON, etc., even though the same code No. 16
is displayed.
With multi-use tester
Afii voltmeter
.44y;pise
Self-diagnosis
check connector
Gro;nd
h
I
\
.
-I
G
:er
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14-120
DIAGNOSIS
._
AUTO-CRUISE CONTROL SYSTEM - Troubleshootinn

DISPLAY
PATTERNS
AND CODES
NUJC
1. Codes indicated by the * symbol are displayed,

if the conditions
are satisfied, even if the system is
normal. In either case, the system is normal if it can be reset. If there is an automatic cancellation
not
intentionally
made by the driver, however. excluding
cancellations
explicitly made by the cancel procedure, there may be a temporary malfunction
such as poor contact of a harness connector even though
the system can be reset, and for that reason it is necessary to check according to each individual check
chart that is applicable.
Display when vehicle speed is approximately

20 km/h (12 mph) or higher, or before the
auto-cruise control system is set
0.5 set
(%,
OFF
04
2.
0.5 set
--03R019~
Diagnosis codes are displayed when, after cancellation

of
the auto-cruise
control system, the vehicle speed decreases to less than approximately
20 km/h (12 mph), and
are erased by switching
OFF the ignition switch or the
MAIN switch.
After the diagnosis codes in the memory are erased, if
(when the power supply of the auto-cruise control unit is
switched
ON once again) the power
supply of the
electronic
control unit is normal, the diagnosis
output
code display will be as below, regardless of whether the
system condition
is normal or not.
0 If a multi-use
tester is used: NORMAL!!
will be
displayed.
0 If a voltmeter
is used:
Continuous
ON/OFF signals will be displayed at 0.5
second intervals.
(Refer to the figure at the left.)
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14-121
INPUT CHECK
Input checks should be made when the auto-cruise control
system cannot be set and when it is necessary to check
(when a malfunction
related to the auto-cruise control system
occurs) whether
or not the input signals are normal.
NOTE
1. lf inspection
of self-diagnosis
is necessary, confirm diagnosis code first and conduct input check.
2. Input check can be conducted
by set operations.
Self-diagnosis
terminal outputs codes number or display
patterns.
3. Display codes are displayed only if the circuit is normal
according to the conditions
shown in the table the next
page.
(1) If a multi-use tester is used, the setting of the tester is the
same as for the self-diagnosis
check, and call-out the
auto-cruise
control system.
(2) The voltmeter
is set in the same way as for the selfdiagnosis
check.
(3) Turn the ignition key to ON. (Check No. Ito No. 3 of the
input check table.)
(4) Start the engine. (Check No. 4 and No. 5 of the input check
table.)
(5) Code call-out
0 Switch ON the SET switch while holding the RESUME
switch ON.
0 This procedure
makes it possible to display the results
of the input check.
(6) Code read-out
0 Perform each input operation according to the input
check table (on the next page) and read the codes.
NOTE
l
Each code will be displayed in an order of priority
beginning
from No. 1.
When each input operation
is performed
and the
signals for the conditions
are received
by the
computer,
each output code will be repeatedly
displayed in the sequence of priority for as long as
that signal continues.
If there is no display, it is possible that there is a
malfunction
of the auto-cruise control unit powersupply circuit or the SET and/or RESUME switch.
so check according to check charts 1, 2 and 3
(P.14-112,
113).
l
If, during the display of output codes, the input
operation
is canceled (if, for example, the SET
switch is set from ON to OFF), the code will be
displayed for one cycle of the display, but will not
be displayed
during the next cycle.
This makes it possible, therefore, to check the OFF
condition (existence of not of a shortcircuit
of the
input line or the switch).
Cp Switch the MAIN switch OFF.
1 TSB Revision
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AUTO-CRUISE
INPUT CHECK TABLE

kzde
Display patterns
21
12v
(output
r
r
ov
22
Each CANCEL switch ON

1 Stop light switch (brake
pedal depressed)
2 Clutch switch *(clutch
pedal depressed)
3 Inhibitor switch qselector
handle to N range)
23
SET s&itch circuit

normal
RESUME switch circuit normal
Each CANCLE circuit normal
When both No. 4

and No. 5 can be
confirmed, vehicle-speed sensor
Driving at approximately to
40 km/h (25 mph) or higher
Driving at less than approxi1 rnn;$Okm/h(25mph)or
<M/-J>
*= <A/T>
AUTO-CRUISE CONTROL RELATED HARNESSES

<ENGINE
Check results
codes)
COMPARTMENT>
1 - Starter motor
2 - Inhibitor switch
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AUTO-CRUISE
14-123
J
I
3.
4.
5.
6.
7.
8.
9.
10.
11.
Combination
meter
Clutch switch
Column switch
ignition switch
Stop light switch
Auto-cruise control unit
Diagnosis check terminal
Overdrive switch
Inhibitor switch
AUTO-CRUISE
CONTROL COMPONENTS
Name
LOCATION
Symbol
Name
Auto-cruise
contol actuator
Inhibitor
Auto-cruise
control
switch
Overdrive switch
Auto-cruise
control
unit
Stop light switch
Vehicle speed sensor (Reed switch)
Clutch pedal switch

NOTE
The Name
column
<M/T>
is arranged
in alphabetical
order.
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switch
<AIT>
Symbol
<A/T>
F
E
14-124
<Engine
- Troubleshooting
<Interior>
compartment>
Speedometer
--
ion
http://vnx.su/
Troubleshooting
SERVICE
Indication
/ gewice
~~ustment
ADJUSTMENT
Procedures
Id-125
PROCEDUF33!
AUTO-CRUISE CONTROL SYSTEM INSPECTION

AUTO-CRUISE
CONTROL
MAIN SWITCH CHECK
(1) Turn the ignition switch to ON.
(2) Check to be sure that the indicator light within the switch
illuminates
when the MAIN switch is switched
ON.
03w572
q 3W572
I
AUTO-CRUISE
CONTROL
SEITING
CHECK
(I) Switch ON the MAIN switch.
(2) Drive at the desired speed within the range of approximately 40-145
km/h (25-90 mph).
(3) Press the SET button.
(4) Check to be sure that the speed is the desired constant
speed when the switch is released.
NOTE
If the vehicle speed decreases to approximately
20 km/h
(12 mph) below the set speed, because of climbing a hill
for example, the auto-cruise
control will be cancelled.
SPEED-INCREASE
SETTING
CHECK
(1) Set to the desired speed.

(2) Turn the control switch to RESUME position.
(3) Check to be sure that acceleration
continues
while the
and that when it is released the constant
time when it was released becomes the
NOTE
Even if, during acceleration,
the vehicle speed reaches or
exceeds the high limit [approximately
145 km/h (90 mph)),
acceleration
will continue,
however, when the switch is
released, the set speed (memorized
seed) will become
the hign limit of the vehicle speed.
03W572
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14-I 26 AUTO-CRUISE CONTROL SYSTEM
03W572
SET
&lE
03W372
Procedures
SPEED REDUCTION
SElTING
CHECK
(1) Set to the desired speed.
(2) Press the SET button.
(3) Check to be sure that deceleration
continues
while the
switch
is pressed,
and that when it is released the
constant speed at the time when it was released becomes
the driving speed.
NOTE
When the vehicle speed reaches the low limit [approximately 40 km/h (25 mph)] during deceleration,
the automatic speed control will be cancelled.
AUTO-CRUISE
CONTROL CANCELLATION
CHECK
(1) Set the auto-cruise
control.
(2) Check to be sure that there is a return to ordinary driving,
and that the illumination
of the auto-cruise indicator goes
out, when either of the operations
below is performed.
0 The brake pedal is depressed.
0 The clutch pedal is depressed.
<M/T>
0 The selector handle is moved to the N range.
<Al-l->
@ The auto-cruise control MAIN switch is switched OFF.
CHECK OF RETURN TO THE SET SPEED BEFORE CANCELLATION
Set the auto-cruise
control.
Check to be sure that the auto-cruise control is cancelled
when either of the operations
below is performed.
0 The brake pedal is depressed.
0 The clutch pedal is depressed.
<M/T>
0 The selector handle is moved to the N range.
<A/T>
Turn
the control switch to RESUME position and release
(3)
(RESUME switch ON PFF)
while driving at a vehicle
speed of approximately
40 km/h (25 mph) or higher.
RESUME switch to OFF there will be a
(4) After switching
return to the auto-cruise
control speed before the autocruise control speed will be cancelled and the vehrcle will
travel at the constant
speed.
1;;
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AUTO-CRUISE
ACCELERATOR
CONTROL
CABLES
Intermediate
(Accelerator
SYSTEM
INSPECTION
AND
14-127
Procedures
ADJUSTMENT
link A
pedal si
Accelerator
(Accelerator
uto-cruise
control
cable A
pedal side)
actuator
lerator cable B
ttle valve side)
Throttle
lever
(1) Confirm there are no sharp bends in accelerator cables.

(2) Check inner cables for correct slack.
(3) If there is too much slack or no slack, adjust play by the
following
procedures.
0 Remove the actuators
protector.
(2, Connect accelerator

dimensions
shown
1
/ TSB Revision
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cable B to the actuator

in the figure).
(at the
--I
,.
l E.
14-l 28 AUTO-CRUISE CONTROL SYSTEM - Service Adjustment
Procedures
@ Slide (in the direction of the arrow) the cable (outer] so

that the cables play wi)) be 1 - 2 mm (.04 - .08 in.), and
secure by using the adjustment
bolts.
Check to be sure that the throttle link contacts the stopper (fixed SAS).
Fixe
Throttle
link
@I Connect
cable A at the dimensions
Adjust so that the play of cable A at the G part is 0 - 1

mm (0 -.04 in.).
@ Check to be sure that the throttle link moves when the
actuator link is turned 1 - 2 mm (04 - .08 in.).
8 Check to be sure that the actuator link and the throttle
link function smoothly when the accelerator
pedal is
fully open and fully closed.
@ Install the protector tothe actuator.
NlwrAo
INDIVIDUAL PARTS INSPECTION
AUTO-CRUISE
CONTROL SWITCH INSPECTlON
Disconnect the column switch connector and check the continuity between the terminals.
O-0 Continuity
-Terminal
OFF
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AUTO-CRUISE
CONTROL
-/
El
s&p
1
@
SYSTEM
Procedures
14- 129
STOP LIGHT SWITCH/BRAKE

SWITCH INSPECTION
(1) Diconnect the connector.
(2) Check for continuity between the terminals of the switch.
O-O :Continuity
Stop light siwtch
1 2
311
When brake pedal

depressed.
When brake pedal
not depressed.
CLUTCH SWITCH INSPECTION

(1) Disconnect the connector.
(2) Check to be sure that there is continuity between
tor terminals when the clutch pedal is depressed.
connec-
INHIBITOR SWITCH (N AND P POSITIONS) INSPECTION

(2) Check to be sure that there is continuity between connector terminals 3 and 4 when the selector handle is moved to
the N and P range.
ACTUATOR INSPECTION
(2) Measure the resistance value of the clutch coil.
Resistance of clutch coil between connector terminals
(V-P)
Standard
value: Approx.
200
ACTUATOR OPERATION CHECK

Disconnect the actuators connector and, in the order described below, check the actuators
operation
and the circuit
testers indication;
replace the actuator assembly if any abnormal condition is discovered.
(1) Checking the clutch coil solenoid operation
Connect terminal (1) of the actuator through the ammeter
to the positive (+) terminal of the battery, and connect terminal (2) to the negative (-) terminal.
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14-130
AUTO-CRUISE CONTROL SYSTEM - Service Adjustment
Procedures
4
II
NOTE
(1) NC: indicates ON at all times.

(21 NO: Indicates OFF at all times.
Actuator
03W587
Judgement
Abnormal
sound
No solenoid sound
--
Normal
Solenoid operation
can be heard.
A>: 0.5-0.7A
sound (click)
NoAs?;;oid
i-
Probable cause
Damaged or disconn&cted
wiring of clutch coil
Short-circuit
of clutch coil
At=coA
(2) Checking the motor (PULL direction)

and limit switch
operation
In the condition described in (I), connect terminal (4) of
the actuator, through the ammeter,
to the positive (+)
side and terminal (3) to the negative (-) side.
16W1711
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AUTO-CRUISE CONTROL SYSTEM - Service Adiustment
Procedures
14-131
Judgement
Normal
Abnormal
Current is cut off when selector

is turned in PULL direction for
full stroke (fully open).
AI: 0.5-0.7A
AZ: less than 0.5A
(when current ON)
Selector moves in PULL direction

but
AZ: equal or more than IA
AI : 0.5-0.7A
Probable cause
l
l
l
Selector doesnt move.

AZ: equal or more than IA
Al: 0.5-0.7A
l
l
l
Selector doesnt
&=OA
AI: 03-0.7A
move.
l
l
l
l
Nith the selector stroke at the

ntermediate
level, disconnect the
:onnection to terminal (1) and
:ut the current flow to the
:lutch coil.
The selector doesnt return to

the original position even if the
current to the clutch coil is cut.
Improper backlash between

gears
Imminent burning between
shaft and metal
Insufficient thrust clearance
Shaft burned
Foreign material
between gears
Motor burned
Damaged or
internal lead
Damaged or
motor wiring
Poor contact
Open diode
caught
disconnected
wire
disconnected
of limit switch
Malfunction of clutch operation

(Clutch plate remains engaged
with clutch)
(3) Checking the motor (REL. direction)

and limit switch
operation
Reverse the connections
to terminal (3) and terminal (4)
from those described
in (2).
Actuator side
connector
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14-132 AUTO-CRUISE CONTROL SYSTEM
Service
Adjustment
Procedures
Judgement
Normal
Zurrent is cut off when selector
s turned in REL. direction for full
stroke (fully closed).
AI: 0.5-D0.7A
AZ: less than 0.5A
(when current ON)
Abnormal
Probable cause
Ye
Selector moves in REL.

direction but
AZ: equal or more than 1A
AI : 0.5-0.7A
Selector doesnt move.
AZ: equal or more than 1A
At: 0.5-0.7A
.-.
Improper backlash between
gears
l
Imminent burning between
shaft and metal
0 Insufficient thrust clearance
l
~-
l
l
Selectordoesnt
Az=OA
AI : 0.3-0.7A
move.
Damaged or disconnected
internal lead wire
Damaged or disconnected
motor wiring
Poor contact of limit switch
Open diode
l
l
l
l
AUTO-CRUISE
CONTROL
Shaft burned
Foreign material caught
between gears
Motor burned
SIGNAL
CIRCUIT
Disconnect
the connector
of the auto-cruise
then check at the body side wiring harness
chart below.
CHECK
control unit, and
acoording to the
IG SW : Ignition switch
MAIN S/W : MAIN switch
OD S/W : Overdrive switch
03W563
Terminal
Connection or measured part
Measurement item
Tester connection
Check conditions
Standard
Clutchswitch
Voltage
l-Ground
IG SiW ON
Clutch switch ON
Approx. 12V
Clutch switch OFF
ov
Inhibitor switch (P, N)
Continuity
2-Ground
P or N range
Continuity
Other than P or N range
No continuity
Stop light switch load

side
Voltage
3-Ground
Press the brake pedal.
Approx. 12V
RESUME switch
Continuity
4-Ground
RESUME switch ON (Turn)

~RESUME switch OFF (Release)
Continuity
SET
-- switch ON (Press)
Continuity
SET switch
Continuity
5-Ground
SET switch OFF (Release)

7
Power supply (MAIN)
Voltage
7-Ground
1 TSB Revision
IG S/W ON, MAIN SW ON
~-
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No continuity
No continuity
.~ _____
Approx. 12V
~~
-~
AUTO-CRUISE CONTROL SYSTEM - Service

Termi- Connection or meanal
/ sured part
Measurement item
Stop light switch

(for auto-cruise
control cancellation)
and actuator (clutch)
Voltage
Actuator (motor)
Resistance
9.20
Tester connection
Adjustment
Procedures
Check conditions
14-133
Standard
Ki
Press brake pedal after checking

9-20
Approx. 120
Actuator selector
(Fully closed position)

10
13
14*2
15
17*
Ground
1 Overdrive solenoid
OD switch
Vehicle speed sensor
Continuity
IQ-Ground
At all times
Continuity
Voltage
1 l-Ground
At all times
Approx. 12V
Continuity
12-Ground
1 At all times
Continuity
1 Continuitv
1 13-Ground
1 At all times
/ Continuity
1 Voltage
1 14-Ground
~ IG SIW ON
Voltage
15-Ground
Self-diagnosis
Actuator
OD S/W ON position
Approx. 12V
OD S/w OFF position
OV
With the ignition key at the ON
4 voltage
position, slowlyturn
meter cable.
changes/ cabie rotation
the speedo-
NOTE
1. As shown by the *l symbol, the limit switch within the actuator will become as shown in the figure at the left if the
actuator selector is at the fully closed position when the
resistance
between
terminals
No. 9 and No. 20 is
measured:
for that reason, after checking the polarity of
the tester, the testers probe should be connected so that
current flows from the No. 20 terminal to the No. 9 terminal.
2. For terminals No. 17 and 14 indicated by the *2 symbol, it is
necessary to check individual terminal voltages with the
auto-cruise
control units harness connector
connected
and with the ignition switch ON.
(1) The No. 17 terminal is normal if the self-diagnosis
code can be confirmed.
(Refer to P. 14-119)
(2) The No. 14 terminal is normal if there is approximately
12V with the autocruise
control system not functioning and the overdrive switch switched ON. (Refer to P.
W-118.)
VEHICLE-SPEED
SENSOR INSPECTION
Refer to GROUP &Meters
and Gauges for checking of vehicle
speedsensor.
[ TSB Revision
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14-134
AUTO-CRUISE CONTROL SYSTEM - Auto-cruise
AUTO-CRUISE
Control
CONTROL
rl
l
Accelerator
Cable Adjustment (Refer
Removal
steps of actuator
1. Protector
2. Accelerator cable B adjusting
3. Accelerator cable A adjusting
4. Actuator side inner cable
5. Actuator connector
6. Actuator
Removal okensor
and switches
7. Accelerator switch <AIT>
8. Stop light switch
9. Clutch switch <M/T>
10. Inhibitor switch <A/T>
41) ++ 11. Vehicle speed sensor
d+ I)+ 12. Auto-cruise control switch
Removal steps of control unit
13. Front rail cover
14. Front door opening trim
15. Cowl side trim
16. Auto-cruise control unit
NOTE
(2) ++
(3) **
nut
nut
to reinstall.
of Removal.
of Installation.
NWDBE
11. REMOVAL
OF VEHICLE SPEED SENSOR

Refer to GROUP 8 - Meters and Gauges.
12. REMOVAL
Refer
OF AUTO-CRUISE
to GROUP
8 - Column
CONTROL
SWITCH
Switch.
INSPECTION
*
a
Check the inner and outer cable for damage.

Check the cable for smooth movement.
l
Check the actuator cover for damage.
CHECKING THE ACTUATOR
Refer
to P.14-129.

12. INSTALLATION
OF AUTO-CRUISE
Refer to GROUP 8 - Column

11. INSTALLATION
OF VEHICLE
Refer to GROUP
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8 - Meters
CONTROL
Switch.
SPEED SENSOR
and Gauges.
NwmOE
SWITCH
AUDIO SYSTEM - Specifications
8-227
IDlO SYSTEM
SPECIFICATIONS
GENERAL SPECIFICATKINS
Model
Rated input power
Center pillar trim
Model
1 TSB
NOBNB-
SR-1 OWZ4-UKE?
15W (Max. 2OW)
SR-1 OWZLGUKB
15W (Max. 2OW)
SR-1 OWZ4-U KB
15W (Max. 2OW)
SR-16SA4-4-DK
15W (Max. 3OW)
SR-16SA4-4-DK
15W (Max. 3OW)
SR-16SA44DK
15W (Max. 3OW)
Revision
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12-z?. lif
:+a
._
._,..
_. .
8-228
AUDIO SYSTEM - Troubleshooting
TROUBLESHOOTING
Item
Problem Symptom
A. Noise
1 Relevant Chart
1. Noise appears at certain places when traveling (AM).
A-l
2. Noise appears at certain places when traveling (FM).
A-2
1 3. Mixed with noise, only at night (AM).
A-3
1 4. Broadcasts can be heard but both AM and FM have a lot of noise. 1
A-4
A-5
A-6
5. There is more noise either on AM or on FM.
1 6. There is noise when starting the engine.

7. Some noise appears when there is vibration or shocks during
traveling.
A-7
8. Noise sometimes appears on FM during traveling.
A-8
1
B. Radio
9. Ever-present noise.
A-9
1. No sound.
B-l
2. No sound from one speaker.
B-2
3. There is noise but no reception for both AM and FM.
B-3
I 4. No sound from
AM, or no sound from FM.
I
I-~B-5
1 5. Insufficient sensitivity.
B-4
1
I
1
) 6. Distortion on AM or on both AM and FM.

I
7. Distortion on FMonly.
B-7
9. Insufficient memory (preset stations are erased).
B-9
1. Cassette tape will not insert.
C-l
2. No sound.
c-2
I 8. Too few automatic select stations.

I
C. Cassette Player
I 3. No sound from one speaker.

1 4. Sound quality is poor, or sound is weak.
I 5. Cassette tape will not eject.
6. Uneven revolution. Tape speed is fast or slow,
C-6
C-8
7. Automatic search does not work (only for models with automatic
search function).
I
8. Faulty auto reverse.

I
9. Tape gets caught in mechanism.
1 TSB Revision
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8-229

CHAFIT
A. Nal!iE
r-1
A-4
Noise appears
at certain
places when traveling
(AM).
Do the following measures eiiminate the noise?
Is there a particular structure?
Yes
1. Change to a different station

with a strong signal to boost resistance to interference.
2. Suppress high tones to reduce
Yes
v
Find out the following information from
2. Locality conditions (valley, mountain,

3. Name and frequency of stations
I<
No
Yes
Inspect the vehicles noise suppressor (refer to A-6).
If due to external noise:

In almost all cases, prevention on the
receiver side is impossible.
Weak signals especially are susceptible
to interference.
If due to vehicle noise:

It may not be possible to prevent noise
if the signal is weak.
1
1
If there is more noise than other radios, find out the noise conditions
and the name and frequency of the receiving stations from the user,
and consult with the service center.
1 TSR
Revision
http://vnx.su/
OK
8-230
p-i-~

1 Nomi
appears
at certain
places when
traveling
(FM).
Do the following measures eliminate the noise?

Change to a different station with a strong signal to boost
resistance to interference.
l Suppress high tones to reduce noise.
o Extend antenna completely.
Yes
OK
No
*
~~-
On radios with an FM stereo switch, is noise still present when

switched to monaural?
No
OK
~,
Yes
1
If there is more noise than other radios, find out the noise conditions and the name and frequency of the receiving stations from
the user, and consult with the service center.
NOTE
About FM waves:
FM waves have the same properties as light, and
can be deflected and blocked. Wave reception is
not possible in the shadow of obstructions such as
buildings or mountains.
The signal becomes weak as the distance from the
transmission
antenna
increases.
stations
Although this may vary according to the signal
strength of the transmitting station and intervening
geographical formations or buildings, the area of
good reception
is approx. 20-25
km (12-16
miles) for stereo reception, and 30-40 km (19-25
miles) for monaural reception.
The signal becomes
weak when an area of
shadow from the transmitting
antenna (places
where there are obstructions such as mountains or
buildings between the antenna and the car), and
noise will appear. <This is called first fading, and
gives a steady buzzing noise.>
FM Broadcast Good Reception Areas
For stereo: 20-25
If a direct signal hits the antenna atthe same time

as a signal reflected by obstructions such as mountains or buildings, interference of the two signals
will generate noise. During traveling, noise will appear each time the vehicles antenna passes
through this kind of obstructed area. The strength
and interval of the noise varies according to the
signal strength and the conditions of deflection.
<This is called multipath noise, and is a repetitious
buzzing.>
Since FM stereo transmission and reception has a
weaker field than monaural, it is often accompanied by a hissing noise.
FM Signal Characteristics
Signal Interference
and
For home stereos: 80-90

(5046
km
miles)
Multioath
intetfkrence
y
l&M554
16AOWi3
1 TSB Revision
~-
http://vnx.su/
m
ii
AUDIO
-1 A-3
1 Mixed
SYSTEM
with noise, only at night
(AM).
The following factors can be considered as possible

causes of noise appearing at night.
1. Factors due to signal conditions: Due to the fact
that long-distance signals are more easily received
at night, even stations that are received without
problem during the day may experience interference in a general worsening
of reception
conditions.
The weaker a station is the more susceptible it is
to interference,
and a change to a different
or the appearance
of a beating sound*
8-231
- Troubleshooting
2.
*Beat sound: Two signals close in frequency interfere with each other, creating a repetitious highpitched sound. This sound is generated not only by
sound signals but by electrical waves as well.
Factors due to vehicle noise : Alternator noise may
be a cause.
station
may occur.
when the lights are turned
Correctly connect
the antenna.
Yes
Yes
NO
Q, Tune to a strong station.

a~ Tune to a station with a
Clean the feeder

wire and ground wire
mounting area.
Mount the antenna
securely.
Inspect the alternator noise

suppressor (refer to A-6).
4
No
Is the noise eliminated?
No
Yes
Move the harness on the

vehicle side away from the
radio body (if the harness
not in the proper
No
If there is more noise than other radios, consult

a service center.
TSB Revision
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8-232
A-4

Broadcasts
can be heard but both
AM and FM have a lot of noise.
(1)
(Nzz;
(2)
(T>
when the engine is)
Yes
1
Do the following measures eliminate the noise?
Inspect the vehicles noise

suppressor. (refer to A-6.)
Tune to a strong station.

Extend the antenna completely.
o Adjust the sound quality to suppress high
l
l
No
Is the radio chassis ground mounted securely?
No
No
Securely tighten the nuts

for the chassis ground.
Yes
Is the antenna plug properly connected to the
Correctly attach the antenna.

-
1Yes
Clean the feeder wire and ground
e wire mounting area. Mount the
antenna securelv.
No
IYes
If there is more noise than other radios, consult a service

center.
-.
1 TSB Revision
http://vnx.su/

1 A-!;
8-233
1 There is more noise either on AM or on FM.
1. There is much noise only on AM

Due to differences in AM and FM systems,
AM is more susceptible
to noise interference.
Were conditions such as the following present when noise

was received?
e Lightning was flashing. A motorcycle was passing.
A vehicle passed close by, but it appeared to be a vehicle generating
large amount of noise radiation.
e Passed beneath a power line. Passed under a bridge.
e Passed beneath a telephone line. Passed close by a signal
Yes
8 Passed close by some other source of electrical noise.
No
Continue to check for static; when static is detected, check for the conditions listed above.
Yes
No
--
v
If the problem is particularly
worse than other radios, consult
a service center.
2.
There is much noise only on FM
Due to differences in FM and AM systems, FM is

not as susceptible as AM to interference from engines, power lines, lightning, etc. On the other
hand, there are cases due to the characteristics of
FM waves of noise or distortion generated by typ-
icad noise interference (first fading and multipath).

(Refer to A-2)
<Noise (hissing) occurs in weak signal areas such
as mountainous
regions, but this is not due to a
problem with the radio.>
1 TSB
Revision
http://vnx.su/
D Noise prevention on the radio side is difficult.

If the problem is particularly worse than other
radios, consult a service center.
8-234
A-6

There is noise when starting
Noise type
Sounds are in
parentheses ( )
AM, FM:
Ignition noise
(Popping, Snapping
Crackling, Buzzing)
AM, FM:
Alternator noise
(AM. FM1
(Swishing)
AM, FM:
Wiper motor
noise
(Low-pitched buzzing
Electrical buzzing)
Other electrical
components
Static electricity
(Crackling, Crinkling)
the engine.
Conditions
Increasing
the
engine
speed causing the popping
sound to speed up, and volume decreases.
l Disappears when the ignition switch is turned to
ACC.
e Noise becomes higher as
engine speed increases,
and in many cases is not
present at idle speed.
l
Appears with wiper operation and increases with

wiper speed. Disappears
when
the wipers are
stopped.
Disappears when the

vehicle
is
completely
stopped.
e Severe when the clutch is
engaged.
* Various noises are produced depending on the
body part of the vehicle.
Cause
l
l
Response
Mainly due to the spark . Noise filter

plugs.
Due to the engine noise.
_
o Noise condenser
l
Ground cabIe
Due to ripples* contained

in the voltage produced by
the alternator.
+ The amount of fluctuation in
voltage during full wave rectification of the three phase
A.C. current of the alternator is called a ripple.
* Due to the wiper motor
brushes.
0 Noise condenser
Noise may appear as electrical

components become older.
Occurs when parts or wiring
move for some reason and
contact metal parts of the
body.
Repair or replace electrical

components.
Return parts or wiring to their
proper position.
Due to detachment from the

body of the front hood,
bumpers, exhaust pipe and
Ground parts by bonding.

Cases where the problem is
not eliminated by a single re-
muffler, suspension, etc.
Noise filter
sponse to one area are cornmon, due to several body

parts
being
imperfectly
grounded.
Caution
1. Connecting
a high tension cable to the noise
filter may destroy the noise filter and should
never be done.
2. Check that there is no external noise. Since failure due this may result in misdiagnosis
due to
inability to identify the noise source, this operation must be performed.
3. Noise prevention
should be performed
by sup
pressing strong sources of noise step by step.
NOTE
1.
Condenser
The condenser does not pass D.C. current, but as
the number of waves increases when it passes
A.C. current, impedance
(resistance
against A.C.)
1 TSB Revision
decreases, and current flow is facilitated. A noise

suppressing condenser which takes advantage of
this property is inserted between the power line
for the noise source and the ground.
This
suppresses noise by grounding the noise component (A.C. or pulse signal) to the body of the vehicle.
2. Coil
The coil passes D.C. current, but impedance rises
as the number of waves increases relative to the
A.C. current. A noise suppressing coil which takes
advantage of this property is inSerted into the
power line for the noise source, arid works by preventing the noise component from flowing or radiating out of the line.
http://vnx.su/
m
R

NOUSEISUPPRESOR LOCATION
<2.6L Engine>
cable
--.
C3.OL Engine>
-E
I
E
-q
http://vnx.su/
8-235
B-236
1 A-7
AUDIO
1 S ome noise appears
when
SYSTEM
there
- Troubleshooting
is vibration
or shocks
during
No
traveling.
Ensure proper t%nnection.

I
Yes
I
Static electricity noisf37
Body static electricity-from the shock
absorber rubber bushings used to prevent vibration, tiresS etc. occurs
because of separation from the
ground, causing a buzzing noise. Since
no measures can be taken on the radio
side, steps should be taken to
discharge the static electricity of the
vehicle body.
switch is turned on while the vehicle is
Yes
Is the radio correctly grounded?
Tighten the screw securely.
Yes
t
s the antenna correctly grounded?
(If noise appears when the antenna is
moved this means the ground is not
If rust is present of the antenna

ground screw clean and tighten the
ground securely.
No
*
c
I
1
Yes
Repair or replace radio. I
/ TSB Revision
http://vnx.su/
8-237
AUDlO SYSTEM - Troubleshooting

1 A-8 1 Noise
sometimes
appears
on FM during
traveling.
Yes
OK
I
-
Yes
I
Is the radio chassis correctly grounded?
(Is the mounting
screw tightened
No
Tighten the screw securely.
I-
Yes
Is the antenna correctly grounded?

noise appears when the antenna i
moved this means the ground is not securely connected.)
c If rust is present of the antenna ground screw clean and tighten

the ground securely.
Yes
1
Repair or replace radio.
*
=
m
=I
m
-
About multipath noise and fading noise

Because the frequency of FM waves is extremely
high, it is highly susceptible to effects from geologjcal formations and buildings. These effects disrupt the broadcast signal and obstruct reception in
sederal ways.
e Multipath noise
This describes the echo that occurs when the

broadcast signal is reflected by a large obstruc1 TSB
Revision
http://vnx.su/
tion and enters the receiver with a slight time

delay relative to the direct signal. (repetitious
buzzing)
Fading noise
This is a buzzing noise that occurs when the
broadcast beam is disrupted by obstructing objects and the signal strength
fluctuates
intricately within a narrow range.
8-238
A-9
c7-i- ,.I
E.-f
m-e
a_>-
Noise.
Noise is often created by the following factors, and often the radio is OK when it is checked individually.
o Traveling conditions of the vehicle
e Terrain of area traveled through
l Surrounding
buildings
a Signal conditions
e Time period
For this reason, if there are still problems with noise even after the measures described in steps A-l to A-8 have
been taken, get information on the factors listed above as well as determining whether the problem occurs with
AM or FM, the station names, frequencies, etc., and contact a service center.
Perform the correct

0peraGn.
-
No
Perform the correct

0peraG.
Perform the correct

operation.
With electronic volume control
press a few seconds in the up
direction to check.
,Yes
s there sound when a cassette tape is inserted?
Repair or-replace radio.
Yes
use replacement?
No
No
?
Is the connector at the back of the radio connecte
properly?
Yes
Is the power voltage for the connector
(both ACC and BAllJ?
norma
Yes
Repair or replace radio.
1 TSR
Rmticinn
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,*
AUDIO SYSTEM - Troubleshootinn

1 B-2
1 MO sound
from one speaker.
Check to see if there is any sound when the

radio fader and balance knobs are centered.
Yes
No
to see if there is any sound when
attached to another radio.
Yes
Repair or replace radio unit.
No
Remove the connector on the back of the
radio and check the speaker harness for
I
I
Yes
It conducts electricity but is

shorted out.
Repair
c speaker
harness
No
Yes
Check the speaker for
Repair speaker harness and

- ensure proper connection of
relay connectors
r-5
No
Repair or
replace speaker
--
connector
cornector
* Conductance
2P
9P
Tester:
f2 range
check method
(1) Remove 9P and 5P connectors from racfio.

(2) insert test probe into connector terminal.
(Concerning
speaker connector,
refer to pages
and 252.) -
ism6e
*2 Conductance
check method
(1) Remove the speaker 2P connector

(2) Insert the test probe into the connector
(3) Refer the results to the above chart
Tester:
R range (xl)
WA0666
1 TSB Revision
http://vnx.su/
terminal
9-250
S-240
1 B-3
AUDIO
SYSTEM
1 There is noise but no reception
- Troubleshooting
for both AM and FM.
s the check being conducted under special

electrical field conditions?
No
Yes
Example: in an
underground garage
or inside a building
1
Is proper performance
obtained when the
No
the antenna plug and radio unit properly
Yes
Does the problem disappear if connected
Yes
Repair or
replace radio
No
4
Repair or
replace antenna
1 B-4
1 No sound from AM, or no sound
from
FM.
Refer to B-3.
1 TSB Revision
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AUDIO SYSTEM - Troubleshootina
I B-5I huff
c
icient sensitivity.
Is the check being conducted under special

electrical field conditions?
Yes
Example: in an
underground garage
or inside a building
v
NO
s proper performance
obtained when the
vehicle is moved?
No
Yes
OK
Does tuning solve the problem?
No
Yes
Electrical field condition

related (multipath noise
or fading noise)
No
No
Ensure porper
connection
Yes
-
Yes
-
Repair or replace radio
No
For multipath noise and fading noise problems,

refer to page 8-237
1 TSB
Revision
http://vnx.su/
-I
8-242
Distortion on AM or on both AM and FM.
B-6
.I
Yes c EEssive
inmt
L
Occasional
antenna
No
Constant
Yes
-.
Remove cords
aw_ay from cone
paper
Rsair or replace
speakers
In_stallspeaker
securely
No
4
Is there tone cone paper or foreignobjects
speakers is removed?
when the
Yes
No
I
s there any deformation
speaker installed
I
wit
Yes
No
B-7
Distortion on FM only.
No
Due to weak electrical

field c$ radio station
Yes
Due to multipath noise
Yes
+
Does distortion increase or decrease when
_I
I TSR
Rmviainn
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=%zF
-.
=I
qi
L--!-s
1 B-B
1 Too few automatic
8-243
select stations.
=I
=:
-.
Is &he check being conducted under

special electrical field conditions?
Example: in an
underground garage or
inside a building
\
plug properly connected to
No
Ensure proper
connection
Yes
Malfunctioning
radio
Yes
No
Repair or
replace antenna
- I_i
TSB
Revision
http://vnx.su/
8-244
AUDIO
1 B-S
SYSTEM
( Insufficient memory (preset stations
- Troubleshooting
are erased).
Yes
Is the problem corrected

when the fuse is replaced?
OK
1 z;pA;ehar;ss
or repair or 1
replace other electrical parts
+
Is the connector on the rear of the radio
properly connected?
No
) rnsure proper
connection
Yes
+
Is connector power voltage (for the memory backup circuit) correct?
/ TSB Revision
Repair harness
http://vnx.su/
AUDIO SYSTEM - Troukleshootina

C. CA!ZSElTE
1 C-4
PLAYER
1 Cassette
tape will not insert.
the
-
Yes
Remove the object(s) *
No
Yes
other tape is inserted?
No
r-
Repair or replace cassette player.
I$OTE
Attempting to force a foreign object (e.g., a coin or clip, etc.) out of the cassette player may damage the mechanism. The
player should be taken to a service dealer for repair.
T2 Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tapes
of C-120 or greater length often get caught in the mechanism and should not be used.
1 C-2
1 No sound
(even after a tape has been inserted).
No
Try again after

correcting.
IYes
No
Try again after

correcting.
Yes
No
Try again after

correcting.
Check the electronic volume by pushing the

volume up button for a few seconds.
No
I
1 TSB
Revision
http://vnx.su/
8-246

No sound
from one speaker.
balance or fader buttons
No
Yes
1 When sound comes from only
left or right channel of the deck
/sound?
Change the tape and
Yes
OK
I
e A prerecorded tape should be used on
both channels
l Ensure that the tape label is not loose,
tha tthe tape itself is not deformed and
that the tape is tightly wound.
e Tapes of C- 120 or greater length often
get caught in the mechanism and should
_ not be used.
the cassette player

and check again.
there any sound when th

ssette player is replaced?
OK
Yes
No
/ TSB Revision
Yes
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Repair or replace
cassette player.

