Mechanical Components.pdf - Ken Gilbert

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C: INSPECTION 1. BASIC INSPECTION Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts. Part name Inspection Corrective action Free play Swinging torque Yawing torque Looseness Universal joint Steering column Standard value of universal joint free play: 0 mm (0 in) Max. value of universal joint swinging torque: 0.3 N·m (0.03 kg-m, 0.2 ft-lb) 2. AIRBAG MODEL INSPECTION WARNING: For airbag model inspection procedures, refer to 5-5 Supplemental Restraint System. SERVICE PROCEDURE 11 [W2C2] 4-3 2. Tilt Steering Column G4M0089 H4M1309A Replace if faulty. Replace steering column assembly.
4-3 [W2D0] SERVICE PROCEDURE 2. Tilt Steering Column D: ASSEMBLY 1) Insert combination switch to upper column shaft, and install lower column cover with tilt lever held in the lowered position. Then route ignition key harness and combination switch harness between column cover mounting bosses. 2) Fit upper column cover to lower column cover, and tighten combination switch and column cover. Tightening torque: 1.2±0.2 N·m (0.12±0.02 kg-m, 0.9±0.1 ft-lb) CAUTION: Don’t overtorque screw. E: INSTALLATION 1) Insert end of steering shaft into toeboard grommet. 2) Tighten steering shaft mounting bolts under instrument panel. Tightening torque: 25±5 N·m (2.5±0.5 kg-m, 18.1±3.6 ft-lb) 3) Connect ignition and combination switch connectors under instrument panel. 4) Connect airbag system connector at harness spool. NOTE: Make sure to apply double lock. 5) Install universal joint. (1) Align bolt hole on the long yoke side of universal joint with the cutout at the serrated section of shaft end, and insert universal joint. (2) Align bolt hole on the short yoke side of universal joint with the cutout at the serrated section of gearbox assembly. Lower universal joint completely. (3) Temporarily tighten bolt on the short yoke side. Raise universal joint to make sure the bolt is properly passing through the cutout at the serrated section. (4) Tighten bolt on the long yoke side, then that on the short yoke side. Tightening torque: 24±3 N·m (2.4±0.3 kg-m, 17.4±2.2 ft-lb) CAUTION: Make sure that universal joint bolts is tightened through notch in shaft serration. Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation. Standard clearance between gearbox to DOJ: Over 15 mm (0.59 in) 12 6) Install knee bolster. S4M0138A 7) Align center of roll connector. (with airbag model) CAUTION: Ensure that front wheels are set in straight forward direction. 8) Set steering wheel to neutral and install it onto steering shaft. Tightening torque: 44±6 N·m (4.5±0.6 kg-m, 32.5±4.3 ft-lb) Column cover-to-steering wheel clearance: 2—4mm(0.08 — 0.16 in) CAUTION: Insert roll connector guide pin into guide hole on lower end of surface of steering wheel to prevent damage. Draw out airbag system connector, horn connector and cruise control connectors from guide hole of steering wheel lower end. (with airbag model) 9) Install airbag module to steering wheel. (with airbag model) WARNING: Always refer to 5-5 Supplemental Restraint System before performing the service operation.
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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
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 and 68: CAUTION: Use a new axle nut. Alwa
Page 69 and 70: 5. Steel Wheel and Tire A: INSPECTI
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: 4-3 [W2B0] 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
Page 123 and 124: 4-3 [K1F0] DIAGNOSTICS 1. Power Ste
Page 125 and 126: 4-3 DIAGNOSTICS MEMO: 54
Page 127 and 128: 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
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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
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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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