Chrysler laser 1990 Technical Information Manual
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Chrysler laser 1990 Technical Information Manual

Chrysler laser 1990 Technical Information Manual

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  • Page 2 ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADE ONLY. All test and repair procedures on components or assemblies in non-automotive applications should be repaired in accordance with instructions supplied by the manufacturer of the total product. Special attention should be exercised when working with spring or tension loaded fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal may cause personal injury.

  • Page 3: Front Suspension

    Heaters and Air Conditioning .... Emission Control Systems Chrysler Motors reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products manufactured.
  • Page 4 abbreviations are used in this manual for classification of model types. following Indicates the manual transaxle, or models equipped ‘with the manual transaxle. Indicates the multi-point injection, or engines equipped with the multi-point injection. Indicates an engine with the double overhead camshaft, or a model equipped with such an engine, Indicates an engine with turbocharger, or a model equipped with such an engine.

  • Page 5: Table Of Contents

    GENERAL VEHICLE IDENTIFICATION .._...._.._ GENERAL DATA AND SPECIFICATIONS ..Engine Model Stamping ................ TECHNICAL FEATURES ..Vehicle Identification Code Chart Plate ....Vehicle Identification Number List Vehicle Identification Number Location ..Basic Construction ..........Vehicle Information Code Plate ......

  • Page 6: Technical Features

    TECHNICAL FEATURES ROOCAAB Low and wide profile for appearance sports car impression. Features No. t Flush surface and low front high rear styling for outstanding aerodynamic performance Pop up headlights of optical horn type Hood bulge indicating DOHC engine Futuristic glass upper body Removable tilt up sunroof (option for all models) Smooth integrated body lines giving a lean appearance Wide tires and wide tread to emphasize power and stability...
  • Page 7 GENERAL - Technical Features Features Cock pit type instrument panel to give sporty image Switches arranged around the driver seat for easy access and operation Hi back seats with integral head rest for comfortable and firm holding Integrally molded door trims with round and smooth transition to the instrument panel Sporty double seat with firm holding Rear quarter trims with built in dynamic speakers Easy to use large capacity console box...

  • Page 8: Basic Construction

    driving across bad roads, and $-wheel independent suspension for comfortable riding. The 4WD vehicles are equipped with 2.OL DOHC Adopted on 2WD vehicles are 2.OL DOHC 16-valve engine, MacPherson strut type front suspension technologies such as full time 4WD of center and torsion axle typ.e 3-link rear suspension.

  • Page 9: Engine

    The engines are the transverse-mounted engine operation, low-noise, low-vibration, consumption features, an engine that fully displays especially for front-engine/front-wheeldrive or the most up-todate engine technology. SPECIFICATIONS Engine model Displacement Max. torque (SAE net) cc (cu.in.1 1997 (122) Turbo 1997 (122) FEATURES High performance and low fuel consumption The rocker arm reduces the valve-actuation torque as well as fuel consumption.
  • Page 10 Features Ignition system The 2coil ignition system without a distributor supplies sufficient ignition energy even in the high speed operation. The oullev orovrded with a torsion- al da’mper ieduces the transmis- sion of vibrations. Valve mechanism The roller rocker arms de- Auto tensioner crease losses.due to friction in The auto tensioner eliminates the...
  • Page 11 Technical Features center differential of vehicle to achieve auto- full time system adopts viscous coupling rear wheels. front and (VCU) unit as the differential limiting device for the Viscous coupling Engine Viscous coupling slip differential interlock device) has been adopted to improve Key interlock device Ignition key cylinder Shift lock device...

  • Page 12: Theft-Alarm System

    minutes when the locked door, hood or liftgate has been forced open without using a key. Furthermore, the starter circuit is interrupted so that To make the vehicle theftproof, this system is so the engine may not be operated, making the vehicle designed that the headlights go on and off and the theftproof.

  • Page 13: Vehicle Identification

    GENERAL VEHICLE IDENTIFICATION V E H I C L E L O C A T I O N The vehicle identification number (V.I.N.) is located on a plate attached to the left top side of the instrument panel. All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.

  • Page 14: Vehicle Identification Number List

    VEHICLES FOR FEDERAL V.I.N. (except sequence number) Brand Engine displacement Models Code Eagle TalonQWD) 2.0 liter (122 cu,in.) [DOHC-MPI] 2.0 liter (122 cu.in.) Eagle Talon (4WD) VEHICLES FOR CALIFORNIA (Can also be sold in Federal States.) I Models Code Eagle Talon (2WD) 2.0 liter (122 cu.in.) [DOHC-MPI] 2.0 liter (122 cu.in.1...

  • Page 15: Vehicle Information Code Plate

    Vehicle information code plate is riveted onto the bulkhead in the engine compartment. The plate shows model code. engine model, transaxle model, and body color code. 1 . M O D E L 2. ENGINE Engine model 3. TRANSAXLE 4. COLOR, TRIM OPT color code ENGINE...

  • Page 16: Vehicle Safety Certification Label

    1. The vehicle safety certification label is attached to the face of left door pillar. 2. This label indicates the month and year of manufacture, Gross Vehicle Weight Rating (G.V.W.R.), Gross Axle Weight Rating (G.A.W.R.) front, rear and Vehicle identification Number (V.I.N.).

  • Page 17: General Data And Specifications

    GENERAL - General Data and Specifications GENERAL DATA AND SPECIFICATIONS Items Vehicle dimensions mm (in.) 1 4,330 (170.5) 4,350 (171.3) 4,380 (172.4) Overall width 2 1,690 (66.5) 1,700 (66.9) 1,700 (66.9) Overall height 3 1,306 (51.4) 1,306 (51.4) 1,321 (52.0) Wheel base 4 2,470 (97.2) 2,470 (97.2)
  • Page 18 Chassis Tire Front suspension Independent strut Independent strut Independent strut Rear suspension Double wishbone Torsion axle Torsion axle Brake Front Disc Disc Disc Rear Disc Disc Disc Steering Gear type Rack and pinion Rack and pinion Rack and pinion Gear ratio Fuel tank Capacity liters (gals.) 60 (16)
  • Page 19 SUSPENSION CONTENTS ANTI-DIVE GEOMETRY ........LOWER ARM ............FRONT AXLE ............NEGATIVE-OFFSET GEOMETRY ....Drive Shaft ......................OFFSET SPRING Hub and Knuckle ..........STABILIZER ............GENERAL INFORMATlON ........ Construction Diagram ........Specifications .............
  • Page 20 FRONT SUSPENSION - General Information GENERAL INFORMATION Excellent braking stability, thanks to the The front suspension has a simple construction, the negative-offset geometry. McPherson strut type independent suspension Greatly improved riding comfort, thanks to the featuring light unsprung weight. offset arrangement of the coil springs. The front Suspension has the following features: Excellent driving stability, thanks to the “antidive”...
  • Page 21 Turbo Non-Turbo terns With a manual With an automatic With a manual transaxle transaxle transaxle McPherson strut with coil spring and compression rod type Suspension system 5’ z!z 30’ Camber Caster 0 It 3 (0 * .12) mm (in.) Toe-in Coil spring Wire dia.
  • Page 22 Specifications Suspension system McPherson strut with coil spring and compression rod type Camber 10’ +- 30’ Caster Toe-in mm (in.) 0 zk 3 (0 f .l2) Coil spring Wire dia. x O.D. x free length mm (in.) 14.0 x 174.0 x 326.5 (.55 x 6.85 x 12.9) Pink x 1 Coil spring identification color Spring constant...
  • Page 23 ANTI-DIVE GEOMETRY Ordinarily, when the brakes are applied, the load is moved toward the front of the vehicle as the result of inertial force, and this causes the phenomenon known as “nose dive”, in which the front of the vehicle is caused to tilt forward and downward. For this front suspension, however, the suspension link design -which has a high “anti-dive”...
  • Page 24 OFFSET SPRING Then, because the coil spring is installed so that its Because struts are installed at an angle, the road centre is greatly offset (toward the outside of the surface reaction force (RI) applied to the tyres tends vehicle) from the centre of the strut, the counterac- to act vertically upon the tyre centre, and that force tive force for the spring tends to become great tries to bend the strut toward the inside of the...
  • Page 25 Arm / Stabilizer LOWER ARM The lower arm is an A-type arm, and is connected, and “hard” characteristics relative to the left via a rubber bushing, to the crossmember. right, so that road surface impacts during travel The rod bushing is optimum tuned, including the alleviated, and also so that changes of alignment spring constant of the arm bushing, to provide caused by lateral forces are reduced, thus assuring...

  • Page 26: Front Axle

    FRONT AXLE The drive shaft is of the Bit-field joint (B.J.)-tripod The knuckle has the wheel bearing assembled a@ joint (T.J.) type. This type features high power the hub press-fitted. The drive shaft and hub are transmission efficiency and low vibration and noise. spline-coupled.
  • Page 27 The construction of the hub and knuckle consists of The wheel bearing is the double-row, angular- the wheel bearing assembled to the knuckle and the contact ball bearing type to withstand the lateral hub pressed in; the drive shaft and hub are coupled (thrust) load.
  • Page 28 REAR AXLE CONTENTS RoJA- GENERAL INFORMATION ........ AXLE SHAFT ............Construction Diagram .................... DIFFERENTIAL Specifications ............ DIFFERENTIAL SUPPORT MEMBER ....VISCOUS COUPLING TYPE LIMITED ..........SLIP DIFFERENTIAL DRIVE SHAFT ............Construction ............ Functions and features ........Operation ............
  • Page 29 GENERAL INFORMATION The differential carrier and axle housing have been and outer) in the axle housing and are coupled with separated from each other, and D.O.J. and B.J. the drive shaft with the companion flange i n * drive shafts arranged in between, They are driven by between.
  • Page 30 Conventional Viscous coupling type differential limited slip defferential (option) Axle shaft Semi-floating type Semi-floating type Shaft dimensions Outer bearing portion dia. mm (in.) 35 (1.38) Inner bearing portion dia. mm (in.) 34.5 (1.36) 34.5 (1.36) Center portion dia. mm (in.) mm (in.) 214.9 (8.46) 214.9 (8.46)

  • Page 31: Axle Shaft

    AXLE SHAFT The axle shaft is a semi-floating type supported by prevent mud that may be deposited around the ball bearings (outer and inner) in the housing. bearing (outer), a dust cover has been provided. Companion flange D.O.J. Trailing arm DRIVE SHAFT On the axle shaft side, they are coupled with the Birfield type constant velocity ball joints have been...
  • Page 32 REAR AXLE DIFFERENTIAL For better serviceability, spacers for adjustment of The differential uses lower torque bearings and final drive gear backlash have been inserted be- lower torque oil seals to improve power perform- A speed difference responsive type viscous cou- For faster differential cooling and higher reliability during high speed operation, a differential carrier outstanding performance during operation on a...
  • Page 33 Side gear (L.H.) Side gear (R.H.) Differential case B Pinion shaft washer Thrust Viscous cokpling Side gear U3.H.) , ,, Differential cover Differential case B ‘Gear cagier Drive pinion front bearing Drive gear rear bearing Bearing cap Normal operating range Hump region (1) The viscous coupling type limited-slip differential is functionally the same as the conventional...
  • Page 34 Coupling Type Limited Slip Differential Drive pinion Rear drive / shaft (L.H.) Rear drive shaft (R.H.1 Serration coupled entry of the differential oil into the viscous coupling. The viscous coupling type limited differential is a The rear drive shaft (L.H.) is serration coupled with “shaft-shaft”...
  • Page 35 Coupling Type Limited Slip Drive force smaller (Slipping side) Drive force larger Rear drive shaft Rear drive shaft resistance smaller) 11 PO071 For example, assume that the right wheel rotates at If a difference in rotating speed occurs between the right and left wheels, the viscous coupling case @ 20 rpm due to the road surface resistance, whereas the left wheel rotates at 30 rpm.
  • Page 36 DIFFERENTIAL SUPPORT MEMBER The differential support member supports the rear side of the differential carrier. That end of the member which is mounted to the body is elastically supported by use of rubber bushings. Section A-A Differential support member Differential member support Differential carrier...
  • Page 37 BRAKES SERVICE AND PARKING CONTENTS SERVICE BRAKES ..........GENERAL INFORMATION ........ Front Disc Brake ..........Construction Diagram ........Rear Disc Brake ..........Features ............Specifications ............ Specifications ............ X Arrangement of Brake Lines ......PARKING BRAKE ..........Construction Diagram ........
  • Page 38 BRAKES - General Information GENERAL INFORMATION The service brakes are a brake system featuring system as a brake system matching the vehicle excellent braking force and a high level of reliability superb driving performance. Models with turbochar- and durability. ger are equipped with a 7 + 8 inch tandem brake booster for lower brake pedal depression efforts.

  • Page 39: Service Brakes

    BRAKES - Service Brakes SERVICE BRAKES SPECIFICATIONS Items Non-Turbo Turbo Master cylinder Tandem (with level sensor) Tandem (with level sensor) mm (in.) 22.2 (718) 23.8 (15/l 6) Multiple-vacuum-boost type Brake booster Effective dia. of Front side: 180 (7.0) Rear side: 205 (8.0) Dual type Proportioning valve Type Dual type...
  • Page 40 B R A K E S - Service Brakes F R O N T D I S C B R A K E The front brake is the M-R44V type featuring highly efficient heat dissipation, quick recovery of braking force when wet, and highly stabilized braking force. Section A-A Piston seal 14AO533...
  • Page 41 ‘he rear brake is the AD30P type, featuring highly The brake system incorporates an auto adjuster that automatically adjusts the clearance between the pad and brake disc when t.he brake pedal is force when wet, and highly stabilized braking force. depressed.
  • Page 42 In addition, disc removal and installation is made disc and the disc wheel are installed to the hub bv easy by the outer disc system, in which the brake the hub nuts. Brake disc installation cross-section Hub nuts Hub nuts Brake disc Brake&c...

  • Page 43: Parking Brake

    PARKING BRAKE The parking brake is of the mechanical rear wheel The parking brake cable is of the V-type and is braking type. accessible for adjustment through the service hole The parking brake is offset toward the driver’s seat provided in the floor console. from the vehicle centerline for greater ease of operation.
  • Page 44 CLUTCH i r - - -.-. CONTENTS GENERAL INFORMATION ....... . CLUTCH CONTROL .

