Daihatsu 1997 Terios J100 Service Manual
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Daihatsu 1997 Terios J100 Service Manual

Daihatsu 1997 Terios J100 Service Manual

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Table of Contents

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DAIHATSU
J100
SECTION INDEX
SECTION NAME
GENERAL INFORMATION
MAINTENANCE
ENGINE MECHANICAL
EMISSION CONTROL
EFI SYSTEM
LUBRICATION SYSTEM
COOLING SYSTEM
IGNITION SYSTEM
STARTING SYSTEM
CHARGING SYSTEM
CLUTCH
MANUAL TRANSMISSION
AUTOMATIC TRANSMISSION
TRANSMISSION & TRANSFER
PROPELLER SHAFT
FRONT & REAR DIFFERENTIAL
FRONT AXLE & SUSPENSION
REAR AXLE & SUSPENSION
BRAKE (Including A.B.S)
STEERING
BODY
BODY ELECTRICAL
HARNESS & WIRING DIAGRAM
SECTION
(
)
Including Airbag system
and immobilizer system
GI
MA
EM
EC
EF
LU
CO
IG
ST
CH
CL
MT
AT
TR
PR
DF
FS
RS
BR
SR
BO
BE
HW

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Do you have a question about the 1997 Terios J100 and is the answer not in the manual?

Questions and answers

Antonio
March 10, 2025

Salve vorrei sapere il gioco valvole

0
1 comments:
Mr. Anderson
March 10, 2025

The valve clearance specification for a 1997 Daihatsu Terios J100 is:

- Intake Valve Side: 0.030 - 0.055 mm
- Exhaust Valve Side: 0.035 - 0.060 mm

The allowable limit is:
- Intake Valve Side: 0.080 mm
- Exhaust Valve Side: 0.090 mm

This answer is automatically generated

0
Михаил
June 22, 2025

Место расположения температурного датчика на блоке двигателя?

0
Faisal Abdullah ali
May 18, 2025

Hi...ineed layout for all motor no.0254334

User image 682a4ab4edc4a
0

Related Manuals for Daihatsu 1997 Terios J100

Summary of Contents for Daihatsu 1997 Terios J100

  • Page 1 SECTION INDEX DAIHATSU SECTION NAME SECTION GENERAL INFORMATION MAINTENANCE J100 ENGINE MECHANICAL EMISSION CONTROL EFI SYSTEM LUBRICATION SYSTEM COOLING SYSTEM IGNITION SYSTEM STARTING SYSTEM CHARGING SYSTEM CLUTCH MANUAL TRANSMISSION AUTOMATIC TRANSMISSION TRANSMISSION & TRANSFER PROPELLER SHAFT FRONT & REAR DIFFERENTIAL FRONT AXLE &...
  • Page 2 NO. 9710-JE DAIHATSU MOTOR CO., LTD. ©1997 DAIHATSU MOTOR CO., LTD. All rights reserved. This material may not be reproduced or copied, in whole or in part, with- out the written permission of Overseas Service Division of Daihatsu Motor Co., ltd.

  • Page 3: General Information

    DAIHATSU J100 TO INDEX GENERAL INFORMATION IMPORTANT SAFETY NOTICE ....GI– 2 WARNINGS, CAUTIONS AND NOTES..GI– 2 HOW TO USE THIS MANUAL ...... GI– 4 CONTENTS OF EXPLANATION ....GI– 4 ABBREVIATION CODES ......GI– 6 GENERAL SERVICE INSTRUCTION ..GI– 7 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER ......

  • Page 4: Important Safety Notice

    GI–2 IMPORTANT SAFETY NOTICE The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is potentially hazard. However, one can handle it safely if he has the required knowledge. Correct service methods and repair procedures are very vital for assuring not only the safety and reliability of a vehicle, but also the safety of service personnel concerned.
  • Page 5 GI–3 The UNITS used in this manual are showed as the SI UNIT (International System of Unit), and alter- natively showed in the metric system. “Example” 24.5 - 34.3 N·m (2.5 - 3.5 kgf-m) JGI00002-00000...

  • Page 6: How To Use This Manual

    GI–4 HOW TO USE THIS MANUAL CONTENTS OF EXPLANATION 1. Schematic Diagram of Components (1) The schematic diagram of components that appears at the beginning of each section describes the nomenclature and installed conditions of each component. Furthermore the tightening torque is posted in the figure.
  • Page 7 GI–5 (4) The inspection in this manual describes only checking operation. Therefore, if you find any malfunc- tion, replace any defective parts with new ones. 3. SST For those operations which require the use of any SST, the SST numbers concerned are given in bold letters.

  • Page 8: Abbreviation Codes

    GI–6 ABBREVIATION CODES The abbreviation codes that appear in this workshop manual stand for the following, respectively. Abbreviation code Original word Meaning Refers to air conditioner. Air Conditioner Automatic Transmission Refers to automatic transmission A/T, AT A/Y or Ay Assembly Refers to an assembled component comprising more than two single parts or sub-assembly parts.

  • Page 9: General Service Instruction

    GI–7 GENERAL SERVICE INSTRUCTION 1. Use fender covers, seat covers and floor sheets so that the vehicle may not get dirty or be scratched. 2. Jacking up (1) When only the front section or rear section of the vehicle is jacked up, be sure to place chocks at the wheels so as to insure safe operations.

  • Page 10: Handling Instructions On Catalytic Converter

    GI–8 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER WARNING: • When a great amount of unburnt gas is admitted into the catalytic converter, overheating is prone to occur, resulting in a fire hazard. To avoid such trouble in advance, be certain to observe the following precautions. Also, be sure to explain such precautions to your customers.

  • Page 11: Jacking Points And Supporting Points Of Safety Stands

    GI–9 JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS CAUTION: • Be sure to support the vehicle at the flat surface of the rocker panel. • Do not support the vehicle at the edge part rocker panel. • Jacking Points Front side …………...
  • Page 12 GI–10 TOWING INFORMATION When towing the model J100 follow the manner mentioned below. CAUTION: • Never perform towing, using sling type equipment. Failure to observe this caution may lead to severe damage on the vehicle body. JGI00020-00000 Flat bed type We recommend this as the most desirable method.
  • Page 13 GI–11 • Never tow the vehicle at speed more than 30 km/h. • Turn the ignition switch of the vehicle to be towed in the “ACC” position during the towing. Never pull out the key or turn the ignition switch to the “LOCK” position during the towing. Failure to observe this warning will loose controllability, causing an accident.
  • Page 14 GI–12 2. When measuring the engine tachometer, connect the fol- lowing SST to the No.8 (REV) terminal of the above SST. SST: 09991-87402-000 JGI00027-00013 3. Utilize the following SST when connecting the terminals in the SST for the diagnosis connector which is specified in the main text.

  • Page 15: Model Variation

    GI–13 MODEL VARIATION General Specification Engine Handle position Grade J100RG J100LG J100RG J100RG J100LG Model code HC-EJ GMDE GMXE GMDE GMXE GMDEQ GMXEQ GMDEW GMXEW GMDEW GMXEW GPDE GPXE GPDE GPXE GPDEQ GPXEQ GPDEW GPXEW GPDEW GPXEW JGI00011-00000 Explanation of vehicle model code Model code J1 : TERIOS Drive system...

  • Page 16: Chassis Serial Number Stamped Position

    GI–14 CHASSIS SERIAL NUMBER STAMPED POSITION Serial number The chassis number is stamped on the cowl panel at the right side in the engine compartment. JGI00013-00004 MANUFACTURER’S PLATE POSITION The manufacturer’s plate is attached on the cowl panel. Manufacturer’s plate JGI00014-00005 CONTENTS OF MANUFACTURER’S PLATE (1) General, Australian, Norwegian and Finnish specifications...

  • Page 17: Engine Number And Engine Type Stamped Positions

    GI–15 ENGINE NUMBER AND ENGINE TYPE STAMPED POSITIONS • The engine number is stamped on the cylinder block. Serial number • The engine type is indicated by embossed letters on the stamped cylinder block. position JGI00016-00007 BODY COLOR INFORMATION Code Body color name Silver metallic Black metallic...

  • Page 18: Jgi00018

    GI–16 COLOR CODE IN THE WORLD Color code Color name SPIES DAIHATSU AKZO DUPONT STANDOX HECKER L8842 B127B 97076 DAHS07 Silver metallic G8742 A403B 96326 DAH6A5 Black metallic F2213 FCN6B 33273 DAHR24 Red mica metallic DAHB36 Turquoise mica metallic F2855...

  • Page 19: Table Of Contents

    DAIHATSU J100 TO INDEX MAINTENANCE MAINTENANCE REQUIREMENTS ... MA– 2 BRAKE MASTER CYLINDER ..MA–35 MAINTENANCE SCHEDULE .... MA– 3 MUFFLER AND EXHAUST PIPE ... MA–37 SCHEDULE FOR SEVERE AUTOMATIC TRANSMISSION ..MA–37 DRIVING ........MA– 5 CLUTCH ........MA–38 MAINTENANCE OPERATION ...

  • Page 20: Maintenance Requirements

    Consequently, potential vehicle damage can be prevented or the degree of the damage can be minimized. Therefore, all of the persons who are concerned with servicing the Daihatsu vehicles should offer the peri- odical maintenance service to Daihatsu car owners in order that they may be protected from accidents or unexpected problems.

  • Page 21: Maintenance Schedule

    • This maintenance schedule prepared based on requirements mentioned in the owner’s manual which are to be performed by the Daihatsu owner thoroughly. ™ ¡ ···Check or inspect.
  • Page 22 MA–4 ™ ¡ ···Check or inspect. ···Change or replace. ×1000 km 1 10 20 30 40 50 60 70 80 90 100 ×1000 miles Section Item What to do Inspection interval 0.6 6 12 18 24 30 36 42 48 54 60 page Years —...

  • Page 23: Schedule For Severe Driving

    MA–5 ™ ¡ ···Check or inspect. ···Change or replace. ×1000 km 1 10 20 30 40 50 60 70 80 90 100 ×1000 miles Section Item What to do Inspection interval 0.6 6 12 18 24 30 36 42 48 54 60 page Years —...

  • Page 24: Maintenance Operation

    MA–6 MAINTENANCE OPERATION ENGINE COLD ENGINE OPERATION 1. Inspection of drive belt (1) Visual inspection of drive belt Visually check the belt for separation of the adhesive rubber above and below the core, core separation from the belt side, severed core, separation of the rib from the adhesive rubber, cracks or separation of the JMA00005-00001 ribs, torn or worn ribs or cracks in the inner ridges of...
  • Page 25 MA–7 (4) Cleaning of air filter element Clean the air filter element with compressed air. First, blow compressed air from the back side of the element thoroughly. Then, blow off the upper side of the element. WARNING: · Protect your eyes with safety goggles during the clean- ing operation.
  • Page 26 MA–8 4. Inspection of fuel line and connection (1) Visually inspect the fuel line including the fuel hose for connecting condition, cracks, tightness, leakage and damage. If cracks or any other damage exists, repair or replace the part as required. (2) Check the connecting section of the fuel line for loose- ness and leakage.
  • Page 27 MA–9 (10) Remove the wire from the fuel pump relay terminal in the relay box. CAUTION: · Never deform or damage the terminals during opera- tion. · Never make connection between terminals except for those specified. Fuel pump relay Even slight contact of the other terminal causes serious trouble.
  • Page 28 MA–10 (4) Start the engine and wait for a little while until the engine stops. (5) Turn off the ignition switch. (6) Jack-up the vehicle and support it with safety stands. (Refer to the GI section.) (7) Detach the fuel hose clips. WARNING: ·...

  • Page 29: Inspection Of Charcoal Canister

    MA–11 e Remove the engine undercover by removing the six attaching bolts. JMA00020-00015 r Disconnect the atmosphere side hose from the frame. t Remove the charcoal canister from the vehicle by pulling up the charcoal canister case to unlock it from the bracket.

  • Page 30: Installation Of Charcoal Canister

    MA–12 t Cleaning of charcoal canister Clean the charcoal canister by blowing com- pressed air of 294.2kPa (3.0 kg/cm ) into the fuel tank side pipe B while holding the purge side of the canister pipes A closed. CAUTION: · Never attempt to wash the charcoal canister.

  • Page 31: Hot Engine Operation

    MA–13 HOT ENGINE OPERATION 1. Change of engine oil and oil filter WARNING: · Protect your eyes by wearing safety goggles. · Never burn yourself with hot engine oil or hot engine components during operation. (1) Park the vehicle on a level surface. (2) Check the oil level.
  • Page 32 MA–14 (17) Pull out the oil level gauge and wipe off the engine oil. ˚C –29 –18 –7 TEMP. –20 ˚F (18) Reinsert the oil level gauge as far as it will go. Engine oil (19) Pull out the oil level gauge again. (4 stroke) *10W-30, 10W-40, 10W-50 (20) Ensure that the engine oil level is between the “L”...
  • Page 33 Remove the No. 1 and No. 3 resistive cords by dis- connecting the connectors from the ignition coils and spark plugs. CAUTION: DAIHATSU · Never disconnect the resistive cords by holding the 16VALVE cord section of the resistive cords.
  • Page 34 MA–16 (4) Removal of spark plug (Refer to the step (3)–6 above.) (5) Visual inspection of spark plug Visually inspect the spark plug for electrode wear, damage in threads or insulation. Replace the spark plug if it exhibits any damage. Recommended Spark Plug: DENSO K20TNR-S...
  • Page 35 (12) Connect the resistive cords to the spark plugs and ig- nition coils properly as shown in the figure. NOTE: DAIHATSU · Never interfere the resistive cord with the ignition coils 16VALVE and attaching nuts of the ignition coils.
  • Page 36 MA–18 3. Inspection and adjustment of valve clearance The measurement and adjustment of the valve clearance are carried out when each piston of the No. 1 and No. 4 cylinders is set to the top dead center at the end of com- pression stroke.
  • Page 37 MA–19 e Check to see if the valve rocker arms of the No. 1 cylinder are free or are being pushed. According to the table below, check and adjust the valve clearance, using a thickness gauge. JMA00051-00042 Pistion position Inkate When valve rocker arms of No.
  • Page 38 MA–20 t Apply the Three Bond ® 1104 to the four points on the cylinder head, as indicated in the figure. JMA00054-00044 y Install the cylinder head cover on the cylinder head. NOTE: • Never damage the rubber grommets for the spark plug tubes during the installation of the cylinder head cover.
  • Page 39 MA–21 CAUTION: • Never allow the tachometer terminal to touch ground. It could result in damage of the ignition system. • As some tachometer are not compatible with this igni- tion system, it is recommended to confirm the compati- bility with your unit before its use. •...
  • Page 40 MA–22 5. Inspection of dashpot (For automatic transmission-equipped model only) Preparation to be made prior to idle speed adjustment · Check and adjust the ignition timing. · Check and adjust the idle speed. · Apply the parking brake fully. · Warm up the engine thoroughly.
  • Page 41 MA–23 6. Change of engine coolant WARNING: · Never open the radiator cap when the engine is still hot. CAUTION: · As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calci- um, magnesium, and so forth.
  • Page 42 MA–24 (27) Slowly pour a proper amount of antifreeze solution into the radiator in accordance with the instruction of the manufacturer of antifreeze solution. CAUTION: · Use a good brand of ethylene-glycol base antifreeze solution. Coolant Capacity: Automatic Transmission: 5.3 liters Manual Transmission: 5.4 liters NOTE:...
  • Page 43 MA–25 (38) Remove the radiator cap. (39) Ensure that the concentration of antifreeze solution in the radiator meets the instruction of the manufacturer of antifreeze solution by a densitometer. Adjust the concentration of the antifreeze solution in the radiator according to the instruction of the manu- facturer of the antifreeze solution, if the concentration does not meet the instruction of the manufacturer of the antifreeze solution.

  • Page 44: Chassis

    MA–26 CHASSIS BRAKE FLUID CHANGE WARNING: · Do not mix the different kind and manufacture of brake fluid. Recommended brake fluid: FMVSS116 DOT3 or SAE J1703 CAUTION: · If the brake fluid is spilled inadvertently over the paint finish surface of the vehicle or the resin made part, immediately wipe off the brake fluid and flush with fresh water.

  • Page 45: Brake Pedal

    MA–27 BRAKE PEDAL FREE PLAY Ensure that the ignition switch is turned OFF. Depress the brake pedal more than five times to release the vacuum saved in the brake booster. Ensure that the specified free play exists on the brake pedal by pushing the brake pedal lightly by hand.

  • Page 46: Brake Hose & Tube

    MA–28 INSPECTION OF EFFECTIVENESS Check to see if the vehicle can be retained in a stationary state on a dry slope with a grade of 1/5 when the parking brake is applied fully. If not, check and repair the rear brake system. JMA00080-00000 BRAKE HOSE &...

  • Page 47: Front Brake

    MA–29 FRONT BRAKE COMPONENTS 83.4 ± 4.9 : Tightening torque (8.5 ± 0.5) Unit : N·m (kgf-m) : Non-reusable parts 49.0 ± 4.9 (5.0 ± 0.5) q Cylinder slide main pin w Cylinder slide sub-pin e Disc brake No. 1 pad r Disc brake No.
  • Page 48 MA–30 INSPECTION OF FRONT BRAKE RUBBER PARTS AND BRAKE PAD FOR DAMAGE 1. Jack up the vehicle and support the vehicle with safety stands. 2. Remove the front wheel. 3. Remove the sub-cylinder slide pins. JMA00084-00065 4. Turn up the disc brake assembly as shown. CAUTION : ·...
  • Page 49 MA–31 11. Ensure that the brake pads, anti-squeal shims and pad guide plates are installed properly. CAUTION: · Be very careful not to deform or lose the anti-squeal shims. 12. Thinly apply the brake rubber grease to the sub-cylinder slide pin boot. JMA00087-00068 13.

  • Page 50: Rear Brake

    MA–32 REAR BRAKE COMPONENTS : Tightening torque Unit : N·m (kgf-m) 9.8 ± 2 (1.0 ± 0.2) : Non-reusable parts !5 !7 !1 1 61 ± 7 (6.25 ± 0.75) q Brake drum subassembly w Brake shoe hold down spring e Shoe hold down spring pin r Tension No.
  • Page 51 MA–33 INSPECTION OF WHEEL CYLINDER FOR LEAKAGE Jack up the vehicle and support it with safety stands. (Refer to the GI section.) Remove the wheels. Release the parking brake fully. Remove the rear brake drum from the rear axle hub by pulling it out.

  • Page 52: Brake Booster Hose

    MA–34 BRAKE BOOSTER HOSE COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 9.8 - 15.7 (1.0 - 1.6) 25.5 ± 2.9 (2.6 ± 0.3) 25.5 ± 2.9 (2.6 ± 0.3) 9.8 - 15.7 (1.0 - 1.6) q Brake booster assembly w Master cylinder push rod clevis e Brake booster bracket gasket r Union to connector tube...

  • Page 53: Brake Master Cylinder

    MA–35 BRAKE MASTER CYLINDER COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 12.7 ± 2.5 (1.3 ± 0.3) 7.9 - 11.7 (0.8 - 1.2) q Brake master cylinder reservoir tank w Reservoir filler cap e Reservoir diagram r Grommet t Brake master cylinder assembly y Tandem master cylinder repair kit...
  • Page 54 MA–36 7. Secure the master cylinder in a vise. 8. Ensure that no brake fluid leakage exists around the pis- ton guide section of the brake master cylinder. If any brake fluid leakage exists, replace the brake master cylinder pistons with piston cups(repair kit) with new ones. (Refer to the BR section.) 9.

  • Page 55: Muffler And Exhaust Pipe

    MA–37 MUFFLER AND EXHAUST PIPE DAMAGE & TIGHTNESS 1. Visually check that the exhaust pipes and mufflers for damage and exhaust gas leakage. Also ensure that there is no possibility of interference with any other parts. WARNING · Never perform this check when the exhaust system is hot.

  • Page 56: Clutch

    MA–38 CHECK OF OIL COOLER HOSE Inspect the following points. If any problem is found, repair them, as required. 1. Hoses and tubes for scratches or cracks. 2. Hoses for aging such as deformation and swelling. 3. Tubes for corrosion or rusting. 4.

  • Page 57: Transfer, Front And Rear Differential

    MA–39 MANUAL TRANSMISSION, TRANSFER, FRONT AND REAR DIFFERENTIAL OIL CHANGE 1. Place a suitable container under the drain plug. 2. Drain the oil by removing the drain plug. 3. Remove the filler plug. 4. Reinstall the drain plug with a new gasket interposed and tighten it to the specified tightening torque.

  • Page 58: Propeller Shaft

    MA–40 PROPELLER SHAFT CHECK OF PROPELLER SHAFT 1. Ensure that no looseness exists on the attaching bolts of the universal joint flange yokes which were connected to the front, rear differential and propeller shaft, using a torque wrench. Tightening Torque: 51.0 - 69.6 N·m (5.2 - 7.1 kgf-m) If any looseness exists, retighten the attaching bolts as re- quired.

  • Page 59: Steering System

    MA–41 STEERING SYSTEM STEERING WHEEL FREE PLAY 1. Set the vehicle in a straight-ahead condition. Play 2. Inspect the steering wheel free play by turning it lightly with your fingers. Specified Value: 10 mm MAX. 10 mm MAX. If the free play fails to meet with the specification, adjust the free play to the specified value.

  • Page 60: Wheel Alignment

    MA–42 POWER STEERING FLUID HOSE Inspect the power steering fluid hose for aging, deformation, cracks, scratches, cut, twist and swelling. If any problem is found, replace the fluid hose with a new one. (Refer to the SR section.) CAUTION: · Never reuse the removed hose bands.

  • Page 61: Shock Absorber

    MA–43 SHOCK ABSORBER DAMAGE AND OIL LEAKAGE Visually inspect each shock absorber for damage and oil leakage. If damage or oil leakage exists, replace the damaged part with a new one. (Refer to FS or RS section.) JMA00124-00104 FUNCTION Rock the vehicle in an up-&-down direction. Ensure that the vehicle emits no abnormal noise and the shake will finish with- in a few times.

  • Page 62: Engine Mechanical

    DAIHATSU J100 TO INDEX ENGINE MECHANICAL ENGINE TUNE-UP ......EM– CYLINDER BORING ...... EM– 86 TIMING BELT ........EM– 10 REPLACEMENT OF REAR OIL COMPONENTS ......EM– 10 SEAL .......... EM– 87 REMOVAL ........EM– 11 REPLACEMENT OF FRONT OIL INSPECTION ........
  • Page 63 EM–2 ENGINE TUNE-UP NOTE: • The adjustments or checks of this section is performed normally when the engine is in a hot condi- tion. • “Hot engine condition” denotes a condition in which the cooling water temperature is 75 - 85°C and the engine oil temperature is above 65°C.
  • Page 64 EM–3 2. Inspection of engine oil (1) Oil quality check Check the engine oil for deterioration, ingress of water, discoloring and dilution. NOTE: • Park the vehicle or a level surface. • The amount of oil between the “L” level and the “F” level equals around one liter.
  • Page 65 EM–4 (1) Inspection of electrode Measure the insulation resistance of the spark plug. Minimum Insulation Resistance: 15 MΩ If the measured insulation resistance is less than the specified value, replace the spark plug with a new one after checking the electrode gap and cleaning the spark plug.
  • Page 66 EM–5 5. Inspection and adjustment of valve clearances The measurement and adjustment of valve clearance are carried out when each of the piston of the No. 1 and No. 4 cylinders is set to the top dead center at the end of com- pression stroke.
  • Page 67 EM–6 6. Inspection and adjustment of ignition timing Check to see if the ignition timing mark of the crankshaft pulley is aligned with the indicator of the timing belt cover by using a timing light under the condition that the T termi- nal has been connected with the ground terminal in the di- agnosis connector by the following SST.
  • Page 68 EM–7 Measure the engine idle speed, using a tachometer which is connector to the “REV” terminal of the diagnosis con- Diagnosis connector nector. NOTE: • Never allow the “REV” terminal to touch the ground. It could result in damage of the ignition system. •...
  • Page 69 EM–8 If the compression of one or more cylinders is low, pour a small amount of engine oil into that cylinder through the spark plug hole and measure the cylinder compression again. • If adding oil helps the compression to improve, chances are that the piston rings and/or cylinder bores are worm or damaged.
  • Page 70 EM–9 Trouble Shooting List Problems Possible causes 1. Faulty ignition • Incorrect ignition timing • Fouled, shorted or improperly gapped spark plugs • Open or crossed high tension cords High Normal Rough idle 2. Incorrect valve clearance 3. Leaky exhaust valves 4.

  • Page 71: Timing Belt

    EM–10 TIMING BELT COMPONENTS FRONT q Fan shroud y Timing belt upper cover w Fan & fluid coupling u Timing belt lower cover e V-ribbed belt i Timing belt tensioner subassembly r Water pump pulley o Timing belt t Crankshaft pulley assembly JEM00025-00017...
  • Page 72 EM–11 REMOVAL IG “OFF” 1. Disconnect the battery ground cable from the negative (–) terminal of the battery. JEM00026-00018 2. Remove the engine undercover. JEM00027-00019 3. Removal of fan and fluid coupling (1) Drain the coolant by loosening the drain plug and the radiator cap.
  • Page 73 EM–12 4. Remove the power steering vane pump drive belt by loos- ening the power steering vane pump attaching bolts. 5. Remove the alternator drive belt. JEM00031-00022 6. Remove the crankshaft pulley. NOTE: • Place the shift lever in the 4th gear position so as to prevent the rotation of the crankshaft in the case of manual transmission-equipped model.
  • Page 74 EM–13 9. Removal of timing belt NOTE: • Prior to removal of the timing belt, put an arrow mark indicating the normal rotating direction on the belt, using a chalk or the like. CAUTION: Mark showing • normal rotating Do not try to pry the timing belt with a screwdriver or direction the like during the removal or installation.
  • Page 75 EM–14 10. Removal of camshaft timing belt pulley (1) Remove the timing belt. (2) Remove the cylinder head cover. JEM00039-00000 (3) Removal of camshaft timing belt pulley While preventing the camshaft timing belt pulley from turning using a suitable iron rod, remove the three at- taching bolts.
  • Page 76 EM–15 (3) Remove the timing belt pulley flange. JEM00044-00034 INSPECTION 1. Inspection of timing belt CAUTION: • Do not bend, twist or turn the belt inside out. • Do not allow the belt to come into contact with oil, water or steam. JEM00045-00035 If there are damages, as shown in the figures, check the following points and replace the timing belt, if necessary.
  • Page 77 EM–16 (4) If there is wear or damage on only one side of the belt, check the pulley flange. JEM00049-00039 (5) If there is noticeable wear on the belt teeth, check the timing cover gasket for damage and check for correct gasket installation.
  • Page 78 EM–17 4. Inspection of tension spring (1) Check the free length of the spring Free Length: 46.5 mm or less (2) Check the tension of the spring at the specified instal- lation length. Specified Value: 29.4 ± 3 N at 50.9 mm If the tension does not conform to the specification, re- place the spring.
  • Page 79 EM–18 (2) Install the attaching bolts of the camshaft timing belt pulley, while preventing the pulley from turning by in- serting an iron rod into the hole of the pulley. Tightening Torque: 14.7 - 21.6 N·m NOTE: • Do not turn the camshaft independently. •...
  • Page 80 EM–19 (2) Align the drilled mark of the camshaft timing belt pul- “F” mark Indicator ley with the top surface line of the cylinder head. (3) Align the drilled mark of the crankshaft timing belt pul- Drilled mark ley with the indicator. (4) Assemble the timing belt in such a way that the two mating marks on the timing belt may be aligned with the corresponding drilled marks on the crankshaft tim-...
  • Page 81 EM–20 (8) Turn the crankshaft further in the normal direction until the “F” mark of the camshaft timing belt pulley is aligned with the indicator of the cylinder head cover. NOTE: • Never turn the crankshaft reversely. • Never turn the crankshaft beyond the point where the “F”...
  • Page 82 EM–21 7. Install the oil pressure switch wire and tighten the wire clamps. 8. Connect the oil pressure switch connector. 9. Install the crankshaft pulley with the attaching bolt. Tighten the bolt to the specified torque. JEM00073-00063 Tightening Torque: 19.6 - 29.4 N·m NOTE: •...
  • Page 83 EM–22 Specified Belt Deflection: New Belt: 4.0 - 5.0 mm With a force of 98.1 N (10 kgf) applied to point indicated in figure Used Belt: 5.0 - 6.0 mm With a force of 98.1 N (10 kgf) applied to point indicated in figure NOTE: •...
  • Page 84 EM–23 19. Install the engine undercover and tighten the attaching bolts. JEM00083-00072 20. Connect the ground cable to the negative (–) terminal of IG “OFF” the battery. JEM00084-00073...

  • Page 85: Cylinder Head

    EM–24 CYLINDER HEAD COMPONENTS : Non-reusable parts Front q Cylinder head cover !4 Camshaft timing belt pulley w Camshaft !5 Spacer e Valve rocker shaft !6 Grommet r Valve guide !7 Oil filler cap t Cylinder head !8 Gasket y Oil seal !9 Timing belt upper cover u Spark plug @0 Timing belt...
  • Page 86 EM–25 INSTRUCTION PRIOR TO OPERATION • Install the fender cover to the fenders so that so scratch may be made to the fenders. • Be sure to read the general information section of the ser- vice manual. JEM00086-00000 CYLINDER HEAD REMOVAL 1.
  • Page 87 EM–26 6. Remove the power steering vane pump from the engine. Suspend the removed steering vane pump at body side, using an adequate rope. JEM00091-00079 7. Removal of alternator (1) Remove the connector and the cable at the rear side of the alternator.
  • Page 88 EM–27 (2) Disconnect the harness clamps by unlocking the clamps. (3) Remove the engine harness from the cylinder head. JEM00096-00083 10. Disconnect the water hoses JEM00097-00084 11. Remove the surge tank stay No. 1, No. 2 and No. 3. JEM00098-00085 12.
  • Page 89 EM–28 14. Removal of intake manifold (1) Disconnect the plugged hose at the cylinder head. JEM00101-00088 (2) Remove the attaching bolts and nuts of the intake manifold by loosen them evenly over two or three stage, following the sequence shown in the right fig- ure.
  • Page 90 EM–29 (5) Loosen the exhaust manifold attaching bolts and nuts evenly over two or three stages in the sequence shown in the right figure. (6) Remove the exhaust manifold from the cylinder head while preventing the interference with other parts. JEM00106-00093 16.
  • Page 91 EM–30 22. Remove the rocker arms, spacers and wave washers from the removed valve rocker shaft. NOTE: • Arrange the removed parts in oder to so that their re- spective original installation positions may be known readily. JEM00111-00098 23. Remove the camshaft bearing caps by removing the at- taching bolts.
  • Page 92 EM–31 OVERHAUL OF CYLINDER HEAD DISASSEMBLY OF CYLINDER HEAD 1. Remove the water temperature sensor gauge from the cylinder head. 2. Remove the engine hanger. JEM00116-00102 3. Remove the valve spring retainer locks, using the follow- ing SST. SST: 09202-87002-000 JEM00117-00103 4.
  • Page 93 EM–32 7. Remove the valve spring seats. NOTE: • Arrange the removed parts in order so that their in- stalling positions may be known easily. JEM00121-00107 8. Wash the disassembled parts except for electrical parts, plastic parts and grease sealed bearings. Dry them by blowing compressed air.
  • Page 94 EM–33 3. Cleaning of combustion chamber Using a wire brush, remove all carbon deposits from the combustion chambers. CAUTION: • Be careful not to scratch the cylinder head gasket con- tact surfaces. JEM00125-00111 4. Cleaning of valve guide bushings Using a valve guide brush and solvent, clean all the valve guide bushings.
  • Page 95 EM–34 JEM00000-00116 7. Inspection of cylinder head for cracks Using a dye penetrant, check the combustion chamber, intake and exhaust ports, cylinder head surface and top of the cylinder head for cracks. If a crack is found, replace the cylinder head. JEM00130-00117 8.
  • Page 96 EM–35 (3) Install the bearing caps and rocker shafts. Tighten them to the specified torque. Tightening Torque M10 Bolt: 28.4 - 36.3 N·m/Dry M8 Bolt: 12.7 - 16.7 N·m/Dry NOTE: • Each bearing cap bears a cap number. • The intake valve rocker shaft can be identified by the recessed sections on it.
  • Page 97 EM–36 (2) Install the camshaft to the cylinder head. Install the bearing caps and rocker shafts and tighten them to the specified torque. Tightening Torque M10 Bolt: 28.4 - 36.3 N·m/Dry M8 Bolt: 12.7 - 16.7 N·m /Dry NOTE: • Each bearing cap bears a cap number.
  • Page 98 EM–37 (2) Visually inspect the valve head for melting or damage. If the valve head exhibits any melting or damage, re- place the valve. If the roughness on the contact surface can be cor- rected, grind the valve seat contact surface with a valve refacer.
  • Page 99 EM–38 11. Inspection and cleaning of valve seats (1) Using a 45-degree valve seat cutter, reface the valve seats. Remove only enough metal stock to clean the seats. 45° (2) Apply a thin film of red lead (or white lead) to the valve seat.
  • Page 100 EM–39 e Using a 70-degree cutter, cut the seat in such way that the width, of the surface refaced by the 45-de- gree cutter may became 1.4 mm. 1.4 mm (0.055 inch) JEM00149-00136 r Using the 45-degree cutter, remove burrs pro- duced during the refacing by the 30-degree and 70-degree cutters.
  • Page 101 EM–40 r Using the 45-degree cutter, remove burrs pro- duced during the refacing by the 20-degree and 70-degree cutters. 70° 45° 20° JEM00154-00141 13. Hand lapping of valves (1) Perform hand lapping of the valves and valve seats, using an abrasive compound. (2) Clean the valves and valve seats after the hand lap- ping of the valves.
  • Page 102 EM–41 w Using an adjustable reamer, ream the valve guide bush to remove any burr or the like. NOTE: • This reaming should be made only enough to remove the burr or the like. JEM00159-00145 e Inspection of oil clearance Ensure that the oil clearance meets the specifica- tions.
  • Page 103 EM–42 (4) Calculation of oil clearance Calculate the oil clearance of each valve according to the following formula. Oil clearance = Inner diameter of valve stem guide – Outer diameter of valve stem Specified Oil Clearance Intake Valve Side: 0.030 - 0.055 mm Exhaust Valve Side: 0.035 - 0.060 mm Allowable Limit...
  • Page 104 EM–43 e Using an adjustable reamer, ream the valve guide bush to remove any burr or the like. NOTE: • This reaming should be made only enough to remove the burr or the like. JEM00168-00153 r Inspection of oil clearance Ensure that the oil clearance meets the specifica- tions.
  • Page 105 EM–44 (3) Check of valve spring edge surface for levelness 49 N q Apply a load of 49 N to the valve spring on a spring tester. w Under the condition q above, insert a thickness gauge at the arrowheaded point “A” at the right fig- ure.
  • Page 106 EM–45 Reference: Recess Timing belt side • Identification of valve rocker shafts • On the intake valve rocker shaft, recesses for the spark plug tube are provided. • Also, the oil grooves are provided very closely to the bolt holes. •...
  • Page 107 EM–46 (2) Checking of cam lobe height Measure the cam lobe height, using a micrometer. Specified Cam Lobe Height: Intake: 33.434 - 33.634 mm Exhaust: 33.17 - 33.37 mm Minimum Limit: Intake: 33.2 mm Exhaust: 33.0 mm JEM00181-00166 (3) Inspection of oil seal contact surface Inspect the oil seal contact surface for abnormal wear.
  • Page 108 EM–47 22. Check the valve spring seats, valve spring retainers and valve retainer locks for damage and cracks. If any damage is present, replace such faulty parts. JEM00186-00171 23. Inspection of cylinder head cover (1) Visually inspect the cylinder head cover gasket for damage.
  • Page 109 EM–48 ASSEMBLY OF CYLINDER HEAD NOTE: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets and oil seals with new ones. JEM00191-00000 1.
  • Page 110 EM–49 (5) Apply a thin film of the Three Bond 1377B to the at- taching section for the heater outlet tube on the cylin- der head. JEM00196-00180 (6) With a wooden piece interposed, drive the heater out- let tube to the point marked in Step (4). JEM00197-00181 (7) After completion of the operation, remove any oozed bond, wooden chips and so forth.
  • Page 111 EM–50 (3) Turn the oil seal slightly by hand to see if it can be turned. NOTE: • Never rotate the oil seal more than one turn, because excessive turning may cause scratches on the oil seal. • If the oil seal can not be turned by hand, it means that the oil seal has been tilted, driven diagonally or press- fitted improperly.
  • Page 112 EM–51 (3) After installing the valve spring retainer lock, lightly tap the valve spring retainer with a hammer or the like so as to ensure that the valve spring retainer locks are in- stalled securely. WARNING: • During this operation, care must be exercised to en- sure that the valve spring retainer or retainer locks may not be jumped out.
  • Page 113 EM–52 10. Install the cylinder head on the cylinder block. JEM00210-00194 11. Coat each cylinder head bolt with a thin film of engine oil. Using these bolts, install the cylinder head to the cylinder block. Tighten the bolts evenly over two or three stages, following the sequence shown in the right figure.
  • Page 114 EM–53 (4) Apply the Three Bond 1104 to the camshaft cap No. 1 attaching section of the cylinder head at those points shown in the right figure. (5) Apply engine oil to the camshaft journal section. NOTE: • Be very careful not to allow any oil to flow into the bear- ing cap attaching holes.
  • Page 115 EM–54 (9) Clean the attaching bolts and dry them with com- pressed air. Install them to the cylinder head through the rocker shafts and camshaft caps. Tighten the bolts evenly over two or three stages to the specified torque. Tightening Torque M10 Bolt: 28.4 - 36.3 N·m/Dry M8 Bolt:...
  • Page 116 EM–55 18. Connect the connector to the water temperature sensor. 19. Install the ignition coil to the cylinder head cover and tight- en it. Tightening Torque: 2.9 - 4.9 N·m 20. Connect the resistive cords between the ignition coil and the spark plug.
  • Page 117 EM–56 (7) Install and tighten the attaching bolt of the oil level gauge guide. (8) Insert the oil level gauge to the oil level gauge guide. JEM00228-00211 (9) Connect the exhaust front pipe to the exhaust manifold with a new gasket interposed. CAUTION: •...
  • Page 118 EM–57 (7) Connect the rubber hoses for brake booster and VSV. (8) Connect the fuel inlet hose and return hose. (9) Connect the water hose. JEM00233-00216 (10) Installation of engine wire q Connect the connector of the engine wire to the fol- lowing parts.
  • Page 119 EM–58 (13) Install the power steering vane pump JEM00238-00220 (14) Install the acceleration cable to the throttle body and adjust it. JEM00239-00221 (15) Installation of air cleaner. q Install the air cleaner lower case to the engine and tighten the attaching bolts. JEM00240-00222 w Install the air filter element to the air cleaner lower case.
  • Page 120 EM–59 (16) Install the battery carrier and the battery. (17) Connect the battery cable to each terminals of the bat- tery. JEM00243-00224 (18) Fill the coolant (Refer to CO section of this manual) JEM00244-00000...

