Mechanical Components.pdf - Ken Gilbert

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DIAGNOSTICS 1. Air Conditioning System Diagnosis 31 [K100] 4-7 1. Air Conditioning System Diagnosis H4M1265A
4-7 [K200] DIAGNOSTICS 2. Performance Test Diagnosis 2. Performance Test Diagnosis If various conditions caused to other air conditioning system, the characteristics revealed on manifold gauge reading are shown in the following. As to the method of a performance test, refer to the item of “Performance Test”. Each shaded area on the following tables indicates a reading of the normal system when the temperature of outside air is 32.5°C (91°F). Condition Probable cause Corrective action INSUFFICIENT REFRIGERANT CHARGE Insufficient cooling. Refrigerant is small, or leaking a little. G4M0673 ALMOST NO REFRIGERANT No cooling action. Serious refrigerant leak. G4M0674 FAULTY EXPANSION VALVE Slight cooling. Sweating or frosted expansion valve inlet. G4M0675 32 Expansion valve restricts refrigerant flow. Expansion valve is clogged. Expansion valve is inoperative. Valve stuck closed. Thermal bulb has lost charge. 1. Leak test. 2. Repair leak. 3. Charge system. Evacuate, as necessary, and recharge system. Stop compressor immediately. 1. Leak test. 2. Discharge system. 3. Repair leak(s). 4. Replace receiver drier if necessary. 5. Check oil level. 6. Evacuate and recharge system. If valve inlet reveals sweat or frost: 1. Discharge system. 2. Remove valve and clean it. Replace it if necessary. 3. Evacuate system. 4. Charge system. If valve does not operate: 1. Discharge system. 2. Replace valve. 3. Evacuate and charge system.
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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
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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
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
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: 4-7 [W17B0] SERVICE PROCEDURE 18. P
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
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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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