  • Page 45: Clutch Control

    CLUTCH - General Information / Clutch Control GENERAL INFORMATION ROBBMA The clutch is the dry single-plate diaphragm type: hydraulic pressure is used for the clutch control. SPECIFICATIONS Items Non-turbo Turbo Clutch operating method Hydraulic type Hydraulic type Clutch disc Single dry disc type Single dry disc type Type Facing diameter...
  • Page 46 CLUTCH The inter-lock switch is a switch provided in order to prevent sudden movement of the vehicle when the engine is star-ted. Thus, the starter motor will not be switched ON unless the clutch pedal is depressed, thereby switching OFF the inter-lock switch.
  • Page 47 COOLING CONTENTS R07A-. TRANSAXLE FLUID COOLER . .._.._.._.._.._.. GENERAL INFORMATION ....... . Coolant Flow ............
  • Page 48 COOLING - General Information GENERAL INFORMATION Ro7BAAA Radiator hose. upper Heater hoses Radi Radiator hose lower cooling system is the liquid-cooled, forced- the motor only when necessary, and it functions to efficiently regulate the temperature of the engine circulation type of system. The cooling (radiator) fan is the electric motordriven type;...
  • Page 49 CLUTCH - General Information <Non-turbo> . pump Water Throttle body Water inlet pipe Water tedperat& gauge unit <Turbo>...
  • Page 50 ----------------l-~).. CLUTCH - General Information / Radiator and Cooling Fan SPECIFICATIONS Specifications Items Water pump Centrifugal impeller type Type Max. 140 (148) at 6,000 rpm . (qt.I/min. Delivery rate Thermostat Wax type with jiggle valve 88 (190) “C (“F) Valve opening temperature V-ribbed type Drive belt RO’ICMA...
  • Page 51 COOLING - Radiator and Cooling Fan / Fluid Cooler Transaxle A flexible support system is used at installation points of Cross-section Radiator installatio the radiator in order to reduce the transmission of vibration and noise to the body. Lower insulator TRANSAXLE FLUtD COOLER On vehicles provided with automatic transaxle, the The transaxle fluid cooling path is as described...
  • Page 52 COOLING - Two-speed Fan Control System TWO-SPEED FAN CONTROL SYSTEM CONTROL SYSTEM CIRCUITRY DIAGRAM ON at 85°C (185°F) or higher OFF ioN and to regulate the speed of the cooling (radiator) This system functions to detect the operation mode fan and of the condenser fan to either the low speed of the air conditioner, the coolant temperature, etc., or the high speed.
  • Page 53 ELECTRICAL - - - - CONTENTS ............DIAGNOSIS SYSTEM - CHECK LlGHTlNG CONNECTORS ........... . Delayed Switch-off Dome Light ....
  • Page 54 ELECTRICAL - Fuses FUSES MAIN FUSIBLE LINKS (DIRECT TO BATTERY) The main fusible links are the cartridge type and are directly mounted to the (+) terminal of the battery. Rated Housing Circuit colour capacity (A) I I 1 I Blue MPI circuit Pink Radiator fan motor circuit...
  • Page 55 ELECTRICAL - Fuses MULTI-PURPOSE FUSES The multi-purpose fuses are located within the junction block at the lower part of the instrument panel (at the driver’s seat side). These fuses are all the blade type; 1 O-ampere, 15-ampere and Fuse No. Power supply circuit Rated Load circuit...
  • Page 56 ELECTRICAL - Fuses / Diagnosis System DEDICATED FUSES For high-load circuits, fuses dedicated to each individual circuit are used. The dedicated fuses are provided in the relay box of the engine compartment. Circuit Rated 1 1 Tail light circuit Fog light circuit 4 ) Upper beam circuit Air conditioner magnet clutch circuit...
  • Page 57 ELECTRICAL The junction block is a feature in which wiring hamess connections are centralized for simpler and more reliable wiring harness connections. The junction block is provided under the instrument panel driver’s seat side. CONSTRUCTION OF JUNCTION BLOCK Rear side To engine compartment wiring harness...
  • Page 58 ELECTRICAL - Junction Block INTERNAL CIRCUIT DIAGRAM I I I I rr, NOTE The alphabetical symbols on the connectors are associated with the connector symbols (P.8-5).
  • Page 59 ELECTRICAL - RELAYS, CONTROL UNITS AND SENSORS The relays, control units and sensor for the various systems are located as described below. Name Symbol Name Magnet clutch relay Air-flow sensor (incorporated within barometric-pressure sensor and intake air temperature sensor) Crank angle sensor and top dead center sensor Detonation sensor <Turbo>...
  • Page 60 ELECTRICAL - Relays, Control Units and Sensors...
  • Page 61 Relays, ELECTRICAL Control Units and Sensors Name Symbol N a m e Symbol Pulse generator B Throttle position sensor Automatic transaxle fluid temperature sensor Vehicle speed sensor (reed switch) Pulse aenerator A NOTE The “Name” column is arranged in alphabetical order. Automatic transaxl fluid temperature sen...
  • Page 62 ELECTRICAL - Relays, Control Units and Sensors ‘O-CRUISE CONTROL SYSTEM Vehicle speed sensor (reed switch) AUTOMATIC SEAT BELT Symbol Name Symbol Name Automatic seat belt motor relay Automatic seat belt control unit...
  • Page 63 8-11 ELECTRICAL - Relays, Control Units and Sensors HEATER AND AIR CONDITIONER Name Symbol Name S y m b o l Condenser fan motor relay Air inlet sensor Engine coolant temperature switch Air therm0 sensor Heater relay Blower motor High relay Magnet clutch relay Radiator fan motor relay NOTE...
  • Page 64 ELECTRICAL - Relays, Control Units and Sensors Blower motor High relay Symt Name Symbol Name Pop-up motor relay Headlight relay Passing control relay NOTE The “Name” column is arranged in alphabetical order.
  • Page 65 8-13 ELECTRICAL OTHER RELAYS AND CONTROL UNITS Name Symbol Name Symbol Alternator relay Power window relay Defogger relay Radiator fan motor relay Defogger timer Dome light relay Starter relay <M/T> Door lock control unit Taillight relay Door lock relay Theft-alarm control unit Daytime running light relay 1,2 Theft-alarm horn relay Fog light relay...
  • Page 66 ELECTRICAL Theft-alarm horn relay unit or Theft-alarm u control unit...
  • Page 67 ELECTRICAL INSPECTION TERMINAL Symbol Name Symbol Name Oxygen sensor check connector Engine speed detecting terminal Self-diagnosis connector Fuel pump check connector Ignition timing adjustment connector NOTE The “Name” column is arranged in alphabetical order.
  • Page 68 ELECTRICAL - Lighting HEADLIGHT right and left headlights: should one mechanism fail, The parallel-link pop-up headlights are employed the other remains operative. that move up or down vertically as they are turned In addition, when the passing light is used, the ON or OFF.
  • Page 69 ELECTRICAL - Lighting The parallel-link pop-up headlight mean that the headlights are facing forward even when they are in the lowered position. When the passing light is used, therefore, the headlights are turned ON and the light is radiated through the optical horn Front turn signal light (Optical horn)
  • Page 70 ELECTRICAL HEADLIGHT RAISING OPERATION 1. Pop-up switch ON, lighting switch OFF When the pop-up switch is turned ON, current from about 180” to the UP stop position, the contact of fusible link @ flows through the up timer circuit of the interlocking U/D switch changes from U to D, the passing control relay, turning ON transistor Trl .
  • Page 71 ELECTRICAL - Lin htina 2. Lighting switch ON, pop-up switch OFF When the lighting switch is turned ON (HEAD position), current from fusible link @ flows through the lighting switch, diode, and the up timer circuit of the passing control relay. turning ON transistor Trl . Then, as in 1, the pop-up motor relay is energized causing the pop-up motor to start rotating, which in turn results in the headlights being raised.
  • Page 72 ELECTRICAL - Lighting HEADLIGHT LOWERING OPERATION 1. Pop-up switch from ON to OFF, lighting switch OFF When the pop-up switch is turned OFF (from the result, the headlights start lowering. When the ON position) with the headlights in the raised crank arm of the popup motor rotates about 180”...
  • Page 73 8-21 ELECTRICAL - Lighting 2. Lighting switch from ON to OFF, pop-up switch OFF...
  • Page 74 ELECTRICAL DELAYED SWITCH-OFF DOME LIGHT Ignition ON switch OFF pr When the door is closed with the dome light switch in tht DOOR position and ignition switch in the OFF position, the Door switch OFF dome light stays lit for a given period of time and then dims before going out.

  • Page 75: Engine Electrical

    8-23 ELECTRICAL - Ermine Electrical ENGINE ELECTRICAL ALTERNATOR Electronic voltage regulator Stern terminal The alternator has a built-in electronic voltage regulator. The output voltage is controlled by the voltage regulator through detection of the battery voltage. SPECIFICATIONS Nominal output .._.._.. and Turbo Engine Regulated voltage .
  • Page 76 ELECTRICAL - Engine Electrical STARTER MOTOR Reduction gear Magnetic switch Shift lever Pinion gear Armature clutch Permanent magnet SPECIFICATIONS Type ........ Reduction drive Nominal output .... 1.2 kW Rotating direction ..Clockwise (viewed from pinion side)
  • Page 77 8-25 ELECTRICAL - Engine Electrical IGNITION SYSTEM Battery Power transfstor Sensors speed detectton spark plugs of the No.1 and No.4 cylinders. The ignition system is a two-coil ignition system that Similarly, power transistor “B” controls ignition coil supplies sufficient energy for ignition up to high “B”...
  • Page 78 ELECTRICAL IGNITION COIL Two compact ignition coils of a molded type featuring outstanding ignition performance are used. , tachometer Being a two-coil type, the ignition coil has a unit to supply signals for the tachometer. Specifications Specifications items at 20°C (68°F) Primary 0.86 coil resistance $2...
  • Page 79 8-27 ELECTRICAL - Engine Electrical IGNITION TIMING CONTROL SYSTEM Ignition switch Air flow sensor Intake air temp. sensor Barometric pressure sensor Engine coolant temp. sensor Top dead center sensor Crank angle sensor Vehicle speed sensor Ignition switch “ST” terminal Detonation sensor for 109 _ turbo engine only Terminal for engine speed detection...
  • Page 80 ELECTRICAL - Engine Electrical IGNITION TIMING CONTROL Control mode Control mode distribution control (selection of power transistor actlvatlon) Power Power is determined by making preset corrections which The above block diagram shows the fljnctions of the has been for engine coolant temperature, intake air engine control unit for ignition timing control.
  • Page 81 . ,-s- ,-T,“~:~y.“‘ ~...:tg== 8-29 ELECTRICAL - Engine Electrical No. 1 TDC No. 3 TDC No 4TDC No 2 TDC angle si g nal Crank Exhaust Intake Combustion No. 1 cylinder stroke stroke stroke Compression Exhaust Intake No. 3 cyltnder stroke stroke stroke...
  • Page 82 ELECTRICAL Ignition Advance Angle Control While cranking temperature temperature pressure sensor , sensor sensor To ignition Engine Intake air Advance angle map value Barometric coil coolant temperature and intake air volume correction The engine control unit has the ignition advance Engine coolant temperature correction: The engine coolant temperature sensor detects the angle value for all cylinder stroke intake air volumes...
  • Page 83 Knocking Control for Turbo Engine Only Advance map value sensor Knock wbral+on If knocking continues, the advance angle map value Engine knocking is detected and the ignition timing is controlled accordingly to prevent continued is corrected gradually in the delay direction. knocking and to protect the engine.
  • Page 84 ELECTRICAL - Theft-alarm System THEFT-ALARM SYSTEM Furthermore, the starter circuit is interrupted in SI a way that the engine cannot be started, if ‘ L When the theft-alarm system has been armed by a ignition key is not used. Note that this system is fixed sequence for locking the doors with the key or controlled by the electronic control unit (ECU).
  • Page 85 8-33 System ELECTRICAL - Theft-alarm ARMING THE SYSTEM After the following procedures have been completed, the SECURITY light illuminates for about 20 seconds, and when illumination stops, the system is armed. (1) Pull out the ignition key from the key cylinder. (2) Open a door.

  • Page 86: Technical Features

    ENGINE CONTENTS GENERAL INFORMATION ................BASE ENGINE Engine Cut-away View ........ Connecting Rod ..........Major Specifications ..................Crankshaft Technical Features ................Crankshaft Pulley Cylinder Block ..........LUBRICATION SYSTEM ........ Cylinder Head ..........Specifications ..........Main Bearing Caps ............
  • Page 87 GENERAL INFORMATION M A J O R Turbo engine Items Non-Turbo engine 4 in-line, longitudinal Number and arrangement of cylinder 4 in-line, longitudinal mm (in.) 85 x 88 (3.346 x 3.465) Cylinder bore x stroke 85 x 88 (3.346 x 3.465) cc (cu.in.1 1997 Total displacement...
  • Page 88 ENGINE - General Information TECHNICAL FEATURES HIGH PERFORMANCE AND .._....FUEL ECONOMY minimizes friction loss. 3. The combustion chamber is of the pentroof type with a squish area that offers outstanding combustion efficiency. 4. The multipoint fuel injection system is electronically controlled.
  • Page 90 ENGINE...
  • Page 91 ENGINE - General Information - -.. _...
  • Page 92 ENGINE BASE ENGINE Valve guide Valve seat Squish area intake port Spark plug hole Exhaust port Camshaft lubricating Camshaft lubricating oil passage type. The two intake and two exhaust ports are combustion chambers. in a crossflow arrangement. There is a squish tions on the intake side, and six on the exhaust area provided in the combustion chamber, which promotes turbulence, further mixing of...
  • Page 93 ENGINE - Base Engine Bearing cap No. No. 6 L: intake stde No. 5 Camshaft Q intake side ROCKER COVER Breather plate Rocker cover Rocker cover From air intake hose Positive crankcase To intake manifold Viewed from bottom of rocker cover Blow-by gas plug cable is installed.

  • Page 94: Cylinder Block

    ENGINE CYLINDER BLOCK Engine oil to Coolant inlet Engine oil main gallery Silent shaft bearing, rear Silent shaft bearing, front rear main gallery of the cylinder block. When the pressure of oil from the main gallery exceeds 200 kPa (2 kg/cm’, 28 psi), the oil pushes open the check valve, spurting over the inside of the piston, thus cooling it.
  • Page 95 ENGINE - Base Engine PISTON For non-turbo engine For turbo engine Pin ;nterline y FPiston ceyerline Steel strut (1) The piston is the autothermic type with steel (2) The depth of the trough in pistonhead varies for struts cast into it. the non-turbo and turbo engines.
  • Page 96 E N G I N E - Base Engine C O N N E C T I N G R O D SOHC engine. used to lubricate the cylinder wall. (3) The big-end bearing is the kelmet metal with metal backing. Front mark (1) The crankshaft is supported by the five main bearings.
  • Page 97 9-12 Drives the water Drives the air pump and alternator conditioner Timing belt cover compressor Rubber Pulley - (1) The crankshaft pulley not only drives the water (2) There are fins provided at the back of the pulley that ventilate the inside of the timing belt cover: pump and alternator, but also functions as a torsional damper to reduce torsional vibration of when the pulley rotates, they draw air out of the._...
  • Page 98 ENGINE - Base Engine VALVE MECHANISM Rocker arm Exhaust ..................
  • Page 99 ROCKER ARM (1) The cam follower of the rocker arm is a roller with nea,.,- bearings. Needle bearing (2) A jet of oil spurts onto the contact area between the cam and roller from an oil jet located on the fulcrum side of the rocker arm.
  • Page 100 ENGINE Base Engine Operation of the Lash Adjuster During the valve opening stroke When the valve starts opening When the valve coiqpletes the opening stroke -- No external load is applied to the plunger, thus A very small amount of oil leaks through the causing the plunger to be pushed clearance between the lash adjuster body and plunger spring, maintaining zero clearance.
  • Page 101 ENGINE Base Engine Hydraulic Flow to Lash Adjusters -Cylinder head bolt hole - V a l v e b o d y To lash adjuster on To tash adjuster on the exhaust side the intake side Relief spring Relief plunger - V a l v e b o d y The oil moves through the cylinder head bolt hoie to then has its pressure regulated by the valve body k...
  • Page 102 ENGINE CAMSHAR Stamped identification mark - Exhaust camshaft No. 2 cams No. 3 cams cams No. 1 cams Intake camshaft Crank angle sensor NOTE provided for holding the camshaft with a wrench when loosening or tightening the catishaft sprocket bolt. TIMING BELT TRAIN Intake tide Camshaft sprocket...
  • Page 103 ENGINE tensioner absorbs these changes in belt ten+n, (1) The intake camshaft, exhaust camshaft, and the not only to prevent the noise problem oil pump are driven by a single timing belt. getting worse, but to improve durability as weli’l (2) Timing belt tension varies at different engine temperatures and ages of the belt.
  • Page 104 ENGINE Operation of the Auto Tensioner WHEN THE BELT TENSION HAS INCREASED tensioner arm pushes the piston in the direction shown arrow @, hydraulic causing the pressure in the pressure chamber to build up. piston, which causes a small amount of oil to gradually leak through the clearance between the piston and cylinder into the reservoir chamber.