  • Page 121: Cylinder Block

    EM–60 CYLINDER BLOCK COMPONENTS : Non-reusable parts Front q Timing belt cover No. 1 !3 Crankshaft pulley w Timing belt cover No. 2 !4 Crankshaft bearing e Water pump assembly !5 Piston with pin r Water pump gasket !6 Piston ring t Dust seal !7 Connecting rod y Oil pump assembly...
  • Page 122 EM–61 INSTRUCTION PRIOR TO OPERATION • Install the fender cover to the fenders so that no scratch may be made to the fenders. • Be sure to read the general information section of the ser- vice manual. JEM00246-00000 ENGINE REMOVAL 1.
  • Page 123 EM–62 8. Remove the fan and fan shroud. 9. Remove the radiator. JEM00250-00229 10. Remove the air cleaner. JEM00251-00230 11. Remove the alternator. JEM00252-00231 12. Remove the accelerator cable and rubber hoses. JEM00253-00232 13. Disconnect the following connectors and remove the en- gine wire (1) Ignition coils (2) Injectors...
  • Page 124 EM–63 JEM00000-00234 14. Disconnect the fuel inlet hose and return hose. CAUTION: • The fuel pressure at inside of the fuel line is approxi- mately 284 kPa higher than the atmospheric pressure. • Therefore, be sure to gradually pull out the rubber Inlet hoses so as to prevent fuel from splashing.
  • Page 125 EM–64 (3) Remove the bracket of the front exhaust pipe clamp from the transmission. (4) Remove the front exhaust pipe from the engine by dis- connecting the attaching nuts of the main muffler. JEM00259-00239 19. Remove the following stiffener from the engine and the transmission.
  • Page 126 EM–65 24. Place the engine on the suitable engine stand. JEM00264-00000 25. Remove the timing belt. 26. Removal of cylinder head cover. (1) Remove the ignition coils and resistive cords. JEM00265-00244 (2) Remove the cylinder head cover attaching bolts. (3) Remove the cylinder head cover. JEM00266-00245 27.
  • Page 127 EM–66 (4) Remove the cylinder head gasket. (5) Remove any remaining gasket material from the gas- ket surfaces of the cylinder head and cylinder block, using the gasket scraper. JEM00269-00248 DISASSEMBLY OF CYLINDER BLOCK 1. Remove the oil pressure switch and oil filter. JEM00270-00249 2.
  • Page 128 EM–67 4. Remove the crankshaft timing belt pulley. JEM00274-00253 NOTE: • If the crankshaft timing belt pulley can not be removed by hand, install the following SST with the crankshaft timing belt pulley bolt interposed. SST: 09609-20011-000 JEM00275-00254 5. Remove the crankshaft timing belt pulley flange. JEM00276-00255 6.
  • Page 129 EM–68 9. Remove the alternator bracket. JEM00279-00257 10. Remove the water inlet and thermostat. JEM00280-00258 11. Remove the water hose for the throttle body. JEM00281-00259 12. Remove the pressure plate and clutch disc. (M/T vehicle only) NOTE: • Prevent the pressure plate from turning, using the fol- lowing SST.
  • Page 130 EM–69 14. Loosen the attaching bolts of the flywheel or drive plate in the sequence as indicated in the right figure. Remove the flywheel or drive plate. NOTE: • Prevent the flywheel from turning, using the following SST. SST: 09210-87701-000 JEM00284-00262 15.
  • Page 131 EM–70 18. Remove the rear oil seal retainer. JEM00289-00267 19. Remove the oil strainer. Gasket JEM00290-00268 20. Remove the oil pump. JEM00291-00269 21. Measurement of connecting rod thrust clearance. Measure the thrust clearance between the connecting rod and the crankshaft, using a thickness gauge. Thrust Clearance Standard: 0.15 - 0.4 mm...
  • Page 132 EM–71 Reference: Width of big end of connecting rod in thrust direction Side width of crankpin 21.80 - 21.85 mm 22.0 - 22.2 mm Crankshaft HC-EJ engine JEM00293-00271 22. Measurement of crankpin journal oil clearance (1) Install the flywheel temporarily. JEM00294-00272 (2) Wipe off any oil from the side of the mate surface be- tween the connecting rod bearing cap and the con-...
  • Page 133 EM–72 (6) Remove the bearing cap. NOTE: • Replace the crankshaft if the crankpin journals exhibit damages, such as seizure. JEM00297-00275 (7) Place a plastigage on the crankpin journal. NOTE: • Wipe off any oil from the crankpin journal. JEM00298-00276 (8) Install the connecting rod cap, making sure that the mate marks are lined up.
  • Page 134 EM–73 23. Selection of connecting rod bearings Front mark NOTE: • The replacement of the connecting rod bearings should be performed after all inspections have been finished. (1) Read the connecting rod big end bore code number. NOTE: • The connecting rod big end bore code number comes Connecting rod big end in three kinds of 4, 5 and 6.
  • Page 135 EM–74 (3) Lock the flywheel to prevent the crankshaft from turn- ing, using the following SST. SST: 09210-87701-000 (4) Loosen the connecting rod bearing cap nuts evenly over two or three stages. Then, remove the connecting rod bearing cap nuts. 09210-87701- JEM00306-00283 (5) Cover each connecting rod bolt with a short piece of...
  • Page 136 EM–75 26. Check of crankshaft thrust clearance NOTE: • Measure the thrust clearance, using a dial gauge. Thrust Clearance Specified Value: 0.02 - 0.22 mm Allowable Limit: 0.30 mm If the thrust clearance exceeds the allowable limit, mea- sure the width of the crankshaft thrust bearing contact sur- face.
  • Page 137 EM–76 (5) Check the main journals and bearings for pitting or scratches. If the main journals are damaged, replace the crank- shaft. If the main journal bearings are damaged, replace the main journal bearings. JEM00316-00292 (6) Install the main bearings to the cylinder block and crankshaft main bearing cap.
  • Page 138 EM–77 (10) Install the crankshaft bearing caps. Tighten the crank- shaft bearing cap bolts evenly in the sequence indi- cated in the right figure. Tightening Torque: 44.1 - 53.9 N·m JEM00321-00297 (11) Remove the main bearing caps with the lower bear- ings fitted on them.
  • Page 139 EM–78 (2) Measure the diameter of the crankshaft main journals. Crankshaft The measurement should be performed at four points, 90 degrees spaced, for each crankshaft main journal at the points shown in the right figure. The maximum value is regarded as the crankshaft main journal diam- eter.
  • Page 140 EM–79 INSPECTION OF EACH PART INSPECTION OF CYLINDER BLOCK 1. Removal of gasket material Remove all gasket materials from the cylinder block. 2. Cleaning of cylinder block Clean the cylinder block, using a soft brush and cleaning solvent. JEM00328-00303 3. Inspection of top surface of cylinder block Using a precision straightedge and a thickness gauge, check the surface contacting the cylinder head gasket for warpage.
  • Page 141 EM–80 5. Removal of cylinder ridges If ridges are formed at the upper parts of the cylinder bores, use a ridge reamer to remove the ridges. JEM00332-00307 INSPECTION OF PISTONS AND CONNECTING RODS CAUTION: • The piston and piston pin are available only as a set so that the oil clearance may become the specified value.
  • Page 142 EM–81 (2) When measuring oil clearance after disassembling: q Measure the diameter of the whole circumference at the positions A and B indicated in the right fig- ure. The minimum dimension should be the piston pin hole diameter. Specified Value: 19.002 - 19.005 mm Unit: mm JEM00337-00310...
  • Page 143 EM–82 3. Measurement of piston diameter (1) Measure the piston outer diameter horizontally at a specified point shown bellow from the lower end of the piston at right angles to the piston pin. Specified Measuring Point H: 15 mm (2) Calculation of piston-to-cylinder bore clearance Subtract the measured piston outer diameter from the measured cylinder bore diameter.
  • Page 144 EM–83 5. Inspection of piston ring end gap (1) Apply engine oil to the cylinder walls. (2) Insert the piston rings into the cylinder bore. (3) Using a piston, push down the piston ring to a point 110 mm from the cylinder block upper surface. Piston ring JEM00347-00316 (4) Measure the piston ring end gap, using a thickness...
  • Page 145 EM–84 ASSEMBLY/DISASSEMBLY OF PISTON & CONNECTING ROD NOTE: • The piston and piston pin are handled as a set, for their oil clearance is controlled. Therefore, when disassembling the pistons, care must be exercised so that the piston and piston pin may not be mixed with other pistons or piston pins.
  • Page 146 EM–85 3. Inspection of piston pin-to-connecting rod interference fit (1) Measure the outer diameter of the piston pin contact- ing with the connecting rod, using a micrometer. JEM00354-00322 (2) Measure the inner diameter of the connecting rod, using a bore dial gauge. (3) Determine the interference fit by subtracting the inner diameter of the connecting rod from the outer diameter of the piston pin.
  • Page 147 EM–86 (4) Remove the piston and connecting rod assembly from the SST. Remove the SST from the piston pin. JEM00359-00327 CYLINDER BORING NOTE: • When the cylinder is bored, all cylinders should be bored at the same time. • As for piston rings, use oversized piston rings. JEM00360-00000 1.
  • Page 148 EM–87 3. Hone the cylinder after the boring. (1) Bore the cylinder, leaving a honing allowance of 0.02 mm. (2) Hone the cylinder. Honing angle 35° ± 5° 35° ± 5° Honing Angle: Surface Coarse Degree: 1 - 4Z Surface coarse degree 1 - 4Z JEM00364-00329 REPLACEMENT OF REAR OIL SEAL...
  • Page 149 EM–88 REPLACEMENT OF CYLINDER BLOCK NOTE: • The cylinder block is furnished along with the pistons as a set. Hence, make sure that each piston is installed in the mated cylinder bore. 1. Wash the cylinder block using cleaning solvent. 2.
  • Page 150 EM–89 Crankshaft journal diameter Crankshaft bearing Crankshaft jurnal hole code Remarks classification No. 50.000 - 49.995 — 49.994 - 49.989 — 49.988 - 49.983 — 49.982 - 49.976 — 49.975 or less — Crankshaft replacement 50.000 - 49.995 — 49.994 - 49.989 —...
  • Page 151 EM–90 REPLACEMENT OF CRANKSHAFT (Replacement of the crankshaft only) 1. Wash the crankshaft using cleaning solvent. Dry it with compressed air. NOTE: • Make sure that the oil gallery exhibits no restriction due to rust-proof oil. • As for the crankshaft for automatic transmission, drive the rear end bush into the rear end of the crankshaft with a brass rod so as to prevent damage to the bush.
  • Page 152 EM–91 (2) Read the connecting rod big end bore code number. Connecting rod Front mark Connecting rod big end bore code No. JEM00380-00342 (3) Establish the classification number of the connecting rod bearing, using the table below. Crankshaft Crankpin journal diameter code No.
  • Page 153 EM–92 Connecting rod big end bore Crankpin journal diameter Connecting rod bearing Remarks code No. classification No. 45.000 - 44.993 — 44.992 - 44.985 — 44.984 - 44.976 — 44.975 or less — Crankshaft replacement 45.000 - 44.993 — 44.992 - 44.985 —...
  • Page 154 EM–93 4. Pull out the cotter pin, while pushing the spring retainer with nose pliers or the like. NOTE: • Put an appropriate cloth, etc. on the retainer spring so that it may not jump out. JEM00389-00348 5. Remove the oil pump relief valve spring retainer, compres- sion spring and oil pump relief valve.
  • Page 155 EM–94 (4) Check the compression spring for damage. Also, mea- sure its free length. Specified Free Length: 57 mm Replace the compression spring if it exhibits damage or the free length is less than the specified valve. JEM00394-00353 (5) Check the oil pump relief valve spring retainer for damage.
  • Page 156 EM–95 (3) Measure the tip clearance of the rotor set, using a thickness gauge. Tip Clearance: 0.16 - 0.24 mm Replace the rotor set if the tip clearance exceeds the specified value. JEM00399-00358 (4) Measure the side clearance between the oil pump body and the rotor set, using and a straightedge and a thickness gauge.
  • Page 157 EM–96 3. Insert a new cotter pin into the retainer while the retainer is being compressed with pliers, etc. Split the end of the cot- ter pin to form an anchor-like shape. JEM00404-00362 4. Apply engine oil to the rotor set. Assemble the rotor set in the pump body in such a direction that the drilled mark of the rotor may be seen from the outside.
  • Page 158 EM–97 INSPECTION OF CRANKSHAFT PULLEY Check damage 1. Visual inspection of crankshaft pulley or cracks (1) Check the crankshaft pulley attaching seat for defor- mation, wear or cracks. (2) Check the V-ribbed belt attaching surface for scratch- es, deformation or wear. Replace the crankshaft pulley, as required.
  • Page 159 EM–98 INSPECTION OF OIL PAN Visually inspect the oil pan for damage or cracks. Replace the oil pan, as required. JEM00414-00372 INSPECTION OF FLYWHEEL Inspect the flywheel for cracks or damage. Replace the flywheel if it exhibits defects. INSPECTION AND REPLACEMENT OF RING GEAR Inspect the ring gear for damage.
  • Page 160 EM–99 ASSEMBLY OF CYLINDER BLOCK NOTE: • As for those parts to be reassembled, wash them in cleaning solvent (excluding those parts, such as grease-sealed type bearings, dust seals and electrical parts). • Then, dry them using compressed air. • Remove any remaining sealer, etc.
  • Page 161 EM–100 (2) Lubricate the surface of each bearing with engine oil. NOTE: • Do not touch with the front and back surfaces of each bearing. • Never apply engine oil to the crankshaft bearing caps. JEM00422-00379 (3) Install the crankshaft in the cylinder block. JEM00423-00380 (4) Apply engine oil to the thrust washers.
  • Page 162 EM–101 3. Assembly of piston and connecting rod Install the flywheel on the crankshaft temporarily. NOTE: • Care must be exercised to ensure that no oil, etc. gets to the bolts or bolt holes. JEM00427-00384 (1) Install the oil ring spacer expander in the oil ring groove.
  • Page 163 EM–102 (4) Install the compression ring No. 2 with the stamped mark of T, 2T, N or 2N facing upward, using a piston ring expander. NOTE: • Do not expand the piston ring to an extent more than necessary. (5) Install the compression ring No. 1 with the stamped mark of T or N facing upward, using a piston ring ex- pander.
  • Page 164 EM–103 (10) Compress the piston rings by means of the piston ring compressor SST, making sure that the piston ring ends will not move during the installation. SST: 09217-87001-000 (11) Push the piston by hand into the cylinder bore with the front mark facing toward the oil pump side.
  • Page 165 EM–104 (17) Thinly apply engine oil to the connecting rod cap at- taching nuts. Tighten the nuts to the specified torque evenly over two or three stages. Tightening Torque: 34.3 - 44.1 N·m (18) Perform the operations described in the steps (1) through (17) for each cylinder.
  • Page 166 EM–105 (2) Apply engine oil to the inner surface of the oil seal. Install the oil seal retainer to the cylinder block. Perform tightening to the specified torque. Tightening Torque: 5.9 - 8.8 N·m (0.6 - 0.9 kgf-m) JEM00446-00403 6. Install the oil strainer with a new gasket interposed. JEM00447-00404 7.
  • Page 167 EM–106 8. Installation of rear end plate Install the rear end plate to the cylinder block with two at- taching bolts. Tighten the attaching bolts to the specified torque. Tightening Torque: 14.7 - 21.6 N·m JEM00451-00408 9. Installation of flywheel (M/T vehicle only) (1) Install the flywheel on the crankshaft with the spacer interposed.
  • Page 168 EM–107 (3) Tighten the flywheel attaching bolts to the specified torque in the sequence indicated in the right figure. Tightening Torque: 44.1 - 63.7 N·m NOTE: • Prevent the crankshaft from turning at the ring gear section, using the following SST. SST: 09210-87701-000 CAUTION:...
  • Page 169 EM–108 • Never allow alcohol to get to resin or rubber parts, specifically, the rear oil seal. r Wash the centering plate. Then, degrease and dry it. NOTE: • When degreasing the center plate, remove any oil completely, using a solvent such as a degreasing spraying agent or alcohol.
  • Page 170 EM–109 (3) Install the pressure plate, lining up the locating pin of the pressure plate. Tighten the attaching bolts to the specified torque. Tightening Torque: 14.7 - 21.6 N·m 09301-87601-000 JEM00461-00414 12. Install the water hose for the throttle body use to the cylin- der block.
  • Page 171 EM–110 16. Installation of water pump (1) Install a new water pump gasket on the cylinder block. JEM00468-00421 (2) Install and tighten the water pump to the specified torque. Tightening Torque: 14.7 - 21.6 N·m NOTE: • When the stud bolts have been replaced, apply the Three Bond 1377B to the threaded portion at the cylin- der block side.
  • Page 172 EM–111 20. Install the crankshaft timing belt pulley attaching bolt. Tighten the bolt to the specified torque. Tightening Torque: 88.3 - 98.0 N·m NOTE: • Prevent the crankshaft from turning, using the following SST. SST: 09210-87701-000 JEM00473-00426 21. Install the air conditioner compressor bracket. Tightening Torque: 29.4 - 44.1 N·m JEM00474-00427...
  • Page 173 EM–112 23. Installation of oil pressure switch (1) Clean the threaded portion of the oil pressure switch. Wind seal tape around the threaded portion. NOTE: • The new oil pressure switch is coated with sealer. Hence, when the oil pressure switch is replaced with a new one, first remove the sealer thoroughly.
  • Page 174 EM–113 4. Turn the crankshaft, until the “F” mark of the camshaft tim- ing belt pulley comes exactly at the top position. JEM00483-00436 5. Install the cylinder head assembly on the cylinder block. CAUTION: • Be very careful not to damage the cylinder head gasket and cylinder head gasket attaching surface.
  • Page 175 EM–114 (4) Wipe off any oil from the cylinder head cover gasket attaching surface of the cylinder head. JEM00488-00440 (5) Install the cylinder head cover to the cylinder head. CAUTION: • Be very careful not to damage the spark plug tube rub- ber grommet during installation.
  • Page 176 EM–115 11. Install and tighten the engine mounting bracket with the mounting to the engine. 12. Sling the engine, using a chain block. JEM00493-00443 INSTALLATION OF ENGINE 1. Insert the engine to the engine compartment. 2. Joint the engine to the transmission and temporarily install the transmission attaching bolt.
  • Page 177 EM–116 7. Install the clutch housing under cover to the transmission. Tighten the attaching bolts to the specified torque. Tightening Torque: 49 - 68.6 N·m JEM00498-00448 8. Install the engine stiffener to the engine and tighten it to the specified torque. Tightening Torque: 29.0 - 44.0 N·m JEM00499-00449...
  • Page 178 EM–117 (6) Clamp the front exhaust pipe to the clamp bracket. (7) Tighten the front exhaust pipe attaching nuts of the ex- haust manifold to the specified torque. Tightening Torque: 15.2 - 22.8 N·m JEM00503-00453 10. Connect the power train stiffener between the engine .and transfer.
  • Page 179 EM–118 14. Connect the starter wire to the starter motor. 15. Install the accelerator cable to the throttle body and adjust 16. Connect the rubber hoses. JEM00508-00458 17. Install the alternator to the engine and connect the con- nectors. JEM00509-00459 18.
  • Page 180 EM–119 (4) Secure the radiator by installing the radiator brackets with the attaching bolts. (5) Connect the radiator lower hose and cramp the hose band. JEM00513-00463 20. Install the cooling fan with the fluid coupling together with the fan shroud. Tighten the fluid coupling attaching nuts and the fan shroud attaching bolts.
  • Page 181 EM–120 25. Installation of engine hood. (1) Install the engine hood, being very careful not to scratch the vehicle body and engine hood. (2) Tighten the engine hood attaching bolts and adjust the engine hood dimensions. JEM00518-00467 (3) Connect the windshield washer hose to the joint sec- tion.
  • Page 182 EM–121 ENGINE SPECIFICATION Engine type HC-EJ Item Type Petrol, 4-cycle Mounting location Front 4-cylinder-in-line, Cylinder No. and arrangement mounted transversely Combustion chamber type Pent roof type Valve mechanism Belt-driven, SOHC Bore × stroke 76.0 × 71.4 9.5 ± 0.3 Compression ratio 1372.9 Compression pressure kPa (kgf/cm...
  • Page 183 EM–122 Engine type HC-EJ Item Cooling method V-ribed belt driven type Radiator type Corrugation type forced circulation Manual transmission Coolant capacity Cooling [Including 0.434 liter for liter system reserve tank] Automatic transmission Water pump type Centrifugal type belt-driven type Wax pellet type Thermostat type bottom-by-pass type Type...
  • Page 184 EM–123 Engine type HC-EJ Item Voltage 12 [Negative ground] Full transistorized type (ESA) Type battery ignition type TDC 0° ± 2° Ignition timing with the check connector connected with ground terminal Ignition Firing order 1-3-4-2 system DENSO K20TNR-S, K22TNR-S Manufacturer &...
  • Page 185 EM–124 ENGINE MECHANICALS Timing belt pulley Wear limit Camshaft 119.8 mm Crankshaft 59.3 mm Timing belt tension spring Free length 46.5 mm 29.4 ± 3 N at 50.9 mm (3.0 ± 0.3 kg at 50.9 mm) Installation load Camshaft Oil clearance 0.035 - 0.076 mm (Cylinder head to camshaft) Maximum limit...
  • Page 186 EM–125 Valve springs Free length: 45.2 ± 0.5 mm Standard Pink marked spring Orange marked spring About 47.4 mm Minimum Pink marked spring 43.9 mm Orange marked spring 46.1 mm Installed tension at 38.0 mm Pink marked spring 244.9 N (24.97 kgf) Orange marked spring 208.9 N (21.3 kgf) Maximum out-of squareness...
  • Page 187 EM–126 SST (Special Service Tools) Shape Part No. and Name Purpose Remarks 09090-04010-000 Removal and installation of engine Engine sling device 09219-87202-000 Stand for engine overhaul This stand is to be used in combination with Engine overhaul stand engine overhaul attachment.
  • Page 188 EM–127 Shape Part No. and Name Purpose Remarks 09201-87705-000 Removal and installation of valve guide bushes Valve guide bush remover & replacer 09301-87703-000 Assembling clutch Clutch guide tool 09258-00030-000 Plugging rubber hoses Plug set 09648-87201-000 Disconnecting drive shafts Drive shaft replacer 09388-87702-000 Press-fitting of rubber grommets...
  • Page 189 EM–128 TIGHTENING TORQUE Tightening torque Tightening component N·m kgf-m Cylinder head × Spark plug 14.7 - 21.6 1.5 - 2.2 Cylinder head × Cylinder head cover 2.9 - 4.9 0.3 - 0.5 28.4 - 36.3 2.9 - 3.7 Cylinder head × Rocker shaft (camshaft cap) 12.7 - 16.7 1.3 - 1.7 Cylinder head ×...
  • Page 190 EM–129 Tightening torque Tightening component N·m kgf-m Oil pump × Oil pressure switch 11.8 - 19.6 1.2 - 2.0 Oil pump body × Oil pump cover 7.8 - 12.7 0.8 - 1.3 Oil pan 6.9 - 11.8 0.7 - 1.2 Water inlet ×...

  • Page 191: Emission Control Systems

    DAIHATSU J100 TO INDEX EMISSION CONTROL SYSTEMS COMPONENT LAYOUT ......EC– 2 POSITIVE CRANKCASE VENTILATION SYSTEM ..........EC– 3 INSPECTION OF PCV HOSE & CONNECTION ........EC– 4 FUEL EVAPORATIVE EMISSION CONTROL SYSTEM ....... EC– 5 DASHPOT (DP) SYSTEM (only for automatic transmission models) ..

  • Page 192: Component Layout

    EC–2 COMPONENT LAYOUT [Manual transmission Vehicle] Throttle body Air cleaner Intake air pressure sensor Idle-up VSV Intake air temperature sensor Fuel return hose Throttle position sensor To canister JEC00002-00001 [Automatic transmission Vehicle] Throttle body Air cleaner Intake air pressure sensor Idle-up VSV Intake air temperature...

  • Page 193: Positive Crankcase Ventilation System

    EC–3 POSITIVE CRANKCASE VENTILATION SYSTEM The engine equipped with a sealed type blow-by gas recirculating system in order to prevent blow-by gases generated inside the crankcase from being released into atmosphere. When the no blow-by gases is generated in the cylinder, air in the cylinder head cover are ventilated by the fresh air introduced from up stream of the throttle valve to down stream of the throttle valve through inside of the cylinder head cover.
  • Page 194 EC–4 INSPECTION OF PCV HOSE & CONNECTION Visual inspection of hoses and connections Check the hoses and connections for cracks, leakage or damage. If any parts exhibit fault, replace or repair them, as required. JEC00004-00004 Inspection of blow-by gas recirculation device 1.
  • Page 195 EC–5 FUEL EVAPORATIVE EMISSION CONTROL SYSTEM The fuel evaporative emission control system employs a charcoal canister type. The charcoal canister type leads the fuel vapor into the charcoal canister which uses activated carbon to absorb HC emission. The ab- sorbed HC emission is drawn into the throttle body to be burnt together with mixture in the combustion chamber.
  • Page 196 EC–6 3. Inspection of the fuel filler cap Check the fuel filler cap and gasket for damage or defor- mation. Also check the air continuity with some resistance is exist- ing on the fuel filler cap. Replace the cap, if necessary. NOTE: •...
  • Page 197 EC–7 (8) Cleaning of charcoal canister Clean the charcoal can- ister by blowing compressed air of 294.2 kPa ) into the fuel tank side pipe B while hold- (3.0 kg/cm ing the purge side of canister pipes A closed. NOTE: •...
  • Page 198 EC–8 DASHPOT (DP) SYSTEM (only for automatic transmission models) This system prevents the throttle valve from suddenly closing, thus reducing the CO and HC emissions. JEC00014-00010 Conditions Throttle valve Dashpot Idling Idle speed position Pushed in by return force of throttle lever. Normal driving Opened position Pushed out by the diaphragm spring.
  • Page 199 EC–9 4. Slowly release the throttle lever. 5. Ensure that the engine revolution within the specified range. Specified Engine Revolution 2400 ± 100 rpm If not adjust the engine revolution speed by adjusting screw and repeat the step (3) to (5) again. JEC00018-00000 6.
  • Page 200 EC–10 THREE-WAY CATALYST (TWC) SYSTEM In this three-way catalyst, the oxidation of carbon monoxide (CO) and the reduction of nitrogen oxides (NOx) contained in exhaust gas can take place simultaneously. Thus, the three-way catalyst purifies the ex- haust gas by converting its harmful component gas into harmless carbon dioxide (CO ), water vapor (H and nitrogen (N JEC00020-00013...
  • Page 201 EC–11 THREE-WAY CATALYST INSPECTION 1. Check the connection for looseness or damage. 2. Check the three-way catalyst for dents or damage. JEC00024-00016 REMOVAL WARNING: • Do not perform any operation while the exhaust pipe is still hot. 1. Jack up the vehicle and support it with safety stands. JEC00025-00000 2.
  • Page 202 EC–12 INSTALLATION 1. Install a new gasket to the front exhaust pipe and tail pipe. JEC00029-00000 2. Install the front exhaust pipe assembly to the exhaust manifold. Tightening Torque: 36.3 - 51.0 N·m (3.7 - 5.2 kgf-m) NOTE: • Mark sure that the front mark is located at front side. JEC00030-00021 3.
  • Page 203 EC–13 SST (Special Service Tools) Shape Part No. and name Purpose 09991-87402-000 Connecting engine tachometer Tacho pulse pick-up wire 09258-00030-000 Plugging rubber hoses. Plug set JEC00033-00024 TIGHTENING TORQUE Tightening Torque Tightening component N·m kgf-m Remark Cylinder head × Exhaust manifold 29.4 - 44.1 3.0 - 4.5 Exhaust manifold ×...
  • Page 204 DAIHATSU J100 TO INDEX EFI SYSTEM SYSTEM DESCRIPTION ....EF– 2 DIAGNOSIS CODE NO. 43 ... EF–29 LOCATION OF ELECTRONIC DIAGNOSIS CODE NO. 44 ... EF–31 CONTROL PARTS ..... EF– 2 DIAGNOSIS CODE NO. 45 ... EF–33 SYSTEMATIC DIAGRAM ....EF– 2 DIAGNOSIS CODE NO.
  • Page 205 EF–2 SYSTEM DESCRIPTION LOCATION OF ELECTRONIC CONTROL PARTS Pressure sensor EFI ECU Throttle sensor Relay Block Cam angle sensor Injector Oxygen sensor JEF00002-00011 SYSTEMATIC DIAGRAM Throttle Speed sensor position sensor Intake air temp. Pressure sensor sensor IG key Cam angle sensor Aux.
  • Page 206 EF–3 DIAGNOSIS SYSTEM DESCRIPTION A self-diagnosis system is built in the ECU. If any abnormality should occur in the signal systems of various sensors, the self-diagnosis system memorizes the malfunction code num- ber in the ECU. In respect to important abnormalities, the check engine lamp at the instrument panel goes on, thus warning the driver of the abnormality.
  • Page 207 EF–4 EXPLANATION OF DIAGNOSIS CODES 0.25 Sec. 1. Indication of normal code Glowing The engine check lamp glows for 0.25 second, 0.25 sec- ond after the ignition switch has been turned ON. After a lapse of 0.25 second, the check engine lamp again glows for 0.25 second.
  • Page 208 EF–5 SUMMARY OF TROUBLE SHOOTINGS NOTE: • Prior to the troubleshooting according to malfunction phenomena, conduct the basic inspections so as to narrow down the possible causes for malfunctions. For instance, if the spark inspection of the basic inspection proves to be normal, it can be assumed that the ignition system is functioning nor- mally.
  • Page 209 EF–6 CAUTION FOR IMMOBILIZER-EQUIPPED VEHICLE 1. The immobilizer system is formed by communication be- tween the Immobilizer ECU and the EFI ECU by means of the rolling code. The rolling code will be automatically re- tained both in the immobilizer ECU and in the EFI ECU when the engine is started once with the key of the immo- bilizer system.
  • Page 210 EF–7 PRECAUTIONS 1. When resistance or voltage measurement is conducted at the connector section, insert a measuring probe from the back of the connector, being very careful not to damage the harness to terminal connections. In the case of water-proof type connectors, a measure- ment is conducted at the connector section, while the measuring probe is in contact with the terminal at the con- nection side of the connector.
  • Page 211 EF–8 8. When installing the battery, care must be exercised not to mistake the battery polarity. CAUTION: • A battery of 12 volts for automotive use must be used. 9. When the voltage or resistance of the ECU is measured during the check, never touch terminals other than the specified terminals.

  • Page 212: Basic Inspection

    EF–9 BASIC INSPECTION WIRING DIAGRAM OF EFI SYSTEM To heater resister To A/C dual pressure SW To heater relay To off board connector To heater blower SW (SIO) Check engine lamp To head lamp fuse (Combination meter) Idle up VSV To head lamp To defogger SW Idle up VSV(for A/C)
  • Page 213 EF–10 ARRANGEMENT OF EFI ECU TERMINAL ECU Terminal 33 34 35 36 37 38 39 40 41 42 43 52 53 54 55 56 57 58 59 60 61 62 63 20 21 22 23 24 25 26 27 28 29 30 31 2 3 4 5 6 7 8 9 10 11 Connector A Connector B...
  • Page 214 EF–11 Trouble shooting hints 1. In most cases, engine troubles are attributable to systems other than the EFI system. (1) Battery voltage, fuse blown or fusible link blown (2) Body earth (3) Fuel leakage, fuel filter clogged or fuel pump malfunc- tioning (4) Spark plugs faulty, spark plug wires faulty, distributor faulty, igniter faulty, or ignition timing adjusted improp-...
  • Page 215 EF–12 2. Check the EFI main relay. (a) Turn the ignition switch to the “ON” position. Check to see if the relay emits an operating sound. JEF00033-00312 (b) Remove the EFI main relay from the relay box. Check that there is continuity between the terminals 1 and 2.
  • Page 216 EF–13 3. Remove the spark plug(s). 4. Visually inspect the spark plug for electrode wear, thread or insulator damage. 5. Measure the electrode gap, using a plug gap gauge. Specified Value: 0.9 - 1.0 mm (NGK, DENSO) NOTE: • If the gap will not conform to the specification, replace the plug.
  • Page 217 EF–14 2. Disconnect the injector connector of the engine wire. 3. Measure the resistance between the terminals of each in- Derivery pipe jector. 11 - 17 Ω (at 20°C) Specified Resistance: NOTE: • If the resistance is not within the specification, replace the injector.
  • Page 218 EF–15 8. Remove the fuel pump relay. Then, connect the terminal with a jump wire as shown in the illustration. 9. Turn the ignition switch to the “ON” position. Relay terminal JEF00047-00337 10. Connect the SST wire to the battery terminal for 15 sec- SST (09842-30070) onds.
  • Page 219 EF–16 17. Remove the fuel pump relay. Then, connect the terminal with a jump wire as indicated in the illustration. 18. Turn the ignition switch to the “ON” position for 10 sec- onds. Then, turn off the ignition switch. Relay terminal JEF00052-00342 19.
  • Page 220 EF–17 23. Check the idle revolution speed. Diagnosis connector (1) Connect a tachometer to the terminal of the diagnosis connector. (2) Check to see if the fast idle revolution speed is within the reference value. Earth Tacho-meter terminal terminal Reference Value: Around 1400 rpm/25°C NOTE: •...
  • Page 221 EF–18 TROUBLE SHOOTING ACCORDING TO IG “OFF” DIAGNOSIS CODE PREPARATION OF TROUBLE SHOOTING WITH The EFI unit can be checked by measuring the resistance or voltage at the SST terminals. 1. Disconnect the battery ground cable from the negative (–) terminal of the battery.
  • Page 222 EF–19 DIAGNOSIS CODE TABLE When the diagnosis system detects malfunctions, the check engine lamp will go on even if the diagnosis connector test terminal is not connected to the earth terminal. Code Diagnosis Number of flashing Diagnosis contents Trouble area item page •...
  • Page 223 EF–20 DIAGNOSIS CODE NO. 13 CAM ANGLE SENSOR & CIRCUIT EFI ECU Cam angle sensor JEF00063-00501 When no cam angle sensor signal is inputted within 2 sec- onds while the engine is being cranked by the starter motor. 1. Check of cam angle sensor (1) Disconnect the connector of the cam angle sensor.
  • Page 224 EF–21 REFERENCE (1) Prepare an oscilloscope. (2) Connect a probe to the respective terminals. (3) Check to see if a signal shown in the graph appears at the terminals when the engine is being cranked. NOTE: • If not, check the air gap of the signal generator. Refer to the IG section of the service manual.
  • Page 225 EF–22 DIAGNOSIS CODE NO. 21 OXYGEN SENSOR & CIRCUIT EFI ECU VF monitor terminal Oxygen sensor JEF00070-00511 The ECU detects malfunction when the input signal from Diagnosis connector the oxygen sensor shows too lean air-to-fuel mixture con- tinuously for 2 seconds or more when the engine revolu- tion speed is 1500 rpm or more and the engine is in a hot condition.
  • Page 226 EF–23 REFERENCE Diagnosis connector (1) Prepare an oscilloscope. (2) Connect a jump wire to the test terminal and the earth terminal. (3) Connect a probe to the VF terminal and the earth ter- Test Earth minal. terminal terminal terminal (4) Check to see if a signal shown in the graph appears at the terminals while the engine is rotating at 3000 rpm.
  • Page 227 EF–24 (3) Perform the procedure given in the table, according to the measurement results. Measured voltage Remedy 1) Check the oxygen sensor circuit for open wire or short circuit. Remedy causes for too-lean fuel mixture. • Pressure sensor • Pressure regulator The measured voltage varies •...
  • Page 228 EF–25 DIAGNOSIS CODE NO. 31 PRESSURE SENSOR & CIRCUIT EFI ECU Intake Intake air Cooling manifold temp. water pressure sensor temp. sensor sensor JEF00080-00521 When the pressure sensor becomes open or shorted: 1. Check the pressure sensor. (1) Connect the SST between the ECU connectors and the wire harness connectors.
  • Page 229 EF–26 (4) Temporarily connect a vacuum gauge (The MityVac may be used) to the negative pressure port of the VSV so that the inner pressure of the intake manifold may be measured. Next, start the engine and keep it idling. At this time, ensure that the gauge reading and the voltage across the SST terminals 24 and 52 satisfy the following formula given below.
  • Page 230 EF–27 DIAGNOSIS CODE NO. 42 WATER TEMPERATURE SENSOR & CIRCUIT EFI ECU Intake Intake air Cooling manifold temp. water pressure sensor temp. sensor sensor JEF00085-00531 When the pressure sensor becomes open or shorted: 1. Check to see if the connector is connected properly. 2.
  • Page 231 EF–28 3. Check the water temperature sensor unit. (1) Turn off the ignition switch. (2) Disconnect the connector of the water temperature sensor. (3) Drain the engine cooling water. (4) Remove the water temperature sensor unit. NOTE: • Be certain to perform the replacement and repairs of the sensor only after the intake manifold has been re- moved from the cylinder head.
  • Page 232 EF–29 DIAGNOSIS CODE NO. 43 INTAKE AIR TEMPERATURE SENSOR & CIRCUIT EFI ECU Intake Intake air Cooling manifold temp. water pressure sensor temp. sensor sensor JEF00090-00541 When the pressure sensor becomes open or shorted: 1. Check to see if the wire harness connectors are connected properly.
  • Page 233 EF–30 4. Check of wire harness (1) Connect the SST between the ECU connectors and the wire harness connectors. (2) Check that the voltage between the SST terminals 52 and 57 is within the specified value when the ignition switch is turned to the ON position. Reference: 20°C 1.8 - 2.9 V...
  • Page 234 EF–31 DIAGNOSIS CODE NO. 44 AIR CONDITIONER EVAPORATOR TEMPERATURE SENSOR & CIRCUIT IG SW IG No. 1 IG No. 2 Main MAIN EFI ECU Resister JEF00095-00551 When the air conditioner evaporator temperature sensor and circuit becomes open or shorted: 1. Check to see if the wire harness connectors are connected properly.
  • Page 235 EF–32 4. Check of wire harness (1) Connect the SST between the ECU connectors and the wire harness connectors. (2) Check that the voltage between the SST terminals 3 and 52 is within the specified value when the ignition switch is turned to the ON position. Reference: 20°C 1.8 - 2.9 V...
  • Page 236 EF–33 DIAGNOSIS CODE NO. 45 AIR CONDITIONER LOCK SENSOR & CIRCUIT IG SW IG No. 1 IG No. 2 Main MAIN EFI ECU Resister JEF00100-00556 When the ECU detects malfunction of the A/C lock sensor Vane pump pulley Water pump pulley circuit.
  • Page 237 EF–34 4. Check of wire harness (1) If the measured voltage is o volt, check the wiring be- tween the ECU and the A/C lock sensor connector for open wire or short circuit. (2) Check the A/C lock sensor by measuring the output voltage at the sensor connector.
  • Page 238 EF–35 DIAGNOSIS CODE NO. 51 SWITCHING SIGNAL CIRCUIT IG SW IG No. 1 IG No. 2 MAIN Main To starter relay coil Neutral start switch (A/T) Resister EFI ECU Throttle position sensor JEF00105-00561 When the ECU detects malfunction of the switching cir- Diagnosis connector cuit.
  • Page 239 EF–36 (3) Check the voltage between the SST terminals 20 and 23 when the throttle valve is opened and the ignition switch is turned on. Specified Value: 4.5 - 5.5 V JEF00108-00564 (4) Check the voltage between the SST terminals 20 and 54 when the throttle valve is fully closed and the igni- tion switch is turned on.
  • Page 240 EF–37 DIAGNOSIS CODE NO. 52 VEHICLE SPEED SENSOR & CIRCUIT EFI ECU Combination meter Speedometer cable Vehicle speed sensor JEF00113-00571 When the pressure sensor becomes open or shorted: 1. Check of the reed switch (1) Remove the combination meter. (2) Ensure that continuity occurs four times at the termi- nals B10 and B11 of the combination meter while the speedometer drive shaft completes a turn.
  • Page 241 EF–38 NOTE: • If the measured voltage is 0 volt, check that the wire harness or connector is shorted. • If the measured voltage is still 5 volts, check that the wire harness or connector exhibits open wire. • If the diagnosis code No. 43 is flashing, most likely it denotes that open wire occurs intermittently or the shielding is poor.
  • Page 242 EF–39 DIAGNOSIS CODE NO. 81 IMMOBILIZER SIGNAL CIRCUIT EFI ECU IMMOBILIZER ECU Diagnosis connector (DS-21) Antenna (IG key) JEF00117-00581 When the rolling codes cannot be exchanged between the EFI ECU engine EFI ECU and the immobilizer ECU or the rolling Immobilizer ECU codes are not matched.
  • Page 243 EF–40 2. Check the Immobilizer system. NOTE: • In cases where the ECU is replaced with a new EFI ECU, be sure to use the master key to start the engine for the first time. The engine will not start with a key other than the master key.
  • Page 244 EF–41 REPLACEMENT OF ECU INSPECTION NOTE: • Even when the replacement of the ECU is required in previous checks, make sure that the ECU malfunction has not been caused by factors other than the ECU by carrying out the following checks. Then, proceed to re- place the ECU.
  • Page 245 EF–42 CHARACTERISTICS OF ECU OUTPUT (1) Followings are standard voltage or resistance at ECU. Standard Item Terminal Condition Remedies voltage or resistance Check back-up fuse in the 2 – 62 Battery voltage All times relay box. Power supply Ignition switch is turned on. Check main relay in the 11 –...
  • Page 246 EF–43 CHARACTERISTICS ECU OUTPUT (2) Followings are standard voltage or resistance at ECU. Standard Item Terminal Condition Remedies voltage or resistance Approx. battery voltage Check headlamp fuse or Headlamp switch is turned on. 37 – 62 switch. Ignition switch is turned on and Approx.
  • Page 247 EF–44 ECU REPLACEMENT IG “OFF” 1. Disconnect the ground cable terminal from the negative (–) terminal of the battery. 2. Remove the glove compartment subassembly. JEF00127-00707 3. Disconnect the wire harness connector from the ECU. 4. Remove the ECU by removing the attaching bolts and nuts.
  • Page 248 EF–45 INSPECTION OF IDLE-UP CONTROL SYSTEM WIRING DIAGRAM IG SW IG No. 1 IG No. 2 Main MAIN To starter relay Neutral start switch Main relay VSV No. 3 EFI ECU Fuel pump relay VSV No. 2 Fuel VSV No. 1 pump JEF00129-00901 UNIT INSPECTION...