=:
F!
-:
_j
-8
-8
r c-4
Sound
quality
is poor, or sound
is weak.
play properly when another tape
0 Ensure that the

is not deformed
o Tapes of C-120
mechanism and
tape label is not loose, that the tape itself

and that the tape is tightly wound.
or greater length often get caught in the
should not be used.
No
player play properly when the tape playe

head is cleaned?
Yes
OK
No
Yes
Is proper operation obtained when the cassette

player is replaced?
Repair or replace
cassette player.
No
Repair or
replaze speaker I
c-5
T----l
Cassette
tape will not eject.
The problems covered here are all the result of the use of a bad tape (deformed or not properly tightened) or of
a malfunction of the cassette player itself. Malfunctions
involving the tape becoming caught in the mechanism
land ruining the case are also possible, and attempting to force the tape out of the player can cause damage to
the mechanism. The player should be taken to a service dealer for repair.
TSB Revision
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C-6
Uneven
revolution.
Tape speed is fast or slow.
Yes
OK
No
re there any foreign objects inside the cassette
Yes
Remove foreign
object(s).
Is the head or capstan roller dirty?

Pinch roller
Head
Capstan roller
Yes
Clean
INo
I Repair or replace cassette
Automatic
player. I
search does not work
(only for models
with the automatic
oes the MSS (automatic search) button depress
search fun&on).
No
But&n improperly
operated.
-
Yes
Tape used is bad
-
No
. When the time between songs on a tape is less than three seconds, or when there is a three second period in the middle of a
song in which the volume level is extremely low, the automatic
search function may not work properly.
l Ensure that the tape label is not loose, that the tape itself is not
deformed and that the tape is tightly wound. Also, tapes of C- 120
or greater length often get caught in the mechanism and should
not be used.
I TSR
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=--
_/
Faulty
-.
8-249
Lauto reverse.
Does the player play OK if the tape* is

changed?
Yes
OK
-.
-m
-.
No
Ensure that the tape label is not loose, that the

tape* itself is not deformed and that the tape is
tightly wound.
Tapes of C-l 20 or greater length often get
caught in the mechanism and should not be used.
Does the problem only occur while the

vehicle is being driven?
Repair or replace
cassette player.
No
IYes
player properly installe
No
-
to the vehicle?
Ensure cassette
player installation.
5
Yes
Repair or replace
cassette player.
I-- -
1 G-9
1 Tape gets caught
in mechanism?
* When the tape is caught in the mechanism, the case may not eject. When this occurs, do not try
to force the tape out as this may damage ,the tape player mechanism. Take the cassette to a
service dealer for repair.
Does the player play OK if the tape* is

changed?
I
* Ensure that the tape label is not loose, that the tape itself is not
deformed and that the tape is tightly wound. Also, tapes of
No
C-120 or greater length often get caught in the mechanism
and should not be used.
I Repair or replace cassette player. I
1 TSB Revision
http://vnx.su/
Replace tape.
AUDIO SYSTEM - Troubleshoothinn

RADIO/CASSETTE DECK CIRCUIT
JRCUIT DIAGRAM ~2.61
Engine>
rl
r2
Sub fusible
link

[Refer to P&66.]
[Refer to PB-94.1
To dimmer control
[Refer to P.876.1
switch 4 BY
DIN Cable
Tape player
Radio
http://vnx.su/
link
Ignition
switch
AUDIO
SYSTEM
8-251
- Troubleshooting
(R.H.)
1(L.H.)
Front speaker
c-63 \
Rear speaker
El
El
Remarks
(1) For information
concerning the ground
), refer to P.8-12.
(2) I! a symbols 0, 0, etc. indicate that
connected (using the same numerical
facing page.
(In other words, @ on the right page
on the left page.)
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
points (example:
the wiring is
symbol) to the
is connected
to @
G: Green
P: Pink
TSB
L: Blue
Y: Yellow
Revision
http://vnx.su/
Lg: Light green

W: White
8-252
RADIO/CASSElTE
IRCUIT
DIAGRAM
DECK CIRCUIT
c3.OL
Engine>
0Y
Sub fusible
link

[Refer to P.8-68.1
I
--7
terrnlnal
WC)
To cigarette Ii hter
[Refer to P.& 8 4.1
To dome
To clock
[Refer to P.8-94
To dimmer control
[Refer to P.8-77.1
switch
DIN Cable
Tape player
Radio
http://vnx.su/
AUDIO SYSTEM - Troubleshgoting
Front speaker
El
El
(L.H.)
Rear speaker
(2-door vehicles)
(R.H.)
El
El
El
El
(L.H.)
Rear speaker
(4door vehicles)
/=rJ
(R.H.)
El
37w705
Remark(1) Fql sirtformation concerning the ground points (example:

I), refer to P.8-14.
(2) B I le symbols Q), Q, etc. indicate that the wiring is
facing page.
on the left page.)
i/iriifgdor
Li: Light blue
code
Br: Brown
0: Orange
F: ,i,n
:
L: Blue
Y: Yellow
[ TSB Revision
http://vnx.su/
Lg: Light green

W: White
8-254
AUDIO SYSTEM - Radio and Tape Player
RADIO AND TAPE PLAYER

Nae.NJAK
ZMOVAL AND INSTALLATION
16W1696
Removal
steps
1. Knob
2. Plug
3. Center console
4. Connection of center panel wiring harness
to front wiring harness connector
5. Radio panel
6. Radio bracket
I TCR
Rnuicinn
7. Radio
8. Box (Vehicles without tape player)
9. Radio with tape player
NOTE
Reverse the removal
http://vnx.su/
procedures
to reinstSf.
AUDIO SYSTEM - Front Speaker/Rear Speaker
8-255
~FROINTSPEAKER
IERMOVALAND INSTALLATION
NO3NhfAE
16W1593
Rertnovai steps
1. Mounting screws
2. Front speaker
NOTE
REAR SPEAKER
1EMOVAL AND INSTALLATION
<2-door
NO8NOAD
models>
<Cdoor
models>
Removal steps
1.
2.
3.
4.
lSWl699
Mounting screws
Rear garnish
Rear speaker
Bracket
16W1700
NOTE
Re\,erse the removal procedures to reinstall.
1 TSB Revision
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8-256
AUDIO SYSTEM - Antenna
ANTENNA
Removal steps
*+
1. Mounting nut
2. Antenna mast
+I)*4
3. Front fender panel
4. Ground base
5. Antenna base
NOTE
[;I $yrae
(3) -
the remcyal p-ocedyes

to reinstall.,,
: Refer to Service Points of Removal

1. REMOVAL
OF MOUNTING
NUT
Hold the antenna mast, and then
nut.
3.
remove
the mounting
REMOVAL
OF FRONT FENDER PANEL
Refer to GROUP 23 - Front Fender

I
3.
1 TSB Revision
INSTALLATION
OF FRONT FENDER
Refer to GROUP 23 - Front Fender.
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1 _:
PANEL
5--r
-
WIPER AND WASHER SYSTEM - Specifications
WIPER AND WASHER
SYSTEM
SPECIFICATIONS
WINDSHIELD
WIPERS AND
WASHER
Specifications
Items
Windshield
wiper motor
Permanent-magnet
type
Third brush system
Dynamic brake system
Type
Speed control system
Braking system
Revolution no load
rpm
Low speed
High speed
Nm (ftlbs.)
Nominal torque
Windshield wiper blade
Wiping angle
Drivers side
Passengers side
mm (in.)
Wiper blade length
Window washer motor and pump
Motor type
5oi5
75+13
13 (9)
85.50
114
396-401
Pump We
Power consumption
A
Allowable period of continuous use
With washer fluid
Nozzle jet pressure
kPa (psi)
Tank capacity
lit. (qts.)
Intermittent wiper relay
sec.
Intermittent time
sec.
Delay time in washer moving
Working load
W
HEADLIGHT
(i5.6-75.8)
Direct current ferrite magnet type

Centrifugal type
3.5 or less
sec.
Max. 20
70 (12.8) or more
1.5 (1.6) or more
1.5+0.7-10.5+3
0.4-I .2
60
WASHER
Specifications
Items
Washer motor and pump
Motor type
Pump type
Power consumption
A
Nozzle injection pressure
kPa (psi)
Tank capacity
lit. (qts.)
Headlight washer control unit
Time setting
sec.
Check valve
Valve opening and closing pressure
TSB
Ferrite magnet type

Centrifugai type
21 or less
180 (25.6) cr more
3.5 (3.7)
0.52
kPa (psi)
Revision
http://vnx.su/
49-108
(7.1-15.6)
8-203
WlPER AND WASHER SYSTEM - Smcifications

COLUMN
SWITCH
items
Wiper-washer switch
Wrper switch
Rated load
A
Low
Intermittent
High
Lock
V
Voltage drop (at 12V and the rated load)
Washer switch
Rated load
A
V
Headlight washer switch
Rated load
A
V
REAR WIPER
AND
3
0.5 or less
0.5
0.2 or less
WASHER
Specifications
Items
il\liper motor
Motor type
Braking system
rpm
Revolution under no-load
Nm (ft.lbs.1
Nominal torque
/Viper blade
Wiping angle
Blade length
mm (in.)
JVindow washer motor and pump
Motor type
AND
WASHER
Ferrite magnet type

Dynamic braking system
40+5
8 (6)
108
380-385
Pump n/w
Power consumption
A
sec.
Allowable period of continuous use
With washer fluid
Empty operation
Nozzled jet-spray pressure
kPa (psi)
Tank capacity
lit. (qts.)
REAR WIPER
3.5
0.17-0.27
4.5
18
0.2 or less
(75.0- 15.2)
Direct current ferrite magnet type

Centrifugal type
3.5 or less
Max. 60
Max. 20
78 (11.4) or more
1.1 (1.2) or more
SWITCH
Items
Specifications
Rated load
A
Wiper switch
Washer switch
3
5
0.1 or less
1 TSB Revision
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8-205
WIPER AND WASHER SYSTEM - Specifications

Nm
Items
IO-16
lo-16
7-10
35-45
8-12
7-10
7-10
Windshield wiper pivot shaft installing nut

Windshield wiper arm locking nut
Windshield wiper motor
Rear wiper pivot shaft installing nut
Rear wiper arm locking nut
Rear wiper motor
TSB Revision
http://vnx.su/
ft.lbs.
7-12
7-12
5-7
25-33
6-D
5-7
5-7
8-206
WlPER AND WASHER SYSTEM - Troubleshootina
TROUBLESHOOTING
WIPER AND WASHER CIRCUIT
CIRCUIT
I
DIAGRAM
<2.6L
batter-Y
Engine>
3-R 1 13-W-
Main fusible link
&tml
I I
Multi-purpose
fuse
Intermittent
wiper
control
relay
I
3
i
h
tmarks
For information concernin
the
ground points (example: ii ). refer
to P.812.
The symbols Q, @ etc. indicate
that the wiring IS connected
(using the same numerical
symbol) to the facing page.
(In other words, @ on the right
page is connected to @ on the
left page.)
w
B:
L
iring color code

Black
Br: Brown
LI: Light blue 0: Orange
G: Green
P: Pink
Headlight
washer motor
1
;~:~tzy
L: Blue
y:
Yellow
$g $jgegreen
http://vnx.su/
I
Headlight .washer
motor relay
8207
WlPER AND WASHER SYSTEM- Troubleshootina
Column
*1r2
switch
Front wiper switch
-1
I
Rear wiper and