  • Page 105: Lubrication System

    LUBRICATION SYSTEM Oil cooler* Oil filter pressure NOTE through the cartridge-type oil filter before being The lubrication system is the pressure-feed, full- delivered to the various engine parts. flow filter system. The engine oil sent under pressure by the gear-type oil pump is filtered Specifications Items pump...
  • Page 106 9-21 ENGINE - Mounts MOUNTS The transmission of engine vibration to the body the mounts, the principal axis of inertia support is reduced by the installation, via bushings, of system is employed. the centermember to the body. This principal axis of inertia support system of The insulators each have a cavity that serves to mounting functions to support the upper part of the effectively absorb vibrations.
  • Page 107 ENGINE - Mounts PRINCIPAL AXIS INERTIA SUPPORT SYSTEM Principal axi? of inertia The vibrations generated from the engine and drive train consist of such eiements as vertical vibrations caused by the engine’s combustion processes, as well as rollings caused by the torque reaction force of the tyres and the crankshaft rotation etc.
  • Page 108 INTAKE AN EXHAUST CONTENTS RllA--- ..........EXHAUST MANIFOLD ........INTAKE MANIFOLD TURBOCHARGER ..........EXHAUST PIPE ............ Construction Diagram ....-......

  • Page 109: Intake Manifold

    11-2 INTAKE AND EXHAUST - Intake Manifold / Exhaust Manifold INTAKE MANIFOLD Plenum chamber The intake manifold is of the independent port type with a plenum chamber and long intake port which produce inertia supercharging effect for higher air intake efficiency. EXHAUST MANIFOLD The exhaust manifold is the dual exhaust type which minimizes exhaust interference and improves exhaust efficiency.
  • Page 110 11-3 INTAKE AND EXHAUST - Turbocharger TURBOCHARGER RllCBAA From air cleane Turbocharger (2) Lubricant for the turbocharger is introduced to the tur- From exhaust bocharger through the oil pipe from the cylinder head oil path. (3) The coolant flows from the thermostat case to the turbocharger through the water hose and pipe.
  • Page 111 INTAKE AND EXHAUST - Turbocharger 11-4 Coolant from thermostat case Oil inlet /ater pipe Water I From exhaust manifold section Oil outlet To intercoaler To exhaust pipe From air Cieaner LI/ Bearing Turbine wheel Compressor wheel Waste gate actuator 6lN0026...

  • Page 112: Exhaust Pipe

    INTAKE AND EXHAUST EXHAUST PIPE the transmission of vibrations from the exhaust system to the body. using rubber hangers and, in addition, a flexible pipe is used at the front exhaust pipe in order to reduce CONSTRUCTION DIAGRAM <Non-turbo> muffler Center exhaust pipe Catalytic converter Front exhaust pipe...
  • Page 113 FUEL SYSTEM CONTENTS GENERAL ..................ACCELERATOR COMPONENTS IDLE SPEED CONTROL ........AIR CONDITIONER RELAY CONTROL .... 55 ........General Description ........ AIR FLOW SENSOR (AFS) FILTER RESET Idle Speed Control Servo CONTROL <Turbo > ..........INTAKE AIR CONTROL ........AUTO-CRUISE CONTROL SYSTEM ....
  • Page 114 FUEL SYSTEM “GENERAL The fuel system is of the Electronic Control Multi- the engine control unit. point Fuel Injection type, which has an injector for Refer to Group 8 ELECTRICAL for No. 6 IGNITION each cylinder. The system comprises various sen- TIMING CONTROL.
  • Page 115 FUEL SYSTEM - General 14-3 sent to the engine control unit. under pressure by the in-tank The fuel is supplied The crank angle sensor converts the crank type fuel pump, and is injected from injectors into all into an electric that is, engine turning state and sends it to the engine control unit.
  • Page 116 FUEL SYSTEM FUEL SUPPLY AND FUEL PRESSURE CONTROL GENERAL DESCRIPTION Fuel gauge unit Fuel tank Fuel presbre regulator unit Fuel tank Engine control unit Fuel pump check terminal Fuel p&sure regulator...
  • Page 117 FUEL SYSTEM - Fuel Supply and Fuel Pressure Control <Turbo - 4WD> Fuel tank Fuel pump check terminal Canister Check valve Purge control v a l v e \ Fuel injector Fuel p:essure regulator...
  • Page 118 FUEL SYSTEM - Fuel Supply and Fuel Pressure Control intake manifold Fuel Engine The injectors are activated on command from the The fuel supply system comprises electromagnetic engine control unit and inject the fuel to each intake type injectors, a delivery pipe, a fuel pressure port of cylinder head sequentially according to the regulator, a motor-driven fuel pump, and the engine predetermined ignition order.
  • Page 119 FUEL SYSTEM - Fuel Supply and Fuel Pressure Control FUEL TANK that fuel supply is smooth even when there is only a small amount of fuel remaining. A baffle plate arrangement is used at the proper The fuel tank is located below the rear seat floor, place within the fuel tank in order to prevent the thus giving it protection in the event of a generation of abnormal noise caused by the...
  • Page 120 FUEL SYSTEM - Fuel Supply and Fuel Pressure Control FUEL PUMP This fuel pump is known as the in-tank type because discharge pulsation. it is located within the fuel tank itself, surrounded by It has a lower level of operation sound that the the fuel.

  • Page 121: Interior

    Fuel Supply and Fuel Pressure Control A high-pressure type filter is installed at the delivery end of the fuel pump. The fuel pressure regulator maintains the pressure of fuel delivered to the injectors at a constant level of 335 kPa (47.6 psi) (Non-Turbo models) or 255 kPa (36.3 psi) (Turbo models) Diaphragm from intake...
  • Page 122 FUEL SYSTEM - Fuel and Fuel Pressure Control INJECTOR Intake port An injector is mounted on each of the four intake ports of the cylinder head. The injector is activated by electric current controlled by the engine control unit. needle valve, which form a single unit are magnetically attracted, causing the injector nozzle to open and fuel to be injected.
  • Page 123 Fuel Supply and Fuel Pressure Control Fuel-pressure control valve Fuel-pressure regulator To fuel Engine Intake-air control unit As a result. the fuel pressure is increased and the Usually, the negative pressure (vacuum) of the intake manifold is applied to the fuel-pressure generation of fuel vapors caused by high tem- perature is suppressed, thereby maintaining idling regulator, and, because the fuel pressure is thus...
  • Page 124 INTAKE AIR CONTROL , S p e e d a d j u s t i n g s c r e w Throttle valve 0 Fast idle air valve before metenng after metenng oolant from thermostat case To return pipe Control of the volume of intake air is performed by the throttle valve, the speed adjusting screw, the fast idle air valve and the idle speed control servo, all of which are mounted on tti...
  • Page 125 Specifications Throttle body 60 (2.362) mm (in.1 Throttle bore diameter Fast idle air valve Approximately 50 (122) Valve closing temperature Stepper motor type Engine coolant pellet Valve seat air flow rate. The valve is closed completely when The fast idle valve.
  • Page 126 14-14 FUEL SYSTEM - Sensors SENSORS GENERAL DESCRIPTION The types and functions of the sensors are as listed send corresponding signals to the engine control below. These sensors detect engine conditions and unit. SENSORS FUNCTION AIR FLOW SENSOR Senses the intake arr volume with a Karman vortex flow meter. INTAKE AIR TEMPERATURE Senses the Intake air temperature (temperature of air at the point of entry into the air cleaner).
  • Page 127 FUEL SYSTEM - Sensors AIR FLOW SENSOR Power supply Air flow sensor (from control relay) Engine control unit To throttle Vortex The air flow sensor for measuring the volume of engine intake air uses the Karman vortex phenomenon to detect the air flow rate.
  • Page 128 FUEL SYSTEM - Sensors MEASUREMENT OF INTAKE AIR FLOW Transmitter No vortices are generated in the absence of air flow. Therefore, the ultrasonic waves transmitted from the transmitter take a fixed time to reach the receiver. This time is called the “reference time”. This time shall be referred to as “T”.

  • Page 129: Intake Air Temperature Sensor

    FUEL SYSTEM - Sensors when more air is drawn, the modulator a result, when less air is drawn, it generates more pulses, and generates less pulses. air flow sensor measures the intake air flow based on this principle. Pulses generated by modulator Pulses generated by modulator 6FuW INTAKE AIR TEMPERATURE SENSOR Intake air...
  • Page 130 FUEL SYSTEM - Sensors Engine BAROMETRIC PRESSURE SENSOR control unit pressure sensor 760 (30) Barometric pressure mmHg (in.Hg) A barometric pressure sensor is alas mounted on ignition timing. the aif flow sensor. It senses the barometric This ensures improved driveability at high altitudes. pressure and converts it to electrical voltage which The barometric pressure sensor converts the pres- is sent as a signal to the engine control unit.
  • Page 131 FUEL SYSTEM - Sensors THROTTLE POSITION SENSOR Throttle posItIon Throttle sensor Full close open Throttle opening deg. generates, the engine control unit detects the The throttle position sensor is a variable resistor throttle valve opening and determines the engine whose movable contact rotates coaxially with the operation mode (acceleration or deceleration).
  • Page 132 FUEL SYSTEM - Sensors CRANK ANGLE SENSOR Disc Sensor The crank angle sensor is mounted on the cylinder The crank angle sensor consists of a disc -and a head and is directly coupled to the intake camshaft. sensor unit. The disc, made of metal, has four slits located 90 degrees apart on its periphery and two slits located 180 degrees apart inward of the four slits.
  • Page 133 FUEL SYSTEM - Sensors the slit moves beyond the space between the When exposed to light, the photo diode conducts LED/photo diode pair, the light can no longer reach the photo diode, thus the current indicated by the dotted line ceases to flow and the terminal voltage by the arrow and dotted line and a voltage (5 volts) is of the engine control unit becomes 0 volt.
  • Page 134 FUEL SYSTEM - Sensors VEHICLE SPEED SENSOR Engine control unit speed sensor Vehicle speessensor Vehicle speed sensor The vehicle speed sensor is a reed switch type sensor and is installed in the speedometer. It converts the transmission speedometer driven gear revolutions (vehicle speed) to pt signals and sends them to the engine control unit.
  • Page 135 FUEL SYSTEM - Sensors AIR CONDITIONER SWITCH Batten/ ‘Air conditioner Air conditioner unit control unit voltage Dual pressure switch Coolant temperature switch Engine control unit increase the idle speed to the preset rpm. Thus This switch sends the air conditioner ON/OFF signal engine rpm loss due to air conditioner operation to the engine control unit.
  • Page 136 Engine control unit Battery voltage Power steering oil pressure switch activates the idle speed control servo to control the When the steering wheel is turned and the pressure of the power steering oil pump increases, idle speed. Specifically, it prevents the idle speec the power steering oifpressure switch sends an ON from dropping due to oil pump load, thus ensuring stable engine idling.
  • Page 137 FUEL SYSTEM - Sensors IGNITION TlMlNG ADJUSTMENT TERMINAL This terminal is used when adjusting the basic ignition timing or basic idle speed. When this terminal is shorted to ground, the engine control unit cancels the sets the ignition and idle speed control servos in their Terminal for adjusting mode.
  • Page 138 Battery The inhibitor switch’s ON (when “N” or “P”) or OFF (when other than “N” or “P”) signals are input to the engine control unit. The engine control unit, based on these signals, then determines whether the transaxle is in neutral or is in a drive range, and then activates the idle-speed control servo so as tc regulate the idling rpm.
  • Page 139 Engine control unit the sensors described earlier, and then controls and The engine control unit consists of an 8-bit micro activates the necessary actuators as shown in the computer, a random access memory, a read only table below to achieve optimum engine operating memory and an input/output interface.
  • Page 140 FUEL SYSTEM - Ennine Control Unit leshooting. It also has a fail-safe/backup function tc The engine control unit has an onboard diagnosis function, which is used mainly to diagnose the ensure passenger and vehicle safety. sensors, thus facilitating system checks and troub- Mainly for detecting failure of sensors and for outputting diagnosis code.
  • Page 141 FUEL SYSTEM - Engine Control Unit Terminal Connection Terminal Connection Self-diagnosis output Diagnosis/data transfer select terminal Power transrstor for No. 1 and No. 4 cylinder ‘ 3 Turbo meter Power transistor for No. 2 and No. 3 cylinder Oxygen sensor Control relay (Fuel pump control) Power steering oil pressure switch Fuel-pressure control valve...
  • Page 142 FUEL SYSTEM - Engine Control Unit SELF-DIAGNOSIS There are 16 diagnosis items, as listed below; the The diagnosis memory is maintained by backup diagnosis results are stored in computer memory. power from the battery (not by way of the ignition stored results can be ready by connecting a switch) so that it will not be lost even if the ignition...
  • Page 143 FUEL SYSTEM - Engine Control Unit The diagnosis connector is located next to the junction block. By connecting a voltmeter between the No.1 and No.12 terminals of the diagnosis connector, the meter pointer will deflect according to the output pattern shown before so that the diagnosis code can be read.
  • Page 144 Control Unit (2) The backup function of the engine control unit that passenger and vehicle safety can be maxi- ignores the output signal of a failed sensor and instead uses a built-in program or set of values parts. so that the vehicle may continue to function. The If a sensor related to ISC fails, for example, the operating state when the backup function is engine control unit is programmed to prevent...
  • Page 145 FUEL SYSTEM GENERAL DESCRIPTION Air flow sensor Barometric Dressure sensor Coolant temr3erature sensor Top dead center sensor ignition switch Fuel is injected into each cylinder sequentially, and The engine control unit activates the injectors and takes place once for each cylinder every two controls the fuel injection rate in response.
  • Page 146 14-34 FUEL SYSTEM Air flow sensor TDC sensor Reading of input signal Operation mode decision Operation mode decision data Basic valve opening time data Injector activation time control Control factor data of engine coolant temperature, intake air temperature and barometric pressure, etc. Injector activation pulse generation control unit Injector...
  • Page 147 INJECTOR CIRCUIT Control relay Resistor <Turbo> Injector Engine control unit engine control unit causes the power transistor to Electricity from the battery flows to the control relay be turned ON, thus completing the injector ground and then to the resistor (turbocharger-equipped circuit.
  • Page 148 14-36 The resistor functions to regulate the current flowing in the co,. of the injector. Because the injector must respond instantly to fuel-injection signals, the number of windings of the coil is reduced in order to facilitate current rise when the current is flowing in the coil. By doing so, the resistance of the injector coil becomes smaller and a greater amount of current can flow, with the result that the calorific value of the injector coil becomes greater, and...
  • Page 149 14-37 FUEL SYSTEM - Fuel Injection Control Simultaneous Injection INJECTION UPON START CRANKING TDC sensor signal Crank angle sensor signal No. 1 cylinder No. 3 cylinder No. 4 cylinder Combustion Intake Exhaust No. 2 cylinder After the first No. 1 cylinder TDC signal has been During the period immediately following the start of detected, fuel is injected sequentially as described cranking, fuel is first injected once in synchrony with...
  • Page 150 FUEL SYSTEM When cranking the cold engine, fuel is injected into all four cylinders simultaneously twice for every crankshaft revolution, and fuel injection is synchro- nized with the crank angle sensor’s 5” BTDC signal. INCREASED FUEL INJECTION DURING ACCELERATION TDC sensor signal 85”...
  • Page 151 FUEL SYSTEM CONTROL (INJECTOR ACTIVATION DURATION CON- FUEL INJECTION AMOUNT TROL) Open loop control Basic driving time deter- amount control engine coolant temperature temperature Injected fuel Injected fuel during accel- during accel- eration and eration and deceleration deceleration Injector Injector compensation compensation The injector activation duration is determined basi-...
  • Page 152 FUEL SYSTEM BASIC INJECTOR ACTIVATION DURATION In sequential injection under normal operating conditions, fuel is injected into each cylinder once every cycle (i.e., two crankshaft revolutions). The injector activation duration required to inject the amount of fuel that achieves the stoichiometric air-fuel ratio (15 times as much air, by weight, as gasoline, by weight) with regard to the amount of air admitted during one cycle in each cylinder is called the “basic injector activation duration”.
  • Page 153 14-41 FUEL SYSTEM - During normal operation (including idling), the en- input to the engine control unit. gine control unit controls the injector activation time Upon input of this signal, the engine control unit increases the feedback correction factor, thus caus- ing more fuel to be injected.
  • Page 154 14-42 FUEL SYSTEM HIGH ALTITUDE COMPENSATION A change in barometric pressure, which may be caused by change in altitude, alters the intake air density, resulting in an improper air-fuel ratio. To compensate this deviation, the amount of fuel injected is controlled; i.e., the amount of fuel injected is decreased to compensate for the lower intake air density caused by the decreased barometric pressure, or the higher altitude.
  • Page 155 14-43 FUEL SYSTEM Fuel Injection Control during Acceleration During acceleration, acceleration correction described in the section “Simultaneous Injection” is performed in relation to the change in throttle valve opening. Fuel Limiting Control during Deceleration The amount of fuel injected is limited during deceleration in order to prevent the catalyst temperature from going up excessively, and to enhance fuel economy.