  • Page 249: System Inspection

    EF–46 SYSTEM INSPECTION VSV No. 1 1. Connect the SST between the EFI ECU connector and the wire harness connectors. See page EF–18. 2. With the engine running, measure the voltage between the terminals 60 and 62 of the SST. Condition Specified value Until engine is warmed up fully after engine starting...
  • Page 250 EF–47 INSPECTION OF FUEL SYSTEM JEF00137-01001 FUEL TANK UNIT INSPECTION 1. Check the fuel tank for deformation, cracks or fuel leak- age. 2. Check the filler neck for damage or fuel leakage. 3. Check to see if the hose and tube connections are in- stalled as shown in the right figure.
  • Page 251 EF–48 FUEL PUMP IG “OFF” INSPECTION See page EF–14, Check of fuel system. REMOVAL 1. Disconnect the battery ground cable from the negative (–) terminal of the battery. 2. Remove the fuel tank. Refer to the BO section of the sevice manual. WARNING: •...
  • Page 252 EF–49 SST (Special Service Tools) Remarks Shape Purpose Part No. and name 09283-87703-000 * Inspection of injectors Used in combination * Inspection of pressure with 09268-87702-000 Pressure regulator adapter regulator * Inspection of fuel pressure 09268-87702-000 * Inspection of injectors Used in combination * Inspection of pressure with 09283-87703-000...

  • Page 253: Lubrication System

    DAIHATSU J100 TO INDEX LUBRICATION SYSTEM OIL PRESSURE WARNING ......LU– 2 OIL PRESSURE CHECK ......LU– 2 OIL PUMP ............ LU– 3 COMPONENTS ........LU– 3 REMOVAL ..........LU– 3 DISASSEMBLY ........LU– 4 ASSEMBLY ..........LU– 7 INSTALLATION ........LU– 8 TIGHTENING TORQUE .......

  • Page 254: Oil Pressure Warning

    LU–2 OIL PRESSURE WARNING 1. Check to see if the oil pressure warning will be illuminated when the ignition switch is turned on. NOTE: • If the warning lamp will not go on, check to see if the bulb in the combination meter is burnt out. (Refer to the BE section of the service manual.) •...

  • Page 255: Oil Pump

    LU–3 OIL PUMP COMPONENTS Oil pump assembly Oil filter Oil pressure switch Gasket Oil strainer JLU00007-00201 REMOVAL NOTE: • In order to remove/install the oil pump, it is necessary to remove the oil pan. For a reliable service, it is not recommended to perform this operation with the engine mounted on the vehicle.
  • Page 256 LU–4 1. Install the engine unit to the suitable engine stand. Refer to EM section of the service manual. 2. Remove the oil filter element. 3. Remove the attaching bolts and nuts of the oil pan. 4. Separate the oil pan from the cylinder block. JLU00009-00203 5.
  • Page 257 LU–5 3. Remove the oil pump rotor set. JLU00014-00303 4. Pull out the cotter pin, while pushing the spring retainer with nose pliers or the like. NOTE: • Put an appropriate cloth, etc. on the retainer spring so that it may not jump out. 5.
  • Page 258 LU–6 7. Measurement of body clearance, tip clearance and side clearance (1) Apply a thin film of engine oil to the rotor mate surface of the oil pump body as well as to the rotor set. Assemble the rotor set in the oil pump body in such a way that the drilled mark may be seen from the out- side.
  • Page 259 LU–7 ASSEMBLY NOTE: • Wash those parts to be assembled in cleaning solvent. Dry them using compressed air. WARNING: • When you use compressed air, be sure to protect your eyes, wearing goggles. JLU00024-00411 1. Apply engine oil to the relief valve. Then, insert the relief valve into the oil pump body.
  • Page 260 LU–8 6. Install the oil pump cover. Tighten the cover to the speci- fied torque. Tightening Torque: 7.8 - 12.7 N·m JLU00029-00416 7. Turn the rotor by hand. Ensure that the rotor turns smooth- If the rotor will not turn smoothly, overhaul the oil pump. JLU00030-00417 INSTALLATION 1.
  • Page 261 LU–9 6. Install the oil strainer to the cylinder block with a new gas- ket interposed. Tightening Torque: 14.7 - 21.6 N·m Gasket JLU00034-00514 7. Attach the oil pan gaskets to the cylinder block. NOTE: • The oil pan gaskets are provided at two points; one at the oil pump side and the other at the flywheel side.
  • Page 262 LU–10 TIGHTENING TORQUE Tightening torque Tightening components Remarks N·m kgf-m Oil pressure switch × 11.8 - 19.6 1.2 - 2.0 Oil pump Oil pump cover × 7.8 - 12.7 0.8 - 1.3 Oil pump Oil pump × Cylinder 5.9 - 8.8 0.6 - 0.9 block Oil strainer ×...

  • Page 263: Cooling System

    DAIHATSU J100 TO INDEX COOLING SYSTEM DESCRIPTION ........CO– 2 INSPECTION OF WATER RADIATOR ......... CO– 3 PUMP-RELATED PARTS ... CO–11 RADIATOR CAP ......CO– 3 INSTALLATION OF RADIATOR RESERVE TANK ..CO– 3 WATER PUMP ......CO–11 RADIATOR HOSES & PIPES ..CO– 4 THERMOSTAT ........
  • Page 264 CO–2 DESCRIPTION The cooling system is a water-cooled, forced-circulation type. Furthermore, it employs a fluid coupling fan. The cooling system employs a bottom by-pass type in which the thermostat equipped with a by-pass valve is provided at the inlet side. The cooling system is composed of the radiator, water pump, thermostat, cylinder head, water jackets of cylinder block, water hoses and their connecting parts.

  • Page 265: Radiator Cap

    CO–3 RADIATOR JCO00003-00002 Radiator specification Item Specification Fin pitch Radiator water capacity 1.66 (M/T) · 1.54 (A/T) Heat radiating rate 48.3 Core dimensions (width × height × thickness) 572 × 425 × 27 JCO00004-00000 RADIATOR CAP A pressure type radiator cap is installed at the upper part of the radiator.
  • Page 266 CO–4 RADIATOR HOSES & PIPES These components come in four radiator hoses and two radiator pipe subassemblies. Radiator hose No. 1 Radiator pipe No. 1 to radiator upper tank No. 2 Radiator lower tank to inlet of cylinder block section No.

  • Page 267: Cooling Fan

    CO–5 FAN-EQUIPPED FLUID COUPLING The fan-equipped fluid coupling with a temperature control device is employed in order that the noise level may be re- duced. Furthermore, the drop in engine output due to the installation of cooling fan has been kept to a minimum level. JCO00009-00000 1.
  • Page 268 CO–6 Operation of coupling fan During cold operation (Below about 55°C) When the cooling water temperature is low, the port is closed Operating Port by the coupling divider. Consequently, the silicon oil will not Chamber move into the operating chamber. Hence, the coupling body remains at its low speed operation.
  • Page 269 CO–7 THERMOSTAT The thermostat is a wax type with a bypass valve. The thermostat helps the engine to warm up quickly by allowing the cooling water to be recirculated through the cylinder block and cylinder head without passing through the radiator. Furthermore, the thermostat is equipped with a jiggle pin which performs the air bleeding while the engine is stopped.
  • Page 270 CO–8 PRECAUTIONS • As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calcium, magnesium and so forth. • If the coolant gets to the vehicle body, immediately flush away the coolant using water. •...
  • Page 271 CO–9 (8) Fill the radiator and reserve tank with antifreeze solu- tion in accordance with the instructions of the manu- facturer of the antifreeze solution. CAUTION: • Use a Good brand of ethylene-glycol base antifreeze solution. Coolant Capacity (Vehicle with front heater): 5.3 liter (for automatic transmission) 5.4 liter (for manual transmission) JCO00024-00015...

  • Page 272: Water Pump

    CO–10 WATER PUMP COMPONENTS : Non-reusable parts Dust seal Fluid Water pump coupling pulley Gasket Water pump JCO00026-00017 REMOVAL OF WATER PUMP 1. Disconnect the battery ground cable from the negative (–) terminal of the battery. 2. Remove the engine under cover. 3.
  • Page 273 CO–11 INSPECTION OF WATER PUMP-RELATED PARTS 1. Check the water pump pulley for damage or deformation. Replace the water pump if it exhibits damage or deforma- tion. JCO00030-00021 2. Visually inspect the water pump rotor for damage or defor- mation. Replace the water pump if the water pump rotor exhibits damage or deformation.
  • Page 274 CO–12 2. Remove the gasket material from the water pump, using a gasket scraper. JCO00035-00025 3. Install a new gasket to the cylinder block. JCO00036-00026 4. Install the water pump to the cylinder block. Tighten the attaching bolts and nuts evenly over two or three stages to the specified torque.
  • Page 275 CO–13 THERMOSTAT REMOVAL OF THERMOSTAT 1. Disconnect the ground cable terminal from the negative (–) terminal of battery. 2. Drain the coolant (See page CO–8.) WARNING: • Never open the radiator cap and/or drain plug when the coolant is hot. JCO00040-00030 3.
  • Page 276 CO–14 3. Immerse the thermostat in water, and check the valve opening temperature by heating the water gradually. Valve opening Specifications Valve lift temperature ϒC Cold region 8.5 mm or more at 82 - 86 specifications 97ϒC Standard 8.5 mm or more at 76 - 80 specifications 91ϒC...
  • Page 277 CO–15 RADIATOR CLEANING OF RADIATOR Using water or steam cleaner, remove mud and dirt from the radiator core. CAUTION: • When using a high pressure type cleaner, be careful not to deform radiator core fins. • Keep a distance of more than 40 - 50 cm between the radiator core and cleaner nozzle when the cleaner noz- zle pressure is 2.9 - 3.4 MPa (30 - 35 kgf/cm ).
  • Page 278 CO–16 2. Check of cooling system for leakage (1) Fill the radiator with coolant. Attach a radiator cap tester. (2) Warm up the engine. (3) Apply a pressure of 118 kPa (1.2 kgf/cm ) to the cool- ing system by means of a radiator tester. If the pressure drops, check the hoses, radiator, water pump and heater for evidence of leakage.
  • Page 279 CO–17 4. Removal of radiator (1) Temporarily detach the power steering vane pump. (2) Remove the radiator hose No. 1 and the breather hoses at radiator side. CAUTION: • When the radiator hose is loosened, be sure to protect the alternator because the coolant flows out. (3) Disconnect the radiator hose No.
  • Page 280 CO–18 (5) Connect the radiator hose No. 1 and the breather hoses to the radiator upper tank. (6) Connect the radiator hose No. 2 to the radiator lower tank. JCO00062-00052 (7) Connection of oil cooler hoses (A/T vehicle for European market only) q Remove the oil cooler hoses.
  • Page 281 CO–19 TIGHTENING TORQUE Tightening torque Tightening component Remark N·m kgf-m Cylinder head × Water temperature sensor 24.5 - 34.3 2.5 - 3.5 Cylinder block × Water inlet 5.9 - 8.8 0.6 - 0.9 Cylinder block × Water pump 14.7 - 21.6 1.5 - 2.2 Fluid coupling ×...

  • Page 282: Ignition System

    DAIHATSU J100 TO INDEX IGNITION SYSTEM WIRING DIAGRAM ........IG– 2 SPARK TEST ..........IG– 3 SPARK PLUG .......... IG– 3 POWER SUPPLY ........IG– 4 IGNITION WIRE ........IG– 5 IGNITION COIL ........IG– 5 CAM ANGLE SENSOR ......IG– 5 EFI ECU ...........
  • Page 283 IG–2 WIRING DIAGRAM F/L 1.25 IG No. 1 IG No. 2 IG SW Main FUSE FUSE (Back-up) (Engine) Ignition coil (#1,#4 Cylinder) Ignition coil (#2,#3 Cylinder) EFI ECU Vehicle speed sensor Tachometer Cam angle sensor JIG00002-00011...
  • Page 284 IG–3 SPARK TEST SPARK PLUG 1. Remove the air cleaner case and relative parts. 2. Connect a timing light to the ignition wire of the No. 1 cylinder. 3. Ensure that the timing light flashes while the engine is being cranked by the starter motor. NOTE: •...
  • Page 285 IG–4 10. Inspection of electrode gap Measure the electrode gap, using the plug gap gauge. Electrode Gap: See page IG–9 NOTE: • If the electrode gap of a used spark plug is not within the specification, replace the spark plug with a new one.

  • Page 286: Cam Angle Sensor

    IG–5 IGNITION WIRE 1. Remove the air cleaner case and relative parts. 2. Disconnect the connector of the ignition coil. 3. Remove the ignition coil by removing the attaching nuts. 4. Disconnect the spark plug distance piece and the ignition wire from the ignition coil.
  • Page 287 IG–6 5. Remove the cam angle sensor from the cylinder head by removing the attaching bolt. 6. Remove the cam angle sensor cover. 7. Turn the shaft of the rotor, until the signal rotor faces to- ward the signal generator. 8.
  • Page 288 IG–7 EFI ECU 1. Check to see if diagnosis detect malfunction code. (Refer to EF section of the service manual) 2. Connection of SST (Refer to EF section of the service manual) JIG00021-00701 NOTE: • The EFI unit can be checked by measuring the resis- IG “OFF”...
  • Page 289 IG–8 CAUTION: • In cases where the ECU is replaced with a new EFI ECU, be sure to use the master key and connect the test terminal with the earth terminal, to start the engine for the first time. The engine will not start with a key other than the master key.

  • Page 290: Ignition Timing

    IG–9 IGNITION TIMING Diagnosis connector 1. Connect the test terminal and the earth terminal with a jumper wire of the diagnosis connector. 2. Connect a timing light to the ignition wire of the No. 1 Earth Test cylinder. terminal terminal 3.
  • Page 291 IG–10 TIGHTENING TORQUE Tightening torque Tightening components Remarks N·m kgf-m Cam angle censor × 14.7 - 21.6 1.5 - 2.2 Cylinder head Spark plug × Cylinder head 14.7 - 21.6 1.5 - 2.2 JIG00035-00901 SSTs Shape Part number Part name Remarks 09842-87706-000 Inspection of computer...
  • Page 292 DAIHATSU J100 TO INDEX STARTING SYSTEM STARTING SYSTEM CIRCUIT ....ST– 2 STARTER MOTOR ........ST– 3 COMPONENTS ........ST– 3 SERVICING INSTRUCTIONS OF STARTER ..........ST– 4 IN-VEHICLE INSPECTION ...... ST– 4 REMOVAL ..........ST– 5 PLANETARY TYPE STARTER MOTOR ..........
  • Page 293 ST–2 STARTING SYSTEM CIRCUIT Ignition switch Engine Starter relay Neutral start switch Planetary type starter Battery (AT vehicle only) : AT vehicle only JST00002-00001...

  • Page 294: Starter Motor

    ST–3 STARTER MOTOR COMPONENTS 0.8 kW, Planetary Type Starter Motor For automatic transmission vehicles For manual transmission vehicles : Non-reusable parts : Asbestos parts q Bearing !0 Center bearing !9 Brush holder w Drive housing !1 Magnet switch @0 O-ring e Snap ring !2 Internal gear @1 Yoke...
  • Page 295 ST–4 SERVICING INSTRUCTIONS OF STARTER 1. When connecting the starter terminal or battery terminal, perform positive tightening so as to avoid poor connection. If poor connection should exist, it presents the hazard of serious danger that a large amount of current flowing during starter operation can overheat the poor connection.
  • Page 296 ST–5 REMOVAL 1. Disconnect the ground cable terminal from the negative (–) terminal of the battery. JST00007-00000 2. Remove the battery and battery carrier. 3. Jack up the vehicle and support it with safety stands. (Refer to the GI Section of the service manual.) 4.
  • Page 297 ST–6 (2) Connect the negative (–) terminal of the battery to the starter body and magnetic switch terminal. JST00012-00008 (3) Connect the positive (+) terminal to the terminal ST. Ensure that the pinion is pushed outward. If the drive pinion fails to move out, replace the mag- netic switch.
  • Page 298 ST–7 DISASSEMBLY OF PLANETARY TYPE STARTER MOTOR 1. Disconnect the lead wire from the magnetic switch. JST00017-00013 2. Remove the attaching nut of the magnetic switch from the drive housing. JST00018-00014 3. Remove the magnetic switch from the drive housing. JST00019-00015 4.
  • Page 299 ST–8 6. Separate the yoke with armature from the clutch with cen- ter bearing. 7. Remove the O-ring. JST00022-00018 8. Remove the end frame cover by removing the two screws. JST00023-00019 9. Remove the brushes from the brush holder by lifting the brush springs by means of nose pliers or the like.
  • Page 300 ST–9 13. Detach the snap ring by prying it off with snap ring pliers. Then, remove the collar. JST00027-00023 14. Remove the clutch. JST00028-00024 15. Detach the snap ring. Separate the center bearing from the planetary carrier shaft. JST00029-00025 16. Remove the internal gear by aligning the recessed section provided at the outer periphery of the internal gear with the protruded section provided at the inner periphery of the center bearing.
  • Page 301 ST–10 2. Check of commutator continuity Check continuity between each adjacent segment of the commutator, using an ohmmeter. If no continuity exists between any adjacent segments, re- place the armature. JST00032-00028 Check of commutator 1. Check each contact surface of the commutator segments with the brushes for burning.
  • Page 302 ST–11 Check of field coil 1. Field coil continuity test Perform field coil continuity test at a point between the lead wire and the brush, using an ohmmeter. If no continuity exists, replace the yoke. JST00037-00033 2. Field coil short test Perform field coil short test at a point between the brush and the yoke proper, using an ohmmeter.
  • Page 303 ST–12 (3) Stack the plate section of a replacement brush onto the welding side of the lead wire. Make pressure con- nection over the overlaid section by pinching it with pliers. NOTE: • Be sure to take out the brush lead wire in the correct direction.
  • Page 304 ST–13 2. Check of starter clutch While holding the clutch, turn the pinion clockwise. Ensure that the pinion turns smoothly. Turn the pinion counterclockwise. Ensure that the pinion is locked. If the check results are unsatisfactory, replace the starter clutch. JST00047-00043 Check of magnetic switch 1.
  • Page 305 ST–14 2. Measure the inner diameter of the center bearing so as to determine the clearance. Specified Value: 0.04 mm Allowable Limit: 0.15 mm If the clearance exceeds the allowable limit, replace the oilless bearing or the planetary carrier shaft. JST00052-00048 3.
  • Page 306 ST–15 2. Measure the inner diameter of the end frame bearing so as to determine the clearance. Specified Value: 0.035 mm Allowable Limit: 0.1 mm If the clearance exceeds the allowable limit, replace the oilless bearing or the armature. JST00057-00053 3.
  • Page 307 ST–16 3. Bearing replacement (1) Remove the bearing, using a tap having an outer di- ameter of 8 mm. NOTE: • Be certain to clamp the planetary carrier shaft in a vice with a cloth interposed so that no scratch be made on the planetary carrier shaft.
  • Page 308 ST–17 3. Install the plate washer in place. Install the snap ring. JST00067-00063 4. Install the clutch. JST00068-00064 5. Install the stop collar and a new snap ring. Compress the snap ring, using a vise or the like. JST00069-00065 6. Tap the collar so that it may come onto the snap ring, using a screwdriver.
  • Page 309 ST–18 8. Install the yoke to the armature. Install the brushes to the brush holder while lifting the brushes by means of nose pliers or the like. JST00072-00068 9. Install the commutator end frame, together with a new O- ring, to the yoke by means of the two screws. JST00073-00069 10.
  • Page 310 ST–19 13. While hooking the magnetic switch over the drive lever, in- stall the magnetic switch onto the drive housing. Secure the magnetic switch with the two nuts. NOTE: • Be sure to install the rubber boot in the spring section securely.
  • Page 311 ST–20 5. Jack up the vehicle. Remove the safety stands from the vehicle. Then, remove the jack. 6. Install the battery and battery carrier. 7. Connect the ground cable terminal to the negative (–) ter- minal of the battery. JST00082-00000 8.
  • Page 312 ST–21 SERVICE SPECIFICATIONS Reduction type starter Rating voltage and output power 12V 0.8 kW motor No-load characteristic at 11.5V Amperage Less than 90A Brush length Standard 14.0 mm Minimum 11.1 mm Commutator Outer diameter Standard 28 mm Minimum 27 mm Undercut depth Standard 0.45 - 0.75 mm...

  • Page 313: Charging System

    DAIHATSU J100 TO INDEX CHARGING SYSTEM OUTLINE OF CHARGING SYSTEM ... CH– 2 CHARGING SYSTEM CIRCUIT ....CH– 2 PRECAUTIONS ........... CH– 3 IN-VEHICLE INSPECTION ......CH– 3 ALTERNATOR ..........CH– 9 SERVICE SPECIFICATIONS ...... CH–22 TROUBLE SHOOTING ....... CH–22 JCH00001-00000 NO.
  • Page 314 CH–2 OUTLINE OF CHARGING SYSTEM An IC regulator type alternator is employed on this model. Moreover, an alternator cut-off system is adopted on automatic transmission vehicles to shut off the alterna- tor operation so that the startability of the engine may be enhanced when the ambient temperature is ex- tremely low at the starting period.
  • Page 315 CH–3 PRECAUTIONS 1. Prior to the inspection, make sure that the battery cables are connected securely. 2. When a quick charging operation is carried out, first be sure to disconnect the battery cables. 3. Never use a high-voltage insulation resistance tester for the purpose of conducting this inspection. 4.
  • Page 316 CH–4 6. Check of charging circuit under unloaded state NOTE: • If a battery/alternator tester is available, connect such tester to the charging circuit according to the manufac- turer’s instructions of the alternator tester. JCH00008-00000 (1) If a battery/alternator tester is not available, connect a voltmeter and an ammeter to the alternator wiring and alternator as follows: •...
  • Page 317 CH–5 For automatic transmission models, ensure that a voltage of 4.0 volts or higher is applied to between the terminal Terminal F @8 of the SST and the body ground. If the specified voltage is not applied, check the wiring be- tween the EFI ECU and the alternator as follows: JCH00012-00006 a.
  • Page 318 CH–6 Removal of battery WARNING: • Never touch the battery terminals immediately after the engine stopped. • Be certain to turn OFF the ignition switch. • Never allow any fire to be brought near the battery. CAUTION: • Be very careful not to drop the battery or apply strong vibration to the battery.
  • Page 319 CH–7 Battery capacity check 1. Reserve capacity check, using hydrometer 2. Reserve capacity check, using battery tester CAUTION: • The battery tester should be operated in accordance with the operating instructions of the service manual. • The battery to be check should be fully charged. (1) Connect a battery tester to the battery.
  • Page 320 CH–8 INSTALLATION OF BATTERY 1. Clean any dust from the battery carrier. JCH00021-00013 2. Place the battery on the battery carrier in such a direction Terminals that the negative terminal of the battery may come at the front side of the vehicle. 3.
  • Page 321 CH–9 ALTERNATOR COMPONENTS Generator cap Alternator assembly Bolt Wave washer Spacer Alternator rotor assembly Stud bolt Drive end flame assembly Bearing cover Bearing Bolt Retainer plato Alternator pulley Bearing Pulley lock nut Bolt Insulator terminal Brush holder Brush spring Rear end cover Brush Generator regulator assembly Rectifier holder...
  • Page 322 CH–10 REMOVAL OF ALTERNATOR 1. Disconnect the ground cable terminal from the negative terminal of the battery. Attaching bolt 2. Remove the generator cap. 3. Disconnect the terminal B of the alternator wire from the alternator. 4. Disconnect the alternator connector of the alternator wire from the alternator.
  • Page 323 CH–11 2. Remove the alternator pulley. JCH00028-00019 3. Remove the attaching nut of the terminal insulator. 4. Pull out the terminal insulator. 5. Remove the three rear end cover attaching nuts. Terminal insulator 6. Remove the terminal plate attaching bolt. 7.
  • Page 324 CH–12 13. Remove the wave washer from the alternator rotor assem- bly. JCH00033-00024 14. Remove the alternator rotor assembly from the drive end frame assembly. JCH00034-00025 INSPECTION OF ALTERNATOR Rotor 1. Inspection of rotor for open circuit Using an ohmmeter, check to see if the specified resis- tance exists between the rotor slip rings.
  • Page 325 CH–13 (2) Measure the outer diameter of the slip ring, using vernier calipers. Standard Diameter: 14.4 mm Minimum Diameter: 14.0 mm If the slip ring diameter is less than the minimum diam- eter, replace the rotor assembly. JCH00038-00029 Stator 1. Inspection of stator for open circuit Using an ohmmeter, check to see if any open circuit of the stator coil is present between the leads.
  • Page 326 CH–14 (2) Install the brush cord in the brush holder with the spring fitted in place. JCH00043-00034 (3) Solder the brush cord in the brush holder in such a way that the exposed length of the brush meets the specification. Standard Exposed Length: 10.5 mm JCH00044-00035...
  • Page 327 CH–15 Rectifier NOTE: • Be sure to confirm the specification of the ohmmeter to be used for inspection before putting it into use. • The current flow direction differs according to the de- sign of an ohmmeter. • This manual is described, based on a digital tester manufactured by DENSO Japan.
  • Page 328 CH–16 Bearings 1. Inspection of front bearing Ensure that the bearing turns smoothly. Replace the bearing, if necessary. JCH00051-00042 2. Replacement of bearing (1) Remove the four screws and retainer plate. JCH00052-00043 (2) Remove the front bearing from the drive end frame, using a suitable socket wrench in conjunction with a press.
  • Page 329 CH–17 3. Inspection of rear bearing Ensure that the bearing turns smoothly. Replace the bearing, if necessary. JCH00056-00047 4. Replacement of rear bearing (1) Remove the rear bearing cover from the rotor, using the armature bearing puller. CAUTION: • Be very careful not to damage the fan during the re- moval.
  • Page 330 CH–18 ASSEMBLY OF ALTERNATOR 1. Install the rotor in the drive end frame assembly. JCH00060-00052 2. Installation of rectifier end frame on drive end frame (1) Place the wave washer on the rear bearing. (2) Install the rectifier end frame on the drive end frame with the two bolts and two nuts or four attaching nuts.
  • Page 331 CH–19 (3) Connect the coil wires to the rectifier holder with the at- taching screws. (4) Install the rectifier holder and regulator assembly with the attaching screws. NOTE: • Make sure that the regulator assembly is installed properly with the attaching screws as it works. JCH00064-00057 (5) Install the brush holder in such a way that a gap of at least 1 mm is provided between the brush holder and...
  • Page 332 CH–20 6. Install the pulley lock nut by means of an impact wrench. CAUTION: • Be sure to use an impact wrench having a hexagonal hole. • Be sure to set the tightening torque of the impact wrench as follows. Tightening Torque: 110.5 N·m JCH00069-00061...
  • Page 333 CH–21 5. Tension adjustment of drive belt (1) Install the following SST to the alternator and adjusting bar as shown in the right figure. SST: 09286-87701-000 (2) Adjust the drive belt tension to the specified value by adjusting the nut of the SST. Specified Belt Deflection New Belt: 4 - 5 mm...
  • Page 334 CH–22 SERVICE SPECIFICATIONS Battery specific gravity (Except Delco Freedom battery) 1.25 - 1.27 Amperage Rated output 2.9 Ω at 20ϒC (68ϒF) Resistance Rotor coil resistance Standard 14.4 mm Slip ring diameter Alternator: Minimum 14.0 mm 50A (For manual transmission vehicles) Standard Brush exposed length 10.5 mm...
  • Page 335 DAIHATSU J100 TO INDEX CLUTCH OUTLINE ............. CL– 2 CLUTCH SECTIONAL VIEW ....CL– 2 CLUTCH PEDAL ADJUSTMENT ....CL– 3 PEDAL INSTALLATION HEIGHT .... CL– 3 ADJUSTMENT OF CLUTCH PEDAL FREE TRAVEL ........CL– 3 CLUTCH PEDAL & CLUTCH CABLE ..CL– 4 1.
  • Page 336 CL–2 OUTLINE 1. The clutch mechanism has employed a cable-operated mechanical clutch. This clutch has adopted a dry, single disc type diaphragm type which features easy operation and excellent serviceability. 2. The release mechanism employs a lever type featuring superb stroke efficiency and load efficiency, as is the case with S100 series.
  • Page 337 CL–3 CLUTCH PEDAL ADJUSTMENT PEDAL INSTALLATION HEIGHT Loosen the lock nut. Adjust the pedal height by turning the Adjusting bolt adjusting bolt. Pedal Installation Height: 175 - 180 mm (Distance from center of pedal pad upper surface to dash panel) Lock nut Lock Nut Tightening Torque: 11.8 - 27.4 N·m...
  • Page 338 CL–4 CLUTCH PEDAL & CLUTCH CABLE COMPONENTS : Tightening torque FRONT Unit : N·m (kgf-m) 3.9 - 6.9 (0.4 - 0.7) 3.9 - 6.9 (0.4 - 0.7) 10.3 - 24.0 (1.05 - 2.45) 3.9 - 6.9 (0.4 - 0.7) 3.9 - 6.9 (0.4 - 0.7) 6.9 - 15.7 (0.7 - 1.6)
  • Page 339 CL–5 FRONT 3.9 - 6.9 (0.4 - 0.7) 3.9 - 6.9 10.3 - 24.0 (0.4 - 0.7) (1.05 - 2.45) 6.9 - 15.7 (0.7 - 1.6) q Clutch housing cover w Clutch cable bracket e Clutch cable bracket r Clutch cable bracket t Clutch release cable assembly y Pedal shaft u Spring...
  • Page 340 CL–6 1. Main points of clutch pedal installation MP grease (1) Apply MP grease to the points where the inner surface of the clutch pedal subassembly is connected to the clutch release cable assembly; the inner surface and MP grease hook section of the torsion spring;...
  • Page 341 CL–7 CLUTCH RELEASE MECHANISM COMPONENTS 14.7 - 21.6 : Tightening torque Unit : N·m (kgf-m) (1.5 - 2.2) 14.7 - 21.6 (1.5 - 2.2) MP grease MP grease FRONT q Clutch release fork support w Anti-rattle spring MP grease e Clutch release fork r Clutch release bearing hub t Release bearing hub clip y Clutch cover assembly...
  • Page 342 CL–8 3. Check Clutch cover and diaphragm spring Inspect the following parts. Replace any parts which exhibit defects. (1) Check the clutch pressure plate and the clutch disc contracting surface of the flywheel for evidence of wear or burns. (2) Check the diaphragm spring lever for wear, corrosion or damage.
  • Page 343 CL–9 Clutch release fork (1) Check for wear or damage. JCL00018-00016 Anti-rattle spring (1) Check for wear or damage. JCL00019-00017 Clutch release fork support Check for wear or damage. JCL00020-00018 4. Main points of installation (1) Thinly apply EP grease to the clutch release fork or the entire periphery of the sliding surface of the clutch re- lease bearing hub assembly.
  • Page 344 CL–10 (3) Apply EP grease to the entire periphery of the sliding Apply grease surface of the release fork support. JCL00023-00021 (4) Apply EP grease to the entire inner periphery of the clutch release bearing hub assembly. Install the clutch release fork to the transmission.
  • Page 345 CL–11 5. Operation after installation (1) Check the diaphragm spring section for unevenness in height, using the following SST. SST: 09210-87701-000 Limit: 0.5 mm JCL00028-00026 (2) If the check above reveals that the unevenness in height exceeds its limit, correct the unevenness, using the following SST.
  • Page 346 CL–12 APPENDIX SSTs (Special Service Tools) Illustration Tool No. Tool name 09210-87701-000 Flywheel holder Clutch guide tool 09301-87703-000 Clutch diaphragm spring height gauge No.4 09302-87702-000 Clutch diaphragm spring aligner 09333-00013-000 JCL00030-00028 SERVICE SPECIFICATIONS Unit : mm Item Specified value Allowable limit Remark Distance from upper Height...

  • Page 347: Manual Transmission

    DAIHATSU J100 TO INDEX MANUAL TRANSMISSION OUTLINE ..........MT– 2 COMPONENTS ......MT–28 SECTIONAL VIEW OF MANUAL COMPONENTS ......MT–29 TRANSMISSION ....... MT– 2 INSPECTION PRIOR TO SPECIFICATIONS ......MT– 3 OPERATION ......MT–30 POWER FLOW ROUTE ..... MT– 4 DISASSEMBLY ......
  • Page 348 MT–2 OUTLINE 1. The manual transmission employs five gears on all vehicles. 2. The gear train arrangement uses the output reduction type. This design has made possible the follow- ing features given below. (1) The number of pair of gears which are idling during the engine idling has been reduced to only two pairs (first gear and second gear).
  • Page 349 MT–3 SPECIFICATIONS Item Specifications Engine type HC-EJ Forward gears Constant-mesh type Type Reverse gear Selective sliding type 1st gear 4.059 2nd gear 2.045 3rd gear 1.376 Gear ratio 4th gear 1.000 5th gear 0.838 Reverse gear 4.128 Type SAE 75W-85 API GL-3 or GL-4 Oil used Capacity liter...
  • Page 350 MT–4 POWER FLOW ROUTE The gear train has been so designed that the fourth gear makes direct connection, while the fifth gear makes overdrive. Furthermore, as for the gear arrangement, the first gear, reverse gear, second gear, fifth gear and output reduction are located in this sequence, counting from the front. 1st gear 2nd gear 3rd gear...
  • Page 351 MT–5 SHIFT CONTROL MECHANISM 1. The shift control mechanism employs the remote control method in which two push-pull cables are used, in the same way as with S100. Also, for improved shift feeling, an aluminum housing has been adopted. Select cable Housing Shift cable Dust cover...
  • Page 352 MT–6 INSTALLATION/REMOVAL OF MANUAL TRANSMISSION COMPONENTS : Tightening torque Unit : N·m (kgf-m) 29.4 - 44.1 29.4 - 44.1 49.0 - 68.6 (3.0 - 4.5) (3.0 - 4.5) (5.0 - 7.0) 14.7 - 21.6 (1.5 - 2.2) 31.4 - 47.0 (3.2 - 4.8) 29.4 - 44.1 (3.0 - 4.5)
  • Page 353 MT–7 1. OPERATION PRIOR TO REMOVAL (1) Disconnect the negative (–) terminal of the battery. (2) Suspend the engine by means of an engine support Tool bridge. NOTE: · Attach the hook to the engine hanger. (3) Raise the vehicle with a lift. (4) Drain the transmission oil.
  • Page 354 MT–8 3. OPERATION AFTER REMOVAL (1) Ensure that the locating pin is positioned securely at both the transmission and engine sides. NOTE: · Make sure to replace the locating pin that has exhibited severely scored. Locating pin (at engine side) Engine side Transmission side Locating pin...
  • Page 355 MT–9 (5) Tighten the attaching bolts of the engine mounting rear insulator and engine rear support member subassem- bly. Proceed to install the attaching bolts of the engine rear support member subassembly to the body. (6) Remove the transmission jack, etc. Install the front lower frame crossmember subassembly.
  • Page 356 MT–10 DISASSEMBLY/ASSEMBLY OF MANUAL TRANSMISSION COMPONENTS (PART 1) : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 18.6 - 30.4 (1.9 - 3.1) 24.5 - 39.2 (2.5 - 4.0) 14.7 - 21.6 (1.5 - 2.2) 18.6 - 30.4 (1.9 - 3.1) 18.6 - 30.4 14.7 - 21.6 (1.9 - 3.1)
  • Page 357 MT–11 NOTICE PRIOR TO OPERATION This section summarizes the main points of each section of the configuration drawings posted on those pages previous to MT–10, MT–12, MT–20 and MT–28. The description is so arranged that the removal and assembly may readily be understandable when the configuration drawings are referred to the contents posted at the lower section of the page.
  • Page 358 MT–12 COMPONENTS (PART 2) : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 14.7 - 21.6 (1.5 - 2.2) 29.4 - 49.0 (3.0 - 5.0) 14.7 - 21.6 (1.5 - 2.2) 18.6 - 30.4 14.7 - 21.6 (1.9 - 3.1) (1.5 - 2.2) 176.4 - 215.8 (18.0 - 22.0)
  • Page 359 MT–13 COMPONENTS (PART 2) #1 Torsion spring Pay special attention to the assembling direction in the same way as with Item #2 . #2 Reverse restrict cam Pay special attention to the assembling direction during disassembly and assembly, for the reverse restrict cam has the correct assembling direction to be observed. #3 Reverse restrict shaft D = 8 mm, L = 7.15 mm #4 Select lever subassembly...
  • Page 360 MT–14 REMOVAL OF TRANSFER ASSEMBLY NOTE: · For disassembly of the transfer assembly, refer to Section TR. 1. Remove the seven bolts indicated in the right figure. NOTE: · The numeral in the right figure denotes the nominal length of each bolt. (Unit: mm) JMT00023-00016 2.
  • Page 361 MT–15 5. Pull out the shift lever subassembly and shift inner lever by driving out the grooved pin. 6. Remove the reverse restrict cam (A), torsion spring (B) and reverse restrict shaft (C) by removing the hexagon bolt with the gasket. NOTE: ·...
  • Page 362 MT–16 5. Remove the transfer input hub. 6. Remove the rear bearing retainer and transmission mag- net by removing the five bolts. JMT00031-00023 7. Remove the hole snap ring with a snap ring expander. 8. Remove the output shaft from the transmission case. JMT00032-00024 REMOVAL OF SHIFT FORK NOTE:...
  • Page 363 MT–17 REMOVAL OF INPUT SHAFT AND COUNTER GEAR NOTE: · Confirm that each gear can be engaged properly. 1. Pull out the output shaft assembly with the needle roller bearing, synchronizer ring and wave spring. 2. Remove the reverse shift arm by removing the three bolts. 3.
  • Page 364 MT–18 2. Measure the contact width section between the shift heads and the shift inner lever. Unit: mm Shift heads Shift inner lever +0.1 –0.02 Specified Value 12.1 –0.12 JMT00040-00031 REVERSE IDLER GEAR 1. Visually inspect the chamfered section of the reverse idle gear for damage.
  • Page 365 MT–19 INSTALLATION 1. Install the new tight plug as shown in the right figure. 2. Install the new Type T oil seal as shown in the right figure. 3. Ensure that the protrusion section (A) of the Type T oil seal conforms to the specified value.