washer switch
-09
Lc-63
G!
I I
m
-
k-64
II
I
I II
;
--
I
2
-J
~~~
D-10
2
3m
1z
Intermittent
wiper relay
AZ
c-34
I I
A-54
M
rear
Front washer
motor
Front wiper
motor
793 Revision
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Rear washer
motor
motor
8-208
WIPER AND WASHER SYSTEM - Troubleshooting
WIPER AND WASHER CIRCUIT

DlAGFtAM c3.OL Engine>
Sub fusible
Multi-purpose
fuse
To lightin switch
[Refer to B.S-68.~
Intermittent
wiper
control
link
relay
Remarks
(1) The dotted line t....) is applicable to
models equipped with the dual air
conditioner system.
(2) For information concernin
the
?4;,z,pnts
(example: i), refer
(3) The symbols Q, Q, etc. indicate
that the wiring IS connected (using
the same numerical symbol) to the
facing page.
page is connected to @ on the left
w3e.)
Wiring color code
B: Black
Br: Brown
G: Green
P: Pink
Headlight
washer motor
L L.
&!I
r$:,t?y
L: Blue
y: yel,ow
#/; tiFegreen
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Headlight washer
motor relay
8-209
WIPER AND WASHER SYSTEM- Troubleshooting

C-&lb
(gqqq
r-
fq$JGJ
-Column
*
switch
Front wiper
I Headlight
*
-7
switch
Rear wiper and

washer switch
ON
OFF
INT
Intermittent
wiper relay
rear
Faer
motor
I
Front wiper
motor
LY8,
B
BY
a3 L
L
1
Rear washer
motor
Rear wiper
motor
?.7w7w
1 TSB Revision
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8-210
WIPER
AND
WASHER
WINDSHIELD
WIPERS
AND WASHER
OPERATION
Wiper Operation
l
When the wiper switch is at ON with the
ignition switch at either ACC or ON, current flows through
fuse No. 9, rear wiper
motor,
rear wiper switch
and ground;
the
wiper operate.
Wiper Low-speed
and High-speed
Operation
l
When the front wiper switch is at LO with
the ignition switch at either ACC or ON,
current flows through fuse No. 8, front wiper
motor (low-speed
brush), front wiper switch
and ground; the wipers operate at low speed.
l
When the front wiper switch is at HI. current flows through fuse NO. 8. front wiper
motor (high-speed
brush), front wiper switch,
and ground; the wipers operate at high speed.
Wiper Automatic
Stopping
Operation
l
When the front wiper switch is set at OFF
to stop the wipers, current flows through the
front wiper motor (low-speed brush), front wiper switch, intermittent
wiper control relay (contacts), front wiper motor (cam contacts), and
ground, causing the front wiper motor to continue operation unit1 the wiper bleades return
to their park positions.
l
Once the wiper blades have reached park
positions. the front wiper motor cam moves to
open its contacts. This interrupts flow of current to ground,
and the front wiper motor
stops.
Wiper Intermittent
operation
l
With the ignition switch at ACC or ON,
battery voltage is applied to the intermittent
wiper control relay through fuse No. 8.
l
When the front wiper switch is at INT,
current flows through the intermittent
wiper
control relay, front wiper switch, and ground,
and the intermittent
wiper control relay internal
contacts close and open repeatedly.
l
While the contacts are ciosed, current flows
~ through
the front wiper motor
(low-speed
brush), front wiper switch, intermittent
wiper
control relay (contacts),
and ground, causing
the front wiper motor to operate.
l
When the front wiper motor starts operating,
the relay internal contacts open, causing current to flow through the front wiper motor
(cam contacts),
and ground. This keeps the
front wiper motor operating
until the wiper
blades return to their park positions.
l
Once the wiper blades have reached park
positions, the front wiper motor cam moves to
open its contacts. This interrupts flow of current to ground so the front wiper motor stops.
SYSTEM
- Troubleshooting
Wiper Operation
Coordinated
with Washer
o With the ignition key at the ACC or ON
position, voltage is supplied, through fuse No.
8 and the front washer motor, to the front
washer switch.
l
When the front washer
switch is switched
ON, current flows to fuse No.8, the front
washer motor, the front washer switch, and
ground, and, at the same time that the front
washer operates,
the intermittent
wiper control relay is switched ON, and current flows to
fuse No. 8, the front wiper motor (low-speed
brushes), the front wiper switch, the intermittent wiper control relay, and ground, and the
front wiper motor is activated.
TROUBLESHOOTING
HINTS
1. Wipers do not operate
(1) Washer also does not operate
e Check fuse.
l
Check for ground connection.
2. Wipers do not operate at low speed (or high
speed)
l
Check front wiper switch.
3. Wipers do not operate in intermittent
mode
l
Check intermittent
wiper control relay terminal voltage with relay energized.
Check location
Front wiper
switch
Intermittent wiper
control relay
- (Normal)
12V reoeatedtv
4.
Wipers fail to stop

l
Check front wiper motor.
5. Wipers
do not operate
coordinated
with
washer
l
Check intermittent
wiper control relay.
http://vnx.su/
WIPER AND WASHER SYSTEM - Troubleshooting
8-211
REAR WIPERS AND WASHER

OPERATION
Wiper Automatic
Stopping
Operation
* When the rear wiper switch is set at OFF to
stop the wiper, current flows through the rear
wiper motor, rear wiper switch, intermittent
rear wiper relay (contacts),
rear wiper motor
(cam contacts),
and ground, causing the rear
wiper motor to continue
operation
until the
wiper blede return to its park positions.
* Once the wiper blade has reached park positions, the rear wiper motor cam moves to
open its contacts. This interrupts flow of current to ground.
and the rear wiper motor
stops.
Wiper Intermittent
Operation
With the ignition switch at ACC or ON,
battery voltage is applied to the intermittent
rear wiper relay through fuse No. 9.
When the rear wiper switch is at INT, current flows through the intermittent
rear wiper
relay, rear wiper switch, and ground, and the
intermittent
rear wiper relay internal contacts
close and open repeatedly.
While the contacts are closed, current flows
through
the rear wiper
motor,
rear wiper
switch, intermittent
rear wiper relay (contacts),
and ground, causing the rear wiper motor to
operate.
When the rear wiper motor starts operating,
the relay intermal contacts open, causing current to flow through the rear wiper motor (cam
contacts),
and ground. This keeps the rear
wiper motor operating
until the wiper blade
return to their park positions.
Once the wiper blade has reached park positions, the rear wiper motor cam moves to
open its contacts. This interrupts flow of current to ground so the wiper motor stops.
Rear washer operation
l
With the ignition key at the ACC or ON
position, voltage is applied, through fuse No. 9
and the rear washer motor, to the rear washer
switch.
l
When the rear washer switch is switched ON,
currenat flows to fuse No. 9, the rear washer
motor, the rear washer switch, and ground,
and the rear washer begins operation.
FSB
Revision
TROUBLESHOOTING
HINTS
1. Wipers do not operate
(I) Washer also does not operate
l
Check fuse.
l
Check for ground connection,
2. Wipers do not operate in intermittent
mode
0 Check intermittent
wiper relay terminal voltage with relay energized.
Terminal
Voltage
Check location
ov
12v
Rear wiper switch

Intermittent wiper
relay
-(Normal)
Changes between 12V repeatedly

3. Wipers fail to stop
l
Check wiper motor.
http://vnx.su/
8-212
WIPER
WINDSHIELD
WIPERS
REMOVAL
AND
AND
WASHER
SYSTEM
- Windshield
Wipers
INSTALLATION
IO-16 Nm
T-12 ft.lbs.
Lh/
lo-16
Nni
J-12
ft.lbs.
5-7 ft.lbs.
Removal steps
1.
2.
3.
4.
5.
6.
l *
4+
Wiper
Wiper
Wiper
Wiper
Wiper
Wiper
blades
arms
pivot shield caps
pivot collars
motor
link
NOTE
(2) l I) : Refer to Service Points of Removal.
(3) *c
SERVICE
POlNTS
OF REMOVAL
5. WIPER MOTOR
Uncouple the linkage and motor (with the wiper motor
pulled slightly outward).
Caution
Because the installation
position
of the crank arm and
the motor determine
the wiper auto stop angle, do not
disassemble
them unless it is necessary
to do so. If the
crank arm muat be removed
from the motor,
remove
it
only after marking
their mounting
positions.
/---l-T
(1.5 1.9)
37-47
mm (in.)
SERVICE
POINTS
OF INSTALLATION
2. INSTALLATION
OF WIPER ARMS
Install the wiper arm to the pivot shaft so that the wiper
blades stop position is the position shown in the illustration.
i 37-47 (1.G 1.9)

I
h
t
1swssa
evision
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WIPER AND WASHER SYSTEM
- Windshield
Wipers
8-213
INSPECTION
WIPER MOTOR
Disconnect
the wiring connector from the wiper motor
connect battery to the wiper motor connector to check
the wiper motor runs.
and
that
LOW SPEED OPERATION CHECK

Connect batten/ (+) to terminal 1 and battery (-1 to terminal
3 and check that the motor runs at low speed.
Battery
HIGH SPEED OPERATION

CHECK
Connect battery (+) to terminal 1 and battery (-) to terminal
4 and check that the motor runs at high speed.
Battery
L
a
&I
Battery
16W1636
AUTOMATIC
STOP OPERATION CHECK
(1) Connect
battery (+) to terminal 1 and battery (-) to
terminal 3 to run the motor at low speed.
(2) Disconnect terminal 1 during operation to stop the motor.
+
-
16W163n
I
(3) Connect terminal 2 to terminal 3 and connect battery (+)
to terminal 1 and batten/ (-1 to the wiper motor bracket
to check that the motor starts to run at low speed and
then stops.
16W1640
TSB Revision
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8-214
WIPER AND WASHER
SYSTEM
INTERMilTENT
- Windshield
Wipers
WIPER RELAY
Remove the intermittent

wiper relay
part of the left side cowl side trim).
(located
at the upper
CONTINUITY CHECK
Check to see that there
and 5.
is continuity
between
terminals
INTERMITTENT OPERATION CHECK

Test light
16K1921
(1) Connect the battery and the test light to the relay, as
(2) Insert a variabie resistance between
terminal 8 and battery (-1 (VR = G-50 kfi)
(3) The condition is normal if, when the batterys negative
(-) terminal is connected
to terminal 7, the test light
illuminates
at the same time, and thereafter,
in accordance with the value of the variable resistance,
stops
illumination
(approx. 1.5 -sec. - approx. 10.5 sec.) and
then illuminates
(approx. 1 sec.) over and over again.
WASHER INTERLOCK OPERATION CHECK

(1) Connect the battery and the test light to the relay, as
(2) When terminal 3 is connected
to the batterys
negative
(-) terminal, the test light will illuminate approximately
1
second thereafter,
and then there will be a release for
about seconds after connecting
to the batterys negative
(-) terminal.
(3) The condition is normal if about 3 seconds thereafter
the
test light stops illumination.
http://vnx.su/
8-215
WIPER AND WASHER SYSTEM - Rear Wiper
REAR WIPER
Removal
**
l 4
+*
steps
1. Inside handle cover
2. Back door trim and waterproof
3. Wiper blade
4. Wiper arm
5. Wiper pivot cap
6. Wiper pivot washer
7. Wiper pivot packing
8. Wiper motor
film
16wssz
NOTE
(2) l *
: Refer to Service Points of Removal
(3) **

2. REMOVAL
OF BACK DOOR TRIM AND WATERPROOF
RLM
Refer to GROUP 23 - Back Door Trim and Waterproof
Film.

3.
lBK394
INSTALLATION
OF WIPER BLADE
Install the wiper arm so that the wiper
the lower edge of the window glass.
blade is parallel to
2. lNSTALLATlON
OF BACK DOOR TRIM AND WATERPROOF FILM
Refer to GROUP 23 - Back Door Trim and Waterproof
Film.
INSPECTION
WIPER MOTOR
Disconnect the wiring connector
from the wiper motor and
connect battery to the wiper motor connecto;
to check that
the wiper motor runs.
TSB Revision
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*,mm
S-216
WIPER AND WASHER SYSTEM - Rear Wiper/Windshield Washer

OPERATION
CHECK
Connect battery (+) to terminal 1 and battery
3 to check that the motor runs.
(-) to terminal
AUTOMATIC OPERATION
CHECK
(I) Connect
battery (i-1 to terminal
1 and battery (-1 to
terminal 3 to run the motor.
(2) While the motor is running, disconnect terminal 1 to stop
the motor.
16Wl542
(3) Connect terminal 2 to terminal 3 and connect battery (+)

to terminal 1 and battery (-1 to wiper motor bracket to
check that the motor starts to run again and then stops
motor
bracket
WINDSHIELD
WASHER
IEMOVAL AND INSTALLATlON
2--4x
1.
2.
3.
4.
Windshield washer tank

Washer tube
Washer nozzle
NOTE
* indicates
http://vnx.su/
-05
vehicles
with 2.6L engine.
WIPER AND WASHER SYSTEM - Windshield Washer/Rear Washer
+ -I
1
Iii!
INSPECTION
WASHER MOTOR AND PUMP
Make the check while the motor is installed to the washer
tank.
(1) (ZFkck to be sure that there is washer fluid in the washer
(2) Check to be sure that the washer motor operates and the
fluid is forced out under pressure when the batterys
positive (+) terminal is connected to terminal 2 and the
negative (-) terminal is connected to terminal 1.
18K1514
REAR WASHER
-Q-door vehicles>
<4-door vehicles>
Removal
steps
4**C
1.
2.
3.
4.
5.
8-217
Retractor cover
Speaker
Quarter trim
Rear washer tank
Washer motor
and pump
6. pds;uretube.
nozzle
\35-55Nm
4
254Oft. Ibs.
NOTE
(I) The rear washer tank for models equipped with the dual
air conditioner is installed at the left side.
(4) I)+ : Refer to Service Points of Installation.
TSB Revision
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a-218
WIPER AND WASHER SYSTEM - Rear Washer/Headlight
Washer

3.
REMOVAL
OF QUARTER
TRIM
Refer to GROUP 23 - Trims.
INSPECTION
WASHER MOTOR
Refer to P.8-217.
AND
PUMP

3.
INSTALLATION
OF QUARTER
Refer to GROUP 23 - Trims.
TRIM
HEADLIGHT WASHER
NCSKPAA
Removal
steps
1.
2.
3.
4.
5.
6.
;:
Radiator grille
Front combination light
Headlight bezel
Headlight washer nozzle
Washer tube
Check valve
Headlight washer tank
Im -I-
NOTE
INSPECTION
WASHER MOTOR AND PUMP

Make the check while the motor
tank.
(1) Check
is washer
to the washer
fluid in the washer
tank.
(2) Check to be sure that the washer motor operates

fluid
to be sure that there
is installed
16W1544
1 TSB Revision
is forced
out
positive (+) terminal

negative (-1 terminal
http://vnx.su/
under
pressure
is connected
is-connected
when
the
to terminal
to terminal
and the
batterys
2 and the
3.
WIPER AND WASHER SYSTEM - Headlight Washer/Column Switch
8-219
HEADLIGHT WASHER RELAY

Remove the headlight washer relay (located at the upper part
of the left side cowl side trim).
WASHER OPERATION
CHECK
(1) Connect the battery and the test light to the relay as
(2) If, when terminal
1 is connected
to the negative (-)
terminal of the battery, the light illuminates (for about 0.5
second), the unit is operating normally.
Test light
1*ws45
COLUMN
SWITCH
NWKhWF
Refer to P. 8-200.

Refer to P. 8-200.
INSPECTION
Remove the steering
lower cover, and then detach the
connector of the column switch from the wiring harness.
Operate the switch and check the continuity
between
the
terminals.
1 TSB Revision
I
.
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8-220
WIPER AND WASHER SYSTEM WIPER
column
AND
~witch/~esr
piperand
WASHER
Ena
Washer switch
SWITCH
( 20 j 18 j 15 j 14 1 19 j 13
NOTE
(I) C-9
indicates that there is continuity between the
terminals.
(2) The dotted lines indicate that the washer switch ON.
HEADLIGHT
WASHER
16W1666
NOTE
O-0
indicates that there is continuity
terminals.
REAR WIPER AND WASHER SWITCH

4*
I, Rear wiper and washer switch
NOTE
*I)
: Refer to Service
Points of Removal.
1 TSB Revision
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between
the
tumloAa
8-221
WIPER AND WASHER SYSTEM - Rear Wiper and Washer Switch

1. REMOVAL OF REAR WiPER AND WASHER SWITCH

insert the trim stick into the switch and pry the switch
remove it from the instrument
panel.
to
INSPECTION
Operate the switch,
terminals.
and check
1800413
the continuity
between
1860375
Washer switch
NOTE
C-O indicates that there is continuity
terminals.
TSB Revision
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between the
the
23-1
BODY
CONTENTS
.................................
54
BACK DOOR ASSEMBLY
57
BACK DOOR HANDLE AND LATCH .................
BACK DOOR LOCK SWITCH
............................
58
BACK DOOR TRIM ............................................
z:
BACK DOOR WINDOW GLASS .......................
BODY MOUNTING
...........................................
22
.........................................................
BUMPERS
;I
CENTER CONSOLE
..........................................
DOOR ASSEMBLY
............................................
35
48
DOOR HANDLE AND LATCH ...........................
DOOR TRIM AND WATERPROOF
FILM .......... 38
..........................................................
28
FENDERS
77
FLOOR CONSOLE
............................................
....... 39
FRONT DOOR GLASS AND REGULATOR
96
FRONT SEATS ..................................................
FUEL FILLER DOOR ..........................................
26
70
GRILLE, GARNISH
............................................
.................
78
HEADLINING
AND ASSIST STRAP
25
HOOD ................................................................
INSTRUMENT
PANEL ......................................
71
66
LOOSE PANEL ..................................................
32
QUARTER WINDOW GLASS ...........................
REAR DOOR GLASS AND REGULATOR
......... 46
98
REAR SEAT .......................................................
100
SEAT BELTS .....................................................
......... 19
SERVICE ADJUSTMENT
PROCEDURES
................
21
Back Door Installation Adjustment
.........................
19
Door Installation Adjustment
Front Door Glass Adjustment
........................
20
.............
19
Fuel Filler Door Hook Fit Adjustment
19
Hood Fit Adjustment
.....................................
Inside Handle Adjustment
.............................
20
..........................
20
Outside Handle Adjustment
.........................
20
Rear Door Glass Adjustment
Ventilator Window Adjustment
.....................
20
SPECIAL TOOL .................................................

.............................................
SPECIFICATIONS
...................................
.................................
...................................
....................................
.........................................................
SUNROOF
TRIMS ...............................................................
TROUBLESHOOTING
.......................................
Back Door ......................................................
Hard back door operation, abnormal
noise from hinges
...........................
Back Door Locking System
Buzzer ............................................................
Central Locking System .................................
Front Door and Rear Door .................... _.........
Hard door glass operation
No door glass operation
_._.._.
Power Window
.......................................
6,
Sunroof ......................................................
Abnormal noise from motor
Abnormal noise when moving roof lid
Desptie motor rotation, lid does not
move, or stops at non-specified
position
Rushing sound
Water leaks into interior
Wind Noises ..................................................
Wind noise from around the door
Wind noise from back door
UNDER GUARD
................................................
WINDOW GLASS RUNCHANNEL
AND DOOR
..............................
OPENING WEATHERSTRIP
WINDSHIELD
....................................................
http://vnx.su/
5
2
2
5
4
4
:79
6
6
9
16
14
6
IO
18
65
51
29
BODY
- SDecifications
SPECIFICATIONS
GENERAL
r
terns
SPECIFICATIONS
1 P-door vehicles
.-
1 4-door vehicles
iood
Type
Yont door
Construction
Regulator system
Locking system
Iear door
Construction
Regulator system
Locking system
iack door
Construction
Locking System
ilass installation method
Windshield
Quarter window
Front door window
Rear door window
Back door window
ilass thickness
mm (in.)
Windshield
Quarter window glass
Front door glass
Rear door glass
Back door window glass
Ventilator window glass
Stationary window glass
rame type
iectional form
tuspension seat
Suspension mechanism
Up-and-down movement
mm (in)
Body weight adjustment
kg (Ibs.)
Seat height adjustment
ower window motor
Twe
Revolutions under load
Revolutions under load
20 kgcmlh(l7 in.lbs./h)
Bound current
Direction of rotation
Rear hinged, front opening type
Rear hinged, front opening type
Front hinged, sash construction

X-arm type
Pin-fork vpe
Front hinged, sash construcrion

X-arm type
PinTork type
Front hinged, sash construction
Single arm type
Pin-fork type
Right hinged, sash construction

Pin-fork type
Ri@it hinged, sash construction

Pin-fork type
Weatherstrip
Weatherstrip
Weatherstrip
type
type
type
Weatherstrip
type
Weatherstrip
Weatherstrip
Weatherstrip
Weatherstrip
Weatherstrip
5.7 (.22)
4.0 (.16)
4.0(.16)
type
type
type
type
type
5.7 (.22)
4.0(.16)
4.0(.16)
4.0(.16)
4.7I.19)
5.0 (.20)
3.5 (.14)
Ladder type
Box type
4.7 (.19)
5.0 (.20)
Ladder type
Box type
Coil spring type with shock absorber
stroke
rpm
rpm
70 (2.76)
70 (2.76)
50-l 00 (110.2-220.5)
3 levels
50-I 00 (110.2-220.5)
3 levels
Permanentmagnet type (built-incircuitbreaker/ Permanentmagnet type (built-incircuitbreaker)

75
75
50-80
34 or less
Clockwise and counter-clockwise
1 TSB
Revision
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50-80
34 or less
Clockwise and counter-clockwise
<I
BODY
Items
Power window switch
Rated load current
A
Maximum load current
A
Power window power relay
Effective voltage
V
Rated coil current
A
Voltage drop between terminals
(at 2OA)
V
Power window control relay
Effective voltage
V
Motor lock detecting current (at
12V)
A
Open detecting current
A
Door lock actuator
Bound current (at 12V)
A
*Tripping time (at 12V)
second
Operating voltage range
V
Door lock control unit
Effective voltage
V
Current consumption
(when not in operation)
mA
Ioor lock power relay
Range of voltage used
V
Rated load current
A
Voltage drop between terminals
(at5A)
V
3ack door lock switch
Voltage drop
(at 12V and the rated load)
V
sunroof motor
Type
Speed at no load
wm
Speed at load [at 2 Nm (1.45
ft.lbs.)]
rpm
Bound current
A
Turning direction
Limit switch rated load
A
gunroof switch
Rated load current
A
NOTE
*Tripping time is the time consumed
23-3
- Specifications
2-doer vehicles
4-doer vehicles
11
22
11
22
lo-16
MAX. 0.2
IO-16
MAX. 0.2
0.3 or less
0.3 or less
IO-16
IO-16
14-18
1
14-18
1
4.5 or less
5-30
8-15
4.5 or less
5-30
g-15
IO-16
IO-16
3 or less
3 or less
lo-16
0.16
lo-16
0.16
0.3 or less
0.3 or less
0.2 or less
0.2 or less
DC ferrite (with built-in circuit breaker)
155-195
110-150
33 or less
Both clockwise and counter-clockwise
5
IO-20
until current reaches 0.5A after power connection.
1 TSB Revision
http://vnx.su/
23-4
BODY - Specifications
Items
Specifications
Standard values
Front door glass holder mounting position
mm (in.)
Distance between the glass holder (A) and (6)
Distance between the glass holder(B) and the glass edge
Rear door glass holder mounting position
mm (in.)
mm (in.)
Front door outside handle play
Front door inside handle play
mm (in.)
Rear door outside handle play
mm (in.)
Rear door inside handle play
mm (in.)
Back door outside handle play
mm (in.)
Roof lid sliding resistance
N (tbs.)
Sunroof motor clutch slipping force
N (Ibs.)
466.5-467.5 (18.367-18.406)
76.5-77.5(3.012-3.051)
232-238 (9.1-9.4)
3-8(.12-.31)
4-10(.16-.39)
34 (.I 2-.31)
4-10 (.16-.39)
5-10 (.20-/IO)
200 (44) or less
30-40 (7-9)
Item
Nm
Body to frame
Hood hook to hood
Hood latch to body
Hood latch release cable
Front door hinge to door panel
Front door hinge to body
Rear door hinge to door panel
Rear door hinge to body
Ventilator window assembly to door panel
Window regulatorto door panel
Door lower sash to door panel
Back door hinge to body
Back door to back door hinge
Spare tire bracket to back door
Under skid plate to frame
Under cover installation bolts
Snow-protection under cover installation bolts
Transfer case protector to No. 2 crossmember
Transfer case protectorto frame
Cross shaft protector installation bolts
Air ductto body
Seat anchor bolts
Head marked 8
Head marked 10
Front seat cushion to seat adjuster
Front seatback to seat cushion (Reclining adjuster side)
Front seatback to seat cushion
Rear seat leg bracket to body
Rear seatback to seat cushion
All seat belt tightening bolts
28-32
4.c?-6.0
/ 4.0-6.0
1 3.5-4.0
17-26
35-55
17-26
35-55
6
6
6
35-55
35-55
8-10
18-25
IO-13
IO-13
18-25
IO-13
10-13
35-45
4-6
9-14
35-55
17-26
45-60
lo-15
9-14
45-60
35-55
http://vnx.su/
20-23
2.9-4.3
2.9-4.3
2.5-2.9
12-19
25-40
12-19
25-40
4.3
4.3
4.3
25-40
25-46
6-7
13-18
7-9
7-9
13-18
7-9
7-9
25-33
3-4
6.5-10
25-40
12-1s
33-43
7-l 1
6.5-10
33-43
25-40
2.
/ TSB Revision
ft.lbs.
BODY - Specifications/Special
23-5
Tool
NPCET
Items
Front fender and front shield

Front fender and splash shield
Windshield
weatherstrip
Windshield weatherstrip
and windshield
glass
and body flange
Quarterwindow
weatherstrip and quarter
window rear glass <2-door vehicles>
Quarter window weatherstrip and quarter
window <4-door vehicles>
Quarter window weatherstrip and body flange
Back door window weatherstrip and back
doorwindow
glass
Waterproof film
Door window runchannel
Door window runchannel and ventilator sash
assembly
Ventilator window glass, ventilator sash
and ventilator window pad
Ventilator sash assembly and ventilator
windowweatherstrip
Ventilator sash assembly and ventilator
@indow weatherstrip
Back door opening weatherstrip and back
door
tiaterproof pad and fender
Headlining and roof panel
Sunroof rail end cover
3M ART Part No. 8531 or No. 8646, or

equivalent
3M ART Part No. 8626 or 3M Adhesive
EC-5310, or equivalent
equivalent
equivalent
equivalent
3M ART Part No. 8634, or equivalent
3M ART part No. 8001 or No. 8011, or
equivalent
EC-531 0. or equivalnet
3M Adhesive EC-870 or equivalent
3M ART Part No. 8080 or 3M
Adhesive EC-1368, or equivalent
equivalent
equivalent
equivalent
3M ART Part No. 8531 or No. 8646 or3M
Adhesive EC-2153 or EC-5528, or equivalent
Quantity
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
As required
SPECIAL TOOL
Tool
Number
Name
MB990900-01
Door adjusting wrench
1 TSB Revision
http://vnx.su/
Use
Adjustment
of door fit
23-6
BODY - Troubleshooting
TROUBLESHOOTING
FRONT DOOR AND REAR DOOR
Symptom
Door glass fails to
operate up and down
Remedy
Probable cause
Dismount window glass regulator
zDetached sash
Adjust
E
Attach
= Replace
Broken sash
Collapsed sash
Repair or replace
Collapsed window glass regulator arm
Repair or replace
= Replace
Broken window glass regulator

Door glass operates
.rp and down hardly
improper window glass position
.L
;z
Adjust
Repair or replace
Collapsed sash
Collapsed window
regulator arm
~-
Repair or replace
Broken window regulator handle
Replace
BACK DOOR
I Symptom
Back door is hard
when opened/closed;
abnormal noise is
heard from hinges
1 Remedy
1 Probable cause
Apply chassis grease
Improper grease on hinges
SUNROOF
Symptom
Probable cause
Remedy
Water leaks-into
interior
Clogged drain
Clean
Clogged drain pipe-
Blow in air and remove dirt
Drain pipe loose, broken, clip

defective or cracked
Check pipe installation and flange contact

Replace if required
-Check weatherstrip installation
Replace if required
--:
Cracked or worn roof lid

weatherstrip
Rushing sound
Excess gap between roof lid and

body, or inadequate weatherstrip
contact
Correct housing assembly
Loose or defective deflector
Tighten or replace
\ TSi3
Revision
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BODY
- Troubleshooting
23-7
Symptom
Probable cause
Remedy
Abnormal noise when

moving roof lid
Foreign objects engaged in guide

rail
Remove foreign objects
Loose guide rail or lid
Tighten
Foreign objects engaged in guide

rail
Remove foreign objects
Inadequate motor pinion and drive

cable engagement (loose motor or
damaged pinion)
Tighten or replace
Decreased motor clutch slipping

force
Check clutch slipping force

Adjust
Interference of drive cable,

weatherstrip or others due to
incorrect lid adjustment
Check roof lid installation and parts installatior

Measure lid contact resistance.
Replace parts if required
Incorrect limit switch adjustment

position
Check and adjust
Despite motor
rotation, lid does not
move, or stops at
non-specified
position. [Specified
position: about 200
mm (7.9 in.) when
closed1
Abnormal noise from

motor
Incorrect motor pinion and drive

cable engagement
Check pinion installation and motor

in3tallation
Worn or defective motor pinion

bearing
Replace motor
Worn or defective drive cable
Replace
Symptom
Probable cause
Remedy
Wind noise from

around the door
Improper weatherstrip
NOTE
*The clutch slipping
sound in motorwhen fully
spen or closed is normal.
WIND NOISES
Weatherstrip
teriorated
holding force
improperly installed, or de-
Repair or replace
Door fails closing
Adjust
Improper door position
Adjust
Uneven clearance between

runchannel
Deformation
Wind noise from back
door
Adjust the door installation
of the door
Improper weatherstrip
Weatherstrip
teriorated
door glass and
improperly
Adjust
Repair or replace
holding force
installed, or de-
Adjust the back door installation

Repair or replace
Uneven clearance between the body and

back door
Adjust
Deformation
Repair or replace
of the back door
[ TSB Revision
http://vnx.su/
23-8
BODY
- Troubleshooting
HOW TO LOCATE WIND NOISES
(1) Attach cloth tape to every place which might conceivably
be the source of wind noise, such as panel seams,
projections,
moulding seams, glass and body seams, etc.
(2) Then make a road test in order to determine
that the
places not covered by tape are not sources of wind noise.
(3) Then remove the strips of tape one by one, making a road
test after each is removed, until a wind noise source is
discovered.
(4) When such a place is found, cover it again and continue

with the procedure
so as to determine
if there are any
other noise sources.
(5) If no others are found,
source.
ex. Noise
here
the last remaining
tape is the only
produced
(6) Cut the remaining piece of tape into smaller pieces, attach
it again as it was before, and then remove the pieces one
by one in the same way so as to narrow down the source.
Cut tape
into pieces
(7) Check to confirm that wind noise occurs when the last
remaining tape is removed, and that noise does not occur
when it is reattached.
(8) When the source(s) of the wind noise is finally located,
attach butyl tape, body sealer or similar material
to
obstruct this source as much as possible.
wision
-z
http://vnx.su/
BODY
BACK
CIRCUIT
DOOR
LOCKING
23-9
- Troubleshooting
SYSTEM
DIAGRAM
3-w
--------
1.25F-G
A-19
&
c;
,1.25-G
Z-LR
-To
heater
relay
I
1.25F-R
1 11.25-R
u
O-16
4:
Eke. .
,Zcborv&b~~
4.OL
Engine
Cdoor
vehicles&
Back
lock actuator
&
Back door
lock switch
Remarks
(1) Broken lines and line indicated by the R symbol are applicable
P.&liter models.
(2) The chain line L- - - - -1 is applicable to 3.Miter models.
(3) For information
concerning
t e ground pants
(example: 0).
GROUP 8 - Electrical System
Parts Location.
OPERATION
l
Battery voltage is always available, through fuse
No. 6, to the back door lock switch.
l
When the back door lock switch is switched
ON or OFF, current flows to fuse No. 6, the
back door lock switch,
the back door lock
actuator,
the back door lock switch,
and
ground; the back door lock actuators motor is
then activated,
thus locking or unlocking
the
back door.
to the
refer
Wtra color code

B: Black
Br: Brown
to
$;!gT
blue
&:%ge
Y: Yellow
G:
Lg:
P:
W:
Green
Lifht green
Pin
White
TROUBLESHOOTING
HINTS
1. Does not lock or unlock.
(I) The blower motor also does not operate.
l
Check the fuse.
(2) The blower motor operates.
l
Check the back door lock switch.
l
Check the back door lock actuator.
1 TSB Revision
http://vnx.su/
BODY - Troubleshooging
23-10
POWER
CIRCUIT
WINDOW
DIAGRAM
<Z-Door
. B.
m
Vehicles>
ignition
%Y
Sub fusible
switch
link
flasher
,f
To turn signal
1.25-B,,
UP
DOWN
UP
Lock
snitch
Power window
main switch
Rm%information
I21 The symbols@,8.
(In other words,
DOWN
1.25F-Gi
11.256~
12-GL
Z-GL,@
fg-
concerning
the ground
points (example:
8). refer to GROUP 8 - ElEctrical
System
Parts
etc lndlcate
that the wiring is connected
symbol)
to the facing
,
I on the right page is connected
to 0 on the left page.1
OPERATION
l
position, current flows to fuse No. 3. the power
window
relay (coil), and ground, thus causing
the power window
relays points to close.
l
When, in this condition,
the power window
switch
is moved to the UP or DOWN
position, current flows to the power window
relay (points), the power window
switch, the
power
window
motor,
the power window
switch, and ground; the power window motor
is then activated, opening or closing the door
window
glass.
1 TSR Revision
If, however, the power window

lock switch is ON, the door
cannot be op-ened or closed
power window
sub switch.
http://vnx.su/
Location
page.
main switchs
window
glass
by using the
;.=
23-11
Power window
motor 1L.H.)
II
T
I
c-74
2-LR,-/
f-t1n
hd
Power
pcwer
window
relay
Power
cmtrol
aver
am*Z-KL
window
2-RL-2F-G
*-La 2F-L
2-GL 2F-R
L
694 2-GL
c-35
V&ring wlor code

B: Black
Br: Brown
U: Light blue
0: Orange
G: Green
P: Pink
TROUBLESHOOTING
HINTS
1. Neither the left nor right door window
opened.
(I) The turn signals also do not operate.
l
Check the fuse.
(2) The turn signals operate.
l
Check the power window
relay.
l
Power window
main switch.
l
Power window
sub switch.
L: Blue
Y: Yellow
glass
can be
1 TSB Revision
http://vnx.su/
window
relay
23-12
POWER
CIRCUIT
BODY
WINDOW
DIAGRAM
<4-Door
- Troubleshqoting
Vehicles>
OPERATION
l
position, current flows to fuse No. 3, the power
window relay (coil), and ground, thus causing
the power window
relays points to close.
l
When, in this condition,
the power window
switch
is moved to the UP or DOWN
position, current flows to the power window
relay (points), the power window switch, the
power window
motor,
the power window
switch, and ground; the power window motor
is then activated, opening or closing the door
window glass.
1 TSB Revision
If, however, the power window

lock switch is ON, the door
cannot
be opened
or closed
power window
sub switch.
http://vnx.su/
main switchs
window
glass
by using the
23-13
Front power
window nwtor
(L.H.1
Z-RL,ZF-G
z-LEI
IZF-L
z-GLI
IZF-R
I I
oa,,~~,ss
Rearpower
I I I I I
wrndw
switch
ti
Z-G6
! .e
-&,ge3
I '
ill
D-46
2-GY
z?-RY
! !
I
Wring color code
Br: Brown
B: Black
Ll: Light blue
0: Orange
L: Blue
;;$Y
y: Yellow
TROUBLESHOOTING
HINTS
1. Neither the left nor right door window
opened.
(1) The turn signals also do not operate.
l
Check the fuse.
(2) The turn signals operate.
l
Check the power window
relay.
a Power window
main switch.
l
Power window
sub switch.
glass
can be
1 TSB Revision
http://vnx.su/
sub
(L.H.1
23-14
BODY - Troubleshootina
CENTRAL LOCKING SYSTEM

CIRCUIT
DIAGRAM
OPERATION
<UNLOCK>
l
Battery voltage is always applied, via dedicated
fuse, to the door lock-control
unit.
l
When the front door is unlocked, the door lock
switch incorporated
within the door lock actuator is switched ON, and electricity flows to the
door lock-control
unit, the door lock switch,
and ground.
l
When this happens,
electricity
flows for 0.5
second to dedicated fuse, the door lock power
relay (coil at UNLOCK side), the door lockcontrol unit, and ground, and the contacts at
the UNLOCK side of the door lock power relay
close.
When this happens,
electricity
flows to the
door lock power relay (contacts
at UNLOCK
side), the door lock actuators,
the door lock
power
relay (contacts
at LOCK side), and
ground, and the door lock actuators are activated to open the doors.
<LOCK>
l
When the front door is locked, the door lock
switch incorporated
within the door lock actuator is switched OFF, and the ground circuit to
-~
http://vnx.su/
BODY
23-15
- Troubleshooting
Fmnt door lock actuator

(t7.H.)
D-Wd
G?6d
Rear door lock actuator C4door vehicles>

narrlalliS
(1) For derails on the ground point (Nanin
the, illustration).
refer to GROUP 8 - Electri$
(2) In the illustration. the numbered tiring on the ngti hand page corresponds
to the numbering
(0 on the right hand page cormspon
s to @ on the left hand page. etc.)
ycoor
cc-de
U: Light blue
System Pats Location.

on the left hand page.
Br: Brown
0: orange
;j
g;
fr:gy
the door lock-control

unit is interrupted.
When this happens,
electricity
flows for 0.5
second to dedicated fuse, the door lock power
relay (coil at LOCK side), the door lock-control
unit, and ground, and the contacts at the LOCK
side of the door lock relay close.
When this happens,
electricity
flows to the
door lock power relay (contacts at LOCK side),
the door lock actuators,
the door lock power
relay (contacts at UNLOCK side), and ground,
and the door lock actuators
are activated to
lock the door.
y&
$;
$jgP
TROUBLESHOOTING
HINTS
1. The door lock actuators
do not function
for
either locking or unlocking.
(1) The back door lock also do not operate.
l
Check the fusible link.
(2) The back door lock operates.
l
Check the dedicated
fuse.
l
Check the door lock-control
unit.
2. The door lock actuators
operate
for either
locking or unlocking
only.
l
Check the door lock power relay.
http://vnx.su/
23-16
BODY
- Troubleshooting
BUZZER
CIRCUIT
DIAGRAM
To fight control
relay
Multi-purpose
fuse
To hazard flasher unit
Key reminder
switch
Front door
switch (L.H.)
Seat belt
switch
Combination
Keyreminder
and seat belt
warning buzzer
*
w
Seat belt
warning timer
37w719
Q I.
BRB
a3
Remarks
(1) Broken lines and lines indicated by the * symbol are
applicable to the 2.8liter models.
(2) The chain line (- - - - -) is applicable to 3.0~liter models.
(3) For information
concerning
p ). refer to GROUP 8 - Electrical System Parts Location.
Wiring color code
Br: Brown
B: Black
0: Orange
LI: Light blue
G: Green
P: Pink
L: Blue
Y: Yellow
http://vnx.su/
Lg: Light green

W: White
BODY
- Troubleshooting
23-17
OPERATION
Key Reminder
Warning
l
Battery voltage is always applied through fuse No. 1 to the
key reminder switch.
l
If the drivers door is opened while the key remains in the
ignition switch, the door switch contacts close and current
flows through fuse No. 1, key reminder switch, buzzer,
door switch and ground, causing the buzzer to sound.
Seat
Belt Warning
When the ignition
switch is at ON, battery voltage
through
fuse No. 3 is applied to the seat belt warning
timer.
As a result, current flows through fuse No. 1, key reminder
switch, seat belt warning light, seat belt warning timer and
ground, causing the seat belt warning light to go on for
four to eight seconds.
If in this time the driver fails to fasten the seat belt, the
seat belt switch contacts close, causing current to flow
through fuse No. 1, key reminder switch, buzzer, seat belt
switch, seat belt warning timer, and ground so that the
buzzer sounds for four to eight seconds.
Once the driver fastens the seat belt, the seat belt switch
contacts open and the buzzer stops,
TROUBLESHOOTING
HINTS
Key Reminder
Warning
Key reminder
buzzer does not sound
1) Seat belt warning buzzer sounds
l
Check door switch.
2) Seat belt warning buzzer also does
0 Check buzzer.
not sound
Seat Belt Warning

1. Seat belt warning buzzer does not sound
1) Seat belt warning light goes on
l
Check seat belt switch.
2) Seat belt warning
light does not go on, but key
reminder
buzzer is normal
l
Check seat belt warning timer.
3) Seat belt warning
light does not go on, and key
reminder
buzzer does not sound
l
Check key reminder switch.
2. Buzzer fails to stop sounding
after drivers seat belt is
fastened
l
Check seat belt switch.
3. Seat belt warning light does not go on, but buzzer sounds
l
Check bulb.
TSB Revision
http://vnx.su/
23-18
SUNROOF
:IRCUIT
DIAGRAM
ignition swtcl
-
MN
fusible link
t.d
Remark
For details concernin
the ground point (earnpIe: H).
refer to GROUP 8 - E lectr~cal System Parts Location.
Wiring color &ode
B: Black
Br: Brown
it Light blue
0: orange
g; pi,
F;y &v
OPERATION
l
When, with the ignition key at the ACC or
ON position, the sunroof switch is set to the
OPEN position, electricity flows to dedicated
fuse, the sunroof switch, the sunroof motor,
the sunroof switch, and ground, and the sunroof opens.
0 When the sunroof switch is set to the SHUT
position, the process is the reverse of that for
OPEN; electricity flows to the sunroof motor,
and the sunroof closes.
TSB Revision
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BODY - Service
Adjustment
23-19
Procedures
SERVICE ADJUSTMENT
PROCEDURES
NwFAAcb
HOOD FIT ADJUSTMENT
1. Adjust the fit of hood with the hood adjusting bolts, hood
latch adjusting bolts and hood bumper while they are
installed. Loosen the hood adjusting bolts and adjust the
hood laterally with reference to the hood latch.
2. After lateral adjustment
of hood, adjust the hood vertically
with the hood adjusting bolts and hood latch adjusting
bolts.
Make sure that the hood hook is properly engaged with
the hood latch.
NOTE
Apply multipurpose
grease to the sliding portion,
rotating portion and the spring of the hood latch.
the
3. Turn the hood bumper and adjust the vertical position of

the hood by adjusting the hood bumper either up or down.
FUEL FILLER DOOR HOOK FIT ADJUSTM@ll

Loosen the fuel filler door hook mounting
screws and move
the fuel filler door hook to the left and right so that the door is
flush with the body.
DOOR INSTALLATION
ADJUSTMENT
NZXEAC4
1. Use the special tool to loosen the hinge mounting bolts on

the body side, and then adjust so that the clearance
around the door is uniform on all sides.
Caution
Attach protection
place where the
tape
hinge
to the fender
is installed.
edges
near the
2. At the facing surface of the front fender and door panel,

loosen the installation
bolts at the door side, and then
adjust by increasing or decreasing the number of shims.
3. At the facing surfaces of the door and rear pillar outer
panel, adjust by loosening the striker installation
screws.
4. Adjust the engagement
of the striker and door latch by
increasing
or decreasing
the number of stri.ker shims,
and/or by moving the striker.
rision
http://vnx.su/
-.
23-20
BODY - Service
Adjustment
Procedures
FRONT DOOR GLASS ADJUSTMENT
NmFAab
I.
Remove the door trim and waterproof

film. (Refer to P.2336.)
2. Raise the door glass fully, and then adjust the following
items so that the door glass fits evenly into the window
glass runchannel
all the way around.
Loosen the screws and/or bolts securing the window and
rear lower sash.
Move the window,
rear lower
sash and the sub roller
guide (vehicles without ventilator window) of the window
regulator to adjust the door glass position.
VENTkATOR
WINDOW
ADJUSTMENT
N23FJAh
I.
Remove the door trim and waterproof

film. (Refer to P.23
36.)
2. Remove the ventilator
window.
(Refer to P.2339.)
3. Adjust the ventilator window by turning the adjusting nut
so that the ventilator window can be operated smoothly.
Imm
(in.)
NOTE
Fix the adjusting
adjustment.
I.WIl
nut by bending
the lock washer
REAR DOOR GLASS ADJUSTMENT
after the
NZWFBE
1. Remove the door trim and waterproof

2. Raise the door glass fully, and then adjust the following
items so that the door glass fits evenly into the window
glass runchannel
all the_way
around:
(I) Loosen the screw and/or bolts securing the window
center sash.
(2) Move the window center sash to adjust the door glass
position.
INSIDE HANDLE ADJUSTMENT
Nu-

2. Move the mounting position of the inside handle longitudinally in order to adjust the play of the inside handle.
Standardvalue
: 4-10
mm
(.16-.40
in.)
lypFHAl
OUTSIDE HANDLE ADJUSTMENT
FRONT DOOR AND REAR DOOR

film. (Refer to P.23
36.)
2. Disconnect
the outside Gandle from the outside handle
rod, and turn it right to left to adjust the outside handle
play.
Caution
The rod snap
Standard
TSB Revision
value
http://vnx.su/
must
: 3-8
be replaced.
mm
I=
(.I&.31
in.)
Er
_+;
C
BY
-~
=
BODY - Service
Adjustment
BACK
23-21
Procedures
DOOR
1. Remove the back door trim and waterproof

film. (Refer to
P.23-56.)
2. Disconnect
the outside handle from the outside handle
rod, and turn it right to left to adjust the outside handle
play.
Standard
BACK
value
DOOR
: 5-10
mm
(.20-.40
INSTALLATION
in.]
ADJUSTWfZ
(I) To loosen the hinge mounting bolts on the body side, and
then adjust so that the clearance around the back door is
uniform on all sides.
(2) At the facing surface of the right side quarter panel and the
back door, adjust by loosening the installation
bolts.
(3) At the
door,
(4) Adjust
latch
shims,
facing surface of the left side quarter panel and back

adjust by loosening the striker installation
screws.
the engagement
of the striker and the back door
by increasing
or decreasing
the number of striker
and/or by moving the striker.
1 TSB Revision
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23-22
BODY - Body Mounting
BODY MOUNTING
1. Special bolt
2. Plain washer
3. Body mounting rubber (A)
4. Spacer
5. Body mounting rubber (6)
6. Washer
7. Self locking nut
8. Body shim9. Mounting bolt
NOTE
19 :Non-reusable parts
23-32Nm
20-23ftJbs.
1 TSB Revision
20-23ftJbs.
http://vnx.su/
23-32Nm
20-23ft.lbs.
BODY
t4-door
Body
23-23
Mounting
vehicles>
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bolt
Plain washer
Body mounting rubber (A)
Spacer
Body mounting rubber (B)
Washer
Self locking nut
Special bolt
Body shim
Mounting bolt
NOTE
q : Non-reusable parts
D.F
23-32
20-23
Nm
ft.lbs.
28-32
20-23
Nm
ft.lbs.
1 TSB
28-32
20-23
Nm
ft.lbs.
Revision
http://vnx.su/
28-32
20-23
Nm
ftlbs.
23-24
BODY - Body Mounting
REMOVAL
(1) Remove or disconnect the following - parts:
Air cleaner
Accelerator cable
Brake booster vacuum hose
Automatic transmission oil cooler hoses
Radiator assembly
Heater hoses
Steering shaft joint
Power steering oil reservoir assembly and body
connection <3.OL Engine>
Vacuum hoses
Fuel main hose <3.OL Engine>
Fuel return hose <3.OL Engine>
Vapor hoses
Air conditioner compressor and lines connection
Air conditioner compressor connector
Brake tube and brake hose connection
Brake tube-and blend proportioning valve connection <2.6L Engine>
Brake tube and connector assembly connection
<3.OL Engine> ,
Hydraulic clutch hose
Battery cable (+) and starter motor connection
Battery cable (-) and engine connection
Alternator connectors
Engine ground (on body side)
Engine coolant temperature gauge unit connector
Therm0 switch connector <Automatic transmission>
Therm0 switch connector for air conditioner
Oil pressure gauge unit connector
Distributor connector
Carburetor control wiring harness and control
wiring harness connection <2.6L Engine>
<Z-door vehicles>
High-tension cable <2.6L Engine>

Air conditioner vacuum solenoid valve connector
<2.6L Engine>
Engine control wiring harness and control wiring
harness connection <3.OL Engine>
Ignition coil connector <3.OL Engine>
Power transistor connector <3.OL Engine>
LC filter connectors <3.OL Engine>
Noise suppression capacitor <3.OL Engine>
Exhaust gasrecirculation
(EGR) valve connector
<3.OL Engine>
Idle speed control motor connector <3.OL Engine>
Throttle position sensor connector <3.OL Engine>
Transmission
shift
lever knob
<Manual
transmission>
Transmission
control
rod (B) <Automatic
transmission>
Front and rear seats
Parking brake cables
Fuel pipe and body connection <2.6L Engine>
Speedometer cable (transmission side)
Fuel filler hose
Breather hose
4WD indicator wiring harness and transmission
wiring harness connection
Rear combination light connector
Rear side marker light connector
Frame wiring harness and back door wiring
harness connection
Frame wiring harness and side wiring harness
connection <4-door vehicles>
Frame wiring harness and front wiring harness
connection
Rear air conditioner liquid line -+doorvehicles>
Rear air conditioner suction line <4-door vehicles>
Door opening trim
(2) After
removing
the body mounting
bolts and the body
shims, insert wood blocks into the body and gently lift with
a crane.
Caution
Hoist the body carefully after assuring that all the connections
between
body and frame
and engine
are
separated.
Sling wires with a suitable bar or frame used and with
good protection
made by fitting coverings
at necessary
points.
G-door
vehicles>
/ TSBEevision
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23-25
BODY - Hood
HOOD
4.0-6.0 rim
2.9-4.3 ft.lbs.
Hood
I)+
++
removal
steps
1. Hood
2.
3.
4.
Hood latch
++ 5.
6.
7.
Hood rear
8.
Hood hook
Hood hinge
Hood insulator
release cable removal steps
Hood latch
Hood latch release handle
Hood latch release cable
weatherstrip
removal
Hood rear weatherstrip
NOTE
(2) +a : Refer to Service Points of Installation.
L
5. ADJUSTMENT
OF HOOD
LATCH
/2. HOOD
HOOK
(I)
Loosen the hood latch and hood catch stay attaching

bolts.
(2) Adjust the position of the hood latch and hood hook to
align the lock with the hook.
NOTE
Apply multipurpose
grease to the sliding portion, the
rotating portion of the hood hook and hood latch.
1. ADJUSTMENT
OF HOOD
(1) Adjust the longitudinal
and lateral positions
of the
hood by utilizing the oblong holes in the hinge.
(2) Adjust the vertical position of the hood by adjusting
the hood bumper either up or down.
:evision
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23-26
BODY - Fuel Filler Door
FUEL FILLER DOOR

t423MAo

<t-door
vehicles>
<4=door
vehicles>
14
13
12
10
11
17
18WSlO
Fuel filler door panel

I)+
1. Fuel filler door panel
Lock cylinder assembly removal steps
2. Cylinder lock retainer
3. Lock cylinder assembly
Fuel filler door lock release cable removal steps
<bdoor
vehicles>
4. Front scuff plate (L.H.)
5. Ashtray
6. Retractor cover
7. Quarter trim (L.H.)
8. Center pillar trim (L.H.)
9. Rear combination light (L.H.)
16. Lock release handle
I)+ 17. Fuel filler door lock release cable
<4-door vehicles>
10. Center pillar trim (L.H.)
11. Front rail cover (L.H.)
12. Rear rail cover (L.H.)
13. Retractor cover (L.H.)
14. Speaker (L.H.)
I)+

16. Lock release handle
17. Fuel filler door lock release cable
Fuel filler door hook removal steps

<2-doer vehicles>
9. Rear combination
light (L.H.)
17. Fuel-filler door lock release cable connection
*+ 18. Fuel filler door hook
<4-door vehicles>
13. Retractor cover (L.H.)
14. Speaker (L.H.)
17. FueCfiller door lock release cable connection
++ 78. Fuelfitter door hook
NOTE
(I)
Reverse
the removal
procedures
to reinstall.
(2) **
(3) *: 2-door vehicles
http://vnx.su/
BODY - Fuel Filler Door
23-27

18. ADJUSTMENT
OF FUEL FILLER DOOR HOOK
Loosen the fuel filler door hook mounting
screws and
move the fuel filler door hook to the left and right so that
the door is flush with the body.
:2-door
vehicles>
:Cdoor
vehicles>
17. INSTALLATION
OF FUEL FILLER DOOR LOCK RELEASE
CABLE
Install so that the installation position mating mark (yellow
paint) on the release cable is aligned with the position
levision
http://vnx.su/
-.
23-28
BODY
- Fuel Filler Qoor / Fenders

1. ADJUSTMENT
OF FUEL FILLER DOOR PANEL
Loosen the fuel filler door mounting

that the upper and lower clearances
is flush with the body.
screws and adjust so

are equal and the door
FENDERS
[EMOVAL
AND
INSTALLATION
y!YL!Y~sq
Removal
steps
1. Radiator grille
2. Front combination
3. Headlight bezel
light
4. Grille filler panel

5. Front mud guard
6. Partial wheel
lip
NOTE
(2) l 4 : Refer to Service Points of Installation.
7. Splash shield
I)+
8. Front
fender
1 TSB Revision
http://vnx.su/
I~
5~.
E;;
L -
ema&
23-29
BODY - Fenders / Windshield

boss-section
A-A
-T boss-section
B-B

8. INSTALLATION
OF FRONT FENDER
(1) Apply the specified sealant fully to the top part of
fender up to the ends.
Specified
sealant
Butyl rubber
tape
Specified
sealant
: 3M ART No. 8531 or No. 8646,

or equivalent
(2) Apply butyl rubber tape to the flange part of the fender
when installing the splash shield.
Specified
adhesive
: 3M ART Part No. 8626 or 3M

Adhesive
(3) Fasten the fender temporarily

in position, make sure
that clearance is uniform at all points, and then fasten
completely.
steps
1. Upper moulding
2. Lower moulding
4*
++
4*
4+
4e ~4
3.
4.
5.
6.
7.
8.
9.
Upper
Upper
Lower
Lower
moulding,
moulding.
moulding,
moulding,
joint
joint
-R.H.
L.H.
R.H.
L.H.
Side moulding,
R.H.
Side moulding,
Windshield
L.H.
10. Windshield
NOTE
(2) +*
(3) +4
(4)
: Non-reusable
parts
weatherstrip
( TSB Revision
http://vnx.su/
to reinstall.
of Removal.
of Installation.
~.
BODY - Windshield
I.
REMOVAL
MOULDING
On vehicles
ing with the
after sliding
OF UPPER MOULDING
JOINT/S.
LOWER
JOINT/B.
TO 8. MOULDINGS
equipped with mouldings.
remove the mouldweatherstrip
straightened
with a special tool
the moulding
joint.
9.
REMOVAL OF WINDSHIELD/lO.
WINDSHIELD&ATHERSTRIP
Push the windshield
out from the inside of the cabin with
the lip of the weatherstrip
straightened
along the entire
periphery with a screwdriver.
INSPECTlON
l
Check the
body flange
for deformation.

10. INSTALLATION
WINDSHIELD
OF
WINDSHIELD
WEATHERSTRIP/S.
(1) Fill the weatherstrip

with the specified
it to the windshield.
Specified
adhesive
adhesive
and fit
: 3M ART Part No. 8001 or No.

8911, or equivalent
18W776
(2) Set round
strings
in the weatherstrip
NOTE
Make certain that the strings
ends.
mm (in.l
groove.
overlap each other at both
lSS?l
k2j
(3) Apply soap solution to the entire surface of the body

flange.
(4) Place the windshield
in position from outside with the
strings placed inside the cabin.
Soap solution
A
i
18W774
[ TSB Revision
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23-31
BODY - Windshield
(5) With the aid of an assistant to push the windshield

from outside, slowly pull one end of the string at right
angles to the windshield
and fit the lips of the
weatherstrip
correctly on the windshield
flange.
NOTE
Pull the strings,
working
from both sides of the
windshield
toward the center and pushing from the
outside of the glass.
Caution
Press lightly to
flange surface.
hold
the
glass
against
the
body
(6) Apply specified

adhesive
between
the weatherstrip
and the body flange at the locations indicated in the
illustration.
Specified
100
(3.9)
100
13.91
mm (in.)
adhesive

Adhesive
Iav652
(7) Apply an ample amount
around the weatherstrip
flange.
Specified
18w559
TSB Revision
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adhesive
of the specified adhesive all

between
it and the body

8011, or equivalent
23-32
BODY - Quarter Window Glass
QUARTER WINDOW
GLASS
<tDoor
N23l.EaD
Vehicles>
1
-10
Removal
+e +*I
steps
1. Glass and weatherstrip assembly
of step No. 2-10)
2. Quarter window weatherstrip
3. Stopper
4, Stopper
5. Quarter window sash
6. Quarter window runchannel
7. Holder
8. Rubber seal
9. Quarter window front glass
10. Quarter window rear glass
(parts
Slide glass lock removal steps

11. Connector
12. Packing
13. Slide glass lock
NOTE
(1)
(2)

**
(4)
(3) I)+
to reinstall.
of Removal.
: Non-reusable
parts

1. REMOVAL OF GLASS AND WEATHERSTRIP
ASSEMBLY
With the glass in position,
push the quarter window
assembly outward while raising the lip of the weatherstrip
along the periphery.
SERVICE POlNTS OF INSTALLATION

1. APPLICATION
OF ADHESIVE TO GLASS AND WEATHERSTRIP ASSEMBLY
(1) Apply the specified adhesive to the weatherstrip
at the
location indicated in the illustration.
Specified
adhesive
) TSB Revision
http://vnx.su/

8011, or equivalent
BODY - Quarter Window Glass
23-33
(2) After the quarter window rear glass has been installed,
install the stopper by applying the specified adhesive.
Specified
adhesive
: 3M Adhesive
alent
EC-870 or equiv-
180586
(3) Apply the specified adhesive between

and the body flange at the location
illustration.
Specified
Removal
++
<CDoor
adhesive
: 3M ART
equivalent
Part
the weatherstrip
indicated
in the
No.
8834,
Vehicles>
or
Nm.EcA
steps
1. Quarter window
2. Quarter window
weatherstrip
NOTE
(1)

1. APPLICATION
OF ADHESIVE
WEATHERSTRIP
TO QUARTER
WINDOW
Apply the specified

adhesive to the weatherstrip
location indicated
in the illustration.
Specified
8
18W1251
TSR Revision
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adhesive
at the
: 3M ART Part No. 8001 or No. 8011,

or equivalent
23-34
BODY - Back Door Window Glass
BACK DOOR WINDOW GLASS

I
Removal
I
I)*
steps
1 Spare tire lock cylinder
2 Spare tire
3 Wiper arm and blade assembly
with a rear wiper>
4 Rear defogger terminal
5 Back door window weatherstrip
6 Back door window glass
<Vehicles
NOTE
(2) I)+ : Refer to Service Points of Installation.

5. APPLICATION
OF ADHESIVE
WEATHERSTRIP
Specified
adhesive
adhesive
TO RACK DOOR WINDOW

to the weatherstrip.
: 3M ART Part No. 8001

8011, or equivalent
or NO.
(2) As shown in the figure, attach butyt tape between

weatherstrip
and the body flange.
http://vnx.su/
the
23-35
BODY - Door Assembly
DOOR ASSEMBLY
Front
Door
35-65 Nm
Door removal
steps
\
36-65 Nm
25-40 ft.lbs.
1. Door opening trim - front door

<Vehicles with a power
window>
2. Cowl side trim - front door
Center pillar trim - rear door
window>
3. Connection of door
wiring harness connector
window>
4. Spring pin
5: Door
l + 6. Door upper hinge
7. Door upper hinge shim
M
8. Door lower hinge
9. Door lower hinge shim
Striker removal steps
IO. Striker
11. Striker shim
Door switch removal steps
12. Door switch cap
13. Door switch
jawa
Rear Door
17-26 Nm
12-19 Ribs.
law882
NOTE
(2) **
36-65 Nm
25-N ft.lbs.
INSPECTION
l
Check
noise.
the
) TSB Revision
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door
hinges
for cracks,
damage
or abnormal
23-36
BODY - Door Assembly / Door Trim and Waterproof Film

DOOR SWITCH
Operate the switch,
minals.
between
the ter-
fll.;
Y16885
NOTE
C-O indicates thatthere
is continuity between the terminals.

8. APPLICATION
OF GREASE TO DOOR LOWER
DOOR UPPER HINGE
door hinges.
MW722
to the sliding
FILM
<Vehicles
without
a Power Window>
Rear Door
Removal steps
1. Clip
4+
2.
3.
4.
5.
6.
**
*q
Regulator handle
Escutcheon
Armrest
Inside handle cover
Ashtray (rear door)
7. Door trim
8. Door upper trim
9. Waterproof film
part of the
DOOR TRIM AND WATERPROOF

grease
HINGE/G.
NOTE
(2) +I)
(3) l 41 : Refer to Service Points
(4) C
: Clipping position
1 TSB Revision
http://vnx.su/
to reinstall.
of Removal.
of Installation.
w!3MaAu
BODY - Door Trim and Waterproof Film
23-37

1. REMOVAL OF CLIP
Remove the clip by using
regulator handle.
18UO392
a rag, and then
remove
the
18UO430
7.
REMOVAL
OF DOOR TRIM
Insert a plastic trim tool between the trim clip (bushing)
and trim clip (pin), and then pry the trim clip to remove.
1800214
NOTE
If the trim clip (bushing)
and trim clip (pin) come off
together,
separate the trim clip assembly from the trim
and install the trim clip (bushing) at the door side. Then
improvise
a tool (such as shown in the illustration)
to
remove the trim clip (pin).

9. APPLICATION
OF ADHESIVE TO WATERPROOF
FILM
Apply a coating of specified
adhesive to the position
and then attach the waterproof
film.
Specified
1 TSB Revision
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adhesive

Adhesive
._
23-38
REMOVAL
BODY
AND
Door
and
Waterproof
<Vehicles with
INSTALLATION
Trim
Front
Film
a Power Window>
Door
u)W887
10
Rear Door
Removal
+*
steps
1. Armrest
3. Ashtray (rear door)
4. Power window switch cover
5. Door trim
6. Door upper trim
7. Connection of power window
connector
8. Power window switch
9. Connection of power window
10. Waterproof film
switch
NOTE
relay
(11
(21
(3)
(4)

*+ : Refer to Service Points of Removal.
+* : Refer to Service Points of Installation.
C
: Clipping position
I
[ TSB Revision
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I;
BODY
Door Trim and Waterproof
Film / Front Door Glass and Regulator
23-39

5. REMOVAL OF DOOR TRIM
Refer to P. 2337.

10. APPLICATION
Refer
OF ADHESIVE
TO WATERPROOF
FILM
to P. 23-37.
FRONT DOOR GLASS AND REGULATOR

I
Removal
steps
1. Door trim and wateroroof film *9

& Adjustment
of door window glass
2. Outer weatherstrip
a+
3. Inner weatherstrip
4. Center sash protector
++ Adjustment of ventilator window assembly
5. Ventilator window assembly
6. Glass holder
7. Door glass pad
e+ 8. Door window glass
e+ MI 9. Window regulator
l , e+
NOTE
(2) +r)
(3) wq
(4) *
: Refer to Service
: Refer to Service
1
http://vnx.su/
of Removal.
of Installation.
: Vehicles with a power window.
I
[ TSB Revision
Points
Points
:=f=H.
4.x
L+-
-itr,
&
23-40
j__,
,__ __
BODY - Front
Door
Glass
and
Recrulator

1. REMOVAL
OF DOOR
Refer to P.2336.
TRIM
AND
WATERPROOF
FILM
2.
REMOVAL
OF OUTER WEATHERSTRIP
(1) Remove the outer weatherstrip
from the fixing clips by
prying upward with a screwdriver.
rearward.
9.
REMOVAL
OF WINDQW
REGULATOR
Vehicles
with a Power Window
Caution
Because the force of the regulator
spring may cause the
regulator
arm to jump up when the screws attaching
the motor
to the window
regulator
are removed,
remove
the regulator
spring
before
removing
the
screws.
18K324
INSPECTION
18Y151
Power
Power
window
switch
(manual)
POWER WINDOW
MOTOR
(1) Connect the motor terminals
directly to the battery and
check that the motor operates smoothly. Next, reverse the
polarity and check that the motor operates smoothly in the
reverse direction.
