Mechanical Components.pdf - Ken Gilbert

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4-4 [T6C0] DIAGNOSTICS 6. Diagnostics Chart for On-board Diagnosis System Condition a) Brakes Deceleration : g Continuous / Intermittent b) Accelerator Acceleration : g Continuous / Intermittent c) Vehicle speed km/h MPH Advancing Accelerating Reducing speed Low speed Turning Others : d) Tire inflation pressure Front RH tire : kPa Front LH tire : kPa Rear RH tire : kPa Rear LH tire : kPa e) Degree of wear Front RH tire : Front LH tire : Rear RH tire : Rear LH tire : f) Genuine parts are used. : Yes / No g) Chain is passed around tires. : Yes / No h) T tire is used. : Yes / No i) Condition of suspension alignment : j) Loading state : k) Repair parts are used. : Yes / No What : l) Others : C: INSPECTION MODE Reproduce the condition under which the problem has occurred as much as possible. Drive the vehicle at a speed more than 40 km/h (25 MPH) for at least one minute. D: TROUBLE CODES When on-board diagnosis of the ABS control module detects a problem, the information (up to a maximum of three) will be stored in the EEP ROM as a trouble code. When there are more than three, the most recent three will be stored. (Stored codes will stay in memory until they are cleared.) 14
1. CALLING UP A TROUBLE CODE 1) Take out diagnosis connector from side of driver’s seat heater unit. [T6D1] 4-4 DIAGNOSTICS 6. Diagnostics Chart for On-board Diagnosis System B4M0082D 2) Turn ignition switch OFF. 3) Connect diagnosis connector terminal 6 to diagnosis terminal. 4) Turn ignition switch ON. 5) ABS warning light is set in the diagnostic mode and blinks to identify trouble code. 6) After the start code (11) is shown, the trouble codes will be shown in order of the last information first. These repeat for a maximum of 3 minutes. NOTE: When there are no trouble codes in memory, only the start code (11) is shown. 15 B4M0232A
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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
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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
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
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: Behavior of vehicle a) Directional
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&
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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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