  • Page 366: Input Shaft

    MT–20 INPUT SHAFT COMPONENTS : Non-reusable parts : Selection parts q Shaft snap ring !2 Needle roller bearing w Radial ball bearing (front) !3 3rd gear e Input shaft !4 Synchronizer ring No. 1 r Split type needle roller bearing !5 Wave spring t 5th gear !6 Synchromesh shifting key spring...
  • Page 367 MT–21 COMPONENTS q Shaft snap ring This is shared in common with the snap ring of Item !9 . Thickness selection type snap ring w Radial ball bearing e Input shaft Needle roller bearing rotating section: D = 31.971 - 31.991 mm, two points Needle roller bearing rear end section: D = 19.966 - 19.984 mm r Split type needle roller bearing The opening width of mating ends of the bearing should not exceed the shaft diameter +...
  • Page 368 MT–22 INSPECTION PRIOR TO OPERATION 1. Measure the contact section of the shift forks for 3rd gear (A), 5th gear (B) and with the hub sleeves. Unit: mm 3rd gear (A) and 5th gear (B) Fork Hub sleeve –0.1 +0.12 Specified Value –0.3 +0.05...
  • Page 369 MT–23 9. Remove the following parts, using the following SST. SST: 09950-20017-000 NOTE: · The following parts can be removed by driving out the input shaft by means of a press, with the 5th gear sec- tion sustained by the SST (09334-87301-000). (1) Synchronizer No.
  • Page 370 MT–24 4. Measure the dimensions between the outer diameter of the synchronizer No. 2 for 3rd (A) and synchronizer No. 3 for 5th (B) and bore diameter of both hub sleeves. Unit: mm Classifica- Identifica- (A) and (B) Hub sleeve tion tion No.
  • Page 371 MT–25 ASSEMBLY NOTE: · Be sure to apply gear oil to the relevant parts at every process. · Never reuse those parts bearing an asterisked mark posted at the pages MT–20 and 21. JMT00063-00000 1. Install the split type needle roller bearing and apply gear oil to it.
  • Page 372 MT–26 6. Selection procedure for new shaft snap ring (1) Using the table below, select a new shaft snap ring having the same thickness as that measured at the time of the removal, or the thinnest shaft snap ring. Then, install the thus-selected snap ring on the shaft snap ring installation groove of the input shaft.
  • Page 373 MT–27 11. Selection procedure for new shaft snap ring (1) For the selection procedure of the shaft snap ring, refer to the step 6 at page MT–26. JMT00072-00059 (2) Again, ensure that the end play between the hub and the shaft snap ring conforms to the specified value.

  • Page 374: Counter Gear

    MT–28 COUNTER GEAR COMPONENTS : Non-reusable parts : Selection parts q Shaft snap ring !2 Synchromesh shifting key w Radial ball bearing !3 Synchronizer ring No. 3 e 1st gear thrust washer !4 Split type needle roller bearing r Shaft snap ring !5 2nd gear t 1st sub-gear !6 Conical spring washer...
  • Page 375 MT–29 COMPONENTS q Shaft snap ring Thickness selection type w Radial ball bearing Assemble the bearing so that the side having a seal comes at the front. e 1st gear thrust washer Thickness = 3.97 - 4.03 mm Assemble the washer in such a way that the protruding side comes at the front; the oil- groove side comes at the 1st gear side.
  • Page 376 MT–30 INSPECTION PRIOR TO OPERATION 1. Measure the contact width section of the synchronizer No. 1 hub assembly (B) with the 1st & 2nd shift fork (A). Unit: mm –0.1 +0.12 Specified Value –0.3 +0.05 Allowable Limit 10.2 2. Measure and record the thrust clearance for 1st gear (C) and 2nd gear (D) as shown in the right figure.
  • Page 377 MT–31 7. Remove the following parts. (1) Synchronizer No. 1 hub assembly (2) Synchronizer ring No. 3 (3) 2nd gear with sub-gear NOTE: · The parts described above can be removed by press- ing the counter gear, while the 2nd gear (sub-gear sur- face) is supported by means of the following SST.
  • Page 378 MT–32 5. Measure the thickness of the 1st gear thrust washer. 4 ± 0.03 mm Specified Value: JMT00086-00071 6. Measure the dimensions between the outer diameter of the synchronizer No. 1 hub (A) and the bore diameter of synchronizer hub sleeve (B). [Reference information] The parts (A) and (B) are available only as a set.
  • Page 379 MT–33 REPLACEMENT OF CONICAL SPRING WASHER 1. Clamp the 1st gear together with the following SST in a vice as shown in the right figure. SST: 09350-32014-000 2. Remove the conical spring washer and sub-gear by re- moving the shaft snap ring. JMT00090-00075 INSPECTION 1.
  • Page 380 MT–34 2. Install the split type needle roller bearing. CAUTION: · When the split type needle roller bearing is installed, make sure that the gap (A) at the opening of the needle roller bearing will not exceed the outer diameter of the counter gear by more than 5 mm.
  • Page 381 MT–35 11. Selection sequence of new shaft snap ring. (1) Using the table below, select a new shaft snap ring having the same thickness as that measured at the time of removal, or the thinnest shaft snap ring. Then, install the thus-selected shaft snap ring on the shaft snap ring installation groove of the counter gear.
  • Page 382 MT–36 17. Selection sequence of new shaft snap ring (1) For the selection procedure of the shaft snap ring, refer to the step 11 at page MT–35. JMT00103-00087 (2) Ensure that the end play conforms to the specified value. End Play: Specified Value: Allowable Limit: Less than 0.16 mm...

  • Page 383: Output Shaft

    MT–37 OUTPUT SHAFT DISASSEMBLY 1. Remove the radial ball bearing (for rear), using the follow- ing SST. SST: 09306-87602-000 JMT00105-00088 INSPECTION 1. Check the clearance between the synchronizer ring and gear tapered section. Specified Value 0.95 - 1.35 mm 2. Visually inspect the gear and spline section of the output shaft for wear and damage.
  • Page 384 MT–38 2. Attach the tension spring to the input shaft bearing lock plate. 3. Tighten the input shaft bearing lock plate with the three bolts. Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m) 4. Place the two pieces of the shift lock plates on the clutch housing side.
  • Page 385 MT–39 CONFIRMATION OF LENGTH/SHAPE OF SHIFT FORK AND SHIFT FORK SHAFT 9. The following three shift fork shafts differ in the overall length, as shown in the right figure. NOTE: · Be very careful not to make any wrong installation of these shift fork shafts.
  • Page 386 MT–40 12. Install the 3rd & 4th shift fork into the hub sleeve and insert the 3rd & 4th shift fork shaft. NOTE: · Make sure that the gear is in the neutral position. · In order to drive a new slotted spring pin smoothly, it is advisable to prepare a guide pin whose outer diameter is 4.0 mm and whose length is 50.00 mm.
  • Page 387 MT–41 21. Place the output shaft with the needle roller bearing, syn- chronizer ring and wave spring. NOTE: · Make sure to assemble the wave spring according to the convex shape of the synchronizer ring. (See the right figure.) JMT00122-00105 22.
  • Page 388 MT–42 26. With the smaller diameter end placed at the nut side, as- semble the conical spring. NOTE: Conical spring Lock nut · Make sure that the conical spring is assembled in the correct direction. JMT00127-00110 27. Insert a deep socket into the output shaft. [Reference] ·...
  • Page 389 MT–43 35. Install the clutch related parts. JMT00132-00000 36. Install the shift lever boot and shift lever shaft correctly as Apply grease shown in the right illustration. CAUTION: · Ensure that the air bleeding section (A) of the boot faces toward the lower side. NOTE: ·...
  • Page 390 MT–44 38. Install the ball and compression spring and tighten the re- verse restrict pin holder (B) with a new gasket interposed. Tightening Torque: 29.4 - 49.0 N·m (3.0 - 5.0 kgf-m) JMT00137-00119 39. Assemble the torsion spring, reverse restrict cam and re- verse restrict shaft in the transmission case in this se- quence.
  • Page 391 MT–45 3. Install and tighten the transfer assembly with the seven bolts. Tightening Torque: 29.4 - 44.1 N·m (3.0 - 4.5 kgf-m) NOTE: · The numeral in the right figure denotes the nominal length of each bolt. (Unit: mm) JMT00142-00124 JMT00000-00125...
  • Page 392 MT–46 INSTALLATION/REMOVAL OF SHIFT CABLE & SELECT CABLE COMPONENTS 14.7 - 21.6 : Tightening torque (1.5 - 2.2) Unit : N·m (kgf-m) : Non-reusable parts 14.7 - 21.6 (1.5 - 2.2) 14.7 - 21.6 (1.5 - 2.2) 6.9 - 9.8 (0.7 - 1.0) q Cover, shift lever housing dust y Washer, plate...
  • Page 393 MT–47 2. CHECK (1) Check that the inner cables of the shift cable and se- lect cable slide smoothly. (2) Check for boot breakage, other damage or distortion. Boot breakage JMT00146-00129 3. MAIN POINTS OF INSTALLATION (1) Insert the clips t and u until their upper edges be- come flush with the upper edges of the bracket or the retaining surface of the floor shift assembly.
  • Page 394 MT–48 INSTALLATION/REMOVAL OF TRANSMISSION FLOOR SHIFT ASSEMBLY COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 14.7 - 21.6 (1.5 - 2.2) 6.9 - 9.8 (0.7 - 1.0) q Knob, shift lever y Cable assembly shift w Cover, shift lever housing dust u Cable assembly select e Clip i Floor shift assembly, transmission...
  • Page 395 MT–49 2. MAIN POINTS OF INSTALLATION Front (1) Tighten the floor shift assembly with the attaching bolts. Tightening Torque: 14.7 - 21.6 N·m (1.5 - 2.2 kgf-m) NOTE: · Be certain to tighten the attaching bolts in the se- quence specified in the right figure. JMT00150-00133 (2) Install the shift cable assembly and select cable as- sembly in the floor shift assembly.
  • Page 396 MT–50 DISASSEMBLY/ASSEMBLY OF TRANSMISSION FLOOR SHIFT ASSEMBLY COMPONENTS : Tightening torque Unit : N·m (kgf-m) 9.8 - 15.6 MP grease (1.0 - 1.6) MP grease (Outer diameter, spherical sections) MP grease 39.2 - 49.0 (4.0 - 5.0) 39.2 - 49.0 (4.0 - 5.0) q Support, control link i Lever subassembly, control select...
  • Page 397 MT–51 APPENDIX SSTs (Special Service Tools) Shape Part No. Part name 09306-87602-000 Counter gear front bearing puller 09310-87301-000 Counter shaft front bearing replaer 09310-87302-000 Counter shaft rear bearing replacer 09334-87301-000 Transmission rear bearing anvil TOYOTA Automatic transmission tool 09350-32014-000 09606-87201-000 Front hub bearing remover &...
  • Page 398 MT–52 SERVICE SPECIFICATIONS Unit: mm Specified Value Allowable Limit Free length 24.00 — Free length of compression spring for Load as installed: N (kgf) 28.83 (2.43) — reverse restrict pin Height as installed: 17.00 — Free length 40.00 — Free length of compression spring for Load as installed: N (kgf) 47.33 (4.83)
  • Page 399 MT–53 AT THE INPUT SHAFT SIDE Unit: mm Specified Value Allowable Limit –0.1 Contact width section between shift forks Shift forks 3rd & 5th –0.3 and synchronizer No. 2 & No. 3 hub +0.12 Hub sleeves 3rd & 5th sleeves +0.05 0.10 - 0.52 —...
  • Page 400 MT–54 AT THE COUNTER SHAFT SIDE Unit: mm Specified Value Allowable Limit +0.12 Hub sleeve 10.2 +0.05 Contact width section between the synchronizer No. 1 hub sleeve and 1st/2nd shift fork –0.1 Shift fork –0.3 0.10 - 0.52 — Thrust clearance between gear and counter shaft 0.10 - 0.40 —...
  • Page 401 MT–55 TIGHTENING TORQUE Tightening components N·m kgf-m Engine ´ Clutch housing 49.0 - 68.6 5.0 - 7.0 Stiffener right ´ Engine, Clutch housing 29.4 - 44.1 3.0 - 4.5 Stiffener left ´ Engine, Clutch housing 29.4 - 44.1 3.0 - 4.5 Clutch housing undercover ´...

  • Page 402: Automatic Transmission

    DAIHATSU J100 J100 TO INDEX AUTOMATIC TRANSMISSION OUTLINE ..........AT– 2 REMOVAL AND INSTALLATION OF SECTIONAL VIEW OF AUTOMATIC AUTOMATIC TRANSMISSION ..AT–40 TRANSMISSION ......AT– 2 COMPONENTS ......AT–40 SPECIFICATIONS ......AT– 3 CONNECTION AND DISCONNECTION TORQUE CONVERTER ...... AT– 4 OF OIL COOLER HOSES ....
  • Page 403 AT–2 OUTLINE 1. A hydraulic pressure control planetary gear type, four-speed automatic transmission with overdrive is employed, which has been newly developed for FR vehicles with an engine mounted longitudinally. ® 2. The automatic transmission fluid has employed a DEXRON III which features excellent heat and oxida- tion stability.
  • Page 404 AT–3 SPECIFICATIONS Item Specifications Type Three-element, one-stage, two-phase type Torque 2.0/1990 - 2540 rpm Stall torque ratio/Stall revolution speed converter Sprag type One-way clutch type Four forward speeds, one reverse gear, Type planetary gear type 3 set Wet type multiple clutch 1 set Band type brake Control element...

  • Page 405: Torque Converter

    AT–4 TORQUE CONVERTER Stator The torque converter employs a three-element, one-stage, two- phase type converter, as has been hitherto employed. Front cover CONSTRUCTION One-way clutch The torque converter consists of a front cover to which a drive plate is attached, a pump impeller integral with the torque converter cover, a turbine runner which is spline-fitted with the input shaft at the transmission side, a stator, a one-way clutch which supports the stator and so forth.
  • Page 406 AT–5 POWER TRAIN MECHANISM DESCRIPTION In the power train mechanism, the power that has been trans- mitted from the engine to the input shaft of the transmission through the torque converter is transmitted from various clutches to the planetary gear, using reduction ratios optimum for the running condition.
  • Page 407 AT–6 OPERATION (1) Power Train Route The input route of the power train has three routes: One is a route in which the power is transmitted from the input shaft to the front planetary sun gear via the C1 clutch. Another is a route in which the power is transmitted to the rear planetary sun gear via the C2 clutch.
  • Page 408 AT–7 (2) Î and x ranges <1st gear> (without engine brake) When the transmission is in the 1st gear with the shift lever set to the Î or x range, the forward clutch (C2) is activated. Therefore, the rotating force of the input shaft is directly transmitted to the rear planetary sun gear, thus transmitting a counterclockwise rotating force to the planetary short pinion.
  • Page 409 AT–8 (4) Î range <3rd gear> When the transmission is in the 3rd gear, the direct clutch (C1) and forward clutch (C2) are activated. Therefore, the input shaft, front planetary sun gear and rear planetary sun gear rotate in the same direction. As a result, the planetary short pinion and planetary long pinion come in a locked state.
  • Page 410 AT–9 (6) Ò range <1st gear> The rotating force is transmitted in the same way as the 1st gear of the Î range, as previously explained. However, the 1st & reverse brake (B2) operates to prevent the planetary carrier from rotating clockwise at the time of engine braking.
  • Page 411 AT–10 (8) ∏ range When shifted to the ∏ range, the parking cam is pushed out through the parking rod. Thus, the parking cam pushes up the parking pawl. As a result, the parking lock pawl becomes engaged with the parking lock gear.
  • Page 412 AT–11 HYDRAULIC PRESSURE CONTROL SYSTEM DESCRIPTION Utilizing the hydraulic pressure generated at the oil pump, the hydraulic pressure control system switches fluid passages leading to each shift control element of the power train mechanism according to running conditions, regulates the line pressure as well as lubricates each section of the transmission. The following table shows operating conditions of the hydraulic pressure applied to each shift control ele- ment in each shift position.
  • Page 413 AT–12 HYDRAULIC PRESSURE CIRCUIT DIAGRAM JAT00019-00013...
  • Page 414 AT–13 COMPONENTS Oil pump driven gear (1) OIL PUMP A trochoid type gear oil pump has been adopted. The oil pump consists of an oil pump body, an oil pump drive Oil pump drive gear gear, and an oil pump driven gear. The oil pump drive gear, which is driven by the torque converter, drives the oil pump driven gear to send the automatic transmission fluid to the hy- draulic pressure control system under a pressurized state.
  • Page 415 AT–14 2) Regulator valve The regulator valve regulates the pressurized fluid sent from the oil pump to a hydraulic pressure (line pressure) suited for the running condition. The forces applied to the valve are the spring force (force F pushing to the right side), line pressure r (the discharging pressure from the oil pump y flowing via e) (force F pushing to the left side), modifier pressure t (force F...
  • Page 416 AT–15 4) Secondary regulator valve The secondary regulator valve regulates the lubrication pres- Chamber A sure to an optimum hydraulic pressure. The forces applied to the valve are the spring force (force F pushing to the right side), and force pushing the valve by the lubrication pressure q when it enters the chamber A through the fluid passages inside the valve (force F pushing to the...
  • Page 417 AT–16 6) 1-2 shift valve The 1-2 shift valve allows or does not allow the hydraulic pressure be applied to the B1 (the applied side), depending on conditions of the vehicle speed and throttle opening angle. 1. When shifted from 1st gear to 2nd gear: When the shift lever is set to the Î...
  • Page 418 AT–17 7) 2-3 shift valve The 2-3 shift valve allows or does not allow the hydraulic pressure be applied to the C1, C3, and B1’ (at the released side), depending on conditions of the vehicle speed and throttle opening angle. 1.
  • Page 419 AT–18 8) 3-4 shift valve & 3-4 relay valve • 3-4 relay valve The relay valve changes the force applied to the shift valve, depending on the throttle opening angle. The forces applied to the valve are the large spring force (force F pushing to the left side), small spring pushing to the right side) and throttle pressure q (force F force (force F...
  • Page 420 AT–19 9) Throttle modulator valve The throttle modulator valve regulates the throttle modulator pressure which is applied to the 2-3 shift valve as a force counteracting the governor pressure. This throttle modulator valve causes shifting to take place at a low vehicle speed when the throttle is opened slightly;...
  • Page 421 AT–20 10) Servo control valve When gear shift takes place between the 3rd gear and the 4th gear, the servo control valve turns ON and OFF the C1 pressure and B1’ pressure (at released side) simultaneously. Moreover, in order to prevent downshift from the 4th gear to the 2nd gear from taking place all at once (be- cause it will apply a great torque to the forward clutch suddenly), the servo control valve causes downshift to the 3rd gear to take place first.
  • Page 422 AT–21 11) 3-4 & select timing valve When upshift from the 3rd gear to the 4th gear takes place, the 3-4 & select timing valve makes the turning OFF of the pressure C2 synchronized with the turning OFF of the pres- sure B1’, thus preventing the engine from racing and making smooth shifting possible.
  • Page 423 AT–22 13) 2-4 timing valve If upshift from the 2nd gear to the 4th gear takes place all at once (when making the C2 inoperative and the C3 operative), the engine starts racing, for no load is applied temporarily. In order to avoid this, the 2-4 tim- ing valve prevents the pressure C2 from being turned OFF (through shifting to the 3rd gear temporarily), until the pressure C3 reaches a certain pressure.
  • Page 424 AT–23 15) 4-3 timing valve When downshift from the 4th gear to the 3rd gear takes place at a high speed, the 4-3 timing valve retards the rising speed of the line pressure (pressure C2), thus reducing shift im- pacts. Orifice The forces applied to the valve are the spring force (force F pushing to the left side) and governor pressure w (force F...
  • Page 425 AT–24 (3) GOVERNOR VALVE The governor valve is driven by the governor drive gear mounted on the output shaft. The governor valve generates a governor pressure which is corresponding to the vehicle speed (output shaft revolution speed). The forces applied to the valve are the governor weight, centrifugal force of the governor inner weight (force F pushing to the right side), centrifugal force of the governor valve (force F pushing to the right...
  • Page 426 AT–25 CASE & COVER DESCRIPTION The case and cover consist of the transmission case, transmission case side cover, and transmission oil pan. For improved rigidity of the case, the transmission case is integrated with the converter housing. Furthermore, liquid gasket featuring excellent sealing ability has been applied at the mating surfaces of each case.
  • Page 427 AT–26 ELECTRIC CONTROL SYSTEM OVERDRIVE SWITCH DESCRIPTION The overdrive solenoid provided in the transmission valve body is energized (overdrive possible) by turning ON (pushing) the overdrive switch incorporated in the shift lever. Also, the overdrive solenoid is non-ener- gized (overdrive impossible) by turning OFF (releasing) the overdrive switch. Gauge, back O/D OFF indicator Overdrive relay...
  • Page 428 AT–27 SHIFT CONTROL MECHANISM DESCRIPTION 1. The shift control mechanism has employed a remote control type, using a push-pull cable. JAT00044-00037 COMPONENTS (1) Shift lever assembly The floor shift assembly has employed a six-position type having the ∏, Â, ˆ, Î, x and Ò positions. Also, the overdrive switch is incorporated.
  • Page 429 AT–28 PRELIMINARY CHECK • Transmission warming-up method 1. Warm up the engine. 1. Check of transmission fluid level 2. If the vehicle runs for about 15 minutes at a speed of 60 km/h or for about 30 minutes at a speed of 40 NOTE: km/h, the temperature of the fluid inside the •...
  • Page 430 AT–29 (2) With a new gasket interposed, tighten the drain plug securely. Tightening Torque: 19.6 - 29.4 N·m (2.0 - 3.0 kgf-m) (3) Add new fluid through the filler tube. ® Fluid To Be Used: DEXRON Approx. 4.2 R (For EU: 4.29 R) Full Capacity: Approx.
  • Page 431 AT–30 3) Turn the casing cap in the reverse direction of the step 1). (The circlip will be closed so that the cas- ing cap may be secured.) JAT00052-00045 (3) Fully depress the accelerator pedal or turn the throttle link at the engine side, until it comes in contact with the full-open stopper.
  • Page 432 AT–31 (4) Install the SST. Check that the gauge section of the SST is aligned with the scribed line of the neutral start switch. SST: 09302-87201-000 (5) If they are not aligned with each other, loosen the bolt. Then, perform the adjustment by turning the switch section so that they may be aligned.
  • Page 433 AT–32 TESTING CAUTION: • Perform the stall test at the normal fluid operating temperature (70 - 90°C). • Do not conduct this test continuously for more than five seconds. • Wait at least one minute before the switching is made from the Î range to the  range. •...

  • Page 434: Time Lag Test

    AT–33 TIME LAG TEST 1. Apply the parking brake and place chocks at the wheels of the vehicle. 2. Start the engine. 3. While depressing the brake pedal, move the shift lever from the ˆ range to the Î range; and from the ˆ...
  • Page 435 AT–34 2. Plug position for hydraulic pressure test Pressure B2 Throttle pressure Governor Pressure C3 Pressure C1 Test plug tightening torque Pressure B1 Pressure C2 6.9 - 9.8 (0.7 - 1.0) Pressure B1’ Î range pressure Unit: N·m (kgf-m) JAT00063-00051 3.
  • Page 436 AT–35 r Governor pressure (1) Drive the vehicle onto a speedometer tester. (2) Start the engine. (3) With the shift lever moved to the Î range, gradually depress the accelerator pedal. Measure the hy- draulic pressure at each vehicle speed. Specified Value Item Measurement condition...
  • Page 437 AT–36 REFERENCE: • If each hydraulic pressure fails to conform to the specified value, most likely the following malfunc- tions are taking place. 1. Oil pump faulty 2. Oil strainer clogged 3. Faulty O-ring of oil strainer 4. Improper adjustment of throttle cable All line pressures fail to conform to the specified value.
  • Page 438 AT–37 RUNNING TEST NOTE: • Be sure to confirm safety on the road when conducting the running test. • Make sure that the fluid temperature is in a normal running condition (70 - 80 °C). 1. Î range test (1) Move off the vehicle with the shift lever set to the Î range. Check to see if upshift and downshift take place between the 1st gear and the 2nd gear;...
  • Page 439 AT–38 4. ∏ range test (1) Park the vehicle on a grade (approximately 5 degrees or more) in a climbing state and move the shift lever to the ∏ range. Then, release the parking brake. At this time, check that the parking lock mechanism functions and the vehicle will not move.
  • Page 440 AT–39 w Unit inspection • Overdrive switch 1. When the overdrive switch is turned ON (overdrive possi- ble), check that no continuity exists between the terminals q and w of the connector in the right figure. Also, when the overdrive switch is turned OFF (overdrive impossible), check that continuity exists between the same terminals.
  • Page 441 AT–40 REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 29.4 - 39.2 (3.0 - 4.0) 6.9 - 9.8 (0.7 - 1.0) 29.4 - 39.2 (3.0 - 4.0) 6.9 - 9.8 (0.7 - 1.0) 49.04 - 68.64 (5.0 - 7.0) 29.4 - 44.1...
  • Page 442 AT–41 1. Operations prior to removal (1) Disconnect the negative (–) terminal of the battery. (2) Disconnect the throttle cable at the engine side. (3) Drain the automatic transmission fluid. (4) Remove the propeller front shaft. (5) Remove the propeller shaft. (6) Remove the front exhaust pipe.
  • Page 443 AT–42 4. Main points of installation (1) Insert the torque converter assembly into the transmis- sion assembly. Ensure that the torque converter has been inserted securely. Specified Value: Dimension A is 28 mm or more. (Dimension A: Dimension between edge surface of housing and drive plate installation seat of torque con- verter) JAT00079-00061...
  • Page 444 AT–43 (4) Install the power train stiffener. Tighten the bolts in the following sequence. 1) Temporarily tighten the bolt (A). 2) Securely tighten the bolts in the sequence of the bolt (B), bolt (A), bolt (E), bolt (F), bolt (C), and bolt (D).
  • Page 445 AT–44 CONNECTION AND DISCONNECTION OF OIL COOLER HOSES COMPONENTS 1. Operations prior to removal (1) • Remove the center engine undercover. (Except EU specifications) • Remove the center engine undercover, radiator grill and front bumper cover. (EU only) : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 29.4 - 39.2...
  • Page 446 AT–45 2. Main points of removal Table showing identification of oil cooler hose Length (mm) Remarks q Oil cooler hose — w Oil cooler inlet hose — e Oil cooler outlet hose — r Oil cooler front hose — Moulded hose t Oil cooler front inlet hose Moulded hose JAT00087-00000...
  • Page 447 AT–46 DISASSEMBLY AND ASSEMBLY OF AUTOMATIC TRANSMISSION COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 9.8 - 15.7 (1.0 - 1.6) 29.4 - 44.1 14.7 - 21.6 (3.0 - 4.5) (1.5 - 2.2) 14.7 - 21.6 (1.5 - 2.2) 6.9 - 9.8 29.4 - 44.1 (0.7 - 1.0)
  • Page 448 AT–47 COMPONENTS (INNER PARTS) q Clutch drum thrust washer @0 Brake cushion plate w Direct clutch assembly @1 Planetary gear assembly e Thrust needle roller bearing @2 Thrust needle roller bearing r Thrust bearing race @3 Planetary output shaft subassembly t Forward clutch assembly @4 Radial ball bearing y Thrust needle roller bearing...
  • Page 449 AT–48 REMOVAL 1. Remove the bolt of the transmission oil filler tube sub- assembly. 2. Pull out the transmission oil filler tube subassembly toward upside. 3. Remove the O-ring from the transmission oil filler tube subassembly. NOTE: • Never reuse the removed O-ring. JAT00092-00071 4.
  • Page 450 AT–49 (3) Remove the transmission control shaft lever sub- assembly by removing the nut. (4) Remove the neutral start switch assembly by removing the bolt. JAT00097-00000 9. Remove the nine inspection plugs from the transmission. NOTE: • Never reuse the removed plugs. JAT00098-00076 10.
  • Page 451 AT–50 13. Remove the transmission oil pan assembly by removing the fourteen bolts. CAUTION: • Do not turn over the transmission, for this will contami- nate the valve body with foreign materials deposited at the bottom of the oil pan. NOTE: •...
  • Page 452 AT–51 22. Remove the O-ring by sticking a needle into the O-ring for the oil strainer which has been installed at the valve body side. NOTE: • Be very careful not to scratch the valve body when O-ring sticking the needle into the O-ring. •...
  • Page 453 AT–52 29. Remove the roller for manual valve lever shaft subassem- bly, using a standard magnet hand. JAT00112-00090 30. Remove the solenoid wire assembly attaching bolt. 31. Pull out the the solenoid wire assembly from the transmis- sion case. JAT00113-00091 32.
  • Page 454 AT–53 33. Remove the slotted spring pin, using a pin punch and a hammer. NOTE: • When removing the slotted spring pin, be very careful not to drop it into the transmission case. • Never reuse the removed slotted spring pin. 34.
  • Page 455 AT–54 39. Remove the T type oil seal, using the following SST. SST: 09308-10010-000 NOTE: • Never reuse the removed oil seal. JAT00121-00099 40. Remove the seven bolts of the stator shaft & oil pump as- sembly. NOTE: • Be sure to remove the bolts evenly and diagonally. •...
  • Page 456 AT–55 45. Remove the direct clutch together with the forward clutch at the same time. 46. Remove the direct clutch from the forward clutch. JAT00126-00104 47. Remove the thrust needle roller bearing from the forward clutch. 48. Remove the thrust bearing race from the forward clutch. JAT00127-00105 49.
  • Page 457 AT–56 (2) Remove the 2nd brake drum (together with the forward clutch hub). JAT00131-00109 (3) Remove the rear planetary sun gear subassembly from the 2nd brake drum. (4) Remove the thrust needle bearing from the rear plane- tary sun gear subassembly. JAT00132-00110 (5) Remove the forward clutch hub from the 2nd brake drum.
  • Page 458 AT–57 52. Measurement of 1st & reverse brake end play (1) Turn over the transmission case. JAT00136-00114 (2) Measure the 1st & reverse brake end play, using a standard feeler gauge. Specified Value: 1.04 - 1.41 mm NOTE: • Be sure to record the measured value for a guide dur- ing the assembly.
  • Page 459 AT–58 (3) Remove the thrust needle roller bearing (A) from the planetary output shaft subassembly. JAT00141-00119 55. Removal of transmission case side cover (1) Remove the nine bolts and oil guide plate (A). NOTE: • The numerals in the right figure denote the nominal length of each bolt.
  • Page 460 AT–59 60. Removal of planetary output shaft subassembly (1) Tap the planetary output shaft subassembly lightly, using a plastic hammer, until the planetary output shaft subassembly becomes free. (2) Remove the planetary output shaft subassembly from the transmission case side. JAT00145-00123 (3) Remove the hole snap ring, using snap ring pliers.
  • Page 461 AT–60 (5) Hold the first & reverse brake piston, using the follow- ing SSTs (to prevent the piston from being tilted when removing the piston). SSTs: 09351-87201-000 09351-87707-000 09351-87709-000 09351-87710-000 (6) While applying compressed air of 392 - 784 kPa (4 - 8 kgf/cm ) from the oil hole indicated in the right figure, gradually loosen the bolt of the SST and remove the...
  • Page 462 AT–61 DISASSEMBLY AND ASSEMBLY OF COMPONENTS COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 6.9 - 9.8 (0.7 - 1.0) q Transmission case e Transmission case side cover subassembly w T type oil seal r D type oil seal t Breather plug JAT00153-00131 1.
  • Page 463 AT–62 (2) Assemble a new type T oil seal, using the following SST. SST: 09301-87702-000 JAT00155-00133 2. Disassembly and assembly of transmission case side cover subassembly (1) Remove the type D oil seal, using the following SST. SST: 09309-87502-000 NOTE: •...
  • Page 464 AT–63 INSPECTION COMPONENTS q Direct clutch assembly !0 Brake plate w Forward clutch assembly !1 Brake disc e Brake band assembly !2 Brake cushion plate r Intermediate shaft subassembly !3 Planetary gear assembly t Forward clutch hub !4 Planetary output shaft subassembly y 2nd brake drum (A) - (F) Thrust needle roller bearing u Planetary sun gear subassembly...
  • Page 465 AT–64 1. Brake band assembly If the lining of the brake band is exfoliated or discolored, or even a part of the printed number is defaced, replace the brake band. NOTE: • When the brake band assembly is replaced, be sure to check the band contacting surface at the 2nd brake drum side.
  • Page 466 AT–65 (6) While pressing the direct clutch flange with a force of 9.8 - 29.4 N (1.0 - 3.0 kgf), using the following SST (A) in com- bination with a suitable pushable gauge, measure the end play between the direct clutch flange and the snap ring, using a flat thickness gauge (B).
  • Page 467 AT–66 • Operation check of rear clutch piston (1) Blow compressed air of 392 - 784 kPa (4 - 8 kgf/cm into the fluid hole of the input shaft indicated in the right figure. At this time, check that the piston slides smoothly.
  • Page 468 AT–67 4. One-way clutch Hold the one-way clutch and turn the planetary gear assem- bly. NOTE: • Ensure that the one-way clutch turns freely when turned counterclockwise. Also, ensure that it is locked when turned clockwise. JAT00172-00150 5. Thrust bearing specifications Be sure to install the thrust bearings in the correct direction and position.
  • Page 469 AT–68 (6) Install the first & reverse brake piston, using the follow- ing SSTs. SSTs: 09351-87201-000 09351-87707-000 09351-87709-000 09351-87710-000 NOTE: • When installing the first & reverse brake piston, care must be exercised to ensure that the O-ring may not be deviated from the specified position and may not be JAT00176 -00153 scratched.
  • Page 470 AT–69 2. Measure the inner diameter of the planetary output shaft subassembly, using an inner caliper gauge. Specified Value: 12.000 - 12.018 mm Allowable Limit: 12.068 mm NOTE: • Perform the measurement at several points. Calculate the mean value. • If the measured value exceeds the allowable limit, re- place the planetary output shaft subassembly with a new one.
  • Page 471 AT–70 7. Install the output shaft assembly. NOTE: • Securely insert the output shaft assembly into the spline of the planetary output shaft assembly. JAT00185-00161 8. Installation of transmission case side cover (1) Apply the Three Bond 1281B to the entire periphery of the transmission case without any discontinuation, as indicated in the right figure.
  • Page 472 AT–71 10. Install the planetary gear assembly. NOTE: • Ensure that the planetary gear assembly rotates smoothly. JAT00189-00165 11. Installation of first & reverse brake (1) Install the brake cushion plate. NOTE: • Ensure that the stamped mark “O” of the brake cushion plate faces toward the upper side.
  • Page 473 AT–72 (6) Install the hole snap ring to the grooved section of the transmission case. JAT00194-00170 12. Measurement of first & reverse brake end play (1) Turn over the transmission case. JAT00195-00171 (2) Measure the first & reverse brake end play, using a flat thickness gauge.
  • Page 474 AT–73 13. Installation of transmission brake band assembly-related SST(B) parts (1) Install the compression spring to the second brake piston assembly. (2) Install the 2nd brake piston assembly to the transmis- sion case together with the compression spring. (3) While compressing the 2nd brake piston with the fol- lowing SSTs, install the hole snap ring, using snap ring SST(A) pliers.
  • Page 475 AT–74 (2) Assemble the thrust needle roller bearing to the rear planetary sun gear subassembly. NOTE: • Make sure that the thrust needle roller bearing is as- sembled in the correct direction. REFERENCE: Dimensions of thrust needle roller bearing Outer diameter: 35.7 mm Inner diameter: 22.7 mm...
  • Page 476 AT–75 (6) Assemble the thrust needle roller bearing to the 2nd brake drum. NOTE: • Make sure that the thrust needle roller bearing is as- sembled in the correct direction. REFERENCE: Dimensions of thrust needle roller bearing Outer diameter: 46.5 mm Inner diameter: 25 mm Thickness:...
  • Page 477 AT–76 17. Align the pawls of the clutch disc of the forward clutch with each other. 18. While aligning the pawls of the clutch disc of the forward clutch with the groove of the forward clutch hub and with the groove of the intermediate shaft subassembly, assem- ble these parts.
  • Page 478 AT–77 (5) Confirm the height of the oil pump attaching surface from the upper surface of the direct clutch, using the following SST. SST: 09351-87208-000 Specified Height: Approx. 22 mm NOTE: • If the actually measured value is less than the specified height, there is the possibility that the two pawls of the clutch disc are not fitted into the groove of the forward clutch.
  • Page 479 AT–78 (2) Install the clutch drum thrust washer by aligning its protruding section with the recessed section of the oil pump assembly. NOTE: • Be sure to apply vaseline in a small amount enough to prevent the clutch drum thrust washer from dropping. JAT00222-00197 (3) Apply a small amount of vaseline to the race side of the thrust needle roller bearing.
  • Page 480 AT–79 (7) Apply the ATF to the outer periphery of the stator shaft & oil pump assembly. (8) Install the stator shaft & oil pump assembly to the transmission case. NOTE: • Be very careful not to damage or twist the O-ring dur- ing the installation of the stator shaft &...
  • Page 481 AT–80 24. Assembly of stator shaft & oil pump assembly (1) Coat a new O-ring of the stator shaft & oil pump as- sembly with the ATF. (2) Install the two new clutch drum oil seal rings to the sta- tor shaft &...
  • Page 482 AT–81 27. Install the parking lock rod subassembly and parking lock pawl cam support, as indicated in the right figure. Tighten the three bolts. Tightening Torque: 14.7 - 17.7 N·m (1.5 - 1.8 kgf-m) NOTE: • Tightening should be made in the following sequence: (A) (Tighten temporarily.) / (B) (Tighten securely.) / (C) (Tighten securely.) / (A) (Tighten securely.) JAT00235-00209...
  • Page 483 AT–82 (4) Under the condition of the step (3) above, loosen the brake band anchor bolt 3.2 turns counterclockwise (di- rection (A)). JAT00240-00214 (5) Install the nut to the brake band anchor bolt. (6) While holding the brake band anchor bolt by means of a screwdriver or the like, tighten the nut.
  • Page 484 AT–83 (3) Assemble the compression spring and accumulator No. 2 piston to the transmission case. JAT00245-00219 33. Assembly of B1 accumulator piston (1) Measure the free length and outer diameter of the B1 accumulator compression spring. Reference Value: Free Length: 50.5 mm Outer Diameter: 20 mm...
  • Page 485 AT–84 (3) Install the valve body assembly with the aforesaid SST to the transmission case. NOTE: • Ensure that the protrusion of the manual valve lever (A) and grooved section of the manual valve (B) are matched securely. JAT00250-00224 (4) Tighten the bolts of the valve body assembly. Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m) NOTE:...
  • Page 486 AT–85 (3) Apply ATF to the O-ring contact section of the oil 48.5 48.5 (A) strainer. (4) Install the valve body tube (A). (5) Install the oil strainer with the 3 bolts. Tightening Torque: 6.9 - 9.8 N·m (0.7 - 1.0 kgf-m) NOTE: •...
  • Page 487 AT–86 39. Clean the contact surface between the transmission case side cover subassembly and the transfer assembly, using φ 1 mm solvent or the like. Apply the following bond to the transmission case side cover subassembly surface as shown in the right figure. Specified Bond: Three bond 1216 or 1217 NOTE:...
  • Page 488 AT–87 (2) Place the transmission control shaft lever subassem- bly. (3) Push the transmission control shaft lever subassembly toward the front side (ie: ∏ range) (4) Back off the lever two notches to the NEUTRAL posi- tion (5) Remove the transmission control shaft lever sub- assembly.
  • Page 489 AT–88 (2) Coat the whole of governor body assembly with ATF. (3) Install the governor body assembly into the transmis- sion case side cover. JAT00270-00244 (4) Coat a new O-ring with ATF. (5) Install the new O-ring to the governor cover. (6) Install the governor cover to the transmission case side cover.
  • Page 490 AT–89 52. Coat a new O-ring with the ATF. 53. Install the new O-ring to the transmission oil filler tube sub- assembly. NOTE: • Be very careful not to twist or damage the O-ring dur- ing the installation of the transmission oil filler tube sub- assembly.
  • Page 491 AT–90 INSTALLATION AND REMOVAL OF CONTROL CABLE AND FLOOR SHIFT COMPONENTS : Tightening torque Unit : N·m (kgf-m) 14.7 - 21.6 (1.5 - 2.2) 14.7 - 21.6 (1.5 - 2.2) 9.8 - 15.7 (1.0 - 1.6) 6.9 - 9.8 (0.7 - 1.0) q Console rear box assembly w Console panel with shifting hole vessel e Control cable assembly...
  • Page 492 AT–91 2. Check (1) Check that the inner cable of the control cable assem- bly slides smoothly. Also, check that the control cable assembly exhibits no damage and deformation, such as rapture of the boot. Rapture of boot JAT00279-00253 3. Main points of installation (1) Install the control cable assembly.
  • Page 493 AT–92 APPENDIX SSTs (Special Service Tools) Shape Part No. Part name 09302-87201-000 Neutral start switch adjusting gauge Automatic transmission pressure gauge 09325-87201-000 No. 1 adapter 09202-87002-000 Valve cutter remover & replacer 09301-87702-000 Clutch guide tool 09308-10010-000 Oil seal puller 09309-87203-000 4M/T friction dumper No.
  • Page 494 AT–93 Shape Part No. Part name 09350-87202-000 Automatic transmission tool set 09351-87201-000 Piston spring No. 1 compressor 09351-87203-000 Dial gauge attachment 09351-87206-000 Oil pump driver 09351-87207-000 Oil pump guide 09351-87208-000 Direct & forward clutch measure 09351-87210-000 Dial gauge stand base 09351-87211-000 Manual valve setting tool 09350-87704-000...
  • Page 495 AT–94 SERVICE SPECIFICATIONS Unit: mm Items Specified value Allowable limit Free play of input shaft 0.28 - 0.92 — Bush bore diameter of direct clutch drum subassembly 44.000 - 44.025 44.075 Stroke of direct clutch piston 1.22 - 1.53 — End play of direct clutch 0.77 - 1.08 —...
  • Page 496 AT–95 TIGHTENING TORQUE Tightening torque Tightening components N·m kgf-m Drive plate × Crankshaft 78.45 - 98.07 8.0 - 10.0 Transmission × Engine direct-connecting bolt 49.04 - 68.64 5.0 - 7.0 Torque convertor × Drive plate 29.4 - 44.1 3.0 - 4.5 14.7 - 21.6 1.5 - 2.2 Power train stiffener ×...
  • Page 497 DAIHATSU J100 TO INDEX TRANSFER DESCRIPTION ..........TR– 2 CENTER DIFFERENTIAL SYSTEM ..TR– 2 OPERATION OF CENTER DIFFERENTIAL LOCK SYSTEM ..TR– 2 IN-VEHICLE INSPECTION ......TR– 4 COMPONENTS ........... TR– 5 REMOVAL ............ TR– 5 DISASSEMBLY ..........TR– 8 INSPECTION ..........
  • Page 498 TR–2 DESCRIPTION A driving system equipped with a center differential is em- Transmission Transfer ployed. Engine Center differential Rear differential Front differential JTR00002-00101 CENTER DIFFERENTIAL SYSTEM The input power from the transmission of the driving system is always distributed to the front and rear wheels. The transfer system employs a negative pressure-driving actuator type, with a center differential lock mechanism.
  • Page 499 TR–3 1. When center differential lock switch is turned off. To intake (1) The VSV1 and VSV2 become unenergized. Thus, the manifold VSV1 is connected to the air filter side. As a result, the VSV2 Check Differential (green) valve lock switch transfer actuator chamber B becomes equal to the at- mospheric pressure.
  • Page 500 TR–4 IN-VEHICLE INSPECTION 1. Turn the ignition switch to the “ON” position. 2. Check to see if the indicator will illuminate when the differ- ential lock switch is turned on. NOTE: • If not, check the indicator valve. 3. Turns off the differential lock switch. JTR00010-00201 4.
  • Page 501 TR–5 COMPONENTS Hanger T type oil seal Transfer oil Diaphragm cylinder cover supply right pipe Tube Transfer No. 2 Transfer shift shaft oil plate Transfer oil sub-assembly supply left pipe E ring Slotted K type T type Filler plug oil seal O ring oil seal Front drive...
  • Page 502 TR–6 4. Remove the speedometer shaft sleeve by removing the bolt. JTR00018-00403 5. Remove the drain plug. Rib section Filler plug 6. Remove the filler plug. 7. Remove the transfer case by removing the attaching bolts. NOTE: • While lightly tapping the transfer case at the rib sec- tions, using a plastic hammer or the like, remove the transfer case.
  • Page 503 TR–7 12. Remove the radial ball bearing in combination with the gear, using the following SST. SST: 09306-87602-000 JTR00023-00408 13. Remove the transfer output rear shaft with differential gear. JTR00024-00409 14. Remove the ring retainer of the bearing. 15. Remove the radial ball bearing with the transfer clutch inner hub from the transfer case.
  • Page 504 TR–8 19. Remove front drive shift link lever sub-assembly and E ring. JTR00028-00413 20. Remove the diaphragm cylinder cover. JTR00029-00414 21. Remove the transfer shift shaft sub-assembly from the di- aphragm cylinder. JTR00030-00415 DISASSEMBLY 1. Disassemble the transfer clutch inner hub and the radial ball bearing, using the following SST in conjunction with a press.
  • Page 505 TR–9 3. Disassemble the rear bearing from the transfer output front drive shaft, using the following SST in conjunction with a press. SST: 09253-87101-000 09301-87601-000 JTR00033-00503 4. Disassemble the front bearing from the transfer output front drive shaft, using the following SST in conjunction with a press.
  • Page 506 TR–10 8. Remove the following parts from the differential case. (1) Differential side gear No. 2 (2) Differential side gear JTR00038-00508 (3) Differential pinion shafts (4) Differential pinions (5) Differential pinion thrust washers JTR00039-00509 INSPECTION 1. Bearings Visually inspect the roller and roller guide surface for seizure due to poor oil lubrication and so forth.
  • Page 507 TR–11 4. Visually inspect the transfer front drive gear and the trans- fer output front shaft gear for damage or wear. JTR00043-00604 5. Visually inspect the transfer front drive chain for damage or wear. JTR00044-00605 6. Check the contact surface between the differential lock shift fork (A) and the transfer clutch outer hub (B).
  • Page 508 TR–12 9. Visually inspect the transfer gear shift head for damage or wear NOTE: • Also inspect the ball and compression spring for dam- age or wear. JTR00048-00609 10. Measure the outer diameter of the transfer fork shaft. If the measured value does not conform to the specifica- tion, replace the shaft.
  • Page 509 TR–13 15. Visually inspect the differential case sub-assembly for damage or wear. JTR00053-00615 16. Measure the outer diameter of the differential pinion shaft. 17. Measure the inner diameter of the differential pinion. Unit: mm Specified value Allowable limit Inner +0.06 Pinion 15.06 +0.03...
  • Page 510 TR–14 21. Visually inspect the type T oil seal of the transfer output rear shaft for damage or wear. NOTE: • Replace the oil seal if it exhibits damage or wear. SST: 09308-10010-000 09309-87201-000 JTR00058-00621 22. Visually inspect the transfer rear drive output shaft inner oil seal for damage or wear.
  • Page 511 TR–15 ASSEMBLY NOTE: • Prior to the assembly, clean the transfer case and the parts by removing any dirt or the like. And then, apply gear oil to the all parts. 1. Press the radial ball bearing (Front) to the transfer output front shaft.
  • Page 512 TR–16 7. Push the pinion shaft in the shaft hole with finger to the dif- ferential case outside so as to the transfer output rear shaft can go through. Shaft hole JTR00066-00707 8. Install the new snap ring to the transfer output rear shaft. Snap ring JTR00067-00708 9.
  • Page 513 TR–17 INSTALLATION 1. Install the transfer shift shaft sub-assembly to the di- Groove section aphragm cylinder. 2. Install the front drive shift link lever to the transfer case. NOTE: • Make sure that the drive shift link lever is fitted securely in the groove.
  • Page 514 TR–18 14. Insert the transfer front drive gear to the transfer output rear shaft. 15. Install the transfer output front shaft with the chain to the transfer case. NOTE: • Prior to the installation, make sure that the chain is set to the both gears.
  • Page 515 TR–19 23. Apply gear oil to the “O” ring prior to the insertion of the speedometer shaft sleeve. 24. Insert the speedometer shaft sleeve into the output shaft bearing rear retainer. 25. Tighten the speedometer sleeve lock plate with a bolt. Tightening Torque: 5.9 - 8.8 N·m (0.6 - 0.9 kgf-m) 26.
  • Page 516 TR–20 SSTs Shape Part No. and name Purpose See page 09253-87101-000 Removal of bearing TR–9 Transfer output front shaft bearing anvil 09238-87202-000 Removal of output rear TR–9 Transfer output shaft TR–15 front shaft rear bearing replacer Assembling bearing 09253-87202-000 Removal of bearing TR–8 Transfer clutch inner hub bearing anvil...