(2) Check the circuit breaker incorporated
in the motor, as
described below, after installing the motor and regulator
to the body.
0 Press the UP switch to fully close the window glass,
and continue to press the switch for IO to 20 seconds.
0 At the moment that the UP switch is released. press
the DOWN switch. The circuit breaker can be considered good if at rhis time the door window glass begins
to open within 60 seconds.
MAIN SWITCH
Z-Door Vehicfes
Operate the switch,
terminals.
window
1 TSB Revision
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and check
the continuity
between
the
23-41
BODY - Front Door Glass and Regulator
Switch
Lock switch
ON (LOCK)
OFF (FREE)
o---o
NOTE
(I) C-C indicates that there is continuity between the terminals.
(2) The * symbol indicates connection within the switch.
4-Door
Operate
minals.
Vehicles
the switch,
between
the ter-
Switch
Power window switch
(manual)
Power window switch

(automatic)
Lock switch
DOWN HOLD
c--o--o
ON (LOCK)
OFF (FREE)
NOTE
(1) O-3 indicates that there is continuity between the terminals
(2) The * symbol indicates connection within the switch.
[ TSB Revision
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P-F
23-42
BODY - Front
Door
Glass
and
SUB SWITCH
Operate the switch,
minals.
Regulator
between
the ter-
o----o
UP
OFF
t-1
DOWN
NOTE
0-0
indicates that there is continuity between the terminals.
POWER WINDOW POWER RELAY

(1) After removing the cowl side trim, remove
dow power relay.
(2) Connect
between
the power win-
battery to terminal
2 and check
terminals
with terminal 4 grounded.
Power is supplied
l-3
terminals
continuity
Continuitv
SERVICE POINTS OF INSTALLATlbN

9.
INSTALLATION
OF WINDOW
REGULATOR
Vehicles without
a Power Window
grease to the sliding parts
and rotating parts of the window
regulator.
Vehicles with a Power Window
When assembling
the window regulator and power window motor, first install the regulator
spring, and then
proceed with assembly.
1 TSB Revision
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--
BODY
23-43
- Front Door Glass and Regulator

8.
INSTALLATION
OF DOOR
WINDOW
GLASS
When the door glass has been removed from the glass
holder, install to the position shown in illustration.
Standard
value :
Distance X 466.5-467.5
mm (18.366-18.406
Distance
Y 76.5-77.5
mm (3.012-3.051
in.)
Glass holder(B)
ADJUSTMENT
Refer
o
1.
Disassembly
I)+
AND
REASSEMBLY
OF DOOR
WINDOW
GLASS
to P. 23-20.
INSTALLATION
FILM
Refer
WINDOW
to P. 23-20.
ADJUSTMENT
Refer
DISASSEMBLY
OF VENTILATOR
in.)
OF DOOR
TRIM
AND
WATERPROOF
to P. 23-36.
(Ventilator
Window
Assembly)
steps
1. Door window
runchannel
162
2. Screw
3. Screw
4.
5.
6.
7.
8.
9.
10.
11.
Washer
Packing
Hinge
Pin
Ventilator window lock handle
Push button
Push button spring
Wave washer
12. Screw
13. Ventilator open handle
l + Adjustment
of ventilator window
14. Ventilator sash spring kit
I)* 15. Ventilator sash
+* 16. Ventilator window glass pad
I)+ 17. Door ventilator window glass
I)+ 18. Ventilator window weatherstrip
w+ 19. Ventilator sash assembly
FyEeverse
(2) ,d
1 TSB Revision
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the disassembly procedures to reassemble.
23-44
BODY
Front
Door
Glass
and
Regulator
SERViCE POINTS OF REASSEMBLY

lQ.APPLlCATfON
OF ADHESIVE TO VENTILATOR
SASH
ASSEMBLY/IS.
VENTILATOR
WINDOW
WEATHERSTRIP
(1) Apply the specified adhesive to the place marked A
in the figure, between the ventilator sash assembly and
the ventilator window weatherstrip.
Specified
adhesive

in the figure.
Specified
adhesive
: 3M Super Weatherstrip
Adhesive 8001 or 8011 or equivalent
adhesive
to the place marked

Adhesive
17. APPLICATION
OF ADHESIVE TO DOOR VENTILATOR
WINDOW
GLASS/lG.
VENTBATOR
WINDOW
GLASS
PAD/15. VENTILATOR
SASH
(1) The SECT. A-A and VIEW B parts in the illustration are
to be coated with the specified adhesive.
Specified
adhesive
: 3M Super Weatherstrip
Adhesive 8001 or 8011 or equivalent
(2) The SECT. C-C and SECT. D-D parts in the illustration
are to be coated with the specified
adhesive.
Specified
VIEW B
SECT. A-A
Apply the
adhesive so that
SECT.
c-c
adhesive

Adhesive
SECT. D-D
Specified
adhesive
18W805
18W804
-
evision
.i
http://vnx.su/
.~
BODY - Front
Door
.
al
Specifiedadhesive
venhat$
y&he-rip&
,A!B-I
Spec%ed
adhesive
SECT. A-A
.J/
18W800
23-45
Regulator
ADJUSTMENT
OF VENTILATOR
Refer to P.23-20.
Door window
glass runchannel
and
WINDOW
1. APPLICATION
OF ADHESIVE
TO DOOR
WINDOW
GLASS RUNCHANNEL
Apply the specified adhesive between the door window
glass runchannel and the ventilator sash assembly at the
location indicated in the illustration.
Door
window
glass
runchannel
18W800
Glass
18W806
1 TSB Revision
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: 3M ART
Adhesive
Part No. 8080 or 3M

23-46
BODY - Rear Door Glass and Regulator
REAR DOOR GLASS AND REGULATOR

mhlcw
Removal
1. Door trim and waterproof
+I) I)4
+4 Adjustment of door window
2. Outer weatherstrip
+I)
+*
+I) ++
++I)*
3.
4.
5.
6.
7.
8.
9.
1i 0.
film
glass
*lOA
Inner weatherstrip
Window glass runchannel
Window center sash
Stationary window assembly
Glass holder
Door glass pad
Door window glass
Window regulator
6 Nm
4.3 ftlbs.
18W891
NOTE
(2) +I, : Refer to Service Points of Removal.
(4) *: Vehicles with a power window

1. REMOVAL
OF DOOR
Refer to P.2336.
2.
TRIM
AND
WATERPROOF
FILM
REMOVAL
OF OUTER WEATHERSTRIP
from the fixing clips by
prying upward with a screwdriver.
(2) Remove
the
http://vnx.su/
outer weatherstrip
rearward.
BODY - Rear
Door
Glass
and
10. REMOVAL
Refer
23-47
Regulator
OF WINDOW
to P.23-40.
REGULATOR
INSPECTION
POWER WINDOW
Refer to P.2340.
SUB SWlTCH
Refer to P.2342.
MOTOR

IO. INSTALLATION
OF WINDOW
REGULATOR
Vehicles without
a Power Window
grease to the sliding parts
and rotating parts of the window
regulator.
Vehicles with a Power Window
When assembling
the window regulator and power window motor, first install the regulator spring, and then
proceed with assembly.
9.
INSTALLATION
OF DOOR WINDOW
GLASS
When the door glass has been removed from the glass
holder, install to the position shown in the illustration.
Standard
value
: 232-238
ADJUSTMENT
OF DOOR
Refer to P.23-20.
1. INSTALLATION
OF DOOR
FILM
Refer to P.23-36.
1 TSB Revision
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mm
(9.1-9.4
WINDOW
TRIM
in.)
GLASS
AND
WATERPROOF
23-48
BODY - Door Handle and Latch
DOOR HANDLE AND LATCH

REMOVAL ARID INSTALLATION
Rear
Removal steps
+e ++ 1. Door trim and waterproof
film
I)+ Adjustment of outside handle
I)+ Adjustment of inside handle
2. Inside lock knob
3. Outside handle
4. Door latch
5. Inside handle
I)+ 6. Door lock actuator <Vehicles equipped
with central locking system>
1 TSB Revision
NOTE
(21 ++ : Refer to Service Points of RemovaT.
(3) I)* : Refer to Service Points of installation
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BODY
23-49
- Door Handle and Latch

SERVICE
POINTS
OF REMOVAL
1. REMOVAL
OF DOOR
Refer to P.23-36.
TRIM
AND
WATERPROOF
FILM
INSPECTiON
DOOR LOCK CONTROL UNIT
(1) Apply battery voltage to the terminal 0 and earth the terminal @.
(2) Verify that the terminal voltage indicated at the terminals @
and 8 is 12V.
(3) Verify that by earthing the terminal @I or @ the voltage at the
terminal 0 momentarily drops to OV (about 0.5 second), and
then rises back to 12V.
(4) Verify that by removing the earth from the terminal @ or @
in the state as described in (3). the voltage at the terminal @
momentarily
drops to OV (about 0.5 second), and then rises
back to 12V.
DOOR LOCK POWER RELAY

Continuity between the terminals
Remark:
(I) CF-0
(2) O----O
is checked.
indicates continuity between terminals.

indicates connection of power source.
16K757
DOOR LOCK ACTUATOR

Verify that the rod properly
connected as follows:
functions
when
y/1
VIEW A
PUSH
@--. ---e
PULL
em-. --@
Remark:@----e
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indicates
connection
power
source
of power source.
is
23-50
BODY - Door Handle and Latch

Al
Latch

6.
Inside
lock rod
INSTALLATION
OF DOOR LOCK ACTUATOR
Front Door Lock Actuator
(1) Put the door-latch-side
lock rod into the LOCK
position.
(2) Put the door lock actuator
lever into the LOCK
position.
(3) Securely mount the lever-end holder onto the lock rod.
Rear Door Lock Actuator

(1) Put the inside lock rod into the LOCK position.
(2) Put the door lock actuator
lever into the LOCK
position.
(3) Securely mount the lever-end clamp onto the lock rod.
kc
ADJUSTMENT
OF INSIDE
HANDLE
Refer to P. 23-20.
e ADJUSTMENT
OF OUTSIDE HANDLE
Refer to P. 23-20.
1. INSTALLATION
OF DOOR TRIM AND
FILM
Refer to P. 23-36.
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WATERPROOF
BODY
WINDOW
STRIP
REMOVAL
- Window
GLASS
AND
Glass Runchannel
RUNCHANNEL
INSTALLATION
(Front
and Door Opening Weatherstrip
AND DOOR OPENING
23-51
WEATHER-
Door)
N23MEm
6 Nm
4.3 Ribs.
Removal
steps
ei) l +
+e I)+
1.
2.
3.
4.
5.
l IF l +
+* ++
4*
Door trim and waterproof

film
Ventilator window assembly
Door window glass runchannel
Door window glass
6. Door lower sash
7. Door opening weatherstrip
1Sw296
NOTE
(2) ** : Refer to Service Points of Removal.
(3) **
SERVICE
1.
REMOVAL
Refer
2.
5.
OF DOOR
TRIM
AND
WATERPROOF
FILM
OF VENTILATOR
WINDOW
ASSEMBLY
to P.2339.
REMOVAL
Refer
OF REMOVAL
to P.2336.
REMOVAL
Refer
4.
POINTS
OF DOOR
WINDOW
GLASS
to P.23-39.
REMOVAL
OF WINDOW
Remove the window

glass
sides with your fingers.
TSB Revision
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GLASS
RUNCHANNEL
runchannel
by pressing
both
~__
23-52
BODY - Window
Glass
Runchannel
7.
and
Door
Opening
Weatherstrip
REMOVAL OF DQOR OPENING WEATHERSTRIP

Remove the door opening
weatherstrip
with
the
tool

5. APPLICATION
OF ADHESIVE
TO WINDOW
GLASS
RUNCHANNEL
Apply the specified adhesive to the positions shown in
illustration
and install the window
glass runchannel.
Specified
adhesive
: 3M Adhesive
lent
4.
INSTALLATION
OF DOOR
Refer to P.23-39.
2.
INSTALLATION
OF VENTILATOR
Refer to P.2339.
1. INSTALLATlON
OF DOOR
FILM
Refer to P.23-36.
i TSB Revision
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EC-870
WINDOW
TRIM
GLASS
WINDOW
AND
or equive-
ASSEMBLY
WATERPROOF
BODY - Window
REMOVAL
AND
Glass
INSTALLATION
Runchannel
(Rear
and
Door
Opening
+I) e+
+*
a+
*I)
23-53
Door)
NPMEBE
/3
Removal
Weatherstrip
steps
1.
2.
3.
4.
++ 5.
6.
7.
Door trim and waterproof

Window center sash
Stationary window
Door window glass
Door opening weatherstrip
film
18W890
6 Nm
4.3 ft.lbs.
NOTE
(3) w
: Refer to Service Points of Inst8llation.
SERVICE
1.
4.
POINTS
OF REMOVAL
REMOVAL
OF DOOR TRIM
Refer to P. 23-36.
REMOVAL
OF STATIONARY
Refer to P. 2346.
AND
WINDOW
WATERPROOF
FILM
WINDOW
5.
REMOVAL
OF DOOR
Refer to P. 23-46.
GLASS
7.
REMOVAL
OF DOOR OPENING WEATHERSTRIP
Remove the door opening weatherstrip
with the
tool

5.
1.
INSTALLATION
OF DOOR WINDOW
GLASS
Refer to P. 23-47.
INSTALLATION
OF DOOR TRIM AND WATERPROOF
FILM
Refer to P. 23-36.
TSB Revision
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23-54
BODY -
Back
Door
Assembly
BACK DOOR ASSEMBLY

ld
CBdoor
Back door removal
+4
4*
*I)
++
vehicles>
<4-door
steps
1.
2.
3.
4.
5.
Spare tire lock cylinder

Spare tire
Spare tire carrier
Rear opening trim
Retractor cover
<Vehicles with rear seat belts>
6. Speaker <4-doer vehicles>
7. Quarter trim
8. Rear pillar lower trim <Z-door vehicles>
Rear pillar trim <4door vehicles>
Adjustment of back door installation
9. Cotter pin
IO. Clevis pin
11. Connection of rear washer tube
<Vehicles with a rear wiper>
1 TSB Revision
*+
Q+ +4
H
#
Striker
vehicles>
12. Connection of back door wiring

connectors
13. Back door
15. Back door trim
16. Waterproof film
17. Door upper hinge
18. Door lower hinge
removal
steps
19. Striker
20. Striker shim
Door opening
+I) ++
weatherstrip
21. Door opening
weatherstrip
NOTE
(2) +e
(3) w
(4) q
: Non-reusable
parts
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to reinstall.
of Removal.
of Installation.
harness
23-55
BODY - Back Door Assembly

SERVICE
POINTS
OF REMOVAL
7.
REMOVAL
OF QUARTER TRIM
Refer to P.23-67, 90, 92.
8. REMOVAL
OF REAR PILLAR LOWER TRIM <tDoor
Vehicles>
/ REMOVAL
OF REAR PILLAR TRIM <CDoor
Vehicles>
Refer to P.23-67, 90, 92.
15. REMOVAL OF BACK
FiLM
Refer to P.23-56.
DOOR
TRIM/lG.
WATERPROOF
21. REMOVAL
OF DOOR OPENING WEATHERSTRIP
Remove the door opening
weatherstrip
with the
tool

XAPPLlCATlON
OF ADHESIVE
TO DOOR OPENING
WEATHERSTRIP
Apply a coating of specified
adhesive at the position
shown in the illustration, and then attach the door opening
weatherstrip.
Specified adhesive
Adhesive
18.APPLlCATlON
OF
GREASE
TO
DOOR
LOWER
HINGE/17.
DOOR UPPER HINGE
Supply multipurpose
grease from the grease holes of the
door hinges.
NOTE
The nozzle of the grease gun should
tip.
16. WATERPROOF
FILM
Refer to P.23-56.
. ADJUSTMENT
OF BACK DOOR
Refer to P.23-21.
3. INSTALLATION
OF SPARE TIRE
Refer to GROUP 22 - Spare Tire
TSB Revision
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have a smalldiameter
INSTALLATION
CARRIER
Carrier.
23-56
BODY - Back Door Trim
BACK DOOR TRIM

REMOVAL AND [NSTALLATION
Removal
4,
++
steps
1.
2.
3.
4.
5.
inside handle cover

Back door trim
Armrest
Tailgate trim
Waterproof film
NOTE
(2) +I)
Refer to Service Points of Removal.
(3) ++ : Refer to Service Points of Installation
(4) + : Clipping position
-SERVICE POINTS OF REMOVAL

2. REMOVAL
OF BACK DOOR TRIM
Insert a plastic trim tool between
the trim clip (bushing)
and trim clip (pin), and then pry the trim clip to remove.

5.
APPLICATION
OF ADHESIVE TO WATERPROOF
specified
adhesive at the positions shown
Apply
illustration,
and then
Specifiedadhesive
levision
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attach
the waterproof
: 3M ART
Adhesive
z
+
FILM
in the
film.
Part No. 8626 or 3M

23-57
BODY - Back Door Handle and Latch
BACK
DOOR
HANDLE
AND
LATCH
Removal
+e
NxmcAF
steps
+*I 1. Back door trim and waterproof

I)+ Adjustment of outside handle
2. Back door garnish bracket
3. Back
4.
5.
6.
7.
door
film
garnish
Outside handle
Inside handle
Back door latch
Back door lock actuator
NOTE
(2) *+
(3) I)+
to reinstall.
of Removal.
of Installation.
rminal
1. REMOVAL
FILM
Refer
OF BACK DOOR TRIM
AND
WATERPROOF
to P.23-56.
INSPECTION
BACK
16WO46
DOOR
LOCK
ACTUATOR
Connect
the battery
source to the actuator
terminal,
and
check the shaft for operation.
If the shaft moves in opposite
direction
when
the connection
polarity
is changed,
the
actuator
should be considered
to be in normal condition.

l
ADJUSTMENT
Refer
1.
HANDLE
to P.23-21.
INSTALLATION
PROOF FILM
Refer
OF OUTSIDE
to P.23-56.
1 TSB Revision
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OF BACK
DOOR
TRIM
AND
WATER-
23-58
BODY - Back Door Lock Switch

i
++
1. Back door lock switch
NOTE
++ : Refer to Service
Points of Removal.
1. REMOVAL OF BACK DOOR LOCK SWFTCH
(1) Pry off the switch by using the trim stick and pull out the
switch from the meter hood.
(2) Disconnect the connector from the back of the switch and
take out the switch.
INSPECTION
-
Operate the switch,

terminals.
and check
the continuity
between
MC0339
law839
NOTE
O-O indicates that there is continuity between the terminals.
[ TSB Revision
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the
23-59
BODY - Sunroof
SUNROOF
Nz3lAA.l

I
Removal
++ +4
steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
Pre-removal
Sunroof switch
Motor assembly
Clips
Interior lamp harness holding tape
Front set brackets
Rear set brackets
Bolts
Sunroof assembly
Drain pipes
Operation
Removal of the Headlining

(Refer to P. 23-84.)
(1) Checking for Water Leakage

(2) Installation of the Headlining.
NOTE
(2) +* : Refer to Service Points of Removal.
(3) *+ : Refer to Service Points of installation.

2.
REMOVAL
(1) Remove
sunroof.
OF MOTOR
the
motor
ASSEMBLY
assembly
after
fully
NOTE
If the sunroof wont move, make a mating
roof lid and on the guide rail.
closing
the
mark on the
(21 Makea matingmark on the motor assemblysintermittent
gear
TSB Revision
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and the
bracket.
23-60
BODY
- Sunroof
INSPECTIONS
l
Check the gears of the motor assembly for unusual wear.
a Check for foreign material in the guide rail assembly.
* Check the condition
of the deflector.
CHECKING
Check the
below.
Front decoration
cover
1. Remove
2. Remove
cord.
3. Using a
the roof
THE SLIDING RESISTANCE

OF THE ROOF LID
sliding resistance
of the roof lid as described
the front
the front
spring
lid.
decoration
covers.
guide essemblys
front
balance,
measure
the sliding
nut and tie a

resistance
of
Standard
4.
value : 200 N (44 Ibs.) or less

If the sliding resistance
of the roof lid exceeds the
standard value, check the points described
below.
(1) Check the installation
condition
of the guide rail
assembly.
(2) Check the guide bracket for unusual wear, deformation or damage.
(3) Check for stiffness,
catching, etc. of the drive cable.
(4) Check for deformation
of the drive tube.
CHECKING THE CLUTCH SLlDlNG

FORCE
Check the sliding force of the clutch as described
below.
1. Fit the hexagonal wrench (included)
into the hexagonal
hole in the motor drive shaft. Then, using a spring balance,
measure the force when t-he motors clutch just begins to
slip.
Standard
value : 30-48
N (9.9-9.8
Ibs.)
Caution
1. The spring balance must be kept at a 90 angle
relative
to the wrench.
2. Be sure to use the wrench included with the vehicle;
if any other wrench
is used, the clutch slip force
measurement
will change.
2.
3.
if the clutch slip force is not within the standard value,

adjust by turning the motors adjustment
nut to the left
and right.
After the adjustment
is completed,
secure the adjustment
nut by the lock washer.
I
vision
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23-61
BODY - Sunroof
SUNROOF
RELAY
(1) Remove the front headlining.
(Refer to P. 23-84.)
(2) Remove the sunroof power relay and sunroof control
from the drive tube assembly.
Sunroof power relay

Connect batten/ power source to terminal
ween terminals when terminal 4 grounded.
relay
2. Check circuit bet-
Power is supplied
Between l-3 terminals
Continuity
Power is not
supplied
Between l-3 terminals
No continuity
Between 2-4 terminals
Continuity
18G0353
16L6312
16WW6
Sunroof control relay

(1) Connect batten/ to terminal 2 and check
ween terminals with terminal 4 ground.
2
16G63 37
Power is not supplied
continuity
cl--0
0
Power is supplied
00
H
I----
bet-
NOTE
G-O indicates there is continuity between the terminals.
(2) Check diode circuit as follows.
L
18GD384
----
-;:I,,
2 _-
lsGO2
i;
33
I Yes
-I
1 TSB Revision
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BODY - Sunroof
SUNROOF SWITCH
(1) Remove the cover and sunroof switch panel assembly.
(Refer to P. 23435.)
(2) Remove the sunroof switch.
(3) Operate sunroof switch and check circuit between switch
terminals.
$1mrooi switch
-.
Sunroof-switch 0
/ panel assembly ,8W9,,
16Go341
JOTE
O-O indicates there is continuity between the terminals.
1
m
4
160056#
LIMIT SWITCH
(1) Remove the sunroof motor.
(2) Turn sunroof motor and check circuit between
terminals.
limit switch
ON
OFF
NOTE
0
I
O-O indicates there is continuity between the terminals.
SERVICE POINTS OF IiSTALLATlON

2.
/ TSB Revision
INSTALLATION
OF MOTOR ASSEMBLY
grease onto the pinion gear of
motor.
(2) When replacing motor, install with roof lid open [about
200 mm (7.9 in,)] and limit switch OFF.
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_I
BODY
DISASSEMBLY
AND
- Sunroof
23-63
REASSEMBLY
1800471
Disassembly
steps
1. Decoration
covers
2. Roof lid
++
+a
I)+
3.
4.
5.
6.
7.
8.
9.
IO.
11.
12.
13.
Front guide bracket

Snap ring
Link pin
Deflector assembly
Rail end covers
Guide rail assemblies
Sunshade
Drive tube
Rear guide and cable assemblies
Seal tape
Housing assembly
NOTE
(2) IH : Refer to Service Points of Reassembly.

Rear guide and
cable assembly
/
11. APPLICATION
OF GREASE TO REAR GUIDE AND CABLE ASSEMBLY
grease to the guides
moving part, link and cable.
wision
http://vnx.su/
23-64
BODY - Sunroof
7. APPLICATION-mOF
SEALANT
TO RAIL END COVER
INSTALLATION
PART
sealant to the rail end
cover installation
part.
Specified
sealant
: 3M ART Part No. 8531 or 8646 or

3M Adhesive
EC-2153 or EC-5528,
or equivalent
6. APPLICATION
OF GREASE TO DEFLECTOR ASSEMBLY
Apply a coating
of the multipurpose
grease to the
deflector assemblys
link and hinges moving parts.
3. APPLlCATlON
OF GREASE TO FRONT GUIDE BRACKET
grease to the guides
moving part and the link.
1 TSB Revision
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23-65
BODY - Under Guard
UNDER GUARD
NZ3WMA
law786
<Vehicles
with
transmission>
a manual
18-25
13-18
Nm
ftlbs.
7-3 ft.lbs.
18-25 Nm
XI-18ft.lbs.
IO-13 Nm
7-3 ftlbs.
<Vehicles
with
transmission>
an automatic
18-25 Nm
lo-13 Nm
7-9 ft.lbs.
I.
2.
3.
4.
Snow-protection
under cover
Under cover
Under skid plate
Transfer case protector
VI-13 Nm
7-9 ft.lbs.
5. Cross shaft protector

1 TSB Revision
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law787
BODY - Loose Panel
23-66
LOOSE PANEL
3
40-6*Nm
/=-GT?zL
2:!9-4:3 ftlbs.
Waterproof
++ I)+
*+
pad and air duct removal
*+
Front floor cover removal steps

l +
4. Floor console
5. Front floor cover
Radiator
grille bracket
10. Grille filler panel assembly

1 1. Hood catch stay
steps
1. Front fender
2. Waterproof pad
3. Air duct
16
1 2. Hood latch
13. Hood catch bracket assembly
14, Bridge panel cover assembly
Splash
shield removal steps

15. Partial wheel lip
+a 16. Splash shield
Shield rubbers
removal
steps
17. Shield rubber <Vehicles

tic transmission>
18. Shield rubber
6. Radiator grille
7. Radiator grille bracket
Bridge
panel cover assembly

6. Radiator
steps
grille
9. Head
removal
light
with an automa-
light
bezel
1 TSB Revision
F??ev&se
the removaiprocedures
to reinstall.
(21 **
(3) l *
-. -
http://vnx.su/
-1.
23-67
BODY - Loose Panel /Bumpers

1. REMOVAL
OF FRONT
Refer to P.23-28.
4.
FENDER
REMOVAL
OF FLOOR CONSOLE
Refer to P.23-77.

16. INSTALLATION
OF SPLASH
Refer to P.23-28.
12. INSTALLATION
OF HOOD
Refer to P.23-25.
SHIELD
LATCH
2. APPLICATION
OF SEALANT TO WATERPROOF
Apply the specified sealant to the places marked
figure.
Specified
sealant
1. INSTALLATION
Refer
: 3M ART Part No. 8001 or No. 8011,

or equivalent
OF FRONT
FENDER
to P.23-28.
BUMPERS
(Front Bumper)
18W820
[ TSB Revision
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PAD
in the
23-68
BODY - Bumpers
DISASSEMBLY AND REASSEMBLY (Front Bumper)
Disassembly
1.
2.
3.
4.
steps
Bumper stay assembly
Front bumper side
Bumper guard
Front bumper center
NOTE
REMOVAL AND INSTALLATION (Rear Bumper)
Rear bumper assembly
[ TSB Revision
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18W821
BODY - Bumpers
DISASSEMBLY
Disassembly
1.
2.
3.
4.
5.
6.
7.
AND
REASSEMBLY
<Bdoor
vehicles>
<4-door
vehicles>
(Rear Bumper)
steps
Rear
Rear
Rear
Rear
Side
Rear
Rear
bumper
bumper
bumper
bumper
bumper
bumper
bumper
stay
reinforcement
plate
side
stay <2door
stay
face
Q&
vehil
NOTE
Reverse the disassembly procedures to reassemble
1 TSB Revision
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23-69
23-70
BODY - Grille, Garnish
GRILLE, GARNISH
<2-door
<4-door
vehicles>
vehicles_>
1. Radiator grille
3. Headlight bezel
Air outlet
garnish
light
removal
+I) I)+ 4. Upper quarter trim -G&door vehicles>

Plug -G-door vehicles>
5. Air outlet garnish
[)?+vsrse
(3) H

. Refer to Service Points of Removal..
: Refer to Service Points of Instaliation.

4.
REMOVAL
OF UPPER QUARTER
<Pdoor
Vehicles>
Refer
TRIM
to P.23-87.

4.
INSTALLATION
OF UPPER QUARTER
<2-Door
Vehicles>
Refer
1 TSB%evision
to P.23-87.
http://vnx.su/
TRIM
For installation of the instrument panel, the bolts, screws and nut described below are used.
They are indicated by symbols in the illustration in the section SERVICE POINTS OF REMOVAL.
Washer assembled
Washer assembled
TSB Revision
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;9-m.ai
*_
::.-.
23-72
REMOVAL
BODY
AND
- instrument
Panel
INSTALLATION
2!%33 ft.lbs.
Removal
4*
40
++
4*
+*
+I)
+*
+*
+*
steps
1.
2.
3.
4,
5.
6.
7.
8.
9.
10.
11.
Lap heater duct (B)

Lap heater duct (C)
Hood release cable bracket
Demister grille (L.H.)
Demister grille (R.H.)
Glove box
Meter cover
Meter case
Combination meter pad
Combination meter case
Center panel
4*
++
j+
*+
12. Connection of recirculation/fresh

air
changeover control wire
13. Connection of mode selection control
wire
14. Connection of water valve control wire
15. Center reinforcement
16. Horn pad
17. Steering wheel
18. Fuse box cover
19. Fuse box assembly
20. Instrument panel
NOTE
(1) Reverse the remoYal procedures to reinstall.
(2) ** : Refer to Sarvice Points of Removal.
(3) ** : Refer to Service Points of Instaliation.
http://vnx.su/
BODY.
Instrument
23-73
Panel
SERVICE
POINTS
OF REMOVAL
1. REMOVAL OF LAP HEATER DUCT (B)/B.HOOD RELEASE
CABLE BRACKET
Remove the lap heater duct B and hood release cable
bracket.
4.
REMOVAL
OF DEMISTER GRILLE (L.H.) /5. DEMISTER
GRILLE (R.H.)
Remove the right and left demister grilles by raising the
attaching
projections
with a screwdriver.
Caution
Use care not to break
6.
the projections.
REMOVAL
OF GLOVE BOX
(1) Remove the glove box stopper.
(2) Remove side lap heater duct(C) on the assistants
seat.
(3) Remove the glove box frame attaching screws from

the instrument
panel and remove the glove box.
7. REMOVAL
OF METER COVER
Remove the meter cover with a screwdriver.
1 TSB Revision
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23-74
BODY - Instrument
Panel
8. REMOVAL
OF METER CASE
(1) Remove the screws from the bottom
of the case.
(2) Remove the bolt from the upper part of the case.
(3) Disconnect
the speedometer
cable from the meter
case by pushing
the stopper
of the plug on the
speedometer
cable side of the connection.
(4) Disconnect
the connectors
of the meter harness and
also of the body harness.
(5) Disconnect
the connectors
(all located
behind the
meter case at the bottom) of the hazard switch, the
rear window defogger,
rear fog lamp switch, electric
tailgate
locking switch,
and the rear wiper/washer
switch, and then remove the meter case.
9. REMOVAL
OF COMBINATION
METER
Remove the combination
meter pad.
PAD
10. REMOVAL
OF COMBINATION
METER CASE
(1) Remove the meter case attaching
screws.
(2) Disconnect
the connectors
of the meter
located behind the meter case.
harness
Caution
To prevent internal trouble, the meter must not be
dropped
or subjected
to shock or must not be
abruptly
inclined to the extent that the maximum
indication
angle is exceeded.
15. REMOVAL
OF CENTER REINFORCEMENT
(1) Remove the center console. (Refer to P.23-76.)
(2) Remove the center reinforcement
attaching
screws.
(3) Remove the center reinforcement,
radio and car stereo
player as a unit.
(4) Disconnect
the radio and car stereo player from the
front harness and feeder wire.
I/
19w775
/Revision
http://vnx.su/
BODY - Instrument
23-75
Panel
17. REMOVAL
OF STEERING WHEEL
Remove the steering wheel.
NOTE
Before removal, make the mating
shaft and steering wheel.
marks on both steering
20. REMOVAL
OF INSTRUMENT
PANEL
Remove the instrument
panel attaching bolts and nuts,
and withdraw
and remove the instrument
panel toward
you.

H
1BW701
20. INSTALLATION
OF INSTRUMENT
PANEL
(1) Connect all of the connectors
securely.
(2) Make sure that any of the wiring harnesses
pinched.
1.
2.
3.
4.
5.
Assist grip
Instrument pad B
Switch holder
Instrument pad A
Instrument panel
-2
-Q
\
I9W771
1 TSB Revision
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are not
23-76
BODY - Center Console
CENTER CONSOLE
Removal
steps
1.
2.
3.
4.
Knob
Plug
Center panel
Connection of center panel wiring harness to front wiring harness connector
NOTE
USASSEMBLY AND REASSEMBLY

9
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
steps
Plug
Center panel pad
Cigarette lighter
Clock
Ashtray
Ashtray bracket
Cigarette lighter bracket
Light holder
Heater control panel
Center panel wiring harness
Box panel
Center panel
lSW695
NOTE
http://vnx.su/
BODY - Floor
Console
23-77
FLOOR CONSOLE
<Vehicles
automatic
<Vehicles
with a
manual transmission>
with an
transmission>
Removal
steps
1. Front floor console
2. Plate B
3. Rear console panel
4. Inner box
5. Lid assembly
6. Switch cover assembly
7. Screw
8. Floor console
9. Rear floor console
10. Console inner bracket
11. Floor console bracket
NOTE

(2) The * symbol indicates applicability to vehicles equipped
with the dual air conditioner.
1 TSB Revision
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23-78
BODY - Headlining and Assist Strap
HEADLINING
AND ASSIST STRAP
<Z-Door Vehicles>
2?i-40 ft.lbs.
Assist strap
1. Assist strap
2. Assist grip
3. Hook
Headlinings
*I)
*I)
1.
4.
5.
6.
7.
8.
9.
10.
removal
lQW770
steps
+*
o*
+* l +
+I) ++
Assist strap
Door opening trim
Front side roof rail trim
Inside rear view mirror
Sun visor
Front roof rail trim
Rear opening trim
Front seat belt anchor plate
11.
12.
13.
14.
Upper quarter trim

Rear roof rail trim
Rear headlining
Front headlining
NOTE
(2) l * : Refer to Service Points of Removal.
(3) M

5.
REMOVAL
Refer
8.
RAIL TRIM
OF FRONT
ROOF
RAIL TRlM
to P.23-87.
11. REMOVAL
Refer
SIDE ROOF
to P.2387.
REMOVAL
Refer
OF FRONT
OF UPPER QUARTER
to P.23-87.
http://vnx.su/
TRIM
BODY
Headlining
and
Assist
23-79
Strap
12. REMOVAL
OF REAR ROOF RAIL TRIM
Refer to P. 23437.
13. REMOVAL
OF REAR HEADLINING/14.
FRONT HEADLINING
(1) Remove
the dome light.
(2) Slowly peel the headlining away, beginning
with the
corner of the roof panel.
Caution
Make sure that the headlining
is removed slowly;
the sponge portion of the headlining
is left behind
the roof panel,
as
on
(3) Thoroughly remove the drying sealant and sponge left

behind on the roof panel by using a toluol solution, etc.
Caution
Make sure that all remaining
sealant and sponge are
thoroughly
removed,
as they produce
uneven surfaces when the headlining
is bonded
to the roof
panel,

14. APPLICATION
OF SEALANT TO FRONT HEADLINING/
13. REAR HEADUNING
(1) Evenly apply the specified sealant to the roof panel.
When the headlining (rear) is installed, couple the room
dome light connector, put it through the cut hole in the
lining, and bond the lining so that the lining cut hole
matches the dome light attaching
hole.
Specified
sealant
: 3M ART
Adhesive
Part No. 8080 or 3M

(2) Using care to prevent wrinkles and slackness, bond the

headlining and insert the edges securely into the roof
panel flange by using a spatula, etc.
(3) Bond the headlining
Roof panel
flange
lOW547
ieadlining
(front)
Headlining
(rear)
191548
/ TSB Revision
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edges as shown.
BODY - Headlining
<4-Door
and
Assist
Strap
Vehicles without
Pra-removal Operation
. Removal of windshield and quarter
T;Idow glass. (Refer to P. 23-29,
..
7.
8.
9.
10.
11.
12.
13.
14.
Assist strap
1. Assist strap
2. Get on and off grip
Headlining
removal
steps
1. Assist grip
3. Sun visor
lQW769
Front door opening trim

Rear door opening trim
Back door opening trim
Retractor cover
Speaker
Quarter trim
Rear pillar trim
Headlining
q, ++
NOTE
II) Reverse the removal procedures to reinstall.
(2) **
(3) IH : Refer to Service Points of Installation.
4. Inside rear view mirror
:z
NmmAs
a Sunroof>
5. Dome light (front)

6. Dome light (rear)

5.B.
REMOVAL
(I)
Using
(2) Remove
tor.
Remove
OF DOME
a plastic
tool,
remove
the dome light mounting

the dome
Plastic trim tool
1 TSB Revision
trim
LIGHT
http://vnx.su/
light
assembly.
the lens.
screws
and connec-
BODY - Headlining and Assist
Strap
REMOVAL
OF QUARTER TRIM
Refer to P. 23-90.
13. REMOVAL
OF REAR PILLAR TRIM
Refer to P. 23-90.
12
14. REMOVAL
OF HEADLINING
(I) Remove the entire circumference
of the headlining
from the both-side-adhesive
tape.
(2) Lower the lifting wire, compress inward, remove from
the bracket, and remove the headlining.
Caution
If there are collars at the end of the lifting wires,
they will be used during installation,
so check the
installation
positions
and number,
and keep them
for use at that time.
(3) Peel off the both-side-adhesive
tape attached at each
door and each window
opening.
NOTE
For new headlining, there are no holes opened for the
installation
of parts, so be sure to confirm the positions for installation of parts and the notched parts of
the headlining.
Front

14. INSTALLATION
OF HEADLINING
(1) Use the paint color of the end of the lifting wires to
confirm the lifting wire and headlining attachment
positions and the front/rear
direction.
Identification
color
@ Blue
0 None
@White
C9 Green
Gl Yellow
6 Black
CB Red
NOTE
Installation will be easier
installation, a heating fan
to warm the headlining.
(2) Attach both-side-adhesive
each window
and door
illustration.
TSB Revision
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and free of wrinkles if, before

or similar equipment
is used
tape [IO mm (4 in.) wide] to
at the place shown in the
23-82
BODY
- Headlining
and Assist
Strap
(3) After attaching

both ends of the lifting wire to the
brackets installation hole from below, turn upward so
that it is vertical.
Do the rear side first, and then attach all lifting wires.
NOTE
Attach collars
removal.
where
there
were
any at the time
(4) Make a cut, as shown in the illustration,

headlining rear side bag in which the lifting
attached.
of
in the
wire is
approx. 100 mm (3.9 in.

approx. 20 mm (.8 in.)
Rear view
f.&,&
;$j<;@j$++
lining
%m?
mirror
Concave
(5) Align the body and headlining center mating mark, and
while pulling so that there are no wrinkles, attach from
window part and the back door part to the both-sideadhesive tape.
NOTE
Use door opening trim pieces, etc. to temporarily
hold
at the places where is attached
to the both-side
adhesive tape.
(6) Secure exce;bt the pillars.

(7) Use an infra-red light or similar equipment
to apply
heat to the headlining
of the rear pillar, and, while
pulling to stretch, fold it into the back side of the body
panel as shown in the illustration.
ieadlining
I
/Both-side-adhesive
tape
NOTE
Be careful not to bring the light so close that the
headlining
is scorched.
(8) Make cuts at the corner part at each pillar, and attach
to both-side
adhesive tape.
(9) Temporarily attach each doors opening trim, and then,
after checking
the amount that the headlining
protrudes, remove.
(1O)After cutting away (by using a cutter knife) the amount
of headlining protruding
from the door opening trim,
install the door opening trim.
NOTE
Do not cut deeply with the cutter
damaging
the painted surface.
knife, so as to avoid
evision
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-I
~~
BODY - Headlining
(1l)lf
Guide rails
wire
. ..:...
..,.. ..
;:..
..,,.,....+
wrinkles
occur, use an infra-red
equipment
to heat, and then stretch
so they are smoothened.
23-83
fight or similar
the wrinkles out
(12)Attach both-side-adhesive
tape all around both surface
of the flange of the roof panel.
(13)While pulling the headlining, attach it to the both-side
adhesive tape.
Pass the guide rails wire through the corner part at the
front side.
(14)lf the headlining is too long compared to the condition
cut away by using a cutter
knife.
(15)lnstall previously removed parts (guide rail, etc.).
tape
Headhg
1sw12s
and Assist Strap
19w123
) TSB Revision
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23-84
BODY
REMOVAL
AND
INSTALLATION
- Headlining
<4-Door
and Assist
Vehicles
with
Strap
a Sunroof>
19
Assist strap
1.
2.
Headlinings
I.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Assist strap
Get on and off grip
removal steps
Assist strap
Get on and off grip
Sun visor
Dome light (front)
Dome light (rear)
Sunroof switch
Front door opening trim
Rear door opening trim
Rear pillar trim (upper)
Rear roof side trim
Center roof side trim
[ TSB Revision
++
M I)+
14, Front roof side trim

15. Air outlet grille
16. Retainer
17. Headlining trim
18. Joint
19. Front headlining
20. Rear headlining
::
NOTE
(11 Reverse the removal procedures to reinstalL
(31 +*
: Refer to -Setice Points of Installation.
(4) The * symbol indicatesthe rear pillar trim (right) when the
dual air conditioner is installed.
1
http://vnx.su/
BODY - Headlining
Front
SERVICE
Plastic trim tool
Plastic thm
tool
and Assist
POINTS
Strap
23-85
OF REMOVAL
5./6.
REMOVAL
OF DOME LIGHT
(1) Using a plastic trim tool, remove the lens.
(2) Remove the dome light mounting screws and connector. Remove the dome light assembly.
7.
REMOVAL
OF SUNROOF
SWITCH ASSEMBLY
(1) Remove the cover with a flat type screwdriver (small)
or similar tool.
(2) Remove the sunroof
switch mounting
screws and
connector.
Remove the sunroof switch.
,_,~ 1
11. REMOVAL
OF REAR PILLAR TRIM (UPPER)
Using a plastic trim tool, remove the rear pillar trim
(upper).
Plastic
Wehides equipped
with
sir conditioner
(right)
trim tool
dual
12. REMOVAL
OF REAR ROOF SIDE TRIM
Using a plastic trim tool, remove the rear roof side trim.
[ TSB Revision
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23-86
BODY
- Headlining
and Assist Strap
13. REMOVAL
OF CENTER ROOF SIDE TRIM
Using a plastic trim tool, remove the center roof side tirm.
14. REMOVAL
OF FRONT ROOF SIDE TRIM
Using a plastic trim tool, remove the front roof side trim.
Plastic
trim
tool
15. REMOVAL
OF AIR OUTLET GRILLES
Using a plastic trim tool remove the air outlet
19. REMOVAL
OF FRONT HEADLINING
Using a plastic trim tool, remove the front
grille.
headlining.
20. REMOVAL
OF REAR HEADLINING
(1) Remove the rear headlining
mounting
screws.
(2) Using a plastic trim tool, remove the rear headlining.
evision
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~z
BODY - Trims
TRIMS
7
<P-Door Vehicles>
A
4
2
Q
3&
Front
4+
4+
4*
Cowl
4*
Center
**
Quarter
I +*
I
pillar
1.
2.
3.
4.
5.
6.
trim and roof rail trim removal

Front scuff plate
Door opening trim
Assist grip
Front side roof rail trim
Front pillar trim
7. Sun visor
8. Front roof rail trim
steps
Upper
side trim removal steps

1. Front scuff plate
2. Door opening trim
9. Cowl side trim
4*
quarter trim removal steps

12. Retractor cover
13. Quarter trim
14. Front seat belt anchor plate
15. Rear seat belt anchor plate
<Vehides with rear seat belts>
16. Back door opening trim
17. Upper quarter trim
Rear roof rail trim removal steps

16. Back door opening trim
18. Rear roof rail trim
4*
pillar trim removal steps

1. Front scuff plate
10. Speaker
II. Center pillar trim
Rear pillar
12.
13.
16.
19.
4+
trim removal steps

12. Retractor cover
lower trim removal steps

Retractor cover
Quarter trim
Rear pillar lower trim
NOTE
13. Quarter trim
(2) a*
/ TSB Revision
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N23cAT
23-88
BODY - Trims
4.
REMOVAL OF FRONT SIDE ROOF RAIL TRIM

Remove the front side roof rail trim
5. REMOVAL OF FRONT PILLAR TRIM

Remove the front pillar trim.
8.
REMOVAL OF FRONT ROOF RAIL TRlM

Remove the front roof rail trim
9.
REMOVAL
(1) Insert a
remove
(2) Remove
OF COWL SIDE TRIM

plastic trim tool under the cowl side trim and
the clips.
the cowl side trim.
11. REMOVAL
OF CENTER PILLAR TRIM
(I) Remove the clips at two places (upper and lower) at
the foremost
part of the quarter trim.
(2) Insert a plastic trim tool beneath the center pillar trim
and remove the clips.
http://vnx.su/
23-89
BODY - Trims
13. REMOVAL
OF QUARTER
Insert a plastic trim

remove the clips.
Cross section of
portion marked a
Cross section of
portion marked*
Plastic
-I
tool
TRIM
beneath
the quarter
17. REMOVAL
OF UPPER QUARTER TRIM
(1) Insert a plastic trim tool under the upper
and remove the clips.
(2) Remove the upper quarter trim.
trim
and
quarter
trim
18. REMOVAL OF REAR ROOF RAIL TRIM

Remove the rear roof rail trim.
19. REMOVAL OF REAR PILLAR LOWER TRIM

(I) Remove the clips at 2 places at the rear part of the
quarter trim and the 2 clips at the rear pillar part of the
upper quarter trim.
(2) Remove the clip to remove the rear pillar lower trim.
1 TSB Revision
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BODY - Trims
FIEMOVAL AND INSTALLATION
d-Door
Vehicles without
a Sunroof>
35-55 Nm
25-40 ft.lbs.
Pillar trim
steps
+*
Center
steps
(front)
1. Front
2. Front
3. Pillar
4. Cowl
pillar trim
and cowl side trim
removal
mil cover
door opening trim
trim (front)
side trim
and pillar trim (canter)
removal
1, Front rail cover

5. Rear rail cover
6. Rear dodr opening trim
7. Center pillar trim
8 Get on and off grip
9. Front seat belt installation bolt
10. Pillar trim (center)
Quarter trim removal steps
11. Retractor cover
12. Speaker
13. Quarter trim
+*
Rear side trim and pillar trim (quartar) removal
steps
5. Rear rail cover
6. Rear door opening trim
) TSB Revision
11. Retractor cover

12. Speaker
13. Quarter trim
a+
14. Rear side trim
++
15. Quarter trim, upper.
16. Rear seat belt installation bolt
17. Pillar trim (quarter)
Rear pillar trim removal steps
11. Retractor cover
12. Speaker
13. Quarter trim
c*
18. Back door opening trfm
19. Rear pillar trim
NOTE
http://vnx.su/
23-9-l
BODY - Trims
4.
Frim clip (bushing).
Trim
Thm
clio (Din)
mm (in.)
18~899
REMOVAL
(1) Insert a
remove
(2) Remove
OF COWL SIDE TRIM

the clips.
the cowl side trim.
13. REMOVAL
OF QUARTER TRIM
and trim clip (pin) and then pry the trim clip to remove.
NOTE
If the trim clip [bushing)
together,
and install the trim clip (bushing) at the door side. Then
improvise
to
14. REMOVAL
(1) Insert a
remove
(2) Remove
OF REAR SIDE TRIM

plastic trim tool under the rear side trim and
the clips.
the rear side trim.
NOTE
When cutting
body panel.
( TSB Revision
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the clips, be careful
not to scratch
the
23-92
BODY - Trims
<4-Door
Vehicles with
a Sunroof>
N23ucAv
35-55 Nm
25-40 ft.lbs.
22
25*
\ \
15
16
i7
24
35-55 Nm
25-40 ft.lbs.
Quarter
Cowl side trim removal steps

1. Front rail cover
3. Cowl side trim
l +
Front roof side trim and front pillar trim removal
steps
1. Front rail cover
4. Assist grip
5. Front roof side trim
+*
6. Front pillar trim
a:,
Center pillar trim removal steps
1. Front rail cover
7. Rear rail cover
Center roof side trim and pillar trim (center)
removal steps
1. Front rail cover
7. Rear rail cover
10. Assist grip
12. Center roof side trim
13. Front seat belt installation bolt
14. Pillar trim (center)
1 TSB Revision
trim removal steps

15. Retractor cover
16. Speaker
17. Quarter trim
*r)
Rear side trim and pillar trim (quarter) removal
steps
7. Rear rail cover
15. Retractor cover
16. Speaker
17. Quarter trim
++
18. Rear side trim
+*
19. Quarter trim, upper
20. Rear seat belt installation bolt
21. Pillar trim (quarter]
Rear roof side trim removal steps
7. Rear rail cover
22.
Rear roof side trim
+*
Rear pillar trim removal steps
15. Retractor cover
16. Speaker
17. Quarter trim
a+
_ 23. Back door opening trim
24. Rear pillar trim
25. Rear pillar trim (upper)
+*
NOTE
(2) **
(4) The * symbol indicates the rear pillar trim (right) when the
dual air conditioner is installed.
http://vnx.su/
BODY
Plastic
trim
SERVICE
too'
C!ip
23-93
- Trims
POINTS
OF REMOVAL
3.
REMOVAL
(I) Insert a
remove
(2) Remove
OF COWL SIDE TRIM

the clips.
the cowl side trim.
5.
REMOVAL
OF FRONT ROOF SIDE TRIM
Using a plastic trim tool, remove the front roof side trim.
6.
REMOVAL
OF FRONT PILLAR
Remove the front pillar tirm.
TRIM
12. REMOVAL
OF CENTER ROOF SIDE TRIM
Using a plastic trim tool, remove the center roof side trim.
1 TSB Revision
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23-94
BODY - Trims
17. REMOVAL
OF QUARTER TRIM
and trim clip (pin) and then pry the trim clip to remove.
NOTE
If the trim clip (bushing)
together,
and install the trim clie (bushing) at the door side. Then
improvise
to
18. REMOVAL
(1) Insert a
remove
(2) Remove
OF REAR SIDE TRIM

plastic trim tool under
the clips.
the rear side trim.
NOTE
When cutting
body panel.
1
- !d
the rear side trim and
the clips, be careful
not to scratch
22. REMOVAL
OF REAR ROOF SIDE TRIM
Using a plastic trim tool, remove the center
Clip
the
roof side trim.
L TSB Revision
=.
http://vnx.su/
x-
w*
23-95
BODY - Trims
25. REMOVAL
OF REAR PILLAR TRIM (UPPER)
Using a plastic trim tool, remove the rear pillar
(upper).
1 TSB Revision
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trim
23-96
BODY - Front Seats
FRONT SEATS
Suspension
seat
Normal
<2-door
(L.H.)
<4-door
(R.H.)
seat
vehicles>
vehicles>
-Nrn
ft.lbs.
3S-55_- .__..
Nm
WC-IX
Nm
__
25-46 ft.lbs.
5-G
&s.
35-55 Nm
F+?a-a ftlbs.
8
35-65
25-40
Nm
ft.lbs.
Normal
<bdoor
(R.H.)
3545
25-40
Disassembly
e+
seat
vehicles>
Nm
ft.lbs.
36-55
26-46
steps
1.
2.
** 3.
l * 4.
5.
6.
Suspension assembly
Seat support bracket
Parallel link assembly
Seat adjuster
Adjuster cover
Reclining lever knob
7. Front seatback
8. Head restraint
9. Front seat cushion
Nm
fths.
10w789
35-55
25-40
Nm
ft.lbs.
NOTE
1 TSB Revision
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BODY - Front
Seats

4. APPLICATION
OF GREASE TO SEAT ADJUSTER/3.
PARALLEL LINK ASSEMBLY/l.
SUSPENSION
ASSEMBLY
(I) Apply the multipurpose
grease to the following points.
0 Sliding parts of seat adjusters
Q Sliding parts of suspension
8 Sliding parts of parallel links
@ Sliding parts of reclining adjusters
(2) After the seat has been installed, check to ensure that
the seat adjusters lock at all lock positions when the
seatback is moved slowly.
(3) Check to ensure that the forward folding and return
mechanisms
of the parallel links operate smoothly and
lock securely.
Suspension
1Qw787
INSPECTION
Check the springs for damage and deterioration.
Check the shock absorber for noise and fluid leaks.
Check the all tightened points for looseness.
Check the rollers for noise and damage.
Check the links for cracks, bending or dents.
Check the body weight
adjusting
handle for
damage or looseness.
Check the lock lever for bends and damage.
Check the damper rubber for cracks and damage.
l
l
l
l
l
l
l
l
/ TSB Revision
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bends,
BODY - Rear Seat
23-98
REAR SEAT
DISASSEMBLY AND REASSEMBLY <2-Door
Vehicles>
Zli-40 ft.lbs.
Disassembly
I)+
1.
2.
3.
4.
steps
191776
Rear seat leg bracket

Reclining cover
Rear seatback
Rear seat cushion
NOTE
(2) I)+ : Refer to Service Points of Reassembly.

1. APPLICATION
ET
(1) Apply
the
OF GREASE TO REAR SEAT LEG BRACK-
multipurpose
grease
to the following
place.
0 Sliding part of rear seat leg bracket

@ Contacting part of rear seat stopper striker
(2) After the seat has been installed, check to ensure that the
lock release, forward-down.
folding and return mechanisms all operate smoothly.
(3) Check to ensure that when the seat cushion is folded, the
leg bracket locks securely.
[ TSB Revision
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23-99
BODY - Rear Seat

DISASSEMBLY
AND
d-Door
DISASSEMBLY
NfJFAM
Vehicles>
45-60 Nm
33-43 ft.lbs.
Disassembly steps
1. Seat adjuster
+*
2.
3.
4.
5.
25-M R.lbs.
Reclining cover
Rear seatback
Head restraint
Rear seat cushion
NOTE
9-14 Nm
6-10 ft.lbs.
procedures
to reassemble.
Points of Removal.
SERVICE POINTS OF DlSASSEMBLY

1. SEAT ADJUSTER
(1) Raise the seat back, remove the seat cushion
adjuster pins and remove the adjuster.
(2) Remove the protector and disconnect

from the seat adjuster.
Asion
http://vnx.su/
the reclining
to seat
cable
23-100
BODY - Seat
Belts
SEAT BELTS
Cbdoor
(Front Seat Belts)
vehicles>
35-55 Nm
25-40 ft.lbs.
Seat belt extender

(Option)
35-55 Nm
2540 ft.lbs.
-+&door
35k5 Nm
25-40 ft.lbs.
vehicles>
3545 Nm
25-W ft.lbs. -f$f
X-55
z-40
Nm
ft.k.
extender
35-55 N;n
~5-40 ft.lbs.
2E40 ft.lbs.
35-55 Nm
2540 ft.lbs.
,SWIT,
Removal
4+
++ ++
++
steps
2. Front seat belt assembly
3. Connection of seat belt switch
4. Buckle stalk
connector
NOTE
(31 ** : Refer to Service Points of Installation.
http://vnx.su/
BODY - Seat
23-101
Belts

1.
REMOVAL
OF CENTER
Refer to P.23-87.
Refer to P.23-90,
2.
REMOVAL
TRIM
<2door
vehicles>
92. G-door
vehicles>
OF FRONT
Caution
Special bolts (l-in.
mounting
bolts.
Do not disassemble
PILLAR
SEAT BELT ASSEMBLY
bolts)
are used
for the
seat
belt
the retractor.

4.
INSTALLATION
OF BUCKLE STALK
Install the seat belt buckle stalk in parallel with the center
line of the vehicle.
2.
INSTALLATlON
OF FRONT SEAT BELT ASSEMBLY
2-Door Vehicles
Fit the anchor plate anti-turning
boss positively
in the
retractor side hole and jointly tighten the retractor and
anchor plate.
Centerline
of vehicle
Anchor
date
1Retrad;or
;;&tuming
4-Door Vehicles
Fit the anchor plate anti-turning boss positively in the body
side hole and jointly tighten the retractor and anchor plate.
1 plate
Ignition
key
Seat belt
switch
Seat belt
warning
light
ONOFF
ON
SEAT BELT WARNING SYSTEM

When the seat belt switch in ON (seat belts not buckled) with
the ignition key in the ON position, the seat belt warning timer
causes the seat belt warning light to illuminate and the buzzer
to sound for 4 to 8 seconds. If the seat belts switch is set to
OFF (the seat belts buckled) during the seat belt warning timer
interval, only the buzzer is cancelled.
Buzzer
http://vnx.su/
23-102
BODY
- Seat Belts
SYSTEM INSPECTION
1. Disconnect the seat belt warning timer connector.
2. When the YG wire (terminal 2) and B wire (terminal 3) are
connected with a jumper wire, the seat belt warning light
should illuminate.
If it fails to illuminate,
check the bulb,
key-reminder switch and fuse.
3. Also the buzzer should sound when the RB wire (terminal
4) and B wire (terminal 3) are connected
with a jumper
wire. In this condition,
fasten the buckle; if the buzzer
stops sounding, the seat belt switch is good.
4.
If the buzzer does not sound when terminal 3 and terminal

4 are connected
with a jumper wire, check continuity
of
the seat belt switch. If there is continuity
in the seat belt
switch, replace the buzzer.
;I
NOTE
0-O indicates that there is continuity between the terminal.
5. After performing the above inspections.
reconnect the seat
belt warning timer.
6. With the ignition switch turned to IG, verify the function of
the seat belt warning system.
[ TSB Revision
-~
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1.--
23-103
BODY - Seat Belts

<8door
(Rear Seat
Belts)
vehicles>
5-55 Nm
25-48 ft.lbs.
<4-door
35-55 Nm
2540 ft.lbs.
lSW779
vehicles>
35-55 Nm
2540 ftlbs.
lQW780
Removal
+4
(1)
(2)
steps
1. Retractor cover
2. Rear seat belt assembly

*(I
to reinstall.
of Installation.
1 TSB Revision
http://vnx.su/
23-104
BODY - Seat Belts

Parallel to center line

2.
INSTALLATION
OF REAR SEAT BELT ASSEMBLY
Bdoor Vehicles
(1) Position the anchor plates at the center of the vehicle
so that the belts are parallel to the vehicle center line,
and then secure the plates with the bolts.
(2) Fit the anchor plate anti-turning

pin positively in the
body side hole and jointly tighten the retractor and
anchor plate.
Parallel to center
4-door Vehicles
Position the anchor plates at the center of the vehicle so
that the belts are parallel to the vehicle center line, and
then secure the plates with the bolts.
line
NOTE
After tightening
the baits. securely mount
covers for the inner end of the seat belts.
Caution
Special bolts (I-in.
mounting
bolts.
) TSB Revision
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bolts)
.-I
are used
for the
the
anchor
seat
sz
belt
~~
GROUP/SECTION
INDEX -8
Service Manual
Introduction
MONTERO
.....................................
Electrical ...........................................
1989 : Volume
FOREWORD
This Service Manual has been prepared with the
latest service information
available at the time of
publication.
It is subdivided
into various group
categories
and each section contains diagnosis,
disassembly,
repair, and installation
procedures
along with complete specifications
and tightening
references.
Use of this manual will aid in properly
performing
any servicing necessary to maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.
Electrical System Parts

Location .........................................
Relays, Control Units, Sensors,
Fuses, Groundings
Inspection of Harness
Connector ......................................
Wiring Harness .............................
Charging System
..........................
Starting System
............................
Ignition System .............................

Meters and Gauges
......................
Lighting System ............................

Wiper and Washer System
..........
Horn ...............................................
Accessory
A.
4l3_
r:
......................................
Audio System ................................
Back Door Window Defogger ......

Automatic Free-wheeling Hub
Indicator System ..........................
WESUPPORT
VOLUNTARY
TECHNICIAN
CERTlflCATtON
THROUGH
__
AL MITSUBISHI
Mitsubishi
Motors
corporation
reserves
the right to make changes
in
design or to make additions
to or improvements
in its products
without
imposing
any obligations
upon itself to install them on its products
previously
manufactured.
0 1999
Mitsubishi
Motors
Corporation
Printed
in Japan
http://vnx.su/
For Engine,
Chassis
& Body,
refer
to
INTRODUCTION - How To Use This Manual
HOW TO USE THIS MANUAL

CONTENTS
The preceding
page contains the GROUP
which lists the group title and group number.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection
and means the maximum or minimum
value within which the part or
assembly must be kept functionally
or in strength.
It is a value established
outside
the range of
standard value.
INDEX
PAGE NUMBERS
All page numbers consist of two sets of digits
separated by a dash. The digits preceding the dash
identify the number of the group. The digits following the dash represent
the consecutive
page
number within the group. The page numbers can
be found on the top left or right of each page.
Indicates incidental operation

to be performed before removal or after installation
TEXT
Unless otherwise specified, each service procedure
covers all models.
Procedures
covering specific
models are identified by the model codes, or similar
designation
(engine type, transmission
type, etc.).
A description
.of these designations
is covered in
this unit under VEHICLE IDENTIFICATION.
Removal steps : The numbers before part names

correspond to numbers in the illustration and indicate the order of
removal.
Disassembly steps : The numbers before part
names correspond to numbers
in the illustration, and indicate
the order of disassembly.
TROUBLESHOOTING
Installation steps : This is provided if installation

order of Removal steps; omitted if installation in the reverse
order of Removal steps is
possible.
Reassembly steps : This is provided if reassembly
order of Disassembly steps;
omitted if reassembly in the
reverse order of Disassembly
steps is possible.
Troubleshootings
are classified into master troubleshooting and group troubleshooting
and located as
follows:
The master troubleshooting
is prepared when the
trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting
guide is prepared for
causes of problems related to that individual group
only; a troubleshooting
guide is prepared for each
appropriate group.
SERWCE PROCEDURES
The service steps are arranged in numerical order
and attentions to be paid in performing vehicle service are described in detail in SERVICE POINTS.
Classification of
SERVICE POINTS
++ : Removal
*+ : Installation
++ : Disassembly
+4 : Reassembly
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
MODEL INDICATIONS
The following
abbreviations
are used
in this
manual
for classification
of model
types.
M/T : Indicates the manual transmission,

or models equipped
with the manual transmission.
AA : Indicates the automatic transmission,
or models equipped with the automatic
transmission.
F.B.C. : Indicates the feed back carburetor,
or engines equipped
with the feed back carburetor.
M.P.I. : Indicates the multi-point
injection,
or engines equipped
with the multi-point
injection.
2.6 L Engine : Indicates the 2.6 liters (155.9 cu.in.1 engine, or a.model equipped with such an engine.
3.0 L Engine : Indicates the 3.0 liters (181.4 cuin.) engine, or a model equipped with such an engine.
http://vnx.su/
INTRODUCTION
How
To Use
Group title
Section title
This
Manual
1
1
COOLING - Thermostat
7-10
THERMOSTAT
Indicates tightening
torque

I r
1 used parts are shokn.)
Indicates
b
This number corres onds to

the number
in #emoval
steps. Disassembly
steps. Installation
steps
or Reassembly steps.
I
Ramova
-SW
1. Connection of enginecoolanttemperature
witch connectrx(Vehiiles
with an air conditiow
WI
2. Connection of radiator upper hose
3. Water outlet fining
4. Water outlet fining gasket
5. Themlostat
SERVICE POINTS OF INSTALLATlON5.
INSTAUATION
OF THERMOSTAT
Install the thermostat
lo the intake
caution
The thermostat
ansum that the
rile
flange
thsnwxtat
fits
manifold
as illustrated.
owr
the m&fold
soot;
is not installed
at sn angle.
,..I
An explanation
of procedures,
regarding removal, installation,
and reassembly.
http://vnx.su/
notes. etc.
disassembly
INTRODUCTION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER LOCATIONNwu.,
The vehicle identification
number (V.I.N.) is located
attached to the left top side of the instrument
panel.
on a plate
VEHICLE IDENTlFlCATlON CODE CHART KATZ--.

All vehicle identification
numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
1st
digit
Country
JJapan
Make
1 Vehicle
I We
AMitsubishi
!4
(F(Multi4001purpose 5000
vehicle
Ibs. and
(MPV)
with
7hydraulic
Truck
brakes
G50016000
Ibs. and
with
hydraulic
brakes
Others
Line
JMONTERO
6th
digit
7th
digit.
Price
class
Body
4.High
5Premium
1 8th
; digit
l5door
wagon
3S-door
metaltopor
van
9th
1 digit
E2.6liters
(155.9
cuin.)
S3.0liters
(181.4
cuin.)
0
1
2
3
11th
digit
12th thru
17th digit
Model
year
Plant
Serial
number
K1989
year
JNagoya
-3
digit
.
.
9
X
Check digit means a single number or letter X used to verify the accuracy oftranscription
number.
1 TSB Revision
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1
of vehicle identification
-:E
_i
INTRODUCTION
- Vehicle
Identification
VEHICLE IDENTIFICATION NUMBER LIST

FEDERAL
NWCC-

JA7FJ43E
q KJ
JA7FJ43S 0
JA7FJ43S 0
JA7FJ53S IJ
JA4GJ41 S q
JA4GJ41 S cl
JA4GJ51 S q
CALIFORNIA
KJ
KJ
KJ
KJ
KJ
KJ
Model code
2.555 liters (155.9 win.)
LO4PGTNJLF
MITSUBISHI
MONTERO
2.972 liters (181.4 cu.in.)
L141GTNJLF
L141GTRJLF
L141GTRULF
Ll46GVMNJLF
L146GVMRJLF
L146GWMRULF
Engine displacement
Model code
(Can also be sold in Federal states.)

JA7FJ43E cl KJ
JA7FJ43S Cl
JA7FJ43S 0
JA7FJ53S 0
JA4GJ41 S 0
JA4GJ41 S q
JA4GJ51 S I7
Engine displacement
Brand
KJ
KJ
KJ
KJ
KJ
KJ
Brand
2.555 liters (155.9 cu.in.1
I
MITSUBISHI
MONTERO
2.972liters(181.4cu.in.J
1 LO42GTNJLH
L141GTNJLH
Ll41 GTRJLH
L141 GTRULH
L146GVMNJLH
L146GVMRJLH
L146GWMRULH
VEHICLE INFORMATION CODE PLATE

<2.6L
Engine>
NWal-
Vehicle information
code plate is riveted on the cowl top outer
panel (2.6L Engine) or front end upper bar (3.OL Engine) in the
engine compartment.
The plate shows model code, engine model, transmission
model, and body color code.
1. MODEL
2.
ENGINE
6672
I
3. TRANS
AXLE
4.
COLOR, TRIM
OPT
VBMTI
I
L
Transmission
model
H84
Monotone
HlXH84X85
[ TSB Revision
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Engine model
exterior
color code
Two-tone exterior is shown by the exterior

code followed by the two color codes.
I
INTRODUCTION
CHASSIS NUMBER
STAMPING LOCATION
The chassis number is stamped
the right rear wheel.
CHASSIS
NUMBER
L141
NOOCEon the side of the frame near
CODE CHART
v
KJOOOOOI
:I
VEHICLE SAFETY CERTIFICATION LABEL
H-
The vehicle safety certification

label is attached to face of left
door pillar.
This label indicates the month and year of manufacture,
Gross
Vehicle Weiaht Ratina (G.V.W.R.). front and rear Gross Axle
Weight Rating (G.A.W.R.), and Vehicle Identification
Number
(V.I.N.).
ENGINE MODEL STAMPING

The engine model is stamped
top edge of the cylinder block
liter engines, it is stamped at
cylinder block.
These engine model numbers
C3.0 L Engine>
NODCG-
on the right front side on the

(for 2.6liter engines). For 3.0the right rear of the top of the
are as shown
in the following.
Engine model
Engine displacement
G54B
2.555 liters (155.9 cu.inl)
6672
2.972 liters (181.4 cu.in.)
The engine serial number is stamped near the engine

number, and the serial number cycles, as shown below.
Engine serial number
AA0201 to r/9999
[ TSB Revision
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model
/ Number cycling
A40201
----9
AA9999
L ABOOOI
---+
AY9999 T
L BAOOOl
---+
YY9999
1
-
INTRODUCTION
BODY COLOR CODE

Exterior code
Monotone
C46
H84
R82
s55
T86
wo9
R48
x15
Two-tone
Cl XC46X85
H 1XH84X85
RZXR82X85
Sl XS55X85
T6HT86H84
W6XWO9X85
X2HX15H84
1 TSB Revision
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Body color
Brown (M)
Silver (M)
Red
Beige(M)
Blue(M)
White
Red(M)
Black
Brown(M)/
Black
Silver (MM
Black
Redl
Black
Beige (MI/
Black
Blue (MY
Silver(M)
White/
Black
BlacW
Silver(M)
INTRODUCTION - Precautions Before Service
PRECAUTIONS
BEFORE SERVICE
PROTECTING THE VEHICLE
NWDM
If there is a likelihood of damaging