  • Page 156: Idle Speed Control

    FUEL SYSTEM - Idle Speed Control IDLE SPEED CONTROL GENERAL DESCRIPTION If the load changes while idling, the idle speed throttle valve, thus maintaining the optimum idle control servo is activated according to the preset speed. control logic to control the air flow that bypasses the Inhibitor switch <AA>...
  • Page 157 FUEL SYSTEM - Idle Speed Control IDLE SPEED CONTROL SERVO Throttle bodv Extend Magnet rotor Stepper motor degrees whenever a pulse is applied. The idle speed control servo, consisting of a step The pintle meshes with the lead screw on the type motor and pintle, is mounted on the throttle magnet rotor shaft, as shown in the above illustra- body.
  • Page 158 FUEL SYSTEM - Idle Speed Control The rotor rotates in either direction by angular step increments corresponding to the number of pulses coming from the en ? control unit, causing the pintle to extend or retract. As pintle retracts or extends, the gap it forms between the sea: changes, controlling the bypass air flow.
  • Page 159 FUEL SYSTEM 14-47 Coil Al and A2 e Fig. A Fig. B The stepper motor construction is as shown in Fig. A. Its operating principles are explained below, with reference to the schematic Fig. 8. STEP “0” Power Engine control unit Coil B 1 Coil B2 When coils Al and Bl are energized the upper...
  • Page 160 14-48 STEP “1” Power Engine control unit Stepper motor When coil A2 is energized instead of coil Al, the result, the S pole of the rotor is attracted to the N lower half of stator I becomes an N pole. This pole of the stator and the rotor moves, or rotates, means that the N pole is moved one step to the one step to the right.
  • Page 161 FUEL SYSTEM - Idle Speed Control Servo Control the target value. In position control, the idle speed Servo control includes feedback control and position control is adjusted to the target position to cope with conditioner and other load changes. Position the value differs from the target idle speed, the unit drives the stepper motor to adjust actual speed to and decelerating.
  • Page 162 SYSTEM (2) When the engine coolant temperature is low, the fast idle air valve together with the idle speed control serv operated to supply an adequate volume of bypass ,.r according to the engine coolant temperature. adiustina screw Throttle valve Coolant temperature “C (OF) Feedback Control at Idle (1) Basic target idle speed...
  • Page 163 FUEL SYSTEM - Idle Speed Control IDLE CONTROL SERVO POSITION CONTROL WHEN THE ENGINE IS IDLING The basic position is preset as a map value Optimized speed control servo is activated to conform to this position, thereby maintaining the optimum idle speed. This basic position of the idle control servo diiectly corresponds to the basic idle speed described earlier.
  • Page 164 FUEL SYSTEM CONTROL WHEN THE ENGINE SPEED IS UNUSUALLY LOW The followi gcontrols are provided when the engine speec falls below i5;D rpm after the engine has been fully warmed-up [with engine coolant temperature more than 55°C (131”F)]. The idle speed control servo is activated immediately by a particular number of angular steps which represent the feedback correction.
  • Page 165 FUEL SYSTEM - (1) Idling stabilization control immediately after starting Engine has started. Immediately after starting, the idle speed control servo activation steps are increased above the idle position; in other words, bypass air volume is increased. The number of steps decreased gradually afterwards.
  • Page 166 FUEL SYSTEM - Power Supply Control Battery The engine control unit controls the power suv ’ tc the sensors, engine control unit and actuate, the control relay. Ignition switch Control relay To air flow sensor, crank angle sensor, idle speed control Engine control unit...
  • Page 167 14-55 FUEL SYSTEM - Air Conditioner Relay Control AIR CONDITIONER RELAY CONTROL Battery switch Air conditioner OFF ON Coolant temperature switch For models equipped with the automatic transaxle, When the air conditioner switch ON signal is input, when the vehicle is subjected to acceleration at the engine control unit turns the air conditioner relay which the throttle valve opening is great (throttle- ON to activate the air conditioner compressor.
  • Page 168 FUEL SYSTEM - Supercharge Pressure Control <Turbo> SUPERCHARGE PRESSURE CONTROL <Turbo> Engine control relay unit Waste gate A i r c l e a n e r Power Waste gate transistor actuator unit Detonation sensor Knock When using premium-grade gasoline, the engine control unit functions to switch ON the power transistor, then waste gate solenoid valve is turned “ON”.
  • Page 169 Air Flow Sensor (AFSI Filter Reset Control <Turbo> / FUEL SYSTEM AIR FLOW SENSOR (AFS) FILTER RESET CONTROL <Turbo> Engine control unit Air flow sensor Air flow sensor Crank-angle sensor Reset terminal Throttle position sensor When these Signals are input. the air flow sensor When the idle switch is ON, or when the throttle resets the modulator.
  • Page 170 SYSTEM FUEL ACCELERATOR COMPONENTS The accelerator is the cable type, and the pedal is generated. the suspended type. In addition, the accelerator pedal switch, which is A nylon bushing is installed on the end of the used as a control sensor on models with the accelerator cable, preventing contact noise be- tween the cable and accelerator arm from being member.
  • Page 171 FUEL SYSTEM - Auto-cruise Control System AUTO-CRUISE CONTROL SYSTEM The actuator is the motor-driven type for a high using the auto-cruise control system, the vehicle degree of adherence to the set speed. flexible [between km/h mph) or higher and actuator in order to prevent the transaxle of body mph) or lower], as selected by the driver, vibrations to the actuator.
  • Page 172 FUEL SYSTEM - Auto-cruise Control System SYSTEM BLOCK DIAGRAM switch cpJT> Auto-cruise control switch . MAIN switch SET (COAST) switch RESUME Intermedi- Actuator ate l i n k mechanism COMPONENT PARTS AND FUNCTION OUTLINE Component part Function Converts vehicle speed to pulse Vehicle speed sensor Receives signals from sensor and control switches;...
  • Page 173 Auto-cruise Control System signals from the vehicle speed sensor and incorporates a micro- the switches, and outputs computer which provides the set coast, resume, actuator’s motor, the electromagnetic clutch, acceleration, cancel, low-speed limitation, high- and the automatic .transaxle (4 A/T) control unit speed limitation, overdrive OFF control, and accordance with programming (software) of the...
  • Page 174 throttle valve to a degree of opening wk, approximately corresponds the vehicle When the SET (COAST) Switch is Depressed speed; this pulse is output when the auto-cruise The vehicle speed at the moment the SET switch control system is set. was switched from ON to Of F is memorized as the Trim pulse “set vehicle speed”, and thereafter the actuator is...
  • Page 175 FUEL SYSTEM When the SET (COAST) Switch ,is Held Down Fixed Fixed speed -bb- ration While the SET switch is ON, the actuator’s DC motor is caused to rotate to the side; the vehicle speed when the Vehicle switch is as deceleration continues is entered in switched OFF speed...
  • Page 176 FUEL SYSTEM - Auto-cruise Control System When the RESUME (ACCEL) Switch is Kept Turned Fixed Fixed While the RESUME switch is ON, the actuator’s DC mote High caused to rotate to the PULL side; the vehicle speed when the switch is switched OFF as acceleration continues is entered in speed the memory, and is thereafter controlled as the fixed speed.
  • Page 177 FUEL SYSTEM - System Auto-cruise Control In the Overdrive Mode OVERDRIVE-CANCEL FUNCTION <A/T> The control unit microcomputer Outputs an OD-ON fixed-speed driving, the actual vehicle during signal (HIGH) constantly, keeping transistor Tr, speed decreases to (or below) a speed which is a turned ON.
  • Page 178 FUEL SYSTEM - Auto-cruise Control System Timing Chart (when RESUME switch is turned after cancellation of auto-cruise control system by cancel switc OD switch Vehicle speed RESUME switch Acceleration (PULL) Actuator stop (DC motor) Deceleration (RELEASE) Fixed-speed - * control mode CANCEL Fixed-speed RESUME mode...
  • Page 179 FUEL SYSTEM - Auto-cruise Control System Timing Chart (when actual vehicle speed drops to less than set speed) 1.2 sec. 19.8 sets. OD switch Set vehicle speed Vehicle speed Acceleration (PULL) Actuator (DC motor) s t o p Deceleration (RELEASE)
  • Page 180 FUEL SYSTEM ACCELERATOR PEDAL SWITCH OFF FUNCTION In the auto-cruise control mode, the control UP;+ microcomputer outputs an ON signal (HIGH) c, The accelerator pedal switch senses the operating At this time, transistor Tr2 turns OFF, causing ON condition of the accelerator pedal. signal I from .the A/r control unit to be shut off, This function turns OFF the accelerator pedal switch which results in the accelerator pedal switch being...
  • Page 181 FUEL SYSTEM connector SELF-DIAGNOSIS When there is a cancellation of the auto-cruise control system operation not intentionally made by the driver, it is possible to determine which circuit or what operation caused the cancella- tion of the auto-cruise control system by following procedures, in the ON position.
  • Page 182 FUEL SYSTEM System NOTE 1. Codes indicated by the symbol are displayed, if tt- conditions are satisfied, even if the system is normal. I,. 20 km/h (12 mph) or higher, or before the auto-cruise conrrol system is set either case, the system is normal if it can be reset. 2.
  • Page 183 FUEL SYSTEM System ACTUATOR CONSTRUCTION and deenergized magnetic clutch is energized actuator unit consists of a motor, a worm by the control signal supplied by the control unit. gear, a worm wheel, a planetary pinion gear, a The clutch transmits the rotation of the motor to magnetic clutch, and two limit switches.
  • Page 184 FUEL SYSTEM ACTUATOR OPERATION IF SET TO A FIXED SPEED As shown in the illustration, the rotation of the DC motor is transmitted to the worm gear --, worm When the SET switch is set to the ON position, the wheel, sun gear (unified) + planetary pinion.
  • Page 185 FUEL SYSTEM - Auto-cruise Control System IF MAIN SWITCH IS SWITCHED OFF become free relative to the sun gear (DC motor), and the selector is returned to the original position by the return spring installed to the selector. interrupted, the clutch plate is returned from the The planetary pinions turn on their own axes while electromagnetic clutch side to the ring gear side by rotating around the sun gear because of the rotation...
  • Page 186 FUEL SYSTEM a cancel signal is input to the microcomputer. When Canceled by the Stop Light Switch (broad causing the transistor that energizes the actuator solid-line arrows) electromagnetic clutch coil to turn OFF. This results The stop light switch is a four-pole type that in the electromagnetic clutch coil grounding circuit integrates the switch for the stop light (NO) with that for the auto-cruise control (NC).
  • Page 187 __ . . _, _ _ ” -- --.-.., ._ u . - , 4. ::; bt-i 3,. F-7 INTERMEDIATE LINKS Accelerator cable A (accelerator pedal side) Intermediate iink A (accelerator pedal side) During Auto-cruise Control Driving The rotation of the selector causes intermediate link B to turn which opens and closes the throttle valve.
  • Page 188 Auto-cruise Control System Ignition switch IGI control switch RESU Actuator electro- M A I N ;FF -+++& Control unit power supply Microcomputer terminal voltage Auto-cruise control unit NC: Normally closed The auto-cruise control switch is built into the steering column switch.
  • Page 189 - - - - (For stop l i g ht ) OFF +-ON The cancel switches consist of the stop light switch, the clutch switch, and the inhibitor switch (“N” position). auto-cruise control operation is canceled if any one of these switches functions.
  • Page 190 UNIVERSAL JOINTS LOBRO O JOINT ........_...... 3 CENTER BEARING .
  • Page 191 PROPELLER SHAFT - General Information GENERAL INFORMATION 1. No. 2 and No. 4 of the propeller shaft. and a The propeller shaft is a 3-piece, 4-joint type with two slidable Lobro joint with low axial sliding resistance center bearings. The shaft, made of three pieces, is used at joint No.
  • Page 192 PROPELLER SHAFT - General Information / Liibro Joint Specifications terns mm (in.) Length x O.D. 707 x 50.8 (27.8 x 2.00) Front 647.5 x 50.8 (25.5 x 2.00) Center 530.5 x 50.8 (20.9 x 2.00) Rear Universal joint Cross type No.

