Mechanical Components.pdf - Ken Gilbert

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B: AT MODEL (1) Accelerator pedal (2) Bushing (3) Holder (4) Accelerator bracket (5) Stopper (6) Clip (7) Accelerator spring (8) Accelerator pedal spring (9) Spring pin (10) Accelerator pedal COMPONENT PARTS (11) Accelerator stopper (12) Clip (13) Accelerator plate (14) Plug (15) Pedal bracket (16) Stop light switch (17) Spacer (18) Stopper (19) Snap pin (20) Brake pedal pad 5 (21) Brake pedal (22) Clevis pin (23) Brake pedal spring [C1B0] 4-5 1. Pedal H4M1136B Tightening torque: N·m (kg-m, ft-lb) T1: 8±2 (0.8±0.2, 5.8±1.4) T2: 18±5 (1.8±0.5, 13.0±3.6) T3: 29±7 (3.0±0.7, 21.7±5.1)
4-5 [W1A1] SERVICE PROCEDURE 1. Pedal 1. Pedal A: ON-CAR SERVICE 1. BRAKE PEDAL 1) Check position of pedal pad. Pedal height: L 148 mm (5.83 in) (1) Stop light switch (2) Mat (3) Toe board (4) Brake booster operating rod B4M0366B 2) If it is not in specified value, adjust it by adjusting brake booster operating rod length. 3) Measure the clearance between threaded end of stop light switch and stopper. If it is not in specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance: A 0.3 mm (0.012 in) (1) Stop light switch (2) Stopper (3) Brake pedal B4M0617F 4) Apply grease to operating rod connecting pin to prevent it from wearing. 6 2. CLUTCH PEDAL (2200 cc MODEL) 1) Check clutch pedal free play by operating pedal by hand. Free play: L (At clutch pedal pad) 10 — 20 mm (0.39 — 0.79 in) Pedal height: Y 158 mm (6.22 in) Pedal stroke: A 140 — 145 mm (5.51 — 5.71 in) (1) Toe board (2) Mat G4M0318 B4M0367B
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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
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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
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4-3 [W2D0] SERVICE PROCEDURE 2. Til
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4-3 [W3A0] SERVICE PROCEDURE 3. Ste
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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
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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
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1. Front Disc Brake A: EXCEPT 2500
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2. Rear Disc Brake (1) Caliper body
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4. Master Cylinder A: WITH ABS VEHI
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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
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: 4-5 [C1A2] COMPONENT PARTS 1. Pedal
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
Page 219 and 220: 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
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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
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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
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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
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MEMO: DIAGNOSTICS 129 [T10Y8] 4-4 1
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DIAGNOSTICS 10Z1 : CHECK BATTERY SH
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MEMO: DIAGNOSTICS 133 [T10Z6] 4-4 1
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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
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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
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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
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10AJ10 : CHECK G SENSOR. Measure vo
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B: CHECKING THE HYDRAULIC UNIT OPER
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