Mechanical Components.pdf - Ken Gilbert

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4-4 [C4B0] COMPONENT PARTS 4. Master Cylinder B: WITHOUT ABS VEHICLES (1) Cap (2) Filter (3) Reservoir tank (4) Piston retainer (5) Primary piston (6) Secondary piston (7) Cylinder body (8) Seal 10 (9) Pin H4M1354A Tightening torque: N·m (kg-m, ft-lb) T1: 14±4 (1.4±0.4, 10.1±2.9)
5. Brake Booster A: MODELS WITH ABS (1) Push rod (2) Return spring (3) Reaction disc (4) Key B: MODELS WITHOUT ABS (1) Push rod (2) Return spring (3) Diaphragm plate (4) Reaction disc COMPONENT PARTS (5) Filter (6) Silencer (7) Operating rod (8) Poppet valve (5) Plunger valve (6) Key (7) Poppet valve (8) Valve return spring 11 (9) Valve body (10) Plunger valve (11) Diaphragm plate (12) Valve return spring (9) Operating rod (10) Silencer (11) Filter (12) Valve body [C5B0] 4-4 5. Brake Booster B4M1121A B4M1122A
Page 1 and 2:
4-1 [S100] SPECIFICATION AND SERVIC
Page 3 and 4:
4-1 [C100] COMPONENT PARTS 1. Front
Page 5 and 6:
4-1 [C200] COMPONENT PARTS 2. Rear
Page 7 and 8:
4-1 [W1B1] SERVICE PROCEDURE 1. On-
Page 9 and 10:
Page 11 and 12:
Page 13 and 14:
4-1 [W2A0] SERVICE PROCEDURE 2. Fro
Page 15 and 16:
4-1 [W2E0] SERVICE PROCEDURE 2. Fro
Page 17 and 18:
Page 19 and 20:
4-1 [W4C2] SERVICE PROCEDURE 4. Fro
Page 21 and 22:
Page 23 and 24:
4-1 [W6B0] SERVICE PROCEDURE 6. Fro
Page 25 and 26:
4-1 [W7B1] SERVICE PROCEDURE 7. Rea
Page 27 and 28:
4-1 [W7E0] SERVICE PROCEDURE 7. Rea
Page 29 and 30:
4-1 [W8B0] SERVICE PROCEDURE 8. Lat
Page 31 and 32:
4-1 [W8E0] SERVICE PROCEDURE 8. Lat
Page 33 and 34:
4-1 [W9B0] SERVICE PROCEDURE 9. Rea
Page 35 and 36:
4-1 [W10B0] SERVICE PROCEDURE 10. R
Page 37 and 38:
4-1 [W11C0] SERVICE PROCEDURE 11. R
Page 39 and 40:
4-1 DIAGNOSTICS MEMO: 40
Page 41 and 42:
3. Front Drive Shaft Assembly Model
Page 43 and 44:
1. Front Axle (1) Baffle plate (SFJ
Page 45 and 46:
1. Front Axle A: REMOVAL 1) Disconn
Page 47 and 48:
3) Remove disc cover from housing.
Page 49 and 50:
11) Attach hub to ST1 securely. 12)
Page 51 and 52:
8) Disconnect parking brake cable e
Page 53 and 54:
12) Remove bolts which secure later
Page 55 and 56:
3) Clean housing interior completel
Page 57 and 58:
10) Bleed air from brake system. 1
Page 59 and 60:
2. REAR DRIVE SHAFT 1) Disconnect g
Page 61 and 62:
8) Place alignment mark on trunnion
Page 63 and 64:
3) Apply a coat of specified grease
Page 65 and 66:
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 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 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: 4. Master Cylinder A: WITH ABS VEHI
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
Page 179 and 180: SERVICE PROCEDURE 4. CONDITIONS FOR
Page 181 and 182: 15B2 : CHECK G SENSOR. Measure volt
Page 183 and 184: 1. Entire Brake System DIAGNOSTICS
Page 185 and 186:
4-5 [S100] SPECIFICATIONS AND SERVI
Page 187 and 188:
4-5 [C1A2] COMPONENT PARTS 1. Pedal
Page 189 and 190:
4-5 [W1A1] SERVICE PROCEDURE 1. Ped
Page 191 and 192:
4-5 [W1A4] SERVICE PROCEDURE 1. Ped
Page 193 and 194:
4-5 [W1C1] SERVICE PROCEDURE 1. Ped
Page 195 and 196:
4-5 [W1F1] SERVICE PROCEDURE 1. Ped
Page 197 and 198:
4-5 [W3A0] SERVICE PROCEDURE 3. Acc
Page 199 and 200:
4-5 [K100] DIAGNOSTICS 1. Pedal Sys
Page 201 and 202:
1. Heater Unit (1) Vent door (2) DE
Page 203 and 204:
3. Control Unit (1) Temperature con
Page 205 and 206:
3. Blower Motor Assembly A: REMOVAL
Page 207 and 208:
4-7 [S100] SPECIFICATIONS 1. Specif
Page 209 and 210:
4-7 [C200] COMPONENT PARTS 2. Intak
Page 211 and 212:
4-7 [W1A0] SERVICE PROCEDURE 1. Saf
Page 213 and 214:
4-7 [W300] SERVICE PROCEDURE 3. Too
Page 215 and 216:
4-7 [W300] SERVICE PROCEDURE 3. Too
