Mechanical Components.pdf - Ken Gilbert

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4-2 [W4A0] SERVICE PROCEDURE 4. Full Wheel Cap CAUTION: Use a new axle nut. Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing. 13) After tightening axle nut, lock it securely. 30 4. Full Wheel Cap A: REMOVAL Pry off the full wheel cap with a wheel cap remover inserted between openings in the cap. B: INSTALLATION H4M1140 Align the valve hole in the wheel cap with the valve on the wheel and secure the wheel cap by tapping four points by hand.
5. Steel Wheel and Tire A: INSPECTION 1) Deformation or damage on the rim can cause air leakage. Check the rim flange for deformation, crack, or damage, and repair or replace as necessary. 2) Take stone, glass, nail etc. off the tread groove. 3) Replace tire: CAUTION: When replacing a tire, make sure to use only the same size, construction and load range as originally installed. Avoid mixing radial, belted bias or bias tires on the vehicle. (1) when large crack on side wall, damage or crack on tread is found. (2) when the “tread wear indicator” appears as a solid band across the tread. G4M0297 1. INSPECTION OF WHEEL RUNOUT 1) Jack-up vehicle until wheels clear the floor. 2) Slowly rotate wheel to check rim “runout” using a dial gauge. G4M0298 Axial runout limit Radial runout limit Steel wheel 1.5 mm (0.059 in) Aluminum wheel 1.0 mm (0.039 in) SERVICE PROCEDURE 31 [W5A1] 4-2 5. Steel Wheel and Tire H4M1395A 3) If rim runout exceeds specifications, remove tire from rim and check runout while attaching dial gauge to positions shown in figure. 4) If measured runout still exceeds specifications, replace the wheel.
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4-1 [S100] SPECIFICATION AND SERVIC
Page 3 and 4:
4-1 [C100] COMPONENT PARTS 1. Front
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4-1 [C200] COMPONENT PARTS 2. Rear
Page 7 and 8:
4-1 [W1B1] SERVICE PROCEDURE 1. On-
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Page 11 and 12:
Page 13 and 14:
4-1 [W2A0] SERVICE PROCEDURE 2. Fro
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4-1 [W2E0] SERVICE PROCEDURE 2. Fro
Page 17 and 18: 4-1 [W4A0] SERVICE PROCEDURE 4. 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: CAUTION: Use a new axle nut. Alwa
Page 71 and 72: 8. Tire Rotation If tires are maint
Page 73 and 74: 4-3 [S1A0] SPECIFICATIONS AND SERVI
Page 75 and 76: 4-3 [S1C0] SPECIFICATIONS AND SERVI
Page 77 and 78: 4-3 [C200] COMPONENT PARTS 2. Power
Page 79 and 80: 4-3 [C300] COMPONENT PARTS 3. Power
Page 81 and 82: 4-3 [W2B0] SERVICE PROCEDURE 2. Til
Page 83 and 84: 4-3 [W2D0] SERVICE PROCEDURE 2. Til
Page 85 and 86: 4-3 [W3A0] SERVICE PROCEDURE 3. Ste
Page 87 and 88: 4-3 [W3C0] SERVICE PROCEDURE 3. Ste
Page 89 and 90: 4-3 [W3C3] SERVICE PROCEDURE 3. Ste
Page 91 and 92: 4-3 [W3D0] SERVICE PROCEDURE 3. Ste
Page 93 and 94: 4-3 [W3F0] SERVICE PROCEDURE 3. Ste
Page 95 and 96: 4-3 [W4B0] SERVICE PROCEDURE 4. Con
Page 97 and 98: 4-3 [W4C2] SERVICE PROCEDURE 4. Con
Page 99 and 100: 4-3 [W4D1] SERVICE PROCEDURE 4. Con
Page 101 and 102: 4-3 [W5A0] SERVICE PROCEDURE 5. Pip
Page 103 and 104: 4-3 [W5C0] SERVICE PROCEDURE 5. Pip
Page 105 and 106: 4-3 [W6A0] SERVICE PROCEDURE 6. Oil
Page 107 and 108: 4-3 [W6B1] SERVICE PROCEDURE 6. Oil
Page 109 and 110: 4-3 [W6D0] SERVICE PROCEDURE 6. Oil
Page 111 and 112: 4-3 [W6E0] SERVICE PROCEDURE 6. Oil
Page 113 and 114: 4-3 [W7A0] SERVICE PROCEDURE 7. Pow
Page 115 and 116: 4-3 [K1B0] DIAGNOSTICS 1. Power Ste
Page 117 and 118: 4-3 [K1C0] DIAGNOSTICS 1. Power Ste
Page 119 and 120:
4-3 [K1C0] DIAGNOSTICS 1. Power Ste
Page 121 and 122:
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
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5. Brake Booster A: MODELS WITH ABS
Page 137 and 138:
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
Page 155 and 156:
D: ASSEMBLY 1. WHEEL CYLINDER 1) Cl
Page 157 and 158:
4. Parking Brake (Rear Disc Brake)
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D: ADJUSTMENT 1. SHOE CLEARANCE 1)
Page 161 and 162:
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
Page 167 and 168:
11) Remove bolt and clamp from rear
Page 169 and 170:
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
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
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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
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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
Page 205 and 206:
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
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
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DIAGNOSTICS 8E8 : CHECK BATTERY SHO
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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
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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
Page 315 and 316:
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
Page 329 and 330:
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
Page 337 and 338:
10H7 : CHECK POOR CONTACT IN CON- N
Page 339 and 340:
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
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 and 412:
10AJ10 : CHECK G SENSOR. Measure vo
Page 413 and 414:
B: CHECKING THE HYDRAULIC UNIT OPER
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