Mechanical Components.pdf - Ken Gilbert

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1) Measurement of steering effort is as shown in the figures. S4M0169 S4M0170 DIAGNOSTICS 47 [K1C0] 4-3 1. Power Steering 2) Measurement of folding torque of universal joint is as shown in the figures. G4M0199 G4M0200 G4M0201 G4M0202
4-3 [K1C0] DIAGNOSTICS 1. Power Steering 3) Using ST, measure resistances of gearbox. ST 926230000 SPANNER Rotating resistance: Straight-ahead position within 30 mm (1.18 in) from rack center; Less than 11.18 N (1.14 kg, 2.51 lb) Maximum allowable torque; 12.7 N (1.3 kg, 2.9 lb) Sliding resistance: Right-turn steering; 304 N (31 kg, 68 lb) or less G4M0203 G4M0204 48 Left-turn steering; 304 N (31 kg, 68 lb) or less G4M0205
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4-1 [S100] SPECIFICATION AND SERVIC
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4-1 [C100] COMPONENT PARTS 1. Front
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4-1 [C200] COMPONENT PARTS 2. Rear
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4-1 [W1B1] SERVICE PROCEDURE 1. On-
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4-1 [W2A0] SERVICE PROCEDURE 2. Fro
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4-1 [W2E0] SERVICE PROCEDURE 2. Fro
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4-1 [W4C2] SERVICE PROCEDURE 4. Fro
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4-1 [W6B0] SERVICE PROCEDURE 6. Fro
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4-1 [W7B1] SERVICE PROCEDURE 7. Rea
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4-1 [W7E0] SERVICE PROCEDURE 7. Rea
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4-1 [W8B0] SERVICE PROCEDURE 8. Lat
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4-1 [W8E0] SERVICE PROCEDURE 8. Lat
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4-1 [W9B0] SERVICE PROCEDURE 9. Rea
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4-1 [W10B0] SERVICE PROCEDURE 10. R
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4-1 [W11C0] SERVICE PROCEDURE 11. R
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4-1 DIAGNOSTICS MEMO: 40
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3. Front Drive Shaft Assembly Model
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1. Front Axle (1) Baffle plate (SFJ
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1. Front Axle A: REMOVAL 1) Disconn
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3) Remove disc cover from housing.
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11) Attach hub to ST1 securely. 12)
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8) Disconnect parking brake cable e
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12) Remove bolts which secure later
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3) Clean housing interior completel
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10) Bleed air from brake system. 1
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2. REAR DRIVE SHAFT 1) Disconnect g
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8) Place alignment mark on trunnion
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3) Apply a coat of specified grease
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3) Insert DOJ cage onto shaft. NOTE
Page 67 and 68: CAUTION: Use a new axle nut. Alwa
Page 69 and 70: 5. Steel Wheel and Tire A: INSPECTI
Page 71 and 72: 8. Tire Rotation If tires are maint
Page 73 and 74: 4-3 [S1A0] SPECIFICATIONS AND SERVI
Page 75 and 76: 4-3 [S1C0] SPECIFICATIONS AND SERVI
Page 77 and 78: 4-3 [C200] COMPONENT PARTS 2. Power
Page 79 and 80: 4-3 [C300] COMPONENT PARTS 3. Power
Page 81 and 82: 4-3 [W2B0] SERVICE PROCEDURE 2. Til
Page 83 and 84: 4-3 [W2D0] SERVICE PROCEDURE 2. Til
Page 85 and 86: 4-3 [W3A0] SERVICE PROCEDURE 3. Ste
Page 87 and 88: 4-3 [W3C0] SERVICE PROCEDURE 3. Ste
Page 89 and 90: 4-3 [W3C3] SERVICE PROCEDURE 3. Ste