  • Page 193: Center Bearing

    PROPELLER SHAFT - LBbro Joint / Center Bearing ASSEMBLY This joint consists of the inner and outer races each havir,, axially inclined grooves, balls and a cage to hold the balls. When longitudinal or angular change takes place. the balls move the inner and outer race grooves to absorb the change.
  • Page 194 REAR SUSPENSION CONTENTS m7*- REAR SUSPENSION <4WD> ....8 REAR SUSPENSION <ZWD> ....2 DOUBLE WISHBONE SUSPENSION .... ANTI-LIFT GEOMETRY ........4 Construction and Operation ......GENERAL INFORMATION ........ 2 Rear Shock Absorber ................ 2 Construction Diagram Stabilizer ............Specifications ............

  • Page 195: Rear Suspension

    - -- 17-2 REAR SUSPENSION <2WD> - General Information REAR SUSPENSION <ZWD> GENERAL,lNFORMATlON 117BbAA The shock absorbers are the large-capacity type, The rear suspension is light-weight and compact, with little moving resistance, thus assuring a and is a trailing-type, three-link suspension with high stabilized damping force as well as improved rolling rigidity and lateral rigidity.
  • Page 196 17-3 REAR SUSPENSION SPECIFICATIONS Specifications Items 3-link, torsion axle with coil spring type Suspension system Wheel alignment 0 2 3 IO zk .118) Toe-in (left/right wheel difference) mm (in.) Camber Coil spring length 10.2 x 105.2 x 316.5 (.40 x 4.14 x 12.46) Wire dia.
  • Page 197 WHEEL ALIGNMENT The camber and toe-in have been set to the optimum value, in -Wheel center line the same way as for front-wheel alignment. in particular, the camber is negative camber, thus improving straight-ahead driving at high speed. ANTI-LIFT GEOMETRY Ordinarily, when the brakes are applied, the load is mc toward the front of the vehicle as the result of inertial force, c .J this causes the rear end of the vehicle to try to rise upward, but...

  • Page 198: Three-Link Suspension

    REAR SUSPENSION <2WD> - Three-link Suspension THREE-LINK SUSPENSION For this suspension, an U-form axle beam with thus preventing side-slip and maintaining excellent built-in torsional bar that combines the features of handling stability. Moreover, the trailing arm func- the independent suspension and the features of a tions to counteract twisting Of the axle beam and rigid axle with no camber change is employed.

  • Page 199: Suspension Bushings

    REAR SUSPENSION <2WD> - Three-link Suspension SUSPENSION BUSHINGS transmission of tire vibration input to the body itself. In order to improve both the driving stability and Individual independent bushings (with non-linear riding comfort even further, and to reduce vibration characteristics) are also employed at the couplings and noise, the optimum spring characteristic has to the body of the shock absorbers and the coil been employed for each suspension bushing.
  • Page 200 REAR SUSPENSION <2WD> - Rear Hub REAR HUB The rear hub has built-in unit ball bearing to secure high bearing and hub accuracy. By simply tightening the nut to specified torque, optimum preloading is achieved for easier servicing. Unit ball...

  • Page 201: Rear Suspension <4Wd

    REAR SUSPENSION <4WD> - Geneal information GENERAL INFORMATION bushing to external force, and provides excelle The rear suspension is a newly developed double steering stability and a good ride. wishbone independent suspension with a toe-in The special features of this suspension include correction feature utilizing compliance of the Improvement of straight-forward Optimum adjustment of suspension...
  • Page 202 REAR SUSPENSION <4WD> - (nformation THREE SIDE VIEWS Specifications Double wishbone tvpe Suspension system Coil spring Wire dia. x O.D. x free length mm (in.) Purple x 1 Coil spring identification colour 25.0 (2.50, 140) Spring constant N/mm (kg/mm. Ibs.An.1 Shock absorber Hydraulic, cylindrical double-acting We 568 (22.4)
  • Page 203 REAR SUSPENSION <4WD> WHEEL ALIGNMENT This rear suspension has a toe and camber adjustment mechanism. TOE ADJUSTMENT Section A-A Toe can be adjusted by turning the trailing arm attaching bolt at the crossmember and trailing arm connection. CAMBER ADJUSTMENT Section A-A Adjusting (eccentric Camber can be adjusted by turning the upper arm...

  • Page 204: Double Wishbone Suspension

    . -.- REAR SUSPENSION - Double Wishbone DOUBLE WISHBONE SUSPENSION CONSTRUCTION AND OPERATION Left Right Suspension crossmember 2. Upper arm 3. Lower arm 4. Axle housing 5. Trailing arm Middle joint 1. The suspension consists of a pair of lateral arms centerline of the upper and lower arm ball joints (upper arm (2) and lower arm (3)) mounted on as a steering axis.
  • Page 205 This middle joint is located exterior to straight line (p’ connecting the trailing arm end mounted on the crossmet ber side with the axle housing (king pin). Because of this arrangement, the momentary center P (intersection of front member centerline (0,) of the trailing arm and line (02) interconnecting the middle points of the lateral arm mounting points) is positioned rearward of the wheel center.
  • Page 206 Double Wishbone Suspension ber support bushing on the body. The input from the wheel is first damped by the trailing arm and the bushings of the lateral arms. It is then further damped by the member Member support bushing. This dual anti-vibration construction pro bushing vides low vibration and low noise.

  • Page 207: Rear Shock Absorber

    The rear shock absorber consists of a shock The inputs from the shock absorber and coil spr, absorber, coil spring, etc., arranged concentrically. are borne by the upper bushings and spring pad, The shock absorber is a hydraulic cylinder of the respectively, for a better ride and lower vibration double action type with low sliding resistance, and and noise level.

  • Page 208: Trailing Arm

    Suspension a rod rubber and trailing arm bushing. It is inserted The trailing arm has a welded axle housing, knuckle and shock absorber bracket. The axle housing is into the trailing arm and can make a rotary motion machined after welded to the trailing arm to relative to the bolt.
  • Page 209 REAR SUSPENSION - Double Wishbone Suspension STABILIZER The stabilizer bar is a 20 mm I.79 in.) solid bar. This bar and link are joined by a pillow ball type ball joint* to improve stabilizer effect. Stabilizer rubber Lower arm Crossmember...
  • Page 210 POWER STEERING CONTENTS RIB& PINION AND VALVE ASSEMBLY GENERAL INFORMATION ......CONSTRUCTlON N ..........

  • Page 211: General Information

    19-2 POWER STEERING - General Information GENERAL INFORMATION The steering wheel and column have the following integral rack and pinion type. This power steering features for superb operational and safety character- has the following features for greater reliability and istics. improved steering characteristics.
  • Page 212 19-3 POWER STEERING - General Information Specifications Items 372 (14.6) mm (in.) Steering wheel O.D. Steering wheel maximum turns Shaft and joint type Steering angle Inner wheel Outer wheel 30 (1.2) mm (in.1 Tilt stroke Rack and pinion Steering gear type 138 (5.41 mm (in.) Rack stroke...
  • Page 213 TILT STEERING CONSTRUCTION The tilt-steering mechanism is composed of the tilt and the other is left-threaded. with the result that the tilt bracket is sandwiched by the tilt bolts and lever, tilt bracket, a plate, tilt bolts, etc. A tilt screw the plate part of the column when the tilt lever is is welded to the end of the tilt lever;...
  • Page 214 POWER STEERING - Power Steering Gear Box Construction The steering gear box, in the same way as the , ne steering gear box is of the rack and pinion type manual steering gear box, is installed to the body by with a built-in hydraulic control unit which uses a way of the mounting rubber in order to reduce the compact and highly reliable rotary valve.
  • Page 215 POWER STEERING - Pinion and Valve Assembly Construction PINION AND VALVE ASSEMBLY CONSTRUCTION The pinion and valve assembly is composed of the torsion bar, the pinion gear is provided with a input shaft, torsion bar, pinion gear and rotary valve. The input shaft is hollow and incorporates the the steering wheel directly to the pinion gear by torsion bar within it;...
  • Page 216 POWER STEERING - Pinion and Valve Assembly Construction torsion bar is. as shown in the illustration, caused to OPERATION OF THE PINION AND VALVE torque in the direction of turning to the right, with the result that the input shaft rotates by the corresponding amount to the right, and a rotational power cylinder is performed by the input shaft and difference between the input shaft and rotary valve...
  • Page 217 19-8 POWER STEERING - Pinion and Valve Assembly Construction WHEN THE STEERING IS AT THE CENTER POSI- TION Because the input shaft does not rotate, the and chamber “A”, returning to the oil reservoir. position is the center (neutral) position relative to Note that the power assist is not activated, because the rotary valve, and the fluid supplied from the oil no pressure difference develops in the left and right...
  • Page 218 POWER STEERING - Pinion and Valve Assembly Construction WHEN THE STEERING WHEEL IS TURNED TO THE LEFT When this happens, the fluid flows from the oil torsion bar is, as shown in the illustration, caused pump to sleeve “a”. port “a”, “c”...
  • Page 219 POWER STEERING - Oil Pump OIL PUMP The oil pump has a separate oil reservoir; it is a vane-type pump that generates hydraulic pressure by the rotor, vanes and cam reduce the power-assist effect during high-speed driving and thereby improve steering stability) and a relief valve (in order to maintain the hydraulic pressure and steering linkage rela- t i o n s h i p ) .
  • Page 220 POWER STEERING - Pinion and Valve Assembly Construction WHEN THE STEERING WHEEL IS TURNED TO THE LEFT When this happens, the fluid flows from the oil torsion bar is, as shown in the illustration, caused to pump to sleeve “a”, port “a”, “c”...
  • Page 221 POWER STEERING - Oil Pump OIL PUMP The oil pump has a separate oil reservoir; it is a vane-type pump that generates hydraulic pressure by the rotor, vanes and cam reduce the power-assist effect during high-speed driving and thereby improve steering stability) and a relief valve (in order to maintain the hydraulic pressure and steering linkage rela- t i o n s h i p ) .
  • Page 222 POWER STEERING - Oil Pump PERFORMANCE OF THE OIL At pump rotation of 600 rpm and fluid temperature of 4.4 litmin. (268.5 cu.in./min.), or more at pump pressure of 4,000 kPa (569 psi) (pump rpm vs. discharge quantity) Characteristic At pump pressure of 2,000 kPa (285 psi) and fluid temperature of 50-60X (122-140°F): 6.58 lit./min.
  • Page 223 POWER STEERING - Oil Pump WHEN OIL PUMP OPERATES AT LOW SPEED variable orifices. As a result of this action the fluid A part of the fluid discharged from the oil pump passes through the variable and fixed orifices, and is passes through the pilot port and hydraulic pressure sent, by way of the plunger, to the gear box.
  • Page 224 POWER STEERING - Oil Pump WHEN OIL PUMP OPERATES AT HIGH SPEED box then is supplied only from the fixed orifice, with the result that the amount of discharge plunger is pushed further toward the right than for flow is reduced to minimum, and, as a result, the medium speed, and both variable orifices close.
  • Page 225 TRANSAXLE MANUAL AND AUTOMATIC RzlA- - _ CONTENTS ....16 AUTOMATIC TRANSAXLE One-way Clutch ..........Parking Mechanism ........A/T SAFETY-LOCK SYSTEM ......Planetary Gear ..........GENERAL lNFORMATlON ......Power Flow ............. Sectional View ..........Rear Clutch ............ Specifications ..........Select Pattern ..........
  • Page 226 21-2 MANUAL TRANSAXLE <2WD> - General Information MANUAL TRANSAXLE <ZWD> GENERAL INFORMATION RzlBMC One of two types of manual transaxles is based on KM21 0 manual transaxle is a new is equipped which according engine output characteristics. F5M22 product with various reinforcements and with high- manual transaxle is basically the same as former er capacity to match high output of turbo engine.
  • Page 227 MANUAL TRANSAXLE <2WD> Information SECTIONAL VIEW Clutch housing Bear ‘In g retainer gear assembly Rear cover Reverse gear noise-orevention device Intermediate aear Spacer output shaft drive gear...
  • Page 228 MANUAL TRANSAXLE <2WD> - General Information Clutch housing Bearing retainer gear speed synchro- synchronizer nizer assembly assembly . Reyerse gear now-prevention d e v i c e mediate gear Intermediate gear Differential drive gear Spacer Drain plug...
  • Page 229 21-5 MANUAL TRANSAXLE Control For transaxle control, a floor-shift system employing A vibration-absorbing steel plate has been pro- cables for control has been adopted. vided at the shift lever bracket’s cable connec- Rubber vibration-absorbers have been provided tion point in order to reduce the shifting noise. at the points of connection of the shift and Shaking movement of the shift lever during select cables to the transaxle and the body in...
  • Page 230 MANUAL TRANSAXLE <4WD> having wheels. Using the viscous coupling as a device for center differential mounted on the output shaft of limiting differential of the center differential, this the conventional front wheeledrive type transaxle so transaxle is a full time type and provides as to distribute drive power to the front and rear...

  • Page 231: Manual Transaxle

    21-7 MANUAL TRANSAXLE SECTIONAL VIEW Clutch housing Bearing retainer Input shaft - Drive bevel gear intermediate gear shaft Center differential Front differential...
  • Page 232 MANUAL TRANSAXLE <4WD> Viscous coupling Center differential Rear differential Viscous coupling (Option) The 4WD system configuration and a section of the The viscous coupling for the center differential is center differential are shown above. located on rear side of center differential.This The center differential is placed on the center shaft arrangement makes the entire transaxle simpler a and engine power is transmitted to the front and...
  • Page 233 21-9 MANUAL TRANSAXLE <4WD> according differential action of the center differential to the rotating speed difference between the center differential case and the center shaft, thereby through the input shaft and intermediate gear to the center differential. securing drive force. Half of the drive power distributed by the center The center differential which distributes power to differential is transmitted through the front differen-...
  • Page 234 MANUAL TRANSAXLE <4WD> Conventional 4WD systems (direct-coupled 4WD, such operations used to be made manually. The or center differential type 4WDl have their own driver can participate with the merits of 4WD at all merits and demerits; they rely on manual operation (switching between 4WD and 2WD modes, center viscous coupling under representative conditions differential locking) to cope with their demerits.
  • Page 235 MANUAL TRANSAXLE <4WD> - General Information When driving on rough roads In case either a front or rear wheel starts spinning on a slippery or muddy road or when the vehicle is stuck in mud and one tire spins, the drive power will be decreased by differential action. However, as this also causes a sharp increase of speed difference of the viscous coupling, a large differential limiting torque is now applied, with more power transmitted to the tires...
  • Page 236 VISCOUS COUPLING (VCU) Seal Center shaft The construction of the viscous coupling fck the Within the housing, outer plates (with their outer center differential is as shown above. edge fixed to the housing inside splines) and inner The housing is splinecoupled to the center shaft plates (with their inner edge fixed to the hub outF-- and the hub is also spline-coupled to the output flange of the center differential case.
  • Page 237 In contrast, the inner plates have no such spacer rings, and each can slide to some extent over the hub spline shaft between the outer plates. The space between the housing and outer and inner plates is filled with mixture of silicone oil and air. Principles of operation The viscous coupling is a kind of fluid clutch that uses viscous resistance (shear stress) of the fluid to transmit power or limit...
  • Page 238 Hump phenomenon specific to viscous couplings Rotating speed difference Hump is a phenomenon specific to viscous couplings althob,, I it does not occur under normal operating conditions. This phenomenon occurs when the silicone oil temperature has Transmitted risen due to sustained differential action. Normally silicone oil torque fills the space between the inner and outer plates, preventing their direct coupling.
  • Page 239 MANUAL TRANSAXLE , 4~ construction and operation, refer to TRANSAX- LE CONTROL of 2WD system.