painted or interior parts
during service operations,
protect them with suitable covers
(such as seat covers. fender covers, etc.).
(3?
REMOVAL AND DISASSEMBLY

When checking a malfunction,
find the cause of the problem.
If it is determined
that removal and/or disassembly
is necessary, perform the work by following the procedures contained
in this Workshop Manual.
b0
iiiiiii -
OOY555
I
7
If punch marks or mating marks are made to avoid error in

assembly and facilitate the assembly work, be sure to make
them in locations which wit! have no detrimental
effect on
performance
and/or appearances.
If an area having many parts, similar parts, and/or parts which
are symmetrical
right and left is disassembled,
be sure to
arrange the parts so that they do not become mixed during the
assembly process.
1. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which are to
be replaced.
3. If bolts, nuts;etc.,
are to be replaced, be sure to use only
the exact sizespecified.
SPECIAL TOOLS
If other tools are substituted
for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged,
or the mechanic might be injured; therefore,
be
sure to use the special tool whenever
doing any work for
which the use of one is specified.
PARTS TO BIZREPLACED
If any of the following
parts are removed,
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts
[ TSB Revision
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fI_
-1

PARTS
When
replacing
parts,
use MITSUBISHI
genuine
parts.
VEHICLE WASHING
If high-pressure
car-washing equipment
or steam car-washing
equipment
is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (11.8 in.) from
any plastic parts and all opening
parts (doors, luggage
compartment,
etc.).
nm (in.)
so0059
SERVICING ELECTRICAL SYSTEM

1. Note the following
before proceeding
with work on the
electrical system.
Note that the following
must never be done:
Unauthorized
modifications
of any electrical
device or
wiring, because such modifications
might lead to a vehicle
malfunction,
over-capacity
or short-circuit that could result
in a fire in the vehicle.
2. When servicing the electrical
system, disconnect
the
negative cable terminal from the battery.
Caution
1. Before connecting
or disconnecting
the negative
cable, be sure to turn off the ignition switch and the
lighting
switch.
(If this is not done, there is the possibility
of
semiconductor
parts being damaged.)
2. After
completion
of the work
steps [when
the
batterys
negative
(-) terminal
is connected],
warm
up the engine and allow it to idle for approximately
five minutes under the conditions
described
below,
in order to stabilize engine control conditions,
and
then check to be sure that the idling is satisfactory.
For 3.OL Engine models:
If the engine rpm is high,
switch
OFF the ignition
switch,
and then, after
switching
it ON again, let the engine idle for 2 or 3
minutes.
This will cause the engine rpm to decrease
about
until the prescribed idling speed is reached.
: 85%95C (18%203F)
Lights, accessories
: OFF
Transmission
: neutral position
(Automatic
transmission
models:
N or P)
-.
_.
Steering wheel : neutral (center) position
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WIRING HARNESSES
1. Secure the wiring harnesses by using clamps. However,
for any harness which passes to the engine or other
vibrating parts of the vehicle, allow some slack within a
range that does not allow the engine vibrations to cause
the harness to come into contact
with anv of the
surrounding
parts.
Then secure the harness by using a clamp.
In addition, if a mounting
indication mark (yellow tape) is
on a harness, secure the indication mark in the specified
location.
2.
If any section of a wiring harness contacts the edge of a

part, or a corner, wrap the section of the harness with tape
or something
similar in order to protect it from damage.
F16171
3. When disconnecting
a connector,
connector, not the harness.
4.
Disconnect connectors
the direction indicated
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be sure to pull only the
which have catches by pressing

by the arrows in the illustration.
in
INTRODUCTION
11
- Precautions Before Service

5.
Connect connectors
which have catches
connectors
until they snap.
ELECTRICAL
by inserting
the
COMPONENTS
1. When installing any of the vehicle parts, be careful

pinch or damage any of the wiring harnesses.
not to
2. Sensors, relays, etc., are sensitive to strong impacts.

Handle them with care so that they are not dropped
mishandled.
or
3. The electronic parts used for relays, etc., are sensitive to

heat. If any service which causes a temperature
of 80C
(176F) or more is performed,
remove the part or parts in
question before carrying out the service.
FUSES
AND
FUSIBLE
LINKS
1. If a blown-out fuse is to be replaced, be sure to use only a

fuse of the specified capacity. If a fuse of a capacity larger
than that specified is used, parts may be damaged and the
circuit may not be protected
adequately.
Caution
1.
IOA
15A
WV589
If a fuse is blown-out,
be sure to eliminate the cause
of the problem
before installing
a new fuse.
2. Check the condition
of fuse holders. If rust or dirt is
found, clean metal parts with a fine-grained
sandpaper until proper metal-to-metal
contact is made.
Poor contact of any fuse holder will often lead to
voltage
drop or heating
in the circuit and could
result in improper
circuit operation.
[ TSB Revision
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Nominal
size
0.3 mm*
0.5 mm2
0.85 mm
1.25 mm
2.0 mm
3.0 mmZ
5.0 mm2
AWG 22
ii% ::
AWGIB
2% 1:
AWGlO
2.
If additional optional equipment

is to be installed in the
vehicle, follow the procedure
listed in the appropriate
instruction
manual;
however,
be sure to pay careful
attention to the following points:
(1) In order to avoid overloading
the wiring, take the
electrical current load of the optional equipment
into
consideration,
and determine the appropriate wire size.
(2) Where possible, route the wiring through the existing
harnesses.
(3) If an ammeter or similar instrument

is to be connected
to a live-wire circuit. use tape to protect the wire, use a
clamp to secure the wire, and make sure that there is
no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any gasoline,
parts. they might be adversely affected.
oil, etc., or rubber
LUBRICANTS
In accordance
with the instructions
in this Service Manual,
apply the specified lubricants in the specified locations during
assembly
and installation.
BRAKE FLUID
Be careful to avoid spilling
surfaces,
because the paint
damaged.
http://vnx.su/
any brake
coat might
fluid on painted
be discoiored
or
13
DOING SERVICE WORK IN GROUPS OF TWO OR

MORE TECHNICIANS
If the service work is to be done by two or more technicians
working together,
extra caution must be taken.
NOTE ON INSTALLATION OF RADIO EQUlPMkibJ
,o,tagef
Voltage
qm&xlee
Cable
High-frequency
power supply
Antenna
ooYsoo
The computers
of the electronic
control system has been
designed so that external radio waves will not interfere with
their operation.
However, if antenna or cable of amateur transceiver
etc. is
routed near the computers,
it may affect the operation of the
computers,
even if the output of the transceiver
is no more
than 25W.
To protect
each of the computers
from interference
by
transmitter
(hum, transceiver,
etc.), the following
should be
observed.
1. Install the antenna on the roof or rear bumper.
2. Because radio waves are emitted from the coaxial cable of
the antenna,
keep it 200 mm (8 in.) away from the
computers and the wiring harness. If the cable must cross
the wiring harness, route it so that it runs at right angles to
the wiring harness.
3. The antenna and the cable should be well matched, and
the standing-wave
ratio* should be kept low.
4. A transmitter
having a large output should not be installed
in the vehicle.
5. After installation of transmitter,
run the engine at idle. emit
radio waves from the transmitter
engine is not affected.
*STANDING-WAVE
RATIO
If an antenna and a cable having different
impedances
are
connected,
the input impedance
Zi will vary in accordance
with the length of the cable and the frequency
of the
transmitter,
and the voltage distribution
will also vary in
accordance
with the location.
The ratio between
this maximum
voltage and minimum
voltage
is called the standing-wave
ratio. It can also be
represented
by the ratio between
the impedances
of the
antenna and the cable.
The amount of radio waves emitted from the cable increases
as the standing-wave
ratio increases, and this increases the
possibility
of the electronic
components
being adversely
affected.
/ TSB Revisionhttp://vnx.su/
.-
INTRODUCTION
- Towing
TOWING
and Hoisting
AND HOISTING
--
This vehicle can only be towed from the front with conventional sling-type equipment
and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow doily.
A lumber spacer (4 x 4 x 55 wood beam) should be placed
forward of under guard and under towing hook/shipping
tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system must be used. This system must be
completely
independent
of the primary lifting and towing
attachment.
Care must be taken in the installation
of safety
chains to insure they do not cause damage to bumper, painted
surfaces or lights.
LIFTING-GROUND CLEARANCE
Towed vehicle should be raised until wheels are a minimum of
10 cm (4 in.) from the ground.
Be sure there is adequate
ground clearance at the opposite end of the vehicle, especially
when towing over rough terrain or when crossing sharp rises
such as curbs. If necessary;
ground clearance
can be increased by removing the wheels from the lifted end of the
disabled vehicle and carrying the lifted end closer to the
ground. A 20 cm (8 in.) ground clearance must be maintained
between brake drums and ground.
FRONT TOWING PICKUP

The vehicle may be towed on its rear wheels for extended
distances, provided the parking brake is released.
Make certain the transmission
remains in NEUTRAL.
SAFETY PRECAUTIONS
The following
precautions
should be taken when towing the
vehicle.
1. Remove exhaust tips and any other optional equipment,
that interface with the towing sling. Padding (heavy shop
towel or carpeting) should be placed between the towing
sling cross bar and any painted surfaces,
and bumper
surfaces.
2. A safety chain system completely
independent
of the
primary lifting and towing attachment
must be used.
3. Any loose or protruding
parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior
to moving the vehicle.
4. Operator should refrain from going under a vehicle unless
the vehicle is adequately supported
by safety stands.
5. Never allow passengers to ride in a towed vehicle.
6. State and local rules and regulations
must be followed
when towing a vehicle.
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INTRODUCTlbN
95
- T&wing and Hoisting
HOISTING
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with
the proper adapters in order to support the vehicle at the
proper locations.
(Shown in the illustration)
Conventional
hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the side
frame.
FLOOR JACK
A regular floor jack may be used under the front crossmember
or rear axle housing.
Caution
1. A floor jack must never be used on any part of the
underbody.
2. Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent
damage to the
body.
EMERGENCY JACKING
Jack receptacles
are located at the No. 2 crossmember
and
rear axle housing to accept the jack supplied with the vehicle
for emergency
road service. Always block the opposite wheels
and jack only on a levd surface.
FRAME CONTACT
SUPPORT
LOCATIONS
1,175 mm (46.3 in.)

Wheel base
2.350 mm (92.5 in.)
Section A-A
NOTE
The locations of the support point shown as Section A-A are
the same as those of the twin post hoist shown in the next
Daae.
oow553
1 TSB Revision
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16
INTRODUCTION
LIFTING AND JACKING

<2.6L
Engine>
<3.OL
Engine>
C
m
SUPPORT
- Towing
and Hoisting
LOCATIONS
Twin post hoist

Floor jack
Emergency
jacking (jack supplied
1 TSB Revision
with the vehicle)
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INTRODUCTION
- General
Data
and
17
Specifications
GENERAL DATA AND SPECIFICATIONS
<2-door
NomA-
vehicles>
L042G
TNSL F/H
Vehicle dimensions
mm (in.)
Overall length
Without spare tire
With spare tire
Overall width
Overall height
Wheelbase
Tread
Front
Rear
Overhang
Front
Rear
(VW
clearance
Angle of approach
Angle of departure
Vehicle weights
kg (Ibs.)
Curb weight
Gross axle
Front
weight rating
Rear
Seating capacity
0
cp
0
@
6)
L141G
TNJL F/H
TRJL F/H
TRUL F/H
@
QI
@
Q
3,900 (153.5)
3,935 (I 54.9)
1,680 (66.1)
1,840 (72.4)
2,350 (92.5)
1,400(55.1)
1,375(54.1)
685 (27.0)
900 (35.4)
3,905 (153.7)
3,940 ( 155.1)
1,680 (66.1)
1,850 (72.8)
2,350 (92.5)
1,400(55.1)
1,415(55.7)
/685 (27.0)
905 (35.6)
3,905 (153.7)
3,940 (155.1)
1,680 (66.1)
1,850 (72.8)
2,350 (92.5)
1,400 (55.1)
1,415 (55.7)
685 (27.0)
905 (35.6)
3,905 (153.7)
3,940 (155.1)
1,680 (66.1)
1,850 (72.8)
2,350 (92.5)
1,400(55.1)
1,415 (55.7)
685 (27.0)
905 (35.6)
0
0
8
480 (18.9)
440 (17.3)
210 (8.3)
490 (19.3)
450(17.7)
215 (8.5)
490(19.3)
450(17.7)
215 (8.5)
490 (19.3)
450(17.7)
215 (8.5)
0
8
03
38
28
21
38
28
21
38
28
21
38
28
21
1,455 (3,207)
1,910(4.210)
1,100 (2,425)
1,450(3.197)
2
1,585
2,200
I,1 00
1,600
2
TSB
Revision
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(3,494)
(4,850)
(2,425)
(3,527)
i ,600
2,200
1,100
1,600
2
(3.527)
(4,850)
(2,425)
(3,527)
1,605
2,200
1,100
1,600
2
(3.538)
(4,850)
(2.425)
(3,527)
18
INTRODUCTION
- General Data and Specifications

L042G
Engine
Model No.
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Firing order
Model No.
Type
Gear ratio
Transmission
Transfer case
L141G
TNSL F/H
TNJL F/H
TRJL F/H
TRUL F/H
G54B
In-line OHC
4
91.1 mm (3.59 in.)
98.0 mm (3.86 in.)
2,555 cm3
(155.9 cuin.)
8.7
I-34-2
7BTDC r2
6672
V-type, OHC
6
91.1 mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3
(181.4cu.in.)
8.9
I-2-3-4-5-6
5BTDC z 2
6672
V-type, OHC
6
91.1 mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3
(181.4cu.in.)
8.9
1-2-34-5-6
5BTDC 12
6672
V-type, OHC
6
91.1 mm (3.59 in.
76.0 mm (2.99 in.
2,972 cm3
(181.4cu.in.)
8.9
1-2-345-6
5BTDC 2
KM148
&peed automatic
KM148
4-speed automatic
2.826
1.493
1.000
0.688
2.826
1.493
1DO0
0.688
2.703
1.ooo
1.925
4.625
2.703
1.ooo
1.925
4.625
case
KM145
5-speed manual
1st
2nd
3rd
4th
5th
Reverse
High
Low
V5MTl
6-speed manual
3.967
2.136
1.360
1 .ooo
0.856
3.587
1.000
1.944
4.625
3.918
2.261
1.395
1.000
0.829
3.925
1.ooo
1.925
4.625
Dry single disc &

diaphragm spring
Dry single disc &

diaphragm spring
P225t75Rl5
P235i75R 15
Independent
double-wishbone
Independent
Rigid axle
Rigid axle
Disc
Drum
(Leading and trailing)
Disc
3lutch
Type
Chassis
Tire size
Front suspension
Type
double-wishbone
Rear suspension
Type
Brakes
Type
Front
Rear
Power steering
Gear type
Gear ratio
%el tank capacity
liters (gals.)
Integral type
Integral type (Recirculating bail nut)
(Recirculatingball nut)
16.4
16.4
60(15.9)
75119.8)
TCP
Pa..i&.Tn
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lNTRODUCTlON
<Cdoor
vehicles>
L146G
VMNJL F/H
Vehicle dimensions
mm (in.)
Overall length
Without spare tire
With spare tire
Overall width
Overall height
Wheelbase
Tread
Front
Rear
Overhang
Front
Rear
(wt.)
clearance
Angle of approach
Angle of departure
ilehicle weights
kg (Ibs.)
Curb weight
Gross axle
weight rating
Seating capacity
Engine
Model No.
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Firing order
Front
Rear
VMRJL F/H
WMRUL F/H
aI
Cp
@
CD
@
03
CD
BD
@
4,570 (179.9)
4,605 (181.3)
1,680 (66.1)
1,890 (74.4)
2,695(106.1)
1,400 (55.1)
1,415 (55.7)
745 (29.3)
1,165(45.9)
4,570 (179.9)
4,605 (181.3)
1,680 (66.1)
1,890 (74.4)
2,695(106.1)
1,400 (55.1)
1,415(55.7)
745 (29.3)
1,165(45.9)
4,570 ( 179.9)
4,605(181.3)
1,680 (66.1)
1,890 (74.4)
2,695 (106.1)
1,400 (55.1)
I,41 5 (55.7)
745 (29.3)
1 ,I 65 (45.9)
dD
0
Q
480 (19.3)
450(17.7)
215 (8.5)
480(19.3)
450 (17.7)
215 (8.5)
-480(19.3)
450 (17.7)
215 (8.5)
Q
@
38
28
18
38
28
18
1,780
2,400
1,100
1,600
5
(3,924)
(5,291)
(2,425)
(3,527)
6672
V-type, OHC
6
91.1 mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3(181 .4 cu.in.)
8.9
1-2345-6
5BTDC +2
1 TSB Revision
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1,795
2,400
I,1 00
1,600
5
38
28
18
(3,957)
(5,291)
(2,425)
(3,527)
1,805
2,400
1,100
1,600
5
6672
V-type, OHC
6
91 .I mm (3.59 in.)
76.0 mm (2.99 in.)
2,972 cm3(181.4cu.in.)
8.9
1-2-345-6
5BTDC 22
(3,979)
(5,291)
(2,425)
(3,527)
6G72
V-type, OHC
6
91 .I mm (3.59 in.)
76.0 mm (2.99 in.)
2.972cm3(181.4cu.in.)
8.9
l-2-345-6
5BTDC +2
20
INTRODUCTION

L146G
VMNJL F/H
ansmission &transfer
Model No.
VMRJL FM
-
WMRUL-P/H
V5MTl
5-speed manual
KM148
4-speed automatic
KM148
4-speed automatic
3.918
2.261
1.395
1.000
0.829
3.925
1.ooo
1.925
4.625
2826
1.493
1.ooo
0.688
2.826
1.483
1 .ooo
0.688
2.703
1.000
1.925
4.625
2.703
1.000
1.925
4.625
case
Type
Gear ratio
Transmission
1st
2nd
3rd
4th
5th
Reverse
Transfer case
High
Low
utch
Tvpe
Dry single disc &

diaphragm spring
lassis
Tire size
Front suspension
P235175 RI 5
Type
Rear suspension
Independent
Type
Brakes
Rigid axle
Type
Power steering
Gear type
Gear ratio
Fuel tank capacity
.-
Front
Rear
liter (gal.)
double-wishbone
Disc
Integral type (Recirculating
16.4
92 (24.3)
ball nut)
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INTRODUCTION
TIGHTENING
TORQUE
Description
Description
Taper thread for pipes (size)
PTll8
PTll4
PT3t8
Taper thread for dry sealed pipes (size)
NPTF l/l6
NPTF 114
F
-
Head mark
Thread for general purposes

(size x pitch) mm
6x1.0
8x 1.25
10x1.25
12x1.25
14x1.5
16x1.5
18x 1.5
20x1.5
22x1.5
24x1.5
NPTF l/8
Tightening
[ I
21
Torque
Head mark
Nm
ftlbs.
Nm
ft.lbs.
3.0-3.9
7.9-12
16-23
29-43
48-70
67-l 00
100-150
150-190
200-260
260-320
2.2-2.9
5.8-8.7
12-17
2132
35-52
51-77
74-110
1 lo-140
150-190
1go-240
4.9-7.8
13-19
27-39
47-72
77-l 10
130-I 60
180-230
160-320
340-430
420-550
3.6-5.8
9.4-14
20-29
35-53
57-85
90-I 20
130-I 70
190-240
250-320
310-410
Nm
ft.lbs.
I
1
Remarks
7.9-l 2
16-19
19-30
34-45
39-54
59-73
5.8-8.7
12-14
14-22
25-33
2940
43-54
Internal
Internal
Internal
Internal
internal
internal
thread:
thread:
thread:
thread:
thread:
thread:
Aluminum
Cast iron
Aluminum
Cast iron
Aluminum
Cast iron
4.9-7.8
7.9-l 2
7.9-12
16-19
19-13
34-45
3.6-5.8
5.8-8.7
5.8-8.7
12-14
14-22
25-33
Internal
Internal
internal
Internal
Internal
Internal
thread:
thread:
thread:
thread:
thread:
thread:
Aluminum
Cast iron
Aluminum
Cast iron
Aluminum
Cast iron
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NOTE
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ELECTRICAL
CONTENTS
ACCESSORY
.....................................................
Cigarette Lighter ............................................
Clock .............................................................
Troubleshooting
.............................................
224
226
226
225
AUDIO SYSTEM ...............................................

227
Antenna ..........................................................
256
Front Speaker .................................................
255
Radio and Tape Player ..................................
_ 254
Rear Speaker ..................................................
255
................. _..__....___._.__
........... 228
Troubleshooting
AUTOMATlC
FREE-WHEELING
HUB
INDICATOR
SYSTEM .......................................
Automatic
Free-wheeling
Hub .......................
Pulse Generator ............................................
Troubleshooting
.............................................
261
264
263
262
BACK DOOR WINDOW

DEFOGGER ...............
Defogger switch ...........................................
Printed Heater Lines ................. ...._....._.__ _ .............................................
Troubleshooting
267
259
260
258
bnnriuIl~u
CHARGING
n I*^--^LÂlternator
116
126
122
126
125
122
118
SYSTEM
3~a
I rm .......................................
. . . . . . . . . . . . . . . .. . . .. . . . . . . . . . ,
........................
.._ .............................
....................
service Adjustment
Service
Aajusrmen
Procedures
........................................
Battery
Ba
Charging
-
Battery Inspection
........ .__._._.......................
Ba
Charging System Inspection
......................
Troubleshooting
.............................................
ELECTRICAL SYSTEM PARTS LOCATION

.....
Diode ..............................................................
Fusible Link and Fuse ....................................
Grounding <2.6L Engine>
............................
Ground t3.OL Engine>
..................................
3
16
10
12
14
NOEAA-
Inspection Terminal .......................................

Relay and Control Unit ..................................
Sensor t2.6L Engine> .....................
...-*- .- ....
Sensor <3.OL Engine> ......... ___._
.-.__._. ..........
HORN .................................................................
Troubleshooting
....................................
222
. ... . .... 223
IGNITION SYSTEM ...........................................

Distributor <2.6L Engine> ...........................
Distributor <3.OL Engine> ...........................
Ignition Switch ...............................................
Ignition System <2.6L Engine> ...................
Ignition System <3.OL Engine> ...................
Service Adjustment
Procedures
....................
Centrifugal Timing Control Device
Inspection <2.6L Engine only> ................
High Tension Cable Spark Test .................
ignition Timing Adjustment
<2.6L Engine> ............ _I_...._____..._._..........
Ignition Timing Adjustment
<3.OL Engine> .........................................
Spark Plug Cable Test ...............................
Spark Plug Test ................ .._......- ..... ..- . ___._
..
Vacuum Timing Control Device
Inspection t2.6L Engine only> ................
Troubleshooting
............................
___..__.. ._......
INSPECTION OF HARNESS CONNECTOR..
...
Check for Improper Engagement
of
Terminal ..........................................................
Continuity and Voltage Test for Connector ......
Engaging and Disengaging of Connector
Terminal ............................
.______..._. . ..-.- .......
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17
3
6
8
143
158
160
162
151
155
147
149
150
147
148
150
150
149
145
18
18
18
18
LIGHTING SYSTEM ..........................................

Column Switch ...............................................
Dimmer Control Switch ......... __-._._._.____
.........
Hazard Warning Switch ................................
Headlight .......................................................
Service Adjustment
Procedures
....................
Headlight Aiming .......................................
Troubleshooting
..................... ..- ....................
179
200
202
201
199
198
198
180
METERS AND GAUGES

.................................
a-meter Unit ..................................................
Combination
Meter ........................................
Indicators and Warning Lights .......................
Service Adjustment
Procedures
....................
Engine coolant Temperature
Gauge
Simple Test ..........................
- ....................
Engine coolant Temperature
Gauge Unit
Inspection ...................................................
Fuel Gauge Simple Test ............................
Fuel Gauge Unit Inspection
.......................
Oil Pressure Gauge Simple Test ...............
Oil Pressure Gauge Unit Current Check ......
Speedometer
Inspection
...........................
Tachometer
inspection <2.6L Engine> ....
Tachometer
Inspection <3.OL Engine> ....
Voltage Meter Simple Test ........................
Troubleshooting
.............................................
163
175
173
177
170
172
171
171
1712
173
170
170
170
173
165
STARTING SYSTEM .........................................

Starter Motor ......................................
-..._._.
133
136
WIPER AND WASHER SYSTEM .....................

Column Switch ...............................................
Headlight Washer ..........................................
Rear Washer ..................................................
Rear Wiper .....................................................
Rear Wiper and Washer Switch ....................
Troubleshooting
.............................................
Windshield Washer ........................................
Windshield Wipers .........................................
203
219
218
217
215
220
206
216
212
WIRING HARNESS
...........................................
Centralized Junction .......................................
Circuit Diagram ..............................................
Auto-Cruise Control System Circuit ..............
Automatic Free-Wheeling
Hub Indicator
System Circuit ...............................................
21
114
47
62
172
85
Back Door Lock Circuit ..............................

111 _
Buzzer Circuit ..........................
__.____-______ 84
Central Locking System Circuit .................
100
Cigarette Lighter/Clock
Circuit ...................
944
Charging Circuit ..... .._..._....._ ............. ::. ....... 51 _
Defogger Circuit ..................... . ........ ____
.......
95 _
Dome Light Circuit .......................
..-.-. .......
78 I,
Dual Air Conditioner Circuit ........... . ......... 108.
Feed Back Carburetor Circuit .....................
52
Headlight Circuit .................... ._-_____-- _.__ 64
Heater Circuit ..................... ..-.-. ...... . -______102
Horn Circuit ..............................
-.__._- _......_ .. 112
Ignition Circuit ........................
___.. _.._ _ -_____. 49
Instrument
Panel Illumination Circuit .........
76 ..
Meter Circuit ..................................
- _........
80 _
M.P.I. Circuit .........................
..__.....II_._._. .. 56
Overdrive Control System Circuit ............
60 T
Power Window Circuit .......... .._..................
96
Radio/Cassette
Deck Circuit ............ I .........
90 I
Single Air Conditioner
Circuit ...................
104
Starting Circti ............................................
47
Stop Light Circuit .....................
.._ .._- _-_._ ... 74~
Sunroof Circuit .................... ..-........-- .......... 113 _
Tail Light, Position Light, Rear Side
Marker Light. License Plate Light and
Back-up Light Circuit .............. ._.,_. .._...........
66
Turn-Signal and Hazard Light Circuit .........
70 ^
Wiper and Washer Circuit ............... _-..._. ... 86 ..
How to Read Wiring Diagrams ......................
29.
Overall Wiring Diagram ............._r.___ . -- _._._... 36~.
Engine Compartment
t2.6L
Engine>
...... 38 .
Engine Compartment
t3.OL Engine>
...... 40
Instrument
Panel ................. ..___.___
. - _........
42Interior and Frame <4door
vehicles>
...... 44 _
Interior and Frame <2-doer vehicles>
...... 46
...
AUTbCRUISE
CGNTi%bL
SYTEM
...........................
REFER TO GROUP 14
BACK DOOR
LOCK ..........
REFER TO GROUP
23
BUZZER
............................
REFER TO GROUP
23
CENTRAL
SYSTEM
DOOR-LOCKING
...........................
REFER TO GROUP
23
REFER TO GROUP
23
. . . . . . .. .. . . . . . . . . . . ..sn REFER TO GROUP
23
POWER
SUNROOF
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WINDOW
...........
8-3
ELECTRICAL SYSTEM PARTS LOCATION - Relay and Control Unit
ELECTRICAL SYSTEM PARTS eLOCATION

RELAY AND CONTROL UNIT
NWBA--
Name
1 Symbol
1 Symbol
t Heater relay
Intermittent
wiper relay
Intermittent
rear wiper relay
Light control relay
Choke relay <3.OL Engine>
M.P.I. control relay <3.OL Engine>
Condenser blower motor relay

<2.6L Engine>
M.P.I. control unit c3.OL Engine>
Condenser blower motor relay

<3.OL Engine>
Over drive relay

<Vehicles with an automatic
Air conditioner
relay A, B
control unit
Auto choke relay 4!.6L
Automatic
Defogger
hub indicator
Engine>
speed control unit
timmer
unit
Name
/ Power window
power relay
transmission>
1
Feed back carburetor control unit

<2.6L Engine>
Seat belt warning timer
Hazard warning flasher unit
Turn-signal flasher unit
Headlight washer relay
<2.6L
<3.OL
Engine>
TSB
Revision
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Engine>
ndenser
;1 Ii
or
control
unit
Frnnt
I TSR
Rmticinn
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.I
~_
blower

Name
Symbol
Name
8-5
Symbol
Air conditioner relay D, E

<Vehicles with dual air conditioner>
Door lock control unit
Sunroof control relay
Door lock power relay
Sunroof power relay
Power window control relay
1 TSB Revision
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ELECTRICAL SYSTEM PARTS LOCATION - Sensor <2.6L Engine>
SENSOR <2.6L Engine>
16w1601
iu6
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8-7
ELECTRICAL SYSTEM PARTS LOCATION - Sensor <2.6L Engine>

Speedometer
TSB
Revision
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I
1
-.
.,
8-8
ELECTRICAL SYSTEM PARTS LOCATION - Sensor c~.oL Engine>
SENSOR <3.OL Engine>
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ELECTRICAL SYSTEM PARTS LOCATION - Sensor <SOL Engine>
8-9
Speedometer
Vehiclespeed
sensor
16W150@
cooler feed tube
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8-10
ELECTRICAL SYSTEM PARTS LOCATION - Fusible
Link
and
Fuse
FUSIBLE LINK AND FUSE

Symbol
circuit)
Dedicated fusible link (for F.B.C. circuit)
fuse (for center door locking
Main fusible link <2.6L Engine>
Main fusible link <3.OL Engine>
Dedicated fuse (for air conditioner

Dedicated
circuit)
Name
Symbol
Name
Dedicated fuse (for headlight circuit)

Dedicated fuse (for rear air conditioner
circuit1
_._- ~,
Multipurpose
fuse
Dedicated fuse (for sunroof circuit)
Sub fusible link <2.6L Engine>
Dedicated fusible link (for defogger circuit)

c2.6L Engine>
Sub fusible link <3.OL Engine>
Dedicated fusible link (for defogger

<3.OL Engine>
k-e
circuit)
I
NOTE
For detailed information concerning the fusible links and
fuses, refer to the section regarding CENTRALIZED JUNCTION (P.8-114)
<2.6L
._
<3.OL Engine>
Engine>
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ELECTRICAL SYSTEM PARTS LOCATION - Fusible Link and Fuse
TSB Revision
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8-11
8-12
ELECTRICAL SYSTEM PARTS LOCATION - Grounding <2.6L Engine>
GROUNDING
<2.6L Engine>
lSWl601
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ELECTRICAL SYSTEM PARTS LOCATION - Grounding
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c2.6L Engine>
8-13
8-14
ELECTRICAL SYSTEM PARTS LOCATION - Grounding <a.01 Engine>
GROUNDING
<3.OL Engine>
QQ
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ELECTRICAL SYSTEM PARTS LOCATION - Grounding <3.01 Engine>
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8-15
ELECTRICAL SYSTEM PARTS LOCATION - Diode
DIODE
Symbol
Items
Diode (for automatic transmission
temperature warning light)
oil
I TSB Revision
Items
Diode (for maintenance
warning light)
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required
Symbol
B
ELECTRICAL SYSTEM PARTS LOCATION - Inspection Terminal
INSPECTION TERMINAL
Self-diagnosis
check connector
Spark timing adjuster connector
c2.6L Engine>
<3.OL Engine>
16Wl601
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-A-,_
-.~_
*-~
8-18 INSPECTION OF HARNESS CONNECTOR
Inspection
of Harness
Connector
INSPECTION OF HARNESS CONNEClom

CONTINUITY AND VOLTAGE TEST FOR
CONNECTOR
Following procedures
shall be followed for testing continuity
and voltage at connector in order to prevent improper contact
and deterioration
of waterproof
in connector.
CONVENTIONAL
(NON-WATERPROOF)
CONNECTOR
Check shall be done by inserting
a probing needle
harness side.
from
WATER PROOF CONNECTOR

Caution
Do not insert probing
needle from harness side as it will
deteriorates
waterproof
and cause for rusting. To inspect
the energized
circuit, use the ECI checker.
Connect
to E
harness
16UO5W
CHECK FOR IMPROPER ENGAGEMENT OF

TERMINAL
When terminal stopper of connector is out of order, engagement of male and female terminals becomes improper even
when connector
itself is engaged
perfectly
and terminal
sometimes
slips out to rear side of connector.
Ascertain,
therefore, that each terminal does not come off connector by
pulling each harness wife.
16R1317
ENGAGING AND DISENGAGING OF CONNECTOR

TERMINAL
Connector which gives loose engagement
shall be rectified
by removing
female terminal from connector
housing and
raise its lance to establish securer engagement.
Removal of
connector
housing and raise its lance to establish securer
engagement.
Removal of connector
terminal used for ECI
and ELC 4 A/T control circuit shall be done in the following
manner.
COMPUTER
CONNECTOR
(I) Insert screwdriver
[I.4 mm (.06 in.) width] as shown
the figure, disengage front holder and remove it.
(2) Insert harness
connector from
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of terminal
to be rectified
deep
harness side and hold it there.
in
into
INSPECTION OF HARNESS CONNECTPR
inspection
of Harness
Connector
8-19
(3) insert tip of screwdriver

[I .4 mm (.06 in.) width] into
connector
in a manner as shown in the figure, raise
housing lance slightly with it and pull out harness.
NOTE
Tool No. 753787-l
supplied by AMP can be used instead
of screwdriver.
Housing lance
AU
16R1321 I
(4) Insert needle through a hole provided

raise contact point of male terminal.
on terminal
and
Needle
16R1322
ROUND WATERPROOF
CONNECTOR
(I) Remove waterproof
cap by using a screwdriver.
(2) Insert tip of screwdriver
[I.4 mm (06 in.) or 2.0 mm (.08
in.) width] into connector
in a manner as shown in the
figure, raise housing lance slightly with it and pull out
harness.
housing
lance
16Rl323
(3) Insert screwdriver

through a hole provided
and raise contact point of male terminal.
on terminal
16Rl324
RECTANGULAR
(1) Disengage
remove it.
1611326
TSB Revision
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WATERPROOF
CONNECTOR
front holder by using a screwdriver
and
8-20 INSPECTION OF HARNESS CONNECTOR
inspection
of Harness
Connector

[*0.8 mm (.03 in.) width] into
connector
in a manner as shown in the figure, push it
lightly to raise housing lancer and pull out harness.
If right size screwdriver
is not available.
convert a
conventional
driver to suit the size.
l-busing
lance
(3) Press contact,point

of male terminal down by holding a
screwdriver
[I .4 mm (.06 in.1 width] in a manner as
INJECTOR CONNECTOR
(I) Remove waterproof
cap.

[I.4 mm (.06 in.) width] into
connector
in a manner as shown in the figure, press in
terminal lance and pull out harness.
(3) Press contact point of male terminal down by holding a

screwdriver
[I.4 mm (.06 in.) width1 in a manner as
Caution
Correct
lancer
to be in proper
condition
before
terminal
is inserted
into connector.
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8-21
NBWUB
WRING HARNESS - Troubleshooting
WRING
HARNESS
TROUBLESHOOTING
The most important
point in troubleshooting
is to determine
Probable Causes.
Once the probable
causes are determined,
parts to be checked can be limited to those associated with such probable
causes. Therefore,
unnecessary
checks can be eliminated. The determination
of the probable causes must
be based on a theory and be supported by facts and must not be based on intuition only.
TROUBLESHOOTING STEPS
If an attempt
is made to solve a problem without going through correct steps for troubleshooting,
the
problem symptoms
could become more complicated,
resulting in failure to determine the causes correctly
and making incorrect repairs-The four steps below should be followed in troubleshooting.
,
Observation
Symptoms
II
3
Determination
Observe the symptom

other problems.
of Problem
Repair
Parts
Associated
Causes and
of Faultv Parts.
and Confirmation
Check
if there
are also
In determining
the probable causes, it is necessary to check
the wiring diagram to understand
the circuit as a system.
Knowledge of switches, relays and other parts is necessary
for accurate determination.
The causes of similar problems
in the past must be taken into account.
of Probable
CSUSeS
Checking
of
with Probable
Determination
carefully.
Troubleshooting
is carried out by making step by step
checks until the true cause is found. Always go through the
procedures considering what check is to be made where for
the best results.
After the problems are corrected, be sure to check that the

system operates correctly. Also check that new problems
have not been caused by the repair.
INFORMATION
FOR DIAGNOSIS
This manual contains the cable diagrams as well as the individual circuit drawings, operational
explanations, and troubleshooting
hints for each component
required to facilitate the task of troubleshooting.
The
information
is compiled in the following manner:
(I) Cable diagrams show the connector positions, etc., on the actual vehicle as well as the harness path.
(2) Circuit drawings show the configuration
of the circuit with all switches in their normal positions.
(3) Operational
explanations
include circuit drawings of voltage flow when the switch is operated and
how the component
operates in reaction.
(4) Troubleshooting
hints include numerous examples of problems which might occur, traced backward in
a common-sense
manner to the origin of the trouble. Problems whose origins may not be found in
this manner are pursued through the various system circuits.
Remarks
Components
of ECI, ETACS. ECS. etc. with ECU do not include 3 and 4 above. For this information,
refer
to a manual which includes details of these components.
1 TSB Revision
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8-22
WRING HARNESS - Troubleshootina

INSPECTION
1. Visual and aural checks
Check relay operation,
blower motor rotation,
light illumination, etc. visually or aurally. The flow of current is
invisible but can be checked by the operation
of the
parts,
2.
Simple checks
For example, if 3 headlight does not come on and a faulty
fuse or poor grounding
is suspected,
replace the fuse
with a new one or ground the light to the body by a
jumper wire to deter mine which part is responsible
for
the problem.
3.
Checking with instruments

Use and appropriate instrument
in an adequate range and
read the indication
correctly.
You must have sufficient
knowledge
and experience
to handle instruments
correctly.
0
C
"
50
[@
Changeover
knob
INSPECTION lNSTRUMENTS
In inspection, make use of the following instruments.
1. Test lamps
A test lamp consists of a 12 V bulb and lead wires.
used to check voltages or shortcircuits.
2.
It is
Self-power
test light
A self-power
test light consists of bulb, battery and lead
wires connected
in series. It is used to check continuity
or grounding.
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WRING HARNESS - Troubleshooting
8-23
3. Jumper wire
A jumper wire is used to close an open circuit. Never use
one to connect a power supply directly to a load.
4.
Black lead wire
Voltmeter
A voltmeter
is used to measure
the circuit voltage.
Normally, the positive (red lead) probe is applied to the
point of voltage measurement
and the negative (black
lead) probe to the body ground.
5. Ohmmeter
An ohmmeter
is used to check continuity
or measure
resistance of a switch or coil. If the measuring range has
been changed, the zero point must be adjusted before
measurement.
Normal
CHECKING SWITCHES
oDen (NO) me
OFF
In a circuit diagram, a switch is represented

by a symbol and
in the idle state.
1. Normal open or normal close switch
Switches are classified into those which make the circuit
open and those which make the circuit closed when off.
ON
---oh
ax
hrrent
Current
does not flow
flows
Normal close (NC) tYPe

OFF
ON
---oo--I
CAX
Current flows
Current
does not flov

16so**,
/
evision
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a-24
WIRING HARNESS - Troubleshooting

2. SWITCH CONNECTION
This figure illustrates a complex switch. The switch plates
indicated by solid lines move in the direction of the arrow
when operated. The continuity between terminals at each
position is as indicated in the table below.
NOTE
O-O
denotes continuity
between
terminals.
ltEEii
1
16W008
CHECKING RELAYS
Cover
Coil
1. When current flows through the coil of a relay, its core is

magnetized
to attract the iron piece, closing (ON) the
contact at the tip of the iron piece. When the coil current
is turned off, the iron piece is made to return to its
original position by a spring, opening the contact (OFF).
Spring
Iron core
Iron
piece
Contact
Ed
z.
e
1660231
k.&.
2.
Relay
By using a relay, a heavy current can by turned on and off

by a switch of small capacity. For example, in the circuit
shown
here, when the switch is turned on (closed),
current flows to the coil of the relay. Then, its contact is
turned on (closed) and the light comes on. The current
flowing at this time to the switch is the relay coil current
only and is very small.
&E
Em
16BO232
Normal ooen IN01 tvoe

1 Deeneroized staae 1 Enernized stage
1:
ED
The deenergized
3. The relays may be classified into the normal open type

and the normal close type by their contact construction.
NOTE
through
current
:
4
IX
Current does not
state
means
that
the coil and the energized

is flowing through the coil.
no current
state
is flowing
means
that
g-
g:.
BP:=
Current flows
1660233
prevision
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WIRING HARNESS - Troubleshootinn

Normal close (NC) type
Deenergized stage
(
Energized
When a normal close type relay as illustrated

here is
checked, there should be continuity
between
terminals
(I) and (2) and between terminals 3 and 4 when the relay
is deenergized,
and the continuity should be lost between
terminals 3 and 4 when the battery voltage is applied to
the terminals
1 and 2. A relay can be checked in this
manner and it cannot be determined
if a relay is okay or
faulty by checking its state only when it is deenergized
(or energized).
stage
1
:
ED=
4
IX
Current flows
Current
do&
not flow
166023.
CHECKING FUSES
A blade type fuse has test taps provided to allow checking of
the fuse itself without removing it from the fuse block. The
fuse is okay if the test light comes on when its one lead is
connected to the test taps (one at a time) and the other lead
is grounded.
(Change the ignition switch position adequately
so that the
fuse circuit becomes live.)
1600236
State of fuse blown
CAUTIONS IN EVENT OF BLOWN FUSE
due to overcurrent
When a fuse is blown, there are two probable causes as

follows:
One is that it is blown due to flow of current
exceeding
its rating. The other is that it is blown due to
repeated on/off current flowing through it. Which of the two
causes is responsible
can be easily determined
by visual
check as described below.
(I) Fuse blown due to current exceeding rating
The illustration shown the state of a fuse blown due to
this cause. In this case, do not replace the fuse with a
new one hastily since a current heavy enough to blow
the fuse has flowed through it. First, check the circuit for
shorting and check for abnormal electric parts. Only after
the correction of such shorting or parts, fuse of the same
capacity should be used as a replacement.
Never use a
fuse of lager capacity than the one that has blown. If
such a fuse is used, electric parts or wirings could be
damaged before the fuse blows in the event an overcurrent occurs again.
166023,
State of fuse blown
due to thermal
(2) Fuse blown due to repeated current on/off

The illustration shown the state of a fuse blown due to
repeated current on/off. Normally, this type. of problem
occurs after fairly long period of use and hence is less
frequent
than the above type. In this case, you may
simply replace with a new fuse of the same capacity.
fatigue
1660236
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CHECKING CABLES AND WIRES
1. Check connections
for looseness, rust and stains.
2. Check terminals and wires for corrosion by battery electrolyte, etc.
3. Check terminals and wires for open circuit or impending
open circuit.
4. Check wire insulation and coating for damage, cracks and
degrading.
5. Check conductive
parts of terminals
for contact with
other metallic parts (vehicle body and other parts).
6. Check grounding
parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that wirings are so clamped as to prevent contact
with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, pipe, etc.).
9. Check that wirings are clamped firmly to secure enough
clearance from the fan pulley, fan belt and other rotating
or moving parts.
10. Check that the wirings between
the fixed parts such as
the vehicle body and the vibrating
parts such as the
engine are made with adequate allowance for vibrations.
HANDLING ON-VEHICLE BAlTERY

When checking or servicing does not require power from the
on vehicle battery, be sure to disconnect
the cable from the
battery (-) terminal. This is to prevent problems that could
be caused by shorting of the circuit. Disconnect
the (-)
terminal first and reconnect it last.
Caution
1. Before
connecting
or disconnecting
the
negative
cable, be sure to turn off the ignition
switch and the
lighting
switch.
(lf this is not done, there is the possibility
of semiconductor parts being damaged.)
2. After completion
of the work steps [when the batterys negative
(-1 terminal
is connected],
warm up
the engine and allow it to idle for approximately
five
minutes
under the conditions
described
below,
in
order to stabilize
engine control
conditions,
and then
check to be sure that the idling is satisfactory.
For 3.OL Engine models:
lf the engine
rpm is high,
switch
OFF the ignition
switch,
and then,
after
switching
it ON again, let the engine
idle for 2 or 3
minutes.
This will cause the engine
rpm to decrease
about
until the prescribed
idling speed is reached.
8595C
(185203F)
Lights, accessories:
OFF
Transmission:
neutral
position
(Automatic
transmission models:
N or P).
Steering wheel:
neutral (center) position
1 TSB Revision
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8-27

TROUBiiSHOOTlNG
Power supply
A circuit consists of the power supply, switch, relay, load,

ground, etc. There are various methods
to check a circuit
including an overall check, voltage check, shortcircuit
check
and continuity
check. Each of these methods
is briefly
described in the following.
1. VOLTAGE CHECK
(I) Ground one lead wire of the test light. If a voltmeter
is used instead of the test light, ground the grounding
side lead wire.
(2) Connect the other lead wire of the test light to the
power side terminal of the connector 0. The test
light should come on or the voltmeter should indicate
a voltage.
(3) Then, connect
the test light or voltmeter
to the
connector 0. The test light should not come on, or
the voltmeter
should indicate no voltage. When the
switch is turned on in this state, the test light should
come on, or the voltmeter should indicate a voltage,
with the motor starting to run.
(4) The circuit illustrated here is normal but if there is any
problem
such as the motor failing to run, check
voltages beginning
at the connector
nearest to the
motor unit the faulty part is identified.
FLEX3
Motor
2.
Power
supply
CHECKING FOR A SHORT-CIRCUIT

Because the fuse has blown, it is probable that there is a
shot-t-circuited
circuit. Follow the procedures
below to
narrow down the short-circuit
location.
illumination
light
3
kEE NEXT PAGE/
16AOSC
evision
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8-28
WIRING
HARNESS
- Troubleshooting
CONTINUED
FROM
PREVIOUS
PAGE
Power supply
I
/ Switch ON the
(The test light illuminates but the illumination light does not.1
Disconnect
Illumination
iii T
the load
light
16AO6~
NO
Power supply
Test
light
Fuse block
(Remove the fuse.)
Switch
ON l
~
Disconnect
the load
Short-circuit
location
illumination
light
t T
1610504
I
Self power test light
(or ohmmeter)
3.
Switch
I TSB
Revision
CHECKING CONTINUITY
(1) When the switch is in the OFF position, the self
power test light should come on or the ohmmeter
should read 0 LI only when the terminals 2 and 3 are
interconnected.
(2) When the switch is in the ON position, the self power
test light should come on or the ohmmeter
should
read 0 R only when the terminals
1 and 4 are
interconnected.
http://vnx.su/
WJRJNG HARNESS - How to Read Wiring Diagrams
8-29
HOW TO READ WIRING DIAGRAMS

HOW TO READ CONFIGURATION DIAGRAMS
(1) Connector symbols
A wiring diagram shows the installed condition of each connector in a schematic style. The connectors
are shown and classified as follows,
depending
on their locations and are marked by connector
symbols.
In case connectors
of the same shape (same number of wires) are centralized,
their colors are
indicated for identification.
Example:
A-52
T
(Black)
-PET
;~;;~I;;~;,,
Connectors
unrque
number
A, B : Engine compartment
C : Instrument
panel
D : Interior and frame
;Main
fusible
link
4WD indicator switch

A-05 Automatic transmission
temperature
switch
oil
t
wiring diagram
and ihe circuit diagram.
Indicates color of
the A-52 connector.
I
I st5 nevwon
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(serial number)
~~
--
8-30
WIRING
HARNESS
- How to Read Wiring Diagrams
(2) Identification
of connectors
differing according to different vehicle specifications
Without wiring harness connectors,
the inter-device or-wiring harness connectors which van/ in shape
or position
on different
vehicle specifications
are given the specificationdependent
connector
identification
symbol (lower case alphabet) after a serial number.
For detailed information
on this specification-dependent
symbol, refer to Item (8) under HOW TO
READ CIRCUIT DIAGRAMS.
(3) Indication of standard mounting
positions of harnesses
The standard
mounting
positions
of harnesses
are shown with the mark * in wiring harness
configuration
diagrams.
(4) Indication of ground point
The position of ground points are shown in wiring harness configuration
diagrams.
For detailed
information
on the ground portion, refer to ELECTRICAL SYSTEM PARTS LOCATION (Grounding).
Refer to item (3)
Ground symbol
-A
t4
Refer to item (4)
ITSB
Revision
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831
WIRING HARNESS - How to Read Wiring Diagrams

HOW TO READ CIRCUIT DIAGRAMS
The circuit diagrams are functionally

separated.
(1) indication of circuit connected to another circuit
When the circuit in a circuit diagram connected
to another circuit in a different diagram the page
number of that different diagram is indicated so that it can be referred to.
(2) Indication of device connections
The circuit diagram shows whether a device harness connection is one with an attached cable or is a
direct connection
type.
(3) Indication of connectors
in circuit diagrams
A connector in a circuit diagram is shown in a frame and is assigned a connector symbol. This symbol
corresponds
to the symbol in a wiring harness configuration
diagram so that the connector location
can be known easilv. An intermediate
connector has its female side oniv shown as a rule. However
both of the male and female sides are shown when they differ in wiringcolor.
Refer to Item (2)

If a frame showing a connector touches
the symbol of a device, it indicates that
the device harness connection
is a
direct connection type.
B-36
I
H
22-RL
I
B I
u
i2-RL
18
I
-----------------
____
--
----______
1-8-39
On a circuit connected
Indicates
that this connector
TSB Revision
is a B-39
http://vnx.su/
to another
the circuit is connected and pages on

which diagrams of such another circuit
8-32
WIRING
HARNESS
- How to Read Wiring Diagrams
(4) indication of fuses, fusible links and centralized relays

The fuses and fusible links ina circuit diagram are indicated by a wave symbol (-1 and a double wave
symbol (-), respectively.
At a centralized junction, the fuses are given fuse numbers and centralized
relays are given connector symbols.
Example
of centralized
junction
symbol:
A-01
X
-L_-
Centralized junction
Connectors
unique
Connector symbol
indication symbol
number (serial number)
(5) Indication of ground point

The ground point in a circuit diagram is marked by a ground symbol, making it possible for
to a wiring
harness
configuration
diagram
and to ELECTRICAL
SYSTEM
PARTS
(Grounding).
(6) indication of wires
In a circuit diagram, the wire diameter and wire color are shown for each wire. If there
wires of the same color in a connector, their wire color indication symbols should be such
*I and *2 for identification.
Refer to Item (4).
On connectors like this one aiven a
centralized junction identificaiion
symbol (X), refer to CENTRALIZED
JUNCTION for connector shaoe. etc.
you to refer
LOCATION
are several
symbols as
I
I
--:*:on
switch
Dome light
A-16X
rr
------------_I-~
----------------e-39
,rw0*~
BRL l ,
l!LEiE
l2 z
Refer to Item (6)
The connector B-39 has two wires identical
color (RL). so they are given identification
symbols l l and 2 in order to distinguish
in
them.
1 TSB Revision
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.-
8-33
(7) indication of shielded cables

A shielded cable used, for example, in an electronic control circuit for prevention of malfunctions
that
may otherwise -----be caused by radio interference
is indicated by a solid line sandwiched
between
dashed lines (-=I.
(8) Indication of specification-dependent
connectors
With regard to harness connectors,
the inter-device
and harness connectors
which vary in shape or
position on different vehicle specifications,
such as those with rear wipers and turbocharger
and those
without turbocharger,
are given a specificationdependent
connector identification
symbol (lower case
alphabet) following the connector symbol.
Example:
A-Ola
T
Specification
- dependent
a : Vehicles with auto-cruise control
b : Vehicles without auto-cruise control
c : Vehicles with a power window
d : Vehicles without a power window
(9) Shapes of connectors

The connector shapes are indicated by simplified symbolic marks.
female connectors,
refer to HOW TO DENTIP/
CONNECTORS.
For distinction
symbol
between
male and
Refer to Item (8)

The b at the end of the connector
symbol is a specification-dependent
symbol and
indicates that the connector is used
for vehicles without auto-cruise
control.
TSB Revision
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8-34

IDENTIFYING CONNECTORS
Position of guide to prevent
improper connection
I
g-wire
connector
1680219
In circuit diagrams, the connectors

are indicated by symbolic
marks which show the number of their wires and whether
they are male or female connectors.
(I) Number of connector wires
The number of divisions in the connector
diagram indicates the number of wires. A cross in a division, however, indicates- the position of a guide to prevent improper
connection.
The connector
shown here, therefore,
is a
g-wire connector.
(2) Identification
of male and female connectors
Connectors
drawn with double outer lines are male, and
those with single outer lines are female.
Male terminal
On-vehicle
B
Female terminal
connector
Connector in
wiring diagram
(3) Connector direction

The connector
marks show on-vehicle
viewed from the direction shown here.
connectors
as
(4) Identification
of connector terminals
The color codes of a -pair of connectors
(male and
female), if viewed at their joining surfaces, will appear
symmetrical
as illustrated here. When the connectors are
connected,
their joining surfaces are put together in the
way a book is closed so the terminals of identical codes
are connected
together.
NOTE
The color codes of male and female connectors
are not
always identical.
1@~~co,or
I
/ code
Guide to prevent
connection
Dgs
indicate male.
(5) Identification
of sealed connectors
Identification
of round, sealed connectors (water-proof
pin
terminal connectors)
used in radiator fan motor circuits,
turbo circuits, etc. is accomplished
by the same method
as described above.
improper
NumberS?ions
indicates number
of wires
http://vnx.su/
8-35

SYMBOLIC MARKS
Various
equipment
Battery
is indicated
symbolically
Body ground
-
in circuit diagrams
Single hub
as shown
below.
Diode
Resistor
Capacitor
1
El
Fuse
Kso
Equipment
Fusible link
Motor
ground
ariai
Speaker
resik&r
Coil
*
Zener dii
Transistor
WRE COLOR CODES

Wire colors are identified
by the following
color codes.
Example: 1.25 - GB
Zode 1
L
G:
F
(1)
(2)
B:
I Code /
Wire color
LI
Light blue
Orange
Black
Br
Brown
~G
Green
Pink
Gr
Grav
Red
Blue
kl
Light green
1.25: Wire size (mm)

F: Flexible wire
T: Twisted wire
Wire color
Yellow
1 w
White
NOTE
If a cable has two colors the first of the two color code characters
indicates the basic color (color of the cable coating) and the second
indicates the marking color.
No code indicates 0.5 mm

LOO08 in?).
Cable color code in patantheses
indicates 0.3 mm2 LOO05 in.).
TSB
Revision
http://vnx.su/
I
I
8-36
WIRING HARNESS - Overall Wiring Diagram
OVERALL WIRING DIAGRAM

<2.6L Engine>
Roof wiring
Center aanel wirina
shows the main wining
Frame wirin8
harness
4WD indicator
Remark
This diagram
harness
wiring
Back door wiring

/
I wiring
harness
Frame wiring
harness
harness
harness
harness
<3.OL Engine>
P-door vehicles
Roof wiring
ymess
Center pane wiring h*harness

A
\
\ Battery cable (+) //
\
Back door wiring
A
Front wiring
harness
harness
/
te
/
\ \/
hamess
Transmission
Door wiring
4WD indicatdr
Remark
This diagram
-
shows the main wiring
wiring
harness
harnesses.
: TSB Revision http://vnx.su/
harness
wiring
harness
(L.H.)
.~
WIRING
HARNESS
8-37
- Overall Wiring Diagram
~3.01 Engine>
4-door vehicles
Licence
Roof wiring harness

(Vehicles with a sunroof)
Control
wiring
Roof wiring harness

(Vehicle? not equipped
with a sunroof)
Back door wiring
plate
harness
I
hames
amess
Rear door wiring
ion wiring
Engine control wiri

4WD Indicator
wiring
harness
Remarks
(I) This diagram shows the main wiring harnesses.
(2) The dotted line (....) is applicable to models equipped
with the dual air conditioner system.
TSB Revision
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harness
harness
wiring
harness
(L.H.)
lSW16SO
WRING HARNESS - Engine Compartment
ENGINE COMPARTMENT
<2.6L Engine>
A-02
A-03
A-52
t-0; Main fusible link
A.03}4WD
indicator switch
$$}
Back-up light switch
A-06 Pulse generator
A-07 4WD indicator wiring harness and
transmission wirina harness
combination
A-08 Air conditioner solenoid valve
A-09 Front wiper motor
i:jy] Starter
A-12 Engine coolant temperature
gauge
unit
A-l 3 Checker
A-14 Brake fluid level sensor
A-l 5 Front wiring harness and fusible
link combination
c2.6L Engine>
A-51
A-l 6 Front wiring harness and 4WD

indicator wiring harness
combination
A-17 Front wiring harness and fusible
link combination
iI:i)Sub
fusible link
A-26 Carburetor assembly
A-21 Control wiring harness and air
conditioner
wiringharness
combination
A-22 Front wiring harness and control
winno harness combination
A-23 Devi& box
A-24 Auto choke relay
A-25 Front wiring harness and air
conditioner wiring tiamess
combination
1 TSB Revision
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A-26 Condenser fan motor relay

A-27 Headlight washer motor
A-28 Front combination
fight (L.H.1
i$}Light
control relay
A-31 Dedicated fuse (Upper beam
indicator circuit)
A32 Headlight (L.H.)
A-33 Condenser fan motor
A-541
839
WIRING HARNESS - Engine Compartment <2.6L Engine>
A-38
ig
Ignition coil
A-41 I
A-42 Magnetic clutch
Alternator
E.2
A45 Engine coolant temperature
A-48 Engine coolant temperature
circuit)
A-47 Oil pressure gauge unit
flt$
Oxygen sensor
Asr,} Low pressure switch
A37
A-35
sensor
switch
A-51
A-52
AS3
A-54
Headlight (R.H.)
Front wiring harness and air conditioner
Front combination
light (R.H.)
Front washer motor
wiring
harness
(FBC circuit)
(Air conditioner
Remarks
(1) The mark * shows the reference mounting position of
wiring harness.
(2) For information concerning the ground points (example:
0). refer to P.8-12.
1 TSB Revision
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840
WIRING HARNESS - Engine Compartment
ENGINE COMPARTMENT
<3.OL Engine>
Pc
z-v
E3-06
-r\
<3.OL Engine>
B-07
\
B-T2
B-:0
By3
\
B-09 \
B-l,\
\
i-s\-,
B-115
%:
0-;17
1 B-1? 1
I I
B-04
\
E-03
B-02 I
\\\
\I
B-01
\
B-01
uF
Front wiring harness and battery

cable (+) combination
Ei}Altemator
B-04 Noise condenser
LC filter
El
B-07 Idle speed control motor
B-08 Throttle position sensor
B-09 Distributor signal generator
B-10 Front wiring harness and engine
control wirino harness combination
B-11 Power transtitor
B-12 Engine coolant temperature,switch
B-,3 (Overdrive control system crrcult)
B-,4 14WD indicator switch
B-15 EGR temperature
sensor
<California>
B-16 I nition coil
B-17 8 D-OFF solenoid
B-62
~~~-
B-18 Pulse generator