  • Page 517: Propeller Shaft

    DAIHATSU J100 TO INDEX PROPELLER SHAFT COMPONENTS ........... PR– 2 IN-VEHICLE INSPECTION ......PR– 3 REMOVAL ........... PR– 3 INSPECTION ..........PR– 4 INSTALLATION ........... PR– 5 TIGHTENING TORQUE ....... PR– 7 JPR00001-00000 NO. 9710-JE...
  • Page 518 PR–2 COMPONENTS Front 60.3 ± 9.5 (6.15 ± 0.95) Rear 60.3 ± 9.5 (6.15 ± 0.95) 36.8 ± 7.3 (3.75 ± 0.75) q Propeller shaft assembly : Tightening torque Unit : N·m (kgf-m) JPR00002-00001...
  • Page 519 PR–3 IN-VEHICLE INSPECTION Ensure that the universal joint section of the propeller shaft ex- hibits no excessive play by turning it by your hand in up-and- down and right-and-left directions. If any excessive play exists, replace the propeller shaft with a new one.
  • Page 520 PR–4 INSPECTION Front & rear 1. Check the propeller shaft for evidence of damage or bend. Limit of bend: 0.5 mm JPR00007-00007 2. Check the spider bearing cup-fitting section for damage. JPR00008-00008 3. Check the flange yoke and sleeve yoke. (1) Inspect to see whether any damage is present at the differential drive pinion companion flange-contact sec- tion A.
  • Page 521 PR–5 5. Check of universal joint preload Front (1) Hook a spring scale at the bolt hole of the flange yoke as well as at the sleeve yoke end. (2) Gently pull the spring scale to measure the starting torque. Starting Torque: 0.029 - 1.47 N·m (0.003 - 0.15 kgf-m) Replace the propeller shaft, if the preload fails to meet the...
  • Page 522 PR–6 4. Install the propeller shaft yoke flange to the flange of the differential with new four attaching bolts with washers. CAUTION : • Be sure to clean the attaching surface of the yoke and flange properly. Failure to observe this caution may lead to propeller shaft vibration or damage, etc.
  • Page 523 PR–7 TIGHTENING TORQUE Tightening torque Tightening component N·m kgf-m Propeller shaft flange × Differential flange 60.3 ± 9.5 6.15 ± 0.95 Center bearing support × Body 36.8 ± 7.3 3.75 ± 0.75 JPR00017-00000 TO INDEX TO NEXT SECTION...
  • Page 524 DAIHATSU J100 TO INDEX FRONT & REAR DIFFERENTIAL FRONT DIFFERENTIAL ......DF– 2 COMPONENTS ........DF– 2 REAR DIFFERENTIAL ........ DF– 3 COMPONENTS ........DF– 3 IN-VEHICLE SERVICE ........ DF– 4 REPLACEMENT OF FRONT AND REAR DIFFERENTIAL COMPANION FLANGE OIL SEALS ......DF– 4 REPLACEMENT OF FRONT DIFFERENTIAL SIDE OIL SEAL ..
  • Page 525 DF–2 FRONT DIFFERENTIAL COMPONENTS 117.7 + 19.5 (12.0 + 2.0) 83.4 + 4.8 (8.5 + 0.5) 49.1 + 9.7 (5.0 + 1.0) 11.3 + 1.4 (1.15 + 0.15) 20.6 + 2.9 (2.1 + 0.3) 36.8 + 7.3 : Tightening torque (3.75 + 0.75) : Non-reusable parts Unit : N·m (kgf-m)
  • Page 526 DF–3 REAR DIFFERENTIAL COMPONENTS : Non-reusable parts : Tightening torque Unit : N·m (kgf-m) 46.6 ± 7.3 (4.75 ± 0.75) 117.7 ± 19.6 (12.0 ± 2.0) 83.4 ± 4.9 (8.5 ± 0.5) q Differential cap bearing !3 Drive pinion companion flange subassembly w Differential case assembly !4 T type oil seal e Shim...
  • Page 527 DF–4 IN-VEHICLE SERVICE REPLACEMENT OF FRONT AND REAR DIFFERENTIAL COMPANION FLANGE OIL SEALS NOTE: • This section describes the replacement procedure both for the front and rear companion flange oil seals. Therefore, some descriptions and figures may not be applicable or differ from each other. 1.
  • Page 528 DF–5 5. Loosen the lock nut of the companion flange while pre- Front venting the companion flange from turning, using the fol- lowing SST in combination with a long box wrench or the like. SST: 09330-87301-000 6. Remove the lock nut and plate washer. CAUTION: •...
  • Page 529 DF–6 9. Clean the T type oil seal attaching surface with a piece of cloth or the like. 10. Thinly apply the lithium soap base multi-propose grease to the lip section of the T type oil seal. 11. Install a new T type oil seal, using the following SST. SST: 09635-20010-000 CAUTION:...
  • Page 530 DF–7 REPLACEMENT OF FRONT DIFFERENTIAL SIDE OIL SEAL 1. Jack up the vehicle and support it with stands. (As for the jacking-up points and support points for safety stands, refer to the GI section.) 2. Remove the front wheels. 3. Drain the differential oil by removing the drain plug and gasket.
  • Page 531 DF–8 12. Remove the T type oil seal, using the following SST. SST: 09308-00010-000 JDF00020-00019 13. Clean the oil seal attaching surface of the front differential. 14. Apply the lithium soap base multi-purpose grease to the lip section of the new oil seals. 15.
  • Page 532 DF–9 25. Remove the filler plug and gasket. Front 26. Fill the differential oil from the filler plug. Specified differential oil Grade: API GL-5 Viscosity: SAE 80W-90 Capacity: 0.7 liters NOTE: • The specified oil level is 0 to 5 mm from the lower end of the oil filler hole.
  • Page 533 DF–10 9. Support the differential carrier, using a suitable engine hanger, transmission jacks or the like. 10. Remove the three attaching bolts of the differential carrier support bracket and differential carrier assembly. (Only for front differential.) 11. Remove the differential carrier assembly by removing JDF00027-00025 three attaching bolts of the differential carrier support bracket mount.
  • Page 534 DF–11 DISASSEMBLY SSTB 1. Place the differential carrier removed from the vehicle on a disassembly stand. SST: 09219-87202-000 A 09548-87201-000 B SSTA JDF00030-00028 2. Inspection before disassembly (1) Checking of ring gear runout Ensure that the ring gear runout is within the specified value, using a dial gauge.
  • Page 535 DF–12 3. Remove the T type oil seals, using the following SST. SST: 09308-00010-000 (For front differential) JDF00035-00033 4. Put mating marks (paint or the like) on the bearing caps Mating marks and differential carrier. NOTE: • Machining process should be carried out with carrier and cap as a set.
  • Page 536 DF–13 8. Put mating marks on the differential case and ring gear. 9. Loosen the differential ring gear attaching bolts evenly. CAUTION: • Be sure to loosen the attaching bolts evenly. Failure to observe this caution may damage the ring gear or the differential case.
  • Page 537 DF–14 16. Remove the T type oil seal, using the following SST. Front SST: 09308-10010-000 JDF00043-00040 Rear JDF00000-00041 17. Remove the differential drive pinion spacer and shims Front from the differential carrier, using a hydraulic press or tap- ping the drive pinion, using a hydraulic press. CAUTION: •...
  • Page 538 DF–15 19. Remove the front and rear tapered roller bearing outer Front races and shims, using a press in combination with the following SST. SST: 09608-87501-000 (Use No. 2 and No. 5 in the above component, in case front differential.) (Use No.
  • Page 539 DF–16 INSPECTION Inspect each section of the following parts for any sign of damage, wear or excessive looseness. Replace any parts which exhibit defects. 1. Differential drive pinion & ring gear (1) Gear teeth q (2) Spline portion w of drive pinion (3) Bearing fitting section e CAUTION: •...
  • Page 540 DF–17 6. Differential carrier Front (1) Side bearing fitting sections q (2) Tapered roller bearing outer race fitting sections w (3) Oil seal inserting section e (4) Carrier cover attaching section r (5) The differential case proper t JDF00052-00052 Rear JDF00000-00053 7.
  • Page 541 DF–18 ASSEMBLY Front 1. Installation of differential drive pinion (1) Install the shim which was assembled or a shim having the same thickness with the one which was assembled as well as the front and rear tapered roller bearing outer races to the differential carrier, using the follow- ing SST in combination with a hydraulic press.
  • Page 542 DF–19 (5) Install the washer plate and lock nut for drive pinion companion flange subassembly. CAUTION: • Apply the specified differential oil to the threaded por- tion of the lock nut and drive pinion before the installa- tion. • Do not install the spacer, shim and T type oil seal at this moment.
  • Page 543 DF–20 CAUTION: • Be sure to adjust the backlash in such a manner that the thickness of the thrust washers at both sides should be the same or differ not more than 0.1 mm. (4) Install the differential gear to the differential case while aligning the mating marks put at the disassembly pro- cedure.
  • Page 544 DF–21 (5) Adjust the backlash to the specified value by selecting suitable shims from spare part, if the backlash fails to meet the specified value. Shim availability: 0.15 mm 0.20 mm 0.25 mm 0.50 mm (6) Note the selected shim thickness. 4.
  • Page 545 DF–22 JDF00000-00074 6. Adjustment of drive pinion bearing preload (1) Remove the differential bearing caps by removing the attaching bolts and differential case with the shims. (Refer to the disassembly procedure.) NOTE: • Be sure to keep the removed shims at the right and left sides separately for reassembly. (2) Loosen the lock nut of the drive pinion while preventing the companion flange from turning, using the following SST.
  • Page 546 DF–23 (8) Install the drive pinion shaft assembly, drive pinion and companion flange to the differential carrier temporarily. (9) Press the drive pinion shaft bearing into position, using a hydraulic press. CAUTION: • Never apply excessive force to the bearings during pressing.
  • Page 547 DF–24 (2) Install the companion flange subassembly, washer plate and lock nut. (3) Tighten the lock nut to the specified tightening torque while preventing the companion flange from turning, using the following SST. SST: 09330-87301-000 Tightening Torque: 98.1 - 137.2 N·m (10.0 - 14.0 kgf-m) (4) Turn the drive pinion shaft several times.
  • Page 548 DF–25 INSTALLATION (Front differential) 1. Install the differential carrier assembly and differential sup- port bracket with the attaching bolts. 2. Tighten the bolts to the specified tightening torque. Tightening Torque: Differential carrier 68.6 - 83.4 N·m (7.0 - 8.5 kgf-m) Differential support 34.3 - 61.8 N·m JDF00083-00084...
  • Page 549 DF–26 11. Fill the specified differential oil from the filler plug. (Refer to the “REPLACEMENT OF FRONT DIFFERENTIAL COMPANION FLANGE OIL SEAL” section.) 12. Install the filler plug with a new gasket interposed and tighten it to the specified tightening torque. Tightening Torque: Front 39.3 - 58.8 N·m (4.0 - 6.0 kgf-m) 13.
  • Page 550 DF–27 8. Install the filler plug with a new gasket interposed and tighten it to the specified tightening torque. Tightening Torque: 53.9 - 68.6 N·m (5.5 - 7.0 kgf-m) 9. Install the rear wheel. 10. Jack down the vehicle. 11. Ensure that no trouble is persists. JDF00091-00000...
  • Page 551 DF–28 SSTs 09515-10010-000 Rear axle bearing replacer 09309-87201-000 Transmission bearing replacer Axle hub & drive pinion bearing tool set 09608-87501-000 09635-20010-000 Lower ball joint dust cover replacer 09548-87201-000 Differential overhaul attachment 09330-87301-000 Drive pinion flange holding tool 09611-87701-000 Tie rod end puller 09648-87201-000 Drive shaft replacer 09636-20010-000...
  • Page 552 DF–29 09950-20017-000 Universal puller 09950-87701-000 Bearing pulling attachment JDF00092-00090...
  • Page 553 DF–30 TIGHTENING TORQUE Tightening torque Tightening compartment N·m kgf-m Drive pinion companion flange subassembly × lock nut 98.1 - 137.2 10.0 - 14.0 Drain plug (Front) 39.3 - 58.8 4.0 - 6.0 (Rear) 53.9 - 68.6 5.5 - 7.0 Oil filler plug (Front) 39.3 - 58.8 4.0 - 6.0 53.9 - 68.6...
  • Page 554 DAIHATSU J100 TO INDEX FRONT AXLE & SUSPENSION WHEEL ALIGNMENT ......FS– 2 SUSPENSION LOWER ARM ..... FS–17 PREPARATION ......FS– 2 REMOVAL ........FS–17 FRONT AXLE AND SUSPENSION ..FS– 4 INSPECTION ......... FS–17 COMPONENTS ......FS– 4 REPLACEMENT OF SUSPENSION FRONT AXLE ........

  • Page 555: Wheel Alignment

    FS–2 WHEEL ALIGNMENT PREPARATION Prior checks 1. Inspect the wear of tires. 2. Inspect the air pressure of the tires. NOTE: · Perform the check on a level floor. · Make sure that the same maker’s tires having the same size are mounted. ·...
  • Page 556 FS–3 Camber, Caster and Kingpin angle Specified Value 0°30¢ ± 45¢ Camber 2°35¢ ± 1° Caster 13°45¢ ± 1° Kingpin angle NOTE: · No adjustment can be made for the camber, caster and kingpin angle. Therefore, if the camber, caster or king- pin angle fails to meet the specified value, check that JFS00005-00004 no damage or deformation exists on the frame or cor-...
  • Page 557 FS–4 FRONT AXLE AND SUSPENSION COMPONENTS : Tightening torque Unit : N·m (kgf-m) 28.4 - 42.2 37.8 - 56.4 (2.9 - 4.3) (3.85 - 5.75) 12.7 - 23.5 (1.3 - 2.4) 12.7 - 23.5 (1.3 - 2.4) 101.9 - 152.9 (10.4 - 15.6) 12.7 - 23.5 (1.3 - 2.4)
  • Page 558 FS–5 FRONT AXLE REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the front wheels. 3. Remove the attaching bolts of the disc brake assembly. 4. Suspend the disc brake assembly with suitable string. JFS00009-00009 5.
  • Page 559 FS–6 (3) Pull out the front axle hub sub-assembly with inner bearing race, using the following SST. SST: 09520-00031-000 CAUTION: · Never reuse the removed bearing. JFS00014-00014 9. Remove the sensor mounting bracket with the skid control sensor from the steering knuckle by removing the attach- ing bolts.
  • Page 560 FS–7 (3) Disconnection of shock absorber from steering knuck- q Remove the attaching nuts of the steering knuckle to shock absorber. NOTE: · Never reuse the removed bolt and nut. w Disconnect the front shock absorber from the steering knuckle. JFS00018-00018 DISASSEMBLY Front axle hub...
  • Page 561 FS–8 2. Removal of front axle bearing. (1) Detach the hole snap ring, using snap ring pliers. Hole snap ring JFS00023-00023 (2) Remove the bearing from the steering knuckle, using a following SST in combination with the hydraulic press. SSTs: 09544-10010-000 09252-10010-000 (Use the 09550-10012-000 that is a part of the set.) 09506-87302-000...
  • Page 562 FS–9 ASSEMBLY Front axle hub Install the hub bolt to the front axle hub by tapping it with suit- able hammer. JFS00027-00027 Steering knuckle 1. Installation of disc brake dust cover Press the disc brake dust cover until it comes in contact with the steering knuckle, using the following SSTs in com- bination with the hydraulic press.
  • Page 563 FS–10 INSTALLATION 1. Press the front axle hub into the steering knuckle sub-as- sembly using the following SST in combination with hy- draulic press. SST: 09559-10010-000, 09252-10010-000 (Use the 09550-10012-000 that is a part of the set.) NOTE: · Press in the steering knuckle into the axle hub after the axle hub placed on the SST 09506-87302-000.
  • Page 564 FS–11 4. Tightening of drive shaft end nut Inside Outside (1) Install the conical washer to the drive shaft. (2) Install the nut and tighten the nut to specified tighten- ing torque while prevent the front axle hub from turn- ing, using the following SST.

  • Page 565: Front Stabilizer Bar

    FS–12 FRONT STABILIZER BAR REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the stabilizer bar end lower nut. CAUTION: · Never reuse the removed nut. 3. Remove the bush and washer. 4.
  • Page 566 FS–13 ASSEMBLY 1. Install the washer and bush to the stabilizer link rod. 2. Install the stabilizer link rod to the stabilizer bar. Washer 3. Install the bush and washer to the stabilizer link rod. Then, Bush tighten the stabilizer bar end upper nut. CAUTION: Washer ·...
  • Page 567 FS–14 SHOCK ABSORBER AND SPRING REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the front wheels. 3. Remove the brake hose bracket from the shock absorber lower bracket by removing its attaching nut. JFS00046-00046 4.
  • Page 568 FS–15 INSPECTION CAUTION: · Replace the parts with new one, if any damage or mal- function is found in following inspections. Suspension support Visually check that deformation, rust, crack nor other damage are not exists and also check that no damage is exists on the threaded portion of the stud bolts.
  • Page 569 FS–16 7. Temporarily attach the new piston end nut. 8. Hold the front suspension support in a vice. CAUTION: · Never apply the excessive force to the suspension sup- port. 9. Tightening the piston end nut to specified tightening torque. Tightening Torque: 37.8 - 56.4 N·m (3.85 - 5.75 kgf-cm)
  • Page 570 FS–17 SUSPENSION LOWER ARM REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the front wheels. 3. Remove the front stabilizer bar. (Refer to the “STABILIZER” section.) 4. Remove the stabilizer bracket sub-assembly from the sus- pension member.
  • Page 571 FS–18 REPLACEMENT OF SUSPENSION LOWER ARM BUSH 1. Remove the bush, using a suitable tool in combination 25 mm Front side 35 mm with a hydraulic press. NOTE: · Use a suitable tool, such as a tool indicated in the fig- ure.
  • Page 572 FS–19 INSTALLATION 1. Install the suspension lower arm to the suspension mem- Suspension ber with the attaching bolts and nut. member 2. Tighten the attaching bolts and nut to specified tightening torque. Tightening Torque: 117.6 - 176.4 N·m (12.0 - 18.0 kgf-m) CAUTION: ·...

  • Page 573: Drive Shaft

    FS–20 DRIVE SHAFT COMPONENTS q Snap ring w Inboard joint e Snap ring u Snap ring i Boot band o Boot ! 0 Outboard joint JFS00067-00067 REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer of the GI section.) 2.
  • Page 574 FS–21 DISASSEMBLY Inboard joint side 1. Pry up the boot band clip with a screwdriver. NOTE: · Be very careful not to damage the boot. JFS00070-00070 2. Remove the snap ring, using a screwdriver or the like. JFS00071-00071 3. Remove the front axle inboard joint sub-assembly from shaft.
  • Page 575 FS–22 8. Wind vinyl tape to the splined section of the shaft so that the boot may not be damaged during the removal. 9. Remove the boot. vinyl tape JFS00075-00075 Outboard joint side 1. Pry up the boot band clip with a screwdriver. 2.
  • Page 576 FS–23 ASSEMBLY Outboard joint side 1. Wind vinyl tape to the spline section of the inboard joint shaft, so that the boot may not be damaged during the in- stallation. 2. Install the boot to outboard joint in position as shown. 3.
  • Page 577 FS–24 6. Assemble the inner race and cage, and install the ball. While holding the ball to prevent it from dropping, assem- ble the inboard shaft subassembly. JFS00083-00083 7. Install the snap ring to the inboard joint. CAUTION: · Ensure that the snap ring installed in the groove prop- erly after installation.
  • Page 578 FS–25 REPLACEMENT OF TRANSFER OIL SEAL Replace the oil seal, as required. (For the replacement proce- dure, refer to the TR section.) JFS00086-00000 INSTALLATION 1. Apply chassis grease to the whole serrated section of the front drive shaft at the outboard joint side. 2.
  • Page 579 FS–26 TIGHTENING TORQUE Components N·m kgf-m Wheel hub nut 88.2 - 117.6 9.0 - 12.0 Steering knuckle ´ Suspension lower arm 44.1 - 58.8 4.5 - 6.0 Suspension lower arm ´ Member 117.6 - 176.4 12.0 - 18.0 Stabilizer link ´ Suspension lower arm 12.7 - 23.5 1.3 - 2.4 Shock absorber ´...
  • Page 580 FS–27 Shape Part number Part name Remarks 09309-87201-000 Replacer 09310-87302-000 Replacer 09506-87302-000 Replacer 09511-87202-00 Stopper, brake drum 09520-00031-000 Puller, axle shaft 09611-87701-000 Puller, tie-rod end 09648-87201-000 Replacer, drive shaft 09718-87702-000 Replacer, front disc 09722-87702-000 Attachment, camber 09727-87701-000 Compressor, spring 09950-10012-000 Tool set, replacer 09950-20017-000 Puller, universal...
  • Page 581 DAIHATSU J100 J100 TO INDEX REAR AXLE & SUSPENSION REAR AXLE & SUSPENSION ... RS– 2 REAR AXLE SHAFT ......RS–13 COMPONENTS ......RS– 2 REMOVAL ........RS–13 PRIMARY INSPECTION ....RS– 3 DISASSEMBLY ......RS–14 SHOCK ABSORBER ......RS– 4 INSPECTION .........
  • Page 582 RS–2 REAR AXLE & SUSPENSION COMPONENTS : Tightening torque Unit : N·m (kgf-m) 49.0 - 88.3 (5.0 - 9.0) 6.9 - 15.7 (0.7 - 1.6) 73.5 - 93.1 (7.3 - 9.5) 53.9 - 78.5 (5.5 - 8.0) 73.5 - 107.9 (7.3 - 11.0) q Upper rear spring seat !4 Bush...
  • Page 583 RS–3 PRIMARY INSPECTION Inspection of tire & wheel 1. Check that the wheel exhibits no breakage, cracks, dent, and so forth. 2. Check the tire for wear, breakage and cracks. Also, check that no foreign substance is embedded into the tire. 3.

  • Page 584: Shock Absorber

    RS–4 SHOCK ABSORBER REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the rear wheels. 3. Remove the shock absorber attaching nuts. NOTE: • At this stage, do not take out the bolt. 4.
  • Page 585 RS–5 2. Install the shock absorber to the shock absorber attaching stud bolt. 3. Install the bush and plate to the shock absorber attaching stud bolt. CAUTION: • Assemble the plate and bush, as indicated in the figure in Step 1. 4.
  • Page 586 RS–6 LATERAL CONTROL ROD REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the lateral control rod. CAUTION: • Never reuse the removed nuts. JRS00013-00011 3. Remove the dynamic dumper from the lateral control rod. JRS00014-00012 INSPECTION Lateral control rod...
  • Page 587 RS–7 Replacement of lateral control rod bush 1. Remove the bush, using a suitable tool in combination with a hydraulic press. NOTE: • Use a suitable tool, such as a tool indicated in the fig- ure. JRS00018-00016 2. Apply the Samper 107 to a new bush.
  • Page 588 RS–8 5. Temporarily install the lateral control rod to the reinforce- ment. CAUTION: • Make sure that the threaded portions of the bolts face toward the vehicle outside. JRS00023-00021 6. Jack down the vehicle. 7. Rock the vehicle in an up-and-down direction several times so that the suspension may be settled.
  • Page 589 RS–9 UPPER CONTROL ARM REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the rear wheels. 3. Retain the rear axle shaft housing, using a garage jack, etc. JRS00025-00023 4. Remove the speed sensor wire from the bracket at the upper control arm.
  • Page 590 RS–10 2. Install the rear wheels. (Refer to the RS–5.) 3. Jack down the vehicle. 4. Rock the vehicle in an up-and-down direction several times so that the suspension may be settled. 5. Tighten the upper control arm attaching bolt and nut. Tightening Torque: 73.5 - 107.9 N·m (7.5 - 11.0 kgf-m) JRS00030-00028...
  • Page 591 RS–11 LOWER CONTROL ARM REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the rear wheels. 3. Remove the brake cable from the bracket at the lower control arm. 4. Loosen the bolts and nuts at the following sections: Lower control arm ×...
  • Page 592 RS–12 INSTALLATION 1. Temporarily install the lower control arm attaching bolts and nuts. CAUTION: • As regards the bolts connecting the lower control arm to the shock absorber, and the lower control arm to the rear axle shaft housing, make sure that the threaded portions of the bolts face toward the vehicle outside.

  • Page 593: Rear Axle Shaft

    RS–13 REAR AXLE SHAFT REMOVAL 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Remove the rear wheels. 3. Drain the rear differential oil. (Refer to the DF section.) JRS00036-00033 4. Remove the rear brake drum. (Refer to the BR section.) JRS00037-00034 5.
  • Page 594 RS–14 DISASSEMBLY Hand grinder 1. Clamp the rear axle shaft in a vice. 2. Grind off the rear axle shaft bearing inner retainer, using a hand grinder or the like. WARNING: • Be sure to observe the operation instructions by the hand grinder manufacturer.
  • Page 595 RS–15 INSPECTION Rear axle shaft 1. Place the rear axle shaft on a V-block. 2. Ensure that the runout at the flange end surface is within the allowable limit. Maximum Allowable Limit: 0.2 mm NOTE: • This maximum allowable runout does not include the runout caused by roughness on the flange surface.
  • Page 596 RS–16 4. Installation of rear axle shaft bearing inner retainer. Inner retainer (1) Heat the retainer to 150 ± 15°C in an oil bath. 150ϒC NOTE: • Perform this operation promptly before the retainer Oil bath temperature drops. • When the temperature exceeds 150 ± 15°C, the sur- face of the retainer will be turned to yellow.
  • Page 597 RS–17 INSTALLATION 1. Apply Three Bond 11040 or relevant to both sides of the shim, as indicated in the figure. CAUTION: • Do not apply sealer to the drain hole. • As regards the rear axle shaft bearing shim, the thick- ness of the shim has been determined according to the thickness of the backing plate.
  • Page 598 RS–18 REAR AXLE SHAFT HOUSING REMOVAL 1. Drain the brake fluid. (Refer to the BR section.) 2. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 3. Remove the rear wheels. 4. Drain the differential oil. (Refer to the DF section.) 5.
  • Page 599 RS–19 13. Remove the lateral control rod and upper control arm so that the rear axle shaft housing may be retained by the lower control arm and shock absorber. (Refer to the “LAT- ERAL CONTROL ROD, UPPER CONTROL ARM” section.) 14.
  • Page 600 RS–20 INSPECTION Rear axle shaft housing Check that the external appearance of the rear axle shaft housing exhibits no major dent and scores. Also, check that the lateral control rod attaching stud bolt exhibits no scores. If any damage is exists, replace the damaged part with new one.
  • Page 601 RS–21 INSTALLATION 1. Install the rear spring bumper to the body. 2. Install the upper rear spring seat to the body. JRS00070-00067 3. Put the coil spring on the spring seat. Then, lift the rear axle shaft housing to an appropriate height, using a garage jack or the like.
  • Page 602 RS–22 9. Install the rear axle shaft. (Refer to the “REAR AXLE SHAFT” section.) 10. Connect the brake tube to the backing plate. Tightening Toque : 12.8 - 17.6 N·m (1.3 - 1.8 kgf-m) 11. Connect the brake hose to the bracket of the upper con- trol arm.
  • Page 603 RS–23 TIGHTENING TORQUE N·m Components kgf-m Shock absorber × Body 53.9 - 78.5 5.5 - 8.0 Shock absorber × Lower control arm 53.9 - 78.5 5.5 - 8.0 Lateral control rod × Dynamic dumper 6.9 - 15.7 0.7 - 1.6 Lateral control rod ×...
  • Page 604 DAIHATSU J100 TO INDEX BRAKES BASIC CHECK ..........BR– 2 BRAKE PEDAL ........... BR– 5 BRAKE MASTER CYLINDER ....BR– 7 BRAKE BOOSTER ........BR–13 FRONT BRAKE ........... BR–16 REAR BRAKE ..........BR–22 PARKING BRAKE ........BR–30 PROPORTIONING VALVE ......BR–33 BRAKE HOSE ..........
  • Page 605 BR–2 BASIC CHECK BRAKE PEDAL 1. Ensure that the brake pedal height is with in specified valve by measuring the brake pedal height. Specified Value: 162.8 mm (*155.8 mm) CAUTION: · Cushion “*” Mark denote brake pedal height between upper sur- face of brake pedal pad and upper surface of protrude section of floor panel.
  • Page 606 BR–3 5. Pedal reserve travel check (1) Start the engine and run the engine at idling. (2) Depress the brake pedal with a pedal applying force of 300 N (30kgf) with the parking brake lever returned. (3) Measure the distance between the upper surface of brake pedal pad center and the upper surface of pro- trude section of floor panel.
  • Page 607 BR–4 4. Booster air-tight performance check under loaded condition (1) Connect a negative pressure gauge to the booster, using a “T or Y” pipe joint. (2) Start the engine with the brake pedal depressed with a x100mmHg T pipe joint force of 200 N.

  • Page 608: Brake Pedal

    BR–5 BRAKE PEDAL COMPONENTS : Non-reusable parts q Brake pedal subassembly w Brake pedal pad NOTE: e Cushion : The brake pedal shaft installed from right r Brake pedal bracket side when model with left hand drive. t Brake pedal shaft Contrary, the brake pedal shaft installed y Pedal bracket stay from left side when model with right hand...
  • Page 609 BR–6 10. Inspect the following parts. Damage or deformation Wear or damage Wear or damage Wear or damage Wear or damage Bend or twist Damage or deformation JBR00015-00013 INSTALLATION 1. Apply the specified grease to those points indicated in the right figure.
  • Page 610 BR–7 BRAKE MASTER CYLINDER COMPONENTS For conventional model only. NOTE: For ABS model q Brake master cylinder reservoir tank w Reservoir filler cap e Reservoir diaphragm r Grommet t Brake master cylinder assembly y Tandem master cylinder repair kit JBR00018-00015 REMOVAL 1.
  • Page 611 BR–8 4. Remove the master cylinder from the brake booster. NOTE: · The O-ring is installed on the master cylinder. It may be hard to remove the master cylinder from the brake booster. 5. Secure the master cylinder to a vise. JBR00020-00017 6.
  • Page 612 BR–9 11. Remove the piston No. 1 from the master cylinder. CAUTION: · Remove the piston straight, being very careful not to scratch the cylinder bore. 12. Remove the piston No. 2 by lightly applying compressed air at the brake pipe hole. WARNING: ·...
  • Page 613 BR–10 2. Thinly apply brake rubber grease to the lip section of the cups of the piston No. 2 assembly. 3. Install the piston No. 2 into the master cylinder. JBR00028-00025 4. Thinly apply brake rubber grease to the lip section of the cups and O-ring on the piston No.
  • Page 614 BR–11 INSTALLATION 1. Check the clearance between the master cylinder and the brake booster push rod. (1) Prepare the following SSTs. SST: 09730-87401-000 09737-87003-000q 09733-87401-000w 09731-87401-000e 09732-87401-000r 09734-87401-000t 09735-87401-000y JBR00033-00000 O-ring (2) Assemble the components of the above SSTs as fol- lows.
  • Page 615 BR–12 WARNING: · Be sure to adjust the clearance properly. Failure to ob- serve this warning may lead to brake system problem. NOTE: · If the clearance fails to meet the specified value, adjust the clearance between the SST and the push rod of the brake booster to zero, by turning the adjusting tip pro- vided at the top of the push rod of the brake booster.