  • Page 240: Automatic Transaxle

    AUTOMATIC TRANSAXLE - General Information GENERAL INFQRMATION T h e s e F4A22 automatic transaxles are transaxles of KM1 70 Type II series and each is a two-mode electronically controlled automatic transaxle with shift patterns of two modes. SPECIFICATIONS Items Transaxle model Torque convertor 2.17...

  • Page 241: Torque Converter

    AUTOMATIC TRANSAXLE - General Information Torque Low-reverse converter brake Converter housing Pulse “ A ” Transfer ‘Rear cover . Input shaft drive gear Transfer driven gear II 81 II II Transfer shaft Transaxle case Pulse generator “B”...

  • Page 242: Transaxle Control

    AUTOMATIC TRANSAXLE - Transaxle Control TRANSAXLE CONTROL The transaxle control is the cable-type floor-shift amount of vibration transmitted to the vehicle system. Rubber is used at the installation parts of interior. In addition, A/T safety-lock system has been the cable to prevent vibration, thus reducing the used to prevent sudden start due to malfunction, Vibration-prevention Vibration-prevention...
  • Page 243 AUTOMATIC TRANSAXLE - A/T Safety-lock System To prevent sudden start due to malfunction of automatic transaxle vehicle, the following system has been installed. KEY INTERLOCK DEVICE SHIFT LOCK DEVICE It is so designed that unless the brake pedal is It is so designed that unless the shift lever is placed depressed, the shift lever cannot be shifted from the “P”...
  • Page 244 AUTOMATIC TRANSAXLE When brake pedal is not depressed When brake pedal is depressed Brake pedal link mechanism Brake Detent pin Shift lock pin Inner cable Shift lock cable Shift loc& Outer cable The shift lock device consists of the brake pedal link Therefore, the shift lever can be shifted to the mechanism and the shift lock cable.
  • Page 245 21-21 AUTOMATIC TRANSAXLE - A/T Safety-lock System KEY INTERLOCK DEVICE When shift lever is in positions other than “P” position When shift lever is in “P” position position LOCK Projection of rotor Hook Detent pin Lock The key interlock device consists of the ignition key cylinder, interlock cable and the lock cam installed position inside the selector handle.
  • Page 246 AUTOMATIC TRANSAXLE - Torque Converter TORQUE CONVERTER Lock ring Damper Turbine .A When damper clutch is activated clutch is activated When damper Input shaft 175202 The torque-converter is composed of the impeller at the damper clutch activation area, passes be- (rear cover), turbine, stator, damper clutch, one-way tween the torque-converter’s hub and the reaction clutch, front cover, etc.

  • Page 247: General Description

    21-23 AUTOMATIC TRANSAXLE TRANSAXLE MECHANISM GENERAL DESCRIPTION section is composed of the torque-converter power train (which transfers the power from the engine to the transaxle) and the shifting mechanism (which functions to provide the most appropriate rotational speed). The damper clutch is installed in the torque-converter section. and functions to reduce the ainount of power loss resulting from slippage of the torque-converter.
  • Page 248 21-24 AUTOMATIC TRANSAXLE SELECT PATTERN when the vehicle is running. in 2nd. 3rd or 4t,. positions to be manually selected by the driver. This gear. It is performed when the load exceeds the downshift point. T h i s function useful when the driver is function of each position selected.
  • Page 249 21-25 AUTOMATIC TRANSAXLE - Transaxle Mechanism FRONT CLUTCH Clutch plate , Check valve pressure Front clutch retainer - (Selection) 1750213 F r o n t composed of a front clutch retainer, discs, plates, and a piston. The front clutch is actuated when the gear.
  • Page 250 AUTOMATIC TRANSAXLE - Transaxle Mechanism REAR CLUTCH Wave sprmg Rear clutch retainer Clutch pressure plate Rear clutch is of the multiple disc type, and is Number of clutch discs composed of a rear clutch retainer, disc, plates, and a piston. When the piston is actuated by the pressure, the multiple disc clutch is connected, I Number of reaction plates conveying driving force from the input shaft to the...
  • Page 251 21-27 AUTOMATIC TRANSAXLE END CLUTCH End clutch type and is installed at the rear is of the multiple disc plate end of the input shaft. The clutch is actuated in the fourth gear (overdrive) to transmit the power from the input shaft to the planetary gear carrier.

  • Page 252: Kickdown Brake

    AUTOMATIC TRANSAXLE - Transaxle Mechanism switch Apply pressure (2nd pressure) Anchor 1750219 The kickdown brake is a band type brake; it is piston and rod moves toward the left, tightening the composed of a kickdown band, drum, kickdown brake band to hold the kickdown drum. As a result, servo, switch and anchor.
  • Page 253 AUTOMATIC TRANSAXLE - Transaxle Mechanism The kickdown servo switch detects the position of the signal to the transaxle control unit. Using this signal, the the 2nd pressure both before, application of the brake. In the initial control stage or until just before the kickdown brake is applied, a higher 2nd pressure is supplied to the kickdown servo that the control stage or while the brake is being applied, the 2nd...

  • Page 254: Low-Reverse Brake

    AUTOMATIC TRANSAXLE - Transaxle Mechanism LOW-REVERSE. BRAKE Center support Piston Hydraulic pressure. 1750221 Low-Reverse brake is of the multiple disc type and is composed of a center support, disc, plates, and a piston. The brake operates when the shift is in 1st gear in the “L”...

  • Page 255: One-Way Clutch

    AUTOMATIC TRANSAXLE ONE-WAY CLUTCH I ’ Long pinion Carrier Input (Planetary gear carrier) output Held stationary sun gear 170207 clutch outer race, is free to turn in clockwise One-way clutch is of the sprag type and is incorpo- direction. In an engine braking condition under rated between the pinion carrier and the center which the annulus gear is turned first.

  • Page 256: Planetary Gear

    AUTOMATIC TRANSAXLE PLANETARY GEAR Reverse sun gear Outer race .- End clutch shaft Short pmlon The planetary gear set incorporated in thus transaxle connected, conveys driving force to the transfer drive gear installed on the output flange. And the is of the Ravigne’aux-type, and consists of a forward parking sprag is provided on the outer circumfer- sun gear, a reverse sun gear, a short prnion.

  • Page 257: Power Flow

    AUTOMATIC TRANSAXLE POWER FLOW Short Dinion Carrier Forward sun gear iransfer drive gear , Idler gear One-way clutch Rear clutch Long pinion Transfer rear clutch is actuated when the shift is in 1 st gear in the gear which rotates in the clockwise direction. Therefore, torque is conveyed from the forward sun gear through the short pinion (counterclockwise) and the long pinion (clockwise) to the Since the long pinion’s shaft (that is, the carrier) tries to turn...
  • Page 258 21-34 AUTOMATIC TRANSAXLE - Transaxde Mechanism Low/Reverse brake Carrier Short pinion Forward sun gear Long pinion Rear clutch *Low-Reverse brake 1 1750058 When the shift is in 1st gear in the range, the low reverse brake is “L” actuated to fasten the planetan/ gear carrier, so that the gear does not turn in either direction.
  • Page 259 AUTOMATIC TRANSAXLE Forward sun gear Long pinion Rear clutch Reverse sun gear Since the rear and the kickdown brake are actuated when the shift is in 2nd gear in the “0” or the “2” range, driving force is transmitted to the forward sun gear which rotates in the clockwise direction, Therefore, torque is conveyed from the forward sun gear through the short and long pinions to the annulus gear, as in the case of 1 st gear.
  • Page 260 A U T O M A T I C T R A N S A X L E - T r a n s a x l e M e c h a n i s m Forward ,sun gear End clutch , Carrier Front clutch...
  • Page 261 AUTOMATIC TRANSAXLE - Transaxle Mechanism ‘EAR (Overdrive) Long pinion End clutch Reverse sun gear When the shift is in 4th gear, the end clutch and the kickdown brake are actuated, and driving force is transmitted from the input shaft through to the planetary gear set to drive the annulus gear (the output flange) via the long pinion.
  • Page 262 AUTOMATIC TRANSAXLE - Transaxle Mechanism Long pinion Low/Reverse brake Front clutch Reverse sun gear When the shift is in reverse.gear, driving force is transmitted to the reverse sun gear because the front clutch is actuated. And the low reverse brake is also actuated, fastening the planetan/ gear set carrier.
  • Page 263 AUTOMATIC TRANSAXLE - Transaxle Mechanism PARKING MECHANISM rking sprag (Annulus gear) Detent plate Detent ball When the shift is in the “P” range, the parking pawl pressing the spring, collides with the parking paw1 engages with the parking sprag provided on outer and the suppon, and is withheld in this condition.
  • Page 264 AUTOMATIC TRANSAXLE - Transaxle Mechanism START SAFETY MECHANISM Inhibitor switch Manual control lever Connector 1750253 1750149 The start safety mechanism ensures the safety Internal Connection in the inhibitor Switch during the engine starting operation. When the selector tever is in the position other than “P” or Connected circuits “N”, the electrical circuit for starting the engine is kept in the OFF state by the inhibitor switch.
  • Page 265 AUTOMATIC TRANSAXLE - Transaxle Mechanism GENERAL DESCRIPTION Pulse oenerator A Hydraulic-pressure control mechanism ..control solenola valve Pressure control solenoid valve Shift solenoid valve Diagnosis connector Electronic control- The transaxle control system is composed of detected, and, based upon the preset damper clutch engaging range, shift pattern and hydraulic pattern, various type of sensors, the transaxle control unit.
  • Page 266 AUTOMATIC TRANSAXLE - Transaxle Control ELECTRONIC CONTROL DEVICE DAMPER CLUTCH CONTROL The damper clutch is engaged or disengaged amount of slippage by duty signals from the control according to the “map” stored in the transaxle unit. The control unit functions to calculate the control unit.

  • Page 267: Transaxle Control

    AUTOMATIC TRANSAXLE used exclusively. The transaxle control unit monitors the throttle shift patterns, namely the power pattern and the position sensor output (which detects the de- economy pattern in its internal memory. gree that the throttle valve is open) and the The driver selects either of the two shift pulse generator B output (which detects output patterns by using the power/economy select...
  • Page 268 AUTOMATIC TRANSAXLE pattern ECONOMY Output shaft speed (rpm) Vehicle speed (km/h) of the “A” and shift controt solenoid valves “B” Shift control solenoid val. corresponding to the gear shifting sequence. The combination of on/off states of the “A” and “B” shift control solenoid valves in each gear is shown in the table below.
  • Page 269 The transaxle control unit decides the timing of the gear shifting period (during which ‘it per- hydraulic control device functions by hydraulic forms hydraulic pressure control for gear shift- pressure force to change the state of the ing) according to the change in the kickdown clutches and brakes to accomplish the gear drum rotating speed that it detects.
  • Page 270 AUTOMATIC TRANSAXLE Gear Shift Operation (3rd While the vehicle is being drive in 3rd gear, the gear ratio is I : 1; that is, the torque converter turbine rotating speed, i.e. the input shaft rotating speed (NT), the kickdown drum rotating speed (No) and the transfer drive gear rotating speed (No) are all the same.
  • Page 271 AUTOMATIC TRANSAXLE - Transaxle Control The transaxle control unit functions, based upon the data the shift control valve, and to make shifting pattern control and hydraulic during shifting. pressure control The transaxle control unit is installed within the passenger Connections of the transaxle control unit’s terminals” and devices are as described below.
  • Page 272 AUTOMATIC TRANSAXLE PULSE GENERATORS Pulse The pulse generators are installed on the top of the transaxle. The pulse generator “A” generates pulses by holes provided the outer circumference of the kickdown drum. The pulse generator generates pulses by the transfer driven gear according to the number of gear teeth.
  • Page 273 21-49 AUTOMATIC TRANSAXLE - Transaxle Control The throttle position The throttle position sensor variable resistor type throttle valve opening. output voltage is input to the transaxle control unit to compute the throttle opening. The throttle position sensor output voltage can be adjusted by the throttle position sensor body.
  • Page 274 AUTOMATIC TRANSAXLE - Transaxle Control VEHICLE-SPEED SENSOR Vehicle The vehicle-speed sensor is the transistor open collector type; sensor it generates pulse signals (four pulse signals for each rotation of the gear) that are proportional to the rotational speed of the transaxle’s output gear (and therefore proportional to the vehicle speed) and sends these signals to the transaxle control unit.
  • Page 275 AUTOMATIC TRANSAXLE while the vehicle is moving forward at a speed of 7 km/h (4.3 mph) or higher, the hydraulic that provides control to achieve maximum vehicle pressure to the low-reverse brake is electrically safety in the event of an electronic circuit failure or interrupted that the shift cannot be made.
  • Page 276 AUTOMATIC TRANSAXLE The transaxle control unit has self-diagnosis function. Self- diagnosis codes can be read by connecting a voltmeter to the diagnosis connector on the side of the junction block. Self-diagnosis There are 25 diagnosis items, including those items retained even after the Ignition switch is turned to indicating normal conditions;...