B-19 Oxygen sensor
B-20 4WD indicator wiring harness and
transmission wiring harness
combination
B-21 Back-up light switch (Vehicles with
a manual transmission)
4WD indicator wiring harness and
automatic transmission wiring
harness combination
(Vehicles with
an automatic transmission)
B-22 Front wiper motor
B-23 Control wiring harness and fusible
B-24 I link
B-25 Checker
526 Brake fluid level sensor
http://vnx.su/
B-5i 1
550
B-4
B-27 Diode
B-28 Front washer motor
B-29 Control wiring harness and 4WD
oombination
B-30 Front wiring harness and 4WD
combination
B-31 Pu e control solenoid valve
B-32 EG# control solenoid valve
B-33 Magnetic clutch
B-34 Actuator
B-35 Front wiring harness and air
conditioner
wirino.-= harness
c;&bikati;n---..-...--B-36 Headli ht washer
B-37 Auto c7 oke relay
motor
841
WIRING HARNESS - Engine Compartment <3.OL Engine>
B-19
B-18
B-21
B-20
/B-22
B;23
3;25
-B-38
-B-39
BS91
f33yjlnjector
B-38
Dedicated fuse (Upper beam

indicator circuit)
B-39 Front combination
light (L.H.)
i$}
Light control relay
B42 Headlight (L.H.)
B-43 Condenser fan motor or air
conditioner wiring harness and
air conditioner
wiring harness
combination
E
646 Hom
8-47 /
848 Condenser
649
55:
B-82 Headlight (R.H.1