Page 91 and 92: 4-3 [W3D0] SERVICE PROCEDURE 3. Ste
Page 93 and 94: 4-3 [W3F0] SERVICE PROCEDURE 3. Ste
Page 95 and 96: 4-3 [W4B0] SERVICE PROCEDURE 4. Con
Page 97 and 98: 4-3 [W4C2] SERVICE PROCEDURE 4. Con
Page 99 and 100: 4-3 [W4D1] SERVICE PROCEDURE 4. Con
Page 101 and 102: 4-3 [W5A0] SERVICE PROCEDURE 5. Pip
Page 103 and 104: 4-3 [W5C0] SERVICE PROCEDURE 5. Pip
Page 105 and 106: 4-3 [W6A0] SERVICE PROCEDURE 6. Oil
Page 107 and 108: 4-3 [W6B1] SERVICE PROCEDURE 6. Oil
Page 109 and 110: 4-3 [W6D0] SERVICE PROCEDURE 6. Oil
Page 111 and 112: 4-3 [W6E0] SERVICE PROCEDURE 6. Oil
Page 113 and 114: 4-3 [W7A0] SERVICE PROCEDURE 7. Pow
Page 115 and 116: 4-3 [K1B0] DIAGNOSTICS 1. Power Ste
Page 117: 4-3 [K1C0] DIAGNOSTICS 1. Power Ste
Page 121 and 122: 4-3 [K1E0] DIAGNOSTICS 1. Power Ste
Page 123 and 124: 4-3 [K1F0] DIAGNOSTICS 1. Power Ste
Page 125 and 126: 4-3 DIAGNOSTICS MEMO: 54
Page 127 and 128: 2. 2500 cc MODEL SPECIFICATIONS AND
Page 129 and 130: 1. Front Disc Brake A: EXCEPT 2500
Page 131 and 132: 2. Rear Disc Brake (1) Caliper body
Page 133 and 134: 4. Master Cylinder A: WITH ABS VEHI
Page 135 and 136: 5. Brake Booster A: MODELS WITH ABS
Page 137 and 138: B: ABS CONTROL MODULE AND HYDRAULIC
Page 139 and 140: 1. Front Disc Brake A: ON-CAR SERVI
Page 141 and 142: 5) Remove disc rotor from hub. NOTE
Page 143 and 144: 1) Clean mud and foreign particles
Page 145 and 146: 1) Clean mud and foreign particles
Page 147 and 148: F: INSTALLATION 1) Install disc rot
Page 149 and 150: B: REMOVAL (1) Caliper body (2) Air
Page 151 and 152: E: ASSEMBLY 1) Clean caliper body i
Page 153 and 154: NOTE: If it is difficult to remove
Page 155 and 156: D: ASSEMBLY 1. WHEEL CYLINDER 1) Cl
Page 157 and 158: 4. Parking Brake (Rear Disc Brake)
Page 159 and 160: D: ADJUSTMENT 1. SHOE CLEARANCE 1)
Page 161 and 162: 6. Brake Booster A: REMOVAL 1) Remo
Page 163 and 164: 3. OPERATION CHECK 1) With engine o
Page 165 and 166: 7) While holding hexagonal part of
Page 167 and 168: 11) Remove bolt and clamp from rear
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11. Brake Fluid A: REPLACEMENT CAUT
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CAUTION: Do not disassemble or adju
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3. OUTPUT VOLTAGE Output voltage ca
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14. ABS Control Module and Hydrauli
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9) Remove air bleeder screws from t
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SERVICE PROCEDURE 4. CONDITIONS FOR
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15B2 : CHECK G SENSOR. Measure volt
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1. Entire Brake System DIAGNOSTICS
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4-5 [S100] SPECIFICATIONS AND SERVI
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4-5 [C1A2] COMPONENT PARTS 1. Pedal
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4-5 [W1A1] SERVICE PROCEDURE 1. Ped
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4-5 [W1A4] SERVICE PROCEDURE 1. Ped
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4-5 [W1C1] SERVICE PROCEDURE 1. Ped
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4-5 [W1F1] SERVICE PROCEDURE 1. Ped
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4-5 [W3A0] SERVICE PROCEDURE 3. Acc
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4-5 [K100] DIAGNOSTICS 1. Pedal Sys
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1. Heater Unit (1) Vent door (2) DE
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3. Control Unit (1) Temperature con
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3. Blower Motor Assembly A: REMOVAL
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4-7 [S100] SPECIFICATIONS 1. Specif
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4-7 [C200] COMPONENT PARTS 2. Intak
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4-7 [W1A0] SERVICE PROCEDURE 1. Saf
