Mechanical Components.pdf - Ken Gilbert

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4-4 [T11A0] DIAGNOSTICS 11. General Diagnostic Table 11. General Diagnostic Table A: SYMPTOMS AND PROBABLE CAUSES Symptom Probable faulty units/parts ABSCM&H/U (solenoid valve) ABS sensor Brake (caliper & piston, pads) Vehicle pulls to either side. Wheel alignment Tire specifications, tire wear and air pressures Vehicle instability during braking Incorrect wiring or piping connections Road surface (uneven, camber) ABSCM&H/U (solenoid valve) ABS sensor Vehicle spins. Brake (pads) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections ABSCM&H/U (solenoid valve) Long braking/stopping distance Brake (pads) Air in brake line Tire specifications, tire wear and air pressures Incorrect wiring or piping connections ABSCM&H/U (solenoid valve, motor) Wheel locks. ABS sensor Incorrect wiring or piping connections ABSCM&H/U (solenoid valve) ABS sensor Master cylinder Brake dragging Brake (caliper & piston) Poor braking Parking brake Axle & wheels Brake pedal play Long brake pedal stroke Air in brake line Brake pedal play Suspension play or fatigue (reduced damping) Vehicle pitching Incorrect wiring or piping connections Road surface (uneven) ABSCM&H/U (solenoid valve) ABS sensor Unstable or uneven braking Brake (caliper & piston, pads) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections Road surface (uneven) Excessive pedal vibration Incorrect wiring or piping connections Road surface (uneven) ABSCM&H/U (mount bushing) Noise from ABSCM&H/U ABS sensor Brake piping ABSCM&H/U (mount bushing) ABS sensor Vibration and/or noise (while driving on slippery roads) Noise from front of vehicle Master cylinder Brake (caliper & piston, pads, rotor) Brake piping Brake booster & check valve Suspension play or fatigue ABS sensor Brake (caliper & piston, pads, rotor) Noise from rear of vehicle Parking brake Brake piping Suspension play or fatigue 168
B: CHECKING THE HYDRAULIC UNIT OPERATION DIAGNOSTICS 11B1 : PREPARING THE BRAKE TESTER. : Is the brake tester available? : CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER : CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE 169 [T11B1] 4-4 11. General Diagnostic Table
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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
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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
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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
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: 10AJ10 : CHECK G SENSOR. Measure vo
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