  • Page 277: Transaxle Cobrol

    AUTOMATIC TRANSAXLE Output code Diagnosis item Remarks Display pattern Open circuit or poor contact in kickdown servo switch Short circuit in kickdown servo switch Short circuit in accelerator switch or poor adjustment Computer fault Fail-safe item Fail-safe item 1 st gear commanded when driving at high speed Open circuit in pulse generator B Fail-safe item...
  • Page 278 AUTOMATIC TRANSAXLE Output code Remarks Diagnosis item Display pattern Fail-safe item Open circuit in pressure control solenoid Fail-safe item Short circuit in pressure control solenoid Duty control is stopped after Damaged or disconnected wiring of the generation. damper clutch control solenoid valve Short-circuit of the damper clutch control Duty control is stopped after generation.
  • Page 279 21-55 AUTOMATIC TRANSAXLE HYDRAULIC CONTROL SYSTEM The hydraulic control system consists of an oil pump which generates hydraulic pressure for the system, and valves and solenoid valves to control the pressure the oil or switch passages. The valves and solenoid valves are all built in the valve body.
  • Page 280 21-56 AUTOMATIC TRANSAXLE REGULATOR VALVE To torque convener control valve To shift control valve, pressure control valve and N-D control valve (in “D”. ” 2” or “L” range) Oil filter To N-R control valve (in “R” range) Line relief valve Oil pan 1750076 This valve regulates the hydraulic pressure generated by the oil...
  • Page 281 21-57 AUTOMATIC TRANSAXLE - Transaxle Control If the hydraulic pressure increases even more, the regulator valve is forced further leftward and the No. 2 port opens. In this state, the fluid flows through the port toward the suction side of the pump and the line pressure is released. When the line pressure drops, the chamber (A) pressure also drops, and the regulator valve is forced back toward the right by the spring force, closing the No.2...
  • Page 282 AUTOMATIC TRANSAXLE - Transaxle Control TORQUE CONVERTER CONTROL VALVE This valve maintains the torque converter pressure and lubricant pressure at a constant level. regulator valve is directed to the torque converter via the torque converter control valve. The fluid is also directed to chamber B at the right of the torque converter control valve through the small hole in the valve.
  • Page 283 AUTOMATIC TRANSAXLE - Transaxle Control DAMPER CLUTCH CONTROL VALVE AND DAMPER CLUTCH CONTROL SOLENOID VALVE Damper Clutch Control Valve The damper clutch control valve is installed within the lower valve body; it functions to regulate the hydraulic pressure acting upon the damper clutch (incorporated within the Damper Clutch Control Solenoid Valve The damper clutch control solenoid valve is duty-controlled by the signals from the transaxle control unit;...
  • Page 284 AUTOMATIC TRANSAXLE REDUCING VALVE Reducing valve Adjusting ‘screw Line press1 unit N-R control valve &Pressure + control The reducing valve is installed at the lower valve body; it functions to produce a constant pressure which is alwav2 lower than the line pressure. With this pressure as hydraulic pressure source, the control pressure is produced LJY the pressure control solenoid valve, thus activating t h e pressure control valve.
  • Page 285 A U T O M A T I C T R A N S A X L E - Transaxle Control To front clutch Manual valve To low/reverse brake Pressure control solenoid valve 1750089 N-R control valve is moved toward the right by the spring force.
  • Page 286 AUTOMATIC TRANSAXLE - Transaxle Control SHIFT CONTROL VALVE AND SOLENOID VALVES Transaxle control unit Shift control control Shift valve The shift control solenoid valve “A” controls the line, The line pressure acting upon the shift-control valve pressure that acts on the plugs, while the solenoid is controlled by the two shift control solenoid valves valve “B”...
  • Page 287 21-65 AUTOMATIC TRANSAXLE Shift contra solenoid val Shift control valve To N-D control valve To rear clutch 1750231 Meanwhile, the line pressure from the manual valve When the manual valve is shifted to the “D”, “2” or remains applied between the lands of the shift control valve as mentioned previously.
  • Page 288 AUTOMATIC TRANSAXLE - Transaxie Control Plug ’ Stopper To N-D control valve To rear clutch Line pressure 175023: the left plug to the right and the right plug to the lef’ The transaxle control unit deactivates the shift until they are blocked by the stoppers. control solenoid valve “A”...
  • Page 289 AUTOMATIC TRANSAXLE - Transaxle Control Gear control unit Shift control pressure solenoid Stopper Plug Shift control valve To N-D control valve To rear clutch 1750234 Deactivation of the shift control solenoid valve “B” allows pressure to be directed to the shift control ves “A”...
  • Page 290 AUTOMATIC TRANSAXLE - Transaxle Control control unit solenoid valve “8” Shift control valvi To N-D control valve To rear clutch 1 7 5 0 2 3 3 Deactivation of the shift control solenoid valve “B” The transaxle control unit activates the shift control solenoid valve “A”...
  • Page 291 AUTOMATIC TRANSAXLE Pressure Control Solenoid Valve PRESSURE CONTROL VALVE, SOLENOID This valve has its duty controlled by the transaxle mand to corresponding hydraulic pressure. N-R Control Valve clutch under the control of the pressure control This valve prevents shock from occurring when the select lever is shifted from “N”...
  • Page 292 AUTOMATIC TRANSAXLE - Transaxle Control Reducing valve To low/reverse brake via 1 - 2 Line pressure shift valve Line pressure Reducing N-R control P r e s s u r e c o n t r o l 1 b--, ON (Chty 100%) On command from the transaxle control unit, the prevents pressure from being directed to .
  • Page 293 A U T O M A T I C TRANSAXLE “D” or “2”) Reducing To kickdown servo or from clutch via 1 - 2 shift valve Line pressure Line pressure Reducing pressure N-R control, , solenoid valve Duty control 1750097 effectively acts on an area equivalent to the differ- ence in area between these two lands, and pushes the valve to the left;...
  • Page 294 AUTOMATIC TRANSAXLE - Transaxle Control Reducing Low-reverse brake via 1 - 2 shift Line pressure valve Line pressure Reducing pressure N-R control , , vaive 1750090 The low-reverse brake has the capacity that the valve by a certain level before being delivered fror vehicle can be reversed at any point.
  • Page 295 AUTOMATIC TRANSAXLE - Transaxle Control ‘elector Lever in Reducing valve Reducing low-reverse 1750099 directed to the low-reverse brake. Through this en the manual valve is shifted to the “R” range pressure control, the shocks that would occur while shifting to reverse are minimized. Once the low-reverse brake is engaged, the press- to reduce the reducing pressure in the No.23b and to creaje another control.
  • Page 296 AUTOMATIC TRANSAXLE valve Shift control From pressure valve control valve (at “L” range) 1750235 Line pressure apply side valve From pressure control valve 1750236 The valve is actuated by the line pressure that has been regulated by the shift control valve to change the line pressure flow when .shifting is performed directed to the l-2 shift valve through the No.6 between 1st and 2nd gears.
  • Page 297 AUTOMATIC TRANSAXLE - Transaxle Control From kickdown servo apply side Shift control valve 1750237 Downshift from 2nd to 1st Gear If the shift control valve is moved to the 1st gear position, the the left by the spring force. This opens the exhaust port and the released through the No.
  • Page 298 AUTOMATIC TRANSAXLE Front clutch Rear clutch release stde apply side valve Rear clutch exhaust valve valve control valve Line pressure 1750238 The 2-WI-3 shift valve operates in response to tine pressure the pressure acting on the front and rear clutches, and also the Upshift from 2nd to 3rd Gear When the 2-3/4-3 shift valve is free from hydraulic pressure.
  • Page 299 A U T O M A T I C T R A N S A X L E Rear clutch servo release side Front clutch - 1750107 Rear clutch Front clutch control valve p r e s s u r e 1750108 Gear Downshift from 4th to 3rd Gear...
  • Page 300 AUTOMATIC TRANSAXLE N-D CONTROL VALVE rear clutch via rear clutch exhaust valve control valve Pressure control valve p r e s s u r e Reducing pressure pressure Selector Lever in ‘N” The purpose of this valve is to prevent shock from occurring when shifting the select lever from “N”...
  • Page 301 A U T O M A T I C T R A N S A X L E - Transaxle Control S h i f t f r o m “N” to “D” . rear clutch exhaust When the manual valve is shifted from the “N” to the “D” valve range position, the following sequence of events occur.
  • Page 302 AUTOMATIC TRANSAXLE VALVE WITH ORIFICE To low-reverse brake To rear clutch 1 - 2 shift exhaust valve valve W h e n p r e s s u r e - When oressure is applred is released 1750242 If the accelerator pedal is depressed ‘immediately engagement when the fluid temperature is high.
  • Page 303 21-81 AUTOMATIC TRANSAXLE To front clutch To end clutch To kickdown servo release End clutch valve Shift control solenoid valve Shift control solenoid valve - Line pressure 1750243 End clutch valve controls the timing for supplying hydraulic pressure to the end clutch. (1) When hydraulic pressure is not being directed to the end To end clutch valve, it is held pushed to the left by the spring force...
  • Page 304 AUTOMATIC TRANSAXLE - Transaxle Control Upshift from 2nd to 3rd Gear (1) When the shift control valve comes into 3rd gear position valve and the 3rd pressure is established, the pressure is directed to the No.7 port of the end clutch valve through the No.7 line.
  • Page 305 AUTOMATIC TRANSAXLE Gear (1) In 4th gear, the front clutch pressure and the kickdown To end To 2-314-3 release pressure are ‘both released, and therefore, the pressure clutch shift valve port is also at the No. 12 released. pressure (2) Once the pressure starts being released through the No. 12 port, the pressure plug acting on the right end of the...
  • Page 306 AUTOMATIC TRANSAXLE REAR CLUTCH EXHAUST VALVE to front To rear To kickdown clutch clutch servo release side shift valve shift valve Shift control solenoid valve - A Shift control valve - B The valve is actuated by the line pressure controlled the oil pressure to be supplied to the rear clutch by the shift control valve to release the oil pressure when shifting is performed from 4th to 3rd gear.
  • Page 307 21-85 AUTOMATIC TRANSAXLE - Transaxle Control Gear Upshift from 3rd to 4th From rear directed to the rear clutch exhaust valve through the No.8 clutch shift valve line, it pushes the elements “A” and “B” of the rear clutch exhaust valve to the right. (2) The element “B”...
  • Page 308 AUTOMATIC TRANSAXLE SOLENOID VALVE There are four solenoid valves installed on the valve bob,, they are activated, as explained previously, by commands from the transaxle control unit. Pressure control solenoid valve Terminal Damper clutch control solenoid valve Shift control solenoid valve “A” Shift control solenoid valve “6”...
  • Page 309 AUTOMATIC TRANSAXLE...
  • Page 310 AUTOMATIC TRANSAXLE SELECTOR LEVER IN “P”...
  • Page 311 A U T O M A T I C T R A N S A X L E - Transaxle Control...
  • Page 312 AUTOMATIC TRANSAXLE SELECTOR LEVER IN ‘D” (1st Gear)
  • Page 313 21-91 AUTOMATIC TRANSAXLE “II I...
  • Page 314 AUTOMATIC TRANSAXLE SELECTOR LEVER IN “D” (3rd Gear)
  • Page 315 A U T O M A T I C T R A N S A X L E - Transaxle C o n t r o l...
  • Page 316 A U T O M A T I C T R A N S A X L E - Transaxle Control SELECTOR LEVER IN “L”...
  • Page 317 21-95 A U T O M A T I C T R A N S A X L E - Transaxle Control SELECTOR LEVER IN “R”...

  • Page 318: Wiring Diagram

    AUTOMATIC TRANSAXLE - Transaxle Control WIRING DIAGRAM...
  • Page 319 BODY CONTENTS R23A.-- Body Components ..........BODY COLOR CODE ................ Body Major Cross Sections BODY COLOR CODE INTERPRETATION ..............Dash Panel Body Color ............Fender Shield ......................Front Body ............BUMPERS Front Deck ..........- ..CENTRAL DOOR LOCKS ........Front Door ............
  • Page 320 23-2 BODY - Main Body MAIN BODY BODY COMPONENTS...
  • Page 321 BODY Shelf corner bracket Front end upper bar Seat striker reinforcement Headlamp support panel Rear wheelhouse, inner Rear wheelhouse front extension Front end crossmember Quarter panel, inner, upper Fender suppoR panel Quarter panel, inner, lower Front end upper bar reinforcement Front upper frame, outer Center pillar, outer Front upper frame, lower...
  • Page 322 BODY - Main Body 3 0 - >...
  • Page 323 BODY - Main Body Front end upper bar Shelf corner bracket Headlamp support panel Seat striker reinforcement Sidemember to crossmember brace Rear wheelhouse, inner Front end crossmember Rear wheelhouse front extension Fender support panel Quarter panel. inner. upper Front end upper bar reinforcement Quarter panel, inner.
  • Page 324 BODY - Main Body SPECIAL STEEL PANELS Special steel panels (high-tensile steel panel galvanized steel panel) are used in the illustrated positions. galvanized steel panel...
  • Page 325 BODY - Main Body Material Material Part name Pan name 38 Roof panel (for sun roof) Front door beltline reinforcement, 39 Front door inner panel outer Front door, outer, rear 11 Front fender panel Front door, inner, rear 12 Tailgate panel, outer, upper 4 Front fender bracket Cowl top panel, outer Cowl top panel.
  • Page 326 BODY - Main Body...
  • Page 327 BODY - Main Bodv Part name Material Part name Material Front door beltline reinforcement, 44 Front door panel, inner outer 45 Roof panel (for sun roof) Front door, outer, rear 46 Hood panel, inner Front door, inner, rear 47 Front fender panel 4 Front fender bracket 48 Tailgate panel, outer.
  • Page 328 BODY - Main Bodv BODY MAJOR CROSS SECTIONS Front end upper bar Roof panel outer Hood latch bracket Dash panel Front end crossmember. Front end crossmember. reinforcement Muffler hanger reinforcement Front roof rail Front end crossmember. inner Dash panel Strut house bracket Rear pillar.
  • Page 329 BODY - Main Bodv Front pillar, Front floor side sill, Rear end panel, outer inner, upper (A) inner Rear fascia bracket, Rear fascia bracket, Front floor pan Rear floor pan Front pillar, outer, upper Rear end panel. inner Rear end panel. inner Front floor side sill.
  • Page 330 BODY - Main B o d v MAIN BODY Major changes due to adaption of 4WD are as follows: Rear floor sidemember front end changed Rear floor pan changed in shape Propeller shaft bracket added Rear end crossmember added...
  • Page 331 BODY FRONT BODY FRONT DECK (1) A crash bead is provided in the inner cowl top panel that absorbs energy during collision. It prevents the steering wheel from protruding into the driver during collision, thereby ensuring safety of the driver. Crash bead (2) The safety hook prevents the hood from entering the passenger compartment during collision, thereby ensuring...
  • Page 332 BODY - Main Body MAINTENANCE SERVICEABILITY Notches are provided in the door for use in aligning panel positions, thus facilitating the assembly of new parts. Body Center Points Body center points are provided at the following locations, which serve as reference points for measurements at replacement of panels.
  • Page 333 BODY Access Holes Access holes are provided in inner panels including doors and quarter panels to facilitate correction of outer panel sheet metals. Headlamp Support The following component supply formats have been adopted in order to cope with various damage conditions.
  • Page 334 BODY - Main Bodv shield is supplied as an individual part for efficient part replacement. Supply as assembly Cowl top panel Supply as individual parts 4, 5 Front deck crossmember Cowl top Upper frame extension, outer Upper frame extension, inner Dash Panel the front as an individual...