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4-7 [W300] SERVICE PROCEDURE 3. Too
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4-7 [W300] SERVICE PROCEDURE 3. Too
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4-7 [W4D0] SERVICE PROCEDURE 4. O-r
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4-7 [W600] SERVICE PROCEDURE 6. Dis
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4-7 [W7C0] SERVICE PROCEDURE 7. Eva
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4-7 [W8A0] SERVICE PROCEDURE 8. Lea
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4-7 [W8A7] SERVICE PROCEDURE 9. Lub
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4-7 [W11B0] SERVICE PROCEDURE 11. C
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4-7 [W11C0] SERVICE PROCEDURE 11. C
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4-7 [W13A0] SERVICE PROCEDURE 13. R
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4-7 [W15A0] SERVICE PROCEDURE 15. C
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4-7 [W17B0] SERVICE PROCEDURE 18. P
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4-7 [K200] DIAGNOSTICS 2. Performan
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4-7 [K200] DIAGNOSTICS 2. Performan
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4-7 [K400] DIAGNOSTICS 4. Compresso
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4-7 [K600] DIAGNOSTICS 6. Radiator
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4-7 [K800] DIAGNOSTICS 8. Condenser
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B: ELECTRICAL INSPECTION DIAGNOSTIC
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B4M1226B H4M1304A S4M0055A B4M2201C
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MEMO: DIAGNOSTICS 7 [T400] 4-4 4. S
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ABS sensor*2 (Wheel speed sensor) C
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6. Diagnostics Chart for On-board D
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Behavior of vehicle a) Directional
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1. CALLING UP A TROUBLE CODE 1) Tak
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MEMO: [T6D2] 4-4 DIAGNOSTICS 6. Dia
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7A1 : CHECK IF OTHER WARNING LIGHTS
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7A10 : CHECK POOR CONTACT IN CON- N
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7B1 : CHECK INSTALLATION OF ABSCM&H
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7B10 : CHECK WIRING HARNESS. Measur
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7C1 : CHECK DIAGNOSIS TERMINAL. Mea
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8. Diagnostics Chart with Trouble C
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8E1 : CHECK FRONT ABS SENSOR. 1) Tu
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DIAGNOSTICS 8E8 : CHECK BATTERY SHO
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DIAGNOSTICS 8E16 : CHECK GROUND SHO
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8I1 : CHECK INSTALLATION OF ABS SEN
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8I10 : CHECK RESISTANCE OF FRONT AB
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8I16 : CHECK GROUND SHORT OF HAR- N
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MEMO: DIAGNOSTICS [T8I23] 4-4 8. Di
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8J1 : CHECK IF THE WHEELS HAVE TURN
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MEMO: DIAGNOSTICS [T8J14] 4-4 8. Di
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8N1 : CHECK INPUT VOLTAGE OF ABSCM&
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8R1 : CHECK INPUT VOLTAGE OF ABSCM&
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8S1 : CHECK GROUND CIRCUIT OF ABSCM
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8T1 : CHECK GENERATOR. 1) Start eng