  • Page 616: Brake Booster

    BR–13 BRAKE BOOSTER COMPONENTS : Non-reusable parts q Brake booster assembly w Master cylinder push rod clevis e Brake booster bracket gasket r Union to connector tube t Clip y Union u Intake manifold tube clamp i Intake manifold to connector tube o Union to check valve hose JBR00043-00037 REMOVAL...
  • Page 617 BR–14 3. Remove the instrument finish lower panel by removing the two attaching bolts. JBR00045-00039 4. Remove the clip of the push rod clevis pin. 5. Remove the push rod clevis pin. 6. Loosen the brake booster attaching nuts evenly. 7.
  • Page 618 BR–15 6. Install the instrument finish lower panel and install two at- taching screws. 7. Install the brake master cylinder. (Refer to the brake master cylinder section for installation.) CAUTION: · Be sure to follow the installation procedure for the brake master cylinder described in the above men- tioned section.
  • Page 619 BR–16 FRONT BRAKE COMPONENTS : Non-reusable parts q Main cylinder slide pin w Sub-cylinder slide pin e Disc brake No. 1 pad r Disc brake No. 2 pad t Anti-squeal shim y Shim u Disc brake pad guide No. 2 plate i Disc brake pad guide plate o Disc brake cylinder mounting (R, L) !0 Cylinder boot...
  • Page 620 BR–17 REMOVAL NOTE: · The replacement procedure of the brake pads is not mentioned in this service manual. Refer to the proce- dure which is necessary to replace the brake pads. 1. Jack up the vehicle and support the vehicle with safety stands.
  • Page 621 BR–18 11. Ensure that the disc rotor thickness is more than that specified value by means of vernier calipers. Inspect the disc rotor thickness. Specified Thickness: 16 mm Minimum Thickness: 15 mm JBR00057-00048 12. Inspection of disc rotor runout (1) Secure the disc rotor with hub nuts properly. CAUTION: ·...
  • Page 622 BR–19 2. Remove the cylinder boot from the cylinder. JBR00061-00052 Detach the piston seal from the cylinder, using a suitable minor screwdriver or the like. CAUTION: · Be very careful not to score the cylinder bore wall, etc. during the removal. Assembly of front disc brake cylinder assembly JBR00062-00053 NOTE:...
  • Page 623 BR–20 (7) Insert the outer end of the boot to the groove provided on the piston properly. CAUTION: · Never score or damage the boots. (8) Install the cylinder main pin to the disc brake cylinder assembly by hand. JBR00066-00056 INSTALLATION NOTE: ·...
  • Page 624 BR–21 10. Thinly apply the brake rubber grease to the sliding surface of the sub-cylinder slide pin. 11. Install the sub-cylinder slide pin of the disc brake cylinder assembly to the disc brake mounting. CAUTION: · Be very careful not to damage the pin boot during the assembly.
  • Page 625 BR–22 REAR BRAKE COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 9.8 ± 2 (1.0 ± 0.2) 61 ± 7 (6.25 ± 0.75) q Brake drum subassembly w Shoe hold-down spring & retainer e Shoe hold-down spring pin r Tension No.
  • Page 626 BR–23 DISASSEMBLY 1. Jack up the vehicle and support it with safety stands. (Refer to the GI section.) 2. Drain the brake fluid from the rear brake line. (Refer to the Air breeding section.) 3. Remove the rear wheels. 4. Release the parking brake fully. 5.
  • Page 627 BR–24 10. Remove the shoe hold-down spring pin retainers and springs from the shoe hold-down spring pins. 11. Remove the shoe hold-down spring pins. 12. Detach the brake shoes from the backing plate. 13. Remove the leading side brake shoe from the tension No.
  • Page 628 BR–25 22. Disconnect the brake pipe from the wheel cylinder by dis- connecting the flare nut, using a flare nut wrench. 23. Remove the wheel cylinder by removing the attaching bolts. JBR00082-00069 24. Disconnect the parking brake cable from the backing plate by removing the two attaching bolts.
  • Page 629 BR–26 2. Checking of brake lining contacting condition with brake drum (1) Apply powder of chalk to the brake drum. Then, check the brake lining surface contacting condition with the brake drum by rubbing the brake lining in the brake drum.
  • Page 630 BR–27 4. Thinly apply brake grease to the sliding portions of the parking brake shoe lever. 5. Install the parking brake shoe lever to the trailing side brake shoe with the parking brake lever pin together with a new C-ring. Then, retract the C-ring with pliers or the like.
  • Page 631 BR–28 14. Install the compression spring and wheel cylinder pistons with the wheel cylinder boots to the wheel cylinder. NOTE: · Loosen the bleeder plug fully before installing the wheel pistons. JBR00092-00078 15. Apply brake grease to the six brake shoe contacting points on the backing plate, one point each on the wheel cylinder pistons and two points on the brake lining anchor.
  • Page 632 BR–29 Reference: Manual adjusting method of brake shoe-to-drum clear- ance NOTE: · The illustration shows the brake at the right hand side. The brake at the left hand side is symmetric to the brake at the right hand side. (1) Remove the adjusting hole plug provided on the back- Adjusting hole ing plate.

  • Page 633: Parking Brake

    BR–30 PARKING BRAKE COMPONENTS : Tightening torque Unit : N·m (kgf-m) 18.1 ± 3.4 (1.85 ± 0.35) 7.3 ± 1.5 (0.75 ± 0.15) q Rear console box assembly w Parking brake lever assembly e Parking brake left cable assembly r Parking brake right cable assembly JBR00097-00081 INSPECTION 1.
  • Page 634 BR–31 3. Adjust the parking brake control handle travel to the spec- ified number of notches by turning the adjusting nut of the parking brake pull rod. Specified Value: 5 - 7 notches CAUTION: · Be sure to use a hexagon socket (box) wrench for ad- justment to prevent the adjusting nut from being dam- aged.
  • Page 635 BR–32 INSPECTION Inspect the components with the following point. Replace any damaged parts. JBR00104-00087 INSTALLATION NOTE: · The installation procedure is basically reverse to the removal procedure. Therefore, some illustra- tions are not mentioned in this installation procedure. · Please refer to the illustration mentioned in the removal procedure, if any difficulty is encountered. 1.

  • Page 636: Proportioning Valve

    BR–33 PROPORTIONING VALVE COMPONENTS Left Front JBR00106-00088 INSPECTION Inspect the proportioning valve function with a four-wheel brake tester. 1. Place the vehicle on the four-wheel brake tester. 2. Ensure that the rear wheels will not be locked before the front wheels are locked. If the rear wheel will be locked simultaneously or before the front wheels are locked, replace the propor- tioning valve with a new one.

  • Page 637: Brake Hose

    BR–34 BRAKE HOSE COMPONENTS q Front brake No. 8 tube w Front flexible hose e Rear brake No. 1 tube r Front brake No. 6 tube t Front brake No. 7 tube y Front brake No. 9 tube u Front brake No. 1 tube i Rear brake No.
  • Page 638 BR–35 4. Disconnect the brake hose from the disc brake cylinder assembly by removing the union bolts and washers. CAUTION: · Do not reuse the used washers. 5. Remove the brake hose by removing the attaching bolt of the clamp bolts. 6.
  • Page 639 BR–36 ANTI-LOCK BRAKE SYSTEM SYSTEM OUTLINE The ABS is a brake system to prevent the wheels from locking which may cause the vehicle to slip. For this purpose, the ABS assures proper braking forces at all times by maintaining the coefficient of friction be- tween the tires and the road surface to an optimum level through controlling the hydraulic pressure of each of the front right, front left and rear wheels.
  • Page 640 BR–37 JABS CIRCUIT DIAGNOSIS ABS fuse Back-up fuse ABS ECU IG SW(IG2) ECU IG fuse ECUT Diagnosis Tail fuse STOP fuse Body ground connector solenoid ABST stop lamp relay switch 11 SIO Motor relay Front vehicle speed BS BM sensor (right) stop FR–...
  • Page 641 BR–38 ABS RELATED CONNECTORS EFI ECU Ignition switch Vehicle speed sensors SFRH SFLH SFLH SFRH SFLR SFRR SFRR SFLR 13 12 11 Actuator connector Actuator 2 (WA) Stop lamp switch 1 (BS) Inspection diode GGND ABST ECUT Ground Diagnosis connector Solenoid relay Motor relay Gravity sensor...
  • Page 642 BR–39 SST (Sub - harness) SST (Diagnosis connector) Body ground. For DS - 21 (To diagnosis connector) (For inspection side) ABS00000-00004...
  • Page 643 BR–40 ABS CIRCUIT CONNECTION TABLE Terminal No. Terminal ABS ECU name SST (Sub-harness) ABS actuator Gravity sensor Terminal connected to Solenoid relay Motor relay Speed sensor Front Rear Others LH RH LH SFLH terminal of actuator SFLH SFLR terminal of actuator SFLR R+ terminal of motor and solenoid relay MR terminal of motor relay...
  • Page 644 BR–41 Terminal No. Terminal ABS ECU name SST (Sub-harness) ABS actuator Gravity sensor Terminal connected to Solenoid relay Motor relay Speed sensor Front Rear Others LH RH LH Back-up fuse Back-up fuse *3 Body ground Body ground *3 Combination meter *2 ABS warning lamp Inspection diode –...
  • Page 645 BR–42 PRECAUTIONS 1. The ABS system has a self-diagnosis function. The ECU memorizes abnormality as diagnosis codes which are occurring at present or occurred in the past. Memorized diagnosis codes are erased when the power supply is disconnected. Therefore, be sure to read out diagnosis codes before starting any operations.
  • Page 646 BR–43 13. Circuit tester · For trouble shooting, use a volt/ohmmeter whose internal resistance is more than 10 k ohm, whose resolution is 0.1 V or more and 0.5 ohm or more, and whose accuracy is 0 ± 2 % or more. Use of a volt/ohmmeter which has lower specifications than those described above for trouble shooting may lead to wrong diagnosis or mis-judgement.
  • Page 647 BR–44 TROUBLE SHOOTING HINTS 1. Most of troubles related to the electrical system of the ABS are merely caused by poor connections. Ensure the following points carefully before and during the inspection. (1) Visually inspect that the terminals are not damaged or bent.
  • Page 648 BR–45 HOW TO PROCEED TROUBLE SHOOTING The trouble or malfunction of the brake system mainly originates in the mechanical systems, such as the brake pedal, brake booster, brake master cylinder, P valve, wheel cylinders and brake fluid line, or electri- cal systems, such as the ABS actuator, wheel speed sensors, gravity sensor, ABS ECU and ABS related wiring harness.
  • Page 649 BR–46 DIAGNOSIS CODE CHECK 1. Checking of ABS warning lamp (1) Ensure that the ABS warning lamp will glow for about three seconds after the ignition switch is turned ON, and, then, the warning lamp goes out. NOTE: · Proceed to trouble shooting according to the trouble phenomenon if the ABS warning lamp fails to meet the condition above.
  • Page 650 BR–47 DIAGNOSIS CODE TABLE Diagnosis items Diagnosis contents Timing of diagnosis Presumable causes of trouble CODE NO. Solenoid relay Open wire All time · Solenoid relay Immediately after · Solenoid relay-related harness ignition switch is turned Solenoid relay Short circuit Immediately after ·...
  • Page 651 BR–48 1. Erasing procedure by brake pedal (1) Connect the following SST to the diagnosis connector. SST: 09991-87401-000 ECUT (2) Connect the ECUT and GND terminals in the SST ter- minal with the following SST. SST: 09991-87403-000 Ground CAUTION: • Never connect the terminals other than that specified, for even slight contact of other terminals may lead to JABS00017-00011...
  • Page 652 BR–49 3. Erasing diagnosis codes by removing back-up fuse Back-up fuse (1) Ensure that the ignition switch is turned OFF. (2) Remove the back-up fuse from the relay block, using the fuse puller, and install it again after a lapse of more than 10 seconds.
  • Page 653 BR–50 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODES TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. JUDGMENT SOURCE: Comparing voltage being applied to across terminals +B and AST DIAGNOSIS ITEM Solenoid relay of ABS ECU between the ON condition and the OFF condition of solenoid relay DIAGNOSIS CONTENTS Open wire...
  • Page 654 BR–51 Checking procedure Replace solenoid relay. 1. Check solenoid relay. (Refer to unit check.) Replace fusible link. 2. Check ABS fusible link. (Refer to BE section.) Check the harness between battery and 3. Check power supply to terminal +BS of solenoid relay. terminal +BS of solenoid relay or terminal +BM of motor relay for open wire or short circuit.
  • Page 655 BR–52 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. JUDGMENT SOURCE: Monitoring the voltage being applied to terminal AST of the DIAGNOSIS ITEM Solenoid relay ABS ECU when solenoid relay is turned off. DIAGNOSIS CONTENTS Short circuit ABS fuse Body AM fuse ECU IG fuse...
  • Page 656 BR–53 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. JUDGMENT SOURCE: DIAGNOSIS ITEM Motor relay Monitoring voltage being applied to across terminals +B and MT of ABS ECU with motor relay turned ON. DIAGNOSIS CONTENTS Open wire ABS fuse AM fuse ECU IG fuse Ignition...
  • Page 657 BR–54 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. JUDGMENT SOURCE: Comparing voltage being applied to across +B and MT terminals DIAGNOSIS ITEM Motor relay of ABS ECU with motor relay turned OFF. DIAGNOSIS CONTENTS Short circuit ABS fuse AM fuse ECU IG fuse Ignition...
  • Page 658 BR–55 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE JUDGMENT SOURCE: DIAGNOSIS CODE No. 21, 22 and 23 Monitoring the voltage being applied to ABS ECU through each of DIAGNOSIS ITEM Solenoid valve solenoid valves and standard resistance are identified with the prememorized value in the CPU of ABS ECU.
  • Page 659 BR–56 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. Both sides JUDGMENT SOURCE: · Monitoring sensor circuit voltage. Front Rear Front DIAGNOSIS ITEM · Monitoring difference of input signal from each sensor. Vehicle speed sensor · Monitoring missing of input signal from each sensor. ·...
  • Page 660 BR–57 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. 41 or 42 JUDGMENT SOURCE: When power supply voltage to terminal +B of the ABS ECU DIAGNOSIS ITEM Power supply voltage becomes 10 volts or less or 18 volts or more. DIAGNOSIS CONTENTS Abnormal power supply voltage Back-up fuse...
  • Page 661 BR–58 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. JUDGMENT SOURCE: · Monitoring if output signal of gravity sensor meets DIAGNOSIS ITEM Gravity sensor predetermined output form. DIAGNOSIS CONTENTS Abnormal output signal JUDGMENT SOURCE: DIAGNOSIS CODE No. · Monitoring if output signal of gravity sensor meets predetermined output form.
  • Page 662 BR–59 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. JUDGMENT SOURCE: DIAGNOSIS ITEM Stop lamp switch · Monitoring brake lamp circuit DIAGNOSIS CONTENTS Open wire Tail fuse Stop lamp switch Stop fuse Stop Battery lamp JABS00047-00024 Checking points 1. Stop lamp 2.
  • Page 663 BR–60 TROUBLE SHOOTING ACCORDING TO DIAGNOSIS CODE DIAGNOSIS CODE No. JUDGMENT SOURCE: • Monitoring voltage at terminal MT of actuator when actuator DIAGNOSIS ITEM Actuator pump motor pump motor is turned OFF. DIAGNOSIS CONTENTS Operation SFRH SFRR SFLH SFLR Actuator JABS00050-00025 Checking points 1.
  • Page 664 BR–61 TROUBLE SHOOTING ACCORDING TO TROUBLE PHENOMENA TROUBLE SHOOTING ACCORDING TO TROUBLE PHENOMENON TROUBLE PHENOMENA Flow chart number 1. ABS warning lamp remains illuminated immediately after ignition switch is turned ON. 2. ABS warning lamp will not glow immediately after ignition switch is turned ON. 3.
  • Page 665 BR–62 TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 1 PHENOMENA: ABS warning lamp remains illuminated. AM fuse ECU IG fuse Ignition switch To solenoid relay ABS ECU Inspection diode ABS warning lamp Gauge fuse Battery Combination meter JABS00054-00026 Checking point 1. Abnormal input voltage to ABS ECU. 2.
  • Page 666 BR–63 TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 2 PHENOMENA: ABS warning lamp will not glow after ignition switch is turned ON. Ignition switch Fusible link To solenoid relay ABS ECU Inspection diode ABS warning lamp Battery Combination Gauge fuse meter JABS00056-00027 Presumable causes for trouble 1.
  • Page 667 BR–64 TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 3 PHENOMENA: ABS warning lamp blinks immediately after ignition switch is turned ON. ABS ECU To solenoid relay Diagnosis Inspection diode connector 36 ECUT ABS warning lamp ABST Gauge fuse Combination meter JABS00058-00028 Checking point ·...
  • Page 668 BR–65 TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 4 PHENOMENA: ABS warning lamp remains illuminated while driving. Side pull of brake Poor effectiveness ABS operates under normal braking. ABS operates just before vehicle stops under normal braking. Brake pedal vibrates excessively. Wheel locks frequently under ABS operation.
  • Page 669 BR–66 TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 5 PHENOMENA: Starting of ABS operation is late. IG SW ECU IG fuse Tail ABS ECU fuse Stop Stop Gravity fuse lamp sensor GGND GGND FR– Stop Battery lamp Speed FL– sensors RR– RL–...
  • Page 670 BR–67 TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 6 PHENOMENA: Brake pedal working travel is too small NOTE: · No consideration has been taken for function of each wheel cylinder in this procedure. 1. Ensure that the ABS warning lamp is extinguished three Perform trouble shooting according to seconds after ignition switch is turned ON.
  • Page 671 BR–68 TROUBLE SHOOTING PROCEDURE FLOW CHART NUMBER 7 PHENOMENA: Brake pedal working travel is too large. (Reserve travel is too small.) 1. Ensure that the ABS warning lamp is extinguished Perform trouble shooting according to three seconds after ignition switch is turned ON. trouble phenomenon.
  • Page 672 BR–69 (2) Remove the glove compartment box by removing the glove compartment hinge. (Refer to the BO section.) (3) Disconnect the connector of the wire harness which is connected to the ABS ECU. (4) Connect the following SST to the connectors of the wire harness disconnected from the ABS ECU.(Refer to the unit inspection of ABS ECU.) SST:...
  • Page 673 BR–70 UNIT INSPECTION & REPLACEMENT NOTE: · The inspection of each sensor circuit should be performed by reoffering to the ABS RELATED CON- NECTORS and ABS CIRCUIT CONNECTION TABLE. · Utilize the following SST effectively by reoffering to the unit inspection of the ABS ECU. SST: 09842-87401-000 ·...
  • Page 674 BR–71 MOTOR RELAY 1. Turn off the ignition switch. 2. Remove the motor relay from its bracket while unlocking the lock provided on its bracket. 3. Disconnect the connector of the wire harness connected to the motor relay. 4. Ensure that the resistance between the terminals R+ and MR is within the specified value.
  • Page 675 BR–72 4. Turn ON the ignition switch. CAUTION: · Never turn off the ignition switch until the sensor check by the sensor function is completed. 5. Ensure that the ABS warning lamp will indicate the ABS ECU code number once immediately after the ignition switch is turned on.
  • Page 676 BR–73 Diagnosis code table NOTE: · Be sure to perform trouble shooting including its related wire harness hand and connectors of pre- sumable parts mentioned in the table above. Code Output from of diagnosis code Diagnosis contents Presumable causes Normal No trouble on sensor systems 0.25 sec.
  • Page 677 BR–74 GRAVITY SENSOR : Tightening torque Unit : N·m (kgf-m) 6.9 - 9.8 (0.7 - 1.0) q Rear console box assembly w Console panel e Gravity sensor JABS00084-00040 NOTE: · The function check of the gravity sensor should be performed by the sensor check function. The following procedure applies only to the inspection of attaching conditions, removal and installation.
  • Page 678 BR–75 (3) Install the gravity sensor to the floor panel with two attaching bolts in such a direction that the con- nector provided on the gravity sensor faces toward backward. CAUTION: · Never install the gravity sensor in a reverse direction. The gravity sensor can be installed in both di- rections.
  • Page 679 BR–76 2. Checking of sensor rotor Inspect the sensor rotor for the following points. · Ensure that the sensor rotor is pressed in on the drive shaft properly, is free from damage and is not contami- nated by foreign materials. ·...
  • Page 680 BR–77 REAR SPEED SENSOR NOTE: · The check of the speed sensor is basically carried out by the sensor check function. q Speed control rear left sensor 6.9 - 9.8 (0.7 -1.0) w Speed control rear right sensor 6.9 - 9.8 6.9 - 9.8 (0.7 -1.0) (0.7 -1.0)
  • Page 681 BR–78 (3) Ensure that the tips of the speed sensors are free from damage or contamination with foreign mate- rials. Clean the tips of the speed sensors, if they are contaminated. (4) Connect the connector of the rear speed sensor to the connector of the wire harness. 5.
  • Page 682 BR–79 ABS ACTUATOR WARNING: · Be sure to prevent foreign substances from being admitted into the brake actuator. Failure to observe this warning may lead to serius brake malfunction. : Tightening torque Unit : N·m (kgf-m) 15.5 ± 2.5 (1.59 ± 0.26) 4.3 - 6.5 (0.44 - 0.66) 4.3 - 6.5 (0.44 - 0.66) q Nut...
  • Page 683 BR–80 (5) Remove the inspection diode. (Refer to the inspection diode section) (6) Remove the motor relay. (Refer to the motor relay section.) (7) Ensure that the resistance or continuity between the respective terminals is within the specified value, as shown in the table below. NOTE: •...
  • Page 684 BR–81 2. Check of fluid lines in actuator CAUTION: · Be sure to prevent the brake fluid from coming in con- tact with the painted surface and resin parts, using a piece of cloth or the like. If the brake fluid comes in contact with the painted surface and resin parts, imme- diately wipe off the brake fluid and wash with fresh water.
  • Page 685 BR–82 y Disconnect the negative terminal of the ground cable from the negative terminal of the battery. NOTE: • Be sure to read out the diagnosis code of the EFI sys- tem before disconnecting the power supply to the vehi- cle.
  • Page 686 BR–83 y Remove the jump wire in the SST terminals. NOTE: • Proceed to check the remaining right and rear wheels as mentioned in step (3). u Disconnect the negative terminal of the ground cable from the negative terminal of the battery. i Remove the SST from the connector of the wire harness.
  • Page 687 BR–84 (2) Inspection (Refer to the service manual of DS-21 for more details.) q Connect the DS-21 to the diagnosis connector, using the following SST. SST: 09991-87401-000 w Select the function of the actuator drive. NOTE: · When selecting of the actuator drive, release the secu- rity function of DS-21.
  • Page 688 BR–85 6. Installation of ABS actuator NOTE: · The installation procedure is basically procedure in the reverse order of the removal procedure. Therefore, some illustrations are omitted from the installation pro- cedure. Refer to the illustration in the removal proce- dure if any difficulty is encountered.
  • Page 689 BR–86 ABS ECU COMPONENTS q Glove compartment subassembly w Skid control computer assembly : Tightening torque Unit : N·m (kgf-m) 8.3 ± 1.4 (0.85 ± 0.15) 8.3 ± 1.4 (0.85 ± 0.15) JABS00123-00064 CAUTION: · Be sure to read out the diagnosis code of the ABS and EFI systems before disconnecting the battery power supply.
  • Page 690 BR–87 Terminal to be connected Specified value Measuring condition Presumable cause Zero volt Ignition switch OFF Actuator 1 (SFLH) - 40 (GND) Solenoid relay Battery voltage Ignition switch ON After ABS warning lamp is extinguished. Ignition switch OFF Zero volt Actuator 2 (SFLR) - 40 (GND) Solenoid relay...
  • Page 691 BR–88 Terminal to be connected Specified value Measuring condition Presumable cause Zero volt Ignition switch OFF 26 (FL+) - 40 (GND) 1.0 - 3.0 volts Ignition switch ON Front left speed sensor Zero volt Ignition switch OFF 27 (FL–) - 40 (GND) 1.0 - 3.0 volts Ignition switch ON Zero volt...
  • Page 692 BR–89 7. Turn off the ignition switch. 8. Disconnect the negative terminal of the ground cable from the negative terminal of the battery. 9. Disconnect the SST connectors from the ABS ECU. 10. Measure resistance or continuity between the SST terminals specified in the table below and perform the trouble shooting for the part(s) related to the wire harness including the connectors mentioned in the table below.
  • Page 693 BR–90 Replacement of ABS ECU (Refer to the illustration in page BR–86.) 1. Disconnect the negative terminal of the ground cable from the negative terminal of the battery. CAUTION: · Be sure to read out the diagnosis code of the ABS and EFI systems before disconnecting the battery power supply.
  • Page 694 BR–91 TIGHTENING TORQUE Tightening components N·m kgf-m 25.5 ± 2.9 2.6 ± 0.3 Brake pedal clevis Bleeder plug 6.9 - 9.8 0.7 - 1.0 Piston stopper bolt ´ master cylinder 7.9 - 11.7 0.8 - 1.2 Master cylinder ´ brake booster 12.7 ±...
  • Page 695 BR–92 SSTs Shape Part name Part name Remarks 09730-87401-000 Brake booster gauge set 09737-87003-000 (Gauge) 09733-87401-000 (O-ring) 09731-87401-000 (Attachment) 09732-87401-000 (Adapter) 09734-87401-000 (O-ring) 09735-87401-000 (O-ring) 09703-30010-000 Brake shoe return spring tool 09921-00010-000 Spring tension tool Engine control system inspection wire 09991-87401-000 09842-87401-000 ABS computer check sub-harness...
  • Page 696 DAIHATSU J100 J100 TO INDEX STEERING IN-VEHICLE INSPECTION ....SR– 2 REMOVAL ........SR–12 STEERING WHEEL ....... SR– 2 DISASSEMBLY ......SR–13 POWER STEERING INSPECTION ......... SR–14 DRIVE BELT ......SR– 2 ASSEMBLY ........SR–15 POWER STEERING FLUID .... SR– 3 INSTALLATION ......
  • Page 697 SR–2 IN-VEHICLE INSPECTION STEERING WHEEL Check for rattle Move the steering wheel in an axial direction and/or in a per- pendicular direction so as to ensure that no looseness and/or excessive play is present. SRS AIRBAG If any looseness and/or excessive play is present, check the steering wheel for improper installing condition.

  • Page 698: Power Steering Fluid

    SR–3 Check of drive belt tension Measuring point Ensure that the amount of the drive belt deflection within Vane pump Vane pump specified value, by depressing the midpoint of the drive belt Idler pulley pulley pulley between the vane pump and crank shaft pulley (vehicles equipped without air conditioner) or vane pump and air condi- Idler conditioner...
  • Page 699 SR–4 Fluid change 1. Jack up the vehicle and support it with the safety stands. (Refer to the GI section.) 2. Place the suitable container to under the return hose at re- serve tank side. 3. Disconnect the return hose from the reservoir tank so as to allow the fluid to flow out.
  • Page 700 SR–5 3. While turning the steering wheel with the vehicle in its stationary state, check that the power steering system is operating properly or it emits no abnormal noise, etc. Perform this check with the engine run- ning at over 3000 rpm. NOTE: ·...
  • Page 701 SR–6 CAUTION: · Never connect the “IN” and “OUT” side hoses of the oil pressure gauge in wrong way. Failure to ob- serve this caution may lend to damaging the oil pressure gauge. · Never bend or twist the hoses and tubes forcibly. ·...
  • Page 702 SR–7 Check of air control valve 1. Ensure that there is no air continuity exists between port A and port B of the air control valve in the right figure when steering wheel not operated under engine at idling state. 2.
  • Page 703 SR–8 DISASSEMBLY 1. Remove the horn button contact plate. 2. Remove the steering wheel cover from the steering wheel. ASSEMBLY 1. Install the steering wheel cover to the steering wheel. 2. Install the horn button contact plate to the steering wheel. JSR00021-00016 INSTALLATION 1.
  • Page 704 SR–9 STEERING WHEEL(AIRBAG TYPE) COMPONENTS 5.2 - 9.5 (0.53 - 0.97) : Tightening torque Unit : N·m (kgf-m) JSR00025-00020 REMOVAL 1. Turn OFF the ignition switch and disconnect the battery cable from the negative (–) terminal of the battery. 2. Set the steering wheel to a straight-ahead position. Remove the attaching bolts (TORX ®...
  • Page 705 SR–10 4. After the connector is disconnected, remove the pad as- sembly from the steering wheel. WARNING: GOOD DANGER · Be sure to place the removed pad assembly with the pad surface facing upward. The pad assembly placed with the pad surface facing downward is potentially hazard.
  • Page 706 SR–11 4. Ensure that the vehicle is in a straight-ahead state. Then, install the steering wheel assembly to the steering shaft. CAUTION: · Make sure that the steering wheel is installed, making an angle of ±15° from the neutral position. 5.
  • Page 707 SR–12 STEERING COLUMN & INTERMEDIATE SHAFT COMPONENTS : Tightening torque Unit : N·m (kgf-m) 14.7 - 21.6 3.9 - 6.9 (1.5 - 2.2) (0.4 - 0.7) 9.8 - 15.7 (1.8 - 1.6) 24.5 - 34.5 (2.5 - 3.5) q Steering column assembly w Dust cover retainer e Dust cover r Intermediate shaft...
  • Page 708 SR–13 6. Disconnect the connector for the ignition switch. 7. Remove the steering column attaching bolts and nuts. 8. Remove the steering column upper cover. 9. Disconnect the connector for the multi-use lever switch, air bag (if equipped) and immobilizer (if equipped). 10.
  • Page 709 SR–14 4. Remove the ignition switch from the steering column upper bracket by removing the attaching screw. NOTE: · This operation can be performed also on the vehicle. 5. Removal of the steering column upper bracket. JSR00044-00038 NOTE: · Perform this operation only when it becomes neces- sary to replace the steering column upper bracket alone.
  • Page 710 SR–15 Steering column assembly Ensure that the length of the steering column assembly is not less than specified value by measuring the its length. If the length is shorter than the specified length excessively, replace it with a new one. Ensure that the steering column assembly exhibits no defect, such as excessive play at the spline section.
  • Page 711 SR–16 INSTALLATION 1. Install the dust cover to the retainer. 2. Install the dust cover retainer to the dash panel with the at- taching bolts. Tightening Torque: 3.6 - 6.9 N·m (0.4 - 0.7 kgf-m) 3. Insert the steering column to the dust cover hole. 4.

  • Page 712: Steering Gear

    SR–17 STEERING GEAR COMPONENTS : Tightening torque 19.6 - 29.4 Unit : N·m (kgf-m) (2.0 - 3.0) 14.7 - 21.6 (1.5 - 2.2) 19.6 - 29.4 (2.0 - 3.0) 59 - 79 (6.0 - 8.0) 88 - 118 (9.0 - 12.0) #1 #2 59.8 - 89.2 (6.1 - 9.1)
  • Page 713 SR–18 REMOVAL 1. Drainage of power steering fluid (See page SR–4, Fluid change.) 2. Remove the intermediate shaft. (See page SR–12.) 3. Affix a tape or the like to the pinion section of the steering gear so as to prevent the body, etc., from being damaged during the removal of the steering gear assembly.
  • Page 714 SR–19 DISASSEMBLY PRECAUTION · Never reuse non-reusable parts. (Failure to observe this caution may cause serious accidents.) · Prior to the disassembly, be sure to wipe off any sand or mud adhering to the outside of the power steering gear assembly so that they may not get into the inside during the disassembly and assembly. ·...
  • Page 715 SR–20 5. Removal of tie rod end Mating mark (1) Put a mating mark on the tie rod end and steering rack end. (2) Remove the tie rod end by loosening the lock nut. JSR00064-00058 6. Removal of steering rack boots (1) Remove the steering rack boot bands.
  • Page 716 SR–21 9. Remove the lock nut for the rack guide spring cap, using the following SST. SST: 09922-10010-000 (Width across flats: 42 mm) 24 mm 10. Remove the rack guide spring cap, using the following SST. SST: 09612-10020-000 (Width across flats: 24 mm) 42 mm 11.
  • Page 717 SR–22 19. Removal of rack and cylinder side rack oil seal (1) Insert a 20 mm-dia. bar or a suitable tool from the rack housing side. Remove the cylinder side rack oil seal and rack together, using a press. (2) Remove the oil seal from the rack. JSR00073-00067 20.
  • Page 718 SR–23 24. Remove the seal rings of the power steering control valve Seal ring sub-assembly by cutting them by means of a cutter or the like. NOTE: · When cutting the seal rings, be very careful not to scratch the seal ring grooves and side surface. JSR00078-00072 INSPECTION Power steering rack...
  • Page 719 SR–24 Rack housing assembly Check to see if the turn pressure tube attaching hole is not clogged or scored. Check that the external and inner sections exhibit no major scores and dents. If any damage is exists, replace the damaged part with new one.
  • Page 720 SR–25 NOTE: · Do not expand the seal ring excessively. When attaching the ring, apply power steering fluid to the seal ring. Be very careful not to twist the seal ring during the in- stallation. Also, at most care must be exercised so as not to scratch the ring by your finger nails during the in- stallation.
  • Page 721 SR–26 (3) Installation of rack cover tube Rack Cover Tube (SST): 09612-87101-000 q Prepare the rack cover tube and a sheet of paper. NOTE: · The rack cover tube is used to protect the oil seal. Any damage on the tube surface will cause oil leakage. Therefore, prior to use, be sure to check that no burr nor cracks are present at the tube surface before it is contracted.
  • Page 722 SR–27 u Turn the rack cover tube 180 degrees. i Contract the rack cover tube at the back side of the tooth with a dryer in the same manner with the operation above. o Pull out the paper installed to the power steering rack sub-assembly.
  • Page 723 SR–28 4. Install the rack into the cylinder. 5. Installation of cylinder tube side rack oil seal (1) Put the rack housing in a vice, using the following SST. SST: 09612-00012-000 (2) Install the cylinder tube side oil seal to the rack. (3) Install a new O-ring to the cylinder end stopper.
  • Page 724 SR–29 (3) Hold the seal rings attached to the control valve sub- assembly with your fingers and contract it so that the rings may be bedded in. NOTE: · Be very careful not to scratch the edge surface and outer periphery of the ring by your finger nails. JSR00104-00097 (4) Apply power steering fluid to the seal rings again.
  • Page 725 SR–30 (5) Insert the control valve to the control valve housing. NOTE: · To prevent the oil seal damage, wind a vinyl tape on the serration part of the control valve shaft. (6) Install the oil seal to the control valve shaft. (7) Install the bearing guide nut, using the following SST.
  • Page 726 SR–31 (3) Move the steering rack one or two times in the full stroke by turning the control valve shaft, using the fol- lowing SST, so that steering rack may be bedded in. SST: 09616-00010-000 NOTE: · Make sure that the rack end surface will not enter into each end surface of the rack housing sub-assembly.
  • Page 727 SR–32 16. Check the rack hole. JSR00118-00112 17. Attach a new claw washer to the steering rack in the direc- tion indicated in the right figure. NOTE: · Be sure to align the pawl of the claw washer with the cut-out section of the steering rack.
  • Page 728 SR–33 21. Install new steering rack boot bands to the steering rack housing sub-assembly. 22. Install the steering rack boots to the steering rack end sub-assembly. 23. Stake the installed steering rack boot bands. JSR00123-00117 24. Install the clips to the steering rack end sub-assembly. CAUTION: ·...
  • Page 729 SR–34 30. Install the tie rod ends to the steering rack ends according Mating mark to the mating marks that were put during the removal, ex- cept for the installation of a new part. Tighten the nut to the specified torque. Tightening Torque: 59.8 - 89.2 N·m (6.1 - 9.1 kgf-m)
  • Page 730 SR–35 10. Fill the power steering fluid. (See page SR–3.) 11. Perform the air bleeding. (See page SR–4.) 12. Adjust the wheel alignment. (Refer to the FS section.) JSR00133-00000...
  • Page 731 SR–36 VANE PUMP COMPONENTS : Tightening torque Unit : N·m (kgf-m) 39.2 - 49.0 (4.0 - 5.0) 34.3 - 49.0 (4.0 - 5.0) q Vacuum hose w Pressure feed hose e Return tube r Air control valve t Drive belt y Collar u Vane pump assembly JSR00134-00127...
  • Page 732 SR–37 6. Remove the adjusting bolt, collar and plate nut. NOTE: · While removing the adjusting bolt, be very careful not to drop the spacer and the plate nut on the floor. 7. Remove the vane pump mounting bolt. 8. Remove the vane pump drive belt. 9.
  • Page 733 SR–38 AIR CONTROL VALVE Check that the external section exhibits no major scores and dents. For operation check, see page SR–7. If any damage is exists, replace the damage part with new one. JSR00142-00135 VANE PUMP PULLEY Check that the external section exhibits no major scores and dents.
  • Page 734 SR–39 6. Install the pulley to the vane pump. Tightening Torque: 33 - 53 N·m (3.4 - 5.4 kgf-m) JSR00147-00140 7. Temporarily install the vane pump with the vane pump mounting bolt. 8. Install the vane pump drive belt. (Refer to the SR–2.) 9.
  • Page 735 SR–40 SERVICE SPECIFICATIONS Item Specified value Remarks Vane pump When new belt is used: 8 - 11 mm drive belt When pushed with a force of 98 N tension When used belt is used: 11 - 14 mm Hydraulic pressure generated With oil pressure gauge valve +0.5 MPa (55...
  • Page 736 SR–41 SSTs Shape Part No. Part name 09611-87701-000 Tie-rod end puller 09990-87704-000 P/S pressure gauge 09612-00012-000 Rack and pinion steering rack housing stand 09633-00020-000 Power steering hose nut wrench 09922-10010-000 Steering rack end wrench 09617-22030-000 Worm bearing adjusting screw lock nut wrench 09612-10020-000 Hexagon wrench 09616-00010-000...
  • Page 737 SR–42 Shape Part No. Part name 09630-24013-000 Steering rack oil seal tool set 09620-24030-000 Valve cap bearing replacer 09631-20070-000 Seal ring guide 09631-20081-000 Seal ring tool 09631-20060-000 Bearing guide nut wrench 09631-22070-000 Oil seal replacer 09631-12071-000 Steering rack oil seal test tool 09612-87101-000 Rack tube cover JSR00151-00143...
  • Page 738 SR–43 TIGHTENING TORQUE Components N·m kgf-m Steering wheel ´ Steering shaft 25.7 - 41.2 2.8 - 4.2 Steering Wheel ´ Steering wheel pad (Air bag type) 5.2 - 9.5 0.53 - 0.97 Steering column ´ Instrument panel reinforthment (bolt) 14.7 - 21.6 1.5 - 2.2 Steering column ´...
  • Page 739 DAIHATSU J100 TO INDEX BODY ALIGNMENT ADJUSTMENTS ....BO– 2 FRONT BUMPER ........BO– 7 FRONT FENDER ........BO–11 REAR BUMPER .......... BO–13 FENDER LINER .......... BO–16 HOOD & HOOD LOCK CONTROL CABLE ............ BO–18 FUEL LID OPENER ........BO–22 ROOF DRIP MOLDING .......
  • Page 740 BO–2 ALIGNMENT ADJUSTMENTS q Specified value y Specified value 4.4 ± 1.5 mm 5.2 ± 1.5 mm Gap: Gap: Lateral deviation: Not to exceed 1.5 mm Lateral deviation: Not to exceed 1.5 mm 5.9 ± 1.5 mm Difference between right and left sides: Difference in height: u Specified value Not to exceed 1.5 mm...
  • Page 741 BO–3 1. Gap adjustment Engine hood (1) Loosen the bolts attaching the engine hood to the en- gine hood hinge and adjust the engine hood alignment to the specified value mentioned below. Specified Value: 4.4 ± 1.5 mm Gap: Difference Between Right and Left Sides: Not to exceed 1.5 mm Lateral Deviation: Not to exceed 1.5 mm...
  • Page 742 BO–4 2. Adjustment of difference in height Front (1) Front/Rear door hinge side. q Loosen the bolts attaching the door to the door hinges. w Perform the adjustment by changing the attaching position of the front door to the door hinges. e Tighten the bolts attaching the door to the door hinge.
  • Page 743 BO–5 ADJUSTMENT OF BACK DOOR ALIGNMENT q Specified value Door hinge section 10.4 ± 2.0 mm Gap: Lateral deviation: Not to exceed 2.0 mm 1.8 ± 2.0 mm Difference in height: w Specified value 2.0 ± 1.5 mm Gap: Lateral deviation: Not to exceed 1.5 mm 1.5 ±...
  • Page 744 BO–6 2. Adjustment of difference in height (1) Remove the rear bumper. (Refer to the rear bumper section.) (2) Remove the right hand side rear combination lamp. (3) Remove the rear bumper filler by removing the attach- ing bolts. (4) Loosen the attaching bolts of the back door lock strik- (5) Adjust the difference in height by changing the attach- ing position of the back door lock striker.