B-83 Fmnt combination
light (R.H.)
B-84 Front wiring harness and air
conditioner wiring harness
combination
Eg} Low pressure switch
B-87 Fmnt wiring harness and control
B-88 I wiring harness combination
B-89 Power steering oil pressure switch
B-70 Air flow s(enso?
i:$}Sub
fusiblme link
B-73 Condense r fan motor (Dual air
conditioner)
B-74 Sub condenser
fan motor (Dual air
conditioner)
Injector
B-52 Engine coolant temperature

gauge
unit
B-53 Engine coolant temperature
switch
(Overdrive control system circuit)
sensor
B-54 Engine 1coolant temperature
(MPI circuit)
865 Engine coolant temperature
switch
(Air conditioner circuit)
Bemarks
B-56 Oil pressure gauge unit (1) The mark * shows the reference
iz,} Sta tier

?\
\L,
fan motor relay

1 TSB
mounting
position
of
wiring harness.
Revision
http://vnx.su/
For information concerning

0). refer to P.814.
the ground
points (example
._
-i
8-42
WIRING
HARNESS
- instrument
Panel
INSTRUMENT PANEL
c-91
031
C-02
C-03
C-04
C9:
E13
Defog erswitch
Back 8 oor lock switch
Key reminder and seat belt
warning buzzer
I
Combination
Voltage meter
C-17 Heater control
C-18 %$er
switch
C-19 Air conditioner
meter
c-u)
C-97 Diode
C-08 Hazard switch
C-09 Rear wiper and washer switch
~~~}Oil
pressure gauge
C-l 2 fihTbination
gauge illumination
C-21
C-22
C-23
C-24
C-l 3 Combination gauge wiring harness

and front wiring harness
combination
C-14 Combination gauge illumination
light
Remarks
For information
refer to P.813,
concerning
15.
c-02
the ground
points
TSR
c-04
C-05
switch
--,
illumination
.,
(examplem).
Rtavisinn
http://vnx.su/
C-06
C-07
C-08
GO9
-E$}Thermostat
C-28 Self-diagnosis
check connector
C-29 Front wrring harness and roof
wiring harness combination
C-30 Automatic free-wheeling
hub
indicator control unit
C-31 Front wiring harness and control
~ C-32 Defogger timer unit
c-33 OPOFF relay
Intermittent
rear wiper relay
Ei )Fmnt wiring harness and door
C-36 wiring harness (R.H.) combination
c-37 MPI control relay
C-38 Auto-cruise control unit
knob illumination
$jhtower switch (Air conditioner

circuit)
Heater relay
Air conditioner wiring harness and
front wiring harness combination
Air conditioner
relay A
Dedicated fuse (Air conditioner
rim
circuit)tit\
Air conditioner
relay B
C-25
C-03
WRING HARNESS - instrument

G12
8-43
Panel
c-14
28
/
C-38
c-85

or MPI control unit
C-42 Fuel pump drive tem+nal
G43 Blower motor resistor
G44 Front speaker (R.H.)
C-45 Air conditioner
switch
G46 Clock
C-47 Heater control panel illumination
G48 g:tray
illumination
light
C-49 Spare terminal C&C)
p5:
Cigarette lighter rllumrnation
CS2}Qgarette
lighter
light
Shift position
illumination
C66
C-57
C-58
G59
C-60
C-61
G62
Inhibitor switch
OD-OFF switch
Door lock control relay
Door lock power relay
Parking brake switch
Seat belt switch
Front wiring harness and center
panel wiring harness combination
zz}Column
switch
C-65 Column switch (Auto-cruise system
circuit)
g;
p$~m~y-ctch
C-68 Stop light switch/Brake
C-59 Clutch switch
$$}Radio
G55
c-84
switch
SW650
C-73
C-74
C-75
C-76
C-77
C-78
C-79
C80
Cal
C82
C83
C-84
G85
wiring harness and door

harness (L.H.) combination
Turn-signal flasher unit
Power window relay
Intermittent wiper relay
Hazard flasher unit
Headlight washer motor relay
Seat belt warning timer
Front speaker (L.H.)
Dimmer cantml switch
Dedicated fuse (Central locking
system circuit)
Dedicated fuse (Sunroof circuit)
Front wiring harness and roof
(Sunroof circuit)
Dedicated fuse (Dual air
conditioner circuit)
Front wiring harness and air
conditioner wiring harness
light
combination
circuit)
TSB Revision
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(Dual air conditioner
-~~-
e-Ef
8-44
WIRING HARNESS - Interior
and Frame <4-door
Vehicles>
INTERIOR AND FRAME

<4-door Vehicles >
ET :I
Yr-g;:
g.giiEf~
EL--
D-01
D-02
D-03
D-04
E-0;
Power window motor

Power window sub switch
Door lock actuator
Dome light
Door swatch (R.H.)
Dq7}Rear
speaker (R.H.)
D-08 Defogger (-)
D-09 Defogger (t)
D-l 0 Rear wiper motor
D-l 1 Back door wiring harness and license plate light
D-12 Back door wiring harness and defogger cable (+)
combination
D-13 Rear washer motor
D-14 Rear side marker Ught (R.H.)
D-15 Frame wiring harness and back door wiring harness
D-1 6)combination
D-17 Rear combination
light (R.H.)
~~~}License
plate light (R.H.)
k$y}License
plate light (L.H.)
D-22 Back door lock actuator
D-23 Rear side marker light (L.H.)
D-24 Fuel pump (MPI)
light (L.H.)
D-26 Fuel gauge unit
Egi Front wiring harness and frame wrring
combination
D-29 I
E$}Rear
speaker
harness
(L.H.)
E:sg}Door switch (L.H.)

D-34 Door lock actuator
D-35 Power window control relay
D-36 Power window main switch
D-37 Power window motor
D-38 Sunroof power relay
D-39 Dome light <Vehicles with the sunroof>
D-40 Sunroof motor
D-41 Roof wiring harness and sunroof wiring harness
combination
I TSRRmh&m
D-42 Sunroof switch

D-43 Sunroof control relay
D-44 Front wiring harness and rear door wiring harness
D-45 1(R.H.) combination
D-46 Power window sub switch
D-49 Dome light (rear)
D-!?O Door switch-(rear
R.H.)
DSl Frame wirins harness and side wiiing harness (R.H.1
combination
http://vnx.su/
_;
8-45
WRING HARNESS - Interior and Frame CCdoor Vehicles>
D-17
D-63
1 D-61 1
D-62
D-60
D-54
D-53
\
\D-22
D-25
D-23
36w343
;:g
D-29
D-52 Rear evaporator assembly

D-53 Frame wiring harness and side wiring harness (L.H.1
combination
D-54 Frame wiring harness and rear washer wirin
harness combination
<Vehicles
with the %ual air
conditioneo
D-55 Rear washer motor <Vehicles with the dual air
conditioneo
D-56 & conditioner
relay D (Dual air conditioner circuit)
D-57 Air conditioner relay E (Dual air conditioner circuit1
D-58 Frame wiring harness and air conditioner wiring
harness combination
D-59 Door switch (rear L.H.)
TSB Revision

D-61 Blower switch (Dual air conditioner circuit)
D-63 Power window sub switch
D-641Front wirina harness and rear door wiring harness
D-65 [(L.H.) com&ation
Remark
The mark * shows the reference
wiring harness.
http://vnx.su/
mounting
position of
846
WIRING HARNESS - Interior
and Frame <Z-door
Vehicles>
INTERIOR AND FRAME

<2-door Vehicles>
D-01
D-02
D-03
D-04
fg
po7)
D-08
D-09
D-10
D-l 1
Power window motor

Power window sub switch
Door lock actuator
Dome light
Door swatch (R.H.1
Rear speaker (R.H.)
Defogger (-1
Defogger (+)
Rear wiper motor
Back door wiring harness and license plate light wiring
harness combination
D-12 Back door wiring harness and defogger cable (+)
combination
D-13 Rear washer motor
D-14 Rear side marker light (R.H.)
D-15 Frame wiring harness and back door wiring harness
D-l 61 combination
light (R.H.)
ki,}License
plate light (R.H.)
ksy}License
O-22 Back door lock actuator

D-23 Rear side marker liaht (L.H.1
D-24 Fuel pump (MPI) and frame wiring
kzy}Rear
Remark
c;zs;k
speaker
(L.H.)
* shows the reference
plate light (L.H.)
I TSE
Ravisian
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harness
mounting
position
of wiring
8-47
WRING HARNESS - Starting Circuit
1 STARTING CIRCUIT
<Vehicles
with
a Manual Transmission>
Ignition switch
pin
fusible
Battery
Sub fusible link
Starter
Remark
(1) Lines and connectors indicated by the * symbol are
applicable to the 2.6-liter models.
is applicable to the 3X-liter
models only.
(3) For information
0). refer to PI?-12, 14.
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
L: Blue
Y: Yellow
G: Green
P: Pink
1 TSB Revision
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8-48
WRING HARNESS - Starting Circuit
<Vehicles with an Automatic
Transmission>
Id
Sub fusible
(IGN. SW)
0-72
0.85-R
5-wm5-w
I1-1
link
ignition
switch
fsmw
I
-
B-71
Main fusible
Inhibitor
switch
Starter
37W666
Remark
refer to P.&l 4.
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
the ground
points (example:
G: Green
P: Pink
q ),
L: Blue
Y: Yellow
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WRING
HARNESS
8-49
- Ignition Circuit
2 IGNITION CIRCUIT
<26L
Engine>
Ignition switch
/T-Y
C-66
To !eed back rzzzi~

camuretor
control unit
[Refer to P.8-621
Capacitor
Ignition
q am
coil
(g 88
67W67-2
Remark
For information
concerning
refer to P.&l 2.
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
the ground
points (example:
G: Green
P: Pink
II),
Gr: Gray
R: Red
[ TSB Revision
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L: Blue
Y: Yellow
Lg: Light green
W: White
8-50
WIRING
HARNESS
- Ignition
Circuit
<3.OL Engine>
Ignition
switch
OFF
C-66
Main.
fuslote
To multipurpose
fuse e3-BW
To combination
meter
PTACHO)
[Refer to P.8-821
lB+
e
-~ ;
&
Power
transistor
c
I
Distributor
a
H
0
Ignition
coil
F%ilEl
MJ
Capacitor
@
Remark
For information
concerning the ground point (example: q ),
refer to P.8-14.
Fr$cFlor
code
Br: Brown
G: Green
;;:,:y
LI: Light blue
0: Orange
P: Pink
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L: Blue
Y: Yellow
LC filter
m
I!3
Lg: Light green

W: White
s,we*s
WIRING
HARNESS
Charging
8-51
Circuit
3 CHARGING CIRCUIT
Ignition
?k
switch
IG
Z-BW
--
To light
22
h
Alternator
..
Multi-
WB c3.OL Engine onlv>
RL I w I I I
.
I I I I I I I I
Choke relay
Combination
meter
Remark
and connectors indicated by the
* sympol are applicable to the 2.~liter models
(2) z;,cha[n
lme (- - -) IS applicable to 3.0-liter models
(3)

0). refer to P.8-12, 14.
Wiring color code

B: Black
Br: Brown
LI: tight blue
0: Orange
$,y
P: Pink
1 TSB Revision
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Auto choke relay

l-+-l
37w71a
G: Green
L: Blue
Y: Yellow
8-52
WIRING
HARNESS
- Feed Back Carburetor
Circuit
4 FEED BACK CARBURETOR CIRCUIT

Main
fusible
!4
Sub fusible
link
Ignition
switch
15-w
OFF
S:
A-19
CC
C-66
2BRE
2IRL )
2-BW
To alternator
[Refer to P.&51 .I *
o*85-w
To multi-purpose
fuse 4
I
cu
A-24
Feed back
solenoid valve
Slow cut
solenoid valve
hrottle positior
snsor
.G
YR
.GY
Carburetor
assembly
(I)
For ~~en.$io.oyceming
PI F- e symbols
the ground
points
(example:
0, @ etc. indicate that the wiring is

connected (using the same numerical symbol) to the
facing page. (In other words, Q) on the right page is
connected to @ On the left page.)
1 TSB Revision
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WIRING
lgnitior I coil
q
*&2-BW
El
HARNESS
2P
ctics
*~
8-53
- Feed Back Carburetor Circuit
z
4,
To vacuum
solenoid
valve [Refer to P.8104.1
A-3
Feed back
carburetor
control unit
I I I 4
1 Vacuum
switch
1
Device
box
control solenoid
sensor
sensor
1 TSB Revision
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8-54
WIRING HARNESS - Layout of Components
LAYOUT OF COMPONENTS
(F.B.C.)
Items
I Auto choke relay

I Engine coolant temperature
Symbol
Items
I Secondary
sensor
I Slow-cut solenoid valve
1 Engine speed sensor (Ignition coil)
I
I Feed back solenoid
1 Oxygen sensor
valve
(F.B.C.)
/ TSB Revision
air control solenoid valve

(for the air conditioner)
I c I Throttle
1
Symbol
position sensor
1 Vacuum switch
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A
1
-1
E
F
WIRING HARNESS - Layout of Components (F.B.C.)
Throttle posiiion
sensor TTPS)
SFUl
) TSB Revision
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8-55
8-56
WIRING HARNESS - M.P.I. Circuit
5 M.P.I. CIRCUIT
Main fusible link
1
83
[Refer to P.8-47.48.1
Combination
meter
1 TSB Revision
Air flow
s*nsor
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WIRING HARNESS - Overdrive Control System Circuit
Inhibitor
switch
Diode
Engine coolant
teFp?rature
II-i&
OD-OFF
relay
B-27
-iarm-rm
RL
011
(p
&
YR
(Lg)
I
1
To back-up light
[Refer to P.8-88.1
I
I
OD-OFF
solenoid
oil temperature
switch
OD-OFF
switch
@jig
InC
37w683
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
L: Blue
Y: Yellow
1 TSB Revision
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Lg: tight green

W: White
8-62
WIRING
7 AUTO-CRUISE
HARNESS
- Auto-Cruise
Control System Circuit
CONTROL SYSTEM ClRClJlT