  • Page 335: Vehicle Information Code Plate 1

    BODY - Body Color Code / Body Color Code Interpretation / Solid BODY COLOR CODE The body color code is imprinted on the vehicle information code plate, which is mounted on the front deck. BODY COLOR CODE INTERPRETATION The information contained in the body color code is explained in the body color parts.
  • Page 336 BODY - Doors The doors are front hinged, sash doors opening rigidity of the outer panels and the rigidity of the The sash is flush with the body and has had its A two-step door check has been adopted to hold height difference with the glass surface mini- the door securely at the midway position.
  • Page 337 BODY - Central Door Locks CENTRAL DOOR LOCKS <SOME MODELS> The central door-lock system, by which all doors can unlocking each door when passengers get out or be locked or unlocked (from the inside by using the get in, but also maintains passenger safety. inside door lock knob at either front door, or from For the central door-lock system, the operation of the outside by using the door key), not only sewes...
  • Page 338 23-21 BODY - Central Door Locks <Operation when the doors are locked> the doors are locked (by using the inside lock When knobs or the door key), the door lock switch (incorporated within the door lock actuator) is switched OFF, and then, because current flows to the fuse, as well as to the door-control unit and the lock timer, the lock timer causes base current to flow to TrI for 0.5 second, thus switching ON Tr,.
  • Page 339 23-22 BODY - Power Windows POWER WINDOWS <SOME MODELS> Power windows are equipped in order to facilitate A lock switch is provided at the power windows’ the opening and closing of the door glass. The main switches; when the lock switch is ON, the driver’s seat switch incorporates a one-touch open window cannot be opened or closed by using the mechanism that causes the driver’s door window to...
  • Page 340 BODY - Power Windows OPERATION OF THE POWER WINDOWS <During “one-touch” operation> 1. When the switch is operated, contacts “b” and “c” at the “DOWN” side are caused to connect. and current flows from the battery to contact contact “a”‘, resistor R and to ground, and, as a result, the motor rotates to the “DOWN”...
  • Page 341 BODY - Power Windows / Bumpers Batterv 1. After the delay time (0.7 second) has claps,+,,, the voltage (comparison voltage) at the negative ence voltage at the positive (+) side, with the result that the output voltage of ICI becomes low, and the transistor (Tr) is switched OFF.
  • Page 342 BODY - Sunroof cabin with ample openness. It also consists of the glass assembly, tilt handle and removable sunshade. This sunroof has the following features. The roof lid glass can be removed to have as much openness as offered by an open convertible. In addition, a storage bag and fastening belt have been provided to stow the removed glass in the trunk.
  • Page 343 BODY - Sunroof Section A-A Roof lid glass Roof lid glass Section C-C Section B-B Roof lid glass Roof lid glass...
  • Page 344 front doors that smoothly blend into the body styling. They also contribute to the reduced aerody- namic drag. The electric remote control mirror is a two-motor Note that the electric remote control mirror switch type mirror for independent vertical and horizontal is the centralized-control type and is installed on the angle adjustment The mirror system consists of a door trim on the driver’s seat side.
  • Page 345 ADJUSTMENTS TO THE LEFT AND RIGHT The rotational force of motor A is transferred to the worm wheel, and the pivot screw is thus turned; the threaded part of Mirror assembly Connecting the screw functions to move the adjustment nut, thereby plate (f y l c rum Adjustment nut adjusting the mirror assembly in the left or right direction, with...
  • Page 346 BODY - Instrument Panel / Floor Console ne instrument panel is of the round trim type like a It has the following features. cockpit, with shelf styling to give a wide view in surface is covered with soft padding for front without the sense of being boxed in.
  • Page 347 The front seats are sporty highback seats with an integral headrestraint that hold your body in place on (9.1 in.) on the front passenger’s seat]. curves. The driver’s seat on the higher grade model The front passenger’s seat can be folded down to is provided with the lumbar support that is adjust- ensure easy egress/ingress for the rear-seat pas- able in four positions.
  • Page 348 B O D Y - Seat Belts Shoulder belt On Federal and California vehicles automatic seat belts (Manual seat belts on vehicles for Canada) are installed on the front seats and the 3-point seat belts with ELR on the rear seat, both contributing to the enhanced safety and ease of use.
  • Page 349 BODY - Seat Belts OPERATION OF AUTOMATIC SEAT BELTS The operation of the Automatic Seat Belts is as follows. (1) The belts fasten itself around the occupant when the front door is closed with the ignition switch in the “ON” position. (2) The belts release itself from the occupant when the front door is opened with the ignition switch in the *“ON”...
  • Page 350 S e a t Belts CONSTRUCTION AND OPERATION OF THE OUTER Gear e SWITCH Gear B The outer switch is installed at the retractor for the shoulder belt. The component is an assembly supply item, and so is not to be disassembled.
  • Page 351 B O D Y - Seat Belts CONSTRUCTION OF DRIVING DEVICE Gear B Housing cover Drum A Gear Lock plate Gear housing The component is an assembly supply item, and so Drum B is installed to the tape housing by the is not to be disassembled.
  • Page 352 BODY - Seat Belts When the tape is wound out Drive spring Projection Drum B of drum B Motor Drum spring Gear A When the Tape is Wound In (when the automa- tic seat belt is fastened) (1) When the motor shaft rotates in the clockwise (3) At the same time that the tape is wound into direction, gear A and the lock plate also rotate in drum A, the drive spring is also wound in and...
  • Page 353 BODY - Seat Belts Ignition Fusible llnk @ Fusible link @ switch (IGIl Motor “ W h e n “ W h e n key is key is removed installed Buckle switch witch Door latch Door latch switch ’ switch (Passen- ger’s side) (Automatic seatbelt...
  • Page 354 BODY - Seat Belts COMPONENT PARTS AND FUNCTION Located at the quarter panel on the driver’s seat side. The system is controlled based upon various input signals, thereby regulating motor operation, warnrng light illumination or continuous arter panel flashing, and buzzer sounding. Located at the front of the guide rail This switch is for turning the shoulder belt drive motor off.
  • Page 355 BODY - Seat Belts Motor (L.H., R.H.) Manual Procedure Door Latch Switch (L.H., R.H.) The following components also constitute the automatic seat belts system. Ignition Switch (“ON” position) Kev-reminder Switch (A. B) “ON” signals are sent to the control unit by switch A while the key is inserted in the key cylinder;...
  • Page 356 BODY - Belts Seat Fastening Motion (1) If the belt is not in the fastening position (the When the belt is completely fastened, the L.H. or R.H. door latch switch at Door Closed “fasten” switch is switched OFF and the motor position;...
  • Page 357 B O D Y - Seat Belts Warning Alarm when the Automatic Seat Belt is no* Completely Fastened (when the slide anchor, during movement, stops before completion of travel, or when it moves toward the “fasten” side) light flashes if the door is closed, the ignition Door latch warning switch...
  • Page 358 B O D Y - Seat Belts Warning Alarm when the Driver’s Lap Belt is not Fastened switch switch When, belt unfastened (the buckle is switched ON), the ignition switch is tunrned from the Driver’s “LOCK” or position to the “ON” position, the buzzer side buckle will sound intermittently switch...
  • Page 359 23-42 BODY - Seat Belts Input Signals do so within one minute from the time that the The relationship between input signals (as seen ignition switch is turned to the “ON”, “LOCK” or ON/OFF from the control unit) and the status of the “ACC”...
  • Page 360 BODY - Seat Belts shown in the table below. OPERATION (TERMINAL No.201 Output signal waveforms and operation status Status at input side Buzzer Output signal driver’s shoulder belt Driver’s door Closed is not fastened Driver’s shoulder belt (“Fasten” switch) Driver’s outer switch Approx.
  • Page 361 Seat Belts B O D Y - WARNING LIGHT OPERATION (TERMINAL No. 10) Output signal waveforms and operation status Status at input side Light Output signal OFF 3 ON lgnition switch ignition switch is activated Other than as above I ON Warning alarm when automatic seat belt Driver’s or passenger’s seat...
  • Page 362 BODY - Seat Belts Output signal waveforms and operation status Status at input side Motor Output signal Driver’s door Driver’s shoulder belt O p e r a t e s . H Open is released. Driver’s shoulder belt Not released Other than as above stops.
  • Page 363 B O D Y - Seat Belts R E A R S E A T B E L T The rear seat belts are the 3-point seat belts with The buckle can be tilted forward and inward, whicn ELR which ensures safety of the rear-seat passen- helps make the belts tight around the body.

  • Page 364: Air Conditioning

    HEATERS AIR CONDITIONING CONTENTS Rx&-- COMPRESSOR .._..I....... HEATER CONSTRUCTION .._..... Compressor Control ......_ .._ . . IDLE SPEED CONTROL .
  • Page 365 24-2 HEATERS AND AIR CONDITIONING - General Information GENERAL INFORMATION A& The heater is a separated configuration, with the Air conditioner heater unit located at the center of the chassis and High capacity evaporator (cooling unit), com- the blower motor located at the glove box. It is the pressor* and condenser are adopted to secure blend air system for excellent temperature control high cooling performance.
  • Page 366 HEATERS AND AIR CONDITIONING COMPONENTS blend air heater...
  • Page 367 HEATERS AND AIR CONDITIONING - General Information To windshiel (defroster) To side (door) window (side defroster) To face area (side ventilator) To side (door) window (side defroster) Tofacearea / (side ventilator) Temperature control knob , , , , Air-selection lever Blower switch Air conditioner switch OPERATION DIAGRAM OF COMPRESSOR MAGNET...
  • Page 368 HEATERS AND AIR CONDITIONING Section A-A Air intake garnish Section B-B Check The air-selection damper (located at the the btend air damper. Depending on the temper- upper part of the blower motor) can be used to select ature control knob setting, the amount of blend either induction of outside air from the front air which has passed through the heater core deck, or circulation of inside air.
  • Page 369 HEATERS AND AIR CONDITIONING RELATIONSHIP BETWEEN THE DAMPER POSITION AND THE AIR-SELECTION LEVER, MOD: SELECTION KNOB AND TEMPERATURE CONTROL KNOB SETlINt% Air-selection Lever Lever Damper Operation position position When the air-selection lever placed in the illustrated mark position, the air-selection damper closes the inside air inlet (air from the vehicle interior) and opens the outside air inlet (air from the from deck).
  • Page 370 H E A T E R S A N D A I R C O N D I T I O N I N G - Heater Construction Knob posl t i o n Damper position and air flow direction Air outflow locations Outside air Recircu-...
  • Page 371 HEATERS AND AIR CONDITIONING - Compressor COMPRESSOR CONTROL control unit. dual pressure switch, engine coolant When both the blower switch and air conditioner temperature switch and MPI control unit. switch are ON, ON-OFF control of the magnetic clutch is accomplished by the auto compressor Fusible link Sub fusible link...
  • Page 372 HEATERS AND AIR CONDITIONING - Idle Speed Control 1. increasing idle speed to withstand air condition- er load When the compressor is placed in the ON state with the engine at idle, the idling speed of the engine will be increased by approx. 150 rpm to prevent generation of vibration and also to prevent the engine from stalling.- 2.
  • Page 373 EMISSION CONTROL SYSTEMS CONTENTS AIR-FUEL MIXTURE RATIO Purge Control Solenoid Valve CONTROL SYSTEM ......_....<Turbo> ... _ ..........Purge Control Valve <Turbo>...
  • Page 374 EMISSION CONTROL SYSTEMS General Information GENERAL INFORMATION The exhaust emissions-control system reduces the There are three sources of vehicle exhaust emis- amount of carbon monoxide, hydro carbon and sions generated: the exhaust gases resulting from oxides of nitrogen in the exhaust gases by adding combustion, the blow-by gases generated within the exhaust gas recirculation device and the cataly- the crankcase, and the evaporative emissions...
  • Page 375 CONTROL SYSTEMS CONTENTS AIR-FUEL MIXTURE RATIO Purge Control Solenoid Valve CONTROL SYSTEM .._ ........<Turbo>...
  • Page 376 EMISSION CONTROL SYSTEMS - General Information GENERAL INFORMATION The exhaust emissions-control system reduces the There are three sources of vehicle exhaust emis- amount of carbon monoxide, hydro carbon and sions generated: the exhaust gases resulting from oxides of nitrogen in the exhaust gases by adding combustion, the blow-by gases generated within the exhaust gas recirculation device and the cataly- the crankcase, and the evaporative emissions...
  • Page 377 EMISSION CONTROL SYSTEMS Non-Turbo for California solenoid valve EGR control solenoid valve EGR temperature sensor Catalytic converter Turbo for Federal Purge control solenoid valve Catalytic a3nverter...
  • Page 378 EMISSION CONTROL SYSTEMS Turbo for California Purge control valve EGR control solenoid valve EGR temperature sensor Catalytic converter...
  • Page 379 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System vacuum is low during engine idling, or during nitrogen in exhaust emissions. In this system, the wide-open throttle operation, the EGR control valve exhaust gas is partially recirculated from the ex- is closed by the force.of the spring, with the result haust manifold into the intake manifold while EGR that there is no flow of EGR gas.
  • Page 380 EMISSION CONTROL SYSTEMS OPERATION <California> The engine control unit functions to calculate the maintaining driveability during cold. engine load, based upon the intake air volume When, as a result of clogging of the EGR cant’ signals (from the air-flow sensor) and the rpm valve or as a result of an operational malfunctio,., signals (from the crank-angle sensor), and the EGR the EGR flow volume decreases, the EGR gas...
  • Page 381 EMISSION CONTROL SYSTEMS - Exh aust Car Recirculation (EGR) System NOTE Duty ratio The duty ratio is the ON duration ratio of 16.7 Hz pulse or T2/T1. The higher the duty ratio, the more mean current flows to the boost meter. and as a result, the boost meter reads the higher value.
  • Page 382 EMISSION CONTROL SYSTEMS EGR TEMPERATURE SENSOR <California> _ Sensor part Enaine control unit EGR temperature sensor EGR temperature sensor is thermistor type. It to electric signal and sends the signal to the engine detects the temperature of gas passage in EGR control unit.
  • Page 383 EMISSION CONTROL SYSTEMS The catalytic converter is installed on the middle of and surrounded by a stainless steel shell. The catalytic converter oxidizes carbon monoxide the exhaust pipe under the floor. This catalytic converter uses a monolithic type and hydrocarbon, and reduces oxides of nitrogen. catalyst with a honeycomb structure that has its which are present in the exhaust gas, in order to minimize their emission levels.
  • Page 384 EMISSION CONTROL SYSTEMS A closed-type crankcase ventilation system is uti- with blow-by gases, and this mixture passes through the PCV valve into the intake manifold. the atmosphere. The PCV valve has a metered orifice through which This system has a positive crankcase ventilation the mixture of fresh air and blow-by gases is drawn valve (PCV valve) at the rocker cover.
  • Page 385 EMISSION CONTROL SYSTEMS In order to prevent the escape of fuel vapor from the canister in accordance with the intake negative fuel system into the atmosphere. the evaporative pressure (vacuum), the fuel vapors accumulated in emission control system consists of a charcoal the canister are taken from the charcoal and are also canister, a purge control solenoid valve, etc.
  • Page 386 EMISSION CONTROL SYSTEMS Turbo Purge control valve Air cleaner Purge control solenoid valve Fuel check valve Thermal expansion Fuel gauge unit Canister - charger Filter CANISTER fuel tank While the engine is inoperative, fuel vapors generated insidE solenoid valve the fuel tank are absorbed and stored in the canister. When the engine is running, the fuel vapors absorbed in thf canister are drawn into the throttle body through the purge control solenoid valve.
  • Page 387 EMISSION CONTROL SYSTEMS PURGE CONTROL SOLENOID VALVE <Non- To intake air plenum or throttle body Turbo> From canister The purge-control solenoid valve is the ON/OFF control type of solenoid valve; it functions to control the introduction of purge air to the intake air plenum from the canister. Control relav Purge control solenoid valve...
  • Page 388 EMISSION CONTROL SYSTEMS OVERFILL LIMITER (TWO-WAY VALVE) Pressure valve The overfill limiter consists of a pressure valve and a vacuum valve. The pressure valve is designed to open when the fuel tank internal pressure has increased over the normal pressure and the vacuum valve opens when a vacuum has been producted in the tank.
  • Page 389 NOTES...
  • Page 390 NOTES...
  • Page 391 UNITED STATES The special service tools referred to herein are required for certain service operations. These special service tools or their equivalent, if not obtainable through a local source are available through the following outlet. 32615 Park Lane, Garden City, Michigan 48135, U.S.A. TRIANGLE SPECIAL PRODUCTS GROUP (MILLER SPECIAL TOOLS)

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Talon 1990

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