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MEMO: DIAGNOSTICS [T8T7] 4-4 8. Dia
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8U1 : CHECK SPECIFICATIONS OF THE A
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8U10 : CHECK ANY OTHER TROUBLE CODE
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8V1 : CHECK INPUT VOLTAGE OF ABSCM&
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MEMO: DIAGNOSTICS [T8V6] 4-4 8. Dia
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8W1 : CHECK INPUT VOLTAGE OF ABSCM&
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MEMO: DIAGNOSTICS [T8W8] 4-4 8. Dia
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8X1 : CHECK STOP LIGHTS COME ON. De
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8Y1 : CHECK ALL FOUR WHEELS FOR FRE
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DIAGNOSTICS 8Y8 : CHECK GROUND SHOR
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MEMO: DIAGNOSTICS [T8Y14] 4-4 8. Di
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6. FREEZE FRAME DATA NOTE: Data st
Page 325 and 326:
B: LIST OF DIAGNOSTIC TROUBLE CODE
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10C1 : CHECK IGNITION SWITCH. : Is
Page 329 and 330:
MEMO: DIAGNOSTICS 85 [T10C9] 4-4 10
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10D1 : CHECK WIRING HARNESS. 1) Tur
Page 333 and 334:
MEMO: DIAGNOSTICS 89 [T10D6] 4-4 10
Page 335 and 336:
WIRING DIAGRAM: DIAGNOSTICS 91 [T10
Page 337 and 338:
10H7 : CHECK POOR CONTACT IN CON- N
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DIAGNOSTICS 10H16 : CHECK HARNESS/C
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10H23 : CHECK HUB RUNOUT. Measure h
Page 343 and 344:
MEMO: DIAGNOSTICS 99 [T10H28] 4-4 1
Page 345 and 346:
10L1 : CHECK OUTPUT OF ABS SENSOR U
Page 347 and 348:
10L13 : CHECK ABS SENSOR SIGNAL. DI
Page 349 and 350:
DIAGNOSTICS 10L21 : CHECK HARNESS/C
Page 351 and 352:
10L28 : CHECK SHIELD CIRCUIT. DIAGN
Page 353 and 354:
10M1 : CHECK IF THE WHEELS HAVE TUR
Page 355 and 356:
MEMO: DIAGNOSTICS 111 [T10M14] 4-4
Page 357 and 358:
10Q1 : CHECK INPUT VOLTAGE OF ABSCM
Page 359 and 360:
10U1 : CHECK INPUT VOLTAGE OF ABSCM
Page 361 and 362:
10V1 : CHECK GROUND CIRCUIT OF ABSC
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10W1 : CHECK GENERATOR. 1) Start en
Page 365 and 366:
MEMO: DIAGNOSTICS 121 [T10W7] 4-4 1
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10X1 : CHECK GENERATOR. 1) Start en
Page 369 and 370:
MEMO: DIAGNOSTICS 125 [T10X7] 4-4 1
Page 371 and 372:
10Y1 : CHECK SPECIFICATIONS OF THE
Page 373 and 374:
MEMO: DIAGNOSTICS 129 [T10Y8] 4-4 1
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DIAGNOSTICS 10Z1 : CHECK BATTERY SH
Page 377 and 378:
MEMO: DIAGNOSTICS 133 [T10Z6] 4-4 1
Page 379 and 380:
10AA1 : CHECK INPUT VOLTAGE OF ABSC
Page 381 and 382:
10AB1 : CHECK VALVE RELAY IN ABSCM&
Page 383 and 384:
10AC1 : CHECK INPUT VOLTAGE OF ABSC
Page 385 and 386:
10AD1 : CHECK MOTOR RELAY IN ABSCM&
Page 387 and 388:
10AE1 : CHECK INPUT VOLTAGE OF ABSC
Page 389 and 390:
MEMO: DIAGNOSTICS 145 [T10AE8] 4-4
Page 391 and 392:
10AF1 : CHECK OUTPUT OF STOP LIGHT
Page 393 and 394:
MEMO: DIAGNOSTICS 149 [T10AF7] 4-4
Page 395 and 396:
10AG1 : CHECK OUTPUT OF G SENSOR US
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10AG9 : CHECK G SENSOR. Measure vol
Page 399 and 400:
10AH1 : CHECK OUTPUT OF G SENSOR US
Page 401 and 402:
10AH15 : CHECK OPEN CIRCUIT IN G SE
Page 403 and 404:
10AH21 : CHECK POOR CONTACT IN CONN
Page 405 and 406:
10AI1 : CHECK OUTPUT OF G SENSOR US
Page 407 and 408:
10AI10 : CHECK ABSCM&H/U. 1) Turn i
Page 409 and 410:
10AJ1 : CHECK ALL FOUR WHEELS FOR F
Page 411 and 412:
10AJ10 : CHECK G SENSOR. Measure vo
Page 413 and 414:
B: CHECKING THE HYDRAULIC UNIT OPER
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Mechanical Components.pdf - Ken Gilbert

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