  • Page 745: Front Bumper

    BO–7 FRONT BUMPER COMPONENTS q Front bumper cover !1 Front turn signal lamp lens w Front bumper guard base No. 1 bracket !2 Bulb e Front bumper guard right bracket !3 Front fog & turn lamp assembly r Front bumper guard left bracket !4 Turn cord t No.
  • Page 746 BO–8 REMOVAL 1. Removal of front fog & turn signal lamp assembly (Only for front bumper guard garnish equipped model.) (1) Remove the fog lamp attaching screws. (2) Remove the fog lamps by disconnecting its connec- tors. JBO00015-00015 2. Remove the under fender bracket by removing the attach- ing tapping screw and clip.
  • Page 747 BO–9 5. Remove the attaching bolts of the front bumper cover. (On model without the front bumper guard garnish.) 6. Remove the front bumper cover. (On model without the front bumper guard garnish.) 7. Remove the front bumper bar reinforcement by removing the attaching bolts.
  • Page 748 BO–10 7. Installation of radiator grill (1) Ensure that the clips and retainer are installed properly. Also, ensure that no damage exists. If any damage exists or the clip or retainer is missing, replace the clips or retainer with a new one. (2) Install the radiator grill by connecting the retainer and four clips.

  • Page 749: Front Fender

    BO–11 FRONT FENDER COMPONENTS q Hood subassembly w Hood silencer e Clip r Headlamp cover to hood seal (R, L) t Clip y Hood to front end panel seal u Hood front protector i Front fender subassembly (R, L) o Front fender liner !0 Clip !1 Over fender JBO00024-00023...
  • Page 750 BO–12 4. Remove the over fender from the fender panel by discon- necting the retainers while retracting the lock section, using a nosepliers or the like. 5. Remove the side turn signal lamp. 6. Remove the front fender subassembly by removing the five attaching bolts.

  • Page 751: Rear Bumper

    BO–13 REAR BUMPER COMPONENTS !0 !1 q Rear bumper cover u Quarter panel mudguard subassembly w License plate bracket base i Back-up lamp and/or rear fog lamp e Rear bumper filler o Rear combination lamp socket r Rear bumper right protector !0 Bulb t Lower back panel cover !1 Rear lamp lens...
  • Page 752 BO–14 4. Remove the license plate lamps by retracting the lock sections of the license plate lamps from the rear bumper cover. 5. Disconnect the license plate lamps from the connectors. JBO00031-00029 6. Remove the rear bumper cover and license plate bracket base (when equipped) by removing the eight attaching bolts.
  • Page 753 BO–15 INSTALLATION NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered. 1. Install the rear bumper filler with the two attaching bolts. 2.
  • Page 754 BO–16 FENDER LINER COMPONENTS q Front fender liner w Clip e Front fender mudguard subassembly r Grommet t Front bumper bracket JBO00037-00034 REMOVAL 1. Remove the front fender mudguard subassembly by re- moving the three attaching bolts. JBO00038-00035 2. Remove the under fender bracket by removing the grom- met and tapping bolt.
  • Page 755 BO–17 3. Remove the screw grommet for the tapping bolts by cut- ting off the hem section of the grommet as shown. Screw grommet JBO00040-00037 4. Remove the ten screw type grommets by screwing them out. 5. Remove the front fender liner. JBO00041-00038 INSTALLATION NOTE:...
  • Page 756 BO–18 HOOD & HOOD LOCK CONTROL CABLE COMPONENTS q Hood lock control cable assembly w Hood lock assembly e Hood hinge assembly (R, L) r Hood support rod t Hood support clamp y Clip JBO00043-00039 Removal of engine hood 1. Disconnect the window washer hose from the window washer nozzle(s), clamps of the engine hood and clamp.
  • Page 757 BO–19 3. Remove the insulator, the hood-to-front end panel seal and the head lamp cover-to-hood seal by removing the attach- ing retainers. JBO00046-00042 4. Place cloths under the engine hood in order to prevent the painted surface from being damaged. 5.
  • Page 758 BO–20 Removal of hood lock and hood lock control cable 1. Remove the radiator grill. (Refer to the front bumper section.) 2. Remove the front fender liner. (Refer to the front fender liner section.) 3. Removal of hood lock assembly (1) Remove the three attaching bolts of the hood lock as- sembly.
  • Page 759 BO–21 Installation of hood lock and hood lock control cable NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered.
  • Page 760 BO–22 FUEL LID OPENER COMPONENTS A or B section A (RHD) Right Front B (LHD) Floor carpet Center pillar lower garnish Harness Right Inside Front G sectional view E sectional view Front Right Harness Harness Front F section K and L C and D sectional view sectional view...
  • Page 761 BO–23 REMOVAL 1. Remove the front driver’s seat. (Refer to the front seat sec- tion.) 2. Remove the rear seat. (Refer to the rear seat section.) (Left hand drive vehicle only.) 3. Remove the right side rear door scuff plate assembly. (Refer to the trim &...
  • Page 762 BO–24 ROOF DRIP MOLDING COMPONENTS q Roof drip side finish right molding w Roof drip side finish left molding JBO00059-00053 REMOVAL 1. Remove the rear combination lamp. Retainer 2. Removal of roof drip molding Pull up the roof drip molding from the rear side gradually. Then remove the molding by pulling it backward to disen- gage the retainer on the molding from the pin on the roof panel.
  • Page 763 BO–25 ROOF RAIL & ROOF END SPOILER COMPONENTS q Right roof rack assembly w Clip e Rear right roof rack assembly r Clip t Left roof rack assembly y Rear spoiler subassembly u Stop center lamp assembly i Rear spoiler No. 1 cover JBO00062-00055 REMOVAL Hexagon wrench...
  • Page 764 BO–26 : Tightening torque Unit : N·m (kgf-m) Vehicles not equipped with roof end spoiler q Roof rack subassembly (front side) w Roof rear rack subassembly e Roof rack assembly 7.1 ± 1.1 (0.7 ± 0.1) Vehicles equipped with roof end spoiler q Roof rear rack subassembly w Rear spoiler subassembly e Roof rack assembly...
  • Page 765 BO–27 INSTALLATION NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered. 1. Install the three clips to the rear spoiler subassembly. (Model equipped with rear spoiler.) 2.

  • Page 766: Removable Roof

    BO–28 REMOVABLE ROOF COMPONENTS q Removable roof rock garnish w Removable roof rock handle assembly e Removable roof rock base assembly r Removable roof panel assembly t Removable roof auxiliary left director catch assembly y Roof window deflector panel assembly u Sunroof opening trim molding i Removable roof inner weatherstrip o Removable roof trim...
  • Page 767 BO–29 INSTALLATION NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered. 1. Install the removable roof hinge case with the attaching screws. 2.

  • Page 768: Instrument Panel

    BO–30 INSTRUMENT PANEL COMPONENTS !5 !6 q Instrument panel subassembly !8 Shifting hole flame w Instrument panel center register assembly !9 Console panel e Instrument panel hole No. 3 cover @0 Rear console box assembly r Instrument panel hole No. 2 cover @1 Rear console box support bracket t Instrument panel hole No.
  • Page 769 BO–31 REMOVAL 1. Disconnect the battery ground cable terminal from the negative terminal of the battery. 2. Remove the front seats. (Refer to the front seat section.) 3. Removal of console box assembly (1) Remove the rear console box assembly by removing the two attaching screws.
  • Page 770 BO–32 10. Removal of combination meter assembly (1) Remove the three attaching bolts. JBO00076-00066 (2) Gradually raise the combination meter assembly. (3) Disconnect the connectors and speedometer cable from the combination meter assembly. NOTE: · Refer to the BE section for more details. (4) Remove the combination meter.
  • Page 771 BO–33 13. Remove the three attaching screws of the heater control panel assembly. 14. Disconnect the connector of the wire harness from the radio tuner or cassette player. 15. Disconnect the antenna cable from the radio tuner. 16. Remove the radio tuner opening cover, radio tuner or cas- sette player by removing the attaching screws.
  • Page 772 BO–34 21. Remove the instrument panel subassembly by removing the attaching bolts. If any difficulty is encountered in removing the attaching bolt of the rear hood lock control handle attaching bracket of the instrument panel, prior to the removal of the instru- ment panel, remove the hood lock control handle bracket by removing the two attaching bolts.
  • Page 773 BO–35 26. Remove the register assembly No. 2 of the instrument panel by unlocking the lock section on the instrument panel assembly. CAUTION: · Do not enlarge the attaching portion of the instrument panel more than necessary to remove the register. 27.
  • Page 774 BO–36 9. Connect the connector of the wire harness to the connector of the front passenger airbag. WARNING: · Be sure to refer to the instruction in the BE section. Failure to observe this warning may lead to seri- ous trouble or malfunction. 10.

  • Page 775: Front Seat

    BO–37 FRONT SEAT COMPONENTS : Tightening torque Unit : N·m (kgf-m) Right side 25.4 ± 4.9 (2.5 ± 0.5) JBO00094-00082 REMOVAL 1. Disconnect the seat belt warning light switch connector. (Only for seat belt warning-equipped vehicle) 2. Move the front seat to the most rearward position. 3.
  • Page 776 BO–38 INSTALLATION 1. Place the front seat on the attaching surface on the floor while aligning the protrusions of the front seat with the holes on the floor panel. 2. Install the attaching bolts temporarily. 3. Move the front seat to the most forward position and tighten the attaching bolts temporarily. CAUTION: ·...

  • Page 777: Rear Seat

    BO–39 REAR SEAT COMPONENTS : Tightening torque Unit : N·m (kgf-m) 19.5 ± 4.5 (2.0 ± 0.5) 5.5 ± 1.5 (0.6 ± 0.2) 19.5 ± 4.5 (2.0 ± 0.5) 19.5 ± 4.5 (2.0 ± 0.5) JBO00098-00085 REMOVAL 1. Remove the rear seat cushion by removing the two attaching bolts. 2.

  • Page 778: Seat Belt

    BO–40 SEAT BELT FRONT SEAT BELT 9 ± 2 (0.9 ± 0.2) : Tightening torque Unit : N·m (kgf-m) 40.5 ± 12.5 (4.2 ± 1.3) 2.5 ± 1.0 (0.3 ± 0.1) öŸ If the threaded portion is damaged, øŸ use an oversized ET screw. 40.5 ±...
  • Page 779 BO–41 INSPECTION 1. Ensure that the seat belt will not be locked until the seat 45¡ belt retractor is tilted more than 15 degrees in all direc- tions from the installed angle. Also, ensure that the locked state is retained when the re- tractor is tilted 45 degrees or more.

  • Page 780: Rear Seat Belt

    BO–42 REAR SEAT BELT : Tightening torque 40.5 ± 12.5 (4.2 ± 1.3) Unit : N·m (kgf-m) 40.5 ± 12.5 (4.2 ± 1.3) 40.5 ± 12.5 (4.2 ± 1.3) Turning-preventive beads 40.5 ± 12.5 (4.2 ± 1.3) öŸ Tightening should be made, aligning øŸ...
  • Page 781 BO–43 INSPECTION 1. Ensure that the seat belt will not be locked until the seat 45¡ belt retractor is tilted more than 15 degrees in all direc- tions. Also, ensure that the locked state is retained when the re- tractor is tilted 45 degrees or more. 2.

  • Page 782: Front Door

    BO–44 FRONT DOOR COMPONENTS : Non-reusable parts POWER WINDOW POWER LOCK q Front door glass subassembly @0 Front door glass outer weatherstrip w Front door glass run @1 Front door outside handle assembly e Front door outside panel @2 Front door lock link No 1 silencer r Front door panel subassembly @3 Front door open control link assembly t Front door front lower frame subassembly...
  • Page 783 BO–45 DISASSEMBLY 1. Unlock the shaft snap ring of the front door window handle assembly by inserting a piece of cloth between the handle and the door vent window control handle plate. Then, pull the inserted cloth alternately so as to unlock the shaft snap ring.
  • Page 784 BO–46 13. Remove the front door inside handle subassembly by dis- connecting the front door open control link. 14. Remove the door trim bracket by removing the attaching screws. 15. Remove the speaker by removing the three attaching screws. (Only when equipped.) 16.
  • Page 785 BO–47 23. Remove the front door glass subassembly. JBO00121-00103 24. Disconnect the connector of the front door wire harness from the power window motor. (For model equipped with power window) 25. Remove the front door window regulator subassembly by removing the attaching bolts. 26.
  • Page 786 BO–48 30. Remove the cowl side trim board. (Refer to the trim & gar- nish section.) 31. Disconnect the connector of the wire harness (cowl wire) from the connector of the wire harness (front door wire). 32. Disconnect the various clamps of the wire harness from the front door.
  • Page 787 BO–49 ASSEMBLY NOTE: · Basically the assembling procedure is reverse to the disassembling procedure. Therefore, illustra- tions are not mentioned in this assembling procedure. Refer to the illustrations in the disassembling procedure in cases where any difficulty is encountered. 1. Install the front door upper and lower hinges to the front door with the attaching bolts. 2.
  • Page 788 BO–50 19. Install the power window control switch by installing the attaching bolt. (For power window-equipped model.) 20. Install the door control lock knob holder to the front door trim panel assembly. JBO00130-00000 21. Installation of front door service hole cover (1) Affix a butyl tape at the groove provided around the front door panel, as shown.
  • Page 789 BO–51 22. Install the door trim bracket with the attaching screws. 23. Connect the front door inside handle subassembly to the front door open control link. 24. Installation of outside rear view mirror (1) Install the outside rear view mirror with the three attaching nuts. (2) Connect the connector of the front door wire harness to the connector of the remote control mirror.

  • Page 790: Rear Door

    BO–52 REAR DOOR COMPONENTS : Non-reusable parts POWER LOCK q Rear door glass subassembly !7 Rear door locking control link subassembly w Rear door glass outer weatherstrip !8 Rear door locking link clamp e Rear door glass run !9 Rear door locking silencer r Rear door outside panel @0 Rear door lock link clamp t Rear door panel subassembly...
  • Page 791 BO–53 DISASSEMBLY Removal of rear door trim panel assembly 1. Unlock the shaft snap ring of the rear door window regula- tor handle assembly by inserting a piece of cloth between the rear door window regulator handle and the door vent window control handle plate.
  • Page 792 BO–54 14. Disconnect the rear door harness clamp from the door panel. (For the central door lock and/or speaker-equipped vehi- cle.) 15. Disconnect the connector of the rear door wire harness from the door control motor assembly. (For the central door lock and/or speaker-equipped vehi- cle.) JBO00139-00118 16.
  • Page 793 BO–55 20. Remove the rear door glass outer weatherstrip from the rear door panel by disconnecting the rear door glass weatherstrip clip from the rear door panel. 21. Remove the rear door glass run. 22. Remove the rear door window regulator handle assembly by removing the attaching bolts.
  • Page 794 BO–56 31. Remove the center pillar lower garnish. (Refer to the trim & garnish section.) (Only for model equipped with central door lock and/or speaker.) 32. Disconnect the connector of the rear door wire from the wire harness. (Only for model equipped with central door lock and/or speaker.) 33.
  • Page 795 BO–57 15. Install the rear door glass outer weatherstrip to the rear door panel by connecting the rear door glass weatherstrip clip to the rear door panel. 16. Install the rear door regulator subassembly with the attaching bolts. 17. Install the rear door window regulator handle temporarily. 18.
  • Page 796 BO–58 27. Install the door trim No. 1 bracket with the attaching bolts. 28. Connect the rear door inside handle subassembly to the rear door open control link assembly. 29. Ensure that the retainers are installed on the back side of the rear door trim panel assembly properly. 30.

  • Page 797: Back Door

    BO–59 BACK DOOR COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 19.6 - 29.4 (2.0 - 3.0) 6.9 - 15.7 (0.7 - 1.6) q Back door weatherstrip !7 Back door handle assembly w Retainer !8 Back door lock assembly e Back door trim board !9 Door lock striker plate assembly r Back door service hole cover...
  • Page 798 BO–60 DISASSEMBLY 1. Removal of spare wheel (1) Remove the spare wheel by removing the attaching bolts. (2) Remove the spare wheel cover tray by removing the four attaching bolts. (For model equipped with spare wheel carrier.) JBO00154-00131 (3) Remove the spare wheel carrier assembly by remov- ing the four attaching bolts.
  • Page 799 BO–61 5. Disconnect the connectors of the rear wiper motor and door lock control switch. (Only for models equipped with such equipment. Refer to the BE section for the removal procedure.) 6. Remove the rear wiper motor by removing the attaching bolts.
  • Page 800 BO–62 19. Remove the back door check assembly by removing the attaching bolts. JBO00164-00141 20. Remove the right hand side rear combination lamp and rear bumper filler. (Refer to the rear bumper section) 21. Remove the back door by removing the attaching bolts of the back door hinge.
  • Page 801 BO–63 15. Install the rear wiper motor with the attaching bolts. (Only for rear wiper-equipped model. Refer to the BE section for the installation procedure.) 16. Connect the connectors of the rear wiper motor and door lock control switch. (Only for models equipped with such equipment. Refer to the BE section for the installation procedure.) JBO00166-00000 17.
  • Page 802 BO–64 TRIM & GARNISH COMPONENTS !5 (CL) !5 (CX) q Front pillar garnish (R, L) !1 Center pillar lower garnish (R, L) w Retainer !2 Rear door scuff plate assembly (R, L) e Center pillar upper garnish (R, L) !3 Deck side trim (R, L) r Roof side inner garnish (R, L) !4 Lower back trim t Clip...
  • Page 803 BO–65 REMOVAL 1. Remove the front and rear seats. (Refer to the front and rear seat section.) 2. Removal of front door scuff plate (1) Disconnect the four retainers provided under the scuff plate by pulling them up straight. (2) Remove the front scuff plate. JBO00170-00145 3.
  • Page 804 BO–66 8. Removal of front pillar garnish (1) Disconnect the clips provided on the back side of the front pillar garnish, using a clip remover or the like. (2) Remove the front pillar garnish. JBO00175-00150 9. Removal of lower back trim (1) Unlock the clips by pushing the central part of the clips one notch.
  • Page 805 BO–67 15. Removal of inner rear-view mirror assembly and visor as- sembly (1) Disconnect the visor assembly from the visor holder. (2) Remove the visor assembly by removing the two at- taching screws. (3) Remove the visor holder by removing the attaching screws.
  • Page 806 BO–68 INSTALLATION NOTE: · Basically the assembling procedure is reverse to the disassembling procedure. Therefore, some il- lustrations are not mentioned in this assembling procedure. Refer to the illustrations in the disassem- bling procedure in cases where any difficulty is encountered. 1.
  • Page 807 BO–69 11. Install the deck board assembly by installing the attaching bolts. 12. Installation of lower back trim (1) Place the lower back trim in position. (2) Push back the central part of the retainer one click from the position where the central part is flush with the outer part.
  • Page 808 BO–70 WINDOWS COMPONENTS q Windshield glass dam w Windshield glass e Windshield outside molding r Cowl top ventilator louver (R, L) t Hood to cowl top weatherstrip y Windshield glass stopper JBO00184-00157 REMOVAL 1. Preparation prior to removal (1) Remove the front pillar garnish & roof headlining. (Refer to the trim & garnish section.) (2) Remove the instrument panel.
  • Page 809 BO–71 2. Cut off the windshield glass adhesive by a cutter knife or the like to make a small hole, in order to pass a piano wire through the hole. CAUTION: · Be very careful not to damage the paint surface and windshield by the cutter knife or the like.
  • Page 810 BO–72 INSTALLATION 1. Affix locating stoppers to the windshield glass as shown in the figure below. Align both ends with cut-out sections. Unit: mm JBO00190-00162 Affix a windshield glass dam of the windshield glass to the position shown in the figure below. 3.
  • Page 811 BO–73 5. Install the glass, using suction rubbers. Push the entire glass surface lightly so that the glass may fit completely. NOTE: · At this time, assembling should be performed while the marks of the tinted section of the glass are aligned with the windshield glass stoppers.
  • Page 812 BO–74 QUARTER WINDOW GLASS COMPONENTS : Non-reusable parts q Quarter window glass w Quarter window glass molding e Quarter window glass clip r Quarter window glass spacer JBO00195-00166 REMOVAL Protective 1. Preparation prior to removal tape (1) Remove the roof side inner garnish. (Refer to the trim &...
  • Page 813 BO–75 3. Pass a piano wire through the adhesive agent. 4. Hold both ends of the piano wire by pliers or the like and cut off the adhesive by pulling the piano wire one side to the other. NOTE: · Some parts are hard to be cut off, because spacers or retainers are built in between the glass and the body panel.
  • Page 814 BO–76 2. Affix the quater window glass molding to the quater window with a two-faced tape. 3. Affix the spacers in position as shown in the figure below. 4. Apply the primer for the window frame or window to under the adhesive agent applying portion if the adhesive agent has been removed completely.
  • Page 815 BO–77 BACK DOOR WINDOW COMPONENTS : Non-reusable parts Back door trim board Back door hinge cover Back door glass r-1 Back door glass adhesive dam (On vehicles without spoiler) r-2 Back door upper weatherstrip (On vehicles with spoiler) Back window glass clip Back window glass spacer JBO00203-00173 REMOVAL...
  • Page 816 BO–78 (6) Protection for paint surface around windows Protective tape Protect the paint surface around the windows by ap- plying a protective tape or the like. CAUTION: · To protect the paint surface, be sure to apply a protec- tive tape to the inside of the edge (groove around the window attaching surface) as far as it will go.
  • Page 817 BO–79 INSTALLATION 1. Affix the clips of the back door window glass as follows. (1) Install the clips to the holes on the back door panel. (2) Remove the protective sheet of the clip. (3) Place the back door window glass to the body in such a location as shown. (4) Ensure that the clips are sticked to the back door window glass.
  • Page 818 BO–80 2. Affix the spacers in position as shown in the figure below. 3. Affix the dam in position as shown in the figure below. 4. Apply the primer for the window frame and/or window to under the adhesive agent applying portion if the adhesive agent has been removed completely.
  • Page 819 BO–81 9. Install the roof side inner garnish. (Refer to the trim & garnish section of the service manual.) 10. Ensure that no water leakage exists. If any water leakage is found, repair it, as required, or refit the quarter window glass. NOTE: ·...

  • Page 820: Fuel Tank

    BO–82 FUEL TANK COMPONENTS 2.5 - 5.0 (0.25 - 0.5) : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 2.5 - 5.0 (0.25 - 0.5) 2.5 - 5.0 (0.25 - 0.5) q Drain plug w Fuel tube (emission) e Fuel tube (return) r Fuel tube (main) t Fuel tank sub inlet hose y Breather hose...
  • Page 821 BO–83 (4) Install the fuel drain plug with new gasket interposed and tighten it to specified tightening torque. (When fuel tank is reused.) Tightening torque: 65 N·m (0.66 kgf-m) Gasket CAUTION: · Be sure to clean the gasket attaching surface of fuel tank and fuel drain plug before installation.
  • Page 822 BO–84 9. Disconnect the connector of the wire harness from the fuel pump with motor and bracket located upper side of fuel tank while unlocking the lock on the connector. JBO00223-00190 10. Support the fuel tank with suitable jack or bench. 11.
  • Page 823 BO–85 13. Remove the fuel pump assembly and gasket by removing the attaching screws evenly CAUTION: · Never reuse the removed gasket again. Failure to ob- serve this caution may cause to fire. JBO00228-00195 14. Remove the fuel hose from the check valve by removing the hose clamp.
  • Page 824 BO–86 2. Inspection of the check valve (1) Connect the suitable rubber hose to check valve. (2) Ensure that the air continuity is exists when check valve in installed angle. If no air continuity is exists, replace the check valve with new one.
  • Page 825 BO–87 7. Connection of the fuel hoses to fuel pump assembly (1) Connection of the fuel main tube q Clean the fuel main pipe on the fuel pump assem- bly. w Apply the few drops of engine oil to the fuel pipe. e Connect the new fuel hose to the fuel pipe until clicking sounds emits from the retainer.
  • Page 826 BO–88 t Hold the checker as shown and connect the nail sections of checker to the quick connector. y Ensure that the connector is connected properly by pull the connector from the fuel pipe lightly. (4) Connect the fuel return tube to the fuel pipe clamps installed on the fuel tank securely.
  • Page 827 BO–89 13. Install the shut valve to the fuel inlet securely. 14. Connect the fuel tank sub inlet hose with new hose band to the fuel tank temporary. 15. Install the fuel tank to the floor panel with the four attach- ing bolts and tighten the attaching bolts to specified tight- ening torque evenly while supporting the fuel tank with suitable stand or the like.
  • Page 828 BO–90 REMOVAL OF FUEL INLET CAUTION: · Be sure to drain the fuel from the fuel tank before re- moving the fuel inlet when fuel filled-up more than half in the fuel tank. 1. Remove the fuel tank cap assembly. 2.

  • Page 829: Accelerator Pedal

    BO–91 ACCELERATOR PEDAL COMPONENTS q Accelerator cable w Accelerator pedal e Accelerator pedal support bracket r Bush t Accelerator link rod return spring y Cushion u Clamp i Clamp o Clamp JBO00248-00214 INSPECTION OF ACCELERATOR PEDAL Ensure that the accelerator pedal operates smoothly without being caught or interference. If any problem is found, replace the damaged accelerator pedal related part, as required.
  • Page 830 BO–92 INSTALLATION 1. Install the accelerator cable assembly and connect the cable to the throttle body side (Refer to the EM section of the service manual.) 2. Install the accelerator pedal assembly to the floor panel with attaching bolts and tighten the attaching bolts to the specified tightening torque.

  • Page 831: Exhaust Pipe

    BO–93 EXHAUST PIPE COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 24.0 - 56.4 (2.45 - 5.75) q Tail pipe assembly w Exhaust front pipe assembly e Exhaust pipe support bracket No. 1 15.2 - 22.8 r Exhaust pipe gasket (1.6 - 2.3) t Muffler support No.
  • Page 832 BO–94 ENGINE MOUNTING INSULATOR COMPONENTS : Tightening torque Unit : N·m (kgf-m) 34.3 - 61.8 34.3 - 61.8 (3.5 - 6.3) 7 ± 3 mm (3.5 - 6.3) RH 7.5 –2.5 LH 5.5 –2.5 21.6 - 39.2 (2.2 - 4.0) 21.6 - 39.2 (2.2 - 4.0) REAR...
  • Page 833 BO–95 INSPECTION Ensure that the clearance of each mounting is within the specified value, as shown in the figure. If the clearance fails meet with the specified value mentioned in the figure, replace the part with a new one or adjust the clearance by changing the attaching position. REMOVAL/INSTALLATION 1.
  • Page 834 BO–96 TIGHTENING TORQUE Tightening torque determination procedure for general standard bolts and nuts 1. Tightening torque determination procedure for bolts Determine the strength division of the bolt concerned from the table below. Then, locate the tightening torque in the tightening torque table. 2.

  • Page 835: Body Electrical System

    DAIHATSU J100 TO INDEX BODY ELECTRICAL SYSTEM GENERAL DESCRIPTION ......BE– POWER SUPPLY ........BE– IGNITION KEY SWITCH ......BE– COMBINATION METER ......BE– HEAD LAMP ..........BE– 15 HEAD LAMP LEVELING ......BE– 18 FRONT FOG LAMP ........BE– 19 STOP LAMP ..........
  • Page 836 BE–2 GENERAL DESCRIPTION HANDLING PRECAUTION General instructions 1. Never pull the connectors or step on them during the wire harness transport or assembly. (Prevention of pulling-out of terminals, connector cracks, deformation and so forth.) JBE00002-00002 2. Care must be exercised to ensure that no scratch is made to the wire harness by burrs or edges during the wire har- ness transport or assembly.
  • Page 837 BE–3 4. Terminals and connectors Perform the connection of connectors positively. Connector with lock; Ensure that the locking is made. Connector without lock; Connect the connector positively until it stops. JBE00007-00007 Retention by screws · When the tightening torque is specified, be sure to ob- serve the specification strictly.
  • Page 838 BE–4 WARNING: · The wire diameter and capacity of each harness have been determined to assure the normal operation of the electrical system. · Hence, do not take power for accessories carelessly through the original wiring harness. Failure to observe this caution may cause system malfunction or fire.
  • Page 839 BE–5 Double lock type 2nd lock The double lock type connector has been adopted for air bag Spring system to prevent unexpected troubles such as poor connect- ing. NOTE: · Disconnection and connection of each connector lock should be kept at a minimum level. If unnecessary dis- connection or connection is repeated, it may cause un- expected troubles such as poor continuity and chatter- ing.

  • Page 840: Power Supply

    BE–6 POWER SUPPLY JUNCTION BLOCK The junction block assembly is located underneath the steering post at the driver’s seat side. Horn, Hazard (Sub) Horn +B Front turn lamp RH Side turn lamp RH Flasher Head lamp Hi RH relay Head lamp Lo RH socket Clearance lamp RH Head RH 10 A...
  • Page 841 BE–7 RELAY BLOCK The relay block is located near the battery in the engine compartment. q Heater w Back-up e EFI r Horn-Hazard t Magnet clutch 10A FUEL y Fuel pump relay PUMP u Starter relay (for A/T) i EFI main relay ( S T ) o Heater relay !0 Magnet clutch relay (for air conditioner)
  • Page 842 BE–8 IGNITION KEY SWITCH WIRING DIAGRAM Ignition SW IG No. 1 IG No. 2 Main To Starter JBE00022-00201 Removal 1. Turn off the ignition key switch. 2. Disconnect the battery ground cable from the negative (–) terminal of the battery. 3.
  • Page 843 BE–9 COMBINATION METER CONSTRUCTION q Meter assy, Combination w Glass, Front e Plate, window r Gauge, water temperature & Fuel t Speedometer y Tachometer u Plate, Circuit meter JBE00025-00301...
  • Page 844 BE–10 WIRING DIAGRAM Illumination Starter relay coil Air bag Air bag ECU warning circuit EFI ECU Seat belt SW EFI ECU ABS ECU Oil pressure SW Tail Tail Parking brake SW AUS. only Brake fluid level SW Gauge Alternator L J/B earth Rear fog switch EC only...
  • Page 845 BE–11 Removal of combination meter 1. Pull of the hazard warning switch knob. 2. Remove the instrument cluster finish panel from the instru- ment panel by removing the screws. 3. Remove the attaching screws of the combination meter assembly. 4. Disconnect the speedometer cable and wire harness cou- pler at the back side of the combination meter assembly.
  • Page 846 BE–12 FUEL SENDER GAUGE 1. Jack up the vehicle. 2. Disconnect the connector of the wire harness from the sender gauge/fuel pump assembly by the fuel tank. H23 H57 3. Connect a circuit tester between the terminal H23 and ½ H57.
  • Page 847 BE–13 4. Remove the combination meter, measure the resistance With tachometer between the terminals. B7 - B9: approx. 54 W Resistance: B7 - B10: approx. 177 W B9 - B10: approx. 231 W JBE00037-00313 WATER TEMPERATURE SENDER GAUGE In-Vehicle inspection 1.
  • Page 848 BE–14 LOW OIL PRESSURE WARNING Unit inspection 1. Disconnect the connector from the warning switch. 2. Connect a ohm meter. Ensure that continuity exists be- tween the oil pressure switch terminal and the ground while the engine is stopped, whereas no continuity exists while the engine is running.
  • Page 849 BE–15 HEAD LAMP WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up HRN/HAZ Horn, Hazard 15A IG No. 1 IG No. 2 IG SW MAIN Main Multi-use lever SW Head lamp leveling unit LH Junction block Head lamp leveling SW High beam indicator (Combination...
  • Page 850 BE–16 HEAD LAMP SWITCH (without air bag system) Unit inspection Disconnect the connector for multi-use lever switch. Ensure +2 +1 that continuity exists between the respective terminals in ac- cordance with the following continuity table. D2 D1 F– Without air bag specification (at lighting SW side) JBE00050-00404 JBE00051-00405 Aiming adjustment...
  • Page 851 BE–17 NOTE: Center of · Keep the engine speed at 1500 rpm or more during the Dark side Dark side 15¡ headlamp lens aiming adjustment. (2) Draw a vertical straight line on the screen at each cen- ter of the head lamps on both right and left sides. Thus, establish each intersection “F”...
  • Page 852 BE–18 HEAD LAMP LEVELING WIRING DIAGRAM Head lamp Multi-use lever SW Head lamp leveling unit LH Junction block Head lamp leveling SW High beam indicator (Combination meter ) Head lamp Head lamp LH leveling unit RH Head lamp RH JBE00057-00501 HEAD LAMP LEVELING SWITCH Unit inspection 1.

  • Page 853: Front Fog Lamp

    BE–19 FRONT FOG LAMP WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up Horn, Hazard 15A HRN/HAZ IG No. 1 IG No. 2 IG SW Main MAIN Tail SW (Multi-use lever) Junction block Front fog lamp Front fog lamp LH Front fog lamp LH JBE00060-00601 FRONT FOG LAMP SWITCH...

  • Page 854: Stop Lamp

    BE–20 STOP LAMP WIRING DIAGRAM F/L ABS Head lamp TAIL Back up HRN/HAZ Horn, Hazard 15A IG No. 1 IG No. 2 IG SW Main MAIN Junction block JBE00062-00701 STOP LAMP SWITCH Unit inspection 1. Disconnect the connector of the stop lamp switch. (at the brake pedal arm) 2.

  • Page 855: Back Up Lamp

    BE–21 BACK UP LAMP WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up Horn, Hazard 15A HRN/HAZ IG No. 1 IG No. 2 IG SW Main MAIN Junction block Junction block Buzzer [A/T model] [M/T model] Back-up Back-up Back-up Back-up Indicator lamp LH...

  • Page 856: Rear Fog Lamp

    BE–22 REAR FOG LAMP WIRING DIAGRAM F/L ABS Head lamp TAIL Tail Back up Horn, Hazard 15A HRN/HAZ IG No. 1 IG No. 2 IG SW Main MAIN Junction block Buzzer RF SW (Multi-use lever) Rear fog lamp indicator Rear fog lamp (Combination meter) JBE00068-00901 REAR FOG LAMP SWITCH...
  • Page 857 BE–23 REAR FOG LAMP WARNING BUZZER In-vehicle inspection 1. Ensure if the warning buzzer is set off under the conditions given following table. Ignition Rear fog lamp Front door Buzzer Set off Open — OFF / Acc — Close — JBE00070-00904 —...
  • Page 858 BE–24 TAIL LAMP & LICENSE PLATE LAMP WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up Horn,Hazard HRN/HAZ IG No. 1 IG No. 2 IG SW Main MAIN Junction block Buzzer JBE00073-01001 TAIL LAMP SWITCH R.H.D L.H.D Unit inspection L F–...
  • Page 859 BE–25 INTERIOR LAMP & LUGGAGE ROOM LAMP WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up Horn, Hazard 15A HRN/HAZ F/L AM 60A IG No. 1 IG No. 2 IG SW MAIN Main Buzzer Door JBE00076-01101 INTERIOR LAMP SWITCH Unit inspection 1.
  • Page 860 BE–26 LUGGAGE ROOM LAMP SWITCH Unit inspection 1. Lightly pry the lens to detach it and pull out the bulb straight. 2. Turns on the ignition switch. 3. Ensure if the voltage exists between the terminals when the rear gate is opened. Rear gate open Battery voltage Rear gate close...

  • Page 861: Hazard Warning Switch

    BE–27 HAZARD WARNING & HORN WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up Horn,Hazard HRN/HAZ IG No. 1 IG No. 2 IG SW Main MAIN Multi-use Junction block lever SW Turn / Wiper Turn 20 A Hazard Flasher relay Horn JBE00079-01201 HAZARD WARNING SWITCH...
  • Page 862 BE–28 FLASHER RELAY Unit inspection Flasher relay 1. Remove the combination meter. Then remove the flasher unit at the bracket of the cowl panel. 2. Disconnect the connector of the flasher unit. JBE00081-01211 3. Ensure if the voltage exists the respective terminals at wire harness connector when ignition switch is turned on.
  • Page 863 BE–29 HATER & VENTILATION WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up Horn, Hazard 15A HRN/HAZ 15 A 10 A 20 A Heater IG No. 1 IG No. 2 IG SW MAIN Main Junction block Relay block A/C SW EFI ECU VSV3 ACEV ACSW BLW...

  • Page 864: Ventilation System

    BE–30 8. Ensure that each of the air outlet control lever, air intake Brown Green control lever and temperature control lever is functioning smoothly with a positive dent feeling. NOTE: · Gray If not, apply a rubber grease to the points or replace the control panel assembly.
  • Page 865 BE–31 Adjustment of ventilation control Blower Air inlet mode Air outlet 1. Ensure that the control levers move in a right-and-left di- fan switch control lever selector lever rection without stiffness and binding over the full range of VENT mode RECIRC mode each lever.

  • Page 866: Power Door Lock

    BE–32 POWER DOOR LOCK WIRING DIAGRAM IG SW IG No. 1 IG No. 2 Main MAIN (Door rock Control control relay) Door lock motor JBE00094-01401 DOOR LOCK CONTROL SWITCH Unit inspection 1. Remove the door trim-related parts. 2. Disconnect the connector. JBE00095-01402 3.
  • Page 867 BE–33 DOOR LOCK MOTOR Unit inspection 1. Detach the door locking knob from the control link. 2. Remove the door trim-related parts. Motor 3. Remove the link-related parts. 4. Remove the attaching screws of the lock assembly. 5. Take out the lock assembly. 6.

