Mechanical Components.pdf - Ken Gilbert

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3. Front Ball Joint A: REMOVAL 1) Remove the wheels. 2) Pull out the cotter pin from the ball stud, remove the castle nut, and extract the ball stud from the transverse link. 3) Remove the bolt securing the ball joint to the housing. 4) Extract the ball joint from the housing. B: INSPECTION G4M0499 1) Measure play of ball joint by the following procedures. Replace with a new one when the play exceeds the specified value. (1) With 686 N (70 kg, 154 lb) loaded in the direction shown in the figure, measure dimension 1. G4M0500 (2) With 686 N (70 kg, 154 lb) loaded in the opposite direction shown in the figure, measure dimension 2. SERVICE PROCEDURE G4M0501 17 (3) Calculate plays from the following formula. S= 2 − 1 (4) When plays is larger than the following value, replace with a new one. FRONT BALL JOINT Specified play for replacement: S Less than 0.3 mm (0.012 in) 2) When play is smaller than the specified value, visually inspect the dust cover. 3) The ball joint and cover that have been removed must be checked for wear, damage or cracks, and any defective part must be replaced. 4) If the dust cover is damaged, replace with the new ball joint. C: INSTALLATION [W3C0] 4-1 3. Front Ball Joint 1) Install ball joint onto housing. Tightening torque (Bolt): 49 N·m (5.0 kg-m, 36 ft-lb) CAUTION: Do not apply grease to tapered portion of ball stud. 2) Connect ball joint to transverse link. Tightening torque (Castle nut): 39 N·m (4.0 kg-m, 29 ft-lb) 3) Retighten castle nut further within 60° until a slot in castle nut is aligned with the hole in ball stud end, then insert new cotter pin and bend it around castle nut. 4) Install front wheels.
4-1 [W4A0] SERVICE PROCEDURE 4. Front Strut 4. Front Strut A: REMOVAL (1) Dust seal (2) Strut mount (3) Spacer (4) Upper spring seat (5) Rubber seat (6) Dust cover (7) Helper (8) Coil spring (9) Damper strut (10) Adjusting bolt (11) Self-locking nut 1) Remove wheel. 2) Depress brake pedal and hold it down using a wooden block etc. 3) Remove union bolts from caliper. CAUTION: Use brake hose cap to prevent brake fluid from escaping. B4M1170 18 B4M1085A Tightening torque: N·m (kg-m, ft-lb) T1: 20±6 (2.0±0.6, 14.5±4.3) T2: 54±5 (5.5±0.5, 39.8±3.6) T3: 152±20 (15.5±2.0, 112±14) 4) Remove brake hose clamp and disconnect brake hose from strut. Attach brake hose to body using gum tape. G4M0504 5) Scribe an alignment mark on the camber adjusting bolt which secures strut to housing. 6) Remove bolt securing the ABS sensor harness on models equipped with ABS.
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 13 and 14: 4-1 [W2A0] SERVICE PROCEDURE 2. Fro
Page 15: 4-1 [W2E0] SERVICE PROCEDURE 2. Fro
Page 19 and 20: 4-1 [W4C2] SERVICE PROCEDURE 4. Fro
Page 21 and 22: 4-1 [W5A0] SERVICE PROCEDURE 5. Fro
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
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8. Tire Rotation If tires are maint
Page 73 and 74:
4-3 [S1A0] SPECIFICATIONS AND SERVI
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4-3 [S1C0] SPECIFICATIONS AND SERVI
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4-3 [C200] COMPONENT PARTS 2. Power
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4-3 [C300] COMPONENT PARTS 3. Power
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4-3 [W2B0] SERVICE PROCEDURE 2. Til
Page 83 and 84:
4-3 [W2D0] SERVICE PROCEDURE 2. Til
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4-3 [W3A0] SERVICE PROCEDURE 3. Ste
Page 87 and 88:
4-3 [W3C0] SERVICE PROCEDURE 3. Ste
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4-3 [W3C3] SERVICE PROCEDURE 3. Ste
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4-3 [W3D0] SERVICE PROCEDURE 3. Ste
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4-3 [W3F0] SERVICE PROCEDURE 3. Ste
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4-3 [W4B0] SERVICE PROCEDURE 4. Con
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4-3 [W4C2] SERVICE PROCEDURE 4. Con
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4-3 [W4D1] SERVICE PROCEDURE 4. Con
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4-3 [W5A0] SERVICE PROCEDURE 5. Pip
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4-3 [W5C0] SERVICE PROCEDURE 5. Pip
Page 105 and 106:
4-3 [W6A0] SERVICE PROCEDURE 6. Oil
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4-3 [W6B1] SERVICE PROCEDURE 6. Oil
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4-3 [W6D0] SERVICE PROCEDURE 6. Oil
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4-3 [W6E0] SERVICE PROCEDURE 6. Oil
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4-3 [W7A0] SERVICE PROCEDURE 7. Pow
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4-3 [K1B0] DIAGNOSTICS 1. Power Ste
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4-3 [K1C0] DIAGNOSTICS 1. Power Ste
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4-3 [K1C0] DIAGNOSTICS 1. Power Ste
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4-3 [K1E0] DIAGNOSTICS 1. Power Ste
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4-3 [K1F0] DIAGNOSTICS 1. Power Ste
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4-3 DIAGNOSTICS MEMO: 54
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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
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B: ABS CONTROL MODULE AND HYDRAULIC
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1. Front Disc Brake A: ON-CAR SERVI
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5) Remove disc rotor from hub. NOTE
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1) Clean mud and foreign particles
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1) Clean mud and foreign particles
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F: INSTALLATION 1) Install disc rot
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B: REMOVAL (1) Caliper body (2) Air
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E: ASSEMBLY 1) Clean caliper body i
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NOTE: If it is difficult to remove
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D: ASSEMBLY 1. WHEEL CYLINDER 1) Cl
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4. Parking Brake (Rear Disc Brake)
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D: ADJUSTMENT 1. SHOE CLEARANCE 1)
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6. Brake Booster A: REMOVAL 1) Remo
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3. OPERATION CHECK 1) With engine o
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7) While holding hexagonal part of
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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
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
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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
Page 267 and 268:
7B1 : CHECK INSTALLATION OF ABSCM&H
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7B10 : CHECK WIRING HARNESS. Measur
Page 271 and 272:
7C1 : CHECK DIAGNOSIS TERMINAL. Mea
Page 273 and 274:
8. Diagnostics Chart with Trouble C
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8E1 : CHECK FRONT ABS SENSOR. 1) Tu
Page 277 and 278:
DIAGNOSTICS 8E8 : CHECK BATTERY SHO
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DIAGNOSTICS 8E16 : CHECK GROUND SHO
Page 281 and 282:
8I1 : CHECK INSTALLATION OF ABS SEN
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8I10 : CHECK RESISTANCE OF FRONT AB
Page 285 and 286:
8I16 : CHECK GROUND SHORT OF HAR- N
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MEMO: DIAGNOSTICS [T8I23] 4-4 8. Di
Page 289 and 290:
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
Page 301 and 302:
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
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
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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
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
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10H7 : CHECK POOR CONTACT IN CON- N
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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
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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&
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10AC1 : CHECK INPUT VOLTAGE OF ABSC
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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
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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
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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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