Page 217 and 218:
4-7 [W4D0] SERVICE PROCEDURE 4. O-r
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4-7 [W600] SERVICE PROCEDURE 6. Dis
Page 221 and 222:
4-7 [W7C0] SERVICE PROCEDURE 7. Eva
Page 223 and 224:
4-7 [W8A0] SERVICE PROCEDURE 8. Lea
Page 225 and 226:
4-7 [W8A7] SERVICE PROCEDURE 9. Lub
Page 227 and 228:
4-7 [W11B0] SERVICE PROCEDURE 11. C
Page 229 and 230:
4-7 [W11C0] SERVICE PROCEDURE 11. C
Page 231 and 232:
4-7 [W13A0] SERVICE PROCEDURE 13. R
Page 233 and 234:
4-7 [W15A0] SERVICE PROCEDURE 15. C
Page 235 and 236:
4-7 [W17B0] SERVICE PROCEDURE 18. P
Page 237 and 238:
4-7 [K200] DIAGNOSTICS 2. Performan
Page 239 and 240:
4-7 [K200] DIAGNOSTICS 2. Performan
Page 241 and 242:
4-7 [K400] DIAGNOSTICS 4. Compresso
Page 243 and 244:
4-7 [K600] DIAGNOSTICS 6. Radiator
Page 245 and 246:
4-7 [K800] DIAGNOSTICS 8. Condenser
Page 247 and 248:
B: ELECTRICAL INSPECTION DIAGNOSTIC
Page 249 and 250:
B4M1226B H4M1304A S4M0055A B4M2201C
Page 251 and 252:
MEMO: DIAGNOSTICS 7 [T400] 4-4 4. S
Page 253 and 254:
ABS sensor*2 (Wheel speed sensor) C
Page 255 and 256:
6. Diagnostics Chart for On-board D
Page 257 and 258:
Behavior of vehicle a) Directional
Page 259 and 260:
1. CALLING UP A TROUBLE CODE 1) Tak
Page 261 and 262:
MEMO: [T6D2] 4-4 DIAGNOSTICS 6. Dia
Page 263 and 264:
7A1 : CHECK IF OTHER WARNING LIGHTS
Page 265 and 266:
7A10 : CHECK POOR CONTACT IN CON- N
Page 267 and 268:
7B1 : CHECK INSTALLATION OF ABSCM&H
Page 269 and 270:
7B10 : CHECK WIRING HARNESS. Measur
Page 271 and 272:
7C1 : CHECK DIAGNOSIS TERMINAL. Mea
Page 273 and 274:
8. Diagnostics Chart with Trouble C
Page 275 and 276:
8E1 : CHECK FRONT ABS SENSOR. 1) Tu
Page 277 and 278:
DIAGNOSTICS 8E8 : CHECK BATTERY SHO
Page 279 and 280:
DIAGNOSTICS 8E16 : CHECK GROUND SHO
Page 281 and 282:
8I1 : CHECK INSTALLATION OF ABS SEN
Page 283 and 284:
8I10 : CHECK RESISTANCE OF FRONT AB
Page 285 and 286:
8I16 : CHECK GROUND SHORT OF HAR- N
Page 287 and 288:
MEMO: DIAGNOSTICS [T8I23] 4-4 8. Di
Page 289 and 290:
8J1 : CHECK IF THE WHEELS HAVE TURN
Page 291 and 292:
MEMO: DIAGNOSTICS [T8J14] 4-4 8. Di
Page 293 and 294:
8N1 : CHECK INPUT VOLTAGE OF ABSCM&
Page 295 and 296:
8R1 : CHECK INPUT VOLTAGE OF ABSCM&
Page 297 and 298:
8S1 : CHECK GROUND CIRCUIT OF ABSCM
Page 299 and 300:
8T1 : CHECK GENERATOR. 1) Start eng
Page 301 and 302:
MEMO: DIAGNOSTICS [T8T7] 4-4 8. Dia
Page 303 and 304:
8U1 : CHECK SPECIFICATIONS OF THE A
Page 305 and 306:
8U10 : CHECK ANY OTHER TROUBLE CODE
Page 307 and 308:
8V1 : CHECK INPUT VOLTAGE OF ABSCM&
Page 309 and 310:
MEMO: DIAGNOSTICS [T8V6] 4-4 8. Dia
Page 311 and 312:
8W1 : CHECK INPUT VOLTAGE OF ABSCM&
Page 313 and 314:
MEMO: DIAGNOSTICS [T8W8] 4-4 8. Dia
Page 315 and 316:
8X1 : CHECK STOP LIGHTS COME ON. De
Page 317 and 318:
8Y1 : CHECK ALL FOUR WHEELS FOR FRE
Page 319 and 320:
DIAGNOSTICS 8Y8 : CHECK GROUND SHOR
Page 321 and 322:
MEMO: DIAGNOSTICS [T8Y14] 4-4 8. Di
Page 323 and 324:
6. FREEZE FRAME DATA NOTE: Data st
Page 325 and 326:
B: LIST OF DIAGNOSTIC TROUBLE CODE
Page 327 and 328:
10C1 : CHECK IGNITION SWITCH. : Is
Page 329 and 330:
MEMO: DIAGNOSTICS 85 [T10C9] 4-4 10
Page 331 and 332:
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
Page 339 and 340:
DIAGNOSTICS 10H16 : CHECK HARNESS/C
Page 341 and 342:
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
Page 363 and 364:
10W1 : CHECK GENERATOR. 1) Start en
Page 365 and 366:
MEMO: DIAGNOSTICS 121 [T10W7] 4-4 1
Page 367 and 368:
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
Page 375 and 376:
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
Page 397 and 398:
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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