  • Page 868: Power Window

    BE–34 POWER WINDOW WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up HRN/HAZ Horn, Hazard 15A IG No. 1 IG No. 2 IG SW Main MAIN Junction block Master SW Sub SW Cancel Power window motor Power window motor (Driver’s seat side) (Passenger’s seat side) JBE00099-01501...
  • Page 869 BE–35 Unit inspection (Right hand drive) 1. Remove the switch by means of suitable wooden peace. 2. When the switch is operated, ensure that continuity be- tween the terminals conforms to the requirements as indi- cated in the table below. P23 P24 Window Driver’s seat side...
  • Page 870 BE–36 WIPER & WASHER WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up HRN/HAZ Horn, Hazard 15A IG No. 1 IG No. 2 IG SW Main MAIN Junction block Front wiper washer SW I57 I56 I20 I18 I24 Front wiper Rear Washer motor motor...
  • Page 871 BE–37 WIPER MOTOR Unit inspection 1. Low speed operation check (1) Connect the terminal +1 to the positive : terminal of the battery; the body to the negative ; terminal of the battery. Ensure that the wiper operates at the low speed 1 –...

  • Page 872: Rear Wiper Motor

    BE–38 Adjustment of rear wiper arm Center line Inspect the wiping area and stationary position of the wiper blade. Tightening Torque: 4 - 7 N·m Projection zone f50 Defogger line –0 JBE00111-01609 REAR WIPER MOTOR Unit inspection 1. Remove the back door trim. NOTE: ·...
  • Page 873 BE–39 DEFOGGER WIRING DIAGRAM F/L ABS Head lamp Tail TAIL Back up HRN/HAZ Horn, Hazard 15A F/L AM 60A IG No. 1 IG No. 2 IG SW Main MAIN Defogger JBE00115-01701 DEFOGGER WIRE Push NOTE: by your finger Tester probe (1) When wiping the glass surface, use a soft, dry cloth.
  • Page 874 BE–40 REFERENCE: Open wire · If the voltage is 10 V, it means that open wire exists be- Good tween the center of the wire and the end of the positive 4 – 6 V : side. If the voltage is 0 V, it means that open wire ex- ists between the center of the wire and the end of the Open wire...

  • Page 875: Cigarette Lighter

    BE–41 CIGARETTE LIGHTER WIRING DIAGRAM IG No. 1 IG No. 2 IG SW Main MAIN Cigarette lighter JBE00123-01801 In-vehicle inspection 1. Push the cigarette lighter. Ensure that the heater section is heated and glows red. 2. Ensure that the heater section returns to the original posi- tion about 18 seconds.
  • Page 876 BE–42 4. Turn about 2° and pull out 10 mm the cigarette lighter as- sembly. Then turn back about 2° (align the embossed at the connector side) and pull out the cigarette lighter as- sembly from the cigarette lighter bezel. 5.

  • Page 877: Rear View Mirror

    BE–43 REAR VIEW MIRROR WIRING DIAGRAM IG No. 1 IG No. 2 IG SW MAIN Main Rear view mirror SW Rear view mirror Rear view mirror unit (Right side) unit (Left side) JBE00130-01901 REAR VIEW MIRROR SWITCH 1. Pull out the switch assembly from the instrument panel. Disconnect the connector.
  • Page 878 BE–44 REAR VIEW MIRROR UNIT Unit inspection 1. Remove the front door trim assembly. 2. Disconnect the connector of the door mirror. 3. Apply a voltage of 12 V between the following two termi- nals. 4. Ensure that the mirror operates in accordance with the table below.
  • Page 879 BE–45 ITC SYSTEM For enhanced safety of the motor vehicle, the ITC (Integrated Timer Controller) is controlled by an ECU which has the con- trol system interlocked with the following functions. 1. Impact-detecting door unlocking system 2. All-door locking, interlocked with door lock button at dri- ver’s seat side.
  • Page 880 BE–46 Collision sensor Air bag ECU Collision sensor The collision sensor is mounted in front of the air bag ECU. JBE00139-04005 Internal construction of collision sensor The sensor consists of a weight for impact detection and elec- tric contact points. Contact points Weight...
  • Page 881 BE–47 CIRCUIT DIAGRAM Room lamp Stop 10 A Flasher relay Turn signal indicator Door lock SW Wiper/Turn 20 A Gauge 10 A Vehicle Door lock 15 A speed sensor F/L AM 60A Battery Wire F/L 2.0 JBE00144-04010...
  • Page 882 BE–48 TROUBLE-SHOOTING When there is an open wire or a short in the collision sensor of the impact-detecting system, a warning buzzer provided in the ITC ECU is set off, emitting a continuous sound for five seconds. NOTE: • In the case of an open wire with the ignition switch turned on, if the open wire state continues to exist for 200 ms or more, the buzzer is set off.
  • Page 883 BE–49 (5) The hazard lamp flashes. At the same time, the room lamp is illuminated. NOTE: · If the lamp will not go on, check the wire harness and unit itself. If they are satisfactory, disconnect the jump wire. This completes the check. JBE00149-04016 Malfunctions observed during operation check 1.
  • Page 884 BE–50 REFERENCE: · When the buzzer provided in the junction block is set off when the door is opened even if the ignition switch Second stage has been turned off, there is the possibility that the fol- lowing switches given below are turned on. Check these switches.
  • Page 885 BE–51 (4) With a circuit tester set to the ohmmeter range, con- ITC ECU connector (wire harness side) nect the circuit tester to between the terminal UKS of the connector at the vehicle wire harness side and the CHL FL+ T/H E1 LKM body earth, as shown in the figure.

  • Page 886: Srs Air Bag System

    BE–52 SRS AIR BAG SYSTEM IMPORTANT SAFETY NOTICE All information used in this service manual was in effect at the time when the manual was approved for printing. However, the specifications and procedures may be revised due to continuing improvements in the design without advance notice and without incurring any obligation to us.
  • Page 887 BE–53 SYSTEM DESCRIPTION This air bag system is a supplemental device to protect pas- sengers in the event of a frontal collision. The driver’s seat is provided with an air bag and a seat belt. The front passenger seat is provided with a seat belt and optional air bag, whereas the rear passenger seat is provided with seat belts only.
  • Page 888 BE–54 Air bag unit Door pad cover The air bag for the driver’s seat is accommodated in the steer- generator ing wheel pad assembly. Squib The air bag for the front passenger seat is accommodated in the instrument panel. Each air bag is assembled integral with Filter the inflator module.
  • Page 889 BE–55 Terminal double locking mechanism Spacers This mechanism is provided with all connectors. The connector is of a two-piece construction consisting of a housing and a spacer. The terminal holding is double-locked Housings by the lance (primary one) and the spacer (secondary one). JBE00177-05014 Terminal short mechanism This mechanism is provided at the connector between the...
  • Page 890 BE–56 STEERING WHEEL PAD (AIR BAG UNIT FOR THE DRIVER) & STEERING ROLL CONNECTOR COMPONENTS q Steering wheel pad assembly w Steering wheel pad set plate e Steering wheel r Steering wheel cover JBE00182-05019 REMOVAL 1. Turn off the ignition switch and detach the negative (–) ter- IG “OFF”...
  • Page 891 BE–57 4. After each connector is disconnected, remove the pad as- sembly from the steering wheel. WARNING: GOOD · Be sure to place the removed pad assembly with the pad surface facing upward. The pad assembly placed with the pad surface facing downward is potentially hazard.
  • Page 892 BE–58 5. Install the steering wheel assembly to the steering shaft and tighten the lock nut. Specified Torque: 27.5 - 41.2 N·m JBE00191-05028 6. Installation of pad assembly (1) Connect the connector. (2) Secure the pad assembly to the steering wheel assem- bly with the TORX ®...
  • Page 893 BE–59 AIR BAG UNIT (FRONT PASSENGER’S SEAT SIDE) COMPONENTS q Air bag unit (Passenger’s seat side) w Glove box e Clip JBE00194-05031 REMOVAL 1. Turn off the ignition switch and detach the negative (–) ter- IG [OFF] minal of the battery cable from the battery terminal. 2.
  • Page 894 BE–60 4. Remove the air bag unit assembly from the instrument panel by removing attaching bolts and nuts. WARNING: · Be sure to place the removed air bag unit with the pad surface facing upward. The unit placed with the pad surface facing downward is potentially hazard.
  • Page 895 BE–61 AIR BAG ECU COMPONENTS q Console box w Console panel bezel e Console panel r Air bag ECU JBE00201-05038 REMOVAL 1. Turn off the ignition switch and detach the negative (–) ter- IG [OFF] minal of the battery cable from the battery terminal. WARNING: ·...
  • Page 896 BE–62 CIRCUIT DIAGRAM IG No. 1 IG No. 2 IG SW Main MAIN Junction block Air bag ECU connector (at wire harness side) W D– D+ T P– IG2 IG1 Warning lamp (Combination meter) Air bag ECU IG 1 Diode IG 2 circuit Back-up...
  • Page 897 BE–63 Reading of malfunction codes (diagnosis codes) In case of malfunction codes number 21 and 31 When two or more malfunction codes are outputted, the codes are indicated in the sequence of the code numbers, 0.5 Sec. starting form a smaller number, with a four-second distin- 0.5 Sec.
  • Page 898 BE–64 1. Check of cowl wire harness (1) Turn off the ignition switch and wait for 60 seconds. Connector (2) Remove the console panel. Disconnect the connector at the vehicle wire harness side from the air bag ECU connector. (3) Turn on the ignition switch. Check to see if the warning lamp goes on.
  • Page 899 BE–65 2. Check of warning lamp circuit NOTE: · If the warning lamp circuit has open wire, the warning lamp will remain illuminated. This malfunction is record- ed as the malfunction code 16 of the air bag ECU. · However, as long as the warning lamp circuit has open wire, the diagnosis code can not be indicated and the warning lamp remains illuminated.
  • Page 900 BE–66 TROUBLE SHOOTING When proceeding with operations for a malfunctioning vehicle, it is imperative to confirm the malfunction phenomena actually before pinpointing the causes. In order to reproduce the malfunction phenomena, col- lecting information from the customer is of great importance. WARNING: ·...
  • Page 901 BE–67 When diagnosis code 11,14 or 15 is indicated: Possible cause for malfunction: Abnormal power supply volt- age to the air bag system. 1. Battery check Turn off the ignition switch. Measure the voltage across the battery terminals and ensure that the voltage is 12 V or more.
  • Page 902 BE–68 (3) Turn on the ignition switch. With the circuit tester set to the voltmeter mode, con- nect the tester between the connector terminal at the vehicle wire harness side and body earth. Between terminal 18 (IG1) and body earth: Battery voltage Between terminal 17 (IG2) and body earth: !8 IG1...
  • Page 903 BE–69 When diagnosis code 16 is indicated: Possible cause for malfunction: Abnormality in warning lamp illuminating circuit NOTE: · When this code is memorized, it indicates that open wire has taken place in the warning lamp circuit even though it occurred temporarily. However, if this code is now indicated, it means the circuit (wire harnesses, connectors, etc.) has been remedied to the normal condition.
  • Page 904 BE–70 When diagnosis code 21 is indicated: Possible cause for malfunction: Open wire in squib of air bag at driver’s seat side WARNING: · The squib of the air bag consists of a filament of about 2 ohms. Therefore, there is the possibility that a current which is big enough to cause deployment flows when the circuit tester is connected in its ohmmeter mode.
  • Page 905 BE–71 (4) Disconnect the pad assembly connector from the roll connector. Also disconnect the connector for the horn. GOOD WARNING: · When storing the steering pad assembly (air bag unit), be sure to place it with the pad surface facing upward on a flat place which is not exposed to direct sun rays.
  • Page 906 BE–72 When diagnosis code 22 is indicated: Possible cause for malfunction: Circuit of squib of air bag at driver’s seat side is shorted. NOTE: · The squib of the air bag consists of a filament of about 2 ohms. In order to detect open wire or short circuit in the squib circuit, a small amount of current is flown at all times from the air bag ECU.
  • Page 907 BE–73 (3) Disconnect the connector of the steering pad assem- bly from the roll connector. Also disconnect the con- nector for the horn. GOOD WARNING: · When storing the steering pad assembly (air bag unit), be sure to place it with the pad surface facing upward on a flat place which is not exposed to direct sun rays.
  • Page 908 BE–74 (8) Replacement of roll connector WARNING: · When replacing the roll connector, refer to BE-57. Failure to observe this warning may hamper the turning function of the steering wheel or cut the wiring of the roll connector. Therefore, extreme care must be paid. NOTE: ·...
  • Page 909 BE–75 NOTE: · When there is poor connection between the air bag Connector ECU and the squib, the code 31 is indicated, too. (1) Turn off the ignition switch and wait for 60 seconds. (2) Remove the console box. Disconnect the connector at the vehicle wire harness side from the air bag ECU.
  • Page 910 BE–76 2. Confirmation of open wire of squib CAUTION: · To check an electric circuit for open wire, it is an accepted practice to perform measurement with an ohmmeter. However, it is dangerous to use this method to check the squib for open wire, because this method may cause an accidental explosion.
  • Page 911 BE–77 1. Check of wiring harness Ignition SW Air bag ECU Engine fuse IG No. 1 18 IG1 IG No. 2 17 IG2 Air bag Main fuse P– 10 E1 Squib (Passenger’s seat side) P– 5 6 7 8 – 10 11 12 16 17 18 Vehicle side connector...
  • Page 912 BE–78 When diagnosis code 41 is indicated: Possible cause for malfunction: Upstream circuit of squib of air bag at driver’s seat side and/or passen- ger’s seat side is grounded to earth. NOTE: · When this code is indicated, it means that the squib circuit of the air bag is grounded for a certain reason.
  • Page 913 BE–79 (5) Connect a circuit tester to the roll connector terminal and the body earth with the tester set to the ohmmeter range. NOTE: · The wire harness of both terminals of the roll connector is connected at the ECU side connector as was ex- plained before.
  • Page 914 BE–80 (3) Disconnect the connector which connects the wire 2nd lock harness of the air bag unit and the wire cowl. lock Airbag unit side JBE00278-05116 (4) Connect a circuit tester between the connector termi- nal at the wire cowl side and the body earth with the Wire cowl side tester set to the ohmmeter range.
  • Page 915 BE–81 When diagnosis code 42 is indicated: Possible cause for malfunction: Power supply voltage is applied to upstream circuit of squib of air bag at driver’s seat side and/or passenger’s seat side. WARNING: · When this code is indicated, it indicates that the upstream ignition driver is turned on for a certain reason.
  • Page 916 BE–82 (4) With a circuit tester set to the voltmeter mode, connect the roll connector terminal and the body earth. (5) Turn on the ignition switch. Check if the voltmeter reg- isters approximately the battery voltage. NOTE: · Measure the voltage of each connector terminal. (6) Replacement of air bag ECU NOTE: ·...
  • Page 917 BE–83 When diagnosis code 61 is indicated: NOTE: · This code is outputted when the air bag system were operated. This diagnosis code can not be canceled and the air bag ECU can not be used again. It is necessary to replace them.
  • Page 918 BE–84 WARNING: · This connecting operation to the connector should be performed by one person, not by a joint work of plural operators, so as to avoid mistakes. · During this operation, there is the possibility that the air Wire bag may be deployed accidentally.
  • Page 919 BE–85 2. Disposal procedure of air bag at front passenger seat (1) Turn off the ignition switch. Wait for 60 seconds. IG [OFF] (2) Prepare a 12-V battery for automotive use. JBE00298-05138 (3) Remove the console panel. Disconnect the connector Short circuit at the vehicle wire harness side from the air bag ECU bridge...
  • Page 920 BE–86 (8) Disconnect the wires that have been shorted. Connect one wire to the positive terminal of the battery; the other wire to the negative terminal of the battery, there- by deploying the air bag. NOTE: · There is no need for identifying the polarity of the bat- tery.
  • Page 921 BE–87 (3) Protective goggles and gloves (4) A bag for disposal JBE00307-05148 (5) A spacious place whose radius is at least 10 meters CAUTION: · Do not perform the pre-treatment for disposal for the air bag on a windy or rainy day. JBE00308-05149 1.
  • Page 922 BE–88 WARNING: · When storing the steering pad assembly temporarily, be sure to place it with the pad surface facing upward GOOD on a flat place which is not exposed to direct sun rays. Also the storing place shall be away from water and rain.
  • Page 923 BE–89 (9) Since the metal section of the gas generator is ex- tremely hot, leave it at least for thirty minutes to allow it to cool naturally. After the deployed air bag cools down completely, it shall be sealed in a bag to be dis- posed.
  • Page 924 BE–90 (4) Cut the wires at the squib connector of the air bag unit assembly. Remove the covering of the ends of the two cut wires about 10 mm. WARNING: · Connect the sections each other whose wire coverings have been removed so that they may be shorted. Cut out JBE00322-05163 (5) Place the air bag unit assembly at the center of the...

  • Page 925: Immobilizer System

    BE–91 IMMOBILIZER SYSTEM COMPONENTS LAYOUT Immobilizer ECU EFI ECU JBE00327-06001 OUTLINE This system consists of a transponder-built-in key, an antenna coil, an immobilizer ECU and EFI ECU. In the immobilizer system for EFI gasoline engine, if the key ID code can not be collated or the rolling code is not matched with each other, the EFI ECU stops the ignition and fuel injection, thereby stopping the en- gine operation.
  • Page 926 BE–92 WIRING DIAGRAM F/L ABS Head lamp TAIL Tail Back up Horn, Hazard 15A HRN/HAZ IG No. 1 IG No. 2 IG SW Main MAIN Junction block Immobilizer ECU Coil (–) Coil (+) Antenna coil To EFI ECU +B ACC Diagnosis connector SIO T COL –...
  • Page 927 BE–93 CAUTION: · The master key has the following functions. Utmost care must be paid as to its handling. a. Using the master key (black cover), it is possible to perform the new registration and renewal of the sub keys. b.
  • Page 928 BE–94 TROUBLE-SHOOTING TROUBLE-SHOOTING HINTS Before checking the immobilizer system, check the diagnosis code of the EFI system to determine whether the malfunction is caused by the immobilizer system or by the EFI system. CAUTION: · In the immobilizer system, the system is composed with the same rolling code shared in common among the ignition key, immobilizer ECU and EFI ECU.
  • Page 929 BE–95 EXPLANATION OF DIAGNOSIS CODE 0.25 Sec. 1. Indication of normal code Glowing The check lamp glows for 0.25 second, 0.25 second later after the ignition switch has been turned ON. After a lapse of 0.25 second, the check lamp again glows for 0.25 sec- ond.
  • Page 930 BE–96 TABLE OF DIAGNOSIS CODES Code Number of glowing of Diagnosis item Diagnosis contents check lamp Malfunction of transponder When there is no reply from key transponder after the coil has energized key transponder. (This diagnosis code is cleared if ID code can be read normally next time.) Unmatching of ID codes When immobilizer ECU determines that an attempt...
  • Page 931 BE–97 2. Diagnosis code No.12 is indicated. NOTE: Diagnosis code No. 12 is indicated. · In this case, the followings are possible causes. 1. Poor contacts in ECU connector or terminal 2. Open wire or short in antenna coil or harness 3.
  • Page 932 BE–98 4. Diagnosis code No. 23 is indicated. Diagnosis code No. 23 is indicated. Start engine again, using master key. ID code of key that was used for first starting is not registered. · Register key, using registration funcion of master key. Register master key and sup keys in key registration Registration for master key and sub keys have been done mode.
  • Page 933 BE–99 6. Diagnosis code No. 41 is outputted. NOTE: Diagnosis code No. 41 is outputted. · There are cases that this code is outputted when the EFI ECU or immobilizer ECU is borrowed from other vehicles. Check that there is continuity between terminal No. 7 of Repair or replace communication line between immobilizer immobilizer ECU and terminal No.
  • Page 934 BE–100 7. Diagnosis code No. 42 is outputted. Diagnosis code No. 42 is outputted. Check that there is continuity between terminal No. 7 of Repair or replace communication line between immobilizer immobilizer ECU and terminal No. 40 of EFI ECU. ECU and EFI ECU.
  • Page 935 BE–101 FUNCTION CHECK OF IMMOBILIZER SYSTEM The function check of the immobilizer system can be performed by doing the following two checks. 1. Ensure that the engine starts by using the master key and sub key. 2. Ensure that the engine will not start with a key without the transponder. In the check 1., the system can be checked easily by using the master key and sub key.
  • Page 936 BE–102 5. Ensure that the diagnosis code No.81 has been erased and that the normal code is being outputted. Remove the check lamp and jump wire from the diagnosis connector. JBE00355-06035 REPLACEMENT AND INSTALLATION OF ANTENNA COIL IG “OFF” 1. Disconnect the battery ground cable from the negative (–) terminal of the battery.
  • Page 937 BE–103 REGISTRATION OF SUB KEYS The vehicle is provided with one master key and two sub keys. However, up to three sub keys can be memorized in the immobilizer ECU by using the sub key registration function of the master key. CAUTION: ·...
  • Page 938 BE–104 SSTs (Special service tools) Shape Part No. Part name Remarks To read the diagnosis codes for checking BE–94 09991-87211-000 Diagnosis check wire ECU input/output signals JBE00364-07001 TIGHTENING TORQUE Tightening torque Remarks Tightening component kgf-m N·m Water temp. sender gauge ´ Cylinder block 24.5 - 34.3 2.5 - 3.5 Fuel sender gauge ´...
  • Page 939 DAIHATSU J100 TO INDEX HARNESS & WIRING DIAGRAM GENERAL DESCRIPTION ....... HW– 2 O/D OFF SWITCH & DIFFERENTIAL HANDLING PRECAUTION ....HW– 2 LOCK SWITCH ....... HW–26 WIRE SIZE & COLOR CODE ....HW– 3 WIRING HARNESS ........HW–27 INSPECTION ........HW– 4...
  • Page 940 HW–2 GENERAL DESCRIPTION HANDLING PRECAUTION General instructions 1. Never pull the connectors or step on them during the wire harness transport or assembly. (Prevention of pulling-out of terminals, connector cracks, deformation and so forth) Harness 2. Care must be exercised to ensure that no scratch is made to the wire harness by burrs or edges during the wire har- ness transport or assembly.
  • Page 941 HW–3 Retention by screws • When the tightening torque is specified, be sure to observe the specification strictly. (The tightening torque is posted in the table Terminal is bent. separately.) • Ensure that the staked section may not come on the assembling surface.
  • Page 942 HW–4 3.00 Color code Nominal section Wire type JHW00012-00012 Section area Permissible Nominal section Diameter (mm) (mm) current (A) 0.56 0.85 0.88 1.25 1.28 2.00 2.09 3.00 3.29 JHW00013-00013 INSPECTION Tester (Volt/ohmmeter) For the inspection, use a tester having an internal resistance of more than 10 kilo ohm/V.
  • Page 943 HW–5 INSPECTION OF CIRCUIT WITH TESTER If a diode is built in the circuit, perform continuity test by changing the polarities of the measuring terminals. In case of a general type tester, ensure that continuity exists when the negative (–) lead of the tester is connected to the positive (+) side of the diode;...
  • Page 944 HW–6 OPERATION OF LOCK TYPE CONNECTOR Disconnection Pull up Press down The lock type of the connector comes in a push release type, a pull release type, a spring lock type, an one-way lock type and so on. After confirming the shape of the lock, unlock the lock. Disconnect the connector while holding the connector by hand.
  • Page 945 HW–7 ABBREVIATION CODES The abbreviation codes that appear in this service manual stand for the following, respectively. ACC: Accessory ACT: Actuator FUL: Fuel A/C: Air conditioner F/WP: Front wiper ALT: Alternator F/WSH: Front washer AMP: Amplifier GND: Ground ANTN: Antenna HAZ, HZD: Hazard AT, A/T:...
  • Page 946 HW–8 PSI: Position P/W: Power window Pulse R/B: Relay block RDFN: Radiator fan RDI: Radiator RESSTR: Resistor REV: Revolution RLY: relay Right hand RNG: Range Rear RRLH: Rear door (LH) RRRH: Rear door (RH) RTL: Retractable R/TRN: Rear turn signal lamp R/WIP: Rear wiper Seat belt...
  • Page 947 HW–9 CIRCUIT DIAGRAM STARTER & ALTERNATOR Engine For M/T 10 A Neutral starter SW only for A/T Starter relay For M/T F/L AM 60A Battery Wire F/L 2.0 JHW00027-00101...
  • Page 948 HW–10 EFI SYSTEM To heater resister To A/C dual pressure SW To heater relay To off board connector To heater blower SW (SIO) Check engine lamp To head lamp fuse (Combination meter) Idle up VSV To head lamp To defogger SW Idle up VSV(for A/C) To defogger Idle up VSV(for A/T)

  • Page 949: Abs System

    HW–11 ABS SYSTEM ABS F/L Back-up fuse ABS ECU IG SW(IG2) ECU IG fuse ECUT Diagnosis Tail fuse STOP fuse Body ground connector solenoid ABST stop lamp relay switch 11 SIO Motor relay Front vehicle speed BS BM sensor (right) stop FR–...

  • Page 950: Air Bag System

    HW–12 AIR BAG SYSTEM Engine 10 A Air bag 10 A Gauge/Back 10 A F/L AM 60A Battery Wire F/L 2.0 JHW00030-00104...
  • Page 951 HW–13 IMMOBILIZER SYSTEM 15 A ECU IG 10 A F/L AM 60A Battery Wire F/L 2.0 JHW00031-00105...
  • Page 952 HW–14 ITC SYSTEM Room lamp Stop 10 A Flasher relay Turn signal indicator Door lock SW Wiper/Turn 20 A Gauge 10 A Vehicle Door lock 15 A speed sensor F/L AM 60A Battery Wire F/L 2.0 JHW00032-00106...
  • Page 953 HW–15 COMBINATION METER Illumination Starter relay coil Air bag Air bag ECU warning circuit EFI ECU Seat belt SW EFI ECU ABS ECU Oil pressure SW Tail Tail Parking brake SW AUS. only Brake fluid level SW Gauge Alternator L J/B earth Rear fog switch EC only...
  • Page 954 HW–16 HEAD LAMP Head lamp RH Pass Head lamp LH Lighting SW Head lamp F/L AM 60A Battery Wire F/L 2.0 JHW00034-00108...
  • Page 955 HW–17 TAIL LAMP & LICENSE PLATE LAMP Clearance lamp RH Tail lamp RH License plate lamp RH License plate lamp LH Tail lamp LH Clearance lamp LH Tail SW Tail 10 A Tuner illumination Floor console illumination Meter illumination Heater control illumination F/L AM 60A Battery Wire F/L 2.0...
  • Page 956 HW–18 FRONT FOG LAMP, REAR FOG LAMP & STOP LAMP High mounted stop lamp Stop lamp Stop 10 A Stop lamp SW Stop lamp RF SW Rear fog lamp (Multi-use lever) Rear fog lamp SW Rear fog lamp indicator (Combination meter) Gauge Courtesy SW Back...
  • Page 957 HW–19 TURN, HAZARD & HORN Horn SW Turn signal indicator lamp RH Front turn lamp RH Side turn lamp RH Rear turn lamp RH Turn signal indicator lamp LH Front turn lamp LH Side turn lamp LH Rear turn lamp LH F/L AM 60A Battery Wire F/L 2.0...
  • Page 958 HW–20 BACK-UP LAMP Gauge /Back 10 A Neutral start SW Gauge /Back 10 A Back-up lamp SW F/L AM 60A Battery Wire F/L 2.0 JHW00038-00112...

  • Page 959: Interior Lamp

    HW–21 INTERIOR LAMP Luggage room lamp Stop 10 A Gauge Back door courtesy SW & Back 10 A Courtesy SW FR RH Courtesy SW FR RH Room lamp Courtesy SW FR RH Courtesy SW FR RH F/L 2.0 JHW00039-00113...
  • Page 960 HW–22 HEATER & AIR CONDITIONER Dual pressure Air conditioner Resistor Heater blower Gauge /Back Heater blower 10 A motor Heater relay A/C relay Magnet clutch EFI main relay A/C VSV F/L AM 60A Battery Wire F/L 2.0 JHW00040-00114...
  • Page 961 HW–23 POWER WINDOW POWER 30 A F/L AM 60A Battery Wire F/L 2.0 JHW00041-00115...
  • Page 962 HW–24 WIPER, WASHER & DEFOGGER Defogger 15 A Rear defogger Rear wiper motor Rear wiper washer SW Wiper / Turn 20 A Front Washer motor F/L AM 60A Battery Wire F/L 2.0 JHW00042-00116...
  • Page 963 HW–25 ACCESSORY (REAR VIEW MIRROR & CIGARETTE LIGHTER) 15 A 15 A F/L AM 60A Battery Wire F/L 2.0 JHW00043-00117...
  • Page 964 HW–26 O/D OFF SWITCH & DIFFERENTIAL LOCK SWITCH Transfer VSV 2 Gauge /Back 10 A Differential Transfer VSV 1 lock SW Indicator lamp Over Drive off Over Drive off relay solenoid Gauge /Back 10 A O/D OFF Over Drive SW Indicator lamp F/L AM 60A...

  • Page 965: Wiring Harness

    HW–27 WIRING HARNESS JHW00045-00200 CONTENTS OF HARNESS DIAGRAM WIRE NAME WIRE NAME WIRE, FLOOR WIRE, ENGINE WIRE, ENGINE, No.2 WIRE, FLOOR, No.3 WIRE, COWL, RH WIRE, FRONT DOOR (DRIVER'S SIDE) WIRE, COWL, LH WIRE, FRONT DOOR (PASSENGER'S SIDE) WIRE, REAR DOOR WIRE, BACK DOOR, No.1 JHW00046-00201...
  • Page 966 HW–28 WIRE, ENGINE From From Location Terminal Terminal Location Location Terminal Terminal Location MET (CHG) ALT (L) E/G J/C1 (E10) IG COIL NO2 (ECUE) E/G WP BNDR1 (01) ALT (IG) Connect to X38~X46 THROTTLE SSR (VC) E/G WP BNDR1 (01) J/B FUSE ENG (L1) Connect to X53~X96 FUL INJ NO4 (–)
  • Page 967 HW–29 WIRE, ENGINE 82121-87402...
  • Page 968 HW–30 WIRE, ENGINE No. 2 From Location Terminal Terminal Location R/B (+B) BATTERY (+) R/B (+B) ALT (B) BATTERY (–) BATTERY – (BODY) BATTERY (–) BATTERY – (M/T) BATTERY (+B) STARTER (+B) STARTER (ST) ST RLY (L) F/L 2.0 F/L 2.0 82122-87401...
  • Page 969 HW–31 WIRE, ENGINE No. 2 82122-87401...
  • Page 970 HW–32 WIRE, FRONT DOOR (DRIVER’S SEAT SIDE/RHD) From Location Terminal Terminal Location COWL RH J/C5 (08) E MIRROR RH (C) E MIRROR SW (VR) E MIRROR RH (V) E MIRROR SW (HR) E MIRROR RH (H) RADIO (SPR +) SP FR RH (+) RADIO (SPR –) SP FR RH (–) D/L CTR RLY (ULSW)
  • Page 971 HW–33 WIRE, FRONT DOOR (DRIVER’S SEAT SIDE/RHD) 82151-87401...
  • Page 972 HW–34 WIRE, FRONT DOOR (PASSENGER’S SEAT SIDE/RHD) From Location Terminal Terminal Location COWL RH J/C5 (09) E MIRROR LH (C) E MIRROR SW (HL) E MIRROR LH (H) E MIRROR SW (VL) E MIRROR LH (V) RADIO (SPL –) SP FR LH (–) RADIO (SPL +) SP FR LH (+) COWL RH J/C4 (12)
  • Page 973 HW–35 WIRE, FRONT DOOR (PASSENGER’S SEAT SIDE/RHD) 82152-87401...
  • Page 974 HW–36 WIRE, FRONT DOOR (DRIVER’S SEAT SIDE/LHD) From Location Terminal Terminal Location CWL LH J/C3 (12) E MIRROR LH (C) E MIRROR SW (HL) E MIRROR LH (H) E MIRROR SW (VL) E MIRROR LH (V) RADIO (SPL +) SP FR LH (+) RADIO (SPL –) SP FR LH (–) D/L CTR RLY (ULSW)
  • Page 975 HW–37 WIRE, FRONT DOOR (DRIVER’S SEAT SIDE/LHD) 82152-87402...
  • Page 976 HW–38 WIRE, FRONT DOOR (PASSENGER’S SEAT SIDE/LHD) From Location Terminal Terminal Location COWL LH J/C3 (13) E MIRROR RH (C) E MIRROR SW (VR) E MIRROR RH (V) E MIRROR SW (HR) E MIRROR RH (H) RADIO (SPR +) SP FR RH (+) RADIO (SPR –) SP FR RH (–) COWL LH J/C3 (09)
  • Page 977 HW–39 WIRE, FRONT DOOR (PASSENGER’S SEAT SIDE/LHD) 82151-87402...
  • Page 978 HW–40 WIRE, REAR DOOR From Location Terminal Terminal Location FLOOR J/C2 (13) D/L MTR RRRH (LOK +) FLOOR J/C2 (09) D/L MTR RRRH (U/L +) P/W MAS SW (RRU +) P/W SW RRRH (U +) P/W MAS SW (RRD +) P/W SW RRRH (D +) FLOOR J/C1 (09) P/W SW RRRH (B)
  • Page 979 HW–41 WIRE, REAR DOOR 82153-87401...
  • Page 980 HW–42 WIRE, BACK DOOR, No. 1 From Location Terminal Terminal Location FLOOR BNDR 2 (01) H. M. STOP LP (+) BODY EARTH (RRRH) H. M. STOP LP (–) RR WIP MTR (+) J/B F/WP TRN (L3) RR WIP MTR (–) RR WIP SW (B) COWL LH J/C6 (05) DEF (+)
  • Page 981 HW–43 WIRE, BACK DOOR, No. 1 82184-87401...
  • Page 982 HW–44 WIRE, FLOOR (RHD) From From Location Terminal Terminal Location Location Terminal Terminal Location COWL RH J/C5 (12) RR FOG LP (+) FLOOR J/C2 (11) D/L MTR RRLH (LOK +) FLOOR BNDR1 (E01) RR FOG LP (–) FLOOR J/C2 (07) D/L MTR RRLH (U/L +) FLOOR BNDR3 (02) J/B CTY SW (+1)
  • Page 983 HW–45 WIRE, FLOOR (RHD) 82161-87401...
  • Page 984 HW–46 WIRE, FLOOR (LHD) From From Location Terminal Terminal Location Location Terminal Terminal Location FLOOR BNDR3 (02) J/B CTY SW (+1) COWL LH J/C3 (07) FLOOR J/C2 (06) COWL LH J/C4 (12) RR FOG LP (+) FLOOR BNDR1 (E01) ACC PLUG (E) FLOOR BNDR1 (E01) RR FOG LP (–) FUSE ACC (L5)
  • Page 985 HW–47 WIRE, FLOOR (LHD) 82161-87402...
  • Page 986 HW–48 WIRE, FLOOR, No. 3 (RHD) From Location Terminal Terminal Location COWL LH J/C9 (07) ABS ECU (BLS) COWL LH J/C8 (13) ABS ECU (WLAS) ABS P SSR RL (–) ABS ECU (RL 0) ABS P SSR RL (+) ABS ECU (RL 1) ABS ECU (RR 1) ABS P SSR RR (+) ABS ECU (RR 0)
  • Page 987 HW–49 WIRE, FLOOR, No. 3 (RHD) 82163-87401...
  • Page 988 HW–50 WIRE, FLOOR, No. 3 (LHD) From Location Terminal Terminal Location COWL RH J/C3 (03) ABS ECU (BLS) COWL RH J/C9 (02) ABS ECU (WLAS) ABS P SSR RL (–) ABS ECU (RL0) ABS P SSR RL (+) ABS ECU (RL1) ABS ECU (RR1) ABS P SSR RR (+) ABS ECU (RR0)
  • Page 989 HW–51 WIRE, FLOOR, No. 3 (LHD) 82163-87402...
  • Page 990 HW–52 WIRE, COWL, RH (EC/RHD AUS.) From From From Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location IG SW (AM) F/L AM (L) COWL LH J/C8 (08) ST RLY (COL –) F/P RLY (L) FUEL PUMP (+) IG SW (ACC) FUSE ACC (B) STARTER (ST)
  • Page 991 HW–53 WIRE, COWL, RH (EC/RHD AUS.) ABS DIODE & CHECK PD6 PD7 R/B 3-2 FR TURN RH R/B 3-1 OC6 O31 HORN ABS ACT HORN EARTH WS3 WS4 CLEARANCE RH EARTH J/C ABS RLY 2 FENDER RH #3A #3B #3C HEAD LAMP RH TO E/G WIRE...
  • Page 992 HW–54 WIRE, COWL, RH (General/RHD) From From From Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location IG SW (AM) F/L AM (L) RADIO (SPR –) SP FR RH (–) COWL RH J/C3 (07) ABS MAI RLY (COL +) IG SW (ACC) FUSE ACC (B) COWL RH J/C4 (12)
  • Page 993 HW–55 WIRE, COWL, RH (General/RHD) PD6 PD7 R/B 3-2 FR TURN RH R/B 3-1 HORN ABS DIODE & CHECK OC6 O31 HORN ABS ACT CLEARANCE RH ZD2 C25 EARTH TO COWL WIRE LH A EARTH J/C WS3 WS4 FR FOG RH FENDER RH ZQ9 K02 ABS RLY 2...
  • Page 994 HW–56 WIRE, COWL, RH (EC/LHD) From From From From Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location IG SW (AM) F/L AM (L) COWL RH J/C6 (02) EFI ECU (REV) RADIO (SRR –) RR SP RH (–) COWL RH J/C7 (05) OFFBOARD CON (ECUT)
  • Page 995 HW–57 From From Location Terminal Terminal Location Location Terminal Terminal Location ITC ECU (CS –) ALL RNG SSR (–) COWL R BNDR1 (E08) ABS MAI RLY (SWNC) D/LOCK SW (U/L +) ITC ECU (UKS) ABS P SSR FL (+) ABS ECU (FL1) COWL RH J/C4 (18) MET (SPSR) ABS P SSR FL (–)
  • Page 996 HW–58 WIRE, COWL, RH (EC/LHD) R/B 3-2 ABS DIODE & CHECK PD6 PD7 WS3 WS4 R/B 3-1 ABS RLY 2 FR TURN RH HORN WS1 WS2 OC6 O31 ABS ACT ABS ACT 1 EARTH FR WSH MTR CLEARANCE RH WW4 WW3 WW7 WW6 EARTH J/C HEAD LAMP RH...
  • Page 997 HW–59 WIRE, COWL, RH (General/LHD) From From From From Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location IG SW (AM) F/L AM (L) COWL RH J/C (05) MET BRK WNG (–) COWL LH J/C3 (09) D/L MTR FR P (LOK +) COWL RH J/C2 (E03) RB EFI M RLY (E)
  • Page 998 HW–60 From Location Terminal Terminal Location ABS MTR RLY (COL –) ABS ECU (PCO) COWL RH J/C3 (03) ABS ECU (BLS) ABS MAI RLY (COL –) ABS ECU (REL) COWL RH J/C9 (06) ABS ECU (R +) ABS ECU (AST) ABS ACT (AST) ABS ACT (SFRH) ABS ECU (SFRH)
  • Page 999 HW–61 WIRE, COWL, RH (General/LHD) R/B 3-2 ABS DIODE & CHECK PD6 PD7 WS3 WS4 R/B 3-1 ABS RLY 2 FR TURN RH HORN WS1 WS2 OC6 O31 ABS ACT ABS ACT 1 EARTH FR WSH MTR ZD4 C25 CLEARANCE RH WW4 WW3 FR FOG RH WW7 WW6...
  • Page 1000 HW–62 WIRE, COWL, LH (EC/RHD & AUS.) From From From From Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location Location Terminal Terminal Location COWL LH J/C9 (02) H-LP LH (B) COWL LR J/C4 (01) J/B MET (+) RADIO (SRL –) RR SP LH (–) COWL LH J/C7 (05)

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