Sub fusible
ignition
switch
link
IN
ACC
Stoplightswitch,
brake switch
To inhibitor switch
[Refer to P8-48.1
(AJTj
To starter relay (M/T)

[Refer to P.847.1
0.85-G
To hazard switch
[Refer to P.S.72.1 e
z
1
To over drive relay
[Refer to P&60.]
Remarks
(1) For details on the ground point (No. q in the illustration).
refer to P.&14.
(2) In the illustration, the numbered wiring on the right hand
paae corresponds
to the numberina on the left hand
hand page corresponds
Wire color code
B: Black
Br: Brown
G: Green
P: Pink
1.85-RL
to @ on the left
g;:,t;y
L: Blue
Y: Yellow
Lg: Light green

W: White
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To turn si nal flasher

[Refer to 8 .8-72.1
unit
8-63
WIRING HARNESS - Auto-Cruise Control System Circuit
(Reed switch)
BY
B
Self-diagnosis
check
To automatic
free-wheeling
hub
indicator control
unit
[Refer to P.8-85.1
BLBgGY
l-l
l 1
) TSB Revision
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8-64
WIRING HARNESS - Headlight Circuit
8 HEADLIGHT CIRCUIT
Engine>
Sub fusible
link
/yl$n fusible
,
Dâ&^-,
Ignition
switch
- . . , , I ..
u
A-18
I
I
I
m
B
*I *
Combination
meter
Aa,
Dedicated
r
I
2-Bqlm
fuse
A-51
Light control
relay
-1
Lighting
switch
Dimmer
switch
Passing
switch-
nnlnn
(L.H.)
Headlight
Remark
For information
concerning
the ground
points
(example:
81, refer to P.812.
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14.
(R.H.)
37W660
8-65
WIRING HARNESS ,: Headlight Circuit
<3.OL Engine>
pkin
fusible
Ignition
switch
l-w
2-Wn3-W
u
B-71
2-Bq,lfJij
g
I-
2-L
m rii.
I
I2-L
2-B4,10
l,p2-B
w To
c multi-oumose
mc
fuse r-.C
2-Bc#,~
IRI
83
l1.25-y
4b
-_
Light control
relay
Lighting
switch
DirXrtTher Passin!
switch
Column
LI: Light blue
fuse
w
geTeination
pizcrlor
B-38
Dedicated
switch
code
Br: Brown
0: Orange
G: Green
P: Pink
$gY
1 TSB Revision
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L: Blue
Y: Yellow
Headlight
,,,a,
-;n__-*,
--
__I
~~
i
-~
I:
8-66
WIRING HARNESS
Tail Light, Position

Ucense slate tigti
Light. Rear Side Marker

and Back-Up
tight circuit
Light,
<2.6L Engine>
Sub fusible link
OFF
cc
To radio
(Refer to PB-90.1
[Refer to P.8-70.1
GW
SL
I-
I
-t
.co
(GW)
a e .o
ii:%
f
A-16
A-07
Back-up
switch
Wiring color code

8: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
Gr: Gray
R: Red
L: Blue
Y: Yellow
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light
Lg: Light green

W: White
WRING HARNESS-
Column
Position tight, Rear Side Marker tight,

ticense Plate tight and Back-UpUght circuit
Tail tight
8-67
switch
Liaht control
relav
License
plate
light
F-GW nGW
F-B 1 IB
u
D-11
gg
(GWL-JGW)
;L
IRG)
El
RG
D-29
,c4c
Tail light
combination
Rear side
marker light
(L.H.)
D-23
srwesz
( TSB Revision
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CZI
m
-= ffi.i.
:pp
8-68
q:u
_ P
,~~
,._
WIRING HARNESS
Tail tight,
Position
ticense
plate tight
Light, Rear
and Back-Up
Side Marker
Light ~ircuti
Light,
<3.OL Engine>
Sub fusible
link
Ignition
switch
OFF
cc
To radio
[Refer to PB-92.1
To turn-signal
flasher unit
[Refer to P.6-72.1
GW
G
a
cz
24
%
T
I
I
I
I
I
1
1
)
It
GWh
-66
Position
light
Inhibitor
switch
r--r
Ba&p
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
ID\
D-@
B-63
B-211
l
0.85RL
G: Green
P: Pink
1 TSB Revision
L: Blue
Y: Yellow
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light
Lg: Light green

V$ White
WIRING HARNESS
Column
Tail tight,
Pasition
license
plate tight
light
Rear Side Marker
snd Sack-Up
tight cir~ti
Light,
8-69
switch
c-33
I I
A
(3
l-l
D-11
U-H.)
D-21
Tail light
Back-up
light
License
elate
iight
Rear
combination
#!z.,
ReeLI
%zl
Back-up
light
Tail light
Rear
combination
$!E.,
Remarks
(1) The broken lines are applicable to models equipped with
an automatic transmission.
refer to P.&14.
(3) R e symbols 0, Q etc. indicate that the wiring is
facing page.
on the left page.)
1 TSB Revision
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! WTaiI
light
.
37W881
El
!zl
8-70
WIRING
HARNESS
10 TURN-SIGNAL
t2.6L
- Turn-Signal
and Hazard Light Circuit
AND HAZARD LIGHT CIRCUIT
Engine>
ignition
switch
Light
control
relay
To radio
[Refer to P.8-92.1
Turn-signal
and
I-----
km-s&y&end
car nbination
combination
Front
combination
light 1R.H.)
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meter
WRING HARNESS - Turn-Signal and Hazard Light Circuit

M
0 en
Hazard switch
I
Haz?rd
Turn-signal
unit
I
switch
-73
-76
c-64
--
I 1I
IA
.
-1
(BY)
!
, , ,
Rear Combination
light (R.H.)
light
Dimmer
switch
control
GL
GLIB
D-2
~r$jc$lor
LI: Light blue
code
Br: Brown
0: Orange
G: Green
P: Pink
Remarks
.
,-. ~
I I) For lntormatlon concernin
tne ground
(example: 0). refer to P. # -12.
(2) The symbols 0, Q, etc. indicate that
connected (uslng the same numerical
facing page.
(In other words, 0 on the right page
h c. +&.n lnft non,3 \
1: Blue
Y: Yellow
/ TSB Revision
Rear combination
light (L.H.)
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Lg: Light green

W: White
points
tbe wiring is
symbol) to tht
is connected
tl
<3.OL Engine>
Sub fusible
B-72
5-w
3-R
I
Main
fusible link
I
CL
link
0.85-R
5-w-5-w
u
EEEI
3-w
I1-1
ignition
aw
swKch
I!Y
Light
control
relay
Multi-purpose
fuse
To radio
[Refer to P.8-92.1
-GW
-04
B-63
I
I
bb
Al 1
Turn-signal and
hazard light
Front
combination
light (L.H.)
Turn-signal
I.--- d,. I. and
nazam agnr
Combination
._
I I I w
m
Front
combination
light (R.H.)
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meter
I I 0 I si
WIRING
HARNESS
- Turn-Signal
and Hazard Light Circuit
Hazard switch
I
I
Turn-signal
rZ
I
switch
I
I
I
II
Illll
I I I
WR-
Turn-signal
and hazard light
*I
Rear Combination
light (R.H.)
B _
Rear combination
light (L.H.)
nemarks
(example:
J refer to P.8-14.
(2) The symbo P-s 0, Q, etc. indicate thatthe wiring is
facing page.
(In other words, 0 on the right page is connected to
@ on the left page.)
~in&olor
LI: Light blue
code
Br: Brown
0: Orange
G: Green
P: Pink
L: Blue
Y: Yellow
ggy
/ TSB Revision
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37W686
WIRING HARNESS - Stop Light Circuit
11 STOP LIGHT CIRCUIT

<2.6L Engine>
Multi-purpose
fuse 1
C-08
------jh
1 I
0.85-G
Hazard
switch
~I@*-"
0.85-WG
Tumsignal
switch
Remark
For information
refer to PS-12,
concerning
14.
Wiring color code

B: Black
Br: Brown
11: Light blue
0: Orange
the ground
points (example:
G: Green
P: Pink
Stop light
Stop light
Rear combination
light (L.H.)
Rear combination
light (R.H.)
Q).
L: Blue
Y: Yellow
http://vnx.su/
a-75
WIRING HARNESS - Stop Light Circuit
*1
+2
<3.OL Engine>
Sub fusible
link
B-88
3-w-3-w
l-l
C-88b
E
(I
Multi-purpose
yi
I IT
G88a
fuse
I17
QQ
C-08
I
-0.85-G
Efl1p-B
Hazard
switch
/0.85-WG
I r
II
;;0.85-WG
I IWR
I 11.11
,I
ml ml
I I
I LJ.
Tumsignal
switch
Stop light
Stoplight
Rear combination
light (L.H.)
Rear combination
light (R.H.)
37W676
1 TSB Revision
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8-76
WRING HARNESS - Instrument
12 INSTRUMENT
Panel
PANEL ILLUMINATION
<2.6L Engine>
hminatipn
Circuit
CIRCUIT
Sub fusible link
fusible
link
Optical fiber
GW
I I
II
r
I
To radio
[Refer to P.8-90.1
II
G
Lsl!!l
I
Rear
Fwf;gJer
illumination
C-06
Lighting
switch
-46
Ashtray
illumination
liaht
Cigarette
liohter
ilGmination
Heater control 13
Clock
illumination
illumination
light
-g& ight& &
f-g-J
Dimmzl
combination
illi lmination
light
I I St5 newton
http://vnx.su/
meter
light
,&I
_ qg$
Remarks
(1) The broken lines are applicable to models equipped with an automatic transmission.
(2) For information concerning the ground points (example: 0). refer to P.8-12, 14.
switch
57W677
8-77
WIRING HARNESS - Instrument Panel Illumination Circuit
<3.OL Engine>
fusible
fink
Optical
fiber
I
IAL
contml knob
illumination light
Heater
control
knob
io
to P.8-92.1
Lb
Din Irnx
Combination
meter
illumination light
light
Wiring
illumination
light
color code
B: Black
LI: tight
illumination light
light
Br: Brown
blue
L: Blue
Y: Yellow
0: Orange
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switch
WIRING HARNESS - Dome Light Circuit
13 DOME LIGHT CIRCUIT

<tdoor
Vehicles>
PI
t-4
1
To light control
$f?er
Combination
meter
Dome
light
(L.H.)
(R.H.)
Door switch
Remarks
and fusible link indicated
%ssymbol are appkcable to M-liter
2.tNiter models.
(2) Tim;d;Fn
Tim;d;k? line (- - - - -) is applicable to 3.0-liter
by the
(3) Chain lines (-;-(---) and lines indicated by the Q

symbol are applicable to models equipped with the sun
;yoyboI
roof.
.--..
a). refer to P.572. 14.
Wiring color code
Br: Brown
B: Black
LI: Light blue
0: Orange
G: Green
P: Pink
http://vnx.su/
37W7!24
to P.8-54, 65
WRING HARNESS - Dome Light Circuit
al-door
Vehicles>
R
El
Main
13-R
B-m
3-Rn3-R
I
1.25-GB
To hazard
flasher unit
[Refer to P.S-70, 72.1
RGn
D-32
Front
door
switch
El
RG
(R.H.)
E:
switch
Front dome
light
(models not
equipped
with
Front dome light

(models equipped
with the sunroof)
D-49
To sunroof switch
[Refer to P.8113.]
37W662
/ TSB
Revision
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8-80
WRING
HARNESS
- Meter Circuit
14 METER CIRCUIT
ignition
Battery
switch
Main fusible
link
Sub fusible link
Multi-purpose
5

timer
[Refer to P.6-64.1
Toalternator [Referto P.851.1
3 dimmer, passitig.
Nitch and light control
!lay [Refer to P.6-64.1
To
door L^switch
rD^T^n n -,n 1
Combination
http://vnx.su/
meter
fuse
8-81
WIRING HARNESS - Meter Circuit
Wiring color code

0: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
L: Blue
Y: Yellow
Eli
Oil pressure
gauge unit
El
4WD
indicator
switch
El
,r,\
I
I
-1
,
t
dl
, _
IT
A-14
,.OF0)
Parkh;g brake
ypgy
1
BI
IB
Fuel gauge
unit
&
Engine coolant
temperature
gauge unit
I3
iii
For information concerning the ground points

(example:
) refer to PS-12.
(2) The symbo $*s 0, Q, etc. indicate that the wiring
is connected (usina the same numerical svmboll
to the facing page(In other words, @) on the right page is
,
l!h!z!J
C-l 4
Combinati on gauge
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8-82
WIRING
HARNESS
- Meter Circuit
<3.OL Engine>
Sub fusible
El33
link
Ignition
B-68
nw
switch
OFF
ACC
3
CA
3-R m3-R
u
&!I
Al
N B-71

[Refer to P&65.]
Multi-purpose
fuse
To turn-signal switch
[Refer to P.872.1
timer [Refer to P.8-641
buzzer [Refer to P.
To alternator
[Refer to P.8-51
o dimmer. oassina
witch and-light co>tl
clay [Refer to P.8-65.1
To dome liaht
[Refer to P&78.1
To door switch
[Refer to P.878.17
1111
I,
I I
Urii
III
II
II
Ill
I I I
II
I 1
II
II
I
I
iii
ii
II
1 TSB Revision
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Ii
I T)c
,I,1 .lLzP,
D
I I ,a,-@
I
ILYIC@
) IWL/B
I I VI *kh
WlRlNG
HARNESS
8-83
- Meter Circuit
g$y
L: Blue
Y: Yellow
Wiring color code

B: Black
Br: Brown
0: Orange
LI: Light blue
Oil pressure
gauge unit
Lg: Light green

W: White
G: Green
P: Pink
El
switch
IFI
Engine coolant
temperature
gauge unit
Ei
M.P.I%&unit
Combination
gauge
TSB Revision
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Remarks
1). refer to P.8-14.
i 0, Q, etc. indicate that the wiring
lected (using the same numerical symbol)
Facing page.
I
(In otht x words,-@ on the right page is
connec :ted to @ on the left page.1
8-84
WIRING HARNESS - Buzzer Circuit
15 BUZZER CIRCUIT
Sub fusible link
To light control relay d

[Refer to P.6-64. 65.1
Ignition
12 - R
3-R

1.25-GB
[Refer to P.670. 72.1 4
Key reminder
switch
Front door
switch (L.H.)
-04
switch
Key reminder
and seat belt
warning buzzer
Seat belt
warning timer
RLL
B RB
ED
Remarks
(I) Broken lines and lines indicated by the x( symbol are
aonlicable to the 2.6liter models.
(2) The chain line f- - - - -) is applicable to 30litermodels.
gJ), refer to P.B-12. 14.
Wiring color code
Br: Brown
B: Black
LI: Light blue
0: Orange
G: Green
P: Pink
I TSB Revision
L: Blue
Y: Yellow
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Lg: Light green

W: White
switch
WRING HARNESS - Automatic Free-Wheeling Hub Indicator System Circuit 8-85
16 AUTOMATIC
CIRCUIT
FREE-WHEELING HUB INDICATOR SYSTEM
Main fusible
link
Sub fusible link-
0.85-R
11
-1
A-181
- i
[Refer to PB-102,
103.1
indicator control unit
tgnluon swwn
3-w
-1
11
d
I
Liz
d
hub
37W723
Remarks
(1) Lines and connectors indicated by the a symbol are applicable to the 2.8liter models.
concerning the ground points (example: 0). refer to P.S-12, 14.
(2) For information
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
L: Blue
Y: Yellow
G: Green
P: Pink
1 TSB Revision
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Lg: Light green

W: White
17 WIPER AND WASHER CIRCUIT

<2.6L
Light
control
relay
Intermittent
wiper
control
relay
Remarks
(1) For information concernin
the
ground points (example: ii 1, refer 7
to P.8-12,
P
(2) The symbols Q, Q etc. indicate
facing page.
page is connected to @ on the left
page.)
Wiring cotor code
8: Black
Br: Brown
G: Green
P: Pink
Headlight
-washer motor
L L.
Bl
$:8%y
TSR
L: Blue
Y: Yellow
Ravkinn
Headlight washer
motor relay
Lg: Li ht green
W: W 1 ite
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WIRING
HARNESS
8-87
- Wiper and Washer Circuit
Column switch-
-1
Front wiper switch
Rear wiper and

washer switch
switch
ON
OFF
INT
I
L-
I I
c-63
m-
-09
F-?/q-i
I I I I
I I
k-64
D-l 0
AS4
Intermittent
wiper relay
rear
F-washer
motor
Front wiper
motor
TSB Revision
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L----l-
Rear washer
motor
Rear wiper
motor
8-88
WIRING
HARNESS
- Wiper
and
Washer
Circuit
<3.OL Engine>
L.
I
Hii3
Ignition
Light
control
relay
lemarks
1) The dotted line (....) is applicable to
models equipped with the dual air
conditioner system.
2) For information concernin
the
ground points (example: ii ), refer EL
to P.814.
3) The symbols Q, Q. etc. indicate
c:
facing page.
(In other words, 1 on the right
1
page is connecte 9 to @ on the left
page.)
Niring color code
3: Black
Br: Brown
_I: Light blue 0: Orange
G: Green
P: Pink
;;:Ptry
Headlight
washer motor
L: Blue
Y: Yellow
I TSB Revision
Lg: Light green

W: White
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Headlight washer
motor relay
-.=
switch
8-89
WIRING HARNESS - Wiper and Washer Circuit
Column
---
swit_ch
-1
Front wiper
1 Headlight
1 washer
I switch
switch
I I
:A
flFFim=
Rear wiper and

washer switch
I
I
.I
IFront wasier
HI
ON
OFF
INT
@L
0.85-L
2-B
Intermittent
wiper relay
rear
Front wiper
motor
Frontwasher
motor
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motor
Rear wiper
motor
K
WIRING HARNESS --Radio
/ Cassette Deck Circuit
lanition
Sub fusible link
switch
+-d

[Refer to P&66.]
[Refer to P.&94.1
2-R
It-r
To dimmer control swtch

[Refer to P.6-76.1
DIN Cable
Tape player
1 TSR Revision
Radio
http://vnx.su/
Z-RN
2-R
?i
lA
WIRING
HARNESS
Radio
/ Cassette
,
Deck
(R.H.)
8-91
Circuit
t Front speaker
(L.H.)
El
El
Rear speaker
El
El
37W706
(qTm&?nformation
(*) $f), refer to P.&l 2.
e symbols 0, Q, etc. indicate that the wiring is
facing page.
(In other words, @ on the right page is connected to @)
on the left page.)
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
L: Blue
Y: Yellow
G: Green
P: Pink
1 TSB Revision
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Lg: Light green

W: White
8-92
WRING HARNESS - Radio / Cassette Deck Circuit
C3.01 Engine>
L.
m
Sub fu$ble
Ignition
-
link
If-l

[Refer to P&68.]
. ._-.
.-
_.,
To Clock
[Refer to P.894.1
To dimmer control
[Refer to P.877.1
switch
By
II
DIN Cable
l--l
Tape player
[ T$B Revision
_
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switch
8-93
WIRING HARNESS - Radio / Cassette Deck Circuit
*
BR
B
Front speaker
(L.H.)
El
El
Rear speaker
(2door vehicles)
El
El
YL F
YR
YL
YL m
GrL( (
u
YR
(L.H.)
D-53
Rear speaker
&door vehicles)
D-28
p*fl
(R.H.)
Remarks
(1) For information
refer to P.8-14.
(2) w e symbols (i), Q, etc. indicate that the wiring is
facing page.
(In other words, 0 on the right page is connected to @
on the left page.)
LI: tight
code
blue
Br: Brown
0: Orange
G: Green
P: Pink
El
El
371705
y$cclor
q
El
g;:,pJ
1 TSB Revision
L: Blue
Y: Yellow
http://vnx.su/
$f
gf;eween
WIRING
8-94
19 ClGARElTE
HARNESS
Liahter
/ Clock
Circuit
L.
m,
LIGHTER / CLOCK CIRCUIT

Sub fusible
;I;;
5-w
3:R
Main fusible
link
Ciaarette
5-w r5-biZ
-1 Pi, 3-E
an
Ignition switch
link
AI
3-i'
r-----------
iieGt0
To radio
[Refer to P.590.
..-- - -71
,
-~ 1
i,
- *,,. ,
--.. _.-.relay
P.8-66. 68.1
14
Z-R
12-R
I 1
92.1
c

[Refer to PI?-70, 72.1
L-K
To dome light
[Refer to P.8.78.)
lgarette lighter
jmination fight
To heater control
illumination light
[Refer to P.8-76. 77.1
~~%broken
line I----)
and lines indicated
bv * svmbol are aoolicable
to 2.61iter
.
[Refer to P.8-80. 82.1
niodels:
(2) The chain line (- - - - -) is applicable

3.~liter models.
13) For information concerning the ground
(example: 0). refer to P.812. 14.
Wiring color code
Br: Brown
B: Black
to
points
[Refer to P.&76.1
37W720
G: Green
P: Pink
$:P:zy
L: Blue
y:
Yellow
1 TSB Revision
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$y$-
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WIRING
HARNESS
8-95
- Defogger Circuit
20 DEFOGGER CIRCUIT
. 8.
IilcEl
Sub fusible link
Ignition switch
z;n
fusible
Fusible link
:,:a,
To alternator
[Refer to P.8-51 .I
To light control relay ~
[Refer to P.8-66. 68.1
+lEl
Defogger
2-B
2-BR
%I
El
2F-Bn3-B
m
D-l 2
Z-RW
D-l 5
%I
(BYI
1
I
I I
Dimmer
control
switch
uerogger
umer unn
R I
rZ
cl -tlEE3I w LR
Remarks
and lines indicated by the * symbol are applicable to 2.6liter
(2) The chain line (- - - - -) is applicable to 3.0-liter models.
(3) For information concerning the ground points (example: q ), refer to P.8-12. 14.
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
$,,raY
TSB Revision
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L: Blue
Y: Yellow
models.
Lg: Light green

W: White
8-96
WIRING
21 POWER WINDOW
<bdoor
HARNESS
- Power Window
Circuit
CIRCUIT
Vehicles>
l33w
Ignition
td
Sub fusible
flasher unit
[Refer to P.870.
DOWN
UP
r-=-=-l
UP
link
B.
.~
switch
~~
1.25-B eo
72.1
DOWN
@
6
a9
0
03
I
l.XF-S
1.25F-G/ 12-GL
2-GLpo
c-71
D I.
* 0
033
Power window
main switch
Remarks
(1) For information
concerning
the ground points (example:~).
refer to P.812, 14.
etc. indicate that the wiring is connected (using the same n-umerical
on the right page is connected to @) on the left page.)
/ TSB Revision
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symbol)
to the facing page.
WRING HARNESS - Power Window Circuit
8-97
R
BD
Power window
motor (L.H.)
Power window
power relay
g:
RI.
B
LI
EI3
(RL)
Z-LR
O41.25-B
Power window
control relay
1.25-GL
1.25-R
1.25-G
@,r
?-1,25-GL
)+- 1.25-RW
* 1.25-RL
;* 2-L
4 2-B
;- 2-RL
a4
1.25-RL
1.25
1.25-L
Power window
motor (R.H.)
Ai71
0
2-RL.-a
F-G
?-LB. a T-L
Z-GL. a --R
2-GL
-.
Power window
sub switch (R.H.)
CT5
37wo5
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
L: Blue
Y: Yellow
TSB Revision
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Lg: Light green

W: White
.-
I.
8-98
WIRING HARNESS - Power
:4-door
Window
Circuit
Vehicles>
ignition
txl
B G IRU~ lRLl1
v RIB/
LlGLlRY
UP&
-DOWN
Front power
main switch
UP-
switch
Sub fusible link
window
-
DOWN
1.25-RL
J.Z5F-R
>.25F-G
1.25F-R-2-RL
1,25F-G
2-GL
2-RL
2-GL3
l--p%-&
L
B
ED
emarks
I) For details on the ground point (No.uin
the illustration).
refer-to
P.&14.
!) In the illustration. the numbered
wiring on the right hand page corresponds
to
( @ on the right hand page corresponds
to @ on the left hand page. etc.1
1 TSB Revision
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the numbering
on the leti hand page.
WIRING
Power window
control
HARNESS
Power
Window
8-99
Circuit
relay
FFnt power
y;dpw
motor
(N-1
amAD
o,=Z-LR
LFa
Front power
window sub
switch (R.H.1
Rear
pqwy
wfnoow
4.25-RL
l-3
I
Rear power
window sub
switch (L.H.)
@,2-RL
@.2-GL
ear power
vvv;c&w sub
Wiring color code
8: Black
LI: Light blue
Gr: Gray
R: Red
Br: Brown
0: Orange
L: Blue
Y: yellow
G: Green
P: Pink
8;
37W666
#;ewen
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22 CENTRAL LOCKING SYSTEM CIRCUIT
Door lock
control
unit
0
Q
0
@I
0
@I
Door lock
power relay
11
1 TSB
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l 2 r3
WIRING
HARNESS
8-101
- Central Locking System Circuit
Front door lock actuator

(L.H.)
I
(R.H.)
D-63~
,I
D63d
l 2
C36c
~ U-H.)
(R.H.)
Rear door lock actuator
<-door
37W664
vehicles>
/$m??details
on the round point (No. q in the illustration), refer to P.812. 14.
(2) In the illustration, t3, e numbered wiring on the right hand page corresponds to the numbering
(0 on the right hand page correspon
s to @ on the left hand page, etc.)
Wire color code
B: Black
LI: Light blue
Br: Brown
0: Orange
G: Green
P: Pink
!&$y
TSB Revision
C-36d
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L: Blue
Y: Yellow
on the left hand page.
$j; $f$egreen
8-102
WIRING
HARNESS
- Heater Circuit
23 HEATER CIRCUIT
<2.6L
. B.
EEEI
Engine>
LL.
LA
LI
LI
m
Blower
Remark
For information
refer to P.812.
lanition
Blower motor
resistor
w LI
LR I..
El3
switch
concerning
14.
Wiring color code

8: Black
Br: Brown
LI: Light blue
0: Orange
switch
G: Green
P: Pink
1 TSB Revision
Heater relay
37W713
a),
L: Blue
Y: Yellow
http://vnx.su/
8-103
VVIRING HARNESS - Heater Circuit

<3.OL Engine>
C-4
k?
Ml
L
OFF
L
Blower
switch
L I..
LR
La
l5EEl I
Blower
motor
3lower mot0
resistor
La LI
R
ED L.
TSB
Heater rel
37w71s
Revision
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8-104
WIRING HARNESS - Single Air Conditioner
24 SINGLE AIR CONDITIONER
Circuit
CIRCUIT
<2.6L Engine>
Ignition
switch
3-LK
1-Q
IT
Multi-purpose
fuse
To turn si nal flasher unit

[Refer to B .8-70.1
I
To ciaareit<a
-I
1i%ii;
to P.894.1
I I
0.85WB
A-l
~~
Blower
V&irin~cclor
Li: Light blue
code
Br: Brown
0: Orange
switch
G: Green
P: Pink
T-CR
Blower motor
resistor
L: Blue
Y: Yellow
Rnnirinn
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Heater
Lg: Light green

W: White
relay
8-105
WIRING HARNESS - Single Air Conditioner Circuit
Ak;;tditioner
Air conditioner
Id
Air w onditioner
relay B
- . . --.
Thermistor
II&
fxn
relay A
,C -27
-24
23
*I B.
B.
l 2 xl
A-52
*20.B5-BWn0.85-F
I I
Ada
l%zi
Vacuum
solenoid
0.85-WB
I1
5
z
d
:
A-46
li
Engine coolant
temperature
switch
COndenser
blower motor
Lonoenser
orower
motor relay
I3
Magnetic
clutch
(compressor)
tT
378702
(Rlym%%formation
(1) 0). refer to P.612.
(2) The symbols 0, Q, etc. indicate that the wiring is
facing page. (In other words, @ on the right page is
connected to @ on the left page.)
1 TSB Revision
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8-106
WIRING HARNESS - Single Air Conditioner
Circuit
<3.OL Engine>
OFF
To turn signal flasher

[Refer to P.%72.1
unit
0.85-B
I I!Lr!d-LlJ!-
Blower
motor
I
Blower
switch
L L.
LRl-8LI
Em
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
;i ,i,
1 TSB Revision
Blower mote:
resistor
L: Blue
Y: Yellow
http://vnx.su/
Heater relay
Lg: Light green

W: White
WIRING
HARNESS
Single
Air Conditioner
8-107
Circuit
Thermistor
@(3-LR
@-0.85-B
040.85-LW
-RW
c-40
M.P.I. control
@>,0.85-WB
Magnetic
clutch
(compressor)
Condenser
blower motor
Condenser blower
motor relay
37W708
Remarks
(1) 0). refer to P.8-14.
0 The symbols 0, @I, etc. indicate that the wiring is
connected (uslng the same numerical symbol) to the
facing page. (In other words, @ on the right page is
TSB Revision
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~~
7.
~.
8-108
WIRING HARNESS - Dual Air Conditioner
25 DUAL AIR CONDITIONER
Circuit
CIRCUIT
r;l
Ignition
Iawl
switch
Main
Battery
ktbe
q fill
q l1
To turn si nal flasher
[Refer to B .8-72.1
unit
H
M2
Ml
L
OFF
Front blower
-P
switch
Front blower
resistor
motor
l 1
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
1 TSB Revision
L: Blue
Y: Yellow
http://vnx.su/
l z
87w709
wa)
WIRING HARNESS - Dual Air Conditioner Circuit
-0.85-B
&O.SS-LW
8-109
040.85-WB
0.85-BY
Magnetic
clutch
(compressor)
;BW
te%~~~<~&witch
Condenserblower
motor relay
fii@
j TSf3 Revision
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c-40
BW
--Cl
M.P.I.., I
@marks
(I) For information concerning the
ground points (example: II).
refer to P.814.
(2) The symbols 0, 0. etc. indicate
that the wiringis connected
symbol) to the facing paQe.
(In other words
I on the ri ht
page is connecte 9 to @ on t1 e
left page.)
8-110
WIRING
HARNESS
- Back Door Lock Circuit

Magnetic
valve
--
A ,ir conditioner
I
Rear blower
motor
Rear blower
resis tor
motor
relay E
I
D-57
Rear blower
switc h
37w703
Condenser
fan motor
~nb~oy~yse
1 TSB
Rnvicinn
13131
D-56
Remark
In the illustration, the numbered wiring
on this page corresponds to the
numbering on the previous page. (5 on
this page corresponds to @ on the
fir conditioner
preoious iwe. etc.)
relay D
Wire color code
B: Black
Br: Brown
G: Green
L: Blue
Lg: Li ht green
Gr: Gray
3
P: Pm
Y: Yellow
W: White
R: Red
http://vnx.su/
-1
WIRING
HARNESS
8-111
- Back Door Lock Circuit
26 BACK DOOR LOCK CIRCUIT

Sub fusible
1.25F-G
,1.25-G
1.25F-R
link
4+
To heater relay
[Refer to P.&l 02, 103.1
1.25-R
D-16
7:
z:
.
c3.OL Engine>.
4door
pfq+q
Q.6L
Engine>
vehicles&
k
z,:
c::
M
b
Back door
lock actuator
37w712
Rennarks
(1) Broken lines and line indicated
by the il symbol are applicable to the

2.6liter models.
(2) The chain line (- - - - -) is applicable to 3.~liter models.
concerning the ground points (example: 0). refer to
(3) For information
P.812, 14.
1 TSB Revision
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Wire color code

B: Black
Br: Brown
G: Green
Gr: Gray
Lg: U htgreen
bl; Light
L: Blue
blue
0: Orange
Y: Yellow
4
P: Pm
W: White
-.
-.--
WIRING
HARNESS
- Horn
Circuit
27 HORN CIRCUIT
LV
mY
Ignition
switch
OFF
Multi-purpose
fuse
To wiper motor
[Refer to P.&W,
Column
switch
37WO98
Horn
tEvcPEPw
Remarks
(1) Lines indicated by the * symbol are applicable to the
P.&liter models.
8). refer to P.812. 14.
Wiring color code
B: Black
Br: Brown
LI: Light blue
0: Orange
G: Green
P: Pink
I TSB Revision
L: Blue
Y: Yellow
http://vnx.su/
Lg: Li ht green
W: W%te
88.1
WRING HARNESS - Sunroof Circuit
28 SUNROOF CIRCUIT
Ignition
switch
--?.
Battery
B-72
wl+y-J
OFF
ACC
ml
Main
fusible
C-66
link
A
c!l
I
-
Dedicated
fuse
Sunroof power
relay (B&k)
2-LW
%~ultipurpose
-------(R)
1.25-G
1.25-B
Sunroof
motor
Remarks
For details concerning
to P.&14.
D-40
rfb
I
the ground
Wiring color code

B: Black
Br: Brown
LI: Light blue
0: Orange
point (example:
0).
refer
I
Sunroof
switch
37W687
G: Green
P: Pink
g;:$Y
[ TSB Revision
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L: Blue
Y: Yellow
Lg: Light green

W: White
8-114
WIRING HARNESS - Horn Circuit
CENTRALIZED JUNCTION
Multi-purpose
Fuse
r control unit, OD-OFF relay, Power
Fuse block
37w715
37W716
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WIRING HARNESS - Centralized

Main
Fusible
8-115
Junction
Link
Circuit
Housing color
Rated capacity
Sub Fusible
Lighting circuit
Feed back carburetor

control circuitiM.P.1.
control circuit
Blue
100
Green
40
Pink
30
Link
i
Cable color
Fusible link size mm2 (in21
Permissible continuous current
Fusing current
A
Dedicated
Main circuit
Fusible
Air conditioner
circuit
Stop light, door

lock and heater
circuit
Ignition circuit
Red
0.85 1.0013)
34
150
Red
0.85 (.0013)
34
150
Red
0.85 (.0013)
34
150
Link
Power window
Defogger cirtcuit
Cable color
Fusible link size mm2 (in.2)
Permissible continuous current
Fusing current
A
Dedicated
Red
0.85 (.0013)
34
150
Fuse
Items
Rated capacity A
Upper beam indicator circuit

Central locking system circuit
Sunroof circuit
Front air conditioner
Rear air conditioner
15
circuit
2.6L Engine
15
3.OL Engine
20
circuit (Dual type)
20
1 TSB Revision
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VNX - Su Montero 1989 Service Manual PDF

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Lubrication and Maintenance

Front Suspension .. .. ... . ... . ... . ... .. .. .. .. . . y

Rear Axle *.......*.......*................a.....*..

Intake and Exhaust ,.......*..........*......

Fuel System . . .. .. .. .. .. .. ... . ... . .. . ... .. .. .. ... . mE

.. .. .. .. . ... . ... . ... .. .. . ... .. mt

Wheels and Tires .............................

Heater and Air Conditioning

Emission Control Systems .............. &!!!!

. .. .. .. ... ... &!a

INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual

HOW TO USE THIS MANUAL

Removal steps : The numbers before part names b

steps : This is provided if installation

M/T : Indicates the manual transmission,

INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual

kit or set parts are

This number corresponds to

Range tits over the

INTRODUCTION AND MASTER TROUBLESHOOTING -Vehicle Identification

VEHICLE IDENTIFICATION CODE CHART PLATE

numbers contain 17 digits. The ve!h%

INTRODUCTION AND MASTER TROUBLESHOOTING

VIN (except sequence number)

2.555 liters (155.9 cu.in.)

2.972 liters (181.4 cub.)

(Can also be sold in Federal states.]

VIN (except sequence number)

2.555 liters (155.9 cu.in.)

2.972 liters (181.4 win.)

VEHICLE INFORMATION CODE PLATE

Two-tone color code

INTRODUCTION AND MASTER TROUBLESHOOTING

NOOCEon the side of the frame near

VEHICLE SAFETY CERTIFICATION LABEL

The vehicle safety certification

ENGINE MODEL STAMPING

on the right front side on the

2.972 liters (181.4 cu.in.)

liters (155.9 cu.iiTI

The engine serial number is stamped near the engine

Engine serial number

AND MASTER TROUBLESHOOTING

BODY COLOR CODE

8 INTRODUCTION AND MASTER TROUBLESHOOTING

PROTECTING THE VEHICLE

If there is a likelihood of damaging

REMOVAL AND DISASSEMBLY

If punch marks or mating marks are made to avoid error in

AND MASTER TROUBLESHOOTING

SERVICING ELECTRICAL SYSTEM

Note the following

10 INTRODUCTION AND MASTER TROUBLESHOOTiNG - Precautions Before Service

If any section of a wiring harness contacts the edge of a

be sure to pull only the

Disconnect connectors which have catches by pressing

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Servicre 11

2. Sensors, relays, etc., are sensitive to strong impacts.

FUSES AND FUSIBLE LINKS

1. If a blown-out fuse is to be replaced, be sure to use only a

12 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Service

If additional optional equipment

(3) If an ammeter or similar instrument is to be connected

TUBES AND OTHER RUBBER PARTS

oil, etc., or rubber

Rear Axle ..............................a.......

Intake and Exhaust ,.......................