Mechanical Components.pdf - Ken Gilbert

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4-4 [S1B0] SPECIFICATIONS AND SERVICE DATA 1. Brakes B: SERVICE DATA Front brake Rear brake (Disc type) Rear brake (Drum type) Rear brake (Disc type parking) ITEM STANDARD SERVICE LIMIT Pad thickness (including back metal) 17 mm (0.67 in) 7.5 mm (0.295 in) Disc thickness 24 mm (0.94 in) 22 mm (0.87 in) Disc runout — 0.075 mm (0.0030 in) Pad thickness (including back metal) 15 mm (0.59 in) 6.5 mm (0.256 in) Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in) Disc runout — 0.1 mm (0.004 in) Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in) Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in) Inside diameter 170 mm (6.69 in) 171 mm (6.73 in) Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in) Parking brake Lever stroke 7 to 8 notches/196 N (20 kg, 44 lb) Brake booster Brake fluid pressure without engine running Brake fluid pressure with engine running and vacuum at 66.7 kPa (500 mmHg, 19.69 inHg) C: RECOMMENDED BRAKE FLUID FMVSS No. 116, fresh DOT3 or 4 brake fluid CAUTION: Avoid mixing brake fluid of different brands to prevent the fluid performance from degrading. When brake fluid is supplemented, be careful not to allow any dust into the reservoir. Use fresh DOT3 or 4 brake fluid when replacing or refilling the fluid. Without ABS With ABS Brake pedal force Fluid pressure 147 N 785 kPa (15 kg, 33 lb) (8 kg/cm 2 588 kPa , 114 psi) (6 kg/cm 2 , 85 psi) 294 N 2,158 kPa (30 kg, 66 lb) (22 kg/cm 2 1,863 kPa , 313 psi) (19 kg/cm 2 , 270 psi) 147 N 5,492 kPa (15 kg, 33 lb) (56 kg/cm 2 5,394 kPa , 796 psi) (55 kg/cm 2 , 782 psi) 294 N 8,434 kPa (30 kg, 66 lb) (86 kg/cm 2 9,219 kPa , 1,223 psi) (94 kg/cm 2 , 1,337 psi) 4 D: BRAKE FLUID LEVEL INDICATOR Reserve tank with level indicator: Residual fluid quantity at light ON Approx. 80 cm 3 (80 cc, 4.88 cu in) Tank capacity 205 cm 3 (205 cc, 12.51 cu in)
1. Front Disc Brake A: EXCEPT 2500 cc MODEL (1) Caliper body (2) Air bleeder screw (3) Guide pin (Green) (4) Pin boot (5) Piston seal (6) Piston (7) Piston boot (8) Lock pin (Yellow) COMPONENT PARTS (9) Support (10) Pad clip (11) Outer shim (12) Inner shim (13) Pad (Outside) (14) Pad (Inside) (15) Disc rotor (16) Disc cover 5 [C1A0] 4-4 1. Front Disc Brake B4M1208C Tightening torque: N·m (kg-m, ft-lb) T1: 8±1 (0.8±0.1, 5.8±0.7) T2: 18±5 (1.8±0.5, 13.0±3.6) T3: 37±5 (3.8±0.5, 27.5±3.6) T4: 78±10 (8.0±1.0, 58±7)
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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
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CAUTION: Use a new axle nut. Alwa
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5. Steel Wheel and Tire A: INSPECTI
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8. Tire Rotation If tires are maint
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4-3 [S1A0] SPECIFICATIONS AND SERVI
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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 and 118: 4-3 [K1C0] DIAGNOSTICS 1. Power Ste
Page 119 and 120: 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: 2. 2500 cc MODEL SPECIFICATIONS AND
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
Page 169 and 170: 11. Brake Fluid A: REPLACEMENT CAUT
Page 171 and 172: CAUTION: Do not disassemble or adju
Page 173 and 174: 3. OUTPUT VOLTAGE Output voltage ca
Page 175 and 176: 14. ABS Control Module and Hydrauli
Page 177 and 178: 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
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B: LIST OF DIAGNOSTIC TROUBLE CODE
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10C1 : CHECK IGNITION SWITCH. : Is
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MEMO: DIAGNOSTICS 85 [T10C9] 4-4 10
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10D1 : CHECK WIRING HARNESS. 1) Tur
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MEMO: DIAGNOSTICS 89 [T10D6] 4-4 10
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WIRING DIAGRAM: DIAGNOSTICS 91 [T10
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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
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MEMO: DIAGNOSTICS 99 [T10H28] 4-4 1
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10L1 : CHECK OUTPUT OF ABS SENSOR U
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10L13 : CHECK ABS SENSOR SIGNAL. DI
Page 349 and 350:
DIAGNOSTICS 10L21 : CHECK HARNESS/C
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10L28 : CHECK SHIELD CIRCUIT. DIAGN
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10M1 : CHECK IF THE WHEELS HAVE TUR
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MEMO: DIAGNOSTICS 111 [T10M14] 4-4
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10Q1 : CHECK INPUT VOLTAGE OF ABSCM
Page 359 and 360:
10U1 : CHECK INPUT VOLTAGE OF ABSCM
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10V1 : CHECK GROUND CIRCUIT OF ABSC
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10W1 : CHECK GENERATOR. 1) Start en
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MEMO: DIAGNOSTICS 121 [T10W7] 4-4 1
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10X1 : CHECK GENERATOR. 1) Start en
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MEMO: DIAGNOSTICS 125 [T10X7] 4-4 1
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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
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10AB1 : CHECK VALVE RELAY IN ABSCM&
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10AC1 : CHECK INPUT VOLTAGE OF ABSC
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10AD1 : CHECK MOTOR RELAY IN ABSCM&
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10AE1 : CHECK INPUT VOLTAGE OF ABSC
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MEMO: DIAGNOSTICS 145 [T10AE8] 4-4
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10AF1 : CHECK OUTPUT OF STOP LIGHT
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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
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10AH1 : CHECK OUTPUT OF G SENSOR US
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10AH15 : CHECK OPEN CIRCUIT IN G SE
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10AH21 : CHECK POOR CONTACT IN CONN
Page 405 and 406:
10AI1 : CHECK OUTPUT OF G SENSOR US
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10AI10 : CHECK ABSCM&H/U. 1) Turn i
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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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